Komatsu PC2000-8 Hydraulic Excavator Field Assembly Instruction GEN00060-13

Description

• Model List:
  • PC2000-8 Hydraulic Excavator

• 1. COVER
• 2. FOREWORD
• 3. CONTENTS
• 4. SPECIFICATIONS
• 5. PRECAUTIONS FOR FIELD ASSEMBLY
• 6. DISPOSAL OF REMOVED PARTS
• 7. ASSEMBLY PROCEDURE, ASSEMBLY EQUIPMENT AND SCHEDULE
• 8. FLOWCHART OF MAIN ASSEMBLY PROCEDURE
• 9. KIT LAYOUT DIAGRAM
• 10. TRANSPORTATION POSTURES
• 11. LIST OF PARTS SENT INDIVIDUALLY
• 12. TOOLS AND EQUIPMENT TO BE USED FOR LOCAL ASSEMBLY
• 13. TIGHTENING TORQUE
• 14. COATING MATERIALS LIST
• 15. ASSEMBLY OF CHASSIS
• 15.1.
• 15.1.1. A 1. Assembly of track frame assembly and center frame assembly
• 15.1.2. A 2. Installation of idler cushion cylinder piping
• 15.1.3. A 3. Installation of travel motor piping
• 15.1.4. A 4. Installation of travel motor cover
• 15.1.5. A 5. Filling swing circle with grease
• 15.1.6. A 6. Assembly of revolving frame assembly and undercarriage
• 15.1.7. A 7. Installation of swing machinery (front) assembly (27t), Installation of swing motor (front) assembly (32t)
• 15.1.8. A 8. Connection of swivel joint piping
• 15.1.9. A 9. Connection of swing circle grease piping
• 15.2.
• 15.2.1. A10. Installation of hydraulic tank assembly
• 15.2.2. A11. Installation of fuel tank assembly
• 15.2.3. A12. Connection of fuel tank assembly piping and wiring
• 15.2.4. A13. Installation of cab base assembly
• 15.2.5. A14. Installation of emergency escape ladder
• 15.2.6. A15. Installation of left floor assembly
• 15.2.7. A16. Connection of cab base assembly piping
• 15.2.8. A17. Connection of cab base assembly wiring
• 15.2.9. A18. Connection of left floor assembly heater piping
• 15.3.
• 15.3.1. A19. Connection of left floor assembly wiring
• 15.3.2. A20. Installation of tail pipe
• 15.3.3. A21. Installation of power container assembly
• 15.3.4. A22. Connection of suction piping
• 15.3.5. A23. Connection of oil cooler piping and pump drain piping
• 15.3.6. A24. Connection of fan motor drain piping
• 15.3.7. A25. Installation of suction unit undercover
• 15.3.8. A26. Connection of delivery piping
• 15.3.9. A27. Connection of pilot piping and fan motor piping
• 15.3.10. A28. Connection of power container assembly fuel piping
• 15.3.11. A29. Connection of power container assembly air conditioner piping
• 15.3.12. A30. Connection of power container assembly heater piping
• 15.3.13. A31. Connection of power container assembly wiring
• 15.4.
• 15.4.1. A32. Installation of operators cab assembly
• 15.4.2. A33. Installation of rotary lamp (if equipped)
• 15.4.3. A34. Installation of ORBCOMM antenna (if equipped)
• 15.4.4. A35. Connection of operators cab assembly wiring
• 15.4.5. A36. Connection of operators cab assembly hydraulic piping
• 15.4.6. A37. Connection of operators cab assembly window washer hose
• 15.4.7. A38. Connection of operators cab assembly air conditioner piping
• 15.4.8. A39. Connection of operators cab assembly heater piping
• 15.4.9. A40. Installation of operators cab rear floor assembly
• 15.4.10. A41. Installation of handrail around operators cab
• 15.5.
• 15.5.1. A42. Installation of track frame ladder
• 15.5.2. A43. Installation of power container side catwalk assemblies (right and left)
• 15.5.3. A44. Installation of right floor assembly, grease can cover assembly and center floor
• 15.5.4. A45. Installation of fuel tank right catwalk assembly
• 15.5.5. A46. Installation of fuel tank front catwalk assembly
• 15.5.6. A47. Adjustment of exterior parts clearance
• 15.5.7. A48. Connection of grease reel piping
• 15.5.8. A49. Installation of access ladder assembly
• 15.5.9. A50. Installation of counterweight assembly
• 15.5.10. A51. Installation of deformation preventing stoppers for catwalk assemblies (left and right) on the side of power container
