Procedimiento de Armado PC5500E-6

General Assembly Procedure
Hydraulic Mining Shovel PC5500
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PC5500AS rev2 1
Edition 04/2005
Assembly Procedure PC5500
All stated information corresponds

to the present development and is
subject to possible future changes
without prior notice.
PC5500AS rev2 2
Edition 04/2005
Delivery of the Excavator

The excavator is being delivered disassembled into its main components.
For assembling the excavator follow the instructions in this manual.
• Various bolts used e.g. for transport security, blanking plates etc. will be re-
used during final assembly.
• Please take out small parts stored in the cab refrigerator.
Symbols
ã
• WARNING
Refers to orders and prohibitions designed to prevent
injury or extensive damage.
ã Personnel entrusted with work on the machine must have

read the Assembly Manual, the Operation,- Lubrication- 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 questions concerning the assembling procedure, contact your local
Service Center.
Prior to first operation, inspect the excavator thoroughly with the Service 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 maintenance are not covered
by the manufacturers guarantee.
) • If the excavator is equipped with a fire suppression system,

make sure that the system is ready for operation.
Service
For all questions related to your excavator please contact your local Service Center.
In all your written or phoned inquiries please indicate the model and serial number of
your excavator.
PC5500AS rev2 3
Edition 04/2005
PC5500AS rev2 4
Edition 04/2005
• Before assembling/disassembling, lifting or transporting this

ã excavator contact your local Service Center for all the
necessary instructions for safe and economic assembling/
disassembling, lifting and transportation procedures of your
excavator.
Assembling of the Excavator
• Assembling of the excavator must be carried out only by

ã personnel with special knowledge of the excavator. Improper
assembling procedures can cause severe accidents with
personal injury.
The sequence of assembly is shown in this Manual. Disassembling is basically the
reverse order of the assembling procedure.
Transportation and Lifting

The transport dimensions and weights of the excavator’s components are listed in
this manual.
Observe the operating permits of the flat-bed trailers used for transportation. They
contain the permissible load, loading width and height.
•
ã
Observe the federal, state and local laws and regulations for
transportation of heavy units. Know the safety rules and laws before
you transport this excavator.
• Make sure the flat-bed trailer and the components of the excavator
are equipped with the correct safety devices.
• Secure the excavator and all components transported on the trailer
against movement.
• Use exclusively approved handling equipment
• When lifting components make sure that the handling elements do
not cause damage to the component
• Secure the components safety before removing the lifting straps,
ropes or chains.
• Wear safety clothing, goggles, respirator and other safety devices,
whenever working conditions make this necessary.
• Provide hoists of sufficient capacity to lift heavy units. Refer to the
weight specifications.
• Be sure to observe the instructions in the “Assembly Procedure
Manual“.
• Lifting gear, tools and other suspension systems must be in good
condition and of sufficient lifting capacity.
• Be sure hydraulic cylinders and attachment components are properly
supported from hoist and securely remove, before removing
supporting pins.
• Floors must be clean and dry. After draining operations be sure all
spillage is cleaned up.
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Electric energy
• All work on medium and high voltage systems has to be carried out
W by authorized Electricians having the permission to work on medium
and high voltage systems.
• All safety devices requested by the National Safety Administration
must be available and used for work on the medium and high voltage
systems.
Required MANPOWER
Diesel drive Electric drive

5 Mechanics 5 Mechanics
Customer
1 Electrician 2 Electricians
Dealer or
Supervision: 1 Service Engineer 1 Service Engineer
KMG
Average assembly and commissioning time schedule* (Diesel drive)
Days 1 2 3 4 5 6 7 8 9 10 11 12 13 14
Assembly time
Setting and test
* Dependent on mine conditions (shifts, weather, site preparation...)
Average assembly and commissioning time schedule* (Electric drive)
Days 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Assembly time
Setting and test
* Dependent on mine conditions (shifts, weather, site preparation...)
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PC5500AS rev2 8
Edition 04/2005
1. Assembly of the Undercarriage.................................................................................. 21

