KOMATSU PC4000-6 EXCAVATOR HYDRAULIC MINING SHOVEL SHOP MANUAL 8170 – PDF DOWNLOAD

Description

KOMATSU PC4000-6 EXCAVATOR HYDRAULIC MINING SHOVEL SHOP MANUAL 8170 – PDF DOWNLOAD

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

KOMATSU PC4000-6 EXCAVATOR HYDRAULIC MINING SHOVEL SHOP MANUAL 8170 – PDF DOWNLOAD

GENERAL PRECAUTIONS:

• If welding repairs are needed, always have a trained, experienced welder carry out the
  work. When carrying out welding work, always wear welding gloves, apron, glasses, cap
  and other clothes suited for welding work.
• When carrying out any operation with two or more workers, always agree on the
  operating procedure before starting. Always inform your fellow workers before starting
  any step of the operation. Before starting work, hang UNDER REPAIR signs on the
  controls in the operator’s compartment.
• Keep all tools in good condition and learn the correct way to use them.
  Decide a place in the repair workshop to keep tools and removed parts. Always keep the
  tools and parts in their correct places. Always keep the work area clean and make sure
  that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking.
  Never smoke while working.

TABLE OF CONTENTS:

KOMATSU PC4000-6 EXCAVATOR HYDRAULIC MINING SHOVEL SHOP MANUAL 8170 – PDF DOWNLOAD

MAIN MENU 0
COVER 1
CONTENTS 3
TABLE OF CONTENTS 3
SAFETY 4
FOREWARD 7
HOISTING INSTRUCTIONS 8
STANDARD TIGHTENING TORQUE 10
CONVERSION TABLE 11
1 0 MAIN ASSEMBLY GROUPS 18
1 0 MAIN ASSEMBLY GROUPS – GENERAL LAY OUT 20
1 GENERAL LAY OUT – LEGEND FOR ILLUSTRATION\ 20
1 1 SUPERSTRUCTURE – LEGEND FOR ILLUSTRATION 22
1 1 1 MACHINE HOUSE – LEGEND FOR ILLUSTRATION 24
1 1 2 HYDRAULIC OIL RESERVOIR – LEGEND FOR ILLUSTRATION 26
1 1 3 HYDRAULIC OIL COOLER – LEGEND FOR ILLUSTRATION 28
1 1 4 FUEL TANK (FUEL RESERVOIR) – LEGEND FOR ILLUSTRATION 30
1 1 5 COUNTERWEIGHT – LEGEND FOR ILLUSTRATION 32
1 1 6 CAB SUPPORT – LEGEND FOR ILLUSTRATION 34
1 1 7 OPERATOR’S CAB – LEGEND FOR ILLUSTRATION 36
1 1 8 CONTROL BLOCKS – LEGEND FOR ILLUSTRATION 38
1 1 9 SWING GEARS – LEGEND FOR ILLUSTRATION 40
1 2 UNDER CARRIAGE – LEGEND FOR ILLUSTRATION 42
1 3 ATTACHMENT – LEGEND FOR ILLUSTRATION 44
1 3 1 BACKHOE ATTACHMENT (BHA) – LEGEND FOR ILLUSTRATION 44
1 3 2 FRONT SHOVEL ATTACHMENT – LEGEND FOR ILLUSTRATION 46
2 0 PRIME DRIVE ASSEMBLY 47
2 0 PRIME DRIVE ASSEMBLY – GENERAL LAY OUT 47
2 0 PRIME DRIVE ASSEMBLY – LEGEND FOR ILLUSTRATION 49
