Komatsu PC5500-6 HYDRAULIC MINING SHOVEL Shop Manual SMPC550015032 PDF

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Komatsu PC5500-6 HYDRAULIC MINING SHOVEL Shop Manual SMPC550015032  – PDF DOWNLOAD

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Komatsu PC5500-6 HYDRAULIC MINING SHOVEL Shop Manual SMPC550015032  – PDF DOWNLOAD

Language : English
Pages : 842
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu PC5500-6 HYDRAULIC MINING SHOVEL Shop Manual SMPC550015032  – PDF DOWNLOAD

• SERIAL NUMBERS PC5500-6 15032

MAIN MENU . 0
COVER PAGE 1
TABLE OF CONTENTS . 3
SAFETY 5
FOREWORD 8
GENERAL . 8
HOISTING INSTRUCTIONS . 9
STANDARD TIGHTENING TORQUE 11
CONVERSION TABLE 12
TEMPERATURE . 18
1.0 MAIN ASSEMBLY GROUPS 19
GENERAL LAYOUT 21
1.1 SUPERSTRUCTURE 23
1.1.1 MACHINE HOUSE . 25
1.1.2 HYDRAULIC OIL RESERVE . 27
1.1.3 HYDRAULIC OIL COOLER 29
1.1.4 FUEL TANK (FUEL RESERVOIR) 31
1.1.5 COUNTER WEIGHT 33
1.1.6 CAB SUPPORT . 35
1.1.7 OPERATOR’S CAB 37
1.1.8 CONTROL BLOCKS 39
1.1.9 SWING GEARS . 41
1.2 UNDER CARRIAGE 43
1.3 ATTACHMENT 45
1.3.1 BACKHOE ATTACHMENT (BHA) 45
1.3.2 FRONT SHOVEL ATTACHMENT (FSA) . 47
2.0 PRIME DRIVE ASSEMBLY 49
GENERAL LAYOUT 51
2.1 ENGING AND PTO MOUNTS . 53
2.2 COUPLING 57
2.3 AIR FILTER 59
2.4 FAN DRIVE AND RADIATOR ASSEMBLY . 61
2.5 RADIATOR FAN DRIVE SPEED ADJUSTMENT . 67
2.6 PUMP DISTRIBUTOR GEARBOX (PTO) 73
2.7 PUMP-SPLINE LUBRICATION . 75
2.8 PTO LUBRICATION AND COOLING . 77
2.9 HYDRAULIC PUMPS – LOCATION, DRIVE SPEED AND FLOW RATES 81
3.0 HYDRAULIC OIL RESERVOIR . 83
GENERAL LAYOUT 85
3.1 MAIN OIL TANK, LOCATION OF SWITCHES, SENSORS ETC 87
3.2 SUCTION OIL TANK WITH STRAINERS . 89
3.3 RETURN OIL COLLECTOR TUBE WITH STRAINER . 91
3.4 BACK PRESSURE VALVE . 93
3.6 RETURN AND LEAK OIL FILTER 95
3.7 BREATHER FILTER . 97
4.0 HYDRAULIC OIL COOLING . 99
4.1 GENERAL .101
4.2 FUNCTION OF THE HYDRAULIC OIL COOLING CIRCUIT .103
4.3 ADJUSTMENT OF THE BACK PRESSURE VALVE .105
4.4 FAN DRIVE (TWO STAGE COOLER FAN RPM CONTROL) 107
4.5 PRESSURE RELIEF VALVES AND SOLENOID VALVES 111
4.6 FIXED DISPLACEMENT PUMP, WITH VARIABLE SETTING 115
4.7 RADIATOR FAN DRIVE SPEED ADJUSTMENT .117
5.0 CONTROLLING .123
GENERAL LAY OUT .125
5.1 CONTROL AND FILTER PANEL LOCATION OF COMPONENTS .127
5.2 PILOT PRESSURE SUPPLY AND ADJUSTMENTS .129
5.3 REMOTE CONTROL VALVES ARRANGEMENT .137
5.4 FUNCTION PRINCIPLE OF THE ELECTRA-HYDRAULIC-PROPORTIONAL CONTROL 139
