Komatsu PC4000E-6 Hydraulic Mining Shovel Shop Manual PDF

Description

Komatsu PC4000E-6 Hydraulic Mining Shovel Shop Manual – PDF DOWNLOAD

Komatsu PC4000E-6 Hydraulic Mining Shovel Shop Manual – PDF DOWNLOAD

Language : English
Pages : 1855
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu PC4000E-6 Hydraulic Mining Shovel Shop Manual – PDF DOWNLOAD

SERIAL NUMBER 08165- up

Cover 1
00 Foreword 4
Introduction 6
Safety Instructions 11
Safety 11
01 Specification 32
Specification PC4000 34
10 Structure, Function 42
I INTRODUCTION 44
SAFETY 46
FOREWORD 50
HOISTING INSTRUCTIONS 51
STANDARD TIGHTENING TORQUE 53
CONVERSION TABLE 54
TEMPERATURE 60
1 MAIN ASSEMBLY GROUPS 62
1 0 General lay out 63
1 1 Superstructure 65
1 1 1 Machine house 67
1 1 2 Hydraulic Oil Reservoir 69
1 1 3 Hydraulic Oil Cooler 71
1 1 4 Fuel tank (Fuel reservoir) 73
1 1 5 Counter weight 75
1 1 6 Cab support 77
1 1 7 Operators cab 79
1 1 8 Control blocks 81
1 1 9 Swing gears 83
1 2 Under carriage 85
1 3Attachment 87
2 DRIVE 92
2 0 Prime drive assembly 93
2 1 Flexible coupling 95
2 2 Pump distributor gearbox (PTO) 97
2 3 Pump – spline shaft lubrication 99
2 4 PTO Lubrication and cooling 101
2 5 PTO Lubrication and cooling – Adjustments 103
2 6 Hydraulic pumps – location, drive speed and flow rates 106
3 HYDRAULIC OIL TANK 108
3 0 General lay out 109
3 1 Main oil tank, location of switches, sensors etc 111
3 2 Suction oil tank with strainers 113
3 3 Return oil collector tube with strainer 115
3 4 Back pressure valve 117
3 5 Transfer pump (Optional Equipment) 119
Operational area of the Transfer Pump: 122
3 5 1 Evacuation of the suction oil reservoir 123
3 5 2 Evacuation of the return oil collector pipes and cooler circuit 127
3 5 3 Evacuation of the back-pressure valve pipe 129
3 6 Return and Leak Oil Filter 131
3 7 Breather filter 133
4 HYDRAULIC OIL COOLING 136
4 1 General 137
4 2 Function of the hydraulic oil cooling circuit 139
4 3 Adjustment of the Back Pressure Valve 141
4 4 Fan drive (Two stage cooler fan RPM control) 143
4 5 Pressure relief valves and solenoid valve 145
4 5 Pressure relief valves and solenoid valve 147
4 6 Fixed Displacement Pump, with variable setting 149
4 7 Adjustment of the cooler fan drive speed 151
5 CONTROLLING 158
5 0 General lay out 159
5 1 Control and filter panel location of components 161
5 2 Pilot Pressure Supply and Adjustments 165
5 3 Remote control valves arrangement 171
5 4 Function principle of the Electro-Hydraulic- Proportional Control 173
5 5 Potentiometer Control (Lever, Joy Stick) 177
5 6 Potentiometer Control (Pedal) 179
5 7 Proportional Amplifier Module, Type A 181
5 8 Proportional Amplifier Module, Type B 183
5 9 Ramp Time Module 185
5 10 Adjustments of Amplifier Modules (General) 187
5 11 Adjusting the Amplifiers Type B, illustration (Z 21642) 189
5 12 Adjusting the Amplifiers Type B, illustration (Z 21643) 193
5 13 Adjusting the Ramp Time Module 197
5 13 Adjusting the Ramp Time Module 199
6 COMPONENTS 206
6 1 1 Main Control Blocks and High Pressure Filter 207
6 1 2 Main Control Blocks and High Pressure Filter 209
6 1 3 Distributor Manifold – Location of restrictor blocks and anti cavitation valves 211
6 1 4 Distributor Manifold – Location of restrictor blocks and anti cavitation valves 213
6 1 5 Single Control Blocks (Floating) for Stick and Boom 215
6 1 6 Restrictor Block with Pressure Relief Valve 217
6 1 7 Anti Cavitation Valve Block 219
6 1 8 Remote control valves 221
6 1 9 Directional Solenoid Valves (Three positions / 4-ways) 223
6 1 10 Proportional Solenoid Valve 225
6 1 11 High Pressure Filter 227
6 1 12 Control Blocks and Valves 229
6 1 12 Adjusting the Ramp Time Module 235
6 1 13 Travel Brake Valve 241
6 1 14 Pressure Reducing Valve 243
6 1 15 Directional Solenoid Valves (Two positions / 4-ways) 245
