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Komatsu PC3000-6 T2 Hydraulic Mining Shovel Shop Manual PDF
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Komatsu PC3000-6 T2 Hydraulic Mining Shovel Shop Manual 06279-xD-GB-1 – PDF DOWNLOAD
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Description
Komatsu PC3000-6 T2 Hydraulic Mining Shovel Shop Manual 06279-xD-GB-1 – PDF DOWNLOAD
FILE DETAILS:
Komatsu PC3000-6 T2 Hydraulic Mining Shovel Shop Manual 06279-xD-GB-1 – PDF DOWNLOAD
Language : English
Pages : 1632
Downloadable : Yes
File Type : PDF
TABLE OF CONTENTS:
Komatsu PC3000-6 T2 Hydraulic Mining Shovel Shop Manual 06279-xD-GB-1 – PDF DOWNLOAD
SERIAL NUMBERS
06279, 06308, 06309, 06310, 06314 and up
(TIER2 & KOMTRAX Plus)
Shop Manual 1
00 Foreword & Safety 3
1 Foreword 5
1 1 BEFORE READING THIS MANUAL 6
1 2 CONTENTS OF THIS 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 13
2 2 OVERVIEW 14
2 2 1 NORMAL OPERATIONS 14
2 2 2 REGULAR MAINTENANCE 14
2 2 3 TROUBLESHOOTING, ADJUSTMENTS AND REPAIR 14
2 2 4 ADDITIONAL SAFETY PRECAUTIONS 14
2 3 SOUND PRESSURE AND VIBRATION LEVELS IN THE OPERATOR’S CAB 15
2 3 1 SOUND 15
2 3 2 VIBRATION 15
2 4 GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR 16
2 4 1 UNDERSTANDING THE MACHINE 16
2 4 2 PRECAUTIONS BEFORE STARTING OPERATION ON THE EXCAVATOR 16
2 4 2 1 ENSURING SAFE OPERATION 16
2 4 3 PREPARATIONS FOR SAFE OPERATION 16
2 4 3 1 PRECAUTIONS REGARDING SAFETY RELATED EQUIPMENT 16
2 4 3 2 INSPECTING THE MACHINE 16
2 4 3 3 WEAR WELL FITTING CLOTHES AND PROTECTIVE EQUIPMENT 17
2 4 3 4 KEEP MACHINE CLEAN 17
2 4 3 5 PRECAUTIONS INSIDE OPERATOR’S COMPARTMENT 17
2 4 3 6 PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT 18
2 4 3 7 IF A PROBLEM IS FOUND 18
2 4 4 FIRE PREVENTION 18
2 4 4 1 PRECAUTIONS TO PREVENT FIRE 18
2 4 4 2 ACTION IF FIRE OCCURS ON PC3000 19
2 4 4 3 ACTION IF FIRE OCCURS ON PC4000, PC5500, PC7000, PC8000 20
2 4 4 4 EMERGENCY EXIT FROM OPERATOR’S CAB 20
2 4 5 PRECAUTIONS WHEN GETTING ON OR OFF THE MACHINE 21
2 4 5 1 USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF THE MACHINE 21
2 4 5 2 NO JUMPING ON OR OFF THE MACHINE 21
2 4 5 3 NO PEOPLE ON THE ATTACHMENT 21
2 4 5 4 WORKING IN HIGH PLACES 21
2 4 5 5 LEAVING OPERATOR’S SEAT WITH LOCK 22
2 4 5 6 LEAVING THE MACHINE 22
2 4 6 BURN PREVENTION 22
2 4 6 1 Hot coolant 22
2 4 6 2 Hot oil 23
2 4 7 PRECAUTIONS WHEN CLEANING CAB GLASS 23
2 4 8 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES 23
2 4 9 PRECAUTIONS RELATED TO AIRBOURNE AND EJECTED DEBRIS 24
2 4 9 1 UNAUTHORIZED MODIFICATION 24
2 4 9 2 PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS 24
2 4 10 ELECTROMAGNETIC COMPATIBILITY (EMC) 24
2 4 11 PRECAUTIONS AT JOBSITE 25
2 4 11 1 VISIBILITY FROM OPERATOR’S SEAT 26
2 4 11 2 CAMERA SYSTEM WITH MONITORS 26
2 4 11 3 ENSURE GOOD VISIBILITY 26
2 4 11 4 CHECKING SIGNS AND SIGNALMAN’S SIGNALS 26
2 4 11 5 INVESTIGATE AND CONFIRM JOBSITE CONDITIONS 27
2 4 11 6 DO NOT GO CLOSE TO HIGH VOLTAGE CABLES 27
2 4 11 7 Lightning Strikes 28
2 4 11 8 WORKING ON LOOSE GROUND 28
2 4 11 9 GAS, DUST, STEAM, SMOKE AND EXHAUST FUMES 29
2 4 11 10 VENTILATION OF ENCLOSED AREAS 30
2 4 12 STARTING motor 31
2 4 12 1 WARNING TAG 31
2 4 12 2 CHECKS BEFORE STARTING motor 31
2 4 12 3 PRECAUTION WHEN STARTING motor 31
2 4 12 4 PRECAUTION IN COLD AREAS 32
2 4 13 OPERATION 32
2 4 13 1 CHECKS BEFORE OPERATION 32
2 4 13 2 PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE 33
2 4 13 3 PRECAUTIONS WHEN traveling 34
2 4 13 4 TRAVELING ON SLOPES 35
2 4 13 5 OPERATIONS ON SLOPES 36
2 4 13 6 PROHIBITED OPERATIONS 36
2 4 13 7 TRAVELING ON FROZEN OR SNOW COVERED SURFACES 37
2 4 13 8 PARKING THE MACHINE 37
2 4 13 9 TRANSPORTATION 37
2 5 PRECAUTION FOR MAINTENANCE 38
2 5 1 GENERAL PRECAUTIONS 38
2 5 1 1 SELECTION AND QUALIFICATION OF PERSONNEL – BASIC RESPONSIBILITIES 39
2 5 1 2 STOP motor FOR MAINTENANCE 40
2 5 1 3 WARNING TAG 41
2 5 1 4 KEEP WORKPLACE CLEAN AND TIDY 42
2 5 1 5 APPOINT LEADER WHEN WORKING WITH OTHERS 42
2 5 1 6 TWO WORKERS FOR MAINTENANCE WHEN THE MACHINE IS RUNNING 43
2 5 1 7 INSTALLING, REMOVING OR STORING ATTACHMENTS 43
2 5 1 8 PRECAUTIONS WHEN WORKING UNDER THE MACHINE OR EQUIPMENT 44
2 5 1 9 NOISE 44
2 5 1 10 WHEN USING A HAMMER 44
2 5 1 11 PROPER TOOLS 45
2 5 1 12 ACCUMULATOR 45
2 5 1 13 PERSONNEL 45
2 5 2 PRECAUTIONS FOR INSPECTION AND MAINTENANCE 46
2 5 2 1 PRECAUTION WHEN WELDING 46
2 5 2 2 BATTERY HANDLING 46
2 5 3 PRECAUTIONS WITH HIGH PRESSURE FLUID 47
2 5 3 1 PRECAUTIONS WITH HIGH FUEL PRESSURE 48
2 5 3 2 HANDLING HIGH PRESSURES HOSES OR PIPES 49
2 5 3 3 REPLACEMENT OF HOSE LINES 49
2 5 3 4 INSPECTION OF HOSE LINES 49
2 5 3 5 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS 50
2 5 3 6 PRECAUTIONS FOR HIGH VOLTAGE 50
2 5 3 7 AIR CONDITIONING MAINTENANCE 50
2 5 3 8 COMPRESSED AIR 51
2 5 3 9 WASTE MATERIALS 51
2 6 ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS 52
2 6 1 INSPECTION OF THE HYDRAULIC SYSTEM 52
2 6 2 TWO WORKERS ONLY WHEN THE MACHINE IS RUNNING DURING ADJUSTMENTS 52
2 6 3 AREAS OF POTENTIAL DANGER AROUND THE EXCAVATOR 52
