KOMATSU PC5500-6 HYDRAULIC MINING SHOVEL SERVICE REPAIR MANUAL (SN:15025) KOMATSU PC5500 6 – PDF DOWNLOAD

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KOMATSU PC5500-6 HYDRAULIC MINING SHOVEL SERVICE REPAIR MANUAL (SN:15025) KOMATSU PC5500 6

KOMATSU PC5500-6 HYDRAULIC MINING SHOVEL SERVICE REPAIR MANUAL (SN:15025) KOMATSU PC5500 6 – PDF DOWNLOAD:

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KOMATSU PC5500-6 HYDRAULIC MINING SHOVEL SERVICE REPAIR MANUAL (SN:15025) KOMATSU PC5500 6

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.
3. If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, glasses, cap and other clothes suited for welding work.
4. When carrying out any operation with two or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator’s compartment.
5. Keep all tools in good condition and learn the correct way to use them.
6. Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.

TABLE OF CONTENTS:

KOMATSU PC5500-6 HYDRAULIC MINING SHOVEL SERVICE REPAIR MANUAL (SN:15025) KOMATSU PC5500 6

MAIN MENU............................................................................................  0
COVER................................................................................................  1
TABLE OF CONTENTS....................................................................................  3
SAFETY...............................................................................................  4
FOREWORD.............................................................................................  7
1. MAIN ASSEMBLY GROUPS.............................................................................. 17
	TABLE OF CONTENTS SECTION 1.0.................................................................... 17
	GENERAL LAY OUT.................................................................................. 19
	1.1 SUPERSTRUCTURE............................................................................... 21
		1.1.1 MACHINE HOUSE.......................................................................... 23
		1.1.2 HYDRAULIC OIL RESERVOIR................................................................ 25
		1.1.3 HYDRAULIC OIL COOLER................................................................... 27
		1.1.4 FUEL TANK (FUEL RESERVOIR)............................................................. 29
		1.1.5 COUNTER WEIGHT......................................................................... 31
		1.1.6 CAB SUPPORT............................................................................ 33
		1.1.7 OPERATORS CAB.......................................................................... 35
		1.1.8 CONTROL BLOCKS......................................................................... 37
		1.1.9 SWING GEARS............................................................................ 39
	1.2 UNDER CARRIAGE............................................................................... 41
	1.3 ATTACHMENT................................................................................... 43
		1.3.1 BACKHOE ATTACHMENT (BHA)............................................................... 43
		1.3.2 FRON SHOVEL ATTACHMENT (FSA)........................................................... 45
2. DRIVE............................................................................................. 47
	TABLE OF CONTENTS SECTION 2.0.................................................................... 47
	GENERAL LAY OUT.................................................................................. 49
	2.1 ENGINE AND PTO MOUNTS........................................................................ 51
	2.2 COUPLING..................................................................................... 55
	2.3 AIR FILTER................................................................................... 57
	2.4 FAN DRIVE AND RADIATOR ASSEMBLY.............................................................. 59
	2.5 RADIATOR FAN DRIVE SPEED ADJUSTMENT.......................................................... 65
	2.6 PUMP DISTRIBUTOR GEARBOX (PTO)............................................................... 71
	2.7 PUMP-SPLINE LUBRICATION...................................................................... 73
	2.8 PTO LUBRICATION AND COOLING.................................................................. 75
	2.9 HYDRAULIC PUMPS - LOCATION, DRIVE SPEED AND FLOW RATES....................................... 79
3. HYDRAULIC OIL RESERVOIR........................................................................... 81
	TABLE OF CONTENTS SECTION 3.0.................................................................... 81
	GENERAL LAY OUT.................................................................................. 83
	3.1 MAIN OIL TANK, LOCATION OF SWITCHES, SENSORS ETC............................................. 85
	3.2 SUCTION OIL TANK WITH STRAINERS.............................................................. 87
	3.3 RETURN OIL COLLECTOR TUBE WITH STRAINER...................................................... 89
	3.4 BACK PRESSURE VALVE.......................................................................... 91
	3.6 RETURN AND LEAK OIL FILTER................................................................... 93
