KOMATSU PC5500-6 HYDRAULIC MINING SHOVEL OPERATION & MAINTENANCE MANUAL (SN:15050) KOMATSU PC5500-6

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KOMATSU PC5500-6 HYDRAULIC MINING SHOVEL OPERATION & MAINTENANCE MANUAL (SN:15050) KOMATSU PC5500-6

KOMATSU PC5500-6 HYDRAULIC MINING SHOVEL OPERATION & MAINTENANCE MANUAL (SN:15050) KOMATSU PC5500-6:

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KOMATSU PC5500-6 HYDRAULIC MINING SHOVEL OPERATION & MAINTENANCE MANUAL (SN:15050) KOMATSU PC5500-6

Part 1:
Operation Manual
Part 2:
Lubrication- and Maintenance Manual
Part 3:
Depending on the volume of Part 3 a second Binder “Volume 2” is being delivered with the Shovel. This Binder contains the General Assembly Procedure Manual for the Shovel, Specification Booklet, Service Literature for the Power Unit (Diesel Engine or Electric Motor) and for Special Equipment. The Electrical- and Hydraulic Diagrams are attached in the pocket of the front cover.
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 surestmeans 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

TABLE OF CONTENTS:

KOMATSU PC5500-6 HYDRAULIC MINING SHOVEL OPERATION & MAINTENANCE MANUAL (SN:15050) KOMATSU PC5500-6

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 BOOM ACCESS LADDER AND WALKWAY................................................................ 52
		3.2.6 EMERGENCY MOTOR SHUTDOWN FROM GROUND MAN OR OPERATOR WARNING SYSTEM........................... 54
		3.2.7 OPERATOR’S CAB WITH INTEGRATED FALLING OBJECT PROTECTIVE STRUCTURE (FOPS)..................... 56
	3.3 OPERATOR’S CAB - CONTROLS........................................................................... 68
		3.3.1 CONTROLS WITH BACKHOE ATTACHMENT.............................................................. 68
		3.3.2 CONTROLS WITH BOTTOM DUMP BUCKET ATTACHMENT................................................... 72
		3.3.3 HYDRAULIC CONTROL SYSTEM...................................................................... 73
		3.3.4 SAFETY CIRCUIT FOR CONTROLS................................................................... 73
		3.3.5 OPERATOR’S CONSOLE............................................................................ 77
		3.3.6 CONTROL UNITS FOR FIRE DETECTION, ACTUATION AND SUPPRESSION SYSTEM............................ 87
	3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS........................................................ 88
		3.4.1 INTRODUCTION.................................................................................. 89
		3.4.2 OPERATING THE ELECTRONIC MONITORING SYSTEM.................................................... 97
		3.4.3 AUTOMATIC DISPLAY OF MESSAGES.................................................................102
		3.4.4 MENU CONTROL AND SERVICE FUNCTIONS............................................................128
		3.4.5 MENU CONTROL LIST.............................................................................153
		3.4.6 FAULT AND INFORMATION MESSAGE LIST............................................................170
	3.5 OPERATING THE HEATER, VENTILATION AND AIRCONDITIONING..............................................195
	3.6 MACHINERY HOUSE.....................................................................................199
		3.6.1 EMERGENCY MOTOR SHUTDOWN SWITCHES.............................................................200
		3.6.2 SAFETY SWITCH FOR MAINTENANCE.................................................................202
		3.6.3 CONTROL AND FILTER PANEL OF REAR- AND FRONT POWER UNIT........................................204
	3.7 MEDIUM VOLTAGE SWITCH CABINET IN CAB BASE...........................................................205
		3.7.1 COMPONENTS OF THE MEDIUM VOLTAGE SWITCH CABINET...............................................206
		3.7.2 SWITCH BOARD (X2) IN CAB BASE.................................................................208
		3.7.3 MONITOR AND CONTROL PANEL IN CAB BASE.........................................................219
		3.7.4 SWITCH BOARD - MEDIUM VOLTAGE.................................................................221
		3.7.5 COMPONENTS OF ELECTRICAL PREHEATING SYSTEM IN CAB BASE........................................223
	3.8 HYDRAULIC OIL AND PTO GEAR PRE-HEATING..............................................................226
	3.9 HIGH VOLTAGE SWITCH CABINET.........................................................................228
	3.10 CHECKS BEFORE STARTING THE MAIN DRIVE MOTORS.......................................................230
	3.11 STARTING THE MAIN DRIVE MOTORS.....................................................................234
	3.12 MOVING THE SHOVEL..................................................................................241
		3.12.1 TRAVEL CONTROL WITH FOOT PEDALS..............................................................241
		3.12.2 TRAVELLING INSTRUCTIONS......................................................................244
	3.13 SLEWING AND BRAKING THE SUPERSTRUCTURE.............................................................245
		3.13.1 SLEWING THE SUPERSTRUCTURE...................................................................245
	3.14 WORKING WITH THE ATTACHMENT........................................................................248
		3.14.1 MACHINES EQUIPPED WITH ”EURO” CONTROL SYSTEM.................................................248
		3.14.2 MACHINES EQUIPPED WITH ”KMG” CONTROL SYSTEM..................................................249
		3.14.3 BOTTOM DUMP BUCKET...........................................................................250