2 7 SPECIAL SAFETY EQUIPMENT 53
2 7 1 FRONT GUARD PROTECTIVE STRUCTURe ’FOPS’ FOR OPERATOR’S CAB 54
2 7 2 OBJECT HANDLING 54
2 7 3 LIGHTING 54
2 7 4 WARNING BEACON 54
2 7 5 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD) 54
2 7 5 1 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD) 54
2 7 5 2 INSTRUCTIONS FOR USE 56
2 7 5 3 PRIOR TO USING THE HARNESS (1), THE WEARER SHALL 58
2 7 5 4 RECOMMENDATIONS FOR USE OF THE HOLDING HOOKS AND HOLD- BACK HOOKS OF THE SAFETY HARNESS 58
2 7 5 5 INSTRUCTIONS FOR USE 60
01 Specification 61
Specification PC3000-6 63
10 Structure & Function 73
TOC 75
1 Introduction 85
1 1 Foreword 86
1 2 Recommendations for environmentally friendly operation and maintenance of hydraulic mining shovels 87
1 3 Explanation of abbreviations 88
1 4 Diagrams and illustrations in this manual 89
2 Specifications 91
2 1 Lifting Gears 92
2 2 Safety hints for sling accessory 94
2 3 Standard Tightening Torque Chart 95
2 4 Conversion Tables 96
2 5 PT100 TEMPERATURE CHARTS (PT100) g Centigrade – Ohm 102
2 6 Blind plugs 103
2 7 Classification of threads to the nominal width 105
2 8 Plugs and fittings according to ISO 8434-1 / DIN 2353 106
3 Main assembly groups 107
3 1 General layout 108
3 2 Superstructure 110
3 3 Machinery house 112
3 4 Hydraulic oil tank 114
3 5 Hydraulic oil cooler 116
3 6 Fuel tank 118
3 7 Counterweight 120
3 8 Cab base 122
3 9 Operator’s cab 124
3 10 Main Control blocks 126
3 10 1 Main control blocks (FSA) 126
3 10 2 Main control blocks (BHA) 128
3 11 Slew Gear 130
3 11 1 Slew Gear Type 2063 130
3 11 2 Slew Gear type 632770 132
3 12 Undercarriage 134
3 13 Backhoe attachment (BHA) 136
3 14 Front shovel attachment (FSA) 137
3 15 Safety circuit PPC control 138
4 Drive 141
4 1 Prime drive assembly 142
4 2 Engine mounts 144
4 2 1 Torque Support 145
4 3 Coupling (type a) 146
4 4 Flexible coupling (type B) 148
4 4 1 Information for maintenance 150
4 4 2 Coupling elements 151
4 4 3 Separation and assembly of the coupling inner and outer part 152
4 4 4 Operation troubles, causes, and rectification 153
4 5 Radiator Fan drive 154
4 6 Pump distributor gearbox (pto) 156
4 6 1 PTO lubrication and cooling 158
4 6 1 1 Checks and adjustments – PTO lubrication pressure 160
4 6 2 PTO gear oil temperature control 162
4 6 2 1 temperature Adjustment (oil viscosity) 163
4 6 3 Pump spline lubrication 164
4 6 3 1 Oil level in the main pump & gear oil pump drive shaft housing 165
4 7 Hydraulic pumps – arrangement 166
4 8 Air filter 168
5 Hydraulic oil tank 171
5 1 General layout 172
5 2 Hydraulic oil tank, location of the electric equipmenT 174
5 3 Suction oil manifold with strainers 176
5 4 Return oil collector manifold with strainer 178
5 5 Back pressure valve 180
5 6 Transfer pump 182
5 7 Return and leak oil filter 184
5 8 Breather filter 186
6 Hydraulic oil cooling 189
6 1 Overall view of the hydraulic oil cooling 190
6 2 Function of the hydraulic oil cooling circuit 192
6 3 Adjustment of the back pressure valve 194
6 4 Two stage cooler fan RPM control 196
6 4 1 Solenoid valve for fan speed control 198
6 4 2 Pressure reducing valve 200
6 4 3 Temperature converter Relays 202
6 4 3 1 Function check of cooler fan RPM-control 203
6 5 Fan pump 204
6 6 Checks and Adjustments of the cooler fan drive speeds 206
6 6 1 Function Check of Fan Speed Control 209
7 Controlling 211
7 1 General layout 212
7 2 Control and filter plate – location of components 214
7 3 Pilot control frame – location of components 218
7 4 Pilot pressure supply and adjustments 220
7 4 1 Pilot pressure circuit 220
7 4 2 Checks and adjustment of pilot pressure 222
8 Components 225
8 1 Main control blocks and high pressure filters (FSA) 226
8 2 Main control blocks and high pressure Screens (BHA) 230
8 3 Distributor manifold – location of restrictor blocks and anti cavitation valves (FSA) 234
8 4 Distributor manifold – location of restrictor blocks and anti cavitation valves (BHA) 236
8 5 Single control blocks (floating) for stick and boom (FSA) 238
8 6 Restrictor block with secondary relief valve 240
8 7 Anti-cavitation valve (ACV) block 242
8 8 High-pressure screen 244
8 9 Control blocks and valves 246
8 9 1 Spool types 252
8 9 2 MRV, SRV and ACV 254
8 9 3 Load holding valve 256
8 10 Travel brake valve 260
8 11 4/2 Directional solenoid valves 262
8 12 4/3 Directional solenoid valves 264
8 13 Pressure double stage valve 266
8 14 Hydraulic cylinder with NOK-3 sealing 268
8 14 1 Cylinder data markings 271
8 15 Auxiliary gear pumps 272
9 Main hydraulic pumps and pump regulation 273
9 1 General 274
9 1 1 Pump locations and pump data 276
9 2 Main pumps 278
9 2 1 Hydraulic pump type HPV375+375 278
9 2 1 1 Main pump sectional drawings 280
9 2 2 Servo valve 282
9 2 2 1 VC valve servo piston 283
9 2 2 2 EPC valve 288
9 3 Electronic pump regulation system 290
9 3 1 Cut-off function 292
9 3 2 Slew control (volume reduction) 293
9 3 3 Diagnostics and monitoring 293
9 3 4 Temperature control 294
9 3 4 1 temperature Adjustment (hydraulic oil viscosity) 294
9 4 Pump controller CR710 296
