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KOMATSU PC4000-6 DIESEL HYDRAULIC EXCAVATOR SHOP MANUAL – PDF DOWNLOAD
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KOMATSU PC4000-6 DIESEL HYDRAULIC EXCAVATOR SHOP MANUAL SHOP0608175-08197 – PDF DOWNLOAD
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KOMATSU PC4000-6 DIESEL HYDRAULIC EXCAVATOR SHOP MANUAL SHOP0608175-08197 – PDF DOWNLOAD
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KOMATSU PC4000-6 DIESEL HYDRAULIC EXCAVATOR SHOP MANUAL SHOP0608175-08197 – PDF DOWNLOAD
Language : English
Pages : 2032
Downloadable : Yes
File Type : PDF
Serial Number 08175 to 08197
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TABLE OF CONTENTS:
KOMATSU PC4000-6 DIESEL HYDRAULIC EXCAVATOR SHOP MANUAL SHOP0608175-08197 – PDF DOWNLOAD
COVER............................................................................................................... 1 00 Foreword ........................................................................................................ 3 Introduction.................................................................................................... 5 Safety Instructions............................................................................................. 10 01 Specification.................................................................................................... 31 Specification PC4000............................................................................................ 33 10 Structure, Function.............................................................................................. 41 I. INTRODUCTION................................................................................................. 61 I.I Contents of the Binder.................................................................................. 62 I.II Foreword............................................................................................... 63 1.2.1 Importand Note.................................................................................... 65 I.III Explanation of Abbrevations........................................................................... 67 II. SAFETY...................................................................................................... 69 II.I Safety Instructions.................................................................................... 70 II.II General Preauctions................................................................................... 71 II.III Preparations for Work................................................................................ 72 II.IV Precautions during Work............................................................................... 73 II.V Precautions after Work................................................................................. 74 III. SPECIFICATIONS............................................................................................. 105 III.I Lifting Gears......................................................................................... 106 III.II Standard Tightening Torque Chart..................................................................... 108 III.III Conversion Table.................................................................................... 109 III.IV General Specifications............................................................................... 116 1 MAIN ASSEMBLY GROUPS.......................................................................................... 75 1.1 General Layout.......................................................................................... 76 1.2 Superstructure.......................................................................................... 78 1.3 Machine House........................................................................................... 80 1.4 Hydraulic Oil Reservoir................................................................................. 82 1.5 Hydraulic Oil Cooler.................................................................................... 84 1.6 Fuel Tank............................................................................................... 86 1.7 Counterweight........................................................................................... 88 1.8 Cab Support............................................................................................. 90 1.9 Operator’s Cab.......................................................................................... 92 1.10 Control Blocks......................................................................................... 94 1.11 Swing Gears............................................................................................ 96 1.12 Undercarriage.......................................................................................... 98 1.13 Backhoe Attachment (BHA)............................................................................... 100 1.14 Front Shovel Attachment (FSA).......................................................................... 102 2. DRIVE........................................................................................................ 117 2.1 Prime Drive Assembly.................................................................................... 118 2.2 Engine and PTO Mounts................................................................................... 120 2.2.1 Flexible Mounts................................................................................... 121 2.2.2 Torque Support.................................................................................... 123 2.3 Fan Drive and Radiator Assembly......................................................................... 124 2.3.1 Radiator Fan Drive Speed Adjustment............................................................... 128 2.4 Pump Distributor Gearbox (PTO).......................................................................... 132 2.4.1 Spline Shaft Housing.............................................................................. 134 2.4.2 PTO Lubrication and Cooling....................................................................... 136 2.4.3 Hydraulic Pumps – Location, Drive Speed and Flow Rates............................................ 142 2.5 Geislinger Coupling..................................................................................... 144 2.6 Air Filter.............................................................................................. 146 3. HYDRAULIC OIL RESERVOIR...................................................................................... 149 3.1 General Layout.......................................................................................... 150 3.2 Main Oil Tank, Location of Electric Equipment........................................................... 152 3.3 Suction Oil Reservoir with Strainers.................................................................... 154 3.4 Return Oil Collector Tube with Strainer................................................................. 156 3.5 Back Pressure Valve..................................................................................... 158 3.6 Transfer Pump........................................................................................... 160 3.6.1 Evacuation of the suction oil reservoir........................................................... 163 3.6.2 Evacuation of the return oil collector pipes and cooler circuit................................... 165 3.7 Return and Leak Oil Filter.............................................................................. 166 3.8 Breather Filter......................................................................................... 168 4. HYDRAULIC OIL COOLING........................................................................................ 171 4.1 General................................................................................................. 172 4.2 Function of the Hydraulic Oil Cooling Circuit........................................................... 174 4.3 Adjustment of the Back Pressure Valve................................................................... 176 4.4 Fan Drive (Two Stage Cooler Fan RPM Control)............................................................ 178 4.4.1 Fixed Displacement Pump, with Variable Setting.................................................... 180 4.4.2 Pressure Relief Valves............................................................................ 182 4.4.3 fan speed control valve arrangement............................................................... 184 4.5 Adjustment of the Cooler Fan Drive Speed................................................................ 186 4.5.1 Function Check of Fan Speed Control............................................................... 191 5. CONTROLLING.................................................................................................. 193 5.1 General Layout.......................................................................................... 194 5.2 Control and Filter Panel Location of Components......................................................... 196 5.3 Pilot Pressure Supply and Adjustments................................................................... 202 5.3.1 Pilot Pressure Circuit (PPC)...................................................................... 203 5.3.2 Checks and Adjustment of Pilot Pressure........................................................... 206 5.3.3 Remote Control Valves Arrangement................................................................. 208 5.4 Function Electro Hydraulic Control SYSTEM............................................................... 210 5.5 Potentiometer Control (Lever, Joy Stick)................................................................ 214 5.6 Potentiometer Control (Pedal)........................................................................... 216 5.7 Proportional Amplifier Module, Type A................................................................... 218 5.8 Proportional Amplifier Module, Type B................................................................... 220 5.9 Ramp Time Module........................................................................................ 222 5.10 Adjustments of Amplifier Modules....................................................................... 224 5.10.1 General.......................................................................................... 225 5.10.2 Adjusting the amplifiers type B.................................................................. 226 5.10.3 Adjusting the Amplifiers Type A.................................................................. 230 5.11 Adjusting the Ramp Time Module......................................................................... 232 6. COMPONENTS................................................................................................... 241 6.1 Main Control Blocks and High Pressure Filter (FSA)...................................................... 242 6.2 Main Control Blocks and High Pressure Filter (BHA)...................................................... 244 6.3 Distributor Manifold - Location of Restrictor Blocks and Anti Cavitation Valves (FSA)................... 246 6.4 Distributor Manifold - Location of Restrictor Blocks and Anti Cavitation Valves (BHA)................... 248 6.5 Single Control Blocks (Floating) for Stick and Boom (FSA)............................................... 250 6.6 Restrictor Block with Pressure Relief Valve............................................................. 252 6.7 Anti cavitation valve block............................................................................. 254 6.8 Remote Control Valves................................................................................... 256 6.9 Directional Solenoid Valves (Three Positions / 4-Ways).................................................. 258 6.10 Proportional Solenoid Valve............................................................................ 260 6.11 High Pressure Filter................................................................................... 262 6.12 Control Blocks and Valves.............................................................................. 264 6.13 Travel Brake Valve..................................................................................... 276 6.14 Pressure Reducing Valve................................................................................ 278 6.15 Directional Solenoid Valves (Two Positions / 4-Ways)................................................... 280 6.16 Pressure Increasing Valve.............................................................................. 282 6.17 Hydraulic Cylinder..................................................................................... 284 6.18 Swing Ring............................................................................................. 288 7. MAIN HYDRAULIC PUMPS AND PUMP REGULATION..................................................................... 291 7.1 General................................................................................................. 292 7.2 Main Pumps.............................................................................................. 302 7.2.1 Location of Pumps................................................................................. 303 7.2.2 Pump Bearing Flushing / Lubrication............................................................... 304 7.2.3 Operating Principle............................................................................... 306 7.2.4 Checks / Adjustments.............................................................................. 324 7.3 Electronic Pump Regulation System....................................................................... 334 7.3.1 Electronic Load Limiting Control - General........................................................ 335 7.3.2 Microcontroller RC4-4............................................................................. 337 7.3.3 Checks and Adjustments............................................................................ 339 7.4 Hydraulic Constant Regulation System.................................................................... 366 7.4.1 General........................................................................................... 