PDF Assembly Manual Komatsu Hydraulic Mining Shovel PC4000E-6 - 4 MB
This assembly manual provides detailed, step-by-step instructions for the construction and setup of the Komatsu PC4000E-6 Hydraulic Mining Shovel.
It is an essential document for field technicians and assembly crews, covering everything from major component installation to final system checks.
Following these factory procedures is critical for ensuring the structural integrity and operational safety of this massive machine.
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--- Page 1 ---
SHOP 08165E-GB-2
Shop Manual
HYDRAULIC
MINING PC4000E-6
SHOVEL
SERIAL NUMBER 08165- up
Unsafe use of this machine may cause serious
injury or death. Operators and maintenance
personnel must read this manual before
operating or maintaining this machine. This
manual should be kept near the machine for
reference and must be periodically reviewed by all
personnel who will come into contact with it.
Komatsu has Operation and Maintenance Manuals
written in other languages. If a foreign language
manual is required, contact your local distributor for
availability.
PC4000-6
--- Page 3 ---
GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR SAFETY
2.4.3.6 PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT
Always follow the precautions below to prepare for action if any
injury or fire should occur.
β Be sure that fire extinguishers have been provided and read
the labels to ensure that you know how to use them in emer-
gencies.
β Carry out periodic inspection and maintenance to ensure that
the fire extinguisher can always be used.
β Provide a first aid kit. Carry out periodic checks and add to
the contents if necessary (Fig. 3-4).
Fig. 3-4
2.4.3.7 IF A PROBLEM IS FOUND
If you find any problems in the machine during operation and maintenance (noise, vibration, smell, incorrect
gauges, smoke, oil, leakage, etc., or any abnormal display on the warning devices or monitor), report to the person
in charge and have the necessary action taken. Do not operate the machine until the problem has been corrected.
2.4.4 FIRE PREVENTION
2.4.4.1 PRECAUTIONS TO PREVENT FIRE
Fire caused by fuel, oil, antifreeze, or window washer fluid.
Do not bring any flame or fire close to flammable substances such as fuel, oil, antifreeze, or window washer fluid.
There is a danger they may catch fire. To prevent fire, always observe the following:
β Do not smoke or use any flame near fuel or other flamma-
ble substances. (Fig. 3-5)
β Stop the engines before adding fuel.
β Do not leave the machine while adding fuel or oil.
β Tighten all fuel and oil caps securely.
β Be careful not to spill fuel on overheated surfaces or on
parts of the electrical system.
β After adding fuel or oil, wipe up any spillage.
β Put greasy rags and other flammable materials into a safe
container to maintain safety in the workplace.
β When washing parts with oil, use a non-flammable oil. Do Fig. 3-5
not use diesel oil or gasoline. There is a danger that they
may catch fire.
β Do not weld or use a cutting torch to cut any pipe or tubes
that contain flammable liquids.
β Determine well ventilated areas for storing oil and fuel.
Keep the oil and fuel in the determined place and do not
allow unauthorised persons to enter.
REMARKS: Before carrying out grinding or welding work on the machine, remove any flammable materials.
