Manual PC 5500 PDF

SHOP 15016-upE-GB-1
Shop Manual
HYDRAULIC
EXCAVATOR
PC5500E-6
Serial Number 15016 and up

SHOP MANUAL SHOP XS(*%
CONTENTS OF SHOP MANUAL
Binder 1
00 FOREWORD
01 SPECIFICATIONS
10 STRUCTURE, FUNCTION
40 TROUBLESHOOTING (WITHOUT CONTENT)
Binder 2
50 ASSEMBLY AND DISASSEMBLY
Table of contents
SHOP MANUAL SHOP 15016-upE-GB-0
HYDRAULIC EXCAVATOR
PC5500E-6
Machine model Serial number
PC5500E-6 15016 and up
00 Foreword
PC3000-6 1
1.1 CONTENTS OF THE BINDER INTRODUCTION
1.1 CONTENTS OF THE BINDER

Assembled in this file are the Operation- and Maintenance Manu-
als for your KOMATSU Mining Shovel.
4
INTRODUCTION 1.2 DIVISION OF THE BINDER
1.2 DIVISION OF THE BINDER

Part 1:
Operation Manual
Part 2:
Maintenance Manual
Part 3:
Depending on the volume of Part 3 a second Binder "Volume 2" is
being delivered with the Shovel. This Binder contains the General
Assembly Procedure Manual for the Shovel, Specification Book-
let, Service Literature for the Power Unit (Diesel Engine or Elec-
tric Motor) and for Special Equipment. The Electrical- and
Hydraulic Diagrams are attached in the pocket of the front cover.
Refer to the -TABLE OF CONTENTS VOLUME 2 BINDER-

for details.
Read the Manuals before You Start the Engine.
Before operating the machine, familiarize yourself with its instru-

ments and controls.
Observe the instructions in these manuals for:
● your Personal SAFETY
● Operating SAFETY, and
● READY an d E FFICIENT P ERFORMANCE of y our

KOMATSU Shovel.
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 you have any questions concerning this literature please con-

tact
Komatsu Mining Germany GmbH
Service Information
Department 8151.30
P.O. Box 18 03 61
D - 40570 Düsseldorf
GERMANY
5
1.3 DESIGNATED USE OF THE SHOVEL INTRODUCTION
1.3 DESIGNATED USE OF THE SHOVEL

This machine h as been ma nufactured in accor dance with
advanced and up-to-date technology standards including recog-
nized safety rules. Nevertheless, its use may constitute a risk to
life and limb of the user or of third parties, or cause damage to the
machine and to other material property.
The machine must only be used in technically perfect condition in

accordance with its designated use and the instructions set out in
the operation manual. Only trained safety-conscious operators
who are fully aware of the risks involved should operate the
machine. Any functional disorders, especially those affecting the
safety of the machine, should, therefore, be rectified immediately.
The hydraulic Shovel is designed exclusively for excavating, i.e.

excavation of bulk material and natural soil structure (e.g. earth,
clay, sand and stones ashore and off-shore). Observe local and
national safety regulations. Special conditions at the worksite
require additional safe working precautions, follow your com-
pany's safety instructions. Short traveling distances for changing
the working site are considered as part of the designated use of
the Shovel.
Using the Shovel for purposes other than those mentioned above
(such as object handling and use as a transport vehicle) is consid-
ered contrary to its designated use. The manufacturer/supplier
cannot be held liable for any damage resulting from such use.
The risk of such misuse lies entirely with the user.
WARNING
Special use of the Shovel beyond its designated use, e.g.
object handling operations, require written agreement from
the manufacturer and retrofitment of the Shovel with respec-
tive safety related equipment before such special applica-
tions are permitted.
6
INTRODUCTION 1.4 DELIVERY OF THE SHOVEL
1.4 DELIVERY OF THE SHOVEL

The Shovel is being delivered disassembled into its main compo-
nents.
For assembling the Shovel refer to the

”General Assembly Procedure Manual”
in Volume 2 Service Literature Binder.
WARNING
● Improper a ssembling o f t he S hovel can c ause s erious
accidents with personal injury or death.
● Personnel e ntrusted with wor k on the m achine must

have read the Assembly Manual, the Operation- and
Maintenance Manual and in particular the section on
safety before beginning work. Reading the instructions
after work has begun is too late. If there are any ques-
tions concerning safe assembling procedure, contact
your local Komatsu Service Organization.
Prior to first operation, inspect the Shovel thoroughly with the Ser-
vice Engineer responsible for the erection of the machine. Check
all fluid levels according to the Lubrication and Maintenance
Schedule.
Damages and defects caused by incorrect operation and mainte-

nance are not covered by the manufacturers guarantee.
NOTICE
If the Shovel is equipped with a fire suppression system,
make sure that the system is ready for operation.
SPARE PARTS
For your spare part orders refer to the Parts Catalogue.
In order to keep your Shovel in first-class operating condition use

only genuine spare and wear parts.
The use of any part other than the genuine part releases the
KOMATSU MINING GERMANY GmbH from any guarantee.
SERVICE
For all questions related to your Shovel please contact your local
Service Center.
In all your written or phoned inquiries please indicate the model

and serial number of your Shovel.
7
1.5 EXPLANATION OF ABBREVIATIONS INTRODUCTION
1.5 EXPLANATION OF ABBREVIATIONS
ABB Definition
A Ampere
AC Alternating Current
API American Petroleum Institute
cSt Centistoke
°C Degree Celsius
CENSE Engine Monitoring System
CLS Central Lubrication System

DC Direct Current
DIN German Institute for Standardization
EBL Electronic Bucket Levelling System
ECM Electronic Control Module (Engine)
FGPS Front Guard Protective Structure
FOPS Falling-Object Protective Structure
GL Gear Lubricant
h hours of operation
HPF High Pressure Filter

(Hydraulic Oil)
HT High Tension
LED Light Emitting Diode
LT Low Tension
N Newton
Nm Newton meter
QSK Type of Engine Fuel System

PLC Programmable Logic Controller
PM Planned Maintenance
ppm parts per million
Power Take-Off
PTO
(Pump Distributor Gear)
SLS Swing circle pinion Lubrication System
V Volt
VHMS Vehicle Health Monitoring System
1/min Revolutions Per Minute (RPM)
8
SAFETY
2 SAFETY
IGNORING THE INSTRUCTIONS IN THIS MANUAL COULD LEAD TO SERIOUS

INJURY OR DEATH.
Please read and make sure that you fully understand the precautions described in this section and the
safety labels on the machine. When operating or servicing the machine, always follow these precaution
strictly.
2 -1
SAFETY
CONTENTS
2.1 SAFETY INFORMATION ................................................................................................................... 2-3

2.2 OVERVIEW......................................................................................................................................... 2-4
2.2.1 NORMAL OPERATIONS ....................................................................................................... 2-4
2.2.2 REGULAR MAINTENANCE................................................................................................... 2-4
2.2.3 TROUBLESHOOTING, ADJUSTMENTS AND REPAIR ....................................................... 2-4
2.2.4 ADDITIONAL SAFETY PRECAUTIONS FOR ASSEMBLING, DISASSEMBLING AND
TRANSPORTATION OF THE EXCAVATOR......................................................................... 2-4
2.3 SOUND PRESSURE LEVEL IN THE OPERATOR’S CAB. .............................................................. 2-5
2.4 GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR........................... 2-6
2.4.1 UNDERSTANDING THE MACHINE ...................................................................................... 2-6
2.4.2 PRECAUTIONS BEFORE STARTING OPERATION ON THE EXCAVATOR ...................... 2-6
2.4.2.1 ENSURING SAFE OPERATION............................................................................ 2-6
2.4.3 PREPARATIONS FOR SAFE OPERATION.......................................................................... 2-6
2.4.3.1 PRECAUTIONS REGARDING SAFETY RELATED EQUIPMENT........................ 2-6
2.4.3.2 INSPECTING THE MACHINE................................................................................ 2-6
2.4.3.3 WEAR WELL FITTING CLOTHES AND PROTECTIVE EQUIPMENT.................. 2-7
2.4.3.4 KEEP MACHINE CLEAN ....................................................................................... 2-7
2.4.3.5 PRECAUTIONS INSIDE OPERATOR’S COMPARTMENT ................................... 2-7
2.4.3.6 PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT ........................................ 2-8
2.4.3.7 IF A PROBLEM IS FOUND .................................................................................... 2-8
2.4.4 FIRE PREVENTION............................................................................................................... 2-8
2.4.4.1 PRECAUTIONS TO PREVENT FIRE .................................................................... 2-8
2.4.4.2 ACTION IF FIRE OCCURS.................................................................................... 2-9
2.4.4.3 EMERGENCY EXIT FROM OPERATOR’S CAB................................................. 2-10
2.4.5 PRECAUTIONS WHEN CLEANING CAB GLASS .............................................................. 2-10
2.4.6 PRECAUTIONS WHEN GETTING ON OR OFF THE MACHINE ....................................... 2-10
2.4.6.1 USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF THE
MACHINE............................................................................................................. 2-10
2.4.6.2 NO JUMPING ON OR OFF THE MACHINE ........................................................ 2-10
2.4.6.3 NO PEOPLE ON THE ATTACHMENT ................................................................ 2-10
2.4.6.4 WORKING IN HIGH PLACES .............................................................................. 2-10
2.4.6.5 LEAVING OPERATOR’S SEAT WITH LOCK ...................................................... 2-11
2.4.6.6 LEAVING THE MACHINE .................................................................................... 2-11
2.4.7 BURN PREVENTION........................................................................................................... 2-11
2.4.7.1 HOT COOLANT .................................................................................................. 2-11
2.4.7.2 HOT OIL .............................................................................................................. 2-12
2.4.8 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES .......................................... 2-12
2.4.8.1 UNAUTHORIZED MODIFICATION...................................................................... 2-12
2.4.9 PRECAUTIONS AT JOBSITE.............................................................................................. 2-14
2.4.9.1 VISIBILITY FROM OPERATOR’S SEAT ............................................................. 2-15
2.4.9.2 CAMERA SYSTEM WITH MONITORS................................................................ 2-15
2.4.9.3 ENSURE GOOD VISIBILITY................................................................................ 2-15
2.4.9.4 CHECKING SIGNS AND SIGNALMAN’S SIGNALS............................................ 2-15
2.4.9.5 INVESTIGATE AND CONFIRM JOBSITE CONDITIONS.................................... 2-16
2.4.9.6 DO NOT GO CLOSE TO HIGH VOLTAGE CABLES .......................................... 2-16
2.4.9.7 WORKING ON LOOSE GROUND ....................................................................... 2-17
2.4.9.8 GAS, DUST, STEAM AND SMOKE ..................................................................... 2-17
2.4.9.9 VENTILATION OF ENCLOSED AREAS.............................................................. 2-18
2 -2
SAFETY
2.4.10 STARTING ENGINE ............................................................................................................ 2-19

2.4.10.1 WARNING TAG ................................................................................................... 2-19
2.4.10.2 CHECKS BEFORE STARTING ENGINE ............................................................ 2-19
2.4.10.3 PRECAUTION WHEN STARTING ENGINE........................................................ 2-19
2.4.10.4 PRECAUTION IN COLD AREAS ......................................................................... 2-20
2.4.11 OPERATION........................................................................................................................ 2-20
2.4.11.1 CHECKS BEFORE OPERATION ........................................................................ 2-20
2.4.11.2 PRECAUTIONS WHEN TRAVELLING IN FORWARD OR REVERSE ............... 2-21
2.4.11.3 PRECAUTIONS WHEN TRAVELLING ................................................................ 2-22
2.4.11.4 TRAVELLING ON SLOPES ................................................................................. 2-23
2.4.11.5 OPERATIONS ON SLOPES................................................................................ 2-24
2.4.11.6 PROHIBITED OPERATIONS............................................................................... 2-24
2.4.11.7 TRAVELLING ON FROZEN OR SNOW COVERED SURFACES....................... 2-25
2.4.11.8 PARKING THE MACHINE ................................................................................... 2-25
2.4.11.9 TRANSPORTATION ............................................................................................ 2-25
2.5 PRECAUTION FOR MAINTENANCE.............................................................................................. 2-26
2.5.1 GENERAL PRECAUTIONS ................................................................................................. 2-26
2.5.1.1 SELECTION AND QUALIFICATION OF PERSONNEL - BASIC
RESPONSIBILITIES ............................................................................................ 2-27
2.5.1.2 STOP ENGINE FOR MAINTENANCE ................................................................. 2-28
2.5.1.3 WARNING TAG ................................................................................................... 2-28
2.5.1.4 KEEP WORKPLACE CLEAN AND TIDY ............................................................. 2-29
2.5.1.5 APPOINT LEADER WHEN WORKING WITH OTHERS ..................................... 2-30
2.5.1.6 TWO WORKERS FOR MAINTENANCE WHEN THE MACHINE IS
RUNNING ............................................................................................................ 2-30
2.5.1.7 INSTALLING, REMOVING OR STORING ATTACHMENTS ............................... 2-30
2.5.1.8 PRECAUTIONS WHEN WORKING UNDER THE MACHINE OR
EQUIPMENT........................................................................................................ 2-31
2.5.1.9 NOISE .................................................................................................................. 2-31
2.5.1.10 WHEN USING A HAMMER ................................................................................. 2-31
2.5.1.11 PROPER TOOLS................................................................................................. 2-32
2.5.1.12 ACCUMULATOR ................................................................................................. 2-32
2.5.1.13 PERSONNEL ....................................................................................................... 2-32
2.5.2 PRECAUTIONS FOR INSPECTION AND MAINTENANCE................................................ 2-32
2.5.2.1 PRECAUTION WHEN WELDING ........................................................................ 2-32
2.5.2.2 BATTERY HANDLING ......................................................................................... 2-33
2.5.3 PRECAUTIONS WITH HIGH PRESSURE FLUID............................................................... 2-34
2.5.3.1 PRECAUTIONS WITH HIGH FUEL PRESSURE ................................................ 2-34
2.5.3.2 HANDLING HIGH PRESSURES HOSES OR PIPES .......................................... 2-34
2.5.3.3 REPLACEMENT OF HOSE LINES...................................................................... 2-34
2.5.3.4 INSPECTION OF HOSE LINES........................................................................... 2-35
2.5.3.5 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS ............................ 2-35
2.5.3.6 PRECAUTIONS FOR HIGH VOLTAGE............................................................... 2-36
2.5.3.7 AIR CONDITIONING MAINTENANCE ................................................................ 2-36
2.5.3.8 COMPRESSED AIR............................................................................................. 2-36
2.5.3.9 WASTE MATERIALS ........................................................................................... 2-37
2.6 ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND
ADJUSTMENTS............................................................................................................................... 2-38
2.6.1 INSPECTION OF THE HYDRAULIC SYSTEM ................................................................... 2-38
2.6.2 TWO WORKERS ONLY WHEN THE MACHINE IS RUNNING DURING
2 -3
SAFETY
ADJUSTMENTS................................................................................................................... 2-38
2.6.3 AREAS OF POTENTIAL DANGER AROUND THE EXCAVATOR...................................... 2-38
2.7 SPECIAL SAFETY EQUIPMENT..................................................................................................... 2-40
2.7.1 FRONT GUARD PROTECTIVE STRUCTUR ’FOPS’ FOR OPERATOR’S CAB ................ 2-41
2.7.2 OBJECT HANDLING ........................................................................................................... 2-41
2.7.3 LIGHTING ............................................................................................................................ 2-41
2.7.4 WARNING BEACON............................................................................................................ 2-41
2.7.5 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD) ........... 2-41
2.7.5.1 SAFETY HARNESS IN CONFORMITY WITH EN 361
(EUROPEAN STANDARD) .................................................................................. 2-41
2.7.5.2 INSTRUCTIONS FOR USE ................................................................................. 2-43
2.7.5.3 PRIOR TO USING THE HARNESS (1), THE WEARER SHALL ......................... 2-45
2.7.5.4 RECOMMENDATIONS FOR USE OF THE HOLDING HOOKS AND
HOLD-BACK HOOKS OF THE SAFETY HARNESS (1), .................................... 2-45
2 -4
SAFETY SAFETY INFORMATION
2.1 SAFETY INFORMATION

To enable you to use this machine safely, and to prevent injury to operators, service personnel or bystanders, the
precautions and warnings included in this manual and the safety signs attached to the machine must always be
followed.
To identify important safety messages in the manual and on the machine labels, the following signal
words are used.
The "Safety Alert Symbol" identifies important safety messages on machines, in manuals, and elsewhere. When
you see this symbol, be alert to the risk of personal injury or death. Follow the instructions in the safety message.
DANGER
This signal word indicates an imminently hazardous situation which, if not avoided, will result in death or
serious injury.
WARNING
This signal word indicates a potentially hazardous situation which, if not avoided, could result in death or
serious injury.
CAUTION
This signal word indicates a potentially hazardous situation which, if not avoided, may result in minor or
moderate injury.
NOTICE
This signal word is used to alert you to information that must be followed to avoid damage to the machine.
This precaution is given where the machine may be damaged or the service life reduced if the precaution
is not followed.
2 -5
OVERVIEW SAFETY
2.2 OVERVIEW
The appropriate safety information for specific working modes on the excavator can be found in the following:-
2.2.1 NORMAL OPERATIONS

– For normal operating procedures, refer to the OPERATION section of the Operation and Maintenance Manual.
– For operational safety information, refer to section 2.4 on page 3-8.
– For on site safety information, refer to section 2.4.9 on page 3-16.
2.2.2 REGULAR MAINTENANCE

– For information on regular maintenance, including maintenance intervals, refer to the MAINTENANCE section
of the Operation and Maintenance Manual.
– For maintenance safety information, refer to section 2.5 on page 3-28.
2.2.3 TROUBLESHOOTING, ADJUSTMENTS AND REPAIR

– For additional safety information for troubleshooting and adjustments refer to section 2.6 on page 3-40.
– For maintenance solutions, refer to the separate manuals TROUBLESHOOTING manual. Available through
Komatsu Mining Germany.
– For servicing information and adjustments, refer to the separate SERVICE MANUAL. Available through
Komatsu Mining Germany.
2.2.4 ADDITIONAL SAFETY PRECAUTIONS FOR ASSEMBLING,

DISASSEMBLING AND TRANSPORTATION OF THE EXCAVATOR
– Prior to starting assembling, disassembling and transportation of the excavator read and follow the additional
safety precautions given in the ASSEMBLY PROCEDURE MANUAL.
2 -6
SAFETY SOUND PRESSURE LEVEL IN THE OPERATOR’S CAB.
2.3 SOUND PRESSURE LEVEL IN THE OPERATOR’S

CAB.
Fig. 3-1
The sound pressure level in the operator’s cab is measured according to ISO 6396 (Dynamic test method).
The sound pressure value is also shown on the decal attached to the wall inside the operator’s cab, see Fig. 3-1.
2 -7
GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR SAFETY
2.4 GENERAL PRECAUTIONS COMMON TO OPERATION

ON THE EXCAVATOR
WARNING
WHEN MISUSED, THESE MACHINES ARE DANGEROUS.
Mistakes in operation, inspection, or maintenance may result in personal injury or death.
Before carrying out operation, inspection, or maintenance, always read this manual and the safety labels
on the machine carefully and obey the warnings.
2.4.1 UNDERSTANDING THE MACHINE

Before operating the machine, read this manual thoroughly. If there are any places in this manual that you do not
understand, ask the person in charge of safety to give an explanation.
2.4.2 PRECAUTIONS BEFORE STARTING OPERATION ON THE

EXCAVATOR
2.4.2.1 ENSURING SAFE OPERATION

– Only trained and authorized personnel can operate and maintain the machine.
– During operations, personnel are not allowed outside of the operator’s cabin.
– Follow all safety rules, precautions and instructions when operating or performing inspection or maintenance
on the machine.
– If you are not feeling well, or are under the influence of alcohol or medication, your ability to safely operate or
repair your machine may be severly impaired putting yourself and everyone else on your jobsite in danger.
– When working with another operator or with a person on worksite traffic duty, discuss the content of the opera-
tion beforehand and use pre-determined signals when carrying out these operations.
2.4.3 PREPARATIONS FOR SAFE OPERATION
2.4.3.1 PRECAUTIONS REGARDING SAFETY RELATED EQUIPMENT

– Be sure that all guards, covers and mirrors are in their proper positions. Have guards and covers repaired
immediately if they are damaged.
– Understand the method of use of safety features and use them properly.
– Never remove any safety features. Always keep them in good operating condition.
2.4.3.2 INSPECTING THE MACHINE

Check the machine before starting operations. If any abnormality is found, do not operate the machine until repairs
of the problem location have been completed.
2 -8
SAFETY GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR
2.4.3.3 WEAR WELL FITTING CLOTHES AND PROTECTIVE EQUIPMENT

– Do not wear loose clothing and accessories. If these catch on
the control levers or moving parts, there is a danger that it
may cause the machine to move unexpectedly.
– Always wear a hard hat and safety shoes when working on
the machine outside of the cabin. If the nature of the work
requires it, wear safety glasses, mask, gloves, ear plugs and
a safety belt when operating or maintaining the machine (Fig.
3-2).
– If you have long hair and it hangs out from your hard hat,
there is a hazard that it may get caught up in the machine, so
tie your hair up and be careful not to let it get caught.
– Check that all protective equipment functions properly before
using it. Fig. 3-2
2.4.3.4 KEEP MACHINE CLEAN

– If you get on or off the machine or carry out inspection or
maintenance when the machine is dirty with mud or oil, there
is a hazard that you will slip and fall. Wipe off any mud or oil
from the machine. Always keep the machines clean.
– If water gets into the electrical system (Fig. 3-3), there is a
hazard that it will cause malfunctions or a misoperation. If
there is any misoperation, there is a danger that the machine
may move unexpectedly and cause serious personal injury or
death. When washing the machine with water or steam, do
not allow the water or steam to come into direct contact with
electrical components.
Fig. 3-3
2.4.3.5 PRECAUTIONS INSIDE OPERATOR’S COMPARTMENT

– When entering the operator’s compartment, always remove all mud and oil from your shoes. If you operate the
pedal with mud or oil affixed to your shoes, you may slip and this may cause a serious accident.
– Do not leave tools or machine parts lying around inside the operator’s compartment. If tools or parts get into
the control devices, they may obstruct operation and cause the machine to move unexpectedly, resulting in
serious personal injury or death.
– Do not stick suction pads to the window glass. Suction pads act as a lens and may cause fire.
– Do not use a cell phone when driving or operating the machine. This may lead to mistakes in operation, which
could cause serious personal injury or death.
– Never bring any dangerous objects such as flammable or explosive items into the operator’s compartment.
2 -9
2.4.3.6 PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT

Always follow the precautions below to prepare for action if any
injury or fire should occur.
– Be sure that fire extinguishers have been provided and read

the labels to ensure that you know how to use them in emer-
gencies.
– Carry out periodic inspection and maintenance to ensure that
the fire extinguisher can always be used.
– Provide a first aid kit. Carry out periodic checks and add to
the contents if necessary (Fig. 3-4).
Fig. 3-4
2.4.3.7 IF A PROBLEM IS FOUND

If you find any problems in the machine during operation and maintenance (noise, vibration, smell, incorrect
gauges, smoke, oil, leakage, etc., or any abnormal display on the warning devices or monitor), report to the person
in charge and have the necessary action taken. Do not operate the machine until the problem has been corrected.
2.4.4 FIRE PREVENTION
2.4.4.1 PRECAUTIONS TO PREVENT FIRE
Fire caused by fuel, oil, antifreeze, or window washer fluid.
Do not bring any flame or fire close to flammable substances such as fuel, oil, antifreeze, or window washer fluid.
There is a danger they may catch fire. To prevent fire, always observe the following:
– Do not smoke or use any flame near fuel or other flamma-

ble substances. (Fig. 3-5)
– Stop the engines before adding fuel.
– Do not leave the machine while adding fuel or oil.
– Tighten all fuel and oil caps securely.
– Be careful not to spill fuel on overheated surfaces or on
parts of the electrical system.
– After adding fuel or oil, wipe up any spillage.
– Put greasy rags and other flammable materials into a safe
container to maintain safety in the workplace.
– When washing parts with oil, use a non-flammable oil. Do Fig. 3-5
not use diesel oil or gasoline. There is a danger that they
may catch fire.
– Do not weld or use a cutting torch to cut any pipe or tubes
that contain flammable liquids.
– Determine well ventilated areas for storing oil and fuel.
Keep the oil and fuel in the determined place and do not
allow unauthorised persons to enter.
REMARKS: Before carrying out grinding or welding work on the machine, remove any flammable materials.
2 - 10
– Fire caused by accumulation of flammable material.

Remove any dry leaves, chips, pieces of paper, coal dust, or any other flammable materials accumulated or
affixed around the engines, exhaust manifold, muffler or battery, or inside the undercovers.
– Fire coming from electrical wiring
Short circuits in the electrical system can cause fire. To prevent fire, always observe the following:
– Keep all electrical connections clean and securely tightened.
– Check the wiring every day for looseness or damage. Tighten any loose connectors or wiring clamps.
Repair or replace any damaged wiring.
– Fire coming from piping
Check that all hose and tube clamps, guards, and cushions are securely fixed in position.
If they are loose, they may vibrate during operation and rub against other parts. There is a danger that this
may lead to damage to the hoses and cause high pressure oil to spurt out, leading to fire, personal injury, or
death.
– Explosion caused by lighting equipment
– When checking fuel, oil, battery electrolyte, or coolant, always use lighting with anti-explosion specifica-
tions.
– When taking the electrical power for the lighting from the machine itself, follow the instructions of this man-
ual.
2.4.4.2 ACTION IF FIRE OCCURS

– Activate the STOP switch to stop the engine.
– Use the access ladders and steps to get off the machine.
– If it is impossible to escape from the rear of the cab, use the
rope ladder provided for emergency escape to escape from
the side of the cab. (Fig. 3-6.)
Fig. 3-6
– After escaping with the emergency escape ladder, activate

the engine stop chains (1 on Fig. 3-7) to shut down the engine
if they are equipped on your shovel.
Fig. 3-7
2 - 11
2.4.4.3 EMERGENCY EXIT FROM OPERATOR’S CAB

If the cab door does not open, use the sliding window for an emergency escape. On machines without a sliding
window, use the emergency escape hammer to break the window glass and use the window as an emergency
escape.
2.4.5 PRECAUTIONS WHEN CLEANING CAB GLASS

Always keep the cab glass clean to ensure good visibility when operating.
Use an ethyl alcohol based washer liquid. Methyl alcohol based liquid may irritate your eyes, so do not use it.
If the cab glass on the work equipment side is broken, there is a hazard that the intruding objects may contact the
operator's body directly. Stop operation immediately and replace the glass.
2.4.6 PRECAUTIONS WHEN GETTING ON OR OFF THE MACHINE
2.4.6.1 USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF THE MACHINE
To prevent personal injury caused by slipping or falling off the machine, always do as follows.
– Always use the handrails and steps when getting on or off the
machine.
– To ensure safety, always face the machine and maintain
three-point contact (both feet and one hand, or both hands
and one foot - see Fig. 3-8). with the handrails and steps to
ensure that you support yourself.
– When walking around the machine, where possible, move
only in areas that have non-slip padded walkways and non-
slip gratings. Extra care is to be taken when moving around
outside of these areas.
– Before getting on or off the machine, check the handrails and
steps. If there is any oil, grease, or mud on the handrails or
steps, wipe it off immediately. Always keep these parts clean. Fig. 3-8
Repair any damage and tighten any loose bolts.
2.4.6.2 NO JUMPING ON OR OFF THE MACHINE

– Never jump on or off the machine. Never get on or off a moving machine.
– If the machine starts to move when there is no operator on the machine, do not jump onto the machine and try
to stop it.
2.4.6.3 NO PEOPLE ON THE ATTACHMENT

Never let any person mount the boom, arm, bucket, or other attachment without appropriate safety equipment.
There is danger of falling and suffering serious personal injury. For further information refer to section 2.7 on page
3-42.
2.4.6.4 WORKING IN HIGH PLACES

When working in high places, use safety harness and fall absorber to ensure that the work can be carried out
safely. For further information refer to section 2.7 on page 3-42.
2 - 12
2.4.6.5 LEAVING OPERATOR’S SEAT WITH LOCK

– Before standing up from the operator's seat in order to adjust
the seat, always lower the work equipment to the ground, turn
off the engine, relieve the pressure in the hydraulic system
and set lock lever to LOCK position (L, Fig. 3-9.). If the lock is
not applied, there is danger of serious personal injury if the
work equipment control levers are touched by mistake and
the machine moves suddenly. For information on relieving the
pressure in the hydraulic system, refer to chapter ’RELIEV-
ING THE PRESSURE IN THE HYDRAULIC SYSTEM’ in the
’OPERATION’ part of this manual.
Fig. 3-9
2.4.6.6 LEAVING THE MACHINE

– When leaving the machine, always lower the work equipment
completely to the ground, turn off the engine, relieve the pres-
sure in the hydraulic system and set lock lever (1) securely to
the LOCK position (L), then stop the engine. Use the key to
lock all the equipment. Always remove the key, take it with
you, and keep it in the specified place (Fig. 3-10). For infor-
mation on relieving the pressure in the hydraulic system, refer
to chapter ’RELIEVING THE PRESSURE IN THE HYDRAU-
LIC SYSTEM’ in the ’OPERATION’ part of this manual.
Fig. 3-10
2.4.7 BURN PREVENTION
2.4.7.1 HOT COOLANT

– To prevent burns from hot water or steam spurting out when
checking or draining the coolant, wait for the water to cool to a
temperature where it is possible to touch the radiator cap
(Fig. 3-11 and Fig. 3-12) by hand before starting the opera-
tion. Even when the coolant has cooled down, loosen the cap
slowly to relieve the pressure inside the radiator before
removing the cap.
Fig. 3-11
2 - 13
2.4.7.2 HOT OIL

– To prevent burns from hot oil spurting out when checking or
draining the oil, wait for the oil to cool to a temperature where
it is possible to touch the cap or plug by hand before starting
the operation (Fig. 3-12). Even when the oil has cooled down,
loosen the cap or plug slowly to relieve the internal pressure
before removing the cap or plug.
Fig. 3-12
2.4.8 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES

On jobsites where there is a hazard that falling objects (Fig. 3-13),
flying objects (Fig. 3-14), or intruding objects may hit or enter the
operator's cab, consider the operating conditions and install the
necessary guards to protect the operator.
– When carrying out operations in mines or quarries where

there is danger of falling or flying rocks, order/use the option-
ally available front guard.
– When carrying out the above operations, always ensure that
bystanders are a safe distance away and are not in hazard
from falling or flying objects.
– The above recommendations assume that the conditions are Fig. 3-13
for standard operations, but it may be necessary to add addi-
tional guards according to the operating conditions on the job-
site. Always contact your Komatsu distributor for advice.
Fig. 3-14
2.4.8.1 UNAUTHORIZED MODIFICATION

– Komatsu will not be responsible for any injuries, accidents, product failures or other property damage resulting
in modifications made without authorisation from Komatsu.
– Any modifications made without authorisation from Komatsu can create hazards. Before making a modifica-
tion, consult your komatsu distributor.
– Any injuries, accidents, or product failures resulting from the use of unauthorized attachments or parts will not
be the responsibility of Komatsu.
2 - 14
Please continue reading on the next page.
2 - 15
2.4.9 PRECAUTIONS AT JOBSITE
Fig. 3-15
2 - 16
2.4.9.1 VISIBILITY FROM OPERATOR’S SEAT
WARNING
THE AREA AROUND THE EXCAVATOR DURING OPERATION IS EXTREMELY DANGER-
OUS!
Death and serious injury can occur. Make sure the job site is organized in such a way, that the safety of
man and equipment is always ensured.
Fig. 3-15 shows an example of general blind areas of large Komatsu hydraulic mining shovels.
The grey shaded areas (A) show the areas where the view is blocked when the operator is sitting in the operator’s
seat, and the shovel is equipped with standard mirrors. The boundary line (B) shows the distance of 1 meter from
outside surface of the shovel. Please be fully aware that there are places that can not seen when operating the
machine.
REMARKS: The blind areas (A) differ depending on the machine type, attachment and position of attachment.
The International Standard ISO 5006 defines criteria for Operator’s visibility. This standard is not met
and does not apply to large hydraulic mining shovels.
2.4.9.2 CAMERA SYSTEM WITH MONITORS

Komatsu Mining Germany offers optionally camera systems and monitors to improve the overall visibility. See lat-
est version of the OMM for typical arrangement of cameras and monitors.
The camera system can be installed ex works and can also be retrofitted in the field. If you need more information,
please contact your local Komatsu distributor.
2.4.9.3 ENSURE GOOD VISIBILITY

When operating or travelling in places with poor visibility, if it is impossible to confirm the condition of the job side
or obstacle is in the area around the machine, there is danger that the machine may suffer damage or the operator
may suffer serious personal injury. When operating or travelling in places with poor visibility, always observe the
following items strictly.
– If the visibility cannot be sufficiently assured, position a flagman if necessary. The operator should pay careful
attention to the signs and follow the instructions of the flagman.
– The signals should be given only by one flagman.
– When working in dark places, turn on the working lamps and front lamps of the machine, and if necessary, set
up additional lighting in the area.
– Stop operations if there is poor visibility, such as in fog, snow, rain, or sand storms.
– Check the mirrors on the machine before starting operations every day. Clean off any dirt and adjust the view
to ensure good visibility.
– In areas where it is impossible to confirm the area around the machine and observation cameras have been
set up, clean off any dirt from the lens and make sure that the cameras give a clear view of the working area of
the machine.
2.4.9.4 CHECKING SIGNS AND SIGNALMAN’S SIGNALS

– Set up signs to inform of road shoulders or soft ground. If the visibility is not good, position a signalman if nec-
essary. Operators should pay careful attention to the signs and follow the instructions from the signalman.
– Only one signalman should give signals.
Make sure that all workers understand the meaning of all signals and signs before starting work.
2 - 17
2.4.9.5 INVESTIGATE AND CONFIRM JOBSITE CONDITIONS

On the jobsite, there are various hidden dangers that may lead to personal injury or death. Before starting opera-
tions, always check the following to confirm there are no dangers on the jobsite.
– When carrying out operations near combustible materials,

there is a hazard of fire, so be careful when operating.
– Check the terrain and condition of the ground at the worksite,
and determine the safest method of operation. Do not operate
where there is a hazard of landslides or falling rocks.
– If water lines, gas lines, or high-voltage electrical lines may be
buried under the worksite, contact each utility and identify
their locations. Be careful not to sever or damage any of
these lines (Fig. 3-16).
– Take necessary measures to prevent any unauthorized per-
son from entering the operating area.
– If there is a fire near the machine, there is danger of sparks
being sucked in and causing a fire on the machine. Fig. 3-16
– When travelling or operating in shallow water or on soft

ground, check the shape and condition of the bedrock, and
the depth and speed of flow of the water before starting oper-
ations.
– Maintain the travel path on the jobsite so that there is no
obstruction to travel operations.
2.4.9.6 DO NOT GO CLOSE TO HIGH VOLTAGE CABLES
DANGER
HIGH VOLTAGE!
Do not travel or operate the machine near electric cables
(Fig. 3-17). There is a hazard of electric shock, which may
cause serious injury or property damage. Even going close
to high-voltage cables can cause an electric shock, which
may cause serious burns or even death.
Fig. 3-17
2 - 18
On jobsites where the machine may go close to electric cables,

always do as follows.
Voltage of Cables Safety Distance
– Before starting work near electric cables, inform the local 100 V - 200 V Over 2 m (7 ft)
power company of the work to be performed, and ask them to 6,600 V Over 2 m (7 ft)
take the necessary action. 22,000 V Over 3 m (10 ft)
– Always maintain a safe distance (see the table on the right) 66,000 V Over 4 m (14 ft)
between the machine and the electric cable. Check with the 154,000 V Over 5 m (17 ft)
local power company about safe operating procedure before 187,000 V Over 6 m (20 ft)
starting operations. 275,000 V Over 7 m (23 ft)
– To prepare for any possible emergencies, wear rubber shoes 500,000 V Over 11 m (36 ft)
and gloves. Lay a rubber sheet on top of the seat, and be
careful not to touch the chassis with any exposed part of your
body.
– Use a signalman to give warning if the machine approaches
too close to the electric cables.
– When carrying out operations near high voltage cables, do
not let anyone near the machine.
– If the machine should come too close or touch the electric
cable, to prevent electric shock, the operator should not leave
the operator's compartment until it has been confirmed that
the electricity has been shut off. Also, do not let anyone near
the machine.
2.4.9.7 WORKING ON LOOSE GROUND

– Avoid travelling or operating your machine too close to the edge of cliffs, overhangs, and deep ditches. The
ground may be weak in such areas. If the ground should collapse under the weight or vibration of the machine,
there is a hazard that the machine may fall or tip over. Remember that the soil after heavy rain or blasting or
after earthquakes is weak in these areas.
– When working on embankments or near excavated ditches, there is a hazard that the weight and vibration of
the machine will cause the soil to collapse. Before starting operations, take steps to ensure that the ground is
safe and to prevent the machine from rolling over or falling.
2.4.9.8 GAS, DUST, STEAM AND SMOKE
WARNING
RISK OF EXPOLSION AND FIRE!
Welding, flame-cutting and grinding work on the machine increases the risk of explosion and fire which
may result in serious injury or death.
All relevent safety measures must be followed and only under expressly obtained authorization.
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 accumu-
late 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. (See Volume 2 binder)
2 - 19
WARNING
RISK OF EXPLOSION!
Substances and objects igniting can lead to fire or explosion resulting in serious injury or death.
Before carrying out welding, flame-cutting and grinding operations, clean the machine and its surround-
ings from dust and other inflammable substances and make sure that the premises are adequately venti-
lated as there is a risk of explosion.
2.4.9.9 VENTILATION OF ENCLOSED AREAS
WARNING
POISONOUS FUMES!
Unventilated areas where poisonous fumes can accumulate can kill.
Always ensure adequate ventilation.
– Operate internal combustion engines and fuel operated heat-

ing systems only on adequately ventilated premises. Before
starting the machine on enclosed premises, make sure that
there is sufficient ventilation (Fig. 3-18).
Observe the regulations in force at the respective site.
– If it is necessary to start the engine within an enclosed area,
or when handling fuel, flushing oil, or paint, open the doors
and windows to ensure that adequate ventilation is provided
to prevent gas poisoning.
Fig. 3-18
2 - 20
2.4.10 STARTING ENGINE
2.4.10.1 WARNING TAG

– If there is a "DANGER DO NOT OPERATE!" warning tag dis-
played, it means that someone is carrying out inspection and
maintenance on the machine (Fig. 3-19). If the warning sign is
ignored and the machine is operated, there is a danger that
the person carrying out the inspection or maintenance may
be caught in the rotating parts or moving parts and suffer per-
sonal injury or death. Do not start the engine or touch the
levers.
Fig. 3-19
2.4.10.2 CHECKS BEFORE STARTING ENGINE

Carry out the following checks before starting the engine at the beginning of the day's work to ensure that there is
no problem with the operation of the machine. If this inspection is not carried out properly, problems may occur
with the operation of the machine, and there is the danger that this could lead to serious personal injury or death.
– Remove all dirt from the surface of the window glass to

ensure a good view.
– Completely remove all flammable materials accumulated
around the engine and battery, and remove any dirt from the
windows, mirrors, handrails, access ladder and steps.
– Check the coolant levels, fuel levels, and oil levels, and check
for damage to the electric wiring.
– Adjust the operator's seat to a position where it is easy to
carry out operations, check the camera system functions and
check that there is no damage or wear to the seat belt or
mounting clamps.
– Check the operation of the instruments and gauges, check
the angle of the mirror, and check that the control levers are Fig. 3-20
all at the Neutral position.
– Before starting the engine, check that lock lever (Fig. 3-20) is
in LOCK position (L).
– Adjust the mirrors so that the rear of the machine can be seen
clearly from the operator's seat.
– Check that there are no persons or obstacles above, below,
or in the area around the machine.
2.4.10.3 PRECAUTION WHEN STARTING ENGINE

– Start and operate the machine only while seated.
– Do not short circuit the starting motor circuit to start the engine. Short circuiting can cause fire.
– When starting the engine, sound the horn as a warning.
2 - 21
– Do not let any person on the machine other than the operator and the operator's assistant (1 person). For
demonstration purposes or during training, more than two people can be present in the operator’s cabin at the
same time. All personnel within the cabin at such times must secure good hand-holds and be aware of sudden
movements. All appropriate relevant safety measures are to be observed.
2.4.10.4 PRECAUTION IN COLD AREAS

– Carry out the warming-up operation thoroughly. If the machine is not thoroughly warmed up before the control
levers or control pedals are operated, the reaction of the machine will be slow or the machine may move in a
way not expected by the operator. Particularly in cold weather, be sure to carry out the warming-up operation
thoroughly.
– If the battery electrolyte is frozen, do not charge the battery or start the engine with a different power source.
There is a hazard that this will ignite the battery and cause the battery to explode.
– Before charging or starting the engine with a different power source, melt the battery electrolyte and check that
there is no leakage of electrolyte before starting.
2.4.11 OPERATION
2.4.11.1 CHECKS BEFORE OPERATION

If the checks before starting are not carried out properly, the machine will be unable to display its full performance,
and there is also danger that it may lead to serious personal injury or death.
When carrying out the checks, move the machine to a wide area where there are no obstructions, and operate
slowly. Do not allow anyone near the machine.
– Always fasten your seat belt.

– Check that the movement of the machine matches the display on the control pattern label in the cabin. If it
does not match, replace it immediately with the correct control pattern label.
– Check the operation of the gauges and equipment, and check the operation of the bucket, arm, boom, travel
system and swing system.
– Check for any problem in the sound of the machine, vibration, heat, smell, or gauges; check also that there is
no leakage of oil or fuel.
– If any problem is found, carry out repairs immediately.
2 - 22
2.4.11.2 PRECAUTIONS WHEN TRAVELLING IN FORWARD OR REVERSE

– Before travelling, set the machine so that sprocket (1) is
behind the operator's seat (Fig. 3-21).
– If sprocket (1) is in front of the operator's cab, the machine
moves in the opposite direction from the operation of the ped-
als (front and rear travel is reversed, left and right steering is
reversed). Be extremely careful when operating the machine
in this situation.
Fig. 3-21
– Before travelling, check again that there is no one in the sur-

rounding area, and that there are no obstacles (Fig. 3-22).
– Before travelling, sound the horn to warn people in the area.
– Always operate the machine only when seated.
– Do not allow anyone apart from the operator to ride on the
machine.
– Check that the travel alarm works properly.
– Secure the cab door when it is both open and closed.
– Always keep the cab door closed when operating the
machine.
Fig. 3-22
– If there is an area to the rear of the machine which cannot be

seen, position a signal person. Take special care not to hit
other machines, objects or people when turning or swinging
the machine (Fig. 3-23)
Fig. 3-23
NOTE! Always be sure to carry out the above precautions even when the machine is equipped with mirrors
or camera systems.
2 - 23
2.4.11.3 PRECAUTIONS WHEN TRAVELLING

– When travelling on flat ground, keep the work equipment 100
to 150 cm (39 to 59 in) high above the ground (Fig. 3-24).
– If the view to the right side is poor, raise the boom to ensure
better visibility.
– When travelling on rough ground, travel at low speed and do
not operate the steering suddenly. There is danger that the
machine may turn over. The work equipment may hit the
ground surface and cause the machine to lose its balance, or
may damage the machine or structures in the area.
–
Fig. 3-24
– Avoid travelling over obstacles when possible. If the machine

has to travel over an obstacle, keep the work equipment close
to the ground and travel at low speed. Never travel over
obstacles which make the machine tilt strongly to one side
(Fig. 3-25).
– When travelling or carrying out operations, always keep a
safe distance from people, structures or other machines to
avoid coming into contact with them.
Fig. 3-25
2 - 24
2.4.11.4 TRAVELLING ON SLOPES

To prevent the machine from tipping over or slipping to the side,
always do as follows.
– Keep the work equipment 100 - 150 cm (39 - 59 in) above the
ground surface so that the work equipment can be lowered to
the ground immediately to stop the machine in emergencies
(Fig. 3-26).
– When travel up slopes, set the operator's cab facing uphill,
when travel down slopes, set the operator's cab facing down-
hill. Always be aware and informed about the firmness and
bearing capacity of the ground under the machine when trav-
elling. Cavaties and underground mines may cause the
ground beneath the excavator to collapse.
Fig. 3-26
– When travelling up a steep slope, extend the work equipment

to the front to improve the balance, keep the work equipment
approximately 100 to 150 cm (39 to 59 in) above the ground,
and travel at low speed (Fig. 3-27).
Fig. 3-27
– When travelling downhill, keep the travel pedals close to the

neutral position, and travel at low speed.
– Always travel straight up or down a slope. travelling at an
angle or across the slope is extremely dangerous.
– Do not turn on slopes or travel across slopes. Always go
down to a flat place to change the position of the machine,
then travel on to the slope again (Fig. 3-28).
– Travel on slippery ground with low speed. Even with slight
slopes there is a hazard that the machine may slip
Fig. 3-28
2 - 25
2.4.11.5 OPERATIONS ON SLOPES

– When working on slopes, there is a hazard that the machine
may lose its balance and turn over when the swing or work
equipment are operated. This may lead to serious injury or
property damage, so always provide a stable place when car-
rying out these operations, and operate carefully.
– Do not swing the work equipment from the uphill side to the
downhill side when the bucket is loaded. This operation is
dangerous, and may cause the machine to tip over.
– If the machine has to be used on a slope, pile the soil to make
a platform (A on Fig. 3-29) that will keep the machine as hori-
zontal as possible.
Fig. 3-29
2.4.11.6 PROHIBITED OPERATIONS

– Never dig the work face under an overhang. There is a haz-
ard that rocks may fall or that the overhang may collapse and
fall on top of the machine (Fig. 3-30).
Fig. 3-30
– Do not excavate too deeply under the front of the machine.

The ground under the machine may collapse and cause the
machine to fall (Fig. 3-31).
Fig. 3-31
2 - 26
– To make it easier to escape if there is any problem, set the

tracks at right angles to the road shoulder or cliff with the
sprocket at the rear when carrying out operations (Fig. 3-32).
– Generally speaking, the machine is more liable to overturn
when the work equipment is at the side than when it is at the
front or rear.
– Do not suddenly lower, swing, or stop the work equipment.
– Do not suddenly extend or retract the boom cylinder.
There is a hazard that impact will cause the machine to tip
over.
– Do not pass the bucket over the head of other workers or over
the operator's seat of dump trucks or other hauling equip-
ment. The load may spill or the bucket may hit the dump truck Fig. 3-32
and cause serious injury or property damage.
2.4.11.7 TRAVELLING ON FROZEN OR SNOW COVERED SURFACES

– Snow-covered or frozen surfaces are slippery, so be extremely careful when travelling or operating the
machine, and do not operate the pedals suddenly. Even a slight slope may cause the machine to slip, so be
particularly careful when working on slopes.
– With frozen ground surfaces, the ground becomes soft when the temperature rises, and this may cause the
machine to tip over.
– If the machine enters deep snow, there is a hazard that it may tip over or become buried in the snow. Be care-
ful not to leave the road shoulder or to get trapped in a snow drift.
– When clearing snow, the road shoulder and objects placed beside the road are buried in the snow and cannot
be seen. There is a hazard of the machine tipping over or hitting covered objects, so always carry out opera-
tions carefully.
2.4.11.8 PARKING THE MACHINE

– Park the machine on firm, level ground. Select a place where
there is no hazard of falling rocks or landslides, or of flooding
if the land is low.
– Lower the work equipment completely to the ground.
– When leaving the machine, set lock lever (1) to the LOCK
position (L), then stop the engine (Fig. 3-33).
– Always close the operator's cab door, and use the key to lock
all the equipment in order to prevent any unauthorized person
from moving the machine. Always remove the key, take it with
you, and leave it in the specified place.
– If it is necessary to park the machine on a slope, always set
the bucket on the downhill side, then dig it into the ground.
Fig. 3-33
2.4.11.9 TRANSPORTATION
This machine must be disassembled for transportation. When transporting the machine, please consult your
Komatsu distributor.
Use only appropriate means of transport and lifting gear of adequate capacity.
The recommissioning procedure must be strictly in accordance with the General Assembly Procedure Manual.
2 - 27
PRECAUTION FOR MAINTENANCE SAFETY
2.5 PRECAUTION FOR MAINTENANCE
2.5.1 GENERAL PRECAUTIONS

– Observe the adjusting, maintenance and inspection activities and intervals set out in the Operation,- Lubrica-
tion and Maintenance Manual, including information on the replacement of parts and equipment. These activi-
ties may be executed by skilled personnel only.
– Brief operating personnel before beginning special operations and maintenance work, and appoint a person to
supervise the activities.
– In any work concerning the operation, conversion or adjustment of the machine and its safety-oriented devices
or any work related to maintenance, inspection and repair, always observe the start-up and shut-down proce-
dures set out in the Operation,- Lubrication and Maintenance Manual and the information on maintenance
work.
– Ensure that the maintenance area is adequately secured.
– If the machine is completely shut down for maintenance and repair work, it must be secured against inadver-
tent starting by:
– locking the principal control elements and removing the ignition key and/or
– attaching a warning tag to the main switch or control levers.
– setting the maintenance safety switch to the 0 position and securing it with a padlock
– Carry out maintenance and repair work only if the machine is positioned on stable and level ground and has
been secured against inadvertent movement and buckling.
– To avoid the risk of accidents, individual parts and large assemblies being moved for replacement purposes
should be carefully attached to lifting tackle and secured. Use only suitable and technically perfect lifting gear
and suspension systems with adequate lifting capacity. Never work or stand under suspended loads.
– The fastening of loads and the instructing of crane operators should be entrusted to experienced persons only.
The marshaller giving the instructions must be within sight or sound of the operator.
– For carrying out overhead assembly work always use specially designed or otherwise safety-oriented ladders
and working platforms. Never use machine parts as a climbing aid. Wear a safety harness when carrying out
maintenance work at greater heights.
Keep all handles, steps, handrails, platforms, landings and ladders free from dirt, snow and ice.
– Always tighten any screwed connections that have been loosened during maintenance and repair.
– Any safety devices removed for set-up, maintenance or repair purposes must be refitted and checked immedi-
ately upon completion of the maintenance and repair work.
– Ensure that all consumables and replaced parts are disposed of safely and with minimum environmental
impact.
– Before starting any lubrication or maintenance work read the Fundamental Safety Instructions on page 3-1.
– Park the Excavator at a safe place on level ground. Proceed according to the instructions ”Parking the
Shovel”. Lower the attachment flat onto the ground. Move all control levers to neutral position.
– Stop the engines and move all control levers through their shift positions to relieve the pressure in the hydrau-
lic system. Refer to ”Stopping the Engines” for detailed description of the stopping procedure.
– Before any maintenance work is started, set the maintenance safety switch to 0 position.
Find to the location of the maintenance safety switch refer to section 2.5.1.3 on page 3-30. In the 0 position the
engines can not be started. Secure this position by inserting a padlock into the holes of the switch. Up to ten
padlocks can be attached to the holes provided.
– A warning plate ”Caution Machine Maintenance” must be fixed in the Operator’s cab before any lubrication or
maintenance work is started.
– Block the machine to prevent machine movement
2 - 28
SAFETY PRECAUTION FOR MAINTENANCE
– Always use safety devices to block hydraulic cylinders. Never rely on the machine hydraulic system to hold
when working on the loader attachment. A hydraulic line or cylinder could fail or someone could accidently
strike the control levers causing the loader to fall.
– Relieve all pressure in the hydraulic system before servicing the hydraulic system.For information on relieving
the pressure in the hydraulic system, refer to chapter ’Relieving The Pressure In The Hydraulic System’ in the
’Operation’ part of this manual.
– Oily cloth and inflammable material must be removed from the machine. Clean the excavator before starting
maintenance work.
– Switch-off battery main switch and remove key, before working on the electrical system.
– Wear safety clothing, goggles, respirator and other safety devices, whenever working conditions make this
necessary. Observe the local safety rules.
– Never allow unauthorized persons access to the machine during lubrication and maintenance work.
– After servicing, remove oily cloth, inflammable material and all tools from the machine.
– Clean the Excavator with a steam jet, especially after servicing the hydraulic system and fuel system.
WARNING
BEWARE OF STEAM!
Hot steam can cause serious personal injury. When using a steam cleaner, wear safety glasses and pro-
tective clothing.
– For cleaning the Excavator and its components use only fresh water with a salt content of less than 0.05%.
– DO NOT use steam jet, high pressure cleaning device or strong water jet for cleaning headlights, solenoid
valves, sensors, cable connections and bearings.
– Be sure to reinstall safety devices, guards or shields after adjusting and/or servicing the machine.
2.5.1.1 SELECTION AND QUALIFICATION OF PERSONNEL - BASIC RESPONSIBILITIES

– Any work on and with the machine must be executed by reliable personnel only. Statutory minimum age limits
must be observed.
– Employ only trained or instructed staff and set out clearly the individual responsibilities of the personnel for
operation, set-up, maintenance and repair.
– All personnel must be aware of the appropriate safety measures when working on or around the machine.
– Make sure that only authorized personnel works on or with the machine.
– Define the machine operator’s responsibilities - also with regard to observing traffic regulations - giving the
operator the authority to refuse instruction by third parties that are contrary to safety.
– Do not allow persons to be trained or instructed or persons taking part in a general training course on or with
the machine without being permanently supervised by an experienced person.
– Work on the electrical system and equipment of the machine must be carried out only by skilled electricians or
by persons instructed under the supervision and guidance of a skilled electrician and in accordance with elec-
trical engineering rules and regulations.
– Work on the chassis, brake and steering systems must be performed only by skilled personnel who have been
specifically trained for such work.
Work on the hydraulic system must be carried out only by personnel with special knowledge and experience of
hydraulic equipment.
2 - 29
2.5.1.2 STOP ENGINE FOR MAINTENANCE

– Stop the machine (Fig. 3-34) on firm, level ground.
– Select a place where there is no hazard of falling rocks or
landslides, or of flooding if the land is low.
– Lower the work equipment completely to the ground and stop
the engine.
Fig. 3-34
– Turn the main key switch to the ON position. Operate the

work equipment control lever back and forth, left and right at
the full stroke 2 to 3 times to eliminate the remaining internal
pressure in the hydraulic circuit, and then push up lock lever
(1) to the LOCK position (Fig. 3-35).
– Check that the battery main switch is off and main power is
not conducted. (Wait for approx. one minute after activating
the engine STOP switch and press the horn switch. If the
horn does not sound, it is not activated.)
Fig. 3-35
2.5.1.3 WARNING TAG

– Always attach the “DO NOT OPERATE“ warning tag (Fig. 3-
36) to the work equipment control lever in the operator's cab
to alert others that you are performing service or maintenance
on the machine. Attach additional warning tags around the
machine if necessary.
– Keep this warning tag in the tool box while it is not used. If
there is not the tool box, keep the tag in the operation manual
pocket.
– If any other person starts the engine, or touches or operates
the control levers or control pedals while you are performing
service or maintenance, you may suffer serious injury.
Fig. 3-36
2 - 30
– Before entering the machinery house, switch off maintenance

safety switch (Fig. 3-37)
– The maintenance safety switch is located in the machinery
house, next to the entrance door (Pos. 1 on Fig. 3-38).
– Before beginning maintenance operations, set the safety
switch to "0" to prevent a starting of the engines. Secure this
position by inserting a padlock into the holes of the safety
switch. Up to ten padlocks can be attached.
Fig. 3-37
Fig. 3-38
2.5.1.4 KEEP WORKPLACE CLEAN AND TIDY
CAUTION
HAZARD OF ACCIDENTS!
If the work place is not kept clean and tidy, there is the danger that you will trip, slip, or fall over and injure
yourself.
Observe the following points.
– Do not leave hammers or other tools lying around in the work place. Wipe up all grease, oil, or other sub-
stances that will cause you to slip. Always keep the work place clean and tidy to enable you to carry out oper-
ations safely.
– Never drop or insert tools or other objects into the fan or fan belt. Parts may break or be sent flying
2 - 31
2.5.1.5 APPOINT LEADER WHEN WORKING WITH OTHERS

When repairing the machine or when removing and installing the work equipment, appoint a leader and follow his
instructions during the operation.
2.5.1.6 TWO WORKERS FOR MAINTENANCE WHEN THE MACHINE IS RUNNING

– To prevent injury, do not perform maintenance or adjustments
while the engine runs. If work must be carried out with the
engine running, carry out the operation with at least two work-
ers and do as follows:
– One worker must always sit in the operator's seat and be
ready to stop the engine at any time. All workers must
maintain contact with each other and be fully aware of all
relevant safety measures.
– For safety information when working with high pressure oil in
the hydraulic system, refer to section 2.6 on page 3-40.
– When carrying out operations near rotating parts, there is a
hazard of being caught in the parts, so be careful not to come
close (Fig. 3-39). Fig. 3-39
– Do not touch any control levers or pedals. If they must be
operated, always give a signal to other workers to warn them
to move to a safe place.
2.5.1.7 INSTALLING, REMOVING OR STORING ATTACHMENTS

– Appoint a leader before starting removal or installation opera-
tions for attachments.
– Place attachments that have been removed from the machine
in a stable condition so that they do not fall (Fig. 3-40). And
take steps to prevent unauthorized persons from entering the
storage area.
Fig. 3-40
2 - 32
2.5.1.8 PRECAUTIONS WHEN WORKING UNDER THE MACHINE OR EQUIPMENT

– If it is necessary to go under the work equipment or the
machine to carry out service and maintenance (Fig. 3-41),
support the work equipment and machine securely with
blocks and stands strong enough to support the weight of the
work equipment and machine.
– It is extremely dangerous to work under the machine if the
track shoes are lifted off the ground and the machine is sup-
ported only with the work equipment. If any of the control
levers are touched by accident, or there is damage to the
hydraulic piping, the work equipment or the machine will sud-
denly drop. This is extremely dangerous. Never work under
the work equipment or the machine.
Fig. 3-41
2.5.1.9 NOISE
When carrying out maintenance of the engine and you are exposed to noise for long periods of time, wear ear cov-
ers or ear plugs while working. If the noise from the machine is too loud, it may cause temporary or permanent
hearing problems.
2.5.1.10 WHEN USING A HAMMER

When using a hammer, pins may fly out or metal particles may be scattered. This may lead to serious injury.
Always do as follows.
– If hard metal parts such as pins, bucket teeth, cutting edges,

or bearings are hit with a hammer, there is a hazard that
pieces might be scattered and cause injury. Always wear
safety glasses and gloves (Fig. 3-42).
– When hitting pins or bucket teeth, there is a hazard that bro-
ken pieces might be sent flying and injure people in the sur-
rounding area. Always check that there is no one in the
surrounding area.
– There is a hazard that the pin hit with strong force may fly out
and injure people in the surrounding area.
Fig. 3-42
2 - 33
2.5.1.11 PROPER TOOLS

– Use only tools suited to the task and be sure to use the tools
correctly. Using damaged, low quality, faulty, makeshift tools
or improper use of the tools could cause serious personal
injury (Fig. 3-43).
Fig. 3-43
2.5.1.12 ACCUMULATOR
The accumulator is charged with high-pressure nitrogen gas.
When handling the accumulator, careless procedure may cause
an explosion which could lead to serious injury or property dam-
age (Fig. 3-44). For this reason, always observe the following
precautions.
– Do not disassemble the accumulator.

– Do not bring it near flame or dispose of it in fire.
– Do not make holes in it, weld it, or use a cutting torch.
– Do not hit or roll the accumulator, or subject it to any impact.
– When disposing of the accumulator, the gas must be
released. Please contact your Komatsu distributor to have
this work performed. Fig. 3-44
2.5.1.13 PERSONNEL
Only authorized personnel can service and repair the machine. Do not allow unauthorized personnel into the area.
If necessary, employ an observer.
2.5.2 PRECAUTIONS FOR INSPECTION AND MAINTENANCE
2.5.2.1 PRECAUTION WHEN WELDING
WARNING
RISK OF EXPOLSION AND FIRE!
Welding, flame-cutting and grinding work on the machine increases the risk of explosion and fire which
may result in serious injury or death.
All relevent safety measures must be followed and only under expressly obtained authorization.
Welding operations must always be carried out by a qualified welder and in a place equipped with proper equip-
ment. There is a hazard of gas, fire, or electrocution when carrying out welding, so never allow any unqualified
personnel to carry out welding.
2 - 34
2.5.2.2 BATTERY HANDLING
WARNING
RISK OF EXPLOSION AND FIRE!
Battery electrolyte contains sulphuric acid, and batteries generate flammable hydrogen gas, which may
explode. Wrong handling can lead to serious injury or fire. For this reason, always observe the following
precautions.
– Do not use or charge the battery if the battery electrolyte level

is below the LOWER LEVEL line. This may cause an explo-
sion. Check the battery electrolyte level periodically and add
distilled water to bring the electrolyte level to the UPPER
LEVEL line.
– When working with batteries, always wear safety glasses and
rubber gloves.
– Never smoke or use any flame near the battery (Fig. 3-45).
Fig. 3-45
– If you spill acid on your clothes or skin, immediately flush the

area with large amount of water.
– If acid gets into your eyes (Fig. 3-46), flush them immediately
with large amount of water and seek medical attention.
– Before working with batteries, activate the STOP switch and
remove battery main switch key.
Fig. 3-46
As there is a hazard that sparks will be generated, always do as follows.
– Do not let tools or other metal objects make any contact between the battery terminals. Do not leave tools or
other metal objects lying around near the battery.
– When disconnecting the battery terminals, wait for approx. one minute after activating the engine STOP switch
and be sure to disconnect the grounding terminal
(negative (-) terminal) first. Conversely, when connecting them, begin with the positive (+) terminal and then
the grounding (-) terminal. Make sure that all the terminals are connected securely.
– Attach the battery terminal securely.
– Flammable hydrogen gas is generated when the battery is charged, so remove the battery from the chassis,
take it to a well-ventilated place, and remove the battery caps before charging it.
– Tighten the battery caps securely.
– Install the battery securely to the determined place.
2 - 35
2.5.3 PRECAUTIONS WITH HIGH PRESSURE FLUID
WARNING
FLUID UNDER HIGH PRESSURE!
The hydraulic system is always under internal pressure and can lead to serious injury when leaking.
When inspecting or replacing piping or hoses, always check that the pressure in the hydraulic circuit has
been released.
2.5.3.1 PRECAUTIONS WITH HIGH FUEL PRESSURE

– For details of the method of releasing the pressure, see the
latest version of the Operation and Maintenance Manual. If
the circuit is still under pressure, do not carry out any inspec-
tion or replacement operation.
– If there is any leakage from the piping or hoses, the surround-
ing area will be wet, so check for cracks in the piping and
hoses and for swelling in the hoses.
– When carrying out inspections, wear full-face protection and
penetration resistant clothing and gloves (leather).
– There is a hazard that high-pressure oil leaking from small
holes may penetrate your skin or cause blindness if it con-
tacts your eyes directly (Fig. 3-47). If you are hit by a jet of
high-pressure oil and suffer injury to your skin or eyes, wash Fig. 3-47
the place with clean water, and consult a doctor immediately
for medical attention.
High pressure is generated inside the engine fuel piping when the engine is running. When carrying out inspection
or maintenance of the fuel piping system, wait for at least 30 seconds after stopping the engine to let the internal
pressure go down before starting inspection or maintenance.
2.5.3.2 HANDLING HIGH PRESSURES HOSES OR PIPES

– If oil or fuel leaks from high-pressure hoses, it may cause fire or defective operation, which may lead to serious
injury. If any loose bolts are found, stop work and tighten to the specified torque. If any damaged hoses are
found, stop operations immediately and contact your Komatsu distributor.
Replace the hose if any of the following problems are found.
– Damaged or leaking hydraulic fitting.

– Frayed or cut covering or exposed reinforcement wire layer.
– Covering swollen in places.
– Twisted or crushed movable portion.
– Foreign material embedded in covering.
2.5.3.3 REPLACEMENT OF HOSE LINES

Hydraulic hoses are subjected to natural aging. Hence, their usable lifetime is limited to maximum 6 years.
NOTICE
The maximum permissible storage time of hydraulic hoses must be observed.
2 - 36
– This storage period is part of the usable lifetime and must be considered when installing a new hose line. If, for
example, a hose line with a one year storage time is to be installed, the remaining service life of the hose line
must be considered. All hose lines are marked with the date of production.
– Hose lines considered as Safety Critical Parts have to be replaced earlier. Refer to the chapter "Lubrication
and Maintenance Schedule" in the MAINTENANCE section of the Operation and Maintenance Manual for fur-
ther information.
All hydraulic hoses of the Shovel have to be replaced when their service life has expired, even if there is no visible
damage. Refer to the chapter "Lubrication and Maintenance Schedule" in the MAINTENANCE section of the
Operation and Maintenance Manual for further information.
NOTICE
Repairs on hydraulic hoses are not allowed. Use ONLY GENUINE Komatsu Mining Germany replacement
hose lines.
2.5.3.4 INSPECTION OF HOSE LINES
WARNING
FLUID UNDER HIGH PRESSURE!
The hydraulic system is always under internal pressure and can lead to serious injury when leaking.
When inspecting or replacing piping or hoses, always check that the pressure in the hydraulic circuit has
been released.
Inspect all hoses, hose lines and fittings carefully during the course of the daily walk-around inspection. Check for
leaks and damages. Beware of pinhole leakages. Replace damaged parts without delay.
Some examples of faults on hydraulic hoses requiring replacement of the concerned part:
– Damage to the outer layer (e.g. chafed spots, cuts or scratches).

– Brittle top layers. Flaws on the hose material
– Distortion of the hose line (strong deviation from the original shape) under pressurized and pressureless con-
ditions or when kinked or crushed, e.g. disintegration of hose layers or blistering.
– Leaks.
– Detachment of hose and fitting. Damaged hose fitting.
2.5.3.5 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS

To ensure safety at all times when operating the machine, the user of the machine must always carry out periodic
maintenance. In addition, to further improve safety, the user should also carry out periodic replacement of the parts
given in the table. These parts are particularly closely connected to safety and fire prevention.
With these parts, the material changes as time passes, or they easily wear or deteriorate. However, it is difficult to
judge the condition of the parts simply by periodic maintenance, so they should always be replaced after a fixed
time has passed, regardless of their condition. This is necessary to ensure that they always maintain their function
completely. However, if these parts show any abnormality before the replacement interval has passed, they should
be repaired or replaced immediately.
If the hose clamps show any deterioration, such as deformation or cracking, replace the clamps at the same time
as the hoses.
When replacing the hoses, always replace the O-rings, gaskets, and other such parts at the same time.
2 - 37
– Ask your Komatsu distributor to replace safety critical parts.
2.5.3.6 PRECAUTIONS FOR HIGH VOLTAGE
DANGER
HIGH VOLTAGE!
High voltage appliances cause serious injury or death.
Authorized staff only.
– When the engine is running and immediately after it is stopped, high voltage is generated inside the engine
controller and the engine injector.
– The headlights also operates using high voltage. Never perform maintenance on the headlights.
– If it is necessary to touch the inside of the controller or the engine injector portion, or the headlight electrics
please contact your Komatsu distributor.
– The cab base contains high voltage electrical appliances. Access to the cab base for authorized service staff
only.
2.5.3.7 AIR CONDITIONING MAINTENANCE
WARNING
AIR CONDITIONING REFRIGERANT IS HARMFUL!
If air conditioner refrigerant gets into your eyes, it may cause blindness; if it touches your skin, it may
cause frostbite.
Never touch refrigerant.
2.5.3.8 COMPRESSED AIR
WARNING
COMPRESSED AIR IS HAZARDOUS!
When carrying out cleaning with compressed air, there is a hazard of serious injury caused by flying parti-
cles.
Wear protective clothing.
– When using compressed air to clean elements or the radiator, always wear safety glasses, dust mask, gloves,
and other protective equipment.
– Never drop or insert tools or other objects into the fan or fan belt. Parts may break or be sent flying.
2 - 38
2.5.3.9 WASTE MATERIALS

Operation
– Avoid engine idling over long periods. Long periods of idling

(more than 10 minutes), will not only waste fuel, but is also
harmful to the engine.
– Avoid operation against the main relief valves of the hydraulic
system. Move control lever to neutral position before the
loader attachment stalls due to overload.
– Position trucks in such a way, that loading operation can be
carried out in a safe and economic manner. Avoid swing
angles over 90°.
Maintenance Fig. 3-48

– Preserve our environment. To prevent environmental pollu-
tion, pay careful attention to the method of disposing waste
materials.
– Always drain fluids from your machine into containers. Never
drain fluids onto the ground or dump it into the sewage sys-
tem, rivers, the sea or lakes. (Fig. 3-48).
– Dispose of harmful material, such as oil, fuel, coolant, sol-
vent, filters and batteries in accordance with local environ-
mental regulations and laws.
2 - 39
ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS SAFETY
2.6 ADDITIONAL SAFETY INFORMATION

FOR TROUBLESHOOTING AND ADJUSTMENTS
2.6.1 INSPECTION OF THE HYDRAULIC SYSTEM

A hands-on approach to inspecting the hoses and pipes of the hydraulic system can only be made when the exca-
vator is shut down and there is no oil pressure in the hydraulic system.
– Do not use your hands during inspection or move in the vicinity of the hydraulic system’s piping or tubing when
the engine is running before checking for leaks, as hydraulic fluid escaping under pressure can cause serious
injuries.
– Additional to the general personal protective clothing as described on page 3-9, full face protection and pene-
tration resistant clothing and gloves must be worn.
– Troubleshooting and adjustments may only be performed by personnel trained by Komatsu Mining Germany in
safe and correct hydraulic handling procedures.
– Before troubleshooting or adjustments, the inspection of areas of potential dangers for damages, leaks or
loose connections on the pressure lines and hydraulic components must be carried out visually only when the
engine is shutdown and when there is no hydraulic pressure in the system.
– When the machine is running, the areas of potential danger can only be entered when no leakages or other
irregularities have been noticed when the high pressure oil circulation has been brought up to maximum pres-
sure from a safe distance (operator’s cab, machinery house roof, ladder platform).
2.6.2 TWO WORKERS ONLY WHEN THE MACHINE IS RUNNING DURING

ADJUSTMENTS
To prevent injury, do not carry out adjustments with the engine running. If work must be carried out with the engine
running, perform the task with, at maximum, two maintenance workers and an operator and do as follows.
– An operator that has been trained on the machine he is oper-

ating, must always sit in the operator's seat and be ready to
stop the engine at any time. All workers must maintain con-
tact with the other workers and be fully aware of all relevant
safety measures.
– When carrying out operations near the fan, fan belt, or other
rotating parts, there is a hazard of being caught in the parts,
so be careful not to come close (Fig. 3-49).
– Do not touch any control levers or control pedals. If any con-
trol levers or control pedals must be operated, always give a
signal to the other workers to warn them to move to a safe
place.
Fig. 3-49
2.6.3 AREAS OF POTENTIAL DANGER AROUND THE EXCAVATOR
General safety rules for working on the excavator
– Only trained personnel who are aware of all dangers are allowed to work on the hydraulic system
– Visually inspect all potential danger areas for leakages before pressure build up.
– Do not remain on or around the excavator for longer than is absolutely necessary in order to perform your
tasks.
2 - 40
SAFETY ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS
Please continue reading on the next page.
2 - 41
SPECIAL SAFETY EQUIPMENT SAFETY
2.7 SPECIAL SAFETY EQUIPMENT
Fig. 3-50
2 - 42
SAFETY SPECIAL SAFETY EQUIPMENT
2.7.1 FRONT GUARD PROTECTIVE STRUCTUR ’FOPS’ FOR OPERATOR’S

CAB
The Shovel must be equipped with a front guard protective structure ”OPG Front Guard” if it is used for applica-
tions where there is a risk of hitting objects from the front.
2.7.2 OBJECT HANDLING

Object handling operations are not allowed.
2.7.3 LIGHTING
The Shovel must only be operated when the operator has sufficient visibility in relation to the work area.
Disturbing shady areas or dazzling effects must be avoided.
If necessary, the Shovel must be retrofitted with additional lighting equipment (working lights) in order to ensure
sufficient visibility conditions.
2.7.4 WARNING BEACON

The Shovel can be retrofitted with a warning beacon which is fitted on the cab roof by means of a magnetic
bracket.
REMARKS: The above-mentioned special safety devices can be ordered as accessories together with the
Shovel.
They are also available as a field package for installation through our service organization.
2.7.5 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN

STANDARD)
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.
See the following pages for further information.
2.7.5.1 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)
WARNING
RISK OF FALLING!
Injuries can occur when working in high areas. Always use a Safety Harness (1) in conjunction with a
strap type Fall Absorber (2), illust. (Fig. 3-50) before boarding the loader attachment or other unsecured
areas on the Shovel.
– The Safety Harness is located in the Cabinet in the Operator’s Cab.

– The illustration (Fig. 3-50) shows the standard use of the safety harness with a strap type fall absorber.
2 - 43
2 - 44
Legend for Fig. 3-50
(1) Safety Harness according to EN 361
(2) Strap-Type Fall Absorber according to DIN EN 355
(3) Railings (attachment points)
(4) Walkway on the boom
(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
2.7.5.2 INSTRUCTIONS FOR USE

Open the lock, lift the harness by the catch hook (C), ensuring the leg straps hang below (J). Pull the harness over
the shoulders as you would a jacket. Insert the end of the belly strap (E) through the buckle and tighten securely,
as shown in the illustration (Fig. 3-50).
Prevent the shoulder straps from slipping by fastening the breast strap. Pull the leg straps (J) between the legs
and securely buckle them at the front as illustrated. Adjust the harness so that it snugly fits the body ensuring that
the catching hook (C) is in the center of the back.
The safety harness is a personal accessory and should only belong to its owner.
The safety harness should only be used together with connectors acc. to EN 354, and fall arrest acc. to EN 355, or
fall protection devices acc. to EN 360.
The attachment point for the safety harness should be above the wearer, and the carrying capacity of the attach-
ment point should be sufficient to correspond with the minimum carrying capacity acc. to EN 795.
2 - 45
2 - 46
2.7.5.3 PRIOR TO USING THE HARNESS (1), THE WEARER SHALL

– Carry out a visual check of the system or component; correct functioning and perfect working order have to be
assured.
– Make sure that the recommendations for use with other components of the system be observed in conformity
with the instructions for use.
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 sub-
jected to fall be removed from service and sent back to the manufacturer or an authorized qualified repair shop for
maintenance and renewed testing.
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.
Should the harness have 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 Per-
sonal Fall Arrest Systems" have to be observed for protection against danger.
At least every 12 months, the safety harness and its components have to be inspected by a competent person
authorized by the manufacturer and maintained, if the manufacturer considers it necessary.
2.7.5.4 RECOMMENDATIONS FOR USE OF THE HOLDING HOOKS AND HOLD-BACK

HOOKS OF THE SAFETY HARNESS (1),
During the holding function, the connectors may only be placed around a mast or other construction between the
two holding hooks, so that free fall is limited to max. 0.5 m.
It should be strictly seen to it that the connector be not slung around constructions with too small diameter 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.
2 - 47
2 - 48

Strap-Type Fall Absorber acc. to DIN EN 355 (Type E.K.N.-BFD)
Use
Within a fall-arrest system, the strap-type fall absorber (2) has to be used in conjunction with a safety harness (1)
acc. 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, acc. 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 ex-posed to acids, caustic
chemicals, nor to an aggressive atmosphere, and contact with oils 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 service immediately. The strap-type fall absorber must not be changed in any way.
2 - 49
2 - 50
HYDRAULIC MINING EXCAVATOR
PC5500E-6
Machine model Serial numbers

PC5500E-6 15016 and up
01 Specification
® Copyright 2010 KOMATSU MINING GERMANY GmbH
PC5500-6E 1
OPERATING WEIGHT
531-549 ton 1,170,000-1,200,000 lb
SHOVEL CAPACITY
29 m3 38 yd3 SAE 2:1 heaped
BACKHOE CAPACITY
29 m3 38 yd3 SAE 1:1 heaped
PC5500
PC
5500
SUPER SHOVEL
PC 5500 S UPER S HOVEL
WALK-AROUND
Quality
● Quality management ISO 9001 certified.
● Environmental Management
ISO 14001 certified.
● Consistent high quality
through continuous investment
in personnel, design and manufacturing
systems and processes.
Reliability and Durability

Designed for lower operating costs
● Robust structural design developed
from field experience and finite
element analaysis.
● Extended life undercarriage wear parts;
Big diameter rollers, idlers and sprockets.
Large surface area and extensive
precision hardening.
Hardened track link pin bores.
Productivity
Designed for more tons per hour
● Powerful digging forces.
● Ease of bucket filling.
● Proven attachment design.
● All cylinders mounted under the shovel attachment for additional protection.
● Buckets and Wear Packages to suit all material densities and ground conditions.
2
SUPER SHOVEL
PC 5500
MATCHED FOR
Large Comfortable Cab 150 to 320 U.S. ton
Full shift comfort TRUCKS
● Komatsu low noise cab on multiple viscous mounts for
reduced noise and vibration. SHOVEL AND BACKHOE
● Large volume cab with deep wide front window. BUCKET CAPACITY
● Comprehensive climate control with pressurised filtered air 29 m3 38 yd3
ventilation and air conditioning.
● High specification multi-adjustable air suspension seat.
● Well elevated operator position giving good all round view.
Advanced Hydraulics
Extended reliability and precise control
● Comprehensive monitored filtration.
● Simple open circuit hydraulic system with
high efficency swing out oil coolers.
Powerful Diesel Engine

Two Komatsu SSA12V159 engines
● Rated (each) 940 kW 1260 HP, at 1800 rpm.
● Electronic engine management.
● Low engine emission levels meet EPA regulations.
● Time saving oil management system
fitted as standard; Centinel Engine Oil Management,
Reserve Engine Oil Supply and Eliminator
Oil Filter systems.
Option:
● Two Komatsu SDA12V159E-2 engines
Tier 2 certificated
Rated (each) 940 kW 1260 HP at 1800 rpm.
Easy Maintenance
Simple, common-sense design gives quick safe access to all major components
● Generous access to all major service points from machinery house floor level.
● Enclosed, internally lit machinery house with firewall separating engine from pump area.
● Automatic central lubrication.
● ECS electronic monitoring system providing real time information about the operating status of the machine.
● Ground-level access to hydraulically powered swing down service arm with Wiggins connections.
3
SPECIFICATIONS
DIESEL DRIVE SWING SYSTEM

Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2x Komatsu SSA12V159 Hydraulic motors and drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Type . . . . . . . . . . . . . . . . . . . 4-cycle, water-cooled, direct injection Swing brake, service . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic brake
Aspiration . . . . . . . . . . . . . . . . . . . . . Turbocharged and aftercooled Swing brake, parking. . . . . . . . . . . . . . . . . . . . . . Wet, multiple-disc
Number of cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Swing ring teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . External
Rated power. . . . . . . . . . . . . . . . . 2x 940 kW 1260 HP @ 1800 rpm Swing speed (maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1 rpm
(SAE 1995/J1349)
Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . All-speed, electronic
Optional US Tier 2 Version: ELECTRIC DRIVE
Model . . . . . . . . . . . 2x Komatsu SDA12V159E-2 Tier 2 certificated
Type . . . . . . . . . . . . . . . . . . . . . . . 2x Squirrel-cage induction motor
Type . . . . . . . . . . . . . . . . . . . 4-cycle, water-cooled, direct injection
Power output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2x 900 kW
Aspiration . . . . . . . . . . . . . . . . . . . . . Turbocharged and aftercooled
Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6600 V*
Number of cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Amperage (approximate) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215 A
Rated power. . . . . . . . . . . . . . . . . 2x 940 kW 1260 HP @ 1800 rpm
(SAE 1995/J1349) Start-up . . . . . . . . . . . . . . . . . . Soft start each motor in succession
Controller/Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . Quantum Frequency (standard) . . . . . . . . . . . . . . . . . . . . . 50 Hz @ 1500 rpm
Optional frequency . . . . . . . . . . . . . . . . . . . . . . . 60 Hz @ 1800 rpm
The integrated engine oil and filter system combining the oil stabilising
systems, Reserve and Centinel, with the Eliminator self cleaning oil filter *Other voltages available on request
extends, with oil analysis, the oil change interval to 4000 hours.
(not available in Australia)
UNDERCARRIAGE
ELECTRICS Undercarriage consists of one center carbody and two track frames,
each side attached by 80 high torque bolts.
System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 V
Center frame. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-type
Batteries (series/parallel) (diesel version). . . . . . . . . . . . 2 + 6 x 12 V
Track frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steel box-section
Alternator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2x 100 A
Standard working lights. . . . . . . . . . . . . . . . . . . . . . . 8 Xenon lights
Standard service lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 lights
CRAWLER ASSEMBLY
Track adjustment . . . . . . . . . . . . . . . . . . . Automatic hydraulic type
HYDRAULICS Number of shoes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 each side
Number of top rollers. . . . . . . . . . . . . . . . . . . . . . . . . . . 3 each side
The power train consists of two main drives. Diesel engines or electric
Number of bottom rollers. . . . . . . . . . . . . . . . . . . . . . . . 7 each side
motors can be supplied. Each connected to a gearbox and 3 identical
main pumps which draw hydraulic oil from an unpressurized hydraulic
tank. Open circuit hydraulics provide maximum cooling and filtering
efficiency. COOLING SYSTEM
Rated flow (total output) . . . . . . . . . . . . 4200 ltr/min 1110 U.S. gal The high capacity engine radiators are cooled by hydraulically driven
Relief valve setting . . . . . . . . . . . . . . . . . . . . . . . . 310 bar 4,495 psi fans for superior cooling efficiency and require little maintenance.
Swing flow rate . . . . . . . . . . . . . . . . . . . . . 700 ltr/min 185 U.S. gal The hydraulic system includes four large swing-out vertical air-to-oil
High pressure in line filters . . . . . . . . . . . . . . . . . . . . . . 200 microns hydraulic coolers with temperature-regulated hydraulically driven fans.
one per pump located at the valve blocks
Full flow return line filters (10 double elements) . . . . . . . 10 microns AUTOMATIC CENTRALISED
at head of hydraulic tank
Case drain/by-pass return line filters . . . . . . . . . . . . . . . . 3 microns LUBRICATION
The four-circuit system features a load-limiting governor with oil Two hydraulically powered Lincoln single line automatic lubrication
delivery summation to the working circuits and incorporates systems are provided as standard, complete with time and volume
pressure cut-off control. Hydropilot prioritizes hydraulic flow giving variable controls. Activity and malfunction events are linked to the
smooth hydraulic response, simple hydraulic system layout, and a ECS. The central lube grease system is supplied from a refillable
reduced number of components. Filtration is at the oil intake to 300 litre 80 gal. container. A second, identical system supplies open
pumps, valve blocks, heat exchangers and the oil tank. gear lubricant to the swing ring teeth through a lube pinion.
Replenishment of the containers is through the service arm.
DRIVES AND BRAKES

SERVICE CAPACITIES
Travel control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 foot pedals
Gradeability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Up to 50% Hydraulic oil tank . . . . . . . . . . . . . . . . . . .3800 ltr 1,000 U.S. gal
Travel speed (maximum) . . . . . . . . . . . . . . . . . . . 2.1 km/h 1.4 mph Hydraulic system . . . . . . . . . . . . . . . . . . .6000 ltr 1,585 U.S. gal
Service brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic brake Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.800 ltr 2,853 U.S. gal
Parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . Wet, multiple-disc Engine coolant . . . . . . . . . . . . . . . . . . . .2x 360 ltr 2x 95 U.S. gal
Engine oil . . . . . . . . . . . . . . . . . . . . . . . .2x 190 ltr 2x 50 U.S. gal
Centinel engine oil make up tank . . . . . .2x 580 ltr 2x 153 U.S. gal
4
SUPER SHOVEL
PC 5500
CAB
The large welded steel safety cab is mounted with 18 viscous Cab engineering standards are;
damping pads and sound insulated. • ISO 3449 Falling Objects Protection Structure
It is equipped with automatic climate control and is pressurised. • ISO 6396 Noise in operator´s cab is 76 dB(A)
The operator’s seat is fully adjustable, air suspended, electrically • ISO 2631-1/ 5349-1 Vibration and Shock
heated and has a lap seat belt. There is a trainer’s seat. • Air conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . .10kW 34120 Btu
Low effort joy stick controls are electric over hydraulic and foot • Heater/Demister (Diesel version) . . . . . . . . . . . . .10kW 34120 Btu
controls are for front shovel clam, crawler and swing brake. • Heater/Demister (Electric version) . . . . . . . . . . . .12kW 40940 Btu
Full instrumentation and ECS are provided. Space in the console
is provided for an additional monitor. AM/FM radio is fitted. The
windshield wash wiper has two speed and intermittent operation. CS
(Water reservoir 7 litres 1.8 gal.) Amenities include a wash basin HEALTH MONITORING SYSTEM
with running water, water reservoir, (50 litres 13 gal.), refrigerator
The ECS digital diagnostic system, mounted in the operator‘s
and storage cabinets. Powered mirrors are adjusted from inside
console, provides a text display of real time and stored information
the cab.
about the status of the operating machine. Non serious and critical
There are left and right hand sliding windows. All windows
faults are immediately announced, and for major malfunctions the
are tinted parsol green. External metal louvres are provided on the
engines are also shut down. The integrated digital storage provides
cab side windows.
full event history, which can be down loaded with a laptop computer.
The ability to electronically record service events provides precise
service information to assist in reducing downtime.
OPERATING WEIGHTS (APPROXIMATE)
PC 5500 Backhoe: PC 5500 Front Shovel:

Operating weight including 11.000 mm 36’1’’ boom, 5100 mm 16’9’’ stick, Operating weight including 7600 mm 24’11’’ boom, 5600 mm 18’4’’ stick, 29 m3 38 yd3
29 m3 38 yd3 backhoe bucket, operator, lubricant, coolant, full fuel tank and standard shovel bucket, operator, lubricant, coolant, full fuel tank and standard equipment.
equipment.
Shoe Width Operating Weight Ground Pressure Shoe Width Operating Weight Ground Pressure
1350 mm 535 t 23.9 N/cm2 1350 mm 531 t 23.1 N/cm2

53’’ 1,180,000 lb 33.4 psi 53’’ 1,170,000 lb 33.5 psi
1800 mm 549 t 18.3 N/cm2 1800 mm 545 t 18.2 N/cm2

71’’ 1,210,000 lb 26.5 psi 71’’ 1,200,000 lb 26.4 psi
Diesel SKZ 5506_50A Electric SKZ 5506_51
Explanation Variation for Electric Lower-Level

1 Operator’s Cab 6Swing Motors Drive Version Walkways
2 Power Trains 7Fuel Tank 2 Electric Motor Upper-Level
3 Hydraulic Cooler 8Counterweight 7 High Voltage
4 Hydraulic Reservoir 9Autolube Systems Electric Cabinet
5 Valve Blocks (on upper deck)
10 Secondary Egress
5
PRODUCTIVITY-FEATURES
BACKHOE ATTACHMENT
5506074
Boom length 11000 mm 36’ 1” Max. digging height 15500 mm 50’ 10”
Stick length 5100 mm 16’ 9” Max. dumping height 10100 mm 33’ 2”
Break-out force (SAE) 1450 kN 326,250 lb Max. digging depth 8300 mm 27’ 3”
Tear-out force (SAE) 1290 kN 290,250 lb Max. digging reach 19800 mm 64’ 12”
Max. digging reach 18700 mm 61’ 4”
at ground level
Bucket Capacity Width Teeth Wear Weight Max. Material Density Recommended
(Heaped 1 :1) SAE Package (Loose) Mining
cum cuyd mm foot/inch qty *) t lb t/cum lb/cuyd Uses
26.0 34.0 4380 14’4” 5 3 32.2 71,000 2.0 3400 Heavy Duty
29.0 38.0 4380 14’4” 5 2 33.1 73,000 1.8 3000 Standard Mining
*) WP 1 Non abrasive
WP 2 Standard Mining
WP 3 Heavy Duty
Alternative buckets on request
6
SUPER SHOVEL
PC 5500
FRONT SHOVEL ATTACHMENT
5506068
Boom length 7600 mm 24’ 11” Max. cutting height 19500 mm 63’ 12”
Stick length 5600 mm 18’ 4” Max. dumping height 13300 mm 43’ 8”
Break-out force (SAE) 1865 kN 419,200 lb Max. digging depth 2700 mm 8’ 10”
Crowd force (SAE) 1870 kN 420,300 lb Max. digging reach 16500 mm 54’ 2”
Level crowd at ground level 5600 mm 18’ 5”
Bucket opening width 2700 mm 8’ 10”
Bucket Capacity Width Teeth Wear Weight Max. Material Density Recommended
(Heaped 1 : 2) SAE Package (Loose) Mining
cum cuyd mm foot/inch qty *) t lb t/cum lb/cuyd Uses
21.0 27.5 4410 14’6” 5 4 48.6 107,200 2.6 4400 Heavy Duty
26.0 34.0 4570 14’12” 6 3 48.9 107,800 2.2 3700 Standard Mining
29.0 38.0 4570 14’12” 6 3 49.5 109,100 1.9 3200 Standard Mining
*) WP 1 Non abrasive
WP 2 Light abrasive
WP 3 Standard Mining
WP 4 Heavy Duty
Alternative buckets on request
7
STANDARD EQUIPMENT
Hydraulic Mining Shovel with Diesel Drive ● SUPERSTRUCTURE Windshield wash wipers with two speed
will comprise: The main frame mounted over an and intermittent operation. (reservoir 7 ltr
externally toothed swing circle carries 1.8 gal). AM-FM radio. External metal sun
● FRONT SHOVEL ATTACHMENT
the main drive module, including two blinds. Left and right hand sliding windows.
7.6 m 24'11" boom and 5.6 m 18'4"
Komatsu SSA12V159 diesel engines, All windows tinted parsol green.
stick complete with cylinders. 29 m3
oil and fuel reservoirs, counterweight,
38 yd3 (SAE 2:1) shovel bucket with ● LUBRICATION
operator’s cab and base.
mechanical teeth and lip system. LINCOLN central lubrication for basic
● LIGHTING machine, attachment, and bucket.
OR
8 Xenon high performance working lights. 300 ltr 80 gal refillable container.
● BACKHOE ATTACHMENT 14 service lights throughout platform. LINCOLN automatic pinion lubrication
11.0 m 36'1" boom and 5.1 m 16'9" system for swing circle teeth with
● OPERATOR’S CAB
stick with 29 m3 38 yd3 (SAE 1:1) 300 ltr 80 gal refillable container.
Fully enclosed steel cab which
bucket with mechanical teeth and
incorporates the ISO 3449 standard Service point (diesel version only as standard)
lip system.
FOPS structure and CARRIER SÜTRAK on hydraulic arm carrying WIGGINS fluid
● CRAWLER UNDERCARRIAGE air-conditioning unit. Mounted on viscous receiving connectors for filling of fuel,
Heavy-duty shovel type undercarriage pads. GRAMMER full suspension engine oil and coolant, hydraulic oil, grease,
consisting of a center carbody and 2 operator´s seat with lap-belt. An auxiliary cabwater and the evacuation of coolant,
heavy box-type track frames, each seat. Full selection of controls, switches, and hydraulic and engine oils.
having 7 bottom rollers, 3 top rollers, and ECS (Electronic Health Monitor).
and 1350 mm 53" cast steel track shoes. Joy stick and pedal-operated controls ● ACCESSORIES
Hydraulic track adjustment and parking are electric over hydraulic. Acoustic travel alarm
brake provided. Hydraulically actuated ground access
ladder
Electric air horn
OPTIONAL EQUIPMENT
● 1800 mm 71’’ track shoes ● Electric drive ● Low temperature package

● Extra or alternative, lighting ● Cable reel (Electric version) (incl. KIM hot start)
● Fire suppression system ● Independant LINCOLN central lubrication
system for bucket
DIMENSIONS
BASIC MACHINE WITH COUNTERWEIGHT

N OR
M L O
A 1350mm 53" H 3310mm 10'10"
B 1800mm 71" I 3100mm 10'2"
CA 7540mm 24'9" J 7910mm 25'11"
CB 7990mm 26'3" K 8610mm 28'10" K I
J
D 2715mm 8'11" L 3970mm 13'0"
E 3712mm 12'2" M 3300mm 10'10"
D H
F 7424mm 24'4" N 7900mm 25'11"
G 9720mm 31'11" O 7260mm 23'10" A E
OR 7550mm 24'9" B F
CA G
CB
Ground Clearance: 995mm 3'3" SKZ5506_49 SKZ5506_48
QESS0556 04 ©2008 Komatsu Printed in Germany
KOMATSU MINING GERMANY GMBH

BUSCHERHOFSTRASSE 10
D-40599 DÜSSELDORF
PHONE +49 (0) 211/ 71 09-0
FAX +49 (0) 211/ 71 58 22
www.komatsu-mining.de Materials and specifications are subject to change without notice.

is a trademark of Komatsu Ltd. Japan.
SHOP MANUAL
HYDRAULIC EXCAVATOR
PC5500-6 Diesel
PC5500E-6 15016 and up
10 Structure, function
PC5500-6 1
Contents and 00_Foreworda15028.doc 04.01.07
CONTENTS
TABLE OF CONTENTS
00 Safety - Foreword
01 Technical DATA (Leaflet)
02 Assembly PROCEDURE (Brochure)
Section
1. Main assembly groups
2. Drive.
3. Hydraulic oil tank.
4. Hydraulic oil cooling.
5. Controlling.
6. Components
7. Main hydraulic pumps and pump regulation.
8. Operating hydraulic.
9. Hydraulic track tensioning system.
10. Hydraulic operated access ladder
11. Cable weel
12. Hints for the hydraulic circuit diagram
13. Hints for the electric circuit diagram
14. ECS-T
15. Lubrication Systems
APPENDIX
) • Each section includes a detailed table of contents.

SAFTEY SAFTEY NOTICE
SAFETY
SAFETY NOTICE
• IMPORTANT SAFETY NOTICE

Proper service and repair is extremely important for safe machine operation. The
service and repair techniques recommended by Komatsu and described in this manual
are both effective and safe. Some of these techniques require the use of tools specially
designed by Komatsu for the specific purpose.
The following Symbols are used in this Manual to designate Instructions of

particular Importance.
WARNING - Serious personal injury or extensive property damage can

result if the warning instructions are not followed.
To prevent injury to workers, this symbol is used to mark
safety precautions in this manual. The cautions
accompanying these symbols should always be followed
carefully. If any dangerous situation arises or may possibly
arise, first consider safety, and take the necessary actions to
deal with the situation.
CAUTION - Minor personal injury can result or a part, an assembly, or

the shovel can be damaged if the caution instructions are not
followed.
) NOTICE - Refers to special information
GENERAL PRECAUTIONS
Mistakes in operation are extremely dangerous. Read the OPERATION & MAINTENANCE
MANUAL carefully BEFORE operating the machine.
1. Before carrying out any greasing or repairs, read all the precautions given on the decals
which are fixed to the machine.
2. When carrying out any operation, always wear safety shoes and helmet. Do not wear
loose work clothes, or clothes with buttons missing.
• Always wear safety glasses when hitting parts with a hammer.
• Always wear safety glasses when grinding parts with a grinder, etc.
continued
00-1
Cont'd:
GENERAL PRECAUTIONS
3. If welding repairs are needed, always have a trained, experienced welder carry out the
work. When carrying out welding work, always wear welding gloves, apron, glasses, cap
and other clothes suited for welding work.
4. When carrying out any operation with two or more workers, always agree on the
operating procedure before starting. Always inform your fellow workers before starting
any step of the operation. Before starting work, hang UNDER REPAIR signs on the
controls in the operator's compartment.
5. Keep all tools in good condition and learn the correct way to use them.
6. Decide a place in the repair workshop to keep tools and removed parts. Always keep the
tools and parts in their correct places. Always keep the work area clean and make sure
that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking.
Never smoke while working.
PREPARATIONS FOR WORK
7. Before adding oil or making repairs, park the machine on hard, level ground, and block
the wheels or tracks to prevent the machine from moving.
8. Before starting work, lower bucket, hammer or any other work equipment to the ground.
If this is not possible, insert the safety pin or use blocks to prevent the work equipment
from falling. In addition, be sure to lock all the control levers and hang warning signs on
them.
9. When disassembling or assembling, support the machine with blocks, jacks or stands
before starting work.
10. Remove all mud and oil from the steps or other places used to get on and off the machine.
Always use the handrails, ladders or steps when getting on or off the machine. Never
jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a
stand to provide safe footing.
PRECAUTIONS DURING WORK
11. When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs,
loosen them slowly to prevent the oil from spurting out.
Before disconnecting or removing components of the oil, water or air circuits, first
remove the pressure completely from the circuit.
12. The water and oil in the circuits are hot when the engine is stopped, so be careful not to
get burned.
Wait for the oil and water to cool before carrying out work on the oil or water circuits.
continued
00-2
Cont'd:
PRECAUTIONS DURING WORK
13. Before starting work, remove the leads from the battery. ALWAYS remove the lead from
the negative (-) terminal first.
14. When raising heavy components, use a hoist or crane.
Check that the wire rope, chains and hooks are free from damage.
Always use lifting equipment which has ample capacity.
Install the lifting equipment at the correct places. Use a hoist or crane and operate slowly
to prevent the component from hitting any other part. Do not work with any part still
raised by the hoist or crane.
15. When removing covers which are under internal pressure or under pressure from a spring,
always leave two bolts in position on opposite sides. Slowly release the pressure, then
slowly loosen the bolts to remove.
16. When removing components, be careful not to break or damage the wiring, Damaged
wiring may cause electrical fires.
17. When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips on to
the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip, or can
even start fires.
18. As a general rule, do not use gasoline to wash parts.
19. Be sure to assemble all parts again in their original places. Replace any damaged part
with new parts.
• When installing hoses and wires, be sure that they will not be damaged by contact
with other parts when the machine is being operated.
20. When installing high pressure hoses, make sure that they are not twisted. Damaged tubes
are dangerous, so be extremely careful when installing tubes for high pressure circuits.
Also check that connecting parts are correctly installed.
21. When assembling or installing parts, always use the specified tightening torques. When
installing protective parts such as guards, or parts which vibrate violently or rotate at high
speed, be particularly careful to check that they are installed correctly.
22. When aligning two holes, never insert your fingers or hand. Be careful not to get your
fingers caught in a hole.
23. When measuring hydraulic pressure, check that the measuring tool is correctly assembled
before taking any measurements.
24. Take care when removing or installing the tracks of track-type machines. When removing
the track, the track separates suddenly, so never let anyone stand at either end of the
track.
00-3
ENVIRONMENT PROTECTION Environment NOTICE
RECOMMENDATIONS FOR ENVIRONMENTALLY FRIENDLY OPERATION

AND MAINTENANCE OF HYDRAULIC MINING SHOVELS
OPERATION
• Avoid engine idling over long periods. Long periods of idling, more than 10 minutes,
will not only waste fuel, but is also harmful to the engine.
• Avoid operation against the main relief valves of the hydraulic system. Move control
lever to neutral position before the loader attachment stalls due to overload.
• Position trucks in such a way, that loading operation can be carried out in a safe and
economic manner. Avoid swing angles over 90°.
MAINTENANCE
• Preserve our environment. To prevent environmental pollution, pay careful attention

to the method of disposing waste materials.
• Always drain fluids from your machine into containers. Never drain fluids onto the
ground or dump it into the sewage system, rivers, the sea or lakes.
• Dispose of harmful material, such as oil, fuel, coolant, solvent, filters and batteries in
accordance with environmental regulations and laws.
00-3
ENVIRONMENT PROTECTION Environment NOTICE
FOREWORD
GENERAL
With this SERVICE MANUAL KOMATSU provides you with the

description of the construction and the function of the major systems of the
Hydraulic Excavator PC5500-E.
We describe for you all functions and how to carry out the inspections and
adjustments.
How do you find "your" desired information?
In the table of CONTENT all the functions and components are shown in
their sequence of the description.
If after reading this SERVICE MANUAL you can give us suggestions and
comments for improvements - please do not hesitate to contact us.

- Service Training -
Postfach 180361
40570 Düsseldorf
Tel.:0211 / 7109 - 206

Fax.:0211 / 74 33 07
The editorial staff will be pleased about your co-operation.
- FROM THE PRACTICE - FOR THE PRACTICE -
) • This service manual corresponds to the state of development of the

machine at the time the manual was produced.
Variations based on special customers request and special equipment
are not included in this manual
00-4
FOREWORD HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
HOISTING
• Heavy parts (25 kg or more) must be lifted with a hoist etc.
) • If a part cannot be smoothly removed from the machine by hoisting,

the following checks should be made:
1. Check for removal of all bolts fastening the part to the relative
parts.
2. Check for existence of another part causing interface with the part
to be removed.
WIRE ROPES
1. Use adequate ropes depending on the weight of parts to be hoisted, referring

to the table below:
Wire ropes
(Standard "Z" or "S" twist ropes without galvanizing)
Rope diameter 10,0 11,2 12,5 14,0 16,0 18,0 20,0 22,4 30,0 40,0 50,0 60,0
[mm]
Allowable 1,0 1,4 1,6 2,2 2,8 3,6 4,4 5,6 10,0 18,0 28,0 40,0
load [tons]
) • The allowable load value is estimated to be 1/6 or 1/7 of the breaking

strength of the rope used.
2. Sling wire ropes from the middle portion of the hook. Slinging near the edge
of the hook may cause the rope to slip off the hook during hoisting, and a
serious accident can result. Hooks have maximum strength at the middle
portion.
continued
Cont'd:
00-5
FOREWORD HOISTING INSTRUCTIONS
WIRE ROPES
3. Do not sling a heavy load with one rope alone, but sling with two or more
ropes symmetrically wound on to the load.
• 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 can result in a dangerous
accident.
4. 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. The table below shows the
variation of allowable load (kg) when 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
suspended. 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.
00-6
FOREWORD STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUE (1Kgm = 9,806Nm)

STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS
Bolt Wrench Tightening torque

dia. size [mm] [Nm]
Quality grades
8.8 10.9 12.9

M 8 13 6 21 31 36
M 10 17 8 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 32 3500 4950 5800
M 45 70 4350 6200 7200
M 48 75 35 5200 7500 8700
M 52 80 6700 9600 11200
M 56 85 41 8400 12000 14000
M 60 90 10400 14800 17400
M 64 95 46 12600 17900 20900
M 68 100 15200 21600 25500
Insert all bolts lubricated with MPG, KP2K
00-7
FOREWORD CONVERSION TABLE
CONVERSION TABLE
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.
1. Convert 55 mm into inches.

(a) Locate the number 5 in the vertical column at the left side, take this as (A),
then draw a horizontal line from (A).
(b) Locate the number 5 in the row across the top, take this as (B), then draw a
perpendicular line down from (B).
(c) 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.
2. Convert 550 mm into inches.

(a) 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.
(b) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
(c) 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.
00-8
00-9
00-10
00-11
00-12
Basic Values in Ohm according to DIN 43 76

For Measuring Resistor PT100
°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
0 100,00 99,61 99,22 98,83 98,44 98,04 97,65 97,26 96,87 96,48
°C 0 1 2 3 4 5 6 7 8 9
0 100,00 100,39 100,78 101,17 101,56 101,95 102,34 102,73 103,12 103,51
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
00-13
TEMPERATURE
Fahrenheit – Centigrade Conversion; a simple way to convert a Fahrenheit
temperature reading into a Centigrade temperature reading or vise versa is to enter
the accompanying table in the center or boldface column of figures.
These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees, consider the
center column as a table of Fahrenheit temperatures and read the corresponding
Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the
center column as a table of Centigrade values, and read the corresponding
Fahrenheit temperature on the right.
00-14
Main Assembly Groups Section 1.0
Page 1
Table of contents section 1.0
Section Page
1.0 Main assembly groups
General lay out 2
1.1 Superstructure 3
1.1.1 Machine house 4
1.1.2 Hydraulic Oil Reservoir 5
1.1.3 Hydraulic Oil Cooler 6
1.1.4 High tension switch cabinet 7
1.1.5 Counter weight 8
1.1.6 Cab support 9
1.1.7 Operators cab 10
1.1.8 Control Blocks 11
1.1.9 Swing gears 12
1.2 Under carriage 13
1.3 Attachment
1.3.1. Backhoe Attachment (BHA) 14
1.3.2. Front Shovel Attachment (FSA) 15
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Page 2
1. General lay out
Legend for illustration (Z 22387):

(1) Superstructure
(2) Under carriage
(3) Front Shovel Attachment (FSA)
(4) Backhoe Attachment (BHA)
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1.1 Superstructure

(1) Operators Cab with integrated FOPS
(2) Cable drum
(3)
(4) Cab support (contains the low tension electric switch board)
(5) Swing ring connection
(6) Switch cabinet, middle tension (main electric supply )
(7) Hydraulic ladder
(8) Counter weight
(9) Hydraulic oil cooler with hydraulic driven fans
(10) Hydraulic oil reservoir
(11) Batteries
(12) Swing Gear
(13) Grease pump of the Central Lubrication System (CLS)
(14) Grease pump of the Swing gear pinion Lubrication System (SLS)
(15) Main Control blocks with high pressure filters
(16) Main electric motor 1

(17) Flexible coupling
(18) PTO gear with hydraulic pumps
(19) Main hydraulic pumps 1, 2 and 3
(20) Capacitor motor 1
(21) Main electric motor 2

(22) Flexible coupling
(23) PTO gear with hydraulic pumps
(24) Main hydraulic pumps 4, 5 and 6
(25) Capacitor motor 2
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1.1 Superstructure
1.1.1 Machine house
Legend for illustration (Z 22390a):
A View from the back of machinery house without counter weight

B View from the right side of machinery house
C Top view
(1) Motor coolant air outlet

(2) Main motor supply cable
(3) Capacitor
(4) Hydraulic control and filter panel
(5) PTO gear box
(6) Main hydraulic pumps
(7) Auxiliary pumps, installed at the drive through shaft of the main
hydraulic pumps (piggyback pumps)
(8) Hydraulic pump for radiator fan drive
(9) Hydraulic pump for the hydraulic oil cooler fan drive
(10) Suction oil reservoir
(11) Flexible coupling, oil filled
(12) Batteries
(13) Engine 1
(14) Engine 2
(15) Hydraulic motor for the radiator fan drive
(16) Radiator for the engine cooling system
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1.1 Superstructure
1.1.2 Hydraulic Oil Reservoir

(1) Breather filter
(2) Temperature controlled back pressure valve
(3) Drain coupling of the hydraulic oil reservoir
(4) Return oil filter
(5) Case drain (leak oil) filter
(6) Main shut-off valve (Gate valve) with compensator
(7) Return oil collector tube
(8) Drain coupling of the Return oil collector tube
(9) Back pressure valves for swing motors
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1.1 Superstructure
1.1.3 Hydraulic Oil Cooler

(1) Cooler frame with swing out facility
(2) Hydraulic motor of upper fan
(3) Upper fan
(4) Fan guard
(5) Outer part of the upper radiator set
(6) Inner part of the upper radiator set
(7) Hydraulic motor of lower fan
(8) Lower fan
(9) Fan guard
(10) Outer part of the lower radiator set
(11) Inner part of the lower radiator
(12) Swing out doors
(13) Locking bars to secure the swing out doors
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1.1 Superstructure
1.1.4 High tension switch cabinet
A Left side view

B Front side view
C Top view
X High tension switch cabinet
(1) Main fuses, high tension

(2) Main supply switch, manual controlled
(3) Main motor switches, remote controlled
(4) Current transformer
(5) Main transformer
(6) Air condition for switch cabinet
(7) Access stair
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1.1 Superstructure
1.1.5 Counter weight

(1) Counter weight
Total weight
~40000 kg
(2) Mounting bolts

Quantity Bolt size Grade SW* Tightening
(mm) (mm) torque (Nm)
16 M 48 x 380 10.9 75 7500
* SW = Wrench size
(3) Lifting points
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1.1 Superstructure
1.1.6 Cab support

(1) Cab support (Location of electrical switch board “X2”)
(2) Mounting bolts
6 M 36 x 320 10.9 55 3100
* SW = Wrench size
(3) Mounting bolts

6 M 36 x 160 10.9 55 3100
* SW = Wrench size
(4) Door
(5) Gasket
(6) Door handle (adjustable)
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1.1 Superstructure
1.1.7 Operators cab
(1) Monitor panel

(2) Switch panel
(3) Operators seat
(E19) Control lever
– EURO Control
– KMG Control
(E20) Control lever

– EURO Control
– KMG Control
(E21a) Control pedal A - forward

Left track
B - reverse
(E21b) Control pedal A - forward

Right track
B - reverse
(E22) Control pedal - Swing brake
(E23) Control pedal (left) Clam closing
(E24) Control pedal (right) Clam opening
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1.1 Superstructure
1.1.8 Control blocks

(1) Control block carrier
(2) Remote control valves
(3) Main control blocks
(4) High pressure filter
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1.1 Superstructure
1.1.9 Swing gears

(1) Swing gear box
(2) Swing parking brake – Spring loaded multi disk brake
(Released by oil pressure)
(3) Parking brake Control port (X)
(4) Oil level gauge - gear box
(5) Breather – gear box
(6) Oil filling plug – gear box
(7) Oil level gauge – motor adapter housing
(8) Breather – motor adapter housing
(9) Oil drain plug – motor adapter housing
(10) Oil drain plug - gear box
(20.1 + 20.2) Swing motor
(49.1 + 49.2) Swing brake valve block
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1.2 Under carriage

(1) Undercarriage center body
(2) Crawler carrier R.H.-side
(3) Crawler carrier L.H.-side
(4) Connecting pins, center body to crawler carriers
(5) Crawler tracks
(6) Rotary distributor
(7) Brake valves
(8) Travel motors
(9) Parking brakes, spring loaded disk type brakes
(10) Travel gear
(11) Sprocket
(12) Track rollers
(13) Carrier rollers
(14) Guide wheel (Idler)
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1.3 Attachment
1.3.1 Backhoe attachment (BHA)

(1) Boom
(2) Boom Cylinders
(3) Stick
(4) Stick Cylinders
(5) Bucket
(6) Bucket Cylinders
(7) Control arm
(8) Linkage
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1.3 Attachment
1.3.2 Front Shovel Attachment (FSA)

(1) Boom
(2) Boom Cylinders
(3) Stick
(4) Stick Cylinders
(5) Bucket backwall
(6) Bucket Cylinders
(7) Clam
(8) Bucket Clam cylinders
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Drive Section 2.0
Page 1
Section Page
2.0 Prime drive assembly
General 2
2.1 Coupling 3
2.2 Pump-spline lubrication 4
2.3 PTO Lubrication and cooling 5-6
2.4 Hydraulic pumps – location, drive speed and flow rates 7
2.0
2
Drive Section 2.0
Page 2
2.0 Prime drive assembly

(1) Cooling air intake
(2) Cooling air exhaust
(3) Electric Motor
(4) Alignment shims
(5) Alignment supports
(6) Motor frame
(7) Coupling
(8) Pump distributor gear (PTO)
General
The two electric motors are solid bolted to the motor frame (6).
The alignment shims (4) thickness must be determined due the alignment
procedure. The alignment must be done in accordance to the Parts & Service
News AH01523, last edition.
) • The alignment shims thickness must be also determined when

replacing the electric motor! Never use the existing shims without
determination.
2.0
3
Drive Section 2.0
Page 3
2.1 Coupling

(1) Input drive hub
(2) Output drive flange
(3) Outside rubber support ring
(4) Rubber element
(5) Motor drive shaft
(6) Gearbox input flange
(7) Hub looking washer
(8) Coupling ring
) • Repair and replacement have to be done accordingly to Parts &

Service News AH01523, last edition.
Design:
VULASTIC-L – coupling type are provided with one flexible rubber element
(4). The flexible ring connect the input drive hub (1) via the coupling ring (8)
with the output drive flange (2) of the coupling.
Function:
The high flexible VLULASTIC–L coupling transfers the torque without any
rotational gap. They are wear-resisting and maintenance free. Because of
symmetrical arrangement of the flexible rings, there are no returning forces
either by the torque transfer or the centrifugal forces.
VULASTIC-L couplings dampen rotating vibrations, reducing same by
partial storing of the shock energy and damp noises.
The coupling allows in an acceptable range axial, radial and angular
misalignment of the shafts.
Replacement and alignment refer to Parts & Service News AH01523, last
edition.
2.0
4
Drive Section 2.0
Page 4
2.2 Pump-spline lubrication

Drive shaft housings

(1) Oil filler plug with breather pipe of main pump drive shaft housing
(2) Oil collector reservoir for auxiliary pump drive shaft housing
(M) Configuration, main pump drives
(A) Configuration, auxiliary pump drives
All drive shaft housings are filled with the same gear oil as the pump
distributor gear.
This is done for two reasons:

1. To lubricate the multi-spline connections, to prevent wear and corrosion.
2. It makes it easier to determine a sealring leak at one of the drive shaft
connections.
Function:
M If the oil level increases the oil drops out of the breather pipe (1).
If this oil is gear oil it indicates a possible leak at the gearbox side.
If the oil is a mixture of gear oil and hydraulic oil it shows a possible
leak at the pump side.
If at an oil level check a loss of oil is found it may be due to worn or
defective radial seal rings.
Function:
A The oil is filled in via the oil collector reservoir (2). All auxiliary drive
shaft housings are connected by pipes with the reservoir. The reservoir
is filled approx. one half with oil.
If the oil level in the reservoir increases due to leakage the oil drops out
from the breather filter (with oil level gauge) on top of the reservoir.
Now a check has to be done to find out which one of the drive shafts
seals is damaged.
It can be done by disconnecting temporary the pipe to the reservoir.
Disconnect the pipe at the drive shaft housing, plug the pipe and leave
the union open.
If now at operation the oil still comes out of the union, this drive shaft
seal is gone.
Otherwise check sequential all auxiliary drives.
2.0
5
Drive Section 2.0
Page 5
2.3 PTO Lubrication and cooling

Legend for illustration (Z 22410e):
The machine is equipped with two motors and gearboxes. The motor close to
the counter weight is called motor 1 and the motor to the front is called motor
2. The extension of the component designation shows the mounted position.
Example: Pressure filter (69.1) is the pressure filter for the PTO lubrication of
motor 1 and (69.2) of motor 2.
(1) Line to the cooler (hot oil)
(2) Return line from the cooler (cooled oil)
(3) Return line from valve
(4) Suction line from PTO oil pan to the pump
(P) Pressure port
(8.1)(8.4) Gear pump PTO-gearbox lubrication
(69.1)(69.2) Pressure filter - PTO gear lubrication
(74.1)(74.2) Pressure relief valve, 7,5 bar
(78.14)(78.15) Solenoid valve (Y53-x), (reduction of relief valve pressure)
(105.3+105.4) Oil cooler, part of hydraulic oil cooler motor 1
(105.1+105.2) Oil cooler, part of hydraulic oil cooler motor 2
(M1-1)(M1-2) Pressure check point
(B17-1)(B17-2) Pressure switch, 0,5 bar
(B27-1)(B27-2) Maintenance switch, 5 bar
(B49-1) Temperature sensor
Function:
Pump (8.1)/(8.4) forces the gear oil from the gear oil pan through filter
(69.1)/(69.2)) to pressure relief valve (74.1/74.2). This pressure relief valve
acts as a back pressure valve causing that most of the oil passes through the
gear oil coolers (105.3+105.4)/(105.1+105.2).
The gear oil coolers are a small part of the hydraulic oil coolers, thus the gear
oil gets cooled by the same air stream as the hydraulic oil. From the coolers
the oil flows to the port (P) of the gear and internally via a system of pipes to
the several spray nozzles. The spray nozzles in the gear case ensure proper
and adequate distribution of the lube oil. The circuit is monitored by the
pressure switches (B17-1). At too low lube oil pressure (0.5 bar), a fault
message will be displayed on the monitor at the dash board.
The gear oil temperature is monitored by the sensor unit (B49-1) (B49-2). At too
high oil temperature a fault message will be displayed on the monitor at the dash
board.
If the oil temperature is to low, solenoid valve (Y53-1) (Y53-2) energised and
opened port X of the pressure relive valve (74.1) (74.2). This reduced the relieve
valve pressure setting. The main gear oil flow direct back to the PTO to quick
warm up of the gear oil.
continued
2.0
6
Drive Section 2.0
Page 6
Cont`d.
2.3 PTO Lubrication and cooling

(1) Pilot operated relief valve (8) Valve spring
(2) Plug screw (9) Seal rings
(3) Valve piston (B27-x) Maintenance switch
(4) Port for pressure switch B17-1 (74.x) Pressure relief valve
(6) Port for pressure check stud (A) Pressure port
(7) Jet bore (T) Return from valve
Adjustments:
• The adjustment of the maximum permissible PTO lube pressure, has
to be carried out with cold oil to avoid serious damages to the coolers.
• The check for a sufficient PTO lube pressure has to be carried out
with warm oil to avoid serious damages gearbox.
Setting the pressure relief valve (74.x) at cold oil.

1. Connect a pressure gauge to check point (M1.x).
2. Disconnect plug of solenoid valve Y53-1/ Y53-2
3. Start the respective motor
4. Required pressure: 7,5 bar.
If adjustment is required:
5. Remove protection cap (1a).
6. Loosen lock nut (1b).
7. Set the pressure with set screw (1c).
8. Tighten lock nut (1b) and re-install protection cap (1a)
9. Reconnect plug of Y53-1/ Y53-2
) • If the pressure of 7,5 bar cannot be adj. 100 %, adj. to the maximum
visible pressure.
Checking the PTO lube pressure at operating temperature (warm oil)

1. Connect a pressure gauge to check point (M1.x).
2. Start the motor and let it run with max. speed.
3. Required pressure: 2-7,5 bar.
2.0
7
Drive Section 2.0
Page 7
2.4 Hydraulic pumps – location, drive speed and flow rates
Legend for illustration (Z 22415b):

(1 - 6) Axial piston pump (swash plate type)
pump volume Vg = 500 cm³/rev
theoretical flow rate, each Qmax = 700 Liter/min
Drive speed* n = 1409 min-1
for all working motions pmax = 310 bar
(10.1), (10.2) Axial piston pump

pump volume Vg = 80 cm³
theoretical flow rate Qmax = 142 Liter/min
for oil cooler fan drive pmax = 180 bar
(8.1), (8.4) Gear pump

pump volume Vg = 58.7 cm³/rev
theoretical flow rate Qmax = 82,2 Liter/min
for PTO gear lubrication pmax = 7,5 bar
(8.2), (8.5) Gear pump

for hydraulic oil circulation pmax = 15 bar
(7.1), (7.2) Gear pump

for pilot pressure supply pmax = 60 bar
) • * at 1500 min-1 (50Hz) or 1800 min-1 (60Hz) input drive speed

Hydraulic Oil Reservoir Section 3.0
Page 1
Section Page
3.0 Hydraulic oil reservoir
General lay out 2
3.1 Main oil tank, location of switches, sensors etc. 3

3.2 Suction oil tank with strainers 4
3.3 Return oil collector tube with strainer 5
3.4 Back pressure valve 6
3.5
3.6 Return and Leak Oil Filter 8
3.7 Breather Filter 9
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3. General lay out

(1) Filter cover retainer
(2) Filter cover
(3) (A) – Return oil filter – 10 µm (4x)
(B) – Case drain filter – 3 µm (1x)
(4) Man hole cover
(5) Hydraulic oil filler plug
(6) Differential pressure switch, screen filter monitoring
(7) Test port, back pressure 8 bar
(8) Test port, back pressure swing motor 15 bar
(24) Pressure switch B24 – monitors item (132.1+132.2)
(39) Hydraulic oil level gauge
(41) Main oil reservoir
(114) Return oil collector tube with pressure check point M10
(115) Back pressure valve
(118) Oil drain, quick release coupling
(128) Shut off valve (Gate valve) with monitoring switch S31
(129) Compensator
(132.1 + 132.2) Breather filter
(178) Oil cooler filter (screen filter)
The hydraulic oil tank is a welded sheet-metal construction.

