Komatsu PC3000-11 T4 Hydraulic Mining Excavator Field Assembly Manual 06373up-xD-GD-1

Description

• Model List:
  • PC3000-11 T4 Hydraulic Mining Excavator

• 1. Frontcover
• 2. Foreword
• 2.1. Foreword
• 2.2. Precautions for field assembly
• 2.2.1. How to work
• 2.2.2. Preparation and check of protective gear, slings and tools
• 2.2.3. Check during actual work
• 2.3. Disposal of removed parts
• 3. SAFETY
• 3.1. Safety information
• 3.2. Overview
• 3.2.1. Normal operations
• 3.2.2. Regular maintenance
• 3.2.3. Troubleshooting, adjustments and repair
• 3.2.4. Additional safety precautions
• 3.3. Sound pressure and vibration levels in the operators cab
• 3.3.1. Sound
• 3.3.2. Vibration
• 3.4. General precautions common to operation on the excavator
• 3.4.1. Understanding the excavator
• 3.4.2. Precautions before starting operation on the excavator
• 3.4.3. Preparations for safe operation
• 3.4.4. Fire prevention
• 3.4.5. Precautions when getting on or off the excavator
• 3.4.6. Burn prevention
• 3.4.7. Precautions when cleaning cab glass
• 3.4.8. Precautions related to protective structures
• 3.4.9. Precautions related to airborne and ejected debris
• 3.4.10. Electromagnetic comparability (EMC)
• 3.4.11. Precautions at jobsite
• 3.4.12. Starting motor
• 3.4.13. Operation
• 3.5. Precaution for maintenance
• 3.5.1. Isolate the excavator using the transfer pump
• 3.5.2. Isolate the excavator
• 3.5.3. Deisolate the excavator
• 3.5.4. General precaution
• 3.5.5. Precautions for inspection and maintenance
• 3.5.6. Precautions with high pressure fluid
• 3.6. Additional safety information for troubleshooting and adjustments
• 3.6.1. Inspection of the hydraulic system
• 3.6.2. Two workers only when the excavator is running during adjustments
• 3.6.3. Areas of potential danger around the excavator
• 3.7. Special safety equipment
• 3.7.1. Front guard protective structure FOPS for operators cab
• 3.7.2. Object handling
• 3.7.3. Lighting
• 3.7.4. Warning beacon
• 3.7.5. Safety harness in conformity with EN 361 (European standard)
• 3.8. Additional safety precautions
• 3.8.1. When assembling the excavator
• 3.8.2. When disassembling the excavator
• 4. GENERAL
• 4.1. General
• 4.1.1. Delivery of the excavator
• 4.1.2. Assembling the excavator
• 4.1.3. Lifting and transportation
• 4.1.4. Electrical energy
• 4.1.5. Electromagnetic compatibility (EMC)
• 4.1.6. Monitoring system of the machine
• 4.2. Assembly site requirements
• 4.2.1. Configuration of components on erection site (example)
• 4.2.2. Required crane
• 4.2.3. Manpower / assembly time
• 4.2.4. Tools and equipment for assembly
• 4.3. Standard application torque chart
• 4.3.1. Metric standard thread
• 4.3.2. Metric fine thread
• 4.4. Special tightening torques
• 4.5. Torque charts for flange joints
• 4.6. Tightening torque for hydraulic hose connection nut
• 4.7. General installation procedures for hydraulic hose lines
• 4.8. General installation instructions for attachment pins
• 4.8.1. Preparations for assembly
• 4.9. Transportation postures
• 5. ASSEMBLY SEQUENCE
• 5.1. Assembly sequence of the face shovel excavators
• 5.1.1. ASSEMBLY SEQUENCE UNDER CONSIDERATION OF THE MACHINES STABILITY
• 5.2. Assembly sequence of the backhoe excavators
• 5.2.1. ASSEMBLY SEQUENCE UNDER CONSIDERATION OF THE MACHINES STABILITY
• 5.3. Assembling of the undercarriage (tracks, center body, track frames)
• 5.3.1. Assembling of center body to crawler carrier
• 5.3.2. DETERMINING THE TIGHTENING TORQUE
• 5.3.3. Connecting the hydraulic lines to the travel motors
• 5.4. Assembling of the travel gear protection and final assembly
• 5.4.1. Assembling of the travel gear box protection
• 5.4.2. Final assembly of undercarriage
• 5.5. Assembling of the machinery house
• 5.5.1. Assembling of the handrails
• 5.5.2. Assembling of the traverse with SCR catalyst and def tank
• 5.5.3. Assembling of the air cleaner assembly
