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Komatsu PC5500-6 Hydraulic Mining Shovel Shop Manual SMPC550015019 PDF

Komatsu PC5500-6 Hydraulic Mining Shovel Shop Manual SMPC550015019 PDF

Name: Komatsu PC5500-6 Hydraulic Mining Shovel Shop Manual SMPC550015019 PDF
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Komatsu PC5500-6 Hydraulic Mining Shovel Shop Manual SMPC550015019 – PDF DOWNLOAD

SERIAL NUMBERS PC5500-6 15019

Category: komatsu Tags: KOMATSU PC5500-6 HYDRAULIC MINING SHOVEL SHOP, Komatsu PC5500-6 Hydraulic Mining Shovel Shop Manual SMPC550015019, Komatsu PC5500-6 Hydraulic Mining Shovel Shop Manual SMPC550015019 - PDF DOWNLOAD Vendor: MechanicVault

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Description

Description

Komatsu PC5500-6 Hydraulic Mining Shovel Shop Manual SMPC550015019 – PDF DOWNLOAD

FILE DETAILS:

Komatsu PC5500-6 Hydraulic Mining Shovel Shop Manual SMPC550015019 – PDF DOWNLOAD

Language : English
Pages : 727
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Komatsu PC5500-6 Hydraulic Mining Shovel Shop Manual SMPC550015019 – PDF DOWNLOAD

SERIAL NUMBERS PC5500-6 15019

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.

PREPARATIONS FOR WORK:

7. Before adding oil or making repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the machine from moving.

8. Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not possible, insert the safety pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them.

9. When disassembling or assembling, support the machine with blocks, jacks or stands before starting work.

10. Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing.

PRECAUTIONS DURING WORK :

11. When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out. Before disconnecting or removing components of the oil, water or air circuits, first remove the pressure completely from the circuit.

12. The water and oil in the circuits are hot when the engine is stopped, so be careful not to get burned. Wait for the oil and water to cool before carrying out any work on the oil or water circuits.

13. Before starting work, remove the leads from the battery. ALWAYS remove the lead from the negative (-) terminal first.

TABLE OF CONTENTS:

Komatsu PC5500-6 Hydraulic Mining Shovel Shop Manual SMPC550015019 – PDF DOWNLOAD

