R & R PC-5500
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Descripción: pc 5500 komatsu...
Description
Remove & Replace Procedures R & R Procedures
PC5500-6
HYDRAULIC MINING SHOVEL
This material is proprietary to Komatsu Mining Germany GmbH and is not to be reproduced, used, or disclosed except in accordance with written authorization from Komatsu Mining Germany GmbH. It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make changes or add improvements at any time without incurring any obligation to install such changes on products sold previously. Due to this continous program of research and development, periodic revisions may be made to this publication. It is recommended that customer contact their distributor for information on the latest revision.
Version 2009/2
Copyright 2008
Overview
Overview 1 INTRODUCTION 2 SAFETY AND STANDARDS 3 SUPERSTRUCTURE 4 UNDERCARRIAGE 5 ATTACHMENT 6 SERVICE INFORMATION 7 TOOLS CATALOGUE 8 PARTS & SERVICE NEWS 9 SUPPLIER’S DOCUMENTATION
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Overview
Overview - 2
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Table of contents
Table of contents 1 INTRODUCTION........................................................................................ 1-1 1.1
CONTENTS OF THE BINDER ........................................................................................................... 1-2
1.2
FOREWORD ...................................................................................................................................... 1-3 1.2.1 SERVICE ............................................................................................................................... 1-4
2 SAFETY AND STANDARDS ..................................................................... 2-1 2.1
SAFETY INSTRUCTIONS.................................................................................................................. 2-2 2.1.1 METHOD OF USING THIS MANUAL .................................................................................... 2-2 2.1.2 GENERAL PRECAUTIONS ................................................................................................... 2-4 2.1.3 PREPARATIONS FOR WORK .............................................................................................. 2-5 2.1.4 PRECAUTIONS DURING WORK.......................................................................................... 2-6 2.1.5 WARNING OF SPECIAL DANGERS..................................................................................... 2-8 2.1.5.1 ELECTRICAL ENERGY ......................................................................................... 2-8 2.1.5.2 GAS, DUST, STEAM AND SMOKE ....................................................................... 2-9 2.1.5.3 HYDRAULIC, AIR CONDITIONING AND PNEUMATIC EQUIPMENT................ 2-10 2.1.5.4 NOISE .................................................................................................................. 2-10 2.1.5.5 HEAT.................................................................................................................... 2-11 2.1.5.6 OIL, GREASE AND OTHER CHEMICAL SUBSTANCES ................................... 2-11 2.1.5.7 HEIGHT................................................................................................................ 2-11 2.1.6 SPECIAL SAFETY EQUIPMENT ........................................................................................ 2-13 2.1.6.1 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD) .................................................................................. 2-13 2.1.6.2 INSTRUCTIONS FOR USE ................................................................................. 2-15 2.1.6.3 RECOMMENDATIONS FOR USE OF THE HOLDING HOOKS AND HOLD-BACK HOOKS OF THE SAFETY HARNESS........................................... 2-17 2.1.6.4 INSTARUCTIONS FOR USING THE FALL ABSORBER .................................... 2-19 2.1.7 SAFETY HINTS FOR HYDRAULIC HOSE INSTALLATION ............................................... 2-20 2.1.8 SAFETY HINTS FOR LIFTING HEAVY PARTS.................................................................. 2-23 2.1.9 SAFETY HINTS FOR WIRE ROPES................................................................................... 2-23 2.1.10 SAFETY HINTS FOR SLING ACCESSORY ....................................................................... 2-25 2.1.11 WEIGHT TABLES ................................................................................................................ 2-26 2.1.11.1 SUPERSTRUCTURE........................................................................................... 2-26 2.1.11.2 UNDERCARRIAGE.............................................................................................. 2-29 2.1.11.3 BACKHOE ATTACHMENT (BHA) ....................................................................... 2-31 2.1.11.4 FACE SHOVEL ATTACHMENT (FSA) ................................................................ 2-32
2.2
TORQUE CHARTS ACCORDING TO DIN ...................................................................................... 2.2.1 METRIC STANDARD THREAD........................................................................................... 2.2.2 METRIC FINE THREAD ...................................................................................................... 2.2.3 CUMMINS MOTOR TORQUES - METRIC.......................................................................... 2.2.4 CUMMINS MOTOR TORQUES - U.S. CUSTOMARY......................................................... 2.2.5 SAE FLANGE CONNECTIONS ...........................................................................................
2-33 2-33 2-34 2-35 2-35 2-36
2.3
BLIND PLUGS ................................................................................................................................. 2.3.1 DUMMY PLATES FOR SAE-FLANGES .............................................................................. 2.3.2 CLASSIFICATION OF THREADS TO THE NOMINAL WIDTH ........................................... 2.3.3 PLUGS AND FITTINGS ACCORDING TO DIN 2353..........................................................
2-37 2-37 2-39 2-40
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2.4
CONVERSION TABLE..................................................................................................................... 2.4.1 METHOD OF USING THE CONVERSION TABLE ............................................................. 2.4.2 MILLIMETER - INCH & KILOGRAM - POUND .................................................................... 2.4.3 LITER - U.S. GALLON & LITER - U.K. GALLON................................................................. 2.4.4 NM - FT.LB........................................................................................................................... 2.4.5 BAR - PSI / PSI - BAR ......................................................................................................... 2.4.6 BASIC VALUES IN OHM ACCORDING TO DIN 43 76 ....................................................... 2.4.7 TEMPERATURE ..................................................................................................................
2-41 2-41 2-42 2-43 2-44 2-45 2-46 2-47
2.5
TOOLS.............................................................................................................................................. 2-48 2.5.1 STANDARD TOOL CASE.................................................................................................... 2-48
2.6
EXPLANATION OF ABBREVIATIONS ........................................................................................... 2-50
3 SUPERSTRUCTURE................................................................................. 3-1 3.1
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DIESEL ENGINE ................................................................................................................................ 3-2 3.1.1 REMOVAL OF THE DIESEL ENGINES ................................................................................ 3-2 3.1.1.1 PREPARATORY WORK FOR DIESEL ENGINES REMOVAL .............................. 3-2 3.1.1.2 REMOVAL OF THE FRONT DIESEL ENGINE (ENGINE 2) ................................. 3-7 3.1.1.3 REPLACEMENT OF THE FRONT DIESEL ENGINE (ENGINE 2) ...................... 3-11 3.1.1.4 REMOVAL OF THE REAR DIESEL ENGINE (ENGINE 1).................................. 3-14 3.1.1.5 REPLACEMENT OF THE REAR DIESEL ENGINE (ENGINE 1) ........................ 3-14 3.1.2 ENGINE TORQUE SUPPORT AND ENGINE/PTO MOUNTS ............................................ 3-16 3.1.2.1 FLEXIBLE MOUNTS ............................................................................................ 3-17 3.1.2.2 TORQUE SUPPORT............................................................................................ 3-19 3.1.3 ALTERNATOR ..................................................................................................................... 3-20 3.1.3.1 REMOVAL OF THE ALTERNATOR .................................................................... 3-20 3.1.3.2 REPLACEMENT OF THE ALTERNATOR ........................................................... 3-21 3.1.4 BATTERIES ......................................................................................................................... 3-22 3.1.4.1 REMOVAL OF THE BATTERIES......................................................................... 3-22 3.1.4.2 REPLACEMENT OF THE BATTERIES ............................................................... 3-24 3.1.5 RADIATOR FAN .................................................................................................................. 3-26 3.1.5.1 REMOVAL OF THE RADIATOR FAN ASSEMBLY ............................................. 3-27 3.1.5.2 REPLACEMENT OF THE RADIATOR FAN ASSEMBLY .................................... 3-31 3.1.5.3 REMOVAL OF THE RADIATOR FAN.................................................................. 3-33 3.1.5.4 REPLACEMENT OF THE RADIATOR FAN ........................................................ 3-33 3.1.5.5 REMOVAL OF THE RADIATOR FAN DRIVE PUMP .......................................... 3-34 3.1.5.6 REPLACEMENT OF THE RADIATOR FAN DRIVE PUMP ................................. 3-36 3.1.6 RADIATORS ........................................................................................................................ 3-38 3.1.6.1 REMOVAL OF THE RADIATOR ASSEMBLY...................................................... 3-38 3.1.6.2 REPLACEMENT OF THE RADIATOR ASSEMBLY ............................................ 3-41 3.1.7 STARTER SYSTEM............................................................................................................. 3-42 3.1.7.1 REMOVAL OF THE STARTER MOTOR ............................................................. 3-42 3.1.7.2 REPLACEMENT OF THE STARTER MOTOR .................................................... 3-43 3.1.8 TORSION TYPE COUPLING (GEISLINGER) ..................................................................... 3-44 3.1.8.1 REMOVAL OF THE GEISLINGER COUPLING................................................... 3-45 3.1.8.2 REPLACEMENT OF THE GEISLINGER COUPLING ......................................... 3-49
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3.2
PTO .................................................................................................................................................. 3.2.1 MAIN PUMPS ...................................................................................................................... 3.2.1.1 PREPARATORY WORKS FOR MAIN PUMP REMOVAL ................................... 3.2.1.2 REMOVAL OF MAIN PUMPS.............................................................................. 3.2.1.3 REPLACEMENT OF MAIN PUMPS .................................................................... 3.2.2 PTO OIL PUMP (AUXILIARY PUMP) .................................................................................. 3.2.2.1 REMOVAL OF PTO OIL PUMP (AUXILIARY PUMP) ......................................... 3.2.2.2 REPLACEMENT OF THE PTO OIL PUMP (AUXILIARY PUMP) ........................ 3.2.3 OIL CIRCULATION PUMP (AUXILIARY PUMP) ................................................................. 3.2.3.1 REMOVAL OF OIL CIRCULATION PUMP (AUXILIARY PUMP) ........................ 3.2.3.2 REPLACEMENT OF THE OIL CIRCULATION PUMP (AUXILIARY PUMP) ....... 3.2.4 PUMP DISTRIBUTOR GEARBOX (PTO)............................................................................ 3.2.4.1 REMOVAL OF THE PUMP DISTRIBUTOR GEARBOX (PTO) ........................... 3.2.4.2 REPLACEMENT OF THE PUMP DISTRIBUTOR GEARBOX (PTO)..................
