KOMATSU PC3000-6 EXCAVATOR HYDRAULIC MINING SHOVEL OPERATION & MAINTENANCE MANUAL 06372 – PDF DOWNLOAD
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KOMATSU PC3000-6 EXCAVATOR HYDRAULIC MINING SHOVEL OPERATION & MAINTENANCE MANUAL 06372 – PDF DOWNLOAD
FOREWORD:
This is the original version of the Operation & Maintenance Manual, compiled in English, according to the serial number stated on the front cover.
BEFORE READING THIS MANUAL:
- This manual gives details of the operation and methods of inspection and maintenance for this excavator that must
be obeyed in order to use the excavator safely. Most accidents are caused by the failure to follow fundamental
safety rules for the operation and maintenance of excavators. - Read, understand and follow all precautions and warnings in this manual and on the excavator before performing
operation and maintenance. Failure to do so may result in serious injury or death. - Komatsu cannot predict every circumstance that may involve a potential hazard when the excavator is used.
Therefore, the safety messages in this manual and on the excavator may not include all possible safety precautions. If you carry out any operation, inspection or maintenance 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 operation and maintenance of the excavator can be hazardous and could result in serious injury or death.
TABLE OF CONTENTS:
KOMATSU PC3000-6 EXCAVATOR HYDRAULIC MINING SHOVEL OPERATION & MAINTENANCE MANUAL 06372 – PDF DOWNLOAD
1 FOREWORD 3
1 1 BEFORE READING THIS MANUAL 4
1 2 EC DECLARATION OF CONFORMITY 5
1 3 PRIVACY POLICY ON EXCAVATORS EQUIPPED WITH excavator MONITORING SYSTEMS FOR THE EEA 6
1 4 RADIO WAVE REGULATIONS FOR KOMTRAX AND KOMTRAX PLUS 9
1 5 DIRECTIONS OF THE EXCAVATOR 10
1 6 SPECIFICATION AND SERIAL PLATE 11
1 6 1 PRODUCT IDENTIFICATION NUMBER 11
1 7 DIVISION OF THE BINDER 12
1 8 DESIGNATED USE OF THE EXCAVATOR 13
1 9 DELIVERY OF THE EXCAVATOR 14
1 9 1 SPARE PARTS 14
1 9 2 SERVICE 14
1 10 EXPLANATION OF ABBREVIATIONS 15
1 11 CONTENTS 17
2 SAFETY 25
2 1 SAFETY INFORMATION 26
2 2 OVERVIEW 27
2 2 1 NORMAL OPERATIONS 27
2 2 2 REGULAR MAINTENANCE 27
2 2 3 TROUBLESHOOTING, ADJUSTMENTS AND REPAIR 27
2 2 4 ADDITIONAL SAFETY PRECAUTIONS 27
2 3 SOUND PRESSURE AND VIBRATION LEVELS IN THE OPERATOR’S CAB 28
2 3 1 SOUND 28
2 3 2 VIBRATION 28
2 4 GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR 29
2 4 1 UNDERSTANDING THE excavator 29
2 4 2 PRECAUTIONS BEFORE STARTING OPERATION ON THE EXCAVATOR 29
2 4 2 1 ENSURING SAFE OPERATION 29
2 4 3 PREPARATIONS FOR SAFE OPERATION 29
2 4 3 1 PRECAUTIONS REGARDING SAFETY RELATED EQUIPMENT 29
2 4 3 2 INSPECTING THE excavator 29
