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PC5500-6
Komatsu PC5500-6 User Manual
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MAINTENANCE
4.5
STANDARD TORQUE LIST
317
4.5
ST
A
NDARD TORQUE LIST
Bolt
dia.
Wrench
size [mm]
Tight
eni
ng to
rqu
e
Nm
lbs.ft.
Quality grad
es
8.8
10.9
12.9
M 10
17
43
63
73
32
47
54
M 12
19
74
108
127
54.6
80
94
M 14
22
1
1
8
173
202
87
128
149
M 16
24
179
265
310
132
196
229
M 18
27
255
360
425
188
265
313
M20
30
360
510
600
265
376
443
M 22
32
485
690
810
358
509
597
M 24
36
620
880
1030
457
649
760
M 27
41
920
1310
15
30
679
966
11
2
8
M 30
46
1250
177
0
2080
922
1305
1534
M 33
50
1690
240
0
2800
1246
177
0
2065
M 36
55
2170
310
0
3600
1600
228
6
2655
M 39
60
2800
400
0
4700
2065
295
0
3466
Inse
rt all bolts l
ubricate
d with MPG
, KP2
K
316
318
Table of Contents
Introduction
3
Contents of the Binder
4
Division of the Binder
5
Designated Use of the Shovel
6
Delivery of the Shovel
7
Explanation of Abbreviations
8
Table of Contents
9
Safety
15
Safety Instructions
16
Warnings and Symbols
16
Basic Operation and Designated Use of the Hydraulic Shovel
16
Organizational Measures
17
Selection and Qualification of Personnel - Basic Responsibilities
19
Safety Instructions Governing Specific Operational Phases
20
Warning of Special Dangers
23
Transporting and Towing -Recommissioning
25
Special Safety Equipment
25
Safety Harness in Conformity with en 361 (European Standard)
29
Operation
37
Foreword
38
Construction of the Shovel
39
Overall View
39
Undercarriage and Superstructure
40
Hydraulically Operated Access Ladder
46
Emergency Escape Ladder
50
Emergency Engine Shutdown from Ground man or Operator Warning System
52
Operator's Cab with Integrated Falling Object Protective Structure (Fops)
54
(Fops)
54
Engine Oil Management System
64
Operator's Cab - Controls
72
Controls with Backhoe Attachment
72
Controls with Bottom Dump Bucket Attachment
76
Operator's Console
81
Interface Panel for Diagnostics
89
Control Module for Auxiliary Cab Heater
91
Electronic Monitoring and Control System Ecs
92
Introduction
93
Operating the Electronic Monitoring System
101
Automatic Display of Messages
105
Menu Control and Service Functions
129
Menu Control List
154
Fault and Information Message List
172
Operating the Heater, Ventilation and Air Conditioning
198
Auxiliary Heater for Operator's Cab
201
Machinery House
202
Emergency Engine Shutdown Switches
203
Safety Switch for Maintenance
205
Control and Filter Panel of Rear- and Front Power Unit
207
Electrical Equipment in Cab Base
208
Standard Components in Cab Base
209
Switch Board (X2) in Cab Base
211
Components of Electrical Preheating System in Cab Base
219
Preheating Systems for Oil, Coolant and Batteries
222
Checks before Starting the Engines
228
Starting the Engines
234
Starting Procedure
237
Moving the Shovel
245
Travel Control with Foot Pedals
245
Travelling Instructions
248
Slewing and Braking the Superstructure
249
Slewing the Superstructure
249
Working with the Attachment
252
Machines Equipped with "Euro" Control System
252
Machines Equipped with "Kmg" Control System
253
Bottom Dump Bucket
254
Drop Ball Operation
255
Combined Operation Cycles
258
Working Instructions
260
Stability of the Shovel
260
Shovel Operation
260
Parking the Shovel
263
Stopping the Engines
264
Relieve Pressure in the Hydraulic System
267
Operation of the Lubrication System
268
Central Lubrication System -Cls- for Superstructure and Attachment
268
Swing Circle Pinion Lubrication System "Sls
270
Fire Detection and Suppression System
272
High Level Alarm "Fire
275
Engine Shut-Down through Fuel Shut-Off Solenoid Valve
275
Actuation Modes of the Fire Suppression System
275
Indication of Operational Modes at Control Module, after Automatic Actuation of the Fire Suppression System
277
Location of the Extinguishing Agent Tank Assemblies and Expellant Gas Cartridges on Power House Roof
279
Transfer Pump for Hydraulic Oil
280
Operating the Transfer Pump
281
Functions of the Transfer Pump
283
Central Refilling System
286
Systems Connected to the Refilling System
287
Operating the Hydraulic Service Arm
289
Receiver Panel with Monitor Box
291
Refillable Grease Containers of the Automatic Lubrication Systems
297
Work on the Loader Attachment
