Komatsu PC4000-6 Diesel Hydraulic Excavator Shop Manual 08199-upD-GB-1

Description

• Model List:
  • PC4000-6 Diesel Hydraulic Excavator

• 1. COVER
• 2. Foreword
• 2.1. Introduction
• 2.2. Safety Instructions
• 3. Specification
• 3.1. Specification PC4000
• 4. Structure, Function
• 4.1. Table of Contents
• 4.2. INTRODUCTION
• 4.2.1. I Contents of the Binder
• 4.2.2. II Foreword
• 4.2.3. III Explanation of Abbrevations
• 4.2.4. IV EXPLANATION OF ABBREVATIONS
• 4.2.5. V DIAGRAMS AND ILLUSTRATIONS IN THIS MANUAL
• 4.3. III. SPECIFICATIONS
• 4.3.1. III.I Lifting Gears
• 4.3.2. III.II Standard Tightening Torque Chart
• 4.3.3. III.III Conversion Table
• 4.3.4. III.IV General Specifications
• 4.3.5. III.V BLIND PLUGS
• 4.3.6. III.VI CLASSIFICATION OF THREADS TO THE NOMINAL WIDTH
• 4.3.7. III.VII PLUGS AND FITTINGS ACCORDING TO ISO 84341 / DIN 2353
• 4.4. MAIN ASSEMBLY GROUPS
• 4.4.1. General Layout
• 4.4.2. Superstructure
• 4.4.3. Machine House
• 4.4.4. Hydraulic Oil Reservoir
• 4.4.5. Hydraulic Oil Cooler
• 4.4.6. Fuel Tank
• 4.4.7. Counterweight
• 4.4.8. Cab Support
• 4.4.9. Operators Cab
• 4.4.10. Control Blocks
• 4.4.11. Swing Gears
• 4.4.12. Undercarriage
• 4.4.13. Backhoe Attachment (BHA)
• 4.4.14. Front Shovel Attachment (FSA)
• 4.5. DRIVE
• 4.5.1. Prime Drive Assembly
• 4.5.2. Engine and PTO Mounts
• 4.5.3. Fan Drive and Radiator Assembly
• 4.5.4. FAN DRIVE AND RADIATOR ASSEMBLY
• 4.5.5. PUMP DISTRIBUTOR GEARBOX (PTO)
• 4.5.6. Air Filter
• 4.6. HYDRAULIC OIL TANK
• 4.6.1. General Layout
• 4.6.2. Main Oil Tank, Location of Electric Equipment.
• 4.6.3. Suction Oil Reservoir with Strainers
• 4.6.4. Return Oil Collector Tube with Strainer
• 4.6.5. Back Pressure Valve
• 4.6.6. Transfer Pump
• 4.6.7. Return and Leak Oil Filter
• 4.6.8. Breather Filter
• 4.7. HYDRAULIC OIL COOLING
• 4.7.1. OVERALL VIEW OF THE HYDRAULIC OIL COOLING
• 4.7.2. Function of the Hydraulic Oil Cooling Circuit
• 4.7.3. Adjustment of the Back Pressure Valve
• 4.7.4. Fan Drive (Two Stage Cooler Fan RPM Control)
• 4.7.5. Adjustment of the Cooler Fan Drive Speed
• 4.8. CONTROLLING
• 4.8.1. General Layout
• 4.8.2. Control and Filter Panel Location of Components
• 4.8.3. Pilot Pressure Supply and Adjustments
• 4.8.4. Function Electro Hydraulic Control SYSTEM
• 4.8.5. Potentiometer Control (Lever, Joy Stick)
• 4.8.6. Potentiometer Control (Pedal)
• 4.8.7. Proportional Amplifier Module, Type A
• 4.8.8. Proportional Amplifier Module, Type B
• 4.8.9. Ramp Time Module
• 4.8.10. Adjustments of Amplifier Modules
• 4.8.11. Adjusting the Ramp Time Module
• 4.9. COMPONENTS
• 4.9.1. Main Control Blocks and High Pressure Filter (FSA)
• 4.9.2. Main Control Blocks and High Pressure Filter (BHA)
• 4.9.3. Distributor Manifold Location of Restrictor Blocks and Anti Cavitation Valves (FSA)
• 4.9.4. Distributor Manifold Location of Restrictor Blocks and Anti Cavitation Valves (BHA)
• 4.9.5. Single Control Blocks (Floating) for Stick and Boom (FSA)
• 4.9.6. Restrictor Block with Pressure Relief Valve
• 4.9.7. Anti cavitation valve block
• 4.9.8. Remote Control Valves
• 4.9.9. Directional Solenoid Valves (Three Positions / 4Ways)
• 4.9.10. Proportional Solenoid Valve
• 4.9.11. High Pressure Filter
• 4.9.12. Control Blocks and Valves
• 4.9.13. Travel Brake Valve
• 4.9.14. Pressure Reducing Valve
