Komatsu PC5500-6 Hydraulic Mining Shovel Shop Manual SMPC550015022 PDF

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Komatsu PC5500-6 Hydraulic Mining Shovel Shop Manual SMPC550015022 – PDF DOWNLOAD

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Komatsu PC5500-6 Hydraulic Mining Shovel Shop Manual SMPC550015022 – PDF DOWNLOAD

Language : English
Pages : 772
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu PC5500-6 Hydraulic Mining Shovel Shop Manual SMPC550015022 – PDF DOWNLOAD

• SERIAL NUMBERS   PC5500-6 15022

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 HYRDRAULIC 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 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
2 DRIVE 47
TABLE OF CONTENTS SECTION 2 0 47
2 0 PRIME DRIVE ASSEMBLY 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, ECT 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
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 A 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-RESTRICTOR BLOCKS FSA 179
6 1 4 DISTRIBUTOR MANIFOLD-RESTRICTOR BLOCKS 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 213
TABLE OF CONTENTS SECTION 7 0 213
7 0 MAIN HYDRAULIC PUMPS AND PUMP REGULATION SYSTEM GENERAL LAYOUT (HYDRAULIC ONLY) 216
7 1 MAIN PUMPS 224
7 1 1 LOCATION OF PUMPS 224
7 1 2 PUMP BEARING FLUSHING/LUBRICATION 226
7 1 3 OPERATING PRINCIPLES 228
7 1 4 CHECKS/ADJUSTMENTS 244
7 2 ELECTRONIC PUMP REGULATION SYSTEM 254
7 2 1 ELECTRONIC LOAD LIMITING CONTROL-GENERAL 254
7 2 2 MICRO CONTROLLER MC7 256
7 2 3 CHECKS AND ADJUSTMENTS 258
METHOD A – X1-PRESSURE WITH 24V SUPPLY TO SEPARATING TERMINALS AT THE X2-SWITCH BOARD 260
METHOD B – WITH THE ELECTRONIC SERVICE TOOL BB-3 262
LANGUAGE SELECTION 262
EXCAVATOR TYPE SELECTION 266
X1-PRESSURE (MAX CURRENT) ADJUST 270
METHOD C – WITH A LAPTOP AND BODEM SOFTWARE 274
STARTING THE PROGRAM 274
LANGUAGE SELECTION 278
EXCAVATOR TYPE SELECTION 280
X1-PRESSURE (MAX CURRENT) ADJUST 282
7 3 HYDRAULIC CONSTANT REGULATION SYSTEM 284
7 3 1 GENERAL 284
7 3 2 X1-PRESSURE ADJUSTMENT (CONSTANT-PRESSURE) 286
7 4 DETERMINATION OF THE PEAK POINT 288
7 5 ENGINE SPEED SENSOR (PICK UP) 292
8 OPERATING HYDRAULIC 293
TABLE OF CONTENTS SECTION 8 0 293
8 0 GENERAL 295
8 0 1 FLOATING FUNCTION OF BOOM AND STICK CYLINDERS FSA 297
8 1 HYDRAULIC FOR THE ATTACHMENT CYLINDERS FSA AND BHA 301
TABLE OF CONTENTS SECTION 8 1 301
8 1 1 ELECTRIC/HYDRAULIC FLOWCHART “BOOM RAISING” FSA 303
8 1 2 ELECTRIC/HYDRAULIC FLOWCHART “BOOM LOWERING” FSA, AUTO FLOAT OFF 307
8 1 3 ELECTRIC/HYDRAULIC FLOWCHART “STICK EXTENDING” FSA 313
8 1 4 ELECTRIC/HYDRAULIC FLOWCHART “STICK RETRACTING” FSA AUTO FLOAT OFF 317
8 1 5 ELECTRIC/HYDRAULIC FLOWCHART “BUCKET FILLING” FSA 323
8 1 6 ELECTRIC/HYDRAULIC FLOWCHART “BUCKET DUMP” FSA 327
8 1 8 ELECTRIC/HYDRAULIC FLOWCHART “CLAM OPENING” FSA 331
8 1 9 ELECTRIC/HYDRAULIC FLOWCHART “CLAM CLOSING” FSA 333
8 1 10 CHECKS AND ADJUSTMENTS OF THE MAIN RELIEF VALVES (MRV) PRIMARY VALVES 335
8 1 11 CHECKS AND ADJUSTMENTS OF THE SERVICE LINE RELIEF VALVES (SRV) 339
BOOM CYLINDER “PISTON SIDE” FSA + BHA 339
BOOM CYLINDER “PISTON ROD SIDE” FSA + BHA 343
STICK CYLINDER”PISTON SIDE” FSA 347
STICK CYLINDER “PISTON SIDE” BHA 351
STICK CYLINDER “PISTON ROD SIDE” FSA 355
STICK CYLINDER “PISTON ROD SIDE” BHA 361
BUCKET CYLINDER “PISTON SIDE” FSA 365
BUCKET CYLINDER “PISTON SIDE” BHA 369
BUCKET CYLINDER “PISTON ROD SIDE” FSA 373
