Remove & Replace 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 insta
ll
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
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 ... 2-33
2.2.1 METRIC STANDARD THREAD... 2-33 2.2.2 METRIC FINE THREAD ... 2-34 2.2.3 CUMMINS MOTOR TORQUES - METRIC... 2-35 2.2.4 CUMMINS MOTOR TORQUES - U.S. CUSTOMARY... 2-35 2.2.5 SAE FLANGE CONNECTIONS... 2-36
2.3 BLIND PLUGS ... 2-37
2.3.1 DUMMY PLATES FOR SAE-FLANGES... 2-37 2.3.2 CLASSIFICATION OF THREADS TO THE NOMINAL WIDTH ... 2-39 2.3.3 PLUGS AND FITTINGS ACCORDING TO DIN 2353... 2-40
Table of contents
2.4 CONVERSION TABLE... 2-41
2.4.1 METHOD OF USING THE CONVERSION TABLE ... 2-41 2.4.2 MILLIMETER - INCH & KILOGRAM - POUND ... 2-42 2.4.3 LITER - U.S. GALLON & LITER - U.K. GALLON... 2-43 2.4.4 NM - FT.LB... 2-44 2.4.5 BAR - PSI / PSI - BAR ... 2-45 2.4.6 BASIC VALUES IN OHM ACCORDING TO DIN 43 76 ... 2-46 2.4.7 TEMPERATURE ... 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 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
Table of contents
3.2 PTO ... 3-50
3.2.1 MAIN PUMPS ... 3-50 3.2.1.1 PREPARATORY WORKS FOR MAIN PUMP REMOVAL ... 3-51 3.2.1.2 REMOVAL OF MAIN PUMPS... 3-54 3.2.1.3 REPLACEMENT OF MAIN PUMPS ... 3-56 3.2.2 PTO OIL PUMP (AUXILIARY PUMP)... 3-58 3.2.2.1 REMOVAL OF PTO OIL PUMP (AUXILIARY PUMP) ... 3-58 3.2.2.2 REPLACEMENT OF THE PTO OIL PUMP (AUXILIARY PUMP)... 3-60 3.2.3 OIL CIRCULATION PUMP (AUXILIARY PUMP)... 3-61 3.2.3.1 REMOVAL OF OIL CIRCULATION PUMP (AUXILIARY PUMP) ... 3-61 3.2.3.2 REPLACEMENT OF THE OIL CIRCULATION PUMP (AUXILIARY PUMP) ... 3-63 3.2.4 PUMP DISTRIBUTOR GEARBOX (PTO)... 3-64 3.2.4.1 REMOVAL OF THE PUMP DISTRIBUTOR GEARBOX (PTO) ... 3-66 3.2.4.2 REPLACEMENT OF THE PUMP DISTRIBUTOR GEARBOX (PTO)... 3-70
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
Table of contents
3.3.10 ANTI-CAVITATION VALVES (ACV) ... 3-138 3.3.10.1 REMOVAL OF ACV ON MANIFOLD ... 3-139 3.3.10.2 REPLACEMENT OF THE ACV ON MANIFOLD... 3-144 3.3.10.3 REMOVAL OF ACV ON MAIN CONTROL VALVE BLOCKS ... 3-145 3.3.10.4 REPLACEMENT OF ACV ON MAIN CONTROL VALVE BLOCKS... 3-148 3.3.11 THROTTLE CHECK VALVES ... 3-150 3.3.11.1 REMOVAL OF THROTTLE CHECK VALVES ... 3-152 3.3.11.2 REPLACEMENT OF THROTTLE CHECK VALVES... 3-155 3.3.12 MANIFOLD... 3-156 3.3.12.1 REMOVAL OF THE MANIFOLD ... 3-156 3.3.12.2 REPLACEMENT OF THE MANIFOLD... 3-158
3.4 SLEW DRIVE... 3-159