1.1 Track tensioning system............................................................................................. 31
2. Assembly of the Cable Reel Unit ............................................................................... 33
3. Assembly of the Superstructure Platform onto the Undercarriage .......................... 35
4. Assembly of the Prime Drive Unit to the Superstructure Platform..........................37
4.a Mounting of the hydraulic access ladder....................................................................39
5. Assembly of the Boom Cylinders and the Stick Cylinder to the Boom..................... 43
5.a. Assembly of the Boom ............................................................................................... 45
6. Assembly of the Counterweight ................................................................................. 49
7. Mounting of the Fuel Tank or Main Switch Cabinet for Electrical Driven Unit .......51
8. Mounting of the Cab Base.......................................................................................... 53
9. Mounting of the Cab with Support Frame..................................................................55
10. Mounting of the High Pressure Hoses and Hydraulic Oil Tank ................................ 57
11. Mounting of the Hydraulic Oil Cooler .......................................................................63
12. Mounting of the Hand Rails, Cat Walks, Steps and the Fat Barrel Crane .................69
13. Mounting of Cable transfer to the Operators Cab ......................................................71
13a. Installation of Hydraulic Hoses to the Attachment and Rotary Joint.........................73
14. Checking of direction motor rotation .........................................................................75
15. Connection of Electric Cables....................................................................................77
16. Filling the Hydraulic System......................................................................................81
17. Pre-checks prior Initial Start-up .................................................................................83
17.1 General ....................................................................................................................... 83
17.2 Only with Electric Drive ............................................................................................ 85
17.3 Initial Start up............................................................................................................. 85
18. Assembly of the Stick to the Boom............................................................................ 87
19. Mounting of the Stick Cylinders to the Stick............................................................. 89
20. Assembly of the Bullclam Bucket to the Stick...........................................................91
21. Mounting of the Pin Seals .......................................................................................... 95
22. Putting the Lubrication System into operation........................................................... 97
23. Checks and Adjustments Prior Commisionning ........................................................99
Metric standard thread .........................................................................................................101
Metric fine thread................................................................................................................. 103
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Assembly Site Requirements

− Well leveled and compacted ground approx. 150 x 150 ft/50 x 50 m
− A container to store the tools, to keep the paper work and for sheltering
− 2 mobile cranes, one 150 and one 100 metric tons.
− 1 small crane, load capacity approx. 25 metric tons (temporary)
− 1 Lifting platform (for the installation)
Qty. Specification Designation

01 6t Telescopic fork lift
04 6t Chain pull
02 50t Shackles
04 35t Shackles
04 5t Shackles
04 1t Shackles
04 30t - 8m length Ropes
04 12t - 8m length Ropes
01 ∅ 50mm x 1000mm length Pry bar (in the cab box)
01 5kg Large hammer
20 300 x 300 x 1000mm Wooden blocks
10 300 x 300 x 2500mm Wooden blocks
02 10t Hydraulic jacks
02 50t Hydraulic jacks
01 50m Cable drum
01 100m 5 pole extended cable (temporary) #
01 each 6/7/8/9/10/12/13/14/15/17/19 Combination spanner
01 each 41/46/50/55/60/ 65mm Single ended open spanner
01 each 7mm up to 55mm Double end open spanner
01 3/4“ Impact wrench
01 1/2“ Impact wrench
01 1/2“ Ratchet
01 3/4“ Ratchet
01 each 13mm up to 19mm Sockets for ½“ Ratchet
01 24mm up to 36mm Socket for 3/4“ Ratchet
01 Only useable with torque wrench Special tightening tool for bolts
(PN793 374 73) center section side frame
(refer to page 28) connection (PN793 376 73)
01 0 – 9900 Nm Hydraulic torque wrench
(refer to page 28) (PN793 374 73)
01 1.2 l; till 700 bar Electric hydraulic power pack
(refer to page 28) (PN793 375 73)
01 30/32/36/41/46/55/65mm Sockets HD for hydraulic torque
01 Range 0 - 250Nm Torque wrench ⇒ drive ½“
01 Electric welding machine
04 Lights for the illumination the working area
01 Hand lamp
# For testing purpose on electric driven machines only !
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06 400 bar Pressure gauge (factory supplied)
01 15 bar Pressure gauge
01 Range 250 - 600Nm Torque wrench ⇒ 3/4“
2 Multimeter Part No. 232 619 40*
01 0 - 2500min-1 Contactless revolution indicator
02 1,5mm² 30m electric extension cables with connectors
01 from M6 - M 36 Thread cutting set
01 Level gauge
01 Set Allen key
01 Set Cable connector
01 Crimp pliers Part No. 792 536 73
01 Set Screw driver
01 Side cutter
01 Tip pliers
01 Combination pliers
01 Pipe pliers
02 Cleaning rags
01 Part No. 232 621 40 Cordless Headphone Intercom
* If available an electronic testing device for pressure, voltage and RPM, similar
Hydrotechnic System 6000
For electric driven machines only.
01 5-10 kV Part No. 232 389 40 Electronic unipolar voltage meter
3-6 kV Part No. 232 390 40
01 Part No. 232 386 40 Universal grounding short-circuiting device
01 Part No. 232 387 40 Insulation tester
01 Part No. 232 388 40 Phase-sequence indicator
01 Part No. 232 593 40 Shock pulse measuring instrument
01 Part No. 232 594 40 Shock pulse transducer
01 Part No. 232 595 40 Shock pulse transducer
Space and Placing Requirements

On the following page, the components are indicated in their approximate dimensions.
They are unloaded in a way that a min. space of 1 meter (3 ft) is left between the components,
and that there is enough space for the trucks and the cranes.
Preparation for Assembly
− Unload all components so that no more move is necessary!
− All pins, bushings, borings, bearings and contact surfaces of components must be clean.
− Torque values are listed in the Lubrication- and Maintenance Manual - unless being listed
in this Assembly Procedure Booklet.
− Obey all applicable safety and local regulations strictly!
− Ensure correct lifting procedures and ensure use of adequate lifting gears!
− High voltage installation works must be carried out by authorized specialists only.
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Service Weight Crawler Assembly*

