Komatsu Hydraulic Mining Shovel PC5500-6 PC5500-6 Shop Manual SMPC550015035 PDF

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Komatsu Hydraulic Mining Shovel PC5500-6 PC5500-6 Shop Manual SMPC550015035 – PDF DOWNLOAD

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Komatsu Hydraulic Mining Shovel PC5500-6 PC5500-6 Shop Manual SMPC550015035 – PDF DOWNLOAD

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Komatsu Hydraulic Mining Shovel PC5500-6 PC5500-6 Shop Manual SMPC550015035 – PDF DOWNLOAD

SERIAL NUMBERS PC5500-6 15031,15035 & UP

GENERAL PRECAUTIONS
Mistakes in operation are extremely dangerous. Read the OPERATION & MAINTENANCE
MANUAL carefully BEFORE operating the machine.
1. Before carrying out any greasing or repairs, read all the precautions given on the decals
which are fixed to the machine.
2. When carrying out any operation, always wear safety shoes and helmet. Do not wear
loose work clothes, or clothes with buttons missing.
• Always wear safety glasses when hitting parts with a hammer.
• Always wear safety glasses when grinding parts with a grinder, etc.

TABLE OF CONTENTS:

Komatsu Hydraulic Mining Shovel PC5500-6 PC5500-6 Shop Manual SMPC550015035 – PDF DOWNLOAD

