The document provides information on the drive assembly of a hydraulic mining shovel, including:
1. The drive unit consists of two engines and two pump distributor gears bolted to the power frame, with flexible couplings connecting the engines to the gears.
2. The engine and pump distributor gear mounts include flexible bearings to absorb vibrations, with instructions provided to check the mounts and bearings.
3. The flexible couplings between the engines and gears help reduce torsional vibrations using leaf springs and oil damping.
4. The air filter system includes main and safety filter elements monitored by a maintenance switch.
This service manual section provides information on the prime drive assembly for a hydraulic mining shovel. It includes 3 sentences:
The section describes the engine, coupling, air filter, fan drive, radiator assembly, pump distributor gearbox, hydraulic pump locations and drive speeds. The drive unit consists of two engines and pump distributor gears bolted to the power frame, with flexible couplings connecting the engines to the gears. The section provides maintenance instructions for checking mounts and couplings, replacing worn components, and adjusting clearances.
This service manual provides descriptions of the major systems of the Komatsu PC5500 hydraulic excavator. It describes the construction and functions of the main assembly groups, including:
1. The superstructure, which contains the operator's cab, engines, hydraulic components, fuel and oil reservoirs, and counterweight.
2. The hydraulic oil cooler and radiators that are used to cool engine oil and hydraulic fluid.
3. The fuel tank and hydraulic oil reservoir that supply fuel and hydraulic fluid to the machine.
The manual explains how to find information on specific components and functions, and provides illustrations and part numbers to aid in maintenance and repairs. It is intended to help technicians service the machine safely and effectively
The document is a service manual for a hydraulic mining shovel. It provides instructions for assembly, maintenance, and repair of the machine's major systems. The manual includes sections on technical data, assembly procedures, components, pumps, hydraulics, and electrical systems. Safety notices are provided at the beginning to ensure safe service and repair techniques.
The document is a service manual for a hydraulic mining shovel. It provides instructions for assembly, maintenance, and repair of the machine's major systems. The manual includes sections on technical data, assembly procedures, components, pumps, hydraulics, and other systems. Safety notices are included at the beginning to warn technicians of hazards involved with service and repair work.
Komatsu pc5500 6 hydraulic mining shovel service repair manual (sn 15031 and up)ufjjdjkksdekmd
The document provides a shop manual for a Komatsu PC5500-6 hydraulic mining shovel. It includes safety notices and contents for sections covering the machine's main assembly groups, technical data, assembly procedures, components, hydraulic and electrical systems, lubrication systems, and appendix. The main assembly groups section describes the superstructure, which contains the operator cab, engine house, fuel and hydraulic tanks, cooler, and controls. It also describes the undercarriage and available attachments.
The document provides a shop manual for a PC5500-6 hydraulic mining shovel. It includes:
- Safety notices and general precautions for working on the shovel
- A breakdown of the shovel's main assembly groups including the superstructure, undercarriage, and attachment options
- Sections that will describe the construction and function of the shovel's major systems
This service manual provides descriptions of the major systems of the Komatsu PC5500 hydraulic excavator. It describes the construction and functions of the main assembly groups, including:
1. The superstructure, which contains the operator's cab, engines, hydraulic components, fuel and oil reservoirs, and counterweight.
2. The hydraulic oil cooler and radiators that are used to cool engine oil and hydraulic fluid.
3. The fuel tank and hydraulic ladders that are mounted on the superstructure.
4. Details are given for maintenance, inspections, and adjustments to keep the excavator functioning properly.
This service manual provides descriptions of the major systems of the Komatsu PC5500 hydraulic excavator. It describes the construction and functions of the main assembly groups, including:
1. The superstructure, which contains the operator's cab, engines, hydraulic components, fuel and oil reservoirs, and counterweight.
2. The hydraulic oil cooler and radiators that are used to cool engine oil and hydraulic fluid.
3. The fuel tank and hydraulic oil reservoir that supply fuel and hydraulic fluid to the machine.
4. Additional groups like the cab support, counterweight, and operator's cab with controls.
Detailed illustrations and parts lists are provided to aid in maintenance and repair of the excavator
This service manual section provides information on the prime drive assembly for a hydraulic mining shovel. It includes 3 sentences:
The section describes the engine, coupling, air filter, fan drive, radiator assembly, pump distributor gearbox, hydraulic pump locations and drive speeds. The drive unit consists of two engines and pump distributor gears bolted to the power frame, with flexible couplings connecting the engines to the gears. The section provides maintenance instructions for checking mounts and couplings, replacing worn components, and adjusting clearances.
