Hydraulic Mining Shovel: Remove & Replace Procedures

Remove & Replace Procedures
R & R Procedures
PC5500-6
HYDRAULIC MINING SHOVEL
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 add improvements at any time without incurring any obligation to install
such changes on products sold previously.
Due to this continous program of research and development, periodic revisions may be made to this
publication. It is recommended that customer contact their distributor for information on the latest
revision.
Version 2009/2
Copyright 2008
Overview
Overview
1 INTRODUCTION
2 SAFETY AND STANDARDS
3 SUPERSTRUCTURE
4 UNDERCARRIAGE
5 ATTACHMENT
6 SERVICE INFORMATION
7 TOOLS CATALOGUE
8 PARTS & SERVICE NEWS
9 SUPPLIERS DOCUMENTATION
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Overview - 1
Overview
Overview - 2
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Version 2009/2
Table of contents
Table of contents
1 INTRODUCTION........................................................................................ 1-1
1.1
CONTENTS OF THE BINDER ........................................................................................................... 1-2
1.2
FOREWORD ...................................................................................................................................... 1-3

1.2.1 SERVICE ............................................................................................................................... 1-4
2 SAFETY AND STANDARDS ..................................................................... 2-1

2.1
SAFETY INSTRUCTIONS.................................................................................................................. 2-2

2.1.1 METHOD OF USING THIS MANUAL .................................................................................... 2-2
2.1.2 GENERAL PRECAUTIONS ................................................................................................... 2-4
2.1.3 PREPARATIONS FOR WORK .............................................................................................. 2-5
2.1.4 PRECAUTIONS DURING WORK.......................................................................................... 2-6
2.1.5 WARNING OF SPECIAL DANGERS..................................................................................... 2-8
2.1.5.1 ELECTRICAL ENERGY ......................................................................................... 2-8
2.1.5.2 GAS, DUST, STEAM AND SMOKE ....................................................................... 2-9
2.1.5.3 HYDRAULIC, AIR CONDITIONING AND PNEUMATIC EQUIPMENT................ 2-10
2.1.5.4 NOISE .................................................................................................................. 2-10
2.1.5.5 HEAT.................................................................................................................... 2-11
2.1.5.6 OIL, GREASE AND OTHER CHEMICAL SUBSTANCES ................................... 2-11
2.1.5.7 HEIGHT................................................................................................................ 2-11
2.1.6 SPECIAL SAFETY EQUIPMENT ........................................................................................ 2-13
2.1.6.1 SAFETY HARNESS IN CONFORMITY WITH EN 361
(EUROPEAN STANDARD) .................................................................................. 2-13
2.1.6.2 INSTRUCTIONS FOR USE ................................................................................. 2-15
2.1.6.3 RECOMMENDATIONS FOR USE OF THE HOLDING HOOKS AND
HOLD-BACK HOOKS OF THE SAFETY HARNESS........................................... 2-17
2.1.6.4 INSTARUCTIONS FOR USING THE FALL ABSORBER .................................... 2-19
2.1.7 SAFETY HINTS FOR HYDRAULIC HOSE INSTALLATION ............................................... 2-20
2.1.8 SAFETY HINTS FOR LIFTING HEAVY PARTS.................................................................. 2-23
2.1.9 SAFETY HINTS FOR WIRE ROPES................................................................................... 2-23
2.1.10 SAFETY HINTS FOR SLING ACCESSORY ....................................................................... 2-25
2.1.11 WEIGHT TABLES ................................................................................................................ 2-26
2.1.11.1 SUPERSTRUCTURE........................................................................................... 2-26
2.1.11.2 UNDERCARRIAGE.............................................................................................. 2-29
2.1.11.3 BACKHOE ATTACHMENT (BHA) ....................................................................... 2-31
2.1.11.4 FACE SHOVEL ATTACHMENT (FSA) ................................................................ 2-32
2.2
TORQUE CHARTS ACCORDING TO DIN ......................................................................................

2.2.1 METRIC STANDARD THREAD...........................................................................................
2.2.2 METRIC FINE THREAD ......................................................................................................
2.2.3 CUMMINS MOTOR TORQUES - METRIC..........................................................................
2.2.4 CUMMINS MOTOR TORQUES - U.S. CUSTOMARY.........................................................
2.2.5 SAE FLANGE CONNECTIONS ...........................................................................................
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2.3
BLIND PLUGS .................................................................................................................................

2.3.1 DUMMY PLATES FOR SAE-FLANGES ..............................................................................
2.3.2 CLASSIFICATION OF THREADS TO THE NOMINAL WIDTH ...........................................
2.3.3 PLUGS AND FITTINGS ACCORDING TO DIN 2353..........................................................
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2.4
CONVERSION TABLE.....................................................................................................................
2.4.1 METHOD OF USING THE CONVERSION TABLE .............................................................
2.4.2 MILLIMETER - INCH & KILOGRAM - POUND ....................................................................
2.4.3 LITER - U.S. GALLON & LITER - U.K. GALLON.................................................................
2.4.4 NM - FT.LB...........................................................................................................................
2.4.5 BAR - PSI / PSI - BAR .........................................................................................................
2.4.6 BASIC VALUES IN OHM ACCORDING TO DIN 43 76 .......................................................
2.4.7 TEMPERATURE ..................................................................................................................
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2.5
TOOLS.............................................................................................................................................. 2-48
2.5.1 STANDARD TOOL CASE.................................................................................................... 2-48
2.6
EXPLANATION OF ABBREVIATIONS ........................................................................................... 2-50
3 SUPERSTRUCTURE................................................................................. 3-1
3.1
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DIESEL ENGINE ................................................................................................................................ 3-2

3.1.1 REMOVAL OF THE DIESEL ENGINES ................................................................................ 3-2
3.1.1.1 PREPARATORY WORK FOR DIESEL ENGINES REMOVAL .............................. 3-2
3.1.1.2 REMOVAL OF THE FRONT DIESEL ENGINE (ENGINE 2) ................................. 3-7
3.1.1.3 REPLACEMENT OF THE FRONT DIESEL ENGINE (ENGINE 2) ...................... 3-11
3.1.1.4 REMOVAL OF THE REAR DIESEL ENGINE (ENGINE 1).................................. 3-14
3.1.1.5 REPLACEMENT OF THE REAR DIESEL ENGINE (ENGINE 1) ........................ 3-14
3.1.2 ENGINE TORQUE SUPPORT AND ENGINE/PTO MOUNTS ............................................ 3-16
3.1.2.1 FLEXIBLE MOUNTS ............................................................................................ 3-17
3.1.2.2 TORQUE SUPPORT............................................................................................ 3-19
3.1.3 ALTERNATOR ..................................................................................................................... 3-20
3.1.3.1 REMOVAL OF THE ALTERNATOR .................................................................... 3-20
3.1.3.2 REPLACEMENT OF THE ALTERNATOR ........................................................... 3-21
3.1.4 BATTERIES ......................................................................................................................... 3-22
3.1.4.1 REMOVAL OF THE BATTERIES......................................................................... 3-22
3.1.4.2 REPLACEMENT OF THE BATTERIES ............................................................... 3-24
3.1.5 RADIATOR FAN .................................................................................................................. 3-26
3.1.5.1 REMOVAL OF THE RADIATOR FAN ASSEMBLY ............................................. 3-27
3.1.5.2 REPLACEMENT OF THE RADIATOR FAN ASSEMBLY .................................... 3-31
3.1.5.3 REMOVAL OF THE RADIATOR FAN.................................................................. 3-33
3.1.5.4 REPLACEMENT OF THE RADIATOR FAN ........................................................ 3-33
3.1.5.5 REMOVAL OF THE RADIATOR FAN DRIVE PUMP .......................................... 3-34
3.1.5.6 REPLACEMENT OF THE RADIATOR FAN DRIVE PUMP ................................. 3-36
3.1.6 RADIATORS ........................................................................................................................ 3-38
3.1.6.1 REMOVAL OF THE RADIATOR ASSEMBLY...................................................... 3-38
3.1.6.2 REPLACEMENT OF THE RADIATOR ASSEMBLY ............................................ 3-41
3.1.7 STARTER SYSTEM............................................................................................................. 3-42
3.1.7.1 REMOVAL OF THE STARTER MOTOR ............................................................. 3-42
3.1.7.2 REPLACEMENT OF THE STARTER MOTOR .................................................... 3-43
3.1.8 TORSION TYPE COUPLING (GEISLINGER) ..................................................................... 3-44
3.1.8.1 REMOVAL OF THE GEISLINGER COUPLING................................................... 3-45
3.1.8.2 REPLACEMENT OF THE GEISLINGER COUPLING ......................................... 3-49
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3.2
PTO ..................................................................................................................................................
3.2.1 MAIN PUMPS ......................................................................................................................
3.2.1.1 PREPARATORY WORKS FOR MAIN PUMP REMOVAL ...................................
3.2.1.2 REMOVAL OF MAIN PUMPS..............................................................................
3.2.1.3 REPLACEMENT OF MAIN PUMPS ....................................................................
3.2.2 PTO OIL PUMP (AUXILIARY PUMP) ..................................................................................
3.2.2.1 REMOVAL OF PTO OIL PUMP (AUXILIARY PUMP) .........................................
3.2.2.2 REPLACEMENT OF THE PTO OIL PUMP (AUXILIARY PUMP) ........................
3.2.3 OIL CIRCULATION PUMP (AUXILIARY PUMP) .................................................................
3.2.3.1 REMOVAL OF OIL CIRCULATION PUMP (AUXILIARY PUMP) ........................
3.2.3.2 REPLACEMENT OF THE OIL CIRCULATION PUMP (AUXILIARY PUMP) .......
3.2.4 PUMP DISTRIBUTOR GEARBOX (PTO)............................................................................
3.2.4.1 REMOVAL OF THE PUMP DISTRIBUTOR GEARBOX (PTO) ...........................
3.2.4.2 REPLACEMENT OF THE PUMP DISTRIBUTOR GEARBOX (PTO)..................
3.3
HYDRAULICS .................................................................................................................................. 3-71

3.3.1 HYDRAULIC COOLER FAN DRIVE PUMP ........................................................................ 3-71
3.3.1.1 REMOVAL OF THE HYDRAULIC COOLER FAN DRIVE PUMP ........................ 3-72
3.3.1.2 REPLACEMENT OF THE HYDRAULIC COOLER FAN DRIVE PUMP .............. 3-75
3.3.2 HYDRAULIC COOLER FAN ASSEMBLY ........................................................................... 3-76
3.3.2.1 REMOVAL OF HYDRAULIC COOLER FAN ASSEMBLY ................................... 3-77
3.3.2.2 REPLACEMENT OF HYDRAULIC COOLER FAN ASSEMBLY.......................... 3-80
3.3.2.3 REMOVAL OF HYDRAULIC COOLER FAN AND MOTOR ................................ 3-82
3.3.2.4 REPLACEMENT OF HYDRAULIC COOLER FAN AND MOTOR ....................... 3-84
3.3.3 HYDRAULIC OIL COOLERS ............................................................................................... 3-86
3.3.3.1 REMOVAL OF THE HYDRAULIC OIL COOLERS .............................................. 3-88
3.3.3.2 REPLACEMENT OF THE HYDRAULIC OIL COOLERS ..................................... 3-92
3.3.3.3 REMOVAL OF THE HYDRAULIC OIL COOLER FRAME ................................... 3-94
3.3.3.4 REPLACEMENT OF THE HYDRAULIC OIL COOLER FRAME.......................... 3-98
3.3.4 MAIN RELIEF VALVES (MRV) ............................................................................................ 3-99
3.3.4.1 REMOVAL OF THE MRV .................................................................................... 3-99
3.3.4.2 REPLACEMENT OF THE MRV ........................................................................ 3-100
3.3.5 PILOT OIL PUMP (GEAR PUMP) ..................................................................................... 3-101
3.3.5.1 REMOVAL OF THE PILOT OIL PUMP .............................................................. 3-101
3.3.5.2 REPLACEMENT OF THE PILOT OIL PUMP .................................................... 3-103
3.3.6 MAIN GATE VALVE........................................................................................................... 3-104
3.3.6.1 REMOVAL OF THE MAIN GATE VALVE .......................................................... 3-104
3.3.6.2 REPLACEMENT OF THE MAIN GATE VALVE................................................. 3-105
3.3.7 HYDRAULIC OIL RESERVOIR ......................................................................................... 3-106
3.3.7.1 REMOVAL OF THE HYDRAULIC OIL RESERVOIR......................................... 3-108
3.3.7.2 REPLACEMENT OF THE HYDRAULIC OIL RESERVOIR ............................... 3-114
3.3.8 MAIN CONTROL VALVE BLOCKS ................................................................................... 3-117
3.3.8.1 REMOVAL OF THE MAIN CONTROL VALVE BLOCKS................................... 3-126
3.3.8.2 REPLACEMENT OF THE MAIN CONTROL VALVE BLOCKS ......................... 3-132
3.3.9 SERVICE LINE RELIEF VALVES (SRV) ........................................................................... 3-133
3.3.9.1 REMOVAL OF SRV ON MAIN CONTROL VALVE BLOCK .............................. 3-133
3.3.9.2 REPLACEMENT OF SRV ON MAIN CONTROL VALVE BLOCKS................... 3-136
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3.3.10 ANTI-CAVITATION VALVES (ACV) .................................................................................

3.3.10.1 REMOVAL OF ACV ON MANIFOLD .................................................................
3.3.10.2 REPLACEMENT OF THE ACV ON MANIFOLD................................................
3.3.10.3 REMOVAL OF ACV ON MAIN CONTROL VALVE BLOCKS ............................
3.3.10.4 REPLACEMENT OF ACV ON MAIN CONTROL VALVE BLOCKS...................
3.3.11 THROTTLE CHECK VALVES ...........................................................................................
3.3.11.1 REMOVAL OF THROTTLE CHECK VALVES ...................................................
3.3.11.2 REPLACEMENT OF THROTTLE CHECK VALVES..........................................
3.3.12 MANIFOLD.........................................................................................................................
3.3.12.1 REMOVAL OF THE MANIFOLD ........................................................................
3.3.12.2 REPLACEMENT OF THE MANIFOLD...............................................................
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3-150
3-152
3-155
3-156
3-156
3-158
3.4
SLEW DRIVE..................................................................................................................................
3.4.1 SLEW GEAR......................................................................................................................
3.4.1.1 REMOVAL OF THE SLEW GEAR .....................................................................
3.4.1.2 REPLACEMENT OF THE SLEW GEAR............................................................
3.4.2 SWING MOTOR.................................................................................................................
3.4.2.1 REMOVAL OF THE SWING MOTOR ................................................................
3.4.2.2 REPLACEMENT OF THE SWING MOTOR.......................................................
3.4.3 SLEW PARKING BRAKE...................................................................................................
3.4.3.1 REMOVAL/DISASSEMBLY OF THE SLEW PARKING BRAKE (L&S) .............
3.4.3.2 REPLACEMENT/ASSEMBLY OF THE SLEW PARKING BRAKE (L&S) ..........
3.4.3.3 REMOVAL OF THE SLEW PARKING BRAKE (SIEBENHAAR) .......................
3.4.3.4 REPLACEMENT OF THE SLEW PARKING BRAKE (SIEBENHAAR) ..............
3.4.4 DYNAMIC SLEW BRAKE ..................................................................................................
3.4.4.1 REMOVAL OF THE SLEW BRAKE VALVE.......................................................
3.4.4.2 REPLACEMENT OF THE SLEW BRAKE VALVE .............................................
3.4.5 SWING CIRCLE LUBRICATION PINION (DUMMY WHEEL) ...........................................
3.4.5.1 REMOVAL OF THE LUBRICATION PINION ASSEMBLY.................................
3.4.5.2 REPLACEMENT OF THE LUBRICATION PINION ASSEMBLY .......................
3.4.6 SWING CIRCLE.................................................................................................................
3.4.6.1 REMOVAL OF THE SWING CIRCLE ................................................................
3.4.6.2 REPLACEMENT OF THE SWING CIRCLE.......................................................
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3-198
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3.5
LUBRICATION PUMPS ................................................................................................................. 3-212

3.5.1 REMOVAL OF THE LUBRICATION PUMP....................................................................... 3-214
3.5.2 REPLACEMENT OF THE LUBRICATION PUMP ............................................................. 3-216
3.6
PUMP CONTROLLER MC7 ........................................................................................................... 3-217

3.6.1 REMOVAL OF THE PUMP CONTROLLER MC7.............................................................. 3-217
3.6.2 REPLACEMENT OF THE PUMP CONTROLLER MC7 .................................................... 3-217
3.7
OPERATORS CAB .......................................................................................................................

3.7.1 REMOVAL OF THE OPERATORS CAB...........................................................................
3.7.2 REPLACEMENT OF THE OPERATORS CAB .................................................................
3.7.3 CAB-MOUNTS ...................................................................................................................
3.7.3.1 REMOVAL OF THE CAB-MOUNTS ..................................................................
3.7.3.2 REPLACEMENT OF THE CAB-MOUNTS .........................................................
3.7.4 FRONT WINDOW (WINDSCREEN) ..................................................................................
3.7.4.1 REMOVAL OF THE FRONT WINDOW .............................................................
3.7.4.2 REPLACEMENT OF THE FRONT WINDOW ....................................................
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3.7.5
3.7.6
3.7.7
3.7.8
3.7.9
OPERATORS SEAT .........................................................................................................

3.7.5.1 REMOVAL OF THE OPERATORS SEAT.........................................................
3.7.5.2 REPLACEMENT OF THE OPERATORS SEAT ...............................................
ECS....................................................................................................................................
3.7.6.1 REMOVAL OF THE ECS TEXT DISPLAY.........................................................
3.7.6.2 REPLACEMENT OF THE ECS TEXT DISPLAY ...............................................
ACCESS LADDER.............................................................................................................
3.7.7.1 REMOVAL OF THE ACCESS LADDER ............................................................
3.7.7.2 REPLACEMENT OF THE ACCESS LADDER...................................................
3.7.7.3 REMOVAL OF THE ACCESS LADDER CYLINDER .........................................
3.7.7.4 REPLACEMENT OF THE ACCESS LADDER CYLINDER ...............................
REMOVAL OF THE CAB BASE ........................................................................................
REPLACEMENT OF THE CAB BASE ...............................................................................
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3.8
COUNTERWEIGHT........................................................................................................................ 3-252
3.8.1 REMOVAL OF THE COUNTERWEIGHT .......................................................................... 3-253
3.8.2 REPLACEMENT OF THE COUNTERWEIGHT................................................................. 3-255
3.9
SUPERSTRUCTURE LIFTING ...................................................................................................... 3-257

3.9.1 REMOVE THE SUPERSTRUCTURE FROM THE UNDERCARRIAGE ........................... 3-257
3.9.2 INSTALL THE SUPERSTRUCTURE ONTO THE UNDERCARRIAGE............................. 3-261
3.10 FUEL TANK ................................................................................................................................... 3-264

3.10.1 REMOVAL OF THE FUEL TANK ...................................................................................... 3-265
3.10.2 REPLACEMENT OF THE FUEL TANK ............................................................................. 3-269
4 UNDERCARRIAGE.................................................................................... 4-1
4.1
TRAVEL SYSTEM.............................................................................................................................. 4-2

4.1.1 TRACK GROUP..................................................................................................................... 4-2
4.1.1.1 CHANGING OF THE TRACK GROUP .................................................................. 4-2
4.1.2 SPROCKET ........................................................................................................................... 4-7
4.1.2.1 REMOVAL OF THE SPROCKET........................................................................... 4-7
4.1.2.2 REPLACEMENT OF THE SPROCKET ............................................................... 4-12
4.1.2.3 REMOVAL OF THE SEGMENTED SPROCKET
(ONLY FOR TYPE WITH PINNED UNDERCARRIAGE UP TO SN 025)............ 4-14
4.1.2.4 REPLACEMENT OF THE SEGMENTED SPROCKET
(ONLY FOR TYPE WITH PINNED UNDERCARRIAGE UP TO SN 025)............ 4-18
4.1.3 GUIDE WHEELS ................................................................................................................. 4-20
4.1.3.1 REMOVAL OF THE GUIDE WHEEL ASSEMBLY ............................................... 4-20
4.1.3.2 REPLACEMENT OF THE GUIDE WHEEL ASSEMBLY ..................................... 4-22
4.1.4 TRACK TENSIONING ACCUMULATORS .......................................................................... 4-23
4.1.4.1 REMOVAL OF THE LOW PRESSURE ACCUMULATORS ................................ 4-23
4.1.4.2 REPLACEMENT OF THE LOW PRESSURE ACCUMULATORS ....................... 4-25
4.1.4.3 REMOVAL OF THE HIGH PRESSURE ACCUMULATORS ............................... 4-26
4.1.4.4 REPLACEMENT OF THE HIGH PRESSURE ACCUMULATORS ...................... 4-27
4.1.5 TRACK TENSION VALVE BLOCK ...................................................................................... 4-28
4.1.5.1 REMOVAL OF THE TRACK TENSIONING VALVE BLOCK ............................... 4-28
4.1.5.2 REPLACEMENT OF THE TRACK TENSIONING VALVE BLOCK...................... 4-29
4.1.6 HYDRAULIC HOSES OF THE TRACK TENSIONING SYSTEM ........................................ 4-31
4.1.6.1 SUBSTITUTE THE HYDRAULIC HOSES ........................................................... 4-31
4.1.7 TRAVEL BRAKE VALVE BLOCK (OVERSPEED VALVE).................................................. 4-34
4.1.7.1 REMOVAL OF THE TRAVEL BRAKE VALVE BLOCK ....................................... 4-35
4.1.7.2 REPLACEMENT OF THE TRAVEL BRAKE VALVE BLOCK .............................. 4-37
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4.1.8
TRACK TENSIONING CYLINDERS ....................................................................................

4.1.8.1 REMOVAL OF THE TRACK TENSIONING CYLINDERS ...................................
4.1.8.2 REPLACEMENT OF THE TRACK TENSIONING CYLINDERS ..........................
TRAVEL MOTOR.................................................................................................................
4.1.9.1 REMOVAL OF THE TRAVEL MOTORS..............................................................
4.1.9.2 REPLACEMENT OF THE TRAVEL MOTORS ....................................................
TRAVEL PARKING BRAKE.................................................................................................
4.1.10.1 REMOVAL OF THE TRAVEL PARKING BRAKE ................................................
4.1.10.2 REPLACEMENT OF THE TRAVEL PARKING BRAKE.......................................
TRAVEL GEARBOX ............................................................................................................
4.1.11.1 REMOVAL OF THE TRAVEL GEARBOX............................................................
4.1.11.2 REPLACEMENT OF THE TRAVEL GEARBOX ..................................................
4.1.11.3 REMOVAL OF THE TRAVEL GEARBOX
(ONLY FOR TYPE WITH PINNED UNDERCARRIAGE UP TO SN 025) ............
4.1.11.4 REPLACEMENT OF THE TRAVEL GEARBOX
(ONLY FOR TYPE WITH PINNED UNDERCARRIAGE UP TO SN 025) ............
CARRIER ROLLER..............................................................................................................
4.1.12.1 REMOVAL OF THE CARRIER ROLLER ASSEMBLY.........................................
4.1.12.2 REPLACEMENT OF THE CARRIER ROLLER ASSEMBLY ...............................
TRACK ROLLER..................................................................................................................
4.1.13.1 REMOVAL OF THE TRACK ROLLER ASSEMBLY.............................................
4.1.13.2 REPLACEMENT OF THE TRACK ROLLER ASSEMBLY ...................................
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CAR BODY.......................................................................................................................................
4.2.1 REMOVAL OF THE CAR BODY AND THE CRAWLER CARRIERS
(TYPE WITH PINNED UNDERCARRIAGE) ........................................................................
4.2.2 REPLACEMENT OF THE CAR BODY AND THE CRAWLER CARRIERS
(TYPE WITH PINNED UNDERCARRIAGE) ........................................................................
4.2.3 REMOVAL OF THE CAR BODY AND THE CRAWLER CARRIERS
(TYPE WITH BOLTED UNDERCARRIAGE) .......................................................................
4.2.4 REPLACEMENT OF THE CAR BODY AND THE CRAWLER CARRIERS
(TYPE WITH BOLTED UNDERCARRIAGE) .......................................................................
4.2.4.1 TIGHTENING TORQUE FOR THE CRAWLER CARRIER MOUNTING BOLTS
4.2.5 ROTARY JOINT...................................................................................................................
4.2.5.1 REMOVAL OF THE ROTARY JOINT ..................................................................
4.2.5.2 REPLACEMENT OF THE ROTARY JOINT .........................................................
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4.1.11
4.1.12
4.1.13
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5 ATTACHMENT........................................................................................... 5-1
5.1
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BACKHOE.......................................................................................................................................... 5-2
5.1.1 BOOM .................................................................................................................................... 5-4
5.1.1.1 REMOVAL OF THE BOOM.................................................................................... 5-4
5.1.1.2 REPLACEMENT OF THE BOOM .......................................................................... 5-8
5.1.1.3 REMOVAL OF BOOM CYLINDERS .................................................................... 5-10
5.1.1.4 REPLACEMENT OF BOOM CYLINDERS........................................................... 5-16
5.1.2 STICK................................................................................................................................... 5-20
5.1.2.1 REMOVAL OF THE STICK .................................................................................. 5-20
5.1.2.2 REPLACEMENT OF THE STICK......................................................................... 5-24
5.1.2.3 REMOVAL OF STICK CYLINDERS..................................................................... 5-26
5.1.2.4 REPLACEMENT OF STICK CYLINDERS ........................................................... 5-32
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5.1.3
5.1.4
5.1.5
5.1.6
BUCKET ..............................................................................................................................
5.1.3.1 REMOVAL OF THE BUCKET..............................................................................
5.1.3.2 REPLACEMENT OF THE BUCKET ....................................................................
5.1.3.3 REMOVAL OF BUCKET CYLINDERS ................................................................
5.1.3.4 REPLACEMENT OF BUCKET CYLINDERS .......................................................
BUCKET LINK ROD AND STEERING RODS .....................................................................
5.1.4.1 REMOVAL OF THE BUCKET LINK ROD ............................................................
5.1.4.2 REPLACEMENT OF THE BUCKET LINK ROD ..................................................
5.1.4.3 REMOVAL OF THE STEERING RODS...............................................................
5.1.4.4 REPLACEMENT OF THE STEERING RODS .....................................................
GROUND ENGAGING TOOLS (GET).................................................................................
5.1.5.1 REMOVAL AND REPLACEMENT OF THE GET ................................................
HYDRAULIC HOSES AT THE BACKHOE ATTACHMENT.................................................
5.1.6.1 SUBSTITUTE THE BOOM ARC HOSES ............................................................
5.1.6.2 SUBSTITUTE THE BOOM CYLINDER HOSES ..................................................
5.1.6.3 SUBSTITUTE THE STICK CYLINDER HOSES ..................................................
5.1.6.4 SUBSTITUTE THE BUCKET CYLINDER HOSES ..............................................
5-36
5-36
5-39
5-40
5-46
5-49
5-49
5-51
5-52
5-55
5-56
5-57
5-58
5-58
5-62
5-66
5-70
5.2
FACE SHOVEL ................................................................................................................................ 5-74

5.2.1 USING THE INSTALLATION TOOLS FOR HYDRAULIC CYLINDERS.............................. 5-75
5.2.2 BOOM .................................................................................................................................. 5-76
5.2.2.1 REMOVAL OF THE BOOM ................................................................................. 5-76
5.2.2.2 REPLACEMENT OF THE BOOM ........................................................................ 5-81
5.2.2.3 REMOVAL OF THE BOOM CYLINDERS ............................................................ 5-86
5.2.2.4 REPLACEMENT OF THE BOOM CYLINDERS .................................................. 5-91
5.2.3 STICK .................................................................................................................................. 5-94
5.2.3.1 REMOVAL OF THE STICK.................................................................................. 5-94
5.2.3.2 REPLACEMENT OF THE STICK ........................................................................ 5-98
5.2.3.3 REMOVAL OF THE STICK CYLINDERS .......................................................... 5-100
5.2.3.4 REPLACEMENT OF THE STICK CYLINDERS ................................................. 5-105
5.2.4 BULL CLAM BUCKET ....................................................................................................... 5-108
5.2.4.1 REMOVAL OF THE BULL CLAM BUCKET ....................................................... 5-110
5.2.4.2 REPLACEMENT OF THE BULL CLAM BUCKET ............................................. 5-114
5.2.4.3 REMOVAL OF THE BUCKET CYLINDERS ...................................................... 5-116
5.2.4.4 REPLACEMENT OF THE BUCKET CYLINDERS ............................................. 5-121
5.2.4.5 REMOVAL OF THE CLAM CYLINDERS ........................................................... 5-124
5.2.4.6 REPLACEMENT OF THE CLAM CYLINDERS ................................................. 5-129
5.2.5 GROUND ENGAGING TOOLS (GET)............................................................................... 5-132
5.2.5.1 REMOVAL AND REPLACEMENT OF THE GET .............................................. 5-133
5.2.6 HYDRAULIC HOSES AT THE FACE SHOVEL ATTACHMENT ....................................... 5-134
5.2.6.1 SUBSTITUTE THE BOOM ARC HOSES .......................................................... 5-134
5.2.6.2 SUBSTITUTE THE BOOM CYLINDER HOSES ................................................ 5-138
5.2.6.3 SUBSTITUTE THE STICK ARC HOSES ........................................................... 5-142
5.2.6.4 SUBSTITUTE THE STICK CYLINDER HOSES ................................................ 5-146
5.2.6.5 SUBSTITUTE THE BUCKET CYLINDER HOSES ............................................ 5-150
5.2.6.6 SUBSTITUTE THE CLAM CYLINDER HOSES ................................................. 5-154
5.3
METERING VALVES (GREASE INJECTORS) AT THE ATTACHMENT ..................................... 5-162

5.3.1 REMOVAL OF THE METERING VALVES (GREASE INJECTORS)................................. 5-162
5.3.2 REPLACEMENT OF THE METERING VALVES (GREASE INJECTORS) ....................... 5-163
5.4
CYLINDER BYPASS TEST ........................................................................................................... 5-164
Version 2009/2
PC5500-6
TOC - 7
Table of contents
6 SERVICE INFORMATION ......................................................................... 6-1

6.1
FLUIDS AND LUBRICANTS.............................................................................................................. 6-2

6.1.1 LUBRICANTS FOR OPERATION IN MODERATE AND HOT CLIMATES ........................... 6-2
6.1.2 LUBRICANTS FOR OPERATION IN COLD AND ARCTIC CLIMATES ................................ 6-4
6.2
FILLING CAPACITIES ....................................................................................................................... 6-5
6.3
WORK INSTRUCTIONS..................................................................................................................... 6-7

6.3.1 SURFACE COATING WITH INTERZINC 697 ....................................................................... 6-7
6.3.2 REMOVE / INSTALL THE CRAWLER CARRIER.................................................................. 6-9
6.4
USED SPECIAL TOOLS (OVERVIEW) ........................................................................................... 6-10
7 TOOLS CATALOGUE ................................................................................ 7-1

8 PARTS & SERVICE NEWS ....................................................................... 8-1
AH00511
Installation procedure for the swing circle / Slew Ring (SR)
AH00514
Track group - Hints for sprocket exchange
AH00515
Final drive: Wear and tear measurements Mounting procedures
AH00519
Adhesive lubricants for the Slew Ring Gear
AH01513
Bleeding of hydraulic pumps
AH01521
Diesel engine suspension
AH01531
Hydraulic accumulators - testing and refilling
AH02513
Testing wear and tear of swing circle bearing
AH02521
Track group wear measurement
AH03506
Hydraulic oil cooler and water cooler fan bearings
AH03509
Slew gear GFB 174 E 9017 (Part No. 917 915 40)
AH03510
ESCO bucket tooth system
AH03511
Pilot Pressure Pump Part No. 907 209 40
AH03512
Gear Pumps (Part Nos. 907 209 40; 906 442 40; 896 730 40 and 654 930 40
AH04518
Welding procedure for welded counterweight
AH05501
Abnormal vibration on hydraulic pipes
AH05510
Bearing flushing of the A4VS variable displacement axial piston pump
AH05511
Dual cone seal ring mounting
TOC - 8
PC5500-6
Version 2009/2
Table of contents
AH05520
Installation hints for a new type of pilot pump
AH05525
Suction elbows of the Main Pumps
AH05535
Hints for replacing by the slewing gear of an other manufacturer
AH05546
Automatic lubrication system - Vent valve (PN 769 879 73)
AH06524
Hydraulic cylinder
AH06529
AH06530
Relieving of the track chain tension
AH06542
Swash plate pump H-A4VSO500
AH06543
Gear pumps PN 907 622 40 and PN 940 048 40 (supplied from the company Kracht) (Pilot pressure pump;
gear oil pump; circulation pump)
AH06545
Hydraulic cylinder bushings
AH07509
Swing brake manufactured by "Siebenhaar" (Swing gear PN 902 550 40 and PN 925 864 40)
AH07526
Bolted undercarriage: Protective coating on the flange plates
AH08503
Track drive
AH08504
Windscreen
AH08507
Steel structure
AH08508
Bushings of the attachment and at the undercarriage
9 SUPPLIERS DOCUMENTATION ............................................................. 9-1

AVANTI HYTORQUE
Version 2009/2
PC5500-6
TOC - 9
Table of contents
TOC - 10
PC5500-6
Version 2009/2
Introduction
1 INTRODUCTION
Version 2009/2
PC5500-6
1 -1
Contents of the binder
1.1
Introduction
CONTENTS OF THE BINDER
Assembled in this file are the R&R Procedures with explanations

of removing, installing, and adjustments of the major components
and circuits for your KOMATSU Hydraulic Mining Shovel.
1 -2
PC5500-6
Version 2009/2
Introduction
1.2
Foreword
FOREWORD
Observe the instructions in this manual for:

z
Your Personal SAFETY
Operating SAFETY, and
READY and EFFICIENT PERFORMANCE of your

KOMATSU Hydraulic Mining Shovel.
With this R&R Procedures Manual, KOMATSU provides you with

the description of proper removal and replacement procedures of
main components.
How do you find "your" desired information?

In the TABLE OF CONTENTS all R&R PROCEDURES are
shown in their sequence of description.
CAUTION
Periodic preventive inspections and maintenance are the
surest means of keeping the machine in proper working
order. Prompt detection and correction of minor irregularities
and immediate replacement of worn out or broken parts will
prevent failures and avoid expenses.
Replace damaged graphics and symbols.

Observe safety precautions to prevent injury and damage.
If, after reading this R&R Procedures Manual, you can give us
suggestions and comments for improvements - please do not
hesitate to contact us.
Komatsu Mining Germany GmbH

Service Training and Manuals
Department 8151.30
P.O. Box 18 03 61
D - 40570 Dsseldorf
GERMANY
Version 2009/2
PC5500-6
1 -3
Foreword
Introduction
WARNING
Personnel entrusted with work on the machine must have
read the section 2 SAFETY AND STANDARDS before beginning work. Reading the instructions after work has begun is
too late.
Damages and defects caused by incorrect operation and maintenance are not covered by the manufacturers guarantee.
In order to keep your shovel in first-class operating condition only
use genuine spare and wear parts.
The use of any part other than the genuine part releases the
KOMATSU MINING GERMANY GmbH from any guarantee.
1.2.1
SERVICE
In all your written or phoned inquiries, please indicate the model

and serial number of your shovel.
1 -4
PC5500-6
Version 2009/2
Safety and Standards
2 SAFETY AND STANDARDS
Version 2009/2
PC5500-6
2 -1
Safety Instructions
2.1
SAFETY INSTRUCTIONS
2.1.1
METHOD OF USING THIS MANUAL
When removing or installing a unit assembly, the order of

work and techniques used are given for the removal procedure. The order of work for the installation is only given if the
installation procedure differs from installation in reverse order
of removal, for example any special technique needs to be
applied.
Tightening torques according to DIN are not explicitly given in

the installation procedures.
For tightening torques according to DIN, refer to section 2.2
on page 2-33.
Figure references that appear in the operation procedures

use the format (Fig. 4-12, Pos. 4), which means position number 4 in figure 12 of section 4.
Special requirements such as listing of special tools or size or

numbers of blind plugs etc. are listed in a table at the beginning of each operation procedure.
Special tools that appear in the lists are given with part name,
part number, and quantity
(2 x thread protector, PN 409 329 40).
For the special tools list, refer to section 6.4 on page 6-10.
The following symbols are used in the manual to designate

additional information:
Kind and amount of drained fluids
(e.g. drain oil, 1500 liters).
Lifting weight of an assembly (e.g. 140 kg).
Kind and amount of fluids to fill
(e.g. fill oil, 1500 liters).
Special tightening torques for bolts etc., if not
according to DIN, refer to section 2.2 on page 2-33
(e.g. 129 Nm).
General information concerning a section, e.g.
tightening torques according to DIN, refer to section
2.2 on page 2-33.
Special authorized personnel is required.
All PARTS & SERVICE NEWS which are mentioned in the procedures are listed in chapter 8. The numbers of the PARTS & SERVICE NEWS do not label the latest edition. Ensure that the latest
edition is always filed to the binder of this manual.
2 -2
PC5500-6
Version 2009/2
Safety Instructions
The following symbols and designations are used in the manual to designate instructions of particular importance:
DANGER
Refers to orders and prohibitions designed to prevent serious injury or death.
WARNING
Refers to orders and prohibitions designed to prevent injury
or extensive damage.
CAUTION
Refers to special information and/or orders and prohibitions
directed towards preventing damage.
NOTE: Refers to special information on removing or installing

assemblies, for example if any special technique needs
to be applied.
Version 2009/2
PC5500-6
2 -3
Safety Instructions
2.1.2
GENERAL PRECAUTIONS
CAUTION
Proper service and repair is important for safe machine operation. The service and repair techniques recommended by
Komatsu Mining Germany and described in this manual are
both effective and safe. Some of these techniques require
the use of tools specially designed by Komatsu Mining Germany for the specific purpose.
NOTE: Always attend to local regulations regarding the Personal

Protective Equipment.
WARNING
z
Mistakes in operation and service are extremely dangerous. Read the OPERATION & MAINTENANCE MANUAL
carefully BEFORE operating the machine.
Before carrying out any greasing or repairs, read all the

precautions given on the decals which are fixed to the
machine.
When carrying out any operation, always wear safety

shoes and a 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.
Assure fire prevention according to the Operation &

Maintenance Manual.
If welding repairs are needed, refer to the welding precautions given in the Operation & Maintenance Manual.
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
cab.
Keep all tools in good condition and learn the correct

way to use them.
Decide on 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.
2 -4
PC5500-6
Version 2009/2
Safety Instructions
DANGER
Danger of explosion!
Serious injury, permanent disfigurement, and scarring may
result!
Special care must be taken before welding, flame-cutting,
and grinding operations are carried out on the counterweight. The filling of the counterweight chambers can create
explosive gases which will accumulate in the chambers of
the counterweight. These gases must be expelled before
welding, flame-cutting, and grinding operations are carried
out on the counterweight.
Follow the instructions given in PARTS & SERVICE NEWS
No. "AH04518" for expelling the gases from the counterweight chambers.
2.1.3
PREPARATIONS FOR WORK

WARNING
Before adding oil or making repairs, park the machine on

hard, level ground large enough to accommodate the
machine, boom, and additional working equipment
(crane mobile working platforms, forklift etc.).
If the ground condition is too poor to guarantee safe and

stable stand of the machine and the additional working
equipment (crane mobile working platforms, forklift etc.),
make sure that the machine is moved to a place with
appropriate ground conditions.
Block the tracks to prevent the machine from moving.
Before starting work, lower bucket, hammer, or any other

work equipment to the ground. If this procedure is not
possible, insert the safety pin or use blocks to prevent
the work equipment from falling. Additionally, be sure to
lock all the control levers and hang warning signs on
them.
When disassembling or assembling, support the

machine with blocks, jacks, or stands before starting
work.
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.
Version 2009/2
PC5500-6
2 -5
Safety Instructions
2.1.4
PRECAUTIONS DURING WORK

WARNING
When removing the oil filler cap, drain plug, or hydraulic

pressure measuring plugs, loosen them slowly to prevent the oil from spurting out. The water and oil in the circuits are hot when the engine is stopped, so be careful
not to get burnt. Wait for the oil and water to cool before
carrying out work on the oil or water circuits.
Before starting work, isolate the machine according to

local regulations.
Remove the leads from the battery. ALWAYS remove the
lead from the negative (-) terminal first.
When raising heavy components (25 kg or more), 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.
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.
When removing components, be careful not to break or

damage the wiring. Damaged wiring may cause electrical
fires.
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.
As a general rule, do not use gasoline to wash parts.
Be sure to assemble all parts in their original places

again. Replace any damaged parts with new parts.
2 -6
PC5500-6
Version 2009/2
Safety Instructions
WARNING
z
When installing hoses and wires, be sure that they will

not be damaged by contact with other parts when the
machine is being operated.
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.
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.
When aligning two holes, never insert your fingers or

hand. Be careful not to get your fingers caught in a hole.
Version 2009/2
PC5500-6
2 -7
Safety Instructions
2.1.5
WARNING OF SPECIAL DANGERS
2.1.5.1 ELECTRICAL ENERGY

WARNING
z
Use only original fuses and circuit breakers with the

specified current rating. Switch off the machine immediately if trouble occurs in the electrical system.
When working with the machine, maintain a safe distance

from overhead electric lines. If work is to be carried out
close to overhead lines, the working equipment must be
kept well away from them. Caution, danger! Check out
the prescribed safety distances.
If your machine comes into contact with a live wire:

z
do not leave the machine
drive the machine out of the hazard zone
warn others against approaching and touching the

machine
have the live wire de-energized
do not leave the machine until the damaged line has

been safely de-energized.
Work on the electrical system or equipment may only be

carried out by a skilled electrician himself or by specially
instructed personnel under the control and supervision
of such electrician and in accordance with the applicable
electrical engineering rules.
If provided for in the regulations, the power supply to

parts of the machine, on which inspection, maintenance,
and repair work is to be carried out must be cut off.
Before starting any work, check the de-energized parts
for the presence of power and ground or short-circuit
them in addition to insulating adjacent live parts and elements.
The electrical equipment of the machine is to be

inspected and checked at regular intervals. Defects such
as loose connections or scorched cables must be rectified immediately.
2 -8
PC5500-6
Version 2009/2
Safety Instructions
WARNING
z
Necessary work on live parts and elements must be carried out only in the presence of a second person who can
cut off the power supply in case of danger by actuating
the emergency shut-off or main power switch. Secure the
working area with a red-and-white safety chain and a
warning sign. Use insulated tools only.
Before starting work on high-voltage assemblies and

after cutting off the power supply, the feeder cable must
be grounded and components such as capacitors shortcircuited with a grounding rod.
2.1.5.2 GAS, DUST, STEAM AND SMOKE

WARNING
z
Operate internal combustion engines and fuel operated

heating systems only on adequately ventilated premises.
Before starting the machine on enclosed premises, make
sure that there is sufficient ventilation.
Observe the regulations in force at the respective site.
Carry out welding, flame-cutting and grinding work on

the machine only if this has been expressly approved, as
there may be a risk of explosion and fire.
Special care must be taken before welding, flame-cutting

and grinding operations are carried out on the counterweight. The filling of the counterweight chambers can
create explosive gases which will accumulate in the
chambers of the counterweight. These gases must be
expelled before welding, flame-cutting and grinding operations are carried out on the counterweight. Danger of
explosion.
Follow the instructions given in PARTS & SERVICE
NEWS No. "AH04518" for expelling the gases from the
counterweight chambers.
Before carrying out welding, flame-cutting and grinding

operations, clean the machine and its surroundings from
dust and other inflammable substances and make sure
that the premises are adequately ventilated (risk of explosion).
Version 2009/2
PC5500-6
2 -9
Safety Instructions
2.1.5.3 HYDRAULIC, AIR CONDITIONING AND PNEUMATIC EQUIPMENT

WARNING
z
Work on hydraulic equipment and the air conditioning

system may only be carried out by persons having special knowledge and experience in this systems.
Check all lines, hoses and screwed connections regularly for leaks and obvious damage. Repair any damage
immediately. Splashed oil may cause injury and fire.
Depressurize all system sections and pressure pipes

(hydraulic system, compressed-air system) to be
removed in accordance with the specific instructions for
the unit concerned before carrying out any repair work.
Refrigerant in the air conditioning system must be

sucked off by authorized service specialists only before
opening the refrigerant loop (e.g. removing pipes).
Hydraulic, air conditioning and compressed-air lines

must be laid and fitted properly. Ensure that no connections are interchanged. The fittings, lengths, and quality
of the hoses must comply with the technical requirements.
2.1.5.4 NOISE
WARNING
z
During operation, all sound baffles must be closed.
Always wear the prescribed ear protectors.
2 - 10
PC5500-6
Version 2009/2
Safety Instructions
2.1.5.5 HEAT
WARNING
z
Do not start working on hot machine parts until the temperature is below 50 C.
Be careful when handling hot materials (risk of burning

or scalding) such as:
Fuel
Engine coolant
Hydraulic oil
Engine oil
Grease
Use gloves when handling hot machine parts.
2.1.5.6 OIL, GREASE AND OTHER CHEMICAL SUBSTANCES

WARNING
z
When handling oil, grease, and other chemical substances, observe the product-related safety regulations
given in the material safety data sheet (MSDS).
Be careful when handling hot materials (risk of burning

or scalding).
2.1.5.7 HEIGHT
WARNING
When working in heights above 1.00 m, a special safety harness is required, refer to section 2.1.6 on page 2-13.
Version 2009/2
PC5500-6
2 - 11
Safety Instructions
Fig. 2-1
2 - 12
Safety harness in conformity with EN 361

PC5500-6
Version 2009/2
2.1.6
Safety Instructions
SPECIAL SAFETY EQUIPMENT
2.1.6.1 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)

The safety harness (Fig. 2-1) should only be used together with
connectors according to EN 354, and fall arrest according to
EN 355, or fall protection devices according to EN 360.
Legend for Fig. 2-1:
(1)
Safety harness according to EN 361
(2)
Strap-type fall absorber according to DIN EN 355
(3)
Ladder to cab roof and railings (attachment points)
(4)
Protection hoods for roof mounted air conditioning, if

so equipped
(A)
Shoulder strap
(B)
Back plate
(C)
Catching hook
(D)
Shoulder-strap fixing
(E)
Belly strap
(F)
Holding hook
(G)
Hold-back hook
(H)
Pelvis strap
(J)
Leg strap
WARNING
Always use the safety harness (Fig. 2-1, Pos. 1) in conjunction with strap-type fall absorber (Fig. 2-1, Pos. 2), before
mounting onto the loader attachment or other unsecured
places of the shovel.
NOTE: The illustration (Fig. 2-1) shows a typical use of the safety
harness. Shovels with the new type operators cab are
not equipped with ladder (Fig. 2-1, Pos. 3), because the
air conditioner unit of the new type cab is located on the
back wall of the cab.
Version 2009/2
PC5500-6
2 - 13
Safety Instructions
Fig. 2-2
2 - 14

PC5500-6
Version 2009/2
Safety Instructions
2.1.6.2 INSTRUCTIONS FOR USE

Open the lock and lift the harness by the catch hook (Fig. 2-2,
Pos. C). The blue straps (leg straps Fig. 2-2, Pos. J) must be at
the bottom. The harness is being put on just like a jacket. Pull the
belly strap (Fig. 2-2, Pos. E) through the lock, as shown in the
illustration, and secure it.
By closing the breast strap, you avoid the shoulder straps to sideslip. Bring the leg straps (Fig. 2-2, Pos. J) around the legs to the
front, pull them in, as shown in the illustration, and tighten them.
Adapt the harness to body form, seeing to perfect fit, in particular
that the catching hook (Fig. 2-2, Pos. C) is aligned in the center of
the back.
The safety harness should belong to its wearer personally.
The safety harness should only be used together with connectors
according to EN 354, and fall arrest according to EN 355, or fall
protection devices according to EN 360.
The attachment point for the safety harness should be above the
wearer, and the carrying capacity of the attachment point should
be sufficient to correspond with the minimum carrying capacity
according to EN 795.
z
Before using the harness:

z
Carry out a visual check of the system or components.

The correct functioning and perfect working order have to
be assured.
Make sure that the recommendations for use with other

components of the system are observed in conformity
with the instructions for use.
WARNING
The system or component must no longer be used, if there

are any doubts in respect of its safe condition. The equipment has to be inspected by the manufacturer or by a qualified person.
It is essential for safety reasons that a fall protection system
or system component which has already been subjected to
fall is removed from the service and sent back to the manufacturer or to an authorized qualified repair shop for maintenance and renewed testing.
Version 2009/2
PC5500-6
2 - 15
Safety Instructions
Fig. 2-3
2 - 16

PC5500-6
Version 2009/2
Safety Instructions
Fall protection systems have to be treated with care and to be

kept clean and ready for use. It has to be warned against bringing
the systems into contact with acids or other caustic liquids and
gases, oils, detergents, or sharp-edged objects.
If the harness has become wet during use or cleaning, do not dry
near a fire or other sources of heat, but rather in a natural way in
not too warm rooms. Keep the harness freely suspended or
loosely rolled up.
When using the fall protection systems, the pertaining safety regulations in force and the "Rules for Use of Personal Fall Arrest
Systems" have to be observed for protection against danger.
WARNING
At least every 12 months, the safety harness and its components have to be inspected by a competent person authorized by the manufacturer and they have to be maintained, if
the manufacturer considers it to be necessary.
2.1.6.3 RECOMMENDATIONS FOR USE OF THE HOLDING HOOKS AND HOLD-BACK

HOOKS OF THE SAFETY HARNESS
During the holding function, the connectors may only be placed
around a mast or any other construction between the two holding
hooks, so that the free fall is limited to max. 0.5 m.
It should be strictly seen to it that the connector is not slung
around constructions with too small diameters or sharp edges.
With the lateral holding hooks, work may only be carried out on
horizontal or almost horizontal surfaces (roofs). The connectors
have to be adjusted in such a way that the area, where danger of
falling down prevails, cannot be reached.
Version 2009/2
PC5500-6
2 - 17
Safety Instructions
Fig. 2-4
2 - 18

PC5500-6
Version 2009/2
Safety Instructions
2.1.6.4 INSTARUCTIONS FOR USING THE FALL ABSORBER

Strap-type fall absorber according to DIN EN 355 (type E.K.N.BFD)
Use
Within a fall-arrest system, the strap-type fall absorber (Fig. 2-4,
Pos. 2) has to be used in conjunction with a safety harness
(Fig. 2-4, Pos. 1) according to DIN EN 361. The maximum length
including the safety rope must not exceed 2.0 m. For longer
ropes, a rope-shortening device has to be applied in addition.
Fix the rope to the attachment point and attach the strap-type fall
absorber to the catching hook in the back of the safety harness.
The attachment point should be above the wearer and its minimum carrying capacity should be 10 kN, according to DIN EN
795.
The strap-type fall absorber and the safety rope must not be damaged, e.g. never pull them over sharp edges nor get them burnt
by welding sparks.
Storing and maintenance
The strap-type fall absorber has to be kept dry in an airy and
shady room. It must not be exposed to acids, caustic chemicals,
nor to an aggressive atmosphere, and contact with any oil has to
be avoided. If the strap-type fall absorber is dirty, it may be
cleaned with a little water and a light-duty detergent. Dry it in a
shady place (nowhere near fire or other sources of heat). Protect
it from sharp-edged objects.
Inspection
Prior to use, all parts have to be inspected for safe condition and
damages. At least once a year, the strap-type fall absorber has to
be tested by a competent person. A damaged or used strap-type
fall absorber has to be removed from the service immediately.
The strap-type fall absorber must not be changed in any way.
Repair work has to be done by the manufacturer or by an authorized qualified repair shop.
Version 2009/2
PC5500-6
2 - 19
Safety Instructions
2.1.7
SAFETY HINTS FOR HYDRAULIC HOSE INSTALLATION

WARNING
The hydraulic hoses undergo natural aging.

Hence, as they are safety critical parts, their usable lifetime is
limited to a maximum of 6 years (including storage time).
For further information refer to the Operation and Maintenance Manual, chapter 4, section "REPLACEMENT OF
HYDRAULIC HOSE LINES AND FUEL HOSE".
To avoid damage to the hydraulic hose lines, follow the installation procedures listed below:
CAUTION
Pay attention to the Natural curvature of the hose!
Fig. 2-5
CAUTION
Do not twist the hoses during installation!
Fig. 2-6
2 - 20
PC5500-6
Version 2009/2
Safety Instructions
CAUTION
Mount angled flanges at first!
Fig. 2-7
CAUTION
Pay attention to the changing in hose length, depending on
the pressure inside the hose!
Fig. 2-8
CAUTION
Pay attention to the bending radius!
Fig. 2-9
Version 2009/2
PC5500-6
2 - 21
Safety Instructions
CAUTION
Pay attention to the bending radius!
Fig. 2-10
2 - 22
PC5500-6
Version 2009/2
2.1.8
Safety Instructions
SAFETY HINTS FOR LIFTING HEAVY PARTS
NOTE: In order to avoid damage to the lifting devices or parts

that have to be lifted, use edge protection at all sharp
edges.
CAUTION
Heavy parts (25 kg or more) must be lifted with a hoist etc.
CAUTION
If any part cannot be removed from the machine smoothly by
hoisting, the following checks should be made:
Check for the removal of all bolts fastening the component to
other parts.
Check for existence of another part causing interference with
the component to be removed.
2.1.9
z
SAFETY HINTS FOR WIRE ROPES
Use adequate ropes depending on the weight of the parts to

be hoisted, referring to the below table:
Wire ropes
(Standard "Z" or "S" twist ropes without galvanizing)
Rope diameter
[mm]
10.0
11.2
12.5
14.0
16.0
18.0
20.0
22.4
30.0
40.0
50.0
60.0
Allowable load
[Metric tons]
1.0
1.4
1.6
2.2
2.8
3.6
4.4
5.6
10.0
18.0
28.0
40.0
CAUTION
The allowable load value is estimated to be 1/6 or 1/7 of the
breaking strength of the rope used.
WARNING
The table above may differ from local standards.
Always attend to local standards when using wire ropes.
Version 2009/2
PC5500-6
2 - 23
Safety Instructions
Sling wire ropes around the middle portion of the hook. Slinging near the tip of the hook may cause the rope to slip off the
hook during hoisting, which may cause a serious accident.
Hooks have the maximum strength at the middle portion, see
Fig. 2-11.
Do not sling a heavy load with one rope alone, but sling it with
two or more ropes wound symmetrically around the load.
Fig. 2-11
WARNING
Slinging with one rope may cause turning of the load during
hoisting, untwisting of the rope, or slipping of the rope from
its original winding position on the load, which may cause a
serious accident.
Do not sling a heavy load with ropes forming a wide hanging

angle from the hook. When hoisting a load with two or more
ropes, the force subjected to each rope will increase with the
hanging angles. Figure 2-12 shows the variation of allowable
load (kg) where hoisting is made with two ropes, each of
which is allowed to sling up to 1000 kg vertically, at various
hanging angles. When two ropes sling a load vertically, up to
2000 kg of total weight can be lifted. This weight becomes
1000 kg when two ropes make a 120 hanging angle. On the
other hand, two ropes are subject to an excessive force as
large as 4000 kg if they sling a 2000 kg load at a lifting angle
of 150.
2 - 24
PC5500-6
Fig. 2-12
Version 2009/2
Safety Instructions
2.1.10 SAFETY HINTS FOR SLING ACCESSORY

WARNING
Always attend to local standards when using sling accessory.
Do not use rigid eye bolts from steel C 15 for lifting

(e.g. DIN 580). These eye bolts may only be loaded vertically
or with a maximum permissible angle of 45 to the ring.
Always use suitable swivel hoist rings according to local standards or Vario-Starpoint hoist rings recommended by
Komatsu, see following table:
Thread
Komatsu Part Number
Tightening Torque
M8
941 650 40
10 Nm
M10
941 651 40
10 Nm
M12
906 519 40
25 Nm
M16
906 780 40
60 Nm
M20
906 782 40
115 Nm
M24
906 783 40
190 Nm
M30
906 421 40
330 Nm
M36
906 233 40
590 Nm
DANGER
Vario-Starpoint hoist rings are not suited for turning under
load.
After installing Starpoint hoist ring disengage the star key.
Adjust ring plane in direction of pull before attaching sling
accessory.
DANGER
Eye bolts or sling accessory which is not suitable can result
in serious accidents.
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.
Version 2009/2
PC5500-6
2 - 25
Safety Instructions
2.1.11 WEIGHT TABLES

2.1.11.1 SUPERSTRUCTURE
Part or assembly
Weight
Diesel engine
7000 kg
Roof plate engine housing
397 kg
max.
Beam (Bridge)
285 kg
Alternator
depending on
type
38.25 kg
Battery
62 kg
Radiator fan
35 kg
Hydraulic fan motor
18 kg
Bearing block
each
77.5 kg
Radiator fan drive pump
40 kg
Radiator assembly
650 kg
Roof plate over radiator
116 kg
Fan cowl
67 kg
Starter motor
35.5 kg
Starter motor with prelubrication pump
43.6 kg
Geislinger coupling assembly
160 kg
Roof plate engine housing
260 kg
Main pump assembly with flanged gear pump
362.4 kg
Oil circulation pump (auxiliary pump)
each
25 kg
PTO (pump distributor gearbox)
1900 kg
Control frame assembly
260 kg
Hydraulic cooler fan drive pump
40 kg
Hydraulic cooler fan assembly
each
117.4 kg
Hydraulic cooler fan
19 kg
Hydraulic cooler fan mounting assembly
72 kg
Hydraulic motor assembly
26.4 kg
Hydraulic oil cooler
275 kg
Hydraulic oil cooler frame incl. Hydraulic oil coolers
3950 kg
Pilot oil pump
27.4 kg
Main gate valve
12.3 kg
Hydraulic oil reservoir incl. Back pressure valve
3465 kg
Main control valve block 1, incl. ACVs & SRVs
717 kg
2 - 26
Remark
PC5500-6
each element
Version 2009/2
Safety Instructions
Part or assembly
Weight
726 kg
High pressure filter (main control block 2)
44.6 kg
713 kg
Main control valve block 4
143 kg
High pressure filter (main control block 4)
15 kg
Anti cavitation valve on main control block (ACV)
3 kg
Throttle check valve on main control block (SRV)
4 kg
Single anti cavitation valve on manifold
15 kg
Double anti cavitation valve on manifold
44.6 kg
Manifold without valves
408 kg
Pressure relief valve assembly on manifold
18.2 kg
Throttle check valve on manifold (long version)
31 kg
Throttle check valve on manifold (short version)
28 kg
Manifold incl. ACVs & SRVs (BHA)
921.2 kg
Manifold incl. ACVs & SRVs (FSA)
893.2 kg
Slew gear (Siebenhaar)
1700 kg
Slew gear (L&S)
1880 kg
Swing motor
170 kg
Bearing ring of the slew parking brake (L&S)
32 kg
Slew brake valve
97
Pinion cover
11.6 kg
Lubrication pinion assembly
18.2 kg
Lubrication pump
28 kg
Operator's cab
2700 kg
Viscous mount
4 kg
Absorber plate incl. 2 viscous mount
11.9 kg
Absorber plate incl. 3 viscous mounts
17.4 kg
Front window
112 kg
Operator's seat
62 kg
Access ladder
167 kg
Access ladder cylinder
23 kg
Cab base
3785 kg
Support frame
987 kg
Counterweight
46,000 k
Version 2009/2
Remark
PC5500-6
2 - 27
Safety Instructions
Part or assembly
Weight
Superstructure incl. Diesel engine without counterweight, attachment and fluids
137,215
kg
Fuel tank (empty)
4486 kg
2 - 28
PC5500-6
Remark
Version 2009/2
Safety Instructions
2.1.11.2 UNDERCARRIAGE
Part or assembly
Weight
Track group 1350 mm
Remark
32.192 kg
Pin between track shoes (Track group 1350 mm)
19 kg
Track group 1800 mm
39.066 kg
Pin between track shoes (Track group 1800 mm)
20.2 kg
Sprocket
4382 kg
Hollow shaft
612 kg
Drive shaft
1007 kg
Three segmented sprocket assembly
2250 kg
Sprocket segment 1 (5 teeth)
794.25 kg
794.25 kg
661.5 kg
Three segmented sprocket assembly (oversize)
2745 kg
Sprocket segment 1 (5 teeth, oversize)
968.99 kg
968.99 kg
807.02 kg
Guide wheel assembly
3323 kg
Low pressure accumulator
12 kg
High pressure accumulator
23 kg
Track tensioning valve block
40 kg
Hydraulic hoses of the track tensioning system
10 kg
max
Travel brake valve block
75 kg
Track tensioning cylinder
400 kg
Travel motor
110 kg
Travel parking brake
75 kg
Travel gearbox
4020 kg
Carrier roller assembly (bolted connection)
205 kg
Carrier roller assembly (with mounting pins)
175 kg
Track roller assembly
654 kg
depending on
type
each
each
Car body without crawler carrier (with mounting pins)
42,000 kg
Crawler carrier assembly (track width 1350 mm, with mounting pins)
70,000 kg
each
80,000 kg
each
Car body without crawler carrier (bolted connection)
46,000 kg
Crawler carrier assembly (track width 1350 mm, bolted connection)
76,722 kg
Version 2009/2
PC5500-6
each
2 - 29
Safety Instructions
Part or assembly
Weight
83,646 kg
Rotary joint
261 kg
Swing circle
10,000 kg
2 - 30
PC5500-6
Remark
each
Version 2009/2
Safety Instructions
2.1.11.3 BACKHOE ATTACHMENT (BHA)

Part or assembly
Weight
Boom
Remark
45,100 kg
Pin boom/superstructure
365 kg
Pin boom cylinder/boom
177 kg
Pin boom cylinder/superstructure
224 kg
Boom cylinder
6500 kg
Stick
each
19,160 kg
Pin stick/boom
1440 kg
Stick cylinder
4600 kg
Pin stick cylinder/stick
127 kg
Pin stick cylinder/boom
179 kg
Bucket
each
30,600 kg
Pin bucket/stick
574 kg
Pin bucket/bucket link rod
822 kg
Bucket cylinder
3210 kg
Pin bucket cylinder/stick
86 kg
Pin bucket cylinder/steering rod
865 kg
Rod protection cover
360 kg
Nut-Cap
35 kg
Bucket link rod
2280 kg
Steering rod
1300 kg
Pin steering rod/stick
479 kg
Point (ESCO)
55 kg
Shroud (ESCO)
337 kg
Tooth adapter (ESCO)
182 kg
Boom arc hose
39 kg
each
Boom cylinder hoses
29.5 kg
39 kg
depending on
length
Stick cylinder hoses
23 kg
27,5 kg
depending on
length
Bucket cylinder hoses
33 kg
Metering valve
<25 kg
Version 2009/2
PC5500-6
2 - 31
Safety Instructions
2.1.11.4 FACE SHOVEL ATTACHMENT (FSA)

Part or assembly
Boom with attached stick and boom cylinders
Weight
Remark
52,900 kg
boom without
cylinders:
34,800 kg
Pin boom/superstructure
365 kg
Pin boom cylinder/boom
234 kg
Pin boom cylinder/superstructure
224 kg
Boom cylinder
5680 kg
Stick
21,000
Pin stick/boom
168 kg
Stick cylinder
3340 kg
Pin stick cylinder/stick
90 kg
Pin stick cylinder/boom
90 kg
Bucket
35,060 kg
Pin bucket cylinder/bucket
190 kg
Pin bucket/stick
318 kg
Bucket cylinder
4005 kg
Pin bucket cylinder/boom
168 kg
Clam cylinder
885 kg
Upper pin at clam cylinder
48 kg
Lower pin at clam cylinder
66 kg
Point (tooth) (ESCO)
55 kg
Shroud (ESCO)
270 kg
Tooth adapter (ESCO)
182 kg
Boom arc hose
39 kg
Boom cylinder hose
30.5 kg
Stick arc hose
29.5 kg
Stick cylinder hose
25 kg
27.4 kg
depending on
length
Bucket cylinder hose
28 kg
depending on
length
Clam cylinder hose at stick
28 kg
Clam cylinder hose at clam cylinder
8.8 kg
9.8 kg
10 kg
11.2 kg
Metering valve
<25 kg
2 - 32
PC5500-6
depending on
length and
type
Version 2009/2
Torque charts according to DIN
2.2
TORQUE CHARTS ACCORDING TO DIN
2.2.1
METRIC STANDARD THREAD
Bolt
diameter
Wrench size
[mm]
Tightening torque
[Nm]
Bolt quality grades
Metric regular
8.8
10.9
12.9
M 8
13
21
31
36
M 10
17
43
63
73
M 12
19
10
74
108
127
M 14
22
12
118
173
202
M 16
24
14
179
265
310
M 18
27
14
255
360
425
M 20
30
17
360
510
600
M 22
32
17
485
690
810
M 24
36
19
620
880
1030
M 27
41
19
920
1310
1530
M 30
46
22
1250
1770
2080
M 33
50
24
1690
2400
2800
M 36
55
27
2170
3100
3600
M 39
60
2800
4000
4700
M 42
65
3500
4950
5800
M 45
70
4350
6200
7200
M 48
75
5200
7500
8700
M 52
80
6700
9600
11200
M 56
85
8400
12000
14000
M 60
90
10400
14800
17400
M 64
95
12600
17900
20900
M 68
100
15200
21600
25500
32
35
41
46
NOTE: Threads and bolts must be greased carefully with grease

KP2K. Contact surfaces which should be screwed
together must be free of grease.
Version 2009/2
PC5500-6
2 - 33
2.2.2
METRIC FINE THREAD
Bolt
diameter
Wrench size
[mm]
Tightening torque
[Nm]
Bolt quality grades
Metric
fine
8.8
10.9
12.9
M 8 x 1.0
13
23
33
39
M 10 x 1.0
17
48
70
82
M 12 x 1.25
19
10
81
119
139
M 14x1.5
22
12
127
187
219
M 16 x 1.5
24
14
191
280
330
M 18 x 2.0
27
14
270
385
450
M 20 x 2.0
30
17
380
540
630
M 22 x 2.0
32
17
510
720
850
M 24 x 2.0
36
19
680
960
1130
M 27 x 2.0
41
19
990
1410
1650
M 30 x 2.0
46
22
1380
1960
2300
M 33 x 2.0
50
24
1850
2650
3100
M 36 x 3.0
55
27
2300
3250
3850
M 39 x 3.0
60
3000
4200
4950
M 42 x 3.0
65
3750
5300
6200
M 45 x 3.0
70
4600
6600
7700
M 48 x 3.0
75
5700
8100
9500
M 52 x 3.0
80
7300
10400
12100
M 56 x 4.0
85
8900
12600
14800
M 60 x 4.0
90
11000
15600
18300
M 64 x 4.0
95
13300
19000
22200
M 68 x 4.0
100
16100
22900
27000
32
35
41
46
NOTE: Threads and bolts must be greased carefully with grease

KP2K. Contact surfaces which should be screwed
together must be free of grease.
CAUTION
Bolts at the slew rings have different torques, refer to Service
NEWS No. "AH00511" last edition!
2 - 34
PC5500-6
Version 2009/2
2.2.3
CUMMINS MOTOR TORQUES - METRIC
Grade
8.8
10.9
12.9
Body size
Torque
Torque
Torque
Diameter
Cast iron
Aluminium
Cast iron
Aluminium
Cast iron
Aluminium
[mm]
[Nm]
[ft-lb]
[Nm]
[ft-lb]
[Nm]
[ft-lb]
[Nm]
[ft-lb]
[Nm]
[ft-lb]
[Nm]
[ft-lb]
13
10
14
14
11
18
14
11
23
18
11
23
17
18
14
33
25
18
14
40
29
18
14
10
45
33
30
25
65
50
30
25
70
50
30
25
12
80
60
55
40
115
85
55
40
125
95
55
40
14
125
90
90
65
180
133
90
65
195
145
90
65
16
195
140
140
100
280
200
140
100
290
210
140
100
18
280
200
180
135
390
285
180
135
400
290
180
135
20
400
290
550
400
2.2.4
CUMMINS MOTOR TORQUES - U.S. CUSTOMARY

Grade
5 (three radial lines on cap)
8 (six radial lines on cap)
Body size
Torque
Torque
Diameter - threads
Cast iron
Aluminium
Cast iron
Aluminium
[Nm]
[ft-lb]
[Nm]
[ft-lb]
[Nm]
[ft-lb]
[Nm]
[ft-lb]
1/4 - 20
15
11
1/4 - 28
12
18
13
5/16 - 18
20
15
16
12
30
22
16
12
5/16 - 24
23
17
19
14
33
24
19
14
3/8 - 16
40
30
25
20
55
40
25
20
3/8 - 24
40
30
35
25
60
45
35
25
7/16 - 14
60
45
45
35
90
65
45
35
7/16 - 20
65
50
55
40
95
70
55
40
1/2 - 13
95
70
75
55
130
95
75
55
1/2 - 20
100
75
80
60
150
110
80
60
9/16 - 12
135
100
110
80
190
140
110
80
Version 2009/2
PC5500-6
2 - 35
2.2.5
SAE FLANGE CONNECTIONS
Fig. 2-13 Torques for SAE-flange connections
2 - 36
PC5500-6
Version 2009/2
Blind plugs
2.3
BLIND PLUGS
2.3.1
DUMMY PLATES FOR SAE-FLANGES
Fig. 2-14 Forms / types of dummy plates for SAE-flanges

Up to 3000 PSI
SAE size
Form / type
according to
Fig. 2-142-14
PN
DN
(hose / pipe)
1/2"
506 521 98
12
3/4"
506 583 98
20
1 1/4"
506 584 98
32
1 1/2"
506 522 98
40
2"
506 523 98
50
2 1/2"
506 585 98
65
3"
512 570 98
80
3/4"
516 826 98
20
1 1/4
517 479 98
32
1 1/2"
506 528 98
40
2"
506 529 98
50
2 1/2"
506 530 98
65
3"
512 571 98
80
Version 2009/2
PC5500-6
2 - 37
Blind plugs
Up to 6000 PSI
2 - 38
SAE size
Form / type
according to
Fig. 2-142-14
PN
DN
(hose / pipe)
3/4"
506 580 98
20
1"
506 519 98
25
1 1/4"
506 520 98
32
1 1/2"
506 581 98
40
2"
506 582 98
50
1"
506 524 98
25
1 1/4"
506 525 98
32
1 1/2"
506 526 98
40
2"
506 527 98
50
1 1/4"
516 499 98
32
1 1/2"
509 375 98
40
2"
509 376 98
50
PC5500-6
Version 2009/2
2.3.2
Blind plugs
CLASSIFICATION OF THREADS TO THE NOMINAL WIDTH

Heavy class
(up to 6000 PSI)
Light class
(up to 3000 PSI)
Size
Ra
DN
Ra
DN
M 12 x 1.5
M 14 x 1.5
M 16 x 1.5
10
M 18 x 1.5
10
12
10
M 20 x 1.5
12
M 22 x 1.5
14
10
15
12
M 24 x 1.5
16
12
M 26 x 1.5
18
16
M 30 x 1.5
M 30 x 2
20
16
22
20
M 36 x 2
25
20
28
25
M 38 x 1.5
M 42 x 2
30
25
M 45 x 1.5
M 45 x 2
35
32
M 52 x 1.5
M 52 x 2
38
32
42
40
M 65 x 2
Method of using the above table to find an appropriate plugs and

fittings according to Table 2.3.3 on page 40:
EXAMPLE:
To cover up a hose / tube with a diameter of 25 mm, for a pressure up to 3000 PSI perform the following steps:
z
Locate the 25 in the column "DN" in the category "up to 3000

PSI".
Check the digit in the column "Ra" next to DN 25 in the same

row and category.
For this example the proper plug and fitting is BUZ 28-L and
ROV 28-L, refer to Table 2.3.3 on page 40.
NOTE: The column "Size" indicates the thread-size for the

ROV-fittings.
Version 2009/2
PC5500-6
2 - 39
Blind plugs
2.3.3
PLUGS AND FITTINGS ACCORDING TO DIN 2353

Up to 3000 PSI
BUZ (plugs)
PN
ROV (fittings)
PN
8-L
501 692 98
8-L
518 113 98
10-L
371 852 99
10-PL
513 789 98
12-L
371 854 99
12-PL
513 547 98
15-L
371 855 99
15-PL
507 051 98
18-L
371 856 99
18-PL
513 787 98
22-L
371 857 99
22-PL
513 788 98
28-L
371 858 99
28-PL
509 377 98
35-L
371 859 99
35-PL
516 770 98
42-L
371 860 99
42-PL
513 790 98
Up to 6000 PSI
2 - 40
BUZ (plugs)
PN
ROV (fittings)
PN
8-PS
515 921 98
10-PS
507 023 98
12-PS
507 022 98
16-S
371 866 99
20-S
371 853 99
20-PS
512 005 98
25-S
371 867 99
25-PS
508 033 98
30-S
371 868 99
30-PS
507 021 98
38-S
371 869 99
38-PS
507 020 98
PC5500-6
Version 2009/2
Conversion table
2.4
CONVERSION TABLE
2.4.1
METHOD OF USING THE CONVERSION TABLE
The Conversion Table in this section is provided to enable simple

conversion of figures. For details of the method of using the Conversion Table, see the example given below.
EXAMPLE:
Method of using the Conversion Table to convert from millimeters
to inches.
Convert 55 mm into inches:
z
Locate the number 50 in the vertical column at the left side,

take this as (A), then draw a horizontal line from (A).
Locate the number 5 in the row across the top, take this as
(B), then draw a perpendicular line down from (B).
Take the point where the two lines cross as (C). This point (C)
gives the value when converting from millimeters to inches.
Therefore, 55 millimeters = 2.165 inches.
Convert 550 mm into inches:

z
The number 550 does not appear in the table, so divide by 10

(move the decimal one place to the left) to convert it to 55
mm.
Carry out the same procedure as above to convert 55 mm to

2.165 inches.
The original value (550 mm) was divided by 10, so multiply

2.165 inches by 10 (move the decimal one place to the right)
to return to the original value. This gives 550 mm = 21.65
inches.
Version 2009/2
PC5500-6
2 - 41
Conversion table
2.4.2
2 - 42
MILLIMETER - INCH & KILOGRAM - POUND
PC5500-6
Version 2009/2
2.4.3
Conversion table
LITER - U.S. GALLON & LITER - U.K. GALLON
Version 2009/2
PC5500-6
2 - 43
Conversion table
2.4.4
0
10
20
30
40
50
60
70
80
90
100
110
120
130
140
150
160
170
180
190
200
NM - FT.LB
0
0
7.37
14.74
22.11
29.48
36.85
44.22
51.59
58.96
66.33
73.70
81.07
88.44
95.81
103.18
110.55
117.92
125.29
132.66
140.03
147.40
1
0.74
8.11
15.48
22.85
30.22
37.59
44.96
52.33
59.07
67.07
74.44
81.81
89.18
96.55
103.92
111.29
118.66
126.03
133.40
140.77
148.14
2
1.47
8.84
16.21
23.58
30.95
38.32
45.69
53.06
60.43
67.80
75.17
82.54
89.91
97.28
104.65
112.02
119.39
126.76
134.13
141.50
148.87
3
2.21
9.58
16.95
24.32
31.69
39.06
46.43
53.08
61.17
68.54
75.91
83.28
90.65
98.02
105.39
112.76
120.13
127.50
134.87
142.24
149.61
4
2.95
10.32
17.69
25.06
32.43
39.80
47.17
54.54
61.91
69.28
76.65
84.02
91.39
98.76
106.13
113.50
120.87
128.24
135.61
142.98
150.35
5
3.69
11.06
18.43
25.80
33.17
40.54
47.91
55.28
62.65
70.02
77.39
84.76
92.13
99.50
106.87
114.24
121.61
128.98
136.35
143.72
151.09
6
4.42
11.79
19.16
26.53
33.90
41.27
48.64
56.01
63.38
70.75
78.12
85.49
92.86
100.23
107.60
114.97
122.34
129.71
137.08
144.45
151.82
7
5.16
12.53
19.90
27.27
34.64
42.01
49.38
56.75
64.12
71.49
78.86
86.23
93.60
100.97
108.34
115.71
123.08
130.45
137.82
145.19
152.56
8
5.90
13.27
20.64
28.01
35.38
42.75
50.12
57.49
64.86
72.23
79.60
86.97
94.34
101.71
109.08
116.45
123.82
131.19
138.56
145.93
153.30
9
6.63
14.00
21.37
28.74
36.11
43.48
50.85
58.22
65.59
72.96
80.33
87.70
95.07
102.44
109.81
117.18
124.55
131.92
139.29
146.66
154.03
1 Nm = 0,737 FT.LB
2 - 44
PC5500-6
Version 2009/2
2.4.5
Conversion table
BAR - PSI / PSI - BAR

Conversion Table
bar / PSI
bar - PSI
bar
1
5
10
15
20
25
30
35
40
45
50
55
60
65
70
75
80
85
90
95
100
105
110
115
120
125
130
135
140
145
150
155
160
165
170
175
180
185
190
195
200
PSI
14,5033
73
145
218
290
363
435
508
580
653
725
798
870
943
1015
1088
1160
1233
1305
1378
1450
1523
1595
1668
1740
1813
1885
1958
2030
2103
2175
2248
2321
2393
2466
2538
2611
2683
2756
2828
2901
PSI - bar
bar
205
210
215
220
225
230
235
240
245
250
255
260
265
270
275
280
285
290
295
300
305
310
315
320
325
330
335
340
345
350
355
360
365
370
375
380
385
390
395
400
PSI
2973
3046
3118
3191
3263
3336
3408
3481
3553
3626
3698
3771
3843
3916
3988
4061
4133
4206
4278
4351
4424
4496
4569
4641
4714
4786
4859
4931
5004
5076
5149
5221
5294
5366
5439
5511
5584
5656
5729
5801
PSI
1
75
150
225
300
375
450
525
600
675
750
825
900
975
1050
1125
1200
1275
1350
1425
1500
1575
1650
1725
1800
1875
1950
2025
2100
2175
2250
2325
2400
2475
2550
2625
2700
2775
2850
2925
3000
bar
0,06895
5,17
10
16
21
26
31
36
41
47
52
57
62
67
72
78
83
88
93
98
103
109
114
119
124
129
134
140
145
150
155
160
165
171
176
181
186
191
197
202
207
PSI
3075
3150
3225
3300
3375
3450
3525
3600
3675
3750
3825
3900
3975
4050
4125
4200
4275
4350
4425
4500
4575
4650
4725
4800
4875
4950
5025
5100
5175
5250
5325
5400
5475
5550
5625
5700
5775
5850
5925
6000
bar
212
217
222
228
233
238
243
248
253
259
264
269
274
279
284
290
295
300
305
310
315
321
326
331
336
341
346
352
357
362
367
372
378
383
388
393
398
403
409
414
PSI
bar
14,5033 = PSI
bar
14,5033
Version 2009/2
PC5500-6
2 - 45
Conversion table
2.4.6
BASIC VALUES IN OHM ACCORDING TO DIN 43 76
Conversion Table - Ohm to Centigrade of PT100 sensors

C
-0
-1
-2
-3
-4
-5
-6
-7
-8
-9
-50
80.31
79.91
79.51
79.11
78.72
78.32
77.92
77.52
77.13
76.73
-40
84.27
83.88
83.48
83.08
82.69
82.29
81.89
81.50
81.10
80.70
-30
88.22
87.83
87.43
87.04
86.64
86.25
85.85
85.46
85.06
84.67
-20
92.16
91.77
91.37
90.98
90.59
90.19
89.80
89.40
89.01
88.62
-10
96.09
95.69
95.30
94.91
94.52
94.12
93.73
93.34
92.95
92.55
100.00
99.61
99.22
98.83
98.44
98.04
97.65
97.26
96.87
96.48
100.00
100.39
100.78
101.17
101.56
101.95
102.34
102.73
103.12
103.51
10
103.90
104.29
104.68
105.07
105.46
105.85
106.24
106.63
107.02
107.40
20
107.79
108.18
108.57
108.96
109.35
109.73
110.12
110.51
110.90
111.28
30
111.67
112.06
112.45
112.83
113.22
113.61
113.99
114.38
114.77
115.15
40
115.54
115.93
116.31
116.70
117.08
117.47
117.85
118.24
118.62
119.01
50
119.40
119.78
120.16
120.55
120.93
121.32
121.70
122.09
122.47
122.86
60
123.24
123.62
124.01.
124.39
124.77
125.16
125.54
125.92
126.31
126.69
70
127.07
127.45
127.84
128.22
128.60
128.98
129.37
129.75
130.13
130.51
80
130.89
131.27
131.66
132.04
132.42
132.80
133.18
133.56
133.94
134.32
90
134.70
135.08
135.46
135.84
136.22
136.60
136.98
137.36
137.47
138.12
100
138.50
138.88
139.26
139.64
140.02
140.39
140.77
141.15
141.53
141.91
110
142.29
142.66
143.04
143.42
143.80
144.17
144.55
144.93
145.31
145.68
120
146.06
146.44
146.81
147.19
147.57
147.94
148.32
148.70
149.07
149.45
130
149.82
150.20
150.57
150.95
151.33
151.70
152.08
152.45
152.83
153.20
140
153.58
153.95
154.32
154.70
155.07
155.45
155.82
156.19
156.57
156.94
150
157.31
157.69
158.06
158.43
158.81
159.18
159.55
159.93
160.30
16067
2 - 46
PC5500-6
Version 2009/2
2.4.7
Conversion table
TEMPERATURE
The figures in the table below refer to the temperature in either

degree Fahrenheit or degree Celsius.
If it is desired to convert from degree Fahrenheit to degree Celsius, consider the center column as a table of Fahrenheit temperatures and read the corresponding Celsius temperature in the
column at the left.
If it is desired to convert from degree Celsius to degree Fahrenheit, consider the center column as a table of Celsius values, and
read the corresponding Fahrenheit temperature on the right.
Version 2009/2
PC5500-6
2 - 47
Tools
2.5
TOOLS
2.5.1
STANDARD TOOL CASE
Komatsu provides a standard tool case, PN 232 709 40.

Qty
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
3
2
1
1
1
1
1
2
2
1
1
1
Part name
Measuring tape 3 m long
Hammer 500 g
Sliding caliper, 200 mm long
Reamer (countersink, stem diameter 10 mm; reamer diameter 20 mm
Socket wrench - set (WS 10 - 32)
Internal hexagon socket, 1/2 - set, (WS 5 - 17)
Double ended open wrench - set (WS 6 - 32)
Combination wrenches - set (WS 10 - 32)
Twist drill - set (1 - 13 mm)
Needle files - set
Tool bag
Toolbox L= 460; B= 170; L= 310
Socket wrench - set (WS 3 - 13)
Drift punch 3 - 8 mm
Socket wrench with ball head - set (1.5 - 10 mm)
Side cutter insulated up to 1000 Volt, 190 mm
Combination pliers insulated up to 1000 Volt, 185 mm
Bent nose pliers, Knipex
Water pump pliers 250 mm long
Cable stripping knife 4 - 16 mm
Screwdriver for slotted screws 11 x 300 mm
Screwdriver for slotted screws 13 x 390 mm
Crosstip screwdriver size 0
Infrared thermometer IR 1
LCD-Digital Multimeter VC 444
VDE Screwdriver, WERA
Hydraulic mini testing kit
Pressure gauge 400 bar
Measuring hose 2.5 m
Pressure gauge fitting G
Set Screwdriver
Side cutting pliers, Knipex
Stripping- and cutting tool Stripax for PVC-isolation up to 6 mm, 20 mm
Crimp pliers, rimp capacity 0.5 - 4 mm
Crimp pliers HTN 21
Testing wire 4mm Type 410 (red)
Testing wire 4mm Type 410 (black)
Testing tip "Hirschmann Prf 2" (red)
Testing tip "Hirschmann Prf 2" (black)
Clip terminal "Hirschmann Ak 2 S" (red)
2 - 48
PC5500-6
Part number
470 615 40
232 130 40
232 107 40
232 690 40
232 691 40
232 570 40
232 692 40
232 693 40
232 207 40
232 199 40
232 694 40
232 695 40
232 696 40
232 697 40
232 698 40
232 401 40
232 400 40
232 403 40
232 139 40
232 699 40
232 120 40
232 121 40
232 111 40
232 112 40
232 113 40
232 665 40
232 688 40
232 689 40
232 591 40
793 363 73
896 483 40
232 501 40
907 696 40
232 700 40
232 663 40
232 661 40
232 701 40
232 702 40
232 703 40
232 704 40
232 705 40
232 706 40
Version 2009/2
Qty
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Tools
Part name
Clip terminal "Hirschmann Ak 2 S" (black)
Fluke 179 Digital-Multimeter
Rollbox K 412 (740 x 365 x 375)
Tachometer Moviport
Magnet-stick
Electric set with pliers
Software (Bodem 24)
Bodem connection cable
Crimp-pliers for revolved contacts
Cable set
Prostat Cable VL 3 (X27 -PC)
Prosyd Cable VL 12 (PLC-PC)
TazETM Cable VL 10 (ETM-PC)
Cable VL 9a
Cable VL 9b
PC4000-6 VHMS download-cable (new for 08156 and up)
Converter, cable, and software as set
Converter
USB extension wire
UMG diagnostic software (CD)
Version 2009/2
PC5500-6
Part number
232 707 40
232 708 40
232 711 40
232 551 40
232 712 40
793 265 73
796 726 73
896 791 40
793 729 73
796 443 73
659 820 40
926 503 40
891 175 40
891 176 40
891 177 40
894 580 40
796 442 73
796 439 73
796 440 73
796 441 73
2 - 49
Explanation of abbreviations
2.6
EXPLANATION OF ABBREVIATIONS
Abbrev.
Definition
Ampere
AC
Alternating Current
ACV
Anti-Cavitation Valve
API
American Petroleum Institute
BHA
Backhoe Attachment
Degree Celsius
CLS
Central Lubrication System
CO
Cut Off function (main pump)
DC
Direct Current
DFT
Dry paint Film Thickness [1/1000 inch]
FSA
Front Shovel Attachment
GET
Ground Engaging Tools
HP
High Pressure
HT
High Tension
LED
Light Emitting Diode
MRV
Main Relief Valve
PIV
Pressure Increasing Valve
PTO
Power Take-Off
(Pump Distributor Gear)
Qmax
Maximum pump delivery = maximum swash

plate angle
Qmin
Minimum pump delivery = minimum swash plate

angle
1/2 Qmax
1/2 pump delivery
SLS
Swing circle pinion Lubrication System
SRV
Secondary Relief Valve
Volt
WFT
Wet paint Film Thickness [1/1000 inch]
1/min
Revolutions Per Minute (RPM)
2 - 50
PC5500-6
Version 2009/2
Superstructure
3 SUPERSTRUCTURE
Version 2009/2
PC5500-6
3 -1
Diesel engine
3.1
Superstructure
DIESEL ENGINE
The excavator is powered by two Komatsu Diesel engines:

Model:
SSA 12V 159
Type:
4-cycle, water-cooled, direct injection
Aspiration:
Turbocharged with intercooler
Number of
cylinders:
12
Rated power:
940 kW (1260 HP) @ 1800 rpm
3.1.1
REMOVAL OF THE DIESEL ENGINES
3.1.1.1 PREPARATORY WORK FOR DIESEL ENGINES REMOVAL

Special tools:
n/a
Additional equipment:
Crane
4 x swivel hoist rings: M16
Empty coolant storage tank
Oil drain pans
Roof plate: 397 kg max.
Beam (transfer carrier): 285 kg
Dogman/rigger
For further information about the needed blind plugs, refer to section
2.3 on page 2-37.
z
Prepare an area of flat ground large enough to accommodate

the machine, boom, and crane.
Park the machine on the prepared flat ground area.
NOTE: If the ground condition is too poor to guarantee safe and

equipment (crane, mobile working platforms, forklift, etc.),
make sure that the machine is moved to any location with
appropriate ground condition.
z
Isolate the machine according to local regulations.
3 -2
PC5500-6
Version 2009/2
Superstructure
Diesel engine
WARNING
Do not carry out the following work on a hot engine. Wait
until the temperature of the engine is below 50 C.
Disobedience may result in personal injury from heated coolant or steam.
Drain the engine coolant of the engine to be

removed, approx. 360 liters.
Refer to the Operation & Maintenance Manual,
chapter 3, section "CENTRAL REFILLING SYSTEM", and the Engine Operation & Maintenance
Manual.
Drain the engine oil from the engine oil pan of the
engine to be removed, approx. 190 liters. Refer to
the Operation & Maintenance Manual, chapter 3,
section "CENTRAL REFILLING SYSTEM", and the
Engine Operation & Maintenance Manual.
Drain the engine oil reserve tank of the engine to be

removed, approx. 580 liters.
Manual.
Disconnect the hoses (Fig. 3-1, Pos. 1and 2) to the injector

valves of all cold start systems.
DANGER
Risk of fire!
Serious injury, permanent disfigurement and
scarring, or death may result.
DO NOT smoke or use an open flame when working around
inflammable fuels.
Fig. 3-1
Version 2009/2
PC5500-6
3 -3
Diesel engine
Superstructure
Fig. 3-2
z
Remove all engine air cleaners (Fig. 3-2, Pos. 1), and all
exhaust mufflers (Fig. 3-2, Pos. 2) from the roof.
WARNING
Pay attention to the Fire Detection and Suppression System.

Refer to the separate manuals "Fire Detection and Actuating
System" and "Fire Suppression System"
The wires of the Fire Detection and Suppression System
must not be bent excessively or be damaged to remain functional.
3 -4
PC5500-6
Version 2009/2
Superstructure
Fig. 3-3
Diesel engine
Roof plate removal
(1 to 3)
Roof plate
(4)
Sealing
(5, 6)
Bolt with lock washer
(7)
Bolt
(8)
Resilient sleeve
Clear all wire harnesses from the roof plates (Fig. 3-3,
Pos. 1 to 3).
Dismount all attached parts from the roof plates (Fig. 3-3,
Pos. 1 to 3).
Remove all bolts (Fig. 3-3, Pos. 5, Pos. 7) and resilient

sleeves (Fig. 3-3, Pos. 8) of the roof plates (Fig. 3-3,
Pos. 1 to 3).
Remove the roof plates (Fig. 3-3, Pos. 1 to 3) with a crane

using swivel hoist rings.
DANGER
Risk of falling weights!