3.4.1 SLEW GEAR... 3-160 3.4.1.1 REMOVAL OF THE SLEW GEAR ... 3-161 3.4.1.2 REPLACEMENT OF THE SLEW GEAR... 3-165 3.4.2 SWING MOTOR... 3-168 3.4.2.1 REMOVAL OF THE SWING MOTOR ... 3-169 3.4.2.2 REPLACEMENT OF THE SWING MOTOR... 3-172 3.4.3 SLEW PARKING BRAKE... 3-174 3.4.3.1 REMOVAL/DISASSEMBLY OF THE SLEW PARKING BRAKE (L&S) ... 3-177 3.4.3.2 REPLACEMENT/ASSEMBLY OF THE SLEW PARKING BRAKE (L&S) ... 3-180 3.4.3.3 REMOVAL OF THE SLEW PARKING BRAKE (SIEBENHAAR) ... 3-183 3.4.3.4 REPLACEMENT OF THE SLEW PARKING BRAKE (SIEBENHAAR) ... 3-186 3.4.4 DYNAMIC SLEW BRAKE ... 3-190 3.4.4.1 REMOVAL OF THE SLEW BRAKE VALVE... 3-193 3.4.4.2 REPLACEMENT OF THE SLEW BRAKE VALVE ... 3-195 3.4.5 SWING CIRCLE LUBRICATION PINION (DUMMY WHEEL) ... 3-196 3.4.5.1 REMOVAL OF THE LUBRICATION PINION ASSEMBLY... 3-198 3.4.5.2 REPLACEMENT OF THE LUBRICATION PINION ASSEMBLY ... 3-200 3.4.6 SWING CIRCLE... 3-202 3.4.6.1 REMOVAL OF THE SWING CIRCLE ... 3-203 3.4.6.2 REPLACEMENT OF THE SWING CIRCLE... 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 ... 3-218
3.7.1 REMOVAL OF THE OPERATOR’S CAB... 3-221 3.7.2 REPLACEMENT OF THE OPERATOR’S CAB ... 3-226 3.7.3 CAB-MOUNTS ... 3-228 3.7.3.1 REMOVAL OF THE CAB-MOUNTS ... 3-228 3.7.3.2 REPLACEMENT OF THE CAB-MOUNTS ... 3-230 3.7.4 FRONT WINDOW (WINDSCREEN) ... 3-232 3.7.4.1 REMOVAL OF THE FRONT WINDOW ... 3-232 3.7.4.2 REPLACEMENT OF THE FRONT WINDOW ... 3-233
Table of contents
3.7.5 OPERATOR’S SEAT ... 3-234 3.7.5.1 REMOVAL OF THE OPERATOR’S SEAT... 3-234 3.7.5.2 REPLACEMENT OF THE OPERATOR’S SEAT ... 3-235 3.7.6 ECS... 3-236 3.7.6.1 REMOVAL OF THE ECS TEXT DISPLAY... 3-236 3.7.6.2 REPLACEMENT OF THE ECS TEXT DISPLAY ... 3-236 3.7.7 ACCESS LADDER... 3-238 3.7.7.1 REMOVAL OF THE ACCESS LADDER ... 3-241 3.7.7.2 REPLACEMENT OF THE ACCESS LADDER... 3-243 3.7.7.3 REMOVAL OF THE ACCESS LADDER CYLINDER... 3-245 3.7.7.4 REPLACEMENT OF THE ACCESS LADDER CYLINDER ... 3-247 3.7.8 REMOVAL OF THE CAB BASE ... 3-248 3.7.9 REPLACEMENT OF THE CAB BASE... 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
Table of contents
4.1.8 TRACK TENSIONING CYLINDERS ... 4-38 4.1.8.1 REMOVAL OF THE TRACK TENSIONING CYLINDERS ... 4-38 4.1.8.2 REPLACEMENT OF THE TRACK TENSIONING CYLINDERS ... 4-39 4.1.9 TRAVEL MOTOR... 4-40 4.1.9.1 REMOVAL OF THE TRAVEL MOTORS... 4-40 4.1.9.2 REPLACEMENT OF THE TRAVEL MOTORS ... 4-42 4.1.10 TRAVEL PARKING BRAKE... 4-44 4.1.10.1 REMOVAL OF THE TRAVEL PARKING BRAKE ... 4-46 4.1.10.2 REPLACEMENT OF THE TRAVEL PARKING BRAKE... 4-48 4.1.11 TRAVEL GEARBOX ... 4-50 4.1.11.1 REMOVAL OF THE TRAVEL GEARBOX... 4-51 4.1.11.2 REPLACEMENT OF THE TRAVEL GEARBOX ... 4-53 4.1.11.3 REMOVAL OF THE TRAVEL GEARBOX
