Komatsu PC3000-6 Manuals

Manuals and User Guides for Komatsu PC3000-6. We have 3 Komatsu PC3000-6 manuals available for free PDF download: Operation & Maintenance Manual, Assembly Procedure

Komatsu PC3000-6 Operation & Maintenance Manual (447 pages)

HYDRAULIC MINING SHOVEL

Brand: Komatsu | Category: Construction Equipment | Size: 8.88 MB

Introduction
3
Contents of the Binder
4
Division of the Binder
5
Designated Use of the Shovel
6
Delivery of the Shovel
7
Explanation of Abbreviations
8
Table of Contents
9
Safety
15
Safety Instructions
16
Warnings and Symbols
16
Basic Operation and Designated Use of the Hydraulic Shovel
16
Organizational Measures
17
Selection and Qualification of Personnel - Basic Responsibilities
19
Safety Instructions Governing Specific Operational Phases
20
Warning of Special Dangers
23
Transporting and Towing -Recommissioning
25
Special Safety Equipment
25
Safety Harness in Conformity with en 361 (European Standard)
29
Operation
37
Foreword
38
Construction of the Shovel
39
Overall View
39
Undercarriage and Superstructure
40
Hydraulically Operated Access Ladder
46
Emergency Escape Ladder
50
Emergency Escape Ladder and Escape Hatch in the Machinery House (Special Equipment)
52
(Special Equipment)
52
Emergency Engine Shutdown from Ground man or Operator Warning System
54
System
54
Operator's Cab with Integrated Falling Object Protective Structure (Fops)
56
Engine Oil Management System
64
Operator's Cab - Controls
72
Controls with Backhoe Attachment
72
Controls with Bottom Dump Bucket
76
Operator's Console
81
Electronic Text Monitoring System Etm
88
Introduction
89
System Components
93
Functions of the Etm System
95
Display the Contents of the Record (Protocol) Memory
99
Several Message Conditions Occur at the same Time
111
Settings of the Text Display Unit
113
Operating the Heater, Ventilation and Air Conditioning
128
Control Module for Auxiliary Cab Heater (if so Equipped)
133
Auxiliary Heater for Operators Cab (if so Equipped)
135
Auxilliary Heater for Operators Cab (if so Equipped)
137
Fuel Pump Arrangement
139
Machinery House
140
Emergency Engine Shutdown Switches
141
Electrical Equipment in Cab Base
142
Switch Box (X2) in Cab Base
147
Components of Electrical Preheating System in Cab Base
151
Preheating Systems
156
For Oil, Coolant and Batteries
156
Heaters for Machinery House (Special Equipment)
162
Checks before Starting the Engine
164
Starting the Engine
170
Starting Procedure
171
Starting Procedure at Ambient Temperature up to -25
173
Moving the Shovel
182
Travel Control with Foot Pedals
182
Travelling Instructions
185
Slewing and Braking the Superstructure
186
Slewing the Superstructure
186
Working with the Attachment
189
Machines Equipped With"Euro" Control System
189
Machines Equipped With"Kmg" Control System
190
Bottom Dump Bucket
191
Drop Ball Operation
192
Combined Operation Cycles
195
Working Instructions
197
Stability of the Shovel
197
Shovel Operation
197
Parking the Shovel
200
Stopping the Engine
202
Relieve Pressure in the Hydraulic System
205
Automatic Lubrication Systems
206
Operation of the Automatic Lubrication Systems
207
Fire Detection and Suppression System
210
High Level Alarm "Fire
213
Engine Shut-Down through Fuel Shut-Off Solenoid Valve
213
Actuation Modes of the Fire Suppression System
213
Indication of Operational Modes at Control Module, after Automatic Actuation of the Fire Suppression System
215
Location of the Extinguishing Agent Tank Assemblies and Expellant Gas Cartridges on Power House Roof
217
Central Refilling System
218
Systems Connected to the Refilling System
219
Operating the Hydraulic Service Arm
221
Receiver Panel with Monitor Box
223
Refillable Grease Containers of the Automatic Lubrication Systems
227
Transfer Pump for Hydraulic Oil
228
Operating the Transfer Pump
229
Functions of the Transfer Pump
