Komatsu PC3000-6 Hydraulic Mining Shovel Shop Manual PDF
$37.95
Komatsu PC3000-6 Hydraulic Mining Shovel Shop Manual – PDF DOWNLOAD
46151 and up
Description
Komatsu PC3000-6 Hydraulic Mining Shovel Shop Manual – PDF DOWNLOAD
FILE DETAILS:
Komatsu PC3000-6 Hydraulic Mining Shovel Shop Manual – PDF DOWNLOAD
Language : English
Pages : 1455
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu PC3000-6 Hydraulic Mining Shovel Shop Manual – PDF DOWNLOAD
46151 and up
EXCAVATOR
2.4.2.1 ENSURING SAFE OPERATION
– Only trained and authorized personnel can operate and maintain the machine.
– During operations, personnel are not allowed outside of the operator’s cabin.
– Follow all safety rules, precautions and instructions when operating or performing inspection or maintenance
on the machine.
– If you are not feeling well, or are under the influence of alcohol or medication, your ability to safely operate or
repair your machine may be severly impaired putting yourself and everyone else on your jobsite in danger.
– When working with another operator or with a person on worksite traffic duty, discuss the content of the operation
beforehand and use pre-determined signals when carrying out these operations.
2.4.3 PREPARATIONS FOR SAFE OPERATION
2.4.3.1 PRECAUTIONS REGARDING SAFETY RELATED EQUIPMENT
– Be sure that all guards, covers and mirrors are in their proper positions. Have guards and covers repaired
immediately if they are damaged.
– Understand the method of use of safety features and use them properly.
– Never remove any safety features. Always keep them in good operating condition.
2.4.3.2 INSPECTING THE MACHINE
Check the machine before starting operations. If any abnormality is found, do not operate the machine until repairs
of the problem location have been completed.
TABLE OF CONTENTS:
Komatsu PC3000-6 Hydraulic Mining Shovel Shop Manual – PDF DOWNLOAD
COVER 0
00 Foreword 5
Introduction 6
Safety Instructions 11
01 Specifications 67
Specifications PC3000 69
10 Structure, Function 77
01 INTRODUCTION 85
02 SAFETY 91
03 SPECIFICATIONS 141
04 MAIN ASSEMBLY GROUPS 155
4 1 General layout 156
4 2 Superstructure 158
4 3 Power House 160
4 4 Hydraulic Oil Reservoir 162
4 5 Hydraulic Oil Cooler 164
4 6 Fuel tank (Fuel reservoir) 166
4 7 Counter weight 168
4 8 Cab support 170
4 9 Operators cab 172
4 10 Control blocks 174
4 11 Swing gears 176
4 12 Under carriage 178
05 DRIVE 181
5 1 Prime drive assembly 182
5 2 Engine and gearbox mount 184
5 3 Torque supports 189
5 4 Radiator fan Drive Assy 190
5 5 Pump distributor gearbox (PTO) 192
5 5 1 Spline shaft housing 194
5 5 2 PTO lubrication and cooling 196
5 5 3 PTO valve adjustments 198
5 6 Coupling 202
Oil filled type coupling “Geisslinger” 203
5 7 Air cleaner 204
06 HYDRAULIC OIL RESERVOIR 207
6 1 Hydraulic oil reservoir 208
6 2 Return and leak oil filter 212
6 3 Breather Filter 216
6 4 Location of electrical components 218
6 5 Transfer Pump, hydraulic service 220
07 HYDRAULIC OIL COOLING 229
7 1 General 230
7 2 Hydraulic oil cooling circuit 232
7 3 Back pressure valve adjustment 236
7 4 Fan drive 238
7 4 1 Fan pump 240
7 4 2 Pressure relieve valve 241
7 4 3 Temperature relay 243
4 5 Cooler fan drive adjustment 192
08 CONTROLLING 247
8 1 Pilot pressure supply and adjustment 248
8 1 1 Pilot control arrangement 250
8 1 2 Pilot pressure adjustment 252
8 1 3 Check of Control Pressure 254
8 2 Slew brakes 256
8 3 Travel parking brake 259
8 4 Check of the pilot control logic 261
8 4 1 Check sheet FSA Page 1 263
8 4 2 Check sheet BHA Page 1 276
09 COMPONENTS 285
9 1 Main control block and valve arrangement 286
9 1 1 FSA arrangement 288
9 1 2 BHA arrangement 292
