Komatsu PC4000E-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 motor
    • 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 EMERGENCY MOTOR SHUTDOWN FROM GROUND MAN AND OPERATOR WARNING SYSTEM
    • 3.2.6 OPERATOR’S CAB WITH INTEGRATED FALLING OBJECT PROTECTIVE STRUCTURE (FOPS)
    • 3.2.7 UNDERCARRIAGE
    • 3.2.8 WORKING ATTACHMENT
  • 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 OPERATORS CONSOLE, OVERVIEW
    • 3.3.7 INTERFACE PANEL FOR DIAGNOSTICS
  • 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS
    • 3.4.1 INTRODUCTION
    • 3.4.2 OPERATING THE ELECTRONIC MONITORING SYSTEM
    • 3.4.3 AUTOMATIC DISPLAY OF MESSAGES
    • 3.4.4 MENU CONTROL, SERVICE FUNCTIONS AND INPUTS/OUTPUTS
    • 3.4.5 FAULT AND INFORMATION MESSAGE LIST
  • 3.5 CAMERA SYSTEM WITH MONITOR
    • 3.5.1 LOCATION OF MONITOR AND CONTROL UNIT
  • 3.6 OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING
    • 3.6.1 Digital Display
    • 3.6.2 Luminous Indication
    • 3.6.3 Additional Air Conditioning/Heater Unit in Operator’s Cab
  • 3.7 MACHINERY HOUSE
    • 3.7.1 EMERGENCY MOTOR SHUTDOWN SWITCHES
    • 3.7.2 MAINTENANCE SAFETY SWITCH AND BATTERY MAIN SWITCHES
    • 3.7.3 CENTRAL CONTROL AND FILTER PANEL
  • 3.8 MEDIUM VOLTAGE SWITCH CABINET IN CAB BASE
    • 3.8.1 SWITCH BOARD (X2) IN CAB BASE
    • 3.8.2 COMPONENTS IN THE MEDIUM VOLTAGE SWITCH CABINET
    • 3.8.3 MONITOR AND CONTROL PANEL
    • 3.8.4 PREHEATING SYSTEM
  • 3.9 CHECKS BEFORE STARTING THE MAIN DRIVE MOTOR
    • 3.9.1 WALK AROUND INSPECTION
    • 3.9.2 TURNING ON THE POWER SUPPLY
    • 3.9.3 Hydraulic System – Check Oil Level
    • 3.9.4 Machinery House Doors
    • 3.9.5 Operator’s Seat Adjustment
  • 3.10 STARTING THE MAIN DRIVE MOTOR
    • 3.10.1 STARTING PROCEDURE
  • 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 MOTOR.
    • 3.16.1 RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM
  • 3.17 GROUNDING PROCEDURE FOR THE HIGH VOLTAGE SYSTEM
    • 3.17.1 ISOLATING THE POWER SUPPLY
    • 3.17.2 PROCEDURE FOR ISOLTING THE POWER SUPPLY
    • 3.17.3 PERFORMING GROUNDING PROCEDURES
  • 3.18 OPERATION OF THE LUBRICATION SYSTEM
    • 3.18.1 CENTRAL LUBRICATION SYSTEM -CLS- FOR SUPERSTRUCTURE AND ATTACHMENT
    • 3.18.2 ADJUSTMENTS OF THE CENTRAL LUBRICATION SYSTEM
    • 3.18.3 SWING CIRCLE PINION LUBRICATION SYSTEM ”SLS”
  • 3.19 TRANSFER PUMP FOR HYDRAULIC OIL.
    • 3.19.1 OPERATING THE TRANSFER PUMP
    • 3.19.2 FUNCTIONS OF THE TRANSFER PUMP
  • 3.20 FIRE DETECTION, ACTUATION AND SUPPRESSION SYSTEM.
    • 3.20.1 CONTROL UNITS FOR THE FIRE DETECTION, ACTUATION AND SUPPRESSION SYSTEMS
    • 3.20.2 REMOTE HIGH LEVEL ALARM *FIRE* LOCATED ON THE CAB
    • 3.20.3 ACTUATION MODES OF THE FIRE SUPPRESSION SYSTEM
    • 3.20.4 IN The CASE OF A FIRE
  • 3.21 CENTRAL REFILLING SYSTEM.
