Komatsu PC5500-6 Hydraulic Mining Shovel Shop Manual SMPC550015027 PDF

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Komatsu PC5500-6 Hydraulic Mining Shovel Shop Manual SMPC550015027 – PDF DOWNLOAD 

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Komatsu PC5500-6 Hydraulic Mining Shovel Shop Manual SMPC550015027 – PDF DOWNLOAD 

Language : English
Pages : 804
Downloadable : Yes
File Type : PDF

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DESCRIPTION:

Komatsu PC5500-6 Hydraulic Mining Shovel Shop Manual SMPC550015027 – PDF DOWNLOAD 

SERIAL NUMBERS PC5500-6 15027

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.
continued
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 bucket, hammer 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.

TABLE OF CONTENTS:

Komatsu PC5500-6 Hydraulic Mining Shovel Shop Manual SMPC550015027 – PDF DOWNLOAD 

SERIAL NUMBERS PC5500-6 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
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