Komatsu PC7000-11 T4 Hydraulic Mining Excavator Shop Manual – PDF DOWNLOAD

Komatsu PC7000-11 T4 Hydraulic Mining Excavator Shop Manual – PDF DOWNLOAD

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Komatsu PC7000-11 T4 Hydraulic Mining Excavator Shop Manual – PDF DOWNLOAD

Language : English
Pages : 2592
Downloadable : Yes
File Type : PDF
Size: 66.8 MB

DESCRIPTION:

Komatsu PC7000-11 T4 Hydraulic Mining Excavator Shop Manual – PDF DOWNLOAD

SERIAL NUMBER 35013 and up

BEFORE READING THIS MANUAL:

• This manual gives details of the methods of inspection, maintenance and troubleshooting for this excavator
  that must be obeyed in order to use the excavator safely. Most accidents are caused by the failure to follow
  fundamental safety rules for the inspection, maintenance and troubleshooting of excavators.
• Read, understand and follow all precautions and warnings in this manual and on the excavator before performing
  inspection, maintenance or troubleshooting. Failure to do so may result in serious injury or death.
• Komatsu cannot predict every circumstance that may involve a potential hazard when the excavator is used.
  Therefore, the safety messages in this manual and on the excavator may not include all possible safety
  precautions. If you carry out any inspection, maintenance and troubleshooting under conditions that are not
  described in this manual, understand that it is your responsibility to take the necessary precautions to ensure
  safety. In no event should you or others engage in prohibited uses or actions described in this manual.
• Improper inspection, maintenance and troubleshooting of the excavator can be hazardous and could result in
  serious injury or death.
• If you sell the excavator, be sure to give this manual to the new owner together with the excavator.
• This manual uses the international units (SI) for units of measurement. For reference, units that have been used
  in the past are given in ( ).
• The explanations, values, and illustrations in this manual have been prepared based on the latest information
  available as of the date of publication. Continuing improvements in the design of this excavatore may lead to
  additional changes that are not reflected in this manual. Consult Komatsu or your Komatsu distributor for the
  latest available information concerning your excavator or with questions regarding information contained in this
  manual.
• Komatsu delivers excavators that comply with all applicable regulations and standards of the country to which
  it has been shipped. If the excavator has been purchased in another country, it may lack certain safety devices
  and specifications that are necessary for use in your country. If there is any question about whether your
  product complies with the applicable standards and regulations of your country, consult Komatsu or your
  Komatsu distributor before operating the excavator.

CONTENTS OF THIS BINDER:

This Shop Manual has been prepared as a SERVICE GUIDE for the mechanic responsible for the upkeep of your
hydraulic excavator.
It is compiled into different sections and summarizes the procedures for inspection, maintenance and troubleshooting
on the excavator.
All information, illustrations and specifications contained herein are based on the development at printing time
