Komatsu Hydraulic Mining Shovel PC5500 Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Mining Shovel PC5500, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Komatsu Hydraulic Mining Shovel PC5500 workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
PRODUCT DETAILS:
Total Pages: 27,752 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
SMPC550015011 - Hydraulic Mining Shovel PC5500-6 Shop Manual.pdf
SMPC550015018 - Hydraulic Mining Shovel PC5500-6 Shop Manual.pdf
SMPC550015019 - Hydraulic Mining Shovel PC5500-6 Shop Manual.pdf
SMPC550015022 - Hydraulic Mining Shovel PC5500-6 Shop Manual.pdf
SMPC550015023 - Hydraulic Mining Shovel PC5500-6 Shop Manual.pdf
SMPC550015025 - Hydraulic Mining Shovel PC5500-6 Shop Manual.pdf
SMPC550015027 - Hydraulic Mining Shovel PC5500-6 Shop Manual.pdf
SMPC550015032 - Hydraulic Mining Shovel PC5500-6 Shop Manual.pdf
SMPC550015035 - Hydraulic Mining Shovel PC5500-6 Shop Manual.pdf
SMPC550015038 - Hydraulic Mining Shovel PC5500-6 Shop Manual.pdf
SMPC550015039 - Hydraulic Mining Shovel PC5500-6 Shop Manual.pdf
PC5500615025SM - Hydraulic Shovel PC5500-6 Electrical & Hydraulic Diagrams.pdf
FAMPC5500-04 - Hydraulic Mining Shovel PC5500 General Assembly Procedure.pdf
Hydraulic Excavator PC5500 Service Manual (SN15014&up).pdf
Hydraulic Excavator PC5500 Service Manual (SN15016&up).pdf
Hydraulic Excavator PC5500 Service Manual (SN15017&up).pdf
Hydraulic Excavator PC5500 Service Manual (SN15031&up).pdf
Hydraulic Excavator PC5500 Service Manual (SN15046&up).pdf
Hydraulic Excavator PC5500 Service Manual (SN15050&up).pdf
GZEAM15066 - Hydraulic Mining Shovel PC5500-6 Operation & Maintenance Manual.pdf
Hydraulic Mining Shovel PC5500-6 Operation & Maintenance Manual (SN15012&15013).pdf
Hydraulic Mining Shovel PC5500-6 Operation & Maintenance Manual (SN15014).pdf
Hydraulic Mining Shovel PC5500-6 Operation & Maintenance Manual (SN15016).pdf
Hydraulic Mining Shovel PC5500-6 Operation & Maintenance Manual (SN15027).pdf
Hydraulic Mining Shovel PC5500-6 Operation & Maintenance Manual (SN15028&15029&15030).pdf
Hydraulic Mining Shovel PC5500-6 Operation & Maintenance Manual (SN15032&15039).pdf
Hydraulic Mining Shovel PC5500-6 Operation & Maintenance Manual (SN15033).pdf
Hydraulic Mining Shovel PC5500-6 Operation & Maintenance Manual (SN15035&up).pdf
Hydraulic Mining Shovel PC5500-6 Operation & Maintenance Manual (SN15036).pdf
Hydraulic Mining Shovel PC5500-6 Operation & Maintenance Manual (SN15038).pdf
Hydraulic Mining Shovel PC5500-6 Operation & Maintenance Manual (SN15040).pdf
Hydraulic Mining Shovel PC5500-6 Operation & Maintenance Manual (SN15041).pdf
Hydraulic Mining Shovel PC5500-6 Operation & Maintenance Manual (SN15044).pdf
Hydraulic Mining Shovel PC5500-6 Operation & Maintenance Manual (SN15045&up).pdf
Hydraulic Mining Shovel PC5500-6 Operation & Maintenance Manual (SN15049&up).pdf
Hydraulic Mining Shovel PC5500-6 Operation & Maintenance Manual (SN15050).pdf
Hydraulic Mining Shovel PC5500-6 Operation & Maintenance Manual (SN15052).pdf
Hydraulic Mining Shovel PC5500-6 Operation & Maintenance Manual (SN15060&15062).pdf
OMPC550015011 - Hydraulic Mining Shovel PC5500-6 Operation & Maintenance Manual.pdf
OMPC550015018 - Hydraulic Mining Shovel PC5500-6 Operation & Maintenance Manual.pdf
OMPC550015019 - Hydraulic Mining Shovel PC5500-6 Operation & Maintenance Manual.pdf
OMPC550015022 - Hydraulic Mining Shovel PC5500-6 Operation & Maintenance Manual.pdf
OMPC550015023 - Hydraulic Mining Shovel PC5500-6 Operation & Maintenance Manual.pdf
OMPC550015025 - Hydraulic Mining Shovel PC5500-6 Operation & Maintenance Manual.pdf
OMPC550015027 - Hydraulic Mining Shovel PC5500-6 Operation & Maintenance Manual.pdf
OMPC550015032 - Hydraulic Mining Shovel PC5500-6 Operation & Maintenance Manual.pdf
OMPC550015035 - Hydraulic Mining Shovel PC5500-6 Operation & Maintenance Manual.pdf
OMPC550015038 - Hydraulic Mining Shovel PC5500-6 Operation & Maintenance Manual.pdf
OMPC550015039 - Hydraulic Mining Shovel PC5500-6 Operation & Maintenance Manual.pdf
MAIN SECTIONS
FAMPC5500-04 - Hydraulic Mining Shovel PC5500 General Assembly Procedure.....5
Cover.....5
Contents.....13
1. Assembly of the Undercarriage (Z 24016a, Z 24018a) .....25
1.1 Assembly .....25
2. Assembly of the Cable Reel Unit (Z21885) .....37
3. Assembly of the Superstructure Platform onto the Undercarriage (Z21886) .....39
4. Assembly of the Prime Drive Unit to the Superstructure Platform (Z 21887) .....41
4. a Mounting of the hydraulic access ladder (Z21136) .....43
5. Assembly of the Boom Cylinders and the Stick Cylinder to the Boom (Z 21888a; Z 21941, Z 21944) .....47
5.a. Assembly of the Boom (Z21889a) .....49
6. Assembly of the Counterweight (Z21891b) .....51
7. Mounting of the Fuel Tank (Z 21892) or Main Switch Cabinet for Electrical Driven Unit.....53
8. Mounting of the Cab Base (Z 21893) .....55
9. Mounting of the Cab with Support Frame (Z 21894) .....57
10. Mounting of the High Pressure Hoses (Z 21896) and the Hydraulic Oil Tank (Z 21897) .....59
11. Mounting of the Hydraulic Oil Cooler (Z 21895) .....65
12. Mounting of the Hand Rails, Cat Walks, Steps and the Grease Barrel Crane* (Z 21901) .....71
13. Mounting of Cable transfer to the Operators Cab (Z22937) .....73
13a. Installation of Hydraulic Hoses to the Attachment and Rotary Joint .....75
14. Checking of direction motor rotation Z 22644a .....77
15. Connection of Electric Cables .....79
16. Filling the Hydraulic System (Z25026) .....83
17. Pre-checks prior Initial Start-up .....85
17.1 General .....85
17.2 Only with Electric Drive .....87
17.3 Initial Start up .....87
18. Assembly of the Stick to the Boom: Z 21890 .....89
19. Mounting of the Stick Cylinders to the Stick (Z 21903) .....91
20. Assembly of the Bullclam Bucket to the Stick: Z 21904 .....93
21. Mounting of the Pin Seals (Z 21906) .....97
22. Putting the Lubrication System into operation (Z25022) .....99
23. Checks and Adjustments Prior Commissioning .....101
Metric standard thread .....103
Metric fine thread .....105
GZEAM15066 - Hydraulic Mining Shovel PC5500-6 Operation & Maintenance Manual.....109
1. INTRODUCTION.....111
1.1 CONTENTS OF THE BINDER.....112
1.2 DIVISION OF THE BINDER.....113
1.3 DESIGNATED USE OF THE SHOVEL.....114
1.4 DELIVERY OF THE SHOVEL.....115
1.5 EXPLANATION OF ABBREVIATIONS.....116
1.6 TABLE OF CONTENTS.....117
2. SAFETY.....123
2.1 SAFETY INSTRUCTIONS.....124
2.1.1 WARNINGS AND SYMBOLS.....124
2.1.2 BASIC OPERATION AND DESIGNATED USE OF THE HYDRAULIC SHOVEL.....124
2.1.3 ORGANIZATIONAL MEASURES.....125
2.1.4 SELECTION AND QUALIFICATION OF PERSONNEL - BASIC RESPONSIBILITIES.....127
2.1.5 SAFETY INSTRUCTIONS GOVERNING SPECIFIC OPERATIONAL PHASES.....128
2.1.6 WARNING OF SPECIAL DANGERS.....131
2.1.7 TRANSPORTING AND TOWING -RECOMMISSIONING.....133
2.1.8 SPECIAL SAFETY EQUIPMENT.....133
2.1.9 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD).....137
3. OPERATION.....145
3.1 FOREWORD.....146
3.2 CONSTRUCTION OF THE SHOVEL.....147
3.2.1 OVERALL VIEW.....147
3.2.2 UNDERCARRIAGE AND SUPERSTRUCTURE.....148
3.2.3 HYDRAULICALLY OPERATED ACCESS LADDER.....154
3.2.4 EMERGENCY ESCAPE LADDER.....158
3.2.5 BOOM ACCESS LADDER AND WALKWAY.....160
3.2.6 EMERGENCY ENGINE SHUTDOWN FROM GROUND MAN OR OPERATOR WARNING SYSTEM.....162
3.2.7 OPERATORS CAB WITH INTEGRATED FALLING OBJECT PROTECTIVE STRUCTURE (FOPS).....164
3.2.8 ENGINE OIL MANAGEMENT SYSTEM.....174
3.3 OPERATORS CAB - CONTROLS.....178
3.3.1 CONTROLS WITH BACKHOE ATTACHMENT.....178
3.3.2 CONTROLS WITH BOTTOM DUMP BUCKET ATTACHMENT.....182
3.3.3 OPERATORS CONSOLE.....187
3.3.4 INTERFACE PANEL FOR DIAGNOSTICS.....195
3.3.5 CONTROL MODULE FOR AUXILIARY CAB HEATER.....197
3.4 VEHICLE HEALTH MONITORING SYSTEM VHMS HEALTH MONITOR.....198
3.4.1 SEQUENCE OF DISPLAYS.....199
3.4.2 OPENING SCREEN.....199
3.4.3 MAIN GAUGE SCREENS 1 TO 4.....200
3.4.4 FUEL CONSUMPTION SCREEN.....207
3.4.5 FAILURE MESSAGE HISTORY SCREEN FOR OPERATOR.....208
3.4.6 MAIN SCREEN - CHANGE >TIME >SMR >DATE.....208
3.4.7 MAINTENANCE MONITOR.....209
3.4.8 SETTINGS FOR OPERATOR.....210
3.4.9 AUTOMATIC MESSAGES.....215
3.4.10 TABLE OF ALL TOP MESSAGES PROVIDED BY THE SYSTEM.....220
3.4.11 TABLE OF AVAILABLE INSTRUCTION MESSAGES.....231
3.5 CAMERA SYSTEM WITH MONITORS.....234
3.5.1 LOCATION OF MONITORS AND CONTROL UNITS.....235
3.6 OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING.....242
3.6.1 AUXILIARY HEATER FOR OPERATORS CAB.....247
3.7 MACHINERY HOUSE.....248
3.7.1 EMERGENCY ENGINE SHUTDOWN SWITCHES.....249