367 7.4.2 X1-Pressure Adjustment (Constant-Pressure)........................................................ 368 7.5 Determination of the Peak Point (Engine Performance).................................................... 370 7.6 Engine Speed Sensor (Pick up)........................................................................... 372 7.6.1 General........................................................................................... 373 7.6.2 Engine Speed Sensor (Pick up) Adjustment.......................................................... 373 7.7 Energy Efficiency....................................................................................... 374 7.7.1 General........................................................................................... 375 7.7.2 Checks and Adjustments............................................................................ 376 8. OPERATING HYDRAULIC.......................................................................................... 381 8.1 General................................................................................................. 382 8.1.1 FLOATING SYSTEM................................................................................... 384 8.2 Hydraulic for the Attachment Cylinder FSA and BHA....................................................... 386 8.2.1 Electric / Hydraulic flowchart "Boom raising" FSA................................................. 386 8.2.2 Electric / Hydraulic Flowchart "Boom Raising" BHA................................................. 388 8.2.3 Electric / Hydraulic Flowchart "Boom Lowering" FSA................................................ 390 8.2.4 Electric / Hydraulic Flowchart "Boom Lowering" BHA................................................ 392 8.2.5 Electric / Hydraulic flowchart "Stick extending" FSA.............................................. 394 8.2.6 Electric / Hydraulic Flowchart "Stick Extending" BHA.............................................. 396 8.2.7 Electric / Hydraulic Flowchart "Stick Retracting" FSA............................................. 398 8.2.8 Electric / Hydraulic Flowchart "Stick Retracting" BHA............................................. 400 8.2.9 Electric / Hydraulic Flowchart "Bucket Filling" FSA............................................... 402 8.2.10 Electric / Hydraulic Flowchart "Bucket Filling" BHA.............................................. 404 8.2.11 Electric / Hydraulic Flowchart "Bucket Emptying" FSA............................................. 406 8.2.12 Electric / Hydraulic Flowchart "Bucket Emptying" BHA............................................. 408 8.2.13 Electric / Hydraulic Flowchart "Clam Opening" FSA................................................ 410 8.2.14 Electric / Hydraulic Flowchart "Clam Closing" FSA................................................ 412 8.2.15 Checks and Adjustments of the Main Relief Valves (FSA)........................................... 414 8.2.16 Checks and Adjustments of the Main Relief Valves (BHA)........................................... 416 8.2.17 Checks and Adjustments of the Service Line Relief Valves (SRV)................................... 418 8.2.18 Stick Cylinder "Piston Rod Side" FSA............................................................. 435 8.3 Hydraulic for the Swing Circuit......................................................................... 482 8.3.1 Swing Circuit..................................................................................... 482 8.3.2 Swing Motor....................................................................................... 486 8.3.3 Swing Gear Box.................................................................................... 488 8.3.4 Swing Parking Brake (Gear House Brake)............................................................ 490 8.3.5 Swing Brake Valve................................................................................. 492 8.3.6 Electric / Hydraulic Flowchart "Swing Left"....................................................... 494 8.3.7 Electric / Hydraulic Flowchart "Swing Right"...................................................... 496 8.3.8 Checks and Adjustments for the Swing Circuit...................................................... 498 8.3.9 Function Check for Hydraulic Swing Brake.......................................................... 504 8.3.10 Function Check for the Swing Parking Brake....................................................... 506 8.4 Hydraulic for the Travel Circuit........................................................................ 508 8.4.1 Travel Circuit.................................................................................... 508 8.4.2 Travel Motor...................................................................................... 512 8.4.3 Rotary Distributor................................................................................ 514 8.4.4 Travel Gear....................................................................................... 516 8.4.5 Travel Parking Brake (Gear House Brake)........................................................... 518 8.4.6 Travel Brake Valve................................................................................ 520 8.4.7 Electric / Hydraulic Flowchart “Traveling Forward”................................................ 522 8.4.8 Electric / Hydraulic Flowchart “Traveling Backward”............................................... 524 8.4.9 Checks and Adjustments for the Travel Circuit..................................................... 526 8.4.10 Function Check for the Travel Parking Brake...................................................... 528 9. HYDRAULIC TRACK TENSIONING SYSTEM............................................................................ 531 9.1 General................................................................................................. 532 9.2 Pressure Increasing Valve............................................................................... 536 9.3 Tensioning Cylinder..................................................................................... 538 9.4 Adjustments / Checks.................................................................................... 540 9.5 Functional Test......................................................................................... 542 10. ACCESS LADDER HYDRAULICALLY OPERATED........................................................................ 545 10.1 General................................................................................................ 546 10.2 Function of Hydraulically Operated Access Ladder....................................................... 548 10.3 Adjustments / Checks................................................................................... 552 11. CENTRAL REFILLING SYSTEM (Service ARM)...................................................................... 555 11.1 General................................................................................................ 556 11.2 Function............................................................................................... 558 12. HINTS FOR READING THE HYDRAULIC DIAGRAM..................................................................... 561 12.1 General................................................................................................ 562 12.2 Symbolic............................................................................................... 564 12.2.1 Lines, Unions.................................................................................... 565 12.2.2 Components, Valves............................................................................... 566 12.2.3 Sensors.......................................................................................... 567 12.2.4 Valves, Valve Components......................................................................... 568 12.2.5 Pump, Motor, Cylinder............................................................................ 572 13. HINTS FOR READING THE ELECTRIC CIRCUIT DIAGRAM.............................................................. 577 13.1 Designation of electrical components................................................................... 579 13.2 Electric symbols....................................................................................... 580 13.3 Symbols................................................................................................ 582 13.4 Drawing Concept........................................................................................ 584 13.5 Reading a Circuit Diagram.............................................................................. 588 13.6 Component List......................................................................................... 592 14 VEHICLE HEALTH MONITORING SYSTEM............................................................................. 655 14.1 General................................................................................................ 656 14.2 Specifications for Operators........................................................................... 658 14.2.1 Sequence of Displays............................................................................. 659 14.2.2 Opening Screen................................................................................... 659 14.2.3 Main Gauge Screens 1 to 3........................................................................ 660 14.2.4 Fuel Consumption Screen.......................................................................... 664 14.2.5 Failure Message History Screen for Operator...................................................... 667 14.2.6 Main Screen - Chance Time SMR Date............................................................... 667 14.2.7 Maintenance Monitor.............................................................................. 668 14.2.8 Settings for Operator............................................................................ 670 14.2.9 Automatic Messages............................................................................... 676 14.2.10 Table of all Top Messages provided by the System................................................ 680 14.2.11 Table of available Instruction Messages......................................................... 690 14.3 Specifications for Service............................................................................. 692 14.3.1 Main Screen Flow Chart for the Operater Mode..................................................... 693 14.3.2 Main Screen Flow Chart for the Service Mode...................................................... 694 14.3.3 Entering the Service Menu........................................................................ 698 14.3.4 Service Menu Select Screen....................................................................... 700 14.3.5 Real Time Menu Select Screen..................................................................... 701 14.3.6 PM-Clinic........................................................................................ 711 14.3.7 Serial/GCC No. Setting........................................................................... 713 14.3.8 Memory Clear..................................................................................... 714 14.3.9 Failure History.................................................................................. 716 14.3.10 Maintenance Monitor............................................................................. 718 14.3.11 Snapshot........................................................................................ 719 14.3.12 Settings........................................................................................ 720 14.4 Wiring of the Main Components.......................................................................... 728 14.4.1 Wiring of the Engine............................................................................. 730 14.4.2 Wiring of the VHMS-Controller.................................................................... 732 14.4.3 Wiring of the CGD-Monitor........................................................................ 736 14.4.4 Wiring of the PLC................................................................................ 738 14.5 General Design of THE PLC.............................................................................. 740 14.5.1 Input and Output of the PLC...................................................................... 743 14.5.2 Task............................................................................................. 743 14.5.3 PLC DIGSY plus ®................................................................................. 744 14.6 How to proceed the Maintenance and Installation........................................................ 746 14.6.1 Meaning of the +5 V Status LED................................................................... 747 14.6.2 Meaning of the DIAG Status LED................................................................... 749 14.6.3 Short Circuit Marker-LED “MK”.................................................................... 752 14.6.4 Diagnostic for analogue-Module “ANM”............................................................. 752 14.7 Front Connector Arrangement............................................................................ 753 14.7.1 Front Connector Arrangement, BIM Module (Digital Input / Output)................................. 753 14.7.2 Front Connector Arrangement, ANM-Module (Analogues Input)........................................ 755 14.7.3 Ground Connection of the Control Unit............................................................ 757 14.7.4 Interface-Connection VHMS-Controller............................................................. 758 14.8 Power Supply........................................................................................... 760 14.8.1 Operation Voltages +24 V......................................................................... 761 14.8.2 Safety Precautions for Troubleshooting........................................................... 762 14.8.3 CPU Voltage Range and Electric Classification.................................................... 763 14.8.4 Fuse............................................................................................. 763 14.9 Function Explanations with Electrical Diagram.......................................................... 