KOMATSU PC-3000-6 HYDRAULIC MINING SHOVEL(SMPC30006219)SERIAL NUMBER PC3000-6 6219-PDF Download

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KOMATSU PC-3000-6 HYDRAULIC MINING SHOVEL(SMPC30006219)SERIAL NUMBER PC3000-6 6219

KOMATSU PC-3000-6 HYDRAULIC MINING SHOVEL(SMPC30006219)SERIAL NUMBER PC3000-6 6219-PDF DOWNLOAD:

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KOMATSU PC-3000-6 HYDRAULIC MINING SHOVEL(SMPC30006219)SERIAL NUMBER PC3000-6 6219

• With this SERVICE MANUAL KOMATSU provides you with the description of the construction and the function of the major systems of the Hydraulic Excavator PC 3000-6 D. We describe for you all functions and how to carry out the inspections and adjustments.
• Mistakes in operation and service are extremely dangerous.
• Read the OPERATION & MAINTENANCE MANUAL carefully BEFORE operating the machine.
• Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the
  machine.
• When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or
  clothes with buttons missing.
• Always wear safety glasses when hitting parts with a hammer.
• Always wear safety glasses when grinding parts with a grinder, etc.If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, glasses, cap and other clothes suited for welding work.
• When carrying out any operation with two or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator’s compartment.
• Keep all tools in good condition and learn the correct way to use them.
• Decide a place in the repair workshop to keep

Table of Contents:

KOMATSU PC-3000-6 HYDRAULIC MINING SHOVEL(SMPC30006219)SERIAL NUMBER PC3000-6 6219

MAIN MENU...............................................................................................  0
COVER...................................................................................................  1
I. INTRODUCTION.........................................................................................  3
	I.I CONTENTS OF BINDER..............................................................................  4
	I.II FOREWARD.......................................................................................  5
	I.III EXPLANATION OF ABBREVATIONS...................................................................  7
	I.IV TABLE OF CONTENTS..............................................................................  8
II. SAFETY.............................................................................................. 15
	II.I SAFETY INSTRUCTIONS............................................................................ 16
	II.II GENERAL PRECAUTIONS........................................................................... 17
	II.III PREPARATIONS FOR WORK........................................................................ 18
	II.IV PRECAUTIONS DURING WORK....................................................................... 19
III. SPECIFICATIONS..................................................................................... 21
	III.I LIFTING GEARS................................................................................. 22
	III.II STANDARD TIGHTENING TORQUE CHART............................................................. 24
	III.III CONVERSION TABLE............................................................................ 25
	III.IV EXPLANATION OF ABBREVATIONS.................................................................. 31
	III.V GENERAL SPECIFICATIONS........................................................................ 32
1. MAIN ASSEMBLY GROUPS................................................................................. 33
	1.1 General layout.................................................................................. 34
	1.2 Superstructure.................................................................................. 36
	1.3 Power House..................................................................................... 38
	1.4 Hydraulic Oil Reservoir......................................................................... 40
	1.5 Hydraulic Oil Cooler............................................................................ 42
	1.6 Fuel tank (Fuel reservoir)...................................................................... 44
	1.7 Counter weight.................................................................................. 46
	1.8 Cab support..................................................................................... 48
	1.9 Operators cab................................................................................... 50
	1.10 Control blocks................................................................................. 52
	1.11 Swing gears.................................................................................... 54
	1.12 Under carriage................................................................................. 56
2. DRIVE................................................................................................ 59
	2.1 Prime drive assembly............................................................................ 60
	2.2 Engine and gearbox mount........................................................................ 62
	2.3 Torque supports................................................................................. 65
	2.4 Radiator fan Drive Assy......................................................................... 66
	2.5 Pump distributor gearbox (PTO).................................................................. 68
		2.5.1 Spline shaft housing...................................................................... 70
		2.5.2 PTO lubrication and cooling............................................................... 72
		2.5.3 PTO valve adjustments..................................................................... 74
	2.6 Coupling........................................................................................ 78
	2.7 Air Filter...................................................................................... 80
3. HYDRAULIC OIL RESERVOIR.............................................................................. 83
	3.1 Hydraulic oil reservoir......................................................................... 84
	3.2 Return and leak oil filter...................................................................... 88
	3.3 Breather Filter................................................................................. 92
	3.4 Location of electrical components............................................................... 94
4. HYDRAULIC OIL COOLING................................................................................ 97
	4.1 General......................................................................................... 98
	4.2 Hydraulic oil cooling circuit...................................................................100
	4.3 Back pressure valve adjustment..................................................................104
	4.4 Fan drive.......................................................................................106
		4.4.1 Fan pump..................................................................................108
		4.4.2 Pressure relieve valve....................................................................109
		4.4.3 Temperature relay.........................................................................111
	4.5 Cooler fan drive adjustment.....................................................................112
5. CONTROLLING..........................................................................................115
	5.1 Pilot pressure supply and adjustment............................................................116
		5.1.1 Pilot control arrangement.................................................................119
		5.1.2 Pilot pressure adjustment.................................................................121
		5.1.3 Check of Control Pressure.................................................................123
	5.2 Slew brakes.....................................................................................125
	5.3 Travel parking brake............................................................................128
	5.4 Check of the pilot control logic................................................................130
		5.4.1 Check sheet BHA Page 1....................................................................132
		5.4.2 Check sheet FSA Page 1....................................................................145
6. COMPONENTS...........................................................................................155
	6.1 Main control block and valve arrangement........................................................156
		6.1.1 FSA arrangement...........................................................................158
		6.1.2 BHA arrangement...........................................................................162
	6.2 Distributor manifold............................................................................166
		6.2.1 Front shovel attachment FSA...............................................................166
		6.2.2 Back hoe attachment BHA...................................................................168
		6.2.3 SRV with throttle check valve.............................................................170
		6.2.4 Anti cavitation valve (check valve).......................................................172
	6.3 Main control block..............................................................................174