3.7.2 SAFETY SWITCH FOR MAINTENANCE.....251
3.7.3 CONTROL AND FILTER PANEL OF REAR- AND FRONT POWER UNIT.....253
3.8 ELECTRICAL EQUIPMENT IN CAB BASE.....254
3.8.1 STANDARD COMPONENTS IN CAB BASE.....255
3.8.2 SWITCH BOARD (X2) IN CAB BASE.....257
3.8.3 COMPONENTS OF ELECTRICAL PREHEATING SYSTEM IN CAB BASE.....267
3.9 PREHEATING SYSTEMS FOR OIL, COOLANT AND BATTERIES.....270
3.10 CHECKS BEFORE STARTING THE ENGINES.....276
3.11 STARTING THE ENGINES.....282
3.11.1 STARTING PROCEDURE.....285
3.11.2 ENGINE WARM-UP.....293
3.11.3 HYDRAULIC OIL WARM-UP.....293
3.12 MOVING THE SHOVEL.....295
3.12.1 TRAVEL CONTROL WITH FOOT PEDALS.....295
3.12.2 TRAVELLING INSTRUCTIONS.....298
3.13 SLEWING AND BRAKING THE SUPERSTRUCTURE.....299
3.13.1 SLEWING THE SUPERSTRUCTURE.....299
3.14 WORKING WITH THE ATTACHMENT.....302
3.14.1 MACHINES EQUIPPED WITH EURO CONTROL SYSTEM.....302
3.14.2 MACHINES EQUIPPED WITH KMG CONTROL SYSTEM.....303
3.14.3 BOTTOM DUMP BUCKET.....304
3.14.4 DROP BALL OPERATION.....305
3.14.5 COMBINED OPERATION CYCLES.....308
3.15 WORKING INSTRUCTIONS.....310
3.15.1 STABILITY OF THE SHOVEL.....310
3.15.2 SHOVEL OPERATION.....310
3.16 PARKING THE SHOVEL.....313
3.17 STOPPING THE ENGINES.....314
3.17.1 RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM.....317
3.18 OPERATION OF THE LUBRICATION SYSTEM.....318
3.18.1 CENTRAL LUBRICATION SYSTEM -CLS- FOR SUPERSTRUCTURE AND ATTACHMENT.....318
3.18.2 SWING CIRCLE PINION LUBRICATION SYSTEM -SLS-.....320
3.19 FIRE DETECTION AND SUPPRESSION SYSTEM.....322
3.19.1 HIGH LEVEL ALARM FIRE.....327
3.19.2 ENGINE SHUT-DOWN THROUGH FUEL SHUT-OFF SOLENOID VALVE.....327
3.19.3 ACTUATION MODES OF THE FIRE SUPPRESSION SYSTEMS.....327
3.19.4 INDICATION OF OPERATIONAL MODES AT CONTROL MODULE, AFTER AUTOMATIC ACTUATION OF THE FIRE S......329
3.19.5 LOCATION OF THE EXTINGUISHING AGENT TANK ASSEMBLIES AND EXPELLANT GAS CARTRIDGES ON POWER......331
3.20 TRANSFER PUMP FOR HYDRAULIC OIL.....332
3.20.1 OPERATING THE TRANSFER PUMP.....333
3.20.2 FUNCTIONS OF THE TRANSFER PUMP.....335
3.21 CENTRAL REFILLING SYSTEM.....338
3.21.1 SYSTEMS CONNECTED TO THE REFILLING SYSTEM.....339
3.21.2 OPERATING THE HYDRAULIC SERVICE ARM.....341
3.21.3 RECEIVER PANEL WITH MONITOR BOX.....343
3.21.4 REFILLABLE GREASE CONTAINERS OF THE AUTOMATIC LUBRICATION SYSTEMS.....349
3.22 WORK ON THE LOADER ATTACHMENT.....350
3.23 TRANSPORTATION AND LIFTING OF THE SHOVEL.....351
3.23.1 DISASSEMBLING OF THE SHOVEL.....351
3.23.2 TRANSPORTATION AND LIFTING.....351
3.24 RETRIEVAL PROCEDURE.....352
3.25 SHOVEL STORAGE.....353
3.25.1 PREPARING FOR STORAGE.....353
3.25.2 ONE MONTH REPETITIVE SERVICE PERIOD.....354
3.25.3 SIX MONTH REPETITIVE SERVICE PERIOD.....354
3.25.4 PREPARING FOR OPERATION.....355
3.26 TROUBLE SHOOTING.....356
3.26.1 ENGINE.....356
3.26.2 HYDRAULIC SYSTEM.....357
3.26.3 FINAL DRIVES AND SWING GEAR.....358
3.26.4 CRAWLER TRACKS.....358
4. MAINTENANCE.....359
4.1 FOREWORD.....360
4.2 SAFETY PRECAUTIONS FOR MAINTENANCE.....361
4.3 FLUIDS AND LUBRICANTS.....363
4.3.1 LUBRICANTS FOR OPERATION IN COLD AND ARCTIC CLIMATES.....363
4.3.2 FLUIDS AND LUBRICANTS FOR MODERATE AND HOT CLIMATES.....364
4.4 FILLING CAPACITIES.....366
4.5 STANDARD TORQUE LIST.....367
4.6 LUBRICATION AND MAINTENANCE SCHEDULE.....368
4.6.1 INITIAL SERVICING.....368
4.6.2 PERIODIC SERVICING INTERVALS.....368
4.6.3 PERIODIC SERVICING SCHEDULE.....369
4.6.4 REPLACEMENT OF HYDRAULIC HOSE LINES AND FUEL HOSE LINES.....374
4.6.5 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS.....375
4.6.6 EXTENDED SERVICE INTERVALS FOR ENGINES EQUIPPED WITH ENGINE OIL MANAGEMENT SYSTEM.....379
4.6.7 MAINTENANCE OF THE ENGINES.....383
4.6.8 ENGINE FUEL FILTER LOCATION.....385
4.7 WHEN NECESSARY.....388
4.7.1 ENGINE AIR CLEANER MAINTENANCE.....389
4.7.2 SWING CIRCLE TOOTHING LUBRICATION.....393
4.7.3 AUTOMATIC LUBRICATION SYSTEMS FILL GREASE CONTAINERS.....395
4.7.4 TRACK ROLLERS AND GUIDE WHEELS - REPLACE FLOATING SEALS.....399
4.7.5 COLD STARTING AID, REPLACE FLUID CYLINDER.....401
4.8 EVERY 10 OPERATING HOURS OR DAILY.....402
4.8.1 WALK - AROUND INSPECTION.....403
4.8.2 AIR CLEANER - CLEAN PRE-CLEANER.....413
4.8.3 RADIATORS - CHECK COOLANT LEVEL.....415
4.8.4 TRACK GROUPS - CLEAN.....415
4.9 EVERY 50 OPERATING HOURS OR WEEKLY.....416
4.9.1 SWING GEARS, BRAKE HOUSINGS AND MOTOR ADAPTER HOUSINGS - CHECK OIL LEVELS.....417
4.9.2 TRAVEL GEARS, MOTOR ADAPTER HOUSINGS AND FINAL DRIVES CHECK OIL LEVELS.....423
4.9.3 PTOs (PUMP DISTRIBUTOR GEARS) AND OIL RESERVOIR - CHECK OIL LEVEL.....429
4.9.4 HYDRAULIC ACCESS LADDER - CHECK SAFETY SENSOR.....433
4.9.5 HYDRAULIC OIL COOLERS - INSPECT AND CLEAN IF NECESSARY.....435
4.10 EVERY 250 OPERATING HOURS OR MONTHLY.....436
4.10.1 AIR CONDITIONING COMPRESSOR - CHECK DRIVE BELT TENSION.....437
4.10.2 SIGNAL HORN COMPRESSOR - LUBRICATE.....439
4.10.3 HYDRAULIC OIL COOLER FAN BEARINGS - CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER.....439
4.10.4 RADIATOR FAN BEARINGS - CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER.....439
4.10.5 AUTOMATIC LUBRICATION SYSTEMS - CLEAN IN-LINE GREASE FILTER AND CHECK BREATHER FILTER.....441
4.10.6 CAB AIR CLEANER - CLEAN OR REPLACE FILTER ELEMENT.....443
4.10.7 AIR CONDITIONING FOR OPERATORS CAB - CHECK REFRIGERANT LEVEL.....447
4.10.8 WINDSHIELD WASHER SYSTEM - CHECK FLUID LEVEL.....449
4.11 EVERY 500 OPERATING HOURS OR QUARTERLY.....450
4.11.1 BATTERIES - CHECK FLUID LEVEL.....451
4.11.2 FUEL TANK - DRAIN CONDENSATION.....453
4.11.3 CRAWLER TRACK - INSPECTION.....455
4.11.4 GROUND CABLES OF ENGINE AND ALTERNATOR - CHECK FOR CORRECT CONNECTION.....461
4.11.5 GROUND CABLE OF OPERATORS CAB - CHECK FOR CORRECT CONNECTION.....463
4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH.....464
4.12.1 HIGH STRENGTH BOLT CONNECTIONS - CHECK TORQUE LOAD.....465
4.12.2 HYDRAULIC SYSTEM - FILTER SERVICE.....523
4.12.3 PTOS (PUMP DISTRIBUTOR GEARS), SWING GEARS AND TRAVEL GEARS - OIL SAMPLE ANALYSIS.....537
4.12.4 SIGNAL HORN COMPRESSOR - CLEAN AND LUBRICATE.....539
4.12.5 HYDRAULIC TRACK TENSIONING SYSTEM - CHECK PRESSURE ACCUMULATORS.....541
4.12.6 WATER FILTER - REPLACE FILTER CARTRIDGE.....543
4.12.7 HYDRAULIC OIL COOLER - INSPECT AND LUBRICATE DOOR HINGES.....545
4.12.8 MACHINERY HOUSE DOORS - INSPECT AND LUBRICATE DOOR HINGES.....547
4.13 EVERY 2000 OPERATING HOURS OR YEARLY.....548
4.13.1 HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER.....549
4.13.2 EMERGENCY ESCAPE LADDER - INSPECTION.....561
4.14 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR.....562
4.14.1 SWING GEARS, BRAKE HOUSINGS AND MOTOR ADAPTER HOUSINGS - CHANGE OIL.....563
4.14.2 TRAVEL GEARS, MOTOR ADAPTER HOUSINGS AND FINAL DRIVES CHANGE OIL.....571
4.14.3 PTO (PUMP DISTRIBUTOR GEAR) - CHANGE OIL.....575
4.15 FIRE PREVENTION.....578
4.16 WELD REPAIRS.....580
4.16.1 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE UNDERCARRIAGE.....583
4.16.2 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE LOADER ATTACHMENT.....585
4.16.3 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE SUPERSTRUCTURE.....587
4.16.4 AFTER FINISHING THE WELD REPAIRS ON THE SUPERSTRUCTURE.....589
Hydraulic Excavator PC5500 Service Manual (SN15014&up).....597
Hydraulic Excavator PC5500 Service Manual (SN15016&up).....1034
PC5500-6-E_Sec_7-0_rev1.pdf.....0
8.pdf.....0
Example for ESR 1:.....1276
Example for ESR 2:.....1276
Example for ESR 3:.....1276
Example for ESR 2:.....1276
SET 1.....1302
Hydraulic Excavator PC5500 Service Manual (SN15017&up).....1662
PC5500-6_Sec_Appendix_rev1.pdf.....0
2. MC7 Fault Code, Diagnostic.....2296
.....2296
Blink.....2296
High Speed 2.....2296
Hydraulic Excavator PC5500 Service Manual (SN15031&up).....2298
Contents and 00_Foreworda_15031.pdf.....2298
.....2308
PC5500-6-D_Sec_1-0_rev4.pdf.....2316
PC5500-6-D_Sec_1-0_rev4.pdf.....2316
Leerseite.pdf.....2345
PC5500-6-D_Sec_4-0_rev3.pdf.....2396
PC5500-6-D_Sec_4-0_rev3.pdf.....2396
Leerseite.pdf.....2419
PC5500-6-D_Sec_5-0_rev3.pdf.....2420
PC5500-6-D_Sec_5-0_rev3.pdf.....2420
Leerseite.pdf.....2467
PC5500-6-D_Sec_6-0_rev1.pdf.....2468
PC5500-6-D_Sec_7-0_rev5c.pdf.....2512
PC5500-6_Sec_8-0_rev1.pdf.....2592
PC5500-6-D_Sec_8-1_rev3.pdf.....2600
PC5500-6-D_Sec_8-2_rev4.pdf.....2706
PC5500-6-D_Sec_8-3_rev2.pdf.....2744
PC5500-6-D_Sec_9-0_rev0.pdf.....2768
PC5500-6-D_Sec_10-0_rev1.pdf.....2786
PC5500-6-D_Sec_10-0_rev1.pdf.....2786
Leerseite.pdf.....2793
PC5500-6-D_Sec_11-0_rev0.pdf.....2794
PC5500-6_Sec_12-0_rev3.pdf.....2800
PC5500-6_Sec_13_0_rev0neu.pdf.....2817
PC5500-6-D_Sec_14-0_rev2.doc.....2832
