Komatsu PC3400-11M0 Hydraulic Excavator Field Assembly Instruction Manual GEN00237-00 – PDF DOWNLOAD

Description

Komatsu PC3400-11M0 Hydraulic Excavator Field Assembly Instruction Manual GEN00237-00 – PDF DOWNLOAD

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TABLE OF CONTENTS:

Komatsu PC3400-11M0 Hydraulic Excavator Field Assembly Instruction Manual GEN00237-00 – PDF DOWNLOAD

1 FOREWORD 1-1
1 1 FOREWORD 1-2
1 2 PRECAUTIONS FOR FIELD ASSEMBLY 1-3
1 2 1 HOW TO DO WORK 1-3
1 2 2 PREPARATION AND CHECK OF PROTECTIVE GEAR, SLINGS AND TOOLS 1-3
1 2 3 CHECK DURING ACTUAL WORK 1-3
1 3 DISPOSAL OF REMOVED PARTS 1-4
2 SAFETY 2-1
2 1 SAFETY INFORMATION 2-2
2 2 OVERVIEW 2-3
2 2 1 NORMAL OPERATIONS 2-3
2 2 2 REGULAR MAINTENANCE 2-3
2 2 3 TROUBLESHOOTING, ADJUSTMENTS AND REPAIR 2-3
2 2 4 ADDITIONAL SAFETY PRECAUTIONS 2-3
2 3 SOUND PRESSURE AND VIBRATION LEVELS IN THE OPERATOR’S CAB 2-4
2 3 1 SOUND 2-4
2 3 2 VIBRATION 2-4
2 4 GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR 2-5
2 4 1 UNDERSTANDING THE EXCAVATOR 2-5
2 4 2 PRECAUTIONS BEFORE STARTING OPERATION ON THE EXCAVATOR 2-5
2 4 2 1 ENSURING SAFE OPERATION 2-5
2 4 3 PREPARATIONS FOR SAFE OPERATION 2-5
2 4 3 1 PRECAUTIONS REGARDING SAFETY RELATED EQUIPMENT 2-5
2 4 3 2 INSPECTING THE EXCAVATOR 2-5
2 4 3 3 WEAR WELL FITTING CLOTHES AND PROTECTIVE EQUIPMENT 2-6
2 4 3 4 KEEP EXCAVATOR CLEAN 2-6
2 4 3 5 PRECAUTIONS INSIDE OPERATOR’S COMPARTMENT 2-6
2 4 3 6 PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT 2-7
2 4 3 7 IF A PROBLEM IS FOUND 2-7
2 4 4 FIRE PREVENTION 2-7
2 4 4 1 PRECAUTIONS TO PREVENT FIRE 2-7
2 4 4 2 ACTION IF FIRE OCCURS, EMERGENCY EXIT FROM OPERATOR’S CAB 2-9
2 4 5 PRECAUTIONS WHEN GETTING ON OR OFF THE EXCAVATOR 2-10
2 4 5 1 USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF
THE EXCAVATOR 2-10
2 4 5 2 NO JUMPING ON OR OFF THE EXCAVATOR 2-10
2 4 5 3 NO PEOPLE ON THE ATTACHMENT 2-10
2 4 5 4 WORKING IN HIGH PLACES 2-10
2 4 5 5 LEAVING OPERATOR’S SEAT WITH LOCK 2-11
2 4 5 6 LEAVING THE EXCAVATOR 2-11
2 4 6 BURN PREVENTION 2-11
2 4 6 1 HOT COOLANT 2-11
2 4 6 2 HOT OIL 2-12
2 4 7 PRECAUTIONS WHEN CLEANING CAB GLASS 2-12
2 4 8 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES 2-12
2 4 9 PRECAUTIONS RELATED TO AIRBOURNE AND EJECTED DEBRIS 2-13
TOC – 2 PC3400-11 AM-36301-xD-EN-1
2 4 9 1 UNAUTHORIZED MODIFICATION 2-13
2 4 9 2 PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS 2-13
