Komatsu PC4000 Manual
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Komatsu PC4000 Manual

General assembly procedure hydraulic mining shovel
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General Assembly Procedure
Hydraulic Mining Shovel PC4000
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PC4000Asrev05
1
Edition 08/2005

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Summary of Contents for Komatsu PC4000

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

  • Page 3: Table Of Contents

    Assembly Procedure PC4000 PAGE GENERAL CONTENT Overviews Superstructure Engine House General Delivery of the Excavator Assembling of the Excavator Transportation and Lifting Manpower / Assembly Time Assembly Site Requirements Space and Placing Requirements Preparation for Assembly Basic Measurements and Weights...
  • Page 4 Assembly Procedure PC4000 Z22586 PC4000Asrev05 Edition 08/2005...
  • Page 5 Assembly Procedure PC4000 1.1 Overview Superstructure (Z22586) Operator's cab with Falling Object Protective Structure (FOPS) Battery main switches Air cleaner for engine Cab support, contains the electric control system Swing circle Fuel tank Hydraulically operated access ladder Counter weight Hydraulic oil cooler...
  • Page 6 Assembly Procedure PC4000 Z21446 PC4000Asrev05 Edition 08/2005...

  • Page 7: Engine House

    Assembly Procedure PC4000 1.2 Overview Engine House (Z21446) Exhaust mufflers Engine air cleaner Expansion tank for radiator Central control and filter carrier Power take off (PTO) Main hydraulic pumps Auxiliary piggipack hydraulic pumps Hydraulic pump for radiator fan drive Hydraulic pump for the hydraulic oil cooler fan drive...
  • Page 8 Assembly Procedure PC4000 PC4000Asrev05 Edition 08/2005...

  • Page 9: General

    Assembly Procedure PC4000 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 10 Assembly Procedure PC4000 PC4000Asrev05 Edition 08/2005...

  • Page 11: Transportation And Lifting

    Assembly Procedure PC4000 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 12 Assembly Procedure PC4000 PC4000Asrev05 Edition 08/2005...

  • Page 13: Manpower / Assembly Time

    Assembly Procedure PC4000 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 14 Assembly Procedure PC4000 PC4000Asrev05 Edition 08/2005...

  • Page 15: Assembly Site Requirements

    Assembly Procedure PC4000 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 (1...
  • Page 16 Assembly Procedure PC4000 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 17 Assembly Procedure PC4000 Qty. Specification Designation 5, 6, 8, 10, 12, 14 mm Screw driver sockets for 1/2” drive 14, 17, 19 mm Screw driver sockets for 3/4” drive 2 up to 19 mm Hex keys (Allen keys) L-type Electric welding machine...
  • Page 18 Assembly Procedure PC4000 PC4000Asrev05 Edition 08/2005...

  • Page 19: Space And Placing Requirements

    Assembly Procedure PC4000 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.
  • Page 20 Assembly Procedure PC4000 Z23038 PC4000Asrev05 Edition 08/2005...

  • Page 21: Transport Dimensions And Weights

    Assembly Procedure PC4000 Basic Measurements (Z23038) Transport Dimensions and Weights (as example) (For exact Dimensions and Weights refer to the packing list of your machine.) Face Shovel Backhoe L.H. and R.H. Crawler side frame L.H. and R.H. Crawler side frame...
  • Page 22 Assembly Procedure PC4000 Z21859 Z 21859 PC4000Asrev05 Edition 08/2005...

  • Page 23: Assembly Of Undercarriage

    Assembly Procedure PC4000 3.1. Assembly of Undercarriage (Z21859) Align side frame horizontally in both directions very exactly. From outside place water level gauge onto steel structure of side frame. Pull back all 8 pins (05) out of the outer borings (2+3) of the center section.
  • Page 24 Assembly Procedure PC4000 Z23036 PC4000Asrev05 Edition 08/2005...

  • Page 25: Mounting Of Travel Gear Breather Filters

    Assembly Procedure PC4000 3.1.1. Mounting of travel gear breather filters (Z21860) • Locate the breather filters of both travel gears in the centre part of the undercarriage. • Route the hoses as shown in the illustration. PC4000Asrev05 Edition 08/2005...
  • Page 26 Assembly Procedure PC4000 Z23037 PC4000Asrev05 Edition 08/2005...