PC5500-6-D_Sec_15-0_rev1.pdf.....2890
PC5500-6-D_Sec_Appendix_rev1.pdf.....2946
PC5500-6-D_Sec_Appendix_rev0.pdf.....2946
PC5500_6_FS.PDF.....2964
MC7_Flashcode.doc.....2982
Hydraulic Excavator PC5500 Service Manual (SN15046&up).....2984
Contents and 00_Foreworda_15046.pdf.....2984
PC5500-6-D_Sec_1-0_rev4.pdf.....3002
PC5500-6-D_Sec_1-0_rev4.pdf.....3002
Leerseite.pdf.....3031
PC5500-6-D_Sec_2-0_rev3.pdf.....3032
PC5500-6-D_Sec_3-0_rev2.pdf.....3066
PC5500-6-D_Sec_4-0_rev4a.pdf.....3082
PC5500-6-D_Sec_5-0_rev4.pdf.....3106
PC5500-6-D_Sec_6-0_rev3.pdf.....3154
PC5500-6-D_Sec_7-0_rev5d.pdf.....3198
PC5500-6_Sec_8-0_rev1.pdf.....3278
PC5500-6-D_Sec_8-1_rev3.pdf.....3286
PC5500-6-D_Sec_8-2_rev4.pdf.....3392
PC5500-6-D_Sec_8-3_rev2.pdf.....3430
PC5500-6-D_Sec_9-0_rev0.pdf.....3454
PC5500-6-D_Sec_10-0_rev1.pdf.....3472
PC5500-6-D_Sec_10-0_rev1.pdf.....3472
Leerseite.pdf.....3479
PC5500-6-D_Sec_11-0_rev0.pdf.....3480
PC5500-6_Sec_12-0_rev3.pdf.....3486
PC5500-6_Sec_13_0_rev0neu.pdf.....3502
PC5500-6-D_Sec_15-0_rev1.pdf.....3576
PC5500-6_Sec_Appendix_rev2.pdf.....0
PC5500-6-D_Sec_Appendix_rev1 Code.pdf.....0
MC7_Flashcode.doc.....3652
Hydraulic Excavator PC5500 Service Manual (SN15050&up).....3654
Contents and 00_Foreworda15050.pdf.....3654
PC5500-6-E_Sec_1-0_rev2.pdf.....3672
PC5500-6-E_Sec_2-0_rev3.pdf.....3702
PC5500-6-E_Sec_3-0_rev2.pdf.....3716
PC5500-6-E_Sec_4-0_rev3.pdf.....3732
PC5500-6-E_Sec_5-0_rev3.pdf.....3756
PC5500-6-E_Sec_6-0_rev3.pdf.....3804
PC5500-6-E_Sec_7-0_15016E_rev2.pdf.....3848
PC5500-6_Sec_8-0_rev1.pdf.....3948
PC5500-6-D_Sec_8-1_rev3.pdf.....3956
PC5500-6-D_Sec_8-2_rev4.pdf.....4062
PC5500-6-D_Sec_8-3_rev2.pdf.....4100
PC5500-6-E_Sec_9-0_rev1.pdf.....4124
PC5500-6-E_Sec_10-0_rev1.pdf.....4142
PC5500-6-E_Sec_11-0_rev1.pdf.....4150
PC5500-6_Sec_12-0_rev3.pdf.....4164
PC5500-6_Sec_13_0_rev0.pdf.....4181
PC5500-6-D_Sec_15-0_rev1.pdf.....4256
Hydraulic Mining Shovel PC5500-6 Operation & Maintenance Manual (SN15012&15013).....4312
COVER.....4312
1. INTRODUCTION.....4314
1.1 CONTENTS OF THE BINDER.....4315
1.2 DIVISION OF THE BINDER.....4316
1.3 DESIGNATED USE OF THE SHOVEL.....4317
1.4 DELIVERY OF THE SHOVEL.....4318
1.5 EXPLANATION OF ABBREVATIONS.....4319
1.6 TABLE OF CONTENTS.....4320
2. SAFETY.....4326
2.1 SAFETY INSTRUCTIONS.....4327
2.1.1 WARNINGS AND SYMBOLS.....4327
2.1.2 BASIC OPERATION AND DESIGNATED USE OF THE HYDRAULIC EXCAVATOR.....4327
2.1.3 ORGANIZATIONAL MEASURES.....4328
2.1.4 SELECTION AND QUALIFICATION OF PERSONNEL - BASIC RESPONSIBILITIES.....4330
2.1.5 SAFETY INSTRUCTIONS GOVERNING SPECIFIC OPERATIONAL PHASES.....4331
2.1.6 WARNING OF SPECIAL DANGERS.....4334
2.1.7 TRANSPORTING AND TOWING -RECOMMISSIONING.....4336
2.1.8 SPECIAL SAFETY EQUIPMENT.....4336
2.1.9 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD).....4340
3. OPERATION.....4348
3.1 FOREWORD.....4349
3.2 CONSTRUCTION OF THE SHOVEL.....4350
3.2.1 OVERALL VIEW.....4350
3.2.2 UNDERCARRIAGE AND SUPERSTRUCTURE.....4351
3.2.3 HYDRAULICALLY OPERATED ACCESS LADDER.....4357
3.2.4 EMERGENCY ESCAPE LADDER.....4361
3.2.5 EMERGENCY ENGINE SHUTDOWN FROM GROUND MAN OR OPERATOR WARNING SYSTEM.....4363
3.2.6 OPERATORS CAB WITH INTEGRATED FALLING OBJECT PROTECTIVE STRUCTURE (FOPS).....4365
3.2.7 ENGINE OIL MANAGEMENT SYSTEM.....4373
3.3 OPERATORS CAB - CONTROLS.....4377
3.3.1 HYDRAULIC CONTROL SYSTEM.....4378
3.3.2 SAFETY CIRCUIT FOR CONTROLS.....4378
3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS.....4391
3.4.1 OPERATING THE ELECTRONIC MONITORING SYSTEM.....4400
3.4.2 MENU CONTROL CHART.....4449
3.4.3 FAULT AND INFORMATION MESSAGE LIST.....4469
3.5 OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING.....4493
3.5.1 A - HEATING.....4494
3.5.2 B - COOLING.....4494
3.5.3 COMBINED OPERATION OF AIR CONDITIONING AND HEATING.....4494
3.6 POWER HOUSE.....4495
3.6.1 EMERGENCY ENGINE SHUTDOWN SWITCHES.....4496
3.6.2 CONTROL AND FILTER PANEL OF REAR- AND FRONT POWER UNIT.....4498
3.7 ELECTRICAL EQUIPMENT IN CAB BASE.....4499
3.7.1 STANDARD COMPONENTS IN CAB BASE.....4500
3.7.2 SWITCH BOARD (X2) IN CAB BASE.....4502
3.7.3 COMPONENTS OF ELECTRICAL PREHEATING SYSTEM IN CAB BASE.....4510
3.8 PREHEATING SYSTEMS FOR OIL, COOLANT AND BATTERIES.....4513
3.9 GENERATOR SET.....4519
3.9.1 OPERATING THE GENERATOR SET.....4522
3.10 CHECKS BEFORE STARTING THE ENGINES.....4525
3.11 STARTING THE ENGINES.....4531
3.11.1 COLD SEASON STARTING.....4532
3.11.2 STARTING PROCEDURE.....4538
3.12 MOVING THE SHOVEL.....4552
3.12.1 TRAVEL CONTROL WITH FOOT PEDALS.....4552
3.12.2 TRAVELLING INSTRUCTIONS.....4555
3.13 SLEWING AND BRAKING THE SUPERSTRUCTURE.....4556
3.13.1 SLEWING THE SUPERSTRUCTURE.....4556
3.14 WORKING WITH THE ATTACHMENT.....4559
3.14.1 MACHINES EQUIPPED WITH EURO CONTROL SYSTEM.....4559
3.14.2 MACHINES EQUIPPED WITH KMG CONTROL SYSTEM.....4560
3.14.3 BOTTOM DUMP BUCKET.....4561
3.14.4 DROP BALL OPERATION.....4562
3.14.5 COMBINED OPERATION CYCLES.....4565
3.15 WORKING INSTRUCTIONS.....4567
3.15.1 STABILITY OF THE SHOVEL.....4567
3.15.2 SHOVEL OPERATION.....4567
3.16 PARKING THE SHOVEL.....4570
3.17 STOPPING THE ENGINES.....4571
3.18 OPERATION OF THE LUBRICATION SYSTEM.....4575
3.18.1 CENTRAL LUBRICATION SYSTEM CLS.....4575
3.18.2 SWING CIRCLE PINION LUBRICATION SYSTEM SLS.....4577
3.19 FIRE DETECTION AND SUPPRESSION SYSTEM.....4579
3.19.1 HIGH LEVEL ALARM FIRE.....4582
3.19.2 ENGINE SHUT-DOWN THROUGH FUEL SHUT-OFF SOLENOID VALVES.....4582
3.19.3 ACTUATION MODES OF THE FIRE SUPPRESSION SYSTEM.....4582
3.19.4 INDICATION OF OPERATIONAL MODES AT CONTROL MODULE, AFTER AUTOMATIC ACTUATION OF THE FIRE S......4584
3.19.5 LOCATION OF THE EXTINGUISHING AGENT TANK ASSEMBLIES AND EXPELLANT GAS CARTRIDGES ON POWER......4586
3.20 TRANSFER PUMP FOR HYDRAULIC OIL.....4587
3.20.1 OPERATING THE TRANSFER PUMP.....4588
3.20.2 FUNCTIONS OF THE TRANSFER PUMP.....4590
3.21 CENTRAL REFILLING SYSTEM.....4593
3.21.1 SYSTEMS CONNECTED TO THE REFILLING SYSTEM.....4594
3.21.2 OPERATING THE HYDRAULIC SERVICE ARM.....4596
3.21.3 RECEIVER PANEL WITH MONITOR BOX.....4598
3.21.4 CENTRAL LUBRICATION SYSTEM AND SWING CIRCLE LUBRICATION SYSTEM.....4604
3.22 WORK ON THE LOADER ATTACHMENT.....4605
3.23 TRANSPORTATION AND LIFTING OF THE SHOVEL.....4606
3.23.1 DISASSEMBLING OF THE SHOVEL.....4606
3.23.2 TRANSPORTATION AND LIFTING.....4606
3.24 RETRIEVAL PROCEDURE.....4607
3.25 SHOVEL STORAGE.....4608
3.25.1 PREPARING FOR STORAGE.....4608
3.25.2 ONE MONTH REPETITIVE SERVICE PERIOD.....4609
3.25.3 SIX MONTH REPETITIVE SERVICE PERIOD.....4609
3.25.4 PREPARING FOR OPERATION.....4610
3.26 TROUBLE SHOOTING.....4611
3.26.1 ENGINE.....4611
3.26.2 HYDRAULIC SYSTEM.....4612
3.26.3 FINAL DRIVES AND SWING GEAR.....4613
3.26.4 CRAWLER TRACKS.....4613
4. MAINTENANCE.....4614
4.1 FOREWORD.....4615
4.2 PRECAUTIONS FOR MAINTENANCE.....4616
4.3 FUEL AND LUBRICANTS.....4617
4.3.1 LUBRICANTS FOR OPERATION IN COLD AND ARCTIC CLIMATES.....4617
4.3.2 FUEL AND LUBRICANTS FOR MODERATE AND HOT CLIMATES.....4618
4.4 FILLING CAPACITIES.....4620
4.5 STANDARD TORQUE LIST.....4621
4.6 LUBRICATION AND MAINTENANCE SCHEDULE.....4622
4.6.1 INITIAL SERVICING.....4622
4.6.2 PERIODIC SERVICING INTERVALS.....4622
4.6.3 PERIODIC SERVICING SCHEDULE.....4623
4.6.4 EXTENDED SERVICE INTERVALS FOR ENGINES WITH ENGINE OIL MANAGEMENT SYSTEM.....4630
4.6.5 MAINTENANCE OF THE ENGINES.....4634
4.7 WHEN NECESSARY.....4635
4.7.1 ENGINE AIR CLEANER MAINTENANCE.....4636
4.7.2 SWING CIRCLE TOOTHING LUBRICATION.....4640
4.7.3 AUTOMATIC LUBRICATION SYSTEMS FILL GREASE CONTAINERS.....4642
4.7.4 TRACK ROLLERS AND GUIDE WHEELS - REPLACE FLOATING SEALS.....4646
4.7.5 COLD STARTING AID, REPLACE FLUID CYLINDER.....4648
4.8 EVERY 10 OPERATING HOURS OR DAILY.....4649
4.8.1 VISUAL INSPECTIONS.....4650
4.8.2 AIR CLEANER - CLEAN PRE-CLEANER.....4658
4.8.3 RADIATORS - CHECK COOLANT LEVEL.....4660
4.8.4 TRACK GROUPS - CLEAN.....4660
4.9 EVERY 50 OPERATING HOURS OR WEEKLY.....4661
4.9.1 SWING GEARS AND MOTOR ADAPTER HOUSINGS - CHECK OIL LEVELS.....4662
4.9.2 TRAVEL GEARS, BRAKE HOUSINGS AND MOTOR ADAPTER HOUSINGS - CHECK OIL LEVELS.....4664
4.9.3 PTOs (PUMP DISTRIBUTOR GEARS) AND OIL RESERVOIR - CHECK OIL LEVEL.....4670
4.9.4 HYDRAULIC ACCESS LADDER - CHECK SAFETY SENSOR.....4674
4.9.5 HYDRAULIC OIL COOLERS - INSPECT AND CLEAN IF NECESSARY.....4676
4.10 EVERY 250 OPERATING HOURS OR MONTHLY.....4677
4.10.1 AIR CONDITIONING COMPRESSOR - CHECK DRIVE BELT TENSION.....4678
4.10.2 UNDERCARRIAGE PIN CONNECTIONS - LUBRICATE.....4680
4.10.3 SIGNAL HORN COMPRESSOR - LUBRICATE.....4680
