KOMATSU PC3000E-6 EXCAVATOR HYDRAULIC MINING SHOVEL SHOP MANUAL 06249-46225 – PDF DOWNLOAD
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
KOMATSU PC3000E-6 EXCAVATOR HYDRAULIC MINING SHOVEL SHOP MANUAL 06249-46225 – PDF DOWNLOAD
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 PC3000E-6 EXCAVATOR HYDRAULIC MINING SHOVEL SHOP MANUAL 06249-46225 – PDF DOWNLOAD
COVER 1
00 FOREWORD 3
1 Foreword 5
1 1 Before reading this manual 6
1 2 Contents of this binder 7
1 2 1 Contacting the Service 7
1 2 2 Guarantee 7
1 3 Division of the binder 8
2 SAFETY 9
2 1 SAFETY INFORMATION 11
2 2 OVERVIEW 12
2 2 1 NORMAL OPERATIONS 12
2 2 2 REGULAR MAINTENANCE 12
2 2 3 TROUBLESHOOTING, ADJUSTMENTS AND REPAIR 12
2 2 4 ADDITIONAL SAFETY PRECAUTIONS FOR ASSEMBLING, DISASSEMBLING AND TRANSPORTATION OF THE EXCAVATOR 12
2 3 SOUND PRESSURE LEVEL IN THE OPERATOR’S CAB 13
2 4 GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR 14
2 4 1 UNDERSTANDING THE MACHINE 14
2 4 2 PRECAUTIONS BEFORE STARTING OPERATION ON THE EXCAVATOR 14
2 4 2 1 ENSURING SAFE OPERATION 14
2 4 3 PREPARATIONS FOR SAFE OPERATION 14
2 4 3 1 PRECAUTIONS REGARDING SAFETY RELATED EQUIPMENT 14
2 4 3 2 INSPECTING THE MACHINE 14
2 4 3 3 WEAR WELL FITTING CLOTHES AND PROTECTIVE EQUIPMENT 15
2 4 3 4 KEEP MACHINE CLEAN 15
2 4 3 5 PRECAUTIONS INSIDE OPERATOR’S COMPARTMENT 15
2 4 3 6 PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT 16
2 4 3 7 IF A PROBLEM IS FOUND 16
2 4 4 FIRE PREVENTION 16
2 4 4 1 PRECAUTIONS TO PREVENT FIRE 16
2 4 4 2 ACTION IF FIRE OCCURS 17
2 4 4 3 EMERGENCY EXIT FROM OPERATOR’S CAB 18
2 4 5 PRECAUTIONS WHEN GETTING ON OR OFF THE MACHINE 18
2 4 5 1 USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF THE MACHINE 18
2 4 5 2 NO JUMPING ON OR OFF THE MACHINE 18
2 4 5 3 NO PEOPLE ON THE ATTACHMENT 18
2 4 5 4 WORKING IN HIGH PLACES 18
2 4 5 5 LEAVING OPERATOR’S SEAT WITH LOCK 19
2 4 5 6 LEAVING THE MACHINE 19
2 4 6 BURN PREVENTION 20
2 4 6 1 Hot coolant 20
2 4 6 2 Hot oil 20
2 4 7 PRECAUTIONS WHEN CLEANING CAB GLASS 20
2 4 8 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES 21
2 4 8 1 UNAUTHORIZED MODIFICATION 21
2 4 8 2 PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS 21
2 4 9 PRECAUTIONS AT JOBSITE 22
2 4 9 1 VISIBILITY FROM OPERATOR’S SEAT 23
2 4 9 2 CAMERA SYSTEM WITH MONITORS 23
2 4 9 3 ENSURE GOOD VISIBILITY 23
2 4 9 4 CHECKING SIGNS AND SIGNALMAN’S SIGNALS 23
2 4 9 5 INVESTIGATE AND CONFIRM JOBSITE CONDITIONS 24
2 4 9 6 DO NOT GO CLOSE TO HIGH VOLTAGE CABLES 24
2 4 9 7 WORKING ON LOOSE GROUND 25
2 4 9 8 GAS, DUST, STEAM AND SMOKE 25
2 4 9 9 VENTILATION OF ENCLOSED AREAS 26
2 4 10 STARTING ENGINE 27
2 4 10 1 WARNING TAG 27
2 4 10 2 CHECKS BEFORE STARTING ENGINE 27
2 4 10 3 PRECAUTION WHEN STARTING ENGINE 27
2 4 10 4 PRECAUTION IN COLD AREAS 28
2 4 11 OPERATION 28
2 4 11 1 CHECKS BEFORE OPERATION 28
2 4 11 2 PRECAUTIONS WHEN TRAVELLING IN FORWARD OR REVERSE 29
2 4 11 3 PRECAUTIONS WHEN travelling 30
2 4 11 4 TRAVELLING ON SLOPES 31
2 4 11 5 OPERATIONS ON SLOPES 32
2 4 11 6 PROHIBITED OPERATIONS 32
2 4 11 7 TRAVELLING ON FROZEN OR SNOW COVERED SURFACES 33
2 4 11 8 PARKING THE MACHINE 33
2 4 11 9 TRANSPORTATION 33
2 5 PRECAUTION FOR MAINTENANCE 34
2 5 1 GENERAL PRECAUTIONS 34
2 5 1 1 SELECTION AND QUALIFICATION OF PERSONNEL – BASIC RESPONSIBILITIES 35
2 5 1 2 STOP ENGINE FOR MAINTENANCE 36
2 5 1 3 WARNING TAG 37
2 5 1 4 KEEP WORKPLACE CLEAN AND TIDY 38
2 5 1 5 APPOINT LEADER WHEN WORKING WITH OTHERS 38
2 5 1 6 TWO WORKERS FOR MAINTENANCE WHEN THE MACHINE IS RUNNING 39
2 5 1 7 INSTALLING, REMOVING OR STORING ATTACHMENTS 39
2 5 1 8 PRECAUTIONS WHEN WORKING UNDER THE MACHINE OR EQUIPMENT 40
2 5 1 9 NOISE 40
2 5 1 10 WHEN USING A HAMMER 40
2 5 1 11 PROPER TOOLS 41
2 5 1 12 ACCUMULATOR 41
2 5 1 13 PERSONNEL 41
2 5 2 PRECAUTIONS FOR INSPECTION AND MAINTENANCE 42
2 5 2 1 PRECAUTION WHEN WELDING 42
2 5 2 2 BATTERY HANDLING 42
2 5 3 PRECAUTIONS WITH HIGH PRESSURE Fluid 43
2 5 3 1 PRECAUTIONS WITH HIGH FUEL PRESSURE 43
2 5 3 2 HANDLING HIGH PRESSURES HOSES OR PIPES 44
2 5 3 3 REPLACEMENT OF HOSE LINES 44
2 5 3 4 INSPECTION OF HOSE LINES 44
2 5 3 5 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS 45
2 5 3 6 PRECAUTIONS FOR HIGH VOLTAGE 45
2 5 3 7 AIR CONDITIONING MAINTENANCE 45
2 5 3 8 COMPRESSED AIR 46
2 5 3 9 WASTE MATERIALS 46
2 6 ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS 47
2 6 1 INSPECTION OF THE HYDRAULIC SYSTEM 47
