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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 DOWNLOADΒ
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 DOWNLOADΒ
SERIAL NUMBERS
06279, 06308, 06309, 06310, 06314 and up
(TIER2 & KOMTRAX Plus)
Shop ManualΒ Β 1
00 Foreword & SafetyΒ Β 3
1 ForewordΒ Β 5
1 1 BEFORE READING THIS MANUALΒ Β 6
1 2 CONTENTS OF THIS BINDERΒ Β 7
1 2 1 Contacting the Service 7
1 2 2 GuaranteeΒ 7
1 3 DIVISION OF THE BINDER 8
2 SAFETYΒ 9
2 1 SAFETY INFORMATION 13
2 2 OVERVIEWΒ 14
2 2 1 NORMAL OPERATIONSΒ 14
2 2 2 REGULAR MAINTENANCEΒ Β 14
2 2 3 TROUBLESHOOTING, ADJUSTMENTS AND REPAIR 14
2 2 4 ADDITIONAL SAFETY PRECAUTIONSΒ 14
2 3 SOUND PRESSURE AND VIBRATION LEVELS IN THE OPERATORβS CAB 15
2 3 1 SOUNDΒ 15
2 3 2 VIBRATION 15
2 4 GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATORΒ 16
2 4 1 UNDERSTANDING THE MACHINEΒ Β 16
2 4 2 PRECAUTIONS BEFORE STARTING OPERATION ON THE EXCAVATOR 16
2 4 2 1 ENSURING SAFE OPERATIONΒ 16
2 4 3 PREPARATIONS FOR SAFE OPERATIONΒ Β 16
2 4 3 1 PRECAUTIONS REGARDING SAFETY RELATED EQUIPMENTΒ Β 16
2 4 3 2 INSPECTING THE MACHINEΒ Β 16
2 4 3 3 WEAR WELL FITTING CLOTHES AND PROTECTIVE EQUIPMENTΒ 17
2 4 3 4 KEEP MACHINE CLEAN 17
2 4 3 5 PRECAUTIONS INSIDE OPERATORβS COMPARTMENTΒ 17
2 4 3 6 PROVIDE FIRE EXTINGUISHER AND FIRST AID KITΒ Β 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 PC3000Β Β 19
2 4 4 3 ACTION IF FIRE OCCURS ON PC4000, PC5500, PC7000, PC8000Β Β 20
2 4 4 4 EMERGENCY EXIT FROM OPERATORβS CABΒ Β 20
2 4 5 PRECAUTIONS WHEN GETTING ON OR OFF THE MACHINEΒ Β 21
2 4 5 1 USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF THE MACHINEΒ Β 21
2 4 5 2 NO JUMPING ON OR OFF THE MACHINEΒ 21
2 4 5 3 NO PEOPLE ON THE ATTACHMENT 21
2 4 5 4 WORKING IN HIGH PLACESΒ Β 21
2 4 5 5 LEAVING OPERATORβS SEAT WITH LOCK 22
2 4 5 6 LEAVING THE MACHINEΒ Β 22
2 4 6 BURN PREVENTION 22
2 4 6 1 Hot coolantΒ 22
2 4 6 2 Hot oilΒ Β 23
2 4 7 PRECAUTIONS WHEN CLEANING CAB GLASSΒ 23
2 4 8 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURESΒ 23
2 4 9 PRECAUTIONS RELATED TO AIRBOURNE AND EJECTED DEBRIS 24
2 4 9 1 UNAUTHORIZED MODIFICATIONΒ Β 24
2 4 9 2 PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONSΒ Β 24
2 4 10 ELECTROMAGNETIC COMPATIBILITY (EMC) 24
2 4 11 PRECAUTIONS AT JOBSITEΒ 25
2 4 11 1 VISIBILITY FROM OPERATORβS SEATΒ 26
2 4 11 2 CAMERA SYSTEM WITH MONITORSΒ Β 26
2 4 11 3 ENSURE GOOD VISIBILITYΒ 26
2 4 11 4 CHECKING SIGNS AND SIGNALMANβS SIGNALS 26
2 4 11 5 INVESTIGATE AND CONFIRM JOBSITE CONDITIONSΒ Β 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 AREASΒ Β 30
2 4 12 STARTING motor 31
2 4 12 1 WARNING TAG 31
2 4 12 2 CHECKS BEFORE STARTING motorΒ 31
2 4 12 3 PRECAUTION WHEN STARTING motorΒ Β 31
2 4 12 4 PRECAUTION IN COLD AREASΒ Β 32
2 4 13 OPERATIONΒ Β 32
2 4 13 1 CHECKS BEFORE OPERATION 32
2 4 13 2 PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSEΒ Β 33
2 4 13 3 PRECAUTIONS WHEN traveling 34
2 4 13 4 TRAVELING ON SLOPESΒ 35
2 4 13 5 OPERATIONS ON SLOPES 36
2 4 13 6 PROHIBITED OPERATIONSΒ Β 36
2 4 13 7 TRAVELING ON FROZEN OR SNOW COVERED SURFACES 37
2 4 13 8 PARKING THE MACHINEΒ 37
2 4 13 9 TRANSPORTATION 37
2 5 PRECAUTION FOR MAINTENANCEΒ 38
2 5 1 GENERAL PRECAUTIONSΒ Β 38
2 5 1 1 SELECTION AND QUALIFICATION OF PERSONNEL – BASIC RESPONSIBILITIESΒ 39
2 5 1 2 STOP motor FOR MAINTENANCEΒ 40
2 5 1 3 WARNING TAGΒ 41
2 5 1 4 KEEP WORKPLACE CLEAN AND TIDYΒ 42
2 5 1 5 APPOINT LEADER WHEN WORKING WITH OTHERS 42
2 5 1 6 TWO WORKERS FOR MAINTENANCE WHEN THE MACHINE IS RUNNINGΒ Β 43
2 5 1 7 INSTALLING, REMOVING OR STORING ATTACHMENTSΒ Β 43
2 5 1 8 PRECAUTIONS WHEN WORKING UNDER THE MACHINE OR EQUIPMENTΒ Β 44
2 5 1 9 NOISEΒ 44
2 5 1 10 WHEN USING A HAMMERΒ 44
2 5 1 11 PROPER TOOLSΒ Β 45
2 5 1 12 ACCUMULATOR 45
2 5 1 13 PERSONNELΒ Β 45
2 5 2 PRECAUTIONS FOR INSPECTION AND MAINTENANCE 46
2 5 2 1 PRECAUTION WHEN WELDINGΒ 46
2 5 2 2 BATTERY HANDLINGΒ Β 46
2 5 3 PRECAUTIONS WITH HIGH PRESSURE FLUID 47
2 5 3 1 PRECAUTIONS WITH HIGH FUEL PRESSUREΒ 48
2 5 3 2 HANDLING HIGH PRESSURES HOSES OR PIPESΒ 49
2 5 3 3 REPLACEMENT OF HOSE LINESΒ Β 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 VOLTAGEΒ Β 50
2 5 3 7 AIR CONDITIONING MAINTENANCEΒ Β 50
2 5 3 8 COMPRESSED AIRΒ 51
2 5 3 9 WASTE MATERIALS 51
2 6 ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTSΒ 52
2 6 1 INSPECTION OF THE HYDRAULIC SYSTEMΒ Β 52
2 6 2 TWO WORKERS ONLY WHEN THE MACHINE IS RUNNING DURING ADJUSTMENTS 52
2 6 3 AREAS OF POTENTIAL DANGER AROUND THE EXCAVATORΒ Β 52
2 7 SPECIAL SAFETY EQUIPMENT 53
2 7 1 FRONT GUARD PROTECTIVE STRUCTURe βFOPSβ FOR OPERATORβS CABΒ Β 54
2 7 2 OBJECT HANDLING 54
2 7 3 LIGHTINGΒ 54
2 7 4 WARNING BEACONΒ 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 USEΒ 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 USEΒ 60
01 SpecificationΒ Β 61
Specification PC3000-6Β 63
10 Structure & FunctionΒ 73
TOCΒ Β 75
1 Introduction 85
1 1 ForewordΒ 86
1 2 Recommendations for environmentally friendly operation and maintenance of hydraulic mining shovelsΒ 87
1 3 Explanation of abbreviationsΒ Β 88
1 4 Diagrams and illustrations in this manualΒ 89
2 SpecificationsΒ 91
2 1 Lifting GearsΒ Β 92
2 2 Safety hints for sling accessoryΒ 94
2 3 Standard Tightening Torque ChartΒ 95
2 4 Conversion TablesΒ 96
2 5 PT100 TEMPERATURE CHARTS (PT100) g Centigrade – OhmΒ Β 102
2 6 Blind plugs 103
2 7 Classification of threads to the nominal widthΒ 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 houseΒ Β 112
3 4 Hydraulic oil tankΒ Β 114
3 5 Hydraulic oil cooler 116
3 6 Fuel tankΒ Β 118
3 7 CounterweightΒ 120
3 8 Cab base 122