765 14.9.1 General.......................................................................................... 765 14.9.2 Pressure Measuring (Hydraulic System)............................................................ 766 14.9.3 Temperature Measuring and Troubleshooting........................................................ 768 14.9.4 Temperature – Resistance Chart PT100............................................................. 770 14.10 Hints for Reading the Functional Flow Charts.......................................................... 771 14.10.1 General......................................................................................... 771 14.10.2 Example: Monitoring the X1-Pressure for Pump Control............................................ 772 15. LUBRICATION SYSTEMS......................................................................................... 775 15.1 Introduction........................................................................................... 777 15.2 Central Lubrication System (CLS)....................................................................... 778 15.3 Lubrication Pump Station (SLS)......................................................................... 784 15.3.1 Hydraulically driven Lube Pump................................................................... 790 15.3.2 Vent Valve....................................................................................... 792 15.3.3 End of Line Switch............................................................................... 794 15.3.4 In-Line Filter................................................................................... 796 15.3.5 Lubricant Level Sensor........................................................................... 798 15.3.6 Lubricant Pressure Sensor........................................................................ 799 15.3.7 Lubricant Injector............................................................................... 800 15.3.8 Lubrication pinion............................................................................... 805 15.4 Operating and Controlling.............................................................................. 807 15.4.1 Operating Flow, Electrical Flow.................................................................. 808 15.5 Adjustments............................................................................................ 812 15.5.1 Pump Speed and Working Pressure.................................................................. 813 15.5.2 Injectors........................................................................................ 816 15.5.3 End of Line Switch Setting CLS................................................................... 818 15.5.4 End of Line Switch Setting SLS................................................................... 820 15.6 Troubleshooting........................................................................................ 822 15.7 Commissioning.......................................................................................... 826 15.7.1 Commissioning of the CLS......................................................................... 826 15.7.2 Fine Adjustment.................................................................................. 827 15.7.3 Commissioning of the SLS......................................................................... 827 40 Troubleshooting.................................................................................................. 831 Table of Contents............................................................................................... 835 Introduction & general information for troubleshooting.......................................................... 843 Description of this troubleshooting manual.................................................................. 843 Safety Notes................................................................................................ 843 1. General precautions...................................................................................... 843 2. Preparations for work................................................................................ 844 Precautions when carrying out any operation......................................................... 846 1. Precautions when carrying out removal work................................................... 846 2. Precautions when carrying out installation work.............................................. 846 3. Precautions when completing the operation.................................................... 847 3. Precautions during work.............................................................................. 845 1. Air bleeding of various hydraulic parts.......................................................... 856 A) Air bleeding from the hydraulic pumps............................................................ 856 B) Air bleeding from hydraulic cylinders............................................................ 856 2. Cylinder bypass test............................................................................. 857 Information on the PLC.............................................................................. 858 1. Design and allocation of PLC LEDs and wiring diagrams............................................ 858 2. General description of the PLC................................................................... 858 3. Troubleshooting of the PLC....................................................................... 858 4. Information on the PLC emergency indication via LEDs............................................. 859 Cable colour identification......................................................................... 860 Part III........................................................................................ 861 Mounting locations, connector types and electrical standard values.............................................. 861 1. Component location....................................................................................... 861 1.1 View onto the superstructure............................................................................ 861 1.2 Location of engine electrical parts (1)................................................................. 863 1.3 Location of engine electrical parts (2)................................................................. 864 1.4 Location of hydraulic components........................................................................ 865 1.5 Location of the remote control valves................................................................... 866 1.6 Location of the high pressure and differential pressure switches........................................ 867 1.7 View onto the SLS and CLS grease barrel................................................................. 868 1.8 View onto the cab base with electrical components....................................................... 869 1.9 Hydraulic oil tank [Type 1] - location of electrical components......................................... 871 1.10 Hydraulic oil tank [Type 2] - location of electrical components........................................ 873 1.11 Hydraulically operated access ladder................................................................... 875 2. Overview connector types and connector pin numbers....................................................... 876 3. Standard value table for electrical components........................................................... 878 4. PT100 temperature charts................................................................................. 891 Part IV................................................................................................. 893 Troubleshooting by trouble code................................................................................. 893 G00001 - Trouble Shut-Off (gate) valve...................................................................... 893 G00001 - Trouble Shut-Off (gate) valve...................................................................... 894 G00001 - Trouble Shut-Off (gate) valve...................................................................... 895 View onto the VHMS settings for proximity switch S31........................................................ 896 View onto the gap of the proximity switch S31............................................................... 896 Circuit diagram related to trouble code G00001.............................................................. 897 G00002 - Test speed 1800 rqm................................................................................ 898 G00002 - Test speed 1800 rqm................................................................................ 899 Circuit diagram related to trouble code G00002.............................................................. 900 G00003 - Trouble pump controller............................................................................ 901 G00003 - Trouble pump controller............................................................................ 902 G00003 - Trouble pump controller............................................................................ 903 G00003 - Trouble pump controller............................................................................ 904 G00005 - Low hydraulic oil level............................................................................ 905 G00005 - Low hydraulic oil level............................................................................ 906 Circuit diagram (trouble code G00005) and the defined position of the attachment............................ 907 G00007 - Trouble hydraulic oil level........................................................................ 908 G00007 - Trouble hydraulic oil level........................................................................ 909 Circuit diagram (trouble code G00007) and the defined position of the attachment............................ 910 G00008 - Trouble HPF #1..................................................................................... 911 G00009 - Trouble HPF #2..................................................................................... 911 G00010 - Trouble HPF #3..................................................................................... 911 G00011 - Trouble HPF #4..................................................................................... 911 G00008 - Trouble HPF #1..................................................................................... 912 G00009 - Trouble HPF #2..................................................................................... 912 G00010 - Trouble HPF #3..................................................................................... 912 G00011 - Trouble HPF #4..................................................................................... 912 G00012 - CLS grease level too low........................................................................... 913 G00013 - SLS grease level too low........................................................................... 913 G00012 - CLS grease level too low........................................................................... 914 G00013 - SLS grease level too low........................................................................... 914 G00012 - CLS grease level too low........................................................................... 915 G00013 - SLS grease level too low........................................................................... 915 Circuit diagram 1 related to trouble codes G00012 and G00013................................................ 916 Circuit diagram 2 related to trouble codes G00012 and G00013................................................ 917 G00020 - Trouble Shut-Off (gate) valve (Start blocked)...................................................... 918 G00020 - Trouble Shut-Off (gate) valve (Start blocked)...................................................... 919 G00020 - Trouble Shut-Off (gate) valve (Start blocked)...................................................... 920 Circuit diagram related to trouble code G00020.............................................................. 920 View onto the VHMS settings for proximity switch S31........................................................ 921 View onto the gap of the proximity switch S31............................................................... 921 G00021 - Trouble monitoring HPF #1.......................................................................... 922 G00022 - Trouble monitoring HPF #2.......................................................................... 922 G00023 - Trouble monitoring HPF #3.......................................................................... 922 G00024 - Trouble monitoring HPF #4.......................................................................... 922 G00021 - Trouble monitoring HPF #1.......................................................................... 923 G00022 - Trouble monitoring HPF #2.......................................................................... 923 G00023 - Trouble monitoring HPF #3.......................................................................... 923 G00024 - Trouble monitoring HPF #4.......................................................................... 923 G00021 - Trouble monitoring HPF #1.......................................................................... 924 G00022 - Trouble monitoring HPF #2.......................................................................... 924 G00023 - Trouble monitoring HPF #3.......................................................................... 924 G00024 - Trouble monitoring HPF #4.......................................................................... 924 View onto a differential pressure switch.................................................................... 925 G00060 - Fire in the power house............................................................................ 926 G00060 - Fire in the power house............................................................................ 927 Circuit diagram related to trouble code G00060.............................................................. 927 G00061 - Trouble monitoring, engine speed too low........................................................... 928 Circuit diagram related to trouble code G00061.............................................................. 