SERIAL NUMBERS PC5500-6 15019

MAIN MENU 0
COVER 1
TABLE OF CONTENTS 3
SAFETY 4
SAFETY NOTICE 4
GENERAL PRECAUTIONS 5
PRECAUTIONS DURING WORK 6
FOREWORD 7
GENERAL 7
HOISTING INSTRUCTIONS 8
STANDARD TIGHTENING TORQUE 10
CONVERSION TABLE 11
TEMPERATURE 16
SECTION 1 0 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 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
SECTION 2 0 DRIVE 47
TABLE OF CONTENTS SECTION 2 0 47
2 0 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
SECTION 4 0 HYDRAULIC OIL COOLING 81
TABLE OF CONTENTS SECTION 4 0 81
4 1 GENERAL 83
4 2 FUNCTION OF THE HYDRAULIC OIL COOLING CIRCUIT 85
4 3 ADJUSTMENT OF THE BACK PRESSURE VALVE 87
4 4 FAN DRIVE (TWO STAGE COOLER FAN RPM CONTROL) 89
4 5 PRESSURE RELIEF VALVES AND SOLENOID VALVES 93
4 6 FIXED DISPLACEMENT PUMP, WITH VARIABLE SETTING 97
4 7 RADIATOR FAN DRIVE SPEED ADJUSTMENT 99
SECTION 5 0 CONTROLLING 105
TABLE OF CONTENTS SECTION 5 0 105
GENERAL LAY OUT 107
5 1 CONTROL AND FILTER PANEL LOCATION OF COMPONENTS 109
5 2 PILOT PRESSURE SUPPLY AND ADJUSTMENTS 111
5 3 REMOTE CONTROL VALVES ARRANGEMENT 119
5 4 FUNCTION PRINCIPLE OF THE ELECTRO-HYDRAULIC-PROPORTIONAL CONTROL 121
5 5 POTENTIOMETER CONTROL (LEVER, JOY STICK) 125
5 6 POTENTIOMETER CONTROL (PEDAL) 127
5 7 PROPORTIONAL AMPLIFIER MODULE, TYPE A 129
5 8 PROPORTIONAL AMPLIFIER MODULE, TYPE B 131
5 9 RAMP TIME MODULE 133
5 10 ADJUSTMENTS OF AMPLIFIER MODULES (GENERAL) 135
5 11 ADJUSTING THE AMPLIFIERS TYPE B 137
5 12 ADJUSTING THE AMPLIFIERS TYPE A 141
5 13 ADJUSTING THE RAMP TIME MODULE 145
SECTION 6 0 COMPONENTS 153
TABLE OF CONTENTS SECTION 6 0 153
6 1 1 MAIN CONTROL BLOCKS AND HIGH PRESSURE FILTER FSA 155
6 1 2 MAIN CONTROL BLOCKS AND HIGH PRESSURE FILTER BACK HOE ATTACHMENT 159
6 1 3 DISTRIBUTOR MANIFOLD- RESTRICTOR BLOCKS FSA 163
6 1 4 DISTRIBUTOR MANIFOLD- RESTRICTOR BLOCKS BHA 165
6 1 5 RESTRICTOR BLOCK WITH PRESSURE RELIEF VALVE 167
6 1 6 ANTI CAVITATION VALVE BLOCK 169
6 1 7 REMOTE CONTROL VALVES 171
6 1 8 DIRECTIONAL SOLENOID VALVES 173
6 1 9 PROPORTIONAL SOLENOID VALVE 175
6 1 10 HIGH PRESSURE FILTER 177
6 1 11 CONTROL BLOCKS AND VALVES 179
6 1 12 LOAD HOLDING VALVE 187
6 1 13 TRAVEL BRAKE VALVE 189
6 1 14 PRESSURE REDUCING VALVE 191
6 1 15 DIRECTIONAL SOLENOID VALVES 193
6 1 16 PRESSURE INCREASING VALVE 195
SECTION 7 0 MAIN HYDRAULIC PUMPS AND PUMP REGULATION SYSTEM 197
TABLE OF CONTENTS SECTION 7 0 197
7 0 GENERAL LAY OUT 199
7 1 MAIN PUMPS 207
7 1 1 LOCATION OF PUMPS 207
7 1 2 PUMP BEARING FLUSHING/LUBRICATION 209
7 1 3 OPERATING PRINCIPLES 211
7 1 4 CHECKS/ADJUSTMENTS 227
7 2 ELECTRONIC PUMP REGULATION SYSTEM 237
7 2 1 ELECTRONIC LOAD LIMITING CONTROL 237
7 2 2 MICROCONTROLLER MC7 239
7 2 3 CHECKS AND ADJUSTMENTS 241
