PDF Field Assembly Manual Komatsu PC2000-11R Hydraulic Excavator - 6 MB
This is the field assembly instruction manual for the Komatsu PC2000-11R Hydraulic Excavator.
This highly specialized document provides step-by-step procedures for the correct assembly of the machine on-site.
It is an essential guide for certified technicians responsible for commissioning this massive excavator.
Following these factory instructions is critical for ensuring structural integrity and operational safety.
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--- Page 1 ---
GEN00218-02
HYDRAULIC PC2000 -11R
EXCAVATOR SERIAL NUMBERS 30019 and up
--- Page 3 ---
FLOWCHART OF MAIN ASSEMBLY PROCEDURE
Work necessary to assembly
from 27 ton parts
Assembly of undercarriage
(Coupling of crawler and center)
Assembly of undercarriage Coupling of revolving frame Sub-assembly of cab base
(Coupling of crawler and center)
Installation of fuel tank Installation of cab base Installation of machinery
(front)
Installation of left floor
Installation of power module
Installation of cab
Installation of external covers
and steps
Installation of counterweight
Motoring
Installation of boom cylinder
Installation of boom Sub-assembly of boom
Installation of arm Sub-assembly of arm
Installation of bucket
5
--- Page 4 ---
• Method of installing chassis hanging jig
15
--- Page 5 ---
LIST OF PARTS SENT INDIVIDUALLY (operator's cab)
㻌E 㻌 E
Assembly
No. Part No. Part Name Q’ty Remarks
Procedure No.
E-1 21T-54-34151-XC COVER 1 A-32
E-2 01034-81225 BOLT 6 A-32
E-3 21T-54-37980 BRACKET 6 A-32
E-4 21T-54-36680 PLATE 9 A-32
E-5 21T-54-36690 PLATE 12 A-32
E-6 01024-81030 BOLT 12 A-32
E-7 21T-54-37990 CUSHION 6 A-32
E-8 21T-54-35312 -NK BRACKET 8 A-32
E-9 8230-46-1130 BOLT 16 A-32
E-10 01643-32060 WASHER 16 A-32
E-11 21T-54-36661 PLATE 16 A-32
E-12 21T-54-36671 PLATE 8 A-32
E-13 21T-54-35321 CUSHION 8 A-32
E-14 21T-54-35732 PIN 4 A-32
E-15 04020-00514 COTTER PIN 8 A-32
E-16 01050-52040 BOLT 4 A-32
E-17 01643-32060 WASHER 4 A-32
E-18 8295-06-1480 LAMP 1 A-33
E-19 21T-06-17430-XC BRACKET 1 A-33
E-20 01024-81225 BOLT 2 A-33
E-21 8295-06-1480 LAMP 1 A-33
E-22 21T-06-33610-XC PLATE 1 A-33
E-23 21T-06-17430-XC BRACKET 1 A-33
E-24 01024-81225 BOLT 2 A-33
E-25 04434-51012 CLIP 1 A-33
E-26 01024-81220 BOLT 1 A-33
E-27 01024-81020 BOLT 1 A-35
E-28 207-62-62770-NK BRACKET 1 A-35
E-29 01024-81225 BOLT 2 A-35
E-30 04434-53212 CLIP 1 A-35
E-31 01024-81225 BOLT 2 A-35
25
--- Page 6 ---
LIST OF PARTS SENT INDIVIDUALLY (Coupling of Bucket)
J㻌
Assembly
No. Part No. Part Name Q’ty Remarks
Procedure No.
J-1 209-72-11261 SEAL 4 C-12
J-2 209-70-71370 O-RING 4 C-12
J-3 205-09-61240 BOLT 4 C-12
J-4 01640-20610 WASHER 8 C-12
J-5 01596-00606 NUT 4 C-12
J-6 8247-62-1810 SWIVEL 2 C-12
J-7 07000-12011 O-RING 2 C-12
J-8 21T-70-34333-NK COVER 2 C-12
J-9 07000-15195 O-RING 2 C-12
J-10 01010-83695 BOLT 12 C-12
J-11 01643-33690 WASHER 12 C-12
J-12 21T-70-33171 PIN 2 C-12
J-13 21T-70-34341-NK COVER 2 C-12
J-14 07000-15175 O-RING 2 C-12
J-15 01010-83685 BOLT 12 C-12
J-16 01643-33690 WASHER 12 C-12
J-18 21T-70-33250-NK PIN 2 C-13
J-19 21T-72-73170-NK STOPPER 2 C-13
J-20 01010-81645 BOLT 6 C-13
J-21 01643-31645 WASHER 6 C-13
J-22 21N-72-11230 SHIM 2 C-13
35
--- Page 7 ---
COATING MATERIALS LIST
a The coating materials such as adhesives, gasket sealants, and greases used for disassembly and assembly
are listed below.
a For coating materials not listed below, use the equivalent of products shown in this list.
