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
0000
________________________
________________________________
__________________________
______________________________
______________________________
__
________________________
________________________________
__________________________
______________________________
______________________________
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urur
e PC4000e PC4000
PC4000Asrev05PC4000Asrev05
Edition 08/2005Edition 08/2005
22
Z23038Z23038
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to the present development and isto the present development and is
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sible future changessible future changes
without prior without prior
noticenotice
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AssAss
embemb
ly ly
ProPro
cedced
urur
e PC4000e PC4000
PC4000Asrev05PC4000Asrev05
Edition 08/2005Edition 08/2005
22
Z23038Z23038
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tattat
ed ied i
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oror
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ioio
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to the present development and isto the present development and is
subject to possubject to pos
sible future changessible future changes
without prior without prior
noticenotice
..

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embemb
ly ly
ProPro
cedced
urur
e PC4000e PC4000
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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nn
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As
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ly
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ced
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Edition 08/2005
4
Z22586

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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
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PC4000Asrev05
Edition 08/2005
6
Z21446

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ced
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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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PC4000Asrev05
Edition 08/2005
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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.

Ass
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Edition 08/2005
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Edition 08/2005
11
ã
•
Before
asse
mbling/disassembling, lifting or t
ransporting thi
s
excava
tor c
ont
act your l
ocal Se
rvi
ce C
enter for all the
nece
ssary instr
uctions
for
safe a
nd economic
asse
mbling/
disasse
mbling
, 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.
2.
3
Transport
ation
and
Lif
tin
g
The transport dimensions and weights
of the
excavator’s component
s
are listed in this manual are for general information only. For the correct
dimensions and weights please refer to the packing list of your
machine.
Observe the operating permits of the low-bed trailers used for
transporta
tion. They contain the permissible load,
loading width and
height.
ã
•
Observe the fede
ral, state a
nd lo
cal laws and regulatio
ns fo
r
transportation of
hea
vy unit
s. Know t
he sa
fety rules and laws
before you transport
this
Exca
vator.
•
Ma
ke sure the flat-be
d trail
er a
nd the comp
onents of t
he
Excava
tor are equipped wit
h the corr
ect safety devices.
•
Secure the Excavator and all components transported on the
trailer against movement.
•
Use exclusively approved handling equipment.
•
Whe
n li
fting
components make sure that the handling
ele
ments
do not c
ause
damage
to th
e component.
•
Se
cure the components safely before removing the lif
ting
straps, ropes or
chains.

Ass
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PC4000Asrev05
Edition 08/2005
12

Ass
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PC4000Asrev05
Edition 08/2005
13
ã
•
Wear safety clothing, goggles, respirator and other safety
device
s, whene
ver worki
ng
conditi
ons
make this necessa
ry.
•
Provide hoists of
suffici
ent ca
pacity to l
ift
hea
vy unit
s. R
efe
r to
the weight specifications.
•
Be sure
to observe the
instruct
ions in the ”
Assembly
Procedure
Ma
nual”
.
•
Liftin
g gea
r, tools and other suspension systems must
be in
good conditi
on and
of suffi
cient lifting capacity.
•
Be sure hydraulic cyli
nders and atta
chment compon
ents are
properly supp
orted from
hoist
and secure
ly fastened,
before
removing supporting pins.
•
Floors must
be clea
n and dry. Aft
er draining operations be sure
all spil
lage is cleane
d up.
2.
4
Ma
npow
er
/
Assembl
y
Time
*
Electric Drive
Version 1 day
longer
Schedule may change, depending on site preparation, man power, daily
working hours and regulations.
Training time may vary, depending on knowledge and number of
people.
M a
n P o
w
e r
(
10 ho
u r s h
i
ft)
1
S u p e r v i s o r 
K M G o
r D e a l
e r 
1 5 d a y s
6
C u s t o m e r
M e c h a n i c s
1 0 d a y s
1
O
p
e
r
a
t
o
r
T
r
a
i
n
e
r 
5 d a y s
d e p e n d i n g o n d e m a n d
Time S
ch
edul
e
Responsible
Dept.
Ass
emb
ly
Service
8*
Setting and Test
Service
2
Customer Acceptance
Service
2
Operator Training
Techn. Support/
Application
5
Ma
intenance Trainin
g
Service
5
10 Hours Day