3.3
HYDRAULICS .................................................................................................................................. 3-71 3.3.1 HYDRAULIC COOLER FAN DRIVE PUMP ........................................................................ 3-71 3.3.1.1 REMOVAL OF THE HYDRAULIC COOLER FAN DRIVE PUMP ........................ 3-72 3.3.1.2 REPLACEMENT OF THE HYDRAULIC COOLER FAN DRIVE PUMP .............. 3-75 3.3.2 HYDRAULIC COOLER FAN ASSEMBLY ........................................................................... 3-76 3.3.2.1 REMOVAL OF HYDRAULIC COOLER FAN ASSEMBLY ................................... 3-77 3.3.2.2 REPLACEMENT OF HYDRAULIC COOLER FAN ASSEMBLY.......................... 3-80 3.3.2.3 REMOVAL OF HYDRAULIC COOLER FAN AND MOTOR ................................ 3-82 3.3.2.4 REPLACEMENT OF HYDRAULIC COOLER FAN AND MOTOR ....................... 3-84 3.3.3 HYDRAULIC OIL COOLERS ............................................................................................... 3-86 3.3.3.1 REMOVAL OF THE HYDRAULIC OIL COOLERS .............................................. 3-88 3.3.3.2 REPLACEMENT OF THE HYDRAULIC OIL COOLERS ..................................... 3-92 3.3.3.3 REMOVAL OF THE HYDRAULIC OIL COOLER FRAME ................................... 3-94 3.3.3.4 REPLACEMENT OF THE HYDRAULIC OIL COOLER FRAME.......................... 3-98 3.3.4 MAIN RELIEF VALVES (MRV) ............................................................................................ 3-99 3.3.4.1 REMOVAL OF THE MRV .................................................................................... 3-99 3.3.4.2 REPLACEMENT OF THE MRV ........................................................................ 3-100 3.3.5 PILOT OIL PUMP (GEAR PUMP) ..................................................................................... 3-101 3.3.5.1 REMOVAL OF THE PILOT OIL PUMP .............................................................. 3-101 3.3.5.2 REPLACEMENT OF THE PILOT OIL PUMP .................................................... 3-103 3.3.6 MAIN GATE VALVE........................................................................................................... 3-104 3.3.6.1 REMOVAL OF THE MAIN GATE VALVE .......................................................... 3-104 3.3.6.2 REPLACEMENT OF THE MAIN GATE VALVE................................................. 3-105 3.3.7 HYDRAULIC OIL RESERVOIR ......................................................................................... 3-106 3.3.7.1 REMOVAL OF THE HYDRAULIC OIL RESERVOIR......................................... 3-108 3.3.7.2 REPLACEMENT OF THE HYDRAULIC OIL RESERVOIR ............................... 3-114 3.3.8 MAIN CONTROL VALVE BLOCKS ................................................................................... 3-117 3.3.8.1 REMOVAL OF THE MAIN CONTROL VALVE BLOCKS................................... 3-126 3.3.8.2 REPLACEMENT OF THE MAIN CONTROL VALVE BLOCKS ......................... 3-132 3.3.9 SERVICE LINE RELIEF VALVES (SRV) ........................................................................... 3-133 3.3.9.1 REMOVAL OF SRV ON MAIN CONTROL VALVE BLOCK .............................. 3-133 3.3.9.2 REPLACEMENT OF SRV ON MAIN CONTROL VALVE BLOCKS................... 3-136
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3.3.10 ANTI-CAVITATION VALVES (ACV) ................................................................................. 3.3.10.1 REMOVAL OF ACV ON MANIFOLD ................................................................. 3.3.10.2 REPLACEMENT OF THE ACV ON MANIFOLD................................................ 3.3.10.3 REMOVAL OF ACV ON MAIN CONTROL VALVE BLOCKS ............................ 3.3.10.4 REPLACEMENT OF ACV ON MAIN CONTROL VALVE BLOCKS................... 3.3.11 THROTTLE CHECK VALVES ........................................................................................... 3.3.11.1 REMOVAL OF THROTTLE CHECK VALVES ................................................... 3.3.11.2 REPLACEMENT OF THROTTLE CHECK VALVES.......................................... 3.3.12 MANIFOLD......................................................................................................................... 3.3.12.1 REMOVAL OF THE MANIFOLD ........................................................................ 3.3.12.2 REPLACEMENT OF THE MANIFOLD...............................................................
3-138 3-139 3-144 3-145 3-148 3-150 3-152 3-155 3-156 3-156 3-158
3.4
SLEW DRIVE.................................................................................................................................. 3.4.1 SLEW GEAR...................................................................................................................... 3.4.1.1 REMOVAL OF THE SLEW GEAR ..................................................................... 3.4.1.2 REPLACEMENT OF THE SLEW GEAR............................................................ 3.4.2 SWING MOTOR................................................................................................................. 3.4.2.1 REMOVAL OF THE SWING MOTOR ................................................................ 3.4.2.2 REPLACEMENT OF THE SWING MOTOR....................................................... 3.4.3 SLEW PARKING BRAKE................................................................................................... 3.4.3.1 REMOVAL/DISASSEMBLY OF THE SLEW PARKING BRAKE (L&S) ............. 3.4.3.2 REPLACEMENT/ASSEMBLY OF THE SLEW PARKING BRAKE (L&S) .......... 3.4.3.3 REMOVAL OF THE SLEW PARKING BRAKE (SIEBENHAAR) ....................... 3.4.3.4 REPLACEMENT OF THE SLEW PARKING BRAKE (SIEBENHAAR) .............. 3.4.4 DYNAMIC SLEW BRAKE .................................................................................................. 3.4.4.1 REMOVAL OF THE SLEW BRAKE VALVE....................................................... 3.4.4.2 REPLACEMENT OF THE SLEW BRAKE VALVE ............................................. 3.4.5 SWING CIRCLE LUBRICATION PINION (DUMMY WHEEL) ........................................... 3.4.5.1 REMOVAL OF THE LUBRICATION PINION ASSEMBLY................................. 3.4.5.2 REPLACEMENT OF THE LUBRICATION PINION ASSEMBLY ....................... 3.4.6 SWING CIRCLE................................................................................................................. 3.4.6.1 REMOVAL OF THE SWING CIRCLE ................................................................ 3.4.6.2 REPLACEMENT OF THE SWING CIRCLE.......................................................
