HYDRAULIC EXCAVATOR PC1800-6 Field Assembly Instruction

COVER
CONTENTS
GENERAL
1. SPECIFICATIONS
2. POINTS REGARDING LOCAL ASSEMBLY
3. BOLT TIGHTENING TORQUE AND BOLT TIGHTENING TOOLS
4. SEPARATE UNITS
5. LIST OF PARTS SENT INDIVIDUALLY
6. ASSEMBLY PROCEDURE, ASSEMBLY EQUIPMENT AND SCHEDULE
7. KIT LAYOUT DIAGRAM
8. TOOLS AND EQUIPMENT TO BE USED
COMPONENTS TO BE ASSEMBLED IN HARBOR
COOLING SUB ASS’Y
FUEL TANK SUB ASS’Y
HYDRAULIC TANK SUB ASS’Y
SUCTION TUBE SUB ASS’Y
OIL COOLER LINE
SWING MACHINERY SUB ASS’Y
HOOD (SMALL) SUB ASS’Y
RIGHT SIDE DOOR SUB ASS’Y
RIGHT SIDE DUCT SUB ASS’Y
PARTITION COVER
MUFFLER COVER
BATTERY CASE SUB ASS’Y
A. ASSEMBY OF CHASSIS
A-1: ASSEMBLY OF TRACK FRAME AND AXLE
A-2: TRAVEL MOTOR PIPING
A-3: IDLER CUSHION CYLINDER PIPING
A-4: INSTALLATION OF TRAVEL MOTOR GUARD
A-5: FILLING SWING CIRCLE WITH GREASE
A-6: ASSEMBLY OF REVOLVING FRAME ASSEMBLY AND AXLE ASSEMBLY
A-7: SWIVEL TRAVEL PIPING
A-8: SWING CIRCLE GREASE TUBE PIPING
A-9: INSTALLATION OF LEFT AND RIGHT LADDERS
A-10: INSTALLATION OF LEFT CATWALK (STD)
A-11: INSATLLATION OF RIGHT CATWALK
A-12: INSATLLATION OF CATWALK, HANDRAIL BESIDE OPERATOR’S CAB
A-13: INSTALLATION OF OPERATOR’S CAB LADDER
A-14: INSTALLSTION OF OPERATOR’S CAB HANDRAIL
A-16: INSTALLSTION OF HANDRAIL AT REAR OF OPERATOR’S CAB
A-18: OPERATOR’S CAB FRONT FRAME, HANDRAIL
A-20: RIGHT DECK HANDRAIL
A-21: INSTALLATION OF LADDER ON TOP OF HYDRAULIC TANK
A-22: INSTALLATION OF COUNTERWEIGHT
A-23: INSTALLATION OF COUNTERWEIGHT LADDERS (LEFT AND RIGHT)
A-24: INSTALLATION OF HANDRAIL ON TOP OF FUEL TANK, COUNTERWEIGHT
A-25: INSTALLATION OF FUEL TANK VIBRATION STOPPER BRACKET
A-26: INSTALLATION OF GREASE REEL, HOSE, BRACKET
A-27: INSTALLATION OF LEFT CAB BASE ASSEMBLY
A-28: INSTALLATION OF OPERATOR’S CAB ASSEMBLY
A-29: INSTALLATION OF WIPER MOTOR COVER INSIDE OPERATOR’S CAB
A-30: INSTALLATION OF UPPER HANDRAIL OF LEFT-HAND DOOR COVER
A-31: HANDRAILS ABOVE THE RH DOOR AND BAOVE THE HYDRAULIC OIL TANK
A-32: EMERGENCY STOP SWITCH, FUEL CUT LEVER
A-33: HANDRAIL ABOVE THE RADIATOR
A-34: CONNECTION OF HYDRAULIC PIPING OPERATOR’S CAB ASSEMBLY
A-35: CONNECTION OF WINDOW WASHER HOSE OF OPERATOR’S CAB ASSEMBLY
A-36: CONNECTION OF AIR PIPING OF LEFT CAB BASE ASSEMBLY
A-37: CONNECTION OF GREASE PIPING OF OPERATION’S CAB ASSEMBLY
A-38: CONNECTION OF WIRING HAMESS IN CAB BASE
A-39: PIPING OF AIR CONDITIONER DISCHARGE HOSE
A-40: INSTALLATION OF HEAD GUARD
A-41: INSTALLATION OF ORBCOMM ANTENNA
A-42: CONNECTION OF BATTERY CABLE
A-43: START ENGINE
A-44: FINAL TIGHTENING OF SWING CIRCLE MOUNTING BOLTS
