HYDRAULIC EXCAVATOR PC4000-6 (08205 and up) Field Assembly Manual

2 SAFETY
2.1 SAFETY INFORMATION
2.2 OVERVIEW
2.3 SOUND PRESSURE LEVEL IN THE OPERATOR’S CAB.
2.4 GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR
2.5 PRECAUTION FOR MAINTENANCE
2.6 ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS
2.7 SPECIAL SAFETY EQUIPMENT
2.8 ADDITIONAL SAFETY PRECAUTIONS FOR ASSEMBLY
3 GENERAL
3.1 GENERAL
3.2 ASSEMBLY SITE REQUIREMENTS
3.3 GENERAL INSTALLATION PROCEDURES FOR HYDRAULIC HOSE LINES
4 ASSEMBLY SEQUENCE
4.1 ASSEMBLY SEQUENCE OF FACE SHOVEL MACHINES
4.2 ASSEMBLY SEQUENCE OF BACKHOE MACHINES
4.3 ASSEMBLY OF UNDERCARRIAGE
4.4 MOUNTING SUPERSTRUCTURE PLATFORM ONTO UNDERCARRIAGE
4.5 ASSEMBLY OF MACHINERY HOUSE ROOF
4.6 MOUNTING MACHINERY HOUSE ONTO THE SUPERSTRUCTURE PLATFORM
4.7 MOUNTING OF BATTERY BOX AND HYDRAULIC ACCESS LADDER
4.8 CONNECTING ENGINE OIL RESERVE SYSTEM
4.9 PRE-ASSEMBLY OF FACE SHOVEL BOOM
4.10 PRE-ASSEMBLY OF BACKHOE BOOM
4.11 MOUNTING OF COUNTERWEIGHT
4.12 MOUNTING OF THE FUEL TANK
4.13 ATTACHING THE CAB BASE
4.14 ATTACHING THE CAB WITH SUPPORT FRAME TO THE CAB BASE
4.15 CONNECTING HYDRAULIC LINES BETWEEN MACHINERY HOUSE AND SUPERSTRUCTURE
4.16 ATTACHING THE HYDRAULIC OIL RESERVOIR
4.17 ATTACHING THE HYDRAULIC OIL COOLER
4.18 CONNECTING SWING GEAR HYDRAULIC LINES
4.19 CONNECTING THE RETURN AND PRESSURE OIL HOSES FROM VALVE BLOCK
4.20 CONNECTING THE HOSE LINES OF THE TRANSFER PUMP
4.21 CONNECTING HYDRAULIC LINES TO THE ROTARY JOINT
4.22 ATTACHING THE HANDRAILS, CATWALKS AND STEPS
4.23 MOUNTING OF THE FIRE EXTINGUISHING TANK ASSEMBLIES
4.24 CENTRAL REFILLING SYSTEM
4.25 CONNECTING THE GREASE LINES OF THE AUTOMATIC LUBRICATION SYSTEMS
4.26 MOUNTING THE CAN-NODE BOXES ONTO THE MACHINERY HOUSE ROOF
4.27 PRE-CHECKS PRIOR TO INITIAL START UP
4.28 FILLING AND BLEEDING THE HYDRAULIC SYSTEM
4.29 ASSEMBLY FACE SHOVEL ATTACHMENT
4.30 BLEEDING HYDRAULIC CIRCUITS
4.31 ATTACHING FACE SHOVEL TO THE STICK
4.32 ASSEMBLY BACKHOE ATTACHMENT
4.33 BLEEDING HYDRAULIC CIRCUITS
4.34 ATTACHING BACKHOE BUCKET TO THE STICK
4.35 BLEEDING HYDRAULIC CIRCUITS OF THE TRAVEL MOTORS
5 FINAL CHECKS AND ADJUSTMENTS
5.0.1 COMMISSIONING CHECK LIST
5.0.2 ADJUSTMENT OF AUTOMATIC LUBRICATION SYSTEMS
5.0.3 MAIN PUMP ADJUSTMENT IN RELATION TO ALTITUDE AT THE MINE SITE
5.0.4 PRESSURE COMPENSATION OF SEALED COMPONENTS
5.0.5 PLACING THE FIRE DETECTION AND SUPPRESSION SYSTEM IN SERVICE
5.0.6 COMMISSIONING OF THE AIR CONDITIONING
5.1 PERFORM THE PM-CLINIC PROCEDURE ACCORDING TO THE PM-CLINIC MANUAL
5.2 HANDLING OF DOCUMENTATION AFTER ASSEMBLY AND COMMISSIONING
6 DISASSEMBLY OF THE MACHINE
6.0.1 DISASSEMBLY SEQUENCE OF FACE SHOVEL MACHINES
6.0.2 SAFETY PRECAUTIONS FOR DISASSEMBLING THE MACHINE
6.0.3 DISASSEMBLY SEQUENCE OF BACKHOE MACHINES
6.0.4 SAFETY PRECAUTIONS FOR DISASSEMBLING THE MACHINE
6.0.5 DISPOSAL OF WASTE MATERIAL