2 6 2 TWO WORKERS ONLY WHEN THE MACHINE IS RUNNING DURING ADJUSTMENTS 47
2 6 3 AREAS OF POTENTIAL DANGER AROUND THE EXCAVATOR 47
2 7 SPECIAL SAFETY EQUIPMENT 48
2 7 1 FRONT GUARD PROTECTIVE STRUCTUR ’FOPS’ FOR OPERATOR’S CAB 49
2 7 2 OBJECT HANDLING 49
2 7 3 LIGHTING 49
2 7 4 WARNING BEACON 49
2 7 5 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD) 49
2 7 5 1 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD) 49
2 7 5 2 INSTRUCTIONS FOR USE 51
2 7 5 3 PRIOR TO USING THE HARNESS (1), THE WEARER SHALL 53
2 7 5 4 RECOMMENDATIONS FOR USE OF THE HOLDING HOOKS AND HOLD-BACK HOOKS OF THE SAFETY HARNESS (1), 53
2 7 5 5 INSTRUCTIONS FOR USE 55
2 8 SAFETY WARNING SIGNS 56
2 8 1 LOCATION AND DESCRIPTION OF THE SIGNS 57
01 SPECIFICATION 71
PC3000 73
10 STRUCTURE, FUNCTION 81
I INTRODUCTION 91
II SAFETY 97
III SPECIFICATIONS 103
1 MAIN ASSEMBLY GROUPS 121
1 1 General layout 122
1 2 Superstructure 124
1 3 Power House 126
1 4 Hydraulic Oil Reservoir 128
1 5 Hydraulic Oil Cooler 130
1 6 High voltage switch cabinet 132
1 7 Counter weight 134
1 7 1 Safety instruction of counterweight handling 137
1 8 Cab support 138
1 9 Operators cab 140
1 10 Control blocks 142
1 11 Swing machinery 144
1 12 Undecarriage 146
1 13 Slip ring unit 148
2 DRIVE 151
2 1 Electric drive – Safety and operation instruction documents 152
2 2 Prime drive assembly 154
2 3 Electric motor 156
2 3 1 Motor type plate 156
2 3 2 Type plate for the motor bearings 157
2 3 3 Motor bearings & grease equipment 158
2 3 4 Monitoring of the motor temperatures 160
2 3 5 Checking of the bearing condition 162
2 3 6 Capacitor assembly 164
2 4 Initial Start-up procedure 166
2 4 1 Main supply cable 167
2 4 2 Motor protection relay (SPAM 150 C) 168
2 4 3 Motor alignment 172
2 4 4 Motor rotation direction 174
2 4 5 Starting & Re-starting the electric motor 174
2 4 6 Supervision during the first motor running period 175
2 5 Flexible coupling 176
2 5 1 Check motor rotation direction 179
2 5 2 Coupling handling 179
2 5 3 Coupling inspection 180
2 5 4 Coupling replacement 181
2 6 Pump distributor gearbox (PTO) 182
2 6 1 Spline shaft housing 184
2 6 2 PTO lubrication and cooling 186
2 6 3 PTO valve adjustments 188
2 6 4 Temperature relay 192
3 HYDRAULIC OIL RESERVOIR 195
3 1 Hydraulic oil reservoir 196
3 2 Return and leak oil filter 200
3 3 Breather Filter 204
3 4 Location of electrical components 206
3 5 Transfer pump, hydraulic service 208
3 5 1 Evacuation of the suction oil reservoir 211
3 5 2 Evacuation of the return oil collector pipes and cooler circuit 213
4 HYDRAULIC OIL COOLING 215
4 1 General 216
4 2 Hydraulic oil cooling circuit 218
4 3 Back pressure valve adjustment 222
4 4 Fan drive 224
4 4 1 Fan pump 226
4 4 2 Pressure relieve valve 228
4 4 3 Temperature relay 230
4 5 Cooler fan drive adjustment 232
5 CONTROLLING 235
5 1 General Layout 236
5 1 1 Pilot control 238
5 2 Control and filter panel 240
5 3 Pilot oil gear pump 244
5 4 Pilot pressure supply and adjustment 246
5 4 1 Pilot pressure adjustment 248
5 4 2 Check of pilot pressure 250
6 COMPONENTS 253
6 1 Main control block and valve arrangement 254
6 1 1 FSA arrangement 256
6 1 2 BHA arrangement 260
6 2 Distributor manifold 264
6 2 1 Front shovel attachment FSA 264
6 2 2 Back hoe attachment BHA 266
6 2 3 SRV with throttle check valve 268
6 2 4 Anti cavitation valve (check valve) 270
6 3 SINGLE CONTROL BLOCKS (FLOATING) FOR STICK AND BOOM (FSA) 272
6 4 Main control block 274
6 4 1 Load holding valve 282
6 4 2 High pressure filter 284
6 4 3 Pressure relieve valves and anti-cavitation valve 286
6 4 4 Pressure relieve valves and anti-cavitation valve 288
6 5 4/2 Directional valves 290
6 6 Travel brake valve 292
6 7 Pressure double stage valve 294
6 8 Hydraulic cylinder 296
6 9 Swing ring 300
7 MAIN HYDRAULIC PUMPS AND PUMP REGULATION 303
7 1 General 304
7 1 1 Pump location 306
7 2 Main pump operating principles 308
7 2 1 Main pump operating principals 308
7 2 2 Main pump function 313
7 3 Main pump checks and adjustments 316
7 3 1 Power check 316
7 3 2 Cut off function 319
7 3 3 Swing pump volume reduction 321
7 4 Electronic pump regulation 322
7 4 1 General 322
7 4 2 Signal rectifier module (ESR) 324
7 5 Pump controller CR700 328
7 6 Multi Monitor 330
7 7 Multimonitor software instruction 332
7 7 1 Multimonitor main control 332
7 7 2 Service Menu screen 332
7 7 3 Monitoring (menu item 01) 333
7 7 4 Abnormality Record (menu item 02) 334
7 7 5 Default (menu item 03) 337
