Komatsu PC3000-6 Assembly Procedure
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Komatsu PC3000-6 Assembly Procedure

Komatsu PC3000-6 Assembly Procedure

Hydraulic mining shovel
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General Assembly Procedure
Hydraulic Mining Shovel PC3000-6
AS PC3000-6 rev7
Edition October 2005
1

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Summary of Contents for Komatsu PC3000-6

  • Page 1 General Assembly Procedure Hydraulic Mining Shovel PC3000-6 AS PC3000-6 rev7 Edition October 2005...
  • Page 2 Assembly Procedure PC3000-6 All stated information corresponds to the present development and is subject to possible future changes without prior notice. AS PC3000-6 rev7 Edition October 2005...

  • Page 3: Table Of Contents

    Assembly Procedure PC3000-6 GENERAL CONTENT PAGE General ....................5 Delivery of the Excavator ..............5 Assembling of the Excavator............. 5 Transportation and Lifting..............7 Manpower / Assembly Time*............. 9 Assembly Site Requirements ............11 Space and Placing Requirements ........... 15 Preparation for Assembly ..............15 Basic Measurements (Z 24015) ............
  • Page 4 Assembly Procedure PC3000-6 AS PC3000-6 rev7 Edition October 2005...

  • Page 5: General

    Assembly Procedure PC3000-6 General Delivery of the Excavator The excavator is being delivered disassembled into its main components. For the correct dimensions and weights please refer to the packing list of your machine. For assembling the excavator follow the instructions in this manual.
  • Page 6 Assembly Procedure PC3000-6 AS PC3000-6 rev7 Edition October 2005...

  • Page 7: Transportation And Lifting

    Assembly Procedure PC3000-6 ã • Before assembling/disassembling, lifting or transporting this excavator contact your local Service Center for all the necessary instructions for safe and economic assembling/ disassembling, lifting and transportation procedures of your excavator. The sequence of assembly as shown in this Manual. Disassembling is basically the reverse order of the assembling procedure.
  • Page 8 Assembly Procedure PC3000-6 AS PC3000-6 rev7 Edition October 2005...

  • Page 9: Manpower / Assembly Time

    Assembly Procedure PC3000-6 ã • Wear safety clothing, goggles, respirator and other safety devices, whenever working conditions make this necessary. • Provide hoists of sufficient capacity to lift heavy units. Refer to the weight specifications. • Be sure to observe the instructions in the ”Assembly Procedure Manual”.
  • Page 10 Assembly Procedure PC3000-6 AS PC3000-6 rev7 Edition October 2005...

  • Page 11: Assembly Site Requirements

    Assembly Procedure PC3000-6 Assembly Site Requirements Assembly Site Requirements: − Well leveled and compacted ground approx. 150 x 150 ft/50 x 50 m − A container to store the tools, to keep the paper work and for sheltering − 2 mobile cranes 90 metric tons −...
  • Page 12 Assembly Procedure PC3000-6 Yazaki Connector Set Qty. Designation Part No. Connector 3-pole 891 040 40 Connector 3-pole 891 032 40 Connector 2-pole 891 039 40 Connector 2-pole 891 031 40 Connector 1-pole 891 038 40 Connector 1-pole 891 030 40...
  • Page 13 Assembly Procedure PC3000-6 Qty. Specification Designation 30/32/36/41/46/55/65/75 mm Sockets HD for hydr. torque wrench Torque wrench ⇒ drive ½” Range 0 - 250 Nm Torque wrench ⇒ 3/4” Range 250 - 600 Nm Range to 140 Nm Cordless Impact Wrench 1/2 “...
  • Page 14 Assembly Procedure PC3000-6 AS PC3000-6 rev7 Edition October 2005...

  • Page 15: Space And Placing Requirements

    Assembly Procedure PC3000-6 Space and Placing Requirements On the following page, the components are indicated in their approx. dimensions. They are unloaded in a way that a min. space of 1 meter (3 ft) is left between the components, and that there is enough space for the trucks and the cranes.
  • Page 16 Assembly Procedure PC3000-6 Z 24015 AS PC3000-6 rev7 Edition October 2005...

  • Page 17: Basic Measurements (Z24015)

    Assembly Procedure PC3000-6 Basic Measurements (Z24015) Transport Dimensions and Weights (as example) AS PC3000-6 rev7 Edition October 2005...
  • Page 18 Assembly Procedure PC3000-6 AS PC3000-6 rev7 Edition October 2005...

