Komatsu PC5500-6 Hydraulic Mining Shovel Operation and Maintenance Manual OMPC550015036

Description

• Model List:
  • PC5500-6 Hydraulic Mining Shovel

• 1. COVER
• 2. INTRODUCTION
• 2.1. CONTENTS OF THE BINDER
• 2.2. DIVISION OF THE BINDER
• 2.3. DESIGNATED USE OF THE SHOVEL
• 2.4. DELIVERY OF THE SHOVEL
• 2.5. EXPLANATION OF ABBREVIATIONS
• 2.6. TABLE OF CONTENTS
• 3. SAFETY
• 3.1. SAFETY INSTRUCTIONS
• 3.1.1. WARNINGS AND SYMBOLS
• 3.1.2. BASIC OPERATION AND DESIGNATED USE OF THE HYDRAULIC SHOVEL
• 3.1.3. ORGANIZATIONAL MEASURES
• 3.1.4. SELECTION AND QUALIFICATION OF PERSONNEL BASICRESPONSIBILITIES
• 3.1.5. SAFETY INSTRUCTIONS GOVERNING SPECIFIC OPERATIONAL PHASES
• 3.1.6. WARNING OF SPECIAL DANGERS
• 3.1.7. TRANSPORTING AND TOWING RECOMMISSIONING
• 3.1.8. SPECIAL SAFETY EQUIPMENT
• 3.1.9. SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEANSTANDARD)
• 4. OPERATION
• 4.1. FOREWORD
• 4.2. CONSTRUCTION OF THE SHOVEL
• 4.2.1. OVERALL VIEW
• 4.2.2. UNDERCARRIAGE AND SUPERSTRUCTURE
• 4.2.3. HYDRAULICALLY OPERATED ACCESS LADDER
• 4.2.4. EMERGENCY ESCAPE LADDER
• 4.2.5. EMERGENCY MOTOR SHUTDOWN FROM GROUND MAN OR OPERATOR WARNING SYSTEM
• 4.2.6. OPERATORS CAB WITH INTEGRATED FALLING OBJECT PROTECTIVE STRUCTURE (FOPS)
• 4.3. OPERATORS CAB CONTROLS
• 4.3.1. CONTROLS WITH BACKHOE ATTACHMENT
• 4.3.2. CONTROLS WITH BOTTOM DUMP BUCKET ATTACHMENT
• 4.3.3. OPERATORS CONSOLE
• 4.3.4. CONTROL UNITS FOR FIRE DETECTION, ACTUATION AND SUPPRESSION SYSTEMS
• 4.4. ELECTRONIC MONITORING AND CONTROL SYSTEM ECS
• 4.4.1. INTRODUCTION
• 4.4.2. OPERATING THE ELECTRONIC MONITORING SYSTEM
• 4.4.3. AUTOMATIC DISPLAY OF MESSAGES
• 4.4.4. MENU CONTROL AND SERVICE FUNCTIONS
• 4.4.5. MENU CONTROL LIST
• 4.4.6. FAULT AND INFORMATION MESSAGE LIST
• 4.5. CAMERA SYSTEM WITH MONITORS
• 4.5.1. LOCATION OF MONITORS AND CONTROL UNITS
• 4.6. OPERATING THE HEATER, VENTILATION AND AIRCONDITIONING
• 4.6.1. A HEATING
• 4.6.2. B COOLING
• 4.6.3. COMBINED OPERATION OF AIR CONDITIONING AND HEATING
• 4.7. MACHINERY HOUSE
• 4.7.1. EMERGENCY MOTOR SHUTDOWN SWITCHES
• 4.7.2. SAFETY SWITCH FOR MAINTENANCE
• 4.7.3. CONTROL AND FILTER PANEL OF REAR AND FRONT POWER UNIT
• 4.8. MEDIUM VOLTAGE SWITCH CABINET IN CAB BASE
• 4.8.1. COMPONENTS OF THE MEDIUM VOLTAGE SWITCH CABINET
• 4.8.2. SWITCH BOARD (X2) IN CAB BASE
• 4.8.3. MONITOR AND CONTROL PANEL IN CAB BASE
• 4.8.4. SWITCH BOARD MEDIUM VOLTAGE
• 4.9. HIGH VOLTAGE SWITCH CABINET
• 4.10. CHECKS BEFORE STARTING THE MAIN DRIVE MOTORS
• 4.11. STARTING THE MAIN DRIVE MOTORS
• 4.12. MOVING THE SHOVEL
• 4.12.1. TRAVEL CONTROL WITH FOOT PEDALS
• 4.12.2. TRAVELLING INSTRUCTIONS
