Komatsu HYDRAULIC MINING SHOVEL PC3000-6 Shop Manual 06208-upD-GB-04 – PDF DOWNLOAD

Description

Komatsu HYDRAULIC MINING SHOVEL PC3000-6 Shop Manual 06208-upD-GB-04 – PDF DOWNLOAD

FILE DETAILS:

Komatsu HYDRAULIC MINING SHOVEL PC3000-6 Shop Manual 06208-upD-GB-04 – PDF DOWNLOAD

Language : English
Pages :1455
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu HYDRAULIC MINING SHOVEL PC3000-6 Shop Manual 06208-upD-GB-04 – PDF DOWNLOAD

SERIAL NUMBER 06208 and up
46151 and up

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.
The safety information in this manual does not replace any safety rules or laws in your area.
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

TABLE OF CONTENTS:

Komatsu HYDRAULIC MINING SHOVEL PC3000-6 Shop Manual 06208-upD-GB-04 – PDF DOWNLOAD

SERIAL NUMBER 06208 and up
46151 and up

COVER 1
00 Foreword 5
Introduction 6
Safety Instructions 11
01 Specifications 67
Specifications PC3000 69
10 Structure, Function 77
01 INTRODUCTION 85
02 SAFETY 91
03 SPECIFICATIONS 141
04 MAIN ASSEMBLY GROUPS 155
41 General layout 156
42 Superstructure 158
43 Power House 160
44 Hydraulic Oil Reservoir 162
45 Hydraulic Oil Cooler 164
46 Fuel tank (Fuel reservoir) 166
47 Counter weight 168
48 Cab support 170
49 Operators cab 172
410 Control blocks 174
411 Swing gears 176
412 Under carriage 178
05 DRIVE 181
51 Prime drive assembly 182
52 Engine and gearbox mount 184
53 Torque supports 189
54 Radiator fan Drive Assy 190
55 Pump distributor gearbox (PTO) 192
551 Spline shaft housing 194
552 PTO lubrication and cooling 196
553 PTO valve adjustments 198
56 Coupling 202
Oil filled type coupling “Geisslinger” 203
57 Air cleaner 204
06 HYDRAULIC OIL RESERVOIR 207
61 Hydraulic oil reservoir 208
62 Return and leak oil filter 212
63 Breather Filter 216
64 Location of electrical components 218
65 Transfer Pump, hydraulic service 220
07 HYDRAULIC OIL COOLING 229
71 General 230
72 Hydraulic oil cooling circuit 232
73 Back pressure valve adjustment 236
74 Fan drive 238
741 Fan pump 240
742 Pressure relieve valve 241
743 Temperature relay 243
45 Cooler fan drive adjustment 192
08 CONTROLLING 247
81 Pilot pressure supply and adjustment 248
811 Pilot control arrangement 250
812 Pilot pressure adjustment 252
813 Check of Control Pressure 254
82 Slew brakes 256
83 Travel parking brake 259
84 Check of the pilot control logic 261
841 Check sheet FSA Page 1 263
842 Check sheet BHA Page 1 276
09 COMPONENTS 285
91 Main control block and valve arrangement 286
911 FSA arrangement 288
912 BHA arrangement 292
92 Distributor manifold 296
921 Front shovel attachment FSA 296
922 Back hoe attachment BHA 298
923 SRV with throttle check valve 300
924 Anti cavitation valve (check valve) 302
93 Main control block 304
931 Load holding valve 310
932 High pressure filter 312
933 Pressure relieve valves and anti-cavitation valve 314
934 Pressure relieve valves and anti-cavitation valve 316
94 Compact valve blocks 318
95 Compact valve blocks 320
96 Auxiliary gear pumps 322
97 Hydraulic cylinder 324
98 Swing ring 326
10 MAIN HYDRAULIC PUMPS AND PUMP REGULATION 329
101 General 330
1011 Pump location 332
102 Main pump operating principles 334
1021 Main pump function 339
103 Main pump checks and adjustments 342
1031 Peak point diesel engine test 342
