KOMATSU PC5500E-6 HYDRAULIC MINING SHOVEL ASSEMBLY AND TRANSPORT MANUAL 15028 & up – PDF DOWNLOAD
DESCRIPTION:
KOMATSU PC5500E-6 HYDRAULIC MINING SHOVEL ASSEMBLY AND TRANSPORT MANUAL 15028 & up – PDF DOWNLOAD
SAFETY INFORMATION:
- To enable you to use this machine safely, and to prevent injury to operators, service personnel or bystanders, the
precautions and warnings included in this manual and the safety signs attached to the machine must always be
followed. - The safety information in this manual does not replace any safety rules or laws in your area.
To identify important safety messages in the manual and on the machine labels, the following signal words are
used. - The “Safety Alert Symbol” identifies important safety messages on machines, in manuals, and elsewhere. When
you see this symbol, be alert to the risk of personal injury or death. Follow the instructions in the safety message.
TABLE OF CONTENTS:
KOMATSU PC5500E-6 HYDRAULIC MINING SHOVEL ASSEMBLY AND TRANSPORT MANUAL 15028 & up – PDF DOWNLOAD
2 SAFETY 9
2 1 SAFETY INFORMATION 10
2 2 OVERVIEW 11
2 2 1 NORMAL OPERATIONS 11
2 2 2 REGULAR MAINTENANCE 11
2 2 3 TROUBLESHOOTING, ADJUSTMENTS AND REPAIR 11
2 2 4 ADDITIONAL SAFETY PRECAUTIONS FOR ASSEMBLING, DISASSEMBLING AND TRANSPORTATION OF THE EXCAVATOR 11
2 3 SOUND PRESSURE LEVEL IN THE OPERATOR’S CAB 12
2 4 GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR 13
2 4 1 UNDERSTANDING THE MACHINE 13
2 4 2 PRECAUTIONS BEFORE STARTING OPERATION ON THE EXCAVATOR 13
2 4 3 PREPARATIONS FOR SAFE OPERATION 13
2 4 4 FIRE PREVENTION 15
2 4 5 PRECAUTIONS WHEN GETTING ON OR OFF THE MACHINE 17
2 4 6 BURN PREVENTION 19
2 4 7 PRECAUTIONS WHEN CLEANING CAB GLASS 19
2 4 8 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES 20
2 4 9 ELECTROMAGNETIC COMPATIBILITY (EMC) 21
2 4 10 PRECAUTIONS AT JOBSITE 22
2 4 11 STARTING ENGINE 27
2 4 12 OPERATION 28
2 5 PRECAUTION FOR MAINTENANCE 34
2 5 1 GENERAL PRECAUTIONS 34
2 5 2 PRECAUTIONS FOR INSPECTION AND MAINTENANCE 42
2 5 3 PRECAUTIONS WITH HIGH PRESSURE FLUID 43
2 6 ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS 47
2 6 1 INSPECTION OF THE HYDRAULIC SYSTEM 47
2 6 2 TWO WORKERS ONLY WHEN THE MACHINE IS RUNNING DURING ADJUSTMENTS 47
2 6 3 AREAS OF POTENTIAL DANGER AROUND THE EXCAVATOR 47
2 7 SPECIAL SAFETY EQUIPMENT 48
2 7 1 FRONT GUARD PROTECTIVE STRUCTUR ’FOPS’ FOR OPERATOR’S CAB 49
2 7 2 OBJECT HANDLING 49
2 7 3 LIGHTING 49
2 7 4 WARNING BEACON 49
2 7 5 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD) 49
2 8 ADDITIONAL SAFETY PRECAUTIONS 57
2 8 1 WHEN ASSEMBLING THE EXCAVATOR 57
2 8 2 WHEN DISASSEMBLING THE EXCAVATOR 57