4.10.4 HYDRAULIC OIL COOLER FAN BEARING HOUSINGS - CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER.....4680
4.10.5 RADIATOR FAN BEARING HOUSINGS - CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER.....4680
4.10.6 AUTOMATIC LUBRICATION SYSTEMS - CLEAN IN-LINE GREASE FILTER.....4682
4.10.7 CAB AIR CLEANER - CLEAN OR REPLACE FILTER ELEMENT.....4684
4.11 EVERY 500 OPERATING HOURS OR MONTHLY.....4685
4.11.1 BATTERIES - CHECK FLUID LEVEL.....4686
4.11.2 FLEXIBLE DRIVE COUPLINGS - CHECK OIL LEVEL.....4688
4.11.3 FUEL TANK - DRAIN CONDENSATION.....4690
4.11.4 CRAWLER TRACK - INSPECTION.....4692
4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH.....4697
4.12.1 HIGH STRENGTH BOLT CONNECTIONS - CHECK TORQUE LOAD.....4698
4.12.2 HYDRAULIC SYSTEM - FILTER SERVICE.....4752
4.12.3 PTOS (PUMP DISTRIBUTOR GEARS), SWING GEARS AND TRAVEL GEARS - OIL SAMPLE ANALYSIS.....4766
4.12.4 SIGNAL HORN COMPRESSOR - CLEAN AND LUBRICATE.....4768
4.12.5 HYDRAULIC TRACK TENSIONING SYSTEM - CHECK PRESSURE ACCUMULATORS.....4770
4.12.6 WATER FILTER - REPLACE FILTER CARTRIDGE.....4772
4.13 EVERY 2000 OPERATING HOURS OR YEARLY.....4773
4.13.1 HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER.....4774
4.13.2 EMERGENCY ESCAPE LADDER - INSPECTION.....4786
4.14 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR.....4787
4.14.1 SWING GEARS AND MOTOR ADAPTER HOUSING - CHANGE OIL.....4788
4.14.2 TRAVEL GEARS, BRAKE AND MOTOR ADAPTER HOUSINGS - CHANGE OIL.....4792
4.14.3 PTO (PUMP DISTRIBUTOR GEAR) - CHANGE OIL.....4798
4.15 FIRE PREVENTION.....4801
4.16 REPAIR WELDINGS.....4803
4.16.1 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE UNDERCARRIAGE.....4806
4.16.2 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE LOADER ATTACHMENT.....4808
4.16.3 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE SUPERSTRUCTURE.....4810
4.16.4 AFTER FINISHING THE REPAIR WELDINGS ON THE SUPERSTRUCTURE.....4812
Hydraulic Mining Shovel PC5500-6 Operation & Maintenance Manual (SN15014).....4819
COVER.....4819
1. INTRODUCTION.....4821
1.1 CONTENTS OF THE BINDER.....4822
1.2 DIVISION OF THE BINDER.....4823
1.3 DESIGNATED USE OF THE EXCAVATOR.....4824
1.4 DELIVERY OF THE EXCAVATOR.....4825
1.5 EXPLANATION OF ABBREVATIONS.....4826
1.6 TABLE OF CONTENTS.....4827
2. SAFETY.....4833
2.1 SAFETY INSTRUCTIONS.....4834
2.1.1 WARNINGS AND SYMBOLS.....4834
2.1.2 BASIC OPERATION AND DESIGNATED USE OF THE HYDRAULIC EXCAVATOR.....4834
2.1.3 ORGANIZATIONAL MEASURES.....4835
2.1.4 SELECTION AND QUALIFICATION OF PERSONNEL - BASIC RESPONSIBILITIES.....4837
2.1.5 SAFETY INSTRUCTIONS GOVERNING SPECIFIC OPERATIONAL PHASES.....4838
2.1.6 WARNING OF SPECIAL DANGERS.....4841
2.1.7 TRANSPORTING AND TOWING -RECOMMISSIONING.....4843
2.1.8 SPECIAL SAFETY EQUIPMENT.....4843
2.1.9 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD).....4847
3. OPERATION.....4855
3.1 FOREWORD.....4856
3.2 CONSTRUCTION OF THE EXCAVATOR.....4857
3.2.1 OVERALL VIEW.....4857
3.2.2 UNDERCARRIAGE AND SUPERSTRUCTURE.....4858
3.2.3 HYDRAULICALLY OPERATED ACCESS LADDER.....4864
3.2.4 EMERGENCY ESCAPE LADDER.....4868
3.2.5 EMERGENCY ENGINE SHUTDOWN FROM GROUND MAN OR OPERATOR WARNING SYSTEM.....4870
3.2.6 OPERATORS CAB WITH INTEGRATED FALLING OBJECT PROTECTIVE STRUCTURE (FOPS).....4872
3.2.7 Engine Oil Management System.....4880
3.3 OPERATORS CAB - CONTROLS.....4884
3.3.1 HYDRAULIC CONTROL SYSTEM.....4885
3.3.2 SAFETY CIRCUIT FOR CONTROLS.....4885
3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS.....4898
3.5 OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING.....5000
3.5.1 A - HEATING.....5000
3.5.2 B - COOLING.....5001
3.5.3 COMBINED OPERATION OF AIR CONDITIONING AND HEATING.....5001
3.6 POWER HOUSE.....5002
3.6.1 EMERGENCY ENGINE SHUTDOWN SWITCHES.....5003
3.6.2 CONTROL AND FILTER PANEL OF REAR- AND FRONT POWER UNIT.....5005
3.7 ELECTRICAL EQUIPMENT IN CAB BASE.....5006
3.7.1 SWITCH BOARD (X2) IN CAB BASE.....5009
3.8 CHECKS BEFORE STARTING THE ENGINES.....5022
3.9 STARTING THE ENGINES.....5028
3.9.1 STARTING PROCEDURE.....5031
3.10 MOVING THE EXCAVATOR.....5039
3.10.1 TRAVEL CONTROL WITH FOOT PEDALS.....5039
3.10.2 TRAVELLING INSTRUCTIONS.....5042
3.11 SLEWING AND BRAKING THE SUPERSTRUCTURE.....5043
3.11.1 SLEWING THE SUPERSTRUCTURE.....5043
3.12 WORKING WITH THE ATTACHMENT.....5046
3.12.1 MACHINES EQUIPPED WITH EURO CONTROL SYSTEM.....5046
3.12.2 MACHINES EQUIPPED WITH KMG CONTROL SYSTEM.....5047
3.12.3 BOTTOM DUMP BUCKET.....5048
3.12.4 DROP BALL OPERATION.....5049
3.12.5 COMBINED OPERATION CYCLES.....5052
3.13 WORKING INSTRUCTIONS.....5054
3.13.1 STABILITY OF THE EXCAVATOR.....5054
3.13.2 EXCAVATOR OPERATION.....5054
3.14 PARKING THE EXCAVATOR.....5057
3.15 STOPPING THE ENGINES.....5058
3.16 OPERATION OF THE LUBRICATION SYSTEM.....5062
3.16.1 CENTRAL LUBRICATION SYSTEM CLS.....5062
3.16.2 SWING CIRCLE PINION LUBRICATION SYSTEM SLS.....5064
3.17 FIRE DETECTION AND SUPPRESSION SYSTEM.....5066
3.17.1 HIGH LEVEL ALARM FIRE.....5069
3.17.2 ENGINE SHUT-DOWN THROUGH FUEL SHUT-OFF SOLENOID VALVE.....5069
3.17.3 ACTUATION MODES OF THE FIRE SUPPRESSION SYSTEM.....5069
3.17.4 INDICATION OF OPERATIONAL MODES AT CONTROL MODULE, AFTER AUTOMATIC ACTUATION OF THE FIRE S......5071
3.17.5 LOCATION OF THE EXTINGUISHING AGENT TANK ASSEMBLIES AND EXPELLANT GAS CARTRIDGES ON POWER......5073
3.18 CENTRAL REFILLING SYSTEM.....5074
3.18.1 SYSTEMS CONNECTED TO THE REFILLING SYSTEM.....5075
3.18.2 OPERATING THE HYDRAULIC SERVICE ARM.....5077
3.18.3 RECEIVER PANEL WITH MONITOR BOX.....5079
3.18.4 REFILLABLE GREASE CONTAINERS OF THE CENTRAL LUBRICATION SYSTEM AND SWING CIRCLE LUBRICATIO......5085
3.19 WORK ON THE LOADER ATTACHMENT.....5086
3.20 TRANSPORTATION AND LIFTING OF THE EXCAVATOR.....5087
3.20.1 DISASSEMBLING OF THE EXCAVATOR.....5087
3.20.2 TRANSPORTATION AND LIFTING.....5087
3.21 RETRIEVAL PROCEDURE.....5088
3.22 EXCAVATOR STORAGE.....5089
3.22.1 PREPARING FOR STORAGE.....5089
3.22.2 ONE MONTH REPETITIVE SERVICE PERIOD.....5090
3.22.3 SIX MONTH REPETITIVE SERVICE PERIOD.....5090
3.22.4 PREPARING FOR OPERATION.....5091
3.23 TROUBLE SHOOTING.....5092
3.23.1 ENGINE.....5092
3.23.2 HYDRAULIC SYSTEM.....5093
3.23.3 FINAL DRIVES AND SWING GEAR.....5094
3.23.4 CRAWLER TRACKS.....5094
4. MAINTENANCE.....5095
4.1 FOREWORD.....5096
4.2 PRECAUTIONS FOR MAINTENANCE.....5097
4.3 FUEL AND LUBRICANTS.....5099
4.4 FILLING CAPACITIES.....5101
4.5 STANDARD TORQUE LIST.....5102
4.6 LUBRICATION AND MAINTENANCE SCHEDULE.....5103
4.6.1 INITIAL SERVICING.....5103
4.6.2 PERIODIC SERVICING INTERVALS.....5103
4.6.3 PERIODIC SERVICING SCHEDULE.....5104
4.6.4 EXTENDED SERVICE INTERVALS FOR ENGINES WITH ENGINE OIL MANAGEMENT SYSTEM.....5111
4.6.5 MAINTENANCE OF THE ENGINES.....5115
4.7 WHEN NECESSARY.....5116
4.7.1 ENGINE AIR CLEANER MAINTENANCE.....5117
4.7.2 SWING CIRCLE TOOTHING LUBRICATION.....5121
4.7.3 AUTOMATIC LUBRICATION SYSTEMS FILL GREASE CONTAINERS.....5123
4.7.4 TRACK ROLLERS AND GUIDE WHEELS - REPLACE FLOATING SEALS.....5127
4.7.5 COLD STARTING AID, REPLACE FLUID CYLINDER.....5129
4.8 EVERY 10 OPERATING HOURS OR DAILY.....5130
4.8.1 VISUAL INSPECTIONS.....5131
4.8.2 AIR CLEANER - CLEAN PRE-CLEANER.....5139
4.8.3 RADIATORS - CHECK COOLANT LEVEL.....5141
4.8.4 TRACK GROUPS - CLEAN.....5141
4.9 EVERY 50 OPERATING HOURS OR WEEKLY.....5142
4.9.1 SWING GEARS AND MOTOR ADAPTER HOUSINGS - CHECK OIL LEVELS.....5143
4.9.2 TRAVEL GEARS, BRAKE HOUSINGS AND MOTOR ADAPTER HOUSINGS - CHECK OIL LEVELS.....5145
4.9.3 PTOs (PUMP DISTRIBUTOR GEARS) AND OIL RESERVOIR - CHECK OIL LEVEL.....5151
4.9.4 HYDRAULIC ACCESS LADDER - CHECK SAFETY SENSOR.....5155
4.9.5 HYDRAULIC OIL COOLERS - INSPECT AND CLEAN IF NECESSARY.....5157
4.10 EVERY 250 OPERATING HOURS OR MONTHLY.....5158
4.10.1 AIR CONDITIONING COMPRESSOR - CHECK DRIVE BELT TENSION.....5159
4.10.2 UNDERCARRIAGE PIN CONNECTIONS - LUBRICATE.....5161
4.10.3 SIGNAL HORN COMPRESSOR - LUBRICATE.....5161
4.10.4 HYDRAULIC OIL COOLER FAN BEARINGS - CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER.....5161
4.10.5 RADIATOR FAN BEARINGS - CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER.....5161
4.10.6 AUTOMATIC LUBRICATION SYSTEMS - CLEAN IN-LINE GREASE FILTER.....5163
4.10.7 CAB AIR CLEANER - CLEAN OR REPLACE FILTER ELEMENT.....5165
4.11 EVERY 500 OPERATING HOURS OR MONTHLY.....5166
4.11.1 BATTERIES - CHECK FLUID LEVEL.....5167
4.11.2 FLEXIBLE DRIVE COUPLINGS - CHECK OIL LEVEL.....5169
4.11.3 FUEL TANK - DRAIN CONDENSATION.....5171
4.11.4 CRAWLER TRACK - INSPECTION.....5173