(ONLY FOR TYPE WITH PINNED UNDERCARRIAGE UP TO SN 025)... 4-55 4.1.11.4 REPLACEMENT OF THE TRAVEL GEARBOX
(ONLY FOR TYPE WITH PINNED UNDERCARRIAGE UP TO SN 025)... 4-61 4.1.12 CARRIER ROLLER... 4-66 4.1.12.1 REMOVAL OF THE CARRIER ROLLER ASSEMBLY... 4-66 4.1.12.2 REPLACEMENT OF THE CARRIER ROLLER ASSEMBLY ... 4-68 4.1.13 TRACK ROLLER... 4-69 4.1.13.1 REMOVAL OF THE TRACK ROLLER ASSEMBLY... 4-69 4.1.13.2 REPLACEMENT OF THE TRACK ROLLER ASSEMBLY ... 4-71
4.2 CAR BODY... 4-72
4.2.1 REMOVAL OF THE CAR BODY AND THE CRAWLER CARRIERS
(TYPE WITH PINNED UNDERCARRIAGE) ... 4-72 4.2.2 REPLACEMENT OF THE CAR BODY AND THE CRAWLER CARRIERS
(TYPE WITH PINNED UNDERCARRIAGE) ... 4-76 4.2.3 REMOVAL OF THE CAR BODY AND THE CRAWLER CARRIERS
(TYPE WITH BOLTED UNDERCARRIAGE) ... 4-80 4.2.4 REPLACEMENT OF THE CAR BODY AND THE CRAWLER CARRIERS
(TYPE WITH BOLTED UNDERCARRIAGE) ... 4-85 4.2.4.1 TIGHTENING TORQUE FOR THE CRAWLER CARRIER MOUNTING BOLTS 4-88 4.2.5 ROTARY JOINT... 4-92 4.2.5.1 REMOVAL OF THE ROTARY JOINT ... 4-94 4.2.5.2 REPLACEMENT OF THE ROTARY JOINT... 4-96
5 ATTACHMENT... 5-1
5.1 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
Table of contents
5.1.3 BUCKET ... 5-36 5.1.3.1 REMOVAL OF THE BUCKET... 5-36 5.1.3.2 REPLACEMENT OF THE BUCKET ... 5-39 5.1.3.3 REMOVAL OF BUCKET CYLINDERS ... 5-40 5.1.3.4 REPLACEMENT OF BUCKET CYLINDERS ... 5-46 5.1.4 BUCKET LINK ROD AND STEERING RODS ... 5-49 5.1.4.1 REMOVAL OF THE BUCKET LINK ROD... 5-49 5.1.4.2 REPLACEMENT OF THE BUCKET LINK ROD ... 5-51 5.1.4.3 REMOVAL OF THE STEERING RODS... 5-52 5.1.4.4 REPLACEMENT OF THE STEERING RODS ... 5-55 5.1.5 GROUND ENGAGING TOOLS (GET)... 5-56 5.1.5.1 REMOVAL AND REPLACEMENT OF THE GET ... 5-57 5.1.6 HYDRAULIC HOSES AT THE BACKHOE ATTACHMENT... 5-58 5.1.6.1 SUBSTITUTE THE BOOM ARC HOSES ... 5-58 5.1.6.2 SUBSTITUTE THE BOOM CYLINDER HOSES... 5-62 5.1.6.3 SUBSTITUTE THE STICK CYLINDER HOSES ... 5-66 5.1.6.4 SUBSTITUTE THE BUCKET CYLINDER HOSES ... 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
Table of contents
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
Table of contents
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
Introduction
Contents of the binder Introduction
1.1
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.
