Komatsu PC4000 Manual

PC4000Asrev05PC4000Asrev05
Edition 08/2005Edition 08/2005
11
GG
eneene
ral Asral As
sembly sembly
PP
roro
cedurecedure
HydrHydr
auliauli
c Minic Mini
ng Shong Sho
vel PCvel PC
4040
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Edition 08/2005Edition 08/2005
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PC4000Asrev05PC4000Asrev05
Edition 08/2005Edition 08/2005
22
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subject to possubject to pos
sible future changessible future changes
without prior without prior
noticenotice
..

AssAss
embemb
ly ly
ProPro
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PC4000Asrev05PC4000Asrev05
Edition 08/2005Edition 08/2005
33
PAGEPAGE
GENERAL CONTENTGENERAL CONTENT
1. Overviews1. Overviews
1.1 1.1
Superstructure Superstructure
55
1.2 1.2
Engine Engine
House House
77
22
..
GeneralGeneral
2.1 2.1
Delivery Delivery
of of
the the
Excavator Excavator
99
2.2 2.2
Assembling Assembling
of of
the the
Excavator Excavator
99
2.3 2.3
TransportaTransporta
tion tion
and and
Lifting Lifting
1111
2.4 2.4
Manpower Manpower
/ /
Assembly Assembly
Time Time
1313
2.5 2.5
Assembly Assembly
Site Site
Requirements Requirements
1515
2.6 2.6
Space Space
and and
Placing Placing
Requirements Requirements
1919
2.7 2.7
Preparation Preparation
for for
Assembly Assembly
1919
2.8 2.8
Basic Basic
Measurements Measurements
and and
Weights Weights
1919
2.9 2.9
Transport Transport
Dimensions Dimensions
and and
Weights Weights
2121
3. 3.
AssemblAssembl
y y
sequencesequence
3.1. 3.1.
Assembly Assembly
of of
UndercarriUndercarri
age age
2323
3.1.1 3.1.1
Mounting Mounting
of of
travel travel
gear gear
breather breather
filters filters
22
55
3.1.2 3.1.2
Track Track
tensioning tensioning
system system
2727
3.2 3.2
Assembly Assembly
of of
Superstructure Superstructure
onto onto
the the
UndercarriagUndercarriag
e e
2929
3.3 3.3
Assembly Assembly
of of
engine engine
house house
3131
3.4 3.4
Mounting Mounting
of of
Boom Boom
3333
3.5 3.5
Mounting Mounting
of of
Hydraulic Hydraulic
Oil Oil
Tank Tank
3535
3.6 3.6
Mounting Mounting
of of
Hydraulic Hydraulic
Oil Oil
Cooler Cooler
3737
3.7 3.7
Mounting Mounting
of of
Fuel Fuel
Tank Tank
3939
3.8 3.8
Mounting Mounting
of of
Hydraulic Hydraulic
access access
Ladder Ladder
4141
3.9 3.9
Mounting Mounting
of of
Cab Cab
Base Base
4343
3.10 3.10
Mounting Mounting
of of
Counterweight Counterweight
4545
3.11 3.11
Mounting Mounting
of of
Handrails, Handrails,
Steps Steps
and and
Gratings Gratings
4747
3.12 3.12
Mounting Mounting
of of
Cable Cable
transfer transfer
to to
the the
Operators Operators
Cab Cab
4949
3.13 3.13
Mounting Mounting
of of
Cab Cab
5353
3.13.1 3.13.1
Mounting Mounting
of of
cab cab
air air
cleaner cleaner
5555
3.14 3.14
Mounting Mounting
of of
Bucket Bucket
Cylinders Cylinders
5757
3.15 3.15
Mounting Mounting
of of
Stick Stick
5959
3.15.1 3.15.1
Mounting Mounting
of of
stick stick
(backhoe) (backhoe)
6161
3.16 3.16
Filling Filling
up up
hydraulic hydraulic
oil oil
tank tank
6363
3.17 3.17
Bleed Bleed
air air
from from
all all
hydraulic hydraulic
tanks tanks
6565
3.18 3.18
Filling Filling
up up
fuel fuel
tank tank
6767
3.19 3.19
Pre-checks Pre-checks
prior prior
Initial Initial
Start-up Start-up
6969
3.20 3.20
Mounting Mounting
of of
stick stick
cylinders cylinders
to to
the the
stick stick
7373
3.21 3.21
Assembly Assembly
of of
Bullclam Bullclam
Bucket Bucket
to to
the the
Stick Stick
7575
3.22 3.22
Mounting Mounting
of of
the the
pin pin
seals seals
7979
3.22.1 3.22.1
Mounting Mounting
of of
pin pin
seals seals
(backhoe) (backhoe)
8181
3.23 3.23
Connection Connection
of of
the the
cable cable
harnessesharnesses
to to
the the
terminal terminal
rails rails
in in
the the
switch switch
box box
“X2” “X2”
8383
3.24 3.24
Putting Putting
the the
Central Central
Lubrication Lubrication
System System
into into
operation operation
8787
3.25 3.25
Standard Standard
Application Application
Torque Torque
Chart Chart
8989
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PC4000Asrev05
Edition 08/2005
4
Z22586