Death or serious injury may result.
When lifting the roof plats, make sure that nobody steps
below the weight.
Version 2009/2
PC5500-6
3 -5
Diesel engine
Superstructure
WARNING
NOTE: Remove the sealings (Fig. 3-3, Pos. 4).
Clear all wire harnesses from the beam (transfer carrier)

(Fig. 3-4, Pos. 1) and dismount all attached parts from the
beam.
Remove the mounting bolts (Fig. 3-4, Pos. 3) and resilient

sleeves (Fig. 3-4, Pos. 2).
Remove the beam (transfer carrier) (Fig. 3-4, Pos. 1) with a

crane.
DANGER

When lifting the beam, make sure that nobody steps below
the weight.
Dismount all attached parts from the fire protection wall

(Fig. 3-5, Pos. 1) of the engine to be removed.
Remove the fire protection wall (Fig. 3-5, Pos. 1) of the

engine to be removed.
Fig. 3-4
DANGER
When lifting the fire protection wall, make sure that nobody
steps below the weight.
Fig. 3-5
3 -6
PC5500-6
Version 2009/2
Superstructure
Diesel engine
3.1.1.2 REMOVAL OF THE FRONT DIESEL ENGINE (ENGINE 2)

Special tools:
n/a
Crane
Oil drain pan
Diesel engine: 7000 kg
Dogman/rigger
2.3 on page 2-37.
Carry out preparatory work for diesel engines removal, refer

to section 3.1.1.1 on page 3-2.
Disconnect the fuel feeding hose (Fig. 3-6, Pos. 2) from the
fuel filters.
Disconnect the fuel return hose (Fig. 3-6, Pos. 1).
NOTE: When a fuel hose is disconnected, the fuel inside the

hose will flow out. Catch it in an oil pan.
Cap the openings with blind plugs to avoid contamination.
DANGER
Risk of fire!
Fig. 3-6

inflammable fuels.
Disconnect the coolant hoses (Fig. 3-7, Pos. 1) leading to the

heating of the operators cab.
Fig. 3-7
Version 2009/2
PC5500-6
3 -7
Diesel engine
Superstructure
Disconnect the (upper) main coolant lines (Fig. 3-8, Pos. 1).
Disconnect the (lower) main coolant return lines.
NOTE: For further information about the coolant lines, refer to

section 3.1.6.1 on page 3-38.
Fig. 3-8
z
Disconnect all wire harnesses leading to the engine

(Fig. 3-9).
Fig. 3-9
z
Disconnect all oil hoses of the oil management system

(Fig. 3-10, Pos. 1).
Disconnect the oil filling hose leading from the engine oil pan
to the service arm.
Fig. 3-10
3 -8
PC5500-6
Version 2009/2
Superstructure
Diesel engine
Remove the compressor (Fig. 3-11, Pos. 1) of the air conditioning system with attached refrigerant hoses and put it
aside.
NOTE: Do not disconnect the refrigerant hoses of the air conditioning from the compressor, because the air conditioning
must be serviced by authorized refrigeration specialists
only.
Fig. 3-11
z
Remove the Geislinger coupling, refer to section 3.1.8.1 on

page 3-45.
Remove the bolts attaching the PTO to the engine.
Attach the engine to a crane using the four lifting shackles

(Fig. 3-12, arrow) at the engine.
Fig. 3-12
z
Remove eight rear engine mounting bolts (Fig. 3-13, Pos. 1)

on both sides of the engine.
Fig. 3-13
Version 2009/2
PC5500-6
3 -9
Diesel engine
Superstructure
Remove the cover (Fig. 3-14, Pos. 1).
Fig. 3-14
z
Remove the engine mounting bolts (Fig. 3-15, Pos. 1) from

the engine torque support (Fig. 3-15, Pos. 2).
Move the engine with the crane away from the PTO at first
and then lift it out of the engine house.
DANGER

When removing the engine, make sure that nobody steps
below the weight.
Remove the bolts (Fig. 3-15, Pos. 3 and 4) and the engine
torque support (Fig. 3-15, Pos. 2) from the engine mounts
(Fig. 3-15, Pos. 5).
Fig. 3-15
NOTE: For further information about the engine torque support,

refer to section 3.1.2 on page 3-16.
3 - 10
PC5500-6
Version 2009/2
Superstructure
Diesel engine
3.1.1.3 REPLACEMENT OF THE FRONT DIESEL ENGINE (ENGINE 2)

Special tools:
n/a
Crane
Compound "KP2K", PN 324 969 40
Diesel engine: 7000 kg
Roof plate: 397 kg max.
Beam (transfer carrier): 285 kg
Dogman/rigger
If there is nothing mentioned explicitly, tighten all bolts according to
DIN, refer to section 2.2 on page 2-33.
Replace all flexible bearings and rubber-bounded metal bars

of the flexible mounts (Fig. 3-16, Pos. 5). Refer to PARTS &
SERVICE NEWS No. "AH01521".
Mount the engine torque support (Fig. 3-16, Pos. 2) onto the
flexible mounts.
Install the bolts (Fig. 3-16, Pos. 3 and 4) and tighten the bolts
hand-tight.
Attach the new engine to the crane and move it into mounting
position and install the engine mounting bolts (Fig. 3-16,
Pos. 1).
DANGER

Fig. 3-16
When installing the engine, make sure that nobody steps

below the weight.
Install a new Geislinger coupling, refer to section 3.1.8.2 on

page 3-49.
Reinstall the mounting bolts attaching the PTO to the engine.
Version 2009/2
PC5500-6
3 - 11
Diesel engine
Superstructure
Install eight rear engine mounting bolts (Fig. 3-17, Pos. 1) on

both sides and tighten them to the specified torque.
Tightening torque for rear engine mounting bolts:
400 Nm
Fig. 3-17
z
Tighten all bolts at the engine torque support, refer to section

3.1.2 on page 3-16 or to the PARTS & SERVICE NEWS
No. "AH01521".
Carry out further installation in reverse order to removal.
Use new mounting bolts (Fig. 3-18, Pos. 1 and Pos. 2) of

grade 10.9. Apply compound "KP2K", PN 324 969 40 on
heads and threads of the mounting bolts and tighten them to
the specified tightening torque.
Tightening torque for beam (transverse carrier)
mounting bolts: 880 Nm
Tightening torque for roof plats mounting bolts:

108 Nm
Fig. 3-18
Refill the engine coolant, approx. 360 liters.

chapter 3, section "CENTRAL REFILLING SYSTEM".
Refill the engine oil pan with engine oil, approx. 190
liters. Refer to the Operation & Maintenance Manual, chapter 3, section "CENTRAL REFILLING
SYSTEM".
Refill the engine oil reserve tank with engine oil,

approx. 580 liters. Refer to the Operation & Maintenance Manual, chapter 3, section "CENTRAL
REFILLING SYSTEM".
3 - 12
PC5500-6
Version 2009/2
Superstructure
Diesel engine
Bleed the fuel lines to the engine:

DANGER
Risk of fire!
inflammable fuels.
Assure that the emergency shut off valves (Fig. 3-19,

Pos. 1) and the shut-off-cock (Fig. 3-19, Pos. 2) are
opened.
Disconnect the feeding line at the engine fuel filter.
Wait until the fuel flows out.
Fig. 3-19
NOTE: Catch the leaking fuel in an oil pan.

z
Reconnect the feeding line to the engine fuel filter.
Disconnect the feeding line at the engine fuel pump.

z
Reconnect the feeding line to the engine fuel pump.

DANGER
Risk of fire!
Loose or missing ground cables can cause fire, serious
injury or death.
After repairs on the Diesel engines or starter motors, make
sure that the ground cables are correctly connected before
starting the engines.
DANGER
Risk of fire!
Serious injury, permanent disfigurement and scarring, or
death may result.
NEVER attempt to start the engines by shorting across
starter terminals.
Start the engines from the operators seat only.
Version 2009/2
PC5500-6
3 - 13
Diesel engine
Superstructure
WARNING
Before each starting make sure that all controls are in neutral
position. Be sure to sound the signal horn before starting to
make your intention clear.
NOTE: Before starting the engines pay attention to the hydraulic

oil temperature. Refer to the Operation & Maintenance
Manual, chapter 3, section "STARTING PROCEDURE".
3.1.1.4 REMOVAL OF THE REAR DIESEL ENGINE (ENGINE 1)

The removal of the rear diesel engine (engine 1, Fig. 3-20,
Pos. 1) is analogously the same as the removal of the front diesel
engine (engine 2, Fig. 3-20, Pos.2), refer to section 3.1.1.2 on
page 3-7.
NOTE: The rear diesel engine (engine 1) has no compressor for
the air conditioning system.
The coolant hoses leading to the heating of the operators cab only connected at the front engine (engine 2).
Fig. 3-20
3.1.1.5 REPLACEMENT OF THE REAR DIESEL ENGINE (ENGINE 1)

The replacement of the rear diesel engine (engine 1, Fig. 3-20,
Pos. 1) is analogously the same as the replacement of the front
diesel engine (engine 2, Fig. 3-20, Pos.2), refer to section 3.1.1.3
on page 3-11.
NOTE: The rear diesel engine (engine 1) has no compressor for
The coolant hoses leading to the heating of the operators cab only connected at the front engine (engine 2).
3 - 14
PC5500-6
Version 2009/2
Superstructure
Diesel engine
This page was left blank intentionally.
Version 2009/2
PC5500-6
3 - 15
Diesel engine
3.1.2
Superstructure
ENGINE TORQUE SUPPORT AND ENGINE/PTO MOUNTS
Fig. 3-21 Engine and PTO mounts with torque support
3 - 16
PC5500-6
Version 2009/2
Superstructure
Diesel engine

Quantity
both power
units
Size
Grade
WS*
Torque
(1)
Flexible bearing
24
(2)
Tie bolt
12
M24
10.9
36
snug
(3)
Self-locking nut
12
M24
8.0
36
snug
(4)
Rubber-bounded metal bar
12
(5)
Stop bolt
M36
10.9
55
to distance "A"
(6)
Cup springs
28
(7 per bolt)
(7)
Lock nut
M36
10.0
55
(8)
Engine mounting bolt, rear
32
3/410 UNC
(9)
Bolt
12
M24
10.9
36
880
(10)
Engine mounting bolt, front
M18
10.9
27
360
(11)
PTO mounting bolt
M30
10.9
46
1770
400
* Wrench Size
3.1.2.1 FLEXIBLE MOUNTS

The flexible mounts are installed to absorb the vibrations and the
torsional forces. They carry the total weight of the engine and the
pump distributor gear with all hydraulic pumps.
For this reason, all connections must be checked frequently
according to the maintenance manual (high-strength bolt connections) or when engine or PTO were replaced.
In the case of fatigue or damage of a metal rubber guide
(Fig. 3-21, Pos. 1), all metal rubber guides and their fastening
bolts with nuts must be replaced.
Also inspect the metal-rubber-bar (Fig. 3-21, Pos. 4) for fatigue or
damage and replace if necessary.
The bolt (Fig. 3-21, Pos. 2) must not have any axial play.
If necessary, re-tighten the nut (Fig. 3-21, Pos. 3) until rubber is
squeezed slightly out of rubber bar (Fig. 3-21, Pos. 4).
NOTE: For further information, refer to PART & SERVICE
NEWS No. "AH01521".
Version 2009/2
PC5500-6
3 - 17
Diesel engine
Superstructure
Fig. 3-22 Engine and PTO mounts with torque support
3 - 18
PC5500-6
Version 2009/2
Superstructure
Diesel engine
3.1.2.2 TORQUE SUPPORT

To absorb the torque force, the front engine support is additionally
supported with a cup spring package.
Check the cup springs (Fig. 3-22, Pos. 6) of both supports for
fatigue or damage regularly and replace them if necessary. Turn
the bolt (Fig. 3-22, Pos. 5) down until it slightly pre-stresses the
cup spring and secure with the lock nut.
(Distance between engine torque support and bolt head
"A" = 29 mm)
NOTE: The lock nuts (Fig. 3-22, Pos. 7) can be re-used 3 to 4
times. Assumed the bolt (Fig. 3-22, Pos. 2) thread is
cleaned thoroughly before turning the nut on or off, otherwise the locking part of the nut will be damaged and the
lock is not ensured.
Version 2009/2
PC5500-6
3 - 19
Diesel engine
3.1.3
Superstructure
ALTERNATOR
3.1.3.1 REMOVAL OF THE ALTERNATOR

Special tools:
n/a
n/a
Alternator: 38.25 kg

the machine and boom.
Remove the keys from the battery main switches

WARNING

Disobedience may result in personal injury from heated
engine parts.
Fig. 3-23
z
Remove all electrical connections from the alternator

(Fig. 3-24, Pos. 1) and remove the alternator.
NOTE: A second person is required to remove the alternator.

For further information refer to the Engine Operation &
Maintenance Manual.
Fig. 3-24
3 - 20
PC5500-6
Version 2009/2
Superstructure
Diesel engine
3.1.3.2 REPLACEMENT OF THE ALTERNATOR

Special tools:
n/a
Belt tension gauge

Alignment chart (steel ruler)
Alternator: 38.25 kg
Carry out installation in reverse order to removal.
NOTE: A second person is required to remove the alternator.

z
Check the alignment of the pulleys using an alignment chart.
NOTE: For the correct belt tension and use of the belt tension
gauge, refer to the Engine Operation & Maintenance
Manual and the User Instructions delivered together with
the belt tension gauge.
z
Check charging current of the new alternator.
Version 2009/2
PC5500-6
3 - 21
Diesel engine
3.1.4
Superstructure
BATTERIES
3.1.4.1 REMOVAL OF THE BATTERIES

Special tools:
n/a
Crane or forklift
Battery: 62 kg each
Dogman/rigger

the machine, boom, and crane or forklift.

z

DANGER
Danger of explosion due to hydrogen gas!

Blindness, serious injury, permanent disfigurement, and
scaring may result.
Never allow sparks or open flame near the batteries!
DO NOT short circuit or ground any terminals of the batteries!
3 - 22
PC5500-6
Version 2009/2
Superstructure
Diesel engine
Remove the keys from the battery main switches (Fig. 3-25,
Pos. 1).
NOTE: The batteries are located below the hinged floor plats
(Fig. 3-25, Pos. 2) in separate boxes.
z
Remove floor plate fastening bolts and open the hinged floor
plates (Fig. 3-25, Pos. 2).
NOTE: Wash the dirt of the floor plates (Fig. 3-25, Pos. 2) as
they can be very heavy.
z
Secure the open floor plates against falling down using the
safety chains provided.
Fig. 3-25
z
Disconnect the cables from the batteries (Fig. 3-26, Pos. 1).
DANGER
Risk of electrical and fire hazard!

Death, serious injury, shock, or burns may result.
Disconnect the ground cables (-) of both batteries first.
Remove the angles (Fig. 3-26, Pos. 2) from the batteries.
Take the batteries out of the battery boxes.
Fig. 3-26
WARNING
Use the provided loops to carry the batteries.
Do not drop the battery.
CAUTION
Never run the engine with disconnected batteries. This may
cause alternator damage.
Version 2009/2
PC5500-6
3 - 23
Diesel engine
Superstructure
3.1.4.2 REPLACEMENT OF THE BATTERIES

Special tools:
n/a
n/a
Battery: 62 kg each
Dogman/rigger
z

DANGER
Risk of electrical and fire hazard!

Death, serious injury, shock, or burns may result.
Connect the positive cables (+) of the batteries first.
WARNING
Avoid spilling any electrolyte on hands or clothing.
Repair or replace all broken wires immediately.
All terminals must be clean and securely fastened.
Never paint connections.
3 - 24
PC5500-6
Version 2009/2
Superstructure
Diesel engine
Version 2009/2
PC5500-6
3 - 25
Diesel engine
3.1.5
Superstructure
RADIATOR FAN
Fig. 3-27 Radiator fan assembly
3 - 26
PC5500-6
Version 2009/2
Superstructure
Diesel engine

(1)
Fan cage
(2)
Fan cowl
(3)
Bolt
(4)
Locking plate
(5)
Radiator fan
(6)
Hydraulic fan motor
(7)
Bolt
(8)
Fan bearing block
(9)
Bolt
(10)
Cover
The engine cooling system is a dual-circuit cooling circulation system. One cooling circuit cools the engine crankcase and the cylinder heads, the other circuit lowers the temperature of the
aftercooling system.
3.1.5.1 REMOVAL OF THE RADIATOR FAN ASSEMBLY

Special tools:
n/a
Crane
Chain hoist
Oil drain pan
Radiator fan: 35 kg
Hydraulic fan motor: 18 kg
Bearing block: 77.5 kg
Dogman/rigger
2.3 on page 2-37.


z
Relieve the pressure in the hydraulic system, refer to the

Operation & Maintenance Manual, chapter 3, section
"RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM".
Version 2009/2
PC5500-6
3 - 27
Diesel engine
Superstructure
3 - 28
PC5500-6
Version 2009/2
Superstructure
Diesel engine
NOTE: Carry out the following three steps only if the hydraulic
fan motor must be removed.
z
Remove the radiator fan,

refer to section 3.1.5.3 on page 3-33.
Close the hand wheel (Fig. 3-29, Pos. 1) of the main gate
valve between suction oil reservoir and main oil reservoir.
Transfuse the oil from the suction oil reservoir into the
main oil reservoir, refer to the Operation & Maintenance
Manual, chapter 3, section "FUNCTION OF THE TRANSFER PUMP".
Disconnect the hydraulic hoses from the hydraulic fan motor

(Fig. 3-28, Pos. 6).
Fig. 3-29
NOTE: When the hydraulic hoses are disconnected, the oil

inside the piping will flow out. Catch it in an oil pan.
Remove the bolts (Fig. 3-28, Pos. 7) and pull the hydraulic
fan motor (Fig. 3-28, Pos. 6) out of the fan bearing block
(Fig. 3-28, Pos. 9).
NOTE: The hydraulic lines may still be connected at the hydraulic fan motor if only the bearing block (Fig. 3-28, Pos. 9) is
being removed.
NOTE: Check if a lifting eye (Fig. 3-30, Pos. 1) is installed at the
roof plate over the hydraulic motor. Use the lifting eye to
hook a chain hoist.
If no lifting eye is installed, it has to be welded to the roof
plate.
WARNING
For welding follow the welding precautions given in the
Operation & Maintenance Manual, chapter 4, section "WELD
REPAIRS" and refer to PARTS & SERVICE NEWS
No. "AH08507".
Fig. 3-30
Version 2009/2
PC5500-6
3 - 29
Diesel engine
Superstructure
3 - 30
PC5500-6
Version 2009/2
Superstructure
Diesel engine
Sling the bearing block (Fig. 3-31, Pos. 8).
Remove the bolts (Fig. 3-31, Pos. 9) and remove the bearing
block using the chain hoist.
DANGER
May result in death or serious injury
When removing the parts through the PVG sound silencer
gate, make sure that nobody steps below the weight.
3.1.5.2 REPLACEMENT OF THE RADIATOR FAN ASSEMBLY

Special tools:
Rotational speed infrared probe DS03, PN 793 788 73 (if hydraulic fan
motor was replaced)
Chain hoist
Radiator fan: 35 kg
Hydraulic fan motor: 18 kg
Bearing block: 77.5 kg
Dogman/rigger
NOTE: If the hydraulic fan motor (Fig. 3-31, Pos. 6) was

replaced, the fan speed needs to be adjusted, refer to the
Service Manual for further information.
z
Bleed air from the hydraulic system, refer to the Operation &
Maintenance Manual, chapter 4, section "HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS
AND PULSATION DAMPER" and PARTS & SERVICE NEWS
No. "AH01513".
Add hydraulic oil up to the specified level.
Version 2009/2
PC5500-6
3 - 31
Diesel engine
Superstructure
Fig. 3-32 Removal and replacement of the radiator fan
3 - 32
PC5500-6
Version 2009/2
Superstructure
Diesel engine
3.1.5.3 REMOVAL OF THE RADIATOR FAN

Special tools:
n/a
n/a
Radiator fan: 35 kg
Removes the upper fan cage (Fig. 3-32, Pos. 1) from the fan
cowl (Fig. 3-32, Pos. 2).
Remove the six attaching bolts (Fig. 3-32, Pos. 3) with the
three locking plates (Fig. 3-32, Pos. 4).
NOTE: Discard the locking plates.

z
Remove the radiator fan (Fig. 3-32, Pos. 5) from the fan cowl
(Fig. 3-32, Pos. 2).
WARNING
Fan blades could have sharp edges. Use gloves!
CAUTION
Remove the assembly carefully in order not to damage the
radiator or the fan blades.
NOTE: A second person is required to remove the radiator fan.
3.1.5.4 REPLACEMENT OF THE RADIATOR FAN

Special tools:
n/a
n/a
Radiator fan: 35 kg
NOTE: Use new locking plates (Fig. 3-32, Pos. 4).

z
NOTE: A second person is required to install the radiator fan.
Version 2009/2
PC5500-6
3 - 33
Diesel engine
Superstructure
3.1.5.5 REMOVAL OF THE RADIATOR FAN DRIVE PUMP

Special tools:
n/a
Crane
Chain hoist
Oil drain pan
Radiator fan drive pump: 40 kg
Dogman/rigger
2.3 on page 2-37.
NOTE: The removal of the radiator fan drive pump (rear engine,
Fig. 3-33, Pos. 1) is analogously the same as the removal
of the radiator fan drive pump (front engine, Fig. 3-33,
Pos. 2).
Fig. 3-33
z


z

Open the PVG sound silencer gate on the right side of the
engine housing.
3 - 34
PC5500-6
Version 2009/2
Superstructure
Diesel engine
valve between suction oil reservoir and main oil reservoir.
Transfuse the oil from the suction oil reservoir into the main
oil reservoir, refer to the Operation & Maintenance Manual,
chapter 3, section "FUNCTION OF THE TRANSFER PUMP".
Fig. 3-34
roof plate over the pump. Use the lifting eye to hook a
chain hoist.
plate.
WARNING
No. "AH08507".
Fig. 3-35
WARNING
Hot hydraulic oil!
Do not carry out the following work on a hot machine. Wait
until the temperature of the hydraulic oil is below 50 C.
Disobedience may result in personal injury from heated oil.
Disconnect the pressure hose (Fig. 3-36, Pos. 1) and the suction hose (Fig. 3-36, Pos. 2) from the radiator fan drive pump.
NOTE: When the pump hoses are disconnected, the oil inside
the piping will flow out. Catch it in an oil pan.
z
Sling the pump, remove the mounting bolts and remove the
radiator fan drive pump by pulling it out of the PTO using a
chain hoist.
NOTE: To simplify the removal, move the pump assembly lightly

up and down.
When the pump assembly is removed, oil will flow out of
the spline shaft housing. Catch it in an oil pan.
Fig. 3-36
Version 2009/2
PC5500-6
3 - 35
Diesel engine
Superstructure
Check the O-ring at the pump flange and replace it if required.
Remove the radiator fan drive pump through the PVG sound
silencer gate using a crane.
DANGER

When removing the radiator fan drive pump through the PVG
sound silencer gate, make sure that nobody steps below the
weight.
3.1.5.6 REPLACEMENT OF THE RADIATOR FAN DRIVE PUMP

Special tools:
Rotational speed infrared probe DS03, PN 793 788 73
Paste "Optimol White" PN 999 039

Radiator fan drive pump: 40 kg
Dogman/rigger
z
NOTE: Use "Optimol White" on the spline shafts of the pumps.

Always use new O-rings at the SAE-flange connections.
Use new bolts (Fig. 3-36, Pos. 4) with grade 8.8 at the
mounting flanges.
Tighten the bolts to the specified tightening torque.
Tightening torque for mounting bolts:
74 Nm
3 - 36
PC5500-6
Version 2009/2
Superstructure
Diesel engine
Refill the oil collector reservoir (Fig. 3-37, Pos. 1) for the
spline shaft housing with lubricant, refer to the Operation
& Maintenance Manual, chapter 4, section "PTOs
(PUMP DISTRIBUTOR GEARS) AND OIL RESERVOIR
- CHECK OIL LEVEL".
For the proper lubricant, refer to section 6.1 on page 6-2.
Fig. 3-37
z
No. "AH01513".
Check for leaks and proper operation.
Check the hydraulic oil level again and add oil if required.
Check and adjust the speed of the radiator fan, refer to the
Operation & Maintenance Manual, section 2.5.
Version 2009/2
PC5500-6
3 - 37
Diesel engine
3.1.6
Superstructure
RADIATORS
The engine cooling system is a dual-circuit cooling circulation system. One cooling circuit cools the engine crankcase and the cylinder heads, the other circuit lowers the temperature of the
aftercooling system. Both circuits have separate radiators built in
one single assembly.
3.1.6.1 REMOVAL OF THE RADIATOR ASSEMBLY

Special tools:
n/a
Crane
Empty coolant storage tank
Roof plate: 116 kg
Radiator assembly: 650 kg
Fan cowl: 67 kg
Dogman/rigger
2.3 on page 2-37.


z

WARNING

Disobedience may result in personal injury from hot coolant
or steam.
Drain the engine coolant, approx. 360 liters.

Manual.
3 - 38
PC5500-6
Version 2009/2
Superstructure
Diesel engine
Disconnect all lines on both side of the roof plate (Fig. 3-38,
Pos. 1).
NOTE: When the oil hoses are disconnected, the oil inside the
piping will flow out. Catch it in an oil pan.
z
Dismount all attached parts from the roof plate (Fig. 3-38,
Pos. 1).
Remove all bolts (Fig. 3-38, Pos. 2) and resilient sleeves

(Fig. 3-38, Pos. 3) of the roof plate (Fig. 3-38, Pos. 1).
Sling the roof plate (Fig. 3-38, Pos. 1) and remove it using a
crane.
Fig. 3-38
DANGER
When removing the roof plate, make sure that nobody steps
below the weight.
Remove the upper and lower fan cage (Fig. 3-39, Pos. 1).
Remove the radiator fan,

Fig. 3-39
z
Open the hose clips (Fig. 3-40, Pos. 1) and disconnect the
upper coolant hoses (Fig. 3-40, Pos.3) from the radiator
assembly.
Disconnect the bypass hoses (Fig. 3-40, Pos. 4) and remove

the union (Fig. 3-40, Pos. 2).
Fig. 3-40
Version 2009/2
PC5500-6
3 - 39
Diesel engine
Superstructure
Open the hose clips (Fig. 3-41, Pos. 1) and disconnect the
coolant hoses (Fig. 3-41, Pos. 2) from the radiator assembly
(Fig. 3-41, Pos. 3).
Fig. 3-41
Sling the radiator at the eyes (Fig. 3-42, arrow) and attach it
to a crane.
Fig. 3-42
z
Disconnect all lines attached at the cowl (Fig. 3-43, Pos. 5).
Remove all mounting bolts (Fig. 3-43, Pos. 7) with locking

plates (Fig. 3-43, Pos. 8), and connector plates (Fig. 3-43,
Pos. 8). Discard the locking plates.
Take off the cowl (Fig. 3-43, Pos. 5) from the radiator
(Fig. 3-43, Pos. 5).
Remove all mounting bolts (Fig. 3-43, Pos. 1) and locking

plates (Fig. 3-43, Pos. 2) attaching the radiator assembly
(Fig. 3-43, Pos. 3) to the mount (Fig. 3-43, Pos. 4). Discard
the locking plates.
Remove the radiator assembly from the machine house.
Fig. 3-43
3 - 40
PC5500-6
Version 2009/2
Superstructure
Diesel engine
3.1.6.2 REPLACEMENT OF THE RADIATOR ASSEMBLY

Special tools:
n/a
Crane
Roof plate: 116 kg
Radiator assembly: 650 kg
Fan cowl: 67 kg
Dogman/rigger
NOTE: Use new locking plates and use new roof plate mounting
bolts of grade 10.9.
Apply compound "KP2K", PN 324 969 40 on heads and
threads of the mounting bolts and tighten them to the
specified tightening torque.
Tightening torque for roof plate mounting bolts:

108 Nm
Fill up the engine coolant, approx. 360 liters.

Manual.
z
Run engine to circulate the coolant through the system.
Check the coolant level again. Refer to the Operation & Maintenance Manual, section 3.9. Add coolant if required.
Version 2009/2
PC5500-6
3 - 41
Diesel engine
3.1.7
Superstructure
STARTER SYSTEM
Each diesel engine is equipped with two single starter motors.

One of the starter motors is equipped with an attached prelubrication pump. This prelubrication system is activated by the starter
switch. Turning and holding the starter switch in the start position
sends current to the prelubrication starter solenoid. The starter
motor starts spinning and propels the prelubrication pump. The
prelubrication procedure runs until a pressure of 17 kPa (2.5 psi)
has been attained in the cam oil rifle. After a 3 second delay, the
current is directed to the starter solenoid switch for cranking the
engine.
NOTE: At low ambient temperatures and cold diesel engine, the
prelubrication procedure will take more time.
3.1.7.1 REMOVAL OF THE STARTER MOTOR

Special tools:
n/a
n/a
Starter motor: 35.5 kg
Starter motor with prelubrication pump: 43.6 kg
Remove the keys from the battery main switches.

WARNING

Disobedience may result in personal injury from heated parts
or oil.
Disconnect the positive cable (Fig. 3-44, Pos. 2) from the

starter motor.
Disconnect the positive cable (Fig. 3-44, Pos. 6) and the control cables from the starter solenoid switch.
NOTE: Carry out the following step only if the starter motor with
the prelubrication pump (Fig. 3-44, Pos. 1) needs to be
removed.
z
Disconnect the suction hose (Fig. 3-44, Pos. 3) and the pressure hose (Fig. 3-44, Pos. 4) of the prelubrication system.
NOTE: When the oil hoses are disconnected, the motor oil inside
z
Fig. 3-44
Remove the multi-point mounting bolts and remove the

starter motor (second person is required).
3 - 42
PC5500-6
Version 2009/2
Superstructure
Diesel engine
3.1.7.2 REPLACEMENT OF THE STARTER MOTOR

Special tools:
n/a
n/a
Starter motor: 35.5 kg
Starter motor with prelubrication pump: 43.6 kg

Tightening torque for starter motor mounting
bolts (multi-point): 215 Nm
Refill engine oil to the specified level. Refer to the Engine

Operation and Maintenance Manual volume 2.
DANGER
Risk of fire!
Loose or missing ground cables can cause fire, serious
injury or death.
After repairs on the Diesel engines or starter motors, make
sure that the ground cables are correctly connected before
starting the engines.
DANGER
Risk of fire!
death may result.
NEVER attempt to start the engines by shorting across
starter terminals.
Start the engines from the operators seat only.
WARNING
Before each starting make sure that all controls are in neutral
position. Be sure to sound the signal horn before starting to
make your intention clear.
NOTE: Before starting the engines pay attention to the hydraulic

oil temperature. Refer to the Operation & Maintenance
Manual, chapter 3, section "STARTING PROCEDURE".
Version 2009/2
PC5500-6
3 - 43
Diesel engine
3.1.8
Superstructure
TORSION TYPE COUPLING (GEISLINGER)
Fig. 3-45 Geislinger coupling

(1)
Coupling assembly
(2)
Input drive flange
(3)
Leaf spring assembly
(4)
Output drive flange
(5)
Dip stick
(6)
Bleeder plug
(7)
O-rings
(8)
Spacer
(E)
Engine input flange
(G)
Gear box output flange
3 - 44
PC5500-6
Version 2009/2
Superstructure
Diesel engine
The combination of the high elasticity of its leaf springs with complimentary viscous damping by oil displacement, ensures that the
torsion type coupling removes major critical speeds outside the
engine speed range and dampens minor torsional vibrations
effectively.
The widest engine speed range free of vibration periods and dangerous resonance is thus obtained.
Furthermore, employment of these couplings with their highly
dampening characteristics generally results in lower stress in all
engine driving shafts and gears as well as in the crankshaft permitting further power development on standard components.
In any similar application, a simple vibration damper and/or a
pure flexible coupling would not confer the same advantages.
The springs (Fig. 3-45, Pos. 3) together with the inner driving and
outer driven member, form the chambers A and B (Fig. 3-45,
Pos. 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 spacer (Fig. 3-45, Pos. 8) limits the movement of the leaf
springs.
3.1.8.1 REMOVAL OF THE GEISLINGER COUPLING

Special tools:
n/a
Swivel hoist ring: M16

Chain hoist
Crane
Coupling assembly: 160 kg
Dogman/rigger


z
Version 2009/2
PC5500-6
3 - 45
Diesel engine
Superstructure
Fig. 3-46 Geislinger coupling - drain oil

WARNING
Do not carry out the following work on a hot engine.
Wait until the temperature of the engine is below 50C.
Disobedience may result in personal injury from heated
engine or PTO parts.
3 - 46
PC5500-6
Version 2009/2
Superstructure
Diesel engine
Remove the guard (Fig. 3-46, Pos. 1).
Turn flexible coupling using barring device (Fig. 3-46,

Pos. 2) to bring the bleeder plug (Fig. 3-46, Pos. 4) in its
lowermost (6 oclock) position.
NOTE: To use the barring device, remove the clip and push the
device shaft toward the flywheel. The barring device must
be rotated counter clockwise to turn the flywheel (flexible
coupling) in the direction of normal rotation.
Drain the coupling oil, approx 1.45 liters, by removing the bleeder plug (Fig. 3-46, Pos. 4).
NOTE: When the plug is removed, the oil inside the coupling will
flow out. Catch it in an oil pan.
z
Remove the dip stick (Fig. 3-46, Pos. 3), to speed-up the
draining procedure.

roof plate over the coupling. Use the lifting eye to hook a
chain hoist.
plate.
WARNING
No. "AH08507".
Fig. 3-47
Install a swivel hoist ring at the thread

(Fig. 3-48, Pos. 1) in the engine flange of the coupling.
Fig. 3-48
Version 2009/2
PC5500-6
3 - 47
Diesel engine
Superstructure
Fig. 3-49 Removal of the coupling

z
Remove the bolts (Fig. 3-49, Pos. 1) attaching the coupling

assembly (Fig. 3-49, Pos. 4) to the PTO input flange and to
the spacer (Fig. 3-49, Pos. 3).
Sling coupling. Dismantle the coupling assembly (Fig. 3-49,

Pos. 4) from the drive using a chain hoist.
NOTE: The coupling (Fig. 3-49, Pos. 4) must be compressed to

dismantle it from the PTO input flange.
z
Remove the bolts (Fig. 3-49, Pos. 5) and demount the spacer
(Fig. 3-49, Pos. 3).
Open the PVG sound silencer gate on the right side of the
engine housing and remove the coupling through the gate
using a crane.
3 - 48
PC5500-6
Version 2009/2
Superstructure
Diesel engine
3.1.8.2 REPLACEMENT OF THE GEISLINGER COUPLING

Special tools:
n/a
Swivel hoist ring: M16

Chain hoist
Crane
Coupling assembly: 160 kg
Dogman/rigger
z
Insert the new coupling into the engine housing through the
PVG sound silencer gate using a crane.

Before installing the guard (Fig. 3-50, Pos. 1) refill the
Geislinger coupling with lubricant approx. 1.45 liters,
refer to the Operation & Maintenance Manual, chapter 4,
section "FLEXIBLE DRIVE COUPLINGS- CHECK OIL
LEVEL".
Fig. 3-50
Version 2009/2
PC5500-6
3 - 49
PTO
Superstructure
3.2
PTO
3.2.1
MAIN PUMPS
Fig. 3-51 Main pumps assembly
3 - 50
PC5500-6
Version 2009/2
Superstructure
PTO

(1)
Main pump 1
(2)
Main pump 2
(3)
Main pump 3
(4)
Main pump 4
(5)
Main pump 5
(6)
Main pump 6
(7)
Pump distributor gear box (engine 2)
(8)
Pump distributor gear box (engine 1)
(9)
O-ring
The rotative energy from each main motor or engine propels the
gears in the pump distributor gear boxes (Fig. 3-51, Pos. 7,
Pos. 8) and the gears propel the main and auxiliary pumps.
The pumps create a hydraulic oil flow to the cylinders or hydraulic
motors. The main high pressure hydraulic circuits are supplied
from six swash plate type variable displacement pumps
(Fig. 3-51, Pos. 1 to 6). All Main pumps are additionally equipped
with gear pumps.
3.2.1.1 PREPARATORY WORKS FOR MAIN PUMP REMOVAL

Special tools:
n/a

Crane
Roof plate: 260 kg
Dogman/rigger


z

Version 2009/2
PC5500-6
3 - 51
PTO
Superstructure
valve between the suction oil reservoir and the main oil reservoir.
To accelerate the draining of oil from the pumps, loosen the

vent plugs on the main pumps, refer to Operation & Maintenance Manual, chapter 4, section "HYDRAULIC SYSTEM CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER".
Fig. 3-52
NOTE: The following steps indicate the standard procedure for

main pump removal. It is also possible to access the
main pump assemblies with a crane by opening the PVG
sound silencer gate on the right side of the engine house.
Carry out the following steps only if you refer to the standard procedure.
z
Remove all cables which lead through the roof plates over the
pumps.
WARNING

3 - 52
PC5500-6
Version 2009/2
Superstructure
PTO
Fig. 3-53 Right roof plate removal

(1)
Roof plate
(2)
Bolt
(3)
Resilient sleeve

(Fig. 3-53, Pos. 3) of the roof plate.
Remove the roof plate (Fig. 3-53, Pos. 1 and 2) with a crane
using swivel hoist rings.
Version 2009/2
PC5500-6
3 - 53
PTO
Superstructure
3.2.1.2 REMOVAL OF MAIN PUMPS

Special tools:
n/a
Crane
Oil drain pans
Main pump assembly with flanged gear pump: 362.4 kg each
Dogman/rigger
2.3 on page 2-37.
NOTE: The removal of all main pumps (Fig. 3-54, Pos. 1 - 6) is

analogously always the same.
Fig. 3-54
z
Carry out the preparatory work, refer to section 3.2.1.1 on

page 3-51.
If equipped with, remove fasteners for hoses of the main

pump assembly to be removed.
Mark all pipes and hoses at that main pump assembly of the
main pump to be removed.
DANGER
Danger of hydraulic pressure!

Blindness, serious injury, permanent disfigurement, or scaring may result.
The hydraulic system may be pressurized. Make sure that the
pressure is relieved before any hydraulic line will be
removed.
3 - 54
PC5500-6
Version 2009/2
Superstructure
PTO
Drain the drive shaft housing oil, approx. 1.5 liters by

removing the drain plug (Fig. 3-55, Pos. 3) of the
Remove the level plug opening (Fig. 3-55, Pos. 2) to
speed up the draining procedure.
NOTE: When the plugs are removed, the oil inside the drive shaft
housing will flow out. Catch it in an oil pan.
Fig. 3-55
z
Disconnect the SAE-flanges of the pressure hose and the

suction hose from the gear pump (Fig. 3-56, Pos. 4) of the
z
Disconnect the leak oil hose and all control hoses from the
control block (Fig. 3-56, Pos. 1).
Disconnect the bearing flushing/lubrication hose from the

right side of the pump mounting flange.
Disconnect the high pressure hose (Fig. 3-56, Pos. 2) from

the main pump assembly.
Disconnect the suction hose (Fig. 3-56, Pos. 3) at the bottom

side of the pump.
Fig. 3-56
Version 2009/2
PC5500-6
3 - 55
PTO
Superstructure
Sling pump assembly as shown in Fig. 3-57.
Remove mounting bolts. Then remove pump assembly by

pulling it out of the pump distributor gear box.
DANGER

When removing the main pump assembly, make sure that
nobody steps below the weight.

up and down.
Fig. 3-57

z
Check the O-ring (Fig. 3-57, Pos. 1) at the pump assembly

flange and replace it if required.
3.2.1.3 REPLACEMENT OF MAIN PUMPS

Special tools:
n/a
Crane
Paste Optimol White, PN 999 039
Main pump assembly with flanged gear pump: 362.4 kg each
Dogman/rigger
NOTE: When mounting a new pump, activate the external flushing of bearing. Refer to PARTS & SERVICE NEWS
No. "AH05510".
z
NOTE: Use "Optimol White" on the spline shaft of the pump.

Use new bolts with grade 8.8 at the mounting flanges of
the main pump.
Tightening torque for the mounting bolts:
360 Nm
3 - 56
PC5500-6
Version 2009/2
Superstructure
PTO
NOTE: Connecting the suction hose, refer to

PARTS & SERVICE NEWS No. "AH05525".
NOTE: Always use new O-rings at the SAE-flange connections
and hose fittings.
Refill lubricant in the drive shaft housing approx.
1.5 liters, refer to Operation & Maintenance Manual,
chapter 4, section "PTOs (PUMP DISTRIBUTOR
GEARS) AND OIL RESERVOIR - CHECK OIL LEVEL".
Fill up to lower edge of level plug opening (Fig. 3-58,
Pos. 2).
Fig. 3-58
z
Bleed air from the hydraulic system, refer to Operation &

No. "AH01513".
Adjust main pump, refer to the Service Manual for further

information and refer to PARTS & SERVICE NEWS
No. "AH06542".
Check for leaks and proper operation.
Check the hydraulic oil level again and correct the oil level if
required.
Version 2009/2
PC5500-6
3 - 57
PTO
3.2.2
Superstructure
PTO OIL PUMP (AUXILIARY PUMP)
The gear oil pumps (Fig. 3-59, Pos. 1) for the PTO gear lubrication aspirate gear oil from the PTO gear boxes sump and pumps it
through filters and coolers back to the PTOs.
The gear oil pumps are attached at the main pump 1 assembly or,
respectively, at main pump 4 assembly.
Fig. 3-59
3.2.2.1 REMOVAL OF PTO OIL PUMP (AUXILIARY PUMP)

Special tools:
n/a
Oil drain pan

PTO oil pump: 25 kg
Dogman/rigger
2.3 on page 2-37.
z


z

Disconnect the SAE-flanges of pressure hose and suction

hose from the PTO oil pump (Fig. 3-59, Pos. 1) to be
removed.
3 - 58
PC5500-6
Version 2009/2
Superstructure
PTO
z
Remove the two bolts (Fig. 3-60, Pos. 1) and pull the PTO oil
pump (Fig. 3-60, Pos. 7) out of the adapter (Fig. 3-60, Pos. 2).
Remove the four bolts (Fig. 3-60, Pos. 6) and disconnect the
adapter (Fig. 3-60, Pos. 2) from the main pump assembly
(Fig. 3-60, Pos. 5).
Discard the O-ring (Fig. 3-60, Pos. 4).
NOTE: Check the joint element (Fig. 3-60, Pos. 3) for wear and
replace it if required.
Fig. 3-60
Version 2009/2
PC5500-6
3 - 59
PTO
Superstructure
3.2.2.2 REPLACEMENT OF THE PTO OIL PUMP (AUXILIARY PUMP)

Special tools:
Hydraulic testing kit, PN 232 591 40

PTO oil pump: 25 kg
Dogman/rigger
z
Check PTO oil pump before installing, refer to PARTS & SERVICE NEWS No. "AH03511" and "AH03512".
Remove the two bolts (Fig. 3-60, Pos. 1) at the new PTO oil
pump and disconnect the new adapter (Fig. 3-60, Pos. 1)
carefully.
To avoiding of corrosion coat the adapter surfaces and the

pump surface with Optimol White, refer to PARTS & SERVICE NEWS No. "AH06543".
NOTE: Use "Optimol White" on the spline shaft of the pump and
use a new O-ring (Fig. 3-60, Pos. 4).
NOTE: Use new mounting bolts with grade 8.8 at the mounting
flanges of the pump and adapter.
74 Nm
z

No. "AH01513".
Run machine to warm, test pressure of the PTO oil pump and
adjust if required. Refer to Service Manual.
3 - 60
PC5500-6
Version 2009/2
Superstructure
3.2.3
PTO
OIL CIRCULATION PUMP (AUXILIARY PUMP)
The oil circulation pumps (Fig. 3-61, Pos. 1) together with back
pressure valves prevent cavitation in the swing motors during the
swing down phases. For further information refer to section 3.4.4
on page 3-190 and the Service Manual.
The oil circulation pumps are attached at the main pump 2
assembly or, respectively, at the main pump 5 assembly 5.
Fig. 3-61
3.2.3.1 REMOVAL OF OIL CIRCULATION PUMP (AUXILIARY PUMP)

Special tools:
n/a
Oil drain pan

Oil circulation pump: 25 kg
Dogman/rigger
2.3 on page 2-37.
z


z


hose from the circulation pump (Fig. 3-61, Pos. 1) to be
removed.
Version 2009/2
PC5500-6
3 - 61
PTO
Superstructure
z
Remove the two bolts (Fig. 3-62, Pos. 1) and pull the oil circulation pump (Fig. 3-62, Pos. 7) out of the adapter (Fig. 3-62,
Pos. 2).
adapter (Fig. 3-62, Pos. 2) from the main pump assembly
(Fig. 3-62, Pos. 5).
Check the joint element (Fig. 3-62, Pos. 3) for wear and
Fig. 3-62
3 - 62
PC5500-6
Version 2009/2
Superstructure
PTO
3.2.3.2 REPLACEMENT OF THE OIL CIRCULATION PUMP (AUXILIARY PUMP)

Special tools:
Hydraulic testing kit, PN 232 59140

Oil circulation pump: 25 kg
Dogman/rigger
z
Check the oil circulation pump before installing, refer to

PARTS & SERVICE NEWS No. "AH03511" and "AH03512".
Remove the two bolts (Fig. 3-62, Pos. 1) at the new oil
circulation pump and disconnect the new adapter (Fig. 3-60,
Pos. 1) carefully.

NOTE: Use "Optimol White" on the spline shaft of the pump and
use a new O-ring (Fig. 3-62, Pos. 4).
NOTE: Use new mounting bolts with grade 8.8 at the mounting
flanges of the pump and adapter.
74 Nm
z

No. "AH01513".
Run machine to warm, test pressure of the oil circulation

pump and adjust if required. Refer to Service Manual.
Version 2009/2
PC5500-6
3 - 63
PTO
3.2.4
Superstructure
PUMP DISTRIBUTOR GEARBOX (PTO)
Fig. 3-63 Pump distributor gearbox
3 - 64
PC5500-6
Version 2009/2
Superstructure
PTO

(1)
Oil level gauge
(2)
Oil filler plug
(3)
Breather filter
(4)
Oil collector reservoir for auxiliary pump drive shaft

housing
(5)
Breather filter with oil level gauge

(drive shaft housing)
(6)
Main pump drive shaft housings
(7)
Oil level plug of main pump drive shaft housing
(8)
Oil filler plug with breather pipe of main pump drive

shaft housing
(9)
Oil drain plug of main pump drive shaft housing
(10)
Oil drain plug of PTO gear
(11)
Flange for heater studs
(12)
Gear oil temperature sensor mounting bore
(14)
Suction port to PTO lubrication pump
(16)
Return line connection from gear oil cooler
(D)
Drive flange
(M)
Power take off for main pumps
(R)
Power take off for engine radiator fan drive pump
(C)
Power take off for hydraulic oil cooler fan drive pump
The pump distribution gear (PTO gear) is from a spur gear design
and driven by a Diesel engine. It is equipped with an external
lubrication/cooling system.
The PTO gear runs in anti friction bearings and has been provided with a splash lubrication system. The oil supply of the bearings and tooth contacts takes place by an injection. The
gearwheels are of case-hardened steel. The hydraulic pumps are
directly attached to the gearbox. The O-rings included in the delivery seal the unit statically and reliably.
The gear box housing is a one-piece design and made of grey
cast iron. Gear box design allows a direct attachment to the diesel
engine via a connection flange. The gear box has been provided
with connections for a separate cooling system or for a preheating
system.
Always check gear box oil level with unlocked dip stick and
stopped engine.
Version 2009/2
PC5500-6
3 - 65
PTO
Superstructure
3.2.4.1 REMOVAL OF THE PUMP DISTRIBUTOR GEARBOX (PTO)

Special tools:
n/a
Crane
Oil drain pans
PTO: 1900 kg each
Control- and filter plate assembly: 260 kg each
Dogman/rigger
2.3 on page 2-37.
z
Carry out the preparatory work, refer to section 3.2.1.1 on

page 3-51.
NOTE: The removal of the pump distributor gearbox 1 (Fig. 3-64,

Pos. 7) and pump distributor gearbox 2 (Fig. 3-64,
Pos. 8) is analogously the same.
Drain the gear oil of the PTO to be removed, approx.
95 liters. Refer to Operation & Maintenance Manual,
chapter 4, section "PTO (PUMP DISTRIBUTOR
GEAR) - CHANGE OIL".
z
Remove main pump assemblies 1-3 (Fig. 3-64, Pos. 1-3)

respectively main pump assemblies 4-6 (Fig. 3-64, Pos. 4-6),
Fig. 3-64
Remove the radiator fan drive pump of the PTO to be

removed, refer to section 3.1.5.5 on page 3-34.
Remove the hydraulic cooler fan drive pump of the PTO to be

removed, refer to section 3.3.1.1 on page 3-72.
Relieve pilot pressure at the pressure check point M40 for

accumulator, refer to Service Manual.
3 - 66
PC5500-6
Version 2009/2
Superstructure
PTO
Fig. 3-65 PTO 1+2 with control- and filter plates
(1)
Pump distributor gearbox (PTO), engine 1
(2)
Pump distributor gearbox (PTO), engine 2
(3)
Control- and filter plate (engine 1)
(4)
Control- and filter plate (engine 2)
Mark and disconnect all hydraulic lines and electrical wires

leading to the control- and filter plate assembly of the PTO to
be removed (Fig. 3-65, Pos. 3 respectively Fig. 3-65, Pos. 4).
z
Sling the control- and filter plate assembly of the PTO to be

removed (Fig. 3-65, Pos. 3 respectively Fig. 3-65, Pos. 4) to a
crane.
Version 2009/2
PC5500-6
3 - 67
PTO
Superstructure
Remove mounting bolts (Fig. 3-66, Pos. 1) with resilient

sleeves (Fig. 3-66, Pos. 2).
Remove the control- and filter plate assembly (Fig. 3-66,

Pos. 3) using a crane.
DANGER

When removing the control frame assembly make sure that
Fig. 3-66
z
Disconnect all hydraulic hoses from the PTO.
NOTE: When the hoses are disconnected, the oil inside the piping will flow out. Catch it in an oil pan.
z
Disconnect all retainers for hydraulic hoses and electrical

wires at the PTO.
Fig. 3-67
z
Disconnect the temperature sensor (Fig. 3-68, Pos. 1).
Disconnect the heating and the thermo switch if equipped.
Remove the coupling (Fig. 3-68, Pos. 2, refer to section

3.1.8.1 on page 3-45.
Fig. 3-68
3 - 68
PC5500-6
Version 2009/2
Superstructure
PTO
Attach the PTO to a crane, using the lifting eyes (Fig. 3-69,
arrows).
Fig. 3-69
z
Remove the bolts (Fig. 3-70, Pos. 1) with resilient sleeves

(Fig. 3-70, Pos. 2) attaching the PTO to the support
(Fig. 3-70, Pos. 3).
Fig. 3-70
z
Remove the bolts attaching the PTO to the engine.
Remove the PTO using the crane.

DANGER

When removing the PTO, make sure that nobody steps below
the weight.
Version 2009/2
PC5500-6
3 - 69
PTO
Superstructure
3.2.4.2 REPLACEMENT OF THE PUMP DISTRIBUTOR GEARBOX (PTO)

Special tools:

Crane
PTO: 1900 kg each
Control- and filter plate assembly: 260 kg each
Dogman/rigger
z
If required, install the temperature sensor, the heating, and

the thermo switch to the replacement PTO.
Check the flexible bearings (Fig. 3-71, Pos. 4) for damage

and signs of fatigue, refer to the Operation & Maintenance
Manual, chapter 4, section "HIGH STRENGTH BOLT CONNECTIONS - CHECK TORQUE LOAD". Replace the bearings if necessary.
NOTE: Always use new O-rings at all SAE-flange connections.

NOTE: Use the specified tightening torque for PTO mounting
bolts (Fig. 3-71, Pos. 1) at the support (Fig. 3-71,
Pos. 3).
Tightening torque for the PTO mounting bolts:
1770 Nm
Fig. 3-71
Refill gear oil of the PTO, approx. 95 liters.
chapter 4, section "PTO (PUMP DISTRIBUTOR
GEAR) - CHANGE OIL".
z
Run machine to warm, test pressure of the circulation pump

and adjust if required. Refer to Service Manual for further
information.
3 - 70
PC5500-6
Version 2009/2
Superstructure
Hydraulics
3.3
HYDRAULICS
3.3.1
HYDRAULIC COOLER FAN DRIVE PUMP
The hydraulic cooler fan drive pump is a fixed displacement pump

with variable setting. The pump of the type A7F0 is a variable displacement pump, designed to operate in open circuits. It has an
internal case drain return. The rotary group is a robust self aspirating unit. External forces may be applied to the drive shaft.
The right hydraulic pump on PTO 1 (Fig. 3-72, Pos. 1) supplies
the lower and the right hydraulic pump on PTO 2 (Fig. 3-72, Pos.
2) supplies the upper hydraulic fan motor. The fans are mounted
directly to the hydraulic motors drive shaft.
Fig. 3-72
Changing the swivel angle of the rotary group is achieved by sliding the control lens along a cylindrical formed track by means of
an adjusting screw.
z
With an increase in the swivel angel, the pump output

increases together with the necessary drive torque.
With an decrease in the swivel angel, the pump output

decreases together with the necessary drive torque.
NOTE: When increasing to maximum swivel angle, there is a

danger of cavitation and over-speeding the hydraulic
motor.
Version 2009/2
PC5500-6
3 - 71
Hydraulics
Superstructure
3.3.1.1 REMOVAL OF THE HYDRAULIC COOLER FAN DRIVE PUMP

Special tools:
n/a
Chain hoist
Crane
Oil drain pan
Hydraulic cooler fan drive pump: 40 kg
Dogman/rigger
2.3 on page 2-37.
z


z

chapter 3, section "FUNCTIONS OF THE TRANSFER
PUMP".
Fig. 3-73
3 - 72
PC5500-6
Version 2009/2
Superstructure
Hydraulics

roof plate over the pump. Use the lifting eye to hook a
chain hoist.
plate.
WARNING
No. "AH08507".
Fig. 3-74
WARNING
Hot hydraulic oil!
Dismantle the hose mounting plate (Fig. 3-75, Pos. 1).
z
Disconnect the pressure hose (Fig. 3-75, Pos. 2) and the suction hose (Fig. 3-75, Pos. 3) from the hydraulic cooler fan
drive pump (Fig. 3-75, Pos. 5).
Sling the pump, remove the bolts (Fig. 3-75, Pos. 4), and
remove the hydraulic cooler fan drive pump (Fig. 3-75,
Pos. 5) by pulling it out of the PTO using a chain hoist.
Fig. 3-75
Version 2009/2
PC5500-6
3 - 73
Hydraulics
Superstructure

up and down.
z
Check the O-ring at the pump flange and replace it if required.
Remove the hydraulic cooler fan drive pump through the PVG
sound silencer gate using a crane.
DANGER

When removing the hydraulic cooler fan drive pump through
the PVG sound silencer gate, make sure that nobody steps
below the weight.
3 - 74
PC5500-6
Version 2009/2
Superstructure
Hydraulics
3.3.1.2 REPLACEMENT OF THE HYDRAULIC COOLER FAN DRIVE PUMP

Special tools:
Crane
Chain Hoist
Hydraulic cooler fan drive pump: 40 kg
Dogman/rigger
z

Always use new O-rings at the SAE-flange connections.
Use new bolts (Fig. 3-75, Pos. 4) with grade 10.9 at the
mounting flanges.
threads of the bolts and tighten them to the specified
tightening torque.
74 Nm
Refill the oil collector reservoir (Fig. 3-76, Pos. 1) for the
spline shaft housing.

No. "AH01513".
Fig. 3-76
Check and adjust the speed of the hydraulic cooler fan, refer
to the Operation and Maintenance Manual, chapter 3, section
"ELECTRONIC MONITORING AND CONTROL SYSTEM
ECS".
Version 2009/2
PC5500-6
3 - 75
Hydraulics
3.3.2
Superstructure
HYDRAULIC COOLER FAN ASSEMBLY
There are four (temperature range up to 40 C) hydraulic oil coolers in front of the hydraulic oil reservoir on the right-hand side of
the platform.
Two cooler elements are mounted in one frame at a time, one
above the other. So two frames are installed with two cooler elements installed in each frame. The air stream needed for the cooling is produced by hydraulically driven fans. The air flows from
inside to outside through the coolers.
For better cleaning, the cooler frames are mounted via hinges to
the cooler support so the cooler frames can be opened. ("swing
out cooler").
The two cooler fans are driven by hydraulic motors. Each motor is
supplied by one hydraulic pump. The right hydraulic pump on
PTO 1 (Fig. 3-77, Pos. 1) supplies the lower and the right hydraulic pump on PTO 2 (Fig. 3-77, Pos. 2) supplies the upper hydraulic
fan motor. The fans are mounted directly to the hydraulic motors
drive shaft.
Fig. 3-77
3 - 76
PC5500-6
Version 2009/2
Superstructure
Hydraulics
3.3.2.1 REMOVAL OF HYDRAULIC COOLER FAN ASSEMBLY

Special tools:
n/a
Oil drain pan

Crane
Hydraulic cooler fan assembly: 117.4 kg
Dogman/rigger
2.3 on page 2-37.
z


z

Version 2009/2
PC5500-6
3 - 77
Hydraulics
Superstructure
Fig. 3-78 Position of the hydraulic cooler fan assembly

z
Open the hydraulic fan guard (Fig. 3-78, Pos. 1)

WARNING
Hot hydraulic oil!

DANGER
removed.
Disconnect the hydraulic pressure hoses (Fig. 3-78, Pos. 3)

and the leak oil hose (Fig. 3-78, Pos. 2) from the hydraulic
motor.
3 - 78
PC5500-6
Version 2009/2
Superstructure
Hydraulics
NOTE: When the hoses are removed, the oil inside the hoses will
z
Remove the hydraulic cooler fan assembly (Fig. 3-79,

Pos. 1) from the main cooler frame support, supported using
a crane.
WARNING
CAUTION
Remove the assembly carefully in order not to damage the
oil cooler or the fan blades.
Fig. 3-79
DANGER
When removing the hydraulic cooler fan drive pump through
the PVG sound silencer gate, make sure that nobody steps
below the weight.
Version 2009/2
PC5500-6
3 - 79
Hydraulics
Superstructure
3.3.2.2 REPLACEMENT OF HYDRAULIC COOLER FAN ASSEMBLY

Special tools:
Crane
Hydraulic cooler fan assembly: 117.4 kg
Dogman/rigger
z
Carry out installation in reverse order to removal. Refer to

WARNING
CAUTION
Install the assembly carefully in order not to damage the oil
cooler or the fan blades.

"AH01513".
Check and adjust the speed of the hydraulic cooler fan, refer
to the Operation and Maintenance Manual, chapter 3, section
"ELECTRONIC MONITORING AND CONTROL SYSTEM
ECS".
3 - 80
PC5500-6
Version 2009/2
Superstructure
Hydraulics
Version 2009/2
PC5500-6
3 - 81
Hydraulics
Superstructure
3.3.2.3 REMOVAL OF HYDRAULIC COOLER FAN AND MOTOR

Special tools:
n/a
Oil drain pan

Fan: 19 kg
Hydraulic cooler fan mounting assembly: 72 kg
Hydraulic motor assembly: 26.4 kg
Dogman/rigger
Remove the hydraulic cooler fan assembly, refer to section

3.3.2.1 on page 3-77.
Fig. 3-80 Hydraulic cooler fan assembly
3 - 82
PC5500-6
Version 2009/2
Superstructure
Hydraulics

(1)
Bolt
(2)
Locking plate
(3)
Cooler fan
(4)
Drive shaft
(5)
Shaft protecting sleeve
(6)
Drive shaft seal
(7)
Bearing
(8)
Distance sleeve
(9)
Bearing group carrier
(10)
Bearing
(11)
Circlip
(12)
O-ring
(13)
Hydraulic motor
(14)
Bolt
WARNING
NOTE: Carry out the two following two steps only if cooler fan
needs to be removed.
Remove the attaching bolts (Fig. 3-80, Pos. 1) with the

locking plates (Fig. 3-80, Pos. 2). Discard the locking
plates.
Remove the cooler fan (Fig. 3-80, Pos. 3) from the drive
shaft (Fig. 3-80, Pos. 4).
Remove the four bolts (Fig. 3-80, Pos. 14) and remove the
hydraulic motor (Fig. 3-80, Pos. 13) from the bearing group
carrier (Fig. 3-80, Pos. 9). Discard the O-ring (Fig. 3-80,
Pos. 12).
NOTE: When the hydraulic motor is disconnected from the bearing group carrier, the oil inside the bearing group carrier
will flow out. Catch it in an oil pan.
z
If required remove the circlip (Fig. 3-80, Pos. 11), extract the
drive shaft (Fig. 3-80, Pos. 4) out of the bearing group carrier
(Fig. 3-80, Pos. 9), and remove the drive shaft seal (Fig. 3-80,
Pos. 6), the bearings (Fig. 3-80, Pos. 7 and 10), and the
sleeves (Fig. 3-80, Pos. 5 and 8).
Version 2009/2
PC5500-6
3 - 83
Hydraulics
Superstructure
3.3.2.4 REPLACEMENT OF HYDRAULIC COOLER FAN AND MOTOR

Special tools:
n/a
n/a
Fan: 19 kg
Hydraulic cooler fan mounting assembly: 72 kg
Hydraulic motor assembly: 26.4 kg
Dogman/rigger
Fig. 3-81 Hydraulic cooler fan assembly

z
Carry out installation in reverse order to removal. Refer to

NOTE: If the drive shaft (Fig. 3-81, Pos. 4) is removed, check the
drive shaft.
Check drive shaft seal (Fig. 3-81, Pos. 6) for wear and
damage. Replace if required.
NOTE: Use a new O-ring (Fig. 3-81, Pos. 12) and new locking
plates (Fig. 3-81, Pos. 2).
3 - 84
PC5500-6
Version 2009/2
Superstructure
Hydraulics
WARNING
Install the hydraulic cooler fan assembly, refer to section

3.3.2.2 on page 3-80.
NOTE: Check the oil level in the bearing group carrier (Fig. 3-81,
Pos. 9) and add oil if required, refer to the Operation &
Maintenance Manual, chapter 4, section "HYDRAULIC
OIL COOLER FAN BEARINGS - CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER".
z

No. "AH01513".
Version 2009/2
PC5500-6
3 - 85
Hydraulics
3.3.3
Superstructure
HYDRAULIC OIL COOLERS
Fig. 3-82 Hydraulic oil cooler circuit

3 - 86
PC5500-6
Version 2009/2
Superstructure
Hydraulics

(1)
Back pressure valve
(2)
Solenoid valve (4/2-directional control valve)
(3)
Return lines from control blocks
(4)
Return oil collector tube
(5)
Restrictor (shock absorbers for the hydraulic oil

cooler)
(6)
Lines to cooler (hot oil)
(7)
(8)
Lines to hydraulic oil reservoir
(9)
Hydraulic oil reservoir
The returning oil from the system flows via the ines (Fig. 3-82,
Pos. 3) into the collector tube (Fig. 3-82, Pos. 4). On the top side
of it the back pressure valve (Fig. 3-82, Pos. 1) is installed. The
back pressure valve causes a back pressure which forces most of
the relative hot oil via the lines (Fig. 3-82, Pos. 6) to the cooler
(Fig. 3-82, Pos. 7).
On the flow to the cooler the hydraulic oil passes the restrictor,
gets cooled in the cooler and then flows through the lines
(Fig. 3-82, Pos. 8) into the filter chamber of the hydraulic oil
reservoir (Fig. 3-82, Pos. 9).
The restrictors acts as shock absorbers to prevent cooler cracks
created from pressure peaks.
Besides the back pressure valve acts as an oil flow control valve
as far as the oil temperature has not reached its steady temperature. During the warm up period (1/2 Qmax) the back pressure
valve (Fig. 3-82, Pos. 1) is wide open, because the solenoid valve
(Fig. 3-82, Pos. 2) is energized, which results in less oil flow
through the cooler which causes the oil getting its optimum operating temperature quicker.
With increasing oil temperature the oil gets thinner, so that the
main pumps can be shifted to Qmax position and simultaneously
the solenoid valve (Fig. 3-82, Pos. 2) will be de-energized, so that
the valve piston will be closed further by the force of the spring
resulting in more oil passing the cooler.
NOTE: Each oil cooler contains the hydraulic oil cooler and PTO
gear oil cooler. The machine is equipped with four oil
coolers.
Version 2009/2
PC5500-6
3 - 87
Hydraulics
Superstructure
3.3.3.1 REMOVAL OF THE HYDRAULIC OIL COOLERS

Special tools:
n/a
Safety harness in conformity with DIN EN 361

Crane
Mobile elevator working platform
Oil drain pans
Hydraulic oil cooler: 275 kg each
Dogman/rigger
2.3 on page 2-37.
z


z

"RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM"
3 - 88
PC5500-6
Version 2009/2
Superstructure
Hydraulics
Transfuse the oil from the return manifold into the main oil
reservoir, refer to the Operation & Maintenance Manual,
PUMP".
Open the hydraulic oil cooler door. Refer to Operation & Maintenance Manual, chapter 4, section "HYDRAULIC OIL
COOLERS - INSPECT AND CLEAN IF NECESSARY".
WARNING
Fig. 3-83
Hot hydraulic oil!

Do not carry out the following work on a hot machine.
Wait until the temperature of the hydraulic oil is below
50 C. Disobedience may result in personal injury from
heated oil.
Always wear a safety harness when working at the

hydraulic oil coolers.
Disconnect the hoses (Fig. 3-84, Pos. 1 and 2) from the PTO
gear oil cooler.
NOTE: When the hoses are removed, oil will flow out of the oil
coolers. Catch it in an oil pan.
Fig. 3-84
Version 2009/2
PC5500-6
3 - 89
Hydraulics
Superstructure
Disconnect all inlet hoses (Fig. 3-85, Pos. 2) and outlet hoses
(Fig. 3-85, Pos. 1) from the hydraulic oil cooler.
NOTE: When the hoses are removed, oil will flow out of the oil
coolers. Catch it in an oil pan.
Fig. 3-85
z
Sling the oil cooler (Fig. 3-86).
Fig. 3-86
3 - 90
PC5500-6
Version 2009/2
Superstructure
Hydraulics
Fig. 3-87 Removal of the oil cooler

z
Remove the bolts (Fig. 3-87, Pos. 2), the washers (Fig. 3-87,
Pos. 3) and locking plates (Fig. 3-87, Pos. 4), and clear the oil
cooler (Fig. 3-87, Pos. 1) from the angle (Fig. 3-87, Pos. 8).
Lift the oil cooler (Fig. 3-87, Pos. 1) out of the radiator mounting (Fig. 3-87, Pos. 9) using a crane.
DANGER

When removing the hydraulic oil cooler, make sure that
NOTE: Discard locking plates (Fig. 3-87, Pos. 4).

Check condition of buffer elements (Fig. 3-87, Pos. 10),
and replace them if required.
Version 2009/2
PC5500-6
3 - 91
Hydraulics
Superstructure
3.3.3.2 REPLACEMENT OF THE HYDRAULIC OIL COOLERS

Special tools:
n/a

Crane
Glue PN 256 952 40
Hydraulic oil cooler: 275 kg each
Dogman/rigger
Fig. 3-88 Installation of the oil cooler
3 - 92
PC5500-6
Version 2009/2
Superstructure
Hydraulics
WARNING
Always wear a safety harness when working at the hydraulic
oil coolers.
Exchange the restrictor (Fig. 3-82, Pos. 5) from the old oil
cooler to the new oil cooler.
Apply glue PN 256 952 40 to the profiled joints (Fig. 3-88,

Pos. 5 to 7) and attach them in the same manner as they
were fixed to the old oil cooler.
NOTE: Use new locking plates (Fig. 3-88, Pos. 4).

z
No."AH01513".
Add PTO gear oil to the specified level.
Version 2009/2
PC5500-6
3 - 93
Hydraulics
Superstructure
3.3.3.3 REMOVAL OF THE HYDRAULIC OIL COOLER FRAME

Special tools:
n/a

Crane
Oil drain pans
Hydraulic oil cooler frame: 3950 kg
Dogman/rigger
2.3 on page 2-37.
z


z

PUMP".
Open the hydraulic oil cooler door. Refer to Operation & Maintenance Manual, chapter 4, section "HYDRAULIC OIL
COOLERS - INSPECT AND CLEAN IF NECESSARY".
Fig. 3-89
3 - 94
PC5500-6
Version 2009/2
Superstructure
Hydraulics
WARNING
z
Hot hydraulic oil!

Wait until the temperature of the hydraulic oil is below
heated oil.

hydraulic oil cooler frame.
Disconnect all wiring harness connectors from the hydraulic

oil cooler frame.
If required, remove the following parts from the hydraulic oil

cooler frame (Fig. 3-90, Pos. 4):
1. Plate (Fig. 3-90, Pos. 1)

2. Rail (Fig. 3-90, Pos. 2)
3. Rail (Fig. 3-90, Pos. 3)
Fig. 3-90
z
Disconnect hydraulic inlet hoses (Fig. 3-91, Pos. 1) from the

hydraulic cooler fan motor (Fig. 3-91, Pos. 2).
NOTE: When the hoses are disconnected, oil will flow out of the
hoses. Catch it in an oil pan.
Fig. 3-91
Version 2009/2
PC5500-6
3 - 95
Hydraulics
Superstructure
Disconnect the return hose (Fig. 3-92, Pos. 1) and the leak oil
hose (Fig. 3-92, Pos. 2) from the hydraulic cooler fan motor.
Fig. 3-92
z
Disconnect hydraulic hoses (Fig. 3-93, Pos. 1 and 2) at the

shown joints.
Fig. 3-93
z
Disconnect PTO oil hoses (Fig. 3-94, Pos. 1 and 2).
Fig. 3-94
3 - 96
PC5500-6
Version 2009/2
Superstructure
Hydraulics
Insert the swivel hoist rings (M36) into the threads (Fig. 3-95,
Pos. 1) of the hydraulic oil cooler frame (Fig 3-95, Pos. 2).
Sling hydraulic oil cooler frame (Fig. 3-95, Pos. 2) at the hoist
rings.
Fig. 3-95
z
Remove mounting bolts (Fig. 3-96, Pos. 2 and 3) and remove

the hydraulic oil cooler frame (Fig. 3-96, Pos. 1) from the
superstructure using a crane.
DANGER

When removing the hydraulic oil cooler, make sure that
Rest the hydraulic oil cooler frame on the ground on an

appropriate stand and carry out the following steps if required.
Fig. 3-96
z
If required, remove the hydraulic oil cooler from the hydraulic

oil cooler frame, refer to section 3.3.3.1 on page 3-88.
If required, remove the cooler fan assembly from the hydraulic oil cooler frame, refer to section 3.3.2.1 on page 3-77.
Version 2009/2
PC5500-6
3 - 97
Hydraulics
Superstructure
3.3.3.4 REPLACEMENT OF THE HYDRAULIC OIL COOLER FRAME

Special tools:
n/a

Crane
Hydraulic oil cooler frame: 3950 kg
Dogman/rigger
WARNING
oil cooler frame.
NOTE: Use new mounting bolts (Fig. 3-97, Pos. 2 and 3) of

heads and threads of the mounting bolts and tighten
them to the specified tightening torque.
Tightening torque for mounting bolts (Fig. 3-97,
Pos. 2 and 3): 1770 Nm.
Fig. 3-97
z
AND PULSATION DAMPER" and PARTS & SRVICE NEWS
No. "AH01513".
Add PTO gear oil to the specified level.
3 - 98
PC5500-6
Version 2009/2
Superstructure
3.3.4
Hydraulics
MAIN RELIEF VALVES (MRV)
MRV (main relief valves) are pilot operated relief valves. The
MRV limit the maximum pump supply line pressure. The valves
are designed with an opening characteristic. That means, if the
valve is activated after the response procedure, no further pressure increase is possible and damage is avoided.
The valves are installed in the main control valve blocks.
3.3.4.1 REMOVAL OF THE MRV

Special tools:
36 mm Socket wrench, PN 232 374 40
n/a
NOTE: For additional information about the MRV on the main

control valve blocks, refer to section 3.3.8 on page 3-117.
z

PUMP".
Fig. 3-98
WARNING
Hot hydraulic oil!
Remove the MRV (Fig. 3-99, Pos. 1, 2 or 3) from the main

control valve block.
NOTE: When the MRV is removed, oil will flow out of the main
control valve block. Catch it in an oil pan.
Version 2009/2
PC5500-6
Fig. 3-99
3 - 99
Hydraulics
Superstructure
3.3.4.2 REPLACEMENT OF THE MRV

Special tools:
36 mm Socket wrench, PN 232 374 40

n/a
NOTE: Fit new O-rings to the MRV.

z
NOTE: Tighten the MRV to the specified torque.

Tightening torque for MRV:
300 Nm
z
No. "AH01513".
Check and adjust the MRV. Refer to Service Manual.

WARNING
Wear hearing protection when checking relief pressure.
3 - 100
PC5500-6
Version 2009/2
Superstructure
3.3.5
Hydraulics
PILOT OIL PUMP (GEAR PUMP)
3.3.5.1 REMOVAL OF THE PILOT OIL PUMP

Special tools:
n/a
n/a
Pilot oil pump: 27.4 kg
2.3 on page 2-37.


z

The pilot oil pump (Fig. 3-100, Pos. 1) generates the pilot
pressure that is used for all hydraulic control operations.
The pilot oil pump is attached at the main pump assembly 2.

hose from the pilot oil pump (Fig. 3-100, Pos. 1).
Fig. 3-100
Version 2009/2
PC5500-6
3 - 101
Hydraulics
Superstructure
Remove the two bolts (Fig.3-101, Pos. 1) and pull the pilot oil
pump (Fig. 3-101, Pos. 7) out of the adapter (Fig. 3-101,
Pos. 2).
adapter from the main pump assembly (Fig. 3-101, Pos. 5).
NOTE: Check the joint element (Fig. 3-101, Pos. 3) for wear and
Fig. 3-101
3 - 102
PC5500-6
Version 2009/2
Superstructure
Hydraulics
3.3.5.2 REPLACEMENT OF THE PILOT OIL PUMP

Special tools:

Pilot oil pump: 27.4 kg
Dogman/rigger
z
Check the pilot oil pump before installing, refer to PARTS &
SERVICE NEWS No. "AH03511" and "AH03512".
Remove the two bolts (Fig. 3-102, Pos. 1) at the new pilot oil
pump and disconnect the adapter (Fig. 3-102, Pos. 2) carefully.

Carry out installation in reverse order to removal, refer to

Fig. 3-102
NOTE: Use a new O-ring (Fig. 3-102, Pos. 4) and new mounting
bolts (Fig. 3-102, Pos. 1 and Pos. 6) with grade 8.8 at the
mounting flanges of the pump and the adapter.
Tighten the mounting bolts to the specified tightening
torque.
74 Nm
z

No. "AH01513".
NOTE: Check and adjust the pilot pressure if required.

Refer to Service Manual.
Version 2009/2
PC5500-6
3 - 103
Hydraulics
3.3.6
Superstructure
MAIN GATE VALVE
The connection between the suction reservoir and the hydraulic

oil reservoir can be closed with the main gate valve to prevent oil
flow during repairs. This unit is monitored by the switch S31. It
makes sure that an engine start is not possible with a closed main
gate valve. Fault message Start blocked because of main
shut-off (gate) valve is displayed on the operators dashboard.
3.3.6.1 REMOVAL OF THE MAIN GATE VALVE

Special tools:
n/a
Oil tank (4450 liters)

Main gate valve: 12.3 kg


z
PUMP".
Fig. 3-103
Drain hydraulic oil from the hydraulic oil reservoir,
approx. 4450 liters.
chapter 4, section "HYDRAULIC SYSTEM CHANGE OIL, REPLACE SUCTION STRAINERS
AND PULSATION DAMPER".
3 - 104
PC5500-6
Version 2009/2
Superstructure
Hydraulics
Disconnect the harness connector S31 from the proximity

switch at the main gate valve. Refer to Fig. 3-112
on page 3-111.
Remove the bolts (Fig. 3-104, Pos. 1), dismantle the compensator (Fig. 3-104, Pos. 2), and the main gate valve
(Fig. 3-104, Pos. 3).
NOTE: When the main gate valve (Fig. 3-104, Pos. 3) and the
compensator (Fig. 3-104, Pos. 2) are removed some oil
inside the piping will flow out.
Catch it in an oil pan.
Check condition of the compensator (Fig. 3-104, Pos. 2)
and replace as necessary.
Fig. 3-104
3.3.6.2 REPLACEMENT OF THE MAIN GATE VALVE

Special tools:
n/a
Oil tank (4450 liters)

Main gate valve: 12.3 kg

Fill hydraulic oil into the hydraulic oil reservoir,

No. "AH01513".
Version 2009/2
PC5500-6
3 - 105
Hydraulics
3.3.7
Superstructure
HYDRAULIC OIL RESERVOIR
Fig. 3-105 Hydraulic oil reservoir
3 - 106
PC5500-6
Version 2009/2
Superstructure
Hydraulics

(A)
View from machine center
(B)
View from pump compartment
(C)
Top view
(1)
Main hydraulic oil reservoir
(2)
Oil level sight gauge
(3)
Auxiliary return oil connections
(4)
Breather filter
(5)
Leakage oil line connections
(6)
Back-pressure valve, temperature controlled
(7)
Return oil collector tube with strainer
(8)
Oil reservoir outlet (suction pipe)
(9)
Main gate valve
(10)
Drain coupling an collector pipe
(11)
Mounting brackets
(12)
Compensator
(13)
Drain coupling, main oil reservoir
(14)
Access cover
(15)
Return oil filters (four)
(16)
Refill plug
(17)
Leakage oil filter (one)
Version 2009/2
PC5500-6
3 - 107
Hydraulics
Superstructure
3.3.7.1 REMOVAL OF THE HYDRAULIC OIL RESERVOIR

Special tools:
Socket wrench 46 mm, PN 232 377 40

Crane
4 x swivel hoist rings: M 36
Hydraulic oil reservoir incl. back pressure valve: 3465 kg
Dogman/rigger
2.3 on page 2-37.
z


z

WARNING

oil reservoir.
Drain hydraulic oil from the hydraulic oil reservoir,

3 - 108
PC5500-6
Version 2009/2
Superstructure
Hydraulics
Remove the main gate valve, refer to section 3.3.6.1 on page

3-104.
Remove the plates (Fig. 3-106, Pos. 1) beside the threads

(Fig. 3-106, Pos. 2).
Insert swivel hoist rings (M 36) into the threads (Fig. 3-106,
Pos. 2).
Fig. 3-106
z
Remove the rails (Fig. 3-107, Pos. 1) from the hydraulic oil
Fig. 3-107
z
Disconnect the hydraulic outlet hoses (Fig. 3-108, Pos. 1),

leading from the hydraulic coolers, from the hydraulic oil reservoir.
Disconnect the hydraulic inlet hoses (Fig. 3-108, Pos. 2),

leading to the hydraulic coolers, from the hydraulic oil reservoir.

Fig. 3-108
Version 2009/2
PC5500-6
3 - 109
Hydraulics
Superstructure
Loosen all clamps (Fig. 3-109, Pos. 2) mounted at the

hydraulic oil reservoir to clear all hydraulic lines from the
hydraulic oil reservoir (Fig. 3-109, Pos. 3).
Mark and disconnect all hydraulic lines (Fig. 3-109, Pos. 1)

from the hydraulic oil reservoir.
NOTE: When the hydraulic hoses/pipes are disconnected, the oil

Fig. 3-109
Disconnect the electrical wiring (Fig. 3-110, Pos. 1) from the

transfer pump (Fig. 3-110, Pos. 7) and the hydraulic oil reservoir.
Shut the cock valves at the hydraulic hoses

(Fig. 3-110, Pos. 3) and disconnect the hydraulic hoses from
the union (Fig. 3-110, Pos. 4).
Clear all hydraulic hoses from the hydraulic oil reservoir.
Disconnect all hydraulic lines from the standpipe

(Fig. 3-110, Pos. 5).
NOTE: When the hydraulic hoses/pipes are disconnected, the oil

z
Remove the grating (Fig. 3-110, Pos. 6).
Disconnect all hydraulic lines (Fig. 3-111, Pos. 1) from the

standpipe below the hydraulic oil reservoir.
Fig. 3-110

z
Loosen all clamps (Fig. 3-111, Pos. 2) below the hydraulic oil
reservoir to clear all hydraulic lines from the hydraulic oil reservoir.
Fig. 3-111
3 - 110
PC5500-6
Version 2009/2
Superstructure
Hydraulics
Disconnect all wiring harness connectors (Fig. 3-112,

Pos. Bxx, Y101) and the head light assembly (Fig. 3-112,
Pos. H49b).
Remove the wiring harnesses from the hydraulic oil reservoir.
Fig. 3-112
z
Attach the hydraulic oil reservoir to a crane.
Remove two mounting bolts (Fig. 3-113, Pos. 1) from each

mounting flange (Fig. 3-113, Pos. 3) of the hydraulic oil reservoir (Fig. 3-113, Pos. 2).
Lift the hydraulic oil reservoir (Fig. 3-113, Pos. 2) off the
superstructure using the crane and place it on the ground.
DANGER

When removing the hydraulic oil reservoir, make sure that
Fig. 3-113
Version 2009/2
PC5500-6
3 - 111
Hydraulics
Superstructure
Fig. 3-114 Filter assembly/provided parts
(R)
Return oil filter location
(L)
Leakage oil filter location
(1)
Mounting bolt
(2)
Filter cover retainer
(3)
Filter cover assembly
(4)
Return and leakage filter unit
(5)
Oil filler plug
(6)
Gasket
(7)
Cover
(8)
Breather filter
Remove filters and all provided parts (Fig. 3-114, Pos. 1 - 8)

from the top of the old hydraulic oil reservoir if required.
NOTE: Check O-rings and replace if required.

Discard the gasket (Fig. 3-114, Pos. 6).
3 - 112
PC5500-6
Version 2009/2
Superstructure
Hydraulics
Carry out the following steps only if required:

z
Remove the back pressure valve (Fig. 3-115, Pos. 2) and

discard the gaskets (Fig. 3-115, Pos. 1 and 3).
Remove the whole standpipe (Fig. 3-115, Pos. 4).
Remove all covers (Fig. 3-115, Pos. 5).
Remove all plugs (Fig. 3-115, Pos. 6).
Remove the oil level plate (Fig. 3-115, Pos. 8) and

hydraulic oil level sight gauge (Fig. 3-115, Pos. 7).
Remove all other equipment (clamps, bolts, etc.) if

required.
Fig. 3-115
Version 2009/2
PC5500-6
3 - 113
Hydraulics
Superstructure
3.3.7.2 REPLACEMENT OF THE HYDRAULIC OIL RESERVOIR

Special tools:
Socket wrench 46 mm, PN 232 377 40


Crane
Hydraulic oil reservoir incl. back pressure valve: 3465 kg
Dogman/rigger
WARNING
oil reservoir.
If required, install all provided parts (Fig. 3-114, Pos. 1 - 8) at

the new hydraulic oil reservoir.
NOTE: Use new gasket (Fig. 3-114, Pos. 6) at the cover

(Fig. 3-114, Pos. 7).
Use new filter units (Fig. 3-114, Pos. 4).
Check O-rings and replace if required.
Replace the return oil strainer (Fig. 3-116, Pos. 1).
NOTE: Use new gaskets (Fig. 3-116, Pos. 2).
Fig. 3-116
z
If required, install all provided parts (Fig. 3-115, Pos. 1 - 8) at

the new hydraulic oil reservoir.
NOTE: Use new gaskets (Fig. 3-115, Pos. 1 and 3) at the back
pressure valve (Fig. 3-115, Pos. 2).
Check O-rings and replace if required.
z
3 - 114
PC5500-6
Version 2009/2
Superstructure
Hydraulics
NOTE: Use new bolts (Fig. 3-117, Pos. 1) of grade 10.9 at the
mounting flanges (Fig. 3-117, Pos. 3) of the hydraulic oil
threads of the bolts (Fig. 3-117, Pos. 1) and tighten them
to the specified tightening torque.
1770 Nm
Fill hydraulic oil into the hydraulic oil reservoir,

chapter 4, section "HYDRAULIC SYSTEM - CHANGE
OIL, REPLACE SUCTIONSTRAINERS AND
PULSATION DAMPER"
z

No. "AH01513".
Check and adjust the back pressure if required, refer to Service Manual.
Fig. 3-117
Version 2009/2
PC5500-6
3 - 115
Hydraulics
Superstructure
3 - 116
PC5500-6
Version 2009/2
Superstructure
3.3.8
Hydraulics
MAIN CONTROL VALVE BLOCKS
Fig. 3-118 Main control valve blocks overview

(1)
Main control valve block I
(2)
Main control valve block II
(3)
Main control valve block III
(4)
Swing control valve block IV
(5)
High pressure filter 1
(6)
(7)
(8)
There are three main control valve blocks (I - III) and one swing
control valve block (IV) on each control and filter panel.
Individual valve plugs are mounted on each main control valve
block. These valves are anti-cavitation valves (ACV), service line
relief valves (SRV), or main relief valves (MRV).
Version 2009/2
PC5500-6
3 - 117
Hydraulics
Superstructure
Fig. 3-119 Main control valve blocks 1 and 2 (BHA)
3 - 118
PC5500-6
Version 2009/2
Superstructure
Hydraulics

Main control valve block I (BHA)
(L.H. Travel, Stick, Bucket, Boom)
(46.1)
High pressure filter, Pump 2 and 5
(31.1)
SRV Travel motors left backward
(32.1)
ACV Travel motors left backward
(31.2)
SRV Travel motors left forward
(32.2)
ACV Travel motors left forward
(33.1)
SRV Stick cylinder piston side
(32.3)
ACV Stick cylinder piston side
(32.4)
AVC Stick cylinder rod side
(32.5)
ACV Bucket cylinder rod side
(32.6)
ACV Bucket cylinder piston side
(32.7)
ACV Boom cylinder rod side
(32.8)
ACV Boom cylinder piston side
Main control valve block II (BHA)

(Bucket, Boom, Reserved, Stick)
(44.2)
High pressure filter, Pump 4
(32.9)
(32.10)
ACV Bucket piston side
(33.6)
SRV Boom cylinder rod side
(32.11)
(32.12)
(33.5)
SRV Stick cylinder piston side
(32.15)
(32.16)
ACV Stick cylinder rod side
NOTE: The numbers in brackets are component numbers for the

hydraulic diagram.
NOTE: There is one MRV in each control block.
Version 2009/2
PC5500-6
3 - 119
Hydraulics
Superstructure
Fig. 3-120 Main control valve blocks 3 and 4 (BHA)
3 - 120
PC5500-6
Version 2009/2
Superstructure
Hydraulics

Main control valve block III (BHA)
(R.H. Travel, Boom, Bucket, Stick)
(46.2)
(31.3)
SRV Travel motors right backward
(32.17)
ACV Travel motors right backward
(31.4)
SRV Travel motors right forward
(32.18)
ACV Travel motors right forward
(32.19)
(32.20)
(32.21)
(32.22)
(32.23)
(32.24)
Main control valve block IV (BHA)

(Single spool for swing)
(44.1)

hydraulic diagram.
Version 2009/2
PC5500-6
3 - 121
Hydraulics
Superstructure
Fig. 3-121 Main control valve blocks 1 and 2 (FSA)
3 - 122
PC5500-6
Version 2009/2
Superstructure
Hydraulics

Main control valve block I (FSA)
(L.H. Travel, Stick, Bucket, Boom)
(46.1)
High pressure filter, Pump 2 an 5
(31.1)
SRV Travel motors left backward
(32.1)
ACV Travel motors left backward
(31.2)
SRV Travel motors left forward
(32.2)
ACV Travel motors left forward
(33.1)
SRV Stick cylinder rod side
(32.3)
(32.4)
(32.5)
(33.2)
SRV Bucket cylinder rod side
(32.6)
(32.7)
(32.8)
Main control valve block II (FSA)

(Bucket, Boom, Reserved, Stick)
(44.2)
(32.9)
ACV bull clam cylinder rod side
(32.10)
ACV bull clam cylinder piston side
(30)
SRV bull clam cylinder piston side
(33.6)
SRV Bucket cylinder rod side
(32.11)
(32.12)
(32.13)
(33.4)
SRV Boom cylinder rod side
(32.14)
(32.15)
(191)
SRV (pressure increasing valve) Stick cylinder rod

side
(32.16)

hydraulic diagram.
Version 2009/2
PC5500-6
3 - 123
Hydraulics
Superstructure
Fig. 3-122 Main control valve blocks 3 and 4 (FSA)
3 - 124
PC5500-6
Version 2009/2
Superstructure
Hydraulics

Main control valve block III (FSA)
(R.H. Travel, Boom, Bucket, Stick)
(46.2)
(31.3)
SRV Travel motors right forward
(32.17)
ACV Travel motors right forward
(31.4)
SRV Travel motors right backward
(32.18)
ACV Travel motors right backward
(32.19)
(32.20)
(32.21)
(32.22)
(32.23)
(32.24)
Main control valve block IV (FSA)

(Single spool for swing)
(44.1)

hydraulic diagram.
Version 2009/2
PC5500-6
3 - 125
Hydraulics
Superstructure
3.3.8.1 REMOVAL OF THE MAIN CONTROL VALVE BLOCKS

Special tools:
n/a
Crane
Oil drain pan
Main control valve block I: 717 kg
Main control valve block II: 726 kg
High pressure filter (main control block II): 44.6 kg
Main control valve block III: 713kg
Main control valve block IV: 143 kg
High pressure filter (main control block IV): 15 kg
Dogman/rigger
2.3 on page 2-37.


z

PUMP".
Fig. 3-123
3 - 126
PC5500-6
Version 2009/2
Superstructure
Hydraulics
WARNING
Hot hydraulic oil!
Remove all SRVs from the main control valve block, refer to
Remove all ACVs from the main control valve block, refer to
If required remove the load holding valves from the main control valve block.
Version 2009/2
PC5500-6
3 - 127
Hydraulics
Superstructure
Fig. 3-124
z
Disconnect all hydraulic lines (Fig. 3-124, Pos. 3) at the

respective main control valve block.
Disconnect all pilot lines from the spool valves

(Fig. 3-124, Pos. 1) at the respective main control valve block.
NOTE: When the hydraulic lines are removed, the oil inside the
lines will flow out. Catch it in an oil pan.
z
Discard the O-rings (Fig. 3-124, Pos. 2) of the SAE-flanges.
3 - 128
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Version 2009/2
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Hydraulics
Disconnect the return line (Fig. 3-125, Pos. 1) at the respective main control valve block (I - IV) and discard the O-ring
(Fig. 3-230, Pos. 2) of the SAE-flange.
NOTE: When the return line is removed, the oil inside the line will
Fig. 3-125
Removal of the Main Valve Control Blocks I and III
z
Disconnect the pressure line (Fig. 3-126, Pos. 1) at the

respective main control valve block (I or III) and discard the
O-ring (Fig. 3-126, Pos. 2) of the SAE-flange.
NOTE: When the pressure line is removed, the oil inside the line
z
Disconnect the harness connectors and clear the wiring harness from the main control valve block.
Fig. 3-126
z
Wind a lifting belt around the spool valves (Fig. 3-124, Pos. 1)
and sling the main control valve block at the lifting belt as
shown in Fig. 3-127.
Remove the mounting bolts and dismantle the main control

valve block from the control valve carrier using a crane.
Fig. 3-127
WARNING
When removing the main control valve blocks, make sure
that nobody steps below the weight.
Version 2009/2
PC5500-6
3 - 129
Hydraulics
Superstructure
Removal of the Main Valve Control Block II

z
Remove the pressure filter (Fig. 3-128, Pos. 3) from the main
control valve block II (Fig. 3-128, Pos. 1).
If required, disconnect the pressure lines (Fig. 3-128, Pos. 6)

from the pressure filter (Fig. 3-128, Pos. 3) and discard the Oring (Fig. 3-126, Pos. 2) at the pressure filter side (Fig. 3-128,
Pos. 3) and the quad ring (Fig. 3-128, Pos. 4) at the block
side (Fig. 3-128, Pos. 5).
NOTE: When the pressure lines are removed, the oil inside the
z
Wind a lifting belt around the spool valves and sling the main
control valve block at the lifting belt as shown in Fig. 3-129.

