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Komatsu PC4000, Assembly Procedure

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Komatsu PC4000 Assembly Procedure Download Page 1

PC4000Asrev05

PC4000Asrev05

Edition 08/2005

Edition 08/2005

1

1

G

Gene

eneral As

ral Assembly 

sembly P

Pro

rocedure

cedure

Hydr

Hydrauli

aulic Mini

c Mining Sho

ng Shovel PC

vel PC40

4000

00

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Summary of Contents for PC4000

Page 1: ...i c Mining Sho ng Shovel PC vel PC40 4000 00 ____________ ____________________________ _____________________________ ____________________________ ______________________________ ________________ _ ____...

Page 2: ...5 Edition 08 2005 2 2 Z23038 Z23038 Al All s l stat tated i ed inf nfor ormat matio ion c n cor orres respo pond nds s to the present development and is to the present development and is subject to po...

Page 3: ...5 Edition 08 2005 2 2 Z23038 Z23038 Al All s l stat tated i ed inf nfor ormat matio ion c n cor orres respo pond nds s to the present development and is to the present development and is subject to po...

Page 4: ...39 3 8 3 8 Mounting Mounting of of Hydraulic Hydraulic access access Ladder Ladder 41 41 3 9 3 9 Mounting Mounting of of Cab Cab Base Base 43 43 3 10 3 10 Mounting Mounting of of Counterweight Counte...

Page 5: ...Assembly Procedure PC4000 PC4000Asrev05 Edition 08 2005 4 Z22586...

Page 6: ...ontrol 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 Flexibl...

Page 7: ...Assembly Procedure PC4000 PC4000Asrev05 Edition 08 2005 6 Z21446...

Page 8: ...ntrol 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 dri...

Page 9: ...Assembly Procedure PC4000 PC4000Asrev05 Edition 08 2005 8...

Page 10: ...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 proc...

Page 11: ...Assembly Procedure PC4000 PC4000Asrev05 Edition 08 2005 10...

Page 12: ...rrect 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 wi...

Page 13: ...Assembly Procedure PC4000 PC4000Asrev05 Edition 08 2005 12...

Page 14: ...efore 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 cha...

Page 15: ...Assembly Procedure PC4000 PC4000Asrev05 Edition 08 2005 14...

Page 16: ...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 3...

Page 17: ...8 2005 16 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...

Page 18: ...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...

Page 19: ...Assembly Procedure PC4000 PC4000Asrev05 Edition 08 2005 18...

Page 20: ...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 se...

Page 21: ...Assembly Procedure PC4000 PC4000Asrev05 Edition 08 2005 20 Z23038...

Page 22: ...lb Fuel tank Dimensions mm 2400 x 2100 x 3230 Weight 4 800 kg 10 600 lb Hydraulic tank Dimensions mm 2400 x 1200 x 3300 Weight 3 200 kg 7 100 lb Hydraulic tank Dimensions mm 2400 x 1200 x 3300 Weight...

Page 23: ...Assembly Procedure PC4000 PC4000Asrev05 Edition 08 2005 22 Z 21859 Z21859...

Page 24: ...is approx 100 mm higher than the attached side This makes it easier to attach the 2nd side frame Lift the 2nd side frame with the crane and align with the carbody Lower borings first and insert pins...

Page 25: ...Assembly Procedure PC4000 PC4000Asrev05 Edition 08 2005 24 Z23036...

Page 26: ...00 PC4000Asrev05 Edition 08 2005 25 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 sh...

Page 27: ...Assembly Procedure PC4000 PC4000Asrev05 Edition 08 2005 26 Z23037...

Page 28: ...sition Closed Ex works closed 2 Working position Open Ex works closed 3 Marking below the washer shows the valve position O open C closed The valve position open or closed is not depend on the lever p...

Page 29: ...Assembly Procedure PC4000 PC4000Asrev05 Edition 08 2005 28 Z 21863 Z21863...

Page 30: ...of the bolts Refer PARTS SERVICE NEWS AH 00511 last edition Install 2 threaded pins M36 x 200 mm long one end pointed to be manufactured displaced by 180 to slew ring at superstructure This simplifie...

Page 31: ...Assembly Procedure PC4000 PC4000Asrev05 Edition 08 2005 30 Z 21863...

Page 32: ...s A 2 Lower the unit as required so that two bolts with washers 02 03 for guiding can be inserted 3 Lower the unit fully and insert all bolts with washers Tighten the bolts with the resp torque This m...

Page 33: ...Assembly Procedure PC4000 PC4000Asrev05 Edition 08 2005 32 Z 21864 Z21864...

Page 34: ...n other crane or chain pull and disconnect the transport fastenings Don t open the plugged hydraulic ports of the cylinder Open the transport fastenings very carefully because of a sliding cylinder ro...

Page 35: ...Assembly Procedure PC4000 PC4000Asrev05 Edition 08 2005 34 Z 21865a Z23039...