2 - 10
--- Page 4 ---
PC 4000 S UPER S HOVEL
PRODUCTIVITY-FEATURES
4006078
DIGGING FORCES
Break-out force 1155 kN 260,000 lb Maximum reach at ground level . . . . . . . . .16.650 mm 54β8ββ
Tear-out force 1050 kN 236,000 lb Maximum digging depth . . . . . . . . . . . . . . . .8000 mm 26β3ββ
BACKHOE BUCKET, STICK AND BOOM COMBINATION
Bucket Width Weight Teeth Boom Length
Capacity 9750 mm 32β 0ββ
SAE including Stick Length
Heaped 1 : 1 Wear package -2 4500 mm 14β 9ββ
22 m3 29 yd3 3790 mm 12β5ββ 23.4 t 51,590 lb 6
Material weight to 1.8 t/m3 3000 lb/yd3
Alternative buckets / wear packages are available
6
--- Page 5 ---
FOREWORD CONVERSION TABLE
Basic Values in Ohm according to DIN 43 76
For Measuring Resistor PT100
Β°C -0 -1 -2 -3 -4 -5 -6 -7 -8 -9
-50 80,31 79,91 79,51 79,11 78,72 78,32 77,92 77,52 77,13 76,73
-40 84,27 83,88 83,48 83,08 82,69 82,29 81,89 81,50 81,10 80,70
-30 88,22 87,83 87,43 87,04 86,64 86,25 85,85 85,46 85,06 84,67
-20 92,16 91,77 91,37 90,98 90,59 90,19 89,80 89,40 89,01 88,62
-10 96,09 95,69 95,30 94,91 94,52 94,12 93,73 93,34 92,95 92,55
0 100,00 99,61 99,22 98,83 98,44 98,04 97,65 97,26 96,87 96,48
Β°C 0 1 2 3 4 5 6 7 8 9
0 100,00 100,39 100,78 101,17 101,56 101,95 102,34 102,73 103,12 103,51
10 103,90 104,29 104,68 105,07 105,46 105,85 106,24 106,63 107,02 107,40
20 107,79 108,18 108,57 108,96 109,35 109,73 110,12 110,51 110,90 111,28
30 111,67 112,06 112,45 112,83 113,22 113,61 113,99 114,38 114,77 115,15
40 115,54 115,93 116,31 116,70 117,08 117,47 117,85 118,24 118,62 119,01
50 119,40 119,78 120,16 120,55 120,93 121,32 121,70 122,09 122,47 122,86
60 123,24 123,62 124,01, 124,39 124,77 125,16 125,54 125,92 126,31 126,69
70 127,07 127,45 127,84 128,22 128,60 128,98 129,37 129,75 130,13 130,51
80 130,89 131,27 131,66 132,04 132,42 132,80 133,18 133,56 133,94 134,32
90 134,70 135,08 135,46 135,84 136,22 136,60 136,98 137,36 137,47 138,12
100 138,50 138,88 139,26 139,64 140,02 140,39 140,77 141,15 141,53 141,91
110 142,29 142,66 143,04 143,42 143,80 144,17 144,55 144,93 145,31 145,68
120 146,06 146,44 146,81 147,19 147,57 147,94 148,32 148,70 149,07 149,45
130 149,82 150,20 150,57 150,95 151,33 151,70 152,08 152,45 152,83 153,20
140 153,58 153,95 154,32 154,70 155,07 155,45 155,82 156,19 156,57 156,94
150 157,31 157,69 158,06 158,43 158,81 159,18 159,55 159,93 160,30 16067
00-13
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Main Assembly Groups Section 1.0
Page 9
1.1 Superstructure
1.1.6 Cab support
Legend for illustration (Z 21475):
(1) Cab support (Location of electrical switch board βX2β)
(2) Mounting bolts
Quantity Bolt size Grade SW* Tightening
(mm) (mm) torque (Nm)
4 M 36 x 240 10.9 55 3100
* SW = Wrench size
(3) Mounting bolts
Quantity Bolt size Grade SW* Tightening
(mm) (mm) torque (Nm)
4 M 36 x 240 10.9 55 3100
* SW = Wrench size
(4) Door
(5) Gasket
(6) Door handle (adjustable)
Vorlaeufig_#08165_PC4000_#08156-7_Sec_1-0 _rev0.doc 02.03.05
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2.0
4
PC4000-6-E_#08165_Sec_2-0_rev0.doc 02.03.05
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Hydraulic Oil Reservoir Section 3.0
Page 9
3.3 Return oil collector tube with strainer
Legend for illustration (Z 21497):
(1) Return oil collector tube - Part 1 -
(2) Return oil collector tube - Part 2 -
(3) Return oil collector tube - Part 3 -
(4) Strainer
(5) Bolt
Quantity Bolt size Grade SW* Tightening
(mm) (mm) torque (Nm)
8 M 20 x 80 10.9 30 510
(6) Bolt
Quantity Bolt size Grade SW* Tightening
(mm) (mm) torque (Nm)
8 M 20 x 70 10.9 30 510
(7) Self locking nut
(8) Gasket
* SW = Wrench size
Task:
The strainer is installed to prevent the hydraulic oil coolers from getting
clogged up in case of contamination in the main return circuit oil.
