KOMATSU PC3400-11MO HYDRAULIC EXCAVATOR FIELD ASSEMBLY MANUAL 36301 – PDF DOWNLOAD
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DESCRIPTION:
KOMATSU PC3400-11MO HYDRAULIC EXCAVATOR FIELD ASSEMBLY MANUAL 36301 – PDF DOWNLOAD
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.
TABLE OF CONTENTS:
KOMATSU PC3400-11MO HYDRAULIC EXCAVATOR FIELD ASSEMBLY MANUAL 36301 – PDF DOWNLOAD
COVER 1
1 FOREWORD 8
1 1 Foreword 9
1 2 Precautions for field assembly 10
1 2 1 How to do work 10
1 2 2 Preparation and check of protective gear, slings and tools 10
1 2 3 Check during actual work 10
1 3 Disposal of removed parts 11
2 SAFETY 12
2 1 SAFETY INFORMATION 13
2 2 OVERVIEW 14
2 2 1 NORMAL OPERATIONS 14
2 2 2 REGULAR MAINTENANCE 14
2 2 3 TROUBLESHOOTING, ADJUSTMENTS AND REPAIR 14
2 2 4 ADDITIONAL SAFETY PRECAUTIONS 14
2 3 SOUND PRESSURE AND VIBRATION LEVELS IN THE OPERATOR’S CAB 15
2 3 1 SOUND 15
2 3 2 VIBRATION 15
2 4 GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR 16
2 4 1 UNDERSTANDING THE excavator 16
2 4 2 PRECAUTIONS BEFORE STARTING OPERATION ON THE EXCAVATOR 16
2 4 2 1 ENSURING SAFE OPERATION 16
2 4 3 PREPARATIONS FOR SAFE OPERATION 16
2 4 3 1 PRECAUTIONS REGARDING SAFETY RELATED EQUIPMENT 16
2 4 3 2 INSPECTING THE excavator 16
2 4 3 3 WEAR WELL FITTING CLOTHES AND PROTECTIVE EQUIPMENT 17
2 4 3 4 KEEP excavator CLEAN 17
2 4 3 5 PRECAUTIONS INSIDE OPERATOR’S COMPARTMENT 17
2 4 3 6 PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT 18
2 4 3 7 IF A PROBLEM IS FOUND 18
2 4 4 FIRE PREVENTION 18
2 4 4 1 PRECAUTIONS TO PREVENT FIRE 18
2 4 4 2 ACTION IF FIRE OCCURS, EMERGENCY EXIT FROM OPERATOR’S CAB 20
2 4 5 PRECAUTIONS WHEN GETTING ON OR OFF THE EXCAVATOR 21
2 4 5 1 USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF THE EXCAVATOR 21
2 4 5 2 NO JUMPING ON OR OFF THE excavator 21
2 4 5 3 NO PEOPLE ON THE ATTACHMENT 21
2 4 5 4 WORKING IN HIGH PLACES 21
2 4 5 5 LEAVING OPERATOR’S SEAT WITH LOCK 22
2 4 5 6 LEAVING THE excavator 22
2 4 6 BURN PREVENTION 22
2 4 6 1 Hot coolant 22
2 4 6 2 Hot oil 23
2 4 7 PRECAUTIONS WHEN CLEANING CAB GLASS 23
2 4 8 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES 23
2 4 9 PRECAUTIONS RELATED TO AIRBOURNE AND EJECTED DEBRIS 24
2 4 9 1 UNAUTHORIZED MODIFICATION 24
2 4 9 2 PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS 24
2 4 10 ELECTROMAGNETIC COMPATIBILITY (EMC) 24
2 4 11 PRECAUTIONS AT JOBSITE 25
2 4 11 1 VISIBILITY FROM OPERATOR’S SEAT 26
2 4 11 2 Proximity VISIBILITY 26
2 4 11 3 12m radius visibility 26
2 4 11 4 24 m Radius visibility 26
2 4 11 5 CHECKING SIGNS AND SIGNALMAN’S SIGNALS 27
2 4 11 6 INVESTIGATE AND CONFIRM JOBSITE CONDITIONS 27
2 4 11 7 DO NOT GO CLOSE TO HIGH VOLTAGE CABLES 27
2 4 11 8 Lightning Strikes 28
2 4 11 9 WORKING ON LOOSE GROUND 28
2 4 11 10 GAS, DUST, STEAM, SMOKE AND EXHAUST FUMES 28
2 4 11 11 VENTILATION OF ENCLOSED AREAS 29
2 4 12 STARTING motor 30
2 4 12 1 WARNING TAG 30
2 4 12 2 CHECKS BEFORE STARTING motor 30
2 4 12 3 PRECAUTION WHEN STARTING motor 30
2 4 12 4 PRECAUTION IN COLD AREAS 31
2 4 13 OPERATION 31
2 4 13 1 CHECKS BEFORE OPERATION 31
2 4 13 2 PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE 32
2 4 13 3 PRECAUTIONS WHEN traveling 33
2 4 13 4 TRAVELING ON SLOPES 34
2 4 13 5 OPERATIONS ON SLOPES 35
2 4 13 6 PROHIBITED OPERATIONS 35