SERIAL NUMBERS PC5500-6 15031,15035 & UP

MAIN MENU 0
COVER 1
CONTENTS – TABLE OF CONTENTS 2
SAFETY 3
FOREWORD 6
SECTION 10 MAIN ASSEMBLY GROUPS 17
TABLE OF CONTENTS SECTION 10 17
GENERAL LAYOUT 19
11 SUPERSTRUCTURE 21
111 MACHINE HOUSE 23
112 HYDRAULIC OIL RESERVOIR 25
113 HYDRAULIC OIL COOLER 27
114 FUEL TANK (FUEL RESERVOIR) 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 FRONT SHOVEL ATTACHMENT (FSA) 45
SECTION 20 DRIVE 46
TABLE OF CONTENTS SECTION 20 46
PRIME DRIVE ASSEMBLY – GENERAL LAY OUT 48
21 ENGINE AND PTO MOUNTS 50
22 COUPLING 54
23 AIR FILTER 56
24 FAN DRIVE AND RADIATOR ASSEMBLY 58
25 RADIATOR FAN DRIVE SPEED ADJUSTMENT 64
26 PUMP DISTRIBUTOR GEARBOX (PTO) 70
27 PUMP-SPLINE LUBRICATION 72
28 PTO LUBRICATION AND COOLING 74
29 HYDRAULIC PUMPS – LOCATION, DRIVE SPEED AND FLOW RATES 78
SECTION 30 HYDRAULIC OIL RESERVOIR 79
TABLE OF CONTENTS SECTION 30 79
GENERAL LAY OUT 81
31 MAIN OIL TANK, LOCATION OF SWITCHES, SENSORS, ETC 83
32 SUCTION OIL TANK WITH STRAINERS 85
33 RETURN OIL COLLECTOR TUBE WITH STRAINER 87
34 BACK PRESSURE VALVE 89
36 RETURN AND LEAK OIL FILTER 91
37 BREATHER FILTER 93
SECTION 40 HYDRAULIC OIL COOLING 94
TABLE OF CONTENTS SECTION 40 94
41 GENERAL 96
42 FUNCTION OF THE HYDRAULIC OIL COOLING CIRCUIT 98
43 ADJUSTMENT OF THE BACK PRESSURE VALVE100
44 FAN DRIVE (TWO STAGE COOLER FAN RPM CONTROL)102
45 PRESSURE RELIEF VALVES AND SOLENOID VALVES106
46 FIXED DISPLACEMENT PUMP, WITH VARIABLE SETTING110
47 RADIATOR FAN DRIVE SPEED ADJUSTMENT112
SECTION 50 CONTROLLING117
TABLE OF CONTENTS SECTION 50117
GENERAL LAY OUT119
51 CONTROL AND FILTER PANEL LOCATION OF COMPONENTS121
52 PILOT PRESSURE SUPPLY AND ADJUSTMENTS123
53 REMOTE CONTROL VALVES ARRANGEMENT131
54 FUNCTION PRINCIPLE OF THE ELECTRO-HYDRAULIC-PROPORTIONAL CONTROL133
55 POTENTIOMETER CONTROL (LEVER, JOY STICK)137
56 POTENTIOMETER CONTROL (PEDAL)139
57 PROPORTIONAL AMPLIFIER MODULE, TYPE A141
58 PROPORTIONAL AMPLIFIER MODULE, TYPE B143
59 RAMP TIME MODULE145
510 ADJUSTMENTS OF AMPLIFIER MODULES (GENERAL)147
511 ADJUSTING THE AMPLIFIERS TYPE B149
512 ADJUSTING THE AMPLIFIERS TYPE B153
513 ADJUSTING THE RAMP TIME MODULE157
SECTION 60 COMPONENTS164
TABLE OF CONTENTS SECTION 60164
61 HYDRAULIC166
611 MAIN CONTROL BLOCKS AND HIGH PRESSURE FILTER FRONT SHOVEL ATTACHMENT FSA166
612 MAIN CONTROL BLOCKS AND HIGH PRESSURE FILTER BACKHOE ATTACHMENT BHA170
613 DISTRIBUTOR MANIFOLD – LOCATION OF RESTRICTOR BLOCKS AND ANTI CAVITATION VALVES FSA174
614 DISTRIBUTOR MANIFOLD – LOCATION OF RESTRICTOR BLOCKS AND ANTI CAVITATION VALVES BHA176
615 RESTRICTOR BLOCK WITH PRESSURE RELIEF VALVE178
616 ANTI CAVITATION VALVE BLOCK180
617 REMOTE CONTROL VALVES182
618 DIRECTIONAL SOLENOID VALVES184
619 PROPORTIONAL SOLENOID VALVE186
6110 HIGH PRESSURE FILTER188
6111 CONTROL BLOCKS AND VALVES190
6112 LOAD HOLDING VALVE198
6113 TRAVEL BRAKE VALVE200
6114 PRESSURE REDUCING VALVE202
6115 DIRECTIONAL SOLENOID VALVES (2 POSITIONS / 4-WAYS)204
6116 PRESSURE INCREASING VALVE206
SECTION 70 MAIN HYDRAULIC PUMPS AND PUMP REGULATION SYSTEM207
TABLE OF CONTENTS SECTION 70207
