Komatsu PC3000-6 Diesel 46151 & Up, 06208 & Up 06208_46151-upD-GB-2 (Preview)
COVER
00 Foreword
– Introduction
– Safety Instructions
01 Specifications
– Specifications PC3000
10 Structure, Function
– 01 INTRODUCTION
– 02 SAFETY
– 03 SPECIFICATIONS
– 04 MAIN ASSEMBLY GROUPS
— 4.1 General layout
— 4.2 Superstructure
— 4.3 Power House
— 4.4 Hydraulic Oil Reservoir
— 4.5 Hydraulic Oil Cooler
— 4.6 Fuel tank (Fuel reservoir)
— 4.7 Counter weight
— 4.8 Cab support
— 4.9 Operators cab
— 4.10 Control blocks
— 4.11 Swing gears
— 4.12 Under carriage
– 05 DRIVE
— 5.1 Prime drive assembly
— 5.2 Engine and gearbox mount
— 5.3 Torque supports
— 5.4 Radiator fan Drive Assy.
— 5.5 Pump distributor gearbox (PTO)
— 5.5.1 Spline shaft housing
— 5.5.2 PTO lubrication and cooling
— 5.5.3 PTO valve adjustments
— 5.6 Coupling
— Oil filled type coupling “Geisslinger”
— 5.7 Air cleaner
– 06 HYDRAULIC OIL RESERVOIR
— 6.1 Hydraulic oil reservoir
— 6.2 Return and leak oil filter
— 6.3 Breather Filter
— 6.4 Location of electrical components
— 6.5 Transfer Pump, hydraulic service
– 07 HYDRAULIC OIL COOLING
— 7.1 General
— 7.2 Hydraulic oil cooling circuit
— 7.3 Back pressure valve adjustment
— 7.4 Fan drive
— 7.4.1 Fan pump
— 7.4.2 Pressure relieve valve
— 7.4.3 Temperature relay
— 4.5 Cooler fan drive adjustment
– 08 CONTROLLING
— 8.1 Pilot pressure supply and adjustment
— 8.1.1 Pilot control arrangement
— 8.1.2 Pilot pressure adjustment
— 8.1.3 Check of Control Pressure
— 8.2 Slew brakes
— 8.3 Travel parking brake
— 8.4 Check of the pilot control logic
— 8.4.1 Check sheet FSA Page 1
— 8.4.2 Check sheet BHA Page 1
– 09 COMPONENTS
— 9.1 Main control block and valve arrangement
— 9.1.1 FSA arrangement
— 9.1.2 BHA arrangement
— 9.2 Distributor manifold
— 9.2.1 Front shovel attachment FSA
— 9.2.2 Back hoe attachment BHA
— 9.2.3 SRV with throttle check valve
— 9.2.4 Anti cavitation valve (check valve)
— 9.3 Main control block
— 9.3.1 Load holding valve
— 9.3.2 High pressure filter
— 9.3.3 Pressure relieve valves and anti-cavitation valve
— 9.3.4 Pressure relieve valves and anti-cavitation valve
— 9.4 Compact valve blocks
— 9.5 Compact valve blocks
— 9.6 Auxiliary gear pumps
— 9.7 Hydraulic cylinder
— 9.8 Swing ring
– 10 MAIN HYDRAULIC PUMPS AND PUMP REGULATION
— 10.1 General
— 10.1.1 Pump location
— 10.2 Main pump operating principles
— 10.2.1 Main pump function
— 10.3 Main pump checks and adjustments
— 10.3.1 Peak point diesel engine test
— 10.3.2 Pressure transducer test
— 10.3.3 Cut off function
— 10.3.4 Pump regulation
— 10.3.5 Swing pump volume reduction
— 10.4 Electronic pump regulation
— 10.5 Pump Controller CR700
— 10.6 Multi Monitor
— 10.7 Multimonitor software instruction
— 10.7.1 Multimonitor main control
— 10.7.2 Service Menu screen
— 10.7.3 Monitoring (menu item 01)
— 10.7.4 Abnormality Record (menu item 02)