This service manual provides descriptions of the major systems of the Komatsu PC5500 hydraulic excavator. It describes the construction and functions of the main assembly groups, including:
1. The superstructure, which contains the operator's cab, engines, hydraulic components, fuel and oil reservoirs, and counterweight.
2. The hydraulic oil cooler and radiators that are used to cool engine oil and hydraulic fluid.
3. The fuel tank and hydraulic oil reservoir that supply fuel and hydraulic fluid to the machine.
The manual explains how to find information on specific components and functions, and provides illustrations and part numbers to aid in maintenance and repairs. It is intended to help technicians service the machine safely and effectively
The document is a service manual for a hydraulic mining shovel. It provides instructions for assembly, maintenance, and repair of the machine's major systems. The manual includes sections on technical data, assembly procedures, components, pumps, hydraulics, and electrical systems. Safety notices are provided at the beginning to ensure safe service and repair techniques.
The document is a service manual for a hydraulic mining shovel. It provides instructions for assembly, maintenance, and repair of the machine's major systems. The manual includes sections on technical data, assembly procedures, components, pumps, hydraulics, and other systems. Safety notices are included at the beginning to warn technicians of hazards involved with service and repair work.
Komatsu pc5500 6 hydraulic mining shovel service repair manual (sn 15031 and up)ufjjdjkksdekmd
The document provides a shop manual for a Komatsu PC5500-6 hydraulic mining shovel. It includes safety notices and contents for sections covering the machine's main assembly groups, technical data, assembly procedures, components, hydraulic and electrical systems, lubrication systems, and appendix. The main assembly groups section describes the superstructure, which contains the operator cab, engine house, fuel and hydraulic tanks, cooler, and controls. It also describes the undercarriage and available attachments.
The document provides a shop manual for a PC5500-6 hydraulic mining shovel. It includes:
- Safety notices and general precautions for working on the shovel
- A breakdown of the shovel's main assembly groups including the superstructure, undercarriage, and attachment options
- Sections that will describe the construction and function of the shovel's major systems
This service manual provides descriptions of the major systems of the Komatsu PC5500 hydraulic excavator. It describes the construction and functions of the main assembly groups, including:
1. The superstructure, which contains the operator's cab, engines, hydraulic components, fuel and oil reservoirs, and counterweight.
2. The hydraulic oil cooler and radiators that are used to cool engine oil and hydraulic fluid.
3. The fuel tank and hydraulic ladders that are mounted on the superstructure.
4. Details are given for maintenance, inspections, and adjustments to keep the excavator functioning properly.
This service manual provides descriptions of the major systems of the Komatsu PC5500 hydraulic excavator. It describes the construction and functions of the main assembly groups, including:
1. The superstructure, which contains the operator's cab, engines, hydraulic components, fuel and oil reservoirs, and counterweight.
2. The hydraulic oil cooler and radiators that are used to cool engine oil and hydraulic fluid.
3. The fuel tank and hydraulic oil reservoir that supply fuel and hydraulic fluid to the machine.
4. Additional groups like the cab support, counterweight, and operator's cab with controls.
Detailed illustrations and parts lists are provided to aid in maintenance and repair of the excavator
New holland tt55 tier3 engine, 2 wd tractor service repair manualfujsjejfkskemm
The document is a service manual for tractor models TT55, TT65, and TT75. It contains safety information and instructions for servicing various tractor systems, including the engine, transmission, axles, brakes, hydraulics, steering, wheels, and electrical systems. The manual provides part numbers and diagrams to aid technicians in maintenance and repairs. Safety is emphasized, warning technicians to follow procedures, wear protective equipment, and avoid hazards like operating machinery with the engine running.
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New holland t5050 tractor service repair manualfujsjejfkskemm
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New holland t8.320 continuously variable transmission (cvt) tractor service r...fujsjejfkskemm
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New holland t7.270 auto command tractor service repair manualfujsjejfkskemm
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New holland t7.250 power command tractor service repair manualfujsjejfkskemm
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New holland t7.210 range command tractor service repair manualfujsjejfkskemm
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New holland t7.210 power command tractor service repair manualfujsjejfkskemm
The document is a service manual that provides technical specifications, descriptions of functionality, and troubleshooting information for the hydraulic, pneumatic, electrical, and electronic systems of various tractor models. It includes sections on the primary and secondary hydraulic power systems, hydraulic and pneumatic components, electrical systems, electronics, and fault codes. The primary hydraulic power system section provides specifications for the hydraulic pump and charge pump, as well as descriptions of how the system functions statically for different tractor models.
