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MAINTENANCE 4.16 WELD REPAIRS

525

4.16.1 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON

THE UNDERCARRIAGE

See illustration Z 20674

On standard Excavators there are no special protective measures

necessary.

However, the general protective measures (A and B) must be

observed.

On Excavators with a power unit (generator set) mounted to the

undercarriage, all electrical connections between the Excavator

and the power unit have to be disconnected.

Introduction3
Contents of the Binder4
Division of the Binder5
Designated Use of the Shovel6
Delivery of the Shovel7
Explanation of Abbreviations8
Table of Contents9
Safety15
Safety Instructions16
Warnings and Symbols16
Basic Operation and Designated Use of the Hydraulic Shovel16
Organizational Measures17
Selection and Qualification of Personnel - Basic Responsibilities19
Safety Instructions Governing Specific Operational Phases20
Warning of Special Dangers23
Transporting and Towing -Recommissioning25
Special Safety Equipment25
Safety Harness in Conformity with en 361 (European Standard)29
Operation37
Foreword38
Construction of the Shovel39
Overall View39
Undercarriage and Superstructure40
Hydraulically Operated Access Ladder46
Emergency Escape Ladder50
Emergency Engine Shutdown from Ground man or Operator Warning System52
Operator's Cab with Integrated Falling Object Protective Structure (Fops)54
(Fops)54
Engine Oil Management System64
Operator's Cab - Controls72
Controls with Backhoe Attachment72
Controls with Bottom Dump Bucket Attachment76
Operator's Console81
Interface Panel for Diagnostics89
Control Module for Auxiliary Cab Heater91
Electronic Monitoring and Control System Ecs92
Introduction93
Operating the Electronic Monitoring System101
Automatic Display of Messages105
Menu Control and Service Functions129
Menu Control List154
Fault and Information Message List172
Operating the Heater, Ventilation and Air Conditioning198
Auxiliary Heater for Operator's Cab201
Machinery House202
Emergency Engine Shutdown Switches203
Safety Switch for Maintenance205
Control and Filter Panel of Rear- and Front Power Unit207
Electrical Equipment in Cab Base208
Standard Components in Cab Base209
Switch Board (X2) in Cab Base211
Components of Electrical Preheating System in Cab Base219
Preheating Systems for Oil, Coolant and Batteries222
Checks before Starting the Engines228
Starting the Engines234
Starting Procedure237
Moving the Shovel245
Travel Control with Foot Pedals245
Travelling Instructions248
Slewing and Braking the Superstructure249
Slewing the Superstructure249
Working with the Attachment252
Machines Equipped with "Euro" Control System252
Machines Equipped with "Kmg" Control System253
Bottom Dump Bucket254
Drop Ball Operation255
Combined Operation Cycles258
Working Instructions260
Stability of the Shovel260
Shovel Operation260
Parking the Shovel263
Stopping the Engines264
Relieve Pressure in the Hydraulic System267
Operation of the Lubrication System268
Central Lubrication System -Cls- for Superstructure and Attachment268
Swing Circle Pinion Lubrication System "Sls270
Fire Detection and Suppression System272
High Level Alarm "Fire275
Engine Shut-Down through Fuel Shut-Off Solenoid Valve275
Actuation Modes of the Fire Suppression System275
Indication of Operational Modes at Control Module, after Automatic Actuation of the Fire Suppression System277
Location of the Extinguishing Agent Tank Assemblies and Expellant Gas Cartridges on Power House Roof279
Transfer Pump for Hydraulic Oil280
Operating the Transfer Pump281
Functions of the Transfer Pump283
Central Refilling System286
Systems Connected to the Refilling System287
Operating the Hydraulic Service Arm289
Receiver Panel with Monitor Box291
Refillable Grease Containers of the Automatic Lubrication Systems297
Work on the Loader Attachment298
Transportation and Lifting of the Shovel299
Disassembling of the Shovel299
Transportation and Lifting299