	3.7 BREATHER FILTER.............................................................................. 95
4. HYDRAULIC OIL COOLING............................................................................. 97
	TABLE OF CONTENTS SECTION 4.0.................................................................... 97
	4.1 GENERAL...................................................................................... 99
	4.2 FUNCTION OF THE HYDRAULIC OIL COOLING CIRCUIT................................................101
	4.3 ADJUSTMENT OF THE BACK PRESSURE VALVE........................................................103
	4.4 FAN DRIVE (TWO STAGE COOLER FAN RPM CONTROL).................................................105
	4.5 PRESSURE RELIEF VALVES AND SOLENOID VALVES...................................................109
	4.6 FIXED DISPLACEMENT PUMP, WITH VARIABLE SETTING...............................................113
	4.7 RADIATOR FAN DRIVE SPEED ADJUSTMENT..........................................................115
5. CONTROLLING.......................................................................................121
	TABLE OF CONTENTS SECTION 5.0....................................................................121
	5.0 GENERAL LAY OUT..............................................................................123
	5.1 CONTROL AND FILTER PANEL LOCATION OF COMPONENTS..............................................125
	5.2 PILOT PRESSURE SUPPLY AND ADJUSTMENTS........................................................127
	5.3 REMOTE CONTROL VALVES ARRANGEMENT............................................................135
	5.4 FUNCTION PRINCIPLE OF THE ELECTRO-HYDRAULIC-PROPORTIONAL CONTROL.............................137
	5.5 POTENTIOMETER CONTROL (LEVER, JOY STICK).....................................................141
	5.6 POTENTIOMETER CONTROL (PEDAL)................................................................143
	5.7 PROPORTIONAL AMPLIFIER MODULE, TYPE A........................................................145
	5.8 PROPORTIONAL AMPLIFIER MODULE, TYPE B........................................................147
	5.9 RAMP TIME MODULE.............................................................................149
	5.10 ADJUSTMENTS OF AMPLIFIER MODULES (GENERAL)..................................................151
	5.11 ADJUSTING THE AMPLIFIERS TYPE B.............................................................153
	5.12 ADJUSTING THE AMPLIFIERS TYPE B.............................................................157
	5.13 ADJUSTING THE RAMP TIME MODULE..............................................................161
6. COMPONENTS........................................................................................169
	TABLE OF CONTENTS SECTION 6.0....................................................................169
	6.1.1 MAIN CONTROL BLOCKS AND HIGH PRESSURE FILTER FSA...........................................171
	6.1.2 MAIN CONTROL BLOCKS AND HIGH PRESSURE FILTER BHA...........................................175
	6.1.3 DISTRIBUTOR MANIFOLD-LOCATION OF RESTRICTOR BLOCKS AND ANIT CAVITATION VALVES FSA..........179
	6.1.4 DISTRIBUTOR MANIFOLD-LOCATION OF RESTRICTOR BLOCKS AND ANTI CAVITATION VALVES BHA..........181
	6.1.5 RESTRICTOR BLOCK WITH PRESSURE RELIEF VALVE................................................183
	6.1.6 ANTI CAVITATION VALVE BLOCK................................................................185
	6.1.7 REMOTE CONTROL VALVES......................................................................187
	6.1.8 DIRECTIONAL SOLENOID VALVES................................................................189
	6.1.9 PROPORTIONAL SOLENOID VALVE................................................................191
	6.1.10 HIGH PRESSURE FILTER......................................................................193
	6.1.11 CONTROL BLOCKS AND VALVES.................................................................195
	6.1.12 LOAD HOLDING VALVE........................................................................203
	6.1.13 TRAVEL BRAKE VALVE........................................................................205
	6.1.14 PRESSURE REDUCING VALVE...................................................................207
	6.1.15 DIRECTIONAL SOLENOID VALVES (2 POSITIONS / 4-WAYS)........................................209
	6.1.16 PRESSURE INCREASING VALVE.................................................................211
7. MAIN HYDRAULIC PUMPS AND PUMP REGULATION SYSTEM...................................................213
	TABLE OF CONTENTS SECTION 7.0....................................................................213
	7.1 MAIN PUMPS...................................................................................223
		7.1.1 LOCATION OF PUMPS......................................................................223
		7.1.2 PUMP BEARING FLUSHING/LUBRICATION......................................................225
		7.1.3 OPERATING PRINCIPLES...................................................................227
		7.1.4 CHECKS / ADJUSTMENTS...................................................................243
	7.2 ELECTRONIC PUMP REGULATION SYSTEM............................................................253
