This complete service repair workshop manual PDF download for the PC4000-6 Komatsu Hydraulic Mining Excavator (S/N: 08199 and up) has easy to read text sections with top quality diagrams, pictures and illustrations. The step by step instructions show you how to fault find or complete any repair or overhaul, correctly and efficiently, saving time and avoiding costly mistakes. All specifications and tolerances are listed. Functions of components and systems are also explained.
APPLICABLE MODELS :
Machine Model : PC4000-6
Serial Numbers : 08199 and up
TABLE OF CONTENTS :
00 Foreword
01 Specification
10 Structure, Function
40 Troubleshooting
50 Disassembly and Assembly
MANUAL SPECIFICATION :
File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : SHOP 08199-upD-GB-1
Total Pages : 1986
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Shop 08199-upD-GB-0 PC4000-6 HYDRAULIC MINING SHOVEL
00 Foreword
Introduction
Safety Instructions
01 Specification
Specification PC4000
10 Structure, Function
Table of Contents
I. INTRODUCTION
I.I Contents of the Binder
I.II Foreword
I.III Explanation of Abbrevations
I.IV EXPLANATION OF ABBREVATIONS
I.V DIAGRAMS AND ILLUSTRATIONS IN THIS MANUAL
III. SPECIFICATIONS
III.I Lifting Gears
III.II Standard Tightening Torque Chart
III.III Conversion Table
III.IV General Specifications
III.V BLIND PLUGS
III.VI CLASSIFICATION OF THREADS TO THE NOMINAL WIDTH
III.VII PLUGS AND FITTINGS ACCORDING TO ISO 8434-1 / DIN 2353
1 MAIN ASSEMBLY GROUPS
1.1 General Layout
1.2 Superstructure
1.3 Machine House
1.4 Hydraulic Oil Reservoir
1.5 Hydraulic Oil Cooler
1.6 Fuel Tank
1.7 Counterweight
1.8 Cab Support
1.9 Operator’s Cab
1.10 Control Blocks
1.11 Swing Gears
1.11.1 SWING MACHINERY L&S
1.11.2 SWING MACHINERY SIEBENHAAR
1.12 Undercarriage
1.13 Backhoe Attachment (BHA)
1.14 Front Shovel Attachment (FSA)
2. DRIVE
2.1 Prime Drive Assembly
2.2 Engine and PTO Mounts
2.2.1 Flexible Mounts
2.2.2 Torque Support
2.3 Fan Drive and Radiator Assembly
2.4 FAN DRIVE AND RADIATOR ASSEMBLY
2.4.1 RADIATOR FAN DRIVE SPEED ADJUSTMENT
2.5 PUMP DISTRIBUTOR GEARBOX (PTO)
2.5.3 HYDRAULIC PUMPS
2.5.1 PUMP DRIVE SHAFT HOUSING
2.5.2 PTO LUBRICATION AND COOLING
2.6 Air Filter
3. HYDRAULIC OIL TANK
3.1 General Layout
3.2 Main Oil Tank, Location of Electric Equipment.
3.3 Suction Oil Reservoir with Strainers
3.4 Return Oil Collector Tube with Strainer
3.5 Back Pressure Valve
3.6 Transfer Pump
3.7 Return and Leak Oil Filter
3.8 Breather Filter
4. HYDRAULIC OIL COOLING
4.1 OVERALL VIEW OF THE HYDRAULIC OIL COOLING
4.2 Function of the Hydraulic Oil Cooling Circuit
4.3 Adjustment of the Back Pressure Valve
4.4 Fan Drive (Two Stage Cooler Fan RPM Control)
4.4.1 Fixed Displacement Pump, with Variable Setting
4.4.2 Pressure Relief Valves
4.4.3 fan speed control valve arrangement
4.5 Adjustment of the Cooler Fan Drive Speed
4.5.1 Function Check of Fan Speed Control
5. CONTROLLING
5.1 General Layout
5.2 Control and Filter Panel Location of Components
5.3 Pilot Pressure Supply and Adjustments
5.3.1 Pilot Pressure Circuit (PPC)
5.3.2 Checks and Adjustment of Pilot Pressure
5.3.3 Remote Control Valves Arrangement
5.4 Function Electro Hydraulic Control SYSTEM
5.5 Potentiometer Control (Lever, Joy Stick)
5.6 Potentiometer Control (Pedal)
5.7 Proportional Amplifier Module, Type A
5.8 Proportional Amplifier Module, Type B
5.9 Ramp Time Module
5.10 Adjustments of Amplifier Modules
5.10.1 General
5.10.2 Adjusting the amplifiers type B
5.10.3 Adjusting the Amplifiers Type A
5.11 Adjusting the Ramp Time Module
6. COMPONENTS
6.1 Main Control Blocks and High Pressure Filter (FSA)
