Komatsu PC5500-6 Hydraulic Mining Shovel Remove & Replace Procedures Manual

Assembled in this file are the Remove & Replace Procedures with explanations of removing, installing, and adjustments of the major components and circuits for your PC5500-6 KOMATSU Hydraulic Mining Shovel.


TABLE OF CONTENTS :

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


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Total Pages : 918


With this R&R Procedures Manual, KOMATSU provides you with the description of proper removal and replacement procedures of main components.

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1 Introduction
1.1 Contents of the binder
1.2 Foreword
1.2.1 Service

2 Safety and Standards
2.1 Safety Instructions
2.1.1 Method of using this manual
2.1.2 General precautions
2.1.3 Preparations for work
2.1.4 Precautions during work
2.1.5 Warning of special dangers
2.1.5.1 Electrical energy
2.1.5.2 Gas, dust, steam and smoke
2.1.5.3 Hydraulic, air conditioning and pneumatic equipment
2.1.5.4 Noise
2.1.5.5 Heat
2.1.5.6 Oil, grease and other chemical substances
2.1.5.7 Height
2.1.6 Special safety equipment
2.1.6.1 Safety harness in conformity with EN 361 (european standard)
2.1.6.2 Instructions for use
2.1.6.3 Recommendations for use of the holding hooks and hold-back hooks of the safety harness
2.1.6.4 Instaructions for using the fall absorber
2.1.7 Safety hints for hydraulic hose installation
2.1.8 Safety hints for lifting heavy parts
2.1.9 Safety hints for wire ropes
2.1.10 Safety hints for sling accessory
2.1.11 Weight tables
2.1.11.1 Superstructure
2.1.11.2 Undercarriage
2.1.11.3 Backhoe attachment (BHA)
2.1.11.4 Face shovel attachment (FSA)
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
2.3 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
2.4 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
2.5 Tools
2.5.1 Standard tool case
2.6 Explanation of abbreviations

3 Superstructure
3.1 Diesel engine
3.1.1 Removal of the diesel engines
3.1.1.1 Preparatory work for diesel engines removal
3.1.1.2 Removal of the front diesel engine (engine 2)
3.1.1.3 Replacement of the front diesel engine (engine 2)
3.1.1.4 Removal of the rear diesel engine (engine 1)
3.1.1.5 Replacement of the rear diesel engine (engine 1)
3.1.2 Engine torque support and engine/PTO mounts
3.1.2.1 Flexible mounts
3.1.2.2 Torque support
3.1.3 Alternator
3.1.3.1 Removal of the alternator
3.1.3.2 Replacement of the alternator
3.1.4 Batteries
3.1.4.1 Removal of the batteries
3.1.4.2 Replacement of the batteries
3.1.5 Radiator fan
3.1.5.1 Removal of the radiator fan assembly
3.1.5.2 Replacement of the radiator fan assembly
3.1.5.3 Removal of the radiator fan
3.1.5.4 Replacement of the radiator fan
3.1.5.5 Removal of the radiator fan drive pump
3.1.5.6 Replacement of the radiator fan drive pump
3.1.6 Radiators
3.1.6.1 Removal of the radiator assembly
3.1.6.2 Replacement of the radiator assembly
3.1.7 Starter system
3.1.7.1 Removal of the starter motor
3.1.7.2 Replacement of the starter motor
3.1.8 Torsion type coupling (GEISLINGER)
3.1.8.1 Removal of the Geislinger coupling
3.1.8.2 Replacement of the Geislinger coupling
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
3.3.1 Hydraulic cooler fan drive pump
3.3.1.1 Removal of the hydraulic cooler fan drive pump
3.3.1.2 Replacement of the hydraulic cooler fan drive pump
3.3.2 Hydraulic cooler fan assembly
3.3.2.1 Removal of hydraulic cooler fan assembly
3.3.2.2 Replacement of hydraulic cooler fan assembly
3.3.2.3 Removal of hydraulic cooler fan and motor
3.3.2.4 Replacement of hydraulic cooler fan and motor
3.3.3 Hydraulic oil coolers
3.3.3.1 Removal of the hydraulic oil coolers
3.3.3.2 Replacement of the hydraulic oil coolers
3.3.3.3 Removal of the hydraulic oil cooler frame
3.3.3.4 Replacement of the hydraulic oil cooler frame
3.3.4 Main relief valves (MRV)
3.3.4.1 Removal of the MRV
3.3.4.2 Replacement of the MRV
3.3.5 Pilot oil pump (gear pump)
3.3.5.1 Removal of the pilot oil pump
3.3.5.2 Replacement of the pilot oil pump
3.3.6 Main gate valve
3.3.6.1 Removal of the main gate valve
3.3.6.2 Replacement of the main gate valve
3.3.7 Hydraulic oil reservoir
3.3.7.1 Removal of the hydraulic oil reservoir
3.3.7.2 Replacement of the hydraulic oil reservoir
3.3.8 Main control valve blocks
3.3.8.1 Removal of the main control valve blocks
3.3.8.2 Replacement of the main control valve blocks
3.3.9 Service line relief valves (SRV)
3.3.9.1 Removal of SRV on main control valve block
3.3.9.2 Replacement of SRV on main control valve blocks
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
3.4 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
3.5 Lubrication pumps
3.5.1 Removal of the lubrication pump
3.5.2 Replacement of the lubrication pump
3.6 Pump controller MC7
3.6.1 Removal of the pump controller MC7
3.6.2 Replacement of the pump controller MC7
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
3.7.5 Operator’s seat
3.7.5.1 Removal of the operator’s seat
3.7.5.2 Replacement of the operator’s seat
3.7.6 ECS
3.7.6.1 Removal of the ECS text display
3.7.6.2 Replacement of the ECS text display
3.7.7 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
3.7.8 Removal of the cab base
3.7.9 Replacement of the cab base
3.8 Counterweight
3.8.1 Removal of the counterweight
3.8.2 Replacement of the counterweight
3.9 Superstructure lifting
3.9.1 Remove the superstructure from the undercarriage
3.9.2 Install the superstructure onto the undercarriage
3.10 Fuel tank
3.10.1 Removal of the fuel tank
3.10.2 Replacement of the fuel tank

