Komatsu PC4000-6 Hydraulic Mining Shovel Remove & Replace Procedures Manual – PDF DOWNLOAD

Description

Komatsu PC4000-6 Hydraulic Mining Shovel Remove & Replace Procedures Manual

FILE DETAILS:

Komatsu PC4000-6 Hydraulic Mining Shovel Remove & Replace Procedures Manual

Brands: Komatsu
Equipment Type:  Hydraulic Mining Shovel
Manuals Type:Remove & Replace Procedures Manual
Machine Model: PC4000-6
Language: English
Pages: 836
File Format: Portable Document Format (PDF)

KOMATSU PC4000-6 HYDRAULIC MINING SHOVEL REMOVE & REPLACE PROCEDURES MANUAL – PDF DOWNLOAD:

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DESCRIPTION:

Komatsu PC4000-6 Hydraulic Mining Shovel Remove & Replace Procedures Manual

FOREWORD:

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 R&R Procedures Manual, KOMATSU provides you with the description of changing or repairing worn out or broken parts to assure the function of the major systems of the Hydraulic Excavator PC 4000-6 D.
We describe for you all functions and how to carry out the inspections and adjustments. How do you find “your” desired information?
In the TABLE OF CONTENTS all the functions and components are shown in their sequence of description.

TABLE OF CONTENTS:

Komatsu PC4000-6 Hydraulic Mining Shovel Remove & Replace Procedures Manual

1 Introduction................................................................................................ 13
	1.1 Contents of the binder................................................................................ 14
	1.2 Foreword.............................................................................................. 15
		1.2.1 Service......................................................................................... 16
2 Safety...................................................................................................... 17
	2.1 Safety Instructions................................................................................... 18
		2.1.1 Method of using this manual..................................................................... 18
		2.1.2 General precautions............................................................................. 20
		2.1.3 Preparations for work........................................................................... 21
		2.1.4 Precautions during work......................................................................... 22
		2.1.5 WARNING OF SPECIAL DANGERS...................................................................... 24
			2.1.5.1 ELECTRICal ENERGY......................................................................... 24
			2.1.5.2 GAS, DUST, STEAM AND SMOKE................................................................ 25
			2.1.5.3 HYDRAULIC, AIR CONDITIONING AND PNEUMATIC EQUIPMENT....................................... 26
			2.1.5.4 NOISE..................................................................................... 26
			2.1.5.5 Heat...................................................................................... 27
			2.1.5.6 OIL, GREASE AND OTHER CHEMICAL SUBSTANCES................................................. 27
			2.1.5.7 Height.................................................................................... 27
		2.1.6 SPECIAL SAFETY EQUIPMENT........................................................................ 29
			2.1.6.1 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD).............................. 29
			2.1.6.2 INSTRUCTIONS FOR USE...................................................................... 31
			2.1.6.3 RECOMMENDATIONS FOR USE OF THE HOLDING HOOKS AND HOLD-BACK HOOKS OF THE SAFETY HARNESS.... 33
			2.1.6.4 INSTRUCTIONS FOR USE...................................................................... 35
	2.2 Lifting Gears......................................................................................... 36
		2.2.1 Wire ropes...................................................................................... 36
		2.2.2 Sling accessory................................................................................. 38
		2.2.3 Weight tables................................................................................... 39
			2.2.3.1 Superstructure............................................................................ 39
			2.2.3.2 Undercarriage............................................................................. 41
			2.2.3.3 Backhoe AttachmenT (BHA).................................................................. 42
			2.2.3.4 Faceshovel Attachment (FSA)............................................................... 43
	2.3 Torque charts according to DIN........................................................................ 45
		2.3.1 Metric standard thread.......................................................................... 45
		2.3.2 Metric fine thread.............................................................................. 46
		2.3.3 Cummins motor torques - metric.................................................................. 47
		2.3.4 Cummins motor torques - U.S. Customary.......................................................... 47
		2.3.5 Flange connections.............................................................................. 48
	2.4 Conversation table.................................................................................... 49
		2.4.1 Method of using the conversation table.......................................................... 49
		2.4.2 Millimeter - Inch & Kilogram - Pound............................................................ 50
		2.4.3 Liter - U.S. Gallon & Liter - U.K. Gallon....................................................... 51
		2.4.4 KGm - ft.lb..................................................................................... 52
		2.4.5 bar - PSI / PSI - bar........................................................................... 53
		2.4.6 Basic Values in Ohm according to DIN 43 76...................................................... 54
		2.4.7 Temperature..................................................................................... 55
	2.5 Explanation of abbreviations.......................................................................... 56
3 Superstructure.............................................................................................. 57
	3.1 Diesel Engine......................................................................................... 58
		3.1.1 Removal of the Diesel engine.................................................................... 58
		3.1.2 Replacement of the Diesel engine................................................................ 65
		3.1.3 Engine torque support and engine/PTO mounts..................................................... 68
			3.1.3.1 Flexible mounts........................................................................... 69
			3.1.3.2 Torque support............................................................................ 71
		3.1.4 Alternator...................................................................................... 72
			3.1.4.1 Removal of the alternator................................................................. 72
			3.1.4.2 Replacement of the alternator............................................................. 73
		3.1.5 Batteries....................................................................................... 74
			3.1.5.1 Removal of the batteries.................................................................. 74
			3.1.5.2 Replacement of the batteries.............................................................. 76
		3.1.6 Radiator fan.................................................................................... 78
			3.1.6.1 Removal of the radiator fan assembly...................................................... 79
			3.1.6.2 Replacement of the radiator fan assembly.................................................. 83
			3.1.6.3 Removal of the radiator fan............................................................... 85
			3.1.6.4 Replacement of the radiator fan........................................................... 85
			3.1.6.5 Removal of the radiator fan drive pump.................................................... 86
			3.1.6.6 Replacement of the radiator fan drive pump................................................ 88
		3.1.7 Radiators....................................................................................... 89
