pc4000 gzebm08199-1 (completo)mm

Shop Manual

HYDRAULICEXCAVATOR

SHOP 08199-upD-GB-1

PC4000-6DieselSerial Number 08199 and up

PC4000-6D 1

HYDRAULIC MINING EXCAVATOR

PC4000-6D

Machine model Serial numbers

PC4000-6D 08199 and up

00 Foreword

Copyright 2009 KOMATSU MINING GERMANY GmbH

2 PC4000-6D

1.1 CONTENTS OF THE BINDER INTRODUCTION

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1.1 CONTENTS OF THE BINDER

Assembled in this file are the Operation- and Maintenance Manu-als for your KOMATSU Mining Shovel.

INTRODUCTION 1.2 DIVISION OF THE BINDER

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1.2 DIVISION OF THE BINDER

Part 1:Operation Manual

Part 2:Maintenance Manual

Part 3:Depending on the volume of Part 3 a second Binder "Volume 2" isbeing delivered with the Shovel. This Binder contains the GeneralAssembly Procedure Manual for the Shovel, Specification Book-let, Service Literature for the Power Unit (Diesel Engine or Elec-tric Motor) and for Special Equipment. The Electrical- andHydraulic Diagrams are attached in the pocket of the front cover.

Refer to the -TABLE OF CONTENTS VOLUME 2 BINDER-for details.

Read the Manuals before You Start the Engine.

Before operating the machine, familiarize yourself with its instru-ments and controls.

Observe the instructions in these manuals for:

your Personal SAFETY

Operating SAFETY, and

READY and EFFICIENT PERFORMANCE of yourKOMATSU Shovel.

Periodic preventive inspections and maintenance are the surestmeans of keeping the machine in proper working order. Promptdetection and correction of minor irregularities, and immediatereplacement of worn out or broken parts will prevent failures andavoid expenses.

Replace damaged graphics and symbols.

Observe safety precautions to prevent injury and damage.If you have any questions concerning this literature please con-tact

Komatsu Mining Germany GmbH

Service InformationDepartment 8151.30P.O. Box 18 03 61D - 40570 DsseldorfGERMANY

1.3 DESIGNATED USE OF THE SHOVEL INTRODUCTION

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1.3 DESIGNATED USE OF THE SHOVEL

This machine has been manufactured in accordance withadvanced and up-to-date technology standards including recog-nized safety rules. Nevertheless, its use may constitute a risk tolife and limb of the user or of third parties, or cause damage to themachine and to other material property.

The machine must only be used in technically perfect condition inaccordance with its designated use and the instructions set out inthe operation manual. Only trained safety-conscious operatorswho are fully aware of the risks involved should operate themachine. Any functional disorders, especially those affecting thesafety of the machine, should, therefore, be rectified immediately.

The hydraulic Shovel is designed exclusively for excavating, i.e.excavation of bulk material and natural soil structure (e.g. earth,clay, sand and stones ashore and off-shore). Observe local andnational safety regulations. Special conditions at the worksiterequire additional safe working precautions, follow your com-pany's safety instructions. Short traveling distances for changingthe working site are considered as part of the designated use ofthe Shovel.Using the Shovel for purposes other than those mentioned above(such as object handling and use as a transport vehicle) is consid-ered contrary to its designated use. The manufacturer/suppliercannot be held liable for any damage resulting from such use.The risk of such misuse lies entirely with the user.

WARNINGSpecial use of the Shovel beyond its designated use, e.g.object handling operations, require written agreement fromthe manufacturer and retrofitment of the Shovel with respec-tive safety related equipment before such special applica-tions are permitted.

INTRODUCTION 1.4 DELIVERY OF THE SHOVEL

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1.4 DELIVERY OF THE SHOVEL

The Shovel is being delivered disassembled into its main compo-nents.

For assembling the Shovel refer to the General Assembly Procedure Manual in Volume 2 Service Literature Binder.

WARNING Improper assembling of the Shovel can cause serious

accidents with personal injury or death. Personnel entrusted with work on the machine must

have read the Assembly Manual, the Operation- andMaintenance Manual and in particular the section onsafety before beginning work. Reading the instructionsafter work has begun is too late. If there are any ques-tions concerning safe assembling procedure, contactyour local Komatsu Service Organization.

Prior to first operation, inspect the Shovel thoroughly with the Ser-vice Engineer responsible for the erection of the machine. Checkall fluid levels according to the Lubrication and MaintenanceSchedule.

Damages and defects caused by incorrect operation and mainte-nance are not covered by the manufacturers guarantee.

NOTICEIf the Shovel is equipped with a fire suppression system,make sure that the system is ready for operation.

SPARE PARTS

For your spare part orders refer to the Parts Catalogue.

In order to keep your Shovel in first-class operating condition useonly genuine spare and wear parts.

The use of any part other than the genuine part releases the

KOMATSU MINING GERMANY GmbH from any guarantee.

SERVICE

For all questions related to your Shovel please contact your localService Center.

In all your written or phoned inquiries please indicate the modeland serial number of your Shovel.

1.5 EXPLANATION OF ABBREVIATIONS INTRODUCTION

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1.5 EXPLANATION OF ABBREVIATIONS

ABB Definition

A Ampere

AC Alternating Current

API American Petroleum Institute

cSt Centistoke

C Degree Celsius

CENSE Engine Monitoring System

CLS Central Lubrication System

DC Direct Current

DIN German Institute for Standardization

EBL Electronic Bucket Levelling System

ECM Electronic Control Module (Engine)FGPS Front Guard Protective Structure

FOPS Falling-Object Protective StructureGL Gear Lubricant

h hours of operation

HPF High Pressure Filter (Hydraulic Oil)

HT High Tension

LED Light Emitting Diode

LT Low Tension

N Newton

Nm Newton meter

QSK Type of Engine Fuel System

PLC Programmable Logic Controller

PM Planned Maintenance

ppm parts per million

PTO Power Take-Off (Pump Distributor Gear)SLS Swing circle pinion Lubrication System

V Volt

VHMS Vehicle Health Monitoring System

1/min Revolutions Per Minute (RPM)

SAFETY

2 - 1

2 SAFETY

IGNORING THE INSTRUCTIONS IN THIS MANUAL COULD LEAD TO SERIOUS INJURY OR DEATH.Please read and make sure that you fully understand the precautions described in this section and the safety labels on the machine. When operating or servicing the machine, always follow these precaution strictly.

SAFETY

2 - 2

CONTENTS

2.1 SAFETY INFORMATION ................................................................................................................... 2-32.2 OVERVIEW......................................................................................................................................... 2-4

2.2.1 NORMAL OPERATIONS ....................................................................................................... 2-42.2.2 REGULAR MAINTENANCE................................................................................................... 2-42.2.3 TROUBLESHOOTING, ADJUSTMENTS AND REPAIR ....................................................... 2-42.2.4 ADDITIONAL SAFETY PRECAUTIONS FOR ASSEMBLING, DISASSEMBLING AND

TRANSPORTATION OF THE EXCAVATOR......................................................................... 2-4

2.3 SOUND PRESSURE LEVEL IN THE OPERATORS CAB. .............................................................. 2-52.4 GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR........................... 2-6

2.4.1 UNDERSTANDING THE MACHINE ...................................................................................... 2-62.4.2 PRECAUTIONS BEFORE STARTING OPERATION ON THE EXCAVATOR ...................... 2-6

2.4.2.1 ENSURING SAFE OPERATION............................................................................ 2-62.4.3 PREPARATIONS FOR SAFE OPERATION.......................................................................... 2-6

2.4.3.1 PRECAUTIONS REGARDING SAFETY RELATED EQUIPMENT........................ 2-62.4.3.2 INSPECTING THE MACHINE................................................................................ 2-62.4.3.3 WEAR WELL FITTING CLOTHES AND PROTECTIVE EQUIPMENT.................. 2-72.4.3.4 KEEP MACHINE CLEAN ....................................................................................... 2-72.4.3.5 PRECAUTIONS INSIDE OPERATORS COMPARTMENT................................... 2-72.4.3.6 PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT ........................................ 2-82.4.3.7 IF A PROBLEM IS FOUND .................................................................................... 2-8

2.4.4 FIRE PREVENTION............................................................................................................... 2-82.4.4.1 PRECAUTIONS TO PREVENT FIRE .................................................................... 2-82.4.4.2 ACTION IF FIRE OCCURS.................................................................................... 2-92.4.4.3 EMERGENCY EXIT FROM OPERATORS CAB................................................. 2-10

2.4.5 PRECAUTIONS WHEN CLEANING CAB GLASS .............................................................. 2-102.4.6 PRECAUTIONS WHEN GETTING ON OR OFF THE MACHINE ....................................... 2-10

2.4.6.1 USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF THEMACHINE............................................................................................................. 2-10

2.4.6.2 NO JUMPING ON OR OFF THE MACHINE ........................................................ 2-102.4.6.3 NO PEOPLE ON THE ATTACHMENT ................................................................ 2-102.4.6.4 WORKING IN HIGH PLACES .............................................................................. 2-102.4.6.5 LEAVING OPERATORS SEAT WITH LOCK ...................................................... 2-112.4.6.6 LEAVING THE MACHINE .................................................................................... 2-11