70 MAIN HYDRAULIC PUMPS AND PUMP REGULATION SYSTEM GENERAL LAYOUT (HYDRAULIC ONLY)209
71 MAIN PUMPS217
711 LOCATION OF PUMPS217
712 PUMP BEARING FLUSHING / LUBRICATION219
713 OPERATING PRINCIPLES221
714 CHECKS / ADJUSTMENTS237
72 ELECTRONIC PUMP REGULATION SYSTEM247
723 CHECKS AND ADJUSTMENTS MICRO CONTROLLER MC7251
METHOD A253
METHOD B255
LANGUAGE SELECTION255
EXCAVATOR TYPE SELECTION259
X1-PRESSURE (MAXIMUM CURRENT) ADJUSTMENT263
METHOD C267
STARTING THE PROGRAM267
LANGUAGE SELECTION271
EXCAVATOR TYPE SELECTION273
X1-PRESSURE (MAXIMUM CURRENT) ADJUSTMENT275
721 ELECTRONIC LOAD LIMITING CONTROL – GENERAL247
722 MICRO CONTROLLER MC7249
73 HYDRAULIC CONSTANT REGULATION SYSTEM277
731 GENERAL277
732 X1-PRESSURE ADJUSTMENT (CONSTANT-PRESSURE)279
74 DETERMINATION OF THE PEAK POINT (ENGINE PERFORMANCE)281
75 ENGINE SPEED SENSOR (PICK UP)285
SECTION 80 OPERATING HYDRAULIC286
TABLE OF CONTENTS SECTION 80286
80 GENERAL288
801 FLOATING FUNCTION OF BOOM AND STICK CYLINDERS FSA290
81 HYDRAULIC FOR THE ATTACHMENT CYLINDERS293
TABLE OF CONTENTS SECTION 81293
811 ELECTRIC / HYDRAULIC FLOWCHART “BOOM RAISING” FSA295
812 ELECTRIC / HYDRAULIC FLOWCHART “BOOM LOWERING” FSA, AUTO FLOAT OFF299
813 ELECTRIC / HYDRAULIC FLOWCHART “STICK EXTENDING” FSA305
814 ELECTRIC / HYDRAULC FLOWCHART “STICK RETRACTING” FSA AUTO FLOAT OFF309
815 ELECTRIC / HYDRAULIC FLOWCHART “BUCKET FILLING” FSA315
816 ELECTRIC / HYDRAULIC FLOWCHART “BUCKET DUMP” FSA319
818 ELECTRIC / HYDRAULIC FLOWCHART “CLAM OPENING” FSA323
819 ELECTRIC / HYDRAULIC FLOWCHART “CLAM CLOSING” FSA325
8110 CHECKS AND ADJUSTMENTS OF THE MAIN RELIEF VALVES (MRV)327
8111 CHECKS AND ADJUSTMENTS OF THE SERVICE LINE RELIEF VALVES (SRV)331
BOOM CYLINDER “PISTON SIDE” FSA + BHA331
BOOM CYLINDER “PISTON ROD SIDE” FSA + BHA335
STICK CYLINDER “PISTON SIDE” FSA339
STICK CYLINDER “PISTON SIDE” BHA343
STICK CYLINDER “PISTON ROD SIDE” FSA347
STICK CYLINDER “PISTON ROD SIDE” BHA353
BUCKET CYLINDER “PISTON SIDE” FSA357
BUCKET CYLINDER “PISTON SIDE” BHA361
BUCKET CYLINDER “ROD SIDE” FSA365
BUCKET CYLINDER “PISTON ROD SIDE” BHA369
CLAM CYLINDER “ROD SIDE” (CLAM OPENING) FSA373
CLAM CYLINDER “PISTON SIDE (CLAM CLOSING) FSA375
8112 CHECKS AND ADJUSTMENTS OF THE LOWERING SPEED377
GENERAL: FLOW RESTRICTORS BOOM CYLINDER FSA377
BOOM CYLINDER BHA383
STICK CYLINDER FSA385
STICK CYLINDER BHA389
BUCKET CYLINDER FSA391
BUCKET CYLINDER BHA393
CLAM CYLINDER FSA395
8113 CHECKS FOR THE VALVE CONTROL LOGIC397
82 HYDRAULIC FOR THE SWING CIRCUIT398
TABLE OF CONTENTS SECTION 82398
821 SWING CIRCUIT (BRIEF DESCRIPTION)400
822 SWING MOTOR404
823 SWING GEAR BOX412
824 SWING PARKING BRAKE (GEAR HOUSE BRAKE)414
825 SWING BRAKE VALVE416
826 ELECTRIC / HYDRAULIC FLOWCHART “SWING LEFT”422
827 ELECTRIC / HYDRAULIC FLOWCHART “SWING RIGHT”424
828 SWING MONITORING SYSTEM426
829 CHECKS AND ADJUSTMENTS FOR THE SWING CIRCUIT430
8210 CHECKS AND ADJUSTMENTS FOR THE SWING CIRCUIT434
83 HYDRAULIC FOR THE TRAVEL CIRCUIT435
TABLE OF CONTENTS SECTION 83435
831 TRAVEL CIRCUIT (BRIEF DESCRIPTION)437
832 ROTARY DISTRIBUTOR441
833 SIDE FRAME COMPONENTS445