2 4 10 ELECTROMAGNETIC COMPATIBILITY (EMC) 2-13
2 4 11 PRECAUTIONS AT JOBSITE 2-14
2 4 11 1 VISIBILITY FROM OPERATOR’S SEAT 2-15
2 4 11 2 PROXIMITY VISIBILITY 2-15
2 4 11 3 12M RADIUS VISIBILITY 2-15
2 4 11 4 24 M RADIUS VISIBILITY 2-15
2 4 11 5 CHECKING SIGNS AND SIGNALMAN’S SIGNALS 2-16
2 4 11 6 INVESTIGATE AND CONFIRM JOBSITE CONDITIONS 2-16
2 4 11 7 DO NOT GO CLOSE TO HIGH VOLTAGE CABLES 2-16
2 4 11 8 LIGHTNING STRIKES 2-17
2 4 11 9 WORKING ON LOOSE GROUND 2-17
2 4 11 10 GAS, DUST, STEAM, SMOKE AND EXHAUST FUMES 2-17
2 4 11 11 VENTILATION OF ENCLOSED AREAS 2-18
2 4 12 STARTING MOTOR 2-19
2 4 12 1 WARNING TAG 2-19
2 4 12 2 CHECKS BEFORE STARTING MOTOR 2-19
2 4 12 3 PRECAUTION WHEN STARTING MOTOR 2-19
2 4 12 4 PRECAUTION IN COLD AREAS 2-20
2 4 13 OPERATION 2-20
2 4 13 1 CHECKS BEFORE OPERATION 2-20
2 4 13 2 PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE 2-21
2 4 13 3 PRECAUTIONS WHEN TRAVELING 2-22
2 4 13 4 TRAVELING ON SLOPES 2-23
2 4 13 5 OPERATIONS ON SLOPES 2-24
2 4 13 6 PROHIBITED OPERATIONS 2-24
2 4 13 7 TRAVELING ON FROZEN OR SNOW COVERED SURFACES 2-25
2 4 13 8 PARKING THE EXCAVATOR 2-25
2 4 13 9 TRANSPORTATION 2-25
2 5 PRECAUTION FOR MAINTENANCE 2-26
2 5 1 GENERAL PRECAUTIONS 2-26
2 5 1 1 SELECTION AND QUALIFICATION OF PERSONNEL –
BASIC RESPONSIBILITIES 2-27
2 5 1 2 STOP MOTOR FOR MAINTENANCE 2-28
2 5 1 3 WARNING TAG 2-29
2 5 1 4 POWER SOCKETS 2-31
2 5 1 5 KEEP WORKPLACE CLEAN AND TIDY 2-31
2 5 1 6 APPOINT SUPERVISOR WHEN WORKING WITH OTHERS 2-31
2 5 1 7 TWO WORKERS FOR MAINTENANCE WHEN THE EXCAVATOR
IS RUNNING 2-32
2 5 1 8 INSTALLING, REMOVING OR STORING ATTACHMENTS 2-32
2 5 1 9 PRECAUTIONS WHEN WORKING UNDER THE EXCAVATOR OR
EQUIPMENT 2-33
2 5 1 10 NOISE 2-33
2 5 1 11 WHEN USING A HAMMER 2-33
2 5 1 12 PROPER TOOLS 2-34
2 5 1 13 ACCUMULATOR 2-34
2 5 1 14 PERSONNEL 2-34
2 5 2 PRECAUTIONS FOR INSPECTION AND MAINTENANCE 2-35
2 5 2 1 PRECAUTION WHEN WELDING 2-35
AM-36301-xD-EN-1 PC3400-11 TOC – 3
2 5 2 2 BATTERY HANDLING 2-35
2 5 3 PRECAUTIONS WITH HIGH PRESSURE FLUID 2-36
2 5 3 1 PRECAUTIONS WITH HIGH FUEL PRESSURE 2-37
2 5 3 2 HANDLING HIGH PRESSURES HOSES OR PIPES 2-38
2 5 3 3 REPLACEMENT OF HOSE LINES 2-38
2 5 3 4 INSPECTION OF HOSE LINES 2-38
2 5 3 5 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS 2-39
2 5 3 6 AIR CONDITIONING MAINTENANCE 2-39
2 5 3 7 COMPRESSED AIR 2-39
