Komatsu Pc5500-6 Hydraulic Mining Shovel Operation & Maintenance Manual SN 15036 – PDF DOWNLOAD

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Komatsu Pc5500-6 Hydraulic Mining Shovel Operation & Maintenance Manual

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Komatsu Pc5500-6 Hydraulic Mining Shovel Operation & Maintenance Manual

Model Specification: KOMATSU PC5500-6 HYDRAULIC MINING SHOVEL
Language: English
File Format: PDF
Total Pages: 515
Requirements: Adobe PDF Reader
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KOMATSU PC5500-6 HYDRAULIC MINING SHOVEL OPERATION & MAINTENANCE MANUAL SN 15036 – PDF DOWNLOAD:

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DESCRIPTION:

Komatsu Pc5500-6 Hydraulic Mining Shovel Operation & Maintenance Manual

Read the Manuals before You Start the Engines.

Before operating the machine, familiarize yourself with its instruments and controls.

Observe the instructions in these manuals for:

• your Personal SAFETY
•  Operating SAFETY, and
• READY and EFFICIENT PERFORMANCE of your KOMATSU Hydraulic Mining Shovel.

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 wfll prevent failures and avoid expenses.

 DESIGNATED USE OF THE SHOVEL:

• This machine has been manufactured in accordance with advanced and up-to-date technology standards inclucfing recog- nized safety rules. Nevertheless, its use may constitute a risk to life and limb ofthe 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 afiecting the safety of the machine, should, therefore, w 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 com- paan safety instructions. Short travefing cfistances for changing the working site are considered as part of the designated use of the Shovel.
• Using the Shovel for purposes other than those mentioned above (such as object handling and use as a transport vehicle) is consid- ered contrary to its designated use. The manufacturer/supplier cannot be held liable for any damage resulting from such use. The risk of such misuse lies entirely with the user.

TABLE OF CONTENTS:

