Komatsu Hydraulic Mining Shovel PC5500-6 Shop Manual SMPC550015039 PDF

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Komatsu Hydraulic Mining Shovel PC5500-6 Shop Manual SMPC550015039 – PDF DOWNLOAD

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Komatsu Hydraulic Mining Shovel PC5500-6 Shop Manual SMPC550015039 – PDF DOWNLOAD

Language : English
Pages :857
Downloadable : Yes
File Type : PDF

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Komatsu Hydraulic Mining Shovel PC5500-6 Shop Manual SMPC550015039 – PDF DOWNLOAD

SERIAL NUMBER PC5500-6 15039

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 Shop Manual SMPC550015039 – PDF DOWNLOAD

SERIAL NUMBER PC5500-6 15039

MAIN MENU 0
COVER PAGE 1
CONTENTS 3
TABLE OF CONTENTS 3
SAFETY 5
FORWARD 8
HOISTING INSTRUCTIONS 9
STANDARD TIGHTENING TORQUE 11
CONVERSION TABLE 12
10 MAIN ASSEMBLY GROUPS 19
GENERAL LAYOUT 21
11 SUPERSTRUCTURE 23
111 MACHINE HOUSE 25
112 HYDRAULIC OIL RESERVOIR 27
113 HYDRAULIC OIL COOLER 29
114 FUEL TANK 31
115 COUNTER WEIGHT 33
116 CAB SUPPORT 35
117 OPERATOR’S CAB 37
118 CONTROL BLOCKS 39
119 SWING GEARS 41
12 UNDER CARRIAGE 43
13 ATTACHMENT 45
131 BACKHOE ATTACHMENT (BHA) 45
132 FRONT SHOVEL ATTACHMENT (FSA) 47
20 DRIVE 49
GENERAL 51
21 ENGINE AND PTO MOUNTS 53
22 COUPLING 57
23 AIR FILTER 59
24 FAN DRIVE AND RADIATOR ASSEMBLY 61
25 RADIATOR FAN DRIVE SPEED ADJUSTMENT 67
26 PUMP DISTRIBUTOR GEARBOX (PTO) 73
27 PUMP-SPLINE LUBRICATION 75
28 PTO LUBRICATION AND COOLING 77
29 HYDRAULIC PUMPS – LOCATION, DRIVE SPEED AND FLOW RATES 81
30 HYDRAULIC OIL RESERVOIR 83
GENERAL LAY OUT 85
31 MAIN OIL TANK, LOCATION OF SWITCHES, SENSORS, ETC 87
32 SUCTION OIL TANK WITH STRAINERS 89
33 RETURN OIL COLLECTOR TUBE WITH STRAINER 91
34 BACK PRESSURE VALVE 93
36 RETURN AND LEAK OIL FILTER 95
37 BREATHER FILTER 97
40 HYDRAULIC OIL COOLING 99
41 GENERAL101
42 FUNCTION OF THE HYDRAULIC OIL COOLING CIRCUIT103
43 ADJUSTMENT OF THE BACK PRESSURE VALVE105
44 FAN DRIVE (TWO STAGE COOLER FAN RPM CONTROL)107
45 PRESSURE RELIEF VALVES AND SOLENOID VALVES111
46 FIXED DISPLACEMENT PUMP, WITH VARIABLE SETTING115
47 RADIATOR FAN DRIVE SPEED ADJUSTMENT117
50 CONTROLLING123
GENERAL LAY OUT125
51 CONTROL AND FILTER PANEL LOCATION OF COMPONENTS127
52 PILOT PRESSURE SUPPLY AND ADJUSTMENTS129
53 REMOTE CONTROL VALVES ARRANGEMENT137
54 FUNCTION PRINCIPLE OF THE ELECTRO-HYDRAULIC-PROPORTIONAL CONTROL139
55 POTENTIOMETER CONTROL (LEVER, JOY STICK)143
56 POTENTIOMETER CONTROL (PEDAL)145
57 PROPORTIONAL AMPLIFIER MODULE, TYPE A147
58 PROPORTIONAL AMPLIFIER MODULE, TYPE B149
59 RAMP TIME MODULE151
510 ADJUSTMENTS OF AMPLIFIER MODULES (GENERAL)153
511 ADJUSTING THE AMPLIFIERS TYPE B155
512 ADJUSTING THE AMPLIFIERS TYPE B159
513 ADJUSTING THE RAMP TIME MODULE163
60 COMPONENTS171
611 MAIN CONTROL BLOCKS AND HIGH PRESSURE FILTER (FSA)173
612 MAIN CONTROL BLOCKS AND HIGH PRESSURE FILTER (BHA)177
613 DISTRIBUTOR MANIFOLD – RESTRICTOR BLOCKS (FSA)181