			3.1.7.1 Removal of the Radiator assembly.......................................................... 89
			3.1.7.2 Replacement of the radiator assembly...................................................... 93
		3.1.8 Fuel cooler..................................................................................... 94
			3.1.8.1 Removal of the fuel cooler................................................................ 94
			3.1.8.2 Replacement of the fuel cooler............................................................ 96
		3.1.9 Starter system.................................................................................. 97
			3.1.9.1 Removal of the starter motor.............................................................. 97
			3.1.9.2 Replacement of the starter motor.......................................................... 97
		3.1.10 Geislinger coupling............................................................................ 98
			3.1.10.1 Removal of the Geislinger coupling....................................................... 99
			3.1.10.2 Replacement of the Geislinger coupling...................................................101
	3.2 PTO...................................................................................................102
		3.2.1 Main pumps......................................................................................102
			3.2.1.1 Preparatory works for main pump removal...................................................103
			3.2.1.2 Removal of Main Pump 1....................................................................106
			3.2.1.3 Replacement of main pump 1................................................................107
			3.2.1.4 Removal of Main Pump 2....................................................................109
			3.2.1.5 Replacement of main pump 2................................................................111
			3.2.1.6 Removal of Main Pump 3....................................................................113
			3.2.1.7 Replacement of main pump 3................................................................115
			3.2.1.8 Removal of Main Pump 4....................................................................116
			3.2.1.9 Replacement of main pump 4................................................................118
		3.2.2 PTO oil circulation pump (auxiliary pump).......................................................119
			3.2.2.1 Removal of the oil circulation pump (auxiliary pump)......................................119
			3.2.2.2 Replacement of the oil circulation pump (auxiliary pump)..................................121
		3.2.3 Pump distributor gearbox (PTO)..................................................................122
			3.2.3.1 Removal of the Pump distributor gearbox (PTO).............................................124
			3.2.3.2 Replacement of the Pump distributor gearbox (PTO).........................................127
	3.3 Hydraulics............................................................................................128
		3.3.1 Hydraulic cooler fan Drive Pump.................................................................128
			3.3.1.1 Removal of the hydraulic cooler fan drive pump............................................128
			3.3.1.2 Replacement of the hydraulic cooler fan drive pump........................................131
		3.3.2 Hydraulic Cooler Fan Assembly...................................................................132
			3.3.2.1 Removal of hydraulic cooler fan assembly..................................................132
			3.3.2.2 Replacement of hydraulic cooler fan assembly..............................................135
			3.3.2.3 Removal of hydraulic cooler Fan and motor.................................................136
			3.3.2.4 Replacement of hydraulic cooler Fan and motor.............................................138
		3.3.3 Hydraulic Oil Coolers...........................................................................140
			3.3.3.1 Removal of the hydraulic oil coolers......................................................142
			3.3.3.2 Replacement of the hydraulic oil coolers..................................................146
			3.3.3.3 Removal of the hydraulic oil cooler frame.................................................148
			3.3.3.4 Replacement of the hydraulic oil cooler frame.............................................153
		3.3.4 Main Relief Valves (MRV)........................................................................154
			3.3.4.1 Removal of the MRV........................................................................154
			3.3.4.2 Replacement of the MRV....................................................................155
		3.3.5 pilot oil pump (Gear pump)......................................................................156
			3.3.5.1 Removal of the pilot oil pump)............................................................156
			3.3.5.2 Replacement of the pilot oil pump.........................................................158
		3.3.6 Main Gate Valve.................................................................................158
			3.3.6.1 Removal of the main gate valve............................................................159
			3.3.6.2 Replacement of the main gate valve........................................................160
		3.3.7 Hydraulic Oil Reservoir.........................................................................162
			3.3.7.1 Removal of the hydraulic oil reservoir....................................................164
			3.3.7.2 Replacement of the hydraulic oil reservoir................................................171
		3.3.8 Main Control Valve Blocks.......................................................................173
			3.3.8.1 Removal of the main control valve blocks..................................................182
			3.3.8.2 Replacement of the main control valve blocks..............................................186
		3.3.9 Service line Relief Valves (SRV)................................................................187
			3.3.9.1 Removal of SRV on main Control valve block................................................187
			3.3.9.2 Replacement of SRV on main control valve blocks...........................................190
		3.3.10 Anti-cavitation Valves (ACV)...................................................................192
			3.3.10.1 Removal of ACV on Manifold...............................................................193
			3.3.10.2 Replacement of ACV on Manifold...........................................................198
			3.3.10.3 Removal of ACV on main control valve blocks..............................................199
			3.3.10.4 Replacement of ACV on main control valve blocks..........................................201
		3.3.11 Throttle check valves..........................................................................202
			3.3.11.1 Removal of throttle check valves.........................................................204
			3.3.11.2 Replacement of throttle check valves.....................................................207
