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KOMATSU EXCAVATOR
PC 3000-6
SHOP MANUAL
I.IV TABLE OF CONTENTS
I. INTRODUCTION ...........................................................................................1
I.I CONTENTS OF THE BINDER............................................................................................................ 2
I.II FOREWORD ....................................................................................................................................... 3
I.III EXPLANATION OF ABBREVATIONS ............................................................................................... 5
I.IV TABLE OF CONTENTS...................................................................................................................... 6
II. SAFETY.......................................................................................................13
II.I SAFETY INSTRUCTIONS................................................................................................................. 14
II.II GENERAL PRECAUTIONS.............................................................................................................. 15
II.III PREPARATIONS FOR WORK ......................................................................................................... 16
II.IV PRECAUTIONS DURING WORK..................................................................................................... 17
III. SPECIFICATIONS.......................................................................................19
III.I LIFTING GEARS............................................................................................................................... 20
III.II STANDARD TIGHTENING TORQUE CHART ................................................................................. 22
III.III CONVERSION TABLE...................................................................................................................... 23
III.IV EXPLANATION OF ABBREVATIONS ............................................................................................. 30
III.V GENERAL SPECIFICATIONS .......................................................................................................... 31
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1. MAIN ASSEMBLY GROUPS...................................................................... 33
1.1 General layout.................................................................................................................................. 34
1.2 Superstructure................................................................................................................................. 36
1.3 Power House.................................................................................................................................... 38
1.4 Hydraulic Oil Reservoir................................................................................................................... 40
1.5 Hydraulic Oil Cooler ........................................................................................................................ 42
1.6 Fuel tank (Fuel reservoir)................................................................................................................ 44
1.7 Counter weight................................................................................................................................. 46
1.8 Cab support...................................................................................................................................... 48
1.9 Operators cab .................................................................................................................................. 50
1.10 Control blocks.................................................................................................................................. 52
1.11 Swing gears...................................................................................................................................... 54
1.12 Under carriage ................................................................................................................................. 56
2. DRIVE.......................................................................................................... 59
2.1 Prime drive assembly...................................................................................................................... 60
2.2 Engine and gearbox mount ............................................................................................................ 62
2.3 Torque supports .............................................................................................................................. 65
2.4 Radiator fan Drive Assy. ................................................................................................................ 66
2.5 Pump distributor gearbox (PTO) .................................................................................................... 68
2.5.1 Spline shaft housing ............................................................................................................. 70
2.5.2 PTO lubrication and cooling ................................................................................................. 72
2.5.3 PTO valve adjustments ........................................................................................................ 74
2.6 Coupling ........................................................................................................................................... 78
2.7 Air Filter............................................................................................................................................ 80
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3. HYDRAULIC OIL RESERVOIR ..................................................................83
3.1 Hydraulic oil reservoir .................................................................................................................... 84
3.2 Return and leak oil filter.................................................................................................................. 88
3.3 Breather Filter .................................................................................................................................. 92
3.4 Location of electrical components ................................................................................................ 94
4. HYDRAULIC OIL COOLING.......................................................................97
4.1 General ............................................................................................................................................. 98
4.2 Hydraulic oil cooling circuit.......................................................................................................... 100
4.3 Back pressure valve adjustment.................................................................................................. 104
4.4 Fan drive......................................................................................................................................... 106
4.4.1 Fan pump ........................................................................................................................... 108
4.4.2 Pressure relieve valve ........................................................................................................ 109
4.4.3 Temperature relay .............................................................................................................. 111
4.5 Cooler fan drive adjustment ......................................................................................................... 112
5. CONTROLLING ........................................................................................115
5.1 Pilot pressure supply and adjustment......................................................................................... 116
5.1.1 Pilot control arrangement ................................................................................................... 118
5.1.2 Pilot pressure adjustment ................................................................................................... 120
5.1.3 Check of Control Pressure ................................................................................................. 122
5.2 Slew brakes .................................................................................................................................... 124
5.3 Travel parking brake...................................................................................................................... 127
5.4 Check of the pilot control logic .................................................................................................... 129
5.4.1 Check sheet FSA Page 1 ................................................................................................... 131
5.4.2 Check sheet BHA Page 1................................................................................................... 144
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6. COMPONENTS......................................................................................... 153
6.1 Main control block and valve arrangement................................................................................. 154
6.1.1 FSA arrangement ............................................................................................................... 156
6.1.2 BHA arrangement............................................................................................................... 160
6.2 Distributor manifold ...................................................................................................................... 164
6.2.1 Front shovel attachment FSA............................................................................................. 164
6.2.2 Back hoe attachment BHA ................................................................................................. 166
6.2.3 SRV with throttle check valve............................................................................................. 168
6.2.4 Anti cavitation valve (check valve) ..................................................................................... 170
6.3 Main control block ......................................................................................................................... 172
6.3.1 Load holding valve ............................................................................................................. 178
6.3.2 High pressure filter ............................................................................................................. 180
6.3.3 Pressure relieve valves and anti-cavitation valve............................................................... 182
6.3.4 Pressure relieve valves and anti-cavitation valve............................................................... 184