614 DISTRIBUTOR MANIFOLD – RESTRICTOR BLOCKS – (BHA)183
615 RESTRICTOR BLOCK WITH PRESSURE RELIEF VALVE185
616 ANTI CAVITATION VALVE BLOCK187
617 REMOTE CONTROL VALVES189
618 DIRECTIONAL SOLENOID VALVES191
619 PROPORTIONAL SOLENOID VALVE193
6110 HIGH PRESSURE FILTER195
6111 CONTROL BLOCKS AND VALVES197
6112 LOAD HOLDING VALVE205
6113 TRAVEL BRAKE VALVE207
6114 PRESSURE REDUCING VALVE209
6115 DIRECTIONAL SOLENOID VALVES (2 POSITIONS / 4-WAYS)211
6116 PRESSURE INCREASING VALVE213
70 MAIN HYDRAULIC PUMPS AND PUMP REGULATION 215
71 MAIN PUMPS225
711 LOCATION OF PUMPS225
712 PUMP BEARING FLUSHING / LUBRICATION227
713 OPERATING PRINCIPLES229
714 CHECKS / ADJUSTMENTS245
72 ELECTRONIC PUMP REGULATION SYSTEM255
721 ELECTRONIC LOAD LIMITING CONTROL -GENERAL255
722 MICRO CONTROLLER MC7257
723 CHECKS AND ADJUSTMENTS259
METHOD A – X1 PRESSURE WITH 24V SUPPLY TO SEPARATING TERMINALS AT THE X2-SWITCH BOARD261
METHOD B – WITH THE ELECTRONIC SERVICE TOOL BB-3263
LANGUAGE263
EXCAVATOR TYPE SELECTION267
X1 – PRESSURE (MAX CURRENT) ADJUSTMENT271
METHOD C – WITH A LAPTOP AND BODEM SOFTWARE275
STARTING THE PROGRAM275
LANGUAGE SELECTION279
EXCAVATOR TYPE SELECTION281
X1 – PRESSURE (MAXIMUM CURENT) ADJUSTMENT283
73 HYDRAULIC CONSTANT REGULATION SYSTEM285
731 GENERAL285
732 X1-PRESSURE ADJUSTMENT(CONSTANT-PRESSURE)287
74 DETERMINATION OF THE PEAK POINT289
75 ENGINE SPEED SENSOR (PICK UP)293
751 ENGINE SPEED SENSOR (PICK UP) ADJUSTMENT293
80 OPERATING HYDRAULIC295
GENERAL297
801 FLOATING FUNCTION OF BOOM AND STICK CYLINDERS FSA299
81 HYDRAULIC FOR THE ATTACHMENT CYLINDERS303
811 ELECTRIC / HYDRAULIC FLOWCHART “BOOM RAISING” 305
812 ELECTRIC / HYDRAULIC FLOWCHART “BOOM LOWERING”309
813 ELECTRIC / HYDRAULIC FLOWCHART “STICK EXTENDING”315
814 ELECTRIC / HYDRAULIC FLOWCHART “STICK RETRACTING”319
815 ELECTRIC / HYDRAULIC FLOWCHART “BUCKET FILLING”325
816 ELECTRIC / HYDRAULIC FLOWCHART “BUCKET DUMP”329
818 ELECTRIC / HYDRAULIC FLOWCHART “CLAM OPENING”333
819 ELECTRIC / HYDRAULIC FLOWCHART “CLAM CLOSING”335
8110 CHECKS AND ADJUSTMENTS OF THE MAIN RELIEF VALVES (MRV)337
8111 CHECKS AND ADJUSTMENTS OF THE SERVICE LINE RELIEF VALVES (SRV)341
BOOM CYLINDER “PISTON SIDE” FSA + BHA341
BOOM CYLINDER “PISTON ROD SIDE” FSA + BHA345
STICK CYLINDER “PISTON SIDE” FSA349
STICK CYLINDER “PISTON SIDE” BHA353
STICK CYLINDER “PISTON ROD SIDE” FSA357
STICK CYLINDER “PISTON ROD SIDE” BHA363
BUCKET CYLINDER “PISTON SIDE” FSA367
BUCKET CYLINDER “PISTON SIDE” BHA371
BUCKET CYLINDER “ROD SIDE” FSA375
BUCKET CYLINDER “PISTON ROD SIDE” BHA379
CLAM CYLINDER “ROD SIDE” (CLAM OPENING ) FSA383
CLAM CYLINDER “PISTON SIDE” (CLAM CLOSING) FSA385
8112 CHECKS AND ADJUSTMENTS OF THE LOWERING SPEED387
BOOM CYLINDER FSA389
BOOM CYLINDER BHA393
STICK CYLINDER FSA395
STICK CYLINDER BHA399
BUCKET CYLINDER FSA401
BUCKET CYLINDER BHA403
CLAM CYLINDER FSA405
8113 CHECKS FOR THE VALVE CONTROL LOGIC407
82 HYDRAULIC FOR THE SEING CIRCUIT409
821 SWING CIRCUIT (BRIEF DESCRIPTION)411
822 SWING MOTOR415