6.2 Main Control Blocks and High Pressure Filter (BHA)
6.3 Distributor Manifold – Location of Restrictor Blocks and Anti Cavitation Valves (FSA)
6.4 Distributor Manifold – Location of Restrictor Blocks and Anti Cavitation Valves (BHA)
6.5 Single Control Blocks (Floating) for Stick and Boom (FSA)
6.6 Restrictor Block with Pressure Relief Valve
6.7 Anti cavitation valve block
6.8 Remote Control Valves
6.9 Directional Solenoid Valves (Three Positions / 4-Ways)
6.10 Proportional Solenoid Valve
6.11 High Pressure Filter
6.12 Control Blocks and Valves
6.13 Travel Brake Valve
6.14 Pressure Reducing Valve
6.15 Directional Solenoid Valves (Two Positions / 4-Ways)
6.16 Pressure Increasing Valve
6.17 Hydraulic Cylinder
6.18 Swing Ring
7. MAIN HYDRAULIC PUMPS AND PUMP REGULATION
7.1 General
7.2 Main Pumps
7.2.1 Location of Pumps
7.2.2 Pump Bearing Flushing / Lubrication
7.2.3 Operating Principle
7.2.4 Checks / Adjustments
7.3 Electronic Pump Regulation System
7.3.1 Electronic Load Limiting Control – General
7.3.2 Microcontroller RC4-4
7.3.3 Checks and Adjustments
7.4 Hydraulic Constant Regulation System
7.4.1 General
7.4.2 X1-Pressure Adjustment (Constant-Pressure)
7.5 Determination of the Peak Point (Engine Performance)
7.6 Engine Speed Sensor (Pick up)
7.6.1 General
7.6.2 Engine Speed Sensor (Pick up) Adjustment
7.7 Energy Efficiency
7.7.1 General
7.7.2 Checks and Adjustments
8. OPERATING HYDRAULICS
8.1 General
8.1.1 FLOATING SYSTEM
8.2 Hydraulic for the Attachment Cylinder FSA and BHA
8.2.1 Electric / Hydraulic flowchart “Boom raising” FSA
8.2.2 Electric / Hydraulic Flowchart “Boom Raising” BHA
8.2.3 Electric / Hydraulic Flowchart “Boom Lowering” FSA
8.2.4 Electric / Hydraulic Flowchart “Boom Lowering” BHA
8.2.5 Electric / Hydraulic flowchart “Stick extending” FSA
8.2.6 Electric / Hydraulic Flowchart “Stick Extending” BHA
8.2.7 Electric / Hydraulic Flowchart “Stick Retracting” FSA
8.2.8 Electric / Hydraulic Flowchart “Stick Retracting” BHA
8.2.9 Electric / Hydraulic Flowchart “Bucket Filling” FSA
8.2.10 Electric / Hydraulic Flowchart “Bucket Filling” BHA
8.2.11 Electric / Hydraulic Flowchart “Bucket Emptying” FSA
8.2.12 Electric / Hydraulic Flowchart “Bucket Emptying” BHA
8.2.13 Electric / Hydraulic Flowchart “Clam Opening” FSA
8.2.14 Electric / Hydraulic Flowchart “Clam Closing” FSA
8.2.15 Checks and Adjustments of the Main Relief Valves (FSA)
8.2.16 Checks and Adjustments of the Main Relief Valves (BHA)
8.2.17 Checks and Adjustments of the Service Line Relief Valves (SRV)
8.2.18 Stick Cylinder “Piston Rod Side” FSA
8.3 Hydraulic for the Swing Circuit
8.3.1 Swing Circuit
8.3.2 Swing Motor
8.3.3 Swing Gear Box
8.3.4 Swing Parking Brake (Gear House Brake)
8.3.5 Swing Brake Valve
8.3.6 Electric / Hydraulic Flowchart “Swing Left”
8.3.7 Electric / Hydraulic Flowchart “Swing Right”
8.3.8 Checks and Adjustments for the Swing Circuit
8.3.9 Function Check for Hydraulic Swing Brake
8.3.10 Function Check for the Swing Parking Brake
8.3.11 FUNCTION CHECK FOR THE HYDRAULIC SWING BRAKE
8.3.12 FUNCTION CHECK FOR THE SLEW PARKING BRAKE
8.4 Hydraulic for the Travel Circuit
8.4.1 Travel Circuit
8.4.2 Travel Motor
8.4.3 Rotary Joint
8.4.4 TRAVEL GEARBOX (L&S)
8.4.5 TRAVEL GEARBOX (ZOLLERN)
8.4.6 TRAVEL PARKING BRAKE (GEAR HOUSE BRAKE)
8.4.7 TRAVEL BRAKE VALVE
8.4.8 ELECTRIC / HYDRAULIC FLOWCHART “TRAVEL FORWARD”
8.4.9 ELECTRIC / HYDRAULIC FLOWCHART “TRAVEL BACKWARDS”
8.4.10 CHECKS AND ADJUSTMENTS FOR THE TRAVEL CIRCUIT
8.4.11 FUNCTION CHECK FOR THE TRAVEL PARKING BRAKE
9. HYDRAULIC TRACK TENSIONING SYSTEM
9.1 General
9.2 FUNCTIONAL DESCRIPTION
9.3 PRESSURE DOUBLE STAGE VALVE
9.4 TENSIONING CYLINDER