9 4 1 Connector and pin arrangement at CR710 (10K032) 298
9 5 Multimonitor 302
9 5 1 Service menu screen 305
9 5 2 Service menu, option: 01 Monitoring 306
9 5 2 1 Hold function 309
9 5 3 Service menu, option: 02 Abnormality Record 310
9 5 3 1 Troubleshooting procedures 310
9 5 3 2 Table of Pump-controller-Codes (Multi Monitor) 312
9 5 4 Service menu, option: 03 Default 314
9 5 5 Service menu, option: 04 Adjustment 315
9 5 6 Adjustable parameters 317
9 5 7 Emergency mode 317
9 5 8 Description of the Primary P-Factor 318
9 5 8 1 Adjustment, item 1: Primary P-factor 318
9 5 9 Adjustment, items 23 28: Sol_adj_min_P1 Sol_adj_min_P6 319
9 5 10 Adjustment, items 39 44: Sol_adj_mAX_P1 Sol_adj_mAX_P6 320
9 5 11 Available parameters list 321
9 5 12 Service menu, option: 05 Display Setup 323
9 6 Checks and adjustments 324
9 6 1 Engine power check 324
9 6 2 Cut-off function check 327
9 6 2 1 Cut-off for clam close (FSA only) 328
9 7 Engine speed sensor (pick-up) 330
9 7 1 General 331
9 7 2 Engine speed sensor (pick-up) adjustment 331
10 Operating hydraulics 333
10 1 General 334
10 1 1 Floating system (FSA) 336
10 2 Checks and adjustments of the main relief valve (MRV) 338
10 3 Hydraulics for the attachment cylinders 342
10 3 1 Checks and adjustments of the secondary relief valves (SRV) 342
10 3 1 1 Boom cylinders, piston side (BHA & FSA), boom up 342
10 3 1 2 Boom Cylinder, Piston Rod Side (BHA & FSA), boom down 346
10 3 1 3 Stick cylinders, piston side (FSA), stick out 350
10 3 1 4 Stick cylinders, piston side (BHA), stick in 354
10 3 1 5 Stick cylinders, piston rod side (FSA), stick in 358
10 3 1 6 Stick cylinders, piston rod side (BHA), stick out 362
10 3 1 7 Bucket cylinders, piston side (FSA), bucket fill 366
10 3 1 8 Bucket cylinders, piston side (BHA), bucket fill 370
10 3 1 9 Bucket cylinders, piston rod side (FSA), bucket dump 374
10 3 1 10 Bucket cylinders, piston rod side (BHA), bucket dump 378
10 3 1 11 Clam cylinders, piston rod side (FSA), clam open 382
10 3 1 12 Clam cylinders, piston side (FSA), clam close 386
10 3 2 Checks and adjustments of the lowering speed 390
10 3 2 1 Checks and adjustments of the lowering speed – boom (FSA) 390
10 3 2 2 Checks and adjustments of the lowering speed – boom (BHA) 396
10 3 2 3 Checks and adjustments of the lowering speed – stick (FSA) 398
10 3 2 4 Checks and adjustments of the lowering speed – stick (BHA) 404
10 3 2 5 Checks and adjustments of the lowering speed – bucket (FSA) 406
10 3 2 6 Checks and adjustments of the lowering speed – bucket (BHA) 408
10 3 2 7 Checks and adjustments of the lowering speed – clam (FSA) 410
10 4 Hydraulics for the slew circuit 412
10 4 1 Slew circuit 412
10 4 2 Slew motor 414
10 4 3 Slew gearbox of type 2063 416
10 4 4 Slew gearbox of type 632770 418
10 4 5 Slew parking brake of type 2063 420
10 4 6 Slew parking brake of type 632770 422
10 4 7 Slew brake valve 424
10 4 8 Checks and adjustments for the slew circuit 428
10 4 8 1 Checks & adjustments, double stage valve 428
10 4 8 2 checks & adjustments, slew Brake pilot pressure 431
10 4 8 3 Crosscheck of the DSV setting 431
10 4 8 4 Checks and Adjustment of the slew motion detection 432
10 4 9 Function check for the hydraulic slew brake 434
10 5 Hydraulics for the travel circuit 436
10 5 1 Travel circuit 436
10 5 2 Travel motor 438
10 5 3 Rotary joint 440
10 5 4 Travel gearbox 442
10 5 5 Travel parking brake 444
10 5 5 1 Travel parking brake 444
10 6 Travel brake valve 446
10 6 1 Checks and adjustments 448
10 6 1 1 Checks and adjustments for the travel circuit 448
10 6 1 2 Function check for the travel parking brake 450
11 Hydraulic track tensioning system 453
11 1 General 454
11 2 Functional description 456
11 3 Double stage valve 458
11 4 Tensioning cylinder 460
11 5 Adjustments / checks 462
12 Access ladder, hydraulically operated 465
12 1 General 466
12 2 Function of the hydraulically operated access ladder 468
12 3 Adjustments / checks 472
13 Central refilling system (refilling arm) 475
13 1 Refilling arm location 476
13 2 Function 478
14 Hints for reading the hydraulic diagram 481
14 1 General 482
14 2 Hydraulic symbols 484
14 2 1 Lines, unions 485
14 2 2 Components, valves 487
14 2 3 Sensors 487
14 2 4 Valves, valve components 488
14 2 5 Pump, motor, cylinder 492
15 Hints for reading the electric wiring diagram 497
15 1 General 498
15 2 Reference code of the electrical components 499
15 2 1 Area code 499
15 2 2 Component identifying letter 501
15 3 Graphical symbols 502
15 4 Drawing concept 506
15 5 Cable marking 515
16 KOMTRAX Plus 517
16 1 General 518
16 1 1 location of KOMTRAX Plus components in cab base 520
16 2 Specifications for operators 522
16 2 1 Opening screen 523
16 2 2 Main gauge screens 1 to 2 524
16 2 3 Fuel consumption screen 528
16 2 4 Failure message history for the operator 530
16 2 5 Main gauge screens – Changing of Time / SMR / Date 531
16 2 6 Maintenance monitor 532
16 2 7 Settings for operator 534
16 2 7 1 USER ID Screen 535
16 2 7 2 Reset Truck Counter 1 & 2 536
16 2 7 3 Screen Adjustment Displays 538