Machine w/o attachment 365 t / 804 lb Track width 1350 mm / 53 “
Attachment(face shovel) 79 t / 175,5 lb Ground pressure 23,9 N/cm2 34 psi
Bucket w/wear plates 46 t./.101 lb Track wide (optional) 1800 mm / 71”
Total 490 t / 1080,5 lb Ground pressure 18,4 N/cm2 26,6 psi
* As example
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Dimensions and weights have been designed to allow transportation within

limits of most states. But also a quick assembly has been considered as an
added feature of these dimensions and weights which are subject to change.
) • In the table below are only circa values. You find the exact
values of your excavator in your packing-list
Excavator with backhoe attachment
5130 2130 42
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Dimensions and weights have been designed to allow transportation within

limits of most states. But also a quick assembly has been considered as an
added feature of these dimensions and weights which are subject to change.
) • In the table below are only circa values. You find the exact
values of your excavator in your packing-list.
Excavator with bucket attachment
5130 2130 42
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Configuration of Components on Erection Site.
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Z 24016a
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1. Assembly of the Undercarriage (Z 24016a, Z 24018a)
1.1 Assembly
1. Align right side frame horizontally in both directions very exactly.
From outside place water level gauge onto steel structure of side
frame.
) • Do not remove the protective coating on the flange plates.
2. Attach carbody to the crane (oil supply lines to the travel motors
pointing in direction of the travel motors).
3. Align carbody with the side frame.
4. Lubricate all bolts (M48) (head supporting surface and thread) with
International Compound No. 2 (PN 324 969 40).
5. Insert the bolts (2 x 39 pieces + 2 measuring bolts (1)* with a resilient
sleeve and tighten with 2100 Nm.
6. Support carbody with wooden blocks in a way that the free side is
approx. 200 mm higher than the attached side. (This makes it easier to
attach the 2nd side frame).
*Insert the 2 measuring bolts(1) at the upper corners!
) • Insert the corresponding lines for the chain tensioning system

before installing the side frame.
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Z 24018a
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7. Lift the 2nd side frame with the crane and align with the carbody.
) • Do not remove the protective coating on the flange plates.
8. Insert the bolts (2 x 39 pieces + 2 measuring bolts(1)* with a resilient

sleeve and tighten with 2100 Nm.
9. Lift the undercarriage so far that it is possible to remove the wooden
blocks.
*Insert the 2 measuring bolts(1) at the upper corner - refer to

drawings page before and next page!
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Z 24019a
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Assembly Procedure PC3000-6
1.2 Determination of the tightening torque (Z24019a, Z 24020a)
The required tightening torque for all fastening bolts has to be determined
with the 4 measuring bolts (1), which dimension is analogous to the fastening
bolts.
The required axial tension force of the bolts is determined by means of the
elongation of the fastening bolts.
The tightening torque must be determined 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 (PN 92847640) is delivered with the
excavator.
To determine the tightening torque, 4 specially prepared measuring bolts are
supplied besides the normal fastening bolts. The measuring bolts can be
recognized at the milled area in the end of the threads.
The measuring device is composed of the following items and will be
delivered with each new machine (refer to drawing 24020a).
Procedure to determine the tightening torque for the first assembly

1. Loosen all 4 measuring bolts. Do not lubricate the measuring bolts again.
2. Tighten the 4 measuring bolts with 150 Nm.
3. Install the measuring device (refer to drawing Z 24020a).
4. Adjust the dial gauge to the zero position.
5. Install the special hydraulic torque wrench
(Z 24021; PN 79337473 + 79337673).
6. Increase the pressure at the hydraulic torque wrench as far as a torque of
2100Nm is reached and tighten the measuring bolt.
7. List the pressure and the change of the bolt length in a table.
8. Increase the pressure further by steps of 10 bar until the required
elongation of 0.93 mm of the measuring bolts is reached.
9. Note down the corresponding hydraulic pressure.
10. Repeat this procedure for all 4 measuring bolts.
11. Add all 4 determined hydraulic pressures and then divide by 4.
12. With this average pressure tighten all other bolts.
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Z24020a
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Procedure to determine the tightening torque for inspection after 1000

operating hours (Z 24020a)
1. Loosen all 4 measuring bolts (1).
Do not lubricate the measuring bolts again.
2. Tighten the 4 measuring bolts with 150 Nm.
3. Install the measuring device (refer to drawing Z 24020a).
4. Adjust the dial gauge to the zero position.
5. Install the special hydraulic torque wrench
(Z 24021; PN 79337473 + 79337673).
6. Increase the pressure at the hydraulic torque wrench as far as a torque
of 2100Nm is reached and tighten the measuring bolt.
7. List the pressure and the change of the bolt length in a table.
8. Increase the pressure further by steps of 10 bar until the required
elongation of 0.93 mm of the measuring bolts is reached.
9. Note down the corresponding hydraulic pressures.
10. Repeat this procedure for all 4 measuring bolts.
11. Add all 4 determined hydraulic pressures and then divide by 4.
12. Now only loosen one of the other bolts and tighten up to the
determined average pressure.
13. Repeat this procedure for all the other bolts step by step.
W
• Do not lubricate the bolts again.
• Do not loosen more than one bolt at the same time.
Measuring Device (PN 92847640) (Z 24020a)
Position Part name Part No. Number

