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Komatsu PC5500-6 Hydraulic Mining Shovel Shop Manual 15031, 15035 & UP – PDF DOWNLOAD
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Komatsu PC5500-6 Hydraulic Mining Shovel Shop Manual
SERIAL NUMBERS PC5500-6 15031,15035 & UP
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Description
Komatsu PC5500-6 Hydraulic Mining Shovel Shop Manual
FILE DETAILS:
Komatsu PC5500-6 Hydraulic Mining Shovel Shop Manual
Brands: Komatsu
Equipment Type: Hydraulic Mining Shovel
Manuals Type: Shop Manual
Machine Model: PC5500-6
Serial Number: 15031, 15035 & up
Language: English
Pages: 810
File Format: Portable Document Format (PDF)
KOMATSU PC5500-6 HYDRAULIC MINING SHOVEL SHOP MANUAL 15031, 15035 & UP – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu PC5500-6 Hydraulic Mining Shovel Shop Manual
Komatsu PC5500-6 Hydraulic Mining Shovel Shop Manual
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-E.
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.
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.
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 Shop Manual
MAIN MENU........................................................................................ 0 COVER............................................................................................ 1 CONTENTS - TABLE OF CONTENTS..................................................................... 2 SAFETY........................................................................................... 3 FOREWORD......................................................................................... 6 SECTION 1.0 MAIN ASSEMBLY GROUPS................................................................. 17 TABLE OF CONTENTS SECTION 1.0................................................................ 17 GENERAL LAYOUT............................................................................... 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 FRONT SHOVEL ATTACHMENT (FSA)...................................................... 45 SECTION 2.0 DRIVE................................................................................ 46 TABLE OF CONTENTS SECTION 2.0................................................................ 46 PRIME DRIVE ASSEMBLY - GENERAL LAY OUT....................................................... 48 2.1 ENGINE AND PTO MOUNTS.................................................................... 50 2.2 COUPLING................................................................................. 54 2.3 AIR FILTER............................................................................... 56 2.4 FAN DRIVE AND RADIATOR ASSEMBLY.......................................................... 58 2.5 RADIATOR FAN DRIVE SPEED ADJUSTMENT...................................................... 64 2.6 PUMP DISTRIBUTOR GEARBOX (PTO)........................................................... 70 2.7 PUMP-SPLINE LUBRICATION.................................................................. 72 2.8 PTO LUBRICATION AND COOLING.............................................................. 74 2.9 HYDRAULIC PUMPS - LOCATION, DRIVE SPEED AND FLOW RATES................................... 78 SECTION 3.0 HYDRAULIC OIL RESERVOIR.............................................................. 79 TABLE OF CONTENTS SECTION 3.0................................................................ 79 GENERAL LAY OUT.............................................................................. 81 3.1 MAIN OIL TANK, LOCATION OF SWITCHES, SENSORS, ETC........................................ 83 3.2 SUCTION OIL TANK WITH STRAINERS.......................................................... 85 3.3 RETURN OIL COLLECTOR TUBE WITH STRAINER.................................................. 87 3.4 BACK PRESSURE VALVE...................................................................... 89 3.6 RETURN AND LEAK OIL FILTER............................................................... 91 3.7 BREATHER FILTER.......................................................................... 93 SECTION 4.0 HYDRAULIC OIL COOLING................................................................ 94 TABLE OF CONTENTS SECTION 4.0................................................................ 94 4.1 GENERAL.................................................................................. 96 4.2 FUNCTION OF THE HYDRAULIC OIL COOLING CIRCUIT............................................ 98 4.3 ADJUSTMENT OF THE BACK PRESSURE VALVE....................................................100 4.4 FAN DRIVE (TWO STAGE COOLER FAN RPM CONTROL).............................................102 4.5 PRESSURE RELIEF VALVES AND SOLENOID VALVES...............................................106 4.6 FIXED DISPLACEMENT PUMP, WITH VARIABLE SETTING...........................................110 4.7 RADIATOR FAN DRIVE SPEED ADJUSTMENT......................................................112 SECTION 5.0 CONTROLLING..........................................................................117 TABLE OF CONTENTS SECTION 5.0................................................................117 GENERAL LAY OUT..............................................................................119 5.1 CONTROL AND FILTER PANEL LOCATION OF COMPONENTS..........................................121 5.2 PILOT PRESSURE SUPPLY AND ADJUSTMENTS....................................................123 5.3 REMOTE CONTROL VALVES ARRANGEMENT........................................................131 5.4 FUNCTION PRINCIPLE OF THE ELECTRO-HYDRAULIC-PROPORTIONAL CONTROL.........................133 5.5 POTENTIOMETER CONTROL (LEVER, JOY