Komatsu Hydraulic Mining Shovel PC5500-6 PC5500-6 Shop Manual SEBM018000 PDF

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Komatsu Hydraulic Mining Shovel PC5500-6 PC5500-6 Shop Manual SEBM018000 – PDF DOWNLOAD

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Komatsu Hydraulic Mining Shovel PC5500-6 PC5500-6 Shop Manual SEBM018000 – PDF DOWNLOAD

Language : English
Pages :727
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu Hydraulic Mining Shovel PC5500-6 PC5500-6 Shop Manual SEBM018000 – PDF DOWNLOAD

SERIAL NUMBERS PC5500-6 15018

FOREWORD
GENERAL

• With this SERVICE MANUAL KOMATSU provides you with the description of the construction and the function of the major systems of the Hydraulic Excavator PC5500.
• We describe for you all functions and how to carry out the inspections and adjustments.
• How do you find “your” desired information?
• In the table of CONTENT all the functions and components are shown in their sequence of the description.
• If after reading this SERVICE MANUAL you can give us suggestions and comments for improvements – please do not hesitate to contact us.

TABLE OF CONTENTS:

Komatsu Hydraulic Mining Shovel PC5500-6 PC5500-6 Shop Manual SEBM018000 – PDF DOWNLOAD

SERIAL NUMBERS PC5500-6 15018

MAIN MENU 0
COVER 1
TABLE OF CONTENTS 3
SAFETY 4
SAFETY NOTICE 4
GENERAL PRECAUTIONS 5
PRECAUTIONS DURING WORK 6
FOREWORD 7
GENERAL 7
HOISTING INSTRUCTIONS 8
STANDARD TIGHTENING TORQUE 10
CONVERSION TABLE 11
TEMPERATURE 16
SECTION 10 MAIN ASSEMBLY GROUPS 17
TABLE OF CONTENTS SECTION 10 17
GENERAL LAY OUT 19
11 SUPERSTRUCTURE 21
111 MACHINE HOUSE 23
112 HYDRAULIC OIL RESERVOIR 25
113 HYDRAULIC OIL COOLER 27
114 FUEL TANK 29
115 COUNTER WEIGHT 31
116 CAB SUPPORT 33
117 OPERATORS CAB 35
118 CONTROL BLOCKS 37
119 SWING GEARS 39
12 UNDER CARRIAGE 41
13 ATTACHMENT 43
131 BACKHOE ATTACHMENT (BHA) 43
132 FRON SHOVEL ATTACHMENT (FSA) 45
SECTION 20 DRIVE 47
TABLE OF CONTENTS SECTION 20 47
20 GENERAL LAY OUT 49
21 ENGINE AND PTO MOUNTS 51
22 COUPLING 55
23 AIR FILTER 57
24 FAN DRIVE AND RADIATOR ASSEMBLY 59
25 RADIATOR FAN DRIVE SPEED ADJUSTMENT 65
26 PUMP DISTRIBUTOR GEARBOX (PTO) 71
27 PUMP-SPLINE LUBRICATION 73
28 PTO LUBRICATION AND COOLING 75
29 HYDRAULIC PUMPS – LOCATION, DRIVE SPEED AND FLOW RATES 79
SECTION 40 HYDRAULIC OIL COOLING 81
TABLE OF CONTENTS SECTION 40 81
41 GENERAL 83
42 FUNCTION OF THE HYDRAULIC OIL COOLING CIRCUIT 85
43 ADJUSTMENT OF THE BACK PRESSURE VALVE 87
44 FAN DRIVE (TWO STAGE COOLER FAN RPM CONTROL) 89
45 PRESSURE RELIEF VALVES AND SOLENOID VALVES 93
46 FIXED DISPLACEMENT PUMP, WITH VARIABLE SETTING 97
47 RADIATOR FAN DRIVE SPEED ADJUSTMENT 99
SECTION 50 CONTROLLING105
TABLE OF CONTENTS SECTION 50105
GENERAL LAY OUT107
51 CONTROL AND FILTER PANEL LOCATION OF COMPONENTS109
52 PILOT PRESSURE SUPPLY AND ADJUSTMENTS111
53 REMOTE CONTROL VALVES ARRANGEMENT119
54 FUNCTION PRINCIPLE OF THE ELECTRO-HYDRAULIC-PROPORTIONAL CONTROL121
55 POTENTIOMETER CONTROL (LEVER, JOY STICK)125
56 POTENTIOMETER CONTROL (PEDAL)127
57 PROPORTIONAL AMPLIFIER MODULE, TYPE A129