16 2 7 4 Date and Time Adjustment 540
16 2 7 5 Language selection 541
16 2 8 Automatic messages 542
16 3 Tables of all provided messages 544
16 3 1 Table of komtrax plus trouble codes 544
16 3 2 TABLE OF Cummins trouble CODES (TIER 2) 548
16 3 3 Table of Pump-controller-Codes (Multi Monitor) 553
16 3 4 Table of available Instruction Messages 555
16 4 Flow charts (1-4) of KOMTRAX Plus main screens 558
16 5 KOMTRAX Plus service level 562
16 5 1 Explanation of the button symbols (Service Level) 564
16 5 2 Service Menu Select Screen 565
16 5 3 Real Time Menu Select Screen 566
16 5 3 1 Real Time Menu, option: 01 Engine 1 567
16 5 3 2 Real Time Menu, option: 02 PTO 1 568
16 5 3 3 Real Time Menu, option: 03 Hydraulic 569
16 5 3 4 Real Time Menu, option: 04 Electrical Equipment 570
16 5 3 5 Real Time Menu, option: 05 Emergency Stop 571
16 5 3 6 Real Time Menu, option: 06 Manual Switch 572
16 5 3 7 Real Time Menu, option: 07 Central Lube System 1 573
16 5 3 8 Real Time Menu, option: 08 Slew Ring Gear Lube System 574
16 5 3 9 Real Time Menu, option: 09 Pilot Control 575
16 5 3 10 Real Time Menu, option: 10 Other Items 576
16 5 3 11 Real Time Menu, option: 11 Output Signals 577
16 5 4 PM-Clinic 578
16 5 4 1 General 578
16 5 4 2 Power Check 579
16 5 5 Serial/GCC no setting 581
16 5 6 Memory Clear 582
16 5 6 1 Input Memory Clear ID 582
16 5 6 2 Memory Clear screen 583
16 5 7 Failure History 584
16 5 8 Maintenance Monitor 585
16 5 9 Snapshot 586
16 5 10 Settings 588
16 5 10 1 Central Lubrication System (CLS 1), screen 1/4 588
16 5 10 2 Slew Lubrication System (SLS), screen 2/4 589
16 5 10 3 Other Settings 1/2, screen 3/4 589
16 5 10 4 Other Settings 2/2, screen 4/4 590
16 6 Interface-Connection KOMTRAX Plus controller 592
16 6 1 KOMTRAX Plus controller 593
16 7 7-segment error code indication 594
16 8 Wiring of the KOMTRAX Plus controller 596
16 9 Global layout of the internal CAN BUS 600
16 9 1 General information CAN BUS system 600
16 9 1 1 General CAN BUS description 601
16 9 1 2 CAN BUS troubleshooting 601
16 9 2 Can BUS wiring 602
16 9 2 1 CAN bus end resistor 603
17 Lubrication system 605
17 1 General overview (SLS & CLS) 606
17 1 1 General description 607
17 2 Basic function of the lubrication systems 608
17 3 Lubrication systems (SLS & CLS) 610
17 3 1 Lubrication pump station 610
17 3 2 General Information on CLS 612
17 3 3 General information on SLS 612
17 4 Lubrication cycle 614
17 4 1 Time segments & switch points of a lubrication cycle 615
17 4 2 Automatic lubrication mode CLS 616
17 4 2 1 Function 617
17 4 2 2 System monitoring 617
17 4 3 Automatic lubrication mode SLS 618
17 4 3 1 Function 619
17 4 3 2 System monitoring 619
17 4 4 Automatic lubrication mode adjustments 620
17 4 4 1 Pause time adjustment & fault time monitoring adjustment 620
17 4 4 2 Lube cycle monitoring time adjustment 621
17 4 5 Manual lubrication mode (CLS & SLS) 622
17 4 6 Resetting a faulty lubrication system 622
17 5 Hydraulically driven lube pump 624
17 5 1 Adjustment of lube pump speed 626
17 5 1 1 Stroke speed adjustment 627
17 5 1 2 Working pressure 627
17 6 Lubricant injectors 628
17 6 1 Tightening torques for fittings at grease injectors 629
17 6 2 Description 629
17 6 3 Adjustment of the lubricant output 630
17 6 4 Operation principle of lubricant injectors 632
17 6 4 1 Function description 633
17 6 5 Connection of one or more injectors 634
17 7 Vent valve and grease outlet filter 636
17 7 1 Vent valve description 637
17 8 End-line switch 638
17 8 1 Description 639
17 8 2 CLS & SLS end-line switch adjustment 640
17 9 Lubricant level sensors 642
17 9 1 Description 643
17 9 1 1 Checks 643
17 10 Commissioning 644
17 10 1 Commissioning of the CLS lubrication system 644
17 10 2 Fine adjustment 645
17 10 3 Commissioning of the SLS lubrication system 646
18 Deep temperature equipment (option) 649
18 1 General information 650
18 1 1 Introduction 650
18 1 2 Deep temperature components overview 650
18 1 3 Power supply preconditions for preheating 651
18 1 4 Power requirements for preheating systems 652
18 2 Preheating procedure 653
18 2 1 Global flow chart of the preheating procedure 653
18 2 2 Starting the preheating procedure 654
18 2 3 Preheating of operator’s cab and Diesel engine [coolant system] 655
18 2 4 Preheating of lubricants and superstructure (Diesel) [electric system] 656
18 3 Constant heating of travel motors (TTT equipment below-40°C only) 657
18 4 Component location 658
18 4 1 Electric heating elements for hydraulic & batteries [electric machine] 658
18 4 2 Electric heating elements for hydraulics [Diesel machine] 660
18 4 3 Electric heating elements for engines & batteries [Diesel machine] 662
18 5 Components of TT equipment 664
18 5 1 Preheating components on a Diesel machine 664
18 5 2 Preheating components on an electric machine 666
18 5 3 Exemplary Wiring Diagrams for preheating systems 667
18 5 3 1 Wiring diagram “Hydraulic Oil Tank Preheating” part 1 of 3 667
18 5 3 2 Wiring diagram “Hydraulic Oil Tank Preheating” part 2 of 3 668
18 5 3 3 Wiring diagram “Hydraulic Oil Tank Preheating” part 3 of 3 669