3-159 3-160 3-161 3-165 3-168 3-169 3-172 3-174 3-177 3-180 3-183 3-186 3-190 3-193 3-195 3-196 3-198 3-200 3-202 3-203 3-206
3.5
LUBRICATION PUMPS ................................................................................................................. 3-212 3.5.1 REMOVAL OF THE LUBRICATION PUMP....................................................................... 3-214 3.5.2 REPLACEMENT OF THE LUBRICATION PUMP ............................................................. 3-216
3.6
PUMP CONTROLLER MC7 ........................................................................................................... 3-217 3.6.1 REMOVAL OF THE PUMP CONTROLLER MC7.............................................................. 3-217 3.6.2 REPLACEMENT OF THE PUMP CONTROLLER MC7 .................................................... 3-217
3.7
OPERATOR’S CAB ....................................................................................................................... 3.7.1 REMOVAL OF THE OPERATOR’S CAB........................................................................... 3.7.2 REPLACEMENT OF THE OPERATOR’S CAB ................................................................. 3.7.3 CAB-MOUNTS ................................................................................................................... 3.7.3.1 REMOVAL OF THE CAB-MOUNTS .................................................................. 3.7.3.2 REPLACEMENT OF THE CAB-MOUNTS ......................................................... 3.7.4 FRONT WINDOW (WINDSCREEN) .................................................................................. 3.7.4.1 REMOVAL OF THE FRONT WINDOW ............................................................. 3.7.4.2 REPLACEMENT OF THE FRONT WINDOW ....................................................
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3.7.5
3.7.6
3.7.7
3.7.8 3.7.9
OPERATOR’S SEAT ......................................................................................................... 3.7.5.1 REMOVAL OF THE OPERATOR’S SEAT......................................................... 3.7.5.2 REPLACEMENT OF THE OPERATOR’S SEAT ............................................... ECS.................................................................................................................................... 3.7.6.1 REMOVAL OF THE ECS TEXT DISPLAY......................................................... 3.7.6.2 REPLACEMENT OF THE ECS TEXT DISPLAY ............................................... ACCESS LADDER............................................................................................................. 3.7.7.1 REMOVAL OF THE ACCESS LADDER ............................................................ 3.7.7.2 REPLACEMENT OF THE ACCESS LADDER................................................... 3.7.7.3 REMOVAL OF THE ACCESS LADDER CYLINDER ......................................... 3.7.7.4 REPLACEMENT OF THE ACCESS LADDER CYLINDER ............................... REMOVAL OF THE CAB BASE ........................................................................................ REPLACEMENT OF THE CAB BASE ...............................................................................
3-234 3-234 3-235 3-236 3-236 3-236 3-238 3-241 3-243 3-245 3-247 3-248 3-250
3.8
COUNTERWEIGHT........................................................................................................................ 3-252 3.8.1 REMOVAL OF THE COUNTERWEIGHT .......................................................................... 3-253 3.8.2 REPLACEMENT OF THE COUNTERWEIGHT................................................................. 3-255
3.9
SUPERSTRUCTURE LIFTING ...................................................................................................... 3-257 3.9.1 REMOVE THE SUPERSTRUCTURE FROM THE UNDERCARRIAGE ........................... 3-257 3.9.2 INSTALL THE SUPERSTRUCTURE ONTO THE UNDERCARRIAGE............................. 3-261
3.10 FUEL TANK ................................................................................................................................... 3-264 3.10.1 REMOVAL OF THE FUEL TANK ...................................................................................... 3-265 3.10.2 REPLACEMENT OF THE FUEL TANK ............................................................................. 3-269
4 UNDERCARRIAGE.................................................................................... 4-1 4.1
TRAVEL SYSTEM.............................................................................................................................. 4-2 4.1.1 TRACK GROUP..................................................................................................................... 4-2 4.1.1.1 CHANGING OF THE TRACK GROUP .................................................................. 4-2 4.1.2 SPROCKET ........................................................................................................................... 4-7 4.1.2.1 REMOVAL OF THE SPROCKET........................................................................... 4-7 4.1.2.2 REPLACEMENT OF THE SPROCKET ............................................................... 4-12 4.1.2.3 REMOVAL OF THE SEGMENTED SPROCKET (ONLY FOR TYPE WITH PINNED UNDERCARRIAGE UP TO SN 025)............ 4-14 4.1.2.4 REPLACEMENT OF THE SEGMENTED SPROCKET (ONLY FOR TYPE WITH PINNED UNDERCARRIAGE UP TO SN 025)............ 4-18 4.1.3 GUIDE WHEELS ................................................................................................................. 4-20 4.1.3.1 REMOVAL OF THE GUIDE WHEEL ASSEMBLY ............................................... 4-20 4.1.3.2 REPLACEMENT OF THE GUIDE WHEEL ASSEMBLY ..................................... 4-22 4.1.4 TRACK TENSIONING ACCUMULATORS .......................................................................... 4-23 4.1.4.1 REMOVAL OF THE LOW PRESSURE ACCUMULATORS ................................ 4-23 4.1.4.2 REPLACEMENT OF THE LOW PRESSURE ACCUMULATORS ....................... 4-25 4.1.4.3 REMOVAL OF THE HIGH PRESSURE ACCUMULATORS ............................... 4-26 4.1.4.4 REPLACEMENT OF THE HIGH PRESSURE ACCUMULATORS ...................... 4-27 4.1.5 TRACK TENSION VALVE BLOCK ...................................................................................... 4-28 4.1.5.1 REMOVAL OF THE TRACK TENSIONING VALVE BLOCK ............................... 4-28 4.1.5.2 REPLACEMENT OF THE TRACK TENSIONING VALVE BLOCK...................... 4-29 4.1.6 HYDRAULIC HOSES OF THE TRACK TENSIONING SYSTEM ........................................ 4-31 4.1.6.1 SUBSTITUTE THE HYDRAULIC HOSES ........................................................... 4-31 4.1.7 TRAVEL BRAKE VALVE BLOCK (OVERSPEED VALVE).................................................. 4-34 4.1.7.1 REMOVAL OF THE TRAVEL BRAKE VALVE BLOCK ....................................... 4-35 4.1.7.2 REPLACEMENT OF THE TRAVEL BRAKE VALVE BLOCK .............................. 4-37
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4.1.8
TRACK TENSIONING CYLINDERS .................................................................................... 4.1.8.1 REMOVAL OF THE TRACK TENSIONING CYLINDERS ................................... 4.1.8.2 REPLACEMENT OF THE TRACK TENSIONING CYLINDERS .......................... TRAVEL MOTOR................................................................................................................. 4.1.9.1 REMOVAL OF THE TRAVEL MOTORS.............................................................. 4.1.9.2 REPLACEMENT OF THE TRAVEL MOTORS .................................................... TRAVEL PARKING BRAKE................................................................................................. 4.1.10.1 REMOVAL OF THE TRAVEL PARKING BRAKE ................................................ 4.1.10.2 REPLACEMENT OF THE TRAVEL PARKING BRAKE....................................... TRAVEL GEARBOX ............................................................................................................ 4.1.11.1 REMOVAL OF THE TRAVEL GEARBOX............................................................ 4.1.11.2 REPLACEMENT OF THE TRAVEL GEARBOX .................................................. 4.1.11.3 REMOVAL OF THE TRAVEL GEARBOX (ONLY FOR TYPE WITH PINNED UNDERCARRIAGE UP TO SN 025) ............ 4.1.11.4 REPLACEMENT OF THE TRAVEL GEARBOX (ONLY FOR TYPE WITH PINNED UNDERCARRIAGE UP TO SN 025) ............ CARRIER ROLLER.............................................................................................................. 4.1.12.1 REMOVAL OF THE CARRIER ROLLER ASSEMBLY......................................... 4.1.12.2 REPLACEMENT OF THE CARRIER ROLLER ASSEMBLY ............................... TRACK ROLLER.................................................................................................................. 4.1.13.1 REMOVAL OF THE TRACK ROLLER ASSEMBLY............................................. 4.1.13.2 REPLACEMENT OF THE TRACK ROLLER ASSEMBLY ...................................