2 5 3 8 WASTE MATERIALS 2-40
2 6 ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS 2-41
2 6 1 INSPECTION OF THE HYDRAULIC SYSTEM 2-41
2 6 2 TWO WORKERS ONLY WHEN THE EXCAVATOR IS RUNNING DURING
ADJUSTMENTS 2-41
2 6 3 AREAS OF POTENTIAL DANGER AROUND THE EXCAVATOR 2-41
2 7 SPECIAL SAFETY EQUIPMENT 2-42
2 7 1 FRONT GUARD PROTECTIVE STRUCTURE ’FOPS’ FOR OPERATOR’S CAB 2-43
2 7 2 OBJECT HANDLING 2-43
2 7 3 LIGHTING 2-43
2 7 4 WARNING BEACON 2-43
2 7 5 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD) 2-43
2 7 5 1 INSTRUCTIONS FOR USE 2-45
2 7 5 2 PRIOR TO USING THE HARNESS (1), THE WEARER SHALL 2-47
2 7 5 3 RECOMMENDATIONS FOR USE OF THE HOLDING HOOKS AND
HOLD-BACK HOOKS OF THE SAFETY HARNESS 2-47
2 7 5 4 INSTRUCTIONS FOR USE 2-49
3 GENERAL 3-1
3 1 GENERAL 3-2
3 1 1 DELIVERY OF THE EXCAVATOR 3-2
3 1 2 ASSEMBLING THE EXCAVATOR 3-2
3 1 2 1 CHECKS PRIOR TO INITIAL START-UP 3-2
3 1 3 LIFTING AND TRANSPORTATION 3-3
3 1 4 ELECTRICAL ENERGY 3-3
3 1 5 ELECTROMAGNETIC COMPATIBILITY (EMC) 3-3
3 1 6 MONITORING SYSTEM OF THE MACHINE 3-3
3 2 ASSEMBLY SITE REQUIREMENTS 3-4
3 2 1 CONFIGURATION OF COMPONENTS ON ERECTION SITE (EXAMPLE) 3-4
3 2 2 REQUIRED CRANES 3-6
3 2 3 MANPOWER / ASSEMBLY TIME 3-6
3 2 4 TOOLS AND EQUIPMENT FOR ASSEMBLY 3-7
3 3 STANDARD APPLICATION TORQUE CHART 3-9
3 3 1 METRIC STANDARD THREAD 3-9
3 3 2 METRIC FINE THREAD 3-10
3 4 SPECIAL TIGHTENING TORQUES 3-11
3 5 TORQUE FOR FLANGE JOINTS 3-12
3 6 TIGHTENING TORQUE FOR HYDRAULIC HOSE CONNECTING NUT 3-13
3 7 GENERAL INSTALLATION PROCEDURES FOR HYDRAULIC HOSE LINES 3-14
TOC – 4 PC3400-11 AM-36301-xD-EN-1
3 8 GENERAL INSTALLATION INSTRUCTIONS FOR ATTACHMENT PINS 3-17
3 8 1 PREPARATIONS FOR ASSEMBLY 3-19
3 9 TRANSPORTATION POSTURES 3-20
4 ASSEMBLY SEQUENCE 4-1
4 1 ASSEMBLE SEQUENCE 4-2
4 1 1 ASSEMBLY SEQUENCE UNDER CONSIDERATION OF THE EXCAVATOR’S
STABILITY 4-2
4 2 ASSEMBLE THE UNDERCARRIAGE (CENTER BODY, TRACK FRAMES) 4-4
4 2 1 PREPARATIONS BEFORE WORKING 4-4
4 2 2 ATTACH CENTER BODY TO TRACK FRAMES 4-4
4 2 2 1 ATTACH CENTER BODY TO L H TRACK FRAME 4-4
4 2 2 2 ATTACH R H TRACK FRAME TO CENTER BODY 4-6
4 2 2 3 DETERMINING THE TIGHTENING TORQUE 4-8
4 2 3 SPECIAL HYDRAULIC TORQUE WRENCH 4-11
4 2 4 CONNECT HYDRAULIC LINES TO THE TRAVEL MOTORS 4-12
4 2 5 HYDRAULIC TRACK TENSIONING SYSTEM 4-14
4 2 5 1 CONNECT HYDRAULIC LINES TO THE TRACK TENSIONING SYSTEM 4-16
4 2 6 FINAL ASSEMBLY OF UNDERCARRIAGE 4-17
