KOMATSU PC3000-1 EXCAVATOR HYDRAULIC MINING SHOVEL OPERATION & MAINTENANCE MANUAL OMPC30006202 – PDF DOWNLOAD
DESCRIPTION:
KOMATSU PC3000-1 EXCAVATOR HYDRAULIC MINING SHOVEL OPERATION & MAINTENANCE MANUAL OMPC30006202 – PDF DOWNLOAD
SERIAL NO-6202
Designated Use of the Hydraulic Excavator:
- This machine has been manufactured in accordance with
advanced and up-to-date technology standards including recognized
safety rules. Nevertheless, its use may constitute a risk to life and limb
of the user or of third parties, or cause damage to the machine and to
other material property. - The machine must only be used in technically perfect condition in
accordance with its designated use and the instructions set out in the
operation manual. Only trained safety-conscious operators who are
fully aware of the risks involved should operate the machine. Any
functional disorders, especially those affecting the safety of the
machine, should, therefore, be rectified immediately.
TABLE OF CONTENTS:
KOMATSU PC3000-1 EXCAVATOR HYDRAULIC MINING SHOVEL OPERATION & MAINTENANCE MANUAL OMPC30006202 – PDF DOWNLOAD
Main Menu 0
Cover 1
Introduction 2
Part 1 – Operation Manual 8
Table of Contents – Operation Manual 8
Section A – Explanation of Abbreviations Used in this Manual 10
Section 1 0 – Foreward 12
Section 2 0 – Construction of the Excavator 14
2 – Overall View 14
2 1 – Superstructure 16
2 3 – Attachment 20
Backhoe Attachment 20
Section 3 0 – Safety Instructions 22
Fundamental Safety Instructions 23
1 1 – Warnings and Symbols 23
1 2 – Basic Operation and Designated Use of Hydraulic Excavator 23
1 3 – Organizational Measures 24
1 4 – Selection and Qualification of Personal 26
1 5 – Safety Instructions Governing Specific Operational Phases 27
1 6 – Warning of Special Dangers 32
1 7 – Transporting and Towing – Recommissioning 35
1 8 – Special Safety Equipment 36
Safety Harness 38
Instructions for Use 38
Prior to Using Harness 40
Recommendations for Use of Holding Hooks and Hold-Back Hooks 42
Instructions for Use of Strap-Type Fall Absorber 42
Section 3 1 – Ladder, Walkways, and Access Doors 44
Superstructure 44
Sea Protection Covers 47
Section 3 2 – Transport of Excavator 48
Short Transport with Calm Sea Conditions Drawing 49
Long Transport with Rough Sea Conditions Drawing 50
Location of Plug Socket for Hydraulic Oil Heating System 51
Section 3 3 – Operator’s Seat 54
Section 4 0 – Operator’s Cab – Controls and Monitors 56
Control Levers and Control Pedals 56
Safety Circuit for Controls 56
Switch Board 60
Instruments and Pontoon Controls 62
Section 5 0 – Electronic Text Monitoring System Komatsu ETM 64
Introduction 64
Further Features of the ETM System 64
Messages are Divided into Two Main Groups 64
Function of the Keys (1 to 8) of Keyboard 66
System Components 68
Switches for Adjustment of the ETM 70
Message Classification 70
Functions of the ETM System 72
Display the Content of Record (PROTOCOL) Memory 78
Display the Content of Static Memory 80
Print Out Content of Static Memory 82
Print Out Content of Record (PROTOCOL) Memory 82
Change-over from English to German Language 88
Change-over from German to English Language 88
Several Massage Conditions Occur at Same Time 90
Setting the Display Unit 92
Erase Record (PROTOCOL) and STATISTICS Memory 94
Return to System Level 96
Setting Screen Brightness 96
Table of Messages 97
Basic Display (Message Page no 0) 97
Message Page Number 1 to 5 97
Message Page Number 6 to 11 98
Message Page Number 12 to 18 99
Message Page Number 19 to 26 100