New holland t5.95 electro command tractor service repair manualfujsjejfkskemm
This service manual provides information for servicing the engine, transmission, axles, brakes, hydraulics and other systems for T5.95, T5.105 and T5.115 Electro Command tractors. It includes specifications, maintenance procedures, troubleshooting and repair instructions in sections dedicated to the different systems. Fluid types and capacities are also provided to aid in maintenance and repairs.
New holland t4.105 v tractor service repair manualfujsjejfkskemm
This document is a service manual for tractor models T4.75N/T4.85N/T4.95N/T4.105N and T4.65V/T4.75V/T4.85V/T4.95V/T4.105V. It contains sections on the engine, transmission, axles, brakes, hydraulics, hitches, steering, wheels, climate control, electrical systems, cab, and safety information. The manual provides repair and maintenance instructions for technicians working on these tractor models.
New holland t4.65 v tractor service repair manualfujsjejfkskemm
This document is a service manual for tractor models T4.75N, T4.85N, T4.95N, T4.105N, T4.65V, T4.75V, T4.85V, T4.95V, and T4.105V. The manual contains information on the engine, clutch, transmission, four-wheel drive system, front and rear axle systems, power take-off, brakes and controls, and hydraulic systems of the tractors. It provides maintenance and repair instructions for technicians working on these systems.
New holland t3.65 f tractor service repair manualfujsjejfkskemm
This document is a service manual that provides information for servicing and repairing T3.50F, T3.55F, T3.65F, and T3.75F tractors. It contains sections on the engine, clutch, transmission, four-wheel drive system, front and rear axle systems, hydrostatic drive, power take-off, brakes and controls, hydraulic systems, steering, wheels, electrical systems, and the operator platform. Safety guidelines are provided at the beginning, advising technicians to follow procedures carefully, use proper safety equipment, and take precautions such as disabling the engine before working.
New holland l218 tier 4 b (final) skid steer loader service repair manual pin...fujsjejfkskemm
This document is a service manual for CNH Industrial's L218 and L220 Tier 4B (final) 200 Series Skid Steer Loaders. It contains over 200 sections covering the engine, front and rear axle systems, hydrostatic drive, brakes, hydraulic systems, frames, wheels, cab climate control, electrical systems, front loader/bucket, platform/cab/bodywork, and safety rules. The manual provides maintenance and repair instructions for qualified dealership personnel and is intended to ensure safe operation and avoid damage to the equipment.
New holland l213 tier 4 b (final) skid steer loader service repair manual pin...fujsjejfkskemm
This document is a service manual for the L213 and L216 200 Series Skid Steer Loaders with Tier 4B engines. It provides information on engine systems, front and rear axle systems, hydrostatic drive systems, brakes and controls, hydraulic systems, frames and ballasting, wheels, cab climate control, electrical systems, front loader and bucket, platform, cab, bodywork and decals. The manual contains part numbers, replacement part numbers, and sections for various components with instructions. Safety rules are provided regarding personal safety and machine safety.
New holland l213 tier 3 skid steer loader service repair manual pin nem459110...fujsjejfkskemm
This document is a service manual for CNH Industrial L213 Tier 3 and L216 Tier 4B 200 Series Skid Steer Loaders that:
- Contains sections on the engine, front and rear axle systems, hydrostatic drive, brakes and controls, hydraulic systems, frames and ballasting, wheels, cab climate control, electrical systems, front loader and bucket, and platform, cab, bodywork, and decals.
- Warns that all repair and maintenance work listed must only be carried out by qualified dealership personnel strictly following the instructions and using special tools, and that anyone performing unauthorized work will be responsible for damages.
- Provides general specifications, capacities, product identification information
New holland e50 bsr mini excavator service repair manualfujsjejfkskemm
This service manual provides maintenance and repair instructions for the E45B SR, E50B SR, and E55B mini excavators. It contains sections covering the engine, hydraulic systems, frames and ballasting, tracks and track suspension, cab climate control, electrical systems, booms, dippers, buckets, dozer blades, and the platform, cab, bodywork and decals. Safety information is provided to ensure personal safety during maintenance and repair.
