KOMATSU HYDRAULIC EXCAVATOR PC3000-6 Diesel Shop Manual GZESM06208 PDF

46151 and up
06208 and up

GENERAL PRECAUTIONS COMMON TO OPERATION ON
THE EXCAVATOR
Mistakes in operation, inspection, or maintenance may result in personal injury or death. Before carrying out operation,
inspection, or maintenance, always read this manual and the safety labels on the machine carefully and
obey the warnings.
PRECAUTIONS BEFORE STARTING OPERATION ON THE EXCAVATOR
ENSURING SAFE OPERATION
􀁺 Only trained and authorized personnel can operate and maintain the machine.
􀁺 During operations, personnel are not allowed outside of the operator’s cabin.
􀁺 Follow all safety rules, precautions and instructions when operating or performing inspection or maintenance
on the machine.
􀁺 If you are not feeling well, or are under the influence of alcohol or medication, your ability to safely operate or
repair your machine may be severly impaired putting yourself and everyone else on your jobsite in danger.
􀁺 When working with another operator or with a person on worksite traffic duty, discuss the content of the operation
beforehand and use the determined signals when carrying out this operation.
UNDERSTANDING THE MACHINE
Before operating the machine, read this manual thoroughly. If there are any places in this manual that you do not
understand, ask the person in charge of safety to give an explanation.
PREPARATIONS FOR SAFE OPERATION
PRECAUTIONS REGARDING SAFETY RELATED EQUIPMENT
􀁺 Be sure that all guards, covers and mirrors are in their proper positions. Have guards and covers repaired
immediately if they are damaged.
􀁺 Understand the method of use of safety features and use them properly.
􀁺 Never remove any safety features. Always keep them in good operating condition.
INSPECTING THE MACHINE
Check the machine before starting operations. If any abnormality is found, do not operate the machine until repairs
of the problem location have been completed.

46151 and up
06208 and up

COVER 1
00 Foreword 3
Introduction 4
Safety Instructions 9
01 Specifications 58
Specifications PC3000 59
10 Structure, Function 67
I INTRODUCTION 69
II SAFETY 81
III SPECIFICATIONS 87
1 MAIN ASSEMBLY GROUPS 101
11 General layout 102
12 Superstructure 104
13 Power House 106
14 Hydraulic Oil Reservoir 108
15 Hydraulic Oil Cooler 110
16 Fuel tank (Fuel reservoir) 112
17 Counter weight 114
18 Cab support 116
19 Operators cab 118
110 Control blocks 120
111 Swing gears 122
112 Under carriage 124
2 DRIVE 127
21 Prime drive assembly 128
22 Engine and gearbox mount 130
23 Torque supports 133
24 Radiator fan Drive Assy 134
25 Pump distributor gearbox (PTO) 136
251 Spline shaft housing 138
252 PTO lubrication and cooling 140
253 PTO valve adjustments 142
26 Coupling 146
261 Rubber type coupling “Reich”, (replaces “Geislinger Coupling”) 146
262 Oil filled type coupling “Geisslinger” 148
27 Air cleaner 150
3 HYDRAULIC OIL RESERVOIR 153
31 Hydraulic oil reservoir 154
32 Return and leak oil filter 158
33 Breather Filter 162
34 Location of electrical components 164
4 HYDRAULIC OIL COOLING 167
41 General 168
42 Hydraulic oil cooling circuit 170
43 Back pressure valve adjustment 174
44 Fan drive 176
441 Fan pump 178
442 Pressure relieve valve 179
443 Temperature relay 181
45 Cooler fan drive adjustment 182
5 CONTROLLING 185
51 Pilot pressure supply and adjustment 186
511 Pilot control arrangement 188
512 Pilot pressure adjustment 190
513 Check of Control Pressure 192
52 Slew brakes 194
53 Travel parking brake 197
54 Check of the pilot control logic 199
541 Check sheet FSA Page 1 201
542 Check sheet BHA Page 1 214
6 COMPONENTS 223
61 Main control block and valve arrangement 224
611 FSA arrangement 226
612 BHA arrangement 230
62 Distributor manifold 234
621 Front shovel attachment FSA 234
622 Back hoe attachment BHA 236
623 SRV with throttle check valve 238
624 Anti cavitation valve (check valve) 240
63 Main control block 242
631 Load holding valve 248
632 High pressure filter 250
633 Pressure relieve valves and anti-cavitation valve 252
