Komatsu PC3000-6 Hydraulic Mining Shovel Operation & Maintenance Manual SN 06253 and up – DOWNLOAD

Description

Komatsu PC3000-6 Hydraulic Mining Shovel Operation & Maintenance Manual

TABLE OF CONTENTS:

Komatsu PC3000-6 Hydraulic Mining Shovel Operation & Maintenance Manual

COVER...........................................................................................................  1
1. INTRODUCTION................................................................................................  3
	1.1 CONTENTS OF THE BINDER..................................................................................  4
	1.2 DIVISION OF THE BINDER..................................................................................  5
	1.3 DESIGNATED USE OF THE SHOVEL............................................................................  6
	1.4 DELIVERY OF THE SHOVEL..................................................................................  7
	1.5 EXPLANATION OF ABBREVIATIONS............................................................................  8
	1.6 TABLE OF CONTENTS.......................................................................................  9
2. SAFETY...................................................................................................... 15
	2.1 SAFETY INSTRUCTIONS..................................................................................... 16
		2.1.1 WARNINGS AND SYMBOLS.............................................................................. 16
		2.1.2 BASIC OPERATION AND DESIGNATED USE OF THE HYDRAULIC SHOVEL........................................ 16
		2.1.3 ORGANIZATIONAL MEASURES........................................................................... 17
		2.1.4 SELECTION AND QUALIFICATION OF PERSONNEL - BASICRESPONSIBILITIES................................. 19
		2.1.5 SAFETY INSTRUCTIONS GOVERNING SPECIFIC OPERATIONAL PHASES......................................... 20
		2.1.6 WARNING OF SPECIAL DANGERS........................................................................ 23
		2.1.7 TRANSPORTING AND TOWING -RECOMMISSIONING.......................................................... 25
		2.1.8 SPECIAL SAFETY EQUIPMENT.......................................................................... 25
		2.1.9 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEANSTANDARD)...................................... 29
3. OPERATION................................................................................................... 37
	3.1 FOREWORD................................................................................................ 38
	3.2 CONSTRUCTION OF THE SHOVEL.............................................................................. 39
		3.2.1 OVERALL VIEW...................................................................................... 39
		3.2.2 UNDERCARRIAGE AND SUPERSTRUCTURE.................................................................. 40
		3.2.3 HYDRAULICALLY OPERATED ACCESS LADDER.............................................................. 46
		3.2.4 EMERGENCY ESCAPE LADDER........................................................................... 50
		3.2.5 EMERGENCY ESCAPE LADDER AND ESCAPE HATCH IN THE MACHINERY HOUSE (SPECIAL EQUIPMENT)............... 52
		3.2.6 EMERGENCY ENGINE SHUTDOWN FROM GROUND MAN OR OPERATOR WARNING SYSTEM.............................. 54
		3.2.7 OPERATOR’S CAB WITH INTEGRATED FALLING OBJECT PROTECTIVE STRUCTURE (FOPS)......................... 56
		3.2.8 ENGINE OIL MANAGEMENT SYSTEM...................................................................... 64
	3.3 OPERATOR’S CAB - CONTROLS............................................................................... 72
		3.3.1 CONTROLS WITH BACKHOE ATTACHMENT.................................................................. 72
		3.3.2 CONTROLS WITH BOTTOM DUMP BUCKET.................................................................. 76
		3.3.3 OPERATOR’S CONSOLE................................................................................ 81
	3.4 ELECTRONIC TEXT MONITORING SYSTEM ETM................................................................... 88
		3.4.1 INTRODUCTION...................................................................................... 89
		3.4.2 SYSTEM COMPONENTS................................................................................. 93
		3.4.3 FUNCTIONS OF THE ETM SYSTEM....................................................................... 95
		3.4.4 DISPLAY THE CONTENTS OF THE RECORD (PROTOCOL) MEMORY.............................................. 99
		3.4.5 SEVERAL MESSAGE CONDITIONS OCCUR AT THE SAME TIME.................................................111
		3.4.6 SETTINGS OF THE TEXT DISPLAY UNIT.................................................................113
	3.5 OPERATING THE HEATER, VENTILATION AND AIRCONDITIONING..................................................128
		3.5.1 CONTROL MODULE FOR AUXILIARY CAB HEATER (IF SO EQUIPPED)..........................................133
		3.5.2 AUXILIARY HEATER FOR OPERATORS CAB (IF SO EQUIPPED)...............................................135
		3.5.3 AUXILLIARY HEATER FOR OPERATORS CAB (IF SO EQUIPPED)..............................................137
		3.5.4 FUEL PUMP ARRANGEMENT.............................................................................139
	3.6 MACHINERY HOUSE.........................................................................................140
		3.6.1 EMERGENCY ENGINE SHUTDOWN SWITCHES................................................................141
	3.7 ELECTRICAL EQUIPMENT IN CAB BASE........................................................................142
		3.7.1 SWITCH BOX (X2) IN CAB BASE.......................................................................147
		3.7.2 COMPONENTS OF ELECTRICAL PREHEATING SYSTEM IN CAB BASE............................................151
	3.8 PREHEATING SYSTEMS......................................................................................156
		3.8.1 FOR OIL, COOLANT AND BATTERIES....................................................................156
		3.8.2 HEATERS FOR MACHINERY HOUSE (SPECIAL EQUIPMENT)...................................................162
	3.9 CHECKS BEFORE STARTING THE ENGINE.......................................................................164
	3.10 STARTING THE ENGINE....................................................................................170
		3.10.1 STARTING PROCEDURE...............................................................................171