58 PROPORTIONAL AMPLIFIER MODULE, TYPE B131
59 RAMP TIME MODULE133
510 ADJUSTMENTS OF AMPLIFIER MODULES (GENERAL)135
511 ADJUSTING THE AMPLIFIERS TYPE B137
512 ADJUSTING THE AMPLIFIERS TYPE A141
513 ADJUSTING THE RAMP TIME MODULE145
SECTION 60 COMPONENTS153
TABLE OF CONTENTS SECTION 60153
611 MAIN CONTROL BLOCKS AND HIGH PRESSURE FILTER FSA155
612 MAIN CONTROL BLOCKS AND HIGH PRESSURE FILTER BACK HOE ATTACHMENT159
613 DISTRIBUTOR MANIFOLD- RESTRICTOR BLOCKS FSA163
614 DISTRIBUTOR MANIFOLD- RESTRICTOR BLOCKS BHA165
615 RESTRICTOR BLOCK WITH PRESSURE RELIEF VALVE167
616 ANTI CAVITATION VALVE BLOCK169
617 REMOTE CONTROL VALVES171
618 DIRECTIONAL SOLENOID VALVES173
619 PROPORTIONAL SOLENOID VALVE175
6110 HIGH PRESSURE FILTER177
6111 CONTROL BLOCKS AND VALVES179
6112 LOAD HOLDING VALVE187
6113 TRAVEL BRAKE VALVE189
6114 PRESSURE REDUCING VALVE191
6115 DIRECTIONAL SOLENOID VALVES193
6116 PRESSURE INCREASING VALVE195
SECTION 70 MAIN HYDRAULIC PUMPS AND PUMP REGULATION SYSTEM197
TABLE OF CONTENTS SECTION 70197
70 GENERAL LAY OUT199
71 MAIN PUMPS207
711 LOCATION OF PUMPS207
712 PUMP BEARING FLUSHING/LUBRICATION209
713 OPERATING PRINCIPLES211
714 CHECKS/ADJUSTMENTS227
72 ELECTRONIC PUMP REGULATION SYSTEM237
721 ELECTRONIC LOAD LIMITING CONTROL237
722 MICROCONTROLLER MC7239
723 CHECKS AND ADJUSTMENTS241
METHOD A243
METHOD B245
LANGUAGE SELECTION245
EXCAVATOR TYPE SELECTION249
1-PRESSURE (MAX CURRENT) ADJUSTMENT253
METHOD C257
STARTING THE PROGRAM257
LANGUAGE SELECTION261
EXCAVATOR TYPE SELECTION263
X1-PRESSURE (MAX CURRENT) ADJUSTMENT265
73 HYDRAULIC CONSTANT REGULATION SYSTEM267
731 GENERAL267
732 X1-PRESSURE ADJUSTMENT (CONSTANT-PRESSURE)269
74 DETERMINATION OF THE PEAK POINT271
75 ENGINE SPEED SENSOR (PICK UP)275
SECTION 80 OPERATING HYDRAULIC277
TABLE OF CONTENTS SECTION 80277
80 GENERAL279
801 FLOATING FUNCTION OF BOOM AND STICK CYLINDERS FSA281
81 HYDRAULIC FOR THE ATTACHMENT CYLINDERS FSA AND BHA285
TABLE OF CONTENTS SECTION 81285
811 ELECTRIC/HYDRAULIC FLOWCHART “BOOM RAISING” FSA287
812 ELECTRIC/HYDRAULIC FLOWCHART “BOOM LOWERING” FSA, AUTO FLOAT OFF291
813 ELECTRIC/HYDRAULIC FLOWCHART “STICK EXTENDING” FSA297
814 ELECTRIC/HYDRAULIC FLOWCHART “STICK RETRACTING” FSA AUTO FLOAT OFF301
815 ELECTRIC/HYDRAULIC FLOWCHART “BUCKET FILLING” FSA307
816 ELECTRIC/HYDRAULIC FLOWCHART “BUCKET DUMP” FSA311
818 ELECTRIC/HYDRAULIC FLOWCHART “CLAM OPENING” FSA315
819 ELECTRIC/HYDRAULIC FLOWCHART “CLAM CLOSING” FSA317
8110 CHECKS AND ADJUSTMENTS OF THE MAIN RELIEF VALVES (MRV)319
8111 CHECKS AND ADJUSTMENTS OF THE SERVICE LINE RELIEF VALVES (SRV)323
BOOM CYLINDER “PISTON SIDE” FSA + BHA323
BOOM CYLINDER “PISTON ROD SIDE” FSA + BHA327
STICK CYLINDER “PISTON SIDE” FSA331
STICK CYLINDER “PISTON SIDE” BHA335
STICK CYLINDER “PISTON ROD SIDE” FSA339
STICK CYLINDER “PISTON ROD SIDE” BHA345
BUCKET CYLINDER “PISTON SIDE” FSA349
BUCKET CYLINDER “PISTON SIDE” BHA353
BUCKET CYLINDER “PISTON ROD SIDE” FSA357
BUCKET CYLINDER “PISTON ROD SIDE” BHA361
CLAM CYLINDER “PISTON ROD SIDE” FSA365
CLAM CYLINDER “PISTON SIDE” FSA367