  • Page 27: Track Tensioning System

    Assembly Procedure PC4000 3.1.2 Track tensioning system (Z23037) Working position: Closed Ex works: closed Working position: Open Ex works: closed Marking below the washer shows the valve position “O” open “C” closed • The valve position (open or closed) is not depend on the lever position.
  • Page 28 Assembly Procedure PC4000 Z21863 Z 21863 PC4000Asrev05 Edition 08/2005...

  • Page 29: Assembly Of Superstructure Onto The Undercarriage

    Assembly Procedure PC4000 3.2. Assembly of Superstructure onto the Undercarriage (Z23863) Attach the superstructure to the cranes, lift up the superstructure and very carefully clean the contact surfaces of the slew ring and the carbody from the paste with a appropriate solvent.
  • Page 30 Assembly Procedure PC4000 Z 21863 PC4000Asrev05 Edition 08/2005...

  • Page 31: Assembly Of Engine House

    Assembly Procedure PC4000 Assembly of engine house (Z21863) Attach the unit to the crane (use only the attached lifting points (A). Lower the unit as required so that two bolts with washers (02 + 03) for guiding can be inserted.
  • Page 32 Assembly Procedure PC4000 Z21864 Z 21864 PC4000Asrev05 Edition 08/2005...

  • Page 33: Mounting Of Boom

    Assembly Procedure PC4000 Mounting of Boom (Z21864) • For the mounting of the pin seals please refer to page 78. Lift the boom with the cylinders attached.(You can alleviate your job, if you lift the front part of the boom higher than the back part.)
  • Page 34 Assembly Procedure PC4000 Z23039 Z 21865a PC4000Asrev05 Edition 08/2005...

  • Page 35: Mounting Of Hydraulic Oil Tank

    Assembly Procedure PC4000 3.5. Mounting of Hydraulic Oil Tank (Z23039) Lift the Hydraulic Oil Tank. Lifting eyes are delivered with the machine. Align the Hydraulic Oil Tank with the superstructure. Lower the Hydraulic Oil Tank fully down and install all bolts.
  • Page 36 Assembly Procedure PC4000 Z21866 Z 21866 PC4000Asrev05 Edition 08/2005...

  • Page 37: Mounting Of Hydraulic Oil Cooler

    Assembly Procedure PC4000 3.6. Mounting of Hydraulic Oil Cooler (Z21866) Lift the Hydraulic Oil Cooler. Lifting eyes are delivered with the machine. Align the Hydraulic Oil Cooler with the superstructure. (Pay attention to the course of the hydraulic lines!) Lower the Hydraulic Oil Cooler fully down and install all 8 bolts .
  • Page 38 Assembly Procedure PC4000 Z21867 Z 21867a PC4000Asrev05 Edition 08/2005...

  • Page 39: Mounting Of Fuel Tank

    Assembly Procedure PC4000 3.7. Mounting of Fuel Tank (Z21867) 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. torque.
  • Page 40 Assembly Procedure PC4000 Z21871 Z 21871 PC4000Asrev05 Edition 08/2005...

  • Page 41: Mounting Of Hydraulic Access Ladder

    Assembly Procedure PC4000 Mounting of hydraulic access ladder (Z21871) Mount hinged ladder(01); Connect ladder lifting cylinder (03); Assemble ladder bearing (17); Tighten the self locking nuts (06) according to the values listed below. Tightening Torque of Self Locking Nuts (06): •...
  • Page 42 Assembly Procedure PC4000 Z21868 Z 21868 PC4000Asrev05 Edition 08/2005...

  • Page 43: Mounting Of Cab Base

    Assembly Procedure PC4000 3.9. Mounting of Cab Base (Z21868) 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. torque.
  • Page 44 Assembly Procedure PC4000 Z21869 Z 21869 PC4000Asrev05 Edition 08/2005...

  • Page 45: Mounting Of Counterweight

    Assembly Procedure PC4000 3.10 Mounting of Counterweight (Z21869) Lift the counterweight with 2 cranes. (The hooks are delivered with the machine). Align the counterweight with the superstructure. Lower the counterweight fully down and fasten it with the bolts(13) and washers (14). Tighten the bolts with the resp.
  • Page 46 Assembly Procedure PC4000 Z23033 PC4000Asrev05 Edition 08/2005...

  • Page 47: Mounting Of Handrails, Steps And Gratings

    Assembly Procedure PC4000 3.11 Mounting of Handrails, Steps and Gratings (Z23033) 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. • Clean the contact surfaces between handrail flange and mounting flange from anticorrosive paste and paint.
  • Page 48 Assembly Procedure PC4000 Z22937 PC4000Asrev05 Edition 08/2005...