18 5 3 4 Wiring diagram “Suction Oil Manifold Preheating” 670
18 5 3 5 Wiring diagram “PTO Preheating” 671
18 5 3 6 Wiring diagram “Battery heater pads” 672
40 Troubleshooting 673
TOC 675
1 Introduction 685
1 1 Overview 686
1 1 1 General advice when using troubleshooting charts 686
1 2 General Precautions 687
2 General Information for Troubleshooting 689
2 1 Preparations For Work 690
2 2 Precautions During Work 690
2 3 Precautions When Carrying Out Any Operation 691
2 3 1 Precautions when carrying out removal work 691
2 3 2 Precautions when carrying out installation work 691
2 3 3 Precautions when completing the operation 692
2 4 Fundamental Requirements for Troubleshooting 693
2 4 1 Technical documentation 693
2 4 2 Tools 693
2 4 2 1 Reference Guide for Deutsch Removal Tools 696
2 4 3 Personnel 697
2 5 Points To Remember When Troubleshooting 697
2 6 Sequence Of Events In Troubleshooting 699
2 7 Checks Before Troubleshooting 700
2 8 Handling Of Electric Equipment And Hydraulic Components 701
2 8 1 Points to remember when handling electric equipment 701
2 8 2 Points To Remember When Handling Hydraulic Equipment 704
2 9 General working procedures 706
2 9 1 Air Bleeding of Various Hydraulic Parts 706
2 9 2 Air bleeding from the hydraulic pumps 706
2 9 3 Air bleeding from hydraulic cylinders 706
2 10 Cylinder bypass test 707
2 11 Basics about “How to crimp” (with strain relief) 708
2 11 1 Crimp tool & repair kit 708
2 11 2 General 709
2 11 3 Select the required connector components 709
2 11 4 Stripping a wire 710
2 11 5 Crimping 711
2 11 6 Connector assembly after crimping 712
2 12 Cable Shielding 713
3 Mounting Locations and Connector Types 715
3 1 Component location 716
3 1 1 View at the Superstructure 716
3 1 2 Engine – location of electrical components (1) 718
3 1 3 Engine – location of electrical components (2) 720
3 1 4 Control and filter plate – location of Components 722
3 1 5 PTO and suction oil tank – location of electrical components 724
3 1 6 Pilot control frame – location of electrical components 726
3 1 7 Main control blocks – location of components 728
3 1 8 Lubrication system – location of electrical components 730
3 1 9 Cab base – location of electrical components 732
3 1 10 Hydraulic Oil Tank – Location of Electrical Components 734
3 1 11 Hydraulically operated access ladder – location of electrical Components 736
3 1 12 Refilling arm – location of electrical Components 737
3 1 13 Air filter and fuel tank – location of electrical components 738
3 2 Connector Types Overview 740
4 Standard Value Table for Electrical Components 743
5 References for Troubleshooting 755
5 1 7-segment error code indication 756
5 2 Relay checks 758
5 2 1 Switch contact testing using the Test button 758
5 2 2 Measuring of the coil resistance 760
6 Tables for Testing and Troubleshooting 761
6 1 PT100 TEMPERATURE CHARTS (PT100) g Centigrade – Ohm 762
6 2 Test Value Table for pressure Sensors 763
6 2 1 Transducers with output voltage range: 0 5 4 5 Volt 763
6 2 2 Transducers with output voltage range: 0 5 9 5 Volt 763
6 3 Trouble Code Tables 764
6 3 1 TABLE OF Cummins trouble CODES (TIER 2) 764
6 3 2 TABLE OF KOMTRAX PLUS TROUBLE CODES 769
6 3 3 Table of Pump-controller-Codes (Multi Monitor) 773
6 4 Table of Instruction Messages 775
6 5 Table of symptom codes 778
6 5 1 SYMPTOMS OF THE ENGINES AND RELATED ELECTRICAL SYSTEMS 778
6 5 2 SYMPTOMS OF THE HYDRAULIC SYSTEM 778
6 5 3 SYMPTOMS OF THE MECHANICAL SYSTEM 779
6 5 4 SYMPTOMS OF ADDITIONAL SYSTEMS 779
6 6 Cable colour identification 780
7 Troubleshooting by KOMTRAX Plus trouble code 781
G00001 – Trouble Shut-Off (gate) valve 782
View onto the gap of proximity switch 40B031 784
Input signal of the proximity switch 40B031 on the REAL TIME MONITOR 784
Wiring Diagram (40B031) for trouble code G00001 (Main gate valve open) 785
G00002 – Test speed 1800 1/min engine 1 786
Input signal of the switch 11S041-1 on the REAL TIME MONITOR 786
Wiring Diagram (11S041-1) for trouble code G00002 787
G00007 – Trouble hydraulic oil level 788
Wiring Diagram (40B004) and the defined position of the attachment (G00007) 791
G00012 – Central lubrication system grease level too low 792
G00013 – Slew ring gear lubr system grease level too low 792
Input signals of grease level sensors 62B108b & 62B109b on the REAL TIME MONITOR 795
Wiring Diagram for trouble codes G00012 & G00013 796
Wiring Diagram (junction box) for trouble codes G00012 & G00013 797
G00031 – Set engine to low idle 798
Wiring Diagram (20S030) for trouble code G00031 799
Input signal of the resistor 11T080 on the REAL TIME MONITOR 799
G00060 – Fire in the power house 800
Wiring Diagram (fire alarm & safety circuit) for trouble code G00060 802
G00065 – Very low hydraulic oil level 803
View onto the hydraulic oil level label 803
G00066 – Trouble hydraulic oil temperature 804
Hydraulic oil temperature table – 11K039 adjustment (T4 switch point) 806
Wiring Diagram (59B015 and 11K039) for G00066 807
G00067 – Trouble battery voltage too high 808