Introduction Foreword
1.2
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
Foreword Introduction
WARNING
Personnel entrusted with work on the machine must have read the section 2 SAFETY AND STANDARDS before begin-ning work. Reading the instructions after work has begun is too late.
Damages and defects caused by incorrect operation and mainte-nance 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.
Safety and Standards
Safety Instructions 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 proce-dure. 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 num-ber 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 begin-ning 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:
All PARTS & SERVICE NEWS which are mentioned in the proce-dures are listed in chapter 8. The numbers of the PARTS & SER-VICE NEWS do not label the latest edition. Ensure that the latest edition is always filed to the binder of this manual.
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.
Safety and Standards Safety Instructions
z The following symbols and designations are used in the man-ual to designate instructions of particular importance:
DANGER
Refers to orders and prohibitions designed to prevent seri-ous 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.
Safety Instructions Safety and Standards
2.1.2
GENERAL PRECAUTIONS
CAUTION
Proper service and repair is important for safe machine oper-ation. 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 Ger-many for the specific purpose.
NOTE: Always attend to local regulations regarding the Personal
Protective Equipment.
WARNING
z Mistakes in operation and service are extremely danger-ous. 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 pre-cautions given in the Operation & Maintenance Manual. z When carrying out any operation with two or more wor-kers, always agree on the operating procedure before starting. Always inform your fellow workers before star-ting any step of the operation. Before starstar-ting 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.
Safety and Standards Safety Instructions
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 counter-weight. 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 counter-weight 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 hand-rails, ladders, or steps when getting on or off the machine. Never jump on or off the machine. If it is impos-sible to use the handrails, ladders, or steps, use a stand to provide safe footing.
Safety Instructions Safety and Standards
2.1.4
PRECAUTIONS DURING WORK
WARNING
z When removing the oil filler cap, drain plug, or hydraulic pressure measuring plugs, loosen them slowly to pre-vent the oil from spurting out. The water and oil in the cir-cuits 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 compo-nent 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 pres-sure or under prespres-sure 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
Safety and Standards Safety Instructions
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 pres-sure circuits. Also check that connecting parts are cor-rectly 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.
Safety Instructions Safety and Standards
2.1.5
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 immedi-ately 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 ele-ments.
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 recti-fied immediately.
Safety and Standards Safety Instructions
WARNING
z Necessary work on live parts and elements must be car-ried 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 short-circuited 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 counter-weight. 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 oper-ations 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 explo-sion).
Safety Instructions Safety and Standards
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 spe-cial knowledge and experience in this systems.
z Check all lines, hoses and screwed connections regu-larly 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 connec-tions are interchanged. The fittings, lengths, and quality of the hoses must comply with the technical require-ments.
2.1.5.4 NOISE
WARNING
z During operation, all sound baffles must be closed. z Always wear the prescribed ear protectors.
Safety and Standards Safety Instructions
2.1.5.5 HEAT
WARNING
z Do not start working on hot machine parts until the tem-perature is below 50 °C.
z Be careful when handling hot materials (risk of burning or scalding) such as:
z Fuel
z Engine coolant z Hydraulic oil z Engine oil z Grease
z 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 sub-stances, 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 har-ness is required, refer to section 2.1.6 on page 2-13.
Safety Instructions Safety and Standards
Safety and Standards Safety Instructions
2.1.6
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:
WARNING
Always use the safety harness (Fig. 2-1, Pos. 1) in conjunc-tion 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.
(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
Safety Instructions Safety and Standards
Safety and Standards 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 side-slip. 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 equip-ment has to be inspected by the manufacturer or by a quali-fied 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 manu-facturer or to an authorized qualified repair shop for mainte-nance and renewed testing.
