Komatsu PC4000-6 Shovel Index:

• 1 FOREWORD
  • 1.1 BEFORE READING THIS MANUAL
  • 1.2 DIRECTIONS OF THE MACHINE
  • 1.3 SPECIFICATION AND SERIAL PLATE
    • 1.3.1 PRODUCT IDENTIFICATION NUMBER
  • 1.4 DIVISION OF THE BINDER
  • 1.5 DESIGNATED USE OF THE SHOVEL
  • 1.6 DELIVERY OF THE SHOVEL
    • 1.6.1 SPARE PARTS
    • 1.6.2 SERVICE
  • 1.7 EXPLANATION OF ABBREVIATIONS
  • 1.8 CONTENTS
• 2 SAFETY
  • 2.1 SAFETY INFORMATION
  • 2.2 OVERVIEW
    • 2.2.1 NORMAL OPERATIONS
    • 2.2.2 REGULAR MAINTENANCE
    • 2.2.3 TROUBLESHOOTING, ADJUSTMENTS AND REPAIR
    • 2.2.4 ADDITIONAL SAFETY PRECAUTIONS FOR ASSEMBLING, DISASSEMBLING AND TRANSPORTATION OF THE EXCAVATOR
  • 2.3 SOUND PRESSURE LEVEL IN THE OPERATOR’S CAB.
  • 2.4 GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR
    • 2.4.1 UNDERSTANDING THE MACHINE
    • 2.4.2 PRECAUTIONS BEFORE STARTING OPERATION ON THE EXCAVATOR
    • 2.4.3 PREPARATIONS FOR SAFE OPERATION
    • 2.4.4 FIRE PREVENTION
    • 2.4.5 PRECAUTIONS WHEN GETTING ON OR OFF THE MACHINE
    • 2.4.6 BURN PREVENTION
    • 2.4.7 PRECAUTIONS WHEN CLEANING CAB GLASS
    • 2.4.8 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES
    • 2.4.9 ELECTROMAGNETIC COMPATIBILITY (EMC)
    • 2.4.10 PRECAUTIONS AT JOBSITE
    • 2.4.11 STARTING ENGINE
    • 2.4.12 OPERATION
  • 2.5 PRECAUTION FOR MAINTENANCE
    • 2.5.1 GENERAL PRECAUTIONS
    • 2.5.2 PRECAUTIONS FOR INSPECTION AND MAINTENANCE
    • 2.5.3 PRECAUTIONS WITH HIGH PRESSURE FLUID
  • 2.6 ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS
    • 2.6.1 INSPECTION OF THE HYDRAULIC SYSTEM
    • 2.6.2 TWO WORKERS ONLY WHEN THE MACHINE IS RUNNING DURING ADJUSTMENTS
    • 2.6.3 AREAS OF POTENTIAL DANGER AROUND THE EXCAVATOR
  • 2.7 SPECIAL SAFETY EQUIPMENT
    • 2.7.1 FRONT GUARD PROTECTIVE STRUCTUR ’FOPS’ FOR OPERATOR’S CAB
    • 2.7.2 OBJECT HANDLING
    • 2.7.3 LIGHTING
    • 2.7.4 WARNING BEACON
    • 2.7.5 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)
  • 2.8 SAFETY WARNING SIGNS
    • 2.8.1 LOCATION AND DESCRIPTION OF THE SIGNS
• 3 OPERATION
  • 3.1 FOREWORD