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
7 Measuring bolt 928 477 40 4
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PN79337673
PN79337473
PN79337573
Z 24021a
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1.3 Final works (Z24021a)
1. Connect hose pipes between the oil supply lines of the carbody to the
travel motors.
2. Open the cocks inside the side frames for the hydraulic crawler tensioning
system (refer to the Maintenance Manual).
W
• Do not open the cocks before all hydraulic lines are connected
with the rotary joint. The lines in the side frame are under
pressure!
Fill up and/or check the gear oil levels (travel gear, final drive - refer to the
Maintenance Manual).
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Z25032
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1.1 Track tensioning system (Z23037)
1. Working position: Closed

Ex works: Closed
2. Working position: Open
Ex works: Closed
3. Protection sleeves between crawler and center carbody
4. Marking below the washer shows the valve position
“O” open
“C” closed
) • The valve position (open or closed) is not depend on the

lever position.
• For the real status of the valve look at the groove on the
square head of the valve (below the lever).
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2. Assembly of the Cable Reel Unit (Z21885)
1. Lift cable reel unit and align with the undercarriage.

2. Connect the cable reel frame by means of the bolts, sleeves and nuts
(1-3) with the undercarriage.
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3. Assembly of the Superstructure Platform

onto the Undercarriage (Z21886)
) • For slew ring assembling refer to Service Bulletin AH00511

last edition.
1. Lift the superstructure platform off the ground to clean the surface
(contact area) of the slew ring.
Clean very carefully the contact surface for the slew ring on the
center carbody.
2. Check if the „S“ position of the inner and outer ring of the slew ring
is correct. (Ref. Service New AH00511 last edition).
3. Prepare all bolts (07 + 08) and thrust washers (02) and lubricate the
threads as well as the head surface of the bolts.
4. On electric driven machines only
Introduce high voltage cable. Pay attention alignment of the driving
pins for the slip ring.
5. Align superstructure platform to the center carbody and lower it as
required to insert 4 bolts.
6. Install one bolt at each 90° (for alignment) and lower superstructure
platform so that there is very little clearance between slew ring and
center carbody.
7. Install all bolts and pre-tighten.
Tighten the bolts cross-wise with the determined value .
) • If approx. 10 bolts (front and rear) are tightened the

superstructure platform can be unhooked from the cranes.
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4. Assembly of the Prime Drive Unit to the

Superstructure Platform (Z 21887)
1. Attach the unit to the cranes (use only the attached lifting points (A).
2. Lower the unit as required so that two bolts with washers (02 + 03)
for guiding can be inserted.
3. Lower the unit fully and insert all bolts with washers.
Tighten the bolts with the resp. torque. (This must be done directly
because later-on it may be difficult to reach the bolts).
4. Remove the lifting brackets (A).
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4. a Mounting of the hydraulic access ladder (Z21136)
) • Connect ladder platform(02) and ladder(01) with the

bearings(17) before mounting the ladder platform to the
excavator.
1. Connect hinged ladder(01) to the platform (02) with the

bearings(17);
2. Mount the platform(02) with ladder (01) to the excavator;
Tighten self locking nut (06):
Tightening torque of self locking nuts (06)

– New nut: 1000 Nm
– Used nut: 800 Nm
3. Connect ladder lifting cylinder (03);

4. Lubricate both eyes of hydraulic cylinder (03);
5. Make sure both pivot pins (12, 13) are properly secured with cotter
pins (15).
6. Check hydraulic lines (23 and 24) for leakage and damages.
7. Install the stop (04);
8. Connect the cables according to the electric circuit diagrams.
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Bullclam bucket attachment
Z 21888a
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Backhoe attachment
Boom cylinder
Backhoe attachment
Stick cylinder
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5. Assembly of the Boom Cylinders and the Stick Cylinder to the Boom
(Z 21888a; Z 21941, Z 21944)
1. Lift up the boom.

Place wooden blocks on the ground up to a height of approx. 1.5 m.
Pay attention that there is enough place to install boom and stick
cylinders.
2. Lift the boom and stick cylinders align them according to their
bearings.
3. Install pins and pin locking parts.
4. By means of ropes and chain pulls secure all cylinders to the boom.
Cylinder weight approx. 8 tons.
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5.a. Assembly of the Boom (Z21889a)
1. Lift the boom with boom and stick cylinders attached.