Safety Instructions Safety and Standards
Safety and Standards 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 reg-ulations 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 compo-nents have to be inspected by a competent person autho-rized 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.
Safety Instructions Safety and Standards
Safety and Standards 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 mini-mum carrying capacity should be 10 kN, according to DIN EN 795.
The strap-type fall absorber and the safety rope must not be dam-aged, 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 autho-rized qualified repair shop.
Safety Instructions Safety and Standards
2.1.7
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 Mainte-nance Manual, chapter 4, section "REPLACEMENT OF HYDRAULIC HOSE LINES AND FUEL HOSE".
To avoid damage to the hydraulic hose lines, follow the installa-tion procedures listed below:
CAUTION
Pay attention to the Natural curvature of the hose!
Fig. 2-5
CAUTION Do not twist the hoses during installation!
Safety and Standards Safety Instructions
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!
Safety Instructions Safety and Standards
CAUTION Pay attention to the bending radius!
Safety and Standards Safety Instructions
2.1.8
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
SAFETY HINTS FOR WIRE ROPES
z Use adequate ropes depending on the weight of the parts to be hoisted, referring to the below table:
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.
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
Safety Instructions Safety and Standards
z Sling wire ropes around the middle portion of the hook. Sling-ing 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.
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.
Fig. 2-11
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
Safety and Standards Safety Instructions
2.1.10 SAFETY HINTS FOR SLING ACCESSORY
WARNING
Always attend to local standards when using sling acces-sory.
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
stan-dards or Vario-Starpoint hoist rings recommended by Komatsu, see following table:
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
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
Safety Instructions Safety and Standards
2.1.11 WEIGHT TABLES
2.1.11.1 SUPERSTRUCTURE
Part or assembly Weight Remark
Diesel engine 7000 kg
Roof plate engine housing 397 kg max. depending on type
Beam (Bridge) 285 kg
Alternator 38.25 kg
Battery 62 kg each
Radiator fan 35 kg
Hydraulic fan motor 18 kg
Bearing block 77.5 kg
Radiator fan drive pump 40 kg
Radiator assembly 650 kg
Roof plate over radiator 116kg
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 each
Oil circulation pump (auxiliary pump) 25 kg
PTO (pump distributor gearbox) 1900 kg
Control frame assembly 260 kg each
Hydraulic cooler fan drive pump 40 kg
Hydraulic cooler fan assembly 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 each element
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
Safety and Standards Safety Instructions
Part or assembly Weight Remark
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
Safety Instructions Safety and Standards
Part or assembly Weight Remark
Superstructure incl. Diesel engine without counterweight, attachment and fluids 137,215 kg
Safety and Standards Safety Instructions
2.1.11.2 UNDERCARRIAGE
Part or assembly Weight Remark
Track group 1350 mm 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 depending on type