  • 3.2 CONSTRUCTION OF THE SHOVEL
    • 3.2.1 OVERALL VIEW
    • 3.2.2 SUPERSTRUCTURE
    • 3.2.3 HYDRAULICALLY OPERATED ACCESS LADDER
    • 3.2.4 EMERGENCY ESCAPE LADDER
    • 3.2.5 BOOM ACCESS LADDER AND WALKWAY
    • 3.2.6 EMERGENCY ENGINE SHUTDOWN FROM GROUND MAN OR OPERATOR WARNING SYSTEM
    • 3.2.7 OPERATOR’S CAB WITH INTEGRATED FALLING OBJECT PROTECTIVE STRUCTURE (FOPS)
    • 3.2.8 UNDERCARRIAGE
    • 3.2.9 WORKING ATTACHMENT
    • 3.2.10 DIESEL ENGINE TYPE SDA 16V160E-2
    • 3.2.11 ENGINE OIL MANAGEMENT SYSTEM
  • 3.3 OPERATOR’S CAB – CONTROLS
    • 3.3.1 CONTROLS WITH BACKHOE ATTACHMENT
    • 3.3.2 SAFETY CIRCUIT FOR CONTROLS
    • 3.3.3 CONTROLS WITH BOTTOM DUMP BUCKET ATTACHMENT
    • 3.3.4 SAFETY CIRCUIT FOR CONTROLS
    • 3.3.5 AUTOMATIC FLOAT POSITION FOR BOOM AND STICK
    • 3.3.6 OPERATOR’S CONSOLE
    • 3.3.7 INTERFACE PANEL FOR DIAGNOSTICS
    • 3.3.8 CONTROL MODULE FOR AUXILIARY CAB HEATER
  • 3.4 VEHICLE HEALTH MONITORING SYSTEM VHMS – HEALTH MONITOR (KOMTRAX PLUS)
    • 3.4.1 SEQUENCE OF DISPLAYS
    • 3.4.2 OPENING SCREEN
    • 3.4.3 MAIN GAUGE SCREENS 1 TO 3
    • 3.4.4 FUEL CONSUMPTION SCREEN
    • 3.4.5 FAILURE MESSAGE HISTORY SCREEN FOR OPERATOR
    • 3.4.6 MAIN SCREEN – CHANGE >TIME >SMR >DATE
    • 3.4.7 MAINTENANCE MONITOR
    • 3.4.8 SETTINGS FOR OPERATOR
    • 3.4.9 AUTOMATIC MESSAGES
    • 3.4.10 TABLE OF ALL TOP MESSAGES PROVIDED BY THE SYSTEM
    • 3.4.11 TABLE OF AVAILABLE INSTRUCTION MESSAGES
  • 3.5 CAMERA SYSTEM WITH MONITORS
    • 3.5.1 LOCATION OF MONITORS AND CONTROL UNITS
  • 3.6 OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING
    • 3.6.1 Digital Display
    • 3.6.2 AUXILIARY HEATER FOR OPERATOR’S CAB
  • 3.7 POWER HOUSE
    • 3.7.1 EMERGENCY ENGINE SHUTDOWN SWITCHES
    • 3.7.2 MAINTENANCE SAFETY SWITCH AND BATTERY MAIN SWITCHES
    • 3.7.3 CENTRAL CONTROL AND FILTER PANEL
  • 3.8 ELECTRICAL EQUIPMENT IN CAB BASE
    • 3.8.1 STANDARD COMPONENTS IN CAB BASE
    • 3.8.2 LOW VOLTAGE SWITCH BOARD IN CAB BASE
    • 3.8.3 MASTER TURBO CONTROLLER MTC – LED INDICATIONS
    • 3.8.4 BINARY FAULT CODE LIST.
