Komatsu Hydraulic Mining Shovel PC5500-6 Operation & Maintenance Manual
FILE DETAILS:
Komatsu Hydraulic Mining Shovel PC5500-6 Operation & Maintenance Manual
Size : 6.37 MB
Format : PDF
Language : English
Brand: Komatsu
Type of machine: Hydraulic Mining Shovel
Type of document: Operation & Maintenance Manual
Model: PC5500-6
Serial: 15011
Number of Pages : 483 Pages
VIDEO PREVIEW OF THE MANUAL:
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DESCRIPTION:
Komatsu Hydraulic Mining Shovel PC5500-6 Operation & Maintenance Manual
Read the Manuals before You Start the Engines.
Before operating the machine, familiarize yourself with its instruments and controls.
Observe the instructions in these manuals for:
- your Personal SAFETY
- Operating SAFETY, and
- READY and EFFICIENT PERFORMANCE of your KOMATSU Hydraulic Mining Shovel.
Periodic preventive inspections and maintenance are the surest means of keeping the machine in proper working order. Prompt detection and correction of minor irregularities, and immediate replacement of worn out or broken parts wfll prevent failures and avoid expenses.
DESIGNATED USE OF THE SHOVEL:
- This machine has been manufactured in accordance with advanced and up-to-date technology standards inclucfing recog- nized safety rules. Nevertheless, its use may constitute a risk to life and limb ofthe user or of third parties, or cause damage to the machine and to other material property. The machine must only be used in technically perfect condition in accordance with its designated use and the instructions set out in the operation manual.
- Only trained safety-conscious operators who are fully aware of the risks involved should operate the machine. Any functional disorders, especially those afiecting the safety of the machine, should, therefore, w rectified immediately. The hydraulic Shovel is designed exclusively for excavating, i.e. excavation of bulk material and natural soil structure (e.g. earth, clay, sand and stones ashore and off-shore). Observe local and national safety regulations.
- Special conditions at the worksite require additional safe working precautions, follow your com- paan safety instructions. Short travefing cfistances for changing the working site are considered as part of the designated use of the Shovel.
- Using the Shovel for purposes other than those mentioned above (such as object handling and use as a transport vehicle) is consid- ered contrary to its designated use. The manufacturer/supplier cannot be held liable for any damage resulting from such use. The risk of such misuse lies entirely with the user.
TABLE OF CONTENTS:
Komatsu Hydraulic Mining Shovel PC5500-6 Operation & Maintenance Manual
MAIN MENU..................................................................................................................... 0 COVER......................................................................................................................... 1 1. INTRODUCTION............................................................................................................... 2 1.1 CONTENTS OF THE BINDER................................................................................................ 3 1.2 DIVISION OF THE BINDER................................................................................................ 4 1.3 DESIGNATED USE OF THE EXCAVATOR....................................................................................... 5 1.4 DELIVERY OF THE EXCAVATOR............................................................................................. 6 1.5 EXPLANATION OF ABBREVATIONS........................................................................................... 7 1.6 TABLE OF CONTENTS..................................................................................................... 8 2. SAFETY..................................................................................................................... 14 2.1 SAFETY INSTRUCTIONS................................................................................................... 15 2.1.1 WARNINGS AND SYMBOLS............................................................................................ 15 2.1.2 BASIC OPERATION AND DESIGNATED USE OF THE HYDRAULIC EXCAVATOR................................................... 15 2.1.3 ORGANIZATIONAL MEASURES......................................................................................... 16 2.1.4 SELECTION AND QUALIFICATION OF PERSONNEL - BASIC RESPONSIBILITIES............................................... 18 2.1.5 SAFETY INSTRUCTIONS GOVERNING SPECIFIC OPERATIONAL PHASES....................................................... 19 2.1.6 WARNING OF SPECIAL DANGERS...................................................................................... 22 2.1.7 TRANSPORTING AND TOWING -RECOMMISSIONING........................................................................ 24 2.1.8 SPECIAL SAFETY EQUIPMENT........................................................................................ 24 2.1.9 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD).................................................... 28 3. OPERATION.................................................................................................................. 36 3.1 FOREWORD.............................................................................................................. 