Komatsu PC5500-6 Hydraulic Mining Shovel Operation and Maintenance Manual OMPC550015014

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 EXCAVATOR
• 2.4. DELIVERY OF THE EXCAVATOR
• 2.5. EXPLANATION OF ABBREVATIONS
• 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 EXCAVATOR
• 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 EXCAVATOR
• 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. HYDRAULIC CONTROL SYSTEM
• 4.3.2. SAFETY CIRCUIT FOR CONTROLS
• 4.4. ELECTRONIC MONITORING AND CONTROL SYSTEM ECS
• 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
• 4.6. POWER HOUSE
• 4.6.1. EMERGENCY ENGINE SHUTDOWN SWITCHES
• 4.6.2. CONTROL AND FILTER PANEL OF REAR AND FRONT POWER UNIT
• 4.7. ELECTRICAL EQUIPMENT IN CAB BASE
• 4.7.1. SWITCH BOARD (X2) IN CAB BASE
• 4.8. CHECKS BEFORE STARTING THE ENGINES
• 4.9. STARTING THE ENGINES
• 4.9.1. STARTING PROCEDURE
• 4.10. MOVING THE EXCAVATOR
• 4.10.1. TRAVEL CONTROL WITH FOOT PEDALS
• 4.10.2. TRAVELLING INSTRUCTIONS
• 4.11. SLEWING AND BRAKING THE SUPERSTRUCTURE
• 4.11.1. SLEWING THE SUPERSTRUCTURE
• 4.12. WORKING WITH THE ATTACHMENT
• 4.12.1. MACHINES EQUIPPED WITH EURO CONTROL SYSTEM
• 4.12.2. MACHINES EQUIPPED WITH KMG CONTROL SYSTEM
• 4.12.3. BOTTOM DUMP BUCKET
• 4.12.4. DROP BALL OPERATION
• 4.12.5. COMBINED OPERATION CYCLES
• 4.13. WORKING INSTRUCTIONS
• 4.13.1. STABILITY OF THE EXCAVATOR
• 4.13.2. EXCAVATOR OPERATION
• 4.14. PARKING THE EXCAVATOR
• 4.15. STOPPING THE ENGINES
• 4.16. OPERATION OF THE LUBRICATION SYSTEM
• 4.16.1. CENTRAL LUBRICATION SYSTEM CLS
• 4.16.2. SWING CIRCLE PINION LUBRICATION SYSTEM SLS
• 4.17. FIRE DETECTION AND SUPPRESSION SYSTEM
• 4.17.1. HIGH LEVEL ALARM FIRE
• 4.17.2. ENGINE SHUTDOWN THROUGH FUEL SHUTOFF SOLENOID VALVE
• 4.17.3. ACTUATION MODES OF THE FIRE SUPPRESSION SYSTEM
• 4.17.4. INDICATION OF OPERATIONAL MODES AT CONTROL MODULE, AFTER AUTOMATIC ACTUATION OF THE FIRE S…
• 4.17.5. LOCATION OF THE EXTINGUISHING AGENT TANK ASSEMBLIES AND EXPELLANT GAS CARTRIDGES ON POWER…
• 4.18. CENTRAL REFILLING SYSTEM
• 4.18.1. SYSTEMS CONNECTED TO THE REFILLING SYSTEM
• 4.18.2. OPERATING THE HYDRAULIC SERVICE ARM
• 4.18.3. RECEIVER PANEL WITH MONITOR BOX
• 4.18.4. REFILLABLE GREASE CONTAINERS OF THE CENTRAL LUBRICATION SYSTEM AND SWING CIRCLE LUBRICATIO…
• 4.19. WORK ON THE LOADER ATTACHMENT
• 4.20. TRANSPORTATION AND LIFTING OF THE EXCAVATOR
• 4.20.1. DISASSEMBLING OF THE EXCAVATOR
• 4.20.2. TRANSPORTATION AND LIFTING
• 4.21. RETRIEVAL PROCEDURE
• 4.22. EXCAVATOR STORAGE
• 4.22.1. PREPARING FOR STORAGE
• 4.22.2. ONE MONTH REPETITIVE SERVICE PERIOD
• 4.22.3. SIX MONTH REPETITIVE SERVICE PERIOD
• 4.22.4. PREPARING FOR OPERATION
• 4.23. TROUBLE SHOOTING
• 4.23.1. ENGINE
• 4.23.2. HYDRAULIC SYSTEM
• 4.23.3. FINAL DRIVES AND SWING GEAR
• 4.23.4. 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. MAINTENANCE OF THE ENGINES
• 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. VISUAL INSPECTIONS
• 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, BRAKE HOUSINGS AND MOTOR ADAPTER HOUSINGS 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. UNDERCARRIAGE PIN CONNECTIONS LUBRICATE
• 5.10.3. SIGNAL HORN COMPRESSOR LUBRICATE
• 5.10.4. HYDRAULIC OIL COOLER FAN BEARINGS CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER
• 5.10.5. RADIATOR FAN BEARINGS CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER
• 5.10.6. AUTOMATIC LUBRICATION SYSTEMS CLEAN INLINE GREASE FILTER
• 5.10.7. CAB AIR CLEANER CLEAN OR REPLACE FILTER ELEMENT
• 5.11. EVERY 500 OPERATING HOURS OR MONTHLY
• 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
• 5.13. 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, BRAKE AND MOTOR ADAPTER HOUSINGS CHANGE OIL
• 5.14.3. PTO (PUMP DISTRIBUTOR GEAR) CHANGE OIL
• 5.15. FIRE PREVENTION
• 5.16. REPAIR WELDINGS
• 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