4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH.....5178
4.12.1 HIGH STRENGTH BOLT CONNECTIONS - CHECK TORQUE LOAD.....5179
4.12.2 HYDRAULIC SYSTEM - FILTER SERVICE.....5229
4.12.3 PTOS (PUMP DISTRIBUTOR GEARS), SWING GEARS AND TRAVEL GEARS - OIL SAMPLE ANALYSIS.....5243
4.12.4 SIGNAL HORN COMPRESSOR - CLEAN AND LUBRICATE.....5245
4.12.5 HYDRAULIC TRACK TENSIONING SYSTEM - CHECK PRESSURE ACCUMULATORS.....5247
4.12.6 WATER FILTER - REPLACE FILTER CARTRIDGE.....5249
4.13 EVERY 2000 OPERATING HOURS OR YEARLY.....5250
4.13.1 HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER.....5251
4.13.2 EMERGENCY ESCAPE LADDER - INSPECTION.....5263
4.14 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR.....5264
4.14.1 SWING GEARS AND MOTOR ADAPTER HOUSING - CHANGE OIL.....5265
4.14.2 TRAVEL GEARS, BRAKE AND MOTOR ADAPTER HOUSINGS - CHANGE OIL.....5269
4.14.3 PTO (PUMP DISTRIBUTOR GEAR) - CHANGE OIL.....5275
4.15 FIRE PREVENTION.....5278
4.16 REPAIR WELDINGS.....5280
4.16.1 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE UNDERCARRIAGE.....5283
4.16.2 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE LOADER ATTACHMENT.....5285
4.16.3 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE SUPERSTRUCTURE.....5287
4.16.4 AFTER FINISHING THE REPAIR WELDINGS ON THE SUPERSTRUCTURE.....5289
Hydraulic Mining Shovel PC5500-6 Operation & Maintenance Manual (SN15016).....5296
COVER.....5296
1. INTRODUCTION.....5298
1.1 CONTENTS OF THE BINDER.....5299
1.2 DIVISION OF THE BINDER.....5300
1.3 DESIGNATED USE OF THE SHOVEL.....5301
1.4 DELIVERY OF THE SHOVEL.....5302
1.5 EXPLANATION OF ABBREVATIONS.....5303
1.6 TABLE OF CONTENTS.....5304
2. SAFETY.....5310
2.1 SAFETY INSTRUCTIONS.....5311
2.1.1 WARNINGS AND SYMBOLS.....5311
2.1.2 BASIC OPERATION AND DESIGNATED USE OF THE HYDRAULIC SHOVEL.....5311
2.1.3 ORGANIZATIONAL MEASURES.....5312
2.1.4 SELECTION AND QUALIFICATION OF PERSONNEL - BASIC RESPONSIBILITIES.....5314
2.1.5 SAFETY INSTRUCTIONS GOVERNING SPECIFIC OPERATIONAL PHASES.....5315
2.1.6 WARNING OF SPECIAL DANGERS.....5318
2.1.7 TRANSPORTING AND TOWING -RECOMMISSIONING.....5320
2.1.8 SPECIAL SAFETY EQUIPMENT.....5320
2.1.9 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD).....5324
3. OPERATION.....5332
3.1 FOREWORD.....5333
3.2 CONSTRUCTION OF THE SHOVEL.....5334
3.2.1 OVERALL VIEW.....5334
3.2.2 UNDERCARRIAGE AND SUPERSTRUCTURE.....5335
3.2.3 HYDRAULICALLY OPERATED ACCESS LADDER.....5341
3.2.4 EMERGENCY ESCAPE LADDER.....5345
3.2.5 EMERGENCY MOTOR SHUTDOWN FROM GROUND MAN OR OPERATOR WARNING SYSTEM.....5347
3.2.6 OPERATORS CAB WITH INTEGRATED FALLING OBJECT PROTECTIVE STRUCTURE (FOPS).....5349
3.3 OPERATORS CAB - CONTROLS.....5357
3.3.1 HYDRAULIC CONTROL SYSTEM.....5358
3.3.2 SAFETY CIRCUIT FOR CONTROLS.....5358
3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS.....5371
3.4.1 OPERATING THE ELECTRONIC MONITORING SYSTEM.....5380
3.4.2 MENU CONTROL CHART.....5429
3.4.3 FAULT AND INFORMATION MESSAGE LIST.....5447
3.5 OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING.....5470
3.6 POWER HOUSE.....5471
3.6.1 EMERGENCY MOTOR SHUTDOWN SWITCHES.....5472
3.6.2 CONTROL AND FILTER PANEL OF REAR- AND FRONT POWER UNIT.....5474
3.7 MEDIUM VOLTAGE SWITCH CABINET IN CAB BASE.....5475
3.7.1 COMPONENTS OF THE MEDIUM VOLTAGE SWITCH CABINET.....5476
3.7.2 SWITCH BOARD (X2) IN CAB BASE.....5478
3.7.3 MONITOR AND CONTROL PANEL IN CAB BASE.....5484
3.7.4 SWITCH BOARD - MEDIUM VOLTAGE.....5486
3.8 HIGH VOLTAGE SWITCH CABINET.....5487
3.9 CHECKS BEFORE STARTING THE MAIN DRIVE MOTORS.....5489
3.10 STARTING THE MAIN DRIVE MOTORS.....5493
3.11 MOVING THE SHOVEL.....5500
3.11.1 TRAVEL CONTROL WITH FOOT PEDALS.....5500
3.11.2 TRAVELLING INSTRUCTIONS.....5503
3.12 SLEWING AND BRAKING THE SUPERSTRUCTURE.....5504
3.12.1 SLEWING THE SUPERSTRUCTURE.....5504
3.13 WORKING WITH THE ATTACHMENT.....5507
3.13.1 MACHINES EQUIPPED WITH EURO CONTROL SYSTEM.....5507
3.13.2 MACHINES EQUIPPED WITH KMG CONTROL SYSTEM.....5508
3.13.3 BOTTOM DUMP BUCKET.....5509
3.13.4 DROP BALL OPERATION.....5510
3.13.5 COMBINED OPERATION CYCLES.....5513
3.14 WORKING INSTRUCTIONS.....5515
3.14.1 STABILITY OF THE SHOVEL.....5515
3.14.2 SHOVEL OPERATION.....5515
3.15 PARKING THE SHOVEL.....5518
3.16 STOPPING THE MAIN DRIVE MOTORS.....5519
3.17 OPERATION OF THE LUBRICATION SYSTEM.....5523
3.17.1 CENTRAL LUBRICATION SYSTEM CLS.....5523
3.17.2 SWING CIRCLE PINION LUBRICATION SYSTEM SLS.....5525
3.18 TRANSFER PUMP FOR HYDRAULIC OIL.....5527
3.18.1 OPERATING THE TRANSFER PUMP.....5528
3.18.2 FUNCTIONS OF THE TRANSFER PUMP.....5530
3.19 CENTRAL REFILLING SYSTEM.....5533
3.19.1 SYSTEMS CONNECTED TO THE REFILLING SYSTEM.....5534
3.19.2 CENTRAL LUBRICATION SYSTEM AND SWING CIRCLE LUBRICATION SYSTEM.....5538
3.20 CABLE DRUM.....5539
3.20.1 CABLE DRUM OPERATION.....5540
3.20.2 TRAVELLING INSTRUCTIONS.....5542
3.21 SERVICE CRANE.....5545
3.21.1 OPERATING THE SERVICE CRANE.....5546
3.22 WORK ON THE LOADER ATTACHMENT.....5549
3.23 TRANSPORTATION AND LIFTING OF THE SHOVEL.....5550
3.23.1 DISASSEMBLING OF THE SHOVEL.....5550
3.23.2 TRANSPORTATION AND LIFTING.....5550
3.24 RETRIEVAL PROCEDURE.....5551
3.25 SHOVEL STORAGE.....5552
3.25.1 PREPARING FOR STORAGE.....5552
3.25.2 ONE MONTH REPETITIVE SERVICE PERIOD.....5552
3.25.3 SIX MONTH REPETITIVE SERVICE PERIOD.....5553
3.25.4 PREPARING FOR OPERATION.....5553
3.26 TROUBLE SHOOTING.....5554
3.26.1 MAIN DRIVE MOTOR.....5554
3.26.2 HYDRAULIC SYSTEM.....5555
3.26.3 FINAL DRIVES AND SWING GEAR.....5556
3.26.4 CRAWLER TRACKS.....5556
4. MAINTENANCE.....5558
4.1 FOREWORD.....5559
4.2 PRECAUTIONS FOR MAINTENANCE.....5560
4.3 LUBRICANTS.....5561
4.3.1 LUBRICANTS FOR MODERATE AND HOT CLIMATES.....5561
4.4 FILLING CAPACITIES.....5565
4.5 STANDARD TORQUE LIST.....5566
4.6 LUBRICATION AND MAINTENANCE SCHEDULE.....5567
4.6.1 INITIAL SERVICING.....5567
4.6.2 PERIODIC SERVICING INTERVALS.....5567
4.6.3 PERIODIC SERVICING SCHEDULE.....5568
4.6.4 MAINTENANCE OF THE MAIN DRIVE MOTORS.....5572
4.7 WHEN NECESSARY.....5575
4.7.1 SWING CIRCLE TOOTHING LUBRICATION.....5576
4.7.2 AUTOMATIC LUBRICATION SYSTEMS FILL GREASE CONTAINERS.....5578
4.7.3 TRACK ROLLERS AND GUIDE WHEELS - REPLACE FLOATING SEALS.....5582
4.8 EVERY 10 OPERATING HOURS OR DAILY.....5583
4.8.1 VISUAL INSPECTIONS.....5584
4.8.2 TRACK GROUPS - CLEAN.....5592
4.9 EVERY 50 OPERATING HOURS OR WEEKLY.....5593
4.9.1 SWING GEARS AND MOTOR ADAPTER HOUSINGS - CHECK OIL LEVELS.....5594
4.9.2 TRAVEL GEARS, BRAKE HOUSINGS AND MOTOR ADAPTER HOUSINGS - CHECK OIL LEVELS.....5596
4.9.3 PTOs (PUMP DISTRIBUTOR GEARS) AND OIL RESERVOIR - CHECK OIL LEVEL.....5602
4.9.4 HYDRAULIC ACCESS LADDER - CHECK SAFETY SENSOR.....5606
4.9.5 HYDRAULIC OIL COOLERS - INSPECT AND CLEAN IF NECESSARY.....5608
4.10 EVERY 250 OPERATING HOURS OR MONTHLY.....5609
4.10.1 UNDERCARRIAGE PIN CONNECTIONS - LUBRICATE.....5610
4.10.2 SIGNAL HORN COMPRESSOR - LUBRICATE.....5610
4.10.3 HYDRAULIC OIL COOLER FAN BEARING HOUSINGS - CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER.....5610
4.10.4 RADIATOR FAN BEARING HOUSINGS - CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER (DIESEL VERSIO......5610
4.10.5 AUTOMATIC LUBRICATION SYSTEMS - CLEAN IN-LINE GREASE FILTER.....5612
4.10.6 CAB AIR CLEANER - CLEAN OR REPLACE FILTER ELEMENT.....5614
4.10.7 AIR CONDITIONING FOR OPERATORS CAB AND SWITCH CABINETS.....5616
4.10.8 WINDSHIELD WASHER SYSTEM - CHECK FLUID LEVEL.....5620
4.11 EVERY 500 OPERATING HOURS OR MONTHLY.....5621
4.11.1 BATTERIES - CHECK FLUID LEVEL.....5622
4.11.2 CRAWLER TRACK - INSPECTION.....5624
4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH.....5629
4.12.1 HIGH STRENGTH BOLT CONNECTIONS - CHECK TORQUE LOAD.....5630
4.12.2 HYDRAULIC SYSTEM - FILTER SERVICE.....5678
4.12.3 PTOS (PUMP DISTRIBUTOR GEARS), SWING GEARS AND TRAVEL GEARS - OIL SAMPLE ANALYSIS.....5692
4.12.4 SIGNAL HORN COMPRESSOR - CLEAN AND LUBRICATE.....5694
4.12.5 HYDRAULIC TRACK TENSIONING SYSTEM - CHECK PRESSURE ACCUMULATORS.....5696
4.12.6 WATER FILTER - REPLACE FILTER CARTRIDGE.....5698
4.12.7 SLIP RING UNIT - LUBRICATE.....5700
4.13 EVERY 2000 OPERATING HOURS OR YEARLY.....5701
4.13.1 HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER.....5702
4.13.2 EMERGENCY ESCAPE LADDER - INSPECTION.....5714
4.14 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR.....5715
4.14.1 SWING GEARS AND MOTOR ADAPTER HOUSING - CHANGE OIL.....5716
4.14.2 TRAVEL GEARS, BRAKE AND MOTOR ADAPTER HOUSINGS - CHANGE OIL.....5720
4.14.3 PTO (PUMP DISTRIBUTOR GEAR) - CHANGE OIL.....5726
4.15 FIRE PREVENTION.....5729