• 4.13. SLEWING AND BRAKING THE SUPERSTRUCTURE
• 4.13.1. SLEWING THE SUPERSTRUCTURE
• 4.14. WORKING WITH THE ATTACHMENT
• 4.14.1. MACHINES EQUIPPED WITH EURO CONTROL SYSTEM
• 4.14.2. MACHINES EQUIPPED WITH KMG CONTROL SYSTEM
• 4.14.3. BOTTOM DUMP BUCKET
• 4.14.4. DROP BALL OPERATION
• 4.14.5. COMBINED OPERATION CYCLES
• 4.15. WORKING INSTRUCTIONS
• 4.15.1. STABILITY OF THE SHOVEL
• 4.15.2. SHOVEL OPERATION
• 4.16. PARKING THE SHOVEL
• 4.17. STOPPING THE MAIN DRIVE MOTORS
• 4.17.1. RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM
• 4.18. OPERATION OF THE LUBRICATION SYSTEM
• 4.18.1. CENTRAL LUBRICATION SYSTEM CLS FOR SUPERSTRUCTURE AND ATTACHMENT
• 4.18.2. SWING CIRCLE PINION LUBRICATION SYSTEM SLS
• 4.19. FIRE DETECTION, ACTUATION AND SUPPRESSION SYSTEMS
• 4.19.1. CONTROL UNITS FOR THE FIRE DETECTION, ACTUATION AND SUPPRESSION SYSTEMS
• 4.19.2. REMOTE HIGH LEVEL ALARM FIRE LOCATED ON THE CAB
• 4.19.3. ACTUATION MODE OF THE CARBON DIOXIDE FIRE SUPPRESSION SYSTEM
• 4.19.4. IN CASE OF FIRE
• 4.19.5. ACTUATION MODE OF THE DRY CHEMICAL POWDER FIRE SUPPRESSION SYSTEM
• 4.19.6. LOCATION OF THE EXTINGUISHING AGENT TANKS AND EXPELLANT GAS CARTRIDGES ON MACHINERY HOUSE…
• 4.20. TRANSFER PUMP FOR HYDRAULIC OIL
• 4.20.1. OPERATING THE TRANSFER PUMP
• 4.20.2. FUNCTIONS OF THE TRANSFER PUMP
• 4.21. CENTRAL REFILLING SYSTEM
• 4.21.1. SYSTEMS CONNECTED TO THE REFILLING SYSTEM
• 4.21.2. REFILLABLE GREASE CONTAINERS OF THE AUTOMATIC LUBRICATION SYSTEMS
• 4.22. CABLE DRUM
• 4.22.1. OPERATION OF THE CABLE DRUM
• 4.22.2. TRAVELLING INSTRUCTIONS
• 4.23. FOLDING PEDESTEL ON THE OPERATORS CAB
• 4.24. SERVICE CRANE (SPECIAL EQUIPMENT)
• 4.24.1. OPERATING THE CRANE
• 4.25. WORK ON THE LOADER ATTACHMENT
• 4.26. TRANSPORTATION AND LIFTING OF THE SHOVEL
• 4.26.1. DISASSEMBLING OF THE SHOVEL
• 4.26.2. TRANSPORTATION AND LIFTING
• 4.27. RETRIEVAL PROCEDURE
• 4.28. SHOVEL STORAGE
• 4.28.1. PREPARING FOR STORAGE
• 4.28.2. ONE MONTH REPETITIVE SERVICE PERIOD
• 4.28.3. SIX MONTH REPETITIVE SERVICE PERIOD
• 4.28.4. PREPARING FOR OPERATION
• 4.29. TROUBLE SHOOTING
• 4.29.1. MAIN DRIVE ELECTRIC MOTOR
• 4.29.2. HYDRAULIC SYSTEM
• 4.29.3. FINAL DRIVES AND SWING GEAR
• 4.29.4. CRAWLER TRACKS
• 5. MAINTENANCE
• 5.1. FOREWORD
• 5.2. PRECAUTIONS FOR MAINTENANCE
• 5.3. FUEL AND LUBRICANTS
• 5.4. FILLING CAPACITIES
• 5.5. STANDARD TORQUE LIST
• 5.6. LUBRICATION AND MAINTENANCE SCHEDULE
• 5.6.1. INITIAL SERVICING
• 5.6.2. PERIODIC SERVICING INTERVALS
• 5.6.3. PERIODIC SERVICING SCHEDULE
• 5.6.4. MAINTENANCE OF THE MAIN DRIVE MOTORS
• 5.7. WHEN NECESSARY
• 5.7.1. SWING CIRCLE TOOTHING LUBRICATION