929 G00062 - Trouble monitoring, engine speed too high.......................................................... 930 G00062 - Trouble monitoring, engine speed too high.......................................................... 931 G00062 - Trouble monitoring, engine speed too high.......................................................... 932 Circuit diagram related to trouble code G00062.............................................................. 933 G00063 - Trouble monitoring hydraulic oil temp.............................................................. 934 G00064 - Trouble monitoring hydraulic oil level............................................................. 935 G00064 - Trouble monitoring hydraulic oil level............................................................. 936 Circuit diagram related to trouble code G00064.............................................................. 937 G00065 - Very low hydraulic oil level....................................................................... 938 G00065 - Very low hydraulic oil level....................................................................... 939 Circuit diagram related to trouble code G00065.............................................................. 940 G00066 - Trouble hydraulic oil temperature.................................................................. 941 G00066 - Trouble hydraulic oil temperature.................................................................. 942 Circuit diagram related to trouble code G00066.............................................................. 943 Hydraulic oil table......................................................................................... 943 G00067 - Trouble battery voltage too high................................................................... 944 Circuit diagram and component location related to trouble code G00067....................................... 945 G00069 - Trouble monitoring oil temp gear (PTO)............................................................. 946 Circuit diagram and component location related to trouble code G00069....................................... 946 G00070 - Trouble oil temperature gear (PTO)................................................................. 947 G00070 - Trouble oil temperature gear (PTO)................................................................. 948 Location of the PTO gear oil level dipstick and temperature sensor B49...................................... 949 G00071 - Trouble gear lubrication (PTO)..................................................................... 950 Circuit diagram related to trouble code G00071.............................................................. 951 G00072 - Trouble monitoring hydraulic oil level............................................................. 952 G00072 - Trouble monitoring hydraulic oil level............................................................. 953 Circuit diagram related to trouble code G00072.............................................................. 954 G00073 - Trouble monitoring remote engine oil level......................................................... 955 G00073 - Trouble monitoring remote engine oil level......................................................... 956 Circuit diagram related to trouble code G00073.............................................................. 957 G00074 - Trouble monitoring grease pressure (central)....................................................... 958 G00075 - Trouble monitoring grease pressure (swing)......................................................... 958 G00074 - Trouble monitoring grease pressure (central)....................................................... 959 G00075 - Trouble monitoring grease pressure (swing)......................................................... 959 Circuit diagram 1 related to trouble code G00074 and G00075................................................. 960 Circuit diagram 2 related to trouble code G00074 and G00075................................................. 961 G00076 - Trouble monitoring pressure suction tank........................................................... 962 G00076 - Trouble monitoring pressure suction tank........................................................... 963 Circuit diagram related to trouble code G00076.............................................................. 964 G00077 - Trouble monitoring grease level (central).......................................................... 965 G00078 - Trouble monitoring grease level (swing)............................................................ 965 G00077 - Trouble monitoring grease level (central).......................................................... 966 G00078 - Trouble monitoring grease level (swing)............................................................ 966 Circuit diagram 1 related to trouble codes G00077 and G00078................................................ 967 Circuit diagram 2 related to trouble codes G00077 and G00078................................................ 968 G00079 - Trouble monitoring pressure oil cooler............................................................. 969 G00079 - Trouble monitoring pressure oil cooler............................................................. 970 Circuit diagram related to trouble code G00079.............................................................. 971 G00080 - Trouble monitoring pressure preload valve.......................................................... 972 G00080 - Trouble monitoring pressure preload valve.......................................................... 973 Circuit diagram related to trouble code G00080.............................................................. 974 G00081 - Trouble lubrication system......................................................................... 975 G00081 - Trouble lubrication system......................................................................... 976 Operation cycles of the lubrication systems................................................................. 976 Circuit diagram 1 related to trouble code G00081............................................................ 977 Circuit diagram 2 related to trouble code G00081............................................................ 978 G00090 (G00099) - Trouble power supply...................................................................... 979 Circuit diagram related to trouble code G00090 (G00099)..................................................... 980 G00091 - Pilot control cut out.............................................................................. 981 G00091 - Pilot control cut out.............................................................................. 982 View onto the lock lever and the cover of switch S105....................................................... 982 G00092 - Emergency shut-down at access ladder............................................................... 983 G00093 - Emergency shut-down at valve block................................................................. 983 G00094 - Emergency shut-down at hydr. control panel......................................................... 983 G00095 - Emergency shut-down in cab......................................................................... 983 Circuit diagram related to trouble code G00092 - G00095..................................................... 984 G00096 - Pilot control cut out.............................................................................. 985 Circuit diagram related to trouble code G00096.............................................................. 986 G00097 - Emergency shut-down at counterweight (option)...................................................... 987 G00098 - Emergency shut-down at radiator (option)........................................................... 987 G00100 - Maintenance safety switch.......................................................................... 988 Circuit diagram related to trouble code G00100.............................................................. 989 G00101 - Faulty switch M7_LD................................................................................ 990 G00101 - Faulty switch M7_LD................................................................................ 991 Circuit diagram 1 related to trouble code G00101............................................................ 992 Circuit diagram 2 related to trouble code G00101............................................................ 993 G00102 - Switch off wiper................................................................................... 994 G00103 - Faulty switch M4_UR................................................................................ 995 G00103 - Faulty switch M4_UR................................................................................ 996 Circuit diagram 1 related to trouble code G00103............................................................ 997 Circuit diagram 2 related to trouble code G00103............................................................ 998 G00104 - Trouble battery current............................................................................ 999 Circuit diagram related to trouble code G00104..............................................................1000 G00105 - Trouble battery charging current too low...........................................................1001 G00140 - Trouble monitoring X1-1 pressure...................................................................1002 G00140 - Trouble monitoring X1-1 pressure...................................................................1003 G00141 - Trouble monitoring X2 pressure.....................................................................1004 G00141 - Trouble monitoring X2 pressure.....................................................................1005 Circuit diagram for the X2 pressure sensor B86..............................................................1006 G00143 - Trouble monitoring pump 1..........................................................................1007 G00144 - Trouble monitoring pump 2..........................................................................1007 G00145 - Trouble monitoring pump 3..........................................................................1007 G00146 - Trouble monitoring pump 4..........................................................................1007 G00143 - Trouble monitoring pump 1..........................................................................1008 G00144 - Trouble monitoring pump 2..........................................................................1008 G00145 - Trouble monitoring pump 3..........................................................................1008 G00146 - Trouble monitoring pump 4..........................................................................1008 Circuit diagram related to trouble codes G00143 - G00146....................................................1009 G00147 - Trouble monitoring gear lubrication (PTO)..........................................................1010 G00147 - Trouble monitoring gear lubrication (PTO)..........................................................1011 Circuit diagram related to trouble code G00147..............................................................1012 G00148 - Trouble monitoring fuel level......................................................................1013 G00148 - Trouble monitoring fuel level......................................................................1014 Circuit diagram and component location (B63)................................................................1015 G00149 - Trouble monitoring ambient temperature.............................................................1016 G00151 - Trouble monitoring gear (PTO) oil filter...........................................................1017 G00151 - Trouble monitoring gear (PTO) oil filter...........................................................1018 Circuit diagram related to trouble code G00151..............................................................1019 G00153 - Trouble monitoring oil filter pump control.........................................................1020 G00153 - Trouble monitoring oil filter pump control.........................................................1021 Circuit diagram related to trouble code G00153..............................................................1022 G00154 - Trouble monitoring return oil filter...............................................................1023 G00154 - Trouble monitoring return oil filter...............................................................1024 Circuit diagram related to trouble code G00154..............................................................1025 G00155 - Trouble monitoring leak oil filter.................................................................1026 G00155 - Trouble monitoring leak oil filter.................................................................1027 Circuit diagram related to trouble code G00155..............................................................1028 G00157 - Trouble monitoring oil filter radiator.............................................................1029 G00157 - Trouble monitoring oil filter radiator.............................................................1030 Circuit diagram related to trouble code G00157..............................................................1031 G00158 - Trouble monitoring oil filter fan drive oil cooler.................................................1032 G00158 - Trouble monitoring oil filter fan drive oil cooler.................................................1033 Circuit diagram related to trouble code G00158..............................................................1034 G00159 - Trouble monitoring breather filter.................................................................1035 G00158 - Trouble monitoring oil filter fan drive oil cooler.................................................1036 Circuit diagram related to trouble code G00159..............................................................1037 G00160 - Trouble monitoring engine air cleaner..............................................................1038 G00158 - Trouble monitoring engine air cleaner..............................................................1039 Circuit