KOMATSU PC4000-6 HYDRAULIC MINING SHOVEL Operation & Maintenance Manual (SN:PC4000-6 8152) KOMATSU PC4000-6 – PDF DOWNLOAD

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KOMATSU PC4000-6 HYDRAULIC MINING SHOVEL Operation & Maintenance Manual (SN:PC4000-6 8152) KOMATSU PC4000-6 

KOMATSU PC4000-6 HYDRAULIC MINING SHOVEL OPERATION & MAINTENANCE MANUAL (SN:PC4000-6 8152) KOMATSU PC4000-6 – PDF DOWNLOAD:

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KOMATSU PC4000-6 HYDRAULIC MINING SHOVEL Operation & Maintenance Manual (SN:PC4000-6 8152) KOMATSU PC4000-6

Part 1:
Operation Manual
Part 2:
Lubrication- and Maintenance Manual
Part 3:
Excavator Assembly Manual. Technical Data Booklet. Service Literature for the Power Unit (Diesel Engine or Electric Motor) and for Special Equipment. Electrical- and Hydraulic Diagrams.
Refer to the table of contents for details.
Read the Manuals before You Start the Engine.
Before operating the machine, familiarize yourself with its instruments and controls.
Observe the instructions In these manuals for:

• your Personal SAFETY
• Operating SAFETY, and
• READY and EFFICIENT PERFORMANCE of your KOMATSU Excavator.

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 you have any questions concerning this literature please contact

TABLE OF CONTENTS:

KOMATSU PC4000-6 HYDRAULIC MINING SHOVEL Operation & Maintenance Manual (SN:PC4000-6 8152) KOMATSU PC4000-6