7 7 6 Adjustment (menu item 04) 338
7 7 7 Display Setup (menu item 05) 340
7 7 8 Table of fault messages and adjustments 341
7 8 Trouble shooting pump and pump regulation 350
8 OPERATING HYDRAULIC 351
8 1 General layout 352
8 2 Floating function of boom and stick (only FSA) 354
8 3 Check and Adjustments for MRV and SRV 356
8 3 1 Check and Adjustments for MRV 357
8 3 2 Check and Adjustment for SRV 360
8 3 3 Check and Adjustment for SRV’s of FSA attachment 364
8 3 4 Check and Adjustment for SRV’s of BHA attachment 366
8 3 5 Check and adjustment of the throttle check valves 368
8 4 Hydraulic for the swing circuit 370
8 4 1 Swing motor 372
8 4 2 Swing gearbox (L&S) 376
8 4 3 Swing gearbox (Siebenhaar) 378
8 4 4 Swing parking brake (L&S) 382
8 4 5 Swing parking brake (Siebenhaar) 384
8 4 6 Swing service brake valve 386
8 4 7 Checks and adjustments for the swing circuit 390
8 4 8 Function check of swing parking brake 394
8 5 Hydraulics for the travel circuit 396
8 5 1 Travel circuit 396
8 5 2 Rotary joint 398
8 5 3 Travel motor A2FMt 402
8 5 4 Travel gearbox 406
8 5 5 Travel parking brake 408
8 5 6 Check and Adjustment for the travel circuit 410
8 5 7 Function check for the travel parking brake 412
9 TRACK TENSION SYSTEM 415
9 1 General layout 416
9 2 Functional description 418
9 2 1 Cushioning 420
9 2 2 Double stage valve 422
9 3 Checks and adjustments 426
10 ACCESS LADDER HYDRAULICALLY OPERATED 429
10 1 Access ladder 430
10 2 Access ladder functional description 432
11 HINTS FOR READING THE HYDRAULIC CIRCUIT DIAGRAM 437
11 1 General 438
11 2 Symbolic 440
11 2 1 Lines, unions 441
11 2 2 Components, valves 443
11 2 3 Sensors 443
11 2 4 Valves, valve components 444
11 2 5 Pump, motor, cylinder 448
12 HINTS FOR READING THE ELECTRIC CIRCUIT DIAGRAM 453
12 1 Designation of electrical components 455
12 2 Electric symbols 456
12 3 Symbols 458
12 3 1 Drawing concept 460
12 3 2 Reading of the circuit diagram 466
13 ELECTRONIC TEXT MONITORING SYSTEM ETM 471
13 1 Introduction 472
14 AUTOMATIC LUBRICATION SYSTEM 475
14 1 General Function 476
14 1 1 Central lubrication system (CLS) 478
14 1 2 Swing ring lubrication system (SLS) 480
14 2 Lubrication cycle 482
14 3 Hydraulically driven lubrication pump 490
14 3 1 Function of the pump 492
14 3 2 Adjustment of lubricating pump speed & working pressure 494
14 4 Lubricant Injector (metering valve) 498
14 4 1 Tightening torques for fittings at grease injectors 499
14 4 2 Injector type description 501
14 4 3 Adjustment of the lubricant output 501
14 4 4 Connection of one or more injectors 502
14 4 5 Operation principle of lubricant injectors 504
14 5 Vent valve 508
14 6 End-line pressure switch 510
14 6 1 End-line switch adjustment 512
14 7 Lubricant in-line filter 514
14 8 Adjustment of the lubrication intervals 516
14 8 1 Timing adjustment 517
14 9 Commissioning 518
14 9 1 Commissioning of the CLS lubrication system 518
14 9 2 Fine adjustment 519
14 9 3 Commissioning of the SLS lubrication system 520
40 TROUBLE SHOOTING 523
TABLE OF CONTENTS 525
INTRODUCTION 529
Introduction & general information for troubleshooting 530
Description of this troubleshooting manual 530
Precautions when carrying out any operation 533
Fundamental requirements for troubleshooting 534
Points to remember when troubleshooting 535
Sequence of events in troubleshooting 538
Checks before troubleshooting 539
Handling of electric equipment and hydraulic components 540
General working procedures 544
Information on the ETM Versions and the Electronic Pump Controller CR700 548
service level password 550
ELECTRICAL PARTS 553
Mounting locations of electrical parts, connector types and electrical standard values 554
Component locations 554
Location of electrical parts Capacitor / electric motor 556
Location of electrical parts on PTO, Suction Oil Reservoir and Central Control and Filter Panel 558
Location of electrical parts on Pilot Control Frame 560
Location of electrical parts on Main Hydraulic Oil Reservoir 562
Location of electrical parts on Switch Board X2 in Cab Base 564
Location of electrical parts of the hydraulically operated Access Ladder 566
Location of electrical parts of the automatic Lubrication Systems 568
Overview connector types and connector pin numbers 572
Standard value table for electrical components 575
PT100 temperature charts 583
TROUBLESHOOTING BY TROUBLE CODE 585
Message -1- Gear lubrication out of function (B17) 586
