Komatsu PC5500-6 Diesel Hydraulic Excavator Shop Manual – Serial 15046 & Up

Description

Komatsu PC5500-6 Diesel Hydraulic Excavator Shop Manual

This is the complete Komatsu shop manual for the PC5500-6 Diesel hydraulic mining shovel, covering machines from serial number 15046 and up. The document carries the reference number SHOP 15046-upD-GB-0 and is the same body of workshop literature Komatsu Mining Germany assembled for the PC5500-6, split into Operation, Maintenance and Shop volumes. Everything inside is written for the technician working on the machine itself, not for the operator glancing at a decal.

The Komatsu PC5500-6 Diesel Hydraulic Excavator Shop Manual is a large, deeply detailed document. It begins with foreword, designated use and delivery information, moves through the complete safety section, then goes into specifications, structure and function descriptions of every major assembly, the electronic control system, all hydraulic circuits, and closes with troubleshooting and disassembly/assembly procedures. If you own, run or repair a PC5500-6, this manual answers the questions the Operation & Maintenance book cannot.

File Details

• Manual type: Shop Manual (Service / Workshop)
• Brand: Komatsu (Komatsu Mining Germany GmbH)
• Model: PC5500-6 Diesel Hydraulic Excavator
• Document number: SHOP 15046-upD-GB-0
• Serial number coverage: 15046 and up
• Language: English
• File format: PDF
• Approximate page count: 1,350+ pages
• Document parts included: Foreword, Specification, Structure & Function, Troubleshooting, Disassembly & Assembly

Chapters Covered

The Komatsu PC5500-6 shop manual follows the standard Komatsu Mining Germany section numbering system. The main areas of content are:

• 00 Foreword – contents of the binder, division of the binder, designated use of the shovel, delivery of the shovel, explanation of abbreviations
• 2 Safety – safety information, signal words, sound pressure level in the operator’s cab, general precautions common to operation, fire prevention, burn prevention, protective structures, jobsite precautions, engine starting, operation, maintenance precautions, high-pressure fluid precautions, additional safety information for troubleshooting and adjustments, special safety equipment
• 01 Specification – PC5500 capacities, quality and reliability, productivity, cab, advanced hydraulics, diesel engine, easy maintenance, full specification tables, working ranges for backhoe and front shovel attachments, bucket capacities, operating weights, ground pressure, dimensions
• 08 / 10 Structure and Function – main assembly groups, superstructure, undercarriage, attachment (BHA and FSA), prime drive assembly, engine and PTO mounts, coupling (Geislinger and Reish types), air cleaner, fan drive and radiator assembly, radiator fan drive speed adjustment, pump distributor gearbox (PTO), pump spline lubrication, PTO lubrication and cooling, hydraulic pumps and flow rates
• Hydraulic Oil Reservoir – main oil tank and switches/sensors, suction oil tank with strainers, return oil collector tube with strainer, back pressure valve, transfer pump (optional), return and leak oil filter, breather filter
• Hydraulic Oil Cooling – general, function of the hydraulic oil cooling circuit, adjustment of the back pressure valve, fan drive (two-stage cooler fan RPM control), pressure relief valves and solenoid valves, fixed displacement pump with variable setting, radiator fan drive speed adjustment
• Controlling – control and filter panel component locations, pilot pressure supply and adjustments, remote control valves arrangement, function principle of the electro-hydraulic proportional control, potentiometer controls (lever and pedal), proportional amplifier module Type A and Type B, ramp time module, adjustments of amplifier modules, adjusting the amplifiers Type B, adjusting the ramp time module
• Components – main control blocks and high pressure filter (FSA and BHA), distributor manifold and restrictor blocks, restrictor block with pressure relief valve, anti-cavitation valve block, remote control valves, directional solenoid valves, proportional solenoid valves, high pressure filter, control blocks and valves, load holding valve, travel brake valve, pressure reducing valve, pressure increasing valve
• Main Hydraulic Pumps and Pump Regulation System – main pumps location and specifications, pump bearing flushing/lubrication, operating principles, checks and adjustments, electronic pump regulation system (RC4 controller), hydraulic constant regulation system, peak point determination, engine speed sensor adjustment
• Operating Hydraulic – general, floating function of boom and stick cylinders, hydraulic for attachment cylinders, hydraulic for the swing circuit (swing motor, swing gear box, swing parking brake, swing brake valve, swing monitoring system), hydraulic for the travel circuit (travel circuit, rotary distributor, side frame components, travel gear and parking brake)
• Hydraulic Track Tensioning System – general, functional description, pressure increasing valve, tensioning cylinder, adjustments and checks, functional test
• Access Ladder (hydraulically operated) – general, function of the hydraulic operated access ladder
• Hydraulic Operated Refilling Arm – general, function
• Hints for Reading the Hydraulic Circuit Diagram – symbols for lines, unions, components, valves, sensors, pumps, motors, cylinders, assemblies and main components
• Hints for Reading the Electric Circuit Diagram – designation of electrical devices, symbols, general information, reading a circuit diagram
• Electronic Control System ECS – general design of the ECS-T system, inputs and outputs of the PLC, task, PLC DIGSY plus, definitions and abbreviations, maintenance and installation procedures, status LED meanings, short circuit marker LED, diagnostic for temperature module ANM, front connector arrangements (BIM and ANM modules), power supply, function explanations with electrical diagram, pressure measuring, temperature measuring, temperature-resistance chart PT100, hints for reading functional flow charts
• Lubrication System – general function, oscillation cylinder and control block, adjustments, one-line system, electrical function, capacitive analog sensor for lubricant level monitoring, end-of-line switch setting, injectors, pinion type (dummy wheel) system, hydraulically driven lube pump, in-line filter, vent valve
• 40 Troubleshooting – troubleshooting procedures
• 50 Disassembly and Assembly – full component removal and replacement procedures covering superstructure (engines, alternator, batteries, radiator fan, radiators, starter, Geislinger coupling, PTO, main pumps, hydraulics, slew drive, lubrication pumps, pump controller MC7, operator’s cab, counterweight, superstructure lifting, fuel tank), undercarriage (travel system, sprocket, guide wheels, track tensioning accumulators, travel brake valve, travel motors, travel parking brake, travel gearbox, carrier roller, track roller, car body, rotary joint), and attachment (backhoe and face shovel boom, stick, bucket, cylinders, link rods, steering rods, GET, hydraulic hoses, metering valves, cylinder bypass test)
• Service Information – fluids and lubricants for moderate/hot climates and cold/arctic climates, filling capacities, work instructions (surface coating with Interzinc 697, remove/install crawler carrier), used special tools overview
• Tools Catalogue – assembly tools for screws and nuts, pliers, metal working tools, measuring tools, data transfer and IT tools, other tools, paint and accessories, auxiliaries/cleaner/adhesive & sealant
• PARTS & SERVICE NEWS index – AH00511, AH00514, AH00515, AH00519, AH01513, AH01521, AH01531, AH02513, AH02521, AH03506, AH03509, AH03510, AH03511, AH03512, AH04518, AH05501, AH05510, AH05511, AH05520, AH05525, AH05535, AH05546, AH06524, AH06529, AH06530, AH06542, AH06543, AH06545, AH07509, AH07526, AH08503, AH08504, AH08507, AH08508
• Supplier’s Documentation – Avanti Hytorque

