Komatsu Pc5500-6 Mining Hydraulic Shovel Shop Manual SN 15039 – PDF DOWNLOAD

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Komatsu Pc5500-6 Mining Hydraulic Shovel Shop Manual

FILE DETAILS:

Komatsu Pc5500-6 Mining Hydraulic Shovel Shop Manual 

Size : 10.8 MB
Format : PDF
Language : English
Brand: Komatsu
Type of machine: Hydraulic Mining Shovel
Type of document: Operation & Maintenance Manual
Model: PC5500-6
Serial: 15039 and up
Number of Pages : 530 Pages

KOMATSU PC5500-6 MINING HYDRAULIC SHOVEL SHOP MANUAL SN 15039 – PDF DOWNLOAD:

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Komatsu Pc5500-6 Mining Hydraulic Shovel Shop 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 Mining Hydraulic Shovel Shop Manual 

MAIN MENU.......................................................................................................  0
COVER PAGE......................................................................................................  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 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...................................................................... 64
	3.3 OPERATOR’S CAB - CONTROLS............................................................................... 72
		3.3.1 CONTROLS WITH BACKHOE ATTACHMENT.................................................................. 72
		3.3.2 CONTROLS WITH BOTTOM DUMP BUCKET ATTACHMENT....................................................... 76
		3.3.3 OPERATOR’S CONSOLE................................................................................ 81
		3.3.4 INTERFACE PANEL FOR DIAGNOSTICS AND CONTROLS FOR HEATING AND AIR CONDITIONING..................... 89
	3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS............................................................ 92
		3.4.1 INTRODUCTION...................................................................................... 93
		3.4.2 OPERATING THE ELECTRONIC MONITORING SYSTEM........................................................101
		3.4.3 AUTOMATIC DISPLAY OF MESSAGES.....................................................................105
		3.4.4 MENU CONTROL AND SERVICE FUNCTIONS................................................................129
		3.4.5 MENU CONTROL LIST.................................................................................154
		3.4.6 FAULT AND INFORMATION MESSAGE LIST................................................................172
	3.5 OPERATING THE HEATER, VENTILATION AND AIRCONDITIONING..................................................196
		3.5.1 A - HEATING.......................................................................................197
		3.5.2 B - COOLING.......................................................................................197
		3.5.3 COMBINED OPERATION OF AIR CONDITIONING AND HEATING................................................197
		3.5.4 AUXILIARY HEATER FOR OPERATOR’S CAB...............................................................199
	3.6 MACHINERY HOUSE.........................................................................................200
		3.6.1 EMERGENCY ENGINE SHUTDOWN SWITCHES................................................................201
		3.6.2 SAFETY SWITCH FOR MAINTENANCE.....................................................................203
		3.6.3 CONTROL AND FILTER PANEL OF REAR- AND FRONT POWER UNIT............................................205
	3.7 ELECTRICAL EQUIPMENT IN CAB BASE........................................................................206
		3.7.1 STANDARD COMPONENTS IN CAB BASE...................................................................207
		3.7.2 SWITCH BOARD (X2) IN CAB BASE.....................................................................209
		3.7.3 CENSE ENGINE MONITORING SYSTEM....................................................................215
		3.7.4 COMPONENTS OF ELECTRICAL PREHEATING SYSTEM IN CAB BASE............................................221
	3.8 PREHEATING SYSTEMS FOR OIL, COOLANT AND BATTERIES.......................................................224
	3.9 CHECKS BEFORE STARTING THE ENGINES......................................................................230
	3.10 STARTING THE ENGINES...................................................................................236
		3.10.1 STARTING PROCEDURE...............................................................................239
	3.11 MOVING THE SHOVEL......................................................................................247
		3.11.1 TRAVEL CONTROL WITH FOOT PEDALS..................................................................247
		3.11.2 TRAVELLING INSTRUCTIONS..........................................................................250
	3.12 SLEWING AND BRAKING THE SUPERSTRUCTURE.................................................................251
		3.12.1 SLEWING THE SUPERSTRUCTURE.......................................................................251
	3.13 WORKING WITH THE ATTACHMENT............................................................................254
		3.13.1 MACHINES EQUIPPED WITH ”EURO” CONTROL SYSTEM.....................................................254
		3.13.2 MACHINES EQUIPPED WITH ”KMG” CONTROL SYSTEM......................................................255
		3.13.3 BOTTOM DUMP BUCKET...............................................................................256
		3.13.4 DROP BALL OPERATION..............................................................................257
		3.13.5 COMBINED OPERATION CYCLES........................................................................260
