KOMATSU PC3000-1 HYDRAULIC MINING EXCAVATOR Operation & Maintenance Manual (SN:PC3000-1 6202) KOMATSU PC3000-1 – PDF DOWNLOAD

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KOMATSU PC3000-1 HYDRAULIC MINING EXCAVATOR Operation & Maintenance Manual (SN:PC3000-1 6202) KOMATSU PC3000-1

KOMATSU PC3000-1 HYDRAULIC MINING EXCAVATOR OPERATION & MAINTENANCE MANUAL (SN:PC3000-1 6202) KOMATSU PC3000-1 – PDF DOWNLOAD:

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KOMATSU PC3000-1 HYDRAULIC MINING EXCAVATOR Operation & Maintenance Manual (SN:PC3000-1 6202) KOMATSU PC3000-1

• This machine has been manufactured in accordance with advanced and up-to-date technology standards including recognized safety rules. Nevertheless, its use may constitute a risk to life and limb of the user or of third parties, or cause damage to the machine and to other material property.
• The machine must only be used in technically perfect condition in accordance with its designated use and the instructions set out in the operation manual. Only trained safety-conscious operators who are fully aware of the risks involved should operate the machine. Any functional disorders, especially those affecting the safety of the machine, should, therefore, be rectified immediately.
• The hydraulic excavator 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 and national safety regulations. Special conditions at the worksite require additional safe working precautions, follow your company’s safety instructions.
• Short traveling distances for changing the working site are considered as part of the designated use of the excavator. Using the excavator for purposes other than those mentioned above (such as object handling and use as a transport vehicle) is considered contrary to its designated use. The manufacturer/supplier cannot be held liable for any damage resulting from such use. The risk of such misuse lies entirely with the user.

TABLE OF CONTENTS:

KOMATSU PC3000-1 HYDRAULIC MINING EXCAVATOR Operation & Maintenance Manual (SN:PC3000-1 6202) KOMATSU PC3000-1