		3.10.2 STARTING PROCEDURE AT AMBIENT TEMPERATURE UP TO -25.............................................173
	3.11 MOVING THE SHOVEL......................................................................................182
		3.11.1 TRAVEL CONTROL WITH FOOT PEDALS..................................................................182
		3.11.2 TRAVELLING INSTRUCTIONS..........................................................................185
	3.12 SLEWING AND BRAKING THE SUPERSTRUCTURE.................................................................186
		3.12.1 SLEWING THE SUPERSTRUCTURE.......................................................................186
	3.13 WORKING WITH THE ATTACHMENT............................................................................189
		3.13.1 MACHINES EQUIPPED WITH”EURO” CONTROL SYSTEM......................................................189
		3.13.2 MACHINES EQUIPPED WITH”KMG” CONTROL SYSTEM.......................................................190
		3.13.3 BOTTOM DUMP BUCKET...............................................................................191
		3.13.4 DROP BALL OPERATION..............................................................................192
		3.13.5 COMBINED OPERATION CYCLES........................................................................195
	3.14 WORKING INSTRUCTIONS...................................................................................197
		3.14.1 STABILITY OF THE SHOVEL..........................................................................197
		3.14.2 SHOVEL OPERATION.................................................................................197
	3.15 PARKING THE SHOVEL.....................................................................................200
	3.16 STOPPING THE ENGINE....................................................................................202
		3.16.1 RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM.........................................................205
	3.17 AUTOMATIC LUBRICATION SYSTEMS..........................................................................206
		3.17.1 OPERATION OF THE AUTOMATIC LUBRICATION SYSTEMS...................................................207
	3.18 FIRE DETECTION AND SUPPRESSION SYSTEM..................................................................210
		3.18.1 HIGH LEVEL ALARM ”FIRE”..........................................................................213
		3.18.2 ENGINE SHUT-DOWN THROUGH FUEL SHUT-OFF SOLENOID VALVE............................................213
		3.18.3 ACTUATION MODES OF THE FIRE SUPPRESSION SYSTEM...................................................213
		3.18.4 INDICATION OF OPERATIONAL MODES AT CONTROL MODULE, AFTER AUTOMATIC ACTUATION OF THE FIRE S.......215
		3.18.5 LOCATION OF THE EXTINGUISHING AGENT TANK ASSEMBLIES AND EXPELLANT GAS CARTRIDGES ON POWER.......217
	3.19 CENTRAL REFILLING SYSTEM...............................................................................218
		3.19.1 SYSTEMS CONNECTED TO THE REFILLING SYSTEM........................................................219
		3.19.2 OPERATING THE HYDRAULIC SERVICE ARM..............................................................221
		3.19.3 RECEIVER PANEL WITH MONITOR BOX..................................................................223
		3.19.4 REFILLABLE GREASE CONTAINERS OF THE AUTOMATIC LUBRICATION SYSTEMS................................227
	3.20 TRANSFER PUMP FOR HYDRAULIC OIL........................................................................228
		3.20.1 OPERATING THE TRANSFER PUMP......................................................................229
		3.20.2 FUNCTIONS OF THE TRANSFER PUMP...................................................................229
	3.21 WORK ON THE LOADER ATTACHMENT..........................................................................232
	3.22 TRANSPORTATION AND LIFTING OF THE SHOVEL...............................................................233
		3.22.1 DISASSEMBLING OF THE SHOVEL......................................................................233
		3.22.2 TRANSPORTATION AND LIFTING.......................................................................233
	3.23 RETRIEVAL PROCEDURE....................................................................................234
	3.24 SHOVEL STORAGE.........................................................................................235
		3.24.1 PREPARING FOR STORAGE............................................................................235
		3.24.2 ONE MONTH REPETITIVE SERVICE PERIOD..............................................................236
		3.24.3 SIX MONTH REPETITIVE SERVICE PERIOD..............................................................236
		3.24.4 PREPARING FOR OPERATION..........................................................................237
	3.25 TROUBLE SHOOTING.......................................................................................238
		3.25.1 ENGINE...........................................................................................238
		3.25.2 HYDRAULIC SYSTEM.................................................................................239
		3.25.3 FINAL DRIVES AND SWING GEAR......................................................................240
		3.25.4 CRAWLER TRACKS...................................................................................240
4. MAINTENANCE.................................................................................................241
	4.1 FOREWORD................................................................................................242
	4.2 PRECAUTIONS FOR MAINTENANCE.............................................................................243
	4.3 FLUIDS AND LUBRICANTS...................................................................................245
		4.3.1 LUBRICANTS FOR OPERATION IN COLD AND ARCTIC CLIMATES..............................................245
		4.3.2 FLUIDS AND LUBRICANTS FOR MODERATE AND HOT CLIMATES...............................................246
	4.4 FILLING CAPACITIES......................................................................................248
	4.5 STANDARD TORQUE LIST....................................................................................249
	4.6 LUBRICATION AND MAINTENANCE SCHEDULE....................................................................250
		4.6.1 INITIAL SERVICING.................................................................................250
