KOMATSU PC3000-6 HYDRAULIC MINING SHOVEL SERVICE MANUAL – PDF DOWNLOAD

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KOMATSU PC3000-6 HYDRAULIC MINING SHOVEL SERVICE MANUAL – PDF DOWNLOAD

FILE DETAILS:

KOMATSU PC3000-6 HYDRAULIC MINING SHOVEL SERVICE MANUAL – PDF DOWNLOAD

Language : English
Pages : 434
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

KOMATSU PC3000-6 HYDRAULIC MINING SHOVEL SERVICE MANUAL – PDF DOWNLOAD

I. INTRODUCTION.........................................................................................  3
II. SAFETY.............................................................................................. 15
III. SPECIFICATIONS..................................................................................... 21
1. MAIN ASSEMBLY GROUPS................................................................................. 35
	1.1 General layout.................................................................................. 36
	1.2 Superstructure.................................................................................. 38
	1.3 Power House..................................................................................... 40
	1.4 Hydraulic Oil Reservoir......................................................................... 42
	1.5 Hydraulic Oil Cooler............................................................................ 44
	1.6 Fuel tank (Fuel reservoir)...................................................................... 46
	1.7 Counter weight.................................................................................. 48
	1.8 Cab support..................................................................................... 50
	1.9 Operators cab................................................................................... 52
	1.10 Control blocks................................................................................. 54
	1.11 Swing gears.................................................................................... 56
	1.12 Under carriage................................................................................. 58
2. DRIVE................................................................................................ 61
	2.1 Prime drive assembly............................................................................ 62
	2.2 Engine and gearbox mount........................................................................ 64
	2.3 Torque supports................................................................................. 67
	2.4 Radiator fan Drive Assy......................................................................... 68
	2.5 Pump distributor gearbox (PTO).................................................................. 70
		2.5.1 Spline shaft housing...................................................................... 72
		2.5.2 PTO lubrication and cooling............................................................... 74
		2.5.3 PTO valve adjustments..................................................................... 76
	2.6 Coupling........................................................................................ 80
	2.7 Air Filter...................................................................................... 82
3. HYDRAULIC OIL RESERVOIR.............................................................................. 85
	3.1 Hydraulic oil reservoir......................................................................... 86
	3.2 Return and leak oil filter...................................................................... 90
	3.3 Breather Filter................................................................................. 94
	3.4 Location of electrical components............................................................... 96
4. HYDRAULIC OIL COOLING................................................................................ 99
	4.1 General.........................................................................................100
	4.2 Hydraulic oil cooling circuit...................................................................102
	4.3 Back pressure valve adjustment..................................................................106
	4.4 Fan drive.......................................................................................108
		4.4.1 Fan pump..................................................................................110
		4.4.2 Pressure relieve valve....................................................................111
		4.4.3 Temperature relay.........................................................................113
	4.5 Cooler fan drive adjustment.....................................................................114
5. CONTROLLING..........................................................................................117
	5.1 Pilot pressure supply and adjustment............................................................118
		5.1.1 Pilot control arrangement.................................................................120
		5.1.2 Pilot pressure adjustment.................................................................122
		5.1.3 Check of Control Pressure.................................................................124
	5.2 Slew brakes.....................................................................................126
	5.3 Travel parking brake............................................................................129
	5.4 Check of the pilot control logic................................................................131
		5.4.1 Check sheet FSA Page 1....................................................................133
		5.4.2 Check sheet BHA Page 1....................................................................146
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........................................................................180
		6.3.2 High pressure filter......................................................................182
		6.3.3 Pressure relieve valves and anti-cavitation valve.........................................184
		6.3.4 Pressure relieve valves and anti-cavitation valve.........................................186
	6.4 Compact valve blocks............................................................................188
	6.5 Compact valve blocks............................................................................190
	6.6 Auxiliary gear pumps............................................................................192
	6.7 Hydraulic cylinder..............................................................................194
	6.8 Swing ring......................................................................................196
7. MAIN HYDRAULIC PUMPS AND PUMP REGULATION.............................................................199
	7.1 General.........................................................................................200
		7.1.1 Pump location.............................................................................202
	7.2 Main pump operating principles..................................................................204
		7.2.1 Main pump function........................................................................209
	7.3 Main pump checks and adjustments................................................................212
		7.3.1 Peak point diesel engine test.............................................................212
		7.3.2 Pressure transducer test..................................................................214
		7.3.3 Cut off function..........................................................................215
		7.3.4 Pump regulation...........................................................................217
		7.3.5 Swing pump volume reduction...............................................................218
	7.4 Electronic pump regulation......................................................................219
	7.5 Pump Controller CR700...........................................................................222
	7.6 Multi Monitor...................................................................................224
	7.7 Multimonitor software instruction...............................................................226
		7.7.1 Multimonitor main control.................................................................226
		7.7.2 Service Menu screen.......................................................................226
		7.7.3 Monitoring (menu item 01).................................................................227
		7.7.4 Abnormality Record (menu item 02).........................................................228
		7.7.5 Default (menu item 03)....................................................................231
		7.7.6 Adjustment (menu item 04).................................................................232
		7.7.7 Display Setup (menu item 05)..............................................................234
		7.7.8 Table of fault messages and adjustments...................................................235
	7.8 Trouble shooting pump and pump regulation.......................................................244
8. OPERATING HYDRAULIC..................................................................................245
