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KOMATSU PC5500-6 HYDRAULIC MINING SHOVEL SERVICE REPAIR MANUAL (SN:15027) – PDF DOWNLOAD
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- KOMATSU PC5500-6 HYDRAULIC MINING SHOVEL SERVICE REPAIR MANUAL
- SERIAL NUMBER:15027
- PUBLICATION NUMBER:SMPC550015027
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Description
KOMATSU PC5500-6 HYDRAULIC MINING SHOVEL SERVICE REPAIR MANUAL (SN:15027)
KOMATSU PC5500-6 HYDRAULIC MINING SHOVEL SERVICE REPAIR MANUAL (SN:15027) – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU PC5500-6 HYDRAULIC MINING SHOVEL SERVICE REPAIR MANUAL (SN:15027)
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:15027)
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 15027 Flowchart 934 986 40.pdf................................................................663 20051031083036_93498640001.tif...................................................................663 20051031083048_93498640002.tif...................................................................664 20051031083110_93498640003.tif...................................................................665 20051031083132_93498640004.tif...................................................................666 20051031083225_93498640005.tif...................................................................667 20051031083252_93498640006.tif...................................................................668 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20051102073123_93498440907.tif...................................................................731 PC5500 15027 Electric Plan 934 985 40.pdf............................................................732 20051031082901_93498540001.tif...................................................................732 20051031082907_93498540002.tif...................................................................733 20051031082913_93498540003.tif...................................................................734 20051031082923_93498540004.tif...................................................................735 20051031082925_93498540005.tif...................................................................736 20051031082935_93498540006.tif...................................................................737 20051031082942_93498540007.tif...................................................................738 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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.