Input signal of the resistor 11T080 on the REAL TIME MONITOR 809
Wiring Diagram (11T080) for G00067 809
G00070 – Trouble oil temperature gear (PTO 1) 810
PTO gear oil temperature table – 11K143 adjustment 812
Input signal of 57B079 on the REAL TIME MONITOR 812
Wiring Diagram (59B049 / 11K143) for G00070 813
G00071 – Trouble gear lubrication (PTO 1) 814
PTO gear oil temperature table – 11K182 adjustment 816
Wiring Diagram (57B017) for trouble code G00071 816
Wiring Diagram (57B182 & 11K182) for G00071 817
Input signal of 57B017 on the REAL TIME MONITOR 817
G00091 – Pilot control cut out 818
View onto the lock lever and the cover of 20S105 (G00091) 819
Wiring Diagram (20S105 and wiring) for G00091 819
G00092 – Emergency shut-down at access ladder 820
G00093 – Emergency shut-down at valve block 820
G00095 – Emergency shut-down in cabin 820
Wiring Diagram 1 (emergency switches) for G00092~G00095 821
Wiring Diagram 2 (emergency switches signal lines) for G00092~G00095 822
G00100 – Maintenance Safety Switch 823
Wiring Diagram (50S058) for trouble code G00100 824
G00104 – Trouble battery current 825
Input signal of the converter 11T117 on the REAL TIME MONITOR 826
Wiring Diagram 1 (71T003 & 52G005) for trouble code G00104 827
Wiring Diagram 2 (52G005, 52M001-1 & 52M002-1) for trouble code G00104 828
G00105 – Trouble battery charging current too low 829
Input signals of 11T080 & 11T117on the REAL TIME MONITOR 830
Wiring Diagram 1 (71T003 & 11T117) for trouble code G00105 831
Wiring Diagram 2 (11T080) for trouble code G00105 832
G00164 – Trouble air cleaner 1 833
View onto the engine air cleaner (G00164) 834
G00165 – Trouble breather filter hydraulic oil tank 835
View onto the pressure sensor 40B024 (G00165) 836
Input signal of 40B024 (filter clogged) on the REAL TIME MONITOR 836
G00166 – Trouble oil filter gear (PTO 1) 837
Hydraulic oil temperature table – 11K026 adjustment (T3 switch point) 837
View onto the PTO 1 gear oil filter with pressure sensor 57B027 (G00166) 838
Input signal of 57B027 (filter clogged) on the REAL TIME MONITOR 838
G00169 – Trouble return oil filter hydraulic oil tank 839
Hydraulic oil temperature table – 11K026 adjustment (T3 switch point) 839
View onto the pressure sensor 40B026 (G00169) 840
Input signal of 40B026 (filter clogged) on the REAL TIME MONITOR 840
G00170 – Trouble leak oil filter hydraulic oil tank 841
Hydraulic oil temperature table – 11K026 adjustment (T3 switch point) 841
View onto the pressure sensor 40B025 (G00170) 842
Input signal of 40B025 (filter clogged) on the REAL TIME MONITOR 842
G00176 – Trouble battery voltage too low 843
Wiring Diagram (71T003) for trouble code G00176 845
G00177 – Trouble battery charging circuit 846
Wiring Diagram (measuring points 1-3) for trouble code G00177 847
G00178 – Trouble battery charging current too high 848
Wiring Diagram (71T003 & 11T117) for trouble code G00178 849
G00184 – Central lubrication system empty 850
Wiring Diagram 1 (62B108c & 62B109c) for trouble codes G00184 & G00187 853
Wiring Diagram 2 (wiring to 14K300) for trouble codes G00184 & G00187 854
Wiring Diagram 3 (junction box) for trouble codes G00184 & G00187 855
Input signals of grease level sensors 62B108c & 62B109c on the REAL TIME MONITOR 856
G00185 – Trouble central lubrication system 857
Wiring Diagram 1 (relays) for trouble code G00185 862
Wiring Diagram 2 (11K50 & trouble signal circuit CLS/SLS) for trouble code G00185 863
Wiring Diagram 3 (10K511a) for trouble code G00185 864
View onto the vent valve 62Q507a 865
Action chart for lube cycles 866
G00187 – Slew ring gear lubrication system empty 867
G00188 – Trouble slew ring gear lubrication system 867
Wiring Diagram 1 (relays) for trouble code G00188 873
Wiring Diagram 2 (11K50 & trouble signal circuit CLS/SLS) for trouble code G00188 874
Wiring Diagram 3 (10K511a) for trouble code G00188 875
View onto the pressure switch 10B047 and wiring Diagram 3 for trouble code G00188 876
View onto the vent valve 62Q509a 877
Action chart for lube cycles 878
G00207 – Engine remote oil tank 1 empty 879
G00222 – Load limiting clam defective 880
Wiring Diagram (10B155 & 10B156) for trouble code G00222 882
G00243 – Fill up fuel tank 883
G00245 – Engine shutdown from ground 884
G00256 – Operator warning system 885
G00262 – Trouble screen at hydr cooler entry clogged 886
Location of 40B165 and the strainer at the intermediate pipe (G00262) 887
G00422 – Can-net sys (J1939) 888
Wiring Diagram (CAN-BUS) for trouble code G00422 889
G00491 – Communication failure MH800 <=> K+ Controller 890
Wiring Diagram (K+ monitor (MH801) → K+ controller) for trouble code G00491 891
DBBQKR – Communication failure CR710 <=> KOMTRAX Plus Controller 892
Wiring Diagram (CR710 <=> KOMTRAX Plus) for trouble code DBBQKR 893
DBB3KK – Abnormality in VBAT voltage (KOMTRAX Plus VBAT<10V) 894
DBB0KK – KOMTRAX Plus source voltage Error 895
Wiring Diagram – K+ controller 24V supply and GND connections 896
DBB0KQ – KOMTRAX Plus Connector Mismatch 897
DGH2KA – Hyd Oil Temp Sensor Failure 898
Wiring Diagram (59B032-1) for trouble code DGH2KA 899