4-38 4-38 4-39 4-40 4-40 4-42 4-44 4-46 4-48 4-50 4-51 4-53
CAR BODY....................................................................................................................................... 4.2.1 REMOVAL OF THE CAR BODY AND THE CRAWLER CARRIERS (TYPE WITH PINNED UNDERCARRIAGE) ........................................................................ 4.2.2 REPLACEMENT OF THE CAR BODY AND THE CRAWLER CARRIERS (TYPE WITH PINNED UNDERCARRIAGE) ........................................................................ 4.2.3 REMOVAL OF THE CAR BODY AND THE CRAWLER CARRIERS (TYPE WITH BOLTED UNDERCARRIAGE) ....................................................................... 4.2.4 REPLACEMENT OF THE CAR BODY AND THE CRAWLER CARRIERS (TYPE WITH BOLTED UNDERCARRIAGE) ....................................................................... 4.2.4.1 TIGHTENING TORQUE FOR THE CRAWLER CARRIER MOUNTING BOLTS 4.2.5 ROTARY JOINT................................................................................................................... 4.2.5.1 REMOVAL OF THE ROTARY JOINT .................................................................. 4.2.5.2 REPLACEMENT OF THE ROTARY JOINT .........................................................
4-72
4.1.9
4.1.10
4.1.11
4.1.12
4.1.13
4.2
4-55 4-61 4-66 4-66 4-68 4-69 4-69 4-71
4-72 4-76 4-80 4-85 4-88 4-92 4-94 4-96
5 ATTACHMENT........................................................................................... 5-1 5.1
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BACKHOE.......................................................................................................................................... 5-2 5.1.1 BOOM .................................................................................................................................... 5-4 5.1.1.1 REMOVAL OF THE BOOM.................................................................................... 5-4 5.1.1.2 REPLACEMENT OF THE BOOM .......................................................................... 5-8 5.1.1.3 REMOVAL OF BOOM CYLINDERS .................................................................... 5-10 5.1.1.4 REPLACEMENT OF BOOM CYLINDERS........................................................... 5-16 5.1.2 STICK................................................................................................................................... 5-20 5.1.2.1 REMOVAL OF THE STICK .................................................................................. 5-20 5.1.2.2 REPLACEMENT OF THE STICK......................................................................... 5-24 5.1.2.3 REMOVAL OF STICK CYLINDERS..................................................................... 5-26 5.1.2.4 REPLACEMENT OF STICK CYLINDERS ........................................................... 5-32
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5.1.3
5.1.4
5.1.5 5.1.6
BUCKET .............................................................................................................................. 5.1.3.1 REMOVAL OF THE BUCKET.............................................................................. 5.1.3.2 REPLACEMENT OF THE BUCKET .................................................................... 5.1.3.3 REMOVAL OF BUCKET CYLINDERS ................................................................ 5.1.3.4 REPLACEMENT OF BUCKET CYLINDERS ....................................................... BUCKET LINK ROD AND STEERING RODS ..................................................................... 5.1.4.1 REMOVAL OF THE BUCKET LINK ROD ............................................................ 5.1.4.2 REPLACEMENT OF THE BUCKET LINK ROD .................................................. 5.1.4.3 REMOVAL OF THE STEERING RODS............................................................... 5.1.4.4 REPLACEMENT OF THE STEERING RODS ..................................................... GROUND ENGAGING TOOLS (GET)................................................................................. 5.1.5.1 REMOVAL AND REPLACEMENT OF THE GET ................................................ HYDRAULIC HOSES AT THE BACKHOE ATTACHMENT................................................. 5.1.6.1 SUBSTITUTE THE BOOM ARC HOSES ............................................................ 5.1.6.2 SUBSTITUTE THE BOOM CYLINDER HOSES .................................................. 5.1.6.3 SUBSTITUTE THE STICK CYLINDER HOSES .................................................. 5.1.6.4 SUBSTITUTE THE BUCKET CYLINDER HOSES ..............................................
5-36 5-36 5-39 5-40 5-46 5-49 5-49 5-51 5-52 5-55 5-56 5-57 5-58 5-58 5-62 5-66 5-70
5.2
FACE SHOVEL ................................................................................................................................ 5-74 5.2.1 USING THE INSTALLATION TOOLS FOR HYDRAULIC CYLINDERS.............................. 5-75 5.2.2 BOOM .................................................................................................................................. 5-76 5.2.2.1 REMOVAL OF THE BOOM ................................................................................. 5-76 5.2.2.2 REPLACEMENT OF THE BOOM ........................................................................ 5-81 5.2.2.3 REMOVAL OF THE BOOM CYLINDERS ............................................................ 5-86 5.2.2.4 REPLACEMENT OF THE BOOM CYLINDERS .................................................. 5-91 5.2.3 STICK .................................................................................................................................. 5-94 5.2.3.1 REMOVAL OF THE STICK.................................................................................. 5-94 5.2.3.2 REPLACEMENT OF THE STICK ........................................................................ 5-98 5.2.3.3 REMOVAL OF THE STICK CYLINDERS .......................................................... 5-100 5.2.3.4 REPLACEMENT OF THE STICK CYLINDERS ................................................. 5-105 5.2.4 BULL CLAM BUCKET ....................................................................................................... 5-108 5.2.4.1 REMOVAL OF THE BULL CLAM BUCKET ....................................................... 5-110 5.2.4.2 REPLACEMENT OF THE BULL CLAM BUCKET ............................................. 5-114 5.2.4.3 REMOVAL OF THE BUCKET CYLINDERS ...................................................... 5-116 5.2.4.4 REPLACEMENT OF THE BUCKET CYLINDERS ............................................. 5-121 5.2.4.5 REMOVAL OF THE CLAM CYLINDERS ........................................................... 5-124 5.2.4.6 REPLACEMENT OF THE CLAM CYLINDERS ................................................. 5-129 5.2.5 GROUND ENGAGING TOOLS (GET)............................................................................... 5-132 5.2.5.1 REMOVAL AND REPLACEMENT OF THE GET .............................................. 5-133 5.2.6 HYDRAULIC HOSES AT THE FACE SHOVEL ATTACHMENT ....................................... 5-134 5.2.6.1 SUBSTITUTE THE BOOM ARC HOSES .......................................................... 5-134 5.2.6.2 SUBSTITUTE THE BOOM CYLINDER HOSES ................................................ 5-138 5.2.6.3 SUBSTITUTE THE STICK ARC HOSES ........................................................... 5-142 5.2.6.4 SUBSTITUTE THE STICK CYLINDER HOSES ................................................ 5-146 5.2.6.5 SUBSTITUTE THE BUCKET CYLINDER HOSES ............................................ 5-150 5.2.6.6 SUBSTITUTE THE CLAM CYLINDER HOSES ................................................. 5-154
5.3
METERING VALVES (GREASE INJECTORS) AT THE ATTACHMENT ..................................... 5-162 5.3.1 REMOVAL OF THE METERING VALVES (GREASE INJECTORS)................................. 5-162 5.3.2 REPLACEMENT OF THE METERING VALVES (GREASE INJECTORS) ....................... 5-163
5.4
CYLINDER BYPASS TEST ........................................................................................................... 5-164
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6 SERVICE INFORMATION ......................................................................... 6-1 6.1
FLUIDS AND LUBRICANTS.............................................................................................................. 6-2 6.1.1 LUBRICANTS FOR OPERATION IN MODERATE AND HOT CLIMATES ........................... 6-2 6.1.2 LUBRICANTS FOR OPERATION IN COLD AND ARCTIC CLIMATES ................................ 6-4
6.2
FILLING CAPACITIES ....................................................................................................................... 6-5
6.3
WORK INSTRUCTIONS..................................................................................................................... 6-7 6.3.1 SURFACE COATING WITH INTERZINC 697 ....................................................................... 6-7 6.3.2 REMOVE / INSTALL THE CRAWLER CARRIER.................................................................. 6-9
6.4