Excessive increase of the hydraulic oil temperature can be an indication for a
restricted strainer, i.e. bad cooling performance due to insufficient oil flow
through the coolers.
In case that main components such as cylinders or motors are internal
fragmentary damaged, the strainer should be inspected for metal chips.
--- Page 10 ---
Hydraulic Oil Cooling Section 4.0
Page 10
4.7 Adjustment of the cooler fan drive speed
Cont'd
Basic Adjustment β Maximum Speed, illustration (Z 21932b)
6. Check the fan speed with a non-contact rev counter
Required fan speed: 1250 min-1
Γ£ β’ Be careful not to get caught in the fan or other rotating parts
7. Increase the output flow of pump (5.1), by adjusting the swivel angle,
until the fan speed will be 20 min-1 higher than required:
To do this, loosen both lock nuts (6.1 + 7.1) and turn in bolt (6)
and turn out bolt (7) the same length.
This is necessary to avoid a loose positioning pin (10), resulting in
oscillating of the cylinder barrel.
Tighten the lock nuts (6.1 + 7.1).
Γ£ β’ Do not exceed the maximum permissible operating pressure of 230bar.
) β’ Note down the lengths βL1β and βL2β as reference measurements.
8. Loosen lock nut (b) of the relief valve (31.1), and decrease the pressure
with set screw (c) until the correct fan speed is obtained.
9. Tighten lock nut (b) and fix protection cap (a).
)
β’ Both fans have to be checked. A difference of approx. 50 rpm is
normal due to the higher resistance for the air stream for the lower
fan. If the speed difference between both fans is higher than 50 rpm, a
possible cause could be a worn hydraulic motor or defective bearings.
continued
PC4000-6-E_#08165_Sec_4-0_rev0.doc 02.03.05
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5.0
9
PC4000-6-E_#08165_Sec_5-0_rev0_.doc 02.03.05
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Controlling Section 5.0
Page 18
5.11 Adjusting the Amplifiers Type B, illustration (Z 21642)
Cont'd:
11. If the setting with either positive or negative potential was successful, turn
the potentiometer (P) of the service module into the opposite direction and
check the settings with the other polarity i.e. if the first setting was done
with positive potential then turn the pot into negative direction; otherwise
vice versa.
12. Repeat the setting as described under item 7 to 10.
13. Remove multimeter, test wire, close* the terminals and reconnect the wire
to terminal 5 of the amplifier module.
Adjusting the Ramp Time
1. Turn potentiometer (Rt) 30 revolutions counter clockwise, to guarantee the
correct start position at the complete left side.
2. Turn potentiometer (Rt) so many revolutions clockwise as shown in the
table below (part of the electrical circuit diagram).
* How to open and close the terminal:
Push the yellow stud (1) down with a screw driver and turn it 90Β° to the left to
open or to the right to close the terminal. A spring pushes then the stud
outwards and the contacts are either open or closed.
PC4000-6-E_#08165_Sec_5-0_rev0_.doc 02.03.05
--- Page 13 ---
6.0
4
PC4000-6-E_#08165_Sec_6-0_rev0.doc 02.03.05
--- Page 14 ---
Components Section 6.0
Page 13
6.1.12 Control Blocks and Valves
) β’ This is a principle drawing, showing valve block II and IV.
Legend for illustration (Z 21702):
(1) Control block housing
(2) Main relief valve (MRV)
(3) Boom lifting / lowering, Spool (special)
(4) Long cap ("B" side)
(5) "B" side service line ports
(6) Centering springs
(7) Solid spool
(8) Short cap ("A" side)
(9) "A" side service line ports
(10) Load check valves
(11) Pilot oil warm up and flushing grooves
(12) Fine controlling grooves
(13) Type plate
Control blocks with "Open Center and Closed Ports".
Control blocks I and III are 3 spool blocks II and IV are 4 spool blocks.
See hydraulic circuit diagram for spool details.
Each spool is provided with "Fine Controlling Grooves", ring grooves for
hydraulically centering of the spool and βPilot oil warm up and flushingβ
grooves.
Between 8 and 19 bar pilot pressure the spools are moved in their fine control
range.