This document is a service manual for liquid-cooled horizontal crankshaft engines models LH630, LH685, LH750, and LH760. It contains 11 sections covering safety, troubleshooting, various engine systems, disassembly, inspection, and reassembly. Section 1 provides important safety information, including warnings about rotating parts, hot parts, accidental starts, carbon monoxide, electrical shock, hot liquids, explosive gases, flammable solvents, and recommendations for proper oil, coolant, and fuel types.
Fleet management these days is next to impossible without connected vehicle solutions. Why? Well, fleet trackers and accompanying connected vehicle management solutions tend to offer quite a few hard-to-ignore benefits to fleet managers and businesses alike. Let’s check them out!
New holland tt55 tier3 engine, 2 wd tractor service repair manualfujsjejfkskemm
The document is a service manual for tractor models TT55, TT65, and TT75. It contains safety information and instructions for servicing various tractor systems, including the engine, transmission, axles, brakes, hydraulics, steering, wheels, and electrical systems. The manual provides part numbers and diagrams to aid technicians in maintenance and repairs. Safety is emphasized, warning technicians to follow procedures, wear protective equipment, and avoid hazards like operating machinery with the engine running.
New holland tn75 d tractor service repair manualfujsjejfkskemm
This document provides a service manual for TN55D-TN75S tractors. It includes sections on the engine, clutch, transmissions, and other components. Each section provides specifications, diagrams, troubleshooting information, removal and installation instructions, and other maintenance and repair guidance.
New holland t5050 tractor service repair manualfujsjejfkskemm
The document provides information on tractor engines, including general specifications, torque specifications, special tools, and an engine view diagram. It covers topics such as the engine model, cooling system, lubrication system, fuel system, intake and exhaust systems. Key components discussed include the cylinder block, cylinder head, pistons, crankshaft, camshaft, valves and valve train.
New holland t5040 tractor service repair manualfujsjejfkskemm
The document is a service manual for tractor models T5030 through T5070. It contains sections on general guidelines, the engine, clutch, transmissions, drive lines, mechanical transmissions, power take-off, brakes, hydraulic systems, steering, axles and wheels, air conditioning, electrical systems, and platform/bodywork. The manual provides instructions on maintenance, repair work, safety procedures, and notes on parts and tools.
New holland t4030 n tractor service repair manualfujsjejfkskemm
This document is a service manual for tractor models T4030N, T4040N, T4050N, T4060N, T4020V, T4030V, T4040V, and T4050V. It provides the engine type for each tractor model and market region combination, linking the product code to the appropriate engine. The manual contains model year ranges, identification codes, and markets for coverage of the listed tractor models.
New holland t3020 tractor service repair manualfujsjejfkskemm
This document is a service manual for T3010, T3020, T3030, and T3040 tractors. It contains sections on general guidelines, the engine, clutch, transmissions, front and rear mechanical transmissions, power take-off, brakes, hydraulic systems, steering, cab air conditioning, and electrical systems. Each section provides specifications, torque settings, removal and installation instructions, troubleshooting, and disassembly/assembly procedures for maintaining and repairing the components.
New holland t8.320 continuously variable transmission (cvt) tractor service r...fujsjejfkskemm
This document is a service manual for CNH Industrial America LLC tractor models T8.320, T8.350, T8.380, T8.410, and T8.435 from November 2014. It contains over 90 sections covering the engine, transmission, axles, hydraulics, electrical systems, cab, and other components. Each section provides information for maintenance and repair of the corresponding systems.
New holland t7.270 auto command tractor service repair manualfujsjejfkskemm
This document is a service manual for CNH Industrial tractor models T7.230, T7.245, T7.260, and T7.270. It provides specifications and repair instructions for the engine, transmission, axles, hydraulics, electrical systems, and other components. The manual is divided into sections covering specific systems such as the engine, clutch, transmission, front and rear axles, power take-off, brakes, hydraulics, pneumatics, hitches and couplings, frames, steering, wheels, cab climate control, and electrical systems. It also includes a table linking the tractor models to their engines.
New holland t7.250 power command tractor service repair manualfujsjejfkskemm
This document is a service manual for tractor models T7.220, T7.235, T7.250, T7.260, and T7.270. It contains information on engine systems, transmission, 4-wheel drive systems, front and rear axles, power take-off systems, brakes, hydraulic systems, hitches and couplings, frames, steering, wheels, cab climate control, and electrical systems. The manual is intended to assist service technicians in maintaining and repairing components of the tractors.