9.5 ADJUSTMENTS / CHECKS
10. ACCESS LADDER HYDRAULICALLY OPERATED
10.1 General
10.2 FUNCTION OF HYDRAULICALLY OPERATED ACCESS LADDER
10.3 Adjustments / Checks
11. CENTRAL REFILLING SYSTEM (SERVICE ARM)
11.1 General
11.2 Function
12. HINTS FOR READING THE HYDRAULIC DIAGRAM
12.1 General
12.2 HYDRAULIC SYMBOLS
12.2.1 Lines, Unions
12.2.2 Components, Valves
12.2.3 Sensors
12.2.4 Valves, Valve Components
12.2.5 Pump, Motor, Cylinder
13. HINTS FOR READING THE ELECTRIC CIRCUIT DIAGRAM
13.1 GENERAL
13.2 REFERENCE DESIGNATION OF THE ELECTRICAL COMPONENTS
13.3 GRAPHICAL SYMBOLS
13.4 Drawing Concept
13.5 CABLE MARKING
13.6 TABLE OF NEW AND OLD COMPONENT DESIGNATIONS
14 VEHICLE HEALTH MONITORING SYSTEM & MTC CONTROL SYSTEM
14.1 General
14.2 Specifications for Operators
14.2.1 Sequence of Displays
14.2.2 Opening Screen
14.2.3 Main Gauge Screens 1 to 3
14.2.4 Fuel Consumption Screen
14.2.5 Failure Message History Screen for Operator
14.2.6 Main Screen – Chance Time SMR Date
14.2.7 Maintenance Monitor
14.2.8 Settings for Operator
14.2.9 Automatic Messages
14.2.10 Table of all Top Messages provided by the System
14.3 FLOW CHARTS (1-4) VHMS MAIN SCREENS
14.3.1 Main Screen Flow Chart for the Operater Mode
14.3.2 Main Screen Flow Chart for the Service Mode
14.3.3 Entering the Service Menu
14.3.4 Service Menu Select Screen
14.3.5 Real Time Menu Select Screen
14.3.6 PM-Clinic
14.3.7 Serial/GCC No. Setting
14.3.8 Memory Clear
14.3.9 Failure History
14.3.10 Maintenance Monitor
14.3.11 Snapshot
14.3.12 Settings
14.4 VHMS SERVICE LEVEL
14.4.1 EXPLANATION OF THE BUTTON SYMBOLS
14.4.2 SERVICE MENU SELECT SCREEN
14.4.3 REAL TIME MENU SELECT SCREEN
14.4.4 PM-CLINIC
14.5 INTERFACE-CONNECTION VHMS-CONTROLLER
14.5.1 VHMS-CONTROLLER
14.6 WIRING OF THE VHMS-CONTROLLER
14.7 GLOBAL LAYOUT OF THE MTC CONTROL SYSTEM
14.7.1 MTC (MASTER TURBO CONTROLLER)
14.8 GLOBAL LAYOUT OF THE INTERNAL CAN BUS
14.8.1 GENERAL INFORMATION ABOUT A CAN BUS SYSTEM
14.9 THE NODES IN THE CAN BUS SYSTEM
14.9.1 GLOBAL LAYOUT
14.9.2 INTRODUCTION
14.9.3 NODE DIP-SWITCHES
14.9.4 NODE BOX
14.9.5 NODE LOCATIONS ON THE MACHINE
15. AUTOMATIC LUBRICATION SYSTEMS
15.1 GENERAL OVERVIEW CLS & SLS
15.1.1 GENERAL DESCRIPTION
15.2 BASIC FUNCTION OF THE LUBRICATION SYSTEMS
15.3 CENTRAL LUBRICATION SYSTEM (CLS)
15.3.1 GENERAL INFORMATION ON CLS
15.4 LUBRICATION PUMP STATION (SLS)
15.4.1 Operating Flow, Electrical Flow
15.5 Adjustments
15.5.1 Pump Speed and Working Pressure
15.5.2 Injectors
15.5.3 End of Line Switch Setting CLS
15.5.4 End of Line Switch Setting SLS
15.6 Troubleshooting
15.7 Commissioning
15.7.1 Commissioning of the CLS
15.7.2 Fine Adjustment
15.7.3 Commissioning of the SLS
40 Troubleshooting
Table of Contents
1. SAFETY
2. Introduction & general information for troubleshooting
Description of this troubleshooting manual
Precautions when carrying out any operation
Fundamental requirements for troubleshooting
Points to remember when troubleshooting
Sequence of events in troubleshooting
Checks before troubleshooting
Handling of electric equipment and hydraulic components
General working procedures
Information about MTC & Nodes
Basics about „How to crimp”
Cable colour identification
3. Mounting locations, connector types and electrical standard values
1. Component location
1.1 View onto the superstructure
1.2 Location of engine electrical parts
1.3 Location of engine electrical parts
1.4 Location of hydraulic components
1.5 Location of hydraulic components
1.6 Location of the remote control valves
1.7 Location of the high pressure sensors
1.8 View onto the SLS and CLS grease barrel and the lubrication cycle components
