Komatsu PC3000-6 Hydraulic Mining Shovel Shop Manual 06279-xG-GB-1 PDF

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Komatsu PC3000-6 Hydraulic Mining Shovel Shop Manual 06279-xG-GB-1 –  PDF DOWNLOAD

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Komatsu PC3000-6 Hydraulic Mining Shovel Shop Manual 06279-xG-GB-1 –  PDF DOWNLOAD

Language : English
Pages : 1628
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu PC3000-6 Hydraulic Mining Shovel Shop Manual 06279-xG-GB-1 –  PDF DOWNLOAD

• SERIAL NUMBERS
  06279, 06308, 06309, 06310,
  06314 and up
  (TIER2 & KOMTRAX Plus)

Shop Manual . 1
00 Foreword and Safety Instructions . 2
1 Foreword 5
1.1 Before reading this manual 6
1.2 Contents of the binder 7
1.2.1 Contacting the Service 7
1.2.2 Guarantee . 7
1.3 Division of the binder . 8
2 SAFETY 9
2.1 SAFETY INFORMATION 10
2.2 OVERVIEW 11
2.2.1 NORMAL OPERATIONS . 11
2.2.2 REGULAR MAINTENANCE . 11
2.2.3 TROUBLESHOOTING, ADJUSTMENTS AND REPAIR . 11
2.2.4 ADDITIONAL SAFETY PRECAUTIONS . 11
2.3 SOUND PRESSURE AND VIBRATION LEVELs IN THE OPERATOR’S CAB . 12
2.3.1 SOUND . 12
2.3.2 VIBRATION . 12
2.4 GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR 13
2.4.1 UNDERSTANDING THE MACHINE . 13
2.4.2 PRECAUTIONS BEFORE STARTING OPERATION ON THE EXCAVATOR 13
2.4.2.1 ENSURING SAFE OPERATION . 13
2.4.3 PREPARATIONS FOR SAFE OPERATION . 13
2.4.3.1 PRECAUTIONS REGARDING SAFETY RELATED EQUIPMENT 13
2.4.3.2 INSPECTING THE MACHINE 13
2.4.3.3 WEAR WELL FITTING CLOTHES AND PROTECTIVE EQUIPMENT 14
2.4.3.4 KEEP MACHINE CLEAN 14
2.4.3.5 PRECAUTIONS INSIDE OPERATOR’S COMPARTMENT . 14
2.4.3.6 PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT . 15
2.4.3.7 IF A PROBLEM IS FOUND . 15
2.4.4 FIRE PREVENTION . 15
2.4.4.1 PRECAUTIONS TO PREVENT FIRE . 15
2.4.4.2 ACTION IF FIRE OCCURS . 17
2.4.4.3 EMERGENCY EXIT FROM OPERATOR’S CAB 17
2.4.5 PRECAUTIONS WHEN GETTING ON OR OFF THE MACHINE 18
2.4.5.1 USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF THE MACHINE 18
2.4.5.2 NO JUMPING ON OR OFF THE MACHINE 18
2.4.5.3 NO PEOPLE ON THE ATTACHMENT . 18
2.4.5.4 WORKING IN HIGH PLACES 18
2.4.5.5 LEAVING OPERATOR’S SEAT WITH LOCK . 19
2.4.5.6 LEAVING THE MACHINE . 19
2.4.6 BURN PREVENTION . 19
2.4.6.1 Hot coolant . 19
2.4.6.2 Hot oil . 20
2.4.7 PRECAUTIONS WHEN CLEANING CAB GLASS . 20
2.4.8 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES 20
2.4.8.1 UNAUTHORIZED MODIFICATION . 21
2.4.8.2 PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS 21
2.4.9 ELECTROMAGNETIC COMPATIBILITY (EMC) . 21
2.4.10 PRECAUTIONS AT JOBSITE . 22
2.4.10.1 VISIBILITY FROM OPERATOR’S SEAT 23
2.4.10.2 CAMERA SYSTEM WITH MONITORS 23
2.4.10.3 ENSURE GOOD VISIBILITY . 23
2.4.10.4 CHECKING SIGNS AND SIGNALMAN’S SIGNALS . 23
2.4.10.5 INVESTIGATE AND CONFIRM JOBSITE CONDITIONS . 24
2.4.10.6 DO NOT GO CLOSE TO HIGH VOLTAGE CABLES . 24
2.4.10.7 WORKING ON LOOSE GROUND 25
2.4.10.8 GAS, DUST, STEAM AND SMOKE . 25
2.4.10.9 VENTILATION OF ENCLOSED AREAS 26
2.4.11 STARTING motor . 27
2.4.11.1 WARNING TAG 27
2.4.11.2 CHECKS BEFORE STARTING motor . 27
2.4.11.3 PRECAUTION WHEN STARTING motor . 27
2.4.11.4 PRECAUTION IN COLD AREAS . 28
2.4.12 OPERATION 28
2.4.12.1 CHECKS BEFORE OPERATION 28
2.4.12.2 PRECAUTIONS WHEN TRAVELLING IN FORWARD OR REVERSE 29
2.4.12.3 PRECAUTIONS WHEN travelling 30
2.4.12.4 TRAVELLING ON SLOPES . 31
2.4.12.5 OPERATIONS ON SLOPES . 32
2.4.12.6 PROHIBITED OPERATIONS 32
2.4.12.7 TRAVELLING ON FROZEN OR SNOW COVERED SURFACES 33
2.4.12.8 PARKING THE MACHINE 33
2.4.12.9 TRANSPORTATION . 33
2.5 PRECAUTION FOR MAINTENANCE 34
2.5.1 GENERAL PRECAUTIONS . 34
2.5.1.1 SELECTION AND QUALIFICATION OF PERSONNEL – BASIC RESPONSIBILITIES . 35
2.5.1.2 STOP motor FOR MAINTENANCE 36
2.5.1.3 WARNING TAG . 37
2.5.1.4 KEEP WORKPLACE CLEAN AND TIDY . 38
2.5.1.5 APPOINT LEADER WHEN WORKING WITH OTHERS . 38
2.5.1.6 TWO WORKERS FOR MAINTENANCE WHEN THE MACHINE IS RUNNING . 39
2.5.1.7 INSTALLING, REMOVING OR STORING ATTACHMENTS . 39
2.5.1.8 PRECAUTIONS WHEN WORKING UNDER THE MACHINE OR EQUIPMENT . 40
2.5.1.9 NOISE . 40
2.5.1.10 WHEN USING A HAMMER 40
2.5.1.11 PROPER TOOLS . 41
2.5.1.12 ACCUMULATOR 41
2.5.1.13 PERSONNEL 41
2.5.2 PRECAUTIONS FOR INSPECTION AND MAINTENANCE 42
2.5.2.1 PRECAUTION WHEN WELDING . 42
2.5.2.2 BATTERY HANDLING 42
2.5.3 PRECAUTIONS WITH HIGH PRESSURE FLUID 43
2.5.3.1 PRECAUTIONS WITH HIGH FUEL PRESSURE . 43
2.5.3.2 HANDLING HIGH PRESSURES HOSES OR PIPES 44
2.5.3.3 REPLACEMENT OF HOSE LINES . 44
2.5.3.4 INSPECTION OF HOSE LINES 44
2.5.3.5 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS . 45
2.5.3.6 PRECAUTIONS FOR HIGH VOLTAGE 45
2.5.3.7 AIR CONDITIONING MAINTENANCE 45
2.5.3.8 COMPRESSED AIR 46
2.5.3.9 WASTE MATERIALS . 46
2.6 ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS . 47
2.6.1 INSPECTION OF THE HYDRAULIC SYSTEM 47
2.6.2 TWO WORKERS ONLY WHEN THE MACHINE IS RUNNING DURING ADJUSTMENTS . 47
2.6.3 AREAS OF POTENTIAL DANGER AROUND THE EXCAVATOR 47
2.7 SPECIAL SAFETY EQUIPMENT 48
2.7.1 FRONT GUARD PROTECTIVE STRUCTUR ’FOPS’ FOR OPERATOR’S CAB . 49
2.7.2 OBJECT HANDLING . 49
2.7.3 LIGHTING 49
2.7.4 WARNING BEACON 49
2.7.5 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD) 49
2.7.5.1 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD) 49
2.7.5.2 INSTRUCTIONS FOR USE 51
2.7.5.3 PRIOR TO USING THE HARNESS (1), THE WEARER SHALL 53
2.7.5.4 RECOMMENDATIONS FOR USE OF THE HOLDING HOOKS AND HOLD- BACK HOOKS OF THE SAFETY HARNESS . 53
2.7.5.5 INSTRUCTIONS FOR USE 55
01 Specification 57
PC3000-6 58
10 Structure & Function . 67
Table of Contents . 69
1 Introduction 79
1.1 Foreword 80
1.2 Recommendations for environmentally friendly operation and maintenance of hydraulic mining shovels 81
1.3 Explanation of abbreviations 82
1.4 Diagrams and illustrations in this manual . 83
2 Specifications 85
2.1 Lifting Gears . 86
2.2 Safety hints for sling accessory 88
2.3 Standard Tightening Torque Chart 89
2.4 Conversion Tables . 90
2.5 PT100 TEMPERATURE CHARTS (PT100) g Centigrade – Ohm . 96
2.6 Blind plugs . 97
2.7 Classification of threads to the nominal width 99
2.8 Plugs and fittings according to ISO 8434-1 / DIN 2353 . 100
3 Main assembly groups 101
3.1 General layout 102
3.2 Superstructure 104
3.3 Machine house . 106
3.4 Hydraulic oil tank 108
3.5 Hydraulic oil cooler 110
3.6 Fuel tank . 112
3.7 Counterweight . 114
3.8 Cab base 116
3.9 Operator’s cab 118
3.10 Main Control blocks 120
3.10.1 Main control blocks (FSA) 120
3.10.2 Main control blocks (BHA) 122
3.11 Slew machinery . 124
3.11.1 Slew machinery L&S . 124
3.11.2 Slew machinery SIEBENHAAR 126
3.12 Undercarriage 128
3.13 Backhoe attachment (BHA) . 130
3.14 Front shovel attachment (FSA) 131
4 Drive . 133
4.1 Prime drive assembly 134
4.2 Engine mounts . 136
4.2.1 Checks and adjustments 137