METHOD A 243
METHOD B 245
LANGUAGE SELECTION 245
EXCAVATOR TYPE SELECTION 249
1-PRESSURE (MAX CURRENT) ADJUSTMENT 253
METHOD C 257
STARTING THE PROGRAM 257
LANGUAGE SELECTION 261
EXCAVATOR TYPE SELECTION 263
X1-PRESSURE (MAX CURRENT) ADJUSTMENT 265
7 3 HYDRAULIC CONSTANT REGULATION SYSTEM 267
7 3 1 GENERAL 267
7 3 2 X1-PRESSURE ADJUSTMENT (CONSTANT-PRESSURE) 269
7 4 DETERMINATION OF THE PEAK POINT 271
7 5 ENGINE SPEED SENSOR (PICK UP) 275
SECTION 8 0 OPERATING HYDRAULIC 277
TABLE OF CONTENTS SECTION 8 0 277
8 0 GENERAL 279
8 0 1 FLOATING FUNCTION OF BOOM AND STICK CYLINDERS FSA 281
8 1 HYDRAULIC FOR THE ATTACHMENT CYLINDERS FSA AND BHA 285
TABLE OF CONTENTS SECTION 8 1 285
8 1 1 ELECTRIC/HYDRAULIC FLOWCHART “BOOM RAISING” FSA 287
8 1 2 ELECTRIC/HYDRAULIC FLOWCHART “BOOM LOWERING” FSA, AUTO FLOAT OFF 291
8 1 3 ELECTRIC/HYDRAULIC FLOWCHART “STICK EXTENDING” FSA 297
8 1 4 ELECTRIC/HYDRAULIC FLOWCHART “STICK RETRACTING” FSA AUTO FLOAT OFF 301
8 1 5 ELECTRIC/HYDRAULIC FLOWCHART “BUCKET FILLING” FSA 307
8 1 6 ELECTRIC/HYDRAULIC FLOWCHART “BUCKET DUMP” FSA 311
8 1 8 ELECTRIC/HYDRAULIC FLOWCHART “CLAM OPENING” FSA 315
8 1 9 ELECTRIC/HYDRAULIC FLOWCHART “CLAM CLOSING” FSA 317
8 1 10 CHECKS AND ADJUSTMENTS OF THE MAIN RELIEF VALVES (MRV) 319
8 1 11 CHECKS AND ADJUSTMENTS OF THE SERVICE LINE RELIEF VALVES (SRV) 323
BOOM CYLINDER “PISTON SIDE” FSA + BHA 323
BOOM CYLINDER “PISTON ROD SIDE” FSA + BHA 327
STICK CYLINDER “PISTON SIDE” FSA 331
STICK CYLINDER “PISTON SIDE” BHA 335
STICK CYLINDER “PISTON ROD SIDE” FSA 339
STICK CYLINDER “PISTON ROD SIDE” BHA 345
BUCKET CYLINDER “PISTON SIDE” FSA 349
BUCKET CYLINDER “PISTON SIDE” BHA 353
BUCKET CYLINDER “PISTON ROD SIDE” FSA 357
BUCKET CYLINDER “PISTON ROD SIDE” BHA 361
CLAM CYLINDER “PISTON ROD SIDE” FSA 365
CLAM CYLINDER “PISTON SIDE” FSA 367
8 1 12 CHECKS AND ADJUSTMENTS OF THE LOWERING SPEED 369
BOOM CYLINDER FSA 369
BOOM CYLINDER BHA 375
STICK CYLINDER FSA 377
STICK CYLINDER BHA 381
BUCKET CYLINDER FSA 383
BUCKET CYLINDER BHA 385
CLAM CYLINDER FSA 387
8 1 13 CHECKS FOR THE VALVE CONTROL LOGIC 389
8 2 HYDRAULIC FOR THE SWING CIRCUIT 391
TABLE OF CONTENTS SECTION 8 2 391
8 2 1 SWING CIRCUIT (BRIEF DESCRIPTION) 393
8 2 2 SWING MOTOR 397
8 2 3 SWING GEAR BOX 405
8 2 4 SWING PARKING BRAKE (GEAR HOUSE BRAKE) 407
8 2 5 SWING BRAKE VALVE 409
8 2 6 ELECTRIC/HYDRAULIC FLOWCHART “SWING LEFT” 415
8 2 7 ELECTRIC/HYDRAULIC FLOWCHART “SWING RIGHT” 417
8 2 8 SWING MONITORING SYSTEM 419
8 2 9 CHECKS AND ADJUSTMENTS FOR THE SWING CIRCUIT 423
8 3 HYDRAULIC FOR THE TRAVEL CIRCUIT 429
TABLE OF CONTENTS SECTION 8 3 429
8 3 1 TRAVEL CIRCUIT (BRIEF DESCRIPTION) 431
8 3 2 ROTARY DISTRIBUTOR 435
8 3 3 SIDE FRAME COMPONENTS, CROSS SECTIONS 439