and may be subject to possible future changes by KOMATSU without prior notice.
Also note that all procedures given in this manual are for a basic excavator. Your excavator may be differently
equipped and/or otherwise customized.
This manual may contain attachments and optional equipment that are not available in your area. Please consult
your local Komatsu distributor for those items you may require. Materials and specifications are subject to change
without notice.

TABLE OF CONTENTS:

Komatsu PC7000-11 T4 Hydraulic Mining Excavator Shop Manual – PDF DOWNLOAD

1 INTRODUCTION 1-1
1 1 FOREWORD 1-2
1 2 RECOMMENDATIONS FOR ENVIRONMENTALLY FRIENDLY OPERATION
AND MAINTENANCE OF HYDRAULIC MINING EXCAVATORS 1-3
1 3 EXPLANATION OF ABBREVIATIONS 1-4
1 4 DIAGRAMS AND ILLUSTRATIONS IN THIS MANUAL 1-5
2 SPECIFICATIONS 2-1
2 1 LIFTING GEARS 2-2
2 2 SAFETY HINTS FOR SLING ACCESSORY 2-4
2 3 STANDARD TIGHTENING TORQUE CHART 2-5
2 4 CONVERSION TABLE 2-6
2 5 BLIND PLUGS 2-12
2 6 CLASSIFICATION OF THREADS TO THE NOMINAL WIDTH 2-14
2 7 PLUGS & FITTINGS ACCORDING TO ISO 8434-1 / DIN 2353 2-15
3 MAIN ASSEMBLY GROUPS 3-1
3 1 GENERAL LAYOUT 3-2
3 2 SUPERSTRUCTURE 3-4
3 2 1 SIDE VIEW 3-4
3 2 2 SUPERSTRUCTURE TOP VIEW 3-6
3 3 MACHINERY HOUSE 3-8
3 4 HYDRAULIC OIL TANK 3-10
3 5 HYDRAULIC OIL COOLER 3-12
3 6 FUEL TANK WITH WIGGINS SERVICE SYSTEM VR300 3-14
3 7 CAB SUPPORT 3-16
3 8 OPERATOR’S CAB 3-18
3 9 MAIN CONTROL BLOCKS (FSA) 3-20
3 10 SLEW MACHINERY 3-22
3 10 1 SLEW GEAR TYPE 2063 3-22
3 10 2 SLEW GEAR TYPE 632770 3-24
3 11 UNDERCARRIAGE 3-26
3 12 SLEW RING 3-28
3 13 ATTACHMENT 3-30
3 13 1 FRONT SHOVEL ATTACHMENT (FSA) 3-30
3 13 2 BACKHOE ATTACHMENT (BHA) 3-32
3 14 COUNTERWEIGHT 3-34
3 15 PPC SAFETY CIRCUIT 3-36
3 16 KOMVISION CAMERA SYSTEM 3-39
TOC – 2 PC7000-11 T4 SHOP-10 35013-xD-GB-0
4 DRIVE 4-1
4 1 PRIME DRIVE ASSEMBLY 4-2
4 2 ENGINE AND PTO MOUNTS 4-4
4 2 1 CHECKS AND ADJUSTMENTS 4-5
4 3 FLEXIBLE COUPLING 4-6
4 3 1 INFORMATION FOR MAINTENANCE 4-8
4 3 2 COUPLING ELEMENTS 4-9
4 3 3 SEPARATION AND ASSEMBLY OF THE COUPLING INNER AND OUTER PART 4-10
4 3 4 OPERATION TROUBLES, CAUSES, AND RECTIFICATION 4-11
4 4 RADIATOR ASSEMBLY AND FAN DRIVE 4-12
4 4 1 RADIATOR ASSEMBLY 4-12
4 4 2 FAN MOTOR 4-14
4 4 3 EXPANSION TANKS 4-15
4 4 4 RADIATOR FAN DRIVE 4-16
4 4 4 1 HYDRAULIC SCHEMATIC OF RADIATOR FAN DRIVE 4-18
4 4 5 FAN PUMP TYPE HPV190 4-20
4 4 6 RADIATOR FAN SPEED TESTING & ADJUSTMENT 4-22
4 4 6 1 TESTING & READJUSTMENT PROCEDURE 4-24
4 4 6 2 BASIC ADJUSTMENT PROCEDURE 4-25
4 5 FUEL COOLING (T4 EQUIPMENT) 4-26
4 6 PUMP DISTRIBUTOR GEARBOX (PTO) 4-28
4 6 1 PTO OIL FILLING, OIL LEVEL, AND VENTILATION 4-30
4 6 2 PUMP SPLINE LUBRICATION 4-32
4 6 2 1 OIL LEVEL IN MAIN PUMP & GEAR OIL PUMP DRIVE SHAFT HOUSING 4-33
4 6 3 PTO LUBRICATION AND COOLING 4-34
4 6 3 1 HYDRAULIC COMPONENTS AND SCHEMATIC OF COOLING CIRCUIT-1 4-34
4 6 3 2 SCHEMATIC OVERVIEW – PTO GEAR OIL COOLING CIRCUIT-1 4-36
4 6 3 3 CHECKS AND ADJUSTMENTS 4-38
4 7 HYDRAULIC PUMPS – LOCATION, DRIVE SPEED AND FLOW RATES 4-40
4 8 AIR CLEANER 4-44
4 9 FUEL FILTRATION SYSTEM STAGE 1 (HYDAC) 4-46
4 9 1 STATUS LIGHT & FLASH LIGHTS FOR FUEL FILTRATION 4-48
5 HYDRAULIC OIL TANK 5-1
5 1 GENERAL LAYOUT 5-2
5 1 1 HYDRAULIC OIL LEVEL DEFINITION 5-4
5 2 HYDRAULIC OIL TANK, LOCATION OF THE ELECTRIC EQUIPMENT 5-6
5 3 SUCTION OIL TANK WITH STRAINERS 5-8
5 4 RETURN OIL COLLECTOR PIPE WITH STRAINER 5-10
5 5 BACK PRESSURE VALVE 5-12
