HYDRAULIC EXCAVATOR PC5500-6 (1503115035 & UP) Shop Manual

MAIN MENU
COVER
CONTENTS – TABLE OF CONTENTS
SAFETY
FOREWORD
SECTION 1.0 MAIN ASSEMBLY GROUPS
TABLE OF CONTENTS SECTION 1.0
GENERAL LAYOUT
1.1 SUPERSTRUCTURE
1.2 UNDER CARRIAGE
1.3 ATTACHMENT
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
7.2 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)
SECTION 8.0 OPERATING HYDRAULIC
TABLE OF CONTENTS SECTION 8.0
8.0 GENERAL
8.1 HYDRAULIC FOR THE ATTACHMENT CYLINDERS
8.2 HYDRAULIC FOR THE SWING CIRCUIT
8.3 HYDRAULIC FOR THE TRAVEL CIRCUIT
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
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
14.2 HOW TO PROCEED DUE MAINTENANCE AND INSTALLATION
14.3 FRONT CONNECTOR ARRANGEMENT
14.4 POWER SUPPLY
14.5 FUNCTION EXPLANATIONS WITH ELECTRICAL DIAGRAM
14.6 HINTS FOR READING THE FUNCTIONAL FLOW CHARTS
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
FUNCTION PINION TYPE (DUMMY WHEEL) SYSTEM
ELECTRICAL FUNCTION
CAPACITIVE ANALOG SENSOR FOR LUBRICANT LEVEL MONITORING
ADJUSTMENTS
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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