    • 3.8.5 TABLE OF LOCATION NUMBERS FOR ELECTRICAL COMPONENTS
    • 3.8.6 COMPONENTS OF ELECTRICAL PREHEATING SYSTEM IN CAB BASE
  • 3.9 CHECKS BEFORE STARTING THE ENGINE
    • 3.9.0.1 Coolant Level
    • 3.9.0.2 Machinery House Doors
    • 3.9.0.3 Operator’s Seat Adjustment
  • 3.10 STARTING THE ENGINE
    • 3.10.1 STARTING PROCEDURE
    • 3.10.2 ENGINE WARM-UP
    • 3.10.3 HYDRAULIC OIL WARM-UP
    • 3.10.4 JUMP START WITH BOOSTER BATTERIES
  • 3.11 MOVING THE SHOVEL
    • 3.11.1 TRAVEL CONTROL WITH FOOT PEDALS
    • 3.11.2 TRAVELLING INSTRUCTIONS
  • 3.12 SLEWING AND BRAKING THE SUPERSTRUCTURE
    • 3.12.1 SLEWING THE SUPERSTRUCTURE
    • 3.12.2 BRAKING THE SUPERSTRUCTURE
    • 3.12.3 SLEW PARKING BRAKE
  • 3.13 WORKING WITH THE ATTACHMENT
    • 3.13.1 MACHINES EQUIPPED WITH ”EURO” CONTROL SYSTEM
    • 3.13.2 MACHINES EQUIPPED WITH ”KMG” CONTROL SYSTEM
    • 3.13.3 BOTTOM DUMP BUCKET
    • 3.13.4 DROP BALL OPERATION
    • 3.13.5 COMBINED OPERATION CYCLES
  • 3.14 WORKING INSTRUCTIONS
    • 3.14.1 STABILITY OF THE SHOVEL
    • 3.14.2 SHOVEL OPERATION
  • 3.15 PARKING THE SHOVEL
    • 3.15.0.1 CLEANING THE TRACK GROUPS
  • 3.16 STOPPING THE ENGINE
    • 3.16.1 RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM
  • 3.17 OPERATION OF THE LUBRICATION SYSTEM
    • 3.17.1 CENTRAL LUBRICATION SYSTEM ”CLS”
    • 3.17.2 SWING CIRCLE PINION LUBRICATION SYSTEM ”SLS”
  • 3.18 FIRE DETECTION AND SUPPRESSION SYSTEMS
    • 3.18.0.1 FIRE DETECTION AND SUPPRESSION SYSTEMS
    • 3.18.1 HIGH LEVEL ALARM ”FIRE”
    • 3.18.2 ENGINE SHUT-DOWN THROUGH FUEL SHUT-OFF SOLENOID VALVE
    • 3.18.3 ACTUATION MODES OF THE FIRE SUPPRESSION SYSTEMS
    • 3.18.4 INDICATION OF OPERATIONAL MODES AT CONTROL MODULE, AFTER AUTOMATIC ACTUATION OF THE FIRE SUPPRESSION SYSTEMS
    • 3.18.5 EXTINGUISHING AGENT TANK ASSEMBLIES AND EXPELLANT GAS CARTRIDGES ON POWER HOUSE ROOF
  • 3.19 TRANSFER PUMP FOR HYDRAULIC OIL
    • 3.19.1 OPERATING THE TRANSFER PUMP
    • 3.19.2 FUNCTIONS OF THE TRANSFER PUMP
  • 3.20 CENTRAL REFILLING SYSTEM
    • 3.20.1 SYSTEMS CONNECTED TO THE REFILLING SYSTEM
    • 3.20.2 OPERATING THE HYDRAULIC SERVICE ARM
    • 3.20.3 RECEIVER PANEL WITH MONITOR BOX
    • 3.20.4 REFILLABLE GREASE CONTAINERS OF THE CENTRAL LUBRICATION SYSTEM AND SWING CIRCLE PINION LUBRICATION SYSTEM
  • 3.21 WORK ON THE LOADER ATTACHMENT
    • 3.21.0.1 OBSERVE THE FOLLOWING INSTRUCTIONS
  • 3.22 TRANSPORTATION AND LIFTING OF THE SHOVEL
    • 3.22.1 DISASSEMBLING OF THE SHOVEL