Spool (3) is special designed, to keep the pressure channel connected to the
center channel during the function βBoom loweringβ is selected, so that pump
flow is available for other functions.
The Load Holding Valves are installed beneath a plug from the service port
side of the control block.
The MRV is a pilot operated pressure relief valve.
PC4000-6-E_#08165_Sec_6-0_rev0.doc 02.03.05
--- Page 15 ---
6.0
23
PC4000-6-E_#08165_Sec_6-0_rev0.doc 02.03.05
--- Page 16 ---
Main Hydraulic Pumps Section 7.0
and Page 9
Pump Regulation System
7.1 Main Pumps
7.1.3 Operating Principles
Cont'd:
Symbol of main hydraulic pump A4VSLO 750 LR3DN / 30L
Legend for illustration (Z 21550):
(1) Main pump (swash plate pump, variable displacement)
(2) Charging pump (impeller type pump)
(3) Pump bearing group
(4) Drive shaft
(5) Non return valves
(6) Remote control valve
(6.1) Mechanical stroke limitation*
(6.2) Remote pressure (PST) operated piston for item 6
(6.3) Mechanical stroke limitation*
(7) Spool valve (pressure balance valve)
(8) Nozzle
(9) Power control valve
(10) Nozzle
(11) Pressure cut-off valve
(12) Auxiliary pump (Gear pump, fixed displacement
(13) Positioning piston
(14) Slipper pad piston
(15) Lever
(16) Cam
(17) Through drive shaft
) β’ * Factory side adjusted, no field adjustment required
B/B1 Pressure port
S Oil intake (suction port)
MB Operating pressure check point
ML Charging pressure check point
MST Control pressure check point
R Filler and bleeder port
T Connection port for chip indicator
P Pump support pressure (βX4β-pressure)
PST Remote control pressure port (βX3β-pressure)
U Bearing flushing port
XLR Regulating pressure port (βX1β-pressure)
continued
PC4000-6-E_#08165_Sec_7-0_rev1.doc 09.07.10
--- Page 17 ---
7.0
19
PC4000-6-E_#08165_Sec_7-0_rev1.doc 09.07.10
--- Page 18 ---
Main Hydraulic Pumps Section 7.0
and Page 28
Pump Regulation System
7.2 Electronic Pump Regulation System
7.2.3 Checks and adjustments Microcontroller MC7, illustration (Z 22629c)
Cont'd:
Method A - Demanded power adjustment
Pre-conditions: Normal operating temperature, correct pilot pressure setting and
the system must be free of air.
1. Connect pressure gauges to check points M11, M12, M13 and M14 at the high
pressure filters.
2. Connect pressure a gauge to the X1 pressure check point M5.1.
3. Unplug solenoid valves Y6a and Y6b to ensure that the hydraulic oil cooler fans
are running with maximum speed.
4. Start the motor.
5. Set the MRV individually to approx. 120 bar *, to prevent the motor from
overloading during the adjustment.
6. Shift the three way cock valves (253.1) to position βHydraulic (constant)
Regulation Modeβ.
7. Set the X1-pressure at pressure reducing valves (253.2) > 34 bar **, to ensure that
the pumps remain in Q-max. flow position during the adjustment.
8. Apply max. load to all pumps (e.g. extend the bucket cylinders to the stop position
until the hydraulic system stalls), and increase the pressure at all 4 MRVβs *
equally until the motor draw β
128 Ampere. (reading of text display)
Expected system pressure at 128 Ampere = 4 times 172 bar (peak point).
Record this pressure for other tests.
) β’ If the operating pressure is higher respectively the motor current is
lower than required there is probably not the full volume available.
*Altering the MRV-Setting:
β Remove dust cap (a).
β Loosen lock nut (b).
β Turning the set screw (c) cw the pressure will increase.
β Turning the set screw ccw the pressure will decrease.
**Altering the X1-Setting:
β Loosen the lock nut (e).
β Turning the set screw (f) cw the pressure will increase.