2 4 3 3 WEAR WELL FITTING CLOTHES AND PROTECTIVE EQUIPMENT 30
2 4 3 4 KEEP excavator CLEAN 30
2 4 3 5 PRECAUTIONS INSIDE OPERATOR’S COMPARTMENT 30
2 4 3 6 PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT 31
2 4 3 7 IF A PROBLEM IS FOUND 31
2 4 4 FIRE PREVENTION 31
2 4 4 1 PRECAUTIONS TO PREVENT FIRE 31
2 4 4 2 ACTION IF FIRE OCCURS ON PC3000 32
2 4 4 3 ACTION IF FIRE OCCURS ON PC4000, PC5500, PC7000, PC8000 33
2 4 4 4 EMERGENCY EXIT FROM OPERATOR’S CAB 33
2 4 5 PRECAUTIONS WHEN GETTING ON OR OFF THE EXCAVATOR 34
2 4 5 1 USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF THE excavator 34
2 4 5 2 NO JUMPING ON OR OFF THE excavator 34
2 4 5 3 NO PEOPLE ON THE ATTACHMENT 34
2 4 5 4 WORKING IN HIGH PLACES 34
2 4 5 5 LEAVING OPERATOR’S SEAT WITH LOCK 35
2 4 5 6 LEAVING THE excavator 35
2 4 6 BURN PREVENTION 35
2 4 6 1 Hot coolant 35
2 4 6 2 Hot oil 36
2 4 7 PRECAUTIONS WHEN CLEANING CAB GLASS 36
2 4 8 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES 36
2 4 9 PRECAUTIONS RELATED TO AIRBOURNE AND EJECTED DEBRIS 37
2 4 9 1 UNAUTHORIZED MODIFICATION 37
2 4 9 2 PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS 37
2 4 10 ELECTROMAGNETIC COMPATIBILITY (EMC) 37
2 4 11 PRECAUTIONS AT JOBSITE 38
2 4 11 1 VISIBILITY FROM OPERATOR’S SEAT 39
2 4 11 2 CAMERA SYSTEM WITH MONITORS 39
2 4 11 3 ENSURE GOOD VISIBILITY 39
2 4 11 4 CHECKING SIGNS AND SIGNALMAN’S SIGNALS 39
2 4 11 5 INVESTIGATE AND CONFIRM JOBSITE CONDITIONS 40
2 4 11 6 DO NOT GO CLOSE TO HIGH VOLTAGE CABLES 40
2 4 11 7 Lightning Strikes 41
2 4 11 8 WORKING ON LOOSE GROUND 41
2 4 11 9 GAS, DUST, STEAM, SMOKE AND EXHAUST FUMES 42
2 4 11 10 VENTILATION OF ENCLOSED AREAS 43
2 4 12 STARTING motor 44
2 4 12 1 WARNING TAG 44
2 4 12 2 CHECKS BEFORE STARTING motor 44
2 4 12 3 PRECAUTION WHEN STARTING motor 44
2 4 12 4 PRECAUTION IN COLD AREAS 45
2 4 13 OPERATION 45
2 4 13 1 CHECKS BEFORE OPERATION 45
2 4 13 2 PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE 46
2 4 13 3 PRECAUTIONS WHEN traveling 47
2 4 13 4 TRAVELING ON SLOPES 48
2 4 13 5 OPERATIONS ON SLOPES 49
2 4 13 6 PROHIBITED OPERATIONS 49
2 4 13 7 TRAVELING ON FROZEN OR SNOW COVERED SURFACES 50
2 4 13 8 PARKING THE excavator 50
2 4 13 9 TRANSPORTATION 50
2 5 PRECAUTION FOR MAINTENANCE 51
2 5 1 GENERAL PRECAUTIONS 51
2 5 1 1 SELECTION AND QUALIFICATION OF PERSONNEL – BASIC RESPONSIBILITIES 52
2 5 1 2 STOP motor FOR MAINTENANCE 53
2 5 1 3 WARNING TAG 53
2 5 1 4 Maintenance safety Switch 53
2 5 1 5 KEEP WORKPLACE CLEAN AND TIDY 54
2 5 1 6 APPOINT LEADER WHEN WORKING WITH OTHERS 55
2 5 1 7 TWO WORKERS FOR MAINTENANCE WHEN THE excavator IS RUNNING 55
2 5 1 8 INSTALLING, REMOVING OR STORING ATTACHMENTS 55