2. Align the boom with the boom hinge bearings of the A-frame.
3. Lower the boom so that the borings of the boom and the boom hinge
bearings are aligned.
4. Insert the two pins (2) and secure with the retainers (4) and with bolts
and washers (5).
5. Lower the boom cylinder until the boring of the cylinder and the
superstructure bearings are aligned.
) • If necessary lower or raise the boom for easier alignment.
6. Insert the pin (6) and secure with the retainers (4) and install bolts (5).
7. Fix the 2nd cylinder in the same way.
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Diesel drive version
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) • Remove the pull eyes “A” before mounting the

counterweight.
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Electric drive version
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6. Assembly of the Counterweight (Z21891; Z21891a)
1. Lift the counterweight.

2. Align the counterweight according to the holes for bolts (1).
3. Install bolts (1) (M48) and washers (2).
4. Tighten the bolts with the resp. torque.
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7. Mounting of the Fuel Tank (Z 21892) or

Main Switch Cabinet for Electrical Driven Unit
1. Lift the fuel tank.
) • Using slings for the heavy parts together with a chain pull
allows easy alignment.
2. Align the fuel tank to the superstructure platform and lower the fuel tank
as required so that two bolts (1) M30 with washers (2) can be inserted.
3. Lower the fuel tank fully and insert all bolts (1/3) M30 with washers (2).
Tighten the bolts with the resp. torque.
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8. Mounting of the Cab Base (Z 21893)
1. Lift the cab base.

Lifting eyes are delivered with the machine.
2. Align the cab base with the superstructure.
3. Lower the cab base fully down and install all bolts.
Tighten the bolts with the resp. torque.
4. Connect electric cables.
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Z21894
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9. Mounting of the Cab with Support Frame (Z 21894)
1. Apply sealing compound “ Epple 28” onto the whole contact surfaces (A) of
the cab base.
The sealing compound is delivered with the machine in a 1 liter can.
2. Lift the cab. Lifting eyebolts are delivered with the cab.
3. Connect the air hose (H) to the cab support.
4. Insert the corresponding cables to the cab support.
5. Put the corresponding hoses in the shaft behind the cab in direction to the
middle of the machine before lowering the cab.
6. Align the cab support frame (B) with the cab base contact surfaces (A).
7. Lower the cab support frame onto cab base.
8. Apply “Loctite 222” onto the thread of all 34 mounting bolts (C) and fasten
the cab support frame (B) with bolts (C) and resilient sleeves onto the cab
base. Loctite 222 is delivered with the machine in a 250 ml tube.
9. Connect electric cables.
10. If the machine is equipped with an air conditioner, connect the refrigerant
hoses and electrical cables.
11. Mount the handrails to the cab support frame.
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10. Mounting of the High Pressure Hoses (Z 21896) and the

Hydraulic Oil Tank (Z 21897)
1. Install 6 high pressure hoses (HP) between the 6 check valves (20)
and the main pumps (30).
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Z 21897
2. Align the hydraulic oil tank to the superstructure platform and lower
the tank as required so that the bolts with washers (02, 03 + 04) can
be inserted. Insert all bolts with washers. Tighten the bolts with the
resp. torque.
) • Using slings for the heavy part together with a chain pull
allows easy alignment.
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Z 21898
3. Mount compensator (34) to the tube (35) by means of 8 bolts (14)

and nuts (15).
Do not damage the gasket and the surfaces.
Tightening torque for bolts (14) 80 Nm, so that the resulting gap
between the flanges on both sides is equal.
Do this carefully to prevent cavitation from the pumps.
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11. Mounting of the Hydraulic Oil Cooler (Z 21895)
1. Lift the cooler and align with thread bores on the superstructure
platform.
2. Install the 8 mounting bolts (1)
upper ones M30 x 160 mm,
lower ones M30 x 340 mm with washers (2) and tighten.
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Z 21899 / Z 21900
1. Connect lines (R) + (F) not all shown coming from control block (1),
manifold (3) and coolers to the tank.
2. Connect all remaining return lines to the tank (refer to hydraulic
diagram).
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12. Mounting of the Hand Rails, Cat Walks, Steps and the
Fat Barrel Crane* (Z 21901)
Install all handrails, cat walks, steps, cover counterweight, fat barrel crane*
and ladder by means of screws and distance sleeves.
*( if so equipped)
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Z22937
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13. Mounting of Cable transfer to the Operators Cab (Z22937)
The special Cable Transfer Elements for sealing the cab are stored in the cab
refrigerator.
Install it as shown in the pictures on the previous pages.
) • Install these elements on the ground of the cab support for

all cable inputs and on the roof of the cab support for the
cables to the cabin.
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Edition 04/2005
13a. Installation of Hydraulic Hoses to the Attachment and Rotary Joint
1. Connect hydraulic hoses from manifold to boom connections.

