Komatsu PC5500-6 Hydraulic Mining Shovel Shop Manual – SMPC550015035

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Komatsu PC5500-6 Hydraulic Mining Shovel Service Repair Workshop Manual – SMPC550015035

This complete service repair workshop manual PDF download for the Komatsu PC5500-6 Hydraulic Mining Shovel has easy to read text sections with top quality diagrams, pictures and illustrations. The step by step instructions show you how to fault find or complete any repair or overhaul, correctly and efficiently, saving time and avoiding costly mistakes. All specifications and tolerances are listed. Functions of components and systems are also explained.

APPLICABLE MODELS :

Machine Model : PC5500-6
Serial Numbers : 15031, 15035 and up

TABLE OF CONTENTS :

00 Safety – Foreword
01 Technical DATA (Leaflet)
02 Assembly PROCEDURE (Brochure)

Section
1. Main assembly groups
2. Drive.
3. Hydraulic oil tank.
4. Hydraulic oil cooling.
5. Controlling.
6. Components
7. Main hydraulic pumps and pump regulation.
8. Operating hydraulic.
9. Hydraulic track tensioning system.
10. Hydraulic operated access ladder
11. Hydraulic operated refilling arm
12. Hints for the hydraulic circuit diagram
13. Hints for the electric circuit diagram
14. ECS-T
15. Lubrication Systems

APPENDIX

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : SMPC550015035
Total Pages : 810

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SECTION 1.0 MAIN ASSEMBLY GROUPS
TABLE OF CONTENTS SECTION 1.0
GENERAL LAYOUT
1.1 SUPERSTRUCTURE
1.1.1 MACHINE HOUSE
1.1.2 HYDRAULIC OIL RESERVOIR
1.1.3 HYDRAULIC OIL COOLER
1.1.4 FUEL TANK (FUEL RESERVOIR)
1.1.5 COUNTER WEIGHT
1.1.6 CAB SUPPORT
1.1.7 OPERATORS CAB
1.1.8 CONTROL BLOCKS
1.1.9 SWING GEARS
1.2 UNDER CARRIAGE
1.3 ATTACHMENT
1.3.1 BACKHOE ATTACHMENT (BHA)
1.3.2 FRONT SHOVEL ATTACHMENT (FSA)

SECTION 2.0 DRIVE
TABLE OF CONTENTS SECTION 2.0
PRIME DRIVE ASSEMBLY – GENERAL LAY OUT
2.1 ENGINE AND PTO MOUNTS
2.2 COUPLING
2.3 AIR FILTER
2.4 FAN DRIVE AND RADIATOR ASSEMBLY
2.5 RADIATOR FAN DRIVE SPEED ADJUSTMENT
2.6 PUMP DISTRIBUTOR GEARBOX (PTO)
2.7 PUMP-SPLINE LUBRICATION
2.8 PTO LUBRICATION AND COOLING
2.9 HYDRAULIC PUMPS – LOCATION, DRIVE SPEED AND FLOW RATES

SECTION 3.0 HYDRAULIC OIL RESERVOIR
TABLE OF CONTENTS SECTION 3.0
GENERAL LAY OUT
3.1 MAIN OIL TANK, LOCATION OF SWITCHES, SENSORS, ETC.
3.2 SUCTION OIL TANK WITH STRAINERS
3.3 RETURN OIL COLLECTOR TUBE WITH STRAINER
3.4 BACK PRESSURE VALVE
3.6 RETURN AND LEAK OIL FILTER
3.7 BREATHER FILTER

SECTION 4.0 HYDRAULIC OIL COOLING
TABLE OF CONTENTS SECTION 4.0
4.1 GENERAL
4.2 FUNCTION OF THE HYDRAULIC OIL COOLING CIRCUIT
4.3 ADJUSTMENT OF THE BACK PRESSURE VALVE
4.4 FAN DRIVE (TWO STAGE COOLER FAN RPM CONTROL)
4.5 PRESSURE RELIEF VALVES AND SOLENOID VALVES
4.6 FIXED DISPLACEMENT PUMP, WITH VARIABLE SETTING
4.7 RADIATOR FAN DRIVE SPEED ADJUSTMENT