  • Page 19: Illust. Configuration Of Components On Erection Site

    Assembly Procedure PC3000-6 1.10 Illust. Configuration of Components on Erection Site Assembly sequence Subject Illustr. Page Assembly of Undercarriage (Z 24017) 21 Assembly of Superstructure onto the Undercarriage (Z 9031a) 31 Mounting of Boom and boom cylinders (Z 9032) Mounting of Fuel Tank...
  • Page 20 Assembly Procedure PC3000-6 AS PC3000-6 rev7 Edition October 2005...

  • Page 21: Assembly Of Undercarriage (Z 24016; Z 24017; Z 24018)

    Assembly Procedure PC3000-6 2.1. Assembly of Undercarriage (Z 24016; Z 24017; Z 20418) 2.1.1 Assembly Align right side frame horizontally in both directions very exactly. From outside place water level gauge onto steel structure of side frame. Clean the flange areas metallically blank (free of oil, grease; paint; ..) Attach carbody to the crane (oil supply lines to the travel motors pointing in direction of the travel motors).
  • Page 22 Assembly Procedure PC3000-6 Z 24018 AS PC3000-6 rev7 Edition October 2005...
  • Page 23 Assembly Procedure PC3000-6 Clean the flange areas of the second side also metallically blank (free of oil, grease; paint; ...). Lift the 2nd side frame with the crane and align with the carbody. Insert the bolts (2 x 18 pieces + 2 measuring bolts)* with a resilient sleeve and tighten with 2100 Nm.
  • Page 24 Assembly Procedure PC3000-6 Z24019 AS PC3000-6 rev7 Edition October 2005...

  • Page 25: Determination Of The Tightening Torque

    Assembly Procedure PC3000-6 2.1.2 Determination of the tightening torque The required tightening torque for all fastening bolts has to be determined with the 4 measuring bolts (7), which dimension is analogous to the fastening bolts. The required axial tension force of the bolts is determined by means of the elongation of the fastening bolts.
  • Page 26 Assembly Procedure PC3000-6 AS PC3000-6 rev7 Edition October 2005...
  • Page 27 Assembly Procedure PC3000-6 Procedure to determine the tightening torque for inspection after 1000 operating hours Loosen all 4 measuring bolts. Do not lubricate the measuring bolts again. Tighten the 4 measuring bolts with 150 Nm. Install the measuring device (refer to drawing Z 24020).
  • Page 28 Assembly Procedure PC3000-6 PN79337673 PN79337473 PN79337573 AS PC3000-6 rev7 Edition October 2005...

  • Page 29: Final Works

    Assembly Procedure PC3000-6 2.1.3 Final works 1. Connect hose pipes between the oil supply lines of the carbody to the travel motors. 2. Open the cocks inside the side frames for the hydraulic crawler tensioning system (refer to the Maintenance Manual).
  • Page 30 Assembly Procedure PC3000-6 Z 9031a AS PC3000-6 rev7 Edition October 2005...

  • Page 31: Assembly Of Superstructure Onto The Undercarriage (Z 9031A)

    Assembly Procedure PC3000-6 Assembly of Superstructure onto the Undercarriage (Z 9031a) • Hang the superstructure platform horizontally at the cranes. Attach the superstructure to the cranes, lift up the superstructure and carefully clean the surface (contact area) of the slew ring.
  • Page 32 Assembly Procedure PC3000-6 AS PC3000-6 rev7 Edition October 2005...
  • Page 33 Assembly Procedure PC3000-6 AS PC3000-6 rev7 Edition October 2005...
  • Page 34 Assembly Procedure PC3000-6 Z 20949 AS PC3000-6 rev7 Edition October 2005...

  • Page 35: Mounting Of Boom And Boom Cylinders(Z 9032; Z 20949)

    Assembly Procedure PC3000-6 2.3. Mounting of Boom and Boom cylinders(Z 9032; Z 20949) • For the mounting of the pin seals please refer to page 65. • We recommend mounting stick cylinders to the boom before installing the boom. Lift the boom with the stick cylinders and boom cylinders attached.
  • Page 36 Assembly Procedure PC3000-6 AS PC3000-6 rev7 Edition October 2005...

  • Page 37: Mounting Of Fuel Tank (Z21924)

    Assembly Procedure PC3000-6 2.4. Mounting of Fuel Tank (Z 21924) Lift the fuel tank. Lifting eyes are delivered with the machine. Align the fuel tank with the superstructure. Lower the fuel tank fully down and install all bolts. Tighten the bolts with the resp.
  • Page 38 Assembly Procedure PC3000-6 Z 24022 AS PC3000-6 rev7 Edition October 2005...

