Komatsu PC5500-6 Hydraulic Mining Shovel Operation & Maintenance Manual – OMPC550015011

This manual PDF download describes procedures for operation, handling, lubrication, maintenance, checking, and adjustment for the PC5500-6 Komatsu Hydraulic Mining Shovel. It will help the operator or anyone realize peak performance through effective, economical and safe machine operation and maintenance.

APPLICABLE MODELS :

Komatsu PC5500-6 – S/N: 15011

TABLE OF CONTENTS :

1. INTRODUCTION
2. SAFETY
3. OPERATION
4. MAINTENANCE

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : OMPC550015011
Total Pages : 466

This manual provides rules and guidelines which will help you use this machine safely and effectively. The precautions in this manual must be followed at all times when performing operation and maintenance.

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CONTENTS

1. INTRODUCTION
1.1 CONTENTS OF THE BINDER
1.2 DIVISION OF THE BINDER
1.3 DESIGNATED USE OF THE EXCAVATOR
1.4 DELIVERY OF THE EXCAVATOR
1.5 EXPLANATION OF ABBREVATIONS
1.6 TABLE OF CONTENTS

2. SAFETY
2.1 SAFETY INSTRUCTIONS
2.1.1 WARNINGS AND SYMBOLS
2.1.2 BASIC OPERATION AND DESIGNATED USE OF THE HYDRAULIC EXCAVATOR
2.1.3 ORGANIZATIONAL MEASURES
2.1.4 SELECTION AND QUALIFICATION OF PERSONNEL – BASIC RESPONSIBILITIES
2.1.5 SAFETY INSTRUCTIONS GOVERNING SPECIFIC OPERATIONAL PHASES
2.1.6 WARNING OF SPECIAL DANGERS
2.1.7 TRANSPORTING AND TOWING -RECOMMISSIONING
2.1.8 SPECIAL SAFETY EQUIPMENT
2.1.9 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)

3. OPERATION
3.1 FOREWORD
3.2 CONSTRUCTION OF THE EXCAVATOR
3.2.1 OVERALL VIEW
3.2.2 UNDERCARRIAGE AND SUPERSTRUCTURE
3.2.3 HYDRAULICALLY OPERATED ACCESS LADDER
3.2.4 EMERGENCY ESCAPE LADDER
3.2.5 EMERGENCY ENGINE SHUTDOWN FROM GROUND MAN OR OPERATOR WARNING SYSTEM
3.2.6 OPERATOR’S CAB WITH INTEGRATED FALLING OBJECT PROTECTIVE STRUCTURE (FOPS)
3.3 OPERATOR’S CAB – CONTROLS
3.3.1 HYDRAULIC CONTROL SYSTEM
3.3.2 SAFETY CIRCUIT FOR CONTROLS
3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS
3.5 OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING
3.5.1 A – HEATING
3.5.2 B – COOLING
3.5.3 COMBINED OPERATION OF AIR CONDITIONING AND HEATING
3.6 POWER HOUSE
3.6.1 EMERGENCY ENGINE SHUTDOWN SWITCHES
3.6.2 CONTROL AND FILTER PANEL OF REAR- AND FRONT POWER UNIT
3.7 ELECTRICAL EQUIPMENT IN CAB BASE
3.7.1 SWITCH BOARD (X2) IN CAB BASE
3.8 CHECKS BEFORE STARTING THE ENGINES
3.9 STARTING THE ENGINES
3.9.1 STARTING PROCEDURE
3.10 MOVING THE EXCAVATOR
3.10.1 TRAVEL CONTROL WITH FOOT PEDALS
3.10.2 TRAVELLING INSTRUCTIONS
3.11 SLEWING AND BRAKING THE SUPERSTRUCTURE
3.11.1 SLEWING THE SUPERSTRUCTURE
3.12 WORKING WITH THE ATTACHMENT
3.12.1 MACHINES EQUIPPED WITH ”EURO” CONTROL SYSTEM
3.12.2 MACHINES EQUIPPED WITH ”KMG” CONTROL SYSTEM
3.12.3 BOTTOM DUMP BUCKET
3.12.4 DROP BALL OPERATION
3.12.5 COMBINED OPERATION CYCLES
3.13 WORKING INSTRUCTIONS
3.13.1 STABILITY OF THE EXCAVATOR
3.13.2 EXCAVATOR OPERATION
3.14 PARKING THE EXCAVATOR
3.15 STOPPING THE ENGINES
3.16 OPERATION OF THE LUBRICATION SYSTEM
3.16.1 CENTRAL LUBRICATION SYSTEM ”CLS”
3.16.2 SWING CIRCLE PINION LUBRICATION SYSTEM ”SLS”
3.17 FIRE DETECTION AND SUPPRESSION SYSTEM
3.17.1 HIGH LEVEL ALARM ”FIRE”
3.17.2 ENGINE SHUT-DOWN THROUGH FUEL SHUT-OFF SOLENOID VALVE
3.17.3 ACTUATION MODES OF THE FIRE SUPPRESSION SYSTEM
3.17.4 INDICATION OF OPERATIONAL MODES AT CONTROL MODULE, AFTER AUTOMATIC ACTUATION OF THE FIRE SUPPRESSION SYSTEM
3.17.5 LOCATION OF THE EXTINGUISHING AGENT TANK ASSEMBLIES AND EXPELLANT GAS CARTRIDGES ON POWER HOUSE ROOF
3.18 CENTRAL REFILLING SYSTEM
3.18.1 SYSTEMS CONNECTED TO THE REFILLING SYSTEM
3.18.2 OPERATING THE HYDRAULIC SERVICE ARM
3.18.3 RECEIVER PANEL WITH MONITOR BOX
3.18.4 REFILLABLE GREASE CONTAINERS OF THE CENTRAL LUBRICATION SYSTEM AND SWING CIRCLE LUBRICATION SYSTEM
3.19 WORK ON THE LOADER ATTACHMENT
3.20 TRANSPORTATION AND LIFTING OF THE EXCAVATOR
3.20.1 DISASSEMBLING OF THE EXCAVATOR
3.20.2 TRANSPORTATION AND LIFTING
3.21 RETRIEVAL PROCEDURE
3.22 EXCAVATOR STORAGE
3.22.1 PREPARING FOR STORAGE
3.22.2 ONE MONTH REPETITIVE SERVICE PERIOD
3.22.3 SIX MONTH REPETITIVE SERVICE PERIOD
3.22.4 PREPARING FOR OPERATION
3.23 TROUBLE SHOOTING
3.23.1 ENGINE
3.23.2 HYDRAULIC SYSTEM
3.23.3 FINAL DRIVES AND SWING MACHINERY
3.23.4 CRAWLER TRACKS