— 10.7.5 Default (menu item 03)
— 10.7.6 Adjustment (menu item 04)
— 10.7.7 Display Setup (menu item 05)
— 10.7.8 Table of fault messages and adjustments
— 10.8 Trouble shooting pump and pump regulation
– 11 OPERATING HYDRAULIC
— 11.1 General layout
— 11.2 Floating function of boom and stick only FSA
— 11.3 Check and Adjustments for MRV’s and SRV’s
— 11.3.1 Check and Adjustments for MRV
— 11.3.2 Check and Adjustment for SRV’s
— 11.3.3 Check and adjustment of the throttle check valves
— 11.4 Hydraulic for the swing circuit
— 11.4.1 Hydraulic for the swing circuit
— 11.4.2 Slew gear box L & S
— 11.4.3 Slew parking brake
— 11.4.4 Slew service brake valve
— 11.4.5 Checks and adjustment of the slew pressure valve
— 11.5 Travel circuit
— 11.5.1 Rotary joint
— 11.5.2 Travel motor A2FMt
— 11.5.3 Travel gear
— 11.5.4 Travel parking brake
— 11.5.5 Travel control function
— 11.5.6 Check and Adjustment SRV travel system
– 12 TRACK TENSION SYSTEM
— 12.1 General layout
— 12.2 Track tensioning function
— 12.2.1 Cushioning
— 12.2.2 Pressure Increasing valve PIV
— 12.3 Track tensioning adjustment
— 12.3.1 Track tensioning function check
– 13 ACCESS LADDER HYDRAULICALLY OPERATED
— 13.1 Access ladder
— 13.2 Access ladder functional description
– 14 CENTRAL REFILLING SYSTEM
— 14.0.1 Functional description
– 15 HINTS FOR READING THE HYDRAULIC CIRCUIT DIAGRAM
— 15.1 General
— 15.2 Symbolic
— 15.2.1 Lines, unions
— 15.2.2 Components, valves
— 15.2.3 Sensors
— 15.2.4 Valves, valve components
— 15.2.5 Pump, motor, cylinder
– 16 HINTS FOR READING THE ELECTRIC CIRCUIT DIAGRAM
— 16.1 Designation of electrical components
— 16.2 Electric symbols
— 16.3 Symbols
— 16.3.1 Drawing concept
— 16.3.2 Reading of the circuit diagram
– 17 ELECTRONIC TEXT MONITORING SYSTEM ETM
— 17.1 General Function
– 18 AUTOMATIC LUBRICATION SYSTEM
— 18.1 General Function
— 18.2 Function of a lubrication cycle
— 18.3 Lubrication pump drive
— 18.4 Lubrication pump
— 18.4.1 Adjustments lubricating pump speed
— 18.4.2 Adjustments lubricating pump pressure
— 18.5 Lubricant Injector (metering valve)
— 18.5.1 Connection of one or more injectors
— 18.5.2 Function lubrication injector (metering valve)
— 18.6 End line pressure switch
— 18.7 Lubricant in line filter
— 18.8 Lubricant level sensor
— 18.8.1 Capacitive digital type for machines with ETM
— 18.8.2 Capacitive analog type for machines with PLC
— 18.9 Lubrication system function and controlling
— 18.9.1 Central Lubrication System (CLS) function and controlling with ETM system (PC 3000)
— 18.9.2 Swing ring lubrication system (SLS) function and controlling with ETM system (PC3000)
— 18.10 Adjustment of the lubrication system with ETM
— 18.11 Trouble shooting lubricating system
— 18.11.1 Lubrication pump cylinder does not move
— 18.11.2 Lubricant pressure built up very slowly or not at all.