4.16 REPAIR WELDINGS.....5731
4.16.1 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE UNDERCARRIAGE.....5734
4.16.2 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE LOADER ATTACHMENT.....5736
4.16.3 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE SUPERSTRUCTURE.....5738
4.16.4 AFTER FINISHING THE REPAIR WELDINGS ON THE SUPERSTRUCTURE.....5738
Hydraulic Mining Shovel PC5500-6 Operation & Maintenance Manual (SN15027).....5745
COVER.....5745
1. INTRODUCTION.....5747
1.1 CONTENTS OF THE BINDER.....5748
1.2 DIVISION OF THE BINDER.....5749
1.3 DESIGNATED USE OF THE SHOVEL.....5750
1.4 DELIVERY OF THE SHOVEL.....5751
1.5 EXPLANATION OF ABBREVIATIONS.....5752
1.6 TABLE OF CONTENTS.....5753
2. SAFETY.....5759
2.1 SAFETY INSTRUCTIONS.....5760
2.1.1 WARNINGS AND SYMBOLS.....5760
2.1.2 BASIC OPERATION AND DESIGNATED USE OF THE HYDRAULIC SHOVEL.....5760
2.1.3 ORGANIZATIONAL MEASURES.....5761
2.1.4 SELECTION AND QUALIFICATION OF PERSONNEL - BASIC RESPONSIBILITIES.....5763
2.1.5 SAFETY INSTRUCTIONS GOVERNING SPECIFIC OPERATIONAL PHASES.....5764
2.1.6 WARNING OF SPECIAL DANGERS.....5767
2.1.7 TRANSPORTING AND TOWING -RECOMMISSIONING.....5769
2.1.8 SPECIAL SAFETY EQUIPMENT.....5769
2.1.9 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD).....5773
3. OPERATION.....5781
3.1 FOREWORD.....5782
3.2 CONSTRUCTION OF THE SHOVEL.....5783
3.2.1 OVERALL VIEW.....5783
3.2.2 UNDERCARRIAGE AND SUPERSTRUCTURE.....5784
3.2.3 HYDRAULICALLY OPERATED ACCESS LADDER.....5790
3.2.4 EMERGENCY ESCAPE LADDER.....5794
3.2.5 EMERGENCY ENGINE SHUTDOWN FROM GROUND MAN OR OPERATOR WARNING SYSTEM.....5796
3.2.6 OPERATORS CAB WITH INTEGRATED FALLING OBJECT PROTECTIVE STRUCTURE (FOPS).....5798
3.2.7 ENGINE OIL MANAGEMENT SYSTEM.....5806
3.3 OPERATORS CAB - CONTROLS.....5814
3.3.1 CONTROLS WITH BACKHOE ATTACHMENT.....5814
3.3.2 CONTROLS WITH BOTTOM DUMP BUCKET ATTACHMENT.....5818
3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS.....5832
3.5 OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING.....5936
3.5.1 A - HEATING.....5936
3.5.2 B - COOLING.....5937
3.5.3 COMBINED OPERATION OF AIR CONDITIONING AND HEATING.....5937
3.6 POWER HOUSE.....5938
3.6.1 EMERGENCY ENGINE SHUTDOWN SWITCHES.....5939
3.6.2 CONTROL AND FILTER PANEL OF REAR- AND FRONT POWER UNIT.....5941
3.7 ELECTRICAL EQUIPMENT IN CAB BASE.....5942
3.7.1 SWITCH BOARD (X2) IN CAB BASE.....5945
3.8 CHECKS BEFORE STARTING THE ENGINES.....5958
3.9 STARTING THE ENGINES.....5964
3.9.1 STARTING PROCEDURE.....5967
3.10 MOVING THE SHOVEL.....5975
3.10.1 TRAVEL CONTROL WITH FOOT PEDALS.....5975
3.10.2 TRAVELLING INSTRUCTIONS.....5978
3.11 SLEWING AND BRAKING THE SUPERSTRUCTURE.....5979
3.11.1 SLEWING THE SUPERSTRUCTURE.....5979
3.12 WORKING WITH THE ATTACHMENT.....5982
3.12.1 MACHINES EQUIPPED WITH EURO CONTROL SYSTEM.....5982
3.12.2 MACHINES EQUIPPED WITH KMG CONTROL SYSTEM.....5983
3.12.3 BOTTOM DUMP BUCKET.....5984
3.12.4 DROP BALL OPERATION.....5985
3.12.5 COMBINED OPERATION CYCLES.....5988
3.13 WORKING INSTRUCTIONS.....5990
3.13.1 STABILITY OF THE SHOVEL.....5990
3.13.2 SHOVEL OPERATION.....5990
3.14 PARKING THE SHOVEL.....5993
3.15 STOPPING THE ENGINES.....5994
3.16 OPERATION OF THE LUBRICATION SYSTEM.....5998
3.16.1 CENTRAL LUBRICATION SYSTEM CLS.....5998
3.16.2 SWING CIRCLE PINION LUBRICATION SYSTEM SLS.....6000
3.17 FIRE DETECTION AND SUPPRESSION SYSTEM.....6002
3.17.1 HIGH LEVEL ALARM FIRE.....6005
3.17.2 ENGINE SHUT-DOWN THROUGH FUEL SHUT-OFF SOLENOID VALVE.....6005
3.17.3 ACTUATION MODES OF THE FIRE SUPPRESSION SYSTEM.....6005
3.17.4 INDICATION OF OPERATIONAL MODES AT CONTROL MODULE, AFTER AUTOMATIC ACTUATION OF THE FIRE S......6007
3.17.5 LOCATION OF THE EXTINGUISHING AGENT TANK ASSEMBLIES AND EXPELLANT GAS CARTRIDGES ON POWER......6009
3.18 CENTRAL REFILLING SYSTEM.....6010
3.18.1 SYSTEMS CONNECTED TO THE REFILLING SYSTEM.....6011
3.18.2 OPERATING THE HYDRAULIC SERVICE ARM.....6013
3.18.3 RECEIVER PANEL WITH MONITOR BOX.....6015
3.18.4 REFILLABLE GREASE CONTAINERS OF THE AUTOMATIC LUBRICATION SYSTEMS.....6021
3.19 SERVICE CRANE.....6022
3.19.1 OPERATING THE CRANE.....6023
3.20 WORK ON THE LOADER ATTACHMENT.....6026
3.21 TRANSPORTATION AND LIFTING OF THE SHOVEL.....6027
3.21.1 DISASSEMBLING OF THE SHOVEL.....6027
3.21.2 TRANSPORTATION AND LIFTING.....6027
3.22 RETRIEVAL PROCEDURE.....6028
3.23 SHOVEL STORAGE.....6029
3.23.1 PREPARING FOR STORAGE.....6029
3.23.2 ONE MONTH REPETITIVE SERVICE PERIOD.....6030
3.23.3 SIX MONTH REPETITIVE SERVICE PERIOD.....6030
3.23.4 PREPARING FOR OPERATION.....6031
3.24 TROUBLE SHOOTING.....6032
3.24.1 ENGINE.....6032
3.24.2 HYDRAULIC SYSTEM.....6033
3.24.3 FINAL DRIVES AND SWING GEAR.....6034
3.24.4 CRAWLER TRACKS.....6034
4. MAINTENANCE.....6035
4.1 FOREWORD.....6036
4.2 PRECAUTIONS FOR MAINTENANCE.....6037
4.3 FUEL AND LUBRICANTS.....6039
4.4 FILLING CAPACITIES.....6041
4.5 STANDARD TORQUE LIST.....6042
4.6 LUBRICATION AND MAINTENANCE SCHEDULE.....6043
4.6.1 INITIAL SERVICING.....6043
4.6.2 PERIODIC SERVICING INTERVALS.....6043
4.6.3 PERIODIC SERVICING SCHEDULE.....6044
4.6.4 EXTENDED SERVICE INTERVALS FOR ENGINES WITH ENGINE OIL MANAGEMENT SYSTEM.....6051
4.6.5 RESETTING THE ENGINE OIL BURNING SYSTEM CENTINEL.....6053
4.6.6 MAINTENANCE OF THE ENGINES.....6055
4.6.7 ENGINE FUEL FILTER LOCATIONS.....6057
4.7 WHEN NECESSARY.....6058
4.7.1 ENGINE AIR CLEANER MAINTENANCE.....6059
4.7.2 SWING CIRCLE TOOTHING LUBRICATION.....6063
4.7.3 AUTOMATIC LUBRICATION SYSTEMS FILL GREASE CONTAINERS.....6065
4.7.4 TRACK ROLLERS AND GUIDE WHEELS - REPLACE FLOATING SEALS.....6069
4.7.5 COLD STARTING AID, REPLACE FLUID CYLINDER.....6071
4.8 EVERY 10 OPERATING HOURS OR DAILY.....6072
4.8.1 WALK - AROUND INSPECTION.....6073
4.8.2 AIR CLEANER - CLEAN PRE-CLEANER.....6081
4.8.3 RADIATORS - CHECK COOLANT LEVEL.....6083
4.8.4 TRACK GROUPS - CLEAN.....6083
4.9 EVERY 50 OPERATING HOURS OR WEEKLY.....6084
4.9.1 SWING GEARS AND MOTOR ADAPTER HOUSINGS - CHECK OIL LEVELS.....6085
4.9.2 TRAVEL GEARS, MOTOR ADAPTER HOUSINGS AND FINAL DRIVES CHECK OIL LEVELS.....6089
4.9.3 PTOs (PUMP DISTRIBUTOR GEARS) AND OIL RESERVOIR - CHECK OIL LEVEL.....6095
4.9.4 HYDRAULIC ACCESS LADDER - CHECK SAFETY SENSOR.....6099
4.9.5 HYDRAULIC OIL COOLERS - INSPECT AND CLEAN IF NECESSARY.....6101
4.10 EVERY 250 OPERATING HOURS OR MONTHLY.....6102
4.10.1 AIR CONDITIONING COMPRESSOR - CHECK DRIVE BELT TENSION.....6103
4.10.2 SIGNAL HORN COMPRESSOR - LUBRICATE.....6105
4.10.3 HYDRAULIC OIL COOLER FAN BEARINGS - CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER.....6105
4.10.4 RADIATOR FAN BEARINGS - CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER.....6105
4.10.5 AUTOMATIC LUBRICATION SYSTEMS - CLEAN IN-LINE GREASE FILTER AND CHECK BREATHER FILTER.....6107
4.10.6 CAB AIR CLEANER - CLEAN OR REPLACE FILTER ELEMENT.....6109
4.10.7 AIR CONDITIONING FOR OPERATORS CAB - CHECK REFRIGERANT LEVEL.....6111
4.11 EVERY 500 OPERATING HOURS OR QUARTERLY.....6112
4.11.1 BATTERIES - CHECK FLUID LEVEL.....6113
4.11.2 FLEXIBLE DRIVE COUPLINGS - CHECK OIL LEVEL.....6115
4.11.3 FUEL TANK - DRAIN CONDENSATION.....6117
4.11.4 CRAWLER TRACK - INSPECTION.....6119
4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH.....6124
4.12.1 HIGH STRENGTH BOLT CONNECTIONS - CHECK TORQUE LOAD.....6125
4.12.2 HYDRAULIC SYSTEM - FILTER SERVICE.....6183
4.12.3 PTOS (PUMP DISTRIBUTOR GEARS), SWING GEARS AND TRAVEL GEARS - OIL SAMPLE ANALYSIS.....6197
4.12.4 SIGNAL HORN COMPRESSOR - CLEAN AND LUBRICATE.....6199
4.12.5 HYDRAULIC TRACK TENSIONING SYSTEM - CHECK PRESSURE ACCUMULATORS.....6201
4.12.6 WATER FILTER - REPLACE FILTER CARTRIDGE.....6203
4.12.7 HYDRAULIC OIL COOLER - INSPECT AND LUBRICATE DOOR HINGES.....6205
4.12.8 MACHINERY HOUSE DOORS - INSPECT AND LUBRICATE DOOR HINGES.....6207
4.13 EVERY 2000 OPERATING HOURS OR YEARLY.....6208
4.13.1 HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER.....6209
4.13.2 EMERGENCY ESCAPE LADDER - INSPECTION.....6221
4.14 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR.....6222
4.14.1 SWING GEARS AND MOTOR ADAPTER HOUSING - CHANGE OIL.....6223
4.14.2 TRAVEL GEARS, MOTOR ADAPTER HOUSINGS AND FINAL DRIVES CHANGE OIL.....6231
4.14.3 PTO (PUMP DISTRIBUTOR GEAR) - CHANGE OIL.....6235
4.15 FIRE PREVENTION.....6238
4.16 WELD REPAIRS.....6240
4.16.1 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE UNDERCARRIAGE.....6243
4.16.2 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE LOADER ATTACHMENT.....6245
4.16.3 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE SUPERSTRUCTURE.....6247