3 9 Operatorβs 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 GearΒ 130
3 11 1 Slew Gear Type 2063 130
3 11 2 Slew Gear type 632770Β 132
3 12 Undercarriage 134
3 13 Backhoe attachment (BHA)Β 136
3 14 Front shovel attachment (FSA)Β Β 137
3 15 Safety circuit PPC controlΒ Β 138
4 Drive 141
4 1 Prime drive assembly 142
4 2 Engine mountsΒ 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 maintenanceΒ Β 150
4 4 2 Coupling elements 151
4 4 3 Separation and assembly of the coupling inner and outer partΒ Β 152
4 4 4 Operation troubles, causes, and rectificationΒ Β 153
4 5 Radiator Fan driveΒ Β 154
4 6 Pump distributor gearbox (pto)Β Β 156
4 6 1 PTO lubrication and coolingΒ Β 158
4 6 1 1 Checks and adjustments – PTO lubrication pressureΒ 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 filterΒ 168
5 Hydraulic oil tankΒ Β 171
5 1 General layout 172
5 2 Hydraulic oil tank, location of the electric equipmenTΒ Β 174
5 3 Suction oil manifold with strainers 176
5 4 Return oil collector manifold with strainerΒ 178
5 5 Back pressure valveΒ 180
5 6 Transfer pumpΒ 182
5 7 Return and leak oil filter 184
5 8 Breather filterΒ Β 186
6 Hydraulic oil coolingΒ Β 189
6 1 Overall view of the hydraulic oil cooling 190
6 2 Function of the hydraulic oil cooling circuitΒ Β 192
6 3 Adjustment of the back pressure valveΒ 194
6 4 Two stage cooler fan RPM control 196
6 4 1 Solenoid valve for fan speed controlΒ Β 198
6 4 2 Pressure reducing valve 200
6 4 3 Temperature converter RelaysΒ 202
6 4 3 1 Function check of cooler fan RPM-controlΒ 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 componentsΒ 214
7 3 Pilot control frame – location of components 218
7 4 Pilot pressure supply and adjustmentsΒ 220
7 4 1 Pilot pressure circuitΒ 220
7 4 2 Checks and adjustment of pilot pressureΒ Β 222
8 ComponentsΒ 225
8 1 Main control blocks and high pressure filters (FSA)Β Β 226
8 2 Main control blocks and high pressure Screens (BHA)Β Β 230
8 3 Distributor manifold – location of restrictor blocks and anti cavitation valves (FSA)Β 234
8 4 Distributor manifold – location of restrictor blocks and anti cavitation valves (BHA)Β 236
8 5 Single control blocks (floating) for stick and boom (FSA)Β Β 238
8 6 Restrictor block with secondary relief valve 240
8 7 Anti-cavitation valve (ACV) blockΒ Β 242
8 8 High-pressure screen 244
8 9 Control blocks and valvesΒ 246
8 9 1 Spool types 252
8 9 2 MRV, SRV and ACVΒ 254
8 9 3 Load holding valveΒ Β 256
8 10 Travel brake valveΒ 260
8 11 4/2 Directional solenoid valves 262
8 12 4/3 Directional solenoid valves 264
8 13 Pressure double stage valveΒ 266
8 14 Hydraulic cylinder with NOK-3 sealing 268
8 14 1 Cylinder data markings 271
8 15 Auxiliary gear pumpsΒ Β 272
9 Main hydraulic pumps and pump regulationΒ 273
9 1 GeneralΒ 274
9 1 1 Pump locations and pump dataΒ 276
9 2 Main pumpsΒ 278
9 2 1 Hydraulic pump type HPV375+375Β Β 278
9 2 1 1 Main pump sectional drawingsΒ 280
9 2 2 Servo valve 282
9 2 2 1 VC valve ο servo piston 283
9 2 2 2 EPC valveΒ Β 288
9 3 Electronic pump regulation systemΒ Β 290
9 3 1 Cut-off functionΒ 292
9 3 2 Slew control (volume reduction)Β 293
9 3 3 Diagnostics and monitoring 293
9 3 4 Temperature controlΒ 294
9 3 4 1 temperature Adjustment (hydraulic oil viscosity)Β Β 294
9 4 Pump controller CR710Β Β 296
9 4 1 Connector and pin arrangement at CR710 (10K032) 298
9 5 MultimonitorΒ Β 302
9 5 1 Service menu screenΒ 305
9 5 2 Service menu, option: 01 Monitoring 306
9 5 2 1 Hold functionΒ 309
9 5 3 Service menu, option: 02 Abnormality RecordΒ 310
9 5 3 1 Troubleshooting procedures 310
9 5 3 2 Table of Pump-controller-Codes (Multi Monitor)Β 312
9 5 4 Service menu, option: 03 Default 314
9 5 5 Service menu, option: 04 Adjustment 315
9 5 6 Adjustable parametersΒ Β 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-factorΒ Β 318
9 5 9 Adjustment, items 23Β Β 28: Sol_adj_min_P1Β Β Sol_adj_min_P6Β 319
9 5 10 Adjustment, items 39Β Β 44: Sol_adj_mAX_P1Β Β Sol_adj_mAX_P6 320
9 5 11 Available parameters list 321
9 5 12 Service menu, option: 05 Display SetupΒ Β 323
9 6 Checks and adjustmentsΒ 324
9 6 1 Engine power checkΒ Β 324
9 6 2 Cut-off function checkΒ 327
9 6 2 1 Cut-off for clam close (FSA only)Β Β 328
9 7 Engine speed sensor (pick-up) 330
9 7 1 GeneralΒ 331
9 7 2 Engine speed sensor (pick-up) adjustmentΒ 331
10 Operating hydraulicsΒ Β 333
10 1 General 334
10 1 1 Floating system (FSA)Β 336
10 2 Checks and adjustments of the main relief valve (MRV)Β Β 338
10 3 Hydraulics for the attachment cylindersΒ 342
10 3 1 Checks and adjustments of the secondary relief valves (SRV)Β Β 342
10 3 1 1 Boom cylinders, piston side (BHA & FSA), boom upΒ 342
10 3 1 2 Boom Cylinder, Piston Rod Side (BHA & FSA), boom downΒ Β 346
10 3 1 3 Stick cylinders, piston side (FSA), stick outΒ 350
10 3 1 4 Stick cylinders, piston side (BHA), stick inΒ Β 354
10 3 1 5 Stick cylinders, piston rod side (FSA), stick inΒ 358
10 3 1 6 Stick cylinders, piston rod side (BHA), stick out 362
10 3 1 7 Bucket cylinders, piston side (FSA), bucket fillΒ 366
10 3 1 8 Bucket cylinders, piston side (BHA), bucket fillΒ 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 dumpΒ Β 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 speedΒ Β 390
10 3 2 1 Checks and adjustments of the lowering speed β boom (FSA)Β 390
10 3 2 2 Checks and adjustments of the lowering speed β boom (BHA)Β 396
10 3 2 3 Checks and adjustments of the lowering speed β stick (FSA) 398
10 3 2 4 Checks and adjustments of the lowering speed β stick (BHA) 404
10 3 2 5 Checks and adjustments of the lowering speed β bucket (FSA)Β Β 406