1.9 View onto the cab base with electrical components
1.10 Hydraulic oil tank – Location of electrical components
1.11 Hydraulically operated access ladder
2. Overview connector types and connector pin numbers
3. Standard value table for electrical components
4. PT100 temperature charts
4. Troubleshooting by trouble code
G00001 – Trouble Shut-Off (gate) valve
G00002 – Test speed 1800 rqm
G00003 – Trouble pump controller
G00005 – Low hydraulic oil level
G00007 – Trouble hydraulic oil level
G00012 – Central lubrication system grease level too low
G00013 – Slew ring gear lubr. system grease level too low
G00020 – Trouble Shut-Off (gate) valve (Start blocked)
G00060 – Fire in the power house
G00061 – Trouble monitoring, engine 1 speed too low
G00062 – Trouble monitoring, engine 1 speed too high
G00063 – Trouble monitoring hydraulic oil temp
G00064 – Trouble monitoring hydraulic oil level
G00065 – Very low hydraulic oil level
G00066 – Trouble hydraulic oil temperature
G00067 – Trouble battery voltage too high
G00069 – Trouble monitoring oil temperature gear (PTO 1)
G00070 – Trouble oil temperature gear (PTO 1)
G00071 – Trouble gear lubrication (PTO 1)
G00081 – Trouble lubrication system
G00090 – Trouble power supply
G00099 – Trouble power supply
G00091 – Pilot control cut out
G00092 – Emergency shut-down at access ladder
G00093 – Emergency shut-down at valve block
G00094 – Emergency shut-down at hydraulic control panel
G00095 – Emergency shut-down in cabin
G00096 – Pilot control cut out
G00100 – Maintenance safety switch
G00102 – Switch off wiper
G00103 – Faulty switch 20M004
G00104 – Trouble battery current
G00105 – Trouble battery charging current too low
G00140 – Trouble monitoring X1-1 pressure
G00141 – Trouble monitoring X2 pressure
G00143 – Trouble monitoring 61B087a
G00144 – Trouble monitoring 61B087b
G00145 – Trouble monitoring 61B087c
G00146 – Trouble monitoring 61B087d
G00147 – Trouble monitoring gear lubrication (PTO 1)
G00148 – Trouble monitoring fuel level
G00149 – Trouble monitoring ambient temperature
G00151 – Trouble monitoring gear (PTO) oil filter 1
G00154 – Trouble monitoring return oil filter
G00155 – Trouble monitoring leak oil filter
G00159 – Trouble monitoring breather filter
G00160 – Trouble monitoring engine air cleaner 1
G00161 – Trouble monitoring battery voltage
G00162 – Trouble monitoring charging-/discharging current
G00163 – Trouble monitoring pilot control
G00164 – Trouble air cleaner 1
G00165 – Trouble breather filter hydraulic oil tank
G00166 – Trouble oil filter gear (PTO 1)
G00169 – Trouble return oil filter hydraulic oil tank
G00170 – Trouble leak oil filter hydraulic oil tank
G00176 – Trouble battery voltage too low
G00177 – Trouble battery charging circuit
G00178 – Trouble battery charging current too high
G00179 – Trouble control pressure X1-1
G00180 – Trouble pilot pressure X2 too low
G00181 – Trouble pilot pressure X2 too high
G00184 – Central lubrication system empty
G00187 – Slew ring gear lubrication system empty
G00185 – Trouble central lubrication system
G00188 – Trouble slew ring gear lubrication system
G00186 – Trouble central lubrication system
G00189 – Trouble slew ring gear lubrication system
G00207 – Engine remote oil tank 1 empty
G00240 – Trouble hydraulic oil temperature
G00242 – Engine 1 already running
G00243 – Fill up fuel tank
G00245 – Engine shutdown from ground
G00246 – Hydraulic oil temperature
G00247 – Slew ring gear house break
G00252 – Emergency shut-down at access ladder
G00253 – Emergency shut-down at valve block
G00254 – Emergency shut-down at hydraulic control panel
