KOMATSU PC5500-6 HYDRAULIC MINING SHOVEL OPERATION & MAINTENANCE MANUAL 15016 – PDF DOWNLOAD

Description

KOMATSU PC5500-6 HYDRAULIC MINING SHOVEL OPERATION & MAINTENANCE MANUAL 15016 – PDF DOWNLOAD

DESCRIPTION:

KOMATSU PC5500-6 HYDRAULIC MINING SHOVEL OPERATION & MAINTENANCE MANUAL 15016 – PDF DOWNLOAD

DESIGNATED USE OF THE SHOVEL:

• This machine has been manufactured in accordance with
  advanced and up-to-date technology standards including recognized
  safety rules. Nevertheless, its use may constitute a risk to
  life and limb of the user or of third parties, or cause damage to the
  machine and to other material property.
• The machine must only be used in technically perfect condition in
  accordance with its designated use and the instructions set out in
  the operation manual. Only trained safety-conscious operators
  who are fully aware of the risks involved should operate the
  machine. Any functional disorders, especially those affecting the
  safety of the machine, should, therefore, be rectified immediately.
• The hydraulic Shovel is designed exclusively for excavating, i.e.
  excavation of bulk material and natural soil structure (e.g. earth,
  clay, sand and stones ashore and off-shore). Observe local and
  national safety regulations. Special conditions at the worksite
  require additional safe working precautions, follow your company’s
  safety instructions. Short traveling distances for changing
  the working site are considered as part of the designated use of
  the Shovel.

TABLE OF CONTENTS:

KOMATSU PC5500-6 HYDRAULIC MINING SHOVEL OPERATION & MAINTENANCE MANUAL 15016 – PDF DOWNLOAD

COVER 1
1  INTRODUCTION 3
1 1 CONTENTS OF THE BINDER 4
1 2 DIVISION OF THE BINDER 5
1 3 DESIGNATED USE OF THE SHOVEL 6
1 4 DELIVERY OF THE SHOVEL 7
1 5 EXPLANATION OF ABBREVATIONS 8
1 6 TABLE OF CONTENTS 9
2  SAFETY 15
2 1 SAFETY INSTRUCTIONS 16
2 1 1 WARNINGS AND SYMBOLS 16
2 1 2 BASIC OPERATION AND DESIGNATED USE OF THE HYDRAULIC SHOVEL 16
2 1 3 ORGANIZATIONAL MEASURES 17
2 1 4 SELECTION AND QUALIFICATION OF PERSONNEL – BASICRESPONSIBILITIES 19
2 1 5 SAFETY INSTRUCTIONS GOVERNING SPECIFIC OPERATIONAL PHASES 20
2 1 6 WARNING OF SPECIAL DANGERS 23
2 1 7 TRANSPORTING AND TOWING -RECOMMISSIONING 25
2 1 8 SPECIAL SAFETY EQUIPMENT 25
2 1 9 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEANSTANDARD) 29
3  OPERATION 37
3 1 FOREWORD 38
3 2 CONSTRUCTION OF THE SHOVEL 39
3 2 1 OVERALL VIEW 39
3 2 2 UNDERCARRIAGE AND SUPERSTRUCTURE 40
3 2 3 HYDRAULICALLY OPERATED ACCESS LADDER 46
3 2 4 EMERGENCY ESCAPE LADDER 50
3 2 5 EMERGENCY MOTOR SHUTDOWN FROM GROUND MAN OR OPERATOR WARNING SYSTEM 52
3 2 6 OPERATOR’S CAB WITH INTEGRATED FALLING OBJECT PROTECTIVE STRUCTURE (FOPS) 54
3 3 OPERATOR’S CAB – CONTROLS 62
3 3 1 HYDRAULIC CONTROL SYSTEM 63
3 3 2 SAFETY CIRCUIT FOR CONTROLS 63
3 4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS 76
3 4 1 OPERATING THE ELECTRONIC MONITORING SYSTEM 85
3 4 2 MENU CONTROL CHART 134
3 4 3 FAULT AND INFORMATION MESSAGE LIST 152
3 5 OPERATING THE HEATER, VENTILATION AND AIRCONDITIONING 175
3 6 POWER HOUSE 176
3 6 1 EMERGENCY MOTOR SHUTDOWN SWITCHES 177
3 6 2 CONTROL AND FILTER PANEL OF REAR- AND FRONT POWER UNIT 179
3 7 MEDIUM VOLTAGE SWITCH CABINET IN CAB BASE 180
3 7 1 COMPONENTS OF THE MEDIUM VOLTAGE SWITCH CABINET 181
3 7 2 SWITCH BOARD (X2) IN CAB BASE 183
3 7 3 MONITOR AND CONTROL PANEL IN CAB BASE 189
3 7 4 SWITCH BOARD – MEDIUM VOLTAGE 191
3 8 HIGH VOLTAGE SWITCH CABINET 192
3 9 CHECKS BEFORE STARTING THE MAIN DRIVE MOTORS 194
3 10 STARTING THE MAIN DRIVE MOTORS 198
3 11 MOVING THE SHOVEL 205
3 11 1 TRAVEL CONTROL WITH FOOT PEDALS 205
3 11 2 TRAVELLING INSTRUCTIONS 208
3 12 SLEWING AND BRAKING THE SUPERSTRUCTURE 209
3 12 1 SLEWING THE SUPERSTRUCTURE 209
3 13 WORKING WITH THE ATTACHMENT 212
3 13 1 MACHINES EQUIPPED WITH ”EURO” CONTROL SYSTEM 212
3 13 2 MACHINES EQUIPPED WITH ”KMG” CONTROL SYSTEM 213
3 13 3 BOTTOM DUMP BUCKET 214
3 13 4 DROP BALL OPERATION 215
3 13 5 COMBINED OPERATION CYCLES 218
3 14 WORKING INSTRUCTIONS 220
3 14 1 STABILITY OF THE SHOVEL 220
3 14 2 SHOVEL OPERATION 220
3 15 PARKING THE SHOVEL 223
3 16 STOPPING THE MAIN DRIVE MOTORS 224
3 17 OPERATION OF THE LUBRICATION SYSTEM 228
3 17 1 CENTRAL LUBRICATION SYSTEM ”CLS” 228
3 17 2 SWING CIRCLE PINION LUBRICATION SYSTEM ”SLS” 230
3 18 TRANSFER PUMP FOR HYDRAULIC OIL 232
3 18 1 OPERATING THE TRANSFER PUMP 233
3 18 2 FUNCTIONS OF THE TRANSFER PUMP 235
3 19 CENTRAL REFILLING SYSTEM 238
3 19 1 SYSTEMS CONNECTED TO THE REFILLING SYSTEM 239
3 19 2 CENTRAL LUBRICATION SYSTEM AND SWING CIRCLE LUBRICATION SYSTEM 243
3 20 CABLE DRUM 244
3 20 1 CABLE DRUM OPERATION 245
3 20 2 TRAVELLING INSTRUCTIONS 247
3 21 SERVICE CRANE 250
3 21 1 OPERATING THE SERVICE CRANE 251
3 22 WORK ON THE LOADER ATTACHMENT 254
3 23 TRANSPORTATION AND LIFTING OF THE SHOVEL 255
3 23 1 DISASSEMBLING OF THE SHOVEL 255
3 23 2 TRANSPORTATION AND LIFTING 255
3 24 RETRIEVAL PROCEDURE 256
3 25 SHOVEL STORAGE 257
3 25 1 PREPARING FOR STORAGE 257
3 25 2 ONE MONTH REPETITIVE SERVICE PERIOD 257
3 25 3 SIX MONTH REPETITIVE SERVICE PERIOD 258