		4.6.2 PERIODIC SERVICING INTERVALS......................................................................250
		4.6.3 PERIODIC SERVICING SCHEDULE.......................................................................251
		4.6.4 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS.....................................................257
		4.6.5 EXTENDED SERVICE INTERVALS FOR ENGINES WITH ENGINE OIL MANAGEMENT SYSTEM..........................261
		4.6.6 RESETTING THE ENGINE OIL BURNING SYSTEM CENTINEL..................................................263
		4.6.7 MAINTENANCE OF THE ENGINE.........................................................................267
	4.7 WHEN NECESSARY..........................................................................................268
		4.7.1 ENGINE AIR CLEANER MAINTENANCE....................................................................269
		4.7.2 SWING CIRCLE TOOTHING LUBRICATION.................................................................273
		4.7.3 AUTOMATIC LUBRICATION SYSTEMS FILL GREASE CONTAINERS..............................................275
		4.7.4 TRACK ROLLERS AND GUIDE WHEELS - REPLACE FLOATING SEALS...........................................279
		4.7.5 COLD STARTING AID, REPLACE FLUID CYLINDER.........................................................281
	4.8 EVERY 10 OPERATING HOURS OR DAILY.......................................................................282
		4.8.1 WALK - AROUND INSPECTION..........................................................................283
		4.8.2 AIR CLEANER - CLEAN PRE-CLEANER...................................................................295
		4.8.3 RADIATOR - CHECK COOLANT LEVEL....................................................................297
		4.8.4 TRACK GROUPS - CLEAN..............................................................................297
		4.8.5 FUEL SYSTEM WATER SEPARATOR - DRAIN WATER.........................................................299
	4.9 EVERY 50 OPERATING HOURS OR WEEKLY......................................................................300
		4.9.1 SWING GEAR AND MOTOR ADAPTER HOUSING - CHECK OIL LEVEL............................................301
		4.9.2 TRAVEL GEARS, BRAKE HOUSINGS AND MOTOR ADAPTER HOUSINGS - CHECK OIL LEVELS........................305
		4.9.3 PTO (PUMP DISTRIBUTOR GEAR) - CHECK OIL LEVEL.....................................................309
		4.9.4 HYDRAULIC ACCESS LADDER - CHECK SAFETY SENSOR.....................................................311
		4.9.5 HYDRAULIC OIL COOLERS - INSPECT AND CLEAN IF NECESSARY............................................313
	4.10 EVERY 250 OPERATING HOURS OR MONTHLY...................................................................314
		4.10.1 AIR CONDITIONING COMPRESSOR - CHECK DRIVE BELT TENSION...........................................315
		4.10.2 RADIATOR FAN BELT AND AUTOMATIC BELT TENSIONER - MAINTENANCE CHECK...............................317
		4.10.3 GENERATOR - CHECK BELT TENSION...................................................................321
		4.10.4 SIGNAL HORN COMPRESSOR - LUBRICATE...............................................................323
		4.10.5 HYDRAULIC OIL COOLER FAN - CHECK CONDITION AND FASTENING.........................................323
		4.10.6 AUTOMATIC LUBRICATION SYSTEMS - CLEAN IN-LINE GREASE FILTER AND CHECK BREATHER FILTER............325
		4.10.7 CAB AIR CLEANER - CLEAN OR REPLACE FILTER ELEMENT................................................329
		4.10.8 WINDSHIELD WASHER RESERVOIR - CHECK FLUID LEVEL..................................................331
		4.10.9 AIR CONDITIONING FOR OPERATOR’S CAB - CHECK REFRIGERANT LEVEL....................................331
	4.11 EVERY 500 OPERATING HOURS OR MONTHLY...................................................................332
		4.11.1 BATTERIES - CHECK FLUID LEVEL....................................................................333
		4.11.2 FLEXIBLE DRIVE COUPLING - CHECK OIL LEVEL........................................................335
		4.11.3 FUEL TANK - DRAIN CONDENSATION...................................................................337
		4.11.4 CRAWLER TRACK - INSPECTION.......................................................................339
	4.12 EVERY 1000 OPERATING HOURS OR EVERY 6MONTH............................................................344
		4.12.1 HIGH STRENGTH BOLT CONNECTIONS - CHECK TORQUE LOAD...............................................345
		4.12.2 HYDRAULIC SYSTEM - FILTER SERVICE................................................................377
		4.12.3 PTO (PUMP DISTRIBUTOR GEAR), SWING GEAR AND TRAVEL GEARS - OIL SAMPLE ANALYSIS...................391
		4.12.4 SIGNAL HORN COMPRESSOR - CLEAN AND LUBRICATE.....................................................393
		4.12.5 HYDRAULIC TRACK TENSIONING SYSTEM - CHECK PRESSURE ACCUMULATORS..................................395
		4.12.6 HYDRAULIC OIL COOLER - INSPECT AND LUBRICATE DOOR HINGES.........................................397
		4.12.7 MACHINERY HOUSE DOORS - INSPECT AND LUBRICATE DOOR HINGES........................................397
	4.13 EVERY 2000 OPERATING HOURS OR YEARLY...................................................................398
		4.13.1 HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER....................399
		4.13.2 EMERGENCY ESCAPE LADDER - INSPECTION.............................................................413
	4.14 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR................................................414
		4.14.1 SWING GEAR AND MOTOR ADAPTER HOUSING - CHANGE OIL................................................415
		4.14.2 TRAVEL GEARS, BRAKE AND MOTOR ADAPTER HOUSINGS - CHANGE OIL......................................423
		4.14.3 PTO (PUMP DISTRIBUTOR GEAR) - CHANGE OIL.........................................................427
	4.15 FIRE PREVENTION........................................................................................430
	4.16 WELD REPAIRS...........................................................................................432
		4.16.1 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE UNDERCARRIAGE............................435
		4.16.2 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE LOADER ATTACHMENT........................437
		4.16.3 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE SUPERSTRUCTURE...........................439
		4.16.4 AFTER FINISHING THE REPAIR WELDINGS ON THE SUPERSTRUCTURE........................................441