		3.3.12 manifold.......................................................................................208
			3.3.12.1 Removal of the manifold..................................................................208
			3.3.12.2 Replacement of the manifold..............................................................210
			3.3.12.3 Removal of the Diffuser on the Manifold (FSA only).......................................211
			3.3.12.4 Replacement of Diffuser on Manifold (FSA only)...........................................213
	3.4 Slew Drive............................................................................................215
		3.4.1 Slew Gear.......................................................................................216
			3.4.1.1 Removal of the slew gear..................................................................217
			3.4.1.2 Replacement of the slew gear..............................................................219
		3.4.2 Swing Motor.....................................................................................222
			3.4.2.1 Removal of the swing motor................................................................223
			3.4.2.2 Replacement of the swing motor............................................................226
		3.4.3 Slew parking brake..............................................................................229
			3.4.3.1 Removal/Disassembly of the slew parking brake.............................................231
			3.4.3.2 Replacement/assembly of the slew parking brake............................................234
		3.4.4 Dynamic Slew Brake..............................................................................236
			3.4.4.1 Removal of the slew brake valve...........................................................239
			3.4.4.2 Replacement of the slew brake valve.......................................................241
		3.4.5 Swing circle lubrication pinion (dummy wheel)...................................................242
			3.4.5.1 Removal of the lubrication pinion assembly................................................244
			3.4.5.2 Replacement of the lubrication pinion assembly............................................246
	3.5 Lubrication pumps.....................................................................................247
		3.5.1 Removal of the Lubrication pump.................................................................247
		3.5.2 Replacement of the lubricating pump.............................................................249
	3.6 Pump controller MC7...................................................................................250
		3.6.1 Removal of the pump controller MC7..............................................................250
		3.6.2 Replacement of the pump controller MC7..........................................................251
	3.7 Operator’s Cab........................................................................................252
		3.7.1 Removal of the operator’s cab...................................................................255
		3.7.2 Replacement of the operator’s cab...............................................................260
		3.7.3 Cab-mounts......................................................................................261
			3.7.3.1 Removal of the cab-mounts.................................................................261
			3.7.3.2 replacement of the cab-mounts.............................................................263
		3.7.4 FRONT WINDOW....................................................................................264
			3.7.4.1 Removal of the Front window...............................................................264
			3.7.4.2 Replacement of the front window...........................................................265
		3.7.5 Operator’s seat.................................................................................266
			3.7.5.1 Removal of the operator’s seat............................................................266
			3.7.5.2 Replacement of the operator’s seat........................................................267
		3.7.6 VHMS............................................................................................268
			3.7.6.1 Removal of the VHMS-Controller............................................................268
			3.7.6.2 Replacement of the VHMS-Controller........................................................269
		3.7.7 Access Ladder...................................................................................270
			3.7.7.1 Removal of the access Ladder..............................................................273
			3.7.7.2 Replacement of the access ladder..........................................................275
			3.7.7.3 Removal of the access ladder cylinder.....................................................277
			3.7.7.4 Replacement of the access ladder cylinder.................................................279
		3.7.8 Removal of the cab base.........................................................................280
		3.7.9 Replacement of the cab base.....................................................................282
	3.8 Counterweight.........................................................................................284
		3.8.1 Removal of the counterweight....................................................................285
		3.8.2 Replacement of the counterweight................................................................287
	3.9 Superstructure Lifting................................................................................288
		3.9.1 Remove the Superstructure from the Undercarriage................................................288
		3.9.2 Install the Superstructure onto the undercarriage...............................................291
	3.10 Fuel Tank............................................................................................294
		3.10.1 Removal of the Fuel tank.......................................................................295
		3.10.2 Replacement of the Fuel tank...................................................................298
4 Undercarriage...............................................................................................301
	4.1 Travel System.........................................................................................302
		4.1.1 Track group.....................................................................................302
			4.1.1.1 Changing of the track group...............................................................302
		4.1.2 Sprocket........................................................................................306
			4.1.2.1 Removal of the sprocket...................................................................306
			4.1.2.2 Replacement of the sprocket...............................................................310
		4.1.3 Guide wheels....................................................................................312
			4.1.3.1 Removal of the guide wheel assembly.......................................................312