2 1 ENGINE AND PTO MOUNT 51
2 2 COUPLING 55
2 2 COUPLING LEGEND FOR ILLUSTRATION 55
2 3 AIR FILTER 57
2 3 AIR FILTER – LEGEND FOR ILLUSTRATION 57
2 4 FAN DRIVE AND RADIATOR ASSEMBLY 59
2 4 FAN DRIVE AND RADIATOR ASSEMBLY – LEGEND FOR ILLUSTRATION 59
2 5 RADIATOR FAN DRIVE SPEED ADJUSTMENT 63
2 6 PUMP DISTRIBUTOR GEARBOX (PTO) 67
2 7 PUMP-SPLINE LUBRICATION 69
2 8 PTO LUBRICATION AND COOLING 71
2 8 PTO LUBRICATION AND COOLING – LEGEND OF ILLUSTRATION 71
2 9 HYDRAULIC PUMPS – LOCATION, DRIVE SPEED AND FLOW RATES 75
3 0 HYDRAULIC OIL RESERVOIR 76
3 0 HYDRAULIC OIL RESERVOIR GENERAL LAYOUT 76
3 1 MAIN OIL TANK, LOCATION OF SWITCHES, SENSORS ETC 80
3 2 SUCTION OIL TANK WITH STRAINERS 82
3 3 RETURN OIL COLLECTOR TUBE WITH STRAINER 84
3 4 BACK PRESSURE VALVE 86
3 5 TRANSFER PUMP (OPTIONAL EQUIPMENT) 88
3 6 RETURN AND LEAK OIL FILTER 90
3 7 BREATHER FILTER 92
4 0 HYDRAULIC OIL COOLING 93
4 1 GENERAL 95
4 2 FUNCTION OF THE HYDRAULIC OIL COOLING CIRCUIT 97
4 3 ADJUSTMENT OF THE BACK PRESSURE VALVE 99
4 4 FAN DRIVE (TWO STAGE COOLER FAN PRM CONTROL) 101
4 5 PRESSURE RELIEF VALVES AND SOLENOID VALVE 103
4 6 FIXED DISPLACEMENT PUMP, WITH VARIABLE SETTING 107
5 0 CONTROLLING 108
5 0 GENERAL LAYOUT – LEGEND FOR ILLUSTRATIONS 110
5 1 CONTROL AND FILTER PANEL LOCATION OF COMPONENTS (VALVES, SWITCHES, SENSORS ETC) 112
5 2 PILOT PRESSURE SUPPLY AND ADJUSTMENTS 116
5 3 REMOTE CONTROL VALVES ARRANGEMENT 122
5 4 FUNCTION PRINCIPLEOF THE ELECTRO-HYDRAULIC-PROPORTIONAL CONTROL 124
5 5 POTENTIOMETER CONTROL (LEVER, JOY STICK) 128
5 6 POTENTIOMETER CONTROL (PEDAL) 130
5 7 PROPORTIONAL AMPLIFIER MODULE, TYPE A 132
5 8 PROPORTIONAL AMPLIFIER MODULE, TYPE B 134
5 9 RAMP TIME MODULE 136
5 10 ADJUSTMENTS OF AMPLIFIER MODULES (GENERAL) 138
5 11 ADJUSTING THE AMPLIFIERS TYPE B, ILLUSTRATION 140
5 12 ADJUSTING THE AMPLIFIERS TYPE B, ILLUSTRATION 144
5 13 ADJUSTING THE RAMP TIME MODULE 148
6 0 COMPONENTS 153
6 1 HYDRAULIC 153
6 1 1 MAIN CONTROL BLOCKS AND HIGH PRESSURE FILTER – FRONT SHOVEL ATTACHMENT 155
6 1 2 MAIN CONTROL BLOCKS AND HIGH PRESSURE FILTER BACK HOE ATTACHMENT 157
6 1 3 DISTRIBUTOR MAINFOLD – LOCATION OF RESTRICTOR BLOCKS AND CAVITATION VALVES – FRONT SHOVEL ATTACHMENT 159
6 1 4 DISTRIBUTOR MANIFOLD – LOCATION OF RESTRICTOR BLOCKS AND CAVITATION VALVES – BACKHOE ATTACHMENT 161
6 1 5 SINGLE CONTROL BLOCKS (FLOATING) FOR STICK AND BOOM FRONT SHOVEL ATTACHMENT 163