10 3 2 6 Checks and adjustments of the lowering speed β bucket (BHA)Β Β 408
10 3 2 7 Checks and adjustments of the lowering speed β clam (FSA)Β 410
10 4 Hydraulics for the slew circuit 412
10 4 1 Slew circuitΒ 412
10 4 2 Slew motor 414
10 4 3 Slew gearbox of type 2063 416
10 4 4 Slew gearbox of type 632770Β 418
10 4 5 Slew parking brake of type 2063 420
10 4 6 Slew parking brake of type 632770Β 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 pressureΒ Β 431
10 4 8 3 Crosscheck of the DSV settingΒ Β 431
10 4 8 4 Checks and Adjustment of the slew motion detectionΒ Β 432
10 4 9 Function check for the hydraulic slew brake 434
10 5 Hydraulics for the travel circuitΒ 436
10 5 1 Travel circuitΒ Β 436
10 5 2 Travel motorΒ 438
10 5 3 Rotary jointΒ 440
10 5 4 Travel gearboxΒ Β 442
10 5 5 Travel parking brakeΒ Β 444
10 5 5 1 Travel parking brakeΒ Β 444
10 6 Travel brake valveΒ 446
10 6 1 Checks and adjustments 448
10 6 1 1 Checks and adjustments for the travel circuitΒ 448
10 6 1 2 Function check for the travel parking brake 450
11 Hydraulic track tensioning systemΒ 453
11 1 General 454
11 2 Functional description 456
11 3 Double stage valveΒ 458
11 4 Tensioning cylinder 460
11 5 Adjustments / checksΒ Β 462
12 Access ladder, hydraulically operated 465
12 1 General 466
12 2 Function of the hydraulically operated access ladder 468
12 3 Adjustments / checksΒ Β 472
13 Central refilling system (refilling arm) 475
13 1 Refilling arm location 476
13 2 FunctionΒ Β 478
14 Hints for reading the hydraulic diagramΒ 481
14 1 General 482
14 2 Hydraulic symbolsΒ Β 484
14 2 1 Lines, unions 485
14 2 2 Components, valvesΒ 487
14 2 3 Sensors 487
14 2 4 Valves, valve componentsΒ 488
14 2 5 Pump, motor, cylinderΒ 492
15 Hints for reading the electric wiring diagramΒ 497
15 1 General 498
15 2 Reference code of the electrical components 499
15 2 1 Area codeΒ 499
15 2 2 Component identifying letter 501
15 3 Graphical symbolsΒ Β 502
15 4 Drawing conceptΒ 506
15 5 Cable marking 515
16 KOMTRAX PlusΒ 517
16 1 General 518
16 1 1 location of KOMTRAX Plus components in cab baseΒ Β 520
16 2 Specifications for operators 522
16 2 1 Opening screenΒ Β 523
16 2 2 Main gauge screens 1 to 2 524
16 2 3 Fuel consumption screenΒ Β 528
16 2 4 Failure message history for the operator 530
16 2 5 Main gauge screens – Changing of Time / SMR / DateΒ Β 531
16 2 6 Maintenance monitor 532
16 2 7 Settings for operatorΒ 534
16 2 7 1 USER ID ScreenΒ Β 535
16 2 7 2 Reset Truck Counter 1 & 2 536
16 2 7 3 Screen Adjustment DisplaysΒ Β 538
16 2 7 4 Date and Time AdjustmentΒ 540
16 2 7 5 Language selectionΒ 541
16 2 8 Automatic messagesΒ 542
16 3 Tables of all provided messages 544
16 3 1 Table of komtrax plus trouble codesΒ Β 544
16 3 2 TABLE OF Cummins trouble CODES (TIER 2)Β 548
16 3 3 Table of Pump-controller-Codes (Multi Monitor) 553
16 3 4 Table of available Instruction MessagesΒ 555
16 4 Flow charts (1-4) of KOMTRAX Plus main screens 558
16 5 KOMTRAX Plus service levelΒ Β 562
16 5 1 Explanation of the button symbols (Service Level) 564
16 5 2 Service Menu Select ScreenΒ Β 565
16 5 3 Real Time Menu Select Screen 566
16 5 3 1 Real Time Menu, option: 01 Engine 1Β Β 567
16 5 3 2 Real Time Menu, option: 02 PTO 1Β Β 568
16 5 3 3 Real Time Menu, option: 03 HydraulicΒ 569
16 5 3 4 Real Time Menu, option: 04 Electrical EquipmentΒ Β 570
16 5 3 5 Real Time Menu, option: 05 Emergency StopΒ Β 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 1Β 573
16 5 3 8 Real Time Menu, option: 08 Slew Ring Gear Lube SystemΒ Β 574
16 5 3 9 Real Time Menu, option: 09 Pilot Control 575
16 5 3 10 Real Time Menu, option: 10 Other ItemsΒ 576
16 5 3 11 Real Time Menu, option: 11 Output SignalsΒ 577
16 5 4 PM-ClinicΒ 578
16 5 4 1 General 578
16 5 4 2 Power CheckΒ Β 579
16 5 5 Serial/GCC noΒ setting 581
16 5 6 Memory ClearΒ 582
16 5 6 1 Input Memory Clear IDΒ 582
16 5 6 2 Memory Clear screen 583
16 5 7 Failure HistoryΒ 584
16 5 8 Maintenance Monitor 585
16 5 9 SnapshotΒ Β 586
16 5 10 SettingsΒ 588
16 5 10 1 Central Lubrication System (CLS 1), screen 1/4Β Β 588
16 5 10 2 Slew Lubrication System (SLS), screen 2/4Β 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 controllerΒ Β 592
16 6 1 KOMTRAX Plus controllerΒ Β 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 descriptionΒ 601
16 9 1 2 CAN BUS troubleshootingΒ Β 601
16 9 2 Can BUS wiringΒ Β 602
16 9 2 1 CAN bus end resistorΒ Β 603
17 Lubrication systemΒ 605
17 1 General overview (SLS & CLS) 606
17 1 1 General description 607
17 2 Basic function of the lubrication systemsΒ Β 608
17 3 Lubrication systems (SLS & CLS) 610
17 3 1 Lubrication pump stationΒ 610
17 3 2 General Information on CLSΒ Β 612
17 3 3 General information on SLSΒ Β 612
17 4 Lubrication cycleΒ Β 614
17 4 1 Time segments & switch points of a lubrication cycle 615
17 4 2 Automatic lubrication mode CLSΒ 616
17 4 2 1 FunctionΒ Β 617
17 4 2 2 System monitoringΒ Β 617
17 4 3 Automatic lubrication mode SLSΒ 618
17 4 3 1 FunctionΒ Β 619
17 4 3 2 System monitoringΒ Β 619
17 4 4 Automatic lubrication mode adjustmentsΒ Β 620
17 4 4 1 Pause time adjustment & fault time monitoring adjustmentΒ Β 620
17 4 4 2 Lube cycle monitoring time adjustment 621
17 4 5 Manual lubrication mode (CLS & SLS)Β Β 622
17 4 6 Resetting a faulty lubrication system 622
17 5 Hydraulically driven lube pumpΒ 624
17 5 1 Adjustment of lube pump speedΒ Β 626
17 5 1 1 Stroke speed adjustmentΒ Β 627
17 5 1 2 Working pressure 627
17 6 Lubricant injectors 628
17 6 1 Tightening torques for fittings at grease injectorsΒ 629
17 6 2 DescriptionΒ Β 629