USED SPECIAL TOOLS (OVERVIEW) ........................................................................................... 6-10
7 TOOLS CATALOGUE ................................................................................ 7-1 8 PARTS & SERVICE NEWS ....................................................................... 8-1 AH00511 Installation procedure for the swing circle / Slew Ring (SR) AH00514 Track group - Hints for sprocket exchange AH00515 Final drive: Wear and tear measurements Mounting procedures AH00519 Adhesive lubricants for the Slew Ring Gear AH01513 Bleeding of hydraulic pumps AH01521 Diesel engine suspension AH01531 Hydraulic accumulators - testing and refilling AH02513 Testing wear and tear of swing circle bearing AH02521 Track group – wear measurement AH03506 Hydraulic oil cooler and water cooler fan bearings AH03509 Slew gear GFB 174 E 9017 (Part No. 917 915 40) AH03510 ESCO bucket tooth system AH03511 Pilot Pressure Pump Part No. 907 209 40 AH03512 Gear Pumps (Part Nos. 907 209 40; 906 442 40; 896 730 40 and 654 930 40 AH04518 Welding procedure for welded counterweight AH05501 Abnormal vibration on hydraulic pipes AH05510 Bearing flushing of the A4VS variable displacement axial piston pump AH05511 Dual cone seal ring mounting
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AH05520 Installation hints for a new type of pilot pump AH05525 Suction elbows of the Main Pumps AH05535 Hints for replacing by the slewing gear of an other manufacturer AH05546 Automatic lubrication system - Vent valve (PN 769 879 73) AH06524 Hydraulic cylinder AH06529 Track group - Hints for sprocket exchange AH06530 Relieving of the track chain tension AH06542 Swash plate pump H-A4VSO500 AH06543 Gear pumps PN 907 622 40 and PN 940 048 40 (supplied from the company “Kracht”) (Pilot pressure pump; gear oil pump; circulation pump) AH06545 Hydraulic cylinder bushings AH07509 Swing brake manufactured by "Siebenhaar" (Swing gear PN 902 550 40 and PN 925 864 40) AH07526 Bolted undercarriage: Protective coating on the flange plates AH08503 Track drive AH08504 Windscreen AH08507 Steel structure AH08508 Bushings of the attachment and at the undercarriage
9 SUPPLIER’S DOCUMENTATION ............................................................. 9-1 AVANTI HYTORQUE
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PC5500-6
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Introduction
1 INTRODUCTION
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Contents of the binder
1.1
Introduction
CONTENTS OF THE BINDER
Assembled in this file are the R&R Procedures with explanations of removing, installing, and adjustments of the major components and circuits for your KOMATSU Hydraulic Mining Shovel.
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1.2
Foreword
FOREWORD
Observe the instructions in this manual for: z
Your Personal SAFETY
z
Operating SAFETY, and
z
READY and EFFICIENT PERFORMANCE of your KOMATSU Hydraulic Mining Shovel.
With this R&R Procedures Manual, KOMATSU provides you with the description of proper removal and replacement procedures of main components.
How do you find "your" desired information? In the TABLE OF CONTENTS all R&R PROCEDURES are shown in their sequence of description.
CAUTION Periodic preventive inspections and maintenance are the surest means of keeping the machine in proper working order. Prompt detection and correction of minor irregularities and immediate replacement of worn out or broken parts will prevent failures and avoid expenses.
Replace damaged graphics and symbols. Observe safety precautions to prevent injury and damage. If, after reading this R&R Procedures Manual, you can give us suggestions and comments for improvements - please do not hesitate to contact us.
Komatsu Mining Germany GmbH Service Training and Manuals Department 8151.30 P.O. Box 18 03 61 D - 40570 Düsseldorf GERMANY
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Introduction
WARNING Personnel entrusted with work on the machine must have read the section 2 SAFETY AND STANDARDS before beginning work. Reading the instructions after work has begun is too late.
Damages and defects caused by incorrect operation and maintenance are not covered by the manufacturer’s guarantee. In order to keep your shovel in first-class operating condition only use genuine spare and wear parts. The use of any part other than the genuine part releases the KOMATSU MINING GERMANY GmbH from any guarantee.
1.2.1
SERVICE
In all your written or phoned inquiries, please indicate the model and serial number of your shovel.
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2 SAFETY AND STANDARDS
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Safety and Standards
2.1
SAFETY INSTRUCTIONS
2.1.1
METHOD OF USING THIS MANUAL
z
When removing or installing a unit assembly, the order of work and techniques used are given for the removal procedure. The order of work for the installation is only given if the installation procedure differs from installation in reverse order of removal, for example any special technique needs to be applied.
z
Tightening torques according to DIN are not explicitly given in the installation procedures. For tightening torques according to DIN, refer to section 2.2 on page 2-33.
z
Figure references that appear in the operation procedures use the format (Fig. 4-12, Pos. 4), which means position number 4 in figure 12 of section 4.
z
Special requirements such as listing of special tools or size or numbers of blind plugs etc. are listed in a table at the beginning of each operation procedure.
z
Special tools that appear in the lists are given with part name, part number, and quantity (2 x thread protector, PN 409 329 40). For the special tools list, refer to section 6.4 on page 6-10.
z
The following symbols are used in the manual to designate additional information: Kind and amount of drained fluids (e.g. drain oil, 1500 liters). Lifting weight of an assembly (e.g. 140 kg). Kind and amount of fluids to fill (e.g. fill oil, 1500 liters). Special tightening torques for bolts etc., if not according to DIN, refer to section 2.2 on page 2-33 (e.g. 129 Nm). General information concerning a section, e.g. tightening torques according to DIN, refer to section 2.2 on page 2-33. Special authorized personnel is required.
All PARTS & SERVICE NEWS which are mentioned in the procedures are listed in chapter 8. The numbers of the PARTS & SERVICE NEWS do not label the latest edition. Ensure that the latest edition is always filed to the binder of this manual. 2 -2
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z
Safety Instructions
The following symbols and designations are used in the manual to designate instructions of particular importance: DANGER
Refers to orders and prohibitions designed to prevent serious injury or death.
WARNING Refers to orders and prohibitions designed to prevent injury or extensive damage.
CAUTION Refers to special information and/or orders and prohibitions directed towards preventing damage.
NOTE: Refers to special information on removing or installing assemblies, for example if any special technique needs to be applied.
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2.1.2
Safety and Standards
GENERAL PRECAUTIONS CAUTION
Proper service and repair is important for safe machine operation. The service and repair techniques recommended by Komatsu Mining Germany and described in this manual are both effective and safe. Some of these techniques require the use of tools specially designed by Komatsu Mining Germany for the specific purpose.
NOTE: Always attend to local regulations regarding the Personal Protective Equipment. WARNING z
Mistakes in operation and service are extremely dangerous. Read the OPERATION & MAINTENANCE MANUAL carefully BEFORE operating the machine.
z
Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine.
z
When carrying out any operation, always wear safety shoes and a helmet. Do not wear loose work clothes or clothes with buttons missing.
z
Always wear safety glasses when hitting parts with a hammer. Always wear safety glasses when grinding parts with a grinder, etc.
z
Assure fire prevention according to the Operation & Maintenance Manual.
z
If welding repairs are needed, refer to the welding precautions given in the Operation & Maintenance Manual.
z
When carrying out any operation with two or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator's cab.
z
Keep all tools in good condition and learn the correct way to use them.
z
Decide on a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.
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DANGER Danger of explosion! Serious injury, permanent disfigurement, and scarring may result! Special care must be taken before welding, flame-cutting, and grinding operations are carried out on the counterweight. The filling of the counterweight chambers can create explosive gases which will accumulate in the chambers of the counterweight. These gases must be expelled before welding, flame-cutting, and grinding operations are carried out on the counterweight. Follow the instructions given in PARTS & SERVICE NEWS No. "AH04518" for expelling the gases from the counterweight chambers.