Page 36: ...Tank with the superstructure 3 Lower the Hydraulic Oil Tank fully down and install all bolts Tighten the bolts with the resp torque Refer to section 4 12 of the Maintenance Manual 4 Remove transport c...

Page 37: ...Assembly Procedure PC4000 PC4000Asrev05 Edition 08 2005 36 Z 21866 Z21866...

Page 38: ...yes are delivered with the machine 2 Align the Hydraulic Oil Cooler with the superstructure Pay attention to the course of the hydraulic lines 3 Lower the Hydraulic Oil Cooler fully down and install a...

Page 39: ...Assembly Procedure PC4000 PC4000Asrev05 Edition 08 2005 38 Z 21867a Z21867...

Page 40: ...tank Lifting eyes are delivered with the machine 2 Align the fuel tank with the superstructure 3 Lower the fuel tank fully down and install all bolts Tighten the bolts with the resp torque Refer to se...

Page 41: ...Assembly Procedure PC4000 PC4000Asrev05 Edition 08 2005 40 Z 21871 Z21871...

Page 42: ...locking nuts 06 according to the values listed below Tightening Torque of Self Locking Nuts 06 New nut 440 Nm Used nut 350 Nm Check clamping torque of the free turning nuts 06 before tightening the b...

Page 43: ...Assembly Procedure PC4000 PC4000Asrev05 Edition 08 2005 42 Z 21868 Z21868...

Page 44: ...Z21868 1 Lift the cab base Lifting eyes are delivered with the machine 2 Align the cab base with the superstructure 3 Lower the cab base fully down and install all bolts Tighten the bolts with the re...

Page 45: ...Assembly Procedure PC4000 PC4000Asrev05 Edition 08 2005 44 Z 21869 Z21869...

Page 46: ...achine 2 Align the counterweight with the superstructure 3 Lower the counterweight fully down and fasten it with the bolts 13 and washers 14 Tighten the bolts with the resp torque Refer to section 4 1...

Page 47: ...Assembly Procedure PC4000 PC4000Asrev05 Edition 08 2005 46 Z23033...

Page 48: ...unted 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 pas...

Page 49: ...Assembly Procedure PC4000 PC4000Asrev05 Edition 08 2005 48 Z22937...

Page 50: ...rev05 Edition 08 2005 49 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 t...

Page 51: ...Assembly Procedure PC4000 PC4000Asrev05 Edition 08 2005 50 Z22938...

Page 52: ...Assembly Procedure PC4000 PC4000Asrev05 Edition 08 2005 51 Before lowering the cab onto the cab base mount the air hose to cab bottom Refer to Illust 22940 pos 8 page 54...

Page 53: ...Assembly Procedure PC4000 PC4000Asrev05 Edition 08 2005 52 Z22939...

Page 54: ...h the machine 3 Align the cab support frame B with the cab base contact surfaces A 4 Lower the cab support frame onto cab base 5 Apply Loctite 222 onto the thread of all 34 mounting bolts C and fasten...

Page 55: ...Assembly Procedure PC4000 PC4000Asrev05 Edition 08 2005 54 Z22940...

Page 56: ...r 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 Blower housing 7 Air hose to ba...

Page 57: ...Assembly Procedure PC4000 PC4000Asrev05 Edition 08 2005 56 Z 21873 Z21873...

Page 58: ...rox 45 up to the bearings at the boom Align the rod eyes with borings at the boom Install pin 1 Install axle stirrup 2 Install shackle 3 with washer 04 and bolt 5 Place lower end of the cylinders onto...

Page 59: ...Assembly Procedure PC4000 PC4000Asrev05 Edition 08 2005 58 Z 21874...

Page 60: ...tick Bullclam bucket Z21874 1 Lift the stick to the bearing position stick to the boom 2 Lower the stick until stick and boom borings are aligned 3 Install pin 1 stirrups 2 plate 3 washer 4 and bolt 5...

Page 61: ...Assembly Procedure PC4000 PC4000Asrev05 Edition 08 2005 60 Z23034...

Page 62: ...ounting whirl 6 Safety bolt 7 Hole for the cotter pin 8 Cotter pin Installing of this kind of pins 1 Secure the thread with the mounting cap 2 Install the pin 3 Remove the mounting cap 4 Install a whi...

Page 63: ...Assembly Procedure PC4000 PC4000Asrev05 Edition 08 2005 62 Z21585...

Page 64: ...Servi rvice S ce SET ETTI TING NGS S grou group of p of the VH the VHMS MS Me Menu Contr nu Control ol 1 1 On On machines machines equipped equipped with with Central Central Refilling Refilling Syste...

Page 65: ...Ass Assemb embly ly Pro Proced cedur ure PC4000 e PC4000 PC4000Asrev05 PC4000Asrev05 Edition 08 2005 Edition 08 2005 64 64 Z21693 Z21693 Z22513 Z22513...

Page 66: ...tion Proceed as oceed as follows follows 1 1 Open Open vent vent plug plug on on top top of of pumps pumps 1 1 and and 2 2 Close Close the the vent vent plugs plugs as as soon as bubble free oil flows...

