Description
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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 ENGINE SHUTDOWN FROM GROUND MAN OR OPERATOR WARNING SYSTEM
- 4.2.6. OPERATORS CAB WITH INTEGRATED FALLING OBJECT PROTECTIVE STRUCTURE (FOPS)
- 4.2.7. ENGINE OIL MANAGEMENT SYSTEM
- 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. INTERFACE PANEL FOR DIAGNOSTICS AND CONTROLS FOR HEATING AND AIR CONDITIONING
- 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. OPERATING THE HEATER, VENTILATION AND AIRCONDITIONING
- 4.5.1. A HEATING
- 4.5.2. B COOLING
- 4.5.3. COMBINED OPERATION OF AIR CONDITIONING AND HEATING
- 4.5.4. AUXILIARY HEATER FOR OPERATORS CAB
- 4.6. MACHINERY HOUSE
- 4.6.1. EMERGENCY ENGINE SHUTDOWN SWITCHES
- 4.6.2. SAFETY SWITCH FOR MAINTENANCE
- 4.6.3. CONTROL AND FILTER PANEL OF REAR AND FRONT POWER UNIT
- 4.7. ELECTRICAL EQUIPMENT IN CAB BASE
- 4.7.1. STANDARD COMPONENTS IN CAB BASE
- 4.7.2. SWITCH BOARD (X2) IN CAB BASE
- 4.7.3. CENSE ENGINE MONITORING SYSTEM
- 4.7.4. COMPONENTS OF ELECTRICAL PREHEATING SYSTEM IN CAB BASE
- 4.8. PREHEATING SYSTEMS FOR OIL, COOLANT AND BATTERIES
- 4.9. CHECKS BEFORE STARTING THE ENGINES
- 4.10. STARTING THE ENGINES
- 4.10.1. STARTING PROCEDURE
- 4.11. MOVING THE SHOVEL
- 4.11.1. TRAVEL CONTROL WITH FOOT PEDALS
- 4.11.2. TRAVELLING INSTRUCTIONS
- 4.12. SLEWING AND BRAKING THE SUPERSTRUCTURE
- 4.12.1. SLEWING THE SUPERSTRUCTURE
- 4.13. WORKING WITH THE ATTACHMENT
- 4.13.1. MACHINES EQUIPPED WITH EURO CONTROL SYSTEM
- 4.13.2. MACHINES EQUIPPED WITH KMG CONTROL SYSTEM
- 4.13.3. BOTTOM DUMP BUCKET
- 4.13.4. DROP BALL OPERATION
- 4.13.5. COMBINED OPERATION CYCLES
- 4.14. WORKING INSTRUCTIONS
- 4.14.1. STABILITY OF THE SHOVEL
- 4.14.2. SHOVEL OPERATION
- 4.15. PARKING THE SHOVEL
- 4.16. STOPPING THE ENGINES
- 4.16.1. RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM
- 4.17. OPERATION OF THE LUBRICATION SYSTEM
- 4.17.1. CENTRAL LUBRICATION SYSTEM CLS FOR SUPERSTRUCTURE AND ATTACHMENT
- 4.17.2. SWING CIRCLE PINION LUBRICATION SYSTEM SLS
- 4.18. FIRE DETECTION AND SUPPRESSION SYSTEM
- 4.18.1. HIGH LEVEL ALARM FIRE
- 4.18.2. ENGINE SHUTDOWN THROUGH FUEL SHUTOFF SOLENOID VALVE
- 4.18.3. ACTUATION MODES OF THE FIRE SUPPRESSION SYSTEM
- 4.18.4. INDICATION OF OPERATIONAL MODES AT CONTROL MODULE, AFTER AUTOMATIC ACTUATION OF THE FIRE S…
- 4.18.5. LOCATION OF THE EXTINGUISHING AGENT TANK ASSEMBLIES AND EXPELLANT GAS CARTRIDGES ON POWER…
- 4.19. TRANSFER PUMP FOR HYDRAULIC OIL