8 3 4 TRAVEL GEAR AND PARKING BRAKE 441
8 3 5 PARKING BRAKE 443
8 3 6 ELECTRIC/HYDRAULIC FLOW CHARTS 445
8 3 7 ADJUSTMENTS/CHECKS 447
FUNCTION CHECK OF THE TRAVEL GEAR HOUSE BRAKE 451
SECTION 9 0 HYDRAULIC TRACK TENSIONING SYSTEM 453
TABLE OF CONTENTS SECTION 9 0 453
9 0 GENERAL 455
9 1 FUNCTIONAL DESCRIPTION 457
9 2 PRESSURE INCREASING VALVE 461
9 3 TENSIONING CYLINDER 463
9 4 ADJUSTMENTS/CHECKS 465
9 5 FUNCTIONAL TEST 469
SECTION 10 0 ACCESS LADDER HYDRAULICALLY OPERATED 471
TABLE OF CONTENTS SECTION 10 0 471
10 0 GENERAL 473
10 1 FUNCTION OF HYDRAULIC OPERATED ACCESS LADDER 475
SECTION 11 0 HYDRAULID OPERATED REFILLING ARM 479
TABLE OF CONTENTS SECTION 11 0 479
11 0 GENERAL 481
11 1 FUNCTION OF HYDRAULIC OPERATED REFILLING ARM 483
SECTION 12 0 HINTS FOR READING THE HYDRAULIC CIRCUIT DIAGRAM 485
TABLE OF CONTENTS SECTION 12 0 485
12 1 GENERAL 487
SECTION 13 0 HINTS FOR READING THE ELECTRIC CIRCUIT DIAGRAM 489
TABLE OF CONTENTS SECTION 13 0 489
13 1 DESIGNATION OF ELECTRICAL DEVICES 491
13 2 SYMBOLS 493
13 3 GENERAL INFORMATION 497
13 4 READING A CIRCUIT DIAGRAM 501
SECTION 14 0 VHMS/ECS-T/ETM 506
TABLE OF CONTENTS SECTION 14 0 506
14 0 SAFETY INSTRUCTIONS 506
14 1 GENERAL DESIGN OF THE ECS-T SYSTEM 512
14 1 1 INPUT AND OUTPUT OF HTE PLC 514
14 1 2 TASK 514
14 1 3 PLC DIGSY PLUS 516
14 1 4 DEFINITIONS; SYMBOLS AND ABBREVIATIONS 518
14 2 HOW TO PROCEED DUE MAINTENANCE AND INSTALLATION 524
14 2 1 MEANING OF THE STATUS LED’S 528
14 2 2 SHORT CIRCUIT MARKET-LED “MK” 532
14 2 3 DIAGNOSTIC FOR TEMPERATURE-MODULE “TPM” 534
14 3 FRONT CONNECTOR ARRANGEMENT 536
14 3 1 FRON CONNECTOR ARRANGEMENT BIM MODULE 536
14 3 2 FRONT CONNECTOR ARRANGEMENT, TPM-MODULE 538
14 3 4 FOUR WIRE (CONDUCTOR) TECHNIQUE 540
14 3 5 SENSOR WIRE BREAKAGE MONITORING 540
14 3 6 EARTHING OF THE CONTROL UNIT 542
14 4 POWER SUPPLY 546
14 4 1 OPERATING VOLTAGES +24V 546
14 4 2 SAFETY PRECAUTIONS FOR FAULTFINDING 548
14 4 3 CPU VOLTAGE RANGE 550
14 4 4 ELECTRIC CLASSIFICATION 550
14 4 5 FUSE 550
14 5 FUNCTION EXPLANATIONS WITH ELECTRIC DIAGRAM 552
14 5 1 GENERAL 552
14 5 2 CONTROLLING 554
14 5 3 PRESSURE MEASURING 558
14 5 4 TEMPERATURE MEASURING 560
14 5 5 TEMPERATURE-RESISTANCE CHART PT100 561
14 7 HINTS FOR READING THE FUNCTIONAL FLOW CHARTS 562
14 7 1 GENERAL 562
14 7 2 EXAMPLE 1 564
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Komatsu PC5500-6 Hydraulic Mining Shovel Shop Manual SMPC550015019 PDF

Komatsu PC5500-6 Hydraulic Mining Shovel Shop Manual SMPC550015019 – PDF DOWNLOAD

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Komatsu PC5500-6 Hydraulic Mining Shovel Shop Manual SMPC550015019 – PDF DOWNLOAD

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