Komatsu PC3400-11M0 Hydraulic Mining Shovel Field Assembly Instructions Manual GEN00237-02

Description

Komatsu PC3400-11M0 Hydraulic Mining Shovel Field Assembly Instructions Manual – GEN00237-02

This Komatsu PC3400-11M0 Field Assembly Instructions manual is the complete guide for assembling the PC3400-11M0 hydraulic mining shovel at the job site. Because the PC3400-11M0 is shipped from the factory in pre-assembled units to meet transport regulations, this manual explains step by step how those units are recombined into the complete working machine, and then how to reverse the process for future disassembly and relocation. Form No. GEN00237-02 covers the undercarriage, superstructure, machine house, cab, attachment, counterweight, and all connecting hydraulic and electrical work, with dedicated chapters for backhoe (BH) and front shovel (FS) configurations.

File Details

• Manual type: Field Assembly Instructions
• Brand: Komatsu
• Model: PC3400-11M0 Hydraulic Mining Shovel
• Document number: GEN00237-02
• Date: 06-2022
• Language: English
• Page count: 349
• File format: PDF

Chapters Covered

• Foreword – delivery of the excavator, precautions for field assembly, selection of work place, preparation and check of protective gear, slings and tools, disposal of removed parts
• Safety – safety information and signal words, sound pressure and vibration levels, general precautions, fire prevention and emergency escape, precautions when getting on or off, burn prevention, high voltage, EMC, jobsite precautions, starting motor, operation, maintenance precautions, accumulator, high-pressure fluid, battery handling, periodic replacement of safety critical parts, special safety equipment including safety harness EN 361
• General – delivery of the excavator, checks prior to initial start-up, lifting and transportation, electrical energy, EMC, monitoring system, assembly site requirements, configuration of components on erection side, required cranes, manpower/assembly time, tools and equipment, standard application torque chart (metric standard and fine thread), special tightening torques, flange joint torques, hydraulic hose connecting nut torques, hydraulic hose line installation, attachment pin installation, transportation postures
• Assembly Sequence – undercarriage (center body, track frames), main valve block, floating valve block (FS), superstructure platform, machine house, air cleaner, exhaust muffler, handrails, service center, L.H. platform, hydraulically operated stairway, machine house L.H. platform, cab base and walks, operator’s cab, fuel tank top platform, lubrication pump station, hydraulic oil tank and platform, superstructure floor frame, R.H. platforms, emergency escape ladder, oil cooler, backhoe boom pre-assembly, front shovel boom pre-assembly, counterweight, boom installation, piping around boom foot, pre-checks before engine start, filling and bleeding the hydraulic system, stick installation, bucket cylinder bleeding, bucket assembly, front shovel attachment, track tensioning bleeding, slew circuit bleeding, track system bleeding
• Disassembly of the Excavator – backhoe disassembly sequence, front shovel disassembly sequence, safety precautions, disposal of waste material
• Final Checks and Adjustments – commissioning check list, adjustment of automatic lubrication systems (CLS and SLS), charging air conditioner with refrigerant, PM-Clinic commissioning procedure, handling of documentation
• ORBCOMM Initialization – PC configuration tool for KOMTRAX Plus / ORBCOMM, method of camera calibration for KomVision (automatic and manual procedures, calibration marker points)

Beyond the sequence itself, the manual supplies the supporting data a field crew actually works from: tightening torques for metric standard and fine threads, flange joint torques, hydraulic hose connecting nut torques, and the special procedure for tightening the undercarriage side frame mounting bolts using the measuring-bolt method with the supplied measuring device (PN 928 476 40). Component weights, dimensions, centre-of-gravity markings, and lifting points are given for every major assembly so that crane capacity and rigging can be planned before the machine arrives on site.

Coverage and Application

The document covers both attachment configurations. Backhoe (BH) chapters walk through pre-assembling the boom and stick cylinders, installing the pre-assembled boom at the superstructure, connecting the stick at the boom, and mounting the bucket. Front shovel (FS) chapters cover pre-assembly of the FS boom with stick and railings, attaching the bucket cylinders to the boom, attaching the stick, and connecting the distributor manifold and cylinder hoses. Where the two configurations differ – hydraulic routing, floating valve block, hose clamp rails, bleeding – the manual gives separate BH and FS illustrations and steps.

Hydraulic work is treated in detail. The manual describes the hydraulic track tensioning system, the filling and bleeding procedure for the main hydraulic system, static bleeding of main, fan, and PPC pumps, dynamic bleeding in three stages, parking brake bleeding for slew and travel, air bleeding from the hydraulic oil tank, track tensioning system, slew circuit, and track system. Every flange connection is called out with the reminder to verify flat seal installation and a flat, level sealing surface.

Safety and Special Procedures

A substantial portion of the manual is given to safety. Signal words (Danger, Warning, Caution, Notice) are defined, and specific hazards are treated page by page: high voltage, high pressure fluid, floating loads, sharp-edged grooves in bushings, squeezing and shearing points, residual energy during welding, and the correct use of the EN 361 safety harness with strap-type fall absorber while working on the boom. The field assembly supervisor’s responsibilities – safety meeting, PPE check, sling and tool inspection, crane signalman appointment, and the daily work plan briefing – are set out in the foreword and repeated where they apply.

Final checks and adjustments are covered separately. The commissioning check list is referenced, automatic lubrication system (CLS and SLS) pause time and injector output adjustment through KOMTRAX Plus is explained, and air conditioner refrigerant charging is described with the safety precautions. The PM-Clinic commissioning procedure and the handling of delivery, commissioning, and EC Declaration of Conformity documentation after assembly are also included, along with ORBCOMM initialization and KomVision camera calibration.

Who This Manual Is For

This is a working document for Komatsu service engineers, field assembly supervisors, crane operators, and technicians responsible for assembling, disassembling, transporting, or commissioning a PC3400-11M0. It assumes the reader is already familiar with heavy equipment practice and is intended to be used alongside the Operation and Maintenance Manual and the separate Troubleshooting and Service manuals.

Get the Komatsu PC3400-11M0 Field Assembly Instructions

With the PC3400-11M0 Field Assembly Instructions manual on hand, an assembly crew can plan lifts, sequence the undercarriage and superstructure correctly, torque the side frame and swing circle bolts to specification, route and connect hydraulic lines without contaminating the circuit, bleed every system in the right order, and hand the machine over in a condition that will pass the commissioning check list. Correct assembly procedure is what keeps a large mining shovel stable through every stage of the build, and this manual is the field reference for exactly that.

IMAGES PREVIEW

Delivered as an instant PDF download after payment, with no shipping and no waiting. Read it on a laptop, tablet, or phone in the assembly area, print the pages you need for the crew, and keep the file for the next time the machine is disassembled for transport. The document number GEN00237-02 makes it easy to confirm you have the correct edition for your machine.