634 Pressure relieve valves and anti-cavitation valve 254
64 Compact valve blocks 256
65 Compact valve blocks 258
66 Auxiliary gear pumps 260
67 Hydraulic cylinder 262
68 Swing ring 264
7 MAIN HYDRAULIC PUMPS AND PUMP REGULATION 267
71 General 268
711 Pump location 270
72 Main pump operating principles 272
721 Main pump function 277
73 Main pump checks and adjustments 280
731 Peak point diesel engine test 280
732 Pressure transducer test 282
733 Cut off function 283
734 Pump regulation 285
735 Swing pump volume reduction 286
74 Electronic pump regulation 287
75 Pump Controller CR700 290
76 Multi Monitor 292
77 Multimonitor software instruction 294
771 Multimonitor main control 294
772 Service Menu screen 294
773 Monitoring (menu item 01) 295
774 Abnormality Record (menu item 02) 296
775 Default (menu item 03) 299
776 Adjustment (menu item 04) 300
777 Display Setup (menu item 05) 302
778 Table of fault messages and adjustments 303
78 Trouble shooting pump and pump regulation 312
8 OPERATING HYDRAULIC 313
81 General layout 314
82 Floating function of boom and stick only FSA 318
83 Check and Adjustments for MRV’s and SRV’s 320
831 Check and Adjustments for MRV 322
832 Check and Adjustment for SRV’s 324
833 Check and adjustment of the throttle check valves 332
84 Hydraulic for the swing circuit 334
841 Hydraulic for the swing circuit 338
842 Slew gear box L & S 342
843 Slew parking brake 346
844 Slew service brake valve 350
845 Checks and adjustment of the slew pressure valve 355
85 Travel circuit 358
851 Rotary joint 360
852 Travel motor A2FMt 362
853 Travel gear 364
854 Travel parking brake 366
855 Travel control function 368
856 Check and Adjustment SRV travel system 371
9 TRACK TENSION SYSTEM 373
91 General layout 374
92 Track tensioning function 376
921 Cushioning 378
922 Pressure Increasing valve PIV 380
93 Track tensioning adjustment 384
931 Track tensioning function check 386
10 ACCESS LADDER HYDRAULICALLY OPERATED 389
101 Access ladder 390
102 Access ladder functional description 392
11 CENTRAL REFILLING SYSTEM 397
1101 Functional description 398
12 HINTS FOR READING THE HYDRAULIC CIRCUIT DIAGRAM 403
121 General 404
122 Symbolic 406
1221 Lines, unions 407
1222 Components, valves 409
1223 Sensors 409
1224 Valves, valve components 410
1225 Pump, motor, cylinder 414
13 HINTS FOR READING THE ELECTRIC CIRCUIT DIAGRAM 419
131 Designation of electrical components 421
132 Electric symbols 422
133 Symbols 424
1331 Drawing concept 426
1332 Reading of the circuit diagram 432
14 ELECTRONIC TEXT MONITORING SYSTEM ETM 437
141 General Function 438
15 AUTOMATIC LUBRICATION SYSTEM 441
151 General Function 442
152 Function of a lubrication cycle 444
153 Lubrication pump drive 452
154 Lubrication pump 454
1541 Adjustments lubricating pump speed 456
1542 Adjustments lubricating pump pressure 458
155 Lubricant Injector (metering valve) 460
1551 Connection of one or more injectors 462
1552 Function lubrication injector (metering valve) 464
156 End line pressure switch 468
157 Lubricant in line filter 470
158 Lubricant level sensor 472
1581 Capacitive digital type for machines with ETM 472
1582 Capacitive analog type for machines with PLC 474
159 Lubrication system function and controlling 476
1591 Central Lubrication System (CLS) function and controlling with ETM system (PC 3000) 478
1592 Swing ring lubrication system (SLS) function and controlling with ETM system (PC3000) 482
1510 Adjustment of the lubrication system with ETM 489
1511 Trouble shooting lubricating system 490
15111 Lubrication pump cylinder does not move 491
15112 Lubricant pressure built up very slowly or not at all 493
15113 Insufficient lubricant supply to one or more attachment bearings 493
15114 Insufficient lubricant at the swing ring gear 495
40 Troubleshooting 505
Table of Contents 507
Introduction 511
Safety Notes 512
Description of this Troubleshooting Manual 512
General Precautions 513
Electrical Parts 533
Componant Locations 534
Engine Electrical Parts 536
Electrical Parts On PTO, etc 538
Electrical Parts on Pilot Control Frame 540