The filling capacity is about 3800 litres. The tank contains four return oil
filters (3-A) and one case drain filter (3-B).
The breather filter (132.1 + 132.2) cleans the air that streams into the tank.
The back pressure valve (115) and the pressure check point (M10) are located
at the collector tube (114) for return oil.
The connection to the suction tank can be closed with the shut- off valve (118)
to prevent oil flow during repairs on the hydraulic pumps. This unit is
controlled by the switch S31, to prevent a motor start with closed shut-off
valve. Fault message ”Start blocked because of main Shut-Off (gate) valve” is
displayed at the operators dash board.
The screen filter (178) protect the oil cooler for internal contamination, the
filter is monitored by differential pressure switch (178).
The back pressure valves (8) increase the circulation pump pressure to 15 bar
for cavitation protection of the swing motors.
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3.1 Main oil tank, location of switches, sensors etc.

(B4) Oil level sensor “Hydraulic oil level too low”
(B15) Hydraulic oil temperature probe
“Hydraulic oil temperature below: too hot”
(B24) Breather filter pressure switch
(B25) Pressure switch – Pressure leak oil chamber
(B26) Pressure switch – Pressure return oil chamber
(B32) Hydraulic oil temperature probe “Temp. gauge cabin”
(B42) Oil level sensor “Oil level maximum”
(B50) Oil level sensor “Hydraulic oil refill level”
(Y101) Solenoid valve “Back pressure reduction”
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3.2 Suction oil tank with strainers

(1) Suction oil reservoir
(2) Drain coupling
(3) Bolt
(4) Gaskets
(5) Main suction oil strainer
(6) Gaskets
(7) Intermediate pipe
(8) Nut
(9) Bolt
(10) Compensator
(11) Suction strainer – one for each main pump
(12) Suction hose connection pipe
The suction oil tank (1) is a welded sheet-metal construction.

The capacity is 187 liters.
The suction lines of all hydraulic pumps are connected to the suction tank.
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3.3 Return oil collector tube with strainer

(1) Return oil collector tube - Part 1 -
(4) Strainer
(5) Bolt
(6) Self locking nut
(7) Gasket
(8) Differential pressure switch B165
Task:
The strainer is installed to prevent the hydraulic oil coolers from getting
clogged up in case of contamination in the main return oil circuit.
Excessive increase of the hydraulic oil temperature can be an indication for a
restricted strainer, i.e. bad cooling performance due to insufficient oil flow
through the coolers.
In case that main components such as cylinders or motors are internal
fragmentary damaged, the strainer should be inspected for metal chips.
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3.4 Back pressure valve

(1) Back pressure valve assembly
(2) Solenoid valve (Y101)
Task:
The back pressure valve has to fulfill two functions in the hydraulic system:
1. To ensure a sufficient pressure within the return oil circuit, i.e. to supply
oil via the anticavitaton valves to the low pressure side of cylinders,
respectively motors.
2. To force the return oil through the coolers depending on the present
hydraulic oil temperature, controlled by solenoid valve Y101.
- Low temperature ⇒ low volume through the coolers
- High temperature ⇒ high volume through the coolers
) • Further information about the function principle and adjustments,

refer to Section 4.0 this Manual.
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3.6 Return and Leak Oil Filter

(2) Filter cover with o-ring
(3) Pre-tensioning spring
(4) Retainer
(5) Filter assembly
(6) Filter pot with machined cover
(7) Main filter element, 10 micron absolute
(8) Safety filter element (200 micron strainer)
(9) By pass-valve, 2.3bar
(9.1) Valve cone
(9.2) Valve spring
(9.3) O-ring
(10) Profile gasket
(11) Seal ring
Function:
The returning oil flows into the filter chamber (A) of the hydraulic tank. (The
sketch shows one section only).
The chamber is split into two sections; one sections with 4 filters for the return oil
and one for the leak oil. But the five filters are all the same. The hydraulic oil
enters the filter at the top and passes then on its way to the entire tank the filter-
element (7). "Inside to outside filtration."
The filter element condition is monitored by a pressure switch (B25, 0.5 bar for
the leak oil filter) and (B26, 2 bar for the return oil filter).
As soon as the pressure inside the filter chamber reaches the set pressure of those
switches due to the restriction of the filter-element which is caused by foreign
matters, the fault message ”Return oil filter restricted" or ”Leak oil filter
restricted” is displayed at the operator's dash board The filter elements must be
replaced. For safety pre-cautions the filter is equipped with a by-pass valve. As
the filter chamber pressure increases the by-pass valve opens at 2.3 bar and
protects the element from bursting.
But the oil flows not totally unfiltered into the tank because it must flow through
the strainer (8).
•
)
The switch point of the pressure switch for the leak oil has been
chosen so low with best intention to protect first of all the radial seal
rings of the hydraulic motors.
Because the filter is oversized for this purpose, the message ”Leak
oil filter restricted” is displayed very seldom under normal
circumstances.
• Maintenance see MAINTENANCE MANUAL
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3.7 Breather filter

(1) Nut
(2) Cover
(3) Filter element
(4) Filter pot
A breather filter is installed to clean the air that streams into the tank any time
the oil level decreases while extending attachment cylinders
The filter element condition is monitored by a vacuum type pressure switch
(B24, 80mbar).
Maintenance see MAINTENANCE MANUAL
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04.01.07 PC5500-6-E_Sec_3-0_rev2.doc
Hydraulic Oil Cooling Section 4.0
Page 1
Section Page
4.0 Hydraulic oil cooling
4.1 General 2
4.2 Function of the hydraulic oil cooling circuit 3
4.3 Adjustment of the Back Pressure Valve 4
4.4 Fan drive (Two stage cooler fan RPM control) 5+6
4.5 Pressure relief valves and solenoid valve 7+8
4.6 Fixed Displacement Pump, with variable setting 9
4.7 Radiator fan drive speed adjustment 10 –
12
30.08.0630.08.0615.06.05 PC5500-6-E_Sec_4-0_rev3.docPC5500-6-E_Sec_4-0_rev2.doc
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Page 2
4.1 General
The hydraulic oil cooling system maintains the hydraulic oil at a normal
operating temperature.
Legend for illustration (Z 21594)

(1) Noise shield
(1) Cooler (Radiator)
(2) Cooler frame
(3) Fan
(4) Fan motor (Axial piston motor)
(5) Bolt
(6) Bolt
(7) Drive shaft
(8) Shaft protecting Sleeve
(9) Drive shaft seal
(10) Ball bearings
(11) Seeger clip ring
(12) Bearing group carrier
(13) Oil level plug
(14) Breather filter
Design:
There are four hydraulic oil coolers in front of the hydraulic tank on the R.H.
side of the platform.
They are in pairs mounted in one frame, one above the other. The air stream
needed for the cooling is produced by hydraulic driven fans. The air flows
from inside to outside through the coolers.
For a better cleaning, the coolers can be moved to the side. (“Swing out
cooler”)
The bearing group carrier is filled with oil to lubricate the bearings.
4.0
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Page 3
4.2 Function of the hydraulic oil cooling circuit
Legend for illustration (Z 22419aa)

(107.1-107.4) Restrictor, shock absorbers for the hydraulic oil cooler
(106.1-106.4) Hydraulic oil cooler
(L6 + L7) Return line from control blocks
(C1 + C2) Supply line for the anticavitation circuit of the swing
motors
(M10) Pressure check point
(C1 + C2) Supply line for the anticavitation circuit of the swing
motors
(Y101) Solenoid valve – 4/2-directional control valve
(H) Lines to cooler (hot oil)
(C) Lines to tank (cold oil)
Function:
The returning oil from the system flows via the lines (L6 - L7) into the
collector tube (114). On the top of it is the Back Pressure Valve (115)
installed.
The back pressure valve (115) causes a back pressure which forces most of
the relative hot oil through the lines (H) to the cooler (106.1-106.4).
On its flow through the cooler the hydraulic oil gets cooled and flows than
through the restrictors (107.1-107.4) and the lines (C) into the filter chamber
of the main oil reservoir (41).
The restrictors are acting like shock absorbers to prevent cooler cracking at
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 (115) is wide
open, because solenoid valve Y101 is energized, which results in less oil
flows through the cooler which causes that the oil gets quicker its optimum
With increasing oil temperature the oil gets thinner, so that the main pumps
can be shifted to Qmax position and simultaneously solenoid valve Y101 will
be de-energized, so that the valve piston will be more closed by the force of
the spring thus that more oil passes the cooler.
4.0
4
Page 4
4.3 Adjustment of the Back Pressure Valve
Checks and settings only at normal operating temperature of the hydraulic oil,
main pumps in maximum flow position and "Idle Time" control eliminated
(service switch S151 actuated)!
1. Connect a pressure gauge to check point (M10).

2. Disconnect plug connector (13) of solenoid valve Y101.
3. Actuate service switch S151 ().
4. Start both both the motors..
5. Required pressure: 8 ±0,5 bar
a) Take off protective cap (12).
b) Loosen lock nut (5).
c) Adjust the pressure with the set screw (6).
d) Tighten lock nut (5) and refit protective cap (12).
6. Disconnect the pressure gauge, reconnect solenoid valve Y101 and
switch back service switch S151.
Legend for illustration (Z 21596c):

(1) Control oil port
(2) "Y"- port (external return to tank)
(2a) "X"- port (external return to tank via solenoid valve Y101)
(3) Poppet
(4) Valve spring
(5) Lock nut
(6) Set screw
(7) Jet bore (large)
(8) Valve spring
(9) Valve piston
(10) Jet bore (small)
(11) Plug screw
(12) Protective cap
(13) Plug connector
(A) Return to tank (Filter chamber)
(Z) Pressure oil to valve
4.0
5
Page 5
4.4 Fan drive (Two stage cooler fan RPM control)
Legend for illustration (Z 22420aa)

(10.2) Axial piston pump Motor 1 (fixed displacement pump, with
variable setting)
(10.4) Axial piston pump Motor 2 (fixed displacement pump, with
variable setting)
(22.1) Fan motor (Axial piston motor)
(22.2) Fan motor (Axial piston motor)
(168.1) Pressure relief valve – Motor 1 radiator fan drive
(168.2) Pressure relief valve – Motor 2 radiator fan drive
(68.1) Pressure filter with pressure differential switch B28-1 (Motor 1)
(68.2) Pressure filter with pressure differential switch B28-2 (Motor 2)
(103.1) Check valve– (Anti cavitation valve for fan drive motor)
(103.2) Check valve– (Anti cavitation valve for fan drive motor)
(148.11) 4/3 direction flow valve – Motor 1 radiator fan speed (stop, low and
high speed), solenoid Y6A-1 + Y6B-1
(148.12) 4/3 direction flow valve – Motor 2 radiator fan speed (stop, low and
high speed), solenoid Y6A-2 + Y6B-2
(169.1) pressure reduction valve (low fan speed adjusting) motor 1
(169.2) pressure reduction valve (low fan speed adjusting) motor 2
(L) Leak oil (case drain) to tank
(P) Pressure to motor
(R) Return oil to tank
Mot1 Mot1 PVG PVG of Motor 1
Mot2 Mot2 PVG PVG of Motor 2
4.0
6
Page 6
Function:
From pump (10.x) flows the oil through the filter (68.x) to the fan motor (22.x) and
then back to the tank.
The check valve (103.x) act as an anti cavitation valve and is installed, because the
fan motor -driven by inertial force- is running for a short period after the oil flow is
interrupted by solenoid valve (Y6A-x/Y6B-x) or if the motor has been switched off.
The hydraulic circuit "Fan drive" is secured by the pilot controlled pressure relief
valves (168.x) and (169.x).
These valves are working together with the solenoid valve (Y6A-x/Y6B-x),
controlled by the PLC, depending on the hydraulic oil temperature:
• With de-energized solenoids Y6A-x and Y6B-x the relief valve (168.x) is
functioning and the fans are running with max. adjusted speed (1300 RPM)
• With solenoid Y6A-x energized the relief valve (168.x) is not functioning and
the fans are running with a very low speed caused by the flow resistance only.
• With solenoid Y6b energized the relief valve (169.x) is controlling the relief
valve (168.x) and the fans are running with 1000 RPM RPM only.
(See also description on next page)
4.0
7
Page 7
4.5 Pressure relief valves and solenoid valves

Pressure relief valves (168.x)
Legend for illustration (Z 21598b)

(1) Valve cartridge
(2) Spring
(3) Spring chamber
(4) "X" port
(5) Jet bore, Pilot poppet
(6) Jet bore, Main piston
(7) Main piston
(8) Valve housing
(9) Pilot poppet
(Y) External leak oil port
(A) Pressure port
(B) Return oil port
Function:
Pressure in line A affects the main piston (7). At the same time there is pressure
via the jet bore (6) on the spring-loaded side of the main piston and via jet bore (5)
at the pilot poppet (9) of the relief valve cartridge (1).
If system pressure in line A exceeds the value set at the spring (2), pilot poppet (9)
opens. The signal for this comes from line A via the jet bores (6) and (5).
The oil on the spring-loaded side of the main piston (7) now flows via the jet bore
(5) and poppet (9) into the spring chamber (3).
From here it is fed internally by means of the control line (Y) to tank (port B).
Due to the state of equilibrium at the main piston (7), oil flows from line A to line
B, while the set operating pressure is maintained.
The pressure relief valve can be changed (Remote controlled) by means of the
port "X" and the function of the solenoid valve Y6A-x / Y6B-x and pressure
reduction valve 169.x. .( Function see next page)
continued
4.0
8
Page 8
Cont’d.
4.5 Pressure relief valves and solenoid valve, illustration (Z 21599c)
Function:
With de-energized solenoids (Y6A-x and Y6B-x), the spool (3) of the 4/3
direction flow valve 148.x keeps the "X" connection of valve (168.x) and port
“B“ to port “P“ closed. The pressure relief valve (168.x) operates normal with
the max. adjusted pressure. The fan turn with maximum speed.
The energized solenoid Y6B, operate the spool (3) of the 4/3 direction flow
valve 148.x and a connection is made between port “P“ , port “B“ and port "X"
of valve (168.x)
The system pressure now opens main piston (7) of valve (168.x), because via
solenoid Y6B (P to B) the oil from the rear side of piston (7) flows from the
"X"-port to the “P“ port of valve (169.x). This valve (169.x) reduce now the
max. adjusted pressure of valve (168.x) to a lower value. The fan turn with
reduced speed.
The energized solenoid Y6A, operate the spool (3) of the 4/3 direction flow
valve (148.x) and a connection is made between port “P“ and port “A” and port
"X" of relief valve (168.x).
The system pressure now opens the main piston (7) of valve (168.x) because
via the "X"-port the oil from the rear side of piston (7) flows to tank. The
normal relief valve function is eliminated. The fan turn with minimum speed,
nearly stand still.
4.0
9
Page 9
4.6 Fixed Displacement Pump, with variable setting

(1) Drive shaft
(2) Bearings
(3) Cylinder with pistons
(4) Center pin
(5) Control lens
(6) Q-min adjustment bolt
(7) Q-max adjustment bolt
(8) Pressure port
(9) Tank port
Description.
Pump 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.
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.
• With an increase in the swivel angel, the pump output increase together
with necessary drive torque.
• With an decrease in the swivel angel, the pump output decreases together
with the necessary drive torque.
• When increasing to maximum swivel angle, there is a danger of

cavitation and over-speeding the hydraulic motor!
4.0
10
Page 10
4.7 Oil cooler Radiator fan drive speed adjustment
Basic Adjustment

(1) Dust cap
(2) Lock nut
(3) Set screw
(P) Axial piston pump (fixed displacement pump, with variable
setting)
(6) Qmin stop bolt
(6.1) Lock nut
(7) Qmax stop bolt
(7.1) Lock nut
(10) Positioning pin (mover)
(168.1) Pressure relief valve – bottom oil cooler fan (Motor 1)
(168.4) Pressure relief valve – top oil cooler fan (Motor 2)
(169.1) pressure reduction valve – bottom oil cooler fan (Motor 1)
(169.2) pressure reduction valve – top oil cooler fan (Motor 2)
(Y6A-1 /Y6B-1) 4/3 direction flow valve – Motor 1
(Y6A-2 /Y6B-2) 4/3 direction flow valve – Motor 2
(L1) Measurement of Qmin stop bolt
(L2) Measurement of Qmax stop bolt
(M5-1) Pressure check points - Motor 1 oil cooler fan drive operating
pressure
(M5-2) Pressure check points - Motor 2 oil cooler fan drive operating
pressure
) • A blocked cooler, restricted air flow, defect cooler seal or bend fan
influence the fan RPM and air flow.
• Basic adjustment has to be carried out whenever one of the following
components has been replaced:
- pump
- relief valve
- hydraulic motor
continued
4.0
11
Page 11
Cont'd
4.7 Oil cooler fan drive speed adjustment Radiator fan drive speed
adjustment
Basic Adjustment max fan speed
1. Reduce the output flow of the respective pump (P),by adjusting the
minimum possible swivel angle, to avoid over speeding the fan:
To do this, loosen both lock nuts (6.1 + 7.1) and turn out bolt (6)and
turn in bolt (7) up to final stop.
This is necessary to avoid a loose positioning pin (10), resulting in
oscillating of the cylinder barrel.
Tighten the lock nuts.
2. Remove protection cap (1) from relief valve (168.x), loosen lock nut
(2) and turn set screw (3) fully clockwise and then a half turn
counter clockwise.
3. Disconnect the plug connectors (Y6A-x and Y6B-x) of the 4/3
direction flow valve, to ensure that the full flow of pump P will be
delivered to the fan motor. The valve is in neutral position and all
ports are blocked.
4. Connect a pressure gauge to check point (M5-x).
5. Start the respective motor. and let it run in high idle.
6. Check the fan speed with a non-contact rev counter
Required fan speed: 1300250 RPM
• Be careful not to get caught in the fan or other rotating parts
7. Increase the output flow of pump P ,by adjusting the swivel angle, until
the fan speed is 20 RPM higher than required:
To do this, loosen both lock nuts (6.1 + 7.1) and turn in bolt (6) and
turn out bolt (7) the same length.
This is necessary to avoid a loose positioning pin (10), resulting in
oscillating of the cylinder barrel.
Tighten the lock nuts (6.1 + 7.1).
• Do not exceed the maximum permissible operating pressure of
230 bar
) • Note down the lengths ”L1” and ”L2” as reference measurements.
continued
4.0
12
Page 12
Cont'd
8. Loosen lock nut (2) of the relief valve (168.x), and decrease the
pressure with set screw (3) until the correct fan speed is obtained.
9. Tighten lock nut (2) and fix protection cap (3).
Basic Adjustment middle fan speed

10. Activate the 4/3 direction flow valve (Y6B-x), by connecting the
solenoid plug (Y6B-x ) to permanent 24 V. Use a the 24V socket
(close to the motor house light switch or emergency switch.at the
PTO *) or activate the fan via PLC control ( digital output, key
switch required).
11. Check the fan speed with a non-contact rev counter Required fan
speed: 1000 RPM
12. If adjustment is necessary loosen lock nut (5) of the relief valve
(169.x), and decrease the pressure with set screw (4) until the correct
fan speed is obtained.
13. Stop motor and reconnect the plugs to the correct positions.
14. Disconnect the pressure gauge from check point (M5-x).
Fan speed check

If the maximum fan speed is out of adjustment, increase or decrease first the
pressure at relief valve (168.x), to change the speed.
• Do not exceed the maximum permissible operating pressure of 230 bar
If the speed can not be raised by increasing the pressure then increase the
output flow of pump (10.x).
*) Prepare a test wire with a plug ET-No. 891 039 40, and a plug
ET-No. 440 305 99. Connect terminal 1 to positive (+)
(center off plug 440 305 99) and terminal 2 to ground (-).
Controlling Section 5.0
Page 1
Section Page
5.0 Controlling
General lay out 2
5.1 Control and filter panel location of components 3

(valves, switches, sensors etc.)
5.2 Pilot Pressure Supply and Adjustments 4–7
5.3 Remote control valves arrangement 8
5.4 Function principle of the 9 + 10
Electro-Hydraulic- Proportional Control
5.5 Potentiometer Control (Lever, Joy Stick) 11
5.6 Potentiometer Control (Pedal) 12
5.7 Proportional amplifier module, Type A 13
(for swing brake only)
5.8 Proportional amplifier module, Type B 14
(for Boom, Stick, Bucket, Swing and Travel)
5.9 Ramp Time Module 15
(Analogue command value module for Boom,
Stick, Travel and Swing function)
5.10 Adjustments of Amplifier Modules (General) 16
5.11 Adjusting the Amplifiers Type B 17 + 18
5.12 Adjusting the Amplifiers Type A 19 + 20
5.13 Adjusting the Ramp Time Module 21 + 23
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5.0
2
X4 - pump support
pressure X3 – remote control
pressure (1/2Qmax; Qmin)
X2
pump regulation
pilot pressure
X1 - pump regulation
pressure
to (45.2); (45.3) and (43) Z 22429
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Page 2
5.0 General lay out

(7.1 / (7.2) Pumps for pilot pressure and pump regulation system
(84.1 / 84.2) Check valve (for combined operation)
(68.1) Filter
(70.1) Pressure relief valve (X4 – pressure)
(70.2) Pressure relief valve (X2 – pressure)
(85) Pressure accumulator (10 Liter, 10 bar pre-charge
pressure)
(91) Check valve
(45.1; 45.2 ;45.3, 43) Remote control valves
(14; 15; 16; 13)) Control blocks
General
The controlling includes the pilot pressure system and the pump regulation
system.
The pumps (7.1 / 7.2) forcing the oil through the filter (68.1) to all involved
valves.
The pressure accumulator ensures that under any circumstances enough pilot
pressure oil is available. The accumulator (85) is also functioning as a
hydraulic battery for a certain time when the motor was shut down or to
pressure relive the system for repair works.
When the operator is using his controls an electrical signal causes energizing
of the selected solenoid valve of the remote control valves(14).
By the function of the remote control valves pilot pressure oil is send to the
relevant control block spools which in turn allows operating hydraulic oil to
the users.
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Page 3
5.1 Control and filter panel location of components Legend for illustration (Z 22497):
Solenoid valves
Motor 1 Motor 2
(Y5) Swing gear house brake (swing parking brake)
(Y6A-1) (Y6B-1) Oil cooler fan RPM control
(Y6A-2) (Y6B-2) Oil cooler fan RPM control
(Y14A-1) (Y14A-2) Radiator fan RPM control, low speed (only diesel drive)
(Y14B-1) (Y14B-2) Radiator fan RPM control, middle speed (only diesel drive)
(Y16) Travel gear house brake (travel parking brake)
(Y17) Idle time control (Qmin)
(Y17a) ½ Q-max (reduced oil flow at cold oil)
(Y127) Swing service brake control
(Y61.1) (Y61.2) „XLR“ pressure, pumps 1 - 3, „XLR“ pressure, pumps 4 - 6
(Y102.1) (Y102.2) „X4“ pressure, pumps 1 - 3, „X4“ pressure, pumps 4 - 6
(Y124A/B) Refilling arm – up and down (only with diesel engines)
(Y124c) Refilling arm lock (only with diesel engines)
(Y48) Swing motor power/ speed control
(Y120) Emergency swing service brake control
(Y123A/B) ladder up and down
(Y125) ladder speed control
Pressure switches:
(B16) Pilot pressure for Swing gear house brake (24 bar)
(B21.1) (B21.2) Radiator fan drive filter differential switch (filters 68.3+5) (only diesel)
(B22) Differential pressure switch, pilot pressure system filter
(B27.1) (B27.2) Differential pressure switch, PTO gear oil filter
(B28.1) (B28.2) Pressure switch, cooler fan drive filter
(B48) Pilot pressure for travel gear house brake (24 bar)
(B97.1) (B97.2) „X4.1“ pressure, pumps 1 - 3, „X4.2“ pressure, pumps 4 - 6
(B85.1) (B85.2) “X1.1” pressure, pumps 1+2; “X1.2” pressure pumps 4 - 6
(B86) X2 pressure sensor
Pressure check points:
(M1.1) (M1.2) Pressure PTO gear lubrication
(M2) X4 - pressure
(M3) X2 - pressure
(M5.1) (M5.2) Cooler fan drive pressure
(M6) Pressure travel gear house brake
(M7) Pressure Swing gear house brake
(M11) Pressure swing brake (safety circuit )
(M18) Pressure for hydraulic pump regulation (electronic out)
(M19.1) (M19.2) Radiator fan drive pressure (only with diesel engines)
(M20.1) (M20.2) X1 pressure pumps 1, 2, 4, 5, 6
(M30) X3 pressure for pumps at ½ flow position
(M32) X3 pressure for pumps at ½ flow position
(M40) Pilot pressure, X-2
Filter:
(68.1) Pilot pressure and pump regulation
(68.2) (68.4) Oil cooler fan drive
(68.3) (68.5) Engine radiator fan drive (only with diesel engines)
(69.1) (69.2) PTO gear lubrication
continued
04.01.07 PC5500-6-E_Sec_5-0_rev3.doc
5.0
4
04.01.07 PC5500-6-E_Sec_5-0_rev3.doc
Page 4
5.2 Pilot Pressure Supply and Adjustments
Pilot Pressure Circuit

The pilot pressure oil is used for the following functions.
To move the control block spools, to supply the main pump regulation
system, to lubricate the main pump bearings, to release the travel- and swing
gear house brakes (spring loaded multi disk brakes), to drive the Lincoln
Lubrication pumps, to move the hydraulic operated ladder, to move the
hydraulic operated refilling arm and to supply the hydraulic track tensioning
system.

(7.1 / 7.2) Pilot pressure pumps
(84.1 / 84.2) Check valve (for combined operation)
(68.1) Filter
(70.1) Pressure relief valve 60 bar
(70.2) Pressure relief valve 35 bar
(85) Pressure accumulator
(43 + 45.x) Remote control valves
(M2) 60 bar pressure check point (X4-Pressure)
(M3) 35 bar pressure check point (X2-Pressure)
(M40) 35 bar pres. check point (X2-Pressure in front of accumulator)
Function:
Study together with the hydraulic circuit diagram
The pumps (7.1 and 7.2) are delivering the oil through the filter (68.1) to port A
of the pressure relief valve (70.1) and the pressure relief valve (70.2) port A.
The pressure relief valve (70.1) maintains the adjusted pressure of 60 bar it is
called X4-pressure.
X4 - pressure: Pump support pressure
Pump bearing lubrication
Actuation of refilling arm and ladder
Lubrication system
Track tensioning system
continued
04.01.07 PC5500-6-E_Sec_5-0_rev3.doc
5.0
5
04.01.07 PC5500-6-E_Sec_5-0_rev3.doc
Page 5
Cont’d.:
The pressure relief valve (70.2) maintains the adjusted pressure of 35 bar it is
the X2-pressure.
X2 – pressure: Pilot pressure system

Pump regulation system
Capacity regulation swing motors
Travel- and Swing gear house brakes (spring loaded multi -
disk brakes)
The pressure accumulator (85) holds an amount of oil under pressure to ensure
sufficient pilot pressure during normal operations and a limited number of
operations without motor power.
The check valves (91) prevents return flow of the pilot pressure oil.
04.01.07 PC5500-6-E_Sec_5-0_rev3.doc
5.0
6
04.01.07 PC5500-6-E_Sec_5-0_rev3.doc
Page 6
Cont'd:
Pilot Pressure Circuit

(91) Check valve
(85) Bladder Accumulator – 10 liter, 10 bar (located behind the filter and
valve panel of motor 2 on top of the PTO)
(PX2) Pilot pressure line
(LX2) Leak / return oil line from the remote control blocks
Function:
The pilot pressure oil flows via line (PX2) to port (P) of each remote control
block and is present via a gallery at all proportional and directional solenoid
valves.
These solenoid valves are energized by the function of the Electro
proportional controls (Joy sticks or pedals) and direct the pilot pressure oil to
the respective spools of the main control blocks with a variable pilot pressure
proportional to the deflection of the controls.
) • For the location and designation of the proportional and directional

solenoid valves of the remote control blocks see “5.3 Remote control
valves arrangement” in this section.
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Checks and Adjustment of Pilot Pressure

(85) Bladder Accumulator – 10 liter, 10 bar pre-charge pressure
(located underneath the catwalk in front of the PTO)
(70.1) Pressure relief valve for pump support pressure X4 (60 bar)
(70.2) Pressure relief valve for pilot pressure X2 (35 bar)
(M2) Pressure check point X4, pump support pressure (60 bar)
(M3) Pressure check point X2 pressure, pilot pressure (35 bar)
(M40) Pressure check point for accumulator (If not factory installed, fit a
T-union with test connector as shown in illustration Z 21635a)
) • Since the “X2” and the “X4” pressure are influencing each other it is
always necessary to adjust both valves 70.1+70.2 alternately.
60 bar pressure „X4“, valve 70.1:
1. Connect pressure gauge to check point (M2)
2. Start both motors
3. Read pressure, required = 60 -2 bar
If readjustment is required *:
35 bar pressure „X2“, valve 70.2:
1. Connect pressure gauge to check point (M3)
2. Start both motors
3. Read pressure, required = 35+3 bar
If readjustment is required *:
* Valve adjustment:
a Remove dust cap (1).
b. Loosen lock nut (2).
c. Set pressure with set screw (3).
d. Tighten lock nut (2) and re-fit dust cap (1).
Checking of Accumulator Function

1. Connect pressure gauge to check point (M40).
2. Start one motor.
3. After build-up of pressure stop the motor, but do not turn the
key switch to zero position.
4. Watch pressure gauge. Pressure should remain constant for at
least 5 minutes.
) • If the pressure droops the system must be checked for leakage’s.

• To check the accumulator charging pressure refer to SERVICE
BULLETIN AH01531a latest edition.
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5.3 Remote control valves arrangement
No. Solenoid Proportional Function

valve valve FSA BHA
Y20a Y20 L.H. Crawler forward

Y20b L.H. Crawler reverse
Y21a Y21 Stick extending
45.1 Y21b Stick retracting
Y22a Y22 Bucket filling (curl)
Y22b Bucket emptying (dump)
Y23a Y23 Boom raising
Y23b Boom lowering
Y24a Y24 Clam closing Bucket filling (curl)

X24b Clam opening Bucket emptying (dump)
Y25a Y25 Bucket filling (curl) Boom raising
45.2 Y25b Bucket emptying (dump) Boom lowering
Y26a Y26 Boom raising Reserved
Y26b Boom lowering Reserved
Y27a Y27 Stick extending Stick extending
Y27b Stick retracting Stick retracting
Y28a Y28 R.H. Crawler reverse

Y28b R.H. Crawler forward
Y29a Y29 Boom raising
45.3 Y29b Boom lowering
Y30a Y30 Bucket filling (curl)
Y30b Bucket emptying (dump)
Y31a Y31 Stick extending
Y31b Stick retracting
43 Y32a Y32 R.H. Swing

Y32b L.H. Swing
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5.4 Function principle of the Electro-Hydraulic- Proportional Control

(1) Pump
(2) Filter
(3) Pressure relief valve
(4) Check valve
(5) Pressure Accumulator
(6) Directional Solenoid valve, a side
(7) Directional Solenoid valve, b side
(8) Proportional Solenoid valve
(9) Control valve block
(10) Battery
(11) Electronic units with amplifiers etc.
(12) Control lever
Function:
The electric-hydraulic control system is used to control the direction and
volume of oil flow to the operating cylinders and motors via the control valve
blocks.
Hydraulically:
The oil volume of pump (1) flows through filter (2) into the pilot pressure
system. The pressure is limited by the pressure relief valve (3).
With the pressurized oil stored in accumulator (5), a limited number of spool
movements can be carried out with the motors at standstill.
When a lever (or pedal) is actuated, proportional solenoid valve (8) and one
of the directional solenoid valves (either 6 or 7) are energized, and allows the
pilot pressure oil to flow to the spools of the control blocks.
Electrical
Whenever a lever or a pedal is moved out of its neutral position, an amplifier
will created a current between 0 and 1000 mA. (For detailed information refer
to page 10 in this section)
Depending on the lever direction, simultaneously one of the directional
solenoid valves (either 6 or 7) is energized.
The proportional solenoid valve alters the pilot pressure, proportional to the
lever deflection, this results a spool movement between neutral and full
stroke position.
continued
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Cont'd:
5.4 Function principle of the Electro-Hydraulic- Proportional Control
(Exemplary illustration of the function of two axis with one Amplifier only)
Legend for illustration (Z 21638a)
(1) Control lever (joystick)
(2) Capacitor-Module
(3) Ramp time module
(4) Proportional-Amplifier-Module
(5) Relay (Supply Voltage)
(6) Proportional solenoid valve-(Pressure-Reducing Valve)
(7) Directional solenoid valve
(8) Control block spool
General Function
Control lever (1) is supplied with 24 VDC battery voltage for the switch contacts
and for the internal electronics to create the signal voltage.
When moving lever (1) out of its neutral position, 24 VDC battery voltage arrives
at relay (5) and energizes the Proportional Amplifier (4) with capacitor
supported 24 VDC via terminal 1.
Depending on the function of the control lever, 1 to 4 Amplifiers can be involved
for the „Y-axis“ (forward/ backwards direction) and 1 to 4 Amplifiers for the „X-
axis“ (left/right direction.)
The polarity of the Output Signal from joystick (1), either positive or negative,
between 0 and 10 VDC indicates the direction of the lever movement and is
proportional to the lever deflection. This is the Input Signal to the ramp time
module (3) at terminal 5 which will arrive after the adjusted ramp time delay via
terminal 7 to the proportional amplifier (4) at terminal 5.
This Input Signal (between 0 and 10 VDC) is amplified to an Output Signal
between 0 to 1000 mA and is simultaneously send via terminal 7 (negative) or
terminal 8 (positive) to the Proportional Solenoid valve (6) and to the
Directional solenoid valve (7) via terminal 3 (negative) or terminal 9 (positive)
to the “a” or “b”-side.
The proportional Solenoid valve (6) alters the pilot pressure (“X2”) of 35 bar to a
value proportional to the Current Signal.
This pressure controls the movement of the control block spool (8) between
neutral and full stroke position.
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5.5 Potentiometer Control (Lever, Joy Stick)
Legend for illustration (Z 21639b)

(1) Push button *
(2) Toggle switch *
(3) Inductive linear transmitter
(4) Universal joint
(5) Electronics
(6) Push pin
(7) Shaft seal
(8) Reset spring
(9) Coil core
(10) Coil
* Alternative application
The non-contacting lever control (inductive linear transmitter) contains both

the electronic and mechanical components which converts the lever
movement into a proportional electrical voltage. The lever can be operate in
two axes:
Axis "Y", splitted into the half axis Y- and Y + (backward and forward)
Axis "X", splitted into the half axis X- and X + (left and right)
Of course the lever can be moved in any other direction (Joy stick function)
In order to be able to monitor the direction of the lever movement and the
neutral position, the electronics (8) sends a 24V signal as soon as the lever
gets moved out of its neutral position.
For one axis are used two inductive linear transmitter (3). The motion of the
coil core (9) connected to the push pin (6) causes a variation of the induction
in the coils (10). The electronics convert this inductive signal into a
proportional output signal of –10...0...+10 V for the amplifiers.
The electronic part of the lever is equipped with a internal fault detector. In
case of a internal electronic fault the electronic send a 24V signal to the test
output. The test input is used for a lever system check before motor start. The
inductive system is designed as a redundant system with two separate coils.
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5.6 Potentiometer Control (Pedal)

(1) Potentiometer Control Unit
(2) Pedal
(3) Standard cable
(4) Connection cable for combined operation
Application for:
(A) Swing foot brake
(B) Clam Opening/closing, (only face shovel attachment)
(C) Travelling
The Potentiometer Control (inductive linear transmitter) contains both the

electronic and mechanical components which converts the pedal movement
into a proportional electrical voltage.
In order to be able to electrically monitor the pedal (2) action a neutral

position switch is fitted.
This switch closes when the pedal is moved out of the rest position.
When using the double unit (B) (combined operation) only the signal output
from one unit is used for the Clam Operation.
Due to the cross lined connection via the connection cable (4) the signal is
once positive and once negative (inverted), depending on the Pedal used.
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5.7 Proportional Amplifier Module, Type A

Type A (for swing brake only)
(LED) LED for Solenoid A or B
(P) Set Potentiometer
R1 for the lowest current value
R2 for the highest current value
The amplifier module is snapped onto mounting rails inside the X2-box.
The amplifier module contains the necessary electronics for the control of
two proportional solenoids. Depending on the input polarity, either solenoid
A or solenoid B is operated.
The solenoid current (solenoid A - solenoid B) is measured and compared
with the external input value. Differences between feed-back and input
values, for example caused by changes in solenoid temperature or supply
voltage, are compensated.
The module also generates a direction-dependent voltage signal (solenoid A -
solenoid B) as soon as the solenoid current reaches the lowest set value.
The lowest and highest values are set externally via the potentiometer R1 + R2.
The brightness of the LED's changes with the current.
This function should not be used for setting.
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5.8 Proportional Amplifier Module, Type B

Type B (for Boom, Stick, Bucket, Clam, Swing and Travel)
(LED) (P) Set Potentiometer:

AX: Proportional output AX active - 10% for the lowest current value
AS: Switched output AS active - J2 for the highest current value
BX: Proportional output BX active (Pt) Set Potentiometer for the „Ramp
BS: Switched output BS active Time“
Power: Internal supply voltage
Fault: Fault indication
The amplifier module is snapped onto mounting rails inside the X2-box.
The amplifier module contains the necessary electronics for the control of
two proportional solenoids and two directional solenoids. The outputs for
proportional solenoids Ax and Bx and the switched outputs As and Bs are
activated by connecting a minimum of approx. 10 % signal voltage at the
amplifier input.
A positive signal voltage controls outputs A, a negative signal voltage
controls output B.
A signal voltage of approx. 10% with respect to +/- 10 V input voltage at the
amplifier, produces a stepped output voltage. The height of this 10% jump
may be set separately for proportional outputs Ax and Bx via external
potentiometer. As the signal voltage rises the solenoid current for the
proportional outputs increases linearly.
A further step in output current occurs at approx. 90% signal voltage.
The maximum current or the 90% jump may be set separately for outputs Ax
and Bx via external potentiometers and hence the gradient of the output curve
may be influenced.
LED’s indicate the current output to each proportional and switched output,
whereby the brightness is approx. proportional to the solenoid current in Ax
and Bx. This function should not be used for setting.
A Ramp Time function is included in the amplifier which may be externally
changed by a set potentiometer. The setting range for the ramp time is
approx. from 80 ms to 1s. The time setting applies to both up and down
ramps and to both proportional solenoids.
A fault is indicated by the LED „Fault“.
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5.9 Ramp Time Module

(Analogue command value module for Boom, Stick, Travel and Swing
function)

Potentiometer:
"t1" to "t5" ⇒ Ramp times
"w1" to "w4" ⇒ Command value call-ups
"G" ⇒ Zero point matching
"Z" ⇒ Amplitude attenuation for the differential input
LED displays:
(1) green ⇒ Operational power
(2) "4-Q" ⇒ Quadrant recognition
(3) "INV" ⇒ Inversion active
(4) yellow ⇒ display for potentiometer t1 to t4
(5) yellow ⇒ display for potentiometer w1 to w4
(6) Measurement sockets: "t" ⇒ Actual ramp time
"w" ⇒ Internal adjustment variable
"⊥" ⇒ Reference potential / GND
General
The Ramp Time Module is snapped onto mounting rails inside the X2-box.
The electrical connection is done via screw terminals.
The module is operated with 24 VDC. A power supply provides the internally
required positive and negative supply voltages.
As soon as the power supply is in operation the green LED (power) lights up.
Internal command values
The internal command value signal is generated from the external command
value signal which is being applied to the differential input, a called-up signal
and an offset signal (zero point potentiometer "Z").
The external command value signal can, via potentiometer "G", changed from
0 % to approx. 110 %.
Command value call-ups
The call-up signals w1 to w4 also have an adjustment range of 0 % to 110 %.
No settings required. (factory set to 100 %).
Ramp time call up
If the quadrant recognition is not activated, then each command value call-up
"w1" to "w4" is allocated its own ramp time "t1" to "t4".
As long as there is a signal change, the LED allocated to the actual ramp time
is alight.
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5.10 Adjustments of Amplifier Modules (General)

(1) Potentiometer control
(2) Terminal with a separating possibility
(4) Amplifier
(5) Solenoid valve
(6) Service module
Introduction:
The illustration shows simplified the route of the signal voltage from
Potentiometer Control (1) to Solenoid-Valve (5):
A. With ramp time module,
i.e. Boom,- Stick,- Travel,- and Swing Function.
B. Without ramp time module,
i.e. Bucket and Clam Function.
The ramp time modules (3) and the amplifiers (4) are adjustable.
Adjustments are required:
Ramp time modules Amplifiers
• When commissioning the machine • When replacing a solenoid valve
• When replacing a module • When replacing an amplifier
For Checking and Setting the Signal Current at the Proportional-Amplifier (4),
both separating terminal (2) before and behind the Amplifier (4) must be opened.
For the setting procedure the signal voltage from the potentiometer control (1) can
be simulated with the potentiometer of Service-Module (6),which is installed on
the X2-panel.
Accessories required for the adjustments: "a" "b" "c" "d"

a) A multimeter, good readable for
mA VDC
values between 0 and 1000 mA.
b) More convenient is a second meter
for reading voltage simultaneously.
c) A simple wire, 1m length, or better
a prepared test lead same length
d) Four test leads, 1m length, with
banana type connectors on each
end.
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5.11 Adjusting the Amplifiers Type B, illustration (Z 21642a)
Procedure applicable for all amplifiers except the one for the swing
brake:
(Do not start the motors leave only the key switch in ON – position.)
1. Open* the respective separating terminal (T1) between the lever unit and
the amplifier module to be set.
2. Open* the respective separating terminal (T2) between the amplifier module
to be set and the proportional solenoid valve.
3. Disconnect the wire from terminal five.
4. Connect the positive output of the service module with terminal five of the
amplifier module, using test lead (2).
5. Attach a multimeter for voltage reading to the service module, using test
lead (3).
6. Attach a multimeter (in series) for Amp reading to the terminal between
amplifier module and solenoid valve, using test leads (3).
7. Move the lever of the Potentiometer Control into its final position; or
override manual the relay which allows 24 V operating voltage to the
amplifier module; thus the amplifier gets 24 V operating voltage. The
power LED and simultaneously LED A(+) or B(-) lights up, depending on
the polarity.
8. Turn the potentiometer (P) of the Service-Module until the multimeter
shows 1 VDC (it may be either positive or negative); the multimeter for the
current reading will show a value which should correspond to the value
giving in the electric circuit diagram (see page adjustments of amplifier and
time ramp modul) e.g. 330 mA. (The first step (10 %) value)
If necessary correct the value with potentiometer (10%).
9. Turn the potentiometer (P) of the Service-Module further until the
multimeter shows 9 VDC; the multimeter for the current reading will show
a value which should correspond to the value giving in the circuit diagram
e.g. 570 mA. (The second step (90 %) value).
If necessary correct the value with potentiometer (J2).
* How to open and close the terminal:

Push the yellow stud (1) down with a screw driver and turn it 90° to the left to
open or to the right to close the terminal. A spring pushes then the stud
outwards and the contacts are either open or closed.
continued
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Cont'd:
5.11 Adjusting the Amplifiers Type B, illustration (Z 21642)
10. Repeat settings of item 8 and 9 until both mA values are stabilized, because
the 10% and J2 adjustment influence each other.
11. If the setting with either positive or negative potential was successful, turn
the potentiometer (P) of the service module into the opposite direction and
check the settings with the other polarity i.e. if the first setting was done with
positive potential then turn the pot into negative direction; otherwise ice
versa.
Attantion! The adjustment values can be different betwin the directions (poitiv A
or negative B) and the single amplifier. Use the respective electric diagram of
your machine (page: adjustments of amplifier and time ramp modul)
12. Repeat the setting as described under item 7 to 10.
13. Remove multimeter, test wire, close* the terminals and reconnect the wire to
terminal 5 of the amplifier module.
Adjusting the Ramp Time

In the amplifier module is a ramp time function integrated which is active
when there is no additional ramp time module in the respective control
circuit.
1. Turn potentiometer (time) 30 revolutions counter clockwise to guarantee the
correct start position at the complete left side.
2. Turn potentiometer (time) so many revolutions clockwise as shown in the
table below (part of the electrical circuit diagram).

Push the yellow stud (1) down with a screw driver and turn it 90° to the left to open
or to the right to close the terminal. A spring pushes then the stud outwards and the
contacts are either open or closed.
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The amplifiers for the crawler foot pedals are adjustable in the same way as
the amplifiers for the joy sticks.(refer to page 17 and 18 in this section)
The amplifier for the swing foot brake is similar.
Procedure for the swing foot brake:

1. Open* the respective separating terminal (T1) between the pedal unit and
the amplifier module to be set.
2. Open* the respective separating terminal (T2) between the amplifier module
to be set and the proportional solenoid valve.
3. Disconnect the wire from terminal five.
4. Connect the positive output of the service module with terminal five of the
amplifier module, using test lead (2).
5. Attach a multimeter for voltage reading to the service module, using test
lead (3).
6. Attach a multimeter (in series) for Amp reading to the terminal between
amplifier module and solenoid valve, using test lead (3).
7. Press the pedal fully down ; or manual override the relay which allows 24 V
operating voltage to the amplifier module; thus the amplifier gets 24 V
operating voltage.
8. Turn the potentiometer (P) of the Service-Module until the multimeter
shows 1 VDC ; the multimeter for the current reading will show a value
which should correspond to the value giving in the circuit diagram e.g. 10
mA. (10 % value)
If necessary correct the value with potentiometer (R1).

continued
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Cont'd:
9. Turn the potentiometer (P) of the Service-Module further until the

multimeter shows 10 VDC; the multimeter for the current reading will show
a value which should correspond to the value giving in the circuit diagram
e.g. 500 mA. (100 % value).
If necessary correct the value with potentiometer (R2).
) • It is important that the pilot pressure for the pressure increasing valve
is 19± 1 bar.
For more information refer to section 8.2 „Swing Circuit“
10. Repeat settings of item 8 and 9 until both mA values are stabilized, because
R1 and R2 influence each other.
11. Remove multimeter, test wire, close* the terminals and reconnect the wire
to terminal 5 of the amplifier module.

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5.13 Adjusting the Ramp Time Module

(6) Service module
(P) Potentiometer
) • The following adjustments have to be done when commissioning the

machine and whenever the Ramp Time Module has been replaced.
• Do not start the motors turn only the key switch in ON – position.
Basic Adjustment:
1. Connect 0 VDC with a test lead from the red positive terminal of the
service module (6) to terminal 5 of the Ramp Time Module (3) and
adjust with "Pot Z" a value of 0 VDC measured at terminal 7.
Disconnect the test lead after the setting is done.
2. Connect +10 VDC with a test lead from the red positive terminal of
the service module (6) to terminal 5 of the Ramp Time Module (3)
and adjust with "Pot G" a value of 10 VDC measured at terminal 7.
Check the negative voltage as well(- 10 VDC). Disconnect the test
lead after the setting is done.
) • Repeat settings of item 1 and 2 until both values are stabilized,

because "Pot Z" and "Pot G" influence each other.
• The factory setting of potentiometer "w1" to "w4" for the command
value call-ups must not be adjusted.
continued
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Cont'd:
5.13 Adjusting the Ramp Time Module

(1) Control lever (joystick)
(4) Proportional-Amplifier-Module
(5) Relay (Supply Voltage)
Ramp time adjustment in relation to the operating movements:
3. Disconnect the cables at terminal 3 and terminal 5 of the respective

module.
Connect 24 Volt with a test lead to terminal 9, 10, 11 and 12 one after
another and adjust with the respective "Pot t1, t2, t3 and t4" the values
giving in the table on the next page. (Measure the voltage only at the
Measurement socket "t" of the ramp time module)
4. To check the adjustments under operating conditions reconnect terminal

3 and terminal 5 and measure the ramp time with a stopwatch.
5. If the above mentioned values are not suitable for the local working
conditions, for example due to, different Attachments or different
operation feeling of the operator,
the ramp time can be changed according to the NOTE on illustration
Z 21645, to ensure smooth and efficient working cycles.
continued
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Cont'd:
5.13 Adjusting the Ramp Time Module (values as a example only)
E48 Stick
24 Volt at Joy stick Signal Pot Value to be measured at socket "t"
Terminal 9 Neutral ⇒ Stick out 0V to +10V t1 0,10 Volt = 1000 ms
Terminal 10 Stick out ⇒ Neutral +10V to 0V t2 0,10 Volt = 1000 ms
Terminal 11 Neutral ⇒ Stick in 0V to -10V t3 0,10 Volt = 1000 ms
Terminal 12 Stick in ⇒ Neutral -10V to 0V t4 0,10 Volt = 1000 ms
E49 Boom
Terminal 9 Neutral ⇒ Lower 0V to +10V t1 0,10 Volt = 1000 ms
Terminal 10 Lower ⇒ Neutral +10V to 0V t2 5,00 Volt = 20 ms
Terminal 11 Neutral ⇒ Lift 0V to -10V t3 0,10 Volt = 1000 ms
Terminal 12 Lift ⇒ Neutral -10V to 0V t4 5,00 Volt = 20 ms
E50 Swing
Terminal 9 Neutral ⇒ Swing R 0V to +10V t1 0,20 Volt = 500 ms
Terminal 10 Swing R ⇒ Neutral +10V to 0V t2 0,10 Volt = 1000 ms
Terminal 11 Neutral ⇒ Swing L 0V to -10V t3 0,20 Volt = 500 ms
Terminal 12 Swing L ⇒ Neutral -10V to 0V t4 0,10 Volt = 1000 ms
E50B Swing brake

Terminal 9 Neutral ⇒ counter 0V to +10V t1 0,10 Volt = 1000 ms
swing right
Terminal 10 Counter swing right +10V to 0V t2 0,500 Volt = 20 ms
⇒ Neutral
Terminal 11 Neutral ⇒ counter 0V to -10V t3 0,10 Volt = 1000 ms
swing left
Terminal 12 Counter swing left -10V to 0V t4 0,500 Volt = 20 ms
⇒ Neutral
continued
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E51 Left crawler

Terminal 9 Neutral ⇒ Forward 0V to +10V t1 0,500 Volt = 20 ms
Terminal 10 Forward ⇒ Neutral +10V to 0V t2 0,500 Volt = 20 ms
Terminal 11 Neutral ⇒ 0V to -10V t3 0,500 Volt = 20 ms
Backward
Terminal 12 Backward ⇒ -10V to 0V t4 0,500 Volt = 20 ms
Neutral
E52 Right crawler

Terminal 9 Neutral ⇒ 0V to +10V t1 0,500 Volt = 20 ms
Backward
Terminal 10 Backward ⇒ +10V to 0V t2 0,500 Volt = 20 ms
Neutral
Terminal 11 Neutral ⇒ Forward 0V to -10V t3 0,500 Volt = 20 ms
Terminal 12 Forward ⇒ Neutral -10V to 0V t4 0,500 Volt = 20 ms
E59 Bucket (only BHA)

Terminal 9 Neutral ⇒ Fill 0V to +10V t1 0,05 Volt = 2000 ms
Terminal 10 Fill ⇒ Neutral +10V to 0V t2 0,10 Volt = 1000 ms
Terminal 11 Neutral ⇒ Dump 0V to -10V t3 0,10 Volt = 1000 ms
Terminal 12 Dump ⇒ Neutral -10V to 0V t4 0,10 Volt = 1000 ms
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Components Section 6.0
Page 1
Section Page
6.0 Components
6.1 Hydraulic
6.1.1 Main Control Blocks and High Pressure Filter FSA 2-3
6.1.2 Main Control Blocks and High Pressure Filter BHA 4-5
6.1.3 Distributor Manifold – Restrictor blocks FSA 6
6.1.4 Distributor Manifold – Restrictor blocks BHA 7
6.1.5 Restrictor Block with Pressure Relief Valve 8
6.1.6 Anti Cavitation Valve Block 9
6.1.7 Remote Control Valves 10
6.1.8 Directional Solenoid Valves (4 way / 3 positions) 11
6.1.9 Proportional Solenoid Valves 12
6.1.10 High Pressure Filter 13
6.1.11 Control Blocks and Valves 14-17
6.1.12 Load Holding Valve 18
6.1.13 Travel Brake Valve 19
6.1.14 Pressure Reducing Valve 20
6.1.15 Directional Solenoid Valves (2 positions / 4-ways) 21
6.1.16 Pressure Increasing Valve 22
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6.1.1 Main Control Blocks and High Pressure Filter

Front Shovel Attachment FSA

Pump circuit No. I
(14 / I ) Control block I (L.H. Travel, Stick, Bucket, Boom,)
(46.1) High pressure filter, Pump 2 and 5
(31.01) SRV Travel motors left backward
(32.01) ACV Travel motors left backward
(31.02) SRV Travel motors left forward
(32.02) ACV Travel motors left forward
(33.1) SRV Stick cylinder piston side
(32.3) ACV Stick cylinder piston side
(32.4) ACV Stick cylinder rod side
(32.5) ACV Bucket cylinder rod side
(33.2) SRV 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
Pump circuit No. II

(15 / II) Control block II (Bucket, Boom, Reserved, Stick)
(44.2) High pressure filter, Pump4
(32.10) ACV Bucket piston side
(30) SRV Clam cylinder piston side
(191) SRV (pressure increasing valve) Stick cylinder rod side
continue
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Pump circuit No. III

(176 / III) Control block (R. H. Travel, Boom, Bucket, Stick)
(31.03) SRV Travel motors right forward
(32.17) ACV Travel motors right forward
(31.04) SRV Travel motors right backward
(32.18) ACV Travel motors right backward
Pump circuit No. IV

(13 / IV) Control block IV (Single spool for swing)
(44.1) High pressure filter, Pump 3
) • There is one MRV in each control block.
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6.1.2 Main Control Blocks and High Pressure Filter

Backhoe Attachment

Pump circuit No. I
(175 / I ) Control block I (L.H. Travel, Stick, Bucket, Boom,)
Pump circuit No. II

(15 / II) Control block II (Bucket, Boom, Reserved, Stick)
(44.2) High pressure filter, Pump4
(33.06) SRV Boom cylinder rod side
continue
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Cont’d
Main Control Blocks and High Pressure Filter BHA
Pump circuit No. III

(176 / III) Control block (R. H. Travel, Boom, Bucket, Stick)
Pump circuit No. IV

(13 / IV) Control block IV (Single spool for swing)
(44.1) High pressure filter, Pump 3
) • There is one MRV in each control block.
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6.1.3 Distributor Manifold - Location of restrictor blocks and anti cavitation

valves
Front Shovel Attachment (FSA)

(1) Distributor manifold
(2) Synchronization (Equalization) lines
(4) Anti Cavitation Valve Block (ACV)
(5) Restrictor Block (Throttle valve)
(6) Restrictor Block (Throttle valve)
(7) Service-line Relief Valve
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6.1.4 Distributor Manifold - Location of restrictor blocks and anti cavitation

valves
Backhoe Attachment

(4) ACV Block Section A ,Boom cylinder rod side
Pressure check point
(7) Restrictor blocks
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6.1.5 Restrictor Block with Pressure Relief Valve
) • A restrictor block is used for limiting cylinder lowering speeds.

• A Service Line Relief Valve is installed to limit the maximum system
pressure due to external forces.
(1) Adjustment spindle

(2 + 3) O-ring with back-up ring
(4) Retainer
(5 + 6) O-ring with back-up ring
(7) Spring
(8) Spring cup
(9) Throttle sleeve
(10) O-ring
(11 Housing
(12) Return line port, T
(13) Pressure relief valve
(14) Allen bolt
(15) Clip ring
(16) Lock nut
A+B Line ports
M Pressure check point
Y Control oil drain port
Function:
Setting of the maximum permissible cylinder speed (flow B to A) is carried
out by spindle (1). Depending on the spindle setting, the radial holes (9.1) in
the valve poppet (9) will be partially opened to achieve the required throttling
of the oil flow.
The extra holes (fixed throttle 9.2) prevents the valve from becoming
completely closed.
For the lifting operation (flow A to B), the valve poppet (9), which is guided
by the spindle (1), is pressed against spring (7) so that the valve will be
completely open.
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6.1.6 Anti Cavitation Valve Block
) • ACVs are installed to avoid cavitation damages on users (hydraulic

cylinders), by compensating a possible lack of oil, when the SRV at the
opposite side of the cylinder opens (see circuit diagram).

(Type 64.1 to 64.9 of the hydraulic circuit diagram)
(1) Housing
(2) Valve cone
(3) Spring
(4) O-ring
(5) Control and leak oil bore
(6) Cap screw (torque 900 Nm)
S Supply line (Return oil pressurized to approximately 10 bar by
back pressure valve)
A and B Line connections
Function:
The circuit pressure in the line A and B hold the valve cone (2) closed. The
pressure of the supply line 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
the circuit.
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6.1.7 Remote control valves
) • Remote control valves are part of the electric-hydraulic control system

(1) Pilot pressure supply port (marked with P)
(2) Pilot pressure return port to tank (marked with L)
(3) Pilot pressure output lines to the control block
(marked with A1/B1, A2/B2, . . . . )
(4) Directional solenoid valve, 3 position / 4 ports
(5) Proportional solenoid valve, (0 – 700 mA, 0 – 35 bar).
Function:
The electric-hydraulic control system is used to control the direction and
volume of oil flow to the operating cylinders and motors via the main control
valve blocks.
When a lever (or pedal) is actuated, a proportional solenoid valve (5) and one
of the directional solenoid valves (3 either Ax or Bx) are energized, and
allows the pilot pressure oil to flow to the spools of the main control blocks.
The proportional solenoid valve alters the pilot pressure, proportional to the
lever deflection, this results a spool movement between neutral and full
stroke position.
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6.1.8 Directional Solenoid Valves

(4/3 direction flow valve = 4 way / 3 positions)
) • This solenoid operated directional spool valves are installed to control

the start, stop and direction of an oil flow.

(1) Housing
(2) Solenoids
(3) Control spool
(4) Reset springs
(5) Plunger
(6) End cover
Function:
In un-operated condition the control spool (3) is held in the neutral or
starting position by the reset springs (4). Operation of the control spool is by
means of oil immersed solenoids (2).
The force of the solenoid (2) acts via the plunger (5) on the control spool (3)
and pushes its from its resting position into the required end position. This
results in the required free flow from P to A and B to T or from P to B and
A to T.
When the solenoid (2) is de-energised, the control spool (3) is returned to its
original position by the reset springs (4).
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6.1.9 Proportional Solenoid Valve
) • This valves are responsible for the creation of a variable control

pressure proportional to the electrical signal output of an amplifier.

(1) Proportional solenoid (5) Pressure measuring spool
(2) Control piston (6) Connection plug
(3) Valve housing (7) Return spring
(4) Pressure measuring spool (8) Bleed screw
Function:
In un-operated condition the control spool (2) is held in the neutral or starting
position by reset springs.
The control spool (2) is directly operated by the proportional solenoid (1).
If the solenoid is energized, it produces a force to operate the control spool (2) via
the pressure measuring spool (4) and moves the spool to the left. Oil flows from P
to A. As pressure in A increases, it passes via the radial borings in the control
spool (2) to the inner end of the pressure measuring spool (2).
The force generated by the pressure now works against the solenoid force and
pushes the control spool (2) to the right (closing direction) until a balance is
achieved between the two forces. In order to achieve this, the pressure measuring
spool (2) moves to the left until it is supported by the pin (5).
When the force balance is achieved, the connection between P and A is interrupted
and the pressure in line A is held constant.
Any reduction in the solenoid force leads to the pressure force exceeding the
solenoid force on the control spool (2). The control spool is then moved to the right
causing a connection from A to T allowing the pressure to fall until a balance is re-
established at a lower level.
At rest, when the solenoid is de-energized, ports A and B are open to tank, whilst
port P is blocked from both ports A and B.
W
• In order to achieve optimum functioning of the valve, it must be bleed
when commissioning:
- Supply pressure to the valve
- Remove plug 8
- When no more air bubbles appear screw in plug 8.
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6.1.10 High Pressure Filter
) • There is one filter in each pump line installed.

(1) Filter head
(2) Drain plug
(3) Filter case
(4) Hexagon
(5) Filter element
(6) Seal
(7) O-ring
(8) Back-up ring
(9) O-ring
(10) Spring
(11) Differential pressure switch
P1 Input pressure
P2 Output pressure
a Electrical connection
b REED contact
c Permanent magnet piston
d Spring
e Plug screw
Function:
High-pressure in-line filters prevent contamination from entering the
hydraulic circuits. The high pressure filters are installed between the main
hydraulic pumps and main control blocks. All hydraulic components, behind
the pumps, are effectively protected from damage and undue wear. Each filter
is equipped with a differential pressure switch to monitor the filter flow
restriction. If the pressure reaches an unsafe difference of 8.5 bar, a
visual/acoustic warning appears on the display in the cab and the engines will
be shifted automatically to low idle.
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6.1.12 Control Blocks and Valves
) • This is a principle drawing, showing valve block I, II and III.

(1) Control block housing
(2) Cab ("A side)
(3) Cap ("B" side)
(4) Solid spool
(5) "B" side service line ports
(6) Centering springs
(7) MRV, main relief valve
(8) Port A, to cylinder/motor
(9) Port B, to cylinder / motor
(10) Fine controlling grooves
(11) Port P, from pumps
(12) Port T, to tank
(13) Load holding valves
(14) Spin look spool extension (only block I and II)
(15) Spin look balls (only block I and II)
(16) Spin look cab extension
Control blocks with "Open Center and Closed Ports".

Control blocks I, II and III are 4 spool blocks and IV is a 1 spool block.
See hydraulic circuit diagram for spool details.
Each spool is provided with "Fine Controlling Grooves" and ring grooves for
hydraulically centering of the spool.
Between 8 and 19 bar pilot pressure the spools are moved in their fine control
range.
Spool number 4 of block I, 2 of block II and 4 of block III are special designed,
to keep the pressure channel connected to the center channel during the floating
function is activated, so that pump flow is available for other functions. This
spools are marked in the hydraulic diagram with (#) symbol.
The Load Holding Valves are installed inside of the spool, for each port to the
cylinder or motor one valve. The hydraulic diagram shows only one.
The MRV is a pilot operated pressure relief valve.
Control block I, II and III are equipped with a spool spin look system (item 14,
15, 16) to prevent spool spinning because of high oil flow during lowering
function.
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(1) Main relief valve (MRV)Control block housing
(2) Load holding valve
(3) Anti cavitation valve (ACV)
(4) Service line relief valve (SRV)
Explanation of the schematic drawing of the control block:

The hydraulic oil flows through the control block from port P to T, if all
spools are in neutral position ("pressure-less circuit" or “Free circulation“).
(A) 4 valve block

E.g. the spools moves up when pilot pressure is build up in the control pipe
line a1. (Imagine the lower symbol box moves to the center position.)
Now pump oil flows through holding valve (2) to the user port A1 because
the free flow circulation to the hydraulic reservoir is closed. The main relief
valve (1) limits the maximum operation pressure in this circuit. Via port B1
the return oil from the user is flowing back to the hydraulic reservoir.
During down hill travelling motion and stopping procedure (e.g. travel
motors) the anti cavitation valves (3) prevents cavitation on the hydraulic
motors. Because during these short periods of time the hydraulic motor needs
a higher oil supply than the pump can deliver.
E.g. the spool (4) moves up when pilot pressure is build up in the control pipe
A4. Now the user port A4 is connected to the pump pressure line and the free
circulation to the tank. There is no high pressure build up only 8 bar from the
back pressure valve and line resistance. Via port B4 the return oil from the
user is flowing back to the hydraulic reservoir. Service line relief valve (4) is
additional installed in this circuit to protect the circuit for extreme pressure.
The shortly extreme pressure closes also the holding valve (2) which secures
the hydraulic pump from extreme pressure peaks.
The holding valves (2) have also the function of load holding valves because
during the fine controlling period all lines are connected together (negative
over-lapping). The load pressure is for a moment higher than the pump
pressure.
(B) single valve block
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(1) Spool
(2) Reset springs
Function:
Reset springs (2) moves the spool (1) in neutral position.
Fine control grooves provide for sensitive controlling, because a motion is

started always while the pressure oil and the return oil first passes this fine
control grooves before spool (1) is inter connecting the entire groove to the
user channel.
In neutral position of spool (1) the pump oil is flowing back via port PU to the
tank.
Lower picture:
Example. The spool is moved by pilot pressure on the left spool side to right
position: Port PU is closed and the connection through the holding valve (3)
to the user (port A) is open. Also the connection from the other user side (port
B return)is connected to the port T (return line to tank).
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(01) Service -Line Relief Valve (9) Set screw
(02) Anti Cavitation Valve (10 Lock nut
(03) Main Relief Valve (11) Spring, pilot part
(04) Closing plate (12) Poppet
(5) Plug screw (13) + 16) Jet bore
(6) Spring (14) Spring, main cone
(7) Valve cone (15) Main valve cone
(8) Dust cap (17) Pilot oil dump line to tank
MRVs and SRVs are pilot operated relief valves. The MRV limits the max.
Pump supply line pressure. The SRV limits the max. possible pressure peak in
the service-line.
The valves have an „opening characteristic“. That means, that in case of
contamination after the response procedure no further pressure increasing is
possible and damages are avoided.
Function:
The circuit pressure P forces with the force F1 on the piston surface A of the
main valve cone (15). Because there is via the jet bore (16) the same pressure on
the back side of the main cone, this results together with the spring (14) force in
a force F2 that keeps the main cone closed. Via the jet bore (13) the circuit
pressure is in front of the poppet (12). Exceeds the circuit pressure the setting
value of the spring (11), the poppet opens against the force of the spring (11).
This causes that the force F2 decreases and there is no more balance condition
between F1 and F2. Valve cone (15) is moved upwards by the greater force F1.
That means there is now a direct connection from port P to T (tank).
ACVs serve for compensation possible lack of feed when the SRV at the
opposite port is actuated (see circuit diagram) and for avoiding cavitation
damages. In addition, to supply a user in case it is continuously moved by
acceleration forces at zero position of the control spool.
Function:
The circuit pressure inside the spring chamber closes the valve cone (7).
The back pressure of the return line acts on the surface of the valve cone (7).
Whenever the pressure in the service-line is lower than the springs force the
valve cone opens by the force of the back pressure and hydraulic oil is additional
supplied.
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6.1.12 Load Holding Valve

(1) Spool
(2) Reset springs
Control Blocks I to IV (4 spool blocks and single spool block)

Two load holding valves are fitted into each spool of the control blocks, one
valve for each port (A and B).
They have three tasks:

1. When circuit pressure due to attachment weight is higher than pump
pressure these valves prevent dropping of the attachment, within their
sensitive (fine controlling) range.
2. Due suddenly pressure peaks in the service lines the valves also protect
the pump.
3. When two pumps flows are used for one user they ensure that at least
the flow of one pump reaches the user in case one MRV is defect or not
more correct adjusted.
That means: Up to the max. Pressure of the defective valve both load holding
valves are open allowing the flow of both pumps to the user, then one valve will
be closed by the higher pressure and the flow of one pump only flows to the
user.
Function:
The system pressure forces onto the front area of the valve cone (1). This force
moves the valve cone against the spring and allows the oil to flow from the
pump through the spool centre to the port.
In neutral position of the spool no further flow is possible. (see circuit diagram)
If the spool is not more in neutral the flow continues to the user.
If due to an external force the pressure directed to the pump overcomes the
pump line pressure, this pressure forces the valve onto its seat (closed position)
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6.1.13 Travel Brake Valve
Illustration Z 21695
Task:
Travel brake valves control the oil flow from the hydraulic motor to the tank
depending on operating pressure. This braking action prevents the motors from
over speeding.
Function:
Spring force keeps the spool in the lowest flow position. with increasing
operating pressure the opening for the return oil flow becomes larger.
On its way to the hydraulic motor the oil flows from A to A1 respectively from
B to B1 depending on the selected travel motion.
Example:
Operating pressure at port A moves spool (1) against the force of the spring (2)
and opens the way for the return oil (B1 to B).
Holding valve (3) prevents a direct oil flow from B1 to B.
If the operating pressure decreases to such an extend that the spring force
overcomes the pressure, the flow to the tank becomes restricted, resulting in
braking of the machine.
For more information and adjustment see section 8.3.
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6.1.14 Pressure Reducing Valve
) • Pressure reducing valves are installed to reduce the common 35 bar

pilot pressure to a lower pressure for other systems, e.g. the pump
regulation system.

(1) Set screw
(2) Spool
(3) Compression spring
(4) Threaded sleeve
(5) Non return valve
(6) Boring
(7) Spring chamber
(8) Control land
Function:
Pressure reducing valves type DR & DP are direct operated valves of 3 way
design, e.g. with a pressure relief function on the reduced pressure side.
At rest, the valve is normally open, and fluid can flow unhindered from port P
to A. Pressure in port A is also present on the end of the spool (2), via control
line (6), opposing the compression spring (3). When the pressure in port A
reaches the pressure level set at spring (3), spool (2) moves to the control
position and holds the pressure in port A constant.
Fluid to control the valve is taken from port A via the boring (6).
If the pressure in port A rises still further due to external forces, the spool (2)
is moved still further towards the compression spring (3).
This causes a flow path to be opened over control land (8) in the control spool (2)
to tank. Sufficient fluid then flows to tank to prevent any further rise in pressure.
An optional non return valve (5) is available to allow free flow from A to P.
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6.1.15 Directional Solenoid Valves (2 positions / 4-ways)
) • This solenoid operated directional spool valves are installed to control

the start, stop or direction of an oil flow.

(1) Housing
(2) Solenoid
(3) Control spool
(4) Return spring
(5) Plunger
(6) Dust cap with stem for manual operation
Function:
When there is no flow through the valve, control spool (3) is held in neutral
or output position by means of the return springs (4). The control spool (3) is
operated by means of oil immersed solenoid (2).
The force of the solenoid (2) effects control spool (3) by means of the plunger
(5) and pushes it from its resting position to the required end position.
This results in free flow from P to B and A to T.
When solenoid (2) is de-energized, control spool (3) is moved back to its
resting position by means of return springs (4).
An optional hand emergency (6) allows movement of the control spool (3)
without energizing the solenoid.
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6.1.16 Pressure Increasing Valve
) • The pressure increasing valve is a remote controlled pressure relief

valve, actuated by hydraulic pressure. The individual pressure is in
such a way determined by the pilot pressure.

(1) Pilot valve with valve seat
(2) Valve poppet
(4) Main valve with sleeve
(5) Main piston
(6) Closing spring
(7+8) Set screws
(9) Piston
(10) Pin
(11+12) Jet bore
(13+14) Lock nut
Function:
The valve poppet (2) is connected via the jet bores (11) and (12) with the
pressure port (P).
If static pressure increase above the set pressure value, the valve poppet (2)
opens and allows oil to flow freely via port (T1) to tank. This out flowing oil
generates a pressure drop in the spring chamber of the main spool (5). The
closing force of the spring (6) is now lower as the oil pressure from the
pressure port (P) and the main piston (5) opens to release pressurized oil to the
tank via port (T2).
Damped opening and closing is obtained by the throttled volumetric change.
By applying external pressure of Pst max = 35 bar to the main spool (9) via
port X, the pre-tensioning of the pressure spring (3) is increased by the amount
of the piston stroke "S" and system pressure is increased correspondingly.
The maximal possible pressure (P) adjustment is 440 bar with max. control
pressure at port X.
The lower setting is fixed by means of the setting screw (7) and lock nut (13);
1 turn of setting screw reduce or increase the pressure about ~150 bar.
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Main Hydraulic Pumps Section 7.0
and Page 1
Pump Regulation System
Section Page
7.0 Main hydraulic pumps and pump regulation system
General 2–5
7.1 Main Pumps
7.1.1 Location of Pumps 6
7.1.2 Pump bearing flushing / lubrication 7
7.1.3 Operating Principles 8 - 15
7.1.4 Checks and Adjustments 16 - 20
7.2 Electronic Pump Regulation System
7.2.1 Electronic load limiting control - General 21
7.2.2 Electronic Power Module EPM 22
7.2.3 Electronic Signal Rectifier ESR 23 - 24
7.2.4 Microcontroller MC7 25
7.2.5 Checks and adjustments - General 26
Method A - With 24V supply to terminals
- X1- pressure adjustment 27
- Demanded power adjustment 28 - 29
- PID – Factor adjustment 30
Method B - With the electronic service tool BB-3
- Language selection 31 - 32
- Adjustment mode SET1 and SET2 33
- Number of motor selection 34
- X1-pressure (max. current) adjust. 35
- Demanded power adjustment 36
- Storage new settings 38
Method C - With a laptop and BODEM software
- Starting the program 39 - 40
- Language selection 41
- Entering of the password 42
- Number of Motor selection 43
- X1-pressure (max. current) adjust. 44
- Demanded power adjustment 45 - 47
7.3 Hydraulic Constant Regulation System
7.3.1 General 49
7.3.2 X1-pressure adjustment (constant-pressure) 50
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and Page 2
Pump regulation system general

(1 - 6) Main hydraulic pumps
(7.1) Pilot pressure pumps, motor 1
(7.2) Pilot pressure pumps, motor 2
(68.1) Pilot pressure filter unit
(70.1) 60 bar pressure relief valve
(70.2) 35 bar pressure relief valve
(Y17) Solenoid valve: "Idle time control and low hydraulic oil temperature"
Q-min flow for all main pumps
(Y17a) Solenoid valve: "Remote control pressure" ½ Q-max flow reduction
for all main pumps (low hydraulic oil temperature)
(Y102-1) Solenoid valve: "Pump regulation support pressure and pump bearing
lubrication"
(Y102-2) Solenoid valve:
"Pump regulation support pressure and pump bearing lubrication"
(81.1) Pressure reducing valve: "Remote control pressure" ½ Q-max flow re-
duction for the warming-up period
(81.2) Pressure reducing valve: "Pump regulation pressure X1 at hydraulic
pump regulation" (Hydraulic constant regulation mode)
(Y61-1) Proportional solenoid valve: "Pump regulation pressure X1 at electronic
pump regulation, motor 1" (Standard operation mode)
pump regulation, motor 1" (Standard operation mode)
(79.1) Change over valve: "Electronic or Hydraulic pump regulation", motor 1
(79.2) Change over valve: "Electronic or Hydraulic pump regulation", motor 2
7.0
3
and Page 3
Controlled output flow of the main pumps is necessary:

• To utilize the available motor power most efficiently in every operating mode.
• To limit the power consumption of the hydraulic pumps depending of the load of
the motor. (Electronic pump regulation with micro-controller MC7)
• For additional functions, such as rotating dependent or temperature-dependent flow
reduction.
Function:
X1 – pump regulation pressure (0 – 24 bar):

The power controller of the main pumps can be remotely controlled by applying an ex-
ternal pilot pressure (X1 ) at port X LR to the spring chamber of the power control valve.
The start of destroking can be varied in proportion to the applied X1 - pressure.
X2 – pilot pressure (35 bar):

Constant pilot pressure to regulate the main pumps at special circumstances, e.g. to fix
pump # 3 in Q-max position (pump for swinging.)
X3 – remote control pressure (0 / 16 / 35bar):

Basic setting Q-min (0 bar), the flow rate increases with the
pilot pressure X3 at port Pst, up to Q-max (35 bar).
The hyperbolic power control is superimposed on the pilot pressure
signal and keeps the specified drive power constant. (p x Vg = constant).
The flow rates are:
Q-min.: X3 = 0 bar
½ Q-max.: X3 = 16 bar
Q-max.: X3 = 35 bar
X4 – pump support pressure (60 bar):

Constant pilot pressure to support the regulation function at low operating pressure and to
lubricate the main pump bearings.
7.0
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and Page 4
Function:
Solenoid valve Y17: (33/7)*

If de-energized pumps #1-6 are in Q-min position. It gets energized as soon as one of
the control levers/pedals has been operated and de-energized when ever all controls
are in neutral position for more than 20 seconds.
Solenoid valve Y17a: (33/5)*

The solenoid is de-energized as long the hydraulic oil temperature is below the val-
ues of temperature range „T2“ (depending on the filled in hydraulic oil) shown in the
table. ( pumps #1-6 are in ½ Q-max. position)
Note: * Electric circuit diagram page / column (based on Id # 897 899 40)
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and Page 5
Function:
Proportional Solenoid valve Y61-1 and Y61-2: (40/2)*

This valves, connected to the MC7 micro-controller E32 (electronic pump regula-
tion), creates a X1-pressure depending on the load of the motor.
This X1-pressure is the information to reduce pump delivery, in order to keep the
motor at rated power.
Pressure reducing valve 81.1:

"Remote control pressure" (X3)
- ½ Q-max flow reduction during the warming-up period for all pumps by the
function of solenoid valve Y17a.
- ½ Q-max flow reduction only for pump #1 while swinging with max. speed by
the function of solenoid valve Y126.
Pressure reducing valve 81.2:

Pump regulation pressure X1 at "hydraulic pump regulation" (Hydraulic constant
regulation mode) by the function of change over valve (79.1 / 79.2). One valve for
both motors. This valve create a constant X1 pressure, the pressure can be change for
different pump regulation checks and adjustments.
Change over valve 79.1 and 79.2:

Change over three way cock valve to select "Electronic or constant regulation
mode", one for each motor.
Note: * Electric circuit diagram page / column (based on Id # 897 878 40)
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and Page 6
7.1 Main Pumps
7.1.1. Location of Pumps

(1 - 6) Axial piston pump (swash plate type)
theoretical flow rate, each Qmax = 700 Liter/min
for all working motions pmax = 310 bar
(10.2), (10.4) Axial piston pump

for oil cooler fan drive pmax = 180 bar
(8.1), (8.4) Gear pump

for PTO gear lubrication pmax = 7,5 bar
(8.2), (8.5) Gear pump

for hydraulic oil circulation pmax = 15 bar
(7.1), (7.2) Gear pump

for pilot pressure supply pmax = 60 bar
) • * at 1500 min-1 input drive with electric motor speed

7.0
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and Page 7
7.1 Main Pumps
7.1.2. Pump bearing flushing / lubrication

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 reach the restricted guidance of the coolant for external bearing flushing, the throt-
tle screw (located behind the union at port U) must screwed in all the way.
An information sign is fixed at the pump.

(1 – 4) Main pumps
(147.1-147.6) Orifice (one for each main pump)
(33) Filter for pilot pressure
(P) Ports for X4-pressure (pump support pressure)
(U) Port for the pump bearing flushing / lubrication
7.0
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and Page 8
7.1 Main Pumps
7.1.3 Operating Principles

Main hydraulic pump A4VSO 500 LR3DN / 30L
Type code explanation:
A4VSO 500 LR 3 D N / 30 L
Rotation
Series
Basic adjustment for minimum displacement
With pressure control
Hydraulic remote adjustment facility
Constant power with hyperbolic curve
Max displacement in cm3 at one (1) revolution
Axial piston pump series 4, variable displacement ,swash plate design for open circuits
Function and characteristics:

• The A4VSO variable displacement axial piston pump in swash plate design is
intended for drives in open circuit operation.
• The flow volume is proportional to the drive speed and the displacement. By
adjusting the swash plate a infinitely variable flow adjustment is possible.
• Pumps of the same nominal size can be built onto the trough drive. Combina-
tions with gear pumps are also possible.

The lower illustration shows only a principle pump construction
(1) Drive shaft
(2) Cylindrical roller bearing
(3) Slipper pad
(4) Swivel angle indicator
(5) Positioning piston
(6) Swivel pin
(7) Cylinder with pistons
(8) Final connecting plate
(9) Cylindrical roller bearing
(10) Splints for the through drive coupling (Aux. pump drive)
(11) Swivel cradle
(12) Q-min stop bolt
(13) Power control valve
(14) Pressure balance valve
(15) Power curve correction
(16) Pressure cut off valve
(17) Q-max. stop bolt
(18) Remote control valve
continued
7.0
9
and Page 9
7.1 Main Pumps

Cont'd:
Symbol of main hydraulic pump A4VSO 500 LR3DN / 30L
(1) Main pump (swash plate pump, variable displacement)
(2) Pump bearing group
(3) Drive shaft
(4) Non return valves
(5.1) Mechanical stroke limitation*
(5.2) Remote pressure (PST) operated piston for item 6
(5.3) Mechanical stroke limitation*
(6) Spool valve (pressure balance valve)
(7) Nozzle
(9) Nozzle
(10) Pressure cut-off valve
(11) Auxiliary pump (Gear pump, fixed displacement
(13) Slipper pad piston
(14) Lever
(15) Cam
(16) Through drive shaft
)
• * Factory side adjusted, no field adjustment required
B/B1 Pressure port

S Oil intake (suction port)
MB Operating pressure check point
Mst Control pressure check point
R(L) Filler and bleeder port
T, K1, K2 Connection port for chip indicator
P Pump support pressure (”X4”-pressure)
Pst Remote control pressure port (”X3”-pressure)
U Bearing flushing port
XLR Regulating pressure port (”X1”-pressure)
continued
7.0
10
and Page 10
7.1 Main Pumps

Cont'd:
Sectional drawing of Power Controller LR3DN / 30L

(5.1) Mechanical stroke limitation
(5.2) Remote pressure (PST) operated piston for item 6
(5.3) Mechanical stroke limitation
(6) Spool valve (pressure balance valve)
(13) Slipper pad piston
(14) Lever
) • Refer also to illustration Z 22447 on the previous page.

7.0
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and Page 11
7.1 Main Pumps
7.1.3 Operating Principles, illustration (Z 21552a)

Cont'd:
Q-min position: (remember Q means volume)
When are the pumps in Q-min position?

A: Motor at standstill
B: Motor running and the controls are not used for 20 sec. or longer
at low operating temperature
C: Motor running and service switch S150 activated
Example C with the following conditions:

• Motor running
• Pump pressure lower as X4 = 60 bar (pump support pressure)
• X1 = 24 bar (pump regulation pressure), this pressure will not influence
the Q-min position under these conditions.
• X3 = 0 bar (remote control pressure); Y17 de-energized (S150 activated)
for pumps #1, #2 #4, #5, #6 and #3 except during swinging than the pump
is out of regulation and keeps in Qmax.
• X4 = 60 bar (pump support pressure)
Pump support pressure is present at valve #6, the slipper pad of
piston #13 and the small area side of the positioning piston #12
Response of pump control mechanism:

Valve #6 moves to position "b" because the X4-pressure will overcome the spring
force, since the oil behind nozzle (7) flows through valve #5 (which is in position
"a", due to the missing remote control pressure X3) back to tank.
Pump support pressure X4 passes valve #6 position "b" and flows via power control
valve #8 position "a" to the large area side of positioning piston #12.
Because the large area side of positioning piston #12 is approximately three times larger
as the small area side, the pump support pressure X4 of 60 bar present on both sides, re-
sulting in stronger force at the large area side, keeps the pump in Q-min position.
The pump remains in Q-min position

continued
7.0
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and Page 12
7.1 Main Pumps

Cont'd:
Q-max position: (remember Q means volume)

When does the pumps move into Q-max position?
Motor running
and hydraulic oil at normal operating temperature (> T2)
and the controls frequently used within 20 sec.
(or Service switch S151 activated)
and a pump pressure below start of de-stroking.
Example with the following conditions:

• Motor running
• Pump pressure between 60 bar and 300 bar, present at the slipper pad
of piston #13 and the small area side of the positioning piston #12
• X1 = 24 bar (pump regulation pressure)
• X3 = 35 bar (remote control pressure); Y17 and Y17a energized
for all six pumps.
• X4 = 60 bar (pump support pressure), present at valve #6.

Valve #6 moves to position "a" because the spring force is supported by the X4-
pressure, since the oil flow back to tank is blocked at valve #5 (which is in position
"b", due to the 35 bar remote control pressure X3).
The large area side of positioning piston #12 is connected, via power control valve
(8) position "a" and pressure balance valve (6) position "a", to the return oil line.
The pump moves into Q-max position, because the pump pressure acts only at the
small area side of positioning piston #12.
The pump moves into Q-max position
continued
7.0
13
and Page 13
7.1 Main Pumps

Cont'd:
½ Q-max position: (remember Q means volume)

When does the pumps move into half Q-max position?
Motor running
and hydraulic oil below normal operating temperature (< T2)
and the controls frequently used within 20 sec.
(or Service switch S151 activated)
and a pump pressure below start of de-stroking.

• Motor running
• Pump pressure between 60 bar and 300 bar, present at the slipper pad
of piston #14 and the small area side of the positioning piston #13
• X1 = 24 bar (pump regulation pressure)
• X3 = 16 bar (remote control pressure); Y17 energized and Y17a de-
energized
for all six pumps.

Valve #6 moves to an intermediate position (in-between "a" and "b"), since a certain
amount of oil behind nozzle (7) flows through valve #5 (which is also in an interme-
diate position, due to the 16 bar remote control pressure X3) back to tank.
The large area side of positioning piston #12 is connected, via power control valve
(8) position "a" and pressure balance valve (6), to the return oil line.
The pump moves into ½ Q-max position, because the return oil flow through pres-
sure balance valve (6) is restricted (due to its intermediate position), resulting in a
pressure at the large area side of the positioning piston (12).
The pump moves into ½ Q-max position
continued
7.0
14
and Page 14
7.1 Main Pumps

Cont'd:
Destroking: (Pump moves from Q-max. into of Q-min. direction)
When does the pumps start to destroke

Motor running
and hydraulic at normal operating temperature (> T2)
and Service switch S150 deactivated
and The hydraulic load is higher than the rated power of the motor.
⇒ (The electronic pump regulation system will reduce the X1-pressure)
or With pump pressure above ≈ 150 bar (Hydraulic constant regulation)
(Constant X1-pressure of approximately 8 bar)

• Motor running
• Pump pressure 260 bar adjustable at main relief valve, present at the slipper
pad of piston #13 and the small area side of the positioning piston #12
• X1 = 12 bar (constant regulation pressure adjustable at pressure reducing
valve 81.2) Change over valve (79.1 / 73.2) switched to hydraulic mode
• X3 = 35 bar (remote control pressure); Y17 energized and Y17a energized

Valve #6 moves to position "a" because the spring force is supported by the X4-
pressure, since the oil flow back to tank is blocked at valve #5 (which is in position
"b", due to the 35 bar remote control pressure X3).
The operating pressure (with the value for start of de-stroking) at the slipper pad of
piston #13 moves the power control valve (8) into position "b" (against the spring
force supported by the X1-pressure).
This in turn connects the operating pressure to the large area side of positioning pis-
ton #12.
Because the large area side of positioning piston #12 is approximately three times
larger as the small area side, the operating pressure present on both sides, resulting in
stronger force at the large area side, moving the pump in Q-min direction.
The pump de-strokes until the forces at positioning piston #12 are balanced
continued
7.0
15
and Page 15
7.1 Main Pumps

Cont'd:
Pressure cut-off valve: (DR control valve, Pump moves into Q-min. position)
When is the pressure cut-off valve active?

Motor running
and With pump pressure above ≈ 300 bar

Motor running
Pump pressure 300 bar
X1 = 24 bar (pump regulation pressure)
X3 = 35 bar (remote control pressure)
X4 = 60 bar (pump support pressure)

Independent of the position of power control valve #8 the pressure cut-off valve #10
causes the pump to de-stroke to the pre-adjusted Q-min position.
The operating pressure moves the pressure cut-off valve #10 (at set pressure) into
position "b" and flows to the large area side of positioning piston #12.
Because the large area side of positioning piston #12 is approximately three times
larger as the small area side, the operating pressure present on both sides, resulting in
stronger force at the large area side, moving the pump in Q-min position.
The pump moves into Q-min position

7.0
16
and Page 16
7.1 Main Pumps
7.1.4 Checks / Adjustments
Location of Adjustments
Legend for , illustration (Z21557)
(2) Q-min. stop bolt
(3) Pressure balance valve
(4) Start of destroking
(5) Power curve correction
(7) Q-max. stop bolt
(8) Angle indicator
The average length of the measurement "L" is: set screws (bolts)
location Length “L” (mm)

1 13.4
2 21.9
3 7,6
4 8.1
5 ----
6 6.0
7 27.6
) • The measurement "L" is an orientation only if the adjustment is to-

tally out of requirements.
They must not be used for final adjustments.
The detail for (5) shows the position of the housing edge and the edge
of the eccentric set bolt. The example shows them in parallel position
which is mostly not the case. The adjustment should never be altered.
Further information see next pages

7.0
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and Page 17
7.1 Main Pumps
Pressure balance valve (Δ P 20bar), illustration (Z21558)
Pressure balance valve, illustration (Z 21558b)
• The pressure balance valve is bench adjusted. There is no field set-

ting with a sufficient result possible.
continued
7.0
18
and Page 18
7.1 Main Pumps

Cont'd:
Start of destroking(LR valve), illustration (Z21559)
The reason of this check is to make sure, the pump starts destroking at an operating
pressure of 150 bar with a pump regulation pressure X1 of 0 bar.
1. Connect a 400 bar pressure gauge to the pressure check point at the respective
high pressure filter for the pumps being checked.
2. Connect a 25 bar pressure gauge to respective pressure check point M20-1 or
M20-2 at the control and filter panel (X1-pressure).
3. Change over the respective three way cock to electronic regulation.
4. Unplug the respective proportional valve Y61.1 / Y61.2.
5. Insert an Allen key into the angle indicator bolt (see illustration) for better visi-
bility of the start of.
6. Start the respective motor. The X1-pressure should be 0 bar.
7. Stall the hydraulic for the pump to be checked and alter the operating pressure
with the MRV between 140 and 160 bar.
Start of de-stroking should be at an operating pressure of 150 bar, shown at the
gauge connected to the high pressure filter.
If readjustment is required proceed as follow:

a) Adjust with the MRV an operating pressure of 150 bar.
b) Loosen lock nut #6 (Power control valve).
c) Turn set bolt #7, so that the pump is still in Q-max. position,
but just at the beginning of de-stroking.
d) Tighten lock nut #6.
8. Re-adjust the operating pressure at the MRV to 310+10 bar and plug on the
Y61.1 resp. Y61.2
(For exact values refer to the final test report.)
9. Remove Allen key and gauges.
continued
7.0
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and Page 19
7.1 Main Pumps
7.1.4 Checks and Adjustments

Cont'd:
Pressure cut-off valve (DR control valve), illustration (Z21560)
The sense of this check is to make sure that the pump is in Q-min. position at an op-
erating pressure between 300 bar and 310 bar.
1. Connect a 400 bar pressure gauge to the pressure check point at the respec-
tive high pressure filter for the pumps being checked.
2. Insert an Allen key into the angle indicator bolt (see illustration) for better
visibility of the start of de-stroking.
3. Start the respective motor, stall the hydraulic only for the pump to be
checked and alter the operating pressure with the respective MRV between
280 and 310 bar.
• Stall only one pump per motor to prevent an influence of the regula-
tion system..
Recommendation to stall the respective pump with FSA:

Pump 1 and 6: a) Unplug solenoid valve Y16 (park brake travel motor active)
b) Activate carefully the left travel motor with full pressed
pedal in one direction
Pump 3 and 4: a) Activate carefully the clam open function and keep it in final
position
Pump 2 and 5 a) Unplug solenoid valve Y16 (park brake travel motor active)
b) Activate carefully the right travel motor with fully pressed
pedal in one direction and keep it in this position.
4. The angle indicator must indicate Q-min. position at a pressure of 300 bar
shown at the gauge connected to the high pressure filter.
If readjustment is required proceed as follow:
a) Loosen lock nut #8.
b) Turn set bolt #9, so that the pump is in Q-min. at the required value.
c) Tighten lock nut #8.
5. Re-adjust the operating pressure at the MRV to 310+10 bar
6. Remove Allen key, gauges and plug in the unplugged plugs.
continued
7.0
20
and Page 20
7.1 Main Pumps

7.1.4 Checks and Adjustments
Cont'd:
Q-max. and Q-min. stop bolt, illustration (Z21561)
1. Unscrew box nut (10 or 14).

2. Loosen the lock nut (11 or 13)
3. Turn the stop (12 or 15) in or out until required length
Length "X" or "Y"
5. Tighten the lock nut and screw on box nut (12).
• Turning the Q-min. stop bolt too much out can cause serious damage
to the pump.
The pump moves over 0 (zero) position into the opposite drive direc-
tion: (suction line becomes pressure line and pressure line becomes
suction line)
7.0
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and Page 21
7.2.1 Electronic load limiting control - General, illustration (Z 22448)
The drive train of the excavator consists of two electric motors, several hydraulic pumps,
which supply cylinders and hydraulic motors.
The load limiting control ensures optimum use of the power required for the excavator
under varying operating conditions and avoiding overload of the motors.
Illustration Z22407a shows the principle of the electronic load limiting control.
The MC7 (E32-1) processes the following input signals:
• Voltage (Pin 47) from electronic signal rectifier (A32)
• Current motor 1 (Pin 45) from electronic signal rectifier (A33-1)
• Current motor 2 (Pin 46) from electronic signal rectifier (A33-2)
The MC7 (E32-1) processes the following output signals:

• Signal value to control the proportional solenoid valve Y61-1 (Pin 28) Motor 1
• Signal value to control the proportional solenoid valve Y61-2 (Pin 30) Motor 2
• Switch signals (Pin 32 and 33), diagnostic of the MC7 (E32-1)
Each electric motor drives three variable displacement pumps by means of a PTO-
gearbox. Each pump is equipped with a hydraulic power controller (HPC).
This controller limits the input torque of the pump to an adjusted command value (X1-
pressure, for start of destroking).
The command value (X1-pressure) is present via proportional solenoid valves Y61-1 re-
spectively Y61-2 at the hydraulic power controllers of each pump.
) • The auxiliary hydraulic pumps and other consumers can be operated

without being directly affected by the load limiting control.
Function:
The ESR-Module (A32) transforms an AC Voltage, which is proportional to the net volt-
age, into a proportional DC Voltage and transfers it into the MC7 (E32-1).
The ESR-Module (A33-1 + A33-2) transforms an AC Voltage, which is proportional to the
respective motor current, into a proportional DC Voltage and transfers it also into the MC7
(E32-1).
These input signals are the information about the actual load to the motors and serves the
MC7 (E32-1)
The control algorithm of the load limiting control (MC7) always compares the actual re-
quired power with the rated power.
With increasing load the motor torque will rise and in turn the required power.
For this reason the electronic load limiting control will be initiated when the required
power is higher than the rated power, i.e. the torque of the main pumps will be lowered (by
reducing the X1-pressure) until the rated power is attained again.
7.0
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and Page 22
7.2.2 Electronic Power Module EPM, illustration (Z 22624b)
The power – Module A31a transforms the 24 VDC battery voltage into posi-
tive/negative 15 VDC and the power Module A31b into positive 5 VDC which is the
supply voltage for the ESR Modules.
Function check:
Measure the supply voltage. (24 VDC; GND = 0 V).
If the supply voltage is not there, check the supply cable and the circuit breaker. If
the circuit breaker always trips there may be a short within the cables to the Power
Module or a short in the unit itself.
If the supply voltage is ok. the Output Voltages have to be checked.
Check pos. 15 VDC, neg. 15 VDC, 5 VDC to GND.
If the supply voltages are not ok. the short circuit monitoring system of the Power
Modules might be activated, therefore disconnect the cables at the terminals
(+15 VDC, -15 VDC and +5 VDC) and repeat the voltage check.
If now (with disconnected cables) the voltages are as they should be there is ei-
ther a short within the cables or in the other modules itself. To determine the fault
connect the entire modules in sequence.
If the voltage is not ok., even when the cables are disconnected from the Power
Module, the Module is defect.
7.0
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and Page 23
7.2.3 Electronic Signal Rectifier ESR – Modules, illustration (Z 22625a)

Function:
The ESR-Module transforms an AC signal-voltage, which is proportional to the net-
work voltage respectively the motor current, into a proportional DC Voltage and trans-
fers it into the MC7.
Testing the ESR-Module, A32 + A33.1 + A33.2
Testing the ESR input/output voltage

For a transformer function test the AC-Input Voltage and the
DC-Output Voltage must be measured and compared.
• The potentiometer settings are under no circumstances

allowed to be altered, because the setting is possible only with a HF-
Generator and an Oscilloscope.
• If the potentiometer set-positions have been altered, a new Module,
with sealed potentiometers, must be ordered.
Procedure: Same procedure for all three Modules
1. Disconnect the wire from terminal 23 of the ESR Module.
2. Start the motor and let it run without an extra load on it.
3. Measure the AC-Voltage between the terminals 21 and 41 and record it.
4. Measure the DC-Voltage between the terminals 23 and 11 and record it.
5. The measured DC-Voltage must be 1/4 of the AC-Voltage.
Example: 2.5 VDC

________ = 1/4 = 0,25 (1 % plus/minus is ok)
10 VAC
Small variations are based on amplitude variations of the AC-Input voltage while
measuring the DC-Output voltage.
Greater variations denotes a faulty ESR Module.
continued
7.0
24
and Page 24
7.2.3 Electronic Signal Rectifier ESR – Modules, illustration (Z 22626a)

Cont'd:
The DC-Output Voltage (UaDC ) can be compared with a calculated Voltage Value.
The calculation can be done with the ratios of the intermediate transformers given in
the circuit diagram, and by the Voltmeter and Ammeter readings of the cab gauges.
) • The picture shows a schematic design only and not the actual circuit
diagram, the voltage- and current values may vary, therefore they are
exemplary used.
With the below shown formulas the exact Output Voltages UaDC of an ESR can be
calculated.
Small variations are caused by the transformers.
Variations greater than 20 % denotes a faulty transformer.
EXAMPLE FOR ESR 1:

U 6570 V
ESR1 ----------------- --------------- = 2,488 VDC Voltage
T1 x T2 x T3 66 x 10 x 4
EXAMPLE FOR ESR 2:

I 80 A
ESR2 ----------------- ----------------- = 1,333 VDC Current Motor 1
T1 x T2 x T3 30 x 0.5 x 4
EXAMPLE FOR ESR 3:

I 75 A
ESR3 ----------------- ----------------- = 1,25 VDC Current Motor 2
T1 x T2 x T3 30 x 0.5 x 4
The AC Input Voltage for an ESR-Module can be calculated with the same formula
but without the value for T3.
EXAMPLE FOR ESR 2:

I 80
ESR2 ----------- ----------- = 5,333 VDC
T1 x T2 30 x 0.5
7.0
25
and Page 25
7.2.4 Microcontroller MC7, illustration (Z 21716)

The MC7 microcontroller is used for the programmable control of a maximum of four
proportional solenoids and two additional switching functions.
As input signals, the microprocessor processes analog voltages in the 0V to 5V range
and switching information. All inputs are protected against over-voltage and electrical
interference.
As output signals, the output stages of the MC7 deliver closed loop controlled currents
for the connection of proportional solenoids.
The analog voltage output is suitable for the simple forwarding of analog information to
other electronic circuits.
Characteristics
• Closed loop control of solenoid currents, i.e. independent of voltage and temperature.
• Pulse width modulated (PWM) solenoid currents for minimal hysteresis.
• Internal buzzer for programmable monitoring of functions or errors.
Setting and Display Facilities
All calibration operations and the display of functions, faults and system variables are con-
nected via the serial interface to the BB-3 control panel or to a PC running the BODEM
software.
MC7 - Unit Dimensions
Plug Contacts
8 junior power timer contacts

47 micro timer I contacts
MC7 - Block Circuit Diagram
7.0
26
and Page 26
7.2.5 Checks and adjustments General

Microcontroller MC7, illustration (Z 21714c)
The adjustment of the X1-pressure can be done with three different methods:
A. With 24V supply to separating terminals at the X2-switch board
or
B. With the electronic service tool (EST) BB-3 connected to the serial inter-
face X13-1 (located in the operators cab)
or
C. With a laptop, running the BODEM software, connected to the serial inter-
face X13-1 (located in the operators cab)
) • Procedure B and C should only be carried out by authorized person-

nel. [ Dealer or KMG-factory staff ]
Because it is possible to influence the behavior of the pump regulation
system.
On the following pages are only the necessary setups described.
If additional information is required, please contact KMG-Service de-
partment.
7.0
27
and Page 27
7.2.5 Checks and adjustments Microcontroller MC7, illustration (Z 22628)

Method A - X1-pressure adjustment
with 24V supply to separating terminals at the X2-panel.
Pre-conditions: Normal operating temperature, correct pilot pressure setting and the
system must be free of air.
1. Make sure the change over valves (79.1 – motor 1 respectively 79.2– motor 2) are in
position “Electronic Pump Regulation”
2. Connect a pressure gauge to the respective check points (M20.1 or M20.2), using a
long pressure gauge hose to be able reading the pressure in front of the X2-panel.
3. Selection of adjusting mode:
Turn the main key switch in on position and activate the adjusting mode as follows:
Connect 24V, simultaneously to terminal 54 and 55 for 10 seconds, using two test
leads and disconnect the voltage thereafter.
4. Selection of the motor and in turn the required
proportional solenoid valve :
With the main key switch still in on position, select the applying terminal for propor-
tional solenoid valve Y61-1 or Y61-2 as follows:
Motor1 →Y 61-1 → No connection to 24V required.
Motor2 →Y 61-2 → Connect permanent 24V to terminal 53, using a test lead.
5. Adjusting the X1-pressure:
Start the respective motor.
Read the pressure, required = 24± 0,5 bar
If necessary increase the X1-pressure as follows:
Connect 24V to terminal 54.
)
• As long as voltage is supplied, the X1-pressure drops to zero.
After interrupting the voltage supply, the gauge pointer will move
slowly to the new present X1-pressure.
• Example: Keeping voltage supply for two seconds , will increase the
X1-pressure of approximately 1bar.
• The adjusted value will be saved immediately and will be available
after power off.
6. To decrease the X1-pressure connect 24V to terminal 55 and proceed as described
under item 5, keeping voltage supply for two seconds , will decrease the X1-pressure
of approximately 1bar.
7. After the adjustment is finished, remove the test leads and pressure gauge and turn
the main key switch in OFF position to deactivate the adjusting mode.
continued
7.0
28
and Page 28
7.2.5 Checks and adjustments Microcontroller MC7, illustration (Z 22629a)

Cont'd:
Method A - Demanded power adjustment
) • The adjustment has to be carried out separately for each motor
1. Connect pressure gauges to check points M12.1, M12.2, M12.3 and M12.4 at the
high pressure filters.
2. Connect pressure gauges to the X1 pressure check points M20.1 and M20.2.
3. Unplug solenoid valves Y6a-1, Y6b-1 and Y6a-2, Y6b-2 to ensure that the hy-
draulic oil cooler fans are running with maximum speed.
4. Start main motor of the circuit to be adjusted.
5. Set the MRV individually to approx. 120 bar *, to prevent the motors from over-
loading during the adjustment.
6. Shift the three way cock valves (79.1 and 79.2) to position “Hydraulic (con-
stant) Regulation Mode”.
7. Set the X1-pressure at pressure reducing valve (81.2) > 25 bar **, to ensure that
the pumps remain in Q-max. flow position during the adjustment.
8. Apply max. load to all pumps (e.g. extend the bucket cylinders to the final stop
position and keep it fully under load), and increase the pressure at all 4 MRV’s *
equally to 212 bar.
Expected motor current at 3 times 212 bar ≅ 88 Ampere (reading of text display)
(peak point).
Record this current for other tests.
)
• If the motor current is lower respectively the operating pressure is
higher than required there is probably not the full volume available.
*Altering the MRV-Setting:

− Remove dust cap (a).
− Loosen lock nut (b).
− Turning the set screw (c) cw the pressure will increase.
− Turning the set screw ccw the pressure will decrease.
**Altering the X1-Setting:

− Loosen the lock nut (e).
− Turning the set screw (f) cw the pressure will increase.
continued
7.0
29
and Page 29

Cont'd:
Method A - Demanded power adjustment

1. Store the demanded power (peak point) into the MC7 as follows:
a) Activate the adjusting mode:
Connect 24V, simultaneously to terminal 54 and 55 for 10 seconds, using test
leads and disconnect the voltage thereafter.
b) Select the demanded power adjusting mode of Motor 1:
Connect 24V, simultaneously to terminal 50 and 52 permanent.
c) Select the demanded power adjusting mode of Motor 2:
Connect 24V, simultaneously to terminal 50, 52 and 53 permanent.
d) Stall the hydraulic with the values of item 8 (Peak point)
3 times ≅ 212 bar => ≅ 88 Ampere (each motor) (all pumps Q-max position
and cooler fans with max. speed).
e) Save the actual measured power:
Connect 24V to terminal 55 for 1 second and disconnect the voltage thereafter.
) • The actual measured power will be saved immediately as the de-

manded power
2. Re-set the X1-pressure at pressure reducing valves (81.2) as recorded**.
3. Shift the three way cock valves (79.1 and 79.2) to position “Electronic Regulation
Mode”
4. Reset the MRV’s to 310 bar+5bar , and remove the gauges.
5. After the adjustments are finished, remove the test leads and pressure gauges, stop
the motors and turn the main key switch in OFF position to deactivate the adjusting
mode.


continued
7.0
30
and Page 30

7.2.5 Checks and adjustments Microcontroller MC7, illustration (Z 22636)
Cont'd:
Method A - PID - Factor adjustment to obtain the most efficient pump
regulation characteristic.
• With the PID-Factor adjustment (proportional, integral and differen-
) tial factors) it is possible to influence the regulation dynamics.
• The PID-Factor adjustment range is between 80 % and 120 %
• The voltage at the analogue output (terminal 60) represents the actual
adjusted value. (80 % = 0VDC / 100 % = 2,5VDC / 120 %= 5VDC)
• This factor is multiplied with all PID parameters.
1. Jerky movements while lifting and swinging at the same time:

Connect 24V, simultaneously to terminal 54 and 55 for 10 seconds, using
two test leads and disconnect the voltage thereafter.
b) Select the PID-factor adjusting mode:
Connect 24V, to terminal 50 permanent, using a test lead.
c) Connect a multi-meter to terminal 60 (reading DC-voltage) and note down
the value (represents the actual adjusted value)
d) Reduce the voltage in steps of 250mV until the system works smoothly, by
connecting 24V to terminal 55. (As close as possible to the boarder line)
2. No Jerky movements:
Connect 24V, simultaneously to terminal 54 and 55 for 10 seconds, using
two test leads and disconnect the voltage thereafter.
b) Select the PID-factor adjusting mode:
Connect 24V, to terminal 50 permanent, using a test lead.
c) Connect a multi-meter to terminal 60 (reading DC-voltage) and note down
the value (represents the actual adjusted value)
e) Increase the voltage in steps of 250 mV until the system jerks, by connect-
ing 24V to terminal 54. (As close as possible to the boarder line)
f) Now reduce the voltage in steps of 250mV until the system works
smoothly again, as described under item 1d.
3. After the adjustments are finished, remove the test leads and multi-meter, stop
the motors and turn the main key switch in OFF position to deactivate the ad-
justing mode.
7.0
31
and Page 31

Method B -
With the electronic service tool (EST) BB-3 connected to the serial interface X13
(located in the operators cab)
1. Make sure the respective change over valve is in position “Electronic Pump Regu-
lation”
2. Connect a pressure gauge to check point (respective M20-1, M20-2 ), using a
long pressure gauge hose to be able reading the pressure inside the operators
cab.
3. Connect the electronic service tool (BB-3) to the data link adapter X13,
with key switch (S1) in OFF position.
4. Turn key switch (S1) in ON position:
After switching on the power for the Control panel BB-3 the following functions
are carried out and shown on the display:
4.1 Self-test and baud rate recognition:
The BB-3 automatically recognizes the rate
of data transmission from the MC electronics.
4.2 Identification:
On recognition of the MC electronics the
relevant software in the BB-3 will be started up.
4.3 Main menu:
Initialization of remote control unit BB-3 is complete.
One of the four main menu items can be selected using the given keys.
First screen (main menu) after connection and Key switch turned ON in German.
F1 Config/Cal.
F2 Diagnostic
PROC Status
TE ACH Storage
Language selection
To change the language press simultaneously The language selection menu appears
the buttons ALT + Clear
F1 Config/Cal.
ALT + CLEAR F2 Diagnostic
PROC Status
TE ACH Storage
continued
7.0
32
and Page 32
Cont'd:
Method B Language selection
Press button 2 The language will change to English

and the display show the main menu
1. Deutsch
2 2. English
3. - - -
4. - - -
One of the four main menu items can be selected using the given keys.
7.0
33
and Page 33
Method B - A: Adjustment mode SET 1 and SET 2
There are two adjustment modes (SET 1 and SET 2) integrated. SET 1 is for the main settings
and SET 2 is only for the basic adjustments. SET 2 can only activated with a password.
After start up of the MC7 with connected BB3 the adjustment modes SET 1 is active.
Main display SET 1 Main display SET 2

Standard after start up Only with password
F1 Config/Cal. F1’ Config/Cal.

F2 Diagnostic F2 Diagnostic
PROC Status PROC Status
TE ACH Storage TE ACH Storage
Change from SET 1 to SET 2:
SET 1 F1 Config/Cal.
Press F1 Config/Cal F2 Diagnostic
PROC Status
TE ACH Storage
1 Demand Power
Press ALT + in the same time 2 Max current
3 PID - Factor
4 Error Lamp
A password will be requested
Enter password (5 7 0 8 7 5)
?: _
1 ... 9
SET 2 1 Configuration
Press MENU to go back to the main menue 2 PID Control
3 Low Voltage
4 –––
F1’ Config/Cal.
F2 Diagnostic
PROC Status
TE ACH Storage
To switch back to SET 1 repeat this procedure
or switch off and on the MC7.
continued
7.0
34
and Page 34
Method B - Number of motor selection:
Activate adjustment mode SET 2 as

described on page 65
F1’ Config/Cal.
F2 Diagnostic
Press F1 Config/Cal
PROC Status
TE ACH Storage
1 Configuration
Press
1 Configuration 2
3
PID Control
Low Voltage
4 –––
1 No of valves
Press 2 No of motors 2
3
No of motors
––
4 ––
Select desired number of motors 2 No of motors
use or 1 motor
2 No of motors
Press ENTER Acceptation
2 motors
1 No valves
Press. 2 x MENU Return to sub menu. 2 No motors
3 ––
4 ––
F1’ Config/Cal.
F2 Diagnostic
PROC Status
TE ACH Storage
Save setting to the EEPROM of the MC7 as described at page 75.
continued
7.0
35
and Page 35
7.2.5 Checks and adjustments Micro-controller MC7, illustration (Z 22357a)
Method B
X1-Pressure (maximum current) Adjustment:
Press F1 Config/Cal F1
F2
Config/Cal.
Diagnostic
PROC Status
If sub menu SET 2 is displayed change to
TE ACH Storage
sub menu SET 2 as described on page 65.
1 Demand Power
Press
2 Max current 2
3
Max current
PID - Factor
4 Error Lamp
Select desired valve
Press 1 Valve 1, Motor1

1
2
Valve
Valve
1
2
Mot.
Mot.
1
1
or 3 Valve 1 Mot. 2
Press
3 Valve 1, Motor2 4 Valve 2 Mot. 2
Example Motor 1, Valve1 1 Valve 1 Mot. 1

0 – 100±1
71
Start the respective motor. Do not load the motor.
Check the X1-pressure with a pressure gauge and set
it to the desired value by:
1 Valve 1 E1
0 – 100±1
pressing or 78
1 Valve 1 Mot. 1
Press ENTER Accept tion 2 Valve 2 Mot. 1
3 Valve 1 Mot. 2
4 Valve 2 Mot. 2
F1 Config/Cal.
Press. 2 x MENU Return to main menu F2 Diagnostic
PROC Status
TE ACH Storage

continued
7.0
36
and Page 36
7.2.5 Checks and adjustments Microcontroller MC7, illustration (Z 22357)a
Method B -
Demanded power adjustment:
Cont'd:
F1 Config/Cal.
Press F1 Config/Cal F2 Diagnostic
PROC Status
If sub menu SET 2 is displayed change to TE ACH Storage
1 Demand Power
2 Max current
Press 1 Configuration
3 PID-Factor
4 Error Lamp
Select desired demand power adjustment

SET 1 1 Set demand m. 1
Press 1 demand power Motor1 2 Set demand m. 2
or 3 Demand power 1
4 Demand power 2
Press
2 demand power Motor2
1 Set demand m. 1
Example Motor 1 0–0±1
0
and
Load respective Motor with max power
Start?
––> <ENTER>
Press ENTER Selection
Cancel?
––> <ENTER>
Press ENTER Starting Function ended

Saved
Press <ENTER>
Press ENTER Confirm

F1 Config/Cal.
F2 Diagnostic
Press. 2 x MENU Return to main menu PROC Status
TE ACH Storage

continued
7.0
37
and Page 37
Method B
Cont'd:
PID-Factor adjustment:
Jerky movements while lifting with full bucket and swinging at the same time:
Reduce jerking ⇒ Reduce the PID-Factor in short steps.
To obtain the most efficient pump regulation characteristic adjust to the PID-Factor until
the system jerks as close as possible to the boarder line.
F1 Config/Cal.
Press F1 Config/Cal
F2 Diagnostic
PROC Status
If sub menu SET 2 is displayed change to TE ACH Storage
SET 1 1 Demand Power

Press 3 PID-Factor. 2
3
Max current
PID-Factor
4 Error Lamp
1 PID-Factor
Press
1 PID-Factor. 2
3
–––
–––
4 –––
Adjust the PID-Factor

1 PID-Factor
by pressing . 80–120±1%
or 100
1 PID-Factor
2 –––
Press ENTER Acception 3 –––
4 –––
and check the machine movement again
if necessary repeat PID-Factor adjustment
F1 Config/Cal.
Press. 2 x MENU Return to main menu. F2 Diagnostic
PROC Status
TEACH Storage

continued
7.0
38
and Page 38
Method B
Cont'd:
Storage all new settings to the MC7:
This menu item permits storage of all edited parameters to the EEPROM
of the MC electronics
.
F1 Config/Cal.
Press TEACH Activate storage menu F2 Diagnostic
PROC Status
TE ACH Storage
1 Save Params
Press 1 Save Params 2
3
Default Rarams
Get EEPROM
4 Send EEPROM
Teach?
Press ENTER Store parameters ––> <ENTER>
Cancel?
––> <ENTER>
1 Save Params
Press. MENU Return to main menu. 2 Default Rarams
3 Get EEPROM
4 Send EEPROM
If all adjustments are correct and stored in the MC7, proceed as follow:
• Stop the motors and turn key switch (S1) in OFF position
• Disconnect the electronic service tool (BB-3) and the pressure gauge.
7.0
39
and Page 39
Method C - With a laptop computer and BODEM software connected to the

serial interface X13 (located in the operators cab)
Starting the program
Pre-conditions: Normal operating temperature, correct pilot pressure set-
ting and the system must be free of air.
1. Connect the laptop computer to the data link adapter X13,
with key switch (S1) in OFF position.
2. Make sure that the dongle is connected to the laptop computer. If not
3. Turn key switch (S1) in ON position.

4. Start the computer.
5. Click on the Bottom - icon to start the program.
continued
7.0
40
and Page 40
Method C, Starting the program

Cont'd:
6. The program starts (only) the first time with the Demo Version.
7. Open menu FILE → INTERFACE , select the required interface connection

(Standard COM1), confirm with OK and leave the program.
8. Start the program again. Now the computer is connected to the Microcontroller.
During uploading of the MC7 data to the PC a window opened and shows some hard-
ware and software information.
7.0
41
and Page 41
Method C
Language selection
Open menu FILE → Language , select the required language and confirm with OK .
7.0
42
and Page 42
Method C
Entering of the password:
) • The password is only required to adjust the number of valves or en-

gines and for fine tuning of special regulation parameters. All other
adjustments are possible without the password.
Open menu Parameters and select Enter password.... Write the correct password and con-
firm with OK. (Password 570875)
) • After entering a correct password and confirming with OK the BODEM

software start a new upload from the MC7 memory to the PC.
7.0
43
and Page 43
Method C
Cont'd:
Number of Motor selection:
Pre condition: The correct password was entered as described on page 83.
Open Parameters and select Display / Edit Parameters. Then select in the left window
Configuration. Now on the right side there two pull down menus.
Example: select for PC 5500 1 valve per motor and 2 Motors.
Write new setting permanent to the MC7 EEPROM with Apply and confirm with OK.
7.0
44
and Page 44
Method C
X1-Pressure (maximum current) Adjustment:

Make sure the change over valve is in position “Electronic Pump Regulation”
Connect a pressure gauge to the respective check point (M20-x), using a long pressure gauge
hose to be able reading the pressure inside the operators cab.
Open menu Parameters select Display/Edit parameters and Max current,
start respective motor without load and wait 30 sec.. The X1-pressure will raise to the max.
adjusted value. If necessary adjust the required pressure (according to the final test report or
hydraulic diagram) with the respective slide bar. (Valve 1 Mot. 1 is the X1-1 pressure and
Valve 1 Mot. 2 the X1-2 pressure).
Write new setting permanent to the MC7 EEPROM with Apply and confirm with OK.
7.0
45
and Page 45
Method C
Demand power adjustment:
Pre-conditions: Normal operating temperature, correct pilot pressure setting and the sys-
tem must be free of air.
Open menu Parameters and in the pull down window the menu point Display / Edit Pa-
rameters.... Now the window with the demand power adjustment will be on screen.
Screen with password Screen without password.