4 3 ASSEMBLE THE MAIN VALVE BLOCK ASSEMBLY 4-18
4 4 ASSEMBLE THE SUPERSTRUCTURE PLATFORM 4-20
4 5 ASSEMBLE THE MACHINE HOUSE ASSEMBLY 4-26
4 5 1 ASSEMBLE THE AIR CLEANER ASSEMBLY 4-32
4 5 2 ASSEMBLE THE EXHAUST MUFFLER ASSEMBLY 4-37
4 5 3 ASSEMBLE THE HANDRAILS 4-42
4 5 4 CONNECT SERVICE CENTER 4-44
4 6 ASSEMBLE THE L H PLATFORM 4-46
4 7 ASSEMBLE HYDRAULICALLY OPERATED STAIRWAY 4-58
4 8 ASSEMBLE THE MACHINE HOUSE L H PLATFORM 4-62
4 9 ASSEMBLE THE CAB BASE 4-68
4 9 1 ASSEMBLE THE CAB BASE WALKS AND ATTACHMENTS 4-74
4 10 ASSEMBLE THE OPERATOR’S CAB 4-80
4 11 ASSEMBLE THE FUEL TANK TOP PLATFORM 4-88
4 12 ASSEMBLE THE LUBRICATION PUMP STATION 4-90
4 13 ASSEMBLE THE HYDRAULIC OIL TANK 4-94
4 13 1 ASSEMBLE THE PLATFORM BETWEEN MACHINE HOUSE AND
HYDRAULIC OIL TANK 4-102
4 14 ASSEMBLE THE SUPERSTRUCTURE FLOOR FRAME 4-106
4 15 ASSEMBLE THE MACHINE HOUSE R H PLATFORM 4-109
4 16 ASSEMBLE THE HYDRAULIC OIL TANK R H PLATFORM 4-110
4 17 ASSEMBLE THE EMERGENCY ESCAPE LADDER AT THE MACHINE HOUSE 4-112
4 18 ASSEMBLE THE OIL COOLER ASSEMBLY 4-114
4 19 PRE-ASSEMBLE BOOM & HYDRAULIC CYLINDER 4-126
4 19 1 PREPARATORY WORK 4-126
4 19 1 1 REMOVE THE PRE-INSTALLED PINS AT THE BOOM 4-129
AM-36301-xD-EN-1 PC3400-11 TOC – 5
4 19 1 2 REMOVE THE PRE-INSTALLED BOOM FOOT PINS AND BOOM
CYLINDER FOOT PINS FROM THE SUPERSTRUCTURE PLATFORM 4-131
4 19 1 3 REMOVE THE BOOM CYLINDER FOOT PIN 4-131
4 19 1 4 REMOVE THE PRE-INSTALLED BOOM CYLINDER FOOT PINS FROM
THE BOOM CYLINDERS 4-132
4 19 2 ASSEMBLE THE BOOM CYLINDERS 4-133
4 19 3 ASSEMBLE THE STICK CYLINDERS 4-136
4 20 ASSEMBLE THE COUNTERWEIGHT 4-139
4 21 INSTALL THE PRE-ASSEMBLED BOOM AT THE SUPERSTRUCTURE 4-146
4 21 1 INSTALL THE BOOM CYLINDER AT THE SUPERSTRUCTURE 4-150
4 22 CONNECT THE COMPONENTS AND PIPING AROUND THE BOOM FOOT 4-152
4 23 PRE-CHECKS BEFORE ENGINE START 4-156
4 23 1 PRE-CHECKS PRIOR TO INITIAL START UP 4-156
4 23 2 FILLING AND BLEEDING THE HYDRAULIC SYSTEM 4-158
4 23 2 1 FILLING THE HYDRAULIC SYSTEM 4-160
4 23 2 2 BLEEDING THE HYDRAULIC SYSTEM 4-162
4 24 INSTALL THE STICK AT THE BOOM 4-170
4 25 CONNECT THE STICK CYLINDERS AND STICK 4-174
4 26 CONNECT THE COMPONENTS AND PIPING AROUND THE STICK 4-176
4 27 BLEEDING THE BUCKET CYLINDER 4-178
4 28 ASSEMBLE THE BUCKET 4-179
4 29 BLEED AIR FROM TRACK TENSIONING SYSTEM 4-183
4 30 BLEED SLEW CIRCUIT 4-184
4 31 BLEED AIR FROM TRACK SYSTEM 4-185