A-45: PARTS TO BE TOUCHED UP AFTER FIELD ASSEMBLY
L-1: INSTALLATION OF LEFT-HAND CATWALK AND POWER-ASSISTED LADDER
C. PC1800 INSTALLATION OF BACKHOE WORK EQUIPMENT
C-1: INSTALLATION OF BOOM CYLINDER TO CHASSIS
C-2: INSTALLATION OF BOOM CYLINDER PIPING
C-3: BLEEDING AIR FROM BOOM CYLINDER
C-4: BOOM SUB-ASSEMBLY
C-5: INSTALLATION OF BOOM ASSEMBLY
C-6: INSTALLATION OF BOOM CYLINDER TOP PIN
C-7: CONNECTION OF ARM ASSEMBLY TO BOOM
C-8: INSTALLATION OF HOSES BETWEEN BOOM AND CHASSIS
C-9: INSATLLATION OF ARM CYLINDER TOP PIN
C-10: BLEEDING AIR FROM ARM CYLINDER
C-11: INSTALLATION OF HYDRAULIC HOSES BETWEEN BOOM AND ARM
C-12: CONNECTION OF GREASE PIPING
C-13: CONNECTION OF WIRING BETWEEN BOOM AND CHASSIS
C-14: INSTALLATION OF HOSES BETWEEN BOOM AND CHASSIS
C-16: CONNECTION OF BUCKET ASSEMBLY TO ARM
C-17: INSTALLATIPN OF BUCKET LINK
C-18: BLEEDING AIR FROM BUCKET CYLINDER
ASSEMBLY MANUAL FOR LOADING SHOVEL WORK EQUIPMENT
LS-1: INSTALLATION OF ARM CYLINDER TUBES AND HOSES
LS-2: INSTALLATION OF BUCKET HOSES
LS-3: INSTALLATION OF BOTTOM DUMP HOSES AND TUBES
LS-4: INSTALLATION OF PILOT SOLENOID VALVE
LS-5: INSTALLATION OF BOTTOM PRIORITY VALVE
LS-6: INSTALLATION OF ARM PILOT DRAIN CIRCUIT
LS-7: INSTALLATION OF CONTROL PARTS
LS-8: INSTALLATION OF HORN SWITCH
LS-9: CHANGE OF ARM PILOT PIPING
LS-10: REMOVAL OF BOOM FOOT HANDRAIL
LS-11: INSTALLATION OF ARM CYLINDER BOTTOM PARTS
LS-12: INSTALLATION OF BOOM CYLINDER TO MACHINE BODY
LS-13: INSTALLATION OF BOOM CYLINDER PIPING
LS-14: INSTALLATION OF BOOM ASSEMBLY
LS-15: INSTALLATION OF BOOM CYLINDER HEAD PINS
LS-16: INSTALLATION OF GREASE FEED HOSE BETWEEN MACHINE BODY AND BOOM
LS-17: INSTALLATION OF BUCKET CYLINDER ASSEMBLY
LS-18: INSTALLATION OF ARM ASSEMBLY
LS-19: INSTALLATION OF ARM CYLINDER ASSEMBLY
LS-20: INSTALLATION OF HOSES BETWEEN BOOM AND ARM
LS-21: INSATLLATION OF BUCKET CYLINDER HOSES
LS-22: INSTALLATION OF GREASE FEED HOSE OF BUCKET CYLINDER
LS-23: INSTALLATION OF BUCKET ASSEMBLY
LS-24: INSTALLATION OF BOTTOM DUMP HOSE AND GREASE FEED HOSE BETWEEN ARM AND BUCKET
M. INSPECTION AND SERVICING PROCEDURES AFTER FINNISHING ALL THE ASSEMBLY AND INSTALLATION WORKS
M-1: 1. INSPECTING THE OIL LEVEL AND WATER LEVEL IN RESPECTIVE SECTIONS AND REFILLING THEM
M-1: 2. SELECTION OF THE APPROPRIATE FUEL TYPE AND LUBRICATING OIL TYPE FITTING TO THE ATMOSPHERIC TEMPERATURE RANGE
M-2: FLUSHING OF HYDRAULIC CIRCUIT
M-3: RELEASING RESIDUAL PRESSURE FROM HYDRAULIC CIRCUIT
INITIALIZATION PROCEDURES FOR VHMS CONTROLLER
SETTING PROCEDURES FOR REPLACING VHMS CONTROLLER
FIELD ASSEMBLY INSPECTION REPORT