Komatsu PC5500-6 Hydraulic Mining Shovel Operation and Maintenance Manual OMPC550015039

Description

• Model List:
  • PC5500-6 Hydraulic Mining Shovel

• 1. MAIN MENU
• 2. COVER PAGE
• 3. INTRODUCTION
• 3.1. CONTENTS OF THE BINDER
• 3.2. DIVISION OF THE BINDER
• 3.3. DESIGNATED USE OF THE SHOVEL
• 3.4. DELIVERY OF THE SHOVEL
• 3.5. EXPLANATION OF ABBREVIATIONS
• 3.6. TABLE OF CONTENTS
• 4. SAFETY
• 4.1. SAFETY INSTRUCTIONS
• 4.1.1. WARNINGS AND SYMBOLS
• 4.1.2. BASIC OPERATION AND DESIGNATED USE OF THE HYDRAULIC SHOVEL
• 4.1.3. ORGANIZATIONAL MEASURES
• 4.1.4. SELECTION AND QUALIFICATION OF PERSONNEL BASICRESPONSIBILITIES
• 4.1.5. SAFETY INSTRUCTIONS GOVERNING SPECIFIC OPERATIONAL PHASES
• 4.1.6. WARNING OF SPECIAL DANGERS
• 4.1.7. TRANSPORTING AND TOWING RECOMMISSIONING
• 4.1.8. SPECIAL SAFETY EQUIPMENT
• 4.1.9. SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEANSTANDARD)
• 5. OPERATION
• 5.1. FOREWORD
• 5.2. CONSTRUCTION OF THE SHOVEL
• 5.2.1. OVERALL VIEW
• 5.2.2. UNDERCARRIAGE AND SUPERSTRUCTURE
• 5.2.3. HYDRAULICALLY OPERATED ACCESS LADDER
• 5.2.4. EMERGENCY ESCAPE LADDER
• 5.2.5. EMERGENCY ENGINE SHUTDOWN FROM GROUND MAN OR OPERATOR WARNING SYSTEM
• 5.2.6. OPERATORS CAB WITH INTEGRATED FALLING OBJECT PROTECTIVE STRUCTURE (FOPS)
• 5.2.7. ENGINE OIL MANAGEMENT SYSTEM
• 5.3. OPERATORS CAB CONTROLS
• 5.3.1. CONTROLS WITH BACKHOE ATTACHMENT
• 5.3.2. CONTROLS WITH BOTTOM DUMP BUCKET ATTACHMENT
• 5.3.3. OPERATORS CONSOLE
• 5.3.4. INTERFACE PANEL FOR DIAGNOSTICS AND CONTROLS FOR HEATING AND AIR CONDITIONING
• 5.4. ELECTRONIC MONITORING AND CONTROL SYSTEM ECS
• 5.4.1. INTRODUCTION
• 5.4.2. OPERATING THE ELECTRONIC MONITORING SYSTEM
• 5.4.3. AUTOMATIC DISPLAY OF MESSAGES
• 5.4.4. MENU CONTROL AND SERVICE FUNCTIONS
• 5.4.5. MENU CONTROL LIST
• 5.4.6. FAULT AND INFORMATION MESSAGE LIST
• 5.5. OPERATING THE HEATER, VENTILATION AND AIRCONDITIONING
• 5.5.1. A HEATING
• 5.5.2. B COOLING
• 5.5.3. COMBINED OPERATION OF AIR CONDITIONING AND HEATING
• 5.5.4. AUXILIARY HEATER FOR OPERATORS CAB
• 5.6. MACHINERY HOUSE
• 5.6.1. EMERGENCY ENGINE SHUTDOWN SWITCHES
• 5.6.2. SAFETY SWITCH FOR MAINTENANCE
• 5.6.3. CONTROL AND FILTER PANEL OF REAR AND FRONT POWER UNIT
• 5.7. ELECTRICAL EQUIPMENT IN CAB BASE
• 5.7.1. STANDARD COMPONENTS IN CAB BASE
• 5.7.2. SWITCH BOARD (X2) IN CAB BASE
• 5.7.3. CENSE ENGINE MONITORING SYSTEM
• 5.7.4. COMPONENTS OF ELECTRICAL PREHEATING SYSTEM IN CAB BASE
• 5.8. PREHEATING SYSTEMS FOR OIL, COOLANT AND BATTERIES
• 5.9. CHECKS BEFORE STARTING THE ENGINES
• 5.10. STARTING THE ENGINES
• 5.10.1. STARTING PROCEDURE
• 5.11. MOVING THE SHOVEL
• 5.11.1. TRAVEL CONTROL WITH FOOT PEDALS
• 5.11.2. TRAVELLING INSTRUCTIONS
• 5.12. SLEWING AND BRAKING THE SUPERSTRUCTURE