2 5 1 9 PRECAUTIONS WHEN WORKING UNDER THE excavator OR EQUIPMENT 56
2 5 1 10 NOISE 56
2 5 1 11 WHEN USING A HAMMER 56
2 5 1 12 PROPER TOOLS 57
2 5 1 13 ACCUMULATOR 57
2 5 1 14 PERSONNEL 57
2 5 2 PRECAUTIONS FOR INSPECTION AND MAINTENANCE 58
2 5 2 1 PRECAUTION WHEN WELDING 58
2 5 2 2 BATTERY HANDLING 58
2 5 3 PRECAUTIONS WITH HIGH PRESSURE FLUID 59
2 5 3 1 PRECAUTIONS WITH HIGH FUEL PRESSURE 60
2 5 3 2 HANDLING HIGH PRESSURES HOSES OR PIPES 61
2 5 3 3 REPLACEMENT OF HOSE LINES 61
2 5 3 4 INSPECTION OF HOSE LINES 61
2 5 3 5 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS 62
2 5 3 6 PRECAUTIONS FOR HIGH VOLTAGE 62
2 5 3 7 AIR CONDITIONING MAINTENANCE 62
2 5 3 8 COMPRESSED AIR 63
2 5 3 9 WASTE MATERIALS 63
2 6 ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS 64
2 6 1 INSPECTION OF THE HYDRAULIC SYSTEM 64
2 6 2 TWO WORKERS ONLY WHEN THE EXCAVATOR IS RUNNING DURING ADJUSTMENTS 64
2 6 3 AREAS OF POTENTIAL DANGER AROUND THE EXCAVATOR 64
2 7 SPECIAL SAFETY EQUIPMENT 66
2 7 1 FRONT GUARD PROTECTIVE STRUCTURE ’FOPS’ FOR OPERATOR’S CAB 67
2 7 2 OBJECT HANDLING 67
2 7 3 LIGHTING 67
2 7 4 WARNING BEACON 67
2 7 5 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD) 67
2 7 5 1 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD) 67
2 7 5 2 INSTRUCTIONS FOR USE 68
2 7 5 3 RECOMMENDATIONS FOR USE OF THE HOLDING HOOKS AND HOLD- BACK HOOKS OF THE SAFETY HARNESS 69
2 7 5 4 INSTRUCTIONS FOR USE 69
2 8 SAFETY WARNING SIGNS 71
2 8 1 LOCATION AND DESCRIPTION OF THE SIGNS 72
2 8 2 LOCATION AND DESCRIPTION OF THE SIGNS FOR PC3400 74
3 OPERATION 101
3 1 FOREWORD 102
3 1 1 Connection of customer electrical installations to the excavator 102
3 2 CONSTRUCTION OF THE EXCAVATOR 103
3 2 1 OVERALL VIEW 103
3 2 2 UNDERCARRIAGE AND SUPERSTRUCTURE 104
3 2 2 1 SUPERSTRUCTURE – TOP VIEW 106
3 2 2 2 MACHINERY HOUSE 108
3 2 3 HYDRAULICALLY OPERATED ACCESS LADDER 111
3 2 3 1 STANDARD OPERATION OF THE HYDRAULIC ACCESS LADDER 113
3 2 3 2 EMERGENCY OPERATION OF THE HYDRAULIC ACCESS LADDER 115
3 2 4 EMERGENCY ESCAPE LADDER 116
3 2 5 EMERGENCY ESCAPE LADDER AND ESCAPE HATCH IN THE MACHINERY HOUSE 118
3 2 6 EMERGENCY ENGINE SHUTDOWN FROM GROUND MAN OR OPERATOR WARNING SYSTEM 120
3 2 6 1 Engine Shutdown System actuated from Ground Man 121
3 2 6 2 Operator Warning System 121
3 2 7 OPERATOR’S CAB WITH INTEGRATED FALLING OBJECT PROTECTIVE STRUCTURE (FOPS) 122
3 2 7 1 Operator’s Seat Adjustment 127
3 2 7 2 Co-driver’s Seat 128
3 2 7 3 INSTRUCTIONS TO using and looking after THE SEAT BELTS 129
3 3 OPERATOR’S CAB – CONTROLS 130
3 3 1 CONTROLS WITH BACKHOE ATTACHMENT 130
3 3 1 1 Hydraulic Control System 131
3 3 1 2 Safety Circuit for Controls 131