4.3 Flexible Coupling . 138
4.3.1 Geislingenr coupling 138
4.3.2 CentaFlex COUPLING 140
4.3.2.1 Information for maintenance . 142
4.3.2.2 Coupling elements . 143
4.3.2.3 Separation and assembly of the coupling inner and outer part 144
4.3.2.4 OPERATION TROUBLES, CAUSES, AND RECTIFICATION . 145
4.4 Radiator Fan drive 146
4.5 PTO . 148
4.5.1 PTO lubrication and cooling . 150
4.5.1.1 Checks and adjustments – PTO lubrication pressure . 152
4.5.2 PTO gear oil temperature control 154
4.5.2.1 temperature Adjustment (oil viscosity) 154
4.5.2.2 Adjustment of the line resistance compensation 155
4.5.3 Pump spline lubrication . 156
4.5.3.1 Oil level in the main pump & gear oil pump drive shaft housing 157
4.6 Hydraulic pumps – arrangement . 158
4.7 Air filter 160
5 Hydraulic oil tank 163
5.1 General layout 164
5.2 Hydraulic oil tank, location of the electric equipmenT 166
5.3 Suction oil manifold with strainers . 168
5.4 Return oil collector manifold with strainer . 170
5.5 Back pressure valve . 172
5.6 Transfer pump . 174
5.7 Return and leak oil filter 176
5.8 Breather filter . 178
6 Hydraulic oil cooling . 181
6.1 Overall view of the hydraulic oil cooling . 182
6.2 Function of the hydraulic oil cooling circuit . 184
6.3 Check and Adjustment of the back pressure valve . 186
6.4 Two stage cooler fan RPM control 188
6.4.1 Solenoid valve for fan speed control 190
6.4.2 Pressure reducing valve (fan control valve) . 192
6.4.3 Temperature converter relays 194
6.4.3.1 Function check of cooler fan RPM-control 195
6.4.3.2 Adjustment of the line resistance compensation 195
6.5 Fan pump 196
6.6 Checks and Adjustments of the cooler fan drive speeds . 198
6.6.1 Function Check of Fan Speed Control . 201
7 Controlling . 203
7.1 General layout 204
7.2 Control and filter plate – location of components . 206
7.3 Pilot control frame – location of components 210
7.4 Pilot pressure supply and adjustments . 212
7.4.1 Pilot pressure circuit 212
7.4.2 Checks and adjustment of pilot pressure . 214
8 Components 217
8.1 Main control blocks and high pressure filters (FSA) . 218
8.2 Main control blocks and high pressure filters (BHA) . 222
8.3 Distributor manifold – location of restrictor blocks and anti cavitation valves (FSA) . 226
8.4 Distributor manifold – location of restrictor blocks and anti cavitation valves (BHA) . 228
8.5 Single control blocks (floating) for stick and boom (FSA) . 230
8.6 Restrictor block with secondary relief valve 232
8.7 Anti-cavitation valve (ACV) block . 234
8.8 High-pressure filter (screen) . 236
8.9 Control blocks and valves . 238
8.9.1 Spool types . 244
8.9.2 MRV, SRV and ACV 246
8.9.3 Load holding valve 248
8.10 Travel brake valve . 252
8.11 4/2 Directional solenoid valves 254
8.12 4/3 Directional solenoid valves 256
8.13 Pressure double stage valve 258
8.14 Hydraulic cylinder . 260
8.15 Auxiliary gear pumps . 264
9 Main hydraulic pumps and pump regulation 265
9.1 General . 266
9.1.1 Pump locations and pump data 268
9.2 Main pumps 270
9.2.1 Hydraulic pump type HPV375+375 270
9.2.1.1 Main pump sectional drawings 272
9.2.2 Servo valve . 274
9.2.2.1 VC valve  servo piston . 275
9.2.2.2 EPC valve . 280
9.3 Electronic pump regulation system . 282
9.3.1 Cut-off function 284
9.3.2 Slew control (volume reduction) . 285
9.3.3 Diagnostics and monitoring 285
9.3.4 Temperature control . 286
9.3.4.1 temperature Adjustment (hydraulic oil viscosity) 286
9.3.4.2 Adjustment of the line resistance compensation 287
9.4 Pump controller CR710 . 288
9.4.1 Connector and pin arrangement at CR710 (10K032) . 290
9.5 Multimonitor 294
9.5.1 Service menu screen . 297
9.5.2 Service menu, option: 01 Monitoring . 298
9.5.2.1 Hold function . 301
9.5.3 Service menu, option: 02 Abnormality Record . 302
9.5.3.1 Troubleshooting procedures 302
9.5.3.2 Table of Pump-controller-Codes (Multi Monitor) 304
9.5.4 Service menu, option: 03 Default 306
9.5.5 Service menu, option: 04 Adjustment . 307
9.5.6 Adjustable parameters . 309
9.5.7 Emergency mode 309
9.5.8 Description of the Primary P-Factor . 310
9.5.8.1 Adjustment, item 1: Primary P-factor 310
9.5.9 Adjustment, items 23 .28: Sol_adj_min_P1 .Sol_adj_min_P6 311
9.5.10 Adjustment, items 39 .44: Sol_adj_mAX_P1 .Sol_adj_mAX_P6 . 312
9.5.11 Available parameters list 313
9.5.12 Service menu, option: 05 Display Setup . 315
9.6 Checks and adjustments 316
9.6.1 Engine power check 316
9.6.2 Cut-off function check 319
9.6.2.1 Cut-off for clam close (FSA only) . 320
9.7 Engine speed sensor (pick-up) . 322
9.7.1 General . 323
9.7.2 Engine speed sensor (pick-up) adjustment 323
10 Operating hydraulics . 325
10.1 General 326
10.1.1 Floating system (FSA) 328
10.2 Checks and adjustments of the main relief valve (MRV) 330
10.3 Hydraulics for the attachment cylinders 334
10.3.1 Checks and adjustments of the secondary relief valves (SRV) 334
10.3.1.1 Boom cylinders, piston side (BHA & FSA), boom up . 334
10.3.1.2 Boom Cylinder, Piston Rod Side (BHA & FSA), boom down 338
10.3.1.3 Stick cylinders, piston side (FSA), stick out 342
10.3.1.4 Stick cylinders, piston side (BHA), stick in . 346
10.3.1.5 Stick cylinders, piston rod side (FSA), stick in . 350
10.3.1.6 Stick cylinders, piston rod side (BHA), stick out 354
10.3.1.7 Bucket cylinders, piston side (FSA), bucket fill . 358
10.3.1.8 Bucket cylinders, piston side (BHA), bucket fill . 362
10.3.1.9 Bucket cylinders, piston rod side (FSA), bucket dump . 366
10.3.1.10 Bucket cylinders, piston rod side (BHA), bucket dump 370
10.3.1.11 Clam cylinders, piston rod side (FSA), clam open 374
10.3.1.12 Clam cylinders, piston side (FSA), clam close . 378
10.3.2 Checks and adjustments of the lowering speed . 382
10.3.2.1 Checks and adjustments of the lowering speed – boom (FSA) 382
10.3.2.2 Checks and adjustments of the lowering speed – boom (BHA) 388
10.3.2.3 Checks and adjustments of the lowering speed – stick (FSA) . 390
10.3.2.4 Checks and adjustments of the lowering speed – stick (BHA) . 396
10.3.2.5 Checks and adjustments of the lowering speed – bucket (FSA) 398
10.3.2.6 Checks and adjustments of the lowering speed – bucket (BHA) 400
10.3.2.7 Checks and adjustments of the lowering speed – clam (FSA) 402
10.4 Hydraulics for the slew circuit 404
10.4.1 Slew circuit . 404
10.4.2 Slew motor . 406
10.4.3 Slew gearbox (L&S) . 408
10.4.4 Slew gearbox (SIEBENHAAR) 410
10.4.5 Slew parking brake (L&S) . 412
10.4.6 Slew parking brake (SIEBENHAAR) 414
10.4.7 Slew brake valve . 416
10.4.8 Checks and adjustments for the slew circuit 420
10.4.8.1 Checks & adjustments, double stage valve . 420
10.4.8.2 checks & adjustments, slew Brake pilot pressure 423
10.4.8.3 Crosscheck of the DSV setting 423
10.4.8.4 Adjustment of the slew motion detection 424
10.4.9 Function check for the hydraulic slew parking brake 426