Category Komatsu code Part No. Q'ty Container Main features and applications
• Used to prevent rubber gaskets, rub-
LT-1A 790-129-9030 150 g Tube ber cushions, and cock plugs from
coming out.
• Used for plastic (except polyethyl-
ene, polypropylene, tetrafluoroethyl-
20 g Polyethylene ene and vinyl chloride), rubber,
LT-1B 790-129-9050 (2 pcs.) container metal, and non-metal parts which re-
quire immediate and strong adhe-
sion.
• Features: Resistance to heat and
Polyethylene
LT-2 09940-00030 50 g chemicals
container • Used to fix and seal bolts and plugs.
Adhesive: • Used to stick metal, glass, and plas-
790-129-9060 tics.
1 kg
LT-3 (Set of adhesive Can
Hardener:
and hardener) 500 g
Adhesive Polyethylene • Used to seal plugs.
LT-4 790-129-9040 250 g container
Holtz • Heat-resistant seal used to repair en-
790-126-9120 75 g Tube gines
MH 705
• Quick-setting adhesive
Threebond Polyethylene • Setting time: Within 5 sec. to 3 min.
790-129-9140 50 g
1735 container • Used mainly to stick metals, rubbers,
plastics, and woods.
• Quick-setting adhesive
• Quick-setting type (max. strength is
Aron-alpha Polyethylene
790-129-9130 2g obtained after 30 minutes)
201 container • Used mainly to stick rubbers, plas-
tics, and metals.
• Features: Resistance to heat and
Loctite Polyethylene chemicals
79A-129-9110 50 cc
648-50 container • Used for fitted portions used at high
temperatures.
• Used to stick or seal gaskets and
LG-1 790-129-9010 200 g Tube packings of power train case, etc.
• Used to seal various threaded por-
Polyethylene tions, pipe joints, and flanges.
LG-5 790-129-9080 1 kg container • Used to seal tapered plugs, elbows,
and nipples of hydraulic piping.
• Features: Silicon-based heat and
cold-resistant sealant
• Used to sea flange surfaces and
LG-6 790-129-9020 200 g Tube threaded portions.
• Used to seal oil pan, final drive case,
Gasket etc.
sealant
• Features: Silicon-based quick-set-
ting sealant
LG-7 790-129-9070 1 kg Tube • Used to seal flywheel housing, intake
manifold, oil pan, thermostat hous-
ing, etc.
Three bond • Gasket sealant used to repair engine
790-129-9090 100 g Tube
1211
• Features: Silicon-based, heat and
Three bond cold-resistant, vibration-resistant,
419-15-18131 100 g Tube
1207B impact-resistant sealant
• Used to seal transfer case, etc.
• Used to lubricate sliding portions (to
LM-G 09940-00051 60 g Can prevent squeaking).
Molybdenu • Used to prevent scuffing and seizure
m disulfide of press-fitted portions, shrink-fitted
lubricant LM-P 09940-00040 200 g Tube portions, and threaded portions.
• Used to lubricate linkages, bearings,
etc.
45
--- Page 8 ---
Assembly procedure
Installation of travel motor cover (1/3)
A-4
Travel motor guard
Travel motor cover
Crawler frame
No. Part No. Parts name Q'ty
A-15 01010-82460 Bolt 16
A-16 01643-32460 Washer 16
A-17 21T-30-32370 Collar 16
Precautions Tools required Equipment required
Travel motor guard is installed to crawler Name Q’ty Name Q’ty
frame assembly when transported. Air impact wrench 1
Travel motor cover is installed temporarily to
crawler frame assembly when transported. Socket 36mm in width across flats 1
a Before performing this item, bleed air from
the travel motor.
Others
55
--- Page 9 ---
Assembly procedure
Installation of hydraulic tank assembly (2/5)
A-10
For disassembly to 27 t
Clamp air conditioner hoses
at 4 places marked with .
Clamp PPC hoses
at 3 places marked with .
Precautions Tools required Equipment required
Name Q’ty Name Q’ty
Others
65
--- Page 10 ---
Assembly procedure
Installation of left floor assembly (1/5)
A-15
Left floor assembly
2,100 kg
Sling position
Install eyebolt.