6 1 16 Pressure Increasing Valve 247
6 1 17 Hydraulic Cylinder 250
6 4 Distributor Manifold – Location of Restrictor Blocks and Anti Cavitation Valves (BHA) 251
6 5 Single Control Blocks (Floating) for Stick and Boom (FSA) 253
6 6 Restrictor Block with Pressure Relief Valve 255
6 7 Anti cavitation valve block 257
6 8 Remote Control Valves 259
6 9 Directional Solenoid Valves (Three Positions / 4-Ways) 261
6 10 Proportional Solenoid Valve 263
6 11 High Pressure Filter 265
6 12 Control Blocks and Valves 267
6 13 Travel Brake Valve 279
6 14 Pressure Reducing Valve 281
6 15 Directional Solenoid Valves (Two Positions / 4-Ways) 283
6 16 Pressure Increasing Valve 285
6 17 Hydraulic Cylinder 287
6 18 Swing Ring 291
7 MAIN HYDRAULIC PUMPS AND PUMP REGULATION 252
7 0 Main hydraulic pumps and pump regulation system 253
7 6 Energy Efficiency 351
7 1 Main Pumps 261
7 2 3 Main Pumps 305
7 2 1 Electronic Pump Regulation System 291
7 2 2 General 295
7 2 3 Checks and adjustments Microcontroller MC7, illustration (Z 22629c) Cont’d: 307
7 2 3 Checks and adjustments Microcontroller MC7, illustration (Z 22636) Cont’d: 309
7 2 3 Checks and adjustments Microcontroller MC7, illustration (Z 22358f) 327
7 2 3 Checks and adjustments Microcontroller MC7, illustration (Z 22358f) 340
7 2 3 Checks and adjustments Microcontroller MC7, illustration (Z 22358f) Method C 338
7 2 3 Checks and adjustments Microcontroller MC7, illustration (Z 22639f) Method C 342
8 OPERATING HYDRAULICS 358
8 0 General 359
8 1 Table of contents section 363
8 1 1 Electric / Hydraulic flowchart “ Boom raising ” FSA 365
8 1 1 Electric / Hydraulic flowchart “ Boom raising ” BHA 367
8 1 2 Electric / Hydraulic flowchart “ Boom lowering ” FSA 369
8 1 2 Electric / Hydraulic flowchart “ Boom lowering ” BHA 371
8 1 3 Electric / Hydraulic flowchart “ Stick extending ” FSA 373
8 1 3 Electric / Hydraulic flowchart “ Stick extending ” BHA 375
8 1 4 Electric / Hydraulic flowchart “ Stick retracting ” FSA 377
8 1 4 Electric / Hydraulic flowchart “ Stick retracting ” BHA 379
8 1 5 Electric / Hydraulic flowchart “ Bucket filling ” FSA 381
8 1 5 Electric / Hydraulic flowchart “ Bucket filling ” BHA 383
8 1 6 Electric / Hydraulic flowchart “ Bucket emptying ” FSA 385
8 1 6 Electric / Hydraulic flowchart “ Bucket emptying ” BHA 387
8 1 7 Electric / Hydraulic flowchart “ Clam opening ” FSA 389
8 1 8 Electric / Hydraulic flowchart “ Clam closing ” FSA 391
8 1 9 Checks and adjustments of the Main Relief Valves (MRV), illustration (Z 21972): 393
8 1 9 Checks and adjustments of the Main Relief Valves (MRV), illustration (Z 21972): 395
8 1 10 Checks and adjustments of the Service Line Relief Valves (SRV),illustration (Z 21973): 397
8 1 10 Checks and adjustments of the Service Line Relief Valves (SRV),illustration (Z 21973): 399
8 1 10 Checks and adjustments of the Service Line Relief Valves (SRV),illustration (Z 21974): 401
8 1 10 Checks and adjustments of the Service Line Relief Valves (SRV),illustration (Z 21974): 403
8 1 10 Checks and adjustments of the Service Line Relief Valves (SRV),illustration (Z 21977): 405
8 1 10 Checks and adjustments of the Service Line Relief Valves (SRV),illustration (Z 21977): 407
8 1 10 Checks and adjustments of the Service Line Relief Valves (SRV),illustration (Z 21978): 409
8 1 10 Checks and adjustments of the Service Line Relief Valves (SRV),illustration (Z 21978): 411
8 1 10 Checks and adjustments of the Service Line Relief Valves (SRV),illustration (Z 21979): 413
8 1 10 Checks and adjustments of the Service Line Relief Valves (SRV),illustration (Z 21979): 415
8 1 10 Checks and adjustments of the Service Line Relief Valves (SRV),illustration (Z 21980a): 417
8 1 10 Checks and adjustments of the Service Line Relief Valves (SRV),illustration (Z 21980a): 419