STICK).................................................137 5.6 POTENTIOMETER CONTROL (PEDAL)............................................................139 5.7 PROPORTIONAL AMPLIFIER MODULE, TYPE A....................................................141 5.8 PROPORTIONAL AMPLIFIER MODULE, TYPE B....................................................143 5.9 RAMP TIME MODULE.........................................................................145 5.10 ADJUSTMENTS OF AMPLIFIER MODULES (GENERAL)..............................................147 5.11 ADJUSTING THE AMPLIFIERS TYPE B.........................................................149 5.12 ADJUSTING THE AMPLIFIERS TYPE B.........................................................153 5.13 ADJUSTING THE RAMP TIME MODULE..........................................................157 SECTION 6.0 COMPONENTS...........................................................................164 TABLE OF CONTENTS SECTION 6.0................................................................164 6.1 HYDRAULIC................................................................................166 6.1.1 MAIN CONTROL BLOCKS AND HIGH PRESSURE FILTER FRONT SHOVEL ATTACHMENT FSA...............166 6.1.2 MAIN CONTROL BLOCKS AND HIGH PRESSURE FILTER BACKHOE ATTACHMENT BHA....................170 6.1.3 DISTRIBUTOR MANIFOLD - LOCATION OF RESTRICTOR BLOCKS AND ANTI CAVITATION VALVES FSA....174 6.1.4 DISTRIBUTOR MANIFOLD - LOCATION OF RESTRICTOR BLOCKS AND ANTI CAVITATION VALVES BHA....176 6.1.5 RESTRICTOR BLOCK WITH PRESSURE RELIEF VALVE............................................178 6.1.6 ANTI CAVITATION VALVE BLOCK............................................................180 6.1.7 REMOTE CONTROL VALVES..................................................................182 6.1.8 DIRECTIONAL SOLENOID VALVES............................................................184 6.1.9 PROPORTIONAL SOLENOID VALVE............................................................186 6.1.10 HIGH PRESSURE FILTER..................................................................188 6.1.11 CONTROL BLOCKS AND VALVES.............................................................190 6.1.12 LOAD HOLDING VALVE....................................................................198 6.1.13 TRAVEL BRAKE VALVE....................................................................200 6.1.14 PRESSURE REDUCING VALVE...............................................................202 6.1.15 DIRECTIONAL SOLENOID VALVES (2 POSITIONS / 4-WAYS)....................................204 6.1.16 PRESSURE INCREASING VALVE.............................................................206 SECTION 7.0 MAIN HYDRAULIC PUMPS AND PUMP REGULATION SYSTEM......................................207 TABLE OF CONTENTS SECTION 7.0................................................................207 7.0 MAIN HYDRAULIC PUMPS AND PUMP REGULATION SYSTEM GENERAL LAYOUT (HYDRAULIC ONLY)..........209 7.1 MAIN PUMPS...............................................................................217 7.1.1 LOCATION OF PUMPS..................................................................217 7.1.2 PUMP BEARING FLUSHING / LUBRICATION................................................219 7.1.3 OPERATING PRINCIPLES...............................................................221 7.1.4 CHECKS / ADJUSTMENTS...............................................................237 7.2 ELECTRONIC PUMP REGULATION SYSTEM........................................................247 7.2.3 CHECKS AND ADJUSTMENTS MICRO CONTROLLER MC7........................................251 METHOD A.............................................................................253 METHOD B.............................................................................255 LANGUAGE SELECTION...............................................................255 EXCAVATOR TYPE SELECTION.........................................................259 X1-PRESSURE (MAXIMUM CURRENT) ADJUSTMENT.........................................263 METHOD C.............................................................................267 STARTING THE PROGRAM.............................................................267 LANGUAGE SELECTION...............................................................271 EXCAVATOR TYPE SELECTION.........................................................273 X1-PRESSURE (MAXIMUM CURRENT) ADJUSTMENT.........................................275 7.2.1 ELECTRONIC LOAD LIMITING CONTROL - GENERAL.........................................247 7.2.2 MICRO CONTROLLER MC7...............................................................249 7.3 HYDRAULIC CONSTANT REGULATION SYSTEM.....................................................277 7.3.1 GENERAL............................................................................277 7.3.2 X1-PRESSURE ADJUSTMENT (CONSTANT-PRESSURE).........................................279 7.4 DETERMINATION OF THE PEAK POINT (ENGINE PERFORMANCE).....................................281 7.5 ENGINE SPEED SENSOR (PICK UP)............................................................285 SECTION 8.0 OPERATING HYDRAULIC..................................................................286 TABLE OF CONTENTS SECTION 8.0................................................................286 8.0 GENERAL..................................................................................288 8.0.1 FLOATING FUNCTION OF BOOM AND STICK CYLINDERS FSA..................................290 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 / HYDRAULC FLOWCHART "STICK RETRACTING" FSA AUTO 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 "ROD