KOMATSU PC5500-6 HYDRAULIC MINING SHOVEL SHOP MANUAL SMPC550015035 – PDF DOWNLOAD

Description

KOMATSU PC5500-6 HYDRAULIC MINING SHOVEL SHOP MANUAL SMPC550015035 – PDF DOWNLOAD

DESCRIPTION:

KOMATSU PC5500-6 HYDRAULIC MINING SHOVEL SHOP MANUAL SMPC550015035 – PDF DOWNLOAD

SERIAL NUMBERS PC5500-6 15031,15035 & UP

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.

TABLE OF CONTENTS:

KOMATSU PC5500-6 HYDRAULIC MINING SHOVEL SHOP MANUAL SMPC550015035 – PDF DOWNLOAD

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

IMAGES PREVIEW OF THE MANUAL:

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PLEASE NOTE:

• This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
• This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
• Require some other service manual or have any queries: please WRITE to us at [email protected]

I.G