3 3 1 3 EURO Control Pattern 133
3 3 2 CONTROLS WITH BOTTOM DUMP BUCKET 134
3 3 2 1 Hydraulic Control System 135
3 3 2 2 Safety Circuit for Controls 135
3 3 2 3 Automatic Float Position for Boom and Stick 135
3 3 2 4 EURO Control Pattern 137
3 3 3 OPERATOR’S CONSOLE 139
3 3 3 1 Control Panel 141
3 3 3 2 Rear Panel Controls 145
3 4 MACHINE MONITOR KOMTRAX PLUS) 146
3 4 1 SEQUENCE OF DISPLAYS 147
3 4 2 OPENING SCREEN 147
3 4 3 MAIN GAUGE SCREENS 1 TO 2 148
3 4 4 Function of Keys F1 to F6 150
3 4 5 FUEL CONSUMPTION SCREEN 153
3 4 6 FAILURE MESSAGE HISTORY SCREEN FOR OPERATOR 154
3 4 7 MAIN SCREEN – CHANGE >TIME >SMR >DATE 154
3 4 8 MAINTENANCE MONITOR 155
3 4 8 1 Maintenance confirmation through Service Personnel 155
3 4 9 SETTINGS FOR OPERATOR 156
3 4 9 1 Settings for Operator 157
3 4 9 2 User ID Screen 157
3 4 9 3 Reset Truck Counter 1 157
3 4 9 4 Screen Adjustment 158
3 4 9 5 Date Adjustment Screen 160
3 4 9 6 Clock Adjustment Screen 160
3 4 9 7 Language Selection Screen 160
3 4 10 AUTOMATIC MESSAGES 161
3 4 10 1 Automatic Messages 162
3 4 10 2 Automatic Messages 163
3 4 10 3 Automatic Messages 164
3 4 11 TABLE OF ALL TOP MESSAGES PROVIDED BY THE SYSTEM 165
3 5 CAMERA SYSTEM WITH MONITORs (SPECIAL EQUIPMENT) 178
3 5 1 LOCATION OF MONITORS AND CONTROL UNITS 179
3 5 1 1 Operating the Monitors 181
3 5 1 2 ADjustments of the Monitor 181
3 5 1 3 Typical Arrangement of the Cameras 185
3 6 OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING 186
3 6 1 Digital Display 186
3 6 2 CONTROL MODULE FOR AUXILIARY CAB HEATER (IF SO EQUIPPED) 191
3 6 3 AUXILIARY HEATER FOR OPERATORS CAB (IF SO EQUIPPED) 193
3 6 4 AUXILIARY HEATER FOR OPERATORS CAB (IF SO EQUIPPED) 195
3 6 5 FUEL PUMP ARRANGEMENT 197
3 7 MACHINERY HOUSE 198
3 7 1 EMERGENCY ENGINE SHUTDOWN SWITCHES 199
3 8 ELECTRICAL EQUIPMENT IN CAB BASE 200
3 8 1 Access Cover for the Headlights mounted on Cab Base 203
3 8 2 SWITCH BOX (X2) IN CAB BASE 205
3 9 PREHEATING SYTEM (OPTIONAL) 207
3 9 1 COMPONENTS OF ELECTRICAL PREHEATING SYSTEM IN CAB BASE 207
3 9 2 COMPONENTS OF ELECTRICAL PREHEATING SYSTEM ON THE COUNTERWEIGHT 211
3 10 CHECKS BEFORE STARTING THE ENGINE 212
3 10 1 CHECK THE FOLLOWING ITEMS 213
3 10 1 1 Coolant Level 215
3 10 1 2 HYDRAULIC SYSTEM – CHECK OIL LEVEL 217
3 10 1 3 OPERATOR’S SEAT ADJUSTMENT 217
3 11 STARTING THE ENGINE 218
3 11 1 STARTING PROCEDURE 219
3 11 2 STARTING PROCEDURE AT AMBIENT TEMPERATURE UP TO -25° 221
3 11 2 1 Cold Weather Starting at ambient Temperatures below 0°C to -25°C 221
3 11 2 2 Cold Weather Starting at ambient Temperatures below –25°C 223
3 11 2 3 Hydraulic Oil Viscosity and Temperature Chart 227
3 12 MOVING THE EXCAVATOR 228