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PC4000Asrev05
Edition 08/2005
5
1.1
Overvi
ew
Supers
tr
uc
tur
e
(Z2
258
6)
(1)
Operator'
s
cab
with
Falling
Object
Protective
Structure
(FOPS)
(2)
Battery
main
switches
(3)
Air
cleaner
for
engine
(4)
Cab
support,
contains
the
electric
control
system
(5)
Swing
circle
(6)
Fuel
tank
(7)
Hydraulically
operated
access
ladder
(8)
Counter
weight
(9)
Hydraulic
oil
cooler
(10)
Hydraulic
oil
reservoir
(11)
Power
take
off
(PTO)
with
hydraulic
pumps
(12)
Flexible
coupling,
oil
filled
(13)
Diesel
engine
(14) Batteries
(15) Radiator
(16)
Control
valves
with
high
pressure
in-line
filters
(17)
Swing
machinery
(18)
Central
lubrication
system
(CLS)
(19)
Swing
circle
pinion
lubrication
system
(SLS)
(20)
Emergency
escape
ladder

Ass
emb
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Pro
ced
ur
e PC4000
PC4000Asrev05
Edition 08/2005
6
Z21446

Ass
emb
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Pro
ced
ur
e PC4000
PC4000Asrev05
Edition 08/2005
7
1.2
Overvi
ew
Engi
ne
Hous
e
(Z2
144
6)
(1)
Exhaust
mufflers
(2)
Engine
air
cleaner
(3)
Expansion
tank
for
radiator
(4)
Central
control
and
filter
carrier
(5)
Power
take
off
(PTO)
(6)
Main
hydraulic
pumps
(7)
Auxiliary
piggipack
hydraulic
pumps
(8)
Hydrauli
c
pump
for
radiator
fan
drive
(9)
Hydraulic
pump
for
the
hydraulic
oil
cooler
fan
drive
(10)
Suction
oil
reservoir
(11)
Flex
coupling,
oil
filled
(12) Batteries
(13)
Diesel
engine
(14)
Hydraulic
motor
for
radiator
fan
drive
(15)
Coolant
radiator
with
fuel
cooler
section

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ced
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PC4000Asrev05
Edition 08/2005
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Ass
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Pro
ced
ur
e PC4000
PC4000Asrev05
Edition 08/2005
9
2. General
2.
1
De
liv
ery
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.
2.
2
Assembl
ing
of
the
Excavator
ã
•
Pe
rsonnel entrusted w
ith
work
on th
e machine must have rea
d
the Assembly Manual, the Operation,- Lubrication- and
Ma
int
enance
Ma
nual and in parti
cular th
e se
cti
on on safety
before be
ginning
work. Re
ading the instruct
ions
afte
r wo
rk has
commenced is too
late
If there are any questions concerning the assembling procedure,
contact your local Service Center.
Prior to first operation, inspect the excavator thoroughly with the
Service
Engineer responsible for the erection of the
machine. Check all fluid
levels according to the Lubrication and
Maintenance Schedule.
Damages and defects caused by incorrect operation and maintenance
are not covered by the manufacturers guarantee.

•
If the exca
vator is
equipped with a fir
e suppression system,
make
sur
e that the
syst
em is ready for operatio
n.