Fig. 3-128
Fig. 3-129
WARNING
3 - 130
PC5500-6
Version 2009/2
Superstructure
Hydraulics
Removal of the Main Valve Control Block IV

z
Disconnect the pressure line (Fig. 3-130, Pos. 3) at the main

control valve block (Fig.3-130, Pos.1) and discard the O-ring
(Fig. 3-130, Pos. 2) of the SAE-flange.
Remove the pressure filter (Fig. 3-130, Pos. 4) from the main
control valve block (Fig. 3-130, Pos. 1) and discard the O-ring
(Fig. 3-130, Pos. 2) at the pressure filter.
If required, disconnect the pressure line (Fig. 3-130, Pos. 5)

from the pressure filter (Fig. 3-130, Pos. 4) and discard the
O-ring (Fig. 3-130, Pos. 2) of the SAE-flange.
NOTE: When the pressure lines are removed, the oil inside the
z
Sling main control valve block using suitable sling accessory.

Fig. 3-130
WARNING
Version 2009/2
PC5500-6
3 - 131
Hydraulics
Superstructure
3.3.8.2 REPLACEMENT OF THE MAIN CONTROL VALVE BLOCKS

Special tools:
Crane
Main control valve block I: 717 kg
Main control valve block II: 726 kg
High pressure filter (main control block II): 44.6 kg
Main control valve block III: 713kg
Main control valve block IV: 143 kg
High pressure filter (main control block IV): 15 kg
Dogman/rigger
NOTE: Ensure that the mating surfaces are clean and free of
paint before assembly. Fit new O-rings.
z
NOTE: Use new mounting bolts (Fig. 3-131, Pos. 1 and 2) of

grade 10.9 and new screw nuts (Fig. 3-131, Pos. 4) for
the respective main control valve block (I - III).
Tightening torques for the mounting bolts
(Fig. 3-131, Pos. 1 and 2) at the main control
valve blocks: 510 Nm
NOTE: Use new mounting bolts (Fig. 3-131, Pos. 3) of grade
10.9 for main control valve block IV.
Fig. 3-131
Tightening torques for the mounting bolts

(Fig. 3-131, Pos. 3) at the main control valve block
IV: 265 Nm
z
Mount the pressure filter at main control block II (Fig.3-128,

Pos. 3). If required, install the pressure lines using new bolts,
a new O-ring (Fig.3-128, Pos.2) and a new quad ring
(Fig 3-128, Pos. 4).
Mount the pressure filter at main control block IV (Fig.3-130,

Pos. 4). If required, install the pressure lines using new bolts
and a new O-rings (Fig.3-130, Pos. 2).
NOTE: Refer to PARTS & SERVICE NEWS No. "AH05501".
3 - 132
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Version 2009/2
Superstructure
Hydraulics
No. "AH01513".
Check pressure of all circuits of the control valve block (use

400 bar gauge).
3.3.9
SERVICE LINE RELIEF VALVES (SRV)
The service relief valves are pilot operated relief valves. The SRV
limit the maximum possible pressure in the service lines created
by external force. The valves are designed with an opening characteristic. That means, if the valve is activated after the response
procedure, no further pressure increase is possible and damage
is avoided. Service relief valves are located on the main control
valve blocks on the manifold build and in the throttle check
valves, refer to section 3.3.11.1 on page 3-152.
NOTE: SRVs are also installed in the travel system, refer to section 4.1.7.1 on page 4-35.
3.3.9.1 REMOVAL OF SRV ON MAIN CONTROL VALVE BLOCK

Special tools:
n/a
Oil drain pan
NOTE: For additional information about the SRV on the main

z
Relieve the pressure in the hydraulic system. Refer to the

reservoir. Refer to the Operation & Maintenance Manual,
PUMP".
Fig. 3-132
Version 2009/2
PC5500-6
3 - 133
Hydraulics
Superstructure
Fig. 3-133 SRV on the main control valve blocks (BHA)
Fig. 3-134 SRV on the main control valve blocks (FSA)
3 - 134
PC5500-6
Version 2009/2
Superstructure
Hydraulics
WARNING
Hot hydraulic oil!
Disconnect the hose from the SRV.
Remove the four bolts (Fig. 3-133 or Fig. 3-134, Pos. 1)

attaching the SRV to the main control valve block.
Remove the SRV (Fig. 3-133 or Fig. 3-134, Pos. 2) and cap
the openings with blind plugs to avoid contamination.
Remove the O-rings (Fig. 3-135, Pos. 1) and discard them.
NOTE: Carry out the following steps only if required:

z
Remove the support rings (Fig. 3-135, Pos. 2) from the valve
body (Fig. 3-135, Pos. 4).
Remove the pressure relief valve (Fig. 3-135, Pos. 3) from the
valve body (Fig. 3-135, Pos. 4).
CAUTION
Different SRVs with different pressures are installed.

If removing more than one SRV at the same time, mark the
SRV and the position where it is installed.
Version 2009/2
PC5500-6
Fig. 3-135
3 - 135
Hydraulics
Superstructure
3.3.9.2 REPLACEMENT OF SRV ON MAIN CONTROL VALVE BLOCKS

Special tools:
n/a
paint before assembly.
z
Fit new O-rings (Fig. 3-135, Pos. 1) to the SRV.
NOTE: If the pressure relief valve (Fig. 3-135, Pos. 3) was

removed from the valve body (Fig. 3-135, Pos. 4) tighten
it to the specified torque:
Tightening torque for the built-in SRV:
300 Nm
z
No. "AH01513".
Check and adjust the SRV. Refer to Service Manual.
3 - 136
PC5500-6
Version 2009/2
Superstructure
Hydraulics
Version 2009/2
PC5500-6
3 - 137
Hydraulics
Superstructure
3.3.10 ANTI-CAVITATION VALVES (ACV)
Fig. 3-136 Anti cavitation valve (ACV)

(1)
ACV housing
(2)
Valve cone
(3)
Spring
(4)
O-ring
(5)
Control leak oil bore
(6)
Cap screw (torque 900 Nm)
(S)
Supply line
(A/B)
Line connections
The anti-cavitation valves (ACV) are installed to avoid cavitation

damages on users (hydraulic cylinders) by compensating a lack
of oil when the SRV at the opposite side of the cylinder opens.
See hydraulic circuit diagram.
The circuit pressure in the line (Fig. 3-136, Pos. A/B) hold the
valve cone (Fig. 3-136, Pos. 2) closed. The pressure of the supply
line (Fig. 3-136, Pos. S) forces onto the valve cone. The valve
cone opens, whenever the pressure at the A and B side is lower
than the back pressure at return oil port S, to allow necessary oil
supply into circuit.
3 - 138
PC5500-6
Version 2009/2
Superstructure
Hydraulics
The ACVs are installed at the attachment manifold and at the

main control valve blocks.
3.3.10.1 REMOVAL OF ACV ON MANIFOLD

Special tools:
n/a
Crane
Oil drain pan
Single-anti cavitation valve: 15 kg
Double-anti cavitation valve: 44.6 kg
Dogman/rigger
2.3 on page 2-37.
z


z

PUMP".
Fig. 3-137
Version 2009/2
PC5500-6
3 - 139
Hydraulics
Superstructure
Fig. 3-138 Positions of the ACV at the BHA manifold

NOTE: The numbers (Fig.3-138, Pos.140.1 - 140.9) are component numbers for the hydraulic diagram.
NOTE: For further information about the ACV at the BHA manifold, refer to the hydraulic diagram and the Service Manual.
3 - 140
PC5500-6
Version 2009/2
Superstructure
Hydraulics
Fig. 3-139 Positions of the ACV at the FSA manifold

NOTE: The numbers (Fig.3-139, Pos.140.1 - 140.10) are component numbers for the hydraulic diagram.
NOTE: For further information about the ACV at the FSA manifold, refer to the hydraulic diagram and the Service Manual.
Version 2009/2
PC5500-6
3 - 141
Hydraulics
Superstructure
NOTE: In the following steps one ACV of the of the FSA manifold
is removed exemplarily.
The procedure is identical for all the ACV, except for the
valves with other valves attached, so carry out the following four steps only if required:
WARNING
Hot hydraulic oil!
If required, remove the throttle check valve to gain access

to the anti-cavitation valve, refer to section 3.3.11.1 on
page 3-152.
If required, remove the non return valve (analogously to throttle

check valve removal) to gain access to the anti-cavitation valve,
z
Remove the four bolts attaching the oil pipe (Fig. 3-140,
Pos. 3) to the main control valve block and the four bolts
(Fig. 3-140, Pos. 2) at the ACV (Fig. 3-140, Pos. 1) end.
Remove the oil pipe and the two flange seals (Fig. 3-140,
Pos. 4). Discard the seals.
NOTE: When the pipe is disconnected, the oil inside the piping
Fig. 3-140
3 - 142
PC5500-6
Version 2009/2
Superstructure
Hydraulics
Disconnect the flex hoses (Fig. 3-141, Pos. 2) and remove

the joint (Fig. 3-141, Pos. 3) from the anti-cavitation valve
(Fig. 3-141, Pos. 1).
NOTE: When the flex hose is disconnected, the oil inside the
hose and the valve will flow out. Catch it in an oil pan.
Cap the openings with blind plugs to avoid contamination
Fig. 3-141
z
Remove the four bolts (Fig. 3-142, Pos. 1) attaching the ACV
to the manifold.
Remove the ACV (Fig. 3-142, Pos. 2) and the O-ring

(Fig. 3-142, Pos. 3). Discard the O-ring.
If required, repeat the procedure to remove the other ACV

from the manifold.
Fig. 3-142
Version 2009/2
PC5500-6
3 - 143
Hydraulics
Superstructure
3.3.10.2 REPLACEMENT OF THE ACV ON MANIFOLD

Special tools:
n/a
Crane
Single-anti cavitation valve: 15 kg
Double-anti cavitation valve: 44.6 kg
Dogman/rigger
z
Fit a new O-ring (Fig. 3-143, Pos. 3) to the new ACV

(Fig. 3-143, Pos. 2).
Apply compound "KP2K", PN 324 969 40 on threads of the

mounting bolts (Fig. 3-143, Pos. 1).
Align the new ACV to the manifold and insert the mounting
bolts.
Fig. 3-143
z
NOTE: Carry out the following four steps only if required:

z
If required, install the throttle check valve onto the ACV,

If required, install the non return valve (analogously to the

throttle check valve installation), refer to section 3.3.11.2
on page 3-155.
Maintenance Manual chapter 4, section "HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS
No. "AH01513".
3 - 144
PC5500-6
Version 2009/2
Superstructure
Hydraulics
3.3.10.3 REMOVAL OF ACV ON MAIN CONTROL VALVE BLOCKS

Special tools:
n/a
Oil drain pan
NOTE: For additional information about the ACV on the main

z

PUMP".
Fig. 3-144
Version 2009/2
PC5500-6
3 - 145
Hydraulics
Superstructure
Fig. 3-145 ACV on the main control valve blocks (BHA)
Fig. 3-146 ACV on the main control valve blocks (FSA)

3 - 146
PC5500-6
Version 2009/2
Superstructure
Hydraulics
NOTE: The numbers (Fig. 3-145 or Fig. 3-146, Pos. 32.1 - 32.24)
are component numbers for the hydraulic diagram.
NOTE: For further information about the ACV at the main control
valve blocks, refer to the hydraulic diagram and the Service Manual.
WARNING
Hot hydraulic oil!
Remove the four bolts (Fig. 3-145 or Fig. 3-146, Pos. 1)

attaching the ACV to the main control valve block.
Remove the ACV (Fig. 3-145 or Fig. 3-146, Pos. 2).
NOTE: When the ACV is removed, the oil inside the valves will
Cap the openings to avoid contamination.
z
Remove the O-rings (Fig. 3-147, Pos. 1) and discard them.
Remove the support rings (Fig. 3-147, Pos. 2) from the valve
body (Fig. 3-147, Pos. 3) only if required.
Fig. 3-147
Version 2009/2
PC5500-6
3 - 147
Hydraulics
Superstructure
3.3.10.4 REPLACEMENT OF ACV ON MAIN CONTROL VALVE BLOCKS

Special tools:
n/a
n/a
Fit new O-rings to the ACV (Fig. 3-147, Pos. 1).
z
No. "AH01513".
3 - 148
PC5500-6
Version 2009/2
Superstructure
Hydraulics
Version 2009/2
PC5500-6
3 - 149
Hydraulics
Superstructure
3.3.11 THROTTLE CHECK VALVES
Fig. 3-148 Throttle check valve with built-in SRV
3 - 150
PC5500-6
Version 2009/2
Superstructure
Hydraulics

NOTE: The illustration shows the valve block up side down
(1)
Throttle adjustment pin
(2)
Back-up ring
(3)
O-ring
(4)
Retainer
(5)
Back-up ring
(6)
O-ring
(7)
Spring
(8)
Spring cup
(9)
Throttle valve sleeve
(9.1)
Adjustable throttle holes
(9.2)
Permanent throttle holes (safety channel)
(10)
O-ring
(11)
Housing
(12)
Return line port, T
(13)
SRV
(14)
Bolt
(15)
Clip ring
(16)
Lock nut
(A)
Line ports from the control valve
(B)
Line port to the cylinder
(M)
Pressure check point
(Y)
Control oil drain port
The maximum permissible cylinder speed is set by the pin

(Fig. 3-148, Pos.1). Depending on the pin setting, the radial holes
(Fig. 3-148, Pos. 9.1) in the valve sleeve (Fig. 3-148, Pos. 9) will
be opened partially to achieve the required throttling of the oil
flow. The safety holes (Fig. 3-148, Pos. 9.2) prevent the valve
from becoming completely closed.
For the lifting operation the valve sleeve which is guided by the
spindle (Fig. 3-148, Pos. 1) is pressed against the spring
(Fig. 3-148, Pos. 7) so that the valve will be completely open.
The build-in SRV (Fig. 3-148, Pos. 13) limits the maximum system
pressure from the cylinder and relieves oil to the tank line when
the pressure reaches the valve setting.
Version 2009/2
PC5500-6
3 - 151
Hydraulics
Superstructure
3.3.11.1 REMOVAL OF THROTTLE CHECK VALVES

Special tools:
n/a
Crane
Oil drain pan
Throttle check valve (long version): 31 kg
Throttle check valve (short version): 28 kg
Dogman/rigger
2.3 on page 2-37.
Fig. 3-149 Positions of the throttle check valves BHA

NOTE: The numbers (Fig. 3-149, Pos. 138.1 - 145.5) are component numbers for the hydraulic diagram.
NOTE: For further information about the SRV at the BHA manifold, refer to the hydraulic diagram and the Service Manual.
3 - 152
PC5500-6
Version 2009/2
Superstructure
Hydraulics
Fig. 3-150 Positions of the throttle check valves FSA

NOTE: The numbers (Fig. 3-150, Pos. 141.1 - 158) are component numbers for the hydraulic diagram.
NOTE: For further information about the SRV at the FSA manifold, refer to the hydraulic diagram and the Service Manual.
z


z

Version 2009/2
PC5500-6
3 - 153
Hydraulics
Superstructure
PUMP".
WARNING
Hot hydraulic oil!

Disconnect the flex hose (Fig. 3-152, Pos. 5) from the throttle
check valve (Fig. 3-152, Pos. 1).
Remove the four bolts (Fig. 3-152, Pos. 2) and remove the
pipe (Fig. 3-152, Pos. 3) from the throttle check valve
(Fig. 3-152, Pos. 1).
Fig. 3-151
piping and the valve will flow out. Catch it in an oil pan.
Fig. 3-152
z
Remove the four bolts (Fig. 3-153, Pos. 5) attaching the throttle check valve (Fig. 3-153, Pos. 1) to the manifold
(Fig. 3-153, Pos. 2).
Remove the throttle check valve (Fig. 3-153, Pos. 1) and the
O-ring (Fig. 3-153, Pos. 3). Discard the O-ring.
NOTE: When the throttle check valve is removed, the oil inside
the valve and the manifold will flow out. Catch it in an oil
pan. Cap the openings with blind plugs to avoid contamination.
z
If required, remove the adaptor (Fig. 3-153, Pos. 4) from the

throttle check valve.
Fig. 3-153
If required, repeat the procedure to remove the other throttle

check valves from the manifold.
If required, remove the built-in SRV (Fig. 3-148, Pos. 13) from
the throttle check valves housing (Fig. 3-148, Pos. 11).
3 - 154
PC5500-6
Version 2009/2
Superstructure
Hydraulics
3.3.11.2 REPLACEMENT OF THROTTLE CHECK VALVES

Special tools:
n/a
Crane
Throttle check valve (long version): 31 kg
Throttle check valve (short version): 28 kg
Dogman/rigger
Fit a new O-ring (Fig. 3-153, Pos. 3) to the throttle check
valve (Fig. 3-153, Pos. 1).
z
NOTE: If the built-in SRV (Fig. 3-148, Pos. 13) has been
removed from the housing (Fig. 3-148, Pos. 11), tighten it
to the specified tightening torque:
Tightening torque for the built-in SRV:
300 Nm
NOTE: Apply compound "KP2K", PN 324 969 40 on heads and
threads of the throttle check valve mounting bolts
(Fig. 3-153, Pos. 5).
z
Maintenance Manual, section 4.13.
Check and adjust the throttle check valve. Refer to the

Service Manual, section 8.1.11.
Check and adjust the built-in SRV in the throttle check valves
if required. Refer to the Service Manual, section 8.1.10.
Version 2009/2
PC5500-6
3 - 155
Hydraulics
Superstructure
3.3.12 MANIFOLD
3.3.12.1 REMOVAL OF THE MANIFOLD
Special tools:
n/a

Crane
Oil drain pan
Manifold BHA incl. ACVs and SRVs: 921.2 kg
Manifold FSA incl. ACVs and SRVs: 893.2 kg
Dogman/rigger
2.3 on page 2-37.
z


z

PUMP".
Fig. 3-154
3 - 156
PC5500-6
Version 2009/2
Superstructure
Hydraulics
WARNING
Hot hydraulic oil!
Disconnect all hydraulic hoses (Fig. 3-155, Pos. 1) leading to

the attachment, refer to section 5.1.6.1 on page 5-58 (BHA)
or refer to section 5.2.6.1 on page 5-134 (FSA).
WARNING
Always wear a safety harness when working at the front side

of the manifold.
Disconnect the hydraulic piping (Fig. 3-155, Pos. 2) at the

front of the manifold.
hydraulic lines will flow out. Catch it in an oil pan.
z
Sling the manifold.
Remove four mounting bolts (Fig. 3-155, Pos. 3).
Remove the manifold using a crane.
Remove the anti cavitation valves (ACV) from the manifold,

Remove the throttle check valves from the manifold, refer to

Fig. 3-155
DANGER
When removing the manifold, make sure that nobody steps
below the weight.
Version 2009/2
PC5500-6
3 - 157
Hydraulics
Superstructure
3.3.12.2 REPLACEMENT OF THE MANIFOLD

Special tools:
n/a

Crane
Manifold BHA incl. ACVs and SRVs: 921.2 kg
Manifold FSA incl. ACVs and SRVs: 893.2 kg
Dogman/rigger
Fit new O-rings to the SAE-flanges.
threads of the manifold mounting bolts (Fig. 3-155,
Pos. 3) and tighten them to the specified tightening
torque.
WARNING
Always wear a safety harness when working at the front side
of the manifold.
No. "AH01513".
3 - 158
PC5500-6
Version 2009/2
Superstructure
3.4
Slew drive
SLEW DRIVE
Fig. 3-156
The PC5500-6 is equipped with two slew gear arrangements. For
further information, refer to the Service Manual.
Multi disc brakes (Fig. 3-156, Pos. 3) are installed between the
swing motors (Fig. 3-156, Pos. 2) and the gear boxes (Fig. 3-156,
Pos. 4). These brakes are safety brakes, applied by spring force
and released by oil pressure.
To operate the rotary motion, slew brake valves (Fig. 3-156,
Pos. 1) are directly flanged to the swing motor heads. For further
information, refer to the Service Manual.
Version 2009/2
PC5500-6
3 - 159
Slew drive
3.4.1
Superstructure
SLEW GEAR
Fig. 3-157 Slew gear unit (Siebenhaar)

NOTE: The machine can be equipped either with a slew gear of
manufacturer "L&S" or of manufacturer "Siebenhaar".
The Removal and the Replacement of the slew gear by
different manufacturer are analogously the same. Refer
to the data plate on each slew gear housing to find out
the manufacturer of the slew gear.
3 - 160
PC5500-6
Version 2009/2
Superstructure
Slew drive
3.4.1.1 REMOVAL OF THE SLEW GEAR

Special tools:
n/a
Crane
Swing motor with attached slew service brake valve: 292.5
Slew gear (Siebenhaar): 1700 kg
Slew gear (L&S): 1880 kg
Dogman/rigger
2.3 on page 2-37.


z

Fig. 3-158
z
Remove the swing motor (Fig. 3-157, Pos. 2) from the slew
gearbox (Fig. 3-157, Pos. 3), refer to section 3.4.2.1 on page
3-169. Leave the hydraulic hoses and the slew service brake
valve (Fig. 3-157, Pos. 1) attached to the swing motor if possible. If not disconnect the hydraulic lines.
Version 2009/2
PC5500-6
3 - 161
Slew drive
Superstructure
DANGER
removed.
Disconnect the oil pressure line from the slew parking brake.
NOTE: When the hydraulic lines are disconnected, the oil inside
the lines will flow out. Catch it in an oil pan.
z
Removing the rear slew gear, the hydraulic line (Fig. 3-159,
Pos. 2) and the mounting (Fig. 3-159, Pos. 1) for hydraulic
hoses have to be removed.
NOTE: When the hydraulic line is disconnected, the oil inside the
line will flow out. Catch it in an oil pan.
Fig. 3-159
3 - 162
PC5500-6
Version 2009/2
Superstructure
Slew drive
Fig. 3-160 Slew gear (Siebenhaar)

z
Remove the protection caps (Fig. 3-160, Pos. 1) from the bolt
heads and remove the slew gear mounting bolts (Fig. 3-160,
Pos. 2) and washers (Fig. 3-160, Pos. 3). Discard the bolts.
Disconnect the lubrication lines below the slew gear.
Install four swivel hoist rings (M16) displaced by 90 into the

threaded bores for the swing motor mounting bolts and attach
a crane.
Version 2009/2
PC5500-6
3 - 163
Slew drive
Superstructure
Remove the slew gear (Fig. 3-160, Pos. 4) using a crane.

DANGER

When removing the slew gear, make sure that nobody steps
below the weight.
Remove the bleeder valves (Fig. 3-161, Pos. 1)

Drain the gear oil from the slew gear (Fig. 3-161,
Pos. 3 respectively Pos. 5) at the drain coupling
(Fig. 3-161, Pos. 2),
approx 60 liters (Siebenhaar),
approx. 42 liters (L&S),
refer to the Operation & Maintenance Manual, chapter
4, section "SWING GEARS AND MOTOR ADAPTER
HOUSING - CHANGE OIL"
Remove the oil drain coupling (Fig. 3-161, Pos. 2) and if

equipped with remove the union (Fig. 3-161, Pos. 4) from the
slew gear (Fig. 3-161, Pos. 3 respectively Pos. 5).
Fig. 3-161
3 - 164
PC5500-6
Version 2009/2
Superstructure
Slew drive
3.4.1.2 REPLACEMENT OF THE SLEW GEAR

Special tools:
Feeler gauge (customary)
Crane
Swing motor with attached slew service brake valve: 292.5
Slew gear (Siebenhaar): 1700 kg
Slew gear (L&S): 1880 kg
Dogman/rigger
WARNING
New slew gears are delivered without gear oil.
NOTE: The machine can be equipped either with a slew gear of

manufacturer "Siebenhaar" or of manufacturer "L&S".
Refer to the data plate on each slew gear housing to find
out the manufacturer of the slew gear.
Both slew gears are replaceable using of a special
modification kit. Refer to PARTS & SERVICE NEWS
No. "AH05535".
z
Install the oil drain coupling (Fig. 3-162, Pos. 2) with the union
(Fig. 3-162, Pos. 4) if equipped, at the new slew gear
(Fig. 3-162, Pos. 3 respectively Pos. 5).
Clean the bleeder valves (Fig. 3-162, Pos. 1) with compressed air from inside to outside and reinstall at the new
slew gear (Fig. 3-162, Pos. 3 respectively Pos. 5).
Fig. 3-162
Version 2009/2
PC5500-6
3 - 165
Slew drive
Superstructure
Fig. 3-163 Slew gear unit (Siebenhaar)
3 - 166
PC5500-6
Version 2009/2
Superstructure
Slew drive

a crane.
Insert the new slew gear (Fig. 3-163, Pos. 3) and mount it to
the superstructure with the mounting bolts (Fig. 3-163,
Pos. 1) and the washers (Fig. 3-163, Pos. 2).
NOTE: Use new slew gear mounting bolts (Fig. 3-163, Pos. 1) of
heads and threads of the mounting bolts and tighten
them to the specified tightening torque..
Tightening torque for the slew gear mounting
bolts: 1030 Nm
z
Connect the lubrication lines.

WARNING
Make sure to use the specified bolts and tightening torque

for the swing motor mounting bolts, refer to section 3.4.2.2
on page 3-172.
Fill gear oil into the slew gear,

approx. 60 liters (Siebenhaar),
approx. 42 liters (L&S).
Fill oil into the motor adapter housing,
approx. 0.6 liters (L&S),
up to level gauge marking (Siebenhaar).
Fill oil into the brake housing (Siebenhaar only),
approx. 0.2 liters. Refer to the Operation & Maintenance Manual, chapter 4, section "SWING GEARS
AND MOTOR ADAPTER HOUSING - CHANGE
OIL".
For the proper lubricant, refer to section 6.1 on
page 6-2.
z
Check the tooth backlash between slew ring and slew pinion
with a feeler gauge.
Refer to PARTS & SERVICE NEWS No. "AH00511".
Version 2009/2
PC5500-6
3 - 167
Slew drive
3.4.2
Superstructure
SWING MOTOR
Fig. 3-164 Swing motor assembly

(1)
Bolt
(12)
Bolt (only Siebenhaar)
(2)
Slew brake valve
(13)
Washer (only Siebenhaar)
(3)
O-ring
(14)
Expansion tank of the slew gear

(only Siebenhaar)
(4)
Bolt
(15)
Sleeve (only Siebenhaar)
(5)
Intermediate plate
(6)
O-ring
(7)
Bolt
(8)
Washer
(9)
Swing motor
(10)
O-ring
(11)
Slew gear
3 - 168
PC5500-6
Version 2009/2
Superstructure
Slew drive
3.4.2.1 REMOVAL OF THE SWING MOTOR

Special tools:
n/a
Crane
Oil drain pan
Swing motor: 170 kg
Dogman/rigger
2.3 on page 2-37.
z


z

Fig. 3-165
WARNING
Hot hydraulic oil!
Version 2009/2
PC5500-6
3 - 169
Slew drive
Superstructure
Drain gear oil from the motor adapter housing.

Refer to the Operation & Maintenance Manual, chapter 4, section "SWING GEARS AND MOTOR
ADAPTER HOUSING - CHANGE OIL"
z
Disconnect all hydraulic hoses (Fig. 3-166, Pos. 1), attached

to the swing motor (Fig. 3-166, Pos. 2).
NOTE: When the hydraulic hoses are disconnected, hydraulic oil

from inside the hoses and the swing motor will flow out.
Fig. 3-166
Fig. 3-167 Removal of the swing motor
3 - 170
PC5500-6
Version 2009/2
Superstructure
Slew drive
Remove the four mounting bolts (Fig. 3-167, Pos. 1) and take
the slew brake valve (Fig. 3-167, Pos. 2) off. Discard the
O-ring (Fig. 3-167, Pos. 3). For further information, refer to
NOTE: The hydraulic hoses remain at the slew brake valve.

When the slew brake valve is removed, the oil inside the
valve will flow out. Catch it in an oil pan.
z
Remove the mounting bolts (Fig. 3-167, Pos. 4) and take off
the intermediate plate (Fig. 3-167, Pos. 5). Discard the O-ring
(Fig. 3-167, Pos. 6).
Only slew gear (Siebenhaar): Remove the bolts (Fig. 3-167,

Pos. 12), with washers (Fig. 3-167, Pos. 13), and the sleeves
(Fig. 3-167,Pos. 15). Put the expansion tank (Fig. 3-167,
Pos. 14) of the slew gear aside. Discard the bolts.
Remove the bolts (Fig. 3-167, Pos. 7) and the washers

(Fig. 3-167, Pos. 8). Discard the bolts.
Sling the swing motor (Fig. 3-167, Pos. 9).
Pull the swing motor out of the slew gear (Fig. 3-167, Pos. 11)
using a crane. Place the swing motor on the ground.

DANGER

When removing the swing motor, make sure that nobody
Version 2009/2
PC5500-6
3 - 171
Slew drive
Superstructure
3.4.2.2 REPLACEMENT OF THE SWING MOTOR

Special tools:
Crane
Swing motor: 170 kg
Dogman/rigger
Fig. 3-168 Installation of the swing motor
3 - 172
PC5500-6
Version 2009/2
Superstructure
Slew drive
Fit new O-rings (Fig. 3-168, Pos. 3, Pos. 6 and Pos. 10).
z
Apply "Optimol White" to the spline shaft of the motor.
NOTE: Use new swing motor mounting bolts (Fig. 3-168,

Pos. 7 and 12) of grade 10.9. Apply compound "KP2K",
PN 324 969 40 on heads and threads of the bolts and
tighten them to the specified torque.
Tightening torque for the swing motor mounting bolts: 265 Nm
z

No. "AH01513".

approx. 0.6 liters (L&S),
up to level gauge marking (Siebenhaar).
chapter 4, section "SWING GEARS AND MOTOR
ADAPTER HOUSING - CHANGE OIL".
page 6-2.
Check the adjustments of the swing motors. Refer to the Service Manual for further information.
Check the slew brake valve and adjust it if required. Refer to

the Service Manual for further information.
Version 2009/2
PC5500-6
3 - 173
Slew drive
3.4.3
Superstructure
SLEW PARKING BRAKE
NOTE: The machine can be equipped either with a slew parking

brake of manufacturer "Siebenhaar" or of manufacturer
"L&S".
For the removal and the replacement, the "L&S" slew
parking brake has to be disassembled/assembled.
The "Siebenhaar" slew parking brake assembly can be
exchanged completely.
Slew parking brake (L&S)

(1)
Disc housing
(10)
Thrust washer
(2)
Thrust washer
(11)
Circlip
(3)
Inner discs
(12)
Drive shaft
(4)
Outer discs
(13)
Oil pressure port
(5)
Sinus spacer ring
(14)
Bolt
(6)
Piston
(15)
Bearing ring
(7)
Quad ring with back up ring
(16)
Rotary shaft seal
(8)
Quad ring with back up ring
(17)
Cylinder assembly
(9)
Springs
3 - 174
PC5500-6
Version 2009/2
Superstructure
Slew drive
General:
Brake applied:
The outer disks engaged to the housing by serration and the inner
disks in serrated connection with the drive shaft are pressed
together by the springs. This results in a fixed connection
between housing and drive shaft due to the friction between the
spring pressurized discs.
Brake released:
Oil pressure via the pilot port reaches the bottom of the piston and
forces the piston upwards against the thrust washer and the
spring force. This eliminates the spring force towards the disks so
that the friction between the discs is released and the inner shaft
can rotate. Only the brake of the L&S gear box uses an additional
spacer ring (sinus ring) to keep the discs apart. It should reduce
the friction in released condition.
The minimum release pressure is 19 - 20 bar. In normal working
conditions, the releasing pressure is about 60 bar.
NOTE: The slew parking brake must only be applied with the
superstructure at a complete standstill. Applying the parking brake with superstructure still slewing may result in
severe damage to the brake.
WARNING
z
Only use the slew parking brake in emergency situations

to stop the rotating superstructure.
If the parking brake has been used for an emergency

stop, it is necessary to shut down the excavator and to
have the parking brake of each swing gear inspected and
repaired if necessary. Contact your Komatsu dealer for
repairing the brakes.
Version 2009/2
PC5500-6
3 - 175
Slew drive
Superstructure
3 - 176
PC5500-6
Version 2009/2
Superstructure
Slew drive
3.4.3.1 REMOVAL/DISASSEMBLY OF THE SLEW PARKING BRAKE (L&S)

Special tools:
n/a
Crane
Swing motor with attached slew service brake valve: 267 kg
Bearing ring: 32 kg
Dogman/rigger
NOTE: The slew parking brake is attached to the slew gear with
eight hexagon socket bolts. It is removed by disassembling it.
z
Remove the swing motor from the slew gear, refer to section
3.4.2.1 on page 3-169. Leave the hydraulic hoses and the
slew service brake valve attached to the swing motor.
NOTE: For further information relating the parking brake, refer to

z

a crane.
Remove the mounting bolts (Fig. 3-169, Pos. 1) at the swing

motor flange.
Remove the inner snap ring (Fig. 3-169, Pos. 2).
Dismantle the bearing ring (Fig. 3-169, Pos. 3) from the slew
gearbox using a crane.
Fig. 3-169
Version 2009/2
PC5500-6
3 - 177
Slew drive
Superstructure
Fig. 3-170 Slew parking brake (L&S)

z
Check rotary shaft seal (Fig. 3-170, Pos. 16) for wear and
damage. Replace it if required.
Disconnect the pressure hose from the oil pressure port

(Fig. 3-170, Pos. 13).
NOTE: When the pressure hose is removed, the oil inside the
hose and the cylinder (Fig. 3-170, Pos. 17) will flow out.
WARNING
The piston (Fig. 3-170, Pos. 6) of the break assembly is
spring loaded.
Remove the two socket head cap bolts (Fig. 3-170, Pos. 14)
and relieve the spring load of the springs (Fig. 3-170, Pos. 9)
on the piston (Fig. 3-170, Pos. 6).
Take off the cylinder assembly (Fig. 3-170, Pos. 17).
3 - 178
PC5500-6
Version 2009/2
Superstructure
Slew drive
Dismount 10 inner discs (Fig. 3-170, Pos. 3), 11 outer discs

(Fig. 3-170, Pos. 4), and 10 sinus spacer rings (Fig. 3-170,
Pos. 5) from the disc housing (Fig. 3-170, Pos. 1).
Remove the drive shaft (Fig. 3-170, Pos. 12).
Remove the thrust washer (Fig. 3-170, Pos. 2) from the disc
housing (Fig. 3-170, Pos. 1).
Check the inner discs (Fig. 3-170, Pos. 3), the outer discs
(Fig. 3-170, Pos. 4), the sinus spacer rings (Fig. 3-170,
Pos. 5), and the thrust washer (Fig. 3-170, Pos. 2) for wear
and damage. Replace if required.
Version 2009/2
PC5500-6
3 - 179
Slew drive
Superstructure
3.4.3.2 REPLACEMENT/ASSEMBLY OF THE SLEW PARKING BRAKE (L&S)

Special tools:
n/a
Crane
Hydraulic power unit (60 bar) with fitting (M18 x 1.5)
Bearing ring: 32 kg
Dogman/rigger
Fig. 3-171 Slew parking brake (L&S)
3 - 180
PC5500-6
Version 2009/2
Superstructure
Slew drive
NOTE: Replace all O-rings.

For further information relating the parking brake, refer to
z
Install the thrust washer (Fig. 3-171, Pos. 2).
Install the drive shaft (Fig. 3-171, Pos. 12).
NOTE: Apply "Optimol White" to the spline shaft.

z
Install new discs according to the following order:

At first an outer disc (Fig. 3-171, Pos. 4), then an inner disc
(Fig. 3-171, Pos. 3), and then a sinus spacer ring
(Fig. 3-171, Pos. 5). Apply oil to the discs.
NOTE: Before reinstallation, apply pressure (max. 60 bar) to the

cylinder assembly (Fig. 3-171, Pos. 17), otherwise the
two socket head cap bolts (Fig. 3-171, Pos. 14) are prestressed (spring loaded).
z
Install the cylinder assembly (Fig. 3-171, Pos. 17).

WARNING
Make sure to use the specified bolts and torque for the swing
motor mounting bolts, refer to section 3.4.2.2 on page 3-172.

approx. 0.6 liters.
page 6-2.
z
Check slew parking brake for proper function. Refer to the

Service Manual.
Version 2009/2
PC5500-6
3 - 181
Slew drive
Superstructure
3 - 182
PC5500-6
Version 2009/2
Superstructure
Slew drive
3.4.3.3 REMOVAL OF THE SLEW PARKING BRAKE (SIEBENHAAR)

Special tools:
n/a
Crane
Slew parking brake assembly: 115 kg
Dogman/rigger
2.3 on page 2-37.
NOTE: There can be two different types of "Siebenhaar" slew
parking brake assemblies installed at the machines
(depending on gear type):
Old type: PN 925 864 40
New type: PN 936 540 40
If an old type is installed, it is recommended by
KOMATSU to rebuild the brake assembly according to
the PARTS & SERVICE NEWS No. "AH07509".
Only the removal of the "new type" slew parking brake is
described below.
z
Remove the swing motor from the slew parking brake, refer to
section 3.4.2.1 on page 3-169. Leave the hydraulic hoses and
the slew service brake valve (Fig. 3-157, Pos. 1) attached to
the swing motor.
Drain oil of the brake housing, approx. 0.2 liters.
NOTE: After draining the oil of the brake housing, cap the openings with blind plugs to avoid contamination.
DANGER
removed.
Disconnect the pilot oil pressure line from the slew parking
brake.
Version 2009/2
PC5500-6
3 - 183
Slew drive
Superstructure
NOTE: When the pilot oil pressure line is disconnected, the oil
inside the line will flow out. Catch it in an oil pan.
z
Remove all hydraulic pipes (Fig. 3-172, Pos. 3) from the slew
parking brake (Fig. 3-172, Pos.23) and cap the openings with
blind plugs to avoid contamination.
DANGER
Danger of parts blasting off!

death may result!
The piston of the slew parking break assembly is spring
loaded.
It is necessary to release the brake manually (see following
procedure) before removing the mounting bolts (Fig. 3-172,
Pos. 1) attaching the complete slew parking brake (Fig. 3-172,
Pos. 2) to the slew gear box (Fig. 3-172, Pos. 4).
Never open the brake by removing the flange mounting bolts
(Fig. 3-173, Pos. 3) before the slew parking brake is manually
released!
Fig. 3-172
Fig. 3-173 Slew parking brake (Siebenhaar), drawn released
3 - 184
PC5500-6
Version 2009/2
Superstructure
Slew drive
Releasing the slew parking brake manually:

z
Insert two crews (Fig. 3-174, Pos. 1) of suitable length with

nuts (Fig. 3-174, Pos. 3) in the threaded borings
(Fig. 3-173, Pos. 2) of the piston (Fig. 3-174, Pos. 2) opposed
to each other.
Tighten each nut (Fig. 3-174, Pos. 3) alternately with a half

turn, to withdraw the piston Fig. 3-174, Pos. 2) to the flange
(Fig. 3-174, Pos. 4).
NOTE: Avoid tilting the piston!

z
Only remove the mounting bolts (Fig. 3-172 and 3-173,

Pos. 1) attaching the complete slew parking brake
(Fig. 3-174, Pos. 2) to the slew gearbox.
Fig. 3-174
DANGER
Serious injury, permanent disfigurement and scarring,
or death may result!
loaded.
released!
Insert swivel hoist rings (M16) displaced by 180 into the

threads of the swing motor mounting bolts and attach a crane.
Remove the slew parking brake (Fig. 3-172, Pos. 2) from the
slew gearbox (Fig. 3-172, Pos. 4), using a crane.
DANGER

below the weight.
Version 2009/2
PC5500-6
3 - 185
Slew drive
Superstructure
3.4.3.4 REPLACEMENT OF THE SLEW PARKING BRAKE (SIEBENHAAR)

Special tools:
n/a
Crane
Slew parking brake assembly: 115 kg
Dogman/rigger
NOTE: There can be two different types of "Siebenhaar" slew
parking brake assemblies installed at the machines
(depending on gear type):
Old type: PN 925 864 40
New type: PN 936 540 40
If an old type is installed, it is recommended by
KOMATSU to rebuild the brake assembly according to
the PARTS & SERVICE NEWS No. "AH07509".
Only the replacement of the "new type" slew parking
brake is described below.
Fig. 3-175 Slew parking brake (Siebenhaar) , drawn released

3 - 186
PC5500-6
Version 2009/2
Superstructure
Slew drive
DANGER
death may result!
loaded.
released!
z
Apply paste "Optimol White" on the spline shaft at the adapter

cover (Fig. 3-176, Pos. 4) of the gearbox.
Install swivel hoist rings (M16) on the new pre-assembled

slew parking brake, displaced by 180 into the threads of the
swing motor mounting bolts and attach the brake assembly to
a crane.
Insert a new O-Ring (Fig. 3-176, Pos. 3).
Centre the new pre-assembled slew parking brake

(Fig. 3-176, Pos. 2) onto the adapter cover (Fig. 3-176,
Pos. 4) of the gearbox.
DANGER
Fig. 3-176

below the weight.
Releasing the slew parking brake manually:

z
Insert two bolts (Fig. 3-177, Pos. 1) of suitable length with

nuts (Fig. 3-177, Pos. 3) in the threaded borings
(Fig. 3-175, Pos. 2) of the piston (Fig. 3-177, Pos. 2) opposed
to each other.
Tighten each nut (Fig. 3-177, Pos. 3) alternately with a half

turn, to withdraw the piston Fig. 3-177, Pos. 2) to the flange
(Fig. 3-177, Pos. 4).
NOTE: Avoid tilting the piston!

z
Turn the slew parking brake (Fig. 3-176, Pos. 2) until the
bores in slew parking brake are aligned to threads in the
adapter cover (Fig. 3-176, Pos. 3).
Insert new mounting bolts (Fig. 3-176, Pos. 1) and tighten

them crosswise.
Remove the release bolts (Fig. 3-177, Pos. 1) with nuts alternately stepwise to prevent the piston from tilting.
Version 2009/2
PC5500-6
Fig. 3-177
3 - 187
Slew drive
Superstructure

WARNING
Make sure to use the specified bolts and torques for the
swing motor mounting bolts, refer to section 3.4.2.2 on page
3-172.
Fill oil into the motor adapter housing, up to level

gauge marking.
Fill oil in the brake housing approx. 0.2 liters.
page 6-2.
z
Check slew parking brake for proper function. Refer to the

Service Manual.
3 - 188
PC5500-6
Version 2009/2
Superstructure
Slew drive
Version 2009/2
PC5500-6
3 - 189
Slew drive
3.4.4
Superstructure
DYNAMIC SLEW BRAKE
Fig. 3-178 Slew brake valve
3 - 190
PC5500-6
Version 2009/2
Superstructure
Slew drive

(1)
Pressure increasing valve
(2)
Check valve circuit A
(3)
Check valve circuit B
(4)
Anti-cavitation valve circuit B (check valve)
(5)
Anti cavitation valve circuit A (check valve)
(6)
Jet bore of main relief valve spool
(7)
Spring of main relief valve spool
(8)
Jet bore pilot relief valve
(9)
Valve cone of pilot relief valve
(10)
Spring of pilot relief valve
(11)
Intermediate pin
(12)
Control piston for pressure increase
(13)
Main relief valve spool
(X)
Pilot control port for pressure increase
(Y)
Leak oil, pilot valve drain
(T)
Return oil to tank / reservoir
(A)
Service line from main control valve block
(A)
Service line to the motor
(B)
Service line from main control valve block
(B)
Service line to the motor
(MA)
Check point circuit A
(MB)
Check point circuit B
When ever a swing motion is carried out or the foot brake is used,
pilot pressure is present at port X of the pressure increase valve
(Fig. 3-178, Pos. 1). The pilot pressure preloads the relief valve.
The oil for the hydraulic motor from the main control valve block
feeds the service line port A or B depending of the slew direction
left or right. The ports A and B are internally connected to the
ports A and B and these ports in turn with the hydraulic motor.
The operating pressure at either port A or B closes the anti-cavitation valves (Fig. 3-178, Pos. 4 and 5) and opens the check valves
(Fig. 3-178, Pos. 2 and 3). That means the service lines are connected to the pressure increase valve by the check valves
(Fig. 3-178, Pos. 2 and 3).
When ever the pressure is higher than the setting of the pressure
increase valve, the valve opens and dumps oil into the return line
T to the reservoir. If the superstructure is slewing by dynamical
momentum, the motor is driven by the slew gear and acts as a
pump. The pressure in the service lines to the motor changes.
Version 2009/2
PC5500-6
3 - 191
Slew drive
Superstructure
The low pressure return line becomes pressurized and the pressurized service line changes to suction line. The service line is
closed at the main control valve block so the oil can only circulate
through the brake valve blocks pressure increase valve.
Fig. 3-179 Pressure increase valve

Whenever a swinging motion is carried out or the foot brake is
used, pilot pressure is present at port X of the pressure increasing
valve. The pilot pressure preloads the relief valve.
By applying pilot pressure via the external port X to piston
(Fig. 3-179, Pos. 12), the pretension of the spring (Fig. 3-179,
Pos. 10) is increased by the amount of the piston stroke S which
results in a higher pressure setting for the pilot valve.
The system pressure is present at the main piston (Fig. 3-179,
Pos. 13) and via the jet bore (Fig. 3-179, Pos. 6) in the chamber
of the spring (Fig. 3-179, Pos. 7) as well. System pressure also is
present at the pressure relief valve cone (Fig. 3-179, Pos. 9) via
the jet bore (Fig. 3-179, Pos. 8).
Due to the force balance, the piston (Fig. 3-179, Pos. 13) is kept
in its position, supported by the spring (Fig. 3-179, Pos. 7).
If the system pressure is higher than the setting of the valve
(Fig. 3-179, Pos. 9) the valve opens a channel to the drain port Y.
Due to the drop of pressure, the piston (Fig. 3-179, Pos. 13) is
moved by the spring (Fig. 3-179, Pos. 7). The pressure line is
connected to the return line T.
Dampened opening and closing is obtained by the throttled volumetric change that is caused by the jet bores.
3 - 192
PC5500-6
Version 2009/2
Superstructure
Slew drive
3.4.4.1 REMOVAL OF THE SLEW BRAKE VALVE

Special tools:
n/a
Crane
Slew brake valve: 97 kg
Dogman/rigger
2.3 on page 2-37.
z


z

Fig. 3-180
Version 2009/2
PC5500-6
3 - 193
Slew drive
Superstructure
WARNING
Hot hydraulic oil!
Disconnect the service hoses (Fig. 3-181, Pos. 2), the return
hose (Fig. 3-181, Pos. 3), the leak oil hose (Fig. 3-181,
Pos. 4), and the pilot hose (Fig. 3-181, Pos. 5) from the slew
brake valve (Fig. 3-181, Pos. 6).
NOTE: When the hydraulic hoses are removed, hydraulic oil

from inside the valve and the piping will flow out.
z
Sling the slew brake valve (Fig. 3-181, Pos. 6).
Remove the four mounting bolts (Fig. 3-181, Pos. 1) and

demount the slew brake valve (Fig. 3-181, Pos. 6) from the
swing motor (Fig. 3-181, Pos. 7), using a crane.
Fig. 3-181
DANGER
When removing the slew brake valve, make sure that nobody
Discard the O-ring from below the slew brake valve

(Fig. 3-181, Pos. 6).
NOTE: When the slew brake valve is removed, hydraulic oil from
inside the valve will flow out. Catch it in an oil pan.
3 - 194
PC5500-6
Version 2009/2
Superstructure
Slew drive
3.4.4.2 REPLACEMENT OF THE SLEW BRAKE VALVE

Special tools:
n/a
Slew brake valve: 97 kg
Dogman/rigger
Fit new O-rings below the slew brake valve and the SAEflanges.
z

No. "AH01513".
Check and adjust the slew brake valve. Refer to the Service
Manual.
Check dynamic slew brake for proper function. Refer to the

Service Manual.
Version 2009/2
PC5500-6
3 - 195
Slew drive
3.4.5
Superstructure
SWING CIRCLE LUBRICATION PINION (DUMMY WHEEL)
Fig. 3-182 Slew ring lubrication
3 - 196
PC5500-6
Version 2009/2
Superstructure
Slew drive

(1)
Lubrication pump station (SLS)
(2)
Lubricant supply line from pump to injector
(3)
Injectors
(4)
End line pressure switch
(5)
Lubricant feed line from injector to lubrication pinion
(6)
Lubrication pinion
(7)
Slew ring
(8)
Lubrication pinion
(9)
Lubricant outlet
(10)
Lubrication pinion center shaft with distributing

drillings
The Swing circle lubrication system (SLS) lubricates the open

gear of the outer slew ring with special open gear lubricant.
The lubricant pump station (Fig. 3-182, Pos. 1) is identical with
the central lubrication system (CLS), refer to section 3.5 on page
3-212. To apply the lubricant equably to the outer slew ring teeth
(Fig. 3-182, Pos. 7), a special lubrication pinion (Fig. 3-182,
Pos. 8) is mounted near the drive pinion of the front slew gear.
The lubrication pinion (Fig. 3-182, Pos. 8) distributes the lubricant
from the injectors (Fig. 3-182, Pos. 3) evenly to the teeth. Normally two or more small SL1 injectors (Fig. 3-182, Pos. 3) are
parallel connected to supply the required amount of lubricant to
the lubrication pinion.
NOTE: The pinion center shaft (Fig. 3-182, Pos. 10) acts as a
rotary joint and distributes lubricant through radial
drillings only to the teeth, witch are in contact with the
outer slew ring gear teeth.
Outlet bores (Fig. 3-182, Pos. 9 on different position of
the pinion gear distribute the lubricant equably to the
outer slew ring teeth (Fig. 3-182, Pos. 7).
Version 2009/2
PC5500-6
3 - 197
Slew drive
Superstructure
3.4.5.1 REMOVAL OF THE LUBRICATION PINION ASSEMBLY

Special tools:
n/a

Pinion cover: 11.6 kg
Lubrication pinion assembly: 18.2 kg

the machine, boom, and mobile working platform.
Park the machine on the prepared flat ground area with the
lubrication pinion placed between the crawler carriers, so that
the lubrication pinion can be accessed by a mobile working
platform.

z

WARNING
Before maintenance, stop the engine and remove ignition

key in order to prevent operation of the lubrication system.
Assure that the system pressure of the lubrication system is
relieved before maintenance.
Relieve system pressure of the lubrication system by actuating the vent valve (Fig. 3-195, Pos. 2) by hand, refer to
WARNING
Always wear a safety harness when working at the lubrication pinion.
NOTE: A second person is required for the work at the lubrication pinion.
3 - 198
PC5500-6
Version 2009/2
Superstructure
Slew drive
Fig. 3-183 Lubrication pinion assembly, removal and replacement

z
Remove the mounting bolts (Fig. 3-183, Pos. 6) with sleeves

(Fig. 3-183, Pos. 7) and remove the pinion cover (Fig. 3-183,
Pos. 1).
NOTE: A second person is required for this work.

z
Disconnect the lubrication lines (Fig. 3-183, Pos. 4).
Remove the nuts (Fig. 3-183, Pos. 5) and take the lubrication
pinion assembly (Fig. 3-183, Pos. 3) with connector plate
(Fig. 3-183, Pos. 2) off the superstructure.
Version 2009/2
PC5500-6
3 - 199
Slew drive
Superstructure
3.4.5.2 REPLACEMENT OF THE LUBRICATION PINION ASSEMBLY

Special tools:
n/a

Pinion cover: 11.6 kg
Lubrication pinion assembly: 18.2 kg
WARNING
Always wear a safety harness when working at the lubrication pinion.

z
After installation is complete, the swing circle lubrication system has to be activated manually, refer to the Operation &
Maintenance Manual, chapter 3, section "SWING CIRCLE
PINION LUBRICATION SYSTEM SLS.
Activate the switch S26 at the dash board until the correct
pressure is reached.
Reset the lubrication cycle counter of the slew ring lubrication

system. Refer to the Operation & Maintenance Manual, chapter 3, section "SWING CIRCLE PINION LUBRICATION SYSTEM SLS.
3 - 200
PC5500-6
Version 2009/2
Superstructure
Slew drive
Version 2009/2
PC5500-6
3 - 201
Slew drive
3.4.6
Superstructure
SWING CIRCLE
Fig. 3-184 Slew ring assembly
3 - 202
PC5500-6
Version 2009/2
Superstructure
Slew drive

(1)
Superstructure
(2)
Swing circle
(3)
Bolt
(4)
Washer
(5)
Swing circle protection covers
(6)
Washer
(7)
Bolt
(8)
Car body
(9)
Bolt
(10)
Resilient sleeve
The swing circle is the movable connection between the superstructure and the car body.
The swing circle bearing is connected to the central lubrication
system. The outer ring gear is lubricated by an own lubrication
system SLS which uses a special open gear lubricant.
NOTE: For wear limits, refer to PARTS & SERVICE NEWS No.
"AH02513".
For additional information, refer to PARTS & SERVICE
NEWS No. "AH00511" last edition.
3.4.6.1 REMOVAL OF THE SWING CIRCLE
Special tools:
Mounting cross, PN 477 577 40

Hydraulic torque wrench, PN 232 615 40
Electro-hydraulic pump set, PN 232 613 40
55 mm hexagon impact socket wrench, PN 232 267 40
2 x Crane (2nd. crane for superstructure lifting)

Swing circle: 10,000 kg
Dogman/rigger

the machine, boom, and two cranes.

Version 2009/2
PC5500-6
3 - 203
Slew drive
Superstructure
Remove the superstructure from the car body (counterweight,

fluids and attachment removed), refer to section 3.9.1 on
page 3-257.
Place the superstructure on appropriate supports, high

enough to handle the mounting cross underneath the swing
circle.
CAUTION
Supports need to be substantial enough to carry total weight

of the superstructure (without counterweight, fluids and
attachment), total weight 137,215 kg.
Before removing swing circle, mark location of both slew rings

to superstructure and the car body as well for further investigations.
Disconnect all slew ring bearing lubrication hoses (Fig. 3-185,

Pos. 1) from the inner slew ring (Fig. 3-185, Pos. 3), removing
the unions (Fig. 3-185, Pos. 2).
Fig. 3-185
z
Position the mounting cross, PN 477 577 40 underneath the

swing circle.
Connect the lifting device to a crane.
NOTE: In order to avoid damage to the sling accessory, use

edge protection at all sharp edges.
The lifting device is accessible from the centre of the
machine (Fig. 3-186, arrow).
CAUTION
Move the sling accessory carefully between the pipe work/
hoses at the manifold to prevent the pipe work from being
damaged or ripped off.
Fig. 3-186
3 - 204
PC5500-6
Version 2009/2
Superstructure
Slew drive
Lift the mounting cross (Fig. 3-187, Pos. 1) to place it under

the swing circle (Fig. 3-187, Pos. 2).
Remove the mounting bolts of the inner slew ring to dismount

the swing circle (Fig. 3-187, Pos. 2) from the superstructure
(Fig. 3-187, Pos. 3).
NOTE: In order to avoid damage to the lifting devices, use edge

protection at all sharp edges.
Fig. 3-187
Lower the mounting cross with the swing circle (Fig. 3-188,
Pos. 3) resting on it to the ground.
NOTE: The guides (Fig. 3-188, Pos. 2) ensure that the swing
circle is aligned accurately with the superstructure
(Fig. 3-188, Pos. 1) while it is removed and installed
respectively.
Do not remove the guides.
Fig. 3-188
z
Install four swivel hoist rings evenly distributed at the inner

slew ring and remove the swing circle from the mounting
cross using a crane.
DANGER

Death or serious injury result.
When removing the swing circle, make sure that nobody
Version 2009/2
PC5500-6
3 - 205
Slew drive
Superstructure
3.4.6.2 REPLACEMENT OF THE SWING CIRCLE
Special tools:
Mounting cross, PN 477 577 40

Measuring jaw, PN 376 792 40
8 x Measuring bolt, PN 409 437 40 and 8 x Measuring bolt (cold
weather) respectively, PN 409 484 40
Test block, PN 379 077 40
55 mm hexagon impact socket wrench, PN 232 267 40
2 x Crane (2nd. crane for superstructure lifting)

Laser device for checking the level of bearing area
Swing circle: 10,000 kg
Dogman/rigger
z
Check the level of bearing area with a laser device before

installing a new slew ring. Refer to PARTS & SERVICE
NEWS No. "AH00511".
Check the outer diameter of the new slew ring top surface
and compare with the outer diameter of the factory machined
surface of the superstructure. Refer to PARTS & SERVICE
NEWS No. "AH00511" last edition. Remove the shoulder by
machining if necessary.
WARNING
Shocks to the swing circle (especially radial shocks)

must be avoided.
Transport and store the new swing circle exclusively with

transport star fitted.
It is strictly forbidden to hook up the new swing circle at

the transport star.
Hang up and/or transport and store the swing circle only

horizontally. If a special attachment is available, the
transportation and storage in inclined position may be
carried out.
Only hang swing circle at four swivel hoist rings evenly

distributed in screw circle of the inner slew ring.
3 - 206
PC5500-6
Version 2009/2
Superstructure
Slew drive
NOTE: When replacing the swing circle, all fastening bolts must
also be replaced.
z
Install four swivel hoist rings evenly distributed at the inner

slew ring and lift it using a crane.
DANGER

When removing the swing circle, make sure that nobody
Place the swing circle (Fig. 3-189, Pos. 2) onto the mounting
cross (Fig. 3-189, Pos. 1).
Centre the swing circle (Fig. 3-189, Pos. 2) on the mounting

cross (Fig. 3-189, Pos. 1) using the transport star.
Position the mounting cross with the swing circle resting on it

under the superstructure (Fig. 3-189, Pos. 3) and connect the
mounting cross to a crane.
Fig. 3-189
NOTE: In order to avoid damage to the sling accessory, use
edge protection at all sharp edges.
The lifting device is accessible from the centre of the
machine (Fig. 3-186, arrow).
CAUTION
Move the sling accessory carefully between the pipe work/
hoses at the manifold to prevent the pipe work from being
damaged or ripped off.
Fig. 3-190
Version 2009/2
PC5500-6
3 - 207
Slew drive
Superstructure
Fig. 3-191 Swing circle installation

z
Mating surfaces must be absolutely fat-free. Even the solvent

must be rinsed away before assembling.
Check flatness of the mating surfaces.
Prepare new bolts (Fig. 3-191, Pos. 3) and washers

(Fig. 3-191, Pos. 4). Lubricate the threads and the head
surface of the bolts with compound "KP2K", PN 324 969 40.
3 - 208
PC5500-6
Version 2009/2
Superstructure
Slew drive
Align the "S-spots".
NOTE: The unhardened spot of race surfaces (changeover area

between beginning and end of hardening process) is
punch-marked with an "S" at the inner resp. outer side of
each slew ring (Fig. 3-191, Pos. 1 and 2).
These spots "S" must not be placed within the main load
area of the swing circle. Hence, the unhardened spot "S"
has to be turned in an angle of 90 to the main load area
refer to Fig. 3-191.
z
Remove the transport cross.
Align the teeth of the outer slew ring with the lubrication pinions and the pinions of the slew gears.
Lift the swing circle (Fig. 3-192, Pos. 3) to approx. 10 mm

below the superstructure platform (Fig. 3-192, Pos. 1) by
means of the mounting cross.
Align the holes in the inner slew ring with the treads in the
superstructure platform. The guides (Fig. 3-192, Pos. 2) centre the swing circle horizontally (observe the unhardened
"S-spots").
NOTE: The guides ensure that the swing circle is aligned accurately into its mounting position.
Do not remove the guides (Fig. 3-192, Pos. 2) after
installation.
z
Install bolts (Fig. 3-191, Pos. 3) and washers (Fig. 3-191,

Pos. 4) to the inner slew ring.
Join the swing circle (Fig. 3-191, Pos. 5) on to the supporting

surface at the superstructure platform (Fig. 3-191, Pos. 6) by
tightening the bolts crosswise manually.
Remove the mounting cross.
Connect all lubrication lines (Fig. 3-193, Pos. 1) to the unions

(Fig. 3-193, Pos. 2) at the inner slew ring (Fig. 3-193, Pos. 3).
Fig. 3-192
Fig. 3-193
Version 2009/2
PC5500-6
3 - 209
Slew drive
Superstructure
Check the tooth backlash between slew ring and slew pinion
with a feeler gauge.
Tighten all bolts (Fig. 3-191, Pos. 3) of the inner
slew ring crosswise to the required torque, refer
to PARTS & SERVICE NEWS No. "AH00511" last
edition.
NOTE: The procedure of tightening has to be performed twice or

three times, to ensure a setting of the bolts. Refer to
PARTS & SERVICE NEWS No. "AH00511" last edition.
z
After tightening all bolts (Fig. 3-191, Pos. 3) the tooth back
lash has to be checked once more at 4 points. Refer to
PARTS & SERVICE NEWS No. "AH00511" last edition.
If necessary adjust again.
Lift the superstructure (Fig. 3-191, Pos. 6) and install the

superstructure onto the undercarriage, refer to section 3.9.2
on page 3-261.
DANGER

When lifting the superstructure, make sure that nobody

3 - 210
PC5500-6
Version 2009/2
Superstructure
Slew drive
Version 2009/2
PC5500-6
3 - 211
Lubrication pumps
3.5
Superstructure
LUBRICATION PUMPS
Fig. 3-194 Lubrication pumps
3 - 212
PC5500-6
Version 2009/2
Superstructure
Lubrication pumps

(1)
Coupling on service arm for filling up the grease container (3) of the Swing circle gear Lubrication
(2)
Grease filter for Swing circle gear Lubrication

System "SLS"
(3)
Grease container of the Swing circle gear

Lubrication "SLS"
(4)
Hydraulic motor with pump unit
(5)
Grease pressure gauge for "SLS"
(6)
Receiver panel on service arm
(7)
Coupling on service arm for filling the grease container (9) of the Central Lubrication System
(8)
Grease filter for Central Lubrication System "CLS"
(9)
Grease container of the Central Lubrication System
(10)
Hydraulic motor with pump unit
(11)
Grease pressure gauge for "CLS"
(12)
Mounting bolts of the grease container housing
The lubrication pump is a hydraulically driven seal-free differential

piston pump. The pump pumps lubricant during the up and down
stroke but sucks lubricant only during the up stroke. The scoop
piston at the pump bottom supports the main pump with high viscosity lubricants. There is only one dynamic seal at the piston rod
on top of the pump pipe.
The lubrication pump is divided in two main components, the
pump drives hydraulic cylinder and the pump. The pump drive
and only the pump outlet are outside on top of the lubricant container, the pump itself is inside and reaches into the lubricant.
Version 2009/2
PC5500-6
3 - 213
Lubrication pumps
3.5.1
Superstructure
REMOVAL OF THE LUBRICATION PUMP
Special tools:
n/a
Crane
Lubrication pump: 28 kg
Dogman/rigger


z

WARNING
Before maintenance, stop the engine and remove ignition

key in order to prevent operation of the lubrication system.
Assure that the system pressure of the lubrication system is
relieved before maintenance.
Relieve system pressure of the lubrication system by actuating the vent valve (Fig. 3-195, Pos. 1) by hand, refer to
Disconnect the hydraulic lines (Fig. 3-195, Pos. 2) from the

lubrication pump.
Disconnect the quick coupling from the grease feeding line

(Fig. 3-195, Pos. 3).
Fig. 3-195
3 - 214
PC5500-6
Version 2009/2
Superstructure
Lubrication pumps
Disconnect the grease feeding line (Fig. 3-196, Pos. 1) from

the lubrication pump.
Fig. 3-196
z
Remove the bolt (Fig. 3-197, Pos. 1).
Fig. 3-197
Sling the lubrication pump (Fig. 3-197, Pos. 1) at the installed

lifting eye (Fig. 3-197, Pos. 1) and pull the lubrication pump
out of the grease container.
Fig. 3-198
Version 2009/2
PC5500-6
3 - 215
Lubrication pumps
3.5.2
Superstructure
REPLACEMENT OF THE LUBRICATION PUMP
Special tools:
n/a
Crane
Lubrication pump: 28 kg
Dogman/rigger
z
After replacement, bleed the pump at the breather port

(Fig. 3-199, Pos. 1).
Fig. 3-199
z
Adjust the lubrication pump speed and pressure. Refer to the

Service Manual.
3 - 216
PC5500-6
Version 2009/2
Superstructure
Pump controller MC7
3.6
PUMP CONTROLLER MC7
3.6.1
REMOVAL OF THE PUMP CONTROLLER MC7
Special tools:
n/a
n/a
Remove the wiring harness connector X14 (Fig. 3-200,

Pos. 2) from the electronic pump controller MC7
(Fig. 3-200, Pos. 3).
Remove four bolts and remove the pump controller MC7 from
the wall of the cab base (Fig. 3-200, Pos. 1).
Fig. 3-200
3.6.2
REPLACEMENT OF THE PUMP CONTROLLER MC7
Special tools:
n/a
n/a
Check and adjust the parameters of the pump controller.

Refer to the Service Manual for further information.
Version 2009/2
PC5500-6
3 - 217
Operators cab
3.7
Superstructure
OPERATORS CAB
Fig. 3-201 Operators cab overview

3 - 218
PC5500-6
Version 2009/2
Superstructure
Operators cab

A
Rear View of Operators Cab
(1)
Door handle
(2)
Door latch (with door fully opened)
(3)
Door locking pin, engages into latch when the cab

door is fully opened
(4)
Light switch for access area lighting
(5)
Light switch for interior cab lighting
(6)
Air conditioner door
(7)
Outside mirrors with integrated heaters, both mirrors

are adjusted electrically via a control switch on the
instrument panel
(8)
Main working lights
(9)
Adapter for warning beacon
Front View of Operators Cab
(10)
Release lever for door lock (2 - 3)
(11)
Door opener push button
(12)
Lock lever
(13)
Control levers for working attachment
(14)
Operators seat
(15)
Upper windshield wiper
(16)
Lower windshield wiper
WARNING
The operators cab is equipped with an integrated Falling
Object Protective Structure (FOPS) that meets the requirements of ISO 3449. Any modifications on the steel structure
of the cab are inadmissible. Repairs on the FOPS must only
be carried out by specialists having the authorization for
repair work on Falling Object Protective Structures and in
accordance with the manufacturers repair instructions.
Version 2009/2
PC5500-6
3 - 219
Operators cab
Superstructure
3 - 220
PC5500-6
Version 2009/2
Superstructure
3.7.1
Operators cab
REMOVAL OF THE OPERATORS CAB
Special tools:
n/a

Crane
Tank for coolant storage
Oil drain pan
Operators cab: 3785 kg
Dogman/rigger
Air condition service specialist
2.3 on page 2-37.
z


z

WARNING
Always wear a safety harness when working at the operators

cab.
until the temperature of the coolant is below 50 C.
Disobedience may result in personal injury from heated coolant or steam.
Drain the engine coolant of engine 2,

approx. 360 liters.
Manual.
Version 2009/2
PC5500-6
3 - 221
Operators cab
Superstructure
Dismount the grommet plate (Fig. 3-202, Pos. 1) inside the

cab base.
If machine is equipped with harness connectors:

z
Disconnect all harness connectors at the back side of the

grommet plate.
Disconnect all other harnesses leading to the operators

cab from the X2-board and pull it out of the grommet
plate.
If machine is not equipped with harness connectors:

z
Disconnect all harnesses leading to the operators cab Fig. 3-202

from the X2C-board and remove the cable transfer elements.
Dismount the grommet plate (Fig. 3-203, Pos. 1) inside the

cab base.

z
Disconnect all harness connectors of the manipulators at

the back side of the grommet plate.

z
Disconnect all harnesses leading to the operators cab

from the X2-board and remove the cable transfer elements.
Fig. 3-203
Remove the ground cable (Fig. 3-204, Pos. 1) in the cab base
(Fig. 3-204, Pos. 2) from the left lower fixing bolt at the
X2-board and pull it out of the grommet plate.
Fig. 3-204
3 - 222
PC5500-6
Version 2009/2
Superstructure
Operators cab
Remove the cover (Fig. 3-205, Pos. 1) inside the cab base.
Disconnect the hose (Fig. 3-205, Pos. 2) between cab support and operators cab from the other side of the cover.
Fig. 3-205
DANGER
Danger of high pressure.
The air conditioning system is pressurized. Make sure that
the refrigerant is sucked from the system before any lines
will be removed.
Aspirate the refrigerant from the air condition system.

WARNING
The air conditioning must be serviced by authorized service

specialists only.
Open the plate (Fig. 3-206, Pos. 3) at the fuel tank and disconnect the refrigerant couplings (Fig. 3-206, Pos. 1) at the
refrigerant hoses below the cab support (Fig. 3-206, Pos. 2).
Cap the openings with blind plugs to avoid contamination of

Disconnect the condensate lines from the air conditioning

unit.
Clear all hoses from the operators cab.
Version 2009/2
Fig. 3-206
PC5500-6
3 - 223
Operators cab
Superstructure
Sling the operators cab (Fig. 3-207, Pos. 2) at the lifting eye
bolts (Fig. 3-207, Pos. 1) delivered with the cab.
Fig. 3-207
Fig. 3-208 Removal of the operators cab, overview
3 - 224
PC5500-6
Version 2009/2
Superstructure
Operators cab
Remove the hoses (Fig. 3-208, Pos. 7) of the operators cab

heating from inside the cab base.
NOTE: When the hoses of the operators cab heating are

removed, fluid from inside the piping will flow out.
z
Open the hose clips (Fig. 3-208, Pos. 5) and remove the
water hoses (Fig. 3-208, Pos. 6).
Remove the gratings (Fig. 3-208, Pos. 8) from the cab support (Fig. 3-208, Pos. 9).
Remove the bolts (Fig. 3-208, Pos. 2) and resilient sleeves

(Fig. 3-208, Pos. 3) from the viscous mounts (Fig. 3-208,
Pos. 4).
Remove operators cab (Fig. 3-208, Pos. 1) using a crane.
NOTE: Lift the operaters cab slowly while using a second person inside the cab base to guide the harnesses through
the grommet plates.
DANGER
When removing the operators cab make sure that nobody
Version 2009/2
PC5500-6
3 - 225
Operators cab
3.7.2
Superstructure
REPLACEMENT OF THE OPERATORS CAB
Special tools:
n/a

Crane
Dogman/rigger
Air condition service specialist
Fig. 3-209 Replacement of the operators cab, overview

3 - 226
PC5500-6
Version 2009/2
Superstructure
Operators cab
WARNING
cab.
WARNING
Ensure no one stands between the cabin and the cab base
during lowering.
NOTE: Use new bolts (Fig. 3-209, Pos. 2) of the grade 10.9 at
the viscous mounts (Fig. 3-209, Pos. 4).
torque.
NOTE: When lowering the operators cab have a second person
inside the cab base to guide the harnesses through the
grommet plates.
880 Nm
z
Evacuate the air conditioning system and add refrigerant.

WARNING
The air conditioning must be filled with refrigerant "R134a"

by authorized service specialists only.
Refill the engine coolant, approx. 360 liters.

Manual.
Version 2009/2
PC5500-6
3 - 227
Operators cab
3.7.3
Superstructure
CAB-MOUNTS
3.7.3.1 REMOVAL OF THE CAB-MOUNTS

Special tools:
n/a

Crane
Viscous mount: 4 kg
Absorber plate incl. 2 viscous mounts: 11.9 kg
Dogman/rigger


z

WARNING

cab.
Sling the operators cab (Fig. 3-207, Pos. 2) at the lifting eye
bolts (Fig. 3-207, Pos. 1) delivered with the cab.
Fig. 3-210
3 - 228
PC5500-6
Version 2009/2
Superstructure
Operators cab
Fig. 3-211 Removal of the cab-mounts, overview

z
Remove the gratings (Fig. 3-211, Pos. 8) from the cab support (Fig. 3-211, Pos. 9).
Remove the bolts (Fig. 3-211, Pos. 2) and resilient sleeves

(Fig. 3-211, Pos. 3) from the viscous mounts (Fig. 3-208,
Pos. 4).
Raise the operators cab (Fig. 3-208, Pos. 1) only a few millimeters, just enough to clear the viscous mounts (Fig. 3-208,
Pos. 4).
Remove the bolts (Fig. 3-211, Pos. 5) from the absorber plate
(Fig. 3-211, Pos. 6) and remove the absorber plate with the
viscous mounts.
Remove the bolts (Fig. 3-211, Pos. 7) and dismount the viscous mounts (Fig. 3-208, Pos. 4) from the absorber plate
(Fig. 3-211, Pos. 6).
Version 2009/2
PC5500-6
3 - 229
Operators cab
Superstructure
3.7.3.2 REPLACEMENT OF THE CAB-MOUNTS

Special tools:
n/a

Crane
Viscous mount: 4 kg
Dogman/rigger
Fig. 3-212 Replacement of the cab-mounts, overview

3 - 230
PC5500-6
Version 2009/2
Superstructure
Operators cab
WARNING
cab.
NOTE: Always use new mounting bolts of the grade 10.9.

torque.
Tightening torque for the mounting bolts
(Fig. 3-212, Pos. 7) at the cab mounts
(Fig. 3-212, Pos. 4): 180 Nm
Tightening torque for the mounting bolts
(Fig. 3-212, Pos. 5) at the absorber plates
(Fig. 3-212, Pos. 6): 880 Nm
Tightening torque for the operators cab mounting bolts (Fig. 3-212, Pos. 2): 880 Nm
Version 2009/2
PC5500-6
3 - 231
Operators cab
3.7.4
Superstructure
FRONT WINDOW (WINDSCREEN)
3.7.4.1 REMOVAL OF THE FRONT WINDOW

Special tools:
n/a
Suction lifters with hoist rings

Crane
Front window: 112 kg
Dogman/rigger


z

WARNING

cab.
Remove the wiper arms (Fig. 3-213, Pos. 1).
Use suction lifters with hoist rings at the front window

(Fig. 3-213, Pos. 4) to sling the front window.
Remove the bolts (Fig. 3-213, Pos. 2). Hold nut (Fig. 3-213,
Pos. 3) from inside the cab.
Remove the front window (Fig. 3-213, Pos. 4) using a crane.
Fig. 3-213
3 - 232
PC5500-6
Version 2009/2
Superstructure
Operators cab
3.7.4.2 REPLACEMENT OF THE FRONT WINDOW

Special tools:
n/a
Suction lifters with hoist rings

Crane
Front window: 112 kg
Dogman/rigger
WARNING
cab.
NOTE: A different holes pattern is used since January 2007 for

the frame of the front window.
KOMATSU recommends to use front windows with new
holes pattern in the frame, also for shovels, delivered
before 2007.
For further information refer to the PARTS & SERVICE
NEWS No. "AH08504".
z
Check the correct end position of the wiper arm(s) after installation of the front window.
Version 2009/2
PC5500-6
3 - 233
Operators cab
3.7.5
Superstructure
OPERATORS SEAT
3.7.5.1 REMOVAL OF THE OPERATORS SEAT

Special tools:
n/a
Crane
Operators seat: 62 kg
Dogman/rigger


z
Disconnect the wire harness connector (Fig. 3-214, Pos. 1) of

the air suspension.
Remove both control lever carriers (Fig. 3-214, Pos. 2 and 3).
Remove all mounting bolts (Fig. 3-214, Pos. 4) from the cover
plate (Fig. 3-214, Pos. 5).
Remove the cover plate (Fig. 3-214, Pos. 5) by removing all

seat mounting bolts (Fig. 3-214, Pos. 6) and nuts (Fig. 3-214,
Pos. 7) from the operators seat (Fig. 3-214, Pos. 8).
NOTE: A second person is required to carry the operators seat

out of the operators cab.
z
Sling the operators seat and lift it off the machine using a
crane.
3 - 234
PC5500-6
Fig. 3-214
Version 2009/2
Superstructure
Operators cab
3.7.5.2 REPLACEMENT OF THE OPERATORS SEAT

Special tools:
n/a
Crane
Operators seat: 62 kg
Dogman/rigger
z
Remove both control lever carriers from the new seat.
NOTE: A second person is required to carry the operators seat

into the operators cab.
Version 2009/2
PC5500-6
3 - 235
Operators cab
3.7.6
Superstructure
ECS
3.7.6.1 REMOVAL OF THE ECS TEXT DISPLAY

Special tools:
n/a
n/a
Open the operators console.
Disconnect the data cables (Fig. 3-215, Pos. 1 and 2) from

the ECS text display (Fig. 3-215, Pos. 4).
Remove the wing nuts (Fig. 3-215, Pos. 3) and take the ECS
text display (Fig. 3-215, Pos. 4) out of the operators console.
Fig. 3-215
3.7.6.2 REPLACEMENT OF THE ECS TEXT DISPLAY

Special tools:
n/a
n/a
Set time, date and operating hours, refer to the Operation &
Maintenance Manual, chapter 3, section "ELECTRONIC
MONITORING AND CONTROL SYSTEM ECS".
3 - 236
PC5500-6
Version 2009/2
Superstructure
Operators cab
Version 2009/2
PC5500-6
3 - 237
Operators cab
3.7.7
Superstructure
ACCESS LADDER
Fig. 3-216 Access ladder assembly
3 - 238
PC5500-6
Version 2009/2
Superstructure
Operators cab

(1)
Access ladder
(2)
Pin
(3)
Pin
(4)
Access ladder cylinder
(5)
Cotter pin
(6)
Washer
(7)
Socket
(8)
Hydraulic hose
(9)
Hydraulic hose
(10)
Self-locking nut
(11)
Distance sleeve
(12)
Bearing
(13)
Shaft seal
(14)
Dowel Screw
(15)
Ladder bearing assembly
Version 2009/2
PC5500-6
3 - 239
Operators cab
Superstructure
Fig. 3-217 Access ladder removal
3 - 240
PC5500-6
Version 2009/2
Superstructure
Operators cab
3.7.7.1 REMOVAL OF THE ACCESS LADDER

Special tools:
n/a

Oil drain pan
Crane
Access ladder: 167 kg
Dogman/rigger


z
Lower the access ladder (Fig. 3-217, Pos. 1) to the ground.

Isolate the machine according to local regulation.
NOTE: Relieve the remaining pilot pressure at the Minimess test

point M40 on the control and filter plate at engine 2.
WARNING
z
Provide an adequate working platform for safe access to

the access ladder bearing.

access ladder assembly.
Secure the access ladder cylinder (Fig. 3-217, Pos. 4) in its

position.
Version 2009/2
PC5500-6
3 - 241
Operators cab
Superstructure
Fig. 3-218 Access ladder replacement
3 - 242
PC5500-6
Version 2009/2
Superstructure
Operators cab
CAUTION
Assure that the pressure in the hydraulic system is completely relieved before removing the pivot pin (Fig. 3-218,
Pos. 2).
Clear the access ladder (Fig. 3-218, Pos. 1) by removing the

pin (Fig. 3-218, Pos. 2) from the access ladder cylinder moving rod.
Sling the access ladder and remove the self locking nuts
(Fig. 3-218, Pos. 10) from the ladder bearing assemblies
(Fig. 3-218, Pos. 15).
Remove the ladder bearing assemblies and the ladder. Rest it

on the ground.
3.7.7.2 REPLACEMENT OF THE ACCESS LADDER

Special tools:
n/a

Crane
Access ladder: 167 kg
Dogman/rigger
WARNING
z


NOTE: Apply grease to the pin (Fig. 3-218, Pos. 2) at the access
ladder cylinder moving rod.
z
NOTE: Always use new self-locking nuts (Fig. 3-218, Pos. 10).
Tightening procedure for the self-locking nuts
(Fig. 3-218, Pos. 10): 1000 Nm
Version 2009/2
PC5500-6
3 - 243
Operators cab
Superstructure
Fig. 3-219 Access ladder cylinder removal
3 - 244
PC5500-6
Version 2009/2
Superstructure
Operators cab
3.7.7.3 REMOVAL OF THE ACCESS LADDER CYLINDER

Special tools:
n/a

Oil drain pan
Crane
Access ladder cylinder: 23 kg
2.3 on page 2-37.

the machine, boom, and elevator working platform.

z
Lower the access ladder (Fig. 3-219, Pos. 1) to the ground.

NOTE: Relieve the remaining pilot pressure at the Minimess test

point M40 on the control and filter plate at engine 2.
WARNING
z


Assure that the pressure in the hydraulic system is completely relieved before removing the pivot pin (Fig. 3-219,
Pos. 10) or disconnecting any hydraulic hoses.
Remove hydraulic hoses (Fig. 3-219, Pos. 8 and 9) with the

socket (Fig. 3-219, Pos. 8) from the access ladder cylinder
(Fig. 3-219, Pos. 4).
NOTE: When the hydraulic hoses are removed, hydraulic oil

from inside the piping will flow out.
Version 2009/2
PC5500-6
3 - 245
Operators cab
Superstructure
Fig. 3-220 Access ladder cylinder installation
3 - 246
PC5500-6
Version 2009/2
Superstructure
Operators cab
Support the access ladder cylinder (Fig. 3-220, Pos. 4) from

the bottom side.
Remove the pins (Fig. 3-220, Pos. 2 and 3) and remove the
access ladder cylinder (Fig. 3-220, Pos. 4).
3.7.7.4 REPLACEMENT OF THE ACCESS LADDER CYLINDER

Special tools:
n/a

Oil drain pan
Crane
Access ladder cylinder: 23 kg
WARNING
z


NOTE: Apply grease to the pins (Fig. 3-220, Pos. 2 and 3).
z

Version 2009/2
PC5500-6
3 - 247
Operators cab
3.7.8
Superstructure
REMOVAL OF THE CAB BASE
Special tools:

55 mm hexagon impact socket wrench (1"), PN 232 267 40

Tank for coolant storage
Crane
Support frame: 987 kg
Cab base: 3785 kg
Dogman/rigger
z

the machine, boom, elevator working platform and crane.

z
Remove the operators cab,

WARNING
Always wear a safety harness when working at the cab base.
Disconnect all harnesses inside the cab base and pull the
harnesses out of the cable transfer elements at the bottom of
the cab base.
Clear all harnesses leading to the cab base from the cable
channels at the cab base and at the tank.
Remove the hoses of the operators cab heating from the cab
base.
NOTE: When the hoses of the operators cab heating are

removed, fluid from inside the piping will flow out.
3 - 248
PC5500-6
Version 2009/2
Superstructure
Operators cab
Sling the support frame (Fig. 3-221, Pos. 2).
Remove the bolts (Fig. 3-221, Pos. 1) from within the cab
base (Fig. 3-221, Pos. 3) and remove the support frame
(Fig. 3-221, Pos. 2) using a crane.
Fig. 3-221
z
Sling cab base (Fig. 3-222, Pos. 1), refer to Fig. 3-223.
Remove bolts (Fig. 3-222, Pos. 2) attaching the cab base to

the superstructure (Fig. 3-222, Pos. 2).
Fig. 3-222
z
Remove the cab base using a crane.

DANGER

When moving cab base, make sure that nobody steps below
the lifted cab base.
Fig. 3-223
Version 2009/2
PC5500-6
3 - 249
Operators cab
3.7.9
Superstructure
REPLACEMENT OF THE CAB BASE
Special tools:


Crane
Compound "Epple 28", PN 592 199 40
Compound "Loctite 222", PN 414 299 40
Support frame: 987 kg
Cab base: 3785 kg
Dogman/rigger
WARNING
Always wear a safety harness when working at the cab base.
Sling the new cab base and align it with the superstructure
using a crane (Fig. 3-224).
DANGER

When moving cab base, make sure that nobody steps below
the lifted cab base.
Fig. 3-224
3 - 250
PC5500-6
Version 2009/2
Superstructure
Operators cab
Install bolts (Fig. 3-225, Pos. 2) attaching the cab base

(Fig. 3-225, Pos. 1) to the superstructure (Fig. 3-225, Pos. 2).

10.9. Apply compound "KP2K", PN 324 969 40 on heads
and threads of the mounting bolts and tighten them to the
Fig. 3-225
Tightening torque for cab base mounting bolts

(Fig. 3-225, Pos. 2): 3100 Nm
Apply sealing compound "Epple 28" onto the whole contact

surfaces (Fig. 3-226, arrows) of the cab base.
Install the support frame (Fig. 3-226, Pos. 2) using a crane.
Apply compound "Loctite 222" on the threats of all bolts

(Fig. 3-226, Pos. 1).
Install bolts (Fig. 3-226, Pos. 1) attaching the support frame

(Fig. 3-226, Pos. 2) to the cab base (Fig. 3-226, Pos. 3).

10.9 and tighten the mounting bolts to the specified tightening torque.
Fig. 3-226
Tightening torque for support frame mounting

bolts (Fig. 3-226, Pos. 1): 265 Nm
z
Version 2009/2
PC5500-6
3 - 251
Counterweight
3.8
Superstructure
COUNTERWEIGHT
Fig. 3-227 Counterweight

(1)
Counterweight
(2)
Lifting situation for horizontal transport
(3)
Lifting situation for vertical transport
(4)
Lifting situation for raising up the counterweight
(5)
Bolt
(6)
Washer
WARNING
Make sure that the maximum rope angle depending on the
lifting situation (Fig. 3-227, Pos. 2 to 4) is not exceeded.
3 - 252
PC5500-6
Version 2009/2
Superstructure
Counterweight
DANGER
Risk of explosion!
Blindness, serious injury, permanent disfigurement and
Do not weld, flame-cut, grind, or drill at the counterweight!
Follow the instructions given in PARTS & SERVICE NEWS
No. "AH04518" for expelling the gases from the counterweight chambers!
NOTE: The chambers of the counterweight are filled with a mixture of concrete, granulated ore and steel pellets. This
mixture can create explosive gases which will accumulate in the chambers of the counterweight.
Before any welding, flame-cutting, grinding, or drilling
procedures are carried out on the counterweight, it is vital
to expel these gases from the counterweight chambers.
Failure to properly expel the gases from the counterweight chambers can result in an explosion with serious
personal injury or death.
Follow the instructions given in PARTS & SERVICE
NEWS No. "AH04518" for expelling the gases from the
counterweight chambers.
3.8.1
REMOVAL OF THE COUNTERWEIGHT
Special tools:

75 mm hexagon impact socket wrench (2 1/2"), PN 232 269 40

Crane
Counterweight: 42,000 kg
Dogman/rigger

Park the machine on the prepared flat area and position the
bucket on the ground.

z
Version 2009/2
PC5500-6
3 - 253
Counterweight
Superstructure
WARNING
Always wear a safety harness when working at the counter
weight.
Secure the counterweight (Fig. 3-227, Pos. 1) at the lifting

eyes using a crane.
WARNING
Make sure that the maximum rope angle of 40 is not

exceeded. Refer to Fig. 3-227, Pos. 3.
Remove the rails (Fig. 3-228, Pos. 1) from the counterweight.
Remove all additional equipment from the counterweight, if

required.
Remove the tanks (Fig. 3-228, Pos. 2) and wires of the Fire
Detection and Suppression System, if equipped.
WARNING

Remove all mounting bolts (Fig. 3-227, Pos. 5).
Remove counterweight using the crane.
Fig. 3-228
DANGER
When moving counterweight, make sure that nobody steps
below the lifted counterweight.
3 - 254
PC5500-6
Version 2009/2
Superstructure
3.8.2
Counterweight
REPLACEMENT OF THE COUNTERWEIGHT
Special tools:

65 mm hexagon impact socket wrench (1 1/2"), PN 232 521 40

Crane
Counterweight: 42,000 kg
Dogman/rigger
WARNING
Always wear a safety harness when working at the counter
weight.
NOTE: Assure that the mounting surfaces are absolutely free of

dirt, oil, fat, and paint before installation.
z

WARNING
Make sure that the maximum rope angle of 40 is not

exceeded. Refer to Fig. 3-227, Pos. 3.
NOTE: Apply compound "KP2K", PN 324 969 40 on heads and

threads of the bolts. Tighten the mounting bolts to the
4950 Nm
Version 2009/2
PC5500-6
3 - 255
Counterweight
Superstructure
3 - 256
PC5500-6
Version 2009/2
Superstructure
Superstructure lifting
3.9
SUPERSTRUCTURE LIFTING
3.9.1
REMOVE THE SUPERSTRUCTURE FROM THE UNDERCARRIAGE
Special tools:

Electro-hydraulic pump aggregate, PN 232 613 40

2 x crane
Superstructure without counterweight, attachment and fluids:
137,215 kg
Dogman/rigger
Crane operators trained in dual crane lift
2.3 on page 2-37.


z

Relieve the pressure in the track tensioning system. Refer to

the Operation & Maintenance Manual, chapter 4, section
"CRAWLER TRACK - INSPECTION".
PUMP".
WARNING
Fig. 3-229
Always wear a safety harness when working in height.
Version 2009/2
PC5500-6
3 - 257
Superstructure
Fig. 3-230 Superstructure lifting

z
Remove the counterweight from the superstructure, refer to

section 3.8.1 on page 3-253.
Install shackels (Fig. 3-230, Pos. 6) delivered with the

machine to the flanges of the counterweight using the mounting bolts of the counterweight.
Tighten the mounting bolts to the specified tightening torque.
4950 Nm
3 - 258
PC5500-6
Version 2009/2
Superstructure
Remove the complete attachment, refer to section 5.1 on

page 5-2.
Disconnect all hydraulic hoses leading to the superstructure

from the rotary joint, refer to section 4.2.5.1 on page 4-94.
If the machine is equipped with slew ring protection covers
(Fig. 3-230, Pos. 9):
z

(Fig. 3-230, Pos. 8) attaching the protection covers to the
superstructure (Fig. 3-230, Pos. 4).
If equipped, remove the rotation direction sensors B98

and B99 from the slew ring protection cover.
WARNING
Before lifting the superstructure, make sure that the crane

operators are trained in dual crane lift.
Attach the superstructure to two cranes.
Remove all bolts (Fig. 3-230, Pos. 1) and washers

(Fig. 3-230, Pos. 2) attaching the slew ring to the undercarriage (Fig. 3-230, Pos. 5).
Lift off the superstructure using the two cranes and rest it on
appropriate supports on the ground.
DANGER

When moving superstructure, make sure that all personnel
are clear.
Version 2009/2
PC5500-6
3 - 259
Superstructure
3 - 260
PC5500-6
Version 2009/2
Superstructure
3.9.2
INSTALL THE SUPERSTRUCTURE ONTO THE UNDERCARRIAGE
Special tools:

Gauge device for testing bolts M36, PN 376 762 40

2 x Crane
2 thread pins (M 36 x 250)
Superstructure without counterweight, attachment and fluids:
137,215 kg
Dogman/rigger

WARNING
Always wear a safety harness when working in height.
Version 2009/2
PC5500-6
3 - 261
Superstructure
Fig. 3-231 Superstructure lifting

z
Clean the contact surfaces of the slew ring and the undercarriage very carefully and thoroughly.
WARNING
Before lifting the superstructure, make sure that the crane

operators are trained in dual crane lift.
Attach the superstructure to two cranes and lift it up. Refer to

Fig. 3-231.
3 - 262
PC5500-6
Version 2009/2
Superstructure
DANGER
When moving superstructure, make sure that all personnel
are clear.
NOTE: The unhardened spot of race surfaces (changeover area

between beginning and ending of hardening process) is
punch-marked with an "S" at the inner resp. outer side of
each slew ring (Fig. 3-232, Pos. 1 and 2). Refer to
z
Align the spots (Fig. 3-232, Pos. S) to each other.
Prepare new bolts, washers and sleeves. Lubricate the

threads and the head surface of the bolts with compound
"KP2K", PN 324 969 40.
Fig. 3-232
z
Remove the torque support lever of the rotary joint

before installing the superstructure, refer to section 4.2.5.1 on
page 4-94.
Align the superstructure to the undercarriage and lower the

superstructure.
To simplify the alignment of the slew ring to the undercarriage, install two thread pins (M 36 x 250) displaced by
180 at the outer slew ring.
Insert 4 bolts (Fig. 3-231, Pos. 1) with washers (Fig. 3-231,

Pos. 2) displaced by 90 and lower the superstructure.
Remove the two thread pins from the outer slew ring.
Install all remaining bolts and tight them manually.