3 12 1 TRAVEL CONTROL WITH FOOT PEDALS 228
3 12 1 1 TRAVEL ALARM / BACK-UP ALARM 230
3 12 2 traveling INSTRUCTIONS 230
3 12 2 1 TRAVELING 233
3 12 2 2 TRAVELING LONG DISTANCES 235
3 13 SLEWING AND BRAKING THE SUPERSTRUCTURE 236
3 13 1 SLEWING THE SUPERSTRUCTURE 236
3 13 1 1 excavatorS WITH “EURO” CONTROL 236
3 13 1 2 BRAKING THE SUPERSTRUCTURE 237
3 13 2 SLEW PARKING BRAKE 237
3 13 2 1 Hydraulic slew brake actuated by hydraulic access Ladder and Service Arm of Central Refilling System 238
3 13 2 2 Important Instructions for Slewing the Superstructure 238
3 14 WORKING WITH THE ATTACHMENT 239
3 14 0 1 Front shovel BUCKET 240
3 14 1 COMBINED OPERATION CYCLES 241
3 15 WORKING INSTRUCTIONS 244
3 15 1 STABILITY OF THE excavator 244
3 15 2 FURTHER OPERATING PRACTICES 246
3 15 3 Loading Trucks 250
3 16 PARKING THE excavator 251
3 16 1 CLEANING THE TRACK GROUPS 251
3 17 STOPPING THE ENGINE 252
3 17 1 RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM 255
3 18 AUTOMATIC LUBRICATION SYSTEMS 256
3 18 1 OPERATION OF THE AUTOMATIC LUBRICATION SYSTEMS 257
3 19 FIRE DETECTION AND SUPPRESSION SYSTEM 260
3 19 1 FIRE DETECTION AND SUPPRESSION SYSTEMS 261
3 19 2 HIGH LEVEL ALARM -FIRE- 265
3 19 3 ENGINE SHUT-DOWN THROUGH FUEL SHUT-OFF SOLENOID VALVE 265
3 19 4 ACTUATION MODES OF THE FIRE SUPPRESSION SYSTEM 265
3 19 4 1 MANUAL ACTUATION 265
3 19 4 2 AUTOMATIC ACTUATION 265
3 19 5 INDICATION OF OPERATIONAL MODES AT CONTROL MODULE, AFTER AUTOMATIC ACTUATION OF THE FIRE SUPPRESSION SYSTEM 267
3 19 6 LOCATION OF THE EXTINGUISHING AGENT TANK ASSEMBLIES AND EXPELLANT GAS CARTRIDGES ON POWER HOUSE ROOF 269
3 20 CENTRAL REFILLING SYSTEM 270
3 20 1 SYSTEMS CONNECTED TO THE REFILLING SYSTEM 271
3 20 1 1 Operation of the hydraulic Service Arm 271
3 20 2 OPERATING THE HYDRAULIC SERVICE ARM 273
3 20 3 RECEIVER PANEL WITH MONITOR BOX 275
3 20 4 REFILLABLE GREASE CONTAINERS OF THE AUTOMATIC LUBRICATION SYSTEMS 279
3 21 TRANSFER PUMP FOR HYDRAULIC OIL 280
3 21 1 OPERATING THE TRANSFER PUMP 281
3 21 2 FUNCTIONS OF THE TRANSFER PUMP 281
3 22 SERVICE CRANE (SPECIAL EQUIPMENT) 285
3 23 WORK ON THE LOADER ATTACHMENT 286
3 23 1 OBSERVE THE FOLLOWING INSTRUCTIONS 286
3 24 TRANSPORTATION AND LIFTING OF THE excavator 287
3 24 1 DISASSEMBLING OF THE excavator 287
3 24 2 TRANSPORTATION AND LIFTING 287
3 25 RETRIEVAL PROCEDURE 288
3 25 1 GENERAL 288
3 26 excavator STORAGE 289
3 26 1 GENERAL 289
3 26 2 PREPARING FOR STORAGE 289
3 26 3 ONE MONTH REPETITIVE SERVICE PERIOD 289
3 26 4 SIX MONTH REPETITIVE SERVICE PERIOD 289
3 26 5 PREPARING FOR OPERATION 290
3 27 TROUBLE SHOOTING 291
3 27 1 GENERAL 291
3 27 2 ENGINE 291
3 27 3 HYDRAULIC SYSTEM 292
