komatsu pc3000 1e hydraulic mining shovel operation and maintenance manual gzeam06251 1

komatsu pc3000 1e hydraulic mining shovel operation and maintenance manual gzeam06251 2

komatsu pc3000 1e hydraulic mining shovel operation and maintenance manual gzeam06251 3

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Komatsu PC3000-1E Hydraulic Mining Shovel Operation and Maintenance Manual GZEAM06251

$20.00

Type Of Manual: Operation and Maintenance Manual
Manual ID: GZEAM06251
Format: PDF
Size: 13.5MB
Number of Pages: 372

Category: Komatsu Operation and Maintenance Manual PDF

Model List:
- PC3000-1E Hydraulic Mining Shovel

1. COVER
2. INTRODUCTION
2.1. CONTENTS OF THE BINDER
2.2. DIVISION OF THE BINDER
2.3. DESIGNATED USE OF THE SHOVEL
2.4. DELIVERY OF THE SHOVEL
2.5. EXPLANATION OF ABBREVIATIONS
2.6. TABLE OF CONTENTS
3. SAFETY
3.1. SAFETY INSTRUCTIONS
3.1.1. WARNINGS AND SYMBOLS
3.1.2. BASIC OPERATION AND DESIGNATED USE OF THE HYDRAULIC SHOVEL
3.1.3. ORGANIZATIONAL MEASURES
3.1.4. SELECTION AND QUALIFICATION OF PERSONNEL BASIC RESPONSIBILITIES
3.1.5. SAFETY INSTRUCTIONS GOVERNING SPECIFIC OPERATIONAL PHASES
3.1.6. WARNING OF SPECIAL DANGERS
3.1.7. TRANSPORTING AND TOWING RECOMMISSIONING
3.1.8. SPECIAL SAFETY EQUIPMENT
3.1.9. SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)
4. OPERATION
4.1. FOREWORD
4.2. CONSTRUCTION OF THE SHOVEL
4.2.1. OVERALL VIEW
4.2.2. UNDERCARRIAGE AND SUPERSTRUCTURE
4.2.3. HYDRAULICALLY OPERATED ACCESS LADDER
4.2.4. EMERGENCY ESCAPE LADDER
4.2.5. EMERGENCY ESCAPE LADDER AND ESCAPE HATCH IN THE MACHINERY HOUSE (SPECIAL EQUIPMENT)
4.2.6. EMERGENCY MOTOR SHUTDOWN FROM GROUND MAN OR OPERATOR WARNING SYSTEM
4.2.7. OPERATORS CAB
4.3. OPERATORS CAB CONTROLS
4.3.1. CONTROLS WITH BACKHOE ATTACHMENT
4.3.2. CONTROLS WITH BOTTOM DUMP BUCKET
4.3.3. OPERATORS CONSOLE
4.4. ELECTRONIC TEXT MONITORING SYSTEM ETM
4.4.1. INTRODUCTION
4.4.2. SYSTEM COMPONENTS
4.4.3. FUNCTIONS OF THE ETM SYSTEM
4.4.4. SEVERAL MESSAGE CONDITIONS OCCUR AT THE SAME TIME
4.4.5. SETTINGS OF THE TEXT DISPLAY UNIT (Z 20919)
4.5. MACHINERY HOUSE
4.6. ELECTRICAL SWITCH CABINET
4.6.1. High Voltage switch cabinet, Illust. (Z 25367)
4.6.2. Medium Voltage Switch Cabinet, illust. (Z 25369)
4.7. CHECKS BEFORE STARTING THE MAIN MOTOR
4.8. STARTING THE MAIN DRIVE MOTOR
4.8.1. Lowest permissible starting temperature (ambient temperature) 20 C, see column 1
4.8.2. Operating temperature min. 8 C max. 55 C, see column2
4.9. STOPPING THE MAIN DRIVE MOTORS
4.9.1. P a r k t h e Excavator at a safe place on level and solid ground. Observe the instructions in section 8.0 PARKING THE EXCAVATOR.
4.9.2. Lower the working attachment onto the ground, proceed as follows
4.9.3. Move all controls into neutral position.
4.9.4. Turn stop switch (8) to the right for stopping the motor. After the motor has come to a standstill, relieve the pressure in the hydraulic system.