2. Connect hydraulic hoses from boom to stick connections.
3. Connect hydraulic hoses from control blocks to rotary joint.
4. Connect hydraulic hoses from the rotary joint to the travel motors.
5. Connect all remaining hydraulic lines.
Legend for illustration Z21771

(11) Connector on travel gear box breather filter (18)
(16) Connectors on motor adapter housing for breather filter (19)
(18) Breather filter for travel gears
(19) Breather filters for motor adapter housings
(20) Pilot oil pressure hydraulic lines for releasing the parking brakes
Check the four breather filters (18 and 19), locate inside the center frame, for
restriction. If necessary, remove breather filters, blow out with compressed
air from inside to outside and reinstall.
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Z22644a
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14. Checking of direction motor rotation Z 22644a
1. Remove bolts (1)

2. Start motor for a short run up, just enough to determine direction of rotation.
Direction should be counter clockwise (ccw) viewed from PTO gear.
If direction of rotation is wrong change the power supply cable terminal use.
3. Re-install bolts (1)
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15. Connection of Electric Cables
1. Connect the plug connections from operators cab to the cab base.
2. Connect the cables to the junction box X3 at the tank.
3. Connect the plug connections and cables below the cab support (A).
4. Connect two battery cables from switch cabinet (cab support) to engine
house roof (option electric driven machines)
5. Connect all cables for different working lights.
Å
• Electric Driven Machines only:
This have to be done by authorized personnel only.
6. Connect cables from medium voltage cabinet into high voltage cabinet.
7. Connect high voltage cables
7.1a From slip ring into high voltage cabinet

7.2 From slip ring into cable reel unit junction box
7.3a From high voltage switch cabinet to electric motor
(connection box)
7.4 From power supply into cable reel unit.
This have to be done only from mine site personnel.
All 24 volt wires are blue and have a printed code (every 10 cm) at each end of the wire.
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
PC5500AS rev2 77
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X2 - box
Z25019
PC5500AS rev2 78
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No. Harnesses Terminal strip

1 Hydraulic oil tank X2H/X2S
2 Engine 1 rear 1 X2M
3 Engine 1rear 2 X2M
4 Engine 1 in front X2M
5 Engine 2 rear 1 X2N
6 Engine 2 rear 2 X2N
7 Engine 2 in front X2N
8 Control plate 1 X2S
9 Control plate 2 X2T
10 Engine housing X2A/X2E/X2L
11 Control plate assy. X2F
12 High pressure filter X2D
13 Sprocket sensors X2E
14 Ladder X2E
15 Main gate valve X2H
16 Engine air filter X2L
17 Control plate 1 X2S
18 Control plate 2 X2T
19 Travel alarm X2L
20 Engine oil X2M/X2N
21 Engine oil pump 1 X2M
22 Engine oil pump 2 X2N
23 Fuel shut off solenoid X2V
24 Pressure tranducer X1-1,X2 X2S
25 Pressure transducer X1-2 X2T
26 Centinel engine 1 X2M
27 Centinel engine 2 X2N
28 Lighting Atrium X2L
29 Lighting counter weight X2L
30 Level sensor hydraulic tank X2K
31 Battery box X2B - X0-9 X2B
32 Battery - X2B X2B
33 Lubrication system X2R/X2Z
34 End of line pressure switch slew ring X2R
35 End of line pressure switch central X2Z
36 Refilling equipment X2K
37 Operator warning system X2L
38 Cab cable K1=30x1mm² X2C
41 Cab cable K4=20x2,5mm² X2C
42 Cab cable K5=20x2,5mm² X2C
44 Cab cable K7=4x1mm² ; shielded X2C
46 Cab cable Kabel E19 X2C
48 Cab cable Kabel E21A X2C
49 Cab cable Kabel E21B X2C
PC5500AS rev2 79
Edition 04/2005
MAX
80°C
50°C
MAX
80°C
MIN 50°C
MIN
MAX
MAX
30°C
10°C
30°C
10°C
MIN
MIN
Z25026
PC5500AS rev2 80
Edition 04/2005
16. Filling the Hydraulic System (Z25026)
) • Connect all lines of the refilling arm* (hydraulic oil; fuel;