diagram related to trouble code G00160..............................................................1040 G00161 - Trouble monitoring battery voltage.................................................................1041 G00161 - Trouble monitoring battery voltage.................................................................1042 Circuit diagram and component location related to trouble code G00161.......................................1043 G00162 - Trouble monitoring charging-/discharging current...................................................1044 G00162 - Trouble monitoring charging-/discharging current...................................................1045 Circuit diagram related to trouble code G00162..............................................................1046 G00163 - Trouble monitoring pilot control...................................................................1047 G00163 - Trouble monitoring pilot control...................................................................1048 G00163 - Trouble monitoring pilot control...................................................................1049 View onto extracts from wiring diagrams for the time relay D32..............................................1049 View onto extracts from wiring diagrams for the time relay D32..............................................1050 G00164 - Trouble air cleaner................................................................................1051 View onto the engine air cleaner............................................................................1052 G00165 - Trouble breather filter hydraulic oil tank.........................................................1053 Label showing temperature information and defined positions.................................................1054 G00166 - Trouble oil filter gear (PTO)......................................................................1055 Trouble code G00166 - view onto the PTO gear oil filter with pressure sensor B27-1..........................1056 G00168 - Trouble oil filter pump control....................................................................1057 View onto the oil filter for X4 pressure with pressure sensor B22...........................................1058 G00169 - Trouble return oil filter hydraulic oil tank.......................................................1059 G00170 - Trouble leak oil filter hydraulic oil tank.........................................................1060 G00171 - Trouble oil filter fan drive oil cooler............................................................1061 View onto the oil filter 34.1 (oil cooler fan) & pressure sensor B28-1......................................1062 G00172 - Trouble oil filter fan drive radiator..............................................................1063 View onto the oil filter 34.2 (coolant cooler fan) & pressure sensor B21-1..................................1064 G00173 - Trouble monitoring swing gear house brake..........................................................1065 G00173 - Trouble monitoring swing gear house brake..........................................................1066 Circuit and hydraulic diagram related to trouble code G00173................................................1067 G00174 - Trouble monitoring travel gear house brake.........................................................1068 G00174 - Trouble monitoring travel gear house brake.........................................................1069 Circuit and hydraulic diagram related to trouble code G00174................................................1070 G00175 - Trouble travel gear house brake....................................................................1071 Location of Y16 and circuit diagram of pressure sensor B48..................................................1072 G00176 - Trouble battery voltage............................................................................1073 Alternator 3G5-1, shunt resistor R3, and batteries G1-G4 & G8-G9............................................1074 G00177 - Trouble battery charging circuit...................................................................1075 G00178 - Trouble battery charging current to high...........................................................1076 G00179 - Trouble control pressure X1........................................................................1077 View onto the valve and filter plate........................................................................1078 G00180 - Trouble pilot pressure X2 too low..................................................................1079 View onto the valve and filter plate with X2 pressure sensor B86 & M1.2.....................................1080 G00181 - Trouble pilot pressure X2 too high.................................................................1081 View onto the valve and filter plate with X2 pressure sensor B86 & M1.2.....................................1082 G00184 - Central lubrication system empty...................................................................1083 G00187 - Swing gear lubrication system empty................................................................1083 G00185 - Trouble central lubrication system.................................................................1084 G00188 - Trouble swing gear lubrication system..............................................................1084 G00185 - Trouble central lubrication system.................................................................1085 G00188 - Trouble swing gear lubrication system..............................................................1085 Trouble codes G00185 and G00188 - view onto the vent valve..................................................1086 Allocation of vent valves and end-of-line switches..........................................................1087 Circuit diagram related to trouble codes G00185 and G00188..................................................1087 G00186 - Trouble central lubrication system.................................................................1088 G00189 - Trouble swing gear lubrication system..............................................................1088 Allocation of the vent valves...............................................................................1088 Time diagram for the operation cycles of the lubrication systems CLS and SLS................................1089 Trouble codes G00186 and G00189 - view onto the vent valve..................................................1089 G00207 - Engine remote oil tank empty.......................................................................1090 G00240 - Trouble hydraulic oil temperature..................................................................1091 G00242 - Engine already running.............................................................................1092 G00243 - Fill up fuel tank..................................................................................1093 G00245 - Engine shutdown from ground........................................................................1094 Circuit diagrams related to trouble code G00245.............................................................1095 G00246 - Hydraulic oil temperature..........................................................................1096 G00247 - Swing gear house break.............................................................................1097 G00251 - VHMS is by-passed..................................................................................1098 G00252 - Emergency shut-down at access ladder...............................................................1099 G00253 - Emergency shut-down at valve block.................................................................1099 G00254 - Emergency shut-down at hydraulic control panel.....................................................1099 G00255 - Emergency shut-down in cab.........................................................................1099 Circuit diagram related to trouble code G00252 - G00255.....................................................1100 G00256 - Operator warning system............................................................................1101 Circuit diagram related to trouble code G00256..............................................................1101 G00257 - Hydraulic oil temperature..........................................................................1102 G00258 - Emergency shut-down at counterweight (option)......................................................1103 G00259 - Emergency shut-down at radiator (option)...........................................................1103 G00261 - Maintenance safety switch..........................................................................1104 Circuit diagram related to trouble code G00261..............................................................1105 G00262 - Trouble screen at hydraulic cooler entry clogged...................................................1106 View onto the hydraulic oil strainer in the collector pipe..................................................1107 G00417 - Communication failure PLC <=> VHMS controller......................................................1108 CAN bus harness and ports between PLC and VHMS controller...................................................1108 G00420 - Connector sel error................................................................................1109 G00421 - Farm sys error.....................................................................................1110 G00422 - Can-net sys (J1939)................................................................................1111 G00423 - Application sys error..............................................................................1112 G00425 - Settings impossible to take over into the PLC......................................................1113 Overview for G00425: Display (MH801) → VHMS controller → PLC................................................1114 G00491 - Communication failure MH801 - VHMS Controller......................................................1115 Overview for G00491: Display (MH801) → VHMS controller......................................................1116 Remaining troublecodes which are not used...................................................................1117 Part V..................................................................................................1119 Troubleshooting by symptoms.....................................................................................1119 Symptoms of the engine and related electrical system........................................................1119 SEL001 - Engine does not start (engine does not rotate).....................................................1119 SEL001 - Engine does not start (engine does not rotate).....................................................1120 Circuit diagram 1 related to trouble code SEL001............................................................1121 Circuit diagram 2 related to trouble code SEL001............................................................1122 SEL002 - Engine stops while in operation....................................................................1123 SEL002 - Engine stops while in operation....................................................................1124 View onto the fuel system water separator...................................................................1125 SEL003 - Engine speed is hunting during boom-up movement....................................................1126 SEL004 - Engine does not stop...............................................................................1127 SEL005 - Engine lacks output (no power).....................................................................1128 SEL005 - Engine lacks output (no power).....................................................................1129 SEL006 - Exhaust smoke is black.............................................................................1130 SEL006 - Exhaust smoke is black.............................................................................1131 SEL007 - Oil consumption is excessive.......................................................................1132 SEL007 - Oil consumption is excessive.......................................................................1133 SEL008 - Oil becomes contaminated quickly...................................................................1134 SEL008 - Oil becomes contaminated quickly...................................................................1135 SEL009 - Fuel consumption is excessive......................................................................1136 SEL009 - Fuel consumption is excessive......................................................................1137 SEL010 - Oil is in engine coolant...........................................................................1138 SEL010 - Oil is in engine coolant...........................................................................1139 SEL011 - Oil level rises....................................................................................1140 SEL011 - Oil level rises....................................................................................1141 SEL012 - Coolant temperature becomes too high (overheating).................................................1142 SEL012 - Coolant temperature becomes too high (overheating).................................................1143 Symptoms of the hydraulic system............................................................................1144 SHY001 - All the work equipment shows lack of power or slow movement (especially the "boom up" function)....1144 SHY001 - All the work equipment shows lack of power or slow.................................................1145 movement (especially the "boom up" function)................................................................1145 SHY002 - Engine speed sharply drops or engine stalls too much...............................................1515 SHY002 - Engine speed sharply drops or engine stalls too much...............................................1147 SHY003 - No work equipment, travel or swing movement........................................................1148 SHY004 - Work equipment has too much hydraulic drift........................................................1149 SHY004 - Work equipment has too much hydraulic drift........................................................1150 