Komatsu PC3400-11M0 Hydraulic Mining Shovel Field Assembly Manual GEN00237-03

Description

• Model List:
  • PC3400-11M0 Hydraulic Mining Shovel

• 1. COVER
• 2. FOREWORD
• 2.1. Foreword
• 2.2. Precautions for field assembly
• 2.2.1. How to do 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 airbourne and ejected debris
• 3.4.10. Electromagnetic compatibility (EMC)
• 3.4.11. Precautions at jobsite
• 3.4.12. Starting motor
• 3.4.13. Operation
• 3.5. Precaution for maintenance
• 3.5.1. General precautions
• 3.5.2. Precautions for inspection and maintenance
• 3.5.3. 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 for assembly
• 3.8.1. When assembling the excavator
• 3.8.2. When disassembling the excavator
• 3.8.3. When transporting the disassembled 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 side (example)
• 4.2.2. Required cranes
• 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 for flange Joints
• 4.6. Tightening Torque for hydraulic hose connecting 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. ASSEMBLE SEQUENCE OF BACKHOE (BH) SPEC
• 5.1.1. Assembly sequence under consideration of the excavators stability
• 5.2. ASSEMBLE SEQUENCE OF FRONT SHOVEL (FS) SPEC
• 5.2.1. Assembly sequence under consideration of the excavators stability
• 5.3. Assemble the undercarriage (center body, track frames)
• 5.3.1. Preparations before working
• 5.3.2. Attach Center body to Track Frames
• 5.3.3. Special hydraulic torque wrench
• 5.3.4. Connect Hydraulic Lines to the travel motors
• 5.3.5. Connect Hydraulic Lines to the travel motors
• 5.3.6. Hydraulic track tensioning system
• 5.3.7. Final Assembly of undercarriage
• 5.4. Assemble the main valve block assembly (IF NOT EQUIPPED)
• 5.5. Assemble the floating valve block assembly (for FRONT SHOVEL (FS))
• 5.6. Assemble the superstructure platform
• 5.7. Assemble the machine house assembly
• 5.7.1. Assemble the air cleaner Assembly
• 5.7.2. Assemble the exhaust muffler assembly
• 5.7.3. Assemble the handrails
• 5.7.4. Connect service center
• 5.8. Assemble the L.H. platform
• 5.9. Assemble hydraulically operated stairway
• 5.10. Assemble the machine house L.H. platform
• 5.11. Assemble the cab base
• 5.11.1. Assemble the cab base walks and attachments
• 5.12. Assemble the operators cab
• 5.13. Assemble the fuel tank top platform
• 5.14. Assemble the lubrication pump station
• 5.15. Assemble the hydraulic oil tank
• 5.15.1. Assemble the platform between machine house and hydraulic oil tank
• 5.16. Assemble the superstructure floor frame
• 5.17. Assemble the machine house R.H. platform
• 5.18. Assemble the hydraulic oil tank R.H. platform
• 5.19. Assemble the emergency escape ladder at the machine house
• 5.20. Assemble the oil cooler assembly
• 5.21. Preassemble for backhoe (BH) BOOM
• 5.21.1. Preparatory work
• 5.21.2. Assemble the boom cylinders
• 5.21.3. Assemble the stick cylinders
• 5.21.4. Install the Preassembled boom at the superstructure
• 5.21.5. Connect the components and piping around the boom foot
• 5.22. Preassembly of front shovel boom
• 5.22.1. ATTACHMENT POINTS FOR SAFETY HARNESS ON BOOM
• 5.22.2. GENERAL INSTALLATION INSTRUCTIONS FOR ATTACHMENT PINS
• 5.22.3. ATTACH BOOM CYLINDERS AND STICK CYLINDERS TO THE BOOM
• 5.22.4. ATTACH BOOM TO SUPERSTRUCTRE AFRAME
• 5.23. Assemble the counterweight
• 5.24. Prechecks before engine start
• 5.24.1. Prechecks prior to initial start up
• 5.24.2. Filling and bleeding the hydraulic system
• 5.25. Assembly backhoe attachment
• 5.25.1. Install the stick at the boom (for backhoe (BH))
• 5.25.2. Connect the stick cylinders and stick (for backhoe (BH))
• 5.25.3. Connect the components and piping around the stick (for backhoe (BH))
• 5.25.4. Assemble the bucket (for backhoe (BH))
• 5.26. Assembly front shovel attachment
• 5.26.1. Attaching the bucket cylinders to the boom
• 5.26.2. Attaching the stick to the boom
• 5.26.3. Connecting hose lines from main valve block to boom
• 5.26.4. Connecting hose lines from boom to boom cylinders
• 5.26.5. Connecting hose lines from boom to stick cylinders
• 5.26.6. Connecting hose lines from stick to bucket cylinders
• 5.26.7. Connecting stick cylinders to the stick
• 5.26.8. ASSEMBLE THE BUCKET (FOR FRONT SHOVEL (FS))
• 5.27. Bleed hydraulic circuits
• 5.27.1. Bleed air from hydraulic oil tank
• 5.27.2. Bleed air from track tensioning system
• 5.27.3. Bleed slew circuit
• 5.27.4. Bleed air from track system
• 5.27.5. Bleeding the attachment Backhoe (BH) / Front shovel (FS)
• 6. DISASSEMBLY OF THE EXCAVATOR
• 6.1. Disassembly sequence of backhoe excavators
• 6.2. Disassembly sequence of front shovel
• 6.3. Safety precautions for disassembling the excavator
• 6.3.1. Disposal of the waste material
• 7. FINAL CHECKS AND ADJUSTMENTS
• 7.1. Commissioning check list
• 7.2. Adjustment of automatic lubrication systems
• 7.2.1. Setting of pause time and grease injector output (continued)
• 7.3. Charging air conditioner with refrigerant
• 7.4. Perform the PM Clinic commissioning procedure according to the PM Clinic manual
• 7.4.1. Visual inspection
• 7.4.2. Traveling instructions
• 7.5. Handling of documentation after assembly and commissioning
• 8. ORBCOMM INITIALIZATION
• 8.1. PC configuration tool for KOMTRAX Plus / ORBCOMM
• 8.2. Method of camera calibration for KomVision
• 8.2.1. Calibration procedure
• 8.2.2. Reference