Komatsu PC3000-6 Hydraulic Mining Shovel Operation and Maintenance Manual OMPC30006219

Description

• Model List:
  • PC3000-6 Hydraulic Mining Shovel

• 1. MAIN MENU
• 2. COVER
• 3. INTRODUCTION
• 3.1. CONTENTS OF THE BINDER
• 3.2. DIVISION OF THE BINDER
• 3.3. DESIGNATED USE OF THE SHOVEL
• 3.4. DELIVERY OF THE SHOVEL
• 3.5. EXPLANATION OF ABBREVIATIONS
• 3.6. TABLE OF CONTENTS
• 4. SAFETY
• 4.1. SAFETY INSTRUCTIONS
• 4.1.1. WARNINGS AND SYMBOLS
• 4.1.2. BASIC OPERATION AND DESIGNATED USE OF THE HYDRAULIC SHOVEL
• 4.1.3. ORGANIZATIONAL MEASURES
• 4.1.4. SELECTION AND QUALIFICATION OF PERSONNEL BASIC RESPONSIBILITIES
• 4.1.5. SAFETY INSTRUCTIONS GOVERNING SPECIFIC OPERATIONAL PHASES
• 4.1.6. WARNING OF SPECIAL DANGERS
• 4.1.7. TRANSPORTING AND TOWING RECOMMISSIONING
• 4.1.8. SPECIAL SAFETY EQUIPMENT
• 4.1.9. SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)
• 5. OPERATION
• 5.1. FOREWORD
• 5.2. CONSTRUCTION OF THE SHOVEL
• 5.2.1. OVERALL VIEW
• 5.2.2. UNDERCARRIAGE AND SUPERSTRUCTURE
• 5.2.3. HYDRAULICALLY OPERATED ACCESS LADDER
• 5.2.4. EMERGENCY ESCAPE LADDER
• 5.2.5. EMERGENCY ENGINE SHUTDOWN FROM GROUND MAN OR OPERATOR WARNING SYSTEM
• 5.2.6. OPERATORS CAB WITH INTEGRATED FALLING OBJECT PROTECTIVE STRUCTURE (FOPS)
• 5.2.7. ENGINE OIL MANAGEMENT SYSTEM
• 5.3. OPERATORS CAB CONTROLS
• 5.3.1. CONTROLS WITH BACKHOE ATTACHMENT
• 5.3.2. CONTROLS WITH BOTTOM DUMP BUCKET
• 5.3.3. OPERATORS CONSOLE
• 5.4. ELECTRONIC TEXT MONITORING SYSTEM ETM
• 5.4.1. INTRODUCTION
• 5.4.2. SYSTEM COMPONENTS
• 5.4.3. FUNCTIONS OF THE ETM SYSTEM
• 5.4.4. DISPLAY THE CONTENTS OF THE RECORD (PROTOCOL) MEMORY
• 5.4.5. SEVERAL MESSAGE CONDITIONS OCCUR AT THE SAME TIME
• 5.4.6. SETTINGS OF THE TEXT DISPLAY UNIT
• 5.5. OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING
• 5.6. MACHINERY HOUSE
• 5.6.1. EMERGENCY ENGINE SHUTDOWN SWITCHES
• 5.7. ELECTRICAL EQUIPMENT IN CAB BASE
• 5.7.1. SWITCH BOX (X2) IN CAB BASE
• 5.8. CHECKS BEFORE STARTING THE ENGINE
• 5.9. STARTING THE ENGINE
• 5.9.1. STARTING PROCEDURE
• 5.10. MOVING THE SHOVEL
• 5.10.1. TRAVEL CONTROL WITH FOOT PEDALS
• 5.10.2. TRAVELLING INSTRUCTIONS
• 5.11. SLEWING AND BRAKING THE SUPERSTRUCTURE
• 5.11.1. SLEWING THE SUPERSTRUCTURE
• 5.12. WORKING WITH THE ATTACHMENT
• 5.12.1. MACHINES EQUIPPED WITHEURO CONTROL SYSTEM
• 5.12.2. MACHINES EQUIPPED WITHKMG CONTROL SYSTEM
• 5.12.3. BOTTOM DUMP BUCKET
• 5.12.4. DROP BALL OPERATION
• 5.12.5. COMBINED OPERATION CYCLES
• 5.13. WORKING INSTRUCTIONS