1032 Pressure transducer test 344
1033 Cut off function 345
1034 Pump regulation 347
1035 Swing pump volume reduction 348
104 Electronic pump regulation 349
105 Pump Controller CR700 352
106 Multi Monitor 354
107 Multimonitor software instruction 356
1071 Multimonitor main control 356
1072 Service Menu screen 356
1073 Monitoring (menu item 01) 357
1074 Abnormality Record (menu item 02) 358
1075 Default (menu item 03) 361
1076 Adjustment (menu item 04) 362
1077 Display Setup (menu item 05) 364
1078 Table of fault messages and adjustments 365
108 Trouble shooting pump and pump regulation 374
11 OPERATING HYDRAULIC 375
111 General layout 376
112 Floating function of boom and stick only FSA 380
113 Check and Adjustments for MRV’s and SRV’s 382
1131 Check and Adjustments for MRV 384
1132 Check and Adjustment for SRV’s 386
1133 Check and adjustment of the throttle check valves 394
114 Hydraulic for the swing circuit 396
1141 Hydraulic for the swing circuit 400
1142 Slew gear box L & S 404
1143 Slew parking brake 408
1144 Slew service brake valve 412
1145 Checks and adjustment of the slew pressure valve 417
115 Travel circuit 420
1151 Rotary joint 422
1152 Travel motor A2FMt 424
1153 Travel gear 426
1154 Travel parking brake 428
1155 Travel control function 430
1156 Check and Adjustment SRV travel system 433
12 TRACK TENSION SYSTEM 435
121 General layout 436
122 Track tensioning function 438
1221 Cushioning 440
1222 Pressure Increasing valve PIV 442
123 Track tensioning adjustment 446
1231 Track tensioning function check 448
13 ACCESS LADDER HYDRAULICALLY OPERATED 451
131 Access ladder 452
132 Access ladder functional description 454
14 CENTRAL REFILLING SYSTEM 459
1401 Functional description 460
15 HINTS FOR READING THE HYDRAULIC CIRCUIT DIAGRAM 465
151 General 466
152 Symbolic 468
1521 Lines, unions 470
1522 Components, valves 471
1523 Sensors 472
1524 Valves, valve components 472
1525 Pump, motor, cylinder 476
16 HINTS FOR READING THE ELECTRIC CIRCUIT DIAGRAM 481
161 Designation of electrical components 483
162 Electric symbols 484
163 Symbols 486
1631 Drawing concept 488
1632 Reading of the circuit diagram 494
17 ELECTRONIC TEXT MONITORING SYSTEM ETM 499
171 General Function 500
18 AUTOMATIC LUBRICATION SYSTEM 503
181 General Function 504
182 Function of a lubrication cycle 506
183 Lubrication pump drive 514
184 Lubrication pump 516
1841 Adjustments lubricating pump speed 518
1842 Adjustments lubricating pump pressure 520
185 Lubricant Injector (metering valve) 522
1851 Connection of one or more injectors 524
1852 Function lubrication injector (metering valve) 526
186 End line pressure switch 530
187 Lubricant in line filter 532
188 Lubricant level sensor 534
1881 Capacitive digital type for machines with ETM 534
1882 Capacitive analog type for machines with PLC 536
189 Lubrication system function and controlling 538
1891 Central Lubrication System (CLS) function and controlling with ETM system (PC 3000) 540
1892 Swing ring lubrication system (SLS) function and controlling with ETM system (PC3000) 544
1810 Adjustment of the lubrication system with ETM 551
1811 Trouble shooting lubricating system 552
18111 Lubrication pump cylinder does not move 553
18112 Lubricant pressure built up very slowly or not at all 555