	3.14 WORKING INSTRUCTIONS...................................................................................262
		3.14.1 STABILITY OF THE SHOVEL..........................................................................262
		3.14.2 SHOVEL OPERATION.................................................................................262
	3.15 PARKING THE SHOVEL.....................................................................................265
	3.16 STOPPING THE ENGINES...................................................................................266
		3.16.1 RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM.........................................................269
	3.17 OPERATION OF THE LUBRICATION SYSTEM....................................................................270
		3.17.1 CENTRAL LUBRICATION SYSTEM -CLS- FOR SUPERSTRUCTURE AND ATTACHMENT...............................270
		3.17.2 SWING CIRCLE PINION LUBRICATION SYSTEM ”SLS”.....................................................272
	3.18 FIRE DETECTION AND SUPPRESSION SYSTEM..................................................................274
		3.18.1 HIGH LEVEL ALARM ”FIRE”..........................................................................277
		3.18.2 ENGINE SHUT-DOWN THROUGH FUEL SHUT-OFF SOLENOID VALVE............................................277
		3.18.3 ACTUATION MODES OF THE FIRE SUPPRESSION SYSTEM...................................................277
		3.18.4 INDICATION OF OPERATIONAL MODES AT CONTROL MODULE, AFTER AUTOMATIC ACTUATION OF THE FIRE S.......279
		3.18.5 LOCATION OF THE EXTINGUISHING AGENT TANK ASSEMBLIES AND EXPELLANT GAS CARTRIDGES ON POWER.......281
	3.19 TRANSFER PUMP FOR HYDRAULIC OIL........................................................................282
		3.19.1 OPERATING THE TRANSFER PUMP......................................................................283
		3.19.2 FUNCTIONS OF THE TRANSFER PUMP...................................................................285
	3.20 CENTRAL REFILLING SYSTEM...............................................................................288
		3.20.1 SYSTEMS CONNECTED TO THE REFILLING SYSTEM........................................................289
		3.20.2 OPERATING THE HYDRAULIC SERVICE ARM..............................................................291
		3.20.3 RECEIVER PANEL WITH MONITOR BOX..................................................................293
		3.20.4 REFILLABLE GREASE CONTAINERS OF THE AUTOMATIC LUBRICATION SYSTEMS................................299
	3.21 SERVICE CRANE (SPECIAL EQUIPMENT)......................................................................300
		3.21.1 OPERATING THE CRANE..............................................................................301
	3.22 WORK ON THE LOADER ATTACHMENT..........................................................................304
	3.23 TRANSPORTATION AND LIFTING OF THE SHOVEL...............................................................305
		3.23.1 DISASSEMBLING OF THE SHOVEL......................................................................305
		3.23.2 TRANSPORTATION AND LIFTING.......................................................................305
	3.24 RETRIEVAL PROCEDURE....................................................................................306
	3.25 SHOVEL STORAGE.........................................................................................307
		3.25.1 PREPARING FOR STORAGE............................................................................307
		3.25.2 ONE MONTH REPETITIVE SERVICE PERIOD..............................................................308
		3.25.3 SIX MONTH REPETITIVE SERVICE PERIOD..............................................................308
		3.25.4 PREPARING FOR OPERATION..........................................................................309
	3.26 TROUBLE SHOOTING.......................................................................................310
		3.26.1 ENGINE...........................................................................................310
		3.26.2 HYDRAULIC SYSTEM.................................................................................311
		3.26.3 FINAL DRIVES AND SWING GEAR......................................................................312
		3.26.4 CRAWLER TRACKS...................................................................................312
4. MAINTENANCE.................................................................................................313
	4.1 FOREWORD................................................................................................314
	4.2 PRECAUTIONS FOR MAINTENANCE.............................................................................315
	4.3 FUEL AND LUBRICANTS.....................................................................................317
	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 EXTENDED SERVICE INTERVALS FOR ENGINES WITH ENGINE OIL MANAGEMENT SYSTEM..........................329
		4.6.5 RESETTING THE ENGINE OIL BURNING SYSTEM CENTINEL..................................................331
		4.6.6 MAINTENANCE OF THE ENGINES........................................................................333
		4.6.7 ENGINE FUEL FILTER LOCATIONS......................................................................335
	4.7 WHEN NECESSARY..........................................................................................336
		4.7.1 ENGINE AIR CLEANER MAINTENANCE....................................................................337