SHY005 - Work equipment has big time lag....................................................................1151 SHY006 - Machine deviates during travel movement............................................................1152 SHY007 - Hydraulic system has lack of power (energy efficiency).............................................1153 SHY007 - Hydraulic system has lack of power (energy efficiency).............................................1154 SHY008 - Machine does not swing.............................................................................1155 SHY009 - Swing acceleration is poor.........................................................................1156 SHY009 - Swing acceleration is poor.........................................................................1157 SHY010 - Excessive overrun when stopping swing..............................................................1158 SHY010 - Excessive overrun when stopping swing..............................................................1159 SHY011 - Floating system without function...................................................................1160 SHY012 - Abnormal noise coming from SRV or MRV..............................................................1161 SHY013 - Track tensioning system without function...........................................................1162 SHY014 - Ladder does not move, or slow movement.............................................................1163 SHY014 - Ladder does not move, or slow movement.............................................................1164 SHY015 - Refilling arm does not move, or slow movement......................................................1165 SHY016 - The hydraulic driven grease pump does not move.....................................................1166 SHY017 - Trouble pump bearing lubrication...................................................................1167 SHY018 - Abnormal track chain movement during digging.......................................................1168 SHY019 - Swing parking brake without function...............................................................1169 SHY020 - Travel parking brake without function..............................................................1170 Symptoms of the mechanical system...........................................................................1171 SME001 - Abnormal noise is made.............................................................................1171 SME001 - Abnormal noise is made.............................................................................1172 SME002 - Abnormal noise around the PTO / hydraulic pumps....................................................1173 SME002 - Abnormal noise around the PTO / hydraulic pumps....................................................1174 SME003 - Vibration is excessive (engine mountings)..........................................................1175 SME003 - Vibration is excessive (engine mountings)..........................................................1176 SME004 - Vibration is excessive (engine torsion)............................................................1177 SME005 - There is a big shock when stopping swing...........................................................1178 SME006 - There is a big abnormal noise when moving/stopping swing...........................................1179 SME006 - There is a big abnormal noise when moving/stopping swing...........................................1180 SME007 - Fan hub bearing noise is abnormal..................................................................1181 SME008 - Abnormal noise coming from a travel gearbox........................................................1182 SME008 - Abnormal noise coming from a travel gearbox........................................................1183 SME009 - Abnormal noise coming from the work equipment (lack of grease).....................................1184 SME009 - Abnormal noise coming from the work equipment (lack of grease).....................................1185 SME010 - Abnormal idler movement............................................................................1186 SME011 - Leak at the PTO shaft seal.........................................................................1187 SME011 - Leak at the PTO shaft seal.........................................................................1188 Symptoms of additional systems..............................................................................1189 SAD001 - Air conditioner does not work......................................................................1189 View onto the AC unit.......................................................................................1190 SAD002 - Air conditioner compressor clutch is burnt.........................................................1191 SAD002 - Air conditioner compressor clutch is burnt.........................................................1192 View onto the AC compressor and its mounting................................................................1192 SAD003 - Air conditioning system defective (pipes and hoses full of moister)................................1193 SAD004 - Travel alarm does not sound........................................................................1194 Wiring diagram for trouble code SAD004......................................................................1195 50 Disassembly and Assembly.........................................................................................1197 1. Introduction.................................................................................................1209 1.1 Contents of the binder..................................................................................1210 1.2 Foreword................................................................................................1211 1.2.1 Service...........................................................................................1212 2. Safety.......................................................................................................1213 2.1 Safety Instructions.....................................................................................1214 2.1.1 Method of using this manual.......................................................................1214 2.1.2 General precautions...............................................................................1216 2.1.3 Preparations for work.............................................................................1217 2.1.4 Precautions during work...........................................................................1218 2.1.5 WARNING OF SPECIAL DANGERS........................................................................1220 2.1.5.1 ELECTRICal ENERGY...........................................................................1220 2.1.5.2 GAS, DUST, STEAM AND SMOKE..................................................................1221 2.1.5.3 HYDRAULIC, AIR CONDITIONING AND PNEUMATIC EQUIPMENT.........................................1222 2.1.5.4 NOISE.......................................................................................1222 2.1.5.5 Heat........................................................................................1223 2.1.5.6 OIL, GREASE AND OTHER CHEMICAL SUBSTANCES...................................................1223 2.1.5.7 Height......................................................................................1223 2.1.6 SPECIAL SAFETY EQUIPMENT..........................................................................1225 2.1.6.1 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)................................1225 2.1.6.2 INSTRUCTIONS FOR USE........................................................................1227 2.1.6.3 RECOMMENDATIONS FOR USE OF THE HOLDING HOOKS AND HOLD-BACK HOOKS OF THE SAFETY HARNESS......1229 2.1.6.4 INSTRUCTIONS FOR USE........................................................................1231 2.2 Lifting Gears...........................................................................................1232 2.2.1 Wire ropes........................................................................................1232 2.2.2 Sling accessory...................................................................................1234 2.2.3 Weight tables.....................................................................................1235 2.2.3.1 Superstructure..............................................................................1235 2.2.3.2 Undercarriage...............................................................................1237 2.2.3.3 Backhoe AttachmenT (BHA)....................................................................1238 2.2.3.4 Faceshovel Attachment (FSA).................................................................1239 2.3 Torque charts according to DIN..........................................................................1241 2.3.1 Metric standard thread............................................................................1241 2.3.2 Metric fine thread................................................................................1242 2.3.3 Cummins motor torques - metric....................................................................1243 2.3.4 Cummins motor torques - U.S. Customary............................................................1243 2.3.5 Flange connections................................................................................1244 2.4 Conversation table......................................................................................1245 2.4.1 Method of using the conversation table............................................................1245 2.4.2 Millimeter - Inch & Kilogram - Pound..............................................................1246 2.4.3 Liter - U.S. Gallon & Liter - U.K. Gallon.........................................................1247 2.4.4 KGm - ft.lb.......................................................................................1248 2.4.5 bar - PSI / PSI - bar.............................................................................1249 2.4.6 Basic Values in Ohm according to DIN 43 76........................................................1250 2.4.7 Temperature.......................................................................................1251 2.5 Explanation of abbreviations............................................................................1252 3. Superstructure...............................................................................................1253 3.1 Diesel Engine...........................................................................................1254 3.1.1 Removal of the Diesel engine......................................................................1254 3.1.2 Replacement of the Diesel engine..................................................................1261 3.1.3 Engine torque support and engine/PTO mounts.......................................................1264 3.1.3.1 Flexible mounts.............................................................................1265 3.1.3.2 Torque support..............................................................................1267 3.1.4 Alternator........................................................................................1268 3.1.4.1 Removal of the alternator...................................................................1268 3.1.4.2 Replacement of the alternator...............................................................1269 3.1.5 Batteries.........................................................................................1270 3.1.5.1 Removal of the batteries....................................................................1270 3.1.5.2 Replacement of the batteries................................................................1272 3.1.6 Radiator fan......................................................................................1274 3.1.6.1 Removal of the radiator fan assembly........................................................1275 3.1.6.2 Replacement of the radiator fan assembly....................................................1279 3.1.6.3 Removal of the radiator fan.................................................................1281 3.1.6.4 Replacement of the radiator fan.............................................................1281 3.1.6.5 Removal of the radiator fan drive pump......................................................1282 3.1.6.6 Replacement of the radiator fan drive pump..................................................1284 3.1.7 Radiators.........................................................................................1285 3.1.7.1 Removal of the Radiator assembly............................................................1285 3.1.7.2 Replacement of the radiator assembly........................................................1289 3.1.8 Fuel cooler.......................................................................................1290 3.1.8.1 Removal of the fuel cooler..................................................................1290 3.1.8.2 Replacement of the fuel cooler..............................................................1292 3.1.9 Starter system....................................................................................1293 3.1.9.1 Removal of the starter motor................................................................1293 3.1.9.2 Replacement of the starter motor............................................................1293 3.1.10 Geislinger coupling..............................................................................1294 3.1.10.1 Removal of the Geislinger coupling.........................................................1295 3.1.10.2 Replacement of the Geislinger coupling.....................................................1297 3.2 PTO.....................................................................................................1298 3.2.1 Main pumps........................................................................................1298 3.2.1.1 Preparatory works for main pump removal.....................................................1299 3.2.1.2 Removal of Main Pump 1......................................................................1302 3.2.1.3 Replacement of main pump 1..................................................................1303 3.2.1.4 Removal of Main Pump 