5 6 TRANSFER PUMP 5-14
5 7 RETURN AND LEAK OIL FILTER 5-16
5 8 BREATHER FILTER 5-18
SHOP-10 35013-xD-GB-0 PC7000-11 T4 TOC – 3
6 HYDRAULIC OIL COOLING 6-1
6 1 OVERALL VIEW ON THE HYDRAULIC OIL COOLING 6-2
6 2 FUNCTION OF THE HYDRAULIC OIL COOLING CIRCUIT 6-4
6 3 ADJUSTMENT OF THE BACK PRESSURE VALVE 6-6
6 4 STEPLESS COOLER FAN RPM CONTROL 6-8
6 4 1 PRESSURE LIMITING VALVES 6-10
6 4 2 COMPONENTS OF THE FAN DRIVE CIRCUITS 6-12
6 4 3 FAN PUMP TYPE HPV190 6-14
6 5 OIL COOLER FAN SPEED 6-16
6 6 OC FAN RESONANCE SPEED 6-18
6 6 1 HYDRAULIC OIL TEMPERATURE CHARTS 6-20
7 CONTROLLING 7-1
7 1 GENERAL LAYOUT 7-2
7 2 CONTROL AND FILTER PANELS – LOCATION OF COMPONENTS 7-4
7 2 1 CONTROL AND FILTER PANEL ENGINE 1 (REAR) 7-4
7 2 2 VALVE CARTRIDGE BLOCK ENGINE 1 (REAR) 7-6
7 2 3 CONTROL AND FILTER PANEL ENGINE 2 (FRONT) 7-8
7 3 PILOT PRESSURE SUPPLY AND ADJUSTMENTS 7-10
7 3 1 PILOT PRESSURE CONTROL (PPC) CIRCUIT 7-10
7 3 2 PILOT PRESSURE OPERATING THE MAIN BLOCK SPOOLS 7-12
7 3 3 CHECKS AND ADJUSTMENT OF PILOT PRESSURE 7-14
7 3 4 REMOTE CONTROL VALVES ARRANGEMENT 7-16
7 4 FUNCTION OF THE ELECTRO HYDRAULIC CONTROL SYSTEM 7-18
7 4 1 ILLUSTRATION OF THE JOYSTICK SIGNAL FLOW (EXAMPLE) 7-20
7 5 HAND LEVER (JOYSTICK) CONTROL 7-22
7 5 1 VOLTAGE SUPPLY OF LH HAND LEVER 20S020 7-23
7 5 2 DIRECTION SIGNAL COURSE FROM HAND LEVER TO CONTROLLERS 7-24
7 5 3 DOUBLE RATIOMETRIC* OUTPUT DIAGRAM 7-25
7 6 FOOT PEDAL CONTROL 7-26
7 6 1 VOLTAGE SUPPLY OF FOOT PEDAL 20S021A 7-28
7 6 2 DIRECTION SIGNAL COURSE FROM FOOT PEDAL TO CONTROLLERS 7-29
7 6 3 DOUBLE RATIOMETRIC* OUTPUT DIAGRAM FOR 2 DIRECTION PEDAL 7-30
7 6 4 SINGLE RATIOMETRIC* OUTPUT DIAGRAM FOR 1 DIRECTION PEDAL 7-31
7 7 HAND LEVER & FOOT PEDAL MONITORING 7-32
7 7 1 LEVER MONITORING SCREENS (EXAMPLE) 7-34
7 7 2 VALVE MONITORING SCREEN (EXAMPLE) 7-36
7 8 VALVE SOLENOID ADJUSTMENT 7-38
7 8 1 OVERVIEW SOL MIN/MAX CURRENT & ADJUSTMENT RANGE 7-39
7 9 ACCEL & DECEL TIME ADJUSTMENT 7-40
7 9 1 ACCEL & DECEL TIMES 7-40
8 COMPONENTS 8-1
8 1 MAIN CONTROL BLOCKS AND HIGH PRESSURE SCREENS (FSA) 8-2
TOC – 4 PC7000-11 T4 SHOP-10 35013-xD-GB-0
8 2 MAIN CONTROL BLOCKS WITH VALVES AND HP SCREENS (FSA) 8-4
8 3 MAIN CONTROL BLOCKS WITH VALVES AND HP SCREENS (BHA) 8-6
8 4 DISTRIBUTOR MANIFOLD – LOCATION OF RESTRICTOR BLOCKS
AND ANTI CAVITATION VALVES (FSA) 8-8
8 5 DISTRIBUTOR MANIFOLD – LOCATION OF RESTRICTOR BLOCKS
AND ANTI CAVITATION VALVES (BHA) 8-10
8 6 RESTRICTOR BLOCK WITH SECONDARY RELIEF VALVE 8-12
8 7 ANTI-CAVITATION VALVE (ACV) BLOCK 8-14
8 7 1 SINGLE ACV BLOCK ON THE MANIFOLD 8-14
8 7 2 DOUBLE ACV BLOCK ON THE MANIFOLD 8-16
8 8 REMOTE CONTROL VALVES 8-18
8 9 4/3 DIRECTIONAL SOLENOID VALVES 8-20
8 10 PROPORTIONAL SOLENOID VALVES 8-22
8 11 HIGH-PRESSURE SCREEN 8-24
8 12 CONTROL BLOCKS AND VALVES 8-26
8 12 1 MAIN CONTROL BLOCKS I, II, III (4 SPOOL BLOCKS) 8-26
8 12 1 1 SPIN LOCK FOR VALVE BLOCKS (ND52) 8-27
8 12 2 HYDRAULIC DIAGRAM OF A 4-SPOOL VALVE BLOCK 8-28
8 12 3 SPOOL TYPES 8-29
8 12 4 SPOOL POSITIONS (CONTROL BLOCK) 8-32
8 12 5 MRV, SRV, AND ACV 8-34
8 12 6 LOAD HOLDING VALVE 8-36
8 12 7 MAIN CONTROL BLOCK IV (SLEW) 8-38
8 13 TRAVEL BRAKE VALVE 8-40
8 14 PRESSURE REDUCING VALVE 8-42
8 15 4/2 DIRECTIONAL VALVES 8-44
8 16 PRESSURE DOUBLE STAGE VALVE 8-46
8 17 HYDRAULIC CYLINDER 8-48
8 17 1 HYDRAULIC CYLINDER – CHEVRON® SEALING 8-48
8 17 2 HYDRAULIC CYLINDER – CHESTERTON® 11KE SEALING 8-50
