Komatsu Mining Shovel PC4000-11 T2 service & repair manual

Description Komatsu Mining Shovel PC4000-11 T2 service & repair manual

Komatsu Mining Shovel PC4000-11 T2 pdf workshop service manual

Serial numbers:
08237 and up
08267
08271
08273

Specifications, maintenance, technical data, adjusting, troubleshooting, diagrams, schematics, assembly, disassembly, removal, installation instructions and other information

MANUAL CONTENT:
Foreword & Safety
1 Foreword
1.1 BEFORE READING THIS MANUAL
1.2 CONTENTS OF THIS BINDER
1.3 DIVISION OF THE BINDER
SAFETY
2.1 SAFETY INFORMATION
2.2 OVERVIEW
2.3 SOUND PRESSURE AND VIBRATION LEVELS IN THE OPERATOR’S CAB.
2.4 GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR
2.5 PRECAUTION FOR MAINTENANCE
2.6 ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS
2.7 SPECIAL SAFETY EQUIPMENT

Specification

Structure & Function
1 Introduction
2 Specifications
3 Main assembly groups
4 Drive
5 Hydraulic oil tank
6 Hydraulic oil cooling
7 Controlling
8 Components
9 Main hydraulic pumps and pump regulation
10 Operating hydraulics
11 Hydraulic track tensioning system
12 Access stairway, hydraulically operated
13 Central refilling system (Service arm)
14 Hints for reading the Hydraulic Diagram
15 Hints for reading the electric Wiring Diagram
16 Monitoring & Control System
17 Lubrication system
18 Deep temperature equipment (option)

Troubleshooting
1 Introduction
1.1 Overview
1.2 General Precautions
2 General Information for Troubleshooting
2.1 Preparations For Work
2.2 Precautions During Work
2.3 Precautions When Carrying Out Any Operation
2.4 Fundamental Requirements for Trouble shooting
2.5 Points To Remember When Trouble- shooting
2.6 Sequence Of Events In Troubleshooting
2.7 Checks Before Troubleshooting
2.8 Handling Of Electric Equipment And Hydraulic Components
2.9 General working procedures
2.10 Cylinder bypass test
2.11 Basics about "How to crimp" (with strain relief)
2.12 Cable Shielding
3 Mounting Locations and Connector Types
3.1 View onto the superstructure
3.2 Location of engine electrical parts
3.3 Location of hydraulic components
3.4 View onto the SLS or CLS grease barrel and the lubrication cycle components
3.5 Hydraulic oil tank & suction oil tank - Location of electrical components
3.6 Hydraulically operated access stairway
3.7 Service arm
3.8 Connector Types Overview
4 Standard Value Table for Electrical Components
5 Tables for Testing and Troubleshooting
5.1 Test Value Tables for Transducers
5.2 Hydraulic oil temperature charts
5.3 PTO gear oil temperature charts
5.4 Table of failure codes
5.5 Table of C-codes - Diesel engine Tier2
5.6 Tables of Symptom Codes
5.7 Cable colour identification
6 Troubleshooting by Trouble Code
7 Troubleshooting by Symptoms
7.1 Symptoms of the engine and related electrical system
7.2 Symptoms of the Hydraulic System
7.3 Symptoms of the Mechanical System
7.4 Symptoms of Additional Systems

Disassembly & Assembly
1 Introduction
1.1 Foreword
1.2 Recommendations for environmentally friendly operation and maintenance of hydraulic mining shovels
1.3 Diagrams and illustrations in this manual
1.4 Procedures for disassembling and assembling in this manual
2 Safety
2.1 Overview
2.2 General precautions
2.3 Precautions for maintenance and repair
3 Superstructure
3.1 Superstructure
3.2 Machine house
3.3 Hydraulic System
3.4 Slew system
3.5 Lubrication pumps
3.6 Operator’s cab
3.7 Cab base
3.8 stairways and platforms
3.9 Counterweight
3.10 Fuel tank
3.11 Superstructure Lifting
4 Undercarriage
4.1 Undercarriage overview
4.2 Travel system
4.3 Undercarriage center body
5 Attachment
5.1 Repair procedures
5.2 Backhoe Attachment (BHA)
5.3 Front Shovel Attachment (FSA)
5.4 Metering valves (grease injectors) at the attachment
5.5 Ground engaging tools (GET)
5.6 Cylinder bypass test
6 Service Information
6.1 Fluids and lubricants
6.2 Lifting Gears
6.3 Safety hints for sling accessory
6.4 Weight tables
6.5 Torque charts according to KOMATSU company standard
6.6 Blind plugs
6.7 Conversion table
6.8 Tools
6.9 Work instructions
7 Parts & Service News
7.1 List of relevant PARTS AND SERVICE NEWS