Komatsu PC4000E-6 Hydraulic Mining Shovel Shop Manual 08165E-GB-2

Description

• Model List:
  • PC4000E-6 Hydraulic Mining Shovel

• 1. Foreword
• 1.1. Introduction
• 1.2. Safety Instructions
• 2. Specification
• 2.1. Specification PC4000
• 3. Structure, Function
• 3.1. INTRODUCTION
• 3.1.1. I Contents of the Binder
• 3.1.2. II Foreword
• 3.1.3. III Explanation of Abbrevations
• 3.2. II SAFETY
• 3.3. III. SPECIFICATIONS
• 3.3.1. III.I Lifting Gears
• 3.3.2. III.II Standard Tightening Torque Chart
• 3.3.3. III.III Conversion Table
• 3.3.4. III.IV General Specifications
• 3.4. MAIN ASSEMBLY GROUPS
• 3.4.1. General Layout
• 3.4.2. Superstructure
• 3.4.3. Machine House
• 3.4.4. Hydraulic Oil Reservoir
• 3.4.5. Hydraulic Oil Cooler
• 3.4.6. Fuel Tank
• 3.4.7. Counterweight
• 3.4.8. Cab Support
• 3.4.9. Operators Cab
• 3.4.10. Control Blocks
• 3.4.11. Swing Gears
• 3.4.12. Undercarriage
• 3.4.13. Backhoe Attachment (BHA)
• 3.4.14. Front Shovel Attachment (FSA)
• 3.5. DRIVE
• 3.5.1. Prime Drive Assembly
• 3.5.2. Engine and PTO Mounts
• 3.5.3. Fan Drive and Radiator Assembly
• 3.5.4. Pump Distributor Gearbox (PTO)
• 3.5.5. Geislinger Coupling
• 3.5.6. Air Filter
• 3.6. HYDRAULIC OIL TANK
• 3.6.1. General Layout
• 3.6.2. Main Oil Tank, Location of Electric Equipment.
• 3.6.3. Suction Oil Reservoir with Strainers
• 3.6.4. Return Oil Collector Tube with Strainer
• 3.6.5. Back Pressure Valve
• 3.6.6. Transfer Pump
• 3.6.7. Return and Leak Oil Filter
• 3.6.8. Breather Filter
• 3.7. HYDRAULIC OIL COOLING
• 3.7.1. General
• 3.7.2. Function of the Hydraulic Oil Cooling Circuit
• 3.7.3. Adjustment of the Back Pressure Valve
• 3.7.4. Fan Drive (Two Stage Cooler Fan RPM Control)
• 3.7.5. Adjustment of the Cooler Fan Drive Speed
• 3.8. CONTROLLING
• 3.8.1. General Layout
• 3.8.2. Control and Filter Panel Location of Components
• 3.8.3. Pilot Pressure Supply and Adjustments
• 3.8.4. Function Electro Hydraulic Control SYSTEM
• 3.8.5. Potentiometer Control (Lever, Joy Stick)
• 3.8.6. Potentiometer Control (Pedal)
• 3.8.7. Proportional Amplifier Module, Type A
• 3.8.8. Proportional Amplifier Module, Type B
• 3.8.9. Ramp Time Module
• 3.8.10. Adjustments of Amplifier Modules
• 3.8.11. Adjusting the Ramp Time Module
• 3.9. COMPONENTS
• 3.9.1. Main Control Blocks and High Pressure Filter (FSA)
• 3.9.2. Main Control Blocks and High Pressure Filter (BHA)
• 3.9.3. Distributor Manifold Location of Restrictor Blocks and Anti Cavitation Valves (FSA)
• 3.9.4. Distributor Manifold Location of Restrictor Blocks and Anti Cavitation Valves (BHA)
• 3.9.5. Single Control Blocks (Floating) for Stick and Boom (FSA)
• 3.9.6. Restrictor Block with Pressure Relief Valve
• 3.9.7. Anti cavitation valve block
• 3.9.8. Remote Control Valves
• 3.9.9. Directional Solenoid Valves (Three Positions / 4Ways)
• 3.9.10. Proportional Solenoid Valve
• 3.9.11. High Pressure Filter
• 3.9.12. Control Blocks and Valves
• 3.9.13. Travel Brake Valve
• 3.9.14. Pressure Reducing Valve
• 3.9.15. Directional Solenoid Valves (Two Positions / 4Ways)
• 3.9.16. Pressure Increasing Valve
• 3.9.17. Hydraulic Cylinder
• 3.9.18. Swing Ring
• 3.10. MAIN HYDRAULIC PUMPS AND PUMP REGULATION
• 3.10.1. General
• 3.10.2. Main Pumps
• 3.10.3. Electronic Pump Regulation System
• 3.10.4. Hydraulic Constant Regulation System
• 3.10.5. Determination of the Peak Point (Engine Performance)
