Komatsu PC5500-6 Shovel Operation and Maintenance Manual (GZEAM15176-0)

Komatsu PC5500-6 Shovel Operation and Maintenance Manual (GZEAM15176-0)

Komatsu PC5500-6 Shovel Index:

• 1 FOREWORD
  • 1.1 BEFORE READING THIS MANUAL
  • 1.2 EC DECLARATION OF CONFORMITY
  • 1.3 PRIVACY POLICY ON MACHINES EQUIPPED WITH MACHINE MONITORING SYSTEMS FOR THE EEA
  • 1.4 RADIO WAVE REGULATIONS FOR KOMTRAX AND KOMTRAX PLUS
  • 1.5 DIRECTIONS OF THE MACHINE
  • 1.6 SPECIFICATION AND SERIAL PLATE
    • 1.6.1 PRODUCT IDENTIFICATION NUMBER
  • 1.7 DIVISION OF THE BINDER
  • 1.8 DESIGNATED USE OF THE SHOVEL
  • 1.9 DELIVERY OF THE SHOVEL
    • 1.9.1 SPARE PARTS
    • 1.9.2 SERVICE
  • 1.10 EXPLANATION OF ABBREVIATIONS
  • 1.11 CONTENTS
• 2 SAFETY
  • 2.1 SAFETY INFORMATION
  • 2.2 OVERVIEW
    • 2.2.1 NORMAL OPERATIONS
    • 2.2.2 REGULAR MAINTENANCE
    • 2.2.3 TROUBLESHOOTING, ADJUSTMENTS AND REPAIR
    • 2.2.4 ADDITIONAL SAFETY PRECAUTIONS
  • 2.3 SOUND PRESSURE AND VIBRATION LEVELS IN THE OPERATOR’S CAB.
    • 2.3.1 SOUND
    • 2.3.2 VIBRATION
  • 2.4 GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR
    • 2.4.1 UNDERSTANDING THE MACHINE
    • 2.4.2 PRECAUTIONS BEFORE STARTING OPERATION ON THE EXCAVATOR
    • 2.4.3 PREPARATIONS FOR SAFE OPERATION
    • 2.4.4 FIRE PREVENTION
    • 2.4.5 PRECAUTIONS WHEN GETTING ON OR OFF THE MACHINE
    • 2.4.6 BURN PREVENTION
    • 2.4.7 PRECAUTIONS WHEN CLEANING CAB GLASS
    • 2.4.8 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES
    • 2.4.9 PRECAUTIONS RELATED TO AIRBOURNE AND EJECTED DEBRIS
    • 2.4.10 ELECTROMAGNETIC COMPATIBILITY (EMC)
    • 2.4.11 PRECAUTIONS AT JOBSITE
    • 2.4.12 STARTING motor
    • 2.4.13 OPERATION
  • 2.5 PRECAUTION FOR MAINTENANCE
    • 2.5.1 GENERAL PRECAUTIONS
    • 2.5.2 PRECAUTIONS FOR INSPECTION AND MAINTENANCE
    • 2.5.3 PRECAUTIONS WITH HIGH PRESSURE FLUID
  • 2.6 ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS
    • 2.6.1 INSPECTION OF THE HYDRAULIC SYSTEM
    • 2.6.2 TWO WORKERS ONLY WHEN THE MACHINE IS RUNNING DURING ADJUSTMENTS
    • 2.6.3 AREAS OF POTENTIAL DANGER AROUND THE EXCAVATOR
  • 2.7 SPECIAL SAFETY EQUIPMENT
    • 2.7.1 FRONT GUARD PROTECTIVE STRUCTURe ’FOPS’ FOR OPERATOR’S CAB
    • 2.7.2 OBJECT HANDLING
    • 2.7.3 LIGHTING
    • 2.7.4 WARNING BEACON
    • 2.7.5 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)
  • 2.8 SAFETY WARNING SIGNS
    • 2.8.1 LOCATION AND DESCRIPTION OF THE SIGNS
• 3 OPERATION
  • 3.1 FOREWORD
  • 3.2 CONSTRUCTION OF THE SHOVEL
    • 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 BOOM ACCESS LADDER AND WALKWAY
    • 3.2.6 ENGINE SHUTDOWN FROM GROUND MAN OR OPERATOR WARNING SYSTEM
    • 3.2.7 OPERATOR’S CAB WITH INTEGRATED FALLING OBJECT PROTECTIVE STRUCTURE (FOPS)