  • Page 39: Mounting Of Hydraulic Access Ladder (Z 24022)

    Assembly Procedure PC3000-6 Mounting of Hydraulic access Ladder (Z 24022) 1. Install the platform (1) with 8 bolts(45) – M24x130 and the sleeves (46). 2. Install the appendant handrails (2). 3. Mount the hinged ladder according to “Detail A” Position Designation...
  • Page 40 Assembly Procedure PC3000-6 Z24023 AS PC3000-6 rev7 Edition October 2005...

  • Page 41: Mounting Of Cab Base (Z 24023)

    Assembly Procedure PC3000-6 2.5. Mounting of Cab Base (Z 24023) Lift the cab base. Lifting eyes are delivered with the machine. Align the cab base with the superstructure. Lower the cab base fully down and install all bolts. Tighten the bolts with the resp.
  • Page 42 Assembly Procedure PC3000-6 M42x550 4950 Nm Z 24024 AS PC3000-6 rev7 Edition October 2005...

  • Page 43: Mounting Of Counterweight (Z 24024)

    Assembly Procedure PC3000-6 2.6. Mounting of Counterweight (Z 24024) Lift the counterweight. Clean surfaces “A” absolutely free of dirt; oil; fat and paint (metallic clean). Align the counterweight with the superstructure. Lower the counterweight fully down and fasten it with the bolts and washers (01 + 02).
  • Page 44 Assembly Procedure PC3000-6 Z24025 AS PC3000-6 rev7 Edition October 2005...

  • Page 45: Mounting Of Handrails, Steps And Gratings (Z 24025)

    Assembly Procedure PC3000-6 2.7. Mounting of Handrails, Steps and Gratings (Z 24025) During this stage of assembly the handrails, steps and gratings can be mounted to the superstructure, cab base and machinery house. This provides more safety during further assembly.
  • Page 46 Assembly Procedure PC3000-6 Z 24029 AS PC3000-6 rev7 Edition October 2005...

  • Page 47: Mounting Of Cab (Z 24029)

    Assembly Procedure PC3000-6 2.8. Mounting of Cab (Z 24029) Lift the cab. Lifting eyebolts are delivered with the machine. Align the cab with the cab base. Lower the cab fully down and fasten the cab with bolts (1) M16x2 and sleeves (02).
  • Page 48 Assembly Procedure PC3000-6 Z 20371a AS PC3000-6 rev7 Edition October 2005...

  • Page 49: Pre-Checks Prior Initial Start Up

    Assembly Procedure PC3000-6 Pre-checks prior Initial Start up Engine commissioning ã • The local working safety rules must be strictly observed. • Only service personnel necessary for first start up testing are allowed to be on the excavator. • The operator must have read and understood the operation manual.
  • Page 50 Assembly Procedure PC3000-6 Z 25014 AS PC3000-6 rev7 Edition October 2005...
  • Page 51 Assembly Procedure PC3000-6 HYDRAULIC SYSTEM - Vent Hydraulic Pumps (Z25014) Loosen vent plug (A) of suction oil reservoir (1). Retighten vent plug (A) when the out flowing oil is free of air bubbles. Vent main pump (2) by loosening leakage oil line connector(B) and by opening vent valve (C).
  • Page 52 Assembly Procedure PC3000-6 Z 24030 AS PC3000-6 rev7 Edition October 2005...

  • Page 53: Mounting Of Stick

    Assembly Procedure PC3000-6 2.10 Mounting of Stick 2.10.1 Backhoe Attachment (Z 24030) Lift the boom with the excavator hydraulic. Lift the stick by a crane in nearly vertical position. Lower the stick until stick and boom borings are aligned. Insert pin (1) with mounting sleeve* (2).
  • Page 54 Assembly Procedure PC3000-6 Z 20950 AS PC3000-6 rev7 Edition October 2005...

  • Page 55: Bullclam Bucket Attachment (Z 20950; Z 20951; 20952)

    Assembly Procedure PC3000-6 2.10.2 Bullclam Bucket Attachment (Z 20950; Z 20951; 20952) Hook up bucket cylinders that way that rod side shows approx. 45° up to the bearings at the boom. Align the rod eyes with borings at the boom.
  • Page 56 Assembly Procedure PC3000-6 Z 20951 AS PC3000-6 rev7 Edition October 2005...
  • Page 57 Assembly Procedure PC3000-6 Lift the stick. Lift the stick to the bearing position stick to the boom. Lower the stick until stick and boom borings are aligned. Install pin (1), stirrups (2), Plate (3); washers (4) and bolts (5). Lower the stick by means of crane and place lower end onto a pile of wood.
  • Page 58 Assembly Procedure PC3000-6 Z 20952 AS PC3000-6 rev7 Edition October 2005...
  • Page 59 Assembly Procedure PC3000-6 11. Hook up stick cylinder to chain pull and remove transport fastening. 12. Lower stick cylinder by means of chain pull and extend cylinder rod. Align with bearing at stick. 13. Install pin (1), plates (2) and washers (3) with bolts (4).
  • Page 60 Assembly Procedure PC3000-6 Z 23005 AS PC3000-6 rev7 Edition October 2005...