The demand power adjustment is possible both modes.
continued
7.0
46
and Page 46

Cont'd:
Method C
Demand power adjustment:
1. Connect pressure gauges to the high pressure check points at the high pres-
sure filters. (M12.1, M12.2, M12.3 and M12.4)
2. Connect pressure gauges to the X1 pressure check points (M20.1 and M20.2).
3. Unplug fan control solenoid valves (Y6a-1, Y6b-1 and Y6a-2, Y6b-2) to ensure
that the hydraulic oil cooler fans are running with maximum speed.
4. Shift the three way cock valves (79.1 and 79.2) to position “Hydraulic (constant)
Regulation Mode”.
5. Start one motor.
6. Set the X1-pressure at pressure reducing valve (81.2) > 25 bar **, to ensure that
the pumps remain in Q-max. flow position during the adjustment.
7. Apply max. load to all pumps (e.g. extend the bucket cylinders to the stop posi-
tion until the hydraulic system stalls), and increase the pressure at all 4 MRV’s *
equally to the demand power pressure written in the final test report (PC5500,
S/N 15016 = 212 bar). Check the current drawn of the respective motor at this
stage (reading of text display)
Expected approx. ~ 88 Ampere. Record this values for other tests.


continued
7.0
47
and Page 47

Cont'd:
Method C Demand power adjustment:
8. Select Execute... of menu point Set demand m. 1 for motor 1 or

Set demand m. 2 for motor 2.
Select Start to set the actual power as demand power. Confirm with OK. The
new actual demand power will be only shown after a new upload of the MC7
settings. Exit the BODEM software and start again.
9. Stop motor and repeat from item 5 for the second motor.
7.0
48
and Page 48

Cont'd:
PID Factor adjustment: Method C

to obtain the most efficient pump regulation characteristic.
• With the PID-Factor adjustment (proportional, integral and differen-
) tial factors) it is possible to influence the regulation dynamics.
• This factor is multiplied with all PID parameters.
• Only one factor / adjustment for both motors
Open Parameters and select Display / Edit Parameters. Select in the left window PID
control. Adjust now the PID-Factor with the slide bar or write direct the requested
value to the window with the % value. Write new adjustment permanent to the MC7
EEPROM with Apply and confirm with OK.
• Jerky movements while lifting and swinging at the same time: Reduce the PID-
Factor in short steps until the system works smoothly. (As close as possible to the
boarder line)
• No Jerky movements:
1. Increase the PID-Factor in short steps until the system jerks. (As close as possi-
ble to the boarder line)
2. Now reduce the PID-Factor in short steps until the system works smoothly
again.
7.0
49
and Page 49
7.3.1 General
The pilot pressure pumps ( 7.1 and 7.2) deliver the oil through the pressure filter
(68.1) to port A of the pressure relief valve (70.1) for limiting the pump support
pressure X4 to 60 bar. By the function of pressure reducing valve (70.2), the X4
pressure of 60 bar is reduced to the pilot pressure X2 of 35 bar. The common X2
pressure will be reduced by the function of pressure reducing valves ( 81.2 ) to the
necessary constant X1 pressure, to prevent the motors from overloading.
) • For testing purposes the pump regulation system can be changed to

the hydraulic operation mode. In case of a failure in the electronic
regulation system the hydraulic operation mode can also be used for
emergency operation.
• The standard operation mode of the pump regulation system is the
Electronic Operation Mode.

(1 - 3) Main hydraulic pumps (driven by Motor 1)
(4 - 6) Main hydraulic pumps (driven by Motor 2)
(7.1) Pilot pressure pump (driven by Motor 1)
(7.2) Pilot pressure pump (driven by Motor 2)
(68.1) Pilot pressure filter unit
(70.1) Pressure relief valve 60 bar (X4)
(70.2) Pressure reducing valve 35 bar (X2)
(81.1) Pressure reducing valve: "½ Qmax , remote control X3 pressure”
(81.2) Pressure reducing valve: "Pump regulation pressure X1 at hydraulic
constant regulation mode "
operation mode" (Standard mode Motor 1)
operation mode" (Standard mode Motor 2)
(79.1) Change over valve: "Electr. or Hydr. pump regulation" Motor 1
(79.1) Change over valve: "Electr. or Hydr. pump regulation" Motor 2
7.0
50
and Page 50
7.3.2 X1-pressure adjustment (constant-pressure), illustration (Z 22639a)

1. Connect pressure gauges to check points M12.1, M12.2, M12.3 and M12.4 at
the high pressure filters.
2. Connect pressure gauges to the X1 pressure check points M20.1 and M20.2.
3. Unplug solenoid valves Y6a-1, Y6b-1 and Y6a-2, Y6b-2 to ensure that the hy-
draulic oil cooler fans are running with maximum speed.
4. Shift the three way cock valves (79.1 and 79.2) to position “Hydraulic (constant)
Regulation Mode”.
5. Start motor 1.
6. Set the X1-pressure at pressure reducing valve (81.2) to approx. 3 bar **
7. Apply max. load to all pumps (e.g. extend the bucket cylinders to the stop position
until the hydraulic system stalls), and increase the pressure at all 4 MRV’s *
equally to 260bar.
8. Check the current drawn of motor 1 at this stage (reading of text display)
Expected approx. .. ≅ 70±5 Ampere. If necessary adjust the X1-pressure at pres-
sure reducing valve (81.2) . Record this values for other tests.
9. Stop motor 1 and start motor 2 .
10. Apply max. load to all pumps (e.g. extend the bucket cylinders to the stop position
until the hydraulic system stalls), and set the pressure at all 4 MRV’s * equally to
260 bar.
11. Check the current drawn of motor 2 at this stage (reading of text display)
The current of motor 1 should be approx. ≅ 70±5 Ampere depend on the setting
of motor 1. There is only one valve (81.2) for both motors.
12. Shift the three way cock valves (253.1 and 254.1) to position “Electronic regulation“.
13. Plug on the unplugged solenoid valve.
14. Reset the MRV’s * to 310 bar+5bar , and remove the gauges.


− Remove dust cap (d).
04.01.07 rev.2 PC5500-6-E_Sec_7-0_15016E_rev2.doc

04.01.07 rev.2 PC5500-6-E_Sec_7-0_15016E_rev2.doc
Operating Hydraulic Section 8.0
Page 1

Section Page
8.0 Operating Hydraulic
General 2
8.0.1 Floating function of boom and stick cylinders 3+4
8.1 Hydraulic for the attachment cylinder FSA and BHA
8.2 Hydraulic for the swing circuit
8.3 Hydraulic for the travel circuit
01.04.03 PC5500-6_Sec_8-0_rev1.doc
8.0
&2
01.04.03 PC5500-6_Sec_8-0_rev1.doc
Page 2
8.0 General
Overall view of the Hydraulic system, illustration (Z 21955):
(1 – 6) Main pumps
(7) High pressure filters
(8) Main control blocks
(10) Attachment cylinders
(11) Swing motors
(12) Rotary joint
(13) Travel motors
General information
The control blocks, the piping to the distributor manifold and the connecting
hoses to the attachment are in some points different between the Backhoe
Attachment (BHA) and the Front Shovel Attachment (FSA). If a conversion is
required, contact the service department for further information.
Function:
F •
•
Study together with the circuit diagram.
The following numbering refers to the hydraulic circuit diagram.
Each main pump (1 to 6) delivers oil trough the high pressure filter (44.1,
44.2, 46.1 and 46.2) to port P of the main control blocks (FSA – 14, 15, 16
and 13) (BHA - 175, 15,176 and 13). The single valve block IV (13) is in line
to valve block II (15) connected.
This results in three main circuits.
If all spools of the control blocks (1 to 6) are in neutral position, the oil leaves
the block at port T and returns via return oil pipes, return oil collector
manifold (35), return oil pipes (L6 and L7), return oil collector tube (114),
back pressure valve (115) and the return oil filters (117.1-117.4) into the tank
(41).
The function of back pressure valve (115) ensures:
- sufficient oil supply for all anti-cavitation valves
- and that sufficient oil is forced through the oil coolers.
If a control lever or pedal is actuated, pilot pressure oil moves the spools of the
control blocks, directing the oil flow from the main pumps to one side of the
user (either cylinders or motors). From the opposite side of the user the oil
returns to the control block and from there via the return oil circuit back into
the tank.
Each circuit is provided with one MRV (also called primary valve, at least one
SRV (also called secondary valve) and at least one flow restrictor.
continued
01.04.03 PC5500-6_Sec_8-0_rev1.doc
8.0
&3
01.04.03 PC5500-6_Sec_8-0_rev1.doc
8.0
&4
8.0 General
Cont'd:
8.0.1 Floating function of boom and stick cylinders FSA:

illustration (Z 22568):
The Excavator (only front shovel attachment) operates automatically with the float
position for boom and stick activated.
That means the lowering movement of boom and stick is always done in the float
position.
For deactivation of the float position, two push buttons are installed:
a) S95 in the right joy stick (E19) for the Boom function
b) S95a in the left joy stick (E20) for the Stick function
Press the respective button and keep it depressed as long as the float position shall
be deactivated.
When releasing the button the float position is activated again.
Function:
There are different main valve spools in the three main valve blocks (14, 15 and
16) for boom and stick installed. Only by lowering of the boom or retracting of the
stick is the floating function active if the button on the lever is not pushed. The
piston and rod side of the respective cylinders are in floating position direct
connect to the return line (tank). The pressure free pump circulation is still active
there is no pump pressure to the respective cylinders. By external force the
cylinder can move up or down with negligible hydraulically resistance.
In floating position of the boom only valve spool 4 of main valve block I and 2 of
block III active.
In floating position of the stick only valve spool 2 of Main valve block I and 4 of
block III active.
To push down the boom or retract the stick by hydraulically force the respective
button on the lever must by activated.
S98 for the Stick cylinders
S95 for the Boom cylinders
In normal operation mode (i.e. float position) the piston side, the rod side and the
tank are connected together when lowering the boom or retracting the stick.
If a pressurised lowering of the boom or retracting of the stick cylinders is
required the connection of piston side, rod side and tank must be disconnected and
the rod side must be connected to the pump pressure. This is done by
disconnecting the respective special floating valve spool and activating the
respective standard valve spool. Now pressurised pump oil can flow to the
cylinder rod side.
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Boom:
S95 ON K160 ON Float position deactivated
A10 deactivated Floating spool block I section 4 off

A10A activated Standard spool block II section 3 ON
S95 OFF K160 OFF Float position activated
A10 activated Floating spool block I section 4 ON

A10A deactivated Standard spool block II section can be on or off
Stick:
S98 ON K170 ON Float position deactivated
A8B deactivated Floating spool block III section 4 off

A8A activated Standard spool block II section 4 ON
S98 OFF K170 OFF Float position activated
A8B activated Floating spool block III section 4 ON

A8A deactivated Standard spool block II section can be on or off
F
• Due to the two different operation modes for lowering, the lowering
speed of boom and stick cylinder must be adjusted twice:
A. Float position deactivated
B. Float position activated
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Hydraulic for the Section 8.1
Attachment Cylinders Page 1

Section Page
8.1 Hydraulic for the attachment cylinder FSA and BHA
8.1.1 Electric / Hydraulic Flowchart Boom raising 2+3
8.1.2 Electric / Hydraulic Flowchart Boom lowering 4+6
8.1.3 Electric / Hydraulic Flowchart Stick extending 7+8
8.1.4 Electric / Hydraulic Flowchart Stick retracting 9 + 11
8.1.5 Electric / Hydraulic Flowchart Bucket filling (curl) 12 + 13
8.1.6 Electric / Hydraulic Flowchart Bucket emptying 14 + 15
8.1.8 Electric / Hydraulic Flowchart Clam opening 17
8.1.9 Electric / Hydraulic Flowchart Clam closing 18
8.1.10 Checks and adjustments of the 19 + 20
Main Relief Valves (Primary valves)
8.1.11 Checks and adjustments of the
Service Line Relief Valves (Secondary valves)
Boom cylinder piston side FSA + BHA 21 + 22
Boom cylinder piston rod side FSA + BHA 23 + 24
Stick cylinder piston side FSA 25 + 26
Stick cylinder piston side BHA 27 + 28
Stick cylinder piston rod side FSA 29 + 31
Stick cylinder piston rod side BHA 32 + 33
Bucket cylinder piston side FSA 34 + 35
Bucket cylinder piston side BHA 36 + 37
Bucket cylinder piston rod side FSA 38 + 39
Bucket cylinder piston rod side BHA 40 + 41
Clam cylinder piston rod side FSA 42
Clam cylinder piston side FSA 43
8.1.12 Checks and adjustments for the lowering speed. 44

General: Flow Restrictors
Boom cylinder FSA (Float position activated / deactivated) 44 + 46
Boom cylinder BHA 47
Stick cylinder FSA (Float position activated / deactivated) 48 + 49
Stick cylinder BHA 50
Bucket cylinder FSA 51
Bucket cylinder BHA 52
Clam cylinder 53
8.1.13 Checks for the valve control logic. 54
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8.1.1 Electric / Hydraulic flowchart “ Boom raising ” FSA

(E19) Control lever (Joy stick)
(D32) Time relay – Pilot control: Neutral position monitoring
(Y-) Direction (axis) of joy stick
(-10V) Signal voltage (Maximum)
(gn) Color code of signal voltage cable ( Joy stick)
(X2...) Terminal rail with number
(E49) Ramp time module
(A10) Amplifier module – Boom
(A10A) Amplifier module – Boom
(A10B) Amplifier module – Boom
(K79) Relay – pilot control:
Contacts 8 / 12 only closed while lifting the boom.
(K160) Relay – Floating control:
Contacts 2 / 10 closed auto floating active .
Contacts 2 / 10 open while bucket filling (priority function).
(K76A) Relay – pilot control:
Contacts 2 / 10 open while stick extending (priority
function).
(45.1 – 45.3) Remote control valves
(Y23, Y26, Y29) Proportional solenoid valve
(Y23a, Y26a, Y29a) Directional solenoid valve
(I – III) Main control blocks I – III
Electrical signal flow (EURO control).

Signal voltage of joy stick (E19) arrives via ramp time module (E49) and the
relay contacts (K79, K160) at terminal 5 of the three amplifier modules (A10,
A10a and A10b) and further to the proportional and directional solenoid valves
of the remote control blocks (45.1, 45.2, and 45.3).
Hydraulic signal flow. (pilot pressure)
When the respective proportional and directional solenoid valves are energized
pilot pressure oil flows to the pilot pressure ports of the main control blocks.
Hydraulic oil flow
Now the oil of the main pumps flows through the main control blocks (I to IV)
and arrives via the distributor manifold at the hydraulic cylinders.
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8.1.1 Electric / Hydraulic flowchart “ Boom raising ” BHA

(D32) Time relay – Pilot control: Neutral position
monitoring
(YD) Direction (axis) of joy stick
(A10a) Amplifier module – Boom
(A10b) Amplifier module – Boom
(Y23, 25 + Y29) Proportional solenoid valve
(175, 15, 176) Main control blocks I – IV

Signal voltage of joy stick (E19) arrives via ramp time module (E49) at
terminal 5 of the amplifier modules (A10 to A10b) and further to the
proportional and directional solenoid valves of the remote control blocks (45.1,
45.2, 45.3).
When the proportional and directional solenoid valves are energized pilot
pressure oil flows to the pilot pressure ports of the main control blocks.
Hydraulic oil flow
Now the oil of the main pumps flows through the main control blocks (I to III)
and arrives via distributor manifold at the hydraulic cylinders piston side.
The piston extend and the boom move up.
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8.1.2 Electric / Hydraulic flowchart “ Boom lowering ” FSA, Auto Float off

(+Y) Direction (axis) of joy stick
(+10V) Signal voltage (Maximum)
Contacts 6 / 10 open while extending the stick.
Contacts 6 / 10 open while filling the bucket.
Contacts 8 / 12 closed while moving the boom up.
Contacts 2 / 10 closed and 5 / 9 open while auto floating on.
(K207C) Relay – pilot control:
Contacts 5 / 9 closed while warming up hydraulic oil (S205).
(Y23b, Y26b, Y29b) Directional solenoid valve
(I – III) Main control blocks I – IV

The auto float button in the right lever E19 is still engaged this will energize
relay K160. Signal voltage of joy stick (E19) arrives via ramp time module
(E49) only at terminal 5 of the amplifier modules (A10a and A10b) and further
to the proportional and directional solenoid valve of the remote control blocks
(45.2 and 45.3).
When the proportional and directional solenoid valves are energized pilot pressure
oil flows to the pilot pressure ports of the respective main control blocks.
Hydraulic oil flow
Only the oil of main pump 3 and 4 flows through the main control blocks (II)
and arrives via the distributor manifold at the boom hydraulic cylinders piston
rod side. Through main valve block III for boom lowering is no pressure oil
flow depend on a different valve spool with closed pressure port.
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5
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8.1.2 Electric / Hydraulic flowchart “ Boom lowering ” FSA, Auto Float on

Contacts 6 / 10 open while extending the stick.
Contacts 6 / 10 open while filling the bucket.
Contacts 8 / 12 closed while moving the boom up.
Contacts 2 / 10 closed and 5 / 9 open while auto floating on.
Contacts 5 / 9 closed while warming up hydraulic oil (S205).

The auto float button in the right lever E19 is disengaged and relay K160 is de-
energized. Signal voltage of joy stick (E19) arrives via ramp time module
(E49) only at terminal 5 of the amplifier modules (A10 and A10b) and further
to the proportional and directional solenoid valve of the remote control blocks
(45.1 and 45.3).
Hydraulic oil flow
Now the pump oil flow still back to the return line. Both pressure lines at valve
block I section 3 (A3 and B3) are connected to the same back pressure charged
return line. Valve spool 2 of main valve block III connect only port B2 to the
return line. The return line, the piston side and the piston rod side of the boom
cylinders now connected together. The boom can moved up and down by external
force.
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6
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8.1.2 Electric / Hydraulic flowchart “ Boom lowering ” BHA

(A10a) Amplifier module – Boom
(A10b) Amplifier module – Boom
(Y23, 25 + Y29) Proportional solenoid valve
(175, 15, 176) Main control blocks I – IV

Signal voltage of joy stick (E19) arrives via ramp time module (E49) at terminal 5
of the amplifier modules (A10, A10a and A10b) and further to the proportional
and directional solenoid valves of the remote control blocks (45.1 – 45.3).
oil flows to the pilot pressure ports of the main control blocks.
Hydraulic oil flow
and arrives via distributor manifold at the hydraulic cylinders piston rod side.
The piston retract extend and the boom move down..
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8.1.3 Electric / Hydraulic flowchart “ Stick extending ” FSA

monitoring
(YC) Direction (axis) of joy stick
(A8) Amplifier module – Stick
(A8a) Amplifier module – Stick
(A8b) Amplifier module – Stick
Contacts 7 / 11 and 8 / 12 closed while extending the stick.
Contacts 1 / 9 open while bucket filling.
Contacts 5 / 9 closed and 7 / 11 opened while floating
system active.
(45.1, 45.2, 45.3) Remote control valves
(I, II + III) Main control blocks I – III

of the amplifier modules (A8, A8a and A8b) and further to the proportional and
directional solenoid valves of the remote control blocks (45.1, 45.2 and 45.3).
oil flows to the pilot pressure ports of the main control blocks .
Hydraulic oil flow
Now the oil of the main pumps flows through the main control blocks (I, II, III)
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8
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8.1.3 Electric / Hydraulic flowchart “ Stick extending ” BHA

(Y+) Direction (axis) of joy stick
(45.1-45.3) Remote control valves
(Y21a, Y27a, Y27b) Directional solenoid valve
(I, II, III) Main control blocks I, II III

directional solenoid valves of the remote control blocks (45.1, 45.2, and 45.3).
Hydraulic oil flow
and arrives via distributor manifold at the hydraulic cylinders.
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8.1.4 Electric / Hydraulic flowchart “ Stick retracting ” FSA Auto Float off

monitoring
(YD) Direction (axis) of joy stick
Contacts 7 /11 and 8 / 12 open while retracting the stick.
Contacts 1 / 9 only open while bucket moving.
Contacts 1 / 9 closed and 3 / 11 open while auto floating
off.
Contacts 5 / 9 closed while warming up hydraulic oil
(S205).
(45.1, 45.2, 45.3) Remote control valves
(I + III) Main control blocks I + III

of the amplifier modules (A8, A8a) and further to the proportional and directional
solenoid valves of the remote control blocks (45.1 and 45.2).
oil flows to the pilot pressure ports of the control blocks ( I and II ).
Hydraulic oil flow
Only the oil of main pump 3 and 4 flows through the main control block (II)
and arrives via the distributor manifold at the stick hydraulic cylinders piston
side. Through main valve block I for stick retracting is no pressure oil flow
depend on a different valve spool with closed pressure port.
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8.1.3 Electric / Hydraulic flowchart “ Stick retracting ” FSA, Auto Float active

(-Y) Direction (axis) of joy stick
(Y21a, Y27a, Y27b) Directional solenoid valve
(I, II, III) Main control blocks I, II III

The auto float button in the left lever E20 is disengaged relay K170 is de-
energized. Signal voltage of joy stick (E20) arrives via ramp time module
(E48) at terminal 5 of the amplifier modules (A8, A8a and A8b) and further to
the proportional and directional solenoid valve of the remote control blocks
(45.1 and 45.3). Amplifier module A8a disengaged with open K80 if bucket
filling is actuated..
Hydraulic oil flow
Both pressure lines at valve block III section 4 (A4 and B4) are connected to the
same back pressure charged return line. Valve spool 4 of main valve block I
connect only port B2 to the return line. The return line, the piston side and the
piston rod side of the stick cylinders now connected together. The stick can move
forward and backward by external force.
If only the stick retracting function is active section 4 of main valve block II
opened additional port A4 and B4 to extend the max. oil flow for max. stick
speed.
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8.1.4 Electric / Hydraulic flowchart “ Stick retracting ” BHA

monitoring
(Y-) Direction (axis) of joy stick
(Y21b, Y27b, Y31a) Directional solenoid valve
(I, II, III) Main control blocks I, II, III

directional solenoid valves of the remote control blocks (45.1, 45.2 and 45.3).
Hydraulic oil flow
and arrives via distributor manifold at the hydraulic cylinders.
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8.1.5 Electric / Hydraulic flowchart “ Bucket filling ” FSA

monitoring
(-X) Direction (axis) of joy stick
(ws / gn) Color code of signal voltage cable ( Joy stick)
(A9) Amplifier module – Bucket
(A9a) Amplifier module – Bucket
(A9b) Amplifier module – Bucket
(K50) Relay – pilot control: Bucket cut-off
Contacts 6 / 10 only closed if the hydraulic oil is in normal
Contacts 1 / 9 only open while bucket dump.
Contacts 1 / 9 only open while lifting the boom.
(45., 45.2, 45.3) Remote control valves
(Y22A, Y24A, Y30A) Directional solenoid valve

Signal voltage of joy stick (E19) arrives via relay contacts K50 at terminal 5 of
the amplifier modules (A9, A9a, A9b) and further to the proportional and
directional solenoid valves of the remote control blocks (45.1, 45.2, 45.3).
Hydraulic oil flow
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13
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8.1.5 Electric / Hydraulic flowchart “ Bucket filling ” BHA

monitoring
(XB) Direction (axis) of joy stick
Contacts 6 / 10 only closed if the hydraulic oil is
overheated.
(I, II, III) Main control blocks I, II, III

Signal voltage of joy stick (E19) arrives terminal 5 of the amplifier modules (A9,
A9a, A9b) and further to the proportional and directional solenoid valves of the
remote control blocks (45.,45.2 and 45.3).
Hydraulic oil flow
and arrives via distributor the manifold at the hydraulic cylinders.
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14
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8.1.6 Electric / Hydraulic flowchart “ Bucket dump ” FSA

monitoring
(+X) Direction (axis) of joy stick
Contacts 6 / 10 only closed if the hydraulic oil is in normal
Contacts 1 / 9 only open while bucket dump.
Contacts 1 / 9 only open while lifting the boom.
Contacts 1 / 3 only open while S205 activated (hydraulic
oil warming up)
(45., 45.2, 45.3) Remote control valves
(Y22A, Y24A, Y30A) Directional solenoid valve

the ELB modules. From ELB modules the signal voltage arrives at terminal 5 of
directional solenoid valves of the remote control blocks (45.1, 45.2, 45.3). Only
while bucket dump together with boom up K78 and K79 opened the contacts 1 / 9
and deactivate amplifier module A9 (priority to the boom).
Hydraulic oil flow
and arrives via the distributor manifold at the hydraulic cylinders. There is no oil
flow through main control block I to the bucket cylinder if bucket dump and boom
up is activated.
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8.1
15
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8.1.6 Electric / Hydraulic flowchart “ Bucket dump ” BHA

(+X) Direction (axis) of joy stick
Contacts 6 / 10 only closed if the hydraulic oil is overheated.
(14.1 + 14.3) Remote control valves
(Y64) Proportional solenoid valve
(Y71 + Y75) Proportional solenoid valve
(Y23 + Y45) Directional solenoid valve
(Y37) Directional solenoid valve
(II, III + IV) Main control blocks II, III + IV
Electrical signal flow (EURO control)

directional solenoid valves of the remote control blocks (45.1, 45,2 and 45.3).
Hydraulic oil flow
Now the oil of the main pumps flows through the main control blocks (II, III, IV)
and arrives via distributor manifold (42) at the hydraulic cylinders.
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8.1.8 Electric / Hydraulic flowchart “ Clam opening ” FSA

(E24) Control pedal
(rs) Color code of signal voltage cable ( Joy stick)
(A11) Amplifier module – Clam
Contacts 7 / 11 only closed while traveling the left crawler.
(II) Main control block II

Signal voltage of control pedal (E24) arrives via relay contact at terminal 5 of the
amplifier module (A11) and further to the proportional and directional solenoid
valves of the remote control block (15).
oil flows to the pilot pressure port of the main control block .
Hydraulic oil flow
Now the oil of the main pump flows through the main control block (II) and
arrives via distributor manifold (42) at the hydraulic cylinders.
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18
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8.1.9 Electric / Hydraulic flowchart “ Clam closing ” FSA

(E23) Control pedal
(rs) Color code of signal voltage cable ( Joy stick)
(A11) Amplifier module – Clam
Contacts 7 / 11 only closed while traveling the left crawler.
(II) Main control block II

Signal voltage of control pedal (E23) arrives via relay contact at terminal 5 of the
amplifier module (A11) and further to the proportional and directional solenoid
valves of the remote control block (15).
oil flows to the pilot pressure port of the main control block .
Hydraulic oil flow
Now the oil of the main pump flows through the main control block (II) and
arrives via distributor manifold (42) at the hydraulic cylinders.
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8.1.10 Checks and adjustments of the Main Relief Valves (MRV),

There are four main relief valves (primary valves) installed, one in each main
control block, to limit the maximum pump supply line pressure (operating
pressure).
MRV Check
Functions FSA
block point
Pump circuit
I M12.1 travel stick bucket boom
I
Pump circuit
II M12.3 clam bucket Boom stick
II
Pump circuit
III M12.4 travel boom bucket stick
III
Pump circuit
IV M12.2 Swing, (if no swing active circuit II)
IV
Each Pump circuit can be checked or adjusted individually by selecting one

function of the required pump circuit.
Checking:
1. Connect the gauge to the required check point M12.1 - M12.4.
2. Start both motors.
3. Extend or retract the cylinder to the stop position for the valve being
tested until the hydraulic system stalls.
4. Read the pressure. Required: 310 + 5 bar
If the pressure is not correct, carry out a comparative measurement with an
other function, in order to avoid wrong measuring results caused by
wrongly adjusted SRV or other defects in the system.
) • When using the single function “bucket fill”, (gray shadow), all MRV
can be adjusted, because all four pump circuits are engaged.
Adjusting:
1. Remove protective cap (a).
2. Loosen lock nut (b).
3. Turn set screw (c) -clockwise to increase pressure, Counter-clock
wise to decrease pressure.
4. Tighten lock nut (b) and install cap (a).
• It is important that the valve body of MRV-valve and the SRV-valve

) are firmly tightened with 300 Nm.
Otherwise, the internal sealing is not properly which results in loud
flow noises and wrong adjustments.
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8.1.10 Checks and adjustments of the Main Relief Valves (MRV),

There are four main relief valves (primary valves) installed, one in each main
control block, to limit the maximum pump supply line pressure (operating
pressure).
MRV in Check Functions BHA

control block point
Pump circuit I I M12.1 Travel Stick Bucket Boom
Pump circuit II II M12.3 Bucket Boom - Stick
Pump circuit III III M12.4 Travel Boom Bucket Stick
Pump circuit IV IV M12.2 Swing, (if no swing active circuit II)
Each Pump circuit can be checked or adjusted individually by selecting one

function of the required pump circuit.
Checking:
1. Connect the gauge to the required check point M12.1 – M12.4.
2. Start both motors..
3. Extend or retract the cylinder to the stop position for the valve being
tested until the hydraulic system stalls.
4. Read the pressure. Required: 310 + 5 bar
If the pressure is not correct, carry out a comparative measurement with an
other function, in order to avoid wrong measuring results caused by
wrongly adjusted SRV or other defects in the system.
) • When using the single function “bucket fill”, (gray shadow), all MRV
can be adjusted, because all four pump circuits are engaged.
Adjusting:
1. Remove protective cap (a).
2. Loosen lock nut (b).
3. Turn set screw (c) -clockwise to increase pressure, Counter-
clock wise to decrease pressure.
5. Tighten lock nut (b) and install cap (a).

) are firmly tightened (with 300 Nm).
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8.1.11 Checks and adjustments of the Service Line Relief Valves (SRV),
Boom cylinder “piston side” FSA + BHA
There are three service line relief valves (secondary valves) installed, all three
at the distributor manifold, to limit the maximum possible pressure peaks in
the service line.
Since the opening pressure of the SRV’s is higher than the setting of the Main
Relief Valves (MRV’s) it is necessary to increase the main relief pressure for
testing and adjusting purposes.
SRV FSA SRV BHA Press. check point Location

141.1 138.1 M23 Manifold section B
141.2 138.2. M29.1 Manifold section N
141.3 138.3 M29.2 Manifold section N
MRV I M12.1 (at HP filter) Double HP filter R.H.
MRV II M12.3 (at HP filter) Single HP filter, block II
MRV III M12.4 (at HP filter) Double HP L.H..
MRV IV M12.2 (at HP filter) Single HP filter, block IV
1. Connect gauges to all above listed check points (min. 400 bar).
3. Extend the boom cylinder to the stop position until the hydraulic
system stalls.
4. Increase slowly the pump supply line pressure, by turning in set screws (3)
of the MRV’s in control block I, II, III and IV, while observing the
pressure gauges. Stop as soon the pressure does not raise any further.
The gauge pointers should remain at 350 bar + 5 bar.
)
• Since the piston side of the boom cylinders are protected by several
SRV’s, the pressure gauges show the pressure of that valve with the
lowest setting.
Even when the gauges show the required pressure it is possible that
one or more valves have a higher setting.
• To ensure that only the SRV’s open during checks and adjustments
it is necessary to further increase the setting of both MRV’s.
5. Remove protective cap (1) of MRV.

6. Loosen lock nut (2).
7. Turn set screw (3) of the MRV’s ½ turn further in, the gauge
pointers will remain at the value shown at item #4 (350 bar + 5 bar).
8. Tighten lock nut (2).
continued
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Cont'd:
illustration (Z 22482a):
Boom cylinder “piston side” FSA +BHA

9. Adjust all three SRV’s equally, until all gauges show a pressure of
360 bar.
Adjust in steps of ¼ turn of set screw (3) in the following sequence:
141.1 þ 141.2 þ 141.3
Remove protective cap (1) of SRV’s.
Loosen lock nut (2).
Turn set screw (3) -clockwise to increase pressure, Counter-clock
Tighten lock nut (2) and install cap (1).
10. Reduce the pressure, at SRV- 141.1 to a value below the required value,
and then increase up to the required pressure (350 bar), while
observing all gauges.
) • Now all gauges will show the same value of 350 bar,
but only SRV-143.1 has the correct setting.
11. Proceed with the other valves in the same manner in the following
sequence:
141.2 þ 141.3
• Strong pulsation of the return line hoses, indicates deviation in

opening pressure of SRV’s and must be avoided.
Repeat the adjusting procedure until the oil returns well-balanced
via all six service line relief valves.
12. Reset the MRV’s to 310 bar + 5 bar after the check / adjustment is finished,
as follows:
Remove protective cap (1).

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8.1
23
06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
illustration (Z 22483b):
Boom cylinder “piston rod side” FSA +BHA
There is one service line relief valve (secondary valve) installed in the main
control block II, to limit the maximum possible pressure peaks in the service
line. Since the opening pressure of the SRV is higher than the setting of the
Main Relief Valves (MRV’s) it is necessary to increase the main relief pressure
for testing and adjusting purposes.
Valve Press. check point Location

SRV 33.4 FSA M12.3 (High pressure filter) Control block II, section A3 FSA
SRV 33.6 BHA section A2 BHA
MRV circuit II M12.3 (High pressure filter) Single high pressure filter,
control block II
MRV circuit IV M12.2 (High pressure filter) Single high pressure filter,
control block IV
1. Connect gauges to all above listed check points.

3. Press floating system button S95 at the lever with the boom function
and retract the boom cylinder to the stop position until the hydraulic
system stalls.
4. Increase slowly the pump supply line pressure, by turning in set
screws (3) of the MRV in control blocks II, while observing the
If there is a setting required follow
5. Turn set screw (3) of the MRV ¼ turn further in, the gauge pointers
will remain at the value shown at item #4 .
)
• To ensure that only the SRV open during checks and adjustments it
is necessary to further increase the setting of MRV control block II..
continued
06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
8.1
24
06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
illustration (Z 22483b):
Cont'd:
7. Adjust the SRV until the gauges show a pressure of 350 bar.
9. Reset the MRV to 310 bar + 5 bar after the check / adjustment is finished
11. Stop engine.
12. Install all protective cups (1).

06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
8.1
25
06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
Stick cylinder “piston side” FSA
the service line.

SRV 142.5 Manifold section F
SRV 142.6 M27.1 Manifold section F
SRV 142.7 Manifold section J
MRV circuit I M12.1 (High pressure filter) Double high pressure filter R.H.
MRV circuit II M12.3 (High pressure filter) Single HP filter, control block II
MRV circuit III M12.4 (High pressure filter) Double high pressure filter L.H..
MRV circuit IV M12.2 (High pressure filter) Single HP filter, control block IV

3. Extend the stick cylinder to the stop position until the hydraulic
system stalls.
of the MRV in control block IV, while observing the pressure gauges.
Stop as soon the pressure does not raise any further.
)
• Since the piston side of the stick cylinders are protected by several
lowest setting.
it is necessary to further increase the setting of the MRV’s.

7. Turn set screw (3) of the MRV ½ turn further in, the gauge
8. Tighten lock nut (2) and install cap (1).
continued
06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
8.1
26
06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
Cont'd:
Stick cylinder “piston side” FSA

9. Adjust all three SRV’s equally, until all gauges show a pressure of 360
bar.
142.5 þ 142.6 þ 142.7
Turn set screw (3) -clockwise to increase, Counter-clock wise to
decrease the setting.
10. Reduce the pressure at SRV 142.5 to a value below the required value,
and increase up to the required pressure (350 bar), while observing all
gauges.
sequence: 142.6 þ 142.7

via all three service line relief valves.
12. Reset the MRV to 310 bar + 5 bar (320 bar block IV) after the check /
adjustment is finished, as follows:

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06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
Stick cylinder “piston side” BHA
There are two service line relief valves (secondary valves) installed, in main
control blocks I and II, to limit the maximum possible pressure peaks in the
service line.

SRV 33.1 M12.1 (High pressure filter) Control block I, section A2
SRV 33.5 M12.3 (High pressure filter) Control block II, section A42
MRV circuit I M12.1 (High pressure filter) Control block I
MRV circuit II M12.3 (High pressure filter) Control block II
MRV circuit IV M12.2 (High pressure filter) Control block IV

3. Extend the stick cylinder (stick retracting) to the stop position until
the hydraulic system stalls.
of the MRV’s in the control blocks, while observing the pressure gauges.
)
• Since the piston side of the stick cylinders are protected by several
lowest setting.

7. Turn set screw (3) of the MRV’s ½ turn further in, the gauge
continued
06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
8.1
28
06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
Cont'd:
Stick cylinder “piston side” BHA

9. Adjust all two SRV’s equally, until all gauges show a pressure of
360 bar.
33.1 þ 33.5
sequence: 33.1 þ 33.5

12. Reset the MRV to 310 bar + 5 bar after the check / adjustment is finished,
as follows:

06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
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29
06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
Stick cylinder “piston rod side” FSA
There are two service line relief valves (secondary valves) installed, in main
control blocks I and II, to limit the maximum possible pressure peaks in the
service line.

SRV 33.1 M12.1 (High pressure filter) Double high pressure filter R.H.
SRV 33.5 M12.3 (High pressure filter) Single HP filter, control block II

5. Retract the stick cylinder to the stop position until the hydraulic
system stalls.
of MRV’s in all above listed control blocks I, II, IV, while observing the
respective pressure gauges. Stop as soon the pressure does not raise any
further. The gauge pointers should remain at 350 bar + 5 bar.
a) Remove protective cap (1).

c) Turn set screw (3) -clockwise to increase pressure, Counter-
clock wise to decrease pressure.
d) Tighten lock nut (2).
continued
06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
8.1
30
06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
Cont'd:
)
• Since the piston rod side of the stick cylinders are protected by
several SRV’s, the pressure gauges show the pressure of that valve
with the lowest setting.
one valves have a higher setting
7. Turn set screw (3) of both MRV’s ½ turn further in, the gauge pointers
will remain at the value shown at item #6 (350 bar + 5 bar).
8. Adjust the SRV’s equally, until all gauges show a pressure of 360 bar.
Adjust in steps of ¼ turn of set screw (1) (SRV’s) in the following
sequence : 33.1 þ 33.5
9. Turn set screw (3)-clockwise to increase pressure, Counter-clockwise to
decrease pressure.
Adjust pressure at SRV 33.1 to ~360 bar if the pressure don’t increase
turn set screw from the last setting max. ¼ turn in (c.w.).
10. Adjust pressure at the SRV 33.5 to ~350 bar.
11. Reduce the pressure, at SRV 33.1 to a value below the required value and
then increase up to the required pressure (350 bar), while observing all
gauges.
06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
8.1
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06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
Cont'd:

via all service line relief valves.
14. Reset the MRV’s to 310 bar + 5 bar after the check / adjustment is finished
15. Stop engine.
16. Install all protective cups (1).

06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
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06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
Stick cylinder “Piston rod side” BHA

There are three service line relief valves (secondary valves) installed at the
distributor manifold, to limit the maximum possible pressure peaks in the
service line.

SRV 142.5 M27.1 Manifold (42) section G
SRV 142.6 M27.2 Manifold (42) section J
SRV 142.7 M28 Manifold (42) section J
MRV circuit II M12.3 (High pressure filter) Single high pressure filter,
control block II
MRV circuit IV M12.2 (High pressure filter) Single high pressure filter,
control block IV

3. Retract the stick cylinder (extend the stick) to the stop position until
of MRV’s in the control blocks, while observing the pressure gauges. Stop
as soon the pressure does not raise any further. The gauge pointers should
remain at 350 bar + 5 bar.
)
• Since the piston rod side of the stick cylinders are protected by

7. Turn set screw (3) of both MRV’s ½ turn further in, the gauge
continued
06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
8.1
33
06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
Cont'd:
Stick cylinder “Piston rod side” BHA

9. Adjust all SRV’s equally, until all gauges show a pressure of
360 bar.
142.5 þ 142.6þ 142.7
and then increase up to the required pressure (350 bar), while observing
all gauges.
sequence: 142.6þ 142.7

as follows:
Turn set screw (3) -clockwise to increase pressure, Counter-clock wise
to decrease pressure.
• It is important that the valve body of MRV and the SRV are firmly
) tightened (with 300 Nm).
06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
8.1
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06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
Bucket cylinder “Piston side” FSA
the service line.

SRV 142.1 M24.1 Manifold (42) section C
SRV 142.2 M24.2 Manifold (42) section C
SRV 142.3 M25 Manifold (42) section D
MRV circuit I M12.1 (High pressure filter) Double high pressure (HP) filter R.H.
MRV circuit III M12.4 (High pressure filter) Double HP filter L.H..
1. Connect gauges to check points M12.1.to M12.4 and M24.1.

3. Extend the Bucket cylinder to the stop position until the hydraulic
system stalls.
of all four MRV’s in control block I to IV, while observing the
)
• Since the piston side of the bucket cylinders are protected by several
lowest setting.

continued
06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
8.1
35
06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
Cont'd:
Bucket cylinder “Piston rod side” FSA

360 bar.
142.1 þ 142.2 þ 142.3
sequence:
142.2 þ 142.3

via all six service line relief valves.
as follows:
06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
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36
06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
Bucket cylinder “Piston side” BHA
distributor manifold, to limit the maximum possible pressure peaks in the service
line.
Since the opening pressure of the SRV’s is higher than the setting of the Main Relief
Valves (MRV’s) it is necessary to increase the main relief pressure for testing and
adjusting purposes.

SRV 142.1 M24.1 Manifold section C
SRV 142.2 M24.2 Manifold section C
SRV 142.3 M25 Manifold section D
MRV circuit II M12.3 (High pressure filter) Single high pressure filter, block II
MRV circuit IV M12.2 (High pressure filter) Singe high pressure filter, block IV

2. Start both engines and let them run with max. speed.
3. Extend the bucket cylinder (Bucket filling) to the stop position until
of MRV in control block I, II, III and IV, while observing the pressure
gauges. Stop as soon the pressure does not raise any further. The gauge
pointers should remain at 350 bar + 5 bar.
)
• Since the piston side of the bucket cylinders are protected by several
lowest setting.

continued
06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
8.1
37
06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
Cont'd:
Bucket cylinder “Piston side” BHA

360 bar.
142.1 þ 142.2 þ 142.3
sequence: 142.2 þ 142.3 þ 142.

as follows:

06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
8.1
38
06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
Bucket cylinder “Rod side” FSA

There are two service line relief valves (secondary valves) installed, one in
main control block I section 3 and one in block II section 2, to limit the
maximum possible pressure peaks in the service line.

MRV circuit IV M12.2 (High pressure filter) Single high pressure filter, block IV

3. Stall the system with full retracted bucket cylinder in final stop position.
of MRV’s in the control blocks, while observing the pressure gauges.
)
• Since the piston rod side of the bucket cylinders are protected by

continued
06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
8.1
39
06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
Cont'd:
Bucket cylinder “Rod side” FSA

9. Adjust both SRV’s equally, until all gauges show a pressure of
360 bar.
33,2 þ 33.6
all gauges.
11. Proceed with the other valve in the same manner.

as follows:
06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
8.1
40
06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
Bucket cylinder “Piston rod side” BHA
distributor manifold, to limit the maximum possible pressure peaks in the
service line.

SRV 142.8 M34.1 Manifold section L
SRV 142.9 M34.2 Manifold section L
SRV 142.10 M34.3 Manifold section M
MRV circuit IV M12.2 (High pressure filter) Single high pressure filter, block IV
2. Start both engines and let it run with max. speed.
3. Retract the Bucket cylinder (Bucket dump) to the stop position until
of MRV’s in control block I, I, III and IV, while observing the pressure
gauges. Stop as soon the pressure does not raise any further.
)
• Since the piston rod side of the bucket cylinders are protected by
it is necessary to further increase the setting of the MRV.

continued
06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
8.1
41
06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
Cont'd:
Bucket cylinder “Piston rod side” BHA

9. Adjust all SRV’s equally, until all gauges show a pressure of 360 bar.
142.8 þ 142.9 þ 142.10
Turn set screw (3) -clockwise to increase pressure, Counter-clock wise
to decrease pressure.
10. Reduce the pressure, at SRV- 142.8 to a value below the required value
all gauges.
sequence: 142.9 þ 142.10

as follows:

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06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
Page 42
Attachment Cylinders
Clam cylinder “Rod side” (clam opening) FSA
There is one service line relief valve (secondary valve) installed at the distributor
manifold section E, to limit the maximum possible pressure peaks in the service line.
Since the opening pressure of the SRV is higher than the setting of the Main Relief
Valves (MRV’s) it is necessary to increase the main relief pressure for testing and
adjusting purposes.

SRV 142.4 M26 Manifold (42) section E
MRV circuit II M12.3 (High pressure filter) Control block II
MRV circuit IV M12.2 (High pressure filter) Control block IV
1. Connect gauges to the above listed check points.

2. Start engine 2 and let it run in high idle.
3. Retract the clam cylinder (open the bucket) to the stop position until the
hydraulic system stalls.
4. Increase slowly the pump supply line pressure, by turning in set screws (3) of
MRV in control block II and IV, while observing the pressure gauges.
If necessary correct the adjustment as follows:
7. Turn set screw (3) of the MRV ½ turn further in, the gauge pointers will
remain at the value shown at item #4 (350 bar + 5 bar).
9. Reduce the pressure, at SRV 142.4 to a value below the required value, and
then increase up to the required pressure (350 bar), while observing all auges.
10. Reset the MRV to 310 bar + 5 bar after adjustment is finished, as follows:
Turn set screw (3) -clockwise to increase pressure, Counter-clock wise to
decrease pressure.
06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
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06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
Clam cylinder “Piston side” (clam closing) FSA
There are three service line relief valves (secondary valves) installed, two at
distributor manifold section K and one at main control block II section 1, to
limit the maximum possible pressure in the service line when closing the
bucket.
To avoid damages at the clam shell, due to wrong operation, the SRV’s
should be adjusted in a way that the pressure is just sufficient to close the
clam with horizontal back wall.

SRV 144 (1) M22 Manifold section K
SRV 144 (2) M22 Manifold section K
SRV 32.10 MM12.3 (High pressure filter) Control block II

2. Start engine 2 and let them run in high idle.
3. Raise the attachment and bring the back wall of the bucket in a
horizontal position (bucket dump).
4. Press carefully pedal “bucket closing”. The clam should close complete
and must stay closed after pedal in neutral position.
Adjust the SRV’s as follows:
Turn set screw (3) -clockwise to increase pressure,
Counter-clock wise to decrease pressure while
depressed pedal “clam closing”.
Adjust all three SRV’s equally, until the gauges show a pressure of 220 bar.
Now reduce the pressure at one SRV in steps of 5 bar until the bucket opens
by gravity (check with released pedal).
Now read the pressure and adjust 10% plus the reading to compensate the
weight of material stuck at the clam shell.
)
• Since the piston side of the clam cylinders are protected by several
lowest setting.
• Because of different wear packages the pressure can be between 150
bar and more as 200 bar.
06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
8.1
44
06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
8.1.12 Checks and adjustments of the lowering speed,

General
On excavators equipped with Face Shovel Attachment (FSA) there are two
different operation modes for lowering the boom and stick:
I. Float position activated the lowering speed has to be adjusted by altering
the flow restrictors (throttle valves) at the distributor manifold section B,
throttle valve 141.1 and section N, throttle valve 141.3.
II. Float position deactivated the lowering speed has to be adjusted by
altering the flow restrictor (throttle valve) at the distributor manifold
section N, throttle valve 141.2.
On excavators equipped with Backhoe Attachment (BHA) the lowering speed has
to be adjusted at all flow restrictors on distributor manifold section B and N,
throttle valves 141.1, 141.2 and 141.3.
Purpose of the Flow Restrictors:

• To avoid an interruption of the pump delivery.
• To provide an uniform and smooth cylinder travel.
• To limit the return oil flow through the control block to the maximum
permissible volume.
Checks and Adjustments:

• Activate service switch S151 (located in the cab base) during the checks and
adjustments, to ensure that the main pumps are in Qmax position.
• Standard test method is measuring the total cylinder running time by using a
stop watch. If it is impossible to move the cylinder over the whole way, mark a
distance of one meter with permanent pen P/N 621 566 40 on the piston rod
and measure the time for only one meter movement.
• Adjust the restrictor as follows:
• For easy turning of set screw (2) lower the attachment to ground, stop engines
and allow pressure equalizing by moving the lever several times.
• Loosen the lock nut (1) and turn the bolt (2) cw for more restriction and ccw
for less restriction. If more than one restrictor is used for one movement make
sure all set screws are equally adjusted.
) During commissioning, a throttle adjustment has to be carried out on

all machines. For safety reasons, the throttle valves are completely
screwed in before each machine is leaving the factory.
For more information refer to the respective newest Service Bulletin
06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
8.1
45
06.10.05 PC5500-6-D_Sec_8-1_rev3.doc

Boom cylinder FSA
Due to the two different operation modes for lowering the boom, the lowering
speed must be adjusted twice:
I. Float position activated
II. Float position deactivated
Maximum permissible lowering speed for both operation modes:
Cylinder retracting time/meter (s /m) Total time(s)

Boom FSA 1,4 4,3
Adjustments / Checks:
I. Float position activated:

1. Use a stop watch to measure the cylinder running time.
2. Raise the fully extended attachment with empty bucket to the maximum
height position (A).
3. Shift both engines to high idle speed.
4. Rapidly move the control lever (E19) to the front end position (start the stop
watch) and hold it until the final position (B) is reached.(stop the stop
watch).
• Lower the boom so, that the bucket stops just above the ground.
5. If the lowering speed is too high, i.e. the measured time is less than the
permissible time, the speed must be reduced by altering the throttle valves
141.1 (section B) and 141.3 (section N, pointing to the attachment).
Adjust as follows:
To decrease the lowering speed loosen lock nut (1) and turn the bolt (2) cw.
To increase the lowering speed loosen lock nut (1) and turn the bolt (2) ccw.
Since there are several valves throttling the return oil flow the valves
must be set synchronously. The adjusting screws have to be turned in
by the same amount of revolutions.
O.K.
6. Check lowering speed again and repeat the adjustment if necessary.

7. If the adjustment is finished tighten lock nut (1).
continued
06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
8.1
46
06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
Cont'd:
Boom cylinder FSA

II. Float position deactivated (with push button S95):

1. Adjust the throttle adjustment bold of throttle valve 141.2 to the same amount
of revolutions as the valve 141.1 and 141.3.
4. Shift the engines to high idle speed.
5. Press push button S95 and keep it depressed while lowering the attachment.
Rapidly move the control lever (E19) to the front end position (start the stop
watch) and hold it until the final position (B) is reached.(stop the stop watch).
6. The lowering speed will be the same as with floating position. If the lowering
speed is too high, i.e. the measured time is less than the permissible time, the
speed must be reduced by altering the throttle valve 141.1, 141.2 and
synchronous 141.3 at the distributor manifold section B and N.
Adjust as follows:
To decrease the lowering speed loosen lock nut (1) and turn the bolt (2) cw. To
increase the lowering speed loosen lock nut (1) and turn the bolt (2) ccw.
The adjusting screws have to be turned in by the same amount of
revolutions.
O.K.

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8.1
47
06.10.05 PC5500-6-D_Sec_8-1_rev3.doc

Boom cylinder BHA
Maximum permissible lowering speed:
Cylinder retracting time/meter Total time

(s /m) (s)
Boom BHA 1,4 5,0
3. Shift the engines to high idle speed.
4. Rapidly move the control lever (E19) to the front end position (start the stop
watch).
141.1, 141.2 and 141.3 at the distributor manifold.
Adjust as follows:
To decrease the lowering speed loosen the lock nut (1) and turn the bolt (2)
cw. To increase the lowering speed loosen the lock nut (1) and turn the bolt
(2) ccw.
Since there are several valves throttling the return oil flow of the boom
cylinder the valves must be set synchronously. The adjusting screws have
to be turned in by the same amount of revolutions.
O.K.

If the adjustment is finished tighten lock nut (1).
06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
8.1
48
06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
8.1.12 Checks and adjustments of the lowering speed, illustration (Z 22490):

Stick cylinder FSA
Due to the two different operation modes for lowering the stick, the lowering
speed must be adjusted twice:
I. Float position activated
II. Float position deactivated
Maximum permissible lowering speed for both operation modes:

(s /m) (s)
Stick FSA 0,9 2,4
I. Float position activated:

3. Rapidly move the control lever (E20) to the rear end position (start the stop
watch until the stick start moving) and hold it until close to the final position
(B) is reached.(stop the stop watch).
142.5 and 142.7 at the distributor manifold.
Adjust as follows:
To decrease the lowering speed loosen lock nut (1) and turn the bolt (2) cw. To
increase the lowering speed loosen lock nut (1) and turn the bolt (2) ccw.
Since there are several valves throttling the return oil flow of the stick
O.K.

If the adjustment is finished tighten lock nut (1).
continued
06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
8.1
49
06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
Cont'd:
8.1.12 Checks and adjustments of the lowering speed, illustration (Z 22490):
Stick cylinder FSA

II. Float position deactivated (with push button S95a):

1. Adjust the throttle adjustment bold of throttle valve 142.6 to the same amount
of revolutions as the valve 142.5 and 142.7.
3. Start both engines and let it run in high idle.
5. Press push button S95a and keep it depressed while lowering the stick.
Rapidly move the control lever (E20) to the rear end position (start the stop
watch) and hold it until the final position (B) is reached.(stop the stop watch).
6. The lowering speed will be the same as with floating position. If the lowering
speed is too high, i.e. the measured time is less than the permissible time, the
speed must be reduced by altering the throttle valve 142.5, 142.6 and
synchronous 142.7 at the distributor manifold section F and J.
Adjust as follows:
Since there are several valves throttling the return oil flow of the
stick cylinder the valves must be set synchronously. The adjusting
screws have to be turned in by the same amount of revolutions.
O.K.

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50
06.10.05 PC5500-6-D_Sec_8-1_rev3.doc

Stick cylinder BHA
Cylinder extending time/meter Total time

(s /m) (s)
Stick BHA 0,6 1,5
4. Rapidly move the control lever (E20) to the rear end position (start the stop
watch) and hold it until close to the final position (B) is reached.(stop the
stop watch).
142.5, 142.6 and 142.7 at the distributor manifold.
Adjust as follows:
(2) ccw.
Since there are several valves throttling the return oil flow of the stick
O.K.

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8.1
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06.10.05 PC5500-6-D_Sec_8-1_rev3.doc

Bucket cylinder FSA

(s /m) (s)
Bucket FSA 1,1 3,0
4. Rapidly move the control lever (E19) to the r.h. end position (start the stop
watch).
142.1, 142.2 and 142,3 at the distributor manifold section C and D.
Adjust as follows:
Since there are several valves throttling the return oil flow of the
bucket cylinder the valves must be set synchronously. The
adjusting screws have to be turned in by the same amount of
revolutions.
O.K.

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8.1
52
06.10.05 PC5500-6-D_Sec_8-1_rev3.doc

Bucket cylinder BHA

(s /m) (s)
Bucket BHA 0,5 1,1
4. Rapidly move the control lever (E19) to the r.h. end position (start the stop
watch).
142.1, 142.2, 142.3, 142.8, 142.9 and 142.10 at the distributor manifold.
Adjust as follows:
(2) ccw.
Since there are several valves throttling the return oil flow of the bucket
O.K.

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Clam cylinder FSA


3. Open the clam of the empty bucket to the maximum position (A).
4. Rapidly push the control pedal (E23) to the end position (start the stop
watch) and hold it until the final position (B) is nearly reached.(stop the stop
watch).
5. If the lowering speed is too high, i.e. the speed is uncomfortable, the speed
must be reduced by altering the throttle valve 142.4 at the distributor
manifold section E.
Adjust as follows:
7. If the adjustment is finished tighten lock nut (1) and write down the adjusted
running time for later checks.
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8.1
54
06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
8.1.13 Checks for the valve control logic

(1) Main pump condition Ö P = pressurized outlet
(2) Main pump condition Ö (-) = free flow to reservoir
(3) Pilot ports a = outlet ports a
(4) Pilot ports b = outlet ports b
(5) Port condition Ö (-) = closed port
(6) Port condition Ö O = open port
(7) Respective function
(8) Single control valve block for swing
(9) control valve block number
(10) Swing parking brake switch S29
General:
For harmonic attachment motion and well working floating function the valve
spools must be activated with different priorities. The whole valve control logic is
a arrangement of electric relay controlling and the main hydraulic control valve
sequence.
The correct function of the valve control logic can be checked by pressure gauges
(0 -50bar) connected to the pressure test ports at the control valve cabs.
Checks:
a) Connect the pressure gauges (0-50 bar) to all test ports at the pilot control
cabs (26 gauges necessary *) and (0-400 bar) to the high pressure filter
test ports M44.1, 44.2, 46.1, 46.2
b) Mark the control cab with the respective function and port designation.
c) Use the Check list for the Valve Logic in the appendix in this binder.
d) Unplug solenoid valve Y16 (travel parking brake closed) and activate the
swing brake with the switch at the dash board. The ladder and the
refilling arm are in high position (working position) the operator sits on
the operators seat. Make sure that the machine can move hazardless all
functions
e) Start one motor.
f) The operator activate carefully step for step the respective lever or pedal
as shown in the check list. Compare each step with the pressure condition
of the control cabs and main pressure to the check list.
If there is a wrong result, check the respective electric circuit and hydraulic
pilot circuit.
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06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
Hydraulic for the Swing Circuit Section 8.2
Page 1
Section Page
8.2 Hydraulic for the swing circuit
8.2.1 Swing Circuit (Brief description) 2+3
8.2.2 Swing Motor 4-7
8.2.3 Swing Gear Box 8
8.2.4 Swing Parking Brake (Gear house Brake) 9
8.2.5 Swing Brake Valve 10+12
8.2.6 Electric / Hydraulic flowchart “Swing Left” 13
8.2.7 Electric / Hydraulic flowchart “Swing Right” 14
8.2.8 Swing Monitoring System 15 + 16
8.2.9 Adjustments for the swing circuit 17 - 19
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8.2
2
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Page 2
8.2.1 Swing Circuit (Brief description)
(I - VI) Main pumps

(13) Single control block IV
(48) Manifold
(20.1+ 20.2) Swing motors
(71.1+ 71.2) Manifold at the control and filter panel
(25.2) Double check valve
(49.1 + 49.2) Pressure increasing valve (swing brake valve)
(Y48) Swing motors power control valve
(Y120) Solenoid valve
(43) Remote control valve block
(Y32) Proportional valve of the remote control block
(Y32a/b) Directional solenoid valve of the remote control block
(20) Control lever left hand
(50) Ramp module
(A7) Amplifier module
Brief description (Control circuits)

(Study together with the for the machine valid hydraulic and electric circuit
diagram).
When the lever (E20) is moved out of its neutral position, proportional
solenoid valves Y32 are energized. Simultaneously the directional solenoid
valves Y32a (R.H.-swing) or Y32b (L.H.-swing) are energized.
By the function of the remote control valve (43) pilot pressure oil is sent to
one side of the control block (13/IV) when operating the control lever for
"Swinging". At the same time by the function of the proportional valve
(Y127) pilot pressure (proportional to the lever deflection) is present at port
„X“ pressure increasing valve (PIV)of each brake valve block (49.1+ 49.2)
thus a internal pressure built up (higher as 150 bar) in the service lines is
possible.
continued
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3
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Page 3
Cont'd.:
8.2.1 Functional description:
Illustration (Z 22501b):
Brief description (Service circuits)
(Study together with the for the machine valid hydraulic and electric circuit
diagram).
The swing motors (20.1 + 20.2) are feed by the main pump (III). This pump is
at port XLR permanent with 35 bar X2- pressure fix adjusted to Qmax.
The oil flows from the pumps through check valve (47.3) and filter (153.3) to
the single control block (13 / IV).
In neutral position of the spool oil flows via port C into control block II for
additional oil volume from pump 3 to valve circuit II. If no function of
control block II is activated the oil flow via port T in to the collector tube (35)
and further via the return oil lines (L6 + L7) into the tank.
On its way to tank the oil must flow through the back pressure valve (115)
and the return oil filter (117.2 - 117.5). (Back pressure valve function see
chapt. 4.)
When operating the control lever for "Swinging" the pump line is connected
in the control block (33/IV) with the corresponding service line (A1 or B1) to
the swing motors (20.1 + 20.2).
The oil flows from the control block through each one of the swing brake
valves (49.1 + 49.2; description see page 6 and 7) and the swing motors (20.1
+ 20.2).
Each swing gear includes one spring loaded multi disk brake (House brake)
for locking the superstructure.
The leak oil (case drain) flows through the line (L11 + L12) and the leak oil
filter (108) back to tank.
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8.2
4
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Swing motor A6VM Section 8.2
Page 4
8.2.2 Swing Motor Axial Piston Motor A6VM355 HD1D

(1) Check valve
(2) Check valve
(3) Governor valve
(5) Boost pressure valve
(6) Flushing valve (16l/min)
(7) Flow control valve
(8) Constant pressure control valve (adjusted: 280 bar)
General:
A6VM355 HD1D is a variable displacement motor with an axial piston rotary
group of bent axis design for hydrostatic drives.
Its control range allows the variable displacement motor to meet both, high speed
and torque requirements. The output speed is proportional to its displacement.
The output speed increases with decreased displacement trough lower
operating pressure.
The output torque increases with increased displacement trough higher
operating pressure.
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5
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Page 5
8.2.1 Swing Motor Axial Piston Motor A6VM355 HD1D
Hydraulic control, illustration Z22430

By switching pilot pressure to port X at the motor (0 bar or 35 bar) the displacement is
fixed in Vg max or variable.
Without pilot pressure at port X (0 bar) the displacement is fixed to Vg max .
With pilot pressure at port X (35 bar) the displacement is variable from
Vg min (175 cm3/rpm) to Vg max (355 cm3/rpm).
With a swing speed of 0 up to 120 impulses per minute (measured by a proximity
switch located at the swing gear) the motors are in maximum displacement position,
i.e. min. speed and max. torque available.
With a swing speed of more as 120 imp./min. pilot pressure is directed via a solenoid
valve to port X at the motors, to actuate governor valve (3). Now the output speed is
variable depending on the operating pressure, controlled by the function of control
valve (8).
As a result of decreasing operating pressure the motors are reducing their
displacement so that the swing speed will increase.
If the operating pressure rises as a result of load torque, to the setting of the constant
pressure control valve (280 bar), the motors are swiveled out to a greater angel (higher
displacement) and the swing speed will decrease.
Function Speed X- Operating Torque Motor

indicator pressure pressure displacement
imp/min bar bar
Start swing 0-120 0 310 à ~280 Max. Vg max
Standstill to low speed
Swing movement 120-max. 35 280 à ~75 Reduced Vg max à Vg min
Low speed to Max. speed variable
Swing movement Max. 35 ~75 Reduced Vg min
Max. speed
Swing down path 120-0 0 ~170 à 0 Max. Vg max
Control lever in neutral
Counter Swing (braking) 120-0 0 330 à 0 Max. Vg max
Control lever moved to the
opposite side of swing direction
Continued
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6
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Page 6
8.2.2 Hydraulic Motor Axial Piston Motor A6VM355 HD1D
Hydraulic control, illustration Z22431b

Cont'd:
A Flow from A to B without „X-pressure“ (slow swing speed) :

The operating pressure opens check valve (1) and closes the opposite valve (2). The
same pressure is present at the control port of pressure control valve (8) and inside
the small area side of the positioning piston (4). The large area side is connected via
the governor valve (3) to tank (port T2).
The motor remains in Vgmax position. = max. torque by low speed.
B Flow from A to B, with „X-pressure“ (higher swing speed),

operating pressure 0 –280 bar:
Operating pressure opens check valve (1) and closes the opposite valve (2). The
same pressure is present at the control port of pressure control valve (8) and inside
the small area side of the positioning piston (4).
Because of the „X“ pressure at the control port of governor valve (3) a connection
is made from the operating pressure to the large area side of positioning piston (4).
Same pressure on both sides but different areas causes a greater force at the piston
side moving the motor into the Vgmin position.
The motor is in regulation mode due to 35 bar “X-pressure”
Motor displacement to Vgmin position (<280bar).
C Flow from A to B, with „X-pressure“ (higher swing speed),

operating pressure 280-310 bar:
Depending on the system pressure (more as 280 bar), valve (8) connect the large
area side of the positioning piston (4) with the pressure less return line (T2). Low
pressure at the large side cause a greater force at the pressurized small area side of
the positioning piston (4) moving the motor into the Vgmax position.
The motor is in regulation mode due to high operating pressure (>280bar) :
Motor displacement to Vgmax position (>280bar).
As a result of decreasing operating pressure the motors are reducing their

displacement so that the swing speed will increase.
If the operating pressure rises as a result of load torque, to the setting of the constant
pressure control valve (280 bar), the motors are swiveled out to a greater angel (higher
displacement) and the swing speed will decrease.
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Page 6
PC5500-6-D_Sec_8-2_rev4.doc 06.10.05
Page 7
8.2.2 Checks and Adjustments, illustration Z22432

Preconditions before starting checks and adjustments:
1. Main pump 3 must be in full flow position (X1-pressure = 35 bar), no action
required because stabilized X1 pressure is automatic activated during swinging
2. MRV’s and SRV’s (pressure increasing valves) correctly adjusted.
Checking the Q-max. and Q-min. stop bolt setting.

Q-max : The average outer length of 25.1 mm must not be altered because the
max. possible swivel angle is used.
Q-min : The Qmin. adjustment depends on the max. permissible swing speed (with
reduced swivel angle). The average outer length is 36.1 mm
) • It is important that the adjustment is equal on both motors!
How to check the Q-min. adjustment.

1. Lift the extended attachment to horizontal position.
2. Measure the time for 5 revolutions after swinging one turn as an approach swing.
The time should be t5rev = 90+5 sec .
3. If a adjustment is required:
Turn off box nut (1) and loosen lock nut (3)
Turn bolt (2) further in for less speed or further out for higher speed.
One turn of the Qmin bolt (2) cause a change of approx. ∆t5rev = 4.6 sec.
4. Re-check speed and tighten lock nut and re-fit box nut (1) after setting is finished.
How to check / adjust the start of regulation.

1. Activate manually relay K153 to energize Y48 to pressurized swing motor port
X with X2-pressur.
2. Connect a pressure gauge (0-400 bar) to check point M12.2 at high pressure
filter of single control block IV.
3. Measure and note outer length (L) of Qmax stop bolt (2) (for resetting later on)
Loosen lock nut (3) approx. ½ turn without turning the stop bolt..
4. Start engine 1 and let it run in high idle.
5. Apply the swing parking brake.
6. Operate carefully the control lever for swing in one direction and keep it in end
position. The resulting operating pressure should be 320 bar.
7. Loosen look nut of MRV at single control block IV.
8. Decrease / increase alternately the operating pressure between 300 bar and 260 bar
at MRV set screw. Check by turning the Qmax stop bolt (2) by hand, if the motor
control lens touches the Qmax stop bolt:
The lens must touch the stop bolt with a pressure higher than 280 bar.
The lens must not touch the stop bolt with a pressure lower than 280 bar
9. Correct the start of regulation with valve (8) if necessary.
10. Reset MRV. Stop engine and deactivate K153
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8.2
8
PC5500-6-D_Sec_8-2_rev4.doc 06.10.05
Page 8
8.2.3 Swing Gear Box
Legend for illustration (Z 25305), manufacturer: Siebenhaar

(1) Drive housing (11) Bearing ring
(2) Drive shaft (12) Cartridge
(3) Sun gear shaft (13) Spherical roller bearing
(4) Multi disc brake, spring (14) Oil drain plug, gear box
loaded pilot pressure released (15) Cylindrical roller bearing
(5) Breather filter motor adapter (16) Oil level gauge (dipstick)
housing for gear box
(6) Oil level gauge (dipstick) (17) First planetary stage
for drive shaft housing (18) Drive shaft to second stage
(7) Disk brake housing (19) Second planetary stage
(8) Cylindrical roller bearing (20) Radial seal ring
(9) Internal ring gear (21) Drive pinion
(10) Cylindrical roller bearing (22) Grease line port
(23) Centering circle
The swing gear is of compact design with a two stage planetary gear including a
multi disk house brake.
The gear is bolted to the superstructure and fits firmly due to the machined
diameter (A) and the bolt torque.
The torque loaded on the hydraulic motor is transmitted by drive shafts (2)
and sun gear shaft (3) to the first planetary stage (17).
The sun shaft (17) of the first planetary stage transmits the torque into the
second planetary stage (19). By the planetary gears the output drive shaft is
rotated and transmits the torque to the pinion (21).
The drive housing, and the gearbox are filled with gear oil.
Aeration is done by breather filters.
A grease nipple is via a hose connected to the bearing lubrication port (22).
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8.2
9
PC5500-6-D_Sec_8-2_rev4.doc 06.10.05
Page 9
8.2.4 Swing Parking Brake (Gear house Brake)
The Spring Loaded Multi-disk Brake is a safety brake; applied by

spring force and released by oil pressure.

(1) Clip ring (circlip)
(2) Thrust washer
(3) Outer discs
(4) Inner discs
(5) Piston
(6) Quad ring with back up ring
(7) Quad ring with back up ring
(8) Springs
(9) Piston back up ring and seal retainer
(10) O ring
(11) Clip ring (circlip)
(12) Oil pressure port
Function:
Brake applied:
The outer disks (3) engaged to the housing by serration and the inner disks (4) in
serrated connection with drive shaft are pressed together by the springs (8). This
results in a fixed connection between housing and drive shaft.
Brake released:
Oil pressure via port (12) reaches the bottom of the piston (5) and forces the
piston upwards against the thrust washer (2).
This function eliminates the spring force to the disc (3) and (4) thus the brake is
released.
The releasing pressure is 12 - 20 bar, the maximum permissible pressure
60 bar.
This is a so named "Wet Brake" because the brake housing is filled with oil.
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8.2
10
PC5500-6-D_Sec_8-2_rev4.doc 06.10.05
Page 10
8.2.5 Swing Brake Valve

(1) Pressure increasing valve (7) Spring of main piston
(items 6 - 13) (8) Jet bore
(2) Check valve circuit A (9) Valve poppet
(3) Check valve circuit B (10) Spring
(4) Anti-cavitation valve circuit B (11) Intermediate piston
(5) Anti-cavitation valve circuit A (12) Pilot pressure piston
(6) Jet bore, of main piston plug (13) Main piston
Ports:
(Y) Leak oil
(T) Return oil
(A) Service line from control block
(A1) Service line to the motor
(B) Service line from control block
(B1) Service line to the motor
Pressure check points:

(MA) Circuit A
(MB) Circuit B
Explanation of the function by the symbol:

When ever a swing motion is carried out or the foot brake is used, pilot
pressure arrives the pressure increasing valve (1) at port "X".
The pilot pressure pre-loads these valves.
The oil for the hydraulic motor from the control block arrives the service line
port A or B, depending if a R.H. or a L.H. swing motion is carried out.
The ports A and B are internally connected to the ports A1 and B1 and these
ports in turn with the hydraulic motor.
The operating pressure, at either port A or B closes the anti-cavitation valves
(4 or 5) and opens the check valves (2 or 3).
That means by the check valves (2 or 3) the service lines are connected to the
pressure increasing valve.
When ever the pressure is higher than the setting of the pressure increasing
valve, this valves opens and dumps the oil into the return line (T) to tank.
The pressure can be checked at the check points MA or MB.
continued
PC5500-6-D_Sec_8-2_rev4.doc 06.10.05
8.2
11
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Page 11
Cont'd.:
8.2.5 Swing Brake Valve
If after a swing motion the joy stick is released into neutral position
without using the foot brake, the superstructure is turned by inertial force
and the hydraulic motor acts as a pump because it is driven by the swing
gear.
Both service line’s (pump line and tank line) are blocked at the control
valve block. In this period the service line (previously pump line) acts now
as suction line and the return line (previously return line) acts now as
output line. Because of the closed service ports at the control block all oil
from the swing motor must pass the brake valve block. The pressure
increasing valve in the brake valve block acts now as a back pressure
valve. This variable back pressure is the brake force.
Function of the pressure increasing valve.

When ever a swing motion is carried out or the foot brake is used, pilot
pressure arrives the pressure increasing valve (1) at port "X". The pilot
pressure pre-loads these valves.
By applying pilot pressure via the external port X to piston (12), the pre-
tensioning of the pressure spring (10) is increased by the amount of the piston
stroke "S", which results in the actual valve setting.
The system pressure is in front of the main piston (13) and via the jet bore (6)
also in the chamber of the spring (7) and via the jet bore (8) at the pressure
relief valve poppet (9).
Due to the force balance the piston (13) is kept in its position supported by
the spring (7).
Overcomes the system pressure the setting of the valve (9), this valve opens a
channel to the dump line port (Y). Due to the drop of force the piston (13) is
moved to the right.
The pressure line gets connected with the return line (T).
Damped opening and closing are obtained by the throttled volumetric change
that is caused by the jet bores.
continued
PC5500-6-D_Sec_8-2_rev4.doc 06.10.05
8.2
12
PC5500-6-D_Sec_8-2_rev4.doc 06.10.05
Page 12
Cont'd.:
8.2.5 Swing Brake Valves

Anti cavitation prevention. Illustration Z 22672a
(2) Main back pressure valve
(3) Gear pump (8.2 + 8.5)..
(4) Swing motor back pressure valve blocks (195.1 + 195.2)
(5) Swing brake valve blocks (49.1 + 49.2).
(6) Swing motor (20.1 + 20.2)
(7) Pressure relieve valve (swing motor back pressure)
(8) Check valve
(9) Pressure check point M35.1 and M35.2
(10) Valve drain connection
A Input from gear pump
B Output to swing brake block
T Tank connection to return oil collector tube
During the swing down phases the swing motors (6) are working as “pumps”.
It means that the pressure side change to a suction side and the suction side
change to a pressure side. To prevent cavitation in the swing motors during
this change there are two back pressure valves (4) fitted. The valves (4)
together with the gear pumps (3) increase the main back pressure up to 15
bar. Port B is direct connected to the tank port (return line) of the swing brake
valve block (5).
Adjustments - Measurements -Settings

Setting of the swing circuit back pressure valves (3)
1. Connect pressure gauge (0 – 25 bar) to check points M35.1 and M35.2

at the valve blocks (195.1 +195.2). The valve blocks fitted at the return
oil collector tube in front of the hydraulic tank.
2. Start both engines and let them run in high idle.
3. The pressure at the gauges should be 15 bar if the gauges shows a
different value the pressure relieve valves in the back pressure valve
must be adjusted.
a) Loosen look nut

b) Turn in or out set screw to increase or decrease the pressure.
c) Tighten look nut
4. Stop engines
5. Disconnect the gauges.
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8.2
13
PC5500-6-D_Sec_8-2_rev4.doc 06.10.05
Page 13
8.2.6 Electric / Hydraulic flowchart “Swing Left”

(13) Main control block IV
(20.1 + 20.2) Swing motors
(48) Distribution block
(49.1 + 49.2) Swing brake valve blocks
(A7) Amplifier module – Swing (Y32 + Y32a/b – Block IV)
(A16) Amplifier module – Swing brake
(E50B) Ramp time module – Swing brake
(K165) Relay counter lock (option)
(K253) Relay controlled by swing brake (foot brake)
(ws/gn) Colour code of signal voltage cable ( Joy stick)
(-X) Direction (axis) of joy stick (minus x = left)
(X2F...) Terminal rail with number
(Y32a + Y32b) Directional solenoid valve
(Y127) Proportional valve, controlling pressure increasing valve
The electrical signal.

terminal 5 of the amplifier module (A7) and further via relay K165 (if
equipped) to the proportional and directional solenoid valves of the remote
control blocks (43). In the same time signal voltage of joy stick arrives via
K253 and ramp time module E50B to terminal 5 of the amplifier module A16.
Relay contact 2 / 10 of relay K165 (if equipped) opened if the excavator
superstructure swing in a different direction as the lever direction (counter
look). Relay K253 energized if the swing brake pedal is activated this
eliminate the ramp time function of E50B.
The hydraulic signal. (pilot pressure)
pressure oil flows to the pressure ports of the main control blocks.
Proportional valve Y127 increase proportional to the lever deflection the pilot
pressure to the pressure increasing valves.
The hydraulic oil flow
Now the oil of the main pump 3 flows through the main control block (IV) and
arrives via swing brake valves (49.1 + 49.2) at the swing motors (20.1 + 20.2).
PC5500-6-D_Sec_8-2_rev4.doc 06.10.05
8.2
14
PC5500-6-D_Sec_8-2_rev4.doc 06.10.05
Page 14
8.2.7 Electric / Hydraulic flowchart “Swing Right”

(13) Main control block IV
(20.1 + 20.2) Swing motors
(48) Distribution block
(49.1 + 49.2) Swing brake valve blocks
(A7) Amplifier module – Swing (Y32 + Y32a/b – Block IV)
(A16) Amplifier module – Swing brake
(E50B) Ramp time module – Swing brake
(K165) Relay counter lock (option)
(K253) Relay controlled by swing brake (foot brake)
(ws/gn) Colour code of signal voltage cable ( Joy stick)
(+X) Direction (axis) of joy stick (plus x = right)
(X2F...) Terminal rail with number
(Y32a + Y32b) Directional solenoid valve
(Y127) Proportional valve, controlling pressure increasing valve
The electrical signal.

terminal 5 of the amplifier module (A7) and further via relay K165 K165 (if
equipped) to the proportional and directional solenoid valves of the remote
control blocks (43). In the same time signal voltage of joy stick arrives via
K253 and ramp time module E50B to terminal 5 of the amplifier module A16.
Relay contact 2 / 10 of relay K165 (option) opened if the excavator
superstructure swing in a different direction as the lever direction (counter
look). Relay K253 energized if the swing brake pedal is activated this
eliminate the ramp time function of E50B.
The hydraulic signal. (pilot pressure)
pressure oil flows to the pressure ports of the main control blocks.
Proportional valve Y127 increase proportional to the lever deflection the pilot
pressure to the pressure increasing valves.
The hydraulic oil flow

Now the oil of the main pump 3 flows through the main control block (IV) and
arrives via swing brake valves (49.1 + 49.2) at the swing motors (20.1 + 20.2).
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8.2
15
PC5500-6-D_Sec_8-2_rev4.doc 06.10.05
Page 15
8.2.8 Swing Monitoring System, illustration (Z 21947a)

There are two reasons why the swing monitoring system is installed:
a) ⇒ To prevent adverse effects of a counter action.
b) ⇒ To increase the swing speed, by reducing the swivel angel of the
swing motor (lowering the required oil volume per motor rotation)
Function of the swing monitoring system:

The two sensors B98 and B99, (Proximity switches mounted into a housing
near the ring-gear) sensing the direction of rotation.
How?
Because the distance from sensor to sensor (B) is less than the distance of two
teeth (A), one of the sensors recognizes first a swing action.
The signals of both sensors are used as input signals for the module (E42)
which monitors the swing direction.
The same signals from sensor B99 are send to the module E43 for sensing the
swing speed.
Proximity switch B99 together with module E43 monitors the swing speed to
control via relay K154 and K153 solenoid valve (Y48).
• Activated solenoid valve Y48 allows full X2 pressure to swing motors
(20.1 + 20.2) port X = if the working pressure is less then 280 bar
increasing of swing speed is possible.
• De activated solenoid valve Y48 causes no X2 pressure to swing motor
(20.1 + 20.2) port X = the motors are fixed in maximum swivel angel
(max. volume = max. torque and min. speed)
⇒ Acceleration
During the first acceleration phase the maximum torque by minimum speed is
required, the motors must be in maximum swivel angel (x-port 0 bar). E43
detect the swing speed, if the speed is below 120 Imp./min. relays K154 and
K153 are still de energized and further solenoid valve Y48 de-energized (x-
port = 0 bar = max. motor swivel angel = max torque). After this first
acceleration the required torque and hydraulic pressure droops and the swing
speed increase. E43 detect more as 120 Imp./min and energize relay K154. If
the lever direction and the swing direction is the same K153 energized and
further D153 energized solenoid valve Y48 (x-port = 35 bar = variable motor
swivel angel is possible).
⇒ “ Braking ” with counter position of the lever
If the operator release the lever or move the lever to counter position relay
K153 opened contact 5 / 9 it de energize time relay D153. After the time is
elapsed (one second) solenoid valve Y48 de energize and change over in
neutral position so that pilot line L18 release the pressure to the tank (port X =
0 bar). The swing motors move to maximum swivel angel. Now a maximum
breaking torque is available.
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8.2
16
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Page 16
8.2.8 Swing Monitoring System, illustration (Z 21947a)
(Study together with the valid hydraulic and electric circuit diagram for the
machine)
Adjustments - Measurements -Settings
a) Distance between Swing ring teeth and the switches B98 and B99
The sensors B98 and B99 are inductive switches with own electronic.
Sensor B98 switches 24V via cable “Sig” to terminal 4 of E42 and
Sensor B99 switches 24V via cable “Sig” to terminal 11 of E42 if a
tooth comes close to the sensor head.
Simultaneously these signal arrives at E43 terminal 4.
Adjust the distance “C” of the sensors B98 and B99 to 5±1 mm.
b) E42 for monitoring the slew direction

E42 is an programmable module which is factory programmed with the
parameters are shown in the electric diagram. Therefore no adjustments
or settings are required.
The indication light (In1 from B98 / In2 from B99) lights/pulses if a
input signal comes up. The indication light (Out1 for swing left / Out2
for swing right) lights if the module indicates a swing direction.
c) E43 for monitoring the slew direction

E43 is an programmable module which is factory programmed with the
parameters are shown in the electric diagram below.
Settings:
E43 (speed monitor) “counter prevention”
No Function nominal setting
1 Setting the start up delay Not used set to “0”
2 Fine setting of the preset value (pulses / min.) 12 imp/min (i.e.120)
3 Setting the hysteresis Not used set to “0”
4 LED: lights when the output relay is energised ---
5 Setting the switching function Set to “III”
6 Coarse setting of the preset value (pulses / min) X x 10 imp/min
If necessary increase or decrease the imp/min with set screw no. 2

until a smooth slew operation is possible.
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8.2
17
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Page 17
8.2.9 Checks and adjustments for the swing circuit
) • It is important that the complete MRV-valve and the Pressure

Increasing Valve is firmly (with 300 Nm) tightened.
Otherwise, the internal sealing sealed not properly which results in:
difficulty setting, loud flow noises and abnormal temperatures.
• Whenever pressure checks are carried out, they must be carried out
for both, r.h. and l.h. swing, to make sure the check valves in the brake
valve are in good shape.
• Because the Swing motors are working hydraulically in combined
operation, the pressure gauge shows the pressure of the pressure
increasing valve with the lowest setting. Even when the gauge shows
the required pressure it is possible that one valve has a higher setting.
Therefore lower the pressure on one valve below the required pressure
and then increase up to required pressure. Proceed with next valve in
the same manner.
High pressure check / adjustment

1. Connect the gauge (0-400 bar) to check point M12.2 at the high
pressure filter units (153.3) of single control block IV.
2. Release the pilot pressure by several movements of the lever with
motor / engine stand still. The key switch S1 must be on the ladder and
service arm must be in up position. Disconnect carefully the pilot
pressure lines from the pressure increasing valves and close the lines
with a suitable plug.
3. Loosen lock nut (3) of both pressure increasing valves (PIV) and screw
in set screw (4) until piston (5) comes to stop.
4. Start engine and let it run with max. speed.
5. Lower attachment to ground and apply house brake (swing parking
brake).
6. Actuate either l.h. or r.h. rotation until the hydraulic system stalls and
increase slowly the MRV-pressure while observing the pressure gauge.
Gauge value must remain at 330 -5 bar. Increase MRV setting
additional 1/8 turn cw..
7. If the gauge shows a lower or higher value the pressure increasing
valves must be adjusted.
continue
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18
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Page 18
Cont'd:
High pressure check / adjustment
Pressure Increasing Valve (PIV) high pressure adjustment
Procedure:
a) Loosen lock nut (1) of the first pressure increasing valve PIV.
b) Adjust pressure with set screw (2) to ~340 bar if the pressure don’t
increase turn set crew from the last setting max. ¼ turn in (c.w.).
c) Secure by tightening lock nut (1).
d) Loosen lock nut (1) of the second PIV.
e) Adjust pressure with set screw (2) to 330 –5 bar.
f) Secure adjusted set screw (2) by tightening lock nut (1)
g) Loosen lock nut (1) of the first PIV.
h) Adjust pressure with set screw (2) of the first PIV to 330 –5 bar
(lower pressure c.c.w. just as the pressure gauge show a reaction)
i) Secure adjusted set screw (2) by tightening lock nut (1)
j) Re-check pressure setting.
k) Re-set MRV to 310 + 5 bar after the check / adjustment is finished.
Low pressure check / adjustment (Swinging down path (drifting)

(with still disconnected pilot pressure line )
8. Actuate either l.h. or r.h. rotation until the hydraulic system stalls.
a) loosen lock nut (3) at the first PIV and turn out set screw (4)
until 150 +5 bar is reached.
b) Tighten lock nut (3).
c) Loosen lock nut (3) at the second PIV and turn out set screw
(4) until the gauge start lowering the pressure.
d) Re-check pressure setting.
9. Re-connect the pilot pressure line. Proceed like item 2.
) • For later one pressure checks the steps 2 + 3 must not be done.
• The Swinging down path may be extended, means the low pressure
may be decreased a little; e.g. for greater operating radius such as at
strip Mining. But a little only otherwise disturbance due Swinging will
occur.
• The Swinging down path may be shortened, means the low pressure
may be increased approx. 20 bar; but not more because that means
greater shocks in the systems which will shorten the life time of the
components.
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8.2
19
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Page 19
Cont'd:
Brake pilot pressure - check / adjustment

1. Connect the gauge to the check point M4.
2. Start engine and let it run with max. speed.
3. Depress fully the foot brake pedal and read the pressure.
The pressure must be 19 +3 bar.

Alter the position of the potentiometer R2 of the amplifier A16 as long as the
pressure is 19 +3 bar.
Basic adjustment for A16 see section 5
PC5500-6-D_Sec_8-2_rev4.doc 06.10.05
PC5500-6-D_Sec_8-2_rev4.doc 06.10.05
Hydraulic for the travel circuit Section 8.3
Page 1
Section Page
8.3 Travel System
8.3.1 Travel Circuit (Brief description) 2+3
8.3.2 Rotary Distributor 4+5
8.3.3 Side Frame Components 6
8.3.4 Travel Gear and Parking Brake 7
8.3.5 Parking Brake 8
8.3.6 Electric / Hydraulic Flow Chart 9
8.3.7 Adjustment / Checks 10 + 12
PC5500-6-D_Sec_8-3_rev2.doc 06.10.05
8.3
2
PC5500-6-D_Sec_8-3_rev2.doc 06.10.05
Travel System Section 8.3
Page 2
Travel Circuit
(1; 2; 5; 6) Main pumps

(14 / I) L.H. Control block
(16 / III) R.H. Control block
(21.1- 21.4) Travel motors (A2FM 355)
(28.1+28.2) Travel motors valve blocks
(34) Rotary distributor
(40) Suction tank
(46.1+46.2) Double filter
(52.1 + 52.4) Travel gear house brakes
(M12.1 + M12.4) High pressure check points
(M33.1, M33.2) High pressure check points left travel motors
(M33.3, M33.4) High pressure check points right travel motors
Brief description
(Study together with the machine valid hydraulic and electric circuit dia-
gram).
Control circuits, not shown

By the function of the remote control valve (45.1 + 45.3) pilot pressure oil is
sent to one side of each control block (14/I + 16/III) when operating the foot
pedal for travelling "Forward or Reverse“.
PC5500-6-D_Sec_8-3_rev2.doc 06.10.05
8.3
3
PC5500-6-D_Sec_8-3_rev2.doc 06.10.05
Page 3
8.3.1 Service circuits ( Z22521)
(Study together with the valid hydraulic and electric circuit diagram for the
machine).
The travel motors (21.1 - 21.4) are driven by the pumps (1; 2; 5; 6).
The oil flows from the pumps through check valves and the filters (46.1 + 46.2)
to the control blocks (14 / I + 16 / III).
In neutral position of the spools the oil flows via the return oil lines into the col-
lector tube (35, not shown). From the collector tube (35) flows the oil via the re-
turn oil lines (L6 + L7, not shown) into the collector tube (114) and further to
the tank. On its way to tank the oil must flow through the back pressure valve
(115) or the oil coolers (106.1 – 106.4) and the return oil filter (117.1 - 117.4).
(Back pressure valve function see section 4.)
When operating the foot pedal for "Travelling" the pump line of each control
block is connected with the corresponding service line (A1 or B1) via the rotary
distributor (34) and the valve blocks (175 + 176) to the travel motors (21.1 -
21.4).
The oil flows from the travel motors via the rotary distributor back to the control
blocks and further to tank.
Each travel gear includes two spring loaded multi disk brakes (House brakes)
(52.1 - 52.4). They are used as parking brakes, automatically applied (by the
function of Y16) whenever both motors stoped. The brake release pressure is
monitored by the pressure switch (B48).
The leak oil (case drain) flows through the line (L) and the leak oil filter (108)
back to tank.
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8.3
4
PC5500-6-D_Sec_8-3_rev2.doc 06.10.05
Page 4
8.3.2 Rotary Distributor
Task:
The rotary distributor (joint) permits a hydraulic connection between the su-
perstructure and the undercarriage, that means between the rotating and the
stationary part.
(1) Rotor
(2) Rotary distributor housing
(3) Cover
(4) Thrust washer
(6) Sealing plunger
(8+9) Seal ring and O-ring
(10) PTFE Sealing
(11) V – Sealing
(12) Rotor guide rings
(13) O-ring
Translations:
Schnitt = Cross section
Versetzt gezeichnet = Offset drawn
Verschlußschraube mit Loctite gesichert = Plug screw sealed with Loctite
mit Körnerschlag gesichert = sealed with punch mark
Kammer mit Fett gefüllt = Chamber grease filled
Ports:
A-D Service lines
L Leak oil
ST Control oil „Travel break“
X Control oil (travel motor flushing)
K1 Track tensioning
K2 Track tensioning
continued
PC5500-6-D_Sec_8-3_rev2.doc 06.10.05
8.3
5
PC5500-6-D_Sec_8-3_rev2.doc 06.10.05
Page 5
Cont’d.
Function (Z 22522):
During operation superstructure and under carriage rotate towards each other.
The travel oil motors must be supplied with hydraulic oil in every position in
which the superstructure is turned in regard to the undercarriage. Oil is di-
rected by the control blocks to the ports (A-D) of the housing (2).
The oil flows to the outlet ports (A-D), of the rotor (1), via ring grooves as
well as longitudinal and cross holes. The rotor is bolted to the under carriage
and the housing (stator) is fixed by the upper structure. The sealing of the ring
grooves among one another is done by seal rings (8) and o-rings (9).
The hydraulic connection for the travel motor case drain and the travel motor
house brake is done via the ports (L) and (St).
The rotor (1) is at the top and bottom section guided in the housing by the
guide rings (12).
PC5500-6-D_Sec_8-3_rev2.doc 06.10.05
8.3
6
PC5500-6-D_Sec_8-3_rev2.doc 06.10.05
Page 6
8.3.3 Side Frame Components, Cross Sections

A Under carriage view from the back side

B Final drive with
C Side frame with top and bottom roller
D Track tensioning cylinder
PC5500-6-D_Sec_8-3_rev2.doc 06.10.05
8.3
7
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Page 7
8.3.4 Travel Gear and Parking Brake
Function principle ( illustration Z22524a):

The spur gear stage (B) is driven by two hydraulic motors via two drive
shafts (A). This in turn causes that by the shaft (C) the first planetary stage
(D) is driven; opposite the input drive direction.
The planetary gears of the second planetary stage are connected to the hollow
shaft (G).
The drive sprocket is mounted to the hollow shaft (G).
For maintenance see MAINTENANCE MANUAL

For more details see PARTS BOOK.
PC5500-6-D_Sec_8-3_rev2.doc 06.10.05
8.3
8
PC5500-6-D_Sec_8-3_rev2.doc 06.10.05
Page 8
8.3.5 Parking Brake

The Spring Loaded Multi-disk Brake is used as a safety brake (parking
brake); applied by spring force and released by oil pressure.
Legend:
(1) Disk housing
(2) Piston
(3) Back-up ring with radial seal rings (15)
(4) Bach-up ring
(5) Coupler
(6) Inner disks (lamellas)
(7) Outer disks
(8 + 9) Springs
(10 - 12) O-ring
(13) Clip ring
(14) Clip ring
(16) Release pressure port
(17) Quad-Ring with back-up rings (18)
(19) Quad-Ring with back-up rings (20)
(21 + 22) Plug screw with seal ring
Function:
Brake applied:
The outer disks (7) engaged to the housing by serration and the inner disks (6) in
serration connection with the coupler, are pressed together by the springs (8 +
9). This results in a fixed connection between housing and coupler.
Brake released:
Oil pressure via port (16) reaches the left side of the piston (2) and forces the
piston towards the back-up ring (4), as shown.
This function eliminates the spring force onto the disks thus the brake is re-
leased.
The releasing pressure is 18 bar, the maximum permissible pressure 60 bar.
This brake named "Wet Brake" because the brake housing is filled with gear oil.
For maintenance see MAINTENANCE MANUAL
For more details see PARTS BOOK
PC5500-6-D_Sec_8-3_rev2.doc 06.10.05
8.3
9
PC5500-6-D_Sec_8-3_rev2.doc 06.10.05
Page 9
Electric / Hydraulic Flow Charts
On the following pages are shown the electric / hydraulic flow charts for the
travel circuit.
The electrical signal created by the foot pedals (E21a and E21b) reach first
of all the ramp modules (E51 and E52) and further the amplifier modules
(A12 and A13). It is a voltage signal from –10 up to +10 Volt dependent to
the pedal deflection and direction. The amplifier modules changes this signal
in a current signal from 0 to 1000 mA and a directional signal (0 or 24 V).
The current signal activate the proportional valve and the directional signal
the directional solenoid valve of the remote control block (45.1 and 45.3).
The valves in case activate the pilot pressure to the main control valve blocks.
This hydraulic signal (pilot pressure) from the remote control valves flow to
the main control blocks (175 and 176) to the pilot pressure ports a1 or b1
which in case push the main control valve spool to control the main hydraulic
oil flow from the main pump.
The main hydraulic oil flows now from the main control blocks via the ro-
tary distributor (34) to the hydraulic motors (21.1 - 21.4).
PC5500-6-D_Sec_8-3_rev2.doc 06.10.05
8.3
10
PC5500-6-D_Sec_8-3_rev2.doc 06.10.05
Page 10
Adjustments / Checks
) • It is important that the complete MRV-valve is firmly (with 300 Nm)

tightened.
Otherwise, the internal sealing sealed not properly which results in:
difficulty setting, loud flow noises and abnormal temperatures.
High pressure check / adjustment (illustration Z 22528)

1. Connect the gauge (0-400 bar) to the check points M12.1. and M12.4
at the double high pressure filters.
2. Unplug solenoid valve Y16 (Z 22529, filter and valve panel motor 2) to
keep the parking brake applied.
4. Engage carefully desired travel motion and hold foot pedal in final po-
sition to built up max. pressure.
5. Increase * slowly the MRV-pressure while observing the pressure
gauge. Gauge value must remain at 310 +5 bar.
Motor 2
continued
PC5500-6-D_Sec_8-3_rev2.doc 06.10.05
8.3
11
PC5500-6-D_Sec_8-3_rev2.doc 06.10.05
Page 11
Cont’d.
If the gauge shows a lower or higher value and to be sure both SRVs are correct
adjusted the SRVs (main valve block and brake valve block) must be adjusted.
) • A faulty anti cavitation valve (32.1; 32.2; 32.13; 32.14) can influence
the SRV pressure reading / setting. In a doubt inspect the valve. Re-
pair or replace faulty valve if necessary.
• A faulty rotary distributor or motor gives the same problems.
Repair or replace faulty part.
Procedure:
6. Set MRV of main valve block I and III to a higher setting (~ 340 bar,
for adjustment use the function “stick extending”
7. Engage carefully desired travel motion and hold foot pedal in final po-
sition to built up max. pressure
8. Adjust* the respective SRV to a higher setting (~330 bar)
9. Connect pressure gauge to check points M33.1, M33.2, M33.3 and
M33.4 at the travel valve block in the car body. The respective high
pressure check point is on the other side diagonal to the SRV.
10. Adjust* the SRV at the desired travel function to 310 bar.
11. Reset the respective SRV at the main valve block to 310 bar, increase
the setting from a lower pressure just to the point when the gauge stop
increasing it should be 310 bar (provided setting from the SRV at the
brake valve is correct).
12. Create max. pump pressure with “stick extending” to the max. position
and re-set MRV to 310 + 5 bar after the check / adjustment is finished
and re-plug solenoid valve Y16
13. Stop enignes.
*
a) Remove dust cap of the SRV (1)
c) Adjust pressure with set screw (3).
d) Secure adjustment by tightening lock nut (2).
e) Re-fit dust cap (1).
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8.3
12
PC5500-6-D_Sec_8-3_rev2.doc 06.10.05
Page 13
Function Check of the Travel Gear House Brake
1. Connect pressure gauge to check point (M6) at the filter and valve
panel motor 2.
3. Read the pressure. Gauge must show common pilot pressure (norm.
35 + 1 bar). If not check the pilot pressure. If the pressure is below
24 bar, the text display must show „Travel gear house brake ON“.
4. Operate the travel foot pedals, the machine must travel.
In case the machine doesn’t travel the text display must show
„Travel gear house brake ON“
5. Unplug solenoid (Y16) and operate the travel foot pedals, the ma-
chine must not travel.
The text display must show „Travel gear house brake ON“
) • In a case of malfunctioning check the electrical controlling and the

solenoid valve Y16.
Function check of the pressure switch (B48)

1. Connect pressure gauge to check point (M6).
2. Start one motor. The gauge must show common pilot pressure (norm.
35 + 1 bar).
3. Set pilot pressure relief valve (70.2) to 22 bar X2 pressure.
4. Unplug solenoid valve Y16 to allow pressure release from the pres-
sure line of the house brake.
5. Reconnect solenoid valve Y16.
The text display must show „Travel gear house brake ON“
6. Increase the pilot pressure up to 26 bar
„Travel gear house brake ON“ must disappear
If not check the pressure switch B48 and exchange it if it is out of
the range.
7. Reset pilot pressure to 35 bar
PC5500-6-D_Sec_8-3_rev2.doc 06.10.05

PC5500-6-D_Sec_8-3_rev2.doc 06.10.05
Hydraulic Track Tensioning System Section 9.0
Page 1
Section Page
9.0 Hydraulic Track Tensioning System
General 2
9.1 Functional description 3+4

9.2 Pressure Increasing Valve 5
9.3 Tensioning Cylinder 6
9.4 Adjustments / Checks 7–9
9.5 Functional test 9
17.01.07 PC5500-6-E_Sec_9-0_rev1.doc
9.0
2
17.01.07 PC5500-6-E_Sec_9-0_rev1.doc
Page 2
9.0 General:

(62.1 – 62.4) Track tensioning cylinders
(M15.3 + M15.4) Bleeder and hydraulic pressure check points at the
R.H.- tensioning cylinders.
(M15.1 + M15.2) Bleeder and hydraulic pressure check points at the
L.H.- tensioning cylinders.
(M15.5) Bleeder and hydraulic pressure check point at the bladder
accumulator (59.1) for the L.H.-side.
accumulator (59.2) for the R.H.-side.
(60.1 + 60.2) Membrane accumulator, 1,3 liter (pre-charge pressure 31bar)
(54.2) Service shut-off cock for the L.H.-side
(54.3) Service shut-off cock for the R.H.-side
* "O" = open - "C" = closed
(59.1 + 59.2) Bladder accumulator, 5 liter (pre-charge pressure 150bar)
(34) Rotary joint
L3 (St) Supply line from solenoid valve Y16 over rotary joint port St
The hydraulic track tensioning system ensures automatically the correct track
tension.
The pilot pressure pumps (7.1+7.2, see hydraulic diagram page 02) will supply
oil to all four tensioning cylinders (62.1-62.4).
The maximum pressure is limited by the pressure increasing valve (182), one
for both sides.
The pressure in the tensioning cylinders transmits the required force to move
the guide wheels to the front, until the correct track tension is obtained.
External forces acting at the guide wheels will be absorbed through the
pressure accumulators (60.1 + 60.2, first stage) and (59.1 + 59.2, second stage).
) For information about the preventative track inspection, refer to the

Operation and Maintenance Manual.
Functional description on next page
17.01.07 PC5500-6-E_Sec_9-0_rev1.doc
9.0
3
17.01.07 PC5500-6-E_Sec_9-0_rev1.doc
Page 3
9.1 Functional description:
Illustration Z 22454:
) Under normal operating condition the shut-off cock (54.1) located on

the valve block (181) in the car body are closed. The shut-off cock
(184) located on the valve block (181) in the car body and (54.2 and
54.3) located inside the side frames are open.
The oil flow of the pilot pressure pumps (7.1 + 7.2), filtered by pressure filter
(68.1) enters port "P" of the solenoid valves Y16 via hydraulic line L3 and
the rotary joint to the track tensioning valve block (181) in the car body.
If solenoid valves Y16 is actuated (i.e. pressure at sensor B48), the oil flows
(X2-pressure with 35 bar) via the pressure relive valve (83), rotary joint (34), the
shut-off cock (184) and check valves (180.1+180.2) into the tensioning cylinders
(62.1 - 62.4).
The resulting force moves the guide wheels toward the front, until the correct
track tension is obtained.
Simultaneously the system is connected to the pressure increasing valve (182).
External forces acting at the guide wheels will be absorbed through the pressure
accumulators (60.1 + 60.2, first stage) and (59.1 + 59.2, second stage).
Purpose of the pressure increasing valve

The two system pressures
• 35 bar with motors stopped
• 315 bar with motors running
are controlled by the pressure increasing valve as follows.
With stopped motors and switched off ignition there is no pilot pressure (X2) at
the pressure increasing valve (182) and only the lowest adjusted pressure of 35
bar remains in the system.
As soon as one motor has been started, the pilot pressure (X2) of 35 bar act
on the pressure increasing valve. As a result the system pressure can rise to
the adjusted pressure of 315 bar.
continued
17.01.07 PC5500-6-E_Sec_9-0_rev1.doc
9.0
4
17.01.07 PC5500-6-E_Sec_9-0_rev1.doc
Page 4
Cont'd.:
9.1 Functional description:
Illustration (Z 22454):
Cushioning Function
When the tensioning cylinders (62.1 - 62.4) are moved in by external forces,
the none return valves (179.1 + 179.2) will be closed.
A certain amount from the displaced oil of the tensioning cylinders is taken
up by the pressure accumulators.
First stage: at a pressure higher than 31 bar, is taken up by the side frame
accumulators (60.1.1 + 60.2).
Second stage: at a pressure higher than 150 bar, is taken up by the center section
accumulators (59.1 + 59.2).
The system pressure can rise up to 315 bar pressure increasing valve (182)
setting.
With reduction of external forces, the oil is pushed back by the accumulator
pressure into the tensioning cylinders.
If the displaced oil volume was higher than the accumulators could take up,
oil is added from the pilot pressure circuit (X2), as soon as the pressure in the
lines to the tensioning cylinder is lower than 35 bar.
17.01.07 PC5500-6-E_Sec_9-0_rev1.doc
9.0
5
17.01.07 PC5500-6-E_Sec_9-0_rev1.doc
Page 5
9.2 Pressure Increasing Valve
) The pressure increasing valve is a remote controlled pressure relief

valve.

(1) Pilot valve with valve seat
(2) Valve poppet
(4) Main valve with sleeve
(5) Main piston
(6) Closing spring
(7) Set screw - low pressure 35 bar
(8) Set screw - high pressure 310bar
(9) Piston
(10) Pin
(11+12) Jet bore
(13+14) Lock nut
Function:
The valve poppet (2) is connected via the jet bores (11) and (12) with the P
port.
If static pressure increases above the set pressure value, the valve poppet (2)
opens and allows oil to flow freely to tank (T1). This oil generates a pressure
drop in the spring chamber of the main spool, the closing force of the spring
(6) is cancelled, and the main piston (5) opens to allow the pump flow to flow
to tank (T2).
Damped opening and closing is obtained by the throttled volumetric change.
By applying external pressure of Pst max = 60 bar to the main spool (9) via
port X, the pre-tensioning of the pressure spring (3) is increased by the amount
of the piston stroke "S" and system pressure is increased correspondingly.
The setting is fixed by means of the setting screw (7) and lock nut (13); one
turn of the screw ~ 150 bar. The possible max. pressure setting with the set
screw (8) on block is about 440 bar.
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6
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Page 6
9.3 Tensioning cylinder:
(1) Cylinder tube

(2) Piston
(3) Piston guide ring
(4) Piston guide strap
(5) Seal ring
(6) O-ring
(7) Scraper
(8) Retracting device
(M) Bleeder port
(P) Oil supply
• Maximum permissible piston stroke 350mm!

During bench test an external stroke limitation must be used!
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7
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Page 7
9.4 Adjustments / Checks

(182) Pressure increasing valve
(54.3) Service shut-off cock for the R.H.-side
(54.2) Service shut-off cock for the L.H.-side (not illustrated)
(59.2) Bladder accumulator 150 bar
(60.2) Accumulator 31 bar
(MRV) Main relief valve – Operating pressure of main control
block I
(M12.4) Pressure check point – Operating pressure of main control
block I
accumulator (59.2) for the R.H.-side.
accumulator (59.1) for the L.H.-side (not illustrated).
(M15.3) Pressure check point - track tensioning system
operating pressure – R.H.
(62.3+62.4) Track tensioning cylinder R.H.
Checking / Setting the pressure increasing valve

Pre-conditions: Correct MRV, SRV and pilot pressure setting and the system
must be free of air.
The description is only for the R.H. track. The same procedure applies also
for the L.H. side.
Basic Adjustment:
1. Connect a pressure gauge (min.400 bar) to check point M12.4.
2. Start one motor.
3. Increase the MRV-setting (Block I), ~ 330 to 340 bar.
4. Switch OFF the motor, open cock valve (54.1) to allow pressure
relieve of the R.H. track, and close it again.
continued
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Page 8
Cont'd.:
5. Move the pressure gauge from M12.4 to M15.3

6. Connect pressure check point M12.4 with pressure check point M16.1,
using a long pressure gauge hose. (required for the oil supply)
7. Disconnect the pilot pressure line at port X of the pressure increasing
valve (182) and close the hose (P) ith a plug.
8. Loosen lock nut (4) of the pressure increasing valve and screw in set
sleeve (5) until piston (1) comes to stop. (substitution of X2 pressure)
9. Start one motor.
10. Stall the hydraulic with the bucket filling function (bucket cylinders
completely extended) and observe pressure at check point M15.3.
A pressure of 315 + 5 bar must reached within a time period of 10 – 15
minutes and must remain at this value.
The maximum pressure will be shown only after the accumulators are
completely filled with oil.
When the pressure reaches the pre-charge gas pressure ( 31 bar and
150 bar) the gauge pointer moves slower depending on the gas
compression.
If the gauge shows a lower or higher value the pressure increasing valve
must be adjusted.
Setting procedure, high pressure stage (Valve 58.2)
a) Loosen lock nut (2).
b) Adjust pressure with set screw (3).
c) Secure adjustment by tightening lock nut (2).
11. The low pressure setting of the pressure increasing valve must now be
reset (with the pilot pressure line at port X still disconnected):
Setting procedure, low pressure stage (Valve 58.2)
a) Stall the hydraulic with the bucket filling function (bucket
cylinders completely extended) and observe pressure at check
point M15.3.
b) loosen lock nut (4) and turn set screw (5) ccw until gauge at
check-point M15.8 shows 35 bar.
c) Tighten lock nut (4).
continued
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9
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Page 9
Cont'd.:
12. Switch OFF the motor and open cock (54.1) to allow pressure relieve.
13. Re-connect the pilot pressure line to port X of the pressure increasing
valve (182).
13. Remove the pressure gauge hose between pressure check point M12.4
and pressure check point M16.1.
15. Close the cock (54.1).
16. Re-set MRV to 310 + 5 bar after the check / adjustment is finished.
9.5 Functional Test
After all adjustments are finished, do the following:

a) Bleed all air from the system
b) Place shutoff and pressure relief cocks into correct operating position.
c) Connect pressure gauge to check point (M15.3).
d) Start both motors.
e) Travel approx. 10 m with the shovel. The pressure should be rise to a
higher value.
f) Stop the motors.
g) The pressure must drop to 35 bar.
If the pressure remains at a higher or lower pressure*, re-adjust the low

pressure setting at the pressure increasing valve (182) is necessary.
) * The pressure may drop below 35 bar after a longer time, this is o.k.
because of internal leakage.
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17.01.07 PC5500-6-E_Sec_9-0_rev1.doc
Access ladder Section 10.0
Page 1
hydraulically operated
Section Page
10.0 Access ladder hydraulic operated
10.0 General 2
10.1 Function of hydraulic operated access ladder 3+4
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10.0
2
17.01.07 PC5500-6-E_Sec_10-0_rev0.doc
Page 2
10. Access ladder hydraulic operated

General
legend for Illustration Z22494

(A) Access ladder in lowered position
(B) Access ladder way to upper position
(C) Stop bar
(Z) Hydraulic cylinder
(S84) Ladder control switch “up”
(S84B) Ladder control switch “down”
(S84A) safety switch operated from ground level for lowering (pull switch)
(S22) Control sensor : Cut off the pilot control system and actuation of the
slew brake with ladder in lowered position.
(S91) Monitor and control sensor: It monitors the ladder position and
controls the moving speed of the ladder. In case the sensor (S22)
fails, the sensor (S91) prevents unintended movement of the ladder .
The access ladder is hydraulic driven by the hydraulic cylinder (Z) via the 60
bar X4 pressure. S84 is the control switch to move the ladder up and down.
The additional pull switch S84A move the ladder only down from the ground.
To lower the ladder the motor can run or stand still. Only to move the ladder
up the motor must running.
) If the ladder is out of the upper position the pilot control system
switches off (all machine movements stoped) and the solenoid valve
Y120 activates the service swing brake. The text display in the cab
shows a message.
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Access ladder Section 10
Page 3
10.1 Function of hydraulic operated access ladder

Legend:
(7.1+7.2) Pumps
(84.1+84.2) Check valves
(68.1) Filter with filter monitoring switch B22
(70.1) Pressure relieve valve (60 bar)
(70.2) Pressure relieve valve (35 bar)
(162.3 – 5) Check valves
(171) Pressure relieve valve (70 bar)
(174) Ladder cylinder
(172) Orifice
Y125 Solenoid valve: lower speed limit
Y123A Solenoid valve: ladder up
Y123B Solenoid valve: ladder down
The motor is running

Additional to the hydraulic diagram Z22495 use the electric diagram on next
page
The pumps (7.1) and (7.2) are delivering oil through filter (68.1) to port P of the
solenoid valve Y123A/B and the pressure relief valve (70.1) port A. The pressure
relief valve (70.1) maintains the adjusted pressure of maximum 60 bar.
Solenoid valve Y123A/B lead pump oil to the cylinder if one of the solenoids is
energised. Depend on the activated solenoid valve the ladder move up or down.
The pressure relief valve (171) limits the pressure of the ladder cylinder to max.
70 bar.
Return oil from the cylinder flows back via solenoid valve Y123A/B to the
solenoid valve Y125. With energised solenoid this valve lead back oil unhindered
to the oil tank It is energised when both approximately switch S22 and S91 are not
activated (ladder between upper and lower end position). A short way before the
ladder reached one of the end positions one sensor (S 22 – in up position; S 91 –
in down position) switch on and de energise Y125. Now back oil must pass the
orifice (172). By the flow resistance of the orifice the ladder motion will be
slowed down.
If the ladder is in the “Up – position” the activated sensor S22 de-energised Y125
and energised Y123A, now the still connected pump pressure to the cylinder
piston side keep the ladder in the final up position.
If switch S84 is in neutral position and the ladder in “down – position” sensor S91
de-energise all solenoids (Y125; Y123 A+B) and the ladder is “blocked”.
continued
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9 Page 4
Cont'd:
The motor is out and the ladder is in the “Up – position”
With activated switch S84 to position 2 (ladder down) solenoid valve Y123B
and relay K132 are active. Y123B opened the piston side of the cylinder to
the tank and K132 activate Y125 that the oil can flow without resistance to
the tank. Now the ladder can move down only by its own mass (gravity). The
operator have to push the ladder slightly until it starts moving down by its
own weight.
The rod site of the cylinder receives oil via anti-cavitation valve (162.3).
It is no key contact necessary this function is direct supplied to the battery via
fuse F17.
There is an additional pull switch S84A below the ladder support. With this
switch the ladder can moved down from the ground.
• Make sure that there are no obstacles in the moving range of the
ladder. Stop raising the ladder by releasing the control switch (S84) if
there are any obstacles in the moving range.
• Mount the ladder only in completely lowered position.
• Do not lift persons or objects (tools) with the hydraulic access ladder.
Serious injury or death can be the result.
17.01.07 PC5500-6-E_Sec_10-0_rev0.doc
17.01.07 PC5500-6-E_Sec_10-0_rev0.doc
Section 11.0
Cable drum
Page 1
Section Page
11.0 Cable drum
11.0 General 2
11.1 Components 3
11.2 Function
11.2.1 Controlling of the drive motor 4
11.2.2 Travel motion control 5
11.3 Checks and Adjustments 6
11.4 Description and operating instruction for cam switch 5S4 and 5S6 7
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11.0
2
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Section 11.0
Cable drum
Page 2
11.0 Cable drum
General
Legend for Illustration Z 22831a

(5M6) Brake motor
(5S3) Rotation direction indicator (switch)
(5R1) Resistor for brake motor torque adjustment
(5S4) Gear type cam switch for resistor controlling and for
monitoring of the two last cable windings.
(5S6) Pendulum control cam switch, to detect slack or tight cable
(5S8, 5S9) Proximity switch to detect cable deflection to right or left
(5S10, 5S11) Proximity switch for ground contact protection.
Task:
The cable drum, driven by a brake motor with slip ring rotor, is installed to
wind up or unwind the power supply cable automatically.
1. To considerably improve the mobility of the excavator.
2. To make the operation safer (Material and personnel) i.e. less risk to
damage the cable when travelling backwards and less danger of injury
because the cable must not manual moved.
3. To increase the lifetime of the cable, because the cable is not dragging on
the ground.
) For the optimal use of the cable drum it is necessary that the operator
understands the system very well.
Regular maintenance is essential
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11.0
3
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Section 11.0
Cable drum
Page 3
11.1 Components
(5M6) Brake motor
(5S1) Service switch for manual actuation of cable drum.
(5S4) Gear type cam switch for resistor controlling and for
monitoring of the two last cable.
(5S6) Pendulum control cam switch, to detect slack or tight cable.
(5S8, 5S9) Proximity switch to detect cable deflection to right or left
(5S10, 5S11) Proximity switch to detect ground contact
(5K7, 5K8, 5K12, 5K13) Relay for brake motor direction controlling
(5K10, 5K11) Relay for brake motor torque controlling
(5F13) Circuit breakers
(5B79) Brake motor temperature probe
(F79) Motor temperature control unit
(X8) Terminal box
The resistor 5R1 serves as a series resistor for a three- phase motor with a slip ring rotor
(stand still, sliding rotor-brake motor)
It is a resistor with one or more taps (as a function of drum design), to make a selection of
different star bridges possible. The taps serve to regulate the motor and brake torque during
winding up and unwinding.
With service switch 5S1 is it possible to control the cable drum manually in both directions
(windup, unwind, stop and automatic)
The terminal box X8 contains the terminal rails , the relays 5K7, 5K8, 5K10, 5K11, circuit
breakers 5F13 + 5F14 and motor temperature control unit F79.
Direction of rotation monitoring switch 5S3 opens its contact and de-energizes 5K10 and
5K11 while unwinding (traveling forward) and eliminates the resistor which controls the
star bridge. (Lowest tensioning force)
Gear type cam switch 5S4* reduces the tensioning as soon as half of the cable is unwinded
(contact 21/22 opens and de-energizes 5K11) or stops reverse travelling as soon as the max.
length of the cable is winded up (contact 31/32 opens and de-energizes K178).
The proximity switch 5S8 stops L.H. crawler reverse travelling at too much deflection of
the power supply cable to the left (contact br/sw opens and de-energizes K179).
The proximity switch 5S9 stops R.H. crawler reverse travelling at too much deflection of
the power supply cable to the right (contact br/sw opens and de-energizes K180).
Pendulum control cam switch 5S6* stops forward travelling at too tight power supply
cable (contact 11/12 opens and de-energizes K177) or reverse travelling at too much slack of
power supply cable (contact 21/22 opens and de-energizes K178).
The limit switch 5S7* stops forward travelling by de-energizing K177 as soon as the safety
cable length on the drum gets unwinded.
The motor temperature control unit F79 interrupts all travel motions as soon as drive
motor 5M6 reaches a critical temperature (monitored by sensor 5B79).
*Refer to page 7 for adjustment procedure
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11.0
4
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Section 11.0
Cable drum
Page 4
11.2 Function
(5M6) Brake motor
(5S4) Gear type cam switch for resistor controlling
(5K7, 5K8) Relay for brake motor direction controlling
(5K10, 5K11) Relay for brake motor torque controlling
(5F13) Circuit breakers
(F79) Motor temperature control unit
(X2 + X8) Terminal board
D53 Time relay at the X2 board
11.2.1 Controlling of the drive motor
General:
In the automatic mode of control switch 5S1, the power supply to drive motor 5M6 is
controlled by the function of the travel control system, which controls relay 5K7, i.e.
while traveling the contacts of 5K7 are closed and kept closed for further 10 seconds
after stopping the travelling motion (controlled by time relay D53), before the power
supply will be interrupted and the motor brake is active.
The torque of drive motor 5M6 is controlled by the function of the relay 5K10 and
5K11; which changes the resistance at the star bridge (5R1). Both relay are
simultaneously controlled by switch 5S3 (Direction of rotation monitoring switch),
to ensure the lowest tensioning force while unwinding (i.e. traveling forward)
Winding up (automatic mode of control switch 5S1):

While winding up the NC-contact of switch 5S3 remains closed which allows
voltage to the relay 5K10 and (if the contact 21/22 of switch 5S4 is closed) also to
5K11.
Example travelling reverse:
Cable length on drum: ½Max. – Max. => 5K10 ON + 5K11 ON => max. torque
Cable length on drum: Min. – ½Max. => 5K10 ON + 5K11 OFF => reduced torque
Unwinding (automatic mode of control switch 5S1):

The NC-contact of switch 5S3 opens while traveling forward and de-energizes
simultaneously 5K10 and 5K11, with the result that there is just enough torque to
hold the cable tight.
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11.0
5
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Section 11.0
Cable drum
Page 5
11.2 Function
11.2.2 Travel motion control, illustration Z 22835
General:
The cable drum is equipped with safety switches for the protection of the power
supply cable during travelling and turning operations. Movements which could
damage the power cable are automatically switched off.
Cable condition Monitored by Travel shut off relay Directional Travel response
Solenoid valves
Switch / contacts
1. Too tight 5S6 / 11–12 K177 Y20b + Y28b crawler left + crawler right
forward motion stopped
2. Too slack 5S6 / 21–22 K178 Y20a + Y28a crawler left + crawler right
reverse motion stopped
3. Too strong deflection to the left 5S8 / br–sw K179 Y20a crawler left
4. Too strong deflection to the right 5S9 / br–sw K180 Y28a crawler right
5. Maximum permissible cable 5S4 / 31–32 K178 Y20a + Y28a crawler left + crawler right
length on the drum
6. Safety cable winding unwinded 5S4 / 11–12 K177 Y20b + Y28b crawler left + crawler right
forward motion stopped
7. Ground contact 5S10 and/or 5S11 K178 Y20a + Y28a crawler left + crawler right
) If the reverse motion stopped because of a activated ground contact

switch 5S10 or 5S11 it is possible to activate the reverse motion manually
via activation of horn switch at the left control lever in the cab.
) Refer to section 8.3 in this Manual for further information.
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11.0
6
PC5500-6-E_Sec_11-0_rev0.doc 17.01.07
Section 11.0
Cable drum
Page 6
11.3 Checks and Adjustments

No adjustment required. Check the function of contact 2/P.
The built-in switch must open while unwinding.
(5S4) Gear type cam switch for resistor controlling and safety switch
to detect full cable drum and the last two safety cable windings.
The contact 31/32 must open as soon as the maximum
permissible cable length is on the drum, travel reverse will stop
by deactivated relay K178.
As soon as the last second winding comes up contact 11/12
opens and travel forward will stop by deactivated relay K177.
Adjusting procedure see section 11.4 on next page and check the
function under operating conditions.
(5S6) Pendulum control cam switch, to detect slack or tight cable.
Adjust the switch in such a way that contact 11/12 opens at
too tight cable and contact 21/22 opens at too slack cable.
Check the function under operating conditions. Make sure
that the shock absorber at the pendulum will work in its
permissible range.
Adjusting procedure see section 11.4 on next page.
(5S7)
(5S8, 5S9) Proximity switch to detect cable deflection to right or left.
Adjust the distance between switch and metal bar to 7mm.
Check the function under operating conditions.
(F79) Motor temperature control unit with monitoring LED’s.
(R) – red LED on => motor temperature to high.
(G) – green LED on => permissible temperature range.
Hysteresis:
Rcold ≤ 1kΩ, Rswitch point ≥ 3kΩ (Sensor between P1 and P2)
Check the function with potentiometer.
(D53) Time relay for power cut off after 10 seconds without travelling.
Check adjustment, refer to service Bulletin 21-584 for more
information.
(X2 + X8) Terminal board
PC5500-6-E_Sec_11-0_rev0.doc 17.01.07
11.0
7
PC5500-6-E_Sec_11-0_rev0.doc 17.01.07
Section 11.0
Cable drum
Page 7
11.4 Description and operating instruction for cam switch 5S4
Legend for Illustration Z 22837

(1) Micro switch housing
(2) Actuator (Roller lever)
(3) Cam disc
(4) Adjusting spanner
(5) Cup spring
(6) Tension nut
The cam discs (3), arranged in pairs on the centering discs, can be adjusted
individually and continuously by means of a adjusting spanner (4) The centering
discs can be reversed and are fixed to the square shaft without clearance.
Adjustment can be performed in any position without having to turn the control
shaft. The cam discs, separated from each other by the guard plate, slide past each
other without touching during adjustment. The cam ring next to the cam ring to be
adjusted will not shift and remains in the set position.
Hollow-type rivets prevent accidental shifting of the cam discs.
By selecting the appropriate contact - either make or brake - any angle between 0°
and 350° can be set without changing the cam rings.
When the cam hits the actuator (2), the latter will operate the micro switch (1).
Adjustment of the switch mechanism.