- 4.19.1. OPERATING THE TRANSFER PUMP
- 4.19.2. FUNCTIONS OF THE TRANSFER PUMP
- 4.20. CENTRAL REFILLING SYSTEM
- 4.20.1. SYSTEMS CONNECTED TO THE REFILLING SYSTEM
- 4.20.2. OPERATING THE HYDRAULIC SERVICE ARM
- 4.20.3. RECEIVER PANEL WITH MONITOR BOX
- 4.20.4. REFILLABLE GREASE CONTAINERS OF THE AUTOMATIC LUBRICATION SYSTEMS
- 4.21. SERVICE CRANE (SPECIAL EQUIPMENT)
- 4.21.1. OPERATING THE CRANE
- 4.22. WORK ON THE LOADER ATTACHMENT
- 4.23. TRANSPORTATION AND LIFTING OF THE SHOVEL
- 4.23.1. DISASSEMBLING OF THE SHOVEL
- 4.23.2. TRANSPORTATION AND LIFTING
- 4.24. RETRIEVAL PROCEDURE
- 4.25. SHOVEL STORAGE
- 4.25.1. PREPARING FOR STORAGE
- 4.25.2. ONE MONTH REPETITIVE SERVICE PERIOD
- 4.25.3. SIX MONTH REPETITIVE SERVICE PERIOD
- 4.25.4. PREPARING FOR OPERATION
- 4.26. TROUBLE SHOOTING
- 4.26.1. ENGINE
- 4.26.2. HYDRAULIC SYSTEM
- 4.26.3. FINAL DRIVES AND SWING GEAR
- 4.26.4. 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. EXTENDED SERVICE INTERVALS FOR ENGINES WITH ENGINE OIL MANAGEMENT SYSTEM
- 5.6.5. RESETTING THE ENGINE OIL BURNING SYSTEM CENTINEL
- 5.6.6. MAINTENANCE OF THE ENGINES
- 5.6.7. ENGINE FUEL FILTER LOCATIONS
- 5.7. WHEN NECESSARY
- 5.7.1. ENGINE AIR CLEANER MAINTENANCE
- 5.7.2. SWING CIRCLE TOOTHING LUBRICATION
- 5.7.3. AUTOMATIC LUBRICATION SYSTEMS FILL GREASE CONTAINERS
- 5.7.4. TRACK ROLLERS AND GUIDE WHEELS REPLACE FLOATING SEALS
- 5.7.5. COLD STARTING AID, REPLACE FLUID CYLINDER
- 5.8. EVERY 10 OPERATING HOURS OR DAILY
- 5.8.1. WALK AROUND INSPECTION
- 5.8.2. AIR CLEANER CLEAN PRECLEANER
- 5.8.3. RADIATORS CHECK COOLANT LEVEL
- 5.8.4. 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. AIR CONDITIONING COMPRESSOR CHECK DRIVE BELT TENSION
- 5.10.2. SIGNAL HORN COMPRESSOR LUBRICATE
- 5.10.3. HYDRAULIC OIL COOLER FAN BEARINGS CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER
- 5.10.4. RADIATOR FAN BEARINGS CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER
- 5.10.5. AUTOMATIC LUBRICATION SYSTEMS CLEAN INLINE GREASE FILTER AND CHECK BREATHER FILTER
- 5.10.6. CAB AIR CLEANER CLEAN OR REPLACE FILTER ELEMENT
- 5.10.7. AIR CONDITIONING FOR OPERATORS CAB CHECK REFRIGERANT LEVEL
- 5.11. EVERY 500 OPERATING HOURS OR QUARTERLY
- 5.11.1. BATTERIES CHECK FLUID LEVEL
- 5.11.2. FLEXIBLE DRIVE COUPLINGS CHECK OIL LEVEL
- 5.11.3. FUEL TANK DRAIN CONDENSATION
- 5.11.4. 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
- 5.13. 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
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