		4.7.2 SWING CIRCLE TOOTHING LUBRICATION.................................................................341
		4.7.3 AUTOMATIC LUBRICATION SYSTEMS FILL GREASE CONTAINERS..............................................343
		4.7.4 TRACK ROLLERS AND GUIDE WHEELS - REPLACE FLOATING SEALS...........................................347
		4.7.5 COLD STARTING AID, REPLACE FLUID CYLINDER.........................................................349
	4.8 EVERY 10 OPERATING HOURS OR DAILY.......................................................................350
		4.8.1 WALK - AROUND INSPECTION..........................................................................351
		4.8.2 AIR CLEANER - CLEAN PRE-CLEANER...................................................................359
		4.8.3 RADIATORS - CHECK COOLANT LEVEL...................................................................361
		4.8.4 TRACK GROUPS - CLEAN..............................................................................361
	4.9 EVERY 50 OPERATING HOURS OR WEEKLY......................................................................362
		4.9.1 SWING GEARS AND MOTOR ADAPTER HOUSINGS - CHECK OIL LEVELS.........................................363
		4.9.2 TRAVEL GEARS, MOTOR ADAPTER HOUSINGS AND FINAL DRIVES CHECK OIL LEVELS............................367
		4.9.3 PTO’s (PUMP DISTRIBUTOR GEARS) AND OIL RESERVOIR - CHECK OIL LEVEL................................373
		4.9.4 HYDRAULIC ACCESS LADDER - CHECK SAFETY SENSOR.....................................................377
		4.9.5 HYDRAULIC OIL COOLERS - INSPECT AND CLEAN IF NECESSARY............................................379
	4.10 EVERY 250 OPERATING HOURS OR MONTHLY...................................................................380
		4.10.1 AIR CONDITIONING COMPRESSOR - CHECK DRIVE BELT TENSION...........................................381
		4.10.2 SIGNAL HORN COMPRESSOR - LUBRICATE...............................................................383
		4.10.3 HYDRAULIC OIL COOLER FAN BEARINGS - CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER..................383
		4.10.4 RADIATOR FAN BEARINGS - CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER..............................383
		4.10.5 AUTOMATIC LUBRICATION SYSTEMS - CLEAN IN-LINE GREASE FILTER AND CHECK BREATHER FILTER............385
		4.10.6 CAB AIR CLEANER - CLEAN OR REPLACE FILTER ELEMENT................................................387
		4.10.7 AIR CONDITIONING FOR OPERATOR’S CAB - CHECK REFRIGERANT LEVEL....................................389
		4.10.8 WINDWHIELD WASHER SYSTEM - CHECK FLUID LEVEL.....................................................391
	4.11 EVERY 500 OPERATING HOURS OR QUARTERLY.................................................................392
		4.11.1 BATTERIES - CHECK FLUID LEVEL....................................................................393
		4.11.2 FLEXIBLE DRIVE COUPLINGS - CHECK OIL LEVEL.......................................................395
		4.11.3 FUEL TANK - DRAIN CONDENSATION...................................................................397
		4.11.4 CRAWLER TRACK - INSPECTION.......................................................................399
	4.12 EVERY 1000 OPERATING HOURS OR EVERY 6MONTH............................................................404
		4.12.1 HIGH STRENGTH BOLT CONNECTIONS - CHECK TORQUE LOAD...............................................405
		4.12.2 HYDRAULIC SYSTEM - FILTER SERVICE................................................................463
		4.12.3 PTO’S (PUMP DISTRIBUTOR GEARS), SWING GEARS AND TRAVEL GEARS - OIL SAMPLE ANALYSIS...............477
		4.12.4 SIGNAL HORN COMPRESSOR - CLEAN AND LUBRICATE.....................................................479
		4.12.5 HYDRAULIC TRACK TENSIONING SYSTEM - CHECK PRESSURE ACCUMULATORS..................................481
		4.12.6 WATER FILTER - REPLACE FILTER CARTRIDGE..........................................................483
		4.12.7 HYDRAULIC OIL COOLER - INSPECT AND LUBRICATE DOOR HINGES.........................................485
		4.12.8 MACHINERY HOUSE DOORS - INSPECT AND LUBRICATE DOOR HINGES........................................487
	4.13 EVERY 2000 OPERATING HOURS OR YEARLY...................................................................488
		4.13.1 HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER....................489
		4.13.2 EMERGENCY ESCAPE LADDER - INSPECTION.............................................................501
	4.14 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR................................................502
		4.14.1 SWING GEARS AND MOTOR ADAPTER HOUSING - CHANGE OIL...............................................503
		4.14.2 TRAVEL GEARS, MOTOR ADAPTER HOUSINGS AND FINAL DRIVES CHANGE OIL.................................511
		4.14.3 PTO (PUMP DISTRIBUTOR GEAR) - CHANGE OIL.........................................................515
	4.15 FIRE PREVENTION........................................................................................518
	4.16 WELD REPAIRS...........................................................................................520
		4.16.1 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE UNDERCARRIAGE............................523
		4.16.2 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE LOADER ATTACHMENT........................525
		4.16.3 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE SUPERSTRUCTURE...........................527
		4.16.4 AFTER FINISHING THE REPAIR WELDINGS ON THE SUPERSTRUCTURE........................................529

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