Komatsu 15045 Manual

Operation & Maintenance
Manual
PC5500-6
HYDRAULIC MINING SHOVEL
SERIAL NUMBER 15045 and up
This material is proprietary to Komatsu Mining Germany GmbH and is not to be reproduced, used,
or disclosed except in accordance with written authorization from Komatsu Mining Germany GmbH.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve
the right to make changes or add improvements at any time without incurring any obligation to install
such changes on products sold previously.
Due to this continuos program of research and development, periodic revisions may be made to this
publication. It is recommended that customer contact their distributor for information on the latest
revision.
August 2006 Copyright 2006

3
1. INTRODUCTION

1.1 CONTENTS OF THE BINDER INTRODUCTION
4
1.1 CONTENTS OF THE BINDER
Assembled in this file are the Operation-, Lubrication- and Mainte-
nance Manuals for your KOMATSU Hydraulic Mining Shovel.

INTRODUCTION 1.2 DIVISION OF THE BINDER
5
1.2 DIVISION OF THE BINDER
Part 1:
Operation Manual
Part 2:
Lubrication- and Maintenance Manual
Part 3:
Depending on the volume of Part 3 a second Binder "Volume 2" is
being delivered with the Shovel. This Binder contains the General
Assembly Procedure Manual for the Shovel, Specification Book-
let, Service Literature for the Power Unit (Diesel Engine or Elec-
tric Motor) and for Special Equipment. The Electrical- and
Hydraulic Diagrams are attached in the pocket of the front cover.
Refer to the "TABLE OF CONTENTS VOLUME 2 BINDER"
for details.
Read the Manuals before You Start the Engines.
Before operating the machine, familiarize yourself with its instru-
ments 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 will prevent failures and
avoid expenses.
Replace damaged graphics and symbols.
Observe safety precautions to prevent injury and damage.
If you have any questions concerning this literature please con-
tact
Komatsu Mining Germany GmbH
Service Information
Department 8151.40
P.O. Box 18 03 61
D - 40570 Düsseldorf
GERMANY

1.3 DESIGNATED USE OF THE SHOVEL INTRODUCTION
6
1.3 DESIGNATED USE OF THE SHOVEL
This machine has been manufactured in accordance with
advanced and up-to-date technology standards including recog-
nized safety rules. Nevertheless, its use may constitute a risk to
life and limb of the 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 affecting the
safety of the machine, should, therefore, be 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-
pany's safety instructions. Short traveling distances 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.
WARNING
Special use of the Shovel beyond its designated use, e.g.
object handling operations, require written agreement from
the manufacturer and retrofitment of the Shovel with respec-
tive safety related equipment before such special applica-
tions are permitted.

INTRODUCTION 1.4 DELIVERY OF THE SHOVEL
7
1.4 DELIVERY OF THE SHOVEL
The Shovel is being delivered disassembled into its main compo-
nents.
For assembling the Shovel refer to the separate Manual
”Assembly Procedure” in Volume 2 Binder.
WARNING
Personnel entrusted with work on the machine must have
read the Assembly Manual, the Operation,- Lubrication- and
Maintenance Manual and in particular the section on safety
before beginning work. Reading the instructions after work
has begun is too late.
If there are any questions concerning the assembling procedure,
contact your local Service Center.
Prior to first operation, inspect the Shovel thoroughly with the Ser-
vice Engineer responsible for the erection of the machine. Check
all fluid levels according to the Lubrication and Maintenance
Schedule.
Damages and defects caused by incorrect operation and mainte-
nance are not covered by the manufacturers guarantee.
N
OTICE
If the Shovel is equipped with a fire suppression system,
make sure that the system is ready for operation.
SPARE PARTS
For your spare part orders refer to the Parts Catalogue.
In order to keep your Shovel in first-class operating condition use
only genuine spare and wear parts.
The use of any part other than the genuine part releases the
KOMATSU MINING GERMANY GmbH from any guarantee.
SERVICE
For all questions related to your Shovel please contact your local
Service Center.
In all your written or phoned inquiries please indicate the model
and serial number of your Shovel.

1.5 EXPLANATION OF ABBREVIATIONS INTRODUCTION
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1.5 EXPLANATION OF ABBREVIATIONS
ABB. Definition
A Ampere
AC Alternating Current
API American Petroleum Institute
cSt Centistoke
°C Degree Celsius
CENTRY Engine Electronic Control System
CLS Central Lubrication System
DC Direct Current
DIN German Institute for Standardization
EBL Electronic Bucket Levelling System
ECM Electronic Control Module (Engine)
ECS Electronic Control and Monitoring System
FGPS Front Guard Protective Structure
FOPS Falling-Object Protective Structure
GL Gear Lubricant
h hours of operation
HPF High Pressure Filter
(Hydraulic Oil)
HT High Tension
LED Light Emitting Diode
LT Low Tension
MPG Multi-Purpose Grease
NNewton
Nm Newton meter
PLC Programmable Logic Controller
PM Planned Maintenance
ppm parts per million
PTO Power Take-Off
(Pump Distributor Gear)
SLS Swing circle pinion Lubrication System
VVolt
1/min Revolutions Per Minute (RPM)

