Pm-Clinic Service: Inspection Procedure Manual

PM-CLINIC SERVICE
INSPECTION PROCEDURE MANUAL
MEASURING
PC5500-6 E
HYDRAULIC EXCAVATOR
INSTRUCTIONS FOR FILLING OUT PC5500-6
THE PM-CLINIC DATA SHEETS Electro
PM-CLINIC SERVICE
General
In order to ensure a reliable and efficient performance of your KOMATSU
Excavator, the PM-CLINIC SERVICE should be carried out through
authorized KOMATSU Dealer every 1000 operating hours.
Customer’s Benefits Distributor’s Benefits

• Machine condition reports including • Uniform Methods of Gathering
recommendations Information
• Maintenance before major failure • Easy Analysis of Data to Show Trends
- Reduced cost • Reduction and Organisation of Field Data
- Reduced Down-Time • Systematic Analysis with Komatsu
- Maintain high machine availability Criteria
• Reports and graphs with trend analysis • Various reports and graphs
Items which have to be checked

The items which have to be checked during the PM-CLINIC SERVICE are
listed in the attached PM-CLINIC DATA SHEETS.
The measured values have to be entered into the column ”Actual Values” and
confirmed by marking S for satisfied or U for unsatisfied.
Handling of the PM-CLINIC DATA SHEETS

After all items have been checked, fill out the PM-CLINIC DATA SHEETS.
and send the original to our Service Department.
Komatsu Mining Germany GmbH
Department 8151
Buscherhofstraße 10
D - 40570 Düsseldorf
GERMANY
One copy should remain at the customer and one copy should be filed in the
dealer records.
The above field test reports provide the responsible departments with the
relevant information about the performance history of the machine.
Table of contents page

Part I: Instructions for filling out the PM-CLINIC DATA SHEETS 1 to 12
Part II: PM-CLINIC DATA SHEETS 1 to 4
17.07.031 Page 1 of 17 PM_ 5500E_rev1_15016.doc

F • Fill in on each single sheet the Serial No and the Date of Inspection.
Item No of data sheet Sheet Action required

1. Hydraulic Oil 1 Mark the viscosity grade, manufacturer and
trade name of the actual filled in hydraulic oil.
If necessary contact the responsible
maintenance crew.
2. Attachment 1 Mark the installed type of attachment and the
size of boom, stick, and bucket. If necessary
check the machine record for detailed
information.
3. Shoe Width 1 Mark the installed size of track shoes. If
necessary measure the dimension or check the
machine record for detailed information.
4. Kind of Job 1 Mark the kind of job and add additional
information if necessary.
5. Kind of Soil 1 Mark the kind of soil and add additional
information if necessary.
6. Kind of Operation 1 Mark the kind of operation
7. Scheduled Working 1 Mark the scheduled working hours of the
Hours machine:
• Hours per shift and
• Shifts per day and
• Working days per week
8. Machine History 1 Read out the statistics and protocol memory
by using:
• a printer, (refer to section 5 of the
operation manual) or
• by using a computer (refer to Service
Bulletin No 21-538)
Attach the print out, respectively a floppy
disk to the PM-CLINIC DATA SHEET


9. Operator’s Opinion 2 • Before starting the inspection, ask if the operator
detected any abnormality at the machine and fill
in this information if necessary.
• Fill in the current hydraulic oil temperature
during the test.
Normal operating temperature required,
if necessary warm it up.( refer to section 6.2 of
the operation manual)
• Fill in the current ambient temperature during the
test.
• Fill in the approximate altitude.
all nominal values correspond at
Faltitudes up to 1000 meter.
10. Work Equipment 2 Inspect visual the components for cracks and confirm
Crack Check the result by marking
• s = satisfied (no cracks found)
or
• u = unsatisfied (cracks found or assumed)
If cracks are found in the steel construction of
your Excavator, please inform our Service
Department as soon as possible. Attach suitable
information material (photos, catalogue drawings
etc.) showing the location and nature of the crack.
11. PTO Inspection 2 Inspect the pump distributor gear boxes (PTO’s) for
leaks and abnormal noise and confirm the result by
marking
• s = satisfied
or
• u = unsatisfied
If the result is unsatisfied, please attach suitable
information material (photos, catalogue drawings
etc.) showing the location and describe nature of
the abnormality.