4.9.5. Set main switch key (23) to 0 position and remove
4.10. MOVING THE EXCAVATOR
4.10.1. Travel Control With Foot Pedals
4.10.2. TRAVELLING INSTRUCTIONS
4.11. SLEWING AND BRAKING THE SUPERSTRUCTURE
4.11.1. SLEWING THE SUPERSTRUCTURE
4.12. WORKING WITH THE ATTACHMENT
4.12.1. MACHINES EQUIPPED WITHEURO CONTROL SYSTEM
4.12.2. MACHINES EQUIPPED WITHKMG CONTROL SYSTEM
4.12.3. BOTTOM DUMP BUCKET
4.12.4. DROP BALL OPERATION
4.12.5. COMBINED OPERATION CYCLES
4.13. WORKING INSTRUCTIONS
4.13.1. STABILITY OF THE SHOVEL
4.13.2. SHOVEL OPERATION
4.14. PARKING THE SHOVEL
4.15. OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING
4.15.1. Air conditioning (special equipment, illust. ( Z 20423)
4.16. OPERATION OF THE LUBRICATION SYSTEM
4.17. FIRE DETECTION AND SUPPRESSION SYSTEM
4.18. CENTRAL REFILLING SYSTEM
4.18.1. Refilling system for hydraulic oil reservoir, grease barrels of the central lubrication system and slew ring gear lubrication system
4.18.2. Refilling procedure
4.18.3. Refilling the grease containers of the automatic lubrication system
4.19. WORK ON THE LOADER ATTACHMENT
4.20. TRANSPORTATION AND LIFTING OF THE SHOVEL
4.20.1. DISASSEMBLING OF THE SHOVEL
4.20.2. TRANSPORTATION AND LIFTING
4.21. RETRIEVAL PROCEDURE
4.22. SHOVEL STORAGE
4.22.1. PREPARING FOR STORAGE
4.22.2. ONE MONTH REPETITIVE SERVICE PERIOD
4.22.3. SIX MONTH REPETITIVE SERVICE PERIOD
4.22.4. PREPARING FOR OPERATION
4.23. TROUBLE SHOOTING
4.23.1. MAIN DRIVE ELECTRIC MOTOR
4.23.2. HYDRAULIC SYSTEM
4.23.3. FINAL DRIVES AND SWING GEAR
4.23.4. CRAWLER TRACKS
5. MAINTENANCE
5.1. FOREWORD
5.2. PRECAUTIONS FOR MAINTENANCE
5.3. FLUIDS AND LUBRICANTS
5.3.1. LUBRICANTS FOR OPERATION IN COLD AND ARCTIC CLIMATES
5.3.2. FLUIDS AND LUBRICANTS FOR MODERATE AND HOT CLIMATES
5.3.3. MAIN DRIVE ELECTRIC MOTORS BEARING LUBRICATION
5.4. FILLING CAPACITIES
5.5. STANDARD TORQUE LIST
5.6. LUBRICATION AND MAINTENANCE SCHEDULE
5.6.1. INITIAL SERVICING
5.6.2. PERIODIC SERVICING INTERVALS
5.6.3. PERIODIC SERVICING SCHEDULE
5.6.4. MAINTENANCE OF THE MAIN DRIVE MOTORS
5.6.5. REPLACEMENT OF HYDRAULIC HOSE LINES
5.6.6. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS
5.7. WHEN NECESSARY
5.7.1. SWING CIRCLE TOOTHING LUBRICATION
5.7.2. AUTOMATIC LUBRICATION SYSTEMS FILL GREASE CONTAINERS
5.7.3. TRACK ROLLERS AND GUIDE WHEELS REPLACE FLOATING SEALS
5.8. EVERY 10 OPERATING HOURS OR DAILY
5.8.1. WALK AROUND INSPECTION
5.8.2. Cleaning the track group, illust. (Z 9550)
5.9. EVERY 50 OPERATING HOURS OR WEEKLY
5.9.1. SWING GEAR AND MOTOR ADAPTER HOUSING CHECK OIL LEVEL
5.9.2. TRAVEL GEARS, BRAKE HOUSINGS AND MOTOR ADAPTER HOUSINGS CHECK OIL LEVELS
5.9.3. PTO (PUMP DISTRIBUTOR GEAR) CHECK OIL LEVEL
5.9.4. Hydraulic Oil Cooler, illust. (20009) Inspect and clean if necessary
5.9.5. HYDRAULIC ACCESS LADDER CHECK SAFETY SENSOR
5.10. EVERY 250 OPERATING HOURS OR MONTHLY