2.4.7 BURN PREVENTION........................................................................................................... 2-112.4.7.1 HOT COOLANT .................................................................................................. 2-112.4.7.2 HOT OIL .............................................................................................................. 2-12

2.4.8 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES .......................................... 2-122.4.8.1 UNAUTHORIZED MODIFICATION...................................................................... 2-12

2.4.9 PRECAUTIONS AT JOBSITE.............................................................................................. 2-142.4.9.1 VISIBILITY FROM OPERATORS SEAT ............................................................. 2-152.4.9.2 CAMERA SYSTEM WITH MONITORS................................................................ 2-152.4.9.3 ENSURE GOOD VISIBILITY................................................................................ 2-152.4.9.4 CHECKING SIGNS AND SIGNALMANS SIGNALS............................................ 2-152.4.9.5 INVESTIGATE AND CONFIRM JOBSITE CONDITIONS.................................... 2-162.4.9.6 DO NOT GO CLOSE TO HIGH VOLTAGE CABLES .......................................... 2-162.4.9.7 WORKING ON LOOSE GROUND ....................................................................... 2-172.4.9.8 GAS, DUST, STEAM AND SMOKE ..................................................................... 2-172.4.9.9 VENTILATION OF ENCLOSED AREAS.............................................................. 2-18

SAFETY

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2.4.10 STARTING ENGINE ............................................................................................................ 2-192.4.10.1 WARNING TAG ................................................................................................... 2-192.4.10.2 CHECKS BEFORE STARTING ENGINE ............................................................ 2-192.4.10.3 PRECAUTION WHEN STARTING ENGINE........................................................ 2-192.4.10.4 PRECAUTION IN COLD AREAS......................................................................... 2-20

2.4.11 OPERATION........................................................................................................................ 2-202.4.11.1 CHECKS BEFORE OPERATION ........................................................................ 2-202.4.11.2 PRECAUTIONS WHEN TRAVELLING IN FORWARD OR REVERSE ............... 2-212.4.11.3 PRECAUTIONS WHEN TRAVELLING................................................................ 2-222.4.11.4 TRAVELLING ON SLOPES ................................................................................. 2-232.4.11.5 OPERATIONS ON SLOPES................................................................................ 2-242.4.11.6 PROHIBITED OPERATIONS............................................................................... 2-242.4.11.7 TRAVELLING ON FROZEN OR SNOW COVERED SURFACES....................... 2-252.4.11.8 PARKING THE MACHINE ................................................................................... 2-252.4.11.9 TRANSPORTATION ............................................................................................ 2-25

2.5 PRECAUTION FOR MAINTENANCE.............................................................................................. 2-262.5.1 GENERAL PRECAUTIONS................................................................................................. 2-26

2.5.1.1 SELECTION AND QUALIFICATION OF PERSONNEL - BASIC RESPONSIBILITIES ............................................................................................ 2-27

2.5.1.2 STOP ENGINE FOR MAINTENANCE................................................................. 2-282.5.1.3 WARNING TAG ................................................................................................... 2-282.5.1.4 KEEP WORKPLACE CLEAN AND TIDY............................................................. 2-292.5.1.5 APPOINT LEADER WHEN WORKING WITH OTHERS ..................................... 2-302.5.1.6 TWO WORKERS FOR MAINTENANCE WHEN THE MACHINE IS

RUNNING ............................................................................................................ 2-302.5.1.7 INSTALLING, REMOVING OR STORING ATTACHMENTS............................... 2-302.5.1.8 PRECAUTIONS WHEN WORKING UNDER THE MACHINE OR

EQUIPMENT........................................................................................................ 2-312.5.1.9 NOISE .................................................................................................................. 2-312.5.1.10 WHEN USING A HAMMER ................................................................................. 2-312.5.1.11 PROPER TOOLS................................................................................................. 2-322.5.1.12 ACCUMULATOR ................................................................................................. 2-322.5.1.13 PERSONNEL ....................................................................................................... 2-32

2.5.2 PRECAUTIONS FOR INSPECTION AND MAINTENANCE................................................ 2-322.5.2.1 PRECAUTION WHEN WELDING........................................................................ 2-322.5.2.2 BATTERY HANDLING ......................................................................................... 2-33

2.5.3 PRECAUTIONS WITH HIGH PRESSURE FLUID............................................................... 2-342.5.3.1 PRECAUTIONS WITH HIGH FUEL PRESSURE ................................................ 2-342.5.3.2 HANDLING HIGH PRESSURES HOSES OR PIPES.......................................... 2-342.5.3.3 REPLACEMENT OF HOSE LINES...................................................................... 2-342.5.3.4 INSPECTION OF HOSE LINES........................................................................... 2-352.5.3.5 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS ............................ 2-352.5.3.6 PRECAUTIONS FOR HIGH VOLTAGE............................................................... 2-362.5.3.7 AIR CONDITIONING MAINTENANCE ................................................................ 2-362.5.3.8 COMPRESSED AIR............................................................................................. 2-362.5.3.9 WASTE MATERIALS ........................................................................................... 2-37

2.6 ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS............................................................................................................................... 2-382.6.1 INSPECTION OF THE HYDRAULIC SYSTEM ................................................................... 2-382.6.2 TWO WORKERS ONLY WHEN THE MACHINE IS RUNNING DURING

SAFETY

2 - 4

ADJUSTMENTS................................................................................................................... 2-382.6.3 AREAS OF POTENTIAL DANGER AROUND THE EXCAVATOR...................................... 2-38

2.7 SPECIAL SAFETY EQUIPMENT..................................................................................................... 2-402.7.1 FRONT GUARD PROTECTIVE STRUCTUR FOPS FOR OPERATORS CAB ................ 2-412.7.2 OBJECT HANDLING ........................................................................................................... 2-412.7.3 LIGHTING ............................................................................................................................ 2-412.7.4 WARNING BEACON............................................................................................................ 2-412.7.5 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD) ........... 2-41

2.7.5.1 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD) .................................................................................. 2-41

2.7.5.2 INSTRUCTIONS FOR USE ................................................................................. 2-432.7.5.3 PRIOR TO USING THE HARNESS (1), THE WEARER SHALL ......................... 2-452.7.5.4 RECOMMENDATIONS FOR USE OF THE HOLDING HOOKS AND

HOLD-BACK HOOKS OF THE SAFETY HARNESS (1), .................................... 2-452.7.5.5 INSTRUCTIONS FOR USE ................................................................................. 2-47

SAFETY SAFETY INFORMATION

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2.1 SAFETY INFORMATION

To enable you to use this machine safely, and to prevent injury to operators, service personnel or bystanders, the precautions and warnings included in this manual and the safety signs attached to the machine must always be followed.

To identify important safety messages in the manual and on the machine labels, the following signal words are used.

The "Safety Alert Symbol" identifies important safety messages on machines, in manuals, and elsewhere. When you see this symbol, be alert to the risk of personal injury or death. Follow the instructions in the safety message.

DANGERThis signal word indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

WARNINGThis signal word indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

CAUTIONThis signal word indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

NOTICEThis signal word is used to alert you to information that must be followed to avoid damage to the machine. This precaution is given where the machine may be damaged or the service life reduced if the precaution is not followed.

OVERVIEW SAFETY

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2.2 OVERVIEW

The appropriate safety information for specific working modes on the excavator can be found in the following:-

2.2.1 NORMAL OPERATIONS

For normal operating procedures, refer to the OPERATION section of the Operation and Maintenance Manual.

For operational safety information, refer to section 2.4 on page 3-8.

For on site safety information, refer to section 2.4.9 on page 3-16.

2.2.2 REGULAR MAINTENANCE

For information on regular maintenance, including maintenance intervals, refer to the MAINTENANCE section of the Operation and Maintenance Manual.

For maintenance safety information, refer to section 2.5 on page 3-28.

2.2.3 TROUBLESHOOTING, ADJUSTMENTS AND REPAIR

For additional safety information for troubleshooting and adjustments refer to section 2.6 on page 3-40.

For maintenance solutions, refer to the separate manuals TROUBLESHOOTING manual. Available through Komatsu Mining Germany.

For servicing information and adjustments, refer to the separate SERVICE MANUAL. Available through Komatsu Mining Germany.

2.2.4 ADDITIONAL SAFETY PRECAUTIONS FOR ASSEMBLING, DISASSEMBLING AND TRANSPORTATION OF THE EXCAVATOR

Prior to starting assembling, disassembling and transportation of the excavator read and follow the additional safety precautions given in the ASSEMBLY PROCEDURE MANUAL.

SAFETY SOUND PRESSURE LEVEL IN THE OPERATORS CAB.

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2.3 SOUND PRESSURE LEVEL IN THE OPERATORS CAB.

The sound pressure level in the operators cab is measured according to ISO 6396 (Dynamic test method).

The sound pressure value is also shown on the decal attached to the wall inside the operators cab, see Fig. 3-1.

Fig. 3-1

GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR SAFETY

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2.4 GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR

WARNINGWHEN MISUSED, THESE MACHINES ARE DANGEROUS.Mistakes in operation, inspection, or maintenance may result in personal injury or death. Before carrying out operation, inspection, or maintenance, always read this manual and the safety labels on the machine carefully and obey the warnings.