  • Page 49: Mounting Of Cable Transfer To The Operators Cab

    Assembly Procedure PC4000 3.12 Mounting of Cable transfer to the Operators Cab (Z22937) The special Cable Transfer Elements for sealing the cab are stored in the cab refrigerator. Install it as shown in the pictures on the previous pages. PC4000Asrev05...
  • Page 50 Assembly Procedure PC4000 Z22938 PC4000Asrev05 Edition 08/2005...
  • Page 51 Assembly Procedure PC4000 • Before lowering the cab onto the cab base mount the air hose to cab bottom. Refer to Illust. 22940 pos. (8) page 54. PC4000Asrev05 Edition 08/2005...
  • Page 52 Assembly Procedure PC4000 Z22939 PC4000Asrev05 Edition 08/2005...

  • Page 53: Mounting Of Cab

    Assembly Procedure PC4000 3.13 Mounting of Cab with Support Frame (Z22938; Z22939) Apply sealing compound “ Epple 28” onto the whole contact surfaces (A) of the cab base. The sealing compound is delivered with the machine in a 1 liter can.
  • Page 54 Assembly Procedure PC4000 Z22940 PC4000Asrev05 Edition 08/2005...

  • Page 55: Mounting Of Cab Air Cleaner

    Assembly Procedure PC4000 3.13.1 Mounting of the Cab air cleaner (Cab support to Cab) (Z22940) Legend for illustration Z22940 1. Air cleaner housing located on cab base 2. Filter element 3. Cab base wall 4. Seal ring 5. Cab blower 6.
  • Page 56 Assembly Procedure PC4000 Z21873 Z 21873 PC4000Asrev05 Edition 08/2005...

  • Page 57: Mounting Of Bucket Cylinders

    Assembly Procedure PC4000 3.14 Mounting of Bucket Cylinders (Z21873) 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. Install pin (1).
  • Page 58 Assembly Procedure PC4000 Z 21874 PC4000Asrev05 Edition 08/2005...

  • Page 59: Mounting Of Stick

    Assembly Procedure PC4000 3.15 Mounting of Stick (Bullclam bucket) (Z21874) 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), washer (4) and bolt (5).
  • Page 60 Assembly Procedure PC4000 Z23034 PC4000Asrev05 Edition 08/2005...

  • Page 61: Mounting Of Stick (Backhoe)

    Assembly Procedure PC4000 3.15.1 Mounting of Stick (Backhoe attachment) (Z23034) Legend Location of Pins with a fine thread end Cap for mounting Final cap Nut for mounting the final cap Nut for mounting whirl Safety bolt Hole for the cotter pin...
  • Page 62 Assembly Procedure PC4000 Z21585 PC4000Asrev05 Edition 08/2005...

  • Page 63: Filling Up Hydraulic Oil Tank

    Assembly Procedure PC4000 3.16 Filling up hydraulic oil tank (Z21585) • Connect all lines of the refilling arm* (hydraulic oil; fuel; grease). *if so equipped • Make sure main shut-off valve is in open position and all connections are securely tightened.
  • Page 64 Assembly Procedure PC4000 Z22513 Z21693 PC4000Asrev05 Edition 08/2005...

  • Page 65: Bleed Air From All Hydraulic Tanks

    Assembly Procedure PC4000 3.17 Bleed air from all hydraulic pumps and check the Oil Level in all four Main Pump Housings (Z21693; Z22513) Legend for illust. Z 21693 I – IV Main hydraulic pumps (swash plate type) Axial piston pump for hydraulic oil cooler fan drive...
  • Page 66 Assembly Procedure PC4000 PC4000Asrev05 Edition 08/2005...

  • Page 67: Filling Up Fuel Tank

    Assembly Procedure PC4000 3.18 Filling up fuel tank If so equipped do it via the service arm below the engine house, otherwise fill up direct through the refilling plug on top of the fuel tank. Filling up via the service arm: Connect the fuel supply hose from the fuel service truck to the coupling of the service arm.
  • Page 68 Assembly Procedure PC4000 PC4000Asrev05 Edition 08/2005...