		3.14.4 DROP BALL OPERATION..........................................................................251
		3.14.5 COMBINED OPERATION CYCLES....................................................................254
	3.15 WORKING INSTRUCTIONS...............................................................................256
		3.15.1 STABILITY OF THE SHOVEL......................................................................256
		3.15.2 SHOVEL OPERATION.............................................................................256
	3.16 PARKING THE SHOVEL.................................................................................259
	3.17 STOPPING THE MAIN DRIVE MOTORS.....................................................................260
		3.17.1 RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM.....................................................263
	3.18 OPERATION OF THE LUBRICATION SYSTEM................................................................264
		3.18.1 CENTRAL LUBRICATION SYSTEM -CLS- FOR SUPERSTRUCTURE AND ATTACHMENT...........................264
		3.18.2 SWING CIRCLE PINION LUBRICATION SYSTEM ”SLS”.................................................266
	3.19 FIRE DETECTION, ACTUATION AND SUPPRESSION SYSTEM...................................................268
		3.19.1 CONTROL UNITS FOR THE FIRE DETECTION, ACTUATION AND SUPPRESSION SYSTEMS......................269
		3.19.2 REMOTE HIGH LEVEL ALARM *FIRE* LOCATED ON THE CAB............................................273
		3.19.3 ACTUATION MODES OF THE FIRE SUPPRESSION SYSTEM:..............................................273
		3.19.4 IN CASE OF FIRE..............................................................................275
	3.20 TRANSFER PUMP FOR HYDRAULIC OIL....................................................................276
		3.20.1 OPERATING THE TRANSFER PUMP..................................................................277
		3.20.2 FUNCTIONS OF THE TRANSFER PUMP...............................................................279
	3.21 CENTRAL REFILLING SYSTEM...........................................................................282
		3.21.1 SYSTEMS CONNECTED TO THE REFILLING SYSTEM....................................................283
		3.21.2 REFILLABLE GREASE CONTAINERS OF THE AUTOMATIC LUBRICATION SYSTEMS............................287
	3.22 SERVICE CRANE (SPECIAL EQUIPMENT)..................................................................288
		3.22.1 OPERATING THE CRANE..........................................................................289
	3.23 CABLE DRUM.........................................................................................292
		3.23.1 OPERATION OF THE CABLE DRUM..................................................................293
		3.23.2 TRAVELLING INSTRUCTIONS......................................................................297
	3.24 WORK ON THE LOADER ATTACHMENT......................................................................300
	3.25 TRANSPORTATION AND LIFTING OF THE SHOVEL...........................................................301
		3.25.1 DISASSEMBLING OF THE SHOVEL..................................................................301
		3.25.2 TRANSPORTATION AND LIFTING...................................................................301
	3.26 RETRIEVAL PROCEDURE................................................................................302
	3.27 SHOVEL STORAGE.....................................................................................303
		3.27.1 PREPARING FOR STORAGE........................................................................303
		3.27.2 ONE MONTH REPETITIVE SERVICE PERIOD..........................................................303
		3.27.3 SIX MONTH REPETITIVE SERVICE PERIOD..........................................................304
		3.27.4 PREPARING FOR OPERATION......................................................................304
	3.28 TROUBLE SHOOTING...................................................................................305
		3.28.1 MAIN DRIVE ELECTRIC MOTOR....................................................................305
		3.28.2 HYDRAULIC SYSTEM.............................................................................306
		3.28.3 FINAL DRIVES AND SWING GEAR..................................................................307
		3.28.4 CRAWLER TRACKS...............................................................................307
4. MAINTENANCE.............................................................................................309
	4.1 FOREWORD............................................................................................310
	4.2 PRECAUTIONS FOR MAINTENANCE.........................................................................311
	4.3 FLUIDS AND LUBRICANTS...............................................................................313
		4.3.1 LUBRICANTS FOR OPERATION IN COLD AND ARCTIC CLIMATES..........................................313
		4.3.2 FLUIDS AND LUBRICANTS FOR MODERATE AND HOT CLIMATES...........................................314
	4.4 FILLING CAPACITIES..................................................................................318
	4.5 STANDARD TORQUE LIST................................................................................319
	4.6 LUBRICATION AND MAINTENANCE SCHEDULE................................................................320
		4.6.1 INITIAL SERVICING.............................................................................320
