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KOMATSU PC3000-1 HYDRAULIC MINING SHOVEL SERVICE REPAIR MANUAL (SN:PC3000-1 6199) KOMATSU PC3000-1 – PDF DOWNLOAD
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- KOMATSU PC3000-1 HYDRAULIC MINING SHOVEL SERVICE REPAIR MANUAL
- SERIAL NUMBER:PC3000-1 6199
- PUBLICATION NUMBER:SMPC300006199
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Description
KOMATSU PC3000-1 HYDRAULIC MINING SHOVEL SERVICE REPAIR MANUAL (SN:PC3000-1 6199) KOMATSU PC3000-1
KOMATSU PC3000-1 HYDRAULIC MINING SHOVEL SERVICE REPAIR MANUAL (SN:PC3000-1 6199) KOMATSU PC3000-1 – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU PC3000-1 HYDRAULIC MINING SHOVEL SERVICE REPAIR MANUAL (SN:PC3000-1 6199) KOMATSU PC3000-1
With this SERVICE MANUAL KOMATSU MINING GERMANY GmbH provides you with the description of the construction and the function of the major systems of the hydraulic excavator PC 3000. We describe for you all functions and how to carry out the inspections and adjustments.
How do you find ”your” desired information?
In the table of CONTENTS all the functions and components are shown in their sequence of the description.
Correct service and repair is extremely important for the safe operation of the machine.
The machine has been designed to suit your work, but it is still impossible to totally avoid any danger due to the size of the machine. When working on the machine, always try to avoid any possible danger.
KEEP IN MIND
– BE CAREFUL
– BE ALERT
– THINK ABOUT WHAT YOU ARE DOING
Any PERSON doing any work in or around the machine must be familiar with the local SAFETY INSTRUCTIONS and with the specific SAFETY INSTRUCTIONS REGARDING TO HIS OCCUPATION
TABLE OF CONTENTS:
KOMATSU PC3000-1 HYDRAULIC MINING SHOVEL SERVICE REPAIR MANUAL (SN:PC3000-1 6199) KOMATSU PC3000-1
Main Menu.................................................................... 0 Cover........................................................................ 1 Introduction................................................................. 2 Foreward..................................................................... 3 Table of Contents............................................................ 6 Section 1 - Main Assembly Groups............................................. 8 Table of Contents........................................................ 8 General Layout....................................................... 10 Drive................................................................ 12 Control Blocks, Swing Gear........................................... 14 Undercarriage, Travel Drive.......................................... 16 Driver's Cab......................................................... 18 Section 2 - Drive............................................................ 20 Table of Contents........................................................ 20 Prime Drive Assembly................................................. 22 Engine Mounts........................................................ 24 Fan Drive and Cooler Assembly........................................ 26 Coupling............................................................. 28 Air Filter........................................................... 30 Pump Distributor Gear................................................ 32 Spline - Lubrication................................................. 34 Gear Lubrication..................................................... 36 Location of Pumps, Drive Speeds, and Flow Rates...................... 40 Section 3 - Hydraulic Oil Tank............................................... 42 Table of Contents........................................................ 42 Main Oil Tank........................................................ 44 Return and Leak Oil Filter........................................... 46 Breather Filter...................................................... 48 Location of Pressure Switches and Sensors............................ 50 Section 4 - Hydraulic Oil Cooling............................................ 52 Table of Contents........................................................ 52 General.............................................................. 54 Hydraulic Oil Cooling Circuit........................................ 56 Measuring / Setting the Back Pressure Valve.......................... 58 Fan Drive............................................................ 62 Pressure Relief Valve and Solenoid Valve............................. 64 Axial Piston Pump.................................................... 66 Measuring and Setting the Fan Speed.................................. 68 Function Check for RPM-Control....................................... 72 Section 5 - Controlling...................................................... 74 Table of Contents........................................................ 74 Pilot Pressure Supply................................................ 76 Checks and Adjustments of Pilot Pressure............................. 80 Measuring and Adjustment of Control Pressure......................... 82 Checking of Accumulator Function................................. 82 Checking of Pre-charge Pressure.................................. 82 Travel Parking Brake................................................. 84 Function Check of Travel Parking Brake............................... 86 Function Check of Pressure Switch (B48).............................. 86 Swing Parking (House) Brake.......................................... 88 Section 6 - Components....................................................... 90 Table of Contents........................................................ 90 Main Control Blocks and High Pressure Filter......................... 92 Bull-clam Attachment............................................. 92 Back Hoe Attachment.............................................. 94 Distributor Manifold................................................. 96 Bull-clam Attachment............................................. 96 Back Hoe Attachment.............................................. 