    • 3.21.1 SYSTEMS CONNECTED TO THE REFILLING SYSTEM
    • 3.21.2 RECEIVER PANEL AND MONITOR BOX
    • 3.21.3 Refilling Procedure:
    • 3.21.4 REFILLABLE GREASE CONTAINERS OF THE CENTRAL LUBRICATION SYSTEM AND SWING CIRCLE PINION LUBRICATION SYSTEM
  • 3.22 CABLE DRUM (IF SO EQUIPPED)
    • 3.22.1 OPERATION OF THE CABLE DRUM
    • 3.22.2 TRAVELLING INSTRUCTIONS
  • 3.23 CABLE GUIDE (IF SO EQUIPPED)
    • 3.23.1 LIFTING DEVICE FOR THE POWER CABLE
  • 3.24 WORK ON THE LOADER ATTACHMENT
    • 3.24.1 OBSERVE THE FOLLOWING INSTRUCTIONS
  • 3.25 TRANSPORTATION AND LIFTING OF THE SHOVEL
    • 3.25.1 DISASSEMBLING OF THE SHOVEL
    • 3.25.2 TRANSPORTATION AND LIFTING
  • 3.26 RETRIEVAL PROCEDURE
    • 3.26.0.1 GENERAL
  • 3.27 SHOVEL STORAGE
    • 3.27.0.1 GENERAL
    • 3.27.1 PREPARING FOR STORAGE
    • 3.27.2 ONE MONTH REPETITIVE SERVICE PERIOD
    • 3.27.3 SIX MONTH REPETITIVE SERVICE PERIOD
    • 3.27.4 PREPARING FOR OPERATION
  • 3.28 TROUBLE SHOOTING
    • 3.28.0.1 GENERAL
    • 3.28.0.2 motor
    • 3.28.1 HYDRAULIC SYSTEM
    • 3.28.2 FINAL DRIVES AND SWING GEAR
    • 3.28.3 CRAWLER TRACKS
• 4 MAINTENANCE
  • 4.1 FOREWORD
    • 4.1.0.1 DEFINITIONS
    • 4.1.0.2 GENERAL RECOMMENDATIONS
  • 4.2 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
    • 4.3.3 MAIN DRIVE ELECTRIC MOTOR – BEARING LUBRICATION
  • 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 SCHEDULEPERIODIC SERVICING SCHEDULE
    • 4.6.4 MAINTENANCE SCHEDULES OF FILTER ELEMENTS AND OTHER COMPONENTS OF THE HYDRAULIC SYSTEM
    • 4.6.5 MAINTENANCE OF THE MAIN DRIVE ELECTRIC MOTOR
  • 4.7 SAFETY CRITICAL PARTS
    • 4.7.1 REPLACEMENT OF HYDRAULIC HOSE LINES
    • 4.7.2 INSPECTION OF HYDRAULIC HOSE LINES
    • 4.7.3 PERIODIC REPLACEMENT OF FURTHER SAFETY CRITICAL PARTS
  • 4.8 WHEN NECESSARY
    • 4.8.1 SWING CIRCLE TOOTHING LUBRICATION
    • 4.8.2 AUTOMATIC LUBRICATION SYSTEMS FILL GREASE BARRELS
    • 4.8.3 TRACK ROLLERS AND GUIDE WHEELS – REPLACE FLOATING SEALS
  • 4.9 EVERY 10 OPERATING HOURS OR DAILY
    • 4.9.1 WALK-AROUND INSPECTION
    • 4.9.2 CLEANING THE TRACK GROUPS
  • 4.10 EVERY 50 OPERATING HOURS OR WEEKLY
    • 4.10.1 SWING MACHINERY AND MOTOR ADAPTER HOUSINGS – CHECK OIL LEVELS
    • 4.10.2 TRAVEL GEARS, BRAKE HOUSINGS AND MOTOR ADAPTER HOUSINGS MANUFACTURED BY “L&S” – CHECK OIL LEVELS
    • 4.10.3 FINAL DRIVE HOUSINGS – CHECK OIL LEVEL
    • 4.10.4 TRAVEL GEARS AND MOTOR ADAPTER HOUSINGS MANUFACTURED BY “ZOLLERN” – CHECK OIL LEVELS
    • 4.10.5 FINAL DRIVE HOUSINGS – CHECK OIL LEVEL
    • 4.10.6 PTO (PUMP DISTRIBUTOR GEAR) AND OIL RESERVOIR – CHECK OIL LEVEL
    • 4.10.7 HYDRAULIC ACCESS LADDER – CHECK SAFETY SENSOR
    • 4.10.8 HYDRAULIC OIL COOLERS – INSPECT AND CLEAN IF NECESSARY