Message Page Number 27 to 30 101
Message Page Number 31 to 38 102
Message Page Number 39 to 44 103
Message Page Number 45 to 52 104
Message Page Number 53 to 64 105
Grouping Messages According to their Priority 107
1st Priority Group 107
2nd Priority Group 108
3rd Priority Group 108
4th Priority Group 109
Explanation of the Statics Print-Out 110
Time Diagram of Statics Print 111
Section 5 1 – Power House Controls 114
Section 5 2 – Electrical Equipment in Cab Base 118
Main Switch X2 in Cab Base 120
Diagnostic Fault Codes of Engine Centry System 120
Switch Box X7 for Cab Heating and Air Conditioning 122
Section 5 3 – Preheating System for Hydraulic Oil 124
General 124
Operating the Heating System 124
Section 5 4 – Engine Oil Management System 126
General 126
Centinel Diagnostic Lamps 128
Check Centinel Diagnostic Lamps for Faults 128
Clearing Active Faults and Reset the Centinel System 130
Resetting the Centinel System is Necessary 130
Check the Centinel System for Proper Operation 130
Calibration Plug for Engine Oil Quality 130
Oil Burning System Centinel Combined with Reverse System 131
Eliminator Engine Oil Filter 132
Section 5 5 – Operator’s Cab Arrangement of Components 134
Section 6 1 – Ceheck Before Starting the Engine 136
Section 6 2 – Starting the Engine 140
Before Starting 140
Starting Procedure 140
Cold Weather Starting 142
After Starting 142
Automatic Engine Shut-Down System (Safety Chain) 144
Untitled 146
Engine Warm-Up 146
Hydraulic Oil Warm-Up 146
Hydraulic Oil Viscosity and Temperature Chart 148
Section 6 3 – Stopping the Engine 150
Stopping Procedure 150
Section 6 4 – Pontoon Operation 152
Warping of the Pontoon 154
Float Position of Backhoe Attachment 154
Determination of Directions 154
Shut-off Cocks for the Pontoon Hydraulic System 156
Section 6 5 – Slewing and Braking the Superstructure 158
6 5 1 – Rotating the Superstructure 158
6 5 2 – Swing Angle Limitation System 158
6 5 3 – Braking the Superstructure 158
6 5 4 – Swing Parking Brake 160
Section 6 6 – Working with the Attachment 162
Section 6 7 – Combined Operation Cycles 166
Section 6 8 – Operating the Heater, Ventilation, and Air Conditioning 168
Heating 168
Air Conditioning (Special Equipment 170
Combined Operation of Air Conditioning and Heating 170
Section 6 11 – Automatic Lubrication Systems 172
Central Lubrication System and Swing Ring Gear Lubrication System 172
Controls of Automatic Lubrication Systems 172
Factory Adjustments 174
Section 6 13 – Fire Detection and Suppression System (Special Equipment) 176
Section 6 15 – Transfer Pump for Hydraulic Oil Reservoir 184
Functions of the Transfer Pump 184
Transfer Procedure 186
Section 7 0 – Working Instructions 190
Excavator Operation 190
Barge Warping 190
Pontoon Warping 192
Maintaining the Pontoon in the Flow 192
Slowing Down Pontoon Motions 192
Working Ashore or at Banks from the Pontoon 192
Working in Shallow Waters 192
Depositing the Attachment During Working Breaks 194
Section 7 1 – Emergency Operation System 196
Section 9 0 – Refueling the Excavator 198
Section 10 0 – Exchange of Attachment and/or Components 200
Part 2 – Lubrication and Maintenance Manual 202
Table of Contents – Lubrication and Maintenance Manual 202
Section 1 0 – Foreward 204
Section Contents 204
Definitions 205
Section 1 1 – Fire Prevention 208
Section 1 2 – Repair Welding 212
Section 2 0 – Safety Instructions 220
Section 3 0 – Fuel and Lubricants 222
Section 4 0 – Filling Capacities 224
Section 5 0 – Lubrication and Maintenance Schedule 226
5 1 – Initial Servicing 226