3 25 4 PREPARING FOR OPERATION 258
3 26 TROUBLE SHOOTING 259
3 26 1 MAIN DRIVE MOTOR 259
3 26 2 HYDRAULIC SYSTEM 260
3 26 3 FINAL DRIVES AND SWING GEAR 261
3 26 4 CRAWLER TRACKS 261
4  MAINTENANCE 263
4 1 FOREWORD 264
4 2 PRECAUTIONS FOR MAINTENANCE 265
4 3 LUBRICANTS 266
4 3 1 LUBRICANTS FOR MODERATE AND HOT CLIMATES 266
4 4 FILLING CAPACITIES 270
4 5 STANDARD TORQUE LIST 271
4 6 LUBRICATION AND MAINTENANCE SCHEDULE 272
4 6 1 INITIAL SERVICING 272
4 6 2 PERIODIC SERVICING INTERVALS 272
4 6 3 PERIODIC SERVICING SCHEDULE 273
4 6 4 MAINTENANCE OF THE MAIN DRIVE MOTORS 277
4 7 WHEN NECESSARY 280
4 7 1 SWING CIRCLE TOOTHING LUBRICATION 281
4 7 2 AUTOMATIC LUBRICATION SYSTEMS FILL GREASE CONTAINERS 283
4 7 3 TRACK ROLLERS AND GUIDE WHEELS – REPLACE FLOATING SEALS 287
4 8 EVERY 10 OPERATING HOURS OR DAILY 288
4 8 1 VISUAL INSPECTIONS 289
4 8 2 TRACK GROUPS – CLEAN 297
4 9 EVERY 50 OPERATING HOURS OR WEEKLY 298
4 9 1 SWING GEARS AND MOTOR ADAPTER HOUSINGS – CHECK OIL LEVELS 299
4 9 2 TRAVEL GEARS, BRAKE HOUSINGS AND MOTOR ADAPTER HOUSINGS – CHECK OIL LEVELS 301
4 9 3 PTO’s (PUMP DISTRIBUTOR GEARS) AND OIL RESERVOIR – CHECK OIL LEVEL 307
4 9 4 HYDRAULIC ACCESS LADDER – CHECK SAFETY SENSOR 311
4 9 5 HYDRAULIC OIL COOLERS – INSPECT AND CLEAN IF NECESSARY 313
4 10 EVERY 250 OPERATING HOURS OR MONTHLY 314
4 10 1 UNDERCARRIAGE PIN CONNECTIONS – LUBRICATE 315
4 10 2 SIGNAL HORN COMPRESSOR – LUBRICATE 315
4 10 3 HYDRAULIC OIL COOLER FAN BEARING HOUSINGS – CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER 315
4 10 4 RADIATOR FAN BEARING HOUSINGS – CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER (DIESEL VERSIO 315
4 10 5 AUTOMATIC LUBRICATION SYSTEMS – CLEAN IN-LINE GREASE FILTER 317
4 10 6 CAB AIR CLEANER – CLEAN OR REPLACE FILTER ELEMENT 319
4 10 7 AIR CONDITIONING FOR OPERATOR’S CAB AND SWITCH CABINETS 321
4 10 8 WINDSHIELD WASHER SYSTEM – CHECK FLUID LEVEL 325
4 11 EVERY 500 OPERATING HOURS OR MONTHLY 326
4 11 1 BATTERIES – CHECK FLUID LEVEL 327
4 11 2 CRAWLER TRACK – INSPECTION 329
4 12 EVERY 1000 OPERATING HOURS OR EVERY 6MONTH 334
4 12 1 HIGH STRENGTH BOLT CONNECTIONS – CHECK TORQUE LOAD 335
4 12 2 HYDRAULIC SYSTEM – FILTER SERVICE 383
4 12 3 PTO’S (PUMP DISTRIBUTOR GEARS), SWING GEARS AND TRAVEL GEARS – OIL SAMPLE ANALYSIS 397
4 12 4 SIGNAL HORN COMPRESSOR – CLEAN AND LUBRICATE 399
4 12 5 HYDRAULIC TRACK TENSIONING SYSTEM – CHECK PRESSURE ACCUMULATORS 401
4 12 6 WATER FILTER – REPLACE FILTER CARTRIDGE 403
4 12 7 SLIP RING UNIT – LUBRICATE 405
4 13 EVERY 2000 OPERATING HOURS OR YEARLY 406
4 13 1 HYDRAULIC SYSTEM – CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER 407
4 13 2 EMERGENCY ESCAPE LADDER – INSPECTION 419
4 14 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR 420
4 14 1 SWING GEARS AND MOTOR ADAPTER HOUSING – CHANGE OIL 421
4 14 2 TRAVEL GEARS, BRAKE AND MOTOR ADAPTER HOUSINGS – CHANGE OIL 425
4 14 3 PTO (PUMP DISTRIBUTOR GEAR) – CHANGE OIL 431
4 15 FIRE PREVENTION 434
4 16 REPAIR WELDINGS 436
4 16 1 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE UNDERCARRIAGE 439
4 16 2 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE LOADER ATTACHMENT 441
4 16 3 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE SUPERSTRUCTURE 443
4 16 4 AFTER FINISHING THE REPAIR WELDINGS ON THE SUPERSTRUCTURE 443

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PLEASE NOTE:

• This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
• This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
• Require some other service manual or have any queries: please WRITE to us at [email protected]

I.G