KOMATSU PC5500 EXCAVATOR HYDRAULIC MINING SHOVEL OPERATION & MAINTENANCE MANUAL 15011 – PDF DOWNLOAD

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KOMATSU PC5500 EXCAVATOR HYDRAULIC MINING SHOVEL OPERATION & MAINTENANCE MANUAL 15011 – PDF DOWNLOAD

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DESCRIPTION:

KOMATSU PC5500 EXCAVATOR HYDRAULIC MINING SHOVEL OPERATION & MAINTENANCE MANUAL 15011 – PDF DOWNLOAD

DESIGNATED USE OF THE EXCAVATOR:

• 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 Excavator 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 Excavator.

TABLE OF CONTENTS:

KOMATSU PC5500 EXCAVATOR HYDRAULIC MINING SHOVEL OPERATION & MAINTENANCE MANUAL 15011 – 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 EXCAVATOR 6
1 4 DELIVERY OF THE EXCAVATOR 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 EXCAVATOR 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 EXCAVATOR 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 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 5 OPERATING THE HEATER, VENTILATION AND AIRCONDITIONING 178
3 5 1 A – HEATING 178
3 5 2 B – COOLING 179
3 5 3 COMBINED OPERATION OF AIR CONDITIONING AND HEATING 179
3 6 POWER HOUSE 180
3 6 1 EMERGENCY ENGINE SHUTDOWN SWITCHES 181
3 6 2 CONTROL AND FILTER PANEL OF REAR- AND FRONT POWER UNIT 183
3 7 ELECTRICAL EQUIPMENT IN CAB BASE 184
3 7 1 SWITCH BOARD (X2) IN CAB BASE 187
3 8 CHECKS BEFORE STARTING THE ENGINES 200
3 9 STARTING THE ENGINES 204
3 9 1 STARTING PROCEDURE 207
3 10 MOVING THE EXCAVATOR 215
3 10 1 TRAVEL CONTROL WITH FOOT PEDALS 215
3 10 2 TRAVELLING INSTRUCTIONS 218
3 11 SLEWING AND BRAKING THE SUPERSTRUCTURE 219
3 11 1 SLEWING THE SUPERSTRUCTURE 219
3 12 WORKING WITH THE ATTACHMENT 222
3 12 1 MACHINES EQUIPPED WITH ”EURO” CONTROL SYSTEM 222
3 12 2 MACHINES EQUIPPED WITH ”KMG” CONTROL SYSTEM 223
3 12 3 BOTTOM DUMP BUCKET 224
3 12 4 DROP BALL OPERATION 225
3 12 5 COMBINED OPERATION CYCLES 228
3 13 WORKING INSTRUCTIONS 230
3 13 1 STABILITY OF THE EXCAVATOR 230
3 13 2 EXCAVATOR OPERATION 230
3 14 PARKING THE EXCAVATOR 233
3 15 STOPPING THE ENGINES 234
3 16 OPERATION OF THE LUBRICATION SYSTEM 238
3 16 1 CENTRAL LUBRICATION SYSTEM ”CLS” 238
3 16 2 SWING CIRCLE PINION LUBRICATION SYSTEM ”SLS” 240
3 17 FIRE DETECTION AND SUPPRESSION SYSTEM 242
3 17 1 HIGH LEVEL ALARM ”FIRE” 245
3 17 2 ENGINE SHUT-DOWN THROUGH FUEL SHUT-OFF SOLENOID VALVE 245
3 17 3 ACTUATION MODES OF THE FIRE SUPPRESSION SYSTEM 245
3 17 4 INDICATION OF OPERATIONAL MODES AT CONTROL MODULE, AFTER AUTOMATIC ACTUATION OF THE FIRE S 247
3 17 5 LOCATION OF THE EXTINGUISHING AGENT TANK ASSEMBLIES AND EXPELLANT GAS CARTRIDGES ON POWER 249
3 18 CENTRAL REFILLING SYSTEM 250
3 18 1 SYSTEMS CONNECTED TO THE REFILLING SYSTEM 251
3 18 2 OPERATING THE HYDRAULIC SERVICE ARM 253
3 18 3 RECEIVER PANEL WITH MONITOR BOX 255
3 18 4 REFILLABLE GREASE CONTAINERS OF THE CENTRAL LUBRICATION SYSTEM AND SWING CIRCLE LUBRICATIO 261
3 19 WORK ON THE LOADER ATTACHMENT 262
3 20 TRANSPORTATION AND LIFTING OF THE EXCAVATOR 263
3 20 1 DISASSEMBLING OF THE EXCAVATOR 263
3 20 2 TRANSPORTATION AND LIFTING 263
3 21 RETRIEVAL PROCEDURE 264
3 22 EXCAVATOR STORAGE 265
3 22 1 PREPARING FOR STORAGE 265
3 22 2 ONE MONTH REPETITIVE SERVICE PERIOD 266
3 22 3 SIX MONTH REPETITIVE SERVICE PERIOD 266
3 22 4 PREPARING FOR OPERATION 267
3 23 TROUBLE SHOOTING 268
3 23 1 ENGINE 268
