KOMATSU PC1000-1 HYDRAULIC EXCAVATOR Field Assembly Manual (SEAW021N0103) KOMATSU PC1000-1
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KOMATSU PC1000-1 HYDRAULIC EXCAVATOR Field Assembly Manual (SEAW021N0103) KOMATSU PC1000-1
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KOMATSU PC1000-1 HYDRAULIC EXCAVATOR Field Assembly Manual (SEAW021N0103) KOMATSU PC1000-1
MAIN MENU........................................................................................................ 0 COVER PAGE....................................................................................................... 1 TABLE OF CONTENTS................................................................................................ 2 A. GENERAL...................................................................................................... 5 A-1: BEFORE ASSEMBLY........................................................................................ 5 A-2: LIST OF PARTS SENT INDIVIDUALLY........................................................................ 9 A-3: POINTS REGARDING LOCAL ASSEMBLY........................................................................ 30 A-4: PRECAUTIONS WHEN ASSEMBLING, TIGHTENING TORQUE OF BOLTS, SCREWS AND TAPER SEAL HOSES................... 31 A-5: TABLE OF TOOLS FOR LOCAL ASSEMBLY...................................................................... 34 A-6: PLACE TO SET (UNLOAD) EACH UNIT........................................................................ 35 B. ASSEMBLY OF MACHINE (PART I)................................................................................. 36 B-1: INSTALLATION OF LEFT, RIGHT TRACK FRAMES............................................................... 37 B-2: INSTALLATION OF TRAVEL PIPING.......................................................................... 39 B-3: EXCHAING RETURN FILTER (STANDARD PART - SPECIAL FLUSHING PART)......................................... 42 B-4: CHECK OF OIL AND WATER LEVELS.......................................................................... 44 B-5: CHECK CENTRAL MONITOR.................................................................................. 45 B-6: BLEEDING AIR FROM HYDRAULIC PUMP, SWING PUMP........................................................... 46 B-7: FLUSHING TRAVEL CIRCUIT................................................................................ 47 B-8: INSTALLATION OF TRAVEL PIPING.......................................................................... 48 C. ASSEMBLY OF MACHINE (PART II)................................................................................ 49 C-1: INSTALLATION OF LEFT SIDE STEP......................................................................... 50 C-2: INSTALLATION OF STEP................................................................................... 51 C-3: INSTALLATION OF HANDRAIL............................................................................... 52 C-4: INSTALLATION OF STEP (ONLY WHEN INSTALLING HIGH CAB)................................................... 53 C-5: INSTALLATION OF OPERATOR'S CAB ASSEMBLY................................................................ 54 C-6: CONNECTION OF ELECTRICAL COMPONENTS IN OPERATOR'S CAB (ONLY WHEN INSTALLING HIGH CAB).................. 55 C-7: INSTALLATION OF AIR CONDITIONER (ONLY WHEN INSTALLING HIGH CAB)........................................ 56 C-8: INSTALLATION OF OPERATOR'S SEAT ASSEMBLY (ONLY WHEN INSTALLING HIGH CAB)............................... 59 C-9: INSTALLATION OF ADDITIONAL REAR VIEW MIRROR (OPTION)................................................... 60 C-10: INSTALLATION OF FOPS (OPTION)......................................................................... 61 C-11: INSTALLATION OF MUFFLER TAIL PIPE..................................................................... 65 C-12: INSTALLATION OF COUNTERWEIGHT ASSEMBLY................................................................ 67 C-13: EXCHANGING RETURN FILTER (STANDARD PART - SPECIAL FLUSHING PART)...................................... 68 C-14: CHECK OF OIL AND WATER LEVELS......................................................................... 69 C-15: CHECK CENTRAL MONITOR (CARRY OUT ONLY WHEN MACHINE IS DIVIDED INTO THREE PARTS FOR TRANSPORTATION).... 69 C-16: BLEEDING AIR FROM TRAVEL MOTOR CIRCUIT................................................................ 70 C-17: BLEEDING AIR FROM HYDRAULIC IDLER CUSHION CIRCUIT..................................................... 71 C-18: ADJUSTMENT OF HYDRAULIC IDLER CUSHION CYLINDER........................................................ 73 C-19: ADJUSTING TRACK TENSION............................................................................... 74 D. PROCEDURE FOR ASSEMBLY OF WORK EQUIPMENT (BACKHOE SPECIFICATION)............................................. 75 D-1: ASSEMBLY OF BOOM ASSEMBLY.............................................................................. 76 D-2: RELEASING PRESSURE FROM HYDRAULIC CIRCUIT.............................................................. 77 D-3: WORK EQUIPMENT PIPING (BETWEEN CHASSIS AND BOOM) (BETWEEN CHASSIS AND BOOM CYLINDER)................... 