BUCKET CYLINDER “PISTON ROD SIDE” BHA 377
CLAM CYLINDER “PISTON ROD SIDE” FSA 381
CLAM CYLINDER “PISTON SIDE” FSA 383
8 1 12 CHECKS AND ADJUSTMENTS OF THE LOWERING SPEED 385
GENERAL: FLOW RESTRICTORS 385
BOOM CYLINDER FSA 389
BOOM CYLINDER BHA 391
STICK CYLINDER FSA 393
STICK CYLINDER BHA 397
BUCKET CYLINDER FSA 399
BUCKET CYLINDER BHA 401
CLAM CYLINDER FSA 403
8 1 13 CHECKS FOR THE VALVE CONTROL LOGIC 405
8 2 HYDRAULIC FOR THE SWING CIRCUIT 407
TABLE OF CONTENTS SECTION 8 2 407
8 2 1 SWING CIRCUIT (BRIEF DESCRIPTION) 409
8 2 2 SWING MOTOR 413
8 2 3 SWING GEAR BOX 421
8 2 4 SWING PARKING BRAKE (GEAR HOUSE BRAKE) 423
8 2 5 SWING BRAKE VALVE 425
8 2 6 ELECTRIC/HYDRAULIC FLOWCHART “SWING LEFT” 431
8 2 7 ELECTRIC/HYDRAULIC FLOWCHART “SWING RIGHT” 433
8 2 8 SWING MONITORING SYSTEM 435
8 2 9 CHECKS AND ADJUSTMENTS FOR THE SWING CIRCUIT 439
8 3 HYDRAULIC FOR THE TRAVEL CIRCUIT 446
TABLE OF CONTENTS SECTION 8 3 446
8 3 1 TRAVEL CIRCUIT 448
8 3 1 SERVICE CIRCUITS 450
8 3 2 ROTARY DISTRIBUTOR 452
8 3 3 SIDE FRAME COMPONENTS 456
8 3 4 TRAVEL GEAR AND PARKING BRAKE 458
8 3 5 PARKING BRAKE 460
8 3 6 ELECTRIC/HYDRAULIC FLOW CHARTS 462
8 3 7 ADJUSTMENTS/CHECKS 464
9 HYDRAULIC TRACK TENSIONING SYSTEM 470
TABLE OF CONTENTS SECTION 9 0 470
9 0 GENERAL 472
9 1 FUNCTIONAL DESCRIPTION 474
9 2 PRESSURE INCREASING VALVE 478
9 3 TENSIONING CYLINDER 480
9 4 ADJUSTMENTS/CHECKS 482
9 5 FUNCTIONAL TEST 486
10 HYDRAULIC OPERATED ACCESS LADDER 488
TABLE OF CONTENTS SECTION 10 0 488
GENERAL 490
10 1 FUNCTION OF HYDRAULIC OPERATED ACCESS LADDER 492
11 CENTRAL REFILLING SYSTEM 496
GENERAL 498
11 1 FUNCTION OF HYDRAULIC OPERATED REFILLING ARM 500
12 HINTS FOR READING THE HYDRAULIC CIRCUIT DIAGRAM 502
TABLE OF CONTENTS SECTION 11 0 502
12 1 HINTS FOR READING THE CIRCUIT DIAGRAM 504
12 2 SYMBOLS 506
13 HINTS FOR READING THE ELECTRIC CIRCUIT DIAGRAM 512
Table of contents section 13 0 512
13 1 Designation of electrical devices 514
13 2 Symbols 516
13 3 General information 520
13 4 Reading a Circuit Diagram 524
14 ECS 528
TABLE OF CONTENTS SECTION 14 0 528
14 1 GENERAL DESIGN OF THE ECS-T SYSTEM 534
14 1 1 INPUT AND OUTPUT OF THE PLC 536
14 1 2 TASK 536
14 1 3 PLC DIGSY 538
14 1 4 DEFINITIONS; SYMBOLS AND ABBREVIATIONS 540
14 2 HOW TO PROCEED DUE MAINTENANCE AND INSTALLATION 546
14 2 1 MEANING OF THE STATUS LED’S 550
14 2 2 SHORT CIRCUIT MARKER-LED “MK” 554
14 2 3 DIAGNOSTIC FOR TEMPERATURE-MODULE “ANM” 556
14 3 FRONT CONNECTOR ARRANGEMENT 558
14 3 1 FRONT CONNECTOR ARRANGEMENT BIM-MODULE 558
14 3 2 FRONT CONNECTOR ARRANGEMENT, ANM-MODULE 562
14 3 3 GROUND CONNECTOR OF THE CONTROL UNIT 566
14 4 POWER SUPPLY 568
14 4 1 OPERATION VOLTAGES +24 V 568
14 4 2 SAFETY PRECAUTIONS FOR FAULTFINDING 570
14 4 3 CPU VOLTAGE RANGE 572
14 4 4 ELECTRIC CLASSIFICATION 572
14 4 5 FUSE 572
14 5 FUNCTION EXPLANATIONS WITH ELECTRIC DIAGRAM 574
14 5 1 GENERAL 574
14 5 2 CONTROLLING 576
14 5 3 PRESSURE MEASURING AND TROUBLE SHOOTING 580
14 5 4 TEMPERATURE MEASURING AND TROUBLE SHOOTING 582
14 5 5 TEMPERATURE-RESISTANCE CHART PT100 586
14 7 HINTS FOR READING THE FUNCTIONAL FLOW CHARTS 588
14 7 1 GENERAL 588
14 7 2 EXAMPLE 1 590
14 8 CABLES AND EXTERNAL MONITORING COMPONENTS 614
APPENDIX 615
CHECK LIST VALVE LOGIC 617
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DESCRIPTION:

Komatsu PC5500-6 Hydraulic Mining Shovel Shop Manual SMPC550015022 – PDF DOWNLOAD

• SERIAL NUMBERS   PC5500-6 15022

G.B 18/12/24