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Komatsu PC4000, Процедура сборки

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Komatsu PC4000 Скачать руководство пользователя страница 32

 Ass emb ly  Proced ur e PC4000

PC4000Asrev05

Edition 08/2005

31

3.3 

Ass embl y of engin e hou se (Z21863)

1. 

Attach the unit to the crane (use only the attached lifting points

(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 must be done

directly because later-on it may be difficult to reach the bolts).

W

•

There are two kin ds of b olts:

(4): 

8 bol ts 

M30 x 420 lon g

and: 

18 bolt s 

M30 x 440 long

Содержание PC4000

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

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

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

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