8 1 10 Checks and adjustments of the Service Line Relief Valves (SRV),illustration (Z 21997): 421
8 1 10 Checks and adjustments of the Service Line Relief Valves (SRV),illustration (Z 21997): 423
8 1 10 Checks and adjustments of the Service Line Relief Valves (SRV),illustration (Z 21998): 425
8 1 10 Checks and adjustments of the Service Line Relief Valves (SRV),illustration (Z 21998): 427
8 1 10 Checks and adjustments of the Service Line Relief Valves (SRV),illustration (Z 21999): 429
8 1 10 Checks and adjustments of the Service Line Relief Valves (SRV),illustration (Z 21999): 431
8 1 10 Checks and adjustments of the Service Line Relief Valves (SRV),illustration (Z 22000): 433
8 1 10 Checks and adjustments of the Service Line Relief Valves (SRV),illustration (Z 22000): 435
8 1 10 Checks and adjustments of the Service Line Relief Valves (SRV),illustration (Z 22001): 437
8 1 10 Checks and adjustments of the Service Line Relief Valves (SRV),illustration (Z 22002): 439
8 1 11 Checks and adjustments of the lowering speed,illustration (Z 22033): 441
8 1 11 Checks and adjustments of the lowering speed,illustration (Z 22006): 443
8 1 11 Checks and adjustments of the lowering speed,illustration (Z 22021): 445
8 1 11 Checks and adjustments of the lowering speed,illustration (Z 22022): 447
8 1 11 Checks and adjustments of the lowering speed,illustration (Z 22025): 449
8 1 11 Checks and adjustments of the lowering speed,illustration (Z 22026): 451
8 1 11 Checks and adjustments of the lowering speed,illustration (Z 22029): 453
8 1 11 Checks and adjustments of the lowering speed,illustration (Z 22030): 455
8 1 11 Checks and adjustments of the lowering speed,illustration (Z 22031): 457
8 1 11 Checks and adjustments of the lowering speed,illustration (Z 22032): 461
8 2 Table of contents section 462
8 2 1 Swing Circuit 464
Cont’d :8 2 1 Swing Circuit 466
8 2 2 Swing Motor 468
Cont’d :8 2 2 Swing Motor, illustration (Z 21936) 470
8 2 3 Swing Gear Box 472
8 2 4 Swing Parking Brake (Gear house Brake) 474
8 2 5 Swing Brake Valve 476
Cont’d :8 2 5 Swing Brake Valve, illustration (Z 21935) 478
8 2 6 Electric / Hydraulic flowchart “Swing Left” 480
8 2 7 Electric / Hydraulic flowchart “Swing Right” 482
8 2 8 Checks and adjustments for the swing circuit 484
8 2 8 Checks and adjustments for the swing circuit, illu (Z 21948b) 486
8 2 8 Checks and adjustments for the swing circuit, illu (Z 21948b) 488
8 2 9 Function check for hydraulic swing brake 490
8 2 10 Function check for the swing parking brake 492
8 3 Table of contents section 494
8 3 1 Travel Circuit 496
Cont’d :8 3 1 Travel Circuit 498
8 3 2 Travel Motor 500
8 3 3 Rotary Distributor 502
8 3 4 Travel gear 504
8 3 5 Travel parking brake (Gear house brake) 506
8 3 6 Travel Brake Valve 508
8 3 7 Electric / Hydraulic flowchart “ Traveling forward ” 510
8 3 8 Hydraulic for the Travel Circuit 511
8 3 9 Checks and adjustments for the travel circuit 514
8 3 10 Travel Motor 515
9 HYDRAULIC TRACK TENSIONING SYSTEM 518
9 0 General: 520
9 1 Functional description: 522
9 1 Functional description: 524
9 2 Pressure Increasing Valve 526
9 2 Pressure Increasing Valve 539
9 3 Tensioning cylinder: 528
9 3 Tensioning Cylinder 541
9 4 Adjustments / Checks 530
9 4 Adjustments / Checks 532
9 4 Adjustments / Checks 534
9 4 Adjustments / Checks 536
9 4 Adjustments / Checks 543
9 5 Functional Test 545
10 ACCESS LADDER HYDRAULICALLY OPERATED 538
10 0 General 540
10 1 Function of hydraulically operated access ladder 542
10 1 Function of hydraulically operated access ladder 544
10 2 Adjustments / Checks 546
11 CABLE DRUM 548
11 0 General 549
11 1 Components 552
11 2 Function 553
11,2 Function 555
11 3 Checks and Adjustments 557