5 2 – Periodic Servicing Intervals 226
Service Interval Chart 227
Replacement of Hydraulic Hose Lines 232
Inspection of Hydraulic Hose Lines 232
5 3 – Extended Service Intervals for Engines with Engine Oil Management System 234
Servicing Intervals 234
Every 10 Operating Hours 234
Every 500 Operating Hours 236
Every 4000 Operating Hours 236
Engine Oil Reserve Tank 236
5 3 1 – Resetting of Engine Oil Burning System Centinel 238
5 4 – Maintenance of Engine 238
5 5 – Maintenance of Eliminator Oil Filtration System 238
Lubrication Point and Maintence Chart 239
Section 6 1 – Every 10 Operating Hours or Daily 242
1 – Visual Inspection 242
1 1 – Central Lubrication System 246
Backhoe Attachment 246
Bullclam Bucket Attachment 248
Slweing Connection 250
1 2 – Grease Injectors, Corrective Actions 250
1 3 – Check Slew Ring Teeth for Proper Lubrication 252
2 – Maintenance of Engines 254
3 – Lubrication of Attachment 254
3 1 – Lubrication of Backhoe Attachment 254
3 2 – Lubrication of Front Loader Attachment 254
4 – Lubrication of Slewing Connection 256
5 – Engine Air Cleaners 258
6 – Not Used 258
7 – Radiator – Check Coolant Level 260
8 – Track Groups 260
9 – Fuel System, Water Separator 260
Section 6 2 – Every 50 Operating Hours or Weekly 262
10 – Slew Gear and Motor Adapter Housing 262
11 – Not Used 264
12 – Pump Distributor Geat (PTO) and Oil Reservoirs 264
13 – Radiator and Hydraulic Oil Coolers 268
14 – Air Conditioning 268
15 – Maintenance of Engines 268
Section 6 3 – Every 250 Operating Hours or Monthly 270
50 – Engine 270
51 – Drive Belts 270
52 – Not Used 278
53 – Not Used 278
54 – Hydraulic Oil Cooler – Lubricate Fan Bearings 278
55 – Not Used 278
56 – Not Used 278
57 – Compressor for Signal Horn 280
58 – Automatic Lubrication Systems, Clean In-Line-Grease-Filters 282
59 – Air Cleaner for Operator’s Cab 284
60 – Air Conditioning 284
61 – Not Used 284
62 – Not Used 284
63 – Air Conditioning Refrigerant Compressor 286
Section 6 4 – Every 500 Operating Hours or Every 3 Months 288
70 – Engine 288
71 – Batteries 288
72 – Fuel Tank, Drain Water and Sediments 290
73 – Flexible Drive Coupling 292
74 – Rotary Distributor Lubrication 294
Section 6 5 – Every 1000 Operating Hours or Every 6 Months 296
80 – High-Strength Bolt Connections 296
Bolt Torque Chart 320
81 – Maintenance of Engines 322
82 – Hydraulic System 322
83 – Pump Distributor Gears, Slew Gears, and Travel Gears 336
84 – Compressor for Signal Horn 338
85 – Not Used 338
86 – Air Conditioning 338
Section 6 6 – Every 2000 Operating Hours or Yearly 340
100 – Hydraulic System 340
Section 6 7 – Every 3000 operating operating Hours but at Least Once a Year 348
111 – Slew Gear and Motor Adapter Housing 348
111 – Pump Distributor Gear (PTO) 352
Section – 6 8 – When Necessary 356
120 – Servicing the Engine Air Cleaners 356
121 – Additional Fuel System Water Separator 362
122 – Slew Gear 364
123 – Automatic Lubrication Systems with Replaceable Grease Barrels 366
124 – Not Used 368
125 – Not Used 368
126 – Not Used 368
127 – Not Used 368
128 – Hydraulic System 368
129 – Cold Starting Aid, Replace Fluid Cylinder 368
130 – Electrical Switch Board (X2) 370
Section 7 0 – Excavator Storage 372
General 372
1 Preparing for Storage 372
2 One Month Repetitive Service Peroid 373
3 Six Month Repetitive Service Period 373
4 Preparing for Operation 374
Section 8 0 – Troubleshooting 376
General 376
Engine 376
Hydraulic System 377
Travel and Slew Gears 378
Crawler Tracks 378
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