18113 Insufficient lubricant supply to one or more attachment bearings 555
18114 Insufficient lubricant at the swing ring gear 557
40 Troubleshooting 565
Table of Contents 567
Introduction 571
Safety Notes 572
Description of this Troubleshooting Manual 572
General Precautions 573
Electrical Parts 593
Componant Locations 594
Engine Electrical Parts 596
Electrical Parts On PTO, etc 598
Electrical Parts on Pilot Control Frame 600
Electrical Parts on Main Hydraulic Reservoir 602
Electrical Parts on Switch Board X2 604
Electrical Parts on Hydraulic Ldder 606
Electrical Parts of Automatic Lube System 608
Electrical Parts on Air Cleaner and Fuel Tank 612
Overview Connector Types 613
Standard Value Table for Electrical Componants 616
PT100 Temperature Charts 626
Troubleshooting by Trouble Code 629
Message 1 – Gear Lubrication out of Function (PTO) 630
Message 2 – Engine Air Filter Restricted 633
Message 3 – Filter for Control Oil Restricted 635
Message 4 – Oil Tank Breather Filter Restricted 638
Message 5 – Return Oil Filter Restricted 641
Message 6 – Leak Oil Filter Restricted 644
Message 7 – Hydraulic Oil Temperature Too High 647
Message 9 – Low Idle Too High Coolant Temperature 653
Message 10 – Engine Shutdown: Too Low Engine Oil Temperature 658
Message 14 – Too Low Hydraulic Oil Level 663
Message 15 – Caution, Slew Gear House Brake On 667
Message 16 – Caution, Travel Gear House Brake On 672
Message 17 – No Clearance For Starting, Shift Engine to Low Idle 677
Message 18 – Central Lube System Fault 678
Message 19 – Slew Ring Gear Lubrication Fault 685
Message 20 – Pilot Control Cut-Out 693
Message 21 – Central Lube System Empty Grease Barrel 695
Message 22 – Central Lube System Empty Grease Barre 695
Message 24 – Engine Problem: Stop All Control 702
Message 32 – PTO Gear Lube Filter Restricted 707
Message 33 – Cooler Fan Drive Filter Restricted 710
Message 39 – Engine Shutdown Main Shut-Off (Gate) Volve 713
Message 42 – Too Low Coolant Pressure 717
Message 43 – Engine Shutdown: Emergency Stop Switch Actuated 722
Message 44 – Engine Shutdown Safety Switch Actuated 726
Message 45 – Warning Signal from Engine Control Module 730
Message 48 – Too High PTO Gear Oil Temperature 733
Message 50 – Caution, Pull Switch From Ground Man Actuated 736
Message 51 – Engine Shutdown: Pull Switch From Ground Man Actuated 737
Message 52 – Load Limit Clam Defective 739
Message 53 – Pressure Switch of CLS Actuated 742
Message 55 – Refill Hyrdaulic Oil 743
Message 57 – Load Limit Regulation Fault 747
Message 58 – Strainer Oil Cooler Restricted 748
Message 59 – CLS Refill Grease Container 750
Message 60 – SLS Refill Grease Barrel 750
Troubleshooting by Symptoms 757
Symptoms of the Hydraulic System 778
50 Disassembly and Assembly 821
1 INTRODUCTION 835
11 Contents of the binder 836
12 Foreword 837
121 Service 838
2 SAFETY 839
3 SUPERSTRUCTURE 865
31 Superstructure overview 866
32 Engine House 868
33 Diesel Engine 872
34 Torsion Coupling 898
35 PTO 909
36 Hydraulics 934
37 Slew Drive1021
38 Lubrication Pumps1068
39 Operaotor’s Cab1070
310 Cab Base1085
311 Access Ladder1090
312 Counterweight1097
313 Superstructure Lifting1103
314 Fuel Tank1110
4 UNDERCARRIAGE1117
41 Undercarriage Overview1118
42 Travel System1120
43 Car Body1182