Electrical Parts on Main Hydraulic Reservoir 542
Electrical Parts on Switch Board X2 544
Electrical Parts on Hydraulic Ldder 546
Electrical Parts of Automatic Lube System 548
Electrical Parts on Air Cleaner and Fuel Tank 552
Overview Connector Types 553
Standard Value Table for Electrical Componants 556
PT100 Temperature Charts 566
Troubleshooting by Trouble Code 569
Message 1 – Gear Lubrication out of Function (PTO) 570
Message 2 – Engine Air Filter Restricted 573
Message 3 – Filter for Control Oil Restricted 575
Message 4 – Oil Tank Breather Filter Restricted 578
Message 5 – Return Oil Filter Restricted 581
Message 6 – Leak Oil Filter Restricted 584
Message 7 – Hydraulic Oil Temperature Too High 587
Message 9 – Low Idle Too High Coolant Temperature 593
Message 10 – Engine Shutdown: Too Low Engine Oil Temperature 598
Message 14 – Too Low Hydraulic Oil Level 603
Message 15 – Caution, Slew Gear House Brake On 607
Message 16 – Caution, Travel Gear House Brake On 612
Message 17 – No Clearance For Starting, Shift Engine to Low Idle 617
Message 18 – Central Lube System Fault 618
Message 19 – Slew Ring Gear Lubrication Fault 625
Message 20 – Pilot Control Cut-Out 633
Message 21 – Central Lube System Empty Grease Barrel 635
Message 22 – Central Lube System Empty Grease Barre 635
Message 24 – Engine Problem: Stop All Control 642
Message 32 – PTO Gear Lube Filter Restricted 647
Message 33 – Cooler Fan Drive Filter Restricted 650
Message 39 – Engine Shutdown Main Shut-Off (Gate) Volve 653
Message 42 – Too Low Coolant Pressure 657
Message 43 – Engine Shutdown: Emergency Stop Switch Actuated 662
Message 44 – Engine Shutdown Safety Switch Actuated 666
Message 45 – Warning Signal from Engine Control Module 670
Message 48 – Too High PTO Gear Oil Temperature 673
Message 50 – Caution, Pull Switch From Ground Man Actuated 676
Message 51 – Engine Shutdown: Pull Switch From Ground Man Actuated 677
Message 52 – Load Limit Clam Defective 679
Message 53 – Pressure Switch of CLS Actuated 682
Message 55 – Refill Hyrdaulic Oil 683
Message 57 – Load Limit Regulation Fault 687
Message 58 – Strainer Oil Cooler Restricted 688
Message 59 – CLS Refill Grease Container 690
Message 60 – SLS Refill Grease Barrel 690
Troubleshooting by Symptoms 697
Symptoms of the Hydraulic System 718
50 Disassembly and Assembly 761
1 INTRODUCTION 773
11 Contents of the binder 774
12 Foreword 775
121 Service 91
2 SAFETY 9
Safety Instructions 9
22 Lifting Gears 777
221 Wire ropes 777
222 Sling accessory 779
223 Weight tables 780
2231 Superstructure 780
2232 Undercarriage 782
2233 Attachment 783
23 Torque charts according to DIN 784
231 Metric standard thread 784
232 Metric fine thread 785
233 Cummins motor torques – metric 786
234 Cummins motor torques – US Customary 786
235 Flange connections 787
24 Conversation table 788
241 Method of using the conversation table 788
242 Millimeter – Inch & Kilogram – Pound 789
243 Liter – US Gallon & Liter – UK Gallon 790
244 KGm – ftlb 791
245 bar – PSI / PSI – bar 792
246 Basic Values in Ohm according to DIN 43 76 793
247 Temperature 794
25 Explanation of abbreviations 795
3 SUPERSTRUCTURE 796
31 Diesel Engine 797
311 Removal of the Diesel engine 797
312 Replacement of the Diesel engine 803
313 Engine torque support and engine/PTO mounts 805
3131 Flexible mounts 806
3132 Torque support 808
314 Alternator 809
3141 Removal of the alternator 809
3142 Replacement of the alternator 811
315 Batteries 812
3151 Removal of the batteries 812
3152 Replacement of the batteries 814
316 Radiator fan 815
3161 Removal of the radiator fan 816
3162 Replacement of the radiator fan 817
317 Radiator 818
3171 Removal of the Radiator 818
3172 Replacement of the radiator 821
318 Starter system 822
3181 Removal of the starter motor 822
3182 Replacement of the starter motor 823
319 Geislinger coupling 825
3191 Removal of the Geislinger coupling 827
3192 Replacement of the Geislinger coupling 829
32 PTO 830
321 Main pumps 830
3211 Preparatory works for main pump removal 832
3212 Removal of Main Pump 1 836
3213 Replacement of main pump 1 838