4 Undercarriage
4.1 Travel system
4.1.1 Track group
4.1.1.1 Changing of the track group
4.1.2 Sprocket
4.1.2.1 Removal of the sprocket
4.1.2.2 Replacement of the sprocket
4.1.2.3 Removal of the segmented sprocket (only for type with pinned undercarriage up to SN 025)
4.1.2.4 Replacement of the segmented sprocket (only for type with pinned undercarriage up to SN 025)
4.1.3 Guide wheels
4.1.3.1 Removal of the guide wheel assembly
4.1.3.2 Replacement of the guide wheel assembly
4.1.4 Track tensioning accumulators
4.1.4.1 Removal of the low pressure accumulators
4.1.4.2 Replacement of the low pressure accumulators
4.1.4.3 Removal of the high pressure accumulators
4.1.4.4 Replacement of the high pressure accumulators
4.1.5 Track tension valve block
4.1.5.1 Removal of the track tensioning valve block
4.1.5.2 Replacement of the track tensioning valve block
4.1.6 Hydraulic hoses of the track tensioning system
4.1.6.1 Substitute the hydraulic hoses
4.1.7 Travel brake valve block (overspeed valve)
4.1.7.1 Removal of the travel brake valve block
4.1.7.2 Replacement of the travel brake valve block
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
4.1.9 Travel motor
4.1.9.1 Removal of the travel motors
4.1.9.2 Replacement of the travel motors
4.1.10 Travel parking brake
4.1.10.1 Removal of the travel parking brake
4.1.10.2 Replacement of the travel parking brake
4.1.11 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)
4.1.12 Carrier roller
4.1.12.1 Removal of the carrier roller assembly
4.1.12.2 Replacement of the carrier roller assembly
4.1.13 Track roller
4.1.13.1 Removal of the track roller assembly
4.1.13.2 Replacement of the track roller assembly
4.2 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

5 Attachment
5.1 Backhoe
5.1.1 Boom
5.1.1.1 Removal of the boom
5.1.1.2 Replacement of the boom
5.1.1.3 Removal of boom cylinders
5.1.1.4 Replacement of boom cylinders
5.1.2 Stick
5.1.2.1 Removal of the stick
5.1.2.2 Replacement of the stick
5.1.2.3 Removal of stick cylinders
5.1.2.4 Replacement of stick cylinders
5.1.3 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
5.1.4 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
5.1.5 Ground engaging tools (GET)
5.1.5.1 Removal and replacement of the GET
5.1.6 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
5.2 Face shovel
5.2.1 Using the installation tools for hydraulic cylinders
5.2.2 Boom
5.2.2.1 Removal of the boom
5.2.2.2 Replacement of the boom
5.2.2.3 Removal of the boom cylinders
5.2.2.4 Replacement of the boom cylinders
5.2.3 Stick
5.2.3.1 Removal of the stick
5.2.3.2 Replacement of the stick
5.2.3.3 Removal of the stick cylinders
5.2.3.4 Replacement of the stick cylinders
5.2.4 Bull clam bucket
5.2.4.1 Removal of the bull clam bucket
5.2.4.2 Replacement of the bull clam bucket
5.2.4.3 Removal of the bucket cylinders
5.2.4.4 Replacement of the bucket cylinders
5.2.4.5 Removal of the clam cylinders
5.2.4.6 Replacement of the clam cylinders
5.2.5 Ground engaging tools (GET)
5.2.5.1 Removal and replacement of the GET
5.2.6 Hydraulic hoses at the face shovel attachment
5.2.6.1 Substitute the boom arc hoses
5.2.6.2 Substitute the boom cylinder hoses
5.2.6.3 Substitute the stick arc hoses
5.2.6.4 Substitute the stick cylinder hoses
5.2.6.5 Substitute the bucket cylinder hoses
5.2.6.6 Substitute the clam cylinder hoses
5.3 Metering valves (grease injectors) at the attachment
5.3.1 Removal of the metering valves (grease injectors)
5.3.2 Replacement of the metering valves (grease injectors)
5.4 Cylinder bypass test

6 Service Information
6.1 Fluids and lubricants
6.1.1 Lubricants for operation in moderate and hot climates
6.1.2 Lubricants for operation in cold and arctic climates
6.2 Filling capacities
6.3 Work instructions
6.3.1 Surface coating with INTERZINC 697
6.3.2 Remove / install the crawler carrier
6.4 Used special tools (overview)

7 Tools catalogue

8 Parts & Service News

9 Supplier’s documentation

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