G00255 – Emergency shut-down in cabin
G00257 – Hydraulic oil temperature
G00261 – Maintenance safety switch
G00262 – Trouble screen at hydr. cooler entry clogged
G00417 – Communication failure PLC <== VHMS controller
G00420 – Connector sel error
G00421 – Farm sys error
G00422 – Can-net sys (J1939)
G00423 – Application sys error
G00425 – Settings impossible to take over into the PLC
G00491 – Communication failure MH800 <== VHMS-Controller
5. Troubleshooting by symptoms
Symptoms of the engine and related electrical system
SEL001 – Engine does not start (engine does not rotate)
SEL002 – Engine stops while in operation
SEL003 – Engine speed is hunting during boom-up movement
SEL004 – Engine does not stop
SEL005 – Engine lacks output (no power)
SEL006 – Exhaust smoke is black
SEL007 – Oil consumption is excessive
SEL008 – Oil becomes contaminated quickly
SEL009 – Fuel consumption is excessive
SEL010 – Oil is in engine coolant
SEL011 – Oil level rises
SEL012 – Coolant temperature becomes too high (overheating)
Symptoms of the hydraulic system
SHY001 – All the work equipment shows lack of power or slow movement
SHY002 – Engine speed sharply drops or engine stalls too much
SHY003 – No work equipment, travel or swing movement
SHY004 – Work equipment has too much hydraulic drift
SHY005 – Work equipment has big time lag
SHY006 – Machine deviates during travel movement
SHY007 – Hydraulic system has lack of power (energy efficiency)
SHY008 – Machine does not swing
SHY009 – Swing acceleration is poor
SHY010 – Excessive overrun when stopping swing
SHY011 – Floating system without function
SHY012 – Abnormal noise coming from SRV or MRV
SHY013 – Track tensioning system without function
SHY014 – Ladder does not move, or slow movement
SHY015 – Refilling arm does not move, or slow movement
SHY016 – The hydraulic driven grease pump does not move
SHY017 – Trouble pump bearing lubrication
SHY018 – Abnormal track chain movement during digging
SHY019 – Swing parking brake without function
SHY020 – Travel parking brake without function
Symptoms of the mechanical system
SME001 – Abnormal noise is made
SME002 – Abnormal noise around the PTO / hydraulic pumps
SME003 – Vibration is excessive (engine mountings)
SME004 – Vibration is excessive (engine torsion)
SME005 – There is a big shock when stopping swing
SME006 – There is a big abnormal noise when moving/stopping swing
SME007 – Fan hub bearing noise is abnormal
SME008 – Abnormal noise coming from a travel gearbox
SME009 – Abnormal noise coming from the work equipment (lack of grease)
50 Disassembly and Assembly
1. Introduction
1.1 Contents of the binder
1.2 Foreword
1.2.1 Service
2. Safety
2.1 Safety Instructions
2.1.1 Method of using this manual
2.1.2 General precautions
2.1.3 Preparations for work
2.1.4 Precautions during work
2.1.5 WARNING OF SPECIAL DANGERS
2.1.5.1 ELECTRICal ENERGY
2.1.5.2 GAS, DUST, STEAM AND SMOKE
2.1.5.3 HYDRAULIC, AIR CONDITIONING AND PNEUMATIC EQUIPMENT
2.1.5.4 NOISE
2.1.5.5 Heat
2.1.5.6 OIL, GREASE AND OTHER CHEMICAL SUBSTANCES
2.1.5.7 Height
2.1.6 SPECIAL SAFETY EQUIPMENT
2.1.6.1 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)
2.1.6.2 INSTRUCTIONS FOR USE
2.1.6.3 RECOMMENDATIONS FOR USE OF THE HOLDING HOOKS AND HOLD-BACK HOOKS OF THE SAFETY HARNESS
2.1.6.4 INSTRUCTIONS FOR USE
2.2 Lifting Gears
2.2.1 Wire ropes
2.2.2 Sling accessory
2.2.3 Weight tables
2.2.3.1 Superstructure
2.2.3.2 Undercarriage
2.2.3.3 Backhoe AttachmenT (BHA)
2.2.3.4 Faceshovel Attachment (FSA)
2.3 Torque charts according to DIN
2.3.1 Metric standard thread
2.3.2 Metric fine thread
2.3.3 Cummins motor torques – metric
2.3.4 Cummins motor torques – U.S. Customary