2 4 13 7 TRAVELING ON FROZEN OR SNOW COVERED SURFACES 36
2 4 13 8 PARKING THE excavator 36
2 4 13 9 TRANSPORTATION 36
2 5 PRECAUTION FOR MAINTENANCE 37
2 5 1 GENERAL PRECAUTIONS 37
2 5 1 1 SELECTION AND QUALIFICATION OF PERSONNEL – BASIC RESPONSIBILITIES 38
2 5 1 2 STOP motor FOR MAINTENANCE 39
2 5 1 3 WARNING TAG 40
2 5 1 4 Power sockets 42
2 5 1 5 KEEP WORKPLACE CLEAN AND TIDY 42
2 5 1 6 APPOINT SUPERVISOR WHEN WORKING WITH OTHERS 42
2 5 1 7 TWO WORKERS FOR MAINTENANCE WHEN THE excavator IS RUNNING 43
2 5 1 8 INSTALLING, REMOVING OR STORING ATTACHMENTS 43
2 5 1 9 PRECAUTIONS WHEN WORKING UNDER THE excavator OR EQUIPMENT 44
2 5 1 10 NOISE 44
2 5 1 11 WHEN USING A HAMMER 44
2 5 1 12 PROPER TOOLS 45
2 5 1 13 ACCUMULATOR 45
2 5 1 14 PERSONNEL 45
2 5 2 PRECAUTIONS FOR INSPECTION AND MAINTENANCE 46
2 5 2 1 PRECAUTION WHEN WELDING 46
2 5 2 2 BATTERY HANDLING 46
2 5 3 PRECAUTIONS WITH HIGH PRESSURE FLUID 47
2 5 3 1 PRECAUTIONS WITH HIGH FUEL PRESSURE 48
2 5 3 2 HANDLING HIGH PRESSURES HOSES OR PIPES 49
2 5 3 3 REPLACEMENT OF HOSE LINES 49
2 5 3 4 INSPECTION OF HOSE LINES 49
2 5 3 5 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS 50
2 5 3 6 AIR CONDITIONING MAINTENANCE 50
2 5 3 7 COMPRESSED AIR 50
2 5 3 8 WASTE MATERIALS 51
2 6 ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS 52
2 6 1 INSPECTION OF THE HYDRAULIC SYSTEM 52
2 6 2 TWO WORKERS ONLY WHEN THE EXCAVATOR IS RUNNING DURING ADJUSTMENTS 52
2 6 3 AREAS OF POTENTIAL DANGER AROUND THE EXCAVATOR 52
2 7 SPECIAL SAFETY EQUIPMENT 53
2 7 1 FRONT GUARD PROTECTIVE Structure ’FOPS’ FOR OPERATOR’S CAB 54
2 7 2 OBJECT HANDLING 54
2 7 3 LIGHTING 54
2 7 4 WARNING BEACON 54
2 7 5 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD) 54
2 7 5 1 INSTRUCTIONS FOR USE 56
2 7 5 2 PRIOR TO USING THE HARNESS (1), THE WEARER SHALL 58
2 7 5 3 RECOMMENDATIONS FOR USE OF THE HOLDING HOOKS AND HOLD- BACK HOOKS OF THE SAFETY HARNESS 58
2 7 5 4 INSTRUCTIONS FOR USE 60
3 GENERAL 62
3 1 General 63
3 1 1 DELIVERY OF THE EXCAVATOR 63
3 1 2 ASSEMBLING THE EXCAVATOR 63
3 1 2 1 Checks prior to initial start-up 63
3 1 3 LIFTING AND TRANSPORTATION 64
3 1 4 ELECTRICAL ENERGY 64
3 1 5 ELECTROMAGNETIC COMPATIBILITY (EMC) 64
3 1 6 MONITORING SYSTEM OF THE Machine 64
3 2 Assembly site requirements 65
3 2 1 Configuration of components on erection side (example) 65
3 2 2 Required cranes 67
3 2 3 Manpower / Assembly Time 67
3 2 4 Tools and equipment for assembly 68
3 3 Standard application for torque chart 70
3 3 1 Metric standard thread 70
3 3 2 Metric fine thread 71
3 4 Special Tightening Torques 72
3 5 Torque for flange Joints 73
3 6 Tightening Torque for hydraulic hose connecting nut 74
3 7 General installation procedures for hydraulic hose lines 75
3 8 General installation instructions for attachment pins 78
3 8 1 Preparations for assembyl 80
3 9 Transportation Postures 81
4 ASSEMBLY SEQUENCE 94
4 1 Assemble sequence 95
4 1 1 Assembly sequence under consideration of the excavator’s stability 95
4 2 Assemble the undercarriage (center body, track frames) 97
4 2 1 Preparations before working 97
4 2 2 Attach Center body to Track Frames 97
4 2 2 1 Attach Center body to L H Track Frame 97
4 2 2 2 Attach R H Track Frame to Center body 99
4 2 2 3 Determining the Tightening Torque 101
4 2 3 Special hydraulic torque wrench 104