5.5 POTENTIOMETER CONTROL (LEVER, JOY STICK) 143
5.6 POTENTIOMETER CONTROL (PEDAL) .145
5.7 PROPORTIONAL AMPLIFIER MODULE, TYPE A .147
5.8 PROPORTIONAL AMPLIFIER MODEL, TYPE B 149
5.9 RAMP TIME MODULE 151
5.10 ADJUSTMENTS OF AMPLIFIER MODULES (GENERAL) .153
5.11 ADJUSTING THE AMPLIFIERS, TYPE B .155
5.12 ADJUSTING THE AMPLIERS, TYPE B .159
5.13 ADJUSTING THE RAMP TIME MODULE .163
6.0 COMPONENTS 171
6.1.1 MAIN CONTROL BLOCKS AND HIGH PRESSURE FILTER FSA 173
6.1.2 MAIN CONTROL BLOCKS AND HIGH PRESSURE FILTER BHA 177
6.1.3 DISTRIBUTOR MANIFOLD – RESTRICTOR BLOCKS FSA 181
6.1.4 DISTRIBUTOR MANIFOLD – RESTRICTOR BLOCKS BHA 183
6.1.5 RESTRICTOR BLOCK WITH PRESSURE RELIEF VALVE .185
6.1.6 ANTI CAVITATION VALVE BLOCK .187
6.1.7 REMOTE CONTROL VALVES .189
6.1.8 DIRECTIONAL SOLENOID VALVES .191
6.1.9 PROPORTIONAL SOLENOID VALVE .193
6.1.10 HIGH PRESSURE FILTER .195
6.1.11 CONTROL BLOCKS AND VALVES 197
6.1.12 LOAD HOLDING VALVE .205
6.1.13 TRAVEL BRAKE VALVE .207
6.1.14 PRESSURE REDUCING VALVE 209
6.1.15 DIRECTIONAL SOLENOID VALVES (2 POSITIONS / 4-WAYS) .211
6.1.16 PRESSURE INCREASING VALVE 213
7.0 MAIN HYDRAULIC PUMPS AND PUMP REGULATION 215
GENERAL LAYOUT 217
7.1 MAIN PUMPS 225
7.1.1 LOCATION OF PUMPS .225
7.1.2 PUMP BEARING FLUSHING / LUBRICATION .227
7.1.3 OPERATING PRINCIPLES 229
7.1.4 CHECKS / ADJUSTMENTS 245
7.2 ELECTRONIC PUMP REGULATION SYSTEM .255
7.2.1 ELECTRONIC LOAD LIMITING CONTROL – GENERAL 255
7.2.2 MICRO CONTROLLER MC7 257
7.2.3 CHECKS AND ADJUSTMENTS 259
METHOD A -X1 PRESSURE WITH 24V SUPPLY TO SEPARATING TERMINALS AT THE X2-SWITCH BOARD 261
METHOD B – WITH THE ELECTRONIC SERVICE TOOL BB-3 .263
LANGUAGE SELECTION 263
EXCAVATOR TYPE SELECTION 267
X1-PRESSURE (MAXIMUM CURRENT) ADJUSTMENT 271
METHOD C – WITH A LAPTOP COMPUTER AND BODEM SOFTWARE 275
STARTING THE PROGRAM 275
LANGUAGE SELECTION 279
EXCAVATOR TYPE SELECTION 281
X1-PRESSURE (MAXIMUM CURRENT) ADJUSTMENT 283
7.3 HYDRAULIC CONSTANT REGULATION SYSTEM 285
7.3.1 GENERAL .285
7.3.2 X1-PRESSURE ADJUSTMENT (CONSTANT-PRESSURE) 287
7.4 DETERMINATION OF THE PEAK POINT (ENGINE PERFORMANCE) 289
7.5 ENGINE SPEED SENSOR (PICK UP) .293
7.5.1 ENGINE SPEED SENSOR (PICK UP) ADJUSTMENT 293
8.0 OPERATING HYDRAULIC .295
GENERAL .297
8.0.1 FLOATING FUNCTION OF BOOM AND STICK CYLINDERS .299
8.1 HYDRAULIC FOR THE ATTACHMENT CYLINDER FSA AND BHA .303
8.1.1 ELECTRIC / HYDRAULIC FLOWCHART “BOOM RAISING” 305
8.1.2 ELECTRIC / HYDRAULIC FLOWCHART “BOOM LOWERING” 309