2.4.1 UNDERSTANDING THE MACHINE

Before operating the machine, read this manual thoroughly. If there are any places in this manual that you do not understand, ask the person in charge of safety to give an explanation.

2.4.2 PRECAUTIONS BEFORE STARTING OPERATION ON THE EXCAVATOR

2.4.2.1 ENSURING SAFE OPERATION Only trained and authorized personnel can operate and maintain the machine.

During operations, personnel are not allowed outside of the operators cabin. Follow all safety rules, precautions and instructions when operating or performing inspection or maintenance

on the machine.

If you are not feeling well, or are under the influence of alcohol or medication, your ability to safely operate or repair your machine may be severly impaired putting yourself and everyone else on your jobsite in danger.

When working with another operator or with a person on worksite traffic duty, discuss the content of the opera-tion beforehand and use pre-determined signals when carrying out these operations.

2.4.3 PREPARATIONS FOR SAFE OPERATION

2.4.3.1 PRECAUTIONS REGARDING SAFETY RELATED EQUIPMENT Be sure that all guards, covers and mirrors are in their proper positions. Have guards and covers repaired

immediately if they are damaged.

Understand the method of use of safety features and use them properly.

Never remove any safety features. Always keep them in good operating condition.

2.4.3.2 INSPECTING THE MACHINECheck the machine before starting operations. If any abnormality is found, do not operate the machine until repairs of the problem location have been completed.

SAFETY GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR

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2.4.3.3 WEAR WELL FITTING CLOTHES AND PROTECTIVE EQUIPMENT

2.4.3.4 KEEP MACHINE CLEAN

2.4.3.5 PRECAUTIONS INSIDE OPERATORS COMPARTMENT When entering the operators compartment, always remove all mud and oil from your shoes. If you operate the

pedal with mud or oil affixed to your shoes, you may slip and this may cause a serious accident.

Do not leave tools or machine parts lying around inside the operators compartment. If tools or parts get into the control devices, they may obstruct operation and cause the machine to move unexpectedly, resulting in serious personal injury or death.

Do not stick suction pads to the window glass. Suction pads act as a lens and may cause fire.

Do not use a cell phone when driving or operating the machine. This may lead to mistakes in operation, which could cause serious personal injury or death.

Never bring any dangerous objects such as flammable or explosive items into the operators compartment.

Do not wear loose clothing and accessories. If these catch on the control levers or moving parts, there is a danger that it may cause the machine to move unexpectedly.

Always wear a hard hat and safety shoes when working on the machine outside of the cabin. If the nature of the work requires it, wear safety glasses, mask, gloves, ear plugs and a safety belt when operating or maintaining the machine (Fig. 3-2).

If you have long hair and it hangs out from your hard hat, there is a hazard that it may get caught up in the machine, so tie your hair up and be careful not to let it get caught.

Check that all protective equipment functions properly before using it. Fig. 3-2

If you get on or off the machine or carry out inspection or maintenance when the machine is dirty with mud or oil, there is a hazard that you will slip and fall. Wipe off any mud or oil from the machine. Always keep the machines clean.

If water gets into the electrical system (Fig. 3-3), there is a hazard that it will cause malfunctions or a misoperation. If there is any misoperation, there is a danger that the machine may move unexpectedly and cause serious personal injury or death. When washing the machine with water or steam, do not allow the water or steam to come into direct contact with electrical components.

Fig. 3-3


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2.4.3.6 PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT

2.4.3.7 IF A PROBLEM IS FOUNDIf 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:

REMARKS: Before carrying out grinding or welding work on the machine, remove any flammable materials.

Always follow the precautions below to prepare for action if any injury or fire should occur.

Be sure that fire extinguishers have been provided and read the labels to ensure that you know how to use them in emer-gencies.

Carry out periodic inspection and maintenance to ensure that the fire extinguisher can always be used.

Provide a first aid kit. Carry out periodic checks and add to the contents if necessary (Fig. 3-4).

Fig. 3-4

Do not smoke or use any flame near fuel or other flamma-ble substances. (Fig. 3-5)

Stop the engines before adding fuel.

Do not leave the machine while adding fuel or oil.

Tighten all fuel and oil caps securely.

Be careful not to spill fuel on overheated surfaces or on parts of the electrical system.

After adding fuel or oil, wipe up any spillage.

Put greasy rags and other flammable materials into a safe container to maintain safety in the workplace.

When washing parts with oil, use a non-flammable oil. Do not use diesel oil or gasoline. There is a danger that they may catch fire.

Do not weld or use a cutting torch to cut any pipe or tubes that contain flammable liquids.

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.

Fig. 3-5


2 - 11

Fire caused by accumulation of flammable material.Remove any dry leaves, chips, pieces of paper, coal dust, or any other flammable materials accumulated or affixed around the engines, exhaust manifold, muffler or battery, or inside the undercovers.

Fire coming from electrical wiringShort circuits in the electrical system can cause fire. To prevent fire, always observe the following:

Keep all electrical connections clean and securely tightened.

Check the wiring every day for looseness or damage. Tighten any loose connectors or wiring clamps. Repair or replace any damaged wiring.

Fire coming from pipingCheck that all hose and tube clamps, guards, and cushions are securely fixed in position.If they are loose, they may vibrate during operation and rub against other parts. There is a danger that this may lead to damage to the hoses and cause high pressure oil to spurt out, leading to fire, personal injury, or death.

Explosion caused by lighting equipment

When checking fuel, oil, battery electrolyte, or coolant, always use lighting with anti-explosion specifica-tions.

When taking the electrical power for the lighting from the machine itself, follow the instructions of this man-ual.

2.4.4.2 ACTION IF FIRE OCCURS Activate the STOP switch to stop the engine.

Use the access ladders and steps to get off the machine.

If it is impossible to escape from the rear of the cab, use the rope ladder provided for emergency escape to escape from the side of the cab. (Fig. 3-6.)

Fig. 3-6

After escaping with the emergency escape ladder, activate the engine stop chains (1 on Fig. 3-7) to shut down the engine if they are equipped on your shovel.

Fig. 3-7


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2.4.4.3 EMERGENCY EXIT FROM OPERATORS CABIf the cab door does not open, use the sliding window for an emergency escape. On machines without a sliding window, use the emergency escape hammer to break the window glass and use the window as an emergency escape.

2.4.5 PRECAUTIONS WHEN CLEANING CAB GLASS

Always keep the cab glass clean to ensure good visibility when operating. Use an ethyl alcohol based washer liquid. Methyl alcohol based liquid may irritate your eyes, so do not use it. If the cab glass on the work equipment side is broken, there is a hazard that the intruding objects may contact the operator's body directly. Stop operation immediately and replace the glass.

2.4.6 PRECAUTIONS WHEN GETTING ON OR OFF THE MACHINE

2.4.6.1 USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF THE MACHINETo prevent personal injury caused by slipping or falling off the machine, always do as follows.

2.4.6.2 NO JUMPING ON OR OFF THE MACHINE Never jump on or off the machine. Never get on or off a moving machine.

If the machine starts to move when there is no operator on the machine, do not jump onto the machine and try to stop it.

2.4.6.3 NO PEOPLE ON THE ATTACHMENT Never let any person mount the boom, arm, bucket, or other attachment without appropriate safety equipment. There is danger of falling and suffering serious personal injury. For further information refer to section 2.7 on page 3-42.

2.4.6.4 WORKING IN HIGH PLACESWhen working in high places, use safety harness and fall absorber to ensure that the work can be carried out safely. For further information refer to section 2.7 on page 3-42.

Always use the handrails and steps when getting on or off the machine.

To ensure safety, always face the machine and maintain three-point contact (both feet and one hand, or both hands and one foot - see Fig. 3-8). with the handrails and steps to ensure that you support yourself.

When walking around the machine, where possible, move only in areas that have non-slip padded walkways and non-slip gratings. Extra care is to be taken when moving around outside of these areas.

Before getting on or off the machine, check the handrails and steps. If there is any oil, grease, or mud on the handrails or steps, wipe it off immediately. Always keep these parts clean. Repair any damage and tighten any loose bolts.

Fig. 3-8


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2.4.6.5 LEAVING OPERATORS SEAT WITH LOCK

2.4.6.6 LEAVING THE MACHINE

2.4.7 BURN PREVENTION

2.4.7.1 HOT COOLANT

Before standing up from the operator's seat in order to adjust the seat, always lower the work equipment to the ground, turn off the engine, relieve the pressure in the hydraulic system and set lock lever to LOCK position (L, Fig. 3-9.). If the lock is not applied, there is danger of serious personal injury if the work equipment control levers are touched by mistake and the machine moves suddenly. For information on relieving the pressure in the hydraulic system, refer to chapter RELIEV-ING THE PRESSURE IN THE HYDRAULIC SYSTEM in the OPERATION part of this manual.

Fig. 3-9

When leaving the machine, always lower the work equipment completely to the ground, turn off the engine, relieve the pres-sure in the hydraulic system and set lock lever (1) securely to the LOCK position (L), then stop the engine. Use the key to lock all the equipment. Always remove the key, take it with you, and keep it in the specified place (Fig. 3-10). For infor-mation on relieving the pressure in the hydraulic system, refer to chapter RELIEVING THE PRESSURE IN THE HYDRAU-LIC SYSTEM in the OPERATION part of this manual.