Komatsu Pc5500-6 Hydraulic Mining Shovel Operation & Maintenance Manual

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 ABBREVIATIONS............................................................................  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............................................................................... 64
		3.3.1 CONTROLS WITH BACKHOE ATTACHMENT.................................................................. 64
		3.3.2 CONTROLS WITH BOTTOM DUMP BUCKET ATTACHMENT....................................................... 68
		3.3.3 OPERATOR’S CONSOLE................................................................................ 73
		3.3.4 CONTROL UNITS FOR FIRE DETECTION, ACTUATION AND SUPPRESSION SYSTEMS............................... 83
	3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS............................................................ 84
		3.4.1 INTRODUCTION...................................................................................... 85
		3.4.2 OPERATING THE ELECTRONIC MONITORING SYSTEM........................................................ 93
		3.4.3 AUTOMATIC DISPLAY OF MESSAGES..................................................................... 97
		3.4.4 MENU CONTROL AND SERVICE FUNCTIONS................................................................121
		3.4.5 MENU CONTROL LIST.................................................................................146
		3.4.6 FAULT AND INFORMATION MESSAGE LIST................................................................163
	3.5 CAMERA SYSTEM WITH MONITORS.............................................................................188
		3.5.1 LOCATION OF MONITORS AND CONTROL UNITS............................................................189
	3.6 OPERATING THE HEATER, VENTILATION AND AIRCONDITIONING..................................................196
		3.6.1 A - HEATING.......................................................................................196
		3.6.2 B - COOLING.......................................................................................197
		3.6.3 COMBINED OPERATION OF AIR CONDITIONING AND HEATING................................................197
	3.7 MACHINERY HOUSE.........................................................................................198
		3.7.1 EMERGENCY MOTOR SHUTDOWN SWITCHES.................................................................199
		3.7.2 SAFETY SWITCH FOR MAINTENANCE.....................................................................201
		3.7.3 CONTROL AND FILTER PANEL OF REAR- AND FRONT POWER UNIT............................................203
	3.8 MEDIUM VOLTAGE SWITCH CABINET IN CAB BASE...............................................................204
		3.8.1 COMPONENTS OF THE MEDIUM VOLTAGE SWITCH CABINET...................................................205
		3.8.2 SWITCH BOARD (X2) IN CAB BASE.....................................................................207
		3.8.3 MONITOR AND CONTROL PANEL IN CAB BASE.............................................................217
		3.8.4 SWITCH BOARD - MEDIUM VOLTAGE.....................................................................219
	3.9 HIGH VOLTAGE SWITCH CABINET.............................................................................220
	3.10 CHECKS BEFORE STARTING THE MAIN DRIVE MOTORS...........................................................222
	3.11 STARTING THE MAIN DRIVE MOTORS.........................................................................226
	3.12 MOVING THE SHOVEL......................................................................................233
		3.12.1 TRAVEL CONTROL WITH FOOT PEDALS..................................................................233
		3.12.2 TRAVELLING INSTRUCTIONS..........................................................................236
	3.13 SLEWING AND BRAKING THE SUPERSTRUCTURE.................................................................237
		3.13.1 SLEWING THE SUPERSTRUCTURE.......................................................................237
	3.14 WORKING WITH THE ATTACHMENT............................................................................240
		3.14.1 MACHINES EQUIPPED WITH ”EURO” CONTROL SYSTEM.....................................................240
		3.14.2 MACHINES EQUIPPED WITH ”KMG” CONTROL SYSTEM......................................................241
		3.14.3 BOTTOM DUMP BUCKET...............................................................................242
		3.14.4 DROP BALL OPERATION..............................................................................243
		3.14.5 COMBINED OPERATION CYCLES........................................................................246
	3.15 WORKING INSTRUCTIONS...................................................................................248
		3.15.1 STABILITY OF THE SHOVEL..........................................................................248
		3.15.2 SHOVEL OPERATION.................................................................................248
	3.16 PARKING THE SHOVEL.....................................................................................251
	3.17 STOPPING THE MAIN DRIVE MOTORS.........................................................................252
		3.17.1 RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM.........................................................255
	3.18 OPERATION OF THE LUBRICATION SYSTEM....................................................................256
		3.18.1 CENTRAL LUBRICATION SYSTEM -CLS- FOR SUPERSTRUCTURE AND ATTACHMENT...............................256
		3.18.2 SWING CIRCLE PINION LUBRICATION SYSTEM ”SLS”.....................................................258
	3.19 FIRE DETECTION, ACTUATION AND SUPPRESSION SYSTEMS......................................................260
		3.19.1 CONTROL UNITS FOR THE FIRE DETECTION, ACTUATION AND SUPPRESSION SYSTEMS..........................261
		3.19.2 REMOTE HIGH LEVEL ALARM *FIRE* LOCATED ON THE CAB................................................267
		3.19.3 ACTUATION MODE OF THE CARBON DIOXIDE FIRE SUPPRESSION SYSTEM.....................................267
		3.19.4 IN CASE OF FIRE..................................................................................269
		3.19.5 ACTUATION MODE OF THE DRY CHEMICAL POWDER FIRE SUPPRESSION SYSTEM................................271
		3.19.6 LOCATION OF THE EXTINGUISHING AGENT TANKS AND EXPELLANT GAS CARTRIDGES ON MACHINERY HOUSE.......273
	3.20 TRANSFER PUMP FOR HYDRAULIC OIL........................................................................274
		3.20.1 OPERATING THE TRANSFER PUMP......................................................................275
		3.20.2 FUNCTIONS OF THE TRANSFER PUMP...................................................................277
	3.21 CENTRAL REFILLING SYSTEM...............................................................................280
		3.21.1 SYSTEMS CONNECTED TO THE REFILLING SYSTEM........................................................281
		3.21.2 REFILLABLE GREASE CONTAINERS OF THE AUTOMATIC LUBRICATION SYSTEMS................................285
	3.22 CABLE DRUM.............................................................................................286
		3.22.1 OPERATION OF THE CABLE DRUM......................................................................287
		3.22.2 TRAVELLING INSTRUCTIONS..........................................................................291
	3.23 FOLDING PEDESTEL ON THE OPERATOR’S CAB.................................................................294
	3.24 SERVICE CRANE (SPECIAL EQUIPMENT)......................................................................298
		3.24.1 OPERATING THE CRANE..............................................................................299
	3.25 WORK ON THE LOADER ATTACHMENT..........................................................................302