• 5.7.2. AUTOMATIC LUBRICATION SYSTEMS FILL GREASE CONTAINERS
• 5.7.3. TRACK ROLLERS AND GUIDE WHEELS REPLACE FLOATING SEALS
• 5.8. EVERY 10 OPERATING HOURS OR DAILY
• 5.8.1. WALK AROUND INSPECTION
• 5.8.2. TRACK GROUPS CLEAN
• 5.9. EVERY 50 OPERATING HOURS OR WEEKLY
• 5.9.1. SWING GEARS AND MOTOR ADAPTER HOUSINGS CHECK OIL LEVELS
• 5.9.2. TRAVEL GEARS, MOTOR ADAPTER HOUSINGS AND FINAL DRIVES CHECK OIL LEVELS
• 5.9.3. PTOs (PUMP DISTRIBUTOR GEARS) AND OIL RESERVOIR CHECK OIL LEVEL
• 5.9.4. HYDRAULIC ACCESS LADDER CHECK SAFETY SENSOR
• 5.9.5. HYDRAULIC OIL COOLERS INSPECT AND CLEAN IF NECESSARY
• 5.10. EVERY 250 OPERATING HOURS OR MONTHLY
• 5.10.1. SIGNAL HORN COMPRESSOR LUBRICATE
• 5.10.2. HYDRAULIC OIL COOLER FAN BEARINGS CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER
• 5.10.3. RADIATOR FAN BEARINGS CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER (DIESEL VERSION ONLY)
• 5.10.4. AUTOMATIC LUBRICATION SYSTEMS CLEAN INLINE GREASE FILTER AND CHECK BREATHER FILTER
• 5.10.5. CAB AIR CLEANER CLEAN OR REPLACE FILTER ELEMENT
• 5.10.6. AIR CONDITIONING FOR OPERATORS CAB AND SWITCH CABINETS
• 5.10.7. WINDSHIELD WASHER SYSTEM CHECK FLUID LEVEL
• 5.11. EVERY 500 OPERATING HOURS OR QUARTERLY
• 5.11.1. BATTERIES CHECK FLUID LEVEL
• 5.11.2. CRAWLER TRACK INSPECTION
• 5.12. EVERY 1000 OPERATING HOURS OR EVERY 6MONTH
• 5.12.1. HIGH STRENGTH BOLT CONNECTIONS CHECK TORQUE LOAD
• 5.12.2. HYDRAULIC SYSTEM FILTER SERVICE
• 5.12.3. PTOS (PUMP DISTRIBUTOR GEARS), SWING GEARS AND TRAVEL GEARS OIL SAMPLE ANALYSIS
• 5.12.4. SIGNAL HORN COMPRESSOR CLEAN AND LUBRICATE
• 5.12.5. HYDRAULIC TRACK TENSIONING SYSTEM CHECK PRESSURE ACCUMULATORS
• 5.12.6. WATER FILTER REPLACE FILTER CARTRIDGE
• 5.12.7. HYDRAULIC OIL COOLER INSPECT AND LUBRICATE DOOR HINGES
• 5.12.8. MACHINERY HOUSE DOORS INSPECT AND LUBRICATE DOOR HINGES
• 5.12.9. SLIP RING UNIT LUBRICATE
• 5.13. EVERY 2000 OPERATING HOURS OR YEARLY
• 5.13.1. HYDRAULIC SYSTEM CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER
• 5.13.2. EMERGENCY ESCAPE LADDER INSPECTION
• 5.14. EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR
• 5.14.1. SWING GEARS AND MOTOR ADAPTER HOUSING CHANGE OIL
• 5.14.2. TRAVEL GEARS, MOTOR ADAPTER HOUSINGS AND FINAL DRIVES CHANGE OIL
• 5.14.3. PTO (PUMP DISTRIBUTOR GEAR) CHANGE OIL
• 5.15. FIRE PREVENTION
• 5.16. WELD REPAIRS
• 5.16.1. PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE UNDERCARRIAGE
• 5.16.2. PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE LOADER ATTACHMENT
• 5.16.3. PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE SUPERSTRUCTURE
• 5.16.4. AFTER FINISHING THE REPAIR WELDINGS ON THE SUPERSTRUCTURE