3 27 4 FINAL DRIVES AND SLEW GEAR 293
3 27 5 CRAWLER TRACKS 293
4 MAINTENANCE 295
4 1 FOREWORD 296
4 1 1 DEFINITIONS 296
4 1 2 GENERAL RECOMMENDATIONS 296
4 2 PRECAUTIONS FOR MAINTENANCE 297
4 3 FLUIDS AND LUBRICANTS 298
4 3 1 FLUIDS AND LUBRICANTS FOR MODERATE AND HOT CLIMATES 298
4 3 2 LUBRICANTS FOR OPERATION IN COLD AND ARCTIC CLIMATES 300
4 3 2 1 Recommended Hydraulic Oils 301
4 3 2 2 General Information to selecting hydraulic oils 302
4 4 FILLING CAPACITIES 304
4 5 STANDARD TORQUE LIST 305
4 5 1 Torque for Flange Joints 306
4 5 2 TORQUES FOR SPECIAL COMPONENTS 307
4 6 LUBRICATION AND MAINTENANCE SCHEDULE 309
4 6 1 INITIAL SERVICING 309
4 6 1 1 INITIAL RUNNING-IN 309
4 6 1 2 AFTER THE FIRST 250 OPERATING HOURS 309
4 6 1 3 AFTER THE FIRST 1000 OPERATING HOURS OR AFTER COMPONENT REPLACEMENT 309
4 6 2 SERVICING THE CRITICAL BOLT CONNECTIONS 310
4 6 3 PERIODIC SERVICING INTERVALS 310
4 6 4 PERIODIC SERVICING SCHEDULE 310
4 6 4 1 WHEN NECESSARY 310
4 6 4 2 EVERY 10 OPERATING HOURS OR DAILY 311
4 6 4 3 EVERY 50 HOURS OR WEEKLY 311
4 6 4 4 EVERY 250 HOURS OR MONTHLY 312
4 6 4 5 EVERY 500 HOURS OR QUATERLY 312
4 6 4 6 EVERY 1000 HOURS OR 6 MONTHLY 313
4 6 4 7 EVERY 2000 HOURS OR YEARLY 313
4 6 4 8 EVERY 3000 HOURS HOWEVER AT LEAST ONCE A YEAR 314
4 6 4 9 EVERY 6000 HOURS OPERATING HOURS OR AT LEAST ONCE A YEAR 314
4 6 5 MAINTENANCE SCHEDULES OF FILTER ELEMENTS AND OTHER COMPONENTS OF THE HYDRAULIC SYSTEM 315
4 7 SAFETY CRITICAL PARTS 316
4 7 1 REPLACEMENT OF HYDRAULIC HOSE LINES AND FUEL HOSE LINES 316
4 7 2 INSPECTION OF HOSE LINES 316
4 7 3 PERIODIC REPLACEMENT OF FURTHER SAFETY CRITICAL PARTS 317
4 7 4 VENTING THE AIR FROM THE FUEL FILTERS 321
4 8 INITIAL SERVICING 322
4 8 1 WORKING ATTACHMENT – INITIAL CHECKS FOR PROPER LUBRICATION 323
4 8 2 SLEW CIRCLE – CHECK GREASE INJECTORS 325
4 8 3 CAR BODY AND RACEWAY OF SLEW RING 327
4 8 4 SLEW circle – CHECK TORQUE OF BOLT CONNECTIONS 329
4 8 5 RETIGHTENING PROCEDURE OF THE CRAWLER CARRIER MOUNTING BOLTS 331
4 9 WHEN NECESSARY 336
4 9 1 ENGINE AIR CLEANER MAINTENANCE 337
4 9 1 1 General Service Tips 339
4 9 2 SLEW CIRCLE TOOTHING LUBRICATION 341
4 9 3 AUTOMATIC LUBRICATION SYSTEMS FILL GREASE CONTAINERS 343
4 9 3 1 Service the Grease Filters for Refillable Grease Containers of the Central Lubrication System and SLEW circle pinion Lubrication System 345
4 9 4 GUIDE WHEELS – REPLACE FLOATING SEALS 345
4 9 5 COLD STARTING AID, REPLACE FLUID CYLINDER 347
4 9 6 CLEANING THE EXCAVATOR 349
4 9 6 1 Precautions for cleaning 349
4 10 EVERY 10 OPERATING HOURS OR DAILY 352
4 10 1 WALK – AROUND INSPECTION 353
4 10 1 1 GROUND CABLES – CHECK CONNECTION POINTS 357
4 10 2 AIR CLEANER – CLEAN PRECLEANER 359