		7.2.1 ELECTRONIC LOAD LIMITING CONTROL-GENERAL...............................................253
		7.2.2 MICRO CONTROLLER MC7...................................................................255
		7.2.3 CHECKS AND ADJUSTMENTS MICRO CONTROLLER MC7............................................257
			METHOD A - X1-PRESSURE WITH 24V SUPPLY TO SEPARATING TERMINALS AT THE X2-SWITCH BOARD....259
			METHOD B - WITH THE ELECTRONIC SERVICE TOOL BB-3.........................................261
				LANGUAGE SELECTION...................................................................261
				EXCAVATOR TYPE SELECTION.............................................................265
				X1-PRESSURE (MAX CURRENT) ADJUSTMENT.................................................269
			METHOD C - WITH A LAPTOP COMPUTER AND BODEM SOFTWARE.....................................273
				STARTING THE PROGRAM.................................................................273
				LANGUAGE SELECTION...................................................................277
				EXCAVATOR TYPE SELECTION.............................................................279
				X1-PRESSURE (MAX CURRENT) ADJUSTMENT.................................................281
	7.3 HYDRAULIC CONSTANT REGULATION SYSTEM.........................................................283
		7.3.1 GENERAL................................................................................283
		7.3.2 X1-PRESSURE ADJUSTMENT (CONSTANT-PRESSURE).............................................285
	7.4 DETERMINATION OF THE PEAK POINT (ENGINE PERFORMANCE).........................................287
	7.5 ENGINE SPEED SENSOR (PICK UP)................................................................291
		7.5.1 ENGINE SPEED SENSOR (PICK UP) ADJUSTMENT...............................................291
8.1 HYDRAULIC FOR THE ATTACHMENT CYLINDERS...........................................................293
	TABLE OF CONTENTS SECTION 8.1....................................................................293
	8.1.1 ELECTRIC / HYDRAULIC FLOWCHART "BOOM RAISING" FSA..........................................295
	8.1.2 ELECTRIC / HYDRAULIC FLOWCHART "BOOM LOWERING" FSA, AUTO FLOAT OFF.........................299
	8.1.3 ELECTRIC / HYDRAULIC FLOWCHART "STICK EXTENDING" FSA.......................................305
	8.1.4 ELECTRIC / HYDRAULIC FLOWCHART "STICK RETRACTING" FSA AUTOR FLOAT OFF......................309
	8.1.5 ELECTRIC / HYDRAULIC FLOWCHART "BUCKET FILLING" FSA........................................315
	8.1.6 ELECTRIC / HYDRAULIC FLOWCHART "BUCKET DUMP" FSA...........................................319
	8.1.8 ELECTRIC / HYDRAULIC FLOWCHART "CLAM OPENING" FSA..........................................323
	8.1.9 ELECTRIC / HYDRAULIC FLOWCHART "CLAM CLOSING" FSA..........................................325
	8.1.10 CHECKS AND ADJUSTMENTS OF THE MAIN RELIEF VALVES (MRV)....................................327
	8.1.11 CHECKS AND ADJUSTMENTS OF THE SERVICE LINE RELIEF VALVES (SRV)............................331
		BOOM CYLINDER PISTON SIDE FSA + BHA..........................................................331
		BOOM CYLINDER PISTON ROD SIDE FSA + BHA......................................................335
		STICK CYLINDER PISTON SIDE FSA...............................................................339
		STICK CYLINDER PISTON SIDE BHA...............................................................343
		STICK CYLINDER PISTON ROD SIDE FSA...........................................................347
		STICK CYLINDER PISTON ROD SIDE BHA...........................................................353
		BUCKET CYLINDER PISTON SIDE FSA..............................................................357
		BUCKET CYLINDER PISTON SIDE BHA..............................................................361
		BUCKET CYLINDER PISTON ROD SIDE FSA..........................................................365
		BUCKET CYLINDER PISTON ROD SIDE BHA..........................................................369
		CLAM CYLINDER PISTON ROD SIDE FSA............................................................373
		CLAM CYLINDER PISTON SIDE FSA................................................................375
	8.1.12 CHECKS AND ADJUSTMENTS OF THE LOWERING SPEED..............................................377
		GENERAL FLOW RESTRICTORS.....................................................................377
			BOOM CYLINDER FSA........................................................................377
			BOOM CYLINDER BHA........................................................................383
			STICK CYLINDER FSA.......................................................................385
			STICK CYLINDER BHA.......................................................................389
			BUCKET CYLINDER FSA......................................................................391
			BUCKET CYLINDER BHA......................................................................393
			CLAM CYLINDER FSA........................................................................395
	8.1.13 CHECKS FOR THE VALVE CONTROL LOGIC........................................................397
8.2 HYDRAULIC FOR THE SWING CIRCUIT..................................................................399