New holland t7.210 range command tractor service repair manualfujsjejfkskemm
The document is a service manual that provides technical specifications, descriptions of operation, and repair procedures for the hydraulic, pneumatic, electrical, and electronic systems of various tractor models. It includes sections on the primary and secondary hydraulic power systems, hydraulic control systems, pneumatic systems, electrical power systems, electronic systems, and fault codes. The primary hydraulic power system section provides specifications for the hydraulic pump and charge pump, as well as descriptions of how the primary hydraulic system operates with different remote valve configurations.
New holland t7.210 power command tractor service repair manualfujsjejfkskemm
The document is a service manual that provides technical specifications, descriptions of functionality, and troubleshooting information for the hydraulic, pneumatic, electrical, and electronic systems of various tractor models. It includes sections on the primary and secondary hydraulic power systems, hydraulic and pneumatic components, electrical systems, electronics, and fault codes. The primary hydraulic power system section provides specifications for the hydraulic pump and charge pump, as well as descriptions of how the system functions statically for different tractor models.
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New holland t4.65 v tractor service repair manualfujsjejfkskemm
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New holland l218 tier 4 b (final) skid steer loader service repair manual pin...fujsjejfkskemm
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- Contains sections on the engine, front and rear axle systems, hydrostatic drive, brakes and controls, hydraulic systems, frames and ballasting, wheels, cab climate control, electrical systems, front loader and bucket, and platform, cab, bodywork, and decals.
- Warns that all repair and maintenance work listed must only be carried out by qualified dealership personnel strictly following the instructions and using special tools, and that anyone performing unauthorized work will be responsible for damages.
- Provides general specifications, capacities, product identification information
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This document is a service manual for liquid-cooled horizontal crankshaft engines models LH630, LH685, LH750, and LH760. It contains 11 sections covering safety, troubleshooting, various engine systems, disassembly, inspection, and reassembly. Section 1 provides important safety information, including warnings about rotating parts, hot parts, accidental starts, carbon monoxide, electrical shock, hot liquids, explosive gases, flammable solvents, and recommendations for proper oil, coolant, and fuel types.
Fleet management these days is next to impossible without connected vehicle solutions. Why? Well, fleet trackers and accompanying connected vehicle management solutions tend to offer quite a few hard-to-ignore benefits to fleet managers and businesses alike. Let’s check them out!
Ever been troubled by the blinking sign and didn’t know what to do?
Here’s a handy guide to dashboard symbols so that you’ll never be confused again!
Save them for later and save the trouble!
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What Could Be Behind Your Mercedes Sprinter's Power Loss on Uphill RoadsSprinter Gurus
Unlock the secrets behind your Mercedes Sprinter's uphill power loss with our comprehensive presentation. From fuel filter blockages to turbocharger troubles, we uncover the culprits and empower you to reclaim your vehicle's peak performance. Conquer every ascent with confidence and ensure a thrilling journey every time.
The Octavia range embodies the design trend of the Škoda brand: a fusion of
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1. SMPC550015019
Shop
Manual
PC5500-6
HYDRAULIC MINING SHOVEL
SERIAL NUMBERS PC5500-6 15019
This material is proprietary to Komatsu Mining Germany GmbH and is not to be reproduced, used, or disclosed except
in accordance with written authorization from Komatsu Mining Germany GmbH.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to
make changes or improvements at any time without incurring any obligation to install such changes on products
sold previously.
Due to this continuous program of research and development, revisions may be made to this publication. It is
recommended that customers contact their distributor for information on the latest revision.
Copyright 2006 Komatsu
Printed in U.S.A.
Komatsu Mining Germany
August 2006
2. 25.03.03 PC5500_Contents and 00_Foreword_15017.doc
CONTENTS
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. Central refilling system
12. Hints for the hydraulic circuit diagram
13. Hints for the electric circuit diagram
14 VHMS / ECS-T / ETM
15 Lubrication Systems
APPENDIX
F • Each section includes a detailed table of contents.
3. SAFTEY SAFTEY NOTICE
00-1
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SAFETY
SAFETY NOTICE
• IMPORTANT SAFETY NOTICE
Proper service and repair is extremely important for safe machine operation. The
service and repair techniques recommended by Komatsu and described in this manual
are both effective and safe. Some of these techniques require the use of tools specially
designed by Komatsu for the specific purpose.
The following Symbols are used in this Manual to designate Instructions of
particular Importance.
ã
WARNING - Serious personal injury or extensive property damage can
result if the warning instructions are not followed.