17 6 3 Adjustment of the lubricant output 630
17 6 4 Operation principle of lubricant injectorsΒ 632
17 6 4 1 Function descriptionΒ Β 633
17 6 5 Connection of one or more injectorsΒ Β 634
17 7 Vent valve and grease outlet filterΒ Β 636
17 7 1 Vent valve description 637
17 8 End-line switchΒ 638
17 8 1 DescriptionΒ Β 639
17 8 2 CLS & SLS end-line switch adjustmentΒ 640
17 9 Lubricant level sensorsΒ Β 642
17 9 1 DescriptionΒ Β 643
17 9 1 1 ChecksΒ 643
17 10 CommissioningΒ Β 644
17 10 1 Commissioning of the CLS lubrication systemΒ Β 644
17 10 2 Fine adjustment 645
17 10 3 Commissioning of the SLS lubrication systemΒ Β 646
18 Deep temperature equipment (option)Β Β 649
18 1 General information 650
18 1 1 IntroductionΒ 650
18 1 2 Deep temperature components overviewΒ 650
18 1 3 Power supply preconditions for preheatingΒ Β 651
18 1 4 Power requirements for preheating systemsΒ Β 652
18 2 Preheating procedureΒ Β 653
18 2 1 Global flow chart of the preheating procedureΒ 653
18 2 2 Starting the preheating procedureΒ 654
18 2 3 Preheating of operatorβs cab and Diesel engine [coolant system]Β 655
18 2 4 Preheating of lubricants and superstructure (Diesel) [electric system] 656
18 3 Constant heating of travel motors (TTT equipment below-40Β°C only)Β Β 657
18 4 Component locationΒ 658
18 4 1 Electric heating elements for hydraulic & batteries [electric machine] 658
18 4 2 Electric heating elements for hydraulics [Diesel machine]Β 660
18 4 3 Electric heating elements for engines & batteries [Diesel machine]Β 662
18 5 Components of TT equipmentΒ Β 664
18 5 1 Preheating components on a Diesel machineΒ Β 664
18 5 2 Preheating components on an electric machineΒ Β 666
18 5 3 Exemplary Wiring Diagrams for preheating systemsΒ 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”Β 670
18 5 3 5 Wiring diagram “PTO Preheating” 671
18 5 3 6 Wiring diagram “Battery heater pads”Β 672
40 TroubleshootingΒ Β 673
TOCΒ 675
1 IntroductionΒ Β 685
1 1 Overview 686
1 1 1 General advice when using troubleshooting chartsΒ Β 686
1 2 General PrecautionsΒ 687
2 General Information for TroubleshootingΒ Β 689
2 1 Preparations For WorkΒ Β 690
2 2 Precautions During Work 690
2 3 Precautions When Carrying Out Any OperationΒ 691
2 3 1 Precautions when carrying out removal workΒ Β 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 PersonnelΒ Β 697
2 5 Points To Remember When TroubleshootingΒ Β 697
2 6 Sequence Of Events In TroubleshootingΒ 699
2 7 Checks Before Troubleshooting 700
2 8 Handling Of Electric Equipment And Hydraulic ComponentsΒ 701
2 8 1 Points to remember when handling electric equipmentΒ Β 701
2 8 2 Points To Remember When Handling Hydraulic EquipmentΒ 704
2 9 General working procedures 706
2 9 1 Air Bleeding of Various Hydraulic PartsΒ Β 706
2 9 2 Air bleeding from the hydraulic pumpsΒ 706
2 9 3 Air bleeding from hydraulic cylindersΒ 706
2 10 Cylinder bypass testΒ Β 707
2 11 Basics about “How to crimp” (with strain relief)Β 708
2 11 1 Crimp tool & repair kitΒ Β 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 CrimpingΒ Β 711
2 11 6 Connector assembly after crimpingΒ 712
2 12 Cable ShieldingΒ 713
3 Mounting Locations and Connector Types 715
3 1 Component locationΒ Β 716
3 1 1 View at the Superstructure 716
3 1 2 Engine – location of electrical components (1)Β 718
3 1 3 Engine – location of electrical components (2)Β 720
3 1 4 Control and filter plate – location of ComponentsΒ 722
3 1 5 PTO and suction oil tank – location of electrical componentsΒ Β 724
3 1 6 Pilot control frame – location of electrical componentsΒ 726
3 1 7 Main control blocks – location of components 728
3 1 8 Lubrication system – location of electrical componentsΒ Β 730
3 1 9 Cab base – location of electrical components 732
3 1 10 Hydraulic Oil Tank – Location of Electrical ComponentsΒ 734
3 1 11 Hydraulically operated access ladder – location of electrical ComponentsΒ 736
3 1 12 Refilling arm – location of electrical Components 737
3 1 13 Air filter and fuel tank – location of electrical componentsΒ 738
3 2 Connector Types OverviewΒ Β 740
4 Standard Value Table for Electrical ComponentsΒ 743
5 References for TroubleshootingΒ Β 755
5 1 7-segment error code indicationΒ 756
5 2 Relay checksΒ Β 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 – OhmΒ Β 762
6 2 Test Value Table for pressure SensorsΒ 763
6 2 1 Transducers with output voltage range: 0 5 4 5 VoltΒ Β 763
6 2 2 Transducers with output voltage range: 0 5 9 5 VoltΒ Β 763
6 3 Trouble Code TablesΒ 764
6 3 1 TABLE OF Cummins trouble CODES (TIER 2)Β Β 764
6 3 2 TABLE OF KOMTRAX PLUS TROUBLE CODES 769
6 3 3 Table of Pump-controller-Codes (Multi Monitor)Β 773
6 4 Table of Instruction Messages 775
6 5 Table of symptom codesΒ 778
6 5 1 SYMPTOMS OF THE ENGINES AND RELATED ELECTRICAL SYSTEMSΒ Β 778
6 5 2 SYMPTOMS OF THE HYDRAULIC SYSTEM 778
6 5 3 SYMPTOMS OF THE MECHANICAL SYSTEMΒ Β 779
6 5 4 SYMPTOMS OF ADDITIONAL SYSTEMSΒ Β 779
6 6 Cable colour identificationΒ Β 780
7 Troubleshooting by KOMTRAX Plus trouble code 781
G00001 – Trouble Shut-Off (gate) valveΒ 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)Β 785
G00002 – Test speed 1800 1/min engine 1 786
Input signal of the switch 11S041-1 on the REAL TIME MONITORΒ Β 786
Wiring Diagram (11S041-1) for trouble code G00002Β 787
G00007 – Trouble hydraulic oil level 788
Wiring Diagram (40B004) and the defined position of the attachment (G00007)Β Β 791
G00012 – Central lubrication system grease level too lowΒ 792
G00013 – Slew ring gear lubrΒ 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 & G00013Β Β 796
