Komatsu PC4000 User manual

PC4000Asrev05
Edition 08/2005 1
General Assembly Procedure
Hydraulic Mining Shovel PC4000
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Assembly Procedure PC4000
PC4000Asrev05
Edition 08/2005 2
Z23038
All stated information corresponds
to the present development and is
subject to possible future changes
without prior notice.

Assembly Procedure PC4000
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PAGE
GENERAL CONTENT
1. Overviews
1.1 Superstructure 5
1.2 Engine House 7
2. General
2.1 Delivery of the Excavator 9
2.2 Assembling of the Excavator 9
2.3 Transportation and Lifting 11
2.4 Manpower / Assembly Time 13
2.5 Assembly Site Requirements 15
2.6 Space and Placing Requirements 19
2.7 Preparation for Assembly 19
2.8 Basic Measurements and Weights 19
2.9 Transport Dimensions and Weights 21
3. Assembly sequence
3.1. Assembly of Undercarriage 23
3.1.1 Mounting of travel gear breather filters 25
3.1.2 Track tensioning system 27
3.2 Assembly of Superstructure onto the Undercarriage 29
3.3 Assembly of engine house 31
3.4 Mounting of Boom 33
3.5 Mounting of Hydraulic Oil Tank 35
3.6 Mounting of Hydraulic Oil Cooler 37
3.7 Mounting of Fuel Tank 39
3.8 Mounting of Hydraulic access Ladder 41
3.9 Mounting of Cab Base 43
3.10 Mounting of Counterweight 45
3.11 Mounting of Handrails, Steps and Gratings 47
3.12 Mounting of Cable transfer to the Operators Cab 49
3.13 Mounting of Cab 53
3.13.1 Mounting of cab air cleaner 55
3.14 Mounting of Bucket Cylinders 57
3.15 Mounting of Stick 59
3.15.1 Mounting of stick (backhoe) 61
3.16 Filling up hydraulic oil tank 63
3.17 Bleed air from all hydraulic tanks 65
3.18 Filling up fuel tank 67
3.19 Pre-checks prior Initial Start-up 69
3.20 Mounting of stick cylinders to the stick 73
3.21 Assembly of Bullclam Bucket to the Stick 75
3.22 Mounting of the pin seals 79
3.22.1 Mounting of pin seals (backhoe) 81
3.23 Connection of the cable harnesses
to the terminal rails in the switch box “X2” 83
3.24 Putting the Central Lubrication System into operation 87
3.25 Standard Application Torque Chart 89
2 cranes
1 crane

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Z22586

Assembly Procedure PC4000
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1.1 Overview Superstructure (Z22586)
(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

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Z21446

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1.2 Overview Engine House (Z21446)
(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) Hydraulic 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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Assembly Procedure PC4000
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2. General
2.1 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.
2.2 Assembling of the Excavator
ã
•Personnel entrusted with work on the machine must have read
the Assembly Manual, the Operation,- Lubrication- and
Maintenance Manual and in particular the section on safety
before beginning work. Reading the instructions after work 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 excavator is equipped with a fire suppression system,
make sure that the system is ready for operation.

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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.
2.3 Transportation and Lifting
The transport dimensions and weights of the excavator’s components
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
transportation. They contain the permissible load, loading width and
height.
ã
•Observe the federal, state and local laws and regulations for
transportation of heavy units. Know the safety rules and laws
before you transport this Excavator.
•Make sure the flat-bed trailer and the components of the
Excavator are equipped with the correct safety devices.
•Secure the Excavator and all components transported on the
trailer against movement.
•Use exclusively approved handling equipment.
•When lifting components make sure that the handling elements
do not cause damage to the component.
•Secure the components safely before removing the lifting
straps, ropes or chains.

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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”.
•Lifting gear, tools and other suspension systems must be in
good condition and of sufficient lifting capacity.
•Be sure hydraulic cylinders and attachment components are
properly supported from hoist and securely fastened, before
removing supporting pins.
•Floors must be clean and dry. After draining operations be sure
all spillage is cleaned up.
2.4 Manpower / Assembly 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.
Man Power (10 hour shift)
1Supervisor
KMG orDealer 15 days
6Customer
Mechanics 10 days
1 Operator Trainer 5 days
depending on demand
Time Schedule Responsible
De
p
t.
Assembly Service 8*
Setting and Test Service 2
Customer Acceptance Service 2
Operator Training Techn. Support/
Application 5
Maintenance Training Service 5
10 Hours Day

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2.5 Assembly Site Requirements
•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 (1st to 3rd day)
•1 mobile crane 60 metric tons (1st to 5th day)
•1 mobile crane 25 metric tons (3rd to 7th day)
•1 mobile hydraulic lift
Qty. Specification Designation
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 Emergency 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(slugging) 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

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Yazaki Connector Set
No. Qty. Designation 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

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Qty. Specification Designation
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 electric driven machines only
Qty. Specification Designation
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-circuiting device
01 Part No. 232 387 40 Insulation tester
01 Part No. 232 388 40 Phase-sequence 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 Cli
p
-on ammeter
(
1000A ac/dc
)

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2.6 Space and Placing Requirements
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 Preparation for Assembly
•Unload all components so that no more move is necessary!
•All pins, bushings, borings, bearings and contact surfaces of components
must be clean
•Torque values are listed in section 4.12 of the Lubrication- and Maintenance
Manual - unless being listed in this Assembly Procedure Booklet.
•Obey all applicable safety and local regulations strictly!
•Ensure correct lifting procedures and ensure use of adequate lifting gears!
•High voltage installation works must be carried out by authorized specialists
only.

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