Retrieval Procedure300
Shovel Storage301
Preparing for Storage301
One Month Repetitive Service Period302
Six Month Repetitive Service Period302
Preparing for Operation303
Trouble Shooting304
Engine304
Hydraulic System305
Final Drives and Swing Gear306
Crawler Tracks306
Maintenance307
Foreword308
Precautions for Maintenance309
Fluids and Lubricants311
Lubricants for Operation in Cold and Arctic Climates311
Fluids and Lubricants for Moderate and Hot Climates312
Filling Capacities316
Standard Torque List317
Lubrication and Maintenance Schedule318
Initial Servicing318
Periodic Servicing Intervals318
Periodic Servicing Schedule319
Extended Service Intervals for Engines with Engine Oil Management System326
Extended Service Intervals for Engines with Engine Oil Management System328
Resetting the Engine Oil Burning System Centinel328
Maintenance of the Engines331
Engine Fuel Filter Locations333
When Necessary334
Engine Air Cleaner Maintenance335
Swing Circle Toothing Lubrication339
Automatic Lubrication Systems Fill Grease Containers341
Track Rollers and Guide Wheels - Replace Floating Seals345
Cold Starting Aid, Replace Fluid Cylinder347
Every 10 Operating Hours or Daily348
Walk - Around Inspection349
Air Cleaner - Clean Pre-Cleaner357
Radiators - Check Coolant Level359
Track Groups - Clean359
Every 50 Operating Hours or Weekly360
Swing Gears and Motor Adapter Housings - Check Oil Levels361
Travel Gears, Motor Adapter Housings and Final Drives Check Oil Levels365
Pto's (PUMP DISTRIBUTOR GEARS) and OIL RESERVOIR - CHECK OIL LEVEL371
Hydraulic Access Ladder - Check Safety Sensor375
Hydraulic Oil Coolers - Inspect and Clean if Necessary377
Every 250 Operating Hours or Monthly378
Air Conditioning Compressor - Check Drive Belt Tension379
Signal Horn Compressor - Lubricate381
Hydraulic Oil Cooler Fan Bearings - Check for Leakage and Clean Breather Filter381
Radiator Fan Bearings - Check for Leakage and Clean Breather Filter381
Automatic Lubrication Systems - Clean In-Line Grease Filter and Check Breather Filter383
Breather Filter383
Cab Air Cleaner - Clean or Replace Filter Element385
Air Conditioning for Operator's Cab - Check Refrigerant Level387
Windshield Washer System - Check Fluid Level389
Every 500 Operating Hours or Quarterly390
Batteries - Check Fluid Level391
Flexible Drive Couplings - Check Oil Level393
Fuel Tank - Drain Condensation395
Crawler Track - Inspection397
Ground Cables of Engine and Alternator - Check for Correct Connection403
Ground Cable of Operator's Cab - Check for Correct Connection405
Every 1000 Operating Hours or Every 6 Month406
High Strength Bolt Connections - Check Torque Load407
Hydraulic System - Filter Service465
Pto's (Pump Distributor Gears), Swing Gears and Travel Gears - Oil Sample Analysis479
Signal Horn Compressor - Clean and Lubricate481
Hydraulic Track Tensioning System - Check Pressure Accumulators483
Water Filter - Replace Filter Cartridge485
Hydraulic Oil Cooler - Inspect and Lubricate Door Hinges487
Machinery House Doors - Inspect and Lubricate Door Hinges489
Every 2000 Operating Hours or Yearly490
Hydraulic System - Change Oil, Replace Suction Strainers and Pulsation Damper491
Hydraulic System - Change Oil, Replace Suction Strainers and Pulsation Damper493
Emergency Escape Ladder - Inspection503
Every 3000 Operating Hours However at Least Once a Year504
Swing Gears and Motor Adapter Housing - Change Oil505
Travel Gears, Motor Adapter Housings and Final Drives Change Oil513
Pto (Pump Distributor Gear) - Change Oil517
Fire Prevention520
Weld Repairs522
Protective Measures before Starting Weld Repairs on the Undercarriage525
Protective Measures before Starting Weld Repairs on the Loader Attachment527
Protective Measures before Starting Weld Repairs on the Superstructure529
After Finishing the Repair Weldings on the Superstructure531

Brand	Komatsu
Model	PC5500-6
Category	Excavators
Language	English

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