1. Loosen the tensioning nut (6) with the handle of the adjusting spanner (4).
2. Bring the adjusting spanner (4) in the position shown on illustration Z22837.
3. Set the cam discs (3) to the required position.
4. Adjust all other cam discs, following this procedure.
5. When all cam discs have been adjusted, tighten the tensioning nut.
PC5500-6-E_Sec_11-0_rev0.doc 17.01.07

PC5500-6-E_Sec_11-0_rev0.doc 17.01.07
Hints for reading the Section 12.0
Page 1
Hydraulic Circuit Diagram
Section Page
12.0 Hints for reading the hydraulic circuit diagram
General 2
12.1 Symbols 5
12.1.1 Lines, unions 5-6
12.1.2 Components, valves 7
12.1.3 Sensors 8
12.1.4 Valves, valve components 9-12
12.1.5 Pumps, motors, cylinders 13-14
12.1.6 Assemblies and main components 15-16
04.01.07 PC5500-6_Sec_12-0_rev3.doc
12.0
2
04.01.07 PC5500-6_Sec_12-0_rev3.doc
Page 3
12.0 General:
Legend for Illustration Z22987
) •
•
The illustrations are used for exemplary explanations only.
Use original circuit diagram for detailed reading
• There are more symbols on the following pages shown as in the
diagrams drawn. Some symbols of the diagrams not shown in the
following pages.
Item Description Number / Code Explanation
A Diagram No. and Type of the 897 895 40 a Diagram No. only for the
respective machine PC8000-E respective machine
B Respective Serial No. 12041
C Sheet-No. / Quantity of sheets 01 / 04 1st of four sheets
D Co-ordinates to describe the 1 C 10 Page 1 on co-ordinate C vertical
location of a component and 10 horizontal Remote control
valve 102.1
E Component-No. 127 127 Main control block I
F Line-No. with cross hint, L37/3B9 Case drain line (Line No.37)
comes from / goes to sheet 2
coordinate E7
• All the components drawn in neutral and pressure less position.

• Full wide continues black line shows a main component or assembly. (Ex.: Valve
and Filter panel, Main pump, Hydraulic tank, ...)
• Continues black line shows a main hydraulic line. This lines are temporary or
continues load with high or pilot pressure.
• Broken line shows a return, drain or control oil line.
• Black dot shows a connection point. The position of this connection is not definitely
fixed.
• White dot shows a connection or port of a component with a fix definitely position
or port number.
• Page 1 shows the high pressure main hydraulic circuits with all pilot control valves,
control blocks, distributor manifold and cylinders or motors.
• Page 2 shows all main pumps and pilot pressure pumps with the main pump control
system and the other auxiliary pilot pressure circuits as lubrication system and
ladder.
• Page 3 shows the main pump control arrangement, the auxiliary circuits with oil
cooling system and the hydraulic tank.
• Page 4 shows the car body hydraulic with travel brakes, travel motors and track
04.01.07 PC5500-6_Sec_12-0_rev3.doc
12.0
4
04.01.07 PC5500-6_Sec_12-0_rev3.doc
Page 5
12.1 Symbols
12.1.1 Lines, unions
Symbol Description Used as / at / on
1 Oil supply line, can be a Suction line or pressurized
hose or a pipe. line of main hydraulic circuit
or pilot pressure circuit or
auxiliary circuits (e.g. fan
drive).
2 Return oil line, can be a Return lines, connected to
hose or a pipe. the return oil filter chamber
of the main oil reservoir.
3 Case drain (leak) oil line, Return lines, connected to

can be a hose or a pipe. the case drain (leak) oil filter
chamber of the main oil
reservoir.
4 Control oil line, can be a Pilot control line, pump
hose or a pipe. regulation line and parking
brake control lines.
5 Crossed lines Pipes or hoses not

connected
6 Connection point, is a Connection between

connection of hydraulic several lines
lines without definite
position
7 Component connection Connection to components
point, is a connection with like, valve blocks, tanks,
a definite position at a pumps, ...
component
8 Plugged connection point, Not used connection
can be plugged with any points.
kind of plugs.
9 Plugged line inside of a Not used connection

manifold, can be plugged points.
with different kind of plugs.
04.01.07 PC5500-6_Sec_12-0_rev3.doc
12.0
6
12.1 Symbols
12.1.1 Line, union

10 Compensator, Oil tank outlet to the
Compensate line length pumps
differences depend on
vibration and temperature.
11 Quick coupling, Tank drain couplings, often
is a special union with removed lines (e.g. at grease
integrated check valve systems with removable
barrels).
12 Blind, Orifice, e.g. Oil cooler inlet,
not adjustable with
orifice diameter in mm
13 Pressure check point HP Filter, Fan valve

With a special quick block....at all important
coupling. circuits
14 Distributor block Connection of lines with

the same destination e.g.
return lines to tank
04.01.07 PC5500-6_Sec_12-0_rev3.doc
Page 7
12.1 Symbols
12.1.2 Components, valves

15 Accumulator, Input line to the remote
is filled with nitrogen gas control valves, return oil
with for the respective collecting tube, track
accumulator specified tensioning system
pressure
16 Screen filter, Installed in suction lines to
the screen size is 1.0 mm the pumps, oil tank outlet,
return oil collecting tube
17 Oil cooler, Hydraulic oil cooler,

PTO oil cooler
18 Breather filter, On top of PTO or

hydraulic tank
19 Spray nozzles, Gearbox (PTO) cooling

inside of a case for and lubricating system
cooling and lubricating
continued
04.01.07 PC5500-6_Sec_12-0_rev3.doc
12.0
8
12.1 Symbols
12.1.3 Sensors
20 Pressure switch / sensor e.g. return / leak oil
Input = pressure chamber (digital), high
Output = electrical signal pressure filter (analogue)
analogue or digital
21 Pressure switch e.g. swing or travel

Input = pressure detection PC3000,
Output = digital electrical
The switch point is 24 bar
22 Temperature sensor, e.g. hydraulic tank

Input = temperature
Output = electric signal
proportional to the
temperature
23 Level sensor, Hydraulic tank, fuel tank

Input = fluid level
Output = electrical signal
analogue or digital
24 Chip sensor, Main pumps

Input = contaminate oil
Output = electrical digital
signal
04.01.07 PC5500-6_Sec_12-0_rev3.doc
Page 9
12.1 Symbols
12.1.4 Valves, valve components

25 Manuel operated unit Valve in track tensioning
Lever system,
26 Electric / magnetic Solenoid valve

operated unit
Solenoid
27 Pilot pressure Pressure relief valve, disc

controlled unit brake, ...
28 Spring, Solenoid valves,

with fixed force
29 Spring adjustable Pressure relieve valves,....

spring force is adjustable
30 Check valve e.g. main pump outlet,

In drawn pos.: from right swing brake valve block,
to left free flow, from left anti cavitation valves at
to right blocked flow. main control blocks or
distribution manifold
31 Check valve spring By pass of the return oil
loaded filter, by pass of
Opened in flow direction secondary filter
only against spring force
= pressure
32 Double check valve, Swing brake control,
in drawn pos.: opened
only from the left to the
bottom or from the right
to bottom
04.01.07 PC5500-6_Sec_12-0_rev3.doc
12.0
10
12.1 Symbols
12.1.4 Valves, valve components

33 Shut-off Valve with Gate valve between main oil
monitoring switch, reservoir and suction tank
the adjustable switch
monitors the valve position
34 2/2 control valve Track tensioning system

manual operated,
2/2 cock valve
35 3/2 control valve Change over valve from

manual operated, electronically pump
3/2 cock valve regulation to emergency
mode (hydraulically
pump regulation)
36 4/2 directional control valve e.g. swing parking brake,
as solenoid valve travel parking brake,
4/2 way solenoid valve, ladder controlling,,
electrically controlled.
Neutral position:
P-A and B-T connected.
37 Variable throttle valve Travel brake valve,
hydraulically controlled located in the car body
pilot control port pressure
less = maximum restriction
38 3/2 directional control Service arm controlling
solenoid valve, seat
design = leak oil free
3/2 way solenoid valve,
neutral = port P-A open
39 4/3 directional control Ladder controlling,
solenoid valve service arm controlling
4/2 way solenoid valve,
in neutral all ports closed
40 External pilot PC 3000 and PC4000
controlled proportional with floating system
floating valve
04.01.07 PC5500-6_Sec_12-0_rev3.doc
Page 11
12.1 Symbols
12.1.4 Valves and valve components

41 Main control valve Standard control valve for
“standard function” two directions of cylinder or
In neutral position: motor.
open pump flow (P-PU) and
control port flushing (T – a, T
– b), in position a or b closed
circulation port (P- PU)
42 Main control valve Control valve for pressure

“pressure less lowering” less lowering. Used to assist
Neutral position: open pump the floating function of boom
flow (P-PU), control port and stick,
flushing (T– a, T– b)
Position b: closed circulation
port (P-PU), normal function
P – B and B - T,
Position a: open circulation
port P – PU, only port B – T
connected
43 Main control valve “floating Control valve with floating
function” function in position a,
Neutral position: open pump e.g. floating valve for boom
flow (P-PU), control port or stick, .
flushing (T– a, T– b),
Position b: closed circulation
port (P-PU), normal function
P – B and B - T,
Position a: open circulation
port (P – PU) = A, B, T, P
connected together via tank
44 Pressure reducing valve, Emergency mode
assembly pressure (X3-pressure),
Variable inlet pressure at port pilot oil pressure
B and constant lower output
pressure at port A, output
pressure is adjustable.
04.01.07 PC5500-6_Sec_12-0_rev3.doc
12.0
12
12.1 Symbols
12.1.4 Valves and valve components

45 Pressure relief valve, e.g. ladder controlling,
direct controlled and service arm controlling ..
adjustable
46 Pressure relief valve Secondary relieve valve

with anti cavitation at main control blocks
valve (check valve)
Assembly, external drain
at port Y
47 Pressure increasing valve Swing brake block, track

pressure relieve valve with tensioning system.
variable setting, pilot
pressure controlled via port
X. Low pilot pressure = low
relieve pressure
48 Proportional pressure Remote control valves to

valve, reduce the control the main control
pressure in port A blocks,
proportional to the
solenoid current.
49 4 port proportional Pump regulation, only
pressure relief valve, output port A is used for
direct operated by a our systems
proportional solenoids.
50 Pressure relief valve, Radiator and oil cooler

mechanical and fan drive
hydraulically via pilot
port X adjustable, oil
drain port Y
51 Throttle check valve Distribution manifold
with secondary relieve normally in the line to the
valve, throttle and cylinder piston side.
secondary valve
mechanical adjustable,
external drain at port Y.
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Page 13
12.1 Symbols
12.1.5 Pump, motor, cylinder

52 Single acting Cylinder, Track tensioning system
pressurised moving only
in one direction, return by
external force
53 Double acting Cylinder, Attachment i.e. boom,

Cylinder in which the fluid stick, bucket or clam
pressure operates alternately cylinder
in both directions (forward
A B and backward strokes)
A = Piston side
B = Rod side
54 Drive shaft of a motor Main pumps, swing
or pump with one motor, fan drive, travel
direction drive
55 Hydraulic pump with fix Fan pump, circulation

volume per revolution pump, pilot pump, PTO
suction port S and pressure lubrication pump
outlet P
56 Hydraulic pump with Main pumps

variable output volume
per revolution
with external case drain
57 Hydraulic pump Main pumps

assembly
with pump bearing
lubrication, one direction
and external case drain
04.01.07 PC5500-6_Sec_12-0_rev3.doc
12.0
14
12.1 Symbols
12.1.5 Pump, motor, cylinder

58 Variable hydraulic Main pump
pump with charge
pump
and external drive shaft
bearing lubrication
59 Hydraulic motor Fan motor

can be used in both
direction, with external
case drain L
60 Motor with disc brake Travel motor

disc brake is spring
loaded it means:
pressure less pilot line =
maximal brake torque
61 Variable swing motor Swing motor PC5500

with integrated control
valves and flushing
valves
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Page 15
12.1 Symbols
12.1.6 Assembly and main components

62 Lubricant pump drive Lubricant pump station
differential cylinder with for central lubrication
integrated control valves system and swing ring
to propel the grease pump lubrication system
63 Swing brake valve Swing brake system.

assembly,
act as a hydraulical back
pressure system parallel
to a motor with variable
pressure setting and
independent pressure
side. Input port A or B
and outlet on the opposite
connection to the motor..
64 Rotary joint Hydraulical connection

Upper part with between superstructure
connections drawn to and car body
the top, lower part with
connections drawn to
the bottom
65 Travel brake valve block mounted in the supply

with secondary pressure line to the travel motors,
relieve valve is located in the car body
is connected in the line to
the travel motors. The
return oil flow is restricted
according to the pressure
inlet.
04.01.07 PC5500-6_Sec_12-0_rev3.doc
12.0
16
12.1 Symbols
12.1.6 Assembly and main components

66 Remote control lever to Control lever in the
control the main control operators cabin
blocks
67 Remote control pedal to Control lever in the

control the main control operators cabin
blocks
68 Hydraulic oil tank with Main hydraulic tank

leak and return oil filter,
back pressure valve and
sensors
04.01.07 PC5500-6_Sec_12-0_rev3.doc
Page 17
04.01.07 PC5500-6_Sec_12-0_rev3.doc
Page 1
Electric Circuit Diagram
Section Page
13.0 Hints for reading the electric circuit diagram
13.1 Designation of electrical devices 2

13.2 Symbols 3+4
13.3 General information 5+6
13.4 Reading a circuit diagram 7+8
13.0
2
Page 2
13.1 Designation of electrical devices
Indicating letter Kind of component

A System, subassembly, parts group, trigger boxes, control units
B Transducer for conversion of non-electrical variables to electrical
variables, and vice versa.
Speed sensors, pressure sensors, pressure switches, oil-pressure
switches, temperature sensors
C Condenser, capacitor, Condensers and capacitors, general
D Elements with time lag, memory elements, binary elements
E Various devices and equipment
F Protection device
Fuses, current protection circuits
G Power supply, generator
Batteries, generators, alternators
H Monitor, alarm, signaling device
Indicator lights, signal lights, headlights, warning buzzers, horn
K Relay, contactors
L Inductor
Coils, windings
M Motor
N Regulators, amplifiers
P Measuring instrument
Q High voltage switching units
R Resistors, heating devices
S Switches, selectors
T Transformer
U Modulator, converter from one electrical in an other electrical value
V Semiconductor, electron tubes, diodes, rectifiers, zener diodes
W Transmission path, conductor, antenna
X Terminal, Plug, Plug and socket connection
Y Electrically actuated mechanical device
Solenoid-operated valves
Z Compensating units, filters, limiters cable connection
13.0
3
Page 3
13.2 Symbols
Our common used symbols in accordance to VDE/IEC (Association of

German Electrical Engineers DIN 40710 - 40716 and the International
Electrical Commission) differ for the most part from the symbols in
accordance to JIC/ASA (Joint Industrial Concil and American Standard
Association) USA and Canada JIC EMP-1-1967 and ASA 2 32-3).
For this reason the following comparative chart.
1) Normally open 2) Maintained 3) Single pole

contact contact two way contact
break before make
4) Normally 5) Push-button 6) Limit switch
closed contact switch NO contact
NC contact
7) Manual operated 8) Foot-operated 9) Pressure
switch isolator, push-button operated switch
disconnect switch switch
10) NO contact with 11) Multi-position 12) Indicating
time lag switch selector instrument
(general) symbol
13) Contacts with 14) Resistor 15) Ammeter
time lag general
16) Battery 17) Tapped 18) Voltmeter

resistor
19) Inductive 20) Continuously 21) Recording

resistance adjustable, instrument
general
22) With iron core 23) Adjustable in 24) Signal lamps

steps pilot lights
25) Continuously 26) Potentiometer 27) Operating coil

adjustable rhesostat solenoid
28) Transformer 29) Capacitor 30) Rectifier, semi

general, conductor
continuously
adjustable
13.0
4
Page 4
13.2 Symbols
31) Rectifier bridge 32) Thermal over load limit 33) Phase, 4-wire system
34) Current transformer 35) Undervoltage relay 36) Junction of conductors
37) Voltage transformer 38) Temperature relay 39) Junction
40) Circuit interrupter 41) Contactor 42) Terminal
43) Circuit breaker, three 44) Generator (G)- 45) Terminal

phase Motor (M)
46) Thermal over- ground, 47) 3-phase-motor 48) Earthing, general

load protection
49) Magnetic over- socket 50) 3-phase squirrel cage

current protection
51) Plug and 52) Slipring motor
53) Fuse with bolted contacts 54) 3-phase squirrel cage

induction motor in
Star-delta starting
55) Thermal overload relay 55) Two speed motor
(tapped windings)
(for ex. 8 to 4 poles)
13.0
5
Page 5
13.3 General information
Komatsu circuit diagrams

Each sheet has the following information in the bottom right hand corner:
Diagram Number example: 897 844 40
Machine Type example: PC4000-6
Sheet Number and Total Number of sheets 01/63 - 02/ . etc.
Each sheet is numbered from 8 (at the left corner) to 1 (at the right corner) along the
top and bottom lines, and lettered down from F (at the top) to A (at the bottom)
along the left and right side lines.
This coordinate system enables you to find components easily.
On the table of contents, page one, the individual circuits are listed up with the
respective page number.
Example: The circuit for the superstructure lighting is shown on page 39.
Pages number two, three and four are cross reference lists of component codes
related to page numbers.
Example: The relay with the component code “K1-1” is shown on page 8.
On page five is a list of answers to frequently asked questions (FAQ) concerning

abbreviations, function of components (e.g. time relays) mathematical symbols etc.
used in the diagram.
All electrical components are connected via cable harnesses to the main switch
board “X2”. There is only one Plug connector in between, which is always located
close to the respective component like sensors, solenoids etc.
All 24 volt wires are blue and have a printed code (every 10 cm) at each end of the
wire. (see illustration)
The first part of the code shows the required connection and the second part gives
the information what is connected at the other side of the wire.
Example:
going to coming from coming from going to
X2S = X2-Board, terminal group “S” Y136 = Plug connector to solenoid

45 = Terminal No 45 .1 = Terminal 1 of connector
All circuits are shown currentless and all relays and switches are in neutral position.
13.0
6
Page 6
13.3 General information
Explanation of the Drawing Concept
(1) Drawing number

(2) Sheet number / quantity of sheets
(3) Designation of drawing
(4) Designation of component or assembly
(5) Column (vertical sections)
(6) Lines (horizontal sections)
(7) Component symbol
(8) Neutral wire / machine ground
(9) Designation of phase
(10) Phase strip
(11) Terminal strip and terminal
(12) Cable plug and pin number
(13) Relay coil
(14) Relay contacts, partially with detailed information
(15) Cross reference for the continuation, Page / Column
(16) Indication where the relay contact opens or closes
Location of the Main Terminal Boxes
(X1) Dashboard inside the cabin

(X2) Main switch board inside the cab base
(3E14-1) Electronic control module (ECM- Quantum) left bank of the engine
(3E54-1) Electronic control module (ECM- Cense) flywheel end of the engine
13.0
7
Page 7
13.4 Reading a Circuit Diagram.
• Examples are shown by sectional drawings out of the electric circuit

) diagram 897 844 40 page 08.
(1) Section F8 / sheet 08

The hint F11/06.1 indicates that the wire from F11 is continued on
sheet 06 column 1.
(2) Section C4 / sheet 08

Shown is the relay coil K51-1 only and not its contacts.
The contacts are shown somewhere else in the diagram.
Switching and contact positions are shown below at the foot of that
particular circuit in row C-C as shown below.
Example for K51-1:

1 9
08.5 5 opens on sheet 8 section 5 when relay is energized
2 10
: 6 Not used
3 11
: 7 Not used
4 12
: 8 Not used
When diodes are fitted to a relay, they are fitted to allow a current flow in one
direction only. An LED* (Light Emitting Diode) indicates a current flow if it
lights up.
When diodes ** are fitted anti-parallel to a relay coil, they absorb the high
induced voltage caused by making and breaking the current flow through the
coil.
This occurs each time we operate a switch supplying current to the coil. The
diode effect allows the induced current to circulate within the coil windings and
decay when the energy to the coil is cut.
* LED between A1 and coil

** Diode between A1 and A2.
(3) Section F7 / sheet 08

Connectors and Terminals are identified by a letter and number
code. X2 o 23-28 = Terminal box X2 Terminals 23 to 28 are linked
with a metal bridge.
continued
13.0
8
Page 8
Cont.:
13.4 Reading a Circuit Diagram.
(4) Section E 1 sheet 08

The components have a letter and a number prefix, and these are
explained below in rows A and B.
Components are depicted in a system unique to VDE/IEC
(Association of German Electrical Engineers DIN 40710-40716 and
the International Electrical Commission) or to KMG standard.
S27 = Toggle switch (with non-automatic return)
a. F11 = Circuit breaker (24V power supply)
b. F11 / 10.5 = Power line F11, comes from circuit breaker F11, sheet
08 section 8 and continues on sheet 10 section 5.
c. S27 / 20.7 = Line S27, comes from switch S27, sheet 08 section 1
and continues on sheet 20 section 7.
Function:
If switch S27 is actuated, terminal A and B are connected and 24VDC will
energize the coils of K121 and K121a on page 08 and simultaneously via line
S27 a digital input to the PLC on sheet 20 section 7.
Now the machine can be operated in emergency mode and a warning text
appears on the display.
Electronic Control System Section 14.0
ECS Page 1

Section Page
14.0 Electronic Control System ECS
14.1 General Design of the ECS-T System 2

14.1.1 Input and outputs of the PLC 3
14.1.2 Task 3
14.1.3 PLC DIGSY plus ® 4
14.1.4 Definitions; Symbols and Abbreviations 5 + 6 +7
14.2 How to Proceed due Maintenance and Installation 8+9

14.2.1 Meaning of the Status LED’s 10 + 11
14.2.2 Short Circuit Marker -LED “MK” 12
14.2.3 Diagnostic for Temperature-Module “ANM” 13
14.3 Front Connector Arrangement 14

14.3.1 Front Connector Arrangement BIM-Module 14 + 15
14.3.2 Front Connector Arrangement, ANM-Module 16 + 17
14.3.3 Ground connection of the Control Unit 18
14.3.4 Interface-Connection COM SP /SK 19
14.4 Power supply 20

14.4.1 Operation Voltages +24 V 20
14.4.2 Safety Precautions for Faultfinding 21
14.4.3 CPU Voltage Range 22
14.4.4 Electric Classification 22
14.4.5 Fuse 22
14.5 Function explanations with electrical diagram 23

14.5.1 General 23
14.5.2 Pressure Measuring 24
14.5.3 Temperature Measuring 25 + 26
14.5.4 Temperature – Resistance Chart PT100 27
14.6 Hints for reading the functional flow charts 28

14.6.1 General 28
14.6.2 Example 29
PC5500-6-D_Sec_14-0_rev2.doc 31.07.07
14.0
2
PC5500-6-D_Sec_14-0_rev2.doc 31.07.07
ECS Page 2
14.1 General Design of the ECS System
ECS Electronic Control System
Legend: Illust. Z 21407a
(1) PLC Programmable Logic Control (DIGSY plus ®)

(2) Text display
(3) Keys for function control and pre-adjustments
(4) Outlet “X27” for data transfer
(5) Field computer system (like MODULAR MINING)
(6) Printer
(7) Memory card unit
(8) Laptop
I/ O Input / Output data transfer
) • Items 5 to 8 are optional equipment
Meaning of the PLC front cover codes

• BIM Binary Module
• ANM Analogous Module
• MK Short Circuit Memory
• A Digital Output
• E Digital Input
• DIAG Diagnostic
More in detail see page 4
PC5500-6-D_Sec_14-0_rev2.doc 31.07.07
14.0
3
PC5500-6-D_Sec_14-0_rev2.doc 31.07.07
ECS Page 3
14.1.1 Input and Output of the PLC, Illust. Z 21408
PLC = Programmable Logic Control

(Programmable Logic Control = Control system with a write-reading-
memory, whose content can be altered (via an serial interface) by a PC and
the resp. Software.
No mechanical action necessary.)
14.1.2 Task
The PLC receives from the monitored excavator components the actual
values and does an evaluation.
The evaluation results in a control and display function.
See I / O connection table (chapter 10) and electric circuit diagram for I / O
levels and ports.
) • The picture shows as an example the application for a two motor

version.
PC5500-6-D_Sec_14-0_rev2.doc 31.07.07
14.0
4
PC5500-6-D_Sec_14-0_rev2.doc 31.07.07
ECS Page 4
14.1.3 PLC DIGSY plus ® (circuit diagram code E6)
Legend for illustration Z 21409b

1. Central Processing Unit (CPU) board.
2. Binary Module (BIM) board.
3. Analogues Module (ANM) board.
4. MK Output short circuit marker LED red
5. Input state-LED green, Inputs E1.1 - E1.8 up to E14.1-E14.8
6. Input or Output State-LED red (A2/ E9, Af/E10, A6/E11,
A8/E12, A14/E21) Can be used as Inputs or Outputs
7. Output state-LED red, Output A1.1 - A1.8 up to A13.1-E13.8
8. Diagnostic-LED (DIAG), (green flashing = OK.)
5Volt Voltage-LED (+5V), (green = OK.)
9. Diagnostic LED for ANM
10. COM SP Interface (COM SP) (Text display connection)
11. COM SK Interface (COM SK) (PC-Connection)
12. Binary Module BIM-plug-in location (slots) (X1-X5)
13. Analogous Module ANM-plug-in location (slots) (X6-X8)
14. Ground Connection (GND)
) • The quantity and configuration of the BIM and ANM Module can be
vary, depend on the excavator typ and additional options.
MK-LED, The short circuit marker are used to indicate an external short to GND
• MK1, MK3, MK5, MK7 & MK9- LED for outputs A1.1 - A1.8
A3.1 - A3.8, A5.1 - A5.8, A7.1 - A7.8 & A13.1 – A13.8
• MK2, MK4 , MK6, MK8 and MK10 if there groups as outputs used
• A MK-marker is placed, if an output (e.g. A1.1) gets from the program an output signal
and at the same output happens an external short. The red MK 1-LED lights ON
)
• If there is a short all outputs of the resp. Output group i.e.. A1.1 - A1.8)
are switched Off
• The short circuit marker remains until the control system gets switched
Off/ON (after eliminating the short).
State-LED Input lights up with a present 24 Volt signal.

State-LED Output lights up with a switched On output.
5V-LED, indicate specified operation states by different colors and duration of

lightning (Continuos On or flashing). For detail information see Section 4.
DIAG-LED, indicate specified operation states by different colors and duration of

lightning (Continuos On or flashing). For detail information see Section 4.
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ECS Page 5
14.1.4 Definitions; Symbols and Abbreviations

≡ Sign used for “corresponds to”
≠ Sign used for “not equal to”
Bit A bit is the smallest unit for information. It can assume only two
conditions: logical 0 or logical 1 ( also referred to as logical L-Level and
logical H-Level).
Boolean algebra Mathematical rules for binary variables and conditions. For Boolean
equations the following signs are used:
Logical AND operation (AND or &) ∧
Logical OR operation (OR or >=1) ∨
Logical Negation (NOT or 0) ¬
Byte Unit for Information unit comprised of 8 bits. A byte can assume a value
between 0 and 255.
Word Memory unit comprised of 2 byte or 16 bit. A word covers the numeric
range from –32767 to +32767.
Clock Signal pulse
VWP VerWaltungProgramm: (management program) A control program

created by the user.
AWP AnWender Program: (Application program, user program) A control

program created by the user.
AWL AnWeisungsListe: (instruction sequence) Representation of a program

using alphanumeric signs and symbols as defined in DIN 19239.
Programming in AWL (selection logic) is the at present widely applied
method of programming.
CMOS Complementary Metal-Oxide Semiconductor: Complementary metal-

oxide semiconductor technology with very low-level closed circuit
current. These semiconductors are used above all for accumulator and
battery buffering.
RAM Random Access Memory: Read-write memory in which each memory cell
can be addressed in order to read, write or delete at any time. RAM losses
all of its information when the computer is turned off which is why it is
often buffered by accumulators or batteries.
EPROM Erasable Programmable Read Only Memory: Read-only memory erasable

by ultraviolet light and electrically programmable. With this memory type,
the contents remain intact in the event of a power failure. In the case of
DIGSY plus ® this memory contains the management program (firmware).
continued
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ECS Page 6
Cont'd:
EEPROM Electrically Erasable Programmable Read-Only Memory (also called
E2PROM):Electrically erasable and programmable memory. In the event
of a power failure, the contents of this type of memory remain intact. The
DIGSY plus ® application program (AWP) is loaded into this type of
memory.
COMPILER A program that translates the instructions of a programming language

(e.g. instruction sequence [AWL]) into machine code (processor
instructions).
EDITOR Utility program for the creation and changing of programs.
Loop Program loop.
Off-Line Operational method of a programming device without attached

automation device.
On-Line Operational method of a programming device (PC) is connected to the

automation device thereby enabling data and programs to be read or
changed.
PC Personal Computer: Programmable unit for the DIGSY plus ®.
Watch-Dog: Internal supervisory unit in computers and automation devices used to

recognize system and memory errors.
CPU Central Processing Unit: Control and central unit in an automation

device usually based on a microprocessor. It can read the application
program code and run the instructions contained therein.
Cycle Time Time required for the application program to run through once.
continued
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ECS Page 7
Cont'd:
Coding Types and Number Systems

ASCII American Standard Code for Information Interchange: A standardized
information processing code developed in the USA based on
7 bits = 0 – 127 (7-bit code), (extended ASCII-code of 8-bit = 0 - 255)
Digital (Eng. Digit) is the representation of a continuos value or a physical

quantity (e.g. voltage) in several levels as a numeric value.
With regard to automation devices one also refers to “word processing”
in which case a “word” is a number (e.g. 573).
Analogue is the representation of a continuos physical quantity (e.g. current or

voltage) which corresponds to the value of a proportional condition
(e.g. rotational speed, routing, temperature, etc.)
For an automation device this physical value converted into 1024 levels,
for example (10-bit analogues-digital conversion). The digitalized value
thus acts within a defined range (e.g. 0 ≡ 0 volts to 1024 ≡ 10 volts) in
proportion to a certain input quantity (e.g. voltage). Conversely, by using
a digital-analog conversion, a digitalized value can be converted into a
continuous output signal (current, voltage).
Numeral A value expressed in one digit: from 0 to 9 in the decimal system and 0-F
in the hexadecimal system.
Number Value consisting of one or more numeric characters.
Baud Unit used in serial transmission of data: bits per second (bit/s).
Baud Rate Modulation rate or transmission speed of serial transmission of binary

numbers. The DIGSY plus uses a baud rate of 2400 baud for
communication and down-loading.
Binary Numbers, data and information which are exclusively expressed using
the two values 0 and 1 are bivalent = binary dates and information,
exclusive with the use of digits 0 and 1 (e.g. 1 = current 0 = no current).
Dual(Binary) Number (Dual = 2) is the simplest binary numeric expression. Each

position is arranged according to increasing powers of 2.
Example: 13463dec. = 0011 0100 1001 0111dual
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ECS Page 8
14.2 How to Proceed due Maintenance and Installation
Keep in mind
• - BE CAREFUL
• - BE ALERT
• - THINK ABOUT WHAT YOU ARE DOING
Any PERSON doing any work in or around the machine must be familiar
with the local SAFETY INSTRUCTIONS and with the specific SAFETY
INSTRUCTIONS REGARDING TO HIS OCCUPATION.
• Serious damage may happen at unqualified actions at the System or

Unit or when not paying attention to the hints given in this manual or
on labels at the units
Qualified persons in sense of the safety relevant hints in this manual or on the
product, are persons which are
• either as project engaged person familiar with the safety concept for
automatic control systems;
• or as operating personal for the use of an automatic control system being
instructed;
• or having the authorization and occupation to put such systems into operation
or doing repair work as well as having the authorization and occupation to put
such systems/units into operation regarding the power
circuits and there safety standards and, to earth and to mark it.
continued
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14.2 How to Proceed due Maintenance and Installation

Cont’d.:
• Serious damage may happen at irrelevant opening and improper repair.

Open always the resp. circuit breaker before opening a unit.
I/O – cables may only be connect or disconnect in a powerless state.
A BIM module will be damaged while supplying an external power

of 24VDC to the inputs and/ or outputs. If it is necessary for
faultfinding or external unit checks the connection to the PLC has to be
interrupted.
• Without power interruption the interface cable are only allowed to be

disconnect or connect when following preconditions are given:
1. The cable must be shielded and the shield must be connected to the
cover of the plug-in connector.
2. A potential balance must be made by connecting the GND
potential parts of the plug connector parts before connecting
the cables.
• Replace the fuses only by fuses which matches the values given in the
technical dates
m • Do not through batteries into open flame and do not solder at their cell
body, explosion can occur (max. Temperature 100° C). Do not open and
do not recharge batteries that contain lithium or mercury. Replace
them by same type only!
• Dispose batteries and accumulators as special waste.
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14.2.1 Meaning of the Status LED’s, Illust. Z 21431b
The DIGSY plus performs by the function of the Status LED’s (5V and DIAG) and
the so named Diagnostic Words* (DW1 up to DW256) many data and statuses.
With a PC and the Program- and Diagnostic Software the. Diagnostic Words are
visible on a monitor.
The following sections explain the diagnostic possibilities more in detail.
* Can be called-up by PC assistance only.
Table: Statuses of the +5 V-LED and their meaning

LED Effect Cause Remedy
5 V-LED Voltage
green o.k.
5 V-LED CPU not working Supply Check the
red (RESET) < 4,65V +24 V Supply
DIAG-LED red if not o.k. *)
5 V-LED CPU not working Supply Check the
OFF (except the is missing +24 Volt
LED is defect)
Fuse S1 Replace the **
defect Fuse F1
LED defect *)
(if DIAG
LED is ON)
others *)
5 V-LED
flashing
red/green cyclically Watchdog *)

new starts in operation
red/
orange Continuos Reset Component fault *)
** Replacement only after co-ordination with Komatsu Mining Germany, Dept. 8124.1
*) = Return PLC to manufacturer
continued
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14.2.1 Meaning of the Status LED’s, Illust. Z 21431b

Cont’d.:
Table: State of the DIAG-LED and their meaning
LED Effect Cause Remedy
DIAG-LED Program Communication via Check the cable
green in operation Interface COM-SP connection and the
not active Interface port
(interrupted)
COM-SP<╪> Text
display
DIAG-LED Program- Temperature External cooling
orange state inside housing
unchanged too high
+24 VCPU < 14 V Increase the voltage
Accumulator voltage Replace the
too low accumulator module
Fixed operands Check the
deleted accumulator
connections
SPS in start loop wait
after voltage ON
programming in Stop the
operation programming *1)
DIAG-LED Program EEPROM not Initialize
RED not running (stopped) Initialized EEPROM *1)
EEPROM- or Initialize
RAM- fault EEPROM *1)
if the fault is
still present *2)
DIAG-LED Program Program Start program *1)
OFF not running stopped
(except LED
defect) No Program Load program *1)
otherwise LED
defect *2)
DIAG Program- Communication via
flashing state Interface COM-SP
unchanged or COM-SK active
Color State COM-SP⇔ Text
depending Display
COM-SK⇔ (PC)
*1) Function of the Programming Software PROSYD
*2) = Return PLC to manufacturer
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14.2.2 Short Circuit Marker -LED “MK”
The short circuit markers are used to indicate a short of the outputs at an external
short to GND.
A “MK” marker will be initialized if by the user-program an output signal is
given and at the same output is an external short present.
The “MK” marker remains until (after short elimination) the control system is
switched OFF and ON.
See also Section 14.1.3 page 4
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14.2.3 Diagnostic for Temperature-Module “ANM”
For the function control a two-color LED is used, visible at the front cover.
The diagnostic - LED indicates following states:
- LED red: System in reset mode or range overflow of
one or more analogous outputs.
- LED green: Ordinary operation, no range overflow.
- LED red/green flashing (2Hz) Watch-dog timer response or cyclically

overflow of one ore more analogous outputs.
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14.3 Front Connector Arrangement

14.3.1 Front Connector Arrangement, BIM Module (Digital Input / Output)
) • .This is an example for the first Slot. Additional BIM Modules can
be vary depend on configuration of the variable input/output port
A2/E9/ A4E10, A6/E11, A8/E12 or A14/E21.
• The configuration for the respective excavator is written in the
EA-Configuration chart (EA-Belegungsliste) see Apendix.
Pin Symbol Operand Definition

1 Input 1.1 E 1.1 Input 1 of the input group. 1
2 Input 1.2 E 1.2 Input 2 of the input group. 1
3 Input 1.3 E 1.3 Input 3 of the input group 1
9 Input 9.1 E 9.1 Input 1 of the output group 2
17 0 V (GND) Ground
18 Input 2.2 E2.2 Input 2 of the input group 2
continued
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14.3.1 Front Connector Arrangement, BIM Module (Digital Input / Output)
Cont’d.:
Pin Symbol Operand Definition
22 Output 1.1 A 1.1 Output 1 of the output group 1
29 Output 1.8 A1.8 Output 8 of the output group 1
30 UE/A Under Load Voltage UE/A =
31 UE/A Under Load Voltage Voltage.
32 UE/A Under Load Voltage Input / Output
33 UCPU DIGSY (plus)- Operation Voltage
41 Output1.4 A 1.4 Output 4 of the output group 1
42 Output1.5 A 1.5 Output 5 of the output group 1
45 Output 1.8 A1.8 Output 8 of the output group 1
46 UE/A Under Load Voltage
49 UCPU DIGSY (plus)- Operation Voltage.
50 0 V (GND) Ground / GND
There are two pins (two channels) parallel connected only for output A1.1 –
A1.8 (the same for additional boards A3, A5, A7, A13).
• E1, E2,...E7, E13 and E14 input port fix configured.

• A2/E9, A4/E10, A6/E11, A8/E12 and A14/E21 variable input or output
ports depend on software programming.
• A1/A9, A3/A10, A5/A11, A7/A12 and A13/A21 output ports fix
configured.
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14.3.2 Front Connector Arrangement, ANM-Module (Analogues Input)
) • .This is an example for the first ANM slot. Additional ANM modules
configuration can be vary depend on configuration (temperature or
pressure).
• The configuration for the respective excavator is written in the EA-
Configuration chart (EA-Belegungsliste) see Appendix and the
respective electric diagram.
PIN PIN-NAME OPERAND COMMENTARY

1 KR Relay contact
2 KG Relay contact
3 KA Relay contact
4 GND/ANA Analogous GND
8 A1I AW Z.1 Current output 1
9 A1U AW Z.1 Tension output 1
16 A4G GND – Output 4
19 GND/ANA Analogues - GND
22 E8G GND – input 8
• All pins are internal connected
continued
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14.3.2 Front Connector Arrangement, ANM-Module (Analogues Input)
Cont’d.:
PIN PIN-NAME OPERAND COMMENTARY
26 A1G GND - Output 1
27 4U+E4G GND - Input 4
29 E3G GND - Input 3
34 GND/ANA Analogues – GND
35 E8 EW Z+1.4 Input (U/I) 8
37 E7 EW Z +1.3 Input (U/I) 7
39 E6 EW Z +1.3 Input (U/I) 6
41 E5 EW Z +1.3 Input (U/I) 5
43 E4 EW Z.4 Input (U/I) 4
• All pins are internal connected
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14.3.3 Ground connection of the Control Unit
Attention: The complete shield of the analogous cable must be connected to the
ground (GND) bolt of the PLC housing. This bolt must be connected to the
X2 frame / machine ground by a cable (as short as possible) with 2,5 mm2
cross section.
When using plug connectors with metal boxes and connected shield the
additional complete shielding of the analogous cable with the ground bolt
is not necessary. But attention must be played that the metal box is
connected by screws with the PLC housing.
The twisted signal lines are pair wise shielded and already via the 50-pol
female part of the connector connected to ground. The single shielding at
the free end of the cable must not be connected with earth.
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14.3.4 Interface-connection COM SK / SP
Legend for illustration Z 21425a (Exemplary picture about what possible)

(1) Text display
(2) PLC
(3) Plug socket “X27”
(4) Laptop computer
(5) Memory card system
(6) Portable printer
(7) Field dispatch system
Cables:
VL3 X27 to Laptop
VL4 X27 to Memory Card System
VL5 24V Power supply to Memory Card System
VL6 X27 to Portable Printer
VL7 24V Power supply to Portable Printer
VL8 X27 to Field Computer System
Communication interface:
COM-SK => Programming interface (Baud rate 19200)
COM-SP => Communication with text display (Baud rate 9600)
) • Data cables and/or communication systems are optional equipment.

• For more detailed information see OPERATION MANUAL of the
shovel
and the Software Program for the individual Communication System
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14.4 Power supply

14.4.1 Operation Voltages +24 V, Illust. Z 21426
Study together with the relevant circuit diagram
50-pin SUB Connector:
+ 24 V CPU-Supply: Pin 33 and 49

GND: Pin 17 and 50
+ 24 V I/O-Supply: Pin 30 - 32, 46 – 48
This supply voltage is the operating voltage for the module outputs. It must
be strong enough to carry the load current of all outputs.
It is provided with a LOAD-DUMP protection to protect (for short times)
wrong polarity and over voltage peaks.
• Wrong polarity causes destroying of the module!

• External 24 V supply to the outputs causes destroying of the module!
See next page for more information
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14.4 Power supply

14.4.2 Safety Precautions for Faultfinding, Illust. Z21427
• As already mentioned no external 24 V supply is allowed to the

outputs of the BIM modules of the PLC.
• If it is necessary while tracing faults, the cable to the PLC must be
disconnected subsequent to a component check, thus as relays,
solenoids or others by the PLC controlled components.
Procedure: Study together with the relevant circuit diagram

1. Find the terminal between the component and the PLC.
2. Example terminal 8X2-280 for the solenoid valve 8Y6.1.
3. Disconnect the wire on one side of the terminal.
4. Now supply 24 V to the solenoid and check function of it.
5. Finally re-connect the wire to the terminal
Binary Outputs A
2A-Short circuit proof
Each single Output of the Output group can withstand a load of 2A, but the
total load must not exceed 10 A. The Output group will be switched OFF if
one of the Output becomes overloaded (> 2 A), the short circuit marker will
be set and the “MK”- LED comes ON.
(A1¿ MK1, A3¿ MK3, A5¿ MK5)
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14.4 Power supply

14.4.3 CPU Voltage Range
• Electrical requirements +24 supply volt
• 14 V up to 36 V without any restrictions regarding the max. current
consumption of 4 amps out of the +5 V logic voltage.
• At voltage drops below 18 V the 2amps-outputs switched OFF due to
safety reasons. The short circuit markers initiated.
• The +24 V CPU is monitored on the CPU plus
DB16.1
After the diagnostic bit “Under-voltage UCPU “ DB16.1 has been set, all
access to the EEPROM memory of the CPU plus is blocked
• A drop below 9V results in a reset.
• During and after voltage drops according to DIN 40839 part 2 operates the
CPU plus normally.
14.4.4 Electric classification

The voltage supply meets the requirements according to:
• ISO 7637-2 Automotive Technique 24V
• DIN 0871-B
• IEC 801-4 step 4, VDE 0843-4.
• DIN/VDE 0470 part1 (old DIN 40050)
14.4.5 Fuse
TR5 / 2.5AT IEC 127-3 Manufacturer Wickmann,
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14.5 Function explanations with electrical diagram

14.5.1 General
Signal Status
Voltage level:
„1“ = 24 V* between E (Input) and GND
„0“ = 0 V** between E (Input) and GND
* 13 V up to actual supply voltage
** 0V up to 5 V
The left half of the picture shows so named PULL-DOWN resistors and the
right half PULL-UP resistors. The resistors are installed to get a low ohmical
input. A system with contacts only leads to a (high ohmical) input if dust or
moisture bridges the contacts.
PULL-DOWN resistors are installed with a normal NC contact (means with a
de-energized relay or normal closed switch contact) thus the ECS recognize a
fault after switching ON the system.
PULL-UP resistors are installed with a normal NO contact (means with a de-
energized relay or normal open switch contact) thus the ECS recognize a fault
after switching ON the system.
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14.5.2 Pressure Measuring (Hydraulic System), Illustration Z 22805
(study with the respective circuit diagram)
(Program run see Flowchart)
Analogous Inputs:
„EW 14.1“ for pressure sensor B87A (0 up to 500 bar)
Measuring channel: 0......10 V
Function:
- Voltage supply for the pressure sensor: 24 V
- Output voltages Ua (OUT+, pin 2) of the pressure sensors:
Sensor 0 – 0,4 bar ¿ K= 25 V / bar
Sensor 0 – 60 bar ¿ K= 0,1667 V / bar
Sensor 0 – 500 bar ¿ K= 0,02 V / bar
(Pressure sensors with +1 V Offset)
Possible voltage checks:

24 V Supply between supply line 15 (start at circuit breaker) and GND.
Output voltage OUT (pin 2) of the sensor
between GND. Use respective circuit diagram for terminal numbers.
* How to calculate the Output voltage Ua:

Ua = output voltage proportional to the pressure input.
P = input pressure
K = calculation factor for the respective pressure sensor.
Ua = (P x K) + 1 V
Example for 200 bar and a 0 – 500 bar sensor:

Ua = (200 x 0,02) + 1 V = 5 V
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14.5.3 Temperature Measuring and trouble shooting Illustration Z22803a
General: (study with the respective circuit diagram)

The signal of the PT100 temperature probe can’t connect direct to the ANM –
Module (Analog input of the PLC). A temperature transducer module change
the PT100 signal (Ohm) into a suitable current (mA) signal for the ANM –
Module. The temperature probe is connected with a four wire technique to
compensate the line resistance of the long wire between the X2 switch board
and the temperature probe.
Analogous Inputs (eg.: Hydraulic oil temperature sensor B15)

The temperature probe B15 is with 4-wire technology (distorting compensation)
connected to the transducer U15 terminal 1, 4, 2, and 3 (measuring range: -50°
C......+150° C). The output terminal 5 and 6 of the transducer is connected to the
ECS analogues input „EW 2.1“ (input range 4 – 20 mA). The transducer need 24
V power supply via terminal 7 and 8 (+24V, ground).
Function:
The temperature transducer convert the
measured values from the PT100 temperature
probe into electrically standardized analog
signals. With the four wire technique the length
and the cross section of the wires are not
important; because the electrical resistance of the
two current lines gets compensated. The sensor
is supplied with a low electrical current from the
temperature transducer (I+ and I-). Additional to
the temperature probe (PT100) resistance the
line resistance influence the current “flow” what
falsified the PT100 measurement. To
compensate the line resistance there are two
additional lines (U+ and U-) close to the PT100
connected. Via this lines the transducer measure
exact a tension drop between in- and output of
the PT100 probe witch is only created by the
PT100 resistance. Because there is no current “flow” through this lines witch
are influenced by the line resistance (compared to hydraulic system- it’s like
a test hose with a pressure gauge). The module convert this tension drop into
a current signal (4-20mA) which is proportional to the temperature.
In the interest of proper function must the line resistance not exceed 50 Ω.
Additional the lines must be shielded according to the standards. The picture
shows the wiring of a PT100 probe to a temperature transducer in four wire
technique.
continued
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14.5.3 Temperature Measuring and trouble shooting, illustration Z22803a
Cont’d.:
Possible measurements PT100:

Disconnect the wires at the resistor and measure the resistance across the
resistor.
Compare the measured resistance with the values given in the table on next
page.
If the value correspond to the temperature measured with an other temperature
gauge the PT100 resistor is OK.; otherwise replace resistor.
Wiring:
Disconnect the wires at the resistor and inside X2-box at the temperature
transducer terminal 1, 2, 3, and 4.
Measure the line resistance to the ground.
All single wire resistance must be the same.
Transducer:
Connect a Ampere-meter in line between terminal 5 of the transducer and the
disconnected wire to the ECS. Select mA range and check the current. The value
must compare to the PT100 resistance with the following calculation:
I = [( 50 + t ) x 0,08 ] + 4
t = temperature [°C]
(Check temperature via PT100 resistance and temperature chart next page)
I = current [mA] to the ECS
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14.5.4 Temperature – Resistance Chart PT100
Basic Values in Ohm according to DIN 43 76
For Measuring Resistor PT100
°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
0 100,00 99,61 99,22 98,83 98,44 98,04 97,65 97,26 96,87 96,48
°C 0 1 2 3 4 5 6 7 8 9
0 100,00 100,39 100,78 101,17 101,56 101,95 102,34 102,73 103,12 103,51
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
Example: 84 ° C Ì 80° + 4° = 132,42 Ω

124,4 Ω Ì 124,4 ≈ 124,39 = 60° + 3° = 63 °C
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14.6 Hints for reading the functional flow charts

14.6.1 General
) • Probably the best aid for trouble shooting is the confidence of knowing
the system and how to use the ECS. Every component has a purpose in
the system. The construction and operating characteristics of each one
should be understood.
• Use always the electric/hydraulic circuit diagram the flowchart and
the operation manual for the specific machine.
1. Select on page 1 of the flow chart, (which contains the table of contents
and the main program) the respective subprogram, for example the
Power-Master lube system.
2. Components in the flow chart, have the same identification code as in the
electric/hydraulic circuit diagram, as shown in cross reference list (page 2-4).
For example: Relay K50 = ?
On page 2 (cross reference list) you find out that relay K50 is shown on
page 43 of the flowchart.
3. On each page of the respective subprogram you will find the functional
description in plain text.
In case of problems concerning reading the program loops, you may find
answers in the frequently asked questions list on page 6 and 7 of the flow
chart.
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14.6 Hints for reading the functional flow charts

14.6.2 Example: Monitoring the X1-pressure for pump control,
illustration Z25072
Grey shaded fields in the table below shows the normal way , used from the program,
if the excavator is in “standard condition”.
Item query Yes No

1) Sensor or cable B85-X : 5 sec. < --6bar B85-X : 5 sec. : Voltage
defect? i.e. <1V at EW13.3 between 1V and 11V at
or EW13.3
B85-X : 5 sec. > +55,3bar
i.e. > 11V at EW13.3
⇓
Fault message No 1190
2) _running_motor-x Motor X is running for Motor X is not running
> 15 sec ? more than 15 seconds
3) X1-pressure to B85-X : 2 sec. > 40bar B85-X : 5 sec. : Voltage
high? i.e. > 6,5V at EW13.3 below 6,5V at EW13.3
⇓
Fault message No 962
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Section 15.0
Lubrication System
Page 1
Table of contents
Page
General Function 3
Oscillation Cylinder and Control Block 9
Adjustments 11
One line system 13
Electrical function 17
Capacitive analog sensor for lubricant level monitoring 21
Adjustments
End Line pressure switch 23
Injectors 25
Function Pinion type (dummy wheel) system 27
Electrical Function (dummy wheel) system 31
Capacitive analog sensor for lubricant level monitoring 35
Adjustments
End-Of-Line Switch setting 37
Injectors 39
Components
Hydraulically driven lube pump 41
Injectors 45
End-Line Switch 51
In line Filter 53
Vent valve (Solenoid valve) 55
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15.0
2 Lubrication System
Section 15.0
Lubrication System
Page 3
General Function
Legend: illustration Z 24042a

(1) Lubricant pump drive (Hydraulic cylinder)
(2) Solenoid valve (Oil pressure supply)
(4) Pressure reducing valve
(5) Hydraulic oil supply line (Pilot pressure)
(6) Hydraulic oil return line
(7) Vent valve (Solenoid valve, de-energized open to barrel)
(8) Grease supply line to injectors
(9) Lubricant level indication (capacitively analog sensor)
(10) Lubricant barrel
(11) Pump mechanism
(12) Lubricant filter
(13) Hydraulic pressure test plug (Operating pressure)
(14) Lubricant pressure gauge (Operating pressure)
(15) Vent line to barrel
(16) Breather
(17) Electrical terminal box
) • Cylinder pressure must not exceed 650 psi (45 bar)
continued

15.0
Cont'd.
X-axis Time
Y-axis Lubricant supply line pressure
PI Pressure Increasing
S+ Switch point ON of the end of line pressure switch
PH Pressure Holding
S- Switch point OFF of the end of line pressure switch
PR Pressure Relieve
PT Pause Time
Section 15.0
Lubrication System
Page 5
Function of a lubrication cycle illustration Z24042c and Z22023a
PT-phase
With the pump and controller system in a rest state a pre-set pause time interval
occurs as determined by the PLC.
Diagram position (a):

A 24 VDC signal from the PLC activate solenoid valve (2) that opens and activate
the lubrication pump. (*). As solenoid valve (2) opens hydraulic oil flows through
the pressure reducing valve (4), it lowers the hydraulically pilot oil pressure to the
operating range of the hydraulic driven lube pump. The reduced pilot oil pressure
operates now the grease pump. The oil cylinder shuttle’s the grease cylinder at 18
– 20 double strokes per minute and delivering 612 – 680 cm³ (37.3 – 41.5 in³) of
lubricant per minute (approx. 550 – 612 g / 19.64 – 21.45 oz.)
At the same time a 24 V signal energize release valve (7), it close now the release
line to the lubrication container.
PI-phase
With energized release valve (7) (*) and solenoid valve (2) the pump continues to
cycle until maximum pressure is achieved and the injectors have metered
lubricant to the bearings.
S+ point, diagram position (b)

When the maximum system pressure is reached the end-of-line switch (*) open its
contact. In the normal application is the end-of-line switch adjusted to 185 bar
(2630 psi. ).The pressure increasing phase is now finished.
The open pressure switch (*) signals the controller to stop the pumping cycle and
the controller terminates the signal to the solenoid valves (2) The pilot oil flow to
the pump stops.
Solenoid valve 2 Vent valve 7 end-of-line switch

Y7, CLS Y7a, CLS (1) B43, CLS
Y8a, CLS (2)
Y9, SLS Y9a, SLS B46, SLS
SLS = Slew Ring Teeth Lubrication System
CLS = Central Lubrication System
(*) check respective circuit diagram
continued
15.0
Cont'd.
X-axis Time
Y-axis Lubricant supply line pressure
PI Pressure Increasing
S+ Switch point ON of the end of line pressure switch
PH Pressure Holding
S- Switch point OFF of the end of line pressure switch
PR Pressure Relieve
PT Pause Time
Section 15.0
Lubrication System
Page 7
Cont'd.
PH-phase
Release valve (7) is still energized to keep the pressure in the lubricant line for a
fix adjusted time (pressure holding time normally 5 min).
Diagram position (c):

With expired pressure holding time vent valve (7) de-energize. It opens the
release line to the lubricant container. The lubricant line pressure drop to zero so
the injectors can recharge for the next lubricant injection. (PR-phase).
PR-phase
In the pressure relieve phase the end of line switch (*) move back to neutral
contact position it signals the PLC that the lube pressure relieve phase is now
active.
PT-phase
The system is now at rest (pause time), ready for another lube cycle and the
sequence repeats itself.

15.0
Section 15.0
Lubrication System
Page 9
Oscillation Cylinder and Control Block, illustration Z 21174
Description:
Oscillation cylinder (6) is auto directional controlled, non pressure related. This
differential cylinder is connected to the pilot pressure suppliy line (P) and a tank
line (T). The speed is contolled by a flow contol valve (3) and the maximum
working pressure is controlled by a pressure reducing valve (2).
Function:
The Oscillatin cylinder (6) starts as soon pilot pressure is send via the connection
(P) to the control block (1). Design related the cylinder (6) retract always first
after start or from any position the piston has stopped before. When the cylinder
reaches the fully retracted position the flow will be redirected automatically and
the cylinders moves in the extending position. If the cylinder comes to an stop in
between the end positions weather the oil supply get stopped or the cylinder is
hold back by a higher work resistance than the supply pressure, the cylinder
changes direction and retracts.

15.0
Section 15.0
Lubrication System
Page 11
Adjustments (illustration Z21175b):
Stroke speed
For a sufficient lube pump operation 18 – 20 double strokes / min for the pump
drive cylinder are required. Therefore the flow reducing valve (3) has to be
adjusted accordingly.
Procedure:
1. Remove electrical plug connection form the discharge valve (7), so no
pressure built up will take place during the following test.
2. Start engine and run at high idle.
3. Switch “ON” the lube system annually and count strokes per minute, visible
on the moving up and down of pipe (1).
a. Loosen lock nut (3.1)
b. Turn adjustment (3) until the right number of strokes is achieved.
turn set screw ccw for more speed and cw to reduce the speed
c. Tighten lock nut (3.1).
Working pressure
The pressure reducing valve (2) mounted in the oscillation control block reduce
the supply pressure internally to maximal allowed 45 bar.
The pressure ration is 6,55 to 1, that means 45 bar supply pressure result in 295 bar
maximum lubricant pressure.
At the end of line pressure switch the pressure should be 180 ±0,5 bar. With the
lubricant line resistance and different lubricant viscosity the pressure at the
lubricant pump output must be higher as 180 bar. For standard condition adjust the
maximum pump pressure to 220 bar –250 bar, depend on lubricant line resistance
and different lubricant viscosity.
Procedure:
1. Disconnect quick coupling (8), so the pump will be blocked when started.
2. Start engine and run at high idle.
3. Switch “ON” the lube system manually, the gauge should show 220-250 bar.
a. Loosen lock nut (2.1)
d. Turn adjustment (2) until the right pressure is shown at the gauge.
turn set screw ccw for lower pressure and cw to increase the pressure
b. Tighten lock nut (2.1).
c. Reconnect quick coupling (8).
• If the required pressure can’t be adjusted, check adjustment of the 60

) bar pilot pressure valve (X-4 pressure) at the filter and control panel in
the machinery house.

15.0
Section 15.0
Lubrication System
Page 13
One line system

Legend: illustr. Z 21176
(2) Solenoid valve (Oil pressure supply)
(7) Vent valve (Solenoid valve, de-energized open to barrel)
(9) Lubricant level indication (capacitively analog sensor)
(11) Pump mechanism
(16) End-of-line switch
(17) (Pressure check point)
(18) Injector block
(19) Lubricant feed line to bearing
Function:
As soon as the adj. "Pause-Time" is finished the solenoid valves
(2) and (7) are energized. The lubricant pump (1) start to pump lubricant in
the lubricant supply line.
By the function of the solenoid valve (7) the port to the vent line (15) (return
line to the lubricant container) is closed, thus a pressure built up is possible.
The high-pressure barrel pump (1) supplies lubricant into the supply line (8). It
continuos through the lubricant filter (12) to the injectors (metering valves) (18).
) • The picture shows an example only. The hole system includes much
more injectors which are connected via pipes or hoses to the supply
line (8).
In the Injectors the lubricant forced with full pump pressure via the feed lines
(19) to the lube points.
The actual operating pressure can be monitored at the pressure gauge (14)
and checked at the pressure check point (17).
continued

15.0
Section 15.0
Lubrication System
Page 15
Cont'd.
Illustr. Z 21176
When all injectors pistons have reached there final position no more lubricant
is accepted from the supply line which causes a pressure increase in the
supply line (8).
As soon as the pressure reaches the adjusted value of the end-of-line switch
(16) the solenoid valves (2) de-energized and the lubricant pump switched
Off. Depend on different factory settings vent valve (7) de energize together
with solenoid valve (2) or after a fix adjusted time of max. 5 minutes.
With de-energized solenoid valve (7) the port to vent line (15) ( return line to
the lubricant container ) opened and release the lubricant and lubricant
pressure in to the container.
With the diminishing pressure in the main line the pistons of the injector (18)
are forced by spring force in their initial position and the discharge chambers
are filled with grease for the following lubrication cycle.
The system is now prepared for a new lubrication cycle. The operation is re-
initiated after the next "Pause Time" is elapsed.
The proper build-up of the pressure in the supply line (8) is monitored by the
end-of-line switch (16).
If the pressure adjusted at the end-of-line switch will not reached within the
adjusted "Monitoring Time" the fault message ”Central lubrication system
fault” comes up on the text display and the system switch off
W • Grease qualities to be used:

According to NLGI classes 000, 00, 0 and 1 according to the lowest
ambient temperature in the operation area
) 1. The content of molybdenum must not exceed 5 %.

2. Only synthetic graphite allowed in graphite contained lubricants

15.0
Section 15.0
Lubrication System
Page 17
Electrical function. illustr. Z 21177a
) • It follows an exemplary explanation for a central lubrication system

for machines equipped with PLC System. For details see the circuit
diagram of the respective machine. The Lubrication Systems are
PLC controlled. No relay adjustment necessary.
Central lubrication system controlling :

The PLC from the ECS System controls the whole lubrication systems.
The solenoid valves (Y7, Y7A or Y9, Y9A) on top of the lubrication stations are
direct connected to digital output ports of the PLC.
On a few machines there are additional relays between PLC outputs and the
solenoid valves.
Depend on a PLC input from the end-of-line pressure switch (B43 or B46) and a
PLC internal time counter the grease system start a lubrication cycle.
The lubrication cycle starts.
If the pause time elapsed the PLC energize both solenoid valves (Y7, Y7A or
Y9, Y9A) of the respective lubrication system. The engine must run in high idle.
The pilot pump pressure activate now the lubrication pump and the lubrication
pressure to the injectors increase.
If the lubricant pressure reach the adjusted pressure of the end-of-line pressure
switch (B43 or B46) its contact change and the PLC input signal change.
The PLC de energize the respective lubrication pump supply valve (Y7 or Y9) to
stop the pump. For the next 5 min the respective pressure releasing valve (Y7A
or Y9A) are continued energized to keep the lubricant pressure still on a high
level to be able all injectors inject the hole adjusted amount of lubricant.
After the 5 min. pressure holding time the PLC de energize the respective
pressure releasing valve (Y7A or5 Y9A) The lubricant pressure drops and the
injectors move by spring load back in its initial position. A PLC internal counter
is still counting a additional decreasing time to monitor the end-of-line pressure
switch (B43 or B46) position. The PLC internal time counter is still counting up
to the next lubrication cycle.
The lubrication cycle is finished.
continued

15.0
Section 15.0
Lubrication System
Page 19
Cont'd:
Illustr. Z 21177a
The next lubrication cycle starts after the decreasing time and pause time has
expired.
With the switch S24 an additional lubrication can be carried out any time provided
the end of line pressure switch (B43) contact is closed.
Monitoring:
The orderly built-up of the pressure in the lubricant supply line is monitored by
the end-of-line switch (B43 or B46).
If the pressure adjusted at the end-of-line switch is not reached within the adjusted
maximal increasing time the PLC switch off both solenoid (Y7 and Y7A or Y9
and Y9A) valves and send the fault message ”Central lubrication system fault” or
“Swing ring lubrication system fault” to the text display at the dash board.
If the excavator is still working additional four hours with faulty lubrication
system the PLC stop the bucket function. This function is to prevent trouble
depend on a lack of lubricant.
Continued

15.0
Section 15.0
Lubrication System
Page 21
Capacitive analog sensor for lubricant level monitoring,

Illustration Z 21179f
Task:
A lubricant (L) maximum filling level monitoring is necessary to prevent an
overfilling of the grease barrel (C) via the refilling system (only systems with
refilling arm). The PLC use the analog level signal from the sensor to activate a
lamp at the refilling arm just in the moment when the lubricant container is full.
The sensor (S) is mounted on top of the lubricant container and reaches into the
lubricant.
The refilling level activate only a message at the text display to inform that the
lubricant level must be filled up. The message comes up if the lubricant level
reach 5% (910 mm from the cover plate).
The minimum level stop the respective lubrication pump and release the
lubricant pressure until the lubricant level reach the 0% mark (950 mm from the
cover plate). It is necessary to stop the lubrication system with empty lubricant
container to prevent the lubrication pump from running dry. With empty
lubricant container the bucket motion will be switched off after four hours.
Function:
The capacitively level sensor (S) check continuous the lubricant level (L) and
convert the capacitive signal into a current signal between 4 and 20mA. The
current signal increase with increasing lubricant level.
Use the specific electric circuit diagram and program flow charts.
) • The capacitively proximity switch used in our machines are

programmed by the supplier and therefor no adjustment or settings
required.

15.0
Section 15.0
Lubrication System
Page 23
Adjustments
End line switch setting. Illustration Z 21180
1. Connect pressure gauge to check point.
) • Use an other gauge as for checking hydraulic pressures because the

gauge remains filled with grease after the test
2. Start engine.
3. Start a lube cycle with the dashboard switch S24.
+
4. Watch pressure gauge. At a pressure of 180 10 bar the end-line switch
must react and the lubricants pump must stop.*
* If at the same time the pressure shown at the built-in gauge is noted
down, this pressure can be taken for later on checks as a reference
pressure.
) • 180 bar is the normal setting.

Under particular circumstances it may be necessary to increase the
pressure slightly
If re-setting is required:
5. Screw out screw 1 and take off cover 2.
6. Alter the spring tension with adjustment screw 3 that the switch
operates at 180 bar.
7. Install cover 2 and screw 1.
continued

15.0
Section 15.0
Lubrication System
Page 25
Cont'd:
Injectors, illustr. 21181:
Series SL-1 injector:

Lubricant output adjustable from 0.13 up to 1.3 cm³ per cycle. Hydraulic type
fitting with screw type cover cap is provided for initial filling of feeder line, and
may also be used for visual check of injector operation.
Series SL-1 injectors incorporate a stainless steel visual indicator.

Lubricant output adjustable from 0.82 up to 8.2 cm³ per cycle.
Designed for systems where a high amount of lubricant is required.
Principle of operation similar to series SL-1.
Adjusting the lubricant output:

1. Loosen lock nut (C).
2. Turn adjusting screw (A) counterclockwise (OUT) for more lubricant
output or clockwise (IN) for less lubricant output.
3. Tighten lock nut (C).
) • The max. lubricant output is adjusted if the indicator stem (B) moves
not more further outwards

15.0
Section 15.0
Lubrication System
Page 27
Function Pinion type (dummy wheel) system.
Legend: Z 21183a
(2) Solenoid valve Y9 (Oil pressure supply)
(7) Vent valve Y9A (Solenoid valve, de-energized open)
(9) Lubricant level indication
(11) Pump mechanism
(16) Breather
(17) Electrical terminal box
Principle of operation:
By the lubricant pump, the lubricant is supplied to the centered bore hole (B) of the
lubrication type pinion (R). Bore hole (B) must be perfectly aligned to the center of
the lubrication type pinion (A) to be greased, so that lubricant leaves the tooth flank
always when the gear tooth is in contact. The grease outlet (D) of the lubricating type
pinion is arranged at a different angle for each tooth, so that the lubricant is distributed
in a uniform and perfect manners on the tooth flank of the drive pinion to be
lubricated.
Function:
As soon as the adjusted "Pause-Time" elapse the solenoid valves (2 + 7). energized
and the lubricant pump (1) start to pump lubricant.
By the function of the solenoid valve (8) the port to the vent line (15) (return line to
the lubricant container) closed, thus a pressure built up is possible.
The high-pressure lubricant pump (1) supplies lubricant into the supply line (8). It
continuos through the lubricant filter (12) to the injectors (metering valves) (18).
• The picture shows an example with one pinion only. There are also
machines which have more lubrication type pinion (dummy wheel).
By the injectors the lubricant is forced with full pump pressure via the feed line
(19) to the centered bore hole (B) of the lubricating type pinion (R).
continued

15.0
Section 15.0
Lubrication System
Page 29
Cont'd.
Illustr. Z 21183a
The actual operating pressure can be monitored at the pressure gauge (14)
and checked at the pressure check point (17). When all injector pistons have
reached there final position no more lubricant will accepted from the supply
line (8) which causes a pressure increase in the supply line.
Depend on different factory settings vent valve (7) de energize together with
solenoid valve (2) or after a fix adjusted time of max. 5 minutes.
With de-energized solenoid valve (7) the port to vent line (15) ( return line to
the lubricant container ) opened and release the lubricant and lubricant
pressure in to the container.
With the diminishing pressure in the main line the pistons of the injector (18)
are forced by spring force in their initial position and the discharge chambers
fill up with grease for the following lubrication cycle.
The system is prepared for the next lubrication cycle. The operation is
reinitiated after the next "Pause Time".
The proper build-up of the pressure in the supply line (8) is monitored by the
end-of-line switch (16).
If the pressure adjusted at the end-of-line switch is not reached within the
adjusted "Monitoring Time" the fault message ”Slew ring gear lubrication
system fault” is shown on the text display and the pump switch off.
• Grease qualities to be used:

According to NLGI classes 000, 00, 0 and 1 according to the lowest
ambient temperature in the operation area
) 1. The content of molybdenum must not exceed 5 %.

2. Only synthetic graphite must be contained in graphic lubricants

15.0
Section 15.0
Lubrication System
Page 31
Electrical function. Illustration Z 21177b
) • It follows an exemplary explanation for a Slew Ring Lubrication

System for machines equipped with ECS System. For details see the
circuit diagram of the respective machine. The Lubrication Systems
are controlled through the ECS. No relay adjustment required.
Slew Ring Gear Lubrication (Teeth lubrication) controlling :

The PLC from the ECS System control the whole lubrication systems.
Solenoid valves (Y9, Y9A) on top of the lubrication container are direct
connected to digital output ports of the PLC.
On few machines there are additional relays between PLC and the solenoid
valves.
Depend on a PLC input from the end-of-line pressure switch (B43 or B46) and a
PLC internal time counter the grease system start a lubrication cycle.
The lubrication cycle starts.
If the pause time elapsed and the swing function was activated for a short time
the PLC energize both solenoid valves ( Y9 , Y9A ). To start one swing ring
gear lubrication cycle the swing function must be activated one time.
If the lubricant pressure reach the adjusted pressure of the end of line pressure
switch its contact change the position now the input port of the PLC change.
The PLC de energize the respective lubrication pump supply valve (Y9) to stop
the pump. For the next 5 min the respective pressure releasing valve (Y9A) are
continued energized to keep the lubricant pressure still on a high level to be able
all injectors inject the hole amount of lubricant.
After 5 min. pressure holding time the PLC de energize the respective pressure
releasing valve (Y9A) The lubricant pressure drops and the injectors move by
spring load back in its initial position. A internal counter is still counting a
additional decreasing time to prevent a to early new lubrication cycle with the
risk of not complete reset injectors.
The lubrication cycle is finished.
continued

15.0
Section 15.0
Lubrication System
Page 33
Cont'd:
Illustr. Z 21177b
The next lubrication cycle starts after the decreasing time and pause time has
expired.
With the switch S26 an additional lubrication can be carried out any time provided
the end of line pressure switch (B46) contact is closed.
Monitoring:
The orderly built-up of the pressure in the lubricant supply line is monitored by
the end-of-line switch (B46).
If the pressure adjusted at the end-of-line switch is not reached within the adjusted
maximal increasing time the PLC switch off both solenoid valves (Y9 and Y9A)
and send the fault message ”Central lubrication system fault” to the text display at
the dash board.
If the excavator was working additional four hours with faulty lubrication system
the PLC stop the bucket function. This function is to prevent trouble depend on a
lack of lubricant.
Continued

15.0
Section 15.0
Lubrication System
Page 35
Capacitive analog sensor for lubricant level monitoring,

Illustration Z 21179f
Task:
A lubricant (L) maximum filling level monitoring is necessary to prevent an
overfilling of the grease barrel (C) via the refilling system (only systems with
refilling arm). The PLC use the analog level signal from the sensor to activate a
lamp at the refilling arm just in the moment when the lubricant container is full.
The sensor (S) is mounted on top of the lubricant container and reaches into the
lubricant.
The refilling level activate only a message at the text display to inform that the
lubricant level must be filled up. The message comes up if the lubricant level
reach 5% (910 mm from the cover plate).
The minimum level stop the respective lubrication pump and release the
lubricant pressure until the lubricant level reach the 0% mark (950 mm from the
cover plate). It is necessary to stop the lubrication system with empty lubricant
container to prevent the lubrication pump from running dry. With empty
lubricant container the bucket motion will be switched off after four hours.
Function:
The capacitively level sensor (S) check continuous the lubricant level (L) and
convert the capacitive signal into a current signal between 4 and 20mA. The
current signal increase with increasing lubricant level.
Use the specific electric circuit diagram and program flow charts.
) • The capacitively proximity switch used in our machines are

programmed by the supplier and therefor no adjustment or settings
required. If there is a new calibration required refer to Service News
AH 04503

15.0
Section 15.0
Lubrication System
Page 37
Adjustments
End of line switch setting, illustration Z 21185
1. Connect pressure gauge to check point close to the end of line pressure
switch.
) • Use an other gauge as for checking hydraulic pressures because the

gauge remains filled with grease after the test
2. Block the swing function with the swing ring parking, use the switch at
the dash board.
3. Start engine.
4. Start a lube cycle with the dashboard switch S26 and activate for a short
time the swing function to the left or right.
+
5. Watch pressure gauge. At a pressure of 180 10 bar the end of line
switch must react and the lubricants pump must be stopped.*
* If at the same time the pressure shown at the built-in gauge is noted
down, this pressure can be taken for later on checks as a reference
pressure.
But be careful this pressure is higher than the pressure shown at the test
gauge because of the long distance between pump and end of the
supply line.
) • 180 bar is the normal setting.

Under particular circumstances it may be necessary to increase the
pressure slightly
If re-setting is required:
6. Screw out screw (1) and take off cover (2).

7. Alter the spring tension with adjustment screw (3) that the switch
operates at 180 bar.
8. Install cover (2) and screw (1).
continued

15.0
Section 15.0
Lubrication System
Page 39
Cont'd:
Injectors, illustr. 21181:

Lubricant output adjustable from 0.13 up to 1.3 cm³ per cycle. Hydraulic type
fitting with screw type cover cap is provided for initial filling of feeder line, and
may also be used for visual check of injector operation.
Series SL-1 injectors incorporate a stainless steel visual indicator.

Lubricant output adjustable from 0.82 up to 8.2 cm³ per cycle.
Designed for systems where a high amount of lubricant is required.
Principle of operation similar to series SL-1.
Adjusting the lubricant output:

1. Loosen lock nut (C).
2. Turn adjusting screw (A) counterclockwise (OUT) for more lubricant
output or clockwise (IN) for less lubricant output.
3. Tighten lock nut (C).
) • The max. lubricant output is adjusted if the indicator stem (B) moves
not more further outwards

15.0
Section 15.0
Lubrication System
Page 41
Hydraulically driven “Power Master III” lube pump, illustr. Z 21186

Legend: (more detailed see parts list 90-0781) Fig.: 12
(P) Hydraulic oil supply
(T) Hydraulic oil return
(Pr) Pressure reducing valve
(Q) Flow regulator valve
(1) Hydr. actuator piston
(2) Oscillator control block
(3) Pump tube
(4) Breather port
(5) Grease outlet port
(6) Piston rod
(7) Breather plug
(8) Ball, outlet check valve
(9) Ball and seat, check valve
(10) Main piston and plunger
(11) Piston rod set
(12) Inlet valve
(13) Scoop piston
(14) Grease inlet
HINT:
Loss of pressure or to short pump strokes indicates:
A Foreign material lodged under Piston Ball Checks or between Upper

and Lower Inlet Checks (8 + 9).
To correct this problem the upper lower inlet checks (8 + 9) and inlet
valve (13) should be removed and cleaned thoroughly.
If sealing surfaces between upper and lower inlet checks (8 + 9) are
rough or pitted, replace or resurface if damages are slight.
B Shovel rod packing worn or damaged. Before installing new packing,

inspect surface of shovel rod and replace if rough or pitted.
Do not grip shovel rod when disassembling lower pump tube assembly.
continued

15.0
Section 15.0
Lubrication System
Page 43
Trouble shooting, illustr. Z 21186
If the following procedures do not correct the problem, contact a factory

authorized service center.
PROBLEMS:
CYLINDER PRESSURE GAUGE DOES NOT REGISTER PRESSURE.

A. Check system pressure to pump.
B. Check for 24 VDC signal at solenoids.
C. Pressure reducing valve set too low. Check pressure.
PUMP PRESSURE BUILT UP VERY SLOWLY OR NOT AT ALL.

A. No oscillation of pump, check oscillation control block (2).
B. Pressure reducing valve (Pr) may be setting too low.
C. Grease viscosity may be too high for the actual ambient temperature.
D. If pressure is not building up at all, solenoid valve (pilot pressure
supply solenoid) may be inoperative.
E. Pump piston (11) and inlet checks may have foreign matter trapped
causing leakage. Remove, inspect and clean if necessary.
F. Inspect sealing surface on upper and lower checks (8 + 9). Replace if
rough or pitted.
G. Replace scoop piston if rough or pitted. Replace rod packing (15) if
it is leaking.
H. Inspect lubricant supply line for leaks or breaks.

15.0
Section 15.0
Lubrication System
Page 45
Lubricant Injector (metering valve), illustr. Z 21187
TASK:
A readjusted (at the injector) volume of grease is pushed with the injectors to
the bearings or to the progressive distributors.
Design: (model SL1) Design: (model SL11)

(01+02) Metering valve, assy. (01) Metering valve, assy.
(03+04) Injector bar (02) Adjusting screw
(05) Adjusting screw (03) Nut
(06) Nut (04) Plug screw
(07) Plug screw (05) O-ring
(08) Seal ring (06) Disk
(09) Disk (07) Seal ring
(11) Bolt with nut (09) Guide
(12) Disk (10) Indicator pin
(13) Seal ring (11) Seal ring
(14) Piston (12) Piston
(15) Compression spring (13) Seal ring
(16) Spring retainer (14) Pin
(17) Seal ring (15) Compression spring
(18) Disk (16) Spring retainer
(19) Seal ring (17) Bolt with piston
(21) Piston (19) Valve housing
(22) Seal (20) Union
(23) Adapter bolt
(24) Valve housing
(25) Union
continued

15.0
Section 15.0
Lubrication System
Page 47
Cont'd:
Function: illustr. Z 21188
Pos. 1 The injector piston (2) is in its normal or rest position. The discharge
chamber (9) is filled with lubricant from the previous cycle.
Under the pressure of incoming lubricant the slide valve (4) is about
to open the passage (5) leading to the piston.
Pos. 2 When the slide valve (4) uncovers the passage lubricant is admitted to
the top of piston (2) forcing the piston down. The piston force
lubricant from the discharge chamber (9) through the outlet port (10)
to the bearing or progressive distributor.
The lubricant pressure at the bearing or the progressive distributor is
always the same as the pump pressure.
Pos. 3 As the piston completes its stroke, it pushes the slide valve (4) past the
passage, cutting off further admission of lubricant to the passage.
Piston and slide valve remain in this position until lubricant pressure
in the supply line is vented (relieved) at the pump.
This is indicated by the injector stem (8). (fully in)
Pos. 4 After pressure is relieved the compressed spring (3) moves the slide
valve (4) to closed position.
This opens the port from the measuring chamber and permits the
lubricant to be transferred from the top of the piston to the discharge
chamber.
This is also indicated by the injector stem (8) (fully out)
continued

15.0
Section 15.0
Lubrication System
Page 49
Cont'd:
Connection of one or more injectors, illustr. Z 21189
The injectors are designed so that the lubricant output of two or more
injectors can be combined without the use of tees.
The injector body (1) has two outlets ports (a + b), one above the other.
The connector tube (2) is used to couple the injectors together.
Lubricant from injector No. 1 is directed through the connector tube into the
discharge chamber of injector No. 2 but simply combines with the lubricant
delivery of injector No. 2 to yield double output from the outlet of injector
No. 2.
This does not interfere with the operation of injector No. 2.

15.0
Section 15.0
Lubrication System
Page 51
End-line switch
TASK:
The pressure control unit is monitoring and controlling the centralized lube
system.
Design: illustr. Z 21190

(1) Piston
(2) Disk
(3) Switch contact
(4) Spring
(5) Pressure switch
(6) Adjustment sleeve
(7) Connection to pressure circuit
(8) Electrical connection
Function:
One pressure control unit is installed in each greasing circuit. The grease
pressure, produced by the pneumatic barrel pump, is with his force also at the
piston (1)
If the grease pressure reaches the tension of the spring (4), the piston (1) is
forced against the disk (2), thus that the contacts of the switch (5) are
operated and a electric impulse is given to the electronic control unit of the
greasing equipment.
Adjusting has to be done with the sleeve (6). Clockwise - higher switch point,
counterclockwise - lower switch point.

15.0
Section 15.0
Lubrication System
Page 53
In-line filter

(1) Plug screw
(2) Plug screw gasket
(3) Filter element
(4) Filter housing
(5) Spring guide
(6) Spring
• Before servicing stop the motor and remove ignition key in order to
prevent operation of the system.
) • A clogged filter element will be moved against the spring force by the
lubricant pressure and unfiltered lubricant reaches the system!
For maintenance proceed as follows:

1. Remove plug screw (1) using 36 mm width wrench.
2. Remove plug screw gasket (2).
3. Take out spring (6), spring guide (5) and filter element (3).
4. Clean all parts and inspect for damage.
Replace as necessary.
5. Insert filter element, spring guide (5) and spring.
6. Install plug screw (1) with gasket (2) and tighten with a wrench.
) • For service intervals see SERVICE LITERATURE chapter 6.6

15.0
Section 15.0
Lubrication System
Page 55
Vent valve, illustr. Z 21192
TASK:
By the function of the vent valve the lubricant supply line gets pressure-
relieved, after the lubrication cycle is finished. The injector pistons can move
into their initial position.
Legend: (Valve VP1 S-G). Fig. 19

(1) Solenoid
(2) Valve assy.
(3) Solenoid stem
(4) Lever
(5) Main valve cone
(6) Auxiliary valve cone
(7) Reset spring
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 or vice versa
along the main valve cone (5).

15.0
Section 15.0
Lubrication System
Page 45
Lubricant Injector (metering valve), illustr. Z 21187
TASK:
A readjusted (at the injector) volume of grease is pushed with the injectors to the
bearings or to the progressive distributors.
Design: (model SL1) Design: (model SL11)

(01+02) Metering valve, assy. (01) Metering valve, assy.
(03+04) Injector bar (02) Adjusting screw
(05) Adjusting screw (03) Nut
(06) Nut (04) Plug screw
(07) Plug screw (05) O-ring
(11) Bolt with nut (09) Guide
(12) Disk (10) Indicator pin
(13) Seal ring (11) Seal ring
(14) Piston (12) Piston
(15) Compression spring (13) Seal ring
(16) Spring retainer (14) Pin
(17) Seal ring (15) Compression spring
(18) Disk (16) Spring retainer
(19) Seal ring (17) Bolt with piston
(21) Piston (19) Valve housing
(22) Seal (20) Union
(23) Adapter bolt
(24) Valve housing
(25) Union
continued

15.0
Section 15.0
Lubrication System
Page 47
Cont'd:
Function: illustr. Z 21188
Pos. 1 The injector piston (2) is in its normal or rest position. The discharge
chamber (9) is filled with lubricant from the previous cycle.
Under the pressure of incoming lubricant the slide valve (4) is about to
open the passage (5) leading to the piston.
Pos. 2 When the slide valve (4) uncovers the passage lubricant is admitted to the
top of piston (2) forcing the piston down. The piston force lubricant from
the discharge chamber (9) through the outlet port (10) to the bearing or
progressive distributor.
The lubricant pressure at the bearing or the progressive distributor is
always the same as the pump pressure.
Pos. 3 As the piston completes its stroke, it pushes the slide valve (4) past the
passage, cutting off further admission of lubricant to the passage.
Piston and slide valve remain in this position until lubricant pressure in
the supply line is vented (relieved) at the pump.
This is indicated by the injector stem (8). (fully in)
Pos. 4 After pressure is relieved the compressed spring (3) moves the slide valve
(4) to closed position.
This opens the port from the measuring chamber and permits the
lubricant to be transferred from the top of the piston to the discharge
chamber.
This is also indicated by the injector stem (8) (fully out)
continued

15.0
Section 15.0
Lubrication System
Page 49
Cont'd:
Connection of one or more injectors, illustr. Z 21189
The injectors are designed so that the lubricant output of two or more injectors
can be combined without the use of tees.
The injector body (1) has two outlets ports (a + b), one above the other.
The connector tube (2) is used to couple the injectors together.
Lubricant from injector No. 1 is directed through the connector tube into the
discharge chamber of injector No. 2 but simply combines with the lubricant
delivery of injector No. 2 to yield double output from the outlet of injector No.
2.
This does not interfere with the operation of injector No. 2.

15.0
Section 15.0
Lubrication System
Page 51
End-line switch
TASK:
The pressure control unit is monitoring and controlling the centralized lube
system.
Design: illustr. Z 21190

(1) Piston
(2) Disk
(3) Switch contact
(4) Spring
(5) Pressure switch
(6) Adjustment sleeve
(7) Connection to pressure circuit
(8) Electrical connection
Function:
One pressure control unit is installed in each greasing circuit. The grease
pressure, produced by the pneumatic barrel pump, is with his force also at the
piston (1)
If the grease pressure reaches the tension of the spring (4), the piston (1) is
forced against the disk (2), thus that the contacts of the switch (5) are operated
and a electric impulse is given to the electronic control unit of the greasing
equipment.
Adjusting has to be done with the sleeve (6). Clockwise - higher switch point,
counterclockwise - lower switch point.

15.0
Section 15.0
Lubrication System
Page 53
In-line filter

(1) Plug screw
(2) Plug screw gasket
(3) Filter element
(4) Filter housing
(5) Spring guide
(6) Spring
• Before servicing stop the motor and remove ignition key in order to
prevent operation of the system.
) • A clogged filter element will be moved against the spring force by the
lubricant pressure and unfiltered lubricant reaches the system!
For maintenance proceed as follows:

1. Remove plug screw (1) using 36 mm width wrench.
2. Remove plug screw gasket (2).
3. Take out spring (6), spring guide (5) and filter element (3).
4. Clean all parts and inspect for damage.
Replace as necessary.
5. Insert filter element, spring guide (5) and spring.
6. Install plug screw (1) with gasket (2) and tighten with a wrench.
) • For service intervals see SERVICE LITERATURE chapter 6.6

15.0
Section 15.0
Lubrication System
Page 55
Vent valve, illustr. Z 21192
TASK:
By the function of the vent valve the lubricant supply line gets pressure-relieved,
after the lubrication cycle is finished. The injector pistons can move into their
initial position.
Legend: (Valve VP1 S-G). Fig. 19

(1) Solenoid
(2) Valve assy.
(3) Solenoid stem
(4) Lever
(5) Main valve cone
(6) Auxiliary valve cone
(7) Reset spring
Function:
The solenoid gets energized. When the lubrication starts.
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 or vice versa along the main
valve cone (5).

15.0
HYDRAULIC MINING EXCAVATOR
PC5500E-6

PC5500E-6 15016 and up
40 Troubleshooting
Troubleshooting procedures
® Copyright 2010 KOMATSU MINING GERMANY GmbH
PC5500-6E 1
2 PC3000-6D
SHOP MANUAL
HYDRAULIC EXCAVATOR
PC5500E-6
PC5500E-6 15016 and up
50 Disassembly and assembly
PC5500-6 1
Overview
Overview
1 INTRODUCTION
2 SAFETY
3 SUPERSTRUCTURE
4 UNDERCARRIAGE
5 ATTACHMENT
6 SERVICE INFORMATION
7 TOOLS CATALOGUE
8 PARTS & SERVICE NEWS
9 SUPPLIER’S DOCUMENTATION
Version 2010/1 PC5500-6E Overview - 1

Overview
Overview - 2 PC5500-6E Version 2010/1

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 ..................................................................................................... 2-1

2.1 GENERAL INFORMATION ................................................................................................................ 2-2
2.1.1 METHOD OF USING THIS MANUAL .................................................................................... 2-2
2.2 SAFETY INSTRUCTIONS.................................................................................................................. 2-4
2.2.1 GENERAL PRECAUTIONS ................................................................................................... 2-4
2.2.2 PREPARATIONS BEFORE WORK ....................................................................................... 2-6
2.2.3 PRECAUTIONS DURING WORK.......................................................................................... 2-7
2.2.3.1 PRECAUTIONS WITH HIGH PRESSURE OIL ..................................................... 2-9
2.2.4 WARNING OF SPECIAL DANGERS................................................................................... 2-10
2.2.4.1 ELECTRICAL ENERGY ....................................................................................... 2-10
2.2.4.2 GAS, DUST, STEAM AND SMOKE..................................................................... 2-11
2.2.4.3 NOISE .................................................................................................................. 2-11
2.2.4.4 OIL, GREASE AND OTHER CHEMICAL SUBSTANCES ................................... 2-11
2.2.4.5 HYDRAULIC, AIR CONDITIONING AND PNEUMATIC EQUIPMENT................ 2-12
2.2.4.6 HEAT.................................................................................................................... 2-12
2.2.4.7 HEIGHT................................................................................................................ 2-12
2.2.5 SPECIAL SAFETY EQUIPMENT ........................................................................................ 2-15
2.2.5.1 SAFETY HARNESS IN CONFORMITY WITH
EN 361 (EUROPEAN STANDARD) ..................................................................... 2-15
2.2.5.3 RECOMMENDATIONS FOR USE OF THE HOLDING HOOKS AND
HOLD-BACK HOOKS OF THE SAFETY HARNESS........................................... 2-19
2.2.5.4 INSTARUCTIONS FOR USING THE FALL ABSORBER .................................... 2-21
2.2.6 SAFETY HINTS FOR HYDRAULIC HOSE INSTALLATION ............................................... 2-22
2.2.7 SAFETY HINTS FOR LIFTING HEAVY PARTS.................................................................. 2-25
2.2.8 SAFETY HINTS FOR WIRE ROPES................................................................................... 2-25
2.2.9 SAFETY HINTS FOR SLING ACCESSORY ....................................................................... 2-27
2.3 GROUNDING PROCEDURE OF THE HIGH VOLTAGE SYSTEM ................................................. 2-28
2.4 EXPLANATION OF ABBREVIATIONS ........................................................................................... 2-31
3 SUPERSTRUCTURE................................................................................. 3-1
3.1 SUPERSTRUCTURE OVERVIEW ..................................................................................................... 3-2
3.2 SERVICE CRANE (OPTIONAL) ........................................................................................................ 3-5
3.2.1 REMOVAL OF THE SERVICE CRANE ................................................................................. 3-5
3.2.2 REPLACEMENT OF THE SERVICE CRANE ....................................................................... 3-7
3.3 ELECTRIC MOTORS ......................................................................................................................... 3-9
3.3.1 PREPARATORY WORK FOR ELECTRIC MOTOR REMOVAL ........................................... 3-9
3.3.2 REMOVAL OF THE REAR ELECTRIC MOTOR (MOTOR 1) ............................................. 3-13
3.3.3 REPLACEMENT OF THE REAR ELECTRIC MOTOR (MOTOR 1) .................................... 3-17
3.3.4 REMOVAL OF THE FRONT ELECTRIC MOTOR (MOTOR 2) ........................................... 3-22
3.3.5 REPLACEMENT OF THE FRONT ELECTRIC MOTOR (MOTOR 2).................................. 3-22
Version 2010/1 PC5500-6E TOC - 1

Table of contents
3.3.6 FINAL ALIGNMENT OF THE ELECTRIC MOTORS ........................................................... 3-23

3.3.7 CAPACITOR ASSEMBLIES ................................................................................................ 3-26
3.3.7.1 REMOVAL OF THE CAPACITOR ASSEMBLY (MOTOR 1) ............................... 3-27
3.3.7.2 REPLACEMENT OF THE CAPACITOR ASSEMBLY (MOTOR 1) ...................... 3-29
3.3.7.3 REMOVAL OF THE CAPACITOR ASSEMBLY (MOTOR 2) ............................... 3-29
3.3.7.4 REPLACEMENT OF THE CAPACITOR ASSEMBLY (MOTOR 2) ...................... 3-29
3.4 BATTERIES...................................................................................................................................... 3-30
3.4.1 REMOVAL OF THE BATTERIES ........................................................................................ 3-30
3.4.2 REPLACEMENT OF THE BATTERIES ............................................................................... 3-32
3.5 FLEXIBLE COUPLING..................................................................................................................... 3-34
3.5.1 VULKAN COUPLING ........................................................................................................... 3-34
3.5.1.1 REMOVAL OF THE VULKAN COUPLING .......................................................... 3-35
3.5.1.2 REPLACEMENT OF THE VULKAN COUPLING ................................................. 3-37
3.6 PTO................................................................................................................................................... 3-38
3.6.1 MAIN PUMPS ...................................................................................................................... 3-38
3.6.1.1 PREPARATORY WORKS FOR MAIN PUMP REMOVAL ................................... 3-39
3.6.1.2 REMOVAL OF MAIN PUMPS .............................................................................. 3-42
3.6.1.3 REPLACEMENT OF MAIN PUMPS..................................................................... 3-44
3.6.2 PTO OIL PUMP (AUXILIARY PUMP) .................................................................................. 3-46
3.6.2.1 REMOVAL OF PTO OIL PUMP (AUXILIARY PUMP).......................................... 3-46
3.6.2.2 REPLACEMENT OF THE PTO OIL PUMP (AUXILIARY PUMP) ........................ 3-48
3.6.3 OIL CIRCULATION PUMP (AUXILIARY PUMP) ................................................................. 3-49
3.6.3.1 REMOVAL OF OIL CIRCULATION PUMP (AUXILIARY PUMP)......................... 3-49
3.6.3.2 REPLACEMENT OF THE OIL CIRCULATION PUMP (AUXILIARY PUMP) ....... 3-51
3.6.4 PUMP DISTRIBUTOR GEARBOX (PTO)............................................................................ 3-52
3.6.4.1 REMOVAL OF THE PUMP DISTRIBUTOR GEARBOX (PTO) ........................... 3-54
3.6.4.2 REPLACEMENT OF THE PUMP DISTRIBUTOR GEARBOX (PTO) .................. 3-58
3.7 HYDRAULICS .................................................................................................................................. 3-59
3.7.1 HYDRAULIC COOLER FAN DRIVE PUMP......................................................................... 3-59
3.7.1.1 REMOVAL OF THE HYDRAULIC COOLER FAN DRIVE PUMP ........................ 3-60
3.7.1.2 REPLACEMENT OF THE HYDRAULIC COOLER FAN DRIVE PUMP............... 3-63
3.7.2 HYDRAULIC COOLER FAN ASSEMBLY............................................................................ 3-64
3.7.2.1 REMOVAL OF HYDRAULIC COOLER FAN ASSEMBLY ................................... 3-65
3.7.2.2 REPLACEMENT OF HYDRAULIC COOLER FAN ASSEMBLY .......................... 3-68
3.7.2.3 REMOVAL OF HYDRAULIC COOLER FAN AND MOTOR................................. 3-70
3.7.2.4 REPLACEMENT OF HYDRAULIC COOLER FAN AND MOTOR ....................... 3-72
3.7.3 HYDRAULIC OIL COOLERS ............................................................................................... 3-74
3.7.3.1 REMOVAL OF THE HYDRAULIC OIL COOLERS .............................................. 3-76
3.7.3.2 REPLACEMENT OF THE HYDRAULIC OIL COOLERS ..................................... 3-80
3.7.3.3 REMOVAL OF THE HYDRAULIC OIL COOLER FRAME ................................... 3-82
3.7.3.4 REPLACEMENT OF THE HYDRAULIC OIL COOLER FRAME .......................... 3-86
3.7.4 MAIN RELIEF VALVES (MRV) ............................................................................................ 3-87
3.7.4.1 REMOVAL OF THE MRV..................................................................................... 3-87
3.7.4.2 REPLACEMENT OF THE MRV .......................................................................... 3-88
3.7.5 PILOT OIL PUMP (GEAR PUMP)........................................................................................ 3-89
3.7.5.1 REMOVAL OF THE PILOT OIL PUMP ................................................................ 3-89
3.7.5.2 REPLACEMENT OF THE PILOT OIL PUMP....................................................... 3-91
3.7.6 MAIN GATE VALVE............................................................................................................. 3-92
3.7.6.1 REMOVAL OF THE MAIN GATE VALVE ............................................................ 3-92
3.7.6.2 REPLACEMENT OF THE MAIN GATE VALVE ................................................... 3-93
TOC - 2 PC5500-6E Version 2010/1

Table of contents
3.7.7 HYDRAULIC OIL RESERVOIR ........................................................................................... 3-94

3.7.7.1 REMOVAL OF THE HYDRAULIC OIL RESERVOIR........................................... 3-96
3.7.7.2 REPLACEMENT OF THE HYDRAULIC OIL RESERVOIR ............................... 3-102
3.7.8 MAIN CONTROL VALVE BLOCKS ................................................................................... 3-105
3.7.8.1 REMOVAL OF THE MAIN CONTROL VALVE BLOCKS................................... 3-114
3.7.8.2 REPLACEMENT OF THE MAIN CONTROL VALVE BLOCKS ......................... 3-120
3.7.9 SERVICE LINE RELIEF VALVES (SRV) ........................................................................... 3-121
3.7.9.1 REMOVAL OF SRV ON MAIN CONTROL VALVE BLOCK .............................. 3-121
3.7.9.2 REPLACEMENT OF SRV ON MAIN CONTROL VALVE BLOCKS................... 3-124
3.7.10 ANTI-CAVITATION VALVES (ACV) ................................................................................. 3-126
3.7.10.1 REMOVAL OF ACV ON MANIFOLD ................................................................. 3-127
3.7.10.2 REPLACEMENT OF THE ACV ON MANIFOLD................................................ 3-132
3.7.10.3 REMOVAL OF ACV ON MAIN CONTROL VALVE BLOCKS ............................ 3-133
3.7.10.4 REPLACEMENT OF THE ACV ON MAIN CONTROL VALVE BLOCKS .......... 3-136
3.7.11 THROTTLE CHECK VALVES .......................................................................................... 3-138
3.7.11.1 REMOVAL OF THROTTLE CHECK VALVES ................................................... 3-140
3.7.11.2 REPLACEMENT OF THROTTLE CHECK VALVES.......................................... 3-143
3.7.12 MANIFOLD ........................................................................................................................ 3-144
3.7.12.1 REMOVAL OF THE MANIFOLD ........................................................................ 3-144
3.7.12.2 REPLACEMENT OF THE MANIFOLD .............................................................. 3-146
3.8 SLEW SYSTEM.............................................................................................................................. 3-147
3.8.1 SLEW GEAR...................................................................................................................... 3-148
3.8.1.1 REMOVAL OF THE SLEW GEAR ..................................................................... 3-149
3.8.1.2 REPLACEMENT OF THE SLEW GEAR............................................................ 3-153
3.8.2 SWING MOTOR ................................................................................................................ 3-158
3.8.2.1 REMOVAL OF THE SWING MOTOR ................................................................ 3-159
3.8.2.2 REPLACEMENT OF THE SWING MOTOR ...................................................... 3-162
3.8.3 SLEW PARKING BRAKE .................................................................................................. 3-165
3.8.3.1 REMOVAL/DISASSEMBLY OF THE SLEW PARKING BRAKE (L&S) ............. 3-167
3.8.3.2 REPLACEMENT/ASSEMBLY OF THE SLEW PARKING BRAKE (L&S) .......... 3-170
3.8.3.3 REMOVAL OF THE SLEW PARKING BRAKE (SIEBENHAAR) ....................... 3-173
3.8.3.4 REPLACEMENT OF THE SLEW PARKING BRAKE (SIEBENHAAR) .............. 3-176
3.8.4 DYNAMIC SLEW BRAKE .................................................................................................. 3-180
3.8.4.1 REMOVAL OF THE SLEW BRAKE VALVE ...................................................... 3-183
3.8.4.2 REPLACEMENT OF THE SLEW BRAKE VALVE ............................................. 3-185
3.8.5 SWING CIRCLE................................................................................................................. 3-186
3.8.5.1 REMOVAL OF THE SWING CIRCLE ................................................................ 3-189
3.8.5.2 REPLACEMENT OF THE SWING CIRCLE....................................................... 3-192
3.9 LUBRICATION SYSTEM ............................................................................................................... 3-198
3.9.1 SWING CIRCLE LUBRICATION PINION (DUMMY WHEEL) ........................................... 3-198
3.9.1.1 REMOVAL OF THE LUBRICATION PINION ASSEMBLY ................................ 3-200
3.9.1.2 REPLACEMENT OF THE LUBRICATION PINION ASSEMBLY ....................... 3-202
3.9.2 LUBRICATION PUMP STATION....................................................................................... 3-204
3.9.2.1 REMOVAL OF THE LUBRICATION PUMP STATION ...................................... 3-208
3.9.2.2 REPLACEMENT OF THE LUBRICATION PUMP STATION ............................. 3-210
3.9.3 REMOVAL OF THE LUBRICATION PUMP....................................................................... 3-211
3.9.4 REPLACEMENT OF THE LUBRICATION PUMP ............................................................. 3-213
3.10 OPERATOR’S CAB ....................................................................................................................... 3-214
3.10.1 REMOVAL OF THE OPERATOR’S CAB .......................................................................... 3-217
3.10.2 REPLACEMENT OF THE OPERATOR’S CAB ................................................................. 3-222

Table of contents
3.10.3 VISCOUS CAB-MOUNTS.................................................................................................. 3-224

3.10.3.1 REMOVAL OF THE VISCOUS CAB-MOUNTS ................................................. 3-224
3.10.3.2 REPLACEMENT OF THE CAB-MOUNTS ......................................................... 3-226
3.10.4 FRONT WINDOW (WINDSCREEN) .................................................................................. 3-228
3.10.4.1 REMOVAL OF THE FRONT WINDOW ............................................................. 3-228
3.10.4.2 REPLACEMENT OF THE FRONT WINDOW .................................................... 3-229
3.10.5 OPERATOR’S SEAT ......................................................................................................... 3-230
3.10.5.1 REMOVAL OF THE OPERATOR’S SEAT ......................................................... 3-230
3.10.5.2 REPLACEMENT OF THE OPERATOR’S SEAT ............................................... 3-231
3.10.6 ECS.................................................................................................................................... 3-232
3.10.6.1 REMOVAL OF THE ECS TEXT DISPLAY ......................................................... 3-232
3.10.6.2 REPLACEMENT OF THE ECS TEXT DISPLAY ............................................... 3-232
3.11 CAB BASE (MEDIUM VOLTAGE SWITCH CABINET)................................................................. 3-233
3.11.1 REMOVAL OF THE CAB BASE ........................................................................................ 3-233
3.11.2 REPLACEMENT OF THE CAB BASE ............................................................................... 3-236
3.11.3 PUMP CONTROLLER ....................................................................................................... 3-238
3.11.3.1 REMOVAL OF THE PUMP CONTROLLER....................................................... 3-238
3.11.3.2 REPLACEMENT OF THE PUMP CONTROLLER ............................................. 3-239
3.12 ACCESS LADDER ......................................................................................................................... 3-240
3.12.1 REMOVAL OF THE ACCESS LADDER ............................................................................ 3-243
3.12.2 REPLACEMENT OF THE ACCESS LADDER................................................................... 3-245
3.12.3 REMOVAL OF THE ACCESS LADDER CYLINDER......................................................... 3-247
3.12.4 REPLACEMENT OF THE ACCESS LADDER CYLINDER ............................................... 3-249
3.13 COUNTERWEIGHT........................................................................................................................ 3-250
3.13.1 REMOVAL OF THE COUNTERWEIGHT .......................................................................... 3-250
3.13.2 REPLACEMENT OF THE COUNTERWEIGHT ................................................................. 3-254
3.14 SUPERSTRUCTURE LIFTING ...................................................................................................... 3-256
3.14.1 REMOVE THE SUPERSTRUCTURE FROM THE UNDERCARRIAGE ........................... 3-256
3.14.2 INSTALL THE SUPERSTRUCTURE ONTO THE UNDERCARRIAGE............................. 3-261
3.15 HIGH VOLTAGE SWITCH CABINET ............................................................................................ 3-266
3.15.1 REMOVAL OF THE HIGH VOLTAGE SWITCH CABINET................................................ 3-268
3.15.2 REPLACEMENT OF THE HIGH VOLTAGE CABINET ..................................................... 3-272
3.16 SLIP RING UNIT............................................................................................................................. 3-274
3.16.1 REMOVAL OF THE SLIP RING UNIT ............................................................................... 3-275
3.16.2 REPLACEMENT OF THE SLIP RING UNIT...................................................................... 3-277
4 UNDERCARRIAGE.................................................................................... 4-1
4.1 UNDERCARRIAGE OVERVIEW........................................................................................................ 4-2
4.2 TRAVEL SYSTEM.............................................................................................................................. 4-4
4.2.1 TRACK GROUP..................................................................................................................... 4-4
4.2.1.1 CHANGING OF THE TRACK GROUP .................................................................. 4-4
4.2.2 SPROCKET ........................................................................................................................... 4-9
4.2.2.1 REMOVAL OF THE SPROCKET ........................................................................... 4-9
4.2.2.2 REPLACEMENT OF THE SPROCKET ............................................................... 4-14
4.2.2.3 REMOVAL OF THE SEGMENTED SPROCKET (ONLY FOR TYPE WITH
PINNED UNDERCARRIAGE UP TO SN 025) ..................................................... 4-16
4.2.2.4 REPLACEMENT OF THE SEGMENTED SPROCKET (ONLY FOR TYPE
WITH PINNED UNDERCARRIAGE UP TO SN 025) ........................................... 4-20

Table of contents
4.2.3 GUIDE WHEELS ................................................................................................................. 4-22

4.2.3.1 REMOVAL OF THE GUIDE WHEEL ASSEMBLY ............................................... 4-22
4.2.3.2 REPLACEMENT OF THE GUIDE WHEEL ASSEMBLY ..................................... 4-24
4.2.4 TRACK TENSIONING ACCUMULATORS .......................................................................... 4-25
4.2.4.1 REMOVAL OF THE LOW PRESSURE ACCUMULATORS ................................ 4-25
4.2.4.2 REPLACEMENT OF THE LOW PRESSURE ACCUMULATORS ....................... 4-27
4.2.4.3 REMOVAL OF THE HIGH PRESSURE ACCUMULATORS ............................... 4-28
4.2.4.4 REPLACEMENT OF THE HIGH PRESSURE ACCUMULATORS ...................... 4-29
4.2.5 TRACK TENSION VALVE BLOCK ...................................................................................... 4-30
4.2.5.1 REMOVAL OF THE TRACK TENSIONING VALVE BLOCK ............................... 4-30
4.2.5.2 REPLACEMENT OF THE TRACK TENSIONING VALVE BLOCK...................... 4-32
4.2.6 HYDRAULIC HOSES OF THE TRACK TENSIONING SYSTEM ........................................ 4-33
4.2.6.1 SUBSTITUTE THE HYDRAULIC HOSES ........................................................... 4-33
4.2.7 TRACK TENSIONING CYLINDERS .................................................................................... 4-37
4.2.7.1 REMOVAL OF THE TRACK TENSIONING CYLINDERS ................................... 4-37
4.2.7.2 REPLACEMENT OF THE TRACK TENSIONING CYLINDERS .......................... 4-39
4.2.8 TRAVEL BRAKE VALVE BLOCK (OVERSPEED VALVE).................................................. 4-40
4.2.8.1 REMOVAL OF THE TRAVEL BRAKE VALVE BLOCK ....................................... 4-41
4.2.8.2 REPLACEMENT OF THE TRAVEL BRAKE VALVE BLOCK .............................. 4-43
4.2.9 TRAVEL MOTORS .............................................................................................................. 4-44
4.2.9.1 REMOVAL OF THE TRAVEL MOTORS.............................................................. 4-44
4.2.9.2 REPLACEMENT OF THE TRAVEL MOTORS .................................................... 4-46
4.2.10 TRAVEL PARKING BRAKE................................................................................................. 4-48
4.2.10.1 REMOVAL OF THE TRAVEL PARKING BRAKE ................................................ 4-50
4.2.10.2 REPLACEMENT OF THE TRAVEL PARKING BRAKE....................................... 4-52
4.2.11 TRAVEL GEARBOX ............................................................................................................ 4-54
4.2.11.1 REMOVAL OF THE TRAVEL GEARBOX............................................................ 4-55
4.2.11.2 REPLACEMENT OF THE TRAVEL GEARBOX .................................................. 4-57
4.2.11.3 REMOVAL OF THE TRAVEL GEARBOX
(ONLY FOR TYPE WITH PINNED UNDERCARRIAGE UP TO SN 025)............ 4-59
4.2.11.4 REPLACEMENT OF THE TRAVEL GEARBOX
(ONLY FOR TYPE WITH PINNED UNDERCARRIAGE UP TO SN 025)............ 4-65
4.2.12 CARRIER ROLLER ............................................................................................................. 4-70
4.2.12.1 REMOVAL OF THE CARRIER ROLLER ASSEMBLY ........................................ 4-70
4.2.12.2 REPLACEMENT OF THE CARRIER ROLLER ASSEMBLY ............................... 4-72
4.2.13 TRACK ROLLER ................................................................................................................. 4-73
4.2.13.1 REMOVAL OF THE TRACK ROLLER ASSEMBLY ............................................ 4-73
4.2.13.2 REPLACEMENT OF THE TRACK ROLLER ASSEMBLY ................................... 4-75
4.3 CAR BODY....................................................................................................................................... 4-76
4.3.1 REMOVAL OF THE CAR BODY AND THE CRAWLER CARRIERS
(TYPE WITH PINNED UNDERCARRIAGE) ........................................................................ 4-76
4.3.2 REPLACEMENT OF THE CAR BODY AND THE CRAWLER CARRIERS
(TYPE WITH PINNED UNDERCARRIAGE) ........................................................................ 4-80
(TYPE WITH BOLTED UNDERCARRIAGE) ....................................................................... 4-84
4.3.4 REPLACEMENT OF THE CAR BODY AND THE CRAWLER CARRIERS
(TYPE WITH BOLTED UNDERCARRIAGE) ....................................................................... 4-89
4.3.4.1 TIGHTENING TORQUE FOR THE CRAWLER CARRIER MOUNTING BOLTS 4-92
4.3.5 ROTARY JOINT................................................................................................................... 4-96
4.3.5.1 REMOVAL OF THE ROTARY JOINT .................................................................. 4-98
4.3.5.2 REPLACEMENT OF THE ROTARY JOINT....................................................... 4-101

Table of contents
4.3.6 CABLE DRUM.................................................................................................................... 4-102

4.3.6.1 PREPARATORY WORK FOR THE REMOVAL AND REPLACEMENT
OF THE CABLE DRUM ASSEMBLY ................................................................ 4-103
4.3.6.2 REMOVAL OF THE CABLE DRUM ASSEMBLY............................................... 4-104
4.3.6.3 REPLACEMENT OF THE CABLE DRUM ASSEMBLY ..................................... 4-105
4.3.7 CABLE SUPPLY (OPTIONAL)........................................................................................... 4-108
4.3.7.1 PREPARATORY WORK FOR THE REMOVAL AND REPLACEMENT
OF THE CABLE SUPPLY .................................................................................. 4-109
4.3.7.2 REMOVAL OF THE CABLE SUPPLY................................................................ 4-110
4.3.7.3 REPLACEMENT OF THE CABLE SUPPLY ASSEMBLY.................................. 4-112
5 ATTACHMENT........................................................................................... 5-1
5.1 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
5.1.3 BUCKET............................................................................................................................... 5-36
5.1.3.1 REMOVAL OF THE BUCKET .............................................................................. 5-36
5.1.3.2 REPLACEMENT OF THE BUCKET..................................................................... 5-39
5.1.3.3 REMOVAL OF BUCKET CYLINDERS................................................................. 5-40
5.1.3.4 REPLACEMENT OF BUCKET CYLINDERS ....................................................... 5-46
5.1.4 BUCKET LINK ROD AND STEERING RODS ..................................................................... 5-49
5.1.4.1 REMOVAL OF THE BUCKET LINK ROD ............................................................ 5-49
5.1.4.2 REPLACEMENT OF THE BUCKET LINK ROD................................................... 5-51
5.1.4.3 REMOVAL OF THE STEERING RODS............................................................... 5-52
5.1.4.4 REPLACEMENT OF THE STEERING RODS ..................................................... 5-55
5.1.5 GROUND ENGAGING TOOLS (GET)................................................................................. 5-56
5.1.5.1 REMOVAL AND REPLACEMENT OF THE GET................................................. 5-57
5.1.6 HYDRAULIC HOSES AT THE BACKHOE ATTACHMENT................................................. 5-58
5.1.6.1 SUBSTITUTE THE BOOM ARC HOSES............................................................. 5-58
5.1.6.2 SUBSTITUTE THE BOOM CYLINDER HOSES .................................................. 5-62
5.1.6.3 SUBSTITUTE THE STICK CYLINDER HOSES .................................................. 5-66
5.1.6.4 SUBSTITUTE THE BUCKET CYLINDER HOSES .............................................. 5-70
5.2 FACE SHOVEL (FSA)...................................................................................................................... 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 ........................................................................ 5-82
5.2.2.3 REMOVAL OF THE BOOM CYLINDERS ............................................................ 5-88
5.2.2.4 REPLACEMENT OF THE BOOM CYLINDERS................................................... 5-93
5.2.3 STICK................................................................................................................................... 5-96
5.2.3.1 REMOVAL OF THE STICK .................................................................................. 5-96
5.2.3.2 REPLACEMENT OF THE STICK....................................................................... 5-100

Table of contents
5.2.3.3 REMOVAL OF THE STICK CYLINDERS .......................................................... 5-104

5.2.3.4 REPLACEMENT OF THE STICK CYLINDERS ................................................. 5-109
5.2.4 BULL CLAM BUCKET ....................................................................................................... 5-112
5.2.4.1 REMOVAL OF THE BULL CLAM BUCKET ....................................................... 5-114
5.2.4.2 REPLACEMENT OF THE BULL CLAM BUCKET ............................................. 5-118
5.2.4.3 REMOVAL OF THE BUCKET CYLINDERS ...................................................... 5-120
5.2.4.4 REPLACEMENT OF THE BUCKET CYLINDERS ............................................. 5-125
5.2.4.5 REMOVAL OF THE CLAM CYLINDERS ........................................................... 5-130
5.2.4.6 REPLACEMENT OF THE CLAM CYLINDERS ................................................. 5-135
5.2.5 GROUND ENGAGING TOOLS (GET)............................................................................... 5-138
5.2.5.1 REMOVAL AND REPLACEMENT OF THE GET .............................................. 5-140
5.2.6 HYDRAULIC HOSES AT THE FACE SHOVEL ATTACHMENT ....................................... 5-142
5.2.6.1 SUBSTITUTE THE BOOM ARC HOSES .......................................................... 5-142
5.2.6.2 SUBSTITUTE THE BOOM CYLINDER HOSES ................................................ 5-146
5.2.6.3 SUBSTITUTE THE STICK ARC HOSES ........................................................... 5-150
5.2.6.4 SUBSTITUTE THE STICK CYLINDER HOSES ................................................ 5-154
5.2.6.5 SUBSTITUTE THE BUCKET CYLINDER HOSES ............................................ 5-158
5.2.6.6 SUBSTITUTE THE CLAM CYLINDER HOSES ................................................. 5-162
5.3 METERING VALVES (GREASE INJECTORS) AT THE ATTACHMENT ..................................... 5-170
5.3.1 OPERATION TEST OF THE METERING VALVES (GREASE INJECTORS)................... 5-171
5.3.2 REMOVAL OF THE METERING VALVES (GREASE INJECTORS)................................. 5-172
5.3.3 REPLACEMENT OF THE METERING VALVES (GREASE INJECTORS) ....................... 5-174
5.4 CYLINDER BYPASS TEST ........................................................................................................... 5-175
6 SERVICE INFORMATION ......................................................................... 6-1

6.1 FLUIDS AND LUBRICANTS.............................................................................................................. 6-2
6.2 FILLING CAPACITIES ....................................................................................................................... 6-2
6.3 WORK INSTRUCTIONS .................................................................................................................... 6-4
6.3.1 SURFACE COATING WITH INTERZINC 697 ....................................................................... 6-4
6.3.2 REMOVE / INSTALL THE CRAWLER CARRIER ................................................................. 6-6
6.4 WEIGHT TABLES .............................................................................................................................. 6-7
6.4.1 SUPERSTRUCTURE ............................................................................................................ 6-7
6.4.2 UNDERCARRIAGE ............................................................................................................. 6-10
6.4.3 BACKHOE ATTACHMENT (BHA) ....................................................................................... 6-12
6.4.4 FACE SHOVEL ATTACHMENT (FSA) ................................................................................ 6-13
6.5 TORQUE CHARTS ACCORDING TO KOMATSU COMPANY STANDARD ................................. 6-14
6.5.1 METRIC STANDARD THREAD........................................................................................... 6-14
6.5.2 METRIC FINE THREAD ...................................................................................................... 6-15
6.5.3 SAE FLANGE CONNECTIONS ........................................................................................... 6-16
6.6 BLIND PLUGS ................................................................................................................................. 6-18
6.6.1 DUMMY PLATES FOR SAE FLANGES .............................................................................. 6-18
6.6.2 CLASSIFICATION OF THREADS TO THE NOMINAL WIDTH ........................................... 6-20
6.6.3 PLUGS AND FITTINGS ACCORDING TO DIN 2353 / ISO 8434-1 .................................... 6-21