    • 3.2.8 ENGINE OIL MANAGEMENT SYSTEM
  • 3.3 OPERATOR’S CAB – CONTROLS
    • 3.3.1 CONTROLS WITH BACKHOE ATTACHMENT
    • 3.3.2 CONTROLS WITH BOTTOM DUMP BUCKET ATTACHMENT
    • 3.3.3 OPERATOR’S CONSOLE
    • 3.3.4 INTERFACE PANEL FOR DIAGNOSTICS
    • 3.3.5 CONTROL MODULE FOR AUXILIARY CAB HEATER
  • 3.4 VEHICLE HEALTH MONITORING SYSTEM (Komtrax Plus)– HEALTH MONITOR
    • 3.4.1 SEQUENCE OF DISPLAYS
    • 3.4.2 OPENING SCREEN
    • 3.4.3 MAIN GAUGE SCREENS 1 TO 4
    • 3.4.4 FUEL CONSUMPTION SCREEN
    • 3.4.5 FAILURE MESSAGE HISTORY SCREEN FOR OPERATOR
    • 3.4.6 MAIN SCREEN – CHANGE >TIME >SMR >DATE
    • 3.4.7 MAINTENANCE MONITOR
    • 3.4.8 SETTINGS FOR OPERATOR
    • 3.4.9 AUTOMATIC MESSAGES
  • 3.5 OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING
    • 3.5.1 Digital Display
    • 3.5.2 Luminous Indication.
  • 3.6 CAMERA SYSTEM WITH MONITORS
    • 3.6.1 LOCATION OF MONITORS AND CONTROL UNITS
    • 3.6.2 AUXILIARY HEATER FOR OPERATOR’S CAB
  • 3.7 MACHINERY HOUSE
    • 3.7.1 EMERGENCY ENGINE SHUTDOWN SWITCHES
    • 3.7.2 SAFETY SWITCH FOR MAINTENANCE
    • 3.7.3 CONTROL AND FILTER PANEL OF REAR- AND FRONT POWER UNIT
  • 3.8 ELECTRICAL EQUIPMENT IN CAB BASE
    • 3.8.1 STANDARD COMPONENTS IN CAB BASE
    • 3.8.2 LOW VOLTAGE SWITCH BOARD IN CAB BASE
    • 3.8.3 MASTER TURBO CONTROLLER MTC – LED INDICATIONS
    • 3.8.4 BINARY FAULT CODE LIST.
    • 3.8.5 TABLE OF LOCATION NUMBERS FOR ELECTRICAL COMPONENTS
    • 3.8.6 COMPONENTS OF ELECTRICAL PREHEATING SYSTEM IN CAB BASE (WHEN EQUIPPED)
  • 3.9 PREHEATING SYSTEMS FOR OIL, COOLANT AND BATTERIES (WHEN EQUIPPED)
    • 3.9.1 Engine Coolant and Engine Oil Reserve Tank Heating
  • 3.10 CHECKS BEFORE STARTING THE ENGINES
    • 3.10.1 Coolant Level
  • 3.11 STARTING THE ENGINES
    • 3.11.1 STARTING PROCEDURE
    • 3.11.2 ENGINE WARM-UP
    • 3.11.3 HYDRAULIC OIL WARM-UP
  • 3.12 MOVING THE SHOVEL
    • 3.12.1 TRAVEL CONTROL WITH FOOT PEDALS
    • 3.12.2 TRAVELLING INSTRUCTIONS
    • 3.12.3 UNDERCARRIAGE TRACK SLIDERS
  • 3.13 SLEWING AND BRAKING THE SUPERSTRUCTURE
    • 3.13.1 SLEWING THE SUPERSTRUCTURE
  • 3.14 WORKING WITH THE ATTACHMENT
    • 3.14.0.1 FACE SHOVEL BUCKET
    • 3.14.1 COMBINED OPERATION CYCLES
  • 3.15 WORKING INSTRUCTIONS
    • 3.15.1 STABILITY OF THE SHOVEL
    • 3.15.2 FURTHER OPERATING PRACTICES
    • 3.15.3 Loading Trucks
  • 3.16 PARKING THE SHOVEL
    • 3.16.0.1 CLEANING THE TRACK GROUPS
  • 3.17 STOPPING THE ENGINES
    • 3.17.1 RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM
  • 3.18 OPERATION OF THE LUBRICATION SYSTEM
    • 3.18.1 CENTRAL LUBRICATION SYSTEM ”CLS”
    • 3.18.2 SWING CIRCLE PINION LUBRICATION SYSTEM ”SLS”
  • 3.19 FIRE DETECTION AND SUPPRESSION SYSTEM