	8.1 General layout..................................................................................246
	8.2 Floating function of boom and stick only FSA....................................................250
	8.3 Check and Adjustments for MRV’s and SRV’s.......................................................252
		8.3.1 Check and Adjustments for MRV.............................................................254
		8.3.2 Check and Adjustment for SRV’s............................................................256
		8.3.3 Check and adjustment of the throttle check valves.........................................264
	8.4 Hydraulic for the swing circuit.................................................................266
		8.4.1 Hydraulic for the swing circuit...........................................................270
		8.4.2 Slew gear box L & S.......................................................................274
		8.4.3 Slew parking brake........................................................................278
		8.4.4 Slew service brake valve..................................................................282
		8.4.5 Checks and adjustment of the slew pressure valve..........................................287
	8.5 Travel circuit..................................................................................290
		8.5.1 Rotary joint..............................................................................292
		8.5.2 Travel motor A2FMt........................................................................294
		8.5.3 Travel gear...............................................................................296
		8.5.4 Travel parking brake......................................................................298
		8.5.5 Travel control function...................................................................300
		8.5.6 Check and Adjustment SRV travel system....................................................303
9. TRACK TENSION SYSTEM.................................................................................305
	9.1 General layout..................................................................................306
	9.2 Track tensioning function.......................................................................308
		9.2.1 Cushioning................................................................................310
		9.2.2 Pressure Increasing valve PIV.............................................................312
	9.3 Track tensioning adjustment.....................................................................316
		9.3.1 Track tensioning function check...........................................................318
10. ACCESS LADDER HYDRAULICALLY OPERATED................................................................321
	10.1 Access ladder..................................................................................322
	10.2 Access ladder functional description...........................................................324
11. CENTRAL REFILLING SYSTEM............................................................................329
	11.0.1 Functional description.......................................................................330
12. HINTS FOR READING THE HYDRAULIC CIRCUIT DIAGRAM.....................................................335
	12.1 General........................................................................................336
	12.2 Symbolic.......................................................................................338
		12.2.1 Lines, unions............................................................................339
		12.2.2 Components, valves.......................................................................341
		12.2.3 Sensors..................................................................................341
		12.2.4 Valves, valve components.................................................................342
		12.2.5 Pump, motor, cylinder....................................................................346
13. HINTS FOR READING THE ELECTRIC CIRCUIT DIAGRAM......................................................351
	13.1 Designation of electrical components...........................................................353
	13.2 Electric symbols...............................................................................354
	13.3 Symbols........................................................................................356
		13.3.1 Drawing concept..........................................................................358
		13.3.2 Reading of the circuit diagram...........................................................364
14. ELECTRONIC TEXT MONITORING SYSTEM ETM...............................................................369
	14.1 General Function...............................................................................370
15. AUTOMATIC LUBRICATION SYSTEM........................................................................373
	15.1 General Function...............................................................................374
	15.2 Function of a lubrication cycle................................................................376
	15.3 Lubrication pump drive.........................................................................384
	15.4 Lubrication pump...............................................................................386
		15.4.1 Adjustments lubricating pump speed.......................................................388
		15.4.2 Adjustments lubricating pump pressure....................................................390
	15.5 Lubricant Injector (metering valve)............................................................392
		15.5.1 Connection of one or more injectors......................................................394
		15.5.2 Function lubrication injector (metering valve)...........................................396
	15.6 End line pressure switch.......................................................................400
	15.7 Lubricant in line filter.......................................................................402
	15.8 Lubricant level sensor.........................................................................404
		15.8.1 Capacitive digital type for machines with ETM............................................404
		15.8.2 Capacitive analog type for machines with PLC.............................................406
	15.9 Lubrication system function and controlling....................................................408
		15.9.1 Central Lubrication System (CLS) function and controlling with ETM system (PC 3000)......409
		15.9.2 Swing ring lubrication system (SLS) function and controlling with ETM system (PC3000)....413
	15.10 Adjustment of the lubrication system with ETM.................................................419
	15.11 Trouble shooting lubricating system...........................................................420
		15.11.1 Lubrication pump cylinder does not move.................................................421
		15.11.2 Lubricant pressure built up very slowly or not at all...................................423
		15.11.3 Insufficient lubricant supply to one or more attachment bearings........................423
		15.11.4 Insufficient lubricant at the swing ring gear...........................................425

DESCRIPTION:

KOMATSU PC3000-6 HYDRAULIC MINING SHOVEL SERVICE MANUAL – PDF DOWNLOAD

• When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out. The water and oil in the circuits are hot when the engine is stopped, so be careful not to get burned. Wait for the oil and water to cool before carrying out work on the oil or water circuits.
• Before starting work, remove the leads from the battery. ALWAYS remove the lead from the negative (-) terminal first.
• When raising heavy components, use a hoist or crane.
• Check that the wire rope, chains and hooks are free from damage.
• Always use lifting equipment which has ample capacity.
• Install the lifting equipment at the correct places. Use a hoist or crane and operate slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane.
• When removing covers which are under internal pressure or under pressure from a spring, always leave two bolts in position on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove.
• When removing components, be careful not to break or damage the wiring, Damaged wiring may cause electrical fires.
• When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips on to the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip, or can even start fires.
• As a general rule, do not use gasoline to wash parts.
• Be sure to assemble all parts again in their original places. Replace any damaged part with new parts.
• When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine is being operated.
• When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely careful when installing tubes for high pressure circuits. Also check that connecting parts are correctly installed.
• When assembling or installing parts, always use the specified tightening torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed correctly.
• When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole.

S.S 18/12/24