12. Cycle Time Inspection 2
• Check throttle valve setting during initial test and write it down. Count the number of turns from
the bottom stop position.
• For all further test’s confirm that the initial setting was not changed.
• Use a stop watch to measure the cycle time.
• Start both motors.
• Select menu item “Power Check” according to operation manual.
• Carry out all tests with empty bucket.
• Rapidly move the control lever to the respective end position (start the stop watch) and hold it
until the final position of the movement is reached.(stop the stop watch).
• Watch the respective pressure and write down the minimum and maximum value.
• Fill in the measured time in the column actual value.
• Confirm the result by marking:
s = satisfied (within the tolerances) or u = unsatisfied (out-of-tolerance)
Boom
FSA BHA
• Stick cylinders completely extended • Stick cylinders completely retracted.
• Bucket parallel to the ground. • Bucket cylinders comp. retracted.
• Lower the boom so, that the bucket is just • Lower the boom so, that the bucket is just
above the ground. above the ground..
2 2
1 1
1. Start Position Boom Raise or Stop Position Boom Lowering
2. Start Position Boom Lowering or Stop Position Boom Raise
Stick
FSA BHA
• Stick cylinders comp. retracted. • Bucket cylinders comp. retracted.
• Lift the boom so, that the bucket is at • Lift the boom so that the bucket have enough
position 3 on the level of the slew ring. clearance to the ground (~1m).
• Bucket parallel to the ground. • Stick cylinders completely extended at pos. 3.
4
4
3 3
3. Start Position Stick Extending or Stop Position Stick Retracting

4. Start Position Stick Retracting or Stop Position Stick Extending


Bucket
FSA BHA
A) • Stick cylinders comp. retracted
• Boom cylinder completely extended • Bucket cylinders comp. retracted.
• Sick and Bucket cylinder completely • Lift the boom so, that the bucket is in
retracted. eye level.
5
6
B)
• Extend the stick cylinder until the
mechanical stop position is obtained.
•
5. Start Position curl or Stop Position dump

6. Start Position dump or Stop Position Curl


Clam (opening and closing)
• Back wall in vertical position.
7. Start Position Clam Open or 8. Stop Position Clam Open or

Stop Position Clam Close. Start Position Clam Close.
Clam (Close):
• Back wall in horizontal position.
10
9
9. Start Position Clam Close 10. Position Clam Close


Swing LH and RH Sprocket LH and RH
• Position of work equipment: Max. reach • Raise one track off the ground,
• Measure time taken to swing for 5 turns, • Let it spin one revolution, then measure
after swinging one turn as an approach the time required for it to spin 5
swing. revolutions.
• Repeat this procedure for the other track.
Swing brake
13. Swing brake 2 • Start both motors.
performance test
• Move equipment to the position as described
below:
• Move the control lever to the respective end
position (L.H. or R.H.) and swing one turn as an
approach swing. Return the control lever rapidly
in neutral position and estimate the angle until the
swing motion stops comp..
• One time without using the foot brake and
secondly by using it.
• Fill in the values in the column actual value.
• Confirm the results by marking
• s = satisfied (within the tolerances) or
u = unsatisfied (out-of-tolerance)
Brake angle
• Position of work equipment: Max. reach


14. Power Check 3
• If the machine is cool, warm it up completely.
F Make sure that the cooler fans are
running with max. speed.
• Start both motors

• Select menu item “Power Check” according to
operation manual.
• Read the following values from the Text-
Display .
M20-1 Alternatively connect suitable pressure gauges
M20-2 to check point M20-1 and M20-2 for X1-1,X1-2
pressure and M12.1, M12.2, M12.3 and M12.4
for the main pump pressure (p1 – p6).
• Motor Current:
• Cooler fans running with max. speed
• Pedals and lever in neutral position
• Make sure that the main pumps in Qmax , (carry
out one function only for a short time to
eliminate the pause time control).
• Read the Motor current from the Text-Display
• Supply Tension:
Read the tension from the analog gauge.
• X1-1, X1-2 Pressure:

Make sure the change over valves (79.1 and
79.2) are in position E (electronic pump
regulation).
• Read the X1-1 and X1-2 pressure.
• Fill in the actual values
• Confirm the result by marking

s = satisfied or
u = unsatisfied


14. Power Check 4 • If the machine is cool, warm it up completely.
F Make sure that the cooler fans are

running with max. speed.
• Make sure the change over valves (79.1 and

79.2) are in position E (electronic pump
regulation).
• Read the following values from the text-display
on the Power Check page.
Alternative connect suitable pressure gauges to
the check point
M20-1 and M20-2 for X1 pressure and M12.1,
M12.2, M12.3 and M12.4 for the main pump
pressure (p1 – p6).
1. Peak value:
• Create max. pressure to all pumps with the
function “bucket curl” in final position.
(all pumps engaged).
• Adjust the Main Relieve Valves (MRV) of
control block I, II, III to the peak value pressure
(nominal value).
• Read the X1-1, X1-2 pressure and the motor
current Imot1, Imot2 (display designation: M1 and
M2).
• Write down the actual values.
2. Electronic Pump Regulation and pressure cut