• 5.13.1. STABILITY OF THE SHOVEL
• 5.13.2. SHOVEL OPERATION
• 5.14. PARKING THE SHOVEL
• 5.15. STOPPING THE ENGINE
• 5.15.1. RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM
• 5.16. AUTOMATIC LUBRICATION SYSTEMS
• 5.16.1. OPERATION OF THE AUTOMATIC LUBRICATION SYSTEMS
• 5.17. FIRE DETECTION AND SUPPRESSION SYSTEM
• 5.17.1. HIGH LEVEL ALARM FIRE
• 5.17.2. ENGINE SHUTDOWN THROUGH FUEL SHUTOFF SOLENOID VALVE
• 5.17.3. ACTUATION MODES OF THE FIRE SUPPRESSION SYSTEM
• 5.17.4. INDICATION OF OPERATIONAL MODES AT CONTROL MODULE, AFTER AUTOMATIC ACTUATION OF THE FIRE SUPPRESSION SYSTEM
• 5.17.5. LOCATION OF THE EXTINGUISHING AGENT TANK ASSEMBLIES AND EXPELLANT GAS CARTRIDGES ON POWER HOUSE ROOF
• 5.18. CENTRAL REFILLING SYSTEM
• 5.18.1. SYSTEMS CONNECTED TO THE REFILLING SYSTEM
• 5.18.2. OPERATING THE HYDRAULIC SERVICE ARM
• 5.18.3. RECEIVER PANEL WITH MONITOR BOX
• 5.18.4. REFILLABLE GREASE CONTAINERS OF THE AUTOMATIC LUBRICATION SYSTEMS
• 5.19. TRANSFER PUMP FOR HYDRAULIC OIL
• 5.19.1. OPERATING THE TRANSFER PUMP
• 5.19.2. FUNCTIONS OF THE TRANSFER PUMP
• 5.20. WORK ON THE LOADER ATTACHMENT
• 5.21. TRANSPORTATION AND LIFTING OF THE SHOVEL
• 5.21.1. DISASSEMBLING OF THE SHOVEL
• 5.21.2. TRANSPORTATION AND LIFTING
• 5.22. RETRIEVAL PROCEDURE
• 5.23. SHOVEL STORAGE
• 5.23.1. PREPARING FOR STORAGE
• 5.23.2. ONE MONTH REPETITIVE SERVICE PERIOD
• 5.23.3. SIX MONTH REPETITIVE SERVICE PERIOD
• 5.23.4. PREPARING FOR OPERATION
• 5.24. TROUBLE SHOOTING
• 5.24.1. ENGINE
• 5.24.2. HYDRAULIC SYSTEM
• 5.24.3. FINAL DRIVES AND SWING GEAR
• 5.24.4. CRAWLER TRACKS
• 6. MAINTENANCE
• 6.1. FOREWORD
• 6.2. PRECAUTIONS FOR MAINTENANCE
• 6.3. FUEL AND LUBRICANTS
• 6.4. FILLING CAPACITIES
• 6.5. STANDARD TORQUE LIST
• 6.6. LUBRICATION AND MAINTENANCE SCHEDULE
• 6.6.1. INITIAL SERVICING
• 6.6.2. PERIODIC SERVICING INTERVALS
• 6.6.3. PERIODIC SERVICING SCHEDULE
• 6.6.4. EXTENDED SERVICE INTERVALS FOR ENGINES WITH ENGINE OIL MANAGEMENT SYSTEM
• 6.6.5. RESETTING THE ENGINE OIL BURNING SYSTEM CENTINEL
• 6.6.6. MAINTENANCE OF THE ENGINE
• 6.7. WHEN NECESSARY
• 6.7.1. ENGINE AIR CLEANER MAINTENANCE
• 6.7.2. SWING CIRCLE TOOTHING LUBRICATION
• 6.7.3. AUTOMATIC LUBRICATION SYSTEMS FILL GREASE CONTAINERS
• 6.7.4. TRACK ROLLERS AND GUIDE WHEELS REPLACE FLOATING SEALS
• 6.7.5. COLD STARTING AID, REPLACE FLUID CYLINDER
• 6.8. EVERY 10 OPERATING HOURS OR DAILY
• 6.8.1. WALK AROUND INSPECTION
• 6.8.2. AIR CLEANER CLEAN PRECLEANER
• 6.8.3. RADIATOR CHECK COOLANT LEVEL
• 6.8.4. TRACK GROUPS CLEAN