834 TRAVEL GEAR AND PARKING BRAKE447
835 PARKING BRAKE449
836 ELECTRIC / HYDRAULIC FLOW CHART451
837 ADJUSTMENT / CHECKS 453
SECTION 90 HYDRAULIC TRACK TENSIONING SYSTEM458
TABLE OF CONTENTS SECTION 90458
GENERAL460
91 FUNCTIONAL DESCRIPTION462
92 PRESSURE INCREASING VALVE466
93 TENSIONING CYLINDER468
94 ADJUSTMENTS / CHECKS470
95 FUNCTIONAL TEST474
SECTION 100 ACCESS LADDER HYDRAULICALLY OPERATED475
TABLE OF CONTENTS SECTION 100475
GENERAL477
100 FUNCTION OF HYDRAULIC OPERATED ACCESS LADDER479
SECTION 110 HYDRAULIC OPERATED REFILLING ARM482
TABLE OF CONTENTS SECTION 110482
GENERAL484
111 FUNCTION OF HYDRAULIC OPERATED REFILLING ARM486
SECTION 120 HINTS FOR READING THE HYDRAULIC CIRCUIT DIAGRAM487
TABLE OF CONTENTS SECTION 120487
GENERAL489
121 SYMBOLS491
1211 LINES, UNIONS491
1212 COMPONENTS, VALVES493
1213 SENSORS494
1214 VALVES, VALVE COMPONENTS495
1215 PUMP, MOTOR, CYLINDER499
1216 ASSEMBLY AND MAIN COMPONENTS501
SECTION 130 HINTS FOR READING THE ELECTRIC CIRCUIT DIAGRAM503
TABLE OF CONTENTS SECTION 130503
131 DESIGNATION OF ELECTRICAL DEVICES504
132 SYMBOLS506
133 GENERAL INFORMATION510
134 READING A CIRCUIT DIAGRAM514
SECTION 140 ELECTRONIC CONTROL SYSTEM ECS517
TABLE OF CONTENTS SECTION 140517
141 GENERAL DESIGN OF THE ECS SYSTEM519
1411 INPUT AND OUTPUT OF THE PLC521
1412 TASK521
1413 PLC DIGSY plus ®523
1414 DEFINITIONS; SYMBOLS AND ABBREVIATIONS524
142 HOW TO PROCEED DUE MAINTENANCE AND INSTALLATION527
1421 MEANING OF THE STATUS LED’S530
1422 SHORT CIRCUIT MARKER – LED “MK”534
1423 DIAGNOSTIC FOR TEMPERATURE-MODULE “ANM”536
143 FRONT CONNECTOR ARRANGEMENT537
1431 FRONT CONNECTOR ARRANGEMENT, BIM MODULE (DIGITAL INPUT/OUTPUT)537
1432 FRONT CONNECTOR ARRANGEMENT, ANM-MODULE (ANALOGUES INPUT)539
1433 GROUND CONNECTION OF THE CONTROL UNIT541
1434 INTERFACE-CONNECTION COM SK / SP543
144 POWER SUPPLY545
1441 OPERATION VOLTAGES +24 V545
1442 SAFETY PRECAUTIONS FOR FAULTFINDING547
1443 CPU VOLTAGE RANGE548
1444 ELECTRIC CLASSIFICATION548
1445 FUSE548
145 FUNCTION EXPLANATIONS WITH ELECTRICAL DIAGRAM549
1451 GENERAL549
1452 PRESSURE MEASURING (HYDRAULIC SYSTEM)551
1453 TEMPERATURE MEASURING AND TROUBLE SHOOTING553
1454 TERMPERATURE – RESISTANCE CHART PT100556
146 HINTS FOR READING THE FUNCTIONAL FLOW CHARTS557
1461 GENERAL557
1462 EXAMPLE: MONITORING THE X1-PRESSURE FOR PUMP CONTROL559
SECTION 150 LUBRICATION SYSTEM560
TABLE OF CONTENTS560
GENERAL FUNCTION562
OSCILLATION CYLINDER AND CONTROL BLOCK568
ADJUSTMENTS570
ONE LINE SYSTEM572
ELECTRICAL FUNCTION576
CAPACITIVE ANALOG SENSOR FOR LUBRICANT LEVEL MONITORING580
ADJUSTMENTS582
END LINE SWITCH SETTING582
INJECTORS584
FUNCTION PINION TYPE (DUMMY WHEEL) SYSTEM586
ELECTRICAL FUNCTION590
CAPACITIVE ANALOG SENSOR FOR LUBRICANT LEVEL MONITORING594
ADJUSTMENTS596
END OF LINE SWITCH SETTING596
INJECTORS598
COMPONENTS600
HYDRAULICALLY DRIVEN LUBE PUMP600
LUBRICANT INJECTOR604
END-LINE SWITCH610
IN-LINE FILTER612
VENT VALVE614
APPENDIX615
TABLE OF CONTENTS APPENDIX615
CHECK SINGLE MOVEMENTS617
MC7 FAULT CODE DIAGNOSTIC644
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