78 D-4: FLUSHING WORK EQUIPMENT PIPING......................................................................... 81 D-5: INSTALLATION OF BOOM CYLINDER FOOT PIN................................................................. 82 D-6: INSTALLING BOOM CYLINDER HOSES......................................................................... 83 D-7: INSTALLATION OF BOOM CYLINDER TOP PIN.................................................................. 84 D-8: INSTALLATION OF ARM CYLINDER FOOT PIN.................................................................. 85 D-9: WORK EQUIPMENT PIPING (ARM CYLINDER)................................................................... 86 D-10: INSTALLATION OF ARM AND ARM CYLINDER TOP PIN.......................................................... 87 D-11: WORK EQUIPMENT PIPING (BOOM-BUCKET CYLINDER).......................................................... 88 D-12: ASSEMBLY OF BUCKET ASSEMBLY........................................................................... 89 D-13: MAINTENANCE STANDARD.................................................................................. 91 D-14: INSTALLATION OF WORK EQUIPMENT GREASE PIPING.......................................................... 93 D-15: INSTALLATION OF WORK EQUIPMENT WIRING AND WORK EQUIPMENT HOSE CLAMPS.................................. 95 D-16: BLEEDING AIR FROM CYLINDER............................................................................ 97 D-17: CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL............................................................ 98 E. PROCEDURE FOR ASSEMBLY OF WORK EQUIPMENT (FRONT LOADING SHOVEL SPECIFICATION)................................ 99 E-1: INSTALLATION OF ARM CYLINDER FOOT PIN..................................................................100 E-2: CONNECTION OF BOOM AND ARM.............................................................................101 E-3: INSTALLATION OF ARM CYLINDER TOP PIN...................................................................102 E-4: INSTALLATION OF BUCKET CYLINDER FOOT PIN...............................................................103 E-5: CONNECTION OF LINK AND BUCKET CYLINDER TOP PIN.........................................................104 E-6: ASSEMBLY OF BOOM ASSEMBLY..............................................................................106 E-7: RELEASING PRESSURE FROM HYDRAULIC CIRCUIT..............................................................108 E-8: WORK EQUIPMENT PIPING (BETWEEN CHASSIS AND BOOM).......................................................109 E-9: WORK EQUIPMENT PIPING..................................................................................110 E-10: FLUSHING WORK EQUIPMENT PIPING........................................................................115 E-11: INSTALLATION OF BOOM CYLINDER FOOT PIN................................................................117 E-12: INSTALLATION OF BOOM CYLINDER HOSES...................................................................118 E-13: INSTALLATION OF BOOM CYLINDER TOP PIN.................................................................119 E-14: INSTALLATION OF ARM CYLINDER HOSES....................................................................120 E-15: INSTALLATION OF BUCKET CYLINDER PIPING................................................................121 E-16: INSTALLATION OF BOTTOM DUMP CYLINDER PIPING...........................................................122 E-17: INSTALLATION OF BUCKET ASSEMBLY.......................................................................123 E-18: MAINTENANCE STANDARD..................................................................................125 E-19: INSTALLATION OF BOTTOM DUMP CYLINDER PIPING...........................................................127 E-20: INSTALLATION OF WORK EQUIPMENT PIPING CLAMPS..........................................................128 E-21: INSTALLATION OF WORKING LAMP..........................................................................130 E:22: INSTALLATION OF WORK EQUIPMENT GREASE PIPING..........................................................131 E-23: BLEEDING AIR FROM WORK EQUIPMENT CIRCUIT..............................................................134 E-24: CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL............................................................135 E-25: INSTALLATION OF BOOM FOOT POTENTIOMETER...............................................................136 E-26: 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)...............................................................................147 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. PCIOOO-1 55°C AUSTRALIA SPECIFICATION........................................................................153 APPENDIX.........................................................................................................169 FIELD ASSEMBLY INSPECTION REPORT.............................................................................169
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