11 4 Description and operating instruction for cam switch 5S4 and 5S6 560
12 HINTS FOR READING THE HYDRAULIC DIAGRAM 562
12 0 General: 563
12 1 SymbolsIllustration Z 22988 566
12 1 Symbols 567
12 1 Symbols 569
12 1 Symbols 571
12 1 Symbols 573
12 1 Symbols 575
12 2 Legend for the circuit diagram (929 663 40): 578
12 2 Legend for the circuit diagram (929 663 40): 580
12 2 Legend for the circuit diagram (929 663 40): 582
12 2 Legend for the circuit diagram (929 663 40): 584
13 HINTS FOR READING THE ELECTRIC CIRCUIT DIAGRAM 586
13 1 Designation of electrical devices 588
13 2 Symbols 589
13 2 Symbols 591
13 3 General information 593
13 3 General information 595
13 4 Reading a Circuit Diagram 598
13 4 Reading a Circuit Diagram 600
14 ELECTRONIC CONTROL SYSTEM (ECS) 602
14 1 General Design of the ECS System 604
14 1 1 Input and Output of the PLC, Illust Z 21408 606
14 1 3 PLC DIGSY plus ® (circuit diagram code E6) 608
14 1 4 Definitions; Symbols and Abbreviations 610
14 1 4 Definitions; Symbols and Abbreviations 612
14 1 4 Definitions; Symbols and Abbreviations 614
14 2 How to Proceed due Maintenance and Installation 616
14 2 How to Proceed due Maintenance and Installation 618
14 2 1 Meaning of the Status LED’s, Illust Z 21431b 620
14 2 1 Meaning of the Status LED’s, Illust Z 21431b 622
14 2 2 Short Circuit Marker -LED “MK” 624
14 2 3 Diagnostic for Temperature-Module “ANM” 626
14 3 Front Connector Arrangement 628
14 3 Front Connector Arrangement 630
14 3 Front Connector Arrangement 632
14 3 Front Connector Arrangement 634
14 3 Front Connector Arrangement 636
14 3 Front Connector Arrangement 638
14 4 Power supply 639
14 4 Power supply 642
14 5 Function explanations with electrical diagram 646
14 5 Function explanations with electrical diagram 648
14 5 3 Temperature Measuring and trouble shooting Illustration Z22803a 650
14 5 3 Temperature Measuring and trouble shooting, illustration Z22803a 652
14 5 Function explanations with electrical diagram 654
14 6 Hints for reading the functional flow charts 656
14 6 Hints for reading the functional flow charts 658
15 AUTOMATIC LUBRICATION SYSTEMS 736
15 1 GENERAL DESCRIPTION 737
15 2 BASIC FUNCTION OF THE LUBRICATION SYSTEMS 739
15 3 CENTRAL LUBRICATION SYSTEM (CLS) 741
15 3 1 GENERAL INFORMATION ON CLS 743
15 4 LUBRICATION PUMP STATION (SLS) 745
15 4 1 GENERAL INFORMATION ON SLS 747
15 5 LUBRICATION CYCLE 748
15 5 2 LUBRICATION CYCLE – COMPONENTS 749
15 5 3 LUBRICATION CYCLE – PROCESSING 751
15 5 4 TIME SEGMENTS & SWITCH POINTS OF A LUBRICATION CYCLE 752
15 5 5 LUBRICATION MODES 753
15 6 HYDRAULICALLY DRIVEN LUBE PUMP 755
15 6 1 ADJUSTMENT OF LUBE PUMP SPEED & WORKING PRESSURE 757
15 6 1 1 STROKE SPEED ADJUSTMENT 758
15 7 LUBRICANT INJECTORS 759
15 7 2 DESCRIPTION 760
15 7 4 OPERATION PRINCIPLE OF LUBRICANT INJECTORS 761
15 7 4 1 FUNCTION DESCRIPTION 763
15 8 VENT VALVE 765
15 9 END-LINE SWITCH 767
15 9 2 CLS END-LINE SWITCH ADJUSTMENT 769
15 9 3 SLS END-LINE SWITCH ADJUSTMENT 771
15 10 IN-LINE FILTER 773
15 10 1 DESCRIPTION 774
15 11 LUBRICANT LEVEL SENSOR 775
15 11 1 DESCRIPTION 776
15 12 LUBRICATION PINION (SLS) 779
15 12 1 DESCRIPTION 780
15 13 Central Lubrication System (CLS) 781
15 13 2 FINE ADJUSTMENT 782
15 13 3 COMMISSIONING OF THE SLS LUBRICATION SYSTEM 783
50 Dissassembly and Assembly 834
Table of contents 837
1 Introduction 846
1 1 Contents of this binder 847
1 2 Preface 848
1 2 1 Contacting the Service 848
1 2 2 Guarantee 848
2 SAFETY 850
3 Superstructure 852
3 1 Superstructure / machine house overview 853
3 2 Batteries 855
3 2 1 Removal of the batteries 855
3 2 2 Replacement of the batteries 857
3 3 Electric motor 858
3 3 1 Removal of the electric motor 858
3 3 2 Replacement of the electric motor 863
3 3 3 Final alignment of the electric motor 866
3 3 4 Capacitor assembly 867