9 2 Distributor manifold 296
9 2 1 Front shovel attachment FSA 296
9 2 2 Back hoe attachment BHA 298
9 2 3 SRV with throttle check valve 300
9 2 4 Anti cavitation valve (check valve) 302
9 3 Main control block 304
9 3 1 Load holding valve 310
9 3 2 High pressure filter 312
9 3 3 Pressure relieve valves and anti-cavitation valve 314
9 3 4 Pressure relieve valves and anti-cavitation valve 316
9 4 Compact valve blocks 318
9 5 Compact valve blocks 320
9 6 Auxiliary gear pumps 322
9 7 Hydraulic cylinder 324
9 8 Swing ring 326
10 MAIN HYDRAULIC PUMPS AND PUMP REGULATION 329
10 1 General 330
10 1 1 Pump location 332
10 2 Main pump operating principles 334
10 2 1 Main pump function 339
10 3 Main pump checks and adjustments 342
10 3 1 Peak point diesel engine test 342
10 3 2 Pressure transducer test 344
10 3 3 Cut off function 345
10 3 4 Pump regulation 347
10 3 5 Swing pump volume reduction 348
10 4 Electronic pump regulation 349
10 5 Pump Controller CR700 352
10 6 Multi Monitor 354
10 7 Multimonitor software instruction 356
10 7 1 Multimonitor main control 356
10 7 2 Service Menu screen 356
10 7 3 Monitoring (menu item 01) 357
10 7 4 Abnormality Record (menu item 02) 358
10 7 5 Default (menu item 03) 361
10 7 6 Adjustment (menu item 04) 362
10 7 7 Display Setup (menu item 05) 364
10 7 8 Table of fault messages and adjustments 365
10 8 Trouble shooting pump and pump regulation 374
11 OPERATING HYDRAULIC 375
11 1 General layout 376
11 2 Floating function of boom and stick only FSA 380
11 3 Check and Adjustments for MRV’s and SRV’s 382
11 3 1 Check and Adjustments for MRV 384
11 3 2 Check and Adjustment for SRV’s 386
11 3 3 Check and adjustment of the throttle check valves 394
11 4 Hydraulic for the swing circuit 396
11 4 1 Hydraulic for the swing circuit 400
11 4 2 Slew gear box L & S 404
11 4 3 Slew parking brake 408
11 4 4 Slew service brake valve 412
11 4 5 Checks and adjustment of the slew pressure valve 417
11 5 Travel circuit 420
11 5 1 Rotary joint 422
11 5 2 Travel motor A2FMt 424
11 5 3 Travel gear 426
11 5 4 Travel parking brake 428
11 5 5 Travel control function 430
11 5 6 Check and Adjustment SRV travel system 433
12 TRACK TENSION SYSTEM 435
12 1 General layout 436
12 2 Track tensioning function 438
12 2 1 Cushioning 440
12 2 2 Pressure Increasing valve PIV 442
12 3 Track tensioning adjustment 446
12 3 1 Track tensioning function check 448
13 ACCESS LADDER HYDRAULICALLY OPERATED 451
13 1 Access ladder 452
13 2 Access ladder functional description 454
14 CENTRAL REFILLING SYSTEM 459
14 0 1 Functional description 460
15 HINTS FOR READING THE HYDRAULIC CIRCUIT DIAGRAM 465
15 1 General 466
15 2 Symbolic 468
15 2 1 Lines, unions 470
15 2 2 Components, valves 471
15 2 3 Sensors 472
15 2 4 Valves, valve components 472
15 2 5 Pump, motor, cylinder 476
16 HINTS FOR READING THE ELECTRIC CIRCUIT DIAGRAM 481
16 1 Designation of electrical components 483
16 2 Electric symbols 484
16 3 Symbols 486
16 3 1 Drawing concept 488
16 3 2 Reading of the circuit diagram 494
17 ELECTRONIC TEXT MONITORING SYSTEM ETM 499
17 1 General Function 500
18 AUTOMATIC LUBRICATION SYSTEM 503
18 1 General Function 504
18 2 Function of a lubrication cycle 506
18 3 Lubrication pump drive 514
18 4 Lubrication pump 516
18 4 1 Adjustments lubricating pump speed 518
18 4 2 Adjustments lubricating pump pressure 520
18 5 Lubricant Injector (metering valve) 522
18 5 1 Connection of one or more injectors 524
18 5 2 Function lubrication injector (metering valve) 526
18 6 End line pressure switch 530
18 7 Lubricant in line filter 532
18 8 Lubricant level sensor 534
18 8 1 Capacitive digital type for machines with ETM 534
18 8 2 Capacitive analog type for machines with PLC 536