5 DISASSEMBLY OF THE EXCAVATOR 5-1
5 1 DISASSEMBLY SEQUENCE OF BACKHOE EXCAVATORS 5-2
5 1 1 SAFETY PRECAUTIONS FOR DISASSEMBLING THE EXCAVATOR 5-3
5 1 2 DISPOSAL OF WASTE MATERIAL 5-4
6 FINAL CHECKS AND ADJUSTMENTS 6-1
6 1 COMMISSIONING CHECK LIST 6-2
6 2 ADJUSTMENT OF AUTOMATIC LUBRICATION SYSTEMS 6-3
6 2 1 SETTING OF PAUSE TIME AND GREASE INJECTOR OUTPUT (CONTINUED) 6-5
6 3 CHARGING AIR CONDITIONER WITH REFRIGERANT 6-7
6 4 PERFORM THE PM – CLINIC COMMISSIONING PROCEDURE ACCORDING TO
THE PM – CLINIC MANUAL 6-9
6 4 1 VISUAL INSPECTION 6-10
6 4 2 TRAVELING INSTRUCTIONS 6-10
6 5 HANDLING OF DOCUMENTATION AFTER ASSEMBLY AND COMMISSIONING 6-11
7 ORBCOMM INITIALIZATION 7-1
7 1 PC CONFIGURATION TOOL FOR KOMTRAX PLUS / ORBCOMM 7-2
7 2 KOMVISION CALIBRATION 7-3

DESCRIPTION:

Komatsu PC3400-11M0 Hydraulic Excavator Field Assembly Instruction Manual GEN00237-00 – PDF DOWNLOAD

SERIAL NUMBERS 36301 and up

FOREWORD:

• Since this excavator is large in size, it is divided into some units to meet the transportation conditions and
  regulations applied to the transportation route when shipped from our factory.
• This manual describes how to assemble the units into the complete excavator in the field. We hope that this excavator
  will display its quality and you will use it safely according to the operation manual.
• Many units are large in size and heavy in weight and may be handled in a dangerous place or posture and many
  workers may have to work together to sling them with cranes.
• Accordingly, before starting the assembly work, the work supervisor is required to hold a safety meeting to oblige
  the workers to put on protective gear and appoint a work leader and a crane work signal man and allot roles to all
  the workers for safe work.
• In particular, the above meeting is more important when worker of different languages work together.
  Note that this manual does not describe the whole specification of the excavator but describes only the basic
  specification.
• If you have any question when dividing and transporting the excavator by yourself in future, ask one of our
  distributors.

PLEASE NOTE:

• This is the SAME exact manual used by your dealers to fix your vehicle.
• The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
• Any queries / doubts regarding your purchase, please feel free to contact [email protected]

S.V