8 17 3 CYLINDER DATA MARKINGS 8-52
9 MAIN HYDRAULIC PUMPS, PUMP REGULATION, VALVE CONTROL
& MONITORING SYSTEM 9-1
9 1 GENERAL 9-2
9 1 1 PUMP DATA 9-4
9 2 MAIN PUMPS 9-8
9 2 1 HYDRAULIC PUMP TYPE HPV375+375 9-8
9 2 1 1 MAIN PUMP SECTIONAL DRAWINGS 9-10
9 2 2 SERVO VALVE 9-12
9 2 2 1 VC VALVE  SERVO PISTON 9-13
9 2 3 EPC VALVE 9-18
9 3 ELECTRONIC PUMP REGULATION SYSTEM 9-20
9 3 1 CUT-OFF FUNCTION 9-22
9 3 2 SLEW CONTROL 9-22
9 3 3 TEMPERATURE CONTROL 9-22
SHOP-10 35013-xD-GB-0 PC7000-11 T4 TOC – 5
9 3 3 1 HYDRAULIC OIL TEMPERATURE CHARTS 9-23
9 4 PUMP & VALVE CONTROLLERS 9-26
9 4 1 SERVICE MENU SCREEN 9-28
9 4 2 SERVICE ID 9-28
9 4 3 SERVICE MENU – 01 MONITORING 9-28
9 5 MONITORING PUMP 1 CONTROLLER 9-29
9 5 1 MONITORING PUMP 2 CONTROLLER 9-30
9 6 MONITORING VALVE 0 CONTROLLER 9-31
9 7 MONITORING VALVE 1 CONTROLLER 9-32
9 8 MONITORING VALVE 2 CONTROLLER 9-33
9 9 USING MACHINE MONITOR FUNCTIONS FOR MONITORING 9-34
9 10 ERROR INDICATION OF PUMP CONTROLLERS 9-34
9 11 ADJUSTMENTS FOR PUMP CONTROLLERS 9-35
9 11 1 ADJUSTMENTS FOR PUMP 1 CONTROLLER 9-35
9 11 2 ADJUSTMENTS FOR PUMP 2 CONTROLLER 9-36
9 12 DETAILS ON ADJUSTABLE PARAMETERS 9-37
9 12 1 PUMP1 CONTROLLER 9-37
9 12 2 PUMP2 CONTROLLER 9-39
9 12 3 DESCRIPTION OF THE PRIMARY P-FACTOR 9-41
9 12 4 PUMP SOL MIN CURRENT VALUES ACCORDING TO PUMP TYPE PLATE 9-42
9 12 5 PUMP SOL MAX CURRENT VALUES ACCORDING TO PUMP TYPE PLATE 9-43
9 13 CHECKS AND ADJUSTMENTS 9-44
9 13 1 ENGINE POWER CHECK 9-44
9 13 2 CUT-OFF FUNCTION CHECK 9-46
9 13 2 1 CUT-OFF FOR CLAM CLOSE (FSA ONLY) 9-47
9 14 ENGINE SPEED SENSORS (PICK-UP) 9-48
9 14 1 GENERAL 9-49
9 14 2 ENGINE SPEED SENSOR (PICK-UP) ADJUSTMENT 9-49
9 14 3 IN CASE OF PROBLEMS – WHEN CORRECT SPEED SENSOR ADJUSTMENT
IS GUARANTEED 9-50
10 OPERATING HYDRAULICS 10-1
10 1 GENERAL 10-2
10 1 1 ALLOCATION OF PUMPS AND MAIN VALVE BLOCKS 10-4
10 2 SPOOL FUNCTIONS (FSA) 10-6
10 2 1 FLOATING FUNCTION FOR BOOM AND STICK CYLINDERS 10-6
10 2 2 SPOOL FUNCTIONS (BHA) 10-8
10 3 HYDRAULICS FOR THE ATTACHMENT CYLINDERS 10-10
10 3 1 ELECTRIC / HYDRAULIC FLOWCHART “BOOM UP” (FSA) 10-10
10 3 2 ELECTRIC / HYDRAULIC FLOWCHART “BOOM UP” (BHA) 10-12
10 3 3 ELECTRIC / HYDRAULIC FLOWCHART “BOOM DOWN” (FSA),
SINGLE MOVEMENT AND AUTO-FLOAT ON 10-14
10 3 4 ELECTRIC / HYDRAULIC FLOWCHART “BOOM DOWN” (FSA),
AUTO-FLOAT OFF – BUTTON 20S095 PRESSED AND SINGLE MOVEMENT 10-16
10 3 5 ELECTRIC / HYDRAULIC FLOWCHART “BOOM DOWN” (BHA) 10-18
10 3 6 ELECTRIC / HYDRAULIC FLOWCHART “STICK OUT” (FSA) 10-20
10 3 7 ELECTRIC / HYDRAULIC FLOWCHART “STICK OUT” (BHA) 10-22
TOC – 6 PC7000-11 T4 SHOP-10 35013-xD-GB-0
10 3 8 ELECTRIC / HYDRAULIC FLOWCHART “STICK IN” (FSA),
AUTO-FLOAT ON AND SINGLE MOVEMENT 10-24
10 3 9 ELECTRIC / HYDRAULIC FLOWCHART “STICK IN” (FSA),
AUTO-FLOAT OFF – 20S098 PRESSED & SINGLE MOVEMENT 10-26
10 3 10 ELECTRIC / HYDRAULIC FLOWCHART “STICK IN” (BHA) 10-28
10 3 11 ELECTRIC / HYDRAULIC FLOWCHART “BUCKET FILL” (FSA) 10-30
10 3 12 ELECTRIC / HYDRAULIC FLOWCHART “BUCKET FILL” (BHA) 10-32
10 3 13 ELECTRIC / HYDRAULIC FLOWCHART “BUCKET DUMP” (FSA) 10-34
10 3 14 ELECTRIC / HYDRAULIC FLOWCHART “BUCKET DUMP” (BHA) 10-36
10 3 15 ELECTRIC / HYDRAULIC FLOWCHART “CLAM OPEN” (FSA) 10-38
10 3 16 ELECTRIC / HYDRAULIC FLOWCHART “CLAM CLOSE” (FSA) 10-40
10 3 17 CHECKS & ADJUSTMENTS OF MAIN RELIEF VALVE (MRV) 10-42
10 3 18 CHECKS AND ADJUSTMENTS OF THE SECONDARY RELIEF VALVES (SRV) 10-44