MAIN MENU.....................................................................................................................  0
COVER.........................................................................................................................  1
1. INTRODUCTION...............................................................................................................  3
	1.1 CONTENTS OF THE BINDER................................................................................................  4
	1.2 DIVISION OF THE BINDER................................................................................................  5
	1.3 DESIGNATED USE OF THE EXCAVATOR.......................................................................................  6
	1.4 DELIVERY OF THE EXCAVATOR.............................................................................................  7
	1.5 EXPLANATION OF ABBREVATIONS...........................................................................................  8
	1.6 TABLE OF CONTENTS.....................................................................................................  9
2. SAFETY..................................................................................................................... 15
	2.1 SAFETY INSTRUCTIONS................................................................................................... 16
		2.1.1 WARNINGS AND SYMBOLS............................................................................................ 16
		2.1.2 BASIC OPERATION AND DESIGNATED USE OF THE HYDRAULIC EXCAVATOR................................................... 16
		2.1.3 ORGANIZATIONAL MEASURES......................................................................................... 17
		2.1.4 SELECTION AND QUALIFICATION OF PERSONNEL - BASIC RESPONSIBILITIES............................................... 19
		2.1.5 SAFETY INSTRUCTIONS GOVERNING SPECIFIC OPERATIONAL PHASES....................................................... 20
		2.1.6 WARNING OF SPECIAL DANGERS...................................................................................... 23
		2.1.7 TRANSPORTING AND TOWING - RECOMMISSIONING....................................................................... 25
		2.1.8 SPECIAL SAFETY EQUIPMENT........................................................................................ 25
		2.1.9 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD).................................................... 29
3. OPERATION.................................................................................................................. 37
	3.1 FOREWORD.............................................................................................................. 38
	3.2 CONSTRUCTION OF THE EXCAVATOR......................................................................................... 39
		3.2.1 OVERALL VIEW.................................................................................................... 39
		3.2.2 SUPERSTRUCTURE.................................................................................................. 40
		3.2.3 HYDRAULICALLY OPERATED ACCESS LADDER............................................................................ 48
		3.2.4 EMERGENCY ESCAPE LADDER......................................................................................... 52
		3.2.5 EMERGENCY ENGINE SHUTDOWN FROM GROUND MAN AND OPERATOR WARNING SYSTEM........................................... 54
		3.2.6 OPERATOR'S CAB WITH INTEGRATED FALLING OBJECT PROTECTIVE STRUCTURE (FOPS)....................................... 56
		3.2.7 UNDERCARRIAGE................................................................................................... 63
		3.2.8 WORKING ATTACHMENT.............................................................................................. 64
		3.2.9 DIESEL ENGINE TYPE SDA 16V160................................................................................... 66
	3.3 OPERATOR'S CAB - CONTROLS............................................................................................. 72
		3.3.1 HYDRAULIC CONTROL SYSTEM........................................................................................ 73
		3.3.2 SAFETY CIRCUIT FOR CONTROLS..................................................................................... 73
	3.4 VEHICLE HEALTH MONITORING SYSTEM VHMS - HEALTH MONITOR................................................................ 84
		3.4.1 INITIALIZATION SCREEN NO. 0.0................................................................................... 84
		3.4.2 OPERATOR INFORMATION SCREEN NO. 1.1............................................................................. 84
		3.4.3 STANDARD MONITOR 1 (NO. 1.2).................................................................................... 85
		3.4.4 TABLE OF ALL TOP MESSAGES PROVIDED BY THE SYSTEM................................................................ 99
		3.4.5 TABLE OF AVAILABLE INSTRUCTION MESSAGES.........................................................................111
	3.5 OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING................................................................114
		3.5.1 A - HEATING.....................................................................................................114
		3.5.2 B - COOLING.....................................................................................................115
		3.5.3 COMBINED OPERATION OF AIR CONDITIONING AND HEATING..............................................................115
	3.6 POWER HOUSE...........................................................................................................116
		3.6.1 EMERGENY SHUTDOWN SWITCHES AND BATTERY MAIN SWITCHES............................................................117
		3.6.2 CENTRAL CONTROL AND FILTER PANEL................................................................................119
	3.7 ELECTRICAL EQUIPMENT IN CAB BASE......................................................................................120
		3.7.1 SWITCH BOARD (X2) IN CAB BASE...................................................................................123
	3.8 CHECKS BEFORE STARTING THE ENGINE.....................................................................................132
	3.9 STARTING THE ENGINE...................................................................................................138
		3.9.1 STARTING PROCEDURE..............................................................................................141
		3.9.2 ENGINE WARM-UP..................................................................................................145
		3.9.3 HYDRAULIC OIL WARM-UP...........................................................................................145