    • 3.19.0.1 FIRE DETECTION AND SUPPRESSION SYSTEMS
    • 3.19.1 DISPLAY MODULE
    • 3.19.2 INTERFACE CONTROL MODULE
    • 3.19.3 LOCATION OF THE EXTINGUISHING AGENT TANK ASSEMBLIES AND EXPELLANT GAS CARTRIDGES ON POWER HOUSE ROOF
  • 3.20 TRANSFER PUMP FOR HYDRAULIC OIL
    • 3.20.1 OPERATING THE TRANSFER PUMP
    • 3.20.2 FUNCTIONS OF THE TRANSFER PUMP
  • 3.21 CENTRAL REFILLING SYSTEM
    • 3.21.1 SYSTEMS CONNECTED TO THE REFILLING SYSTEM
    • 3.21.2 OPERATING THE HYDRAULIC SERVICE ARM
    • 3.21.3 RECEIVER PANEL WITH MONITOR BOX
    • 3.21.4 REFILLABLE GREASE CONTAINERS OF THE AUTOMATIC LUBRICATION SYSTEMS MOUNTED ON THE POWER HOUSE ROOF
  • 3.22 SERVICE CRANE (SPECIAL EQUIPMENT)
    • 3.22.1 OPERATING THE CRANE
  • 3.23 WORK ON THE LOADER ATTACHMENT
    • 3.23.0.1 OBSERVE THE FOLLOWING INSTRUCTIONS
  • 3.24 TRANSPORTATION AND LIFTING OF THE SHOVEL
    • 3.24.1 DISASSEMBLING OF THE SHOVEL
    • 3.24.2 TRANSPORTATION AND LIFTING
  • 3.25 RETRIEVAL PROCEDURE
    • 3.25.1 GENERAL
  • 3.26 SHOVEL STORAGE
    • 3.26.1 GENERAL
    • 3.26.2 PREPARING FOR STORAGE
    • 3.26.3 ONE MONTH REPETITIVE SERVICE PERIOD
    • 3.26.4 SIX MONTH REPETITIVE SERVICE PERIOD
    • 3.26.5 PREPARING FOR OPERATION
  • 3.27 TROUBLE SHOOTING
    • 3.27.1 GENERAL
    • 3.27.2 ENGINE
    • 3.27.3 HYDRAULIC SYSTEM
    • 3.27.4 FINAL DRIVES AND SWING GEAR
    • 3.27.5 CRAWLER TRACKS
• 4 MAINTENANCE
  • 4.1 FOREWORD
    • 4.1.1 DEFINITIONS
    • 4.1.2 GENERAL RECOMMENDATIONS
  • 4.2 PRECAUTIONS FOR MAINTENANCE
    • 4.2.1 FLUIDS AND LUBRICANTS FOR MODERATE AND HOT CLIMATES
    • 4.2.2 LUBRICANTS FOR OPERATION IN COLD AND ARCTIC CLIMATES
  • 4.3 FILLING CAPACITIES
  • 4.4 STANDARD TORQUE LIST
    • 4.4.1 Torque for Flange Joints
    • 4.4.2 TORQUES FOR SPECIAL COMPONENTS
  • 4.5 LUBRICATION AND MAINTENANCE SCHEDULE
    • 4.5.1 INITIAL SERVICING
    • 4.5.2 SERVICING THE CRITICAL BOLT CONNECTIONS
    • 4.5.3 PERIODIC SERVICING INTERVALS
    • 4.5.4 PERIODIC SERVICING SCHEDULE
    • 4.5.5 MAINTENANCE SCHEDULES OF FILTER ELEMENTS AND OTHER COMPONENTS OF THE HYDRAULIC SYSTEM
  • 4.6 SAFETY CRITICAL PARTS
    • 4.6.1 REPLACEMENT OF HYDRAULIC HOSE LINES AND FUEL HOSE LINES
    • 4.6.2 INSPECTION OF HOSE LINES
    • 4.6.3 PERIODIC REPLACEMENT OF FURTHER SAFETY CRITICAL PARTS
  • 4.7 EXTENDED SERVICE INTERVALS FOR ENGINES WITH ENGINE OIL MANAGEMENT SYSTEM
    • 4.7.0.1 Servicing Intervals
    • 4.7.0.2 Extended Service Intervals for Engines with Engine Oil Management System
    • 4.7.1 MAINTENANCE OF THE ENGINES
    • 4.7.2 ENGINE FUEL FILTER LOCATIONS
    • 4.7.3 VENTING THE AIR FROM THE FUEL FILTERS
  • 4.8 INITIAL SERVICING
    • 4.8.1 WORKING ATTACHMENT – INITIAL CHECKS FOR PROPER LUBRICATION
    • 4.8.2 ATTACHMENT – CHECK GREASE INJECTORS AND GREASE CONNECTIONS