Message -2- Motor shutdown: Fire suppression system actuated 589
Message -3- Oil filter for control oil restricted (B22) 593
Message -4- Oil tank breather filter restricted (B24) 596
Message -5- Return oil filter restricted (B26) 599
Message -6- Leak oil filter restricted (B25) 602
Message -7- Hydraulic oil temperature too high (B15) 605
Message -8- (Not used) 611
Message -9- Main transformer temperature too high (1K4) 611
Message -10- Low voltage monitoring actuated 615
Message -11- (Not used) 619
Message -12- (Not used) 619
Message -13- (Not used) 619
Message -14- Motor-shutdown: Too low hydraulic oil level! (B4) 620
Message -15- Caution, slew gear house brake ON 624
Message -16- Caution, travel gear house brake ON 629
Message -17- No clearance for starting, wrong direction of motor rotation 634
Message -18- Central lubrication system fault 637
Message -19- Slew ring gear lubrication system fault 644
Message -20- Motor shutdown: Motor protection relay released (1K2) 652
Message -21- Central lubrication system, empty grease barrel 656
Message -22- Slew ring gear lubrication system, empty grease barrel 656
Message -23- Motor shutdown: Motor bearing temperature too high (1K14) 662
Message -24- Caution, Insulation monitoring actuated (1K10) 667
Message -25- No clearance for starting by motor protection relay (1K3) 670
Message -26- Attention! Overheating protection of cab heating has triggered 673
Message -27- (Not used) 677
Message -28- (Not used) 677
Message -29- (Not used) 677
Message -30- (Not used) 677
Message -31- (Not used) 677
Message -32- PTO-gear lubrication filter restricted (B27) 677
Message -33- Cooler fan drive filter restricted (B28) 680
Message -34- (Not used) 683
Message -35- (Not used) 683
Message -36- (Not used) 683
Message -37- (Not used) 683
Message -38- (Not used) 683
Message -39- Motor-shutdown: Shut-Off (gate) valve S31 closed 684
Message -40- Caution, switch-cabinet temperature too high (6B1, 6B2) 688
Message -41- Motor shutdown: Engine temperature too high (1K6) 692
Message -42- (Not used) 697
Message -43- Motor-shutdown: Emergency stop switch actuated 697
Message -44- Motor-shutdown: Safety switch actuated (1K58) 701
Message -45- Motor-shutdown: Capacitor failed (1K12) 705
Message -46- (Not used) 709
Message -47- (Not used) 709
Message -48- Too high PTO-gear oil temperature (B49) 709
Message -50- Caution, pull switch from ground man actuated 712
Message -51- Motor shutdown: pull switch from ground man actuated 713
Message -52- Load limiting clam defective 715
Message -53- Pressure switch of the central lubrication system actuated (B43) 718
Message -54- Pressure switch of the slew ring gear lubrication system actuated (B46) 718
Message -55- Refill hydraulic oil 719
Message -56- Pilot control cut out 723
Message -57- Pump regulation faulty 727
Message -58- Strainer oil cooler restricted (B165) 727
Message -59- Central lubrication system, refill grease barrel 729
Message -60- Slew ring gear lubrication system, refill grease barrel 729
TROUBLESHOOTING BY SYMPTOMS 735
Symptoms of the electric motor and related electrical system 736
SEM001 – Motor does not start 736
SEM002 – Motor does not stop 740
SEM003 – Excessive motor vibration 742
SEM004 – Abnormal noise from motor 743
SEM005 – Motor lacks output (low power) 744
SEM006 – Air to Air cooling system not sufficient 745
SEM007 – Motor shuts down during start 746
SEM008 – Sub Station main circuit breaker trips 748
Symptoms of the hydraulic system 750
SHY001 – All the work equipment shows lack of power or slow movement (especially the BOOM UP function) 750
SHY002 – No work equipment, travel or swing movement 752
SHY003 – Work equipment has too much hydraulic drift 753
SHY004 – Work equipment has big time lag 754
SHY005 – Machine deviates during travel movement 755
SHY006 – Machine does not swing 756
SHY007 – Swing acceleration is poor 757
SHY008 – Excessive overrun when stopping swing 759
SHY009 – Floating system without function 761
SHY010 – Abnormal noise coming from SRV or MRV 762
SHY011 – Track tensioning system without function 763
SHY012 – Ladder does not move, or slow movement 764
SHY013 – The hydraulic driven grease pump does not move 766
SHY014 – Abnormal track chain movement during digging 767
SHY015 – Swing parking brake without function 768
SHY016 – Travel parking Brake without function 769
Symptoms of the mechanical system 770