4.16.4 AFTER FINISHING THE REPAIR WELDINGS ON THE SUPERSTRUCTURE.....6249
Hydraulic Mining Shovel PC5500-6 Operation & Maintenance Manual (SN15028&15029&15030).....6256
COVER.....6256
1. INTRODUCTION.....6258
1.1 CONTENTS OF THE BINDER.....6259
1.2 DIVISION OF THE BINDER.....6260
1.3 DESIGNATED USE OF THE SHOVEL.....6261
1.4 DELIVERY OF THE SHOVEL.....6262
1.5 EXPLANATION OF ABBREVIATIONS.....6263
1.6 TABLE OF CONTENTS.....6264
2. SAFETY.....6270
2.1 SAFETY INSTRUCTIONS.....6271
2.1.1 WARNINGS AND SYMBOLS.....6271
2.1.2 BASIC OPERATION AND DESIGNATED USE OF THE HYDRAULIC SHOVEL.....6271
2.1.3 ORGANIZATIONAL MEASURES.....6272
2.1.4 SELECTION AND QUALIFICATION OF PERSONNEL - BASIC RESPONSIBILITIES.....6274
2.1.5 SAFETY INSTRUCTIONS GOVERNING SPECIFIC OPERATIONAL PHASES.....6275
2.1.6 WARNING OF SPECIAL DANGERS.....6278
2.1.7 TRANSPORTING AND TOWING -RECOMMISSIONING.....6280
2.1.8 SPECIAL SAFETY EQUIPMENT.....6280
2.1.9 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD).....6284
3. OPERATION.....6292
3.1 FOREWORD.....6293
3.2 CONSTRUCTION OF THE SHOVEL.....6294
3.2.1 OVERALL VIEW.....6294
3.2.2 UNDERCARRIAGE AND SUPERSTRUCTURE.....6295
3.2.3 HYDRAULICALLY OPERATED ACCESS LADDER.....6301
3.2.4 EMERGENCY ESCAPE LADDER.....6305
3.2.5 EMERGENCY MOTOR SHUTDOWN FROM GROUND MAN OR OPERATOR WARNING SYSTEM.....6307
3.2.6 OPERATORS CAB WITH INTEGRATED FALLING OBJECT PROTECTIVE STRUCTURE (FOPS).....6309
3.3 OPERATORS CAB - CONTROLS.....6319
3.3.1 CONTROLS WITH BACKHOE ATTACHMENT.....6319
3.3.2 CONTROLS WITH BOTTOM DUMP BUCKET ATTACHMENT.....6323
3.3.3 OPERATORS CONSOLE.....6328
3.3.4 CONTROL UNITS FOR FIRE DETECTION, ACTUATION AND SUPPRESSION SYSTEM.....6338
3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS.....6339
3.4.1 INTRODUCTION.....6340
3.4.2 OPERATING THE ELECTRONIC MONITORING SYSTEM.....6348
3.4.3 AUTOMATIC DISPLAY OF MESSAGES.....6352
3.4.4 MENU CONTROL AND SERVICE FUNCTIONS.....6376
3.4.5 MENU CONTROL LIST.....6401
3.4.6 FAULT AND INFORMATION MESSAGE LIST.....6418
3.5 OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING.....6443
3.5.1 A - HEATING.....6443
3.5.2 B - COOLING.....6444
3.5.3 COMBINED OPERATION OF AIR CONDITIONING AND HEATING.....6444
3.6 MACHINERY HOUSE.....6445
3.6.1 EMERGENCY MOTOR SHUTDOWN SWITCHES.....6446
3.6.2 SAFETY SWITCH FOR MAINTENANCE.....6448
3.6.3 CONTROL AND FILTER PANEL OF REAR- AND FRONT POWER UNIT.....6450
3.7 MEDIUM VOLTAGE SWITCH CABINET IN CAB BASE.....6451
3.7.1 COMPONENTS OF THE MEDIUM VOLTAGE SWITCH CABINET.....6452
3.7.2 SWITCH BOARD (X2) IN CAB BASE.....6454
3.7.3 MONITOR AND CONTROL PANEL IN CAB BASE.....6464
3.7.4 SWITCH BOARD - MEDIUM VOLTAGE.....6466
3.8 HIGH VOLTAGE SWITCH CABINET.....6467
3.9 CHECKS BEFORE STARTING THE MAIN DRIVE MOTORS.....6469
3.10 STARTING THE MAIN DRIVE MOTORS.....6473
3.11 MOVING THE SHOVEL.....6480
3.11.1 TRAVEL CONTROL WITH FOOT PEDALS.....6480
3.11.2 TRAVELLING INSTRUCTIONS.....6483
3.12 SLEWING AND BRAKING THE SUPERSTRUCTURE.....6484
3.12.1 SLEWING THE SUPERSTRUCTURE.....6484
3.13 WORKING WITH THE ATTACHMENT.....6487
3.13.1 MACHINES EQUIPPED WITH EURO CONTROL SYSTEM.....6487
3.13.2 MACHINES EQUIPPED WITH KMG CONTROL SYSTEM.....6488
3.13.3 BOTTOM DUMP BUCKET.....6489
3.13.4 DROP BALL OPERATION.....6490
3.13.5 COMBINED OPERATION CYCLES.....6493
3.14 WORKING INSTRUCTIONS.....6495
3.14.1 STABILITY OF THE SHOVEL.....6495
3.14.2 SHOVEL OPERATION.....6495
3.15 PARKING THE SHOVEL.....6498
3.16 STOPPING THE MAIN DRIVE MOTORS.....6499
3.16.1 RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM.....6502
3.17 OPERATION OF THE LUBRICATION SYSTEM.....6503
3.17.1 CENTRAL LUBRICATION SYSTEM -CLS- FOR SUPERSTRUCTURE AND ATTACHMENT.....6503
3.17.2 SWING CIRCLE PINION LUBRICATION SYSTEM SLS.....6505
3.18 FIRE DETECTION, ACTUATION AND SUPPRESSION SYSTEM.....6507
3.18.1 CONTROL UNITS FOR THE FIRE DETECTION, ACTUATION AND SUPPRESSION SYSTEMS.....6508
3.18.2 REMOTE HIGH LEVEL ALARM *FIRE* LOCATED ON THE CAB.....6512
3.18.3 ACTUATION MODES OF THE FIRE SUPPRESSION SYSTEM:.....6512
3.18.4 IN CASE OF FIRE.....6514
3.19 TRANSFER PUMP FOR HYDRAULIC OIL.....6515
3.19.1 OPERATING THE TRANSFER PUMP.....6516
3.19.2 FUNCTIONS OF THE TRANSFER PUMP.....6518
3.20 CENTRAL REFILLING SYSTEM.....6521
3.20.1 SYSTEMS CONNECTED TO THE REFILLING SYSTEM.....6522
3.20.2 REFILLABLE GREASE CONTAINERS OF THE AUTOMATIC LUBRICATION SYSTEMS.....6526
3.21 CABLE DRUM.....6527
3.21.1 OPERATION OF THE CABLE DRUM.....6528
3.21.2 TRAVELLING INSTRUCTIONS.....6532
3.22 SERVICE CRANE (SPECIAL EQUIPMENT).....6535
3.22.1 OPERATING THE CRANE.....6536
3.23 WORK ON THE LOADER ATTACHMENT.....6539
3.24 TRANSPORTATION AND LIFTING OF THE SHOVEL.....6540
3.24.1 DISASSEMBLING OF THE SHOVEL.....6540
3.24.2 TRANSPORTATION AND LIFTING.....6540
3.25 RETRIEVAL PROCEDURE.....6541
3.26 SHOVEL STORAGE.....6542
3.26.1 PREPARING FOR STORAGE.....6542
3.26.2 ONE MONTH REPETITIVE SERVICE PERIOD.....6542
3.26.3 SIX MONTH REPETITIVE SERVICE PERIOD.....6543
3.26.4 PREPARING FOR OPERATION.....6543
3.27 TROUBLE SHOOTING.....6544
3.27.1 MAIN DRIVE ELECTRIC MOTOR.....6544
3.27.2 HYDRAULIC SYSTEM.....6545
3.27.3 FINAL DRIVES AND SWING GEAR.....6546
3.27.4 CRAWLER TRACKS.....6546
4. MAINTENANCE.....6548
4.1 FOREWORD.....6549
4.2 PRECAUTIONS FOR MAINTENANCE.....6550
4.3 FUEL AND LUBRICANTS.....6552
4.4 FILLING CAPACITIES.....6556
4.5 STANDARD TORQUE LIST.....6557
4.6 LUBRICATION AND MAINTENANCE SCHEDULE.....6558
4.6.1 INITIAL SERVICING.....6558
4.6.2 PERIODIC SERVICING INTERVALS.....6558
4.6.3 PERIODIC SERVICING SCHEDULE.....6559
4.6.4 MAINTENANCE OF THE MAIN DRIVE MOTORS.....6562
4.7 WHEN NECESSARY.....6565
4.7.1 SWING CIRCLE TOOTHING LUBRICATION.....6566
4.7.2 AUTOMATIC LUBRICATION SYSTEMS FILL GREASE CONTAINERS.....6568
4.7.3 TRACK ROLLERS AND GUIDE WHEELS - REPLACE FLOATING SEALS.....6572
4.8 EVERY 10 OPERATING HOURS OR DAILY.....6573
4.8.1 WALK - AROUND INSPECTION.....6574
4.8.2 TRACK GROUPS - CLEAN.....6584
4.9 EVERY 50 OPERATING HOURS OR WEEKLY.....6585
4.9.1 SWING GEARS AND MOTOR ADAPTER HOUSINGS - CHECK OIL LEVELS.....6586
4.9.2 TRAVEL GEARS, MOTOR ADAPTER HOUSINGS AND FINAL DRIVES CHECK OIL LEVELS.....6590
4.9.3 PTOs (PUMP DISTRIBUTOR GEARS) AND OIL RESERVOIR - CHECK OIL LEVEL.....6596
4.9.4 HYDRAULIC ACCESS LADDER - CHECK SAFETY SENSOR.....6600
4.9.5 HYDRAULIC OIL COOLERS - INSPECT AND CLEAN IF NECESSARY.....6602
4.10 EVERY 250 OPERATING HOURS OR MONTHLY.....6603
4.10.1 SIGNAL HORN COMPRESSOR - LUBRICATE.....6604
4.10.2 HYDRAULIC OIL COOLER FAN BEARINGS - CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER.....6604
4.10.3 RADIATOR FAN BEARINGS - CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER (DIESEL VERSION ONLY).....6604
4.10.4 AUTOMATIC LUBRICATION SYSTEMS - CLEAN IN-LINE GREASE FILTER AND CHECK BREATHER FILTER.....6606
4.10.5 CAB AIR CLEANER - CLEAN OR REPLACE FILTER ELEMENT.....6608
4.10.6 AIR CONDITIONING FOR OPERATORS CAB AND SWITCH CABINETS.....6610
4.10.7 WINDSHIELD WASHER SYSTEM - CHECK FLUID LEVEL.....6614
4.11 EVERY 500 OPERATING HOURS OR QUARTERLY.....6615
4.11.1 BATTERIES - CHECK FLUID LEVEL.....6616
4.11.2 CRAWLER TRACK - INSPECTION.....6618
4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH.....6623
4.12.1 HIGH STRENGTH BOLT CONNECTIONS - CHECK TORQUE LOAD.....6624
4.12.2 HYDRAULIC SYSTEM - FILTER SERVICE.....6680
4.12.3 PTOS (PUMP DISTRIBUTOR GEARS), SWING GEARS AND TRAVEL GEARS - OIL SAMPLE ANALYSIS.....6694
4.12.4 SIGNAL HORN COMPRESSOR - CLEAN AND LUBRICATE.....6696
4.12.5 HYDRAULIC TRACK TENSIONING SYSTEM - CHECK PRESSURE ACCUMULATORS.....6698
4.12.6 WATER FILTER - REPLACE FILTER CARTRIDGE.....6700
4.12.7 HYDRAULIC OIL COOLER - INSPECT AND LUBRICATE DOOR HINGES.....6702
4.12.8 MACHINERY HOUSE DOORS - INSPECT AND LUBRICATE DOOR HINGES.....6704
4.12.9 SLIP RING UNIT - LUBRICATE.....6706
4.13 EVERY 2000 OPERATING HOURS OR YEARLY.....6707
4.13.1 HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER.....6708
4.13.2 EMERGENCY ESCAPE LADDER - INSPECTION.....6720
4.14 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR.....6721
4.14.1 SWING GEARS AND MOTOR ADAPTER HOUSING - CHANGE OIL.....6722
4.14.2 TRAVEL GEARS, MOTOR ADAPTER HOUSINGS AND FINAL DRIVES CHANGE OIL.....6730
4.14.3 PTO (PUMP DISTRIBUTOR GEAR) - CHANGE OIL.....6734
4.15 FIRE PREVENTION.....6737
4.16 WELD REPAIRS.....6739
4.16.1 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE UNDERCARRIAGE.....6742
4.16.2 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE LOADER ATTACHMENT.....6744
4.16.3 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE SUPERSTRUCTURE.....6746
