Komatsu PC5500-6 Hydraulic Mining Shovel Remove & Replace Procedures Manual – 2009 PDF

Description

Komatsu PC5500-6 Hydraulic Mining Shovel — Remove & Replace Procedures Manual (2009)

This complete Remove & Replace (R&R) Procedures Manual covers the Komatsu PC5500-6 hydraulic mining shovel in exhaustive detail. Published under Version 2009/2, this manual provides the precise removal, replacement, and adjustment procedures for every major component and circuit on the machine — from the twin diesel engines and main hydraulic pumps to the undercarriage, attachment, and operator’s cab. If you maintain, repair, or overhaul a PC5500-6, this is the reference that tells you exactly how the job is done, what to lift, what to torque, and what to watch for.

File Details

• Manual Type: Remove & Replace (R&R) Procedures Manual
• Brand: Komatsu
• Model: PC5500-6
• Language: English
• Page Count: 918
• File Format: PDF
• Edition: Version 2009/2
• Publication Date: 2009

Chapters Covered

• 1. Introduction
• 2. Safety and Standards
• 3. Superstructure
• 4. Undercarriage
• 5. Attachment
• 6. Service Information
• 7. Tools Catalogue
• 8. Parts & Service News
• 9. Supplier’s Documentation

Superstructure — Engines, Hydraulics, and Drivetrain

The Superstructure chapter is the largest section of this PC5500-6 manual, covering the twin SSA 12V 159 Komatsu diesel engines and every major system they drive. You get step-by-step removal and replacement procedures for the front (Engine 2) and rear (Engine 1) diesel engines, including preparatory work, engine torque support and flexible mounts, alternators, batteries, radiator fans, radiators, starter systems, and the Geislinger torsion-type coupling. The hydraulic section walks through main pumps, PTO oil pumps, oil circulation pumps, the pump distributor gearbox (PTO), hydraulic cooler fan drive pumps, hydraulic oil coolers, main relief valves (MRV), pilot oil pumps, main gate valves, the hydraulic oil reservoir, main control valve blocks, service line relief valves (SRV), anti-cavitation valves (ACV), throttle check valves, and the manifold. The slew drive chapter covers slew gears, swing motors, slew parking brakes (both L&S and Siebenhaar types), dynamic slew brakes, swing circle lubrication pinions, and the swing circle itself. Additional sections cover lubrication pumps, the pump controller MC7, the operator’s cab (including cab mounts, front window, seat, ECS, and access ladder), counterweight removal, superstructure lifting, and the fuel tank.

Undercarriage — Travel System and Car Body

The Undercarriage chapter gives you the complete procedure set for the PC5500-6 travel system. This includes changing the track group, removing and replacing the sprocket (including segmented sprocket variants for pinned undercarriage up to SN 025), guide wheels, track tensioning accumulators (low and high pressure), track tension valve blocks, hydraulic hoses of the track tensioning system, travel brake valve blocks (overspeed valve), track tensioning cylinders, travel motors, travel parking brakes, travel gearboxes, carrier rollers, and track rollers. The car body section covers removal and replacement of the car body and crawler carriers for both pinned and bolted undercarriage types, including tightening torque procedures for the crawler carrier mounting bolts, and the rotary joint.

Attachment — Backhoe and Face Shovel

The Attachment chapter is split into two major sections. The Backhoe section covers the boom, stick, bucket, bucket link rod and steering rods, ground engaging tools (GET), hydraulic hoses at the backhoe attachment, and the cylinder bypass test. The Face Shovel section covers using the installation tools for hydraulic cylinders, the boom, stick, bull clam bucket, GET, and hydraulic hoses at the face shovel attachment. You get detailed procedures for removing and replacing boom cylinders, stick cylinders, bucket cylinders, and clam cylinders, along with the specialized tooling required for each.

Service Information, Tools, and Parts News

The Service Information chapter covers fluids and lubricants for both moderate/hot and cold/arctic climates, filling capacities, and work instructions including surface coating with INTERZINC 697 and crawler carrier removal/installation. The Tools Catalogue lists the complete Komatsu tool inventory with part numbers. The Parts & Service News section collects technical bulletins covering swing circle installation, sprocket exchange hints, final drive wear measurements, hydraulic pump bleeding, diesel engine suspension, hydraulic accumulator testing, track group wear measurement, fan bearings, slew gear modifications, GET tooth systems, pilot pressure pumps, counterweight welding, hydraulic pipe vibration, dual cone seal mounting, and more. The Supplier’s Documentation section covers AVANTI HYTORQUE equipment.

Who This Manual Is For

This R&R manual is written for the heavy equipment technician, field service engineer, or maintenance planner working on the PC5500-6 hydraulic mining shovel. It assumes you have the mechanical knowledge to perform major component removal and replacement, and it provides the manufacturer’s exact procedures, lifting weights, special tool part numbers, torque values, and safety warnings you need to do the work correctly. The manual includes weight tables for every major assembly, torque charts according to DIN, conversion tables, blind plug and fitting references, and detailed exploded-view illustrations throughout.

Why Correct Procedures Matter

The PC5500-6 is a 550-ton-class mining shovel with components that weigh thousands of kilograms. An incorrect lifting point, a missed torque sequence, or a misaligned spline can turn a planned component replacement into a catastrophic failure. This manual gives you the manufacturer’s own R&R sequences — the same procedures used by Komatsu-trained technicians — so you can plan the job safely, prepare the right tooling, and complete the work to specification. The manual also flags critical safety points throughout, from hydraulic pressure relief requirements to counterweight gas explosion hazards.

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Instant PDF Delivery — No Shipping, No Waiting

This Komatsu PC5500-6 Remove & Replace Procedures Manual is delivered as an instant PDF download. There is no physical book to ship, no waiting for delivery, and no risk of a damaged or lost package. Once your payment is processed, you can download the complete manual and access it on any device — laptop, tablet, or smartphone. The PDF is printable, so you can print the specific procedures you need for the job and take them into the field or the workshop. Whether you need the full 918-page manual for your service library or just the specific chapter for tomorrow’s component swap, the PDF format gives you immediate access to the information you need.

Don’t risk expensive downtime or component damage by working without the correct procedures. Get the complete Komatsu PC5500-6 Hydraulic Mining Shovel Remove & Replace Procedures Manual today and have the manufacturer’s own removal and replacement sequences at your fingertips.