Table of contents
6.7 CONVERSION TABLE..................................................................................................................... 6-22

6.7.1 METHOD OF USING THE CONVERSION TABLE ............................................................. 6-22
6.7.2 MILLIMETER - INCH & KILOGRAM - POUND .................................................................... 6-23
6.7.3 LITER - U.S. GALLON & LITER - U.K. GALLON................................................................. 6-24
6.7.4 NM - FT.LB........................................................................................................................... 6-25
6.7.5 BAR - PSI - KPA - MPA ....................................................................................................... 6-26
6.7.6 BASIC VALUES IN OHM ACCORDING TO DIN 4376 / IEC 751 ........................................ 6-27
6.7.7 TEMPERATURE .................................................................................................................. 6-28
6.8 TOOLS.............................................................................................................................................. 6-29
6.8.1 STANDARD TOOL CASE.................................................................................................... 6-29
6.8.2 USED SPECIAL TOOLS (OVERVIEW) ............................................................................... 6-31
7 TOOLS CATALOGUE ................................................................................ 7-1

8 PARTS & SERVICE NEWS ....................................................................... 8-1
AH00511
Installation procedure for the swing circle (SC)
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
AH01523
Replacement of the elastic coupling (electro drive shovels)
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
AH03528
Pilot control safety line
AH04518
Welding procedure for welded counterweight
AH05501
Abnormal vibration on hydraulic pipes
AH05510
Bearing flushing of the A4VS variable displacement axial piston pump

Table of contents
AH05511
Dual cone seal ring mounting
AH05518
Swing circle pinion
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
Track group - hints for sprocket exchange
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
AH09505
Hoses between boom and stick
AH09522
Wishbone and rod
9 SUPPLIER’S DOCUMENTATION ............................................................. 9-1

AVANTI HYTORQUE

Table of contents
TOC - 10 PC5500-6E Version 2010/1

Introduction
1 INTRODUCTION
Version 2010/1 PC5500-6E 1 -1

Contents of the binder Introduction
1.1 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 PC5500-6E Version 2010/1

Introduction Foreword
1.2 FOREWORD
Observe the instructions in this manual for:
z Your Personal SAFETY
z Operating SAFETY, and
z 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.
Service Training and Manuals

Department 8151.30
P.O. Box 18 03 61
D - 40570 Düsseldorf
GERMANY
Version 2010/1 PC5500-6E 1 -3

Foreword Introduction
WARNING
Personnel entrusted with work on the machine must have
read the section 2 SAFETY AND STANDARDS before begin-
ning work. Reading the instructions after work has begun is
too late.
Damages and defects caused by incorrect operation and mainte-

nance are not covered by the manufacturer’s 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 PC5500-6E Version 2010/1

Safety
2 SAFETY
Version 2010/1 PC5500-6E 2 -1

General information Safety
2.1 GENERAL INFORMATION
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 pro-
cedure differs from installation in reverse order of removal, for
example any special technique needs to be applied.
Tightening torques according to the KOMATSU company stan-

dard are not explicitly given in the installation procedures.
For tightening torques according to the KOMATSU company stan-
dard, refer to section 6.5 on page 6-14.
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 6.8.2 on page 6-31.
The following text designations are used in the manual with the
following intend:
– Refers to listings of none particular order.
z Refers to working steps within the procedures.
The following symbols are used in the manual to designate addi-

tional information as shown in the following examples:
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 the company standard (e.g. 129 Nm).
General information concerning a section, e.g.

tightening torques according to the company
standard, refer to section 6.5 on page 6-14.
Special authorized personnel is required.
2 -2 PC5500-6E Version 2010/1

Safety General information
All PARTS & SERVICE NEWS which are mentioned in the proce-
dures are listed in chapter 8. The numbers of the PARTS & SER-
VICE NEWS do not label the latest edition. Ensure that the latest
edition is always filed to the binder of this manual.
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 seri-
ous 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 2010/1 PC5500-6E 2 -3

Safety instructions Safety
2.2 SAFETY INSTRUCTIONS
2.2.1 GENERAL PRECAUTIONS
CAUTION
Proper service and repair is important for safe machine oper-
ation. 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 Ger-
many for the specific purpose.
NOTE: Always attend to local regulations regarding the Personal

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

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

shoes and a helmet. Do not wear loose work clothes or
clothes with buttons missing.
z Always wear safety glasses when hitting parts with a

hammer.
Always wear safety glasses when grinding parts with a
grinder, etc.
z Assure fire prevention according to the Operation &

Maintenance Manual.
z If welding repairs are needed, refer to the welding pre-

cautions given in the Operation & Maintenance Manual.
z When carrying out any operation with two or more wor-

kers, always agree on the operating procedure before
starting. Always inform your fellow workers before star-
ting any step of the operation. Before starting work, hang
UNDER REPAIR signs on the controls in the operator's
cab.
z Keep all tools in good condition and learn the correct

way to use them.
2 -4 PC5500-6E Version 2010/1

Safety Safety instructions
WARNING
Decide on a place in the repair workshop to keep tools and
removed parts. Always keep the tools and parts in their cor-
rect 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.
DANGER
Hazardous Voltage!
Risk of electric shocks. Death or serious burns may result.
An pilot control safety line monitores all safety relevant com-

ponents at the high voltage system. This pilot control safety
line must be connected properly at the excavator and at the
power plant / external transformer station. For further infor-
mation about the monitored components, refer to the PARTS
& SERVICE NEWS No. "AH03528" and the wiring diagram of
the excavator.
Version 2010/1 PC5500-6E 2 -5

2.2.2 PREPARATIONS BEFORE WORK
WARNING
Before beginning any work operations set the maintenance
safety switch (Fig. 2-1, Pos. 3) to -0- position to prevent start-
ing of the engines during the work. Fold up the flap (Fig. 2-1,
Pos. 2) and secure this position by inserting a padlock into
the holes (Fig. 2-1, Pos. 4) of the flap (Fig. 2-1, Pos. 2) and the
safety switch (Fig. 2-1, Pos. 1).
Fig. 2-1
WARNING
z 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.).
z 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.
z 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.
z When disassembling or assembling, support the

machine with blocks, jacks, or supports before starting
work.
z Remove all mud and oil from the steps or other places
used to get on and off the machine. Always use the hand-
rails, ladders, or steps when getting on or off the
machine. Never jump on or off the machine. If it is impos-
sible to use the handrails, ladders, or steps, use a stand
to provide safe footing.
2 -6 PC5500-6E Version 2010/1

DANGER
Hazardous Voltage!
Any work on the high voltage system has to be carried out by

authorized electricians having the permission to work on
high voltage systems only.
Perform the grounding procedure of the high voltage system,
refer to section 2.3 on page 2-28.
2.2.3 PRECAUTIONS DURING WORK
WARNING
z When removing the oil filler cap, drain plug, or hydraulic
pressure measuring plugs, loosen them slowly to pre-
vent the oil from spurting out. The oil can be very hot, so
be careful not to get burnt. Wait for the oil to cool down
before carrying out work.
z 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.
z When raising heavy components (25 kg or more), use a

hoist or crane.
z Check that the wire rope, chains, and hooks are free from
damage.
z Always use lifting equipment which has ample capacity.
z Install the lifting equipment at the correct places. Use a

hoist or crane and operate slowly to prevent the compo-
nent from hitting any other part. Do not work with any
part still raised by the hoist or crane.
z When removing covers which are under internal pres-

sure 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.
z When removing components, be careful not to break or

damage the wiring.
Damaged wiring may cause electrical fires.
z When removing any piping, stop the fluids from spilling

out. If any oil drips on to the floor, wipe it up immediately.
Oil on the floor can cause you to slip, or can even start
fires.
Version 2010/1 PC5500-6E 2 -7

WARNING
z As a general rule, do not use gasoline to wash parts.
z Be sure to assemble all parts in their original places

again. Replace any damaged parts with new parts.
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.
z 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 pres-
sure circuits. Also check that connecting parts are cor-
rectly installed.
z 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.
z When aligning two holes, never insert your fingers or

hand. Be careful not to get your fingers caught in a hole.
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 counter-
weight. 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 counter-
weight chambers.
2 -8 PC5500-6E Version 2010/1

2.2.3.1 PRECAUTIONS WITH HIGH PRESSURE OIL
DANGER
The hydraulic system is always under internal pressure.
When inspecting or replacing piping or hoses, always check
that the pressure in the hydraulic circuit has been released. If
the circuit is still under pressure, it will lead to serious injury.
do not carry out any inspection or replacement operation.
If there is any leakage from the piping or hoses, the surrounding

area will be wet, so check for cracks in the piping and hoses and
for swelling in the hoses.
WARNING
When carrying out inspections, wear full-face protection and
penetration resistant clothing and gloves.
DANGER
There is a hazard that high-pressure oil leaking from small
holes may penetrate your skin or cause blindness if it con-
tacts your eyes directly. If you are hit by a jet of high-pres-
sure oil and suffer injury to your skin or eyes, wash the place
with clean water, and consult a doctor immediately for medi- Fig. 2-2
cal attention.
WARNING
Leaks in high-pressure hoses may cause fire or defective
operation, which may lead to serious injury.
z Replace the hose if a damaged or leaking hydraulic fit-

ting is found.
z Replace the hose if a frayed or cut covering or an

exposed reinforcement wire layer is found.
z Replace the hose if a covering is swollen in places.
z Replace the hose if movable portions are wisted or

crushed.
z Replace the hose if foreign material (splinters etc.) is

embedded in the covering of the hose.
Version 2010/1 PC5500-6E 2 -9

2.2.4 WARNING OF SPECIAL DANGERS
2.2.4.1 ELECTRICAL ENERGY
WARNING
z Use only original fuses and circuit breakers with the
specified current rating. Switch off the machine immedi-
ately if trouble occurs in the electrical system.
z 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.
z 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 ele-
ments.
z If your machine comes into contact with a live wire:
z do not leave the machine.
z drive the machine out of the hazard zone.
z warn others against approaching and touching the

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

been safely de-energized.
z 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 recti-
fied immediately.
z Necessary work on live parts and elements must be car-

ried 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.
z Any work on the high voltage system has to be carried

out by authorized electricians having the permission to
work on high voltage systems only.
2 - 10 PC5500-6E Version 2010/1

2.2.4.2 GAS, DUST, STEAM AND SMOKE
WARNING
z 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.
z Special care must be taken before welding, flame-cutting

and grinding operations are carried out on the counter-
weight. 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 oper-
ations 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.
z Before carrying out welding, flame-cutting and grinding

operations, clean the machine and its surrounding from
dust and other inflammable substances and make sure
that the premises are adequately ventilated (risk of explo-
sion).
2.2.4.3 NOISE
WARNING
z During operation, all sound baffles must be closed.
z Always wear the prescribed ear protectors.
2.2.4.4 OIL, GREASE AND OTHER CHEMICAL SUBSTANCES
WARNING
When handling oil, grease, and other chemical substances,
observe the product-related safety regulations given in the
material safety data sheet (MSDS).
Version 2010/1 PC5500-6E 2 - 11

2.2.4.5 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 spe-
cial knowledge and experience in this systems.
z Check all lines, hoses and screwed connections regu-

larly for leaks and obvious damage. Repair any damage
immediately. Splashed oil may cause injury and fire.
z 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.
z Refrigerant in the air conditioning system must be

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

must be laid and fitted properly. Ensure that no connec-
tions are interchanged. The fittings, lengths, and quality
of the hoses must comply with the technical require-
ments.
2.2.4.6 HEAT
WARNING
z Do not start working on hot machine parts until the tem-
perature is below 50 °C.
z Be careful when handling hot materials (risk of burning

or scalding) such as:
z Hot cables
z Hydraulic oil
z Grease
z Use gloves when handling hot machine parts.
2.2.4.7 HEIGHT
WARNING
When working in heights above 1.00 m, a special safety har-
ness is required, refer to section 2.2.5 on page 2-15.
2 - 12 PC5500-6E Version 2010/1

This page was left blank intentionally.
Version 2010/1 PC5500-6E 2 - 13

Fig. 2-3 Safety harness in conformity with EN 361
2 - 14 PC5500-6E Version 2010/1

2.2.5 SPECIAL SAFETY EQUIPMENT
2.2.5.1 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)

The safety harness (Fig. 2-3) 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. 2-3:
(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. 2-3, Pos. 1) in conjunc-
tion with strap-type fall absorber (Fig. 2-3, Pos. 2), before
mounting onto the loader attachment or other unsecured
places of the shovel.
NOTE: The illustration (Fig. 2-3) shows a typical use of the safety
harness. Shovels with the new type operator’s cab are
not equipped with ladder (Fig. 2-3, Pos. 3), because the
air conditioner unit of the new type cab is located on the
back wall of the cab.
Version 2010/1 PC5500-6E 2 - 15

2 - 16 PC5500-6E Version 2010/1


Open the lock and lift the harness by the catch hook (Fig. 2-4,
Pos. C). The blue straps (leg straps Fig. 2-4, Pos. J) must be at
the bottom. The harness is being put on just like a jacket.
Pull the belly strap (Fig. 2-4, Pos. E) through the lock, as shown in
the illustration, and secure it.
By closing the breast strap, you avoid the shoulder straps to side-
slip. Bring the leg straps (Fig. 2-4, 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. 2-4, 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.
z 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 equip-
ment has to be inspected by the manufacturer or by a quali-
fied 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 manu-
facturer or to an authorized qualified repair shop for mainte-
nance and renewed testing.
Version 2010/1 PC5500-6E 2 - 17

2 - 18 PC5500-6E Version 2010/1

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 reg-
ulations 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 compo-
nents have to be inspected by a competent person autho-
rized by the manufacturer and they have to be maintained, if
the manufacturer considers it to be necessary.
2.2.5.3 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 2010/1 PC5500-6E 2 - 19

2 - 20 PC5500-6E Version 2010/1

2.2.5.4 INSTARUCTIONS FOR USING THE FALL ABSORBER

Strap-type fall absorber according to EN 355 (type E.K.N.-BFD)
Use
Within a fall-arrest system, the strap-type fall absorber (Fig. 2-6,

Pos. 2) has to be used in conjunction with a safety harness
(Fig. 2-6, 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 mini-
mum carrying capacity should be 10 kN, according to EN 795.
The strap-type fall absorber and the safety rope must not be dam-
aged, 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 autho-
rized qualified repair shop.
Version 2010/1 PC5500-6E 2 - 21

2.2.6 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 Mainte-

nance Manual, chapter 4, section "REPLACEMENT OF
HYDRAULIC HOSE LINES AND FUEL HOSE".
To avoid damage to the hydraulic hose lines, follow the installa-

tion procedures listed below:
CAUTION
Pay attention to the Natural curvature of the hose!
Fig. 2-7
CAUTION
Do not twist the hoses during installation!
Fig. 2-8
2 - 22 PC5500-6E Version 2010/1

CAUTION
Mount angled flanges at first!
Fig. 2-9
CAUTION
Pay attention to the changing in hose length, depending on
the pressure inside the hose!
Fig. 2-10
CAUTION
Pay attention to the bending radius!
Fig. 2-11
Version 2010/1 PC5500-6E 2 - 23

CAUTION
Pay attention to the bending radius!
Fig. 2-12
2 - 24 PC5500-6E Version 2010/1

2.2.7 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.
2.2.8 SAFETY HINTS FOR WIRE ROPES

z 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 10.0 11.2 12.5 14.0 16.0 18.0 20.0 22.4 30.0 40.0 50.0 60.0
[mm]
Allowable load 1.0 1.4 1.6 2.2 2.8 3.6 4.4 5.6 10.0 18.0 28.0 40.0
[Metric tons]
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 2010/1 PC5500-6E 2 - 25

z Sling wire ropes around the middle portion of the hook. Sling-
ing 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. 2-13.
z Do not sling a heavy load with one rope alone, but sling it with
two or more ropes wound symmetrically around the load. Fig. 2-13
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.
z 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 2-14 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
Fig. 2-14
of 150°.
2 - 26 PC5500-6E Version 2010/1

2.2.9 SAFETY HINTS FOR SLING ACCESSORY
WARNING
Always attend to local standards when using sling acces-
sory.
z Do not use rigid eye bolts from steel C15 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.
z Always use suitable swivel hoist rings according to local stan-

dards 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.
z Check that the wire rope, chains, and hooks are free from
damage.
z Always use lifting equipment which has ample capacity.
z 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 2010/1 PC5500-6E 2 - 27

Grounding procedure of the high voltage system Safety
2.3 GROUNDING PROCEDURE OF THE HIGH VOLTAGE

SYSTEM
Measuring rod, PN 232 390 40 (for voltage range 3…6 kV)

Special tools: Measuring rod, PN 232 389 40 (for voltage range 5…10 kV)
Universal grounding short-circuting device, PN 232 386 40
Additional equipment: n/a
Electrician with permission to work on high voltage systems
The below procedure must be carried out for safety reasons,

before any work is carried out on the high voltage system of the
excavator.
DANGER
Hazardous Voltage!
z The following safety measures have to be carried out

before any work on the high voltage system by autho-
rized electricians having the permission to work on high
voltage system systems only.
z Carry out the work according to the local safety regula-

tions.
z All safety devices requested by the local safety regula-

tions must be available and used for any work on the
high voltage systems.
Safety Measures
z Switch off the power supply from the power station and
ground the power supply line securely.
z Remove the padlock or the bolt (Fig. 2-1, Pos. 3) and open
the flap (Fig. 2-1, Pos. 2) at the high voltage switch cabinet
(Fig. 2-1, Pos. 1) to gain access to the load cut-off.
z Turn the load cut-off (Fig. 2-2, Pos. 5) to OFF position using
the key (Fig. 2-2, Pos. 4).
DANGER
Hazardous Voltage!
Do not open the high voltage switch cabinet door (Fig. 2-1,
Pos. 6) until the load cut-off is in OFF position.
Fig. 2-1
2 - 28 PC5500-6E Version 2010/1

Safety Grounding procedure of the high voltage system
DANGER
Hazardous Voltage!
Do not open the switch cabinet door (Fig. 2-2, Pos. 4) until
the load cut-off is in OFF position.
z Remove the padlock and open high voltage switch cabinet

door (Fig. 2-2, Pos. 1).
z Make sure that the power supply from the power station is
switched off by placing a measuring rod (Fig. 2-2, Pos. 3) to
the ball headed stud (Fig. 2-2, Pos. 2) of the load cut-off
switch copper bar.
The indication on the measuring rod must show zero poten-
tial.
Fig. 2-2
z Make sure the grounding harness (Fig. 2-3, Pos. 8) is ready

for use.
NOTE: The grounding harness is part of the universal grounding

short-circuting device, PN 232 386 40.
z Connect the grounding harness (Fig. 2-3, Pos. 8) as follows:
z Connect the long single cable (Fig. 2-3, Pos. 6) of the

harness to a threaded stud (Fig. 2-3, Pos. 4) and secure
it with the wing nut (Fig. 2-3, Pos. 5).
z Connect the three remaining cables of the grounding har-

ness to the ball headed studs (Fig. 2-3, Pos. 3) of the
load cut-off switch copper bars by means of the clamps
(Fig. 2-3, Pos. 2), using the insulated extension rod
(Fig. 2-3, Pos. 7).
z Secure the clamps (Fig. 2-3, Pos. 2) by tightening the

screws (Fig. 2-3, Pos. 1) using the insulated extension
Fig. 2-3
rod.
NOTE: The insulated extension rod is part of the universal

grounding short-circuting device, PN 232 386 40.
Version 2010/1 PC5500-6E 2 - 29

Grounding procedure of the high voltage system Safety
DANGER
Hazardous Voltage!
Carry out the next steps after relieving the residual voltage
from load cut-off switch bars only.
z Remove one cable (Fig. 2-4, Pos. 3) of the grounding har-

ness from its ball headed stud at the load cut-off switch cop-
per bars using the insulated extension rod (Fig. 2-4, Pos. 4).
z Touch all mounting bolts (Fig. 2-4, Pos. 2) of the phase lines
(L1, L2 and L3) at each current transformer (Fig. 2-4, Pos. 1),
located on the opposed wall of the high voltage switch cabinet
with the cable (Fig. 2-4, Pos. 3) alternately.
NOTE: These connections will also relief the residual voltage Fig. 2-4
from the capacitors.
z Reconnect the cable to the ball headed stud at the load

cut-off switch copper bar.
z Make sure the grounding harness remains connected as long

as any work at the excavator is carried out.
After work:
z Remove the grounding harness from the load cut-off switch

and store it in a safe place.
DANGER
Hazardous Voltage!
For safety reasons, the access to the high voltage switch

cabinet must be blocked for unauthorized personnel.
Lock the switch cabinet door with an appropriate padlock.
z Close the door (Fig. 2-5, Pos. 6) of the high voltage switch
cabinet and lock the door with the provided padlock.
z Close the flap (Fig. 2-5, Pos. 2) of the load cut-off switch and
secure the flap with the provided padlock or a bolt (Fig. 2-5,
Pos. 3). Fig. 2-5
2 - 30 PC5500-6E Version 2010/1

Safety Explanation of abbreviations
2.4 EXPLANATION OF ABBREVIATIONS
Abbrev. Definition
A Ampere
AC Alternating Current
ACV Anti-Cavitation Valve
API American Petroleum Institute

BHA Backhoe Attachment
°C 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
kV Kilo Volt (1000 Volt)
LED Light Emitting Diode
MRV Main Relief Valve
PIV Pressure Increasing Valve
Power Take-Off
PTO
(Pump Distributor Gear)
Maximum pump delivery = maximum swash
Qmax
plate angle
Minimum pump delivery = minimum swash plate

Qmin
angle
1/2 Qmax 1/2 pump delivery

SLS Swing circle pinion Lubrication System
SRV Secondary Relief Valve
V Volt
WFT Wet paint Film Thickness [1/1000 inch]
1/min Revolutions Per Minute (RPM)
Version 2010/1 PC5500-6E 2 - 31

Explanation of abbreviations Safety
2 - 32 PC5500-6E Version 2010/1

Superstructure
3 SUPERSTRUCTURE
Version 2010/1 PC5500-6E 3 -1

Superstructure overview Superstructure
3.1 SUPERSTRUCTURE OVERVIEW
Fig. 3-1 PC5500-6E, superstructure - top view
3 -2 PC5500-6E Version 2010/1

Superstructure Superstructure overview
(1) Operator’s cab
(2) Slip ring unit
(3) Hydraulic oil coolers

(4) Return oil reservoir with return oil filters
(5) Slew gear
(6) Main control valve blocks

(7) Main hydraulic pumps
(8) Flexible coupling cover
(9) Front PTO (pump distributor gear)
(10) Rear PTO (pump distributor gear)
(11) Front electric motor (motor 2)
(12) Rear electric motor (motor 1)
(13) Motor cooling air intake
(14) Capacitor assembly motor 2
(15) Capacitor assembly motor 1
(16) Counterweight
(17) Hydraulically operated access ladder
Version 2010/1 PC5500-6E 3 -3

Superstructure overview Superstructure
Fig. 3-2 PC5500-6E, superstructure - side view
(1) Operator’s cab
(2) Motor cooling air outlet
(3) Automatic lubrication system
(4) Counterweight
(5) Hydraulically operated access ladder
(6) High voltage switch cabinet
(7) Swing circle
(8) Emergency exit ladder

(9) Cab base (medium voltage switch cabinet)
(10) Cab support frame
3 -4 PC5500-6E Version 2010/1

Superstructure Service crane (optional)
3.2 SERVICE CRANE (OPTIONAL)
3.2.1 REMOVAL OF THE SERVICE CRANE

Special tools: n/a
Additional equipment: Crane
Service crane with beam: 1900 kg
Dogman/rigger
z Prepare an area of flat ground large enough to accommodate

the machine, boom, and crane.
z 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 Relieve the pressure in the hydraulic system, refer to the

Operation & Maintenance Manual, chapter 3, section
"RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM".
z Isolate the machine according to local regulations.
DANGER
Hazardous Voltage!
Any work on the high voltage system has to carried out by
z Perform the grounding procedure of the high voltage system,

Version 2010/1 PC5500-6E 3 -5

Service crane (optional) Superstructure
z Make sure that the safety hook of the service crane is safely
connected to the crane base (Fig. 3-1, arrow).
DANGER
Hazardous Voltage!
Any work on the switch box has to carried out by authorized
electricians only.
z Disconnect the wire harness from the switch box (Fig. 3-1,
Pos. 4) at the hydraulic power unit.
z Sling the service crane at the crane base (Fig. 3-1, Pos. 1).
and the upper part of the crane.
Fig. 3-1
WARNING
Observe the center of gravity.
Make sure that the crane can not knock over while lifting off.
z Remove the bolts (Fig. 3-1, Pos. 2) and lift the service crane
off the mounting blocks (Fig. 3-1, Pos. 3) using a crane.
z Place the service crane on the ground.
DANGER
Risk of falling weights!
May result in death or serious injury.
When removing the MKG service crane, make sure that
nobody steps below the weight.
3 -6 PC5500-6E Version 2010/1

Superstructure Service crane (optional)
3.2.2 REPLACEMENT OF THE SERVICE CRANE

Special tools: n/a
Crane
Additional equipment:
Compound "KP2K", PN 324 969 40
Service crane with beam: 1900 kg
Dogman/rigger
If there is nothing mentioned explicitly, tighten all bolts according to

KOMATSU company standard, refer to section 6.5 on page 6-14.
z Carry out installation in reverse order to removal.
DANGER
Hazardous Voltage!
Any work on the switch box has to carried out by authorized
electricians only.
NOTE: Always use new mounting bolts (Fig. 3-1, Pos. 2) of

grade 10.9.
Apply compound "KP2K", PN 324 969 40 on the bolts.
Version 2010/1 PC5500-6E 3 -7

Service crane (optional) Superstructure
3 -8 PC5500-6E Version 2010/1

Superstructure Electric Motors
3.3 ELECTRIC MOTORS

The excavator is powered by two ABB electric motors:
Model: ABB Induction motor

Type: AMA 450L4A BAXYH
Rated power: 900 kW
3.3.1 PREPARATORY WORK FOR ELECTRIC MOTOR REMOVAL

Special tools: n/a
Crane
4 x swivel hoist rings: M12
Roof plate, PTO side: 355 kg
Roof plate, cooling air outlet: 483 kg
Roof plate, capacitor side: 186 kg
Beam (transfer carrier): 285 kg
Dogman/rigger


WARNING
Always wear a safety harness when working at the roof.
z Remove the service crane, if equipped; refer to section 3.2.1

on page 3-5.
WARNING
Do not carry out the following work on a hot motor.
Wait until the temperature of the motor is below 50 °C.
Disobedience may result in personal injury from heated
parts.
Version 2010/1 PC5500-6E 3 -9

Electric Motors Superstructure
Fig. 3-2
(1 to 3) Roof plate
(4) Sealing
(5, 6) Bolt with washer
(7) Bolt
(8) Resilient sleeve
z Clear all wire harnesses from the roof plates (Fig. 3-2, Pos. 2
and 3).
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 func-
tional.
z Dismount all attached parts from the roof plates above the
electric motors (Fig. 3-2, Pos. 2 and 3).
3 - 10 PC5500-6E Version 2010/1

z Remove the air outlets (Fig. 3-3, Pos. 1) of the electric motors
from the roof plate.
NOTE: Check the moldings (Fig. 3-3, Pos. 2) and replace them if
required.
Fig. 3-3
z Remove all bolts (Fig. 3-2, Pos. 5) with washers (Fig. 3-2,
Pos. 6) and all bolts (Fig. 3-2, Pos. 7) with resilient sleeves
(Fig. 3-2, Pos. 8) of the roof plates.
z Remove the roof plates (Fig. 3-2, Pos. 2 and 3) with a crane
using swivel hoist rings.
DANGER
When removing the roof plates, make sure that nobody steps
below the weight.
NOTE: Remove the sealings (Fig. 3-2, Pos. 4).

Replace if required.
Version 2010/1 PC5500-6E 3 - 11

z Clear all wire harnesses and cable ducts from the beam
(transfer carrier) (Fig. 3-4, Pos. 1) and dismount all attached
parts from the beam.
WARNING
System" and "Fire Suppression System"
tional.
Fig. 3-4
z Remove the mounting bolts (Fig. 3-4, Pos. 3) and resilient
sleeves (Fig. 3-4, Pos. 2).
z Remove the beam (transfer carrier) (Fig. 3-4, Pos. 1) with a

crane.
DANGER
When removing the beam, make sure that nobody steps
below the weight.
3 - 12 PC5500-6E Version 2010/1

3.3.2 REMOVAL OF THE REAR ELECTRIC MOTOR (MOTOR 1)

Special tools: n/a
Crane
2 x Lifting bar for electric motor lifting
Electric motor: see rating plate on electric motor
Dogman/rigger
z Carry out preparatory work for electric motor removal, refer to

section 3.3.1 on page 3-9.
DANGER
Hazardous Voltage!

WARNING
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.
z Remove the cover of the electric motor connection box

(Fig. 3-5, Pos. 1).
z Disconnect the power supply cables (Fig. 3-5, Pos. 2) from

the electric motor at the connection box.
z Remove the cable grommet (Fig. 3-5, Pos. 3).
Fig. 3-5
Version 2010/1 PC5500-6E 3 - 13

z Remove the cover of the auxiliary terminal box (Fig. 3-6,

Pos. 1) at the electric motor housing.
z Disconnect and remove the wire harnesses (e.g. temperature

monitoring) from the auxiliary terminal box. Clear the wire
harnesses from the electric motor.
z Disconnect the protective earth from the electric motor.
Fig. 3-6
Fig. 3-7 Removal of the electric motor
z Remove the flexible coupling (Fig. 3-7, Pos. 4), refer to sec-
tion 3.5.1.1 on page 3-35.
3 - 14 PC5500-6E Version 2010/1

z Loosen the adjusting bolts (Fig. 3-7, see arrows) and the jack-
ing bolts (Fig. 3-7, Pos. 1) on both sides of the motor.
z Attach the motor (Fig. 3-8, Pos. 1) to a crane using two lifting
bars (Fig. 3-8, Pos. 3).
CAUTION
Make sure not to damage the motor cooler assembly
(Fig. 3-8, Pos. 2).
z Use the Lifting eyes at the motor (Fig. 3-8, Pos. 1) only.
z Use suitable lifting bars (Fig. 3-8, Pos. 3) which are long
enough that the lifting accessory does not come in con-
tact with the motor cooler assembly.
Fig. 3-8
z Lift the motor out of the machinery house.
DANGER
Death or serious injury may result.
When removing the motor, make sure that nobody steps
below the weight.
z Remove the compensation plates (Fig. 3-7, Pos. 5).
NOTE: The compensation plates should be used as samples for

the shape of new plates to be manufactured according to
the thickness needed for the proper alignment of the
motor.
Version 2010/1 PC5500-6E 3 - 15

3 - 16 PC5500-6E Version 2010/1

3.3.3 REPLACEMENT OF THE REAR ELECTRIC MOTOR (MOTOR 1)

Special tools: n/a
Crane
2 x Lifting bar for electric motor lifting
Electric motor: see rating plate on electric motor
Dogman/rigger

DANGER
Hazardous Voltage!
z Prepare the contact area of the motor stands before mount-

ing.
NOTE: The contact area must be plane and free of dirt and rust.
z Attach the new electric motor (Fig. 3-9, Pos. 1) to a crane

using two lifting bars (Fig. 3-9, Pos. 3).
CAUTION
Make sure not to damage the motor cooler assembly
(Fig. 3-9, Pos. 2).
z Use the Lifting eyes at the motor (Fig. 3-9, Pos. 1) only.
z Use suitable lifting bars (Fig. 3-9, Pos. 3) which are long
enough that the lifting accessory does not come in con-
tact with the motor cooler assembly.
Fig. 3-9
Version 2010/1 PC5500-6E 3 - 17

Fig. 3-10 Replacement of the electric motor
z Lift the new electric motor into mounting position in the

machinery house using a crane.
DANGER
When lifting the motor, make sure that nobody steps below
the weight.
z Screw in the jacking bolts (Fig. 3-10, Pos. 1) completely.
z Insert new motor fixing bolts (Fig. 3-10, Pos.3) of the grade
10.9, and secure the bolts with the nuts (Fig. 3-10, Pos.2).
Tighten the nuts hand-tight.
z If required, install the coupling’s input drive hub onto the

motor power take-off shaft (H7 drive fit), refer to section
3.5.1.2 on page 3-37.
3 - 18 PC5500-6E Version 2010/1

z Carry out the alignment procedure, refer to section 3.3.6 on

page 3-23.
z After completion of the alignment procedure, tighten the

motor fixing bolts / nuts to the specified tightening torque.
Tightening torque for the motor fixing bolts / nuts:

3100 Nm
DANGER
Hazardous Voltage!
z Remove the cover of the motor connection box (Fig. 3-11,

Pos. 1) and the cable grommet (Fig. 3-11, Pos. 3).
z Connect the power supply cables (Fig. 3-11, Pos. 2) to the

electric motor.
z Install the cable grommet (Fig. 3-11, Pos. 3).
z Reinstall the cover of the motor connection box (Fig. 3-11,

Pos. 1).
Fig. 3-11
z Remove the cover of the auxiliary terminal box (Fig. 3-12,

Pos. 1) at the electric motor housing.
z Install the wire harnesses to the electric motor, and connect

the wire harnesses (e.g. temperature monitoring) to the auxil-
iary terminal box.
z Connect the protective earth to the electric motor.
Fig. 3-12
z De-isolate the machine according to local regulations and

according to the grounding procedure of the high voltage sys-
tem, refer to section 2.3 on page 2-28.
Version 2010/1 PC5500-6E 3 - 19

z Check the direction of the electric motor’s rotation.

Change the connection of the phase lines if required.
z Install a new flexible coupling (Fig. 3-10, Pos. 4) to the motor

shaft and the PTO flange, refer to section 3.5.1.2 on page 3-
37.
z Reinstall the protection grid over the coupling.
z Reinstall the beam (Fig. 3-13, Pos. 1) (transfer carrier).
NOTE: Use new beam mounting bolts (Fig. 3-13, Pos. 3) of

grade 10.9.
Apply compound "KP2K", PN 324 969 40 on the mount-
ing bolts.
Install the beam mounting bolts with resilient sleeves and
tighten the mounting bolts to the specified tightening
torque.
Tightening torque for the beam (transfer carrier)

mounting bolts: 880 Nm
Fig. 3-13
WARNING
System" and "Fire Suppression System".
tional.
z Reinstall all previously removed wire harnesses and other

parts to the beam (transfer carrier).
z Install the air outlets (Fig. 3-14, Pos. 1) of the electric motors
to the roof plate.
NOTE: Check the moldings (Fig. 3-14, Pos. 2) and replace them
if required.
Fig. 3-14
3 - 20 PC5500-6E Version 2010/1

Fig. 3-15
z Reinstall the roof plates using swivel hoist rings and a crane.
z Install all mounting bolts with washers and resilient sleeves

respectively at the roof plates.
NOTE: Use new bolts (Fig. 3-15, Pos. 7) of the 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 roof plate mounting

bolts (Fig. 3-15, Pos. 7): 108 Nm
z Mount all previously dismounted parts to the roof plates.
z Reinstall all wire harnesses to the roof plates.
z Reinstall the service crane, if equipped; refer to section 3.2.2

on page 3-7.
z De-isolate the machine according to local regulations.
Version 2010/1 PC5500-6E 3 - 21

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".
3.3.4 REMOVAL OF THE FRONT ELECTRIC MOTOR (MOTOR 2)

The removal of the front electric motor (motor 2) is analogously
the same as the removal of the rear electric motor (motor 1), refer
to section 3.3.2 on page 3-13.
3.3.5 REPLACEMENT OF THE FRONT ELECTRIC MOTOR (MOTOR 2)

The replacement of the front electric motor (motor 2) is analo-
gously the same as the replacement of the rear electric motor
(motor 1), refer to section 3.3.5 on page 3-22.
3 - 22 PC5500-6E Version 2010/1

3.3.6 FINAL ALIGNMENT OF THE ELECTRIC MOTORS

Special tools: n/a
2 x Dial gauge
Laser alignment set (recommended), PN 232 713 40 + PN 232 714 40
For the alignment procedure the following preconditions are con-

sidered:
A new electric motor is installed.
The new motor is jacked up by the jacking bolts.
The flexible coupling is not installed yet.
The coupling’s hubs are already installed at the motor shaft and at
the PTO shaft.
NOTE: Due to higher accuracy, it is recommended to make all

measurements in the alignment procedure with a laser
alignment set instead of dial gauges. Observe the
instructions given in the manual of the laser alignment
set.
z Rotate the rotor of the electric motor and check the axial
clearance.
NOTE: The sleeve bearings of the motor must be lubricated

properly before turning the rotor.
Rough adjustment
z Move the motor (Fig. 3-16, Pos. 1) by using the adjusting

bolts (Fig. 3-16, Pos.3) and the jacking bolts (Fig. 3-18,
Pos.1), until the drive shaft centerline and the centerline at
the PTO drive shaft are aligned roughly.
z Adjust the desired distance between the hubs by using the

adjusting bolts (Fig. 3-16, Pos.3).
For the proper distance for the coupling, refer to the PARTS &
SERVICE NEWS No. "AH01523".
NOTE: Leave all adjusting screws tightened slightly.

Fig. 3-16
Run-out check
The alignment procedure is started by measuring the run-out of

the coupling hubs. This measurement will show any inaccuracy of
the shaft and / or hubs.
z The run-out of the coupling hub in respect to the bearing

housing of the motor is measured.
z Place the dial gauges according to Fig. 3-17 to measure the

run-out at the coupling half.
z Similarly check the run-out of the coupling hub at the PTO

drive shaft in respect to its bearing housing.
Fig. 3-17
NOTE: A simple lever arm is needed to turn the rotor of the elec-
tric motor.
Version 2010/1 PC5500-6E 3 - 23

Fig. 3-18 Alignment of the electric motor
Final alignment
z Mount the dial gauges as shown in Fig. 3-19.
NOTE: It is practical to adjust the dial gauges in such way that

approximately half of the scale is available in either direc-
tion. Check the rigidity of the gauge brackets in order to
eliminate the possibility of sag.
z Measure and record readings for parallel (Fig. 3-19, Pos. 1),
angular (Fig. 3-19, Pos. 2) and axial misalignment in four dif-
ferent positions: top, bottom, right and left, i.e. every 90°,
while both shafts are turned simultaneously.
Fig. 3-19
NOTE: For the permissible alignment tolerances for the coupling,
refer to the PARTS & SERVICE NEWS No. "AH01523".
3 - 24 PC5500-6E Version 2010/1

z Align the motor vertically by turning the jacking bolts

(Fig. 3-18, Pos. 1).
z Measure the distance between the bottom of the motor stand

and the power frame.
z Manufacture corresponding compensation plates (Fig. 3-18,

Pos. 5) and position the compensation plates between power
frame and motor stand.
z Loosen the jacking bolts and tighten the fixing bolts /nuts
(Fig. 3-18, Pos. 2 and 3) to the specified torque:
Tightening torque for motor fixing bolts and nuts

(Fig. 3-18, Pos. 2 and 3): 3100 Nm
z Check the alignment again. Make corrections if necessary.
z Record the data for future checks.
Version 2010/1 PC5500-6E 3 - 25

3.3.7 CAPACITOR ASSEMBLIES
Fig. 3-20 Capacitors
(1) Capacitor assembly
(2) Motor connection box

(3) Motor cooling air intake
(4) High voltage cable
(5) Cable clamp
(6) Capacitor assembly bed-plate
(7) Mounting bolt with resilient sleeve
(8) Machinery housing door (left side of machine)
3 - 26 PC5500-6E Version 2010/1

3.3.7.1 REMOVAL OF THE CAPACITOR ASSEMBLY (MOTOR 1)
Special tools: n/a
Capacitor assembly:125 kg
Dogman/rigger

the machine, boom, and crane or forklift.

DANGER
Hazardous Voltage!

z Open the outer door (Fig. 3-20, Pos. 8) of motor 1 (rear

motor) on the left side of the machine.
WARNING
Do not carry out the following work on a hot capacitor.
Wait until the temperature of the capacitor is below 50 °C.
parts.
Version 2010/1 PC5500-6E 3 - 27

z Open the cover of the capacitor connection box (Fig. 3-21,

Pos. 1) and disconnect the cable (Fig. 3-21, Pos. 3) and the
wires (Fig. 3-21, Pos. 2) from the capacitors.
Fig. 3-21
z Open the cable clamp (Fig. 3-22, Pos. 3) and remove the
cable (Fig. 3-22, Pos. 2).
z Sling the capacitor assembly (Fig. 3-22, Pos. 1) to a crane

with two slings.
z Remove the capacitor fixing bolts (Fig. 3-22, Pos. 7) and resil-
ient sleeves (Fig. 3-22, Pos. 6) from the bed-plate (Fig. 3-22,
Pos. 5).
z Lift the capacitor assembly off the shock absorbers (Fig. 3-22,
Pos. 4) with the crane, and place it on the ground.
DANGER Fig. 3-22

When lifting the capacitor, make sure that nobody steps
below the weight.
3 - 28 PC5500-6E Version 2010/1

3.3.7.2 REPLACEMENT OF THE CAPACITOR ASSEMBLY (MOTOR 1)
Special tools: n/a
Capacitor assembly:125 kg
Dogman/rigger

DANGER
Hazardous Voltage!
CAUTION
Before starting the motors, pay attention to the hydraulic oil
temperature. Refer to the Operation & Maintenance Manual,
chapter 3, section "Starting the main drive motors".
3.3.7.3 REMOVAL OF THE CAPACITOR ASSEMBLY (MOTOR 2)

The removal of the capacitor assembly of motor 2 (front motor) is
analogously the same as the removal of the capacitor assembly
of motor 1 (rear motor), refer to section 3.3.7.1 on page 3-27.
3.3.7.4 REPLACEMENT OF THE CAPACITOR ASSEMBLY (MOTOR 2)

The replacement of the capacitor assembly of motor 2 (front
motor) is analogously the same as the removal of the capacitor
assembly of motor 1 (rear motor), refer to section 3.3.7.2 on page
3-29.
Version 2010/1 PC5500-6E 3 - 29

Batteries Superstructure
3.4 BATTERIES
3.4.1 REMOVAL OF THE BATTERIES

Special tools: n/a
Additional equipment: Crane or forklift
Battery: 62 kg each
Dogman/rigger
Certified electrician

the machine, boom, and crane or forklift.

z Remove the keys from the battery main switches (Fig. 3-23,
Pos. 1).
NOTE: The batteries are located below the hinged floor plats
(Fig. 3-23, Pos. 2) in separate boxes.
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 batter-
ies!
z Remove floor plate fastening bolts and open the hinged floor
plates (Fig. 3-23, Pos. 2).
NOTE: Wash the dirt of the floor plates (Fig. 3-23, Pos. 2) as
they can be very heavy.
Fig. 3-23
z Secure the open floor plates against falling down using the
safety chains provided.
3 - 30 PC5500-6E Version 2010/1

Superstructure Batteries
z Disconnect the cables from the batteries (Fig. 3-24, Pos. 1).
DANGER
Risk of electrical and fire hazard!
Death, serious injury, shock, or burns may result.
Disconnecting the batteries has to be done by a certified

electrician only.
Disconnect the ground cables (-) of both batteries first.
z Remove the angles (Fig. 3-24, Pos. 2) from the batteries.

Fig. 3-24
z Take the batteries out of the battery boxes.
WARNING
Use the provided loops to carry the batteries.
Do not drop the battery.
Version 2010/1 PC5500-6E 3 - 31

Batteries Superstructure
3.4.2 REPLACEMENT OF THE BATTERIES

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

DANGER
Risk of electrical and fire hazard!
Death, serious injury, shock, or burns may result.
Clean hands or clothing immediately if electrolyte was
spilled.
Connecting the batteries has to be done by a certified electri-

cian only.
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.
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 - 32 PC5500-6E Version 2010/1

Superstructure Batteries
Version 2010/1 PC5500-6E 3 - 33

Flexible coupling Superstructure
3.5 FLEXIBLE COUPLING
3.5.1 VULKAN COUPLING
Fig. 3-25 Vulkan coupling
Description
The Vulkan coupling is a torsionally flexible rubber coupling, that

compensates axial, angular and, to a certain degree, radial dis-
placement of the connected machines.
The Vulkan coupling transfers the torque without any slippage.
The disc-shaped elastic element with a "plug-in" teeth at the outer

radius (PTO side) can be replaced without dismantling the motor
and the pump distributor gearbox (PTO) respectively.
3 - 34 PC5500-6E Version 2010/1

Superstructure Flexible coupling
(1) Bolt
(2) Nut
(3) Coupling half, PTO side
(4) PTO flange

(5) Bolt
(6) Coupling element
(7) Bolt
(8) Elastic element
(9) Bolt
(10) Coupling input hub, motor side
(11) Bolt
(12) Housing ring
3.5.1.1 REMOVAL OF THE VULKAN COUPLING
Special tools: n/a
Additional equipment: Chain hoist
Coupling element: 47 kg
Coupling housing ring: 94 kg
Dogman/rigger


Version 2010/1 PC5500-6E 3 - 35

Flexible coupling Superstructure
NOTE: Check if a lifting eye (Fig. 3-26, Pos. 1) is installed at the

roof plate over the coupling. 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. 3-26
WARNING
Do not carry out the following work on a hot motor.
Wait until the temperature of the motor is below 50 °C.
parts.
z Remove the bolts (Fig. 3-27, Pos. 3), resilient sleeves

(Fig. 3-27, Pos. 4), and nuts (Fig. 3-27, Pos. 2).
z Remove the protective cover (Fig. 3-27, Pos. 1).
Fig. 3-27
z Remove the vulkan coupling according to PARTS & SER-

VICE NEWS No. "AH01523".
DANGER
When lifting the motor, make sure that nobody steps below
the weight.
3 - 36 PC5500-6E Version 2010/1

Superstructure Flexible coupling
NOTE: Fig. 3-28 shows the parts for mounting the coupling as
they are delivered already installed to the motor power
take-off shaft (Fig. 3-28, Pos. 8) and the PTO flange
(Fig. 3-28, Pos. 5) respectively.
z Carry out the following step only if required:
z Remove the bolts (Fig. 3-28, Pos. 3) and take the

coupling half (Fig. 3-28, Pos. 4) off the PTO flange
(Fig. 3-28, Pos. 5).
NOTE: The coupling hub (Fig. 3-28, Pos. 1) should not be

drawn-off the motor shaft (Fig. 3-28, Pos. 8), as the motor
is balanced along with the hub.
Fig. 3-28
3.5.1.2 REPLACEMENT OF THE VULKAN COUPLING
Special tools: n/a
Coupling element: 47 kg
Coupling housing ring: 94 kg
Dogman/rigger

z Carry out the following step only if required.
z Install the coupling half (Fig. 3-29, Pos. 4) to the PTO

flange (Fig. 3-29, Pos. 5) and install the bolts (Fig. 3-29,
Pos. 3).
NOTE: Always use new mounting bolts.
Fig. 3-29
z Install the new coupling element and the housing ring of the
Vulkan coupling according to PARTS & SERVICE NEWS
No. "AH01523".
Version 2010/1 PC5500-6E 3 - 37

PTO Superstructure
3.6 PTO
3.6.1 MAIN PUMPS
Fig. 3-30 Main pumps assembly
3 - 38 PC5500-6E Version 2010/1

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 gearbox (motor 1)

(8) Pump distributor gearbox (motor 2)
(9) O-ring
The rotative energy from each main motor or engine propels the
gears in the pump distributor gearboxes (Fig. 3-30, 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. 3-30, Pos. 1 to 6). All Main pumps are additionally equipped
with gear pumps.
3.6.1.1 PREPARATORY WORKS FOR MAIN PUMP REMOVAL
Special tools: n/a

Crane
Roof plate, PTO side: 355 kg

Roof plate, cooling air outlet: 483 kg
Dogman/rigger



Version 2010/1 PC5500-6E 3 - 39

PTO Superstructure
z Close the hand wheel (Fig. 3-31, Pos. 1) of the main gate
valve between the suction oil reservoir and the main oil reser-
voir.
z To accelerate the draining of oil from the pumps, loosen the

vent plugs on the main pumps, refer to Operation & Mainte-
nance Manual, chapter 4, section "HYDRAULIC SYSTEM -
CHANGE OIL, REPLACE SUCTION STRAINERS AND PUL-
SATION DAMPER".
z 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. 3-31
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 stan-
dard procedure.
z Remove all cables which lead through the roof plates over the
pumps.
WARNING
tional.
3 - 40 PC5500-6E Version 2010/1

Superstructure PTO
Fig. 3-32 Roof plate removal
(1) Roof plate, PTO side
(3) Bolt
(4) Bolt
(5) Washer
(6) Sealing
(7) Roof plate, cooling air outlet
z Remove the roof plates (Fig. 3-32, Pos. 1 and 7) above the
main pumps, refer to section 3.3.1 on page 3-9.
Version 2010/1 PC5500-6E 3 - 41

PTO Superstructure
3.6.1.2 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
For further information about the needed blind plugs, refer to section
6.6 on page 6-18.
NOTE: The removal of all main pumps (Fig. 3-33, Pos. 1 - 6) is

analogously always the same.
Fig. 3-33
z Carry out the preparatory work, refer to section 3.6.1.1 on

page 3-39.
z If equipped with, remove fasteners for hoses of the main

pump assembly to be removed.
z 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 - 42 PC5500-6E Version 2010/1

Superstructure PTO
Drain the drive shaft housing oil, approx. 1.5 liters by

removing the drain plug (Fig. 3-34, Pos. 3) of the
Remove the level plug opening (Fig. 3-34, 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. 3-34
WARNING
Hot hydraulic oil!
z Disconnect the SAE flanges of the pressure hose and the

suction hose from the gear pump (Fig. 3-35, Pos. 4) of the
NOTE: When the pump hoses are disconnected, the oil inside
the piping will flow out. Catch it in an oil pan.
Cap the openings with blind plugs to avoid contamina-
tion.
z Disconnect the leak oil hose and all control hoses from the
control block (Fig. 3-35, Pos. 1).
z Disconnect the bearing flushing/lubrication hose from the

right side of the pump mounting flange.
Fig. 3-35
z Disconnect the high pressure hose (Fig. 3-35, Pos. 2) from
the main pump assembly.
z Disconnect the suction hose (Fig. 3-35, Pos. 3) at the bottom

side of the pump.
tion.
Version 2010/1 PC5500-6E 3 - 43

PTO Superstructure
z Sling pump assembly as shown in Fig. 3-36.
z Remove mounting bolts. Then remove pump assembly by

pulling it out of the pump distributor gearbox.
DANGER
When removing the main pump assembly, make sure that
NOTE: To simplify the removal, move the pump assembly lightly Fig. 3-36
up and down.
When the pump assembly is removed, oil will flow out of

the spline shaft housing. Catch it in an oil pan.
z Check the O-ring (Fig. 3-36, Pos. 1) at the pump assembly

flange and replace it if required.
3.6.1.3 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 flush-

ing of bearing. Refer to PARTS & SERVICE NEWS
No. "AH05510".
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.
Tighten the bolts to the specified tightening torque.
Tightening torque for the main pump mounting

bolts: 360 Nm
3 - 44 PC5500-6E Version 2010/1

Superstructure PTO
NOTE: For 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 "PTO’s (PUMP DISTRIBUTOR
GEARS) AND OIL RESERVOIR - CHECK OIL LEVEL".
Fill up to lower edge of level plug opening (Fig. 3-37,
Pos. 2).
For the proper lubricant, refer to the Operation &

Maintenance Manual, chapter 4, section "FLUIDS AND
LUBRICANTS".
Fig. 3-37
z Bleed air from the hydraulic system, refer to Operation &
Maintenance Manual, chapter 4, section "HYDRAULIC SYS-
TEM - CHANGE OIL, REPLACE SUCTION STRAINERS
AND PULSATION DAMPER" and PARTS & SERVICE NEWS
No. "AH01513".
z Add hydraulic oil up to the specified level.
z Adjust main pump, refer to the Service Manual for further

information and refer to PARTS & SERVICE NEWS
No. "AH06542".
z Check for leaks and proper operation.
z Check the hydraulic oil level again and correct the oil level if
required.
Version 2010/1 PC5500-6E 3 - 45

PTO Superstructure
3.6.2 PTO OIL PUMP (AUXILIARY PUMP)

The gear oil pumps (Fig. 3-38, Pos. 1) for the PTO gear lubrica-
tion aspirate gear oil from the PTO gearboxes 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. 3-38
3.6.2.1 REMOVAL OF PTO OIL PUMP (AUXILIARY PUMP)
Special tools: n/a
Additional equipment: Oil drain pan
PTO oil pump: 25 kg
Dogman/rigger
6.6 on page 6-18.



z Disconnect the SAE flanges of pressure hose and suction

hose from the PTO oil pump (Fig. 3-38, Pos. 1) to be
removed.
3 - 46 PC5500-6E Version 2010/1

Superstructure PTO
tion.
z Remove the two bolts (Fig. 3-39, Pos. 1) and pull the PTO oil
pump (Fig. 3-39, Pos. 7) out of the adapter (Fig. 3-39, Pos. 2).
z Remove the four bolts (Fig. 3-39, Pos. 6) and disconnect the
adapter (Fig. 3-39, Pos. 2) from the main pump assembly
(Fig. 3-39, Pos. 5).
z Discard the O-ring (Fig. 3-39, Pos. 4).
NOTE: Check the joint element (Fig. 3-39, Pos. 3) for wear and
replace it if required.
Fig. 3-39
Version 2010/1 PC5500-6E 3 - 47

PTO Superstructure
3.6.2.2 REPLACEMENT OF THE PTO OIL PUMP (AUXILIARY PUMP)
Special tools: Hydraulic testing kit, PN 232 591 40

Additional equipment: Paste "Optimol White" PN 999 039
PTO oil pump: 25 kg
Dogman/rigger

z Check PTO oil pump before installing, refer to PARTS & SER-
VICE NEWS No. "AH03511" and "AH03512".
z Remove the two bolts (Fig. 3-39, Pos. 1) at the new PTO oil
pump and disconnect the new adapter (Fig. 3-39, Pos. 1)
carefully.
z To avoiding of corrosion coat the adapter surfaces and the

pump surface with Optimol White, refer to PARTS & SER-
NOTE: Use "Optimol White" on the spline shaft of the pump and
use a new O-ring (Fig. 3-39, Pos. 4).
NOTE: Use new mounting bolts with grade 8.8 at the mounting
flanges of the pump and adapter.
Tightening torque for the mounting bolts:

74 Nm

No. "AH01513".
z Run machine to warm, test pressure of the PTO oil pump and
adjust if required. Refer to Service Manual.
3 - 48 PC5500-6E Version 2010/1

Superstructure PTO
3.6.3 OIL CIRCULATION PUMP (AUXILIARY PUMP)

The oil circulation pumps (Fig. 3-40, Pos. 1) together with back
pressure valves prevent cavitation in the swing motors during the
swing down phases. For further information refer to section 3.8.4
on page 3-180 and the Service Manual.
The oil circulation pumps are attached at the main pump 2

assembly or, respectively, at the main pump 5 assembly.
Fig. 3-40
3.6.3.1 REMOVAL OF OIL CIRCULATION PUMP (AUXILIARY PUMP)
Special tools: n/a
Oil circulation pump: 25 kg
Dogman/rigger
6.6 on page 6-18.




hose from the circulation pump (Fig. 3-40, Pos. 1) to be
removed.
Version 2010/1 PC5500-6E 3 - 49

PTO Superstructure
tion.
z Remove the two bolts (Fig. 3-41, Pos. 1) and pull the oil circu-
lation pump (Fig. 3-41, Pos. 7) out of the adapter (Fig. 3-41,
Pos. 2).
adapter (Fig. 3-41, Pos. 2) from the main pump assembly
(Fig. 3-41, Pos. 5).
z Check the joint element (Fig. 3-41, Pos. 3) for wear and
replace it if required.
Fig. 3-41
3 - 50 PC5500-6E Version 2010/1

Superstructure PTO
3.6.3.2 REPLACEMENT OF THE OIL CIRCULATION PUMP (AUXILIARY PUMP)

Oil circulation pump: 25 kg
Dogman/rigger

z Check the oil circulation pump before installing, refer to

PARTS & SERVICE NEWS No. "AH03511" and "AH03512".
z Remove the two bolts (Fig. 3-41, Pos. 1) at the new oil
circulation pump and disconnect the new adapter (Fig. 3-39,
Pos. 1) carefully.
z To avoiding of corrosion coat the adapter surfaces and the

NOTE: Use "Optimol White" on the spline shaft of the pump and
use a new O-ring (Fig. 3-41, Pos. 4).
NOTE: Use new mounting bolts with grade 8.8 at the mounting
flanges of the pump and adapter.

74 Nm

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

pump and adjust if required. Refer to Service Manual.
Version 2010/1 PC5500-6E 3 - 51

PTO Superstructure
3.6.4 PUMP DISTRIBUTOR GEARBOX (PTO)
Fig. 3-42 Pump distributor gearbox
3 - 52 PC5500-6E Version 2010/1

Superstructure PTO
(1) Oil level gauge

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

(4)
housing
Breather filter with oil level gauge
(5)
(drive shaft housing)
(6) Main pump drive shaft housings
(7) Oil level plug of main pump drive shaft housing

Oil filler plug with breather pipe of main pump drive
(8)
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

Power take off
(R)
Not used at machines with electric drives
(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 an electric motor. 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 gearbox housing is a one-piece design and made of grey

cast iron. The gearbox design with a drive flange allows a direct
connection of a flexible coupling, which is installed between the
electric motor and the PTO gearbox.
The gearbox has been provided with connections for a separate

cooling system or for a preheating system.
Always check gearbox oil level with unlocked dip stick and
stopped electric motor.
Version 2010/1 PC5500-6E 3 - 53

PTO Superstructure
3.6.4.1 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
6.6 on page 6-18.
z Carry out the preparatory work, refer to section 3.6.1.1 on

page 3-39.
NOTE: The removal of the pump distributor gearbox 1 (Fig. 3-43,

Pos. 7) and pump distributor gearbox 2 (Fig. 3-43,
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. 3-43, Pos. 1-3)

respectively main pump assemblies 4-6 (Fig. 3-43, Pos. 4-6),
refer to section 3.6.1 on page 3-38.
Fig. 3-43
z Remove the hydraulic cooler fan drive pump of the PTO to be

removed, refer to section 3.7.1.1 on page 3-60.
z Relieve pilot pressure at the pressure check point M40 for

accumulator, refer to the Service Manual.
the piping will flow out. Catch it in an oil pan. Cap the
openings with blind plugs to avoid contamination.
3 - 54 PC5500-6E Version 2010/1

Superstructure PTO
Fig. 3-44 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)
z Mark and disconnect all hydraulic lines and electrical wires

leading to the control- and filter plate assembly of the PTO to
be removed (Fig. 3-44, Pos. 3 and Fig. 3-44, Pos. 4 respec-
tively).
z Sling the control- and filter plate assembly of the PTO to be

removed (Fig. 3-44, Pos. 3 and Fig. 3-44, Pos. 4 respectively)
to a crane.
z Remove mounting bolts (Fig. 3-45, Pos. 1) with resilient

z Remove the control- and filter plate assembly (Fig. 3-45,

Pos. 3) using a crane.
DANGER
When removing the control- and filter plate assembly, make
sure that nobody steps below the weight.
Fig. 3-45
Version 2010/1 PC5500-6E 3 - 55

PTO Superstructure
z Disconnect all hydraulic hoses from the PTO.
NOTE: When the hoses are disconnected, the oil inside the pip-
ing will flow out. Catch it in an oil pan.
tion.
z Disconnect all retainers for hydraulic hoses and electrical

wires at the PTO.
Fig. 3-46
z Disconnect the temperature sensor (Fig. 3-47, Pos. 1).
z Disconnect the heating and the thermo switch, if equipped.
z Remove the coupling (Fig. 3-47, Pos. 2), refer to section

3.5.1.1 on page 3-35.
Fig. 3-47
z Attach the PTO to a crane, using the lifting eyes (Fig. 3-48,
arrows).
Fig. 3-48
3 - 56 PC5500-6E Version 2010/1

Superstructure PTO
z Remove the bolts (Fig. 3-49, Pos. 2) with resilient sleeves

(Fig. 3-49, Pos. 3) attaching the PTO (Fig. 3-49, Pos. 1) to the
supports (Fig. 3-49, Pos. 4).
Fig. 3-49
z Lift the PTO out of the machinery house using a crane.
DANGER
When lifting the PTO, make sure that nobody steps below the
weight.
Version 2010/1 PC5500-6E 3 - 57

PTO Superstructure
3.6.4.2 REPLACEMENT OF THE PUMP DISTRIBUTOR GEARBOX (PTO)
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.
NOTE: Before connecting the flexible coupling, check the align-

ment of the electric motor with the pump distributor gear-
box (PTO).
Always use new O-rings at all SAE flange connections.
NOTE: Use new PTO mounting bolts (Fig. 3-50, Pos. 2) of grade
10.9. Apply compound "KP2K", PN 324 969 40 on the
PTO mounting bolts, and tighten the PTO mounting bolts
to the specified tightening torque:
Tightening torque for the PTO mounting bolts:

1770 Nm
Fig. 3-50
Refill gear oil of the PTO, approx. 95 liters.

Refer to the Operation & Maintenance Manual,
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 - 58 PC5500-6E Version 2010/1

Superstructure Hydraulics
3.7 HYDRAULICS
3.7.1 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 dis-
placement pump, designed to operate in open circuits. It has an
internal case drain return. The rotary group is a robust self aspi-
rating unit. External forces may be applied to the drive shaft.
The right hydraulic pump on PTO 1 (Fig. 3-51, Pos. 1) supplies

the lower and the right hydraulic pump on PTO 2 (Fig. 3-51, Pos.
2) supplies the upper hydraulic fan motor. The fans are mounted
directly to the hydraulic motors drive shaft.
Fig. 3-51
Changing the swivel angle of the rotary group is achieved by slid-

ing 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.
z 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 2010/1 PC5500-6E 3 - 59

Hydraulics Superstructure
3.7.1.1 REMOVAL OF THE HYDRAULIC COOLER FAN DRIVE PUMP
Special tools: n/a
Chain hoist
Oil drain pan
Hydraulic cooler fan drive pump: 40 kg
Dogman/rigger
6.6 on page 6-18.



voir.
chapter 3, section "FUNCTIONS OF THE TRANSFER
PUMP".
Fig. 3-52
3 - 60 PC5500-6E Version 2010/1

NOTE: Check if a lifting eye (Fig. 3-53, Pos. 1) is installed at the

roof plate over the pump. 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. 3-53
WARNING
Hot hydraulic oil!
Wait until the temperature of the hydraulic oil is below 50°C.
z Dismantle the hose mounting plate (Fig. 3-54, Pos. 1).
tion.
z Disconnect the pressure hose (Fig. 3-54, Pos. 2) and the suc-
tion hose (Fig. 3-54, Pos. 3) from the hydraulic cooler fan
drive pump (Fig. 3-54, Pos. 5).
z Sling the pump, remove the bolts (Fig. 3-54, Pos. 4), and
remove the hydraulic cooler fan drive pump (Fig. 3-54,
Pos. 5) by pulling it out of the PTO using a chain hoist.
Fig. 3-54
Version 2010/1 PC5500-6E 3 - 61

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.
z Check the O-ring at the pump flange and replace it if required.
z 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 - 62 PC5500-6E Version 2010/1

3.7.1.2 REPLACEMENT OF THE HYDRAULIC COOLER FAN DRIVE PUMP
Special tools: Rotational speed infrared probe DS03, PN 793 788 73

Crane
Chain Hoist
Paste "Optimol White" PN 999 039
Hydraulic cooler fan drive pump: 40 kg
Dogman/rigger

Always use new O-rings at the SAE flange connections.
Use new bolts (Fig. 3-54, Pos. 4) of grade 8.8 at the

mounting flanges.
tightening torque.

74 Nm
Refill the oil collector reservoir (Fig. 3-55, Pos. 1) for the
spline shaft housing.

Maintenance Manual, chapter 4, section "FLUIDS AND
LUBRICANTS".

No. "AH01513".
Fig. 3-55
z 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 2010/1 PC5500-6E 3 - 63

3.7.2 HYDRAULIC COOLER FAN ASSEMBLY

There are four (temperature range up to 40 °C) hydraulic oil coo-
lers 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 ele-
ments installed in each frame. The air stream needed for the cool-
ing 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. 3-56, Pos. 1) supplies the lower and the right hydrau-
lic pump on PTO 2 (Fig. 3-56, Pos. 2) supplies the upper hydraulic
fan motor. The fans are mounted directly to the hydraulic motors
drive shaft.
Fig. 3-56
3 - 64 PC5500-6E Version 2010/1

3.7.2.1 REMOVAL OF HYDRAULIC COOLER FAN ASSEMBLY
Special tools: n/a

Oil drain pan
Crane
Hydraulic cooler fan assembly: 117.4 kg
Dogman/rigger
6.6 on page 6-18.



Version 2010/1 PC5500-6E 3 - 65

Fig. 3-57 Position of the hydraulic cooler fan assembly
z Open the hydraulic fan guard (Fig. 3-57, Pos. 1)
WARNING
Hot hydraulic oil!
DANGER
scaring may result.
3 - 66 PC5500-6E Version 2010/1

z Disconnect the hydraulic pressure hoses (Fig. 3-57, Pos. 3)

and the leak oil hose (Fig. 3-57, Pos. 2) from the hydraulic
motor.
NOTE: When the hoses are removed, the oil inside the hoses will
flow out. Catch it in an oil pan.
tion.
z Remove the hydraulic cooler fan assembly (Fig. 3-58,

Pos. 1) from the main cooler frame support, supported using
a crane.
WARNING
Fan blades could have sharp edges. Use gloves!
CAUTION
Remove the assembly carefully in order not to damage the
oil cooler or the fan blades.
Fig. 3-58
DANGER
When removing the hydraulic cooler fan assembly, make
sure that nobody steps below the weight.
Version 2010/1 PC5500-6E 3 - 67

3.7.2.2 REPLACEMENT OF HYDRAULIC COOLER FAN ASSEMBLY
Special tools: Rotational speed infrared probe DS03, PN 793 788 73

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".
z 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 - 68 PC5500-6E Version 2010/1

Version 2010/1 PC5500-6E 3 - 69

3.7.2.3 REMOVAL OF HYDRAULIC COOLER FAN AND MOTOR
Special tools: n/a

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

3.7.2.1 on page 3-65.
Fig. 3-59 Hydraulic cooler fan assembly
3 - 70 PC5500-6E Version 2010/1

(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.
z Remove the attaching bolts (Fig. 3-59, Pos. 1) with the

locking plates (Fig. 3-59, Pos. 2). Discard the locking
plates.
z Remove the cooler fan (Fig. 3-59, Pos. 3) from the drive
shaft (Fig. 3-59, Pos. 4).
z Remove the four bolts (Fig. 3-59, Pos. 14) and remove the
hydraulic motor (Fig. 3-59, Pos. 13) from the bearing group
carrier (Fig. 3-59, Pos. 9). Discard the O-ring (Fig. 3-59,
Pos. 12).
NOTE: When the hydraulic motor is disconnected from the bear-

ing 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. 3-59, Pos. 11), extract the
drive shaft (Fig. 3-59, Pos. 4) out of the bearing group carrier
(Fig. 3-59, Pos. 9), and remove the drive shaft seal (Fig. 3-59,
Pos. 6), the bearings (Fig. 3-59, Pos. 7 and 10), and the
sleeves (Fig. 3-59, Pos. 5 and 8).
Version 2010/1 PC5500-6E 3 - 71

3.7.2.4 REPLACEMENT OF HYDRAULIC COOLER FAN AND MOTOR
Special tools: n/a

Fan: 19 kg
Hydraulic cooler fan mounting assembly: 72 kg
Hydraulic motor assembly: 26.4 kg
Dogman/rigger

Fig. 3-60 Hydraulic cooler fan assembly
z Carry out installation in reverse order to removal. Refer to

NOTE: If the drive shaft (Fig. 3-60, Pos. 4) is removed, check the
drive shaft.
Check drive shaft seal (Fig. 3-60, Pos. 6) for wear and
damage. Replace if required.
NOTE: Use a new O-ring (Fig. 3-60, Pos. 12) and new locking
plates (Fig. 3-60, Pos. 2).
3 - 72 PC5500-6E Version 2010/1

WARNING
z Install the hydraulic cooler fan assembly, refer to section

3.7.2.2 on page 3-68.
NOTE: Check the oil level in the bearing group carrier (Fig. 3-60,
Pos. 9) and add oil if required, refer to the Operation &
Maintenance Manual, chapter 4, section "HYDRAULIC
OIL COOLER FAN BEARINGS - CHECK FOR LEAK-
AGE AND CLEAN BREATHER FILTER".

No. "AH01513".
Version 2010/1 PC5500-6E 3 - 73

3.7.3 HYDRAULIC OIL COOLERS
Fig. 3-61 Hydraulic oil cooler circuit
3 - 74 PC5500-6E Version 2010/1

(2) Solenoid valve (4/2-directional control valve)
(3) Return lines from control blocks

Restrictor (shock absorbers for the hydraulic oil
(5)
cooler)
(6) Lines to cooler (hot oil)
(7) Hydraulic oil cooler

(8) Lines to hydraulic oil reservoir
(9) Hydraulic oil reservoir
The returning oil from the system flows via the lines (Fig. 3-61,
Pos. 3) into the collector tube (Fig. 3-61, Pos. 4). On the top side
of it the back pressure valve (Fig. 3-61, Pos. 1) is installed. The
back pressure valve causes a back pressure which forces most of
the relative hot oil via the lines (Fig. 3-61, Pos. 6) to the cooler
(Fig. 3-61, 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. 3-61, Pos. 8) into the filter chamber of the hydraulic oil
reservoir (Fig. 3-61, 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 tempera-
ture. During the warm up period (1/2 Qmax) the back pressure
valve (Fig. 3-61, Pos. 1) is wide open, because the solenoid valve
(Fig. 3-61, Pos. 2) is energized, which results in less oil flow
through the cooler which causes the oil getting its optimum oper-
ating 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. 3-61, 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 2010/1 PC5500-6E 3 - 75

3.7.3.1 REMOVAL OF THE HYDRAULIC OIL COOLERS
Special tools: n/a
Safety harness in conformity with EN 361

Crane
Mobile elevator working platform
Oil drain pans
Hydraulic oil cooler: 275 kg each
Dogman/rigger
6.6 on page 6-18.



"RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM"
WARNING
z Always wear a safety harness when working at the
hydraulic oil coolers.
z Most of the following operations require the use of men

safety cages on elevator working platforms.
3 - 76 PC5500-6E Version 2010/1

voir.
z Transfuse the oil from the return manifold into the main oil
reservoir, refer to the Operation & Maintenance Manual,
PUMP".
z Open the hydraulic oil cooler door. Refer to Operation & Main-
tenance Manual, chapter 4, section "HYDRAULIC OIL
COOLERS - INSPECT AND CLEAN IF NECESSARY".
WARNING Fig. 3-62

Hot hydraulic oil!
z Disconnect the hoses (Fig. 3-63, 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.
tion.
Fig. 3-63
z Disconnect all inlet hoses (Fig. 3-64, Pos. 2) and outlet hoses
(Fig. 3-64, 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.
tion.
Fig. 3-64
Version 2010/1 PC5500-6E 3 - 77

z Sling the oil cooler (Fig. 3-65).
Fig. 3-65
Fig. 3-66 Removal of the oil cooler
z Remove the bolts (Fig. 3-66, Pos. 2), the washers (Fig. 3-66,
Pos. 3) and locking plates (Fig. 3-66, Pos. 4), and clear the oil
cooler (Fig. 3-66, Pos. 1) from the angle (Fig. 3-66, Pos. 8).
3 - 78 PC5500-6E Version 2010/1

z Lift the oil cooler (Fig. 3-66, Pos. 1) out of the radiator mount-
ing (Fig. 3-66, Pos. 9) using a crane.
DANGER
When removing the hydraulic oil cooler, make sure that
NOTE: Discard locking plates (Fig. 3-66, Pos. 4).

Check condition of buffer elements (Fig. 3-66, Pos. 10),
and replace them if required.
Version 2010/1 PC5500-6E 3 - 79

3.7.3.2 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. 3-67 Installation of the oil cooler
3 - 80 PC5500-6E Version 2010/1

WARNING
Always wear a safety harness when working at the hydraulic
oil coolers.
z Exchange the restrictor (Fig. 3-61, Pos. 5) from the old oil
cooler to the new oil cooler.
z Apply glue PN 256 952 40 to the profiled joints (Fig. 3-67,

Pos. 5 to 7) and attach them in the same manner as they
were fixed to the old oil cooler.
z Carry out further installation in reverse order to removal.
NOTE: Use new locking plates (Fig. 3-67, Pos. 4).
z Bleed air from the hydraulic system, refer to the Operation &
No."AH01513".
z Add PTO gear oil to the specified level.
Version 2010/1 PC5500-6E 3 - 81

3.7.3.3 REMOVAL OF THE HYDRAULIC OIL COOLER FRAME
Special tools: n/a

Crane
Additional equipment: 2 x swivel hoist rings: M36
Oil drain pans
Hydraulic oil cooler frame: 3950 kg
Dogman/rigger
6.6 on page 6-18.



voir.
PUMP".
z Open the hydraulic oil cooler door. Refer to Operation & Main-
tenance Manual, chapter 4, section "HYDRAULIC OIL
COOLERS - INSPECT AND CLEAN IF NECESSARY".
Fig. 3-68
3 - 82 PC5500-6E Version 2010/1

WARNING
z Hot hydraulic oil!
Wait until the temperature of the hydraulic oil is below
50 °C. Disobedience may result in personal injury from
heated oil.

hydraulic oil cooler frame.

z Disconnect all wiring harness connectors from the hydraulic

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

cooler frame (Fig. 3-69, Pos. 4):
1. Plate (Fig. 3-69, Pos. 1)
2. Rail (Fig. 3-69, Pos. 2)
3. Rail (Fig. 3-69, Pos. 3)
Fig. 3-69
z Disconnect hydraulic inlet hoses (Fig. 3-70, Pos. 1) from the

hydraulic cooler fan motor (Fig. 3-70, Pos. 2).
NOTE: When the hoses are disconnected, oil will flow out of the
hoses. Catch it in an oil pan.
tion.
Fig. 3-70
Version 2010/1 PC5500-6E 3 - 83

z Disconnect the return hose (Fig. 3-71, Pos. 1) and the leak oil
hose (Fig. 3-71, Pos. 2) from the hydraulic cooler fan motor.
tion.
Fig. 3-71
z Disconnect hydraulic hoses (Fig. 3-72, Pos. 1 and 2) at the

shown joints.
tion.
Fig. 3-72
z Disconnect PTO oil hoses (Fig. 3-73, Pos. 1 and 2).
tion.
Fig. 3-73
3 - 84 PC5500-6E Version 2010/1

z Insert the swivel hoist rings (M36) into the threads (Fig. 3-74,
Pos. 1) of the hydraulic oil cooler frame (Fig 3-74, Pos. 2).
z Sling hydraulic oil cooler frame (Fig. 3-74, Pos. 2) at the hoist
rings.
Fig. 3-74
z Remove mounting bolts (Fig. 3-75, Pos. 2 and 3) and remove

the hydraulic oil cooler frame (Fig. 3-75, Pos. 1) from the
superstructure using a crane.
DANGER
When removing the hydraulic oil cooler, make sure that
z Rest the hydraulic oil cooler frame on the ground on an

appropriate stand and carry out the following steps if required.
Fig. 3-75
z If required, remove the hydraulic oil cooler from the hydraulic

oil cooler frame, refer to section 3.7.3.1 on page 3-76.
z If required, remove the cooler fan assembly from the hydrau-

lic oil cooler frame, refer to section 3.7.2.1 on page 3-65.
Version 2010/1 PC5500-6E 3 - 85

3.7.3.4 REPLACEMENT OF THE HYDRAULIC OIL COOLER FRAME
Special tools: n/a

Hydraulic oil cooler frame: 3950 kg
Dogman/rigger

WARNING
oil cooler frame.
NOTE: Use new mounting bolts (Fig. 3-76, Pos. 2 and 3) 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 mounting bolts (Fig. 3-76,

Pos. 2 and 3): 1770 Nm
Fig. 3-76
No. "AH01513".
z Add PTO gear oil to the specified level.
3 - 86 PC5500-6E Version 2010/1

3.7.4 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 pres-
sure increase is possible and damage is avoided.
The valves are installed in the main control valve blocks.
3.7.4.1 REMOVAL OF THE MRV
Special tools: 36 mm Socket wrench, PN 232 374 40
NOTE: For additional information about the MRV on the main

control valve blocks, refer to section 3.7.8 on page 3-105.

voir.
PUMP".
Fig. 3-77
WARNING
Hot hydraulic oil!
z Remove the MRV (Fig. 3-78, 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.
Fig. 3-78
Version 2010/1 PC5500-6E 3 - 87

3.7.4.2 REPLACEMENT OF THE MRV
36 mm Socket wrench, PN 232 374 40

Special tools:
Hydraulic testing kit, PN 232 591 40
NOTE: Fit new O-rings to the MRV.
NOTE: Tighten the MRV to the specified torque.
Tightening torque for MRV:

300 Nm
No. "AH01513".
z Check and adjust the MRV. Refer to Service Manual.
WARNING
Wear ear protection when checking the relief pressure.
3 - 88 PC5500-6E Version 2010/1

3.7.5 PILOT OIL PUMP (GEAR PUMP)
3.7.5.1 REMOVAL OF THE PILOT OIL PUMP
Special tools: n/a
Pilot oil pump: 27.4 kg
6.6 on page 6-18.



voir.
PUMP".
Fig. 3-79
Version 2010/1 PC5500-6E 3 - 89

z The pilot oil pumps (Fig. 3-80, Pos. 1) generate the pilot pres-
sure that is used for all hydraulic control operations.
z The pilot oil pumps are attached to both PTOs.

hose from the pilot oil pump(s) (Fig. 3-80, Pos. 1).
tion.
Fig. 3-80
z Remove the two bolts (Fig. 3-81, Pos. 1) and pull the pilot oil
pump (Fig. 3-81, Pos. 7) out of the adapter (Fig. 3-81,
Pos. 2).
adapter from the main pump assembly (Fig. 3-81, Pos. 5).
NOTE: Check the joint element (Fig. 3-81, Pos. 3) for wear, and
replace it, if required.
Fig. 3-81
3 - 90 PC5500-6E Version 2010/1

3.7.5.2 REPLACEMENT OF THE PILOT OIL PUMP
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".
z Remove the two bolts (Fig. 3-82, Pos. 1) at the new pilot oil
pump, and disconnect the adapter (Fig. 3-82, Pos. 2) care-
fully.
z To avoiding of corrosion, coat the adapter surfaces and the

z Carry out installation in reverse order to removal, refer to

Fig. 3-82
Use a new O-ring (Fig. 3-82, Pos. 4) and new mounting

bolts (Fig. 3-82, 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

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

Refer to Service Manual.
Version 2010/1 PC5500-6E 3 - 91

3.7.6 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 operator’s dashboard.
3.7.6.1 REMOVAL OF THE MAIN GATE VALVE
Special tools: n/a

Additional equipment: Oil tank (4450 liters)
Main gate valve: 12.3 kg


voir.
PUMP".
Fig. 3-83
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 - 92 PC5500-6E Version 2010/1

z Disconnect the harness connector S31 from the proximity

switch at the main gate valve. Refer to Fig. 3-92
on page 3-99.
z Remove the bolts (Fig. 3-84, Pos. 1), dismantle the compen-
sator (Fig. 3-84, Pos. 2), and the main gate valve
(Fig. 3-84, Pos. 3).
NOTE: When the main gate valve (Fig. 3-84, Pos. 3) and the
compensator (Fig. 3-84, Pos. 2) are removed some oil
inside the piping will flow out.
Catch it in an oil pan.
Check condition of the compensator (Fig. 3-84, Pos. 2)

and replace as necessary. Fig. 3-84
3.7.6.2 REPLACEMENT OF THE MAIN GATE VALVE
Special tools: n/a
Additional equipment: Oil tank (4450 liters)
Main gate valve: 12.3 kg

Fill hydraulic oil into the hydraulic oil reservoir,


No. "AH01513".
Version 2010/1 PC5500-6E 3 - 93

3.7.7 HYDRAULIC OIL RESERVOIR
Fig. 3-85 Hydraulic oil reservoir
3 - 94 PC5500-6E Version 2010/1

(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 2010/1 PC5500-6E 3 - 95

3.7.7.1 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
6.6 on page 6-18.


WARNING
hydraulic oil reservoir.
z The following operations require the use of men safety

cages on elevator working platforms.
Drain hydraulic oil from the hydraulic oil reservoir,

3 - 96 PC5500-6E Version 2010/1

z Remove the main gate valve, refer to section 3.7.6.1 on page

3-92.
z Remove the plates (Fig. 3-86, Pos. 1) beside the threads

(Fig. 3-86, Pos. 2).
z Insert swivel hoist rings (M 36) into the threads (Fig. 3-86,
Pos. 2).
Fig. 3-86
z Remove the rails (Fig. 3-87, Pos. 1) from the hydraulic oil res-
ervoir (Fig. 3-87, Pos. 2).
Fig. 3-87
z Disconnect the hydraulic outlet hoses (Fig. 3-88, Pos. 1),

leading from the hydraulic coolers, from the hydraulic oil res-
ervoir.
z Disconnect the hydraulic inlet hoses (Fig. 3-88, Pos. 2), lead-
ing to the hydraulic coolers, from the hydraulic oil reservoir.
NOTE: When the hydraulic hoses are disconnected, the oil

inside the piping will flow out. Catch it in an oil pan.
tion.
Fig. 3-88
Version 2010/1 PC5500-6E 3 - 97

z Loosen all clamps (Fig. 3-89, Pos. 2) mounted at the hydrau-

lic oil reservoir to clear all hydraulic lines from the hydraulic oil
z Mark and disconnect all hydraulic lines (Fig. 3-89, Pos. 1)

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

tion.
Fig. 3-89
z Disconnect the electrical wiring (Fig. 3-90, Pos. 1) from the

transfer pump (Fig. 3-90, Pos. 7) and the hydraulic oil reser-
voir.
z Shut the cock valves at the hydraulic hoses

(Fig. 3-90, Pos. 3) and disconnect the hydraulic hoses from
the union (Fig. 3-90, Pos. 4).
z Clear all hydraulic hoses from the hydraulic oil reservoir.
z Disconnect all hydraulic lines from the standpipe

(Fig. 3-90, Pos. 5).
NOTE: When the hydraulic hoses/pipes are disconnected, the oil

tion.
z Remove the grating (Fig. 3-90, Pos. 6). Fig. 3-90
z Disconnect all hydraulic lines (Fig. 3-91, Pos. 1) from the

standpipe below the hydraulic oil reservoir.

tion.
z Loosen all clamps (Fig. 3-91, Pos. 2) below the hydraulic oil
reservoir to clear all hydraulic lines from the hydraulic oil res-
ervoir.
Fig. 3-91
3 - 98 PC5500-6E Version 2010/1

z Disconnect all wiring harness connectors (Fig. 3-92,

Pos. Bxx, Y101) and the head light assembly (Fig. 3-92,
Pos. H49b).
z Remove the wiring harnesses from the hydraulic oil reservoir.
Fig. 3-92
z Attach the hydraulic oil reservoir to a crane.
z Remove two mounting bolts (Fig. 3-93, Pos. 1) from each

mounting flange (Fig. 3-93, Pos. 3) of the hydraulic oil reser-
voir (Fig. 3-93, Pos. 2).
z Lift the hydraulic oil reservoir (Fig. 3-93, Pos. 2) off the super-
structure using the crane and place it on the ground.
DANGER
When removing the hydraulic oil reservoir, make sure that
Fig. 3-93
Version 2010/1 PC5500-6E 3 - 99

Fig. 3-94 Filter assembly/provided parts
(R) Return oil filter location
(L) Leakage oil filter location

(1) Mounting bolt
(3) Filter cover assembly

(4) Return and leakage filter unit
(5) Oil filler plug
(6) Gasket
(7) Cover
(8) Breather filter
z Remove filters and all provided parts (Fig. 3-94, 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. 3-94, Pos. 6).
3 - 100 PC5500-6E Version 2010/1

z Carry out the following steps only if required:
z Remove the back pressure valve (Fig. 3-95, Pos. 2) and

discard the gaskets (Fig. 3-95, Pos. 1 and 3).
z Remove the whole standpipe (Fig. 3-95, Pos. 4).
z Remove all covers (Fig. 3-95, Pos. 5).
z Remove all plugs (Fig. 3-95, Pos. 6).
z Remove the oil level plate (Fig. 3-95, Pos. 8) and hydrau-
lic oil level sight gauge (Fig. 3-95, Pos. 7).
z Remove all other equipment (clamps, bolts, etc.), if

required.
Fig. 3-95
Version 2010/1 PC5500-6E 3 - 101

3.7.7.2 REPLACEMENT OF THE HYDRAULIC OIL RESERVOIR
Socket wrench 46 mm, PN 232 377 40

Special tools:
Hydraulic testing kit, PN 232 591 40
Crane
Hydraulic oil reservoir incl. back pressure valve: 3465 kg
Dogman/rigger

WARNING
oil reservoir.
z If required, install all provided parts (Fig. 3-94, Pos. 1 - 8) at

the new hydraulic oil reservoir.
NOTE: Use new gasket (Fig. 3-94, Pos. 6) at the cover

(Fig. 3-94, Pos. 7).
Use new filter units (Fig. 3-94, Pos. 4).
Check O-rings and replace if required.
z Replace the return oil strainer (Fig. 3-96, Pos. 1).
NOTE: Use new gaskets (Fig. 3-96, Pos. 2).
Fig. 3-96
z If required, install all provided parts (Fig. 3-95, Pos. 1 - 8) at

the new hydraulic oil reservoir.
NOTE: Use new gaskets (Fig. 3-95, Pos. 1 and 3) at the back
pressure valve (Fig. 3-95, Pos. 2).
Check O-rings and replace if required.
3 - 102 PC5500-6E Version 2010/1

NOTE: Use new bolts (Fig. 3-97, Pos. 1) of grade 10.9 at the
mounting flanges (Fig. 3-97, Pos. 3) of the hydraulic oil
threads of the bolts (Fig. 3-97, 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 SUCTION STRAINERS AND
PULSATION DAMPER"
No. "AH01513".
z Check and adjust the back pressure if required, refer to Ser-

vice Manual.
Fig. 3-97
Version 2010/1 PC5500-6E 3 - 103

3 - 104 PC5500-6E Version 2010/1

3.7.8 MAIN CONTROL VALVE BLOCKS
Fig. 3-98 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
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 2010/1 PC5500-6E 3 - 105

Fig. 3-99 Main control valve blocks 1 and 2 (BHA)
3 - 106 PC5500-6E Version 2010/1

Main control valve block I (BHA)

(L.H. Travel, stick, bucket, boom)
(46.1) High pressure filter, pump 2 and 5


(32.4) AVC Stick cylinder rod side

Main control valve block II (BHA)

(Bucket, Boom, Reserved, Stick)
(44.2) High pressure filter, pump 4
NOTE: The numbers in brackets are component numbers for the

hydraulic diagram.
NOTE: There is one MRV in each control block.
Version 2010/1 PC5500-6E 3 - 107

Fig. 3-100 Main control valve blocks 3 and 4 (BHA)
3 - 108 PC5500-6E Version 2010/1

Main control valve block III (BHA)

(R.H. Travel, boom, bucket, stick)


Main control valve block IV (BHA)

(Single spool for swing)

hydraulic diagram.
Version 2010/1 PC5500-6E 3 - 109

Fig. 3-101 Main control valve blocks 1 and 2 (FSA)
3 - 110 PC5500-6E Version 2010/1

Main control valve block I (FSA)

(L.H. Travel, stick, bucket, boom)
(46.1) High pressure filter, pump 2 an 5

(33.1) SRV Stick cylinder rod side

Main control valve block II (FSA)

(Bucket, boom, reserved, stick)
(32.9) ACV bull clam cylinder rod side
(32.10) ACV bull clam cylinder piston side
(30) SRV bull clam cylinder piston side

SRV (pressure increasing valve) Stick cylinder rod

(191)
side

hydraulic diagram.
Version 2010/1 PC5500-6E 3 - 111

Fig. 3-102 Main control valve blocks 3 and 4 (FSA)
3 - 112 PC5500-6E Version 2010/1

Main control valve block III (FSA)

(R.H. Travel, boom, bucket, stick)


Main control valve block IV (FSA)

(Single spool for swing)

hydraulic diagram.
Version 2010/1 PC5500-6E 3 - 113

3.7.8.1 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
6.6 on page 6-18.



voir.
PUMP".
Fig. 3-103
3 - 114 PC5500-6E Version 2010/1

WARNING
Hot hydraulic oil!
z Remove all SRVs from the main control valve block, refer to
section 3.7.9.1 on page 3-121.
z Remove all ACVs from the main control valve block, refer to
z If required, remove the load holding valves from the main

control valve block.
Version 2010/1 PC5500-6E 3 - 115

Fig. 3-104
z Disconnect all hydraulic lines (Fig. 3-104, Pos. 3) at the

respective main control valve block.
z Disconnect all pilot lines from the spool valves (Fig. 3-104,
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.
tion.
z Discard the O-rings (Fig. 3-104, Pos. 2) of the SAE flanges.
3 - 116 PC5500-6E Version 2010/1

z Disconnect the return line (Fig. 3-105, Pos. 1) at the respec-

tive main control valve block (I - IV) and discard the O-ring
(Fig. 3-219, Pos. 2) of the SAE flange.
NOTE: When the return line is removed, the oil inside the line will
tion.
Fig. 3-105
Removal of the Main control valve blocks I and III
z Disconnect the pressure line (Fig. 3-106, Pos. 1) at the

respective main control valve block (I or III) and discard the
O-ring (Fig. 3-106, Pos. 2) of the SAE flange.
NOTE: When the pressure line is removed, the oil inside the line
tion.
z Disconnect the harness connectors and clear the wiring har-

ness from the main control valve block.
Fig. 3-106
z Wind a lifting belt around the spool valves (Fig. 3-104, Pos. 1)
and sling the main control valve block at the lifting belt as
shown in Fig. 3-107.
z Remove the mounting bolts, and dismantle the main control

valve block from the control valve carrier using a crane.
Fig. 3-107
WARNING
When removing the main control valve blocks, make sure
that nobody steps below the weight.
Version 2010/1 PC5500-6E 3 - 117

Removal of the main control valve block II
z Remove the pressure filter (Fig. 3-108, Pos. 3) from the main
control valve block II (Fig. 3-108, Pos. 1).
z If required, disconnect the pressure lines (Fig. 3-108, Pos. 6)

from the pressure filter (Fig. 3-108, Pos. 3) and discard the O-
ring (Fig. 3-106, Pos. 2) at the pressure filter side (Fig. 3-108,
Pos. 3) and the quad ring (Fig. 3-108, Pos. 4) at the block
side (Fig. 3-108, Pos. 5).
NOTE: When the pressure lines are removed, the oil inside the
tion.
z Disconnect the harness connectors, and clear the wiring har- Fig. 3-108
z Wind a lifting belt around the spool valves, and sling the main
control valve block at the lifting belt as shown in Fig. 3-109.

Fig. 3-109
WARNING
3 - 118 PC5500-6E Version 2010/1

Removal of the main control valve block IV
z Disconnect the pressure line (Fig. 3-110, Pos. 3) at the main

control valve block (Fig.3-110, Pos.1), and discard the O-ring
(Fig. 3-110, Pos. 2) of the SAE flange.
z Remove the pressure filter (Fig. 3-110, Pos. 4) from the main
control valve block (Fig. 3-110, Pos. 1), and discard the
O-ring (Fig. 3-110, Pos. 2) at the pressure filter.
z If required, disconnect the pressure line (Fig. 3-110, Pos. 5)

from the pressure filter (Fig. 3-110, Pos. 4), and discard the
O-ring (Fig. 3-110, Pos. 2) of the SAE flange.
NOTE: When the pressure lines are removed, the oil inside the
Cap the openings with blind plugs to avoid contamina- Fig. 3-110
tion.
z Disconnect the harness connectors, and clear the wiring har-

z Sling main control valve block using suitable sling accessory.

WARNING
Version 2010/1 PC5500-6E 3 - 119

3.7.8.2 REPLACEMENT OF THE MAIN CONTROL VALVE BLOCKS

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.

grade 10.9 and new screw nuts (Fig. 3-111, Pos. 4) for
the respective main control valve block (I - III).
threads of the mounting bolts and tighten them to the
specified tightening torque.
Tightening torques for the mounting bolts

(Fig. 3-111, Pos. 1 and 2) at the main control
valve blocks: 510 Nm
NOTE: Use new mounting bolts (Fig. 3-111, Pos. 3) of grade 10.9
for main control valve block IV.
specified tightening torque. Fig. 3-111
Tightening torques for the mounting bolts

(Fig. 3-111, Pos. 3) at the main control valve
block IV: 265 Nm
z Mount the pressure filter at main control block II (Fig.3-108,

Pos. 3). If required, install the pressure lines using new bolts,
a new O-ring (Fig.3-108, Pos.2) and a new quad ring
(Fig 3-108, Pos. 4).
z Mount the pressure filter at main control block IV (Fig.3-110,

Pos. 4). If required, install the pressure lines using new bolts
and a new O-rings (Fig.3-110, Pos. 2).
NOTE: Refer to PARTS & SERVICE NEWS No. "AH05501".
3 - 120 PC5500-6E Version 2010/1

No. "AH01513".
z Check pressure of all circuits of the control valve block (use

400 bar gauge).
3.7.9 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 char-
acteristic. 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 3.7.11.1 on page 3-140.
NOTE: SRVs are also installed in the travel system, refer to sec-
tion 4.2.8.1 on page 4-41.
3.7.9.1 REMOVAL OF SRV ON MAIN CONTROL VALVE BLOCK
Special tools: n/a
NOTE: For additional information about the SRV on the main

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

voir.
reservoir. Refer to the Operation & Maintenance Manual,
PUMP".
Fig. 3-112
Version 2010/1 PC5500-6E 3 - 121

Fig. 3-113 SRV on the main control valve blocks (BHA)
Fig. 3-114 SRV on the main control valve blocks (FSA)
3 - 122 PC5500-6E Version 2010/1

WARNING
Hot hydraulic oil!
z Disconnect the hose from the SRV.
z Remove the four bolts (Fig. 3-113 or Fig. 3-114, Pos. 1)

attaching the SRV to the main control valve block.
z Remove the SRV (Fig. 3-113 or Fig. 3-114, Pos. 2), and cap
the openings with blind plugs to avoid contamination.
z Remove the O-rings (Fig. 3-115, Pos. 1) and discard them.
NOTE: Carry out the following steps only if required:
z Remove the support rings (Fig. 3-115, Pos. 2) from the valve
body (Fig. 3-115, Pos. 4).
z Remove the pressure relief valve (Fig. 3-115, Pos. 3) from the
valve body (Fig. 3-115, 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. Fig. 3-115
Version 2010/1 PC5500-6E 3 - 123

3.7.9.2 REPLACEMENT OF SRV ON MAIN CONTROL VALVE BLOCKS

paint before assembly.
z Fit new O-rings (Fig. 3-115, Pos. 1) to the SRV.
NOTE: If the pressure relief valve (Fig. 3-115, Pos. 3) was

removed from the valve body (Fig. 3-115, Pos. 4) tighten
it to the specified torque:
Tightening torque for the built-in SRV:

300 Nm
No. "AH01513".
z Check and adjust the SRV. Refer to Service Manual.
3 - 124 PC5500-6E Version 2010/1

Version 2010/1 PC5500-6E 3 - 125

3.7.10 ANTI-CAVITATION VALVES (ACV)
Fig. 3-116 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. 3-116, Pos. A/B) hold the
valve cone (Fig. 3-116, Pos. 2) closed. The pressure of the supply
line (Fig. 3-116, 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 - 126 PC5500-6E Version 2010/1

The ACVs are installed at the attachment manifold and at the

main control valve blocks.
3.7.10.1 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
6.6 on page 6-18.



voir.
PUMP".
Fig. 3-117
Version 2010/1 PC5500-6E 3 - 127

Fig. 3-118 Positions of the ACV at the BHA manifold
NOTE: The numbers (Fig.3-118, Pos.140.1 - 140.9) are compo-

nent numbers for the hydraulic diagram.
NOTE: For further information about the ACV at the BHA mani-
fold, refer to the hydraulic diagram and the Service Man-
ual.
3 - 128 PC5500-6E Version 2010/1

Fig. 3-119 Positions of the ACV at the FSA manifold
NOTE: The numbers (Fig.3-119, Pos.140.1 - 140.10) are compo-

NOTE: For further information about the ACV at the FSA mani-
ual.
Version 2010/1 PC5500-6E 3 - 129

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 follow-
ing four steps only if required:
WARNING
Hot hydraulic oil!
z If required, remove the throttle check valve to gain access

to the anti-cavitation valve, refer to section 3.7.11.1 on
page 3-140.
If required, remove the non return valve (analogously to throttle

check valve removal) to gain access to the anti-cavitation valve,
refer to section 3.7.11.1 on page 3-140.
z Remove the four bolts attaching the oil pipe (Fig. 3-120,
Pos. 3) to the main control valve block and the four bolts
(Fig. 3-120, Pos. 2) at the ACV (Fig. 3-120, Pos. 1) end.
z Remove the oil pipe and the two flange seals (Fig. 3-120,
Pos. 4). Discard the seals.
NOTE: When the pipe is disconnected, the oil inside the piping
tion.
Fig. 3-120
z Disconnect the flex hoses (Fig. 3-121, Pos. 2) and remove

the joint (Fig. 3-121, Pos. 3) from the anti-cavitation valve
(Fig. 3-121, 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. 3-121
3 - 130 PC5500-6E Version 2010/1

z Remove the four bolts (Fig. 3-122, Pos. 1) attaching the ACV
to the manifold.
z Remove the ACV (Fig. 3-122, Pos. 2) and the O-ring

(Fig. 3-122, Pos. 3). Discard the O-ring.
z If required, repeat the procedure to remove the other ACV

from the manifold.
Fig. 3-122
Version 2010/1 PC5500-6E 3 - 131

3.7.10.2 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. 3-123, Pos. 3) to the new ACV

(Fig. 3-123, Pos. 2).
z Apply compound "KP2K", PN 324 969 40 on threads of the

mounting bolts (Fig. 3-123, Pos. 1).
z Align the new ACV to the manifold and insert the mounting
bolts.
Fig. 3-123
NOTE: Carry out the following four steps only if required:
z If required, install the throttle check valve onto the ACV,

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

throttle check valve installation), refer to section 3.7.11.2
on page 3-143.
Maintenance Manual chapter 4, section "HYDRAULIC SYS-
No. "AH01513".
3 - 132 PC5500-6E Version 2010/1

3.7.10.3 REMOVAL OF ACV ON MAIN CONTROL VALVE BLOCKS
Special tools: n/a

NOTE: For additional information about the ACV on the main


voir.
PUMP".
Fig. 3-124
Version 2010/1 PC5500-6E 3 - 133

Fig. 3-125 ACV on the main control valve blocks (BHA)
Fig. 3-126 ACV on the main control valve blocks (FSA)
3 - 134 PC5500-6E Version 2010/1

NOTE: The numbers (Fig. 3-125 or Fig. 3-126, 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 Ser-
vice Manual.
WARNING
Hot hydraulic oil!
z Remove the four bolts (Fig. 3-125 or Fig. 3-126, Pos. 1)

attaching the ACV to the main control valve block.
z Remove the ACV (Fig. 3-125 or Fig. 3-126, 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. 3-127, Pos. 1) and discard them.
z Remove the support rings (Fig. 3-127, Pos. 2) from the valve
body (Fig. 3-127, Pos. 3) only if required.
Fig. 3-127
Version 2010/1 PC5500-6E 3 - 135

3.7.10.4 REPLACEMENT OF THE ACV ON MAIN CONTROL VALVE BLOCKS
Special tools: n/a


Fit new O-rings to the ACV (Fig. 3-127, Pos. 1).
No. "AH01513".
3 - 136 PC5500-6E Version 2010/1

Version 2010/1 PC5500-6E 3 - 137

3.7.11 THROTTLE CHECK VALVES
Fig. 3-128 Throttle check valve with built-in SRV
3 - 138 PC5500-6E Version 2010/1


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. 3-128, Pos.1). Depending on the pin setting, the radial holes
(Fig. 3-128, Pos. 9.1) in the valve sleeve (Fig. 3-128, Pos. 9) will
be opened partially to achieve the required throttling of the oil
flow. The safety holes (Fig. 3-128, Pos. 9.2) prevent the valve
from becoming completely closed.
For the lifting operation the valve sleeve which is guided by the
spindle (Fig. 3-128, Pos. 1) is pressed against the spring
(Fig. 3-128, Pos. 7) so that the valve will be completely open.
The build-in SRV (Fig. 3-128, 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 2010/1 PC5500-6E 3 - 139

3.7.11.1 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
6.6 on page 6-18.
Fig. 3-129 Positions of the throttle check valves BHA
NOTE: The numbers (Fig. 3-129, Pos. 138.1 - 145.5) are compo-
For further information about the SRV at the BHA mani-
ual.
3 - 140 PC5500-6E Version 2010/1

Fig. 3-130 Positions of the throttle check valves FSA
NOTE: The numbers (Fig. 3-130, Pos. 141.1 - 158) are compo-
For further information about the SRV at the FSA mani-
ual.



Version 2010/1 PC5500-6E 3 - 141

voir.
PUMP".
WARNING
Hot hydraulic oil!
Wait until the temperature of the hydraulic oil is below 50 °C. Fig. 3-131
z Disconnect the flex hose (Fig. 3-132, Pos. 5) from the throttle
check valve (Fig. 3-132, Pos. 1).
z Remove the four bolts (Fig. 3-132, Pos. 2) and remove the
pipe (Fig. 3-132, Pos. 3) from the throttle check valve
(Fig. 3-132, Pos. 1).
NOTE: When the hydraulic lines are removed, the oil inside the
piping and the valve will flow out. Catch it in an oil pan.
tion.
Fig. 3-132
z Remove the four bolts (Fig. 3-133, Pos. 5) attaching the throt-
tle check valve (Fig. 3-133, Pos. 1) to the manifold
(Fig. 3-133, Pos. 2).
z Remove the throttle check valve (Fig. 3-133, Pos. 1) and the
O-ring (Fig. 3-133, 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 contami-
nation.
z If required, remove the adaptor (Fig. 3-133, Pos. 4) from the

throttle check valve.
Fig. 3-133
z If required, repeat the procedure to remove the other throttle

check valves from the manifold.
z If required, remove the built-in SRV (Fig. 3-128, Pos. 13) from
the throttle check valve’s housing (Fig. 3-128, Pos. 11).
3 - 142 PC5500-6E Version 2010/1

3.7.11.2 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. 3-133, Pos. 3) to the throttle check
valve (Fig. 3-133, Pos. 1).
NOTE: If the built-in SRV (Fig. 3-128, Pos. 13) has been
removed from the housing (Fig. 3-128, 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. 3-133, Pos. 5).
Maintenance Manual, section 4.13.
z Check and adjust the throttle check valve. Refer to the

Service Manual, section 8.1.11.
z Check and adjust the built-in SRV in the throttle check valves
if required. Refer to the Service Manual, section 8.1.10.
Version 2010/1 PC5500-6E 3 - 143

3.7.12 MANIFOLD
3.7.12.1 REMOVAL OF THE MANIFOLD
Special tools: n/a

Oil drain pan
Manifold BHA incl. ACVs and SRVs: 921.2 kg

Manifold FSA incl. ACVs and SRVs: 893.2 kg
Dogman/rigger
6.6 on page 6-18.



voir.
PUMP".
Fig. 3-134
3 - 144 PC5500-6E Version 2010/1

WARNING
Hot hydraulic oil!
z Disconnect all hydraulic hoses (Fig. 3-135, 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 5-142 (FSA).
WARNING
Always wear a safety harness when working at the front side
of the manifold.
z Disconnect the hydraulic piping (Fig. 3-135, Pos. 2) at the

front of the manifold.
NOTE: When the hydraulic lines are removed, the oil inside the Fig. 3-135
hydraulic lines will flow out. Catch it in an oil pan.
tion.
z Sling the manifold.
z Remove four mounting bolts (Fig. 3-135, Pos. 3).
z Remove the manifold using a crane.
z Remove the anti cavitation valves (ACV) from the manifold,

z Remove the throttle check valves from the manifold, refer to

DANGER
May result in death or serious injury
When removing the manifold, make sure that nobody steps
below the weight.
Version 2010/1 PC5500-6E 3 - 145

3.7.12.2 REPLACEMENT OF THE MANIFOLD
Special tools: n/a

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. 3-135,
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 - 146 PC5500-6E Version 2010/1

Superstructure Slew system
3.8 SLEW SYSTEM
Fig. 3-136
The PC5500-6 is equipped with two slew gear arrangements.

For further information, refer to the Service Manual.
Multi disc brakes (Fig. 3-136, Pos. 3) are installed between the
swing motors (Fig. 3-136, Pos. 2) and the gearboxes (Fig. 3-136,
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. 3-136,

Pos. 1) are directly flanged to the swing motor heads. For further
information, refer to the Service Manual.
Version 2010/1 PC5500-6E 3 - 147

Slew system Superstructure
3.8.1 SLEW GEAR
Fig. 3-137 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 - 148 PC5500-6E Version 2010/1

3.8.1.1 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
6.6 on page 6-18.



voir.
Fig. 3-138
z Remove the swing motor (Fig. 3-137, Pos. 2) from the slew
gearbox (Fig. 3-137, Pos. 3), refer to section 3.8.2.1 on page
3-159. Leave the hydraulic hoses and the slew service brake
valve (Fig. 3-137, Pos. 1) attached to the swing motor if pos-
sible. If not disconnect the hydraulic lines.
Version 2010/1 PC5500-6E 3 - 149

z Remove the bleeder valves (Fig. 3-139, Pos. 1)
Drain the gear oil from the slew gear (Fig. 3-139,
Pos. 3 respectively Pos. 5) at the drain coupling
(Fig. 3-139, 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"
z Remove the oil drain coupling (Fig. 3-139, Pos. 2), and, if
equipped with, remove the union (Fig. 3-139, Pos. 4) from the
slew gear (Fig. 3-139, Pos. 3 respectively Pos. 5).
Fig. 3-139
DANGER
Blindness, serious injury, permanent disfigurement, or scar-
ing may result.
z 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. Cap the
3 - 150 PC5500-6E Version 2010/1

z Removing the rear slew gear, the hydraulic line (Fig. 3-140,
Pos. 2) and the mounting (Fig. 3-140, 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.
tion.
Fig. 3-140
Version 2010/1 PC5500-6E 3 - 151

Fig. 3-141 Slew gear (Siebenhaar)
z Remove the protection caps (Fig. 3-141, Pos. 1) from the bolt
heads and remove the slew gear mounting bolts (Fig. 3-141,
Pos. 2) and washers (Fig. 3-141, Pos. 3). Discard the bolts.
z Disconnect the lubrication lines below the slew gear.
z Install four swivel hoist rings (M16) displaced by 90° into the
threaded bores for the swing motor mounting bolts and attach
a crane.
3 - 152 PC5500-6E Version 2010/1

z Remove the slew gear using a crane.
DANGER
When removing the slew gear, make sure that nobody steps
below the weight.
3.8.1.2 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".
Version 2010/1 PC5500-6E 3 - 153

Fig. 3-142 Slew gear unit (Siebenhaar)
3 - 154 PC5500-6E Version 2010/1

a crane.
z Insert the new slew gear (Fig. 3-142, Pos. 3) and mount it to
the superstructure with the mounting bolts (Fig. 3-142,
Pos. 1) and the washers (Fig. 3-142, Pos. 2).
NOTE: Use new slew gear mounting bolts (Fig. 3-142, Pos. 1) of
grade 12.9. 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 the slew gear mounting

bolts: 1030 Nm
z Install the oil drain coupling (Fig. 3-143, Pos. 2) with the union
(Fig. 3-143, Pos. 4) if equipped, at the new slew gear
(Fig. 3-143, Pos. 3 respectively Pos. 5).
z Clean the bleeder valves (Fig. 3-143, Pos. 1) with com-

pressed air from inside to outside and reinstall at the new
slew gear (Fig. 3-143, Pos. 3 respectively Pos. 5).
Fig. 3-143
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 3.8.2.2
on page 3-162.
Version 2010/1 PC5500-6E 3 - 155

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.
NOTE: Refer to the Operation & Maintenance

Manual, chapter 4, section "SWING
GEARS AND MOTOR ADAPTER HOUS-
ING - CHANGE OIL".
For the proper lubricant, refer to the Opera-

tion & Maintenance Manual, chapter 4,
section "FLUIDS AND LUBRICANTS".
z Check the tooth backlash between slew ring and slew pinion
with a feeler gauge.
Refer to PARTS & SERVICE NEWS No. "AH00511".
3 - 156 PC5500-6E Version 2010/1

Version 2010/1 PC5500-6E 3 - 157

3.8.2 SWING MOTOR
Fig. 3-144 Swing motor assembly
(1) Bolt (12) Bolt (only Siebenhaar)
(2) Slew brake valve (13) Washer (only Siebenhaar)
Expansion tank of the slew gear

(3) O-ring (14)
(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 - 158 PC5500-6E Version 2010/1

3.8.2.1 REMOVAL OF THE SWING MOTOR
Special tools: n/a
Crane
Oil drain pan
Swing motor: 170 kg

Slew brake valve: 97 kg
Dogman/rigger
6.6 on page 6-18.



voir.
Fig. 3-145
WARNING
Hot hydraulic oil!
Version 2010/1 PC5500-6E 3 - 159

Drain gear oil from the motor adapter housing.

Refer to the Operation & Maintenance Manual, chap-
ter 4, section "SWING GEARS AND MOTOR
ADAPTER HOUSING - CHANGE OIL"
z Disconnect all hydraulic hoses (Fig. 3-146, Pos. 1), attached

to the swing motor (Fig. 3-146, Pos. 2).
NOTE: When the hydraulic hoses are disconnected, hydraulic oil

from inside the hoses and the swing motor will flow out.
tion.
Fig. 3-146
Fig. 3-147 Removal of the swing motor
3 - 160 PC5500-6E Version 2010/1

z Remove the four mounting bolts (Fig. 3-147, Pos. 1) and take
the slew brake valve (Fig. 3-147, Pos. 2) off. Discard the
O-ring (Fig. 3-147, 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.
tion.
z Remove the mounting bolts (Fig. 3-147, Pos. 4) and take off
the intermediate plate (Fig. 3-147, Pos. 5). Discard the O-ring
(Fig. 3-147, Pos. 6).
z Only slew gear (Siebenhaar): Remove the bolts (Fig. 3-147,

Pos. 12), with washers (Fig. 3-147, Pos. 13), and the sleeves
(Fig. 3-147,Pos. 15). Put the expansion tank (Fig. 3-147,
Pos. 14) of the slew gear aside. Discard the bolts.
z Remove the bolts (Fig. 3-147, Pos. 7) and the washers

(Fig. 3-147, Pos. 8). Discard the bolts.
z Sling the swing motor (Fig. 3-147, Pos. 9).
z Pull the swing motor out of the slew gear (Fig. 3-147, Pos. 11)
using a crane. Place the swing motor on the ground.
DANGER
When removing the swing motor, make sure that nobody
steps below the weight.
Version 2010/1 PC5500-6E 3 - 161

3.8.2.2 REPLACEMENT OF THE SWING MOTOR
Crane
Swing motor: 170 kg

Dogman/rigger

Fig. 3-148 Installation of the swing motor
3 - 162 PC5500-6E Version 2010/1

Fit new O-rings (Fig. 3-148, 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. 3-148,

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 mount-

ing bolts: 265 Nm

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".

Maintenance Manual, chapter 4, section "FLUIDS
AND LUBRICANTS".
z Check the adjustments of the swing motors.

Refer to the Service Manual for further information.
z Check the slew brake valve and adjust it if required.

Version 2010/1 PC5500-6E 3 - 163

3 - 164 PC5500-6E Version 2010/1

3.8.3 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
Version 2010/1 PC5500-6E 3 - 165

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 gearbox 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 park-
ing 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.
z 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.
3 - 166 PC5500-6E Version 2010/1

3.8.3.1 REMOVAL/DISASSEMBLY OF THE SLEW PARKING BRAKE (L&S)
Special tools: n/a

Crane
Swing motor with attached slew service brake valve: 292.5 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 disassem-
bling it.
z Remove the swing motor from the slew gear, refer to section
3.8.2.1 on page 3-159. 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

a crane.
z Remove the mounting bolts (Fig. 3-149, Pos. 1) at the swing

motor flange.
z Remove the inner snap ring (Fig. 3-149, Pos. 2).
z Dismantle the bearing ring (Fig. 3-149, Pos. 3) from the slew
gearbox using a crane.
Fig. 3-149
Version 2010/1 PC5500-6E 3 - 167

Fig. 3-150 Slew parking brake (L&S)
z Check rotary shaft seal (Fig. 3-150, Pos. 16) for wear and
damage. Replace it if required.
z Disconnect the pressure hose from the oil pressure port

(Fig. 3-150, Pos. 13).
NOTE: When the pressure hose is removed, the oil inside the
hose and the cylinder (Fig. 3-150, Pos. 17) will flow out.
tion.
WARNING
The piston (Fig. 3-150, Pos. 6) of the break assembly is
spring loaded.
z Remove the two socket head cap bolts (Fig. 3-150, Pos. 14)
and relieve the spring load of the springs (Fig. 3-150, Pos. 9)
on the piston (Fig. 3-150, Pos. 6).
z Take off the cylinder assembly (Fig. 3-150, Pos. 17).
3 - 168 PC5500-6E Version 2010/1

z Dismount 10 inner discs (Fig. 3-150, Pos. 3), 11 outer discs

(Fig. 3-150, Pos. 4), and 10 sinus spacer rings (Fig. 3-150,
Pos. 5) from the disc housing (Fig. 3-150, Pos. 1).
z Remove the drive shaft (Fig. 3-150, Pos. 12).
z Remove the thrust washer (Fig. 3-150, Pos. 2) from the disc
housing (Fig. 3-150, Pos. 1).
z Check the inner discs (Fig. 3-150, Pos. 3), the outer discs
(Fig. 3-150, Pos. 4), the sinus spacer rings (Fig. 3-150,
Pos. 5), and the thrust washer (Fig. 3-150, Pos. 2) for wear
and damage. Replace if required.
Version 2010/1 PC5500-6E 3 - 169

3.8.3.2 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. 3-151 Slew parking brake (L&S)
3 - 170 PC5500-6E Version 2010/1

NOTE: Replace all O-rings.
For further information relating the parking brake, refer to

z Install the thrust washer (Fig. 3-151, Pos. 2).
z Install the drive shaft (Fig. 3-151, 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. 3-151, Pos. 4), then an inner disc
(Fig. 3-151, Pos. 3), and then a sinus spacer ring
(Fig. 3-151, Pos. 5). Apply oil to the discs.
NOTE: Before reinstallation, apply pressure (max. 60 bar) to the

cylinder assembly (Fig. 3-151, Pos. 17), otherwise the
two socket head cap bolts (Fig. 3-151, Pos. 14) are pre-
stressed (spring loaded).
z Install the cylinder assembly (Fig. 3-151, Pos. 17).
WARNING
Make sure to use the specified bolts and torque for the swing
motor mounting bolts, refer to section 3.8.2.2 on page 3-162.

approx. 0.6 liters.

AND LUBRICANTS".
z Check slew parking brake for proper function.

Refer to the Service Manual.
Version 2010/1 PC5500-6E 3 - 171

3 - 172 PC5500-6E Version 2010/1

3.8.3.3 REMOVAL OF THE SLEW PARKING BRAKE (SIEBENHAAR)
Special tools: n/a

Crane

Slew parking brake assembly: 115 kg
Dogman/rigger
6.6 on page 6-18.
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 3.8.2.1 on page 3-159. Leave the hydraulic hoses and
the slew service brake valve (Fig. 3-137, 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 open-
ings with blind plugs to avoid contamination.
DANGER
ing may result. The hydraulic system may be pressurized.
z Disconnect the pilot oil pressure line from the slew parking
brake.
NOTE: When the pilot oil pressure line is disconnected, the oil
inside the line will flow out. Catch it in an oil pan. Cap the
Version 2010/1 PC5500-6E 3 - 173

z Remove all hydraulic pipes (Fig. 3-152, Pos. 3) from the slew
parking brake (Fig. 3-152, Pos.23) and cap the openings with
blind plugs to avoid contamination.
DANGER
Danger of parts blasting off!
Serious injury, permanent disfigurement and scarring, or
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. 3-152,
Pos. 1) attaching the complete slew parking brake (Fig. 3-152,
Pos. 2) to the slew gearbox (Fig. 3-152, Pos. 4).
Never open the brake by removing the flange mounting bolts Fig. 3-152
(Fig. 3-153, Pos. 3) before the slew parking brake is manually
released!
Fig. 3-153 Slew parking brake (Siebenhaar), drawn released
3 - 174 PC5500-6E Version 2010/1

Releasing the slew parking brake manually:
z Insert two crews (Fig. 3-154, Pos. 1) of suitable length with

nuts (Fig. 3-154, Pos. 3) in the threaded borings
(Fig. 3-153, Pos. 2) of the piston (Fig. 3-154, Pos. 2) opposed
to each other.
z Tighten each nut (Fig. 3-154, Pos. 3) alternately with a half

turn, to withdraw the piston Fig. 3-154, Pos. 2) to the flange
(Fig. 3-154, Pos. 4).
NOTE: Avoid tilting the piston!
z Only remove the mounting bolts (Fig. 3-152 and 3-153,

Pos. 1) attaching the complete slew parking brake Fig. 3-154
(Fig. 3-154, Pos. 2) to the slew gearbox.
DANGER
Serious injury, permanent disfigurement and scarring,
or death may result!
loaded.
Never open the brake by removing the flange mounting bolts
released!
z Insert swivel hoist rings (M16) displaced by 180° into the

threads of the swing motor mounting bolts and attach a crane.
z Remove the slew parking brake (Fig. 3-152, Pos. 2) from the
slew gearbox (Fig. 3-152, Pos. 4), using a crane.
DANGER
below the weight.
Version 2010/1 PC5500-6E 3 - 175

3.8.3.4 REPLACEMENT OF THE SLEW PARKING BRAKE (SIEBENHAAR)
Special tools: n/a
Crane
Paste "Optimol White", PN 999 039

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. 3-155 Slew parking brake (Siebenhaar), drawn released
3 - 176 PC5500-6E Version 2010/1

DANGER
Serious injury, permanent disfigurement and scarring, or
death may result!
loaded.
Never open the brake by removing the flange mounting bolts
released!
z Apply paste "Optimol White" on the spline shaft at the adapter

cover (Fig. 3-156, Pos. 4) of the gearbox.
z 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.
z Insert a new O-Ring (Fig. 3-156, Pos. 3).
z Centre the new pre-assembled slew parking brake

(Fig. 3-156, Pos. 2) onto the adapter cover (Fig. 3-156,
Pos. 4) of the gearbox.
DANGER
Fig. 3-156
below the weight.
Releasing the slew parking brake manually:
z Insert two bolts (Fig. 3-157, Pos. 1) of suitable length with

nuts (Fig. 3-157, Pos. 3) in the threaded borings
(Fig. 3-155, Pos. 2) of the piston (Fig. 3-157, Pos. 2) opposed
to each other.
z Tighten each nut (Fig. 3-157, Pos. 3) alternately with a half

turn, to withdraw the piston Fig. 3-157, Pos. 2) to the flange
(Fig. 3-157, Pos. 4).
NOTE: Avoid tilting the piston!
z Turn the slew parking brake (Fig. 3-156, Pos. 2) until the
bores in slew parking brake are aligned to threads in the Fig. 3-157
adapter cover (Fig. 3-156, Pos. 3).
z Insert new mounting bolts (Fig. 3-156, Pos. 1) and tighten
them crosswise.
z Remove the release bolts (Fig. 3-157, Pos. 1) with nuts alter-
nately stepwise to prevent the piston from tilting.
Version 2010/1 PC5500-6E 3 - 177

WARNING
Make sure to use the specified bolts and torques for the
swing motor mounting bolts, refer to section 3.8.2.2 on page
3-162.
Fill oil into the motor adapter housing, up to level

gauge marking.
Fill oil in the brake housing approx. 0.2 liters.