2.3.5 Flange connections
2.4 Conversation table
2.4.1 Method of using the conversation table
2.4.2 Millimeter – Inch & Kilogram – Pound
2.4.3 Liter – U.S. Gallon & Liter – U.K. Gallon
2.4.4 KGm – ft.lb
2.4.5 bar – PSI / PSI – bar
2.4.6 Basic Values in Ohm according to DIN 43 76
2.4.7 Temperature
2.5 Explanation of abbreviations
3. Superstructure
3.1 Diesel Engine
3.1.1 Removal of the Diesel engine
3.1.2 Replacement of the Diesel engine
3.1.3 Engine torque support and engine/PTO mounts
3.1.3.1 Flexible mounts
3.1.3.2 Torque support
3.1.4 Alternator
3.1.4.1 Removal of the alternator
3.1.4.2 Replacement of the alternator
3.1.5 Batteries
3.1.5.1 Removal of the batteries
3.1.5.2 Replacement of the batteries
3.1.6 Radiator fan
3.1.6.1 Removal of the radiator fan assembly
3.1.6.2 Replacement of the radiator fan assembly
3.1.6.3 Removal of the radiator fan
3.1.6.4 Replacement of the radiator fan
3.1.6.5 Removal of the radiator fan drive pump
3.1.6.6 Replacement of the radiator fan drive pump
3.1.7 Radiators
3.1.7.1 Removal of the Radiator assembly
3.1.7.2 Replacement of the radiator assembly
3.1.8 Fuel cooler
3.1.8.1 Removal of the fuel cooler
3.1.8.2 Replacement of the fuel cooler
3.1.9 Starter system
3.1.9.1 Removal of the starter motor
3.1.9.2 Replacement of the starter motor.
3.1.10 Geislinger coupling
3.1.10.1 Removal of the Geislinger coupling
3.1.10.2 Replacement of the Geislinger coupling
3.2 PTO
3.2.1 Main pumps
3.2.1.1 Preparatory works for main pump removal
3.2.1.2 Removal of Main Pump 1
3.2.1.3 Replacement of main pump 1
3.2.1.4 Removal of Main Pump 2
3.2.1.5 Replacement of main pump 2
3.2.1.6 Removal of Main Pump 3
3.2.1.7 Replacement of main pump 3
3.2.1.8 Removal of Main Pump 4
3.2.1.9 Replacement of main pump 4
3.2.2 PTO oil circulation pump (auxiliary pump)
3.2.2.1 Removal of the oil circulation pump (auxiliary pump)
3.2.2.2 Replacement of the oil circulation pump (auxiliary pump)
3.2.3 Pump distributor gearbox (PTO)
3.2.3.1 Removal of the Pump distributor gearbox (PTO)
3.2.3.2 Replacement of the Pump distributor gearbox (PTO)
3.3 Hydraulics
3.3.1 Hydraulic cooler fan Drive Pump
3.3.1.1 Removal of the hydraulic cooler fan drive pump
3.3.1.2 Replacement of the hydraulic cooler fan drive pump
3.3.2 Hydraulic Cooler Fan Assembly
3.3.2.1 Removal of hydraulic cooler fan assembly
3.3.2.2 Replacement of hydraulic cooler fan assembly
3.3.2.3 Removal of hydraulic cooler Fan and motor
3.3.2.4 Replacement of hydraulic cooler Fan and motor
3.3.3 Hydraulic Oil Coolers
3.3.3.1 Removal of the hydraulic oil coolers
3.3.3.2 Replacement of the hydraulic oil coolers
3.3.3.3 Removal of the hydraulic oil cooler frame
3.3.3.4 Replacement of the hydraulic oil cooler frame
3.3.4 Main Relief Valves (MRV)
3.3.4.1 Removal of the MRV
3.3.4.2 Replacement of the MRV
3.3.5 pilot oil pump (Gear pump)
3.3.5.1 Removal of the pilot oil pump)
3.3.5.2 Replacement of the pilot oil pump
3.3.6 Main Gate Valve
3.3.6.1 Removal of the main gate valve
3.3.6.2 Replacement of the main gate valve
3.3.7 Hydraulic Oil Reservoir
3.3.7.1 Removal of the hydraulic oil reservoir
3.3.7.2 Replacement of the hydraulic oil reservoir
3.3.8 Main Control Valve Blocks
3.3.8.1 Removal of the main control valve blocks
3.3.8.2 Replacement of the main control valve blocks
3.3.9 Service line Relief Valves (SRV)
3.3.9.1 Removal of SRV on main Control valve block
3.3.9.2 Replacement of SRV on main control valve blocks
3.3.10 Anti-cavitation Valves (ACV)
3.3.10.1 Removal of ACV on Manifold
3.3.10.2 Replacement of ACV on Manifold
3.3.10.3 Removal of ACV on main control valve blocks