DGH2KB – Hyd Oil Temp Sensor Failure 900
Wiring Diagram (59B032-1) for trouble code DGH2KB 901
J100KA – Pilot Press Sensor Failure 902
Wiring Diagram (57B086) for trouble code J100KA 904
J100KB – Pilot Press Sensor Failure 905
Wiring Diagram (57B086) for trouble code J100KB 906
J100L6 – Abnomal Pilot Pump press 907
Wiring Diagram (57B086) for trouble code J100L6 908
DGE5KA – Ambient air temp Sensor Failure 909
Wiring Diagram (13B090) for trouble code DGE5KA 910
DGE5KB – Ambient air temp Sensor Failure 911
Wiring Diagram (13B090) for trouble code DGE5KB 912
F@DANS – Trouble High Exhaust Temperature Cylinder RB1 913
F@DBNS – Trouble High Exhaust Temperature Cylinder RB2 913
F@DCNS – Trouble High Exhaust Temperature Cylinder RB3 913
F@DDNS – Trouble High Exhaust Temperature Cylinder RB4 913
F@DENS – Trouble High Exhaust Temperature Cylinder RB5 913
F@DFNS – Trouble High Exhaust Temperature Cylinder RB6 913
F@DGNS – Trouble High Exhaust Temperature Cylinder LB1 913
F@DHNS – Trouble High Exhaust Temperature Cylinder LB2 913
F@DJNS – Trouble High Exhaust Temperature Cylinder LB3 913
F@DKNS – Trouble High Exhaust Temperature Cylinder LB4 913
F@DLNS – Trouble High Exhaust Temperature Cylinder LB5 913
F@DMNS – Trouble High Exhaust Temperature Cylinder LB6 913
Input signals of the engine cylinder temperature sensors on the REAL TIME MONITOR 914
Wiring Diagram for trouble codes F@D(A M)NS 915
DGTAKX – Trouble monitoring Exhaust Temp Cylinder RB1 916
DGTBKX – Trouble monitoring Exhaust Temp Cylinder RB2 916
DGTCKX – Trouble monitoring Exhaust Temp Cylinder RB3 916
DGTDKX – Trouble monitoring Exhaust Temp Cylinder RB4 916
DGTEKX – Trouble monitoring Exhaust Temp Cylinder RB5 916
DGTFKX – Trouble monitoring Exhaust Temp Cylinder RB6 916
DGTGKX – Trouble monitoring Exhaust Temp Cylinder LB1 916
DGTHKX – Trouble monitoring Exhaust Temp Cylinder LB2 916
DGTJKX – Trouble monitoring Exhaust Temp Cylinder LB3 916
DGTKKX – Trouble monitoring Exhaust Temp Cylinder LB4 916
DGTLKX – Trouble monitoring Exhaust Temp Cylinder LB5 916
DGTMKX – Trouble monitoring Exhaust Temp Cylinder LB6 916
Input signals of the engine cylinder temperature sensors on the REAL TIME MONITOR 917
Wiring Diagram for trouble codes DGT(A M)KX 918
DJF1KX – Trouble monitoring fuel level 919
Wiring Diagram (31B063) for trouble code DJF1KX 921
8 Troubleshooting by Symptoms 923
8 1 Symptoms of the engine and related electrical system 924
SEL001 – Engine does not start (engine does not rotate) 924
Wiring Diagram 1 (engine start) for trouble code SEL001 & SEL001a 926
SEL001a – Engine does not start (Pre-lube does not stop) 927
SEL002 – Engine stops while in operation 928
View onto the fuel system water separator (SEL002) 929
SEL003 – Engine speed is hunting during boom-up movement 930
SEL004 – Engine does not stop 932
SEL005 – Engine lacks output (no power) 934
Judgment Table for SEL005 935
SEL006 – Exhaust smoke is black 936
Judgment Table for SEL006 937
SEL007 – Oil consumption is excessive 938
Judgment Table for SEL007 939
SEL008 – Oil becomes contaminated quickly 940
Judgment Table for SEL008 941
SEL009 – Fuel consumption is excessive 942
Judgment Table for SEL009 943
SEL010 – Oil is in engine coolant 944
Judgment Table for SEL010 945
SEL011 – Oil level rises 946
Judgment Table for SEL011 947
SEL012 – Coolant temperature becomes too high (overheating) 948
Judgment Table for SEL012 949
8 2 Symptoms of the Hydraulic System 950
SHY001 – All the work equipment shows lack of power or slow movement (especially the “boom up” function) 950
SHY002 – Engine speed sharply drops or engine stalls too much 952
SHY003 – No work equipment, travel or slew movement 953
SHY004 – Work equipment has too much hydraulic drift 954
SHY005 – Work equipment has big time lag 955
Hydraulic oil temperature table – 11K026 and 11K171 adjustment 955
SHY006 – Machine deviates during travel movement 956
SHY007 – Hydraulic system has lack of power 957
SHY008 – Machine does not slew 958
Slew brake block (SHY008) 959
SHY009 – Slew acceleration is poor (or slew speed is very low) 960
SHY010 – Excessive overrun when stopping slew movement 962
SHY011 – Floating system without function (FSA only) 964
Floating system – overview (SHY011) 965
SHY012 – Abnormal noise coming from SRV or MRV 966
SHY013 – Track tensioning system without function 967
View onto the elements of the hydraulic track tensioning system (SHY013) 969
SHY014 – Ladder does not move, or slow movement 970
SHY015 – Refilling arm does not move, or slow movement 972
SHY016 – Refilling arm is sagging when engine is not running 974
SHY017 – The hydr driven grease pump does not move 975
SHY018 – Abnormal track chain movement during digging 977
SHY019 – Slew parking brake without function 978
SHY020 – Travel parking brake without function 979
8 3 Symptoms of the Mechanical System 980
SME001 – Abnormal noise is made 980
Judgment Table for SME001 981
SME002 – Abnormal noise around the PTO / hydraulic pumps 982
SME003 – Vibration is excessive (engine mountings) 984
Judgment Table for SME003 985