To prevent injury to workers, this symbol is used to mark
safety precautions in this manual. The cautions
accompanying these symbols should always be followed
carefully. If any dangerous situation arises or may possibly
arise, first consider safety, and take the necessary actions to
deal with the situation.
CAUTION - Minor personal injury can result or a part, an assembly, or
the shovel can be damaged if the caution instructions are not
followed.
F
NOTE - Refers to special information
GENERAL PRECAUTIONS
Mistakes in operation are extremely dangerous. Read the OPERATION & MAINTENANCE
MANUAL carefully BEFORE operating the machine.
1. Before carrying out any greasing or repairs, read all the precautions given on the decals
which are fixed to the machine.
2. When carrying out any operation, always wear safety shoes and helmet. Do not wear
loose work clothes, or clothes with buttons missing.
• Always wear safety glasses when hitting parts with a hammer.
• Always wear safety glasses when grinding parts with a grinder, etc.
continued
4. SAFTEY SAFTEY NOTICE
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Cont'd:
GENERAL PRECAUTIONS
3. If welding repairs are needed, always have a trained, experienced welder carry out the
work. When carrying out welding work, always wear welding gloves, apron, glasses, cap
and other clothes suited for welding work.
4. When carrying out any operation with two or more workers, always agree on the
operating procedure before starting. Always inform your fellow workers before starting
any step of the operation. Before starting work, hang UNDER REPAIR signs on the
controls in the operator's compartment.
5. Keep all tools in good condition and learn the correct way to use them.
6. Decide a place in the repair workshop to keep tools and removed parts. Always keep the
tools and parts in their correct places. Always keep the work area clean and make sure
that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking.
Never smoke while working.
PREPARATIONS FOR WORK
7. Before adding oil or making repairs, park the machine on hard, level ground, and block
the wheels or tracks to prevent the machine from moving.
8. Before starting work, lower bucket, hammer or any other work equipment to the ground.
If this is not. possible, insert the safety pin or use blocks to prevent the work equipment
from falling. In addition, be sure to lock all the control levers and hang warning signs on
them.
9. When disassembling or assembling, support the machine with blocks, jacks or stands
before starting work.
10. Remove all mud and oil from the steps or other places used to get on and off the machine.
Always use the handrails, ladders or steps when getting on or off the machine. Never
jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a
stand to provide safe footing.
PRECAUTIONS DURING WORK
11. When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs,
loosen them slowly to prevent the oil from spurting out.
Before disconnecting or removing components of the oil, water or air circuits, first
remove the pressure completely from the circuit.
12. The water and oil in the circuits are hot when the engine is stopped, so be careful not to
get burned.
Wait for the oil and water to cool before carrying out work on the oil or water circuits.
continued
5. SAFTEY SAFTEY NOTICE
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Cont'd:
PRECAUTIONS DURING WORK
13. Before starting work, remove the leads from the battery. ALWAYS remove the lead from
the negative (-) terminal first.
14. When raising heavy components, use a hoist or crane.
Check that the wire rope, chains and hooks are free from damage.
Always use lifting equipment which has ample capacity.
Install the lifting equipment at the correct places. Use a hoist or crane and operate slowly
to prevent the component from hitting any other part. Do not work with any part still
raised by the hoist or crane.
15. When removing covers which are under internal pressure or under pressure from a spring,
always leave two bolts in position on opposite sides. Slowly release the pressure, then
slowly loosen the bolts to remove.
16. When removing components, be careful not to break or damage the wiring, Damaged
wiring may cause electrical fires.
17. When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips on to
the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip, or can
even start fires.
18. As a general rule, do not use gasoline to wash parts. In particular, use only the minimum
of gasoline when washing electrical parts.
19. Be sure to assemble all parts again in their original places. Replace any damaged part
with new parts.
• When installing hoses and wires, be sure that they will not be damaged by contact with
other parts when the machine is being operated.
20. When installing high pressure hoses, make sure that they are not twisted. Damaged tubes
are dangerous, so be extremely careful when installing tubes for high pressure circuits.
Also check that connecting parts are correctly installed.
21. When assembling or installing parts, always use the specified tightening torques. When
installing protective parts such as guards, or parts which vibrate violently or rotate at high
speed, be particularly careful to check that they are installed correctly.
22. When aligning two holes, never insert your fingers or hand. Be careful not to get your
fingers caught in a hole.
23. When measuring hydraulic pressure, check that the measuring tool is correctly assembled
before taking any measurements.