off check:
• With the same condition as Item 1. Peak value
increase the three MRV’s in steps to 280 bar,
290 bar, 300 bar and finally to the nominal
setting.
• At each step read the X1-1, X1-2 pressure and
the motor current.
• Write down the actual values.
• Confirm the result by marking

s = satisfied or
u = unsatisfied


15. Operating pressure 5 • If the machine is cool, warm it up completely.
Make sure that the cooler fans are
F running with max. speed.
• Start both motors
• Select menu item “Power Check” according to
operation manual.
• Read the following values from the Text-
Display .
Alternatively connect suitable pressure gauges
to the check point M12.1, M12.3 and M12.4
main control valve I, II and III.
Boom, Stick, Bucket and Clam function.
• Extent respectively retract the cylinders of the
selected function completely and hold the
control unit in end position.
• Read the respective pressure.
• Fill in the actual values.
• Confirm the result by marking:
s = satisfied or u = unsatisfied
15. Pilot pressure 5 • Select the analog X2-pressure page in menu

item “Analog input” according to operation
manual.
• Start only one motor. Do the test separately for
both motors.
• Read the “X2-pressure” at the display.
Alternatively Connect a suitable pressure
gauges ( 0 to 60 bar) to test point M3.
• Fill in the actual value.
• Confirm the results by marking:
s = satisfied (within the tolerances) or


16. Back Pressure Valve 5 • If the machine is cool, warm it up completely.
• Connect a suitable pressure gauges
( e.g. 0 to 25bar) to test point M10.
• Make sure that the main pumps in Qmax (eliminate
pause time control).
• Read the “Back-pressure” at the pressure gauge.
• Fill in the actual value.
• Confirm the results by marking:
17. Undercarriage 5 • Move R.H. track group backward respectively

forward, until the contact area sprocket tooth (0) and
the track-pad lug (0) is in the illustrated position and
make a photo.
• Repeat the procedure on the L.H. track group.
• Make a visual inspection at the whole undercarriage
and confirm the results by marking:
Travel forward Travel backward

PC5500-6E
PM-CLINIC DATA SHEET 1 SERVICE 8151
1st Edition 02/2003
Customer Name Location Serial No.
Work Order No. Date of Inspection Inspected By
Engine / Motor model Engine / Motor No Service meter
1. Hydraulic Oil:
VG22 ó VG32 ó VG46 ó VG68 ó VG100 ó Other ......... ó
Manufacturer: Trade name:
2. Attachment:
FSA1) BHA2)
Boom Stick Bucket
FSA FSA FSA
7600 mm ó 5600 mm ó 26.0 m3 ó
.........mm ó ........ mm ó ........m3 ó
BHA BHA BHA
10000 mm ó 5100 mm ó 28.0 m3 ó
...........mm ó .........mm ó ........m3 ó
3. Shoe Width
1350 mm ó
1800 mm ó
4. Kind of Job
Mining ó Other: ó
Quarry ó Aquadigger ó
5. Kind of Soil
Rock: Overburden:
Soft ó Clay ó Other ó
Medium ó Sand ó
Hard ó Soil ó
6. Kind of Operation
7. Scheduled Working Hour

Hours / shift Shifts / day Days / week
8 ó 11 ó 1ó 5ó
9 ó 12 ó 2ó 6ó
10 ó Other................. 3ó 7ó
8. Machine History
Retrieve: PROTOCOL and STATISTICS MEMORY (ETM /ECS)
Floppy disk attached ó
Print out attached ó
1) 2)
FSA = Frond Shovel Attachment BHA = Back Hoe Attachment

PC5500-6E
1st Edition 02/2003
PC5500-6, Electric Drive Serial No. ............... Date of inspection:..................
9. Operator’s Opinion
Before starting, Any abnormality? Current hydraulic oil Temp.: Current Ambient Temp.
T: .............. °C T: .............°C
Altitude: ..............meters
10. Work Equipment Crack Check

Boom: S* ó U** ó Bucket: S* ó U** ó Revolving frame: S* ó U** ó
Stick: S* ó U** ó Carbody S* ó U** ó Track frame: S* ó U** ó Other:.......................
11. PTO Inspection

PTO 1 S* U**
Leaks:
Abnormal noise
PTO 2
Leaks:
Abnormal noise
12. Cycle Time Inspection