10 3 18 1 BOOM CYLINDERS, PISTON SIDE (BHA & FSA), BOOM UP 10-44
10 3 18 2 BOOM CYLINDER, PISTON ROD SIDE (BHA & FSA), BOOM DOWN 10-48
10 3 18 3 STICK CYLINDERS, PISTON SIDE (FSA), STICK OUT 10-52
10 3 18 4 STICK CYLINDERS, PISTON SIDE (BHA), STICK IN 10-56
10 3 18 5 STICK CYLINDERS, PISTON ROD SIDE (FSA), STICK IN 10-60
10 3 18 6 STICK CYLINDERS, PISTON ROD SIDE (BHA), STICK OUT 10-64
10 3 18 7 BUCKET CYLINDERS, PISTON SIDE (FSA), BUCKET FILL 10-68
10 3 18 8 BUCKET CYLINDERS, PISTON SIDE (BHA), BUCKET FILL 10-72
10 3 18 9 BUCKET CYLINDERS, PISTON ROD SIDE (FSA), BUCKET DUMP 10-76
10 3 18 10 BUCKET CYLINDERS, PISTON ROD SIDE (BHA), BUCKET DUMP 10-80
10 3 18 11 CLAM CYLINDERS, PISTON ROD SIDE (FSA), CLAM OPEN 10-84
10 3 18 12 CLAM CYLINDERS, PISTON SIDE (FSA), CLAM CLOSE 10-88
10 3 19 CHECKS AND ADJUSTMENTS OF CYCLE TIMES 10-92
10 3 19 1 CHECKS AND ADJUSTMENTS OF BOOM LOWERING SPEED (FSA) 10-92
10 3 19 2 CHECKS AND ADJUSTMENTS OF BOOM LOWERING SPEED (BHA) 10-96
10 3 19 3 CHECKS AND ADJUSTMENTS OF STICK RETRACT SPEED (FSA) 10-100
10 3 19 4 CHECKS AND ADJUSTMENTS OF STICK RETRACT SPEED (BHA) 10-104
10 3 19 5 CHECKS AND ADJUSTMENTS OF BUCKET DUMP SPEED (FSA) 10-108
10 3 19 6 CHECKS AND ADJUSTMENTS OF BUCKET DUMP SPEED (BHA) 10-112
10 3 19 7 CHECKS AND ADJUSTMENT OF BUCKET CURL SPEED (BHA) 10-116
10 3 19 8 CHECKS AND ADJUSTMENTS OF CLAM CLOSE SPEED (FSA) 10-120
10 4 HYDRAULICS FOR THE SLEW CIRCUIT 10-122
10 4 1 SLEW CIRCUIT WITH VARIABLE SLEW MOTORS 10-122
10 4 2 SLEW MOTOR (VARIABLE DISPLACEMENT) 10-126
10 4 2 1 HYDRAULIC SLEW MOTOR – DISPLACEMENT CONTROL 10-128
10 4 3 SLEW GEARBOX TYPE 2063 10-130
10 4 4 SLEW GEARBOX TYPE 632770 10-132
10 4 5 SLEW PARKING BRAKE (ON SLEW GEAR TYPE 2063) 10-134
10 4 6 SLEW PARKING BRAKE (ON SLEW GEAR TYPE 632770) 10-136
10 4 7 SLEW BRAKE VALVE 10-138
10 4 8 FLUSHING CIRCUIT 10-142
10 4 9 ELECTRIC / HYDRAULIC FLOWCHART “SLEW LEFT” FSA 10-144
10 4 10 ELECTRIC / HYDRAULIC FLOWCHART “SLEW LEFT” BHA 10-146
10 4 11 ELECTRIC / HYDRAULIC FLOWCHART “SLEW RIGHT” FSA 10-148
10 4 12 ELECTRIC / HYDRAULIC FLOWCHART “SLEW RIGHT” BHA 10-150
10 4 13 CHECKS AND ADJUSTMENTS FOR THE SLEW CIRCUIT 10-152
SHOP-10 35013-xD-GB-0 PC7000-11 T4 TOC – 7
10 4 13 1 PRESSURE CHECKS & ADJUSTMENTS – DOUBLE STAGE VALVE
(DSV) 10-153
10 4 13 2 CHECKS & ADJUSTMENTS – BRAKE PILOT PRESSURE 10-155
10 4 13 3 CHECKS & ADJUSTMENTS – SLEW SPEED 10-156
10 4 14 FUNCTION CHECK FOR HYDRAULIC SLEW BRAKE 10-158
10 4 15 FUNCTION CHECK FOR SLEW PARKING BRAKE 10-160
10 4 15 1 SLEW PARKING BRAKE RELEASE PRESSURE CHECK 10-160
10 5 HYDRAULICS FOR THE TRAVEL CIRCUIT 10-162
10 5 1 TRAVEL CIRCUIT 10-162
10 5 2 TRAVEL MOTOR 10-166
10 5 3 ROTARY JOINT 10-168
10 5 4 TRAVEL GEARBOX 10-170
10 5 4 1 TRAVEL GEARBOX TYPE 2063 10-170
10 5 4 2 TRAVEL GEARBOX TYPE 631053 10-172
10 5 5 TRAVEL PARKING BRAKE 10-174
10 5 5 1 TRAVEL PARKING BRAKE ON TRAVEL GEAR TYPE 2063 10-174
10 5 5 2 TRAVEL PARKING BRAKE ON TRAVEL GEAR TYPE 631053 10-175
10 5 5 3 TRAVEL BRAKE VALVE 10-176
10 5 6 ELECTRIC / HYDRAULIC FLOWCHART “TRAVEL FORWARD” 10-178
10 5 7 ELECTRIC / HYDRAULIC FLOWCHART “TRAVEL BACKWARDS” 10-180
10 5 8 CHECKS AND ADJUSTMENTS 10-182
10 5 8 1 CHECKS AND ADJUSTMENTS FOR TRAVEL CIRCUIT 10-182
10 5 8 2 FUNCTION CHECK FOR THE TRAVEL PARKING BRAKE 10-185
11 HYDRAULIC TRACK TENSIONING SYSTEM 11-1
11 1 GENERAL 11-2