10.5 Hydraulics for the travel circuit 428
10.5.1 Travel circuit . 428
10.5.2 Travel motor . 430
10.5.3 Rotary joint . 432
10.5.4 Travel gearbox . 434
10.5.5 Travel parking brake . 436
10.5.5.1 Travel parking brake . 436
10.6 Travel brake valve . 438
10.6.1 Checks and adjustments . 440
10.6.1.1 Checks and adjustments for the travel circuit 440
10.6.1.2 Function check for the travel parking brake 444
11 Hydraulic track tensioning system 447
11.1 General 448
11.2 Functional description . 450
11.3 Double stage valve . 452
11.4 Tensioning cylinder 454
11.5 Adjustments / checks . 456
12 Access ladder, hydraulically operated 459
12.1 General 460
12.2 Function of the hydraulically operated access ladder . 462
12.3 Adjustments / checks . 466
13 Central refilling system (refilling arm) . 469
13.1 Refilling arm location . 470
13.2 Function . 472
14 Hints for reading the hydraulic diagram 475
14.1 General 476
14.2 Hydraulic symbols 478
14.2.1 Lines, unions 479
14.2.2 Components, valves . 481
14.2.3 Sensors 481
14.2.4 Valves, valve components . 482
14.2.5 Pump, motor, cylinder 486
15 Hints for reading the electric wiring diagram 491
15.1 General 492
15.2 Reference code of the electrical components 493
15.2.1 Area code 493
15.2.2 Component identifying letter . 495
15.3 Graphical symbols 496
15.4 Drawing concept 500
15.5 Cable marking 509
16 KOMTRAX Plus . 511
16.1 General 512
16.1.1 location of KOMTRAX Plus components in cab base 514
16.2 Specifications for operators . 516
16.2.1 Opening screen . 517
16.2.2 Main gauge screens 1 to 2 518
16.2.3 Fuel consumption screen 522
16.2.4 Failure message history for the operator . 524
16.2.5 Main gauge screens – Changing of Time / SMR / Date . 525
16.2.6 Maintenance monitor 526
16.2.7 Settings for operator 528
16.2.7.1 USER ID Screen . 529
16.2.7.2 Reset Truck Counter 1 & 2 530
16.2.7.3 Screen Adjustment Displays . 532
16.2.7.4 Date and Time Adjustment . 534
16.2.7.5 Language selection . 535
16.2.8 Automatic messages . 536
16.3 Tables of all provided messages 538
16.3.1 TABLE OF Cummins trouble CODES (TIER 2) 538
16.3.2 TABLE OF KOMTRAX PLUS TROUBLE CODES 543
16.3.3 Table of Pump-controller-Codes (Multi Monitor) . 547
16.3.4 Table of available Instruction Messages 549
16.4 Flow charts (1-4) of KOMTRAX Plus main screens . 552
16.5 KOMTRAX Plus service level . 556
16.5.1 Explanation of the button symbols (Service Level) 558
16.5.2 Service Menu Select Screen . 559
16.5.3 Real Time Menu Select Screen . 560
16.5.3.1 Real Time Menu, option: 01 Engine 1 561
16.5.3.2 Real Time Menu, option: 02 PTO 1 . 562
16.5.3.3 Real Time Menu, option: 03 Hydraulic . 563
16.5.3.4 Real Time Menu, option: 04 Electrical Equipment 564
16.5.3.5 Real Time Menu, option: 05 Emergency Stop 565
16.5.3.6 Real Time Menu, option: 06 Manual Switch . 566
16.5.3.7 Real Time Menu, option: 07 Central Lube System 1 . 567
16.5.3.8 Real Time Menu, option: 08 Slew Ring Gear Lube System 568
16.5.3.9 Real Time Menu, option: 09 Pilot Control . 569
16.5.3.10 Real Time Menu, option: 10 Other Items 570
16.5.3.11 Real Time Menu, option: 11 Output Signals . 571
16.5.4 PM-Clinic 572
16.5.4.1 General 572
16.5.4.2 Power Check 573
16.5.5 Serial/GCC no. setting . 575
16.5.6 Memory Clear . 576
16.5.6.1 Input Memory Clear ID 576
16.5.6.2 Memory Clear screen 577
16.5.7 Failure History 578
16.5.8 Maintenance Monitor 579
16.5.9 Snapshot . 580
16.5.10 Settings 582
16.5.10.1 Central Lubrication System (CLS 1), screen 1/4 582
16.5.10.2 Slew Lubrication System (SLS), screen 2/4 . 583
16.5.10.3 Other Settings 1/2, screen 3/4 583
16.5.10.4 Other Settings 2/2, screen 4/4 584
16.6 Interface-Connection KOMTRAX Plus controller . 586
16.6.1 KOMTRAX Plus controller 587
16.7 7-segment error code indication 588
16.8 Wiring of the KOMTRAX Plus controller 590
16.9 Global layout of the internal CAN BUS 594
16.9.1 General information on a CAN BUS system 594
16.9.1.1 General CAN BUS description 595
16.9.1.2 CAN bus troubleshooting 595
16.9.2 Can bus wiring . 596
16.9.2.1 CAN bus end resistor . 597
17 Lubrication system . 599
17.1 General overview (SLS & CLS) . 600
17.1.1 General description 601
17.2 Basic function of the lubrication systems 602
17.3 Lubrication systems (SLS & CLS) 604
17.3.1 Lubrication pump station . 604
17.3.2 General Information on CLS . 606
17.3.3 General information on SLS . 606
17.4 Lubrication cycle 608
17.4.1 Time segments & switch points of a lubrication cycle . 609
17.4.2 Automatic lubrication mode CLS . 610
17.4.2.1 Function . 611
17.4.2.2 System monitoring 611
17.4.3 Automatic lubrication mode SLS . 612
17.4.3.1 Function . 613
17.4.3.2 System monitoring 613
17.4.4 Automatic lubrication mode adjustments . 614
17.4.4.1 Pause time adjustment & fault time monitoring adjustment . 614
17.4.4.2 Lube cycle monitoring time adjustment 615
17.4.5 Manual lubrication mode (CLS & SLS) 616
17.4.6 Resetting a faulty lubrication system 616
17.5 Hydraulically driven lube pump . 618
17.5.1 Adjustment of lube pump speed 620
17.5.1.1 Stroke speed adjustment 621
17.5.1.2 Working pressure . 621
17.6 Lubricant injectors 622
17.6.1 Tightening torques for fittings at grease injectors 623
17.6.2 Description 623
17.6.3 Adjustment of the lubricant output . 624
17.6.4 Operation principle of lubricant injectors . 626
17.6.4.1 Function description . 627
17.6.5 Connection of one or more injectors 628
17.7 Vent valve and grease outlet filter 630
17.7.1 Vent valve description . 631
17.8 End-line switch 632
17.8.1 Description 633
17.8.2 CLS & SLS end-line switch adjustment . 634
17.9 Lubricant level sensors 636
17.9.1 Description 637
17.9.1.1 Checks . 637
17.10 Commissioning . 638
17.10.1 Commissioning of the CLS lubrication system . 638
17.10.2 Fine adjustment . 639
17.10.3 Commissioning of the SLS lubrication system . 640
18 Deep temperature equipment (option) 643
18.1 General information 644
18.1.1 Introduction . 644
18.1.2 Deep temperature components overview . 644
18.1.3 Power supply preconditions for preheating 645
18.1.4 Power requirements for preheating systems 646
18.2 Preheating procedure . 647
18.2.1 Global flow chart of the preheating procedure 647
18.2.2 Starting the preheating procedure 648
18.2.3 Preheating of operator’s cab and Diesel engine [coolant system] 649
18.2.4 Preheating of lubricants and superstructure (Diesel) [electric system] . 650
18.3 Constant heating of travel motors (TTT equipment below-40°C only) 651
18.4 Component location . 652
18.4.1 Electric heating elements for hydraulic & batteries [electric machine] . 652
18.4.2 Electric heating elements for hydraulics [Diesel machine] 654
18.4.3 Electric heating elements for engines & batteries [Diesel machine] . 656
18.5 Components of TT equipment . 658
18.5.1 Preheating components on a Diesel machine 658