			4.1.3.2 Replacement of the guide wheel assembly...................................................313
		4.1.4 Track tensioning accumulators...................................................................314
			4.1.4.1 Removal of the low pressure accumulators..................................................314
			4.1.4.2 Replacement of the low pressure accumulators..............................................316
			4.1.4.3 Removal of the high pressure accumulators.................................................317
			4.1.4.4 Replacement of the high pressure accumulators.............................................318
		4.1.5 Track tension valve block.......................................................................319
			4.1.5.1 Removal of the track tensioning valve block...............................................319
			4.1.5.2 Replacement of the track tensioning valve block...........................................320
		4.1.6 Hydraulic hoses of the track tensioning system..................................................321
			4.1.6.1 Substitute the hydraulic hoses............................................................321
		4.1.7 Travel brake valve block (overspeed valve)......................................................324
			4.1.7.1 Removal of the travel brake valve block...................................................325
			4.1.7.2 Replacement of the travel brake valve block...............................................327
		4.1.8 Track tensioning cylinders......................................................................328
			4.1.8.1 Removal of the track tensioning cylinders.................................................328
			4.1.8.2 Replacement of the track tensioning cylinders.............................................329
		4.1.9 Travel motor....................................................................................330
			4.1.9.1 Removal of the travel motors..............................................................330
			4.1.9.2 Replacement of the travel motors..........................................................332
		4.1.10 travel parking brake...........................................................................334
			4.1.10.1 Removal/disassembly of the travel parking brake..........................................337
			4.1.10.2 Replacement/assembly of the travel parking brake.........................................340
		4.1.11 Travel gearbox.................................................................................342
			4.1.11.1 Removal of the travel gearbox............................................................343
			4.1.11.2 Replacement of the travel gearbox........................................................345
		4.1.12 Carrier roller.................................................................................346
			4.1.12.1 Removal of the carrier roller assembly...................................................346
			4.1.12.2 Replacement of the carrier roller assembly...............................................348
		4.1.13 Track roller...................................................................................349
			4.1.13.1 Removal of the Track roller assembly.....................................................349
			4.1.13.2 Replacement of the Track roller assembly.................................................351
	4.2 Car body..............................................................................................352
		4.2.1 Removal of the car bodY (previous type with mounting pins)......................................352
		4.2.2 Replacement of the car bodY (previous type with mounting pins)..................................356
		4.2.3 Removal OF the car Body (NEW type with bolted connection).......................................360
		4.2.4 Replacement of the car body (NEW type with bolted connection)...................................365
			4.2.4.1 Tightening torque for the crawler carrier mounting bolts..................................370
		4.2.5 Rotary joint....................................................................................374
			4.2.5.1 Removal of the rotary joint...............................................................376
			4.2.5.2 Replacement of the rotary joint...........................................................379
		4.2.6 swing circle....................................................................................380
			4.2.6.1 Removal of the swing circle...............................................................382
			4.2.6.2 Replacement of the swing circle...........................................................384
5 Attachment..................................................................................................389
	5.1 Backhoe...............................................................................................390
		5.1.1 Boom............................................................................................392
			5.1.1.1 Removal of the Boom.......................................................................392
			5.1.1.2 Replacement of the boom...................................................................396
			5.1.1.3 Removal of boom cylinders.................................................................398
			5.1.1.4 Replacement of boom cylinders.............................................................403
		5.1.2 Stick...........................................................................................406
			5.1.2.1 Removal of the Stick......................................................................406
			5.1.2.2 Replacement of Stick......................................................................410
			5.1.2.3 Removal of Stick Cylinders................................................................412
			5.1.2.4 Replacement of Stick cylinders............................................................417
		5.1.3 Bucket..........................................................................................420
			5.1.3.1 Removal of the bucket.....................................................................420
			5.1.3.2 Replacement of the bucket.................................................................423
			5.1.3.3 Removal of Bucket Cylinders...............................................................424
			5.1.3.4 Replacement of Bucket Cylinders...........................................................429
		5.1.4 Bucket link rod and steering rods...............................................................431
			5.1.4.1 Removal of the bucket link rod............................................................431
			5.1.4.2 Replacement of the bucket link rod........................................................433
			5.1.4.3 Removal of the steering rods..............................................................434
			5.1.4.4 Replacement of the steering rods..........................................................437
		5.1.5 Ground engaging tools (GET).....................................................................438
			5.1.5.1 Removal and replacement of the GET........................................................438