24. Take care when removing or installing the tracks of track-type machines. When removing
the track, the track separates suddenly, so never let anyone stand at either end of the track.
6. SAFTEY SAFTEY NOTICE
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25.03.03 PC5500_Contents and 00_Foreword_15017.doc
FOREWORD
GENERAL
With this SERVICE MANUAL KOMATSU provides you with the
description of the construction and the function of the major systems of the
Hydraulic Excavator PC5500.
We describe for you all functions and how to carry out the inspections and
adjustments.
How do you find "your" desired information?
In the table of CONTENT all the functions and components are shown in
their sequence of the description.
If after reading this SERVICE MANUAL you can give us suggestions and
comments for improvements - please do not hesitate to contact us.
Komatsu Mining Germany GmbH
- Service Training -
Postfach 180361
40570 Düsseldorf
Tel.:0211 / 7109 - 206
Fax.:0211 / 74 33 07
The editorial staff will be pleased about your co-operation.
- FROM THE PRACTICE - FOR THE PRACTICE -
F
• This service manual corresponds to the state of development of the
machine at the time the manual was produced.
Variations based on special customers request and special equipment
are not included in this manual
7. Drive Section 2.0
Page 2
2.0 Prime drive assembly
Legend for illustration (Z 22395):
(1) Engine 1
(2) Torsion type coupling
(2) Pump distributor gear (PTO)
(6) Engine 2
(7) Torsion type coupling
(8) Pump distributor gear (PTO)
(5) Power frame
General
The drive unit, consists of the two PTO gear and the two engines, are bolted
to the power frame.
The connection between engine and PTO gear is a flexible coupling.
11. Drive Section 2.0
Page 4
2.1 Engine and PTO mounts
Cont'd
General
The flexible bearings are installed to take the vibrations and the torsion forces
and they carry the total weight of the engine, the pump distributor gear with
all hydraulic pumps.
Check mounting and security of Diesel engine and pump distributor gear,
illustration (Z 21601)
• Check all flexible bearings (1) for engine and pump distributor gear.
Check the flexible bearings for damage and signs of fatigue. Make sure that there
is no contact between the upper and lower metal brackets of the flexible bearings
(1). Replace the bearings if necessary. Use new bolts and self locking nuts (2).
After new flexible bearings have been installed, check distance (B) on both torque
supports.
F
• All flexible bearings (1) and all rubber-bounded metal bars (4) should
be replaced during engine overhaul.
• Check distance (B) between torque support and stop bolt (8).
With setting of the flexible engine bearings (1) the distance (B) increases and must
be readjusted. To do this, loosen lock nut (9) and tighten stop bolt (8) until the
correct distance (B) is obtained. Tighten lock nut (9) and recheck distance (B).
If new flexible engine bearings (1) have been installed, replace also cup springs
(7) and adjust distance (B) to 29 mm.
• Check tie bolts (3) on front and rear carrier units for looseness.
(four tie bolts)
Check to make sure that the self locking retainer nuts (5) are tight and that there is
no gap between nut and rubber-bounded metal bar (4). If necessary retighten
retainer nuts (5) snugly.
Check rubber-bounded metal bars (4) for signs of fatigue and damage.
Replace as necessary.
F
• Check all bolt connections for correct tightening torque.
• Check condition of engine carrier and brackets. If any damages, failures
or wrong condition are found, corrective action must be taken.
• For more information, refer to Parts & Service News REF NO AH01521.
13. Drive Section 2.0
Page 5
2.2 Coupling
Legend for illustration (Z 21602):
(1) Coupling Assy.
(2) Input drive flange
(3) Leave spring assy.
(4) Output drive flange
(5) Dip stick
(6) Bleeder plug
(7) O-Rings
(8) Spacers
E Engine side
G Gearbox side (PTO-side)
Task:
The coupling is the connecting link between the engine and the PTO
Function: "GEISLINGER COUPLING"
The combination of the high elasticity of its leaf springs with complimentary
viscous damping by oil displacement, ensures that the coupling reduces the
intensity of torsional vibrations effectively.
The widest engine speed range free of vibration periods and dangerous
resonance’s is thus obtained.
The springs (3) together with the inner driving and outer driven member form
chambers A and B which are filled with oil.
If the outer member is displaced in relation to the inner member, the
deflection of the leaf springs displaces oil from one chamber to the next, by
this action the relative movements of the two members of the coupling are
braked and the vibrations are dampened.
The spacers (8) limits the movement of the leaf springs.
