Komatsu Hydraulic Mining Shovel PC5500-6 Operation & Maintenance Manual – PDF DOWNLOAD

Komatsu Hydraulic Mining Shovel PC5500-6 Operation & Maintenance Manual – PDF DOWNLOAD

DESCRIPTION:

Komatsu Hydraulic Mining Shovel PC5500-6 Operation & Maintenance Manual – PDF DOWNLOAD

SERIAL NUMBER 15016

FOREWORD
This Operation Manual contains the instructions for correct operation
of your KOMATSU Shovel. It should always be ready for use
in the Operator’s cab.
WARNING
The information in this manual does not replace any safety
rules or laws used in your area.
Special safety regulations are given in the rules for the prevention
of accidents. It is your responsibility to observe these rules.
Carefully read the Safety Instructions → See “SAFETY”
on page 15.
Before operating the machine, familiarize yourself with its instruments
and controls.
Observe the instructions in this manual for:

your Personal SAFETY

Operating SAFETY, and

READY and EFFICIENT PERFORMANCE of your
KOMATSU Shovel.

WARNING
Improper operation of this machine can cause injury or
death.
NOTICE
Optional equipment and accessories are available. Disregard
the instructions for equipment not on your Shovel.

SAFETY INSTRUCTIONS
2.1.1 WARNINGS AND SYMBOLS
The following signs and designations are used in the manual to
designate in-structions of particular importance.
WARNING
Refers to orders and prohibitions designed to prevent injury
or extensive damage.
CAUTION
Refers to special information and/or orders and prohibitions
directed towards preventing damage.

TABLE OF CONTENTS:

Komatsu Hydraulic Mining Shovel PC5500-6 Operation & Maintenance Manual – PDF DOWNLOAD