SIDE" FSA.......................................................365 BUCKET CYLINDER "PISTON ROD SIDE" BHA................................................369 CLAM CYLINDER "ROD SIDE" (CLAM OPENING) FSA..........................................373 CLAM CYLINDER "PISTON SIDE (CLAM CLOSING) FSA........................................375 8.1.12 CHECKS AND ADJUSTMENTS OF THE LOWERING SPEED......................................377 GENERAL: FLOW RESTRICTORS 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..........................................................398 TABLE OF CONTENTS SECTION 8.2............................................................398 8.2.1 SWING CIRCUIT (BRIEF DESCRIPTION)..................................................400 8.2.2 SWING MOTOR........................................................................404 8.2.3 SWING GEAR BOX.....................................................................412 8.2.4 SWING PARKING BRAKE (GEAR HOUSE BRAKE).............................................414 8.2.5 SWING BRAKE VALVE..................................................................416 8.2.6 ELECTRIC / HYDRAULIC FLOWCHART "SWING LEFT"........................................422 8.2.7 ELECTRIC / HYDRAULIC FLOWCHART "SWING RIGHT".......................................424 8.2.8 SWING MONITORING SYSTEM............................................................426 8.2.9 CHECKS AND ADJUSTMENTS FOR THE SWING CIRCUIT.......................................430 8.2.10 CHECKS AND ADJUSTMENTS FOR THE SWING CIRCUIT......................................434 8.3 HYDRAULIC FOR THE TRAVEL CIRCUIT.........................................................435 TABLE OF CONTENTS SECTION 8.3............................................................435 8.3.1 TRAVEL CIRCUIT (BRIEF DESCRIPTION).................................................437 8.3.2 ROTARY DISTRIBUTOR.................................................................441 8.3.3 SIDE FRAME COMPONENTS..............................................................445 8.3.4 TRAVEL GEAR AND PARKING BRAKE......................................................447 8.3.5 PARKING BRAKE......................................................................449 8.3.6 ELECTRIC / HYDRAULIC FLOW CHART....................................................451 8.3.7 ADJUSTMENT / CHECKS ...............................................................453 SECTION 9.0 HYDRAULIC TRACK TENSIONING SYSTEM....................................................458 TABLE OF CONTENTS SECTION 9.0................................................................458 GENERAL......................................................................................460 9.1 FUNCTIONAL DESCRIPTION...................................................................462 9.2 PRESSURE INCREASING VALVE................................................................466 9.3 TENSIONING CYLINDER......................................................................468 9.4 ADJUSTMENTS / CHECKS.....................................................................470 9.5 FUNCTIONAL TEST..........................................................................474 SECTION 10.0 ACCESS LADDER HYDRAULICALLY OPERATED................................................475 TABLE OF CONTENTS SECTION 10.0...............................................................475 GENERAL......................................................................................477 10.0 FUNCTION OF HYDRAULIC OPERATED ACCESS LADDER............................................479 SECTION 11.0 HYDRAULIC OPERATED REFILLING ARM....................................................482 TABLE OF CONTENTS SECTION 11.0...............................................................482 GENERAL......................................................................................484 11.1 FUNCTION OF HYDRAULIC OPERATED REFILLING ARM............................................486 SECTION 12.0 HINTS FOR READING THE HYDRAULIC CIRCUIT DIAGRAM.....................................487 TABLE OF CONTENTS SECTION 12.0...............................................................487 GENERAL......................................................................................489 12.1 SYMBOLS.................................................................................491 12.1.1 LINES, UNIONS.....................................................................491 12.1.2 COMPONENTS, VALVES................................................................493 12.1.3 SENSORS...........................................................................494 12.1.4 VALVES, VALVE COMPONENTS..........................................................495 12.1.5 PUMP, MOTOR, CYLINDER.............................................................499 12.1.6 ASSEMBLY AND MAIN COMPONENTS......................................................501 SECTION 13.0 HINTS FOR READING THE ELECTRIC CIRCUIT DIAGRAM......................................503 TABLE OF CONTENTS SECTION 13.0...............................................................503 13.1 DESIGNATION OF ELECTRICAL DEVICES.......................................................504 13.2 SYMBOLS.................................................................................506 13.3 GENERAL INFORMATION.....................................................................510 13.4 READING A CIRCUIT DIAGRAM...............................................................514 SECTION 14.0 ELECTRONIC CONTROL SYSTEM ECS.......................................................517 TABLE OF CONTENTS SECTION 14.0...............................................................517 