Tighten all bolts crosswise to the required
torque, refer to PARTS & SERVICE NEWS
No. "AH00511".
NOTE: If approx. 10 bolts (front and rear) are tightened the

superstructure can be unhooked from the crane.
z
Reinstall the torque support lever of the rotary joint.

WARNING
Make sure to use the specified bolts and torque for the
torque support lever mounting bolts, refer to section 4.2.5.2
on page 4-96.
Version 2009/2
PC5500-6
3 - 263
Fuel tank
Superstructure
3.10 FUEL TANK
Fig. 3-233 Fuel tank, overview

(1)
Fuel tank
(2)
Breather valve
(3)
Main fuel shut-off cock
(4)
Drain coupling (to drain fuel, water, and sediments)
(5)
Shut-off cock for pressure transducer
(6)
Pressure transducer for fuel level indication
3 - 264
PC5500-6
Version 2009/2
Superstructure
Fuel tank
3.10.1 REMOVAL OF THE FUEL TANK

Special tools:


Empty fuel storage tank
Crane
Fuel tank (empty): 4486 kg
Dogman/rigger
2.3 on page 2-37.
z


z

WARNING
Always wear a safety harness when working at the fuel tank.
Remove the operators cab (Fig. 3-234, Pos. 3),

Remove the handrails (Fig. 3-234, Pos. 1), the handlebar

(Fig. 3-234, Pos. 2), and the gratings from the fuel tank.
NOTE: For safety, the handrail (Fig. 3-234, Pos. 3) at the steps
will not be removed.
Fig. 3-234
z
Open the hinged cover below the fuel tank.
Version 2009/2
PC5500-6
3 - 265
Fuel tank
Superstructure
Attach a drain hose and open drain coupling (Fig. 3-233,

Pos. 4).
Drain fuel, approx. 10800 liters (max.).
Disconnect the tank breather hose (Fig. 3-235, Pos. 1) from

the tank breather valve (Fig. 3-235, Pos. 2).
WARNING
Risk of fire!
inflammable fuels
Fig. 3-235
.
z
Disconnect the harness connectors (Fig. 3-236, Pos. 1) from

the cab base.
Pull the harnesses out of the cable channels of the cab base
(Fig. 3-236, Pos. 2) and of the tank (Fig. 3-237, Pos. 1).
Z 26172

z
Disconnect all harnesses leading to the operators cab.
Pull the harnesses out of the cable channels of the cab base
(Fig. 3-236, Pos. 2) and of the tank (Fig. 3-237, Pos. 1).
Fig. 3-236
3 - 266
PC5500-6
Version 2009/2
Superstructure
Fuel tank
Remove the brackets and clear all hoses (Fig. 3-237,

Pos. 2 and 3) from the tank.
Disconnect all fuel lines from the tank.

DANGER
Z 26173
Danger of fuel pressure!

May result serious injury, permanent disfigurement and
scarring, or death!
Fuel lines are pressurized by hydrostatic pressure due to the
unknown amount of fuel in the tank.
Be sure that the fuel is completely drained before opening
any fuel lines.
Fig. 3-237
NOTE: When the fuel hoses are disconnected, the fuel inside the
hoses will flow out. Catch it in an oil pan.
z
Open the clamps and clear the hoses of the air conditioning
from the tank.
Disconnect the wire harness connectors B63 and Y99

(Fig. 3-238).
Attach the fuel tank to a crane.
Fig. 3-238
Version 2009/2
PC5500-6
3 - 267
Fuel tank
Superstructure
Remove the mounting bolts (Fig. 3-239, Pos. 1) and lift the
fuel tank (Fig. 3-239, Pos. 6) from the machine.
Discard the mounting bolts (Fig. 3-239, Pos. 1).
DANGER

When moving fuel tank, make sure that nobody steps below
the lifted fuel tank.
Dismantle the handrail at the steps.
If required remove the fuel tank breather valve (Fig. 3-239,

Pos. 3) and the plate (Fig. 3-239, Pos. 4).
Discard the gaskets (Fig. 3-239, Pos. 5).
If required, remove all plugs (Fig. 3-239, Pos. 2).
Fig. 3-239
3 - 268
PC5500-6
Version 2009/2
Superstructure
Fuel tank
3.10.2 REPLACEMENT OF THE FUEL TANK

Special tools:


Crane
Fuel tank (empty): 4486 kg
Dogman/rigger
WARNING
Always wear a safety harness when working at the fuel tank.
If required, install the fuel tank breather valve (Fig. 3-240,

Pos. 3), the plate (Fig. 3-240, Pos. 4) and all plugs
(Fig. 3-240, Pos. 2) to the new tank.
NOTE: Use new gaskets (Fig. 3-240, Pos. 5).

Assure that the mounting surfaces are absolutely free of
z
Install the handrail at the steps at first.
Fig. 3-240
Version 2009/2
PC5500-6
3 - 269
Fuel tank
Superstructure

10.9. Apply compound "KP2K", PN 324 969 40 on heads
and threads of the mounting bolts and tighten them to the
Tightening torque for the fuel tank mounting
bolts (Fig. 3-239, Pos. 1): 1770 Nm.
Refill the fuel tank, approx. 10800 liters.
Bleed air from the fuel lines to the engine:

z
Assure that the emergency shut off valve is opened.
Disconnect the feeding line at the engine fuel filter.

z
Reconnect the feeding line to the engine fuel filter.
Disconnect the feeding line at the engine fuel pump.

z
3 - 270
Reconnect the feeding line to the engine fuel pump.
PC5500-6
Version 2009/2
Undercarriage
4 UNDERCARRIAGE
Version 2009/2
PC5500-6
4 -1
Travel system
Undercarriage
4.1
TRAVEL SYSTEM
4.1.1
TRACK GROUP
4.1.1.1 CHANGING OF THE TRACK GROUP

Special tools:
n/a
Personal Protective Equipment (PPE)

Dozer
Chain hoist
Slide hammer
Welding equipment
Brass drift
Track group 1350 mm: 32,192 kg
Pin track group 1350 mm: 19 kg
Track group 1800mm: 39,066 kg
Pin track group 1800 mm: 20.2 kg
Dogman/rigger
NOTE: Make sure that the wear of the track group was measured according to the PARTS & SERVICE NEWS
No. "AH02521".
z
Prepare an area of flat ground twice as large to accommodate

the machine, the boom, and the dozer.

z
Relieve pressure in the track tensioning system, refer to the

NOTE: Make sure that the slack in the track group is at the lower
part of the guide wheel.
4 -2
PC5500-6
Version 2009/2
Undercarriage
Travel system
Flame-cut the nuts (Fig. 4-1, Pos. 3) from the locking bolts
(Fig. 4-1, Pos. 1). Remove the locking bolts (Fig. 4-1, Pos. 1),
washers (Fig. 4-1, Pos. 2), and nuts (Fig. 4-1, Pos. 3) from
one track shoe (Fig. 4-1, Pos. 5).
WARNING
Ensure nothing flammable is in the working area when flamecutting the nuts.
Pull out two pins (Fig. 4-1, Pos. 4) to open the track group
using a sliding hammer.
Fig. 4-1
NOTE: Open the track group at the guide wheel.

z
Sling the upper end of the track group using a chain and link it
to a dozer in front of the excavator.
De-isolate the machine according to local regulations.

DANGER
Danger of getting overrun or squished.

Serious injury or death may result.
Make sure nobody stays in driving direction of the excavator
or the dozer.
Make sure nobody stays next to the crawler carrier.
Fig. 4-2
z
Drive the excavator and the dozer backwards slowly and

unroll the track group from the excavator (Fig. 4-2).
NOTE: Assure that excavator and dozer have the same speed.
z
When the upper end of the track group runs off the sprocket,
stop the excavator while driving the dozer backwards slowly
to prevent the track from knocking over.
Version 2009/2
PC5500-6
4 -3
Travel system
Undercarriage
Align the new track group on the ground behind the old track
group.
NOTE: Observe the running direction of the new track group.

Make sure that the new track group has the correct running direction as shown in Fig. 4-3.
z
Align the new track group on the ground behind the old track
group.
Remove the chain from the old track group.
Continue to drive the excavator backwards slowly on the new

track group until the end of the of the track group is nearly
reached.
Sling the end of the new track group at the sprocket using a
chain and link it to a dozer in front of the excavator.
DANGER

or the dozer.
Fig. 4-3
Drive the excavator and the dozer forward slowly and pick up
the track group with the sprocket.
Continue to drive the excavator and the dozer forward slowly

to pull up the track group (Fig. 4-4).
Fig. 4-4
z
Stop the excavator and the dozer, when the guide wheel
reaches the end of the track group (approximately 3 track
shoes away from the end of the track group).
Place the track group over the guide wheel as shown in

Fig. 4-5.
Unchain the dozer.
Fig. 4-5
4 -4
PC5500-6
Version 2009/2
Undercarriage
Travel system
Align the holes (Fig. 4-6, Pos. 3) in the two open track shoes
(Fig. 4-6, Pos. 2) in front of the guide wheel (Fig. 4-6, Pos. 1)
using a hoist.
Insert the pins (Fig. 4-7, Pos. 4) into the holes (Fig. 4-6,
Pos. 3).
Fig. 4-6
z
Instal the locking bolts (Fig. 4-7, Pos. 1), washers

(Fig. 4-7, Pos. 2), and nuts (Fig. 4-7, Pos. 3) to the track
shoes (Fig. 4-7, Pos. 5).
Weld the nuts (Fig. 4-7, Pos. 3) to the bolts (Fig. 4-7, Pos. 1).
WARNING
Ensure nothing flammable is in the working area during

welding work.

"WELD REPAIRS".
Fig. 4-7
CAUTION
The bolts (Fig. 4-8, Pos. 1) lock the pins (Fig. 4-8, Pos. 2).
Therefore one side of the bolts head is hardened in order to
prevent wear. This hardened side must face the pin.
The hardened side (Fig. 4-8, arrow) of the bolt heads are
marked.
Fig. 4-8
Version 2009/2
PC5500-6
4 -5
Travel system
Undercarriage
Perform the procedure given in the PARTS & SERVICE

NEWS "AH06530" in reverse order.
4 -6
PC5500-6
Version 2009/2
Undercarriage
4.1.2
Travel system
SPROCKET
4.1.2.1 REMOVAL OF THE SPROCKET

Special tools:
n/a

Hydraulic torque wrench PN 232 614 40
Electro-hydraulic pump aggregate PN 232 613 40
2 x Crane
Dozer
Pulling bolts M30
Sprocket assembly: 4382 kg
Hollow shaft: 612 kg
Drive shaft: 1007 kg
Dogman/rigger
NOTE: Only for removal of the sprocket it is not necessary to

remove the travel gear.
If changing the sprocket (Fig. 4-9, Pos. 2) it is
recommended to change the flange bearings
(Fig. 4-9, Pos. 1 + Pos. 3) too. Therefore the travel gear
(Fig. 4-9, Pos. 4) has to be removed, refer to section
4.1.11.1 on page 4-51.
Fig. 4-9
WARNING
Ensure appropriate (PPE) Personal Protective Equipment is
used during the task.
There maybe sharp edges on the worn sprocket that is being
removed.
Version 2009/2
PC5500-6
4 -7
Travel system
Undercarriage

the machine, the boom, and two cranes.
attachment placed at the final drive end of the machine, counterweight above guide wheels.

z
Relieve pressure in the track tensioning system, refer to

Drain oil of the final drive housing, approx. 165 liters.

Refer to the Operation & Maintenance Manual, chapter
4, section "TRAVEL GEARS, MOTOR ADAPTER
HOUSINGS AND FINAL DRIVES".
z
Check the wear of the sprocket hub, refer to

NOTE: Make sure that the sprocket runs free after opening the
track group and it has no contact to the ground or the
track group. For example drive the excavator with the
track rollers at the respective crawler frame side onto a
knoll.
NOTE: Before beginning the work, block the track group to prevent the track shoes against falling down
(refer to Fig. 4-10).
z
Open the track group at the sprocket end (Fig. 4-10, Pos. 1),
Fig. 4-10
4 -8
PC5500-6
Version 2009/2
Undercarriage
Travel system
to a dozer behind the excavator.

DANGER

or the dozer.
Fig. 4-11
z
Drive the excavator and the dozer forwards slowly and unroll
the track group from the excavator (refer to Fig. 4-11).
z
When the upper end of the track group is over the carrier roll
next to the sprocket, stop the excavator and the dozer.
Fasten the track group to the carrier roll to hold it in position.

z
Sling sprocket (refer to Fig. 4-12).
NOTE: The travel parking brake may need to be released to

allow sprocket to turn slightly to find centre of gravity.
Fig. 4-12
Version 2009/2
PC5500-6
4 -9
Travel system
Undercarriage
Fig. 4-13 Removal of the sprocket

z
Remove the bolts (Fig. 4-13, Pos. 1) and the cover (Fig. 4-13,
Pos. 10).
NOTE: When the cover is removed, oil may flow out.

z
Pull the drive shaft (Fig. 4-13, Pos. 6) out of the hollow shaft
(Fig. 4-13, Pos. 5).
WARNING
Sling the drive shaft as soon as possible and support it using

a crane to prevent the shaft from falling.
DANGER
When lifting the drive shaft, make sure that nobody steps
below the weight.
4 - 10
PC5500-6
Version 2009/2
Undercarriage
Travel system
CAUTION
Make sure that the hollow shaft (Fig. 4-13, Pos. 5) is not
weight loaded before removing the flange bearing (Fig. 4-13,
Pos. 8).
Remove mounting bolts (Fig. 4-13, Pos. 1) and extract the

flange bearing (Fig. 4-13, Pos. 8) including the bush
(Fig. 4-13, Pos. 7) from the crawler carrier using pulling bolts.
Extract the hollow shaft (Fig. 4-13, Pos. 5) from the sprocket
(Fig. 4-13, Pos. 3) and remove it using a crane.
WARNING
Sling the drive shaft as soon as possible and support it using

a crane to prevent the shaft from falling.
DANGER
When lifting the hollow shaft, make sure that nobody steps
below the weight.
Lift the sprocket out of the crawler carrier.

DANGER

When lifting the sprocket, make sure that nobody steps
below the weight.
Discard the dual-cone seals (Fig. 4-13, Pos. 2 and Pos. 4).
NOTE: Dual-cone seals are mounted in the sprocket hub as well

as in the inner and outer flange bearing.
For further information refer to PARTS & SERVICE
NEWS No. "AH05511".
z
If required, remove the sprocket from the hub, refer to PARTS

& SERVICE NEWS No. "AH00514".
Version 2009/2
PC5500-6
4 - 11
Travel system
Undercarriage
4.1.2.2 REPLACEMENT OF THE SPROCKET

Special tools:
Assembly tool for dual-cone seals (locally made)

2 x Crane
Dozer
Paste "Optimol White", PN 999 039
Sprocket assembly: 4382 kg
Hollow shaft: 612 kg
Drive shaft: 1007 kg
Dogman/rigger
Fig. 4-14 Replacement of the sprocket
4 - 12
PC5500-6
Version 2009/2
Undercarriage
Travel system
NOTE: Before reassembly of the sprocket, the axial play has to

be determined, refer to PARTS & SERVICE NEWS No.
"AH06529".
If necessary adjust the axial play, refer to PARTS & SERVICE NEWS No. "AH06529".
For mounting the dual-cone seals (Fig. 4-14, Pos. 2 and
Pos. 4), an assembly tool has to be manufactured, refer
to PARTS & SERVICE NEWS No. "AH05511".
z
Mount new dual-cone seals (Fig. 4-14, Pos. 2 and Pos. 4) into
the flange bearing, on the gear side and into the flange bearing (Fig. 4-14, Pos. 8) on the opposite side. Refer to PARTS
& SERVICE NEWS No. "AH05511".
Mount new dual-cone seals (Fig. 4-14, Pos. 2 and Pos. 4) into
the sprocket hub, refer to PARTS & SERVICE NEWS
No. "AH05511".
NOTE: Observe the mounting position of the drive shaft when

installing it. The splines at the drive shaft have different
lengths.
The longer splines must point to the gearbox.
z
Apply "Optimol White" on the splines of the drive shaft

(Fig. 4-14, Pos. 6), the hollow shaft (Fig. 4-14, Pos. 5), and
the splines of the planet carrier inside the travel gearbox.
NOTE: Apply compound "KP2K", PN 324 969 40 on the sleeve

of the flange bearing (Fig. 4-14, Pos. 8), and on heads
and threads of new mounting bolts (Fig. 4-14,
Pos. 1) of grade 10.9.
Use the new mounting bolts with washers to attach the
flange bearing with bush (Fig. 4-14, Pos. 7) to the track
frame. Tighten the bolts to the specified tightening torque.
Tightening torque for flange bearing mounting
bolts (Fig. 4-14, Pos. 1): 1770 Nm
Refill oil in the final drive housing,

approx. 165 liters.
chapter 4, section "TRAVEL GEARS, MOTOR
ADAPTER HOUSINGS AND FINAL DRIVES".
Version 2009/2
PC5500-6
4 - 13
Travel system
Undercarriage
4.1.2.3 REMOVAL OF THE SEGMENTED SPROCKET

(ONLY FOR TYPE WITH PINNED UNDERCARRIAGE UP TO SN 025)
Special tools:
n/a

Crane
Dozer
4 forcing screws M20
Regular sprocket assembly:
Sprocket segment 1 (5 teeth): 794.25 kg
Oversize sprocket assembly:
Dogman/rigger
NOTE: Make sure that the wear of the track group and the
sprocket was measured according to the PARTS &
NOTE: Only for removal of the segmented sprocket (Fig. 4-15,
Pos. 1, 2 and 3) it is not necessary to remove the travel
gear (Fig. 4-15, Pos. 4).
WARNING
Ensure appropriate (PPE) Personal Protective Equipment is
used during the task.
There maybe sharp edges on the worn sprocket that is being
removed.

the machine, the boom, the dozer and the crane.
attachment placed at the final drive end of he machine, counterweight above the guide wheels.

equipment (crane, mobile working platforms, forklift, etc.)
z
Fig. 4-15
4 - 14
PC5500-6
Version 2009/2
Undercarriage
Travel system
Relieve the pressure in the track tensioning system by opening the ball cock (Fig. 4-16, Pos. 1) at the track tensioning
valve block (Fig. 4-16, Pos. 2) inside the car body.
NOTE: Make sure that the sprocket runs free after opening the
track group and it has no contact to the ground or the
track group. For example drive the excavator with the
track rollers at the respective crawler frame side onto a
knoll.
Fig. 4-16
z
Fig. 4-17
z

DANGER

or the dozer.
Fig. 4-18
z
the track group from the excavator (refer to Fig. 4-18).
z
Fasten the track group to the carrier roll to hold it in position.
Version 2009/2
PC5500-6
4 - 15
Travel system
Undercarriage
Fig. 4-19 Removal of the sprocket segments

z
Turn the sprocket so that the first segment that has to be

removed is in the upper position.
Loosen all bolts (Fig. 4-19, Pos. 1) from the drive sprocket
ring (Fig. 4-19, Pos. 3). Dont remove them.
WARNING

Do not remove all bolts from the drive sprocket ring.
NOTE: Lightly press off drive sprocket ring by means of 4 forcing

screws M20 x 80 mm at the drive sprocket ring
(Fig. 4-20, Pos. 1). To prevent blocking around the ring,
all 4 screws must be tightened evenly.
Fig. 4-20
z
Sling the upper sprocket segment using a crane.
4 - 16
PC5500-6
Version 2009/2
Undercarriage
Travel system
Remove the bolts (Fig. 4-19, Pos. 1) from the drive sprocket
ring (Fig. 4-19, Pos. 3) at the upper sprocket segment.
WARNING

Remove only the bolts from the respective sprocket segment.
Lift the sprocket segment out of the crawler carrier using a

crane.
Rotate the sprocket slowly by actuating the travel drive so

that the next sprocket segment that has to be removed is in
upper position.
To remove the other sprocket segments use the same procedure according to the first segment.
Version 2009/2
PC5500-6
4 - 17
Travel system
Undercarriage
4.1.2.4 REPLACEMENT OF THE SEGMENTED SPROCKET

Special tools:
n/a

Crane
Dozer
Coating compound "INTERZINC 697", PN 674 997 40
Regular sprocket assembly:
Oversize sprocket assembly:
Dogman/rigger
Carefully clean all required contact surfaces of the sprocket

segments, the sprocket drive ring and the travel gear.
The segments of the sprocket have to be erected in the

shown arrangement (Fig. 4-21, Pos. 1, 2 and 3).
Pos. 1: 5 teeth
Pos. 2: 5 teeth
Pos. 3: 4 teeth
NOTE: It is not allowed to replace single sprocket segments.

Always replace all three segments.
Fig. 4-21
NOTE: If it is necessary to install the oversized sprocket segments, refer to PARTS & SERVICE NEWS No.
"AH06529".
z
Apply surface coating with coating compound "INTERZINC

697" at the contact surface (Fig. 4-22, Pos. 1) on both sides
of the sprocket segments, refer to section 6.3.1 on page 6-7.
WARNING
Only reassemble the sprocket segments after the coating

compound has fully hardened.
Fig. 4-22
4 - 18
PC5500-6
Version 2009/2
Undercarriage
Travel system
Fig. 4-23 Replacement of the sprocket segments

z
NOTE: Use new bolts (Fig. 4-23, Pos. 1), nuts (Fig. 4-23, Pos. 2)
and washers to attach the new sprocket segments to the
travel gear (Fig. 4-23, Pos. 7).
Tightening torque for sprocket segment mounting bolts (Fig. 4-23, Pos. 1): 3000 Nm
Version 2009/2
PC5500-6
4 - 19
Travel system
4.1.3
Undercarriage
GUIDE WHEELS
4.1.3.1 REMOVAL OF THE GUIDE WHEEL ASSEMBLY

Special tools:
n/a
Crane
Guide wheel assembly: 3323 kg
Dogman/rigger


z
Fig. 4-24
4 - 20
PC5500-6
Version 2009/2
Undercarriage
Travel system
Remove the track group from the guide wheel, refer to section
4.1.1.1 on page 4-2.
Remove bolts (Fig. 4-25, Pos. 1) and remove the stop plates
(Fig. 4-25, Pos. 2) from both sides of the guide wheel assembly (Fig. 4-25, Pos. 3).
Sling guide wheel assembly (Fig. 4-25, Pos. 3) and pull the
guide wheel assembly out of the crawler carrier.
Fig. 4-25
z
Sling guide wheel assembly (Fig. 4-26) and pull the guide
wheel assembly out of the crawler carrier.
WARNING
Ensure to keep hands away for the component sliding

surfaces during removal.
Fig. 4-26
z
Check condtion of the sliding surfaces on the crawler carrier

and the sliding blocks.
Version 2009/2
PC5500-6
4 - 21
Travel system
Undercarriage
4.1.3.2 REPLACEMENT OF THE GUIDE WHEEL ASSEMBLY

Special tools:
n/a
Crane
Guide wheel assembly: 3323 kg
Dogman/rigger
z
NOTE: Observe the mounting position of the sliding blocks

(Fig. 4-27, Pos. 3).
Assure that the oil plug (Fig. 4-27, Pos. 2) at the guide
wheel (Fig. 4-27, Pos. 1) is facing the inner side of the
excavator.
Fig. 4-27
4 - 22
PC5500-6
Version 2009/2
Undercarriage
4.1.4
Travel system
TRACK TENSIONING ACCUMULATORS
The hydraulic track tensioning system automatically maintains the

correct track tension. The pilot oil pressure of the travel brake
release circuit is used to pressurize the four adjusting cylinders.
The resulting force moves the guide wheels toward the front, until
the correct track tension is obtained. External forces acting upon
the guide wheels are absorbed through the pressure accumulators (Fig. 4-28, Pos. 1 and 2).
Two different types of pressure accumulators are installed:
A high pressure (150 bar) bladder accumulator (Fig. 4-28, Pos. 1)
and a low pressure (31 bar) diaphragm type accumulator
(Fig. 4-28, Pos. 2).
Fig. 4-28
4.1.4.1 REMOVAL OF THE LOW PRESSURE ACCUMULATORS

Special tools:
n/a
Oil drain pan

Low pressure accumulator: 12 kg
2.3 on page 2-37.
Fig. 4-29
Version 2009/2
PC5500-6
4 - 23
Travel system
Undercarriage

WARNING
Hot hydraulic oil!

until the temperature of the hydraulic oil is below 50C.
DANGER
Blindness, serious injury, permanent disfigurement, or
scaring may result.
The hydraulic system may be pressurized.
Make sure that the pressure is relieved before any hydraulic
line will be removed.
Fig. 4-30
Disconnect the pressure hose (Fig. 4-31, Pos. 1).
NOTE: When the pressure hose is removed, hydraulic oil from

inside the piping and the pressure accumulator will flow
out.
z
Remove four bolts (Fig. 4-31, Pos. 4) and remove the pressure accumulator (Fig. 4-31, Pos. 3).
Remove union (Fig. 4-31, Pos. 2).
Fig. 4-31
4 - 24
PC5500-6
Version 2009/2
Undercarriage
Travel system
4.1.4.2 REPLACEMENT OF THE LOW PRESSURE ACCUMULATORS

Special tools:
Testing and refilling device, PN 761 520 73
n/a
Low pressure accumulator: 12 kg
Fill the pressure accumulator with nitrogen gas (N2).

DANGER
Blindness, serious injury, permanent disfigurement, scaring,
or death may result.
Only fill pressure accumulators with nitrogen gas (N2).
Do not use any other gases due to explosion hazard!
Bleed the track tensioning system.

Refer to the Operation & Maintenance Manual, chapter 4,
section "CRAWLER TRACK - INSPECTION".
Check the track tension system and adjust if required. Refer

to the Service Manual for further information.
Version 2009/2
PC5500-6
4 - 25
Travel system
Undercarriage
4.1.4.3 REMOVAL OF THE HIGH PRESSURE ACCUMULATORS

Special tools:
n/a
n/a
High pressure accumulator: 23 kg
2.3 on page 2-37.
WARNING
Hot hydraulic oil!

Wait until the temperature of the hydraulic oil is below 50C.
Fig. 4-32
DANGER
scaring may result.
Disconnect the pressure hose assembly (Fig. 4-33, Pos. 1).

inside the piping and the pressure accumulator will flow
out.
Cap the openings with blind plugs to avoid
contamination.
z
Open two clamp clips (Fig. 4-33, Pos. 2) and remove the
pressure accumulator (Fig. 4-33, Pos. 3).
Remove the socket (Fig. 4-33, Pos. 4) from the pressure

accumulator (Fig. 4-33, Pos. 3).
4 - 26
PC5500-6
Fig. 4-33
Version 2009/2
Undercarriage
Travel system
4.1.4.4 REPLACEMENT OF THE HIGH PRESSURE ACCUMULATORS

Special tools:
Testing and refilling device, PN 761 520 73
n/a
High pressure accumulator: 23 kg
Fill the pressure accumulator with nitrogen gas (N2).

DANGER
Blindness, serious injury, permanent disfigurement, scaring,
or death may result.
Only fill pressure accumulators with nitrogen gas (N2).
Do not use any other gases due to explosion hazard!


Version 2009/2
PC5500-6
4 - 27
Travel system
4.1.5
Undercarriage
TRACK TENSION VALVE BLOCK
4.1.5.1 REMOVAL OF THE TRACK TENSIONING VALVE BLOCK

Special tools:
n/a
Chain host
Oil drain pan
Track tensioning valve block: 40 kg
2.3 on page 2-37.
WARNING
Hot hydraulic oil!

Fig. 4-34
DANGER
removed.
Disconnect all piping (Fig. 4-35, Pos. 2) from the track tensioning valve block (Fig. 4-35, Pos. 1).
NOTE: When the piping is removed, hydraulic oil from inside the
piping and the track tensioning valve block will flow out.
z
Find an appropriate suspension point for the chain hoist and

sling the track tensioning valve block (Fig. 4-35, Pos. 1).
Remove four mounting bolts and let down the track tensioning valve block (Fig. 4-35, Pos. 1) using the chain hoist.
4 - 28
PC5500-6
Fig. 4-35
Version 2009/2
Undercarriage
Travel system
Remove the pressure increase valve (Fig. 4-36, Pos. 1) from

the track tensioning valve block.
Remove the check valves (Fig. 4-36, Pos. 2) from the track
tensioning valve block.
Remove the unions (Fig. 4-36, Pos. 3) from the track tensioning valve block.
Fig. 4-36
4.1.5.2 REPLACEMENT OF THE TRACK TENSIONING VALVE BLOCK

Special tools:
n/a
Chain host
Track tensioning valve block: 40 kg

Check the track tension system and adjust if required.

Version 2009/2
PC5500-6
4 - 29
Travel system
Undercarriage
4 - 30
PC5500-6
Version 2009/2
Undercarriage
4.1.6
Travel system
HYDRAULIC HOSES OF THE TRACK TENSIONING SYSTEM
4.1.6.1 SUBSTITUTE THE HYDRAULIC HOSES

Special tools:
n/a
Oil drain pan

Hydraulic hose: 10 kg max.
2.3 on page 2-37

the machine.
WARNING
Hot hydraulic oil!

Fig. 4-37
DANGER
scaring may result.
NOTE: In the following descriptions, the hydraulic hoses are

replaced one at a time.
Version 2009/2
PC5500-6
4 - 31
Travel system
Undercarriage
Fig. 4-38 Hydraulic hoses of the track tensioning system
4 - 32
PC5500-6
Version 2009/2
Undercarriage
Travel system
Substitute the hydraulic hoses (Fig. 4-38, Pos. 1):

z
If equipped with protection sleeve (Fig. 4-38, Pos. 9), clear

the hydraulic hose to be removed by opening the protection
sleeve.
Disconnect both ends of the hydraulic hose to be removed.
NOTE: When the hose is disconnected, hydraulic oil from inside

the piping and/or the track tensioning valve block will flow
out.
z
Pull out the hydraulic hose completely.
Insert a new hydraulic hose.
Reinstall the cover (Fig. 4-39, Pos. 1).
Fig. 4-39
Substitute the hydraulic hoses (Fig. 4-38, Pos. 3, 4, and 5):

z
Remove the cover (Fig. 4-40, Pos. 2) and open the clamp
(Fig. 4-38, Type B) only if the hoses (Fig. 4-38, Pos. 4 and 5)
for the track tensioning cylinders will be replaced.
Disconnect both ends of the hydraulic hose to be removed

and replace the hose by a new one.

out.
z
Fig. 4-40
Reinstall the cover(s) (Fig. 4-40, Pos. 1, 2).
Substitute the hydraulic hoses (Fig. 4-38, Pos. 2, 6, 7, and 8):

z
Clear the hydraulic hose (Fig. 4-38, Pos. 6, 7, and 8) to be

removed by opening the clamps (Fig. 4-38, Type A or B).
Disconnect both ends of the hydraulic hose to be removed

and replace the hose by a new one.

out.
Version 2009/2
PC5500-6
4 - 33
Travel system
Undercarriage
Subsequent work
z
Bleed the track tensioning system. Refer to the Operation &

Maintenance Manual, chapter 4, section "CRAWLER TRACK
- INSPECTION".

4.1.7
TRAVEL BRAKE VALVE BLOCK (OVERSPEED VALVE)
Fig. 4-41 Travel brake valve blocks

(1)
Travel brake valve block
(2)
Travel motor
The travel brake valve blocks (Fig. 4-41, Pos. 1) protect the travel
motors (Fig. 4-41, Pos. 2) from overspeed during downhill travel.
Two travel brake valve blocks are installed, one valve block for
the two travel motors of each crawler track.
4 - 34
PC5500-6
Version 2009/2
Undercarriage
Travel system
4.1.7.1 REMOVAL OF THE TRAVEL BRAKE VALVE BLOCK

Special tools:
n/a
Chain hoist
Oil drain pan
Travel brake valve block: 75 kg each
2.3 on page 2-37.


WARNING
Hot hydraulic oil!

DANGER
scaring may result.
Version 2009/2
PC5500-6
4 - 35
Travel system
Undercarriage
Disconnect the pressure hoses (Fig. 4-42, Pos. 2) to the

rotary joint from the travel brake valve block (Fig. 4-42,
Pos. 4).
Disconnect the hydraulic lines (Fig. 4-42, Pos. 1) to the travel

motors from the travel brake valve block (Fig. 4-42,
Pos. 4).
Disconnect the leakage oil line from the travel brake valve
block (Fig. 4-42, Pos. 4).
NOTE: When the hydraulic lines are disconnected, hydraulic oil

from inside the piping and the travel brake valve block will
flow out.
z
Discard the O-rings (Fig. 4-42, Pos. 5).
Sling the travel brake valve block (Fig. 4-42, Pos. 4) at the
installed hoist rings.
Remove the mounting bolts (Fig. 4-42, Pos. 3) and lift off the
travel brake valve block (Fig. 4-42, Pos. 4) using a chain
hoist.
Remove the relief valve (Fig. 4-43, Pos. 1) from the travel
brake valve block (Fig. 4-43, Pos. 2).
Fig. 4-42
Fig. 4-43
4 - 36
PC5500-6
Version 2009/2
Undercarriage
Travel system
4.1.7.2 REPLACEMENT OF THE TRAVEL BRAKE VALVE BLOCK

Special tools:
n/a
Chain hoist
Travel brake valve block: 75 kg
NOTE: Tighten the relief valve (Fig. 4-43, Pos. 1) to the specified
torque.
Tightening torque for relief valve
(Fig. 4-43, Pos. 1): 300 Nm
z

Check the travel system and adjust if required.

Version 2009/2
PC5500-6
4 - 37
Travel system
4.1.8
Undercarriage
TRACK TENSIONING CYLINDERS
4.1.8.1 REMOVAL OF THE TRACK TENSIONING CYLINDERS

Special tools:
n/a
Crane
Oil drain pan
Track tension cylinder: 400 kg each
Dogman/rigger
2.3 on page 2-37.
z


z
Remove the guide wheel assembly, refer to section 4.1.3.1 on

page 4-20.

WARNING
Hot hydraulic oil!

Fig. 4-44
4 - 38
PC5500-6
Version 2009/2
Undercarriage
Travel system
DANGER
removed.
Disconnect the pressure hoses from the track tension cylinder, refer to section 4.1.6 on page 4-31.
NOTE: When the pressure hoses are removed, hydraulic oil from
inside the piping and the track tension cylinder will flow
out.
z
Sling the track tension cylinder and pull the cylinder out of its
guidance.
4.1.8.2 REPLACEMENT OF THE TRACK TENSIONING CYLINDERS

Special tools:
n/a
Crane
Track tension cylinder: 400 kg each
Dogman/rigger
z

Refer to Operation & Maintenance Manual, chapter 4, section
"CRAWLER TRACK - INSPECTION".
Check the track tensioning system and adjust if required.

Version 2009/2
PC5500-6
4 - 39
Travel system
4.1.9
Undercarriage
TRAVEL MOTOR
The travel motor is an axial piston unit with fixed displacement.

The drive speed is proportional to the consumption capacity.
The output torque increases with the pressure drop between high
and low pressure side.
4.1.9.1 REMOVAL OF THE TRAVEL MOTORS

Special tools:
n/a
Crane
Oil drain pan
Travel motor: 110 kg each
Dogman/rigger
2.3 on page 2-37.
z


z

If equipped, remove the motor protection, refer to the

Drain oil of the motor adapter housing,
approx. 2 liters (L&S) each, 0.5 liters (Zollern) each.
Refer to Operation & Maintenance Manual,
ADAPTER HOUSINGS AND FINAL DRIVES
CHANGE OIL".
4 - 40
PC5500-6
Version 2009/2
Undercarriage
Travel system
WARNING
Hot hydraulic oil!
DANGER
scaring may result.
Remove the pressure hoses (Fig. 4-45, Pos. 2) and the leak
oil hoses (Fig. 4-45, Pos. 1 / Fig. 4-46, Pos. 4) from the travel
motor (Fig. 4-45, Pos. 3).
NOTE: When the hoses are removed, hydraulic oil from inside
the piping will flow out.
z
Discard the O-rings.

z
Sling travel motor (Fig. 4-45, Pos. 3) and remove the mounting bolts (Fig. 4-45, Pos. 4). Discard the bolts.
Remove the travel motor (Fig. 4-45, Pos. 3) by pulling it out of

the motor adapter housing (Fig. 4-45, Pos. 5) of the travel
parking brake using a crane.
Fig. 4-45
DANGER
When lifting the travel motor, make sure that nobody steps
below the weight.
Fig. 4-46
Version 2009/2
PC5500-6
4 - 41
Travel system
Undercarriage
4.1.9.2 REPLACEMENT OF THE TRAVEL MOTORS

Special tools:
n/a
Crane
Travel motor: 110 kg
Dogman/rigger
z
Apply "Optimol White" at the spline shaft of the travel motor

(Fig. 4-47, Pos. 1) before attaching the travel motor to the
motor adapter housing (Fig. 4-47, Pos. 3).
Fig. 4-47
z
NOTE: Use new mounting bolts (Fig. 4-47, Pos. 2) of grade 10.9.
Tightening torque for travel motor mounting
bolts: 265 Nm
z

Refill oil of the motor adapter housing,
Refer to Operation & Maintenance Manual,
ADAPTER HOUSINGS AND FINAL DRIVES
CHANGE OIL".
If equipped, install the motor protection, refer to the

4 - 42
PC5500-6
Version 2009/2
Undercarriage
Travel system
Version 2009/2
PC5500-6
4 - 43
Travel system
Undercarriage
4.1.10 TRAVEL PARKING BRAKE
Fig. 4-48 Travel parking brake assembly (dry-type)

NOTE: Up to SN 025, the travel gearboxes have been equipped
with wet-type brakes. For information about the fluid,
refer to section 6.1 on page 6-2.
4 - 44
PC5500-6
Version 2009/2
Undercarriage
Travel system

(1)
Disc carrier
(2)
Snap ring
(3)
Retainer
(4)
O-ring
(5)
Seal ring
(6)
Plug screw
(7)
Control pressure port to release the brake
(8)
Spring
(9)
Spring
(10)
O-ring
(11)
Snap ring
(12)
Retainer
(13)
Disk housing
(14)
O-ring
(15)
Radial seal rings
(16)
Piston
(17)
Quad-ring
(18)
Back-up rings
(19)
Back-up rings
(20)
Quad-ring
(21)
Outer discs
(22)
Inner discs
Brake applied:
The outer discs (Fig. 4-48, Pos. 21) engaged to the housing by
serration and the inner discs (Fig. 4-48, Pos. 1) in serration connection with the disc carrier are pressed together by the springs
(Fig. 4-48, Pos. 8 and 9). This results in a fixed connection
between housing and disc carrier (Fig. 4-48, Pos. 23).
Brake released:
Oil pressure via the control pressure port (Fig. 4-48, Pos. 7)
forces the piston (Fig. 4-48, Pos. 16) against the springs
(Fig. 4-48, Pos. 8 and 9) toward the retainer (Fig. 4-48, Pos. 12).
This function eliminates the spring force onto the discs, thus the
brake is released.
The minimum release pressure is 18 bar, the maximum permissible pressure is 60 bar.
Version 2009/2
PC5500-6
4 - 45
Travel system
Undercarriage
4.1.10.1 REMOVAL OF THE TRAVEL PARKING BRAKE

Special tools:
n/a
Crane
Oil drain pan
Travel parking brake: 75 kg
Dogman/rigger
2.3 on page 2-37
z

the machine and boom.

make sure that the machine is moved to a location with
z
Place wedges at front and rear side of both crawlers and

lower the bucket onto the ground.
Relieve the pressure in the hydraulic system. Refer to the


WARNING
Hot hydraulic oil!

4 - 46
PC5500-6
Version 2009/2
Undercarriage
Travel system
DANGER
removed.
Remove the relevant travel motor (Fig. 4-49, Pos. 6 and 7

respectively), refer to section 4.1.9.1 on page 4-40.
Remove the pressure hose (Fig. 4-49, Pos. 3) and the

breather hose (Fig. 4-49, Pos. 4) from the travel parking
brake (Fig. 4-49, Pos. 1 and 5 respectively).

z
Fig. 4-49
If equipped with wet-type travel parking brakes (up to

SN 025):
Drain oil of the travel parking brake housing,
approx. 0.1 liters.
Sling the travel parking brake (Fig. 4-49, Pos. 1 and 5 respectively).
Remove the mounting bolts (Fig. 4-49, Pos. 2) of the travel

parking brake (Fig. 4-49, Pos. 1 and 5 respectively).
Remove the travel parking brake (Fig. 4-49, Pos. 1 and 5

respectively) by pulling it out of the travel gearbox using a
crane.
DANGER

When lifting the parking brake, make sure that nobody steps
below the weight.
Version 2009/2
PC5500-6
4 - 47
Travel system
Undercarriage
4.1.10.2 REPLACEMENT OF THE TRAVEL PARKING BRAKE

Special tools:
n/a
Crane
Portable pressure source (hydraulic or air)
Travel parking brake: 75 kg
Dogman/rigger
z
Apply "Optimol White" at the input spline shaft (Fig. 4-50,

Pos. 4) of the travel gearbox.
DANGER
Risk of retainer (Fig. 4-50, Pos. 3) blasting off!

Do not exceed the maximum pressure of 60 bar at the pressure port.
NOTE: Travel brake may need to be released to allow the

splines to line up or the mounting bolts (Fig. 4-50,
Pos. 1) to be installed.
Therefore first install a portable pressure source to the
pressure port (Fig. 4-50, Pos. 2) (M18 x 1.5) at the travel
parking brake and apply 20 bar.
Fig. 4-50
z
If equipped with wet-type travel parking brakes (machines up

to SN 025):
Refill oil of the travel parking brake housing,
approx. 0.1 liters.
CAUTION
Since SN 026, the travel parking brakes are dry multiple disk
brakes. DO NOT fill the housings with oil.
4 - 48
PC5500-6
Version 2009/2
Undercarriage
Travel system
Perform a function check of the travel parking brake. Refer to

Version 2009/2
PC5500-6
4 - 49
Travel system
Undercarriage
4.1.11 TRAVEL GEARBOX
Fig. 4-51 Travel gearbox removal

(1)
Drive shaft
(2)
O-ring
(3)
Travel gearbox
(4)
Travel motor
(5, 6)
Mounting bolts and washers for travel motor
(7, 8)
Mounting bolts and washers for travel gear to

crawler carrier
(9)
Crawler carrier
4 - 50
PC5500-6
Version 2009/2
Undercarriage
Travel system

Special tools:
n/a

Crane
Oil drain pan
Travel gearbox: 4020 kg
Dogman/rigger
2.3 on page 2-37.
z


z
Place wedges at front and rear side of both crawlers and

lower the bucket onto the ground.

If equipped, remove the travel gearbox protection, refer to the

WARNING
Hot hydraulic oil!

until the temperature of the hydraulic oil is below
heated oil.
Version 2009/2
PC5500-6
4 - 51
Travel system
Undercarriage
Drain oil of the final drive housing,

approx. 165 liters.
Drain oil of the travel gear housing,
approx. 155 liters (L&S), 180 liters (Zollern).
WARNING
removed..
Remove the two travel parking brakes, (Fig. 4-52,

Pos. 1), refer to section 4.1.10.1 on page 4-46.
Remove breather hose (Fig. 4-52, Pos. 2) from the travel

gearbox.
NOTE: Cap the openings with blind plugs to avoid contamination.

z
Remove the driving performance meter (Fig. 4-53, Pos. 4)

and cap the opening to avoid contamination.
Fig. 4-52
z
Sling the travel gearbox (Fig. 4-53, Pos. 3) at the installed

hoist ring (Fig. 4-53, Pos. 2).
Remove the mounting bolts (Fig. 4-53, Pos. 5) with washers

(Fig. 4-53, Pos. 6).
Discard the bolts and washers.
Extract the travel gearbox (Fig. 4-53, Pos. 3) from the crawler
carrier (Fig. 4-53, Pos. 7) using a crane.
Remove the O-ring (Fig. 4-53, Pos. 1) and discard it.
Fig. 4-53
DANGER
When lifting the travel gearbox, make sure that nobody steps
below the weight.
4 - 52
PC5500-6
Version 2009/2
Undercarriage
Travel system

Special tools:
n/a

Crane
Travel gearbox: 4020 kg
Dogman/rigger
NOTE: Ensure that the mating surfaces on the crawler carrier

and travel gearbox (Fig. 4-54, Pos. 2) are clean and free
of paint before assembly.
z
Replace the driving performance meter (Fig. 4-54, Pos. 4).
Insert a new O-ring (Fig. 4-54, Pos. 2).
Apply "Optimol White" at the drive shaft (Fig. 4-54, Pos. 1)

and the splines of the planet carrier inside the travel gearbox.
Sling the travel gearbox at the installed hoist ring (Fig. 4-54,
Pos. 3).
Fig. 4-54
DANGER

below the weight.
Align the travel gearbox to the drive shaft (Fig. 4-54, Pos. 1)
and flange it to the crawler carrier.
Use new mounting bolts (Fig. 4-54, Pos. 5) of grade 10.9 and
apply compound "KP2K", PN 324 969 40 on heads and
threads of the bolts.
Insert the new mounting bolts and washers (Fig. 4-54, Pos. 6)
and tighten the bolts to the specified tigtening torque.
Tightening torque for travel gearbox mounting
bolts (Fig. 4-54, Pos. 6): 3100 Nm
Version 2009/2
PC5500-6
4 - 53
Travel system
Undercarriage

Refill oil of the final drive housing,
approx. 165 liters.
Refill oil of the travel gear housing,
approx. 155 liters (L&S), 180 liters (Zollern).
NOTE: Be sure to fill in the correct oil as specified, refer to section 6.1 on page 6-2.
Refill oil of the motor adapter housing,
z
If equipped with wet-type travel parking brakes (machines up

to SN 025):
Refill oil of the travel parking brake housing,
approx. 0.1 liters.
CAUTION
Since SN 026, the travel parking brakes are dry multiple disk
brakes. DO NOT fill the housings with oil.
Perform a function check of the travel parking brake. Refer to

4 - 54
PC5500-6
Version 2009/2
Undercarriage
Travel system

Special tools:
n/a

Crane
Oil drain pan
Travel motor: 110 kg each
Spur gear housing with mounted brake housing: 580 kg
Support bearing cover: 400 kg
Spindle with installed support bearing: 278 kg
Planetary gear housing with mounted sprocket: 7250 kg (7750 kg with
oversize sprocket assembly)
Drive sprocket ring: 244 kg
Dogman/rigger
2.3 on page 2-37.

the machine, the boom, the dozer and the crane.
attachment placed at the final drive end of the machine, counterweight above the guide wheels.

equipment (crane, mobile working platforms, forklift, etc.)
z
Relieve the pressure in the track tensioning system according

to the PARTS & SERVICE NEWS "AH06530".
NOTE: The procedure in the PARTS & SERVICE NEWS

"AH06530" prevent the track tensioning cylinders to get
pressurized when moving the excavator.
z
Fig. 4-55
Version 2009/2
PC5500-6
4 - 55
Travel system
Undercarriage

DANGER

or the dozer.
Fig. 4-56
z
the track group from the sprocket (refer to Fig. 4-56).
z
NOTE: Fasten the track group to the carrier roll to hold it in position.
Fig. 4-57 Removal / Replacement of the travel gearbox
4 - 56
PC5500-6
Version 2009/2
Undercarriage
Travel system
WARNING
The hydraulic system my be pressurized. Make sure that the
removed.
NOTE: For removal of the travel gearbox (Fig. 4-57, Pos. 1) from
the crawler frame it is not necessary to remove the
sprocket (Fig. 4-57, Pos. 3).
z
Remove the travel motors from the travel gearbox, refer to

WARNING
Hot hydraulic oil!

Drain oil of the spur gear housing,

approx. 10 liters.
Drain oil of the planetary gear housing,
approx. 105 liters.
Drain oil of the support bearing,
approx. 3.5 liters.
Exchange one mounting bolt (Fig. 4-58, Pos. 1) between the

travel motor flanges (Fig. 4-58, Pos. 2) with an adequate
swivel hoist ring.
Fig. 4-58
Version 2009/2
PC5500-6
4 - 57
Travel system
Undercarriage
If equipped, remove the driving performance meter (Fig. 4-59,

Pos. 1) and cap the opening to avoid contamination.
Sling the spur gear housing (Fig. 4-59, Pos. 2) together with
the brake housing (Fig. 4-59, Pos. 3) at the installed swivel
hoist ring and at both brake housings in a way the components are kept in upright position.
Remove the remaining mounting bolts (Fig. 4-59, Pos. 4) and

install 3 threaded pins (M16130, thread length: 30 mm)
evenly distributed at the circumference as guidance elements.
Remove the spur gear housing by pulling it off the spindle

(Fig. 4-59, Pos. 5) of the planetary gear housing.
DANGER

below the weight.
Fig. 4-59
NOTE: To loosen a seized connection, jack bolts (M16) can be

installed at two threaded bores (Fig. 4-58, Pos. 3).
Exchange the upmost mounting bolt (M30) with an adequate

swivel hoist ring (Fig. 4-60, Pos. 1).
Sling the planetary gear housing at the swivel hoist ring

(Fig. 4-60, Pos. 1) and at the sprocket (Fig. 4-60, Pos. 3).
Tense the sling gear to ease the load of the travel gear
mounting bolts.
Fig. 4-60
4 - 58
PC5500-6
Version 2009/2
Undercarriage
Travel system
Remove 3 mounting bolts (Fig. 4-61, Pos. 1) evenly distributed at the support bearing cover and install 3 threaded pins
(M30300, thread length: 80 mm) instead.
Remove the remaining mounting bolts (Fig. 4-61, Pos. 1).
Pull out the support bearing cover (Fig. 4-61, Pos. 2) out of
the bore in the crawler frame using 3 jack bolts inserted in the
threaded bores (Fig. 4-61, Pos. 3).
WARNING
Sling the bearing cover as soon as possible and support it

using an adequate lifting device to prevent the bearing cover
from falling.
Remove the support bearing cover and the threaded pins.
Remove 3 mounting bolts (Fig. 4-62, Pos. 1) evenly distributed at the circumference of the spindle and install 3 threaded
pins (M27300, thread length: 40 mm) instead.
Remove the remaining mounting bolts (Fig. 4-62, Pos. 1) and

pull the spindle (Fig. 4-62, Pos. 2) from the planetary gear
cover (Fig. 4-62, Pos. 3).
Fig. 4-61
WARNING
Sling the spindle (Fig. 4-62, Pos. 2) as soon as possible and
support it using an adequate lifting device to prevent the
spindle from falling.
Discard the dual cone seal halves attached to the bearing

cover and the spindle (Fig. 4-62, Pos. 4).
NOTE: For further information about the dual cone seals, refer to
Version 2009/2
PC5500-6
Fig. 4-62
4 - 59
Travel system
Undercarriage
Remove the mounting bolts (Fig. 4-63, Pos. 1) attaching the

spindle (Fig. 4-63, Pos. 2) to the crawler frame (travel motor
side) (Fig. 4-63, Pos. 3).
Pull the planetary gear housing out of the bore in the crawler
frame and lift it out of the crawler frame using a crane.
DANGER

When lifting the planetary gear housing, make sure that
Fig. 4-63
z
Lower the planetary gear housing (Fig. 4-64, Pos. 1) to the

ground and rest it on appropriate supports (Fig. 4-64, Pos. 2).
NOTE: For the removal of the segmented sprocket (Fig. 4-64,

Pos. 3) and the mounting ring (Fig. 4-64, Pos. 4), refer to
Fig. 4-64
4 - 60
PC5500-6
Version 2009/2
Undercarriage
Travel system

Special tools:
n/a

Crane
3 x Threaded pin M16x130 (thread length: 30 mm)
Paste "Optimol White", PN 999 039
Fluid "Loctite 245", PN 170 470 40
Sealant "Loctite 574", PN 255 239 40
Support bearing cover: 400 kg
Spindle with installed support bearing: 278 kg
Spur gear housing with mounted brake housing: 580 kg
Planetary gear housing with mounted sprocket: 7250 kg (7750 kg with
oversize sprocket assembly)
Drive sprocket ring: 244 kg
Dogman/rigger
2.3 on page 2-37.
NOTE: It is assumed that all parts to be installed are checked

and approved, and parts are replaced if required.
For the following description it is also assumed that the
components to be installed are in the same state of
assembly as after removal.
NOTE: Ensure that the mating surfaces are cleaned thoroughly,
and that sealants are removed completely.
Version 2009/2
PC5500-6
4 - 61
Travel system
Undercarriage
Instal the segmented sprocket (Fig. 4-65, Pos. 3) to the planetary gear housing (Fig. 4-65, Pos. 1), refer to section 4.1.2.4
on page 4-18.
NOTE: Align the sprocket segments to the mounting bores in the

travel gearbox by means of two pipes
(dia. 38 mm1000 mm).
Instal three swivel hoist rings to the drive sprocket ring
(Fig. 4-65, Pos. 4), and put the drive sprocket ring on the
sprocket segments using a crane. Remove the swivel
hoist rings.
Use new bolts, nuts, and washers to attach the sprocket
segments and the sprocket ring to the travel gear
(Fig. 4-65, Pos. 1).
Fig. 4-65
Tightening torque for drive sprocket ring

mounting bolts (Fig. 4-23, Pos. 1): 3000 Nm
z
Install a swivel hoist ring (Fig. 4-66, Pos. 1) to the planetary

gear housing (Fig. 4-66, Pos. 9) in exchange for a mounting
bolt at the rear cover of the planetary gear housing.
NOTE: Pay attention to the position of the oil plugs.

z
Hook up the planetary gear housing at the installed swivel

hoist ring (Fig. 4-66, Pos. 1) and the sprocket (Fig. 4-66,
Pos. 3).
NOTE: Use a chain hoist (Fig. 4-66, Pos. 2) to align the planetary
gear housing vertically.
z
Apply "Optimol White" to the bore (Fig. 4-66, Pos. 8) in the

crawler frame (travel motor side) (Fig. 4-66, Pos. 7).
Lift the planetary gear housing to the inside of the crawler carrier.
Align the spindle (Fig. 4-66, Pos. 4) of the planetary gear

housing to the bores in the crawler frame and move it into the
bore.

threads of the mounting bolts (Fig. 4-66, Pos. 6) and insert
the mounting bolts with washers (Fig. 4-66, Pos. 5).
Tighten all mounting bolts to the specified tightening torque

using the hydraulic torque wrench PN 232 614 40.
Fig. 4-66
Tightening torque for travel gearbox mounting

bolts (Fig. 4-66, Pos. 6): 3000 Nm
4 - 62
PC5500-6
Version 2009/2
Undercarriage
Travel system
NOTE: Leave the planetary gear housing hooked up to the

crane.
z
Install one half of the dual cone seal (Fig. 4-67, Pos. 1) to the
support bearing spindle (Fig. 4-66, Pos. 2).
NOTE: Before installation, moist rubber seal ring with a mixture

of water and spirit.
For further information about mounting dual cone seals
and the assembly tool that has to be used, refer to
z
If required, install a new bearing (Fig. 4-66, Pos. 3) to the

spindle.
Fig. 4-67
z
Install 3 threaded pins (M27300 mm, thread length: 40 mm)

equally distributed at the planetary gear housing
(Fig. 4-68, Pos. 3) into the bores for the spindle mounting
bolts (Fig. 4-68, Pos. 1).
Lift the spindle (Fig. 4-68, Pos. 2) by means of an adequate

lifting device and move it onto the threaded pins.
DANGER

When lifting the support bearing spindle, make sure that
Apply compound "Loctite 245" on the threads of new mounting bolts (Fig. 4-68, Pos. 1) of grade 10.9, insert the mounting
bolts with new HV-washers, and tighten the mounting bolts to
the specified tightening torque.
Fig. 4-68
Tightening torque for spindle mounting bolts:

1520 Nm
z
Remove the threaded pins.
Version 2009/2
PC5500-6
4 - 63
Travel system
Undercarriage
Apply oil onto the support bearing (Fig. 4-69, Pos. 4).
Apply paste "Optimol White" onto the bore in the crawler

frame (Fig. 4-69, Pos. 6).
Install the other half of the dual cone seal (Fig. 4-69, Pos. 5)
to the bearing cover (Fig. 4-69, Pos. 7).
NOTE: Before installation, moist rubber seal ring with a mixture

of water and spirit.
For further information about mounting dual cone seals
and the assembly tool that has to be used, refer to
z
Align the support bearing (Fig. 4-69, Pos. 4) to the bore in the
crawler frame concentrically.
NOTE: Max. allowable eccentricity: 0.05 mm.

If required, lift gear housing by means of hydraulic jacks
and keep it in position using appropriate supports.
z
Install 3 threaded pins (M30300 mm, thread length: 80 mm)

equally distributed to the bores in the crawler frame
(Fig. 4-69, Pos. 6).
Sling the support bearing cover (Fig. 4-69, Pos. 7) and slip it
onto the threaded pins.
Fig. 4-69
DANGER
When lifting the bearing cover, make sure that nobody steps
below the weight.
NOTE: Pay attention to the position of the oil plugs in the bearing
cover.
z
Shift bearing cover over the support bearing into the bore in
the crawler frame by means of 5 bolts (M30160 mm) and
washers, both delivered with the travel gear.
Remove the bolts.
4 - 64
PC5500-6
Version 2009/2
Undercarriage
Travel system
Install new mounting bolts (Fig. 4-69, Pos. 1) of grade 10.9

with washers (Fig. 4-69, Pos. 2).
NOTE: Apply compound "KP2K", PN 324 969 40 and tighten the

bolts to the specified tightening torque.
Tightening torque for bearing cover mounting
bolts: 710 Nm
z
Remove the lifting gear and the supporting tools from the
gear housing.
Sling the spur gear housing (Fig. 4-70, Pos. 3) with the
installed brake housing.
Install new O-ring (Fig. 4-70, Pos. 5) to the spur gear housing.
NOTE: Apply paste "Loctite 574" onto the sealing / mating surfaces (Fig. 4-70, Pos. 2).
z
Install 3 threaded pins (M16130, thread length: 30 mm) into

3 bores for the spur gear mounting bolts (Fig. 4-70, Pos. 6)
evenly distributed at the spindle (Fig. 4-70, Pos. 1) of the
planetary gear housing.
Lift spur gear housing (Fig. 4-70, Pos. 3) and slip it onto the
threaded pins.
DANGER

When lifting the spur gear housing, make sure that nobody
Fig. 4-70
Insert new mounting bolts (Fig. 4-70, Pos. 4) of grade 10.9.
NOTE: Apply compound "KP2K", PN 324 969 40 and tighten the

bolts to the specified tightening torque.
Tightening torque for spur gear housing mounting
bolts: 255 Nm
z
Remove the sling gear.
Replace the swivel hoist ring with a mounting bolt.
Version 2009/2
PC5500-6
4 - 65
Travel system
Undercarriage
4.1.12 CARRIER ROLLER

4.1.12.1 REMOVAL OF THE CARRIER ROLLER ASSEMBLY
Special tools:
n/a
Hydraulic jack 40 tonnes

Forklift (as the most economical device)
Chain hoist
Carrier roller assembly (pinned undercarriage): 175 kg
Carrier roller assembly (bolted undercarriage): 205 kg

the machine, boom, and forklift.

z
Fig. 4-71
z
Push up track shoe assembly (Fig. 4-72, Pos. 3) at the carrier

roller assembly (Fig. 4-72, Pos. 2) to be removed using
hydraulic jack (Fig. 4-72, Pos. 1).
In addition to the hydraulic jack, secure the track shoe assembly using appropriate blocks.
NOTE: Fig. 4-72 shows the crawler carrier of the bolted undercarriage, this step is accordingly identical for the crawler
carrier of the pinned undercarriage.
Fig. 4-72
4 - 66
PC5500-6
Version 2009/2
Undercarriage
Travel system
Carry out the following steps at the crawler carrier of the

bolted undercarriage only:
z
Shove the forks (Fig. 4-73, Pos. 1) together that far, that
the carrier roller (Fig. 4-73, Pos. 2) can rest on the forks.
WARNING
If the forks can not be locked in that position, use a chain

hoist at the forks to prevent them from sliding apart.
Make sure that nobody is in the danger zone while lifting

the carrier roller assembly from the pedestal.
Fig. 4-73
Carry out the following step at the crawler carrier of the

pinned undercarriage only:
z
Sling the carrier roller assembly (Fig. 4-74, Pos. 1)

at both sides and connect the slings to the forks
(Fig. 4-74, Pos. 2) of a forklift.

Fig. 4-74
z
Remove the carrier roller assembly mounting bolts and lift off
the carrier roller assembly using a forklift.
DANGER

When lifting the carrier roller, make sure that nobody steps
below the weight.
Version 2009/2
PC5500-6
4 - 67
Travel system
Undercarriage
4.1.12.2 REPLACEMENT OF THE CARRIER ROLLER ASSEMBLY

Special tools:
n/a
Hydraulic jack 40 tonnes

Forklift (as the most economical device)
Chain hoist
Carrier roller assembly (pinned undercarriage): 175 kg
Carrier roller assembly (bolted undercarriage): 205 kg
NOTE: Observe the mounting position of the carrier rollers. The

oil plug must face the outside of the excavator.
Check the oil level in the carrier roller. The following positions of the oil level and filler plug have been defined for
checking the oil level in the carrier rollers:
z
9.00 o'clock or 3.00 o'clock position, equal to 90 angle

from TOP position of the plug to left or to the right =
MINIMUM oil level.

MAXIMUM oil level (factory filling).
For information about the proper lubricant,

DANGER
Danger of crush or pinch injuries to hands and fingers!

Exercise extreme care when aligning the carrier roller
assembly to the crawler carrier.
4 - 68
PC5500-6
Version 2009/2
Undercarriage
Travel system
4.1.13 TRACK ROLLER

4.1.13.1 REMOVAL OF THE TRACK ROLLER ASSEMBLY
Special tools:
Safety unit for changing track rollers, PN 921 149 40

Tool for changing track rollers (P&S-news in development)
Crane
Track roller assembly: 654 kg
Dogman/rigger


z
Fig. 4-75
z
Jack up the machine with the work equipment.
Support two track rollers with the safety unit for changing
track rollers, PN 921 149 40 (Fig. 4-76, Pos. 1).
Lower the machine and place the work equipment on the

ground.
Support the track roller assembly (Fig. 4-76, Pos. 2) from the
bottom side with the changing tool for track rollers (Fig. 4-78).
Remove the track roller mounting bolts (Fig. 4-76, Pos. 3) and
lower the tool.
Fig. 4-76
Version 2009/2
PC5500-6
4 - 69
Travel system
Undercarriage
NOTE: The track roller mounting bolts (Fig. 4-77, Pos. 1) are
secured with lever-nuts (Fig. 4-77, Pos. 2) inside the
crawler frame.
When the bolts are removed, the nuts may slip away from
their mounting position.
Fig. 4-77
NOTE: Make sure that both sides of the tool are balanced (e.g.
with the new track roller assembly).
z
Remove the track roller assembly.

DANGER

When lifting the track roller, make sure that nobody steps
below the weight.
NOTE: A PARTS & SERVICE NEWS for this tool is under development.
4 - 70
PC5500-6
Fig. 4-78
Version 2009/2
Undercarriage
Travel system
4.1.13.2 REPLACEMENT OF THE TRACK ROLLER ASSEMBLY

Special tools:
Safety unit for changing track rollers, PN 921 149 40

Tool for changing track rollers (P&S-news in development)
Crane
Track roller assembly: 654 kg
Dogman/rigger
NOTE: Observe the mounting position of the track rollers. The oil
plug must face the outside of the excavator.
Check the oil level in the track roller. The following positions of the oil level and filler plug have been defined for
checking the oil level in the track rollers:

MINIMUM oil level.

MAXIMUM oil level (factory filling).
For information about the proper lubricant,


z
When inserting the track roller mounting bolts (Fig. 4-79,

Pos. 1), hold the lever-nuts (Fig. 4-79, Pos. 2) inside the
crawler frame by hand for the first convolutions.
NOTE: Use new track roller mounting bolts of the grade 10.9.
Apply compound "KP2K", PN 324 969 40 to the bolts.
Fig. 4-79
Version 2009/2
PC5500-6
4 - 71
Car body
Undercarriage
4.2
CAR BODY
4.2.1
REMOVAL OF THE CAR BODY AND THE CRAWLER CARRIERS

(TYPE WITH PINNED UNDERCARRIAGE)
Special tools:
n/a
2 x Crane
Dozer
Oil drain pan
Car body: 42,000 kg
Crawler carrier assembly: 40,000 kg each (without track group)
Dogman/rigger
2.3 on page 2-37.
NOTE: At first the wear of the bushes in the car body should be
checked, refer to the PARTS & SERVICE NEWS No.
"AH08508".
z
Remove the track groups from both crawler cariers, refer to

NOTE: Remove both track groups simultaneously.

This can be done using the same dozer.
WARNING
Hot hydraulic oil!
Remove the travel gearboxes from both crawler carriers, refer

Lift the superstructure, refer to section 3.9.1 on page 3-257.
Attach a dozer to the car body by means of a chain.
Move the car body below the lifted superstructure using the
dozer.
NOTE: Move the car body over the unrolled track group.
4 - 72
PC5500-6
Version 2009/2
Undercarriage
Car body
Remove the pressure hoses (Fig. 4-80, Pos. 1) of the track

tensioning system leading to the shut-off cocks (Fig. 4-80,
Pos. 2) and pull them out of the crawler carriers, refer to section 4.1.6.1 on page 4-31.
NOTE: When the pressure hoses are removed, the oil inside the
piping will flow out.
Cap the openings with blind plugs to avoid
contamination.
Fig. 4-80
z
Attach one crawler to two cranes and lift it up (Fig. 4-81).

WARNING
Before lifting, make sure that the crane operators are trained
in dual crane lift.
Fig. 4-81
z
Rest the car body on appropriate supports (see Fig. 4-82).

CAUTION
Supports need to be substantial enough to carry the total

weight of both crawler carrier (40,000 kg) and car body
(42,000 kg).
Version 2009/2
PC5500-6
4 - 73
Car body
Undercarriage
Fig. 4-82 Crawler carrier mounting

z
Remove all bolts (Fig. 4-82, Pos. 6) and the retainer plates
(Fig. 4-82, Pos. 7).
Remove the nuts (Fig. 4-82, Pos. 2), the cover plates
(Fig. 4-82, Pos. 3), and the thread pins (Fig. 4-82, Pos. 4)
only if required (changing to a replacement car body).
Pull out the four mounting pins (Fig. 4-82, Pos. 5) just enough
to clear the crawler carrier assembly (Fig. 4-82, Pos. 1) from
the car body as shown in (Fig. 4-82).
Remove the crawler carrier (Fig. 4-82, Pos. 1) using two

cranes.
WARNING
in dual crane lift.
DANGER
When lifting the crawler carrier, make sure that nobody steps
below the weight.
4 - 74
PC5500-6
Version 2009/2
Undercarriage
Car body
Attach the car body to two cranes (Fig. 4-83).
Clear the other crawler carrier from the car body using the
same procedure as before.
Remove the car body using two cranes.

WARNING
in dual crane lift.
Fig. 4-83
DANGER
When lifting the crawler carrier, make sure that nobody steps
below the weight.

z
Remove the rotary joint from the car body, refer to section
4.2.5.1 on page 4-94.
Remove the high pressure accumulators from the car

body, refer to section 4.1.4.3 on page 4-26.
Remove the track tensioning valve from the car body,

Remove the travel brake valve blocks from the car body,
Remove all hydraulic hoses from the car body, refer to

Version 2009/2
PC5500-6
4 - 75
Car body
4.2.2
Undercarriage
REPLACEMENT OF THE CAR BODY AND THE CRAWLER

CARRIERS (TYPE WITH PINNED UNDERCARRIAGE)
Special tools:
Water level gauge
AL-Compound, PN 509 623 98

2 x Crane
Dozer
Car body: 42,000 kg
Dogman/rigger

z

z
Instal all hydraulic hoses into the new car body, refer to
Instal the rotary joint in the new car body, refer to section
4.2.5.2 on page 4-96.
Instal the high pressure accumulators in the new car

body, refer to section 4.1.4.4 on page 4-27.
Instal the track tensioning valve in the new car body, refer
Instal the travel brake valve blocks in the new car body,
4 - 76
PC5500-6
Version 2009/2
Undercarriage
Car body
If required, install new inner bushings (Fig. 4-84, Pos. 5) and

new outer bushings (Fig. 4-84, Pos. 7) in the new car body.
Instal the thread pins (Fig. 4-84, Pos. 4) and the cover plates
(Fig. 4-84, Pos. 3) with nuts (Fig. 4-84, Pos. 2) and washers
at the four borings for the pins on the car body.
Attach the car body (Fig. 4-84, Pos. 1) to two cranes and lift it
up.
WARNING
in dual crane lift.
DANGER
Fig. 4-84

When lifting the car body, make sure that nobody steps
below the weight.
NOTE: The oil supply lines to the travel motors must be aligned
in the direction of the travel motors.
z
Align the car body (Fig. 4-84, Pos. 1) to the crawler carrier
(Fig. 4-84, Pos. 10) and let it down.
NOTE: The oil supply lines to the travel motors must be aligned
in the direction of the travel motors.
Insert the hydraulic lines for track tensioning into the
crawler carrier before installing it.
If applicable, re-assemble the protection sleeve on the
hydraulic hose at the joint between the crawler carrier
and the car body.
z
Align the upper borings first and insert the mounting pins
(Fig. 4-84, Pos. 6).
NOTE: Lubricate pins (Fig. 4-84, Pos. 6) with AL-Compound,

PN 509 623 98.
z
Align the lower borings and insert the mounting pins.
Instal the retainer plates (Fig. 4-84, Pos. 9) at the mounting

pins and secure the retainer plates with the mounting bolts
(Fig. 4-84, Pos. 8) and washers.
Version 2009/2
PC5500-6
4 - 77
Car body
Undercarriage
For easier mounting of the second crawler carrier, support left

side of the car body with appropriate stands of appr. 1500 mm
hight and lower the car body on the stands (see Fig. 4-85).
CAUTION
Supports need to be substantial enough to carry the total

weight of both crawler carrier (40,000 kg) and car body
(42,000 kg).
NOTE: Assure that the track groups ar parallel and the distance
"A" between track groups is:
4840 mm for track width 1350
4390 mm for track width 1800
Fig. 4-85
Fig. 4-86 Assembly of the car body

z
Instal the thread pins (Fig. 4-86, Pos. 4) and the inner retainer
plates (Fig. 4-86, Pos. 3) with nuts (Fig. 4-86, Pos. 2) and
washers at the four borings for the pins on the car body.
4 - 78
PC5500-6
Version 2009/2
Undercarriage
Car body
Attach the second crawler carrier (Fig. 4-86, Pos. 1) to two

cranes, lift it up and align it to the car body.

WARNING
in dual crane lift.
DANGER
When lifting the car body, make sure that nobody steps
below the weight.
Align the upper borings first and insert the mounting pins
(Fig. 4-86, Pos. 5).
NOTE: Lubricate pins (Fig. 4-86, Pos. 5) with AL-Compound,

PN 509 623 98.
z
Align the lower borings and insert the mounting pins.
Instal the retainer plates (Fig. 4-86, Pos. 7) at the mounting

pins and secure the retainer plates with the mounting bolts
(Fig. 4-86, Pos. 6) and washers.
Lift the undercarriage as far as it is necessary to remove the

stands.
Rest the undercarriage to the ground.
Version 2009/2
PC5500-6
4 - 79
Car body
4.2.3
Undercarriage
REMOVAL OF THE CAR BODY AND THE CRAWLER CARRIERS

(TYPE WITH BOLTED UNDERCARRIAGE)
Special tools:
Hydraulic torque wrench, PN 793 374 73 + PN 793 376 73

2 x Crane
Dozer
Car body: 46,000 kg
Dogman/rigger
2.3 on page 2-37.
Remove the track groups from both crawler carriers, refer to

NOTE: Remove both track groups simultaneously.

This can be done using the same dozer.
z
Remove the travel gearboxes from both crawler carriers, refer

Lift the superstructure, refer to section 3.9.1 on page 3-257.
Attach a dozer to the car body by means of a chain.
Move the car body below the lifted superstructure using the
dozer.
NOTE: Move the car body over the unrolled track group.
Disconnect the pressure hoses (Fig. 4-87, Pos. 1) for the

track tensioning from the shut-off cocks (Fig. 4-87, Pos. 2).
NOTE: When the pressure hoses are removed, the oil inside the
piping will flow out.
z
Remove the hoses from both crawler carriers.
Fig. 4-87
4 - 80
PC5500-6
Version 2009/2
Undercarriage
Car body
Attach one crawler carrier (Fig. 4-88, Pos. 1) to two cranes at

the installed lifting eyes (Fig. 4-88, Pos. 2) and lift it up.
WARNING
in dual crane lift.
Support the car body with appropriate stands so that all of the
track rollers are clear of the track roller path.
CAUTION
Supports need to be substantial enough to carry total weight

of one crawler carrier assembly (44,000 kg) and the car body
(46,000 kg).
Fig. 4-88
NOTE: Place supports between the cross-ties (Fig. 4-89, Pos. 1)

in a manner that the mounting bolts can be removed.
Fig. 4-89
Version 2009/2
PC5500-6
4 - 81
Car body
Undercarriage
Fig. 4-90 Crawler carrier mounting bolts

4 - 82
PC5500-6
Version 2009/2
Undercarriage
Car body
Remove all mounting bolts (Fig. 4-90, Pos. M48) and the two
measuring bolts (Fig. 4-90, Pos. 7) attaching the crawler carrier assembly to the car body using the hydraulic torque
wrench PN 793 374 73 + PN 793 376 73. Discard the bolts.
NOTE: For hints using the hydraulic torque wrench refer to section 6.3.2 on page 6-9, and also refer to chapter 9 "Suppliers documentation", "AVANTI HYTORQUE".
z
Remove the crawler carrier using two cranes.

WARNING
in dual crane lift.
DANGER
When lifting the crawler carriage, make sure that nobody
Carry out the same procedure described above to remove the

second crawler carrier.
Version 2009/2
PC5500-6
4 - 83
Car body
Undercarriage
4 - 84
PC5500-6
Version 2009/2
Undercarriage
4.2.4
Car body
REPLACEMENT OF THE CAR BODY AND THE CRAWLER

CARRIERS (TYPE WITH BOLTED UNDERCARRIAGE)
Special tools:

2 x Crane
Dozer
Car body: 46,000 kg
Dogman/rigger

z
Check the coated flange plates of the new car body for intactness, refer to PARTS & SERVICE NEWS "AH07526".
NOTE: If the coating of flange plates with "INTERZINC 697" has

to be renewed, carry out the surface coating according to
section 6.3.1 on page 6-7.
To ensure an accurate coating, work has to be carried out
in an industrial environment.
z
Carry out further installation in reverse order to removal and

according to section 4.2.2 on page 4-76.
When mounting the crawler carrier to the car body, tighten the
mounting bolts according to the following procedures.
Version 2009/2
PC5500-6
4 - 85
Car body
Undercarriage

4 - 86
PC5500-6
Version 2009/2
Undercarriage
Car body
Insert new bolts (Fig. 4-91, Pos. M48) and two measuring
bolts (Fig. 4-91, Pos. 7) with resilient sleeves.
NOTE: Lubricate all bolts (Fig. 4-91, Pos. M48) with compound
"KP2K", PN 324 969 40.
Clean bottom and top surface of the resilient sleeves and
contact areas completely free of paint.
Insert the two measuring bolts (Fig. 4-91, Pos. 7) into the
upper corners.
The measuring bolts are part of the measuring device,
PN 928 476 40.
z
Pretighten the mounting bolts using the hydraulic torque

wrench PN 793 374 73 + PN 793 376 73, refer to section
6.3.2 on page 6-9.
Pretightening torque for crawler carrier mounting bolts: 2100 Nm
Determine the torque and tighten the crawler carrier mounting

bolts to the determined torque, refer to section 4.2.4.1 on
page 4-88.
NOTE: Check the torque of the crawler carrier mounting bolts

after 1000 operating hours, refer to section 4.2.4.1 on
page 4-88.
Version 2009/2
PC5500-6
4 - 87
Car body
Undercarriage
4.2.4.1 TIGHTENING TORQUE FOR THE CRAWLER CARRIER MOUNTING BOLTS

Special tools:

Measuring device, PN 928 476 40

4 - 88
PC5500-6
Version 2009/2
Undercarriage
Car body
The required tightening torque for all fastening bolts has to be

determined with the 4 measuring bolts (Fig. 4-92, Pos. 7), whose
dimension resembles the fastening bolts (Fig. 4-92, Pos. M48).
The required axial tension force of the bolts depends on the elongation of the fastening bolts.
NOTE: The tightening torque must be determined at the first
assembly of the excavator at the operation site, for the
first inspection, and after 1000 operation hours, or after
replacing either crawler carrier or car body.
The required measuring device, PN 928 476 40 is delivered with
the excavator. To determine the tightening torque, 4 specially prepared measuring bolts are supplied besides the normal fastening
bolts. The measuring bolts can be recognized by the machined
area at the end of the bolt.
The measuring device (Fig. 4-92, Pos. 1 - 6) is composed of the
following items and will be delivered with each new machine.
Refer to Fig. 4-92:
Pos.
Part name
Part number
Qty.
(1)
Angle bar
928 475 40
(2)
Dial gauge
092 706 40
(3)
Screw M5x16
502 515 98
(4)
Feeler
477 172 40
(5)
Bolt M10x25
307 777 99
(6)
Washer
517 122 98
(7)
Measuring bolt
(installed)
933 613 40
WARNING
Pre-condition:
Crawler carrier is assembled and bolts tightened to 2100 Nm
Loosen all 4 measuring bolts (Fig. 4-92, Pos. 7). Do not lubricate the measuring bolts again.
Tighten the 4 measuring bolts (Fig. 4-92, Pos. 7) to

150 Nm.
Instal the measuring device (Fig. 4-92, Pos. 1 - 6).
Set the dial gauge (Fig. 4-92, Pos. 2) to zero.
Instal the special hydraulic torque wrench,

PN 793 374 73 + PN 793 376 73, refer to section 6.3.2 on
page 6-9.
Version 2009/2
PC5500-6
4 - 89
Car body
Undercarriage
4 - 90
PC5500-6
Version 2009/2
Undercarriage
Car body
Adjust the pressure at the hydraulic torque wrench to

2100 Nm and tighten the measuring bolt (Fig. 4-93, Pos. 7).
List the pressure and the changed bolt length in a table.
Increase the pressure in steps of 10 bar until the measuring

bolts have the required elongation of 0.93 mm.
List the corresponding hydraulic pressure in a table.
Repeat this procedure for all 4 measuring bolts.
Add all 4 determined hydraulic pressures and then divide by 4

to obtain an average value.
Loosen one mounting bolt (Fig. 4-93, Pos. M48) and tighten
the bolt with the calculated average pressure.
CAUTION
Do not lubricate the bolts again.

Do not loosen more than one bolt at a time.
Repeat this procedure step by step for all the other bolts.
Version 2009/2
PC5500-6
4 - 91
Car body
4.2.5
Undercarriage
ROTARY JOINT
Fig. 4-94 Rotary joint
4 - 92
PC5500-6
Version 2009/2
Undercarriage
Car body
Legend for illustration Fig. 4-94:

(1)
Stator, housing of rotary joint
(2)
Rotor, center part of rotary joint
(3)
Cover plate
(4)
Trust washer
(5)
O-ring seal between cover plate and stator
(6)
Guide ring
(7)
Shaft seal ring between rotor and stator
(7a)
Back-up ring, O-ring
(8)
Dust seal ring
(9)
Plug
(10)
Longitudinal bores
(11)
Stator connecting ports, cross holes
(12)
Torque support lever
(13)
Rotor connecting ports
(14)
Ring grooves
The rotary distributor (rotary joint) permits a hydraulic connection

between the superstructure and the undercarriage. That means
there is an unrestricted hydraulic connection installed between
the rotating and stationary part which allows free rotation in both
slew directions.
During operation the superstructure and the undercarriage rotate
towards each other. The travel motors must be supplied with
hydraulic oil in each position in which the superstructure is slewed
against the undercarriage.
When slewing, the superstructure moves the stator (Fig. 4-94,
Pos. 1) via the torque support lever (Fig. 4-94, Pos. 12) and the
cover plate (Fig. 4-94, Pos. 3). Hydraulic hoses from the main
control valve blocks and auxiliary systems from the superstructure are connected to the stator ports (Fig. 4-94, Pos. 11). The
main pressure service lines to the travel motor are connected to
the service line ports (Fig. 4-94, Pos. A, B, C, D) at the stator
(Fig. 4-94, Pos. 1). The rotor (Fig. 4-94, Pos. 2) is fix bolted to the
undercarriage and turns in the stator (Fig. 4-94, Pos. 1) while
swinging.
Oil flows from the stator connecting ports (Fig. 4-94, Pos. A, B, C,
D) via cross holes (Fig. 4-94, Pos. 11) through ring grooves
(Fig. 4-94, Pos. 14) and longitudinal bores (Fig. 4-94, Pos. 10) of
the rotor to the outlet port (Fig. 4-94, Pos. A, B, C, D) of the rotor
(Fig. 4-94, Pos. 2). The ring grooves from the rotor are sealed
with special seal rings (Fig. 4-94, Pos. 7). Each seal ring is supported by an O-ring (Fig. 4-94, Pos. 7a). To prevent dust contamination between the rotor (Fig. 4-94, Pos. 2) and stator (Fig. 4-94,
Pos. 1), a dust seal (Fig. 4-94, Pos. 8) is mounted.
Version 2009/2
PC5500-6
4 - 93
Car body
Undercarriage
The stator is locked to the rotor axially with the trust washer
(Fig. 4-94, Pos. 4) which consists of two half segments for disassembling purposes. The stator is guided radially by the guide
rings (Fig. 4-94, Pos. 6).
4.2.5.1 REMOVAL OF THE ROTARY JOINT

Special tools:
n/a
Crane
Rotary joint: 261 kg
Dogman/rigger
2.3 on page 2-37.
z

the machine, boom, and a crane.

z

Relieve pressure in the track tensioning system, refer to the

Close the hand wheel (Fig. 4-95, Pos. 1) of main gate valve
between suction oil reservoir and main oil reservoir.
Transfuse oil from the suction oil reservoir into the main oil
PUMP".
Fig. 4-95
4 - 94
PC5500-6
Version 2009/2
Undercarriage
Car body
WARNING
Hot hydraulic oil!
heated oil.
Mark and disconnect all hydraulic hoses and pipes from the
rotary joint. Discard the O-rings of the SAE-flange connections.
NOTE: When the hydraulic lines are removed, hydraulic oil from
z
Sling rotary joint.
NOTE: The rotary joint is accessible from above, from between

the pipe work at the manifold at the center of the machine
(Fig. 4-96, arrow).
CAUTION
Move the sling carefully between the pipe work/hoses at the
manifold to prevent the pipe work from being damaged or
ripped off.
Fig. 4-96
z
Remove the mounting bolts (Fig. 4-97, Pos. 1) and remove

the torque support lever (Fig. 4-97, Pos. 2) from the rotary
joint (Fig. 4-97, Pos. 3).
Remove eight mounting bolts (Fig. 4-97, Pos. 4) and lift the
rotary joint (Fig. 4-97, Pos. 3) off the center frame (Fig. 4-97,
Pos. 5).
Lift the rotary joint up out of the superstructure and lay it down
on the ground.
DANGER

When lifting the rotary joint, make sure that nobody steps
below the weight.
Fig. 4-97
Version 2009/2
PC5500-6
4 - 95
Car body
Undercarriage
4.2.5.2 REPLACEMENT OF THE ROTARY JOINT

Special tools:
n/a
Crane
Rotary joint: 261 kg
Dogman/rigger
Instal the torque support lever to the new rotary joint

(Fig. 4-98, Pos. 3). Use new mounting bolts (Fig. 4-98,
Pos. 1) of grade 8.8.
Tightening torque for torque support lever
mounting bolts (Fig. 4-98, Pos. 1): 265 Nm
Place the new rotary joint (Fig. 4-98, Pos. 3) at the center
frame (Fig. 4-98, Pos. 5) using a crane.
DANGER

When lifting the rotary joint, make sure that nobody steps
below the weight.
Fig. 4-98
z
Apply compound "KP2K", PN 324 969 40 to new mounting

bolts (Fig. 4-98, Pos. 4) of grade 10.9, insert the mounting
bolts and tighten them to the specified tightening torque.
Tightening torque for rotary joint mounting
bolts (Fig. 4-98, Pos. 4): 265 Nm

4 - 96
PC5500-6
Version 2009/2
Attachment
5 ATTACHMENT
Version 2009/2
PC5500-6
5 -1
Backhoe
Attachment
5.1
BACKHOE
Fig. 5-1
Backhoe attachment overview
(1)
Undercarriage with car body and side frames
(2)
Superstructure
(3)
Boom
(4)
Stick
(5)
Bucket (backhoe)
(6)
Boom cylinder
(7)
Stick cylinder
(8)
Bucket cylinder
(9)
Bucket link rod
(10)
Steering rod
5 -2
PC5500-6
Version 2009/2
Attachment
Backhoe
Version 2009/2
PC5500-6
5 -3
Backhoe
5.1.1
Attachment
BOOM
5.1.1.1 REMOVAL OF THE BOOM
Fig. 5-2
5 -4
Boom, removal and installation
PC5500-6
Version 2009/2
Attachment
Backhoe

(1)
Stick cylinder
(2)
Boom cylinder
(3)
Boom
(4)
Bolt
(5)
Shackle
(6)
Pin
(7)
Bush
(8)
Seal
(9)
Bush
(10)
Seal
(11)
Bush
Special tools:
n/a

Crane
Boom: 45,100 kg
Pin boom/superstructure: 365 kg
Dogman/rigger
2.3 on page 2-37.
z

Park the machine on the prepared flat ground area and position the bucket with its flat side (underside) on the ground.

z
Use blocks and support the bucket from behind to secure the
bucket.
Version 2009/2
PC5500-6
5 -5
Backhoe
Attachment
WARNING
z

attachment.
Most of the following operations require the use of men

safety cages on elevator working platforms.
Remove the stick, refer to section 5.1.2 on page 5-20.
Support the boom with appropriate stands (Fig. 5-3, Pos. 1) of

approx. 1 m height.
Remove the boom cylinders, refer to section 5.1.1.3 on page

5-10.
Disconnect the hydraulic hoses from the boom which are

leading to the manifold, refer to section 5.1.6 on page 5-58.
NOTE: When the hoses are disconnected, the oil inside the
piping will flow out. Catch it in an oil pan.
z
Disconnect all electric wires from the boom.
Disconnect the grease feed lines leading to the boom.
Sling the boom (Fig. 5-4).
Fig. 5-3
Fig. 5-4
z
Remove the two bolts (Fig. 5-5, Pos. 1), and the shackle
(Fig. 5-5, Pos. 2) securing the pin (Fig. 5-5, Pos. 3).
Remove the pin (Fig. 5-5, Pos. 3) connecting the boom to the
superstructure.
WARNING
Sling the pin as soon as possible and support it using a

crane to prevent the pin from falling.
Fig. 5-5
5 -6
PC5500-6
Version 2009/2
Attachment
Backhoe
DANGER
When pulling the pin out of the superstructure, make sure
that the boom is fixed in its position and secured with a
crane.
Remove the boom using a crane and place it on the ground

and in an appropriate position.
DANGER

When moving the boom, make sure that nobody steps below
the lifted boom.
If required, remove all provided parts and the hydraulic piping

from the boom.
Version 2009/2
PC5500-6
5 -7
Backhoe
Attachment
5.1.1.2 REPLACEMENT OF THE BOOM

Special tools:
n/a

Crane
Boom: 45,100 kg
Dogman/rigger
WARNING
z

attachment.