 TABLE OF CONTENTS
1 INTRODUCTION 3
11 CONTENTS OF THE BINDER 4
12 DIVISION OF THE BINDER 5
13 DESIGNATED USE OF THE SHOVEL 6
14 DELIVERY OF THE SHOVEL 7
15 EXPLANATION OF ABBREVATIONS 8
16 TABLE OF CONTENTS 9
2 SAFETY 15
21 SAFETY INSTRUCTIONS 16
211 WARNINGS AND SYMBOLS 16
212 BASIC OPERATION AND DESIGNATED USE OF THE HYDRAULIC SHOVEL 16
213 ORGANIZATIONAL MEASURES 17
214 SELECTION AND QUALIFICATION OF PERSONNEL – BASIC RESPONSIBILITIES 19
215 SAFETY INSTRUCTIONS GOVERNING SPECIFIC OPERATIONAL PHASES 20
216 WARNING OF SPECIAL DANGERS 23
217 TRANSPORTING AND TOWING -RECOMMISSIONING 25
218 SPECIAL SAFETY EQUIPMENT 25
219 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD) 29
3 OPERATION 37
31 FOREWORD 38
32 CONSTRUCTION OF THE SHOVEL 39
321 OVERALL VIEW 39
322 UNDERCARRIAGE AND SUPERSTRUCTURE 40
323 HYDRAULICALLY OPERATED ACCESS LADDER 46
324 EMERGENCY ESCAPE LADDER 50
325 EMERGENCY MOTOR SHUTDOWN FROM GROUND MAN OR OPERATOR WARNING
SYSTEM 52
326 OPERATOR’S CAB WITH INTEGRATED FALLING OBJECT PROTECTIVE STRUCTURE
(FOPS) 54
33 OPERATOR’S CAB – CONTROLS 62
331 HYDRAULIC CONTROL SYSTEM 63
332 SAFETY CIRCUIT FOR CONTROLS 63
16 TABLE OF CONTENTS INTRODUCTION
34 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS 76
341 OPERATING THE ELECTRONIC MONITORING SYSTEM 85
342 MENU CONTROL CHART 134
343 FAULT AND INFORMATION MESSAGE LIST 152
35 OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING 175
36 POWER HOUSE 176
361 EMERGENCY MOTOR SHUTDOWN SWITCHES 177
362 CONTROL AND FILTER PANEL OF REAR- AND FRONT POWER UNIT 179
37 MEDIUM VOLTAGE SWITCH CABINET IN CAB BASE 180
371 COMPONENTS OF THE MEDIUM VOLTAGE SWITCH CABINET 181
372 SWITCH BOARD (X2) IN CAB BASE 183
373 MONITOR AND CONTROL PANEL IN CAB BASE 189
374 SWITCH BOARD – MEDIUM VOLTAGE 191
38 HIGH VOLTAGE SWITCH CABINET 192
39 CHECKS BEFORE STARTING THE MAIN DRIVE MOTORS 194
310 STARTING THE MAIN DRIVE MOTORS 198
311 MOVING THE SHOVEL 205
3111 TRAVEL CONTROL WITH FOOT PEDALS 205
3112 TRAVELLING INSTRUCTIONS 208
312 SLEWING AND BRAKING THE SUPERSTRUCTURE 209
3121 SLEWING THE SUPERSTRUCTURE 209
313 WORKING WITH THE ATTACHMENT 212
3131 MACHINES EQUIPPED WITH ”EURO” CONTROL SYSTEM 212
3132 MACHINES EQUIPPED WITH ”KMG” CONTROL SYSTEM 213
3133 BOTTOM DUMP BUCKET 214
3134 DROP BALL OPERATION 215
3135 COMBINED OPERATION CYCLES 218
314 WORKING INSTRUCTIONS 220
3141 STABILITY OF THE SHOVEL 220
3142 SHOVEL OPERATION 220
315 PARKING THE SHOVEL 223
316 STOPPING THE MAIN DRIVE MOTORS 224
317 OPERATION OF THE LUBRICATION SYSTEM 228
3171 CENTRAL LUBRICATION SYSTEM ”CLS” 228
3172 SWING CIRCLE PINION LUBRICATION SYSTEM ”SLS” 230
318 TRANSFER PUMP FOR HYDRAULIC OIL 232
3181 OPERATING THE TRANSFER PUMP 233
3182 FUNCTIONS OF THE TRANSFER PUMP 235
INTRODUCTION 16 TABLE OF CONTENTS
319 CENTRAL REFILLING SYSTEM 238
3191 SYSTEMS CONNECTED TO THE REFILLING SYSTEM 239
3192 CENTRAL LUBRICATION SYSTEM AND SWING CIRCLE LUBRICATION SYSTEM 243
320 CABLE DRUM 244
3201 CABLE DRUM OPERATION 245
3202 TRAVELLING INSTRUCTIONS 247
321 SERVICE CRANE 250
3211 OPERATING THE SERVICE CRANE 251
322 WORK ON THE LOADER ATTACHMENT 254
323 TRANSPORTATION AND LIFTING OF THE
SHOVEL 255
3231 DISASSEMBLING OF THE SHOVEL 255
3232 TRANSPORTATION AND LIFTING 255
324 RETRIEVAL PROCEDURE 256
325 SHOVEL STORAGE 257
3251 PREPARING FOR STORAGE 257
3252 ONE MONTH REPETITIVE SERVICE PERIOD 257