98 Restrictor Block with Pressure Relief Valve..........................100 Restrictor Block.....................................................102 Anti-Cavitation Valve Block..........................................104 Proportional Solenoid Valve..........................................106 Pressure Filter......................................................108 Control Blocks.......................................................110 Control Blocks and Valves........................................112 Valve at the Control Block.......................................116 Load Holding Valve...............................................118 Travel Brake Valve...................................................120 Pressure Reducing Valve..............................................122 Directional Control Valves (Solenoid Valve)..........................124 Hydraulic Cylinder...................................................126 Auxilliary Pumps (Fan Drive).........................................128 Auxilliary Gear Pumps................................................130 Swing Ring...........................................................132 Section 7 - Main Hydraulic Pumps.............................................134 Table of Contents........................................................134 Main Hydraulic Pump A7V / HD D.......................................136 SL-bearing...........................................................140 Function of the Pump Governor........................................142 Pump Bearing Lubrication.............................................148 Pump Governor Adjustments............................................152 Measuring and Setting Pressure of the Pressure Cut-off Valves....152 Measuring and Setting the start of De-stroking the Main Pumps....156 Adjusting the Damper Bolt........................................158 Pump Regulation, General.............................................160 Stop Gap Operation (Emergency Use Only)..........................162 Electronic Regulation............................................162 Detailed Explanation for Hydraulic Regulation....................164 Hydraulic Regulation.............................................164 Determination of Peak Point (Corner Value).......................166 Setting the X1-Pressure..........................................168 Detailed Explanation for Electronic Regulation...................170 Adjustments / Checks for Electronic Regulation...................172 Adjusting the RPM Sensor (MPU)...............................174 Adjustments at the ELL Module................................176 Testing / Setting for Complete Regulation....................178 Checks / Function Test / Fault Finding at JOB SITE...........180 EPM - Module, Function and Test..............................182 ERM - Module, Function and Test..............................184 ELL - Module, Function and Test..............................188 Amplifier Module, Function and Test..........................192 Simplified Troubleshooting of the Electronic Control.............194 Pre-Conditions...............................................196 Checking Proportional Solenoid Valve Function................196 Section 8 - Operating Hydraulic..............................................198 Table of Contents........................................................198 Hydraulic for Attachment Cylinders...................................200 Adjustments for Attachment Cylinder Hydraulic........................204 Main Relief Valves...............................................204 Service Line Relief Valves.......................................206 Boom Cylinder................................................206 Stick Cylinder...............................................208 Bucket Cylinder..............................................210 Clam Cylinder................................................212 Opening..................................................212 Closing..................................................214 Floating Function of Boom and Stick Cylinders....................216 Adjustments / Checks.............................................218 Swing Circuit, General...............................................222 Swing Motor..........................................................226 Swing Gear and Swing Parking Brake...................................230 Swing Brake Valve....................................................234 Swing Function.......................................................240 Function: R.H. Rotation.........................................240 Function: L.H. Rotation.........................................240 Swinging Down Path (Delay).......................................242 Anticavitation Circuit...........................................244 Braking..........................................................246 Swing Parking Brake..............................................248 Checks and Adjustments...............................................250 Adjustments for the Swing Circuit................................252 Checking Pilot Pressure for Swing Brake..........................256 Travel Circuit, General..............................................258 Rotary Distributor...................................................262 Travel Motor (Axial Piston Motor A2FM)...............................264 Travel Gear and Parking Brake........................................268 Travel Gear......................................................268 Travel Parking Brake.............................................270 Travel, Function.....................................................272 Anti-Cavitation Circuit..........................................276 Adjustments / Checks.................................................278 Test / Park Brake Release Pressure (House Brake Pressure)........282 Section 9 - Hydraulic Track Tension System...................................284 Table of Contents........................................................284 Hydraulic Track Tension System.......................................286 Function.........................................................288 Pressure Increasing Valve Type: MO 7010..........................292 Pressure Relief Valve, Direct Operated Type: DBD S...............294 Adjustments / Pressure Checks....................................296 Adjustments..................................................296 Basic Adjustment.............................................298 Setting Procedure............................................300 Function Check...............................................302 Section 10 - Access Ladder Hydraulic Operated................................304 Table of Contents........................................................304 Access Ladder Hydraulic Operated.....................................306 Section 11 - Central Refilling System........................................310 Table of Contents........................................................310 Central Refilling System.............................................312 Section 12 - Hints for Hydraulic Circuit Diagrams............................316 Table of Contents........................................................316 Hints for Reading Circuit Diagrams...................................320 Legend to the Hydraulic Circuit Diagram..............................321 