229
Work on the Loader Attachment
232
Transportation and Lifting of the Shovel
233
Disassembling of the Shovel
233
Transportation and Lifting
233
Retrieval Procedure
234
Shovel Storage
235
Preparing for Storage
235
One Month Repetitive Service Period
236
Six Month Repetitive Service Period
236
Preparing for Operation
237
Trouble Shooting
238
Engine
238
Hydraulic System
239
Final Drives and Swing Gear
240
Crawler Tracks
240
Maintenance
241
Foreword
242
Precautions for Maintenance
243
Fluids and Lubricants
245
Lubricants for Operation in Cold and Arctic Climates
245
Fluids and Lubricants for Moderate and Hot Climates
246
Filling Capacities
248
Standard Torque List
249
Lubrication and Maintenance Schedule
250
Initial Servicing
250
Periodic Servicing Intervals
250
Periodic Servicing Schedule
251
Periodic Replacement of Safety Critical Parts
257
Extended Service Intervals for Engines with Engine Oil Management System
261
Resetting the Engine Oil Burning System Centinel
263
Maintenance of the Engine
267
When Necessary
268
Engine Air Cleaner Maintenance
269
Swing Circle Toothing Lubrication
273
Automatic Lubrication Systems Fill Grease Containers
275
Track Rollers and Guide Wheels - Replace Floating Seals
279
Cold Starting Aid, Replace Fluid Cylinder
281
Every 10 Operating Hours or Daily
282
Walk - Around Inspection
283
Air Cleaner - Clean Pre-Cleaner
295
Radiator - Check Coolant Level
297
Track Groups - Clean
297
Fuel System Water Separator - Drain Water
299
Every 50 Operating Hours or Weekly
300
Swing Gear and Motor Adapter Housing - Check Oil Level
301
Travel Gears, Brake Housings and Motor Adapter Housings - Check Oil Levels
305
Pto (Pump Distributor Gear) - Check Oil Level
309
Hydraulic Access Ladder - Check Safety Sensor
311
Hydraulic Oil Coolers - Inspect and Clean if Necessary
313
Every 250 Operating Hours or Monthly
314
Air Conditioning Compressor - Check Drive Belt Tension
315
Radiator Fan Belt and Automatic Belt Tensioner - Maintenance Check
317
Radiator Fan Belt and Automatic Belt Tensioner - Maintenance Check
319
Generator - Check Belt Tension
321
Signal Horn Compressor - Lubricate
323
Hydraulic Oil Cooler Fan - Check Condition and Fastening
323
Automatic Lubrication Systems - Clean In-Line Grease Filter and Check Breather Filter
325
Cab Air Cleaner - Clean or Replace Filter Element
329
Windshield Washer Reservoir - Check Fluid Level
331
Air Conditioning for Operator's Cab - Check Refrigerant Level
331
Every 500 Operating Hours or Monthly
332
Batteries - Check Fluid Level
333
Flexible Drive Coupling - Check Oil Level
335
Fuel Tank - Drain Condensation
337
Crawler Track - Inspection
339
Every 1000 Operating Hours or Every 6 Month
344
High Strength Bolt Connections - Check Torque Load
345
Hydraulic System - Filter Service
377
Pto (Pump Distributor Gear), Swing Gear and Travel Gears - Oil Sample Analysis
391
Signal Horn Compressor - Clean and Lubricate
393
Hydraulic Track Tensioning System - Check Pressure Accumulators
395
Hydraulic Oil Cooler - Inspect and Lubricate Door Hinges
397
Machinery House Doors - Inspect and Lubricate Door Hinges
397
Every 2000 Operating Hours or Yearly
398
Hydraulic System - Change Oil, Replace Suction Strainers and Pulsation Damper
399
Emergency Escape Ladder - Inspection
413
Every 3000 Operating Hours However at Least Once a Year
414
Swing Gear and Motor Adapter Housing - Change Oil
415
Travel Gears, Brake and Motor Adapter Housings - Change Oil
423
Pto (Pump Distributor Gear) - Change Oil
427
Fire Prevention
430
Weld Repairs
432
Protective Measures before Starting Weld Repairs on the Undercarriage
435
Protective Measures before Starting Weld Repairs on the Loader Attachment
437
Protective Measures before Starting Weld Repairs on the Superstructure
439
After Finishing the Repair Weldings on the Superstructure
441