3253 SIX MONTH REPETITIVE SERVICE PERIOD 258
3254 PREPARING FOR OPERATION 258
326 TROUBLE SHOOTING 259
3261 MAIN DRIVE MOTOR 259
3262 HYDRAULIC SYSTEM 260
3263 FINAL DRIVES AND SWING GEAR 261
3264 CRAWLER TRACKS 261
4 MAINTENANCE 263
41 FOREWORD 264
42 PRECAUTIONS FOR MAINTENANCE 265
43 LUBRICANTS 266
431 LUBRICANTS FOR MODERATE AND HOT CLIMATES 266
44 FILLING CAPACITIES 270
45 STANDARD TORQUE LIST 271
46 LUBRICATION AND MAINTENANCE SCHEDULE 272
461 INITIAL SERVICING 272
462 PERIODIC SERVICING INTERVALS 272
463 PERIODIC SERVICING SCHEDULE 273
464 MAINTENANCE OF THE MAIN DRIVE MOTORS 277
16 TABLE OF CONTENTS INTRODUCTION
47 WHEN NECESSARY 280
471 SWING CIRCLE TOOTHING LUBRICATION 281
472 AUTOMATIC LUBRICATION SYSTEMS FILL GREASE CONTAINERS 283
473 TRACK ROLLERS AND GUIDE WHEELS – REPLACE FLOATING SEALS 287
48 EVERY 10 OPERATING HOURS OR DAILY 288
481 VISUAL INSPECTIONS 289
482 TRACK GROUPS – CLEAN 297
49 EVERY 50 OPERATING HOURS OR WEEKLY 298
491 SWING GEARS AND MOTOR ADAPTER HOUSINGS – CHECK OIL LEVELS 299
492 TRAVEL GEARS, BRAKE HOUSINGS AND MOTOR ADAPTER HOUSINGS – CHECK OIL
LEVELS 301
493 PTO’s (PUMP DISTRIBUTOR GEARS) AND OIL RESERVOIR – CHECK OIL LEVEL 307
494 HYDRAULIC ACCESS LADDER – CHECK SAFETY SENSOR 311
495 HYDRAULIC OIL COOLERS – INSPECT AND CLEAN IF NECESSARY 313
410 EVERY 250 OPERATING HOURS OR MONTHLY 314
4101 UNDERCARRIAGE PIN CONNECTIONS – LUBRICATE 315
4102 SIGNAL HORN COMPRESSOR – LUBRICATE 315
4103 HYDRAULIC OIL COOLER FAN BEARING HOUSINGS – CHECK FOR LEAKAGE AND
CLEAN BREATHER FILTER 315
4104 RADIATOR FAN BEARING HOUSINGS – CHECK FOR LEAKAGE AND CLEAN BREATHER
FILTER (DIESEL VERSION ONLY) 315
4105 AUTOMATIC LUBRICATION SYSTEMS – CLEAN IN-LINE GREASE FILTER 317
4106 CAB AIR CLEANER – CLEAN OR REPLACE FILTER ELEMENT 319
4107 AIR CONDITIONING FOR OPERATOR’S CAB AND SWITCH CABINETS 321
4108 WINDSHIELD WASHER SYSTEM – CHECK FLUID LEVEL 325
411 EVERY 500 OPERATING HOURS OR MONTHLY 326
4111 BATTERIES – CHECK FLUID LEVEL 327
4112 CRAWLER TRACK – INSPECTION 329
412 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH 334
4121 HIGH STRENGTH BOLT CONNECTIONS – CHECK TORQUE LOAD 335
4122 HYDRAULIC SYSTEM – FILTER SERVICE 383
4123 PTO’S (PUMP DISTRIBUTOR GEARS), SWING GEARS AND TRAVEL GEARS – OIL
SAMPLE ANALYSIS 397
4124 SIGNAL HORN COMPRESSOR – CLEAN AND LUBRICATE 399
4125 HYDRAULIC TRACK TENSIONING SYSTEM – CHECK PRESSURE ACCUMULATORS
401
4126 WATER FILTER – REPLACE FILTER CARTRIDGE 403
4127 SLIP RING UNIT – LUBRICATE 405
413 EVERY 2000 OPERATING HOURS OR YEARLY 406
4131 HYDRAULIC SYSTEM – CHANGE OIL, REPLACE SUCTION STRAINERS AND
PULSATION DAMPER 407
4132 EMERGENCY ESCAPE LADDER – INSPECTION 419
414 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR 420
4141 SWING GEARS AND MOTOR ADAPTER HOUSING – CHANGE OIL 421
INTRODUCTION 16 TABLE OF CONTENTS
4142 TRAVEL GEARS, BRAKE AND MOTOR ADAPTER HOUSINGS – CHANGE OIL 425
4143 PTO (PUMP DISTRIBUTOR GEAR) – CHANGE OIL 431
415 FIRE PREVENTION 434
416 REPAIR WELDINGS 436
4161 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE
UNDERCARRIAGE 439
4162 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE LOADER
ATTACHMENT 441
4163 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE
SUPERSTRUCTURE 443
4164 AFTER FINISHING THE REPAIR WELDINGS ON THE SUPERSTRUCTURE 443
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