	TABLE OF CONTENTS SECTION 8.2....................................................................399
	8.2.1 SWING CIRCUIT..............................................................................401
	8.2.2 SWING MOTOR................................................................................405
	8.2.3 SWING GEAR BOX.............................................................................413
	8.2.4 SWING PARKING BRAKE (GEAR HOUSE BRAKE).....................................................415
	8.2.5 SWING BRAKE VALVE..........................................................................417
	8.2.6 ELECTRIC / HYDRAULIC FLOWCHART SWING LEFT..................................................423
	8.2.7 ELECTRIC / HYDRAULIC FLOWCHART SWING RIGHT.................................................425
	8.2.8 SWING MONITORING SYSTEM....................................................................427
	8.2.9 CHECKS AND ADJUSTMENTS FOR THE SWING CIRCUIT...............................................431
8.3 HYDRAULIC FOR THE TRAVEL CIRCUIT.................................................................437
	TABLE OF CONTENTS SECTION 8.3....................................................................437
	TRAVEL CIRCUIT...................................................................................439
	8.3.2 ROTARY DISTRIBUTOR.........................................................................443
	8.3.3 SIDE FRAME COMPONENTS, CROSS SECTIONS......................................................447
	8.3.4 TRAVEL GEAR AND PARKING BRAKE..............................................................449
	8.3.5 PARKING BRAKE..............................................................................451
	8.3.6 ELECTRIC / HYDRAULIC FLOW CHARTS...........................................................453
	8.3.7 ADJUSTMENTS / CHECKS.......................................................................455
	FUNCTION CHECK OF THE TRAVEL GEAR HOUSE BRAKE....................................................459
	FUNCTION CHECK OF THE PRESSURE SWITCH (B48)......................................................459
9. HYDRAULIC TRACK TENSIONING SYSTEM.................................................................461
	TABLE OF CONTENTS SECTION 9.0....................................................................461
	9.0 GENERAL......................................................................................463
	9.1 FUNCTIONAL DESCRIPTION.......................................................................465
	9.2 PRESSURE INCREASING VALVE....................................................................469
	9.3 TENSIONING CYLINDER..........................................................................471
	9.4 ADJUSTMENTS / CHECKS.........................................................................473
	9.5 FUNCTIONAL TEST..............................................................................477
10. ACCESS LADDER HYDRAULICALLY OPERATED.............................................................479
	TABLE OF CONTENTS SECTION 10.0...................................................................479
	GENERAL..........................................................................................481
	10.1 FUNCTION OF HYDRAULIC OPERATED ACCESS LADDER................................................483
11. HYDRAULIC OPERATED REFILLING ARM.................................................................487
	TABLE OF CONTENTS SECTION 11.0...................................................................487
	GENERAL..........................................................................................489
	11.1 FUNCTION OF HYDRAULIC OPERATED REFILLING ARM................................................491
12. HINTS FOR READING THE HYDRAULIC CIRCUIT DIAGRAM..................................................493
	TABLE OF CONTENTS SECTION 11.0...................................................................493
	12.1 HINTS FOR READING THE CIRCUIT DIAGRAM.......................................................495
	12.2 SYMBOLS.....................................................................................497
13. HINTS FOR READING THE ELECTRIC CIRCUIT DIAGRAM...................................................503
	TABLE OF CONTENTS 13.0...........................................................................503
	13.1 DESIGNATION OF ELECTRICAL DEVICES...........................................................505
	13.2 SYMBOLS.....................................................................................507
	13.3 GENERAL INFORMATION.........................................................................511
	13.4 READING OF CIRCUIT DIAGRAM..................................................................515
14. VHMS / ECS-T / ETM...............................................................................519
	TABLE OF CONTENTS SECTION 14.0...................................................................519
	14.1 GENERAL DESIGN OF THE ECS-T SYSTEM..........................................................525
		14.1.1 INPUT AND OUTPUT OF THE PLC...........................................................527
		14.1.2 TASK..................................................................................527