4.16.4 AFTER FINISHING THE REPAIR WELDINGS ON THE SUPERSTRUCTURE.....6746
Hydraulic Mining Shovel PC5500-6 Operation & Maintenance Manual (SN15032&15039).....6753
COVER.....6753
1. INTRODUCTION.....6755
1.1 CONTENTS OF THE BINDER.....6756
1.2 DIVISION OF THE BINDER.....6757
1.3 DESIGNATED USE OF THE SHOVEL.....6758
1.4 DELIVERY OF THE SHOVEL.....6759
1.5 EXPLANATION OF ABBREVIATIONS.....6760
1.6 TABLE OF CONTENTS.....6761
2. SAFETY.....6767
2.1 SAFETY INSTRUCTIONS.....6768
2.1.1 WARNINGS AND SYMBOLS.....6768
2.1.2 BASIC OPERATION AND DESIGNATED USE OF THE HYDRAULIC SHOVEL.....6768
2.1.3 ORGANIZATIONAL MEASURES.....6769
2.1.4 SELECTION AND QUALIFICATION OF PERSONNEL - BASIC RESPONSIBILITIES.....6771
2.1.5 SAFETY INSTRUCTIONS GOVERNING SPECIFIC OPERATIONAL PHASES.....6772
2.1.6 WARNING OF SPECIAL DANGERS.....6775
2.1.7 TRANSPORTING AND TOWING -RECOMMISSIONING.....6777
2.1.8 SPECIAL SAFETY EQUIPMENT.....6777
2.1.9 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD).....6781
3. OPERATION.....6789
3.1 FOREWORD.....6790
3.2 CONSTRUCTION OF THE SHOVEL.....6791
3.2.1 OVERALL VIEW.....6791
3.2.2 UNDERCARRIAGE AND SUPERSTRUCTURE.....6792
3.2.3 HYDRAULICALLY OPERATED ACCESS LADDER.....6798
3.2.4 EMERGENCY ESCAPE LADDER.....6802
3.2.5 EMERGENCY ENGINE SHUTDOWN FROM GROUND MAN OR OPERATOR WARNING SYSTEM.....6804
3.2.6 OPERATORS CAB WITH INTEGRATED FALLING OBJECT PROTECTIVE STRUCTURE (FOPS).....6806
3.2.7 ENGINE OIL MANAGEMENT SYSTEM.....6816
3.3 OPERATORS CAB - CONTROLS.....6824
3.3.1 CONTROLS WITH BACKHOE ATTACHMENT.....6824
3.3.2 CONTROLS WITH BOTTOM DUMP BUCKET ATTACHMENT.....6828
3.3.3 OPERATORS CONSOLE.....6833
3.3.4 INTERFACE PANEL FOR DIAGNOSTICS AND CONTROLS FOR HEATING AND AIR CONDITIONING.....6841
3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS.....6844
3.4.1 INTRODUCTION.....6845
3.4.2 OPERATING THE ELECTRONIC MONITORING SYSTEM.....6853
3.4.3 AUTOMATIC DISPLAY OF MESSAGES.....6857
3.4.4 MENU CONTROL AND SERVICE FUNCTIONS.....6881
3.4.5 MENU CONTROL LIST.....6906
3.4.6 FAULT AND INFORMATION MESSAGE LIST.....6924
3.5 OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING.....6948
3.5.1 A - HEATING.....6949
3.5.2 B - COOLING.....6949
3.5.3 COMBINED OPERATION OF AIR CONDITIONING AND HEATING.....6949
3.5.4 AUXILIARY HEATER FOR OPERATORS CAB.....6951
3.6 MACHINERY HOUSE.....6952
3.6.1 EMERGENCY ENGINE SHUTDOWN SWITCHES.....6953
3.6.2 SAFETY SWITCH FOR MAINTENANCE.....6955
3.6.3 CONTROL AND FILTER PANEL OF REAR- AND FRONT POWER UNIT.....6957
3.7 ELECTRICAL EQUIPMENT IN CAB BASE.....6958
3.7.1 STANDARD COMPONENTS IN CAB BASE.....6959
3.7.2 SWITCH BOARD (X2) IN CAB BASE.....6961
3.7.3 CENSE ENGINE MONITORING SYSTEM.....6967
3.7.4 COMPONENTS OF ELECTRICAL PREHEATING SYSTEM IN CAB BASE.....6973
3.8 PREHEATING SYSTEMS FOR OIL, COOLANT AND BATTERIES.....6976
3.9 CHECKS BEFORE STARTING THE ENGINES.....6982
3.10 STARTING THE ENGINES.....6988
3.10.1 STARTING PROCEDURE.....6991
3.11 MOVING THE SHOVEL.....6999
3.11.1 TRAVEL CONTROL WITH FOOT PEDALS.....6999
3.11.2 TRAVELLING INSTRUCTIONS.....7002
3.12 SLEWING AND BRAKING THE SUPERSTRUCTURE.....7003
3.12.1 SLEWING THE SUPERSTRUCTURE.....7003
3.13 WORKING WITH THE ATTACHMENT.....7006
3.13.1 MACHINES EQUIPPED WITH EURO CONTROL SYSTEM.....7006
3.13.2 MACHINES EQUIPPED WITH KMG CONTROL SYSTEM.....7007
3.13.3 BOTTOM DUMP BUCKET.....7008
3.13.4 DROP BALL OPERATION.....7009
3.13.5 COMBINED OPERATION CYCLES.....7012
3.14 WORKING INSTRUCTIONS.....7014
3.14.1 STABILITY OF THE SHOVEL.....7014
3.14.2 SHOVEL OPERATION.....7014
3.15 PARKING THE SHOVEL.....7017
3.16 STOPPING THE ENGINES.....7018
3.16.1 RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM.....7021
3.17 OPERATION OF THE LUBRICATION SYSTEM.....7022
3.17.1 CENTRAL LUBRICATION SYSTEM -CLS- FOR SUPERSTRUCTURE AND ATTACHMENT.....7022
3.17.2 SWING CIRCLE PINION LUBRICATION SYSTEM SLS.....7024
3.18 FIRE DETECTION AND SUPPRESSION SYSTEM.....7026
3.18.1 HIGH LEVEL ALARM FIRE.....7029
3.18.2 ENGINE SHUT-DOWN THROUGH FUEL SHUT-OFF SOLENOID VALVE.....7029
3.18.3 ACTUATION MODES OF THE FIRE SUPPRESSION SYSTEM.....7029
3.18.4 INDICATION OF OPERATIONAL MODES AT CONTROL MODULE, AFTER AUTOMATIC ACTUATION OF THE FIRE S......7031
3.18.5 LOCATION OF THE EXTINGUISHING AGENT TANK ASSEMBLIES AND EXPELLANT GAS CARTRIDGES ON POWER......7033
3.19 TRANSFER PUMP FOR HYDRAULIC OIL.....7034
3.19.1 OPERATING THE TRANSFER PUMP.....7035
3.19.2 FUNCTIONS OF THE TRANSFER PUMP.....7037
3.20 CENTRAL REFILLING SYSTEM.....7040
3.20.1 SYSTEMS CONNECTED TO THE REFILLING SYSTEM.....7041
3.20.2 OPERATING THE HYDRAULIC SERVICE ARM.....7043
3.20.3 RECEIVER PANEL WITH MONITOR BOX.....7045
3.20.4 REFILLABLE GREASE CONTAINERS OF THE AUTOMATIC LUBRICATION SYSTEMS.....7051
3.21 SERVICE CRANE (SPECIAL EQUIPMENT).....7052
3.21.1 OPERATING THE CRANE.....7053
3.22 WORK ON THE LOADER ATTACHMENT.....7056
3.23 TRANSPORTATION AND LIFTING OF THE SHOVEL.....7057
3.23.1 DISASSEMBLING OF THE SHOVEL.....7057
3.23.2 TRANSPORTATION AND LIFTING.....7057
3.24 RETRIEVAL PROCEDURE.....7058
3.25 SHOVEL STORAGE.....7059
3.25.1 PREPARING FOR STORAGE.....7059
3.25.2 ONE MONTH REPETITIVE SERVICE PERIOD.....7060
3.25.3 SIX MONTH REPETITIVE SERVICE PERIOD.....7060
3.25.4 PREPARING FOR OPERATION.....7061
3.26 TROUBLE SHOOTING.....7062
3.26.1 ENGINE.....7062
3.26.2 HYDRAULIC SYSTEM.....7063
3.26.3 FINAL DRIVES AND SWING GEAR.....7064
3.26.4 CRAWLER TRACKS.....7064
4. MAINTENANCE.....7065
4.1 FOREWORD.....7066
4.2 PRECAUTIONS FOR MAINTENANCE.....7067
4.3 FUEL AND LUBRICANTS.....7069
4.4 FILLING CAPACITIES.....7071
4.5 STANDARD TORQUE LIST.....7072
4.6 LUBRICATION AND MAINTENANCE SCHEDULE.....7073
4.6.1 INITIAL SERVICING.....7073
4.6.2 PERIODIC SERVICING INTERVALS.....7073
4.6.3 PERIODIC SERVICING SCHEDULE.....7074
4.6.4 EXTENDED SERVICE INTERVALS FOR ENGINES WITH ENGINE OIL MANAGEMENT SYSTEM.....7081
4.6.5 RESETTING THE ENGINE OIL BURNING SYSTEM CENTINEL.....7083
4.6.6 MAINTENANCE OF THE ENGINES.....7085
4.6.7 ENGINE FUEL FILTER LOCATIONS.....7087
4.7 WHEN NECESSARY.....7088
4.7.1 ENGINE AIR CLEANER MAINTENANCE.....7089
4.7.2 SWING CIRCLE TOOTHING LUBRICATION.....7093
4.7.3 AUTOMATIC LUBRICATION SYSTEMS FILL GREASE CONTAINERS.....7095
4.7.4 TRACK ROLLERS AND GUIDE WHEELS - REPLACE FLOATING SEALS.....7099
4.7.5 COLD STARTING AID, REPLACE FLUID CYLINDER.....7101
4.8 EVERY 10 OPERATING HOURS OR DAILY.....7102
4.8.1 WALK - AROUND INSPECTION.....7103
4.8.2 AIR CLEANER - CLEAN PRE-CLEANER.....7111
4.8.3 RADIATORS - CHECK COOLANT LEVEL.....7113
4.8.4 TRACK GROUPS - CLEAN.....7113
4.9 EVERY 50 OPERATING HOURS OR WEEKLY.....7114
4.9.1 SWING GEARS AND MOTOR ADAPTER HOUSINGS - CHECK OIL LEVELS.....7115
4.9.2 TRAVEL GEARS, MOTOR ADAPTER HOUSINGS AND FINAL DRIVES CHECK OIL LEVELS.....7119
4.9.3 PTOs (PUMP DISTRIBUTOR GEARS) AND OIL RESERVOIR - CHECK OIL LEVEL.....7125
4.9.4 HYDRAULIC ACCESS LADDER - CHECK SAFETY SENSOR.....7129
4.9.5 HYDRAULIC OIL COOLERS - INSPECT AND CLEAN IF NECESSARY.....7131
4.10 EVERY 250 OPERATING HOURS OR MONTHLY.....7132
4.10.1 AIR CONDITIONING COMPRESSOR - CHECK DRIVE BELT TENSION.....7133
4.10.2 SIGNAL HORN COMPRESSOR - LUBRICATE.....7135
4.10.3 HYDRAULIC OIL COOLER FAN BEARINGS - CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER.....7135
4.10.4 RADIATOR FAN BEARINGS - CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER.....7135
4.10.5 AUTOMATIC LUBRICATION SYSTEMS - CLEAN IN-LINE GREASE FILTER AND CHECK BREATHER FILTER.....7137
4.10.6 CAB AIR CLEANER - CLEAN OR REPLACE FILTER ELEMENT.....7139
4.10.7 AIR CONDITIONING FOR OPERATORS CAB - CHECK REFRIGERANT LEVEL.....7141
4.10.8 WINDSHIELD WASHER SYSTEM - CHECK FLUID LEVEL.....7143
4.11 EVERY 500 OPERATING HOURS OR QUARTERLY.....7144
4.11.1 BATTERIES - CHECK FLUID LEVEL.....7145
4.11.2 FLEXIBLE DRIVE COUPLINGS - CHECK OIL LEVEL.....7147
4.11.3 FUEL TANK - DRAIN CONDENSATION.....7149
4.11.4 CRAWLER TRACK - INSPECTION.....7151
4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH.....7156
4.12.1 HIGH STRENGTH BOLT CONNECTIONS - CHECK TORQUE LOAD.....7157
4.12.2 HYDRAULIC SYSTEM - FILTER SERVICE.....7215
4.12.3 PTOS (PUMP DISTRIBUTOR GEARS), SWING GEARS AND TRAVEL GEARS - OIL SAMPLE ANALYSIS.....7229
4.12.4 SIGNAL HORN COMPRESSOR - CLEAN AND LUBRICATE.....7231
4.12.5 HYDRAULIC TRACK TENSIONING SYSTEM - CHECK PRESSURE ACCUMULATORS.....7233
4.12.6 WATER FILTER - REPLACE FILTER CARTRIDGE.....7235
4.12.7 HYDRAULIC OIL COOLER - INSPECT AND LUBRICATE DOOR HINGES.....7237
4.12.8 MACHINERY HOUSE DOORS - INSPECT AND LUBRICATE DOOR HINGES.....7239