NOTE: When performing the installation procedures, comply to

the following:
Always discard used seals (Fig. 5-6, Pos. 2) and install
new seals!
Insert new bushes (Fig. 5-6, Pos. 1) if required!
Apply the appropriate grease on every bush and pin on
assembly!
z

Fig. 5-6
DANGER
Never put hands into the holes when aligning the boom to
the superstructure.
Check for leaks and the cylinders operation.
5 -8
PC5500-6
Version 2009/2
Attachment
Backhoe
Version 2009/2
PC5500-6
5 -9
Backhoe
Attachment
5.1.1.3 REMOVAL OF BOOM CYLINDERS
Fig. 5-7
5 - 10
Boom cylinder, removal and installation
PC5500-6
Version 2009/2
Attachment
Backhoe

(1)
O-ring
(2)
Pipe
(3)
Boom cylinder
(4)
Superstructure
(5)
Pin
(6)
Shackle
(7)
Bolt
(8)
Pin
(9)
Catch
(10)
Shackle
(11)
Bolt
(12)
Bush
(13)
Bush
(14)
Seal
(15)
Bush
Special tools:
n/a

Crane
Oil drain pans
Boom cylinder: 6500 kg each
Pin boom cylinder/boom: 177 kg
Pin boom cylinder/superstructure: 224 kg
Dogman/rigger
2.3 on page 2-37.
NOTE: At first the wear of the bushes in the hydraulic cylinder

should be checked, refer to the PARTS & SERVICE
NEWS No. "AH08508".
WARNING
z

attachment.

Version 2009/2
PC5500-6
5 - 11
Backhoe
Attachment

bucket on the ground with the bucket cylinders in fully
extended position (Fig. 5-8).

Fig. 5-8
z

"RELIEVE THE PRESSURE IN THE HYDRAULIC SYSTEM".
Remove grease feed lines and fittings from the boom cylinder(s) to be removed.
Sling boom cylinder (piston rod side) (Fig. 5-9).
Remove the bolts (Fig. 5-9, Pos. 3) and the shackle

Remove the pin (Fig. 5-9, Pos. 2) connecting the boom cylinder to the superstructure.
WARNING
Sling the pin as soon as it is possible and support it using a

DANGER
When pulling the pin out of the superstructure, make sure
that the cylinder is fixed in its position and secured with a
crane.
Fig. 5-9
NOTE: Check bushes (Fig. 5-9, Pos. 1) for wear and damage.
Replace if required.
z
5 - 12
PC5500-6
Version 2009/2
Attachment
Backhoe
Switch S155 to Qmin and retract the boom cylinder to be

removed fully.
NOTE: Use only engine no. 2 at Qmin.

z
Retract the piston rod of the boom cylinder fully.
Tie the piston rod to the cylinder body with a wire rope.

Fig. 5-10
WARNING
Hot hydraulic oil!
DANGER
removed.
Disconnect the main hydraulic hoses from the cylinder, refer


z
Lift the boom cylinder into a horizontal position (Fig. 5-10).
Version 2009/2
PC5500-6
5 - 13
Backhoe
Attachment
Sling the other side of the cylinder additionally.
Ease the load of the pin (Fig. 5-11, Pos. 4) in the boom
(Fig. 5-11, Pos. 5) by lifting the cylinder lightly.

NOTE: The catches (Fig. 5-11, Pos. 3) are welded to the boom.
z
Remove the pin (Fig. 5-11, Pos. 4) connecting the boom cylinder to the boom.
WARNING

Fig. 5-11
DANGER
When pulling the pin out of the boom, make sure that the cylinder is fixed in its position and secured with a crane.
NOTE: Pull the pin (Fig. 5-11, Pos. 4) using two puller bolts at the
threaded holes (Fig. 5-12, Pos. 1).
(Fig. 5-12 is an example)
Fig. 5-12
z
Lower the boom cylinder to the ground and place it in an

appropriate position using a crane.
DANGER

When moving the cylinder, make sure that nobody steps
below the lifted cylinder.
Check bushes for wear and damage. Replace if required.
5 - 14
PC5500-6
Version 2009/2
Attachment
Backhoe
If required, disconnect the other boom cylinder from the boom

and remove it using the same procedure as above.
If required, remove the pipe work from the removed cylinder(s). Discard the O-rings and fit caps to the cylinder(s)
openings to avoid environmental contamination.
Version 2009/2
PC5500-6
5 - 15
Backhoe
Attachment
5.1.1.4 REPLACEMENT OF BOOM CYLINDERS

Special tools:
n/a

Crane
Boom cylinder: 6500 kg each
Dogman/rigger
WARNING
z

attachment.


the following:
Prior to assembly all bushes (Fig. 5-13, Pos. 1) must be
inspected and replaced as required, refer to the PARTS &
new seals!
assembly!
Fig. 5-13
z
Flush out and clean all the pipes.
Install the hydraulic pipe at the boom cylinder, if required.
5 - 16
PC5500-6
Version 2009/2
Attachment
Backhoe
Position the replacement cylinder using a crane (Fig. 5-14).

DANGER

Install the pin (Fig. 5-14, Pos. 4) connecting the boom cylinder to the boom.
DANGER
Never put hands into the holes when aligning the cylinder to
the boom.
NOTE: Align the pins head to the catches (Fig. 5-14, Pos. 3).
z
Install the shackle (Fig. 5-14, Pos. 2) and the bolts (Fig. 5-14,
Pos. 1) to secure the pin (Fig. 5-14, Pos. 4).
Connect the main hydraulic hoses to the boom cylinder, refer

Fig. 5-14
NOTE: Always use new O-rings at the SAE-flange connections.
Remove the wire rope from the cylinder at the side installed to
the boom.
Lower the cylinder until the piston rod points in the direction of
the mounting location at the superstructure (Fig. 5-15).
Fig. 5-15
z
Version 2009/2
PC5500-6
5 - 17
Backhoe
Attachment
Switch S155 to Qmin and retract the boom cylinder fully.

z
Remove the wire rope securing the piston rod to the boom
cylinder body.
Extend and retract the boom cylinder slowly at Qmin

23 times as far as possible to partly bleed the cylinder.
Extend the piston rod to the required position to insert the pin
(Fig. 5-16, Pos. 2) connecting the boom cylinder to the superstructure.
DANGER
the superstructure.
Fig. 5-16
Install the pin (Fig. 5-16, Pos. 2).
NOTE: Put the suitable grease into the bushes (Fig. 5-14,
Pos. 1).
z
Install the bolts (Fig. 5-14, Pos. 3) and the shackle (Fig. 5-14,
Perform the bleeding procedure for the stick cylinders.

5 - 18
PC5500-6
Version 2009/2
Attachment
Backhoe
Version 2009/2
PC5500-6
5 - 19
Backhoe
5.1.2
Attachment
STICK
5.1.2.1 REMOVAL OF THE STICK
Fig. 5-17 Stick assembly
5 - 20
PC5500-6
Version 2009/2
Attachment
Backhoe

(1)
Bucket
(2)
Bucket link rod
(3)
Bucket cylinder
(4)
Stick cylinder
(5)
Steering rod
(6)
Bushes
(7)
Bushes
(8)
Washers
(9)
Bushes
(10)
Stick
Special tools:
Thread protector PN 409 329 40

Swivel hoist ring
Crane
Stick: 19,160 kg
Pin stick/boom: 1440 kg
Nut-Cap: 48 kg
Dogman/rigger
2.3 on page 2-37.
WARNING
z

attachment.



Version 2009/2
PC5500-6
5 - 21
Backhoe
Attachment
Use blocks and support the bucket from behind to secure it.
Remove the bucket, refer to section 5.1.3.1 on page 5-36.
NOTE: Fully retract the bucket cylinders.

z
Disconnect all electric wires attached to the stick.
Disconnect the grease feeding lines leading to the stick.
Remove the pins connecting the stick cylinders to the stick,

NOTE: Support the stick cylinders (Fig. 5-18, Pos. 1) with blocks
(Fig. 5-18, Pos. 2) between stick cylinders and boom
(Fig. 5-18, Pos. 3) .
Fig. 5-18
z
Remove the pins connecting the stick cylinders to the stick,

Sling the stick (Fig. 5-19).
Fig. 5-19
z
Undo the lock of the nut-cap (Fig. 5-20, Pos. 1) at the pin connecting the stick with the boom by removing the cotter pin
(Fig. 5-20, Pos. 2) from the bore (Fig. 5-20, Pos. 3) and
removing the bolt (Fig. 5-20, Pos. 2) at next.
Insert a swivel hoist ring unto the nut-cap

(Fig. 5-20, Pos. 1) and attach it to a crane.
Fig. 5-20
5 - 22
PC5500-6
Version 2009/2
Attachment
Backhoe
Remove the nut-cap (Fig. 5-21, Pos. 2) from the pin

(Fig. 5-21, Pos. 1), then fit the "Thread Protector"
PN 409 329 40.
Pull the pin (Fig. 5-20, Pos. 4) out completely to clear boom
(Fig. 5-21, Pos. 3) and stick.
WARNING

Fig. 5-21
NOTE: Pull the pin (Fig. 5-20, Pos. 4) using two puller bolts at
the threaded holes (Fig. 5-22, Pos.1).
DANGER
When pulling the pin out of the boom, make sure that the
stick is fixed in its position and secured with a crane.
Fig. 5-22
z
Remove the stick using a crane.

DANGER

When moving the stick, make sure that nobody steps below
the lifted stick.
Lower the stick to the ground and rest it in an appropriate

position.
Remove the bucket link rod and the steering rod(s), refer to
section 5.1.4 on page 5-49 accordingly.
Remove the bucket cylinders from the stick, refer to section

5.1.3.3 on page 5-40 accordingly.
Version 2009/2
PC5500-6
5 - 23
Backhoe
Attachment
5.1.2.2 REPLACEMENT OF THE STICK

Special tools:

Swivel hoist ring
Crane
Stick: 19,160 kg
Nut-Cap: 48 kg
Dogman/rigger
WARNING
z

attachment.


the following:
new seals!
Insert new bushes (Fig. 5-23, Pos. 1) if required!
assembly!
z

Fig. 5-23
DANGER
Never put hands into the holes when aligning the stick to the
boom.
5 - 24
PC5500-6
Version 2009/2
Attachment
Backhoe
Version 2009/2
PC5500-6
5 - 25
Backhoe
Attachment
5.1.2.3 REMOVAL OF STICK CYLINDERS
Fig. 5-24 Stick cylinder, removal and installation
5 - 26
PC5500-6
Version 2009/2
Attachment
Backhoe

(1)
Stick cylinder
(2)
Stick
(3)
Boom
(4)
Bolt
(5)
Shackle
(6)
Pin
(7)
Seal
(8)
Bolt
(9)
Shackle
(10)
Catch
(11)
Pin
(12)
Pipe
(13)
O-ring
(14)
Distributor block
(15)
Bush
Special tools:
n/a

Crane
Oil drain pan
Stick cylinder: 4600 kg each
Pin stick cylinder/stick: 127 kg
Pin stick cylinder/boom: 179 kg
Dogman/rigger
2.3 on page 2-37.
WARNING
z

attachment.

At first the wear of the bushes in the hydraulic cylinders

should be checked, refer to the PARTS & SERVICE NEWS
No. "AH08508".
Version 2009/2
PC5500-6
5 - 27
Backhoe
Attachment

bucket on the ground with the cylinders in partially extended
position (Fig. 5-25).

z

Remove grease feed lines and fittings from the stick cylinder(s) to be removed.
Sling the cylinder (Fig. 5-26, Pos. 1) to be removed.
Fig. 5-25
Fig. 5-26
Remove the bolts (Fig. 5-27, Pos. 1), washers, and the
shackle (Fig. 5-27, Pos. 2) securing the pin (Fig. 5-27,
Pos. 3).
Remove the pin (Fig. 5-27, Pos. 3) connecting the stick cylinder to the stick. Remove the two seals (Fig. 5-27, Pos. 4).
WARNING

Fig. 5-27
DANGER
When pulling the pin out of the cylinder, make sure that the
cylinder is fixed in its position and secured with a crane.
5 - 28
PC5500-6
Version 2009/2
Attachment
Backhoe
Switch S155 to Qmin and retract the cylinder(s) to be removed

fully.

z
Tie the piston rod to the cylinder body with a wire rope (refer
to Fig. 5-46).

NOTE: If the stick is to be removed, put the stick cylinders

(Fig. 5-28, Pos. 1) down on blocks (Fig. 5-28, Pos. 2)
between the stick cylinders and the boom (Fig. 5-28,
Pos. 3).
Fig. 5-28
Version 2009/2
PC5500-6
5 - 29
Backhoe
Attachment
If the stick cylinder (Fig. 5-29, Pos. 6) is to be removed,

slightly lift up the cylinder to ease to load on the pin (Fig. 5-29,
Pos. 4).
WARNING
Hot hydraulic oil!

heated oil.
DANGER
removed.
Disconnect the main hydraulic hoses from the stick cylinder,

Fig. 5-29

z
Remove the bolts (Fig. 5-29, Pos. 1), the washers, and the
Pos. 4).
NOTE: The catches (Fig. 5-29, Pos. 3) are welded to the boom.
z
Remove the pin (Fig. 5-29, Pos. 4) connecting the stick cylinder to the boom (Fig. 5-29, Pos. 5).
5 - 30
PC5500-6
Version 2009/2
Attachment
Backhoe
NOTE: Pull the pin (Fig. 5-29, Pos. 4) using two puller bolts at
the threaded holes (Fig. 5-30, Pos. 1).
WARNING
DANGER
When pulling the pin out of the cylinder, make sure that the
cylinder is fixed in its position and secured with a crane.
Remove the stick cylinder using a crane.
Lower the stick cylinder to the ground and place it in an

appropriate position.
Fig. 5-30
DANGER
If required, remove the other stick cylinder from the boom

using the same procedure as above.
If required, remove the hydraulic pipe from the removed cylinder(s). Discard the O-rings and fit caps to the cylinder(s)
openings to avoid environmental contamination.
Version 2009/2
PC5500-6
5 - 31
Backhoe
Attachment
5.1.2.4 REPLACEMENT OF STICK CYLINDERS

Special tools:
n/a

Crane
Pin stick cylinder/boom: 179 kg
Dogman/rigger
WARNING
z

attachment.


the following:
Prior to assembly all bushes (Fig. 5-31, Pos. 1) must be
inspected and replaced as required, refer to the PARTS &
SERVICE NEWS No. "AH06545"!
Always discard used seals and install new seals!
assembly!
z
Insert two seals (Fig. 5-31, Pos. 2) into the bushes (Fig. 5-31,
Pos. 1) of the stick cylinder.
Flush out and clean all pipes.
Clean the mating surfaces at the cylinder mounting hole on

the boom.
If required, install the hydraulic pipe at the cylinder(s).
5 - 32
PC5500-6
Fig. 5-31
Version 2009/2
Attachment
Backhoe
Using a crane, align the replacement cylinder (Fig. 5-32,

Pos. 6).
DANGER


CAUTION
the boom.
NOTE: Align the pins head to the catches (Fig. 5-32, Pos. 3).
z
Pos. 1) with washers to secure the pin (Fig. 5-32, Pos. 4).
Fig. 5-32
Install the hydraulic pipe(s) to the stick cylinders, if required.
Connect the main hydraulic hoses to the cylinder, refer to section 5.1.6.3 on page 5-66.

z
Remove the wire rope from the piston rod.
Switch S155 to Qmin.

z
To partly bleed the new cylinders, perform the following procedure:

z
Extend the cylinders as far as possible.
Fully retract the cylinders.

WARNING
The air in the cylinder will result in slightly jerky movements

of the cylinder.
Version 2009/2
PC5500-6
5 - 33
Backhoe
Attachment
Lower the cylinder and extend the piston rod to the required
position to install the pin into the stick.
WARNING
the stick.
Install the two seals (Fig. 5-33, Pos. 4).
Install the pin (Fig. 5-33, Pos. 3) connecting the stick cylinder
to the stick.
Install the two bolts (Fig. 5-33, Pos. 1), washers, and the
shackle (Fig. 5-33, Pos. 2) to secure the pin (Fig. 5-33,
Pos. 3).
Fig. 5-33
z

5 - 34
PC5500-6
Version 2009/2
Attachment
Backhoe
Version 2009/2
PC5500-6
5 - 35
Backhoe
5.1.3
Attachment
BUCKET
5.1.3.1 REMOVAL OF THE BUCKET
Fig. 5-34 Bucket assembly

(1)
Bucket
(2)
Bucket link rod
(3)
Seal fixing ring
(4)
Seal
(5)
Seal fixing ring
(6)
Seal
5 - 36
PC5500-6
Version 2009/2
Attachment
Backhoe
Special tools:
Crane
Pin bucket/stick: 574 kg
Pin bucket/bucket link rod: 822 kg
Bucket (if lifted): 30,600 kg
Nut-cap: 35 kg
Dogman/rigger
2.3 on page 2-37.


z
Use blocks and support the bucket from behind to secure it.

Remove grease feeding line from the bucket mounting pin

and from the link rod.
Undo the locks of both the nut-caps at the bucket by removing the cotter pin (Fig. 5-35, Pos. 2) from the bore (Fig. 5-35,
Pos. 3) and removing the bolt (Fig. 5-35, Pos. 4) at next.
Insert swivel hoist rings into the nut-caps

(Fig. 5-35, Pos. 1) and attach them to a crane.
Fig. 5-35
Version 2009/2
PC5500-6
5 - 37
Backhoe
Attachment
Remove the seal fixing rings (Fig. 5-36, Pos. 1) located on

both sides of the stick and the bucket link rod.
Remove the nut-caps (Fig. 5-36, Pos. 7) from the pins

(Fig. 5-36, Pos. 3 and 4), then fit the "Thread Protector"
PN 409 329 40.
Remove the rings (Fig. 5-36, Pos. 6).

CAUTION
Tie the link rod to the stick with a wire rope to prevent it from
swinging when the pin is pulled out.
Fig. 5-36
z
Pull the pin (Fig. 5-36, Pos. 3) out completely to clear the
bucket (Fig. 5-36, Pos. 8) from the bucket link rod. Also
remove the seals (Fig. 5-36, Pos. 2) when pulling out the pin.
WARNING

Pull the pin (Fig. 5-36, Pos. 4) out completely to clear the
bucket (Fig. 5-36, Pos. 8) from the stick. Also remove the
seals (Fig. 5-36, Pos. 2) when pulling out the pin.
WARNING

Check bushes (Fig. 5-36, Pos. 5) for wear and damage.

Replace if required.
NOTE: Pull the pins using two puller bolts at the threaded holes
(Fig. 5-37, Pos. 1),
(Fig. 5-37 is an example).
z
Switch S155 to Qmin and lift the boom to clear the bucket.

z
Fig. 5-37
5 - 38
PC5500-6
Version 2009/2
Attachment
Backhoe
5.1.3.2 REPLACEMENT OF THE BUCKET

Special tools:
Crane
Bucket (if lifted): 30,600 kg
Nut-cap: 35 kg
Dogman/rigger

the following:
Always discard used seals and install new seals
(Fig. 5-38, Pos. 2 and 6)!
assembly!
z
Stick the seals (Fig. 5-38, Pos. 2) which are held by the seal
fixing rings (Fig. 5-38, Pos. 1) to both sides of the stick and
the bucket link rod using appropriate grease.
NOTE: During installation, there is not enough space to insert

these seals.
z
Fig. 5-38
Version 2009/2
PC5500-6
5 - 39
Backhoe
Attachment
5.1.3.3 REMOVAL OF BUCKET CYLINDERS
Fig. 5-39 Bucket cylinder, removal and installation
5 - 40
PC5500-6
Version 2009/2
Attachment
Backhoe

(1)
Bucket cylinder
(2)
Cylinder piston rod
(3)
Bucket link rod
(4)
Steering rod
(5)
Bolt
(6)
Shackle
(7)
Pin cylinder/stick
(8)
Nut-cap
(9)
Pin cylinder/steering rods
(10)
Seal fixing ring
(11)
Seal
(12)
Seal
(13)
Bush
(14)
Rod protection cover
(15)
Pipe
Special tools:

2 x Crane
Oil drain pan
Bucket cylinder: 3210 kg each
Pin bucket cylinder/stick: 86 kg
Pin bucket cylinder/steering rods: 865 kg
Nut-Cap: 35 kg
Rod protection cover: 360 kg
Dogman/rigger
2.3 on page 2-37.
WARNING
z

attachment.

Version 2009/2
PC5500-6
5 - 41
Backhoe
Attachment
NOTE: At first the wear of the bushes in the hydraulic cylinder

should be checked, refer to the PARTS & SERVICE
NEWS No."AH08508".
z

Park the machine on the prepared flat ground area and position the bucket on the ground as shown in Fig. 5-40, with the
bucket cylinders not fully retracted.

z
Base the stick on an appropriate stand (Fig. 5-40, Pos. 1).
Base the bucket cylinders with appropriate blocks (Fig. 5-40,

Pos. 2).

Remove grease feed lines and fittings from the cylinder(s) to

be removed.
Carry out the following two steps only if the bucket cylinder is
equipped with a rod protection cover.
z
Connect the rod protection cover (Fig. 5-41, Pos. 1) to a

crane using the shackle (Fig. 5-41, arrow).
Remove the protection cover (Fig. 5-41, Pos. 1) from the

bucket cylinder (Fig. 5-41, Pos. 2).
Fig. 5-40
Fig. 5-41
z
Undo the lock of the nut-cap at the piston rod side of the
bucket cylinder by removing the cotter pin (Fig. 5-42, Pos. 2)
from the bore (Fig. 5-42, Pos. 3) and removing the bolt
(Fig. 5-42, Pos. 4) at next.
Insert a swivel hoist ring into the nut-cap

Fig. 5-42
5 - 42
PC5500-6
Version 2009/2
Attachment
Backhoe

both sides of the cylinder piston rods (Fig. 5-43, Pos. 2).

PN 409 329 40.
Fig. 5-43
z
Sling the steering rods (Fig. 5-44, Pos. 2).
Using a crane, support the bucket link rod (Fig. 5-44, Pos. 1)
if both or the left cylinder needs to be removed.
Pull the pin (Fig. 5-44, Pos. 4) at the bucket cylinders, refer to
WARNING

Fig. 5-44
NOTE: If removing the right-hand cylinder only, pull the pin
(Fig. 5-44, Pos. 4) out just enough to clear the cylinder
piston rod.
NOTE: Pull the pin (Fig. 5-43, Pos. 4) out using two puller bolts
at the threaded holes (Fig. 5-45, Pos. 1).
Fig. 5-45
z
Switch S155 to Qmin and retract the bucket cylinder(s) to be

removed.
Version 2009/2
PC5500-6
5 - 43
Backhoe
Attachment
Tie the piston rod to the cylinder body with a wire rope
(Fig. 5-46).
Fig. 5-46
z

WARNING
Hot hydraulic oil!

heated oil.
DANGER
removed.
Disconnect the main hydraulic hoses from the cylinder(s),


5 - 44
PC5500-6
Version 2009/2
Attachment
Backhoe
Using a crane, sling the cylinder (Fig. 5-47, Pos. 1) to be

removed. Ease the load of the pin (Fig. 5-47, Pos. 2) by lifting
the cylinder lightly.
Fig. 5-47
z
Remove the two bolts (Fig. 5-48, Pos. 2), washers, and the
Pos. 4).
Remove the pin (Fig. 5-48, Pos. 4) connecting the cylinder

(Fig. 5-48, Pos. 1) to the stick. Remove the two seals
(Fig. 5-48, Pos. 5).
WARNING

Fig. 5-48
z
Remove the cylinder using a crane. Lower the cylinder to the

ground and place it in an appropriate position.
DANGER

NOTE: If required, disconnect the other bucket cylinder from the

stick and remove it using the same procedure as above.
z
If required, remove the pipe work, the connecting blocks, and

the seals from the removed cylinder(s). Discard the seals and
fit caps to the cylinder(s) openings to avoid environmental
contamination.
Version 2009/2
PC5500-6
5 - 45
Backhoe
Attachment
5.1.3.4 REPLACEMENT OF BUCKET CYLINDERS

Special tools:

2 x Crane
Bucket cylinder: 3210 kg each
Pin bucket cylinder/stick: 86 kg
Pin bucket cylinder/steering rods: 865 kg
Nut-Cap: 35 kg
Rod protection cover: 360 kg
Dogman/rigger
WARNING
z

attachment.


the following:
Prior to assembly all bushes must be inspected and
replaced as required, refer to the PARTS & SERVICE
NEWS No. "AH06545"!
assembly!
z
Flush out and clean all the pipes and connecting blocks.
5 - 46
PC5500-6
Version 2009/2
Attachment
Backhoe
On the stick at the bucket cylinder mounting hole, clean the

mating surfaces and put appropriate grease on both sides of
two new seals (Fig. 5-49, Pos. 5) and position them on both
sides of the bush.
Using a crane, support and position the replacement bucket

cylinder (Fig. 5-49, Pos. 1).
DANGER

Fig. 5-49

CAUTION
the stick.
Install the shackle (Fig. 5-49, Pos. 3), the two washers, and
the bolts (Fig. 5-49, Pos. 2) to secure the pin (Fig. 5-49,
Pos. 4).
Connect the main hydraulic hoses to the bucket cylinder(s),


z
Remove the wire rope from the piston rod.

z
To partly bleed the new cylinder, perform the following procedure 23 times:
z
Extend the cylinder as far as possible.
Fully retract the cylinder.

WARNING

of the cylinder.
Version 2009/2
PC5500-6
5 - 47
Backhoe
Attachment

5 - 48
PC5500-6
Version 2009/2
Attachment
5.1.4
Backhoe
BUCKET LINK ROD AND STEERING RODS
5.1.4.1 REMOVAL OF THE BUCKET LINK ROD

Special tools:

2 x Crane
Bucket link rod: 2280 kg
Steering rod: 1300 kg
Pin bucket cylinder/steering rod: 865 kg
Nut-cap: 35 kg
Dogman/rigger
2.3 on page 2-37.
WARNING
z

attachment.



z
Base the bucket cylinders with appropriate blocks (Fig. 5-50,

Pos. 2).
Relieve the pressure in the bucket cylinders only. Refer to the

Disconnect the grease feed lines from the bucket link rod.
Version 2009/2
PC5500-6
Fig. 5-50
5 - 49
Backhoe
Attachment
Sling the bucket link rod (Fig. 5-51, Pos. 1) and both steering
rods (Fig. 5-51, Pos. 2).
Remove the pin (Fig. 5-51, Pos. 3) at the bucket cylinders,

WARNING

At Qmin fully retract the bucket cylinder to clear the link rod.
Remove the pin (Fig. 5-51, Pos. 4) at the bucket, refer to section 5.1.3.1 on page 5-36.
Fig. 5-51
WARNING
Remove the bucket link rod (Fig. 5-51, Pos. 1) using a crane.
DANGER

When moving the bucket link rod, make sure that nobody
steps below the lifted weight.
5 - 50
PC5500-6
Version 2009/2
Attachment
Backhoe
5.1.4.2 REPLACEMENT OF THE BUCKET LINK ROD

Special tools:

2 x Crane
Nut-cap: 35 kg
Dogman/rigger
WARNING
z

attachment.

NOTE: Always discard used seals and install new seals!

replaced as required!
assembly!
z
Version 2009/2
PC5500-6
5 - 51
Backhoe
Attachment
5.1.4.3 REMOVAL OF THE STEERING RODS

Special tools:

2 x Crane
Pin steering rod/stick: 479 kg
Nut-cap: 35 kg
Dogman/rigger
2.3 on page 2-37.
WARNING
z

attachment.



z
Base the bucket cylinder with appropriate blocks (Fig. 5-52,

Pos. 2).
Relieve the pressure in the bucket cylinders only. Refer to the

Disconnect the grease feed line from the left side steering
rod.
5 - 52
PC5500-6
Fig. 5-52
Version 2009/2
Attachment
Backhoe
Sling the bucket link rod (Fig. 5-53, Pos. 1) and the steering
rod (Fig. 5-53, Pos. 2) to be removed.
NOTE: If removing the left-hand steering rod only, sling both

steering rods.
z
Remove the pin (Fig. 5-53, Pos. 3) at the bucket cylinders,

WARNING

Fig. 5-53
NOTE: If removing the right-hand steering rod only, pull the pin
out just enough to clear the steering rod.
If removing the left-hand steering rod or both steering
rods, pull out the pin completely to clear both steering
rods.
z
Undo the lock of the nut-cap at the pin (Fig. 5-53, Pos. 4) by
removing the cotter pin (Fig. 5-54, Pos. 2) from the bore
(Fig. 5-54, Pos. 3) and removing the bolt (Fig. 5-54, Pos. 4) at
next.
Insert a swivel hoist ring into the nut-cap

Fig. 5-54
z

both sides between the steering rod (Fig. 5-55, Pos. 3) and
the stick (Fig. 5-55, Pos. 5).

PN 409 329 40.
Pull the pin (Fig. 5-55, Pos. 4) out completely to clear both
steering rods.
WARNING

Version 2009/2
PC5500-6
Fig. 5-55
5 - 53
Backhoe
Attachment
NOTE: Pull the pin (Fig. 5-55, Pos. 5) out using two puller bolts
at the threaded holes (Fig. 5-56, Pos. 1).
If removing the right-hand steering rod only, pull the pin
out just enough to clear the steering rod (Fig. 5-55,
Pos. 3).
If removing the left-hand steering rod or both steering
rods, pull out the pin completely to clear both steering
rods
Fig. 5-56
z
Remove the steering rod(s) using a crane.

DANGER

When moving the steering rod, make sure that nobody steps
below the lifted weight.
5 - 54
PC5500-6
Version 2009/2
Attachment
Backhoe
5.1.4.4 REPLACEMENT OF THE STEERING RODS

Special tools:

2 x Crane
Pin steering rod/stick: 479 kg
Nut-cap: 35 kg
Dogman/rigger
WARNING
z

attachment.

NOTE: Always discard used seals and install new seals!

replaced as required!
assembly!
z
Version 2009/2
PC5500-6
5 - 55
Backhoe
5.1.5
Attachment
GROUND ENGAGING TOOLS (GET)
As ground engaging tools, the ESCO POSILOK Tooth System is

used.
Fig. 5-57 POSILOK System

(1)
Shroud
(2)
Toplok boss
(3)
Wedge
(4)
Point (tooth)
(5)
Lock
(6)
Tooth adapter (center/corner)
(7)
Pin
(8)
Wear cap
5 - 56
PC5500-6
Version 2009/2
Attachment
Backhoe
5.1.5.1 REMOVAL AND REPLACEMENT OF THE GET

Special tools:
POSILOK Pin removal tool PN 795 502 73

Hensley Pin removal tool (ask local dealer)
ESCO POSILOK Tooth System S130

Hensley Tooth System (ask local dealer)
Forklift
Point (tooth): 55 kg (ESCO)
Shroud: 337 kg (ESCO)
Tooth adapter: 182 kg (ESCO)
Dogman/rigger
CAUTION
Hazard of injuries from splinters!
When working on the locking pins, always wear hard hat,
safety glasses, steel-toed shoes, and gloves. To avoid injury
to others, keep people not directly involved well out of the
way.

the machine, bucket, and a forklift.
Park the machine on the prepared flat ground area and position the bucket in an appropriate height for work.

z
For removing and installing the ESCO Tooth System, refer to

Remove and install the Hensley Tooth System accordingly to

PARTS & SERVICE NEWS No. "AH03510", Hensley uses
basically the similar system.
NOTE: Use a forklift to remove and install the GET.
Version 2009/2
PC5500-6
5 - 57
Backhoe
5.1.6
Attachment
HYDRAULIC HOSES AT THE BACKHOE ATTACHMENT
5.1.6.1 SUBSTITUTE THE BOOM ARC HOSES
Fig. 5-58 Arc hoses, removal and installation
5 - 58
PC5500-6
Version 2009/2
Attachment
Backhoe

(1)
Hose clamp
(2)
Clamp line
(3)
Nut
(4)
Manifold
(5)
Hydraulic pipe
(6)
Hydraulic hose
(7)
Bolt
(8)
O-ring
Special tools:
n/a

Crane
Oil drain pan
Boom arc hose: 39 kg
Dogman/rigger
2.3 on page 2-37.
WARNING
Always wear a safety harness when working at the attachment.

extended and the stick cylinders in fully retracted position
(Fig. 5-59).

Fig. 5-59
Version 2009/2
PC5500-6
5 - 59
Backhoe
Attachment
Fig. 5-60 Arc hoses, removal and installation

z

5 - 60
PC5500-6
Version 2009/2
Attachment
Backhoe
Open the hose clamps (Fig. 5-60, Pos. 1) and clear the
hydraulic hose (Fig. 5-60, Pos. 6) to be removed from the
clamp lines (Fig. 5-60, Pos. 2).
WARNING
Hot hydraulic oil!

heated oil.
DANGER
removed.
Sling the hydraulic hose (Fig. 5-60, Pos. 6) to be removed.
Remove the bolts (Fig. 5-60, Pos. 7) as well as the nuts

(Fig. 5-60, Pos. 3) and disconnect the SAE-flanges from the
manifold (Fig. 5-60, Pos. 4) and from the hydraulic pipe
(Fig. 5-60, Pos. 5) at the boom.

z
Remove the hydraulic hose using a crane.
Replace the boom arc hoses by new ones and carry out
installation in reverse order to removal.
NOTE: Always replace the O-rings (Fig. 5-60, Pos. 8) at the

SAE-flange connections.
z
Substitute the other boom arc hoses if required, using the

same procedure.
Perform the bleeding procedure for all cylinders.

Check hydraulic oil level again and add oil if required.
Version 2009/2
PC5500-6
5 - 61
Backhoe
Attachment
5.1.6.2 SUBSTITUTE THE BOOM CYLINDER HOSES
Fig. 5-61 Hoses of the boom cylinders, removal and installation

(1, 2)
Hydraulic hose
(3)
Hydraulic piping at the boom cylinder
(4)
Hydraulic pipe
(5)
Guard plate
(6)
Bolt
(7)
Boom cylinder
(8)
O-ring
5 - 62
PC5500-6
Version 2009/2
Attachment
Backhoe
Special tools:
n/a

Crane
Oil drain pan
Boom cylinder hose (depending on length):
29.5 kg
39 kg
Dogman/rigger
2.3 on page 2-37.
WARNING
z

attachment.


(Fig. 5-62).

Fig. 5-62
z

Version 2009/2
PC5500-6
5 - 63
Backhoe
Attachment
Fig. 5-63 Hoses of the boom cylinders, removal and installation

z
Sling the hydraulic hose (Fig. 5-63, Pos. 1 or 2) to be

removed.
Remove the guard plate (Fig. 5-63, Pos. 5).
5 - 64
PC5500-6
Version 2009/2
Attachment
Backhoe
WARNING
Hot hydraulic oil!
heated oil.
DANGER
removed.
Remove the bolts (Fig. 5-63, Pos. 6) and disconnect the

SAE-flanges from the boom cylinder (Fig. 5-63, Pos. 7)
respective the hydraulic piping (Fig. 5-63, Pos. 3) at the boom
cylinder and from the pipe (Fig. 5-63, Pos. 4) at the boom.

z
Replace the boom cylinder hoses by new ones and carry out

z
Substitute all other boom cylinder hoses if required, using the

same procedure.
Perform the bleeding procedure for the boom cylinder(s).

Version 2009/2
PC5500-6
5 - 65
Backhoe
Attachment
5.1.6.3 SUBSTITUTE THE STICK CYLINDER HOSES
Fig. 5-64 Hoses of the stick cylinders, removal and installation

(1)
Hydraulic hose
(2)
Hydraulic hose
(3)
Hydraulic pipe
(4)
O-Ring
(5)
Bolt
5 - 66
PC5500-6
Version 2009/2
Attachment
Backhoe
Special tools:
n/a

Crane
Oil drain pan
Stick cylinder hose (depending on length):
23 kg
27.5 kg
Dogman/rigger
2.3 on page 2-37.
WARNING
z

attachment.


(Fig. 5-65).

Fig. 5-65
z

Version 2009/2
PC5500-6
5 - 67
Backhoe
Attachment
Fig. 5-66 Hoses of the stick cylinders, removal and installation

z

removed.
WARNING
Hot hydraulic oil!

heated oil.
DANGER
removed.
5 - 68
PC5500-6
Version 2009/2
Attachment
Backhoe

SAE-flanges at the stick cylinder and the hydraulic pipe

z
Replace the stick cylinder hoses by new ones and carry out

z
Substitute all other stick cylinder hoses if required, using the

same procedure.
Perform the bleeding procedure for the stick cylinder(s).

Version 2009/2
PC5500-6
5 - 69
Backhoe
Attachment
5.1.6.4 SUBSTITUTE THE BUCKET CYLINDER HOSES
Fig. 5-67 Hoses of the bucket cylinders, removal and installation

(1)
Hydraulic hose
(2)
Hydraulic hose
(3)
Hydraulic pipe
(4)
O-ring
(5)
Bolt
5 - 70
PC5500-6
Version 2009/2
Attachment
Backhoe
Special tools:
n/a

Crane
Oil drain pan
Bucket cylinder hose: 33 kg
Dogman/rigger
2.3 on page 2-37.
WARNING
z

attachment.


(Fig. 5-68).

Fig. 5-68
z

Version 2009/2
PC5500-6
5 - 71
Backhoe
Attachment
Fig. 5-69 Hoses of the bucket cylinders, removal and installation

z

removed.
WARNING
Hot hydraulic oil!

heated oil.
DANGER
removed.
5 - 72
PC5500-6
Version 2009/2
Attachment
Backhoe

SAE-flanges from the bucket cylinder and the hydraulic pipe

z
Replace the bucket cylinder hoses by new ones and carry out

z
Substitute all other bucket cylinder hoses if required, using

the same procedure.
Perform the bleeding procedure for the bucket cylinder(s).

Version 2009/2
PC5500-6
5 - 73
Face shovel
5.2
Attachment
FACE SHOVEL
Fig. 5-70 Face shovel attachment overview

(1)
Bull clam bucket (clam)
(2)
Bull clam bucket (wall)
(3)
Stick
(4)
Boom
(5)
Bucket cylinder
(6)
Boom cylinder
(7)
Stick cylinder
5 - 74
PC5500-6
Version 2009/2
Attachment
5.2.1
Face shovel
USING THE INSTALLATION TOOLS FOR HYDRAULIC CYLINDERS
Designated use:
Each hydraulic cylinder has a groove (Fig. 5-71, arrow) at each
end of the cylinder body (Fig. 5-71, Pos. 1) . Clamp the installation tool (Fig. 5-71, Pos. 2) on the hydraulic cylinder using the
groove.
Fig. 5-71
The tools are designed to handle the attachments hydraulic cylinders vertically in combination with a forklift. Thereby, the forks of
the forklift are inserted between the cylinder body and the scorpers (Fig. 5-72, Pos. 2). The tools extensions (Fig. 5-72, Pos. 1)
rest on the forks of the forklift.
This is the tools main direction of stress, indicated by "F".
DANGER
Use the installation tools in the proper way shown only!
Cylinders may only be handled vertically when using these
tools.
Misuse may result in death, serious injury, or damage to the
tools.
Version 2009/2
PC5500-6
Fig. 5-72
5 - 75
Face shovel
5.2.2
Attachment
BOOM
5.2.2.1 REMOVAL OF THE BOOM
Fig. 5-73 Boom removal

(1)
Boom
(2)
Pin
(3)
Shackle
(4)
Bolt
(5)
Shackle
(6)
Bolt
(7)
Pin
(8)
Chain hoist
5 - 76
PC5500-6
Version 2009/2
Attachment
Face shovel
Special tools:
n/a

2 x Crane
4 x Chain hoist
Oil drain pan
Boom with attached stick and boom cylinders: 52,900 kg
Dogman/rigger
2.3 on page 2-37.
WARNING
z

attachment.


bucket on the ground with the stick and the bucket cylinders
in vertical position (Fig. 5-74).

Fig. 5-74
z

Remove the stick, refer to section 5.2.3 on page 5-94.
NOTE: Leave the stick cylinders retracted and fixed to the boom.
Secure them under the boom using chain hoists.
Version 2009/2
PC5500-6
5 - 77
Face shovel
Attachment
Fig. 5-75 Boom removal

z
Tie the piston rods to the stick cylinder bodies with a wire
rope (refer to Fig. 5-46).
Disconnect the grease feeding lines leading to the boom.
Disconnect all electric wires from the boom.
Fix the boom cylinders at the boom using chain hoists

(Fig. 5-75, Pos. 8).
Attach the front part of the boom to a crane.
Remove the bolts (Fig. 5-75, Pos. 6) and the shackles

(Fig. 5-75, Pos. 5) securing the pins (Fig. 5-75, Pos. 7).
5 - 78
PC5500-6
Version 2009/2
Attachment
Face shovel
Remove the pins (Fig. 5-75, Pos. 7) attaching the boom cylinders to the superstructure. Note the seals.
WARNING

Switch S155 to Qmin and retract the boom cylinders.

z
Tie the piston rods to the boom cylinder body with a wire rope


DANGER

removed.
Disconnect all hydraulic hoses from the boom which are leading to the manifold, refer to section 5.2.6.1 on page 5-134.

z
Attach the rear part of the boom to another crane.
Remove the bolts (Fig. 5-75, Pos. 4) and the shackles

(Fig. 5-75, Pos. 3) securing the pins (Fig. 5-75, Pos. 2).
Remove the pins (Fig. 5-75, Pos. 2) attaching the boom to the
superstructure.
WARNING

Version 2009/2
PC5500-6
5 - 79
Face shovel
Attachment
Remove the boom with attached stick cylinders and boom

cylinders using two cranes. Place it on appropriate blocks.
WARNING
Make sure that the crane operators are trained in dual crane
lift.
DANGER
the lifted boom.
Carry out the next steps with the boom placed on the ground:
z
Remove the pins of the boom cylinders, refer to section

5.2.2.3 on page 5-86 and remove the boom cylinders
from the boom.
Remove the pins of the stick cylinders, refer to section

5.2.3.3 on page 5-100 and remove the stick cylinders
from the boom.
Remove all provided parts and the hydraulic piping from

the boom.
5 - 80
PC5500-6
Version 2009/2
Attachment
Face shovel
5.2.2.2 REPLACEMENT OF THE BOOM

Special tools:
n/a

2 x Crane
4 x Chain hoist
Boom with attached stick and boom cylinders: 52,900 kg
Dogman/rigger
WARNING
z

attachment.


the following:
new seals!
Insert new bushes (Fig. 5-76, Pos. 2) into the boom
(Fig. 5-76, Pos. 1) if required!
Put the appropriate grease in every bush (Fig. 5-76,
Pos. 2) on assembly!
Fig. 5-76
z
Install all provided parts and the hydraulic piping to the boom.
NOTE: Tie the piston rods to the cylinder bodies with wire ropes
z
Install the boom cylinders to the boom in reverse order to

removal, refer to section 5.1.1.4 on page 5-16.
Install the stick cylinders to the boom in reverse order to

removal, refer to section 5.1.2.4 on page 5-32.
NOTE: Make sure the hydraulic hoses are already connected to

the cylinders at this state.
Version 2009/2
PC5500-6
5 - 81
Face shovel
Attachment
Fig. 5-77 FSA boom installation

z
Fix the cylinders at the boom using chain hoists (Fig. 5-77,
Pos. 8).
Attach the boom to two cranes.

WARNING
Before lifting the boom, make sure that the crane operators
are trained in dual crane lift.
Lift the boom (Fig. 5-77, Pos. 1) with the boom and stick cylinders attached using two cranes.
NOTE: Lift the front part of the boom higher than the back part.
5 - 82
PC5500-6
Version 2009/2
Attachment
Face shovel
DANGER
the lifted boom.
Align the boom (Fig. 5-77, Pos. 1) with the superstructure.

DANGER
the superstructure.
Insert the two pins (Fig. 5-77, Pos. 2).
Detach the rear part ob the boom from the crane.
Install the shackles (Fig. 5-77, Pos. 3), and bolts (Fig. 5-77,
Pos. 4) to secure the pins (Fig. 5-77, Pos. 2).
Connect the hydraulic lines leading from the manifold to the

boom, refer to section 5.2.6.1 on page 5-134.
WARNING
Do not open the plugged hydraulic ports for the cylinders

when the wire ropes are removed, because the cylinder rods
may start sliding by their own mass.
First connect the hydraulic line, then remove the wire ropes.
Remove the wire ropes from the boom cylinders.
Align the boom cylinder to the superstructure by lifting or lowering the boom using the crane.
NOTE: Use the chain hoist (Fig. 5-77, Pos. 8) to lift or lower the
boom cylinders until they point to the mounting location at
the superstructure.
z

2...3 times as far as possible to partly bleed the cylinder.

WARNING
of the cylinder.
Version 2009/2
PC5500-6
5 - 83
Face shovel
Attachment
Extend the boom cylinder as needed to align cylinder and

superstructure.
DANGER
the superstructure.
Insert the pin (Fig. 5-77, Pos. 7).
Install the shackle (Fig. 5-77, Pos. 5) and the bolt (Fig. 5-77,
Fix the other boom cylinder using the same procedure as

above.


5 - 84
PC5500-6
Version 2009/2
Attachment
Face shovel
Version 2009/2
PC5500-6
5 - 85
Face shovel
Attachment
5.2.2.3 REMOVAL OF THE BOOM CYLINDERS
Fig. 5-78 Boom cylinder, removal and installation
5 - 86
PC5500-6
Version 2009/2
Attachment
Face shovel

(1)
Boom cylinder
(2)
Boom
(3)
Catch
(4)
Pin
(5)
Cover
(6)
Bolt
(7)
Seal
(8)
Bush
(9)
Seal
(10)
Bush
(11)
O-ring
(12)
Hydraulic hose
(13)
Bolt
(14)
Bush
(15)
Bush
(16)
Pin
(17)
Superstructure
(18)
Shackle
(19)
Bolt
Special tools:
Installation tool, PN 934 611 40

Forklift
Chain hoist
Mobile elevator working platform (telescopic or articulated boom lift)
Oil drain pan
Boom cylinder: 5680kg
Dogman/rigger
2.3 on page 2-37.
Version 2009/2
PC5500-6
5 - 87
Face shovel
Attachment
WARNING
z

attachment.


Park the machine on the prepared flat area with the superstructure turned by 90 and position the bucket on the ground
as shown (Fig. 5-79).

z

Fig. 5-79
Disconnect the grease feeding lines from the boom cylinder(s) to be removed.
Sling the lower end of the boom cylinder (Fig. 5-80, Pos. 1)
and fix it to the boom (Fig. 5-80, Pos. 2) using a chain hoist.
Remove the bolt (Fig. 5-80, Pos. 3) and the shackle

Remove the pin (Fig. 5-80, Pos. 5) attaching the boom cylinder to the superstructure. Note the seals.
WARNING

Fig. 5-80
z

z
Tie the piston rods to the boom cylinder body with a wire
rope.

5 - 88
PC5500-6
Version 2009/2
Attachment
Face shovel

WARNING
Hot hydraulic oil!

heated oil.
DANGER
removed.
Disconnect the hydraulic hoses from the boom cylinder, refer


inside the piping and the hoses will flow out. Catch it in an
oil pan.
z
Lower the boom cylinder with the chain hoist until the cylinder
is in vertical position.
Install the installation tool PN 934 611 40 at the boom cylinders upper side.
Support the boom cylinder by means of the installation tool

using the forks of the forklift.
Remove the bolts (Fig. 5-81, Pos. 1), the cover (Fig. 5-81,
Pos. 2), and the ring (Fig. 5-81, Pos. 3).
Remove the pin (Fig. 5-81, Pos. 4) with the catches

(Fig. 5-81, Pos. 5) as well as the seals (Fig. 5-82, Pos. 2) at
the boom cylinder.
WARNING

Fig. 5-81
Version 2009/2
PC5500-6
5 - 89
Face shovel
Attachment
Remove the boom cylinder using the forklift.

DANGER

When moving the boom cylinder, make sure that nobody
steps below the lifted cylinder.

the seals from the removed cylinder(s). Discard the seals and
fit caps to the cylinder(s) openings to avoid environmental
contamination.
5 - 90
PC5500-6
Version 2009/2
Attachment
Face shovel
5.2.2.4 REPLACEMENT OF THE BOOM CYLINDERS

Special tools:

Chain hoist
Forklift
Boom cylinder: 5680kg
Dogman/rigger
WARNING
z

attachment.


the following:
new seals!
Insert a new bush (Fig. 5-82, Pos. 3) into the boom cylinder (Fig. 5-82, Pos. 1) if required, refer to the PARTS &
assembly!
Fig. 5-82
z
If required, install the pipe work, the connecting blocks, and

the seals at the cylinder(s).
Install the installation tool PN 934 611 40 at the upper end of

the new boom cylinder.
Tie the moving rod to the cylinder body with a wire rope .
Version 2009/2
PC5500-6
5 - 91
Face shovel
Attachment
Sling the boom cylinder and place it on the forklift in a vertical

position so that the upper end of the cylinder is at the top and
that the cylinder is supported by means of the installation tool.
DANGER

the lifted boom.
Align the upper end of the boom cylinder with the boom using
the forklift.
DANGER
Never put hands into the holes when aligning the boom cylinder to the boom.
Insert the pin (Fig. 5-83, Pos. 4) with the catches

(Fig. 5-83, Pos. 5) and mount the seals (Fig. 5-82, Pos. 2) at
the boom cylinder.
Install the ring (Fig. 5-83, Pos. 3), the cover (Fig. 5-83,
Pos. 2), and the bolts (Fig. 5-83, Pos. 1).
Fig. 5-83
z
Sling the boom cylinder body at the piston rod side using a
chain hoist. Fix the chain hoist to the boom.
Hoist the boom cylinder and align the cylinder with the superstructure using the chain hoist.
Connect the hydraulic lines to the boom cylinder, refer to section 5.2.6.2 on page 5-138.
WARNING
Do not open the plugged hydraulic ports at the cylinder when

the wire ropes are removed, because the cylinder rod starts
sliding by its own mass.
First connect the hydraulic line, then remove the wire ropes.
Fig. 5-84

z
5 - 92
PC5500-6
Version 2009/2
Attachment
Face shovel

z
Remove the wire rope securing the piston rod of the boom
cylinder.

2...3 times as far as possible to partly bleed the cylinder.
WARNING

of the cylinder.
Extend the boom cylinder as needed to align the cylinder with

the superstructure.
DANGER
Never put hands into the holes when aligning the boom cylinder to the superstructure.
Insert the pin (Fig. 5-84, Pos. 5).
Install the shackle (Fig. 5-84, Pos. 4), and the bolt (Fig. 5-84,
Detach the chain hoist from the boom cylinder body.

Version 2009/2
PC5500-6
5 - 93
Face shovel
5.2.3
Attachment
STICK
5.2.3.1 REMOVAL OF THE STICK
Fig. 5-85 Stick, removal and installation
5 - 94
PC5500-6
Version 2009/2
Attachment
Face shovel

(1)
Boom
(2)
Stick
(3)
Bush
(4)
Seal ring
(5)
Catch
(6)
Pin
(7)
Ring
(8)
Cover
(9)
Bolt
(10)
Seal
(11)
Seal
(12)
Flange bush
(13)
Bush
(14)
Pin
(15)
Shackle
(16)
Bolt
Special tools:
n/a

Crane
2 x Chain hoist
Stick: 21,000 kg
Dogman/rigger
2.3 on page 2-37.
WARNING
z

attachment.

Version 2009/2
PC5500-6
5 - 95
Face shovel
Attachment


z

Fig. 5-86
Remove all grease feeding lines and electric wires from the
stick.
Remove the bull clam bucket, refer to section 5.2.4.1 on page

5-110.
Hook up both stick cylinders (Fig. 5-87, Pos. 1) using chain

hoists (Fig. 5-87, Pos. 2).
Carry out the following steps for each stick cylinder:

z

Remove the pin (Fig. 5-87, Pos. 3).

WARNING

NOTE: Note the seals (Fig. 5-87, Pos. 5) when removing the pin. Fig. 5-87
z
Check the bushes (Fig. 5-87, Pos. 6) and replace if

required.
Switch S155 to Qmin and retract the stick cylinders (Fig. 5-87,
Pos. 1) fully.

z

5 - 96
PC5500-6
Version 2009/2
Attachment
Face shovel
DANGER
removed.
Disconnect all hydraulic hoses from the stick leading to the

boom, refer to section 5.2.6.3 on page 5-142.
Sling the stick (Fig. 5-88, Pos. 1) and lift it using a crane.
Remove the bolts (Fig. 5-88, Pos. 2), the covers (Fig. 5-88,
Pos. 3), and the rings (Fig. 5-88, Pos. 4).
Remove the pins (Fig. 5-88, Pos. 6) with the catches

(Fig. 5-88, Pos. 5).
WARNING
Sling the pins as soon as possible and support them using a

crane to prevent the pins from falling.
Remove the stick and rest it on the ground using a crane.

DANGER

the lifted stick.
Fig. 5-88
z
Remove all provided parts and the hydraulic piping from the
stick (Fig. 5-88, Pos. 1).
Version 2009/2
PC5500-6
5 - 97
Face shovel
Attachment
5.2.3.2 REPLACEMENT OF THE STICK

Special tools:
n/a

Crane
2 x Chain hoist
Stick: 21,000 kg
Dogman/rigger
WARNING
z

attachment.


the following:
new seals!
Insert new bushes (Fig. 5-89, Pos. 2) into the stick
(Fig. 5-89, Pos. 1) if required!
Put the appropriate grease in every bush (Fig. 5-89,
Pos. 2) on assembly!
Fig. 5-89
5 - 98
PC5500-6
Version 2009/2
Attachment
Face shovel
Install all provided parts and hydraulic piping to the stick (Fig.
5-90, Pos. 1).
Sling the stick (Fig. 5-90, Pos. 1) and align it to the boom
using a crane.
DANGER

the lifted stick.
DANGER
Never put hands into the holes when aligning the stick to the
boom.
Install the pins (Fig. 5-90, Pos. 6) attaching the stick

(Fig. 5-90, Pos. 1) to the boom.
Install the catches (Fig. 5-90, Pos. 5), the rings (Fig. 5-90,
Pos. 4), the covers (Fig. 5-90, Pos. 3), and the bolts
(Fig. 5-90, Pos. 2) to secure the pins (Fig. 5-90, Pos. 6).
Bring the stick to the position shown in Fig. 5-91 using the
crane.
Switch S155 to Qmin and extend the stick cylinders (Fig. 5-91,
Pos. 1) to align the stick cylinders with the stick horizontally.
Use the chain hoists (Fig. 5-91, Pos. 2) to align the stick cylinders with the stick vertically.
Fig. 5-90

DANGER
Never put hands into the holes when aligning the stick cylinders to the stick.
Fig. 5-91
z
Put the appropriate grease in the bushes (Fig. 5-91, Pos. 6)

and install the pins (Fig. 5-91, Pos. 3) with new seals
(Fig. 5-91, Pos. 5).
Pos. 7) to secure the pins (Fig. 5-91, Pos. 3).
Version 2009/2
PC5500-6
5 - 99
Face shovel
Attachment
5.2.3.3 REMOVAL OF THE STICK CYLINDERS
Fig. 5-92 Stick cylinder, removal and installation
5 - 100
PC5500-6
Version 2009/2
Attachment
Face shovel

(1)
Stick cylinder
(2)
Boom
(3)
Stick
(4)
Seal
(5)
O-ring
(6)
Connecting block
(7)
Pipe
(8)
Pin
(9)
Seal
(10)
Bush
(11)
Bolt
(12)
Catch
(13)
Pin
(14)
Catch
(15)
Bolt
Special tools:
n/a

2 x Chain hoist
Forklift
Oil drain pan
Pin stick cylinder/boom: 90kg
Dogman/rigger
2.3 on page 2-37.
WARNING
z

attachment.

Version 2009/2
PC5500-6
5 - 101
Face shovel
Attachment


Fig. 5-93
z

Remove the grease feeding lines from the stick cylinder(s) to

be removed.
Secure the stick cylinder (Fig. 5-94, Pos. 1) to be removed

under the boom using one chain hoist at each side of the
cylinder.
Pull out the pin connecting the stick cylinder piston rod to the
stick, refer to section 5.2.3.1 on page 5-94.
WARNING

crane to prevent the pin from falling when it is pulled out
completely.
Fig. 5-94
z
Switch S155 to Qmin and retract the stick cylinder (Fig. 5-94,
Pos. 1) fully.
NOTE: Use ony engine no. 2 at Qmin.

z
Tie the piston rod to the cylinder body with a wire rope (refer
to Fig. 5-46).

5 - 102
PC5500-6
Version 2009/2
Attachment
Face shovel
WARNING
Hot hydraulic oil!
heated oil.
DANGER
removed.
Disconnect the hydraulic hoses from the stick cylinder, refer


oil pan.
z
Remove the bolts (Fig. 5-95, Pos. 1) and the catch

(Fig. 5-95, Pos. 2), securing the pin (Fig. 5-95, Pos. 3).
WARNING

crane to prevent the pin from falling when it is pulled out
completely.
NOTE: Note the seals (Fig. 5-95, Pos. 4) when removing the pin.
z
Check bush (Fig. 5-95, Pos. 5) and replace if required.
Fig. 5-95
Version 2009/2
PC5500-6
5 - 103
Face shovel
Attachment
Lower the stick cylinder into a horizontal position using the

chain hoists simultaneously.
Use the Forklift to take over the stick cylinder.
DANGER

When moving the stick cylinder, make sure that nobody
If both stick cylinders are to be removed, repeat the dismounting procedure for the second stick cylinder.

the seals from the removed cylinder(s).
Discard the seals and fit caps to the cylinder(s) openings to
avoid environmental contamination.
5 - 104
PC5500-6
Version 2009/2
Attachment
Face shovel
5.2.3.4 REPLACEMENT OF THE STICK CYLINDERS

Special tools:

Forklift
2 x Chain hoist
Pin stick cylinder/boom: 90kg
Dogman/rigger
WARNING
z

attachment.


the following:
Insert new bushes into the stick cylinder if required, refer
to the PARTS & SERVICE NEWS No. "AH06545".
assembly!
z
If required, install the pipe work, the connecting blocks, and

the seals at the cylinder(s).
Attach two chain hoists to the underside of the boom.
Tie the pistion rod of the stick cylinder to be installed to the

cylinder body with a wire rope (refer to Fig. 5-46).
Place the stick cylinder on a forklift horizontally and position

the stick cylinder right underneath the chain hoists.
Connect a chain hoist to each side ot the stick cylinder.
Version 2009/2
PC5500-6
5 - 105
Face shovel
Attachment
DANGER
When moving the stick cylinder, make sure that nobody
Pull up the stick cylinder using the chain hoists and align the
stick cylinder to the boom.
DANGER
Never put hands into the holes when aligning the stick cylinders to the boom.
Insert the pin (Fig. 5-96, Pos. 3) and the seals (Fig. 5-96,
Pos. 4).
Install the catch (Fig. 5-96, Pos. 2) and the bolts (Fig. 5-96,
Fig. 5-96
z
Connect the hydraulic hoses to the stick cylinder (Fig. 5-97,

Pos. 1) , refer to section 5.2.6.4 on page 5-146.
Switch S155 to Qmin and retract the stick cylinder (Fig. 5-97,
Pos. 1) fully.
NOTE: Use only engine no. at Qmin.

z
Remove the wire rope from the stick cylinder (Fig. 5-97,
Pos. 1).
Extend and retract the stick cylinder (Fig. 5-97, Pos. 1) slowly
at Qmin 23 times as far as possible to partly bleed the cylin- Fig. 5-97
der.
5 - 106
PC5500-6
Version 2009/2
Attachment
Face shovel
WARNING
of the cylinder.
Extend the stick cylinder slowly at Qmin and use the chain
hoist to align the stick cylinder to the stick.
DANGER
Never put hands into the holes when aligning the stick cylinder to the stick.
Install the pin connecting the stick cylinder with the stick, refer


Maintenance Manual, chapter 4, section "HYDRAULIC
SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS
Version 2009/2
PC5500-6
5 - 107
Face shovel
5.2.4
Attachment
BULL CLAM BUCKET
Fig. 5-98 Bull clam bucket, removal and installation
5 - 108
PC5500-6
Version 2009/2
Attachment
Face shovel

(1)
Bull clam bucket
(2)
Bush
(3)
Seal
(4)
Pin
(5)
Axle stirrup
(6)
Catch
(7)
Shackle
(8)
Bolt
(9)
Bush
(10)
Pin
(11)
Axle stirrup
(12)
Catch
(13)
Shackle
(14)
Bolt
(15)
Bucket cylinder
(16)
Seal
(17
Stick
(18)
Seal fixing ring
Version 2009/2
PC5500-6
5 - 109
Face shovel
Attachment
5.2.4.1 REMOVAL OF THE BULL CLAM BUCKET

Special tools:
n/a
Crane
Oil drain pan
Bucket: 35,060 kg
Pin bucket cylinder/bucket: 190 kg
Dogman/rigger
2.3 on page 2-37.


z

Fig. 5-99
Disconnect the grease feeding lines leading to the bucket.
Remove the plate (Fig. 5-100, Pos. 2) from inside the bucket
(Fig. 5-100, Pos. 1) to gain access to the assembly opening.
Fig. 5-100
5 - 110
PC5500-6
Version 2009/2
Attachment
Face shovel
WARNING
Hot hydraulic oil!
Wait until the temperature of the hydraulic oil is below 50 C.
DANGER
Disconnect the hydraulic hoses from the clam cylinder distributor blocks, refer to section 5.2.6.6 on page 5-154.

z
Remove the seal fixing rings (Fig. 5-101, Pos. 1) from the pin
(Fig. 5-101, Pos. 4) located on both sides of the cylinder
respectively the stick (Fig. 5-101, Pos. 3).
NOTE: Always use new seals (Fig. 5-101, Pos. 2).
Fig. 5-101
Version 2009/2
PC5500-6
5 - 111
Face shovel
Attachment
Fig. 5-102 Bull clam bucket removal

z
Sling the bucket cylinders (Fig. 5-102, Pos. 15) to prevent

them from swinging when the pins (Fig. 5-102, Pos. 10) are
removed.
Remove the bolts (Fig. 5-102, Pos. 14) with washers and the
shackle (Fig. 5-102, Pos. 13).
Push the pin (Fig. 5-102, Pos. 10) to the inside just enough to
remove the axle stirrups (Fig. 5-102, Pos. 11) from the
catches (Fig. 5-102, Pos. 12).
NOTE: The catches (Fig. 5-102, Pos. 12) are welded to the
bucket (Fig. 5-102, Pos. 1).
5 - 112
PC5500-6
Version 2009/2
Attachment
Face shovel
Remove the pin (Fig. 5-102, Pos. 10) to clear the bucket cylinder (Fig. 5-102, Pos. 15).
Remove the seals (Fig. 5-101, Pos. 2) when removing the
pin.
WARNING

Remove the bolts (Fig. 5-102, Pos. 8) with washers and the
shackle (Fig. 5-102, Pos. 7).
Push the pins (Fig. 5-102, Pos. 4) to the inside just enough to
remove the axle stirrups (Fig. 5-102, Pos. 5) from the catches
(Fig. 5-102, Pos. 6).
NOTE: The catches (Fig. 5-102, Pos. 6) are welded to the

bucket.
Use the assembly opening (refer to Fig. 5-100) to push
the pins.
z
Push the pins (Fig. 5-103, Pos. 1) out of the inner pin bearing
(Fig. 5-103, Pos. 2) to the outside until the stick is cleared
from the bucket.
Remove the seals (Fig. 5-101, Pos. 2) and the rings
(Fig. 5-102, Pos. 3) when removing the pin
NOTE: When the stick is cleared, the pins can maintain in the
outer pin bearings (Fig. 5-103, Pos. 3).
Fig. 5-103
z
Check bushes (Fig. 5-102, Pos. 2 and 9) for wear or damage

and replace if required.
Lift the boom and move the excavator away.
Version 2009/2
PC5500-6
5 - 113
Face shovel
Attachment
5.2.4.2 REPLACEMENT OF THE BULL CLAM BUCKET

Special tools:
n/a
n/a
Bucket: 35,060 kg
Dogman/rigger
Fig. 5-104 Bull clam bucket replacement
5 - 114
PC5500-6
Version 2009/2
Attachment
Face shovel

the following:
Insert new bushes into the stick (Fig. 5-104, Pos. 17) if
required!
assembly!
z
Stick the seals (Fig. 5-104, Pos. 16) which are held by the
seal fixing rings (Fig. 5-104, Pos. 18) to both sides of the stick
(Fig. 5-104, Pos. 17) using appropriate grease.
Also stick the seals located on both sides of the bucket cylinders to the cylinders, refer to section 5.2.4.4 on page 5-121.
NOTE: During installation, there is not enough space to insert

these seals.
z
NOTE: Perform the bleeding procedure for the clam cylinder.

z
Version 2009/2
PC5500-6
5 - 115
Face shovel
Attachment
5.2.4.3 REMOVAL OF THE BUCKET CYLINDERS
Fig. 5-105 Bucket cylinders, removal and installation
5 - 116
PC5500-6
Version 2009/2
Attachment
Face shovel

(1)
Bucket cylinder
(2)
Stick
(3)
Boom
(4)
Axle stirrup
(5)
Pin
(6)
Ring
(7)
Cover
(8)
Bolt
(9)
Bull clam bucket
(10)
Bush
(11)
Seal fixing ring
(12)
Seal
(13)
Catch
(14)
Shackle
(15)
O-ring
(16)
SAE-flange
(17)
Flange
(18)
Connecting plate
Version 2009/2
PC5500-6
5 - 117
Face shovel
Attachment
Special tools:

Crane
Forklift
Oil drain pan
Bucket cylinder: 4005 kg
Pin bucket cylinder/boom: 168 kg
Dogman/rigger
2.3 on page 2-37.
WARNING
z

attachment.


as shown (Fig. 5-106), bucket cylinders in vertical position.

z

Fig. 5-106
Disconnect the grease feeding lines from the bucket cylinder(s) to be removed.
Install the installation tool, PN 909 374 40 at the piston rod

side of the bucket cylinder,
Support the bucket cylinder by means of the installation tool

using the forks of a forklift.
5 - 118
PC5500-6
Version 2009/2
Attachment
Face shovel
Remove the bolts (Fig. 5-107, Pos. 1), the cover (Fig. 5-107,
Pos. 2), and the ring (Fig. 5-107, Pos. 3).
Remove the pin (Fig. 5-107, Pos. 4) with the catches

(Fig. 5-107, Pos. 5) as well as the seals at the bucket cylinder.
WARNING

Fig. 5-107
z
Switch S155 to Qmin and retract the bucket cylinder fully.

z
Tie the piston rods to the bucket cylinder body with a wire
rope.

WARNING
Hot hydraulic oil!

heated oil.
DANGER
removed.
Disconnect the hydraulic hoses from the bucket cylinder, refer


oil pan.
Version 2009/2
PC5500-6
5 - 119
Face shovel
Attachment
Remove the seal fixing rings (Fig. 5-108, Pos. 1) from the pin
(Fig. 5-108, Pos. 4) located on both sides of the bucket cylinder (Fig. 5-108, Pos. 3).
NOTE: Always use new seals (Fig. 5-108, Pos. 2).

z
Remove the pin connecting the bucket cylinder to the bucket,

Fig. 5-108
z
Remove the bucket cylinder using the forklift.
NOTE: Use a crane to lift the bucket cylinder from the forklift and
to lay it down on the ground.
WARNING
Do not sling the bucket cylinder at the installation tool, refer
to section 5.2.1 on page 5-75.
DANGER
When moving the bucket cylinder, make sure that nobody
5 - 120
PC5500-6
Version 2009/2
Attachment
Face shovel
5.2.4.4 REPLACEMENT OF THE BUCKET CYLINDERS

Special tools:

Crane
Forklift
Bucket cylinder: 4005 kg
Pin bucket cylinder/boom: 168 kg
Dogman/rigger
WARNING
z

attachment.


the following:
assembly!
z
Insert new bushes (Fig. 5-109, Pos. 1) into the bucket cylinder if required, refer to the PARTS & SERVICE NEWS
No. "AH06545".
Install new seals (Fig. 5-109, Pos. 2) into the bushes in the
piston rod.
Stick new seals (Fig. 5-109, Pos. 3) to bucket cylinder using

appropriate grease.
NOTE: During installation of the cylinder, there is not enough

space to insert the seals (Fig. 5-109, Pos. 3).
z
Install the installation tool, PN 909 374 40 at the piston rod

side of the new bucket cylinder.
Fig. 5-109
Sling the bucket cylinder to a crane at the piston rod side,

using the installation tool as a stop for the wire rope.
WARNING
Do not sling the wire rope to the installation tool.
Version 2009/2
PC5500-6
5 - 121
Face shovel
Attachment
Lift the bucket cylinder until it is in upright position.
Take over the bucket cylinder with a forklift, supporting the

cylinder at the installation tool with the forks of the forklift.
DANGER

When moving the bucket cylinder, make sure that nobody
Align the bucket cylinder with the bucket.

DANGER
Never put hands into the holes when aligning the bucket cylinder to the bucket.
Insert the pin (Fig. 5-110, Pos. 1) and the seals (Fig. 5-111,
Pos. 2).
Secure the pin with the axle stirrups (Fig. 5-110, Pos. 2) in the
catches (Fig. 5-110, Pos. 3).
Install the shackle (Fig. 5-110, Pos. 4) and insert the bolts
(Fig. 5-110, Pos. 5) with washers.
Fig. 5-110
z
Install the seal fixing rings (Fig. 5-111, Pos. 1) at the pin
(Fig. 5-111, Pos. 4) located on both sides of the bucket cylinder (Fig. 5-111, Pos. 3) to fix the seals (Fig. 5-111, Pos. 2).
Connect the hydraulic lines to the bucket cylinder, refer to

Fig. 5-111
z
5 - 122
PC5500-6
Version 2009/2
Attachment
Face shovel

z
Extend and retract the bucket cylinder slowly at Qmin

WARNING

of the cylinder.
Extend the bucket cylinder slowly at Qmin and align the piston
rod with the boom vertically. Use the forklift to align the stick
cylinder to the boom horizontally.
DANGER
Never put hands into the holes when aligning the bucket
cylinder to the boom.
Insert the pin (Fig. 5-112, Pos. 4) with the catches

(Fig. 5-112, Pos. 5) and mount the seals (Fig. 5-109, Pos. 2)
at the bucket cylinder.
Install the ring (Fig. 5-112, Pos. 3), the cover (Fig. 5-112,
Pos. 2), and the bolts (Fig. 5-112, Pos. 1).


Fig. 5-112

Version 2009/2
PC5500-6
5 - 123
Face shovel
Attachment
5.2.4.5 REMOVAL OF THE CLAM CYLINDERS
Fig. 5-113 Clam cylinders, removal and installation
5 - 124
PC5500-6
Version 2009/2
Attachment
Face shovel

(1)
Clam cylinder
(2)
Clam
(3)
Seal
(4)
Pin
(5)
Cover
(6)
Bolt
(7)
Bush
(8)
Seal
(9)
Bush
(10)
Hydraulic hose
(11)
O-ring
(12)
Pin
(13)
Bolt
(14)
Plate
(15)
Catch
Special tools:
n/a
Crane
Oil drain pan
Clam cylinder: 885 kg
Clam cylinders upper pin: 48 kg
Clam cylinders lower pin: 66 kg
Dogman/rigger
2.3 on page 2-37.
Version 2009/2
PC5500-6
5 - 125
Face shovel
Attachment

the machine boom and crane.
bucket horizontally on the ground (Fig. 5-114).

z

"RELIEVE THE PRESSURE IN THE HYDRAULIC SYSTEM". Fig. 5-114
Support the clam cylinder with appropriate blocks (Fig. 5-115,

arrows) to fix it in its position.
Disconnect the grease feeding lines from the clam cylinder.
Fig. 5-115
z
Remove the bolts (Fig. 5-116, Pos. 1) and the cover

(Fig. 5-116, Pos. 2) to access the pin connecting the clam cylinder to the clam.
Fig. 5-116
5 - 126
PC5500-6
Version 2009/2
Attachment
Face shovel
Remove the bolts (Fig. 5-117, Pos. 6), the cover

(Fig. 5-117, Pos. 5), and the catches (Fig. 5-117, Pos. 7).
Pull out the pin (Fig. 5-117, Pos. 4) to clear the clam cylinder
(Fig. 5-117, Pos. 2) from the clam (Fig. 5-117, Pos. 1).
Remove the seals (Fig. 5-117, Pos. 3).
Fig. 5-117
z
Switch S155 to Qmin and retract the clam cylinder to be

removed fully.

WARNING
Both clam cylinders are connected to the same hydraulic
line, so when the cleared cylinder is fully retracted, the
clam will open.
Do not open the clam.


WARNING
Hot hydraulic oil!

heated oil.
DANGER
removed.
Version 2009/2
PC5500-6
5 - 127
Face shovel
Attachment
Disconnect the hydraulic hoses from the clam cylinder, refer


Discard the O-rings.
z
Sling the clam cylinder at both ends.
Remove the bolt (Fig. 5-118, Pos. 1) and the plate (Fig. 5-118,
Pos. 2).
Pull out the pin (Fig. 5-118, Pos. 3) using pulling bolts.
Remove the clam cylinder from the bucket using a crane.

DANGER

When moving the clam cylinder, make sure that nobody
Fig. 5-118
5 - 128
PC5500-6
Version 2009/2
Attachment
Face shovel
5.2.4.6 REPLACEMENT OF THE CLAM CYLINDERS

Special tools:
n/a
Crane
Clam cylinder: 885 kg
Clam cylinders upper pin: 48 kg
Clam cylinders lower pin: 66 kg
Dogman/rigger

the following:
new seals!
Insert new bushes (Fig. 5-119, Pos. 1) into the clam cylinder if required, refer to the PARTS & SERVICE NEWS
No. "AH06545".
assembly!
Fig. 5-119
z
Insert the clam cylinder into the bucket using a crane and
align the cylinder with the bucket to insert the lower pin.
DANGER
Never put hands into the holes when aligning the clam
cylinder to the bucket.
NOTE: For easier alignment it is recommended to support the

clam cylinder at the front side and from below with appropriate blocks (Fig. 5-120, arrows) to fix it in its position.
Fig. 5-120
Version 2009/2
PC5500-6
5 - 129
Face shovel
Attachment
Insert the pin (Fig. 5-121, Pos. 3) and install the seals. Fix the
pin with the plate (Fig. 5-121, Pos. 2).
Secure the plate with the bolt (Fig. 5-121, Pos. 1).
Fig. 5-121
z
Connect the hydraulic hoses to the clam cylinder, refer to section 5.2.6.6 on page 5-154.
NOTE: Use new O-rings at the SAE-flange connections.

z
Detach the clam cylinder from the crane.

z
Extend and retract the clam cylinder slowly at Qmin

WARNING
Both clam cylinders are connected to the same hydraulic

line, so when the cleared cylinder is fully retracted, the clam
will open.
Do not open the clam.
WARNING
of the cylinder.
Extend the clam cylinder slowly at Qmin to align the cylinder

piston rod with the clam.
WARNING
Never put hands into the holes when aligning the clam
cylinder to the clam.
5 - 130
PC5500-6
Version 2009/2
Attachment
Face shovel
Insert the pin (Fig. 5-122, Pos. 4) connecting clam cylinder

(Fig. 5-122, Pos. 2) to the clam (Fig. 5-122, Pos. 1) and install
the seals (Fig. 5-122, Pos. 3).
Install the cover (Fig. 5-122, Pos. 5) and the bolts (Fig. 5-122,
Pos. 6).
Fig. 5-122
z
Perform the bleeding procedure for the clam cylinders.

Version 2009/2
PC5500-6
5 - 131
Face shovel
5.2.5
Attachment
GROUND ENGAGING TOOLS (GET)
As ground engaging tools, the ESCO POSILOK Tooth System is

used.
Fig. 5-123 GET

(1)
Shroud
(2)
Toplok boss
(3)
Wedge
(4)
Point (tooth)
(5)
Lock
(6)
Tooth adapter (center/corner)
(7)
Pin
(8)
Wear cap
5 - 132
PC5500-6
Version 2009/2
Attachment
Face shovel
5.2.5.1 REMOVAL AND REPLACEMENT OF THE GET

Special tools:
POSILOK Pin removal tool PN 795 502 73
ESCO POSILOK Tooth System S130

Forklift
Point (tooth): 55 kg (ESCO)
Shroud: 270 kg (ESCO)
Tooth adapter: 182 kg (ESCO)
Dogman/rigger
CAUTION
Hazard of injuries from splinters!
When working on the locking pins, always wear hard hat,
safety glasses steel-toed shoes, and gloves. To avoid injury
to others, keep people not directly involved well out of the
way.

the machine, bucket and a forklift.
Park the machine on the prepared flat ground area and position the bucket in an appropriate height for work.

z
For removing and installing the ESCO Tooth System, refer to

NOTE: Use a forklift to remove and install the GET.
Version 2009/2
PC5500-6
5 - 133
Face shovel
5.2.6
Attachment
HYDRAULIC HOSES AT THE FACE SHOVEL ATTACHMENT
5.2.6.1 SUBSTITUTE THE BOOM ARC HOSES
Fig. 5-124 Boom arc hoses, removal and installation

5 - 134
PC5500-6
Version 2009/2
Attachment
Face shovel

(1)
Hose clamp
(2)
Clamp line
(3)
Nut
(4)
Manifold
(5)
Hydraulic pipe
(6)
Hydraulic hose
(7)
Bolt
(8)
O-ring
Special tools:
n/a

Crane
Oil drain pan
Boom arc hose: 39 kg
Dogman/rigger
2.3 on page 2-37.
WARNING
Always wear a safety harness when working at the attachment.

Park the machine on the prepared flat area with the stick cylinder fully retracted and position the bucket horizontally on
the ground (Fig. 5-125).

Fig. 5-125
Version 2009/2
PC5500-6
5 - 135
Face shovel
Attachment
Fig. 5-126 Boom arc hoses, removal and installation

z

5 - 136
PC5500-6
Version 2009/2
Attachment
Face shovel
Open the hose clamps (Fig. 5-126, Pos. 1) and clear the
hydraulic hose (Fig. 5-126, Pos. 6) to be removed from the
clamp lines (Fig. 5-126, Pos. 2).
WARNING
Hot hydraulic oil!

heated oil.
DANGER
removed.

SAE-flanges from the manifold (Fig. 5-126, Pos. 4) and from
the hydraulic tube (Fig. 5-126, Pos. 5) at the boom.

z
Replace the boom arc hoses by new ones and carry out

z
Substitute the other boom arc hoses if required, using the

same procedure.
Perform the bleeding procedure for all cylinders.

Version 2009/2
PC5500-6
5 - 137
Face shovel
Attachment
5.2.6.2 SUBSTITUTE THE BOOM CYLINDER HOSES
Fig. 5-127 Boom cylinder hoses, removal and installation
5 - 138
PC5500-6
Version 2009/2
Attachment
Face shovel

(1)
Hydraulic hose
(2)
Hydraulic hose
(3)
Bolt
(4)
O-ring
(5)
Ring
(6)
Boom cylinder
Special tools:
n/a

Crane
Oil drain pan
Boom cylinder hose: 30.5 kg
Dogman/rigger
2.3 on page 2-37.
WARNING
z

attachment.



Fig. 5-128
Version 2009/2
PC5500-6
5 - 139
Face shovel
Attachment
Fig. 5-129 Boom cylinder hoses, removal and installation
5 - 140
PC5500-6
Version 2009/2
Attachment
Face shovel


WARNING
Hot hydraulic oil!

heated oil.
DANGER
removed.

removed.

SAE-flanges from the boom cylinder (Fig. 5-129, Pos. 6) and
from the hydraulic tube at the boom.

z
Replace the boom cylinder hoses by new ones and carry out
NOTE: Always replace the O-rings (Fig. 5-129, Pos. 4) and the
rings (Fig. 5-129, Pos. 5) at the SAE-flange connections.
z
Substitute the other boom cylinder hoses if required, using

the same procedure.
Perform the bleeding procedure for the boom cylinder(s).

Version 2009/2
PC5500-6
5 - 141
Face shovel
Attachment
5.2.6.3 SUBSTITUTE THE STICK ARC HOSES
Fig. 5-130 Stick arc hoses, removal and installation

(1)
Hydraulic hose
(2)
Hose clamp line
(3)
Bolt
(4)
O-ring
(5)
Ring
(6)
Hydraulic tube
5 - 142
PC5500-6
Version 2009/2
Attachment
Face shovel
Special tools:
n/a

Crane
Oil drain pan
Stick arc hose: 29.5 kg
Dogman/rigger
2.3 on page 2-37.
WARNING
z

attachment.



Fig. 5-131
Version 2009/2
PC5500-6
5 - 143
Face shovel
Attachment
Fig. 5-132 Stick arc hoses, removal and installation

z

5 - 144
PC5500-6
Version 2009/2
Attachment
Face shovel
Remove the hose clamp lines (Fig. 5-132, Pos. 2).

WARNING
Hot hydraulic oil!

heated oil.
DANGER
removed.

SAE-flanges from the hydraulic tubes (Fig. 5-132, Pos. 6).

z
Replace the stick arc hoses by new ones and carry out installation in reverse order to removal.
z
Substitute the other stick arc hoses if required, using the

same procedure.
Perform the bleeding procedure for the bucket and clam cylinders.
Version 2009/2
PC5500-6
5 - 145
Face shovel
Attachment
5.2.6.4 SUBSTITUTE THE STICK CYLINDER HOSES
Fig. 5-133 Stick cylinder hoses, removal and installation

(1)
Hydraulic hose
(2)
Hydraulic hose
(3)
Bolt
(4)
O-ring
(5)
Ring
5 - 146
PC5500-6
Version 2009/2
Attachment
Face shovel
Special tools:
n/a

Forklift
Oil drain pan
Stick cylinder hose (depending on length):
25 kg
27.4 kg
Dogman/rigger
2.3 on page 2-37.
WARNING
z

attachment.



Fig. 5-134
z

Version 2009/2
PC5500-6
5 - 147
Face shovel
Attachment
Fig. 5-135 Stick cylinder hoses, removal and installation
5 - 148
PC5500-6
Version 2009/2
Attachment
Face shovel

removed using a forklift.
WARNING
Hot hydraulic oil!

heated oil.
DANGER
removed.

SAE-flanges.
NOTE: When the hydraulic hose is disconnected, the oil inside

z
Remove the hydraulic hose using a forklift.
Replace the stick cylinder hoses by new ones and carry out
z
Substitute the other stick cylinder hoses if required, using the

same procedure.
Perform the bleeding procedure for the stick cylinder(s).

Version 2009/2
PC5500-6
5 - 149
Face shovel
Attachment
5.2.6.5 SUBSTITUTE THE BUCKET CYLINDER HOSES
Fig. 5-136 Bucket cylinder hoses, removal and installation

(1)
Hydraulic hose
(2)
Hydraulic hose
(3)
Bolt
(4)
O-ring
(5)
Ring
(6)
Intermediate flange
(7)
Bucket cylinder
(8)
Stick
5 - 150
PC5500-6
Version 2009/2
Attachment
Face shovel
Special tools:
n/a

Crane
Oil drain pan
Bucket cylinder hose (depending on length): 28 kg
Dogman/rigger
2.3 on page 2-37.
WARNING
z

attachment.



Fig. 5-137
z

Version 2009/2
PC5500-6
5 - 151
Face shovel
Attachment
Fig. 5-138 Bucket cylinder hoses, removal and installation

z

removed.
WARNING
Hot hydraulic oil!

heated oil.
5 - 152
PC5500-6
Version 2009/2
Attachment
Face shovel
DANGER
removed.

SAE-flanges.
z
Remove the intermediate flange (Fig. 5-138, Pos. 6) from

the cylinder when removing the bucket cylinder hose
(Fig. 5-138, Pos. 1) on the piston rod side of the bucket
cylinder (Fig. 5-138, Pos. 7).

z
Replace the bucket cylinder hoses by new ones and carry out
z
Substitute the other bucket cylinder hoses if required, using

the same procedure.
Perform the bleeding procedure for the bucket cylinder(s).

Version 2009/2
PC5500-6
5 - 153
Face shovel
Attachment
5.2.6.6 SUBSTITUTE THE CLAM CYLINDER HOSES

The clam cylinder hose set contains two hydraulic hoses at the
stick and four (two for each cylinder) hydraulic hoses at the clam
cylinders.
Substitute the clam cylinder hoses at the stick
Fig. 5-139 Clam cylinder hoses at stick, removal and installation

(1)
Hydraulic hose
(2)
Bolt
(3)
O-Ring
(4)
Ring
5 - 154
PC5500-6
Version 2009/2
Attachment
Face shovel
Special tools:
n/a
Forklift
Oil drain pan
Clam cylinder hose: 28 kg
Dogman/rigger
2.3 on page 2-37.


Fig. 5-140
z

Version 2009/2
PC5500-6
5 - 155
Face shovel
Attachment
Fig. 5-141 Clam cylinder hoses at stick, removal and installation

WARNING
Hot hydraulic oil!
heated oil.
DANGER
removed.
5 - 156
PC5500-6
Version 2009/2
Attachment
Face shovel

SAE-flanges.

z
Remove the hydraulic hose using a forklift.
Replace the clam cylinder hose by a new one and carry out
z
Substitute the other clam cylinder hose if required, using the

same procedure.
If required, substitute the clam cylinder hoses at the clam

cylinders as described in the next section on page 158.
Perform the bleeding procedure for the clam cylinders.

Version 2009/2
PC5500-6
5 - 157
Face shovel
Attachment
Substitute the clam cylinder hoses at the cylinders
Fig. 5-142 Clam cylinder hoses, removal and installation

5 - 158
PC5500-6
Version 2009/2
Attachment
Face shovel

(1)
Hydraulic hose
(2)
Hydraulic hose
(3)
Hydraulic hose
(4)
Hydraulic hose
(5)
Bolt
(6)
O-ring
(7)
Distributor block
(8)
Clam cylinder
(9)
Flange half
Special tools:
n/a
Oil drain pan

Clam cylinder hose (depending on length):
9.8 kg
8.8 kg
10 kg
11.2 kg
Dogman/rigger
2.3 on page 2-37.

the machine.

Fig. 5-143
z

Version 2009/2
PC5500-6
5 - 159
Face shovel
Attachment
Fig. 5-144 Clam cylinder hoses, removal and installation
5 - 160
PC5500-6
Version 2009/2
Attachment
Face shovel
WARNING
Hot hydraulic oil!
DANGER
scaring may result.
Remove the bolts (Fig. 5-144, Pos. 5) from the flange halves
(Fig. 5-144, Pos. 9) to disconnect the SAE-flanges from the
distributor block (Fig. 5-144, Pos. 7) and from the clam cylinder (Fig. 5-144, Pos. 8).

z
Replace the hydraulic hoses (Fig. 5-144, Pos. 1 to 4).
Replace the clam cylinder hoses by a new ones and carry out

z
Perform the bleeding procedure for the clam cylinder(s).

Version 2009/2
PC5500-6
5 - 161
Metering valves (grease injectors) at the attachment
Attachment
5.3
METERING VALVES (GREASE INJECTORS) AT THE

ATTACHMENT
5.3.1
REMOVAL OF THE METERING VALVES (GREASE INJECTORS)
Special tools:
n/a

WARNING
z

attachment.
The work requires the use of men safety cages on elevator working platforms.

the machine, boom, and mobile elevator working platform.
(Fig. 5-145).

z
Fig. 5-145
NOTE: It is described how to remove metering valves at the BHA

boom exemplarily, all other metering valves at the attachment (also FSA) are removed analogously.
z
Disconnect all grease feeding lines (Fig. 5-146, Pos. 2) from

the metering valve assemblies (Fig. 5-146, Pos. 6).
Remove the union (Fig. 5-146, Pos. 3) from the metering

valve assembly (Fig. 5-146, Pos. 6).
Remove the bolts (Fig. 5-146, Pos. 5) and remove the metering valve assemblies (Fig. 5-146, Pos. 6) from the boom
(Fig. 5-146, Pos. 1).
NOTE: Separate the metering valve assemblies (Fig. 5-146,

Pos. 6) at the union (Fig. 5-146, Pos. 4).
Fig. 5-146
5 - 162
PC5500-6
Version 2009/2
Attachment
Metering valves (grease injectors) at the attachment
Remove the adapter bolt (Fig. 5-147, Pos. 2) and remove the
valve housing (Fig. 5-147, Pos. 1) from the metering valve
assembly (Fig. 5-147, Pos. 4).
Fig. 5-147
5.3.2
REPLACEMENT OF THE METERING VALVES (GREASE INJECTORS)
Special tools:
n/a

WARNING
z

attachment.
The work requires the use of men safety cages on elevator working platforms.
Use new seals (Fig. 5-147, Pos. 3) at the valve housing

(Fig. 5-147, Pos. 1).
Check metering valves at the attachment for proper operation, refer to the Operation & Maintenance chapter 4, section
"WALK AROUND INSPECTION".
Version 2009/2
PC5500-6
5 - 163
Cylinder bypass test
5.4
Attachment
CYLINDER BYPASS TEST
Special tools:
n/a
Infrared thermometer
Oil drain pan
Hydraulic hose with 1 1/2" or 2" 6000 PSI SAE-flange

The SAE-flange size depends on the cylinder flange size, the hose
should be long enough to lead from the respective cylinder to an oil
pan.
2.3 on page 2-37.
The cylinder bypass test can be performed to check if a hydraulic

cylinder has an internal leakage.
NOTE: A cylinder with an internal leakage also has a higher temperature (at working temperature of the machine) than a
hydraulic cylinder which has no internal leakage.
WARNING
Always wear a Safety harness when working at the attachment.
NOTE: First check hydraulic cylinder temperature using an infrared thermometer if an internal leakage is assumed. If the
temperature is not higher than the temperature of the
other cylinders, another reason e.g. leakage of a valve
may be the reason for loosing pressure.
If the temperature is higher than the temperature of the
other cylinders, perform the following steps:
z

Operation & Maintenance Manual, section 3.15.1.

WARNING
Hot hydraulic oil!

heated oil.
5 - 164
PC5500-6
Version 2009/2
Attachment
DANGER
Danger of hydraulic pressure.
May result in blindness, serious injury, permanent disfigurement, or scaring.
pressure is relieved before any hydraulic lines will be
removed.
Disconnect the hydraulic hose from the piston rod side of the
respective cylinder.
NOTE: When the hydraulic hose is disconnected, the oil inside

Cap the hydraulic hose with a blind plug to avoid contamination.
z
Connect a hydraulic hose to the piston rod side of the cylinder.

