Komatsu PC3000-6 Hydraulic Mining Shovel* Factory Service / Repair/ Workshop Manual ! (SERIAL NUMBER: 06208 and up; 46151 and up)

Service Manual PC3000-6 HYDRAULIC MINING SHOVEL SERIAL NUMBER 06208 and up This material is proprietary to Komatsu Mining Germany GmbH and is not to be reproduced, used, or disclosed except in accordance with written authorization from Komatsu Mining Germany GmbH. It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make changes or add improvements at any time without incurring any obligation to install such changes on products sold previously . Due to this continuos program of research and development, periodic revisions may be made to this publication. It is recommended that customer contact their distributor for information on the latest revision. June 2006 Copyright 2006 46151 and up

1 I. INTRODUCTION

2 I.I CONTENTS OF THE BINDER Assembled in this file are the Service Manual with explanation and adjustment of the major components and circuits for your KOMATSU Hydraulic Mining Shovel.

3 I.II FOREWORD Observe the instructions in these manuals for: your Personal SAFETY Operating SAFETY, and READY and EFFICIENT PERFORMANCE of your KOMATSU Hydraulic Mining Shovel. With this SERVICE MANUAL KOMATSU provides you with the description of the construction and the function of the major sys- tems of the Hydraulic Excavator PC 3000-6 D. We describe for you all functions and how to carry out the inspections and adjustments. How do you find "your" desired information? In the TABLE OF CONTENT all the functions and components are shown in their sequence of the description. CAUTION Periodic preventive inspections and maintenance are the surest means of keeping the machine in proper working order. Prompt detection and correction of minor irregulari- ties, and immediate replacement of worn out or broken parts will prevent failures and avoid expenses. Replace damaged graphics and symbols. Observe safety precautions to prevent injury and damage. If after reading this SERVICE MANUAL you can give us sugges- tions and comments for improvements - please do not hesitate to contact us. Komatsu Mining Germany GmbH Service Information Department 8151.40 P.O. Box 18 03 61 D - 40570 Düsseldorf GERMANY FROM THE PRACTICE - FOR THE PRACTICE -

4 WARNING Personnel entrusted with work on the machine must have read the Assembly Manual, the Operation,- Lubrication- and Maintenance Manual and in particular the section on safety before beginning work. Reading the instructions after work has begun is too late. Damages and defects caused by incorrect operation and maintenance are not covered by the manufacturers guarantee. NOTICE If the Shovel is equipped with a fire suppression system, make sure that the system is ready for operation. In order to keep your Shovel in first-class operating condition use only genuine spare and wear parts. The use of any part other than the genuine part releases the KOMATSU MINING GERMANY GmbH from any guarantee. SERVICE For all questions related to your Shovel please contact your local Service Center. In all your written or phoned inquiries please indicate the model and serial number of your Shovel.

5 I.III EXPLANATION OF ABBREVATIONS ABB. Definition A Ampere AC Alternating Current API American Petroleum Institute cSt Centistoke °C Degree Celsius CENSE Engine Monitoring System CLS Central Lubrication System DC Direct Current DIN German Institute for Standardization EBL Electronic Bucket Levelling System ECM Electronic Control Module (Engine) ECS Electronic Control and Monitoring System ETM Electronic Text Monitoring FGPS Front Guard Protective Structure FOPS Falling-Object Protective Structure GL Gear Lubricant h hours of operation HPF High Pressure Filter (Hydraulic Oil) HT High Tension LED Light Emitting Diode LT Low Tension N Newton Nm Newton meter QSK Type of Engine Fuel System PLC Programmable Logic Controller PM Planned Maintenance ppm parts per million PTO Power Take-Off (Pump Distributor Gear) SLS Swing circle pinion Lubrication System V Volt 1/min Revolutions Per Minute (RPM)

6 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

7 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

8 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

Komatsu PC3000-6 Hydraulic Mining Shovel* Factory Service / Repair/ Workshop Manual ! (SERIAL NUMBER: 06208 and up; 46151 and up)

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