grease).
* if so aquipped.
1. Make sure main shut off-valve is in open position and all connections
are securely tightened.
2. On machines equipped with Central Refilling System fill main
hydraulic oil reservoir according to section "Central Refilling System"
(Operation and Maintenance Manual).
On machine without central refilling system fill main oil reservoir
through opening (4). The new oil flows through the return oil filter into
the main tank. During filling up observe the filter chamber oil level
through the refilling plug. It can be overflow because of the filter flow
resistance.
Depending on type of attachment and the present oil temperature, select
the applying oil level range on plate (3). Be sure to use the correct
marking on oil level plate (3).
3. Open vent plug (13) on the pump suction port of all six main pumps.
As soon as bubble free oil flows out, tighten the vent plug.
4. Open vent screw on secondary pumps (8 and 9). Close vent screw as
soon as bubble free oil flows out.
5. Open vent plug (13) on the pump suction port of the piggipack gear
pumps and wait until bubble free oil flows out. Then tighten the vent
plugs (13).
6. Check the oil level in all six Main Pump Housings (I – VI):
- Remove leakage oil return line from port (15). The oil level in the
pump housing should reach the lower edge of the filler opening.
7. Check hydraulic oil level and the whole hydraulic system for leakage.
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17. Pre-checks prior Initial Start-up
17.1 General
ã
• All work on the medium and high voltage system has to be
carried out by authorized personnel.
The local working safety rules must be strictly observed.
) • Be sure that all hand rails, catwalks and steps etc. are
correctly installed
• Make sure that all hoses and electrical connections are
correctly established (see also electrical and hydraulic
diagrams). Ex works, all disconnected hose lines and
electrical cables are marked with identification numbers.
• Check all fluid levels and correct if necessary. Refer to
Lubrication- and Maintenance Manual.
• Make sure that the hoses for the clam cylinders are covered
with sealing plates.
• Make sure that the shut off valve between the main- and the
suction tank is completely open.
• Check to make sure that the pressure relief cocks for the
hydraulic track tensioning system are CLOSED and the shut-
off cocks in the crawler carriers are OPEN.
• Open and adjust all lowering throttle valves of working
attachment. Refer to Service Bulletin No. AH02518 (latest
edition).
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17.2 Only with Electric Drive
Å
• Remove main fuses for electric motor.
• Carry out all checks which have to be done without voltage.
• Switch on supply voltage.
• Check supply voltage (voltmeter, operators cab).
• Carry out all functional checks of the electric system that are
necessary before the first start-up.
• Switch off supply voltage
• Install main fuses for electric motor.
• Remove mounting ring from the flexible coupling (electric
drive only).
• Start up the electric motor and check direction of rotation.
View from gear box to the motor the electric motor has to
run anti-clockwise.
• If the direction of rotation is correct re-install mounting ring.
17.3 Initial Start up
Now the engine/motor can be started and the machine can be operated for any
additional assembly.
During and after starting pay attention to the instructions in the Operation
Manual.
Re-fill the hydraulic oil tank according to Operation and Maintenance

Manual.
If the machine is equipped with a central lube system, ensure that the grease
containers are filled up and the system is in working order.
If the machine is equipped with a “Fire Electric Detection and Actuation

System” check the installation and function according to enclosed documents.
PC5500AS rev2 85
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PC5500AS rev2 86
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18. Assembly of the Stick to the Boom: Z 21890
) • You need only one crane from now on.
1. Secure bucket cylinders to the stick (A).

2. Lift the stick with the bucket cylinders attached.
3. Lift the stick over to the bearing position stick to boom.
4. Lower the stick until stick to boom bores are aligned.
5. Insert the pins (74) and secure with locks (75) and retainer (76) and
with the bolts (77).
6. Lower front of stick and support with wooden blocks.
Unhook stick from the crane.
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19. Mounting of the Stick Cylinders to the Stick (Z 21903)
1. Lower the stick cylinders by means of the chain pulls to level of the
connecting pins (stick)
2. Remove transportation rope from the bucket cylinders and let them
hang down vertically.
ã
• When removing the transportation rope, the cylinders will
quickly move out.
Therefore, secure each cylinder with a chain pull.
3. Remove cover plates from stick cylinder bearing points. Push out
connecting pins (1) so far, that the piston rod eye fits into the
bearing.
Only so far that the piston rod eye can pass the bearings
4. Start the engine/motor and extend the stick cylinders to final
connecting position.
5. Push in the 2 connecting pins (1) and secure with cover plates (2).
Install bolts (3) and tighten.
The illustration Z 21943 shows the stick with bucket cylinders with pipes and
hoses for the oil supply.
PC5500AS rev2 89
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Z 12904
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20. Assembly of the Bullclam Bucket to the Stick: Z 21904
Delivery in two part (clam - rear wall)
1. Place the rear wall as shown on the ground.

2. Lift the attachment and retract the stick until the stick is in a vertical
position.
3. Move the excavator to the bucket.
4. Align the bores of the stick with the bores of the bucket.
5. Push the pins (1) and (7) from (A) to (B).
6. Insert pins (1) from outside to inside and secure with the axle stirrups (2).
7. Install the parts (3, 4 and 5). Tighten bolts.
8. By moving extending the bucket cylinders align the cylinder eyes with
the bores of the bucket.
9. Now push pins (7) from outside to inside so far that the axle stirrup (6)
can be installed. Secure the bolts with parts (8, 9 and 10).
W
• For the mounting of the pin seals please refer to page 87.
PC5500AS rev2 91
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Z 21905a
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Edition 04/2005
Legend for illust. Z 21905a
Position Designation
16 Cover
17 Plug
18 Lock washer
19 Bolt
32 Ring
33 O-Ring
34 Plate
35 Thread pin
36 Lock washer
37 Nut
41 Bullclam bucket wall
42 Bucket clam
47 Pin seal ring
49; 50; 51 Pin with plate
52 Catch
53 Shackle
62 Lock washer
63 Bolt
64 Protective frame
66 Catch
68; 69 Square
70 Bolt
1. Place the bucket clam (42) into position as shown.