    • 4.8.3 CAR BODY AND RACEWAY OF SLEW RING – CHECK GREASE INJECTORS AND GREASE CONNECTIONS
    • 4.8.4 SWING CIRCLE Pinion – CHECK GREASE INJECTORS AND GREASE CONNECTIONS
    • 4.8.5 SWING CIRCLE TOOTHING LUBRICATION
    • 4.8.6 Swing circle – Check Torque OF BOLT CONNECTIONS
    • 4.8.7 Retightening procedure of the crawler carrier mounting bolts
  • 4.9 WHEN NECESSARY
    • 4.9.1 ENGINE AIR CLEANER MAINTENANCE
    • 4.9.2 CYLINDER ROD PROTECTION (IF EQUIPPED), CHANGE SLIDING BLOCKS
    • 4.9.3 AUTOMATIC LUBRICATION SYSTEMS FILL GREASE CONTAINERS
    • 4.9.4 GUIDE WHEELS – REPLACE FLOATING SEALS
    • 4.9.5 COLD STARTING AID, REPLACE FLUID CYLINDER
  • 4.10 EVERY 10 OPERATING HOURS OR DAILY
    • 4.10.1 WALK – AROUND INSPECTION
    • 4.10.2 CYLINDER ROD PROTECTION (IF EQUIPPED), VISUAL Check
    • 4.10.3 AIR CLEANER – CLEAN PRE-CLEANER
    • 4.10.4 RADIATORS – CHECK COOLANT LEVEL
    • 4.10.5 TRACK GROUPS – CLEAN
    • 4.10.6 ELECTRICAL EQUIPMENT – CHECK CONDITION
    • 4.10.7 CAMERA SYSTEM
    • 4.10.8 EMERGENCY ESCAPE ROUTE FROM OPERATOR’S CAB
  • 4.11 EVERY 50 OPERATING HOURS OR WEEKLY
    • 4.11.1 SWING GEARS AND MOTOR ADAPTER HOUSINGS – CHECK OIL LEVELS
    • 4.11.2 TRAVEL GEARS, MOTOR ADAPTER HOUSINGS AND FINAL DRIVES CHECK OIL LEVELS
    • 4.11.3 PTO’s (PUMP DISTRIBUTOR GEARS) AND OIL RESERVOIR – CHECK OIL LEVEL
    • 4.11.4 HYDRAULIC ACCESS LADDER – CHECK SAFETY SENSOR
    • 4.11.5 HYDRAULIC OIL COOLERS – INSPECT AND CLEAN IF NECESSARY
  • 4.12 EVERY 250 OPERATING HOURS OR MONTHLY
    • 4.12.1 AIR CONDITIONING COMPRESSOR – CHECK DRIVE BELT TENSION
    • 4.12.2 SIGNAL HORN COMPRESSOR – LUBRICATE
    • 4.12.3 HYDRAULIC OIL COOLER FAN BEARINGS – CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER
    • 4.12.4 RADIATOR FAN BEARINGS – CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER
    • 4.12.5 AUTOMATIC LUBRICATION SYSTEM – CLEAN BREATHER FILTER ON PUMP STATION
    • 4.12.6 CABIN AIR CLEANER – INSPECT
    • 4.12.7 AIR CONDITIONING FOR OPERATOR’S CAB – CHECK REFRIGERANT LEVEL
    • 4.12.8 ADDITIONAL AIR CONDITIONING FOR OPERATOR’S CAB – CHECK REFRIGERANT LEVEL
    • 4.12.9 CABIN HEATER FILTER – INSPECT
    • 4.12.10 Critical BOLT CONNECTIONS – VISUAL CHECK
    • 4.12.11 WINDSHIELD WASHER SYSTEM – CHECK FLUID LEVEL
  • 4.13 EVERY 500 OPERATING HOURS OR QUARTERLY
    • 4.13.1 BATTERIES – CHECK FLUID LEVEL
    • 4.13.2 GREASE INJECTORS – CHECK INDICATOR STEMS
    • 4.13.3 CYLINDER ROD PROTECTION (IF EQUIPPED), Inspect
    • 4.13.4 FUEL TANK – DRAIN CONDENSATION
    • 4.13.5 CRAWLER TRACK – INSPECTION
    • 4.13.6 GROUND CABLES OF ENGINE AND ALTERNATOR – CHECK FOR CORRECT CONNECTION
    • 4.13.7 GROUND CABLE OF OPERATOR’S CAB – CHECK FOR CORRECT CONNECTION
