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KOMATSU PC3000-6 HYDRAULIC MINING SHOVEL SERVICE REPAIR MANUAL (SN: PC3000-6 6224) – PDF Download
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- KOMATSU PC3000-6 HYDRAULIC MINING SHOVEL SERVICE REPAIR MANUAL
- Serial Number: PC3000-6 6224
- PUBLICATION NUMBER:SMPC30006224
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Description
KOMATSU PC3000-6 HYDRAULIC MINING SHOVEL SERVICE REPAIR MANUAL (SN: PC3000-6 6224)
KOMATSU PC3000-6 HYDRAULIC MINING SHOVEL SERVICE REPAIR MANUAL (SN: PC3000-6 6224) – PDF DOWNLOAD:
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SAMPLE PAGE FROM THE MANUAL:
KOMATSU PC3000-6 HYDRAULIC MINING SHOVEL SERVICE REPAIR MANUAL (SN: PC3000-6 6224)
? 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.
TABLE OF CONTENTS:
KOMATSU PC3000-6 HYDRAULIC MINING SHOVEL SERVICE REPAIR MANUAL (SN: PC3000-6 6224)
MAIN MENU............................................................................................... 0 COVER................................................................................................... 1 I. INTRODUCTION......................................................................................... 3 I.I CONTENTS OF BINDER.............................................................................. 4 I.II FOREWARD....................................................................................... 5 I.III EXPLANATION OF ABBREVATIONS................................................................... 7 I.IV TABLE OF CONTENTS.............................................................................. 8 II. SAFETY.............................................................................................. 15 II.I SAFETY INSTRUCTIONS............................................................................ 16 II.II GENERAL PRECAUTIONS........................................................................... 17 II.III PREPARATIONS FOR WORK........................................................................ 18 II.IV PRECAUTIONS DURING WORK....................................................................... 19 III. SPECIFICATIONS..................................................................................... 21 III.I LIFTING GEARS................................................................................. 22 III.II STANDARD TIGHTENING TORQUE CHART............................................................. 24 III.III CONVERSION TABLE............................................................................ 25 III.IV EXPLANATION OF ABBREVATIONS.................................................................. 31 III.V GENERAL SPECIFICATIONS........................................................................ 32 1. MAIN ASSEMBLY GROUPS................................................................................. 33 1.1 General layout.................................................................................. 34 1.2 Superstructure.................................................................................. 36 1.3 Power House..................................................................................... 38 1.4 Hydraulic Oil Reservoir......................................................................... 40 1.5 Hydraulic Oil Cooler............................................................................ 42 1.6 Fuel tank (Fuel reservoir)...................................................................... 44 1.7 Counter weight.................................................................................. 46 1.8 Cab support..................................................................................... 48 1.9 Operators cab................................................................................... 50 1.10 Control blocks................................................................................. 52 1.11 Swing gears.................................................................................... 54 1.12 Under carriage................................................................................. 56 2. DRIVE................................................................................................ 59 2.1 Prime drive assembly............................................................................ 60 2.2 Engine and gearbox mount........................................................................ 62 2.3 Torque supports................................................................................. 65 2.4 Radiator fan Drive Assy......................................................................... 66 2.5 Pump distributor gearbox (PTO).................................................................. 68 2.5.1 Spline shaft housing...................................................................... 70 2.5.2 PTO lubrication and cooling............................................................... 72 2.5.3 PTO valve adjustments..................................................................... 74 2.6 Coupling........................................................................................ 78 2.7 Air Filter...................................................................................... 80 3. HYDRAULIC OIL RESERVOIR.............................................................................. 83 3.1 Hydraulic oil reservoir......................................................................... 84 3.2 Return and leak oil filter...................................................................... 88 3.3 Breather Filter................................................................................. 92 3.4 Location of electrical components............................................................... 94 4. HYDRAULIC OIL COOLING................................................................................ 97 4.1 General......................................................................................... 98 4.2 Hydraulic oil cooling circuit...................................................................100 4.3 Back pressure valve adjustment..................................................................104 4.4 Fan drive.......................................................................................106 4.4.1 Fan pump..................................................................................108 4.4.2 Pressure relieve valve....................................................................109 4.4.3 Temperature relay.........................................................................111 4.5 Cooler fan drive adjustment.....................................................................112 5. CONTROLLING..........................................................................................115 5.1 Pilot pressure supply and adjustment............................................................116 5.1.1 Pilot control arrangement.................................................................119 5.1.2 Pilot pressure adjustment.................................................................121 5.1.3 Check of Control Pressure.................................................................123 5.2 Slew brakes.....................................................................................125 5.3 Travel parking brake............................................................................128 5.4 Check of the pilot control logic................................................................130 5.4.1 Check sheet BHA Page 1....................................................................132 5.4.2 Check sheet FSA Page 1....................................................................145 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........................................................................182 6.3.2 High pressure filter auxiliary