Ｚ M24 (4 places)
After installing exterior parts,
adjust
adjust their level difference
with th
theese shims. (See A-47.)
No. Part No. Parts name Q'ty
C-35 21T-54-43370-NK Cover 1
C-36 01034-81240 Bolt 4
C-37 21T-53-32820-NK Bracket 2
C-38 01034-81240 Bolt 4
Precautions Tools required Equipment required
After the work, return the bolts removed to Name Q’ty Name Q’ty
install the eyebolts. Air impact wrench 1
Socket 19mm in width across flats 1
Others
75
--- Page 11 ---
Assembly procedure
Connection of cab base assembly wiring (3/7)
A-17
"Precautions for connecting DRC multi-pole connector"
Precautions to be observed when connecting DRC multi-pole connector
1. Before connecting
If the seal rubber is broken or deformed,
the connector may not be connected normally.
In this case, replace the connector with new one.
Check the edge for breakage or
17A-06-41830 deformation. If it has any
17A-06-41840 abnormality, replace the whole
connector with new one.
2. Preparation for connection
If the DRC multi-pole connector is at a high place, prepare a work stand so that you can stand stably and connect the con-
nector while checking it visually.
Precautions Tools required Equipment required
Name Q’ty Name Q’ty
Others
85
--- Page 12 ---
Assembly procedure
Installation of power module assembly (1/2)
A-21
Power module assembly
16,400 kg
・Install bolts to the installation hole before installing power
module for ease of transportation of heavy equipment.
Right rear
Take care that mounting section of
power module will not go over guide.
Left rear
Precautions Tools required Equipment required
a Be careful not to fall down yourself. Name Q’ty Name Q’ty
a Before installation, drain remaining oil
from piping.
Others
95
--- Page 13 ---
Assembly procedure
Connection of pilot piping and fan motor piping
A-27
33 32
Le
Left of machine
Front
Fro of machine
No. Part No. Parts name Q'ty
※ D-32 07000-B3025 O-ring 2
D-33 07000-B3032 O-ring 1
Precautions Tools required Equipment required
Name Q’ty Name Q’ty
Air impact wrench 1
Socket 19 mm in width across flats 1
Extension L200 1
Others
105
--- Page 14 ---
Assembly procedure
Installation of operator's cab assembly (2/4)
A-32
3
4
5
6
7
Front of machine
E3 E7 E-6 Left of machine
Cab assembly
When riding in cab ,adjust with shims
so that clearance to be 1.5 to 3 mm.
E4 E5
Z
STD. Quantites of Shim
Portion Part Number Quantities Part Number Quantities
J 21T-54-36690 1 21T-54-36680 1
K 21T-54-36690 1 21T-54-36680 1
L 21T-54-36690 1 21T-54-36680 1 No. Part No. Parts name Q'ty
E-3 21T-54-37980 Bracket 6
M 21T-54-36690 3 t1.6 E-4 21T-54-36680 Plate 9
N 21T-54-36690 2 21T-54-36680 1 t3.2 E-5 21T-54-36690 Plate 12
E-6 01024-81030 Bolt 12
P 21T-54-36690 2 21T-54-36680 1 E-7 21T-54-37990 Cushion 6
Precautions Tools required Equipment required
Take care not to break the mount dowel pin. Name Q’ty Name Q’ty
Air impact wrench 1
Socket 17 mm in width across flats 1
Extension L200 1
Others
115
--- Page 15 ---
Assembly procedure
Connection of operator's cab assembly
A-36 hydraulic piping (2/2)
Connection (Quick coupler)
Blue/Black
Red
Green/Black
Red/Black
Black/Black
Blue
Red/
37
38
No. Part No. Parts name Q'ty
E-37 02896-61012 O-ring 10
E-38 02896-61009 O-ring 2
Precautions Tools required Equipment required
Disconnection of quick coupler Connection of quick coupler Name Q’ty Name Q’ty
(1) Push the hose adapter into the adapter. (4) Hold the hose adapter and push it Spanner 1
(2) Push the cap into the adapter. straight into the adapter until it clicks.
(3) Pull the hose straight. After connecting the hose, pull its adapter
lightly to check that it will not come off.