3 3 4 1 Removal of the capacitor assembly 868
3 3 4 2 Replacement of the capacitor assembly 870
3 4 Coupling assembly 871
3 4 1 Vulkan coupling 871
3 4 1 1 Removal of the Vulkan coupling 873
3 4 1 2 Replacement of the Vulkan coupling 875
3 5 PTO 877
3 5 1 Overview of the PTO and the mounting of the pumps 877
3 5 2 Main pumps 879
3 5 2 1 Preparatory works for main pump removal 879
3 5 2 2 Removal of main pump 1 882
3 5 2 3 Replacement of main pump 1 884
3 5 2 4 Removal of main pump 2 885
3 5 2 5 Replacement of main pump 2 887
3 5 2 6 Removal of main pump 3 888
3 5 2 7 Replacement of main pump 3 888
3 5 2 8 Removal of main pump 4 888
3 5 2 9 Replacement of main pump 4 888
3 5 3 PTO oil circulation pump (auxiliary pump) 889
3 5 3 1 Removal of the oil circulation pump (auxiliary pump) 889
3 5 3 2 Replacement of the oil circulation pump (auxiliary pump) 891
3 5 4 Pilot oil pump 892
3 5 4 1 Removal of the pilot oil pump 892
3 5 4 2 Replacement of the pilot oil pump 892
3 5 5 Hydraulic oil cooler fan drive pump 894
3 5 5 1 Removal of the hydraulic oil cooler fan drive pump 894
3 5 5 2 Replacement of the hydraulic oil cooler fan drive pump 896
3 5 6 Pump distributor gearbox (PTO) 897
3 5 6 1 Removal of the pump distributor gearbox (PTO) 899
3 5 6 2 Replacement of the pump distributor gearbox (PTO) 901
3 6 Hydraulics 903
3 6 1 Hydraulic oil cooler assembly 903
3 6 1 1 Removal of hydraulic cooler fan 904
3 6 1 2 Replacement of hydraulic cooler fan 905
3 6 1 3 Removal of hydraulic cooler fan bearings and motors 906
3 6 1 4 Replacement of hydraulic cooler fan bearings and motors 908
3 6 1 5 Removal of the hydraulic oil coolers 909
3 6 1 6 Replacement of the hydraulic oil coolers 912
3 6 1 7 Removal of the hydraulic oil cooler assembly 913
3 6 1 8 Replacement of the hydraulic oil cooler assembly 918
3 6 2 Main gate valve 919
3 6 2 1 Removal of the main gate valve 919
3 6 2 2 Replacement of the main gate valve 920
3 6 3 Hydraulic oil reservoir 921
3 6 3 1 Removal of the hydraulic oil reservoir 922
3 6 3 2 Replacement of the hydraulic oil reservoir 928
3 6 4 Main control valve blocks 931
3 6 4 1 General information 931
3 6 4 2 Removal of the main control valve blocks 939
3 6 4 3 Replacement of the main control valve blocks 943
3 6 5 Main relief valves (MRV) 944
3 6 5 1 Removal of the MRV at the main control valve blocks 944
3 6 5 2 Replacement of the MRV at the main control valve blocks 945
3 6 6 Service line relief valves (SRV) 947
3 6 6 1 Removal of SRV on main control valve block 948
3 6 6 2 Replacement of SRV on main control valve blocks 949
3 6 7 Anti-cavitation valves (ACV) 950
3 6 7 1 Removal of single ACV at the manifold 952
3 6 7 2 Replacement of single ACV at the manifold 955
3 6 7 3 Removal of ACV with attached check valve at the manifold 956
3 6 7 4 Replacement of ACV with attached check valve at the manifold 958
3 6 7 5 Removal of ACV on main control valve blocks 960
3 6 7 6 Replacement of ACV on main control valve blocks 961
3 6 8 Throttle check valves 963
3 6 8 1 Removal of throttle check valves 966
3 6 8 2 Replacement of throttle check valves 968
3 6 9 Diffuser block (FSA only) 969
3 6 9 1 Removal of the Diffuser block at the manifold 969
3 6 9 2 Replacement of the Diffuser block at the manifold 971
3 6 10 Manifold 972
3 6 10 1 Removal of the manifold 972
3 6 10 2 Replacement of the manifold 975
3 7 Slew system 976
3 7 1 Slew gear 976
3 7 1 1 Removal of the slew gear 978
3 7 1 2 Replacement of the slew gear 981
3 7 2 Swing motor 983
3 7 2 1 Removal of the swing motor 984
3 7 2 2 Replacement of the swing motor 986
3 7 3 Slew parking brake 987
3 7 3 1 Removal/disassembly of the slew parking brake (L&S) 988
3 7 3 2 Replacement/assembly of the slew parking brake (L&S) 991
3 7 3 3 Removal of the slew parking brake (siebenhaar) 994