  • Page 69: Pre-Checks Prior Initial Start-Up

    Assembly Procedure PC4000 3.19 Pre-checks for initial Start-up 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 70 Assembly Procedure PC4000 PC4000Asrev05 Edition 08/2005...
  • Page 71 Assembly Procedure PC4000 (13) Connect main battery switch and activate electrical system by using the key switch S1. (14) Check messages from display. (15) Check function of electrical system. (16) Activate swing parking brake by using switch S29 on dash board.
  • Page 72 Assembly Procedure PC4000 Z21875 Z 21875 PC4000Asrev05 Edition 08/2005...

  • Page 73: Mounting Of Stick Cylinders To The Stick

    Assembly Procedure PC4000 3.20 Mounting of stick cylinders to the stick (Z21875) Hook up stick cylinders to chain pull and remove transport fastening. Lower stick cylinder by means of chain pull. Start the engine and extend cylinder rod. Align with bearing at stick.
  • Page 74 Assembly Procedure PC4000 Z21876 Z 21876 PC4000Asrev05 Edition 08/2005...

  • Page 75: Assembly Of Bullclam Bucket To The Stick

    Assembly Procedure PC4000 3.21 Assembly of Bullclam Bucket to the Stick (Z21876) Delivery in two part (clam - rear wall) Place the rear wall as shown on the ground. Prepare the pin seals according to page 78. Lift the attachment and retract the stick until the stick is in a vertical position.
  • Page 76 Assembly Procedure PC4000 Z21877 Z 21877 PC4000Asrev05 Edition 08/2005...
  • Page 77 Assembly Procedure PC4000 Extend clam cylinders to align them with borings in the clam. Install pins (1) and lock them with catch (2+3). Connect all grease lines to the bucket and ensure that all grease points are greased before machine is put into operation.
  • Page 78 Assembly Procedure PC4000 Z22042 Z 22042 PC4000Asrev05 Edition 08/2005...

  • Page 79: Mounting Of The Pin Seals

    Assembly Procedure PC4000 3.22 Mounting of the Pin Seals (Z22042) The illustration shows the mounting places of the outer bushing seals (A) and the inner bushing seals (B) of the front shovel attachment.. Mounting procedure inner pin seals (B): Remove respective pins Fill the grooves inside of the bushings with grease Install the seals and align it.
  • Page 80 Assembly Procedure PC4000 Z23035 PC4000Asrev05 Edition 08/2005...

  • Page 81: Mounting Of Pin Seals (Backhoe)

    Assembly Procedure PC4000 3.22.1 Mounting of the Pin Seals (Backhoe) (Z23035) Legend illustr. Z 23035: Upper ring half Lower ring half Seal ring PC4000Asrev05 Edition 08/2005...
  • Page 82 Assembly Procedure PC4000 Z21879 Z 21879 PC4000Asrev05 Edition 08/2005...
  • Page 83 Assembly Procedure PC4000 3.23 Connection of the cable harnesses to the terminal rails in the switch box “X2” (Z21879) All harnesses are marked with numbers and letters. You find also these numbers and letters in the X2 – box showed on the picture one page before.
  • Page 84 Assembly Procedure PC4000 Z23039 PC4000Asrev05 Edition 08/2005...
  • Page 85 Assembly Procedure PC4000 Harnesses Terminal strip Harnesses Terminal strip („going to“) („going to“) 1 Battery box 1 29 Pressure hydraulic oil cooler 2 Engine oil tank 30 Level sensor hydraulic tank 3 Engine 31 Control plate 3 4 Engine housing...
  • Page 86 Assembly Procedure PC4000 Z21880 Z 21880 PC4000Asrev05 Edition 08/2005...

  • Page 87: Putting The Central Lubrication System Into Operation

    Assembly Procedure PC4000 3.24 Putting the Central Lubrication System into operation (Z21880) 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 88 Assembly Procedure PC4000 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. PC4000Asrev05 Edition 08/2005...

  • Page 89: Standard Application Torque Chart

    Assembly Procedure PC8000 3.25 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 1030 M 27 1310 1530 M 30 1250 1770...
  • Page 90 Assembly Procedure PC4000 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 1410 1650 M 30x2.00...
  • Page 91 Assembly Procedure PC4000 PC4000Asrev05 Edition 08/2005...
  • Page 92 Assembly Procedure PC4000 PC4000Asrev05 Edition 08/2005...
  • Page 93 Assembly Procedure PC4000 PC4000Asrev05 Edition 08/2005...
  • Page 94 Assembly Procedure PC4000 - Service Information - Buscherhofstr. 10 40599 Düsseldorf Phone +49 (0)211 7109 0 Fax +49 (0)211 74 33 07 PC4000Asrev05 Edition 08/2005...

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