4 10 2 1 Clean dust cups of precleaners 359
4 10 3 RADIATOR – CHECK COOLANT LEVEL 361
4 10 4 TRACK GROUPS – CLEAN 361
4 10 5 FUEL SYSTEM WATER SEPARATOR – DRAIN WATER 363
4 10 6 BOOM – CHECK LADDER AND WALKWAY 365
4 10 7 ELECTRICAL EQUIPMENT – CHECK VISUALLY 365
4 10 8 EMERGENCY ESCAPE ROUTE FROM OPERATOR’S CAB 367
4 11 EVERY 50 OPERATING HOURS OR WEEKLY 368
4 11 1 SLEW GEAR AND MOTOR ADAPTER HOUSING – CHECK OIL LEVEL 369
4 11 1 1 SLEW gear manufactured TYPE 2063 369
4 11 1 2 SLEW Gear TYPE 632770 371
4 11 2 TRAVEL GEARS, BRAKE HOUSINGS AND MOTOR ADAPTER HOUSINGS – CHECK OIL LEVELS 373
4 11 2 1 PLANETARY GEAR BOX – CHECK OIL LEVEL 373
4 11 2 2 SPUR GEAR BOX – CHECK OIL LEVEL 375
4 11 2 3 BRAKE HOUSINGS – CHECK OIL LEVEL 375
4 11 2 4 MOTOR ADAPTER HOUSING – CHECK OIL LEVEL 375
4 11 2 5 MILEAGE INDICATOR (Special Equipment) 375
4 11 3 PTO (PUMP DISTRIBUTOR GEAR) – CHECK OIL LEVEL 377
4 11 3 1 Main Hydraulic Pumps – Check Oil Level in Drive Shaft Housings 377
4 11 4 HYDRAULIC ACCESS LADDER – CHECK SAFETY SENSOR 379
4 11 5 HYDRAULIC OIL COOLERS – INSPECT AND CLEAN IF NECESSARY 381
4 12 EVERY 250 OPERATING HOURS OR MONTHLY 382
4 12 1 AIR CONDITIONING COMPRESSOR – CHECK DRIVE BELT TENSION 383
4 12 2 RADIATOR FAN BELT AND AUTOMATIC BELT TENSIONER – MAINTENANCE CHECK 385
4 12 3 GENERATOR – CHECK BELT TENSION 389
4 12 4 SIGNAL HORN COMPRESSOR – LUBRICATE 391
4 12 5 HYDRAULIC OIL COOLER FAN – CHECK CONDITION AND FASTENING 391
4 12 6 AUTOMATIC LUBRICATION SYSTEMS – CLEAN BREATHER FILTER 393
4 12 7 CAB AIR CLEANER – CLEAN OR REPLACE FILTER ELEMENT 395
4 12 7 1 Clean and inspect filter element (3) as follows: 395
4 12 8 WINDSHIELD WASHER RESERVOIR – CHECK FLUID LEVEL 397
4 12 9 AIR CONDITIONING FOR OPERATOR’S CAB – CHECK REFRIGERANT LEVEL 399
4 13 EVERY 500 OPERATING HOURS OR MONTHLY 400
4 13 1 BATTERIES – CHECK FLUID LEVEL 401
4 13 2 FUEL TANK – DRAIN CONDENSATION 403
4 13 3 CRAWLER TRACK – INSPECTION 405
4 13 3 1 CHECK ADJUSTING RANGE OF GUIDE WHEELS 405
4 13 3 2 CHECK ADJUSTING RANGE FOR GUIDE WHEELS 407
4 13 3 3 CHECK ADJUSTING RANGE FOR GUIDE WHEELS 409
4 13 3 4 Bleeding the System 409
4 13 3 5 GREASE INJECTORS – CHECK INDICATOR STEMS 410
4 13 3 6 CORRECTIVE ACTIONS 410
4 13 4 EMERGENCY LOWERING OF ACCESS LADDER – Test FUNCTIONALITY 413
4 13 5 CYLINDER ROD PROTECTION (IF EQUIPPED), CHANGE SLIDING BLOCKS 415
4 14 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH 416
4 14 1 CRITICAL BOLT CONNECTIONS 417
4 14 2 HYDRAULIC SYSTEM – FILTER SERVICE 423
4 14 2 1 FILTER SERVICE 425
4 14 3 BLEEDING RETURN OIL CHAMBER (IF EQUIPPED WITH OIL LEVEL GAUGE) 437
4 14 4 PTO (PUMP DISTRIBUTOR GEAR), SLEW GEAR AND TRAVEL GEARS – OIL SAMPLE ANALYSIS 441