Page 67: ...Assembly Procedure PC4000 PC4000Asrev05 Edition 08 2005 66...

Page 68: ...ly a correct matched coupling The fuel supply system of the service truck must equipped with a pressure activated cut out nozzle The fuel nozzle cut out pressure should be adjusted to 0 38 bar If this...

Page 69: ...Assembly Procedure PC4000 PC4000Asrev05 Edition 08 2005 68...

Page 70: ...o the engine 5 Make sure that the shut off valve between the main hydraulic tank and the suction tank is completely open 6 Make sure that the hoses for the hydraulic cylinders are covered with sealing...

Page 71: ...Assembly Procedure PC4000 PC4000Asrev05 Edition 08 2005 70...

Page 72: ...egulation system To do this turn screw a few turn out until oil comes out Retighten screw 20 Let engine run in high idle 21 Check function of engine water cooling fan by disconnecting plug to solenoid...

Page 73: ...Assembly Procedure PC4000 PC4000Asrev05 Edition 08 2005 72 Z 21875 Z21875...

Page 74: ...f stick cylinders to the stick Z21875 1 Hook up stick cylinders to chain pull and remove transport fastening 2 Lower stick cylinder by means of chain pull 3 Start the engine and extend cylinder rod Al...

Page 75: ...Assembly Procedure PC4000 PC4000Asrev05 Edition 08 2005 74 Z 21876 Z21876...

Page 76: ...Push the pins 1 from A to B so far as the stick can mount 6 Align the bores of the stick with the bores of the rear wall 7 Insert pins 1 from outside to inside B to A and secure with the axle stirrup...

Page 77: ...Assembly Procedure PC4000 PC4000Asrev05 Edition 08 2005 76 Z 21877 Z21877...

Page 78: ...gs in the clam Install pins 1 and lock them with catch 2 3 18 Connect all grease lines to the bucket and ensure that all grease points are greased before machine is put into operation Connect line to...

Page 79: ...Assembly Procedure PC4000 PC4000Asrev05 Edition 08 2005 78 Z 22042 Z22042...

Page 80: ...ective pins 2 Slide seals 1 on the collar of the respective bushings in the rear wall of bucket Fig X 3 Assemble the stick as described 4 Install both fixing halves 2 over the seal ring 1 and tighten...

Page 81: ...Assembly Procedure PC4000 PC4000Asrev05 Edition 08 2005 80 Z23035...

Page 82: ...Assembly Procedure PC4000 PC4000Asrev05 Edition 08 2005 81 3 22 1 Mounting of the Pin Seals Backhoe Z23035 Legend illustr Z 23035 1 Upper ring half 2 Lower ring half 3 Seal ring...

Page 83: ...Assembly Procedure PC4000 PC4000Asrev05 Edition 08 2005 82 Z 21879 Z21879...

Page 84: ...each cable All cables with the following markings printed on are installed for reserve purposes and must not be connected to the terminal rails during first assembly at job site Markings on cables in...

Page 85: ...Assembly Procedure PC4000 PC4000Asrev05 Edition 08 2005 84 Z23039...

Page 86: ...44 Cab cable K6 7x6mm X2C 17 Ladder X2E 45 Cab cable K7 1x16mm X2C 18 End of line pressure switch X2R 46 Cab cable K9 2x0 5mm shielded can bus Plug Can Bus into the right channel 19 End of line press...

Page 87: ...Ass Assemb embly ly Pro Proced cedur ure PC4000 e PC4000 PC4000Asrev05 PC4000Asrev05 Edition 08 2005 Edition 08 2005 86 86 Z 21880 Z 21880 Z21880 Z21880...

Page 88: ...lying a grease gun to the grease fittings on each grease injector To this remove protection cap 3 and press in grease until a grease To this remove protection cap 3 and press in grease until a grease...

Page 89: ...irst class opera first class operating c ting condition ondition use use only genuine Komatsu Mining only genuine Komatsu Mining Ge Germany r rmany replace eplacement part ment parts s The The use of...

Page 90: ...0 2400 2800 M 36 27 55 2170 3100 3600 M 39 60 2800 4000 4700 M 42 32 65 3500 4950 5800 M 45 70 4350 6200 7200 M 48 35 75 5200 7500 8700 M 52 80 6700 9600 11200 M 56 41 85 8400 12000 14000 M 60 90 1040...

Page 91: ...0 2650 3100 M 36x3 00 27 55 2300 3250 3850 M 39x3 00 60 3000 4200 4950 M 42x3 00 32 65 3750 5300 6200 M 45x3 00 70 4600 6600 7700 M 48x3 00 35 75 5700 8100 9500 M 52x3 00 80 7300 10400 12100 M 56x4 00...

Page 92: ...Assembly Procedure PC4000 PC4000Asrev05 Edition 08 2005 91...

Page 93: ...Assembly Procedure PC4000 PC4000Asrev05 Edition 08 2005 92...

Page 94: ...Assembly Procedure PC4000 PC4000Asrev05 Edition 08 2005 93...

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