Komatsu Manual (EN)

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Field Assembly Manual SEAW021 NO1 03 PC1 000 HYDRAULIC EXCAVATOR PC1 0004 -10001 SERIAL NUMBERS PC1 OOOSE-1 -10001 and up PC1 OOOSP-1 -10351 This material is proprietary to Komatsu Dresser Company and is not to be reproduced, used, or disclosed except in accordance with written authorization from Komatsu Dresser Company. It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make changes or add improvements at any time without incurring any obligation to install such changes on products sold previously. Due to this continuous program of research and development, periodic revisions may be made to this publication.

It is recommended that customers contact their distributor for information on the latest revision. July 1995 Copyright 1995 Komatsu Dresser Company

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TABLE OF CONTENTS

CONTENTS A. GENERAL A- 1: Before assembly ....................................................... 5 A- 2: List of parts sent individually ............................................. 7 A- 3: Points regarding local assembly ............................................ 25 A- 4: Precautions when assembling, tightening torque of bolts, screws and taper seal hoses . . . 26 A- 5:,Table of tools for local assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 A- 6: Place toset (unload) each unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 B.

ASSEMBLY OF MACHINE (Part I) (Start of assembly for machine divided into four parts for transportation) B- 1: Installation of left, right track frames ....................................... 32 B- 2: Installation of travel piping ............................................... 34 B- 3: Exchanging return filter (standard part + special flushing part) ................... 37 B- 4: Check of oil and water levels .............................................. 39 B- 5: Check central monitor ................................................... 40 B- 6: Bleeding air from hydraulic pump, swing pump ............................... 41 B- 7:

Flushing travel circuit ................................................... 42 B- 8: lnstallaion of travel piping ................................................ 43 C. ASSEMBLY OF MACHINE (Part II) (Start of assembly for machine divided into three parts for transportation) (Used also for machine diveded into four parts for transportation) c- 1: Installation of left side step. ............................................... 46 Installation of step ..................................................... 47 c- 2: c- 3: Installation of handrail .................................................. 48 c- 4: Installation of step (only when installing high cab) ............................. 49 c- 5:

Installation of operator’s cab assembly ...................................... 50 C- 6: Connection of electrical components in operator’s cab c- 7: Installation of air conditioner (only when installing high cab) ..................... 52 (only when installing high cab) ............................................ 51 C- 8: Installation of operator’s seat assembly (only when installing high cab) ............. 55 c- 9: Installation of addtional rear view mirror (option) ............................. 56 C-l 0: Installation of FOPS (option) .............................................. 57 C-l 1: Installation of muffler tail pipe ............................................ 61 c-12:

Installation of counterweight assembly ..................................... 62 1

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c-13: Exchanging return filter (standard part + special flushing part) ................... 63 c-14: Check of oil and water levels .............................................. 64 c-15: Check central monitor (carry out only when machine is divided into three parts for transportation) ........ 64 C-16: Bleeding air from travel motor circuit ....................................... 65 C-l 7: Bleeding air from hydraulic idler cushion circuit ............................... 66 C-18: Adjustment of hydraulic idler cushion cylinder ................................ 68 c-19: Adjusting track tension .................................................. 69 D.

PROCEDURE FOR ASSEMBLY OF WORK EQUIPMENT (BACKHOE SPECIFICATION) D- 1: Assembly of boom assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 D- 2: Releasing pressure from hydraulic circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 D- 3: Work equipment piping (between chassis and boom) (between chassis and boom cylinder) ..................... 74 D- 4: Flushing work equipment piping ........................................... 77 Installation of boom cylinder foot pin ...................................... 78 D- 5: D- 6: Installing boom cylinder hoses ............................................ 79 D- 7:

Installation of boom cylinder top pin ....................................... 80 D- 8: Installation of arm cylinder foot pin ........................................ 81 D- 9: Work equipment piping (arm cylinder) ...................................... 82 D-10: Installation of arm and arm cylinder top pin .................................. 83 D-l 2: Assembly of bucket assembly ............................................. 85 D-l 1: Work equipment piping (boom - bucket cylinder) ............................. 84 D-13: Maintenance standard ................................................... 88 D-14: Installation of work equipment grease piping ................................. 90 D-l 5:

Installation of work equipment wiring and equipment hose clamps ................ 92 D-16: Bleeding air from cylinder ................................................ 94 D-17: Check oil level in hydraulic tank, add oil ..................................... 95 E. PROCEDURE FOR ASSEMBLY OF WORK EQUIPMENT (FRONT LOADING SHOVEL SPECIFICATION) E- 1: Installation of arm cylinder foot pin ....................................... 98 E- 2: Connection of boom and arm ............................................ 99 E- 3: Installation of arm cylinder top pin ........................................ 100 E- 4: Installation of bucket cylinder foot pin ..................................... 101 E- 5:

Connection of link and bucket cylinder top pin ............................... 102 E- 6: Assembly of boom assembly .............. +. ............................. 104 E- 7: Releasing pressure from hydraulic circuit ................................... 106 2

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TABLE OF CONTENTS

E- 8: Work equipment piping (between chassis and boom) .......................... 107 E- 9: Work equipment piping ................................................ 108 E-10: Flushing work equipment piping .......................................... 113 E-l 1: Installation of boom cylinder foot pin ..................................... 115 Installation of boom cylinder hoses ........................................ 116 E-12: E-13: Installation of boom cylinder top pin ...................................... 117 E-14: Installation of arm cylinder hoses ......................................... 118 E-15: Installation of bucket cylinder piping ...................................... 119 E-16:

Installation of bottom dump cylinder piping’ ................................. 120 E-17: Installation of bucket assembly ........................................... 121 E-18: E-19: Maintenance standard .................................................. 124 Installation of bottom dump cylinder piping ................................. 126 E-20: Installation of work equipment piping clamps ................................ 127 E-21: Installation of working lamp ............................................. 129 E-22: Installation of work equipment grease piping ................................ 130 E-23: Bleeding air from work equipment circuit ................................... 133 E-24:

Check oil level in hydraulic tank, add oil .................................... 134 E-25: E-26: Installation of boom foot potentiometer .................................... 136 Installation and adjustment of boom top potentiometer (boom - arm joint) ........ 138 E-27: Installation of clamps and cover for boom foot potentiometer ................... 139 E-28: Installation of clamps and cover for boom top potentiometer .................... 140 E-29: Adjustment of work equipment controller (for automatic control of loading shovel) .................................. 141 F. ASSEMBLY OF MACHINE (Part III) F- 1:

Extending track frame gauge width (only when divided into three parts for transportation) . . . . . . . . . . . . . . , . . . . . . . . 148 F- 2: Installation of travel piping covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 G. CHECK OF ALL PARTS DURING AND AFTER ASSEMBLY . . . . . . . . . . . . . . . . . . . . 152 H_ pcqooo-1 &“C AUSTRALIA SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153 APPENDIX FIELD ASSEMBLY INSPECTION REPORT 3

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