3 23 2 HYDRAULIC SYSTEM 269
3 23 3 FINAL DRIVES AND SWING MACHINERY 270
3 23 4 CRAWLER TRACKS 270
4  MAINTENANCE 271
4 1 FOREWORD 272
4 2 PRECAUTIONS FOR MAINTENANCE 273
4 3 FUEL AND LUBRICANTS 275
4 4 FILLING CAPACITIES 277
4 5 STANDARD TORQUE LIST 278
4 6 LUBRICATION AND MAINTENANCE SCHEDULE 279
4 6 1 INITIAL SERVICING 279
4 6 2 PERIODIC SERVICING INTERVALS 279
4 6 3 PERIODIC SERVICING SCHEDULE 280
4 6 4 MAINTENANCE OF THE ENGINES 286
4 7 WHEN NECESSARY 288
4 7 1 ENGINE AIR CLEANER MAINTENANCE 289
4 7 2 SWING CIRCLE TOOTHING LUBRICATION 293
4 7 3 AUTOMATIC LUBRICATION SYSTEMS FILL GREASE BARRELS 295
4 7 4 TRACK ROLLERS AND GUIDE WHEELS – REPLACE FLOATING SEALS 299
4 7 5 COLD STARTING AID, REPLACE FLUID CYLINDER 301
4 8 EVERY 10 OPERATING HOURS OR DAILY 302
4 8 1 VISUAL INSPECTIONS 303
4 8 2 AIR CLEANER – CLEAN PRE-CLEANER 311
4 8 3 RADIATORS – CHECK COOLANT LEVEL 313
4 8 4 TRACK GROUPS – CLEAN 313
4 9 EVERY 50 OPERATING HOURS OR WEEKLY 314
4 9 1 SWING MACHINERY, BRAKE HOUSINGS AND MOTOR ADAPTER HOUSINGS – CHECK OIL LEVELS 315
4 9 2 TRAVEL GEARS, BRAKE HOUSINGS AND MOTOR ADAPTER HOUSINGS – CHECK OIL LEVELS 319
4 9 3 PTO’s (PUMP DISTRIBUTOR GEARS) AND OIL RESERVOIR – CHECK OIL LEVEL 325
4 9 4 HYDRAULIC ACCESS LADDER – CHECK SAFETY SENSOR 329
4 9 5 HYDRAULIC OIL COOLERS – INSPECT AND CLEAN IF NECESSARY 331
4 10 EVERY 250 OPERATING HOURS OR MONTHLY 332
4 10 1 AIR CONDITIONING COMPRESSOR – CHECK DRIVE BELT TENSION 333
4 10 2 UNDERCARRIAGE PIN CONNECTIONS – LUBRICATE 335
4 10 3 SIGNAL HORN COMPRESSOR – LUBRICATE 335
4 10 4 HYDRAULIC OIL COOLER FAN BEARINGS – CHECK OIL LEVEL 335
4 10 5 RADIATOR FAN BEARINGS – CHECK OIL LEVEL 335
4 10 6 AUTOMATIC LUBRICATION SYSTEMS – CLEAN IN-LINE GREASE FILTER 337
4 10 7 CAB AIR CLEANER – CLEAN OR REPLACE FILTER ELEMENT 341
4 11 EVERY 500 OPERATING HOURS OR MONTHLY 342
4 11 1 BATTERIES – CHECK FLUID LEVEL 343
4 11 2 FLEXIBLE DRIVE COUPLINGS – CHECK OIL LEVEL 345
4 11 3 FUEL TANK – DRAIN CONDENSATION 347
4 11 4 CRAWLER TRACK – INSPECTION 349
4 12 EVERY 1000 OPERATING HOURS OR EVERY 6MONTH 354
4 12 1 HIGH STRENGTH BOLT CONNECTIONS – CHECK TORQUE LOAD 355
4 12 2 HYDRAULIC SYSTEM – FILTER SERVICE 405
4 12 3 PTO’S (PUMP DISTRIBUTOR GEARS), SWING MACHINERY AND TRAVEL GEARS – OIL SAMPLE ANALYSIS 419
4 12 4 SIGNAL HORN COMPRESSOR – CLEAN AND LUBRICATE 421
4 12 5 HYDRAULIC TRACK TENSIONING SYSTEM – CHECK ACCUMULATORS 423
4 12 6 WATER FILTER – REPLACE FILTER CARTRIDGE 425
4 13 EVERY 2000 OPERATING HOURS OR YEARLY 426
4 13 1 HYDRAULIC SYSTEM – CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER 427
4 13 2 EMERGENCY ESCAPE LADDER – INSPECTION 439
4 14 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR 440
4 14 1 SWING MACHINERY, BRAKE AND MOTOR ADAPTER HOUSING – CHANGE OIL 441
4 14 2 TRAVEL GEARS, BRAKE AND MOTOR ADAPTER HOUSINGS – CHANGE OIL 447
4 14 3 PTO (PUMP DISTRIBUTOR GEAR) – CHANGE OIL 453
4 15 FIRE PREVENTION 456
4 16 REPAIR WELDINGS 458
4 16 1 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE UNDERCARRIAGE 461
4 16 2 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE LOADER ATTACHMENT 463
4 16 3 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE SUPERSTRUCTURE 465
4 16 4 AFTER FINISHING THE REPAIR WELDINGS ON THE SUPERSTRUCTURE 467

Customer Support: [email protected]

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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]

I.G