2.1.3
PREPARATIONS FOR WORK WARNING
z
Before adding oil or making repairs, park the machine on hard, level ground large enough to accommodate the machine, boom, and additional working equipment (crane mobile working platforms, forklift etc.).
z
If the ground condition is too poor to guarantee safe and stable stand of the machine and the additional working equipment (crane mobile working platforms, forklift etc.), make sure that the machine is moved to a place with appropriate ground conditions. Block the tracks to prevent the machine from moving.
z
Before starting work, lower bucket, hammer, or any other work equipment to the ground. If this procedure is not possible, insert the safety pin or use blocks to prevent the work equipment from falling. Additionally, be sure to lock all the control levers and hang warning signs on them.
z
When disassembling or assembling, support the machine with blocks, jacks, or stands before starting work.
z
Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders, or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders, or steps, use a stand to provide safe footing.
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2.1.4
Safety and Standards
PRECAUTIONS DURING WORK WARNING
z
When removing the oil filler cap, drain plug, or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out. The water and oil in the circuits are hot when the engine is stopped, so be careful not to get burnt. Wait for the oil and water to cool before carrying out work on the oil or water circuits.
z
Before starting work, isolate the machine according to local regulations. Remove the leads from the battery. ALWAYS remove the lead from the negative (-) terminal first.
z
When raising heavy components (25 kg or more), use a hoist or crane.
z
Check that the wire rope, chains, and hooks are free from damage.
z
Always use lifting equipment which has ample capacity.
z
Install the lifting equipment at the correct places. Use a hoist or crane and operate slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane.
z
When removing covers which are under internal pressure or under pressure from a spring, always leave two bolts in position on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove.
z
When removing components, be careful not to break or damage the wiring. Damaged wiring may cause electrical fires.
z
When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips on to the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip, or can even start fires.
z
As a general rule, do not use gasoline to wash parts.
z
Be sure to assemble all parts in their original places again. Replace any damaged parts with new parts.
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WARNING z
When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine is being operated.
z
When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely careful when installing tubes for high pressure circuits. Also check that connecting parts are correctly installed.
z
When assembling or installing parts, always use the specified tightening torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed correctly.
z
When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole.
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2.1.5
Safety and Standards
WARNING OF SPECIAL DANGERS
2.1.5.1 ELECTRICAL ENERGY WARNING z
Use only original fuses and circuit breakers with the specified current rating. Switch off the machine immediately if trouble occurs in the electrical system.
z
When working with the machine, maintain a safe distance from overhead electric lines. If work is to be carried out close to overhead lines, the working equipment must be kept well away from them. Caution, danger! Check out the prescribed safety distances.
z
If your machine comes into contact with a live wire: z
do not leave the machine
z
drive the machine out of the hazard zone
z
warn others against approaching and touching the machine
z
have the live wire de-energized
z
do not leave the machine until the damaged line has been safely de-energized.
z
Work on the electrical system or equipment may only be carried out by a skilled electrician himself or by specially instructed personnel under the control and supervision of such electrician and in accordance with the applicable electrical engineering rules.
z
If provided for in the regulations, the power supply to parts of the machine, on which inspection, maintenance, and repair work is to be carried out must be cut off. Before starting any work, check the de-energized parts for the presence of power and ground or short-circuit them in addition to insulating adjacent live parts and elements.
z
The electrical equipment of the machine is to be inspected and checked at regular intervals. Defects such as loose connections or scorched cables must be rectified immediately.
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WARNING z
Necessary work on live parts and elements must be carried out only in the presence of a second person who can cut off the power supply in case of danger by actuating the emergency shut-off or main power switch. Secure the working area with a red-and-white safety chain and a warning sign. Use insulated tools only.
z
Before starting work on high-voltage assemblies and after cutting off the power supply, the feeder cable must be grounded and components such as capacitors shortcircuited with a grounding rod.
2.1.5.2 GAS, DUST, STEAM AND SMOKE WARNING z
Operate internal combustion engines and fuel operated heating systems only on adequately ventilated premises. Before starting the machine on enclosed premises, make sure that there is sufficient ventilation. Observe the regulations in force at the respective site.
z
Carry out welding, flame-cutting and grinding work on the machine only if this has been expressly approved, as there may be a risk of explosion and fire.
z
Special care must be taken before welding, flame-cutting and grinding operations are carried out on the counterweight. The filling of the counterweight chambers can create explosive gases which will accumulate in the chambers of the counterweight. These gases must be expelled before welding, flame-cutting and grinding operations are carried out on the counterweight. Danger of explosion. Follow the instructions given in PARTS & SERVICE NEWS No. "AH04518" for expelling the gases from the counterweight chambers.
z
Before carrying out welding, flame-cutting and grinding operations, clean the machine and its surroundings from dust and other inflammable substances and make sure that the premises are adequately ventilated (risk of explosion).
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2.1.5.3 HYDRAULIC, AIR CONDITIONING AND PNEUMATIC EQUIPMENT WARNING z
Work on hydraulic equipment and the air conditioning system may only be carried out by persons having special knowledge and experience in this systems.
z
Check all lines, hoses and screwed connections regularly for leaks and obvious damage. Repair any damage immediately. Splashed oil may cause injury and fire.
z
Depressurize all system sections and pressure pipes (hydraulic system, compressed-air system) to be removed in accordance with the specific instructions for the unit concerned before carrying out any repair work.
z
Refrigerant in the air conditioning system must be sucked off by authorized service specialists only before opening the refrigerant loop (e.g. removing pipes).
z
Hydraulic, air conditioning and compressed-air lines must be laid and fitted properly. Ensure that no connections are interchanged. The fittings, lengths, and quality of the hoses must comply with the technical requirements.
2.1.5.4 NOISE WARNING z
During operation, all sound baffles must be closed.
z
Always wear the prescribed ear protectors.
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2.1.5.5 HEAT WARNING z
Do not start working on hot machine parts until the temperature is below 50 °C.
z
Be careful when handling hot materials (risk of burning or scalding) such as:
z
z
Fuel
z
Engine coolant
z
Hydraulic oil
z
Engine oil
z
Grease
Use gloves when handling hot machine parts.
2.1.5.6 OIL, GREASE AND OTHER CHEMICAL SUBSTANCES WARNING z
When handling oil, grease, and other chemical substances, observe the product-related safety regulations given in the material safety data sheet (MSDS).
z
Be careful when handling hot materials (risk of burning or scalding).
2.1.5.7 HEIGHT WARNING When working in heights above 1.00 m, a special safety harness is required, refer to section 2.1.6 on page 2-13.
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Safety and Standards
Safety harness in conformity with EN 361 PC5500-6
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2.1.6
Safety Instructions
SPECIAL SAFETY EQUIPMENT
2.1.6.1 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD) The safety harness (Fig. 2-1) should only be used together with connectors according to EN 354, and fall arrest according to EN 355, or fall protection devices according to EN 360. Legend for Fig. 2-1: (1)
Safety harness according to EN 361
(2)
Strap-type fall absorber according to DIN EN 355
(3)
Ladder to cab roof and railings (attachment points)
(4)
Protection hoods for roof mounted air conditioning, if so equipped
(A)
Shoulder strap
(B)
Back plate
(C)
Catching hook
(D)
Shoulder-strap fixing
(E)
Belly strap
(F)
Holding hook
(G)
Hold-back hook
(H)
Pelvis strap
(J)
Leg strap
WARNING Always use the safety harness (Fig. 2-1, Pos. 1) in conjunction with strap-type fall absorber (Fig. 2-1, Pos. 2), before mounting onto the loader attachment or other unsecured places of the shovel.
NOTE: The illustration (Fig. 2-1) shows a typical use of the safety harness. Shovels with the new type operator’s cab are not equipped with ladder (Fig. 2-1, Pos. 3), because the air conditioner unit of the new type cab is located on the back wall of the cab.