		14.1.3 PLC DIGSY.............................................................................529
		14.1.4 DEFINITIONS; SYMBOLS AND ABBREVIATIONS................................................531
	14.2 HOW TO PROCEED DUE MAINTENANCE AND INSTALLATION.............................................537
		14.2.1 MEANING OF THE STATUS LED'S...........................................................541
		14.2.2 SHORT CIRCUIT MARKER LED 'MK".........................................................545
		14.2.3 DIAGNOSTIC FOR TEMPERATURE-MODULE "ANM"...............................................547
	14.3 FRONT CONNECTOR ARRANGEMENT.................................................................549
		14.3.1 FRONT CONNECTOR ARRANGEMENT, BIM MODULE...............................................549
		14.3.2 FRONT CONNECTOR ARRANGEMENT, ANM-MODULE...............................................553
		14.3.3 GROUND CONNECTION OF THE CONTROL UNIT.................................................557
	14.4 POWER SUPPLY................................................................................559
		14.4.1 OPERATION VOLTAGES +24 V..............................................................559
		14.4.2 SAFETY PRECAUTIONS FOR FAULTFINDING...................................................561
		14.4.3 CPU VOLTAGE RANGE.....................................................................563
		14.4.4 ELECTRIC CLASSIFICATION...............................................................563
		14.4.5 FUSE..................................................................................563
	14.5 FUNCTION EXPLANATIONS WITH ELECTRIC DIAGRAM.................................................565
		14.5.1 GENERAL...............................................................................565
		14.5.2 CONTROLLING...........................................................................567
		14.5.3 PRESSURE MEASURING AND TROUBLE SHOOTING...............................................571
		14.5.4 TERMPERATURE MEASURING AND TROUBLE SHOOTING...........................................573
		14.5.5 TEMPERATURE - RESISTANCE CHART PT100..................................................577
	14.7 HINTS FOR READING THE FUNCTIONAL FLOW CHARTS................................................579
		14.7.1 GENERAL...............................................................................579
		14.7.2 EXAMPLE 1.............................................................................581
	14.8 CABLES AND EXTERNAL MONITORING COMPONENTS...................................................605
15. LUBRICATION SYSTEMS..............................................................................607
	TABLE OF CONTENTS SECTION 15.0...................................................................607
	GENERAL FUNCTION.................................................................................609
	OSCILLATION CYLINDER AND CONTROL BLOCK...........................................................615
	ADJUSTMENTS......................................................................................617
	ONE LINE SYSTEM..................................................................................619
	ELECTRICAL FUNCTION..............................................................................623
	CAPACITIVE ANALOG SENSOR FOR LUBRICANT LEVEL MONITORING..........................................627
	ADJUSTMENTS......................................................................................629
		END LINE SWITCH SETTING......................................................................629
		INJECTORS....................................................................................631
	FUNCTION PINION TYPE (DUMMY WHEEL) SYSTEM........................................................633
	CAPACITIVE ANALOG SENSOR FOR LUBRICANT LEVEL MONITORING..........................................641
	ADJUSTMENTS......................................................................................643
		END OF LINE SWITCH...........................................................................643
		INJECTORS....................................................................................645
	COMPONENTS.......................................................................................647
		HYDRAULICALLY DRIVEN POWER MASTER III LUBE PUMP..............................................647
		LUBRICANT INJECTOR...........................................................................651
		END-LINE SWITCH..............................................................................657
		IN-LINE FILTER...............................................................................659
		VENT VALVE...................................................................................661
PC5500 15025 Flow Chart 934 426 40.pdf...............................................................663
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PC5500 15025 Hydraulic Plan 934 424 40.pdf...........................................................721
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	20050404131403_93442540A071.tif..................................................................802

PLEASE NOTE:

⦁ This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
⦁ Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.