Main Menu.................................................................................  0
Cover.....................................................................................  1
Introduction..............................................................................  2
Part 1 - Operation Manual.................................................................  8
	Table of Contents - Operation Manual..................................................  8
	Section A - Explanation of Abbreviations Used in this Manual.......................... 10
	Section 1.0 - Foreward................................................................ 12
	Section 2.0 - Construction of the Excavator........................................... 14
		2. - Overall View................................................................. 14
		2.1 - Superstructure.............................................................. 16
		2.3 - Attachment.................................................................. 20
			Backhoe Attachment............................................................ 20
	Section 3.0 - Safety Instructions..................................................... 22
		Fundamental Safety Instructions................................................... 23
			1.1 - Warnings and Symbols.................................................... 23
			1.2 - Basic Operation and Designated Use of Hydraulic Excavator............... 23
			1.3 - Organizational Measures................................................. 24
			1.4 - Selection and Qualification of Personal................................. 26
			1.5 - Safety Instructions Governing Specific Operational Phases............... 27
			1.6 - Warning of Special Dangers.............................................. 32
			1.7 - Transporting and Towing - Recommissioning............................... 35
			1.8 - Special Safety Equipment................................................ 36
		Safety Harness.................................................................... 38
			Instructions for Use.......................................................... 38
			Prior to Using Harness........................................................ 40
			Recommendations for Use of Holding Hooks and Hold-Back Hooks.................. 42
			Instructions for Use of Strap-Type Fall Absorber.............................. 42
	Section 3.1 - Ladder, Walkways, and Access Doors...................................... 44
		Superstructure.................................................................... 44
		Sea Protection Covers............................................................. 47
	Section 3.2 - Transport of Excavator.................................................. 48
		Short Transport with Calm Sea Conditions Drawing.................................. 49
		Long Transport with Rough Sea Conditions Drawing.................................. 50
		Location of Plug Socket for Hydraulic Oil Heating System.......................... 51
	Section 3.3 - Operator's Seat......................................................... 54
	Section 4.0 - Operator's Cab - Controls and Monitors.................................. 56
		Control Levers and Control Pedals................................................. 56
		Safety Circuit for Controls....................................................... 56
		Switch Board...................................................................... 60
		Instruments and Pontoon Controls.................................................. 62
	Section 5.0 - Electronic Text Monitoring System Komatsu ETM........................... 64
		Introduction...................................................................... 64
			Further Features of the ETM System............................................ 64
			Messages are Divided into Two Main Groups..................................... 64
			Function of the Keys (1 to 8) of Keyboard..................................... 66
			System Components............................................................. 68
			Switches for Adjustment of the ETM............................................ 70
			Message Classification........................................................ 70
			Functions of the ETM System................................................... 72
			Display the Content of Record (PROTOCOL) Memory............................... 78
			Display the Content of Static Memory.......................................... 80
			Print Out Content of Static Memory............................................ 82
			Print Out Content of Record (PROTOCOL) Memory................................. 82
			Change-over from English to German Language................................... 88
			Change-over from German to English Language................................... 88
			Several Massage Conditions Occur at Same Time................................. 90
			Setting the Display Unit...................................................... 92
			Erase Record (PROTOCOL) and STATISTICS Memory................................. 94
			Return to System Level........................................................ 96
			Setting Screen Brightness..................................................... 96
			Table of Messages............................................................. 97
				Basic Display (Message Page no. 0)........................................ 97
				Message Page Number 1 to 5................................................ 97
				Message Page Number 6 to 11............................................... 98
				Message Page Number 12 to 18.............................................. 99
				Message Page Number 19 to 26..............................................100
				Message Page Number 27 to 30..............................................101
				Message Page Number 31 to 38..............................................102
				Message Page Number 39 to 44..............................................103
				Message Page Number 45 to 52..............................................104
				Message Page Number 53 to 64..............................................105
			Grouping Messages According to their Priority.................................107
				1st Priority Group........................................................107
				2nd Priority Group........................................................108
				3rd Priority Group........................................................108
				4th Priority Group........................................................109
			Explanation of the Statics Print-Out..........................................110
			Time Diagram of Statics Print.................................................111
	Section 5.1 - Power House Controls....................................................114
	Section 5.2 - Electrical Equipment in Cab Base........................................118
		Main Switch X2 in Cab Base........................................................120
		Diagnostic Fault Codes of Engine Centry System....................................120
		Switch Box X7 for Cab Heating and Air Conditioning................................122
	Section 5.3 - Preheating System for Hydraulic Oil.....................................124
		General...........................................................................124
		Operating the Heating System......................................................124
	Section 5.4 - Engine Oil Management System............................................126