AND LUBRICANTS".
z Check slew parking brake for proper function. Refer to the

Service Manual.
3 - 178 PC5500-6E Version 2010/1

Version 2010/1 PC5500-6E 3 - 179

3.8.4 DYNAMIC SLEW BRAKE
Fig. 3-158 Slew brake valve
3 - 180 PC5500-6E Version 2010/1

(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. 3-158, 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-cavita-
tion valves (Fig. 3-158, Pos. 4 and 5) and opens the check valves
(Fig. 3-158, Pos. 2 and 3). That means the service lines are con-
nected to the pressure increase valve by the check valves
(Fig. 3-158, 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 2010/1 PC5500-6E 3 - 181

The low pressure return line becomes pressurized and the pres-
surized 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 block’s pressure increase valve.
Fig. 3-159 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. 3-159, Pos. 12), the pretension of the spring (Fig. 3-159,
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. 3-159,

Pos. 13) and via the jet bore (Fig. 3-159, Pos. 6) in the chamber
of the spring (Fig. 3-159, Pos. 7) as well. System pressure also is
present at the pressure relief valve cone (Fig. 3-159, Pos. 9) via
the jet bore (Fig. 3-159, Pos. 8).
Due to the force balance, the piston (Fig. 3-159, Pos. 13) is kept
in its position, supported by the spring (Fig. 3-159, Pos. 7).
If the system pressure is higher than the setting of the valve
(Fig. 3-159, Pos. 9) the valve opens a channel to the drain port Y.
Due to the drop of pressure, the piston (Fig. 3-159, Pos. 13) is
moved by the spring (Fig. 3-159, Pos. 7). The pressure line is
connected to the return line T.
Dampened opening and closing is obtained by the throttled volu-
metric change that is caused by the jet bores.
3 - 182 PC5500-6E Version 2010/1

3.8.4.1 REMOVAL OF THE SLEW BRAKE VALVE
Special tools: n/a
Dogman/rigger
6.6 on page 6-18.



voir.
Fig. 3-160
Version 2010/1 PC5500-6E 3 - 183

WARNING
Hot hydraulic oil!
z Disconnect the service hoses (Fig. 3-161, Pos. 2), the return
hose (Fig. 3-161, Pos. 3), the leak oil hose (Fig. 3-161,
Pos. 4), and the pilot hose (Fig. 3-161, Pos. 5) from the slew
brake valve (Fig. 3-161, Pos. 6).
NOTE: When the hydraulic hoses are removed, hydraulic oil

from inside the valve and the piping will flow out.
tion.
z Sling the slew brake valve (Fig. 3-161, Pos. 6).
z Remove the four mounting bolts (Fig. 3-161, Pos. 1) and

demount the slew brake valve (Fig. 3-161, Pos. 6) from the Fig. 3-161
swing motor (Fig. 3-161, Pos. 7), using a crane.
DANGER
When removing the slew brake valve, make sure that nobody
z Discard the O-ring from below the slew brake valve

(Fig. 3-161, 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.
tion.
3 - 184 PC5500-6E Version 2010/1

3.8.4.2 REPLACEMENT OF THE SLEW BRAKE VALVE
Dogman/rigger

Fit new O-rings below the slew brake valve and the
SAE flanges.

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

Service Manual.
Version 2010/1 PC5500-6E 3 - 185

3.8.5 SWING CIRCLE
Fig. 3-162 Slew ring assembly
3 - 186 PC5500-6E Version 2010/1

(1) Superstructure
(2) Swing circle
(3) Bolt
(4) Washer
(5) Swing circle protection covers
(6) Washer
(7) Bolt
(8) Car body
(9) Bolt
The swing circle is the movable connection between the super-

structure 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.
Version 2010/1 PC5500-6E 3 - 187

3 - 188 PC5500-6E Version 2010/1

3.8.5.1 REMOVAL OF THE SWING CIRCLE
Mounting cross, PN 477 577 40

Special tools: Hydraulic torque wrench, PN 232 615 40
Electro-hydraulic pump aggregate, PN 793 375 73
55 mm hexagon impact socket wrench (1 1/2"), PN 232 519 40
Additional equipment: 2 x Crane (2nd. crane for superstructure lifting)
Swing circle: 10,000 kg
Dogman/rigger

the machine, boom, and two cranes.

z Remove the superstructure from the car body (counterweight,

fluids and attachment removed), refer to section 3.14.1 on
page 3-256.
z 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.
Version 2010/1 PC5500-6E 3 - 189

z Before removing swing circle, mark location of both slew rings

to superstructure and the car body as well for further investi-
gations.
z Disconnect all slew ring bearing lubrication hoses (Fig. 3-163,

Pos. 1) from the inner slew ring (Fig. 3-163, Pos. 3), removing
the unions (Fig. 3-163, Pos. 2).
Fig. 3-163
z Position the mounting cross, PN 477 577 40 underneath the

swing circle.
z 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. 3-164, 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. 3-164
z Lift the mounting cross (Fig. 3-165, Pos. 1) to place it under

the swing circle (Fig. 3-165, Pos. 2).
z Remove the mounting bolts of the inner slew ring to dismount

the swing circle (Fig. 3-165, Pos. 2) from the superstructure
(Fig. 3-165, Pos. 3).
NOTE: In order to avoid damage to the lifting devices, use edge

protection at all sharp edges.
Fig. 3-165
3 - 190 PC5500-6E Version 2010/1

z Lower the mounting cross with the swing circle (Fig. 3-166,
Pos. 3) resting on it to the ground.
NOTE: The guides (Fig. 3-166, Pos. 2) ensure that the swing
circle is aligned accurately with the superstructure
(Fig. 3-166, Pos. 1) while it is removed and installed
respectively.
Do not loosen nor remove the guides, if the swing circle

will be re-installed.
Fig. 3-166
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 2010/1 PC5500-6E 3 - 191

3.8.5.2 REPLACEMENT OF THE SWING CIRCLE
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
Special tools: weather) respectively, PN 409 484 40
Test block, PN 379 077 40
Hydraulic torque wrench, PN 232 615 40
2 x Crane (2nd. crane for superstructure lifting)

Additional equipment: Laser device for checking the level of bearing area
Swing circle: 10,000 kg
Dogman/rigger

z Check the wear of the swing circle pinions at the slew gears,
refer to PARTS & SERVICE NEWS No. "AH05518".
z Check the level of bearing area with a laser device before

installing a new slew ring. Refer to PARTS & SERVICE
NEWS No. "AH00511".
z 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
z Shocks to the swing circle (especially radial shocks)
must be avoided.
z Transport and store the new swing circle exclusively with

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

the transport star.
z 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.
z Only hang swing circle at four swivel hoist rings evenly

distributed in screw circle of the inner slew ring.
3 - 192 PC5500-6E Version 2010/1

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
z Place the swing circle (Fig. 3-167, Pos. 2) onto the mounting
cross (Fig. 3-167, Pos. 1).
z Centre the swing circle (Fig. 3-167, Pos. 2) on the mounting

cross (Fig. 3-167, Pos. 1) using the transport star.
z Position the mounting cross with the swing circle resting on it

under the superstructure (Fig. 3-167, Pos. 3) and connect the
mounting cross to a crane.
Fig. 3-167
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. 3-164, 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. 3-168
Version 2010/1 PC5500-6E 3 - 193

Fig. 3-169 Swing circle installation
z Mating surfaces between superstructure platform (Fig. 3-169,

Pos. 6) and swing circle (Fig. 3-169, Pos. 5) must be abso-
lutely fat-free. Even the solvent must be rinsed away before
assembling.
z Check flatness of the mating surfaces.
z Prepare new bolts (Fig. 3-169, Pos. 3) and washers

(Fig. 3-169, Pos. 4). Lubricate the threads and the head
surface of the bolts with compound "KP2K", PN 324 969 40.
3 - 194 PC5500-6E Version 2010/1

z 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. 3-169, 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. 3-169.
z Align the teeth of the outer slew ring with the lubrication pin-
ions and the pinions of the slew gears.
z Lift the swing circle (Fig. 3-170, Pos. 3) to approx. 10 mm

below the superstructure platform (Fig. 3-170, Pos. 1) by
means of the mounting cross.
z Align the holes in the inner slew ring with the treads in the
superstructure platform (observe the unhardened "S-spots").
NOTE: When re-installing the swing circle, the guides

(Fig. 3-170, Pos. 2) ensure that the swing circle is aligned
accurately into its original mounting position, so no
adjusting of the tooth backlash is required.
When installing a new swing circle, it could be necessary
to loosen the guides due to disparities in the inner diame-
ter of the inner slew ring of the swing circle.
Fig. 3-170
Do not remove the guides after installation.
z Install the mounting bolts (Fig. 3-169, Pos. 3) with washers

(Fig. 3-169, Pos. 4) to the inner slew ring.
z Join the swing circle (Fig. 3-169, Pos. 5) on to the supporting

surface at the superstructure platform (Fig. 3-169, Pos. 6) by
tightening the bolts crosswise manually.
z Remove the mounting cross.
z Connect all lubrication lines (Fig. 3-171, Pos. 1) to the unions

(Fig. 3-171, Pos. 2) at the inner slew ring (Fig. 3-171, Pos. 3).
Fig. 3-171
Version 2010/1 PC5500-6E 3 - 195

z Check the tooth backlash between slew ring and slew pinions
with a feeler gauge and adjust it if required.
Tighten all bolts (Fig. 3-169, 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. 3-169, 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, repeat adjustment.
z Make sure that the guides (Fig. 3-170, Pos. 2) are in touch
with the inner diameter surface of the inner slew ring.
z Lift the superstructure and install it onto the undercarriage,

DANGER
When lifting the superstructure, make sure that nobody

3 - 196 PC5500-6E Version 2010/1

Version 2010/1 PC5500-6E 3 - 197

Lubrication system Superstructure
3.9 LUBRICATION SYSTEM
3.9.1 SWING CIRCLE LUBRICATION PINION (DUMMY WHEEL)
Fig. 3-172 Slew ring lubrication
3 - 198 PC5500-6E Version 2010/1

Superstructure Lubrication system
(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
Lubrication pinion center shaft with distributing

(10)
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. 3-172, Pos. 1) is identical with
the central lubrication system (CLS), refer to section 3.9.2 on
page 3-204. To apply the lubricant equably to the outer slew ring
teeth (Fig. 3-172, Pos. 7), a special lubrication pinion (Fig. 3-172,
Pos. 8) is mounted near the drive pinion of the front slew gear.
The lubrication pinion (Fig. 3-172, Pos. 8) distributes the lubricant
from the injectors (Fig. 3-172, Pos. 3) evenly to the teeth. Nor-
mally two or more small SL1 injectors (Fig. 3-172, Pos. 3) are
parallel connected to supply the required amount of lubricant to
the lubrication pinion.
NOTE: The pinion center shaft (Fig. 3-172, 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. 3-172, Pos. 9 on different position of
the pinion gear distribute the lubricant equably to the
outer slew ring teeth (Fig. 3-172, Pos. 7).
Version 2010/1 PC5500-6E 3 - 199

3.9.1.1 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.
z 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.

WARNING
Before maintenance, set the key-operated main switch to
"OFF" and the maintenance safety switch (Fig. 3-173, Pos. 1)
to "0" position to prevent operation of the electric motors
during work.
Fold up flap (Fig. 3-173, Pos. 2) and secure this position by
inserting a padlock into the holes (Fig. 3-173, Pos. 4) of the
flap and the safety switch.
Assure that the system pressure of the lubrication system is

relieved before maintenance.
Fig. 3-173
z Relieve system pressure of the lubrication system by actuat-

ing the vent valve (Fig. 3-181, Pos. 2) by hand, refer to
WARNING
Always wear a safety harness when working at the lubrica-
tion pinion.
NOTE: A second person is required for the work at the lubrica-

tion pinion.
3 - 200 PC5500-6E Version 2010/1

Fig. 3-174 Lubrication pinion assembly, removal and replacement
z Remove the mounting bolts (Fig. 3-174, Pos. 6) with sleeves

(Fig. 3-174, Pos. 7) and remove the pinion cover (Fig. 3-174,
Pos. 1).
NOTE: A second person is required for this work.
z Disconnect the lubrication lines (Fig. 3-174, Pos. 4).
z Remove the nuts (Fig. 3-174, Pos. 5) and take the lubrication
pinion assembly (Fig. 3-174, Pos. 3) with connector plate
(Fig. 3-174, Pos. 2) off the superstructure.
Version 2010/1 PC5500-6E 3 - 201

3.9.1.2 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 lubrica-
tion pinion.
z After installation is complete, the swing circle lubrication sys-

tem 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.
z Reset the lubrication cycle counter of the slew ring lubrication

system. Refer to the Operation & Maintenance Manual, chap-
ter 3, section "SWING CIRCLE PINION LUBRICATION SYS-
TEM SLS”.
3 - 202 PC5500-6E Version 2010/1

Version 2010/1 PC5500-6E 3 - 203

3.9.2 LUBRICATION PUMP STATION
Fig. 3-175 Lubrication pump station (old version)
3 - 204 PC5500-6E Version 2010/1

(1) Coupling on service arm for filling up the grease con-

tainer (3) of the swing circle lubrication system (SLS)
(2) Grease filter of the swing circle lubrication system

(SLS)
(3) Grease container of the swing circle lubrication sys-

tem (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 con-
tainer (9) of the central lubrication system (CLS)
(8) Grease filter of the central lubrication system (CLS)
Grease container of the central lubrication system

(9)
(CLS)
(11) Grease pressure gauge for CLS
(12) Mounting bolts of the grease pump station
The lubrication includes two single lubrication pumps and a

grease container for each lubrication pump.
Each lubrication pump has its own lubrication system:
– One lubrication pump of the central lubrication system (CLS).
– One lubrication pump of the swing circle pinion lubrication

system (SLS).
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 vis-
cosity 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 drive’s hydraulic cylinder and the pump. The pump drive
and only the pump outlet are outside on top of the lubricant con-
tainer, the pump itself is inside and reaches into the lubricant.
Version 2010/1 PC5500-6E 3 - 205

Fig. 3-176 Lubrication pump station (actual version)
3 - 206 PC5500-6E Version 2010/1

(1) Grease container of the swing circle lubrication sys-

tem (SLS)
(2) Grease container of the central lubrication system

(CLS) for the lubrication of the swing connection
bearing and of the boom cylinder foot bearing
(3) Grease container of the central lubrication system

(CLS) for the lubrication of the attachment
(5) Grease filter of the swing circle lubrication system

(SLS)
(6) Grease filter of the central lubrication system (CLS)

(7) Grease pressure gauge
(8) In-line high pressure grease filters
The lubrication pump station includes three single lubrication

pumps and a grease container for each lubrication pump.
Each lubrication pump provides different group of components
with grease:
– One lubrication pump for the lubrication of the attachment

(CLS).
– One lubrication pump for the lubrication of the swing connec-

tion bearing and of the boom cylinder foot bearing (CLS).
– One lubrication pump of the swing circle pinion lubrication

system (SLS).
NOTE: The grease containers (Fig. 3-179, Pos. 1 and 2) are

linked together by an opening in the upper part of the of
the containers. This is for grease level compensation dur-
ing refilling.
Version 2010/1 PC5500-6E 3 - 207

3.9.2.1 REMOVAL OF THE LUBRICATION PUMP STATION
Special tools: n/a

Double lubrication pump station: 415 kg

Triple lubrication pump station: 618 kg
Dogman/rigger
NOTE: The removal of the triple lubrication station is analogously

the same.


WARNING
during work.

Fig. 3-177

ing the vent valve by hand, refer to PARTS & SERVICE
NEWS No. "AH05546".
3 - 208 PC5500-6E Version 2010/1

z Disconnect all hydraulic and grease lines (Fig. 3-178, Pos.1)

from the front roof plate.
z Disconnect the wire harnesses from the end of line pressure

switches B43, B46, and B174 (only triple pump). Clear the
harnesses from the lubrication pump station.
z Sling the lubrication pump station (Fig. 3-178, Pos. 3) at the

lifting eyes (Fig. 3-178, see arrows).
z Remove the bolts (Fig. 3-178, Pos. 2) and remove the lubrica-
tion pump station from the roof using a crane.
DANGER
When lifting the lubrication pump station, make sure that
nobody steps below the weight. Fig. 3-178
Version 2010/1 PC5500-6E 3 - 209

3.9.2.2 REPLACEMENT OF THE LUBRICATION PUMP STATION
Special tools: n/a

Double lubrication pump station: 415 kg

Triple lubrication pump station: 618 kg
Dogman/rigger

NOTE: The replacement of the triple lubrication station is

analogously the same as of the double station.
z If required, bleed the pump at the breather port (Fig. 3-178,

Pos. 1).
NOTE: Make sure that the grease hoses are filled with grease.
Therefore it may be necessary to carry out some lubrica-
tion cycles manually.
z Make sure that the end of line pressure switches (see follow-
ing table) are pressurized. If not, start a lubrication cycle of
the corresponding lubrication pump by actuating the appropri-
ate switch at the operator’s console, see following table:
Fig. 3-179
Pressure
Switch Lubrication system
switch
S24 B43 CLS
S26 B46 SLS
Separate attachment lubrication pump

S99 B174
(CLS, triple pump station only)
NOTE: There may be a time gap of up to 11 minutes until the

next manually started cycle is carried out. Refer to the
time table in the flowchart.
z Adjust the lubrication pump speed and pressure.

Refer to the Service Manual.
3 - 210 PC5500-6E Version 2010/1

3.9.3 REMOVAL OF THE LUBRICATION PUMP

Special tools: n/a
Lubrication pump: 28 kg
Dogman/rigger


WARNING
during work.

Fig. 3-180

ing the vent valve (Fig. 3-181, Pos. 1) by hand, refer to
z Disconnect the hydraulic lines (Fig. 3-181, Pos. 2) from the

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

(Fig. 3-181, Pos. 3).
Fig. 3-181
Version 2010/1 PC5500-6E 3 - 211

z Disconnect the grease feeding line (Fig. 3-182, Pos. 1) from

the lubrication pump.
Fig. 3-182
z Remove the bolt (Fig. 3-183, Pos. 1).
Fig. 3-183
z Sling the lubrication pump (Fig. 3-183, Pos. 1) at the installed

lifting eye (Fig. 3-183, Pos. 1) and pull the lubrication pump
out of the grease container.
Fig. 3-184
3 - 212 PC5500-6E Version 2010/1

3.9.4 REPLACEMENT OF THE LUBRICATION PUMP

Special tools: n/a
Lubrication pump: 28 kg
Dogman/rigger

z After replacement, bleed the pump at the breather port

(Fig. 3-185, Pos. 1).
Fig. 3-185
z Adjust the lubrication pump speed and pressure. Refer to the
Service Manual.
Version 2010/1 PC5500-6E 3 - 213

Operator’s cab Superstructure
3.10 OPERATOR’S CAB
Fig. 3-186 Operator’s cab overview
3 - 214 PC5500-6E Version 2010/1

Superstructure Operator’s cab
A Rear View of Operator’s 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
B Front View of Operator’s Cab
(10) Release lever for door lock (2 - 3)
(11) Door opener push button
(12) Lock lever
(13)
Control levers for working attachment
(14) Operator’s seat
(15) Upper windshield wiper

(16) Lower windshield wiper
WARNING
The operator’s cab is equipped with an integrated Falling
Object Protective Structure (FOPS) that meets the require-
ments 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 manufacturer’s repair instructions.
Version 2010/1 PC5500-6E 3 - 215

3 - 216 PC5500-6E Version 2010/1

3.10.1 REMOVAL OF THE OPERATOR’S CAB

Special tools: n/a

Operator’s cab: 3785 kg
Dogman/rigger
Air condition service specialist
6.6 on page 6-18.


DANGER
Hazardous Voltage!
The following safety measures have to be carried out before
any work on the high voltage system by authorized electri-
cians having the permission to work on high voltage sys-
tems only.

z Remove the keys from the battery main switches.
WARNING
Always wear a safety harness when working at the operator’s
cab.
Version 2010/1 PC5500-6E 3 - 217

z Dismount the grommet plate (Fig. 3-187, Pos. 1) inside the

cab base.
If the machine is equipped with harness connectors:
z Disconnect all harness connectors at the back side of the

grommet plate.
z Disconnect all other harnesses leading to the operator’s

cab from the X2-board and pull it out of the grommet
plate.
If the machine is not equipped with harness connectors:
z Disconnect all harnesses leading to the operator’s cab Fig. 3-187

from the X2C-board and remove the cable transfer ele-
ments.
z Dismount the grommet plate (Fig. 3-188, Pos. 1) above the

X2-board inside the cab base.
If the machine is equipped with harness connectors:
z Disconnect all harness connectors of the manipulators at

the back side of the grommet plate.
If the machine is not equipped with harness connectors:
z Disconnect all harnesses leading to the operator’s cab

from the X2-board and remove the cable transfer ele-
ments.
Fig. 3-188
z Remove the ground cable (Fig. 3-189, Pos. 1) in the cab base
(Fig. 3-189, Pos. 2) from the left lower fixing bolt at the
X2-board and pull it out of the grommet plate.
Fig. 3-189
3 - 218 PC5500-6E Version 2010/1

z Remove the cover (Fig. 3-190, Pos. 1) inside the cab base.
z Disconnect the hose (Fig. 3-190, Pos. 2) between cab sup-

port and operator’s cab from the upper side of the cover.
Fig. 3-190
WARNING
The air conditioning must be serviced by authorized service
specialists only.
z Aspirate the refrigerant from the air condition system.
z Disconnect the refrigerant lines (Fig. 3-191, Pos. 2) from the

air conditioning unit (Fig. 3-191, Pos. 1).
NOTE: Cap the openings with blind plugs to avoid contamination

of the air conditioning system.
z Disconnect the condensate lines (Fig. 3-191, Pos. 3) from the

air conditioning unit (Fig. 3-191, Pos. 1).
z Clear all hoses from the operator’s cab. Fig. 3-191
z Sling the operator’s cab (Fig. 3-192, Pos. 2) at the lifting eye
bolts (Fig. 3-192, Pos. 1) delivered with the cab.
Fig. 3-192
Version 2010/1 PC5500-6E 3 - 219

Fig. 3-193 Removal of the operator’s cab, overview
z Remove the hose (Fig. 3-193, Pos. 7) of the operator’s cab

water supply.
z Open the hose clips (Fig. 3-193, Pos. 5) and remove the
water hoses (Fig. 3-193, Pos. 6).
z Remove the gratings (Fig. 3-193, Pos. 8) from the cab sup-
port (Fig. 3-193, Pos. 9).
z Remove the bolts (Fig. 3-193, Pos. 2) and resilient sleeves

(Fig. 3-193, Pos. 3) from the viscous mounts (Fig. 3-193,
Pos. 4).
3 - 220 PC5500-6E Version 2010/1

z Remove operator’s cab (Fig. 3-193, Pos. 1) using a crane.
NOTE: Lift the operator´s cab slowly while using a second per-
son inside the cab base to guide the harnesses through
the grommet plates.
DANGER
When lifting the operator’s cab make sure that nobody steps
below the weight.
Version 2010/1 PC5500-6E 3 - 221

3.10.2 REPLACEMENT OF THE OPERATOR’S CAB

Special tools: n/a

Crane
Dogman/rigger
Air condition service specialist

Fig. 3-194 Replacement of the operator’s cab, overview
3 - 222 PC5500-6E Version 2010/1

WARNING
z Always wear a safety harness when working at the opera-
tor’s cab.
z Ensure no one stands between the cabin and the cab

base during lowering.
DANGER
When lifting the operator’s cab make sure that nobody steps
below the weight.
NOTE: Use new bolts (Fig. 3-194, Pos. 2) of the grade 10.9 at
the viscous mounts (Fig. 3-194, Pos. 4).
torque.
Tightening torque for the mounting bolts

(Fig. 3-194, Pos. 2): 880 Nm
NOTE: When lowering the operator’s cab have a second person

inside the cab base to guide the harnesses through the
grommet plates.
z Evacuate the air conditioning system and add refrigerant.
WARNING
The air conditioning must be filled with refrigerant "R134a"
by authorized service specialists only.
Version 2010/1 PC5500-6E 3 - 223

3.10.3 VISCOUS CAB-MOUNTS
3.10.3.1 REMOVAL OF THE VISCOUS CAB-MOUNTS
Special tools: n/a


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


WARNING
cab.
z Sling the operator’s cab (Fig. 3-192, Pos. 2) at the lifting eye
bolts (Fig. 3-192, Pos. 1) delivered with the cab.
Fig. 3-195
3 - 224 PC5500-6E Version 2010/1

Fig. 3-196 Removal of the viscous cab-mounts, overview
z Remove the gratings (Fig. 3-196, Pos. 8) from the cab sup-
port (Fig. 3-196, Pos. 9).
z Remove the bolts (Fig. 3-196, Pos. 2) and resilient sleeves

(Fig. 3-196, Pos. 3) from the viscous mounts (Fig. 3-193,
Pos. 4).
z Raise the operator’s cab (Fig. 3-193, Pos. 1) only a few milli-
meters, just enough to clear the viscous mounts (Fig. 3-193,
Pos. 4).
z Remove the bolts (Fig. 3-196, Pos. 5) from the absorber plate
(Fig. 3-196, Pos. 6) and remove the absorber plate with the
viscous mounts.
z Remove the bolts (Fig. 3-196, Pos. 7) and dismount the vis-
cous mounts (Fig. 3-193, Pos. 4) from the absorber plate
(Fig. 3-196, Pos. 6).
Version 2010/1 PC5500-6E 3 - 225

3.10.3.2 REPLACEMENT OF THE CAB-MOUNTS
Special tools: n/a

Crane

Viscous mount: 4 kg
Dogman/rigger

Fig. 3-197 Replacement of the cab-mounts, overview
3 - 226 PC5500-6E Version 2010/1

WARNING
cab.
NOTE: Always use new mounting bolts of the grade 10.9.

torque.

(Fig. 3-197, Pos. 7) at the cab mounts
(Fig. 3-197, Pos. 4): 180 Nm

(Fig. 3-197, Pos. 5) at the absorber plates
(Fig. 3-197, Pos. 6): 880 Nm
Tightening torque for the operator’s cab mount-

ing bolts (Fig. 3-197, Pos. 2): 880 Nm
Version 2010/1 PC5500-6E 3 - 227

3.10.4 FRONT WINDOW (WINDSCREEN)
3.10.4.1 REMOVAL OF THE FRONT WINDOW
Special tools: n/a
Suction lifters with hoist rings

Crane
Front window: 112 kg
Dogman/rigger


WARNING
cab.
z Remove the wiper arms (Fig. 3-198, Pos. 1).
z Use suction lifters with hoist rings at the front window

(Fig. 3-198, Pos. 4) to sling the front window.
z Remove the bolts (Fig. 3-198, Pos. 2).

Hold nut (Fig. 3-198, Pos. 3) from inside the cab.
z Remove the front window (Fig. 3-198, Pos. 4) using a crane.
DANGER
When removing the front window, make sure that nobody
Fig. 3-198
3 - 228 PC5500-6E Version 2010/1

3.10.4.2 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 instal-
lation of the front window.
Version 2010/1 PC5500-6E 3 - 229

3.10.5 OPERATOR’S SEAT
3.10.5.1 REMOVAL OF THE OPERATOR’S SEAT
Special tools: n/a
Operator’s seat: 62 kg
Dogman/rigger


z Disconnect the wire harness connector (Fig. 3-199, Pos. 1) of

the air suspension.
z Remove both control lever carriers (Fig. 3-199, Pos. 2 and 8).
z Remove all mounting bolts (Fig. 3-199, Pos. 6) from the cover
plate (Fig. 3-199, Pos. 7) on the heating console (Fig. 3-199,
Pos. 5).
z Remove the cover plate (Fig. 3-199, Pos. 5) from the opera-
tor’s seat (Fig. 3-199, Pos. 9) by removing all mounting bolts
(Fig. 3-199, Pos. 4) and lock washers (Fig. 3-199, Pos. 3).
NOTE: A second person is required to carry the operator’s seat

out of the operator’s cab.
Fig. 3-199
3 - 230 PC5500-6E Version 2010/1

z Sling the operator’s seat and lift it off the machine using a
crane.
DANGER
When lifting the operator’s seat, make sure that nobody
3.10.5.2 REPLACEMENT OF THE OPERATOR’S SEAT
Special tools: n/a
Operator’s seat: 62 kg
Dogman/rigger

z Remove both control lever carriers from the new seat.
DANGER
When lifting the operator’s seat, make sure that nobody
NOTE: A second person is required to carry the operator’s seat

into the operator’s cab.
Version 2010/1 PC5500-6E 3 - 231

3.10.6 ECS
3.10.6.1 REMOVAL OF THE ECS TEXT DISPLAY
Special tools: n/a
z Open the operator’s console.
z Disconnect the data cables (Fig. 3-200, Pos. 1 and 2) from

the ECS text display (Fig. 3-200, Pos. 4).
z Remove the wing nuts (Fig. 3-200, Pos. 3) and take the ECS
text display (Fig. 3-200, Pos. 4) out of the operator’s console.
Fig. 3-200
3.10.6.2 REPLACEMENT OF THE ECS TEXT DISPLAY
Special tools: n/a
z Set time, date and operating hours, refer to the Operation &
Maintenance Manual, chapter 3, section "ELECTRONIC
MONITORING AND CONTROL SYSTEM ECS".
3 - 232 PC5500-6E Version 2010/1

Superstructure Cab base (medium voltage switch cabinet)
3.11 CAB BASE (MEDIUM VOLTAGE SWITCH CABINET)
3.11.1 REMOVAL OF THE CAB BASE

Special tools: Electro-hydraulic pump aggregate, PN 793 375 73

Crane
Forklift
Support frame: 987 kg
Cab base: 4000 kg
Emergency exit ladder: 56 kg
Dogman/rigger

the machine, boom, elevator working platform and crane.

DANGER
Hazardous Voltage!

WARNING
Always wear a safety harness when working at the cab base.
Version 2010/1 PC5500-6E 3 - 233

Cab base (medium voltage switch cabinet) Superstructure
z Remove the operator’s cab (Fig. 3-201, Pos. 1),

z Remove the emergency exit ladder (Fig. 3-201, Pos. 2).
NOTE: For safety reasons, the handrails at the cab support

frame (Fig. 3-201, Pos. 3) remain mounted.
Fig. 3-201
z Disconnect all wire harnesses leading to the cab base inside

the cab base.
z Clear all wire harnesses from the cable channel underneath

the cab base.
z Disconnect the extinguishing agent hose (Fig. 3-202, Pos. 1)

of the fire suppression system between the cab base
(Fig. 3-202, Pos. 3) and the high voltage switch (Fig. 3-202,
Pos. 2) cabinet from the union at the cab base.
z If equipped, disconnect the extinguishing agent hose

of the fire suppression system between the cab base and the
slip ring assembly (Fig. 3-202, Pos. 4) from the union at the
cab base.
Fig. 3-202
z Sling the support frame (Fig. 3-203, Pos. 2).
z Remove the bolts (Fig. 3-203, Pos. 1) from within the cab
base (Fig. 3-203, Pos. 3) and remove the support frame
(Fig. 3-203, Pos. 2) using a crane.
Fig. 3-203
3 - 234 PC5500-6E Version 2010/1

z Install four swivel hoist rings (M36) and sling the cab base
(Fig. 3-204, Pos. 1) at the installed hoist rings, refer to
Fig. 3-205.
z Remove bolts (Fig. 3-204, Pos. 2 and 3) attaching the cab

base to the superstructure (Fig. 3-204, Pos. 4).
Fig. 3-204
z Remove the cab base using a crane.
DANGER
When moving cab base, make sure that nobody steps below
the lifted cab base.
Fig. 3-205
Version 2010/1 PC5500-6E 3 - 235

3.11.2 REPLACEMENT OF THE CAB BASE


Crane
Compound "Epple 28", PN 592 199 40
Compound "Loctite 222", PN 414 299 40
Support frame: 987 kg
Cab base: 4000 kg
Dogman/rigger

WARNING
Always wear a safety harness when working at the cab base.
z Install four swivel hoist rings (M36) and sling the new cab
base at the hoist rings.
z Lift the cab base and align it with the superstructure using a
crane (Fig. 3-206).
DANGER
When lifting the cab base, make sure that nobody steps
below the weight.
Fig. 3-206
3 - 236 PC5500-6E Version 2010/1

z Install the bolts (Fig. 3-207, Pos. 2 and 3) attaching the cab
base (Fig. 3-207, Pos. 1) to the superstructure (Fig. 3-207,
Pos. 4).
NOTE: Use new mounting bolts (Fig. 3-207, 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
Tightening torque for cab base mounting bolts

(Fig. 3-207, Pos. 2 and 3): 3100 Nm
Fig. 3-207
z Apply sealing compound "Epple 28" onto the whole contact

surfaces (Fig. 3-208, arrows) of the cab base.
z Install the support frame (Fig. 3-208, Pos. 2) using a crane.
z Install bolts (Fig. 3-208, Pos. 1) attaching the support frame

(Fig. 3-208, Pos. 2) to the cab base (Fig. 3-208, Pos. 3).
NOTE: Use new mounting bolts (Fig. 3-208, Pos. 1) of grade

10.9. Apply compound "Loctite 222" on the threads of all
bolts (Fig. 3-208, Pos. 1), and tighten the mounting bolts
to the specified tightening torque.
Tightening torque for support frame mounting

bolts (Fig. 3-208, Pos. 1): 265 Nm Fig. 3-208
Version 2010/1 PC5500-6E 3 - 237

3.11.3 PUMP CONTROLLER
3.11.3.1 REMOVAL OF THE PUMP CONTROLLER
Special tools: n/a
DANGER
Hazardous Voltage!

z Remove the wiring harness connector X14 (Fig. 3-209,

Pos. 2) from the electronic pump controller RC4
(Fig. 3-209, Pos. 3).
z Remove four bolts and remove the pump controller RC4 from
the wall of the cab base (Fig. 3-209, Pos. 1).
Fig. 3-209
3 - 238 PC5500-6E Version 2010/1

3.11.3.2 REPLACEMENT OF THE PUMP CONTROLLER
Special tools: n/a


z Check and adjust the parameters of the pump controller.

Version 2010/1 PC5500-6E 3 - 239

Access ladder Superstructure
3.12 ACCESS LADDER
Fig. 3-210 Access ladder assembly
3 - 240 PC5500-6E Version 2010/1

Superstructure Access ladder
(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 2010/1 PC5500-6E 3 - 241

Fig. 3-211 Access ladder removal
3 - 242 PC5500-6E Version 2010/1

3.12.1 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. 3-211, Pos. 1) to the ground.

z 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 motor 2.
WARNING
z Provide an adequate working platform for safe access to
the access ladder bearing.

access ladder assembly.
z Secure the access ladder cylinder (Fig. 3-211, Pos. 4) in its

position.
Version 2010/1 PC5500-6E 3 - 243

Fig. 3-212 Access ladder replacement
3 - 244 PC5500-6E Version 2010/1

CAUTION
Assure that the pressure in the hydraulic system is com-
pletely relieved before removing the pivot pin (Fig. 3-212,
Pos. 2).
z Clear the access ladder (Fig. 3-212, Pos. 1) by removing the

pin (Fig. 3-212, Pos. 2) from the access ladder cylinder mov-
ing rod.
z Sling the access ladder and remove the self locking nuts
(Fig. 3-212, Pos. 10) from the ladder bearing assemblies
(Fig. 3-212, Pos. 15).
z Remove the ladder bearing assemblies and the ladder. Rest it

on the ground.
3.12.2 REPLACEMENT OF THE ACCESS LADDER

Special tools: n/a

Access ladder: 167 kg
Dogman/rigger

WARNING

NOTE: Apply grease to the pin (Fig. 3-212, Pos. 2) at the access
ladder cylinder moving rod.
NOTE: Always use new self-locking nuts (Fig. 3-212, Pos. 10).
Tightening procedure for the self-locking nuts

(Fig. 3-212, Pos. 10): 1000 Nm
Version 2010/1 PC5500-6E 3 - 245

Fig. 3-213 Access ladder cylinder removal
3 - 246 PC5500-6E Version 2010/1

3.12.3 REMOVAL OF THE ACCESS LADDER CYLINDER

Special tools: n/a

Oil drain pan
Crane
Access ladder cylinder: 23 kg
6.6 on page 6-18.

the machine, boom, and elevator working platform.

z Lower the access ladder (Fig. 3-213, Pos. 1) to the ground.

NOTE: Relieve the remaining pilot pressure at the Minimess test

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

z Assure that the pressure in the hydraulic system is com-

pletely relieved before removing the pivot pin (Fig. 3-213,
Pos. 10) or disconnecting any hydraulic hoses.
z Remove hydraulic hoses (Fig. 3-213, Pos. 8 and 9) with the

socket (Fig. 3-213, Pos. 8) from the access ladder cylinder
(Fig. 3-213, Pos. 4).
NOTE: When the hydraulic hoses are removed, hydraulic oil

from inside the piping will flow out.
tion.
Version 2010/1 PC5500-6E 3 - 247

Fig. 3-214 Access ladder cylinder installation
3 - 248 PC5500-6E Version 2010/1

z Support the access ladder cylinder (Fig. 3-214, Pos. 4) from

the bottom side.
z Remove the pins (Fig. 3-214, Pos. 2 and 3) and remove the
access ladder cylinder (Fig. 3-214, Pos. 4).
3.12.4 REPLACEMENT OF THE ACCESS LADDER CYLINDER

Special tools: n/a

Oil drain pan
Crane
Access ladder cylinder: 23 kg

WARNING

NOTE: Apply grease to the pins (Fig. 3-214, Pos. 2 and 3).

Version 2010/1 PC5500-6E 3 - 249

Counterweight Superstructure
3.13 COUNTERWEIGHT
DANGER
Risk of explosion!
Blindness, serious injury, permanent disfigurement and
scarring, or death may result.
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 counter-
weight chambers!
NOTE: The chambers of the counterweight are filled with a mix-

ture of concrete, granulated ore and steel pellets. This
mixture can create explosive gases which will accumu-
late 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 counter-
weight 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.
3.13.1 REMOVAL OF THE COUNTERWEIGHT


Additional equipment: Mobile elevator working platform
Crane
Counterweight: 42,000 kg (BHA) / 46,000 kg (FSA)
Dogman/rigger

3 - 250 PC5500-6E Version 2010/1

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

WARNING
Always wear a safety harness when working at the counter-
weight.
z Remove the rails (Fig. 3-215, Pos. 1) from the counterweight.
z Remove all additional equipment from the counterweight, if

required.
z Remove the tanks (Fig. 3-215, Pos. 2) and wires of the Fire
Detection and Suppression System, if equipped.
WARNING
Fig. 3-215
tional.
Version 2010/1 PC5500-6E 3 - 251

Fig. 3-216 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. 3-216, Pos. 2 to 4) is not exceeded.
z Sling the counterweight (Fig. 3-216, Pos. 1) at the installed

lifting eyes.
3 - 252 PC5500-6E Version 2010/1

z Remove all mounting bolts (Fig. 3-216, Pos. 5).
z Remove the counterweight using the crane.
DANGER
When moving the counterweight, make sure that nobody
steps below the lifted counterweight.
Version 2010/1 PC5500-6E 3 - 253

3.13.2 REPLACEMENT OF THE COUNTERWEIGHT


Crane
Counterweight: 42,000 kg (BHA) / 46,000 kg (FSA)
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.
WARNING
Make sure that the maximum rope angle of 40° is not
exceeded. Refer to Fig. 3-216, Pos. 3.
NOTE: Apply compound "KP2K", PN 324 969 40 on heads and

threads of the bolts. Tighten the mounting bolts to the
Tightening torque for the counterweight

3 - 254 PC5500-6E Version 2010/1

Version 2010/1 PC5500-6E 3 - 255

Superstructure lifting Superstructure
3.14 SUPERSTRUCTURE LIFTING
3.14.1 REMOVE THE SUPERSTRUCTURE FROM THE UNDERCARRIAGE


Additional equipment: Mobile elevator working platform
2 x crane
Superstructure without counterweight, attachment and fluids:

150,000 kg
Dogman/rigger
Crane operators trained in dual crane lift
6.6 on page 6-18.



DANGER
Hazardous Voltage!

3 - 256 PC5500-6E Version 2010/1

Superstructure Superstructure lifting
z Relieve the pressure in the track tensioning system by open-

ing the ball cock (Fig. 3-217, Pos. 1) at the track tensioning
valve block (Fig. 3-217, Pos. 2) inside the car body.
Fig. 3-217
voir.
PUMP".
WARNING
Always wear a safety harness when working in height.
Fig. 3-218
Version 2010/1 PC5500-6E 3 - 257

Fig. 3-219 Superstructure lifting
z Remove the counterweight from the superstructure, refer to

z Install shackles (Fig. 3-219, Pos. 6) delivered with the

machine to the flanges of the counterweight using the mount-
ing bolts of the counterweight.
Tighten the mounting bolts to the specified tightening torque.

7500 Nm
3 - 258 PC5500-6E Version 2010/1

z Remove the complete attachment, refer to section 5.1 on

page 5-2.
z Remove the slip ring unit,

z Disconnect all hydraulic hoses leading to the superstructure

from the rotary joint, refer to section 4.3.5.1 on page 4-98.
If the machine is equipped with slew ring protection covers

(Fig. 3-219, Pos. 9):
z Remove all bolts (Fig. 3-219, Pos. 7) and resilient sleeves

(Fig. 3-219, Pos. 8) attaching the protection covers to the
superstructure (Fig. 3-219, Pos. 4).
z 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.
z Attach the superstructure to two cranes.
z Remove all bolts (Fig. 3-219, Pos. 1) and washers

(Fig. 3-219, Pos. 2) attaching the slew ring to the undercar-
riage (Fig. 3-219, Pos. 5).
z Lift off the superstructure using the two cranes and rest it on
appropriate supports on the ground.
DANGER
When moving the superstructure, make sure that nobody
steps below the lifted weight.
Version 2010/1 PC5500-6E 3 - 259

3 - 260 PC5500-6E Version 2010/1

3.14.2 INSTALL THE SUPERSTRUCTURE ONTO THE UNDERCARRIAGE
Measuring jaw, PN 376 792 40

Measuring bolt, PN 409 437 40
or measuring bolt (cold weather design), PN 409 484 40
Special tools: Gauge device (test block) for bolts M36, PN 379 077 40

Additional equipment: 2 x Crane
2 thread pins (M 36 x 250)
Superstructure without counterweight, attachment and fluids:

150,000 kg
Dogman/rigger

WARNING
Always wear a safety harness when working in height.
DANGER
Hazardous Voltage!

Version 2010/1 PC5500-6E 3 - 261

Fig. 3-220 Superstructure lifting
3 - 262 PC5500-6E Version 2010/1

z Clean the contact surfaces of the slew ring (Fig. 3-220,

Pos. 3) and the undercarriage (Fig. 3-220, Pos. 5) very care-
fully and thoroughly.
NOTE: Check the level of the bearing area with a laser device
before installing a new slew ring. Refer to PARTS & SER-
VICE NEWS No. "AH00511"
z Remove the torque support lever of the rotary joint before

installing the superstructure, refer to section 4.3.5.1 on page
4-98.
WARNING
Before lifting the superstructure, make sure that the crane
operators are trained in dual crane lift.
z Attach the superstructure to two cranes and lift it up. Refer to

Fig. 3-220.
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. 3-221, Pos. 1 and 2). Refer to
z Align the spots (Fig. 3-221, Pos. S) to each other.
z Prepare new bolts, washers and sleeves. Lubricate the

threads and the head surface of the bolts with compound
"KP2K", PN 324 969 40.
Fig. 3-221
z Align the superstructure to the undercarriage and lower the
superstructure.
z To simplify the alignment of the slew ring to the under-

carriage, install two thread pins (M36 x 250) displaced by
180° at the outer slew ring.
z Insert 4 bolts (Fig. 3-220, Pos. 1) with washers (Fig. 3-220,

Pos. 2) displaced by 90° and lower the superstructure.
z Remove the two thread pins from the outer slew ring.
Version 2010/1 PC5500-6E 3 - 263

z 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, refer to

z Reinstall the slip ring unit,

WARNING
Make sure to use the specified bolts and torque for the
torque support lever mounting bolts, refer to section 4.3.5.2
on page 4-101.
3 - 264 PC5500-6E Version 2010/1

Version 2010/1 PC5500-6E 3 - 265

High voltage switch cabinet Superstructure
3.15 HIGH VOLTAGE SWITCH CABINET
Fig. 3-222 High voltage switch cabinet, overview
3 - 266 PC5500-6E Version 2010/1

Superstructure High voltage switch cabinet
(1) High voltage switch cabinet
(2) Bolt
(3) Wing nut (plastic)
(4) Grating
(5) Threaded block
(6) Bolt with washer
(7) Cable channel

(8) Bolt
(9) Superstructure platform
(10) Bolt
(11) Cover
(12) Bolt
(13) Nut
Version 2010/1 PC5500-6E 3 - 267

3.15.1 REMOVAL OF THE HIGH VOLTAGE SWITCH CABINET


Additional equipment: 4 x Swivel hoist ring (M36)
Forklift
Crane
High voltage switch cabinet: 6200 kg

Platform: 150 kg
Support frame (operator’s cab): 987 kg
Dogman/rigger


DANGER
Hazardous Voltage!
The following safety measures have to be carried out before
any work on the high voltage system by authorized
electricians having the permission to work on high voltage
systems only.

WARNING
Always wear a safety harness when working at the high
voltage cabinet.
3 - 268 PC5500-6E Version 2010/1

z Remove the operator’s cab (Fig. 3-223, Pos. 1),

z Remove the mounting bolts attaching the emergency ladder

(Fig. 3-223, Pos. 2) to the operator’s cab support frame (Fig.
3-223, Pos. 3).
Fig. 3-223
z If equipped, remove the platform (Fig. 3-224, Pos. 1):
z Support the platform (Fig. 3-224, Pos. 1) with a forklift.
z Remove the grating (Fig. 3-224, Pos. 3).
z Remove the bolts (Fig. 3-224, Pos. 4) and resilient

z Lower the platform to the ground.
Fig. 3-224
z Clear all hoses and wire harnesses from the support frame
(Fig. 3-225, Pos. 2).
z Sling the support frame.
z Remove the bolts (Fig. 3-225, Pos. 1) from within the cab
base (Fig. 3-225, Pos. 3) and remove the support frame
(Fig. 3-225, Pos. 2) using a crane.
Fig. 3-225
Version 2010/1 PC5500-6E 3 - 269

z Disconnect the extinguishing agent hose (Fig. 3-226, Pos. 2)

of the fire suppression system at the pipework attached to the
high voltage switch cabinet (Fig. 3-226, Pos. 1).
Fig. 3-226
z Disconnect the wire harnesses between the high voltage

cabinet and the cab base inside the high voltage cabinet.
z Pull the disconnected wire harnesses out of the high voltage

cabinet.
z Disconnect the high voltage power supply cable between the

slip ring and the high voltage cabinet from the load cut-off
switch inside the high voltage switch cabinet.
z Disconnect the high voltage power supply cables leading to

the electric motors inside the high voltage switch cabinet.
z Pull the disconnected high voltage cables out of the high volt-
age switch cabinet.
z Open the cable channel underneath the high voltage switch

cabinet and clear all wire harnesses and hoses from the high
voltage switch cabinet.
z Insert 4 swivel hoist rings at the top of the high voltage switch
cabinet.
z Attach the high voltage cabinet to a crane.
3 - 270 PC5500-6E Version 2010/1

z Remove the mounting bolts (Fig. 3-227, Pos. 2 and 3) and lift
the high voltage cabinet (Fig. 3-227, Pos. 1) off the super-
structure (Fig. 3-227, Pos. 4).
DANGER
When lifting the high voltage switch cabinet, make sure that
NOTE: Discard the mounting bolts (Fig. 3-227, Pos. 2 and 3).
Fig. 3-227
z Dismantle the handrails and all other parts from the high
voltage switch cabinet.
Version 2010/1 PC5500-6E 3 - 271

3.15.2 REPLACEMENT OF THE HIGH VOLTAGE CABINET


Crane
High voltage switch cabinet: 6200 kg

Platform: 150 kg
Support frame (operator’s cab): 987 kg
Dogman/rigger

WARNING
Always wear a safety harness when working at the high
voltage cabinet.
DANGER
Hazardous Voltage!
3 - 272 PC5500-6E Version 2010/1

DANGER
When lifting the high voltage cabinet, make sure that nobody

grade 10.9 to attach the high voltage switch cabinet
(Fig. 3-228, Pos. 1) to the superstructure platform
(Fig. 3-228, Pos. 4).
Apply compound "KP2K", PN 324 969 40 to the heads
and threads of the mounting bolts, and tighten the mount-
ing bolts to the specified tightening torque:
Tightening torque for high voltage switch cabinet

mounting bolts (Fig. 3-228, Pos. 2 and 3): 3100 Nm Fig. 3-228
Version 2010/1 PC5500-6E 3 - 273

Slip ring unit Superstructure
3.16 SLIP RING UNIT
Fig. 3-229 Slip ring unit, overview
(1) Slip ring unit

(2) Carrier
(3) Cam
(4) Rotary joint

(5) Bolt
(6) Washer
(7) Nut
3 - 274 PC5500-6E Version 2010/1

Superstructure Slip ring unit
3.16.1 REMOVAL OF THE SLIP RING UNIT

Special tools: n/a
Slip ring unit: 355 kg
Dogman/rigger


DANGER
Hazardous Voltage!

z Remove the boom arc hoses over the slip ring unit, refer to
section 5.1.6.1 on page 5-58 (BHA) or refer to section 5.2.6.1
on page 5-142 (FSA).
z Open the slip ring unit (Fig. 3-230, Pos. 1) and disconnect the
high voltage power supply cables and wiring leading into the
slip ring unit.
z If equipped, disconnect the extinguishing agent hose

(Fig. 3-230, Pos. 2) of the fire suppression system from the
slip ring unit.
z Sling the slip ring unit at the installed hoist rings to a crane.
Fig. 3-230
Version 2010/1 PC5500-6E 3 - 275

Fig. 3-231
z Remove the nuts (Fig. 3-231, Pos. 7), washers (Fig. 3-231,
Pos. 6), and the mounting bolts (Fig. 3-231, Pos. 5) attaching
the slip ring unit to the carriers (Fig. 3-231, Pos. 2) fixed at the
superstructure.
3 - 276 PC5500-6E Version 2010/1

Superstructure Slip ring unit
z Lift the slip ring from the machine and put it down on the
ground carefully.
DANGER
When lifting the slip ring unit, make sure that nobody steps
below the weight.
3.16.2 REPLACEMENT OF THE SLIP RING UNIT

Special tools: n/a
Slip ring unit: 355 kg
Dogman/rigger

DANGER
Hazardous Voltage!
NOTE: When lifting the slip ring unit onto the carriers, make sure
that the cam (Fig. 3-231, Pos. 3) fits accurately in the
counterpart of the bottom plate of the slip ring unit.
Version 2010/1 PC5500-6E 3 - 277

3 - 278 PC5500-6E Version 2010/1

Undercarriage
4 UNDERCARRIAGE
Version 2010/1 PC5500-6E 4 -1

Undercarriage overview Undercarriage
4.1 UNDERCARRIAGE OVERVIEW
Fig. 4-1 PC5500-6E, undercarriage
4 -2 PC5500-6E Version 2010/1

Undercarriage Undercarriage overview
(1) Car body
(2) Track tensioning valve block
(3) Rotary joint

(4) Guide wheel (idler)
(5) Track tensioning cylinder
(6) Low pressure accumulator

(7) Carrier roller
(8) Crawler carrier
(9) Drive Sprocket
(10) Travel gear
(11) Cable drum assembly
(12) High voltage power supply cable
(13) Travel brake valve block
(14) High pressure accumulator
(15) Track group
(16) Track roller
(17) Travel motor
Version 2010/1 PC5500-6E 4 -3

Travel system Undercarriage
4.2 TRAVEL SYSTEM
4.2.1 TRACK GROUP
4.2.1.1 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 mea-
sured 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 Remove the cover (Fig. 4-2, Pos. 1).
z Relieve pressure in the track tensioning system, refer to the

Make sure that the slack in the track group is at the lower part
of the guide wheel.
NOTE: The procedure in the PARTS & SERVICE NEWS

"AH06530" prevent the track tensioning cylinders to get
pressurized when moving the excavator.
Fig. 4-2
4 -4 PC5500-6E Version 2010/1

Undercarriage Travel system
z Flame-cut the nuts (Fig. 4-3, Pos. 3) from the locking bolts
(Fig. 4-3, Pos. 1). Remove the locking bolts (Fig. 4-3, Pos. 1),
washers (Fig. 4-3, Pos. 2), and nuts (Fig. 4-3, Pos. 3) from
one track shoe (Fig. 4-3, Pos. 5).
WARNING
Ensure nothing flammable is in the working area when flame-
cutting the nuts.
z Pull out two pins (Fig. 4-3, Pos. 4) to open the track group
using a sliding hammer.
Fig. 4-3
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.
z Switch S155 to Qmin.
NOTE: Use only motor no. 2 at Qmin.
DANGER
Danger of getting overrun or squished.
Serious injury or death may result.
Make sure nobody stays in driving direction of the excavator Fig. 4-4
or the dozer.
Make sure nobody stays next to the crawler carrier.
z Drive the excavator and the dozer backwards slowly and

unroll the track group from the excavator (Fig. 4-4).
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 2010/1 PC5500-6E 4 -5

z 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 run-
ning direction as shown in Fig. 4-5.
z Remove the chain from the old track group.
z Continue to drive the excavator backwards slowly on the new

track group until the end of the of the track group is nearly
reached.
z 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
Make sure nobody stays in driving direction of the excavator
or the dozer.
Fig. 4-5
z Drive the excavator and the dozer forward slowly and pick up
the track group with the sprocket.
z Continue to drive the excavator and the dozer forward slowly

to pull up the track group (Fig. 4-6).
Fig. 4-6
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).
z Place the track group over the guide wheel as shown in

Fig. 4-7.
z Unchain the dozer.
Fig. 4-7
4 -6 PC5500-6E Version 2010/1

z Align the holes (Fig. 4-8, Pos. 3) in the two open track shoes
(Fig. 4-8, Pos. 2) in front of the guide wheel (Fig. 4-8, Pos. 1)
using a hoist.
z Insert the pins (Fig. 4-9, Pos. 4) into the holes (Fig. 4-8,
Pos. 3).
Fig. 4-8
z Instal the locking bolts (Fig. 4-9, Pos. 1), washers

(Fig. 4-9, Pos. 2), and nuts (Fig. 4-9, Pos. 3) to the track
shoes (Fig. 4-9, Pos. 5).
z Weld the nuts (Fig. 4-9, Pos. 3) to the bolts (Fig. 4-9, Pos. 1).
WARNING
z Ensure nothing flammable is in the working area during
welding work.
z For welding follow the welding precautions given in the

"WELD REPAIRS". Fig. 4-9
CAUTION
The bolts (Fig. 4-10, Pos. 1) lock the pins (Fig. 4-10, Pos. 2).
Therefore one side of the bolt’s head is hardened in order to
prevent wear. This hardened side must face the pin.
The hardened side (Fig. 4-10, arrow) of the bolt heads are
marked.
Fig. 4-10
Version 2010/1 PC5500-6E 4 -7

z Switch S155 to back normal condition.
z Perform the procedure given in the PARTS & SERVICE

NEWS "AH06530" in reverse order.
z Install the cover (Fig. 4-2, Pos. 1).
Fig. 4-11
4 -8 PC5500-6E Version 2010/1

4.2.2 SPROCKET
4.2.2.1 REMOVAL OF THE SPROCKET
Special tools: n/a

Hydraulic torque wrench PN 232 614 40
Additional equipment: 46 mm hexagon impact socket wrench (1"), PN 232 265 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. 4-12, Pos. 2) it is
recommended to change the flange bearings
(Fig. 4-12, Pos. 1 + Pos. 3) too. Therefore the travel gear
(Fig. 4-12, Pos. 4) has to be removed, refer to section
4.2.11.1 on page 4-55.
Fig. 4-12
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 2010/1 PC5500-6E 4 -9


the machine, the boom, and two cranes.
attachment placed at the final drive end of the machine, coun-
terweight 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 pre-
vent the track shoes against falling down
(refer to Fig. 4-13).
z Open the track group at the sprocket end (Fig. 4-13, Pos. 1),
Fig. 4-13
4 - 10 PC5500-6E Version 2010/1

to a dozer behind the excavator.
DANGER
or the dozer.
Fig. 4-14
z Drive the excavator and the dozer forwards slowly and unroll
the track group from the excavator (refer to Fig. 4-14).
z When the upper end of the track group is over the carrier roll
next to the sprocket, stop the excavator and the dozer.
z Fasten the track group to the carrier roll to hold it in position.

z Sling sprocket (refer to Fig. 4-15).
NOTE: The travel parking brake may need to be released to

allow sprocket to turn slightly to find centre of gravity.
Fig. 4-15
Version 2010/1 PC5500-6E 4 - 11

Fig. 4-16 Removal of the sprocket
z Remove the bolts (Fig. 4-16, Pos. 1) and the cover (Fig. 4-16,
Pos. 10).
NOTE: When the cover is removed, oil may flow out.

z Pull the drive shaft (Fig. 4-16, Pos. 6) out of the hollow shaft
(Fig. 4-16, 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 - 12 PC5500-6E Version 2010/1

CAUTION
Make sure that the hollow shaft (Fig. 4-16, Pos. 5) is not
weight loaded before removing the flange bearing (Fig. 4-16,
Pos. 8).
z Remove mounting bolts (Fig. 4-16, Pos. 1) and extract the

flange bearing (Fig. 4-16, Pos. 8) including the bush
(Fig. 4-16, Pos. 7) from the crawler carrier using pulling bolts.
z Extract the hollow shaft (Fig. 4-16, Pos. 5) from the sprocket
(Fig. 4-16, 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.
z Lift the sprocket out of the crawler carrier.
DANGER
When lifting the sprocket, make sure that nobody steps
below the weight.
z Discard the dual-cone seals (Fig. 4-16, 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 2010/1 PC5500-6E 4 - 13

4.2.2.2 REPLACEMENT OF THE SPROCKET
Special tools: Assembly tool for dual-cone seals (locally made)

46 mm hexagon impact socket wrench (1"), PN 232 265 40
2 x Crane
Dozer
Sprocket assembly: 4382 kg
Hollow shaft: 612 kg
Drive shaft: 1007 kg
Dogman/rigger

Fig. 4-17 Replacement of the sprocket
4 - 14 PC5500-6E Version 2010/1

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 & SER-

For mounting the dual-cone seals (Fig. 4-17, 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. 4-17, Pos. 2 and Pos. 4) into
the flange bearing, on the gear side and into the flange bea-
ring (Fig. 4-17, Pos. 8) on the opposite side. Refer to PARTS
z Mount new dual-cone seals (Fig. 4-17, 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. 4-17, Pos. 6), the hollow shaft (Fig. 4-17, 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. 4-17, Pos. 8), and on heads
and threads of new mounting bolts (Fig. 4-17,
Pos. 1) of grade 10.9.
Use the new mounting bolts with washers to attach the
flange bearing with bush (Fig. 4-17, Pos. 7) to the track
frame. Tighten the bolts to the specified tightening torque.
Tightening torque for flange bearing mounting

bolts (Fig. 4-17, 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 2010/1 PC5500-6E 4 - 15

4.2.2.3 REMOVAL OF THE SEGMENTED SPROCKET

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

Crane
Dozer
Additional equipment: 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. 4-18,

Pos. 1, 2 and 3) it is not necessary to remove the travel
gear (Fig. 4-18, 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, coun-
terweight above the guide wheels.
Fig. 4-18
equipment (crane, mobile working platforms, forklift, etc.)
4 - 16 PC5500-6E Version 2010/1


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. 4-19
Fig. 4-20
DANGER
or the dozer.
Fig. 4-21
the track group from the excavator (refer to Fig. 4-21).
z Fasten the track group to the carrier roll to hold it in position.
Version 2010/1 PC5500-6E 4 - 17

Fig. 4-22 Removal of the sprocket segments
z Turn the sprocket so that the first segment that has to be

removed is in the upper position.
z Loosen all bolts (Fig. 4-22, Pos. 1) from the drive sprocket
ring (Fig. 4-22, Pos. 3). Don’t 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. 4-23, Pos. 1). To prevent blocking around the ring,
all 4 screws must be tightened evenly.
Fig. 4-23

z Sling the upper sprocket segment using a crane.
4 - 18 PC5500-6E Version 2010/1

z Remove the bolts (Fig. 4-22, Pos. 1) from the drive sprocket
ring (Fig. 4-22, Pos. 3) at the upper sprocket segment.
WARNING
Remove only the bolts from the respective sprocket seg-
ment.
z Lift the sprocket segment out of the crawler carrier using a

crane.
z Rotate the sprocket slowly by actuating the travel drive so

that the next sprocket segment that has to be removed is in
upper position.
z To remove the other sprocket segments use the same proce-

dure according to the first segment.
Version 2010/1 PC5500-6E 4 - 19

4.2.2.4 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
z Carefully clean all required contact surfaces of the sprocket

segments, the sprocket drive ring and the travel gear.
z The segments of the sprocket have to be erected in the

shown arrangement (Fig. 4-24, 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. 4-24
NOTE: If it is necessary to install the oversized sprocket seg-

ments, refer to PARTS & SERVICE NEWS No.
"AH06529".
z Apply surface coating with coating compound "INTERZINC

697" at the contact surface (Fig. 4-25, Pos. 1) on both sides
of the sprocket segments, refer to section 6.3.1 on page 6-4.
WARNING
Only reassemble the sprocket segments after the coating
compound has fully hardened.
Fig. 4-25
4 - 20 PC5500-6E Version 2010/1

Fig. 4-26 Replacement of the sprocket segments
NOTE: Use new bolts (Fig. 4-26, Pos. 1), nuts (Fig. 4-26, Pos. 2)
and washers to attach the new sprocket segments to the
travel gear (Fig. 4-26, Pos. 7).
Tightening torque for sprocket segment mount-
ing bolts (Fig. 4-26, Pos. 1): 3000 Nm
Version 2010/1 PC5500-6E 4 - 21

4.2.3 GUIDE WHEELS
4.2.3.1 REMOVAL OF THE GUIDE WHEEL ASSEMBLY
Special tools: n/a
Guide wheel assembly: 3323 kg
Dogman/rigger



Fig. 4-27
4 - 22 PC5500-6E Version 2010/1

z Remove the track group from the guide wheel, refer to section
4.2.1.1 on page 4-4.
z Remove bolts (Fig. 4-28, Pos. 1) and remove the stop plates
(Fig. 4-28, Pos. 2) from both sides of the guide wheel assem-
bly (Fig. 4-28, Pos. 3).
z Sling guide wheel assembly (Fig. 4-28, Pos. 3) and pull the
guide wheel assembly out of the crawler carrier.
Fig. 4-28

z Sling guide wheel assembly (Fig. 4-29) 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. 4-29
z Check condition of the sliding surfaces on the crawler carrier

and the sliding blocks.
Version 2010/1 PC5500-6E 4 - 23

4.2.3.2 REPLACEMENT OF THE GUIDE WHEEL ASSEMBLY
Special tools: n/a

Guide wheel assembly: 3323 kg
Dogman/rigger

NOTE: Observe the mounting position of the sliding blocks

(Fig. 4-30, Pos. 3).
Assure that the oil plug (Fig. 4-30, Pos. 2) at the guide
wheel (Fig. 4-30, Pos. 1) is facing the inner side of the
excavator.
Fig. 4-30
4 - 24 PC5500-6E Version 2010/1

4.2.4 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 accumula-
tors (Fig. 4-31, Pos. 1 and 2).
Two different types of pressure accumulators are installed:

A high pressure (150 bar) bladder accumulator (Fig. 4-31, Pos. 1)
and a low pressure (31 bar) diaphragm type accumulator
(Fig. 4-31, Pos. 2).
Fig. 4-31
4.2.4.1 REMOVAL OF THE LOW PRESSURE ACCUMULATORS
Special tools: n/a
Low pressure accumulator: 12 kg
6.6 on page 6-18.

Fig. 4-32
Version 2010/1 PC5500-6E 4 - 25

WARNING
Hot hydraulic oil!
DANGER
Danger of hydraulic pressure! Fig. 4-33
scaring may result.
z Disconnect the pressure hose (Fig. 4-34, Pos. 1).
NOTE: When the pressure hose is removed, hydraulic oil from

inside the piping and the pressure accumulator will flow
out.
tion.
z Remove four bolts (Fig. 4-34, Pos. 4) and remove the pres-
sure accumulator (Fig. 4-34, Pos. 3).
z Remove union (Fig. 4-34, Pos. 2).
Fig. 4-34
4 - 26 PC5500-6E Version 2010/1

4.2.4.2 REPLACEMENT OF THE LOW PRESSURE ACCUMULATORS
Special tools: Testing and refilling device, PN 761 520 73
Low pressure accumulator: 12 kg

z 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!
z Bleed the track tensioning system.

Refer to the Operation & Maintenance Manual, chapter 4,
section "CRAWLER TRACK - INSPECTION".
z Check the track tension system and adjust if required. Refer

to the Service Manual for further information.
Version 2010/1 PC5500-6E 4 - 27

4.2.4.3 REMOVAL OF THE HIGH PRESSURE ACCUMULATORS
Special tools: n/a

High pressure accumulator: 23 kg
6.6 on page 6-18.

WARNING
Hot hydraulic oil!
Fig. 4-35
DANGER
scaring may result.
z Disconnect the pressure hose assembly (Fig. 4-36, 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. 4-36, Pos. 2) and remove the
pressure accumulator (Fig. 4-36, Pos. 3).
Fig. 4-36
z Remove the socket (Fig. 4-36, Pos. 4) from the pressure
accumulator (Fig. 4-36, Pos. 3).
4 - 28 PC5500-6E Version 2010/1

4.2.4.4 REPLACEMENT OF THE HIGH PRESSURE ACCUMULATORS
Special tools: Testing and refilling device, PN 761 520 73
High pressure accumulator: 23 kg

z 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 2010/1 PC5500-6E 4 - 29

4.2.5 TRACK TENSION VALVE BLOCK
4.2.5.1 REMOVAL OF THE TRACK TENSIONING VALVE BLOCK
Special tools: n/a
Chain host
Oil drain pan
Track tensioning valve block: 40 kg
6.6 on page 6-18.

WARNING
Hot hydraulic oil!
Fig. 4-37
DANGER
scaring may result.
z Disconnect all piping (Fig. 4-38, Pos. 2) from the track ten-
sioning valve block (Fig. 4-38, Pos. 1).
NOTE: When the piping is removed, hydraulic oil from inside the
piping and the track tensioning valve block will flow out.
tion.
z Find an appropriate suspension point for the chain hoist and

sling the track tensioning valve block (Fig. 4-38, Pos. 1).
z Remove four mounting bolts and let down the track tension-
ing valve block (Fig. 4-38, Pos. 1) using the chain hoist. Fig. 4-38
4 - 30 PC5500-6E Version 2010/1

z Remove the pressure increase valve (Fig. 4-39, Pos. 1) from

the track tensioning valve block.
z Remove the check valves (Fig. 4-39, Pos. 2) from the track
tensioning valve block.
z Remove the unions (Fig. 4-39, Pos. 3) from the track tension-
ing valve block.
Fig. 4-39
Version 2010/1 PC5500-6E 4 - 31

4.2.5.2 REPLACEMENT OF THE TRACK TENSIONING VALVE BLOCK
Special tools: n/a

Additional equipment: Chain host
Track tensioning valve block: 40 kg


z Check the track tension system and adjust if required.

4 - 32 PC5500-6E Version 2010/1

4.2.6 HYDRAULIC HOSES OF THE TRACK TENSIONING SYSTEM
4.2.6.1 SUBSTITUTE THE HYDRAULIC HOSES
Special tools: n/a
Hydraulic hose: 10 kg max.

6.6 on page 6-18

the machine.

WARNING
Hot hydraulic oil!
Fig. 4-40
DANGER
scaring may result.
NOTE: In the following descriptions, the hydraulic hoses are

replaced one at a time.
Version 2010/1 PC5500-6E 4 - 33

Fig. 4-41 Hydraulic hoses of the track tensioning system
4 - 34 PC5500-6E Version 2010/1

Substitute the hydraulic hoses (Fig. 4-41, Pos. 1):
z If equipped with protection sleeve (Fig. 4-41, Pos. 9), clear

the hydraulic hose to be removed by opening the protection
sleeve.
z 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.
tion.
Fig. 4-42
z Pull out the hydraulic hose completely.
z Insert a new hydraulic hose.
z Reinstall the cover (Fig. 4-42, Pos. 1).
Substitute the hydraulic hoses (Fig. 4-41, Pos. 3, 4, and 5):
z Remove the cover (Fig. 4-43, Pos. 2) and open the clamp
(Fig. 4-41, Type B) only if the hoses (Fig. 4-41, Pos. 4 and 5)
for the track tensioning cylinders will be replaced.
z Disconnect both ends of the hydraulic hose to be removed

and replace the hose by a new one.

out.
tion. Fig. 4-43
z Reinstall the cover(s) (Fig. 4-43, Pos. 1, 2).
Substitute the hydraulic hoses (Fig. 4-41, Pos. 2, 6, 7, and 8):
z Clear the hydraulic hose (Fig. 4-41, Pos. 6, 7, and 8) to be

removed by opening the clamps (Fig. 4-41, Type A or B).
z Disconnect both ends of the hydraulic hose to be removed

and replace the hose by a new one.

out.
tion.
Version 2010/1 PC5500-6E 4 - 35

Subsequent work
z Bleed the track tensioning system. Refer to the Operation &

Maintenance Manual, chapter 4, section "CRAWLER TRACK
- INSPECTION".

4 - 36 PC5500-6E Version 2010/1

4.2.7 TRACK TENSIONING CYLINDERS
4.2.7.1 REMOVAL OF THE TRACK TENSIONING CYLINDERS
Special tools: n/a
Crane
Oil drain pan
Track tension cylinder: 400 kg each
Dogman/rigger
6.6 on page 6-18.


z Remove the guide wheel assembly, refer to section 4.2.3.1 on

page 4-22.
Fig. 4-44
Version 2010/1 PC5500-6E 4 - 37

WARNING
Hot hydraulic oil!
DANGER
scaring may result.
z Disconnect the pressure hoses from the track tension cylin-

der, refer to section 4.2.6 on page 4-33.
NOTE: When the pressure hoses are removed, hydraulic oil from
inside the piping and the track tension cylinder will flow
out.
tion.
z Sling the track tension cylinders (Fig.4-45, Pos. 1) at the

retracting device (Fig. 4-45, arrow) and pull the cylinders out
of their guidance in the crawler carrier (Fig. 4-45, Pos. 2).
Fig. 4-45
4 - 38 PC5500-6E Version 2010/1

4.2.7.2 REPLACEMENT OF THE TRACK TENSIONING CYLINDERS
Special tools: n/a
Track tension cylinder: 400 kg each
Dogman/rigger


Refer to Operation & Maintenance Manual, chapter 4, section
"CRAWLER TRACK - INSPECTION".
z Check the track tensioning system and adjust if required.

Version 2010/1 PC5500-6E 4 - 39

4.2.8 TRAVEL BRAKE VALVE BLOCK (OVERSPEED VALVE)
Fig. 4-46 Travel brake valve blocks
(1) Travel brake valve block
(2) Travel motor
The travel brake valve blocks (Fig. 4-46, Pos. 1) protect the travel
motors (Fig. 4-46, 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 - 40 PC5500-6E Version 2010/1

4.2.8.1 REMOVAL OF THE TRAVEL BRAKE VALVE BLOCK
Special tools: n/a
Chain hoist
Oil drain pan
Travel brake valve block: 75 kg each
6.6 on page 6-18.

WARNING
Hot hydraulic oil!
DANGER
scaring may result.
Version 2010/1 PC5500-6E 4 - 41

z Disconnect the pressure hoses (Fig. 4-47, Pos. 2) to the

rotary joint from the travel brake valve block (Fig. 4-47,
Pos. 4).
z Disconnect the hydraulic lines (Fig. 4-47, Pos. 1) to the travel

motors from the travel brake valve block (Fig. 4-47,
Pos. 4).
z Disconnect the leakage oil line from the travel brake valve
block (Fig. 4-47, Pos. 4).
NOTE: When the hydraulic lines are disconnected, hydraulic oil

from inside the piping and the travel brake valve block will
flow out.
Catch it in an oil pan. Fig. 4-47
tion.
z Discard the O-rings (Fig. 4-47, Pos. 5).
z Sling the travel brake valve block (Fig. 4-47, Pos. 4) at the
installed hoist rings.
z Remove the mounting bolts (Fig. 4-47, Pos. 3) and lift off the
travel brake valve block (Fig. 4-47, Pos. 4) using a chain
hoist.
z Remove the relief valve (Fig. 4-48, Pos. 1) from the travel
brake valve block (Fig. 4-48, Pos. 2).
Fig. 4-48
4 - 42 PC5500-6E Version 2010/1

4.2.8.2 REPLACEMENT OF THE TRAVEL BRAKE VALVE BLOCK
Special tools: n/a

Travel brake valve block: 75 kg

NOTE: Tighten the relief valve (Fig. 4-48, Pos. 1) to the specified
torque.
Tightening torque for relief valve

(Fig. 4-48, Pos. 1): 300 Nm

z Check the travel system and adjust if required.

Version 2010/1 PC5500-6E 4 - 43

4.2.9 TRAVEL MOTORS

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.
4.2.9.1 REMOVAL OF THE TRAVEL MOTORS
Special tools: n/a
Crane
Oil drain pan
Travel motor: 110 kg each
Dogman/rigger
6.6 on page 6-18.



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 - 44 PC5500-6E Version 2010/1

WARNING
Hot hydraulic oil!
DANGER
scaring may result.
z Remove the pressure hoses (Fig. 4-49, Pos. 2) and the leak
oil hoses (Fig. 4-49, Pos. 1 / Fig. 4-50, Pos. 4) from the travel
motor (Fig. 4-49, Pos. 3).
NOTE: When the hoses are removed, hydraulic oil from inside
the piping will flow out.
tion.
z Discard the O-rings.

Fig. 4-49
z Sling travel motor (Fig. 4-49, Pos. 3) and remove the mount-
ing bolts (Fig. 4-49, Pos. 4). Discard the bolts.
z Remove the travel motor (Fig. 4-49, Pos. 3) by pulling it out of

the motor adapter housing (Fig. 4-49, Pos. 5) of the travel
parking brake using a crane.
DANGER
When lifting the travel motor, make sure that nobody steps
below the weight.
Fig. 4-50
Version 2010/1 PC5500-6E 4 - 45

4.2.9.2 REPLACEMENT OF THE TRAVEL MOTORS
Special tools: n/a
Crane
Travel motor: 110 kg
Dogman/rigger

z Clean all drain hoses before assembly.
z Apply "Optimol White" at the spline shaft of the travel motor

(Fig. 4-51, Pos. 1) before attaching the travel motor to the
motor adapter housing (Fig. 4-51, Pos. 3).
Fig. 4-51
NOTE: Use new mounting bolts (Fig. 4-51, Pos. 2) of grade 10.9.
Tightening torque for travel motor mounting

bolts: 265 Nm
Refill oil of the motor adapter housing,

Refer to Operation & Maintenance Manual,
ADAPTER HOUSINGS AND FINAL DRIVES
CHANGE OIL".
z If equipped, install the motor protection, refer to the

4 - 46 PC5500-6E Version 2010/1

Version 2010/1 PC5500-6E 4 - 47

4.2.10 TRAVEL PARKING BRAKE
Fig. 4-52 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 the Operation & Maintenance Manual, chapter 4,
section "FLUIDS AND LUBRICANTS".
4 - 48 PC5500-6E Version 2010/1

(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. 4-52, Pos. 21) engaged to the housing by
serration and the inner discs (Fig. 4-52, Pos. 1) in serration con-
nection with the disc carrier are pressed together by the springs
(Fig. 4-52, Pos. 8 and 9). This results in a fixed connection
between housing and disc carrier (Fig. 4-52, Pos. 23).
Brake released:
Oil pressure via the control pressure port (Fig. 4-52, Pos. 7)
forces the piston (Fig. 4-52, Pos. 16) against the springs
(Fig. 4-52, Pos. 8 and 9) toward the retainer (Fig. 4-52, 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 permissi-

ble pressure is 60 bar.
Version 2010/1 PC5500-6E 4 - 49

4.2.10.1 REMOVAL OF THE TRAVEL PARKING BRAKE
Special tools: n/a

Crane
Oil drain pan
Travel parking brake: 75 kg each
Dogman/rigger
6.6 on page 6-18

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

WARNING
Hot hydraulic oil!
4 - 50 PC5500-6E Version 2010/1

DANGER
scaring may result.
z Remove the relevant travel motor (Fig. 4-53, Pos. 6 and 7

respectively), refer to section 4.2.9.1 on page 4-44.
z Remove the pressure hose (Fig. 4-53, Pos. 3) and the

breather hose (Fig. 4-53, Pos. 4) from the travel parking
brake (Fig. 4-53, Pos. 1 and 5 respectively).

tion.

protection at all sharp edges. Fig. 4-53
z If equipped with wet-type travel parking brakes (up to

SN 025):
Drain oil of the travel parking brake housing,

approx. 0.1 liters.
z Sling the travel parking brake (Fig. 4-53, Pos. 1 and 5 respec-
tively).
z Remove the mounting bolts (Fig. 4-53, Pos. 2) of the travel

parking brake (Fig. 4-53, Pos. 1 and 5 respectively).
z Remove the travel parking brake (Fig. 4-53, 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 2010/1 PC5500-6E 4 - 51

4.2.10.2 REPLACEMENT OF THE TRAVEL PARKING BRAKE
Special tools: n/a
Crane
Portable pressure source (hydraulic or air)
Travel parking brake: 75 kg each
Dogman/rigger

z Apply "Optimol White" at the input spline shaft (Fig. 4-54,

Pos. 4) of the travel gearbox.
DANGER
Risk of retainer (Fig. 4-54, Pos. 3) blasting off!
Do not exceed the maximum pressure of 60 bar at the pres-
sure port.
NOTE: Travel brake may need to be released to allow the

splines to line up or the mounting bolts (Fig. 4-54,
Pos. 1) to be installed.
Therefore first install a portable pressure source to the
pressure port (Fig. 4-54, Pos. 2) (M18 x 1.5) at the travel
parking brake and apply 20 bar.
Fig. 4-54
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 - 52 PC5500-6E Version 2010/1

z Perform a function check of the travel parking brake. Refer to

the Service Manual for further information.
Version 2010/1 PC5500-6E 4 - 53

4.2.11 TRAVEL GEARBOX
Fig. 4-55 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 - 54 PC5500-6E Version 2010/1

Special tools: n/a

Additional equipment: 55 mm hexagon impact socket wrench (1 1/2"), PN 232 519 40
Crane
Oil drain pan
Travel gearbox: 4020 kg
Dogman/rigger
6.6 on page 6-18.


z Place wedges at front and rear side of both crawlers and

lower the bucket onto the ground.

z If equipped, remove the travel gearbox protection, refer to the

WARNING
Hot hydraulic oil!
Version 2010/1 PC5500-6E 4 - 55

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
scaring may result.
line will be removed..
z Remove the two travel parking brakes, (Fig. 4-56,

Pos. 1), refer to section 4.2.10.1 on page 4-50.
z Remove breather hose (Fig. 4-56, Pos. 2) from the travel

gearbox.
NOTE: Cap the openings with blind plugs to avoid contamina-

tion.
z Remove the driving performance meter (Fig. 4-57, Pos. 4)

and cap the opening to avoid contamination.
Fig. 4-56

z Sling the travel gearbox (Fig. 4-57, Pos. 3) at the installed

hoist ring (Fig. 4-57, Pos. 2).
z Remove the mounting bolts (Fig. 4-57, Pos. 5) with washers

(Fig. 4-57, Pos. 6). Discard the bolts and washers.
z Extract the travel gearbox (Fig. 4-57, Pos. 3) from the crawler
carrier (Fig. 4-57, Pos. 7) using a crane.
z Remove the O-ring (Fig. 4-57, Pos. 1) and discard it.
Fig. 4-57
DANGER
When lifting the travel gearbox, make sure that nobody steps
below the weight.
4 - 56 PC5500-6E Version 2010/1

Special tools: n/a

Crane
Paste "Optimol White" PN 999 039
Travel gearbox: 4020 kg
Dogman/rigger

NOTE: Ensure that the mating surfaces on the crawler carrier

and travel gearbox (Fig. 4-58, Pos. 2) are clean and free
of paint before assembly.
z Replace the driving performance meter (Fig. 4-58, Pos. 4).
z Insert a new O-ring (Fig. 4-58, Pos. 2).
z Apply "Optimol White" at the drive shaft (Fig. 4-58, Pos. 1)

and the splines of the planet carrier inside the travel gearbox.
z Sling the travel gearbox at the installed hoist ring (Fig. 4-58,
Pos. 3).
Fig. 4-58
DANGER
below the weight.
z Align the travel gearbox to the drive shaft (Fig. 4-58, Pos. 1)
and flange it to the crawler carrier.
z Use new mounting bolts (Fig. 4-58, 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. 4-58, Pos. 6)
and tighten the bolts to the specified tightening torque.
Tightening torque for travel gearbox mounting

bolts (Fig. 4-58, Pos. 6): 3100 Nm
Version 2010/1 PC5500-6E 4 - 57

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 the

"FLUIDS AND LUBRICANTS".
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.
z Perform a function check of the travel parking brake. Refer to

the Service Manual for further information.
4 - 58 PC5500-6E Version 2010/1


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
6.6 on page 6-18.

the machine, the boom, the dozer and the crane.
terweight 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.
Fig. 4-59
Version 2010/1 PC5500-6E 4 - 59

DANGER
or the dozer.
Fig. 4-60
the track group from the sprocket (refer to Fig. 4-60).
NOTE: Fasten the track group to the carrier roll to hold it in posi-
tion.
Fig. 4-61 Removal / Replacement of the travel gearbox
4 - 60 PC5500-6E Version 2010/1

WARNING
scaring may result.
The hydraulic system my be pressurized.
NOTE: For removal of the travel gearbox (Fig. 4-61, Pos. 1) from
the crawler frame it is not necessary to remove the
sprocket (Fig. 4-61, 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.
z Exchange one mounting bolt (Fig. 4-62, Pos. 1) between the

travel motor flanges (Fig. 4-62, Pos. 2) with an adequate
swivel hoist ring.
Fig. 4-62
Version 2010/1 PC5500-6E 4 - 61

z If equipped, remove the driving performance meter (Fig. 4-63,

Pos. 1) and cap the opening to avoid contamination.
z Sling the spur gear housing (Fig. 4-63, Pos. 2) together with
the brake housing (Fig. 4-63, Pos. 3) at the installed swivel
hoist ring and at both brake housings in a way the compo-
nents are kept in upright position.
z Remove the remaining mounting bolts (Fig. 4-63, Pos. 4) and

install 3 threaded pins (M16×130, thread length: 30 mm)
evenly distributed at the circumference as guidance ele-
ments.
z Remove the spur gear housing by pulling it off the spindle

(Fig. 4-63, Pos. 5) of the planetary gear housing.
DANGER
Fig. 4-63
below the weight.
NOTE: To loosen a seized connection, jack bolts (M16) can be

installed at two threaded bores (Fig. 4-62, Pos. 3).
z Exchange the upmost mounting bolt (M30) with an adequate

swivel hoist ring (Fig. 4-64, Pos. 1).
z Sling the planetary gear housing at the swivel hoist ring

(Fig. 4-64, Pos. 1) and at the sprocket (Fig. 4-64, Pos. 3).
z Tense the sling gear to ease the load of the travel gear
mounting bolts.
Fig. 4-64
4 - 62 PC5500-6E Version 2010/1

z Remove 3 mounting bolts (Fig. 4-65, Pos. 1) evenly distrib-

uted at the support bearing cover and install 3 threaded pins
(M30×300, thread length: 80 mm) instead.
z Remove the remaining mounting bolts (Fig. 4-65, Pos. 1).
z Pull out the support bearing cover (Fig. 4-65, Pos. 2) out of
the bore in the crawler frame using 3 jack bolts inserted in the
threaded bores (Fig. 4-65, Pos. 3).
WARNING
Sling the bearing cover as soon as possible and support it
using an adequate lifting device to prevent the bearing cover Fig. 4-65
from falling.
z Remove the support bearing cover and the threaded pins.
z Remove 3 mounting bolts (Fig. 4-66, Pos. 1) evenly distrib-

uted at the circumference of the spindle and install 3 threaded
pins (M27×300, thread length: 40 mm) instead.
z Remove the remaining mounting bolts (Fig. 4-66, Pos. 1) and

pull the spindle (Fig. 4-66, Pos. 2) from the planetary gear
cover (Fig. 4-66, Pos. 3).
WARNING
Sling the spindle (Fig. 4-66, Pos. 2) as soon as possible and
support it using an adequate lifting device to prevent the
spindle from falling.
z Discard the dual cone seal halves attached to the bearing

cover and the spindle (Fig. 4-66, Pos. 4).
NOTE: For further information about the dual cone seals, refer to Fig. 4-66
Version 2010/1 PC5500-6E 4 - 63

z Remove the mounting bolts (Fig. 4-67, Pos. 1) attaching the

spindle (Fig. 4-67, Pos. 2) to the crawler frame (travel motor
side) (Fig. 4-67, Pos. 3).
z 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. 4-67
z Lower the planetary gear housing (Fig. 4-68, Pos. 1) to the

ground and rest it on appropriate supports (Fig. 4-68, Pos. 2).
NOTE: For the removal of the segmented sprocket (Fig. 4-68,

Pos. 3) and the mounting ring (Fig. 4-68, Pos. 4), refer to
Fig. 4-68
4 - 64 PC5500-6E Version 2010/1


Special tools: n/a

Crane
3 x Threaded pin M16x130 (thread length: 30 mm)
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
6.6 on page 6-18.
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.
Ensure that the mating surfaces are cleaned thoroughly,

and that sealants are removed completely.
Version 2010/1 PC5500-6E 4 - 65

z Instal the segmented sprocket (Fig. 4-69, Pos. 3) to the plan-

etary gear housing (Fig. 4-69, Pos. 1), refer to section 4.2.2.4
on page 4-20.
NOTE: Align the sprocket segments to the mounting bores in the

travel gearbox by means of two pipes
(dia. 38 mm×1000 mm).
Instal three swivel hoist rings to the drive sprocket ring

(Fig. 4-69, 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

Fig. 4-69
segments and the sprocket ring to the travel gear
(Fig. 4-69, Pos. 1).
Tightening torque for drive sprocket ring

mounting bolts (Fig. 4-26, Pos. 1): 3000 Nm
z Install a swivel hoist ring (Fig. 4-70, Pos. 1) to the planetary

gear housing (Fig. 4-70, 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. 4-70, Pos. 1) and the sprocket (Fig. 4-70,
Pos. 3).
NOTE: Use a chain hoist (Fig. 4-70, Pos. 2) to align the planetary
gear housing vertically.
z Apply "Optimol White" to the bore (Fig. 4-70, Pos. 8) in the

crawler frame (travel motor side) (Fig. 4-70, Pos. 7).
z Lift the planetary gear housing to the inside of the crawler car-
rier.
Fig. 4-70
z Align the spindle (Fig. 4-70, Pos. 4) of the planetary gear
housing to the bores in the crawler frame and move it into the
bore.
z Apply compound "KP2K", PN 324 969 40 on heads and

threads of the mounting bolts (Fig. 4-70, Pos. 6) and insert
the mounting bolts with washers (Fig. 4-70, Pos. 5).
z Tighten all mounting bolts to the specified tightening torque

using the hydraulic torque wrench PN 232 614 40.
Tightening torque for travel gearbox mounting

bolts (Fig. 4-70, Pos. 6): 3000 Nm
4 - 66 PC5500-6E Version 2010/1

NOTE: Leave the planetary gear housing hooked up to the

crane.
z Install one half of the dual cone seal (Fig. 4-71, Pos. 1) to the
support bearing spindle (Fig. 4-70, 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. 4-70, Pos. 3) to the

spindle.
Fig. 4-71
z Install 3 threaded pins (M27×300 mm, thread length: 40 mm)

equally distributed at the planetary gear housing
(Fig. 4-72, Pos. 3) into the bores for the spindle mounting
bolts (Fig. 4-72, Pos. 1).
z Lift the spindle (Fig. 4-72, 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
z Apply compound "Loctite 245" on the threads of new mount-

ing bolts (Fig. 4-72, Pos. 1) of grade 10.9, insert the mounting
bolts with new HV-washers, and tighten the mounting bolts to Fig. 4-72
the specified tightening torque.
Tightening torque for spindle mounting bolts:

1520 Nm
z Remove the threaded pins.
Version 2010/1 PC5500-6E 4 - 67

z Apply oil onto the support bearing (Fig. 4-73, Pos. 4).
z Apply paste "Optimol White" onto the bore in the crawler

frame (Fig. 4-73, Pos. 6).
z Install the other half of the dual cone seal (Fig. 4-73, Pos. 5)
to the bearing cover (Fig. 4-73, 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. 4-73, 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. Fig. 4-73
z Install 3 threaded pins (M30×300 mm, thread length: 80 mm)

equally distributed to the bores in the crawler frame
(Fig. 4-73, Pos. 6).
z Sling the support bearing cover (Fig. 4-73, Pos. 7) and slip it
onto the threaded pins.
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 (M30×160 mm) and
washers, both delivered with the travel gear.
z Remove the bolts.
4 - 68 PC5500-6E Version 2010/1

z Install new mounting bolts (Fig. 4-73, Pos. 1) of grade 10.9

with washers (Fig. 4-73, 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.
z Sling the spur gear housing (Fig. 4-74, Pos. 3) with the
installed brake housing.
z Install new O-ring (Fig. 4-74, Pos. 5) to the spur gear housing.
NOTE: Apply paste "Loctite 574" onto the sealing / mating sur-
faces (Fig. 4-74, Pos. 2).
z Install 3 threaded pins (M16×130, thread length: 30 mm) into

3 bores for the spur gear mounting bolts (Fig. 4-74, Pos. 6)
evenly distributed at the spindle (Fig. 4-74, Pos. 1) of the
planetary gear housing.
z Lift spur gear housing (Fig. 4-74, Pos. 3) and slip it onto the
threaded pins.
DANGER
When lifting the spur gear housing, make sure that nobody
steps below the weight. Fig. 4-74
z Insert new mounting bolts (Fig. 4-74, 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.
z Replace the swivel hoist ring with a mounting bolt.
Version 2010/1 PC5500-6E 4 - 69

4.2.12 CARRIER ROLLER
4.2.12.1 REMOVAL OF THE CARRIER ROLLER ASSEMBLY
Special tools: n/a
Hydraulic jack 40 tonnes

Additional equipment: 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.


Fig. 4-75
z Push up track shoe assembly (Fig. 4-76, Pos. 3) at the carrier

roller assembly (Fig. 4-76, Pos. 2) to be removed using
hydraulic jack (Fig. 4-76, Pos. 1).
In addition to the hydraulic jack, secure the track shoe assem-
bly using appropriate blocks.
NOTE: Fig. 4-76 shows the crawler carrier of the bolted under-
carriage, this step is accordingly identical for the crawler
carrier of the pinned undercarriage.
Fig. 4-76
4 - 70 PC5500-6E Version 2010/1

z Carry out the following steps at the crawler carrier of the

bolted undercarriage only:
z Shove the forks (Fig. 4-77, Pos. 1) together that far, that
the carrier roller (Fig. 4-77, Pos. 2) can rest on the forks.
WARNING
z If the forks can not be locked in that position, use a chain
hoist at the forks to prevent them from sliding apart.
z Make sure that nobody is in the danger zone while lifting

the carrier roller assembly from the pedestal.
Fig. 4-77
z Carry out the following step at the crawler carrier of the

pinned undercarriage only:
z Sling the carrier roller assembly (Fig. 4-78, Pos. 1)

at both sides and connect the slings to the forks
(Fig. 4-78, Pos. 2) of a forklift.

Fig. 4-78
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 2010/1 PC5500-6E 4 - 71

4.2.12.2 REPLACEMENT OF THE CARRIER ROLLER ASSEMBLY
Special tools: n/a

Hydraulic jack 40 tonnes
Additional equipment: 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 posi-
tions 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).
z For information about the proper lubricant, refer to the

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 - 72 PC5500-6E Version 2010/1

4.2.13 TRACK ROLLER
4.2.13.1 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)
Track roller assembly: 654 kg
Dogman/rigger



Fig. 4-79
z Jack up the machine with the work equipment.
z Support two track rollers with the safety unit for changing
track rollers, PN 921 149 40 (Fig. 4-80, Pos. 1).
z Lower the machine and place the work equipment on the

ground.
z Support the track roller assembly (Fig. 4-80, Pos. 2) from the
bottom side with the changing tool for track rollers (Fig. 4-82).
z Remove the track roller mounting bolts (Fig. 4-80, Pos. 3) and
lower the tool.
Fig. 4-80
Version 2010/1 PC5500-6E 4 - 73

NOTE: The track roller mounting bolts (Fig. 4-81, Pos. 1) are
secured with lever-nuts (Fig. 4-81, Pos. 2) inside the
crawler frame.
When the bolts are removed, the nuts may slip away from
their mounting position.
Fig. 4-81
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 devel- Fig. 4-82
opment.
4 - 74 PC5500-6E Version 2010/1

4.2.13.2 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)
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 posi-
tions 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).
z For information about the proper lubricant, refer to the

z When inserting the track roller mounting bolts (Fig. 4-83,

Pos. 1), hold the lever-nuts (Fig. 4-83, 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. 4-83
Version 2010/1 PC5500-6E 4 - 75

Car body Undercarriage
4.3 CAR BODY

(TYPE WITH PINNED UNDERCARRIAGE)
Special tools: n/a
2 x Crane
Additional equipment: Dozer
Oil drain pan
Car body: 42,000 kg

Crawler carrier assembly: 40,000 kg each (without track group)
Dogman/rigger
6.6 on page 6-18.
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 carriers, refer to

NOTE: Remove both track groups simultaneously.

This can be done using the same dozer.
WARNING
Hot hydraulic oil!
z Remove the travel gearboxes from both crawler carriers, refer

to section 4.2.11.1 on page 4-55.
z Lift the superstructure, refer to section 3.14.1 on page 3-256.
z Attach a dozer to the car body by means of a chain.
z Move the car body below the lifted superstructure using the
dozer.
NOTE: Move the car body over the unrolled track group.
4 - 76 PC5500-6E Version 2010/1

Undercarriage Car body
z Remove the pressure hoses (Fig. 4-84, Pos. 1) of the track

tensioning system leading to the shut-off cocks (Fig. 4-84,
Pos. 2) and pull them out of the crawler carriers, refer to sec-
tion 4.2.6.1 on page 4-33.
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. 4-84
z Attach one crawler to two cranes and lift it up (Fig. 4-85).

WARNING
Before lifting, make sure that the crane operators are trained
in dual crane lift.
Fig. 4-85
z Rest the car body on appropriate supports (see Fig. 4-86).
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 2010/1 PC5500-6E 4 - 77

Fig. 4-86 Crawler carrier mounting
z Remove all bolts (Fig. 4-86, Pos. 6) and the retainer plates
(Fig. 4-86, Pos. 7).
z Remove the nuts (Fig. 4-86, Pos. 2), the cover plates
(Fig. 4-86, Pos. 3), and the thread pins (Fig. 4-86, Pos. 4)
only if required (changing to a replacement car body).
z Pull out the four mounting pins (Fig. 4-86, Pos. 5) just enough
to clear the crawler carrier assembly (Fig. 4-86, Pos. 1) from
the car body as shown in (Fig. 4-86).
z Remove the crawler carrier (Fig. 4-86, 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 - 78 PC5500-6E Version 2010/1

z Attach the car body to two cranes (Fig. 4-87).
z Clear the other crawler carrier from the car body using the
same procedure as before.
z Remove the car body using two cranes.

WARNING
in dual crane lift.
DANGER Fig. 4-87

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
4.3.5.1 on page 4-98.
z Remove the high pressure accumulators from the car

body, refer to section 4.2.4.3 on page 4-28.
z Remove the track tensioning valve from the car body,

z Remove the travel brake valve blocks from the car body,
z Remove all hydraulic hoses from the car body, refer to

Version 2010/1 PC5500-6E 4 - 79

4.3.2 REPLACEMENT OF THE CAR BODY AND THE CRAWLER

CARRIERS (TYPE WITH PINNED UNDERCARRIAGE)
Special tools: Water level gauge
AL-Compound, PN 509 623 98

Dozer
Car body: 42,000 kg

Dogman/rigger


z Instal all hydraulic hoses into the new car body, refer to
z Instal the rotary joint in the new car body, refer to section
4.3.5.2 on page 4-101.
z Instal the high pressure accumulators in the new car

body, refer to section 4.2.4.4 on page 4-29.
z Instal the track tensioning valve in the new car body, refer
z Instal the travel brake valve blocks in the new car body,
4 - 80 PC5500-6E Version 2010/1

z If required, install new inner bushings (Fig. 4-88, Pos. 5) and

new outer bushings (Fig. 4-88, Pos. 7) in the new car body.
z Instal the thread pins (Fig. 4-88, Pos. 4) and the cover plates
(Fig. 4-88, Pos. 3) with nuts (Fig. 4-88, Pos. 2) and washers
at the four borings for the pins on the car body.
z Attach the car body (Fig. 4-88, Pos. 1) to two cranes and lift it
up.
WARNING
in dual crane lift.
DANGER Fig. 4-88

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. 4-88, Pos. 1) to the crawler carrier
(Fig. 4-88, 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. 4-88, Pos. 6).
NOTE: Lubricate pins (Fig. 4-88, Pos. 6) with AL-Compound,

PN 509 623 98.
z Align the lower borings and insert the mounting pins.
z Instal the retainer plates (Fig. 4-88, Pos. 9) at the mounting

pins and secure the retainer plates with the mounting bolts
(Fig. 4-88, Pos. 8) and washers.
Version 2010/1 PC5500-6E 4 - 81

z For easier mounting of the second crawler carrier, support left

side of the car body with appropriate stands of approx.
1500 mm hight and lower the car body on the stands (see
Fig. 4-89).
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 are parallel and the distance
"A" between track groups is:
4840 mm for track width 1350
4390 mm for track width 1800
Fig. 4-89
Fig. 4-90 Assembly of the car body
z Instal the thread pins (Fig. 4-90, Pos. 4) and the inner retainer
plates (Fig. 4-90, Pos. 3) with nuts (Fig. 4-90, Pos. 2) and
washers at the four borings for the pins on the car body.
4 - 82 PC5500-6E Version 2010/1

z Attach the second crawler carrier (Fig. 4-90, 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.
z Align the upper borings first and insert the mounting pins
(Fig. 4-90, Pos. 5).
NOTE: Lubricate pins (Fig. 4-90, Pos. 5) with AL-Compound,

PN 509 623 98.
z Align the lower borings and insert the mounting pins.
z Instal the retainer plates (Fig. 4-90, Pos. 7) at the mounting

pins and secure the retainer plates with the mounting bolts
(Fig. 4-90, Pos. 6) and washers.
z Lift the undercarriage as far as it is necessary to remove the

stands.
z Rest the undercarriage to the ground.
Version 2010/1 PC5500-6E 4 - 83


(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
6.6 on page 6-18.
z 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

z Lift the superstructure, refer to section 3.14.1 on page 3-256.
z Attach a dozer to the car body by means of a chain.
z Move the car body below the lifted superstructure using the
dozer.
NOTE: Move the car body over the unrolled track group.
z Disconnect the pressure hoses (Fig. 4-91, Pos. 1) for the

track tensioning from the shut-off cocks (Fig. 4-91, Pos. 2).
NOTE: When the pressure hoses are removed, the oil inside the
piping will flow out.
tion.
z Remove the hoses from both crawler carriers.
Fig. 4-91
4 - 84 PC5500-6E Version 2010/1

z Attach one crawler carrier (Fig. 4-92, Pos. 1) to two cranes at

the installed lifting eyes (Fig. 4-92, Pos. 2) and lift it up.
WARNING
in dual crane lift.
z 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. 4-92
NOTE: Place supports between the cross-ties (Fig. 4-93, Pos. 1)

in a manner that the mounting bolts can be removed.
Fig. 4-93
Version 2010/1 PC5500-6E 4 - 85

Fig. 4-94 Crawler carrier mounting bolts
4 - 86 PC5500-6E Version 2010/1

z Remove all mounting bolts (Fig. 4-94, Pos. M48) and the two
measuring bolts (Fig. 4-94, Pos. 7) attaching the crawler car-
rier 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 sec-
tion 6.3.2 on page 6-6, and also refer to chapter 9 "Sup-
plier’s 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
z Carry out the same procedure described above to remove the

second crawler carrier.
Version 2010/1 PC5500-6E 4 - 87

4 - 88 PC5500-6E Version 2010/1

4.3.4 REPLACEMENT OF THE CAR BODY AND THE CRAWLER

CARRIERS (TYPE WITH BOLTED UNDERCARRIAGE)
Hydraulic torque wrench, PN 793 374 73 + PN 793 376 73

Measuring device, PN 928 476 40
2 x Crane
Dozer
Car body: 46,000 kg

Dogman/rigger


z Check the coated flange plates of the new car body for intact-
ness, 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
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 4.3.2 on page 4-80.
When mounting the crawler carrier to the car body, tighten the
mounting bolts according to the following procedures.
Version 2010/1 PC5500-6E 4 - 89

4 - 90 PC5500-6E Version 2010/1

z Insert new bolts (Fig. 4-95, Pos. M48) and two measuring
bolts (Fig. 4-95, Pos. 7) with resilient sleeves.
NOTE: Lubricate all bolts (Fig. 4-95, 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. 4-95, Pos. 7) into the
upper corners.
The measuring bolts are part of the measuring device,
PN 928 476 40.
z Pre-tighten the mounting bolts using the hydraulic torque

wrench PN 793 374 73 + PN 793 376 73, refer to section
6.3.2 on page 6-6.
Pre-tightening torque for crawler carrier moun-

ting bolts: 2100 Nm
z Determine the torque and tighten the crawler carrier mounting

bolts to the determined torque, refer to section 4.3.4.1 on
page 4-92.
NOTE: Check the torque of the crawler carrier mounting bolts

after 1000 operating hours, refer to section 4.3.4.1 on
page 4-92.
Version 2010/1 PC5500-6E 4 - 91

4.3.4.1 TIGHTENING TORQUE FOR THE CRAWLER CARRIER MOUNTING BOLTS
Hydraulic torque wrench, PN 793 374 73 + PN 793 376 73

Measuring device, PN 928 476 40
4 - 92 PC5500-6E Version 2010/1

The required tightening torque for all fastening bolts has to be

determined with the 4 measuring bolts (Fig. 4-96, Pos. 7), whose
dimension resembles the fastening bolts (Fig. 4-96, Pos. M48).
The required axial tension force of the bolts depends on the elon-
gation 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 pre-
pared 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. 4-96, Pos. 1 - 6) is composed of the

following items and will be delivered with each new machine.
Refer to Fig. 4-96:
Pos. Part name Part number Qty.
(1) Angle bar 928 475 40 1
(2) Dial gauge 092 706 40 1
(3) Screw M5x16 502 515 98 1
(4) Feeler 477 172 40 1
(5) Bolt M10x25 307 777 99 2
(6) Washer 517 122 98 2
Measuring bolt
(7) 933 613 40 4
(installed)
WARNING
Pre-condition:
Crawler carrier is assembled and bolts tightened to 2100 Nm
z Loosen all 4 measuring bolts (Fig. 4-96, Pos. 7). Do not lubri-
cate the measuring bolts again.
z Tighten the 4 measuring bolts (Fig. 4-96, Pos. 7) to

150 Nm.
z Instal the measuring device (Fig. 4-96, Pos. 1 - 6).
z Set the dial gauge (Fig. 4-96, Pos. 2) to zero.
z Instal the special hydraulic torque wrench,

PN 793 374 73 + PN 793 376 73, refer to section 6.3.2 on
page 6-6.
Version 2010/1 PC5500-6E 4 - 93

4 - 94 PC5500-6E Version 2010/1

z Adjust the pressure at the hydraulic torque wrench to

2100 Nm and tighten the measuring bolt (Fig. 4-97, Pos. 7).
z List the pressure and the changed bolt length in a table.
z Increase the pressure in steps of 10 bar until the measuring

bolts have the required elongation of 0.93 mm.
z List the corresponding hydraulic pressure in a table.
z Repeat this procedure for all 4 measuring bolts.
z Add all 4 determined hydraulic pressures and then divide by 4

to obtain an average value.
z Loosen one mounting bolt (Fig. 4-97, 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.
z Repeat this procedure step by step for all the other bolts.
Version 2010/1 PC5500-6E 4 - 95

4.3.5 ROTARY JOINT
Fig. 4-98 Rotary joint
4 - 96 PC5500-6E Version 2010/1

Legend for illustration Fig. 4-98:
(1) Rotary joint
(2) Through bore (center of rotary joint)
(3) Cam, attached to the superstructure
(4) Torque support lever
(5) Mounting bolt

(7) Cross beam
(8) Car body
(9) Cover plate

(10) Ring groove
(11) Stator connecting port
(12) Stator, housing of rotary joint
(13) Rotor
(14) Leak oil connection port
(15) Rotor connecting ports
(16) Sealing element with O-ring
(17) Leak (case drain) oil
The rotary distributor (rotary joint) serves as a hydraulic

connection between the superstructure and the undercarriage.
This means that 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

against each other. The travel motors must be supplied with
hydraulic oil in each position in which the superstructure is slewed
against the undercarriage.
The rotary joint is provided with a through bore in its center.

The high voltage power supply cable runs though the bore in the
rotary joint to the slip ring unit attached ot the superstructure.
Version 2010/1 PC5500-6E 4 - 97

4.3.5.1 REMOVAL OF THE ROTARY JOINT
Special tools: n/a
Rotary joint: 261 kg
Dogman/rigger
6.6 on page 6-18.

the machine, boom, and a crane.



Fig. 4-99
4 - 98 PC5500-6E Version 2010/1

z Close the hand wheel (Fig. 4-100, Pos. 1) of main gate valve
between suction oil reservoir and main oil reservoir.
z Transfuse oil from the suction oil reservoir into the main oil
PUMP".
Fig. 4-100
DANGER
Hazardous Voltage!

z Remove the slip ring unit,

z Pull the high voltage power supply cable out of the rotary joint
and the cross beam of the car body.
WARNING
Hot hydraulic oil!
z Mark and disconnect all hydraulic hoses and pipes from the
rotary joint. Discard the O-rings of the SAE flange connec-
tions.
NOTE: When the hydraulic lines are removed, hydraulic oil from
tion.
z Disconnect the grease feeding lines of the central lubrication

system from the rotary joint.
Version 2010/1 PC5500-6E 4 - 99

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. 4-101, 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. 4-101
z Remove the mounting bolts (Fig. 4-102, Pos. 1), and remove
the torque support lever (Fig. 4-102, Pos. 6) from the rotary
joint (Fig. 4-102, Pos. 2).

z Lift the rotary joint (Fig. 4-102, Pos. 3) off the cross beam
(Fig. 4-102, Pos. 3) using a crane and rest the rotary joint on
the ground.
DANGER
When lifting the rotary joint, make sure that nobody steps
below the weight.
Fig. 4-102
4 - 100 PC5500-6E Version 2010/1

4.3.5.2 REPLACEMENT OF THE ROTARY JOINT
Special tools: n/a

Crane
Rotary joint: 261 kg
Dogman/rigger

z Lift the new rotary joint (Fig. 4-103, Pos. 2) onto the cross
beam (Fig. 4-103, Pos. 3) at the car body.
DANGER
When lifting the rotary joint, make sure that nobody steps
below the weight.
z Install the mounting bolts (Fig. 4-103, Pos. 4) with resilient

NOTE: Apply compound "KP2K", PN 324 969 40 to the mounting

bolts.
z Install the torque support lever (Fig. 4-103, Pos. 6) to the Fig. 4-103
rotary joint.
Make sure that the torque support lever fits into the cam at
the superstructure.
NOTE: Apply compound "KP2K", PN 324 969 40 to the mounting

bolts.
z Push up the high voltage power supply cable through the

rotary joint from the bottom of the cross beam.

Version 2010/1 PC5500-6E 4 - 101

4.3.6 CABLE DRUM
Fig. 4-104 Cable drum, overview
(1) Mounting flange
(2) Connection box

(3) Cable drum brake motor
(4) Power cable guiding tube
(5) Carrier
(6) Cable guide mechanism
(7) Cable drum
(8) Brake motor resistor

(9) Maintenance access ladder
4 - 102 PC5500-6E Version 2010/1

4.3.6.1 PREPARATORY WORK FOR THE REMOVAL AND REPLACEMENT OF THE

CABLE DRUM ASSEMBLY
Special tools: n/a
Additional equipment: n/at

z Park the machine on the prepared flat area with the super-
structure turned by 90° and position the bucket on the ground
as shown (Fig. 4-105).

Fig. 4-105
z Unroll the power supply cable from the cable drum til the end
using the manual switch of the unit.
NOTE: If the electric supply has been switched off from the
power plant, loosen the brake of the drum motor, refer to
the Operation & Maintenance Manual of the cable drum
assembly.
DANGER
Hazardous Voltage!

z Disconnect the power supply cable at the power station.
Version 2010/1 PC5500-6E 4 - 103

4.3.6.2 REMOVAL OF THE CABLE DRUM ASSEMBLY
Special tools: n/a
Crane
2 x Chain hoist (carrying capacity: 5000 kg, each)
Cable drum: 7500 kg
Dogman/rigger
z Carry out the preparatory work for the removal and

replacement of the cable drum, refer to section 4.3.6.1 on
page 4-103.
z Open the man hole of the cable drum.
z Disconnect the high voltage power supply cable coming from

the power station inside the drum, and pull the cable out of
the drum.
z Disconnect all cables and wires leading from the car body
(Fig. 4-106, Pos. 1) to the cable drum assembly, and put them
down on the machine.
z Sling the cable drum assembly at the carrier (Fig. 4-106,

Pos. 2) using a crane and two chain hoists.

sleeves (Fig. 4-106, Pos. 4) at the flanges (Fig. 4-106,
Pos. 5).
DANGER
When removing the mounting bolts, make sure that nobody
z Move the cable drum assembly away from the machine care-
fully, and put it down on the ground.
Fig. 4-106
DANGER
When lifting the cable drum assembly, make sure that
4 - 104 PC5500-6E Version 2010/1

4.3.6.3 REPLACEMENT OF THE CABLE DRUM ASSEMBLY
Special tools: n/a
Crane
2 x Chain hoist
Cable drum: 7500 kg
Dogman/rigger


replacement of the cable drum, refer to section 4.3.6.1 on
page 4-103.
z Clean the mating surfaces of the cable drum assembly and

the car body.
NOTE: Ensure that the mating surfaces are free of grease and
rust, and that the surfaces are plane.
z Sling the cable drum assembly (Fig. 4-107, Pos. 2) using a

crane and two chain hoists.
z Bring the cable drum assembly into mounting position at the

car body (Fig. 4-106, Pos. 1).
DANGER
When lifting the cable drum assembly, make sure that

sleeves (Fig. 4-106, Pos. 4) at the mounting flanges
(Fig. 4-106, Pos. 5).
NOTE: Always use new mounting bolts of grade 10.9.

tightening torque:
Fig. 4-107
Tightening torques for the cable drum assembly
z Reconnect all cables and wires leading from the machine to

the cable drum and the connection box of the cable drum
assembly.
Version 2010/1 PC5500-6E 4 - 105

z Open the manhole of the cable drum.
z Reconnect the power supply cable from the power station

inside the cable drum.
z Change the dryer pack according to the Operation & Mainte-

nance Manual of the cable drum assembly.
z Clean the inside of the cable drum.
NOTE: Dirt, water, oil or other contamination is not permissible

inside the cable drum.
z Close the manhole of the cable drum.
NOTE: Ensure that all bolts are fitted.

according to the grounding procedure of the high voltage sys-
tem, refer to section 2.3 on page 2-28.
DANGER
Hazardous Voltage!
NOTE: For the initial operation of the cable drum assembly, refer
to the Operation & Maintenance Manual of the cable
drum assembly, delivered with the machine.
4 - 106 PC5500-6E Version 2010/1

Version 2010/1 PC5500-6E 4 - 107

4.3.7 CABLE SUPPLY (OPTIONAL)
Fig. 4-108 Cable supply, overview
(1) Connection box
(2) Cable supply assembly main beam
(3) Cable lifting rack

(4) Power supply cable
(5) Mounting flange to car body
4 - 108 PC5500-6E Version 2010/1

4.3.7.1 PREPARATORY WORK FOR THE REMOVAL AND REPLACEMENT OF THE

CABLE SUPPLY
Special tools: n/a
Additional equipment: n/at


Fig. 4-109
DANGER
Hazardous Voltage!

z Disconnect the high voltage power supply cable from the

power station.
Version 2010/1 PC5500-6E 4 - 109

4.3.7.2 REMOVAL OF THE CABLE SUPPLY
Special tools: n/a

Cable supply assembly: 640 kg
Dogman/rigger
Fig. 4-110 Cable supply assembly, installation

replacement of the cable supply, refer to section 4.3.7.1 on
page 4-109.
z Open the connection box (Fig. 4-110, Pos. 1).
z Disconnect the power supply cables coming from the slip ring
of the machine (Fig. 4-110, Pos. 9) and the power supply
cable coming from the power station (Fig. 4-110, Pos. 3)
inside the connection box.
4 - 110 PC5500-6E Version 2010/1

z Pull the power supply cables out of the connection box.
z Sling the cable supply assembly (Fig. 4-110, Pos. 2).
z Remove the cable from the cable clamps (Fig. 4-110, Pos. 4).
z Detach the cable pull sock (Fig. 4-110, Pos. 5) from the
shackles (Fig. 4-110, Pos. 6) at the cable supply assembly.
z Lift the cable supply assembly away from the machine and
put it on the ground.
DANGER
When lifting the cable supply assembly, make sure that
Version 2010/1 PC5500-6E 4 - 111

4.3.7.3 REPLACEMENT OF THE CABLE SUPPLY ASSEMBLY
Special tools: n/a

Cable supply assembly: 640 kg
Dogman/rigger

Fig. 4-111 Cable supply assembly, installation

replacement of the cable supply, refer to section 4.3.7.1 on
page 4-109.
z Sling the new cable supply assembly (Fig. 4-111, Pos. 2) to a

crane.
4 - 112 PC5500-6E Version 2010/1

z Lift the cable supply assembly to the mounting position at the

car body.
DANGER
When lifting the cable supply assembly, make sure that

NOTE: Always use new mounting bolts of grade 10.9.

tightening torque:
Tightening torques for the cable supply assembly

z Open the cover of the connection box (Fig. 4-111, Pos. 1).
z Connect the high voltage power cable (Fig. 4-111, Pos. 9)

coming from the slip ring of the machine to the connection
box of the cable supply assembly.
z Pull the power supply cable (Fig. 4-111, Pos. 3) from the
power station to the cable supply assembly using a cable pull
sock (Fig. 4-111, Pos. 5).
z Connect the power supply cable (Fig. 4-111, Pos. 3) to the

connection box.
z Mount the power supply cable (Fig. 4-111, Pos. 3) to the cable
supply assembly with the clamp set (Fig. 4-111,
Pos. 4).
z Hook the cable pull sock (Fig. 4-111, Pos. 5) into the shackles
(Fig. 4-111, Pos. 6) of the cable supply assembly.
z Reconnect the power supply cable (Fig. 4-111, Pos. 3) to the

power station.

according to the grounding procedure of the high voltage
system, refer to section 2.3 on page 2-28.
DANGER
Hazardous Voltage!
Version 2010/1 PC5500-6E 4 - 113

4 - 114 PC5500-6E Version 2010/1

Attachment
5 ATTACHMENT
Version 2010/1 PC5500-6E 5 -1

Backhoe Attachment
5.1 BACKHOE
Fig. 5-1 Backhoe attachment overview
(1) Bucket (backhoe)
(2) Bucket link rod
(3) Bucket cylinder
(4) Stick cylinder
(5) Boom
(6) Boom cylinder

(7) Stick
(8) Steering rod
5 -2 PC5500-6E Version 2010/1

Attachment Backhoe
Version 2010/1 PC5500-6E 5 -3

Backhoe Attachment
5.1.1 BOOM
5.1.1.1 REMOVAL OF THE BOOM
Fig. 5-2 Boom, removal and installation
5 -4 PC5500-6E Version 2010/1

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
Safety harness in conformity with DIN EN 361

Boom: 45,100 kg
Pin boom/superstructure: 365 kg
Dogman/rigger
6.6 on page 6-18.

z Park the machine on the prepared flat ground area and posi-
tion the bucket with its flat side (underside) on the ground.

z Use blocks and support the bucket from behind to secure the
bucket.
Version 2010/1 PC5500-6E 5 -5

Backhoe Attachment
WARNING
attachment.

z Remove the stick, refer to section 5.1.2 on page 5-20.
z Support the boom with appropriate stands (Fig. 5-3, Pos. 1) of

approx. 1 m height.
z Remove the boom cylinders, refer to section 5.1.1.3 on page

5-10.
z 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.
Cap the openings with blind plugs to avoid contamina- Fig. 5-3
tion.
z Disconnect all electric wires from the boom.
z Disconnect the grease feed lines leading to the boom.
z Sling the boom (Fig. 5-4).
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).
z 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 PC5500-6E Version 2010/1

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.
z 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.
z If required, remove all provided parts and the hydraulic piping

from the boom.
Version 2010/1 PC5500-6E 5 -7

Backhoe Attachment
5.1.1.2 REPLACEMENT OF THE BOOM
Special tools: n/a

Boom: 45,100 kg
Dogman/rigger

WARNING
attachment.