		4.6.2 PERIODIC SERVICING INTERVALS..................................................................320
		4.6.3 PERIODIC SERVICING SCHEDULE...................................................................321
		4.6.4 MAINTENANCE OF THE MAIN DRIVE MOTORS..........................................................324
		4.6.5 .PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS................................................328
	4.7 WHEN NECESSARY......................................................................................330
		4.7.1 SWING CIRCLE TOOTHING LUBRICATION.............................................................331
		4.7.2 AUTOMATIC LUBRICATION SYSTEMS FILL GREASE CONTAINERS..........................................333
		4.7.3 TRACK ROLLERS AND GUIDE WHEELS - REPLACE FLOATING SEALS.......................................337
	4.8 EVERY 10 OPERATING HOURS OR DAILY...................................................................338
		4.8.1 WALK - AROUND INSPECTION......................................................................339
		4.8.2 TRACK GROUPS - CLEAN..........................................................................349
	4.9 EVERY 50 OPERATING HOURS OR WEEKLY..................................................................350
		4.9.1 SWING GEARS AND MOTOR ADAPTER HOUSINGS - CHECK OIL LEVELS.....................................351
		4.9.2 TRAVEL GEARS, MOTOR ADAPTER HOUSINGS AND FINAL DRIVES CHECK OIL LEVELS........................355
		4.9.3 PTO’s (PUMP DISTRIBUTOR GEARS) AND OIL RESERVOIR - CHECK OIL LEVEL............................361
		4.9.4 HYDRAULIC ACCESS LADDER - CHECK SAFETY SENSOR.................................................365
		4.9.5 HYDRAULIC OIL COOLERS - INSPECT AND CLEAN IF NECESSARY........................................367
	4.10 EVERY 250 OPERATING HOURS OR MONTHLY...............................................................370
		4.10.1 SIGNAL HORN COMPRESSOR - LUBRICATE...........................................................371
		4.10.2 HYDRAULIC OIL COOLER FAN BEARINGS - CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER..............371
		4.10.3 RADIATOR FAN BEARINGS - CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER (DIESEL VERSION ONLY)....371
		4.10.4 AUTOMATIC LUBRICATION SYSTEMS - CLEAN IN-LINE GREASE FILTER AND CHECK BREATHER FILTER........373
		4.10.5 CAB AIR CLEANER - CLEAN OR REPLACE FILTER ELEMENT............................................375
		4.10.6 AIR CONDITIONING FOR OPERATOR’S CAB AND SWITCH CABINETS......................................379
		4.10.7 WINDSHIELD WASHER SYSTEM - CHECK FLUID LEVEL.................................................383
	4.11 EVERY 500 OPERATING HOURS OR QUARTERLY.............................................................384
		4.11.1 BATTERIES - CHECK FLUID LEVEL................................................................385
		4.11.2 CRAWLER TRACK - INSPECTION...................................................................387
	4.12 EVERY 1000 OPERATING HOURS OR EVERY 6MONTH........................................................392
		4.12.1 HIGH STRENGTH BOLT CONNECTIONS - CHECK TORQUE LOAD...........................................393
		4.12.2 HYDRAULIC SYSTEM - FILTER SERVICE............................................................449
		4.12.3 PTO’S (PUMP DISTRIBUTOR GEARS), SWING GEARS AND TRAVEL GEARS - OIL SAMPLE ANALYSIS...........463
		4.12.4 SIGNAL HORN COMPRESSOR - CLEAN AND LUBRICATE.................................................465
		4.12.5 HYDRAULIC TRACK TENSIONING SYSTEM - CHECK PRESSURE ACCUMULATORS..............................467
		4.12.6 WATER FILTER - REPLACE FILTER CARTRIDGE......................................................469
		4.12.7 HYDRAULIC OIL COOLER - INSPECT AND LUBRICATE DOOR HINGES.....................................471
		4.12.8 MACHINERY HOUSE DOORS - INSPECT AND LUBRICATE DOOR HINGES....................................473
		4.12.9 SLIP RING UNIT - LUBRICATE...................................................................475
	4.13 EVERY 2000 OPERATING HOURS OR YEARLY...............................................................476
		4.13.1 HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER................477
		4.13.2 EMERGENCY ESCAPE LADDER - INSPECTION.........................................................489
	4.14 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR............................................490
		4.14.1 SWING GEARS AND MOTOR ADAPTER HOUSING - CHANGE OIL...........................................491
		4.14.2 TRAVEL GEARS, MOTOR ADAPTER HOUSINGS AND FINAL DRIVES CHANGE OIL.............................499
		4.14.3 PTO (PUMP DISTRIBUTOR GEAR) - CHANGE OIL.....................................................503
	4.15 FIRE PREVENTION....................................................................................506
	4.16 WELD REPAIRS.......................................................................................508
		4.16.1 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE UNDERCARRIAGE........................511
		4.16.2 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE LOADER ATTACHMENT....................513
		4.16.3 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE SUPERSTRUCTURE.......................515
		4.16.4 AFTER FINISHING THE REPAIR WELDINGS ON THE SUPERSTRUCTURE....................................515

PLEASE NOTE:

⦁ This is the SAME exact manual used by your dealers to fix your vehicle.
⦁ The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
⦁ Any queries / doubts regarding your purchase, please feel free to contact [email protected]