• 15.5.11. A52. Installation of handrail on counterweight
• 15.5.12. A53. Installation of handrail clamps
• 15.5.13. A54. Connection of fuel cut wire
• 15.5.14. A55. Connection of drain piping under power container
• 15.5.15. A56. Connection of battery wiring
• 15.6.
• 15.6.1. A57. Setting of hydraulic tank strainer
• 15.6.2. A58. Starting engine, checking oil and coolant levels, bleeding air from each part, and adjusting track
• 15.6.3. A59. Permanent tightening of swing circle bolt
• 15.6.4. A60. Parts to be touched up after field assembly (chassis side)
• 15.6.5. A61. Connection of engine heater connection port
• 15.6.6. A62. Installation of optional harness
• 15.6.7. A63. Installation of rear lamps
• 15.6.8. A64. Installation of rear camera
• 15.6.9. A65. Connection of emergency stop switch (if equipped) (at the right below container)
• 15.6.10. A66. Connection of emergency stop switch (if equipped) (at the left side of ladder)
• 15.6.11. A67. Installation of engine oil and PTO oil pipings
• 15.6.12. A68. Installation of coolant piping
• 15.6.13. A69. Installation of guard bracket (if equipped)
• 16. ASSEMBLY OF BACKHOE
• 16.1.
• 16.1.1. C 1. Installation of boom cylinder
• 16.1.2. C 2. Installation of boom cylinder hoses (Serial No. 20095 and up)
• 16.1.3. C 3. Assembly of boom sub assembly
• 16.1.4. C 4. Installation of boom assembly
• 16.1.5. C 5. Installation of boom cylinder head side
• 16.2.
• 16.2.1. C 6. Installation of hoses between boom and chassis
• 16.2.2. C 7. Installation of arm assembly
• 16.2.3. C 8. Installation of arm cylinder
• 16.2.4. C 9. Connection of hoses between boom and arm
• 16.2.5. C10. Connection of auto grease piping
• 16.2.6. C11. Connection of wiring between boom and chassis
• 16.3.
• 16.3.1. C12. Installation of bucket assembly
• 16.3.2. C13. Installation of bucket link
• 16.3.3. C14. Bleeding air from cylinders
• 16.3.4. C15. Parts to be touched up after field assembly (work equipment side)
• 16.3.5. C16. Bleeding air from auto grease circuit
• 17. LS. ASSEMBLY OF LOADING SHOVEL WORK EQUIPMENT
• 17.1. LS 1. Installation of arm cylinder bottom parts
• 17.2. LS 2. Installation of boom cylinder to machine body
• 17.3. LS 3. Installation of boom cylinder hoses
• 17.4. LS 4. Installation of boom cylinder piping
• 17.5. LS 5. Installation of boom assembly
• 17.6. LS 6. Installation of boom cylinder head pins
• 17.7. LS 7. Installation of hose between machine body and boom
• 17.8. LS 8. Installation of bucket cylinder assembly
• 17.9. LS 9. Installation of arm assembly
• 17.10. LS10. Installation of arm cylinder assembly
• 17.11. LS11. Installation of hoses between boom and arm
• 17.12. LS12. Installation of bucket cylinder hoses
• 17.13. LS13. Installation of grease feed hose of bucket cylinder
• 17.14. LS14. Installation of bucket assembly
• 17.15. LS15. Installation of arm cylinder junction hoses
• 17.16. LS16. Installation of bottom dump hose and grease feed hose between arm and bucket
• 17.17. LS17. Installation of arm dump cushion (proximity switch)
• 18. INSPECTION AND SERVICING PROCEDURES AFTER ASSEMBLY
• 18.1. M 1. Inspection of oil levels and coolant levels and using standard of fuel and lubricant
• 18.2. M 2. Flushing of hydraulic circuit
• 18.3. M 3. Releasing residual pressure from hydraulic circuit
• 18.4. M 4. Releasing residual pressure from HIC circuit and check of gas pressure in HIC accumulator
• 18.5. M 5. Charging air conditioner with refrigerant
• 18.6. M 6. Installed angles of mirrors
• 18.7. M 7. Installed angles of lights
• 19. VHMS CONTOROLLER INITIAL SETTING PROCEDURE
• 20. PC20008 Main pump air bleeding check sheet
• 21. FIELD ASSEMBLY INSPECTION REPORT (BACKHOE)
• 22. FIELD ASSEMBLY INSPECTION REPORT (LOADING SHOVEL)