Throttle FSA1) BHA2)
Motor 1 & 2 Motor 1 & 2
valve
Movements Rev. Unit Nominal Actual Nominal Actual S* U**
Boom : sec 10,3
Raise Pos.1→2
bar ~ 190
sec 5,3
Lowering Pos.2→1
bar 25
Stick : sec 6,5

Extending Pos.3→4
bar ~100
sec 7,0
Retracting Pos.4→3
bar ~25
Bucket: sec 6,6

Curl Pos.5→6
bar ~80
sec 5,6
Dump Pos.6→5
bar ~180
Clam: sec 3,8

Open Pos.7→8
bar ~180
sec 2,4
Close Pos.8→7
bar ~20
sec 3,6
Close Pos.9→10 ~70
bar
1)
FSA = Frond Shovel Attachment
2)
BHA = Back Hoe Attachment
* S = satisfied ** U = unsatisfied Þ corrective action necessary

PC5500-6E
1st Edition 02/2003
12. Cycle Time Inspection

Item Condition Unit Nominal value Actual value S* U*
*
R.H. Swing: sec 93
5 turns Both motors running
(start counting after 1 bar 100
full turn)
L.H. Swing: sec 93
full turn)
R.H. Sprocket : sec 54
full turn)
L.H. Sprocket: sec 54
full turn)
13. Swing brake performance test

Item Condition Unit Nominal value Actual value S* U*
*
Swing RH Joystick in neutral without °∠ ∠= 80±10°
°∠
Brake angle foot brake
(start counting after 1 full turn)
Swing RH Joystick in neutral & °∠ ∠= 25±10°

°∠
Brake angle activated foot brake
Swing LH Joystick in neutral without °∠ ∠= 80±10°

°∠
Brake angle foot brake
Swing LH Joystick in neutral & °∠ ∠= 25±10°

°∠
Brake angle activated foot brake
14. Power Check

Item Condition Unit Nominal value Actual value S* U**
Current Motor 1 Without load
cooler fan max. RPM, Qmin/ Qmax A I1 = 9 /16 I1 = ................
Current Motor 2 Without load &
cooler fan max. RPM, Qmin/ Qmax A I2 = 9 /16 I2 = ................
Supply tension Without load V U = 6600 U = ................

Frequency Hz ƒ = 50 ƒ =.................
X1-1 pressure Without load bar pX1-1 = 25 p X1-1 =.............
X1-2 pressure Without load bar pX1-2 = 25 p X1-2 =.............

PC5500-6E
1st Edition 02/2003

14. Power Check
Set MRV’s to 212 bar. bar p1/6 = 212 p1/6 =........
(Control block I, II, III) bar p2/5 = 212 p2/5 =........
Both motors running
Stall motors by using only bar p3 = 212 p3 =........
1. Peak value
the bucket filling function. bar p4 = 205 p4 =........
Fill in the other values at A I mot1 = 82 Imot1 =........
this moment.
A I mot2 = 82 Imot2 =........
bar ±0,5
pX1-1 =25± pX1-1 =........
bar ±0,5
pX1-2 =25± pX1-2 =........
1. Set MRV’s to 280 bar. bar p1/6 = 280 p1/6 =........
Both motors running
the bucket filling function bar p4 = 275 p4 =........
fill in the other values at A I mot1 = 82 Imot1 =........
this moment.
A I mot2 = 82 Imot2 =........
bar pX1-1 < 17 pX1-1 =........
bar pX1-2 < 17 pX1-2 =........
2. Set MRV’s to 290 bar. bar p1/6 = 290 p1/6 =........
Both motors running
fill in the other values at A I mot1 < 80 Imot1 =........
this moment.
A I mot2 < 80 Imot2 =........
2. Electronic bar pX1-1 >17 pX1-1 =........
pump
regulation and bar pX1-2 >17 pX1-2 =........
pressure cut 3. Set MRV’s to 300 bar. bar p1/6 = 300 p1/6 =........
off (Control block I, II, III) bar p2/5 = 300 p2/5 =........
Both motors running
fill in the other values at A I mot1 ~ 25 Imot1 =........
this moment.
A I mot2 ~ 25 Imot2 =........
bar ±0,5
pX1-1 =25± pX1-1 =........
bar ±0,5
pX1-2 =25± pX1-2 =........
4. Set MRV’s back to bar p1/6 = 310 p1/6 =........
nominal setting bar p2/5 = 310 p2/5 =........
(310-315 bar).
(Control block I, II, III) bar p3 = 320 p3 =........
Both motors running bar p4 = 310 p4 =........
Stall motors by using only A I mot1 ~ 25 Imot1 =........
the bucket filling function
fill in the other values at A I mot2 ~ 25 Imot2 =........
this moment. bar ±0,5
pX1-1 =25± pX1-1 =........
bar ±0,5
pX1-2 =25± pX1-2 =........