Fig. 3-10

To prevent burns from hot water or steam spurting out when checking or draining the coolant, wait for the water to cool to a temperature where it is possible to touch the radiator cap (Fig. 3-11 and Fig. 3-12) by hand before starting the opera-tion. Even when the coolant has cooled down, loosen the cap slowly to relieve the pressure inside the radiator before removing the cap.

Fig. 3-11


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2.4.7.2 HOT OIL

2.4.8 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES

2.4.8.1 UNAUTHORIZED MODIFICATION Komatsu will not be responsible for any injuries, accidents, product failures or other property damage resulting

in modifications made without authorisation from Komatsu.

Any modifications made without authorisation from Komatsu can create hazards. Before making a modifica-tion, consult your komatsu distributor.

Any injuries, accidents, or product failures resulting from the use of unauthorized attachments or parts will not be the responsibility of Komatsu.

To prevent burns from hot oil spurting out when checking or draining the oil, wait for the oil to cool to a temperature where it is possible to touch the cap or plug by hand before starting the operation (Fig. 3-12). Even when the oil has cooled down, loosen the cap or plug slowly to relieve the internal pressure before removing the cap or plug.

Fig. 3-12

On jobsites where there is a hazard that falling objects (Fig. 3-13), flying objects (Fig. 3-14), or intruding objects may hit or enter the operator's cab, consider the operating conditions and install the necessary guards to protect the operator.

When carrying out operations in mines or quarries where there is danger of falling or flying rocks, order/use the option-ally available front guard.

When carrying out the above operations, always ensure that bystanders are a safe distance away and are not in hazard from falling or flying objects.

The above recommendations assume that the conditions are for standard operations, but it may be necessary to add addi-tional guards according to the operating conditions on the job-site. Always contact your Komatsu distributor for advice.

Fig. 3-13

Fig. 3-14


2 - 15

Please continue reading on the next page.


2 - 16

2.4.9 PRECAUTIONS AT JOBSITE

Fig. 3-15


2 - 17

2.4.9.1 VISIBILITY FROM OPERATORS SEAT

WARNINGTHE AREA AROUND THE EXCAVATOR DURING OPERATION IS EXTREMELY DANGER-OUS!Death and serious injury can occur. Make sure the job site is organized in such a way, that the safety of man and equipment is always ensured.

Fig. 3-15 shows an example of general blind areas of large Komatsu hydraulic mining shovels.

The grey shaded areas (A) show the areas where the view is blocked when the operator is sitting in the operators seat, and the shovel is equipped with standard mirrors. The boundary line (B) shows the distance of 1 meter from outside surface of the shovel. Please be fully aware that there are places that can not seen when operating the machine.

REMARKS: The blind areas (A) differ depending on the machine type, attachment and position of attachment.

The International Standard ISO 5006 defines criteria for Operators visibility. This standard is not met and does not apply to large hydraulic mining shovels.

2.4.9.2 CAMERA SYSTEM WITH MONITORSKomatsu Mining Germany offers optionally camera systems and monitors to improve the overall visibility. See lat-est version of the OMM for typical arrangement of cameras and monitors.

The camera system can be installed ex works and can also be retrofitted in the field. If you need more information, please contact your local Komatsu distributor.

2.4.9.3 ENSURE GOOD VISIBILITYWhen operating or travelling in places with poor visibility, if it is impossible to confirm the condition of the job side or obstacle is in the area around the machine, there is danger that the machine may suffer damage or the operator may suffer serious personal injury. When operating or travelling in places with poor visibility, always observe the following items strictly.

If the visibility cannot be sufficiently assured, position a flagman if necessary. The operator should pay careful attention to the signs and follow the instructions of the flagman.

The signals should be given only by one flagman.

When working in dark places, turn on the working lamps and front lamps of the machine, and if necessary, set up additional lighting in the area.

Stop operations if there is poor visibility, such as in fog, snow, rain, or sand storms.

Check the mirrors on the machine before starting operations every day. Clean off any dirt and adjust the view to ensure good visibility.

In areas where it is impossible to confirm the area around the machine and observation cameras have been set up, clean off any dirt from the lens and make sure that the cameras give a clear view of the working area of the machine.

2.4.9.4 CHECKING SIGNS AND SIGNALMANS SIGNALS Set up signs to inform of road shoulders or soft ground. If the visibility is not good, position a signalman if nec-

essary. Operators should pay careful attention to the signs and follow the instructions from the signalman.

Only one signalman should give signals.

Make sure that all workers understand the meaning of all signals and signs before starting work.


2 - 18

2.4.9.5 INVESTIGATE AND CONFIRM JOBSITE CONDITIONSOn the jobsite, there are various hidden dangers that may lead to personal injury or death. Before starting opera-tions, always check the following to confirm there are no dangers on the jobsite.

2.4.9.6 DO NOT GO CLOSE TO HIGH VOLTAGE CABLES

When carrying out operations near combustible materials, there is a hazard of fire, so be careful when operating.

Check the terrain and condition of the ground at the worksite, and determine the safest method of operation. Do not operate where there is a hazard of landslides or falling rocks.

If water lines, gas lines, or high-voltage electrical lines may be buried under the worksite, contact each utility and identify their locations. Be careful not to sever or damage any of these lines (Fig. 3-16).

Take necessary measures to prevent any unauthorized per-son from entering the operating area.

If there is a fire near the machine, there is danger of sparks being sucked in and causing a fire on the machine.

When travelling or operating in shallow water or on soft ground, check the shape and condition of the bedrock, and the depth and speed of flow of the water before starting oper-ations.

Maintain the travel path on the jobsite so that there is no obstruction to travel operations.

Fig. 3-16

DANGERHIGH VOLTAGE!Do not travel or operate the machine near electric cables (Fig. 3-17). There is a hazard of electric shock, which may cause serious injury or property damage. Even going close to high-voltage cables can cause an electric shock, which may cause serious burns or even death.

Fig. 3-17


2 - 19

2.4.9.7 WORKING ON LOOSE GROUND Avoid travelling or operating your machine too close to the edge of cliffs, overhangs, and deep ditches. The

ground may be weak in such areas. If the ground should collapse under the weight or vibration of the machine, there is a hazard that the machine may fall or tip over. Remember that the soil after heavy rain or blasting or after earthquakes is weak in these areas.

When working on embankments or near excavated ditches, there is a hazard that the weight and vibration of the machine will cause the soil to collapse. Before starting operations, take steps to ensure that the ground is safe and to prevent the machine from rolling over or falling.

2.4.9.8 GAS, DUST, STEAM AND SMOKE

WARNINGRISK OF EXPOLSION AND FIRE!Welding, flame-cutting and grinding work on the machine increases the risk of explosion and fire which may result in serious injury or death.All relevent safety measures must be followed and only under expressly obtained authorization.

Special care must be taken before welding, flame-cutting and grinding operations are carried out on the counterweight. The filling of the counterweight chambers can create explosive gases which will accumu-late in the chambers of the counterweight.

These gases must be expelled before welding, flame-cutting and grinding operations are carried out on the counterweight.Follow the instructions given in PARTS & SERVICE NEWS No. AH04518 for expelling the gases from the counterweight chambers. (See Volume 2 binder)

On jobsites where the machine may go close to electric cables, always do as follows.

Before starting work near electric cables, inform the local power company of the work to be performed, and ask them to take the necessary action.

Always maintain a safe distance (see the table on the right) between the machine and the electric cable. Check with the local power company about safe operating procedure before starting operations.

To prepare for any possible emergencies, wear rubber shoes and gloves. Lay a rubber sheet on top of the seat, and be careful not to touch the chassis with any exposed part of your body.

Use a signalman to give warning if the machine approaches too close to the electric cables.

When carrying out operations near high voltage cables, do not let anyone near the machine.

If the machine should come too close or touch the electric cable, to prevent electric shock, the operator should not leave the operator's compartment until it has been confirmed that the electricity has been shut off. Also, do not let anyone near the machine.

Voltage of Cables Safety Distance100 V - 200 V Over 2 m (7 ft)

6,600 V Over 2 m (7 ft)22,000 V Over 3 m (10 ft)66,000 V Over 4 m (14 ft)

154,000 V Over 5 m (17 ft)187,000 V Over 6 m (20 ft)275,000 V Over 7 m (23 ft)500,000 V Over 11 m (36 ft)


2 - 20

WARNINGRISK OF EXPLOSION!Substances and objects igniting can lead to fire or explosion resulting in serious injury or death.Before carrying out welding, flame-cutting and grinding operations, clean the machine and its surround-ings from dust and other inflammable substances and make sure that the premises are adequately venti-lated as there is a risk of explosion.

2.4.9.9 VENTILATION OF ENCLOSED AREAS

WARNINGPOISONOUS FUMES!Unventilated areas where poisonous fumes can accumulate can kill. Always ensure adequate ventilation.

Operate internal combustion engines and fuel operated heat-ing systems only on adequately ventilated premises. Before starting the machine on enclosed premises, make sure that there is sufficient ventilation (Fig. 3-18).Observe the regulations in force at the respective site.