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Edition 08/2005
14

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PC4000Asrev05
Edition 08/2005
15
2.
5
Assembl
y
Site
Re
qui
rements
•
Well
leveled
(not
slanting)
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
•
1
mobile
crane
90
metric
tons
(1
st
to 3
rd
day)
•
1
mobile
crane
60
metric
tons
(1
st
to 5
th
day)
•
1
mobile
crane
25
metric
tons
(3
rd
to 7
th
day)
•
1
mobile
hydraulic
lift
Qty.
Specificati
on
De
sig
nation
01
8
metric
tons
Telescope
fork
lift
04
6
metric
tons
Chain
pull
04
35
metric
tons
Shackles
04
5
metric
tons
t
Shackles
04
1
metric
ton
Shackles
04
Piece
M10
–
M
30
Eye
bolts
04
30
metric
tons
-
8
m
length
Ropes
04
25
metric
tons
-
8
m
length
Ropes
04
16
metric
tons
-
8
m
length
Ropes
04
12
metric
tons
-
8
m
length
Ropes
01
50
mm
x
1000
mm
length
Push
bar
01
50
mm
x
2000
mm
length
Push
bar
02
5
kg
Large
hammer
30
300
x
300
x
1000
mm
Wooden
blocks
10
300
x
300
x
2500
mm
Wooden
blocks
02
10
–
50
metric
tons
Hydraulic
jacks
02
50
m
Cable
drum
01
230/380
V
Emergenc
y
electricity
generator
or power connection
01
6
mm
–
46
mm
Combination
spanners
01
50
mm
–
75
mm
Open
end
spanner
01
3/4”
Impact
wrench
01
1
1/2”
Impact
wrench
01
1/2”
Ratchet
01
3/4”
Ratchet
01
13
mm
-
19
mm
Sockets
for
½”
Ratchet
01
24
mm
-
36
mm
Sockets
for
3/4”
Ratchet
01
30
mm
and
36
mm
Super
heavy
duty
striking(s
lugging)
wrench
01
0
-
7800
Nm
Hydraulic
torque
wrench
PN
232
615
40)
01
300
-
750
Nm
Torque
wrench
(PN
232
262
40)
01
30
-
150
Nm
Torque
wrench
(PN
232
097
40)
01
1/2”
140
Nm
Cordless
Impact
Wrench

Ass
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PC4000Asrev05
Edition 08/2005
16
Yazaki Connector Set
No.
Qty.
Design
atio
n
Part
No.
1
2
Connector
3-pole
891
040
40
2
2
Connector
3-pole
891
032
40
3
2
Connector
2-pole
891
039
40
4
2
Connector
2-pole
891
031
40
5
2
Connector
1-pole
891
038
40
6
2
Connector
1-pole
891
030
40

Ass
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PC4000Asrev05
Edition 08/2005
17
Qty.
Specificati
on
De
sig
nation
01
5,
6,
8,
10,
12,
14
mm
Screw
driver
sockets
for
1/2”
drive
01
14,
17,
19
mm
Screw
driver
sockets
for
3/4”
drive
01
2
up
to
19
mm
Hex
keys
(Allen
keys)
L-type
01
Electric
welding
machine
01
Lights
for
the
illumination
of
the
working
area
01
Hand
lamp
01
13
mm
Chuck
and
drill
bit
Hand
drill
07
600
bar
Pressure
gauge
03
60
bar
Pressure
gauge
03
25
bar
Pressure
gauge
01
15
bar
Pressure
gauge
02
Multi-meter
(PN
232
619
40)
02
Cable
set
(PN
232
496
40)
01
0
-
2500
min-1
Contact
less
revolution
indicator
02
1,5
mm²
30
m
Cables
with
connectors
01
from
M6
-
M
36
Thread
cutting
set
01
Level
gauge
01
Set
Yazaki
connectors
(refer
to
table
at
the
back)
01
Set
Screw
driver
04
Side
cutter
01
Tip
pliers
01
Combination
pliers
01
Pipe
pliers
01
Set
Cordless
headphone
intercom
(PN
232
621
40)
*
If
available
an
electronic
testing
device
for
pressure,
voltage
and
RPM,
similar Hydrotechnic System 6000
For ele
ctric
driven machines only
Qty.
Spe
cif
icatio
n
De
sign
ation
01
5-10
kV
Part
No.
232
389
40
3-6
kV
Part
No.
232
390
40
Electronic unipolar voltage meter
01
Part
No.
232
386
40
Universal
grounding
short-circuit
ing
device
01
Part
No.
232
387
40
Insulatio
n
tester
01
Part
No.
232
388
40
Phase-sequen
ce
indicator
01
Part
No.
232
593
40
Shock
pulse
measuring
instrument
01
Part
No.
232
594
40
Shock
pulse
transducer
01
Part
No.
232
595
40
Shock
pulse
transducer
01
Part
No.
793
827
73
Clip-on
ammeter
(1000A
ac/dc)

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Edition 08/2005
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PC4000Asrev05
Edition 08/2005
19
2.
6
Spa
ce
and
Placing
Re
quir
ements
On the following pages, 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.
2.
7
Prepa
ration
for
Assembl
y
•
Unload
all co
mponents
so t
hat
no m
ore
move
is ne
cessary!
•
All pins,
bushings,
borings,
bearings
and co
ntact
surfaces
of co
mponents
must be clean
•
Torque v
alues are
listed in
section
4.12 of
the Lub
rication-
and Ma
intenance
Manual - unless being listed in
this Assembly Procedure Booklet
.
•
Obey
all
applicable
safety
and
local
regulations
strictly!
•
Ensure
correct
lifting pr
ocedures
and e
nsure
use of
adequate
lifting
gears!
•
High volt
age inst
allation wo
rks m
ust be
carried
out b
y aut
horized
specialists
only.