• 5.6. Assembling of the superstructure platform
• 5.7. Connecting engine oil reserve system
• 5.8. Assembling of the fuel tank
• 5.9. Assembling of the access platform and stairway
• 5.9.1. Assembling of the access platform and the stairway cylinder
• 5.9.2. Assembling of the stairway and the attachment point
• 5.9.3. Assembling of the fuel tank step
• 5.9.4. Assembling of the fuel tank grids and hand rails
• 5.9.5. Assembling of the fuel cooler
• 5.9.6. routing and connecting the hydraulic hose of the stairway cylinder
• 5.10. Assembling of the bha boom
• 5.10.1. Assembling of boom cylinder to the boom (BHA)
• 5.10.2. Assembling of stick cylinder to the boom (BHA)
• 5.10.3. Assembling of boom assembly to superstructure platform (bha)
• 5.11. Assembling of the fsa boom
• 5.11.1. Assembling of boom cylinder and stick cylinder to the boom (FSA attachment)
• 5.11.2. Assembling of the boom assembly
• 5.12. Assembling of the counterweight
• 5.13. Assembling of the cab base
• 5.13.1. Connect cables from the machinery house to cab base
• 5.14. Assembling of the operators cab
• 5.15. Assembling of hydraulic oil cooler assembly
• 5.16. Assembling of the handrails, catwalks and steps
• 5.16.1. Assembling of the catwalk between machinery house and control block frame
• 5.16.2. Assembling of the emergency escape ladder at the cab base
• 5.16.3. Assembling of the emergency escape ladder assembly at the machinery house
• 5.16.4. Assembling of the ladder cylinder
• 5.17. Assembling of additional equipment
• 5.17.1. Assembling of the lubrication pinion assembly
• 5.17.2. Connecting grease lines of the slew circle system
• 5.18. Connecting the central refilling system
• 5.19. Prechecks before initial engine start
• 5.20. Filling and bleeding the hydraulic system
• 5.20.1. FILLING THE HYDRAULIC SYSTEM
• 5.20.2. Bleeding of the suction oil tank
• 5.20.3. Bleeding the main mumps
• 5.20.4. Bleeding the auxiliary pumps PC3000
• 5.20.5. Rebleeding the main pumps after main drive start
• 5.20.6. Bleeding Checklist PC3000
• 5.20.7. Bleeding the hydraulic oil tank
• 5.20.8. Bleeding the slew parking brake
• 5.20.9. Bleeding the travel parking brake
• 5.20.10. Dynamic bleeding
• 5.21. Assembling of the backhoe attachment
• 5.21.1. Assembling of the stick to the boom (BHA attachment)
• 5.21.2. Connecting the hose lines from boom to bucket cylinders
• 5.21.3. Bleeding the bucket cylinder
• 5.21.4. Assembling of the bucket (bha attachment)
• 5.22. Assembling of the face shovel attachment
• 5.22.1. Attach the bucket cylinder to the boom
• 5.22.2. Assembling the stick to the boom
• 5.22.3. Assembling of the bull clam bucket
• 5.22.4. Assembling of the clam
• 5.23. Bleeding of the track tensioning system
• 5.24. Bleeding the slew circuit
• 5.25. Bleeding air from track system
• 6. DISASSEMBLY OF THE MACHINE
• 6.1. Disassembly sequence of the face shovel excavators
• 6.1.1. SAFETY PRECAUTIONS FOR DISASSEMBLING THE MACHINE
• 6.2. Disassembly sequence of the backhoe excavators
• 6.2.1. SAFETY PRECAUTIONS FOR DISASSEMBLING THE MACHINE
• 6.2.2. DISPOSAL OF WASTE MATERIAL
• 7. FINAL CHECKS AND ADJUSTMENTS
• 7.1. COMMISSIONING CHECK LIST
• 7.2. ADJUSTMENT OF AUTOMATIC LUBRICATION SYSTEMS
• 7.2.1. ADJUSTMENT OF AUTOMATIC LUBRICATION SYSTEMS
• 7.2.2. MAIN PUMP ADJUSTMENT IN RELATION TO ALTITUDE AT THE MINE SITE
• 7.2.3. PRESSURE COMPENSATION OF SEALED COMPONENTS
• 7.3. Air conditioning unit
• 7.3.1. COMMISSIONING OF THE AIR CONDITIONING
• 7.3.2. AIR CONDITIONING FOR OPERATORS CAB
• 7.4. PERFORM THE PMCLINIC ACCORDING TO THE PMCLINIC MANUAL
• 7.4.1. VISUAL INSPECTION
• 7.4.2. TRAVELLING INSTRUCTIONS
• 7.5. HANDLING OF DOCUMENTATION AFTER ASSEMBLY AND COMMISSIONING
• 8. ORBCOMM INITIALIZATION
• 8.1. ORBCOMM terminal activation
• 8.1.1. Application form for terminal activation
• 8.2. WebCARE basic information for machine registration