    • 3.22.2 TRANSPORTATION AND LIFTING
  • 3.23 RETRIEVAL PROCEDURE
  • 3.24 SHOVEL STORAGE
    • 3.24.0.1 GENERAL
    • 3.24.1 PREPARING FOR STORAGE
    • 3.24.2 ONE MONTH REPETITIVE SERVICE PERIOD
    • 3.24.3 SIX MONTH REPETITIVE SERVICE PERIOD
    • 3.24.4 PREPARING FOR OPERATION
  • 3.25 TROUBLE SHOOTING
    • 3.25.0.1 GENERAL
    • 3.25.1 ENGINE
    • 3.25.2 HYDRAULIC SYSTEM
    • 3.25.3 FINAL DRIVES AND SWING MACHINERY
    • 3.25.4 CRAWLER TRACKS
• 4 MAINTENANCE
  • 4.1 FOREWORD
    • 4.1.0.1 DEFINITIONS
    • 4.1.0.2 GENERAL RECOMMENDATIONS
  • 4.2 SAFETY PRECAUTIONS FOR MAINTENANCE
  • 4.3 FLUIDS AND LUBRICANTS
    • 4.3.1 LUBRICANTS FOR OPERATION IN COLD AND ARCTIC CLIMATES
    • 4.3.2 FLUIDS AND LUBRICANTS FOR MODERATE AND HOT CLIMATES
  • 4.4 FILLING CAPACITIES
  • 4.5 STANDARD TORQUE LIST
  • 4.6 LUBRICATION AND MAINTENANCE SCHEDULE
    • 4.6.1 INITIAL SERVICING
    • 4.6.2 PERIODIC SERVICING INTERVALS
    • 4.6.3 PERIODIC SERVICING SCHEDULE
  • 4.7 SAFETY CRITICAL PARTS
    • 4.7.1 REPLACEMENT OF HYDRAULIC HOSE LINES AND FUEL HOSE LINES
    • 4.7.2 INSPECTION OF HOSE LINES
    • 4.7.3 PERIODIC REPLACEMENT OF FURTHER SAFETY CRITICAL PARTS
  • 4.8 EXTENDED SERVICE INTERVALS
    • 4.8.1 FOR ENGINES EQUIPPED WITH ENGINE OIL MANAGEMENT SYSTEM
    • 4.8.2 MAINTENANCE OF THE ENGINE
  • 4.9 ENGINE FUEL FILTER LOCATION
    • 4.9.1 fuel line connections on the engine
  • 4.10 WHEN NECESSARY
    • 4.10.1 ENGINE AIR CLEANER SERVICE
    • 4.10.2 SWING CIRCLE TOOTHING LUBRICATION
    • 4.10.3 AUTOMATIC LUBRICATION SYSTEMS FILL GREASE BARRELS
    • 4.10.4 TRACK ROLLERS AND GUIDE WHEELS – REPLACE FLOATING SEALS
  • 4.11 EVERY 10 OPERATING HOURS OR DAILY
    • 4.11.1 WALK-AROUND INSPECTION
    • 4.11.2 AIR CLEANER – CLEAN PRE-CLEANER
    • 4.11.3 RADIATOR – CHECK COOLANT LEVEL
    • 4.11.4 TRACK GROUPS – CLEAN
    • 4.11.5 FUEL SYSTEM WATER SEPARATOR – DRAIN WATER
    • 4.11.6 BOOM – CHECK LADDER AND WALKWAY
  • 4.12 EVERY 50 OPERATING HOURS OR WEEKLY
    • 4.12.1 SWING GEARS AND MOTOR ADAPTER HOUSINGS – CHECK OIL LEVELS
    • 4.12.2 PTO (PUMP DISTRIBUTOR GEAR) AND OIL RESERVOIR – CHECK OIL LEVEL
    • 4.12.3 HYDRAULIC ACCESS LADDER – CHECK SAFETY SENSOR
    • 4.12.4 HYDRAULIC OIL COOLERS – INSPECT AND CLEAN IF NECESSARY
  • 4.13 EVERY 250 OPERATING HOURS OR MONTHLY
    • 4.13.1 AIR CONDITIONING
    • 4.13.2 AIR CONDITIONING COMPRESSOR – CHECK DRIVE BELT TENSION
    • 4.13.3 AIR CONDITIONING FOR OPERATOR’S CAB – CHECK REFRIGERANT LEVEL