8.1.3 ELECTRIC / HYDRAULIC FLOWCHART “STICK EXTENDING” 315
8.1.4 ELECTRIC / HYDRAULIC FLOWCHART “STICK RETRACTING” .319
8.1.5 ELECTRIC HYDRAULIC FLOWCHART “BUCKET .325
8.1.6 ELECTRIC / HYDRAULIC FLOWCHART BUCKET DUMP 329
8.1.8 ELECTRIC / HYDRAULIC FLOWCHART CLAM OPENING .333
8.1.9 ELECTRIC / HYDRAULIC FLOWCHART “CLAM CLOSING” .335
8.1.10 CHECKS AND ADJUSTMENTS OF THE MAIN RELIEF VALVES (MRV) .337
8.1.11 CHECKS AND ADJUSTMENTS OF THE SERVICE LINE RELIEF VALVES (SRV) .341
BOOM CYLINDER “PISTON SIDE FSA +BHA .341
BOOM CYLINDER “PISTON ROD SIDE” FSA + BHA .345
STICK CYLINDER “PISTON SIDE” FSA 349
STICK CYLINDER “PISTON SIDE” BHA 353
STICK CYLINDER “PISTON ROD SIDE” FSA 357
STICK CYLINDER “PISTON ROD SIDE” BHA 363
BUCKET CYLINDER “PISTON SIDE” FSA .367
BUCKET CYLINDER “PISTON SIDE” BHA .371
BUCKET CYLINDER “PISTON ROD SIDE” FSA .369
CLAM CYLINDER “ROD SIDE” FSA 383
CLAM CYLINDER “PISTON SIDE” FSA .385
8.1.12 CHECKS AND ADJUSTMENTS OF THE LOWERING SPEED .387
GENERAL .387
BOOM CYLINDER FSA .389
BOOOM CYLINDER BHA 393
STICK CYLINDER FSA 395
STICK CYLINDER BHA 399
BUCKET CYLINDER FSA .401
BUCKET CYLINDER BHA .403
CLAM CYLINDER .405
8.1.13 CHECKS FOR THE VALVE CONTROL LOGIC .407
8.2 HYDRAULIC FOR THE SWING CIRCUIT .409
8.2.1 SWING CIRCUIT (BRIEF DESCRIPTION) .411
8.2.2 SWING MOTOR .415
8.2.3 SWING GEAR BOX 423
8.2.4 SWING PARKING BRAKE (GEAR HOUSE BRAKE) 425
8.2.5 SWING BRAKE VALVE .427
8.2.6 ELECTRIC / HYDRAULIC FLOWCHART “SWING LEFT” .433
8.2.7 ELECTRIC / HYDRAULIC FLOWCHART “SWING RIGHT” 435
8.2.8 SWING MONITORING SYSTEM .437
8.2.9 CHECKS AND ADJUSTMENTS FOR THE SWING CIRCUIT 441
8.3 TRAVEL SYSTEM .447
8.3.1 SERVICE CIRCUITS 451
8.3.2 ROTARY DISTRIBUTOR 453
8.3.3 SIDE FRAME COMPONENTS, 457
8.3.4 TRAVEL GEAR AND PARKING BRAKE .459
8.3.5 PARKING BRAKE .461
ELECTRIC / HYDRAULIC FLOW CHARTS 463
ADJUSTMENTS / CHECKS 465
9.0 HYDRAULIC TRACK TENSIONING SYSTEM .471
GENERAL .473
9.1 FUNCTIONAL DESCRIPTION 475
9.2 PRESSURE INCREASING VALVE .479
9.3 TENSIONING CYLINDER .481
9.4 ADJUSTMENTS / CHECKS 483
9.5 FUNCTIONAL TEST .487
10.0 HYDRAULIC OPERATED ACCESS LADDER .489
GENERAL .491
10.1 FUNCTION OF HYDRAULIC OPERATED ACCESS LADDER .493
11.0 HYDRAULIC OPERATED REFILLING ARM .497
GENERAL .499
11.1 FUNCTION OF HYDRAULIC OPERATED REFILLING ARM 501
12.0 HINTS FOR READING THE HYDRAULIC CIRCUIT DIAGRAM 503
GENERAL .505
12.1 SYMBOLS 507
12.1.1 LINES, UNIONS 507
12.1.2 COMPONENTS, VALVES .509
12.1.3 SENSORS 510
12.1.4 VALVES, VALVE COMPONENTS .511
12.1.5 PUMP, MOTOR, CYLINDER 515
12.1.6 ASSEMBLY AND MAIN COMPONENTS .517
13.0 HINTS FOR READING THE ELECTRIC CIRCUIT DIAGRAM .520
13.1 DESIGNATION OF ELECTRICAL DEVICES 521
13.2 SYMBOLS 523
13.3 GENERAL INFORMATION 527
13.4 READING A CIRCUIT DIAGRAM 531
14.0 ELECTRONIC CONTROL SYSTEM (ECS) 535
14.1 GENERAL DESIGN OF THE ECS SYSTEM .537
14.1.1 INPUT AND OUTPUT OF THE PLC 539
14.1.2 TASK .539
14.1.3 PLC DIGEST .541
14.1.4 DEFINITIONS: SYMBOLS AND ABBREVIATIONS 542
14.2 HOW TO PROCEED DUE MAINENANCE AND INSTALLATION .545
14.2.1 MEANING OF THE STATUS LEDS .548
14.2.2 SHORT CIRCUIT MARKER – LED “MK” 552
14.2.3 DIAGNOSTIC FOR TEMPERATURE – MODULE “anm” 554
14.3 FRONT CONNECTOR ARRANGEMENT 555
14.3.1 FRONT CONNECTOR ARRANGEMENT, BIM MODULE 556
14.3.2 FRONT CONNECTOR ARRANGEMENT, ANM-MODULE 557
14.3.3 GROUND CONNECTION OF THE CONTROL UNIT 559
14.3.4 INTERFACE-CONNECTION COM SK / SP .561
14.4 POWER SUPPLY .563
14.4.1 OPERATION VOLTAGES +24V 563
14.4.2 SAFETY PRECUATIONS FOR FAULT FINDING .565
14.4.3 CPU VOLTAGE RANGE 566
14.4.4 ELECTRIC CLASSIFICATION 566
14.4.5 FUSE .566
14.5 FUNCTION EXPLANATIONS WITH ELECTRICAL DIAGRAM 567
14.5.1 GENERAL 567
14.5.2 PRESSURE MEASURING 569
14.5.3 TEMPERATURE MEASURING 571
14.5.4 TEMPERATURE – RESISTANCE CHART PT100 .574
14.6 HINTS FOR READING FUNCTIONAL FLOW CHARTS .575
14.6.1 GENERAL 575
14.6.2 EXAMPLE 577
15.0 LUBRICATION SYSTEM .579
GENERAL FUNCTION 581
OSCILLATION CYLINDER AND CONTROL BLOCK 587
ADJUSTMENTS .589
ONE LINE SYSTEM .591
ELECTRICAL FUNCTION .595
CAPACITIVE ANALOG SENSOR FOR LUBRICANT LEVEL MONITORING .599
ADJUSTMENTS .601
END LINE SWITCH SETTING .601
INJECTOR 603
FUNCTION PINION TYPE (DUMMY WHEEL) SYSTEM .605
ELECTRICAL FUNCTION .609
CAPACITIVE ANALOG SENSOR FOR LUBRICANT LEVEL MONITORING .613
END OF LINE SWITCH SETTING 615
INJECTORS .617
COMPONENTS 619
HYDRAULICALLY DRIVEN LUBE PUMP 619
INJECTORS .623
END-LINE SWITCH .629
IN-LINE FILTER 631
VENT VALVE 633
APPENDIX 635
CHECK LIST VALVE LOGIC 637
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DESCRIPTION:

Komatsu PC5500-6 HYDRAULIC MINING SHOVEL Shop Manual SMPC550015032  – PDF DOWNLOAD

• SERIAL NUMBERS PC5500-6 15032

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.

GENERAL PRECAUTIONS:
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.
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 work on the oil or water circuits.

G.B 25/12/24