		6.3.1 Load holding valve........................................................................182
		6.3.2 High pressure filter auxiliary filter.....................................................184
		6.3.3 High pressure filter auxiliary filter.....................................................186
		6.3.4 High pressure filter auxiliary filter.....................................................188
	6.4 Compact valve blocks............................................................................190
	6.5 Compact valve blocks............................................................................192
	6.6 Auxiliary gear pumps............................................................................194
	6.7 Hydraulic cylinder..............................................................................196
	6.8 Swing ring......................................................................................198
7. MAIN HYDRAULIC PUMPS AND PUMP REGULATION.............................................................201
	7.1 General.........................................................................................202
		7.1.1 Pump location.............................................................................204
	7.2 Main pump operating principles..................................................................206
		7.2.1 Main pump function........................................................................211
	7.3 Main pump checks and adjustments................................................................214
		7.3.1 Peak point diesel engine test.............................................................214
		7.3.2 Pressure transducer test..................................................................216
		7.3.3 Cut off function..........................................................................217
		7.3.4 Pump regulation...........................................................................219
		7.3.5 Swing pump volume reduction...............................................................220
	7.4 Electronic pump regulation......................................................................221
		7.4.1 Pump Controller CR700.....................................................................223
		7.4.2 Multi Monitor.............................................................................225
		7.4.3 Multimonitor software instruction.........................................................227
		7.4.4 Table of fault messages and adjustments...................................................234
	7.5 Trouble shooting pump and pump regulation.......................................................243
8. OPERATING HYDRAULIC..................................................................................247
	8.1 General layout..................................................................................248
	8.2 Floating function of boom and stick only FSA....................................................252
	8.3 Check and Adjustments for MRV’s and SRV’s.......................................................254
		8.3.1 Check and Adjustments for MRV.............................................................256
		8.3.2 Check and Adjustment for SRV’s............................................................258
		8.3.3 Check and adjustment of the throttle check valves.........................................266
	8.4 Hydraulic for the swing circuit.................................................................268
		8.4.1 Hydraulic for the swing circuit...........................................................272
		8.4.2 Slew gear box L & S.......................................................................276
		8.4.3 Slew parking brake........................................................................280
		8.4.4 Slew service brake valve..................................................................284
		8.4.5 Checks and adjustment of the slew pressure valve..........................................289
	8.5 Travel circuit..................................................................................292
		8.5.1 Rotary joint..............................................................................294
		8.5.2 Travel motor A2FMt........................................................................296
		8.5.3 Travel gear...............................................................................298
		8.5.4 Travel parking brake......................................................................300
		8.5.5 Travel control function...................................................................302
9. TRACK TENSION SYSTEM.................................................................................307
	9.1 General layout..................................................................................308
	9.2 Track tensioning function.......................................................................310
		9.2.1 Cushioning................................................................................312
		9.2.2 Pressure Increasing valve PIV.............................................................314
	9.3 Truck tensioning adjustment.....................................................................318
		9.3.1 Truck tensioning function check...........................................................320
10. ACCESS LADDER HYDRAULICALLY OPERATED................................................................323
	10.1 Access ladder..................................................................................324
	10.2 Access ladder functional description...........................................................326
11. CENTRAL REFILLING SYSTEM............................................................................331
	11.0.1 Functional description.......................................................................332
12. HINTS FOR READING THE HYDRAULIC CIRCUIT DIAGRAM.....................................................337
	12.1 General........................................................................................338
	12.2 Symbolic.......................................................................................340
		12.2.1 Lines, unions............................................................................341
		12.2.2 Components, valves.......................................................................343
		12.2.3 Sensors..................................................................................343
		12.2.4 Valves, valve components.................................................................344
		12.2.5 Pump, motor, cylinder....................................................................348
	Hydraulic Diagrams - 942 761 40.....................................................................352
		Hydraulic Diagrams - 942 761 40 (1/3)...........................................................352
		Hydraulic Diagrams - 942 761 40 (2/3)...........................................................353
		Hydraulic Diagrams - 942 761 40 (3/3)...........................................................354
13. HINTS FOR READING THE ELECTRIC CIRCUIT DIAGRAM......................................................361
	13.1 Designation of electrical components...........................................................363
	13.2 Electric symbols...............................................................................364
	13.3 Symbols........................................................................................366
		13.3.1 Drawing concept..........................................................................368
		13.3.2 Reading of the circuit diagram...........................................................374
	Electrical Diagrams - 942 762 40....................................................................378
		Electrical Diagrams - 942 762 40 (1/53..........................................................378