NOTE: When performing the installation procedures, comply to

the following:
Always discard used seals (Fig. 5-6, Pos. 2) and install

new seals!
Apply the appropriate grease on every bush (Fig. 5-6,

Pos. 1) and pin on assembly!
Fig. 5-6
z Install new bushes (Fig. 5-7, Pos. 2) into the boom (Fig. 5-7,
Pos. 1) if required, and insert new seals (Fig. 5-7, Pos. 3) into
the bushes.
CAUTION
There is a tolerance gap between bush and seal, so that the
seal can move freely within the groove.
In order to avoid damage to the seals, stick the seals into the
grooves of the bushes with grease, and center the seals in
Fig. 5-7
5 -8 PC5500-6E Version 2010/1

Attachment Backhoe
DANGER
Never put hands into the holes when aligning the boom to
the superstructure.
z Check for leaks and the cylinders operation.
z Check the hydraulic oil level again and add oil if required.
Version 2010/1 PC5500-6E 5 -9

Backhoe Attachment
5.1.1.3 REMOVAL OF BOOM CYLINDERS
Fig. 5-8 Boom cylinder, removal and installation
5 - 10 PC5500-6E Version 2010/1

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
6.6 on page 6-18.
NOTE: At first the wear of the bushes in the hydraulic cylinder

should be checked, refer to the PARTS & SERVICE
NEWS No. "AH08508".
WARNING
attachment.

Version 2010/1 PC5500-6E 5 - 11

Backhoe Attachment

bucket on the ground with the bucket cylinders in fully
extended position (Fig. 5-9).

Fig. 5-9

"RELIEVE THE PRESSURE IN THE HYDRAULIC SYSTEM".
z Remove grease feed lines and fittings from the boom cylin-
der(s) to be removed.
z Sling boom cylinder (piston rod side) (Fig. 5-10).
z Remove the bolts (Fig. 5-10, Pos. 3) and the shackle

z Remove the pin (Fig. 5-10, Pos. 2) connecting the boom cyl-
inder 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 Fig. 5-10
crane.
NOTE: Check bushes (Fig. 5-10, Pos. 1) for wear and damage.
5 - 12 PC5500-6E Version 2010/1

Attachment Backhoe
z Switch S155 to Qmin and retract the boom cylinder to be

removed fully.
z Retract the piston rod of the boom cylinder fully.
z Tie the piston rod to the cylinder body with a wire rope.


Fig. 5-11
WARNING
Hot hydraulic oil!
DANGER
scaring may result.
z Disconnect the main hydraulic hoses from the cylinder, refer



tion.
z Lift the boom cylinder into a horizontal position (Fig. 5-11).
Version 2010/1 PC5500-6E 5 - 13

Backhoe Attachment
z Sling the other side of the cylinder additionally.
z Ease the load of the pin (Fig. 5-12, Pos. 4) in the boom
(Fig. 5-12, Pos. 5) by lifting the cylinder lightly.

NOTE: The catches (Fig. 5-12, Pos. 3) are welded to the boom.
z Remove the pin (Fig. 5-12, Pos. 4) connecting the boom cyl-
inder to the boom.
WARNING
DANGER Fig. 5-12

When pulling the pin out of the boom, make sure that the cyl-
inder is fixed in its position and secured with a crane.
NOTE: Pull the pin (Fig. 5-12, Pos. 4) using two puller bolts at
the threaded holes (Fig. 5-13, Pos. 1).
(Fig. 5-13 is an example)
Fig. 5-13 Example
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.
5 - 14 PC5500-6E Version 2010/1

Attachment Backhoe
z Check bushes for wear and damage. Replace if required.
z If required, disconnect the other boom cylinder from the boom

and remove it using the same procedure as above.
z If required, remove the pipe work from the removed cylin-

der(s). Discard the O-rings and fit caps to the cylinder(s)
openings to avoid environmental contamination.
Version 2010/1 PC5500-6E 5 - 15

Backhoe Attachment
5.1.1.4 REPLACEMENT OF BOOM CYLINDERS
Special tools: n/a

Boom cylinder: 6500 kg each

Dogman/rigger

WARNING
attachment.


the following:

new seals!
Apply the appropriate grease on every bush and pin on

assembly!
z Check the bushes (Fig. 5-14, Pos. 1) and, if required, insert

new bushes into the boom cylinder.
Refer to the PARTS & SERVICE NEWS No. "AH06545".
z Insert new seals (Fig. 5-14, Pos. 2) into the bushes (Fig. 5-14,
Pos. 1) of the boom cylinder.
CAUTION
Fig. 5-14
z Flush out and clean all the pipes.
z Install the hydraulic pipe at the boom cylinder, if required.
5 - 16 PC5500-6E Version 2010/1

Attachment Backhoe
z Position the replacement cylinder (Fig. 5-15, Pos. 6) at the

boom (Fig. 5-15, Pos. 5) using a crane.
DANGER
z Install the pin (Fig. 5-15, Pos. 4) connecting the boom cylin-
der to the boom.
DANGER
Never put hands into the holes when aligning the cylinder to
the boom.
Fig. 5-15
NOTE: Align the pin’s head to the catches (Fig. 5-15, Pos. 3).
z Install the shackle (Fig. 5-15, Pos. 2) and the bolts (Fig. 5-15,
Pos. 1) to secure the pin (Fig. 5-15, Pos. 4).
z Connect the main hydraulic hoses to the boom cylinder, refer

NOTE: Always use new O-rings at the SAE flange connections.
z Remove the wire rope from the cylinder at the side installed to
the boom.
z Lower the cylinder until the piston rod points in the direction of
the mounting location at the superstructure (Fig. 5-16).
Fig. 5-16
Version 2010/1 PC5500-6E 5 - 17

Backhoe Attachment
z Switch S155 to Qmin and retract the boom cylinder fully.
z Remove the wire rope securing the piston rod to the boom
cylinder body.
z Extend and retract the boom cylinder slowly at Qmin

2…3 times as far as possible to partly bleed the cylinder.
z Extend the piston rod to the required position to insert the pin
(Fig. 5-17, Pos. 2) connecting the boom cylinder to the super-
structure.
DANGER
the superstructure.
Fig. 5-17
z Install the pin (Fig. 5-17, Pos. 2).
NOTE: Put the suitable grease into the bushes (Fig. 5-15,
Pos. 1).
z Install the bolts (Fig. 5-15, Pos. 3) and the shackle (Fig. 5-15,
z Perform the bleeding procedure for the stick cylinders.

5 - 18 PC5500-6E Version 2010/1

Attachment Backhoe
Version 2010/1 PC5500-6E 5 - 19

Backhoe Attachment
5.1.2 STICK
5.1.2.1 REMOVAL OF THE STICK
Fig. 5-18 Stick assembly
5 - 20 PC5500-6E Version 2010/1

Attachment Backhoe
(1) Bucket
(2) Bucket link rod
(3) Bucket cylinder
(4) Stick cylinder
(5) Steering rod
(6) Bushes
(7) Bushes
(8) Seal
(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
6.6 on page 6-18.
WARNING
attachment.



Version 2010/1 PC5500-6E 5 - 21

Backhoe Attachment
z Use blocks and support the bucket from behind to secure it.
z 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.
z Disconnect the grease feeding lines leading to the stick.
z Remove the pins connecting the stick cylinders to the stick,

NOTE: Support the stick cylinders (Fig. 5-19, Pos. 1) with blocks
(Fig. 5-19, Pos. 2) between stick cylinders and boom
(Fig. 5-19, Pos. 3).
Fig. 5-19
z Remove the pins connecting the stick cylinders to the stick,

z Sling the stick (Fig. 5-20).
Fig. 5-20
z Undo the lock of the nut-cap (Fig. 5-21, Pos. 1) at the pin con-
necting the stick with the boom by removing the cotter pin
(Fig. 5-21, Pos. 2) from the bore (Fig. 5-21, Pos. 3), and then
removing the bolt (Fig. 5-21, Pos. 2).
z Insert a swivel hoist ring into the nut-cap

(Fig. 5-21, Pos. 1) and attach it to a crane.
Fig. 5-21
5 - 22 PC5500-6E Version 2010/1

Attachment Backhoe
z Remove the nut-cap (Fig. 5-22, Pos. 2) from the pin

(Fig. 5-22, Pos. 1), then fit the "Thread Protector"
PN 409 329 40.
z Pull the pin (Fig. 5-21, Pos. 4) out completely to clear boom
(Fig. 5-22, Pos. 3) and stick.
WARNING
Fig. 5-22
the threaded holes (Fig. 5-23, Pos.1).
(Fig. 5-23 is an example.)
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. 5-23 Example
z Remove the stick using a crane.
DANGER
When moving the stick, make sure that nobody steps below
the lifted stick.
z Lower the stick to the ground and rest it in an appropriate

position.
z Remove the bucket link rod and the steering rod(s), refer to
z Remove the bucket cylinders from the stick, refer to section

5.1.3.3 on page 5-40.
Version 2010/1 PC5500-6E 5 - 23

Backhoe Attachment
5.1.2.2 REPLACEMENT OF THE STICK

Swivel hoist ring
Crane
Stick: 19,160 kg
Nut-Cap: 48 kg
Dogman/rigger

WARNING
attachment.


the following:

new seals!

assembly!
Pos. 1) of the stick.
CAUTION
Fig. 5-24
DANGER
Never put hands into the holes when aligning the stick to the
boom.
5 - 24 PC5500-6E Version 2010/1

Attachment Backhoe
Version 2010/1 PC5500-6E 5 - 25

Backhoe Attachment
5.1.2.3 REMOVAL OF STICK CYLINDERS
Fig. 5-25 Stick cylinder, removal and installation
5 - 26 PC5500-6E Version 2010/1

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) Seal
(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
6.6 on page 6-18.
WARNING
attachment.

z At first the wear of the bushes in the hydraulic cylinders

should be checked, refer to the PARTS & SERVICE NEWS
No. "AH08508".
Version 2010/1 PC5500-6E 5 - 27

Backhoe Attachment

bucket on the ground with the cylinders in partially extended
position (Fig. 5-26).


z Isolate the machine according to local regulations. Fig. 5-26
z Remove grease feed lines and fittings from the stick cylin-
z Sling the cylinder (Fig. 5-27, Pos. 1) to be removed.
Fig. 5-27
z Remove the bolts (Fig. 5-28, Pos. 1), washers, and the
shackle (Fig. 5-28, Pos. 2) securing the pin (Fig. 5-28,
Pos. 3).
z Remove the pin (Fig. 5-28, Pos. 3) connecting the stick cylin-
der to the stick. Remove the two seals (Fig. 5-28, Pos. 4).
WARNING
Fig. 5-28
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 PC5500-6E Version 2010/1

Attachment Backhoe
z 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. 5-47).

NOTE: If the stick is to be removed, put the stick cylinders

(Fig. 5-29, Pos. 1) down on blocks (Fig. 5-29, Pos. 2)
between the stick cylinders and the boom (Fig. 5-29,
Pos. 3).
Fig. 5-29
Version 2010/1 PC5500-6E 5 - 29

Backhoe Attachment
z If the stick cylinder (Fig. 5-30, Pos. 6) is to be removed,

slightly lift up the cylinder to ease to load on the pin (Fig. 5-30,
Pos. 4).
WARNING
Hot hydraulic oil!
DANGER
scaring may result.
z Disconnect the main hydraulic hoses from the stick cylinder,

Fig. 5-30

tion.
z Remove the bolts (Fig. 5-30, Pos. 1), the washers, and the
Pos. 4).
NOTE: The catches (Fig. 5-30, Pos. 3) are welded to the boom.
z Remove the pin (Fig. 5-30, Pos. 4) connecting the stick cylin-
der to the boom (Fig. 5-30, Pos. 5).
5 - 30 PC5500-6E Version 2010/1

Attachment Backhoe
the threaded holes (Fig. 5-31, Pos. 1).
(Fig. 5-31 is an example)
WARNING
DANGER
Risk of falling weights! Fig. 5-31 Example
When pulling the pin out of the cylinder, make sure that the
cylinder is fixed in its position and secured with a crane.
z Remove the stick cylinder using a crane.
z Lower the stick cylinder to the ground and place it in an

appropriate position.
DANGER
z If required, remove the other stick cylinder from the boom

using the same procedure as above.
z If required, remove the hydraulic pipe from the removed cylin-

der(s). Discard the O-rings and fit caps to the cylinder(s)
openings to avoid environmental contamination.
Version 2010/1 PC5500-6E 5 - 31

Backhoe Attachment
5.1.2.4 REPLACEMENT OF STICK CYLINDERS
Special tools: n/a


Dogman/rigger

WARNING
attachment.


the following:
Always discard used seals and install new seals!

assembly!
z Install new bushes (Fig. 5-32, Pos. 1) into the stick cylin-
der(s), if required, refer to the PARTS & SERVICE NEWS
No. "AH06545"!
z Insert two seals (Fig. 5-32, Pos. 2) into the bushes (Fig. 5-32,
Pos. 1) of the stick cylinder(s).
Fig. 5-32
CAUTION
z Flush out and clean all pipes.
z Clean the mating surfaces at the cylinder mounting hole on

the boom.
z Install the hydraulic pipe(s) to the stick cylinders, if required.
5 - 32 PC5500-6E Version 2010/1

Attachment Backhoe
z Using a crane, align the replacement cylinder (Fig. 5-33,

Pos. 6).
DANGER
CAUTION
the boom.
NOTE: Align the pin’s head to the catches (Fig. 5-33, Pos. 3).
Pos. 1) with washers to secure the pin (Fig. 5-33, Pos. 4).
Fig. 5-33
z Connect the main hydraulic hoses to the cylinder, refer to sec-
tion 5.1.6.3 on page 5-66.
z Remove the wire rope from the piston rod.
z To partly bleed the new cylinders, perform the following pro-

cedure:
z Extend the cylinders as far as possible.
z Fully retract the cylinders.
WARNING
The air in the cylinder will result in slightly jerky movements
of the cylinder.
Version 2010/1 PC5500-6E 5 - 33

Backhoe Attachment
z Lower the cylinder and extend the piston rod to the required
position to install the pin into the stick.
WARNING
the stick.
z Install new seals (Fig. 5-34, Pos. 4).
CAUTION
z Install the pin (Fig. 5-34, Pos. 3) connecting the stick cylinder
to the stick.
Fig. 5-34
z Install the two bolts (Fig. 5-34, Pos. 1), washers, and the
shackle (Fig. 5-34, Pos. 2) to secure the pin (Fig. 5-34,
Pos. 3).

5 - 34 PC5500-6E Version 2010/1

Attachment Backhoe
Version 2010/1 PC5500-6E 5 - 35

Backhoe Attachment
5.1.3 BUCKET
5.1.3.1 REMOVAL OF THE BUCKET
Fig. 5-35 Bucket assembly
(1) Bucket
(2) Bucket link rod
(3) Seal fixing ring

(4) Seal
(6) Seal
5 - 36 PC5500-6E Version 2010/1

Attachment Backhoe
Pin bucket/stick: 574 kg

Pin bucket/bucket link rod: 822 kg
Bucket (if lifted): 30,600 kg
Nut-cap: 35 kg
Dogman/rigger
6.6 on page 6-18.


z Use blocks and support the bucket from behind to secure it.

z Remove grease feeding line from the bucket mounting pin

and from the link rod.
z Undo the locks of both the nut-caps at the bucket by remov-

ing the cotter pin (Fig. 5-36, Pos. 2) from the bore (Fig. 5-36,
Pos. 3), and removing the bolt (Fig. 5-36, Pos. 4) afterwards.
z Insert swivel hoist rings into the nut-caps

(Fig. 5-36, Pos. 1) and attach them to a crane.
Fig. 5-36
Version 2010/1 PC5500-6E 5 - 37

Backhoe Attachment
z Remove the seal fixing rings (Fig. 5-37, Pos. 1) located on

both sides of the stick and the bucket link rod.
z Remove the nut-caps (Fig. 5-37, Pos. 7) from the pins

(Fig. 5-37, Pos. 3 and 4), then fit the "Thread Protector"
PN 409 329 40.
z Remove the rings (Fig. 5-37, 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. 5-37
z Pull the pin (Fig. 5-37, Pos. 3) out completely to clear the
bucket (Fig. 5-37, Pos. 8) from the bucket link rod. Also
remove the seals (Fig. 5-37, Pos. 2) when pulling out the pin.
WARNING
z Pull the pin (Fig. 5-37, Pos. 4) out completely to clear the
bucket (Fig. 5-37, Pos. 8) from the stick.
WARNING
NOTE: Pull the pins using two puller bolts at the threaded holes
(Fig. 5-38, Pos. 1), (Fig. 5-38 is only an example).
z Switch S155 to Qmin and lift the boom to clear the bucket.
Fig. 5-38 Example
z Remove and discard the seals (Fig. 5-37, Pos. 2).
z Check bushes (Fig. 5-37, Pos. 5) for wear and damage.

5 - 38 PC5500-6E Version 2010/1

Attachment Backhoe
5.1.3.2 REPLACEMENT OF THE BUCKET

Bucket (if lifted): 30,600 kg
Nut-cap: 35 kg
Dogman/rigger


the following:
Always discard used seals and install new seals

(Fig. 5-39, Pos. 2)!

assembly!
z Slip the seals (Fig. 5-39, Pos. 2) onto the flanges of the
bushes (Fig. 5-39, Pos. 5 and 6) attached to the bucket.
NOTE: During installation, there is not enough space to insert

these seals.
Fig. 5-39
NOTE: Before installing the new bucket, check the grease filling
in the chamber of the bucket link rod (bucket side), refer
to PARTS & SERVICE NEWS No. "AH09522".
Version 2010/1 PC5500-6E 5 - 39

Backhoe Attachment
5.1.3.3 REMOVAL OF BUCKET CYLINDERS
Fig. 5-40 Bucket cylinder, removal and installation
5 - 40 PC5500-6E Version 2010/1

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
(11) Seal
(12) Seal
(13) Bush
(14) Rod protection cover
(15) Pipe

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
6.6 on page 6-18.
WARNING
attachment.

Version 2010/1 PC5500-6E 5 - 41

Backhoe Attachment
NOTE: At first the wear of the bushes in the hydraulic cylinder

NEWS No."AH08508".

tion the bucket on the ground as shown in Fig. 5-41, with the
bucket cylinders not fully retracted.

z Base the stick on an appropriate stand (Fig. 5-41, Pos. 1).

Fig. 5-41
z Base the bucket cylinders with appropriate blocks (Fig. 5-41,
Pos. 2).

z Remove grease feed lines and fittings from the cylinder(s) to

be removed.
z 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. 5-42, Pos. 1) to a

crane using the shackle (Fig. 5-42, arrow).
z Remove the protection cover (Fig. 5-42, Pos. 1) from the

bucket cylinder (Fig. 5-42, Pos. 2).
Fig. 5-42
z Undo the lock of the nut-cap at the piston rod side of the
bucket cylinder by removing the cotter pin (Fig. 5-43, Pos. 2)
from the bore (Fig. 5-43, Pos. 3), and then removing the bolt
(Fig. 5-43, Pos. 4).

Fig. 5-43
5 - 42 PC5500-6E Version 2010/1

Attachment Backhoe

both sides of the cylinder piston rods (Fig. 5-44, Pos. 2).

PN 409 329 40.
Fig. 5-44
z Sling the steering rods (Fig. 5-45, Pos. 2).
z Using a crane, support the bucket link rod (Fig. 5-45, Pos. 1)
if both or the left cylinder needs to be removed.
z Pull the pin (Fig. 5-45, Pos. 4) at the bucket cylinders, refer to
WARNING
Fig. 5-45
NOTE: If removing the right-hand cylinder only, pull the pin
(Fig. 5-45, Pos. 4) out just enough to clear the cylinder
piston rod.
NOTE: Pull the pin (Fig. 5-44, Pos. 4) out using two puller bolts
at the threaded holes (Fig. 5-46, Pos. 1).
Fig. 5-46
z Switch S155 to Qmin and retract the bucket cylinder(s) to be

removed.
Version 2010/1 PC5500-6E 5 - 43

Backhoe Attachment
z Tie the piston rod to the cylinder body with a wire rope
(Fig. 5-47).
Fig. 5-47
WARNING
Hot hydraulic oil!
DANGER
scaring may result.
z Disconnect the main hydraulic hoses from the cylinder(s),



tion.
5 - 44 PC5500-6E Version 2010/1

Attachment Backhoe
z Using a crane, sling the cylinder (Fig. 5-48, Pos. 1) to be

removed. Ease the load of the pin (Fig. 5-48, Pos. 2) by lifting
the cylinder lightly.
Fig. 5-48
z Remove the two bolts (Fig. 5-49, Pos. 2), washers, and the
Pos. 4).
z Remove the pin (Fig. 5-49, Pos. 4) connecting the cylinder

(Fig. 5-49, Pos. 1) to the stick. Remove the two seals
(Fig. 5-49, Pos. 5).
WARNING
Fig. 5-49
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 2010/1 PC5500-6E 5 - 45

Backhoe Attachment
5.1.3.4 REPLACEMENT OF BUCKET CYLINDERS

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
attachment.


the following:

assembly!
z Check all bushes in the bucket cylinder. Replace as required,

refer to the PARTS & SERVICE NEWS No. "AH06545"!
z Flush out and clean all the pipes and connecting blocks.
z If required, install the pipe work, the connecting blocks, and

the seals at the cylinder(s).
5 - 46 PC5500-6E Version 2010/1

Attachment Backhoe
z Insert new seals (Fig. 5-50, Pos. 5) into the bushes at the
bucket cylinder mounting hole in the stick.
CAUTION
z Using a crane, support and position the replacement bucket

cylinder (Fig. 5-50, Pos. 1) at the stick. Fig. 5-50
DANGER
When lifting the cylinder, make sure that nobody steps below
the weight.
CAUTION
the stick.
z Install the shackle (Fig. 5-50, Pos. 3), the two washers, and
the bolts (Fig. 5-50, Pos. 2) to secure the pin (Fig. 5-50,
Pos. 4).
z Connect the main hydraulic hoses to the bucket cylinder(s),
z Remove the wire rope from the piston rod.
Version 2010/1 PC5500-6E 5 - 47

Backhoe Attachment
z To partly bleed the new cylinder, perform the following proce-

dure 2…3 times:
z Extend the cylinder as far as possible.
z Fully retract the cylinder.
WARNING
of the cylinder.

5 - 48 PC5500-6E Version 2010/1

Attachment Backhoe
5.1.4 BUCKET LINK ROD AND STEERING RODS
5.1.4.1 REMOVAL OF THE BUCKET LINK ROD

Bucket link rod: 2280 kg

Steering rod: 1300 kg
Pin bucket cylinder/steering rod: 865 kg
Nut-cap: 35 kg
Dogman/rigger
6.6 on page 6-18.
WARNING
attachment.




Fig. 5-51
z Base the bucket cylinders with appropriate blocks (Fig. 5-51,
Pos. 2).
z Relieve the pressure in the bucket cylinders only. Refer to the
z Disconnect the grease feed lines from the bucket link rod.
Version 2010/1 PC5500-6E 5 - 49

Backhoe Attachment
z Sling the bucket link rod (Fig. 5-52, Pos. 1) and both steering
rods (Fig. 5-52, Pos. 2).
z Remove the pin (Fig. 5-52, Pos. 4) at the bucket cylinders,

WARNING

Fig. 5-52
z At Qmin fully retract the bucket cylinder to clear the link rod.
z Remove the pin (Fig. 5-52, Pos. 3) at the bucket, refer to sec-
tion 5.1.3.1 on page 5-36.
WARNING
z Remove the bucket link rod (Fig. 5-52, Pos. 1) using a crane.
DANGER
When moving the bucket link rod, make sure that nobody
steps below the lifted weight.
5 - 50 PC5500-6E Version 2010/1

Attachment Backhoe
5.1.4.2 REPLACEMENT OF THE BUCKET LINK ROD


Nut-cap: 35 kg
Dogman/rigger

WARNING
attachment.

NOTE: Always discard used seals and install new seals!
Prior to assembly all bushes must be inspected and

replaced as required!
Before installing the new bucket, fill the chamber of the

bucket link rod (bucket side) with grease, refer to PARTS

assembly!
Version 2010/1 PC5500-6E 5 - 51

Backhoe Attachment
5.1.4.3 REMOVAL OF THE STEERING RODS


Pin steering rod/stick: 479 kg
Nut-cap: 35 kg
Dogman/rigger
6.6 on page 6-18.
WARNING
attachment.




Fig. 5-53
z Base the bucket cylinder with appropriate blocks (Fig. 5-53,
Pos. 2).
z Relieve the pressure in the bucket cylinders only. Refer to the

z Disconnect the grease feed line from the left-hand steering

rod.
5 - 52 PC5500-6E Version 2010/1

Attachment Backhoe
z Sling the bucket link rod (Fig. 5-54, Pos. 1) and the steering
rod(s) (Fig. 5-54, Pos. 2) to be removed.
NOTE: If removing the left-hand steering rod only or both steer-

ing rods, sling both steering rods.
If removing the right-hand steering rod only, sling the
right-hand steering rod only.
z Remove the pin (Fig. 5-54, Pos. 3) at the bucket cylinders,

WARNING
Sling the pin as soon as possible and support it using a Fig. 5-54
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. 5-54, Pos. 4) by
removing the cotter pin (Fig. 5-55, Pos. 2) from the bore
(Fig. 5-55, Pos. 3), then removing the bolt (Fig. 5-55, Pos. 4).

Fig. 5-55

both sides between the steering rod (Fig. 5-56, Pos. 3) and
the stick (Fig. 5-56, Pos. 5).

PN 409 329 40.
z Pull the pin (Fig. 5-56, Pos. 4 / Fig. 5-54, Pos. 4) out
completely to clear both steering rods.
WARNING
Sling the pin as soon as possible and support it using a Fig. 5-56
Version 2010/1 PC5500-6E 5 - 53

Backhoe Attachment
NOTE: Pull the pin (Fig. 5-56, Pos. 4) out using two puller bolts
at the threaded holes (Fig. 5-57, Pos. 1).
If removing the right-hand steering rod only, pull the pin

out just enough to clear the steering rod (Fig. 5-56,
Pos. 3).
If removing the left-hand steering rod or both steering

rods, pull out the pin completely to clear both steering
rods
Fig. 5-57
z Remove the steering rod(s) using a crane.
DANGER
When lifting the steering rod, make sure that nobody steps
below the lifted weight.
5 - 54 PC5500-6E Version 2010/1

Attachment Backhoe
5.1.4.4 REPLACEMENT OF THE STEERING RODS


Pin steering rod/stick: 479 kg
Nut-cap: 35 kg
Dogman/rigger

WARNING
attachment.

NOTE: Always discard used seals and install new seals!
Prior to assembly all bushes must be inspected and

replaced as required!

assembly!
NOTE: Before installing the pin connecting the steering rods to

the bucket link rod, check the grease filling in the cham-
ber of the bucket link rod, and fill it up with grease, if
required. Refer to PARTS & SERVICE NEWS No.
"AH09522".
Version 2010/1 PC5500-6E 5 - 55

Backhoe Attachment
5.1.5 GROUND ENGAGING TOOLS (GET)

As ground engaging tools, the ESCO POSILOK Tooth System is
used. (Other feasible systems have a similar build-up.)
Fig. 5-58 POSILOK System
(1) Shroud
(2) Wedge
(3) Toplok boss
(4) Base plate
(5) Wear plate
(6) Wear cap (option)
(7) Tooth adapter (center/corner)

(8) Point (tooth)
(9) Locking pin
(10) Pin
5 - 56 PC5500-6E Version 2010/1

Attachment Backhoe
5.1.5.1 REMOVAL AND REPLACEMENT OF THE GET
POSILOK Pin removal tool PN 793 502 73

Special tools:
Hensley Pin removal tool (ask local dealer)
ESCO POSILOK Tooth System S130

Additional equipment: 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.
tion the bucket in an appropriate height for work.

z For removing and installing the ESCO Tooth System, refer to

z Remove and install the Hensley Tooth System accordingly to

PARTS & SERVICE NEWS No. "AH03510". (Hensley uses a
basically similar system to that from ESCO.)
NOTE: Use a forklift to remove and install the GET.
Version 2010/1 PC5500-6E 5 - 57

Backhoe Attachment
5.1.6 HYDRAULIC HOSES AT THE BACKHOE ATTACHMENT
5.1.6.1 SUBSTITUTE THE BOOM ARC HOSES
Fig. 5-59 Arc hoses, removal and installation
5 - 58 PC5500-6E Version 2010/1

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

Oil drain pan
Boom arc hose: 39 kg
Dogman/rigger

6.6 on page 6-18.
WARNING
Always wear a safety harness when working at the attach-
ment.

extended and the stick cylinders in fully retracted position
(Fig. 5-60).

Fig. 5-60
Version 2010/1 PC5500-6E 5 - 59

Backhoe Attachment
Fig. 5-61 Arc hoses, removal and installation

5 - 60 PC5500-6E Version 2010/1

Attachment Backhoe
z Open the hose clamps (Fig. 5-61, Pos. 1) and clear the
hydraulic hose (Fig. 5-61, Pos. 6) to be removed from the
clamp lines (Fig. 5-61, Pos. 2).
WARNING
Hot hydraulic oil!
DANGER
ring may result.
z Sling the hydraulic hose (Fig. 5-61, Pos. 6) to be removed.
z Remove the bolts (Fig. 5-61, Pos. 7) as well as the nuts

(Fig. 5-61, Pos. 3) and disconnect the SAE flanges from the
manifold (Fig. 5-61, Pos. 4) and from the hydraulic pipe
(Fig. 5-61, Pos. 5) at the boom.


tion.
z Remove the hydraulic hose using a crane.
z Replace the boom arc hoses by new ones and carry out
installation in reverse order to removal.
NOTE: Always replace the O-rings (Fig. 5-61, Pos. 8) at the

SAE flange connections.
z Substitute the other boom arc hoses if required, using the

same procedure.
z Perform the bleeding procedure for all cylinders.

z Check hydraulic oil level again and add oil if required.
Version 2010/1 PC5500-6E 5 - 61

Backhoe Attachment
5.1.6.2 SUBSTITUTE THE BOOM CYLINDER HOSES
Fig. 5-62 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 PC5500-6E Version 2010/1

Attachment Backhoe
Special tools: n/a

Oil drain pan
Boom cylinder hose (depending on length):

29.5 kg
39 kg
Dogman/rigger

6.6 on page 6-18.
WARNING
attachment.


(Fig. 5-63).

Fig. 5-63
Version 2010/1 PC5500-6E 5 - 63

Backhoe Attachment
Fig. 5-64 Hoses of the boom cylinders, removal and installation
z Sling the hydraulic hose (Fig. 5-64, Pos. 1 or 2) to be

removed.
z Remove the guard plate (Fig. 5-64, Pos. 5).
5 - 64 PC5500-6E Version 2010/1

Attachment Backhoe
WARNING
Hot hydraulic oil!
DANGER
scaring may result.
z Remove the bolts (Fig. 5-64, Pos. 6) and disconnect the

SAE flanges from the boom cylinder (Fig. 5-64, Pos. 7)
respective the hydraulic piping (Fig. 5-64, Pos. 3) at the boom
cylinder and from the pipe (Fig. 5-64, Pos. 4) at the boom.


tion.
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.
z Perform the bleeding procedure for the boom cylinder(s).

Version 2010/1 PC5500-6E 5 - 65

Backhoe Attachment
5.1.6.3 SUBSTITUTE THE STICK CYLINDER HOSES
Fig. 5-65 Hoses of the stick cylinders, removal and installation
(1) Hydraulic hose
(2) Hydraulic hose

(3) Hydraulic pipe
(4) O-Ring
(5) Bolt
5 - 66 PC5500-6E Version 2010/1

Attachment Backhoe
Special tools: n/a

Oil drain pan
Stick cylinder hose (depending on length):

23 kg
27.5 kg
Dogman/rigger
6.6 on page 6-18.

WARNING
attachment.


(Fig. 5-66).

Fig. 5-66
Version 2010/1 PC5500-6E 5 - 67

Backhoe Attachment
Fig. 5-67 Hoses of the stick cylinders, removal and installation

removed.
WARNING
Hot hydraulic oil!
DANGER
scaring may result.
5 - 68 PC5500-6E Version 2010/1

Attachment Backhoe

SAE flanges at the stick cylinder and the hydraulic pipe


tion.
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.
z Perform the bleeding procedure for the stick cylinder(s).

Version 2010/1 PC5500-6E 5 - 69

Backhoe Attachment
5.1.6.4 SUBSTITUTE THE BUCKET CYLINDER HOSES
Fig. 5-68 Hoses of the bucket cylinders, removal and installation
(1) Hydraulic hose
(2) Hydraulic hose

(3) Hydraulic pipe
(4) O-ring
(5) Bolt
5 - 70 PC5500-6E Version 2010/1

Attachment Backhoe
Special tools: n/a

Oil drain pan
Bucket cylinder hose: 33 kg
Dogman/rigger

6.6 on page 6-18.
WARNING
attachment.


(Fig. 5-69).

Fig. 5-69

Version 2010/1 PC5500-6E 5 - 71

Backhoe Attachment
Fig. 5-70 Hoses of the bucket cylinders, removal and installation

removed.
WARNING
Hot hydraulic oil!
DANGER
scaring may result.
5 - 72 PC5500-6E Version 2010/1

Attachment Backhoe

SAE flanges from the bucket cylinder and the hydraulic pipe


tion.
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.
z Perform the bleeding procedure for the bucket cylinder(s).

Version 2010/1 PC5500-6E 5 - 73

Face shovel (FSA) Attachment
5.2 FACE SHOVEL (FSA)
Fig. 5-71 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 PC5500-6E Version 2010/1

Attachment Face shovel (FSA)
5.2.1 USING THE INSTALLATION TOOLS FOR HYDRAULIC CYLINDERS

Designated use:
Each hydraulic cylinder has a groove (Fig. 5-72, arrow) at each

end of the cylinder body (Fig. 5-72, Pos. 1). Clamp the installation
tool (Fig. 5-72, Pos. 2) on the hydraulic cylinder using the groove.
Fig. 5-72
The tools are designed to handle the attachment’s hydraulic cylin-

ders vertically in combination with a forklift. Thereby, the forks of
the forklift are inserted between the cylinder body and the scor-
pers (Fig. 5-73, Pos. 2). The tools’ extensions (Fig. 5-73, 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 Fig. 5-73
tools.
Version 2010/1 PC5500-6E 5 - 75

5.2.2 BOOM
5.2.2.1 REMOVAL OF THE BOOM
Fig. 5-74 Boom removal
(1) Boom
(2) Pin
(3) Shackle
(4) Bolt
(5) Shackle
(6) Bolt
(7) Pin
(8) Chain hoist
5 - 76 PC5500-6E Version 2010/1

Special tools: n/a

4 x Chain hoist
Oil drain pan
Boom with attached stick and boom cylinders: 52,900 kg
Dogman/rigger
6.6 on page 6-18.
WARNING
attachment.

NOTE: Before the disassembly of the attachment, the wear of

the bushes of the attachment and at the superstructure
should be checked. Refer to the PARTS & SERVICE
NEWS No. "AH08508".

bucket on the ground with the stick and the bucket cylinders
in vertical position (Fig. 5-75).

Fig. 5-75

z Remove the stick, refer to section 5.2.3 on page 5-96.
NOTE: Leave the stick cylinders retracted and fixed to the boom.
Secure them under the boom using chain hoists.
Version 2010/1 PC5500-6E 5 - 77

Fig. 5-76 Boom removal
z Tie the piston rods to the stick cylinder bodies with a wire
rope (refer to Fig. 5-47).
z Disconnect the grease feeding lines leading to the boom and

the bearing of the boom cylinder rod.
z Disconnect all electric wires from the boom.
z Fix the boom cylinders to the boom using chain hoists

(Fig. 5-76, Pos. 8).
z Attach the front part of the boom to a crane.
z Remove the bolts (Fig. 5-76, Pos. 6) and the shackles

(Fig. 5-76, Pos. 5) securing the pins (Fig. 5-76, Pos. 7).
5 - 78 PC5500-6E Version 2010/1

z Remove the pins (Fig. 5-76, Pos. 7) attaching the boom cylin-
ders to the superstructure. Note the seals.
WARNING
z Switch S155 to Qmin and retract the boom cylinders fully.
z Tie the piston rods to the boom cylinder body with a wire rope

DANGER
scaring may result.
z Disconnect all hydraulic hoses from the boom leading to the

manifold, refer to section 5.2.6.1 on page 5-142.


tion.
z Attach the rear part of the boom to another crane.
z Remove the bolts (Fig. 5-76, Pos. 4) and the shackles

(Fig. 5-76, Pos. 3) securing the pins (Fig. 5-76, Pos. 2).
z Remove the pins (Fig. 5-76, Pos. 2) attaching the boom to the
superstructure.
WARNING
Version 2010/1 PC5500-6E 5 - 79

z Remove the boom with attached stick cylinders and boom

cylinders using two cranes. Place it on appropriate stands.
WARNING
Make sure that the crane operators are trained in dual crane
lift.
DANGER
the lifted boom.
z Carry out the next steps with the boom placed on appropriate
stands:
z Remove the pins of the boom cylinders, refer to section

5.2.2.3 on page 5-88, and remove the boom cylinders
from the boom.
z Remove the pins of the stick cylinders, refer to section

5.2.3.3 on page 5-104, and remove the stick cylinders
from the boom.
z Remove all provided parts and the hydraulic piping from

the boom.
5 - 80 PC5500-6E Version 2010/1

Version 2010/1 PC5500-6E 5 - 81

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
attachment.


the following:
Apply the appropriate grease in every bush and pin on

assembly!
z Install new bushes (Fig. 5-77, Pos. 3 and 5) into the boom
(Fig. 5-77, Pos. 1), if required, and insert new seals
(Fig. 5-77, Pos. 2 and 4) into the bushes.
Fig. 5-77
5 - 82 PC5500-6E Version 2010/1

CAUTION
There is a tolerance gap between the bush (Fig. 5-78, Pos. 2)
in the boom (Fig. 5-78, Pos. 1) and the seal (Fig. 5-78, Pos. 3),
so that the seal can move freely within the groove.
Fig. 5-78
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.
z 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 2010/1 PC5500-6E 5 - 83

Fig. 5-79 FSA boom installation
z Fix the cylinders at the boom using chain hoists (Fig. 5-79,
Pos. 8).
z Attach the boom to two cranes.
WARNING
Before lifting the boom, make sure that the crane operators
are trained in dual crane lift.
z Lift the boom (Fig. 5-79, Pos. 1) with the boom and stick cylin-
ders attached using two cranes.
NOTE: Lift the front part of the boom higher than the back part.
5 - 84 PC5500-6E Version 2010/1

DANGER
the lifted weight.
z Align the boom (Fig. 5-79, Pos. 1) to the superstructure.
DANGER
Never put hands into the holes when aligning the boom to
the superstructure.
z Insert the two pins (Fig. 5-79, Pos. 2).
z Detach the rear part of the boom from the crane.
z Install the shackles (Fig. 5-79, Pos. 3), and bolts (Fig. 5-79,
Pos. 4) to secure the pins (Fig. 5-79, Pos. 2).
z Connect the hydraulic lines leading from the manifold to the

boom, refer to section 5.2.6.1 on page 5-142.
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.
z Align the boom cylinder to the superstructure by lifting or low-

ering the boom using the crane.
NOTE: Use the chain hoist (Fig. 5-79, Pos. 8) to lift or lower the
boom cylinders until they point to the mounting location at
the superstructure.
z Retract the boom cylinder fully.
WARNING
of the cylinder.
z Remove the wire ropes from the boom cylinders.
Version 2010/1 PC5500-6E 5 - 85

z Align the boom cylinders to the superstructure.

Move the boom up and down using the crane, and use the
chain hoists to align the cylinders to the mounting location at
the superstructure.
DANGER
Never put hands into the holes when aligning the boom cyl-
inders to the superstructure.
z Insert the pins (Fig. 5-79, Pos. 7).

z Install the shackle (Fig. 5-79, Pos. 5) and the bolt (Fig. 5-79,
z Lower the boom completely and detach the crane.
z Perform the bleeding procedure for the boom cylinders.

5 - 86 PC5500-6E Version 2010/1

Version 2010/1 PC5500-6E 5 - 87

5.2.2.3 REMOVAL OF THE BOOM CYLINDERS
Fig. 5-80 Boom cylinder, removal and installation
5 - 88 PC5500-6E Version 2010/1

(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
Mobile elevator working platform (telescopic or articulated boom lift)
Oil drain pan
Boom cylinder: 5680kg
Dogman/rigger
6.6 on page 6-18.
Version 2010/1 PC5500-6E 5 - 89

WARNING
attachment.

NOTE: At first, the wear of the bushes in the hydraulic cylinder

NEWS No. "AH08508".



Operation & Maintenance Manual, chapter 3, section Fig. 5-81
z Disconnect the grease feeding lines from the boom cylin-

z Sling the lower end of the boom cylinder (Fig. 5-82, Pos. 1)
and fix it to the boom (Fig. 5-82, Pos. 2) using a chain hoist.
z Remove the bolt (Fig. 5-82, Pos. 3) and the shackle

z Remove the pin (Fig. 5-82, Pos. 5) attaching the boom cylin-
der to the superstructure.
WARNING
Fig. 5-82
z Tie the piston rod to the boom cylinder body with a wire rope.
5 - 90 PC5500-6E Version 2010/1


WARNING
Hot hydraulic oil!
DANGER
scaring may result.
z Disconnect the hydraulic hoses from the boom cylinder, refer


inside the piping and the hoses will flow out. Catch it in an
oil pan.

tion.
z Lower the boom cylinder with the chain hoist until the cylinder
is in vertical position.
z Install the installation tool PN 934 611 40 at the boom cylin-

der’s upper side.
z Support the boom cylinder by means of the installation tool

using the forks of a forklift.
z Remove the bolts (Fig. 5-83, Pos. 1), the cover (Fig. 5-83,
Pos. 2), and the ring (Fig. 5-83, Pos. 3).
z Remove the pin (Fig. 5-83, Pos. 4) with the catches

(Fig. 5-83, Pos. 5).
WARNING
Fig. 5-83
Version 2010/1 PC5500-6E 5 - 91

z Remove the boom cylinder using the forklift.
NOTE: Use a crane to lift the cylinder from 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 - 92 PC5500-6E Version 2010/1

5.2.2.4 REPLACEMENT OF THE BOOM CYLINDERS

Chain hoist
Forklift
Boom cylinder: 5680 kg

Dogman/rigger

WARNING
attachment.


the following:

assembly!
z Insert a new bushes (Fig. 5-84, Pos. 3) into the boom cylinder
(Fig. 5-84, Pos. 1), if required. Refer to the PARTS &
Pos. 3) of the boom cylinder (Fig. 5-84, Pos. 1).
Fig. 5-84
z Install the installation tool PN 934 611 40 at the upper end of
the new boom cylinder.
z Tie the moving rod to the cylinder body with a wire rope.
Version 2010/1 PC5500-6E 5 - 93

z 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.
z Align the upper end of the boom cylinder with the boom using
the forklift.
DANGER
inder to the boom.
z Insert the pin (Fig. 5-85, Pos. 4) with the catches

(Fig. 5-85, Pos. 5).
z Install the ring (Fig. 5-85, Pos. 3), the cover (Fig. 5-85,
Pos. 2), and the bolts (Fig. 5-85, Pos. 1) with lock washers.
Fig. 5-85
z Sling the boom cylinder body at the piston rod side using a
chain hoist. Fix the chain hoist to the boom.
z Hoist the boom cylinder as far as needed to point in the direc-

tion of its mounting position at the superstructure.
z Connect the hydraulic lines to the boom cylinder, refer to sec-

tion 5.2.6.2 on page 5-146.
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. Fig. 5-86
First connect the hydraulic line, then remove the wire ropes.
5 - 94 PC5500-6E Version 2010/1

z Remove the wire rope securing the piston rod of the boom
cylinder.
z Extend and retract the boom cylinder slowly at Qmin

2...3 times as far as possible to partly bleed the cylinder.
WARNING
of the cylinder.
z Extend the boom cylinder as needed to align the cylinder with

the superstructure.
DANGER
inder to the superstructure.
z Insert the pin (Fig. 5-86, Pos. 5).
z Install the shackle (Fig. 5-86, Pos. 4), and the bolt (Fig. 5-86,
z Detach the chain hoist from the boom cylinder body.
z Perform the bleeding procedure for the boom cylinders.

Version 2010/1 PC5500-6E 5 - 95

5.2.3 STICK
5.2.3.1 REMOVAL OF THE STICK
Fig. 5-87 Stick, removal and installation
5 - 96 PC5500-6E Version 2010/1

(1) Boom
(2) Stick
(3) Bush
(4) Seal ring
(5) Catch
(6) Pin
(7) Ring
(8) Cover
(9) Bolt
(10) Seal
(11) Ring (welded to the stick)
(12) Flange bush
(13) Bush
(14) Pin
(15) Shackle
(16) Bolt
Special tools: n/a

Crane
2 x Chain hoist
Stick: 21,000 kg
Stick cylinder: 3340 kg
Dogman/rigger
6.6 on page 6-18.
WARNING
attachment.

Version 2010/1 PC5500-6E 5 - 97




z Remove all grease feeding lines and electric wires from the
stick.
z Remove the bull clam bucket, refer to section 5.2.4.1 on page

5-114.
z Hang up both stick cylinders (Fig. 5-89, Pos. 1) at the boom

using chain hoists (Fig. 5-89, Pos. 2).
z Carry out the following steps for each stick cylinder:

z Remove the pin (Fig. 5-89, Pos. 3).
WARNING
NOTE: Note the seals (Fig. 5-89, Pos. 5) when removing the pin. Fig. 5-89
z Check the bushes (Fig. 5-89, Pos. 6) and replace if

required.
z Switch S155 to Qmin and retract the stick cylinders (Fig. 5-89,
Pos. 1) fully.

5 - 98 PC5500-6E Version 2010/1

DANGER
scaring may result.
z Disconnect all grease feeding lines and hydraulic hoses from

the stick leading to the boom, refer to section 5.2.6.3 on page
5-150.
z Sling the stick (Fig. 5-90, Pos. 1) to a crane, and lift the stick
slightly to ease the load of the pins (Fig. 5-90, Pos. 6).
z Remove the bolts (Fig. 5-90, Pos. 2) and the covers

(Fig. 5-90, Pos. 3).
z Remove the pins (Fig. 5-90, Pos. 6) with the catches

(Fig. 5-90, Pos. 5).
WARNING
Sling the pins as soon as possible and support them using a
crane to prevent the pins from falling.
z Remove the stick and rest it on the ground using a crane.
DANGER
the lifted weight.
Fig. 5-90
z Remove all pieces of equipment and the hydraulic piping from

the stick (Fig. 5-90, Pos. 1).
Version 2010/1 PC5500-6E 5 - 99

5.2.3.2 REPLACEMENT OF THE STICK
Special tools: n/a

Crane
2 x Chain hoist
Stick: 21,000 kg
Dogman/rigger

WARNING
attachment.

NOTE: If the flange connections (Fig. 5-91, Pos. 1) of the

hydraulic lines to the bucket cylinder mounted at the stick
(Fig. 5-91, Pos. 2) are arranged horizontally (as shown in
Fig. 5-91), the hydraulic lines at the stick, the hydraulic
hoses between boom and stick, and the hose clamps
should be replaced.
For further information, refer to the PARTS & SERVICE
NEWS No. "AH09505".
Fig. 5-91

the following:
Put the appropriate grease in every bush on assembly!
5 - 100 PC5500-6E Version 2010/1

z Check the bushes at the stick (Fig. 5-92, Pos. 1), and the
bushes for the stick at the boom. Replace, if required.
z Insert new seals into the grooves (Fig. 5-92, Pos. 3) of the
bushes (Fig. 5-92, Pos. 2).
CAUTION
Fig. 5-92
z Install all provided parts and the hydraulic piping to the stick
(Fig. 5-93, Pos. 1).
z Sling the stick (Fig. 5-93, 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.
z Install the pins (Fig. 5-93, Pos. 6) attaching the stick

(Fig. 5-93, Pos. 1) to the boom.
z Install the catches (Fig. 5-93, Pos. 5), the rings (Fig. 5-93, Fig. 5-93
Pos. 4), the covers (Fig. 5-93, Pos. 3), and the bolts
(Fig. 5-93, Pos. 2) to secure the pins (Fig. 5-93, Pos. 6).
Version 2010/1 PC5500-6E 5 - 101

z Bring the stick to the position shown in Fig. 5-94 using the
crane.
z Switch S155 to Qmin and extend the stick cylinders (Fig. 5-94,
Pos. 1) to align the stick cylinders with the stick horizontally.
Use the chain hoists (Fig. 5-94, Pos. 2) to align the stick cylin-
ders with the stick vertically.
DANGER
Never put hands into the holes when aligning the stick cylin-
ders to the stick.
Fig. 5-94
z Put the appropriate grease in the bushes (Fig. 5-94, Pos. 6)

and install the pins (Fig. 5-94, Pos. 3) with new seals
(Fig. 5-94, Pos. 5).
Pos. 7) to secure the pins (Fig. 5-94, Pos. 3).
z Check the hydraulic oil level again and add oil, if required.
5 - 102 PC5500-6E Version 2010/1

Version 2010/1 PC5500-6E 5 - 103

5.2.3.3 REMOVAL OF THE STICK CYLINDERS
Fig. 5-95 Stick cylinder, removal and installation
5 - 104 PC5500-6E Version 2010/1

(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
Additional equipment: Forklift
Oil drain pan

Dogman/rigger
6.6 on page 6-18.
WARNING
attachment.

Version 2010/1 PC5500-6E 5 - 105



Fig. 5-96
z Secure the stick cylinder (Fig. 5-97, Pos. 1) to be removed

under the boom using one chain hoist at each side of the
cylinder.
z Pull out the pin connecting the stick cylinder piston rod to the
stick, refer to section 5.2.3.1 on page 5-96.
WARNING
crane to prevent the pin from falling when it is pulled out
completely.
Fig. 5-97
z Switch S155 to Qmin and retract the stick cylinder (Fig. 5-97,
Pos. 1) fully.
z Tie the piston rod to the cylinder body with a wire rope (refer
to Fig. 5-47).

5 - 106 PC5500-6E Version 2010/1

WARNING
Hot hydraulic oil!
DANGER
scaring may result.
z Disconnect the hydraulic hoses from the stick cylinder, refer


oil pan.

tion.

(Fig. 5-98, Pos. 2), securing the pin (Fig. 5-98, Pos. 3).
WARNING
crane to prevent the pin from falling when it is pulled out
completely.
NOTE: Note the seals (Fig. 5-98, Pos. 4) when removing the pin.
z Check the bush (Fig. 5-98, Pos. 5), and replace it if required.
Fig. 5-98
Version 2010/1 PC5500-6E 5 - 107

z 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
z If both stick cylinders are to be removed, repeat the dismount-

ing 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 - 108 PC5500-6E Version 2010/1

5.2.3.4 REPLACEMENT OF THE STICK CYLINDERS

Forklift
2 x Chain hoist

Dogman/rigger

WARNING
attachment.


the following:
Always discard used seals, and install new seals!

assembly!
z If required, install the pipe work and the connecting blocks to

the stick cylinder(s).
z Attach two chain hoists to the underside of the boom.
z Tie the piston rod of the stick cylinder to be installed to the

cylinder body with a wire rope (refer to Fig. 5-47).
z Place the stick cylinder on a forklift horizontally, and position

the stick cylinder right underneath the chain hoists.
z Connect a chain hoist to each side ot the stick cylinder.
DANGER
When moving the stick cylinder, make sure that nobody
Version 2010/1 PC5500-6E 5 - 109

Pos. 5) for the stick cylinder at the boom and at the stick.
CAUTION
z 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 cylin- Fig. 5-99
ders to the boom.
z Insert the pin (Fig. 5-99, Pos. 3).
z Connect the hydraulic hoses to the stick cylinder (Fig. 5-100,

Pos. 1), refer to section 5.2.6.4 on page 5-154.
z Switch S155 to Qmin and retract the stick cylinder (Fig. 5-100,
Pos. 1) fully.
NOTE: Use only motor no. at Qmin.
z Remove the wire rope from the stick cylinder (Fig. 5-100,
Pos. 1).
z Extend and retract the stick cylinder (Fig. 5-100, Pos. 1)

slowly at Qmin 2…3 times as far as possible to partly bleed Fig. 5-100
the cylinder.
WARNING
of the cylinder.
z Extend the stick cylinder slowly at Qmin and use the chain
hoist to align the stick cylinder to the stick.
5 - 110 PC5500-6E Version 2010/1

DANGER
Never put hands into the holes when aligning the stick cylin-
der to the stick.
z Install the pin connecting the stick cylinder with the stick, refer


Maintenance Manual, chapter 4, section "HYDRAULIC
SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS
Version 2010/1 PC5500-6E 5 - 111

5.2.4 BULL CLAM BUCKET
Fig. 5-101 Bull clam bucket, removal and installation
5 - 112 PC5500-6E Version 2010/1

(1) Bull clam bucket
(2) Bush
(3) Ring (welded to the bucket)

(4) Pin
(5) Axle stirrup
(6) Catch (welded to the bucket)

(7) Shackle
(8) Bolt
(9) Bush
(10) Pin
(11) Axle stirrup
(12) Catch (welded to the bucket)
(13) Shackle
(14) Bolt
(15) Bucket cylinder
(16) Seal
(17) Stick
(19) Seal
Version 2010/1 PC5500-6E 5 - 113

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
6.6 on page 6-18.



z Disconnect the grease feeding lines leading to the bucket.
z Remove the plate (Fig. 5-103, Pos. 2) from inside the bucket
(Fig. 5-103, Pos. 1) to gain access to the assembly opening.
Fig. 5-103
5 - 114 PC5500-6E Version 2010/1

WARNING
Hot hydraulic oil!
DANGER
scaring may result.
z Disconnect the hydraulic hoses from the clam cylinder distrib-

utor blocks, refer to section 5.2.6.6 on page 5-162.


tion.
z Remove the seal fixing rings (Fig. 5-104, Pos. 1) from the pin
(Fig. 5-104, Pos. 4) located on both sides of the cylinder and
the stick (Fig. 5-104, Pos. 3) respectively.
Fig. 5-104
Version 2010/1 PC5500-6E 5 - 115

Fig. 5-105 Bull clam bucket removal
z Sling the bucket cylinders (Fig. 5-105, Pos. 15) to prevent

them from swinging when the pins (Fig. 5-105, Pos. 10) are
removed.
z Remove the bolts (Fig. 5-105, Pos. 14) with washers and the
shackle (Fig. 5-105, Pos. 13).
5 - 116 PC5500-6E Version 2010/1

z Push the pin (Fig. 5-105, Pos. 10) to the inside just enough to
remove the axle stirrups (Fig. 5-105, Pos. 11) from the
catches (Fig. 5-105, Pos. 12).
NOTE: The catches (Fig. 5-105, Pos. 12) are welded to the
bucket (Fig. 5-105, Pos. 1).
z Remove the pin (Fig. 5-105, Pos. 10) to clear the bucket cyl-
inder (Fig. 5-105, Pos. 15).
Remove the seals (Fig. 5-104, Pos. 2) when removing the
pin.
WARNING
z Remove the bolts (Fig. 5-105, Pos. 8) with washers and the
shackle (Fig. 5-105, Pos. 7).
z Push the pins (Fig. 5-105, Pos. 4) to the inside just enough to
remove the axle stirrups (Fig. 5-105, Pos. 5) from the catches
(Fig. 5-105, Pos. 6).
NOTE: The catches (Fig. 5-105, Pos. 6) are welded to the

bucket.
Use the assembly opening (refer to Fig. 5-103) to push

the pins.
z Push the pins (Fig. 5-106, Pos. 1) out of the inner pin bearing
(Fig. 5-106, Pos. 2) to the outside until the stick is cleared
from the bucket.
Remove the seals (Fig. 5-104, Pos. 2) and the rings
(Fig. 5-105, Pos. 3) when removing the pin.
NOTE: When the stick is cleared, the pins can remain in the
outer pin bearings (Fig. 5-106, Pos. 3).
Fig. 5-106
z Check the bushes (Fig. 5-105, Pos. 2 and 9) for wear or dam-
age, and replace them if required.
z Lift the boom and move the excavator away.
Version 2010/1 PC5500-6E 5 - 117

5.2.4.2 REPLACEMENT OF THE BULL CLAM BUCKET
Fig. 5-107 Bull clam bucket replacement
5 - 118 PC5500-6E Version 2010/1

Special tools: n/a
Bucket: 35,060 kg
Dogman/rigger


the following:
Always discard used seals, and install new seals!
Insert new bushes into the stick (Fig. 5-107, Pos. 17) if
required!

assembly!
z Slip the seals (Fig. 5-107, Pos. 16 and 19) onto the flanges of
the bushes attached to the bull clam bucket (Fig. 5-107,
Pos. 1).
NOTE: During installation, there is not enough space to insert

these seals.
NOTE: Perform the bleeding procedure for the clam cylinder.

z Check the hydraulic oil level again, and add oil if required.
Version 2010/1 PC5500-6E 5 - 119

5.2.4.3 REMOVAL OF THE BUCKET CYLINDERS
Fig. 5-108 Bucket cylinders, removal and installation
5 - 120 PC5500-6E Version 2010/1

(1) Bucket cylinder
(2) Stick
(3) Boom
(4) Axle stirrup
(5) Pin
(6) Ring
(7) Cover
(8) Bolt
(10) Bush
(12) Seal
(13) Catch
(14) Shackle
(15) O-ring
(16) SAE flange
(17) Flange
(18) Connecting plate
Version 2010/1 PC5500-6E 5 - 121


Crane
Additional equipment: Forklift
Oil drain pan
Bucket cylinder: 4005 kg

Pin bucket cylinder/boom: 168 kg
Dogman/rigger
6.6 on page 6-18.
WARNING
attachment.


as shown (Fig. 5-109), bucket cylinders in vertical position.


z Disconnect the grease feeding lines from the bucket cylin-

z Install the installation tool, PN 909 374 40 at the piston rod
side of the bucket cylinder,
z Support the bucket cylinder by means of the installation tool

using the forks of a forklift.
5 - 122 PC5500-6E Version 2010/1

z Remove the bolts (Fig. 5-110, Pos. 1), the cover (Fig. 5-110,
Pos. 2), and the ring (Fig. 5-110, Pos. 3).
z Remove the pin (Fig. 5-110, Pos. 4) with the catches

(Fig. 5-110, Pos. 5) as well as the seals at the bucket cylinder.
WARNING
Fig. 5-110
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!
DANGER
scaring may result.
z Disconnect the hydraulic hoses from the bucket cylinder, refer


oil pan.

tion.
Version 2010/1 PC5500-6E 5 - 123

z Remove the seal fixing rings (Fig. 5-111, Pos. 1) from the pin
(Fig. 5-111, Pos. 4) located on both sides of the bucket cylin-
der (Fig. 5-111, Pos. 3).
NOTE: Always discard used seals (Fig. 5-111, Pos. 2).
Fig. 5-111

z Pull out the pin (Fig. 5-112, Pos.1).

Thereby remove the axle stirrups (Fig. 5-112, Pos.2) from the
NOTE: The catches are welded to the bucket.
Fig. 5-112
z Remove the bucket cylinder using the forklift.
NOTE: Use a crane to lift the bucket cylinder from the forklift and
to put 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 - 124 PC5500-6E Version 2010/1

5.2.4.4 REPLACEMENT OF THE BUCKET CYLINDERS

Crane
Forklift
Bucket cylinder: 4005 kg

Pin bucket cylinder/boom: 168 kg
Dogman/rigger

WARNING
attachment.


the following:

assembly!
z Check the bushes (Fig. 5-113, Pos. 1) of the bucket cylinder

and of the corresponding pin bearings at the boom and at the
bucket. Replace the bushes if required.
z Install new seals (Fig. 5-113, Pos. 2) into the bushes in the
piston rod.
CAUTION
grooves of the bushes with grease, and center the seals in Fig. 5-113
z Slip new seals (Fig. 5-113, Pos. 3) onto the flange of the
bushes installed in the bucket.
NOTE: During installation of the cylinder at the bucket, there is

not enough space to insert the seals.
Version 2010/1 PC5500-6E 5 - 125

z Install the installation tool, PN 909 374 40 at the piston rod

side of the new bucket cylinder.
z 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.
z Lift the bucket cylinder until it is in upright position.
z 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
z Align the bucket cylinder with the bucket.
DANGER
Never put hands into the holes when aligning the bucket
cylinder to the bucket.
NOTE: Pay attention not to damage the seals on the bushes in

the bucket
z Insert the pin (Fig. 5-114, Pos. 1) and the seals (Fig. 5-115,
Pos. 2).
Secure the pin with the axle stirrups (Fig. 5-114, Pos. 2) in the
z Install the shackle (Fig. 5-114, Pos. 4) and insert the bolts
(Fig. 5-114, Pos. 5) with washers.
Fig. 5-114
5 - 126 PC5500-6E Version 2010/1

z Install the seal fixing rings (Fig. 5-115, Pos. 1) at the pin
(Fig. 5-115, Pos. 4) located on both sides of the bucket cylin-
der (Fig. 5-115, Pos. 3) to fix the seals (Fig. 5-115, Pos. 2).
Fig. 5-115
z Remove the installation tool.
NOTE: Continue to hold the bucket cylinder in an upright position

with the forks of the forklift.
z Connect the hydraulic lines to the bucket cylinder, refer to

z Extend and retract the bucket cylinder slowly at Qmin

WARNING
of the cylinder.
z 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.
Version 2010/1 PC5500-6E 5 - 127

z Insert the pin (Fig. 5-116, Pos. 4) with the catches

(Fig. 5-116, Pos. 5) and fix the bucket cylinder.
z Install the ring (Fig. 5-116, Pos. 3), the cover (Fig. 5-116,
Pos. 2), and the bolts (Fig. 5-116, Pos. 1).

Fig. 5-116

5 - 128 PC5500-6E Version 2010/1

Version 2010/1 PC5500-6E 5 - 129

5.2.4.5 REMOVAL OF THE CLAM CYLINDERS
Fig. 5-117 Clam cylinders, removal and installation
5 - 130 PC5500-6E Version 2010/1

(1) Clam cylinder
(2) Hydraulic hose
(3) Bucket clam
(4) Pin
(5) Catch
(6) Shackle
(7) Lock washer

(8) Bolt
(9) Seal
(10) Bush
(11) Seal
(12) Bush
(13) Catch
(14) Bolt
(15) Plate
(16) Pin
(17) Protective frame
Special tools: n/a

Crane
Oil drain pan
Clam cylinder: 885 kg

Clam cylinder’s upper pin: 48 kg
Clam cylinder’s lower pin: 66 kg
Dogman/rigger
6.6 on page 6-18.
Version 2010/1 PC5500-6E 5 - 131


the machine boom and crane.
bucket horizontally on the ground (Fig. 5-118).


"RELIEVE THE PRESSURE IN THE HYDRAULIC SYSTEM". Fig. 5-118
z Support the clam cylinder with appropriate blocks (Fig. 5-119,

arrows) to fix it in its position.
z Disconnect the grease feeding lines from the clam cylinder.
Fig. 5-119
z Remove the bolts (Fig. 5-120, Pos. 1) and the cover

(Fig. 5-120, Pos. 2) to access the pin connecting the clam
cylinder to the bucket clam.
Fig. 5-120
5 - 132 PC5500-6E Version 2010/1

z Remove the bolts (Fig. 5-121, Pos. 6) with lock washers

(Fig. 5-121, Pos. 7), the shackle (Fig. 5-121, Pos. 5), and the
z Pull out the pin (Fig. 5-121, Pos. 3) to clear the clam cylinder
(Fig. 5-121, Pos. 2) from the bucket clam (Fig. 5-121, Pos. 1).
Fig. 5-121
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 other
cylinder will be retracted, and the clam will open.
Do not open the clam.

WARNING
Hot hydraulic oil!
DANGER
scaring may result.
Version 2010/1 PC5500-6E 5 - 133

z Disconnect the hydraulic hoses from the clam cylinder, refer



tion.
Discard the O-rings.
z Sling the clam cylinder at both ends.
z Remove the bolt (Fig. 5-122, Pos. 2) and the plate

(Fig. 5-122, Pos. 3).
NOTE: The catch (Fig. 5-122, Pos. 4) is welded to the bucket.
z Pull out the pin (Fig. 5-122, Pos. 1) using pulling bolts.
Fig. 5-122
z Remove the clam cylinder from the bucket using a crane.
DANGER
When moving the clam cylinder, make sure that nobody
5 - 134 PC5500-6E Version 2010/1

5.2.4.6 REPLACEMENT OF THE CLAM CYLINDERS
Special tools: n/a
Clam cylinder: 885 kg

Clam cylinder’s upper pin: 48 kg
Clam cylinder’s lower pin: 66 kg
Dogman/rigger


the following:

assembly!
z Insert new bushes (Fig. 5-123, Pos. 1) into the clam cylinder,
if required.
z Install new seals (Fig. 5-123, Pos. 2) into the bushes

(Fig. 5-123, Pos. 1).
CAUTION
Fig. 5-123
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 appro-
priate blocks (Fig. 5-124, arrows) to fix it in its position.
Fig. 5-124
Version 2010/1 PC5500-6E 5 - 135

z Insert the pin (Fig. 5-125, Pos. 1) and position it in the catch
(Fig. 5-125, Pos. 4).
z Fix the pin with the plate (Fig. 5-125, Pos. 3).
z Secure the plate with the bolt (Fig. 5-125, Pos. 2).
Fig. 5-125
z Connect the hydraulic hoses to the clam cylinder, refer to sec-

tion 5.2.6.6 on page 5-162.
NOTE: Use new O-rings at the SAE flange connections.
z Extend and retract the clam cylinder slowly at Qmin

WARNING
of the cylinder.
WARNING
Both clam cylinders are connected to the same hydraulic
line, so when the cleared cylinder is fully retracted, the other
cylinder will be retracted, and the clam will open.
Do not open the clam.
z Extend the clam cylinder slowly at Qmin and align the cylinder
piston rod with the clam.
WARNING
Never put hands into the holes when aligning the clam
cylinder to the clam.
5 - 136 PC5500-6E Version 2010/1

z Insert the pin (Fig. 5-126, Pos. 3) connecting the clam

cylinder (Fig. 5-126, Pos. 2) to the bucket clam (Fig. 5-126,
Pos. 1).
z Install the shackle (Fig. 5-126, Pos. 5) with the bolts

(Fig. 5-126, Pos. 6) and lock washers (Fig. 5-126, Pos. 7).
Fig. 5-126
z Perform the bleeding procedure for the clam cylinders.

Version 2010/1 PC5500-6E 5 - 137

5.2.5 GROUND ENGAGING TOOLS (GET)

As ground engaging tools, the ESCO POSILOK Tooth System is
used.
Fig. 5-127 GET
5 - 138 PC5500-6E Version 2010/1

(1) Shroud
(2) Toplok boss
(3) Wedge
(4) Point (tooth)

(5) Wedge
(6) Tooth adapter (center/corner)
(7) Pin
(8) Wear plate
(9) Base plate
(10) Bucket clam (shroud mounting position)

(11) Integral rubber lock
Version 2010/1 PC5500-6E 5 - 139

5.2.5.1 REMOVAL AND REPLACEMENT OF THE GET
Special tools: POSILOK Pin removal tool PN 793 502 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.
tion 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.
5 - 140 PC5500-6E Version 2010/1

Version 2010/1 PC5500-6E 5 - 141

5.2.6 HYDRAULIC HOSES AT THE FACE SHOVEL ATTACHMENT
5.2.6.1 SUBSTITUTE THE BOOM ARC HOSES
Fig. 5-128 Boom arc hoses, removal and installation
5 - 142 PC5500-6E Version 2010/1

(1) Hydraulic hose
(2) Bolt
(3) O-ring
(4) Manifold
(5) Hose clamp
(6) Clamp line
(7) Hydraulic pipe
(8) Nut
Special tools: n/a

Oil drain pan
Boom arc hose: 39 kg
Dogman/rigger
6.6 on page 6-18.

WARNING
Always wear a safety harness when working at the attach-
ment.

z Park the machine on the prepared flat area with the stick
cylinder fully retracted and position the bucket horizontally on
the ground (Fig. 5-129).

Fig. 5-129
Version 2010/1 PC5500-6E 5 - 143

Fig. 5-130 Boom arc hoses, removal and installation
5 - 144 PC5500-6E Version 2010/1


z Open the hose clamps (Fig. 5-130, Pos. 5) and clear the
hydraulic hose (Fig. 5-130, Pos. 1) to be removed from the
clamp lines (Fig. 5-130, Pos. 6).
WARNING
Hot hydraulic oil!
DANGER
scaring may result.

SAE flanges from the manifold (Fig. 5-130, Pos. 4) and from
the hydraulic pipes (Fig. 5-130, Pos. 7) at the boom.


tion.
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.
z Perform the bleeding procedure for all cylinders.

z Check hydraulic oil level again, and add oil if required.
Version 2010/1 PC5500-6E 5 - 145

5.2.6.2 SUBSTITUTE THE BOOM CYLINDER HOSES
Fig. 5-131 Boom cylinder hoses, removal and installation
5 - 146 PC5500-6E Version 2010/1

(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
6.6 on page 6-18.

WARNING
attachment.



Fig. 5-132
Version 2010/1 PC5500-6E 5 - 147

Fig. 5-133 Boom cylinder hoses, removal and installation
5 - 148 PC5500-6E Version 2010/1


WARNING
Hot hydraulic oil!
Wait until the temperature of the hydraulic oil is below 50 C.
DANGER
scaring may result.

removed.

SAE flanges from the boom cylinder (Fig. 5-133, Pos. 6) and
from the hydraulic pipe at the boom.


tion.
z Replace the boom cylinder hoses with new ones and carry
out installation in reverse order to removal.
NOTE: Always replace the O-rings (Fig. 5-133, Pos. 4) and the
rings (Fig. 5-133, Pos. 5) at the SAE flange connections.
z Substitute the other boom cylinder hoses if required, using

the same procedure.
z Perform the bleeding procedure for the boom cylinder(s).

Version 2010/1 PC5500-6E 5 - 149

5.2.6.3 SUBSTITUTE THE STICK ARC HOSES
Fig. 5-134 Stick arc hoses, removal and installation
NOTE: Fig. 5-134 shows the hydraulic hose routing of the

machines up to SN 077 with two hoses leading to the
stick equipped with a 90 degree tube bend.
For machines equipped in this way, the hydraulic hoses
with the 90 degree tube bend, the hydraulic lines at the
stick, and the hose clamps should be replaced.
For further information, refer to PARTS & SERVICE
NEWS No. "AH09505".
5 - 150 PC5500-6E Version 2010/1

(1) Hydraulic hose
(2) Hose clamp line
(3) Bolt
(4) O-ring
(5) Ring
(6) Hydraulic pipe
Special tools: n/a

Crane
Oil drain pan
Stick arc hose: 29.5 kg
Dogman/rigger
6.6 on page 6-18.

WARNING
attachment.



Fig. 5-135
Version 2010/1 PC5500-6E 5 - 151

Fig. 5-136 Stick arc hoses, removal and installation

5 - 152 PC5500-6E Version 2010/1

z Remove the hose clamp line(s) (Fig. 5-136, Pos. 2).
WARNING
Hot hydraulic oil!
Wait until the temperature of the hydraulic oil is below 50 C.
DANGER
scaring may result.

SAE flanges from the hydraulic pipes (Fig. 5-136, Pos. 6).


tion.
z Replace the stick arc hoses by new ones, and carry out
z Substitute the other stick arc hoses, if required, using the

same procedure.
z Perform the bleeding procedure for the bucket and clam cylin-
ders. Refer to PARTS & SERVICE NEWS No. "AH06524".
Version 2010/1 PC5500-6E 5 - 153

5.2.6.4 SUBSTITUTE THE STICK CYLINDER HOSES
Fig. 5-137 Stick cylinder hoses, removal and installation
(1) Hydraulic hose
(2) Hydraulic hose
(3) Bolt
(4) O-ring
(5) Ring
5 - 154 PC5500-6E Version 2010/1

Special tools: n/a

Forklift
Oil drain pan
Stick cylinder hose (depending on length):

25 kg
27.4 kg
Dogman/rigger
6.6 on page 6-18.

WARNING
attachment.



Fig. 5-138
Version 2010/1 PC5500-6E 5 - 155

Fig. 5-139 Stick cylinder hoses, removal and installation
5 - 156 PC5500-6E Version 2010/1


removed using a forklift.
WARNING
Hot hydraulic oil!
DANGER
scaring may result.

SAE-flanges.
NOTE: When the hydraulic hose is disconnected, the oil inside


tion.
z Remove the hydraulic hose using a forklift.
z Replace the stick cylinder hoses by new ones and carry out
z Substitute the other stick cylinder hoses, if required, using the

same procedure.
z Perform the bleeding procedure for the stick cylinder(s).

Version 2010/1 PC5500-6E 5 - 157

5.2.6.5 SUBSTITUTE THE BUCKET CYLINDER HOSES
Fig. 5-140 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 - 158 PC5500-6E Version 2010/1

Special tools: n/a

Crane
Oil drain pan
Bucket cylinder hose: 28 kg
Dogman/rigger
6.6 on page 6-18.

WARNING
attachment.

NOTE: If the flange connections of the hydraulic pipes coming

from the bucket cylinder hoses (Fig. 5-91, Pos. 1) leading
to the boom are arranged horizontally, the hydraulic lines
at the stick, the hydraulic hoses between boom and stick,
and the hose clamps should be replaced.
For further information, refer to the PARTS & SERVICE
NEWS No. "AH09505".


Fig. 5-141

Version 2010/1 PC5500-6E 5 - 159

Fig. 5-142 Bucket cylinder hoses, removal and installation

removed.
WARNING
Hot hydraulic oil!
5 - 160 PC5500-6E Version 2010/1

DANGER
scaring may result.

SAE flanges.
z Remove the intermediate flange (Fig. 5-142, Pos. 6) from

the cylinder when removing the bucket cylinder hose
(Fig. 5-142, Pos. 1) on the piston rod side of the bucket
cylinder (Fig. 5-142, Pos. 7).


tion.
z Replace the bucket cylinder hoses by new ones, and carry

z Substitute the other bucket cylinder hoses, if required, using

the same procedure.
z Perform the bleeding procedure for the bucket cylinder(s).

Version 2010/1 PC5500-6E 5 - 161

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. 5-143 Clam cylinder hoses at stick, removal and installation
(1) Hydraulic hose
(2) Bolt
(3) O-Ring
(4) Ring
5 - 162 PC5500-6E Version 2010/1

Special tools: n/a
Forklift
Oil drain pan
Clam cylinder hose: 28 kg
Dogman/rigger
6.6 on page 6-18.

WARNING
attachment.


structure turned by 90°, and position the bucket on the
ground as shown (Fig. 5-144).

Fig. 5-144
Version 2010/1 PC5500-6E 5 - 163

Fig. 5-145 Clam cylinder hoses at stick, removal and installation
WARNING
Hot hydraulic oil!
DANGER
scaring may result.
5 - 164 PC5500-6E Version 2010/1


SAE flanges.


tion.
z Remove the hydraulic hose using a forklift.
z 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.
z If required, substitute the clam cylinder hoses at the clam

cylinders as described in the next section on page 166.
z Perform the bleeding procedure for the clam cylinders.

Version 2010/1 PC5500-6E 5 - 165

Substitute the clam cylinder hoses at the cylinders
Fig. 5-146 Clam cylinder hoses, removal and installation
5 - 166 PC5500-6E Version 2010/1

(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

Clam cylinder hose (depending on length):

8.8…11.2 kg
Dogman/rigger
6.6 on page 6-18.


the machine.

Fig. 5-147
Version 2010/1 PC5500-6E 5 - 167

Fig. 5-148 Clam cylinder hoses, removal and installation
5 - 168 PC5500-6E Version 2010/1

WARNING
Hot hydraulic oil!
DANGER
scaring may result.
z Remove the bolts (Fig. 5-148, Pos. 5) from the flange halves
(Fig. 5-148, Pos. 9) to disconnect the SAE flanges from the
distributor block (Fig. 5-148, Pos. 7) and from the clam
cylinder (Fig. 5-148, Pos. 8).


tion.
z Replace the hydraulic hoses (Fig. 5-148, Pos. 1 to 4).
z Replace the clam cylinder hoses by a new ones, and carry


z Perform the bleeding procedure for the clam cylinder(s).

Version 2010/1 PC5500-6E 5 - 169

Metering valves (grease injectors) at the attachment Attachment
5.3 METERING VALVES (GREASE INJECTORS) AT THE

ATTACHMENT
Fig. 5-149 Location of the grease injectors at the FSA attachment
5 - 170 PC5500-6E Version 2010/1

Attachment Metering valves (grease injectors) at the attachment
(1) Indicator stem
(2) Output adjusting screw
(3) Boom
(4) Stick
(6) Metering valve group at the boom
(7) Metering valves at the bull clam bucket

(8) Metering valve group at the stick
5.3.1 OPERATION TEST OF THE METERING VALVES

(GREASE INJECTORS)
The operation of the metering valves (Fig. 5-149, Pos. 6 up to 8)
at the attachment can be carried out visually by watching the
cycle indicator stem (Fig. 5-149, Pos. 1) while operating the cen-
tral lubrication system manually. The stem must move in and out
once every lubrication cycle.
NOTE: Remember the timing setting which may cause a delay of

up to 11 minutes, before a manual lubrication loop may
start after its release. If in doubt, refer to the relating
timing diagram in your flowchart.
If any indicator stem does not move during a lubrication cycle, the
grease supply to the lubrication point of the respective valve is
interrupted or clogged.
NOTE: There are two types of metering valves installed:

type "SL1” and type “SL11”.
Version 2010/1 PC5500-6E 5 - 171

5.3.2 REMOVAL OF THE METERING VALVES (GREASE INJECTORS)

Special tools: n/a

WARNING
attachment.
z The work requires the use of men safety cages on eleva-

tor working platforms.

the machine, boom, and mobile elevator working platform.

z For machines with face shovel attachment (FSA) only:

Park the machine on the prepared flat area and position the
attachment in the "defined position" (see Fig. 5-150).
Fig. 5-150
z For machines with backhoe attachment (BHA) only:

Park the machine on the prepared flat area and position the
(Fig. 5-151).
Fig. 5-151
NOTE: In the following, it is described how to remove the meter-

ing valves at the FSA boom exemplarily.
5 - 172 PC5500-6E Version 2010/1

Attachment Metering valves (grease injectors) at the attachment
All other metering valves at the attachment (BHA

included) are removed analogously.
z Disconnect all grease lines (Fig. 5-152, Pos. 2) from the

metering valve assemblies (Fig. 5-152, Pos. 5).
z Disconnect the grease feeding line at the union (Fig. 5-152,

Pos. 3).
z Remove the bolts (Fig. 5-152, Pos. 4), and remove the meter-
ing valve assemblies (Fig. 5-152, Pos. 5) from the boom
(Fig. 5-152, Pos. 1).
Fig. 5-152
z Remove the adapter bolt (Fig. 5-153, Pos. 2), and remove the
valve housing (Fig. 5-153, Pos. 1) from the metering valve
assembly (Fig. 5-153, Pos. 4).
Fig. 5-153
Version 2010/1 PC5500-6E 5 - 173

5.3.3 REPLACEMENT OF THE METERING VALVES (GREASE INJECTORS)

Special tools: n/a


WARNING
attachment.
z The work requires the use of men safety cages on eleva-

tor working platforms.
z Use new seals (Fig. 5-154, Pos. 3) at the valve housing

(Fig. 5-154, Pos. 1).
Fig. 5-154
z Check metering valves at the attachment for proper opera-

tion, refer to section 5.3.1 on page 5-171.
NOTE: Remember the timing setting which may cause a delay of

up to 11 minutes, before a manual lubrication loop may
start after its release. If in doubt, refer to the relating
timing diagram in your flowchart.
5 - 174 PC5500-6E Version 2010/1

Attachment Cylinder bypass test
5.4 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.
6.6 on page 6-18.
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 tem-

perature (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 attach-
ment.
NOTE: First check hydraulic cylinder temperature using an infra-

red 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:

Operation & Maintenance Manual, section 3.15.1.
WARNING
Hot hydraulic oil!
Version 2010/1 PC5500-6E 5 - 175

Cylinder bypass test Attachment
DANGER
Danger of hydraulic pressure.
May result in blindness, serious injury, permanent disfigure-
ment, or scaring.
lines will be removed.
z 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 contam-

ination.
z Connect a hydraulic hose to the piston rod side of the cylin-

der. Put the open end of the hose into an oil pan.
z Switch S155 to Qmin. Fig. 5-155
WARNING
Make sure that nobody is at close range of the hydraulic
hose’s open end when extending the cylinder.
z Fully extend the hydraulic cylinder at Qmin.
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 continuously

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.
5 - 176 PC5500-6E Version 2010/1

Service Information
6 SERVICE INFORMATION
Version 2010/1 PC5500-6E 6 -1

Fluids and lubricants Service Information
6.1 FLUIDS AND LUBRICANTS

Due to extremely different environmental and working conditions
for the excavator as well as special customized approvals for
lubricants, it is not possible to get a general conclusion about the
used fluids and lubricants.
Therefore, no lubrication or other fluids are listed at this point in
this R&R-Manual.
NOTE: For proper fluids and lubricants refer to the Service Man-
ual of your machine.
6.2 FILLING CAPACITIES

NOTE: Capacities listed below are approximated values.
For proper checking use level plugs, dipsticks, and
inspection openings provided for this purpose, and refer
to the Service Manual of the excavator.
Units or system Liters (approximate)
Main hydraulic oil reservoir 3600*1
Complete hydraulic system 6600
Pump distributor gear (PTO), each 95
Oil collector reservoir, auxiliary hydraulic pumps 1
Main hydraulic pumps, drive shaft housing 1.5
Slew gear (L&S), each 42
Motor adapter housing 0.6
Slew gear (Siebenhaar), each 60
Motor adapter housing *2
Brake housing 0.2
Travel gear (L&S, type GFA 1300 K 1003), each
Motor adapter housing 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.
6 -2 PC5500-6E Version 2010/1

Service Information Filling capacities
Units or system Liters (approximate)
Travel gear (L&S, type GFA 305 K 1017), each 155
Motor adapter housing 2
Travel gear (Zollern), each 180
Motor adapter housing 0.5

Final drive housing 165
Guide wheel 3.2
Carrier rollers *3
Track rollers *4
Water tank in operator’s cabin 50
Water reservoir for windshield washer 7
NOTE: *3) Fill up to the specified level, refer to section 4.2.12.2

on page 4-72.
*4) Fill up to the specified level, refer to section 4.2.13.2

on page 4-75.
Version 2010/1 PC5500-6E 6 -3

Work instructions Service Information
6.3 WORK INSTRUCTIONS
6.3.1 SURFACE COATING WITH INTERZINC 697

Additional equipment: 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 accord-
ing to local regulations and standards concerning occu-
pational health and safety.
z 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 dust-
ing and gassing.
Carry out welding or cutting work with personal protective
equipment only.
Dust and gases must be lead away from the workplace.
z 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.
z Set up the surface to be coated with sand paper (grain 60) or

a grinder, according to ISO 8504-1:1998.
z Cover the area around the surface to be coated (e.g. with

plastic film).
z 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.
6 -4 PC5500-6E Version 2010/1

Service Information Work instructions
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
z Don not add liquid to the powder.
z Do not water down the powder or the final coating com-

pound.
z 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 µm

(3.0 Mil) or 125 µm (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 hard-
ening time will increase considerably.
z 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.
z 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.
Version 2010/1 PC5500-6E 6 -5

Work instructions Service Information
6.3.2 REMOVE / INSTALL THE CRAWLER CARRIER
Special tools: Hydraulic torque wrench, PN 793 374 73 + PN 793 376 73

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 aggregate

PN 795 922 73 (picture as example).
For information about the Electro-hydraulic pump aggregate, refer

to chapter 9 "Supplier’s documentation", "AVANTI HYTORQUE".
Fig. 6-1 Hydraulic torque wrench
6 -6 PC5500-6E Version 2010/1

Service Information Weight tables
6.4 WEIGHT TABLES
6.4.1 SUPERSTRUCTURE
Part or assembly Weight Remark
Service crane (MKG) with beam 1900 kg

Electric motor see rating plate on motor
Roof plate, PTO side 355 kg
Roof plate, cooling air outlet 483 kg
Roof plate, capacitor side 186 kg
Beam (Bridge) 285 kg
Capacitor assembly 125 kg each
Battery 62 kg each
Flexible coupling (Vulkan), housing ring 94 kg each
Flexible coupling (Vulkan), coupling element 47 kg each

Main pump assembly with flanged gear pump 362.4 kg each
Oil circulation pump (auxiliary pump) 25 kg
PTO (pump distributor gearbox) 1900 kg each
Control and filter plate assembly 260 kg each
Hydraulic cooler fan drive pump 40 kg
Hydraulic cooler fan assembly 117.4 kg
Hydraulic cooler fan 19 kg
Hydraulic cooler fan mounting assembly 72 kg
Hydraulic cooler fan motor assembly 26.4 kg

Hydraulic oil cooler 275 kg each element
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
High pressure filter (main control block 2) 44.6 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
Version 2010/1 PC5500-6E 6 -7

Weight tables Service Information

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

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
Swing motor with attached slew service brake valve 292.5 kg
Slew brake valve 97 kg

Slew gear (Siebenhaar) 1700 kg
Slew gear (L&S) 1880 kg
Bearing ring of the slew parking brake (L&S) 32 kg
Slew parking brake assembly 115 kg
Swing circle 10,000 kg
Pinion cover 11.6 kg
Lubrication pinion assembly 18.2 kg
Double lubrication pump station 412 kg
Triple lubrication pump station 618 kg

Lubrication pump 28 kg
Operator's cab 3785 kg
Viscous mount 4 kg
Absorber plate incl. 2 viscous mounts 11.9 kg
Absorber plate incl. 3 viscous mounts 17.4 kg
Front window 112 kg

Operator's seat 62 kg
Cab base (medium voltage switch cabinet) 4000 kg
Support frame 987 kg
Emergency exit ladder 55.5 kg
Access ladder 167 kg
Access ladder cylinder 23 kg

Slip ring unit 355 kg
42,000 kg (BHA)
Counterweight
46,000 kg (FSA)
6 -8 PC5500-6E Version 2010/1


Superstructure incl. electric motors, without counterweight, attachment,
150,000 kg
and fluids
High voltage switch cabinet 6200 kg
Platform on the side of the high voltage cabinet 150 kg
Version 2010/1 PC5500-6E 6 -9

6.4.2 UNDERCARRIAGE
Track group 1350 mm 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
Segmented sprocket assembly (3 segments) 2250 kg
Sprocket segment 1 (5 teeth) 794.25 kg

Segmented sprocket assembly (3 segments, oversize) 2745 kg
Sprocket segment 1 (5 teeth, oversize) 968.99 kg
Guide wheel assembly 3323 kg
Low pressure accumulator 12 kg
High pressure accumulator 23 kg
Track tensioning valve block 40 kg

10 kg depending on
Hydraulic hoses of the track tensioning system
max type
Travel brake valve block 75 kg each
Track tensioning cylinder 400 kg each

Travel motor 110 kg each
Travel parking brake 75 kg each
Travel gearbox 4020 kg
Spur gear housing with mounted brake housing 580 kg
Support bearing cover 400 kg
Spindle with installed support bearing 278 kg
7250 kg
Planetary gear housing with mounted sprocket (oversize sprocket)
(7750 kg)
Drive sprocket ring 244 kg
Carrier roller assembly (bolted connection) 205 kg
Carrier roller assembly (with mounting pins) 175 kg
6 - 10 PC5500-6E Version 2010/1


Track roller assembly 654 kg
Car body without crawler carrier (with mounting pins) 42,000 kg
Crawler carrier assembly with mounting pins (without track group) 40,000 kg
Crawler carrier assembly (track width 1350 mm, with mounting pins) 70,000 kg each
Car body without crawler carrier (bolted connection) 46,000 kg
Crawler carrier assembly, bolted connection (without track group) 44,000 kg
Crawler carrier assembly (track width 1350 mm, bolted connection) 76,722 kg each
Rotary joint 261 kg
Cable drum assembly (without high voltage supply cable) 7500 kg
Cable supply assembly 640 kg
Version 2010/1 PC5500-6E 6 - 11

6.4.3 BACKHOE ATTACHMENT (BHA)

Boom 45,100 kg
Pin boom/superstructure 365 kg
Pin boom cylinder/boom 177 kg
Pin boom cylinder/superstructure 224 kg
Boom cylinder 6500 kg each
Stick 19,160 kg
Pin stick/boom 1440 kg
Nut-cap for pin stick/boom 48 kg
Stick cylinder 4600 kg each
Pin stick cylinder/stick 127 kg

Pin stick cylinder/boom 179 kg
Bucket 30,600 kg
Pin bucket/stick 574 kg
Pin bucket/bucket link rod 822 kg
Nut-caps for pin bucket/stick and for pin bucket/bucket link rod 35 kg each
Bucket cylinder 3210 kg each
Pin bucket cylinder/stick 86 kg
Pin bucket cylinder/steering rod 865 kg
Nut-caps for pin bucket cylinder/stick and for pin bucket cylinder/steering rod 35 kg each
Rod protection cover 360 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
29.5 kg depending on
Boom cylinder hoses
39 kg length
23 kg depending on
Stick cylinder hoses
27.5 kg length
Bucket cylinder hoses 33 kg
Metering valve <25 kg
6 - 12 PC5500-6E Version 2010/1

6.4.4 FACE SHOVEL ATTACHMENT (FSA)

boom without
Boom with attached stick and boom cylinders 52,900 kg 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
25 kg depending on
Stick cylinder hose
27.4 kg length
Bucket cylinder hose 28 kg
Clam cylinder hose at stick 28 kg
8.8 kg
depending on
9.8 kg
Clam cylinder hose at clam cylinder length and
10 kg
type
11.2 kg
Metering valve <25 kg
Version 2010/1 PC5500-6E 6 - 13

Torque charts according to KOMATSU company standard Service Information
6.5 TORQUE CHARTS ACCORDING TO KOMATSU

COMPANY STANDARD
6.5.1 METRIC STANDARD THREAD
Bolt Wrench size Tightening torque

diameter [mm] [Nm]
Bolt quality grades
Metric regular
8.8 10.9 12.9
M 8 13 6 21 31 36
M 10 17 8 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 32 3500 4950 5800
M 45 70 4350 6200 7200
M 48 75 35 5200 7500 8700
M 52 80 6700 9600 11200
M 56 85 41 8400 12000 14000
M 60 90 10400 14800 17400
M 64 95 46 12600 17900 20900
M 68 100 15200 21600 25500
NOTE: Threads and bolts must be greased carefully with grease

KP2K. Contact surfaces which should be screwed
together must be free of grease.
6 - 14 PC5500-6E Version 2010/1

Service Information Torque charts according to KOMATSU company standard
6.5.2 METRIC FINE THREAD
Bolt Wrench size Tightening torque

diameter [mm] [Nm]
Bolt quality grades
Metric
fine
8.8 10.9 12.9
M 8 x 1.0 13 6 23 33 39
M 10 x 1.0 17 8 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 32 3750 5300 6200
M 45 x 3.0 70 4600 6600 7700
M 48 x 3.0 75 35 5700 8100 9500
M 52 x 3.0 80 7300 10400 12100
M 56 x 4.0 85 41 8900 12600 14800
M 60 x 4.0 90 11000 15600 18300
M 64 x 4.0 95 46 13300 19000 22200
M 68 x 4.0 100 16100 22900 27000
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!
Version 2010/1 PC5500-6E 6 - 15

Torque charts according to KOMATSU company standard Service Information
6.5.3 SAE FLANGE CONNECTIONS
Fig. 6-2 Torques for SAE flange connections
6 - 16 PC5500-6E Version 2010/1

Service Information Torque charts according to KOMATSU company standard
Version 2010/1 PC5500-6E 6 - 17

Blind plugs Service Information
6.6 BLIND PLUGS
6.6.1 DUMMY PLATES FOR SAE FLANGES
Fig. 6-3 Forms / types of dummy plates for SAE flanges
Up to 3000 PSI
Form / type
DN
SAE size according to PN
(hose / pipe)
Fig. 6-36-3
1/2" A 506 521 98 12

3/4" A 506 583 98 20
1 1/4" A 506 584 98 32
1 1/2" A 506 522 98 40

2" A 506 523 98 50
2 1/2" A 506 585 98 65
3" A 512 570 98 80
3/4" B 516 826 98 20
1 1/4 B 517 479 98 32
1 1/2" B 506 528 98 40

2" B 506 529 98 50
2 1/2" B 506 530 98 65
3" B 512 571 98 80
6 - 18 PC5500-6E Version 2010/1

Service Information Blind plugs
Up to 6000 PSI
Form / type
DN
SAE size according to PN
(hose / pipe)
Fig. 6-36-3
3/4" A 506 580 98 20
1" A 506 519 98 25

1 1/4" A 506 520 98 32
1 1/2" A 506 581 98 40
2" A 506 582 98 50

1" B 506 524 98 25
1 1/4" B 506 525 98 32
1 1/2" B 506 526 98 40
2" B 506 527 98 50
1 1/4" C 516 499 98 32
1 1/2" C 509 375 98 40

2" C 509 376 98 50
Version 2010/1 PC5500-6E 6 - 19

Blind plugs Service Information
6.6.2 CLASSIFICATION OF THREADS TO THE NOMINAL WIDTH
Heavy class Light class

(up to 6000 PSI) (up to 3000 PSI)
Size Ra DN Ra DN
M 12 x 1.5 - - 6 5
M 14 x 1.5 - - 8 6
M 16 x 1.5 8 5 10 8
M 18 x 1.5 10 6 12 10
M 20 x 1.5 12 8 - -
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 6.6.3 on page 21:
EXAMPLE:
To cover up a hose / tube with a diameter of 25 mm, for a pres-

sure up to 3000 PSI perform the following steps:
z Locate the 25 in the column "DN" in the category "up to

3000 PSI".
z 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 6.6.3 on page 21.
NOTE: The column "Size" indicates the thread-size for the

ROV-fittings.
6 - 20 PC5500-6E Version 2010/1

Service Information Blind plugs
6.6.3 PLUGS AND FITTINGS ACCORDING TO DIN 2353 / ISO 8434-1
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
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
Version 2010/1 PC5500-6E 6 - 21

Conversion table Service Information
6.7 CONVERSION TABLE
6.7.1 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 Con-
version 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).
z Locate the number 5 in the row across the top, take this as
(B), then draw a perpendicular line down from (B).
z 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.
z Carry out the same procedure as above to convert 55 mm to

2.165 inches.
z 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.
6 - 22 PC5500-6E Version 2010/1

Service Information Conversion table
6.7.2 MILLIMETER - INCH & KILOGRAM - POUND
Version 2010/1 PC5500-6E 6 - 23

6.7.3 LITER - U.S. GALLON & LITER - U.K. GALLON
6 - 24 PC5500-6E Version 2010/1

6.7.4 NM - FT.LB
0 1 2 3 4 5 6 7 8 9
0 0 0.74 1.47 2.21 2.95 3.69 4.42 5.16 5.90 6.63
10 7.37 8.11 8.84 9.58 10.32 11.06 11.79 12.53 13.27 14.00
20 14.74 15.48 16.21 16.95 17.69 18.43 19.16 19.90 20.64 21.37
30 22.11 22.85 23.58 24.32 25.06 25.80 26.53 27.27 28.01 28.74
40 29.48 30.22 30.95 31.69 32.43 33.17 33.90 34.64 35.38 36.11
50 36.85 37.59 38.32 39.06 39.80 40.54 41.27 42.01 42.75 43.48
60 44.22 44.96 45.69 46.43 47.17 47.91 48.64 49.38 50.12 50.85
70 51.59 52.33 53.06 53.08 54.54 55.28 56.01 56.75 57.49 58.22
80 58.96 59.07 60.43 61.17 61.91 62.65 63.38 64.12 64.86 65.59
90 66.33 67.07 67.80 68.54 69.28 70.02 70.75 71.49 72.23 72.96
100 73.70 74.44 75.17 75.91 76.65 77.39 78.12 78.86 79.60 80.33
110 81.07 81.81 82.54 83.28 84.02 84.76 85.49 86.23 86.97 87.70
120 88.44 89.18 89.91 90.65 91.39 92.13 92.86 93.60 94.34 95.07
130 95.81 96.55 97.28 98.02 98.76 99.50 100.23 100.97 101.71 102.44
140 103.18 103.92 104.65 105.39 106.13 106.87 107.60 108.34 109.08 109.81
150 110.55 111.29 112.02 112.76 113.50 114.24 114.97 115.71 116.45 117.18
160 117.92 118.66 119.39 120.13 120.87 121.61 122.34 123.08 123.82 124.55
170 125.29 126.03 126.76 127.50 128.24 128.98 129.71 130.45 131.19 131.92
180 132.66 133.40 134.13 134.87 135.61 136.35 137.08 137.82 138.56 139.29
190 140.03 140.77 141.50 142.24 142.98 143.72 144.45 145.19 145.93 146.66
200 147.40 148.14 148.87 149.61 150.35 151.09 151.82 152.56 153.30 154.03
1 Nm = 0,737 FT.LB
Version 2010/1 PC5500-6E 6 - 25

6.7.5 BAR - PSI - KPA - MPA

1...200 Bar 205...400 Bar
Bar PSI kPa MPa Bar PSI kPa MPa
1 14.5037 100 0.1 205 2973.18 20500 20.5
5 72.52 500 0.5 210 3045.69 21000 21
10 145.03 1000 1 215 3118.21 21500 21.5
15 217.55 1500 1.5 220 3190.73 22000 22
20 290.07 2000 2 225 3263.24 22500 22.5
25 362.58 2500 2.5 230 3335.76 23000 23
30 435.1 3000 3 235 3408.28 23500 23.5
35 507.62 3500 3.5 240 3480.79 24000 24
40 580.13 4000 4 245 3553.31 24500 24.5
45 652.65 4500 4.5 250 3625.83 25000 25
50 725.17 5000 5 255 3698.34 25500 25.5
55 797.68 5500 5.5 260 3770.86 26000 26
60 870.2 6000 6 265 3843.37 26500 26.5
65 942.71 6500 6.5 270 3915.89 27000 27
70 1015.23 7000 7 275 3988.41 27500 27.5
75 1087.75 7500 7.5 280 4060.92 28000 28
80 1160.26 8000 8 285 4133.44 28500 28.5
85 1232.78 8500 8.5 290 4205.96 29000 29
90 1305.3 9000 9 295 4278.47 29500 29.5
95 1377.81 9500 9.5 300 4350.99 30000 30
100 1450.33 10000 10 305 4423.51 30500 30.5
105 1522.85 10500 10.5 310 4496.02 31000 31
110 1595.36 11000 11 315 4568.54 31500 31.5
115 1667.88 11500 11.5 320 4641.06 32000 32
120 1740.4 12000 12 325 4713.57 32500 32.5
125 1812.91 12500 12.5 330 4786.09 33000 33
130 1885.43 13000 13 335 4858.61 33500 33.5
135 1957.95 13500 13.5 340 4931.12 34000 34
140 2030.46 14000 14 345 5003.64 34500 34.5
145 2102.98 14500 14.5 350 5076.16 35000 35
150 2175.5 15000 15 355 5148.67 35500 35.5
155 2248.01 15500 15.5 360 5221.19 36000 36
160 2320.53 16000 16 365 5293.7 36500 36.5
165 2393.04 16500 16.5 370 5366.22 37000 37
170 2465.56 17000 17 375 5438.74 37500 37.5
175 2538.08 17500 17.5 380 5511.25 38000 38
180 2610.59 18000 18 385 5583.77 38500 38.5
185 2683.11 18500 18.5 390 5656.29 39000 39
190 2755.63 19000 19 395 5728.8 39500 39.5
195 2828.14 19500 19.5 400 5801.32 40000 40
200 2900.66 20000 20
1 Bar = 14.5037 PSI
6 - 26 PC5500-6E Version 2010/1

6.7.6 BASIC VALUES IN OHM ACCORDING TO DIN 4376 / IEC 751
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
0 100.00 99.61 99.22 98.83 98.44 98.04 97.65 97.26 96.87 96.48
°C 0 1 2 3 4 5 6 7 8 9
0 100.00 100.39 100.78 101.17 101.56 101.95 102.34 102.73 103.12 103.51
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
150 157.31 157.69 158.06 158.43 158.81 159.18 159.55 159.93 160.30 160.67
Version 2010/1 PC5500-6E 6 - 27

6.7.7 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 Cel-

sius, consider the center column as a table of Fahrenheit temper-
atures and read the corresponding Celsius temperature in the
column at the left.
If it is desired to convert from degree Celsius to degree Fahren-

heit, consider the center column as a table of Celsius values, and
read the corresponding Fahrenheit temperature on the right.
6 - 28 PC5500-6E Version 2010/1

Service Information Tools
6.8 TOOLS
6.8.1 STANDARD TOOL CASE

Komatsu provides a standard tool case, PN 232 709 40.
Q‘ty Part name Part number

1 Measuring tape 3 m long 470 615 40
1 Hammer 500 g 232 130 40
1 Sliding caliper, 200 mm long 232 107 40
1 Reamer (countersink, stem diameter 10 mm; reamer diameter 20 mm 232 690 40
1 Socket wrench ½“ - set (WS 10 - 32) 232 691 40
1 Internal hexagon socket, 1/2“ - set, (WS 5 - 17) 232 570 40
1 Double ended open wrench - set (WS 6 - 32) 232 692 40
1 Combination wrenches - set (WS 10 - 32) 232 693 40
1 Twist drill - set (1 - 13 mm) 232 207 40
1 Needle files - set 232 199 40
1 Tool bag 232 694 40
1 Toolbox L= 460; B= 170; L= 310 232 695 40
1 Socket wrench ¼“ - set (WS 3 - 13) 232 696 40
1 Drift punch 3 - 8 mm 232 697 40
1 Socket wrench with ball head - set (1.5 - 10 mm) 232 698 40
1 Side cutter insulated up to 1000 Volt, 190 mm 232 401 40
1 Combination pliers insulated up to 1000 Volt, 185 mm 232 400 40
1 Bent nose pliers, Knipex 232 403 40
1 Water pump pliers 250 mm long 232 139 40
1 Cable stripping knife 4 - 16 mm 232 699 40
1 Screwdriver for slotted screws 11 x 300 mm 232 120 40
1 Screwdriver for slotted screws 13 x 390 mm 232 121 40
1 Crosstip screwdriver size 0 232 111 40
1 Infrared thermometer IR 1 232 665 40
1 LCD-Digital Multimeter VC 444 232 688 40
1 VDE Screwdriver, WERA 232 689 40
1 Hydraulic mini testing kit 232 591 40
2 Pressure gauge 400 bar 793 363 73
3 Measuring hose 2.5 m 896 483 40
2 Pressure gauge fitting G¼ 232 501 40
1 Set – Screwdriver 907 696 40
1 Side cutting pliers, Knipex 232 700 40
1 Stripping- and cutting tool Stripax for PVC-isolation up to 6 mm², 20 mm 232 663 40
1 Crimp pliers, rimp capacity 0.5 - 4 mm² 232 661 40
1 Crimp pliers HTN 21 232 701 40
2 Testing wire 4mm Type 410 (red) 232 702 40
2 Testing wire 4mm Type 410 (black) 232 703 40
1 Testing tip "Hirschmann Prüf 2" (red) 232 704 40
1 Testing tip "Hirschmann Prüf 2" (black) 232 705 40
1 Clip terminal "Hirschmann Ak 2 S" (red) 232 706 40
Version 2010/1 PC5500-6E 6 - 29

Tools Service Information
Q‘ty Part name Part number

1 Clip terminal "Hirschmann Ak 2 S" (black) 232 707 40
1 Fluke 179 Digital-Multimeter 232 708 40
1 Rollbox K 412 (740 x 365 x 375) 232 711 40
1 Tachometer Moviport 232 551 40
1 Magnet-stick 232 712 40
1 Electric set with pliers 793 265 73
1 Software (Bodem 24) 796 726 73
1 Bodem connection cable 896 791 40
1 Crimp-pliers for revolved contacts 793 729 73
1 Cable set 796 443 73
1 Prostat Cable VL 3 (X27 -PC) 659 820 40
1 Prosyd Cable VL 12 (PLC-PC) 926 503 40
1 TazETM Cable VL 10 (ETM-PC) 891 175 40
1 Cable VL 9a 891 176 40
1 Cable VL 9b 891 177 40
1 PC4000-6 VHMS download-cable (new for 08156 and up) 894 580 40
1 Converter, cable, and software as set 796 442 73
1 Converter 796 439 73
1 USB extension wire 796 440 73
1 UMG diagnostic software (CD) 796 441 73
6 - 30 PC5500-6E Version 2010/1

6.8.2 USED SPECIAL TOOLS (OVERVIEW)
Component Part number Part name Q‘ty Nature of work, remarks
Universal ground-
PN 232 386 40 ing short-circuting 1
device
Measuring rod Grounding procedure

PN 232 390 40
3...6 kV
Measuring rod
PN 232 389 40
High voltage 5...10 kV
switch cabinet 55 mm hexagon
PN 232 519 40 impact socket 1
wrench (1 1/2")
Removal and installation of the high
Hydraulic torque
PN 232 615 40 1 voltage switch cabinet
wrench
Electro-hydraulic
PN 793 375 73 1
pump aggregate
PN 376 792 40 Measuring jaw 1
PN 409 437 40 Measuring bolt 8
Measuring bolt
PN 409 484 40 8
(cold weather)
PN 379 077 40 Test block 1
PN 477 577 40 Mounting cross 1 Installation of the swing circle.