18.5.2 Preheating components on an electric machine . 660
18.5.3 Exemplary Wiring Diagrams for preheating systems . 661
18.5.3.1 Wiring diagram “Hydraulic Oil Tank Preheating” part 1 of 3 . 661
18.5.3.2 Wiring diagram “Hydraulic Oil Tank Preheating” part 2 of 3 . 662
18.5.3.3 Wiring diagram “Hydraulic Oil Tank Preheating” part 3 of 3 . 663
18.5.3.4 Wiring diagram “Suction Oil Manifold Preheating” . 664
18.5.3.5 Wiring diagram “PTO Preheating” 665
18.5.3.6 Wiring diagram “Battery heater pads” . 666
40 Troubleshooting 667
TABLE OF CONTENTS . 668
1 Introduction 679
1.1 Overview 680
1.1.1 General advice when using troubleshooting charts 680
1.2 General Precautions . 681
2 General Information for Troubleshooting . 683
2.1 Preparations For Work . 684
2.2 Precautions During Work . 684
2.3 Precautions When Carrying Out Any Operation . 685
2.3.1 Precautions when carrying out removal work 685
2.3.2 Precautions when carrying out installation work . 685
2.3.3 Precautions when completing the operation . 686
2.4 Fundamental Requirements for Troubleshooting 687
2.4.1 Technical documentation . 687
2.4.2 Tools . 687
2.4.2.1 Reference Guide for Deutsch Removal Tools . 690
2.4.3 Personnel . 691
2.5 Points To Remember When Troubleshooting . 691
2.6 Sequence Of Events In Troubleshooting . 693
2.7 Checks Before Troubleshooting . 694
2.8 Handling Of Electric Equipment And Hydraulic Components . 695
2.8.1 Points to remember when handling electric equipment . 695
2.8.2 Points To Remember When Handling Hydraulic Equipment 697
2.9 General working procedures 700
2.9.1 Air Bleeding of Various Hydraulic Parts . 700
2.9.2 Air bleeding from the hydraulic pumps . 700
2.9.3 Air bleeding from hydraulic cylinders . 700
2.10 Cylinder bypass test . 701
2.11 Basics about “How to crimp” (with strain relief) . 702
2.11.1 Crimp tool & repair kit 702
2.11.2 General 703
2.11.3 Select the required connector components . 703
2.11.4 Stripping a wire . 704
2.11.5 Crimping . 705
2.11.6 Connector assembly after crimping 706
2.12 Cable Shielding 707
3 Mounting Locations and Connector Types 709
3.1 Component location 710
3.1.1 View at the Superstructure 710
3.1.2 Engine – location of electrical components (1) 712
3.1.3 Engine – location of electrical components (2) 714
3.1.4 Control and filter plate – location of Components . 716
3.1.5 PTO and suction oil tank – location of electrical components 718
3.1.6 Pilot control frame – location of electrical components . 720
3.1.7 Main control blocks – location of components 722
3.1.8 Lubrication system – location of electrical components 724
3.1.9 Cab base – location of electrical components 726
3.1.10 Hydraulic Oil Tank – Location of Electrical Components . 728
3.1.11 Hydraulically operated access ladder – location of electrical Components . 730
3.1.12 Refilling arm – location of electrical Components 731
3.1.13 Air filter and fuel tank – location of electrical components . 732
3.2 Connector Types Overview 734
4 Standard Value Table for Electrical Components 737
5 References for Troubleshooting 749
5.1 7-segment error code indication . 750
5.2 Relay checks 752
5.2.1 Switch contact testing using the Test button 752
5.2.2 Measuring of the coil resistance 754
6 Tables for Testing and Troubleshooting 757
6.1 PT100 TEMPERATURE CHARTS (PT100) g Centigrade – Ohm . 758
6.2 Test Value Table for pressure Sensors . 759
6.2.1 Transducers with output voltage range: 0.5 4.5 Volt 759
6.2.2 Transducers with output voltage range: 0.5 9.5 Volt 759
6.3 Trouble Code Tables . 760
6.3.1 TABLE OF Cummins trouble CODES (TIER 2) . 760
6.3.2 TABLE OF KOMTRAX PLUS TROUBLE CODES . 765
6.3.3 Table of Pump-controller-Codes (Multi Monitor) 769
6.4 Table of Instruction Messages . 771
6.5 TABLES OF SYMPTOM CODES . 774
6.5.1 SYMPTOMS OF THE ENGINES AND RELATED ELECTRICAL SYSTEMS 774
6.5.2 SYMPTOMS OF THE HYDRAULIC SYSTEM 774
6.5.3 SYMPTOMS OF THE MECHANICAL SYSTEM . 775
6.5.4 SYMPTOMS OF ADDITIONAL SYSTEMS 775
6.6 Cable colour identification . 776
7 Troubleshooting by KOMTRAX Plus trouble code 777
G00001 – Trouble Shut-Off (gate) valve 778
View onto the gap of proximity switch 40B031 780
Input signal of the proximity switch 40B031 on the REAL TIME MONITOR 780
Wiring Diagram (40B031) for trouble code G00001 (Main gate valve open) 781
G00002 – Test speed 1800 1/min engine 1 . 782
Input signal of the switch 11S041-1 on the REAL TIME MONITOR 782
Wiring Diagram (11S041-1) for trouble code G00002 . 783
G00007 – Trouble hydraulic oil level 784
Wiring Diagram (40B004) and the defined position of the attachment (G00007) . 787
G00012 – Central lubrication system grease level too low 788
G00013 – Slew ring gear lubr. system grease level too low . 788
Input signals of grease level sensors 62B108b & 62B109b on the REAL TIME MONITOR 791
Wiring Diagram for trouble codes G00012 & G00013 792
Wiring Diagram (junction box) for trouble codes G00012 & G00013 . 793
G00031 – Set engine to low idle . 794
Wiring Diagram (20S030) for trouble code G00031 . 795
Input signal of the resistor 11T080 on the REAL TIME MONITOR 795
G00060 – Fire in the power house 796
Wiring Diagram (fire alarm & safety circuit) for trouble code G00060 798
G00065 – Very low hydraulic oil level . 799
View onto the hydraulic oil level label . 799
G00066 – Trouble hydraulic oil temperature 800
Hydraulic oil temperature table – 11K039 adjustment (T4 switch point) . 802
Wiring Diagram (59B015 and 11K039) for G00066 . 803
G00067 – Trouble battery voltage too high . 804
Input signal of the resistor 11T080 on the REAL TIME MONITOR 805
Wiring Diagram (11T080) for G00067 805
G00070 – Trouble oil temperature gear (PTO 1) . 806
PTO gear oil temperature table – 11K143 adjustment 808
Input signal of 57B049 on the REAL TIME MONITOR . 808
Wiring Diagram (59B049 / 11K143) for G00070 . 809
G00071 – Trouble gear lubrication (PTO 1) . 810
PTO gear oil temperature table – 11K182 adjustment 812
Wiring Diagram (57B017) for trouble code G00071 . 812
Wiring Diagram (57B182 & 11K182) for G00071 . 813
Input signal of 57B017 on the REAL TIME MONITOR . 813
G00091 – Pilot control cut out 814
View onto the lock lever and the cover of 20S105 (G00091) . 815
Wiring Diagram (20S105 and wiring) for G00091 . 815
G00092 – Emergency shut-down at access ladder . 816
G00093 – Emergency shut-down at valve block . 816
G00095 – Emergency shut-down in cabin . 816
Wiring Diagram 1 (emergency switches) for G00092~G00095 . 817
Wiring Diagram 2 (emergency switches signal lines) for G00092~G00095 818
G00100 – Maintenance Safety Switch 819
Wiring Diagram (50S058) for trouble code G00100 . 820
G00104 – Trouble battery current 821
Input signal of the converter 11T117 on the REAL TIME MONITOR . 822
Wiring Diagram 1 (71T003 & 52G005) for trouble code G00104 823