Travel brake valve block 75 kg
Track tensioning cylinder 400 kg each
Travel motor 110 kg
Travel parking brake 75 kg each
Travel gearbox 4020 kg
Carrier roller assembly (bolted connection) 205 kg
Carrier roller assembly (with mounting pins) 175 kg
Track roller assembly 654 kg
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
Safety Instructions Safety and Standards
Part or assembly Weight Remark
Crawler carrier assembly (track width 1800 mm, with mounting pins) 83,646 kg each
Rotary joint 261 kg
Safety and Standards Safety Instructions
2.1.11.3 BACKHOE ATTACHMENT (BHA)
Part or assembly Weight Remark
Boom 45,100 kg
Pin boom/superstructure 365 kg
Pin boom cylinder/boom 177 kg
Pin boom cylinder/superstructure 224 kg
Boom cylinder 6500 kg each
Stick 19,160 kg
Pin stick/boom 1440 kg
Stick cylinder 4600 kg each
Pin stick cylinder/stick 127 kg
Pin stick cylinder/boom 179 kg
Bucket 30,600 kg
Pin bucket/stick 574 kg
Pin bucket/bucket link rod 822 kg
Bucket cylinder 3210 kg each
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
Boom cylinder hoses 29.5 kg39 kg depending on length
Stick cylinder hoses 27,5 kg23 kg depending on length
Bucket cylinder hoses 33 kg
Safety Instructions Safety and Standards
2.1.11.4 FACE SHOVEL ATTACHMENT (FSA)
Part or assembly Weight Remark
Boom with attached stick and boom cylinders 52,900 kg
boom without cylinders: 34,800 kg
Pin boom/superstructure 365 kg
Pin boom cylinder/boom 234 kg
Pin boom cylinder/superstructure 224 kg
Boom cylinder 5680 kg
Stick 21,000
Pin stick/boom 168 kg
Stick cylinder 3340 kg
Pin stick cylinder/stick 90 kg
Pin stick cylinder/boom 90 kg
Bucket 35,060 kg
Pin bucket cylinder/bucket 190 kg
Pin bucket/stick 318 kg
Bucket cylinder 4005 kg
Pin bucket cylinder/boom 168 kg
Clam cylinder 885 kg
Upper pin at clam cylinder 48 kg
Lower pin at clam cylinder 66 kg
Point (tooth) (ESCO) 55 kg
Shroud (ESCO) 270 kg
Tooth adapter (ESCO) 182 kg
Boom arc hose 39 kg
Boom cylinder hose 30.5 kg
Stick arc hose 29.5 kg
Stick cylinder hose 27.4 kg25 kg depending on length
Bucket cylinder hose 28 kg depending on length
Clam cylinder hose at stick 28 kg
Clam cylinder hose at clam cylinder
8.8 kg 9.8 kg 10 kg 11.2 kg depending on length and type Metering valve <25 kg
Safety and Standards Torque charts according to DIN
2.2
TORQUE CHARTS ACCORDING TO DIN
2.2.1
METRIC STANDARD THREAD
NOTE: Threads and bolts must be greased carefully with grease
KP2K. Contact surfaces which should be screwed together must be free of grease.
Bolt diameter Wrench size [mm] Tightening torque [Nm] Metric regular
Bolt quality grades
8.8 10.9 12.9 M 8 13 6 21 31 36 M 10 17 8 43 63 73 M 12 19 10 74 108 127 M 14 22 12 118 173 202 M 16 24 14 179 265 310 M 18 27 14 255 360 425 M 20 30 17 360 510 600 M 22 32 17 485 690 810 M 24 36 19 620 880 1030 M 27 41 19 920 1310 1530 M 30 46 22 1250 1770 2080 M 33 50 24 1690 2400 2800 M 36 55 27 2170 3100 3600 M 39 60 2800 4000 4700 M 42 65 32 3500 4950 5800 M 45 70 4350 6200 7200 M 48 75 35 5200 7500 8700 M 52 80 6700 9600 11200 M 56 85 41 8400 12000 14000 M 60 90 10400 14800 17400 M 64 95 46 12600 17900 20900 M 68 100 15200 21600 25500
Torque charts according to DIN Safety and Standards
2.2.2
METRIC FINE THREAD
NOTE: Threads and bolts must be greased carefully with grease
KP2K. Contact surfaces which should be screwed together must be free of grease.
CAUTION
Bolts at the slew rings have different torques, refer to Service NEWS No. "AH00511" last edition!