3.3.10.4 Replacement of ACV on main control valve blocks
3.3.11 Throttle check valves
3.3.11.1 Removal of throttle check valves
3.3.11.2 Replacement of throttle check valves
3.3.12 manifold
3.3.12.1 Removal of the manifold
3.3.12.2 Replacement of the manifold
3.3.12.3 Removal of the Diffuser on the Manifold (FSA only)
3.3.12.4 Replacement of Diffuser on Manifold (FSA only)
3.4 Slew Drive
3.4.1 Slew Gear
3.4.1.1 Removal of the slew gear
3.4.1.2 Replacement of the slew gear
3.4.2 Swing Motor
3.4.2.1 Removal of the swing motor
3.4.2.2 Replacement of the swing motor
3.4.3 Slew parking brake
3.4.3.1 Removal/Disassembly of the slew parking brake
3.4.3.2 Replacement/assembly of the slew parking brake
3.4.4 Dynamic Slew Brake
3.4.4.1 Removal of the slew brake valve
3.4.4.2 Replacement of the slew brake valve
3.4.5 Swing circle lubrication pinion (dummy wheel)
3.4.5.1 Removal of the lubrication pinion assembly
3.4.5.2 Replacement of the lubrication pinion assembly
3.5 Lubrication pumps
3.5.1 Removal of the Lubrication pump
3.5.2 Replacement of the lubricating pump
3.6 Pump controller MC7
3.6.1 Removal of the pump controller MC7
3.6.2 Replacement of the pump controller MC7
3.7 Operator’s Cab
3.7.1 Removal of the operator’s cab
3.7.2 Replacement of the operator’s cab
3.7.3 Cab-mounts
3.7.3.1 Removal of the cab-mounts
3.7.3.2 replacement of the cab-mounts
3.7.4 FRONT WINDOW
3.7.4.1 Removal of the Front window
3.7.4.2 Replacement of the front window
3.7.5 Operator’s seat
3.7.5.1 Removal of the operator’s seat
3.7.5.2 Replacement of the operator’s seat
3.7.6 VHMS
3.7.6.1 Removal of the VHMS-Controller
3.7.6.2 Replacement of the VHMS-Controller
3.7.7 Access Ladder
3.7.7.1 Removal of the access Ladder
3.7.7.2 Replacement of the access ladder
3.7.7.3 Removal of the access ladder cylinder
3.7.7.4 Replacement of the access ladder cylinder
3.7.8 Removal of the cab base
3.7.9 Replacement of the cab base
3.8 Counterweight
3.8.1 Removal of the counterweight
3.8.2 Replacement of the counterweight
3.9 Superstructure Lifting
3.9.1 Remove the Superstructure from the Undercarriage
3.9.2 Install the Superstructure onto the undercarriage
3.10 Fuel Tank
3.10.1 Removal of the Fuel tank
3.10.2 Replacement of the Fuel tank
4. Undercarriage
4.1 Travel System
4.1.1 Track group
4.1.1.1 Changing of the track group
4.1.2 Sprocket
4.1.2.1 Removal of the sprocket
4.1.2.2 Replacement of the sprocket
4.1.3 Guide wheels
4.1.3.1 Removal of the guide wheel assembly
4.1.3.2 Replacement of the guide wheel assembly
4.1.4 Track tensioning accumulators
4.1.4.1 Removal of the low pressure accumulators
4.1.4.2 Replacement of the low pressure accumulators
4.1.4.3 Removal of the high pressure accumulators
4.1.4.4 Replacement of the high pressure accumulators
4.1.5 Track tension valve block
4.1.5.1 Removal of the track tensioning valve block
4.1.5.2 Replacement of the track tensioning valve block
4.1.6 Hydraulic hoses of the track tensioning system
4.1.6.1 Substitute the hydraulic hoses
4.1.7 Travel brake valve block (overspeed valve)
4.1.7.1 Removal of the travel brake valve block
4.1.7.2 Replacement of the travel brake valve block
4.1.8 Track tensioning cylinders
4.1.8.1 Removal of the track tensioning cylinders
4.1.8.2 Replacement of the track tensioning cylinders
4.1.9 Travel motor
4.1.9.1 Removal of the travel motors
4.1.9.2 Replacement of the travel motors
4.1.10 travel parking brake
4.1.10.1 Removal/disassembly of the travel parking brake
4.1.10.2 Replacement/assembly of the travel parking brake
4.1.11 Travel gearbox
4.1.11.1 Removal of the travel gearbox
4.1.11.2 Replacement of the travel gearbox
4.1.12 Carrier roller