Wiring Diagram (junction box) for trouble codes G00012 & G00013Β Β 797
G00031 – Set engine to low idleΒ Β 798
Wiring Diagram (20S030) for trouble code G00031 799
Input signal of the resistor 11T080 on the REAL TIME MONITORΒ Β 799
G00060 – Fire in the power houseΒ 800
Wiring Diagram (fire alarm & safety circuit) for trouble code G00060 802
G00065 – Very low hydraulic oil levelΒ Β 803
View onto the hydraulic oil level labelΒ Β 803
G00066 – Trouble hydraulic oil temperature 804
Hydraulic oil temperature table – 11K039 adjustment (T4 switch point)Β Β 806
Wiring Diagram (59B015 and 11K039) for G00066Β Β 807
G00067 – Trouble battery voltage too highΒ 808
Input signal of the resistor 11T080 on the REAL TIME MONITORΒ Β 809
Wiring Diagram (11T080) for G00067Β 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 G00070Β 813
G00071 – Trouble gear lubrication (PTO 1)Β 814
PTO gear oil temperature table – 11K182 adjustment 816
Wiring Diagram (57B017) for trouble code G00071 816
Wiring Diagram (57B182 & 11K182) for G00071Β 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)Β Β 819
Wiring Diagram (20S105 and wiring) for G00091Β Β 819
G00092 – Emergency shut-down at access ladder 820
G00093 – Emergency shut-down at valve blockΒ Β 820
G00095 – Emergency shut-down in cabinΒ Β 820
Wiring Diagram 1 (emergency switches) for G00092~G00095Β 821
Wiring Diagram 2 (emergency switches signal lines) for G00092~G00095 822
G00100 – Maintenance Safety SwitchΒ Β 823
Wiring Diagram (50S058) for trouble code G00100 824
G00104 – Trouble battery currentΒ 825
Input signal of the converter 11T117 on the REAL TIME MONITORΒ 826
Wiring Diagram 1 (71T003 & 52G005) for trouble code G00104Β 827
Wiring Diagram 2 (52G005, 52M001-1 & 52M002-1) for trouble code G00104Β 828
G00105 – Trouble battery charging current too lowΒ Β 829
Input signals of 11T080 & 11T117on the REAL TIME MONITOR 830
Wiring Diagram 1 (71T003 & 11T117) for trouble code G00105Β 831
Wiring Diagram 2 (11T080) for trouble code G00105Β 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)Β Β 836
Input signal of 40B024 (filter clogged) on the REAL TIME MONITORΒ 836
G00166 – Trouble oil filter gear (PTO 1)Β Β 837
Hydraulic oil temperature table – 11K026 adjustment (T3 switch point)Β Β 837
View onto the PTO 1 gear oil filter with pressure sensor 57B027 (G00166)Β Β 838
Input signal of 57B027 (filter clogged) on the REAL TIME MONITORΒ 838
G00169 – Trouble return oil filter hydraulic oil tankΒ 839
Hydraulic oil temperature table – 11K026 adjustment (T3 switch point)Β Β 839
View onto the pressure sensor 40B026 (G00169)Β Β 840
Input signal of 40B026 (filter clogged) on the REAL TIME MONITORΒ 840
G00170 – Trouble leak oil filter hydraulic oil tank 841
Hydraulic oil temperature table – 11K026 adjustment (T3 switch point)Β Β 841
View onto the pressure sensor 40B025 (G00170)Β Β 842
Input signal of 40B025 (filter clogged) on the REAL TIME MONITORΒ 842
G00176 – Trouble battery voltage too lowΒ Β 843
Wiring Diagram (71T003) for trouble code G00176 845
G00177 – Trouble battery charging circuitΒ 846
Wiring Diagram (measuring points 1-3) for trouble code G00177Β 847
G00178 – Trouble battery charging current too highΒ 848
Wiring Diagram (71T003 & 11T117) for trouble code G00178 849
G00184 – Central lubrication system emptyΒ 850
Wiring Diagram 1 (62B108c & 62B109c) for trouble codes G00184 & G00187Β 853
Wiring Diagram 2 (wiring to 14K300) for trouble codes G00184 & G00187Β Β 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 systemΒ Β 857
Wiring Diagram 1 (relays) for trouble code G00185Β 862
Wiring Diagram 2 (11K50 & trouble signal circuit CLS/SLS) for trouble code G00185Β Β 863
Wiring Diagram 3 (10K511a) for trouble code G00185 864
View onto the vent valve 62Q507a 865
Action chart for lube cyclesΒ 866
G00187 – Slew ring gear lubrication system empty 867
G00188 – Trouble slew ring gear lubrication systemΒ 867
Wiring Diagram 1 (relays) for trouble code G00188Β 873
Wiring Diagram 2 (11K50 & trouble signal circuit CLS/SLS) for trouble code G00188Β Β 874
Wiring Diagram 3 (10K511a) for trouble code G00188 875
View onto the pressure switch 10B047 and wiring Diagram 3 for trouble code G00188Β Β 876
View onto the vent valve 62Q509a 877
Action chart for lube cyclesΒ 878
G00207 – Engine remote oil tank 1 empty 879
G00222 – Load limiting clam defectiveΒ Β 880
Wiring Diagram (10B155 & 10B156) for trouble code G00222 882
G00243 – Fill up fuel tankΒ 883
G00245 – Engine shutdown from ground 884
G00256 – Operator warning systemΒ 885
G00262 – Trouble screen at hydrΒ cooler entry cloggedΒ 886
Location of 40B165 and the strainer at the intermediate pipe (G00262)Β Β 887
G00422 – Can-net sys (J1939)Β Β 888
Wiring Diagram (CAN-BUS) for trouble code G00422Β Β 889
G00491 – Communication failure MH800 <=> K+ Controller 890
Wiring Diagram (K+ monitor (MH801) β K+ controller) for trouble code G00491Β Β 891
DBBQKR – Communication failure CR710 <=> KOMTRAX Plus ControllerΒ Β 892
Wiring Diagram (CR710 <=> KOMTRAX Plus) for trouble code DBBQKRΒ Β 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 connectionsΒ 896
DBB0KQ – KOMTRAX Plus Connector MismatchΒ Β 897
DGH2KA – HydΒ Oil TempΒ Sensor FailureΒ 898
Wiring Diagram (59B032-1) for trouble code DGH2KAΒ 899
DGH2KB – HydΒ Oil TempΒ Sensor FailureΒ 900
Wiring Diagram (59B032-1) for trouble code DGH2KBΒ 901
J100KA – Pilot PressΒ Sensor Failure 902
Wiring Diagram (57B086) for trouble code J100KA 904
J100KB – Pilot PressΒ 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 FailureΒ Β 909
Wiring Diagram (13B090) for trouble code DGE5KA 910