4. MAINTENANCE
4.1 FOREWORD
4.2 PRECAUTIONS FOR MAINTENANCE
4.3 FUEL AND LUBRICANTS
4.4 FILLING CAPACITIES
4.5 STANDARD TORQUE LIST
4.6 LUBRICATION AND MAINTENANCE SCHEDULE
4.6.1 INITIAL SERVICING
4.6.2 PERIODIC SERVICING INTERVALS
4.6.3 PERIODIC SERVICING SCHEDULE
4.6.4 MAINTENANCE OF THE ENGINES
4.7 WHEN NECESSARY
4.7.1 ENGINE AIR CLEANER MAINTENANCE
4.7.2 SWING CIRCLE TOOTHING LUBRICATION
4.7.3 AUTOMATIC LUBRICATION SYSTEMS FILL GREASE BARRELS
4.7.4 TRACK ROLLERS AND GUIDE WHEELS – REPLACE FLOATING SEALS
4.7.5 COLD STARTING AID, REPLACE FLUID CYLINDER
4.8 EVERY 10 OPERATING HOURS OR DAILY
4.8.1 VISUAL INSPECTIONS
4.8.2 AIR CLEANER – CLEAN PRE-CLEANER
4.8.3 RADIATORS – CHECK COOLANT LEVEL
4.8.4 TRACK GROUPS – CLEAN
4.9 EVERY 50 OPERATING HOURS OR WEEKLY
4.9.1 SWING MACHINERY, BRAKE HOUSINGS AND MOTOR ADAPTER HOUSINGS – CHECK OIL LEVELS
4.9.2 TRAVEL GEARS, BRAKE HOUSINGS AND MOTOR ADAPTER HOUSINGS – CHECK OIL LEVELS
4.9.3 PTO’s (PUMP DISTRIBUTOR GEARS) AND OIL RESERVOIR – CHECK OIL LEVEL
4.9.4 HYDRAULIC ACCESS LADDER – CHECK SAFETY SENSOR
4.9.5 HYDRAULIC OIL COOLERS – INSPECT AND CLEAN IF NECESSARY
4.10 EVERY 250 OPERATING HOURS OR MONTHLY
4.10.1 AIR CONDITIONING COMPRESSOR – CHECK DRIVE BELT TENSION
4.10.2 UNDERCARRIAGE PIN CONNECTIONS – LUBRICATE
4.10.3 SIGNAL HORN COMPRESSOR – LUBRICATE
4.10.4 HYDRAULIC OIL COOLER FAN BEARINGS – CHECK OIL LEVEL
4.10.5 RADIATOR FAN BEARINGS – CHECK OIL LEVEL
4.10.6 AUTOMATIC LUBRICATION SYSTEMS – CLEAN IN-LINE GREASE FILTER
4.10.7 CAB AIR CLEANER – CLEAN OR REPLACE FILTER ELEMENT
4.11 EVERY 500 OPERATING HOURS OR MONTHLY
4.11.1 BATTERIES – CHECK FLUID LEVEL
4.11.2 FLEXIBLE DRIVE COUPLINGS – CHECK OIL LEVEL
4.11.3 FUEL TANK – DRAIN CONDENSATION
4.11.4 CRAWLER TRACK – INSPECTION
4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH
4.12.1 HIGH STRENGTH BOLT CONNECTIONS – CHECK TORQUE LOAD
4.12.2 HYDRAULIC SYSTEM – FILTER SERVICE
4.12.3 PTO’S (PUMP DISTRIBUTOR GEARS), SWING MACHINERY AND TRAVEL GEARS – OIL SAMPLE ANALYSIS
4.12.4 SIGNAL HORN COMPRESSOR – CLEAN AND LUBRICATE
4.12.5 HYDRAULIC TRACK TENSIONING SYSTEM – CHECK ACCUMULATORS
4.12.6 WATER FILTER – REPLACE FILTER CARTRIDGE
4.13 EVERY 2000 OPERATING HOURS OR YEARLY
4.13.1 HYDRAULIC SYSTEM – CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER
4.13.2 EMERGENCY ESCAPE LADDER – INSPECTION
4.14 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR
4.14.1 SWING MACHINERY, BRAKE AND MOTOR ADAPTER HOUSING – CHANGE OIL
4.14.2 TRAVEL GEARS, BRAKE AND MOTOR ADAPTER HOUSINGS – CHANGE OIL
4.14.3 PTO (PUMP DISTRIBUTOR GEAR) – CHANGE OIL
4.15 FIRE PREVENTION
4.16 REPAIR WELDINGS
4.16.1 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE UNDERCARRIAGE
4.16.2 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE LOADER ATTACHMENT
4.16.3 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE SUPERSTRUCTURE
4.16.4 AFTER FINISHING THE REPAIR WELDINGS ON THE SUPERSTRUCTURE

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