37 3.2 CONSTRUCTION OF THE EXCAVATOR......................................................................................... 38 3.2.1 OVERALL VIEW.................................................................................................... 38 3.2.2 UNDERCARRIAGE AND SUPERSTRUCTURE................................................................................ 39 3.2.3 HYDRAULICALLY OPERATED ACCESS LADDER............................................................................ 45 3.2.4 EMERGENCY ESCAPE LADDER......................................................................................... 49 3.2.5 EMERGENCY ENGINE SHUTDOWN FROM GROUND MAN OR OPERATOR WARNING SYSTEM............................................ 51 3.2.6 OPERATOR’S CAB WITH INTEGRATED FALLING OBJECT PROTECTIVE STRUCTURE (FOPS)....................................... 53 3.3 OPERATOR’S CAB - CONTROLS............................................................................................. 61 3.3.1 HYDRAULIC CONTROL SYSTEM........................................................................................ 62 3.3.2 SAFETY CIRCUIT FOR CONTROLS..................................................................................... 62 3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS.......................................................................... 75 3.5 OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING................................................................177 3.5.1 A - HEATING.....................................................................................................177 3.5.2 B - COOLING.....................................................................................................178 3.5.3 COMBINED OPERATION OF AIR CONDITIONING AND HEATING..............................................................178 3.6 POWER HOUSE...........................................................................................................179 3.6.1 EMERGENCY ENGINE SHUTDOWN SWITCHES..............................................................................180 3.6.2 CONTROL AND FILTER PANEL OF REAR- AND FRONT POWER UNIT..........................................................182 3.7 ELECTRICAL EQUIPMENT IN CAB BASE......................................................................................183 3.7.1 SWITCH BOARD (X2) IN CAB BASE...................................................................................186 3.8 CHECKS BEFORE STARTING THE ENGINES....................................................................................199 3.9 STARTING THE ENGINES..................................................................................................203 3.9.1 STARTING PROCEDURE..............................................................................................206 3.10 MOVING THE EXCAVATOR.................................................................................................214 3.10.1 TRAVEL CONTROL WITH FOOT PEDALS................................................................................214 3.10.2 TRAVELLING INSTRUCTIONS........................................................................................217 3.11 SLEWING AND BRAKING THE SUPERSTRUCTURE...............................................................................218 3.11.1 SLEWING THE SUPERSTRUCTURE.....................................................................................218 3.12 WORKING WITH THE ATTACHMENT..........................................................................................221 3.12.1 MACHINES EQUIPPED WITH ”EURO” CONTROL SYSTEM...................................................................221 3.12.2 MACHINES EQUIPPED WITH ”KMG” CONTROL SYSTEM....................................................................222 3.12.3 BOTTOM DUMP BUCKET.............................................................................................223 3.12.4 DROP BALL OPERATION............................................................................................224 3.12.5 COMBINED OPERATION CYCLES......................................................................................227 3.13 WORKING INSTRUCTIONS.................................................................................................229 3.13.1 STABILITY OF THE EXCAVATOR.....................................................................................229 3.13.2 EXCAVATOR OPERATION............................................................................................229 3.14 PARKING THE EXCAVATOR................................................................................................232 3.15 STOPPING THE ENGINES.................................................................................................233 3.16 OPERATION OF THE LUBRICATION SYSTEM..................................................................................237 3.16.1 CENTRAL LUBRICATION SYSTEM ”CLS”...............................................................................237 3.16.2 SWING CIRCLE PINION LUBRICATION SYSTEM ”SLS”...................................................................239 3.17 FIRE DETECTION AND SUPPRESSION SYSTEM................................................................................241 3.17.1 HIGH