DGE5KB – Ambient air temp Sensor FailureΒ Β 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 MONITORΒ Β 914
Wiring Diagram for trouble codes F@D(AΒ Β M)NSΒ Β 915
DGTAKX – Trouble monitoring Exhaust Temp Cylinder RB1Β 916
DGTBKX – Trouble monitoring Exhaust Temp Cylinder RB2Β 916
DGTCKX – Trouble monitoring Exhaust Temp Cylinder RB3Β 916
DGTDKX – Trouble monitoring Exhaust Temp Cylinder RB4Β 916
DGTEKX – Trouble monitoring Exhaust Temp Cylinder RB5Β 916
DGTFKX – Trouble monitoring Exhaust Temp Cylinder RB6Β 916
DGTGKX – Trouble monitoring Exhaust Temp Cylinder LB1Β 916
DGTHKX – Trouble monitoring Exhaust Temp Cylinder LB2Β 916
DGTJKX – Trouble monitoring Exhaust Temp Cylinder LB3Β 916
DGTKKX – Trouble monitoring Exhaust Temp Cylinder LB4Β 916
DGTLKX – Trouble monitoring Exhaust Temp Cylinder LB5Β 916
DGTMKX – Trouble monitoring Exhaust Temp Cylinder LB6Β 916
Input signals of the engine cylinder temperature sensors on the REAL TIME MONITORΒ Β 917
Wiring Diagram for trouble codes DGT(AΒ Β M)KXΒ Β 918
DJF1KX – Trouble monitoring fuel levelΒ 919
Wiring Diagram (31B063) for trouble code DJF1KX 921
8 Troubleshooting by SymptomsΒ Β 923
8 1 Symptoms of the engine and related electrical systemΒ 924
SEL001 – Engine does not start (engine does not rotate)Β Β 924
Wiring Diagram 1 (engine start) for trouble code SEL001 & SEL001a 926
SEL001a – Engine does not start (Pre-lube does not stop)Β 927
SEL002 – Engine stops while in operationΒ Β 928
View onto the fuel system water separator (SEL002) 929
SEL003 – Engine speed is hunting during boom-up movementΒ 930
SEL004 – Engine does not stopΒ 932
SEL005 – Engine lacks output (no power) 934
Judgment Table for SEL005Β 935
SEL006 – Exhaust smoke is blackΒ Β 936
Judgment Table for SEL006Β 937
SEL007 – Oil consumption is excessiveΒ Β 938
Judgment Table for SEL007Β 939
SEL008 – Oil becomes contaminated quicklyΒ 940
Judgment Table for SEL008Β 941
SEL009 – Fuel consumption is excessiveΒ 942
Judgment Table for SEL009Β 943
SEL010 – Oil is in engine coolant 944
Judgment Table for SEL010Β 945
SEL011 – Oil level rises 946
Judgment Table for SEL011Β 947
SEL012 – Coolant temperature becomes too high (overheating)Β 948
Judgment Table for SEL012Β 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)Β 950
SHY002 – Engine speed sharply drops or engine stalls too muchΒ Β 952
SHY003 – No work equipment, travel or slew movement 953
SHY004 – Work equipment has too much hydraulic driftΒ Β 954
SHY005 – Work equipment has big time lagΒ Β 955
Hydraulic oil temperature table – 11K026 and 11K171 adjustment 955
SHY006 – Machine deviates during travel movement 956
SHY007 – Hydraulic system has lack of powerΒ Β 957
SHY008 – Machine does not slew 958
Slew brake block (SHY008)Β 959
SHY009 – Slew acceleration is poor (or slew speed is very low)Β 960
SHY010 – Excessive overrun when stopping slew movement 962
SHY011 – Floating system without function (FSA only)Β Β 964
Floating system – overview (SHY011) 965
SHY012 – Abnormal noise coming from SRV or MRVΒ Β 966
SHY013 – Track tensioning system without functionΒ Β 967
View onto the elements of the hydraulic track tensioning system (SHY013)Β Β 969
SHY014 – Ladder does not move, or slow movementΒ 970
SHY015 – Refilling arm does not move, or slow movement 972
SHY016 – Refilling arm is sagging when engine is not running 974
SHY017 – The hydrΒ driven grease pump does not move 975
SHY018 – Abnormal track chain movement during diggingΒ 977
SHY019 – Slew parking brake without functionΒ 978
SHY020 – Travel parking brake without functionΒ Β 979
8 3 Symptoms of the Mechanical SystemΒ Β 980
SME001 – Abnormal noise is madeΒ Β 980
Judgment Table for SME001Β 981
SME002 – Abnormal noise around the PTO / hydraulic pumpsΒ 982
SME003 – Vibration is excessive (engine mountings)Β 984
Judgment Table for SME003Β 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 movementΒ Β 988
SME007 – Fan blades make abnormal noise 990
SME008 – Abnormal noise coming from a travel gearboxΒ Β 991
SME009 – Abnormal noise coming from the work equipment (lack of grease)Β 993
SME010 – Abnormal idler movementΒ 995
SME011 – Leak at the PTO shaft sealΒ 996
8 4 Symptoms of Additional SystemsΒ Β 998
SAD001 – Air conditioner for the cabin does not workΒ Β 998
View onto the A/C unit (SAD001)Β 999
SAD002 – Air conditioner compressor clutch is burntΒ Β 1000
View onto the A/C compressor and its mounting (SAD002)Β 1001
SAD003 – Air conditioning system defective (pipes and hoses full of moisture) 1002
View onto an A/C filling and service stationΒ Β 1003
9 Troubleshooting by pump controller trouble codes (Multi Monitor) 1005
DXAAKA – Solenoid-1(Pump-1) open circuitΒ 1006
DXABKA – Solenoid-2(Pump-2) open circuitΒ 1006
DXACKA – Solenoid-3(Pump-3) open circuitΒ 1006
DXADKA – Solenoid-4(Pump-4) open circuitΒ 1006
DXAEKA – Solenoid-5(Pump-5) open circuitΒ 1006
DXAFKA – Solenoid-6(Pump-6) open circuitΒ 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 abnormalityΒ Β 1010
DHPGMA – Pump-3/4 pressure sensor abnormalityΒ Β 1010
DHPJMA – Pump-5/6 pressure sensor abnormalityΒ Β 1010
Wiring Diagram – PWR & GND supply for pressure sensors (pumps 1Β Β 3)Β Β 1011
DLE2MA – Engine speed sensor abnormalityΒ 1012
Wiring Diagram – engine RPM signal (52B064) to pump controllerΒ Β 1013
DA25KP – 5V sensor1 power abnormalityΒ 1014
Wiring Diagram – 5V sensor power supply for trouble code DA25KPΒ 1016
DA22KK – Pump Solenoid Power Low Error 1017
DA29KQ – Model Selection AbnormalityΒ Β 1018
10 AppendixΒ 1019
10 1 Comparison of Trouble Codes: VHMS (inclΒ retrofit kit) vsΒ KOMTRAX PlusΒ 1020