		5.1.6 Hydraulic hoses at the backhoe attachment.......................................................440
			5.1.6.1 Substitute the boom arc hoses.............................................................440
			5.1.6.2 Substitute the boom cylinder hoses........................................................444
			5.1.6.3 Substitute the stick cylinder hoses.......................................................448
			5.1.6.4 Substitute the bucket cylinder hoses......................................................452
	5.2 Faceshovel............................................................................................457
		5.2.1 Boom............................................................................................458
			5.2.1.1 Removal of the boom.......................................................................458
			5.2.1.2 Replacement of the boom...................................................................463
			5.2.1.3 Removal of the boom cylinders.............................................................468
			5.2.1.4 Replacement of the boom cylinders.........................................................473
		5.2.2 Stick...........................................................................................476
			5.2.2.1 Removal of the stick......................................................................476
			5.2.2.2 Replacement of the stick..................................................................480
			5.2.2.3 Removal of the stick cylinders............................................................482
			5.2.2.4 Replacement of the stick cylinders........................................................487
		5.2.3 Bullclam bucket.................................................................................490
			5.2.3.1 Removal of the bull clam bucket...........................................................490
			5.2.3.2 Replacement of the bull clam bucket.......................................................496
			5.2.3.3 Removal of the bucket cylinders...........................................................498
			5.2.3.4 Replacement of the bucket cylinders.......................................................502
			5.2.3.5 Removal of the clam cylinders.............................................................506
			5.2.3.6 Replacement of the clam cylinders.........................................................510
		5.2.4 Ground engaging tools (GET).....................................................................512
			5.2.4.1 Removal and replacement of the GET........................................................512
		5.2.5 Hydraulic hoses at the Faceshovel attachment....................................................514
			5.2.5.1 Substitute the boom arc hoses.............................................................514
			5.2.5.2 Substitute the boom cylinder hoses........................................................518
			5.2.5.3 Substitute the stick arc hoses............................................................522
			5.2.5.4 Substitute the stick cylinder hoses.......................................................526
			5.2.5.5 Substitute the bucket cylinder hoses......................................................530
			5.2.5.6 Substitute the clam cylinder hoses........................................................534
	5.3 Metering valves (grease injectors) at the attachment..................................................542
		5.3.1 Removal of the metering valves (grease injectors)...............................................542
		5.3.2 Replacement of the metering valves (grease injectors)...........................................543
	5.4 Cylinder bypass test..................................................................................544
6 Appendix....................................................................................................547
	6.1 Fuel and Lubricants...................................................................................548
	6.2 Filling Capacities....................................................................................550
	6.3 Tools List............................................................................................552
		6.3.1 Used special tools (Overview)...................................................................552
		6.3.2 KOMATSU tools catalogue.........................................................................555
	6.4 Work instructions.....................................................................................602
		6.4.1 Remove / install the crawler carrier............................................................602
		6.4.2 Use of the hydraulic torque wrench (supplier’s documentation)...................................603
	6.5 Service Bulletins.....................................................................................631
		6.5.1 AH00511d........................................................................................633
		6.5.2 AH00514.........................................................................................655
		6.5.3 AH00519.........................................................................................669
		6.5.4 AH01512.........................................................................................675
		6.5.5 AH01521a........................................................................................685
		6.5.6 AH01531A........................................................................................697
		6.5.7 AH02513b........................................................................................709
		6.5.8 AH02521.........................................................................................715
		6.5.9 AH03506B........................................................................................723
		6.5.10 AH03509a.......................................................................................731
		6.5.11 AH03510........................................................................................759
		6.5.12 AH03526a.......................................................................................779
		6.5.13 AH03538........................................................................................783
		6.5.14 AH04518........................................................................................811
		6.5.15 AH05510........................................................................................815
		6.5.16 AH05511........................................................................................819
		6.5.17 AH05546........................................................................................825
		6.5.18 AH06524........................................................................................829
		6.5.19 AH06530........................................................................................833

PLEASE NOTE:

• This is the SAME exact manual used by your dealers to fix your vehicle.
• The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
• Any queries / doubts regarding your purchase, please feel free to contact [email protected]