If it is necessary to start the engine within an enclosed area, or when handling fuel, flushing oil, or paint, open the doors and windows to ensure that adequate ventilation is provided to prevent gas poisoning.

Fig. 3-18


2 - 21

2.4.10 STARTING ENGINE

2.4.10.1 WARNING TAG

2.4.10.2 CHECKS BEFORE STARTING ENGINECarry out the following checks before starting the engine at the beginning of the day's work to ensure that there is no problem with the operation of the machine. If this inspection is not carried out properly, problems may occur with the operation of the machine, and there is the danger that this could lead to serious personal injury or death.

2.4.10.3 PRECAUTION WHEN STARTING ENGINE Start and operate the machine only while seated.

Do not short circuit the starting motor circuit to start the engine. Short circuiting can cause fire.

When starting the engine, sound the horn as a warning.

If there is a "DANGER DO NOT OPERATE!" warning tag dis-played, it means that someone is carrying out inspection and maintenance on the machine (Fig. 3-19). If the warning sign is ignored and the machine is operated, there is a danger that the person carrying out the inspection or maintenance may be caught in the rotating parts or moving parts and suffer per-sonal injury or death. Do not start the engine or touch the levers.

Fig. 3-19

Remove all dirt from the surface of the window glass to ensure a good view.

Completely remove all flammable materials accumulated around the engine and battery, and remove any dirt from the windows, mirrors, handrails, access ladder and steps.

Check the coolant levels, fuel levels, and oil levels, and check for damage to the electric wiring.

Adjust the operator's seat to a position where it is easy to carry out operations, check the camera system functions and check that there is no damage or wear to the seat belt or mounting clamps.

Check the operation of the instruments and gauges, check the angle of the mirror, and check that the control levers are all at the Neutral position.

Before starting the engine, check that lock lever (Fig. 3-20) is in LOCK position (L).

Adjust the mirrors so that the rear of the machine can be seen clearly from the operator's seat.

Check that there are no persons or obstacles above, below, or in the area around the machine.

Fig. 3-20

PC4000-6D 1


PC4000-6D


PC4000-6D 08199 and up

01 Specification


2 PC4000-6D

OPERATING WEIGHT385-397 ton 850,000-875,000 lb

SHOVEL CAPACITY22 m3 29 yd3 SAE 2:1 heaped

BACKHOE CAPACITY22 m3 29 yd3 SAE 1:1 heaped

PC4000PC4000

SU

PE

RS

HO

VE

L

2WALK-AROUNDPC4000 S U P E R S H O V E L

Quality Quality management ISO 9001 certified. Environmental Management

ISO 14001 certified. High consistent quality

through continuous investmentin personnel, design and manufacturingsystems and processes.

Reliability and DurabilityDesigned for lower operating costs Robust structural design developed

from field experience andfinite element analaysis.

Extended life undercarriage wear parts;Big diameter rollers, idlers and sprockets.Large surface area and extensiveprecision hardening.Hardened track link pin bores.

ProductivityDesigned for more tons per hour Powerful digging forces. Ease of bucket filling. Proven attachment design. All cylinders mounted under the shovel attachment for additional protection. Buckets and Wear Packages to suit all material densities and ground conditions.

3MATCHED FOR150 to 240 U.S. ton

TRUCKS

SHOVEL AND BACKHOEBUCKET CAPACITY

22 m3 29 yd3

PC4000SUPER SHOVEL

Large Comfortable CabFull shift comfort Komatsu low noise cab on multiple viscous mounts for

reduced noise and vibration. Large volume cab with deep wide front window. Comprehensive climate control with pressurised filtered air

ventilation and air conditioning. High specification multi-adjustable air suspension seat. Well elevated operator position giving good all round view.

Advanced HydraulicsExtended reliability and precise control Comprehensive monitored filtration. Simple open circuit hydraulic system with

high efficency swing out oil coolers.

Powerful Diesel EngineSingle Komatsu SDA16V160 engine Rated 1400 kW 1875 HP, at 1800 rpm. Electronic engine management. Low engine emission levels meet EPA regulations. Time saving oil management system

fitted as standard; Centinel Engine Oil Management,Reserve Engine Oil Supply and EliminatorOil Filter systems.

Easy MaintenanceSimple, common-sense design gives quick safe access to all major components Generous access to all major service points from machinery house floor level. Enclosed, internally lit machinery house with firewall separating engine from pump area. Automatic central lubrication. VHMS electronic monitoring system providing real time information about the operating status of the machine. Ground-level access to hydraulically powered swing down service arm with Wiggins connections.

4SPECIFICATIONSPC4000 S U P E R S H O V E L

ELECTRIC DRIVE

Type . . . . . . . . . . . . . . . . . . . . . . . . . Squirrel-cage induction motor Power output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1350 kWVoltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6600 V*Amperage (approximate) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145 AStart-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Soft start Frequency (standard) . . . . . . . . . . . . . . . . . . . . . 50 Hz @ 1500 rpmOptional frequency . . . . . . . . . . . . . . . . . . . . . . . 60 Hz @ 1800 rpm

*Other voltages available on request

UNDERCARRIAGE

Undercarriage consists of one center carbody and two track frames,each side attached by 62 high torque bolts.Center frame. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-typeTrack frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steel box-section

CRAWLER ASSEMBLY

Track adjustment . . . . . . . . . . . . . . . . . . . Automatic hydraulic type Number of shoes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 each sideNumber of top rollers. . . . . . . . . . . . . . . . . . . . . . . . . . . 3 each sideNumber of bottom rollers. . . . . . . . . . . . . . . . . . . . . . . . 7 each side

COOLING SYSTEM

The high capacity engine radiators are cooled by hydraulically drivenfans for superior cooling efficiency and require little maintenance.The hydraulic system includes two large swing-out vertical air-to-oilhydraulic coolers with temperature-regulated hydraulically driven fans.

AUTOMATIC CENTRALISEDLUBRICATION

Two hydraulically powered Lincoln single line automatic lubricationsystems are provided as standard, complete with time and volumevariable controls. Activity and malfunction events are linked to theVHMS. The central lube grease system is supplied from a refillable200 litre 53 gal. barrel. A second, identical system supplies open gearlubricant to the swing ring teeth through a lube pinion. Replenishmentof the barrels is through the service arm.

SERVICE CAPACITIES

Hydraulic oil tank . . . . . . . . . . . . . . . . . . . 3900 ltr 1,030 U.S. galHydraulic system . . . . . . . . . . . . . . . . . . . 5900 ltr 1,559 U.S. galFuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6400 ltr 1,691 U.S. galEngine coolant . . . . . . . . . . . . . . . . . . . . . . 475 ltr 125 U.S. galEngine oil . . . . . . . . . . . . . . . . . . . . . . . . . . 290 ltr 77 U.S. galCentinel engine oil make up tank . . . . . . . 460 ltr 122 U.S. gal

DIESEL DRIVE

Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Komatsu SDA16V160Type . . . . . . . . . . . . . . . . . . . 4-cycle, water-cooled, direct injectionAspiration . . . . . . . . . . . . . . . . . . . . . Turbocharged and aftercooledNumber of cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Rated power . . . . . . . . . . . . . . . . . . 1400 kW 1875 HP @ 1800 rpm(SAE 1995/J1349)Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . All-speed, electronicThe integrated engine oil and filter system combining the oil stabilisingsystems, Reserve and Centinel, with the Eliminator self cleaning oil filterextends, with oil analysis, the oil change interval to 4000 hours.(not available in Australia)

ELECTRICS

System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 VBatteries (series/parallel) . . . . . . . . . . . . . . . . . . . . . . . . 2x 3 x 12 VAlternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260 AStandard working lights. . . . . . . . . . . . . . . . . . . . . . . 8 Xenon lights Standard service lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 lights

HYDRAULICS

The power train consists of one main drive. Diesel engine or electricmotor can be supplied. One gearbox drives four identical mainpumps which draw hydraulic oil from an unpressurized hydraulic tank.Open circuit hydraulics provide maximum cooling and filteringefficiency.Rated flow (total output) . . . . . . . . . . . . 4140 ltr/min 1096 U.S. galRelief valve setting . . . . . . . . . . . . . . . . . . . . . . . . 310 bar 4,495 psiSwing flow rate . . . . . . . . . . . . . . . . . . . . 1590 ltr/min 420 U.S. gal

High pressure in line filters . . . . . . . . . . . . . . . . . . . . . . 200 micronsone per pump located at the valve blocks

Full flow return line filters (8 double elements) . . . . . . . . 10 micronsat head of hydraulic tankCase drain/by-pass return line filters . . . . . . . . . . . . . . . . 3 microns

The four-circuit system features a load-limiting governor with oildelivery summation to the working circuits and incorporatespressure cut-off control. Hydropilot prioritizes hydraulic flow givingsmooth hydraulic response, simple hydraulic system layout, and areduced number of components. The hydraulic system includes fourlarge swing-out vertical air-to-oil hydraulic coolers with temperature-regulated hydraulically driven fans.