3 7 3 4 Replacement of the slew parking brake (Siebenhaar) 997
3 7 4 Dynamic slew brake 1001
3 7 4 1 Removal of the slew brake valve 1004
3 7 4 2 Replacement of the slew brake valve 1006
3 7 5 Swing circle 1007
3 7 5 1 Removal of the swing circle 1008
3 7 5 2 Replacement of the swing circle 1011
3 7 6 Swing circle lubrication pinion (dummy wheel) 1015
3 7 6 1 Removal of the lubrication pinion assembly 1016
3 7 6 2 Replacement of the lubrication pinion assembly 1018
3 8 Lubrication pumps 1019
3 8 1 Removal of the lubrication pump 1019
3 8 2 Replacement of the lubricating pump 1021
3 9 Operator’s cab 1023
3 9 1 Removal of the operator’s cab 1025
3 9 2 Replacement of the operator’s cab 1030
3 9 3 Cab-mounts 1031
3 9 3 1 Removal of the cab-mounts 1031
3 9 3 2 replacement of the cab-mounts 1033
3 9 4 Front window 1035
3 9 4 1 Removal of the front window 1035
3 9 4 2 Replacement of the front window 1036
3 9 5 Operator’s seat 1037
3 9 5 1 Removal of the operator’s seat 1037
3 9 5 2 Replacement of the operator’s seat 1038
3 10 Cab base (medium voltage switch cabinet) 1039
3 10 1 Removal of the cab base 1039
3 10 2 Replacement of the cab base 1042
3 10 3 Pump controller 1044
3 10 3 1 Removal of the pump controller 1044
3 10 3 2 Replacement of the pump controller 1045
3 11 Access ladder 1047
3 11 1 Removal of the access ladder 1048
3 11 2 Replacement of the access ladder 1050
3 11 3 Removal of the access ladder cylinder 1052
3 11 4 Replacement of the access ladder cylinder 1054
3 12 Counterweight 1055
3 12 1 Removal of the counterweight 1056
3 12 2 Replacement of the counterweight 1058
3 13 Superstructure Lifting 1059
3 13 1 Remove the superstructure from the undercarriage 1059
3 13 2 Install the superstructure onto the undercarriage 1064
3 14 High voltage switch cabinet 1067
3 14 1 Removal of the high voltage switch cabinet 1067
3 14 2 Replacement of the high voltage switch cabinet 1072
3 15 Slip ring unit 1073
3 15 1 Removal of the slip ring unit 1074
3 15 2 Replacement of the slip ring unit 1077
4 Undercarriage 1078
4 1 Undercarriage overview 1079
4 2 Travel system 1081
4 2 1 Track group 1081
4 2 1 1 Changing of the track group 1081
4 2 2 Sprocket 1086
4 2 2 1 Removal of the sprocket 1086
4 2 2 2 Replacement of the sprocket 1091
4 2 3 Guide wheels 1093
4 2 3 1 Removal of the guide wheel assembly 1093
4 2 3 2 Replacement of the guide wheel assembly 1095
4 2 4 Track tensioning accumulators 1097
4 2 4 1 Removal of the low pressure accumulators 1097
4 2 4 2 Replacement of the low pressure accumulators 1098
4 2 4 3 Removal of the high pressure accumulators 1100
4 2 4 4 Replacement of the high pressure accumulators 1101
4 2 5 Track tension valve block 1102
4 2 5 1 Removal of the track tensioning valve block 1102
4 2 5 2 Replacement of the track tensioning valve block 1104
4 2 6 Track tensioning cylinders 1105
4 2 6 1 Removal of the track tensioning cylinders 1105
4 2 6 2 Replacement of the track tensioning cylinders 1107
4 2 7 Hydraulic hoses of the track tensioning system 1108
4 2 7 1 Precursory work 1108
4 2 7 2 Substitute the hydraulic hoses inside the car body 1110
4 2 7 3 Substitute the hydraulic hoses between car body and crawler frame 1110
4 2 7 4 Substitute the hydraulic hoses inside the crawler frame 1112
4 2 7 5 Subsequent work 1112
4 2 8 Travel brake valve block (overspeed valve) 1114
4 2 8 1 Removal of the travel brake valve block 1117
4 2 8 2 Replacement of the travel brake valve block 1118
4 2 9 Travel motors 1119
4 2 9 1 Removal of the travel motors 1119
4 2 9 2 Replacement of the travel motors 1121
4 2 10 Travel parking brake 1123
4 2 10 1 Travel parking brake overview 1123
4 2 10 2 Removal/disassembly of the travel parking brake (L&S) 1128
4 2 10 3 Replacement/assembly of the travel parking brake (L&S) 1131