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Safety Instructions
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Safety and Standards
Safety harness in conformity with EN 361 PC5500-6
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Safety Instructions
2.1.6.2 INSTRUCTIONS FOR USE Open the lock and lift the harness by the catch hook (Fig. 2-2, Pos. C). The blue straps (leg straps Fig. 2-2, Pos. J) must be at the bottom. The harness is being put on just like a jacket. Pull the belly strap (Fig. 2-2, Pos. E) through the lock, as shown in the illustration, and secure it. By closing the breast strap, you avoid the shoulder straps to sideslip. Bring the leg straps (Fig. 2-2, Pos. J) around the legs to the front, pull them in, as shown in the illustration, and tighten them. Adapt the harness to body form, seeing to perfect fit, in particular that the catching hook (Fig. 2-2, Pos. C) is aligned in the center of the back. The safety harness should belong to its wearer personally. The safety harness should only be used together with connectors according to EN 354, and fall arrest according to EN 355, or fall protection devices according to EN 360. The attachment point for the safety harness should be above the wearer, and the carrying capacity of the attachment point should be sufficient to correspond with the minimum carrying capacity according to EN 795. z
Before using the harness: z
Carry out a visual check of the system or components. The correct functioning and perfect working order have to be assured.
z
Make sure that the recommendations for use with other components of the system are observed in conformity with the instructions for use. WARNING
The system or component must no longer be used, if there are any doubts in respect of its safe condition. The equipment has to be inspected by the manufacturer or by a qualified person. It is essential for safety reasons that a fall protection system or system component which has already been subjected to fall is removed from the service and sent back to the manufacturer or to an authorized qualified repair shop for maintenance and renewed testing.
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Safety Instructions
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Safety and Standards
Safety harness in conformity with EN 361 PC5500-6
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Safety Instructions
Fall protection systems have to be treated with care and to be kept clean and ready for use. It has to be warned against bringing the systems into contact with acids or other caustic liquids and gases, oils, detergents, or sharp-edged objects. If the harness has become wet during use or cleaning, do not dry near a fire or other sources of heat, but rather in a natural way in not too warm rooms. Keep the harness freely suspended or loosely rolled up. When using the fall protection systems, the pertaining safety regulations in force and the "Rules for Use of Personal Fall Arrest Systems" have to be observed for protection against danger. WARNING At least every 12 months, the safety harness and its components have to be inspected by a competent person authorized by the manufacturer and they have to be maintained, if the manufacturer considers it to be necessary.
2.1.6.3 RECOMMENDATIONS FOR USE OF THE HOLDING HOOKS AND HOLD-BACK HOOKS OF THE SAFETY HARNESS During the holding function, the connectors may only be placed around a mast or any other construction between the two holding hooks, so that the free fall is limited to max. 0.5 m. It should be strictly seen to it that the connector is not slung around constructions with too small diameters or sharp edges. With the lateral holding hooks, work may only be carried out on horizontal or almost horizontal surfaces (roofs). The connectors have to be adjusted in such a way that the area, where danger of falling down prevails, cannot be reached.
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Safety Instructions
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Safety and Standards
Safety harness in conformity with EN 361 PC5500-6
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Safety Instructions
2.1.6.4 INSTARUCTIONS FOR USING THE FALL ABSORBER Strap-type fall absorber according to DIN EN 355 (type E.K.N.BFD) Use Within a fall-arrest system, the strap-type fall absorber (Fig. 2-4, Pos. 2) has to be used in conjunction with a safety harness (Fig. 2-4, Pos. 1) according to DIN EN 361. The maximum length including the safety rope must not exceed 2.0 m. For longer ropes, a rope-shortening device has to be applied in addition. Fix the rope to the attachment point and attach the strap-type fall absorber to the catching hook in the back of the safety harness. The attachment point should be above the wearer and its minimum carrying capacity should be 10 kN, according to DIN EN 795. The strap-type fall absorber and the safety rope must not be damaged, e.g. never pull them over sharp edges nor get them burnt by welding sparks. Storing and maintenance The strap-type fall absorber has to be kept dry in an airy and shady room. It must not be exposed to acids, caustic chemicals, nor to an aggressive atmosphere, and contact with any oil has to be avoided. If the strap-type fall absorber is dirty, it may be cleaned with a little water and a light-duty detergent. Dry it in a shady place (nowhere near fire or other sources of heat). Protect it from sharp-edged objects. Inspection Prior to use, all parts have to be inspected for safe condition and damages. At least once a year, the strap-type fall absorber has to be tested by a competent person. A damaged or used strap-type fall absorber has to be removed from the service immediately. The strap-type fall absorber must not be changed in any way. Repair work has to be done by the manufacturer or by an authorized qualified repair shop.
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2.1.7
Safety and Standards
SAFETY HINTS FOR HYDRAULIC HOSE INSTALLATION WARNING
The hydraulic hoses undergo natural aging. Hence, as they are safety critical parts, their usable lifetime is limited to a maximum of 6 years (including storage time). For further information refer to the Operation and Maintenance Manual, chapter 4, section "REPLACEMENT OF HYDRAULIC HOSE LINES AND FUEL HOSE".
To avoid damage to the hydraulic hose lines, follow the installation procedures listed below: CAUTION Pay attention to the Natural curvature of the hose!
Fig. 2-5
CAUTION Do not twist the hoses during installation!
Fig. 2-6
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CAUTION Mount angled flanges at first!
Fig. 2-7
CAUTION Pay attention to the changing in hose length, depending on the pressure inside the hose!
Fig. 2-8
CAUTION Pay attention to the bending radius!
Fig. 2-9
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Safety and Standards
CAUTION Pay attention to the bending radius!
Fig. 2-10
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2.1.8
Safety Instructions
SAFETY HINTS FOR LIFTING HEAVY PARTS
NOTE: In order to avoid damage to the lifting devices or parts that have to be lifted, use edge protection at all sharp edges. CAUTION Heavy parts (25 kg or more) must be lifted with a hoist etc.
CAUTION If any part cannot be removed from the machine smoothly by hoisting, the following checks should be made: Check for the removal of all bolts fastening the component to other parts. Check for existence of another part causing interference with the component to be removed.
2.1.9 z
SAFETY HINTS FOR WIRE ROPES
Use adequate ropes depending on the weight of the parts to be hoisted, referring to the below table: Wire ropes (Standard "Z" or "S" twist ropes without galvanizing) Rope diameter [mm]
10.0
11.2
12.5
14.0
16.0
18.0
20.0
22.4
30.0
40.0
50.0
60.0
Allowable load [Metric tons]
1.0
1.4
1.6
2.2
2.8
3.6
4.4
5.6
10.0
18.0
28.0
40.0
CAUTION The allowable load value is estimated to be 1/6 or 1/7 of the breaking strength of the rope used.
WARNING The table above may differ from local standards. Always attend to local standards when using wire ropes.
Version 2009/2
PC5500-6
2 - 23
Safety Instructions
Safety and Standards
z
Sling wire ropes around the middle portion of the hook. Slinging near the tip of the hook may cause the rope to slip off the hook during hoisting, which may cause a serious accident. Hooks have the maximum strength at the middle portion, see Fig. 2-11.
z
Do not sling a heavy load with one rope alone, but sling it with two or more ropes wound symmetrically around the load.
Fig. 2-11
WARNING Slinging with one rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding position on the load, which may cause a serious accident.
z
Do not sling a heavy load with ropes forming a wide hanging angle from the hook. When hoisting a load with two or more ropes, the force subjected to each rope will increase with the hanging angles. Figure 2-12 shows the variation of allowable load (kg) where hoisting is made with two ropes, each of which is allowed to sling up to 1000 kg vertically, at various hanging angles. When two ropes sling a load vertically, up to 2000 kg of total weight can be lifted. This weight becomes 1000 kg when two ropes make a 120° hanging angle. On the other hand, two ropes are subject to an excessive force as large as 4000 kg if they sling a 2000 kg load at a lifting angle of 150°.