2 8 3 WHEN TRANSPORTING THE DISASSEMBLED EXCAVATOR 58
3 GENERAL 59
3 1 GENERAL 60
3 1 1 DELIVERY OF THE EXCAVATOR 60
3 1 2 ASSEMBLING THE EXCAVATOR 60
3 1 3 LIFTING AND TRANSPORTATION 60
3 1 4 ELECTRICAL ENERGY 61
3 1 5 ELECTROMAGNETIC COMPATIBILITY (EMC) 61
3 1 6 MONITORING SYSTEMS OF THE MACHINE 61
3 2 ASSEMBLY SITE REQUIREMENTS 62
3 2 1 CONFIGURATION OF COMPONENTS ON ERECTION SITE (EXAMPLE) 62
3 2 2 REQUIRED CRANES 63
3 2 3 MANPOWER / ASSEMBLY TIME 63
3 2 4 TOOLS AND EQUIPMENT FOR ASSEMBLY 64
3 2 5 STANDARD APPLICATION TORQUE CHART 67
3 2 6 PREPARATIONS FOR ASSEMBLY 70
3 3 LIFTING OF THE MAIN COMPONENTS 72
3 3 1 SAFETY PRECAUTIONS FOR LIFTING OF COMPONENTS 73
3 3 2 LIFTING ATTACHMENT POINTS AND WEIGHTS 73
3 3 3 CRAWLER SIDE FRAME WITHOUT TRACKS 73
3 3 4 CARBODY 75
3 3 5 SUPERSTRUCTURE PLATFORM 77
3 3 6 MACHINERY HOUSE 79
3 3 7 FACE SHOVEL BOOM 81
3 3 8 BACKHOE BOOM 83
3 3 9 COUNTERWEIGHT LIFTING FOR HORIZONTAL TRANSPORT 85
3 3 10 COUNTERWEIGHT ERECTING FOR VERTICAL TRANSPORT 87
3 3 11 COUNTERWEIGHT LIFTING FOR VERTICAL TRANSPORT 89
3 3 12 HIGH VOLTAGE SWITCH CABINET 91
3 3 13 CAB BASE 93
3 3 14 FACE SHOVEL STICK 95
3 3 15 BACKHOE STICK 97
3 3 16 FACE SHOVEL BACK WALL 99
3 3 17 FACE SHOVEL CLAM SHELL 101
3 3 18 BACKHOE BUCKET 103
3 3 19 BASIC MEASUREMENTS 104
3 4 GENERAL INSTALLATION PROCEDURES FOR HYDRAULIC HOSE LINES 105
4 ASSEMBLY SEQUENCE 107
4 1 ASSEMBLY SEQUENCE OF FACE SHOVEL MACHINES 108
4 1 1 ASSEMBLY SEQUENCE UNDER CONSIDERATION OF THE MACHINE’S STABILITY 109
4 1 2 STABILITY IN RELATION TO ASSEMBLY STAGE 110
4 2 ASSEMBLY SEQUENCE OF BACKHOE MACHINES 114
4 2 1 ASSEMBLY SEQUENCE UNDER CONSIDERATION OF THE MACHINE’S STABILITY 115
4 3 ASSEMBLY OF UNDERCARRIAGE 116
4 3 1 ASSEMBLY OF TRACKS 117
4 3 2 ATTACH CARBODY TO SIDE FRAME 118
4 3 3 DETERMINING THE TIGHTENING TORQUE 125
4 3 4 SPECIAL HYDRAULIC TORQUE WRENCH 129
4 3 5 ATTACHING THE FINAL DRIVES 130
4 3 6 MOUNTING OF TRAVEL GEARS WITH PROTECTION KIT 134
4 3 7 CLOSING THE TRACKS 136
4 3 8 CONNECT HYDRAULIC LINES TO THE TRAVEL MOTORS 137
4 3 9 HYDRAULIC TRACK TENSIONING SYSTEM 142
4 3 10 MOUNTING OF THE CABLE DRUM 145
4 4 MOUNTING SUPERSTRUCTURE PLATFORM ONTO UNDERCARRIAGE 146
4 4 1 INSTALLATION OF SLEW ANGLE WARNING SYSTEM 152
4 5 MOUNTING MACHINERY HOUSE ONTO THE SUPERSTRUCTURE PLATFORM 156
4 6 MOUNTING OF HYDRAULIC ACCESS LADDER 158
4 6 1 CONNECTING THE EMERGENCY ACTUATION CHAINS 160
4 7 PRE-ASSEMBLY OF FACE SHOVEL BOOM 162
4 7 1 GENERAL INSTALLATION INSTRUCTIONS FOR ATTACHMENT PINS 164
4 7 2 ATTACH BOOM CYLINDERS AND STICK CYLINDERS TO THE BOOM 166
4 7 3 ATTACH BOOM TO SUPERSTRUCTRE A-FRAME 170