DRIVES AND BRAKES

Travel control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 foot pedalsGradeability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Up to 50%Travel speed (maximum) . . . . . . . . . . . . . . . . . . . 2.1 km/h 1.3 mphService brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic brakeParking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . Wet, multiple-disc

SWING SYSTEM

Hydraulic motors and drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Swing brake, service. . . . . . . . . . . . . . . . . . . . . . . . Hydraulic brakeSwing brake, parking. . . . . . . . . . . . . . . . . . . . . . Wet, multiple-discSwing ring teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ExternalSwing speed (maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.0 rpm

5PC4000SUPER SHOVEL

2

345

6

7

6 9

8

1

10

10 7

11Lower-LevelUpper-Level

PC 4000 Backhoe:Operating weight including 9750 mm 320 boom, 4500 mm 149 stick, 22 m3 29 yd3

backhoe bucket, operator, lubricant, coolant, full fuel tank and standard equipment.

Shoe Width Operating Weight Ground Pressure

1200 mm 392 t 2.19 kg/cm2

47 865,000 lb 31.2 psi

1500 mm 397 t 1.78 kg/cm2

59 875,000 lb 25.3 psi

PC 4000 Front Shovel:Operating weight including 7150 mm 236 boom, 4900 mm 161 stick, 22 m3 29 yd3

shovel bucket, operator, lubricant, coolant, full fuel tank and standard equipment.

OPERATING WEIGHTS

Explanation

1 Operators Cab

2 Power Train

3 Hydraulic Pumps

4 Hydraulic Tank

5 Hydraulic Coolers

6 Valve Blocks

7 Swing Motor

8 Fuel Tank

9 Counterweight

10 Autolube System

11 Secondary Egress

Shoe Width Operating Weight Ground Pressure

1200 mm 385 t 2.15 kg/cm2

47 850,000 lb 30.6 psi

1500 mm 390 t 1.75 kg/cm2

59 860,000 lb 24.8 psi

SKZ4006_68

CS

CAB

The large welded steel safety cab is mounted with 18 viscousdamping pads and sound insulated.It is equipped with automatic climate control and is pressurised.The operators seat is fully adjustable, air suspended, electricallyheated and has a lap seat belt. There is a trainers seat.Low effort joy stick controls are electric over hydraulic and footcontrols are for front shovel clam, crawler and swing brake.Full instrumentation and VHMS are provided. Space in the consoleis provided for an additional monitor. AM/FM radio is fitted. Thewindshield wash wiper has two speed and intermittent operation.(Water reservoir 7 litres 1.8 gal.) Amenities include a wash basinwith running water, water reservoir, (50 litres 13 gal.), refrigeratorand storage cabinets. Powered mirrors are adjusted from insidethe cab.There are left and right hand sliding windows. All windowsare tinted parsol green. External metal louvres are provided on thecab side windows.

VEHICLE HEALTHMONITORING SYSTEM

VHMS is designed for Komatsu mining equipment to provide real timeand stored information about the status of the operating machine.A touch sensitive flat screen color monitor gives a continuous displayor can be activated to provide operator or service data. Non seriousand critical faults are automatically announced, while for majormalfunctions the engine is also shut down.The integrated digital storage provides a full event history, which canbe down loaded by laptop computer or by wireless link. The abilityto provide real time service information as messages, snap-shot ortrend data automatically to mine control programmes can improvemechanical utilisation and reduce costs.(Electric drive version fitted with ECS Health Monitor)

Cab engineering standards are; ISO 3449 Falling Objects Protection Structure ISO 6396 Noise in operators cab is 73dB(A) ISO 2631-1/5349-1 Vibration and Shock Air conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . .10kW 34120 Btu Heater/Demister (Diesel version) . . . . . . . . . . . . .10kW 34120 Btu

BACKHOE BUCKET, STICK AND BOOM COMBINATION

DIGGING FORCES

Break-out force 1155 kN 260,000 lbTear-out force 1050 kN 236,000 lb

Bucket Width Weight Teeth Boom LengthCapacity 9750 mm 320

SAE including Stick LengthHeaped 1 : 1 Wear package-2 4500 mm 149

Maximum reach at ground level . . . . . . . . .16.650 mm 548Maximum digging depth . . . . . . . . . . . . . . . .8000 mm 263

22 m3 29 yd3 3790 mm 125 23.4 t 51,590 lb 6 Material weight to 1.8 t/m3 3000 lb/yd3

Alternative buckets/wear packages are available

6

PRODUCTIVITY-FEATURESPC4000 S U P E R S H O V E L

4006078

SHOVEL BUCKET, STICK AND BOOM COMBINATION

DIGGING FORCES

Bucket Capacity Width Weight Teeth Boom Length7150 mm 236

SAE/CECE including Stick LengthHeaped 2 : 1 Heaped 1 : 1 Wear package-3 4900 mm 161

Alternative buckets/wear packages are available

22 m3 29 yd3 25 m3 32.7 yd3 4020 mm 132 38.8 t 76,700 lb 5 Material weight to 1.8 t/m3 3000 lb/yd3

Break-out force 1250 kN 280,000 lbCrowd force 1330 kN 300,000 lb

Level crowd at ground level . . . . . . . . . . . . . .5700 mm 188Maximum dumping height . . . . . . . . . . . . . .12.000 mm 394

7

PC4000SUPER SHOVEL

4006077

1500 mm 59 track shoes Electric drive Low temperature package

Extra or alternative, lighting Cable reel (Electric Version) Fire suppression system

D

M

N

L

CA

CB

A

B

JI

H

E

K

G

F

OR

O

DIMENSIONS

OPTIONAL EQUIPMENT

BASIC MACHINE WITH COUNTERWEIGHT

A 1200mm 47" H 3017mm 9'11"B 1500mm 59" I 3085mm 10'2"CA 6750mm 22'2" J 7600mm 24'11"CB 7050mm 23'2" K 8300mm 27'3"D 2480mm 8'2" L 3175mm 10'5"E 3380mm 11'1" M 4700mm 18'6"F 6700mm 22'0" N 7975mm 26'2"G 8842mm 29'0" O 6095mm 20'0"

OR 6500mm 21'4"

Ground Clearance: 930mm 3'0"

STANDARD EQUIPMENT

Hydraulic Mining Shovel with Diesel Drivewill comprise:

FRONT SHOVEL ATTACHMENT7.15 m 23'6" boom and 4.9 m 16'1"stick complete with cylinders. 22 m329 yd3 (SAE 2:1) shovel bucket withmechanical teeth and lip system.

OR

BACKHOE ATTACHMENT9.75 m 32'0" boom and 4.5 m 14'9"stick with 22 m3 29 yd3 (SAE 1:1)bucket.

CRAWLER UNDERCARRIAGEHeavy-duty shovel type undercarriageconsisting of a center carbody and 2heavy box-type track frames, eachhaving 7 bottom rollers, 3 top rollers,and 1200 mm 47" cast steel track shoes.Hydraulic track adjustment and parkingbrake provided.

SUPERSTRUCTUREMain frame mounted over anexternally toothed swing circle carriesthe main drive module, includingKomatsu SDA16V160 diesel engine,oil and fuel reservoirs, counterweight,operators cab and base.

LIGHTING8 Xenon high performance working lights.11 service lights throughout platform.

OPERATORS CABFully enclosed steel cab whichincorporates the ISO 3449 standardFOPS structure and CARRIER STRAKair-conditioning unit. Mounted on viscouspads. GRAMMER fully suspended seatwith lap-belt. Fold-away auxiliary seat.Full selection of controls, switches, andVHMS (Vehicle Health Monitoring System).Joystick and pedal-operated controlsare electric over hydraulic.Windshield wash wipers with two speedand intermittent operation. (reservoir 7 ltr1.8 gal).

AM-FM radio. Washbasin withrunning water (reservoir 50 ltr 13 gal).Refrigerator and storage cabinets.Left and right hand sliding windows.All windows tinted parsol green.

LUBRICATIONLINCOLN central lubrication for basicmachine, attachment, and bucket.200 ltr 53 gal refillable barrel.

LINCOLN automatic pinion lubricationsystem for swing circle teeth with200 ltr 53 gal refillable barrel.

Service point (diesel version only as standard)on hydraulic arm carrying WIGGINS fluidreceiving connectors for filling of fuel,engine oil and coolant, hydraulic oil, grease,cabwater and the evacuation of coolant,and hydraulic and engine oils.

ACCESSORIESAcoustic travel alarmHydraulically actuated ground accessladderElectric air hornEngine oil management System.(Centinel, Reserve & Eliminator Systems)

QESS0046 01 2006 Komatsu Printed in Germany

www.komatsu-mining.com Materials and specifications are subject to change without notice.is a trademark of Komatsu Ltd. Japan.