Komatsu PC3000-6 Operation & Maintenance Manual (405 pages)

HYDRAULIC MINING SHOVEL

Brand: Komatsu | Category: Construction Equipment | Size: 8.62 MB

Introduction
3
Contents of the Binder
4
Division of the Binder
5
Designated Use of the Shovel
6
Delivery of the Shovel
7
Explanation of Abbrevations
8
Table of Contents
9
Safety
15
Safety Instructions
16
Warnings and Symbols
16
Basic Operation and Designated Use of the Hydraulic Shovel
16
Organizational Measures
17
Selection and Qualification of Personnel - Basic Responsibilities
19
Safety Instructions Governing Specific Operational Phases
20
Warning of Special Dangers
23
Transporting and Towing -Recommissioning
25
Special Safety Equipment
25
Safety Harness in Conformity with en 361 (European Standard)
29
Operation
37
Foreword
38
Construction of the Shovel
39
Overall View
39
Undercarriage and Superstructure
40
Hydraulically Operated Access Ladder
46
Emergency Escape Ladder
50
Emergency Engine Shutdown from Ground man or Operator Warning System
52
Operator's Cab with Integrated Falling Object Protective Structure (Fops)
54
(Fops)
54
Engine Oil Management System
62
Operator's Cab - Controls
70
Controls with Backhoe Attachment
70
Controls with Bottom Dump Bucket
74
Operator's Console
79
Electronic Text Monitoring System Etm
86
Introduction
87
System Components
91
Functions of the Etm System
93
Display the Contents of the Record (Protocol) Memory
97
Several Message Conditions Occur at the same Time
109
Settings of the Text Display Unit
111
Operating the Heater, Ventilation and Air Conditioning
126
Machinery House
128
Emergency Engine Shutdown Switches
129
Electrical Equipment in Cab Base
130
Switch Box (X2) in Cab Base
135
Checks before Starting the Engine
136
Starting the Engine
142
Starting Procedure
145
Moving the Shovel
151
Travel Control with Foot Pedals
151
Travelling Instructions
154
Slewing and Braking the Superstructure
155
Slewing the Superstructure
155
Working with the Attachment
158
Machines Equipped With"Euro" Control System
158
Machines Equipped With"Kmg" Control System
159
Bottom Dump Bucket
160
Drop Ball Operation
161
Combined Operation Cycles
164
Working Instructions
166
Stability of the Shovel
166
Shovel Operation
166
Parking the Shovel
169
Stopping the Engine
170
Automatic Lubrication Systems
174
Operation of the Automatic Lubrication Systems
175
Fire Detection and Suppression System
178
High Level Alarm "Fire
181
Engine Shut-Down through Fuel Shut-Off Solenoid Valve
181
Actuation Modes of the Fire Suppression System
181
Indication of Operational Modes at Control Module, after Automatic Actuation of the Fire Suppression System
183
Location of the Extinguishing Agent Tank Assemblies and Expellant Gas Cartridges on Power House Roof
185
Central Refilling System
186
Systems Connected to the Refilling System
187
Operating the Hydraulic Service Arm
189
Receiver Panel with Monitor Box
191
Refillable Grease Containers of the Automatic Lubrication Systems
195
Transfer Pump for Hydraulic Oil
196
Operating the Transfer Pump
197
Functions of the Transfer Pump
197
Work on the Loader Attachment
200
Transportation and Lifting of the Shovel
201
Disassembling of the Shovel
201
Transportation and Lifting
201
Retrieval Procedure
202
Shovel Storage
203
Preparing for Storage
203
One Month Repetitive Service Period
204
Six Month Repetitive Service Period
204
Preparing for Operation
205
Trouble Shooting
206
Engine
206
Hydraulic System
207
Final Drives and Swing Gear
208
Crawler Tracks
208
Maintenance
209
Foreword
210
Precautions for Maintenance
211
Fuel and Lubricants
213
Filling Capacities
215
Standard Torque List
216
Lubrication and Maintenance Schedule
217
Initial Servicing
217
Periodic Servicing Intervals
217
Periodic Servicing Schedule
218
Extended Service Intervals for Engines with Engine Oil Management System
225
Resetting the Engine Oil Burning System Centinel
227
Maintenance of the Engine
229
When Necessary
230
Engine Air Cleaner Maintenance
231
Swing Circle Toothing Lubrication
235
Automatic Lubrication Systems Fill Grease Containers
237
Track Rollers and Guide Wheels - Replace Floating Seals
241
Cold Starting Aid, Replace Fluid Cylinder
243
Every 10 Operating Hours or Daily
244
Walk - Around Inspection
245
Air Cleaner - Clean Pre-Cleaner
253
Radiator - Check Coolant Level
255
Track Groups - Clean
255
Fuel System Water Separator - Drain Water
257
Every 50 Operating Hours or Weekly
258
Swing Gear and Motor Adapter Housing - Check Oil Level
259
Travel Gears, Brake Housings and Motor Adapter Housings - Check Oil Levels
263
Pto (Pump Distributor Gear) - Check Oil Level
267
Hydraulic Access Ladder - Check Safety Sensor
269
Hydraulic Oil Coolers - Inspect and Clean if Necessary
271
Every 250 Operating Hours or Monthly
272
Air Conditioning Compressor - Check Drive Belt Tension
273
Radiator Fan Belt and Automatic Belt Tensioner - Maintenance Check
275
Radiator Fan Belt and Automatic Belt Tensioner - Maintenance Check
277
Generator - Check Belt Tension
279
Signal Horn Compressor - Lubricate
281
Hydraulic Oil Cooler Fan - Check Condition and Fastening
281
Automatic Lubrication Systems - Clean In-Line Grease Filter and Check Breather Filter
283
Cab Air Cleaner - Clean or Replace Filter Element
287
Windshield Washer Reservoir - Check Fluid Level
289
Air Conditioning for Operator's Cab - Check Refrigerant Level
289
Every 500 Operating Hours or Monthly
290
Batteries - Check Fluid Level
291
Flexible Drive Coupling - Check Oil Level
293
Fuel Tank - Drain Condensation
295
Crawler Track - Inspection
297
Every 1000 Operating Hours or Every 6 Month
302
High Strength Bolt Connections - Check Torque Load
303
Hydraulic System - Filter Service
335
Pto (Pump Distributor Gear), Swing Gear and Travel Gears - Oil Sample Analysis
349
Signal Horn Compressor - Clean and Lubricate
351
Hydraulic Track Tensioning System - Check Pressure Accumulators
353
Hydraulic Oil Cooler - Inspect and Lubricate Door Hinges
355
Machinery House Doors - Inspect and Lubricate Door Hinges
355
Every 2000 Operating Hours or Yearly
356
Hydraulic System - Change Oil, Replace Suction Strainers and Pulsation Damper
357
Hydraulic System - Change Oil, Replace Suction Strainers and Pulsation Damper
359
Emergency Escape Ladder - Inspection
371
Every 3000 Operating Hours However at Least Once a Year
372
Swing Gear and Motor Adapter Housing - Change Oil
373
Travel Gears, Brake and Motor Adapter Housings - Change Oil
381
Pto (Pump Distributor Gear) - Change Oil
385
Fire Prevention
388
Repair Weldings
390
Protective Measures before Starting Weld Repairs on the Undercarriage
393
Protective Measures before Starting Weld Repairs on the Loader Attachment
395
Protective Measures before Starting Weld Repairs on the Superstructure
397
After Finishing the Repair Weldings on the Superstructure
399