6.4 Compact valve blocks................................................................................................................... 186
6.5 Compact valve blocks................................................................................................................... 188
6.6 Auxiliary gear pumps .................................................................................................................... 190
6.7 Hydraulic cylinder.......................................................................................................................... 192
6.8 Swing ring ...................................................................................................................................... 194
7. MAIN HYDRAULIC PUMPS AND PUMP REGULATION......................... 197
7.1 General ........................................................................................................................................... 198
7.1.1 Pump location..................................................................................................................... 200
7.2 Main pump operating principles .................................................................................................. 202
7.2.1 Main pump function ............................................................................................................ 207
7.3 Main pump checks and adjustments........................................................................................... 210
7.3.1 Peak point diesel engine test ............................................................................................. 210
7.3.2 Pressure transducer test .................................................................................................... 212
7.3.3 Cut off function ................................................................................................................... 213
7.3.4 Pump regulation ................................................................................................................. 215
7.3.5 Swing pump volume reduction ........................................................................................... 216
7.4 Electronic pump regulation .......................................................................................................... 217
7.5 Pump Controller CR700 ................................................................................................................ 220
7.6 Multi Monitor .................................................................................................................................. 222
7.7 Multimonitor software instruction................................................................................................ 224
7.7.1 Multimonitor main control ................................................................................................... 224
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7.7.2 Service Menu screen.......................................................................................................... 224
7.7.3 Monitoring (menu item 01).................................................................................................. 225
7.7.4 Abnormality Record (menu item 02)................................................................................... 226
7.7.5 Default (menu item 03) ....................................................................................................... 229
7.7.6 Adjustment (menu item 04) ................................................................................................ 230
7.7.7 Display Setup (menu item 05) ............................................................................................ 232
7.7.8 Table of fault messages and adjustments .......................................................................... 233
7.8 Trouble shooting pump and pump regulation ............................................................................ 242
8. OPERATING HYDRAULIC .......................................................................243
8.1 General layout................................................................................................................................ 244
8.2 Floating function of boom and stick only FSA ........................................................................... 248
8.3 Check and Adjustments for MRV’s and SRV’s ........................................................................... 250
8.3.1 Check and Adjustments for MRV ....................................................................................... 252
8.3.2 Check and Adjustment for SRV’s ....................................................................................... 254
8.3.3 Check and adjustment of the throttle check valves ............................................................ 262
8.4 Hydraulic for the swing circuit ..................................................................................................... 264
8.4.1 Hydraulic for the swing circuit............................................................................................. 268
8.4.2 Slew gear box L & S ........................................................................................................... 272
8.4.3 Slew parking brake ............................................................................................................. 276
8.4.4 Slew service brake valve .................................................................................................... 280
8.4.5 Checks and adjustment of the slew pressure valve ........................................................... 285
8.5 Travel circuit .................................................................................................................................. 288
8.5.1 Rotary joint ......................................................................................................................... 290
8.5.2 Travel motor A2FMt............................................................................................................ 292
8.5.3 Travel gear ........................................................................................................................ 294
8.5.4 Travel parking brake........................................................................................................... 296
8.5.5 Travel control function ....................................................................................................... 298
8.5.6 Check and Adjustment SRV travel system......................................................................... 301
9. TRACK TENSION SYSTEM .....................................................................303
9.1 General layout................................................................................................................................ 304
9.2 Track tensioning function............................................................................................................. 306
9.2.1 Cushioning.......................................................................................................................... 308
9.2.2 Pressure Increasing valve PIV ........................................................................................... 310
9.3 Track tensioning adjustment........................................................................................................ 314
9.3.1 Track tensioning function check ......................................................................................... 316
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10. ACCESS LADDER HYDRAULICALLY OPERATED ............................... 319
10.1 Access ladder ................................................................................................................................ 320
10.2 Access ladder functional description.......................................................................................... 322
11. CENTRAL REFILLING SYSTEM.............................................................. 327
11.0.1 Functional description ........................................................................................................ 328
12. HINTS FOR READING THE HYDRAULIC CIRCUIT DIAGRAM.............. 333
12.1 General ........................................................................................................................................... 334
12.2 Symbolic......................................................................................................................................... 336
12.2.1 Lines, unions ...................................................................................................................... 337
12.2.2 Components, valves........................................................................................................... 339
12.2.3 Sensors .............................................................................................................................. 339
12.2.4 Valves, valve components.................................................................................................. 340
12.2.5 Pump, motor, cylinder ........................................................................................................ 344
13. HINTS FOR READING THE ELECTRIC CIRCUIT DIAGRAM................. 349
13.1 Designation of electrical components......................................................................................... 351
13.2 Electric symbols ............................................................................................................................ 352
13.3 Symbols.......................................................................................................................................... 354
13.3.1 Drawing concept................................................................................................................. 356
13.3.2 Reading of the circuit diagram............................................................................................ 362
14. ELECTRONIC TEXT MONITORING SYSTEM
ETM........................................................................................................... 367
14.1 General Function ........................................................................................................................... 368
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15. AUTOMATIC LUBRICATION SYSTEM....................................................371
15.1 General Function ........................................................................................................................... 372
15.2 Function of a lubrication cycle..................................................................................................... 374
15.3 Lubrication pump drive................................................................................................................. 382
15.4 Lubr
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