• 6.8.5. FUEL SYSTEM WATER SEPARATOR DRAIN WATER
• 6.9. EVERY 50 OPERATING HOURS OR WEEKLY
• 6.9.1. HYDRAULIC OIL COOLERS INSPECT AND CLEAN IF NECESSARY
• 6.9.2. SWING GEAR AND MOTOR ADAPTER HOUSING CHECK OIL LEVEL
• 6.9.3. TRAVEL GEARS, BRAKE HOUSINGS AND MOTOR ADAPTER HOUSINGS CHECK OIL LEVELS
• 6.9.4. PTO (PUMP DISTRIBUTOR GEAR) CHECK OIL LEVEL
• 6.9.5. HYDRAULIC ACCESS LADDER CHECK SAFETY SENSOR
• 6.10. EVERY 250 OPERATING HOURS OR MONTHLY
• 6.10.1. AIR CONDITIONING COMPRESSOR CHECK DRIVE BELT TENSION
• 6.10.2. RADIATOR FAN BELT AND AUTOMATIC BELT TENSIONER MAINTENANCE CHECK
• 6.10.3. GENERATOR CHECK BELT TENSION
• 6.10.4. SIGNAL HORN COMPRESSOR LUBRICATE
• 6.10.5. HYDRAULIC OIL COOLER FAN CHECK CONDITION AND FASTENING
• 6.10.6. AUTOMATIC LUBRICATION SYSTEMS CLEAN INLINE GREASE FILTER AND CHECK BREATHER FILTER
• 6.10.7. CAB AIR CLEANER CLEAN OR REPLACE FILTER ELEMENT
• 6.10.8. WINDSHIELD WASHER RESERVOIR CHECK FLUID LEVEL
• 6.10.9. AIR CONDITIONING FOR OPERATORS CAB CHECK REFRIGERANT LEVEL
• 6.11. EVERY 500 OPERATING HOURS OR MONTHLY
• 6.11.1. BATTERIES CHECK FLUID LEVEL
• 6.11.2. FLEXIBLE DRIVE COUPLING CHECK OIL LEVEL
• 6.11.3. FUEL TANK DRAIN CONDENSATION
• 6.11.4. CRAWLER TRACK INSPECTION
• 6.12. EVERY 1000 OPERATING HOURS OR EVERY 6 MONTHS
• 6.12.1. HIGH STRENGTH BOLT CONNECTIONS CHECK TORQUE LOAD
• 6.12.2. HYDRAULIC SYSTEM FILTER SERVICE
• 6.12.3. PTO (PUMP DISTRIBUTOR GEAR), SWING GEAR AND TRAVEL GEARS OIL SAMPLE ANALYSIS
• 6.12.4. SIGNAL HORN COMPRESSOR CLEAN AND LUBRICATE
• 6.12.5. HYDRAULIC TRACK TENSIONING SYSTEM CHECK PRESSURE ACCUMULATORS
• 6.12.6. HYDRAULIC OIL COOLER INSPECT AND LUBRICATE DOOR HINGES
• 6.12.7. MACHINERY HOUSE DOORS INSPECT AND LUBRICATE DOOR HINGES
• 6.13. EVERY 2000 OPERATING HOURS OR YEARLY
• 6.13.1. HYDRAULIC SYSTEM CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER
• 6.13.2. EMERGENCY ESCAPE LADDER INSPECTION
• 6.14. EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR
• 6.14.1. SWING GEAR AND MOTOR ADAPTER HOUSING CHANGE OIL
• 6.14.2. TRAVEL GEARS, BRAKE AND MOTOR ADAPTER HOUSINGS CHANGE OIL
• 6.14.3. PTO (PUMP DISTRIBUTOR GEAR) CHANGE OIL
• 6.15. FIRE PREVENTION
• 6.16. WELD REPAIRS
• 6.16.1. PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE UNDERCARRIAGE
• 6.16.2. PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE LOADER ATTACHMENT
• 6.16.3. PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE SUPERSTRUCTURE
• 6.16.4. AFTER FINISHING THE REPAIR WELDINGS ON THE SUPERSTRUCTURE