Komatsu PC4000-6 Hydraulic Mining Shovel Remove and Replace Procedures RRPC4000-6

Description

• Model List:
  • PC4000-6 Hydraulic Mining Shovel

• 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
• 2.1.6. SPECIAL SAFETY EQUIPMENT
• 2.2. Lifting Gears
• 2.2.1. Wire ropes
• 2.2.2. Sling accessory
• 2.2.3. Weight tables
• 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
• 3.1.4. Alternator
• 3.1.5. Batteries
• 3.1.6. Radiator fan
• 3.1.7. Radiators
• 3.1.8. Fuel cooler
• 3.1.9. Starter system
• 3.1.10. Geislinger coupling
• 3.2.1. Main pumps
• 3.2.2. PTO oil circulation pump (auxiliary pump)
• 3.2.3. Pump distributor gearbox (PTO)
• 3.3. Hydraulics
• 3.3.1. Hydraulic cooler fan Drive Pump
• 3.3.2. Hydraulic Cooler Fan Assembly
• 3.3.3. Hydraulic Oil Coolers
• 3.3.4. Main Relief Valves (MRV)
• 3.3.5. pilot oil pump (Gear pump)
• 3.3.6. Main Gate Valve
• 3.3.7. Hydraulic Oil Reservoir
• 3.3.8. Main Control Valve Blocks
• 3.3.9. Service line Relief Valves (SRV)
• 3.3.10. Anticavitation Valves (ACV)
• 3.3.11. Throttle check valves
• 3.3.12. manifold
• 3.4. Slew Drive
• 3.4.1. Slew Gear
• 3.4.2. Swing Motor
• 3.4.3. Slew parking brake
• 3.4.4. Dynamic Slew Brake
• 3.4.5. Swing circle lubrication pinion (dummy wheel)
• 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. Operators Cab
• 3.7.1. Removal of the operators cab
• 3.7.2. Replacement of the operators cab
• 3.7.3. Cabmounts
• 3.7.4. FRONT WINDOW
• 3.7.5. Operators seat
• 3.7.6. VHMS
• 3.7.7. Access Ladder
• 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
• 4.1.2. Sprocket
• 4.1.3. Guide wheels
• 4.1.4. Track tensioning accumulators
• 4.1.5. Track tension valve block
• 4.1.6. Hydraulic hoses of the track tensioning system
• 4.1.7. Travel brake valve block (overspeed valve)
• 4.1.8. Track tensioning cylinders
• 4.1.9. Travel motor
• 4.1.10. travel parking brake
• 4.1.11. Travel gearbox
• 4.1.12. Carrier roller
• 4.1.13. Track roller
• 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)
• 4.2.5. Rotary joint
• 4.2.6. swing circle
• 5. Attachment
• 5.1. Backhoe
• 5.1.1. Boom
• 5.1.2. Stick
• 5.1.3. Bucket
• 5.1.4. Bucket link rod and steering rods
• 5.1.5. Ground engaging tools (GET)
• 5.1.6. Hydraulic hoses at the backhoe attachment
• 5.2. Faceshovel
• 5.2.1. Boom
• 5.2.2. Stick
• 5.2.3. Bullclam bucket
• 5.2.4. Ground engaging tools (GET)
• 5.2.5. Hydraulic hoses at the Faceshovel attachment
• 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 (suppliers documentation)
• 6.5. Service Bulletins
• 6.5.1. AH03509a
• 6.5.2. AH03510
• 6.5.3. AH03526a