10 1 1 VHMS Trouble codes vsΒ Komtrax Plus trouble codesΒ Β 1020
10 1 2 Pump controller CR700 vsΒ Pump controller CR710 trouble codesΒ Β 1024
50 Disassembly and assemblyΒ 1027
TOC 1029
1 IntroductionΒ 1037
1 1 Contents of this binderΒ Β 1038
1 2 ForewordΒ Β 1038
1 3 Recommendations for environmentally friendly operation and maintenance of hydraulic mining shovelsΒ Β 1040
1 4 Explanation of abbreviations 1041
1 5 Diagrams and illustrations in this manualΒ Β 1042
1 6 Procedures for disassembling and assembling in this manual 1042
2 SafetyΒ 1043
2 1 OverviewΒ Β 1045
2 1 1 Method of using this manualΒ 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 toolsΒ 1048
2 2 5 PersonnelΒ 1048
2 2 6 Fire preventionΒ 1049
2 2 7 Unauthorized modification 1049
2 3 Precautions for maintenance and repairΒ Β 1050
2 3 1 General precautions 1050
2 3 2 Keep work place clean and tidyΒ 1050
2 3 3 Precautions when weldingΒ 1051
2 3 4 Precaution with high pressure fluidsΒ 1051
2 3 4 1 Handling high pressure hoses and pipesΒ Β 1051
2 3 5 Compressed airΒ Β 1051
2 3 6 Waste materialsΒ 1052
3 SuperstructureΒ Β 1053
3 1 Superstructure overviewΒ Β 1054
3 2 Machinery houseΒ 1056
3 2 1 Machinery house roofΒ Β 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 platesΒ 1067
3 2 1 4 Assembling of single machinery house roof cover platesΒ 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 BatteriesΒ 1094
3 2 4 1 Disassembling of the batteriesΒ 1094
3 2 4 2 Assembling of the batteriesΒ 1096
3 2 5 Flexible drive couplingΒ Β 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 assemblyΒ 1101
3 2 6 Radiator fan and fan drive assemblyΒ Β 1104
3 2 6 1 Disassembling of the radiator fan and the fan drive assemblyΒ 1105
3 2 6 2 Assembling of the radiator fan and the fan drive assemblyΒ 1107
3 2 7 Radiator assemblyΒ Β 1108
3 2 7 1 Disassembling of the Radiator assemblyΒ Β 1108
3 2 7 2 Assembling of the radiator assemblyΒ Β 1111
3 2 8 Main pumps assembliesΒ 1114
3 2 8 1 Preparatory works for main pump disassemblingΒ 1115
3 2 8 2 Disassembling of main pump 1Β Β 3 assemblyΒ Β 1117
3 2 8 3 Assembling of main pump 1Β Β 3 assemblyΒ Β 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 pumpΒ 1129
3 2 9 4 Assembling of the PTO oil circulation pumpΒ 1130
3 3 Hydraulics 1132
3 3 1 Hydraulic oil cooler assemblyΒ Β 1132
3 3 1 1 Disassembling of hydraulic cooler fan drive pumpΒ 1132
3 3 1 2 Assembling of hydraulic cooler fan drive pumpΒ 1135
3 3 1 3 Disassembling of the hydraulic cooler fan assemblyΒ Β 1137
3 3 1 4 Assembling of the hydraulic cooler fan assemblyΒ Β 1139
3 3 1 5 Disassembling of hydraulic cooler fan and motorΒ Β 1142
3 3 1 6 Assembling of hydraulic cooler fan and motorΒ Β 1144
3 3 1 7 Disassembling of the hydraulic oil coolersΒ 1146
3 3 1 8 Assembling of the hydraulic oil coolersΒ 1149
3 3 1 9 Disassembling of the hydraulic oil cooler AssemblyΒ Β 1151
3 3 1 10 Assembling of the hydraulic oil cooler AssemblyΒ 1155
3 3 2 Pilot oil pump (Gear pump)Β Β 1158
3 3 2 1 Disassembling of the pilot oil pumpΒ Β 1158
3 3 2 2 Assembling of the pilot oil pumpΒ Β 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 tankΒ 1165
3 3 4 1 Disassembling of the hydraulic oil tankΒ 1165
3 3 4 2 Assembling of the hydraulic oil tankΒ 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 blocksΒ 1186
3 3 5 4 Assembling of the MRV at the main control valve blocksΒ 1187
3 3 5 5 Disassembling of SRV on main control valve blockΒ 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 blocksΒ 1192
3 3 5 8 Assembling of ACV-/SRV-block on main control valve blocksΒ 1194
3 3 6 Distributor ManifoldΒ Β 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 manifoldΒ 1202
3 3 6 4 Assembling of throttle check valves at the distributor manifoldΒ 1204
3 3 6 5 Disassembling of the diffuser block on the distributor manifold (FSA only)Β Β 1206
3 3 6 6 Assembling of the diffuser block on the distributor manifold (FSA only)Β Β 1208
3 3 6 7 Disassembling of the manifoldΒ Β 1209
3 3 6 8 Assembling of the manifoldΒ Β 1211
3 4 Slew systemΒ Β 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 valveΒ 1220
3 4 2 1 Disassembling of the slew service brake valveΒ 1220
3 4 2 2 Assembling of the slew service brake valveΒ 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 brakeΒ 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 632770Β 1237
3 4 4 4 Assembling of the slew parking brake assembly of type 632770Β 1240
3 4 5 Slew circle lubrication pinion (dummy wheel)Β Β 1244
3 4 5 1 Disassembling of the slew circle lubrication pinion assemblyΒ 1244
3 4 5 2 Assembling of the slew circle lubrication pinion assemblyΒ 1245
3 4 6 Slew circleΒ Β 1246
3 4 6 1 Disassembling of the slew circleΒ Β 1247
3 4 6 2 Assembling of the slew circleΒ Β 1250
3 5 Lubrication pumpsΒ Β 1254
3 5 1 Disassembling of the lubrication pump 1254
3 5 2 Assembling of the lubricating pump 1255
3 6 Operatorβs cabΒ Β 1256
3 6 1 Disassembling of the operatorβs cabΒ Β 1256
3 6 2 Assembling of the operatorβs cabΒ Β 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 windowΒ 1270
3 6 4 2 Assembling of the front windowΒ 1271
3 6 5 Operatorβs seatΒ 1272
3 6 5 1 Disassembling of the operatorβs seatΒ 1272
3 6 5 2 Assembling of the operatorβs seatΒ 1273
3 7 Cab baseΒ Β 1274
3 7 1 Disassembling of the cab baseΒ Β 1274
3 7 2 Assembling of the cab baseΒ Β 1276
3 8 Access Ladder 1278
3 8 1 Disassembling of access ladderΒ 1279
3 8 2 Assembling of access ladderΒ 1281
3 8 3 Disassembling of access ladder cylinderΒ 1282
3 8 4 Assembling of access ladder cylinderΒ 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 liftingΒ Β 1300