6 1 6 RESTRICTOR BLOCK WITH PRESSURE RELIEF VALVE 165
6 1 7 ANTI CAVITATION VALVE BLOCK 167
6 1 8 REMOTE CONTROL VALVE 169
6 1 9 DIRECTIONAL SOLENOID VALVES (THREE POSITIONS / 4-WAY) 171
6 1 10 PROPORTIONAL SOLENOID VALVE 173
6 1 11 HIGH PRESSURE FILTER 175
6 1 12 CONTROL BLOCKS AND VALVES 177
6 1 13 TRAVEL BRAKE VALVE 189
6 1 14 PRESSURE REDUCING VALVE 191
6 1 15 DIRECTIONAL SOLENOID VALVES (TWO POSITIONS / 4-WAYS) 193
6 1 16 PRESSURE INCREASING VALVE 195
7 0 MAIN HYDRAULIC PUMPS AND PUMP REGULATION SYSTEM 196
7 0 GENERAL LAYOUT (HYDRAULIC ONLY) 198
7 0 GENERAL LAYOUG (PUMP REGULATION SYSTEM) 200
7 1 MAIN PUMPS 206
7 1 1 LOCATION OF PUMPS 206
7 1 2 PUMP BEARING FLUSHING / LUBRICATION 208
7 1 3 OPERATING PRINCIPLES 210
7 1 4 CHECKS / ADJUSTMENTS 226
7 2 ELECTRONIC PUMP REGULATION SYSTEM 236
7 2 1 ELECTRONIC LOAD LIMITING CONTROL – GENERAL 236
7 2 2 MICROCONTROLLER MC7 238
7 2 3 CHECKS AND ADJUSTMENTS 240
METHOD A X1 PRESSURE WITH 24V SUPPLY 242
METHOD B – WITH ELECTRONIC SERVICE TOOL 244
LANGUAGE SELECTION 244
EXCAVATOR TYPE SELECTION 248
X1 PRESSURE (MAXIMUM CURRENT) ADJUSTMENT 252
METHOD C – WITH A LAPTOP COMPUTER 256
STARTING THE PROGRAM 256
LANGUAGE SELECTION 260
EXCAVATOR TYPE SELECTION 262
X1 PRESSURE (MAXIMUM CURRENT) ADJUSTMENT 264
7 3 HYDRAULIC CONSTANT REGULATION SYSTEM 266
7 3 1 GENERAL 266
7 3 2 X1 PRESSURE ADJUSTMENT (CONSTANT PRESSURE) 268
7 4 DETERMINATION OF THE PEAK POINT (ENGINE PERFORMANCE) 270
8 0 OPERATING HYDRAULIC 271
OPERATING HYDRAULIC – GENERAL 273
8 1 HYDRAULIC FOR THE ATTACHMENT CYLINDER FSA AND BHA 276
8 1 1 ELECTRIC/HYDRAULIC FLOWCHART “BOOM RAISING” 278
8 1 2 ELECTRIC/HYDRAULIC FLOWCHART “BOOM LOWERING” 282
8 1 3 ELECTRIC/HYDRAULIC FLOWCHART “STICK EXTENDING” 286
8 1 4 ELECTRIC/HYDRAULIC FLOWCHART “STICK RETRACTING” 290
8 1 5 ELECTRIC/HYDRAULIC FLOWCHART “BUCKET FILLING” 294
8 1 6 ELECTRIC/HYDRAULIC FLOWCHART “BUCKET EMPTYING” 298
8 1 7 ELECTRIC/HYDRAULIC FLOWCHART “CLAM OPENING” 302
8 1 8 ELECTRIC/HYDRAULIC FLOWCHARG “CLAM CLOSING” 304
8 1 9 CHECKS AND ADJUSTMENTS OF THE MAIN RELIEF VALVES 306
8 1 10 CHECKS AND ADJUSTMENTS OF THE SERVICE LINE RELIEF VALVES 310
Boom cylinder “Piston side” FSA +BHA 312
Boom cylinder “Piston rod side” FSA +BHA 314
Stick cylinder “Piston side” FSA 318
Stick cylinder “Piston side” BHA 322
Stick cylinder “Piston rod side” FSA 326
Stick cylinder “Piston rod side” BHA 330
Bucket cylinder “Piston side” FSA 334
Bucket cylinder “Piston side” BHA 338