Put the open end of the hose into an oil pan.

WARNING
Make sure that nobody is at close range of the hydraulic

hoses open end when extending the cylinder.
Swtich S155 to Qmin and slowly extend the hydraulic cylinder.

NOTE: The oil inside the cylinder will flow out of the hydraulic
hose connected to the piston rod side of the cylinder.
Catch it in the oil pan.
z
When the piston of the cylinder reaches its mechanical stop,

continue to extend the cylinder.
If the cylinder has an internal leakage, some oil will continously

flow out of the hydraulic hose connected to the piston rod side of
the cylinder.
If the cylinder has no internal leakage, oil will stop flowing out of
the hydraulic hose.
Version 2009/2
PC5500-6
5 - 165
Attachment
5 - 166
PC5500-6
Version 2009/2
Service Information
6 SERVICE INFORMATION
Version 2009/2
PC5500-6
6 -1
Fluids and lubricants
Service Information
6.1
FLUIDS AND LUBRICANTS
6.1.1
LUBRICANTS FOR OPERATION IN MODERATE AND HOT CLIMATES
Lubrication
Point
Lubricant
Engine Oil
Coolant
Fuel
Hydraulic System
Travel gears, Final

drives and Swing
gears
Break housings and
Motor adapter housings of Travel gears
*3) and Swing gears
*4)
Ambient
Temperature
[C]
Viscosity
Grades
Quality Grades
DIN/API
Refer to Engine Operation and

Maintenance Manual for specifications.
Hydraulic oil
HLP or
HLPD
with ZINC
anti-wear
additives *1)
Gear oil CLP
*2)
-20 to +11
22
-14 to +21
32
-6 to +31
46
0 to +40
68
+5 to +48
100
-15 to +50
CLP 220
Engine oil
or Hydraulic oil
DIN-51524
T.2 and T.3-HLP
DIN 51517
3 - CLP
SAE 10
all
HLP 32
DIN-51524
T.2 and T.3-HLP
PTO (Pump distributor gear)
Gear oil CLP

*2)
-15 to +50
CLP 150
DIN 51517
3 - CLP
Pump drive shaft

housings
Hydraulic oil
all
HLP 32
DIN-51524
T.2 and T.3-HLP
Fan bearing housings of Radiator and

Gear oil CLP
all
CLP 150
DIN 51517
3 - CLP
NOTE: *1) DO NOT mix zinc-free hydraulic oils with hydraulic

oils containing Zinc.
DO NOT mix mineral hydraulic oils with synthetic hydraulic oils. Mixing the above oils will reduce anti wear properties and oxidation stability of the oil. The oil filters in the
hydraulic system will clog quickly.
*2) Refer to the chart -gear oils- in the binder containing
volume 2 for the released gear oil qualities and viscosity
grades.
*3) Only for wet running brakes of travel gears
GFT 1300 K 1003 manufactured by L&S with a serial no.
up to and including 15025.
*4) Brake housings of swing gears manufactured by L&S
have no separate oil compartment, as brake discs are
lubricated by splash oil from the gear box.
6 -2
PC5500-6
Version 2009/2
Service Information
Point of
lubrication
Grease fittings
(manual lubrication)
Central
lubrication system
Swing circle teeth
(manual lubrication)
Swing circle pinion
lubrication system
Ambient
temperature
C
Lubricant
Viscosity
grades
Quality grades
DIN/API
Multi-purpose
grease "MPG"
Refer to the lubricant chart in the binder containing volume 2 for

the recommended multi-purpose greases. The part numbers of
recommended multi-purpose greases are listed in the parts catalogue.
Adhesive
lubricant
Refer to PARTS & SERVICE NEWS No. "AH00519"

for the recommended adhesive lubricants.
The part numbers of the recommended adhesive lubricants
are listed in the parts catalogue.
Track rollers,
carrier rollers and
guide wheels
Gear oil
"CLP"
all
CLP 220
DIN 51517
3 CLP
Geislinger couplings
Engine oil
"API"
all
SAE 15W-40
API CG-4SH
Air conditioning
system
Refrigerant
compressor
R 134a
Refrigerant
Special oil. See warning below.
The air conditioning is prepared for

refrigerant "R134a" only.
See warning below.
WARNING
The air conditioning may only be filled with refrigerant
"R134a" by authorized service specialists only. DO NOT use
refrigerant "R12", otherwise serious damage to system components could occur.
The lubrication oil for the refrigerant compressor must be
compatible with "R134a" refrigerant.
WARNING
The lubricating instructions in this book refer to the recommended grade specifications. Damages caused by using
lubricants other than specified are not covered by the manufacturers warranty.
Version 2009/2
PC5500-6
6 -3
6.1.2
Service Information
LUBRICANTS FOR OPERATION IN COLD AND ARCTIC CLIMATES

Lubrication Point
Lubricant
Ambient Temperature C
Hydraulic System
(pre-heated)
Shell Tellus Arctic 32

ESSOTRANS EXTRA
- 50 to + 35
- 50 to + 28
Travel Gears
Shell Omala HD 220
All seasons
Final Drives
Shell Omala HD 220
All seasons
Swing Gear
Shell Omala HD 220
All seasons
Track Rollers and Idler Wheels
Shell Omala HD 220
All seasons
Pump Distributor Gears

(pre-heated)
Shell Transaxle Oil 75W-90

Tranself Synthese FE 75W-90
All seasons
- 45 to + 35
Pump drive shaft housing on the

Pump Distributor Gears
Shell Tellus Arctic 32
All seasons
Brake housings *1) and

Motor adapter housing of Gears
Shell Omala HD 220
All seasons
Fan Bearing Housings of Radiators and Hydraulic Oil Coolers
Shell Omala HD 220
All seasons
Central Lubrication System
Fuchs Stabyl L-TS MO

Shell Darina XL 102 Moly
Fuchs Urethyn HGO
- 10 to + 35
- 10 to + 35
- 50 to - 10
Swing Circle Lubrication System
Shell Malleus GL 400

Shell Malleus GL 25
Fuchs Urethyn HGO
- 10 to + 35
- 30 to 0
- 50 to - 10
Refrigerant Lubricant
Shell Clavus Oil R 68
- 50 to + 35
Refrigerant
Shell R 134 a
- 50 to + 35
Engine Oil
SAE 15W-40 API Category CG-4SH
All seasons
Flexible Couplings
SAE 15W-40 API Category CG-4SH
All seasons
Engine Coolant and Fuel
Refer to Engine Operation and Maintenance Manual for specifications
NOTE: *1) For wet running brakes of travel gears

GFT 1300 K 1003 manufactured by L&S with a serial no.
up to and including 15025 only use engine oil SAE 10 or
hydraulic oil HLP 32.
6 -4
PC5500-6
Version 2009/2
Service Information
6.2
Filling capacities
FILLING CAPACITIES
Units or system
Liters (approximate)
Engine cooling system

Front engine (engine 2)
360
Rear engine (engine 1)
360
Engine oil
Front engine (engine 2) oil pan
190
Rear engine (engine 1) oil pan
190
Front engine reserve tank
580 (425 refill)
Rear engine reserve tank
580 (425 refill)
Fuel tank
10.800
Main hydraulic oil reservoir
3600*1
Complete hydraulic system
6600
Pump distributor gear (PTO), each
95
Oil collector reservoir, auxiliary hydraulic pumps
Main hydraulic pumps, drive shaft housing
1.5
Geislinger coupling
1.45
Slew gear (L&S), each
42
Motor adapter housing
0.6
Slew gear (Siebenhaar), each
60
*2
Brake housing
0.2
Travel gear (L&S, type GFT 1300 K 1003), each

2.5 *2
Brake housing
0.1 *2
Spur gear housing
10 *2
Planetary gear housing
105 *2
Support bearing
3.5 *2
NOTE: *1) Oil change quantity, including suction oil tank and
return oil collector pipes, is approx. 4450 liters (when
attachment is in oil level checking position), see oil level
gauge on the main hydraulic oil reservoir.
*2) Fill up to level gauge marking.
Version 2009/2
PC5500-6
6 -5
Filling capacities
Service Information
Units or system
Liters (approximate)
Travel gear (L&S, type GFA 305 K 1017), each
155
Travel gear (Zollern), each
180
0.5
Final drive housing
165
Guide wheel
3.2
Carrier rollers
*3
Track rollers
*3
Water tank in operators cabin
50
Water reservoir for windshield washer
NOTE: *3) Fill up to the specified level, refer to section 4.1.12 on

page 4-66.
NOTE: Capacities listed above are approximate values.
For proper checking use level plugs, dipsticks, and
inspection openings, provided for this purpose.
6 -6
PC5500-6
Version 2009/2
Service Information
Work instructions
6.3
WORK INSTRUCTIONS
6.3.1
SURFACE COATING WITH INTERZINC 697

Thinner, PN 907 886 40
Dust bonding cloths, PN 932 911 40
WARNING
z
All working procedures in coherency with the coating

compound "INTERZINC 697" must be carried out according to local regulations and standards concerning occupational health and safety.
All working procedures in coherency with the coating

compound "INTERZINC 697" must be carried out by
authorized specialists only.
CAUTION
Welding or cutting on parts which have been coated with the
coating compound "INTERZINC 697" results in harmful dusting and gassing.
Carry out welding or cutting work with personal protective
equipment only.
Dust and gases must be lead away from the workplace.
Clean the surface to be coated according to ISO 8504, purity

level 3 with thinner, PN 907 886 40.
The surface to be coated must be completely free of dirt,
grease, or oil.
NOTE: Do not use compressed air because it contains oil.

z
Plug all threads.
Set up the surface to be coated with sand paper (grain 60) or

a grinder, according to ISO 8504-1:1998.
Cover the area around the surface to be coated (e. g. with

plastic film).
Use dust bonding cloths, PN 932 911 40 to clean the surface

to be coated from grinding swarf.
NOTE: Do not use compressed air because it contains oil.

If a rust film has formed at the surface to be coated
before INTERZINC can be applied, repeat the cleaning
procedure.
Version 2009/2
PC5500-6
6 -7
Work instructions
Service Information
NOTE: INTERZINC contains of two parts, a liquid binder and

powder.
z
Pour the powder into the liquid binder while agitating.

Mixing ratio:
1 part liquid binder: 0.7 parts powder (volume)
1 part liquid binder: 4 parts powder (weight)
WARNING
Don not add liquid to the powder.
Do not water down the powder or the final coating compound.
Apply the INTERZINC compound with a clean spraygun

equipped with a 2.5 mm flat spray nozzle.
WARNING
Only use a compressed air supply without air line lubricator.
NOTE: Apply interzinc in one pass only to obtain the permissible

film thickness.
z
The specified dry paint film thickness (DFT) must be 75 m

(3.0 Mil) or 125 m (5.0 Mil) wet paint film thickness (WFT).
WARNING
Do not use brushes or paint rollers.
WARNING
z
The temperature of the surface to be coated must be at

least 10 C (50 F).
The humidity should be 50% to 60%, otherwise the hardening time will increase considerably.
The coated parts must be ventilated well while drying.

The air speed must be at least 0.1 m/s (4 in/sec).
Otherwise the coating will be cracked.
If the coating is cracked, the coating must be removed,
and the coating procedure has to be repeated.
Pay attention to the hardening time.

The hardening time depends on ambient temperature,
humidity and dry paint film thickness (DFT).
At an ambient temperature of 20 C (68 F), the hardening
takes about five days.
6 -8
PC5500-6
Version 2009/2
Service Information
6.3.2
Work instructions
REMOVE / INSTALL THE CRAWLER CARRIER
Special tools:

NOTE: Fig. 6-1 shows the following:

(Fig. 6-1, Pos. 1) Hydraulic wrench PN 793 374 73.
(Fig. 6-1, Pos. 2) Special wrench socket PN 793 376 73.
(Fig. 6-1, Pos. 3) Electro-hydraulic pump set
PN 795 922 73 (picture as example).
For information about the Electro-hydraulic pump set, refer to
chapter 9 "Suppliers documentation", "AVANTI HYTORQUE".
Fig. 6-1
Version 2009/2
PC5500-6
Hydraulic torque wrench
6 -9
Used special tools (overview)
6.4
Service Information
USED SPECIAL TOOLS (OVERVIEW)
Component
Swing circle
mounting
Track rollers
Pressure accumulators of the track

tensioning system
Part number
Part name
Qty
PN 376 792 40
Measuring jaw
PN 409 437 40
Measuring bolt
PN 409 484 40
Measuring bolt
(cold weather)
PN 376 762 40
Test block
PN 921 159 40
Safety unit for

changing track
rollers
Removal and installation of the track

rollers and guide wheel assembly
PN ???
(P&S-news under
development)
Tool for changing

track rollers
Removal and installation of the track

rollers
PN 761 520 73
Testing- and refilling

device
Refilling pressure accumulators
6 - 10
Installation of the swing circle.

Assembly of superstructure onto
undercarriage
PN 409 329 40
Thread protector
Removal and installation of the

bucket BHA
bucket cylinders BHA
steering rods BHA
Removal and installation of the stick
BHA
PN 909 374 40
Installation tool

bucket cylinders FSA
PN 923 828 40
Installation tool
Removal and installation of the stick

cylinders FSA
PN 934 611 40
Installation tool
Removal and installation of the boom

cylinders FSA
PN 793 502 73
POSILOK pin
removal tool
Removal and installation of the GET
Attachment
GET
Nature of work, remarks
PC5500-6
Version 2009/2
Service Information
Component
Part number
Part name
Qty
PN 793 376 73
Hydraulic torque
wrench
PN 793 374 73
Wrench socket with

supporting bar
PN 793 375 73
Electro-hydraulic
pump set
PN 928 476 40
Measuring device
Sprocket
locally made
(refer to PARTS &
SERVICE NEWS
No. "AH05511")
Assembly tool for

dual-cone seals
Installation of new dual-cone seals
Hydraulic system
(general)
PN 232 315 40
Hydraulic testing kit
Measurements of hydraulic pressures
PN 793 788 730
Rotational speed
infrared probe
DS03s
Measurements of rotation fan speed
PN 232 521 40
65 mm hexagon
impact socket
wrench (1 1/2")
PN 232 615 40
Hydraulic torque
wrench (7800 Nm)
PN 795 922 73
Electro-hydraulic
pump set
PN 232 264 40
55 mm hexagon
impact socket
wrench (1")
PN 232 615 40
Hydraulic torque
wrench (7800 Nm)
PN 795 922 73
Electro-hydraulic
pump set
PN 232 265 40
46 mm hexagon
impact socket
wrench (1")
PN 232 615 40
Hydraulic torque
wrench (7800 Nm)
PN 795 922 73
Electro-hydraulic
pump set
Car body/crawler
carrier
Nature of work, remarks
Removal and installation of the car

body/crawler carrier
Installation of the crawler carriers
Radiator fan
assembly
Radiator fan drive
pump
drive pump
assembly
Counterweight
Superstructure
Fuel tank
Version 2009/2
PC5500-6
Removal and installation of the counterweight

superstructure
Removal and installation of the fuel

tank
6 - 11
Service Information
6 - 12
PC5500-6
Version 2009/2
Tools catalogue
7 TOOLS CATALOGUE
Version 2009/2
PC5500-6
7 -1
Tools catalogue
7 -2
PC5500-6
Version 2009/2
Tools and Accessories

Werkzeuge und Zubehr
th
Release: November 11 , 2009

Ausgabe: 11. November 2009
Content / Inhalt
Page No.
Seite
Section 1
Assembly Tools for Screws and Nuts
Gruppe 1
Schraubwerkzeuge
Section 2
Pliers
16
Gruppe 2
Zangen
16
Section 3
Metal Working Tools
19
Gruppe 3
Werkzeuge fr die Metallbearbeitung
19
Section 4
Measuring Tools
22
Gruppe 4
Messwerkzeuge
22
Section 5
Data Transfer and IT Tools
30
Gruppe 5
Datenbertragung und IT-Zubehr
30
Section 6
Others
33
Gruppe 6
Sonstiges
33
Section 7
Paint and Accessories
38
Gruppe 7
Lackiermaterialien
38
Section 8
Auxiliaries, Cleaner, Adhesive & Sealant
40
Gruppe 8
Hilfsstoffe, Reiniger, Kleber
40
Part-No.
Description
ET-Nr.
Gegenstand
Release:
Ausgabe:
th
November 11 , 2009
11. November 2009
Combination wrenches, single

Gabelringschlssel, einzeln
232 001 40
232 002 40
232 002 40
232 003 40
232 004 40
232 005 40
232 006 40
232 007 40
232 008 40
232 009 40
232 010 40
232 011 40
232 012 40
323 013 40
232 014 40
232 015 40
232 016 40
232 017 40
232 018 40
232 019 40
232 557 40
SW 6
SW 7
SW 7
SW 8
SW 9
SW 10
SW 11
SW 12
SW 13
SW 14
SW 15
SW 17
SW 19
SW 22
SW 24
SW 27
SW 30
SW 32
SW 36
SW 41
SW 46
Combination wrenches, single
Gabelringschlssel, einzeln
232 432 40
232 433 40
232 434 40
232 435 40
232 436 40
232 437 40
232 438 40
232 439 40
232 440 40
232 441 40
232 442 40
232 443 40
232 444 40
232 445 40
232 446 40
232 447 40
SW 1/4
SW 5/16
SW 3/8
SW 7/16
SW 1/2
SW 9/16
SW 5/8
SW 11/16
SW 3/4
SW 13/16
SW 7/8
SW 15/16
SW 1
SW 11/16
SW 11/8
SW 11/4
991-1010
Tools
Werkzeug
Schraubwerkzeuge
Section / Gruppe 1
Page / Seite
Continued / Fortsetzung
3
4
Part-No.
Description
ET-Nr.
Gegenstand
Release:
Ausgabe:
th
November 11 , 2009
11. November 2009
Special ring wrench open

Spezial-Ringschlssel offen
232 305 40
232 306 40
232 307 40
232 308 40
SW 41
SW 46
SW 50
SW 60
Double ended open wrenches, single

Doppelgabelschlssel, einzeln
232 020 40
232 021 40
232 022 40
232 023 40
232 024 40
232 025 40
232 026 40
232 027 40
232 028 40
232 029 40
232 030 40
232 031 40
232 032 40
232 033 40
SW 6 x 7
SW 8 x 9
SW 10 x 11
SW 12 x 13
SW 14 x 15
SW 16 x 17
SW 18 x 19
SW 20 x 22
SW 21 x 23
SW 24 x 27
SW 25 x 28
SW 30 x 32
SW 36 x 41
SW 50 x 55
Single ended open wrenches, single
Einfachgabelschlssel, einzeln
232 361 40
232 211 40
232 212 40
232 213 40
232 214 40
232 215 40
232 362 40
232 216 40
232 363 40
232 217 40
SW 41
SW 46
SW 50
SW 55
SW 60
SW 65
SW 70
SW 75
SW 80
SW 85
991-1010
Tools
Werkzeug
Schraubwerkzeuge
Section / Gruppe 1
Page / Seite
4
5
Part-No.
Description
ET-Nr.
Gegenstand
Release:
Ausgabe:
th
November 11 , 2009
11. November 2009
Hook wrenches, single

Hakenschlssel, einzeln
232 275 40
232 276 40
232 277 40
232 278 40
232 279 40
232 280 40
120 130 mm
155 165 mm
180 195 mm
205 220 mm
260 270 mm
280 300 mm
Push-pull ratchet
Knarre
232 337 40
232 047 40
232 562 40
232 563 40
1/4
1/2
3/4
1
Reversible ratchet
Umschaltknarre 1 x 660 mm (26)
232 380 40
232 218 40
3/4 x 620 mm
1 x 660 mm (26)
Torque wrench
Drehmomentschlssel
232 262 40
232 285 40
232 477 40
232 478 40
232 379 40
232 304 40
232 220 40
232 221 40
7 32 mkp
30 75 mkp
50 130 mkp
80 200 mkp
3/4 x 200 mm
3/4 x 430 mm
1 x 250 mm (8)
1 x 405 mm (16)
70 320 Nm
300 750 Nm
500 1300 Nm
800 2000 Nm
991-1010
Tools
Werkzeug
Schraubwerkzeuge
Section / Gruppe 1
Page / Seite
5
6
Part-No.
Description
ET-Nr.
Gegenstand
Release:
Ausgabe:
232 285 40
th
November 11 , 2009
11. November 2009
Torque wrench with scale

DSG-5S, measuring range: 300 - 750Nm
Drehmomentschlssel mit Skala
DSG-5S, Messbereich: 300 - 750 Nm
232 477 40

DSG-6S, measuring range: 500 - 1300 Nm
232 478 40

DSG-7S measuring range: 800 - 2000 Nm
232 681 40
Elbow socket, 28/5 - 3/4 x 70

Einsteck-Winkelstck, 28/5 - 3/4 x 70
232 682 40
Elbow socket, 28/6 - 7; 1 x 70

Einsteck-Winkelstck, 28/6 - 7; 1 x 70
232 574 40
Reducer socket, 1 1/2 - 1

Reduzierstck, 1 1/2 - 1
232 577 40
Extension socket, 1 1/2 - 1

Vergrerungsstck, 1 1/2 - 1
Sliding & tommy bar
Griff mit Gleitstck
232 339 40
232 050 40
232 303 40
232 219 40
1/4
1/2 x 290 mm (12)
3/4 x 500 mm (20)
1 x 640 mm (25)
991-1010
Tools
Werkzeug
Schraubwerkzeuge
Section / Gruppe 1
Page / Seite
6
7
Part-No.
Description
ET-Nr.
Gegenstand
Release:
Ausgabe:
th
November 11 , 2009
11. November 2009
Universal joint
Kardangelenk
232 051 40
1/2
Socket wrench 1/4", single
Stecknuss, 1/4, einzeln
232 326 40
232 327 40
232 328 40
232 329 40
232 330 40
232 331 40
232 332 40
232 333 40
232 334 40
232 335 40
232 336 40
SW 4
SW 4,5
SW 5
SW 5,5
SW 6
SW 7
SW 8
SW 9
SW 10
SW 11
SW 13
Socket wrench, 1/2, single
Steckschlsseleinsatz, 1/2, einzeln
232 034 40
232 035 40
232 036 40
232 037 40
232 038 40
232 039 40
232 040 40
232 041 40
232 042 40
232 340 40
232 043 40
232 044 40
232 045 40
232 046 40
SW 9
SW 10
SW 11
SW 12
SW 13
SW 14
SW 15
SW 17
SW 19
SW 21
SW 24
SW 27
SW 30
SW 32
991-1010
Tools
Werkzeug
Schraubwerkzeuge
Section / Gruppe 1
Page / Seite
7
8
Part-No.
Description
ET-Nr.
Gegenstand
Release:
Ausgabe:
th
November 11 , 2009
11. November 2009

232 448 40
232 449 40
232 450 40
232 451 40
232 452 40
232 453 40
232 454 40
232 455 40
232 456 40
232 457 40
232 458 40
232 459 40
232 460 40
232 461 40
232 462 40
232 463 40
232 464 40
232 465 40
SW 3/8
SW 13/32
SW 7/16
SW 1/2
SW 9/16
SW 19/32
SW 5/8
SW 11/16
SW 3/4
SW 25/32
SW 13/16
SW 7/8
SW 15/16
SW 1
SW 1 1/16
SW 1 1/8
SW 1 3/16
SW 1 1/4
232 369 40
232 370 40
232 371 40
232 372 40
232 373 40
232 374 40
232 375 40
232 376 40
232 377 40
232 378 40
SW 22
SW 24
SW 27
SW 30
SW 32
SW 36
SW 38
SW 41
SW 46
SW 50
991-1010
Tools
Werkzeug
Schraubwerkzeuge
Section / Gruppe 1
Page / Seite
8
9
Part-No.
Description
ET-Nr.
Gegenstand
Release:
Ausgabe:
th
November 11 , 2009
11. November 2009
Socket wrench, 1, single

Steckschlsseleinsatz, 1, einzeln
232 223 40
232 224 40
232 225 40
232 226 40
232 227 40
232 228 40
232 229 40
232 230 40
232 231 40
232 232 40
SW 36
SW 41
SW 46
SW 50
SW 55
SW 60
SW 65
SW 70
SW 75
SW 80
232 569 40
Extra deep socket wrench for grease nipple of grease cylinder

1/2, long, SW 27
Steckschlsseleinsatz fr Schmiernippel am
Schmierzylinder 1/2, lang, SW 27
Internal hexagon socket, 1/2 , single

Innensechskant Steckschlsseleinsatz, 1/2, einzeln
232 052 40
232 053 40
232 054 40
232 055 40
232 056 40
232 057 40
232 058 40
232 059 40
232 060 40
SW 5
SW 6
SW 7
SW 8
SW 9
SW 10
SW 12
SW 14
SW 17
Internal hexagon socket, 1/2", single
Innensechskant Steckschlsseleinsatz, 1/2, einzeln
232 423 40
232 424 40
232 425 40
232 426 40
232 427 40
232 428 40
232 429 40
232 430 40
232 431 40
SW 3/16
SW 7/32
SW 1/4
SW 9/32
SW 5/16
SW 3/8
SW 1/2
SW 9/16
SW 5/8
991-1010
Tools
Werkzeug
Schraubwerkzeuge
Section / Gruppe 1
Page / Seite
9
10
Part-No.
Description
ET-Nr.
Gegenstand
Release:
Ausgabe:
th
November 11 , 2009
11. November 2009
Internal hexagon socket, 1/2, single

Innensechskant-Steckschlsseleinsatz, 1/2, einzeln
232 341 40
232 342 40
232 343 40
232 344 40
232 345 40
232 346 40
SW 5 x 180 mm
SW 6 x 90 mm
SW 8 x 120 mm
SW 10 x 140 mm
SW 12 x 140 mm
SW 14 x 140 mm
Internal hexagon socket, 3/4
Innensechskant Steckschlsseleinsatz, 3/4
232 347 40
232 348 40
232 349 40
232 350 40
SW 14
SW 17
SW 19
SW 22
Internal hexagon socket,1
Innensechskant Steckschlsseleinsatz, 1
232 351 40
232 352 40
232 353 40
SW 19
SW 22
SW 24
Internal Torx socket
Innen-Torx Steckschlsseleinsatz
232 597 40
232 598 40
232 599 40
232 600 40
232 601 40
232 602 40
232 603 40
SW 4 5
SW 4,5 5
SW 4,5 5 6
SW 6 7
SW 7 8
SW 8 10
SW 10
991-1010
Tools
Werkzeug
Schraubwerkzeuge
Section / Gruppe 1
Page / Seite
10
11
Part-No.
Description
ET-Nr.
Gegenstand
Release:
Ausgabe:
th
November 11 , 2009
11. November 2009
External Torx socket

Auen-Torx Steckschlsseleinsatz
232 604 40
232 605 40
232 606 40
232 607 40
232 608 40
232 609 40
232 610 40
SW 4
SW 5
SW 6
SW 6 7
SW 8
SW 10
SW 12
Reducing socket
Reduzierstck
232 573 40
232 096 40
232 574 40
1 3/4
3/4 1/2
1 1/2 1
Expansion socket
Vergrerungsstck
232 575 40
232 576 40
232 577 40
1/2 3/4
3/4 1
1 1 1/2
232 146 40
Strap wrench (fuel-water filter)

Bandschlssel (Kraftstoff-Wasserfilter)
232 511 40
Torque multiplier max. 2700 Nm (2000 lbf-ft)

Drive 3/4
Reduction 1 : 5
Drehmomentvervielfltiger max. 2700 Nm
Antrieb 3/4
Untersetzung 1 : 5
Electric torque wrench
Elektroschrauber
232 611 40
232 612 40
600 2.800
1600 7.000
991-1010
Tools
Werkzeug
Schraubwerkzeuge
Section / Gruppe 1
Page / Seite
11
12
Part-No.
Description
ET-Nr.
Gegenstand
Release:
Ausgabe:
th
November 11 , 2009
11. November 2009
Hydraulic torque wrench

Hydraulikschrauber
232 614 40
232 615 40
0 4500
0 7800
Electro-hydraulic pump aggregate, 220 Volt/800 bar

Elektro-hydraulisches Pumpenaggregat, 220 Volt/800 bar
232 613 40
5 bar
232 269 40
232 366 40
232 367 40
232 097 40
SW 75
SW 80
SW 85
3 15 mkp
232 718 40
Electro-hydraulic pump set, assy
30 150 Nm
Hydraulikaggregat, Satz
793 375 73
Electro-hydraulic pump
Hydraulikaggregat
232 719 40
Transportation box
Transportbox
793 374 73
Servo screw driver for side member assembly

Kraftschrauber fr Seitentrgermontage
793 376 73
Servo screw driver assembly

Kraftschrauber-Aggregat
795 923 73
High pressure hose DN6 x 10000

Hochdruckschlauch DN6 x 10000
Additional equipment / Zusatzteile
232 749 40
Reaction arm
Reaktionsarm
232 750 40
Fixing screw for the reaction arm

Fixierschraube fr den Reaktionsarm
991-1010
Tools
Werkzeug
Schraubwerkzeuge
Section / Gruppe 1
Page / Seite
12
13
Part-No.
Description
ET-Nr.
Gegenstand
Release:
Ausgabe:
232 687 40
th
November 11 , 2009
11. November 2009
Electro-hydraulic aggregate, 230 Volt, for servicing

undercarriage and slew ring.
Max. pressure output 700 bar (10000 psi), double acting, with
wired remote control for the motor
Elektro-hydraulisches Aggregat, 230 Volt, fr die Fahrwerks- und
Zahnkranzwartung.
Max. Betriebsdruck 700 bar, doppelt wirkend, mit
Kabelfernsteuerung fr den Motor
Impact socket wrench, 1, single

Kraftschrauberstecknuss 1, einzeln
232 264 40
232 515 40
232 516 40
232 265 40
232 266 40
232 267 40
232 494 40
232 268 40
SW 36
SW 38
SW 41
SW 46
SW 50
SW 55
SW 60
SW 65
Impact socket wrench, 1 "
Kraftschrauberstecknuss 1 1/2
232 517 40
232 518 40
232 519 40
232 520 40
232 521 40
SW 46
SW 50
SW 55
SW 60
SW 65
Impact internal hexagon socket, 1", single
Kraftschrauberstecknuss Innensechskant, 1 ", einzeln
232 765 40
232 766 40
232 767 40
232 768 40
232 769 40
232 770 40
SW 19
SW 22
SW 24
SW 27
SW 32
SW 36
Screwdriver for slotted screws
Schraubendreher fr Schlitzschrauben
232 120 40
232 121 40
11 x 300 mm
13 x 390 mm
991-1010
Tools
Werkzeug
Schraubwerkzeuge
Section / Gruppe 1
Page / Seite
13
14
Part-No.
Description
ET-Nr.
Gegenstand
Release:
Ausgabe:
th
November 11 , 2009
11. November 2009
Screwdriver, insulated up to 1000 Volt

Schraubendreher, isoliert bis 1000 Volt
232 391 40
232 392 40
232 393 40
232 394 40
232 395 40
2,5 X 75 mm
3,5 x 100 mm
4 x 100 mm
5,5 x 125 mm
6,5 x 150 mm
Crosstip screwdriver, insulated up to 1000 Volt
Kreuzschlitzschraubendreher, isoliert bis 1000 Volt
232 397 40
232 398 40
232 399 40
Gre / size 0
Gre / size 1
Gre / size 2
232 208 40
Screw extractor kit with spiral drills to remove damaged or

broken screws
Schraubenausdrehersatz mit Spiralbohrern zum Entfernen
beschdigter oder abgebrochener Schrauben
Allen head wrench L type, single

Innensechskantschlssel, einzeln
232 066 40
232 067 40
232 068 40
232 069 40
232 070 40
232 071 40
232 072 40
232 073 40
232 074 40
232 075 40
232 076 40
232 077 40
232 078 40
232 079 40
232 080 40
232 081 40
232 082 40
232 354 40
232 355 40
232 356 40
SW 2
SW 2,5
SW 3
SW 4
SW 5
SW 6
SW 7
SW 8
SW 9
SW 10
SW 12
SW 14
SW 17
SW 19
SW 22
SW 24
SW 27
SW 30
SW 32
SW 36
991-1010
Tools
Werkzeug
Schraubwerkzeuge
Section / Gruppe 1
Page / Seite
14
15
Part-No.
Description
ET-Nr.
Gegenstand
Release:
Ausgabe:
th
November 11 , 2009
11. November 2009
Allen head wrench L type

Innensechskantschlssel
232 414 40
232 415 40
232 416 40
232 417 40
232 418 40
232 419 40
232 420 40
232 421 40
232 422 40
SW 3/16
SW 7/32
SW 1/4
SW 5/16
SW 3/8
SW 1/2
SW 9/16
SW 5/8
SW 3/4
Allen head wrench L type, with spherical head
Innensechskantschlssel, mit Kugelkopf
232 582 40
232 583 40
232 584 40
232 585 40
232 586 40
232 587 40
232 588 40
232 589 40
SW 2
SW 3
SW 4
SW 5
SW 6
SW 8
SW 10
SW 12
232 666 40
Pneumatic impact wrench (Bosch)

Druckluft-Schlagschrauber (Bosch)
232 667 40
Pneumatic impact wrench (Bosch)

Druckluft-Schlagschrauber (Bosch)
991-1010
Tools
Werkzeug
Schraubwerkzeuge
Section / Gruppe 1
Page / Seite
15
16
Part-No.
Description
ET-Nr.
Gegenstand
Release:
Ausgabe:
232 139 40
th
November 11 , 2009
11. November 2009
Water pump pliers 250 mm long

Wasserpumpenzange 250 mm lang
232 140 40
Grip pliers 250 mm long

Gripzange 250 mm lang
232 141 40
Stork beak pliers, straight, 200 mm long

Storchschnabelzange, gerade, 200 mm lang
232 142 40
Telephone pliers, 200 mm long, bent jaws

Storchschnabelzange, abgewinkelt, 200 mm lang
232 143 40
Wire strippers 160 mm long

Abisolierzange 160 mm lang
232 663 40
Stripping- and cutting tool Stripax

for PVC-isolation up to 6 mm, 20mm
Abisolier- und Schneidewerkzeug Stripax
fr PVC-Isolation bis 6 mm, 20 mm
232 401 40
Side cutter insulated up to 1000 Volt, 190 mm

Seitenschneider isoliert bis 1000 Volt, 190 mm
232 400 40
Combination pliers insulated up to 1000 Volt, 185 mm

Kombizange isoliert bis 1000 Volt, 185 mm
232 147 40
Pipe wrenches, angeled jaws, with adjusting nut, 350 mm long

Eckrohrzange abgewinkelt, mit Stellmutter, 350 mm lang
232 404 40
Flat nose pliers, insulated up to 1000 Volt, 185 mm

Flachzange, isoliert bis 1000 Volt, 185 mm
232 405 40
Round nose pliers, insulated up to 1000 Volt, 185 mm

Rundzange, isoliert bis 1000 Volt, 185 mm
991-1010
Tools
Pliers
Werkzeug
Zangen
Section / Gruppe 2
Page / Seite
16
17
Part-No.
Description
ET-Nr.
Gegenstand
Release:
Ausgabe:
th
November 11 , 2009
11. November 2009
Circlip pliers, straight, for external circlips

Sicherungsringzange, gerade, fr Auenringe
232 150 40
232 151 40
232 152 40
19 60
40 100
85 140
Circlip pliers, 90, for external circlips
Sicherungsringzange, gewinkelt, fr Auenringe
232 156 40
232 157 40
232 158 40
19 60
40 100
85 140
Circlip pliers, straight, for internal circlips
Sicherungsringzange, gerade, fr Innenringe
232 159 40
232 160 40
232 161 40
19 60
30 100
85 130
Circlip pliers, angled, for internal circlips
Sicherungsringzange, gewinkelt, fr Innenringe
232 153 40
232 154 40
232 155 40
19 60
31 100
85 140
232 281 40
Circlip pliers, straight, for external circlips

122 300 mm
Seegerringzange, gerade, fr Auenringe
122 300 mm
232 282 40
Circlip pliers, angled, for external circlips

122 300 mm
Seegerringzange, gewinkelt, fr Auenringe
122 300 mm
232 283 40
Circlip pliers, straight, for internal circlips

122 300 mm
Seegerringzange, gerade, fr Innenringe
122 300 mm
232 284 40
Circlip pliers, angled, for internal circlips

122 300 mm
Seegerringzange, gewinkelt, fr Innenringe
122 300 mm
991-1010
Tools
Pliers
Werkzeug
Zangen
Section / Gruppe 2
Page / Seite
17
18
Part-No.
Description
ET-Nr.
Gegenstand
Release:
Ausgabe:
232 662 40
th
November 11 , 2009
11. November 2009
Crimp set
Crimp pliers, crimp capacity 0,5 - 4,0 mm
Crimp-Set
Crimpzange, Crimpbereich 0,5 - 4,0 mm
232 661 40
Crimp pliers
Crimp capacity 0,5-4 mm
Crimpzange
Crimpbereich 0,5-4 mm
793 729 73
Crimp-pliers for revolved contacts

Crimpzange fr gedrehte Kontakte
232 209 40
Crimp pliers with cable lugs, set in a metal box

Crimpzange im Kasten mit Kabelschuhsortiment
991-1010
Tools
Pliers
Werkzeug
Zangen
Section / Gruppe 2
Page / Seite
18
19
Part-No.
Description
ET-Nr.
Gegenstand
Release:
Ausgabe:
th
November 11 , 2009
11. November 2009
Hammer
Handhammer
232 129 40
232 130 40
232 131 40
300 g
500 g
1000 g
232 310 40
Sledge hammer, 5 kg
Vorschlaghammer, 5 kg
232 579 40
Plastic hammer, 450 g

Plastikhammer, 450 g
Flat chisel
Flachmeiel
232 135 40
232 136 40
16 x 165 mm
19 x 180 mm
232 137 40
Cape chisel, 6 x 165 mm

Kreuzmeiel, 6 x 165 mm
232 138 40
Center punch, 4 x 130 mm

Krner, 4 x 130 mm
Drift punch
Durchtreiber
232 132 40
232 133 40
232 134 40
5 x 150 mm
6 x 160 mm
8 x 180 mm
Cotter pin drive
Splintentreiber
232 099 40
232 100 40
232 101 40
232 102 40
232 103 40
232 104 40
3 mm
4 mm
5 mm
6 mm
8 mm
10 mm
232 122 40
Hack saw with blade

Metallbgelsge mit Sgeblatt
991-1010
Tools
Metal Working Tools
Werkzeug
Section / Gruppe 3
Page / Seite
19
20
Part-No.
Description
ET-Nr.
Gegenstand
Release:
Ausgabe:
232 123 40
th
November 11 , 2009
11. November 2009
Three square scraper (hollow), 250 mm long

Dreikanthohlschaber, 250 mm lang
232 124 40
Flat scraper, 250 mm long

Flachschaber, 250 mm lang
Adjustable tap wrench for taps
Verstellbares Wendeisen fr Gewindebohrer
232 164 40
232 165 40
232 235 40
Gr. 1 M 1 10
Gr. 4 M 10 27
Gr. 6 M 20 42
Tap
Gewindebohrer
232 166 40
232 167 40
232 168 40
232 169 40
232 170 40
232 171 40
232 172 40
232 173 40
232 174 40
232 357 40
232 175 40
232 240 40
232 241 40
232 242 40
232 243 40
M3
M4
M5
M6
M8
M 10
M 12
M 14
M 16
M 18
M 20
M 24
M 30
M 36
M 42
Tap
Gewindebohrer
232 244 40
232 245 40
232 246 40
232 247 40
232 248 40
232 236 40
232 237 40R
232 238 40
232 239 40
M8x1
M 10 x 1
M 14 x 1,5
M 20 x 1,5
M 24 x 1,5
R 1/8
R 3/8
R 1/4
R 1/2
991-1010
Tools
Metal Working Tools
Werkzeug
Section / Gruppe 3
Page / Seite
20
21
Part-No.
Description
ET-Nr.
Gegenstand
Release:
Ausgabe:
th
November 11 , 2009
11. November 2009
Thread restorer
Gewindefeile
232 162 40
232 163 40
Whitworth
Metric
Holder for threading dies
Schneideisenhalter fr Schneideisen
232 176 40
232 177 40
232 178 40
232 179 40
232 180 40
232 359 40
232 249 40
232 250 40
232 364 40
232 365 40
232 358 40
M3/M4
M5/M6
M 8 / M 8 x 1,0
M 10 / M 10 x 1
M 12 / M 14
M 16 / M 18 / M 20
M 24
M 30 / M 36
M 14 x 1,5 / R 1/8 / R 1/4
M 24 x M 1,5
R 3/8 / R 1/2
20 x 5 mm
20 x 7 mm
25 x 9 mm
30 x 11 mm
38 x 14 mm
45 x 18 mm
55 x 22 mm
65 x 25 mm
38 x 10 mm
55 x 16 mm
45 x 14 mm
Threading die
Schneideisen
232 181 40
232 182 40
232 183 40
232 184 40
232 185 40
232 186 40
232 187 40
232 188 40
232 189 40
232 360 40
232 190 40
232 261 40
232 260 40
232 259 40
232 255 40
232 256 40
232 257 40
232 258 40
232 251 40
232 252 40
232 253 40
232 254 40
M3
M4
M5
M6
M8
M 10
M 12
M 14
M 16
M 18
M 20
M 24
M 30
M 36
M8x1
M 10 x 1
M 14 x 1,5
M 24 x 1,5
R 1/8
R 1/4
R 3/8
R 1/2
947 173 40
Auxiliary tool 1 for threaded pins M12

Hilfswerkzeug 1 fr Gewindestift M12
947 178 40
Auxiliary tool 2 for threaded pins M16

Hilfswerkzeug 2 fr Gewindestift M16
991-1010
Tools
Metal Working Tools
Werkzeug
Section / Gruppe 3
Page / Seite
21
22
Part-No.
Description
ET-Nr.
Gegenstand
Release:
Ausgabe:
232 194 40
th
November 11 , 2009
11. November 2009
Inside caliper, 200 mm long

Lochtaster, 200 mm lang
232 195 40
Outside caliper, 200 mm long

Dickentaster 200 mm lang
232 107 40
Sliding caliper, 200 mm long

Schieblehre, 200 mm lang
232 108 40
Measuring tape, 2000 mm long

Rollbandma, 2000 mm lang
232 590 40
Metal rule, 1000 mm long

Stahlma, 1000 mm lang
232 109 40
Feeler gauge set

Fhlerlehrenset
232 110 40
Thread gauge, metric & whithworth

Gewindeschablone, metrisch & Whitworth
232 668 40
Micrometer gauge
Measuring range: 0 - 150 mm
Bgelmessschraube
Messbereich: 0 - 150 mm
232 669 40
Micrometer gauge
Measuring range: 150 - 300 mm
Bgelmessschraube
Messbereich: 150 - 300 mm
991-1010
Tools
Measuring tools
Werkzeug
Messwerkzeuge
Section / Gruppe 4
Page / Seite
22
23
Part-No.
Description
ET-Nr.
Gegenstand
Release:
Ausgabe:
232 591 40
th
November 11 , 2009
11. November 2009
Hydraulic mini testing kit, consisting of:

1 pressure gauge 0 25 bar
1 pressure gauge 0 60 bar
2 pressure gauges 0 400 bar
2 instrument hoses 3 m each
1 hose 5 m
and diverse adapters
Hydraulik Mini-Messbox, bestehend aus:
1 Manometer 0 25 bar
2 Messschluche je 3 m
1 Messschlauch 5 m
und diverse Anschlsse
79453773
Digital dial gauge, 0 - 12,5 mm

Digitalmessuhr, 0 - 12,5 mm
232 673 40
Magnetic articulated stand, 390 mm, 60 x 50 x 55 mm

Magnet-Gelenkstativ, 390 mm, 60 x 50 x 55 mm
232 720 40
Digital pressure manometer SPG-DIGI

Digitales Druckmanometer SPG-DIGI
232 664 40
Fluke multimeter
Fluke Multimeter
232 753 40
Fuse 440 m
Sicherung 440 mA
232 754 40
Fuse 11 A
Sicherung 11
991-1010
Tools
Measuring tools
Werkzeug
Messwerkzeuge
Section / Gruppe 4
Page / Seite
23
24
Part-No.
Description
ET-Nr.
Gegenstand
Release:
Ausgabe:
232 619 40
th
November 11 , 2009
11. November 2009
Autorange digital multimeter incl. fuse set and temperature

sensor
Specification:
V = : 100 V 1 KV accuracy 0,3% + 2 Dig.
V ~ : 100 V 1 KV accuracy 0,5% + 3 Dig.
A = : 100 nA 20 A accuracy 1% + 5 Dig.
A ~ : 100 nA 20 A accuracy 1% + 5 Dig.
Resistance: 100 mOhm 40 MOhm Genauigkeit 0,5% + 3 Dig.
Frequenz (Hz): 1 Hz 200 kHz accuracy 0,2% + 2 Dig.
Diode test: Test voltage (open) below 3 V
Acust. continuity tester: sounds below 100 Ohm
Voltage supply: 1 x 9 V block battery
Autorange Digital-Multimeter inkl. Sicherungssatz und
Temperatursensor
Technische Daten:
V = : 100 V 1 KV Genauigkeit 0,3% + 2 Dig.
V ~ : 100 V 1 KV Genauigkeit 0,5% + 3 Dig.
A = : 100 nA 20 A Genauigkeit 1% + 5 Dig.
A ~ : 100 nA 20 A Genauigkeit 1% + 5 Dig.
Widerstand: 100 mOhm 40 MOhm Genauigkeit 0,5% + 3 Dig.
Frequenz (Hz): 1 Hz 200 kHz Genauigkeit 0,2% + 2 Dig.
Diodentest: Prfspannung (offen) unter 3 V
akust. Durchgangsprfer: ertnt unter 100 Ohm
Spannungsversorgung: 1 x 9 V Block-Batterie
232 670 40
SUBITO Internal gauge, 280 - 510 mm,

in a case without dial
SUBITO Innenmessgert, 280 - 510 mm,
im Etui ohne Uhr
232 671 40
SUBITO Measuring depth extension

Pipe 18mm, 2000 mm long
SUBITO Messtiefenverlngerung
Rohr 18mm, 2000 mm lang
232 384 40
Flow meter gauge incl. Accessories

Volumenstrom-Messgert inkl. Zubehr
793 787 73
Measuring turbine RE4

Measuring range: 16,0 up to 600 l/min
Messturbine RE4
Messbereich: 16,0 bis 600 l/min
991-1010
Tools
Measuring tools
Werkzeug
Messwerkzeuge
Section / Gruppe 4
Page / Seite
24
25
Part-No.
Description
ET-Nr.
Gegenstand
Release:
Ausgabe:
232 593 40
th
November 11 , 2009
11. November 2009
Shock pulse measuring instrument

Stossimpuls-Messgert
232 665 40
Infrared thermometer
Infrarot-Thermometer
694 944
Electric thermometer with temp. probe tip

Temperaturmessgert mit Temperaturfhler
793 788 73
Infrared revolution counter DS03,

-1
Measuring range : 1 to 9999 min
Infrarot-Drehzahlmesser DS03
-1
Messbereich: 1 bis 999 min
793 789 73
Magnetic holder for DS03

Magnethalter fr DS03
232 551 40
Manual non-contact revolution counter (digital)

Berhrungsloser Drehzahlmesser (digital)
232 756 40
Clamp-on ammeter AC/DC, Fluke 336

incl. carrying case, test lead, 2 batteries (AAA), user manual
Technical data:
Measurement range A/AC & A/DC: 0 - 600 A
Measurement range V/AC & V/DC: 0 - 600 V
Frequency range: 10 - 400 Hz
Measurement range resistance: 0 6000
Strommesszange AC/DC, Fluke 336
inkl. Tragetasche, Messleitung, 2 Batterien (AAA),
Bedienungsanleitung
Technische Daten:
Messbereich A/AC & A/DC: 0 - 600 A
Messbereich V/AC & V/DC: 0 - 600 V
Frequenzbereich: 10 - 400 Hz
Messbereich Widerstand: 0 6000
991-1010
Tools
Measuring tools
Werkzeug
Messwerkzeuge
Section / Gruppe 4
Page / Seite
25
26
Part-No.
Description
ET-Nr.
Gegenstand
Release:
Ausgabe:
232 496 40
th
November 11 , 2009
11. November 2009
Cable set for part no. 232 323 40

Kabelset fr ET-Nr. 232 323 40 (s.o.)
Test manometer, incl. accessories

Prfmanometer, inkl. Zubehr
770 466 73
769 150 73
770 464 73
770 465 75
0 - 60 bar
0 - 400 bar
0 -16 bar
0 - 25 bar
Pressure gauge
Druckmanometer
793 361 73
793 362 73
793 363 73
0-25 bar (1 Stck / pc.)

0-60 bar (1 Stck / pc.)
0-400 bar (2 Stck / pcs.)
232 501 40
Pressure gauge fitting (4 pcs.)

Anschluss fr Druckmanometer (4 Stck)
Measuring hose
Messschlauch
792 283 73
792 284 73
3200 mm lg (2 Stck / pcs.)

5000 mm lg (1 Stck / pc.)
761 520 73
Filling and testing device for piston, diaphragm and bladder

accumulators
0 100 bar (with pressure reducer)
Fll- und Prfvorrichtung fr Kolben-, Membran- und Blasenspeicher
0 100 bar (mit Druckminderer)
232 752 40
Tool case (without tools)

Koffer (ohne Inhalt)
991-1010
Tools
Measuring tools
Werkzeug
Messwerkzeuge
Section / Gruppe 4
Page / Seite
26
27
Part-No.
Description
ET-Nr.
Gegenstand
Release:
Ausgabe:
232 382 40
th
November 11 , 2009
11. November 2009
Filling and testing device for piston and diaphragm and

accumulators
0 25 bar
Fll- und Prfvorrichtung fr Kolben- und Membranspeicher
0 25 bar
Thread reducing fitting (manometer)

Gewindereduzierung (Manometer)
232 506 40
232 507 40
232 508 40
R 1/4
R 3/8
R 1/2
232 385 40
Voltage tester 25 kV
Spannungsprfer 25 kV
232 386 40
Universal grounding short-circuiting device

2
95/35, mm
Universale Erdungs- und Kurzschlievorrichtung
2
95/35, mm
232 387 40
Insulation tester . . . 500 V

Isolationsmesser . . . 500 V
232 713 40
ALIGNEO laser set, for the alignment of horizontal mounted

machines
ALIGNEO Laser-Set, fr die Ausrichtung horizontal verbauter
Maschinen
232 714 40
ALIGNEO Bracket set

ALIGNEO Halterungssatz
991-1010
Tools
Measuring tools
Werkzeug
Messwerkzeuge
Section / Gruppe 4
Page / Seite
27
28
Part-No.
Description
ET-Nr.
Gegenstand
Release:
Ausgabe:
232 388 40
th
November 11 , 2009
11. November 2009
Phase-sequence indicator 100 . . . 600 V

Drehfeldrichtungsanzeiger 100 . . . 600 V
Electronical unipolar voltage meter

Elektronischer einpoliger Spannungsprfer
232 389 40
232 390 40
5 10 kV
3 6 kV
232 594 40
Shock pulse transducer

Stoimpulsaufnehmer
232 595 40
Shock pulse transducer

Stoimpulsaufnehmer
232 596 40
Head receiver for shock pulse measuring instrument

Kopfhrer fr Stoimpulsmessgert
232 762 40
Test box for electrical components with Deutsch connectors

Test-Box fr elektrische Bauteile mit Deutsch-Steckern
991-1010
Tools
Measuring tools
Werkzeug
Messwerkzeuge
Section / Gruppe 4
Page / Seite
28
29
Part-No.
Description
ET-Nr.
Gegenstand
Release:
Ausgabe:
766 138 73
th
November 11 , 2009
11. November 2009
System diagnostic for lubrication system

Systemdiagnose fr Schmieranlage
966 225
Crack detection testing kit, consisting of:

Test-Set Rissprfung, bestehend aus:
966 229
Permanent magnet
Permanentmagnet
966 226
Magnetic powder
Magnetpulver
996 228
Cleaner, spray can, 500 ml

Reiniger, Sprhdose, 500 ml
966 227
Contrasting agent
Kontrastmittel
232 723 40
Universal box
Universalkoffer
991-1010
Tools
Measuring tools
Werkzeug
Messwerkzeuge
Section / Gruppe 4
Page / Seite
29
30
Part-No.
Description
ET-Nr.
Gegenstand
Release:
Ausgabe:
793 780 73
th
November 11 , 2009
11. November 2009
Hand-held measuring unit MH 3020, 3 channels, USB interface,

ISDS
Memory: max. 1 million readings
incl. power supply unit, USB cable and software
Handmessgert MH 3020, 3 Kanle, USB-Schnittstelle, ISDS
Speicher: max. 1 Million Messwerte
inkl. Netzgert, USB-Kabel und Software
793 781 73
Pressure sensor (2 pcs), 0 - 400 bar, ISDS

Druckaufnehmer (2 Stck.), 0 - 400 bar, ISDS
793 783 73
Direct connector for pressure sensor no. 1620 (2 pcs)

Direktanschluss fr Drucksensor Nr. 1620 (2 Stck.)
793 784 73
Screw-in temperature sensor no. 1620 (2 pcs) -50C up to 200C,

ISDS
Temperatur-Einschraubfhler Nr. 1620 (2 Stck.) -50C bis 200C,
ISDS
793 785 73
Rev counter sensor DS 03, incl. 25 reflection foils

Drehzahlsonde DS 03, inkl. 25 Reflexionsfolien
793 787 73
Measuring cable (2 pcs), 5.0 m

Messkabel (2 Stck.), 5,0 m
793 786 73
Measuring extension cable, 5.0 m

Messkabel-Verlngerung, 5,0 m
793 782 73
Carrier box
Transportkoffer
991-1010
Tools
Werkzeug
Section / Gruppe 5
Page / Seite
30
31
Part-No.
Description
ET-Nr.
Gegenstand
Release:
Ausgabe:
796 440 73
th
November 11 , 2009
11. November 2009
USB extension wire

USB-Kabel
793 796 73
Data communication cable USB

Datenbertragungskabel USB
796 441 73
UMG diagnostic software (CD)

UMG-Diagnosesoftware (CD)
796 439 73
Converter
Konverter
796 443 73
Cable set
Kabel-Set
873 570 40
Content:
Inhalt:
Cable VL3
Cable VL12
Cable VL10
Cable VL9a
Cable VL9b
Kabel VL3
Kabel VL12
Kabel VL10
Kabel VL9a
Kabel VL9b
Data transfer, grease, memory ETM, ECS, 1 set

Datenbertragung, Fett, Speicher ETM, ECS, 1 Satz
796 726 73
Bodem PC software
Bodem PC-Software
896 791 40
Bodem connection cable

Bodem Verbindungskabel
991-1010
Tools
Werkzeug
Section / Gruppe 5
Page / Seite
31
32
Part-No.
Description
ET-Nr.
Gegenstand
Release:
Ausgabe:
232 684 40
th
November 11 , 2009
11. November 2009
Vibrotip-Set Trend
Engine analyzer and data collector
Vibrotip-Paket Trend
Maschinen-Analysator und Datensammler
232 686 40
Drill for Vibrotip

Bohrer fr Vibrotip
232 685 40
Sensor with quick coupling

Aufnehmer mit Schnellkupplung
232 747 40
LAN card, USB 2.0, 10/100 Mbit/s

This USB-RJ45-adapter is a high-performance network
converter for the USB 2.0 port
LAN-Karte, USB 2.0, 10/100 Mbit/s
Dieser USB-RJ45-Adapter ist ein leistungsstarker Netzwerkkonverter
fr die USB 2.0-Schnittstelle
232 748 40
CAT-5 Crossover adapter

For fast direct PC connection via LAN (RJ45)
CAT-5 Crossover-Adapter
Fr die schnelle PC-Direktverbindung ber LAN (RJ45)
232 755 40
Crossover cabel, for CAT-5 Crossover adapter, double shielded,

1 meter
Crossover-Patchkabel, fr CAT-5 Crossover-Adapter, doppelt
geschirmt, 1 Meter
991-1010
Tools
Werkzeug
Section / Gruppe 5
Page / Seite
32
33
Part-No.
Description
ET-Nr.
Gegenstand
Release:
Ausgabe:
232 621 40
th
November 11 , 2009
11. November 2009
Cordless headphone intercom

Sprechfunkanlage
232 623 40
Vacuum pump + adaptor

Vakuumpumpe + Adapter
Puller, grip width/depth

Abzieher, Spannweite/Spanntiefe
232 300 40
232 301 40
232 302 40
120 mm/100 mm
200 mm/150 mm
350 mm/200 mm
232 287 40
Grease gun, hand-lever type, with couplings, 400 bar

Handhebelfettpresse, mit Anschlssen, 400 bar
232 288 40
Fitters tub
Montagewanne
232 000 40
Tool box, 5 trays

420 x 200 x 210 mm
Werkzeugkasten, 5-teilig
420 x 200 x 210 mm
232 299 40
Pinch bar with pointed and claw ends, 1000 mm long

Brechstange mit Klaue und Spitze, 1000 mm lang
793 639 73
Removal tool for double-level terminals

Lsewerkzeug fr Doppelstockklemmen
991-1010
Tools
Others
Werkzeug
Sonstiges
Section / Gruppe 6
Page / Seite
33
34
Part-No.
Description
ET-Nr.
Gegenstand
Release:
Ausgabe:
232 542 40
th
November 11 , 2009
11. November 2009
Oil analysis
l-Analyse
232 622 40
Suction pump, extracting oil for testing

Pumpe zur Entnahme einer lprobe
Flat-link chain hoist

Hubzug mit Gelenkkette
232 368 40
232 289 40
???
Lifting capacity 0,75 t

324460 40
Cable suspension, 5 t
Tragkraft 0,75 t
Tragkraft 1,5 t
Tragkraft 3,0 t
Drahtseilgehnge, 5 t
792 005 73
Edge protector
Kantenschoner
792 006 73
Edge protector
Kantenschoner
991-1010
Tools
Others
Werkzeug
Sonstiges
Section / Gruppe 6
Page / Seite
34
35
Part-No.
Description
ET-Nr.
Gegenstand
Release:
Ausgabe:
232 616 40
th
November 11 , 2009
11. November 2009
4-hook chain
WMH S6
A = 1500 mm
4-Strang-Kette
WM 1401
A = 1500 mm
232 617 40
Nylon lifting belt, AL 4

Width 75 mm, length 3500 mm
1500 kg
Nylon Hebegurt, AL 4
Breite 75 mm, Lnge 3500 mm
1500 kg
232 618 40
Nylon lifting belt

Width 25 mm, length 1500 mm
1000 kg
Nylon Hebegurt, AL 5
Breite 25 mm, Lnge 1500 mm
1000 kg
Lifting bolt
Ringschraube
313 500 99
313 501 99
313 502 99
313 503 99
313 504 99
313 505 99
313 510 99
313 506 99
313 507 99
313 508 99
313 514 99
313 527 99
M8
M 10
M 12
M 16
M 20
M 24
M 27
M 30
M 36
M 42
M 48
M 56
Pin-driving press, complete set for crawler chassis
Bolzenpresse, komplett fr Traktorenlaufwerk
232 313 40
100 t, for all excavators up to H 121

100 t, fr alle Bagger bis H 121
232 381 40
150 t, for all excavators up to H 185

150 t fr alle Bagger bis H 185
991-1010
Tools
Others
Werkzeug
Sonstiges
Section / Gruppe 6
Page / Seite
35
36
Part-No.
Description
ET-Nr.
Gegenstand
Release:
Ausgabe:
232 626 40
th
November 11 , 2009
11. November 2009
Mounting bushing set for cylinder repair.

When ordering tools, please always state the identification
number of the cylinder.
Montage-Buchsensatz fr Zylinder-Reparatur.
Bei Bestellung der Werkzeuge unbedingt die Ident-Nr. des Zylinders
angeben.
999 860 73
5 finger gloves, with textile extension, with lining

5-Finger-Handschuhe mit Strickbund, gefttert
999 861 73
Rubber gloves, size F3 and F4

Gummi-Handschuhe, Gre F3 und F4
999 925 73
Working gloves, pork leather, with lining

Arbeits-Handschuhe, Schweinsleder mit Futter
950 642
Canister 10 l (plastics)
Kanister 10 l (Kunststoff)
991-1010
Tools
Others
Werkzeug
Sonstiges
Section / Gruppe 6
Page / Seite
36
37
Part-No.
Description
ET-Nr.
Gegenstand
Release:
Ausgabe:
950 643
th
November 11 , 2009
11. November 2009
Canister 25 l (plastics)
Kanister 25 l (Kunststoff)
232 683 40
Combination angle set

Satz Kombinationswinkel
232 717 40
Stud welding unit for threaded pins, with welding gun

Bolzenschwei-Kompaktanlage, mit Schweipistole
232 712 40
Magnet-Stick
Magnetfeldprfer
232 715 40
Hydro-pump, type IPV 3-8 101

Hydropumpe, Typ IPV 3-8 101
232 716 40
Coupling
Kupplung
991-1010
Tools
Others
Werkzeug
Sonstiges
Section / Gruppe 6
Page / Seite
37
38
Part-No.
Description
ET-Nr.
Gegenstand
Release:
Ausgabe:
766 307 73
766 308 73
766 309 73
766 310 73
766 311 73
766 312 73
766 313 73
766 314 73
766 315 73
766 316 73
766 317 73
766 318 73
766 319 73
766 320 73
766 321 73
766 322 73
766 323 73
768 881 73
797 549 73
th
November 11 , 2009
11. November 2009
Mounting tools for dual cone seal rings at the undercarriage

Montagewerkzeuge fr Gleitdichtringe am Unterwagen
For detailed information refer to

PARTS & SERVICE NEWS AH05511
Ausfhrliche Informationen siehe
PARTS & SERVICE NEWS AH05511
991-1010
Tools
Others
Werkzeug
Sonstiges
Section / Gruppe 6
Page / Seite
38
39
Part-No.
Description
ET-Nr.
Gegenstand
Release:
Ausgabe:
767 566 73
th
November 11 , 2009
11. November 2009
Thinner, 10 kg
Verdnner, 10 kg
767 567 73
Primer, lemon yellow, 1 kg

Grundierung, zitronengelb, 1 kg
083 026
Paint yellow, RAL 1007

Spray can, 400 ml
Farbe gelb, RAL 1007
Spraydose, 400 ml
501 415 98
Paint sky-blue, RAL 5015

Can, 2,5 kg
Farbe himmelblau, RAL 5015
Dose, 2,5 kg
767 568 73
Paint black, RAL 9005

Can, 1 kg
Farbe Schwarz, RAL 9005
Dose, 1 kg
991-1010
Tools
Paint and accessories
Werkzeug
Lackiermaterialien
Section / Gruppe 7
Page / Seite
39
40
Part-No.
Description
ET-Nr.
Gegenstand
Release:
Ausgabe:
767 569 73
th
November 11 , 2009
11. November 2009
Paint yellow = DEMAG KOMATSU colour

Can, 1 kg
Farbe gelb = DEMAG KOMATSU-gelb
Dose, 1 kg
767 570 73
Paint grey = KOMATSU colour

Can, 1 kg
Farbe grau = KOMATSU-grau
Dose, 1 kg
999 019
Nickel spray can, Metaflux 70-81

Nickelspray, Metaflux 70-81
991-1010
Tools
Paint and accessories
Werkzeug
Lackiermaterialien
Section / Gruppe 7
Page / Seite
40
41
Part-No.
Description
ET-Nr.
Gegenstand
Release:
Ausgabe:
592 199 40
th
November 11 , 2009
11. November 2009
Liquid sealing compound (Epple blue, No. 28), 250 ml

Flssigdichtung (Epple blau, Nr. 28), 250 ml
461 798 40
Adhesive Sicomet 85, in tubes,

for sealing the rotary joint (with rollers or balls)
Klebstoff Sicomet 85, in Tuben,
fr die Abdichtung der Rollendrehverbindung,
Kugeldrehverbindung
390 905
Teflon tape
Teflonband
464 814
Insulating tape, 33-19 Tesa PVCd

Isolierband, 33-19 Tesa PVCd
691 959
Filler bottle Startpilot

Fllflasche Startpilot
989 967
Oil binding agent (paper sacks, 8 kg each)

lbindemittel (Papierscke 8 kg)
993 528 73
Cleaning agent
Bio Pent E, for steam blasting cleaners
Reinigungsmittel
Bio Pent E, fr Dampfstrahler
993 529 73
Cleaning agent
Bio Versal, for steam blasting cleaners
Reinigungsmittel
Bio Versal fr Dampfstrahler
999 926 73
Cleaning rags (fleece rags)

35 x 35 cm, bale of 30 kg
Paket Putzlappen (Vliestcher)
35 x 35 cm, in 30 kg-Ballen
991-1010
Tools
Auxiliaries, cleaners, adhesive & sealant
Werkzeug
Hilfsstoffe, Reiniger, Kleber & Dichtungsmittel
Section / Gruppe 8
Page / Seite
41
42
Part-No.
Description
ET-Nr.
Gegenstand
Release:
Ausgabe:
th
November 11 , 2009
11. November 2009
Loctite products
Loctite-Produkte
414 299 40
Loctite No. 222 E, bolt lock fluid, 50 ml

low stability, up to M36
Loctite Nr. 222 E, Schraubensicherung, 50 ml
niedrigfest, bis M 36
973 125
Loctite No. 241, bolt lock fluid, 50 ml

medium stability, up to M12
Loctite Nr. 241, Schraubensicherung, 50 ml
mittelfest, bis M 12
973 130

255 242 40

170 470 40

mittelfest, bis M80
158 856 40

high stability, up to M20
hochfest, bis M20
167 644 40
Loctite No. 307, 50 ml

metal adhesive (only in conjunction with 7471)
Loctite Nr. 307, 50 ml
Metallkleber (nur in Verbindung mit 7471)
288 906 40
Loctite No. 330, bonding set

bonds nearly all materials (except Gi)
Loctite Nr. 330, Klebeset
verbindet nahezu alle Materialien (auer Gi)
461 798 40
Loctite No. 401, 20 g, Cyanacrylat

bonds Kn, rubber, paperboard, leather, wood, and many more
Loctite Nr. 401, 20 g, Cyanacrylat
zum Verkleben von Kn, Gummi, Pappe, Leder, Holz, u.v.m.
991-1010
Tools
Werkzeug
Section / Gruppe 8
Page / Seite
42
43
Part-No.
Description
ET-Nr.
Gegenstand
Release:
Ausgabe:
255 238 40
th
November 11 , 2009
11. November 2009
Loctite No. 511, fluid sealing, 50 ml

low stability, sealing threaded connections up to R2
Loctite Nr. 511, Flssigdichtung, 50 ml
niedrigfest, zum Abdichten von Verschraubungen bis R2
232 554 40
Loctite No. 511, fluid sealing, 250 ml

low stability
niedrigfest
083 399 40
Loctite Nr. 586, fluid sealing, 50 ml

high stability, up to R 2
hochfest, bis R 2
255 239 40
Loctite 574, sealant for surfaces, 50ml

gap size up to 0,5 mm
Loctite Nr. 574, Flchendichtung, 50 ml
Spaltgre bis 0,5 mm
255 237 40
Loctite No. 603, for join connections, 50 ml

high stability
Loctite Nr. 603, Fgeverbindung, 50 ml
hochfest
288 907 40
Loctite No. 706, fast cleaner, 400 ml

Loctite Nr. 706, Schnellreiniger, 400 ml
321 32240
Loctite, removal of adhesives and sealants

spray can, 300 ml
Loctite, Klebstoff- u. Dichtungsentferner
300 ml-Sprhdose
083 376 40
Loctite Nr. 7471, activator, 500 ml

(for hardening of 307 and for the acceleration of the hardening
process)
Loctite Nr. 7471, Aktivator, 500 ml
(zur Aushrtung von 307 und zur Beschleunigung des
Aushrtevorgangs)
991-1010
Tools
Werkzeug
Section / Gruppe 8
Page / Seite
43
-
Parts & Service News
8 PARTS & SERVICE NEWS
Version 2009/2
PC5500-6
8 -1
Contents of this chapter:

SB-No.
Subject
AH00511
Installation procedure for the swing circle / Slew Ring (SR)
AH00514
AH00515
Final drive: Wear and tear measurements Mounting procedures
AH00519
AH01513
AH01521
AH01531
Hydraulic accumulators - testing and refilling
AH02513
AH02521
AH03506
AH03509
AH03510
AH03511
AH03512
Gear Pumps (Part Nos. 907 209 40; 906 442 40; 896 730 40 and 654 930 40
AH04518
AH05501
AH05510
Bearing flushing of the A4VS variable displacement axial piston pump
AH05511
AH05520
Installation hints for a new type of pilot pump
AH05525
AH05535
AH05546
AH06524
Hydraulic cylinder
AH06529
AH06530
AH06542
AH06543
Gear pumps PN 907 622 40 and PN 940 048 40 (supplied from the company Kracht) (Pilot
pressure pump; gear oil pump; circulation pump)
AH06545
AH07509
Swing brake manufactured by "Siebenhaar" (Swing gear PN 902 550 40 and PN 925 864 40)
AH07526
AH08503
Track drive
AH08504
Windscreen
AH08507
Steel structure
8 -2
PC5500-6
Version 2009/2
SB-No.
Subject
AH08508
The numbers of the PARTS & SERVICE NEWS do not label the
latest edition. Ensure that the latest edition is always filed to the
binder of this manual.
Version 2009/2
PC5500-6
8 -3
8 -4
PC5500-6
Version 2009/2
PARTS & SERVICE NEWS
COMPONENT CODE:
2500
REF NO.
AH00511h
DATE
July 7, 2010
Page 1 of 22
This PARTS & SERVICE NEWS supersedes the previous issue No. AH00511g
which should be discarded.
SUBJECT:
Installation procedure for the Swing Circle (SC)
PURPOSE:
Revision
APPLICATION:
PC3000/6; PC4000/6; PC5500/6; PC8000/6
FAILURE CODE:
2500Z9
DESCRIPTION:
Before carrying out any repairs, read all the safety instructions
of the Operation and Maintenance manual of your shovel.
The local safety rules must also be observed.
Content
Page
1.
2.
3.
4.
Safety instructions
General
Measurements of bearing areas
Determining of tightening torques
02
03
04
06
4.1.
Test bolt types

4.1.1. Type 1
4.1.2 Type 2
Two types of measuring devices
4.2.1. Measuring jaw
4.2.2. New measuring device
06
5.
Mounting of a swing circle
11
5.1.
5.2.
5.3.
5.4.
General
Unhardened spot s
Tooth back lash
Hints for rotating the swing circle
12
14
15
17
6.
7.
Checking of the bolts

Lubrication and Maintenance
19
19
7.1
7.2
Roller bearings
Outer toothing
19
21
4.2.
07
AH00511h
Page 2 of 22
1. Safety Instructions
Assign trained or well-instructed personnel only and clearly define the respective
spheres of responsibility for the repair work.
Inform the operating personnel prior to the commencing special and regular
maintenance work.
Secure the maintenance area amply enough, as far as required.
Carry out repair and maintenance work only with the machine standing on firm and
level ground and secured against rolling away and sinking in.
During exchange action, fix and secure individual parts and assemblies carefully to
the lifting devices so that they cannot become dangerous in any way. Use exclusively
suitable lifting devices consistent with sound engineering and load-lifting elements
with sufficient load-bearing capacity! Never stay or work beneath suspended loads!
Entrust experienced personnel only with fastening and securing of loads and guiding
crane operators! The guide has to be within the operator's visual range or have voice
contact with him.
In case of assembly work exceeding body height, use suitable and otherwise secure
means of access and working platforms. Never step on machine parts as an access!
For maintenance work at higher levels, use the appropriate safety devices! Keep all
handles, steps, handrails, landings, working platforms, ladders, etc. free from dirt,
snow and ice!
Retighten immediately all bolted connections loosened during repair and maintenance
work!
If disassembly of safety devices is required for rigging, maintenance, and repair,

reassembly and checking of such safety devices has to be carried out immediately
after having finished the respective work.
Strictly observe all safety instructions and warnings in the country of destination.
AH00511h
Page 3 of 22
2. General
Before removing swing circle mark location of both

- swing circle to superstructure and
- swing circle to the car body as well for further investigations.
Shocks to the swing circle, especially radial ones, must be avoided.
Transport and store exclusively with transport star fitted.

It is strictly forbidden to hook up the SC (Swing Circle) at the transport star.
Hang up and/or transport and store swing circle only horizontally.

If a special attachment is available, the transportation and storage in oblique
position may be carried out.
Only hang SC at four/three eyebolts evenly distributed in screw circle of the

upper ring.
Prior to mounting the SC clean all supporting surfaces and the toothing, if
necessary clean those areas with fat solvents, methylene chloride, cold cleaners.
The cleaning agents must not enter the races. Hence, the swing circle has to be
thoroughly lubricated before and after cleaning.
With each replacement swing circle and each new machine, fastening bolts,
measuring bolts, a measuring device and the special grease for the Bolts will be
delivered.
If this parts delivery is not complete, please get immediately in contact with our
Service Department 8151, because a proper mounting may not be possible in
case of missing items.
AH00511h
Page 4 of 22
3. Measurements of the bearing area
Check the level of bearing area (only center section undercarriage) with a laser device
before installing a new swing circle.
To prevent incorrect measuring results caused by partial sun radiation onto the pedestal
/carbody it is recommended that the whole area be protected from the direct sunlight.
Illustration1
Legend
ID
= Inner diameter swing circle (mm)
OD = Outer diameter swing circle (mm)
= 3.14
P
= Maximum Deviation (deflection) (mm)
P = (OD ID) 1000
Example: OD = 4000 mm
ID = 3600 mm
P=
P=
P=
(4000mm 3600mm) 1000
400mm 1000
0.4 mm
If the measured value exceeds the calculated value P, the

surface has to be remachined.
AH00511h
Page 5 of 22
Check the outer diameter of the new swing circle top surface and compare with the
outer diameter of the factory machined surface of the superstructure.
Remove the shoulder by machining if necessary.
New swing circle

Outer diameter
Illustration 2
Such a shoulder exists only at some older shovels.
AH00511h
Page 6 of 22
4. Determining of tightening torque for the fastening bolts

The required tightening torque for all fastening bolts (inner and outer) has to
be determined with the 8 measuring bolts, which dimension is analogous to the
outer fastening bolts mounted to carbody / swing circle.
The required axial tension force of the bolts is determined by means of the
elongation of the fastening bolts.
The tightening torque must be determined each time the SC (Swing Circle) is
replaced as well as at the first assembling of the shovel at the operation site
and for the first and final inspection after 1000 operation hours.
The required measuring device is delivered with the shovel or with the SC
(Swing Circle).
To determine the tightening torque, eight specially prepared test bolts are
supplied besides the normal fastening bolts. The test bolts can be recognized
at the end of the threads.
There exists two types of measuring devices and for each type, special test
bolts.
Both measuring methods are useful.
4.1
Test bolts types
4.1.1 Test bolts (type 1) for using with measuring jaw
Shovel
Bolts
PC3000/6 M30 x 190

PC4000/6 M36 x 220
PC5500/6 M36 x 230
PC8000/6 M36 x 295
PN Test Bolts
930 631 40
928 844 40*
389 816 40
389 815 40*
409 437 40
409 484 40*
909 004 40
898 287 40*
Illustration 3
*low temperature version
4.1.2 Test bolts (type 2) for using with the new measuring device
Shovel
Bolts
PC3000/6 M30 x 190

PC4000/6 M36 x 220
PC5500/6 M36 x 230
PC8000/6 M36 x 295
PN Test Bolts
954 030 40
954 034 40*
954 029 40
954 033 40*
954 028 40
954 032 40*
954 027 40
954 031 40*
Illustration 4
*low temperature version
AH00511h
Page 7 of 22
4.2
Two Types of measuring devices
4.2.1 Measuring jaw
This measuring device is composed of the following items:
(1) Measuring jaw
1pce.
(2) Test block
1pce.
(3) Measuring bolt (type 1)
8pcs.
(4) Washer *
1pce.
* Only used for PC3000/6 bolts
Illustration 5
Procedure for the determining of the needed tightening torque:

1. Secure the test block (2) against twisting (e.g. on a work bench);
2. Grease the threads and the bolt head bearing areas with International
Compound No. 2 (PN 324 969 40);
Pay special attention for clean threads when determining the

tightening torque of the test bolts.
3. Screw test bolt (3) into test block (2) hand-tight *;

4. Fit jaw (1) and micrometer gauge into the centerings "Z"
of the bolt and set gauge to zero;
5. Increase tightening torque of test bolts by steps of app.
200 Nm until the required elongation of the bolt
according to the table below is reached and list this
torque value;
6. Determine the needed tightening torque as result of
average over the eight listed torque values.
*only for PC3000/6 with washer (4)
AH00511h
Page 8 of 22
Measuring bolts (type 1)

Type
Analogous to the
dimension of the outer
fastening bolts (8)
Quality grade
Wrench size
Required gauge
indication
[mm]
H 185S
M 30 x 230
10.9
46 mm
0.550 0.015
H 255S / PC3000/1
M 30 x 230
10.9
46 mm
0.550 0.015
PC3000/6
M 30 x 230
10.9
46 mm
0.5500.015
PC3000/6
M 30 x 190
10.9
46 mm
0.4420.013
H 285S
M 36 x 220
10.9
55 mm
0.610 0.020
PC4000
M 36 x 220
10.9
55 mm
0.610 0.020
H 455S / PC5500
M 36 x 230
10.9
55 mm
0.580 0.020
H 485S (to 12010)

H 485S (12011 up)
M 36 x 230
M 36 x 270
10.9
10.9
55 mm
55 mm
0.580 0.020
0.650 0.020
M 36 x 270
10.9
55 mm
0.650 0.020
M 36 x 295
10.9
55 mm
0.710 0.020
H 685SP
M 36 x 270
10.9
55 mm
0.650 0.020
H 685SX (12030)
M 36 x 295
10.9
55 mm
0.710 0.020
H 655S
PC8000 (to 12036)
PC8000 (12037 up)
AH00511h
Page 9 of 22
4.2.2 New measuring device
Torque support
No.
PN Measuring device
For shovel type
954 025 40
PC3000/6
954 023 40
PC4000/6
954 021 40
PC5500/6
954 016 40
PC8000/6
Illustration 6
Illustration 7
AH00511h
Page 10 of 22
Measuring bolts (type 2)

Type
Analogous to the
dimension of the outer
fastening bolts
Quality grade
Wrench size
Required
gauge
indication
[mm]
Preload torque *
PC3000/6
M 30 x 190
10.9
46 mm
0.5650.015
100 Nm
PC4000/6
M 36 x 220
10.9
55 mm
0.710 0.020
200 Nm
PC5500/6
M 36 x 230
10.9
55 mm
0.770 0.020
200 Nm
M 36 x 295
10.9
55 mm 0.970 0.020
PC8000 (12037 up)
* Set the micrometer gauge by these preload torques to 0.000 mm
200 Nm
Procedure for determining the needed tightening torque

(refer to illustration 6):
1. Fasten the new measuring device with the two bolts (6) and two nuts (8)
onto a suitable base (e.g. workbench),
2. Grease the threads and the bolt head bearing areas with International
Compound No. 2 (P/N. 324 969 40);
Pay special attention for clean threads when determining the

tightening torque of the test bolts.
3. Screw test bolt (12) into test block and preload the bolt according to the table
above *;
4. Fit micrometer gauge. Make sure that micrometer
gauge contacts the test bolt at the contact area
as shown;
5. Set gauge to zero;
6. Increase tightening torque of test bolt until the
required gauge indication according to the table
above is reached and list this torque value;
7. Repeat the procedure according to the section 2 to 6 with each test bolt;
8. Determine the needed tightening torque as result of average over the
eight listed torque values.
*only for PC3000/6 with washer (11)
AH00511h
Page 11 of 22
5. Mounting of a Swing circle
Illustration 8
PC3000/6
- Install extension sleeve (11);
PC4000/6; PC5500/6; PC8000/6 - Install washers (10)
AH00511h
Page 12 of 22
5.1.
General
When replacing the swing circle, all fastening bolts must also
be replaced.
If scratches are found at supporting surfaces of washers or bushes, they must be

reworked or replaced.
The eight measuring bolts have to be mounted equally distributed on the outer
ring of the swing circle.
Clean the supporting surfaces (A) of car body and platform absolute fat-free
(Illustration 8). Even the solvent must be rinsed away before assembling.
Check surface evenness (A) (refer to section 4).
Alignment the swing circle can be mounted easier with two

center pins.
No.
Type
1
PC3000-6
2
PC4000-6
3
PC5500-6
4
PC8000-6
Loosening lever: 955 797 40
Center Pin
955 798 40
956 902 40
956 902 40
956 904 40
If the Swing circle was aligned to the platform with the two center pins, mount
some fastening bolts and then remove the center pins.
AH00511h
Page 13 of 22
The swing circles (5/6) must have good contact to the carbody and superstructure
platform. Check mating surfaces with feeler gauge.
Check lube lines for correct condition and grease passage.
Check accordance of tapped and through holes in (Swing Circle) with those in
carbody and platform. Discordances may easily cause distortions of SC.
For disassembly and assembly always use a Mounting cross (M).
Fabricate mounting cross (M) according to the drawing or order it.
The construction drawing of the mounting cross has to be ordered
from the Parts Department if necessary.
Swing circle weight
[t]
Mounting cross
PN /Drawing No.
H 185S
3.5
379 383 40
H 255S / PC3000
3.5
379 383 40
H 285S
6.0
379 128 40
PC4000
6.7
379 128 40
9.0 / 10.0
477 577 40
H 485S
14.0
379 129 40
H 655S; PC8000 ( - 12036)
14.0
379 129 40
PC8000 (12037 - )
16.3
379 129 40
H685SX (12030)
16.3
379 129 40
H 685SP
14.0
379 129 40
Type
H 455S / PC5500
AH00511h
Page 14 of 22
Deposit and center SC with transport star (T) on mounting cross (M).
Check length of threads in platform and SC, if necessary retap.
Place SC at its fastening position under the jacked-up platform.
5.2. Unhardened spot S

For the adjustment of the Unhardened spot "S", refer to illustration below.
The Unhardened spot of race surfaces (changeover area between beginning and
ending of hardening process) is punch marked with "S" at the inner resp. outer side
of each race ring.
These spots "S" should not be placed within the main load area of the swing circle.
Hence, the unhardened spot "S" has to be turned in an angle of 90 to the main load
area as illustrated.
AH00511h
Page 15 of 22
Lift SC until approx. 10 mm below the platform (observe unhardened spot "S").
Slightly treat bolt heads, threads and washers with Compound PN 324 969 40.
Screw fastening bolts (7) with washers (10) through swing circle into the platform.
Lift SC to the supporting surface by screwing in the bolts crosswise.
Lower mounting cross.
Remove transport cross.
5.3
Tooth backlash
The tooth backlash is the gap

measured by a feeler gauge in
point D if tooth A presses on the
reference circle (B) against tooth C.
On swing circle where you find a
green color marking on 3 teeth,
rotate the lower ring (6) until the 3
green marked teeth are mating with
the teeth of a swing pinion.
Type
Tooth back lash

[mm]
H 185S
H 255S/PC3000
H 285S
PC4000
H 455S/PC5500
H 485S
H 655S/PC8000 ( -12036)
PC8000 (12037 - )
H685SX (12030)
H 685SP
0.4 0.8
0.4 0.8
0.6 1.0
0.6 1.0
0.6 1.0
0.5 0.9
0.5 0.9
0.5 2.5
0.5 2.5
0.5 0.9
Note:
The green teeth indicate the point of the
SC having the greatest circularity
deviation of the reference circle (positive
deviation).
At this narrowest spot, a tooth backlash
clearance according to the chart should
be measured.
On machines without green color marking
at the teeth, adjust backlash at 4 points
evenly distributed according to the
following dimensions.
AH00511h
Page 16 of 22
Before lowering the platform with SC on center section of the undercarriage:
1. Mark 4 teeth(1; 2; 3; 4 - refer to illustration) displaced by 90 .
The swing gears are marked gear 1, gear 2 and gear 3 (if so present).
2. Rotate the swing circle so far that tooth 1 is engaged at pinion of swing gear 1.
3. Measure play between A and D. Note value in the table below.
C means tooth 1 and must have contact at point B.
4. Rotate superstructure further until tooth 1 is engaged at pinion of swing gear 2.
Measure play as described under step 3.
5. Rotate superstructure further until tooth 1 is engaged at pinion of swing gear 3.
Measure play as described under step 3.
6. Rotate superstructure further that tooth two is engaged at pinion of swing gear 1.
Measure play and note value in table.
7. Carry out same measuring procedure as described for the other teeth.
At the end for every swing gear, four dimensions are noted in the table.
8. If necessary, adjust the backlash by displacement of the SC. For the correct
backlash, refer to chart above.
9. Hints for the three swing gear version
Adjust an equal play at pinion of swing gear 1 and 3 by shifting the swing circle.
For this use the installed adjusting bolts.
Afterwards adjust play at swing gear 2 to the same value before adjusted at gear 1
and gear 3.
Tooth backlash
Swing gear Play nominal value
gear 1
gear 2
gear 3
Tooth 1 Tooth 2 Tooth 3 Tooth 4
refer to table
at page 10
AH00511h
Page 17 of 22
5.4
Hints for rotating the swing circle
1. Remove the swing motor.

2. Remove the hoses at the other swing motor(s) if the shovel is equipped with more than
one swing motor.
3. Loosen the swing brake(s) by applying external pressure (25 - 60 bar).
4. Use the below shown tool in place of the removed swing motor for rotating
the swing circle (drive: 36 mm).
36 mm
The shown tool can be used for Series:

PC3000; PC4000; PC5500; PC8000.
Toothed shaft:
DIN 5480
W 60x2x30x28x9g
Part no.: 864 501 40
AH00511h
Page 18 of 22
Tighten all SC fastening bolts with the torque determined. Use the
same torque multiplier you have used for the determination.
Before mounting the bearing surface of bolt head, threads and

washers have to be applied with compound PN 324 969 40.
Fasten crosswise fastening bolts (7) with the previously determined tightening torque.
This has to be performed twice or three times, to ensure a setting of the bolts.
During tightening check permanently toothed outer ring (6) for easy running. For this
purpose unscrew hydraulic lines of swing motor and loosen all swing brakes by
applying external pressure (25 - 60 bar).
Check for easy motion in all ranges by turning the outer ring (6).
After tightening of all bolts (7) from SC to the superstructure, the tooth backlash
has to be checked once more at 4 points, if necessary adjust again.
Lower platform with SC on center section of the undercarriage. Watch position of

not hardened spot "S" of the ring (6. If necessary turn ring (6).
Screw in 8 measuring bolts with washers resp. bushings (11) evenly distributed
and the other fastening bolts (8) with washers (10), and bushings (11).
Tighten crosswise all fastening bolts (7/8) with the previously determined
tightening torque. This has to be performed twice or three times, to ensure a
setting of the bolts.
AH00511h
Page 19 of 22
6.
Checking of bolts
To compensate settling between SC and parts connected to it the bolts must be

checked after 1000 operation hours. If necessary, retighten bolts with the
determined torque.
Unscrew the eight test bolts (4) of the connection SC / carbody.

Determine the required torque again with these eight test bolts (4)
Retighten all bolts (4/7/8) with the same torque multiplier you have used for the
determination.
7.
Lubrication and maintenance (RDV)
7.1. Roller bearings

Races of roller bearings must be lubricated regularly using high quality brands of
lubricants.
This is particularly important before and after longer interruptions of operation
(e.g. winter intermission).
The grease content in the race system is intended to avoid friction, to seal and to
prevent corrosion. Greasing must be done abundantly until a continuous collar of
grease pours out of the entire circumference of the upper seal "L" and the lower
bearing gap "G".
When greasing check visually the upper bearing seal "L" and, if necessary, replace
immediately in order to prevent dirt and/or water to penetrate into the race system.
Avoid cleaning agents to enter the race system when

cleaning the shovel with high-pressure water or with vapor
blast apparatuses. Before and after each cleaning grease
thoroughly. The even distribution of grease requires swing
circle of the superstructure during greasing.
AH00511h
Page 20 of 22
Lubricating by central lube systems use

With central lube systems, the lubricating intervals are controlled by the time control
unit and the grease quantity is controlled by the adjustable metering valves /
distributor valves in order to meet the local requirements.
Manual greasing
The lubrication intervals can be found in the Lubrication and Maintenance Manual.
Before greasing clean grease nipples.
Shorter intervals must be selected in tropical climate, in high humidity, under
important effects of dust and dirt, considerable changes of temperature and
continuous swing circle motions e.g. during material transfer.
Lubricants
For greasing only use high quality grease which meets the requirements of the
KOMATSU MINING GERMANY Lubricant Specification WN 011 597 99
(Published in July 2001).
When choosing the grease, consider the ambient temperature range
(Refer also to PSN AH02539 latest version).
Exchange of the lip type seal "L" (refer to page 11)
If a damage of the seal is determined while greasing operation, it has to be
exchanged immediately, to avoid damages, caused by contamination.
The exchange has to be performed as follows:
Remove the complete lip type seal.