	3.26 TRANSPORTATION AND LIFTING OF THE SHOVEL...............................................................303
		3.26.1 DISASSEMBLING OF THE SHOVEL......................................................................303
		3.26.2 TRANSPORTATION AND LIFTING.......................................................................303
	3.27 RETRIEVAL PROCEDURE....................................................................................304
	3.28 SHOVEL STORAGE.........................................................................................305
		3.28.1 PREPARING FOR STORAGE............................................................................305
		3.28.2 ONE MONTH REPETITIVE SERVICE PERIOD..............................................................305
		3.28.3 SIX MONTH REPETITIVE SERVICE PERIOD..............................................................306
		3.28.4 PREPARING FOR OPERATION..........................................................................306
	3.29 TROUBLE SHOOTING.......................................................................................307
		3.29.1 MAIN DRIVE ELECTRIC MOTOR........................................................................307
		3.29.2 HYDRAULIC SYSTEM.................................................................................308
		3.29.3 FINAL DRIVES AND SWING GEAR......................................................................309
		3.29.4 CRAWLER TRACKS...................................................................................309
4. MAINTENANCE.................................................................................................311
	4.1 FOREWORD................................................................................................312
	4.2 PRECAUTIONS FOR MAINTENANCE.............................................................................313
	4.3 FUEL AND LUBRICANTS.....................................................................................315
	4.4 FILLING CAPACITIES......................................................................................319
	4.5 STANDARD TORQUE LIST....................................................................................320
	4.6 LUBRICATION AND MAINTENANCE SCHEDULE....................................................................321
		4.6.1 INITIAL SERVICING.................................................................................321
		4.6.2 PERIODIC SERVICING INTERVALS......................................................................321
		4.6.3 PERIODIC SERVICING SCHEDULE.......................................................................322
		4.6.4 MAINTENANCE OF THE MAIN DRIVE MOTORS..............................................................325
	4.7 WHEN NECESSARY..........................................................................................328
		4.7.1 SWING CIRCLE TOOTHING LUBRICATION.................................................................329
		4.7.2 AUTOMATIC LUBRICATION SYSTEMS FILL GREASE CONTAINERS..............................................331
		4.7.3 TRACK ROLLERS AND GUIDE WHEELS - REPLACE FLOATING SEALS...........................................335
	4.8 EVERY 10 OPERATING HOURS OR DAILY.......................................................................336
		4.8.1 WALK - AROUND INSPECTION..........................................................................337
		4.8.2 TRACK GROUPS - CLEAN..............................................................................347
	4.9 EVERY 50 OPERATING HOURS OR WEEKLY......................................................................348
		4.9.1 SWING GEARS AND MOTOR ADAPTER HOUSINGS - CHECK OIL LEVELS.........................................349
		4.9.2 TRAVEL GEARS, MOTOR ADAPTER HOUSINGS AND FINAL DRIVES CHECK OIL LEVELS............................353
		4.9.3 PTO’s (PUMP DISTRIBUTOR GEARS) AND OIL RESERVOIR - CHECK OIL LEVEL................................359
		4.9.4 HYDRAULIC ACCESS LADDER - CHECK SAFETY SENSOR.....................................................363
		4.9.5 HYDRAULIC OIL COOLERS - INSPECT AND CLEAN IF NECESSARY............................................365
	4.10 EVERY 250 OPERATING HOURS OR MONTHLY...................................................................366
		4.10.1 SIGNAL HORN COMPRESSOR - LUBRICATE...............................................................367
		4.10.2 HYDRAULIC OIL COOLER FAN BEARINGS - CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER..................367
		4.10.3 RADIATOR FAN BEARINGS - CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER (DIESEL VERSION ONLY)........367
		4.10.4 AUTOMATIC LUBRICATION SYSTEMS - CLEAN IN-LINE GREASE FILTER AND CHECK BREATHER FILTER............369
		4.10.5 CAB AIR CLEANER - CLEAN OR REPLACE FILTER ELEMENT................................................371
		4.10.6 AIR CONDITIONING FOR OPERATOR’S CAB AND SWITCH CABINETS..........................................373
		4.10.7 WINDSHIELD WASHER SYSTEM - CHECK FLUID LEVEL.....................................................377
	4.11 EVERY 500 OPERATING HOURS OR QUARTERLY.................................................................378
		4.11.1 BATTERIES - CHECK FLUID LEVEL....................................................................379
		4.11.2 CRAWLER TRACK - INSPECTION.......................................................................381
	4.12 EVERY 1000 OPERATING HOURS OR EVERY 6MONTH............................................................386
		4.12.1 HIGH STRENGTH BOLT CONNECTIONS - CHECK TORQUE LOAD...............................................387
		4.12.2 HYDRAULIC SYSTEM - FILTER SERVICE................................................................443
		4.12.3 PTO’S (PUMP DISTRIBUTOR GEARS), SWING GEARS AND TRAVEL GEARS - OIL SAMPLE ANALYSIS...............457
		4.12.4 SIGNAL HORN COMPRESSOR - CLEAN AND LUBRICATE.....................................................459
		4.12.5 HYDRAULIC TRACK TENSIONING SYSTEM - CHECK PRESSURE ACCUMULATORS..................................461
		4.12.6 WATER FILTER - REPLACE FILTER CARTRIDGE..........................................................463
		4.12.7 HYDRAULIC OIL COOLER - INSPECT AND LUBRICATE DOOR HINGES.........................................465
		4.12.8 MACHINERY HOUSE DOORS - INSPECT AND LUBRICATE DOOR HINGES........................................467
		4.12.9 SLIP RING UNIT - LUBRICATE.......................................................................469
	4.13 EVERY 2000 OPERATING HOURS OR YEARLY...................................................................470
		4.13.1 HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER....................471
		4.13.2 EMERGENCY ESCAPE LADDER - INSPECTION.............................................................483
	4.14 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR................................................484
		4.14.1 SWING GEARS AND MOTOR ADAPTER HOUSING - CHANGE OIL...............................................485
		4.14.2 TRAVEL GEARS, MOTOR ADAPTER HOUSINGS AND FINAL DRIVES CHANGE OIL.................................493
		4.14.3 PTO (PUMP DISTRIBUTOR GEAR) - CHANGE OIL.........................................................497
	4.15 FIRE PREVENTION........................................................................................500
	4.16 WELD REPAIRS...........................................................................................502
		4.16.1 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE UNDERCARRIAGE............................505
		4.16.2 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE LOADER ATTACHMENT........................507
		4.16.3 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE SUPERSTRUCTURE...........................509
		4.16.4 AFTER FINISHING THE REPAIR WELDINGS ON THE SUPERSTRUCTURE........................................509

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