• 4.9.15. Directional Solenoid Valves (Two Positions / 4Ways)
• 4.9.16. Pressure Increasing Valve
• 4.9.17. Hydraulic Cylinder
• 4.9.18. Swing Ring
• 4.10. MAIN HYDRAULIC PUMPS AND PUMP REGULATION
• 4.10.1. General
• 4.10.2. Main Pumps
• 4.10.3. Electronic Pump Regulation System
• 4.10.4. Hydraulic Constant Regulation System
• 4.10.5. Determination of the Peak Point (Engine Performance)
• 4.10.6. Engine Speed Sensor (Pick up)
• 4.10.7. Energy Efficiency
• 4.11. OPERATING HYDRAULICS
• 4.11.1. General
• 4.11.2. Hydraulic for the Attachment Cylinder FSA and BHA
• 4.11.3. Hydraulic for the Swing Circuit
• 4.11.4. Hydraulic for the Travel Circuit
• 4.12. HYDRAULIC TRACK TENSIONING SYSTEM
• 4.12.1. General
• 4.12.2. FUNCTIONAL DESCRIPTION
• 4.12.3. PRESSURE DOUBLE STAGE VALVE
• 4.12.4. TENSIONING CYLINDER
• 4.12.5. ADJUSTMENTS / CHECKS
• 4.13. ACCESS LADDER HYDRAULICALLY OPERATED
• 4.13.1. General
• 4.13.2. FUNCTION OF HYDRAULICALLY OPERATED ACCESS LADDER
• 4.13.3. Adjustments / Checks
• 4.14. CENTRAL REFILLING SYSTEM (SERVICE ARM)
• 4.14.1. General
• 4.14.2. Function
• 4.15. HINTS FOR READING THE HYDRAULIC DIAGRAM
• 4.15.1. General
• 4.15.2. HYDRAULIC SYMBOLS
• 4.16. HINTS FOR READING THE ELECTRIC CIRCUIT DIAGRAM
• 4.16.1. GENERAL
• 4.16.2. REFERENCE DESIGNATION OF THE ELECTRICAL COMPONENTS
• 4.16.3. GRAPHICAL SYMBOLS
• 4.16.4. Drawing Concept
• 4.16.5. CABLE MARKING
• 4.16.6. TABLE OF NEW AND OLD COMPONENT DESIGNATIONS
• 4.17. VEHICLE HEALTH MONITORING SYSTEM MTC CONTROL SYSTEM
• 4.17.1. General
• 4.17.2. Specifications for Operators
• 4.17.3. FLOW CHARTS (14) VHMS MAIN SCREENS
• 4.17.4. VHMS SERVICE LEVEL
• 4.17.5. INTERFACECONNECTION VHMSCONTROLLER
• 4.17.6. WIRING OF THE VHMSCONTROLLER
• 4.17.7. GLOBAL LAYOUT OF THE MTC CONTROL SYSTEM
• 4.17.8. GLOBAL LAYOUT OF THE INTERNAL CAN BUS
• 4.17.9. THE NODES IN THE CAN BUS SYSTEM
• 4.18. AUTOMATIC LUBRICATION SYSTEMS
• 4.18.1. GENERAL OVERVIEW CLS SLS
• 4.18.2. BASIC FUNCTION OF THE LUBRICATION SYSTEMS
• 4.18.3. CENTRAL LUBRICATION SYSTEM (CLS)
• 4.18.4. LUBRICATION PUMP STATION (SLS)
• 4.18.5. Adjustments
• 4.18.6. Troubleshooting
• 4.18.7. Commissioning
• 4.19. Troubleshooting
• 4.19.1. Table of Contents
• 4.19.2. SAFETY
• 4.19.3. Introduction general information for troubleshooting
• 4.19.4. Mounting locations, connector types and electrical standard values
• 4.19.5. Troubleshooting by trouble code
• 4.19.6. Troubleshooting by symptoms
• 5. Disassembly and Assembly
• 5.1. Introduction
• 5.1.1. Contents of the binder
• 5.1.2. Foreword
• 5.2. Safety
• 5.2.1. Safety Instructions
• 5.2.2. Lifting Gears
• 5.2.3. Torque charts according to DIN
• 5.2.4. Conversation table
• 5.2.5. Explanation of abbreviations
• 5.3. Superstructure
• 5.3.1. Diesel Engine
• 5.3.3. Hydraulics
• 5.3.4. Slew Drive
• 5.3.5. Lubrication pumps
• 5.3.6. Pump controller MC7
• 5.3.7. Operators Cab
• 5.3.8. Counterweight
• 5.3.9. Superstructure Lifting
• 5.3.10. Fuel Tank
• 5.4. Undercarriage
• 5.4.1. Travel System
• 5.4.2. Car body
• 5.5. Attachment
• 5.5.1. Backhoe
• 5.5.2. Faceshovel
• 5.5.3. Metering valves (grease injectors) at the attachment
• 5.5.4. Cylinder bypass test
• 5.6. Appendix
• 5.6.1. Fuel and Lubricants
• 5.6.2. Filling Capacities
• 5.6.3. Tools List
• 5.6.4. Work instructions
• 5.6.5. Service Bulletins