4 14 4 1 Oil drain plugs 441
4 14 5 SIGNAL HORN COMPRESSOR – CLEAN AND LUBRICATE 443
4 14 6 HYDRAULIC TRACK TENSIONING SYSTEM – CHECK PRESSURE ACCUMULATORS 445
4 14 7 HYDRAULIC OIL COOLER – INSPECT AND LUBRICATE DOOR HINGES 447
4 14 8 MACHINERY HOUSE DOORS – INSPECT AND LUBRICATE DOOR HINGES 447
4 14 9 EMERGENCY ENGINE SHUTDOWN SWITCHES – TEST FUNCTIONALITY 449
4 14 10 ENGINE SHUTDOWN PULL chains (SPECIAL EQUIPMENT) – TEST FUNCTIONALITY 451
4 14 11 ELECTRICAL EQUIPMENT – MAINTENANCE 453
4 14 12 ENGINE AIR CLEANERS- INSPECT AND LUBRICATE HINGES 455
4 14 13 OIL SEPARATOR ELEMENT – REPLACE BREATHER FILTER 457
4 15 EVERY 2000 OPERATING HOURS OR YEARLY 458
4 15 1 HYDRAULIC SYSTEM – CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER 459
4 15 1 1 Sequence of Servicing 459
4 15 1 2 Filling the Hydraulic System 467
4 15 1 3 Hydraulic oil viscosity and adjustment of temperature switch units 469
4 15 1 4 Vent Suction Oil Reservoir and Hydraulic Pumps 471
4 15 2 EMERGENCY ESCAPE LADDERS – INSPECTION 473
4 15 3 PREVENTATIVE MAINTENANCE (PM) CLINIC – PERFORM TEST 475
4 15 4 HYDRAULIC HOSES – CHECK CONDITION 477
4 15 5 EMERGENCY ESCAPE ROUTE FROM OPERATOR’S CAB 479
4 15 5 1 Functionality 479
4 16 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR 480
4 16 1 SLEW GEAR AND MOTOR ADAPTER HOUSING – CHANGE OIL 481
4 16 1 1 SLEW gear TYPE 2063 481
4 16 1 2 SLEW GEAR TYPE 632770 485
4 16 2 TRAVEL GEARS, BRAKE AND MOTOR ADAPTER HOUSINGS – CHANGE OIL 489
4 16 3 PTO (PUMP DISTRIBUTOR GEAR) – CHANGE OIL 493
4 16 4 PTO gear oil viscosity and adjustment of temperature switch units 495
4 16 5 CRITICAL BOLT CONNECTIONS – CHECK TORQUE LOAD 497
4 16 6 OIL SEPARATOR ELEMENT – REPLACE 515
4 17 EVERY 6000 HOURS OR AT LEAST ONCE A YEAR 516
4 17 1 AUTOMATIC LUBRICATION SYSTEMS – Replace GREASE FILTERS 517
4 17 2 CHECK FAN DRIVE BEARING OF COOLANT RADIATOR 519
4 18 FIRE PREVENTION 520
4 18 1 PRECAUTIONS 521
4 19 WELD REPAIRS 522
4 19 1 GENERAL PROTECTIVE MEASURES 523
4 19 2 WELD REPAIRS ON MAJOR COMPONENTS OF THE EXCAVATOR 523
4 19 2 1 COUNTERWEIGHT 523
4 19 3 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE UNDERCARRIAGE 525
4 19 4 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE LOADER ATTACHMENT 527
4 19 5 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE SUPERSTRUCTURE 529
4 19 5 1 Electrical Units in Cab Base 531
4 19 5 2 Engine Electronics 531
4 19 6 AFTER FINISHING THE WELD REPAIRS ON THE SUPERSTRUCTURE 531
5 REVISION 533
5 1 REVISION TABLE 534
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I.GKOMATSU PC3000-6 EXCAVATOR HYDRAULIC MINING SHOVEL OPERATION & MAINTENANCE MANUAL 06372