Bolt diameter Wrench size [mm] Tightening torque [Nm] Metric fine
Bolt quality grades
8.8 10.9 12.9 M 8 x 1.0 13 6 23 33 39 M 10 x 1.0 17 8 48 70 82 M 12 x 1.25 19 10 81 119 139 M 14x1.5 22 12 127 187 219 M 16 x 1.5 24 14 191 280 330 M 18 x 2.0 27 14 270 385 450 M 20 x 2.0 30 17 380 540 630 M 22 x 2.0 32 17 510 720 850 M 24 x 2.0 36 19 680 960 1130 M 27 x 2.0 41 19 990 1410 1650 M 30 x 2.0 46 22 1380 1960 2300 M 33 x 2.0 50 24 1850 2650 3100 M 36 x 3.0 55 27 2300 3250 3850 M 39 x 3.0 60 3000 4200 4950 M 42 x 3.0 65 32 3750 5300 6200 M 45 x 3.0 70 4600 6600 7700 M 48 x 3.0 75 35 5700 8100 9500 M 52 x 3.0 80 7300 10400 12100 M 56 x 4.0 85 41 8900 12600 14800 M 60 x 4.0 90 11000 15600 18300 M 64 x 4.0 95 46 13300 19000 22200 M 68 x 4.0 100 16100 22900 27000
Safety and Standards Torque charts according to DIN
2.2.3
CUMMINS MOTOR TORQUES - METRIC
2.2.4
CUMMINS MOTOR TORQUES - U.S. CUSTOMARY
Grade 8.8 10.9 12.9
Body size Torque Torque Torque
Diameter [mm]
Cast iron Aluminium Cast iron Aluminium Cast iron Aluminium [Nm] [ft-lb] [Nm] [ft-lb] [Nm] [ft-lb] [Nm] [ft-lb] [Nm] [ft-lb] [Nm] [ft-lb] 6 9 5 7 4 13 10 7 4 14 9 7 4 7 14 9 11 7 18 14 11 7 23 18 11 7 8 23 17 18 14 33 25 18 14 40 29 18 14 10 45 33 30 25 65 50 30 25 70 50 30 25 12 80 60 55 40 115 85 55 40 125 95 55 40 14 125 90 90 65 180 133 90 65 195 145 90 65 16 195 140 140 100 280 200 140 100 290 210 140 100 18 280 200 180 135 390 285 180 135 400 290 180 135 20 400 290 - - 550 400 - - -
-Grade 5 (three radial lines on cap) 8 (six radial lines on cap)
Body size Torque Torque
Diameter - threads Cast iron Aluminium Cast iron Aluminium
[Nm] [ft-lb] [Nm] [ft-lb] [Nm] [ft-lb] [Nm] [ft-lb] 1/4 - 20 9 7 8 6 15 11 8 6 1/4 - 28 12 9 9 7 18 13 9 7 5/16 - 18 20 15 16 12 30 22 16 12 5/16 - 24 23 17 19 14 33 24 19 14 3/8 - 16 40 30 25 20 55 40 25 20 3/8 - 24 40 30 35 25 60 45 35 25 7/16 - 14 60 45 45 35 90 65 45 35 7/16 - 20 65 50 55 40 95 70 55 40 1/2 - 13 95 70 75 55 130 95 75 55 1/2 - 20 100 75 80 60 150 110 80 60 9/16 - 12 135 100 110 80 190 140 110 80
Torque charts according to DIN Safety and Standards
2.2.5
SAE FLANGE CONNECTIONS
Safety and Standards Blind plugs
2.3
BLIND PLUGS
2.3.1
DUMMY PLATES FOR SAE-FLANGES
Fig. 2-14 Forms / types of dummy plates for SAE-flanges
Up to 3000 PSI SAE size Form / type according to Fig. 2-142-14 PN (hose / pipe)DN 1/2" A 506 521 98 12 3/4" A 506 583 98 20 1 1/4" A 506 584 98 32 1 1/2" A 506 522 98 40 2" A 506 523 98 50 2 1/2" A 506 585 98 65 3" A 512 570 98 80 3/4" B 516 826 98 20 1 1/4 B 517 479 98 32 1 1/2" B 506 528 98 40 2" B 506 529 98 50 2 1/2" B 506 530 98 65 3" B 512 571 98 80
Blind plugs Safety and Standards Up to 6000 PSI SAE size Form / type according to Fig. 2-142-14 PN (hose / pipe)DN 3/4" A 506 580 98 20 1" A 506 519 98 25 1 1/4" A 506 520 98 32 1 1/2" A 506 581 98 40 2" A 506 582 98 50 1" B 506 524 98 25 1 1/4" B 506 525 98 32 1 1/2" B 506 526 98 40 2" B 506 527 98 50 1 1/4" C 516 499 98 32 1 1/2" C 509 375 98 40 2" C 509 376 98 50
Safety and Standards Blind plugs
2.3.2
CLASSIFICATION OF THREADS TO THE NOMINAL WIDTH
Method of using the above table to find an appropriate plugs and fittings according to Table 2.3.3 on page 40:
EXAMPLE:
To cover up a hose / tube with a diameter of 25 mm, for a pres-sure up to 3000 PSI perform the following steps:
z Locate the 25 in the column "DN" in the category "up to 3000 PSI".