β Turning the set screw ccw the pressure will decrease.
continued
PC4000-6-E_#08165_Sec_7-0_rev1.doc 09.07.10
--- Page 19 ---
7.0
38
PC4000-6-E_#08165_Sec_7-0_rev1.doc 09.07.10
--- Page 20 ---
Main Hydraulic Pumps Section 7.0
and Page 47
Pump Regulation System
7.2 Electronic Pump Regulation System
7.2.3 Checks and adjustments Microcontroller MC7, illustration (Z 22639f)
Method C
Cont'd:
Demand power adjustment:
9. Select Execute of menu point Set demand m. 1 for motor 1 .
Select Start to set the actual power as demand power. Confirm with OK. The
new actual demand power will be only shown after a new upload of the MC7
settings. Exit the BODEM software and start again.
10. Stop the motor.
PC4000-6-E_#08165_Sec_7-0_rev1.doc 09.07.10
--- Page 22 ---
Hydraulic for the Section 8.1
Page 10
Attachment Cylinders
8.1.5 Electric / Hydraulic flowchart β Bucket filling β FSA
Legend for illustration (Z 21965):
(E19) Control lever (Joy stick)
(D32) Time relay β Pilot control: Neutral position monitoring
(XB) Direction (axis) of joy stick
(-10V) Signal voltage (Maximum)
(ws / gn) Colour code of signal voltage cable ( Joy stick)
(X2...) Terminal rail with number
(A9) Amplifier module β Bucket
(A9a) Amplifier module β Bucket
(A9b) Amplifier module β Bucket
(A10b) Amplifier module β Boom up or Bucket when not raising
the boom.
(K50) Relay β pilot control: Bucket cut-off
Contacts 6 / 10 only closed if the hydraulic oil is overheated.
(K58) Relay β pilot control:
Contacts 6 / 10 and 5 / 9 only closed while lifting the boom.
(K71) Relay β pilot control:
Contacts 6 / 10 and 5 / 9 only closed while filling the bucket.
(K74) Relay β pilot control:
Contacts 5 / 9 only closed while extending the stick.
(K76) Relay β pilot control:
Contacts 6 / 10 only closed while traveling the left crawler.
(K78) Relay β pilot control:
Contacts 7 / 11 only closed while traveling the right crawler.
(14.1 β 14.3) Remote control valves
(15) Remote control valves
(Y63 + Y64) Proportional solenoid valve
(Y71 + Y75) Proportional solenoid valve
(Y22 + Y32) Directional solenoid valve
(Y36 + Y44) Directional solenoid valve
(I β IV) Main control blocks I β IV
(42) Distributor manifold
Electrical signal flow.
Signal voltage of joy stick (E19) arrives via relay contacts at terminal 5 of the
amplifier modules (A9, A9a, A9b and A10b) and further to the proportional and
directional solenoid valves of the remote control blocks (14.1, 14.2, 14.3, and 15).
Hydraulic signal flow. (pilot pressure)
When the proportional and directional solenoid valves are energized pilot
pressure oil flows to the pilot pressure ports of the main control blocks.
Hydraulic oil flow
Now the oil of the main pumps flows through the main control blocks (I to IV)
and arrives via distributor manifold (42) at the hydraulic cylinders.
PC4000-6-E_#08165_Sec_8-1_rev0.doc 02.03.05
--- Page 23 ---
8.1
20
PC4000-6-E_#08165_Sec_8-1_rev0.doc 02.03.05
--- Page 24 ---
Hydraulic for the Section 8.1
Page 29
Attachment Cylinders
8.1.10 Checks and adjustments of the Service Line Relief Valves (SRV),
illustration (Z 21980a):
Cont'd:
Stick cylinder βPiston rod sideβ BHA
9. Adjust all SRVβs equally, until all gauges show a pressure of
360 bar.
Adjust in steps of ΒΌ turn of set screw (3) in the following sequence:
70.8 Γ 70.9Γ 70.10
Remove protective cap (1) of SRVβs.
Loosen lock nut (2).
Turn set screw (3) -clockwise to increase pressure, Counter-clock
wise to decrease pressure.
Tighten lock nut (2) and install cap (1).
10. Reduce the pressure, at SRV- 70.8 to a value below the required value,
and then increase up to the required pressure (350 bar), while observing
all gauges.