• 5.12.1. SLEWING THE SUPERSTRUCTURE
• 5.13. WORKING WITH THE ATTACHMENT
• 5.13.1. MACHINES EQUIPPED WITH EURO CONTROL SYSTEM
• 5.13.2. MACHINES EQUIPPED WITH KMG CONTROL SYSTEM
• 5.13.3. BOTTOM DUMP BUCKET
• 5.13.4. DROP BALL OPERATION
• 5.13.5. COMBINED OPERATION CYCLES
• 5.14. WORKING INSTRUCTIONS
• 5.14.1. STABILITY OF THE SHOVEL
• 5.14.2. SHOVEL OPERATION
• 5.15. PARKING THE SHOVEL
• 5.16. STOPPING THE ENGINES
• 5.16.1. RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM
• 5.17. OPERATION OF THE LUBRICATION SYSTEM
• 5.17.1. CENTRAL LUBRICATION SYSTEM CLS FOR SUPERSTRUCTURE AND ATTACHMENT
• 5.17.2. SWING CIRCLE PINION LUBRICATION SYSTEM SLS
• 5.18. FIRE DETECTION AND SUPPRESSION SYSTEM
• 5.18.1. HIGH LEVEL ALARM FIRE
• 5.18.2. ENGINE SHUTDOWN THROUGH FUEL SHUTOFF SOLENOID VALVE
• 5.18.3. ACTUATION MODES OF THE FIRE SUPPRESSION SYSTEM
• 5.18.4. INDICATION OF OPERATIONAL MODES AT CONTROL MODULE, AFTER AUTOMATIC ACTUATION OF THE FIRE S…
• 5.18.5. LOCATION OF THE EXTINGUISHING AGENT TANK ASSEMBLIES AND EXPELLANT GAS CARTRIDGES ON POWER…
• 5.19. TRANSFER PUMP FOR HYDRAULIC OIL
• 5.19.1. OPERATING THE TRANSFER PUMP
• 5.19.2. FUNCTIONS OF THE TRANSFER PUMP
• 5.20. CENTRAL REFILLING SYSTEM
• 5.20.1. SYSTEMS CONNECTED TO THE REFILLING SYSTEM
• 5.20.2. OPERATING THE HYDRAULIC SERVICE ARM
• 5.20.3. RECEIVER PANEL WITH MONITOR BOX
• 5.20.4. REFILLABLE GREASE CONTAINERS OF THE AUTOMATIC LUBRICATION SYSTEMS
• 5.21. SERVICE CRANE (SPECIAL EQUIPMENT)
• 5.21.1. OPERATING THE CRANE
• 5.22. WORK ON THE LOADER ATTACHMENT
• 5.23. TRANSPORTATION AND LIFTING OF THE SHOVEL
• 5.23.1. DISASSEMBLING OF THE SHOVEL
• 5.23.2. TRANSPORTATION AND LIFTING
• 5.24. RETRIEVAL PROCEDURE
• 5.25. SHOVEL STORAGE
• 5.25.1. PREPARING FOR STORAGE
• 5.25.2. ONE MONTH REPETITIVE SERVICE PERIOD
• 5.25.3. SIX MONTH REPETITIVE SERVICE PERIOD
• 5.25.4. PREPARING FOR OPERATION
• 5.26. TROUBLE SHOOTING
• 5.26.1. ENGINE
• 5.26.2. HYDRAULIC SYSTEM
• 5.26.3. FINAL DRIVES AND SWING GEAR
• 5.26.4. CRAWLER TRACKS
• 6. MAINTENANCE
• 6.1. FOREWORD
• 6.2. PRECAUTIONS FOR MAINTENANCE
• 6.3. FUEL AND LUBRICANTS
• 6.4. FILLING CAPACITIES
• 6.5. STANDARD TORQUE LIST
• 6.6. LUBRICATION AND MAINTENANCE SCHEDULE
• 6.6.1. INITIAL SERVICING
• 6.6.2. PERIODIC SERVICING INTERVALS
• 6.6.3. PERIODIC SERVICING SCHEDULE
• 6.6.4. EXTENDED SERVICE INTERVALS FOR ENGINES WITH ENGINE OIL MANAGEMENT SYSTEM
• 6.6.5. RESETTING THE ENGINE OIL BURNING SYSTEM CENTINEL
• 6.6.6. MAINTENANCE OF THE ENGINES
• 6.6.7. ENGINE FUEL FILTER LOCATIONS
• 6.7. WHEN NECESSARY
• 6.7.1. ENGINE AIR CLEANER MAINTENANCE
• 6.7.2. SWING CIRCLE TOOTHING LUBRICATION
• 6.7.3. AUTOMATIC LUBRICATION SYSTEMS FILL GREASE CONTAINERS
• 6.7.4. TRACK ROLLERS AND GUIDE WHEELS REPLACE FLOATING SEALS