Wiring Diagram 2 (52G005, 52M001-1 & 52M002-1) for trouble code G00104 824
G00105 – Trouble battery charging current too low . 825
Input signals of 11T080 & 11T117on the REAL TIME MONITOR 826
Wiring Diagram 1 (71T003 & 11T117) for trouble code G00105 827
Wiring Diagram 2 (11T080) for trouble code G00105 . 828
G00164 – Trouble air cleaner 1 829
View onto the engine air cleaner (G00164) . 830
G00165 – Trouble breather filter hydraulic oil tank . 831
View onto the pressure sensor 40B024 (G00165) . 832
Input signal of 40B024 (filter clogged) on the REAL TIME MONITOR 832
G00166 – Trouble oil filter gear (PTO 1) 833
Hydraulic oil temperature table – 11K026 adjustment (T3 switch point) . 833
View onto the PTO 1 gear oil filter with pressure sensor 57B027 (G00166) 834
Input signal of 57B027 (filter clogged) on the REAL TIME MONITOR 834
G00169 – Trouble return oil filter hydraulic oil tank . 835
Hydraulic oil temperature table – 11K026 adjustment (T3 switch point) . 835
View onto the pressure sensor 40B026 (G00169) . 836
Input signal of 40B026 (filter clogged) on the REAL TIME MONITOR 836
G00170 – Trouble leak oil filter hydraulic oil tank . 837
Hydraulic oil temperature table – 11K026 adjustment (T3 switch point) . 837
View onto the pressure sensor 40B025 (G00170) . 838
Input signal of 40B025 (filter clogged) on the REAL TIME MONITOR 838
G00176 – Trouble battery voltage too low 839
Wiring Diagram (71T003) for trouble code G00176 . 841
G00177 – Trouble battery charging circuit . 842
Wiring Diagram (measuring points 1-3) for trouble code G00177 . 843
G00178 – Trouble battery charging current too high 844
Wiring Diagram (71T003 & 11T117) for trouble code G00178 845
G00184 – Central lubrication system empty . 846
Wiring Diagram 1 (62B108c & 62B109c) for trouble codes G00184 & G00187 849
Wiring Diagram 2 (wiring to 14K300) for trouble codes G00184 & G00187 . 850
Wiring Diagram 3 (junction box) for trouble codes G00184 & G00187 . 851
Input signals of grease level sensors 62B108c & 62B109c on the REAL TIME MONITOR 852
G00185 – Trouble central lubrication system . 853
Wiring Diagram 1 (relays) for trouble code G00185 . 858
Wiring Diagram 2 (11K50 & trouble signal circuit CLS/SLS) for trouble code G00185 . 859
Wiring Diagram 3 (10K511a) for trouble code G00185 860
View onto the vent valve 62Q507a 861
Action chart for lube cycles 862
G00187 – Slew ring gear lubrication system empty 863
G00188 – Trouble slew ring gear lubrication system 863
Wiring Diagram 1 (relays) for trouble code G00188 . 869
Wiring Diagram 2 (11K50 & trouble signal circuit CLS/SLS) for trouble code G00188 . 870
Wiring Diagram 3 (10K511a) for trouble code G00188 871
View onto the pressure switch 10B047 and wiring Diagram 3 for trouble code G00188 . 872
View onto the vent valve 62Q509a 873
Action chart for lube cycles 874
G00207 – Engine remote oil tank 1 empty . 875
G00222 – Load limiting clam defective . 876
Wiring Diagram (10B155 & 10B156) for trouble code G00222 878
G00243 – Fill up fuel tank 879
G00245 – Engine shutdown from ground 880
G00256 – Operator warning system 881
G00262 – Trouble screen at hydr. cooler entry clogged . 882
Location of 40B165 and the strainer at the intermediate pipe (G00262) . 883
G00422 – Can-net sys (J1939) 884
Wiring Diagram (CAN-BUS) for trouble code G00422 885
G00491 – Communication failure MH800 <=> K+ Controller 886
Wiring Diagram (K+ monitor (MH801) → K+ controller) for trouble code G00491 . 887
DBBQKR – Communication failure CR710 <=> KOMTRAX Plus Controller 888
Wiring Diagram (CR710 <=> KOMTRAX Plus) for trouble code DBBQKR . 889
DBB3KK – Abnormality in VBAT voltage (KOMTRAX Plus VBAT<10V) 890
DBB0KK – KOMTRAX Plus source voltage Error 891
Wiring Diagram – K+ controller 24V supply and GND connections . 892
DBB0KQ – KOMTRAX Plus Connector Mismatch 893
DGH2KA – Hyd. Oil Temp. Sensor Failure 894
Wiring Diagram (59B032-1) for trouble code DGH2KA . 895
DGH2KB – Hyd. Oil Temp. Sensor Failure 896
Wiring Diagram (59B032-1) for trouble code DGH2KB . 897
J100KA – Pilot Press. Sensor Failure 898
Wiring Diagram (57B086) for trouble code J100KA . 900
J100KB – Pilot Press. Sensor Failure 901
Wiring Diagram (57B086) for trouble code J100KB . 902
J100L6 – Abnomal Pilot Pump press . 903
Wiring Diagram (57B086) for trouble code J100L6 . 904
DGE5KA – Ambient air temp Sensor Failure 905
Wiring Diagram (13B090) for trouble code DGE5KA . 906
DGE5KB – Ambient air temp Sensor Failure 907
Wiring Diagram (13B090) for trouble code DGE5KB . 908
F@DANS – Trouble High Exhaust Temperature Cylinder RB1 909
F@DBNS – Trouble High Exhaust Temperature Cylinder RB2 909
F@DCNS – Trouble High Exhaust Temperature Cylinder RB3 909
F@DDNS – Trouble High Exhaust Temperature Cylinder RB4 909
F@DENS – Trouble High Exhaust Temperature Cylinder RB5 909
F@DFNS – Trouble High Exhaust Temperature Cylinder RB6 909
F@DGNS – Trouble High Exhaust Temperature Cylinder LB1 909
F@DHNS – Trouble High Exhaust Temperature Cylinder LB2 909
F@DJNS – Trouble High Exhaust Temperature Cylinder LB3 909
F@DKNS – Trouble High Exhaust Temperature Cylinder LB4 909
F@DLNS – Trouble High Exhaust Temperature Cylinder LB5 909
F@DMNS – Trouble High Exhaust Temperature Cylinder LB6 909
Input signals of the engine cylinder temperature sensors on the REAL TIME MONITOR . 910
Wiring Diagram for trouble codes F@D(A .M)NS . 911
DGTAKX – Trouble monitoring Exhaust Temp Cylinder RB1 . 912
DGTBKX – Trouble monitoring Exhaust Temp Cylinder RB2 . 912
DGTCKX – Trouble monitoring Exhaust Temp Cylinder RB3 . 912
DGTDKX – Trouble monitoring Exhaust Temp Cylinder RB4 . 912
DGTEKX – Trouble monitoring Exhaust Temp Cylinder RB5 . 912
DGTFKX – Trouble monitoring Exhaust Temp Cylinder RB6 . 912
DGTGKX – Trouble monitoring Exhaust Temp Cylinder LB1 . 912
DGTHKX – Trouble monitoring Exhaust Temp Cylinder LB2 . 912
DGTJKX – Trouble monitoring Exhaust Temp Cylinder LB3 . 912
DGTKKX – Trouble monitoring Exhaust Temp Cylinder LB4 . 912
DGTLKX – Trouble monitoring Exhaust Temp Cylinder LB5 . 912
DGTMKX – Trouble monitoring Exhaust Temp Cylinder LB6 . 912
Input signals of the engine cylinder temperature sensors on the REAL TIME MONITOR . 913
Wiring Diagram for trouble codes DGT(A .M)KX . 914
DJF1KX – Trouble monitoring fuel level 915
Wiring Diagram (31B063) for trouble code DJF1KX . 917
8 Troubleshooting by Symptoms . 919
8.1 Symptoms of the engine and related electrical system 920
SEL001 – Engine does not start (engine does not rotate) . 920
Wiring Diagram 1 (engine start) for trouble code SEL001 & SEL001a . 922
SEL001a – Engine does not start (Pre-lube does not stop) 923
SEL002 – Engine stops while in operation 924
View onto the fuel system water separator (SEL002) 925
SEL003 – Engine speed is hunting during boom-up movement 926