4 7 4 CLAMP RAILS FOR HYDRAULIC HOSE LINES FROM SUPERSTRUCTURE TO BOOM 173
4 8 PRE-ASSEMBLY OF BACKHOE BOOM 174
4 8 1 ATTACH BOOM CYLINDERS AND STICK CYLINDERS TO THE BOOM 176
4 8 2 ATTACH BOOM TO SUPERSTRUCTRE A-FRAME 180
4 9 MOUNTING OF COUNTERWEIGHT 182
4 10 ATTACHING THE HIGH VOLTAGE SWITCH CABINET 184
4 10 1 MECHANICAL INSTALLATION 185
4 10 2 ESTABLISHING OF HIGH VOLTAGE CABLE CONNECTIONS 187
4 11 ATTACHING THE CAB BASE 190
4 11 1 MECHANICAL INSTALLATION 191
4 11 2 MAKING ELECTRICAL CABLE CONNECTIONS 193
4 11 3 CONNECT THE FIRE SUPPRESSION SYSTEM PIPING BETWEEN HIGH VOLTAGE CABINET AND CAB BASE 195
4 11 4 CABLE CONNECTOR PLATE ON CAB BASE ROOF FOR MACHINES WITH VHMS ONLY 197
4 12 ATTACHING THE CAB WITH SUPPORT FRAME TO THE CAB BASE 198
4 12 1 CABLE CONNECTIONS CAB TO CAB BASE FOR ECS MACHINES ONLY 200
4 13 CONNECTING HIGH PRESSURE HOSES FROM MAIN PUMPS TO CHECK VALVES 202
4 14 ATTACHING INTERMEDIATE PIPE TO THE SUCTION OIL RESERVOIR 204
4 15 ATTACHING THE HYDRAULIC OIL RESERVOIR 206
4 16 ATTACHING THE HYDRAULIC OIL COOLER 208
4 16 1 CONNECTING THE HYDRAULIC HOSE LINES OF RETURN OIL CIRCUIT 210
4 16 2 CONNECTING THE HOSE LINES OF GEAR OIL COOLING CIRCUITS 212
4 16 3 CONNECTING THE HOSE LINES OF THE COOLER FAN MOTORS 215
4 16 4 CONNECTING THE BACK PRESSURE HOSES OF SWING MOTORS 216
4 16 5 CONNECTING THE HOSE LINES OF THE TRANSFER PUMP 218
4 17 CONNECTING HYDRAULIC LINES TO THE ROTARY JOINT 220
4 17 1 CONNECTING THE LEAKAGE OIL LINE, RETURN OIL LINE AND CONTROL OIL LINE TO THE ROTARY JOINT 222
4 18 ATTACHING THE HANDRAILS, CATWALKS AND STEPS 224
4 19 ATTACHING THE CENTRAL LUBRICATION UNIT 226
4 19 1 CONNECTING THE HYDRAULIC LINES AND GREASE LINES 228
4 19 2 CONNECTING GREASE LINES OF THE SWING CIRCLE PINION LUBRICATION SYSTEM 232
4 19 3 CONNECTING GREASE LINES OF THE CENTRAL LUBRICATION SYSTEM 234
4 20 CENTRAL REFILLING SYSTEM 236
4 20 1 CONNECTING THE REFILLING LINES 237
4 21 ATTACHING THE SERVICE CRANE (IF SO EQUIPPED) 238
4 22 PRE-CHECKS PRIOR TO INITIAL START UP 240
4 23 HIGH VOLTAGE INTERLOCK SYSTEM 242
4 23 1 APPLYING HIGH VOLTAGE CURRENT TO THE MACHINE 243
4 24 CHECKING DIRECTION OF MOTOR ROTATION 246
4 25 CHECK AND ADJUST ALIGNMENT OF MAIN MOTORS 248
4 25 1 ALIGNMENT TOLERANCES 255
4 25 2 SHIM SETS 255
4 25 3 RECOMMENDED TOOLS FOR MOTOR ALIGNMENT 257
4 26 FILLING AND BLEEDING THE HYDRAULIC SYSTEM 258
4 26 1 FILLING THE HYDRAULIC SYSTEM 259
4 26 2 BLEEDING THE HYDRAULIC SYSTEM 260
4 27 BLEEDING GEAR PUMPS FOR PTO GEAR LUBRICATION 264
4 28 ASSEMBLY FACE SHOVEL ATTACHMENT 266
4 28 1 ATTACHING THE BUCKET CYLINDERS TO THE BOOM 267