4 2 4 Connect Hydraulic Lines to the Travel Motors 105
4 2 5 Hydraulic Track Tensioning system 107
4 2 5 1 Connect Hydraulic Lines to the Track tensioning system 109
4 2 6 Final Assembly of Undercarriage 110
4 3 Assemble the main valve block assembly 111
4 4 Assemble the superstructure platform 113
4 5 Assemble the machine house assembly 119
4 5 1 Assemble the air cleaner Assembly 125
4 5 2 Assemble the exhaust muffler assembly 130
4 5 3 Assemble the handrails 135
4 5 4 Connect service center 137
4 6 Assemble the L H platform 139
4 7 Assemble hydraulically operated stairway 151
4 8 Assemble the machine house L H platform 155
4 9 Assemble the cab base 161
4 9 1 Assemble the cab base walks and attachments 167
4 10 Assemble the operator’s cab 173
4 11 Assemble the fuel tank top platform 181
4 12 Assemble the lubrication pump station 183
4 13 Assemble the hydraulic oil tank 187
4 13 1 Assemble the platform between machine house and hydraulic oil tank 195
4 14 Assemble the superstructure floor frame 199
4 15 Assemble the machine house r h platform 202
4 16 Assemble the hydraulic oil tank R H platform 203
4 17 Assemble the emergency escape ladder at the machine house 205
4 18 Assemble the oil cooler assembly 207
4 19 Pre-assemble boom & hydraulic cylinder 219
4 19 1 Preparatory work 219
4 19 1 1 Remove the pre-installed pins at the boom 222
4 19 1 2 Remove the pre-installed boom foot pins and boom cylinder foot pins from the superstructure platform 224
4 19 1 3 Remove the boom cylinder foot pin 224
4 19 1 4 Remove the pre-installed boom cylinder foot pins from the boom cylinders 225
4 19 2 Assemble the boom cylinders 226
4 19 3 Assemble the stick cylinders 229
4 20 Assemble the counterweight 232
4 21 Install the Pre-assembled boom at the superstructure 239
4 21 1 Install the boom cylinder at the superstructure 243
4 22 Connect the components and piping around the boom foot 245
4 23 Pre-checks before engine start 249
4 23 1 Pre-checks prior to initial start up 249
4 23 2 Filling and bleeding the hydraulic system 251
4 23 2 1 Filling the hydraulic system 253
4 23 2 2 Bleeding the hydraulic system 255
4 24 Install the stick at the boom 263
4 25 Connect the stick cylinders and stick 267
4 26 Connect the components and piping around the stick 269
4 27 Bleeding the bucket cylinder 271
4 28 Assemble the bucket 272
4 29 Bleed air from track tensioning system 276
4 30 Bleed slew circuit 277
4 31 Bleed air from track system 278
5 DISASSEMBLY OF THE EXCAVATOR 280
5 1 Disassembly sequence of backhoe excavators 281
5 1 1 Safety precautions for disassembling the excavator 282
5 1 2 Disposal of the waste material 283
6 FINAL CHECKS AND ADJUSTMENTS 284
6 1 Commissioning check list 285
6 2 Adjustment of automatic lubrication systems 286
6 2 1 Setting of pause time and grease injector output (continued) 288
6 3 Charging air conditioner with refrigerant 290
6 4 Perform the PM – Clinic commissioning procedure according to the PM – Clinic manual 292
6 4 1 Visual inspection 293
6 4 2 Travelling inspection 293
6 5 Handling of documentation after assembly and commissioning 294
7 ORBCOMM INITIALIZATION 296
7 1 PC configuration tool for KOMTRAX Plus / ORBCOMM 297
7 2 KomVision Calibration 298
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