• 6.7.5. COLD STARTING AID, REPLACE FLUID CYLINDER
• 6.8. EVERY 10 OPERATING HOURS OR DAILY
• 6.8.1. WALK AROUND INSPECTION
• 6.8.2. AIR CLEANER CLEAN PRECLEANER
• 6.8.3. RADIATORS CHECK COOLANT LEVEL
• 6.8.4. TRACK GROUPS CLEAN
• 6.9. EVERY 50 OPERATING HOURS OR WEEKLY
• 6.9.1. SWING GEARS AND MOTOR ADAPTER HOUSINGS CHECK OIL LEVELS
• 6.9.2. TRAVEL GEARS, MOTOR ADAPTER HOUSINGS AND FINAL DRIVES CHECK OIL LEVELS
• 6.9.3. PTOs (PUMP DISTRIBUTOR GEARS) AND OIL RESERVOIR CHECK OIL LEVEL
• 6.9.4. HYDRAULIC ACCESS LADDER CHECK SAFETY SENSOR
• 6.9.5. HYDRAULIC OIL COOLERS INSPECT AND CLEAN IF NECESSARY
• 6.10. EVERY 250 OPERATING HOURS OR MONTHLY
• 6.10.1. AIR CONDITIONING COMPRESSOR CHECK DRIVE BELT TENSION
• 6.10.2. SIGNAL HORN COMPRESSOR LUBRICATE
• 6.10.3. HYDRAULIC OIL COOLER FAN BEARINGS CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER
• 6.10.4. RADIATOR FAN BEARINGS CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER
• 6.10.5. AUTOMATIC LUBRICATION SYSTEMS CLEAN INLINE GREASE FILTER AND CHECK BREATHER FILTER
• 6.10.6. CAB AIR CLEANER CLEAN OR REPLACE FILTER ELEMENT
• 6.10.7. AIR CONDITIONING FOR OPERATORS CAB CHECK REFRIGERANT LEVEL
• 6.10.8. WINDWHIELD WASHER SYSTEM CHECK FLUID LEVEL
• 6.11. EVERY 500 OPERATING HOURS OR QUARTERLY
• 6.11.1. BATTERIES CHECK FLUID LEVEL
• 6.11.2. FLEXIBLE DRIVE COUPLINGS CHECK OIL LEVEL
• 6.11.3. FUEL TANK DRAIN CONDENSATION
• 6.11.4. CRAWLER TRACK INSPECTION
• 6.12. EVERY 1000 OPERATING HOURS OR EVERY 6MONTH
• 6.12.1. HIGH STRENGTH BOLT CONNECTIONS CHECK TORQUE LOAD
• 6.12.2. HYDRAULIC SYSTEM FILTER SERVICE
• 6.12.3. PTOS (PUMP DISTRIBUTOR GEARS), SWING GEARS AND TRAVEL GEARS OIL SAMPLE ANALYSIS
• 6.12.4. SIGNAL HORN COMPRESSOR CLEAN AND LUBRICATE
• 6.12.5. HYDRAULIC TRACK TENSIONING SYSTEM CHECK PRESSURE ACCUMULATORS
• 6.12.6. WATER FILTER REPLACE FILTER CARTRIDGE
• 6.12.7. HYDRAULIC OIL COOLER INSPECT AND LUBRICATE DOOR HINGES
• 6.12.8. MACHINERY HOUSE DOORS INSPECT AND LUBRICATE DOOR HINGES
• 6.13. EVERY 2000 OPERATING HOURS OR YEARLY
• 6.13.1. HYDRAULIC SYSTEM CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER
• 6.13.2. EMERGENCY ESCAPE LADDER INSPECTION
• 6.14. EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR
• 6.14.1. SWING GEARS AND MOTOR ADAPTER HOUSING CHANGE OIL
• 6.14.2. TRAVEL GEARS, MOTOR ADAPTER HOUSINGS AND FINAL DRIVES CHANGE OIL
• 6.14.3. PTO (PUMP DISTRIBUTOR GEAR) CHANGE OIL
• 6.15. FIRE PREVENTION
• 6.16. WELD REPAIRS
• 6.16.1. PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE UNDERCARRIAGE
• 6.16.2. PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE LOADER ATTACHMENT
• 6.16.3. PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE SUPERSTRUCTURE
• 6.16.4. AFTER FINISHING THE REPAIR WELDINGS ON THE SUPERSTRUCTURE