What that list means in practice is that a PC5500-6 technician has every major subsystem of the shovel described at component level. The Komatsu PC5500-6 shop manual explains how the hydraulic pumps regulate themselves under load, how the ECS PLC reads sensors and drives proportional valves, how the two-stage hydraulic oil cooler fans are speed-controlled, how the PTO gearbox is lubricated and cooled, how the swing motors change displacement based on operating pressure, how the track tensioning accumulators absorb shock, and how the boom and stick floating function works on the front shovel attachment. It is not a summary. It is the source document.

Engines and Systems Covered

The PC5500-6 Diesel is powered by two Komatsu SSA12V159 four-cycle, water-cooled, direct-injection, turbocharged and aftercooled diesel engines, each rated at 940 kW (1260 HP) at 1800 rpm. An optional US Tier 2 version is listed as two Komatsu SDA12V159E-2 engines with the same output rating. Both are covered in this shop manual. The hydraulic side is an open-circuit system fed by six swash-plate axial piston main pumps plus auxiliary gear pumps for pilot pressure, PTO lubrication, hydraulic oil circulation and fan drives. The manual documents the pump regulation system in detail, including the RC4-4 microcontroller, the X1, X2, X3 and X4 pressures, and the electronic load limiting control that keeps engine speed at rated rpm.

Why This Shop Manual Matters

Mining shovels of this size are not repaired by guesswork. The Komatsu PC5500-6 Diesel service manual gives the exact relief valve settings, the pump start-of-destroking pressures, the swing brake release pressures, the PTO lube pressure ranges, the track tensioning accumulator pre-charge values, the torque figures for the slew ring, crawler carrier and counterweight bolts, and the measuring methods for setting them. Without this document a technician has no reliable way to confirm that a hydraulic circuit is set correctly or that a torque figure is safe. With it, the machine can be serviced, adjusted and repaired to the same standard as a factory-trained specialist working from the original literature.

The troubleshooting and disassembly/assembly sections are particularly useful. They describe how to remove the diesel engines, the PTO gearboxes, the main pumps, the slew gears, the swing motors, the travel gearboxes, the swing circle, the operator’s cab, the counterweight and the entire front shovel or backhoe attachment. They also cover the hydraulic hose routes at the attachment, the metering valve (grease injector) replacement, and the cylinder bypass test for checking internal leakage. Each procedure is written with the weights and lifting points a rigger needs.

Who This Manual Is For

This Komatsu PC5500-6 workshop manual suits mine maintenance planners, field service technicians, workshop mechanics, hydraulic specialists, electricians working on the ECS PLC and electrical circuits, and owner-operators of PC5500-6 shovels who want the full factory service information on hand. It is also a practical reference for training departments that need to teach PC5500-6 systems from the original source rather than from third-party summaries.

Get Instant Access to the PC5500-6 Shop Manual

Every job this manual supports — engine removal, PTO rebuild, main pump adjustment, swing and travel brake service, track tensioning setup, ECS diagnostics, hydraulic circuit troubleshooting, attachment cylinder rebuilds and complete component replacement — is covered from the perspective of the technician performing the work. Correct procedures and correct specifications are what keep a 531 to 549 tonne shovel productive instead of parked. The Komatsu PC5500-6 Diesel Hydraulic Excavator Shop Manual delivers that information in one document.

IMAGES PREVIEW

Delivery is instant. The file is a PDF supplied for download immediately after payment, with no shipping, no waiting and no physical media. It opens on desktop computers, laptops, tablets and smartphones, and can be printed in whole or in part for use in the workshop. Keep it on a service laptop, a tablet in the cab base, or a printed binder in the tool crib — whichever suits the way your team works.