3214 Removal of Main Pump 2 839
3215 Replacement of main pump 2 842
3216 Removal of Main Pump 3 843
3217 Replacement of main pump 3 846
322 PTO oil circulation pump (auxiliary pump) 847
3221 Removal of the oil circulation pump (auxiliary pump) 847
3222 Replacement of the oil circulation pump (auxiliary pump) 848
323 Pump distributor gearbox (PTO) 849
3231 Removal of the Pump distributor gearbox (PTO) 851
3232 Replacement of the Pump distributor gearbox (PTO) 854
33 Hydraulics 855
331 Hydraulic cooler fan Drive Pump 855
3311 Removal of hydraulic cooler fan drive pump 855
332 Replacement of hydraulic cooler fan drive pump 857
333 Hydraulic Cooler Fan Assembly 858
3331 Removal of hydraulic cooler fan assembly 858
3332 Replacement of hydraulic cooler fan assembly 861
3333 Removal of hydraulic cooler Fan and motor 863
3334 Replacement of hydraulic cooler Fan and motor 864
334 Hydraulic Oil Coolers 865
3341 Removal of the hydraulic oil coolers 868
3342 Replacement of the oil hydraulic cooler 871
3343 Removal of the hydraulic oil cooler frame 873
3344 Replacement of the hydraulic oil cooler frame 877
335 Main Relief Valves (MRV) 878
3351 Removal of the MRV 878
3352 Replacement of the MRV 880
336 pilot oil pump (Gear pump) 881
3361 Removal of the pilot oil pump 882
3362 Replacement of the pilot oil pump 883
337 Main Gate Valve 884
3371 Removal of the main gate valve 884
3372 Replacement of the main gate valve 885
338 Hydraulic Oil Reservoir 887
3381 Removal of the hydraulic oil reservoir 889
3382 Replacement of the hydraulic oil reservoir 897
339 Main Control Valve Blocks 900
3391 Removal of the main control valve blocks 904
3392 Replacement of the main control valve blocks 908
3310 Service line Relief Valves (SRV) 909
33101 Removal of SRV on main Control valve block 909
33102 Replacement of SRV on main control valve blocks 912
3311 Anti-cavitation Valves (ACV) 913
33111 Removal of ACV on Manifold 914
33112 Replacement of ACV on Manifold 918
33113 Removal of ACV on main control valve blocks 920
33114 Replacement of ACV on main control valve blocks 922
3312 Throttle check valves 923
33121 Removal of throttle check valves) 925
33122 Replacement of throttle check valves 928
3313 manifold 929
33131 Removal of the manifold 929
33132 Replacement of the manifold 931
33133 Removal of Diffuser on Manifold 932
33134 Replacement of Diffuser on Manifold 934
34 Slew Drive 936
341 Slew GearBox 937
3411 Removal of the slew gearbox 938
3412 Replacement of the slew gearbox 942
342 Swing Motor 944
3421 Removal of the swing motor 945
3422 Replacement of the swing motor 947
343 Slew parking brake 948
3431 Removal/Disassembly of the parking brake 950
3432 Replacement/assembly of the slew parking brake 953
344 Dynamic Slew Brake 955
3441 Removal of the slew service brake valve 958
3442 Replacement of the slew service brake valve 960
345 Swing circle lubrication pinion 961
3451 Removal of the lubrication pinion assembly 963
3452 Replacement of the lubrication pinion assembly 965
35 Lubrication pumps 966
351 Removal of the Lubrication pump 966
352 Replacement of the lubricating pump 968
36 Pump controller CR700 969
361 Removal of the pump controller CR700 969
362 Replacement of the pump controller CR700 970
37 Operator’s Cab 971
371 Removal of the operator’s cab 973
372 Replacement of the operator’s cab 977
373 Cab mounts 978
3731 Removal of the cab mounts 978
3732 Replacement of the cab mounts 979
374 FRONT WINDOW 980
3741 Removal of the Front window 980
3742 Replacement of the front window 981
375 Operator’s seat 982
3751 Removal of the operator’s seat 982
3752 Replacement of the operator’s seat 983
376 ETM 984
3761 Removal of the ETM 984
3762 Replacement of the ETM 984
377 Access Ladder 985
3771 Removal of access Ladder 986
3772 Replacement of access ladder 988
3773 Removal of access ladder cylinder 989
3774 Replacement of access ladder cylinder 990
378 Removal of the cab base 991
379 Replacement of the cab base 993
38 CounterWeight 995
381 Removal of the counterweight 997
382 Replacement of the counterweight 999