SME001 – Abnormal noise around the PTO / hydraulic pumps 770
SME002 – There is a big shock when stopping swing 772
SME003 – There is a big abnormal noise when moving/stopping swing 773
SME004 – Abnormal noise coming from a travel gearbox 775
SME005 – Abnormal noise coming from the work equipment (lack of grease) 777
SME006 – Abnormal idler movement 779
SME007 – Leak at the PTO shaft seal 780
Symptoms of additional systems 782
SAD001 – Air conditioner does not work 782
SAD002 – Air conditioner HV / LV cabinet does not work 784
50 DISASSEMBLY & ASSEMBLY 787
Table of contents 789
1 SAFETY 799
1 1 SAFETY INFORMATION 803
1 2 OVERVIEW 804
1 2 1 NORMAL OPERATIONS 804
1 2 2 REGULAR MAINTENANCE 804
1 2 3 TROUBLESHOOTING, ADJUSTMENTS AND REPAIR 804
1 2 4 ADDITIONAL SAFETY PRECAUTIONS FOR ASSEMBLING, DISASSEMBLING AND TRANSPORTATION OF THE EXCAVATOR 804
1 3 SOUND PRESSURE LEVEL IN THE OPERATOR’S CAB 805
1 4 GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR 806
1 4 1 UNDERSTANDING THE MACHINE 806
1 4 2 PRECAUTIONS BEFORE STARTING OPERATION ON THE EXCAVATOR 806
1 4 2 1 ENSURING SAFE OPERATION 806
1 4 3 PREPARATIONS FOR SAFE OPERATION 806
1 4 3 1 PRECAUTIONS REGARDING SAFETY RELATED EQUIPMENT 806
1 4 3 2 INSPECTING THE MACHINE 806
1 4 3 3 WEAR WELL FITTING CLOTHES AND PROTECTIVE EQUIPMENT 807
1 4 3 4 KEEP MACHINE CLEAN 807
1 4 3 5 PRECAUTIONS INSIDE OPERATOR’S COMPARTMENT 807
1 4 3 6 PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT 808
1 4 3 7 IF A PROBLEM IS FOUND 808
1 4 4 FIRE PREVENTION 808
1 4 4 1 PRECAUTIONS TO PREVENT FIRE 808
1 4 4 2 ACTION IF FIRE OCCURS 809
1 4 4 3 EMERGENCY EXIT FROM OPERATOR’S CAB 810
1 4 5 PRECAUTIONS WHEN GETTING ON OR OFF THE MACHINE 810
1 4 5 1 USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF THE MACHINE 810
1 4 5 2 NO JUMPING ON OR OFF THE MACHINE 810
1 4 5 3 NO PEOPLE ON THE ATTACHMENT 810
1 4 5 4 WORKING IN HIGH PLACES 810
1 4 5 5 LEAVING OPERATOR’S SEAT WITH LOCK 811
1 4 5 6 LEAVING THE MACHINE 811
1 4 6 BURN PREVENTION 812
1 4 6 1 Hot coolant 812
1 4 6 2 Hot oil 812
1 4 7 PRECAUTIONS WHEN CLEANING CAB GLASS 812
1 4 8 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES 813
1 4 8 1 UNAUTHORIZED MODIFICATION 813
1 4 8 2 PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS 813
1 4 9 PRECAUTIONS AT JOBSITE 814
1 4 9 1 VISIBILITY FROM OPERATOR’S SEAT 815
1 4 9 2 CAMERA SYSTEM WITH MONITORS 815
1 4 9 3 ENSURE GOOD VISIBILITY 815
1 4 9 4 CHECKING SIGNS AND SIGNALMAN’S SIGNALS 815
1 4 9 5 INVESTIGATE AND CONFIRM JOBSITE CONDITIONS 816
1 4 9 6 DO NOT GO CLOSE TO HIGH VOLTAGE CABLES 816
1 4 9 7 WORKING ON LOOSE GROUND 817
1 4 9 8 GAS, DUST, STEAM AND SMOKE 817
1 4 9 9 VENTILATION OF ENCLOSED AREAS 818
1 4 10 STARTING ENGINE 819
1 4 10 1 WARNING TAG 819
1 4 10 2 CHECKS BEFORE STARTING ENGINE 819
1 4 10 3 PRECAUTION WHEN STARTING ENGINE 819
1 4 10 4 PRECAUTION IN COLD AREAS 820
1 4 11 OPERATION 820
1 4 11 1 CHECKS BEFORE OPERATION 820
1 4 11 2 PRECAUTIONS WHEN TRAVELLING IN FORWARD OR REVERSE 821
1 4 11 3 PRECAUTIONS WHEN travelling 822
1 4 11 4 TRAVELLING ON SLOPES 823
1 4 11 5 OPERATIONS ON SLOPES 824
1 4 11 6 PROHIBITED OPERATIONS 824
1 4 11 7 TRAVELLING ON FROZEN OR SNOW COVERED SURFACES 825
1 4 11 8 PARKING THE MACHINE 825
1 4 11 9 TRANSPORTATION 825
1 5 PRECAUTION FOR MAINTENANCE 826
1 5 1 GENERAL PRECAUTIONS 826
1 5 1 1 SELECTION AND QUALIFICATION OF PERSONNEL – BASIC RESPONSIBILITIES 827
1 5 1 2 STOP ENGINE FOR MAINTENANCE 828
1 5 1 3 WARNING TAG 829
1 5 1 4 KEEP WORKPLACE CLEAN AND TIDY 830
1 5 1 5 APPOINT LEADER WHEN WORKING WITH OTHERS 830
1 5 1 6 TWO WORKERS FOR MAINTENANCE WHEN THE MACHINE IS RUNNING 831
1 5 1 7 INSTALLING, REMOVING OR STORING ATTACHMENTS 831
1 5 1 8 PRECAUTIONS WHEN WORKING UNDER THE MACHINE OR EQUIPMENT 832
1 5 1 9 NOISE 832
1 5 1 10 WHEN USING A HAMMER 832
1 5 1 11 PROPER TOOLS 833
1 5 1 12 ACCUMULATOR 833
1 5 1 13 PERSONNEL 833
1 5 2 PRECAUTIONS FOR INSPECTION AND MAINTENANCE 834
1 5 2 1 PRECAUTION WHEN WELDING 834
1 5 2 2 BATTERY HANDLING 834
1 5 3 PRECAUTIONS WITH HIGH PRESSURE Fluid 835
1 5 3 1 PRECAUTIONS WITH HIGH FUEL PRESSURE 835
1 5 3 2 HANDLING HIGH PRESSURES HOSES OR PIPES 836
1 5 3 3 REPLACEMENT OF HOSE LINES 836
1 5 3 4 INSPECTION OF HOSE LINES 836
1 5 3 5 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS 837
1 5 3 6 PRECAUTIONS FOR HIGH VOLTAGE 837
1 5 3 7 AIR CONDITIONING MAINTENANCE 837
1 5 3 8 COMPRESSED AIR 838
1 5 3 9 WASTE MATERIALS 838