2......................................................................1305 3.2.1.5 Replacement of main pump 2..................................................................1307 3.2.1.6 Removal of Main Pump 3......................................................................1309 3.2.1.7 Replacement of main pump 3..................................................................1311 3.2.1.8 Removal of Main Pump 4......................................................................1312 3.2.1.9 Replacement of main pump 4..................................................................1314 3.2.2 PTO oil circulation pump (auxiliary pump).........................................................1315 3.2.2.1 Removal of the oil circulation pump (auxiliary pump)........................................1315 3.2.2.2 Replacement of the oil circulation pump (auxiliary pump)....................................1317 3.2.3 Pump distributor gearbox (PTO)....................................................................1318 3.2.3.1 Removal of the Pump distributor gearbox (PTO)...............................................1320 3.2.3.2 Replacement of the Pump distributor gearbox (PTO)...........................................1323 3.3 Hydraulics..............................................................................................1324 3.3.1 Hydraulic cooler fan Drive Pump...................................................................1324 3.3.1.1 Removal of the hydraulic cooler fan drive pump..............................................1324 3.3.1.2 Replacement of the hydraulic cooler fan drive pump..........................................1327 3.3.2 Hydraulic Cooler Fan Assembly.....................................................................1328 3.3.2.1 Removal of hydraulic cooler fan assembly....................................................1328 3.3.2.2 Replacement of hydraulic cooler fan assembly................................................1331 3.3.2.3 Removal of hydraulic cooler Fan and motor...................................................1332 3.3.2.4 Replacement of hydraulic cooler Fan and motor...............................................1334 3.3.3 Hydraulic Oil Coolers.............................................................................1336 3.3.3.1 Removal of the hydraulic oil coolers........................................................1338 3.3.3.2 Replacement of the hydraulic oil coolers....................................................1342 3.3.3.3 Removal of the hydraulic oil cooler frame...................................................1344 3.3.3.4 Replacement of the hydraulic oil cooler frame...............................................1349 3.3.4 Main Relief Valves (MRV)..........................................................................1350 3.3.4.1 Removal of the MRV..........................................................................1350 3.3.4.2 Replacement of the MRV......................................................................1351 3.3.5 pilot oil pump (Gear pump)........................................................................1352 3.3.5.1 Removal of the pilot oil pump)..............................................................1352 3.3.5.2 Replacement of the pilot oil pump...........................................................1354 3.3.6 Main Gate Valve...................................................................................1354 3.3.6.1 Removal of the main gate valve..............................................................1355 3.3.6.2 Replacement of the main gate valve..........................................................1356 3.3.7 Hydraulic Oil Reservoir...........................................................................1358 3.3.7.1 Removal of the hydraulic oil reservoir......................................................1360 3.3.7.2 Replacement of the hydraulic oil reservoir..................................................1367 3.3.8 Main Control Valve Blocks.........................................................................1369 3.3.8.1 Removal of the main control valve blocks....................................................1378 3.3.8.2 Replacement of the main control valve blocks................................................1382 3.3.9 Service line Relief Valves (SRV)..................................................................1383 3.3.9.1 Removal of SRV on main Control valve block..................................................1383 3.3.9.2 Replacement of SRV on main control valve blocks.............................................1386 3.3.10 Anti-cavitation Valves (ACV).....................................................................1388 3.3.10.1 Removal of ACV on Manifold.................................................................1389 3.3.10.2 Replacement of ACV on Manifold.............................................................1394 3.3.10.3 Removal of ACV on main control valve blocks................................................1395 3.3.10.4 Replacement of ACV on main control valve blocks............................................1397 3.3.11 Throttle check valves............................................................................1398 3.3.11.1 Removal of throttle check valves...........................................................1400 3.3.11.2 Replacement of throttle check valves.......................................................1403 3.3.12 manifold.........................................................................................1404 3.3.12.1 Removal of the manifold....................................................................1404 3.3.12.2 Replacement of the manifold................................................................1406 3.3.12.3 Removal of the Diffuser on the Manifold (FSA only).........................................1407 3.3.12.4 Replacement of Diffuser on Manifold (FSA only).............................................1409 3.4 Slew Drive..............................................................................................1411 3.4.1 Slew Gear.........................................................................................1412 3.4.1.1 Removal of the slew gear....................................................................1413 3.4.1.2 Replacement of the slew gear................................................................1415 3.4.2 Swing Motor.......................................................................................1418 3.4.2.1 Removal of the swing motor..................................................................1419 3.4.2.2 Replacement of the swing motor..............................................................1422 3.4.3 Slew parking brake................................................................................1425 3.4.3.1 Removal/Disassembly of the slew parking brake...............................................1427 3.4.3.2 Replacement/assembly of the slew parking brake..............................................1430 3.4.4 Dynamic Slew Brake................................................................................1432 3.4.4.1 Removal of the slew brake valve.............................................................1435 3.4.4.2 Replacement of the slew brake valve.........................................................1437 3.4.5 Swing circle lubrication pinion (dummy wheel).....................................................1438 3.4.5.1 Removal of the lubrication pinion assembly..................................................1440 3.4.5.2 Replacement of the lubrication pinion assembly..............................................1442 3.5 Lubrication pumps.......................................................................................1443 3.5.1 Removal of the Lubrication pump...................................................................1443 3.5.2 Replacement of the lubricating pump...............................................................1445 3.6 Pump controller MC7.....................................................................................1446 3.6.1 Removal of the pump controller MC7................................................................1446 3.6.2 Replacement of the pump controller MC7............................................................1447 3.7 Operator’s Cab..........................................................................................1448 3.7.1 Removal of the operator’s cab.....................................................................1451 3.7.2 Replacement of the operator’s cab.................................................................1456 3.7.3 Cab-mounts........................................................................................1457 3.7.3.1 Removal of the cab-mounts...................................................................1457 3.7.3.2 replacement of the cab-mounts...............................................................1459 3.7.4 FRONT WINDOW......................................................................................1460 3.7.4.1 Removal of the Front window.................................................................1460 3.7.4.2 Replacement of the front window.............................................................1461 3.7.5 Operator’s seat...................................................................................1462 3.7.5.1 Removal of the operator’s seat..............................................................1462 3.7.5.2 Replacement of the operator’s seat..........................................................1463 3.7.6 VHMS..............................................................................................1464 3.7.6.1 Removal of the VHMS-Controller..............................................................1464 3.7.6.2 Replacement of the VHMS-Controller..........................................................1465 3.7.7 Access Ladder.....................................................................................1466 3.7.7.1 Removal of the access Ladder................................................................1469 3.7.7.2 Replacement of the access ladder............................................................1471 3.7.7.3 Removal of the access ladder cylinder.......................................................1473 3.7.7.4 Replacement of the access ladder cylinder...................................................1475 3.7.8 Removal of the cab base...........................................................................1476 3.7.9 Replacement of the cab base.......................................................................1478 3.8 Counterweight...........................................................................................1480 3.8.1 Removal of the counterweight......................................................................1481 3.8.2 Replacement of the counterweight..................................................................1483 3.9 Superstructure Lifting..................................................................................1484 3.9.1 Remove the Superstructure from the Undercarriage..................................................1484 3.9.2 Install the Superstructure onto the undercarriage.................................................1487 3.10 Fuel Tank..............................................................................................1490 3.10.1 Removal of the Fuel tank.........................................................................1491 3.10.2 Replacement of the Fuel tank.....................................................................1494 4. Undercarriage................................................................................................1497 4.1 Travel System...........................................................................................1498 4.1.1 Track group.......................................................................................1498 4.1.1.1 Changing of the track group.................................................................1498 4.1.2 Sprocket..........................................................................................1502 4.1.2.1 Removal of the sprocket.....................................................................1502 4.1.2.2 Replacement of the sprocket.................................................................1506 4.1.3 Guide wheels......................................................................................1508 4.1.3.1 Removal of the guide wheel assembly.........................................................1508 4.1.3.2 Replacement of the guide wheel assembly.....................................................1509 4.1.4 Track tensioning accumulators.....................................................................1510 4.1.4.1 Removal of the low pressure accumulators....................................................1510 4.1.4.2 Replacement of the low pressure accumulators................................................1512 4.1.4.3 Removal of the high pressure accumulators...................................................1513 4.1.4.4 Replacement of the high pressure accumulators...............................................1514 4.1.5 Track tension valve block.........................................................................1515 4.1.5.1 Removal of the track tensioning valve block.................................................1515 4.1.5.2 Replacement of the track tensioning valve block.............................................1516 4.1.6 Hydraulic hoses of the track tensioning system....................................................1517 4.1.6.1 Substitute the hydraulic hoses..............................................................1517 4.1.7 Travel brake valve block (overspeed valve)........................................................1520 4.1.7.1 Removal of the travel brake valve block.....................................................1521 4.1.7.2 Replacement of the travel brake valve block.................................................1523 4.1.8 Track tensioning cylinders........................................................................1524 4.1.8.1 Removal of the track tensioning cylinders...................................................1524 4.1.8.2 Replacement of the track tensioning cylinders...............................................1525 4.1.9 Travel