    • 4.13.4 UNDERCARRIAGE PIN CONNECTIONS – LUBRICATE
    • 4.13.5 SIGNAL HORN COMPRESSOR – LUBRICATE
    • 4.13.6 HYDRAULIC OIL COOLER FAN BEARING HOUSINGS – CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER
    • 4.13.7 RADIATOR FAN BEARING HOUSING – CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER
    • 4.13.8 AUTOMATIC LUBRICATION SYSTEMS – CLEAN IN-LINE GREASE FILTER
    • 4.13.9 CAB AIR CLEANER – CLEAN OR REPLACE FILTER ELEMENT
    • 4.13.10 WINDSHIELD WASHER SYSTEM – CHECK FLUID LEVEL
  • 4.14 EVERY 500 OPERATING HOURS OR MONTHLY
    • 4.14.1 BATTERIES – CHECK FLUID LEVEL
    • 4.14.2 FLEXIBLE DRIVE COUPLING – CHECK OIL LEVEL
    • 4.14.3 PTO (PUMP DISTRIBUTOR GEAR) MAIN PUMP DRIVE SHAFT HOUSINGS – CHECK OIL LEVEL
    • 4.14.4 FUEL TANK – DRAIN CONDENSATION
    • 4.14.5 CRAWLER TRACK – INSPECTION
    • 4.14.6 GROUND CABLES OF ENGINE, STARTER MOTORS AND ALTERNATOR – CHECK FOR CORRECT CONNECTION
    • 4.14.7 GROUND CABLE OF OPERATOR’S CAB – CHECK FOR CORRECT CONNECTION
  • 4.15 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH
    • 4.15.1 HIGH STRENGTH BOLT CONNECTIONS
    • 4.15.2 HYDRAULIC SYSTEM – FILTER SERVICE
    • 4.15.3 PTO (PUMP DISTRIBUTOR GEAR), SWING GEARS AND TRAVEL GEARS – OIL SAMPLE ANALYSIS
    • 4.15.4 SIGNAL HORN COMPRESSOR – CLEAN AND LUBRICATE
    • 4.15.5 HYDRAULIC TRACK TENSIONING SYSTEM – CHECK ACCUMULATORS
    • 4.15.6 HYDRAULIC OIL COOLER – INSPECT AND LUBRICATE DOOR HINGES
    • 4.15.7 MACHINERY HOUSE DOORS – INSPECT AND LUBRICATE DOOR HINGES
  • 4.16 EVERY 2000 OPERATING HOURS OR YEARLY
    • 4.16.1 HYDRAULIC SYSTEM – CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER
    • 4.16.2 FILLING THE HYDRAULIC SYSTEM
    • 4.16.3 BLEEDING THE HYDRAULIC SYSTEM
    • 4.16.4 GEAR PUMP FOR PTO GEAR LUBRICATION
    • 4.16.5 EMERGENCY ESCAPE LADDER – INSPECTION
  • 4.17 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR
    • 4.17.1 SWING GEARS AND MOTOR ADAPTER HOUSING – CHANGE OIL
    • 4.17.2 PTO (PUMP DISTRIBUTOR GEAR) – CHANGE OIL
  • 4.18 FIRE PREVENTION
    • 4.18.1 PRECAUTIONS
  • 4.19 WELD REPAIRS
    • 4.19.1 GENERAL PROTECTIVE MEASURES
    • 4.19.2 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE UNDERCARRIAGE
    • 4.19.3 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE LOADER ATTACHMENT
    • 4.19.4 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE SUPERSTRUCTURE
    • 4.19.5 AFTER FINISHING THE WELD REPAIRS ON THE SUPERSTRUCTURE