Bucket cylinder “Piston rod side” FSA 342
Bucket cylinder “Piston rod side” BHA 346
Clam cylinder “Piston rod side” FSA 350
Clam cylinder “Piston side” FSA 352
8 1 11 CHECKS AND ADJUSTMENTS OF THE LOWERING SPEED 354
Boom cylinder FSA 356
Boom cylinder BHA 360
Stick cylinder BHA 366
Bucket cylinder FSA 368
Bucket cylinder BHA 370
Clam cylinder BHA 372
8 2 HYDRAULIC FOR THE SWING CIRCUIT 373
8 2 1 SWING CIRCUIT 375
8 2 2 SWING MOTOR 379
8 2 3 SWING GEAR BOX 383
8 2 4 SWING PARKING BRAKE (GEAR HOUSE BRAKE) 385
8 2 5 SWING BRAKE VALVE 387
8 2 6 ELECTRIC/HYDRAULIC FLOWCHART “SWING LEFT” 391
8 2 7 ELECTRIC/HYDRAULIC FLOWCHART “SWING RIGHT” 393
8 2 8 SWING MONITORING SYSTEM 395
8 2 9 CHECKS AND ADJUSTMENTS FOR THE SWING CIRCUIT 399
8 2 10 FUNCTION FOR THE SWING PARKING BRAKE 405
8 3 HYDRAULIC FOR THE SWING CIRCUIT 406
8 3 1 TRAVEL CIRCUIT 408
8 3 2 TRAVEL MOTOR 412
8 3 3 ROTARY DISTRIBUTOR 414
8 3 4 TRAVEL GEAR 416
8 3 5 TRAVEL PARKING BRAKE (GEAR HOUSE BRAKE) 418
8 3 6 TRAVEL BRAKE VALVE 420
8 3 7 ELECTRIC/HYDRAULIC FLOWCHART “TRAVELING FORWARD” 422
8 3 8 ELECTRIC/HYDRAULIC FLOWCHART “TRAVELING BACKWARD” 424
8 3 9 CHECKS AND ADJUSTMENTS FOR THE TRAVEL CIRCUIT 426
8 3 10 FUNCTION CHECK FOR THE TRAVEL PARKING BRAKE 428
9 0 HYDRAULIC TRACK TENSIONING SYSTEM 429
9 0 GENERAL 431
9 1 FUNCTIONAL DESCRIPTION 433
9 2 PRESSURE INCREASING VALVE 437
9 3 TENSIONING CYLINDER 439
9 4 ADJUSTMENTS / CHECKS 441
9 5 FUNCTIONAL TEST 445
10 0 ACCESS LADDER HYDRAULIC OPERAGED 446
10 0 GENERAL 448
10 1 FUNCTION OF HYDRAULIC OPERATED ACCESS LADDER 450
11 0 HYDRAULIC OPERATED REFILLING ARM 453
11 0 GENERAL 455
11 1 FUNCTION OF HYDRAULIC OPERATED REFILLING ARM 457
12 0 HINTS FOR READING THE HYDRAULIC CIRCUIT DIAGRAM 458
12 0 GENERAL 459
12 1 LEGEND FOR THE CIRCUIT DIAGRAM 460
12 2 HOW TO READ THE CIRCUIT DIAGRAM 468
13 0 HINTS FOR READING THE ELECTRIC CIRCUIT DIAGRAM 469
13 1 DESIGNATION OF ELECTRICAL DEVICES 471
13 2 SYMBOLS 473
13 3 GENERAL INFORMATION 477
13 4 READING A CIRCUIT DIAGRAM 481
13 5 COMPONENT LIST 485
14 0 VEHICLE HEALTH MONITORING SYSTEM 631
DATA FLOW CONTROL OF VHMS 632
GENERAL 633
14 1 COLORED GRAPHIC CONSOLE (CGC) SPECS FOR OPERATORS 610
14 1 1 GRAPHIC FLOW CHART 612
14 1 2 INITIALIZATION SCREEN (NO 0 0) 614
14 1 3 OPERATOR INFORMATION SCREEN ( NO 1 1) 614
14 1 4 MONITORING SCREENS 616
STANDARD MONITOR 1 (NO 1 2) 616
EXPANSION MONITOR 2 (NO 1 3) 616
EXPANSION MONITOR 3 (NO 1 4) 616