		Electrical Diagrams - 942 762 40 (2/53..........................................................379
		Electrical Diagrams - 942 762 40 (3/53..........................................................380
		Electrical Diagrams - 942 762 40 (4/53..........................................................381
		Electrical Diagrams - 942 762 40 (5/53..........................................................382
		Electrical Diagrams - 942 762 40 (6/53..........................................................383
		Electrical Diagrams - 942 762 40 (7/53..........................................................384
		Electrical Diagrams - 942 762 40 (8/53..........................................................385
		Electrical Diagrams - 942 762 40 (9/53..........................................................386
		Electrical Diagrams - 942 762 40 (10/53.........................................................387
		Electrical Diagrams - 942 762 40 (11/53.........................................................388
		Electrical Diagrams - 942 762 40 (12/53.........................................................389
		Electrical Diagrams - 942 762 40 (13/53.........................................................390
		Electrical Diagrams - 942 762 40 (14/53.........................................................391
		Electrical Diagrams - 942 762 40 (15/53.........................................................392
		Electrical Diagrams - 942 762 40 (16/53.........................................................393
		Electrical Diagrams - 942 762 40 (17/53.........................................................394
		Electrical Diagrams - 942 762 40 (18/53.........................................................395
		Electrical Diagrams - 942 762 40 (19/53.........................................................396
		Electrical Diagrams - 942 762 40 (20/53.........................................................397
		Electrical Diagrams - 942 762 40 (21/53.........................................................398
		Electrical Diagrams - 942 762 40 (22/53.........................................................399
		Electrical Diagrams - 942 762 40 (23/53.........................................................400
		Electrical Diagrams - 942 762 40 (24/53.........................................................401
		Electrical Diagrams - 942 762 40 (25/53.........................................................402
		Electrical Diagrams - 942 762 40 (26/53.........................................................403
		Electrical Diagrams - 942 762 40 (27/53.........................................................404
		Electrical Diagrams - 942 762 40 (28/53.........................................................405
		Electrical Diagrams - 942 762 40 (29/53.........................................................406
		Electrical Diagrams - 942 762 40 (30/53.........................................................407
		Electrical Diagrams - 942 762 40 (31/53.........................................................408
		Electrical Diagrams - 942 762 40 (32/53.........................................................409
		Electrical Diagrams - 942 762 40 (33/53.........................................................410
		Electrical Diagrams - 942 762 40 (34/53.........................................................411
		Electrical Diagrams - 942 762 40 (35/53.........................................................412
		Electrical Diagrams - 942 762 40 (36/53.........................................................413
		Electrical Diagrams - 942 762 40 (37/53.........................................................414
		Electrical Diagrams - 942 762 40 (38/53.........................................................415
		Electrical Diagrams - 942 762 40 (39/53.........................................................416
		Electrical Diagrams - 942 762 40 (40/53.........................................................417
		Electrical Diagrams - 942 762 40 (41/53.........................................................418
		Electrical Diagrams - 942 762 40 (42/53.........................................................419
		Electrical Diagrams - 942 762 40 (43/53.........................................................420
		Electrical Diagrams - 942 762 40 (44/53.........................................................421
		Electrical Diagrams - 942 762 40 (45/53.........................................................422
		Electrical Diagrams - 942 762 40 (46/53.........................................................423
		Electrical Diagrams - 942 762 40 (47/53.........................................................424
		Electrical Diagrams - 942 762 40 (48/53.........................................................425
		Electrical Diagrams - 942 762 40 (49/53.........................................................426
		Electrical Diagrams - 942 762 40 (50/53)........................................................427
		Electrical Diagrams - 942 762 40 (51/53)........................................................428
		Electrical Diagrams - 942 762 40 (52/53)........................................................429
		Electrical Diagrams - 942 762 40 (53/53)........................................................430
14. ELECTRONIC TEXT MONITORING SYSTEM ETM...............................................................432
	14.1 General Function...............................................................................433
15. AUTOMATIC LUBRICATION SYSTEM........................................................................436
	15.1 General Function...............................................................................437
	15.2 Function of a lubrication cycle................................................................439
	15.3 Lubrication pump drive.........................................................................447
	15.4 Lubrication pump...............................................................................449
		15.4.1 Adjustments lubricating pump speed.......................................................451
		15.4.2 Adjustments lubricating pump pressure....................................................453
	15.5 Lubricant Injector (metering valve)............................................................455
		15.5.1 Connection of one or more injectors......................................................457
		15.5.2 Function lubrication injector (metering valve)...........................................459
	15.6 End line pressure switch.......................................................................463
	15.7 Lubricant in line filter.......................................................................465
	15.8 Lubricant level sensor.........................................................................467
		15.8.1 Capacitive digital type for machines with ETM............................................467
		15.8.2 Capacitive analog type for machines with PLC.............................................469
	15.9 Lubrication system function and controlling....................................................472
		15.9.1 Central Lubrication System (CLS) function and controlling with ETM system (PC 3000)......473
		15.9.2 Swing ring lubrication system (SLS) function and controlling with ETM system (PC3000)....477
	15.10 Adjustment of the lubrication system with ETM.................................................483
	15.11 Trouble shooting lubricating system...........................................................485
		15.11.1 Lubrication pump cylinder does not move.................................................486
		15.11.2 Lubricant pressure built up very slowly or not at all...................................488
		15.11.3 Insufficient lubricant supply to one or more attachment bearings........................488
		15.11.4 Insufficient lubricant at the swing ring gear...........................................490

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