— 18.11.3 Insufficient lubricant supply to one or more attachment bearings
— 18.11.4 Insufficient lubricant at the swing ring gear
40 Troubleshooting
– Table of Contents
– Introduction
— Safety Notes
— Description of this Troubleshooting Manual
— General Precautions
– Electrical Parts
— Componant Locations
— Engine Electrical Parts
— Electrical Parts On PTO, etc
— Electrical Parts on Pilot Control Frame
— Electrical Parts on Main Hydraulic Reservoir
— Electrical Parts on Switch Board X2
— Electrical Parts on Hydraulic Ldder
— Electrical Parts of Automatic Lube System
— Electrical Parts on Air Cleaner and Fuel Tank
— Overview Connector Types
— Standard Value Table for Electrical Componants
— PT100 Temperature Charts
– Troubleshooting by Trouble Code
— Message 1 – Gear Lubrication out of Function (PTO)
— Message 2 – Engine Air Filter Restricted
— Message 3 – Filter for Control Oil Restricted
— Message 4 – Oil Tank Breather Filter Restricted
— Message 5 – Return Oil Filter Restricted
— Message 6 – Leak Oil Filter Restricted
— Message 7 – Hydraulic Oil Temperature Too High
— Message 9 – Low Idle Too High Coolant Temperature
— Message 10 – Engine Shutdown: Too Low Engine Oil Temperature
— Message 14 – Too Low Hydraulic Oil Level
— Message 15 – Caution, Slew Gear House Brake On
— Message 16 – Caution, Travel Gear House Brake On
— Message 17 – No Clearance For Starting, Shift Engine to Low Idle
— Message 18 – Central Lube System Fault
— Message 19 – Slew Ring Gear Lubrication Fault
— Message 20 – Pilot Control Cut-Out
— Message 21 – Central Lube System Empty Grease Barrel
— Message 22 – Central Lube System Empty Grease Barre
— Message 24 – Engine Problem: Stop All Control
— Message 32 – PTO Gear Lube Filter Restricted
— Message 33 – Cooler Fan Drive Filter Restricted
— Message 39 – Engine Shutdown . Main Shut-Off (Gate) Volve
— Message 42 – Too Low Coolant Pressure
— Message 43 – Engine Shutdown: Emergency Stop Switch Actuated
— Message 44 – Engine Shutdown Safety Switch Actuated
— Message 45 – Warning Signal from Engine Control Module
— Message 48 – Too High PTO Gear Oil Temperature.
— Message 50 – Caution, Pull Switch From Ground Man Actuated
— Message 51 – Engine Shutdown: Pull Switch From Ground Man Actuated
— Message 52 – Load Limit Clam Defective
— Message 53 – Pressure Switch of CLS Actuated
— Message 55 – Refill Hyrdaulic Oil
— Message 57 – Load Limit Regulation Fault
— Message 58 – Strainer Oil Cooler Restricted
— Message 59 – CLS Refill Grease Container
— Message 60 – SLS Refill Grease Barrel
– Troubleshooting by Symptoms
— Symptoms of the Hydraulic System
50 Disassembly and Assembly
– 1. INTRODUCTION
— 1.1 Contents of the binder
— 1.2 Foreword
— 1.2.1 Service
– 2. SAFETY
– 3. SUPERSTRUCTURE
— 3.1 Superstructure overview
— 3.2 Engine House
— 3.3 Diesel Engine
— 3.4 Torsion Coupling
— 3.5 PTO
— 3.6 Hydraulics
— 3.7 Slew Drive
— 3.8 Lubrication Pumps
— 3.9 Operaotor’s Cab
— 3.10 Cab Base
— 3.11 Access Ladder
— 3.12 Counterweight
— 3.13 Superstructure Lifting
— 3.14 Fuel Tank
– 4. UNDERCARRIAGE
— 4.1 Undercarriage Overview
— 4.2 Travel System
— 4.3 Car Body
– 5. ATTACHMENT
— 5.2 Face Shovel
— 5.2.1 Using the Installation Tools for Hydraulic Cyllinders
— 5.2.2 Boom
—- 5.2.2.1 Removal of the Boom
—- 5.2.2.2 Replacement of the Boom
—- 5.2.2.3 Removal of the Boom Cylinders
—- 5.2.2.4 Replacement of the Boom Cylinders
— 5.2.3 Stick
—- 5.2.3.1 Removal of the Stick
—- 5.2.3.2 Replacement of the Stick
—- 5.2.3.3 Removal of the Stick Cylinders
—- 5.2.3.4 Replacement of the Stick Cylinders
— 5.2.4 Bull Clam Bucket
—- 5.2.4.1 Removal of the Bull Clam Bucket
—- 5.2.4.2 Replacement of the Bull Clam Bucket
—- 5.2.4.3 Removal of the Bucket Cylinders
—- 5.2.4.4 Replacement of the Bucket Cylinders
—- 5.2.4.5 Removal of the Clam Cylinders
—- 5.2.4.6 Replacement of the Clam Cylinders
— 5.2.5 graound Engaging Tools (GET)
—- 5.2.5.1 Removal of the Ground Engaging Tools
— 5.2.6 Hydraulic Hoses on the Face Shovel Attachment.