14 1 5 BRIGHTNESS AND CONTRAST SETTING SCREEN (NO 1 2 1) 618
14 1 6 FUEL CONSUMPTION SCREEN (NO 1 2 2) 620
14 1 7 SETTINGS FOR OPERATOR, SCREEN (NO 1 2 3) 622
14 1 8 MAINTENANCE MONITOR (NO 1 2 4) 624
14 1 9 FAILURE MESSAGE ( NO 1 2 5) 628
14 1 10 AUTOMATIC MESSAGES 630
14 2 COLORED GRAPHIC CONSOLE (CGC) SPECS FOR SERVICEMEN 551
14 2 1 GRAPHIC FLOW CHART 553
14 2 2 SERVICE ID SETUP SCREEN (NO 2 0) 555
14 2 3 SERVICE MENU SELECT SCREEN (NO 3 1) 557
14 2 4 REAL TIME MENU SELECT SCREEN (NO 4 1 1) 559
ENGINE 5 1 1 – 5 1 4 559
TRANSMISSION 5 2 1 561
HYDRAULIC 5 3 1 – 5 4 2 563
ELECTRICAL EQUIPMENT 5 4 1 – 5 4 2 565
EMERGENCY STOP 5 5 1 567
MANUAL SWITCH 5 6 1 – 5 6 3 569
CENTRAL LUBRICATION SYSTEM 5 7 1 – 5 7 2 571
SWING LUBRICATION SYSTEM 5 8 1 – 5 8 2 573
OTHER ITEMS 5 9 1 – 5 9 3 575
OUTPUT SIGNALS 5 10 1 – 5 10 6 577
14 2 5 PM-CLINIC 579
PM CLINIC GENERAL – 4 2 1 – 4 2 2 579
PM CLINIC POWER CHECK – 4 2 3 – 4 2 5 581
14 2 6 SERIAL NO SETTING 583
MACHINE 4 3 1 583
ENGINE 4 3 2 585
14 2 7 MEMORY CLEAR 587
INPUT ID 4 3 2 587
MEMORY CLEAR 4 4 1 589
14 2 8 MAINTENANCE MONITOR – MAINTENANCE ACKNOWLEDGEMENT – 4 5 – 4 5 1 591
14 2 9 FAILURE HISTORY – 4 6 593
14 2 10 SNAPSHOT TRIGGER- 4 7 595
14 2 11 SETTINGS 597
CENTRAL LUBRICATION SYSTEM 4 8 1 597
SWING LUBRICATION SYSTEM 4 8 2 599
OTHER SETTINGS 1/2 601
LANGUAGE 602
OPERATING HOURS 602
DATE 602
TIME 603
GMT REFERENCE 603
OTHER SETTINGS 2/2 605
OIL VISCOSITY HYDRAULIC 605
OIL VISCOSITY GEAR 605
MESSAGES ON/OFF 607
PLC-AUTOM ON/OFF 607
SHUT DOWN ON OFF 4 8 5 – 4 8 10 609
14 4 WIRING OF THE MAIN COMPONENTS 538
14 4 1 WIRING OF THE ENGINE 542
14 4 2 WIRING OF THE VHMS CONTROLLER 544
14 4 3 WIRING OF THE CGC MONITOR 548
14 4 4 WIRING OF THE PLC 550
15 0 LUBRICATION SYSTEMS 638
15 1 HYDRAULICALLY DRIVEN LUBE PUMP 638
FUNCTION 644
ADJUSTMENTS 648
15 2 ONE LINE SYSTEM WITH HYDRAULICALLY DRIVEN “PUMP MASTER III” PUMP 650
FUNCTION 652
ELECTRICAL FUNCTION 656
SONAR SENSOR FOR GREASE LEVEL 660
ADJUSTMENTS 662
END LINE SWITCH 662
INJECTORS 664
15 3 PINION TYPE SYSTEM WITH HYDRAULIC DRIVEN “POWER MASTER III” PUMP 666
FUNCTION 669
ELECTRICAL FUNCTION 672
LUBRICANT LEVEL 676
ADJUSTMENTS 678
END OF LINE SWITCH SETTING 678
INJECTORS 680
15 4 COMPONENTS 682
HYDRAULICALLY DRIVEN “POWER MASTER III” LUBE PUMP 684
LUBRICANT INJECTORS 688
END-OF-LINE SWITCH 694
FILTER 696
VENT VALVE 698

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