Komatsu PC4000 Manual

PC4000Asrev05PC4000Asrev05

Edition 08/2005Edition 08/2005

eneene

ral Asral As

sembly sembly

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cedurecedure

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PAGEPAGE

GENERAL CONTENTGENERAL CONTENT

1. Overviews1. Overviews

1.1 1.1

Superstructure Superstructure

1.2 1.2

Engine Engine

House House

GeneralGeneral

2.1 2.1

Delivery Delivery

of of

the the

Excavator Excavator

2.2 2.2

Assembling Assembling

of of

the the

Excavator Excavator

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

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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Pro

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PC4000Asrev05

Edition 08/2005

Z22586

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PC4000Asrev05

Edition 08/2005

1.1

Overvi

Supers

tur

(Z2

258

(1)

Operator'

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

Pro

ced

e PC4000

PC4000Asrev05

Edition 08/2005

Z21446

Ass

emb

Pro

ced

e PC4000

PC4000Asrev05

Edition 08/2005

1.2

Overvi

Engi

Hous

(Z2

144

(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

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

Ass

emb

Pro

ced

e PC4000

PC4000Asrev05

Edition 08/2005

Ass

emb

Pro

ced

e PC4000

PC4000Asrev05

Edition 08/2005

2. General

liv

ery

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.

Assembl

ing

the

Excavator

•

rsonnel entrusted w

ith

work

on th

e machine must have rea

the Assembly Manual, the Operation,- Lubrication- and

int

enance

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

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