SEL004 – Engine does not stop . 928
SEL005 – Engine lacks output (no power) . 929
Judgment Table for SEL005 . 930
SEL006 – Exhaust smoke is black . 931
Judgment Table for SEL006 . 932
SEL007 – Oil consumption is excessive . 933
Judgment Table for SEL007 . 934
SEL008 – Oil becomes contaminated quickly . 935
Judgment Table for SEL008 . 936
SEL009 – Fuel consumption is excessive 937
Judgment Table for SEL009 . 938
SEL010 – Oil is in engine coolant . 939
Judgment Table for SEL010 . 940
SEL011 – Oil level rises 941
Judgment Table for SEL011 . 942
SEL012 – Coolant temperature becomes too high (overheating) . 943
Judgment Table for SEL012 . 944
8.2 Symptoms of the Hydraulic System 945
SHY001 – All the work equipment shows lack of power or slow movement (especially the “boom up” function) 945
SHY002 – Engine speed sharply drops or engine stalls too much . 947
SHY003 – No work equipment, travel or slew movement . 949
SHY004 – Work equipment has too much hydraulic drift 950
SHY005 – Work equipment has big time lag 951
Hydraulic oil temperature table – 11K026 and 11K171 adjustment 951
SHY006 – Machine deviates during travel movement 952
SHY007 – Hydraulic system has lack of power . 953
SHY008 – Machine does not slew (or slew speed is very low) 954
Slew brake valve block (SHY008) . 955
SHY009 – Slew acceleration is poor (or slew speed is very low) 956
SHY010 – Excessive overrun when stopping slew movement 958
SHY011 – Floating system without function (FSA only) 960
Floating system – overview (SHY011) . 961
SHY012 – Abnormal noise coming from SRV or MRV 962
SHY013 – Track tensioning system without function (or with poor function) . 963
View onto the elements of the hydraulic track tensioning system (SHY013) 965
SHY014 – Ladder does not move, or slow movement . 966
SHY015 – Refilling arm does not move, or slow movement 968
SHY016 – Refilling arm is sagging when engine is not running 970
SHY017 – The hydr. driven grease pump does not move . 971
SHY018 – Abnormal track chain movement during digging . 973
SHY019 – Slew parking brake without function 974
SHY020 – Travel parking brake without function 975
8.3 Symptoms of the Mechanical System . 976
SME001 – Abnormal noise is made . 976
Judgment Table for SME001 . 977
SME002 – Abnormal noise around the PTO / hydraulic pumps 978
SME003 – Vibration is excessive (engine mountings) 980
Judgment Table for SME003 . 981
SME004 – Vibration is excessive (engine torsion) 982
SME005 – There is a big shock when stopping slew movement . 983
SME006 – There is a big abnormal noise when moving/stopping slew movement . 984
SME007 – Fan blades make abnormal noise . 986
SME008 – Abnormal noise coming from a travel gearbox 987
SME009 – Abnormal noise coming from the work equipment (lack of grease) . 989
SME010 – Abnormal idler movement 991
SME011 – Leak at the PTO shaft seal . 992
8.4 Symptoms of Additional Systems 994
SAD001 – Air conditioner for the cabin does not work 994
View onto the A/C unit (SAD001) . 995
SAD002 – Air conditioner compressor clutch is burnt . 996
View onto the A/C compressor and its mounting (SAD002) 997
SAD003 – Air conditioning system defective (pipes and hoses full of moisture) . 998
View onto an A/C filling and service station 999
9 Troubleshooting by pump controller trouble codes (Multi Monitor) 1001
DXAAKA – Solenoid-1(Pump-1) open circuit 1002
DXABKA – Solenoid-2(Pump-2) open circuit 1002
DXACKA – Solenoid-3(Pump-3) open circuit 1002
DXADKA – Solenoid-4(Pump-4) open circuit 1002
DXAEKA – Solenoid-5(Pump-5) open circuit 1002
DXAFKA – Solenoid-6(Pump-6) open circuit 1002
Wiring Diagram – EPC valve control (pump controller) 1003
DXAAKB – Solenoid-1(Pump-1) short circuit .1004
DXABKB – Solenoid-2(Pump-2) short circuit .1004
DXACKB – Solenoid-3(Pump-3) short circuit .1004
DXADKB – Solenoid-4(Pump-4) short circuit .1004
DXAEKB – Solenoid-5(Pump-5) short circuit .1004
DXAFKB – Solenoid-6(Pump-6) short circuit .1004
Wiring Diagram – EPC valve control (pump controller) 1005
DHPEMA – Pump-1/2 pressure sensor abnormality .1006
DHPGMA – Pump-3/4 pressure sensor abnormality .1006
DHPJMA – Pump-5/6 pressure sensor abnormality .1006
Wiring Diagram – PWR & GND supply for pressure sensors (pumps 1 .3) 1007
DLE2MA – Engine speed sensor abnormality 1008
Wiring Diagram – engine RPM signal (52B064) to pump controller 1009
DA25KP – 5V sensor1 power abnormality .1010
Wiring Diagram – 5V sensor power supply for trouble code DA25KP .1012
DA22KK – Pump Solenoid Power Low Error 1013
DA29KQ – Model Selection Abnormality 1014
10 Appendix .1015
10.1 Comparison of Trouble Codes: VHMS (incl. retrofit kit) vs. KOMTRAX Plus 1016
10.1.1 VHMS Trouble codes vs. Komtrax Plus trouble codes 1016
10.1.2 Pump controller CR700 vs. Pump controller CR710 trouble codes 1020
50 Disassembly and assembly .1023
Table of contents .1024
1 Introduction 1033
1.1 Contents of this binder .1034
1.2 Foreword 1034
1.3 Recommendations for environmentally friendly operation and maintenance of hydraulic mining shovels 1036
1.4 Explanation of abbreviations 1037
1.5 Diagrams and illustrations in this manual .1038
1.6 Procedures for disassembling and assembling in this manual 1038
2 Safety 1039
2.1 Overview 1041
2.1.1 Method of using this manual .1041
2.2 General precautions .1043
2.2.1 General .1043
2.2.2 Personal protective clothing 1043
2.2.3 When using a hammer .1044
2.2.4 Proper tools 1044
2.2.5 Personnel .1044
2.2.6 Fire prevention .1045
2.2.7 Unauthorized modification .1045
2.3 Precautions for maintenance and repair 1046
2.3.1 General precautions .1046
2.3.2 Keep work place clean and tidy 1046
2.3.3 Precautions when welding 1047
2.3.4 Precaution with high pressure fluids 1047
2.3.4.1 Handling high pressure hoses and pipes 1047
2.3.5 Compressed air 1047
2.3.6 Waste materials .1048
3 Superstructure 1049
3.1 Superstructure overview .1050
3.2 Machinery house .1052
3.2.1 Machinery house roof 1054
3.2.1.1 Disassembling of the complete roof frame 1054
3.2.1.2 Assembling of the complete roof frame .1059
3.2.1.3 Disassembling of single machinery house roof cover plates .1063
3.2.1.4 Assembling of single machinery house roof cover plates 1068
3.2.2 Diesel engine .1073
3.2.2.1 Disassembling of the Diesel engine 1073
3.2.3 Assembling of the diesel engine .1079
3.2.3.1 Disassembling of the alternator .1085
3.2.3.2 Assembling of the alternator 1087
3.2.3.3 Disassembling of the starter motor 1088
3.2.3.4 Assembling of the starter motor .1089
3.2.4 Batteries .1090
3.2.4.1 Disassembling of the batteries 1090
3.2.4.2 Assembling of the batteries .1092
3.2.5 Flexible coupling .1093
3.2.5.1 Disassembling of the Geislinger coupling 1093
3.2.5.2 Assembling of the Geislinger coupling .1095
3.2.5.3 Disassembling of the CentaFlex coupling assembly 1097
