KOMATSU PC5500-6 HYDRAULIC MINING SHOVEL OPERATION & MAINTENANCE MANUAL (SN:PC5500-6 15025) KOMATSU PC5500-6 – PDF DOWNLOAD

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KOMATSU PC5500-6 HYDRAULIC MINING SHOVEL OPERATION & MAINTENANCE MANUAL (SN:PC5500-6 15025) KOMATSU PC5500-6

KOMATSU PC5500-6 HYDRAULIC MINING SHOVEL OPERATION & MAINTENANCE MANUAL (SN:PC5500-6 15025) KOMATSU PC5500-6 – PDF DOWNLOAD:

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KOMATSU PC5500-6 HYDRAULIC MINING SHOVEL OPERATION & MAINTENANCE MANUAL (SN:PC5500-6 15025) KOMATSU PC5500-6

● Before beginning work, familiarize yourself with the surroundings and circumstances of the site, such as obstacles in the working and travelling area, the soil bearing capacity and any barriers separating the construction site from public roads.
● Take the necessary precautions to ensure that the machine is used only when in a safe and reliable state. Operate the machine only if all protective and safety-oriented devices, such as re- movable safety devices, emergency shut-off equipment, sound-proofing elements and exhausters, are in place and fully functional.
● Check the machine at least once per working shift for obvious damage and defects. Report any changes (incl. changes in the machine’s working behaviour) to the competent organization/ person immediately. If necessary, stop the machine immediately and lock it.
● In the event of malfunctions, stop the machine immediately and lock it. Have any defects rectified immediately.
● Start the machine from the driver’s seat only.
● During start-up and shut-down procedures always watch the indicators in accordance with the Operation,- Lubrication and Maintenance Manual.
● Before starting up or setting the machine in motion, make sure that nobody is at risk.
● Before starting work or travelling with the machine, check that the braking, steering, signalling and lighting systems are fully functional.
● Before setting the machine in motion always check that the accessories have been safely stowed away.
● When travelling on public roads, ways and places always observe the valid traffic regulations and, if necessary, make sure beforehand that the machine is in a condition compatible with these regulations.
● In conditions of poor visibility and after dark always switch on the lighting system.
● Persons accompanying the driver must be seated on the passenger seat provided for this purpose.
● When crossing underpasses, bridges and tunnels or when passing under overhead lines always make sure that there is sufficient clearance.

TABLE OF CONTENTS:

KOMATSU PC5500-6 HYDRAULIC MINING SHOVEL OPERATION & MAINTENANCE MANUAL (SN:PC5500-6 15025) KOMATSU PC5500-6

MAIN MENU.......................................................................................................  0
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 ENGINE SHUTDOWN FROM GROUND MAN OR OPERATOR WARNING SYSTEM.............................. 52
		3.2.6 OPERATOR’S CAB WITH INTEGRATED FALLING OBJECT PROTECTIVE STRUCTURE (FOPS)......................... 54
		3.2.7 ENGINE OIL MANAGEMENT SYSTEM...................................................................... 62
	3.3 OPERATOR’S CAB - CONTROLS............................................................................... 70
		3.3.1 CONTROLS WITH BACKHOE ATTACHMENT.................................................................. 70
		3.3.2 CONTROLS WITH BOTTOM DUMP BUCKET ATTACHMENT....................................................... 74
	3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS............................................................ 88
	3.5 OPERATING THE HEATER, VENTILATION AND AIRCONDITIONING..................................................192
		3.5.1 A - HEATING.......................................................................................192
		3.5.2 B - COOLING.......................................................................................193
		3.5.3 COMBINED OPERATION OF AIR CONDITIONING AND HEATING................................................193
	3.6 POWER HOUSE.............................................................................................194
		3.6.1 EMERGENCY ENGINE SHUTDOWN SWITCHES................................................................195
		3.6.2 CONTROL AND FILTER PANEL OF REAR- AND FRONT POWER UNIT............................................197
	3.7 ELECTRICAL EQUIPMENT IN CAB BASE........................................................................198
		3.7.1 SWITCH BOARD (X2) IN CAB BASE.....................................................................201
	3.8 CHECKS BEFORE STARTING THE ENGINES......................................................................214
	3.9 STARTING THE ENGINES....................................................................................220
		3.9.1 STARTING PROCEDURE................................................................................223
	3.10 MOVING THE SHOVEL......................................................................................231
		3.10.1 TRAVEL CONTROL WITH FOOT PEDALS..................................................................231
		3.10.2 TRAVELLING INSTRUCTIONS..........................................................................234
	3.11 SLEWING AND BRAKING THE SUPERSTRUCTURE.................................................................235
		3.11.1 SLEWING THE SUPERSTRUCTURE.......................................................................235
	3.12 WORKING WITH THE ATTACHMENT............................................................................238
		3.12.1 MACHINES EQUIPPED WITH ”EURO” CONTROL SYSTEM.....................................................238
		3.12.2 MACHINES EQUIPPED WITH ”KMG” CONTROL SYSTEM......................................................239
		3.12.3 BOTTOM DUMP BUCKET...............................................................................240
		3.12.4 DROP BALL OPERATION..............................................................................241
		3.12.5 COMBINED OPERATION CYCLES........................................................................244
	3.13 WORKING INSTRUCTIONS...................................................................................246
		3.13.1 STABILITY OF THE SHOVEL..........................................................................246
		3.13.2 SHOVEL OPERATION.................................................................................246
	3.14 PARKING THE SHOVEL.....................................................................................249
	3.15 STOPPING THE ENGINES...................................................................................250
	3.16 OPERATION OF THE LUBRICATION SYSTEM....................................................................254
		3.16.1 CENTRAL LUBRICATION SYSTEM ”CLS”.................................................................254
		3.16.2 SWING CIRCLE PINION LUBRICATION SYSTEM ”SLS”.....................................................256
	3.17 FIRE DETECTION AND SUPPRESSION SYSTEM..................................................................258
		3.17.1 HIGH LEVEL ALARM ”FIRE”..........................................................................261
		3.17.2 ENGINE SHUT-DOWN THROUGH FUEL SHUT-OFF SOLENOID VALVE............................................261
		3.17.3 ACTUATION MODES OF THE FIRE SUPPRESSION SYSTEM...................................................261
		3.17.4 INDICATION OF OPERATIONAL MODES AT CONTROL MODULE, AFTER AUTOMATIC ACTUATION OF THE FIRE S.......263
		3.17.5 LOCATION OF THE EXTINGUISHING AGENT TANK ASSEMBLIES AND EXPELLANT GAS CARTRIDGES ON POWER.......265
	3.18 CENTRAL REFILLING SYSTEM...............................................................................266
		3.18.1 SYSTEMS CONNECTED TO THE REFILLING SYSTEM........................................................267
		3.18.2 OPERATING THE HYDRAULIC SERVICE ARM..............................................................269
		3.18.3 RECEIVER PANEL WITH MONITOR BOX..................................................................271
		3.18.4 REFILLABLE GREASE CONTAINERS OF THE AUTOMATIC LUBRICATION SYSTEMS................................277
	3.19 SERVICE CRANE..........................................................................................278
		3.19.1 OPERATING THE CRANE..............................................................................279
	3.20 WORK ON THE LOADER ATTACHMENT..........................................................................282
	3.21 TRANSPORTATION AND LIFTING OF THE SHOVEL...............................................................283
		3.21.1 DISASSEMBLING OF THE SHOVEL......................................................................283
		3.21.2 TRANSPORTATION AND LIFTING.......................................................................283
	3.22 RETRIEVAL PROCEDURE....................................................................................284
	3.23 SHOVEL STORAGE.........................................................................................285
		3.23.1 PREPARING FOR STORAGE............................................................................285
		3.23.2 ONE MONTH REPETITIVE SERVICE PERIOD..............................................................286
		3.23.3 SIX MONTH REPETITIVE SERVICE PERIOD..............................................................286
		3.23.4 PREPARING FOR OPERATION..........................................................................287
	3.24 TROUBLE SHOOTING.......................................................................................288
		3.24.1 ENGINE...........................................................................................288
		3.24.2 HYDRAULIC SYSTEM.................................................................................289
		3.24.3 FINAL DRIVES AND SWING GEAR......................................................................290