SME004 – Vibration is excessive (engine torsion) 986
SME005 – There is a big shock when stopping slew movement 987
SME006 – There is a big abnormal noise when moving/stopping slew movement 988
SME007 – Fan blades make abnormal noise 990
SME008 – Abnormal noise coming from a travel gearbox 991
SME009 – Abnormal noise coming from the work equipment (lack of grease) 993
SME010 – Abnormal idler movement 995
SME011 – Leak at the PTO shaft seal 996
8 4 Symptoms of Additional Systems 998
SAD001 – Air conditioner for the cabin does not work 998
View onto the A/C unit (SAD001) 999
SAD002 – Air conditioner compressor clutch is burnt 1000
View onto the A/C compressor and its mounting (SAD002) 1001
SAD003 – Air conditioning system defective (pipes and hoses full of moisture) 1002
View onto an A/C filling and service station 1003
9 Troubleshooting by pump controller trouble codes (Multi Monitor) 1005
DXAAKA – Solenoid-1(Pump-1) open circuit 1006
DXABKA – Solenoid-2(Pump-2) open circuit 1006
DXACKA – Solenoid-3(Pump-3) open circuit 1006
DXADKA – Solenoid-4(Pump-4) open circuit 1006
DXAEKA – Solenoid-5(Pump-5) open circuit 1006
DXAFKA – Solenoid-6(Pump-6) open circuit 1006
Wiring Diagram – EPC valve control (pump controller) 1007
DXAAKB – Solenoid-1(Pump-1) short circuit 1008
DXABKB – Solenoid-2(Pump-2) short circuit 1008
DXACKB – Solenoid-3(Pump-3) short circuit 1008
DXADKB – Solenoid-4(Pump-4) short circuit 1008
DXAEKB – Solenoid-5(Pump-5) short circuit 1008
DXAFKB – Solenoid-6(Pump-6) short circuit 1008
Wiring Diagram – EPC valve control (pump controller) 1009
DHPEMA – Pump-1/2 pressure sensor abnormality 1010
DHPGMA – Pump-3/4 pressure sensor abnormality 1010
DHPJMA – Pump-5/6 pressure sensor abnormality 1010
Wiring Diagram – PWR & GND supply for pressure sensors (pumps 1 3) 1011
DLE2MA – Engine speed sensor abnormality 1012
Wiring Diagram – engine RPM signal (52B064) to pump controller 1013
DA25KP – 5V sensor1 power abnormality 1014
Wiring Diagram – 5V sensor power supply for trouble code DA25KP 1016
DA22KK – Pump Solenoid Power Low Error 1017
DA29KQ – Model Selection Abnormality 1018
10 Appendix 1019
10 1 Comparison of Trouble Codes: VHMS (incl retrofit kit) vs KOMTRAX Plus 1020
10 1 1 VHMS Trouble codes vs Komtrax Plus trouble codes 1020
10 1 2 Pump controller CR700 vs Pump controller CR710 trouble codes 1024
50 Disassembly and assembly 1027
TOC 1029
1 Introduction 1037
1 1 Contents of this binder 1038
1 2 Foreword 1038
1 3 Recommendations for environmentally friendly operation and maintenance of hydraulic mining shovels 1040
1 4 Explanation of abbreviations 1041
1 5 Diagrams and illustrations in this manual 1042
1 6 Procedures for disassembling and assembling in this manual 1042
2 Safety 1043
2 1 Overview 1045
2 1 1 Method of using this manual 1045
2 2 General precautions 1047
2 2 1 General 1047
2 2 2 Personal protective clothing 1047
2 2 3 When using a hammer 1048
2 2 4 Proper tools 1048
2 2 5 Personnel 1048
2 2 6 Fire prevention 1049
2 2 7 Unauthorized modification 1049
2 3 Precautions for maintenance and repair 1050
2 3 1 General precautions 1050
2 3 2 Keep work place clean and tidy 1050
2 3 3 Precautions when welding 1051
2 3 4 Precaution with high pressure fluids 1051
2 3 4 1 Handling high pressure hoses and pipes 1051
2 3 5 Compressed air 1051
2 3 6 Waste materials 1052
3 Superstructure 1053
3 1 Superstructure overview 1054
3 2 Machinery house 1056
3 2 1 Machinery house roof 1058
3 2 1 1 Disassembling of the complete roof frame 1058
3 2 1 2 Assembling of the complete roof frame 1063
3 2 1 3 Disassembling of single machinery house roof cover plates 1067
3 2 1 4 Assembling of single machinery house roof cover plates 1072
3 2 2 Diesel engine 1077
3 2 2 1 Disassembling of the Diesel engine 1077
3 2 3 Assembling of the diesel engine 1083
3 2 3 1 Disassembling of the alternator 1089
3 2 3 2 Assembling of the alternator 1091
3 2 3 3 Disassembling of the starter motor 1092
3 2 3 4 Assembling of the starter motor 1093
3 2 4 Batteries 1094
3 2 4 1 Disassembling of the batteries 1094
3 2 4 2 Assembling of the batteries 1096
3 2 5 Flexible drive coupling 1097
3 2 5 1 Disassembling of the Geislinger coupling 1097
3 2 5 2 Assembling of the Geislinger coupling 1099
3 2 5 3 Disassembling of the CentaFlex coupling assembly 1101
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 of type 2063 1231
3 4 4 2 Assembling the slew parking brake of type 2063 1234
3 4 4 3 Disassembling of the slew parking brake assembly of type 632770 1237
3 4 4 4 Assembling of the slew parking brake assembly of type 632770 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 Tools catalogue 1627
8 Parts & Service News 1629
8 1 List of The PARTS AND SERVICE NEWS 1630
9 Supplier’s documentation 1631
DESCRIPTION:
Komatsu PC3000-6 T2 Hydraulic Mining Shovel Shop Manual 06279-xD-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 fundamentalsafety 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 performinginspection, 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.
IMAGES PREVIEW OF THE MANUAL:
S.V 28/12/24