4 28 2 ATTACHING THE STICK TO THE BOOM 269
4 28 3 CONNECTING HOSE LINES FROM DISTRIBUTOR MANIFOLD TO BOOM 270
4 28 4 CONNECTING HOSE LINES FROM BOOM TO BOOM CYLINDERS 270
4 28 5 CONNECTING HOSE LINES FROM BOOM TO STICK CYLINDERS 273
4 28 6 CONNECTING HOSE LINES FROM STICK TO BUCKET CYLINDERS 275
4 28 7 CONNECTING STICK CYLINDERS TO THE STICK 276
4 29 BLEEDING HYDRAULIC CIRCUITS 278
4 29 1 BLEEDING THE SWING PARKING BRAKE CIRCUIT 279
4 29 2 BLEEDING THE TRAVEL PARKING BRAKE CIRCUIT 279
4 29 3 BLEEDING THE HYDRAULIC TRACK TENSIONING CIRCUIT 281
4 29 4 BLEEDING HYDRAULIC CIRCUIT OF ACCESS LADDER 282
4 29 5 BLEEDING HYDRAULIC CIRCUIT OF ATTACHMENT CYLINDERS 282
4 29 6 BLEEDING HYDRAULIC CIRCUIT OF SWING MOTORS 283
4 30 ATTACHING FACE SHOVEL TO THE STICK 284
4 30 1 ATTACHING BUCKET BACK WALL TO THE STICK 285
4 30 2 CONNECTING HOSE LINES FROM STICK TO BUCKET CLAM CYLINDERS 287
4 30 3 ATTACHING THE CLAM SHELL TO BUCKET BACK WALL 289
4 30 4 CONNECTING GREASE LINES OF THE FACE SHOVEL ATTACHMENT 291
4 30 5 CONNECTING GREASE LINES ON THE BUCKET 293
4 30 6 BLEEDING HYDRAULIC CIRCUIT OF BUCKET CLAM CYLINDERS 293
4 31 ASSEMBLY BACKHOE ATTACHMENT 294
4 31 1 CONNECTING HOSE LINES FROM DISTRIBUTOR MANIFOLD TO BOOM 295
4 31 2 CONNECTING HOSE LINES FROM BOOM TO BOOM CYLINDERS 296
4 31 3 CONNECTING HOSE LINES FROM BOOM TO STICK CYLINDERS 297
4 31 4 ATTACHING THE STICK TO THE BOOM 299
4 31 5 CONNECTING HOSE LINES FROM BOOM TO BUCKET CYLINDERS 301
4 32 BLEEDING HYDRAULIC CIRCUITS 302
4 32 1 BLEEDING THE SWING PARKING BRAKE CIRCUIT 303
4 32 2 BLEEDING THE TRAVEL PARKING BRAKE CIRCUIT 303
4 32 3 BLEEDING THE HYDRAULIC TRACK TENSIONING CIRCUIT 305
4 32 4 BLEEDING HYDRAULIC CIRCUIT OF ACCESS LADDER 306
4 32 5 BLEEDING HYDRAULIC CIRCUIT OF ATTACHMENT CYLINDERS 306
4 32 6 BLEEDING HYDRAULIC CIRCUIT OF SWING MOTORS 307
4 33 ATTACHING BACKHOE BUCKET TO THE STICK 308
4 33 1 CONNECTING GREASE LINES OF THE BACKHOE ATTACHMENT 313
4 34 BLEEDING HYDRAULIC CIRCUITS OF THE TRAVEL MOTORS 314
5 FINAL CHECKS AND ADJUSTMENTS 315
5 0 1 COMMISSIONING CHECK LIST 317
5 0 2 ADJUSTMENT OF AUTOMATIC LUBRICATION SYSTEMS 317
5 0 3 MAIN PUMP ADJUSTMENT IN RELATION TO ALTITUDE AT THE MINE SITE 319
5 0 4 PRESSURE COMPENSATION OF SEALED COMPONENTS 319
5 0 5 FINAL ADJUSTMENT OF SLEW ANGLE WARNING SYSTEM 320
5 0 6 PLACING THE FIRE DETECTION AND SUPPRESSION SYSTEM IN SERVICE 322
5 1 COMMISSIONING OF THE AIR CONDITIONING 344
5 1 1 AIR CONDITIONING FOR OPERATOR’S CAB 347
5 1 2 AIR CONDITIONING FOR MEDIUM AND HIGH VOLTAGE SWITCH CABINETS 349
5 2 PERFORM THE PM-CLINIC PROCEDURE ACCORDING TO THE PM-CLINIC PROCEDURE MANUAL 355