4 2 10 4 Removal/disassembly of the travel parking brake (Zollern) 1134
4 2 10 5 Replacement/assembly of the travel parking brake (Zollern) 1137
4 2 11 Travel gear box 1139
4 2 11 1 Removal of the travel gear box 1140
4 2 11 2 Replacement of the travel gear box 1142
4 2 12 Carrier roller 1144
4 2 12 1 Removal of the carrier roller assembly 1144
4 2 12 2 Replacement of the carrier roller assembly 1147
4 2 13 Track roller 1148
4 2 13 1 Removal of the track roller assembly 1148
4 2 13 2 Replacement of the track roller assembly 1150
4 3 Car body 1151
4 3 1 Removal of the car body and the crawler carriers (type with mounting pins) 1151
4 3 2 Replacement of the car body and the crawler carriers (type with mounting pins) 1155
4 3 3 Removal of the car Body and the crawler carriers (type with bolted connection) 1159
4 3 4 Replacement of the car body and the crawler carriers (type with bolted connection) 1165
4 3 5 Rotary joint 1173
4 3 5 1 Removal of the rotary joint 1173
4 3 5 2 Replacement of the rotary joint 1176
4 4 Cable drum (optional) 1177
4 4 1 Preparatory work for the removal and replacement of the cable drum assembly 1178
4 4 2 Removal of the cable drum assembly 1179
4 4 3 Replacement of the cable drum assembly 1180
4 5 Cable supply 1183
4 5 1 Preparatory work for the removal and replacement of the cable supply 1184
4 5 2 Removal of the cable supply 1185
4 5 3 Replacement of the cable supply assembly 1187
5 Attachment 1190
5 1 Backhoe 1191
5 1 1 Boom 1192
5 1 1 1 Removal of the Boom 1192
5 1 1 2 Replacement of the boom 1195
5 1 1 3 Removal of the boom cylinders 1197
5 1 1 4 Replacement of the boom cylinders 1202
5 1 2 Stick 1207
5 1 2 1 Removal of the Stick 1207
5 1 2 2 Replacement of the Stick 1211
5 1 2 3 Removal of the Stick Cylinders 1213
5 1 2 4 Replacement of the Stick cylinders 1218
5 1 3 Bucket 1223
5 1 3 1 Removal of the bucket 1223
5 1 3 2 Replacement of the bucket 1226
5 1 3 3 Removal of the Bucket Cylinders 1227
5 1 3 4 Replacement of the Bucket Cylinders 1233
5 1 4 Bucket link rod and steering rods 1236
5 1 4 1 Removal of the bucket link rod 1236
5 1 4 2 Replacement of the bucket link rod 1238
5 1 4 3 Removal of the steering rods 1239
5 1 4 4 Replacement of the steering rods 1242
5 1 5 Ground engaging tools (GET) 1243
5 1 5 1 Removal and replacement of the GET 1243
5 1 6 Hydraulic hoses at the backhoe attachment 1245
5 1 6 1 Substitute the boom arc hoses 1245
5 1 6 2 Substitute the boom cylinder hoses 1251
5 1 6 3 Substitute the stick cylinder hoses 1255
5 1 6 4 Substitute the bucket cylinder hoses 1259
5 2 Faceshovel 1263
5 2 1 Using the installation tools for hydraulic cylinders 1264
5 2 2 Boom 1265
5 2 2 1 Removal of the boom 1265
5 2 2 2 Replacement of the boom 1272
5 2 2 3 Removal of the boom cylinders 1277
5 2 2 4 Replacement of the boom cylinders 1281
5 2 3 Stick 1285
5 2 3 1 Removal of the stick 1285
5 2 3 2 Replacement of the stick 1289
5 2 3 3 Removal of the stick cylinders 1293
5 2 3 4 Replacement of the stick cylinders 1297
5 2 4 Bull Clam bucket 1301
5 2 4 1 Removal of the bull clam bucket 1301
5 2 4 2 Replacement of the bull clam bucket 1307
5 2 4 3 Removal of the bucket cylinders 1309
5 2 4 4 Replacement of the bucket cylinders 1313
5 2 4 5 Removal of the clam cylinders 1317
5 2 4 6 Replacement of the clam cylinders 1321
5 2 5 Ground engaging tools (GET) 1324
5 2 5 1 Removal and replacement of the GET 1324
5 2 6 Hydraulic hoses at the Faceshovel attachment 1325
5 2 6 1 Substitute the boom arc hoses 1325
5 2 6 2 Substitute the boom cylinder hoses 1331
5 2 6 3 Substitute the stick arc hoses 1335
5 2 6 4 Substitute the stick cylinder hoses 1339
5 2 6 5 Substitute the bucket cylinder hoses 1343
5 2 6 6 Substitute the clam cylinder hoses 1347