14.1 GENERAL DESIGN OF THE ECS SYSTEM........................................................519 14.1.1 INPUT AND OUTPUT OF THE PLC.......................................................521 14.1.2 TASK..............................................................................521 14.1.3 PLC DIGSY plus ®..................................................................523 14.1.4 DEFINITIONS; SYMBOLS AND ABBREVIATIONS............................................524 14.2 HOW TO PROCEED DUE MAINTENANCE AND INSTALLATION.........................................527 14.2.1 MEANING OF THE STATUS LED'S.......................................................530 14.2.2 SHORT CIRCUIT MARKER - LED "MK"...................................................534 14.2.3 DIAGNOSTIC FOR TEMPERATURE-MODULE "ANM"...........................................536 14.3 FRONT CONNECTOR ARRANGEMENT.............................................................537 14.3.1 FRONT CONNECTOR ARRANGEMENT, BIM MODULE (DIGITAL INPUT/OUTPUT)....................537 14.3.2 FRONT CONNECTOR ARRANGEMENT, ANM-MODULE (ANALOGUES INPUT).........................539 14.3.3 GROUND CONNECTION OF THE CONTROL UNIT.............................................541 14.3.4 INTERFACE-CONNECTION COM SK / SP..................................................543 14.4 POWER SUPPLY............................................................................545 14.4.1 OPERATION VOLTAGES +24 V..........................................................545 14.4.2 SAFETY PRECAUTIONS FOR FAULTFINDING...............................................547 14.4.3 CPU VOLTAGE RANGE.................................................................548 14.4.4 ELECTRIC CLASSIFICATION...........................................................548 14.4.5 FUSE..............................................................................548 14.5 FUNCTION EXPLANATIONS WITH ELECTRICAL DIAGRAM...........................................549 14.5.1 GENERAL...........................................................................549 14.5.2 PRESSURE MEASURING (HYDRAULIC SYSTEM).............................................551 14.5.3 TEMPERATURE MEASURING AND TROUBLE SHOOTING........................................553 14.5.4 TERMPERATURE - RESISTANCE CHART PT100.............................................556 14.6 HINTS FOR READING THE FUNCTIONAL FLOW CHARTS............................................557 14.6.1 GENERAL...........................................................................557 14.6.2 EXAMPLE: MONITORING THE X1-PRESSURE FOR PUMP CONTROL..............................559 SECTION 15.0 LUBRICATION SYSTEM..................................................................560 TABLE OF CONTENTS............................................................................560 GENERAL FUNCTION.............................................................................562 OSCILLATION CYLINDER AND CONTROL BLOCK.......................................................568 ADJUSTMENTS..................................................................................570 ONE LINE SYSTEM..............................................................................572 ELECTRICAL FUNCTION..........................................................................576 CAPACITIVE ANALOG SENSOR FOR LUBRICANT LEVEL MONITORING......................................580 ADJUSTMENTS..................................................................................582 END LINE SWITCH SETTING..................................................................582 INJECTORS................................................................................584 FUNCTION PINION TYPE (DUMMY WHEEL) SYSTEM....................................................586 ELECTRICAL FUNCTION..........................................................................590 CAPACITIVE ANALOG SENSOR FOR LUBRICANT LEVEL MONITORING......................................594 ADJUSTMENTS..................................................................................596 END OF LINE SWITCH SETTING...............................................................596 INJECTORS................................................................................598 COMPONENTS...................................................................................600 HYDRAULICALLY DRIVEN LUBE PUMP...............................................................600 LUBRICANT INJECTOR...........................................................................604 END-LINE SWITCH..............................................................................610 IN-LINE FILTER...............................................................................612 VENT VALVE...................................................................................614 APPENDIX.........................................................................................615 TABLE OF CONTENTS APPENDIX...................................................................615 CHECK SINGLE MOVEMENTS.......................................................................617 MC7 FAULT CODE DIAGNOSTIC....................................................................644 FLOWCHART 934 983 40 - 77 PAGES..................................................................645 FLOWCHART 934 983 40 PAGE 1 OF 77............................................................645 FLOWCHART 934 983 40 PAGE 2 OF 77............................................................646 FLOWCHART 934 983 40 PAGE 3 OF 77............................................................647 FLOWCHART 934 983 40 PAGE 4 OF 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