• 3.10.6. Engine Speed Sensor (Pick up)
• 3.10.7. Energy Efficiency
• 3.11. OPERATING HYDRAULICS
• 3.11.1. General
• 3.11.2. Hydraulic for the Attachment Cylinder FSA and BHA
• 3.11.3. Hydraulic for the Swing Circuit
• 3.11.4. Hydraulic for the Travel Circuit
• 3.12. HYDRAULIC TRACK TENSIONING SYSTEM
• 3.12.1. General
• 3.12.2. Pressure Increasing Valve
• 3.12.3. Tensioning Cylinder
• 3.12.4. Adjustments / Checks
• 3.12.5. Functional Test
• 3.13. ACCESS LADDER HYDRAULICALLY OPERATED
• 3.13.1. General
• 3.13.2. Function of Hydraulically Operated Access Ladder
• 3.13.3. Adjustments / Checks
• 3.14. CABLE DRUM
• 3.14.1. General
• 3.14.2. Function
• 3.15. HINTS FOR READING THE HYDRAULIC DIAGRAM
• 3.15.1. General
• 3.15.2. Symbolic
• 3.16. HINTS FOR READING THE ELECTRIC CIRCUIT DIAGRAM
• 3.16.1. Designation of electrical components
• 3.16.2. Electric symbols
• 3.16.3. Symbols
• 3.16.4. Drawing Concept
• 3.16.5. Reading a Circuit Diagram
• 3.16.6. Component List
• 3.17. ELECTRONIC CONTROL SYSTEM (ECS)
• 3.17.1. General
• 3.17.2. Specifications for Operators
• 3.17.3. Specifications for Service
• 3.17.4. Wiring of the Main Components
• 3.17.5. General Design of THE PLC
• 3.17.6. How to proceed the Maintenance and Installation
• 3.17.7. Front Connector Arrangement
• 3.17.8. Power Supply
• 3.17.9. Function Explanations with Electrical Diagram
• 3.17.10. Hints for Reading the Functional Flow Charts
• 3.18. AUTOMATIC LUBRICATION SYSTEMS
• 3.18.1. Introduction
• 3.18.2. Central Lubrication System (CLS)
• 3.18.3. Lubrication Pump Station (SLS)
• 3.18.4. Operating and Controlling
• 3.18.5. Adjustments
• 3.18.6. Troubleshooting
• 3.18.7. Commissioning
• 4. Troubleshooting
• 4.1. Safety
• 5. Dissassembly and Assembly
• 5.1. Table of contents
• 5.2. Introduction
• 5.2.1. Contents of this binder
• 5.2.2. Preface
• 5.3. SAFETY
• 5.3.1. SAFETY INFORMATION
• 5.3.2. OVERVIEW
• 5.3.3. SOUND PRESSURE LEVEL IN THE OPERATORS CAB.
• 5.3.4. GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR
• 5.3.5. PRECAUTION FOR MAINTENANCE
• 5.3.6. ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS
• 5.3.7. SPECIAL SAFETY EQUIPMENT
• 5.4. Superstructure
• 5.4.1. Superstructure / machine house overview
• 5.4.2. Batteries
• 5.4.3. Electric motor
• 5.4.4. Coupling assembly
• 5.4.6. Hydraulics
• 5.4.7. Slew system
• 5.4.8. Lubrication pumps
• 5.4.9. Operators cab
• 5.4.10. Cab base (medium voltage switch cabinet)
• 5.4.11. Access ladder
• 5.4.12. Counterweight
• 5.4.13. Superstructure Lifting
• 5.4.14. High voltage switch cabinet
• 5.4.15. Slip ring unit
• 5.5. Undercarriage
• 5.5.1. Undercarriage overview
• 5.5.2. Travel system
• 5.5.3. Car body
• 5.5.4. Cable drum (optional)
• 5.5.5. Cable supply
• 5.6. Attachment
• 5.6.1. Backhoe
• 5.6.2. Faceshovel
• 5.6.3. Metering valves (grease injectors) at the attachment
• 5.6.4. Cylinder bypass test
• 5.7. Service Information
• 5.7.1. Classification of Voltages for KMG Electric Shovels
• 5.7.2. Fluids and lubricants
• 5.7.3. Lifting Gears
• 5.7.4. Safety hints for sling accessory
• 5.7.5. Filling capacities
• 5.7.6. Work instructions
• 5.7.7. Weight tables
• 5.7.8. Torque charts according to KOMATSU company standard
• 5.7.9. Blind plugs
• 5.7.10. Conversion table
• 5.7.11. Tools
• 5.8. Tools catalogue
• 5.9. Parts Service News
• 5.9.1. List of the PARTS AND SERVICE NEWS
• 5.10. Suppliers documentation