Swing circle
Assembly of superstructure onto
mounting
55 mm hexagon undercarriage
wrench (1 1/2")
Hydraulic torque
PN 232 615 40 1
wrench
Electro-hydraulic
PN 793 375 73 1
pump aggregate
Safety unit for

Removal and installation of the track
PN 921 149 40 changing track 1
rollers and guide wheel assembly
rollers
Track rollers
PN ???
Tool for changing Removal and installation of the track
(P&S-news under 1
track rollers rollers
development)
Pressure accumu-
Testing- and refilling
lators of the track PN 761 520 73 1 Refilling pressure accumulators
device
tensioning system
Version 2010/1 PC5500-6E 6 - 31

Removal and installation of the

bucket BHA
bucket cylinders BHA
PN 409 329 40 Thread protector 1
steering rods BHA
Removal and installation of the stick
BHA
Attachment
PN 909 374 40 Installation tool 1
bucket cylinders FSA
Removal and installation of the stick

cylinders FSA
Removal and installation of the boom

cylinders FSA
POSILOK pin
GET PN 793 502 73 1 Removal and installation of the GET
removal tool
Hydraulic system
PN 232 591 40 Hydraulic testing kit 1 Measurement of hydraulic pressures
(general)
Hydraulic cooler fan

drive pump Rotational speed
PN 793 788 73 infrared probe 1 Measurement of fan speed
Hydraulic cooler fan DS03
assembly
75 mm hexagon
wrench (1 1/2")
Removal and installation of the coun-
Counterweight Hydraulic torque
PN 793 374 73 1 terweight
wrench
Electro-hydraulic
PN 793 375 73 1
pump aggregate
55 mm hexagon
wrench (1 1/2")
Superstructure Hydraulic torque
PN 232 615 40 1 superstructure
wrench
Electro-hydraulic
PN 793 375 73 1
pump aggregate
55 mm hexagon
wrench (1 1/2")
Medium voltage Removal and installation of the
Hydraulic torque
cabinet (cab base) PN 232 615 40 1 medium voltage cabinet (cab base)
wrench
Electro-hydraulic
PN 793 375 73 1
pump aggregate
6 - 32 PC5500-6E Version 2010/1

Hydraulic torque
PN 793 374 73 1
wrench
Wrench socket with Removal and installation of the car

PN 793 376 73 1
Car body/crawler supporting bar body/crawler carrier
carrier Electro-hydraulic
PN 793 375 73 1
pump aggregate
Measuring device
PN 928 476 40 1 Installation of the crawler carriers
(kit)
Locally made
(refer to PARTS & Assembly tool for
1 Installation of new dual-cone seals
SERVICE NEWS dual-cone seals
No. "AH05511")
55 mm hexagon
wrench (1 1/2") Installation and removal of the seg-
mented sprocket (up to Sn 025)
Hydraulic torque
Sprocket PN 232 615 40 1
wrench
Electro-hydraulic
PN 793 375 73 1
pump aggregate
Hydraulic torque
PN 232 614 40 1 Installation and removal of the
wrench
sprocket
46 mm hexagon
wrench (1")
Hydraulic torque
PN 232 615 40 1
wrench
Electro-hydraulic
PN 793 375 73 1 Installation and removal of travel
pump aggregate
gearbox and sprocket
55 mm hexagon
Travel gearbox
wrench (1 1/2")
Hydraulic torque
PN 232 614 40 1
wrench
Installation and removal of the travel
46 mm hexagon gearbox (up to Sn 025)
wrench (1")
Version 2010/1 PC5500-6E 6 - 33

6 - 34 PC5500-6E Version 2010/1

Tools catalogue
7 TOOLS CATALOGUE
Version 2010/1 PC5500-6E 7 -1

Tools catalogue
7 -2 PC5500-6E Version 2010/1

Tools and Accessories
th
Release: May 19 , 2010
Contents
Page No.
Section 1 Assembly Tools for Screws and Nuts 3
Section 2 Power Tools 11
Section 3 Pliers 15
Section 4 Metal Working Tools 18
Section 5 Measuring Tools 21
Section 6 Data Transfer and IT Tools 28
Section 7 Repair Sets for Wiring & Connectors 30
Section 8 Repair Sets for Hydraulic Cylinders & Line Fittings 32
Section 9 Others 33
Section 10 Paint and Accessories 37
Section 11 Auxiliaries, Cleaner, Adhesive & Sealant 38

Part-No. Description
th
Combination wrenches, single [mm]
232 001 40 A/F 6

232 002 40 A/F 7
232 003 40 A/F 8
232 004 40 A/F 9
232 005 40 A/F 10
232 006 40 A/F 11
232 007 40 A/F 12
232 008 40 A/F 13
232 009 40 A/F 14
232 010 40 A/F 15
232 011 40 A/F 17
232 012 40 A/F 19
323 013 40 A/F 22
232 014 40 A/F 24
232 015 40 A/F 27
232 016 40 A/F 30
232 017 40 A/F 32
232 018 40 A/F 36
232 019 40 A/F 41
232 557 40 A/F 46
232 693 40 Combination wrenches, set A/F 10 - 32 [mm]
Combination wrenches, single [inch]
232 432 40 A/F 1/4"

232 433 40 A/F 5/16"
232 434 40 A/F 3/8"
232 435 40 A/F 7/16"
232 436 40 A/F 1/2"
232 437 40 A/F 9/16"
232 438 40 A/F 5/8"
232 439 40 A/F 11/16"
232 440 40 A/F 3/4"
232 441 40 A/F 13/16"
232 442 40 A/F 7/8"
232 443 40 A/F 15/16"
232 444 40 A/F 1"
232 445 40 A/F 11/16"
232 446 40 A/F 11/8"
232 447 40 A/F 11/4"
Special ring wrench - open [mm]
232 305 40 A/F 41

232 306 40 A/F 46
232 307 40 A/F 50
232 308 40 A/F 60
A/F = width Across Flats/wrench size

991-1010
Tools Section 1
Assembly Tools for Screws and Nuts
Page 3
th
Double ended open wrenches, single [mm]
232 020 40 A/F 6 x 7

232 021 40 A/F 8 x 9
232 022 40 A/F 10 x 11
232 023 40 A/F 12 x 13
232 024 40 A/F 14 x 15
232 025 40 A/F 16 x 17
232 026 40 A/F 18 x 19
232 027 40 A/F 20 x 22
232 028 40 A/F 21 x 23
232 029 40 A/F 24 x 27
232 030 40 A/F 25 x 28
232 031 40 A/F 30 x 32
232 032 40 A/F 36 x 41
232 033 40 A/F 50 x 55
Single ended open wrenches, single [mm]
232 361 40 A/F 41

232 211 40 A/F 46
232 212 40 A/F 50
232 213 40 A/F 55
232 214 40 A/F 60
232 215 40 A/F 65
232 362 40 A/F 70
232 216 40 A/F 75
232 363 40 A/F 80
232 217 40 A/F 85
Hook wrenches, single
232 275 40 120 - 130 mm Ø

232 276 40 155 - 165 mm Ø
232 277 40 180 - 195 mm Ø
232 278 40 205 - 220 mm Ø
232 279 40 260 - 270 mm Ø
232 280 40 280 - 300 mm Ø
Push-pull ratchet
232 337 40 1/4"

232 047 40 1/2"
232 562 40 3/4"
232 563 40 1"
Reversible ratchet
232 380 40 3/4" x 620 mm (24")

232 218 40 1" x 660 mm (26")
Sliding & tommy bar
232 339 40 1/4"

232 050 40 1/2" x 290 mm (11")
232 303 40 3/4" x 500 mm (20")
232 219 40 1" x 640 mm (25")

991-1010
Tools Section 1
Page 4
th
Torque wrench
232 262 40 70 - 320 Nm

232 285 40 300 - 750 Nm
232 477 40 500 - 1300 Nm
232 478 40 800 - 2000 Nm
232 379 40 3/4" x 200 mm (8")

232 304 40 3/4" x 430 mm (17")
232 220 40 1" x 250 mm (10")
232 221 40 1" x 405 mm (16")
232 285 40 Torque wrench with scale

DSG-5S, measuring range: 300 - 750 Nm
232 681 40 Elbow socket, 28/5 - 3/4" x 70 mm

DSG-6S, measuring range: 500 - 1300 Nm
232 682 40 Elbow socket, 28/6 - 7; 1" x 70 mm

DSG-7S measuring range: 800 - 2000 Nm
232 682 40 Elbow socket, 28/6 - 7; 1" x 70 mm
Socket wrench 1/4", single [mm]
232 326 40 A/F 4

232 327 40 A/F 4,5
232 328 40 A/F 5
232 329 40 A/F 5,5
232 330 40 A/F 6
232 331 40 A/F 7
232 332 40 A/F 8
232 333 40 A/F 9
232 334 40 A/F 10
232 335 40 A/F 11
232 336 40 A/F 13
Socket wrench, 1/2", single [mm]
232 034 40 A/F 9

232 035 40 A/F 10
232 036 40 A/F 11
232 037 40 A/F 12
232 038 40 A/F 13
232 039 40 A/F 14
232 040 40 A/F 15
232 041 40 A/F 17
232 042 40 A/F 19
232 340 40 A/F 21
232 043 40 A/F 24
232 044 40 A/F 27
232 045 40 A/F 30
232 046 40 A/F 32

991-1010
Tools Section 1
Page 5
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Socket wrench, 1/2", single [inch]
232 448 40 A/F 3/8"

232 449 40 A/F 13/32"
232 450 40 A/F 7/16"
232 451 40 A/F 1/2"
232 452 40 A/F 9/16"
232 453 40 A/F 19/32"
232 454 40 A/F 5/8"
232 455 40 A/F 11/16"
232 456 40 A/F 3/4"
232 457 40 A/F 25/32"
232 458 40 A/F 13/16"
232 459 40 A/F 7/8"
232 460 40 A/F 15/16"
232 461 40 A/F 1"
232 462 40 A/F 1 1/16"
232 463 40 A/F 1 1/8"
232 464 40 A/F 1 3/16"
232 465 40 A/F 1 1/4"
Socket wrench, 3/4", single [mm]
232 369 40 A/F 22

232 370 40 A/F 24
232 371 40 A/F 27
232 372 40 A/F 30
232 373 40 A/F 32
232 374 40 A/F 36
232 375 40 A/F 38
232 376 40 A/F 41
232 377 40 A/F 46
232 378 40 A/F 50
Socket wrench, 1", single [mm]
232 223 40 A/F 36

232 224 40 A/F 41
232 225 40 A/F 46
232 226 40 A/F 50
232 227 40 A/F 55
232 228 40 A/F 60
232 229 40 A/F 65
232 230 40 A/F 70
232 231 40 A/F 75
232 232 40 A/F 80
Impact socket wrench, 1", single [mm]
232 264 40 A/F 36

232 515 40 A/F 38
232 516 40 A/F 41
232 265 40 A/F 46
232 266 40 A/F 50
232 267 40 A/F 55
232 494 40 A/F 60
232 268 40 A/F 65

991-1010
Tools Section 1
Page 6
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Impact socket wrench, 1 ½" [mm]
232 517 40 A/F 46

232 518 40 A/F 50
232 519 40 A/F 55
232 520 40 A/F 60
232 521 40 A/F 65
Impact internal hexagon socket, 1", single [mm]
232 765 40 A/F 19

232 766 40 A/F 22
232 767 40 A/F 24
232 768 40 A/F 27
232 769 40 A/F 32
232 770 40 A/F 36
232 569 40 Extra deep socket wrench for grease nipple of grease cylinder
1/2", long, A/F 27 mm
Internal hexagon socket, 1/2", single [mm]
232 052 40 A/F 5

232 053 40 A/F 6
232 054 40 A/F 7
232 055 40 A/F 8
232 056 40 A/F 9
232 057 40 A/F 10
232 058 40 A/F 12
232 059 40 A/F 14
232 060 40 A/F 17
Internal hexagon socket, 1/2", single [inch]
232 423 40 A/F 3/16"

232 424 40 A/F 7/32"
232 425 40 A/F 1/4"
232 426 40 A/F 9/32"
232 427 40 A/F 5/16"
232 428 40 A/F 3/8"
232 429 40 A/F 1/2"
232 430 40 A/F 9/16"
232 431 40 A/F 5/8"
Internal hexagon socket, 1/2", single
232 341 40 A/F 5 x 180 mm

232 342 40 A/F 6 x 90 mm
232 343 40 A/F 8 x 120 mm
232 344 40 A/F 10 x 140 mm
232 345 40 A/F 12 x 140 mm
232 346 40 A/F 14 x 140 mm
Internal hexagon socket, 3/4" [mm]
232 347 40 A/F 14

232 348 40 A/F 17
232 349 40 A/F 19
232 350 40 A/F 22

991-1010
Tools Section 1
Page 7
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Internal hexagon socket, 1" [mm]
232 351 40 A/F 19

232 352 40 A/F 22
232 353 40 A/F 24
Internal Torx socket [mm]
232 597 40 A/F 4 - 5

232 598 40 A/F 4.5 - 5
232 599 40 A/F 4.5 - 5 - 6
232 600 40 A/F 6 - 7
232 601 40 A/F 7 - 8
232 602 40 A/F 8 - 10
232 603 40 A/F 10
External Torx socket [mm]
232 604 40 A/F 4

232 605 40 A/F 5
232 606 40 A/F 6
232 607 40 A/F 6 - 7
232 608 40 A/F 8
232 609 40 A/F 10
232 610 40 A/F 12
Universal joint
232 051 40 1/2"
Reducing socket
232 573 40 1" - 3/4"

232 096 40 3/4" - 1/2"
232 574 40 1 1/2" - 1"
Expansion socket
232 575 40 1/2" - 3/4"

232 576 40 3/4" - 1"
232 577 40 1" - 1 1/2"
232 511 40 Torque multiplier max. 2700 Nm (2000 lbf-ft)
3/4" drive
Reduction 1 : 5
232 208 40 Screw extractor kit with spiral drills to remove damaged or
broken screws

991-1010
Tools Section 1
Page 8
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Screwdriver for slotted screws
232 120 40 11 x 300 mm

232 121 40 13 x 390 mm
Screwdriver, insulated up to 1000 Volt
232 391 40 2.5 x 75 mm

232 764 40 3.0 x 100 mm
232 392 40 3.5 x 100 mm
232 393 40 4.0 x 100 mm
232 394 40 5.5 x 125 mm
232 395 40 6.5 x 150 mm
Crosstip screwdriver, insulated up to 1000 Volt
232 397 40 size 0

232 398 40 size 1
232 399 40 size 2
Allen head wrench "L" type, single [mm]
232 066 40 A/F 2

232 067 40 A/F 2.5
232 068 40 A/F 3
232 069 40 A/F 4
232 070 40 A/F 5
232 071 40 A/F 6
232 072 40 A/F 7
232 073 40 A/F 8
232 074 40 A/F 9
232 075 40 A/F 10
232 076 40 A/F 12
232 077 40 A/F 14
232 078 40 A/F 17
232 079 40 A/F 19
232 080 40 A/F 22
232 081 40 A/F 24
232 082 40 A/F 27
232 354 40 A/F 30
232 355 40 A/F 32
232 356 40 A/F 36
Allen head wrench "L" type [inch]
232 414 40 A/F 3/16"

232 415 40 A/F 7/32"
232 416 40 A/F 1/4"
232 417 40 A/F 5/16"
232 418 40 A/F 3/8"
232 419 40 A/F 1/2"
232 420 40 A/F 9/16"
232 421 40 A/F 5/8"
232 422 40 A/F 3/4"

991-1010
Tools Section 1
Page 9
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Allen head wrench "L" type, with spherical head [mm]
232 582 40 A/F 2

232 583 40 A/F 3
232 584 40 A/F 4
232 585 40 A/F 5
232 586 40 A/F 6
232 587 40 A/F 8
232 588 40 A/F 10
232 589 40 A/F 12
232 698 40 Allen head wrenches "L" type, with spherical head,
set 1.5 - 10 mm

991-1010
Tools Section 1
Page 10
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232 611 40 High-power pneumatic drive wrench, 900 - 4,200 Nm
1'' drive
including reaction arm (long type),
torque adjustment and service unit,
pneumatic hose 6 m, torque certificate,
and silencer
232 612 40 High-power pneumatic drive wrench, 1,500 - 7,100 Nm
1 ½'' drive
including reaction arm (long type),
torque adjustment and service unit,
pneumatic hose 6 m, torque certificate,
and silencer
232 614 40 High-power hydraulic drive wrench, 390 - 3,934 Nm
1'' drive
incl. reaction arm
232 615 40 High-power hydraulic drive wrench, 741 - 7,402 Nm
1 ½'' drive
incl. reaction arm
793 374 73 High-power hydraulic drive wrench, 1,049 - 10,671 Nm,

required for track frame assembly*
1 ½'' drive
incl. reaction arm
* For mounting of track frames the supplemental

extended reaction arm 793 376 73 is required
232 759 40 High-power hydraulic drive wrench & aggregate, set

Torque range 390 - 3,934 Nm
The set contains:

• High-power hydraulic drive wrench (232 614 40)
1'' drive
incl. reaction arm
• High pressure hydraulic aggregate (793 375 73)
Supply voltage 230 V
3-stages-delivery
Setting range up to 700 bar
incl. digital manometer, oil, and 5 m remote control
incl. safety couplings
• High pressure twin-hose NS 6 x 5 m (795 923 73)
Welded
Burst pressure 2,800 bar
• Transportation box (232 719 40)
991-1010
Tools Power Tools Section 2
Page 11
th

Torque range 741 - 7,402 Nm
The set contains:

1 ½'' drive
incl. reaction arm
3-stages-delivery
Welded

Torque range 1,049 - 10,671 Nm
For mounting crawler carriers
The set contains:

1 ½'' drive
incl. reaction arm
3-stages-delivery
Welded
• Torque wrench accessory
Extended reaction arm with tool drive unit M48
suitable for torque wrench 793 374 73,
for bolts with resilient sleeve
991-1010
Page 12
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232 718 40 Electro-hydraulic pump set, assy
793 375 73 Electro-hydraulic pump
232 719 40 Transportation box
793 376 73 Extended reaction arm for crawler carrier mounting
(in combination with high-power hydraulic torque wrench

793 374 73)
795 923 73 High pressure hose DN6 x 5000
Adapted for high-power hydraulic torque wrenches:

232 614 40 • 232 615 40 • 793 374 73
232 749 40 Reaction arm, for high-power hydraulic drive wrenches
Spare part - adapted for high-power hydraulic torque wrenches:

232 614 40 • 232 615 40 • 793 374 73
232 750 40 Fixing screw for the reaction arm
Spare part - adapted for the reaction arm 232 749 40
991-1010
Page 13
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232 666 40 Pneumatic impact wrench
7000 1/min
½'' drive
Torque max. 350 Nm
Bolt ø max. M 18
232 667 40 Pneumatic impact wrench
4500 1/min
¾'' drive
Torque max. 900 Nm
Bolt ø max. M 27
793 828 73 Cordless impact wrench
Torque up to 150 Nm
½" drive
including exchange accumulator 14.4 V 3.3 Ah
in a tool case
Pin-driving press, complete set for crawler chassis
232 313 40 100 t - for all excavators up to H 121
232 381 40 150 t - for all excavators up to H 185
232 717 40 Stud welding unit for threaded pins, with welding gun
991-1010
Page 14
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232 139 40 Water pump pliers, 250 mm long
232 140 40 Grip pliers, 250 mm long
232 141 40 Stork beak pliers, 200 mm long, straight
232 142 40 Telephone pliers, 200 mm long, bent jaws
232 143 40 Wire strippers, 160 mm long
232 401 40 Side cutter, insulated up to 1000 Volt, 190 mm
232 400 40 Combination pliers, insulated up to 1000 Volt, 185 mm
232 147 40 Pipe wrenches, angled jaws, with adjusting nut, 350 mm long
232 404 40 Flat nose pliers, insulated up to 1000 Volt, 185 mm
232 405 40 Round nose pliers, insulated up to 1000 Volt, 185 mm
991-1010
Tools Pliers Section 3
Page 15
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Circlip pliers, straight, for external circlips
232 150 40 19 - 60 mm Ø
232 151 40 40 - 100 mm Ø
232 152 40 85 - 140 mm Ø
Circlip pliers, 90°, for external circlips
232 156 40 19 - 60 mm Ø
232 157 40 40 - 100 mm Ø
232 158 40 85 - 140 mm Ø
Circlip pliers, straight, for internal circlips
232 159 40 19 - 60 mm Ø
232 160 40 30 - 100 mm Ø
232 161 40 85 - 130 mm Ø
Circlip pliers, angled, for internal circlips
232 153 40 19 - 60 mm Ø
232 154 40 31 - 100 mm Ø
232 155 40 85 - 140 mm Ø
232 281 40 Circlip pliers, straight, for external circlips
122 - 300 mm Ø
232 282 40 Circlip pliers, angled, for external circlips
122 - 300 mm Ø
232 283 40 Circlip pliers, straight, for internal circlips
122 - 300 mm Ø
232 284 40 Circlip pliers, angled, for internal circlips
122 - 300 mm Ø
991-1010
Page 16
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232 663 40 Stripping and cutting tool Stripax
for PVC-isolation up to 6 mm², 20 mm
793 729 73 Crimp pliers for Deutsch connectors
Crimp range:
0.35 - 3.0 mm²
12 - 22 AWG
232 662 40 Crimp pliers set for wire end sleeves
Crimp range 0.5 - 4.0 mm²
232 661 40 Crimp pliers
Crimp range 0.5 - 4.0 mm²
232 209 40 Crimp pliers, elbow-lever action with quick-release lever
- Self-grip crimping pliers for crimping and clamping connectors

conforming to DIN and VG standards in a single operation
2
For crimping cable lugs 0.5 - 1.0 / 1.5 - 2.5 / 4 - 6 [mm ]
991-1010
Page 17
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Hammer
232 129 40 300 g

232 130 40 500 g
232 131 40 1000 g
232 310 40 Sledge hammer, 5 kg
232 579 40 Plastic hammer, 450 g
Flat chisel
232 135 40 16 x 165 mm

232 136 40 19 x 180 mm
232 137 40 Cape chisel, 6 x 165 mm
232 138 40 Center punch, 4 x 130 mm
Drift punch
232 132 40 5 x 150 mm

232 133 40 6 x 160 mm
232 134 40 8 x 180 mm
Cotter pin drive
232 099 40 3 mm Ø
232 100 40 4 mm Ø
232 101 40 5 mm Ø
232 102 40 6 mm Ø
232 103 40 8 mm Ø
232 104 40 10 mm Ø
232 122 40 Hack saw with blade
232 123 40 Three square scraper (hollow), 250 mm long
232 124 40 Flat scraper, 250 mm long
991-1010
Tools Metal Working Tools Section 4
Page 18
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Adjustable tap wrench for taps
232 164 40 M 1 - 10
232 165 40 M 10 - 27
232 235 40 M 20 - 42
Tap
232 166 40 M 3
232 167 40 M 4
232 168 40 M 5
232 169 40 M 6
232 170 40 M 8
232 171 40 M 10
232 172 40 M 12
232 173 40 M 14
232 174 40 M 16
232 357 40 M 18
232 175 40 M 20
232 240 40 M 24
232 241 40 M 30
232 242 40 M 36
232 243 40 M 42
Tap
232 244 40 M 8x1

232 245 40 M 10 x 1
232 246 40 M 14 x 1.5
232 247 40 M 20 x 1.5
232 248 40 M 24 x 1.5
232 236 40 R 1/8"

232 237 40 R 3/8"
232 238 40 R 1/4"
232 239 40 R 1/2"
Thread restorer
232 162 40 Whitworth

232 163 40 Metric
991-1010
Page 19
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Holder for threading dies
232 176 40 M 3/M4 20 x 5 mm

232 177 40 M 5/M6 20 x 7 mm
232 178 40 M 8/M8x1 25 x 9 mm
232 179 40 M 10 / M 10 x 1 30 x 11 mm
232 180 40 M 12 / M 14 38 x 14 mm
232 359 40 M 16 / M 18 / M 20 45 x 18 mm
232 249 40 M 24 55 x 22 mm
232 250 40 M 30 / M 36 65 x 25 mm
232 364 40 M 14 x 1.5 / R 1/8" / R 1/4" 38 x 10 mm
232 365 40 M 24 x M 1.5 55 x 16 mm
232 358 40 R 3/8" / R 1/2" 45 x 14 mm
Threading die
232 181 40 M 3
232 182 40 M 4
232 183 40 M 5
232 184 40 M 6
232 185 40 M 8
232 186 40 M 10
232 187 40 M 12
232 188 40 M 14
232 189 40 M 16
232 360 40 M 18
232 190 40 M 20
232 261 40 M 24
232 260 40 M 30
232 259 40 M 36
232 255 40 M 8x1
232 256 40 M 10 x 1
232 257 40 M 14 x 1.5
232 258 40 M 24 x 1.5
232 251 40 R 1/8"

232 252 40 R 1/4"
232 253 40 R 3/8"
232 254 40 R 1/2"
991-1010
Page 20
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232 194 40 Inside caliper, 200 mm long
232 195 40 Outside caliper, 200 mm long
232 107 40 Sliding caliper, 200 mm long
232 108 40 Measuring tape, 2000 mm long
232 590 40 Metal rule, 1000 mm long
232 109 40 Feeler gauge set
232 110 40 Thread gauge, metric & whitworth
232 668 40 Micrometer gauge, measuring range: 0 - 150 mm
232 669 40 Micrometer gauge, measuring range: 150 - 300 mm
232 591 40 Hydraulic 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
79453773 Digital dial gauge, 0 - 12.5 mm
232 673 40 Magnetic articulated stand, 390 mm, 60 x 50 x 55 mm
991-1010
Tools Measuring tools Section 5
Page 21
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232 720 40 Digital pressure manometer SPG-DIGI
Measuring units: mbar, bar, PSI, kPa, MPa

MIN/MAX or 'End of Range Value' display
Display with backlight
Zero correction
Batteries: 2x 1.5 V DC AA (LR6-AA) Alkaline Mignon
Battery condition displayed
232 708 40 Digital Multimeter Fluke 179 True-RMS-DMM
Features:
• True-RMS for precise measurement of non linear signals
• 0,09% basic accuracy
• 6000 count resolution
• Large, easy-to-read display with analog bargraph and backlight
for work in dimly lit areas
• Manual and automatic ranging
• Display Hold and Auto Hold
• Smoothing mode allows filtering of rapidly changing inputs
• Easy battery exchange without opening the case
• Closed case calibration through front panel
• Measuring frequency and capacity
• Resistance, continuity and diode check
• Measuring temperature
• Min/Max/Avg recording
• EN 61010-1 CAT III 1000 V/CAT iV 600 V
232 753 40 Fuse 440 mA
232 754 40 Fuse 11 A
232 619 40 Autorange digital multimeter incl. fuse set and temperature
sensor
Specification:
V = : 100 µV - 1 KV, accuracy ± 0,3% + 2 dig.
V ~ : 100 µV - 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, accuracy ± 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
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 Ω
991-1010
Page 22
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232 670 40 SUBITO Internal gauge, 280 - 510 mm
in a case without dial
232 671 40 SUBITO Measuring depth extension
pipe Ø 18 mm, 2000 mm long
232 384 40 Flow meter gauge
incl. accessories
793 787 73 Measuring turbine RE4
measuring range: 16 up to 600 l/min
232 593 40 Shock pulse measuring instrument
For monitoring the bearing condition of electric motors
232 594 40 Cable for shock pulse transducer (1.5 m)
232 595 40 Shock pulse transducer
232 596 40 Head receiver for the shock pulse measuring instrument
991-1010
Page 23
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232 684 40 Vibrotip-Set "Trend"

Engine analyzer and data collector
232 686 40 Drill for Vibrotip
232 685 40 Sensor with quick coupling for Vibrotip
232 665 40 Infrared thermometer
694 944 Electric thermometer with temp. probe tip
793 788 73 Infrared revolution counter DS03

-1
Measuring range: 1 to 9999 min
793 789 73 Magnetic holder for DS03
232 551 40 Manual non-contact revolution counter (digital)
Test manometer, incl. accessories
770 466 73 0 - 60 bar

769 150 73 0 - 400 bar
770 464 73 0 - 16 bar
770 465 75 0 - 25 bar
991-1010
Page 24
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Pressure gauge
793 361 73 0 - 25 bar (1 pc)

793 362 73 0 - 60 bar (1 pc)
793 363 73 0 - 400 bar (2 pcs)
232 501 40 Pressure gauge fitting (4 pcs)
1/4" to the hydraulic test port of the 'Mini-Mess' test equipment
Measuring hose
792 283 73 3200 mm

792 284 73 5000 mm
761 520 73 Filling and testing device for piston, diaphragm and bladder
accumulators
0 - 100 bar (with pressure reducer)
232 752 40 Tool case (without tools)
232 382 40 Filling and testing device for piston and diaphragm and
accumulators
0 - 25 bar
Thread reducing fitting (manometer)
232 506 40 R 1/4"

232 507 40 R 3/8"
232 508 40 R 1/2"
232 385 40 Voltage tester 25 kV
232 386 40 Universal grounding short-circuiting device (high voltage)

2
Ø 95/35 mm
232 387 40 Insulation tester . . . 500 V
991-1010
Page 25
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232 713 40 ALIGNEO laser set
for the alignment of horizontal mounted machines
232 714 40 ALIGNEO bracket set
232 712 40 Magnet-Stick
232 388 40 Phase-sequence indicator 100 . . . 600 V
Electronical unipolar voltage meter
232 389 40 5 - 10 kV
232 390 40 3 - 6 kV
232 762 40 Test box (breakout box)
for electrical components with Deutsch connectors
942 136 40 CAN bus test box

Under construction
991-1010
Page 26
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766 138 73 Diagnostic device for BEKA-MAX lubrication systems
966 225 Crack detection testing kit, consisting of:
966 229 Permanent magnet
966 226 Magnetic powder
996 228 Cleaner, spray can, 500 ml
966 227 Contrasting agent
232 723 40 Universal box
793 780 73 Hand-held measuring unit MH 3020
3 channels, USB interface, ISDS

Memory: max. 1 million readings
incl. power supply unit, USB cable and software
793 781 73 Pressure sensor (2 pcs) - 0 - 400 bar, ISDS
793 783 73 Direct connector for pressure sensor no. 1620 (2 pcs)
793 784 73 Screw-in temperature sensor no. 1620 (2 pcs)

-50°C up to 200°C, ISDS
793 785 73 Rev counter sensor DS 03 - incl. 25 reflection foils
793 787 73 Measuring cable (2 pcs) - 5.0 m
793 786 73 Measuring extension cable - 5.0 m
793 782 73 Carrier box
991-1010
Page 27
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796 440 73 USB extension wire
793 796 73 Data communication cable USB
796 441 73 KMG diagnostic software (CD)
796 439 73 Converter
796 443 73 Cable set, for data transfer between PC and PLC & text display
Cable VL3 Download of fault messages (protocol) from the

text display to the PC
Cable VL12 Download and upload of the PLC software
Upload of text display setup from the PC to the text display:

Cable VL10 Data bus
Cable VL9a Power supply
Cable VL9b Board net power supply
796 726 73 Bodem PC software
CD-ROM and dongle

For pump controller (MC7/RC4) monitoring and settings
896 791 40 Bodem connection cable
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
232 748 40 CAT-5 Crossover adapter
For fast direct PC connection via LAN (RJ45)
991-1010
Tools Data Transfer and IT Tools Section 6
Page 28
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797 390 73 Electric kit for DEUTSCH connectors
Contains:
Part-No. Qty. Description

932 518 40 10 Cable lug
2
055 104 40 10 Cable lug 0.5-1mm /ø4mm
055 100 40 10 Cable lug
907 511 40 10 Cable lug
600 259 99 10 Cable lug
2
055 107 40 10 Cable lug 1mm /ø5mm
2
055 108 40 10 Cable lug 4.9mm /ø5mm
2
055 110 40 10 Cable lug 3mm /ø6.5mm
055 105 40 10 Cable lug
055 109 40 10 Cable lug
2
055 112 40 10 Cable lug 4.9mm /ø2mm
055 114 40 10 Plug-in sleeve
440 109 40 10 Plug-in sleeve ø4mm
2
055 131 40 10 Plug-in sleeve 4-6mm
323 961 40 10 Sleeve 6.3x0.8mm
907 577 40 10 Distributor
500 090 98 50 Cable sleeve 0.75mm
056 070 40 50 Cable sleeve 1.0-2.5mm
635 042 40 50 Cable sleeve 1.5mm
056 071 40 50 Cable sleeve 2.5-6mm
056 072 40 10 Cable sleeve 4mm
2
269 078 40 10 Cable sleeve ø6mm
907 641 40 50 Cable sleeve
907 501 40 10 Cable sleeve
057 296 40 1 Connection
795 132 73 2 Plug
795 134 73 2 Plug
795 495 73 2 Plug
795 131 73 2 Plug housing
651 461 40 2 Housing assy
898 680 40 2 Relay assy
898 681 40 2 Relay assy
966 661 1 Squeezing pliers
464 814 1 Insulating tape
792 104 73 100 Cable strap 200x4.8
792 105 40 100 Cable strap
792 106 40 100 Cable strap
991-1010
Tools Repair Sets for Wiring & Connectors Section 7
Page 29
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793 265 73 Electric kit for YAZAKI connectors
Contains:

2
055 100 40 10 Cable lug 2.5mm /ø5mm
2
055 102 40 10 Cable lug 1.5-2.5mm
2
055 103 40 10 Cable lug 0.5-1mm
2
055 104 40 10 Cable lug 0.5-1mm /ø4mm
2
055 105 40 10 Cable lug 4-6mm /ø6mm
2
055 107 40 10 Cable lug 1mm /ø5mm
2
055 108 40 10 Cable lug 4.9mm /ø5mm
2
055 109 40 10 Cable lug 12.5mm /ø8.5mm
2
055 110 40 10 Cable lug 3mm /ø6.5mm
2
055 111 40 10 Cable lug 12.5mm /ø4mm
2
055 112 40 10 Cable lug 4.9mm /ø2mm
2
055 114 40 10 Cable lug 2.5mm /ø6.3mm
2
055 115 40 10 Plug-in sleeve 3mm
2
055 120 40 10 Cable lug 1mm
2
055 125 40 10 Pin 7mm
055 131 40 10 Plug-in sleeve 4-6mm
2
055 141 40 10 Connection 1.5-2.5mm
2
055 142 40 10 Connection 4-6mm
056 070 40 50 Cable sleeve 1.0-2.5mm
056 071 40 50 Cable sleeve 2.5-6mm
2
256 084 40 10 Cable lug 1.75mm /ø6.5mm
269 078 40 10 Cable sleeve ø6mm
323 725 40 10 Cable lug ø4mm/ø3mm
323 961 40 10 Sleeve 6.3x0.8mm
2
440 109 40 10 Plug-in sleeve ø4mm
440 151 99 10 Plug-in sleeve 6.3mm
500 090 98 50 Cable sleeve 0.75mm
635 042 40 50 Cable sleeve 1.5mm
891 031 40 2 Plug
891 030 40 2 Plug
891 039 40 2 Plug
891 040 40 2 Plug
891 038 40 2 Plug
891 032 40 2 Plug
464 814 1 Insulating tape
057 296 40 1 Connection
898 680 40 2 Relay assy
898 681 40 2 Relay assy
792 104 73 100 Cable strap 200x4.8
792 105 40 100 Cable strap
792 106 40 100 Cable strap
966 661 1 Squeezing pliers
991-1010
Tools Repair Sets for Wiring & Connectors Section 7
Page 30
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797 391 73 Fitting set for hydraulic line connections
Contains:

371 271 99 2 Nut N-L 6
371 261 99 2 Union nut
371 273 99 2 Nut N-L 10
371 258 99 2 Union nut N-S 10
371 274 99 2 Nut N-L 12
371 275 99 2 Nut N-L 15
371 259 99 2 Nut N-L 12
374 427 99 2 Union SDS-S10XG 3/8A Type E
907 080 40 5 Cutting ring ES-4 S 6
906 347 40 5 Cutting ring ES-4 S12
516 156 98 2 Socket L10
516 183 98 2 Socket L10-G
374 420 99 2 Union SDS-L10xM14X1.5 Type E
374 430 99 2 Union SDS-L12xM16X1.5 Type E
906 346 40 5 Cutting ring ES-4 S10
906 348 40 5 Cutting ring ES-4 L15
906 349 40 5 Cutting ring ES-4 L18
517 242 98 2 Union L08-M
374 416 99 2 Union SDS-L10XG 1/4A-Type E
907 152 40 2 Union SDS-L12XG 1/4A-Type E/OM
516 158 98 2 Union SWE-L 15
515 711 40 2 Union L10
516 184 98 2 Union L12-G
551 379 40 2 Union 12/10-PL/OMD
516 182 98 2 Union L10-M
515 701 40 2 Union L12
371 276 99 2 Nut N-L 18
517 225 98 2 Union L08
374 407 99 2 Union SDS-L15XM18X1.5-Type E
370 312 99 2 Union D L10E
516 157 98 2 Union L12
516 741 98 2 Union SWE-S 12
516 224 98 2 Union L10
371 949 99 2 Union MAV-EV 12-ER
517 073 98 2 Union 10 LRD/OMD
655 426 40 2 Union GV 12-LR
516 962 98 2 Union BH-L 12
516 174 98 2 Union L12
517 226 98 2 Union L08
796 043 73 1 Case
796 045 73 20 Box in the case
796 047 73 21 Box in the case
991-1010
Tools Repair Sets for Hydraulic Cylinders & Line Fittings Section 8
Page 31
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232 621 40 Cordless headphone intercom
232 623 40 Vacuum pump + adaptor
232 626 40 Mounting bushing set for cylinder repair
When ordering tools, please always state the identification number of

the cylinder.
947 173 40 Auxiliary tool 1 for threaded pins M12
947 178 40 Auxiliary tool 2 for threaded pins M16
Used for the repair of hydraulic cylinders
For detailed information refer to the

PARTS & SERVICE NEWS AH08501
(latest edition)
232 299 40 Pinch bar with pointed and claw ends, 1000 mm long
232 146 40 Strap wrench
Puller, grip width/depth
232 300 40 120 mm/100 mm

232 301 40 200 mm/150 mm
232 302 40 350 mm/200 mm
232 287 40 Grease gun, hand-lever type, with couplings, 400 bar
232 288 40 Fitters tub
232 000 40 Tool box, 5 trays
420 x 200 x 210 mm
991-1010
Tools Others Section 9
Page 32
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232 761 40 Tool chest
With 3 wide & 3 small drawers and 1 removable element.

Width 663 mm, height 364 mm, depth 308 mm, weight 25.5 kg.
Delivery without tools.
232 763 40 Universal tool box
Outside:
Width 600 mm, height 330 mm, depth 400 mm, weight 4.5 kg
Inside:
Width 550 mm, height 310 mm, depth 350 mm, capacity 60 ℓ
793 639 73 Removal tool for double-level terminals
232 542 40 Oil analysis
232 622 40 Suction pump, extracting oil for testing
Flat-link chain hoist
232 368 40 Lifting capacity 0.75 t

232 289 40 Lifting capacity 1.5 t
??? Lifting capacity 3.0 t
324460 40 Cable suspension, 5 t
991-1010
Page 33
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792 005 73 Edge protector
792 006 73 Edge protector
232 616 40 4-hook chain, WMH S6
A = 1500 mm
232 617 40 Nylon lifting belt, AL 4
Width 75 mm, length 3500 mm

1500 kg
232 618 40 Nylon lifting belt
Width 25 mm, length 1500 mm

1000 kg
Lifting bolt
941 650 40 M 8
941 651 40 M10
906 519 40 M12
906 780 40 M16
906 782 40 M20
906 783 40 M24
906 421 40 M30
906 233 40 M36
999 860 73 5 finger gloves, with textile extension, with lining
999 861 73 Rubber gloves, size F3 and F4
999 925 73 Working gloves, pork leather, with lining
991-1010
Page 34
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950 642 Canister 10 l (plastics)
950 643 Canister 25 l (plastics)
232 683 40 Combination angle set
232 715 40 Hydro-pump, type IPV 3-8 101
232 716 40 Coupling
766 307 73 Mounting tools for dual cone seal rings at the undercarriage
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 For detailed information refer to the
766 322 73 PARTS & SERVICE NEWS AH05511
766 323 73 (latest edition)
768 881 73
797 549 73
991-1010
Page 35
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Thinner
767 566 73 10 kg
Primer, lemon yellow
767 567 73 1kg
Paint yellow, RAL 1007
083 026 spray can, 400 ml
Paint sky-blue, RAL 5015
501 415 98 can, 2,5 kg
Paint black, RAL 9005
767 568 73 can, 1 kg
Paint yellow = DEMAG KOMATSU colour
767 569 73 can, 1 kg
Paint grey = KOMATSU colour
767 570 73 can, 1 kg
999 019 Nickel spray can, Metaflux 70-81
991-1010
Tools Paint and accessories Section 10
Page 36
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592 199 40 Liquid sealing compound (Epple blue, No. 28), 250 ml
461 798 40 Adhesive Sicomet 85, in tubes
for sealing the rotary joint (with rollers or balls)
390 905 Teflon tape
464 814 Insulating tape, 33-19 Tesa PVCd
691 959 Filler bottle Startpilot
989 967 Oil binding agent
paper sacks, 8 kg each
993 528 73 Cleaning agent
Bio Pent E, for steam blasting cleaners
993 529 73 Cleaning agent
Bio Versal, for steam blasting cleaners
999 926 73 Cleaning rags (fleece rags)
35 x 35 cm, bale of 30 kg
991-1010
Tools Auxiliaries, cleaners, adhesive & sealant Section 11
Page 37
th
Loctite products
414 299 40 Loctite No. 222 E, bolt lock fluid, 50 ml

low stability, up to M36
973 125 Loctite No. 241, bolt lock fluid, 50 ml

medium stability, up to M12
973 130 Loctite No. 24333, bolt lock fluid, 50 ml

255 242 40 Loctite No. 243, bolt lock fluid, 250 ml



high stability, up to M20
167 644 40 Loctite No. 307, 50 ml

metal adhesive (only in conjunction with 7471)
288 906 40 Loctite No. 330, bonding set

bonds nearly all materials (except Gi)
461 798 40 Loctite No. 401, 20 g, Cyanacrylat

bonds Kn, rubber, paperboard, leather, wood, and many more
255 238 40 Loctite No. 511, fluid sealing, 50 ml

low stability, sealing threaded connections up to R2"
232 554 40 Loctite No. 511, fluid sealing, 250 ml

low stability
083 399 40 Loctite Nr. 586, fluid sealing, 50 ml

high stability, up to R2"
255 239 40 Loctite 574, sealant for surfaces, 50ml

gap size up to 0,5 mm
255 237 40 Loctite No. 603, for join connections, 50 ml

high stability
991-1010
Page 38
th
288 907 40 Loctite No. 706, fast cleaner, 400 ml
321 32240 Loctite, removal of adhesives and sealants
spray can, 300 ml
083 376 40 Loctite Nr. 7471, activator, 500 ml
for hardening of 307 and for the acceleration of the hardening

process
991-1010
Page 39
Parts & Service News
8 PARTS & SERVICE NEWS
Version 2010/1 PC5500-6E 8 -1

Contents of this chapter:
SB-No. Subject
AH00511 Installation procedure for the swing circle (SC)
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
AH01523 Replacement of the elastic coupling (electro drive shovels)
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
AH03528 Pilot control safety line
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
AH05518 Swing circle pinion
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 Track group - hints for sprocket exchange
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”)
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
8 -2 PC5500-6E Version 2010/1

SB-No. Subject
AH08504 Windscreen
AH08507 Steel structure
AH08508 Bushings of the attachment and at the undercarriage
AH09505 Hoses between boom and stick
AH09522 Wishbone and rod
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 2010/1 PC5500-6E 8 -3

8 -4 PC5500-6E Version 2010/1

COMPONENT CODE: 2500
REF NO. AH00511e
PARTS & SERVICE NEWS DATE October 6, 2006
Page 1 of 20
This PARTS & SERVICE NEWS supersedes the previous issue No. AH00511d
which should be discarded.
SUBJECT: Installation procedure for the swing circle / Slew Ring (SR)
PURPOSE: Revision
APPLICATION: From H185S (06078) up to PC8000
FAILURE CODE: 2500Z9
DESCRIPTION:
Content Page
1. List of swing circle types 01
2. Safety instructions 02
3. General 03
4. Measurements 04
5. Determination of tightening torques 06
6. Mounting of a swing circle 08
Adjustment: Unhardened spot “s” 11
Tooth back lash 12
Hints for rotating the slew ring 14
7. Checking of fastening bolts 16
8. Lubrication and maintenance 16
8.1 Races of roller bearings 16
8.2 Outer toothing 18
8.3 General 20
Type Slew ring

1. Mounting cross Tooth back lash
Weight P/N [mm]
[t]
H 185S 3,5 379 383 40 0.4 – 0.8
H 255S / PC3000 3,5 379 383 40 0.4 – 0.8
H 285S 6,0 379 128 40 0.6 –1.0
PC4000 6,7 379 128 40 0.6 – 1.0
H 455S / PC5500 9,0 / 10,0 477 577 40 0,6 – 1,0
H 485S 14,0 379 129 40 0.5 – 0.9
H 655S / PC8000 ( - 12036) 14,0 379 129 40 0.5 – 0.9
PC8000 (12037 - ) 16,3 on request 0.5 – 2.5
H 685SP 14,0 379 129 40 0.5 – 0.9
H 685SX (12030) 16,3 on request 0.5 – 2.5
AH00511e
Page 2 of 20
2. 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.
AH00511e
Page 3 of 20
3. General
• Before removing swing circle mark location of both slew rings to superstructure
and the carbody 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 SR (Slew Ring) 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 SR at four/three eyebolts evenly distributed in screw circle of the upper
ring.
• Prior to mounting the SR 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 mounting compound
P/N. 324 969 40 will be delivered. If this parts delivery is not complete, please get
immediately in contact with KOMATSU MINING GERMANY, because a proper
mounting may not be possible in case of missing items.
AH00511e
Page 4 of 20
4. Measurements
• Check the level of bearing area (only center section undercarriage) with a laser device
before installing a new slew ring.
• 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.
Legend
ID = Inner diameter slewring
OD = Outer diameter slewring
Π = 3.14
P = Maximum Deviation (deflection)
P= OD – ID : 100 x 0.2 *
2
* 0.2 = Constant
Example: OD = 4000 mm P = 4000 – 3600 : 100 x 0.2

ID = 3600 mm 2
P = 200 : 100 x 0.2
P = 0.4 mm
W
• If the measured value exceeds the calculated value P, the
surface has to be remachined.
AH00511e
Page 5 of 20
• Check the outer diameter of the new slewring top surface and compare with the outer
diameter of the factory machined surface of the superstructure.
• Remove the shoulder by machining if necessary.
) • A shoulder exists only at some excavators.
AH00511e
Page 6 of 20
5. Determination of tightening torque
The required tightening torque for all fastening bolts (inner and outer) has to be
determined with the 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, carbody and swing circle.
• The tightening torque must be determined each time the SR (Slew Ring) is
replaced as well as at the first assembling of the excavator at the operation site
and for the first and final inspection after 1000 operation hours.
• The required measuring device is delivered with the excavator or with the SR (Slew
Ring)
(see ill.).
• 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 centering (Z) in the bolt head and in the end of the threads.
The measuring device is composed of the following items and will be delivered with
each replacement swing circle and each new machine:
(1) Measuring jaw 1pce. (3) Measuring bolt 8pcs.

(2) Test block 1pce. (4) Washer 1pce.
For the determination of the tightening torque, the eight measuring bolts have to
be mounted one by one to the measuring device as illustrated. Then the bolt has
to be tightened in steps to the prescribed elongation (see table page 05). The
needed tightening torque will be determined as a result of average of eight
tightening torque's. For the exactly procedure refer to the following pages.
AH00511e
Page 7 of 20
For the determination of the torque / or pressure (hydr. torque multiplier) for the
elongation of the test bolts proceed according to illustration on page 03 and the
following description.
Before the mounting of the measuring bolts (3) to the jaw, the bearing surface of
head, threads and washers have to be applied with compound P/N. 324 969 40.
• Screw test bolt (3) with washer (4) in test block (2) and tighten manually.
• Fit jaw (1) and micrometer gauge into the centering "Z" of the bolt and set
gauge to zero.
• Increase tightening torque of test bolts by steps of app. 200 Nm until the
required elongation of the bolt according to the table is reached.
Measuring bolts
Type Analogous to the
Quality
dimension of the outer Wrench size Elongation [mm]
grade
fastening bolts (8)
H 185S M 30 x 230 10.9 46 mm 0.55 ±0.015

H 255S / PC3000/1 M 30 x 230 10.9 46 mm 0.55 ±0.015
PC3000/6 M 30 x 230 10.9 46 mm 0.550±0.015
PC3000/6 M 30 x 190 10.9 46 mm 0.442±0.013
H 285S M 36 x 220 10.9 55 mm 0.61 ±0.020
PC4000 M 36 x 220 10.9 55 mm 0.61 ±0.020
H 455S / PC5500 M 36 x 230 10.9 55 mm 0.58 ±0.020
H 485S (to 12010) M 36 x 230 10.9 55 mm 0.58 ±0.020
H 485S (12011 up) M 36 x 270 10.9 55 mm 0.65 ±0.020
H 655S
M 36 x 270 10.9 55 mm 0.65 ±0.020
PC8000 (to 12036)
PC8000 (12037 up) M 36 x 295 10.9 55 mm 0.71 ±0.020
H 685SP M 36 x 270 10.9 55 mm 0.65 ±0.020
H 685SX (12030) M 36 x 295 10.9 55 mm 0.71 ±0.020
• Note down the tightening values in Nm, ft. lbf. resp. bar.
• Repeat this procedure with all eight test bolts.
• Add all 8 tightening values and than divide by 8.
• Tighten bolts (7) and (8) to the calculated value
(refer to the drawing at the next page).
AH00511e
Page 8 of 20
6. Mounting of a Swing circle (refer to ill. pages 06/08)
Depending on the model, bushes (11) or washers (10) have to be mounted.
AH00511e
Page 9 of 20
) • When replacing the swing circle, all fastening bolts must also
be replaced.
The eight measuring bolts have to be mounted equally distributed on the outer ring
of the swing circle.
If scratches are found at supporting surfaces of washers or bushes, they must be
reworked or replaced.
Replacement swing circles has to be mounted without dowel pins.
If the mounted SR (Slew Ring) was fixed to the platform with dowel pins, remove
these ones.
• Clean fat-free supporting surfaces (A) carbody and platform.
• Supporting surfaces (A) must be absolutely fat-free. Even the solvent must be rinsed
away before assembling.
• Check surface evenness (A).
• 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 SR (Slew Ring) with those in
carbody and platform. Discordance's may easily cause distortions of SR.
AH00511e
Page 10 of 20
• For removal and assembly always use a mounting cross (M).

Fabricate mounting cross (M) according to the drawing or
order it under giving the corresponding P/N. The construction
drawing of the mounting cross has to be ordered from the
Parts Department if necessary.
Swing circle weight Mounting cross

Type
[t] P/N
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
H 455S / PC5500 9.0 / 10.0 477 577 40
H 485S 14.0 379 129 40
H 655S
14.0 379 129 40
PC8000 ( - 12036)
PC8000 (12037 - ) 16.3 864 187 40
H685SX (12030) 16.3 864 187 40
H 685SP 14.0 379 129 40
AH00511e
Page 11 of 20
• Deposit and center SR with transport star (T, see page 07) on mounting cross (M).
• Check length of threads in platform and SR, if necessary retap.
• Place SR at its fastening position under the jacked-up platform.
Adjustment: Unhardened spot „S“

For the adjustment of the Unhardened spot "S", see illustration.
The Unhardened spot of race surfaces (changeover area between beginning and
ending of hardening process) is punch marked with a "S" at the inner resp. outer side
of each race ring (5 and 6), see illustration.
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 as illustrated.
AH00511e
Page 12 of 20
• Lift SR until approx. 10 mm below the platform (observe unhardened spot "S").
• Screw fastening bolts (7) with washers (10) through swing circle into the
platform. Slightly treat bolt heads, threads and washers with Compound,
P/N 324 969 40.
• Lift SR to the supporting surface by screwing in the bolts crosswise.
• Lower mounting cross.
• Remove transport cross.
Tooth back lash Tooth

Type back lash
[mm]
The tooth back lash is the play measured by a H 185S 0.4 – 0.8
feeler gauge in point D if tooth A press on the H 255S/PC3000 0.4 – 0.8
reference circle (B) against tooth C. H 285S 0.6 – 1.0
On swing circle where you find a green PC4000 0.6 – 1.0
color marking on 3 teeth, rotate the lower ring H 455S/PC5500 0.6 – 1.0
(6) until the 3 green marked teeth are mating H 485S 0.5 – 0.9
with the teeth of a slew pinion. H 655S/PC8000 ( -12036) 0.5 – 0.9
PC8000 (12037 - ) 0.5 – 2.5
H685SX (12030) 0.5 – 2.5
H 685SP 0.5 – 0.9
Note:
The green teeth indicate the point of the SR
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.
AH00511e
Page 13 of 20
Before lowering the platform with SR on center section of the undercarriage:

1. Mark 4 teeth(1; 2; 3; 4 - refer to illustration) displaced by 90 °.
The slew gears are marked gear 1, gear 2 and gear 3 (if so present).
2. Rotate the slew ring so far that tooth 1 is engaged at pinion of slew 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 slew gear 2.
Measure play as described under step 3.
5. Rotate superstructure further until tooth 1 is engaged at pinion of slew gear 3.
Measure play as described under step 3.
6. Rotate superstructure further that tooth two is engaged at pinion of slew 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 slew gear, four dimensions are noted in the table.
8. If necessary, adjust the backlash by displacement of the SR. For the correct
backlash, refer to chart above.
9. Hints for the three slew gear version:
Adjust an equal play at pinion of slew gear 1 and 3 by shifting the slew ring.
For this use the installed adjusting bolts.
Afterwards adjust play at slew gear 2 to the same value before adjusted at 1 and 3.
Tooth backlash
Slew gear Play – nominal value Tooth 1 Tooth 2 Tooth 3 Tooth 4

gear 1
refer to table
gear 2
at page 10
gear 3
AH00511e
Page 14 of 20
Hints for rotating the slew ring
1. Remove the slew motor.

2. If the excavator is equipped with more than one slew motor:
Remove the hoses at the other slew motor(s).
3. Loosen the slew brake(s) by applying external pressure (25 - 60 bar).
4. Use the below shown tool in place of the removed slew motor for rotating
the slew ring (drive: 36 mm).
) • The shown tool can be used for Series:

PC3000; PC4000; PC5500; PC8000.
36 mm
Part no.: 864 501 40
AH00511e
Page 15 of 20
Tighten all SR 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
P/N 324 969 40.
• Fasten crosswise fastening bolts (7) with the previously determined tightening torque
(see page 05). 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 slew motor and loosen all slew 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 SR to the superstructure, the tooth backlash
has to be checked once more at 4 points, if necessary adjust again.
• Lower platform with SR on center section of the undercarriage. Watch position of

not hardened spot "S" of the ring (6) according to illustration on page 09. 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.
AH00511e
Page 16 of 20
7. Checking of bolts
To compensate settling between SR and parts connected to it the bolts must be

checked after 1000 operation hours. If necessary retighten bolts with the
determined torque (refer to page 05).
• Unscrew the eight test bolts (4) of the connection SR / carbody.

• Determine the required torque with these eight test bolts (4) in the test block (2).
For the procedure, refer to the pages 03 - 05.
• Retighten all bolts (4/7/8) with the same torque multiplier you have used for the
determination.
• On the models H 285 - H 685 for the retightening of the bolts of the connection SR
/ platform you need an extension, Part-No. 232 511 40.
8. Lubrication and maintenance (RDV)
8.1. Races of roller bearings
Races 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 excavator with high-pressure water or with vapor
blast apparatuses. Before and after each cleaning grease
thoroughly. The even distribution of grease requires slewing
of the superstructure during greasing.
AH00511e
Page 17 of 20
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 slewing
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 011 597 99 (published in July
1995) section A.
When choosing the grease, consider the ambient temperature range.
Exchange of the lip type seal "L" (see ill., page 06)
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 (P/N, 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 P/N 989 965.
AH00511e
Page 18 of 20
8.2. 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 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.
AH00511e
Page 19 of 20
) • Use these Greases for Swing Circle open Gear Lubrication only!
Ambient Temperature
°C ⇒ -50 -40 -30 -20 -10 0 10 20 30 40 50 60
°F ⇒ -58 -40 -22 -4 14 32 50 68 86 104 122 140
Supplier
Castrol Molub-Alloy 936 SF Heavy NG
Castrol Castrol Molub-Alloy 936 SF Heavy

Industrie
GmbH Castrol Molub-Alloy
958 SF
Castrol Molub-Alloy 936 SF Arctic

BERULIT GA 2500 / BERUGEAR W4000
BERULIT GA 800
BECHEM BERUGEAR
W 3000
Beru Gear FG 34 (Biodegradable)

Molub unee lubricant 7059
BEL RAY Molub Gear Tac 6895
Molub Gear Tac

6894 / 6899
ESSO Dynagear Extra
Ceplattyn KG 10 ECO (Biodegradable)

FUCHS
LUBRITECH Ceplattyn KG 10 HMF
URETHYN HGO *1)
MOLYBOND TSG Heavy
Malleus GL 500
SHELL Malleus GL 400
Malleus GL 25
TEXACO Crater 2X Fluid *2)
*1) The URETHYN HGO Grease should be used only 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.
*2) Use the Crater 2X Fluid for Spray systems only.
AH00511e
Page 20 of 20
Lubrication: Manual
The manually lubrication has to be carried out with the following adhesive
lubricants.
Those lubricants are suitable for all temperature ranges.
Company Product T1 T2 T3
-5°C ⇒ +60°C -20°C ⇒ +10°C -40°C ⇒ -10°C
+23°F ⇒ +140°F -4°F ⇒ +10°F -40°F ⇒ +14°F
Komatsu Voler Compound
Mining 2000 E P/N 500 893 98
Germany Spray (0,625kg)
Voler Compound
Special 2000 E
grease Adhesive lub P/N 006 057 98
(indicate quantity
in kg)
8.3 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 slewing connection have been damaged

due to one of the above mentioned reasons they do not fall
under our warranty.
AH00511e
COMPONENT CODE: 3000
REF NO. AH00514
PARTS & SERVICE NEWS DATE 08162000
Page 1 of 11
This PARTS & SERVICE NEWS supercedes the previous issue No. 21 – 251c
dated May 2000 which should be discarded.
SUBJECT: Track group - Hints for sprocket exchange
PURPOSE: Sprocket exchange in case of normal wear
APPLICATION: H 185S; H 241; H 285; H 285S; PC4000; H 485;

H 485S; H 685S/SX; H 655S; PC8000
FAILURE CODE: 3000CA
DESCRIPTION:
1. Sprocket types
1.1 Standard sprocket
1.2 Oversize sprocket
2. Part no.
2.1 Sprockets with hub
2.2 Sprockets without hub / shaering pins
3. Removal sprocket
4. Conversion of the hub
5. Preparing the shearing pins
6. Determination of the Axial Play
7. Remachining
8. Assembly
9. Torque Data for Standard Application
AH00514
Page 2 of 11
1. Sprocket types

The standard sprocket has to be used in case of assembling new machine or
regenerating the track group in connection with new track pads.

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, comes up to 0.5 mm
(see Service Bulletin 21-205 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 conversion of the sprockets is very 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 and Parts
Catalogue for correct choice of the bush type.
Basically, all seals (4; 5; 6; 10, see page 04) according to Parts Catalogue have be
replaced.
. • The difference between the standard version (NT) and the very
low temperature version (TT) are only the bolts. The sprocket
and the shearing pins are the same.
AH00514
Page 3 of 11
2. Part no.
2.1 Standard sprocket (T) with hub Oversize sprocket with hub (T)
Type Part No. Type Part No.

H 185S 429 206 40 H 185S * 448 943 40
H 241 261 678 40 H 241 425 656 40
H 285 352 433 40 H 285 425 654 40
H 285S 643 940 40 H 285S 643 936 40
PC4000 643 936 40 PC4000 643 940 40
H 485 313 343 40 H 485 426 016 40
H 485S 643 930 40 H 485S 643 926 40
H 685S/SX 643 930 40 H 685S/SX 643 926 40
H 655S/ PC8000 643 930 40 H 655S/ PC8000 643 926 40
* Oversize sprocket for H 185S
is available only with hub
AH00514
Page 4 of 11
2.2 Oversize sprocket without hub (R) /

Shearing pins (O)
Type Sprocket (R) Pin Pin (O)

Part No. numbers Part No.
H 241 425 655 40 4 429 638 40
H 285 448 961 40 6 429 691 40
H 285S 887 105 40 6 429 691 40
PC4000 887 105 40 6 429 691 40
H 485 448 969 40 8 429 640 40
H 485S 643 923 40 8 429 692 40
H 685S/SX 643 923 40 8 429 692 40
H 655S/ PC8000 887 115 40 8 429 692 40
AH00514
Page 5 of 11
3. Removal sprocket
• Suspend travel gear (1) to a crane, remove mounting bolts.

• Remove travel gear by using the pulling bolts, put aside.
• Remove cover (2).
• Underpin sprocket (T/R) from below, suspend to a crane.
• Pull out drive shaft (8).
• Remove mounting bolts in flange bearing (7), loosen by using the pulling bolts,
extract.
• Extract hollow shaft (9) to cover side (2), lift sprocket (T/R) out.
• Remove mounting bolts in flange bearing (3), loosen by using the pulling bolts,
extract.
14 22
50
34
AH00514
Page 6 of 11
4. Conversion of the hub
Loosen bolts and bore into

shearing pins.
Pin
Do not drill
through !
Model Pin dia. (mm) Drill dia. (mm) Pin dia. (mm) Drill dia. (mm)
standard oversize
H 241 42 36 44 36
H 285/ H 285S 50 44 52 44
PC4000 50 44 52 44
H 485/ H 485S 55 49 57 49
H 685S/SX 55 49 57 49
H 655/ PC8000 55 49 57 49
Pull out shearing pins.

Separate hub and sprocket, if necessary heat up sprocket to approx. 100°C.
Insert hub into the new sprocket and align corresponding to the existing holes.
Insert bolts and tighten.
AH00514
Page 7 of 11
Drill holes on a vertical boring machine. The sprocket has to be on top. Use Shell
counterbores of high speed steel.
Model Holes for the shearing pins

H 241 4 x 43.5 mm
H 285/ H 285S 6 x 51.5 mm
PC4000 6 x 51.5 mm
H 485/ H485S 8 x 56.5 mm
H 685S/SX 8 x 56.5 mm
H 655/ PC8000 8 x 56.5 mm
Ream the holes for the shearing pins.
Model Holes for the shearing pins

H 241 4 x 44 H7
H 285/ H 285S 6 x 52 H7
PC4000 6 x 52 H7
H 485/ H485S 8 x 57 H7
H 685S/SX 8 x 57 H7
H 655/ PC8000 8 x 57 H7
After reaming bur the holes carefully.
5. Preparing the shearing pins
“A”
sprocket
hub
“B”
By means of a 3 point inside micrometer measure the diameter “A” and “B” at the
spots as shown in the illustration.
Add 0.04 mm to the larger diameter and grind the oversize sharing pin to this
dimension.
Repeat this procedure separately for all pins.
Example:
“A” = 57.01 mm
“B” = 57.02 mm
“B” is bigger. The diameter of the pin has to be : 57.02 mm

+ 0.04 mm
= 57.06 mm
Shearing pins have to be deep-freezed by using liquid nitrogen (-196°C/-320°F and

pushed into the reamed holes.
AH00514
Page 8 of 11
29
50
29
AH00514
Page 9 of 11
After removal, all seals have to be renewed.
• Slide O-ring (5) over flange bearing (3).

• Mount flange bearing (3) without dual-cone seal (29).
• Pay attention to the lubrication-grooves position, they have to be displaced by
22.5° to the vertical line.
• Mount all bolts (50) and tighten according to tightening torques on the last page.
• Suspend sprocket (T/R) to a crane , insert without dual-cone seals(29).
• Mount hollow shaft (9) and slide against collar “B”. By this, the sprocket (T/R) is
moved against the collar of the bushing.
• Mount flange bearing (7) with 3 bolts (22) without dual-cone seal (29).
• Measure dimension “X”.
• Slide sprocket (T/R) to direction “C” until the hollow shaft (9) rests against the
collar “D” of the flange bushing.
• Measure dimension “Y”.
• The axial play result in X – Y .
7. Remachining
If the amount of axial play exceeds 0.9 mm (H 241 > 0.5mm). 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.
Type Original Wear limit

H 185S 0.2 – 0.9 2.75
H 241 0.2 – 0.5 2.00
H 285/ H 285S 0.2 – 0.9 2.75
PC4000 0.2 – 0.9 2.75
H 485/ H485S 0.2 – 0.9 2.75
H 685S/SX 0.2 – 0.9 2.75
H 655S/ PC8000 0.2 – 0.9 2,75
• Suspend sprocket (T/R) to crane, pull out hollow shaft (9), lift sprocket (T/R) out.
AH00514
Page 10 of 11
29
29
50
AH00514
Page 11 of 11
8. Assembly
• Mount dual-cone seal (29) according to SB 10-33 into flange bearing (3).
• Mount dual-cone seals (29) according to SB 10-33 into sprocket (T/R).
• Place sprocket (T/R) into the side frame by using a crane, align and underpin
sprocket in mounting position.
• Mount hollow shaft (9).
• Mount dual-cone seal (29) according to SB 21-558 into flange bearing (7).
• Mount flange bearing (7). The lubrication grooves of the bushing(4) have to be
displaced by 22.5° to the vertical line.
• Tighten bolts (22), according to the tightening torques below.
• Insert O-ring(6) in cover (2). Mount cover (2) with bolts (14).
• Insert O-ring (10).
• Suspend travel gear (1) to a crane and mount to side frame.
• Refill oil and check levels.
. • When selecting tightening torques, observe size and quality

grade of the bolts.

dia. size Nm/lbs.ft.
[mm] [mm] Quality grades
8.8 10.9 12.9
M 10 17 43/32 63/47 73/54
M 12 19 74/54.6 108/80 127/94
M 14 22 118/87 173/128 202/149
M 16 24 179/132 265/196 310/229
M 18 27 255/188 360/265 425/313
M 20 30 360/265 510/376 600/443
M 22 32 485/358 690/509 810/597
M 24 36 620/457 880/649 1030/760
M 27 41 920/679 1310/966 1530/1128
M 30 46 1250/922 1770/1305 2080/1534
M 33 50 1690/1246 2400/1770 2800/2065
M 36 55 2170/1600 3100/2286 3600/2655
Insert all bolts lubricated with MPG, KP2K type lubricant.
AH00514
COMPONENT CODE: 30
REF NO. AH00515c
PARTS & SERVICE NEWS 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
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.
Bearing assy.* Bearing assy.* Bushings *

Type (outside) (inside)
old new old new old new
H 485; H485S; H 685S/SX; 31335540 91159540 31335640 92298040 42964940 92298440
H 655S; PC8000
H 285; H 285S; PC4000 36103640 92253840 36103740 92253940 42965240 92253740
PC5500 (#15026 and up) ---- 93360240 --- 93360440 --- 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.
• For machines with the new bushings (P/N 922 537 40) the radial
• For machines with the new bushings (P/N 933 600 40) the radial
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 Mounting Threaded Gauge (S) Axial play Max.

bolt (2) shaft (mm) (mm) new (mm) permissible
axial play
(mm)
H 185 / S M 12 M 16 316 0.2 – 0.9 2.75
H 285 / S M 16 M 20 360 0.2 – 0.9 2.75
PC4000 M 16 M 20 360 0.2 – 0.9 2.75
PC5500 M 12 M 20 435 0.2 – 0.9 2.75
H 485 / S M 16 M 20 460 0.2 – 0.9 2.75
H 685S / SX M 16 M 20 460 0.2 – 0.9 2.75
H 655S/PC8000 M 16 M 20 460 0.2 – 0.9 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 7
„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 400.56+0.06
PC5500 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 freezed–in 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
PARTS & SERVICE NEWS DATE January 15, 2007
Page 1 of 4
This PARTS & SERVICE NEWS supercedes the previous issue AH00519d
SUBJECT: Adhesive lubricants for the Slew Ring Gear
PURPOSE: Revision
APPLICATION: All types
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

ã 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 ⇒ -50 -40 -30 -20 -10 0 10 20 30 40 50 60
°F ⇒ -58 -40 -22 -4 14 32 50 68 86 104 122 140
Supplier
Castrol Molub-Alloy 936 SF Heavy NG
Castrol Castrol Molub-Alloy 936 SF Heavy

Industrie
GmbH Castrol Molub-Alloy
958 SF
Castrol Molub-Alloy 936 SF Arctic

BERULIT GA 2500 / BERUGEAR W4000
BERULIT GA 800
BECHEM BERUGEAR
W 3000
Beru Gear FG 34 (Biodegradable)

Molub unee lubricant 7059
BEL RAY Molub Gear Tac 6895
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
Crater 2X Fluid *2)
TEXACO
Lubrene Multi ServOGL

LUBRITENE
*1) 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.
*2) 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 T2 T3
-5°C ⇒ +60°C -20°C ⇒ +10°C -40°C ⇒ -10°C
+23°F ⇒ +140°F -4°F ⇒ +10°F -40°F ⇒ +14°F
Voler Compound
KOMATSU 2000 E P/N 500 893 98
Spray
(0,625kg)
Voler Compound
Special 2000 E P/N 006 057 98
grease Adhesive lub
(indicate
quantity in kg)
) • 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
Page 1 of 4
This PARTS & SERVICE NEWS supercedes the previous issues No.: 21–491 which
should be discarded.
SUBJECT: Bleeding of hydraulic pumps
PURPOSE: Avoiding of cavitation
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
Suction
PTO 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
Precondition Þ
• Hydraulic oil reservoir (1)
5 filled
• Cock (2) closed
4 • Suction oil reservoir (3)
1 totally empty or decreased
level
Cock
closed • Suction line (4) empty
• Hydraulic pump (5) empty
3
2
Measure Þ
• Place oil pan for out coming
oil.
5 • Loosen suction line (4)
• Open cock (2), when oil
outflowing
oil
4 runs out, reconnect suction

1 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)

6 Measure Þ
• 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: 10
REF NO. AH01523c
Page 1 of 3
This PARTS & SERVICE NEWS supersedes the previous issue No.AH01523b which
SUBJECT: Replacement of the elastic coupling (Electro drive shovels)
PURPOSE: Revision (Addition of a new model)
APPLICATION: H 185SE (06099 and up); H 255SE (06122 and up);

H 285SE (78137 and up); H 655SE; PC3000; PC4000;
PC5500; PC8000
FAILURE CODE: 1000FA
DESCRIPTION:
The above mentioned excavators are equipped with highly flexible couplings.
The inspection for the indicated tightening torques and the visual inspection for cracks
have to be carried out in the following intervals (refer also to the Maintenance Manual of
your excavator):
• 250 working hours after commissioning

• Every 2000 working hours or every 6 month
When should the elastic elements be changed?
• In case of cracks in the marked area (arrows in illustration A and B)

• After 15.000 working hours or after 10 years.
In case of new installation or exchange, the following alignment tolerances have to be

checked by using a gauge and, if necessary, corrected.
Excavator Clutch Radial (x)* Axial (y)* Angular (z)* Installation

Type Part-No. misalignment misalignment misalignment Dimension (a)
H 185 SE 551 980 40 ± 1,0 mm ± 2,0 mm ± 0,5 ° 477 ± 2 mm
H 255 SE 655 615 40 ± 1,0 mm ± 2,0 mm ± 0,5 ° 527 ± 2 mm
H 285 SE 896 479 40 ± 1,0 mm ± 2,0 mm ± 0,5 ° 645 ± 2 mm
H 655 SE 902 215 40 ± 0,35 mm ± 2,0 mm ± 0,5 ° 866 ± 2 mm
PC3000 E 655 615 40 ± 1,0 mm ± 2,0 mm ± 0,5 ° 527 ± 2 mm
PC4000 E 907 174 40 ± 0,35 mm ± 2,0 mm ± 0,5 ° 866 ± 2 mm
PC5500 E 655 615 40 ± 1,0 mm ± 2,0 mm ± 0,5 ° 527 ± 2 mm
902 215 40
PC8000-E ± 0,35 mm ± 2,0 mm ± 0,5 ° 866 ± 2 mm
907 174 40
* Explanation refers to illustrations at the next page.
AH01523c
Page 2 of 3
radial axial angular z
Inspection of the coupling elements

1. Move the cover ring(3) to the left (refer to the removing procedure)
2. Inspect the surface of the rubber elements visually (If there are 2 rubber elements –
illustration B - use a small mirror)
Removing of the coupling element/s

1. Remove nuts (1) and bolts (2).
2. Move the cover ring (3) to the left.
3. Remove the bolts (4).
4. Move the rubber element/s(5) to the right and remove it/them.
5. Remove the screws (6) and the ring (7).
Installing of the new coupling element/s

1. Bolt ring (7) and the rubber element (5) together with the screws (6).
2. Further installation reverse order to the removal.
Tightening torques Tightening torques Tightening torques

Excavator type
A (Nm)* B (Nm)* C (Nm)*
H 185SE 215.0 560.0 86.0
H 255SE; PC3000;
175.0 +20 480.0 + 50 70.0 + 9
PC5500; H 285 SE
H 655SE; PC8000;
250.0 +30 960.0 +110 960.0 +110
PC4000
* Threads and bolt heads must be greased carefully with engine oil.
AH01523c
Page 3 of 3
3 Illustration A
1
2
A
5
B
4 7
a
gearbox side
6
motor side
Illustration B
3
2 1
A
B
C
gearbox side motor side
5b 5a
AH01523c
COMPONENT CODE: 30; 63
REF NO. AH01531A
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
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 ½ 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
PARTS & SERVICE NEWS DATE January 4, 2005
Page 1 of 4
This PARTS & SERVICE NEWS supersedes the previous issue No. AH02513a
SUBJECT: Testing wear and tear of swing circle bearing
PURPOSE: In time ordering of a new swing circle
in order to prevent unexpected downtime
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: every 5.000 working hours;

2. Period more than 10.000 h: 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.
mm normal wear increased extrem wear

wear
Axial movement/wear
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.
ã
• 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: Serial number:
Planned Actual Date Front Front Mfront = Rear Rear Mrear =

h h M1 M2 (M1 + M2)/2 M1 M2 (M1 + M2)/2
0
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
PARTS & SERVICE NEWS DATE April 3, 2007
Page 1 of 10
This PARTS & SERVICE NEWS supersedes the previous issue Number AH02521a which
SUBJECT: Track group – wear measurement
PURPOSE: Revision
APPLICATION: H 185 to PC8000
FAILURE CODE: 752DCA
DESCRIPTION:
1. Preconditions for the measurements

2. Adjusting range for guide wheels
3. Chain elongation / measured over three track pads (4 pins)
4. Circular pitch (Sprocket / Track pad)
5. Wear of track pads (Roller contact surface)
6. The X-dimension becomes zero
7. 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
• H 185S up to max. 230 mm
• 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.
ã
• 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: Operate at low idle.

Electric motor: 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 : Serial-No. : Operating hours :

Customer : Location : Date of measurement :
NO YES
Oversize sprocket ? : Date of installation: Part-No. of track pad :
(left hand side) Ö ...................
at operating hours:
.....................
NO YES
Oversize sprocket ? : Date of installation:
(right hand side) Ö ...................
at operating hours:
.....................
Chain elongation (Illustration 5): Left hand crawler track “L“

Measuring area L1 L2 L3 L4
W-dimension [mm] via 4 pins
Chain elongation (Illustration 5): Right hand crawler track “R“

Measuring area L1 L2 L3 L4
W-dimension [mm] via 4 pins
Circular pitch:
Illustration 6 “A“ 3 points (equally distributed on the chain)
1 2 3
Sprocket side inside outside inside outside inside outside
X1-dimension [mm] L.H
X1-dimension [mm] R.H
Illustration 6 “B“ 3 points (equally distributed on the chain)

1 2 3
Sprocket side inside outside inside outside inside outside
X2-dimension [mm] L.H
X2-dimension [mm] R.H
Wear of Track pads (Illustration 6 “C“):

Dimension “B“
Track pad Side Number of cracked track pads
[mm]
No.1 L.H. left hand crawler track right hand crawler track
No.2 L.H.
No.3 L.H.
No.4 R.H.
No.5 R.H.
No.6 R.H.
AH02521b
COMPONENT CODE: 03
REF NO. AH03506b

Page 1 of 5
This PARTS & SERVICE NEWS supersedes the previous issue AH03506a which should
be discarded.
SUBJECT: Hydraulic oil cooler and water cooler fan bearings
PURPOSE: Replacement of the bearings
APPLICATION: PC4000; PC5500; PC8000
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
2. Gear oil lubricated bearings

2. Gear oil lubricated bearings
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 Water Oil Water Oil Water
cooler cooler cooler cooler cooler 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 *** 79296573 79296673 79296573 79296673 79296773 79484873 79296873
Press depht
"a" (mm) 4 -0,5 3,7 +0,2 4 -0,5 3,7 +0,2 4 -0,5 6,4 ±0,8 4,3 ±0,8
Shaft dia. "d"
(mm) ∅80 ±0,05 ∅110 ±0,05 ∅80 ±0,05 ∅110 ±0,05 ∅100±0,05 ∅130−0,025 ∅ 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
PARTS & SERVICE NEWS DATE 22nd July 2003
Page 1 of 25
This PARTS & SERVICE NEWS supersedes the previous issue AH03509 which should be
discarded.
SUBJECT: Slew gear GFB 174 E 9017 (Part No. 917 915 40)
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)
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 6

with the complete parking brake unit,
3. Variant (B) –
Modification by machining the swing gear cover. 8
3.1 Modification of the swing gear cover 11
a) Dismounting 11
b) Machining of the swing gear cover 12
c) Reassembly 13
4. Completion of the swing gear cover 24
5. Oil level checking procedure 25
AH03509a
Page 2 of 25
1. Modification Kits
1.0 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. Qty. Description Illustration

1 79227073 1 Cover/brake assy. 3
15 37441299 4 Socket 6
16 90635240 4 Cutting ring 6
17 37126599 4 Union nut 6
14 92582540 4 Oil level gauge tube 6
18 31318499 4 Plug 6
1 90756840 1 Oil level gauge 6
20 92582940 1 Oil level gauge bracket 6
1 972111 1 O-ring 2
2 50774898 1 O-ring 2
1.1.2 PC4000-6 Part No.: 794 017 73

15 37441299 12 Socket 6
16 90635240 12 Cutting ring 6
17 37126599 12 Union nut 6
18 31318499 12 Plug 6
1 972111 2 O-ring 2
2 50774898 2 O-ring 2
(Cover plates must be adapted.)
AH03509a
Page 3 of 25
1.1.3 PC5500 Part No.: 794 018 73

15 37441299 10 Socket 6
16 90635240 10 Cutting ring 6
17 37126599 10 Union nut 6
18 31318499 10 Plug 6
1 972111 2 O-ring 2
2 50774898 2 O-ring 2
1.1.4 PC8000 Part No.: 794 019 73

15 37441299 14 Socket 6
16 90635240 14 Cutting ring 6
17 37126599 14 Union nut 6
18 31318499 14 Plug 6
1 972111 3 O-ring 2
2 50774898 3 O-ring 2
1 92583240 1 Cover plate -
1 92583140 1 Cover plate -
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

15 37441299 4 Socket 6
16 90635240 4 Cutting ring 6
17 37126599 4 Union nut 6
18 31318499 4 Plug 6
99 33132299 1 Plug 4
504 79224973 1 Disc (thickness: 8.5-0.1mm) 4
1; 3; 4 972111 3 O-ring 2
2 50774898 1 O-ring 2
1.2.2 PC4000 Part No.: 794 021 73

15 37441299 12 Socket 6
16 90635240 12 Cutting ring 6
17 37126599 12 Union nut 6
18 31318499 12 Plug 6
99 33132299 2 Plug 4
1; 3; 4 972111 6 O-ring 2
2 50774898 2 O-ring 2
(Cover plates must be adapted.)
AH03509a
Page 5 of 25
1.2.3 PC5500 Part No.: 794 022 73

15 37441299 10 Socket 6
16 90635240 10 Cutting ring 6
17 37126599 10 Union nut 6
18 31318499 10 Plug 6
99 33132299 2 Plug 4
1; 3; 4 972111 6 O-ring 2
2 50774898 2 O-ring 2
1.2.4 PC8000 Part No.: 794 023 73

15 37441299 14 Socket 6
16 90635240 14 Cutting ring 6
17 37126599 14 Union nut 6
18 31318499 14 Plug 6
99 33132299 3 Plug 4
1; 3; 4 972111 9 O-ring 2
2 50774898 3 O-ring 2
1 92583240 1 Cover plate -
1 92583140 1 Cover plate -
AH03509a
Page 6 of 25
2. Variant (A) – Modification by replacing of the swing gear cover with the complete
parking brake unit
1. Prepare the swing gear cover as described on page 23.

2. Drain the motor adapter housing (about 0.6l oil).
3. Remove the 8 bolts (7) M16 mm at the hydraulic motor (refer to illustration 1).
4. 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
2 Oil filler plug swing machinery
3 Breather filter swing machinery
4 Oil level gauge motor adapter housing
5 Breather filter motor adapter housing
6 Oil drain plug
7 Motor fastening bolts
8 - 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
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 ¼ inch.
Illustration 5
45° 45°
R31.5
+0.5
30
30° 30°
Ø524
Ø660
R 1.6
30
G 5/4
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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.
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Before installation supply the piston (116) with pressure (max. 60 bar).
Do not forget to exchange the O-ring.
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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
A3 – Plug
14 – Oil level gauge tube
15 – Socket
16 – Cutting ring
17 – Union nut
18 – Plug
19 – Oil level gauge
Illustration 6 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
PARTS & SERVICE NEWS DATE 2nd June 2003
Page 1 of 18
SUBJECT: ESCO bucket tooth system
PURPOSE: Hints for handling
APPLICATION: PC4000; PC5500 (15012 - ); PC8000
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
1. Overview 2
1.1 Komatsu standard version 2
1.2 Optional version 2
2. The Points 3
2.1 Removing the points 4
2.2 Installing the points 5
3. The Adapters 6
3.1 Adapter removal 6
3.2 Nose rebuild 8
3.2.1 Nose end and sides rebuild 8
3.2.2 Nose flats rebuild 9
3.2.3 Rear corner rebuild 9
3.3 Adapter installation 10
3.4 Retighten Sidewinder Pin 11
4. Wear Caps 11
4.1 Lock style wear caps (PC4000) 11
4.1.1 Removal 11
4.1.2 Installation 12
4.2 Non lock style wear caps 13
(Option PC4000; PC5500; PC8000)
4.2.1 Removal 13
4.2.2 Installation 13
5. The Shrouds 14
5.1 Removal the shrouds 14
5.2 Installing the shrouds 15
5.2.1 Prepare the surface 15
5.2.2 Position the bosses 16
5.2.3 Welding the bosses 17
5.3 Inspecting Worn Shrouds 17
5.4 Installing (Shrouds and Pins) 18
AH03510
Page 2 of 18
1. Overview
1.1 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 Shovel Version Backhoe Version

PC4000 S 110 S 95
PC5500 S 130 S 130
PC8000 S 145 S 145
- ( 12030) S 130 -
- ( 12034) S 130 -
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
3 2
1
1 Point
2 Posilok Locking Pin
3 Integral rubber lock
4 Adapter
5 Mating rails between point and adapter
6 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
(PART tool between the
NO. 79350273) 2. Drive the Posilok Pin out
Posilok Pin and the lock using a removal tool
(Part No.
793 502 73)
Use this end to start Use this end to

the Posilok Pin out. 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 engages the lock.
Posilok Pin securely in place.
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): - Remove the safety pin of the adapter tool and slide the
(for S145) 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): - Guide the lug on the end of the arm through the
(for S130) 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 Nose Side Nose Flats

Template Template
S 95 79350573 79350673
S 110 79350773 79350873
S 130 79350973 79351073
S 145 79400373 79400473
• Weld–rebuild 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 Allen type wrench size Recommended pin torque

S 95 14 mm 160-200 Nm (120-150ft-lb)
S 110 17 mm 200-260 Nm (150-190ft-lb)
S 130 19 mm 260-390 Nm (190-290 ft-lb)
S 145 19 mm 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.
3.4 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 ½ - ¾ 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. The Shrouds
5.1 Removal the shrouds
The Toplok shroud system is engineered to make change-out easy. Before following these
simple steps shown to the Figures, it’s 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 Lift out and remove the lock. Slide the
latch as shown, as a lever to compress it. 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 Shovel Version Backhoe Version

Lip Shroud Template Lip Shroud Template
PC4000 654 547 40 654 627 40
654 548 40 794 005 73 654 628 40 794 006 73
654 629 40
PC5500 655 867 40 or 794 007 73 655 867 40 794 007 73
907 281 40
PC8000 907 006 40 794 008 73 907 448 40 On request
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: 200°F/95°C (350-400°F/175-205°C if air temperature is 40°F/5°C or lower.)
• Interpass: Maintain interpass temperature less than 500°F/260°C.
• Postheat: If air temperature is 40°F or lower, postheat 350-400°F, 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: 200°F/95°C (350-400°F/175-205°C if air temperature is 40°F/5°C or lower.)
• Interpass: Maintain interpass temperature less than 500°F/260°C.
• Postheat: If air temperature is 40°F or lower, postheat 350-400°F, 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 (A) (B) (C)
Location
Boss Depth of Size of fillet Size of fillet
weld plug holes weld-on ends weld-on ends
mm/in mm/in mm/in
TAB Plug Weld 10/.38 Fillet 10/.38 Fillet 3/.19
TBB Plug Weld 13/.50 Fillet 13/.50 Fillet 6/.25
TCB Plug Weld 16/.62 Fillet 13/.50 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
PARTS & SERVICE NEWS DATE 14th April 2003
Page 1 of 2
SUBJECT: Pilot Pressure Pump Part No. 907 209 40
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
PARTS & SERVICE NEWS 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: 63
REF NO. AH03528
PARTS & SERVICE NEWS DATE Sept. 29, 2003
Page 1 of 1
SUBJECT: Pilot control safety line
PURPOSE: Prevention of serious injury or death through high voltage

system
APPLICATION: PC8000-6 Electric Drive
DESCRIPTION:
The pilot line of the above mentioned excavators is a vital safety equipment.
This line controls the security of the following components:
§ Fire suppression system (9K3);
§ Flaps at slip ring unit (OS4 and OS4B);
§ HT – switch cabinet (OS10; OS11);
§ Emergency switch at the cable drum (OS15);
§ Flaps at the cable drum (OS17; OS18);
§ Flap at the terminal box of the cable drum (OS19).
If all these components are in normal working order the pilot line is closed.
If one component is not in normal working order this line will be interrupted and the power
supply of the excavator will be shut off in the external transformer station.
ã
• Make sure that the pilot line is always in proper working order.
A defective or missing pilot line can cause serious injury or
death.
AH03528
COMPONENT CODE: 46
REF NO. AH04518a
PARTS & SERVICE NEWS DATE June 29, 2005
Page 1 of 2
This PARTS & SERVICE NEWS supersedes the previous issue AH04518 which
SUBJECT: Welding procedure for welded counterweight
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)
DESCRIPTION:
ã
• 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
PARTS & SERVICE NEWS DATE September 15, 2006
Page 1 of 1
discarded.
SUBJECT: Abnormal vibration on hydraulic pipes
PURPOSE: Reduction of stress on the pipes
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
PARTS & SERVICE NEWS 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

PARTS & SERVICE NEWS DATE March 23, 2005
Page 1 of 4
This PARTS & SERVICE NEWS supersedes the previous issue No. 21-558 which should
be discarded.
SUBJECT: Dual cone seal ring mounting
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. Description
1 Seal ring
2 Seal face
3 Seal housing
4 Tool
5 O – ring
6 Housing surface
Table for selection of the assembly tool (other tools on inquiry)
Part No. Order-No. Part No. Order-No.

Dual Cone Seal Assembly tool Dual Cone Seal Assembly tool
145 800 40 766 311 73 323 823 40 766 323 73
180 472 40 766 308 73 324 067 40 766 309 73
180 624 40 766 312 73 461 627 40 766 318 73
202 986 40 766 315 73 461 628 40 766 307 73
226 424 40 766 322 73 696 523 73 766 310 73
226 425 40 766 317 73 696 525 73 766 311 73
255 058 40 766 314 73 804 595 73 766 313 73
269 454 40 766 312 73 963 754 766 321 73
270 460 40 766 316 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 ∅a ∅c d ∅b ∅a ∅c d
mm mm mm mm mm mm mm mm
95 100 89,5 1,8 191 198 185 4
99 107 92,5 3,5 200 208 192 4
104 118 98 3 202 209 196 4
110 115 104 2,5 213 220 201 4
111 118 105 4 217 225 210 4
112 120 107 3 231 238 220 4
121 128 115 4 229,5 236,5 220,5 4
127 131 121 3,5 242 249 232 4
126 134 120 3 254 261 242,5 4
139 148 133 3 270,5 279 258,5 4
142 150 135 4 282,8 292 269 4
141,5 149 133 3 295,5 302,5 282 4
143 150 137 4 326 334 321 4
146 153 137,7 4 343,5 350,5 335 4
157 163 150,5 4 348 357 342 7
162 169 155 3 377,5 384,5 369 4
175 182 169 4,5 397 407 385 4
159 166 153,5 3 418 426 410 5
174,5 181,5 162 4 458 468 446 4
177 185 168 4 503 518 495 7
169 176 161 2,8 536,5 545 528,4 5
172,5 180 166,5 3,5 563 578 555 7
169 175 165 2 593 608 585 7
171 177 168 2,5 611 620 603 5
170 176 165 4 703 710 694 5
176 183 167,5 3,5 626 642 618 7
182 190 177 3 753 768 745 7
194 201 182,5 4 890 898 878 10
AH05511
Page 4 of 4
Assembly tools for mounting of dual cone seal
AH05511
COMPONENT CODE: 25
REF NO. AH05518
Page 1 of 2
This PARTS & SERVICE NEWS supersedes the previous issue 21 - 503 which should be
discarded.
SUBJECT: Swing circle pinion
PURPOSE: Wear check every 5000 Operating hours
APPLICATION: PC3000; PC4000; PC5500; PC8000
DESCRIPTION:
All swing pinions are surface hardened to ensure a long service life.
If the depth of the wear reaches the hardening depth, the wear of the pinion will be rapid.
The increased tooth back-lash and the different tooth meshing, could decrease the service
life of the slew ring and the swing gear box(es).
By means of regular wear check , every 5000 operating hours, the depth of the wear
should be compared to the original shape.
AH05518
Page 2 of 2
The following table shows the machines with the pertaining swing gear box(es) and the
corresponding hardening depth:
Type PN Swing gear box Hardening depth

PC3000 898 100 40 2.0
917 915 40 2.0
924 352 40 2.0
926 795 40 2.0
PC4000 898 100 40 2.0
925 864 40 1.8 +0.4
926 795 40 2.0
PC5500 898 100 40 2.0
917 915 40 2.0
925 864 40 1.8 +0.4
926 795 40 2.0
PC8000 917 915 40 2.0
924 325 40 2.0
926 325 40 2.0
) • If the depth of the wear reaches the hardening depth, the slew
pinion should be replaced, to ensure a proper function of the
machine.
AH05518
COMPONENT CODE: J1
REF NO. AH05520a

PARTS & SERVICE NEWS 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 1 Reduction flange
02 385 243 40 1 Flange seal
03 319 272 99 4 Bolt M12 x 30
04 515 812 98 1 Coupling
05 356 209 40 1 Flange seal
06* 319 272 99 4 Bolt M12 x 30
07* 515 658 40 2 Half flange
08* 356 210 40 1 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
Page 1 of 3
SUBJECT: Suction elbows of the Main Pumps
PURPOSE: Hints for sealing
APPLICATION: PC3000-1; PC4000-6 (to # 08156) PC5500 (to # 15019);

PC8000 (to # 12042)
FAILURE CODE: K1T3AA
DESCRIPTION:
1. PC3000-1
2. PC4000; PC5500; PC8000
AH05525
Page 2 of 3
1. PC3000-1
1 Seal
2 Intake
3 Remachining surface
4 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
• In case of leakiness replace the old suction elbow (2) by a new one with an
other sealing system (1)(O-ring).
Type Intake (old) Intake (new) O - ring

891 451 40 928 335 40 517 582 98
PC4000-6
624 085 40 928 706 40 517 582 98
PC5500-6 624 085 40 928 706 40 517 582 98
894 317 40 928 287 40 517 582 98
PC8000-6 894 321 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

PARTS & SERVICE NEWS
DATE May 21, 2007
Page 1 of 22
This PARTS & SERVICE NEWS supersedes the previous issue AH05535b which should
be discarded.
SUBJECT: Hints for replacing by the slewing gear of an other manufacturer
PURPOSE: Revision
APPLICATION: PC3000 (#06193 and up); PC4000 (#08152 and up);

PC5500 (#15018 and up); PC8000 (#12041 and up)
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
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
3.1.1 Replacing “L+S” gear to “Siebenhaar” gear (PC3000-6; illustration 3)
Modification Kit: PN 794 853 73

10 323 460 40 1 Bleeder valve
11 517 676 98 34 Bolt
12 516 920 98 34 Washer
15 507 037 98 2 Nut
16 340 465 99 2 Washer
22 907 142 40 34 Plug
30 307 824 99 2 Bolt
31 374 428 99 1 Union
32 517 905 98 1 Hose assy.
33 500 141 98 2 Union
34 372 174 99 1 Union
35 334 601 99 2 Nut
36 340 469 99 2 Washer
37 0443452511 1 Clip
38 340 467 99 2 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)

11 517 013 98 34 Bolt
20 872 200 40 1 Union
30 925 833 40 1 Pipe
31 517 489 98 1 Socket
32 906 868 40 1 Olive
33 371 264 99 1 Union nut
34 517 490 98 1 Union
35 907 568 40 1 Dipstick
36 921 815 40 1 Cover
37 319 159 99 7 Bolt
38 504 149 98 7 Washer
39 517 073 98 2 Union
40 371 273 99 2 Union nut
41 906 346 40 4 Olive
42 215 627 99 1 Pipe 400 mm
43 517 074 98 1 Union
44 371 258 99 2 Union nut
45 907 228 40 1 Union
AH05535b
Page 10 of 22
Illustration 4
AH05535b
Page 11 of 22


11 515 791 98 34 Bolt
12 516 920 98 34 Washer
15 374 428 99 1 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 1 Cover plate rear r.h.
21 904 618 40 1 Cover plate front r.h.
22 904 614 40 1 Cover plate rear l.h.
23 904 617 40 1 Cover plate front r.h.
24 307 827 99 2 Bolt
26 907 142 40 34 Plug
27 914 777 40 1 Pinion cover l.h.
28 914 775 40 1 Pinion cover r.h.
29 510 213 98 2 Thread pin
30 340 112 99 2 Washer
31 512 545 98 2 Washer
32 334 600 99 2 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)

15 872 200 40 1 Union
20 922 584 40 1 Cover plate
21 922 583 40 1 Cover plate
22 922 586 40 1 Cover plate
23 922 587 40 1 Cover plate
25 516 919 98 34 Bolt
28 921 815 40 1 Cover
29 319 159 99 7 Bolt
30 517 073 98 2 Union
31 371 273 99 2 Union nut
32 906 346 40 2 Olive
33 215 627 99 1 Pipe 400 mm
34 517 074 98 1 Union
35 371 258 99 2 Union nut
36 906 346 40 2 Olive
37 907 228 40 1 Union
38 371 257 99 1 Union nut
39 907 080 40 1 Olive
40 922 580 40 1 Cover
41 922 587 40 1 Cover
42 517 489 98 1 Socket
43 517 490 98 1 Union
44 906 868 40 1 Olive
45 371 264 99 1 Union nut
46 215 787 99 1 Pipe 400 mm
47 907 569 40 1 Dipstick
49 399 907 99 1 Seal ring
AH05535b
Page 14 of 22
Illustration 6
AH05535b
Page 15 of 22


12 307 827 99 2 Screw
15 339 907 99 2 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)

17 921 815 40 1 Cover
18 907 131 40 1 Union
19 214 140 99 1 Pipe 85 mm
20 374 460 99 1 Socket
21 872 200 40 1 Union
22 371 279 99 2 Union nut
23 906 979 40 2 Olive
24 516 929 98 34 Washer
25 517 889 98 34 Bolt
26 907 142 40 34 Plug
27 907 228 40 1 Union
28 517 074 98 1 Union
29 371 258 99 2 Union nut
30 907 227 40 4 Olive
31 517 073 98 2 Union
32 371 273 99 2 Union nut
34 215 627 99 1 Pipe 200mm
35 319 159 99 7 Bolt
36 504 149 98 7 Washer
50 517 489 98 1 Socket
51 517 490 98 1 Union
52 906 868 40 1 Olive
53 371 264 99 1 Union nut
54 215 787 99 1 Pipe 400 mm
55 907 569 40 1 Dipstick
AH05535b
Page 18 of 22
Illustration 8
AH05535b
Page 19 of 22


2 904 613 40 1 Cover plate r.h.
3 904 618 40 1 Cover plate l.h.
7 517 612 98 34 Bolt
8 516 920 98 34 Washer
9 907 142 40 34 Plug
12 307 827 99 2 Bolt
13 374 428 99 1 Union
AH05535b
Page 20 of 22
Illustration 9
AH05535b
Page 21 of 22

2 898 288 40 1 Cover plate
3 914 737 40 1 Cover plate
7 374 460 99 1 Screwed socket
8 371 279 99 2 Union nut
9 906 979 40 2 Olive
10 914 736 40 1 Pipe 85 mm
11 907 131 40 1 Union
12 921 815 40 1 Cover
13 319 159 99 7 Bolt
14 907 569 40 1 Dipstick
15 906 868 40 1 Olive
16 371 264 99 1 Union nut
17 925 830 40 1 Pipe 350 mm
19 517 489 98 1 Socket
20 517 490 98 1 Union
22 872 200 40 1 Union
23 516 919 98 34 Bolt
26 517 073 98 2 Union
27 371 273 99 2 Union nut
28 906 346 40 4 Olive
29 215 627 99 1 Pipe 200 mm
30 907 228 40 1 Union
31 517 074 98 1 Union
32 371 258 99 2 Union nut
AH05535b
Page 22 of 22
Illustration 10
AH05535b
COMPONENT CODE: 8D
REF NO. AH05546

PARTS & SERVICE NEWS DATE December 6, 2005
Page 1 of 2
SUBJECT: Automatic lubrication system - Vent valve (PN 769 879 73)
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 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.
To make easy troubleshooting the 2/2 – Directional valve (7)

Manual actuation
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. AH06524
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
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

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)
DESCRIPTION:
1. Sprocket types
2. Removal sprocket
4. Remachining
5. Radial wear determination
6. Assembly
AH06529
Page 2 of 7
1. Sprocket types

The standard sprocket has to be used in case of assembling new machine or regenerating
the track group in connection with new track pads.

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
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 Original axial play Wear limit

PC5500-6 0.2 – 0.9 mm 2,75 mm
4. 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.
• Suspend sprocket (1) to crane, pull out hollow shaft (32), lift sprocket (1) out.
5. 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.
) • When selecting tightening torques, observe size and quality

grade of the bolts.

dia. size Nm/lbs.ft.
[mm] [mm] Quality grades
8.8 10.9 12.9
M 10 17 43/32 63/47 73/54
M 12 19 74/54.6 108/80 127/94
M 14 22 118/87 173/128 202/149
M 16 24 179/132 265/196 310/229
M 18 27 255/188 360/265 425/313
M 20 30 360/265 510/376 600/443
M 22 32 485/358 690/509 810/597
M 24 36 620/457 880/649 1030/760
M 27 41 920/679 1310/966 1530/1128
M 30 46 1250/922 1770/1305 2080/1534
M 33 50 1690/1246 2400/1770 2800/2065
M 36 55 2170/1600 3100/2286 3600/2655
Insert all bolts lubricated with MPG, KP2K type lubricant.
AH06529
COMPONENT CODE: 32
REF NO. AH06530

Page 1 of 2
SUBJET: Relieving of the track chain tension
PURPOSE: Hints for working at the crawler unit
APPLICATION: PC3000; PC4000; PC5500; PC8000
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
Page 1 of 2
SUBJECT: Swash plate pump H-A4VSO500
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 Q max Turn in

Altitude* setting screw (3)
(revolutions per min) (l/min) (revolutions)
(m)
Diesel Electric Diesel Electric Diesel Electric
0 500 500 735 700 0 0
about 1400 460 483 676 676 1¾ ¾
about 2900 418 440 615 615 3½ 2½
about 3200 405 426 596 596 4¼ 3¼
about 4700 355 373 522 522 6¼ 5½
• 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
Page 1 of 3
discarded.
SUBJECT: Gear pumps PN 907 622 40 and PN 940 048 40

(supplied from the company “Kracht”)
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:
W
• 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.
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

PARTS & SERVICE NEWS DATE November 22, 2006
Page 1 of 3
SUBJECT: Hydraulic cylinder bushings
PURPOSE: Installation hints
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

PARTS & SERVICE NEWS 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.
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.
1.1 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
W
• The local safety rules must also observed.
AH07509
Page 2 of 7
AH07509
Page 3 of 7
(PC4000-6 #08152; 08153; 08154)

1 796 050 73 1 Adapter
2 795 836 73 1 Disc brake
3 972 122 1 O - Ring
4 516 354 98 1 O - Ring
5 501 532 98 1 Hexagon head socket pipe plug
6 339 796 99 1 Seal ring
After conversion the following page of Spare Parts catalogue apply: 991 – 0737.

1 795 840 73 1 Adapter
2 795 836 73 1 Disc brake
3 972 122 1 O - Ring
4 516 354 98 1 O - Ring
5 501 532 98 1 Hexagon head socket pipe plug
6 339 796 99 1 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. The oil must be drained completely before the modification of the gearbox, in
accordance to the Maintenance Manual of the shovel.
2. Take off all oil fittings of the gear to attach them later to the new adapter.
3. Take off all hydraulic pipes from the brake.
W
• 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.
4. Remove all fixing screws of the motor and take off the motor from the gear.
5. Remove the 24 fixing bolts (1) (M24 x 550) of the gear (1).
6. Remove the 4 fixing bolts (2) (M16x360) of the adapter (3).
7. By means of 2 pulling screws loosen adapter (3).
8. Install 2 eye bolts M16 to the adapter (3).
9. Lift off the adapter (3) with attached brake by adequate lifting device.
First lift up approx. 150 mm.
W
• If the sun gear is lifted together with the assy. secure it against
falling down before lifting up completely.
ã
• 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
Page 1 of 5
SUBJECT: Bolted undercarriage: Protective coating on the flange plates
PURPOSE: References to renew the protective coating
APPLICATION: PC5500-6
DESCRIPTION:
W
Check the coated surfaces for spots that may be damaged before assembling or
reassembling. Spots less than 20 cm² are acceptable.
In case of bigger damages the whole surface coating has to be renewed.
1. Spots less than 20 cm²

- Remove carefully all loosen parts of the coated surface.
- Assemble the undercarriage as described in the Assembling Manual.
2. Spots more largely than 20 cm²

- 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 µm,
according to 125 µm wet layer thickness.
• Cure is a function of temperature, humidity and airflow.
The film will exhibit full cure in 5 days at 20°C and 7 days at
10°C (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
® ®
Protective Coatings Interzinc 697

Interzinc 697 S i l i c a t e
( F o r m e r l y : R e d o x S C 5 1 1 5 )
S i l i c a t e All surfaces to be coated should be clean, dry and free from contamination. Prior to
Surface
( F o r m e r l y : R e d o x S C 5 1 1 5 ) paint application all surfaces should be assessed and treated in accordance with
Preparation
ISO 8504:1992.
Product A two component, low VOC, water borne alkali metallic zinc silicate primer. Oil or grease should be removed in accordance with SSPC-SP1 solvent cleaning.
Description Strict adherence to all cleanliness standards is essential for application of water based
coatings.
Abrasive Blast Cleaning
Abrasive blast clean to Sa2½ (ISO 8501-1:1988) or SSPC-SP6. If oxidation has
occurred between blasting and application of Interzinc 697, the surface should be
Intended Uses As a high performance corrosion resistant primer for use on correctly prepared steel reblasted to the specified visual standard.
substrates in new construction situations.
Surface defects revealed by the blast cleaning process, should be ground, filled, or
Suitable for use where a high friction grip is required in accordance with TL 918 treated in the appropriate manner.
300, Page 85.
Application Mixing 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
Practical Colour Grey with a mechanical agitator. DO NOT ADD LIQUID TO POWDER.
Information for Material should be filtered prior to application and should be
Gloss Level Matt constantly agitated in the pot during spraying. Once the unit has
Interzinc 697
Volume Solids 60% been mixed it should be used within the working pot life specified
Typical Thickness 75 microns (3 mils) dry equivalent to 125 microns (5 mils) Mix Ratio 1 part (Part A) : 0.7 parts (Part B) by volume
wet 1 part (Part A) : 4 parts (Part B) by weight
Theoretical Coverage 8 m2/litre at 75 microns d.f.t and stated volume solids Working Pot 20°C (68°F)
Life 8 hours
321 sq.ft/US gallon at 3 mils d.f.t and stated volume solids
Airless Spray Not Suitable
Practical Coverage Allow appropriate loss factors
Air spray Recommended Use suitable proprietary equipment.
Method of Application Airspray, Brush, Roller (Conventional)
Drying Time Brush Suitable - small areas Typically 50-75 microns (2-3 mils) can be
Overcoating Interval with only achieved
recommended topcoats Roller Suitable - small areas Typically 50-75 microns (2-3 mils) can be
Temperature Touch Dry† Hard Dry† Minimum Maximum only achieved
Thinner DO NOT THIN
5°C (41°F) 45 minutes 4 hours N/A N/A
15°C (59°F) 30 minutes 1½ hours N/A N/A Cleaner Clean potable water,
International GTA991
25°C (77°F) 25 minutes 45 minutes N/A N/A
40°C (104°F) 15 minutes 30 minutes N/A N/A 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
† Drying times are dependent upon ambient conditions. The figures quoted above should not be resealed and it is advised that after prolonged
have been determined at the quoted temperature and 60% relative humidity. 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
Regulatory Flash Point Base (Part A) Powder (Part B) Mixed amount sprayed, temperature and elapsed time, including any delays.
Data >100°C (212°F) N/A >100°C (212°F) All surplus materials and empty containers should be disposed of in
accordance with appropriate regional regulations/legislation.
Product Weight 3,62 kg/l (30,2 lb/gal)
VOC 0 g/l (0 lb/gal) (Calculated)
E E
N N
G G
0 0
5 5
0 0
4
Page No. 1 of 4 4 Page 2 of 4
= >?@ABC
® ®
Protective Coatings Interzinc 697

Interzinc 697 S i l i c a t e
S i l i c a t e All surfaces to be coated should be clean, dry and free from contamination. Prior to
Surface
( F o r m e r l y : R e d o x S C 5 1 1 5 ) paint application all surfaces should be assessed and treated in accordance with
Preparation
ISO 8504:1992.
Product A two component, low VOC, water borne alkali metallic zinc silicate primer. Oil or grease should be removed in accordance with SSPC-SP1 solvent cleaning.
Description Strict adherence to all cleanliness standards is essential for application of water based
coatings.
Abrasive Blast Cleaning
Abrasive blast clean to Sa2½ (ISO 8501-1:1988) or SSPC-SP6. If oxidation has
occurred between blasting and application of Interzinc 697, the surface should be
Intended Uses As a high performance corrosion resistant primer for use on correctly prepared steel reblasted to the specified visual standard.
substrates in new construction situations.
Surface defects revealed by the blast cleaning process, should be ground, filled, or
Suitable for use where a high friction grip is required in accordance with TL 918 treated in the appropriate manner.
300, Page 85.
Application Mixing 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
Practical Colour Grey with a mechanical agitator. DO NOT ADD LIQUID TO POWDER.
Information for Material should be filtered prior to application and should be
Gloss Level Matt constantly agitated in the pot during spraying. Once the unit has
Interzinc 697
Volume Solids 60% been mixed it should be used within the working pot life specified
Typical Thickness 75 microns (3 mils) dry equivalent to 125 microns (5 mils) Mix Ratio 1 part (Part A) : 0.7 parts (Part B) by volume
wet 1 part (Part A) : 4 parts (Part B) by weight
Theoretical Coverage 8 m2/litre at 75 microns d.f.t and stated volume solids Working Pot 20°C (68°F)
Life 8 hours
321 sq.ft/US gallon at 3 mils d.f.t and stated volume solids
Airless Spray Not Suitable
Practical Coverage Allow appropriate loss factors
Air spray Recommended Use suitable proprietary equipment.
Method of Application Airspray, Brush, Roller (Conventional)
Drying Time Brush Suitable - small areas Typically 50-75 microns (2-3 mils) can be
Overcoating Interval with only achieved
recommended topcoats Roller Suitable - small areas Typically 50-75 microns (2-3 mils) can be
Temperature Touch Dry† Hard Dry† Minimum Maximum only achieved
Thinner DO NOT THIN
5°C (41°F) 45 minutes 4 hours N/A N/A
15°C (59°F) 30 minutes 1½ hours N/A N/A Cleaner Clean potable water,
International GTA991
25°C (77°F) 25 minutes 45 minutes N/A N/A
40°C (104°F) 15 minutes 30 minutes N/A N/A 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
† Drying times are dependent upon ambient conditions. The figures quoted above should not be resealed and it is advised that after prolonged
have been determined at the quoted temperature and 60% relative humidity. 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
Regulatory Flash Point Base (Part A) Powder (Part B) Mixed amount sprayed, temperature and elapsed time, including any delays.
Data >100°C (212°F) N/A >100°C (212°F) All surplus materials and empty containers should be disposed of in
accordance with appropriate regional regulations/legislation.
Product Weight 3,62 kg/l (30,2 lb/gal)
VOC 0 g/l (0 lb/gal) (Calculated)
E E
N N
G G
0 0
5 5
0 0
4
Page No. 1 of 4 4 Page 2 of 4
Interzinc 697 Interzinc 697
S i l i c a t e
S i l i c a t e
Product Apply by airspray. Thoroughly flush equipment with International 991 thinner, or Additional Further information regarding industry standards, terms and abbreviations used in
Characteristics alcohol, followed by water prior to use. To obtain maximum edge protection and Information this data sheet can be found in the following sections of the International Protective
film build, airspray application is recommended. Application by other methods, Coatings data manual:
e.g. brush or roller, may require more than one coat.
• Definitions & Abbreviations
With all water based coatings careful control of application conditions is required to
ensure good long term performance. International Protective Coatings have • Surface Preparation
available a set of working procedures relating to the application of water borne • Paint Application
paints which are available on request.
• Theoretical & Practical Coverage
The following basic parameters must be adhered to:
Individual copies of these information sections are available upon request.
Interzinc 697 must be protected from freezing at all times during storage.
Safety Precautions This product is intended for use only by professional applicators in industrial
The minimum steel temperature for application must be above 10°C (50°F), and be situations in accordance with the advice given on this sheet, the Material Safety Data
at least 3°C (5°F) above dew point. Sheet and the container(s), and should not be used without reference to the
Material Safety Data Sheet (MSDS) which International Protective Coatings has
Ideally, the relative humidity during application and cure should be kept between 50 provided to its customers.
and 60%, otherwise drying and overcoating times will be severely extended.
All work involving the application and use of this product should be performed in
Good airflow is essential around the object being painted [minimum air speed compliance with all relevant national Health, Safety & Environmental standards and
0.1m/sec (4 inches/sec)]. regulations.
Minor areas which are difficult to ventilate should be brush applied to prevent over- In the event welding or flame cutting is performed on metal coated with this
application. 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 If in doubt regarding the suitability of use of this product, consult International
powdery cracked film which will require removal and re-application. Protective Coatings for further advice.
Maximum continuous dry temperature resistance for Interzinc 697 is 400°C (752°F).
Cure is a function of temperature, humidity and airflow. Normally films at 75 microns Pack Size 1.4 litre unit Interzinc 697 Base 1 kg in a 1 litre container
(3 mils) dry film thickness will exhibit full cure in 5 days at 20°C (68°F) and 7 days at Interzinc 697 Powder 4 kg in a 4 litre container
10°C (50°F).
For availability of other pack sizes contact International Protective Coatings
Shipping Weight 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)
Storage Shelf Life 12 months minimum at 25°C (77°F). Subject to re-inspection

thereafter. Store in dry, shaded conditions away from sources
of heat and ignition.
Disclaimer
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
Systems Interzinc 697 is only recommended for application to correctly prepared steel 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
Compatibility substrate. Terms & Conditions of Sale are contained in International’s 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
Interzinc 697 is not normally overcoated. 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 user’s 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 Asia Region Australasia Region Europe Region Middle East Region North America Region South America Region
P.O Box 20980 3 Neythal Road 115 Hyde Road P.O Box 20980 PO Box 37 6001 Antoine Drive Av Paiva 999,
Oriel House Jurong Town Yeronga Oriel House Dammam 31411 Houston Neves, Sao Gonçalo,
16 Connaught Place Singapore 628570 Brisbane 16 Connaught Place Saudi Arabia Texas 77091 Rio de Janeiro
London, W2 2ZB Queensland London, W2 2ZB Brazil
England Australia England
Tel: (44) 20 7479 6000 Tel: (65) 663 3066 Tel: (61) 7 3892 8888 Tel: (44) 20 7479 6000 Tel: (966) 3 812 1044 Tel: (1) 713 682 1711 Tel: (55) 21 624 7100
Fax: (44) 20 7479 6500 Fax: (65) 266 5287 Fax: (61) 7 3892 4287 Fax: (44) 20 7479 6500 Fax: (966) 3 812 1169 Fax: (1) 713 684 1514 Fax: (55) 21 624 7123
H&S (61) 1800 807 001
E E
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0 0
5 5
0 0
Page No. 3 of 4 4 Page No. 4 4
Interzinc 697 Interzinc 697
S i l i c a t e
S i l i c a t e
Product Apply by airspray. Thoroughly flush equipment with International 991 thinner, or Additional Further information regarding industry standards, terms and abbreviations used in
Characteristics alcohol, followed by water prior to use. To obtain maximum edge protection and Information this data sheet can be found in the following sections of the International Protective
film build, airspray application is recommended. Application by other methods, Coatings data manual:
e.g. brush or roller, may require more than one coat.
• Definitions & Abbreviations
With all water based coatings careful control of application conditions is required to
ensure good long term performance. International Protective Coatings have • Surface Preparation
available a set of working procedures relating to the application of water borne • Paint Application
paints which are available on request.
• Theoretical & Practical Coverage
The following basic parameters must be adhered to:
Individual copies of these information sections are available upon request.
Interzinc 697 must be protected from freezing at all times during storage.
Safety Precautions This product is intended for use only by professional applicators in industrial
The minimum steel temperature for application must be above 10°C (50°F), and be situations in accordance with the advice given on this sheet, the Material Safety Data
at least 3°C (5°F) above dew point. Sheet and the container(s), and should not be used without reference to the
Material Safety Data Sheet (MSDS) which International Protective Coatings has
Ideally, the relative humidity during application and cure should be kept between 50 provided to its customers.
and 60%, otherwise drying and overcoating times will be severely extended.
All work involving the application and use of this product should be performed in
Good airflow is essential around the object being painted [minimum air speed compliance with all relevant national Health, Safety & Environmental standards and
0.1m/sec (4 inches/sec)]. regulations.
Minor areas which are difficult to ventilate should be brush applied to prevent over- In the event welding or flame cutting is performed on metal coated with this
application. 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 If in doubt regarding the suitability of use of this product, consult International
powdery cracked film which will require removal and re-application. Protective Coatings for further advice.
Maximum continuous dry temperature resistance for Interzinc 697 is 400°C (752°F).
Cure is a function of temperature, humidity and airflow. Normally films at 75 microns Pack Size 1.4 litre unit Interzinc 697 Base 1 kg in a 1 litre container
(3 mils) dry film thickness will exhibit full cure in 5 days at 20°C (68°F) and 7 days at Interzinc 697 Powder 4 kg in a 4 litre container
10°C (50°F).
For availability of other pack sizes contact International Protective Coatings
Shipping Weight 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)
Storage Shelf Life 12 months minimum at 25°C (77°F). Subject to re-inspection

thereafter. Store in dry, shaded conditions away from sources
of heat and ignition.
Disclaimer
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
Systems Interzinc 697 is only recommended for application to correctly prepared steel 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
Compatibility substrate. Terms & Conditions of Sale are contained in International’s 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
Interzinc 697 is not normally overcoated. 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 user’s 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
PARTS & SERVICE NEWS
DATE January 18, 2008
Page 1 of 6
SUBJECT: Track drive
PURPOSE: Complete track drive protection
APPLICATION: PC5500-6 (SN 15026 and up)
FAILURE CODE: L510FA
DESCRIPTION:
W
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
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

01 946 685 40 2 Protecting cage
02 946 684 40 4 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
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

(only for gears delivered by L&S - SN 15026 and up)

01 936 639 40 2 Intermediate plate
02 936 631 40 1 Motor protection left
03 936 632 40 1 Motor protection right
04 936 647 40 2 Bolt protection travel gear
05 936 641 40 2 Cover
06 936 642 40 6 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 2 Plug
AH08503
COMPONENT CODE: 55
REF NO. AH08504
PARTS & SERVICE NEWS DATE August 7, 2008
Page 1 of 2
SUBJECT: Windscreen
PURPOSE: Mounting hints
FAILURE CODE: 5532PB
DESCRIPTION:
W
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. Part No. Description

769 528 73 12 mm; green; drilled
01 12 mm; green;
797 251 73
undrilled
Pos. Part No. Description

12 mm; green;
793 739 73
drilled
12 mm; green;
797 253 73
undrilled
01 19 mm, with splinter
796 564 73 shield foil coating;
drilled
19 mm, with splinter
797 254 73 shield foil coating;
undrilled
AH08504
COMPONENT CODE: 71
REF NO. AH08507
PARTS & SERVICE NEWS 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. Introduction
2. General Protective Measures
3. Steps of the weld repair procedure
4. Selection of appropriate electrodes and welding rods
4.1 Selection of appropriate electrodes
4.2 Selection of appropriate welding rods
5. Preparation of the defective Part
6. Carrying out the Weld Repair
7. Post heating
8. 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 former present international
designation
a St52-3N S355J2G3 1.0570 (17G1S)
b GS24Mn6V GS24Mn6V 1.1118
c StE690 S690Q 1.8931
d GS18NiMoCr36 GS18NiMoCr36 1.6759
e TStE355 P355NL1 1.0566
f 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 E 7016
5* E 7018-G
7* E 8018-G
9* 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 f
a 4 4 4 4 7
b 4 4 7 5 7
c 4 7 9 9 7
d 4 5 9 9 7
e 4 - - - 7
f 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 f
a 4 4 4 4 7
b 4 4 7 5 7
c 4 7 9 9 7
d 4 5 9 9 7
e 4 - - - 7
f 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 ER70 S6
25/25a ER100 S1
30 E70 T5
32 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 f
a 21; 30 21; 30 21; 30 21; 30 25; 25a; 32
b 21; 30 21; 30 21; 30 21; 30 ---
c 21; 30 21; 30 25; 25a; 32 25; 25a; 32 25; 25a; 32
d 21; 30 21; 30 32 32 ---
e 21; 30 21; 30 21; 30 21; 30 25; 25a; 32
f 25; 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
Groove Preheat Interpass Post heat
Material depth temperature temperature temperature
(mm) (°C) (°C) (drop per hour)
<10 20 220
S355J2G3
10 - 20 50 220
P355NL1
20 - 50 100 220
10 50 150
S690Q 10 - 20 100 180
50 degree. max.
>20 150 220
<10 50 150
GS24Mn6V
10 - 20 100 180
GS18NiMoCr3
>20 150 180
Hardox 400 >10 150 200
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
Page 1 of 3
SUBJECT: Bushings of the attachment and at the undercarriage
PURPOSE: Wear checking procedure
APPLICATION: PC3000-1; PC3000-6; PC4000-6; PC5500-1; PC5500-6;

PC8000-1; PC8000-6
DESCRIPTION:
W
) • 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
COMPONENT CODE: 6B
REF NO. AH09505
PARTS & SERVICE NEWS DATE May 15, 2009
Page 1 of 4
SUBJECT: Hoses between boom and stick
PURPOSE: Hose standardization and routing improvement
APPLICATION: PC5500-6 (SN to 15077)
FAILURE CODE: 6B00FA
DESCRIPTION:
W
We recommend replacing the hydraulic lines on the stick according to the description at
the following pages and the hydraulic hoses between stick and boom.
Advantages:
• All 6 hydraulic hoses with the same length and straight hose connectors.
• Only one clamp rail for the hoses necessary.
• Routing improvement.
AH09505
Page 2 of 4
Description (refer to drawing below)

1. Remove the both l.h. hydraulic hoses (1) between stick and boom and all pipes on
the stick (4 to 9).
2. Install the new blocks (3).
3. Install the new pipes (4 to 9) to the stick.
4. Install the two new hoses (1) and the new clamp rail (2).
5. Bleed the new hydraulic hoses /lines refer to Parts & Service News AH06524.
Modification kit PN 952 783 40 (Refer to drawing below)

1* 940 328 40 2 Hose NW 50 x 3200
2 952 786 40 1 Clamp rail assy.
3 952 701 40 2 SAE-L-Block 2”
4 952 788 40 1 Pipe assy. 65 x 8 2”
5 952 789 40 1 Pipe assy. 65 x 8 2”
6 952 792 40 1 Pipe assy. left
7 952 794 40 1 Pipe assy. left
8 952 791 40 1 Pipe assy. right
9 952 793 40 1 Pipe assy. right
10 947 597 40 1 Plate 100x8x240
11 934 005 99 2 Plate
12 534 004 99 2 Plate
13 504 818 98 2 Clamp set
14 308 581 99 4 Bolt M 10 x 70
15 319 323 99 8 Bolt M 20 x 90
16 322 430 40 2 Pipe 38x5x260
17 319 313 99 40 Bolt M 20 x 120
18 504 662 98 40 Nut M 20
19 385 243 40 8 Flange Seel
20 319 305 99 8 Bolt M 20 x 60
21 952 790 40 1 Angle Bracket
* Different Parts for cold weather design (- 50°C)

1 940 765 40 2 Hose NW 50 x 3200
AH09505
Page 3 of 4
Illustration 1
AH09505
Page 4 of 4
AH09505
COMPONENT CODE: 71
REF NO. AH09522
Page 1 of 1
SUBJECT: Wishbone and rod
PURPOSE: Prevent pin seizure
APPLICATION: PC3000BH; PC4000BH; PC5500BH; PC8000BH
FAILURE CODE: 716BFR
DESCRIPTION:
W
) • We recommend filling the chambers, shown on the drawing

below, with grease to prevent pin seizure, pin rotating and
breaking off the retainer for the pin.
Grease filling
AH09522
Supplier’s documentation
9 SUPPLIER’S
DOCUMENTATION
Version 2010/1 PC5500-6E 9 -1

Supplier’s documentation
Contents of this chapter:
AVANTI HYTORQUE
9 -2 PC5500-6E Version 2010/1

XXI/Avanti/Stealth SERIES
Operational Manual July 2004
Table of Contents
XXI/Avanti/Stealth SERIES Operational Manual
SECTION I
IMPORTANT SAFETY INSTRUCTIONS
SECTION II 2-1 Working Pressure

BEFORE USE 2-2 Hydraulic Connections
2-3 Electrical Connections
2-4 Air Connections
SECTION III 3-1 General

OPERATION 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 5-2 Hydraulic Connections
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 Tool Dimensions & Parts List

HELPFUL Field-proven Torquing Procedure
INFORMATION 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 specialist’s 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 Electric pumps should never be used in any atmosphere
ENVIRONMENT 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 The pump remote control should be operated by a
STARTING 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 Ensure the pump is properly grounded and the proper
SHOCK 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 page-
HOSES 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 Use genuine HYTORC accessories. Use correct size
ACCESSORIES 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 tool’s 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
page-
2-3 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 manufacturer’s 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
OIL LUBRICATOR AIR FLOW

ADJUSTMENT KNOB ON/OFF LEVER
FILTER CAP
AIR PRESSURE GAUGE
CONDENSATION
BOWL
DRIER AUTO WATER DRAIN PORT
1. Adjust flow to 1-2 drops per minute.

2. Fill half way with grade 46 hydraulic oil supplied.
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 manufacturer’s 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 pump Connect to tool
*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 page-
3-3 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
Loosening Tightening
right hand fastener.
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
Please read
Loosening operating
instructions
prior to use,
Tightening
and use
common sense.
Link release button KEEP HANDS

OFF DURING
OPERATION!
3-4 Reaction Arm 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
3-5 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 manufacturer’s 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 pump’s
external pressure regulator. Then turn the “T” handle counter-
clockwise until it turns freely and easily.
2. Turn the pump “ON”. Using the pump’s remote control pendant, Locking Ring
push down the advance switch (or button on air pump) and hold it.
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
3-7 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
3-8 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 pump’s 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

1) Push lever to position A
2) Cycle tool in manual mode, release advance
button
3) Shut pump off
Disengage lever 4) Remove tool and reset lever to position B
Stealth Release Procedure
STEALTH
1) Push remote to full pressure for final stroke
MADE IN U. S.A.
2) Disengage the reaction pawl by holding the

button in the direction of arrow
3) Release the rocker switch
Disengage button 4) Shut pump off
5) Remove tool
SECTION III
3-9 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
HEX NUT
DISC WASHER
THREADED SEGMENT
Hard Joint LoaDISC Limited Clearance

LoaDISC
SECTION IV
OPERATION – HYTORC LoaDISC and Clamp -continued from the previous page-
4-2 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' PLACE DRIVER
POSITION NUT/LoaDisc
ROTATE
LOOSEN TIGHTEN DRIVER
'CW' 'CCW' ASSEMBLY
DIRECTION DIRECTION 'CCW'
DIRECTION
ROTATE 'CW'
FOR
BY HAND, TO
SNUG LoaDisc
TIGHTEN
LoaDisc TO FLANGE MODE
LOCK-GROOVE
1 2 3
NOTE:
* 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 VERIFY
* DO NOT RE-USE SINGLE-TIME ROTATE

LOCK-RING
USE LoaDISC
LOCK-RING
ENGAGE
LoaDisc
LOCK-GROOVE
4 5
SECTION IV
4-3 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)

LoaDISC Driver Installation for De-tensioning
ROTATE VERIFY
DRIVER
ASSEMBLY ROTATE
'CW' LOCK-RING
DIRECTION
FOR
LOOSEN
MODE
3 4 5
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 pump’s
manual mode. the pump. Shut off the pump, and remove the tool from the nut.
XXI Release Procedure

1) Push slide cover up to position A
HYT RC
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
4-4 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 CAUSE SOLUTION

Driver does not lock Lock ring misaligned with Check for excessive stud protrusion
LoaDISC
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 Tighten LoaDISC to flange surface
flange surface with driver assembly (CW direction)
Driver un-locks during Worn lock-ring Replace lock-ring
verification
Driver un-locks during Lock-ring rotated in wrong Rotate Holding socket and lock-ring
use direction •CCW toward ‘T’ for Tighten
•CW toward ‘L’ for Loosen
Driver does not un-lock Stud driven up into bottom of Check for excessive stud extension.
after torque procedure drive socket
SECTION IV
4-5 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
4-6 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
4-7 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.
5-2 Hydraulic Connections
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 pump’s 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 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 Electric Pump Oil Sight Gauge
*Do not mix different grades of oil.
SECTION V
OPERATION – HYTORC Power Packs -continued from the previous page-
5-3 Prior to Use -Continued-
Make 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 OFF
position. Your HYTORC electric pump has been Retract/Neutral Rocker Switch
designed with an auto shut off system. The pump will Advance
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.
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
Minute. Lubricator Adjust
*Before operating your HYTORC air pump,

check for air leaks on the air hoses/tubing.
Air Pressure gauge

SECTION V
5-5 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 Advance Button
pressure from the pump, put the Air Flow Lever in the
Stop Button
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.
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
5-7 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’ PERSS FOR RUN
position to turn off the system. (TOOL ADVANCE)
RELEASE (TOOL RETRACT)
(NEUTRAL)
AUTOMATIC MODE CONTROL SWITCH
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 PRESS FOR TIGHTENING
to both hydraulic and electric lines. Then cycle system
NEUTRAL LOOSENING
in manual mode for at least one full cycle.
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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SHOP 15016-upE-GB-1

Serial Number 15016 and up

CONTENTS OF SHOP MANUAL

40 TROUBLESHOOTING (WITHOUT CONTENT)

50 ASSEMBLY AND DISASSEMBLY

Machine model Serial number

PC5500E-6 15016 and up

1.1 CONTENTS OF THE BINDER

1.2 DIVISION OF THE BINDER

Refer to the -TABLE OF CONTENTS VOLUME 2 BINDER-

Read the Manuals before You Start the Engine.

Before operating the machine, familiarize yourself with its instru-

Observe the instructions in these manuals for:

● your Personal SAFETY

● Operating SAFETY, and

● READY an d E FFICIENT P ERFORMANCE of y our

Periodic preventive inspections and maintenance are the surest

Replace damaged graphics and symbols.

Observe safety precautions to prevent injury and damage.

If you have any questions concerning this literature please con-

Komatsu Mining Germany GmbH

1.3 DESIGNATED USE OF THE SHOVEL

The machine must only be used in technically perfect condition in

The hydraulic Shovel is designed exclusively for excavating, i.e.

1.4 DELIVERY OF THE SHOVEL

For assembling the Shovel refer to the

● Personnel e ntrusted with wor k on the m achine must

Damages and defects caused by incorrect operation and mainte-

For your spare part orders refer to the Parts Catalogue.

In order to keep your Shovel in first-class operating condition use

KOMATSU MINING GERMANY GmbH from any guarantee.

In all your written or phoned inquiries please indicate the model

1.5 EXPLANATION OF ABBREVIATIONS

API American Petroleum Institute

CENSE Engine Monitoring System

CLS Central Lubrication System

DIN German Institute for Standardization

EBL Electronic Bucket Levelling System

ECM Electronic Control Module (Engine)

FGPS Front Guard Protective Structure

FOPS Falling-Object Protective Structure

HPF High Pressure Filter

LED Light Emitting Diode

QSK Type of Engine Fuel System

ppm parts per million

SLS Swing circle pinion Lubrication System

1/min Revolutions Per Minute (RPM)

IGNORING THE INSTRUCTIONS IN THIS MANUAL COULD LEAD TO SERIOUS

2.1 SAFETY INFORMATION ................................................................................................................... 2-3

2.4.10 STARTING ENGINE ............................................................................................................ 2-19

2.1 SAFETY INFORMATION

2.2.1 NORMAL OPERATIONS

2.2.2 REGULAR MAINTENANCE

2.2.3 TROUBLESHOOTING, ADJUSTMENTS AND REPAIR

2.2.4 ADDITIONAL SAFETY PRECAUTIONS FOR ASSEMBLING,

2.3 SOUND PRESSURE LEVEL IN THE OPERATOR’S

2.4 GENERAL PRECAUTIONS COMMON TO OPERATION

2.4.1 UNDERSTANDING THE MACHINE

2.4.2 PRECAUTIONS BEFORE STARTING OPERATION ON THE

2.4.2.1 ENSURING SAFE OPERATION

2.4.3 PREPARATIONS FOR SAFE OPERATION

2.4.3.1 PRECAUTIONS REGARDING SAFETY RELATED EQUIPMENT

2.4.3.2 INSPECTING THE MACHINE