KOMATSU PC3000-6 HYDRAULIC MINING SHOVEL OPERATION & MAINTENANCE MANUAL SN 06253 AND UP – DOWNLOAD:

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Komatsu PC3000-6 Hydraulic Mining Shovel Operation & Maintenance Manual

BEFORE READING THIS MANUAL:

This manual gives details of the operation and methods of inspection and maintenance for this machine that must be obeyed in order to use the machine safely. Most accidents are caused by the failure to follow fundamental safety rules for the operation and maintenance of machines. Read, understand and follow all precautions and warnings in this manual and on the machine before performing operation and maintenance. Failure to do so may result in serious injury or death.

•  Komatsu cannot predict every circumstance that might involve a potential hazard when the machine is used. Therefore, the safety messages in this manual and on the machine may not include all possible safety precautions. If you carry out any operation, inspection, or maintenance 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 the prohibited uses or actions described in this manual.
• Improper operation and maintenance of the machine can be hazardous and could result in serious injury or death. If you sell the machine, be sure to give this manual to the new owner together with the machine. Always keep this Operation and Maintenance Manual in the location shown on the right so that all relevant personnel can read it at any time. Storage location for the Operation and Maintenance Manual: Pocket (1) at rear of operator’s seat If this manual is lost or damaged, contact your distributor immediately to arrange for its replacement.
• For details regarding the machine serial No. you will need to provide your Komatsu distributor, see “TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR (PAGE 1-7)”. 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 its publication.
• Continuing improvements in the design of this machine 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 machine or with questions regarding information contained in this manual.
• The numbers in circles in the illustrations correspond to the numbers in ( ) in the text. (For example:1 → (1)) Komatsu delivers machines that comply with all applicable regulations and standards of the country to which it has been shipped. If this machine 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 machine.

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• This is the SAME exact manual used by your dealers to fix your vehicle.
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