  • 4.11 EVERY 250 OPERATING HOURS OR MONTHLY
    • 4.11.1 UNDERCARRIAGE PIN CONNECTIONS – LUBRICATE
    • 4.11.2 HYDRAULIC OIL COOLER FAN BEARING
    • 4.11.3 SIGNAL HORN COMPRESSOR – LUBRICATE
    • 4.11.4 AUTOMATIC LUBRICATION SYSTEMS – CLEAN IN-LINE GREASE FILTER
    • 4.11.5 CAB AIR CLEANER – CLEAN OR REPLACE FILTER ELEMENT
    • 4.11.6 CAB AIR CLEANER – CLEAN OR REPLACE FILTER ELEMENT (Heavy duty version, special equipment)
    • 4.11.7 WINDSHIELD WASHER RESERVOIR – CHECK FLUID LEVEL
    • 4.11.8 AIR CONDITIONING FOR OPERATOR’S CAB – CHECK REFRIGERANT LEVEL
    • 4.11.9 AIR CONDITIONING FOR ELECTRICAL SWITCH CABINETS – CHECK REFRIGERANT LEVEL
    • 4.11.10 Air Conditioner Unit for Medium Voltage and High Voltage Switch Cabinets
  • 4.12 EVERY 500 OPERATING HOURS OR MONTHLY
    • 4.12.1 BATTERIES – CHECK FLUID LEVEL
    • 4.12.2 PTO (PUMP DISTRIBUTOR GEAR) MAIN PUMP DRIVE SHAFT HOUSINGS – CHECK OIL LEVEL
    • 4.12.3 FLEXIBLE DRIVE COUPLINGS – CHECK OIL LEVEL
    • 4.12.4 CRAWLER TRACK – INSPECTION
    • 4.12.5 GROUND CABLE OF OPERATOR’S CAB – CHECK FOR CORRECT CONNECTION
  • 4.13 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH
    • 4.13.1 HIGH STRENGTH BOLT CONNECTIONS
    • 4.13.2 HYDRAULIC SYSTEM – FILTER SERVICE
    • 4.13.3 PTO (PUMP DISTRIBUTOR GEAR), SWING MACHINERY AND TRAVEL GEARS – OIL SAMPLE ANALYSIS
    • 4.13.4 SIGNAL HORN COMPRESSOR – CLEAN AND LUBRICATE
    • 4.13.5 HYDRAULIC TRACK TENSIONING SYSTEM – CHECK ACCUMULATORS
    • 4.13.6 HYDRAULIC OIL COOLER – INSPECT AND LUBRICATE DOOR HINGES
    • 4.13.7 MACHINERY HOUSE DOORS – INSPECT AND LUBRICATE DOOR HINGES
    • 4.13.8 SLIP RING UNIT – LUBRICATE
  • 4.14 EVERY 2000 OPERATING HOURS OR YEARLY
    • 4.14.1 HYDRAULIC SYSTEM – CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER
    • 4.14.2 BLEEDING THE HYDRAULIC SYSTEM
    • 4.14.3 GEAR PUMP FOR PTO GEAR LUBRICATION
    • 4.14.4 EMERGENCY ESCAPE LADDER – INSPECTION
  • 4.15 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR
    • 4.15.1 SWING GEARS AND MOTOR ADAPTER HOUSING – CHANGE OIL
    • 4.15.2 TRAVEL GEARS, BRAKE AND MOTOR ADAPTER HOUSINGS MANUFACTURED BY “L&S”- CHANGE OIL
    • 4.15.3 TRAVEL GEARS AND MOTOR ADAPTER HOUSINGS MANUFACTURED BY “ZOLLERN”- CHANGE OIL
    • 4.15.4 FINAL DRIVE HOUSINGS – CHANGE OIL
    • 4.15.5 PTO (PUMP DISTRIBUTOR GEAR) – CHANGE OIL
  • 4.16 FIRE PREVENTION
    • 4.16.1 PRECAUTIONS
  • 4.17 WELD REPAIRS
    • 4.17.1 GENERAL INFORMATION
    • 4.17.2 WELD REPAIRS ON MAJOR COMPONENTS OF THE SHOVEL
    • 4.17.3 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE UNDERCARRIAGE
    • 4.17.4 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE LOADER ATTACHMENT
    • 4.17.5 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE SUPERSTRUCTURE