298
Transportation and Lifting of the Shovel
299
Disassembling of the Shovel
299
Transportation and Lifting
299
Retrieval Procedure
300
Shovel Storage
301
Preparing for Storage
301
One Month Repetitive Service Period
302
Six Month Repetitive Service Period
302
Preparing for Operation
303
Trouble Shooting
304
Engine
304
Hydraulic System
305
Final Drives and Swing Gear
306
Crawler Tracks
306
Maintenance
307
Foreword
308
Precautions for Maintenance
309
Fluids and Lubricants
311
Lubricants for Operation in Cold and Arctic Climates
311
Fluids and Lubricants for Moderate and Hot Climates
312
Filling Capacities
316
Standard Torque List
317
Lubrication and Maintenance Schedule
318
Initial Servicing
318
Periodic Servicing Intervals
318
Periodic Servicing Schedule
319
Extended Service Intervals for Engines with Engine Oil Management System
326
Extended Service Intervals for Engines with Engine Oil Management System
328
Resetting the Engine Oil Burning System Centinel
328
Maintenance of the Engines
331
Engine Fuel Filter Locations
333
When Necessary
334
Engine Air Cleaner Maintenance
335
Swing Circle Toothing Lubrication
339
Automatic Lubrication Systems Fill Grease Containers
341
Track Rollers and Guide Wheels - Replace Floating Seals
345
Cold Starting Aid, Replace Fluid Cylinder
347
Every 10 Operating Hours or Daily
348
Walk - Around Inspection
349
Air Cleaner - Clean Pre-Cleaner
357
Radiators - Check Coolant Level
359
Track Groups - Clean
359
Every 50 Operating Hours or Weekly
360
Swing Gears and Motor Adapter Housings - Check Oil Levels
361
Travel Gears, Motor Adapter Housings and Final Drives Check Oil Levels
365
Pto's (PUMP DISTRIBUTOR GEARS) and OIL RESERVOIR - CHECK OIL LEVEL
371
Hydraulic Access Ladder - Check Safety Sensor
375
Hydraulic Oil Coolers - Inspect and Clean if Necessary
377
Every 250 Operating Hours or Monthly
378
Air Conditioning Compressor - Check Drive Belt Tension
379
Signal Horn Compressor - Lubricate
381
Hydraulic Oil Cooler Fan Bearings - Check for Leakage and Clean Breather Filter
381
Radiator Fan Bearings - Check for Leakage and Clean Breather Filter
381
Automatic Lubrication Systems - Clean In-Line Grease Filter and Check Breather Filter
383
Breather Filter
383
Cab Air Cleaner - Clean or Replace Filter Element
385
Air Conditioning for Operator's Cab - Check Refrigerant Level
387
Windshield Washer System - Check Fluid Level
389
Every 500 Operating Hours or Quarterly
390
Batteries - Check Fluid Level
391
Flexible Drive Couplings - Check Oil Level
393
Fuel Tank - Drain Condensation
395
Crawler Track - Inspection
397
Ground Cables of Engine and Alternator - Check for Correct Connection
403
Ground Cable of Operator's Cab - Check for Correct Connection
405
Every 1000 Operating Hours or Every 6 Month
406
High Strength Bolt Connections - Check Torque Load
407
Hydraulic System - Filter Service
465
Pto's (Pump Distributor Gears), Swing Gears and Travel Gears - Oil Sample Analysis
479
Signal Horn Compressor - Clean and Lubricate
481
Hydraulic Track Tensioning System - Check Pressure Accumulators
483
Water Filter - Replace Filter Cartridge
485
Hydraulic Oil Cooler - Inspect and Lubricate Door Hinges
487
Machinery House Doors - Inspect and Lubricate Door Hinges
489
Every 2000 Operating Hours or Yearly
490
Hydraulic System - Change Oil, Replace Suction Strainers and Pulsation Damper
491
Hydraulic System - Change Oil, Replace Suction Strainers and Pulsation Damper
493
Emergency Escape Ladder - Inspection
503
Every 3000 Operating Hours However at Least Once a Year
504
Swing Gears and Motor Adapter Housing - Change Oil
505
Travel Gears, Motor Adapter Housings and Final Drives Change Oil
513
Pto (Pump Distributor Gear) - Change Oil
517
Fire Prevention
520
Weld Repairs
522
Protective Measures before Starting Weld Repairs on the Undercarriage
525
Protective Measures before Starting Weld Repairs on the Loader Attachment
527
Protective Measures before Starting Weld Repairs on the Superstructure
529
After Finishing the Repair Weldings on the Superstructure
531
5
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Komatsu PC5500-6 Specifications
General
Brand
Komatsu
Model
PC5500-6
Category
Excavators
Language
English
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