SECTION 5.0 CONTROLLING
TABLE OF CONTENTS SECTION 5.0
GENERAL LAY OUT
5.1 CONTROL AND FILTER PANEL LOCATION OF COMPONENTS
5.2 PILOT PRESSURE SUPPLY AND ADJUSTMENTS
5.3 REMOTE CONTROL VALVES ARRANGEMENT
5.4 FUNCTION PRINCIPLE OF THE ELECTRO-HYDRAULIC-PROPORTIONAL CONTROL
5.5 POTENTIOMETER CONTROL (LEVER, JOY STICK)
5.6 POTENTIOMETER CONTROL (PEDAL)
5.7 PROPORTIONAL AMPLIFIER MODULE, TYPE A
5.8 PROPORTIONAL AMPLIFIER MODULE, TYPE B
5.9 RAMP TIME MODULE
5.10 ADJUSTMENTS OF AMPLIFIER MODULES (GENERAL)
5.11 ADJUSTING THE AMPLIFIERS TYPE B
5.12 ADJUSTING THE AMPLIFIERS TYPE B
5.13 ADJUSTING THE RAMP TIME MODULE

SECTION 6.0 COMPONENTS
TABLE OF CONTENTS SECTION 6.0
6.1 HYDRAULIC
6.1.1 MAIN CONTROL BLOCKS AND HIGH PRESSURE FILTER FRONT SHOVEL ATTACHMENT FSA
6.1.2 MAIN CONTROL BLOCKS AND HIGH PRESSURE FILTER BACKHOE ATTACHMENT BHA
6.1.3 DISTRIBUTOR MANIFOLD – LOCATION OF RESTRICTOR BLOCKS AND ANTI CAVITATION VALVES FSA
6.1.4 DISTRIBUTOR MANIFOLD – LOCATION OF RESTRICTOR BLOCKS AND ANTI CAVITATION VALVES BHA
6.1.5 RESTRICTOR BLOCK WITH PRESSURE RELIEF VALVE
6.1.6 ANTI CAVITATION VALVE BLOCK
6.1.7 REMOTE CONTROL VALVES
6.1.8 DIRECTIONAL SOLENOID VALVES
6.1.9 PROPORTIONAL SOLENOID VALVE
6.1.10 HIGH PRESSURE FILTER
6.1.11 CONTROL BLOCKS AND VALVES
6.1.12 LOAD HOLDING VALVE
6.1.13 TRAVEL BRAKE VALVE
6.1.14 PRESSURE REDUCING VALVE
6.1.15 DIRECTIONAL SOLENOID VALVES (2 POSITIONS / 4-WAYS)
6.1.16 PRESSURE INCREASING VALVE

SECTION 7.0 MAIN HYDRAULIC PUMPS AND PUMP REGULATION SYSTEM
TABLE OF CONTENTS SECTION 7.0
7.0 MAIN HYDRAULIC PUMPS AND PUMP REGULATION SYSTEM GENERAL LAYOUT (HYDRAULIC ONLY)
7.1 MAIN PUMPS
7.1.1 LOCATION OF PUMPS
7.1.2 PUMP BEARING FLUSHING / LUBRICATION
7.1.3 OPERATING PRINCIPLES
7.1.4 CHECKS / ADJUSTMENTS
7.2 ELECTRONIC PUMP REGULATION SYSTEM
7.2.3 CHECKS AND ADJUSTMENTS MICRO CONTROLLER MC7
METHOD A
METHOD B
LANGUAGE SELECTION
EXCAVATOR TYPE SELECTION
X1-PRESSURE (MAXIMUM CURRENT) ADJUSTMENT
METHOD C
STARTING THE PROGRAM
LANGUAGE SELECTION
EXCAVATOR TYPE SELECTION
X1-PRESSURE (MAXIMUM CURRENT) ADJUSTMENT
7.2.1 ELECTRONIC LOAD LIMITING CONTROL – GENERAL
7.2.2 MICRO CONTROLLER MC7
7.3 HYDRAULIC CONSTANT REGULATION SYSTEM
7.3.1 GENERAL
7.3.2 X1-PRESSURE ADJUSTMENT (CONSTANT-PRESSURE)
7.4 DETERMINATION OF THE PEAK POINT (ENGINE PERFORMANCE)
7.5 ENGINE SPEED SENSOR (PICK UP)

SECTION 8.0 OPERATING HYDRAULIC
TABLE OF CONTENTS SECTION 8.0
8.0 GENERAL
8.0.1 FLOATING FUNCTION OF BOOM AND STICK CYLINDERS FSA
8.1 HYDRAULIC FOR THE ATTACHMENT CYLINDERS
TABLE OF CONTENTS SECTION 8.1
8.1.1 ELECTRIC / HYDRAULIC FLOWCHART “BOOM RAISING” FSA
8.1.2 ELECTRIC / HYDRAULIC FLOWCHART “BOOM LOWERING” FSA, AUTO FLOAT OFF
8.1.3 ELECTRIC / HYDRAULIC FLOWCHART “STICK EXTENDING” FSA
8.1.4 ELECTRIC / HYDRAULC FLOWCHART “STICK RETRACTING” FSA AUTO FLOAT OFF
8.1.5 ELECTRIC / HYDRAULIC FLOWCHART “BUCKET FILLING” FSA
8.1.6 ELECTRIC / HYDRAULIC FLOWCHART “BUCKET DUMP” FSA
8.1.8 ELECTRIC / HYDRAULIC FLOWCHART “CLAM OPENING” FSA
8.1.9 ELECTRIC / HYDRAULIC FLOWCHART “CLAM CLOSING” FSA
8.1.10 CHECKS AND ADJUSTMENTS OF THE MAIN RELIEF VALVES (MRV)
8.1.11 CHECKS AND ADJUSTMENTS OF THE SERVICE LINE RELIEF VALVES (SRV)
BOOM CYLINDER “PISTON SIDE” FSA + BHA
BOOM CYLINDER “PISTON ROD SIDE” FSA + BHA
STICK CYLINDER “PISTON SIDE” FSA
STICK CYLINDER “PISTON SIDE” BHA
STICK CYLINDER “PISTON ROD SIDE” FSA
STICK CYLINDER “PISTON ROD SIDE” BHA
BUCKET CYLINDER “PISTON SIDE” FSA
BUCKET CYLINDER “PISTON SIDE” BHA
BUCKET CYLINDER “ROD SIDE” FSA
BUCKET CYLINDER “PISTON ROD SIDE” BHA
CLAM CYLINDER “ROD SIDE” (CLAM OPENING) FSA
CLAM CYLINDER “PISTON SIDE (CLAM CLOSING) FSA
8.1.12 CHECKS AND ADJUSTMENTS OF THE LOWERING SPEED
GENERAL: FLOW RESTRICTORS BOOM CYLINDER FSA
BOOM CYLINDER BHA
STICK CYLINDER FSA
STICK CYLINDER BHA
BUCKET CYLINDER FSA
BUCKET CYLINDER BHA
CLAM CYLINDER FSA
8.1.13 CHECKS FOR THE VALVE CONTROL LOGIC
8.2 HYDRAULIC FOR THE SWING CIRCUIT
TABLE OF CONTENTS SECTION 8.2
8.2.1 SWING CIRCUIT (BRIEF DESCRIPTION)
8.2.2 SWING MOTOR
8.2.3 SWING GEAR BOX
8.2.4 SWING PARKING BRAKE (GEAR HOUSE BRAKE)
8.2.5 SWING BRAKE VALVE
8.2.6 ELECTRIC / HYDRAULIC FLOWCHART “SWING LEFT”
8.2.7 ELECTRIC / HYDRAULIC FLOWCHART “SWING RIGHT”
8.2.8 SWING MONITORING SYSTEM
8.2.9 CHECKS AND ADJUSTMENTS FOR THE SWING CIRCUIT
8.2.10 CHECKS AND ADJUSTMENTS FOR THE SWING CIRCUIT
8.3 HYDRAULIC FOR THE TRAVEL CIRCUIT
TABLE OF CONTENTS SECTION 8.3
8.3.1 TRAVEL CIRCUIT (BRIEF DESCRIPTION)
8.3.2 ROTARY DISTRIBUTOR
8.3.3 SIDE FRAME COMPONENTS
8.3.4 TRAVEL GEAR AND PARKING BRAKE
8.3.5 PARKING BRAKE
8.3.6 ELECTRIC / HYDRAULIC FLOW CHART
8.3.7 ADJUSTMENT / CHECKS

SECTION 9.0 HYDRAULIC TRACK TENSIONING SYSTEM
TABLE OF CONTENTS SECTION 9.0
GENERAL
9.1 FUNCTIONAL DESCRIPTION
9.2 PRESSURE INCREASING VALVE
9.3 TENSIONING CYLINDER
9.4 ADJUSTMENTS / CHECKS
9.5 FUNCTIONAL TEST

SECTION 10.0 ACCESS LADDER HYDRAULICALLY OPERATED
TABLE OF CONTENTS SECTION 10.0
GENERAL
10.0 FUNCTION OF HYDRAULIC OPERATED ACCESS LADDER

SECTION 11.0 HYDRAULIC OPERATED REFILLING ARM
TABLE OF CONTENTS SECTION 11.0
GENERAL
11.1 FUNCTION OF HYDRAULIC OPERATED REFILLING ARM

SECTION 12.0 HINTS FOR READING THE HYDRAULIC CIRCUIT DIAGRAM
TABLE OF CONTENTS SECTION 12.0
GENERAL
12.1 SYMBOLS
12.1.1 LINES, UNIONS
12.1.2 COMPONENTS, VALVES
12.1.3 SENSORS
12.1.4 VALVES, VALVE COMPONENTS
12.1.5 PUMP, MOTOR, CYLINDER
12.1.6 ASSEMBLY AND MAIN COMPONENTS

SECTION 13.0 HINTS FOR READING THE ELECTRIC CIRCUIT DIAGRAM
TABLE OF CONTENTS SECTION 13.0
13.1 DESIGNATION OF ELECTRICAL DEVICES
13.2 SYMBOLS
13.3 GENERAL INFORMATION
13.4 READING A CIRCUIT DIAGRAM

SECTION 14.0 ELECTRONIC CONTROL SYSTEM ECS
TABLE OF CONTENTS SECTION 14.0
14.1 GENERAL DESIGN OF THE ECS SYSTEM
14.1.1 INPUT AND OUTPUT OF THE PLC
14.1.2 TASK
14.1.3 PLC DIGSY plus ®
14.1.4 DEFINITIONS; SYMBOLS AND ABBREVIATIONS
14.2 HOW TO PROCEED DUE MAINTENANCE AND INSTALLATION
14.2.1 MEANING OF THE STATUS LED’S
14.2.2 SHORT CIRCUIT MARKER – LED “MK”
14.2.3 DIAGNOSTIC FOR TEMPERATURE-MODULE “ANM”
14.3 FRONT CONNECTOR ARRANGEMENT
14.3.1 FRONT CONNECTOR ARRANGEMENT, BIM MODULE (DIGITAL INPUT/OUTPUT)
14.3.2 FRONT CONNECTOR ARRANGEMENT, ANM-MODULE (ANALOGUES INPUT)
14.3.3 GROUND CONNECTION OF THE CONTROL UNIT
14.3.4 INTERFACE-CONNECTION COM SK / SP
14.4 POWER SUPPLY
14.4.1 OPERATION VOLTAGES +24 V
14.4.2 SAFETY PRECAUTIONS FOR FAULTFINDING
14.4.3 CPU VOLTAGE RANGE
14.4.4 ELECTRIC CLASSIFICATION
14.4.5 FUSE
14.5 FUNCTION EXPLANATIONS WITH ELECTRICAL DIAGRAM
14.5.1 GENERAL
14.5.2 PRESSURE MEASURING (HYDRAULIC SYSTEM)
14.5.3 TEMPERATURE MEASURING AND TROUBLE SHOOTING
14.5.4 TERMPERATURE – RESISTANCE CHART PT100
14.6 HINTS FOR READING THE FUNCTIONAL FLOW CHARTS
14.6.1 GENERAL
14.6.2 EXAMPLE: MONITORING THE X1-PRESSURE FOR PUMP CONTROL

SECTION 15.0 LUBRICATION SYSTEM
TABLE OF CONTENTS
GENERAL FUNCTION
OSCILLATION CYLINDER AND CONTROL BLOCK
ADJUSTMENTS
ONE LINE SYSTEM
ELECTRICAL FUNCTION
CAPACITIVE ANALOG SENSOR FOR LUBRICANT LEVEL MONITORING
ADJUSTMENTS
END LINE SWITCH SETTING
INJECTORS
FUNCTION PINION TYPE (DUMMY WHEEL) SYSTEM
ELECTRICAL FUNCTION
CAPACITIVE ANALOG SENSOR FOR LUBRICANT LEVEL MONITORING
ADJUSTMENTS
END OF LINE SWITCH SETTING
INJECTORS
COMPONENTS
HYDRAULICALLY DRIVEN LUBE PUMP
LUBRICANT INJECTOR
END-LINE SWITCH
IN-LINE FILTER
VENT VALVE

APPENDIX
TABLE OF CONTENTS APPENDIX
CHECK SINGLE MOVEMENTS
MC7 FAULT CODE DIAGNOSTIC

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