		General...........................................................................126
		Centinel Diagnostic Lamps.........................................................128
		Check Centinel Diagnostic Lamps for Faults........................................128
		Clearing Active Faults and Reset the Centinel System..............................130
		Resetting the Centinel System is Necessary........................................130
		Check the Centinel System for Proper Operation....................................130
		Calibration Plug for Engine Oil Quality...........................................130
		Oil Burning System Centinel Combined with Reverse System..........................131
		Eliminator Engine Oil Filter......................................................132
	Section 5.5 - Operator's Cab Arrangement of Components................................134
	Section 6.1 - Ceheck Before Starting the Engine.......................................136
	Section 6.2 - Starting the Engine.....................................................140
		Before Starting...................................................................140
		Starting Procedure................................................................140
		Cold Weather Starting.............................................................142
		After Starting....................................................................142
		Automatic Engine Shut-Down System (Safety Chain)..................................144
		Untitled..........................................................................146
		Engine Warm-Up....................................................................146
		Hydraulic Oil Warm-Up.............................................................146
		Hydraulic Oil Viscosity and Temperature Chart.....................................148
	Section 6.3 - Stopping the Engine.....................................................150
		Stopping Procedure................................................................150
	Section 6.4 - Pontoon Operation.......................................................152
		Warping of the Pontoon............................................................154
		Float Position of Backhoe Attachment..............................................154
		Determination of Directions.......................................................154
		Shut-off Cocks for the Pontoon Hydraulic System...................................156
	Section 6.5 - Slewing and Braking the Superstructure..................................158
		6.5.1 - Rotating the Superstructure...............................................158
		6.5.2 - Swing Angle Limitation System.............................................158
		6.5.3 - Braking the Superstructure................................................158
		6.5.4 - Swing Parking Brake.......................................................160
	Section 6.6 - Working with the Attachment.............................................162
	Section 6.7 - Combined Operation Cycles...............................................166
	Section 6.8 - Operating the Heater, Ventilation, and Air Conditioning.................168
		Heating...........................................................................168
		Air Conditioning (Special Equipment...............................................170
		Combined Operation of Air Conditioning and Heating................................170
	Section 6.11 - Automatic Lubrication Systems..........................................172
		Central Lubrication System and Swing Ring Gear Lubrication System.................172
		Controls of Automatic Lubrication Systems.........................................172
		Factory Adjustments...............................................................174
	Section 6.13 - Fire Detection and Suppression System (Special Equipment)..............176
	Section 6.15 - Transfer Pump for Hydraulic Oil Reservoir..............................184
		Functions of the Transfer Pump....................................................184
		Transfer Procedure................................................................186
	Section 7.0 - Working Instructions....................................................190
		Excavator Operation...............................................................190
		Barge Warping.....................................................................190
		Pontoon Warping...................................................................192
		Maintaining the Pontoon in the Flow...............................................192
		Slowing Down Pontoon Motions......................................................192
		Working Ashore or at Banks from the Pontoon.......................................192
		Working in Shallow Waters.........................................................192
		Depositing the Attachment During Working Breaks...................................194
	Section 7.1 - Emergency Operation System..............................................196
	Section 9.0 - Refueling the Excavator.................................................198
	Section 10.0 - Exchange of Attachment and/or Components...............................200
Part 2 - Lubrication and Maintenance Manual...............................................202
	Table of Contents - Lubrication and Maintenance Manual................................202
	Section 1.0 - Foreward................................................................204
		Section Contents..................................................................204
		Definitions.......................................................................205
	Section 1.1 - Fire Prevention.........................................................208
	Section 1.2 - Repair Welding..........................................................212
	Section 2.0 - Safety Instructions.....................................................220
	Section 3.0 - Fuel and Lubricants.....................................................222
	Section 4.0 - Filling Capacities......................................................224
	Section 5.0 - Lubrication and Maintenance Schedule....................................226
		5.1 - Initial Servicing...........................................................226
		5.2 - Periodic Servicing Intervals................................................226
			Service Interval Chart........................................................227
			Replacement of Hydraulic Hose Lines...........................................232
			Inspection of Hydraulic Hose Lines............................................232
		5.3 - Extended Service Intervals for Engines with Engine Oil Management System....234
			Servicing Intervals...........................................................234
				Every 10 Operating Hours..................................................234
				Every 500 Operating Hours.................................................236
				Every 4000 Operating Hours................................................236
				Engine Oil Reserve Tank...................................................236
			5.3.1 - Resetting of Engine Oil Burning System Centinel.......................238
		5.4 - Maintenance of Engine.......................................................238
		5.5 - Maintenance of Eliminator Oil Filtration System.............................238