) β’ Now all gauges will show the same value of 350 bar,
but only SRV-70.8 has the correct setting.
11. Proceed with the other valves in the same manner in the following
sequence:
70.9 Γ 70.10
Γ£
β’ Strong pulsation of the return line hoses, indicates deviation in
opening pressure of SRVβs and must be avoided.
Repeat the adjusting procedure until the oil returns well-balanced
via all service line relief valves.
12. Reset the MRVβs to 310 bar + 5 bar after the check / adjustment is finished,
as follows:
Remove protective cap (1).
Loosen lock nut (2).
Turn set screw (3) -clockwise to increase pressure, Counter-clock
wise to decrease pressure.
Tighten lock nut (2) and install cap (1).
β’ It is important that the valve body of MRV-valve and the SRV-valve
) are firmly tightened (with 300 Nm).
Otherwise, the internal sealing is not properly which results in loud
flow noises and wrong adjustments.
PC4000-6-E_#08165_Sec_8-1_rev0.doc 02.03.05
--- Page 25 ---
8.1
39
PC4000-6-E_#08165_Sec_8-1_rev0.doc 02.03.05
--- Page 26 ---
Hydraulic for the Section 8.1
Page 48
Attachment Cylinders
8.1.11 Checks and adjustments of the lowering speed,
illustration (Z 22031):
Bucket cylinder BHA
Maximum permissible lowering speed:
Cylinder retracting time/meter Total time
(s /m) (s)
Bucket BHA 2,4 5,2
Adjustments / Checks:
1. Use a stop watch to measure the cylinder running time.
2. Raise the fully extended attachment with empty bucket to the maximum height
position (A).
3. Shift the engine to high idle speed.
4. Rapidly move the control lever (E19) to the r.h. end position (start the stop
watch) and hold it until the final position (B) is reached.(stop the stop watch).
5. If the lowering speed is too high, i.e. the measured time is less than the
permissible time, the speed must be reduced by altering the throttle valves
70.3, 70.4 and 70.12 at the distributor manifold (42).
Adjust as follows:
To decrease the lowering speed loosen the lock nut (1) and turn the bolt (2) cw.
To increase the lowering speed loosen the lock nut (1) and turn the bolt (2) ccw.
Since there are several valves throttling the return oil flow of the
bucket cylinder the valves must be set synchronously. The adjusting
screws have to be turned in by the same amount of revolutions.
O.K.
6. Check lowering speed again and repeat the adjustment if necessary.
7. If the adjustment is finished tighten lock nut (1).
PC4000-6-E_#08165_Sec_8-1_rev0.doc 02.03.05
--- Page 27 ---
8.2
9
PC4000-6-E_#08165_Sec_8-2_rev0.doc 02.03.05
--- Page 28 ---
Hydraulic for the Travel Circuit Section 8.3
Page 2
8.3.1 Travel Circuit
Legend for illustration (Z 22506a):
(2 + 4) Main pumps
(II) Control block
(IV) Control block
(14.2) Remote control valve block
(15) Remote control valve block
(19) Rotary distributor
(21.1+ 21.2) Travel motors
(41) Main oil reservoir
(55) Back pressure valve
(56.1+ 56.2) Travel brake valves
(57.1+ 57.2) Travel parking (house) brakes
(B48) Pressure switch, parking brake release pressure
(M4) Pressure check point for parking brake release pressure
(Y16) Solenoid valve for travel parking brake
(L9) Case drain (leak oil) line
(ST) Pilot pressure line to the travel parking brake
Brief description (Control circuits)
(Study together with the hydraulic and electric circuit diagram).
When the pedals E21a and E21b are moved out of there neutral
position, proportional solenoid valves Y67 and Y70 and simultaneously
the directional solenoid valves Y28 or Y29 (L.H.-crawler) and Y34 or
Y35 (R.H.- crawler) are energized.
(E21a) Control pedal A β forward => Y70 +Y35
Left track
B β reverse => Y70 +Y34
(E21b) Control pedal A β forward => Y67 +Y28
Right track
B β reverse => Y67 +Y29
continued
PC4000-6-E_#08165_Sec_8-3_rev0.doc 02.03.05
--- Page 29 ---
8.3
12