3 11 1 Disassembling the superstructure from the undercarriageΒ Β 1300
3 11 2 Assembling the superstructure onto the undercarriageΒ Β 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 trackΒ Β 1312
4 2 2 SprocketΒ Β 1319
4 2 2 1 Disassembling of the sprocketΒ Β 1319
4 2 2 2 Assembling of the sprocketΒ Β 1322
4 2 3 Guide wheels (Idlers)Β 1325
4 2 3 1 Disassembling of the guide wheel assemblyΒ Β 1325
4 2 3 2 Assembling of the guide wheel assemblyΒ Β 1327
4 2 4 Track tensioning accumulatorsΒ Β 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 accumulatorsΒ Β 1334
4 2 4 4 Assembling of the high pressure accumulatorsΒ Β 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 cylindersΒ Β 1339
4 2 6 1 Disassembling of the track tensioning cylindersΒ Β 1339
4 2 6 2 Assembling of the track tensioning cylindersΒ Β 1341
4 2 7 Substitute the Hydraulic hoses of the track tensioning system 1343
4 2 7 1 Precursory workΒ 1343
4 2 7 2 Replace the hydraulic hoses inside the car bodyΒ Β 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 workΒ 1347
4 2 8 Travel brake valve block (overspeed valve)Β 1348
4 2 8 1 Disassembling of the travel brake valve blockΒ 1348
4 2 8 2 Assembling of the travel brake valve blockΒ 1350
4 2 9 Travel motorΒ 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 brakeΒ 1356
4 2 10 1 Disassembling of the travel parking brakeΒ 1357
4 2 10 2 Assembling of the travel parking brakeΒ 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 rollerΒ 1368
4 2 12 1 Disassembling of the carrier roller assemblyΒ 1368
4 2 12 2 Assembling of the carrier roller assemblyΒ 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 bodyΒ Β 1376
4 3 1 Disassembling of the car body and the crawler carriersΒ 1376
4 3 2 Assembling of the car body and the crawler carriersΒ 1382
4 3 2 1 Install crawler carrier mounting boltsΒ Β 1388
4 3 3 Rotary jointΒ 1390
4 3 3 1 Disassembling of the rotary jointΒ 1390
4 3 3 2 Assembling of the rotary jointΒ 1392
5 Attachment 1395
5 1 Repair proceduresΒ Β 1396
5 1 1 Replacement of bushings at the attachmentΒ Β 1396
5 1 1 1 Removal of the bushingsΒ Β 1396
5 1 1 2 Installation of the bushings 1397
5 1 2 General installation instructions for attachment pinsΒ Β 1398
5 2 Backhoe 1400
5 2 1 OverviewΒ Β 1400
5 2 2 Pin Sealing bucket – Steering Rod – bucket link rodΒ 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 assemblyΒ Β 1418
5 2 4 1 Disassembling of the stickΒ Β 1418
5 2 4 2 Assembling of the stickΒ Β 1422
5 2 4 3 Disassembling of the stick cylindersΒ 1426
5 2 4 4 Assembling of the stick cylindersΒ 1431
5 2 5 Bucket and steering 1437
5 2 5 1 Disassembling of the bucketΒ 1437
5 2 5 2 Assembling of the bucketΒ 1441
5 2 5 3 Disassembling of bucket cylindersΒ 1444
5 2 5 4 Assembling of bucket cylindersΒ 1451
5 2 5 5 Disassembling of the bucket link rodΒ 1458
5 2 5 6 Assembling of the bucket link rodΒ 1461
5 2 5 7 Disassembling of the steering rods 1464
5 2 5 8 Assembling of the steering rodΒ 1470
5 2 6 Hydraulic hoses at the backhoe attachmentΒ Β 1474
5 2 6 1 Replace the boom arc hosesΒ Β 1474
5 2 6 2 Replace the boom cylinder hoses 1478
5 2 6 3 Replace the stick cylinder hosesΒ Β 1482
5 2 6 4 Replace the bucket cylinder hosesΒ 1486
5 3 Face shovelΒ Β 1490
5 3 1 OverviewΒ Β 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 usageΒ Β 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 cylindersΒ Β 1500
5 3 3 4 Assembling of the boom cylindersΒ Β 1505
5 3 4 Stick assemblyΒ Β 1510
5 3 4 1 Disassembling of the stickΒ Β 1510
5 3 4 2 Assembling of the stickΒ Β 1514
5 3 4 3 Disassembling of the stick cylindersΒ 1518
5 3 4 4 Assembling of the stick cylindersΒ 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 cylindersΒ Β 1543
5 3 5 6 Assembling of the clam cylindersΒ Β 1548
5 3 6 Hydraulic hoses at the face shovel attachmentΒ 1554
5 3 6 1 Replace the boom arc hosesΒ Β 1554
5 3 6 2 Replace the boom cylinder hoses 1558
5 3 6 3 Replace the stick arc hosesΒ 1562
5 3 6 4 Replace the stick cylinder hosesΒ Β 1570
5 3 6 5 Replace the bucket cylinder hosesΒ 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)Β 1589
5 5 1 Disassembling and assembling of the GETΒ 1589
5 6 Cylinder bypass testΒ Β 1591
6 Service Information 1593
6 1 Fluids and lubricantsΒ 1594
6 2 Lifting Gears 1594
6 3 Safety hints for sling accessoryΒ Β 1596
6 4 Work instructionsΒ Β 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 carrierΒ 1602
6 5 Weight tables 1603
6 5 1 SuperstructureΒ Β 1603
6 5 2 Undercarriage 1605
6 5 3 Backhoe attachment (BHA)Β 1606
6 5 4 Face shovel attachment (FSA) 1607
6 6 Torque charts according to KOMATSU company standardΒ 1608
6 6 1 Metric standard thread 1608
6 6 2 Metric fine threadΒ 1609
6 6 3 Cummins motor torques – metricΒ 1610
6 6 4 Cummins motor torques – U SΒ customaryΒ Β 1610
6 6 5 SAE-flange connections 1611
6 7 Blind plugsΒ Β 1612
6 7 1 Dummy plates for SAEβflanges 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 tableΒ Β 1616
6 8 2 Millimeter – inch & kilogram – poundΒ 1617
6 8 3 Liter – U SΒ gallon & liter – U KΒ gallonΒ Β 1618
6 8 4 Nm- ft lbΒ 1619
6 8 5 Bar – PSI – kPa – MPaΒ 1620
6 8 6 TemperatureΒ Β 1621
6 9 ToolsΒ Β 1622
6 9 1 Standard tool caseΒ 1622
6 9 2 Used special tools (Overview)Β Β 1624
7 Tools catalogueΒ 1627
8 Parts & Service NewsΒ Β 1629
8 1 List of The PARTS AND SERVICE NEWS 1630
9 Supplierβs documentationΒ 1631
DESCRIPTION:
Komatsu PC3000-6 T2 Hydraulic Mining Shovel Shop Manual 06279-xD-GB-1 – PDF DOWNLOADΒ
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