	3.10 MOVING THE EXCAVATOR.................................................................................................147
		3.10.1 TRAVEL CONTROL WITH FOOT PEDALS................................................................................147
		3.10.2 TRAVELLING INSTRUCTIONS........................................................................................150
	3.11 SLEWING AND BRAKING THE SUPERSTRUCTURE...............................................................................151
		3.11.1 SLEWING THE SUPERSTRUCTURE.....................................................................................151
		3.11.2 BRAKING THE SUPERSTRUCTURE.....................................................................................153
		3.11.3 SLEW PARKING BRAKE.............................................................................................154
	3.12 WORKING WITH THE ATTACHMENT..........................................................................................156
		3.12.1 MACHINES EQUIPPED WITH "EURO" CONTROL SYSTEM...................................................................156
		3.12.2 MACHINES EQUIPPED WITH "KMG" CONTROL SYSTEM....................................................................157
		3.12.3 BOTTOM DUMP BUCKET.............................................................................................158
		3.12.4 DROP BALL OPERATION............................................................................................159
		3.12.5 COMBINED OPERATION CYCLES......................................................................................162
	3.13 WORKING INSTRUCTIONS.................................................................................................164
		3.13.1 STABILITY OF THE EXCAVATOR.....................................................................................164
		3.12.2 EXCAVATOR OPERATION............................................................................................164
	3.14 PARKING THE EXCAVATOR................................................................................................167
	3.15 STOPPING THE ENGINE..................................................................................................168
	3.16 OPERATION OF THE LUBRICATION SYSTEM..................................................................................172
		3.16.1 CENTRAL LUBRICATION SYSTEM "CLS"...............................................................................172
		3.16.2 SWING CIRCLE PINION LUBRICATION SYSTEM "SLS"...................................................................174
	3.17 FIRE DETECTION AND SUPPRESSION SYSTEM................................................................................176
		3.17.1 HIGH LEVEL ALARM "FIRE"........................................................................................179
		3.17.2 ENGINE SHUT-DOWN THROUGH FUEL SHUT-OFF SOLENOID VALVE..........................................................179
		3.17.3 ACTUATION MODES OF THE FIRE SUPPRESSION SYSTEM.................................................................179
		3.17.4 INDICATION OF OPERATIONAL MODES AT CONTROL MODULE, AFTER AUTOMATIC ACTUATION OF THE FIRE SUPPRESSION SYSTEM....181
		3.17.5 LOCATION OF THE EXTINGUISHING AGENT TANK ASSEMBLIES AND EXPELLANT GAS CARTRIDGES ON POWER HOUSE ROOF...........183
	3.18 CENTRAL REFILLING SYSTEM.............................................................................................184
		3.18.1 SYSTEMS CONNECTED TO THE REFILLING SYSTEM......................................................................185
		3.18.2 OPERATING THE HYDRAULIC SERVICE ARM............................................................................187
		3.18.3 RECEIVER PANEL WITH MONITOR BOX................................................................................189
		3.18.4 REFILLABLE GREASE CONTAINERS OF THE CENTRAL LUBRICATION SYSTEM AND SWING CIRCLE PINION LUBRICATION SYSTEM......195
	3.19 WORK ON THE LOADER ATTACHMENT........................................................................................198
	3.20 TRANSPORTATION AND LIFTING OF THE EXCAVATOR..........................................................................199
		3.20.1 DISASSEMBLING OF THE EXCAVATOR.................................................................................199
		3.20.2 TRANSPORTATION AND LIFTING.....................................................................................199
	3.21 RETRIEVAL PROCEDURE..................................................................................................200
	3.22 EXCAVATOR STORAGE....................................................................................................201
		3.22.1 PREPARING FOR STORAGE..........................................................................................201
		3.22.2 ONE MONTH REPETITIVE SERVICE PERIOD............................................................................202
		3.22.3 SIX MONTH REPETITIVE SERVICE PERIOD............................................................................202
		3.22.4 PREPARING FOR OPERATION........................................................................................203
	3.23 TROUBLE SHOOTING.....................................................................................................204
		3.23.1 ENGINE.........................................................................................................204
		3.23.2 HYDRAULIC SYSTEM...............................................................................................205
		3.23.3 FINAL DRIVES AND SWING MACHINERY...............................................................................206
		3.23.4 CRAWLER TRACKS.................................................................................................206
4. MAINTENANCE................................................................................................................207
	4.1 FOREWORD..............................................................................................................208
	4.2 PRECAUTIONS FOR MAINTENANCE...........................................................................................209
	4.3 FUEL AND LUBRICANTS...................................................................................................211
	4.4 FILLING CAPACITIES....................................................................................................213
	4.5 STANDARD TORQUE LIST..................................................................................................214
	4.6 LUBRICATION AND MAINTENANCE SCHEDULE..................................................................................215
		4.6.1 INITIAL SERVICING...............................................................................................215
		4.6.2 PERIODIC SERVICING INTERVALS....................................................................................215