1 6 ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS 839
1 6 1 INSPECTION OF THE HYDRAULIC SYSTEM 839
1 6 2 TWO WORKERS ONLY WHEN THE MACHINE IS RUNNING DURING ADJUSTMENTS 839
1 6 3 AREAS OF POTENTIAL DANGER AROUND THE EXCAVATOR 839
1 7 SPECIAL SAFETY EQUIPMENT 840
1 7 1 FRONT GUARD PROTECTIVE STRUCTUR ’FOPS’ FOR OPERATOR’S CAB 841
1 7 2 OBJECT HANDLING 841
1 7 3 LIGHTING 841
1 7 4 WARNING BEACON 841
1 7 5 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD) 841
1 7 5 1 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD) 841
1 7 5 2 INSTRUCTIONS FOR USE 843
1 7 5 3 PRIOR TO USING THE HARNESS (1), THE WEARER SHALL 845
1 7 5 4 RECOMMENDATIONS FOR USE OF THE HOLDING HOOKS AND HOLD-BACK HOOKS OF THE SAFETY HARNESS (1), 845
1 7 5 5 INSTRUCTIONS FOR USE 847
2 Superstructure 849
2 1 Superstructure overview 850
2 2 Electric motors 852
2 2 1 Removal of the electric motor 852
2 2 2 Replacement of the electric motor 857
2 2 3 Final alignment of the electric motors 860
2 2 4 Capacitor assembly 864
2 2 4 1 Removal of the capacitor assembly 864
2 2 4 2 Replacement of the capacitor assembly 866
2 3 Batteries 867
2 3 1 Removal of the batteries 867
2 3 2 Replacement of the batteries 869
2 4 Torsion Coupling 870
2 4 1 Reich coupling 870
2 4 1 1 Removal of the Reich coupling 871
2 4 1 2 Replacement of the Reich coupling 874
2 5 PTO 876
2 5 1 Main pumps 876
2 5 1 1 Preparatory works for main pump removal 877
2 5 1 2 Removal of main pump 1 881
2 5 1 3 Replacement of main pump 1 883
2 5 1 4 Removal of main pump 2 884
2 5 1 5 Replacement of main pump 2 887
2 5 1 6 Removal of main pump 3 888
2 5 1 7 Replacement of main pump 3 891
2 5 2 PTO oil circulation pump (auxiliary pump) 892
2 5 2 1 Removal of the PTO oil circulation pump 892
2 5 2 2 Replacement of the PTO oil circulation pump 893
2 5 3 Pump distributor gear box (PTO) 894
2 5 3 1 Preparatory work for PTO removal 894
2 5 3 2 Removal of the pump distributor gear box (PTO) 895
2 5 3 3 Replacement of the pump distributor gear box (PTO) 897
2 6 Hydraulics 898
2 6 1 Hydraulic cooler fan drive pump 898
2 6 1 1 Removal of hydraulic cooler fan drive pump 898
2 6 1 2 Replacement of hydraulic cooler fan drive pump 901
2 6 2 Hydraulic oil cooler assembly 902
2 6 2 1 Removal of the hydraulic cooler fan assembly 905
2 6 2 2 Replacement of the hydraulic cooler fan assembly 907
2 6 2 3 Removal of hydraulic cooler fan and motor 908
2 6 2 4 Replacement of hydraulic cooler fan and motor 910
2 6 2 5 Removal of the hydraulic oil coolers 913
2 6 2 6 Replacement of the hydraulic oil coolers 916
2 6 2 7 Removal of the hydraulic oil cooler Assembly 919
2 6 2 8 Replacement of the hydraulic oil cooler Assembly 924
2 6 3 Pilot oil pump (Gear pump) 925
2 6 3 1 Removal of the pilot oil pump 926
2 6 3 2 Replacement of the pilot oil pump 928
2 6 4 Main gate valve 929
2 6 4 1 Removal of the main gate valve 929
2 6 4 2 Replacement of the main gate valve 931
2 6 5 Hydraulic oil reservoir 932
2 6 5 1 Removal of the hydraulic oil reservoir 933
2 6 5 2 Replacement of the hydraulic oil reservoir 939
2 6 6 Main control valve blocks 940
2 6 6 1 General information 940
2 6 6 2 Removal of the main control valve blocks 950
2 6 6 3 Replacement of the main control valve blocks 955
2 6 7 Main relief valves (MRV) 956
2 6 7 1 Removal of the MRV at the main control valve blocks 956
2 6 7 2 Replacement of the MRV at the main control valve blocks 957
2 6 8 Service line relief valves (SRV) 958
2 6 8 1 Removal of SRV on the main control valve blocks 958
2 6 8 2 Replacement of SRV on the main control valve blocks 960
2 6 9 Anti-cavitation valves (ACV) 961
2 6 9 1 Removal of ACV on manifold 962
2 6 9 2 Replacement of ACV on manifold 964
2 6 9 3 Removal of ACV on main control valve blocks 965
2 6 9 4 Replacement of ACV on main control valve blocks 967
2 6 10 Throttle check valves 968
2 6 10 1 Removal of throttle check valves 969
2 6 10 2 Replacement of throttle check valves 972
2 6 10 3 Removal of the diffuser on the manifold (FSA only) 973
2 6 10 4 Replacement of the diffuser on the manifolD (FSA Only) 975
2 6 11 Manifold 976
2 6 11 1 Layout 976
2 6 11 2 Removal of the manifold 978
2 6 11 3 Replacement of the manifold 980
2 7 Slew drive 981
2 7 1 Slew gear box 982
2 7 1 1 Removal of the slew gear box 983
2 7 1 2 Replacement of the slew gear box 986
2 7 2 Swing motor 988
2 7 2 1 Removal of the swing motor 989
2 7 2 2 Replacement of the swing motor 992
