Komatsu PC3000-6 Hydraulic Mining Shovel Service Manual SN 06208, 46151 and up – PDF DOWNLOAD

Description

Komatsu PC3000-6 Hydraulic Mining Shovel Service Manual

FILE DETAILS:

Komatsu PC3000-6 Hydraulic Mining Shovel Service Manual 

Brands: Komatsu
Equipment Type: Hydraulic Mining Shovel
Manuals Type: Shop Manual
Machine Model: PC3000-6
Serial Number: 06208, 46151 and up
Language: English
Pages: 434
File Format: Portable Document Format (PDF)

KOMATSU PC3000-6 HYDRAULIC MINING SHOVEL SERVICE MANUAL SN 06208, 46151 AND UP – PDF DOWNLOAD:

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Komatsu PC3000-6 Hydraulic Mining Shovel Service Manual 

FOREWORD:
Observe the instructions in these manuals for:

•  your Personal SAFETY
•  Operating SAFETY, and
•  READY and EFFICIENT PERFORMANCE of your KOMATSU Hydraulic Mining Shovel.

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.
How do you find “your” desired information?
In the TABLE OF CONTENT all the functions and components
are shown in their sequence of the description.

GENERAL PRECAUTIONS:

•  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.

TABLE OF CONTENTS:

Komatsu PC3000-6 Hydraulic Mining Shovel Service Manual 

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

PLEASE NOTE:

• This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
• Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.