5 2 1 VISUAL INSPECTION 356
5 2 2 TRAVELLING INSTRUCTIONS 356
5 3 HANDLING OF DOCUMENTATION AFTER ASSEMBLY AND COMMISSIONING 357
6 DISASSEMBLY OF THE MACHINE 359
6 0 1 SAFETY PRECAUTIONS FOR DISASSEMBLING THE MACHINE 361
6 0 2 GROUNDING PROCEDURE OF THE HIGH VOLTAGE SYSTEM 361
6 0 3 DISASSEMBLY SEQUENCE OF FACE SHOVEL MACHINES 368
6 0 4 DISASSEMBLY SEQUENCE OF BACKHOE MACHINES 370
6 0 5 DISPOSAL OF WASTE MATERIAL 372
6 0 6 LIFTING AND TRANSPORTATION OF MAIN COMPONENTS 372
7 LIFTING AND TRANSPORTATION OF MAIN COMPONENTS 373
7 1 LIFTING OF THE MAIN COMPONENTS 374
7 1 1 SAFETY PRECAUTIONS FOR LIFTING OF COMPONENTS 375
7 1 2 LIFTING ATTACHMENT POINTS AND WEIGHTS 375
7 1 3 CRAWLER SIDE FRAME WITHOUT TRACKS 375
7 1 4 CARBODY [DIESEL DRIVE] 377
7 1 5 CARBODY [ELECTRIC DRIVE] 379
7 1 6 SUPERSTRUCTURE PLATFORM 381
7 1 7 MACHINERY HOUSE [DIESEL DRIVE] 383
7 1 8 MACHINERY HOUSE [ELECTRIC DRIVE] 385
7 1 9 FACE SHOVEL BOOM 387
7 1 10 BACKHOE BOOM 389
7 1 11 COUNTERWEIGHT LIFTING FOR HORIZONTAL TRANSPORT [DIESEL DRIVE] 391
7 1 12 COUNTERWEIGHT ERECTING FOR VERTICAL TRANSPORT [DIESEL DRIVE] 393
7 1 13 COUNTERWEIGHT LIFTING FOR VERTICAL TRANSPORT [DIESEL DRIVE] 395
7 1 14 COUNTERWEIGHT LIFTING FOR HORIZONTAL TRANSPORT [ELECTRIC DRIVE] 397
7 1 15 COUNTERWEIGHT ERECTING FOR VERTICAL TRANSPORT [ELECTRIC DRIVE] 399
7 1 16 COUNTERWEIGHT LIFTING FOR VERTICAL TRANSPORT [ELECTRIC DRIVE] 401
7 1 17 FUEL TANK [DIESEL DRIVE] 403
7 1 18 HIGH VOLTAGE SWITCH CABINET [ELECTRIC DRIVE] 405
7 1 19 CAB BASE 407
7 1 20 FACE SHOVEL STICK 409
7 1 21 BACKHOE STICK 411
7 1 22 FACE SHOVEL BACK WALL 413
7 1 23 FACE SHOVEL CLAM SHELL 415
7 1 24 BACKHOE BUCKET 417
7 2 TRANSPORTATION OF THE MAIN COMPONENTS 418
7 2 1 SAFETY PRECAUTIONS FOR TRANSPORTATION OF THE MAIN COMPONENTS 418
7 2 2 TIE-DOWN OF UNPACKED EXCAVATOR TRANSPORT UNITS 418
7 2 3 CRAWLER TRACKS [1800 mm] 423
7 2 4 CRAWLER TRACKS [1350 mm] 425
7 2 5 CRAWLER SIDE FRAME WITHOUT TRACKS 427
7 2 6 CARBODY [DIESEL DRIVE] 429
7 2 7 CARBODY [ELECTRIC DRIVE] 431
7 2 8 SUPERSTRUCTURE PLATFORM 433
7 2 9 MACHINERY HOUSE [DIESEL DRIVE] 439
7 2 10 MACHINERY HOUSE [ELECTRIC DRIVE] 441
7 2 11 FACE SHOVEL BOOM 443
7 2 12 BACKHOE BOOM 445
7 2 13 COUNTERWEIGHT [DIESEL DRIVE] 447
7 2 14 COUNTERWEIGHT [ELECTRIC DRIVE] 449
7 2 15 FUEL TANK [DIESEL DRIVE] 451
7 2 16 HIGH VOLTAGE SWITCH CABINET [ELECTRIC DRIVE] 455
7 2 17 CAB BASE 457
7 2 18 FACE SHOVEL STICK 459
7 2 19 BACKHOE STICK 461
7 2 20 FACE SHOVEL BACK WALL 463
7 2 21 FACE SHOVEL CLAM SHELL 465
7 2 22 BACKHOE BUCKET 467
7 2 23 COMPONENTS DELIVERED IN TRANSPORT BOXES 467
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