2 7 3 Slew parking brake 994
2 7 3 1 Removal/disassembly of the slew parking brake (L&S) 995
2 7 3 2 Replacement/assembly of the slew parking brake (L&S) 998
2 7 3 3 Removal of the slew parking brake (siebenhaar) 1001
2 7 3 4 Replacement of the slew parking brake (Siebenhaar) 1004
2 7 4 Dynamic slew brake 1008
2 7 4 1 Removal of the slew service brake valve 1011
2 7 4 2 Replacement of the slew service brake valve 1013
2 7 5 Swing circle lubrication pinion 1014
2 7 5 1 Removal of the lubrication pinion assembly 1015
2 7 5 2 Replacement of the lubrication pinion assembly 1017
2 7 6 Swing circle 1018
2 7 6 1 Removal of the swing circle 1019
2 7 6 2 Replacement of the swing circle 1022
2 8 Lubrication pumps 1026
2 8 1 Removal of the lubrication pump 1026
2 8 2 Replacement of the lubricating pump 1027
2 9 Operator’s cab 1028
2 9 1 Removal of the operator’s cab 1029
2 9 2 Replacement of the operator’s cab 1034
2 9 3 Cab mounts 1035
2 9 3 1 Removal of the cab mounts 1035
2 9 3 2 Replacement of the cab mounts 1036
2 9 4 Front window 1037
2 9 4 1 Removal of the front window 1037
2 9 4 2 Replacement of the front window 1038
2 9 5 Operator’s seat 1039
2 9 5 1 Removal of the operator’s seat 1039
2 9 5 2 Replacement of the operator’s seat 1040
2 9 6 ETM 1041
2 9 6 1 Removal of the ETM 1041
2 9 6 2 Replacement of the ETM 1041
2 10 Cab base (MEDIUM VOLTAGE SWITCH CABINET) 1042
2 10 1 Removal of the cab base 1042
2 10 2 Replacement of the cab base 1044
2 10 3 Pump controller 1046
2 10 3 1 Removal of the pump controller CR700 1046
2 10 3 2 Replacement of the pump controller CR700 1047
2 11 Access Ladder 1048
2 11 1 Removal of access ladder 1049
2 11 2 Replacement of access ladder 1051
2 11 3 Removal of access ladder cylinder 1052
2 11 4 Replacement of access ladder cylinder 1054
2 12 Counterweight 1055
2 12 1 Removal of the counterweight 1058
2 12 2 Replacement of the counterweight 1060
2 13 Superstructure lifting 1061
2 13 1 Remove the superstructure from the undercarriage 1061
2 13 2 Install the superstructure onto the undercarriage 1064
2 14 High voltage switch cabinet 1066
2 14 1 Removal of the High voltage switch cabinet 1067
2 14 2 Replacement of the high voltage switch cabinet 1070
2 15 Slip ring unit 1071
2 15 1 Removal of the slip ring unit 1072
2 15 2 Replacement of the slip ring unit 1074
3 Undercarriage 1075
3 1 Undercarriage overview 1076
3 2 Travel System 1078
3 2 1 Track group 1078
3 2 1 1 changing the track group 1078
3 2 2 Sprocket 1083
3 2 2 1 Removal of the sprocket 1083
3 2 2 2 Replacement of the sprocket 1086
3 2 3 Guide wheels (Idlers) 1088
3 2 3 1 Removal of the guide wheel assembly 1088
3 2 3 2 Replacement of the guide wheel assembly 1090
3 2 4 Track tensioning accumulators 1092
3 2 4 1 Removal of the low pressure accumulators 1092
3 2 4 2 Replacement of the low pressure accumulators 1094
3 2 4 3 Removal of the high pressure accumulators 1095
3 2 4 4 Replacement of the high pressure accumulators 1096
3 2 5 Track tension valve block 1097
3 2 5 1 Removal of the track tensioning valve block 1097
3 2 5 2 Replacement of the track tensioning valve block 1099
3 2 6 Track tensioning cylinders 1100
3 2 6 1 Removal of the track tensioning cylinders 1100
3 2 6 2 Replacement of the track tensioning cylinders 1102
3 2 7 Substitute the Hydraulic hoses of the track tensioning system 1103
3 2 7 1 Precursory work 1103
3 2 7 2 Substitute the hydraulic hoses inside the car body 1105
3 2 7 3 Substitute the hydraulic hose between car body and crawler frame 1105
3 2 7 4 Substitute the hydraulic hoses inside the crawler frame 1107
3 2 7 5 Subsequent work 1108
3 2 8 Travel brake valve block (overspeed valve) 1109
3 2 8 1 Removal of the travel brake valve block 1112
3 2 8 2 Replacement of the travel brake valve block 1113
3 2 9 Travel motor 1114
3 2 9 1 Removal of the travel motors 1114
3 2 9 2 Replacement of the travel motors 1116
3 2 10 Travel parking brake 1118
3 2 10 1 Removal of the travel parking brake 1119
3 2 10 2 Replacement of the travel parking brake 1121
3 2 11 Travel gear box 1122
3 2 11 1 Removal of the travel gear box 1123
3 2 11 2 Replacement of the travel gear box 1127
3 2 12 Carrier roller 1130
3 2 12 1 Removal of the carrier roller assembly 1130
3 2 12 2 Replacement of the carrier roller assembly 1132
3 2 13 Track roller 1133
3 2 13 1 Removal of the track roller assembly 1133
3 2 13 2 Replacement of the track roller assembly 1135
