KOMATSU PC3000-6 EXCAVATOR HYDRAULIC MINING SHOVEL SHOP MANUAL 6224 – PDF DOWNLOAD
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DESCRIPTION:
KOMATSU PC3000-6 EXCAVATOR HYDRAULIC MINING SHOVEL SHOP MANUAL 6224 – PDF DOWNLOAD
GENERAL PRECAUTIONS:
Mistakes in operation and service are extremely dangerous.
Read the OPERATION & MAINTENANCE MANUAL
carefully BEFORE operating the machine.
Before carrying out any greasing or repairs, read all the
precautions given on the decals which are fixed to the
machine.
When carrying out any operation, always wear safety
shoes and helmet. Do not wear loose work clothes, or
clothes with buttons missing.
Always wear safety glasses when hitting parts with a
hammer.
Always wear safety glasses when grinding parts with a
grinder, etc. If welding repairs are needed, always have a
trained, experienced welder carry out the work. When
carrying out welding work, always wear welding gloves,
apron, glasses, cap and other clothes suited for welding
work.
TABLE OF CONTENTS:
KOMATSU PC3000-6 EXCAVATOR HYDRAULIC MINING SHOVEL SHOP MANUAL 6224 – PDF DOWNLOAD
MAIN MENU 0
COVER 1
I INTRODUCTION 3
I I CONTENTS OF BINDER 4
I II FOREWARD 5
I III EXPLANATION OF ABBREVATIONS 7
I IV TABLE OF CONTENTS 8
II SAFETY 15
II I SAFETY INSTRUCTIONS 16
II II GENERAL PRECAUTIONS 17
II III PREPARATIONS FOR WORK 18
II IV PRECAUTIONS DURING WORK 19
III SPECIFICATIONS 21
III I LIFTING GEARS 22
III II STANDARD TIGHTENING TORQUE CHART 24
III III CONVERSION TABLE 25
III IV EXPLANATION OF ABBREVATIONS 31
III V GENERAL SPECIFICATIONS 32
1 MAIN ASSEMBLY GROUPS 33
1 1 General layout 34
1 2 Superstructure 36
1 3 Power House 38
1 4 Hydraulic Oil Reservoir 40
1 5 Hydraulic Oil Cooler 42
1 6 Fuel tank (Fuel reservoir) 44
1 7 Counter weight 46
1 8 Cab support 48
1 9 Operators cab 50
1 10 Control blocks 52
1 11 Swing gears 54
1 12 Under carriage 56
2 DRIVE 59
2 1 Prime drive assembly 60
2 2 Engine and gearbox mount 62
2 3 Torque supports 65
2 4 Radiator fan Drive Assy 66
2 5 Pump distributor gearbox (PTO) 68
2 5 1 Spline shaft housing 70
2 5 2 PTO lubrication and cooling 72
2 5 3 PTO valve adjustments 74
2 6 Coupling 78
2 7 Air Filter 80
3 HYDRAULIC OIL RESERVOIR 83
3 1 Hydraulic oil reservoir 84
3 2 Return and leak oil filter 88
3 3 Breather Filter 92
3 4 Location of electrical components 94
4 HYDRAULIC OIL COOLING 97
4 1 General 98
4 2 Hydraulic oil cooling circuit 100
4 3 Back pressure valve adjustment 104
4 4 Fan drive 106
4 4 1 Fan pump 108
4 4 2 Pressure relieve valve 109
4 4 3 Temperature relay 111
4 5 Cooler fan drive adjustment 112
5 CONTROLLING 115
5 1 Pilot pressure supply and adjustment 116
5 1 1 Pilot control arrangement 119
5 1 2 Pilot pressure adjustment 121
5 1 3 Check of Control Pressure 123
5 2 Slew brakes 125
5 3 Travel parking brake 128
5 4 Check of the pilot control logic 130
5 4 1 Check sheet BHA Page 1 132
5 4 2 Check sheet FSA Page 1 145
6 COMPONENTS 155
6 1 Main control block and valve arrangement 156
6 1 1 FSA arrangement 158
6 1 2 BHA arrangement 162
6 2 Distributor manifold 166
6 2 1 Front shovel attachment FSA 166
6 2 2 Back hoe attachment BHA 168
6 2 3 SRV with throttle check valve 170
6 2 4 Anti cavitation valve (check valve) 172
6 3 Main control block 174
6 3 1 Load holding valve 182
6 3 2 High pressure filter auxiliary filter 184
6 3 3 High pressure filter auxiliary filter 186
6 3 4 High pressure filter auxiliary filter 188
6 4 Compact valve blocks 190
6 5 Compact valve blocks 192
6 6 Auxiliary gear pumps 194
6 7 Hydraulic cylinder 196
6 8 Swing ring 198
7 MAIN HYDRAULIC PUMPS AND PUMP REGULATION 201