823 SWING GEAR BOX423
824 SWING PARKING BRAKE (GEAR HOUSE BRAKE)425
825 SWING BRAKE VALVE427
826 ELECTRIC / HYDRAULIC FLOWCHART “SWING LEFT”433
827 ELECTRIC / HYDRAULIC FLOWCHART “SWING RIGHT”435
828 SWING MONITORING SYSTEM437
829 CHECKS AND ADJUSTMENTS FOR THE SWING CIRCUIT441
83 TRAVEL SYSTEM447
831 TRAVEL CIRCUIT449
832 ROTARY DISTRIBUTOR453
833 SIDE FRAME COMPONENTS457
834 TRAVEL GEAR AND PARKING BRAKE459
835 PARKING BRAKE461
836 ELECTRIC / HYDRAULIC FLOW CHARTS463
837 ADJUSTMENTS / CHECKS465
90 HYDRAULIC TRACK TENSIONING SYSTEM471
GENERAL473
91 FUNCTIONAL DESCRIPTION475
92 PRESSURE INCREASING VALVE479
93 TENSIONING CYLINDER481
94 ADJUSTMENTS / CHECKS483
95 FUNCTIONAL TEST487
100 ACCESS LADDER HYDRAULICALLY OPERATED489
GENERAL491
101 FUNCTION OF HYDRAULIC OPERATED ACCCESS LADDER493
110 HYDRAULIC OPERATED REFILLING ARM497
GENERAL499
111 FUNCTION 501
120 HINTS FOR READING THE HYDRAULIC CIRCUIT DIAGRAM503
GENERAL505
121 SYMBOLS507
1211 LINES, UNIONS507
1212 COMPONENTS, VALVES509
1213 SENSORS510
1214 VALVES, VALVE COMPONENTS511
1215 PUMP MOTOR, CYLINDER515
1216 ASSEMBLY AND MAIN COMPONENTS517
130 HINTS FOR READING THE ELECTRIC CIRCUIT DIAGRAM520
131 DESIGNATION OF ELECTRICAL DEVICES521
132 SYMBOLS523
133 GENERAL INFORMATION527
134 READING A CIRCUIT DIABRAM531
140 ELECTRONIC CONTROL SYSTEM ECS535
141 GENERAL DESIGN OF THE ECS SYSTEM537
1411 INPUT AND OUTPUT OF THE PLC539
1412 TASK539
1413 PLC DIGSY PLUS541
1414 DEFINITIONS; SYMBOLS AND ABBREVIATIONS543
142 HOW TO PROCEED DUE MAINTENANCE AND INSTALLATION549
1421 MEANING OF THE STATUS LED’S553
1422 SHORT CIRCUIT MARKER – LED “MK”557
1423 DIAGNOSTIC FOR TEMPERATURE-MODULE “ANM”559
143 FRONT CONNECTOR ARRANGEMENT561
1431 FRONT CONNECTOR ARRANGEMENT BIM-MODULE561
1432 FRONT CONNECTOR ARRANGEMENT, ANM-MODULE565
1433 GROUND CONNECTION OF THE CONTROL UNIT569
1434 INTERFACE-CONNECTION COM SP/SK571
144 POWER SUPPLY573
1441 OPERATION VOLTAGES +24V573
1442 SAFETY PRECAUTIONS FOR FAULTFINDING575
1443 CPU VOLTAGE RANGE577
1444 ELECTRIC CLASSIFICATION577
1445 FUSE577
145 FUNCTION EXPLANATIONS WITH ELECTRICAL DIAGRAM579
1451 GENERAL579
1452 PRESSURE MEASURING581
1453 TEMPERATURE MEASURING AND TROUBLE SHOOTING583
1454 TEMPERATURE – RESISTANCE CHART PT100587
146 HINTS FOR READING FUNCTIONAL FLOW CHARTS589
1461 GENERAL589
1462 EXAMPLE591
150 LUBRICATION SYSTEM593
GENERAL FUNCTION595
OSCILLATION CYLINDER AND CONTROL BLOCK601
ADJUSTMENTS603
ONE LINE SYSTEM605
ELECTRICAL FUNCTION609
CAPACITIVE ANALOG SENSOR FOR LUBRICANT LEVEL MONITORING613
ADJUSTMENTS615
END LINE SWITCH SETTING615
INJECTORS617
FUNCTION PINION TYPE (DUMMY WHEEL) SYSTEM619
ELECTRICAL FUNCTION623
CAPACITIVE ANALOG SENSOR FOR LUBRICANT LEVEL MONITORING627
ADJUSTMENTS629
END OF LINE SWITCH SETTING629
INJECTORS631
COMPONENTS633
HYDRAULICALLY DRIVEN “POWER MASTER III” LUBE PUMP633
INJECTORS637
END-LINE SWITCH643
IN-LINE FILTER645
VENT VALVE647
APPENDIX649
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