18 9 Lubrication system function and controlling 538
18 9 1 Central Lubrication System (CLS) function and controlling with ETM system (PC 3000) 540
18 9 2 Swing ring lubrication system (SLS) function and controlling with ETM system (PC3000) 544
18 10 Adjustment of the lubrication system with ETM 551
18 11 Trouble shooting lubricating system 552
18 11 1 Lubrication pump cylinder does not move 553
18 11 2 Lubricant pressure built up very slowly or not at all 555
18 11 3 Insufficient lubricant supply to one or more attachment bearings 555
18 11 4 Insufficient lubricant at the swing ring gear 557
40 Troubleshooting 565
Table of Contents 567
Introduction 571
Safety Notes 572
Description of this Troubleshooting Manual 572
General Precautions 573
Electrical Parts 593
Componant Locations 594
Engine Electrical Parts 596
Electrical Parts On PTO, etc 598
Electrical Parts on Pilot Control Frame 600
Electrical Parts on Main Hydraulic Reservoir 602
Electrical Parts on Switch Board X2 604
Electrical Parts on Hydraulic Ldder 606
Electrical Parts of Automatic Lube System 608
Electrical Parts on Air Cleaner and Fuel Tank 612
Overview Connector Types 613
Standard Value Table for Electrical Componants 616
PT100 Temperature Charts 626
Troubleshooting by Trouble Code 629
Message 1 – Gear Lubrication out of Function (PTO) 630
Message 2 – Engine Air Filter Restricted 633
Message 3 – Filter for Control Oil Restricted 635
Message 4 – Oil Tank Breather Filter Restricted 638
Message 5 – Return Oil Filter Restricted 641
Message 6 – Leak Oil Filter Restricted 644
Message 7 – Hydraulic Oil Temperature Too High 647
Message 9 – Low Idle Too High Coolant Temperature 653
Message 10 – Engine Shutdown: Too Low Engine Oil Temperature 658
Message 14 – Too Low Hydraulic Oil Level 663
Message 15 – Caution, Slew Gear House Brake On 667
Message 16 – Caution, Travel Gear House Brake On 672
Message 17 – No Clearance For Starting, Shift Engine to Low Idle 677
Message 18 – Central Lube System Fault 678
Message 19 – Slew Ring Gear Lubrication Fault 685
Message 20 – Pilot Control Cut-Out 693
Message 21 – Central Lube System Empty Grease Barrel 695
Message 22 – Central Lube System Empty Grease Barre 695
Message 24 – Engine Problem: Stop All Control 702
Message 32 – PTO Gear Lube Filter Restricted 707
Message 33 – Cooler Fan Drive Filter Restricted 710
Message 39 – Engine Shutdown Main Shut-Off (Gate) Volve 713
Message 42 – Too Low Coolant Pressure 717
Message 43 – Engine Shutdown: Emergency Stop Switch Actuated 722
Message 44 – Engine Shutdown Safety Switch Actuated 726
Message 45 – Warning Signal from Engine Control Module 730
Message 48 – Too High PTO Gear Oil Temperature 733
Message 50 – Caution, Pull Switch From Ground Man Actuated 736
Message 51 – Engine Shutdown: Pull Switch From Ground Man Actuated 737
Message 52 – Load Limit Clam Defective 739
Message 53 – Pressure Switch of CLS Actuated 742
Message 55 – Refill Hyrdaulic Oil 743
Message 57 – Load Limit Regulation Fault 747
Message 58 – Strainer Oil Cooler Restricted 748
Message 59 – CLS Refill Grease Container 750
Message 60 – SLS Refill Grease Barrel 750
Troubleshooting by Symptoms 757
Symptoms of the Hydraulic System 778
50 Disassembly and Assembly 821
1 INTRODUCTION 835
1 1 Contents of the binder 836
1 2 Foreword 837
1 2 1 Service 838
2 SAFETY 839
3 SUPERSTRUCTURE 865
3 1 Superstructure overview 866
3 2 Engine House 868
3 3 Diesel Engine 872
3 4 Torsion Coupling 898
3 5 PTO 909
3 6 Hydraulics 934
3 7 Slew Drive 1021
3 8 Lubrication Pumps 1068
3 9 Operaotor’s Cab 1070
3 10 Cab Base 1085
3 11 Access Ladder 1090
3 12 Counterweight 1097
3 13 Superstructure Lifting 1103