PC5500-6E
1st Edition 02/2003
15. Operating pressure

Boom raise bar 310 - 315
Floating system
deactivated ***
down bar 310 - 315
Stick out bar 310 – 315
Floating system
deactivated ***
in bar 310 – 315
curl bar 310 – 315
Bucket
dump bar 310 – 315
open bar 310 – 315
Clam
close bar 150 – 200
*** “floating” button at the respective lever activated
16. Pilot pressure

X2-pressure Mot. 1 only bar 35 - 38
X2-pressure Mot. 2 only bar 35 - 38
17. Back Pressure Valve

Back-pressure
Motor 1 & Motor 2 bar 8± 1
18. Undercarriage
Travel forward Travel backward S* U**
Sprocket R.H. Please attach Photos
Travel forward Travel backward

Sprocket L.H. Please attach Photos
Track pads Visual inspection

R.H. crawler
Track pads Visual inspection
L.H. crawler
Rollers Visual inspection
R.H. crawler
Rollers Visual inspection
L.H. crawler

PC5500-6E
1st Edition 02/2003
19. Remarks:
Date: Dealer:Signature and Stamp:
Date: Customer: Signature:

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PM-CLINIC SERVICE

INSPECTION PROCEDURE MANUAL

Customer’s Benefits Distributor’s Benefits

Items which have to be checked

Handling of the PM-CLINIC DATA SHEETS

Table of contents page

17.07.031 Page 1 of 17 PM_ 5500E_rev1_15016.doc

Item No of data sheet Sheet Action required

17.07.031 Page 2 of 17 PM_ 5500E_rev1_15016.doc

Item No of data sheet Sheet Action required

17.07.031 Page 3 of 17 PM_ 5500E_rev1_15016.doc

Item No of data sheet Sheet Action required

3. Start Position Stick Extending or Stop Position Stick Retracting

17.07.031 Page 4 of 17 PM_ 5500E_rev1_15016.doc

Item No of data sheet Sheet Action required

5. Start Position curl or Stop Position dump

17.07.031 Page 5 of 17 PM_ 5500E_rev1_15016.doc

Item No of data sheet Sheet Action required

7. Start Position Clam Open or 8. Stop Position Clam Open or

9. Start Position Clam Close 10. Position Clam Close

17.07.031 Page 6 of 17 PM_ 5500E_rev1_15016.doc

Item No of data sheet Sheet Action required

17.07.031 Page 7 of 17 PM_ 5500E_rev1_15016.doc

Item No of data sheet Sheet Action required

• Start both motors

• X1-1, X1-2 Pressure:

• Read the X1-1 and X1-2 pressure.

• Fill in the actual values

• Confirm the result by marking

17.07.031 Page 8 of 17 PM_ 5500E_rev1_15016.doc

Item No of data sheet Sheet Action required

F Make sure that the cooler fans are

• Make sure the change over valves (79.1 and

2. Electronic Pump Regulation and pressure cut

• Confirm the result by marking

17.07.031 Page 9 of 17 PM_ 5500E_rev1_15016.doc

Item No of data sheet Sheet Action required

15. Pilot pressure 5 • Select the analog X2-pressure page in menu

17.07.031 Page 10 of 17 PM_ 5500E_rev1_15016.doc

Item No of data sheet Sheet Action required

17. Undercarriage 5 • Move R.H. track group backward respectively

17.07.031 Page 11 of 17 PM_ 5500E_rev1_15016.doc

Customer Name Location Serial No.

Work Order No. Date of Inspection Inspected By

Engine / Motor model Engine / Motor No Service meter

7. Scheduled Working Hour

17.07.03 Page 12 of 17 PM_ 5500E_rev1_15016.doc

PC5500-6, Electric Drive Serial No. ............... Date of inspection:..................

10. Work Equipment Crack Check

11. PTO Inspection

12. Cycle Time Inspection

Stick : sec 6,5

Bucket: sec 6,6

Clam: sec 3,8

17.07.03 Page 13 of 17 PM_ 5500E_rev1_15016.doc

PC5500-6, Electric Drive Serial No. ............... Date of inspection:..................

12. Cycle Time Inspection

13. Swing brake performance test

Swing RH Joystick in neutral & °∠ ∠= 25±10°

Swing LH Joystick in neutral without °∠ ∠= 80±10°

Swing LH Joystick in neutral & °∠ ∠= 25±10°

14. Power Check

Supply tension Without load V U = 6600 U = ................