This complete service repair workshop manual PDF download for the PC5500-6 Komatsu 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
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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