11 2 FUNCTIONAL DESCRIPTION 11-6
11 3 DOUBLE STAGE VALVE 11-8
11 4 TENSIONING CYLINDER 11-10
11 5 ADJUSTMENTS / CHECKS 11-12
12 ACCESS STAIRWAY, HYDRAULICALLY OPERATED 12-1
12 1 OVERVIEW 12-2
12 2 FUNCTION OF THE HYDRAULICALLY OPERATED ACCESS STAIRWAY 12-4
12 3 ADJUSTMENTS / CHECKS 12-8
13 CENTRAL REFILLING SYSTEM (SERVICE ARM) 13-1
13 1 REFILLING ARM LOCATION 13-2
13 2 FUNCTION 13-4
14 HINTS FOR READING THE HYDRAULIC DIAGRAM 14-1
14 1 GENERAL 14-2
14 2 HYDRAULIC SYMBOLS 14-4
14 2 1 LINES, UNIONS 14-5
TOC – 8 PC7000-11 T4 SHOP-10 35013-xD-GB-0
14 2 2 COMPONENTS, VALVES 14-7
14 2 3 SENSORS 14-7
14 2 4 VALVES, VALVE COMPONENTS 14-8
14 2 5 PUMP, MOTOR, CYLINDER 14-12
15 HINTS FOR READING THE ELECTRIC WIRING DIAGRAM 15-1
15 1 GENERAL 15-2
15 2 REFERENCE CODE OF THE ELECTRICAL COMPONENTS 15-3
15 2 1 AREA CODE 15-3
15 2 2 COMPONENT IDENTIFYING LETTER 15-4
15 3 GRAPHICAL SYMBOLS 15-5
15 4 CONCEPT OF THE WIRING DIAGRAM 15-10
15 4 1 COVER PAGE OF THE KOMATSU W/D 15-10
15 4 2 EXAMPLE 1 FROM THE SCHEMATICS IN THE W/D 15-12
15 4 3 EXAMPLE 2 FROM THE SCHEMATICS IN THE W/D 15-14
15 4 4 TABLE OF CONTENTS IN THE W/D (PAGE 1 OF 2) 15-16
15 4 5 LOCATION LIST 15-18
15 4 6 CROSS REFERENCE LIST FOR ELECTR COMPONENTS IN THE W/D 15-20
15 4 7 CROSS REFERENCE LIST FOR TERMINALS IN THE W/D 15-22
15 4 8 CROSS REFERENCE LIST FOR CONNECTORS IN THE W/D 15-24
15 4 9 CROSS REFERENCE LIST FOR TERMINAL BOARDS IN THE W/D 15-26
15 4 10 CONNECTION TABLE 15-28
15 5 CABLE AND CONNECTOR MARKING 15-30
15 6 CABLE COLOR IDENTIFICATION 15-32
16 MONITORING & CONTROL SYSTEM 16-1
16 1 CONTROLLER SYSTEM OVERVIEW 16-2
16 2 SYSTEM LAYOUT 16-4
16 2 1 CAN #1 OVERVIEW 16-4
16 2 2 CAN #2 OVERVIEW 16-5
16 2 3 CAN #0 OVERVIEW 16-6
16 2 4 CAN #0 AT 52K014-1/-2 16-6
16 2 5 CAN #3 OVERVIEW 16-6
16 3 INTERFACE CONNECTION 16-7
16 3 1 GENERAL DESCRIPTION 16-8
16 4 MACHINE MONITOR – OPERATOR LEVEL 16-9
16 5 MAIN GAUGE SCREENS 16-10
16 6 OPERATOR MENU / TABS / FUNCTION OF KEYS F1 F6 16-14
16 6 1 OPERATOR MENU → SHOVEL PAYLOAD 16-16
16 6 2 OPERATOR MENU → ECO GUIDANCE – OPERATION RECORDS 16-18
16 6 3 OPERATOR MENU → ECO GUIDANCE – AVERAGE FUEL CONSUMPTION LOGS 16-20
16 6 4 OPERATOR MENU → MACHINE SETTING 16-22
16 6 5 OPERATOR MENU → AFTERTREATMENT CLEANING 16-24
16 6 6 OPERATOR MENU → SCR INFORMATION 16-30
16 6 7 OPERATOR MENU → MAINTENANCE 16-34
16 6 7 1 RESET OF ’REMAINING TIME’ TILL NEXT MAINTENANCE INTERVAL 16-36
SHOP-10 35013-xD-GB-0 PC7000-11 T4 TOC – 9
16 6 7 2 USAGE LIMITATION 16-37
16 6 8 OPERATOR MENU → MONITOR SETTING – SCREEN ADJUSTMENT 16-39
16 6 9 OPERATOR MENU → MONITOR SETTING – CLOCK ADJUSTMENT – CALENDER 16-40
16 6 10 OPERATOR MENU → MONITOR SETTING – CLOCK ADJUSTMENT – TIME 16-41
16 6 11 OPERATOR MENU → MONITOR SETTING – CLOCK ADJUSTMENT –
12H/24H MODE 16-42
16 6 12 OPERATOR MENU → MONITOR SETTING – CLOCK ADJUSTMENT –
DAYLIGHT SAVING TIME 16-43
16 6 13 OPERATOR MENU → MONITOR SETTING – LANGUAGE 16-44
16 6 14 OPERATOR MENU → MONITOR SETTING – ID KEY INFORMATION 16-45
16 7 STATUS INDICATION AND ERRORS ON THE OPERATOR LEVEL 16-46
16 7 1 PROMPTS (STATUS INDICATION) 16-46
16 7 2 CAUTIONS 16-47
16 7 3 EMERGENCY SHUTDOWN SCREEN 16-48
16 7 4 FAULT LEVELS FOR ERROR MESSAGES 16-50
16 7 5 ACTION CODE LEVEL L01 16-51
16 7 6 ACTION CODE LEVEL L02 16-52
16 7 7 ACTION CODE LEVEL L03 16-53
16 7 8 ACTION CODE LEVEL L04 16-54
16 7 9 ERROR LIST 16-55
16 8 TABLE OF FAILURE CODES 16-56