motor......................................................................................1526 4.1.9.1 Removal of the travel motors................................................................1526 4.1.9.2 Replacement of the travel motors............................................................1528 4.1.10 travel parking brake.............................................................................1530 4.1.10.1 Removal/disassembly of the travel parking brake............................................1533 4.1.10.2 Replacement/assembly of the travel parking brake...........................................1536 4.1.11 Travel gearbox...................................................................................1538 4.1.11.1 Removal of the travel gearbox..............................................................1539 4.1.11.2 Replacement of the travel gearbox..........................................................1541 4.1.12 Carrier roller...................................................................................1542 4.1.12.1 Removal of the carrier roller assembly.....................................................1542 4.1.12.2 Replacement of the carrier roller assembly.................................................1544 4.1.13 Track roller.....................................................................................1545 4.1.13.1 Removal of the Track roller assembly.......................................................1545 4.1.13.2 Replacement of the Track roller assembly...................................................1547 4.2 Car body................................................................................................1548 4.2.1 Removal of the car bodY (previous type with mounting pins)........................................1548 4.2.2 Replacement of the car bodY (previous type with mounting pins)....................................1552 4.2.3 Removal OF the car Body (NEW type with bolted connection).........................................1556 4.2.4 Replacement of the car body (NEW type with bolted connection).....................................1561 4.2.4.1 Tightening torque for the crawler carrier mounting bolts....................................1566 4.2.5 Rotary joint......................................................................................1570 4.2.5.1 Removal of the rotary joint.................................................................1572 4.2.5.2 Replacement of the rotary joint.............................................................1575 4.2.6 swing circle......................................................................................1576 4.2.6.1 Removal of the swing circle.................................................................1578 4.2.6.2 Replacement of the swing circle.............................................................1580 5. Attachment...................................................................................................1585 5.1 Backhoe.................................................................................................1586 5.1.1 Boom..............................................................................................1588 5.1.1.1 Removal of the Boom.........................................................................1588 5.1.1.2 Replacement of the boom.....................................................................1592 5.1.1.3 Removal of boom cylinders...................................................................1594 5.1.1.4 Replacement of boom cylinders...............................................................1599 5.1.2 Stick.............................................................................................1602 5.1.2.1 Removal of the Stick........................................................................1602 5.1.2.2 Replacement of Stick........................................................................1606 5.1.2.3 Removal of Stick Cylinders..................................................................1608 5.1.2.4 Replacement of Stick cylinders..............................................................1613 5.1.3 Bucket............................................................................................1616 5.1.3.1 Removal of the bucket.......................................................................1616 5.1.3.2 Replacement of the bucket...................................................................1619 5.1.3.3 Removal of Bucket Cylinders.................................................................1620 5.1.3.4 Replacement of Bucket Cylinders.............................................................1625 5.1.4 Bucket link rod and steering rods.................................................................1627 5.1.4.1 Removal of the bucket link rod..............................................................1627 5.1.4.2 Replacement of the bucket link rod..........................................................1629 5.1.4.3 Removal of the steering rods................................................................1630 5.1.4.4 Replacement of the steering rods............................................................1633 5.1.5 Ground engaging tools (GET).......................................................................1634 5.1.5.1 Removal and replacement of the GET..........................................................1634 5.1.6 Hydraulic hoses at the backhoe attachment.........................................................1636 5.1.6.1 Substitute the boom arc hoses...............................................................1636 5.1.6.2 Substitute the boom cylinder hoses..........................................................1640 5.1.6.3 Substitute the stick cylinder hoses.........................................................1644 5.1.6.4 Substitute the bucket cylinder hoses........................................................1648 5.2 Faceshovel..............................................................................................1653 5.2.1 Boom..............................................................................................1654 5.2.1.1 Removal of the boom.........................................................................1654 5.2.1.2 Replacement of the boom.....................................................................1659 5.2.1.3 Removal of the boom cylinders...............................................................1664 5.2.1.4 Replacement of the boom cylinders...........................................................1669 5.2.2 Stick.............................................................................................1672 5.2.2.1 Removal of the stick........................................................................1672 5.2.2.2 Replacement of the stick....................................................................1676 5.2.2.3 Removal of the stick cylinders..............................................................1678 5.2.2.4 Replacement of the stick cylinders..........................................................1683 5.2.3 Bullclam bucket...................................................................................1686 5.2.3.1 Removal of the bull clam bucket.............................................................1686 5.2.3.2 Replacement of the bull clam bucket.........................................................1692 5.2.3.3 Removal of the bucket cylinders.............................................................1694 5.2.3.4 Replacement of the bucket cylinders.........................................................1698 5.2.3.5 Removal of the clam cylinders...............................................................1702 5.2.3.6 Replacement of the clam cylinders...........................................................1706 5.2.4 Ground engaging tools (GET).......................................................................1708 5.2.4.1 Removal and replacement of the GET..........................................................1708 5.2.5 Hydraulic hoses at the Faceshovel attachment......................................................1710 5.2.5.1 Substitute the boom arc hoses...............................................................1710 5.2.5.2 Substitute the boom cylinder hoses..........................................................1714 5.2.5.3 Substitute the stick arc hoses..............................................................1718 5.2.5.4 Substitute the stick cylinder hoses.........................................................1722 5.2.5.5 Substitute the bucket cylinder hoses........................................................1726 5.2.5.6 Substitute the clam cylinder hoses..........................................................1730 5.3 Metering valves (grease injectors) at the attachment....................................................1738 5.3.1 Removal of the metering valves (grease injectors).................................................1738 5.3.2 Replacement of the metering valves (grease injectors).............................................1739 5.4 Cylinder bypass test....................................................................................1740 6. Appendix.....................................................................................................1743 6.1 Fuel and Lubricants.....................................................................................1744 6.2 Filling Capacities......................................................................................1746 6.3 Tools List..............................................................................................1748 6.3.1 Used special tools (Overview).....................................................................1748 6.3.2 KOMATSU tools catalogue...........................................................................1751 6.4 Work instructions.......................................................................................1798 6.4.1 Remove / install the crawler carrier..............................................................1798 6.4.2 Use of the hydraulic torque wrench (supplier’s documentation).....................................1799 6.5 Service Bulletins.......................................................................................1827 6.5.1 AH00511d..........................................................................................1829 6.5.2 AH00514...........................................................................................1851 6.5.3 AH00519...........................................................................................1865 6.5.4 AH01512...........................................................................................1871 6.5.5 AH01521a..........................................................................................1881 6.5.6 AH01531A..........................................................................................1893 6.5.7 AH02513b..........................................................................................1905 6.5.8 AH02521...........................................................................................1911 6.5.9 AH03506B..........................................................................................1919 6.5.10 AH03509a.........................................................................................1927 6.5.11 AH03510..........................................................................................1955 6.5.12 AH03526a.........................................................................................1975 6.5.13 AH03538..........................................................................................1979 6.5.14 AH04518..........................................................................................2007 6.5.15 AH05510..........................................................................................2011 6.5.16 AH05511..........................................................................................2015 6.5.17 AH05546..........................................................................................2021 6.5.18 AH06524..........................................................................................2025 6.5.19 AH06530..........................................................................................2029
DESCRIPTION:
KOMATSU PC4000-6 DIESEL HYDRAULIC EXCAVATOR SHOP MANUAL SHOP0608175-08197 – PDF DOWNLOAD
Observe the instructions in these manuals for:
Your Personal SAFETY
Operating SAFETY, and
READY and EFFICIENT PERFORMANCE of your KOMATSU Hydraulic Mining Shovel.
With this SERVICE MANUAL KOMATSU provides you with the description of the construction and the function of
the major systems of the Hydraulic Excavator PC 4000-6 D.
We describe you all significant, functions and how to carry out the inspections and adjustments.
How do you find “your” desired information?
In the TABLE OF CONTENT all the functions and components are shown in their sequence of the description.
Periodic preventive inspections and maintenance are the surest means of keeping the machine in proper working order. Prompt detection and correction of minor irregularities, and immediate replacement of worn out or broken parts will prevent failures and avoid expenses.
Replace damaged graphics and symbols.
Observe safety precautions to prevent injury and damage.
If after reading this SERVICE MANUAL you can give us suggestions and comments for improvements – please do not hesitate to contact us.
With this SERVICE MANUAL KOMATSU provides you with the description of the construction and the function of
the major systems of the Hydraulic Excavator PC 4000-6 D.
We describe you all significant, functions and how to carry out the inspections and adjustments.
How do you find “your” desired information?
In the TABLE OF CONTENT all the functions and components are shown in their sequence of the description.
Periodic preventive inspections and maintenance are the surest means of keeping the machine in proper working order. Prompt detection and correction of minor irregularities, and immediate replacement of worn out or broken parts will prevent failures and avoid expenses.
Replace damaged graphics and symbols.
Observe safety precautions to prevent injury and damage.
If after reading this SERVICE MANUAL you can give us suggestions and comments for improvements – please do not hesitate to contact us.
S.S 24/12/24