Clean groove fat-free, remove lip remainder completely
Insert new lip type seal (PN, refer Parts Catalogue).
The seal must not be stretched during pushing in.
Finally, the seal has to be cut to the needed length and the ends has to be glued
together. The gluten is available under PN 989 965.
AH00511h
Page 21 of 22
7.2.
Outer toothing
Adhesive lubricants may be applied by means of an automatic swing circle gear lubrication
system or manually by a spatula, a brush or a spray tin.
Lubrication with automatic lubrication system
Spray lube system
Drop lube system
Swing circle gear lubrication system
The most important requirement of a swing circle gear lubricant, besides the extreme
pressure resistance, is its optimum adhesion to the tooth flanks, which can only be obtained
by using the recommended lubricants in the prescribed temperature ranges. The Parts &
Service News AH00519 (latest version) includes several adhesive lubricants providing
excellent results on several machines under different working conditions.
The use of other lubricants is not recommended before consultation of the
Service Dept. 8151.
Lubrication: Manual
The manually lubrication has to be carried out with the following adhesive
lubricants.
Those lubricants are suitable for all temperature ranges.
AH00511h
Page 22 of 22
General
The adhesive lubricants protect the tooth profile against dust, dirt, and damage
resulting from driving or braking actions. However, this protection is effective only
when the adhesive greases have been applied to clean surfaces where it can form a
continuous coating.
When bright spots show up at the tooth profile the toothing must be sprayed or laid
on immediately with the special adhesive grease.
When visiting customers, the service staff or dealers should also check the machine
equipment and stock of lubricant and advise the exchange, if necessary, to prevent
premature wear of the toothing.
The adhesive lubricants provide totally different features

compared to the Bearing greases / MPG (e.g. used in the central
lubrication system). Hence, those lubricants must not be
replaced against each other or mixed.
Example: This may happen when grease pressed out of the upper
sealing system of the races forms too big collar at the
swing circle and penetrates into the toothing. This
eventuality must be avoided by removing the excess
grease.
If tooth profiles of the swing circle connection have been

damaged due to one of the above-mentioned reasons they do
not fall under our warranty.
AH00511h
COMPONENT CODE:
30
REF NO.
AH00515c
DATE
July 5, 2006
Page 1 of 10
This PARTS & SERVICE NEWS supersedes the previous issue No. AH00515b
SUBJECT:
Final drive:
Wear and tear measurements

Mounting procedures
PURPOSE:
Revision
APPLICATION:
H 185S; H 285; H 285S; PC4000; PC5500 (#15026 and up);

H 485; H485S; H 685S/SX; H 655S; PC8000
FAILURE CODE:
3000CA
DESCRIPTION:
1. Wear and tear measurements
1.1 Radial wear determination
a) Preparation
b) Measuring procedure Method A
c) Measuring procedure Method B
d) Determination of wear depending on the Bushing version Old or New
1.2. Axial play determination of the hollow shaft
a) Measuring procedure
b) Reducing the axial play by remachining
2. Mounting procedures
2.1 Mounting of drive shaft
a) Gap between drive shaft and cover plate
b) Measuring procedure
c) How to establish the recommended gap
2.2 Exchange bushings
a) Freeze shrinking bush
b) Flange Assy. with freezed in bush
3. Final works

The wear- and tear-measurements on the bearing bushings in mounted condition
inform quickly and exactly about the axial and parallel abrasion, without quickly a
time and cost-intensive disassembly of the final drive.
It is recommended to perform the measurements every 5000 working hours to
avoid consequential damages as a result of a too high abrasion amount.
The wear- and tear-measurements are described and illustrated on the following
pages.
AH00515c
Page 2 of 10

1.1. Radial wear determination
a) Preparation
For the measurements proceed according to the following sequence:
Place suitable oil pan for outflowing oil and remove cover (H).
Operate travel gear that the bores (B) in the hollow shaft are placed in vertical
position (see illustration).
Turn the superstructure to the illustrated position.
Hoist the sprocket side by using the attachment, until a wooden plank can be
placed under the track (middle of sprocket).
Lift attachment until the bucket no longer touches the ground.
AH00515c
Page 3 of 10
b) Measuring procedure Method A
Place dial gauge bracket with magnet (1), dial gauge (2) and bolt (3) as shown in
illustration below.
Set dial gauge (2) to 0 when attachment is lifted. Wooden plank must lie under
the sprocket.
Hoist the sprocket side by using the attachment until the wooden plank is free.
Take reading of dial gauge.
c) Measuring procedure Method B
Check by using a feeler gauge between hollow shaft and bearing bush.
AH00515c
Page 4 of 10
d) Determination of wear depending on the Bushing version Old or New
Because of technical development the bushings (P/N 429 649 40 for H 485; H485S;
H 685S/SX; H 655S; PC8000) and (P/N 429 652 40 for PC4000) are made of a new
material and have spiral grooves instead of radial grooves of the former version.
Type
H 485; H485S; H 685S/SX;
H 655S; PC8000
H 285; H 285S; PC4000
PC5500 (#15026 and up)
Bearing assy.*
(outside)
old
new
Bearing assy.*
(inside)
old
new
Bushings *
old
new
31335540
91159540
31335640
92298040
42964940
92298440
36103640
----
92253840
93360240
36103740
---
92253940
93360440
42965240
---
92253740
93360040
* Refer to the respective Parts Catalogue of the machines.
Old bushing version
The radial play after new machine assembly amounts to 0.35 mm to

0.45 mm *.
If the maximum permissible parallel play comes up to 2 mm, the
bushings have to be changed *.
* H 485; H485S; H 685S/SX; H 655S; PC8000 only up to S/N 12041.
PC4000 only up to S/N 08155.
New bushing version
For machines with the new bushings (P/N 922 984 40) the radial
play after installation amounts to 0.74 mm to 0.85 mm.
If the maximum permissible parallel play comes up to 2.0 mm,
the bushings have to be changed.
AH00515c
Page 5 of 10
1.2. Axial play determination of the hollow shaft

a) Measuring procedure
Make bracket (1) as shown in the illustration. The bores dia. have drilled
respectively to the thread diameter (see table).
Screw threaded rods (4) into the hollow shaft.
Mount nuts (3), bracket (1) and bolts (2) as shown in the illustration.
Hoist the sprocket side by using the attachment until the sprocket no longer
touches the ground.
Slide hollow shaft in by using nuts (3) until it comes against the final stop.
Place dial gauge with bracket, set dial gauge to 0.
Slide hollow shaft out by nuts (3) until it comes against the final stop.
Take reading of dial gauge.
When the maximum values (see table) are reached, the play can be reduced to
the new machine value by remachining according to page 5.
Type
H 185 / S
H 285 / S
PC4000
PC5500
H 485 / S
H 685S / SX
H 655S/PC8000
Mounting
bolt (2)
Threaded
shaft (mm)
M 12
M 16
M 16
M 12
M 16
M 16
M 16
M 16
M 20
M 20
M 20
M 20
M 20
M 20
Gauge (S)
(mm)
316
360
360
435
460
460
460
Axial play
new (mm)
0.2 0.9
0.2 0.9
0.2 0.9
0.2 0.9
0.2 0.9
0.2 0.9
0.2 0.9
Max.
permissible
axial play
(mm)
2.75
2.75
2.75
2.75
2.75
2.75
2.75
AH00515c
Page 6 of 10
b) Reducing the axial play by remachining
When the axial play comes up to the maximum value according to the table on page
4, flange (2) can be remachined in area (E) , to bring the axial play to the new
machine condition.
Underpin sprocket, suspend to a crane.

Remove bolts (S) (see page 06), remove flange (2) by means of puller bolts.
Remachine flange (2) in area (E), until the axial play (new value) is reached.
For the mounting , proceed in inverse sequence of the removal.
AH00515c
Page 7 of 10
2. Mounting procedures
2.1 Mounting of drive shaft
a) Gap between drive shaft and cover plate
Install drive shaft (12)
The drive shaft has a multi-spline shaft at both ends.

The correct mounting position is when the longer toothing
faces the gear.
b) Measuring procedure
Check if the drive shaft rests completely against the stop in the gear by means of
a hit with a mounting bar and a metallic click is audible.
Measure dimension A at the cover plate (7).
Measure dimension B according to the illustration by mean of measuring
device (1).
Calculate the existing play with formula:
B minus A = 2 mm.
c) How to establish the recommended gap

Play too much, machine cover plate at surface C.
Play too low, machine cover plate at surface D.
C
Cover
(Drawing
enlarged)
D
B
12
A
AH00515c
Page 8 of 10
2.2 Exchange bushings
The removal of the travel gear is described in Service News

AH00514 (latest version), the mounting of the dual-cone seals
(4) is described in Service Bulletin AH05511 (latest version).
Exchange bushings are available in the following types:

a) Freeze shrinking bush
Exchange bush (3) has to be fixed by freeze- shrinking according to Service Bulletin
21 62a. Afterwards, it has to be remachined to the final dimension according to
table below. Parts (3; 4; 5 and 6) have to be ordered for the conversion. For the part
no. refer to the respective Part Catalogue of the machines.
Type
Dnew (mm)
H 185 / S
355.35+0.07
H 285 / S
400.56+0.06
PC4000
PC5500
400.56+0.06
480.67+0.06
H 485 / S
520.74+0.07
H 685S / SX
520.74+0.07
H655S/PC8000 520.74+0.07
AH00515c
Page 9 of 10
b) Flange Assy. with freezed in bush
If the remachining of the flange under consideration of the tolerances and diameters
is not possible, it is recommended to order the flanges with freezedin and machined
bushings , to shorten the standstill of the machine.
For conversion, the parts shown below (3; 4; 5; 6 and 7) have to be ordered
according to the respective Parts Catalogue of the machines.
AH00515c
Page 10 of 10
3. Final works
(For detailed informations refer to the respective Maintenance Manual of the
machines.)
1. Fill in new oil up to the MAX marking on oil level gauge (3).
2. After short operating period check oil level and gear for leaks.
AH00515c
COMPONENT CODE:
25
REF NO.
AH00519e
DATE
January 15, 2007

Page 1 of 4
This PARTS & SERVICE NEWS supercedes the previous issue AH00519d
SUBJECT:
PURPOSE:
Revision
APPLICATION:
All types
FAILURE CODE:
2500Z9
DESCRIPTION:
The transmission of a torque from the slew pinion to the toothing of the slew ring
causes the slewing of the superstructure. The existing extreme force in this section
requires the separating of the engaged gears by means of grease film, to ensure a
proper damping of shocks and to prevent metallic abrasion.
Adhesive lubricants may be applied by means of an automatic slew ring gear
lubrication system or manually by a spatula, a brush or a spray tin. Automatically
tooth lubrication systems provides the upper most protection because of the
continuously uninterrupted lubrication, permanent checks are not required.
AH00519e
Page 2 of 4
Independent of the lubricant and lubrication system, the

toothing should be visually checked approx. every 500 working
hours. If the check is not possible because of applied lubricant,
the toothing has to be cleaned at several points equally
distributed on the circumference of the slew ring. In case of
wear or damages, Dept. 8151 has to be informed to discuss
suitable remedies.
These adhesive lubricants provide totally different features

compared to the Bearing greases / MPG (e.g. used in the
central lubrication system). Hence, those lubricants must not
replace against each other or mixed.
Example: This may happen when grease (1) pressed out of the
upper sealing system of the races forms too big collar at
the slew ring and penetrates into the toothing (2).
This eventuality must be avoided by removing the excess
grease.
AH00519e
Page 3 of 4
The following table includes several adhesive lubricants providing excellent results on
several machines under different working conditions.
The use of other lubricants is not recommended before consultation of Dept. 8151.
Note: Use these Greases for Swing Circle open Gear Lubrication only
Ambient Temperature
C
F
Supplier
-50
-58
-40
-40
-30
-22
-20
-4
-10
14
0
32
10
50
20
68
30
86
40
104
50
122
60
140
Castrol Molub-Alloy 936 SF Heavy NG

Castrol
Industrie
GmbH
Castrol Molub-Alloy 936 SF Heavy

Castrol Molub-Alloy
958 SF
Castrol Molub-Alloy 936 SF Arctic
BERULIT GA 2500 / BERUGEAR W4000
BECHEM
BERULIT GA 800
BERUGEAR
W 3000
Beru Gear FG 34 (Biodegradable)
Molub unee lubricant 7059
Molub Gear Tac 6895
BEL RAY
Molub Gear Tac
6894 / 6899
ESSO
Dynagear Extra
Ceplattyn KG 10 HMF
FUCHS
LUBRITECH
Ceplattyn KG 10 HMF LT
URETHYN HG O *1)
MOLYBOND
TSG Heavy
Malleus GL 500
SHELL
Malleus GL 400
Malleus GL 25
TEXACO
LUBRITENE
*1)
*2)
Crater 2X Fluid *2)

Lubrene Multi ServOGL
The URETHYN HG O Grease should only be used in Arctic climates where the ambient temperatures fall
to 50 C. In regions where the ambient temperatures do not fall below 40 C,
a grease of the temperature range to 40 C should be used.
Use the Crater 2X Fluid for Spray systems only.
AH00519e
Page 4 of 4
The manually lubrication has to be carried out with the following adhesive lubricants.
Those lubricants are suitable for all temperature ranges.
Company
Product
T1
-5C +60C
+23F +140F
T2
-20C +10C
-4F +10F
T3
-40C -10C
-40F +14F
Voler Compound
KOMATSU
2000 E
Spray
(0,625kg)
P/N 500 893 98
Voler Compound
Special
grease
2000 E
Adhesive lub
(indicate
quantity in kg)
P/N 006 057 98
What has to be done in case of grease exchange according to

the chart on page 03 ?
The new adhesive grease may directly be changed without a
complete cleaning of the toothing. An increased grease supply
after the exchange is recommended until the toothing is
completely applied.
AH00519e
COMPONENT CODE:
K1; J1
REF NO.
AH01513
DATE
06252001
Page 1 of 4
This PARTS & SERVICE NEWS supercedes the previous issues No.: 21491 which
should be discarded.
SUBJECT:
PURPOSE:
Avoiding of cavitation
APPLICATION:
All types
FAILURE CODE:
J100PH; K100PH
DESCRIPTION:
The bleeding of the hydraulic pumps (Axial piston and Gear pumps) and the complete
filling of the suction oil reservoir and the suction lines has strictly be done, to prevent
damages caused by air in the suction system (cavitation). If the oil level decreases in the
suction oil reservoir or the pump flows empty in case of commissioning or repairs the
bleeding of the system is momentous and has to carried out as follows.
The bleeding procedure has to be carried out on all pumps !
Hydraulic
pump
PTO
Suction
line
Hydraulic oil
reservoir
Cock
closed
Suction oil reservoir
AH01513
Page 2 of 4
Hydraulic pumps at the Pump Distributer gear (Example PC4000)
3; 4
Gear pumps
1; 2
Axial piston pump (bent axis design)
I; II; III; IV
Axial piston pump (swashing plate design)
AH01513
Page 3 of 4
1. Gear pump
5
4
Cock
closed
Precondition
Hydraulic oil reservoir (1)
filled
Cock (2) closed
Suction oil reservoir (3)
totally empty or decreased
level
Suction line (4) empty
Hydraulic pump (5) empty
3
2
5
outflowing
oil
Measure
Place oil pan for out coming
oil.
Loosen suction line (4)
Open cock (2), when oil
runs out, reconnect suction
line (4)
Cock
opened
3
2
The a.m. precondition has also be observed for the
axial piston pumps.
2.a Axial piston pump (bent axis design)
Precondition (see above)

Measure
Remove plug (6)
Open cock (2)
When oil flows out of the
bore, insert plug (6) tighten.
Cock
opened
The bleeding plug (6) may be placed different, it depends on
the design and mounting position.
AH01513
Page 4 of 4
2.a Axial piston pump (swashing plate design)

The pump housings has to be filled up with hydraulic oil before installation and after
repairs via the special bore (A) or via the leak oil connection (B).
The suction lines of the Axial piston pumps (swashing plate
design) have to be bled via plug C.

For that open the plug and wait until oil is coming out.
After the bleeding procedure, the hydraulic oil reservoir has to be refilled to the
permissible level.
AH01513
COMPONENT CODE:
A2
REF NO.
AH01521a
DATE
20 Sept. 2002
Page 1 of 9
This PARTS & SERVICE NEWS supersedes the previous issue No.: AH01521
dated November 2001 which should be discarded.
SUBJECT:
PURPOSE:
Hints for checking
APPLICATION:
H 185; H 255; H 285; H 455; H 485; H 655; H 685; PC3000;

PC4000; PC5500; PC8000
FAILURE CODE:
A2T0EH
DESCRIPTION:
Diesel engines are mounted on elastic elements. With increase of life the flexible
mountings will show setting effects.
1.
Inspection intervals
Damages to the engine might arise if the bolts of the flexible

mountings are not tightened correctly.
1.1
Therefore check bolts after the following intervals:
Prior to putting the machine into operation or after replacement of the flexible
mountings
after the first 250 operating hours
every 1000 operating hours or every 6 month latest
1.2
The elastic engine suspension must be checked (visual check):
Every 6 month or every 1000 operation hours (check the flexible mountings for
damage).
1.3
Check the fatigue of the rubber elements according to the appendix

(pages 5 to 9) once a year and give the records to our service department.
Take a calliper.
AH01521a
Page 2 of 9
2.
Kinds of mounts
There are two types of mounts at each location:

Type A: Flexible engine mountings
Type B: Flexible engine mountings with self locking nut item (3) for limiting of the flexible
distance.
3.
Control measures (see also in your Operation and Maintenance Manual)

(Caterpillar-Engine fig.1; Cummins/Komastu - Engine fig.2)
All tests during motor stop!
The bolts of the flexible engine mountings have to be checked as follows:

1. Tighten the bolt (2) to 880 Nm (649 lbf ft).
2. Position the nut (3) so it just touches the steel plate of the rubber mount item (6).
Tighten the nut an additional turn (90).
Over tightening of this nut will result in removing the required

elasticity of the rubber mounts and may cause engine failure.
3. Only by Cummins Engines

Check distance C between torque support and stop bolt(4).
With setting of the flexible engine mountings the distance C increases and must be
readjusted. To do this, loosen lock nut (7) and tighten stop bolt (4) until the correct
distance C is obtained. Tighten lock nut (7) and recheck distance (C).
4. Check all rubber metal bars (1) and all strips (6) for damage.
All rubber metal bars(1), all strips(6) and all cup springs(5)
should be replaced during engine overhaul.
AH01521a
Page 3 of 9
Fig. 1: For example
PC8000 with Caterpillar - engine
2
A
A
B
6
B
A
3
2
M24x150
M24x150
M24x350
Legend:
(A); (B) Two types of engine mounts
(1)
Rubber metal bar
(2)
Bolt of engine mount type (A
(3)
Self locking retainer nut of the
engine mount type (B))
(6)
Strip
AH01521a
Page 4 of 9
Fig. 2: For example
PC4000 with Cummins/Komatsu - engine
LEGEND:
(A); (B) Two types of engine mounts
(C)
Distance between torque support
and stop bolt(4)
(1)
Rubber metal bar
(2)
Bolt of the engine mount type (A)
(3)
Self locking retainer nut of the
engine mount type (B)
(4)
Stop bolt
(5)
Cup spring package
(6)
Stip
(7)
Lock nut
5
C
7
2
6
B
1
A
Lock nut tighten

snugly
B
3
AH01521a
Page 5 of 9
Record of measurement - fatigue of the engine bearings

Excavator model:
PC3000
Inspector:
Serial number:
Date:
Engine manufacturer:
Signature:
Measuring
point
Value (X)
(mm)
1
2
3
4
5
6
7
8
AH01521a
Page 6 of 9

Excavator model:
PC4000
Inspector:
Serial number:
Date:
Signature:
Measuring
point
Value (X)
(mm)
1
2
3
4
5
6
7
8
AH01521a
Page 7 of 9

Excavator model:
PC5500
Inspector:
Serial number:
Date:
Signature:
Measuring points
PC5500
Pump distributer gear
Measuring
point
Value (X)
(mm)
1
6
2
Engine
2
3
4
5
6
7
8
AH01521a
Page 8 of 9

Excavator model:
PC8000
Inspector:
Serial number:
Date:
Signature:
Measuring points
PC 8000
2
Engine
7
Measuring
point
Value (X)
(mm)
1
2
3
4
5
6
7
8
8
AH01521a
Page 9 of 9

Excavator model:
PC8000
Inspector:
Serial number:
Date:
Signature:
Measuring points
PC 8000 (CAT)
Measuring
point
Engine
6
Value (X)
(mm)
1
2
3
4
5
6
7
8
AH01521a
COMPONENT CODE:
30; 63
REF NO.
AH01531A
DATE
06122002
Page 1 of 9
This PARTS & SERVICE NEWS supersedes the previous issues No. 21-426; 21-549 and
AH01531 which should be discarded.
SUBJECT:
Hydraulic accumulators testing and refilling
PURPOSE:
Regular check
APPLICATION:
All types
FAILURE CODE:
307EPB; 6347PB
DESCRIPTION:
The testing and refilling of the hydraulic accumulators have to be performed
by testing- and refilling device Part no. 761 520 73.
When ordering this particular device, please always indicate country of destination.
1. Testing of existing gas

pressure at piston and
diaphragm accumulators
For testing of existing gas
pressure at bladder accumulators,
refer to page 7 9.
Stop engine.
Allow pressure relief of the

system to be checked.
Remove protective cap from accumulator.
Unscrew a union of the feeding line in order

to allow the hydraulic oil to pour out.
AH01531A
Page 2 of 9
The testing- and refilling device includes following pressure gauges:
0 to 25 bar
0 to 100 bar
0 to 250 bar
Screw the pressure gauge with

the correct pressure range into
the testing and refilling device.
Screw home screw (14) at the

filling device.
Loosen the socket-head screw

of the gas valve by turn
with a hex key 6 mm.
Screw filling device without

hose carefully by hand onto
accumulator.
Observe correct position of

the o-ring.
Check valve in hose connection is operative only if hose is not

connected.
Turn T-handle (12) several

times in both directions
until it is engaged in
socket head of gas filler screw (11).
By means of the T-handle unscrew

gas filler screw (11) by 4 to 5 turns
until pressure gauge indicates the
existing gas pressure.
AH01531A
Page 3 of 9
For the specified gas pressure of the piston-diaphragm and bladder

type accumulator, refer to the circuitry diagrams in the Operation Manual.
Compare the pressure reading on the gauge with the specified gas pressure.
If the pressure reading is too low, the accumulator has to be refilled.

To fill the accumulator, a pressure reducing valve must
be used.
Only nitrogen must be used to fill the accumulator.
2. Filling of the accumulator
Close shut-off valve (5) at the bottle pressure reducing valve. Turn
in completely outlet screw (14) of filling device and install the hose.
AH01531A
Page 4 of 9
Open valve (8) of nitrogen

bottle and check bottle pressure.
The bottle pressure must always be
higher than the pressure specified
for the accumulator.
adjust specified accumulator

pressure with pressure-reducing
valve (6).
Turn out the filling screw (11)

by means of the T-handle of the
filling device.
Open slowly shut-off valve at

bottle pressure reducing valve
and let nitrogen flow into
accumulator, until pressure gauge
on filling device indicates the
specified pressure. Then close
shut off valve.
AH01531A
Page 5 of 9
Wait for temperature to be

equalized (approx. 5 min.)
and open outlet screw (14)
to let the pressure drop to
the specified value.
Close outlet screw (14).
Screw in tightly screw (11) by

means of T handle (12).
Open outlet screw to let

nitrogen escape from filling
device.
Disconnect hose connection and

unscrew filling device.
Fasten O - ring (13) to the

testing device.
Tighten the screw (11) by means

of a hex key 6 mm.
AH01531A
Page 6 of 9
Reinstall protective card and

retighten union in feeding line.
Close bottle valve (8).
Turn out completely the

T handle at the pressure
reducing valve (6).
AH01531A
Page 7 of 9
3. Testing of existing gas pressure bladder accumulators

The testing- and refilling device includes
pressure gauges:
0 to 25 bar
0 to 100 bar
0 to 250 bar.
Screw the pressure gauge with the correct

pressure range in the testing- and refilling
device.
Shut down the engine.
Allow pressure relief of the system to be
checked.
Unscrew the feeding line in order to allow the
hydraulic oil to pour out.
Remove cap (1) and nut (2).
Do not remove O - ring (3).
Check valve in hose connection is

operative only when hose is not connected.
Turn the socket head screw (4)

installed in the adapter (2) a little bit.
Mount testing- and refilling device to adapter
(2).
Install adapter (2) to testing connection (3).
Turn in completely outlet screw of the filling
device.
Turn T handle (12) several times in both
directions until it is engaged in the screw (4) of
the adapter (2).
By means of the T handle (12) turn in the
screw so far that the existing gas pressure is
indicated by the pressure gauge.
Do not turn in the screw any further; the gas
valve may be destroyed.
AH01531A
Page 8 of 9
If the pressure reading does not correspond with the nominal filling pressure,
the accumulator has to be refilled.
4. Filling of the bladder accumulator

To fill the accumulator, a pressure reducing valve must be
used.
Only nitrogen must be used to fill the accumulator.
Close the shut off valve (5)

on the pressure-reducing valve.
Turn in completely the outlet

screw (14), see illustration on page 5.
By means of the T-handle (12), turn

out the screw (4) of the adapter (2)
until the gas valve in the testing
connection (3) of the accumulator is
closed. After that, install connecting hose.
Open the valve (8) at the nitrogen

bottle and check the gas pressure of
the bottle.
The gas pressure of the nitrogen bottle
must always be higher than the specified
filling pressure of the accumulator.
Adjust the specified filling pressure

by means of setting screw (6) of the
pressure reducing valve.
Open the gas valve in the testing
connection (3) of the accumulator ba
turning in screw (4).
Slowly open the shut off valve (5) at

the pressure reducing valve and fill
the accumulator until the pressure
gauge (7) of the testing and refilling
device indicates the specified filling
pressure.
Then close the shut-off valve (5).
AH01531A
Page 9 of 9
Wait for temperature to be

equalized (approx. 5 min) and,
if necessary, reduce pressure
with outlet screw (14) or let
the pressure reach the specified
value according to page o4.
Close outlet screw (14).
By means of T-handle (12) turn

out screw (4) from the adapter (2)
till the gas valve in the testing
connection (3) is closed.
Open outlet screw (14) that the

nitrogen can escape from the
filling and testing device.
Close the nitrogen bottle and
remove the filling- and testing
device, filling hose and pressure
reducing valve.
Turn out completely screw (6) of
the pressure-reducing valve.
By doing so, the spring-reducing
valve is discharged.
Re-install protection cap in the

testing connection.
Re-tighten the hydraulic line.
AH01531A
COMPONENT CODE:
25
REF NO.
AH02513b
DATE
January 4, 2005
Page 1 of 4
This PARTS & SERVICE NEWS supersedes the previous issue No. AH02513a
SUBJECT:
PURPOSE:
In time ordering of a new swing circle

in order to prevent unexpected downtime
APPLICATION:
All types
FAILURE CODE:
2500CA
DESCRIPTION:
For assessing the condition of the swing circle bearing, we recommend that its normal
wear rate is determined.
The first measurement must be performed when the excavator is put into operation in order to
obtain a base value for subsequent repeat measurements.
The following measurements have to be effected:
1. Period of the first 10.000 h:
2. Period more than 10.000 h:
every 5.000 working hours;

every 2.500 working hours.
After finishing the measurements, record the values obtained in a tabular form.
The diagram shows the principle of bearing wear progression.
If the increased wear situation is reached, prepare the changing of the swing circle.
We recommend to turn the swing circle (180) after 20 000

working hours.
normal wear
increased extrem wear

wear
Axial movement/wear
mm
Base value
Working hours
h
AH02513b
Page 2 of 4
Measurement procedure
1. Park the machine on level ground.

2. Slew the attachment to the normal working position (idler wheel in front).
3. Remove cover as shown in the photos (Illust. 7 and 8).
4. Clean the center slew gear tooth and the contact point on the superstructure.
5. Install the dial gauge* as shown in the photos.
6. Turn the swing brake switch in the on position.
7. Straighten the attachment fully (lmax) and raise the shovel approx. A=3 m over the
ground (Illust. 1, 3 or 5).
8. Set measuring instrument (dial gauge*) to zero.
Make sure the area below and around the excavator is clear of
all persons before you start operating.
9. Move the attachment in the shown position (Illust. 2, 4 or 6).

Lower the attachment until the track lift off the ground up to the sprocket (B).
Use for all measurements the same distances A and B.
10. Move the attachment in the normal parking position.

11. Read measurement M 1 (out of the memory) and record in the table (page 4).
12. Repeat the measuring procedure at the same point for a 2nd value (M 2).
13. Remove the dial gauge, swing the superstructure 180 degrease and repeat the
measuring procedure two times.
* We recommend to use a digital dial gauge with min. / max. measuring value
memory (Part No. 794 537 73).
Photo only as example
AH02513b
Page 3 of 4
AH02513b
Page 4 of 4
Excavator Typ:
Planned
h
0
Actual
h
Date
Serial number:
Front
M1
Front
M2
Mfront =
(M1 + M2)/2
Rear
M1
Rear
M2
Mrear =
(M1 + M2)/2
5 000
10 000
12 500
15 000
17.500
20 000
22.500
25 000
27.500
30 000
32.500
35 000
37.500
40.000
AH02513b
COMPONENT CODE:
75
REF NO.
AH02521b
DATE
April 3, 2007
Page 1 of 10
This PARTS & SERVICE NEWS supersedes the previous issue Number AH02521a which
SUBJECT:
PURPOSE:
Revision
APPLICATION:
H 185 to PC8000
FAILURE CODE:
752DCA
DESCRIPTION:
1.
2.
3.
4.
5.
6.
7.
Preconditions for the measurements

Adjusting range for guide wheels
Chain elongation / measured over three track pads (4 pins)
Circular pitch (Sprocket / Track pad)
Wear of track pads (Roller contact surface)
The X-dimension becomes zero
Table
The professional and regular inspection increases the service life of the track group and
can avoid early and very expensive repairs, including unforeseen standstill of the machine.
It is recommended to perform the inspections every 3 month or 1500 working hours
according to the description and to fill in the measured values to the table on page 10.
The measurements are described in detail and illustrated on pages 4 to 6.
To prevent unnecessary problems and standstills and to assure fast help when wear limits
are reached, it is recommended to send the filled-in tables in the mentioned intervals to
Komatsu Mining Germany, Service Department 8151.
Illustration 1
AH02521b
Page 2 of 10
1.
Preconditions for the measurements:
1.1.
Cleaning of the track group, according to the Maintenance Manual
Illustration 2
1.2
Track sag (A):

On Machines without the hydraulic track - tensioning system
up to max. 230 mm
H 185S
H 285 - H 285S
up to max. 300 mm
H 485 - H 485S
up to max. 420 mm
1.3
Track sag (A):

On Machines with hydraulic track - tensioning system
No specification, since self-regulating
Illustration 3
AH02521b
Page 3 of 10
2.
Adjusting range for guide wheels
Illustration 4
Legend
(1)Guide wheel
(2)Slide block
(3)Stop plate
X Adjusting range for track tension
The adjusting range for track tension is the distance X between guide wheel slide block
(2) and stop plate (3). Depending on the stretching of the track the slide block (2) may
come in contact with stop plate (3). In such a case, it must be ensured that the track does
not become too loose. Depending on track condition; the removal of one track pad will
restore the adjusting range X. If necessary contact our Service Department for more
information.
AH02521b
Page 4 of 10
3.
Chain elongation / measured over three track pads (4 pins)
This wear check has to be carried out in 4 equally distributed areas of the track chain
(L1 to L4 - l.h. and R1 to R4 - r.h.).
Turn superstructure 90 to the travel direction.
Retract attachment and lower bucket on the ground until the chain has no longer
contact with the ground.
Block the machine against inadvertent lowering with suitable
devices.
Turn sprocket until the first measuring area (L1) is located at the deepest point of sag (T).
To measure the areas L2-L4 turn the chain always forward until
point T is reached.
To obtain a comparable measuring result, stop the main drive motor/engine of short
duration, so that the track tensioning system is released to pilot pressure.
Place the points of the dividers into the centre bores of pins 1 and 4 of the measuring
area L1 / R1, determine the distance and record in the table on page 10.
Repeat measuring procedure at measuring areas L2 / R2 to L4 / R4.
Illustration 5
AH02521b
Page 5 of 10
4.
Circular pitch (Sprocket / Track pad)
For this inspection, the excavator has to be placed on an even surface and only one chain
has to be moved, like turning.
Diesel engine:
Electric motor:
Operate at low idle.

Operate joy-stick slightly.
Move l.h. track group forward (Sprocket rotation F = forward), until the contact area of
the uppermost sprocket tooth (0) and the track-pad lug (0) is in the illustrated position,
(Refer to illustration 6 A, page 6).
Measure gaps (X1). A. Measure inside and outside of the sprocket between the
sprocket teeth (7) and track-pad lug (7) at 3 points, equally distributed on the chain.
Record the values into table -circular pitch A- on page 10.
Repeat the measurements on the r.h. track group.
Move l.h. track group back (Sprocket rotation R = backwards), until the contact area of
the lowest sprocket tooth (0) and the track-pad lug (0) is in the illustrated position,
(Refer to illustration 6 B, page 6).
Measure gaps (X2). Measure inside and outside of the sprocket between the sprocket
teeth (7) and track-pad lug (7) at 3 points, equally distributed on the chain.
Record the values to the table -circular pitch B- on page 10.
Repeat the measurements at the r.h. track group.
5.
Wear of track pads (Roller contact surface)
Stop the engine/motor and secure the machine against unintentional movement.
Mark 3 track pads of each track group (l.h. track group and r.h. track group) to make
repeated measurements in the future comparable.
Take a ruler to measure the wear of the roller contact surface. The ruler needs an even
contact surface, if not exist, prepare the track pad as necessary.
(Refer to illustration 6 C, page 6).
Record the measuring results in the form sheet on page 10.
For wear limits of individual parts please refer to

P&S News AH06507 Undercarriage wear limit values.
AH02521b
Page 6 of 10
Illustration 6
AH02521b
Page 7 of 10
6.
One X-dimension becomes zero
What to do if one X-dimension becomes zero

1.
If the connection point of Roller path depth and Elongation is in the oversize
sprocket area*, change to oversize sprocket.
2.1 If the connection point of Roller path depth and Elongation is in the standard
sprocket area* run further with this configuration as long as you reach the oversize
sprocket area.
2.2 If there becomes a significant interference of sprocket and track pad match; in such
case it could become necessary to change to standard sprocket size.
* refer to illustrations 7 to 10
For the exchange of the oversize sprockets, refer to Service Bulletin AH00514.
AH02521b
Page 8 of 10
Illustration 7
Illustration 8
AH02521b
Page 9 of 10
Illustration 9
Illustration 10
AH02521b
Page 10 of 10
7.
Table for measurements
Machine-Type :
Customer :
Oversize sprocket ? :
(left hand side)
Oversize sprocket ? :
(right hand side)
NO
Serial-No. :
Location :
Date of installation:
...................
at operating hours:
.....................
Date of installation:
...................
at operating hours:
.....................
YES
NO
YES
Chain elongation (Illustration 5):

Measuring area
W-dimension [mm] via 4 pins
Left hand crawler track L

L1
Chain elongation (Illustration 5):

Measuring area
W-dimension [mm] via 4 pins
Operating hours :
Date of measurement :
Part-No. of track pad :
L2
L3
L4
Right hand crawler track R

L1
L2
L3
L4
Circular pitch:
Illustration 6 A
Sprocket side
X1-dimension [mm] L.H
X1-dimension [mm] R.H
inside
3 points (equally distributed on the chain)

1
2
outside
inside
outside
inside
inside
3 points (equally distributed on the chain)

1
2
outside
inside
outside
inside
Illustration 6 B
Sprocket side
X2-dimension [mm] L.H
X2-dimension [mm] R.H
outside
outside
Wear of Track pads (Illustration 6 C):

Track pad
Side
No.1
No.2
No.3
No.4
No.5
No.6
L.H.
L.H.
L.H.
R.H.
R.H.
R.H.
Dimension B
[mm]
Number of cracked track pads

left hand crawler track
right hand crawler track
AH02521b
COMPONENT CODE:
03
REF NO.
AH03506b
DATE
October 25, 2003

Page 1 of 5
This PARTS & SERVICE NEWS supersedes the previous issue AH03506a which should
be discarded.
SUBJECT:
PURPOSE:
Replacement of the bearings
APPLICATION:
PC4000; PC5500; PC8000
FAILURE CODE:
0373CA
DESCRIPTION:
Two types of bearing units are used for the cooler fans at the above mentioned excavator
models:
1. Grease lubricated bearings
2. Gear oil lubricated bearings
We recommend to replace these bearings to avoid

consequential damages according to the following table:
Bearing unit
Replacing time after:
Grease lubricated bearings
8 000 working hours
Gear oil lubricated bearings 10 000 working hours *
* or if damage or a leak has occurred.
The hydraulic motors for the fans should be replaced

preventively every 10.000 working hours.
AH03506b
Page 2 of 5
Hints for replacement:

1. Grease lubricated bearings
1 Bearing retainer
2 Shaft
3 Hydraulic motor
4 Fan
5 Bearing
6 Grease nippel
7 Circlip
8 Bolt
9 Bolt
10 Locking plate
1. Remove the hydraulic and the grease lines; the fan; and then the motor.
2. Remove the bearings and the fan shaft.
3. Clean all parts carefully.
4. Install the first bearing (5) and fill the chamber between the bearings to 50% with
grease.
5. Install the shaft with the first bearing (5) and the grease into the bearing retainer.
6. Install the second bearing and fix it with the circlip (7).
(Install also the sleeve between the bearings if applicable.)
7. Grease the hydraulic motor drive shaft with Optimol paste white T and fill the
chamber in the fan shaft to 50% with normal grease according to the drawing above.
8. Reinstall the bearing hub, the fan and the motor.
9. Reconnect all lines.
Grease the bearings every 500 working hours with maximal 2
strokes with the hand greasing pump.
AH03506b
Page 3 of 5

1 Bearing retainer
2 Shaft
3 Circlip
4 Bearing
5 Shaft grommet
6 Shaft seal
7 Plug
Fill the chamber at the
lip type seal with grease.
1. Remove the hydraulic lines; the fan, then the complete unit.
2. Drain off the gear oil and remove the motor, the bearings, the fan shaft, the shaft
grommet and the shaft seal.
3. Clean all parts carefully.
4. Check the dia. d according to drawing and table at the next page.
5. Install a new shaft grommet with the flanged end at first (press it into depth a see
next page).
6. Do not remove the seam of the shaft grommet.
7. Install the 1st bearing and the shaft seal into the bearing retainer.
8. Grease the shaft and install it.
9. Mount the 2nd bearing(4) and the circlip.
10. Check the spline and grease the hydraulic motor drive shaft with
Optimol paste white T.
11. Reinstall the motor by using a new O ring and mount then the fan.
12. Fill in the bearing retainer gear oil according to the Maintenance Manual.
13. Reconnect the hydraulic lines.
AH03506b
Page 4 of 5
PC4000
PC5500
PC8000
Oil
cooler
Water
cooler
Oil
cooler
Water
cooler
Oil
cooler
Water
cooler*
Part no.
Part no.
Part no.
Part no.
Part no. Part no.**
Part no.
Fan mounting
89590740 90202640 91091140 90479140 90389040 93394140 90968540b
(assy.)
Repair kit ***
Press depht
"a" (mm)
Shaft dia. "d"
(mm)
79296573 79296673 79296573 79296673 79296773 79484873 79296873
4 -0,5
3,7 +0,2
4 -0,5
3,7 +0,2
80 0,05
110 0,05
80 0,05
110 0,05
4 -0,5
6,4 0,8
1000,05 1300,025
4,3 0,8
85 0,05
* Serial No. 12040 up see drawing next page

** Serial No. 12048/12049 only
*** The Repair kit includes: 2 bearings; 1 shaft seal; 1 shaft grommet; 1 O-ring
Fill the chamber at the lip type seal with grease.
AH03506b
Page 5 of 5
PC8000-6 Water cooler fan bearings
Intermediate ring
AH03506b
COMPONENT CODE:
26
REF NO.
AH03509a
DATE
22nd July 2003

Page 1 of 25
This PARTS & SERVICE NEWS supersedes the previous issue AH03509 which should be
discarded.
SUBJECT:
PURPOSE:
Modification to slew gear GFB 174 E 9020 (Part No. 92432540)

including exchanging the sun gear shaft
APPLICATION:
PC8000 (12037 39); PC5500 (15012 15017); PC4000 (08151);

PC3000 (06194)
FAILURE CODE:
2600Z9
DESCRIPTION:
General
In order to increase the lifetime of the parking brake discs the swing gear oil filling capacity
should be reduced by approximately 20 liters. The new filling capacity is approx. 42 liters.
The present oil level gauge on the gear can no longer be used for checking the oil level.
There are two possibilities to modify the oil level checking system.
For increasing the lifetime of the slew gear the sun gear shaft should be changed during the
slew gear modification.
Page
1.
Modification Kits
2
2.
Variant (A) Modification by replacing of the swing gear cover

with the complete parking brake unit,
3.
Variant (B)
Modification by machining the swing gear cover.
3.1 Modification of the swing gear cover
a) Dismounting
b) Machining of the swing gear cover
c) Reassembly
8
11
11
12
13
4.
Completion of the swing gear cover
24
5.
Oil level checking procedure
25
AH03509a
Page 2 of 25
1.
1.0
Modification Kits
One new gear shaft is required for one slew gear
(Part No. 757 360 73 differences to the old sun gear shaft: refer to
illustration 6)
1.1
Kits for modification of the slew gear(s) according to Variant (A)
1.1.1 PC3000-1 Part No.: 794 016 73
Pos.
Part-No.
1
15
16
17
14
18
1
20
1
2
79227073
37441299
90635240
37126599
92582540
31318499
90756840
92582940
972111
50774898
Qty. Description
1
4
4
4
4
4
1
1
1
1
Cover/brake assy.
Socket
Cutting ring
Union nut
Oil level gauge tube
Plug
Oil level gauge
Oil level gauge bracket
O-ring
O-ring
Illustration
3
6
6
6
6
6
6
6
2
2
1.1.2 PC4000-6 Part No.: 794 017 73

Pos.
Part-No.
1
15
16
17
14
18
19
20
1
2
79227073
37441299
90635240
37126599
92582540
31318499
90756840
92582940
972111
50774898
Qty. Description
2
12
12
12
12
12
2
2
2
2
Cover/brake assy.
Socket
Cutting ring
Union nut
Plug
Oil level gauge
O-ring
O-ring
Illustration
3
6
6
6
6
6
6
6
2
2
(Cover plates must be adapted.)
AH03509a
Page 3 of 25
1.1.3 PC5500 Part No.: 794 018 73
Pos.
Part-No.
1
15
16
17
14
18
19
20
1
2
79227073
37441299
90635240
37126599
92582440
31318499
90756940
92582840
972111
50774898
Qty. Description
2
10
10
10
10
10
1
1
2
2
Cover/brake assy.
Socket
Cutting ring
Union nut
Plug
Oil level gauge
O-ring
O-ring
Illustration
3
6
6
6
6
6
6
6
2
2
1.1.4 PC8000 Part No.: 794 019 73

Pos.
Part-No.
1
15
16
17
14
18
19
20
1
2
1
1
79227073
37441299
90635240
37126599
92582440
31318499
90756940
92582840
972111
50774898
92583240
92583140
Qty. Description
3
14
14
14
14
14
2
2
3
3
1
1
Cover/brake assy.
Socket
Cutting ring
Union nut
Plug
Oil level gauge
O-ring
O-ring
Cover plate
Cover plate
Illustration
3
6
6
6
6
6
6
6
2
2
-
AH03509a
Page 4 of 25
1.2
Kits for modification of the slew gear(s) according to Variant (B)
1.2.1 PC3000-1 Part No.: 794 020 73
Pos.
Part-No.
15
16
17
14
18
19
20
99
504
1; 3; 4
2
37441299
90635240
37126599
92582540
31318499
90756840
92582940
33132299
79224973
972111
50774898
Qty. Description
4
4
4
4
4
1
1
1
1
3
1
Socket
Cutting ring
Union nut
Plug
Oil level gauge
Plug
Disc (thickness: 8.5-0.1mm)
O-ring
O-ring
Illustration
6
6
6
6
6
6
6
4
4
2
2
1.2.2 PC4000 Part No.: 794 021 73

Pos.
Part-No.
15
16
17
14
18
19
20
99
504
1; 3; 4
2
37441299
90635240
37126599
92582540
31318499
90756840
92582940
33132299
79224973
972111
50774898
Qty. Description
12
12
12
12
12
2
2
2
2
6
2
Socket
Cutting ring
Union nut
Plug
Oil level gauge
Plug
O-ring
O-ring
Illustration
6
6
6
6
6
6
6
4
4
2
2
(Cover plates must be adapted.)
AH03509a
Page 5 of 25
1.2.3 PC5500 Part No.: 794 022 73
Pos.
Part-No.
15
16
17
14
18
19
20
99
504
1; 3; 4
2
37441299
90635240
37126599
92582440
31318499
90756940
92582840
33132299
79224973
972111
50774898
Qty. Description
10
10
10
10
10
1
1
2
2
6
2
Socket
Cutting ring
Union nut
Plug
Oil level gauge
Plug
O-ring
O-ring
Illustration
6
6
6
6
6
6
6
4
4
2
2
1.2.4 PC8000 Part No.: 794 023 73

Pos.
Part-No.
15
16
17
14
18
19
20
99
504
1; 3; 4
2
1
1
37441299
90635240
37126599
92582440
31318499
90756940
92582840
33132299
79224973
972111
50774898
92583240
92583140
Qty. Description
14
14
14
14
14
2
2
3
3
9
3
1
1
Socket
Cutting ring
Union nut
Plug
Oil level gauge
Plug
O-ring
O-ring
Cover plate
Cover plate
Illustration
6
6
6
6
6
6
6
4
4
2
2
-
AH03509a
Page 6 of 25
2. Variant (A) Modification by replacing of the swing gear cover with the complete
parking brake unit
1.
2.
3.
4.
Prepare the swing gear cover as described on page 23.

Drain the motor adapter housing (about 0.6l oil).
Remove the 8 bolts (7) M16 mm at the hydraulic motor (refer to illustration 1).
Remove the motor with connected hoses and place it beside or if this is not possible,
disconnect the hydraulic lines and close the ports.
5. Remove the 34 gearbox fastening bolts (8) M24 and the 8 mounting screws (8) M16
from the gear box.
6. Install 2 eye bolts M16 and lift the gearbox cover with the brake unit.
7. Replace the sun gear shaft (5) (refer to illustration 2).
8. Install the new Cover-Brake-Unit by using a new O-ring.
9. Modify the Swing gear type on the type plate
old:
GFB 174 E9017 to
new: GFB 174 E9020 with punch marks.
10. Reinstall the hydraulic motor with the brake valve block by using a new O-ring.
11. Fill the motor adapter housing with oil according to the Maintenance Manual.
12. Weld on the oil level gauge brackets (20) on the hydraulic oil reservoir carrier and if so
planed a second one onto the machinery house wall.
13. Insert the attached oil level gauges (19)into the brackets.
14. Check the oil level in the swing gear as described on page 25.
AH03509a
Page 7 of 25
Illustration 1
Illustration 1 before modification
1
Oil level gauge swing machinery
Oil filler plug swing machinery
Breather filter swing machinery
Oil level gauge motor adapter housing
Breather filter motor adapter housing
Oil drain plug
Motor fastening bolts
- Gearbox fastening bolts (quantity: 34)

- Mounting screws (quantity: 8)
AH03509a
Page 8 of 25
3. Variant (B) Modification by machining the swing gear cover
1. Drain the motor adapter housing (about 0.6l oil).
2. Remove the 8 bolts (7) M16 at the hydraulic motor (refer to illustration 1).
3. Remove the motor with connected hoses and place it beside or if this is not possible,
disconnect the hydraulic lines and close the ports.
4. Remove the 34 gearbox fastening bolts (8) M24 and the 8 mounting screws (8) M16
from the gear box (refer to illustration 1).
5. Install 2 eye bolts M16 and lift the gearbox cover with the brake unit.
6. Replace the sun gear shaft (5) (refer to illustration 2).
7. Remove the old O-ring and clean the groove.
8. Modify the swing gear cover as described on pages 11 - 22.
8. Install the modified Cover-Brake-Unit by using a new O-ring.
9. Modify the Swing gear type on the type plate
old:
GFB 174 E9017 Part No. 917 915 40 to
new: GFB 174 E9020 Part No. 924 325 40 with punch marks.
10. Reinstall the hydraulic motor with the brake valve block by using a new O-ring.
11. Fill the motor adapter housing with oil according to the Maintenance Manual.
12. Weld on an oil level gauge bracket (20) on the hydraulic oil reservoir carrier and if so
planed a second one onto the machinery house wall.
13. Insert the attached oil level gauges (19)into the brackets.
14. Check the oil level in the swing gear as described on page 24.
AH03509a
Page 9 of 25
Illustration 2 Overview before modification
1
4
5
AH03509a
Page 10 of 25
Illustration 3 Cover with brake (partly)
Pressure connection
(M18x1.5) max 60 bar
AH03509a
Page 11 of 25
3.1 Modification of the swing gear cover
a) Dismounting
1. Remove the old oil level gauge assy. (390) and close the opening with a plug (99).
2. Remove the both snap rings (508; 549).
3. Loosen the 8 socket head cap screws (519).
4. Remove the bearing ring (503) by using of 2 eyebolts (M 16).
5. Before reinstallation apply the piston (116) with pressure (max. 60 bar)
(see also illustration 4), otherwise the 2 screws (316)are prestressed (springloaded).
6. Remove the 2 socket head cap screws (316).
Remove the piston (116).
6. Dismount the 10 Inner discs (505); the 11 outer discs (506) and the
10 sinus rings (551).
7. Remove the drive shaft (130).
501
8. Remove the disc (504).
99
501
390
316
551
505
503
506
504
130
549
508
116
519
Illustration 4
AH03509a
Page 12 of 25
b) Machining of the swing gear cover (501 disc housing)
1. Mill at the swing gear cover six areas as shown.
2. Drill 6 holes in the milled areas and tap 1 inch.
Illustration 5
45
45
R31.5
30
30
+0.5
30
524
660
R 1.6
30
G 5/4
AH03509a
Page 13 of 25
AH03509a
Page 14 of 25
c) Reassembly
3. Install the new disc (504) as shown.
4. Reinstall the drive shaft (130) with the ball bearing (51353298).
AH03509a
Page 15 of 25
5. Install the new discs. At first an outer disc (grease it with oil), then an inner disc and
then a sinus ring ... and so on.
AH03509a
Page 16 of 25
AH03509a
Page 17 of 25
AH03509a
Page 18 of 25
Before installation supply the piston (116) with pressure (max. 60 bar).
Do not forget to exchange the O-ring.
AH03509a
Page 19 of 25
AH03509a
Page 20 of 25
AH03509a
Page 21 of 25
AH03509a
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AH03509a
Page 23 of 25
AH03509a
Page 24 of 25
4. Completion of the swing gear cover
1. Remove plugs* (A3) from the swing gear cover.
* numbers depends on type of the excavator
2. Install the oil level gauge tubes (14; 15; 16; 17) as shown in the illustration 6.
3. Close the tubes with plugs M24 (18).
20
19
Illustration 6
A3 Plug
14 Oil level gauge tube
15 Socket
16 Cutting ring
17 Union nut
18 Plug
19 Oil level gauge
20 Oil level gauge bracket
AH03509a
Page 25 of 25
5. Oil level checking procedure (engine at standstill)
The design of the swing gear requires four or five locations for oil level checking.
The correct oil level is below the upper planetary stage. To reach this level between the
planetary gears it is necessary to find out at which of the four, five or six tubes the oil level
gauge can be insert to the stop.
Proceed as follow:
1. Take out oil level gauge (19) from bracket (20).
2. Remove plug (18) from one tube (14) and insert gauge (19).
If the gauge can not be moved in to the stop use the next tube (14).
Repeat this procedure until the gauge can be inserted to the stop.
3. The oil level should be between the MIN and MAX marking on the gauge.
Add oil if necessary.
4. Remove oil level gauge from the tube and insert into bracket (20).
5. Close the tubes with the plugs (18).
Do not leave the gauge (19) in the tube (14).

If the gauge is left in the tube the swing gear and the gauge will
be damaged when the swing gear operates.
AH03509a
COMPONENT CODE:
71
REF NO.
AH03510
DATE
2nd June 2003

Page 1 of 18
SUBJECT:
PURPOSE:
Hints for handling
APPLICATION:
PC4000; PC5500 (15012 - ); PC8000
FAILURE CODE:
7168Z9
DESCRIPTION:
At our excavators PC4000; PC5500 (15012-) and PC8000 the new bucket tooth system
POSILOK is used. In the following is showed how to handle the parts of this system.
Page
2
1.
Overview
1.1
1.2
Komatsu standard version

Optional version
2.
The Points
2.1
2.2
Removing the points

Installing the points
4
5
2
2
3.
The Adapters
3.1
3.2
3.2.1
3.2.2
3.2.3
3.3
3.4
Adapter removal
Nose rebuild
Nose end and sides rebuild
Nose flats rebuild
Rear corner rebuild
Adapter installation
Retighten Sidewinder Pin
6
8
8
9
9
10
11
4.
Wear Caps
11
4.1
4.1.1
4.1.2
4.2
11
11
12
13
4.2.1
4.2.2
Lock style wear caps (PC4000)

Removal
Installation
Non lock style wear caps
(Option PC4000; PC5500; PC8000)
Removal
Installation
5.
The Shrouds
14
5.1
5.2
5.2.1
5.2.2
5.2.3
5.3
5.4
Removal the shrouds

Installing the shrouds
Prepare the surface
Position the bosses
Welding the bosses
Inspecting Worn Shrouds
Installing (Shrouds and Pins)
14
15
15
16
17
17
18
13
13
AH03510
Page 2 of 18
1.
1.1
Overview
Komatsu standard version
Additional wearcap for plate

lips version (PC4000)
Wearcap
1.2
Optional version
For changing to optional version new points, new adapters and

the wearcaps are required.
AH03510
Page 3 of 18
Classification of the Tooth Systems to the Excavator Types
Type of Excavator
PC4000
PC5500
PC8000
- ( 12030)
- ( 12034)
Shovel Version
S 110
S 130
S 145
S 130
S 130
Backhoe Version
S 95
S 130
S 145
-
Component Preparation
Prior to installing the new tooth system components:
Thoroughly clean all bearing surfaces on the tooth base, adapter and pin.
Visually inspect top and bottom of tooth base for wear, refer to following sections.
Replace all damaged components.
2.
The points
4
2
5
1
1
Point
Posilok Locking Pin
Integral rubber lock
Adapter
Mating rails between point and adapter
Stabilizing flats
AH03510
Page 4 of 18
2.1
Removing the points
All persons performing maintenance work should wear a

approved hard hat, safety glasses, steel-toed shoes and
gloves.
To avoid injury to others, keep people not directly involved well
out of the way.
1. Removal
tool between the
(PART
NO. 79350273)
Posilok Pin and the lock
2. Drive the Posilok Pin out

using a removal tool
(Part No.
793 502 73)
Use this end to start

the Posilok Pin out.
Use this end to

drive it through.
Remove the vertical drive-through pin using a hammer and a pin removal tool
(Part No. 79350273).
Make sure to insert the tip of the removal tool between the Posilok Pin and the rubber
lock.
In order to loosen the point for removal from the adapter, it may be necessary to tap
the sides of the point to loosen fines.
AH03510
Page 5 of 18
2.2
Installing the points
Preparation
Prior to point replacement, make sure adapters are clean and free of damage.
Carefully inspect adapters for excessive wear.
If the nose is worn or if insufficient wear metal remains to see adapters through their work
cycle, they should be replaced with new ones.
Vertical locking pins: Locking pins may be reused provided they do not show signs of
significant wear, damage or distortion.
Points: If you are going to install new points, make sure the rubber lock is installed so the
arrows embossed on the surface of the lock are pointing forward (toward the tip of the
point).
Position the locking

pin and drive it in.
Vertical
locking pin
Point
Install the points onto the adapters.

After positioning a point onto its adapter, drive in the vertical locking pin using an
4 kg (8lb) hammer.
The rubber lock keeps the
Posilok Pin securely in place.
Posilok Pin engages the lock.
Topside and
forward
Drive in the Posilok Pin until it engages the lock.

When the Posilok Pin is correctly in place, the rubber lock fits
into the slot of the Posilok Pin to secure it.
AH03510
Page 6 of 18
3.
The adapters
3.1
Adapter removal
Prior to using an adapter tool be sure that the following safety
precautions are followed at all times:
Always wear proper safety equipment including hardhat, gloves,
safety glasses and steel-toed shoes.
Never exceed the lifting capacity of the tool.
Lifting tool 122K (Part No. 793 503 73) rated capacity 270kg (600lb)
- for the S145 tooth system.
Tool is intended for vertical lift only.
Always stand clear of the raised adapter.
Never allow anyone to work under the adapter until it is secured to
the lip by the appropriate locking mechanism.
Always use the safety features (lock and safety pin) as indicated.
Never use hand tools or other fastener to secure the sleeve. Never
use anything other than the sleeve provided to support the adapter.
Replace the tool when it becomes visibly damaged or distorted. Do
not attempt to repair a damaged tool.
Position the bucket with the nose tilted slightly upward.

Clean debris from adapter Sidewinder Pin head slot and remove cap from Sidewinder
Pin head.
(The fastening Sidewinder Pin may become frozen in the nose hole by cemented fines.
In this event, use either a hammer and drift or a porta-power, applied directly against
the end of the Sidewinder Pin sleeve, to force the Sidewinder Pin out. Use a striking
plate, as needed, to avoid hammering the end of the Sidewinder Pin base.
With body completely retracted, insert drift that fits inside hex recess and hammer
Sidewinder Pin through nose hole.
Alternately, drift can be placed against outer sleeve. Avoid hammering over hex recess
and thereby peening over the edges of this recess.)
AH03510
Page 7 of 18
Insert Allen hex bit (14; 17 or 19 mm) into the head of Sidewinder Pin and turn
counterclockwise (only for S 95 clockwise) until the Sidewinder Pin body is fully
retracted. Do not continue to turn after stop is felt.
The Sidewinder Pin is designed for operation with a ratchet wrench and should not
normally require use of an air-impact wrench.
For removing the adapter the Sidewinder Pin need not to

remove out off the adapter base if it is in good condition.
If the Sidewinder Pin have to be removed the end opposite the
hex socket must be removed at first.
Lifting tools (refer to drawing next page):

122K (793 503 73):
(for S145)
- Remove the safety pin of the adapter tool and slide the
sleeve off the arm.
- Guide the arm through the square hole in the nose of
the adapter.
- Arm must be pointed towards rear of the adapter.
- Slide the sleeve onto the arm, align the holes in the arm
and sleeve and install safety pin.
112K (793 504 73):

(for S130)
- Guide the lug on the end of the arm through the

D-shaped hole in the nose of the adapter.
- Rotate the arm towards the rear of the adapter until the
tool is aligned with the adapter 90 and slide the lock
down through the D-shaped hole and insert the safety pin.
AH03510
Page 8 of 18
Part No. 793 503 73 (for S145)

Part No. 793 504 73 (for S130)
Rotate the arm 90 for fixing
Safety pin of the adapter tool

Sleeve
Using a boom rated at 270 kg (600 lb) or greater (PC5500 and PC8000)
or a boom rated at 230 kg (500 lb) or greater (PC4000), hook into the shackle at the
top of the arm and remove the adapter.
3.2
Nose rebuild
Nose fit: This tooth system is designed to operate with movement of the adapter on the
nose. However, movement may become excessive over long term service because of
nose wear. In this event, the nose can be rebuilt in the indicated areas with welding and
grinding.
3.2.1 Nose end and sides rebuild
AH03510
Page 9 of 18
Place the nose side template on the centerline of nose.

Nose side template
Size
S 95
S 110
S 130
S 145
Nose Side
Template
79350573
79350773
79350973
79400373
Nose Flats
Template
79350673
79350873
79351073
79400473
Weldrebuild nose end surface and grind flat until gage ends align with front edge of
pin hole. Weld stringer beads should run parallel to the nose width.
Rebuild nose end radii as necessary.
3.2.2 Nose flats rebuild
Place the nose flats template over the nose as shown.

Weld buildup nose flats and radii and grind flat until template contacts nose end.
Nose flat template
3.2.3 Rear corner rebuild
Weld rebuild rear corners of nose.

Chalk or paint weld buildup areas, place adapter as far as possible on nose and then
remove. High spots will be indicated by missing chalk or paint.
Grind weld buildup areas until a new adapter has a little or no movement up and down.
Grind blend smoothly into rear shoulders.
AH03510
Page 10 of 18
3.3
Adapter installation
Prior to using an adapter tool be sure that the following safety
precautions are followed at all times:
Always wear proper safety equipment including hardhat, gloves,
safety glasses and steel-toed shoes.
Never exceed the lifting capacity of the tool.
Tool is intended for vertical lift only.
Always stand clear of the raised adapter.
Never allow anyone to work under the adapter until it is secured to
the lip by the appropriate locking mechanism.
Always use the safety features (lock and safety pin) as indicated.
Never use hand tools or other fastener to secure the sleeve. Never
use anything other than the sleeve provided to support the
adapter.
Replace the tool when it becomes visibly damaged or distorted.
Do not attempt to repair a damaged tool.
The Sidewinder Pin must be fully retracted in the adapter base.

Sidewinder Pin can be inserted from either side of base. Recommend corner positions
be installed from inside.
Position the bucket with the nose tilted slightly upward.
Use a lifting tool and a lifting boom for the movement of the adapter as described in
section 3.1. Test lift the adapter to check for satisfactory adapter tilt angle.
The adapter should tilt downwards at the rear for easy

installation onto the nose.
Lower the adapter and reposition the shackle as needed to achieve appropriate tilt
angle.
Lift the adapter and slide it onto the nose. With the lifting boom still holding the
adapter, install the adapter locking pin:
For applications where soil fines pack and harden, it is

recommended that the outer sleeve of the pin be covered in
grease.
AH03510
Page 11 of 18
Using hex bit and socket drive, turn hex socket end of Sidewinder Pin clockwise
to extend the pin into the pin hole in the opposite side of the adapter.
Tighten to the specified torque value shown below.
Size
S 95
S 110
S 130
S 145
3.4
Allen type wrench size

14 mm
17 mm
19 mm
19 mm
Recommended pin torque

160-200 Nm (120-150ft-lb)
200-260 Nm (150-190ft-lb)
260-390 Nm (190-290 ft-lb)
260-390 Nm (190-290 ft-lb)
Insert the Sidewinder Pin cap to prevent the pin hex socket from filling with soil fines.
Cap should snap into place.
Retighten Sidewinder Pin
Retighten the Sidewinder Pin every 600 to 1200 hours of operating service depending on
the severity of application.
Some loosening of pin - turns is normal. It is not

necessary to keep it tightened to the recommended torque.
4.
Wear Caps
4.1
Lock style wear caps (PC4000)
4.1.1 Removal
Clean debris from the gaps around the wearcap lock.

Do not strike corners or edges with hammer!
Rotate Lock : Use a drift and a 2-4 kg/4-8 lb hammer to rotate the lock to the unlocked
position.
It may be necessary to partially rotate the lock in both directions to break loose soil
fines, before fully rotating it.
Lock must be rotated completely (180 degrees) to release the

wearcap.
Lock can rotate either way.
AH03510
Page 12 of 18
Remove Wearcap:
Slide wearcap out of adapter slots. Use appropriate lifting devices to support and remove
wearcap. It may be necessary to place a pry bar between the adapter and the rear inside
face of the wearcap to lift and free it from soil fines.
4.1.2 Installation
Wearcap tabs, adapter tab slots, and lock recesses must be

thoroughly cleaned. Inspect all components for damage.
Replace any damaged parts.
Position Wearcap Lock

First place the lock flat side down against the inside of the wearcap, adjacent to the
lock opening. Slide it toward the wearcap lug. One of the lock shafts will enter the hole
in the lug. Push the lock up tight against the lug. Then, using a drift placed in one of
the lock pockets, tap the drift with a hammer to cause the lock to rotate halfway
around, until the flat side of the lock is facing you and is lined up with the inside face of
the wearcap.
Wearcap Installation
Place the wearcap on the adapter. The tabs on the inside of the wearcap fit into the
tab slots in the adapter.
Lock Wearcap
Use an suitable tool and hammer to rotate the lock to the locked position. If lock resists
rotation, this indicates more cleaning of the adapter slots is required. When flat is
facing out, the lock is in a locked position.
AH03510
Page 13 of 18
4.2
Non lock style wear caps (Option PC4000; PC5500; PC8000)
For using of these kind of wear caps special points and special
adapters are required.
4.2.1 Removal
Drive out the point pin and remove the point.

Slide the worn wearcap off the adapter.
If soil packs tightly between the wearcap and the adapter, it

may be necessary to strike the flat sides of the wearcap several
times with a hammer, to loosen it for removal.
Do not strike corners or edges with hammer!
4.2.2 Installation
Inspect all components for damage. Replace any damaged parts.

Slide wearcaps onto the adapter top and bottom surfaces, so that the wearcap rear
central and two forward side tabs insert fully into the respective slots of the adapter.
Install and pin the point.
AH03510
Page 14 of 18
5.
5.1
The Shrouds
Removal the shrouds
The Toplok shroud system is engineered to make change-out easy. Before following these
simple steps shown to the Figures, its important to clean fines from pin area by tapping
the shroud to loosen them, then scraping them using a chisel or needle gun (if fines are
heavily packed).
Use a small bar with flat end (19 mm wide maximum) to retract the latch and lift the
pin out.
Pins can be reused if not worn below the locator flange and the insert latch rubber is
fully bonded to the steel tip and fully seated in the pin body.
Place a pry bar or pinch bar behind the

latch as shown, as a lever to compress it.
Lift out and remove the lock. Slide the

shroud off the lip base.
In severe applications assist removal by inserting a pry bar

under the lock from the rear of the shroud and lifting up the
latch end of the pin while prying as shown.
AH03510
Page 15 of 18
5.2
Installing the shroud
5.2.1 Prepare the surface
In order to provide sufficient support for the boss as well as its pin, the mounting surface
must:
Be relatively smooth and free of debris, weld spatter, and other irregularities.
Have a profile that produces a gap no greater than 3 mm or 1/16" at the boss weld.
Any gap greater than 3 mm or 1/16" must be shimmed.
Checking the Fit Pad Areas
The fit pad surface (1) & (2) should be perpendicular to each other.
Make sure 70% of the fit pad surfaces (1) & (2) are in contact with the gauge.
After achieving this, the fit pad surface (3) should be checked.
Use a straight edge to help check the surface consistency.
Plate lips (PC4000)
Cast lips (PC5500 and PC8000)
Templates Part numbers for checking and preparation the lips

Type of Excavator
PC4000
PC5500
PC8000
Shovel Version
Lip Shroud
Template
654 547 40
654 548 40
794 005 73
655 867 40 or
907 281 40
907 006 40
794 007 73
Backhoe
Lip Shroud
654 627 40
654 628 40
654 629 40
655 867 40
Version
Template
794 008 73
907 448 40 On request
794 006 73
794 007 73
AH03510
Page 16 of 18
5.2.2 Position the bosses

Checking the Boss Position
To insure the boss is located correctly, the gap between the gauge and the boss rails
should not exceed 1mm/.04in. If the gap exceeds 1mm/.04in.,the boss has to be removed
and a new boss installed (see below).
The back of the boss should line up with the back of the gauge rail.
If the boss does not line up with the back of the gauge rail, then two repair options are
possible:
(A) If the gap does not exceed 1.5mm/.06in., build up the back of the boss; or
(B) Weld build the leading edge fit pad (2). This may result in the ramp fit pad (3) also
requiring weld build up.
Weld Rebuilding Fit Pads

When weld rebuilding fit pads ensure the weld surface is clean and free of any
contamination that might prevent a good weld. Follow the preheat, interpass and post heat
guidelines below.
Summary of Welding Specifications
Electrodes: E7016 or E7018 low hydrogen (keep dry!)
Wires: E70T-5, E71T-1, or E70T-1 with CO 2 gas.
Preheat: 200F/95C (350-400F/175-205C if air temperature is 40F/5C or lower.)
Interpass: Maintain interpass temperature less than 500F/260C.
Postheat: If air temperature is 40F or lower, postheat 350-400F, then let air cool.
Remove slag after each pass and peen each bead.
New Boss installation
Set the boss onto the gauge rails and locate the back of the boss with the back of the
gauge rails. If no gauge is available, use a new shroud to locate the boss.
Move the gauge onto the lip, making sure the gauge is centered between the nose
bases and the gauge is in contact with fit pad surfaces (1) & (2).
Practice has shown, that the boss will suck down 1/16" during welding. To equalize this
use a 1/16" shim under the boss, even if there is no gap between the fit pad (1) and the
boss. This will ensure the boss height is correct after welding.
If there is a gap between the fit pad surface (1) and the boss, use a thicker shim
accordingly.
AH03510
Page 17 of 18
5.2.3 Welding the bosses
The weld surface must be clean and free of any contamination that might prevent a good
weld. Follow the preheat interweld and post heat guidelines below.
Summary of Welding Specifications
Electrodes: E7016 or E7018 low hydrogen (keep dry!)
Wires: E70T-5, E71T-1, or E70T-1 with CO 2 gas.
Preheat: 200F/95C (350-400F/175-205C if air temperature is 40F/5C or lower.)
Interpass: Maintain interpass temperature less than 500F/260C.
Postheat: If air temperature is 40F or lower, postheat 350-400F, then let air cool.
Remove slag after each pass and peen each bead.
Weld the boss to the lip. Make sure that the boss is shimmed, so that the height of the
boss will be correct after welding.
Weld area (A) completely before welding areas (B) & (C).
Welding Guide
Weld
Location
Boss
TAB
TBB
TCB
(A)
Depth of
weld plug holes
mm/in
Plug Weld 10/.38
Plug Weld 13/.50
Plug Weld 16/.62
(B)
Size of fillet
weld-on ends
mm/in
Fillet 10/.38
Fillet 13/.50
Fillet 13/.50
(C)
Size of fillet
weld-on ends
mm/in
Fillet 3/.19
Fillet 6/.25
Fillet 6/.25
5.3
Inspecting Worn Shrouds
Toplok shrouds protect the bucket lip and wings from abrasive wear. Use of ESCO 12S
abrasion resistant alloy assures long life before change out.
Periodic inspection should be made to determine when to replace a shroud.
Monitor high wear surfaces of the Toplok shroud for wear.
Special wear indicators are special panels that will open up to alert the user of the
need for changing shrouds.
AH03510
Page 18 of 18
5.4
Installing
Installing the shroud
Slide the shroud over the lip and boss to install the pin. If installing a new shroud, the
pin must have contact with the back of the boss and with the back of the shroud without
losing contact at the leading edge.
Installing the pin
Position the pin in the shroud cavity as shown.
A light blow with a hammer will engage the pin.
The shroud is now securely attached.
AH03510
COMPONENT CODE:
J1
REF NO.
AH03511
DATE
14th April 2003

Page 1 of 2
SUBJECT:
PURPOSE:
Good flange connection between main pump and gear pump
APPLICATION:
PC5500
FAILURE CODE:
J100Z9
DESCRIPTION:
1. Control all new pumps before installing.
2. If necessary remachine chamfer that the face of the gear pump fit very well
to the main pump.
3. Install this new pump with surface sealing agent Loctite 510 (Part No. 461 543 40).
AH03511
Page 2 of 2
1.
Remachine this chamfer

2.
AH03511
COMPONENT CODE:
J1
REF NO.
AH03512
DATE
14th April 2003

Page 1 of 1
SUBJECT:
Gear pumps (Part Nos. 907 209 40;

906 442 40;
896 730 40 and
654 930 40)
PURPOSE:
Seal the flange connection
APPLICATION:
H 255; H 455; PC3000; PC4000; PC5500; PC8000
FAILURE CODE:
J100Z9
DESCRIPTION:
At replacement of the above mentioned gear pumps the flange of the new pump has to
seal additional with surface sealing agent Loctite 510.
The Part No. of Loctite 510 is 461 543 40.
AH03512
COMPONENT CODE:
46
REF NO.
AH04518a
DATE
June 29, 2005

Page 1 of 2
This PARTS & SERVICE NEWS supersedes the previous issue AH04518 which
SUBJECT:
PURPOSE:
Emphasize the importance of expelling the accumulate gases from

the counterweight chambers before welding
APPLICATION:
H 255; PC3000; PC5500(SN15011 and up); PC4000;

PC8000(SN12037 and up)
FAILURE CODE:
4621Z9
DESCRIPTION:
Avoid injury or death!

Do not perform welding operation before expelling the
accumulated gases from the counterweight chambers!
The gases may explode!
The welded counterweights are filled with a mixture of iron ore and breech blocks.
They are not fully filled.
It is possible that in the separate chambers explosive gases have collected.
There is a risk of explosion during welding, grinding, cutting and drilling without coolant.
The following outlines the proper gas expelling procedure from counterweight
(Illustrations 1 and 2)
1. Counterweights with a thread connection point(1):
Connect a hose to this point and blow compressed air toward the inside.
At these counterweights all chambers are connected to each other.
2. Counterweights without thread connection point:
Make the holes (2) larger by means of a 10 mm drill.
Blow out carefully all chambers separately through the holes (2).
AH04518a
Page 2 of 2
(1)
(2)
Illustration 2
AH04518a
COMPONENT CODE:
6A
REF NO.
AH05501a
DATE
September 15, 2006

Page 1 of 1
discarded.
SUBJECT:
PURPOSE:
Reduction of stress on the pipes
APPLICATION:
All types
FAILURE CODE:
6A00GB
DESCRIPTION:
To reduce the stress on hydraulic pipes and the flange bolts install a pair* of metal half
clamps (weight approx. 5 kg).
Start in the middle of the line and check the effect by laying on a hand. Try to optimize the
effect by shifting the clamps. Mark the optimal position.
*if required two pairs of half clamps can be used
Description
Pipe 50x6 (PN)
Pipe 65x8 (PN)
Modification kit (assy.)
938 578 40
938 581 40
AH05501a
COMPONENT CODE:
K1
REF NO.
AH05510
DATE
February 16, 2005

Page 1 of 1
SUBJECT:
Bearing flushing of the A4VS variable displacement axial piston

pump
PURPOSE:
Activate the external flushing of bearing by mounting a new pump
APPLICATION:
PC4000 (SN08151 up);

PC5500 (SN15011 up); H 455S (SN15007; 15009);
PC8000 (SN12037 up); H685SP (SN12020; 12030)
FAILURE CODE:
K100FA
DESCRIPTION:
The installed main pumps are provided with an external cooling and lubrication system for
flushing of drive shaft bearing and shaft seal.
Oil supply is provided from the X4-pressure circuit.
To direct the external cooling oil to the bearing and shaft seal it is necessary to turn in the
throttle screw all the way.
Observe also the information plate fixed at the pump.
Drawing and photos as example
AH05510
COMPONENT CODE:
30
REF NO.
AH05511
DATE
March 23, 2005

Page 1 of 4
This PARTS & SERVICE NEWS supersedes the previous issue No. 21-558 which should
be discarded.
SUBJECT:
PURPOSE:
Mounting hints
APPLICATION:
all types
FAILURE CODE:
3047AA
DESCRIPTION:
Leaky dual cone seal rings must be replaced, in order to prevent damages through "dry
running".
Dual cone seals have also to be replaced in case of component repairs.
Dual cone seals are precision parts made from chilled cast iron. Therefore, sharp knocks
and blows should be avoided.
The correct way to install dual cone seals is as follows:
Only remove the seal (1) from its original
wrapping just before installing. This
protects the super - finished seal faces (2)
from damage and contamination.
Seal housing (3) must be free of dirt and
machining residues; all edges in the
housing bore must be rounded.
The illustration shows the preloaded seal (1).
Install the face seal by means of the
assembly tool (4). Pressure is applied
directly via the O-ring (5).
For easier assembly, moisten the housing
bore and O-rings with spirit (no oil or grease!).
Order number for assembly tool (4), refer
to the table on page 2.
For the machining dimensions of the
assembly tool, refer to the illustration and
Fig. on page 3.
The illustration shows the dual cone seal
(1) before mounting it with tool (4) into
housing (3).
AH05511
Page 2 of 4
Press the seal ring (1) with the special tool
like a push button into the housing (3).
Take care that afterwards the housing
surface (6) lies parallel to the seal face (2).
The O-ring (1) must not sit wave-like in
the housing bore or bulge partially
looped out of the bore.
C = correct
W = wrong
Before the seal rings (1) are clamped to

the installation dimensions, apply a
thin grease or oil film to the seal faces
(2), preferably with a soaked chamois
leather cloth.
Fig.
1
2
3
4
5
6
Description
Seal ring
Seal face
Seal housing
Tool
O ring
Housing surface
Table for selection of the assembly tool (other tools on inquiry)

Part No.
Dual Cone Seal
145 800 40
180 472 40
180 624 40
202 986 40
226 424 40
226 425 40
255 058 40
269 454 40
270 460 40
Order-No.
Assembly tool
766 311 73
766 308 73
766 312 73
766 315 73
766 322 73
766 317 73
766 314 73
766 312 73
766 316 73
Part No.
Dual Cone Seal
323 823 40
324 067 40
461 627 40
461 628 40
696 523 73
696 525 73
804 595 73
963 754
Order-No.
Assembly tool
766 323 73
766 309 73
766 318 73
766 307 73
766 310 73
766 311 73
766 313 73
766 321 73
AH05511
Page 3 of 4
Assembly tool (locally made)
The assembly tool consists of two half-shells that are closed around the seal ring. The two
halves are joined by a hinge.
Step (d) grips between the O-ring (5) and the land of the seal ring. The pressure required
to insert the seal is then applied directly via the O-ring (5).
Measure dimension "b" at the dual cone seal.
Determine the machining dimensions "a", "b", "c" and "d" according to this measured
dimension in the chart.
The dimension "X" can be chosen freely.
b
mm
95
99
104
110
111
112
121
127
126
139
142
141,5
143
146
157
162
175
159
174,5
177
169
172,5
169
171
170
176
182
194
a
mm
100
107
118
115
118
120
128
131
134
148
150
149
150
153
163
169
182
166
181,5
185
176
180
175
177
176
183
190
201
c
mm
89,5
92,5
98
104
105
107
115
121
120
133
135
133
137
137,7
150,5
155
169
153,5
162
168
161
166,5
165
168
165
167,5
177
182,5
d
mm
1,8
3,5
3
2,5
4
3
4
3,5
3
3
4
3
4
4
4
3
4,5
3
4
4
2,8
3,5
2
2,5
4
3,5
3
4
b
mm
191
200
202
213
217
231
229,5
242
254
270,5
282,8
295,5
326
343,5
348
377,5
397
418
458
503
536,5
563
593
611
703
626
753
890
a
mm
198
208
209
220
225
238
236,5
249
261
279
292
302,5
334
350,5
357
384,5
407
426
468
518
545
578
608
620
710
642
768
898
c
mm
185
192
196
201
210
220
220,5
232
242,5
258,5
269
282
321
335
342
369
385
410
446
495
528,4
555
585
603
694
618
745
878
d
mm
4
4
4
4
4
4
4
4
4
4
4
4
4
4
7
4
4
5
4
7
5
7
7
5
5
7
7
10
AH05511
Page 4 of 4
Assembly tools for mounting of dual cone seal
AH05511
COMPONENT CODE:
J1
REF NO.
AH05520a
DATE
March 17, 2006

Page 1 of 3
This PARTS & SERVICE NEWS supersedes the previous issue No. AH05520
SUBJECT:
Installation hints for a new type of gear pump (Pilot pump)
PURPOSE:
Product improvement:
Old designs: PN 634 121 40; PN 634 122 40; PN 907 209 40;
PN 907 608 40
New design: PN 907 622 40
APPLICATION:
H 455S (#15003 to 15009); PC5500 (# 15011 to 15024)
FAILURE CODE:
J100FA
DESCRIPTION:
Modification Kit PN 793 749 73 (refer to Illustrations 1 and 2)
Valid for old pumps PN 634 121 40 and PN 634 122 40
Pos.
Part No.
Qty.
Description
01
886 218 40
Reduction flange
02
385 243 40
Flange seal
03
319 272 99
Bolt M12 x 30
04
515 812 98
Coupling
05
356 209 40
Flange seal
06*
319 272 99
Bolt M12 x 30
07*
515 658 40
Half flange
08*
356 210 40
Quad ring
* Positions 06; 07 and 08 will be used for replacing the old pumps PN 907 209 40 and
PN 907 608 40
Close the main gate valve between hydraulic oil tank and suction tank.
Drain the suction tank. (Use the transfusing pump if so equipped).
Remove all lines from the old gear pump.
Replace this pump (illustration 1)**.
Reinstall the suction line as showed on next page (illustration 2).
Reinstall the pressure line (illustration 3).
Open the main gate valve.
Install the coupling (04).
Bleed the hydraulic pump (refer to Service Bulletin AH01513).
Start the engine and let it run for 15 minutes in low idle for bleeding the lines.
Check the hydraulic oil level at the tank.
** For installation of the new pump refer to the next page.
AH05520a
Page 2 of 3
Installation the new pump (PN 907 622 40)
Illustration 1
Remove the two hexagon bolts (2) and the flange (1) from the new pump.
Install the flange (1) by using of the four cylinder head bolts (3) (M12 - 70Nm)
at the big main pump.
Install the new gear pump by using of the two bolts (2) (M12 70 Nm) at the
flange (1).
AH05520a
Page 3 of 3
Illustration 2
Illustration 3
AH05520a
COMPONENT CODE:
K1
REF NO.
AH05525
DATE
September 20, 2005

Page 1 of 3
SUBJECT:
PURPOSE:
Hints for sealing
APPLICATION:
PC3000-1; PC4000-6 (to # 08156) PC5500 (to # 15019);

PC8000 (to # 12042)
FAILURE CODE:
K1T3AA
DESCRIPTION:
1.
2.
PC3000-1
PC4000; PC5500; PC8000
AH05525
Page 2 of 3
1. PC3000-1
1
2
3
4
Seal
Intake
Remachining surface
Bolt
Illustration 1
as example
In case of leakiness disassemble the suction elbow (2) and remachine the
sealing surface (3).
Then reassemble the suction elbow (2) by using a new seal (1).
Install the 4 bolts (4) crosswise and evenly.

Final torque: maximum 179 Nm!
Replace the intake (2) by a new one if necessary.
Check the surface (3) for evenness also of the new intake (2)
before installing. Even it out if necessary.
AH05525
Page 3 of 3
2. PC4000; PC5500; PC8000
Type
PC4000-6
PC5500-6
PC8000-6
In case of leakiness replace the old suction elbow (2) by a new one with an
other sealing system (1)(O-ring).
Intake (old)
Intake (new)
O - ring
891 451 40
928 335 40
517 582 98
624 085 40
928 706 40
517 582 98
624 085 40
928 706 40
517 582 98
894 317 40
928 287 40
517 582 98
894 321 40
928 285 40
517 582 98
894 322 40
928 288 40
517 582 98
894 323 40
928 289 40
517 582 98
624 085 40
928 706 40
517 582 98
Screw in the 4 bolts

(4) crosswise and
evenly.
Final torque:
maximum 179 Nm!
Illustration 2
as example
AH05525
COMPONENT CODE:
26
REF NO.
AH05535c
DATE
May 21, 2007

Page 1 of 22
This PARTS & SERVICE NEWS supersedes the previous issue AH05535b which should
be discarded.
SUBJECT:
PURPOSE:
Revision
APPLICATION:
PC3000 (#06193 and up); PC4000 (#08152 and up);

PC5500 (#15018 and up); PC8000 (#12041 and up)
FAILURE CODE:
2600CA
DESCRIPTION:
New swing gears will be delivered without gear oil.
After replacing the swing gear, fill in oil according to the
Maintenance Manual.
REMARK
The machines can be equipped either with a swing machinery of manufacturer
"L&S"
Part No. 926 795 40 or of manufacturer
"Siebenhaar"
Part No. 925 864 40 or 936 560 40.
Refer to the data plate on each swing machinery housing to find out the manufacturer of
the swing machinery.
Both swing gears are replaceable by using of a special modification kit.
Lubricants
Filling Capacities (liters)
AH05535b
Page 2 of 22
1.
Description (general)
2.
Overview
2.1 Swing Machinery manufactured by "L&S"
2.2 Swing machinery manufactured by Siebenhaaar
3.
Modification kits
3.1 Modification kit PC3000-6
3.1.1
Replacing L+S gear to Siebenhaar gear
3.1.2
Replacing Siebenhaar gear to L+S gear

3.2.1
3.2.2

3.3.1
3.3.2

3.4.1
3.4.2
AH05535b
Page 3 of 22
1.
Description (general)
1. Remove the bolts at the hydraulic motor.