  • Page 61: Assembly Of The Bucket To The Stick

    Assembly Procedure PC3000-6 2.11 Assembly of the bucket to the stick 2.11.1 Assembly of the backhoe to the stick (Z 23005) Position Designation Cap for mounting Final cap Nut for mounting the final cap Nut for mounting whirl Safety bolt...
  • Page 62 Assembly Procedure PC3000-6 Z 20953 AS PC3000-6 rev7 Edition October 2005...

  • Page 63: Assembly Of The Bullclam Bucket To The Stick (Z 20953)

    Assembly Procedure PC3000-6 2.11.2 Assembly of the bullclam bucket to the stick (Z 20953) Place the rear wall as shown on the ground. Lift the attachment and retract the stick cylinders until the stick is in a vertical position. Move the excavator to the bucket.
  • Page 64 Assembly Procedure PC3000-6 Z 20954 AS PC3000-6 rev7 Edition October 2005...
  • Page 65 Assembly Procedure PC3000-6 10. Place the clam shell into the position as shown. Align the rear wall borings by moving boom, stick and bucket cylinder with the clam borings. 11. Install pins (5) and lock catch (3 and 4). 12. Extend clam cylinder to align them with borings in the clam.
  • Page 66 Assembly Procedure PC3000-6 Z23006 AS PC3000-6 rev7 Edition October 2005...

  • Page 67: Mounting Of The Pin Seals

    Assembly Procedure PC3000-6 2.12 Mounting of the Pin Seals 2.12.1 Backhoe (Z 23006) Position Designation 02; 06; 11; 15 seal ring 03; 07; 12; 16 upper ring half 04; 08; 13; 17 lower ring half 05; 10; 14 seal fixing 20;...
  • Page 68 Assembly Procedure PC3000-6 Z 21963 AS PC3000-6 rev7 Edition October 2005...

  • Page 69: Bullclam Bucket (Z 21963)

    Assembly Procedure PC3000-6 2.12.2 Bullclam bucket (Z 21963) The illustration shows the mounting places (A, B; C) of the one piece design seals of the bullclam bucket attachment. Mounting procedure (For example place “B”) Insert both seals (1). Assemble the stick and the rear wall as described on pages before.
  • Page 70 Assembly Procedure PC3000-6 Z24031 AS PC3000-6 rev7 Edition October 2005...

  • Page 71: Putting The Central Lubrication System Into Operation (Z 24031)

    Assembly Procedure PC3000-6 2.13 Putting the Central Lubrication System into operation (Z 24031) In order to ensure adequate pre-lubrication of all attachment bearings. It is necessary to manually lubricate the attachment bearings by applying a grease gun to the grease fittings on each grease injector.
  • Page 72 In order to keep the excavator in first-class operating condition use only genuine Komatsu Mining Germany replacement parts. The use of any part other than the genuine parts releases the Komatsu Mining Germany for any guarantee. AS PC3000-6 rev7 Edition October 2005...

  • Page 73: Standard Application Torque Chart

    Assembly Procedure PC3000-6 2.14 Standard Application Torque Chart 2.14.1 Metric standard thread Wrench size (mm) Tightening torque MA (Nm) Bolt size (mm) 10.9 12.9 M 10 M 12 M 14 M 16 M 18 M 20 M 22 M 24...
  • Page 74 Assembly Procedure PC3000-6 AS PC3000-6 rev7 Edition October 2005...

  • Page 75: Metric Fine Thread

    Assembly Procedure PC3000-6 2.14.2 Metric fine thread Wrench size (mm) Tightening torque MA (Nm) Bolt size (mm) 10.9 12.9 M 8x1.00 M 10x1.00 M 12x1.25 M 14x1.50 M 16x1.50 M 18x2.00 M 20x2.00 M 22x2.00 M 24x2.00 1130 M 27x2.00...

  • Page 76: Torque Chart For Flange Joints

    Assembly Procedure PC3000-6 2.14.3 Torque Chart for Flange Joints - Service Information - Buscherhofstr. 10 40599 Düsseldorf Phone +49 (0)211 7109 0 +49 (0)211 74 33 07 AS PC3000-6 rev7 Edition October 2005...

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