3 14 Fuel Tank 1110
4 UNDERCARRIAGE 1117
4 1 Undercarriage Overview 1118
4 2 Travel System 1120
4 3 Car Body 1182
5 ATTACHMENT 1205
5 2 Face Shovel 1282
5 2 1 Using the Installation Tools for Hydraulic Cyllinders 1283
5 2 2 Boom 1284
5 2 2 1 Removal of the Boom 1284
5 2 2 2 Replacement of the Boom 1291
5 2 2 3 Removal of the Boom Cylinders 1296
5 2 2 4 Replacement of the Boom Cylinders 1301
5 2 3 Stick 1304
5 2 3 1 Removal of the Stick 1304
5 2 3 2 Replacement of the Stick 1308
5 2 3 3 Removal of the Stick Cylinders 1312
5 2 3 4 Replacement of the Stick Cylinders 1317
5 2 4 Bull Clam Bucket 1320
5 2 4 1 Removal of the Bull Clam Bucket 1322
5 2 4 2 Replacement of the Bull Clam Bucket 1326
5 2 4 3 Removal of the Bucket Cylinders 1328
5 2 4 4 Replacement of the Bucket Cylinders 1333
5 2 4 5 Removal of the Clam Cylinders 1338
5 2 4 6 Replacement of the Clam Cylinders 1343
5 2 5 graound Engaging Tools (GET) 1346
5 2 5 1 Removal of the Ground Engaging Tools 1346
5 2 6 Hydraulic Hoses on the Face Shovel Attachment 1348
5 2 6 1 Substitute the Boom Arc Hoses 1348
5 2 6 2 Substitute the Boom Cylinder Hoses 1352
5 2 6 3 Substitute the Stick Arc Hoses 1358
5 2 6 4 Substitute the Stick Cylinder Hoses 1364
5 2 6 5 Substitute the Bucket Cylinder Hoses 1368
5 2 6 6 Substitute the Clam Cylinder Hoses 1372
5 1 Backhoe 1206
5 1 1 Boom 1208
5 1 1 1 Removal of the Boom 1208
5 1 1 2 Replacement of the boom 1212
5 1 1 3 Removal of boom cylinders 1214
5 1 1 4 Replacement of boom cylinders 1220
5 1 3 Stick 1224
5 1 2 1 Removal of the Stick 1224
5 1 3 2 Replacement of Stick 1229
5 1 3 3 Removal of Stick Cylinders 1232
5 1 2 4 Replacement of Stick cylinders 1238
5 1 4 Bucket 1242
5 1 3 1 Removal of the bucket 1242
5 1 3 2 Replacement of the bucket 1245
5 1 3 3 Removal of Bucket Cylinders 1246
5 1 3 4 Replacement of Bucket Cylinders 1253
5 1 4 Bucket link rod and steering rods 1256
5 1 4 1 Removal of the bucket link rod 1256
5 1 4 2 Replacement of the bucket link rod 1258
5 1 4 3 Removal of the steering rods 1259
5 1 4 4 Replacement of the steering rod 1262
5 1 5 Ground engaging tools (GET) 1263
5 1 5 1 Removal and replacement of the GET 1263
5 1 6 Hydraulic hoses at the attachment 1266
5 1 6 1 Substitute the boom arc hoses 1266
5 1 6 2 Substitute the boom cylinder hoses 1270
5 1 6 3 Substitute the stick cylinder hoses 1274
5 1 6 4 Substitute the bucket cylinder hoses 1278
5 3 Metering Valves 1380
5 3 1 Operation test of the metering Valves 1381
5 3 2 Removal of the Metering Valves 1382
Unbenannt 1384
5 4 Cylinder Bypass Test 1385
6 SERVICE INFORMATION 1387
6 1 Fuel and Lubricants 1388
6 2 Filling capacities 1388
6 3 Work Instructions 1390
6 3 1 Surface Coating with Interzinc 697 1390
6 3 2 remove / Install the Crawler carrier 1392
6 4 Weight Tables 1393
6 4 1 Superstructure 1393
6 4 2 Undercarriage 1395
6 4 3 Backhoe Attachment 1396
6 4 4 Face ShoveL Attachment 1397
6 5 Torque Charts 1398
6 5 1 Metric Standard Thread 1398
6 5 2 Metric Fine Thread 1399
6 5 3 Cummins Motor Torques – Metric 1400
6 5 4 Cummins Motor Torques – US 1400
6 5 5 Flange Connections 1401
6 6 Blind Plugs 1402
6 6 1 Dummy Plates for SAE Flanges 1402
6 6 2 Classification of Threads to the Nominal Width 1404
6 6 3 Plugs and Fittings According to DIN 2353 1405
6 7 Conversion Table 1406
6 7 1 Method of Use 1406
6 7 2 Millimeter – Inch & Kilogram – Pound 1407
6 7 3 Liter – US Gallon & Liter – UK Gallon 1408
6 7 4 NM – FT LB 1409
6 7 5 Bar – PSI – KPA – MPA 1410
6 7 6 Basic Values In Ohm According to ISO 43 76 1411
6 7 7 Temperature 1412
6 8 Tools 1413
6 8 1 Standard Tool Case 1413
6 8 2 Used Special Tools (Overview) 1415
7 TOOLS CATALOGUE 1417
S.V 11/12/24