16 8 1 TABLE OF FAILURE CODES FOR MECHANICAL SYSTEMS PC7000-11 T4 16-56
16 8 2 TABLE OF FAILURE CODES FOR ELECTRICAL SYSTEMS PC7000-11 T4 16-58
16 8 3 FAILURE CODES WITHOUT MONITOR INDICATION 16-72
16 8 4 ADDITIONAL TEXT INFORMATION FOR ACTION CODES 16-72
16 9 TABLE OF C-CODES – DIESEL ENGINES QSK50 T4 16-74
16 10 FLOW CHARTS OF MACHINE MONITOR SCREENS 16-92
16 10 1 FLOW CHART OPERATOR LEVEL 16-92
16 10 2 FLOW CHART SERVICE LEVEL 16-93
16 11 MACHINE MONITOR – SERVICE LEVEL 16-94
16 11 1 ENTERING THE SERVICE LEVEL 16-94
16 11 2 KEY SYMBOLS (F1 F6) ON THE SERVICE LEVEL 16-96
16 11 3 SERVICE MENU SELECTION SCREENS 16-97
16 12 SERVICE MENU – ITEM 01 MONITORING / CUSTOM 16-98
16 12 1 MONITORING LIST FOR: ENG1 CONTROLLER 16-98
16 12 2 MONITORING LIST FOR: ENG2 CONTROLLER 16-100
16 12 3 MONITORING LIST FOR: PUMP1 CONTROLLER 16-102
16 12 4 MONITORING LIST FOR: PUMP2 CONTROLLER 16-105
16 12 5 MONITORING LIST FOR: VALVE0 CONTROLLER 16-108
16 12 6 MONITORING LIST FOR: VALVE1 CONTROLLER 16-111
16 12 7 MONITORING LIST FOR: VALVE2 CONTROLLER 16-114
16 12 8 MONITORING LIST FOR: MON (MONITOR) 16-116
16 12 9 MONITORING LIST FOR: KOM PLS (K+ CONTROLLER) 16-118
16 12 10 HOW TO PERFORM THE MONITORING FUNCTION 16-120
16 13 SERVICE MENU – ITEM 02 PM CLINIC 16-122
16 13 1 PM CLINIC (GENERAL) 16-122
16 13 2 PM CLINIC (POWER CHECK) 16-123
16 13 3 FUNCTIONS OF PM CLINIC (POWER CHECK) 16-124
TOC – 10 PC7000-11 T4 SHOP-10 35013-xD-GB-0
16 14 SERVICE MENU – ITEM 03 ABNORMALITY RECORD 16-126
16 14 1 RESET ERROR MESSAGES 16-127
16 15 SERVICE MENU – ITEM 04 MAINTENANCE RECORD 16-128
16 16 SERVICE MENU – ITEM 05 MAINTENANCE MODE SETTING 16-129
16 17 SERVICE MENU – ITEM 06 SNAP SHOT 16-130
16 18 SERVICE MENU – ITEM 07 PHONE NUMBER ENTRY 16-131
16 19 SERVICE MENU – ITEM 08 DEFAULT 16-132
16 20 SERVICE MENU – ITEM 09 UNIT 16-134
16 21 SERVICE MENU – ITEM 10 ADJUSTMENT 16-136
16 21 1 ADJUSTMENTS FOR: PUMP1 CONTROLLER 16-136
16 21 2 ADJUSTMENTS FOR: PUMP2 CONTROLLER 16-140
16 21 3 PUMP SOL ’MIN’ CURRENT VALUES ACCORDING TO PUMP TYPE PLATE 16-143
16 21 4 PUMP SOL ’MAX’ CURRENT VALUES ACCORDING TO PUMP TYPE PLATE 16-144
16 21 5 ADJUSTMENTS FOR: VALVE0 CONTROLLER 16-145
16 21 6 ACCEL & DECEL TIMES 16-151
16 21 7 ADJUSTMENTS FOR: VALVE2 CONTROLLER 16-152
16 21 8 ADJUSTMENTS FOR: KOM PLS CONTROLLER 16-153
16 21 9 ADJUSTMENTS FOR: MON (MONITOR) 16-154
16 21 9 1 USING THE IDLING STOP TIMER 16-155
16 22 SERVICE MENU – ITEM 11 MACHINE CONFIGURATION 16-156
16 22 1 DETAILS OF MACHINE CONFIGURATION FOR PC7000-11 T4 16-157
16 22 2 CHANGING LEVER CONTROL FROM EURO TO KMG 16-158
16 22 2 1 CHANGING LEVER CONTROL FROM KMG TO EURO 16-158
16 22 3 CHANGING ATTACHMENT TYPE FROM FSA TO BHA 16-160
16 22 3 1 CHANGING ATTACHMENT TYPE FROM BHA TO FSA 16-160
16 22 4 IN CASE OF PROBLEMS DURING CHANGING PROCEDURE FOR LEVER
CONTROL OR ATTACHMENT TYPE 16-161
16 22 5 HYDRAULIC OIL & PTO GEAR OIL DEFINITION TABLES 16-162
16 22 5 1 HYDRAULIC OIL TEMPERATURE CHARTS 16-162
16 22 5 2 PTO GEAR OIL TEMPERATURE CHARTS 16-163
16 23 SERVICE MENU – ITEM 12 ABUSE FUNCTION SETTING 16-164
16 24 AUTOMATIC ENGINE SPEED CONTROL 16-165
16 24 1 AUTO-DECELERATION MODE 16-165
16 24 2 AUTO LOW IDLE MODE 16-165
16 24 3 IDLING STOP TIMER 16-166
16 25 KOMTRAX PLUS CONTROLLER (UM600) 16-167
16 26 CR720 CONTROLLER 16-171
16 26 1 LOCATION OF CR720 CONTROLLERS 16-171