LEVEL ALARM ”FIRE”........................................................................................244 3.17.2 ENGINE SHUT-DOWN THROUGH FUEL SHUT-OFF SOLENOID VALVE..........................................................244 3.17.3 ACTUATION MODES OF THE FIRE SUPPRESSION SYSTEM.................................................................244 3.17.4 INDICATION OF OPERATIONAL MODES AT CONTROL MODULE, AFTER AUTOMATIC ACTUATION OF THE FIRE SUPPRESSION SYSTEM....246 3.17.5 LOCATION OF THE EXTINGUISHING AGENT TANK ASSEMBLIES AND EXPELLANT GAS CARTRIDGES ON POWER HOUSE ROOF...........248 3.18 CENTRAL REFILLING SYSTEM.............................................................................................249 3.18.1 SYSTEMS CONNECTED TO THE REFILLING SYSTEM......................................................................250 3.18.2 OPERATING THE HYDRAULIC SERVICE ARM............................................................................252 3.18.3 RECEIVER PANEL WITH MONITOR BOX................................................................................254 3.18.4 REFILLABLE GREASE CONTAINERS OF THE CENTRAL LUBRICATION SYSTEM AND SWING CIRCLE LUBRICATION SYSTEM.............260 3.19 WORK ON THE LOADER ATTACHMENT........................................................................................261 3.20 TRANSPORTATION AND LIFTING OF THE EXCAVATOR..........................................................................262 3.20.1 DISASSEMBLING OF THE EXCAVATOR.................................................................................262 3.20.2 TRANSPORTATION AND LIFTING.....................................................................................262 3.21 RETRIEVAL PROCEDURE..................................................................................................263 3.22 EXCAVATOR STORAGE....................................................................................................264 3.22.1 PREPARING FOR STORAGE..........................................................................................264 3.22.2 ONE MONTH REPETITIVE SERVICE PERIOD............................................................................265 3.22.3 SIX MONTH REPETITIVE SERVICE PERIOD............................................................................265 3.22.4 PREPARING FOR OPERATION........................................................................................266 3.23 TROUBLE SHOOTING.....................................................................................................267 3.23.1 ENGINE.........................................................................................................267 3.23.2 HYDRAULIC SYSTEM...............................................................................................268 3.23.3 FINAL DRIVES AND SWING MACHINERY...............................................................................269 3.23.4 CRAWLER TRACKS.................................................................................................269 4. MAINTENANCE................................................................................................................270 4.1 FOREWORD..............................................................................................................271 4.2 PRECAUTIONS FOR MAINTENANCE...........................................................................................272 4.3 FUEL AND LUBRICANTS...................................................................................................274 4.4 FILLING CAPACITIES....................................................................................................276 4.5 STANDARD TORQUE LIST..................................................................................................277 4.6 LUBRICATION AND MAINTENANCE SCHEDULE..................................................................................278 4.6.1 INITIAL SERVICING...............................................................................................278 4.6.2 PERIODIC SERVICING INTERVALS....................................................................................278 4.6.3 PERIODIC SERVICING SCHEDULE.....................................................................................279 4.6.4 MAINTENANCE OF THE ENGINES......................................................................................285 4.7 WHEN NECESSARY........................................................................................................287 4.7.1 ENGINE AIR CLEANER MAINTENANCE..................................................................................288 4.7.2 SWING CIRCLE TOOTHING LUBRICATION...............................................................................292 4.7.3 AUTOMATIC LUBRICATION SYSTEMS FILL GREASE BARRELS...............................................................294 4.7.4 TRACK ROLLERS AND GUIDE WHEELS - REPLACE FLOATING SEALS.........................................................298 4.7.5 COLD STARTING AID, REPLACE FLUID CYLINDER.......................................................................300 4.8 EVERY 10 OPERATING HOURS OR DAILY.....................................................................................301 4.8.1 VISUAL INSPECTIONS..............................................................................................302 