z Check the digit in the column "Ra" next to DN 25 in the same row and category.
For this example the proper plug and fitting is BUZ 28-L and ROV 28-L, refer to Table 2.3.3 on page 40.
NOTE: The column "Size" indicates the thread-size for the
ROV-fittings. Heavy class (up to 6000 PSI) Light class (up to 3000 PSI) Size Ra DN Ra DN M 12 x 1.5 - - 6 5 M 14 x 1.5 - - 8 6 M 16 x 1.5 8 5 10 8 M 18 x 1.5 10 6 12 10 M 20 x 1.5 12 8 - -M 22 x 1.5 14 10 15 12 M 24 x 1.5 16 12 - -M 26 x 1.5 - - 18 16 M 30 x 1.5 - - - -M 30 x 2 20 16 22 20 M 36 x 2 25 20 28 25 M 38 x 1.5 - - - -M 42 x 2 30 25 - -M 45 x 1.5 - - - -M 45 x 2 - - 35 32 M 52 x 1.5 - - - -M 52 x 2 38 32 42 40 M 65 x 2 - - -
-Blind plugs Safety and Standards
2.3.3
PLUGS AND FITTINGS ACCORDING TO DIN 2353
Up to 3000 PSI
BUZ (plugs) PN ROV (fittings) PN
8-L 501 692 98 8-L 518 113 98 10-L 371 852 99 10-PL 513 789 98 12-L 371 854 99 12-PL 513 547 98 15-L 371 855 99 15-PL 507 051 98 18-L 371 856 99 18-PL 513 787 98 22-L 371 857 99 22-PL 513 788 98 28-L 371 858 99 28-PL 509 377 98 35-L 371 859 99 35-PL 516 770 98 42-L 371 860 99 42-PL 513 790 98 Up to 6000 PSI
BUZ (plugs) PN ROV (fittings) PN
- - 8-PS 515 921 98 - - 10-PS 507 023 98 - - 12-PS 507 022 98 16-S 371 866 99 - -20-S 371 853 99 20-PS 512 005 98 25-S 371 867 99 25-PS 508 033 98 30-S 371 868 99 30-PS 507 021 98 38-S 371 869 99 38-PS 507 020 98
Safety and Standards Conversion table
2.4
CONVERSION TABLE
2.4.1
METHOD OF USING THE CONVERSION TABLE
The Conversion Table in this section is provided to enable simple conversion of figures. For details of the method of using the Con-version Table, see the example given below.
EXAMPLE:
Method of using the Conversion Table to convert from millimeters to inches.
Convert 55 mm into inches:
z Locate the number 50 in the vertical column at the left side, take this as (A), then draw a horizontal line from (A).
z Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down from (B).
z Take the point where the two lines cross as (C). This point (C) gives the value when converting from millimeters to inches. Therefore, 55 millimeters = 2.165 inches.
Convert 550 mm into inches:
z The number 550 does not appear in the table, so divide by 10 (move the decimal one place to the left) to convert it to 55 mm.
z Carry out the same procedure as above to convert 55 mm to 2.165 inches.
z The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
Conversion table Safety and Standards
Safety and Standards Conversion table
Conversion table Safety and Standards