		4.6.3 PERIODIC SERVICING SCHEDULE.....................................................................................216
		4.6.4 EXTENDED SERVICE INTERVALS OF ENGINE OIL RESERVE SYSTEM.........................................................223
		4.6.5 MAINTENANCE OF THE ENGINE.......................................................................................223
	4.7 WHEN NECESSARY........................................................................................................224
		4.7.1 ENGINE AIR CLEANER SERVICE......................................................................................225
		4.7.2 SWING CIRCLE TOOTHING LUBRICATION...............................................................................229
		4.7.3 AUTOMATIC LUBRICATION SYSTEMS FILL GREASE BARRELS...............................................................231
		4.7.4 TRACK ROLLERS AND GUIDE WHEELS - REPLACE FLOATING SEALS.........................................................235
	4.8 EVERY 10 OPERATING HOURS OR DAILY.....................................................................................236
		4.8.1 VISUAL INSPECTIONS..............................................................................................237
		4.8.2 AIR CLEANER - CLEAN PRE-CLEANER.................................................................................247
		4.8.3 RADIATOR - CHECK COOLANT LEVEL..................................................................................249
		4.8.4 TRACK GROUPS - CLEAN............................................................................................249
	4.9 EVERY 50 OPERATING HOURS OR WEEKLY....................................................................................250
		4.9.1 SWING MACHINERY, BRAKE HOUSINGS AND MOTOR ADAPTER HOUSINGS - CHECK OIL LEVELS...................................251
		4.9.2 TRAVEL GEARS, BRAKE HOUSINGS AND MOTOR ADAPTER HOUSINGS - CHECK OIL LEVELS......................................257
		4.9.3 FINAL DRIVE HOUSINGS - CHECK OIL LEVEL..........................................................................259
		4.9.4 PTO (PUMP DISTRIBUTOR GEAR) AND OIL RESERVOIR - CHECK OIL LEVEL.................................................261
		4.9.5 HYDRAULIC ACCESS LADDER - CHECK SAFETY SENSOR...................................................................263
		4.9.6 HYDRAULIC OIL COOLERS - INSPECT AND CLEAN IF NECESSARY..........................................................265
	4.10 EVERY 250 OPERATING HOURS OR MONTHLY.................................................................................266
		4.10.1 AIR CONDITIONING COMPRESSOR - CHECK DRIVE BELT TENSION.........................................................267
		4.10.2 UNDERCARRIAGE PIN CONNECTIONS - LUBRICATE......................................................................269
		4.10.3 SIGNAL HORN COMPRESSOR - LUBRICATE.............................................................................269
		4.10.4 HYDRAULIC OIL COOLER FAN BEARINGS - CHECK OIL LEVEL............................................................269
		4.10.5 RADIATOR FAN BEARING - CHECK OIL LEVEL.........................................................................269
		4.10.6 AUTOMATIC LUBRICATION SYSTEMS - CLEAN IN-LINE GREASE FILTER....................................................271
		4.10.7 CAB AIR CLEANER - CLEAN OR REPLACE FILTER ELEMENT..............................................................275
	4.11 EVERY 500 OPERATING HOURS OR MONTHLY.................................................................................276
		4.11.1 BATTERIES - CHECK FLUID LEVEL..................................................................................277
		4.11.2 FLEXIBLE DRIVE COUPLING - CHECK OIL LEVEL......................................................................279
		4.11.3 PTO (PUMP DISTRIBUTOR GEAR) MAIN PUMP DRIVE SHAFT HOUSINGS - CHECK OIL LEVEL...................................281
		4.11.4 FUEL TANK - DRAIN CONDENSATION.................................................................................283
		4.11.5 CRAWLER TRACK - INSPECTION.....................................................................................285
	4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH..........................................................................290
		4.12.1 HIGH STRENGTH BOLT CONNECTIONS.................................................................................291
		4.12.2 HYDRAULIC SYSTEM - FILTER SERVICE..............................................................................333
		4.12.3 PTO (PUMP DISTRIBUTOR GEAR), SWING MACHINERY AND TRAVEL GEARS - OIL SAMPLE ANALYSIS............................345
		4.12.4 SIGNAL HORN COMPRESSOR - CLEAN AND LUBRICATE...................................................................347
		4.12.5 HYDRAULIC TRACK TENSIONING SYSTEM - CHECK ACCUMULATORS.........................................................349
		4.12.6 WATER FILTER - REPLACE FILTER CARTRIDGE........................................................................351
	4.13 EVERY 2000 OPERATING HOURS OR YEARLY.................................................................................352
		4.13.1 HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER..................................353
		4.13.2 EMERGENCY ESCAPE LADDER - INSPECTION...........................................................................365
	4.14 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR..............................................................366
		4.14.1 SWING MACHINERY, BRAKE AND MOTOR ADAPTER HOUSINGS - CHANGE OIL.................................................367
		4.14.2 TRAVEL GEARS, BRAKE AND MOTOR ADAPTER HOUSINGS - CHANGE OIL....................................................377
		4.14.3 FINAL DRIVE HOUSINGS - CHANGE OIL..............................................................................381
		4.14.4 PTO (PUMP DISTRIBUTOR GEAR) - CHANGE OIL.......................................................................383
	4.15 FIRE PREVENTION......................................................................................................384
	4.16 REPAIR WELDINGS......................................................................................................386
		4.16.1 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE UNDERCARRIAGE..........................................389
		4.16.2 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE LOADER ATTACHMENT......................................391
		4.16.3 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE SUPERSTRUCTURE.........................................393
		4.16.4 AFTER FINISHING THE REPAIR WELDINGS ON THE SUPERSTRUCTURE......................................................393

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