—- 5.2.6.1 Substitute the Boom Arc Hoses
—- 5.2.6.2 Substitute the Boom Cylinder Hoses
—- 5.2.6.3 Substitute the Stick Arc Hoses
—- 5.2.6.4 Substitute the Stick Cylinder Hoses
—- 5.2.6.5 Substitute the Bucket Cylinder Hoses
—- 5.2.6.6 Substitute the Clam Cylinder Hoses
— 5.1 Backhoe
— 5.1.1 Boom
—- 5.1.1.1 Removal of the Boom
—- 5.1.1.2 Replacement of the boom
—- 5.1.1.3 Removal of boom cylinders
—- 5.1.1.4 Replacement of boom cylinders
— 5.1.3 Stick
—- 5.1.2.1 Removal of the Stick
—- 5.1.3.2 Replacement of Stick
—- 5.1.3.3 Removal of Stick Cylinders
—- 5.1.2.4 Replacement of Stick cylinders
— 5.1.4 Bucket
—- 5.1.3.1 Removal of the bucket
—- 5.1.3.2 Replacement of the bucket
—- 5.1.3.3 Removal of Bucket Cylinders
—- 5.1.3.4 Replacement of Bucket Cylinders
— 5.1.4 Bucket link rod and steering rods
—- 5.1.4.1 Removal of the bucket link rod
—- 5.1.4.2 Replacement of the bucket link rod
—- 5.1.4.3 Removal of the steering rods
—- 5.1.4.4 Replacement of the steering rod
— 5.1.5 Ground engaging tools (GET)
—- 5.1.5.1 Removal and replacement of the GET
— 5.1.6 Hydraulic hoses at the attachment
—- 5.1.6.1 Substitute the boom arc hoses
—- 5.1.6.2 Substitute the boom cylinder hoses
—- 5.1.6.3 Substitute the stick cylinder hoses
—- 5.1.6.4 Substitute the bucket cylinder hoses
— 5.3 Metering Valves
— 5.3.1 Operation test of the metering Valves
— 5.3.2 Removal of the Metering Valves
— Unbenannt
— 5.4 Cylinder Bypass Test
– 6. SERVICE INFORMATION
— 6.1 Fuel and Lubricants
— 6.2 Filling capacities
— 6.3 Work Instructions
— 6.3.1 Surface Coating with Interzinc 697
— 6.3.2 remove / Install the Crawler carrier
— 6.4 Weight Tables
— 6.4.1 Superstructure
— 6.4.2 Undercarriage
— 6.4.3 Backhoe Attachment
— 6.4.4 Face ShoveL Attachment
— 6.5 Torque Charts
— 6.5.1 Metric Standard Thread
— 6.5.2 Metric Fine Thread
— 6.5.3 Cummins Motor Torques – Metric
— 6.5.4 Cummins Motor Torques – US
— 6.5.5 Flange Connections
— 6.6 Blind Plugs
— 6.6.1 Dummy Plates for SAE Flanges
— 6.6.2 Classification of Threads to the Nominal Width
— 6.6.3 Plugs and Fittings According to DIN 2353
— 6.7 Conversion Table
— 6.7.1 Method of Use
— 6.7.2 Millimeter – Inch & Kilogram – Pound
— 6.7.3 Liter – US Gallon & Liter – UK Gallon
— 6.7.4 NM – FT.LB
— 6.7.5 Bar – PSI – KPA – MPA
— 6.7.6 Basic Values In Ohm According to ISO 43 76
— 6.7.7 Temperature
— 6.8 Tools
— 6.8.1 Standard Tool Case
— 6.8.2 Used Special Tools (Overview)
– 7. TOOLS CATALOGUE
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