39 Superstructure Lifting1000
391 Remove the Superstructure from the Undercarriage1000
392 Install the Superstructure onto the undercarriage1004
310 Fuel Tank1007
3101 Removal of the Fuel tank1008
3102 Replacement of the Fuel tank1012
4 UNDERCARRIAGE1014
41 Travel system1015
411 Track group1015
4111 Substitute the track group1015
412 Sprocket1020
4121 Removal of the sprocket1020
4122 Replacement of the sprocket1022
413 Guide wheels1023
4131 Removal of the guide wheel assembly1023
4132 Replacement of the guide wheel assembly1024
414 Track tensioning accumulators1025
4141 Removal of the low pressure accumulators1025
4142 Replacement of the low pressure accumulators1027
4143 Removal of the high pressure accumulators1028
4144 Replacement of the high pressure accumulators1029
415 Track tension valve block1030
4151 Removal of the track tensioning valve block1030
4152 Replacement of the track tensioning valve block1031
416 Hydraulic hoses of the track tensioning system1032
4161 Substitute THE HYDRAULIC HOSES1032
417 Travel brake valve block (overspeed valve)1035
4171 Removal of the travel brake valve block1036
4172 Replacement of the travel brake valve block1037
418 Track tensioning cylinders1038
4181 Removal of the track tensioning cylinders1038
4182 Replacement of the track tensioning cylinders1039
419 Travel motor1040
4191 Removal of the travel motors1040
4192 Replacement of the travel motors1044
4110 travel parking brake1045
41101 Removal of the travel parking brake1047
41102 Replacement of the travel parking brake1049
4111 Travel gearbox1051
41111 Removal of the travel gearbox1052
41112 Replacement of the travel gearbox1056
4112 Carrier roller1057
41121 Removal of the carrier roller assembly1057
41122 Replacement of the carrier roller assembly1059
4113 Track roller1061
41131 Removal of the Track roller assembly1061
41132 Replacement of the Track roller assembly1062
42 Car body1063
421 Removal of the car body1063
422 Replacement of the car body1068
4221 Tightening torqe for the crawler carrier mounting bolts1073
423 Rotary joint1077
4231 Removal of the rotary joint1079
4232 Replacement of the rotary joint1082
424 swing circle1083
4241 Removal of the swing circle1085
4242 Replacement of the swing circle1087
5 ATTACHMENT1092
51 Backhoe1093
511 Cylinder bypass test1095
512 Boom1097
5121 Removal of the Boom1097
5122 Replacement of the boom1101
5123 Removal of boom cylinders1103
5124 Replacement of boom cylinders1108
513 Stick1111
5131 Removal of the Stick1111
5132 Replacement of Stick1115
5133 Removal of Stick Cylinders1117
5134 Replacement of Stick cylinders1121
514 Bucket1125
5141 Removal of the bucket1125
5142 Replacement of the bucket1128
5143 Removal of Bucket Cylinders1129
5144 Replacement of Bucket Cylinders1135
515 Bucket link rod and steering rods1137
5151 Removal of the bucket link rod1137
5152 Replacement of the bucket link rod1139
5153 Removal of the steering rods1140
5154 Replacement of the steering rod1142
516 Ground engaging tools (GET)1143
5161 Removal and replacement of the GET1143
517 Hydraulic hoses at the attachment1145
5171 Substitute the boom arc hoses1145
5172 Substitute the boom cylinder hoses1149
5173 Substitute the stick cylinder hoses1153
5174 Substitute the bucket cylinder hoses1157
518 metering valves (grease injectors) at the attachment1161
5181 Removal of the metering valves (grease injectors)1161
5182 Replacement of the metering valves (grease injectors)1162
6 APPENDIX1164
61 Fuel and Lubricants1165
62 Filling capacities1167
63 Tools lists1169
631 used Special tools (Overview)1169
632 Komatsu Tools catalogue1172
64 Work instructions1209
641 Surface coating with INTERZINC 6971209
642 Remove / install the crawler carrier1211
643 Use of the hydraulic torque wrench (supplier’s documentation)1212
65 Service Bulletins1240
651 AH005111242
652 AH005191264
653 AH015181270
654 AH01521a1274
655 AH01531A1286
656 AH02513b1298
657 AH02521b1304
658 AH03509a1312
659 AH035101340
6510 AH045181360
6511 AH055031364
6512 AH055461378
6513 AH065241382
6514 AH065301386
6515 AH075261390