filter.....................................................184 6.3.3 High pressure filter auxiliary filter.....................................................186 6.3.4 High pressure filter auxiliary filter.....................................................188 6.4 Compact valve blocks............................................................................190 6.5 Compact valve blocks............................................................................192 6.6 Auxiliary gear pumps............................................................................194 6.7 Hydraulic cylinder..............................................................................196 6.8 Swing ring......................................................................................198 7. MAIN HYDRAULIC PUMPS AND PUMP REGULATION.............................................................201 7.1 General.........................................................................................202 7.1.1 Pump location.............................................................................204 7.2 Main pump operating principles..................................................................206 7.2.1 Main pump function........................................................................211 7.3 Main pump checks and adjustments................................................................214 7.3.1 Peak point diesel engine test.............................................................214 7.3.2 Pressure transducer test..................................................................216 7.3.3 Cut off function..........................................................................217 7.3.4 Pump regulation...........................................................................219 7.3.5 Swing pump volume reduction...............................................................220 7.4 Electronic pump regulation......................................................................221 7.4.1 Pump Controller CR700.....................................................................223 7.4.2 Multi Monitor.............................................................................225 7.4.3 Multimonitor software instruction.........................................................227 7.4.4 Table of fault messages and adjustments...................................................234 7.5 Trouble shooting pump and pump regulation.......................................................243 8. OPERATING HYDRAULIC..................................................................................247 8.1 General layout..................................................................................248 8.2 Floating function of boom and stick only FSA....................................................252 8.3 Check and Adjustments for MRV’s and SRV’s.......................................................254 8.3.1 Check and Adjustments for MRV.............................................................256 8.3.2 Check and Adjustment for SRV’s............................................................258 8.3.3 Check and adjustment of the throttle check valves.........................................266 8.4 Hydraulic for the swing circuit.................................................................268 8.4.1 Hydraulic for the swing circuit...........................................................272 8.4.2 Slew gear box L & S.......................................................................276 8.4.3 Slew parking brake........................................................................280 8.4.4 Slew service brake valve..................................................................284 8.4.5 Checks and adjustment of the slew pressure valve..........................................289 8.5 Travel circuit..................................................................................292 8.5.1 Rotary joint..............................................................................294 8.5.2 Travel motor A2FMt........................................................................296 8.5.3 Travel gear...............................................................................298 8.5.4 Travel parking brake......................................................................300 8.5.5 Travel control function...................................................................302 9. TRACK TENSION SYSTEM.................................................................................307 9.1 General layout..................................................................................308 9.2 Track tensioning function.......................................................................310 9.2.1 Cushioning................................................................................312 9.2.2 Pressure Increasing valve PIV.............................................................314 9.3 Truck tensioning adjustment.....................................................................318 9.3.1 Truck tensioning function check...........................................................320 10. ACCESS LADDER HYDRAULICALLY OPERATED................................................................323 10.1 Access ladder..................................................................................324 10.2 Access ladder functional description...........................................................326 11. CENTRAL REFILLING SYSTEM............................................................................331 11.0.1 Functional description.......................................................................332 12. HINTS FOR READING THE HYDRAULIC CIRCUIT DIAGRAM.....................................................337 12.1 General........................................................................................338 12.2 Symbolic.......................................................................................340 12.2.1 Lines, unions............................................................................341 12.2.2 Components, valves.......................................................................343 12.2.3 Sensors..................................................................................343 12.2.4 Valves, valve components.................................................................344 12.2.5 Pump, motor, cylinder....................................................................348 Hydraulic Diagrams - 938 367 40.....................................................................352 Hydraulic Diagrams - 938 367 40 (1/3)...........................................................352 Hydraulic Diagrams - 938 367 40 (2/3)...........................................................353 Hydraulic Diagrams - 938 367 40 (3/3)...........................................................354 13. HINTS FOR READING THE ELECTRIC CIRCUIT DIAGRAM......................................................356 13.1 Designation of electrical components...........................................................358 13.2 Electric symbols...............................................................................359 13.3 Symbols........................................................................................361 13.3.1 Drawing concept..........................................................................363 13.3.2 Reading of the circuit diagram...........................................................369 Electrical Diagrams.................................................................................373 Electrical Diagrams - 938 368 40 (1/54).........................................................373 Electrical Diagrams - 938 368 40 (2/54).........................................................374 Electrical Diagrams - 938 368 40 (3/54).........................................................375 Electrical Diagrams - 