5 ATTACHMENT1205
52 Face Shovel1282
521 Using the Installation Tools for Hydraulic Cyllinders1283
522 Boom1284
5221 Removal of the Boom1284
5222 Replacement of the Boom1291
5223 Removal of the Boom Cylinders1296
5224 Replacement of the Boom Cylinders1301
523 Stick1304
5231 Removal of the Stick1304
5232 Replacement of the Stick1308
5233 Removal of the Stick Cylinders1312
5234 Replacement of the Stick Cylinders1317
524 Bull Clam Bucket1320
5241 Removal of the Bull Clam Bucket1322
5242 Replacement of the Bull Clam Bucket1326
5243 Removal of the Bucket Cylinders1328
5244 Replacement of the Bucket Cylinders1333
5245 Removal of the Clam Cylinders1338
5246 Replacement of the Clam Cylinders1343
525 graound Engaging Tools (GET)1346
5251 Removal of the Ground Engaging Tools1346
526 Hydraulic Hoses on the Face Shovel Attachment1348
5261 Substitute the Boom Arc Hoses1348
5262 Substitute the Boom Cylinder Hoses1352
5263 Substitute the Stick Arc Hoses1358
5264 Substitute the Stick Cylinder Hoses1364
5265 Substitute the Bucket Cylinder Hoses1368
5266 Substitute the Clam Cylinder Hoses1372
51 Backhoe1206
511 Boom1208
5111 Removal of the Boom1208
5112 Replacement of the boom1212
5113 Removal of boom cylinders1214
5114 Replacement of boom cylinders1220
513 Stick1224
5121 Removal of the Stick1224
5132 Replacement of Stick1229
5133 Removal of Stick Cylinders1232
5124 Replacement of Stick cylinders1238
514 Bucket1242
5131 Removal of the bucket1242
5132 Replacement of the bucket1245
5133 Removal of Bucket Cylinders1246
5134 Replacement of Bucket Cylinders1253
514 Bucket link rod and steering rods1256
5141 Removal of the bucket link rod1256
5142 Replacement of the bucket link rod1258
5143 Removal of the steering rods1259
5144 Replacement of the steering rod1262
515 Ground engaging tools (GET)1263
5151 Removal and replacement of the GET1263
516 Hydraulic hoses at the attachment1266
5161 Substitute the boom arc hoses1266
5162 Substitute the boom cylinder hoses1270
5163 Substitute the stick cylinder hoses1274
5164 Substitute the bucket cylinder hoses1278
53 Metering Valves1380
531 Operation test of the metering Valves1381
532 Removal of the Metering Valves1382
Unbenannt1384
54 Cylinder Bypass Test1385
6 SERVICE INFORMATION1387
61 Fuel and Lubricants1388
62 Filling capacities1388
63 Work Instructions1390
631 Surface Coating with Interzinc 6971390
632 remove / Install the Crawler carrier1392
64 Weight Tables1393
641 Superstructure1393
642 Undercarriage1395
643 Backhoe Attachment1396
644 Face ShoveL Attachment1397
65 Torque Charts1398
651 Metric Standard Thread1398
652 Metric Fine Thread1399
653 Cummins Motor Torques – Metric1400
654 Cummins Motor Torques – US1400
655 Flange Connections1401
66 Blind Plugs1402
661 Dummy Plates for SAE Flanges1402
662 Classification of Threads to the Nominal Width1404
663 Plugs and Fittings According to DIN 23531405
67 Conversion Table1406
671 Method of Use1406
672 Millimeter – Inch & Kilogram – Pound1407
673 Liter – US Gallon & Liter – UK Gallon1408
674 NM – FTLB1409
675 Bar – PSI – KPA – MPA1410
676 Basic Values In Ohm According to ISO 43 761411
677 Temperature1412
68 Tools1413
681 Standard Tool Case1413
682 Used Special Tools (Overview)1415
7 TOOLS CATALOGUE1417

IMAGES PREVIEW OF THE MANUAL:

S.M 21/12/24