    • 4.13.8 EMERGENCY LOWERING OF ACCESS LADDER – TEST FUNCTIONALITY
  • 4.14 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH
    • 4.14.1 CRITICAL BOLT CONNECTIONS
    • 4.14.2 EMERGENCY ENGINE SHUTDOWN SWITCHES – TEST FUNCTIONALITY
    • 4.14.3 ENGINE SHUTDOWN PULL CHAINS (SPECIAL EQUIPMENT) – TEST FUNCTIONALITY
    • 4.14.4 ELECTRICAL EQUIPMENT – MAINTAINANCE
    • 4.14.5 HYDRAULIC SYSTEM – FILTER SERVICE
    • 4.14.6 PTO’S (PUMP DISTRIBUTOR GEARS), SWING GEARS AND TRAVEL GEARS – OIL SAMPLE ANALYSIS
    • 4.14.7 SIGNAL HORN COMPRESSOR – CLEAN AND LUBRICATE
    • 4.14.8 HYDRAULIC TRACK TENSIONING SYSTEM – CHECK PRESSURE ACCUMULATORS
    • 4.14.9 CABIN AIR CLEANER – REPLACE PRIMARY FILTER
    • 4.14.10 HYDRAULIC OIL COOLER – INSPECT AND LUBRICATE DOOR HINGES
    • 4.14.11 ALL OTHER HINGES AND AREAS TO LUBRICATE
    • 4.14.12 MACHINERY HOUSE DOORS – INSPECT AND LUBRICATE DOOR HINGES
  • 4.15 EVERY 2000 OPERATING HOURS OR YEARLY
    • 4.15.1 HYDRAULIC SYSTEM – CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER
    • 4.15.2 FILLING THE HYDRAULIC SYSTEM
    • 4.15.3 BLEEDING THE HYDRAULIC SYSTEM
    • 4.15.4 GEAR PUMPS FOR PTO GEAR LUBRICATION
    • 4.15.5 EMERGENCY ESCAPE LADDER – INSPECTION
    • 4.15.6 ACCESS LADDER EMERGENCY LOWERING CHAINS – INSPECTION
    • 4.15.7 HYDRAULIC HOSES – Check Condition
    • 4.15.8 PREVENTATIVE MAINTENANCE (PM) CLINIC – PERFORM TEST
    • 4.15.9 EMERGENCY ESCAPE ROUTE FROM OPERATOR’S CAB
  • 4.16 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR
    • 4.16.1 SWING GEARS AND MOTOR ADAPTER HOUSING – CHANGE OIL
    • 4.16.2 TRAVEL GEARS, MOTOR ADAPTER HOUSINGS AND FINAL DRIVES CHANGE OIL
    • 4.16.3 PTO (PUMP DISTRIBUTOR GEAR) – CHANGE OIL
    • 4.16.4 FLEXIBLE COUPLING – VISUAL CHECK
  • 4.17 CRITICAL BOLT CONNECTIONS – EVERY 3000 OPERATING HOURS
    • 4.17.1 CRITICAL BOLT CONNECTIONS – CHECK TORQUE LOAD
    • 4.17.2 CHECKING THE STEEL STRUCTURES
  • 4.18 EVERY 6000 OPERATING HOURS OR ONCE A YEAR
    • 4.18.1 AUTOMATIC LUBRICATION SYSTEMS – replace pump outlet GREASE FILTERS
    • 4.18.2 HYDRAULIC Oil TANK – CHECK LEAKAGE OIL SCREEN FILTER
    • 4.18.3 CHANGING THE HIGH PRESSURE FILTERS
  • 4.19 FIRE PREVENTION
    • 4.19.1 PRECAUTIONS
  • 4.20 WELD REPAIRS
    • 4.20.1 GENERAL INFORMATION
    • 4.20.2 WELD REPAIRS ON MAJOR COMPONENTS OF THE EXCAVATOR
    • 4.20.3 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE UNDERCARRIAGE
    • 4.20.4 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE LOADER ATTACHMENT
    • 4.20.5 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE SUPERSTRUCTURE
    • 4.20.6 AFTER FINISHING THE WELD REPAIRS ON THE SUPERSTRUCTURE

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