5 3 Metering valves (grease injectors) at the attachment 1355
5 3 1 Operation test of the metering valves (grease injectors) 1356
5 3 2 Removal of the metering valves (grease injectors) 1357
5 3 3 Replacement of the metering valves (grease injectors) 1359
5 4 Cylinder bypass test 1360
6 Service Information 1362
6 1 Classification of Voltages for KMG Electric Shovels 1363
6 2 Fluids and lubricants 1363
6 3 Lifting Gears 1364
6 4 Safety hints for sling accessory 1366
6 5 Filling capacities 1367
6 6 Work instructions 1368
6 6 1 Remove / install the crawler carrier 1368
6 7 Weight tables 1369
6 7 1 Superstructure 1369
6 7 2 Undercarriage 1371
6 7 3 Backhoe attachment (BHA) 1372
6 7 4 Face shovel attachment (FSA) 1373
6 8 Torque charts according to KOMATSU company standard 1374
6 8 1 Metric standard thread 1374
6 8 2 Metric fine thread 1375
6 8 3 Cummins motor torques – metric 1376
6 8 4 Cummins motor torques – U S customary 1376
6 8 5 Flange connections 1377
6 9 Blind plugs 1378
6 9 1 Dummy plates for SAE–flanges 1378
6 9 2 Classification of threads to the nominal width 1380
6 9 3 Plugs and fittings according to DIN 2353 1381
6 10 Conversion table 1382
6 10 1 Method of using the conversion table 1382
6 10 2 Millimeter – inch & kilogram – pound 1383
6 10 3 Liter – U S gallon & liter – U K gallon 1384
6 10 4 Nm- ft lb 1385
6 10 5 Bar – PSI – kPa – MPa 1386
6 10 6 Temperature 1387
6 11 Tools 1388
6 11 1 Standard tool case 1388
6 11 2 Used special tools (Overview) 1390
7 Tools catalogue 1394
8 Parts & Service News 1450
8 1 List of the PARTS AND SERVICE NEWS 1451
AH00511 1454
AH00514 1476
AH00515 1488
AH01513 1498
AH01523 1502
AH01531 1506
AH02513 1516
AH02521 1520
AH03509 1536
AH03510 1562
AH03528 1580
AH03528 1582
AH05510 1584
AH05511 1586
AH05518 1590
AH05535 1592
AH05537 1616
AH05546 1632
AH06524 1634
AH06530 1636
AH06544 1638
AH06545 1650
AH08502 1654
AH08504 1662
AH08508 1664
AH08510 1667
AH09504 1673
AH09522 1676
AH11507 1808
AH10530 1817
AH11517 1819
9 Supplier’s documentation 1829

DESCRIPTION:

Komatsu PC4000E-6 Hydraulic Mining Shovel Shop ManuaI – PDF DOWNLOAD 

GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR:
2.4.1 UNDERSTANDING THE MACHINE
Before operating the machine, read this manual thoroughly. If there are any places in this manual that you do not
understand, ask the person in charge of safety to give an explanation.
2.4.2 PRECAUTIONS BEFORE STARTING OPERATION ON THE EXCAVATOR
2.4.2.1 ENSURING SAFE OPERATION
– Only trained and authorized personnel can operate and maintain the machine.
– During operations, personnel are not allowed outside of the operator’s cabin.
– Follow all safety rules, precautions and instructions when operating or performing inspection or maintenance
on the machine.
– If you are not feeling well, or are under the influence of alcohol or medication, your ability to safely operate or
repair your machine may be severly impaired putting yourself and everyone else on your jobsite in danger.
– When working with another operator or with a person on worksite traffic duty, discuss the content of the operation
beforehand and use pre-determined signals when carrying out these operations.
2.4.3 PREPARATIONS FOR SAFE OPERATION
2.4.3.1 PRECAUTIONS REGARDING SAFETY RELATED EQUIPMENT
– Be sure that all guards, covers and mirrors are in their proper positions. Have guards and covers repaired
immediately if they are damaged.
– Understand the method of use of safety features and use them properly.
– Never remove any safety features. Always keep them in good operating condition.
2.4.3.2 INSPECTING THE MACHINE
Check the machine before starting operations. If any abnormality is found, do not operate the machine until repairs
of the problem location have been completed.

S.V 11/12/24