15. Drive Section 2.0
Page 6
2.3 Air Filter
Legend for illustration (Z 22396):
(1) Wing nut
(2) Washer
(3) Seal ring
(4) Main filter element
(5) Cotter pin
(6) Wing nut with service indicator
(7) Safety element
(8) Maintenance switch
(9) Flap for pre-separator
(10) Air intake with pre-separation
The air is filtered by a dry-air-filter with pre-separator for coarse impurities.
One filter housing includes 2 filter sets. Each one consists of a main filter
element (4) and a safety element (7).
The filter condition is monitored by the maintenance switch (8).
A fault message like „Engine air filter restricted“ is displayed at the
operator's dash board as soon as the restriction is too high.
The wing nut (6) incorporates a service indicator.
Green indication = O.K.
Red indication = safety element (7) needs maintenance.
The indication mark must be re-set by blowing through the nut opposite to the
normal air flow or by sucking at the other end, this can be done with the
mouth.
F • For service intervals and procedure refer to the OPERATION AND
MAINTENANCE MANUAL of the corresponding machine.
17. Drive Section 2.0
Page 7
2.4 Fan drive and radiator assembly
Legend for illustration (Z 22398):
(1) Radiator
(2) Fan motor (Axial piston motor)
(3) Intake air fan
(4) Bearing group carrier
(5) Ball bearings
(6) Breather filter
(7) Oil level plug
(8) Check valve (Anti-cavitation valve)
F • For service intervals and procedure refer to the OPERATION AND
MAINTENANCE MANUAL of the corresponding machine.
continued
19. Drive Section 2.0
Page 8
2.4 Fan drive and radiator assembly
Cont'd
Legend for illustration (Z 22399):
(1) Radiator
(2) Intake air fan
(10.1) Axial piston pump Engine 1 (fixed displacement pump, with
variable setting)
(10.3) Axial piston pump Engine 2 (fixed displacement pump, with
variable setting)
(23.1) Fan motor (Axial piston motor)
(23.2) Fan motor (Axial piston motor)
(41) Main oil reservoir
(168.3) Pressure relief valve – Engine 1 radiator fan drive
(168.4) Pressure relief valve – Engine 2 radiator fan drive
(68.3) Pressure filter with pressure differential switch B21-1 (Engine 1)
(68.5) Pressure filter with pressure differential switch B21-2 (Engine 2)
(103.3) Check valve engine 1– (Anti cavitation valve for fan drive motor)
(103.4) Check valve engine 2– (Anti cavitation valve for fan drive motor)
(148.13) 4/3 direction flow valve – Engine 1 radiator fan speed (stop, low and
high speed)
(148.14) 4/3 direction flow valve – Engine 2 radiator fan speed (stop, low and
high speed)
(169.3) pressure reduction valve (low fan speed adjusting) engine 1
(169.4) pressure reduction valve (low fan speed adjusting) engine 2
(L) Leak oil (case drain) to tank
(P) Pressure to motor
(R) Return oil to tank
Function:
From pump (10.1 / 10.3) flows the oil through the filter (68.3 / 68.5) to the fan
motor (23.1 / 23.2) and then back to the tank.
The check valve (103.3 / 103.4) act as an anti cavitation valve and is installed,
because the fan motor -driven by inertial force- is running for a short period after the
engine has been switched off.
The hydraulic circuit "Fan drive" is secured by the pilot controlled pressure relief
valve (168.3 / 168.4). This valve works together with the 4/3 direction flow valve
continued
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22. Drive Section 2.0
Page 9
Cont'd
(148.13 / 148.14) and the pressure reduction valve (169.1 / 169.4). The 4/3 direction
flow valve (148.13 / 148.14) with the solenoids (Y14A-1 and Y14B-1 / Y14A-2 and
Y14B-2) operates depending on engine coolant temperature.
The PLC (Programmable Logic Control) in the cab support controls the 4/3
direction valve (148.13 / 148.14) by aktivating the solenoids (Y14A-1 and Y14B-1 /
Y14A-2 and Y14B-2), depending on the engine coolant temperature.
With de-energized solenoids the fan turn with max. speed.
With aktivated solenoid (Y14A-1 / Y14A2) the fan is running with a very low
speed, caused by the flow resistance only.
With aktivated solenoid (Y14B-1 / Y14B2) the fan is running with middel seted
speed, caused by the reduced pilot pressure on port X of pressure relief valve (168.3
/ 168.4) with the pressure reduction valve (169.1 / 169.4).