4.1.12.1 Removal of the carrier roller assembly
4.1.12.2 Replacement of the carrier roller assembly
4.1.13 Track roller
4.1.13.1 Removal of the Track roller assembly
4.1.13.2 Replacement of the Track roller assembly
4.2 Car body
4.2.1 Removal of the car bodY (previous type with mounting pins)
4.2.2 Replacement of the car bodY (previous type with mounting pins)
4.2.3 Removal OF the car Body (NEW type with bolted connection)
4.2.4 Replacement of the car body (NEW type with bolted connection)
4.2.4.1 Tightening torque for the crawler carrier mounting bolts
4.2.5 Rotary joint
4.2.5.1 Removal of the rotary joint
4.2.5.2 Replacement of the rotary joint
4.2.6 swing circle
4.2.6.1 Removal of the swing circle
4.2.6.2 Replacement of the swing circle
5. Attachment
5.1 Backhoe
5.1.1 Boom
5.1.1.1 Removal of the Boom
5.1.1.2 Replacement of the boom
5.1.1.3 Removal of boom cylinders
5.1.1.4 Replacement of boom cylinders
5.1.2 Stick
5.1.2.1 Removal of the Stick
5.1.2.2 Replacement of Stick
5.1.2.3 Removal of Stick Cylinders
5.1.2.4 Replacement of Stick cylinders
5.1.3 Bucket
5.1.3.1 Removal of the bucket
5.1.3.2 Replacement of the bucket
5.1.3.3 Removal of Bucket Cylinders
5.1.3.4 Replacement of Bucket Cylinders
5.1.4 Bucket link rod and steering rods
5.1.4.1 Removal of the bucket link rod
5.1.4.2 Replacement of the bucket link rod
5.1.4.3 Removal of the steering rods
5.1.4.4 Replacement of the steering rods
5.1.5 Ground engaging tools (GET)
5.1.5.1 Removal and replacement of the GET
5.1.6 Hydraulic hoses at the backhoe attachment
5.1.6.1 Substitute the boom arc hoses
5.1.6.2 Substitute the boom cylinder hoses
5.1.6.3 Substitute the stick cylinder hoses
5.1.6.4 Substitute the bucket cylinder hoses
5.2 Faceshovel
5.2.1 Boom
5.2.1.1 Removal of the boom
5.2.1.2 Replacement of the boom
5.2.1.3 Removal of the boom cylinders
5.2.1.4 Replacement of the boom cylinders
5.2.2 Stick
5.2.2.1 Removal of the stick
5.2.2.2 Replacement of the stick
5.2.2.3 Removal of the stick cylinders
5.2.2.4 Replacement of the stick cylinders
5.2.3 Bullclam bucket
5.2.3.1 Removal of the bull clam bucket
5.2.3.2 Replacement of the bull clam bucket
5.2.3.3 Removal of the bucket cylinders
5.2.3.4 Replacement of the bucket cylinders
5.2.3.5 Removal of the clam cylinders
5.2.3.6 Replacement of the clam cylinders
5.2.4 Ground engaging tools (GET)
5.2.4.1 Removal and replacement of the GET
5.2.5 Hydraulic hoses at the Faceshovel attachment
5.2.5.1 Substitute the boom arc hoses
5.2.5.2 Substitute the boom cylinder hoses
5.2.5.3 Substitute the stick arc hoses
5.2.5.4 Substitute the stick cylinder hoses
5.2.5.5 Substitute the bucket cylinder hoses
5.2.5.6 Substitute the clam cylinder hoses
5.3 Metering valves (grease injectors) at the attachment
5.3.1 Removal of the metering valves (grease injectors)
5.3.2 Replacement of the metering valves (grease injectors)
5.4 Cylinder bypass test
6. Appendix
6.1 Fuel and Lubricants
6.2 Filling Capacities
6.3 Tools List
6.3.1 Used special tools (Overview)
6.3.2 KOMATSU tools catalogue
6.4 Work instructions
6.4.1 Remove / install the crawler carrier
6.4.2 Use of the hydraulic torque wrench (supplier’s documentation)
6.5 Service Bulletins
6.5.1 AH00511d
6.5.2 AH00514
6.5.3 AH00519
6.5.4 AH01512
6.5.5 AH01521a
6.5.6 AH01531A
6.5.7 AH02513b
6.5.8 AH02521
6.5.9 AH03506B
6.5.10 AH03509a
6.5.11 AH03510
6.5.12 AH03526a
6.5.13 AH03538
6.5.14 AH04518
6.5.15 AH05510
6.5.16 AH05511
6.5.17 AH05546
6.5.18 AH06524
6.5.19 AH06530
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Komatsu PC4000-6 Diesel Hydraulic Mining Excavator Service Repair Shop Manual (08199 and up).pdf