SKZ4006_67 SKZ4006_66

PC4000-6D 1


PC4000-6D


PC4000-6D 08199 and up

10 Structure, Function


2 PC4000-6D

I. INTRODUCTION ............................................................................ I-1

I.I CONTENTS OF THE BINDER ........................................................................................... I-2I.II FOREWORD ...................................................................................................................... I-3

1.2.1 IMPORTAND NOTE.............................................................................................. I-5

I.III EXPLANATION OF ABBREVATIONS .............................................................................. I-7

II. SAFETY ......................................................................................... II-1

II.I SAFETY INSTRUCTIONS ................................................................................................. II-2II.II GENERAL PREAUCTIONS .............................................................................................. II-3II.III PREPARATIONS FOR WORK ......................................................................................... II-4II.IV PRECAUTIONS DURING WORK ..................................................................................... II-5II.V PRECAUTIONS AFTER WORK ....................................................................................... II-6 1

1 MAIN ASSEMBLY GROUPS............................................................ 1-1

1.1 GENERAL LAYOUT .......................................................................................................... 1-21.2 SUPERSTRUCTURE ......................................................................................................... 1-41.3 MACHINE HOUSE ............................................................................................................ 1-61.4 HYDRAULIC OIL RESERVOIR ......................................................................................... 1-81.5 HYDRAULIC OIL COOLER ............................................................................................. 1-101.6 FUEL TANK .................................................................................................................... 1-121.7 COUNTERWEIGHT.......................................................................................................... 1-141.8 CAB SUPPORT................................................................................................................ 1-161.9 OPERATORS CAB ......................................................................................................... 1-181.10 CONTROL BLOCKS........................................................................................................ 1-201.11 SWING GEARS................................................................................................................ 1-221.12 UNDERCARRIAGE.......................................................................................................... 1-241.13 BACKHOE ATTACHMENT (BHA) .................................................................................. 1-261.14 FRONT SHOVEL ATTACHMENT (FSA) ......................................................................... 1-28

III. SPECIFICATIONS ........................................................................ III-1

III.I LIFTING GEARS .............................................................................................................. III-2III.II STANDARD TIGHTENING TORQUE CHART ................................................................ III-4III.III CONVERSION TABLE ..................................................................................................... III-5III.IV GENERAL SPECIFICATIONS ....................................................................................... III-12 2

2. DRIVE............................................................................................... 2-1

2.1 PRIME DRIVE ASSEMBLY ............................................................................................... 2-22.2 ENGINE AND PTO MOUNTS ............................................................................................ 2-4

2.2.1 FLEXIBLE MOUNTS ............................................................................................ 2-52.2.2 TORQUE SUPPORT............................................................................................ 2-7

2.3 FAN DRIVE AND RADIATOR ASSEMBLY....................................................................... 2-82.3.1 RADIATOR FAN DRIVE SPEED ADJUSTMENT .............................................. 2-12

2.4 PUMP DISTRIBUTOR GEARBOX (PTO)........................................................................ 2-162.4.1 SPLINE SHAFT HOUSING ................................................................................ 2-182.4.2 PTO LUBRICATION AND COOLING................................................................. 2-202.4.3 HYDRAULIC PUMPS LOCATION, DRIVE SPEED AND FLOW RATES ....... 2-26

2.5 GEISLINGER COUPLING................................................................................................ 2-282.6 AIR FILTER...................................................................................................................... 2-30 3

3. HYDRAULIC OIL RESERVOIR........................................................ 3-1

3.1 GENERAL LAYOUT ......................................................................................................... 3-23.2 MAIN OIL TANK, LOCATION OF ELECTRIC EQUIPMENT. ........................................... 3-43.3 SUCTION OIL RESERVOIR WITH STRAINERS ............................................................. 3-63.4 RETURN OIL COLLECTOR TUBE WITH STRAINER ..................................................... 3-83.5 BACK PRESSURE VALVE ............................................................................................. 3-103.6 TRANSFER PUMP .......................................................................................................... 3-12

3.6.1 EVACUATION OF THE SUCTION OIL RESERVOIR........................................ 3-153.6.2 EVACUATION OF THE RETURN OIL COLLECTOR PIPES AND COOLER CIRCUIT 3-17

3.7 RETURN AND LEAK OIL FILTER .................................................................................. 3-183.8 BREATHER FILTER ....................................................................................................... 3-20 4

4. HYDRAULIC OIL COOLING ............................................................ 4-1

4.1 GENERAL .......................................................................................................................... 4-24.2 FUNCTION OF THE HYDRAULIC OIL COOLING

CIRCUIT 4-44.3 ADJUSTMENT OF THE BACK PRESSURE VALVE........................................................ 4-64.4 FAN DRIVE

(TWO STAGE COOLER FAN RPM CONTROL) 4-84.4.1 FIXED DISPLACEMENT PUMP, WITH VARIABLE SETTING ......................... 4-104.4.2 PRESSURE RELIEF VALVES .......................................................................... 4-124.4.3 FAN SPEED CONTROL VALVE ARRANGEMENT........................................... 4-14

4.5 ADJUSTMENT OF THE COOLER FAN DRIVE SPEED................................................. 4-164.5.1 FUNCTION CHECK OF FAN SPEED CONTROL ............................................. 4-21 5

5. CONTROLLING.............................................................................. 5-23

5.1 GENERAL LAYOUT ........................................................................................................ 5-245.2 CONTROL AND FILTER PANEL LOCATION OF

COMPONENTS 5-265.3 PILOT PRESSURE SUPPLY AND ADJUSTMENTS ...................................................... 5-32

5.3.1 PILOT PRESSURE CIRCUIT (PPC) .................................................................. 5-335.3.2 CHECKS AND ADJUSTMENT OF PILOT PRESSURE..................................... 5-365.3.3 REMOTE CONTROL VALVES ARRANGEMENT.............................................. 5-38

5.4 FUNCTION ELECTRO HYDRAULIC CONTROL SYSTEM 5-40

5.5 POTENTIOMETER CONTROL (LEVER, JOY STICK).................................................... 5-445.6 POTENTIOMETER CONTROL (PEDAL) ........................................................................ 5-465.7 PROPORTIONAL AMPLIFIER MODULE, TYPE A......................................................... 5-485.8 PROPORTIONAL AMPLIFIER MODULE, TYPE B......................................................... 5-505.9 RAMP TIME MODULE .................................................................................................... 5-525.10 ADJUSTMENTS OF AMPLIFIER MODULES ................................................................. 5-54

5.10.1 GENERAL .......................................................................................................... 5-555.10.2 ADJUSTING THE AMPLIFIERS TYPE B........................................................... 5-565.10.3 ADJUSTING THE AMPLIFIERS TYPE A........................................................... 5-60

5.11 ADJUSTING THE RAMP TIME MODULE ....................................................................... 5-62 6

6. COMPONENTS................................................................................ 6-1

6.1 MAIN CONTROL BLOCKS AND HIGH PRESSUREFILTER (FSA) 6-2

6.2 MAIN CONTROL BLOCKS AND HIGH PRESSUREFILTER (BHA) 6-4

6.3 DISTRIBUTOR MANIFOLD - LOCATION OF RESTRICTOR BLOCKS AND ANTI CAVITATION VALVES (FSA) 6-6

6.4 DISTRIBUTOR MANIFOLD - LOCATION OF RESTRICTOR BLOCKS AND ANTI CAVITATION VALVES (BHA) 6-8

6.5 SINGLE CONTROL BLOCKS (FLOATING) FOR STICK AND BOOM (FSA)................ 6-106.6 RESTRICTOR BLOCK WITH PRESSURE RELIEF VALVE........................................... 6-126.7 ANTI CAVITATION VALVE BLOCK................................................................................ 6-146.8 REMOTE CONTROL VALVES ........................................................................................ 6-166.9 DIRECTIONAL SOLENOID VALVES

(THREE POSITIONS / 4-WAYS) 6-186.10 PROPORTIONAL SOLENOID VALVE............................................................................ 6-206.11 HIGH PRESSURE FILTER .............................................................................................. 6-226.12 CONTROL BLOCKS AND VALVES................................................................................ 6-246.13 TRAVEL BRAKE VALVE................................................................................................. 6-366.14 PRESSURE REDUCING VALVE..................................................................................... 6-386.15 DIRECTIONAL SOLENOID VALVES

(TWO POSITIONS / 4-WAYS) 6-406.16 PRESSURE INCREASING VALVE ................................................................................. 6-426.17 HYDRAULIC CYLINDER ................................................................................................. 6-446.18 SWING RING.................................................................................................................... 6-48 7

7. MAIN HYDRAULIC PUMPS AND PUMP REGULATION................. 7-1

7.1 GENERAL .......................................................................................................................... 7-27.2 MAIN PUMPS................................................................................................................... 7-12

7.2.1 LOCATION OF PUMPS ..................................................................................... 7-137.2.2 PUMP BEARING FLUSHING / LUBRICATION.................................................. 7-147.2.3 OPERATING PRINCIPLE .................................................................................. 7-167.2.4 CHECKS / ADJUSTMENTS ............................................................................... 7-34

7.3 ELECTRONIC PUMP REGULATION SYSTEM .............................................................. 7-447.3.1 ELECTRONIC LOAD LIMITING CONTROL - GENERAL .................................. 7-457.3.2 MICROCONTROLLER RC4-4............................................................................ 7-477.3.3 CHECKS AND ADJUSTMENTS ........................................................................ 7-49

7.4 HYDRAULIC CONSTANT REGULATION SYSTEM ....................................................... 7-767.4.1 GENERAL .......................................................................................................... 7-777.4.2 X1-PRESSURE ADJUSTMENT (CONSTANT-PRESSURE)............................. 7-78