		Lubrication Point and Maintence Chart.............................................239
	Section 6.1 - Every 10 Operating Hours or Daily.......................................242
		1. - Visual Inspection............................................................242
			1.1 - Central Lubrication System..............................................246
				Backhoe Attachment........................................................246
				Bullclam Bucket Attachment................................................248
				Slweing Connection........................................................250
			1.2 - Grease Injectors, Corrective Actions....................................250
			1.3 - Check Slew Ring Teeth for Proper Lubrication............................252
		2. - Maintenance of Engines.......................................................254
		3. - Lubrication of Attachment....................................................254
			3.1 - Lubrication of Backhoe Attachment.......................................254
			3.2 - Lubrication of Front Loader Attachment..................................254
		4. - Lubrication of Slewing Connection............................................256
		5. - Engine Air Cleaners..........................................................258
		6. - Not Used.....................................................................258
		7. - Radiator - Check Coolant Level...............................................260
		8. - Track Groups.................................................................260
		9. - Fuel System, Water Separator.................................................260
	Section 6.2 - Every 50 Operating Hours or Weekly......................................262
		10. - Slew Gear and Motor Adapter Housing.........................................262
		11. - Not Used....................................................................264
		12. - Pump Distributor Geat (PTO) and Oil Reservoirs..............................264
		13. - Radiator and Hydraulic Oil Coolers..........................................268
		14. - Air Conditioning............................................................268
		15. - Maintenance of Engines......................................................268
	Section 6.3 - Every 250 Operating Hours or Monthly....................................270
		50. - Engine......................................................................270
		51. - Drive Belts.................................................................270
		52. - Not Used....................................................................278
		53. - Not Used....................................................................278
		54. - Hydraulic Oil Cooler - Lubricate Fan Bearings...............................278
		55. - Not Used....................................................................278
		56. - Not Used....................................................................278
		57. - Compressor for Signal Horn..................................................280
		58. - Automatic Lubrication Systems, Clean In-Line-Grease-Filters.................282
		59. - Air Cleaner for Operator's Cab..............................................284
		60. - Air Conditioning............................................................284
		61. - Not Used....................................................................284
		62. - Not Used....................................................................284
		63. - Air Conditioning Refrigerant Compressor.....................................286
	Section 6.4 - Every 500 Operating Hours or Every 3 Months.............................288
		70. - Engine......................................................................288
		71. - Batteries...................................................................288
		72. - Fuel Tank, Drain Water and Sediments........................................290
		73. - Flexible Drive Coupling.....................................................292
		74. - Rotary Distributor Lubrication..............................................294
	Section 6.5 - Every 1000 Operating Hours or Every 6 Months............................296
		80. - High-Strength Bolt Connections..............................................296
		Bolt Torque Chart.................................................................320
		81. - Maintenance of Engines......................................................322
		82. - Hydraulic System............................................................322
		83. - Pump Distributor Gears, Slew Gears, and Travel Gears........................336
		84. - Compressor for Signal Horn..................................................338
		85. - Not Used....................................................................338
		86. - Air Conditioning............................................................338
	Section 6.6 - Every 2000 Operating Hours or Yearly....................................340
		100. - Hydraulic System...........................................................340
	Section 6.7 - Every 3000 operating operating Hours but at Least Once a Year...........348
		111. - Slew Gear and Motor Adapter Housing........................................348
		111. - Pump Distributor Gear (PTO)................................................352
	Section - 6.8 - When Necessary........................................................356
		120. - Servicing the Engine Air Cleaners..........................................356
		121. - Additional Fuel System Water Separator.....................................362
		122. - Slew Gear..................................................................364
		123. - Automatic Lubrication Systems with Replaceable Grease Barrels..............366
		124. - Not Used...................................................................368
		125. - Not Used...................................................................368
		126. - Not Used...................................................................368
		127. - Not Used...................................................................368
		128. - Hydraulic System...........................................................368
		129. - Cold Starting Aid, Replace Fluid Cylinder..................................368
		130. - Electrical Switch Board (X2)...............................................370
	Section 7.0 - Excavator Storage.......................................................372
		General...........................................................................372
		1. Preparing for Storage..........................................................372
		2. One Month Repetitive Service Peroid............................................373
		3. Six Month Repetitive Service Period............................................373
		4. Preparing for Operation........................................................374
	Section 8.0 - Troubleshooting.........................................................376
		General...........................................................................376
		Engine............................................................................376
		Hydraulic System..................................................................377
		Travel and Slew Gears.............................................................378
		Crawler Tracks....................................................................378

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