2. Remove the motor with connected hoses and place it beside or if this it not possible,
disconnect the hydraulic lines and block the ports.
3. Disconnect the lubrication lines below the gearbox.
4. Remove all fastening bolts from the gearbox.
5. Install 2 eye bolts to lift the gearbox assy.
6. Remove the gearbox from the superstructure frame.
7. Clean the flange area at the superstructure free of grease, oil, dust and paint.
8. Insert the new gearbox and mount it with the new bolts and the washers to the
superstructure
9. Cover the bolt heads with plugs.
10. Swap the drain valves and the breather filters from the old to the new gearbox.
11. Remove the cover below the gearbox and connect the lubrication lines.
12. Reinstall the cover with bolts.
13. Reinstall the motor with bolts.
14. Reconnect all hydraulic lines.
15. Fill in oil to the max. oil level markings*.
16. Install the cover plates (PC3000; PC4000).
* "L&S" gear (Part No. 926 795 40)

2 oil chambers: (gear housing; motor adapter housing);
"Siebenhaar" (Part No. 925 864 40 or 936 560 40)
Three oil chambers: (gear housing; motor adapter housing, brake housing)
AH05535b
Page 4 of 22
2.
Overview
2.1
Swing Machinery manufactured by "L&S"
Legend for illustration 1

Swing gears
(1) Oil level gauge
(2) Oil filler plug
(3) Breather filter
(10) Drain couplings or evacuation nozzles for Wiggins system Motor
Adapter Housing
(4) Oil level gauge and filler opening.
(5) Breather filter
(6) Oil drain plug
Illustration 1
AH05535b
Page 5 of 22
2.2
Swing machinery manufactured by Siebenhaaar
Legend for illustration 2

(1) Swing machinery
(2) Brake housing
(3) Compensator oil tank for swing machinery
(4) Oil level gauge for swing machinery
(5) Oil drain plug for motor adapter housing
(6) Oil level gauge for motor adapter housing
(7) Breather filter for brake housing
(8) Oil level gauge for brake housing
(9) Oil drain plug for brake housing
(10) Breather filter
(11) Drain coupling or evacuation nozzle for Wiggins system
For avoiding overheating of the disks inside the brake a correct adjustment
of the brake oil level (8) is necessary.
Too high oil level reduces the life time of the brake.
AH05535b
Page 6 of 22
Swing machinery manufactured by Siebenhaaar
Illustration 2
AH05535b
Page 7 of 22
3.
Modification kits
3.1
Modification kit PC3000-6
3.1.1 Replacing L+S gear to Siebenhaar gear (PC3000-6; illustration 3)

Modification Kit: PN 794 853 73
Pos.
Part No.
Qty.
Description
10
323 460 40
Bleeder valve
11
517 676 98
34
Bolt
12
516 920 98
34
Washer
15
507 037 98
Nut
16
340 465 99
Washer
22
907 142 40
34
Plug
30
307 824 99
Bolt
31
374 428 99
Union
32
517 905 98
Hose assy.
33
500 141 98
Union
34
372 174 99
Union
35
334 601 99
Nut
36
340 469 99
Washer
37
0443452511
Clip
38
340 467 99
Washer
AH05535b
Page 8 of 22
Illustration 3
AH05535b
Page 9 of 22
3.1.2 Replacing Siebenhaar gear to L+S gear (PC3000-6; illustration 4)
Pos.
Part No.
Qty.
Description
10
323 460 40
Bleeder valve
11
517 013 98
34
Bolt
20
872 200 40
Union
30
925 833 40
Pipe
31
517 489 98
Socket
32
906 868 40
Olive
33
371 264 99
Union nut
34
517 490 98
Union
35
907 568 40
Dipstick
36
921 815 40
Cover
37
319 159 99
Bolt
38
504 149 98
Washer
39
517 073 98
Union
40
371 273 99
Union nut
41
906 346 40
Olive
42
215 627 99
Pipe 400 mm
43
517 074 98
Union
44
371 258 99
Union nut
45
907 228 40
Union
AH05535b
Page 10 of 22
Illustration 4
AH05535b
Page 11 of 22
3.2

Pos.
Part No.
Qty.
Description
11
515 791 98
34
Bolt
12
516 920 98
34
Washer
15
374 428 99
Union
16
507 037 98
10
Nut
17
512 545 98
10
Washer
18
507 488 98
10
Pin bolt
19
506 129 98
10
Washer
20
904 613 40
Cover plate rear r.h.
21
904 618 40
Cover plate front r.h.
22
904 614 40
Cover plate rear l.h.
23
904 617 40
Cover plate front r.h.
24
307 827 99
Bolt
26
907 142 40
34
Plug
27
914 777 40
Pinion cover l.h.
28
914 775 40
Pinion cover r.h.
29
510 213 98
Thread pin
30
340 112 99
Washer
31
512 545 98
Washer
32
334 600 99
Nut
AH05535b
Page 12 of 22
Illustration 5
AH05535b
Page 13 of 22
3.2.2 Replacing Siebenhaar gear to L+S gear (PC4000-6; illustration 6)
Pos.
Part No.
Qty.
Description
15
872 200 40
Union
20
922 584 40
Cover plate
21
922 583 40
Cover plate
22
922 586 40
Cover plate
23
922 587 40
Cover plate
25
516 919 98
34
Bolt
28
921 815 40
Cover
29
319 159 99
Bolt
30
517 073 98
Union
31
371 273 99
Union nut
32
906 346 40
Olive
33
215 627 99
Pipe 400 mm
34
517 074 98
Union
35
371 258 99
Union nut
36
906 346 40
Olive
37
907 228 40
Union
38
371 257 99
Union nut
39
907 080 40
Olive
40
922 580 40
Cover
41
922 587 40
Cover
42
517 489 98
Socket
43
517 490 98
Union
44
906 868 40
Olive
45
371 264 99
Union nut
46
215 787 99
Pipe 400 mm
47
907 569 40
Dipstick
49
399 907 99
Seal ring
AH05535b
Page 14 of 22
Illustration 6
AH05535b
Page 15 of 22
3.3

Pos.
Part No.
Qty.
Description
10
323 460 40
Bleeder valve
12
307 827 99
Screw
15
339 907 99
Seal ring
24
516 920 98
34
Washer
25
517 612 98
34
Bolt
26
907 142 40
34
Plug
AH05535b
Page 16 of 22
Illustration 7
AH05535b
Page 17 of 22
3.3.2 Replacing Siebenhaar gear to L+S gear (PC5500-6; Illustration 8)
Pos.
Part No.
Qty.
Description
17
921 815 40
Cover
18
907 131 40
Union
19
214 140 99
Pipe 85 mm
20
374 460 99
Socket
21
872 200 40
Union
22
371 279 99
Union nut
23
906 979 40
Olive
24
516 929 98
34
Washer
25
517 889 98
34
Bolt
26
907 142 40
34
Plug
27
907 228 40
Union
28
517 074 98
Union
29
371 258 99
Union nut
30
907 227 40
Olive
31
517 073 98
Union
32
371 273 99
Union nut
34
215 627 99
Pipe 200mm
35
319 159 99
Bolt
36
504 149 98
Washer
50
517 489 98
Socket
51
517 490 98
Union
52
906 868 40
Olive
53
371 264 99
Union nut
54
215 787 99
Pipe 400 mm
55
907 569 40
Dipstick
AH05535b
Page 18 of 22
Illustration 8
AH05535b
Page 19 of 22
3.4
Pos.
Part No.
Qty.
Description
904 613 40
Cover plate r.h.
904 618 40
Cover plate l.h.
517 612 98
34
Bolt
516 920 98
34
Washer
907 142 40
34
Plug
10
323 460 40
Bleeder valve
12
307 827 99
Bolt
13
374 428 99
Union
AH05535b
Page 20 of 22
Illustration 9
AH05535b
Page 21 of 22
3.4.2 Replacing Siebenhaar gear to L+S gear
Pos.
Part No.
Qty.
Description
898 288 40
Cover plate
914 737 40
Cover plate
374 460 99
Screwed socket
371 279 99
Union nut
906 979 40
Olive
10
914 736 40
Pipe 85 mm
11
907 131 40
Union
12
921 815 40
Cover
13
319 159 99
Bolt
14
907 569 40
Dipstick
15
906 868 40
Olive
16
371 264 99
Union nut
17
925 830 40
Pipe 350 mm
19
517 489 98
Socket
20
517 490 98
Union
22
872 200 40
Union
23
516 919 98
34
Bolt
26
517 073 98
Union
27
371 273 99
Union nut
28
906 346 40
Olive
29
215 627 99
Pipe 200 mm
30
907 228 40
Union
31
517 074 98
Union
32
371 258 99
Union nut
AH05535b
Page 22 of 22
Illustration 10
AH05535b
COMPONENT CODE:
8D
REF NO.
AH05546
DATE
December 6, 2005
Page 1 of 2
SUBJECT:
PURPOSE:
Hints for trouble shooting
APPLICATION:
All types with Lincoln Lubrication System
FAILURE CODE:
8D00ME
DESCRIPTION:
Manual actuation
(Vent valve: PN 769 879 73)
FUNCTION:
The solenoid gets energized when the lubrication starts.
The connection from A to B gets closed, thus a pressure build-up is possible.
The solenoid gets de-energized, as soon as the lubrication cycle is finished.
This causes opening of the connection A to B, thus the supply line to the
lubricant barrel is open. The lubricant flows from A to B.
TASK (Refer to illustration next page):
By the function of the vent valve (7) the lubricant supply line gets pressure released,
after the lubrication cycle is finished. The injector pistons can move into their initial
position.
AH05546
Page 2 of 2
Troubleshooting:
The solenoid valve (7) sometimes is blocked by dirt and causing that the pumping
pressure will be not built correctly due to bypassed pressure back to grease barrel. On the
monitor in the operators cab any failure in lubrication system will be indicated.
Manual actuation
To make easy troubleshooting the 2/2 Directional valve (7)

is equipped with the possibility of manual actuation.
The valve had a push button on the top to verify whether the
electric problem or the vent valve itself causing the lubrication
pressure bypassed.
For manual actuating of the valve (7) push down the pin on
top of the valve e.g. with a screwdriver.
AH05546
COMPONENT CODE:
REF NO.
DATE
AH06524
September 6, 2006
Page 1 of 2
This PARTS & SERVICE NEWS supersedes the previous issue 21 199b which should
be discarded.
SUBJET:
Hydraulic cylinder
PURPOSE:
Hints for bleeding
APPLICATION:
All types
FAILURE CODE:
H100BJ
DESCRIPTION:
To avoid damages to the hydraulic system caused by air in the cylinders, a bleeding
procedure has to be carried out after each opening or cylinder exchange.
Read the safety instruction in the Operation and Maintenance
Manual carefully, before starting any work on the excavator.
1. Standard procedure for bleeding of hydraulic cylinder

1. Run the engine at low idle.
PC5500 and PC8000: Start for the bleeding procedure only one engine.
Electric driven excavators: Set the service switch S155 (X2 main
board) to position 2 for QMIN control of the main pumps.
2. Extend and retract each cylinder 4 or 5 times without going to the end of
its stroke (stop approx. 100 mm before the end of the stroke).
At first there can be a large amount of air inside the cylinders, so the
cylinder may not move for the first ten seconds. In such cases, do not
operate the joy stick to the end of its travel. Be carefully!
3. Keep the engine running at low idle/or QMIN* and operate each cylinder
from a point 100 mm from the end of its stroke slowly (take at least 10
seconds) to the end of its stroke (fully extended) and hold the work
equipment joy stick at the full stroke position for 3 minutes.
AH06524
Page 2 of 2
4. Next run the engine at high idle/or QMAX* and operate each cylinder
from a point 100 mm from the end of its stroke slowly (take at least 10
seconds) to the end of its stroke (fully extended) and hold the work
equipment joy stick at the full stroke position for 1 minutes.
5. Repeat steps 2 4 if necessary.
6. Make sure that the switch S155 is set to the 0 position as soon as the
bleeding procedure of the hydraulic cylinders is finished.*
* Electric driven excavator
After bleeding the cylinders check oil level in the hydraulic tank
according to the Maintenance Manual and add oil if necessary.
AH06524
COMPONENT CODE:
30
REF NO.
AH06529
DATE
July 31, 2006

Page 1 of 7
SUBJET:
Track group Hints for sprocket exchange
PURPOSE:
Sprocket exchange in case of normal wear
APPLICATION:
PC5500-6 (#15026 and up)
FAILURE CODE:
3000CA
DESCRIPTION:
1.
Sprocket types
1.1
Standard sprocket
1.2
Oversize sprocket
2.
Removal sprocket
3.
Determination of the Axial Play
4.
Remachining
5.
Radial wear determination
6.
Assembly
7.
Torque Data for Standard Application
AH06529
Page 2 of 7
1.
Sprocket types
1.1
Standard sprocket
The standard sprocket has to be used in case of assembling new machine or regenerating
the track group in connection with new track pads.
1.2
Oversize sprocket
The oversize sprocket has to be used to compensate chain elongation, wear on sprocket
diameter and wear in the roller path on track pads, caused by the wear of the chain, if the
X-dimension / circular pitch come up to 0.5 mm (refer to Service Bulletin AH02521 latest
edition).
This retrofitting assures assembly condition of the X dimension of a new machine,
furthermore the service life of the track group will be increased.
The oversize sprocket is available without a sprocket hub, if the old one is reuseable. For
the part no. of sprockets and the mounting procedure, refer to the following pages, the
table below and the part catalogue of your machine.
The conversion of the sprockets is time- and cost-intensive, so it is recommended to
exchange the final-drive bearings at the same time if the dimensions have reached the
wear tolerances, to avoid a standstill of the machine for the final-drive bearing exchange
only.
Before placing the order, pay attention to Service News AH00515 (latest version) and
Parts Catalogue for correct choice of the bush type.
Basically, all seals (13, 23, 27, 28 refer to illustration 1) have to be replaced.
The difference between the standard version (NT) and the very
low temperature version (TT) are only the bolts. The sprocket
and the hub are the same.
PC5500
Part number
Standard sprocket with hub
929 320 40
Oversize sprocket with hub
938 778 40
Drive sprocket standard
933 626 40
Drive sprocket oversize
938 777 40
AH06529
Page 3 of 7
2. Removal sprocket
Remove the drain plug and the filler plug and drain the lubricating oil of the final drive
housing (refer to the Maintenance Manual).
Suspend travel gear (02) to a crane; remove mounting bolts (31).
Remove travel gear by using pulling bolts; put aside.
Remove cover (14).
Suspend sprocket (01) to a crane and underpin it from below.
Pull out drive shaft (06).
Remove mounting bolts (12) in flange bearing (08); loosen by using pulling bolts;
extract.
Extract hollow shaft (32) to cover side (14) and remove it by using the crane or a
fork-lift.
Lift sprocket (01) out.
Remove mounting bolts (12) in flange bearing (25); loosen by using pulling bolts;
extract.
Illustration 1
AH06529
Page 4 of 7
Illustration 2
AH06529
Page 5 of 7
3.
Determination of the Axial Play
After removal, all seals have to be renewed.
Slide O-ring (26) over flange bearing (6).

Mount flange bearing (6) without dual-cone seal (17).
Pay attention to the lubrication-grooves position; they have to be displaced by 22.5 to
the vertical line.
Mount all bolts (61) and tighten according to tightening torques (M30 / 1770Nm).
Suspend the sprocket to a crane; insert without dual-cone seals (17).
Mount hollow shaft (32) and slide against collar B. By this, the sprocket (1) is moved
against the collar A of the bushing.
Mount flange bearing (5) with 3 bolts (61) without dual-cone seal (17).
Measure dimension X.
Slide sprocket (1) to direction C until the hollow shaft (32) rests against the collar D
of the flange bushing.
Measure dimension Y.
The axial play result in X minus Y .
Type
PC5500-6
4.
Original axial play

0.2 0.9 mm
Wear limit
2,75 mm
Remachining
If the amount of axial play exceeds 0.9 mm, area E has to be remachined until the original
dimension, is reached.
If the amount of axial play is less than 0.2 mm, area F has to be remachined until the
original dimension, is reached.
5.
Suspend sprocket (1) to crane, pull out hollow shaft (32), lift sprocket (1) out.
Radial wear determination
The radial play after installation amounts maximally to 0.77 mm.

If the maximum permissible parallel play comes up to 2.0 mm, the bushings have to be
changed.
For determination of the bushings check the inner diameter (D) several times.
If the maximal value reaches 482.7 mm the bushings must be changed.
AH06529
Page 6 of 7
Illustration 3
AH06529
Page 7 of 7
6.
Assembly
Mount dual-cone seal (17) according to Service Bulletin AH05511 into
flange bearing (6).
Mount dual-cone seals (17) according to Service Bulletin AH05511 into sprocket.
Place sprocket into the side frame by using a crane, align and underpin sprocket in
mounting position.
Mount hollow shaft (11).
Mount dual-cone seal (17) according to Service Bulletin AH05511 into
flange bearing (5).
Mount flange bearing (5). The lubrication grooves of the bushing (5.2) have to be
displaced by 22.5 to the vertical line.
Tighten bolts (61) according to the tightening torques (M30 / 1770Nm).
Insert O-ring (25) into the cover (7).
Mount cover (7) with bolts (21).
Tighten bolts (21), according to the tightening torques (M12 / 74Nm).
Insert O-ring (27).
Suspend travel gear (14) to a crane and mount to side frame.
Tighten bolts (59) according to the tightening torques (M36 / 3100Nm).
Refill oil and check levels.
)
7.
When selecting tightening torques, observe size and quality

grade of the bolts.
Torque Data for Standard Application
Bolt
dia.
[mm]
M 10
M 12
M 14
M 16
M 18
M 20
M 22
M 24
M 27
M 30
M 33
M 36
Wrench
size
[mm]
17
19
22
24
27
30
32
36
41
46
50
55
8.8
43/32
74/54.6
118/87
179/132
255/188
360/265
485/358
620/457
920/679
1250/922
1690/1246
2170/1600
Tightening torque
Nm/lbs.ft.
Quality grades
10.9
63/47
108/80
173/128
265/196
360/265
510/376
690/509
880/649
1310/966
1770/1305
2400/1770
3100/2286
12.9
73/54
127/94
202/149
310/229
425/313
600/443
810/597
1030/760
1530/1128
2080/1534
2800/2065
3600/2655
Insert all bolts lubricated with MPG, KP2K type lubricant.
AH06529
COMPONENT CODE:
32
REF NO.
AH06530
DATE
July 24, 2006

Page 1 of 2
SUBJET:
PURPOSE:
Hints for working at the crawler unit
APPLICATION:
PC3000; PC4000; PC5500; PC8000
FAILURE CODE:
3200FA
DESCRIPTION:
Read the safety instruction in the Operation and Maintenance

Manual carefully, before starting repair works.
For avoiding damages at the travel brakes (4) the following procedure should be used:
Turn the superstructure (90) and lift the machine.
Shut off the engine.
Open cock (2) for releasing the pressure.
Close cocks (1) and cock (3) if installed.
Close cock (2) (important!).
Now the engine can be started and the sprocket can be turned to the working
position. The travel brake is released by pilot pressure.
Illustration as example
AH06530
Page 2 of 2
AH06530
COMPONENT CODE:
K1
REF NO.
AH06542
DATE
October 5, 2006
Page 1 of 2
SUBJECT:
PURPOSE:
Efficient Performance at an altitude of more than 1000 m above

sea level
APPLICATION:
PC5500-6
FAILURE CODE:
K100PB
DESCRIPTION:
The H-A4VSO500 is a variable displacement axle piston pump in swash plate design
intended for drives in open circuit operation.
For efficient performance at an altitude of more than 1000 m above sea level the
maximum displacement at one revolution of the pump has to be reduced according
to the following table.
Vg max
(revolutions per min)
Altitude*
(m)
Turn in
setting screw (3)
(revolutions)
Q max
(l/min)
Diesel
Electric
Diesel
Electric
Diesel
Electric
500
500
735
700
about 1400
460
483
676
676
about 2900
418
440
615
615
about 3200
405
426
596
596
about 4700
355
373
522
522
For adjustments of other altitudes please contact our Service Department.
All spare part pumps will be delivered with standard adjustment.

When installing these pumps at an altitude of more than
1000 m an alteration according to the table above has to be
carried out.
If the excavator is displaced to a mine site above an altitude over
3000 m the engine needs also a corresponding adjustment.
Adjustment
1. Unscrew box nut (1).
2. Loosen the lock nut (2).
3. Turn in the stop bolt (3) with an allen key according to the table above.
(The distance X has to be reduced.)
4. Tighten the lock (2) nut and screw on box nut (1).
AH06542
Page 2 of 2
Illustration 1
AH06542
COMPONENT CODE:
J1
REF NO.
AH06543a
DATE
September 20, 2007

Page 1 of 3
discarded.
SUBJECT:
Gear pumps PN 907 622 40 and PN 940 048 40

(supplied from the company Kracht)
(Pilot pressure pump; gear oil pump; circulation pump)
PURPOSE:
Increasing of the life time

Releasing of a new type of shaft seal rings
(Product improvement!)
APPLICATION:
PC5500-6 (PN 15018; 15019, 15022; 15023; 15025;15027;

15032; 15035; 15038, 15040 to 15046; 15048 to 15053, 15055;
15056; 15060; 15062)
FAILURE CODE:
J100AA
DESCRIPTION:
Please check the strainer (35); it must be clean (illustration 1). Dirt and paint have to be
removed.
For increasing of the lifetime, a new type of shaft seal
(Positions 17 and 32 - PN 793 357 73)
was released for the above mentioned pumps.
With order of an old shaft seal the new type will be supplied automatically.
AH06543a
Page 2 of 3
35
Illustration 1
Illustration 2
Illustration 3
AH06543a
Page 3 of 3
Installation hints for the shaft seals
Grease the shaft seals inside and outside before installation (illustration 3).
Use mounting sleeves according to illustration 4.
To avoiding of corrosion coat the adapter surface and the pump surface
(illustration 2 and 3) with one of the following types of grease before mounting
the pump to the adapter:
- CASTROL OPTIMOL PASTE WHITE T
- STABYL L 120
Do not close the strainer (35) with grease.
Illustation 4
AH06543a
COMPONENT CODE:
H2
REF NO.
AH06545
DATE
November 22, 2006

Page 1 of 3
SUBJECT:
PURPOSE:
Installation hints
APPLICATION:
All types
FAILURE CODE:
H2Z6CA
DESCRIPTION:
Pay attention to the position of the lubricating holes and the

lubrication grooves when installing new bushes to ensure
good lubrication and maximum lifetime.
Install the bushes as shown at the next pages.
AH06545
Page 2 of 3
AH06545
Page 3 of 3
AH06545
COMPONENT CODE:
26
REF NO.
AH07509
DATE
May 29, 2007

Page 1 of 7
SUBJECT:
Swing gear brake manufactured by Siebenhaar

(Swing gear PN 902 550 40 and PN 925 864 40)
PURPOSE:
Hints for replacement of the brake assy.
APPLICATION:
PC3000; PC4000; PC5500
FAILURE CODE:
2600FA
DESCRIPTION:
Note
In case of a brake failure we recommend to rebuild the brake assembly according to the
procedure given below.
This method allows later a quick and efficient exchange of the complete brake assembly.
1.
Modification kits
1.1 Modification kit for swing gear PN 902 550 40
(PC4000-6 #08152; 08153; 08154)
2.
Modification instructions
2.1 Disassembly
2.2 Assembly
3.
Appendix
3.1 Spare Parts Catalogue page 991 0737
3.2 Spare parts Catalogue page 991 0715
The local safety rules must also observed.
AH07509
Page 2 of 7
AH07509
Page 3 of 7
1.
Modification kits
(PC4000-6 #08152; 08153; 08154)
Pos.
Part No.
Qty.
Description
796 050 73
Adapter
795 836 73
Disc brake
972 122
O - Ring
516 354 98
O - Ring
501 532 98
Hexagon head socket pipe plug
339 796 99
Seal ring
After conversion the following page of Spare Parts catalogue apply: 991 0737.

Pos.
Part No.
Qty.
Description
795 840 73
Adapter
795 836 73
Disc brake
972 122
O - Ring
516 354 98
O - Ring
501 532 98
Hexagon head socket pipe plug
339 796 99
Seal ring
After conversion the following page of Spare Parts catalogue apply: 991 0715.
AH07509
Page 4 of 7
AH07509
Page 5 of 7
2.
Modification instructions
2.1 Disassembly
1.
2.
3.
The oil must be drained completely before the modification of the gearbox, in
accordance to the Maintenance Manual of the shovel.
Take off all oil fittings of the gear to attach them later to the new adapter.
Take off all hydraulic pipes from the brake.
W
4.
5.
6.
7.
8.
9.
Unscrewing or removing of hydraulic pipes under pressure

resp. of connections is hazardous. Take care that - in case of
works at the brake (mounting, dismounting) -the brake and the
belonging hydraulic pipes are depressurized.
Remove all fixing screws of the motor and take off the motor from the gear.
Remove the 24 fixing bolts (1) (M24 x 550) of the gear (1).
Remove the 4 fixing bolts (2) (M16x360) of the adapter (3).
By means of 2 pulling screws loosen adapter (3).
Install 2 eye bolts M16 to the adapter (3).
Lift off the adapter (3) with attached brake by adequate lifting device.
First lift up approx. 150 mm.
If the sun gear is lifted together with the assy. secure it against
falling down before lifting up completely.
Do not open the brake cause of DANGER OF ACCIDENT. Under
no circumstances you have to unscrew the red marked screws.
AH07509
Page 6 of 7
AH07509
Page 7 of 7
2.2
Assembly
1. Centre the new adapter (1) with put on O-ring (4) into the gear and fasten it
with 4 bolts (M16x360).
2. Fasten the gear with 24 bolts (M24 x 550) back to the machine.
3. Centre the new pre-assembled brake (2) with put on O-ring into the adapter
and fasten it with 8 bolts (M16 x 210).
4. Insert the new O-ring (3) in the groove provided for this purpose at the motor
pivot. The motor pivot has to be pushed into the disc carrier. Centre the motor
into the motor flange and fasten it.
To prevent premature wear at the involute spline joint

(motor/gear driving shaft), the room between motor and gear
gets an oil filling according Maintenance Manual..
5. Fasten the oil fittings back to the gear and the hydraulic pipes back to the
brake.
6. Fill the gear and the brake housing with oil according to the instructions in the
Maintenance Manual.
Too high oil level in the brake housing reduces the life time of
the brake.
Screw in the gauge, see detail A. Remove the gauge.

The oil level should be
1. At the lower mark of the gauge in case the oil is cold.
2. At the upper mark of the gauge in case the oil is warm.
7. Connect the brake to the hydraulic system.
AH07509
COMPONENT CODE:
30
REF NO.
AH07526
DATE
September 27, 2007

Page 1 of 5
SUBJECT:
PURPOSE:
References to renew the protective coating
APPLICATION:
PC5500-6
FAILURE CODE:
3010Z9
DESCRIPTION:
Check the coated surfaces for spots that may be damaged before assembling or
reassembling. Spots less than 20 cm are acceptable.
In case of bigger damages the whole surface coating has to be renewed.
1. Spots less than 20 cm
- Remove carefully all loosen parts of the coated surface.
- Assemble the undercarriage as described in the Assembling Manual.
2. Spots more largely than 20 cm
- Remove the whole surface coating carefully.
- Close the tap holes with plugs (PN 932 313 40).
- Clean the surface oil-free and grease-free.
- Machine the surface with a vibration grinder (emery paper grain 60).
If abrasive blast cleaning is available, this could be done alternatively according
to the attached data sheet.
- Clean the surface with special dust clothes (PN 932 911 40).
- Prepare and use the protective coat according to the attached data sheet.
For laying on the surface coating a conventional air spray has

to be used (no brush or roller).
The prescribed dry layer thickness amounts to 75 m,
according to 125 m wet layer thickness.
Cure is a function of temperature, humidity and airflow.
The film will exhibit full cure in 5 days at 20C and 7 days at
10C (relative humidity between 50 and 60%)
Two pack size (PN 674 997 40) are needed for renew the whole
coating of an undercarriage.
AH07526
= >?@ABC
R e d o x
S C
S i l i c a t e
( F o r m e r l y :
5 1 1 5 )
Product
Description
A two component, low VOC, water borne alkali metallic zinc silicate primer.
Intended Uses
As a high performance corrosion resistant primer for use on correctly prepared steel
substrates in new construction situations.
Suitable for use where a high friction grip is required in accordance with TL 918
300, Page 85.
Practical
Information for
Interzinc 697
Interzinc 697
Protective Coatings
Interzinc 697
S i l i c a t e
( F o r m e r l y :
Application
Mixing
Colour
Grey
Gloss Level
Matt
Volume Solids
60%
Typical Thickness
75 microns (3 mils) dry equivalent to 125 microns (5 mils)

wet
Mix Ratio
Theoretical Coverage
8 m2/litre at 75 microns d.f.t and stated volume solids

321 sq.ft/US gallon at 3 mils d.f.t and stated volume solids
Practical Coverage
Allow appropriate loss factors
Working Pot
Life
Airless Spray
Air spray
(Conventional)
Brush
Temperature
Touch Dry
Hard Dry
Overcoating Interval with

recommended topcoats
Minimum
Maximum
5C (41F)
15C (59F)
25C (77F)
40C (104F)
45 minutes
30 minutes
25 minutes
15 minutes
4 hours
1 hours
45 minutes
30 minutes
N/A
N/A
N/A
N/A
Flash Point
Base (Part A)
>100C (212F)
Powder (Part B)
N/A
Product Weight
3,62 kg/l (30,2 lb/gal)
VOC
0 g/l (0 lb/gal)
Interzinc 697 is supplied in 2 parts, a liquid Binder base component

(Part A) and a Powder component (Part B). Powder (Part B)
should be slowly added to the Liquid Binder (Part A) whilst stirring
with a mechanical agitator. DO NOT ADD LIQUID TO POWDER.
Material should be filtered prior to application and should be
constantly agitated in the pot during spraying. Once the unit has
been mixed it should be used within the working pot life specified
1 part (Part A) : 0.7 parts (Part B) by volume
1 part (Part A) : 4 parts (Part B) by weight
20C (68F)
8 hours
Not Suitable
Recommended
Use suitable proprietary equipment.
Suitable - small areas Typically 50-75 microns (2-3 mils) can be

only
achieved
Roller
only
achieved
Thinner
DO NOT THIN
Cleaner
Clean potable water,
International GTA991
Work Stoppages Do not allow material to remain in hoses, gun or spray equipment.
Thoroughly flush all equipment with clean water followed by
International GTA991. Once units of paint have been mixed they
should not be resealed and it is advised that after prolonged
stoppages work recommences with freshly mixed units.
Clean Up
Clean all equipment immediately after use with clean water followed
by International GTA991.
It is good working practice to periodically flush out spray equipment
during the course of the working day. Frequency should depend upon
amount sprayed, temperature and elapsed time, including any delays.
All surplus materials and empty containers should be disposed of in
accordance with appropriate regional regulations/legislation.
N/A
N/A
N/A
N/A
Drying times are dependent upon ambient conditions. The figures quoted above
have been determined at the quoted temperature and 60% relative humidity.
Page No. 1 of 4
5 1 1 5 )
All surfaces to be coated should be clean, dry and free from contamination. Prior to
paint application all surfaces should be assessed and treated in accordance with
ISO 8504:1992.
Oil or grease should be removed in accordance with SSPC-SP1 solvent cleaning.
Strict adherence to all cleanliness standards is essential for application of water based
coatings.
Abrasive Blast Cleaning
Abrasive blast clean to Sa2 (ISO 8501-1:1988) or SSPC-SP6. If oxidation has
occurred between blasting and application of Interzinc 697, the surface should be
reblasted to the specified visual standard.
Surface defects revealed by the blast cleaning process, should be ground, filled, or
treated in the appropriate manner.
Drying Time
E
N
G
0
5
0
4
S C
Surface
Preparation
Method of Application Airspray, Brush, Roller
Regulatory
Data
R e d o x
Mixed
>100C (212F)
(Calculated)
E
N
G
0
5
0
4
Page 2 of 4
= >?@ABC
R e d o x
S C
S i l i c a t e
( F o r m e r l y :
5 1 1 5 )
Product
Description
A two component, low VOC, water borne alkali metallic zinc silicate primer.
Intended Uses
As a high performance corrosion resistant primer for use on correctly prepared steel
substrates in new construction situations.
Suitable for use where a high friction grip is required in accordance with TL 918
300, Page 85.
Practical
Information for
Interzinc 697
Interzinc 697
Protective Coatings
Interzinc 697
S i l i c a t e
( F o r m e r l y :
Application
Mixing
Colour
Grey
Gloss Level
Matt
Volume Solids
60%
Typical Thickness
75 microns (3 mils) dry equivalent to 125 microns (5 mils)

wet
Mix Ratio
Theoretical Coverage
8 m2/litre at 75 microns d.f.t and stated volume solids

321 sq.ft/US gallon at 3 mils d.f.t and stated volume solids
Practical Coverage
Allow appropriate loss factors
Working Pot
Life
Airless Spray
Air spray
(Conventional)
Brush
Temperature
Touch Dry
Hard Dry
Overcoating Interval with

recommended topcoats
Minimum
Maximum
5C (41F)
15C (59F)
25C (77F)
40C (104F)
45 minutes
30 minutes
25 minutes
15 minutes
4 hours
1 hours
45 minutes
30 minutes
N/A
N/A
N/A
N/A
Flash Point
Base (Part A)
>100C (212F)
Powder (Part B)
N/A
Product Weight
3,62 kg/l (30,2 lb/gal)
VOC
0 g/l (0 lb/gal)
Interzinc 697 is supplied in 2 parts, a liquid Binder base component

(Part A) and a Powder component (Part B). Powder (Part B)
should be slowly added to the Liquid Binder (Part A) whilst stirring
with a mechanical agitator. DO NOT ADD LIQUID TO POWDER.
Material should be filtered prior to application and should be
constantly agitated in the pot during spraying. Once the unit has
been mixed it should be used within the working pot life specified
1 part (Part A) : 0.7 parts (Part B) by volume
1 part (Part A) : 4 parts (Part B) by weight
20C (68F)
8 hours
Not Suitable
Recommended
Use suitable proprietary equipment.

only
achieved
Roller
only
achieved
Thinner
DO NOT THIN
Cleaner
Clean potable water,
International GTA991
Work Stoppages Do not allow material to remain in hoses, gun or spray equipment.
Thoroughly flush all equipment with clean water followed by
International GTA991. Once units of paint have been mixed they
should not be resealed and it is advised that after prolonged
stoppages work recommences with freshly mixed units.
Clean Up
Clean all equipment immediately after use with clean water followed
by International GTA991.
It is good working practice to periodically flush out spray equipment
during the course of the working day. Frequency should depend upon
amount sprayed, temperature and elapsed time, including any delays.
All surplus materials and empty containers should be disposed of in
accordance with appropriate regional regulations/legislation.
N/A
N/A
N/A
N/A
Drying times are dependent upon ambient conditions. The figures quoted above
have been determined at the quoted temperature and 60% relative humidity.
Page No. 1 of 4
5 1 1 5 )
All surfaces to be coated should be clean, dry and free from contamination. Prior to
paint application all surfaces should be assessed and treated in accordance with
ISO 8504:1992.
Oil or grease should be removed in accordance with SSPC-SP1 solvent cleaning.
Strict adherence to all cleanliness standards is essential for application of water based
coatings.
Abrasive Blast Cleaning
Abrasive blast clean to Sa2 (ISO 8501-1:1988) or SSPC-SP6. If oxidation has
occurred between blasting and application of Interzinc 697, the surface should be
reblasted to the specified visual standard.
Surface defects revealed by the blast cleaning process, should be ground, filled, or
treated in the appropriate manner.
Drying Time
E
N
G
0
5
0
4
S C
Surface
Preparation
Method of Application Airspray, Brush, Roller
Regulatory
Data
R e d o x
Mixed
>100C (212F)
(Calculated)
E
N
G
0
5
0
4
Page 2 of 4
Interzinc 697
S i l i c a t e
( F o r m e r l y :
R e d o x
Product
Characteristics
Interzinc 697
S C
S i l i c a t e
( F o r m e r l y :
5 1 1 5 )
Apply by airspray. Thoroughly flush equipment with International 991 thinner, or

alcohol, followed by water prior to use. To obtain maximum edge protection and
film build, airspray application is recommended. Application by other methods,
e.g. brush or roller, may require more than one coat.
R e d o x
S C
5 1 1 5 )
Further information regarding industry standards, terms and abbreviations used in

this data sheet can be found in the following sections of the International Protective
Coatings data manual:
Additional
Information
With all water based coatings careful control of application conditions is required to
ensure good long term performance. International Protective Coatings have
available a set of working procedures relating to the application of water borne
paints which are available on request.
The following basic parameters must be adhered to:
Definitions & Abbreviations
Surface Preparation
Paint Application
Theoretical & Practical Coverage
Individual copies of these information sections are available upon request.
Interzinc 697 must be protected from freezing at all times during storage.
Safety Precautions
The minimum steel temperature for application must be above 10C (50F), and be
at least 3C (5F) above dew point.
Ideally, the relative humidity during application and cure should be kept between 50
and 60%, otherwise drying and overcoating times will be severely extended.
This product is intended for use only by professional applicators in industrial

situations in accordance with the advice given on this sheet, the Material Safety Data
Sheet and the container(s), and should not be used without reference to the
Material Safety Data Sheet (MSDS) which International Protective Coatings has
provided to its customers.
All work involving the application and use of this product should be performed in
compliance with all relevant national Health, Safety & Environmental standards and
regulations.
Good airflow is essential around the object being painted [minimum air speed
0.1m/sec (4 inches/sec)].
Minor areas which are difficult to ventilate should be brush applied to prevent overapplication.
In the event welding or flame cutting is performed on metal coated with this
product, dust and fumes will be emitted which will require the use of appropriate
personal protective equipment and adequate local exhaust ventilation.
Application below the minimum film forming temperature (M.F.F.T.) of the coating
and/or poor ventilation will result in poor film coalescence and will result in a
powdery cracked film which will require removal and re-application.
If in doubt regarding the suitability of use of this product, consult International

Protective Coatings for further advice.
Maximum continuous dry temperature resistance for Interzinc 697 is 400C (752F).
Cure is a function of temperature, humidity and airflow. Normally films at 75 microns
(3 mils) dry film thickness will exhibit full cure in 5 days at 20C (68F) and 7 days at
10C (50F).
1.4 litre unit
Pack Size
Interzinc 697 Base

Interzinc 697 Powder
1 kg in a 1 litre container
For availability of other pack sizes contact International Protective Coatings

Shipping Weight
Storage
U.N. Shipping No. Non-hazardous

1.4 litre unit
1.05 kg (2.31 lb) Base (Part A) 4.36 kg (9.61 lb) Powder (Part B)
Shelf Life
12 months minimum at 25C (77F). Subject to re-inspection

thereafter. Store in dry, shaded conditions away from sources
of heat and ignition.
Disclaimer
Systems
Compatibility
The information given in this sheet is not intended to be exhaustive and any person using the product for any purpose other than that specifically recommended in this sheet
without first obtaining written confirmation from us as to the suitability of the product for the intended purpose does so at his own risk. Any warranty, if given, or specific
Terms & Conditions of Sale are contained in Internationals Terms & Conditions of Sale, a copy of which can be obtained on request. Whilst we endeavour to ensure that all
advice we give about the product (whether in this sheet or otherwise) is correct we have no control over either the quality or condition of the substrate or the many factors affecting
the use and application of the product. Therefore, unless we specifically agree in writing to do so, we do not accept any liability whatsoever or howsoever arising for the
performance of the product or for any loss or damage (other than death or personal injury resulting from our negligence) arising out of the use of the product. The information
contained in this sheet is liable to modification from time to time in the light of experience and our policy of continuous product development.
Interzinc 697 is only recommended for application to correctly prepared steel

substrate.
Interzinc 697 is not normally overcoated.
It is the users responsibility to check that this sheet is current prior to using the product. Issue date: 28/05/2004
Copyright International Paint Ltd.
and International are trademarks.
International Protective Coatings

World Centre
P.O Box 20980
Oriel House
16 Connaught Place
London, W2 2ZB
England
Asia Region
3 Neythal Road
Jurong Town
Singapore 628570
Tel: (44) 20 7479 6000 Tel: (65) 663 3066

Fax: (44) 20 7479 6500 Fax: (65) 266 5287
Page No. 3 of 4
E
N
G
0
5
0
4
Page No. 4
Australasia Region
115 Hyde Road
Yeronga
Brisbane
Queensland
Australia
Europe Region
P.O Box 20980
Oriel House
16 Connaught Place
London, W2 2ZB
England
Middle East Region

PO Box 37
Dammam 31411
Saudi Arabia
North America Region

6001 Antoine Drive
Houston
Texas 77091
Tel: (61) 7 3892 8888

Fax: (61) 7 3892 4287
H&S (61) 1800 807 001
Tel: (44) 20 7479 6000 Tel: (966) 3 812 1044 Tel: (1) 713 682 1711
Fax: (44) 20 7479 6500 Fax: (966) 3 812 1169 Fax: (1) 713 684 1514
South America Region

Av Paiva 999,
Neves, Sao Gonalo,
Rio de Janeiro
Brazil
Tel: (55) 21 624 7100

Fax: (55) 21 624 7123
E
N
G
0
5
0
4
Interzinc 697
S i l i c a t e
( F o r m e r l y :
R e d o x
Product
Characteristics
Interzinc 697
S C
5 1 1 5 )
Apply by airspray. Thoroughly flush equipment with International 991 thinner, or

alcohol, followed by water prior to use. To obtain maximum edge protection and
film build, airspray application is recommended. Application by other methods,
e.g. brush or roller, may require more than one coat.
S i l i c a t e
( F o r m e r l y :
R e d o x
Additional
Information
S C
5 1 1 5 )
Further information regarding industry standards, terms and abbreviations used in

this data sheet can be found in the following sections of the International Protective
Coatings data manual:
With all water based coatings careful control of application conditions is required to
ensure good long term performance. International Protective Coatings have
available a set of working procedures relating to the application of water borne
paints which are available on request.
The following basic parameters must be adhered to:
Definitions & Abbreviations
Surface Preparation
Paint Application
Theoretical & Practical Coverage
Individual copies of these information sections are available upon request.
Interzinc 697 must be protected from freezing at all times during storage.
Safety Precautions
The minimum steel temperature for application must be above 10C (50F), and be
at least 3C (5F) above dew point.
Ideally, the relative humidity during application and cure should be kept between 50
and 60%, otherwise drying and overcoating times will be severely extended.
This product is intended for use only by professional applicators in industrial

situations in accordance with the advice given on this sheet, the Material Safety Data
Sheet and the container(s), and should not be used without reference to the
Material Safety Data Sheet (MSDS) which International Protective Coatings has
provided to its customers.
All work involving the application and use of this product should be performed in
compliance with all relevant national Health, Safety & Environmental standards and
regulations.
Good airflow is essential around the object being painted [minimum air speed
0.1m/sec (4 inches/sec)].
Minor areas which are difficult to ventilate should be brush applied to prevent overapplication.
In the event welding or flame cutting is performed on metal coated with this
product, dust and fumes will be emitted which will require the use of appropriate
personal protective equipment and adequate local exhaust ventilation.
Application below the minimum film forming temperature (M.F.F.T.) of the coating
and/or poor ventilation will result in poor film coalescence and will result in a
powdery cracked film which will require removal and re-application.
If in doubt regarding the suitability of use of this product, consult International

Protective Coatings for further advice.
Maximum continuous dry temperature resistance for Interzinc 697 is 400C (752F).
Cure is a function of temperature, humidity and airflow. Normally films at 75 microns
(3 mils) dry film thickness will exhibit full cure in 5 days at 20C (68F) and 7 days at
10C (50F).
Pack Size
1.4 litre unit
Interzinc 697 Base

Interzinc 697 Powder
For availability of other pack sizes contact International Protective Coatings

Shipping Weight
Storage
U.N. Shipping No. Non-hazardous

1.4 litre unit
1.05 kg (2.31 lb) Base (Part A) 4.36 kg (9.61 lb) Powder (Part B)
Shelf Life
12 months minimum at 25C (77F). Subject to re-inspection

thereafter. Store in dry, shaded conditions away from sources
of heat and ignition.
Disclaimer
Systems
Compatibility
Interzinc 697 is only recommended for application to correctly prepared steel

substrate.
Interzinc 697 is not normally overcoated.
The information given in this sheet is not intended to be exhaustive and any person using the product for any purpose other than that specifically recommended in this sheet
without first obtaining written confirmation from us as to the suitability of the product for the intended purpose does so at his own risk. Any warranty, if given, or specific
Terms & Conditions of Sale are contained in Internationals Terms & Conditions of Sale, a copy of which can be obtained on request. Whilst we endeavour to ensure that all
advice we give about the product (whether in this sheet or otherwise) is correct we have no control over either the quality or condition of the substrate or the many factors affecting
the use and application of the product. Therefore, unless we specifically agree in writing to do so, we do not accept any liability whatsoever or howsoever arising for the
performance of the product or for any loss or damage (other than death or personal injury resulting from our negligence) arising out of the use of the product. The information
contained in this sheet is liable to modification from time to time in the light of experience and our policy of continuous product development.
It is the users responsibility to check that this sheet is current prior to using the product. Issue date: 28/05/2004
Copyright International Paint Ltd.
and International are trademarks.
Deutschland:
H & S Beschichtungssysteme Vertriebs GmbH | Niekamp 24 | 59399 Olfen | Telefon +49 (25 95) 34 35 / 30 16 | Telefax +49 (25 95) 91 20 | info@hus-beschichtungssysteme.de
Page No. 3 of 4
Page No. 4
COMPONENT CODE:
L5
REF NO.
AH08503
DATE
SUBJECT:
Track drive
PURPOSE:
Complete track drive protection
APPLICATION:
PC5500-6 (SN 15026 and up)
FAILURE CODE:
L510FA
January 18, 2008

Page 1 of 6
DESCRIPTION:
For heavy duty use we recommend to install the complete drive protection according to the
drawings below.
1.
Gear box protection (PN 946 692 40)
2.
Motor protection (PN 936 640 40)

(only for diesel drive shovels with L&S travel gears)
AH08503
Page 2 of 6
Illustration 1
AH08503
Page 3 of 6
1.
Illustration 2
Install the 4 intermediate plates (02) by using the new bolts (03) and washers (04)
(remove the respective bolts from the gear box).
Mount the protecting cage (01) by using the bolts (05) as shown.
Pay attention to the hydraulic hoses.
AH08503
Page 4 of 6
1.

Pos.
Part No.
Qty.
Description
01
946 685 40
Protecting cage
02
946 684 40
Intermediate plate
03
518 354 98
20
Bolt
04
255 056 40
20
Washer
05
517 876 98
24
Bolt
06
621 707 40
24
Resilient sleeve
07
501 133 98
24
Nut
08
255 057 40
24
Washer
AH08503
Page 5 of 6
2.
Illustration 3
Mount the intermediate plates (01) by using bolts (07)

(existing bolts have to be replaced);
Install the bolt protection (04) with bolts (07) (not necessary by mounting the gear
box protection);
Now install the motor protection assy. by using the bolts (08); the washers (9) and
the nuts (10).
Pay attention to the hydraulic hoses.
AH08503
Page 6 of 6
2.

(only for gears delivered by L&S - SN 15026 and up)
Pos.
Part No.
Qty.
Description
01
936 639 40
Intermediate plate
02
936 631 40
Motor protection left
03
936 632 40
Motor protection right
04
936 647 40
Bolt protection travel gear
05
936 641 40
Cover
06
936 642 40
Cover
07
517 967 98
40
Bolt
08
304 331 99
20
Bolt
09
316 213 99
40
Washer
10
332 359 99
20
Nut
11
307 800 99
20
Nut
12
324 741 40
Plug
AH08503
COMPONENT CODE:
55
REF NO.
AH08504
DATE
August 7, 2008
Page 1 of 2
SUBJECT:
Windscreen
PURPOSE:
Mounting hints
APPLICATION:
PC4000; PC5500; PC8000
FAILURE CODE:
5532PB
DESCRIPTION:
A different holes pattern is used since January 2007 for the frame of the windscreen.
We offer two types of windscreens for replacement of a damaged one:
1. Windscreen with mounting holes in the frame and
2. Windscreen without mounting holes.
We recommend using windscreen with new holes pattern in the frame, also for shovels,
delivered before 2007.
Advantages:
Only one fitting of new bore holes in the cab.
In case of a next windscreen exchange the same holes can be used.
AH08504
Page 2 of 2
Pos.
01
Pos.
Part No.
769 528 73 12 mm; green; drilled

12 mm; green;
797 251 73
undrilled
Part No.
793 739 73
797 253 73
01
Description
796 564 73
797 254 73
Description
12 mm; green;
drilled
12 mm; green;
undrilled
19 mm, with splinter
shield foil coating;
drilled
19 mm, with splinter
shield foil coating;
undrilled
AH08504
COMPONENT CODE:
71
REF NO.
AH08507
DATE
April 9, 2008
Page 1 of 9
SUBJECT:
Steel structure
PURPOSE:
Repair welding procedure
APPLICATION:
PC3000-6; PC4000-6; PC5500-6; PC8000-6
FAILURE CODE:
7100FE
DESCRIPTION:
W
Content
1.
2.
3.
4.
4.1
4.2
5.
6.
7.
8.
Introduction
General Protective Measures
Steps of the weld repair procedure
Selection of appropriate electrodes and welding rods
Selection of appropriate electrodes
Selection of appropriate welding rods
Preparation of the defective Part
Carrying out the Weld Repair
Post heating
Inspection of Repair
AH08507
Page 2 of 9
1. Introduction
Weld repairs can cause severe damage to an entire structure if performed incorrectly.
Therefore we recommend consulting your Komatsu Service Organization in order to
avoid improper welding procedures. 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.
2. General Protective Measures
Welding operations can cause damage to electronic components (Computers, Control
Units, Sensors etc.) in case the welding current goes through these units. Therefore
protective measures are necessary before any weld repair is started.
1. Observe the prevailing safety and fire prevention regulations. Get advice from
authorized Electricians for all medium and high voltage systems related
questions.
2. Before any weld repair is started, a survey should be made of the area and all
safety considerations satisfied such as fuel tanks, hydraulic oil reservoirs, oil
lines, electrical cables and synthetic materials.
3. Remove the battery main switch keys and switch off all circuit breakers, refer to
the Operation Manual of the Excavator for more information.
4. Attach the welding ground directly to the part that is being repaired. Do not allow
welding current to go through bearings. Welding current could arc the bearings,
resulting in severe damage to the bearing.
3. Steps of the weld repair procedure
1. Clean the damaged part or area to be repaired.
2. Inspect the worn or fractured area by visual inspection and/or non-destructive
testing.
3. Determine the type of material to be repaired.
4. Determine the welding electrode or the welding wire and process to be used.
5. Preheat before welding.
6. Weld by using appropriate welding techniques.
7. Post heat.
8. Make a survey of the repair welding.
AH08507
Page 3 of 9
4. Selection of appropriate welding electrodes and welding wires

Table 1: The components shown in illustrations 3 and 4 are made of six
different materials (a, b, c, d, e or f) as shown in the table below.
Material
designation
former
present
international
St52-3N
S355J2G3
1.0570 (17G1S)
GS24Mn6V
GS24Mn6V
1.1118
StE690
S690Q
1.8931
GS18NiMoCr36
GS18NiMoCr36
1.6759
TStE355
P355NL1
1.0566
Hardox 400
4.1 Selection of appropriate welding electrodes

Table 2: The following welding electrodes are required for the weld repairs:
Key number
Welding Electrode (AWS)
4
5*
7*
9*
E 7016
E 7018-G
E 8018-G
E 100 18-G
* Hydrogen content less than 5mg per 100ml
Table 3: Types of welding electrodes to be used for the different materials

(a to f)
Material
a
b
c
d
e
f
a
4
4
4
4
4
7
b
4
4
7
5
7
c
4
7
9
9
7
d
4
5
9
9
7
f
7
7
7
7
7
7
AH08507
Page 4 of 9
Example: Selection of the correct welding electrode for weld repair a crack in
the welded joint between material (a) and (c). The table 4 shows the
correct electrode with key number 4 in the red shaded field.
Table 4
Material
a
b
c
d
e
f
a
4
4
4
4
4
7
b
4
4
7
5
7
c
4
7
9
9
7
d
4
5
9
9
7
f
7
7
7
7
7
7
4.2. Selection of appropriate welding wires

Table 5: The following welding wires are required for the weld repairs
Key number
Welding wire (AWS)
21
25/25a
30
32
ER70 S6
ER100 S1
E70 T5
E90 T5-G
Table 6: Types of welding wires to be used for the different materials (a to f)

Welding wires
a
b
c
d
e
f
a
21; 30
21; 30
21; 30
21; 30
21; 30
25; 32
b
21; 30
21; 30
21; 30
21; 30
21; 30
---
c
21; 30
21; 30
25; 25a; 32
32
21; 30
25; 25a; 32
d
21; 30
21; 30
25; 25a; 32
32
21; 30
---
f
25; 25a; 32
--25; 25a; 32
--25; 25a; 32
25; 25a; 32
AH08507
Page 5 of 9
5. Preparation of the defective Part

Clean the fractured area or worn part of all oil, grease, paint, moisture, dirt, rust,
spalled material or any other materials, which may be detrimental to a weld.
Inspect the fractured areas carefully by non-destructive testing such as
magnetic particle or dye penetrant inspection.
When removing cracks, a V groove should be made with a 30 to 45 angle.
Remove defective material up to the bottom of the crack.
Illustration 1
Use electrodes out of a freshly opened can or from an electrode holding oven. Dry
the electrodes according to the instructions of the electrode manufacturer.
Preheating of the part before preparing it for weld repair is essential to reduce the
thermal shock. The preheat temperature depends on the composition of the
material, see table 7 for the required temperature. Measure the temperature
beside the joint at a distance equal to the sheet metal thickness using suitable
temperature indicating devices.
Table 7
Material
S355J2G3
P355NL1
S690Q
GS24Mn6V
GS18NiMoCr3
Hardox 400
Groove
depth
(mm)
<10
Preheat
temperature
(C)
20
Interpass
temperature
(C)
220
10 - 20
20 - 50
10
10 - 20
>20
<10
10 - 20
>20
50
100
50
100
150
50
100
150
220
220
150
180
220
150
180
180
>10
150
200
Post heat
temperature
(drop per hour)
50 degree. max.
AH08507
Page 6 of 9
6. Carrying out the Weld Repair
All weld repairs should be carried out by qualified and

experienced welders.
Provide the necessary equipment such as the correct clothing,
head gear, exhausts systems or respirators and if required
platforms for safe access to the repair area.
It is important to maintain the preheat temperature according to table 7
throughout the repair.
The interpass temperature should never exceed the maximum permissible
value shown in table 3. Measure the temperature beside the joint at a distance
equal to the sheet metal thickness using suitable temperature indicating
devices.
All cracks through the parent material will require a welding from both sides,
see illustration 1. The Service Bulletin No. 21-594 contains instructions for
making a Man Hole which is necessary for weld repairs from inside the boom
or stick.
When welding in a vertical position always weld using the vertical up technique.
Properly applied multiple pass welding is the required procedure, illustration 2.
Use a blunt-nosed chisel (C) to calk the weld beads (A and B) with the groove
wall before welding the space between the beads (A and B). Repeat the
calking of beads (A and B) at each weld layer.
Illustration 2
Once a repair has been started by preheating and welding, the part should be
worked on until completed.
A recommended technique for repair is to butter the groove with weld metal.
Buttering is the addition of one or more layers of weld metal to the face of the
joint or surfaces to be welded.
AH08507
Page 7 of 9
After the welding has been completed, check the repair for any undercuts,
overlaps or any other notch type discontinuity while the preheat is still up to
temperature. Make any repair necessary at this time.
After the repair cools, grind all butt-welded repairs smooth using 36 or finer grit
grinding material. All grinding marks should be parallel to the direction of
primary stress if possible. Make sure there is a smooth transition between the
weld metal and the parent plate.
7. Post heating
Maintain the preheat temperature according to table 7 for at least 15 minutes

after the weld repair is finished and then cool the repair area slowly, refer to
table 3 for maximum allowable temperature drop per hour.
8. Inspection of Repair
Inspect the completed weld after it has cooled to the ambient temperature by
non-destructive procedures as dye penetrant, or magnetic particle inspection
and ultrasonic inspection, if possible.
A final inspection of the weld repair should be made after 24 hours in order to
detect hydrogen induced cracks.
If surface defects are found, remove all defects by grinding to a maximum
depth of 1.5 mm. Larger defects have to be removed according to the repair
procedures described on the preceding pages. Grind welds so they blend in
with the parent material. All spot welding also require preheating and post
heating.
It is not recommended to weld on reinforcement plates as the
main stress will remain ~float~ through the steel structure
regardless how many additional plates would be applied to the
structure.
AH08507
Page 8 of 9
Illustration 3
AH08507
Page 9 of 9
Illustration 4
AH08507
COMPONENT CODE:
71
REF NO.
AH08508
DATE
June 13, 2008

Page 1 of 3
SUBJECT:
PURPOSE:
Wear checking procedure
APPLICATION:
PC3000-1; PC3000-6; PC4000-6; PC5500-1; PC5500-6;

PC8000-1; PC8000-6
FAILURE CODE:
7100CA
DESCRIPTION:
For installation of bushes please refer also to Parts & Service

news AH06545.
1. Bushings of the attachment

2. Bushings between bolted track frame and undercarriage
(depends on the execution)
AH08508
Page 2 of 3
1. Bushings of the attachment
Illustration 1
Example for determining the clearance of the boom cylinder bushes
(The procedure for the other attachment bushes is analogues.)
1. Place the attachment on the ground as shown on illustration 1.
2. Raise the attachment a little bit from the ground.
3. Make a line with a felt pen from boom bearing to the boom cylinder barrel
(a = 30 cm).
4. Make a 2nd line with a felt pen from boom bearing to the boom cylinder piston rod
(b = 30 cm).
5. Press the attachment on the ground so far that the chains at c just remove from
the ground.
6. Measure the distances at a and b.
We recommend to renew the bushes if the clearance reaches a

value of about 3 mm.
AH08508
Page 3 of 3
2. Bushings between bolted track frame and undercarriage
1. Position the machine in a position
so that the track frame can be lifted of
the ground.
2. Install a dial gauge so that the

dial gauge magnetic portion is on
the side frame.
3. Set the pointer on to the car body
and set to zero.
4. Raise the track frame slowly off

the ground until the dial gouge
stops moving.
Record the measurement.
We recommend to renew the bushes if the clearance reaches a

value of about 3 mm.
AH08508
Suppliers documentation
9 SUPPLIERS
DOCUMENTATION
Version 2009/2
PC5500-6
9 -1
Suppliers documentation
Contents of this chapter:

AVANTI HYTORQUE
9 -2
PC5500-6
Version 2009/2
XXI/Avanti/Stealth SERIES
Operational Manual
July 2004
Table of Contents
XXI/Avanti/Stealth SERIES Operational Manual
SECTION I
IMPORTANT SAFETY INSTRUCTIONS
SECTION II
BEFORE USE
2-1 Working Pressure

2-2 Hydraulic Connections
2-3 Electrical Connections
2-4 Air Connections
SECTION III
OPERATION
3-1 General
3-2 Connecting the System
3-3 Drive Direction Change
3-4 Reaction Arm XXI/Avanti
3-5 Setting Torque
3-6 Setting Pump Pressure
3-7 Tightening Procedures
3-8 Operating the XXI, Avanti & Stealth Systems
3-9 Loosening Procedures
SECTTION IV
4-1 Tool set up and operation
USE WITH LoaDISC
4-2 LoaDISC Tensioning
WASHER & CLAMP-NUT 4-3 LoaDISC De-tensioning
4-4 LoaDISC Lubrication
4-5 CLAMP-NUT Tensioning
4-6 Clamp-nut De-tensioning
4-7 Clamp Lubrication
SECTTION V
5-1 General Information
OPERATION
HYTORC POWER PACKS 5-3 Prior to Use
5-4 Operation Electric Pump-5-5 Operation Air Pump-5-6 Automatic Pump
5-7 Starting with Automatic System
SECTION VI
HELPFUL
INFORMATION
Tool Dimensions & Parts List

Field-proven Torquing Procedure
Pressure/Torque & Pressure/Load Conversion Chart
Recommended Torque For ASTM A193 Grade B7 Studs
INTRODUCING THE NEW GENERATION HYTORC
Thank you for buying the NEW HYTORC FREEDOM-LINE!

This manual is designed to provide you with the basic knowledge required to operate and maintain
your HYTORC bolting equipment. Please read this manual carefully and follow the instructions
provided. If you have any questions regarding HYTORC bolting equipment, please call us at
201-512-9500 or contact us at hytorsales@hytorc.com.
Your purchase of HYTORC bolting equipment entitles you to the following services at no extra
cost to you.
Free on-site training in the application and operation of your HYTORC bolting equipment
* Free semi-annual training
* Free annual tool inspection.
* Free loner tools in case of failure under warranty
* Free engineering assistance by calling 1-800-FOR-HYTORC or our international office.
Your local HYTORC bolting specialist is available around the clock for your convenience. Should
you require any assistance, please contact us to obtain our local specialists information.
World-wide Warranty
HYTORC bolting equipment is engineered to the latest technological standards and is accompanied
by our exclusive 12 word, 12-month warranty:
YOU BREAK IT UNDER NORMAL USE, WE FIX IT FREE OF CHARGE!
If your HYTORC equipment cannot be repaired on site, FREE loaner equipment will be made
available to you upon request, while under warranty.
INTRODUCTION
HYTORC tools are uniquely multi-purpose. They can be used as accurate bolting
equipment on conventional nuts in open or confined spaces. They also can be used as
reaction arm free tensioning equipments, when used with HYTORC LoaDISC washer or
HYTORC-Clamp, Hydraulically Actuated Mechanical Tensioner.
SECTION I
IMPORTANT SAFETY INSTRUCTIONS
HYTORC tools are designed for the safety of operators. However, they are powerful tools and certain
safety precautions should be observed to avoid accidents or personal injury. The following tips will
assist you.
READ ALL INSTRUCTIONS
KEEP WORK AREA CLEAN AND WELL LIT
CONSIDER WORK AREA
ENVIRONMENT
Electric pumps should never be used in any atmosphere

which can be considered potentially volatile. If there is any
doubt, use an air pump.
Also note: Metal to metal contact can cause sparks. Precautions must be taken.
AVOID PREMATURE TOOL
STARTING
The pump remote control should be operated by a

designated operator and ensure ALL CLEAR prior to
starting and to avoid premature tool starting.
STAY CLEAR DURING OPERATION
In most cases, the tool will allow hands free operation. If

the tool must be reset on bolt during operation, make sure the
remote control operator is aware of turning the pump off.
IMPORTANT NOTE: NEVER HOLD THE TOOL DURING OPERATION!

GUARD AGAINST ELECTRIC
SHOCK
Ensure the pump is properly grounded and the proper

voltage is used.
STORE EQUIPMENT PROPERLY
When not in use, tools and accessories should be properly

stored to avoid deterioration.
USE THE RIGHT TOOL

Do use tools or attachments suitable for the applications.
*refer to our recommended torque/load chart
PROPER SAFETY ATTIRE
When handling/operating hydraulic equipment, wear

work gloves, hard hats, safety shoes, safety glasses and other
applicable clothing.
MOVING EQUIPMENT
Do not use hydraulic hoses, uniswivels, pump power or

remote cords as means of moving the equipment.
SECTION I
IMPORTANT SAFETY INSTRUCTIONS -continued from the previous pageHOSES
Do not kink hoses. Inspect and replace if damaged.
SHROUDS AND COVER PLATES
All tools are equipped with shrouds and/or cover plates

to prevent contact with the moving internal parts. Do not
use tools without these safety covers. If the covers are
missing or damaged, replace immediately.
MAINTAIN TOOLS
For the best results, inspect tools, power packs, hoses,

connectors, electric lines and accessories for visual
damage before each usage. Always follow instructions
for proper tool and pump maintenance.
SAFETY ALERT
Do not use power equipment under the influence of any

mood altering substance.
PRIOR TO OPERATION
Ensure that all hydraulic connectors are securely

connected. Verify that the hydraulic hoses are not
kinked. Insure the square drive and its retainer are
fully and securely engaged.
PRIOR TO USE (if use with reaction arm)
Before placing your tool on the application, cycle it to

ensure proper function. If using the torque mode,
locate a solid and secure reacting point. Be sure the
reaction arm is retained firmly and positioned to face
the same direction as the square drive. Be sure the
hydraulic hoses are free of the reacting point. Pressurize
the system momentarily; if the tool tends to ride up or
to creep, stop and adjust the reaction arm to a solid
and secure position.
NOTE: Remain clear of the reaction arm during operation and never put body parts between
reaction arm and reaction surface.
ALWAYS USE QUALITY
ACCESSORIES
Use genuine HYTORC accessories. Use correct size

accessories and engage them fully. Stay clear of all moving
accessories during operation.
DO NOT USE FORCE
Do not apply any impact by using hard objects on bolting

equipment or accessories. This may cause malfunction or
breakage.
ALWAYS CONSULT
Please contact HYTORC for any questions related to our

equipment or your bolting needs. Safety is always the
number one priority.
SECTION II
INSTRUCTIONS BEFORE USING YOUR NEW HYTORC
READ CAREFULLY: Most malfunctions, in new equipment, are the result of improper operation
and/or set-up.
PREPARATION: Remove HYTORC equipment from shipping container.
INSPECTION: Visually inspect all components for any damage during transportation. If damages
are found, notify HYTORC immediately.
2-1 Working Pressure
The tools maximum
working pressure is 10,000 PSI (700kg/cm2, 690 Bar)
Make sure that all hydraulic equipment used is rated
for 10,000 PSI operating pressure. To set pump
pressure for XXI models to 10,000 PSI for both
advance & retract, locate selector valve underneath
the couplers. Turn the pump off and loosen the lock
nut. Turn the center screw counter-clockwise until
it stops. Tighten the lock-nut. For Avanti & Stealth
models, turn the center screw clockwise until it stops.
Tighten the lock-nut to set the pump pressure to 1,500
PSI for retract.
2-2 Hydraulic Connections With older style pumps, (SST-10, SST-20),
the retract side of the system may remain pressurized after the pump
has been switched off. This trapped pressure makes it impossible to
loosen the retract-side fittings by hand. To release the pressure, find
the 5/16 manual override holes in the end of the black solenoids on the
pump. With a welding rod, Allen-key or similar device, push in on the
ends of both solenoids, each in turn, and the residual pressure will be
released. All fittings will, then, be hand tightened again. Hoses and
couplers must be free and unobstructed before and during the operation
of the tool. External impact on the couplers may break off the fittings.
Current pump models are equipped with an auto-pressure relief. Never disconnect or connect any
hydraulic hoses or fittings without first unloading wrench and the pump. Double check the gauge
reading to assure pressure has been released.
When making connections with quick disconnect couplings, make sure the couplings are fully engaged.
Threaded connections such as fittings and gauges must be clean and securely tightened and leak free.
CAUTION: Loose or improper threaded fittings can be potentially dangerous if pressurized. Severe
over tightening can cause premature thread failure. Never grab, touch or in any way come in contact
with a hydraulic pressure leak. Escaping oil can penetrate the skin and cause injury.
SECTION II
INSTRUCTIONS BEFORE USING YOUR NEW HYTORC -continued from the previous
page2-3 ELECTRICAL CONNECTIONS
Ensure proper power availability to prevent motor failure or
dangerous electrical overloading. Compare the motor nameplate for required amperage. Do not use
electric pump, if three prong electrical plug is not whole. Minimize the length of extension cords and be
sure they are of adequate wire size, with ground connectors. Extension cord up to 50 feet should be #10
AWG gauge.
CAUTION: Electric motors may spark. Do not operate in an explosive atmosphere or in the presence
of conductive liquids. Use an air pump instead.
2-4 AIR CONNECTIONS Ensure that you have sufficient air flow of 80 psi ( 50 cfm) to operate your
pneumatic pump. If in doubt, compare the pump manufacturers recommended air flow rating prior
to pressurizing pump. Improper air flow may damage the pump motor. For best results, use air hose
larger than 3/4 diameter.
Use of a filter regulator lubricator (FRL) is highly recommended. (diagram below)
AIR ADJUSTMENT KNOB
AIR FLOW
ON/OFF LEVER
OIL LUBRICATOR
ADJUSTMENT KNOB
FILTER CAP
AIR PRESSURE GAUGE

CONDENSATION
BOWL
DRIER
1.
2.
Adjust flow to 1-2 drops per minute.

Fill half way with grade 46 hydraulic oil supplied.
AUTO WATER DRAIN PORT
SECTION III
OPERATION Torquing Conventional Nuts
3-1 General All HYTORC tools are supplied completely assembled and are ready to use. A
HYTORC Hydraulic Power Pack, for use with your HYTORC tools, is recommended to provide
the speed, pressure and portability that makes your HYTORC SYSTEM more efficient and accurate.
The SYSTEM accuracy of your HYTORC tool is +-3% based upon manufacturers specifications.
This accuracy maybe certified through calibration by HYTORC or any other qualified calibration
facility whose program is traceable to the National Institute of Standards and Technology (N.I.S.T.)
Using a calibrated gauge enhances the accuracy of your HYTORC SYSTEM.
3-2 Connecting the SYSTEM
The wrench head and power pack are connected by a
10,000 PSI operating pressure (40,000 PSI burst) twin line hose assembly. Each end of the hose have
one male and one female connector to assure proper interconnection between pump and wrench
head.
IMPORTANT:
To avoid tool malfunction, do not reverse connectors.
Connect the twin line hose to the uniswivel as shown below. Make sure male couplers are connected to
female couplers. During the operation, check the connection to ensure the couplers are not loose.
Insure the connectors are fully engaged and screwed snugly and completely together.
Connect to tool
Connect to pump
*Connect male end of hose to female end of both tool and pump &
female end of hose to male end on both tool and pump
From hose
From hose
SECTION III
OPERATION Torquing Conventional Nuts -continued from the previous page3-3 Drive Direction Change
Avanti tools To remove the square drive, disengage the drive retainer assembly by
depressing the retaining round button and gently pulling on the square end of the square drive. The
square drive will slide out. To insert the drive in the tool, place the drive in the desired direction,
engage drive spline and ratchet spline, then twist bushing until engage to the housing spline. Push
drive through ratchet. Depress drive retainer button, engage retainer with drive and release button
to lock.
Button
Drive Retainer
Square Drive
The diagram on the right illustrates the direction that the square
drive should face for tightening and loosening of a standard
right hand fastener.
Loosening
Tightening
Stealth tools The Stealth tools use interchangeable ratcheting links. For tightening, simply engage
the nut with the right side of the link facing down. For loosening, the left side of the link faces down.
Ratcheting link can be detached from the Stealth power head by pulling the power head out while
pressing the button shown below.
STEALTH
MADE IN U.S.A.
STEALTH
MADEIN USA
Loosening
Link release button
3-4 Reaction Arm
Please read
operating
instructions
prior to use,
and use
common sense.
Tightening
KEEP HANDS
OFF DURING
OPERATION!
The Avanti can be used with a 360 degree adjustable universal reaction arm.
Make sure the reaction arm spline is fully

engaged on the square drive spline. Secure
the position by tightening the set screw on
the reaction arm.
*ALWAYS USE A SAFETY HANDLE
SECTION III
OPERATION Torquing Conventional Nuts -continued from the previous page3-5 Setting Torque
Once the SYSTEM is fully connected and the proper power supply is available, it is time to adjust the
pump pressure to the level needed on your job. When tightening, use the manufacturers specifications
to determine the torque value ultimately required. Appendix I which is presented as a guideline for
comparison only gives typical torque values specified for the most commonly encountered fasteners.
Torque sequence varies from plant to plant and even within the same plant may vary depending on the
gasket material and other factors. Always abide by on-site-procedures.
Always refer to the pressure-torque conversion table that came with the tool.
3-6 Setting the Pressure on the Pump
T Handle
To set the pressure on the pump, follow this procedure.

1. Loosen the knurled locking ring below the T handle on the pumps
external pressure regulator. Then turn the T handle counterclockwise until it turns freely and easily.
2. Turn the pump ON. Using the pumps remote control pendant,
push down the advance switch (or button on air pump) and hold it.
Locking Ring
3. While holding the pump in the advance mode, slowly turn the T handle
clockwise and observe the pump pressure gauge rise.
NOTE: Always adjust the regulator pressure up never down.
4. Once the desired pressure is reached. Turn off the pump and LOCK IN the pressure by tightening
the knurled lock nut. Turn on the pump once more and pressurize to verify the pressure is maintained.
3-7 Applying the Avanti the Tightening Process
1. Once your target pressure is set, cycle the tool three or four times to full pressure. Cycling the tool
ensures that the system is operating properly and removes trapped air, if any.
2. Place the proper size driving unit on the square drive and secure properly.
3. Place the tool on the bolt, making sure that everything is fully engaged. Further ensure that the drive
retainer is engaged.
4. Make sure the reaction arm is firmly abutted against a stationary object.
5. When positioning the wrench, make sure that the hose connections are well clear of any obstructions.
6. After all the above are confirmed, apply momentary pressure to the SYSTEM to ensure proper tool
placement.
SECTION III
OPERATION Torquing Conventional Nuts -continued from the previous page3-7 Applying the Stealth the Tightening Process
1. Once the target pressure is set (refer to 3-6) Cycle the tool several times to full pressure to assure
proper operation.
2. Place the right side of the ratchet link directly over the nut. Ensuring the hex is fully engaged
and the reaction pad portion of the link abuts solidly against an adjacent nut or other stationary
object. (see 3-3 for proper tool placement)
3. Ensure hose connections are clear of any obstacles.
4. After all the above are confirmed, apply momentary pressure to the SYSTEM to assure the
reaction point is stable.
3-8 Operating the Avanti and Stealth SYSTEMS
1. By pushing down on the remote control button in the advance position, the rear of the tool will
be pushed back until the reaction surface will contact its reaction point.
2. Continue to hold down the advance button as the socket turns until you hear a CLICK which
will signify the hydraulic cylinder inside the tool is fully extended and will not turn the socket
further.
3. Continuing to hold down the remote control button will result in a rapid buildup of pressure to
the point of where the gauge reads what was preset prior to applying the wrench.
IMPORTANT:
The reading of full preset pressure after the cylinder is extended DOES NOT
INDICATE that this pressure (torque) is applied to the bolt. It only indicates that the cylinder is
fully extended and cannot turn the nut further until the tool automatically resets itself.
Releasing the remote control button will retract the cylinder. The tool will automatically reset
itself and the operator will hear a CLICK indicating he can again push the remote control
button and the socket will turn. Each time the cylinder is extended and retracted, it is called a
cycle. Successive cycles are made until the tool STALLS at the preset Torque/PSI with an
accuracy of +-3%. Repeatability is +-1%.
IMPORTANT:
ALWAYS ATTEMPT ONE FINAL CYCLE
TO INSURE THE STALL POINT HAS BEEN REACHED.
NEVER HOLD THE TOOL DURING OPERATION.
Use safety handle to set and
remove tools.
SECTION III
OPERATION Torquing Conventional Nuts -continued from the previous page3-8 Operating the Avanti and Stealth SYSTEMS
Releasing LOCKED-ON tools.
Should the tool LOCK-ON after the final cycle, slide the slider (or the lever on Avanti) with the
pump off or in retract position. Turn the pump back on and while maintaining the pressure, cycle
Avanti in the pumps manual mode. Should Stealth LOCK-ON, advance pump pressure
and while advancing, press down on the release button located on the sides of the ratchet link.
Once you are able to press down the button without resistance, continue holding the button down
and release the advance pressure on the pump. Shut off the pump, and remove the tool from the nut.
Avanti Release Procedure
Disengage lever
1)
Push lever to position A
2)
Cycle tool in manual mode, release advance

button
3)
Shut pump off
4)
Remove tool and reset lever to position B
Stealth Release Procedure

STEALTH
1)
Push remote to full pressure for final stroke
2)
Disengage the reaction pawl by holding the

button in the direction of arrow
3)
Release the rocker switch
4)
Shut pump off
5)
Remove tool
MADE IN U. S.A.
Disengage button
SECTION III
OPERATION Torquing Conventional Nuts -continued from the previous page3-9 Loosening Procedures Avanti and Stealth SYSTEM
First, set the pump to 10,000PSI. Set the tools for the loosening mode (Refer to 3-3), assuring the
reaction surface abuts squarely off a solid reaction point. Press and hold the remote control button
down. Pressure will decrease as the socket begins to turn. As the cylinder extends fully, you will hear
a CLICK. Release the remote control button and the cylinder automatically retracts, at which time
you again hear a CLICK. Repeat this process until the fastener can be removed by hand.
NOTE:
If the bolt does not loosen with the above procedure, it is an indication that you may
require the next larger size tool to loosen the bolt. Corroded nuts and thread galling on bolts can
cause difficulty in loosening. Please consult your HYTORC bolt specialist.
SECTION IV
OPERATION HYTORC LoaDISC and Clamp
4-1 Tool Set up and Operation
When used in conjunction with the HYTORC LoaDISC Washer or Clamp, the operation is essentially
the same as with the conventional nuts, but with one notable exception: THERE ARE NO
REACTION FORCES TO CONSIDER OR PROVIDE FOR! The reaction forces are absorbed
through the fastener assembly itself. Each individual customer order for LoaDISC or Clamps will be
provided with specific installation instructions for each application. However, the following general
guidelines outline correct installation procedures.
4-2 HYTORC LoaDISC Tensioning
1. Do not use grease or lubricants on LoaDISC , nut, bolt or joint face. LoaDISC is DRY LUBE
protected.
2. Place the LoaDISC over the bolt with the flat surface firmly against joint face.
3. Install the nuts on the bolt and hand tighten snugly on both sides of assembly.
4. Set required pump pressure.
5. Place tooling to engage a nut and the LoaDISC with TIGHTENING side facing the operator.
-continued to the next page-
DRIVE SOCKET
HOLDING SOCKET
Soft Joint LoaDISC
Reusable LoaDISC
Hard Joint LoaDISC
Limited Clearance
HEX NUT
DISC WASHER
THREADED SEGMENT
LoaDISC
SECTION IV
OPERATION HYTORC LoaDISC and Clamp -continued from the previous page4-2 HYTORC LoaDISC Tensioning
6. Verify proper socket engagement by momentarily
pressurizing tool. If tool remains stationary, operate
normally until tool STALLS OUT
7. Should tool rotate during initial pressurizing:
A. Insure both socket and sleeve are fully engaged.
B. Insure that joint faces are free from grease and oil.
*Also refer to the trouble shooting section (4-4)
LoaDISC Driver Installation
for Tensioning
LOCK-RING
'NEUTRAL'
POSITION
PLACE DRIVER
NUT/LoaDisc
ROTATE 'CW'
BY HAND, TO
SNUG LoaDisc
TO FLANGE
LoaDisc
LOCK-GROOVE
NOTE:
ROTATE
DRIVER
ASSEMBLY
'CCW'
DIRECTION
FOR
TIGHTEN
MODE
TIGHTEN
'CCW'
DIRECTION
LOOSEN
'CW'
DIRECTION
* DO NOT GRAB A SWIVEL DURING OPERATION!

* DO NOT PLACE TOOL HOUSING
* TO ABUT AGAINST STATIONARY OBJECTS
* DO NOT STAND UNDERNEATH OR
CLOSE TO TOOL
* DO NOT RE-USE SINGLE-TIME
USE LoaDISC
VERIFY
ROTATE
LOCK-RING
LOCK-RING
ENGAGE
LoaDisc
LOCK-GROOVE
SECTION IV
OPERATION HYTORC LoaDISC and Clamp -continued from the previous page4-3 HYTORC LoaDISC De-tensioning
1. Set pump to maximum pressure.
2. Place tooling to disengage the nut and the LoaDISC with LOOSENING side facing the operator.
3. Verify proper socket engagement by momentarily pressurizing tool. If tool remains stationary,
operate normally until the nut is loose.
4. Should tool rotate during initial pressurizing:
A. Insure both socket and sleeve are fully engaged.
B. Insure that joint faces are free from grease and oil.
*Also refer to the trouble shooting section (4-4)
ROTATE
DRIVER
ASSEMBLY
'CW'
DIRECTION
FOR
LOOSEN
MODE
LoaDISC Driver Installation for De-tensioning
VERIFY
ROTATE
LOCK-RING
Releasing LOCKED-ON tools. (Refer to 3-8 for Avanti and Stealth)

Should the tool LOCK-ON after the final cycle, slide the slider with the pump off or in retract
position. Turn the pump back on and while maintaining the pressure, cycle XXI in the pumps
manual mode. the pump. Shut off the pump, and remove the tool from the nut.
XXI Release Procedure
HYT RC
1)
Push slide cover up to position A
2)
Cycle tool in manual mode, release advance

button
3)
Shut pump off
4)
Remove tool and reset slide cover to position B
SECTION IV
OPERATION HYTORC LoaDISC and Clamp -continued from the previous page4-4 HYTORC LoaDISC Lubrication Instruction & Trouble Shooting
STEP 1:
Make sure all threads and surfaces are free of dirt or grit.
STEP 2:
Apply spray lube TS801 moly spray to nut per procedure indicated below. Allow
spray lube to dry (spray lube is shipped with LoaDISC order). Refer to the Dry-lube
container label for a drying time. Do Not Apply Lube to LoaDISC
STEP 3:
Clean and dry protruding stud threads and nut seat surfaces.
STEP 4:
Install LoaDISC with flat side against joint, turn till snug.
STEP 5:
Install lubricated hex nut on top of LoaDISC , snug against top surface of LoaDISC .
LoaDISC Application of Spray TS801
NOTE:
*Allow sufficient time for spray to dry
before use.
Hex nut can be reused, if re-lubricated
per illustration.
NO NOT REUSE ONE TIME USE LoaDISC
HYTORC LoaDISC Trouble Shooting

SYMPTOM
Driver does not lock
CAUSE
Lock ring misaligned with
LoaDISC
SOLUTION
Check for excessive stud protrusion
Check that holding socket is flush to
flange surface
LoaDISC groove damaged
Replace LoaDISC
Missing or damage lock-ring
Replace lock-ring
LoaDISC not snug against
flange surface
Tighten LoaDISC to flange surface

with driver assembly (CW direction)
Driver un-locks during

verification
Worn lock-ring
Replace lock-ring
Driver un-locks during

use
Lock-ring rotated in wrong

direction
Rotate Holding socket and lock-ring

CCW toward T for Tighten
CW toward L for Loosen
Driver does not un-lock

after torque procedure
Stud driven up into bottom of

drive socket
Check for excessive stud extension.
SECTION IV
OPERATION HYTORC LoaDISC and Clamp -continued from the previous page4-5 HYTORC Clamp Installation - Tensioning
The HYTORC Clamp is provided with lubrication and is shipped ready for use. For re-lubrication,
please refer to lubrication Instructions. (4-6)
1. Thread the Clamp down on the stud, turn the Puller Sleeve to contact the flange, contacting the
flange or the spot face firmly. The Clamp should fit easily onto the spot face.
2. The Puller Sleeve, when properly installed, should protrude no more than 1/16 (15mm) past the
top of the Nut (outside sleeve). If the Puller Sleeve is raised beyond 1/16, hold the Puller Sleeve or
the Bridge by hand and turn the Nut counter-clockwise (loosen direction) until the Puller Sleeve
protrudes no more than 1/16 past the top of the Nut. After adjusting the Nut, turn the entire Clamp
assembly down to contact the flange or the spot face firmly.
3. Before using XXI tool on the Clamp, make sure the tool and the drive member are set properly.
The castellated drive and the splined reaction member should stick out on the right side for
tensioning. Cycle the tool and the drive a few times to ensure that the tool is properly operating.
Repeat this step only when you change the tool or the drive.
4. Refer to the load chart supplied with the Clamp and set the pump pressure to achieve the desired
load. Do not engage drive on the Clamp while setting the pump pressure. Turn the pressure
regulator counter-clockwise to set it below the target pressure. While holding the advanced button
on the remote control, slowly turn the pressure regulator clock wise to increase the pressure to the
desired value. Ensure the pressure value is set properly by holding the advanced button.
5 Before applying the tool and the drive, engage the splined reaction member to the Puller Sleeve
first. Then engage the castellated drive to the castellated section of the Nut. Turn the drive manually
until both castellation are fully engaged.
IMPORTANT: If the castellated teeth do not fully engage, the Puller Sleeve is sticking up too far or
stud protrusion is more than maximum value. Refer back to Step 3. Then reposition the Puller
Sleeve and check stud protrusion.
6 Apply the pump pressure to tension the Clamp, until the target pressure is reached. To ensure that
the proper tension has been applied to the stud, allow the tool to fully retract then advance to the
target pressure a final time.
7 Repeat 5 & 6 until all bolts are fully tensioned.
SECTION IV
OPERATION HYTORC LoaDISC and Clamp -continued from the previous page4-6 HYTORC Clamp Installation - Detensioning
1. Before using XXI or Avanti tool on the Clamp, make sure the tool and the drive member are set
properly. The castellated drive and the splined reaction member should stick out on the left side for
detensioning. Cycle the tool and the drive a few times to ensure that the tool is properly operating.
Repeat this step only when you change the tool or the drive.
2. Detensioning, in general, requires higher pump pressure. Refer to the load chart and set the pump
pressure slightly higher than the value used for tensioning. Turn the pressure regulator counter
clockwise to set it below the target pressure. While holding the advanced button on the remote
control, slowly turn the pressure regulator clockwise to increase the pressure to the desired value.
Ensure the pressure value is set properly by holding the advanced button.
3. Remove drive from tool, engage the splined reaction member to the Puller Sleeve first. Then
engage the castellated drive to the castellated section of the Nut. Turn the drive manually until both
castellation are fully engaged. Place tool on drive with LOOSEN side facing the operator. Install
drive retainer.
4. Apply the pump pressure to detension the Clamp, until it can be turned by hand.
5. Repeat 3 & 4 until all bolts are fully tensioned.
On applications that require two or three passes
to tension, it is advised to detension the last few
bolts in two passes.
If corrosion makes it impossible for the Clamp to
be turned by hand even after detensioning, use
the hex/spine adaptor. To use the hex/spline
adaptor, insert the male spline of the adaptor into
the female spline of the Puller Sleeve. Place a
wrench over the hex of the adaptor and rotate
the Sleeve off the bolt.
NOTE: Before reusing the Clamps, it is imperative that the Clamps are properly cleaned and re
lubricated to prolong their life. Refer to the lubrication instruction on the next page.
SECTION IV
OPERATION HYTORC LoaDISC and Clamp -continued from the previous page4-7 HYTORC Clamp Lubrication Instruction
The Clamp Lubrication Instructions: (Use a clean stiff bristle brush)
STEP 1:
Make sure all threads and splines are free of dirt or grit. Generously grease internal
threads on the Jack-up Sleeve with a brush to get full coverage to the thread root.
STEP 2:
Generously grease external threads on the Puller Sleeve with a brush to get full
coverage to the thread root.
STEP 3:
Grip the bottom splined section and internal threads of the Jack-up Sleeve into
the Jack-up Sleeve as the arrow indicates. Leave the bottom splined section sticking
out the bottom.
STEP 4:
Turn the assembled parts upside-down. Spread excess grease around to coat bottom
surface of the Jack-up Sleeve and splines. Apply grease on the splines if coating is
thin.
STEP 5:
Apply grease to internal splines on the Washer to get full coverage to the spline root.
Coat top surface of the Washer.
STEP 6:
Slide the Washer to the assembled Sleeves as the arrow indicates. When the Puller
Sleeve and the Washer are in contact, the Puller Sleeve and the Washer bottoms
should be flush with each other.
Rotate the Jack-up Sleeve while
holding the Washer to achieve
this desired condition.
SECTION V
OPERATION HYTORC Power Packs
5-1 HYOTRC Power Packs General Information
All HYTORC Power Packs operate at a pressure range from 500 to 10,000 PSI and are fully
adjustable. They have been engineered and designed for portability and high flow for increased
speed. Before using your HYTORC Power Pack, check the following points:
Is the reservoir filled with oil?

Where is the closest electrical outlet at the job site? (Electric pump only)
Is there enough air pressure (100 PSI) and flow (50 CFM) at the job site? (Air units only)
Is the gauge mounted and rated for 10,000 PSI
Is the oil filler plug securely in place?
The Power Packs maximum working pressure is 10,000 PSI (700 kg/cm2, 690 Bar) Make sure all
hydraulic equipment and accessories are rated for 10,000 PSI operating pressure.
When making a connection with quick connect couplings, make sure the couplings are fully
engaged. Threaded connectors such as fittings, gauges etc. must be clean and securely tightened and
leak free.
CAUTION: Loose or improperly threaded couplers can be potentially dangerous if pressurized.
Severe over tightening can cause premature thread failure. Knurled sleeve on couplers need to be
only hand tight. Never grab, touch or in any way come in contact with a hydraulic pressure leak.
Escaping oil can penetrate the skin and cause injury. Do not subject the hose to potential hazard
such as sharp surfaces, extreme heat or heavy impact. Do not allow the hose to kink and twist.
Inspect the hose for wear before each usage.
5-3 Prior to Use
Do not use a power or extension cord that is damaged or has exposed wiring. All single phase motors
come equipped with a three prong grounding type plug to fit the proper grounded type electrical
outlet. Do not use a two prong ungrounded extension cord as the pumps grounded type electrical
outlet. Compare motor nameplate against power availability to prevent motor burnout or dangerous
electrical overloading.
*For electric cord extension, refer to below chart
0-25 Foot Extension
26-50 Foot Extension
Use size 12 gauge cord

Check hydraulic oil level to prevent possible pump burnout.

Look at oil fill level on the oil sight gauge. The oil level
should be approximately 2 from the top of the reservoir
plate-with motor off. Add HYTORC oil as necessary.
Air Pump Oil Sight Gauge
*Do not mix different grades of oil.
Electric Pump Oil Sight Gauge
SECTION V
OPERATION HYTORC Power Packs -continued from the previous page5-3 Prior to Use -ContinuedMake sure all desired gauge, valve, hose and quick coupler connections are tight and secure. The
gauge permits the operator to monitor the load on the wrench.
*Calibrated gauges are available for most application.
Before starting your HYTORC pump, connect your hydraulic hoses to both the pump and torque
wrench. (Refer to 3-2)
5-4 Operation Electric Pump
Push the rocker switch on the hand control pendant in the OFF
position. Then, depress and release the safety button.
NOTE: The safety button is an added feature designed to
prevent premature starting and should only be depressed by
the tool operator.
Safety Button
Push the rocker switch to advance position and release

it. This will start your pump and place it in the retract
position. Your HYTORC electric pump has been
designed with an auto shut off system. The pump will
shut off after approximately 20 seconds of non-cycling.
This will prevent overheating or unnecessary wear and
results in longer life of your pump. To restart the
pump, depress the safety button again.
OFF
Retract/Neutral
Advance
Rocker Switch
5-5 Operation Air Pump

Before connecting air supply line to the Air Filter Lubricator, make sure the Air Flow Lever is in the
OFF position. Then connect air supply line. Open the Air Flow Lever. Check the PSI reading on the
Air Pressure Gauge. It should be at 100 psi. Depress
the Air Adjustment Knob to increase psi reading.
Air Adjustment Knob
Air Flow Lever
Adjust lubricator to approximately one drop per
Lubricator Adjust
Minute.
*Before operating your HYTORC air pump,
check for air leaks on the air hoses/tubing.
Air Pressure gauge
SECTION V
OPERATION HYTORC Power Packs -continued from the previous page5-5 Operation Air Pump
To start the pump, depress the advance button and
release it. This will put the tool in the retract mode.
To advance the tool, depress the advance button and
hold it down. When you are done, depress the stop
button and the motor will stop.
NOTE: The pump is still pressurized. To release the air
pressure from the pump, put the Air Flow Lever in the
OFF position, then depress the advance button on the air
remote control. This will purge the air in the motor.
Now it is safe to disconnect your air supply line.
Advance Button
Stop Button
5-6 Operation of automatic pump

Before operating automatic pump, the cable line attached to each hose must be connected securely
with the appropriate receptacle on the pump manifold and the receptacle on the tool.
Securely connect
NOTE: Connect only the number of tools used on the

application to the pump.
Set pump pressure to achieve desired torque value. (refer to 3-5 and 3-6)
SECTION V
OPERATION HYTORC Power Packs -continued from the previous page5-7 Starting with automatic operation
MANUAL MODE
For manual operation, depress the Mode [M] 3-position
rocker switch to the MANUAL position. Hold down
the Control [C] rocker switch in the RUN position to
advance the tool(s). The switch will toggle to the
NEUTRAL position when released, retracting the
tool(s). Depress the Control [C] switch to the OFF
position to turn off the system.
AUTOMATIC MODE
CONTROL SWITCH
PERSS FOR RUN

(TOOL ADVANCE)
RELEASE (TOOL RETRACT)
(NEUTRAL)
PRESS FOR PUMP OFF
Initialize Computer:
To operate the automatic system, the computer has to
recognize how many tools are attached to the system.
To accomplish this, attach the required number of tools
to both hydraulic and electric lines. Then cycle system
in manual mode for at least one full cycle.
PRESS FOR TIGHTENING

NEUTRAL LOOSENING
PRESS FOR MANUAL
MODE SWITCH
AUTOMATIC TIGHTENING MODE
Initialize the computer (see above). Without shutting
pump off, push Mode switch [M] into TIGHTENING
position. Press and hold control switch [C] in RUN
position. As long as the run switch is held depressed,
the pump will function in automatic tightening mode.
The tool(s) will continue to cycle until the preset torque
Is achieved. Allow sufficient time to be sure that the
tool(s) have stopped rotating before releasing the run
switch. The pump motor will automatically shut off
after 20 seconds, allowing the tool(s) to return to the
retract position. The OFF position on the Control
switch turns off the system.
AUTOMATIC LOOSENING MODE
Initialize the computer (see above). Without shutting
pump off, push Mode switch [M] into LOOSENING position. Press and hold control switch [C]
in RUN position. As long as the run switch is held depressed, the pump will function in automatic
loosening mode. The tool(s) will continue to cycle until the Control switch is released. Cycle tool(s)
until nuts are free and can be removed by hand. Release the Control switch and depress the Control
switch to the OFF position to complete the loosening cycle.

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Remove & Replace Procedures

HYDRAULIC MINING SHOVEL

CONTENTS OF THE BINDER ........................................................................................................... 1-2

FOREWORD ...................................................................................................................................... 1-3

2 SAFETY AND STANDARDS ..................................................................... 2-1

SAFETY INSTRUCTIONS.................................................................................................................. 2-2

TORQUE CHARTS ACCORDING TO DIN ......................................................................................

BLIND PLUGS .................................................................................................................................

EXPLANATION OF ABBREVIATIONS ........................................................................................... 2-50

DIESEL ENGINE ................................................................................................................................ 3-2

HYDRAULICS .................................................................................................................................. 3-71

3.3.10 ANTI-CAVITATION VALVES (ACV) .................................................................................

LUBRICATION PUMPS ................................................................................................................. 3-212

PUMP CONTROLLER MC7 ........................................................................................................... 3-217

OPERATORS CAB .......................................................................................................................

OPERATORS SEAT .........................................................................................................

SUPERSTRUCTURE LIFTING ...................................................................................................... 3-257

3.10 FUEL TANK ................................................................................................................................... 3-264

TRAVEL SYSTEM.............................................................................................................................. 4-2

TRACK TENSIONING CYLINDERS ....................................................................................

FACE SHOVEL ................................................................................................................................ 5-74

METERING VALVES (GREASE INJECTORS) AT THE ATTACHMENT ..................................... 5-162

CYLINDER BYPASS TEST ........................................................................................................... 5-164

6 SERVICE INFORMATION ......................................................................... 6-1

FLUIDS AND LUBRICANTS.............................................................................................................. 6-2

FILLING CAPACITIES ....................................................................................................................... 6-5

WORK INSTRUCTIONS..................................................................................................................... 6-7

USED SPECIAL TOOLS (OVERVIEW) ........................................................................................... 6-10

7 TOOLS CATALOGUE ................................................................................ 7-1

9 SUPPLIERS DOCUMENTATION ............................................................. 9-1

Contents of the binder

CONTENTS OF THE BINDER

Assembled in this file are the R&R Procedures with explanations

Observe the instructions in this manual for:

Your Personal SAFETY

Operating SAFETY, and

READY and EFFICIENT PERFORMANCE of your

With this R&R Procedures Manual, KOMATSU provides you with

How do you find "your" desired information?

Replace damaged graphics and symbols.

Komatsu Mining Germany GmbH

In all your written or phoned inquiries, please indicate the model

Safety and Standards

2 SAFETY AND STANDARDS

Safety and Standards

METHOD OF USING THIS MANUAL

When removing or installing a unit assembly, the order of

Tightening torques according to DIN are not explicitly given in

Figure references that appear in the operation procedures

Special requirements such as listing of special tools or size or

The following symbols are used in the manual to designate

Safety and Standards

Refers to orders and prohibitions designed to prevent serious injury or death.

NOTE: Refers to special information on removing or installing

Safety and Standards

NOTE: Always attend to local regulations regarding the Personal

Before carrying out any greasing or repairs, read all the

When carrying out any operation, always wear safety