5.10.1. SIGNAL HORN COMPRESSOR LUBRICATE
5.10.2. HYDRAULIC OIL COOLER FAN BEARINGS CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER
5.10.3. AUTOMATIC LUBRICATION SYSTEMS CLEAN INLINE GREASE FILTER AND CHECK BREATHER FILTER
5.10.4. CAB AIR CLEANER CLEAN OR REPLACE FILTER ELEMENT
5.10.5. WINDSHIELD WASHER RESERVOIR CHECK FLUID LEVEL
5.10.6. AIR CONDITIONING FOR OPERATORS CAB CHECK REFRIGERANT LEVEL
5.11. EVERY 500 OPERATING HOURS OR MONTHLY
5.11.1. BATTERIES CHECK FLUID LEVEL
5.11.2. CRAWLER TRACK INSPECTION
5.12. EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH
5.12.1. HIGH STRENGTH BOLT CONNECTIONS CHECK TORQUE LOAD
5.12.2. HYDRAULIC SYSTEM FILTER SERVICE
5.12.3. Pump Distributor Gears, Slew Gears and Travel Gears
5.12.4. SIGNAL HORN COMPRESSOR CLEAN AND LUBRICATE
5.12.5. HYDRAULIC TRACK TENSIONING SYSTEM CHECK PRESSURE ACCUMULATORS
5.12.6. HYDRAULIC OIL COOLER INSPECT AND LUBRICATE DOOR HINGES
5.12.7. MACHINERY HOUSE DOORS INSPECT AND LUBRICATE DOOR HINGES
5.13. EVERY 2000 OPERATING HOURS OR YEARLY
5.13.1. HYDRAULIC SYSTEM CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER
5.13.2. EMERGENCY ESCAPE LADDER INSPECTION
5.14. EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR
5.14.1. SWING GEAR AND MOTOR ADAPTER HOUSING CHANGE OIL
5.14.2. TRAVEL GEARS, BRAKE AND MOTOR ADAPTER HOUSINGS CHANGE OIL
5.14.3. PTO (PUMP DISTRIBUTOR GEAR) CHANGE OIL
5.15. FIRE PREVENTION
5.15.1. Keep the excavator clean, especially from inflammable materials. Clean the excavator after servicing the hydraulic system, motor and fuel system by means of a steam jet.
5.15.2. Clean motor compartment, hydraulic pump compartment and service platform of the superstructure. Thereafter hydraulic oil lines for leakage, loose fastenings and damage. If any leakage, damage or loose fastening is found, corrective action must be …
5.15.3. Check all electrical cables, terminals and connections for loose fastenings, damage and wear. Replace or repair defective or worn parts without delay.
5.15.4. Check the turbocharger for correct mounting and tight exhaust, intake and lube oil connections. Carry out all necessary repairs without delay.
5.15.5. On machines equipped with a fire detection, actuation and suppression system Refer to the manufacturers service manuals in volume 2 binder for correct maintenance and inspection of the systems. When checking the filling level of the dry chemical …
5.15.6. Make sure fire extinguishers are charged and ready for use.
5.16. WELD REPAIRS
5.16.1. PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE UNDERCARRIAGE
5.16.2. PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE LOADER ATTACHMENT
5.16.3. PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE SUPERSTRUCTURE
5.16.4. AFTER FINISHING THE WELD REPAIRS ON THE SUPERSTRUCTURE

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