Komatsu PC3000-6 Assembly Procedure (76 pages)

Hydraulic Mining Shovel

Brand: Komatsu | Category: Construction Equipment | Size: 2.94 MB

Table of Contents
3
General
5
Delivery of the Excavator
5
Assembling of the Excavator
5
Transportation and Lifting
7
Manpower / Assembly Time
9
Assembly Site Requirements
11
Space and Placing Requirements
15
Preparation for Assembly
15
Basic Measurements (Z24015)
17
Transport Dimensions and Weights (as Example)
17
Illust. Configuration of Components on Erection Site
19
Assembly Sequence
19
Assembly of Undercarriage (Z 24016; Z 24017; Z 24018)
21
Assembly
21
Determination of the Tightening Torque
25
Final Works
29
Assembly of Superstructure Onto the Undercarriage (Z 9031A)
31
Mounting of Boom and Boom Cylinders(Z 9032; Z 20949)
35
Mounting of Fuel Tank (Z21924)
37
Mounting of Hydraulic Access Ladder (Z 24022)
39
Mounting of Cab Base (Z 24023)
41
Mounting of Counterweight (Z 24024)
43
Mounting of Handrails, Steps and Gratings (Z 24025)
45
Mounting of Cab (Z 24029)
47
Pre-Checks Prior Initial Start up
49
Mounting of Stick
53
Backhoe Attachment (Z 24030)
53
Bullclam Bucket Attachment (Z 20950; Z 20951; 20952)
55
Assembly of the Bucket to the Stick
61
Assembly of the Backhoe to the Stick (Z 23005)
61
Assembly of the Bullclam Bucket to the Stick (Z 20953)
63
Mounting of the Pin Seals
67
Backhoe (Z 23006)
67
Bullclam Bucket (Z 21963)
69
Putting the Central Lubrication System into Operation (Z 24031)
71
Standard Application Torque Chart
73
Metric Standard Thread
73
Metric Fine Thread
75
Torque Chart for Flange Joints
76

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