How to Read Circuit Diagrams.........................................327 Hydraulic Diagrams - 927 596 40..........................................328 Hydraulic Diagram - 927 596 40 (1/3).................................328 Hydraulic Diagram - 927 596 40 (2/3).................................329 Hydraulic Diagram - 927 596 40 (3/3).................................330 Section 13 - Hints for Electric Circuit Diagrams.............................338 Table of Contents........................................................338 Markings of Electrical Components in Circuit Diagrams................340 Symbols..............................................................342 KMG Circuit, General Information.....................................346 Ecplanation of the Drawing Concept...................................348 Location of Main Terminal Boxes and Important Components.............350 Reading a Circuit Diagram............................................354 Adjustments..........................................................358 Component List.......................................................359 Electrical Circuit Diagrams - 927 595 40.................................364 Electrical Circuit Diagrams - 927 595 40 (1/40)......................364 Electrical Circuit Diagrams - 927 595 40 (2/40)......................365 Electrical Circuit Diagrams - 927 595 40 (3/40)......................366 Electrical Circuit Diagrams - 927 595 40 (4/40)......................367 Electrical Circuit Diagrams - 927 595 40 (5/40)......................368 Electrical Circuit Diagrams - 927 595 40 (6/40)......................369 Electrical Circuit Diagrams - 927 595 40 (7/40)......................370 Electrical Circuit Diagrams - 927 595 40 (8/40)......................371 Electrical Circuit Diagrams - 927 595 40 (9/40)......................372 Electrical Circuit Diagrams - 927 595 40 (10/40).....................373 Electrical Circuit Diagrams - 927 595 40 (11/40).....................374 Electrical Circuit Diagrams - 927 595 40 (12/40).....................375 Electrical Circuit Diagrams - 927 595 40 (13/40).....................376 Electrical Circuit Diagrams - 927 595 40 (14/40).....................377 Electrical Circuit Diagrams - 927 595 40 (15/40).....................378 Electrical Circuit Diagrams - 927 595 40 (16/40).....................379 Electrical Circuit Diagrams - 927 595 40 (17/40).....................380 Electrical Circuit Diagrams - 927 595 40 (18/40).....................381 Electrical Circuit Diagrams - 927 595 40 (19/40).....................382 Electrical Circuit Diagrams - 927 595 40 (20/40).....................383 Electrical Circuit Diagrams - 927 595 40 (21/40).....................384 Electrical Circuit Diagrams - 927 595 40 (22/40).....................385 Electrical Circuit Diagrams - 927 595 40 (23/40).....................386 Electrical Circuit Diagrams - 927 595 40 (24/40).....................387 Electrical Circuit Diagrams - 927 595 40 (25/40).....................388 Electrical Circuit Diagrams - 927 595 40 (26/40).....................389 Electrical Circuit Diagrams - 927 595 40 (27/40).....................390 Electrical Circuit Diagrams - 927 595 40 (28/40).....................391 Electrical Circuit Diagrams - 927 595 40 (29/40).....................392 Electrical Circuit Diagrams - 927 595 40 (30/40).....................393 Electrical Circuit Diagrams - 927 595 40 (31/40).....................394 Electrical Circuit Diagrams - 927 595 40 (32/40).....................395 Electrical Circuit Diagrams - 927 595 40 (33/40).....................396 Electrical Circuit Diagrams - 927 595 40 (34/40).....................397 Electrical Circuit Diagrams - 927 595 40 (35/40).....................398 Electrical Circuit Diagrams - 927 595 40 (36/40).....................399 Electrical Circuit Diagrams - 927 595 40 (37/40).....................400 Electrical Circuit Diagrams - 927 595 40 (38/40).....................401 Electrical Circuit Diagrams - 927 595 40 (39/40).....................402 Section 14 - Electronic Text Monitoring System...............................404 Table of Contents........................................................404 Introduction.........................................................406 General..............................................................406 Function.............................................................410 Layout of Dash Board.................................................416 Text Monitoring System...............................................422 Features of the ETM System.......................................422 Two Main Message Groups..........................................422 Function of Keys on Keyboard.....................................424 System Components................................................426 Switches for the Adjustment of ETM...............................428 Message Classification...........................................428 Function of ETM System and their Utilization.....................430 Display the Content Record (PROTOCOL) Memory.....................434 Print Out Content of Statistics Memory...........................437 Print Out Last Entries of Record (PROTOCOL) Memory...............439 Change-over From English to German...............................440 Change-over from German to English...............................440 Several Message Conditions Occur at Same Time....................441 Settongs of Text Display Unit....................................444 Return to System Level...........................................447 Setting Screen Brightness........................................447 Grouping of Message Numbers in Input Signal Modules..............448 Table of Messages................................................449 Message Numbers 1 to 5.......................................449 Message Numbers 6 to 11......................................450 Message Numbers 12 to 18.....................................451 Message Numbers 19 to 26.....................................452 Message Numbers 27 to 30.....................................453 Message Numbers 31 to 38.....................................454 Message Numbers 39 to 44.....................................455 Message Numbers 45 to 52.....................................456 Message Numbers 53 to 64.....................................457 Grouping of Messages According to Priority.......................458 Explanation of Statistics Print-Out..............................462 Time Diagram of Ststics Print....................................463 EFD - Module, Function and Troubleshooting...........................466
PLEASE NOTE:
⦁ This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
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