7 1 General 202
7 1 1 Pump location 204
7 2 Main pump operating principles 206
7 2 1 Main pump function 211
7 3 Main pump checks and adjustments 214
7 3 1 Peak point diesel engine test 214
7 3 2 Pressure transducer test 216
7 3 3 Cut off function 217
7 3 4 Pump regulation 219
7 3 5 Swing pump volume reduction 220
7 4 Electronic pump regulation 221
7 4 1 Pump Controller CR700 223
7 4 2 Multi Monitor 225
7 4 3 Multimonitor software instruction 227
7 4 4 Table of fault messages and adjustments 234
7 5 Trouble shooting pump and pump regulation 243
8 OPERATING HYDRAULIC 247
8 1 General layout 248
8 2 Floating function of boom and stick only FSA 252
8 3 Check and Adjustments for MRV’s and SRV’s 254
8 3 1 Check and Adjustments for MRV 256
8 3 2 Check and Adjustment for SRV’s 258
8 3 3 Check and adjustment of the throttle check valves 266
8 4 Hydraulic for the swing circuit 268
8 4 1 Hydraulic for the swing circuit 272
8 4 2 Slew gear box L & S 276
8 4 3 Slew parking brake 280
8 4 4 Slew service brake valve 284
8 4 5 Checks and adjustment of the slew pressure valve 289
8 5 Travel circuit 292
8 5 1 Rotary joint 294
8 5 2 Travel motor A2FMt 296
8 5 3 Travel gear 298
8 5 4 Travel parking brake 300
8 5 5 Travel control function 302
9 TRACK TENSION SYSTEM 307
9 1 General layout 308
9 2 Track tensioning function 310
9 2 1 Cushioning 312
9 2 2 Pressure Increasing valve PIV 314
9 3 Truck tensioning adjustment 318
9 3 1 Truck tensioning function check 320
10 ACCESS LADDER HYDRAULICALLY OPERATED 323
10 1 Access ladder 324
10 2 Access ladder functional description 326
11 CENTRAL REFILLING SYSTEM 331
11 0 1 Functional description 332
12 HINTS FOR READING THE HYDRAULIC CIRCUIT DIAGRAM 337
12 1 General 338
12 2 Symbolic 340
12 2 1 Lines, unions 341
12 2 2 Components, valves 343
12 2 3 Sensors 343
12 2 4 Valves, valve components 344
12 2 5 Pump, motor, cylinder 348
Hydraulic Diagrams – 938 367 40 352
Hydraulic Diagrams – 938 367 40 (1/3) 352
Hydraulic Diagrams – 938 367 40 (2/3) 353
Hydraulic Diagrams – 938 367 40 (3/3) 354
13 HINTS FOR READING THE ELECTRIC CIRCUIT DIAGRAM 356
13 1 Designation of electrical components 358
13 2 Electric symbols 359
13 3 Symbols 361
13 3 1 Drawing concept 363
13 3 2 Reading of the circuit diagram 369
6
14 ELECTRONIC TEXT MONITORING SYSTEM ETM 428
14 1 General Function 429
15 AUTOMATIC LUBRICATION SYSTEM 432
15 1 General Function 433
15 2 Function of a lubrication cycle 435
15 3 Lubrication pump drive 443
15 4 Lubrication pump 445
15 4 1 Adjustments lubricating pump speed 447
15 4 2 Adjustments lubricating pump pressure 449
15 5 Lubricant Injector (metering valve) 451
15 5 1 Connection of one or more injectors 453
15 5 2 Function lubrication injector (metering valve) 455
15 6 End line pressure switch 459
15 7 Lubricant in line filter 461
15 8 Lubricant level sensor 463
15 8 1 Capacitive digital type for machines with ETM 463
15 8 2 Capacitive analog type for machines with PLC 465
15 9 Lubrication system function and controlling 468
15 9 1 Central Lubrication System (CLS) function and controlling with ETM system (PC 3000) 469
15 9 2 Swing ring lubrication system (SLS) function and controlling with ETM system (PC3000) 473
15 10 Adjustment of the lubrication system with ETM 479
15 11 Trouble shooting lubricating system 481
15 11 1 Lubrication pump cylinder does not move 482
15 11 2 Lubricant pressure built up very slowly or not at all 484
15 11 3 Insufficient lubricant supply to one or more attachment bearings 484
15 11 4 Insufficient lubricant at the swing ring gear 486
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