7.5 DETERMINATION OF THE PEAK POINT(ENGINE PERFORMANCE) 7-80

7.6 ENGINE SPEED SENSOR (PICK UP)............................................................................. 7-827.6.1 GENERAL .......................................................................................................... 7-837.6.2 ENGINE SPEED SENSOR (PICK UP) ADJUSTMENT ..................................... 7-83

7.7 ENERGY EFFICIENCY .................................................................................................... 7-847.7.1 GENERAL .......................................................................................................... 7-857.7.2 CHECKS AND ADJUSTMENTS ........................................................................ 7-86 8

8. OPERATING HYDRAULIC............................................................... 8-1

8.1 GENERAL .......................................................................................................................... 8-28.1.1 FLOATING SYSTEM............................................................................................ 8-4

8.2 HYDRAULIC FOR THE ATTACHMENT CYLINDER FSA AND BHA............................... 8-68.2.1 ELECTRIC / HYDRAULIC FLOWCHART "BOOM RAISING" FSA...................... 8-68.2.2 ELECTRIC / HYDRAULIC FLOWCHART "BOOM RAISING" BHA ..................... 8-88.2.3 ELECTRIC / HYDRAULIC FLOWCHART "BOOM LOWERING" FSA............... 8-108.2.4 ELECTRIC / HYDRAULIC FLOWCHART "BOOM LOWERING" BHA............... 8-128.2.5 ELECTRIC / HYDRAULIC FLOWCHART "STICK EXTENDING" FSA.............. 8-148.2.6 ELECTRIC / HYDRAULIC FLOWCHART "STICK EXTENDING" BHA.............. 8-168.2.7 ELECTRIC / HYDRAULIC FLOWCHART "STICK RETRACTING" FSA............ 8-188.2.8 ELECTRIC / HYDRAULIC FLOWCHART "STICK RETRACTING" BHA ........... 8-208.2.9 ELECTRIC / HYDRAULIC FLOWCHART "BUCKET FILLING" FSA ................. 8-228.2.10 ELECTRIC / HYDRAULIC FLOWCHART "BUCKET FILLING" BHA................. 8-248.2.11 ELECTRIC / HYDRAULIC FLOWCHART "BUCKET EMPTYING" FSA ............ 8-268.2.12 ELECTRIC / HYDRAULIC FLOWCHART "BUCKET EMPTYING" BHA............ 8-288.2.13 ELECTRIC / HYDRAULIC FLOWCHART "CLAM OPENING" FSA................... 8-308.2.14 ELECTRIC / HYDRAULIC FLOWCHART "CLAM CLOSING" FSA ................... 8-328.2.15 CHECKS AND ADJUSTMENTS OF THE MAIN RELIEF VALVES (FSA) ......... 8-348.2.16 CHECKS AND ADJUSTMENTS OF THE MAIN RELIEF VALVES (BHA)......... 8-368.2.17 CHECKS AND ADJUSTMENTS OF THE SERVICE LINE RELIEF VALVES (SRV) 8-38

8.2.17.1 BOOM CYLINDER "PISTON SIDE" FSA + BHA .............................. 8-398.2.17.2 BOOM CYLINDER "PISTON ROD SIDE" FSA +BHA ...................... 8-438.2.17.3 STICK CYLINDER "PISTON SIDE" FSA.......................................... 8-478.2.17.4 STICK CYLINDER "PISTON SIDE" BHA.......................................... 8-51

8.2.18 STICK CYLINDER "PISTON ROD SIDE" FSA .................................................. 8-558.2.18.1 STICK CYLINDER "PISTON ROD SIDE" BHA................................. 8-598.2.18.2 BUCKET CYLINDER "PISTON SIDE" FSA...................................... 8-638.2.18.3 BUCKET CYLINDER "PISTON SIDE" BHA...................................... 8-678.2.18.4 BUCKET CYLINDER "PISTON ROD SIDE" FSA............................. 8-718.2.18.5 BUCKET CYLINDER "PISTON ROD SIDE" BHA............................. 8-758.2.18.6 CLAM CYLINDER "PISTON ROD SIDE" FSA.................................. 8-798.2.18.7 CLAM CYLINDER "PISTON SIDE" FSA........................................... 8-818.2.18.8 CHECKS AND ADJUSTMENTS OF THE LOWERING SPEED....... 8-838.2.18.9 BUCKET CYLINDER FSA ................................................................ 8-978.2.18.10 BUCKET CYLINDER BHA................................................................ 8-998.2.18.11 CLAM CYLINDER BHA .................................................................. 8-101

8.3 HYDRAULIC FOR THE SWING CIRCUIT ..................................................................... 8-1028.3.1 SWING CIRCUIT.............................................................................................. 8-1028.3.2 SWING MOTOR .............................................................................................. 8-1068.3.3 SWING GEAR BOX ......................................................................................... 8-1088.3.4 SWING PARKING BRAKE (GEAR HOUSE BRAKE) ...................................... 8-1108.3.5 SWING BRAKE VALVE ................................................................................... 8-1128.3.6 ELECTRIC / HYDRAULIC FLOWCHART "SWING LEFT" .............................. 8-1148.3.7 ELECTRIC / HYDRAULIC FLOWCHART "SWING RIGHT" ............................ 8-1168.3.8 CHECKS AND ADJUSTMENTS FOR THE SWING CIRCUIT......................... 8-1188.3.9 FUNCTION CHECK FOR HYDRAULIC SWING BRAKE ................................ 8-124 9

8.3.10 FUNCTION CHECK FOR THE SWING PARKING BRAKE............................. 8-126

8.4 HYDRAULIC FOR THE TRAVEL CIRCUIT................................................................... 8-1288.4.1 TRAVEL CIRCUIT ............................................................................................ 8-1288.4.2 TRAVEL MOTOR ............................................................................................. 8-1328.4.3 ROTARY DISTRIBUTOR ................................................................................. 8-1348.4.4 TRAVEL GEAR ................................................................................................ 8-1368.4.5 TRAVEL PARKING BRAKE (GEAR HOUSE BRAKE)..................................... 8-1388.4.6 TRAVEL BRAKE VALVE.................................................................................. 8-1408.4.7 ELECTRIC / HYDRAULIC FLOWCHART TRAVELING FORWARD............. 8-1428.4.8 ELECTRIC / HYDRAULIC FLOWCHART TRAVELING BACKWARD........... 8-1448.4.9 CHECKS AND ADJUSTMENTS FOR THE TRAVEL CIRCUIT ....................... 8-1468.4.10 FUNCTION CHECK FOR THE TRAVEL PARKING BRAKE ........................... 8-148 10

9. HYDRAULIC TRACK TENSIONING SYSTEM ................................ 9-1

9.1 GENERAL .......................................................................................................................... 9-29.2 PRESSURE INCREASING VALVE ................................................................................... 9-69.3 TENSIONING CYLINDER.................................................................................................. 9-89.4 ADJUSTMENTS / CHECKS............................................................................................. 9-109.5 FUNCTIONAL TEST ........................................................................................................ 9-12 11

10. ACCESS LADDER HYDRAULICALLY OPERATED...................... 10-1

10.1 GENERAL ........................................................................................................................ 10-210.2 FUNCTION OF HYDRAULICALLY OPERATED ACCESS LADDER............................. 10-410.3 ADJUSTMENTS / CHECKS............................................................................................. 10-8 12

11. CENTRAL REFILLING SYSTEM (SERVICE ARM) ....................... 11-1

11.1 GENERAL ........................................................................................................................ 11-211.2 FUNCTION ....................................................................................................................... 11-4 13

12. HINTS FOR READING THE HYDRAULIC DIAGRAM ................... 12-1

12.1 GENERAL ........................................................................................................................ 12-212.2 SYMBOLIC....................................................................................................................... 12-4

12.2.1 LINES, UNIONS ................................................................................................. 12-512.2.2 COMPONENTS, VALVES.................................................................................. 12-612.2.3 SENSORS.......................................................................................................... 12-712.2.4 VALVES, VALVE COMPONENTS ..................................................................... 12-812.2.5 PUMP, MOTOR, CYLINDER............................................................................ 12-12 14

13. HINTS FOR READING THE ELECTRIC CIRCUIT DIAGRAM....... 13-1

13.1 DESIGNATION OF ELECTRICAL COMPONENTS ........................................................ 13-313.2 ELECTRIC SYMBOLS..................................................................................................... 13-413.3 SYMBOLS........................................................................................................................ 13-613.4 DRAWING CONCEPT...................................................................................................... 13-813.5 READING A CIRCUIT DIAGRAM.................................................................................. 13-1213.6 COMPONENT LIST........................................................................................................ 13-16 15

14 VEHICLE HEALTH MONITORING SYSTEM................................. 14-1

14.1 GENERAL ........................................................................................................................ 14-214.2 SPECIFICATIONS FOR OPERATORS .......................................................................... 14-4

14.2.1 SEQUENCE OF DISPLAYS............................................................................... 14-514.2.2 OPENING SCREEN........................................................................................... 14-514.2.3 MAIN GAUGE SCREENS 1 TO 3 ...................................................................... 14-614.2.4 FUEL CONSUMPTION SCREEN .................................................................... 14-1014.2.5 FAILURE MESSAGE HISTORY SCREEN FOR

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