3 3 Car body 1136
3 3 1 Removal of the car body and the crawler carriers 1136
3 3 2 Replacement of the car body and the crawler carriers 1142
3 3 2 1 Tightening torque for the crawler carrier mounting bolts 1148
3 3 3 Rotary joint 1150
3 3 3 1 Removal of the rotary joint 1150
3 3 3 2 Replacement of the rotary joint 1152
3 4 Cable supply 1154
3 4 1 Removal of the cable supply 1154
3 4 2 Replacement of the cable supply assembly 1156
4 Attachment 1159
4 1 Backhoe 1160
4 1 1 Boom 1162
4 1 1 1 Removal of the boom 1162
4 1 1 2 Replacement of the boom 1165
4 1 1 3 Removal of boom cylinders 1168
4 1 1 4 Replacement of boom cylinders 1173
4 1 2 Stick 1178
4 1 2 1 Removal of the stick 1178
4 1 2 2 Replacement of stick 1182
4 1 2 3 Removal of stick cylinders 1184
4 1 2 4 Replacement of stick cylinders 1189
4 1 3 Bucket 1192
4 1 3 1 Removal of the bucket 1192
4 1 3 2 Replacement of the bucket 1195
4 1 3 3 Removal of bucket cylinders 1196
4 1 3 4 Replacement of bucket cylinders 1202
4 1 4 Bucket link rod and steering rods 1205
4 1 4 1 Removal of the bucket link rod 1205
4 1 4 2 Replacement of the bucket link rod 1207
4 1 4 3 Removal of the steering rods 1208
4 1 4 4 Replacement of the steering rod 1211
4 1 5 Ground engaging tools (GET) 1212
4 1 5 1 Removal and replacement of the GET 1212
4 1 6 Hydraulic hoses at the backhoe attachment 1214
4 1 6 1 Substitute the boom arc hoses 1214
4 1 6 2 Substitute the boom cylinder hoses 1218
4 1 6 3 Substitute the stick cylinder hoses 1222
4 1 6 4 Substitute the bucket cylinder hoses 1226
4 2 Face shovel 1230
4 2 1 Using the installation tools for hydraulic cylinders 1231
4 2 2 Boom 1232
4 2 2 1 Removal of the boom 1232
4 2 2 2 Replacement of the boom 1239
4 2 2 3 Removal of the boom cylinders 1244
4 2 2 4 Replacement of the boom cylinders 1248
4 2 3 Stick 1252
4 2 3 1 Removal of the stick 1252
4 2 3 2 Replacement of the stick 1256
4 2 3 3 Removal of the stick cylinders 1260
4 2 3 4 Replacement of the stick cylinders 1264
4 2 4 Bull clam bucket 1268
4 2 4 1 Removal of the bull clam bucket 1268
4 2 4 2 Replacement of the bull clam bucket 1274
4 2 4 3 Removal of the bucket cylinders 1276
4 2 4 4 Replacement of the bucket cylinders 1280
4 2 4 5 Removal of the clam cylinders 1284
4 2 4 6 Replacement of the clam cylinders 1288
4 2 5 Ground engaging tools (GET) 1291
4 2 5 1 Removal and replacement of the GET 1291
4 2 6 Hydraulic hoses at the face shovel attachment 1292
4 2 6 1 Substitute the boom arc hoses 1292
4 2 6 2 Substitute the boom cylinder hoses 1296
4 2 6 3 Substitute the stick arc hoses 1300
4 2 6 4 Substitute the stick cylinder hoses 1304
4 2 6 5 Substitute the bucket cylinder hoses 1308
4 2 6 6 Substitute the clam cylinder hoses 1312
4 3 Metering valves (grease injectors) at the attachment 1320
4 3 1 Operation test of the metering valves (grease injectors) 1321
4 3 2 Removal of the metering valves (grease injectors) 1322
4 3 3 Replacement of the metering valves (grease injectors) 1324
4 4 Cylinder bypass test 1325
5 Service Information 1327
5 1 Fluids and lubricants 1328
5 2 Filling capacities 1329
5 3 Work instructions 1330
5 3 1 Surface coating with INTERZINC 697 1330
5 3 2 Remove / install the crawler carrier 1332
5 4 Weight tables 1333
5 4 1 Superstructure 1333
5 4 2 Undercarriage 1335
5 4 3 Backhoe attachment (BHA) 1336
5 4 4 Face shovel attachment (FSA) 1337
5 5 Torque charts according to KOMATSU company standard 1338
5 5 1 Metric standard thread 1338
5 5 2 Metric fine thread 1339
5 5 3 Cummins motor torques – metric 1340
5 5 4 Cummins motor torques – U S customary 1340
5 5 5 Flange connections 1341
5 6 Blind plugs 1342
5 6 1 Dummy plates for SAE-flanges 1342
5 6 2 Classification of threads to the nominal width 1344
5 6 3 Plugs and fittings according to DIN 2353 1345
5 7 Conversation table 1346
5 7 1 Method of using the conversation table 1346
5 7 2 Millimeter – inch & kilogram – pound 1347
5 7 3 Liter – U S gallon & liter – U K gallon 1348
5 7 4 Nm- ft lb 1349
5 7 5 Bar – PSI – kPa – MPa 1350
5 7 6 Basic values in Ohm according to ISO 43 76 1351
5 7 7 Temperature 1352
5 8 Tools 1353
5 8 1 Standard tool case 1353
5 8 2 Used special tools (Overview) 1355
6 Tools catalogue 1357
7 Parts & Service News 1409
7 1 List of The PARTS AND SERVICE NEWS 1410
8 Supplier’s documentation 1759
AVANTI HYTORQUE 1760
VIDEO PREVIEW OF THE MANUAL:
PLEASE NOTE:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
I.G