		3.24.4 CRAWLER TRACKS...................................................................................290
4. MAINTENANCE.................................................................................................291
	4.1 FOREWORD................................................................................................292
	4.2 PRECAUTIONS FOR MAINTENANCE.............................................................................293
	4.3 FUEL AND LUBRICANTS.....................................................................................295
	4.4 FILLING CAPACITIES......................................................................................297
	4.5 STANDARD TORQUE LIST....................................................................................298
	4.6 LUBRICATION AND MAINTENANCE SCHEDULE....................................................................299
		4.6.1 INITIAL SERVICING.................................................................................299
		4.6.2 PERIODIC SERVICING INTERVALS......................................................................299
		4.6.3 PERIODIC SERVICING SCHEDULE.......................................................................300
		4.6.4 EXTENDED SERVICE INTERVALS FOR ENGINES WITH ENGINE OIL MANAGEMENT SYSTEM..........................307
		4.6.5 RESETTING THE ENGINE OIL BURNING SYSTEM CENTINEL..................................................309
		4.6.6 MAINTENANCE OF THE ENGINES........................................................................311
		4.6.7 ENGINE FUEL FILTER LOCATIONS......................................................................313
	4.7 WHEN NECESSARY..........................................................................................314
		4.7.1 ENGINE AIR CLEANER MAINTENANCE....................................................................315
		4.7.2 SWING CIRCLE TOOTHING LUBRICATION.................................................................319
		4.7.3 AUTOMATIC LUBRICATION SYSTEMS FILL GREASE CONTAINERS..............................................321
		4.7.4 TRACK ROLLERS AND GUIDE WHEELS - REPLACE FLOATING SEALS...........................................325
		4.7.5 COLD STARTING AID, REPLACE FLUID CYLINDER.........................................................327
	4.8 EVERY 10 OPERATING HOURS OR DAILY.......................................................................328
		4.8.1 WALK - AROUND INSPECTION..........................................................................329
		4.8.2 AIR CLEANER - CLEAN PRE-CLEANER...................................................................337
		4.8.3 RADIATORS - CHECK COOLANT LEVEL...................................................................339
		4.8.4 TRACK GROUPS - CLEAN..............................................................................339
	4.9 EVERY 50 OPERATING HOURS OR WEEKLY......................................................................340
		4.9.1 SWING GEARS AND MOTOR ADAPTER HOUSINGS - CHECK OIL LEVELS.........................................341
		4.9.2 TRAVEL GEARS, BRAKE HOUSINGS AND MOTOR ADAPTER HOUSINGS - CHECK OIL LEVELS........................345
		4.9.3 PTO’s (PUMP DISTRIBUTOR GEARS) AND OIL RESERVOIR - CHECK OIL LEVEL................................351
		4.9.4 HYDRAULIC ACCESS LADDER - CHECK SAFETY SENSOR.....................................................355
		4.9.5 HYDRAULIC OIL COOLERS - INSPECT AND CLEAN IF NECESSARY............................................357
	4.10 EVERY 250 OPERATING HOURS OR MONTHLY...................................................................358
		4.10.1 AIR CONDITIONING COMPRESSOR - CHECK DRIVE BELT TENSION...........................................359
		4.10.2 UNDERCARRIAGE PIN CONNECTIONS - LUBRICATE........................................................361
		4.10.3 SIGNAL HORN COMPRESSOR - LUBRICATE...............................................................361
		4.10.4 HYDRAULIC OIL COOLER FAN BEARINGS - CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER..................361
		4.10.5 RADIATOR FAN BEARINGS - CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER..............................361
		4.10.6 AUTOMATIC LUBRICATION SYSTEMS - CLEAN IN-LINE GREASE FILTER AND CHECK BREATHER FILTER............363
		4.10.7 CAB AIR CLEANER - CLEAN OR REPLACE FILTER ELEMENT................................................365
	4.11 EVERY 500 OPERATING HOURS OR MONTHLY...................................................................366
		4.11.1 BATTERIES - CHECK FLUID LEVEL....................................................................367
		4.11.2 FLEXIBLE DRIVE COUPLINGS - CHECK OIL LEVEL.......................................................369
		4.11.3 FUEL TANK - DRAIN CONDENSATION...................................................................371
		4.11.4 CRAWLER TRACK - INSPECTION.......................................................................373
	4.12 EVERY 1000 OPERATING HOURS OR EVERY 6MONTH............................................................378
		4.12.1 HIGH STRENGTH BOLT CONNECTIONS - CHECK TORQUE LOAD...............................................379
		4.12.2 HYDRAULIC SYSTEM - FILTER SERVICE................................................................431
		4.12.3 PTO’S (PUMP DISTRIBUTOR GEARS), SWING GEARS AND TRAVEL GEARS - OIL SAMPLE ANALYSIS...............445
		4.12.4 SIGNAL HORN COMPRESSOR - CLEAN AND LUBRICATE.....................................................447
		4.12.5 HYDRAULIC TRACK TENSIONING SYSTEM - CHECK PRESSURE ACCUMULATORS..................................449
		4.12.6 WATER FILTER - REPLACE FILTER CARTRIDGE..........................................................451
		4.12.7 HYDRAULIC OIL COOLER - INSPECT AND LUBRICATE DOOR HINGES.........................................453
		4.12.8 MACHINERY HOUSE DOORS - INSPECT AND LUBRICATE DOOR HINGES........................................455
	4.13 EVERY 2000 OPERATING HOURS OR YEARLY...................................................................456
		4.13.1 HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER....................457
		4.13.2 EMERGENCY ESCAPE LADDER - INSPECTION.............................................................469
	4.14 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR................................................470
		4.14.1 SWING GEARS AND MOTOR ADAPTER HOUSING - CHANGE OIL...............................................471
		4.14.2 TRAVEL GEARS, BRAKE AND MOTOR ADAPTER HOUSINGS - CHANGE OIL......................................479
		4.14.3 PTO (PUMP DISTRIBUTOR GEAR) - CHANGE OIL.........................................................485
	4.15 FIRE PREVENTION........................................................................................488
	4.16 REPAIR WELDINGS........................................................................................490
		4.16.1 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE UNDERCARRIAGE............................493
		4.16.2 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE LOADER ATTACHMENT........................495
		4.16.3 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE SUPERSTRUCTURE...........................497
		4.16.4 AFTER FINISHING THE REPAIR WELDINGS ON THE SUPERSTRUCTURE........................................499

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