8112 CHECKS AND ADJUSTMENTS OF THE LOWERING SPEED369
BOOM CYLINDER FSA369
BOOM CYLINDER BHA375
STICK CYLINDER FSA377
STICK CYLINDER BHA381
BUCKET CYLINDER FSA383
BUCKET CYLINDER BHA385
CLAM CYLINDER FSA387
8113 CHECKS FOR THE VALVE CONTROL LOGIC389
82 HYDRAULIC FOR THE SWING CIRCUIT391
TABLE OF CONTENTS SECTION 82391
821 SWING CIRCUIT (BRIEF DESCRIPTION)393
822 SWING MOTOR397
823 SWING GEAR BOX405
824 SWING PARKING BRAKE (GEAR HOUSE BRAKE)407
825 SWING BRAKE VALVE409
826 ELECTRIC/HYDRAULIC FLOWCHART “SWING LEFT”415
827 ELECTRIC/HYDRAULIC FLOWCHART “SWING RIGHT”417
828 SWING MONITORING SYSTEM419
829 CHECKS AND ADJUSTMENTS FOR THE SWING CIRCUIT423
83 HYDRAULIC FOR THE TRAVEL CIRCUIT429
TABLE OF CONTENTS SECTION 83429
831 TRAVEL CIRCUIT (BRIEF DESCRIPTION)431
832 ROTARY DISTRIBUTOR435
833 SIDE FRAME COMPONENTS, CROSS SECTIONS439
834 TRAVEL GEAR AND PARKING BRAKE441
835 PARKING BRAKE443
836 ELECTRIC/HYDRAULIC FLOW CHARTS445
837 ADJUSTMENTS/CHECKS447
FUNCTION CHECK OF THE TRAVEL GEAR HOUSE BRAKE451
SECTION 90 HYDRAULIC TRACK TENSIONING SYSTEM453
TABLE OF CONTENTS SECTION 90453
90 GENERAL455
91 FUNCTIONAL DESCRIPTION457
92 PRESSURE INCREASING VALVE461
93 TENSIONING CYLINDER463
94 ADJUSTMENTS/CHECKS465
95 FUNCTIONAL TEST469
SECTION 100 ACCESS LADDER HYDRAULICALLY OPERATED471
TABLE OF CONTENTS SECTION 100471
100 GENERAL473
101 FUNCTION OF HYDRAULIC OPERATED ACCESS LADDER475
SECTION 110 HYDRAULID OPERATED REFILLING ARM479
TABLE OF CONTENTS SECTION 110479
110 GENERAL481
111 FUNCTION OF HYDRAULIC OPERATED REFILLING ARM483
SECTION 120 HINTS FOR READING THE HYDRAULIC CIRCUIT DIAGRAM485
TABLE OF CONTENTS SECTION 120485
121 GENERAL487
SECTION 130 HINTS FOR READING THE ELECTRIC CIRCUIT DIAGRAM489
TABLE OF CONTENTS SECTION 130489
131 DESIGNATION OF ELECTRICAL DEVICES491
132 SYMBOLS493
133 GENERAL INFORMATION497
134 READING A CIRCUIT DIAGRAM501
SECTION 140 VHMS/ECS-T/ETM506
TABLE OF CONTENTS SECTION 140506
140 SAFETY INSTRUCTIONS506
141 GENERAL DESIGN OF THE ECS-T SYSTEM512
1411 INPUT AND OUTPUT OF HTE PLC514
1412 TASK514
1413 PLC DIGSY PLUS516
1414 DEFINITIONS; SYMBOLS AND ABBREVIATIONS518
142 HOW TO PROCEED DUE MAINTENANCE AND INSTALLATION524
1421 MEANING OF THE STATUS LED’S528
1422 SHORT CIRCUIT MARKET-LED “MK”532
1423 DIAGNOSTIC FOR TEMPERATURE-MODULE “TPM”534
143 FRONT CONNECTOR ARRANGEMENT536
1431 FRON CONNECTOR ARRANGEMENT BIM MODULE536
1432 FRONT CONNECTOR ARRANGEMENT, TPM-MODULE538
1434 FOUR WIRE (CONDUCTOR) TECHNIQUE540
1435 SENSOR WIRE BREAKAGE MONITORING540
1436 EARTHING OF THE CONTROL UNIT542
144 POWER SUPPLY546
1441 OPERATING VOLTAGES +24V546
1442 SAFETY PRECAUTIONS FOR FAULTFINDING548
1443 CPU VOLTAGE RANGE550
1444 ELECTRIC CLASSIFICATION550
1445 FUSE550
145 FUNCTION EXPLANATIONS WITH ELECTRIC DIAGRAM552
1451 GENERAL552
1452 CONTROLLING554
1453 PRESSURE MEASURING558
1454 TEMPERATURE MEASURING560
1455 TEMPERATURE-RESISTANCE CHART PT100561
147 HINTS FOR READING THE FUNCTIONAL FLOW CHARTS562
1471 GENERAL562
1472 EXAMPLE 1564
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