16 27 CONTROLLER REPLACEMENT PROCEDURE 16-173
16 27 1 SEQUENCE OF THE CONTROLLER REPLACEMENT PROCEDURE 16-173
16 27 2 AFTER CONTROLLER REPLACEMENT 16-174
17 LUBRICATION SYSTEM 17-1
17 1 GENERAL OVERVIEW SLS & CLS1/2 17-2
17 1 1 GENERAL DESCRIPTION 17-3
17 2 BASIC FUNCTION OF LUBRICATION SYSTEMS 17-4
SHOP-10 35013-xD-GB-0 PC7000-11 T4 TOC – 11
17 3 LUBRICATION SYSTEMS (SLS & CLS1/2) 17-6
17 3 1 LUBRICATION PUMP STATION 17-8
17 3 2 GENERAL INFORMATION ON CLS1/2 17-10
17 3 3 GENERAL INFORMATION ON SLS 17-10
17 3 4 MANUAL LUBE ACTIVATION 17-10
17 4 LUBRICATION CYCLE 17-11
17 4 1 OPERATION AND CONTROL 17-11
17 4 2 LUBRICATION CYCLE – PROCESSING 17-12
17 4 3 TIME SEGMENTS & SWITCH POINTS OF A LUBRICATION CYCLE 17-13
17 4 4 LUBRICATION MODES 17-14
17 4 4 1 AUTOMATIC LUBRICATION MODE 17-14
17 4 4 2 MANUAL LUBRICATION MODE 17-14
17 4 4 3 REDUCED PAUSE TIME FOR SERVICE 17-14
17 5 HYDRAULICALLY DRIVEN LUBE PUMP 17-16
17 5 1 ADJUSTMENT OF LUBE PUMP SPEED 17-18
17 5 1 1 STROKE SPEED ADJUSTMENT 17-19
17 5 1 2 WORKING PRESSURE 17-19
17 6 LUBRICANT INJECTORS 17-20
17 6 1 TIGHTENING TORQUES FOR FITTINGS AT GREASE INJECTORS 17-21
17 6 2 DESCRIPTION 17-21
17 6 3 ADJUSTMENT OF LUBRICANT OUTPUT 17-22
17 6 4 OPERATION PRINCIPLE OF LUBRICANT INJECTORS 17-24
17 6 4 1 FUNCTION DESCRIPTION 17-25
17 6 5 CONNECTION OF TWO OR MORE INJECTORS 17-26
17 7 VENT VALVE & GREASE OUTLET FILTER 17-28
17 7 1 VENT VALVE DESCRIPTION 17-29
17 8 END-LINE SWITCH 17-30
17 8 1 DESCRIPTION 17-31
17 8 2 CLS1/2 END-LINE SWITCH ADJUSTMENT 17-32
17 8 3 SLS END-LINE SWITCH ADJUSTMENT 17-34
17 9 LUBRICANT LEVEL SENSORS 17-36
17 9 1 DESCRIPTION 17-37
17 9 2 CHECKS 17-37
17 10 COMMISSIONING 17-38
17 10 1 COMMISSIONING OF CLS1/2 LUBRICATION SYSTEM 17-38
17 10 2 FINE ADJUSTMENT 17-39
17 10 3 COMMISSIONING OF SLS LUBRICATION SYSTEM 17-40
18 DEEP TEMPERATURE EQUIPMENT (OPTION) 18-1
18 1 GENERAL INFORMATION 18-2
18 1 1 INTRODUCTION 18-2
18 1 2 DEEP TEMPERATURE COMPONENTS OVERVIEW 18-2
18 1 3 POWER SUPPLY PRECONDITIONS FOR PREHEATING 18-3
18 1 4 POWER REQUIREMENTS FOR PREHEATING SYSTEMS 18-4
18 2 PREHEATING PROCEDURE 18-5
18 2 1 GLOBAL FLOW CHART OF THE PREHEATING PROCEDURE 18-5
18 2 2 STARTING THE PREHEATING PROCEDURE 18-6
TOC – 12 PC7000-11 T4 SHOP-10 35013-xD-GB-0
18 2 3 PREHEATING OF OPERATOR’S CAB AND DIESEL ENGINE [COOLANT SYSTEM] 18-7
18 2 4 PREHEATING OF LUBRICANTS AND SUPERSTRUCTURE (DIESEL)
[ELECTRIC SYSTEM] 18-8
18 3 CONSTANT HEATING OF TRAVEL MOTORS (TTT EQUIPMENT BELOW-40°C ONLY) 18-9
18 4 COMPONENT LOCATION 18-10
18 4 1 ELECTRIC HEATING ELEMENTS FOR HYDRAULIC & BATTERIES
[ELECTRIC EXCAVATOR] 18-10
18 4 2 ELECTRIC HEATING ELEMENTS FOR HYDRAULICS [DIESEL EXCAVATOR] 18-12
18 4 3 ELECTRIC HEATING ELEMENTS FOR ENGINES & BATTERIES
[DIESEL EXCAVATOR] 18-14
18 5 COMPONENTS OF TT EQUIPMENT 18-16
18 5 1 PREHEATING COMPONENTS ON A DIESEL EXCAVATOR 18-16
18 5 2 PREHEATING COMPONENTS ON AN ELECTRIC EXCAVATOR 18-17
18 5 3 WIRING DIAGRAMS FOR PREHEATING SYSTEMS 18-18
18 5 3 1 WIRING DIAGRAM “HYDRAULIC OIL TANK PREHEATING” PART 1 OF 3 18-18
18 5 3 2 WIRING DIAGRAM “HYDRAULIC OIL TANK PREHEATING” PART 2 OF 3 18-19
18 5 3 3 WIRING DIAGRAM “HYDRAULIC OIL TANK PREHEATING” PART 3 OF 3 18-20
18 5 3 4 WIRING DIAGRAM “SUCTION OIL MANIFOLD PREHEATING” 18-21
18 5 3 5 WIRING DIAGRAM “PTO PREHEATING” 18-22
18 5 3 6 WIRING DIAGRAM “BATTERY HEATER PADS” 18-23

IMAGES PREVIEW OF THE MANUAL: