HYDRAULIC EXCAVATOR PC5500-6 (SN 15023) Shop Manual

MAIN MENU
COVER
TABLE OF CONTENTS
SAFETY
FOREWORD
1. MAIN ASSEMBLY GROUPS
TABLE OF CONTENTS SECTION 1.0
GENERAL LAY OUT
1.1 SUPERSTRUCTURE
1.2 UNDER CARRIAGE
1.3 ATTACHMENT
2. DRIVE
TABLE OF CONTENTS SECTION 2.0
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
3. 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
4. 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
5. CONTROLLING
TABLE OF CONTENTS SECTION 5.0
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
6. COMPONENTS
TABLE OF CONTENTS SECTION 6.0
6.1.1 MAIN CONTROL BLOCKS AND HIGH PRESSURE FILTER FSA
6.1.2 MAIN CONTROL BLOCKS AND HIGH PRESSURE FILTER BHA
6.1.3 DISTRIBUTOR MANIFOLD-LOCATION OF RESTRICTOR BLOCKS AND ANIT 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
7. MAIN HYDRAULIC PUMPS AND PUMP REGULATION SYSTEM
TABLE OF CONTENTS SECTION 7.0
7.1 MAIN PUMPS
7.2 ELECTRONIC PUMP REGULATION SYSTEM
7.3 HYDRAULIC CONSTANT REGULATION SYSTEM
7.4 DETERMINATION OF THE PEAK POINT (ENGINE PERFORMANCE)
7.5 ENGINE SPEED SENSOR (PICK UP)
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 / HYDRAULIC FLOWCHART “STICK RETRACTING” FSA AUTOR 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)
8.1.12 CHECKS AND ADJUSTMENTS OF THE LOWERING SPEED
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
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
8.3 HYDRAULIC FOR THE TRAVEL CIRCUIT
TABLE OF CONTENTS SECTION 8.3
TRAVEL CIRCUIT
8.3.2 ROTARY DISTRIBUTOR
8.3.3 SIDE FRAME COMPONENTS, CROSS SECTIONS
8.3.4 TRAVEL GEAR AND PARKING BRAKE
8.3.5 PARKING BRAKE
8.3.6 ELECTRIC / HYDRAULIC FLOW CHARTS
8.3.7 ADJUSTMENTS / CHECKS
FUNCTION CHECK OF THE TRAVEL GEAR HOUSE BRAKE
FUNCTION CHECK OF THE PRESSURE SWITCH (B48)
9. HYDRAULIC TRACK TENSIONING SYSTEM
TABLE OF CONTENTS SECTION 9.0
9.0 GENERAL
9.1 FUNCTIONAL DESCRIPTION
9.2 PRESSURE INCREASING VALVE
9.3 TENSIONING CYLINDER
9.4 ADJUSTMENTS / CHECKS
9.5 FUNCTIONAL TEST
10. ACCESS LADDER HYDRAULICALLY OPERATED
TABLE OF CONTENTS SECTION 10.0
GENERAL
10.1 FUNCTION OF HYDRAULIC OPERATED ACCESS LADDER
11. HYDRAULIC OPERATED REFILLING ARM
TABLE OF CONTENTS SECTION 11.0
GENERAL
11.1 FUNCTION OF HYDRAULIC OPERATED REFILLING ARM
12. HINTS FOR READING THE HYDRAULIC CIRCUIT DIAGRAM
TABLE OF CONTENTS SECTION 11.0
12.1 HINTS FOR READING THE CIRCUIT DIAGRAM
12.2 SYMBOLS
13. HINTS FOR READING THE ELECTRIC CIRCUIT DIAGRAM
TABLE OF CONTENTS 13.0
13.1 DESIGNATION OF ELECTRICAL DEVICES
13.2 SYMBOLS
13.3 GENERAL INFORMATION
13.4 READING OF CIRCUIT DIAGRAM
14. VHMS / ECS-T / ETM
TABLE OF CONTENTS SECTION 14.0
14.1 GENERAL DESIGN OF THE ECS-T SYSTEM
14.2 HOW TO PROCEED DUE MAINTENANCE AND INSTALLATION
14.3 FRONT CONNECTOR ARRANGEMENT
14.4 POWER SUPPLY
14.5 FUNCTION EXPLANATIONS WITH ELECTRIC DIAGRAM
14.7 HINTS FOR READING THE FUNCTIONAL FLOW CHARTS
14.8 CABLES AND EXTERNAL MONITORING COMPONENTS
15. LUBRICATION SYSTEMS
TABLE OF CONTENTS SECTION 15.0
GENERAL FUNCTION
OSCILLATION CYLINDER AND CONTROL BLOCK
ADJUSTMENTS
ONE LINE SYSTEM
ELECTRICAL FUNCTION
CAPACITIVE ANALOG SENSOR FOR LUBRICANT LEVEL MONITORING
ADJUSTMENTS
FUNCTION PINION TYPE (DUMMY WHEEL) SYSTEM
CAPACITIVE ANALOG SENSOR FOR LUBRICANT LEVEL MONITORING
ADJUSTMENTS
COMPONENTS
FLOWCHART 894 534 40 – 57 PAGES
FLOWCHART 894 534 40 – PAGE 1 OF 57
FLOWCHART 894 534 40 – PAGE 2 OF 57
FLOWCHART 894 534 40 – PAGE 3 OF 57
FLOWCHART 894 534 40 – PAGE 4 OF 57
FLOWCHART 894 534 40 – PAGE 5 OF 57
FLOWCHART 894 534 40 – PAGE 6 OF 57
FLOWCHART 894 534 40 – PAGE 7 OF 57
FLOWCHART 894 534 40 – PAGE 8 OF 57
FLOWCHART 894 534 40 – PAGE 9 OF 57
FLOWCHART 894 534 40 – PAGE 10 OF 57
FLOWCHART 894 534 40 – PAGE 11 OF 57
FLOWCHART 894 534 40 – PAGE 12 OF 57
FLOWCHART 894 534 40 – PAGE 13 OF 57
FLOWCHART 894 534 40 – PAGE 14 OF 57
FLOWCHART 894 534 40 – PAGE 15 OF 57
FLOWCHART 894 534 40 – PAGE 16 OF 57
FLOWCHART 894 534 40 – PAGE 17 OF 57
FLOWCHART 894 534 40 – PAGE 18 OF 57
FLOWCHART 894 534 40 – PAGE 19 OF 57
FLOWCHART 894 534 40 – PAGE 20 OF 57
FLOWCHART 894 534 40 – PAGE 21 OF 57
FLOWCHART 894 534 40 – PAGE 22 OF 57
FLOWCHART 894 534 40 – PAGE 23 OF 57
FLOWCHART 894 534 40 – PAGE 24 OF 57
FLOWCHART 894 534 40 – PAGE 25 OF 57
FLOWCHART 894 534 40 – PAGE 26 OF 57
FLOWCHART 894 534 40 – PAGE 27 OF 57
FLOWCHART 894 534 40 – PAGE 28 OF 57
FLOWCHART 894 534 40 – PAGE 29 OF 57
FLOWCHART 894 534 40 – PAGE 30 OF 57
FLOWCHART 894 534 40 – PAGE 31 OF 57
FLOWCHART 894 534 40 – PAGE 32 OF 57
FLOWCHART 894 534 40 – PAGE 33 OF 57
FLOWCHART 894 534 40 – PAGE 34 OF 57
FLOWCHART 894 534 40 – PAGE 35 OF 57
FLOWCHART 894 534 40 – PAGE 36 OF 57
FLOWCHART 894 534 40 – PAGE 37 OF 57
FLOWCHART 894 534 40 – PAGE 38 OF 57
FLOWCHART 894 534 40 – PAGE 39 OF 57
FLOWCHART 894 534 40 – PAGE 40 OF 57
FLOWCHART 894 534 40 – PAGE 41 OF 57
FLOWCHART 894 534 40 – PAGE 42 OF 57
FLOWCHART 894 534 40 – PAGE 43 OF 57
FLOWCHART 894 534 40 – PAGE 44 OF 57
FLOWCHART 894 534 40 – PAGE 45 OF 57
FLOWCHART 894 534 40 – PAGE 46 OF 57
FLOWCHART 894 534 40 – PAGE 47 OF 57
FLOWCHART 894 534 40 – PAGE 48 OF 57
FLOWCHART 894 534 40 – PAGE 49 OF 57
FLOWCHART 894 534 40 – PAGE 50 OF 57
FLOWCHART 894 534 40 – PAGE 51 OF 57
FLOWCHART 894 534 40 – PAGE 52 OF 57
FLOWCHART 894 534 40 – PAGE 53 OF 57
FLOWCHART 894 534 40 – PAGE 54 OF 57
FLOWCHART 894 534 40 – PAGE 55 OF 57
FLOWCHART 894 534 40 – PAGE 56 OF 57
FLOWCHART 894 534 40 – PAGE 57 OF 57
HYDRAULIC PLAN 894 533 40 – 11 PAGES
Hydraulic Plan 894 533 40 – 1 OF 11 PAGES
Hydraulic Plan 894 533 40 – 2 OF 11 PAGES
Hydraulic Plan 894 533 40 – 3 OF 11 PAGES
Hydraulic Plan 894 533 40 – 4 OF 11 PAGES
Hydraulic Plan 894 533 40 – 5 OF 11 PAGES
Hydraulic Plan 894 533 40 – 6 OF 11 PAGES
Hydraulic Plan 894 533 40 – 7 OF 11 PAGES
Hydraulic Plan 894 533 40 – 8 OF 11 PAGES
Hydraulic Plan 894 533 40 – 9 OF 11 PAGES
Hydraulic Plan 894 533 40 – 10 OF 11 PAGES
Hydraulic Plan 894 533 40 – 11 OF 11 PAGES
ELECTRIC PLAN 894 535 40 – 72 PAGES
ELECTRIC PLAN 894 535 40 – PAGE 1 OF 72
ELECTRIC PLAN 894 535 40 – PAGE 2 OF 72
ELECTRIC PLAN 894 535 40 – PAGE 3 OF 72
ELECTRIC PLAN 894 535 40 – PAGE 4 OF 72
ELECTRIC PLAN 894 535 40 – PAGE 5 OF 72
ELECTRIC PLAN 894 535 40 – PAGE 6 OF 72
ELECTRIC PLAN 894 535 40 – PAGE 7 OF 72
ELECTRIC PLAN 894 535 40 – PAGE 8 OF 72
ELECTRIC PLAN 894 535 40 – PAGE 9 OF 72
ELECTRIC PLAN 894 535 40 – PAGE 10 OF 72
ELECTRIC PLAN 894 535 40 – PAGE 11 OF 72
ELECTRIC PLAN 894 535 40 – PAGE 12 OF 72
ELECTRIC PLAN 894 535 40 – PAGE 13 OF 72
ELECTRIC PLAN 894 535 40 – PAGE 14 OF 72
ELECTRIC PLAN 894 535 40 – PAGE 15 OF 72
ELECTRIC PLAN 894 535 40 – PAGE 16 OF 72
ELECTRIC PLAN 894 535 40 – PAGE 17 OF 72
ELECTRIC PLAN 894 535 40 – PAGE 18 OF 72
ELECTRIC PLAN 894 535 40 – PAGE 19 OF 72
ELECTRIC PLAN 894 535 40 – PAGE 20 OF 72
ELECTRIC PLAN 894 535 40 – PAGE 21 OF 72
ELECTRIC PLAN 894 535 40 – PAGE 22 OF 72
ELECTRIC PLAN 894 535 40 – PAGE 23 OF 72
ELECTRIC PLAN 894 535 40 – PAGE 24 OF 72
ELECTRIC PLAN 894 535 40 – PAGE 25 OF 72
ELECTRIC PLAN 894 535 40 – PAGE 26 OF 72
ELECTRIC PLAN 894 535 40 – PAGE 27 OF 72
ELECTRIC PLAN 894 535 40 – PAGE 28 OF 72
ELECTRIC PLAN 894 535 40 – PAGE 29 OF 72
ELECTRIC PLAN 894 535 40 – PAGE 30 OF 72
ELECTRIC PLAN 894 535 40 – PAGE 31 OF 72
ELECTRIC PLAN 894 535 40 – PAGE 32 OF 72
ELECTRIC PLAN 894 535 40 – PAGE 33 OF 72
ELECTRIC PLAN 894 535 40 – PAGE 34 OF 72
ELECTRIC PLAN 894 535 40 – PAGE 35 OF 72
ELECTRIC PLAN 894 535 40 – PAGE 36 OF 72
ELECTRIC PLAN 894 535 40 – PAGE 37 OF 72
ELECTRIC PLAN 894 535 40 – PAGE 38 OF 72
ELECTRIC PLAN 894 535 40 – PAGE 39 OF 72
ELECTRIC PLAN 894 535 40 – PAGE 40 OF 72
ELECTRIC PLAN 894 535 40 – PAGE 41 OF 72
ELECTRIC PLAN 894 535 40 – PAGE 42 OF 72
ELECTRIC PLAN 894 535 40 – PAGE 43 OF 72
ELECTRIC PLAN 894 535 40 – PAGE 44 OF 72
ELECTRIC PLAN 894 535 40 – PAGE 45 OF 72
ELECTRIC PLAN 894 535 40 – PAGE 46 OF 72
ELECTRIC PLAN 894 535 40 – PAGE 47 OF 72
ELECTRIC PLAN 894 535 40 – PAGE 48 OF 72
ELECTRIC PLAN 894 535 40 – PAGE 49 OF 72
ELECTRIC PLAN 894 535 40 – PAGE 50 OF 72
ELECTRIC PLAN 894 535 40 – PAGE 51 OF 72
ELECTRIC PLAN 894 535 40 – PAGE 52 OF 72
ELECTRIC PLAN 894 535 40 – PAGE 53 OF 72
ELECTRIC PLAN 894 535 40 – PAGE 54 OF 72
ELECTRIC PLAN 894 535 40 – PAGE 55 OF 72
ELECTRIC PLAN 894 535 40 – PAGE 56 OF 72
ELECTRIC PLAN 894 535 40 – PAGE 57 OF 72
ELECTRIC PLAN 894 535 40 – PAGE 58 OF 72
ELECTRIC PLAN 894 535 40 – PAGE 59 OF 72
ELECTRIC PLAN 894 535 40 – PAGE 60 OF 72
ELECTRIC PLAN 894 535 40 – PAGE 61 OF 72
ELECTRIC PLAN 894 535 40 – PAGE 62 OF 72
ELECTRIC PLAN 894 535 40 – PAGE 63 OF 72
ELECTRIC PLAN 894 535 40 – PAGE 64 OF 72
ELECTRIC PLAN 894 535 40 – PAGE 65 OF 72
ELECTRIC PLAN 894 535 40 – PAGE 66 OF 72
ELECTRIC PLAN 894 535 40 – PAGE 67 OF 72
ELECTRIC PLAN 894 535 40 – PAGE 68 OF 72
ELECTRIC PLAN 894 535 40 – PAGE 69 OF 72
ELECTRIC PLAN 894 535 40 – PAGE 70 OF 72
ELECTRIC PLAN 894 535 40 – PAGE 71 OF 72
ELECTRIC PLAN 894 535 40 – PAGE 72 OF 72