3.2.5.4 Assembling of the CentaFlex coupling assembly .1100
3.2.5.5 Replacing the rubber rollers of the CentaFlex coupling 1102
3.2.6 Radiator fan and fan drive assembly .1104
3.2.6.1 Disassembling of the radiator fan and the fan drive assembly 1105
3.2.6.2 Assembling of the radiator fan and the fan drive assembly .1107
3.2.7 Radiator assembly .1108
3.2.7.1 Disassembling of the Radiator assembly 1108
3.2.7.2 Assembling of the radiator assembly .1111
3.2.8 Main pumps assemblies .1114
3.2.8.1 Preparatory works for main pump disassembling .1115
3.2.8.2 Disassembling of main pump 1 .3 assembly .1117
3.2.8.3 Assembling of main pump 1 .3 assembly 1120
3.2.9 Pump distributor gear box (PTO) .1123
3.2.9.1 Disassembling of the pump distributor gear box (PTO) 1123
3.2.9.2 Assembling of the pump distributor gear box (PTO) .1126
3.2.9.3 Disassembling of the PTO oil circulation pump .1129
3.2.9.4 Assembling of the PTO oil circulation pump 1130
3.3 Hydraulics 1132
3.3.1 Hydraulic oil cooler assembly .1132
3.3.1.1 Disassembling of hydraulic cooler fan drive pump 1132
3.3.1.2 Assembling of hydraulic cooler fan drive pump .1135
3.3.1.3 Disassembling of the hydraulic cooler fan assembly 1137
3.3.1.4 Assembling of the hydraulic cooler fan assembly .1139
3.3.1.5 Disassembling of hydraulic cooler fan and motor .1142
3.3.1.6 Assembling of hydraulic cooler fan and motor 1144
3.3.1.7 Disassembling of the hydraulic oil coolers 1146
3.3.1.8 Assembling of the hydraulic oil coolers .1149
3.3.1.9 Disassembling of the hydraulic oil cooler Assembly 1151
3.3.1.10 Assembling of the hydraulic oil cooler Assembly 1155
3.3.2 Pilot oil pump (Gear pump) 1158
3.3.2.1 Disassembling of the pilot oil pump .1158
3.3.2.2 Assembling of the pilot oil pump 1160
3.3.3 Main shut off valve .1162
3.3.3.1 Disassembling of the main shut off valve 1162
3.3.3.2 Assembling of the main shut off valve .1164
3.3.4 Hydraulic oil tank 1165
3.3.4.1 Disassembling of the hydraulic oil tank .1165
3.3.4.2 Assembling of the hydraulic oil tank 1171
3.3.5 Main control valve blocks .1175
3.3.5.1 Disassembling of the main control valve blocks 1175
3.3.5.2 Assembling of the main control valve blocks .1181
3.3.5.3 Disassembling of the MRV at the main control valve blocks .1186
3.3.5.4 Assembling of the MRV at the main control valve blocks 1187
3.3.5.5 Disassembling of SRV on main control valve block 1188
3.3.5.6 Assembling of SRV on main control valve blocks 1190
3.3.5.7 Disassembling of ACV-/SRV-block on main control valve blocks 1192
3.3.5.8 Assembling of ACV-/SRV-block on main control valve blocks .1194
3.3.6 Distributor Manifold 1196
3.3.6.1 Disassembling of anti cavitation valve blocks at the distributor manifold .1198
3.3.6.2 Assembling of anti cavitation valve blocks at the distributor manifold 1200
3.3.6.3 Disassembling of throttle check valves at the distributor manifold 1202
3.3.6.4 Assembling of throttle check valves at the distributor manifold .1204
3.3.6.5 Disassembling of the diffuser block on the distributor manifold (FSA only) 1206
3.3.6.6 Assembling of the diffuser block on the distributor manifold (FSA only) .1208
3.3.6.7 Disassembling of the manifold .1209
3.3.6.8 Assembling of the manifold 1211
3.4 Slew system .1213
3.4.1 Slew gear box .1213
3.4.1.1 Disassembling of the slew gear box 1214
3.4.1.2 Assembling of the slew gear box .1217
3.4.2 slew service brake valve 1220
3.4.2.1 Disassembling of the slew service brake valve .1220
3.4.2.2 Assembling of the slew service brake valve 1222
3.4.3 Slew motor 1224
3.4.3.1 Disassembling of the slew motor .1225
3.4.3.2 Assembling of the slew motor 1228
3.4.4 Slew parking brake 1230
3.4.4.1 Disassembling the slew parking brake (L&S) 1231
3.4.4.2 Assembling the slew parking brake (L&S) .1234
3.4.4.3 Disassembling of the slew parking brake assembly (siebenhaar) .1237
3.4.4.4 Assembling of the slew parking brake assembly (Siebenhaar) 1240
3.4.5 Slew circle lubrication pinion (dummy wheel) 1244
3.4.5.1 Disassembling of the slew circle lubrication pinion assembly 1244
3.4.5.2 Assembling of the slew circle lubrication pinion assembly .1245
3.4.6 Slew circle .1246
3.4.6.1 Disassembling of the slew circle 1247
3.4.6.2 Assembling of the slew circle .1250
3.5 Lubrication pumps .1254
3.5.1 Disassembling of the lubrication pump .1254
3.5.2 Assembling of the lubricating pump 1255
3.6 Operator’s cab 1256
3.6.1 Disassembling of the operator’s cab .1256
3.6.2 Assembling of the operator’s cab 1261
3.6.3 Cab mounts 1266
3.6.3.1 Disassembling of the cab mounts .1266
3.6.3.2 Assembling of the cab mounts 1268
3.6.4 Front window (windshield) .1270
3.6.4.1 Disassembling of the front window .1270
3.6.4.2 Assembling of the front window 1271
3.6.5 Operator’s seat .1272
3.6.5.1 Disassembling of the operator’s seat 1272
3.6.5.2 Assembling of the operator’s seat .1273
3.7 Cab base 1274
3.7.1 Disassembling of the cab base .1274
3.7.2 Assembling of the cab base 1276
3.8 Access Ladder .1278
3.8.1 Disassembling of access ladder 1279
3.8.2 Assembling of access ladder .1281
3.8.3 Disassembling of access ladder cylinder .1282
3.8.4 Assembling of access ladder cylinder 1284
3.9 Counterweight .1286
3.9.1 Disassembling of the counterweight 1287
3.9.2 Assembling of the counterweight .1289
3.10 Fuel tank 1292
3.10.1 Disassembling of the fuel tank .1292
3.10.2 Assembling of the fuel tank 1296
3.11 Superstructure lifting .1300
3.11.1 Disassembling the superstructure from the undercarriage 1300
3.11.2 Assembling the superstructure onto the undercarriage .1304
4 Undercarriage .1309
4.1 Undercarriage overview 1310
4.2 Travel System .1312
4.2.1 Crawler Track .1312
4.2.1.1 Changing the crawler track 1312
4.2.2 Sprocket 1319
4.2.2.1 Disassembling of the sprocket .1319
4.2.2.2 Assembling of the sprocket 1322
4.2.3 Guide wheels (Idlers) .1325
4.2.3.1 Disassembling of the guide wheel assembly .1325
4.2.3.2 Assembling of the guide wheel assembly 1327
4.2.4 Track tensioning accumulators .1330
4.2.4.1 Disassembling of the low pressure accumulators 1330
4.2.4.2 Assembling of the low pressure accumulators .1332
4.2.4.3 Disassembling of the high pressure accumulators .1334
4.2.4.4 Assembling of the high pressure accumulators 1335
4.2.5 Track tension valve block .1336
4.2.5.1 Disassembling of the track tensioning valve block .1336
4.2.5.2 Assembling of the track tensioning valve block 1337
4.2.6 Track tensioning cylinders 1339
4.2.6.1 Disassembling of the track tensioning cylinders .1339
4.2.6.2 Assembling of the track tensioning cylinders 1341
4.2.7 Substitute the Hydraulic hoses of the track tensioning system .1343
4.2.7.1 Precursory work .1343
4.2.7.2 Replace the hydraulic hoses inside the car body .1345
4.2.7.3 Replace the hydraulic hose between car body and crawler frame .1345