INTRODUCTION 1.6 TABLE OF CONTENTS
9
1.6 TABLE OF CONTENTS
1. INTRODUCTION...........................................................................................3
1.1 CONTENTS OF THE BINDER ........................................................................................................... 4
1.2 DIVISION OF THE BINDER ............................................................................................................... 5
1.3 DESIGNATED USE OF THE SHOVEL .............................................................................................. 6
1.4 DELIVERY OF THE SHOVEL ............................................................................................................ 7
1.5 EXPLANATION OF ABBREVIATIONS ............................................................................................. 8
1.6 TABLE OF CONTENTS ..................................................................................................................... 9
2. SAFETY ......................................................................................................15
2.1 SAFETY INSTRUCTIONS ................................................................................................................ 16
2.1.1 WARNINGS AND SYMBOLS .............................................................................................. 16
2.1.2 BASIC OPERATION AND DESIGNATED USE OF THE HYDRAULIC SHOVEL ............... 16
2.1.3 ORGANIZATIONAL MEASURES ....................................................................................... 17
2.1.4 SELECTION AND QUALIFICATION OF PERSONNEL - BASIC RESPONSIBILITIES ...... 19
2.1.5 SAFETY INSTRUCTIONS GOVERNING SPECIFIC OPERATIONAL PHASES ................ 20
2.1.6 WARNING OF SPECIAL DANGERS .................................................................................. 23
2.1.7 TRANSPORTING AND TOWING -RECOMMISSIONING .................................................. 25
2.1.8 SPECIAL SAFETY EQUIPMENT ........................................................................................ 25
2.1.9 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD) ........... 29
3. OPERATION ...............................................................................................37
3.1 FOREWORD .................................................................................................................................... 38
3.2 CONSTRUCTION OF THE SHOVEL ............................................................................................... 39
3.2.1 OVERALL VIEW .................................................................................................................. 39
3.2.2 UNDERCARRIAGE AND SUPERSTRUCTURE ................................................................. 40
3.2.3 HYDRAULICALLY OPERATED ACCESS LADDER ........................................................... 46
3.2.4 EMERGENCY ESCAPE LADDER ...................................................................................... 50
3.2.5 EMERGENCY ENGINE SHUTDOWN FROM GROUND MAN OR OPERATOR WARNING
SYSTEM .............................................................................................................................. 52
3.2.6 OPERATOR’S CAB WITH INTEGRATED FALLING OBJECT PROTECTIVE STRUCTURE
(FOPS) ................................................................................................................................ 54
3.2.7 ENGINE OIL MANAGEMENT SYSTEM ............................................................................. 64
3.3 OPERATOR’S CAB - CONTROLS .................................................................................................. 72
3.3.1 CONTROLS WITH BACKHOE ATTACHMENT .................................................................. 72
3.3.2 CONTROLS WITH BOTTOM DUMP BUCKET ATTACHMENT ......................................... 76

1.6 TABLE OF CONTENTS INTRODUCTION
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3.3.3 OPERATOR’S CONSOLE ................................................................................................... 81
3.3.4 INTERFACE PANEL FOR DIAGNOSTICS ......................................................................... 89
3.3.5 CONTROL MODULE FOR AUXILIARY CAB HEATER ...................................................... 91
3.4 ELECTRONIC MONITORING AND CONTROL SYSTEM ECS ...................................................... 92
3.4.1 INTRODUCTION ................................................................................................................. 93
3.4.2 OPERATING THE ELECTRONIC MONITORING SYSTEM ............................................. 101
3.4.3 AUTOMATIC DISPLAY OF MESSAGES .......................................................................... 105
3.4.4 MENU CONTROL AND SERVICE FUNCTIONS .............................................................. 129
3.4.5 MENU CONTROL LIST ..................................................................................................... 154
3.4.6 FAULT AND INFORMATION MESSAGE LIST ................................................................. 172
3.5 OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING ..................................... 198
3.5.1 AUXILIARY HEATER FOR OPERATOR’S CAB ............................................................... 201
3.6 MACHINERY HOUSE .................................................................................................................... 202
3.6.1 EMERGENCY ENGINE SHUTDOWN SWITCHES .......................................................... 203
3.6.2 SAFETY SWITCH FOR MAINTENANCE .......................................................................... 205
3.6.3 CONTROL AND FILTER PANEL OF REAR- AND FRONT POWER UNIT ...................... 207
3.7 ELECTRICAL EQUIPMENT IN CAB BASE .................................................................................. 208
3.7.1 STANDARD COMPONENTS IN CAB BASE .................................................................... 209
3.7.2 SWITCH BOARD (X2) IN CAB BASE ............................................................................... 211
3.7.3 COMPONENTS OF ELECTRICAL PREHEATING SYSTEM IN CAB BASE .................... 219
3.8 PREHEATING SYSTEMS FOR OIL, COOLANT AND BATTERIES ............................................. 222
3.9 CHECKS BEFORE STARTING THE ENGINES ............................................................................ 228
3.10 STARTING THE ENGINES ............................................................................................................ 234
3.10.1 STARTING PROCEDURE ................................................................................................ 237
3.11 MOVING THE SHOVEL ................................................................................................................. 245
3.11.1 TRAVEL CONTROL WITH FOOT PEDALS ...................................................................... 245
3.11.2 TRAVELLING INSTRUCTIONS ........................................................................................ 248
3.12 SLEWING AND BRAKING THE SUPERSTRUCTURE ................................................................. 249
3.12.1 SLEWING THE SUPERSTRUCTURE .............................................................................. 249
3.13 WORKING WITH THE ATTACHMENT .......................................................................................... 252
3.13.1 MACHINES EQUIPPED WITH ”EURO” CONTROL SYSTEM .......................................... 252
3.13.2 MACHINES EQUIPPED WITH ”KMG” CONTROL SYSTEM ............................................ 253
3.13.3 BOTTOM DUMP BUCKET ................................................................................................ 254
3.13.4 DROP BALL OPERATION ................................................................................................ 255
3.13.5 COMBINED OPERATION CYCLES .................................................................................. 258
3.14 WORKING INSTRUCTIONS .......................................................................................................... 260
3.14.1 STABILITY OF THE SHOVEL ........................................................................................... 260
3.14.2 SHOVEL OPERATION ...................................................................................................... 260