938 368 40 (4/54).........................................................376 Electrical Diagrams - 938 368 40 (5/54).........................................................377 Electrical Diagrams - 938 368 40 (6/54).........................................................378 Electrical Diagrams - 938 368 40 (7/54).........................................................379 Electrical Diagrams - 938 368 40 (8/54).........................................................380 Electrical Diagrams - 938 368 40 (9/54).........................................................381 Electrical Diagrams - 938 368 40 (10/54)........................................................382 Electrical Diagrams - 938 368 40 (11/54)........................................................383 Electrical Diagrams - 938 368 40 (12/54)........................................................384 Electrical Diagrams - 938 368 40 (13/54)........................................................385 Electrical Diagrams - 938 368 40 (14/54)........................................................386 Electrical Diagrams - 938 368 40 (15/54)........................................................387 Electrical Diagrams - 938 368 40 (16/54)........................................................388 Electrical Diagrams - 938 368 40 (17/54)........................................................389 Electrical Diagrams - 938 368 40 (18/54)........................................................390 Electrical Diagrams - 938 368 40 (19/54)........................................................391 Electrical Diagrams - 938 368 40 (20/54)........................................................392 Electrical Diagrams - 938 368 40 (21/54)........................................................393 Electrical Diagrams - 938 368 40 (22/54)........................................................394 Electrical Diagrams - 938 368 40 (23/54)........................................................395 Electrical Diagrams - 938 368 40 (24/54)........................................................396 Electrical Diagrams - 938 368 40 (25/54)........................................................397 Electrical Diagrams - 938 368 40 (26/54)........................................................398 Electrical Diagrams - 938 368 40 (27/54)........................................................399 Electrical Diagrams - 938 368 40 (28/54)........................................................400 Electrical Diagrams - 938 368 40 (29/54)........................................................401 Electrical Diagrams - 938 368 40 (30/54)........................................................402 Electrical Diagrams - 938 368 40 (31/54)........................................................403 Electrical Diagrams - 938 368 40 (32/54)........................................................404 Electrical Diagrams - 938 368 40 (33/54)........................................................405 Electrical Diagrams - 938 368 40 (34/54)........................................................406 Electrical Diagrams - 938 368 40 (35/54)........................................................407 Electrical Diagrams - 938 368 40 (36/54)........................................................408 Electrical Diagrams - 938 368 40 (37/54)........................................................409 Electrical Diagrams - 938 368 40 (38/54)........................................................410 Electrical Diagrams - 938 368 40 (39/54)........................................................411 Electrical Diagrams - 938 368 40 (40/54)........................................................412 Electrical Diagrams - 938 368 40 (41/54)........................................................413 Electrical Diagrams - 938 368 40 (42/54)........................................................414 Electrical Diagrams - 938 368 40 (43/54)........................................................415 Electrical Diagrams - 938 368 40 (44/54)........................................................416 Electrical Diagrams - 938 368 40 (45/54)........................................................417 Electrical Diagrams - 938 368 40 (46/54)........................................................418 Electrical Diagrams - 938 368 40 (47/54)........................................................419 Electrical Diagrams - 938 368 40 (48/54)........................................................420 Electrical Diagrams - 938 368 40 (49/54)........................................................421 Electrical Diagrams - 938 368 40 (50/54)........................................................422 Electrical Diagrams - 938 368 40 (51/54)........................................................423 Electrical Diagrams - 938 368 40 (52/54)........................................................424 Electrical Diagrams - 938 368 40 (53/54)........................................................425 Electrical Diagrams - 938 368 40 (54/54)........................................................426 14. ELECTRONIC TEXT MONITORING SYSTEM ETM...............................................................428 14.1 General Function...............................................................................429 15. AUTOMATIC LUBRICATION SYSTEM........................................................................432 15.1 General Function...............................................................................433 15.2 Function of a lubrication cycle................................................................435 15.3 Lubrication pump drive.........................................................................443 15.4 Lubrication pump...............................................................................445 15.4.1 Adjustments lubricating pump speed.......................................................447 15.4.2 Adjustments lubricating pump pressure....................................................449 15.5 Lubricant Injector (metering valve)............................................................451 15.5.1 Connection of one or more injectors......................................................453 15.5.2 Function lubrication injector (metering valve)...........................................455 15.6 End line pressure switch.......................................................................459 15.7 Lubricant in line filter.......................................................................461 15.8 Lubricant level sensor.........................................................................463 15.8.1 Capacitive digital type for machines with ETM............................................463 15.8.2 Capacitive analog type for machines with PLC.............................................465 15.9 Lubrication system function and controlling....................................................468 15.9.1 Central Lubrication System (CLS) function and controlling with ETM system (PC 3000)......469 15.9.2 Swing ring lubrication system (SLS) function and controlling with ETM system (PC3000)....473 15.10 Adjustment of the lubrication system with ETM.................................................479 15.11 Trouble shooting lubricating system...........................................................481 15.11.1 Lubrication pump cylinder does not move.................................................482 15.11.2 Lubricant pressure built up very slowly or not at all...................................484 15.11.3 Insufficient lubricant supply to one or more attachment bearings........................484 15.11.4 Insufficient lubricant at the swing ring gear...........................................486
PLEASE NOTE:
⦁ This is the SAME exact manual used by your dealers to fix your vehicle.
⦁ The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
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