4.8.2 AIR CLEANER - CLEAN PRE-CLEANER.................................................................................310 4.8.3 RADIATORS - CHECK COOLANT LEVEL.................................................................................312 4.8.4 TRACK GROUPS - CLEAN............................................................................................312 4.9 EVERY 50 OPERATING HOURS OR WEEKLY....................................................................................313 4.9.1 SWING MACHINERY, BRAKE HOUSINGS AND MOTOR ADAPTER HOUSINGS - CHECK OIL LEVELS...................................314 4.9.2 TRAVEL GEARS, BRAKE HOUSINGS AND MOTOR ADAPTER HOUSINGS - CHECK OIL LEVELS......................................318 4.9.3 PTO’s (PUMP DISTRIBUTOR GEARS) AND OIL RESERVOIR - CHECK OIL LEVEL..............................................324 4.9.4 HYDRAULIC ACCESS LADDER - CHECK SAFETY SENSOR...................................................................328 4.9.5 HYDRAULIC OIL COOLERS - INSPECT AND CLEAN IF NECESSARY..........................................................330 4.10 EVERY 250 OPERATING HOURS OR MONTHLY.................................................................................331 4.10.1 AIR CONDITIONING COMPRESSOR - CHECK DRIVE BELT TENSION.........................................................332 4.10.2 UNDERCARRIAGE PIN CONNECTIONS - LUBRICATE......................................................................334 4.10.3 SIGNAL HORN COMPRESSOR - LUBRICATE.............................................................................334 4.10.4 HYDRAULIC OIL COOLER FAN BEARINGS - CHECK OIL LEVEL............................................................334 4.10.5 RADIATOR FAN BEARINGS - CHECK OIL LEVEL........................................................................334 4.10.6 AUTOMATIC LUBRICATION SYSTEMS - CLEAN IN-LINE GREASE FILTER....................................................336 4.10.7 CAB AIR CLEANER - CLEAN OR REPLACE FILTER ELEMENT..............................................................340 4.11 EVERY 500 OPERATING HOURS OR MONTHLY.................................................................................341 4.11.1 BATTERIES - CHECK FLUID LEVEL..................................................................................342 4.11.2 FLEXIBLE DRIVE COUPLINGS - CHECK OIL LEVEL.....................................................................344 4.11.3 FUEL TANK - DRAIN CONDENSATION.................................................................................346 4.11.4 CRAWLER TRACK - INSPECTION.....................................................................................348 4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH..........................................................................353 4.12.1 HIGH STRENGTH BOLT CONNECTIONS - CHECK TORQUE LOAD.............................................................354 4.12.2 HYDRAULIC SYSTEM - FILTER SERVICE..............................................................................404 4.12.3 PTO’S (PUMP DISTRIBUTOR GEARS), SWING MACHINERY AND TRAVEL GEARS - OIL SAMPLE ANALYSIS.........................418 4.12.4 SIGNAL HORN COMPRESSOR - CLEAN AND LUBRICATE...................................................................420 4.12.5 HYDRAULIC TRACK TENSIONING SYSTEM - CHECK ACCUMULATORS.........................................................422 4.12.6 WATER FILTER - REPLACE FILTER CARTRIDGE........................................................................424 4.13 EVERY 2000 OPERATING HOURS OR YEARLY.................................................................................425 4.13.1 HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER..................................426 4.13.2 EMERGENCY ESCAPE LADDER - INSPECTION...........................................................................438 4.14 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR..............................................................439 4.14.1 SWING MACHINERY, BRAKE AND MOTOR ADAPTER HOUSING - CHANGE OIL..................................................440 4.14.2 TRAVEL GEARS, BRAKE AND MOTOR ADAPTER HOUSINGS - CHANGE OIL....................................................446 4.14.3 PTO (PUMP DISTRIBUTOR GEAR) - CHANGE OIL.......................................................................452 4.15 FIRE PREVENTION......................................................................................................455 4.16 REPAIR WELDINGS......................................................................................................457 4.16.1 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE UNDERCARRIAGE..........................................460 4.16.2 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE LOADER ATTACHMENT......................................462 4.16.3 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE SUPERSTRUCTURE.........................................464 4.16.4 AFTER FINISHING THE REPAIR WELDINGS ON THE SUPERSTRUCTURE......................................................466
PLEASE NOTE:
- This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
- Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.
Steven Jeffery –
It is not a free download. Some of the pages were not clear.