4.2.7.4 Replace the hydraulic hoses inside the crawler frame 1347
4.2.7.5 Subsequent work .1347
4.2.8 Travel brake valve block (overspeed valve) 1348
4.2.8.1 Disassembling of the travel brake valve block .1348
4.2.8.2 Assembling of the travel brake valve block 1350
4.2.9 Travel motor 1351
4.2.9.1 Disassembling of the travel motors 1351
4.2.9.2 Assembling of the travel motors .1353
4.2.10 Travel parking brake .1356
4.2.10.1 Disassembling of the travel parking brake 1357
4.2.10.2 Assembling of the travel parking brake .1359
4.2.11 Travel gear box 1360
4.2.11.1 Disassembling of the travel gear box .1361
4.2.11.2 Assembling of the travel gear box 1365
4.2.12 Carrier roller .1368
4.2.12.1 Disassembling of the carrier roller assembly .1368
4.2.12.2 Assembling of the carrier roller assembly 1370
4.2.13 Track roller .1372
4.2.13.1 Disassembling of the track roller assembly .1372
4.2.13.2 Assembling of the track roller assembly 1374
4.3 Car body 1376
4.3.1 Disassembling of the car body and the crawler carriers 1376
4.3.2 Assembling of the car body and the crawler carriers .1382
4.3.2.1 Install crawler carrier mounting bolts 1388
4.3.3 Rotary joint 1390
4.3.3.1 Disassembling of the rotary joint .1390
4.3.3.2 Assembling of the rotary joint 1392
5 Attachment 1395
5.1 Repair procedures .1396
5.1.1 Replacement of bushings at the attachment .1396
5.1.1.1 Removal of the bushings .1396
5.1.1.2 Installation of the bushings 1397
5.1.2 General installation instructions for attachment pins .1398
5.2 Backhoe .1400
5.2.1 Overview 1400
5.2.2 Pin Sealing bucket – Steering Rod – bucket link rod .1402
5.2.3 Boom 1404
5.2.3.1 Disassembling of the boom .1404
5.2.3.2 Assembling of the boom 1406
5.2.3.3 Disassembling of boom cylinders .1409
5.2.3.4 Assembling of boom cylinders 1414
5.2.4 Stick assembly 1418
5.2.4.1 Disassembling of the stick 1418
5.2.4.2 Assembling of the stick .1422
5.2.4.3 Disassembling of the stick cylinders 1426
5.2.4.4 Assembling of the stick cylinders .1431
5.2.5 Bucket and steering .1437
5.2.5.1 Disassembling of the bucket .1437
5.2.5.2 Assembling of the bucket 1441
5.2.5.3 Disassembling of bucket cylinders .1444
5.2.5.4 Assembling of bucket cylinders 1451
5.2.5.5 Disassembling of the bucket link rod 1458
5.2.5.6 Assembling of the bucket link rod .1461
5.2.5.7 Disassembling of the steering rods 1464
5.2.5.8 Assembling of the steering rod 1470
5.2.6 Hydraulic hoses at the backhoe attachment .1474
5.2.6.1 Replace the boom arc hoses 1474
5.2.6.2 Replace the boom cylinder hoses .1478
5.2.6.3 Replace the stick cylinder hoses 1482
5.2.6.4 Replace the bucket cylinder hoses .1486
5.3 Face shovel .1490
5.3.1 Overview 1490
5.3.2 Using the Cylinder Mounting Device for Front shovel attachments (PN 967 000 40) .1492
5.3.2.1 Designated usage 1493
5.3.2.2 Non-designated usage 1493
5.3.3 Boom 1494
5.3.3.1 Disassembling of the boom .1494
5.3.3.2 Assembling of the boom 1497
5.3.3.3 Disassembling of the boom cylinders .1500
5.3.3.4 Assembling of the boom cylinders 1505
5.3.4 Stick assembly 1510
5.3.4.1 Disassembling of the stick 1510
5.3.4.2 Assembling of the stick .1514
5.3.4.3 Disassembling of the stick cylinders 1518
5.3.4.4 Assembling of the stick cylinders .1522
5.3.5 Bull clam bucket 1526
5.3.5.1 Disassembling of the bull clam bucket .1526
5.3.5.2 Assembling of the bull clam bucket 1530
5.3.5.3 Disassembling of the bucket cylinders .1534
5.3.5.4 Assembling of the bucket cylinders 1538
5.3.5.5 Disassembling of the clam cylinders .1543
5.3.5.6 Assembling of the clam cylinders 1548
5.3.6 Hydraulic hoses at the face shovel attachment .1554
5.3.6.1 Replace the boom arc hoses 1554
5.3.6.2 Replace the boom cylinder hoses .1558
5.3.6.3 Replace the stick arc hoses .1562
5.3.6.4 Replace the stick cylinder hoses 1570
5.3.6.5 Replace the bucket cylinder hoses .1574
5.3.6.6 Replace the clam cylinder hoses .1578
5.4 Metering valves (grease injectors) at the attachment 1586
5.4.1 Disassembling of the metering valves (grease injectors) .1586
5.4.2 Assembling of the metering valves (grease injectors) 1588
5.5 Ground engaging tools (GET) .1589
5.5.1 Disassembling and assembling of the GET .1589
5.6 Cylinder bypass test 1591
6 Service Information .1593
6.1 Fluids and lubricants .1594
6.2 Lifting Gears .1594
6.3 Safety hints for sling accessory 1596
6.4 Work instructions .1597
6.4.1 Surface coating with INTERZINC 697 1597
6.4.2 Hints for hydraulic hose installation .1599
6.4.3 Remove / install the crawler carrier 1602
6.5 Weight tables .1603
6.5.1 Superstructure 1603
6.5.2 Undercarriage .1605
6.5.3 Backhoe attachment (BHA) 1606
6.5.4 Face shovel attachment (FSA) 1607
6.6 Torque charts according to KOMATSU company standard .1608
6.6.1 Metric standard thread 1608
6.6.2 Metric fine thread 1609
6.6.3 Cummins motor torques – metric 1610
6.6.4 Cummins motor torques – U.S. customary 1610
6.6.5 SAE-flange connections 1611
6.7 Blind plugs .1612
6.7.1 Dummy plates for SAE–flanges 1612
6.7.2 Classification of threads to the nominal width 1614
6.7.3 Plugs and fittings according to DIN 2353 1615
6.8 Conversion table 1616
6.8.1 Method of using the conversation table 1616
6.8.2 Millimeter – inch & kilogram – pound 1617
6.8.3 Liter – U.S. gallon & liter – U.K. gallon .1618
6.8.4 Nm- ft.lb .1619
6.8.5 Bar – PSI – kPa – MPa .1620
6.8.6 Temperature .1621
6.9 Tools .1622
6.9.1 Standard tool case 1622
6.9.2 Used special tools (Overview) .1624
7 Parts & Service News 1627
7.1 List of The PARTS AND SERVICE NEWS 1628

DESCRIPTION:

Komatsu PC3000-6 Hydraulic Mining Shovel Shop Manual 06279-xG-GB-1 –  PDF DOWNLOAD

• SERIAL NUMBERS
  06279, 06308, 06309, 06310,
  06314 and up
  (TIER2 & KOMTRAX Plus)

• BEFORE READING THIS MANUAL:
  This manual gives details of the methods of inspection, maintenance and troubleshooting 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 inspection, maintenance and troubleshooting of machines.
• Read, understand and follow all precautions and warnings in this manual and on the machine before performing inspection, maintenance or troubleshooting. Failure to do so may result in serious injury or death.
• Komatsu cannot predict every circumstance that may 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 inspection, maintenance and troubleshooting 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 prohibited uses or actions described in this manual. Improper inspection, maintenance and troubleshooting 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.
• 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 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.
• Komatsu delivers machines that comply with all applicable regulations and standards of the country to which it has been shipped. If the 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.

G.B 22/ 12/24