Hose adapter
Hose
Cap
Adapter (Plug or joint)
Others
Adapter (Plug or joint)
125
--- Page 17 ---
Assembly procedure
Installation of right floor assembly,
A-44 grease can cover assembly and center floor (2/2)
Clearance: 20 ± 5mm Clearance: 10 ± 5mm Clearance: 10 ± 5mm Clearance: 17 ± 5mm
Clearance: 15 ± 5mm
No. Part No. Parts name Q'ty
F-15 21T-54-33731-NK Cover 1
F-16 21T-54-33781-NK Cover 1
F-17 21T-54-33791-NK Cover 1
F-18 21T-53-31590-NK Step 1
F-19 01034-81230 Bolt,sems 16
F-20 01034-81285 Bolt 4
Precautions Tools required Equipment required
Name Q’ty Name Q’ty
Air impact wrench 1
Socket 19 mm in width across flats １
Extension L200 １
Others
135
--- Page 18 ---
Assembly procedure
Installation of handrail clamps (2/3)
A-53
41 40 39 38
2 places marked with A
Z
Precautions Tools required Equipment required
Name Q’ty Name Q’ty
Air impact wrench 1
Socket 19 mm in width across flats 1
Extention L200 1
Others
145
--- Page 19 ---
Assembly procedure
Starting engine, checking oil and coolant levels,
A-58 bleeding air from each part, and adjusting track (5/15)
(3) Air bleeding from swing motor circuit (Swing motor)
a When removing and installing the swing motor or when
disconnecting and connecting the swing motor main cir-
cuit pipes, bleed air from the swing motor according to the
following procedures.
k If air was not bled or air was bled insufficiently, the
swing motor may be damaged. So, be sure to bleed
air strictly according to the procedures.
1) Start the engine and operate it while the engine is
idling at low speed.
2) Repeat operations of swing, start, and stop 5 or 6
times.
(4) Air bleeding from swing motor circuit (Parking brake circuit)
a When removing and installing the swing motor or when
disconnecting and connecting the swing holding brake
circuit piping, bleed air from the brake circuit according to
the following procedures.
k If air was not bled or air was bled insufficiently, the
swing holding brake may be dragged. So, be sure to
bleed air strictly according to the procedures.
1) Start the engine and loosen bleeder (11).
a The bleeder is mounted on the front and rear
swing motors.
2) Turn off the swing lock switch.
3) Swing the machine while the engine is idling at low
speed and make sure that bubble-free oil flows out of
bleeder (11). Then, tighten the bleeders.
3 Bleeder : 8.8 – 9.8Nm {0.9 – 1.0kgm}
a The swing operation may be as faintly as the
swing oil pressure switch turns on.
(5) Air Bleeding from travel motor circuit (Travel motor)
a When removing and installing the travel motor or when
disconnecting and connecting the travel motor main cir-
cuit pipes, bleed air from the travel motor according to the
following procedures.
k If air was not bled or air was bled insufficiently, the
travel motor may be damaged. So, be sure to bleed
air strictly according to the procedures.
1) Start the engine and loosen bleeder (12).
a The bleeder is mounted on the LH and RH travel
motors.
2) Make sure that bubble-free oil flows out of the bleed-
ers (12). Then, tighten the bleeder.
3 Bleeder : 8.8 – 9.8Nm {0.9 – 1.0kgm}
155
--- Page 20 ---
Assembly procedure
Starting engine, checking oil and coolant levels,
A-58 bleeding air from each part, and adjusting track (15/15)
Bleeding air from each hydraulic cylinder (Hydraulic ladder spec. or service senter spec.)
(1) Bleeding air from hydlaulic ladder cylinder
1) Raise and lower the ladder 5 – 6 times in a range (B) where the ladder automatic pressing system does not work.
2) Hold the ladder in the ladder storage position (A) for 3 minutes. Keep the engine running in this period.
Lower ladder
Raise ladder
Switch box
(2) Bleeding air from service center cylinder (if equipped)
(for service center)
Service center
(Keep pulling the service arm down switch (yellow) ,or
raising switch (green) for cylinder operation.)
Precautions
1. While the ladder and service center are not in the storage position (While the upper proximity switch is not ON), the control lever
is locked (hydraulically) and the machine cannot be operated. When operating the machine (travelling or swinging the machine
or operating the work equipment), store the ladder and service center.
2. When the cylinder piping needs to be removed, release the pressure in the circuit according to the following procedure, and
then remove the piping.
・With the ladder lowered, hold down the LOWER button for 5 seconds.
・With the service center lowered, hold down the LOWER button for 6 seconds.
165
--- Page 21 ---
Assembly procedure
Installation of KomVision and rear lamp (4/9)
A-63
Installation of KomVision harness
Connect connector Install wiring in the field.
CN-A77