2 - 24
PC5500-6
Fig. 2-12
Version 2009/2
Safety and Standards
Safety Instructions
2.1.10 SAFETY HINTS FOR SLING ACCESSORY WARNING Always attend to local standards when using sling accessory.
z
Do not use rigid eye bolts from steel C 15 for lifting (e.g. DIN 580). These eye bolts may only be loaded vertically or with a maximum permissible angle of 45° to the ring.
z
Always use suitable swivel hoist rings according to local standards or Vario-Starpoint hoist rings recommended by Komatsu, see following table: Thread
Komatsu Part Number
Tightening Torque
M8
941 650 40
10 Nm
M10
941 651 40
10 Nm
M12
906 519 40
25 Nm
M16
906 780 40
60 Nm
M20
906 782 40
115 Nm
M24
906 783 40
190 Nm
M30
906 421 40
330 Nm
M36
906 233 40
590 Nm
DANGER Vario-Starpoint hoist rings are not suited for turning under load. After installing Starpoint hoist ring disengage the star key. Adjust ring plane in direction of pull before attaching sling accessory.
DANGER Eye bolts or sling accessory which is not suitable can result in serious accidents.
z
Check that the wire rope, chains, and hooks are free from damage.
z
Always use lifting equipment which has ample capacity.
z
Install the lifting equipment at the correct places. Use a hoist or crane and operate slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane.
Version 2009/2
PC5500-6
2 - 25
Safety Instructions
Safety and Standards
2.1.11 WEIGHT TABLES 2.1.11.1 SUPERSTRUCTURE Part or assembly
Weight
Diesel engine
7000 kg
Roof plate engine housing
397 kg max.
Beam (Bridge)
285 kg
Alternator
depending on type
38.25 kg
Battery
62 kg
Radiator fan
35 kg
Hydraulic fan motor
18 kg
Bearing block
each
77.5 kg
Radiator fan drive pump
40 kg
Radiator assembly
650 kg
Roof plate over radiator
116 kg
Fan cowl
67 kg
Starter motor
35.5 kg
Starter motor with prelubrication pump
43.6 kg
Geislinger coupling assembly
160 kg
Roof plate engine housing
260 kg
Main pump assembly with flanged gear pump
362.4 kg
Oil circulation pump (auxiliary pump)
each
25 kg
PTO (pump distributor gearbox)
1900 kg
Control frame assembly
260 kg
Hydraulic cooler fan drive pump
40 kg
Hydraulic cooler fan assembly
each
117.4 kg
Hydraulic cooler fan
19 kg
Hydraulic cooler fan mounting assembly
72 kg
Hydraulic motor assembly
26.4 kg
Hydraulic oil cooler
275 kg
Hydraulic oil cooler frame incl. Hydraulic oil coolers
3950 kg
Pilot oil pump
27.4 kg
Main gate valve
12.3 kg
Hydraulic oil reservoir incl. Back pressure valve
3465 kg
Main control valve block 1, incl. ACVs & SRVs
717 kg
2 - 26
Remark
PC5500-6
each element
Version 2009/2
Safety and Standards
Safety Instructions
Part or assembly
Weight
Main control valve block 2, incl. ACVs & SRVs
726 kg
High pressure filter (main control block 2)
44.6 kg
Main control valve block 3, incl. ACVs & SRVs
713 kg
Main control valve block 4
143 kg
High pressure filter (main control block 4)
15 kg
Anti cavitation valve on main control block (ACV)
3 kg
Throttle check valve on main control block (SRV)
4 kg
Single anti cavitation valve on manifold
15 kg
Double anti cavitation valve on manifold
44.6 kg
Manifold without valves
408 kg
Pressure relief valve assembly on manifold
18.2 kg
Throttle check valve on manifold (long version)
31 kg
Throttle check valve on manifold (short version)
28 kg
Manifold incl. ACVs & SRVs (BHA)
921.2 kg
Manifold incl. ACVs & SRVs (FSA)
893.2 kg
Slew gear (Siebenhaar)
1700 kg
Slew gear (L&S)
1880 kg
Swing motor
170 kg
Bearing ring of the slew parking brake (L&S)
32 kg
Slew brake valve
97
Pinion cover
11.6 kg
Lubrication pinion assembly
18.2 kg
Lubrication pump
28 kg
Operator's cab
2700 kg
Viscous mount
4 kg
Absorber plate incl. 2 viscous mount
11.9 kg
Absorber plate incl. 3 viscous mounts
17.4 kg
Front window
112 kg
Operator's seat
62 kg
Access ladder
167 kg
Access ladder cylinder
23 kg
Cab base
3785 kg
Support frame
987 kg
Counterweight
46,000 k
Version 2009/2
Remark
PC5500-6
2 - 27
Safety Instructions
Safety and Standards
Part or assembly
Weight
Superstructure incl. Diesel engine without counterweight, attachment and fluids
137,215 kg
Fuel tank (empty)
4486 kg
2 - 28
PC5500-6
Remark
Version 2009/2
Safety and Standards
Safety Instructions
2.1.11.2 UNDERCARRIAGE Part or assembly
Weight
Track group 1350 mm
Remark
32.192 kg
Pin between track shoes (Track group 1350 mm)
19 kg
Track group 1800 mm
39.066 kg
Pin between track shoes (Track group 1800 mm)
20.2 kg
Sprocket
4382 kg
Hollow shaft
612 kg
Drive shaft
1007 kg
Three segmented sprocket assembly
2250 kg
Sprocket segment 1 (5 teeth)
794.25 kg
Sprocket segment 2 (5 teeth)
794.25 kg
Sprocket segment 3 (4 teeth)
661.5 kg
Three segmented sprocket assembly (oversize)
2745 kg
Sprocket segment 1 (5 teeth, oversize)
968.99 kg
Sprocket segment 2 (5 teeth, oversize)
968.99 kg
Sprocket segment 3 (4 teeth, oversize)
807.02 kg
Guide wheel assembly
3323 kg
Low pressure accumulator
12 kg
High pressure accumulator
23 kg
Track tensioning valve block
40 kg
Hydraulic hoses of the track tensioning system
10 kg max
Travel brake valve block
75 kg
Track tensioning cylinder
400 kg
Travel motor
110 kg
Travel parking brake
75 kg
Travel gearbox
4020 kg
Carrier roller assembly (bolted connection)
205 kg
Carrier roller assembly (with mounting pins)
175 kg
Track roller assembly
654 kg
depending on type
each
each
Car body without crawler carrier (with mounting pins)
42,000 kg
Crawler carrier assembly (track width 1350 mm, with mounting pins)
70,000 kg
each
Crawler carrier assembly (track width 1800 mm, with mounting pins)
80,000 kg
each
Car body without crawler carrier (bolted connection)
46,000 kg
Crawler carrier assembly (track width 1350 mm, bolted connection)
76,722 kg
Version 2009/2
PC5500-6
each 2 - 29
Safety Instructions
Safety and Standards
Part or assembly
Weight
Crawler carrier assembly (track width 1800 mm, with mounting pins)
83,646 kg
Rotary joint
261 kg
Swing circle
10,000 kg
2 - 30
PC5500-6
Remark each
Version 2009/2
Safety and Standards
Safety Instructions
2.1.11.3 BACKHOE ATTACHMENT (BHA) Part or assembly
Weight
Boom
Remark
45,100 kg
Pin boom/superstructure
365 kg
Pin boom cylinder/boom
177 kg
Pin boom cylinder/superstructure
224 kg
Boom cylinder
6500 kg
Stick
each
19,160 kg
Pin stick/boom
1440 kg
Stick cylinder
4600 kg
Pin stick cylinder/stick
127 kg
Pin stick cylinder/boom
179 kg
Bucket
each
30,600 kg
Pin bucket/stick
574 kg
Pin bucket/bucket link rod
822 kg
Bucket cylinder
3210 kg
Pin bucket cylinder/stick
86 kg
Pin bucket cylinder/steering rod
865 kg
Rod protection cover
360 kg
Nut-Cap
35 kg
Bucket link rod
2280 kg
Steering rod
1300 kg
Pin steering rod/stick
479 kg
Point (ESCO)
55 kg
Shroud (ESCO)
337 kg
Tooth adapter (ESCO)
182 kg
Boom arc hose
39 kg
each
Boom cylinder hoses
29.5 kg 39 kg
depending on length
Stick cylinder hoses
23 kg 27,5 kg
depending on length
Bucket cylinder hoses
33 kg
Metering valve
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