Align the rear wall (41) borings by moving boom, stick and bucket
cylinder with the clam brings.
2. Install pins (50) and lock with the shown parts. Do not forget the rings
(32) and the O-Rings (33).
3. Extend clam cylinders to align them with borings in the clam.
Install pins (49 and 51) and lock them as shown.
4. Connect all hose lines to the bucket cylinders and to the clam cylinders
in the rear wall.
5. Connect all grease lines to the bucket cylinders and to the grease points
are greased before machine is put into operation.
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PC5500AS rev2 94
Edition 04/2005
21. Mounting of the Pin Seals (Z 21906)
The illustration shows the mounting places (A, B, C*) of the one piece design
seals of the bull-clam bucket attachment.
* if so equipped
Mounting procedure:
Insert both seals(1)
Install both fixing halves(2) over the seal ring and tighten bolts (3) .
) • Fill the groove of the fixing halves before installing with

grease.
• Proper functioning of the seal is only established in case of
an intact seal ring.
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22. Putting the Lubrication System into operation (Z25022)

Ensure that all main grease lines and hoses to the metering valves are full filled
with the corresponding grease.
Therefor open these lines straight for the metering valves and put the
lubrication pump into operation (refer to the Operation Manual; section ECS).
1. In order to ensure adequate pre-lubrication of all attachment bearings it

is necessary to manually lubricate the attachment bearings by applying
a grease gun to the grease fittings on each grease injector.
To this, remove protection cap (3) and press in the nipple grease until a
grease collar appears at the connected bearing.
Be sure to repeat the procedure until all pivot bearings of the
attachment and cylinder bearings are lubricated.
2. Use the manual actuation mode of the Lubrication System with the
Service Key for testing the electrical and hydraulic function of the
Lubrication system (refer to the section ECS of the Operation Manual).
So you can check the function of all metering valves.
The injector stem(1)has to be moved during the operation.
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23. Checks and Adjustments Prior Commisionning
Refer to the hydraulic and electric circuit diagrams
To bleed all individual hydraulic circuits slowly operate all functions for
some minutes (travel, slew and all attachments motions).
1. Adjustment of the complete hydraulic system.
2. Adjustment of the complete electric system 24 V.
3. Adjustment of the pre-heating system , if installed..
4. Adjustment of EBL (Electronic Bucket Limiting system), if installed.
5. Adjustment of ECS-system. (Refer to the Service Manual ECS-system.)
For electric driven machines only

6. Adjustment of battery charging unit.
7. Adjustment of main motor protection relay.
8. Adjustment of all other motor overload relays.
W
• Before handing over the excavator to the customer the first
PM Clinic Service has to be carried out according to the
Inspection Procedure Manual.
In order to keep the excavator in first-

class operating condition use only
genuine Komatsu Mining Germany
replacement parts.
The use of any part other than the
genuine parts releases the Komatsu
Mining Germany for any guarantee.
PC5500AS rev2 99
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Edition 04/2005
Metric standard thread
Bolt size Wrench size (mm) Tightening torque MA (Nm)

(mm) 8.8 10.9 12.9
M 8 6 13 21 31 36
M 10 8 17 43 63 73
M 12 10 19 74 108 127
M 14 12 22 118 173 202
M 16 14 24 179 265 310
M 18 14 27 255 360 425
M 20 17 30 360 510 600
M 22 17 32 485 690 810
M 24 19 36 620 880 1030
M 27 19 41 920 1310 1530
M 30 22 46 1250 1770 2080
M 33 24 50 1690 2400 2800
M 36 27 55 2170 3100 3600
M 39 60 2800 4000 4700

M 42 32 65 3500 4950 5800
M 45 70 4350 6200 7200
M 48 35 75 5200 7500 8700
M 52 80 6700 9600 11200
M 56 41 85 8400 12000 14000
M 60 90 10400 14800 17400
M 64 46 95 12600 17900 20900
M 68 100 15200 21600 25500

The torque indications on the chart attached are valid only when the bolts are
manufactured according to DIN.
Threads and bolt heads must be greased carefully with grease KP2K.
The surfaces of contact which should screwed together have to be free of grease.
Divergencing torques: Bolts at excavator slew rings (see Service Bulletin AH00511a)
PC5500AS rev2 101

Edition 04/2005
PC5500AS rev2 102

Edition 04/2005
Metric fine thread
Bolt size Wrench size (mm) Tightening torque MA (Nm)

(mm) 8.8 10.9 12.9
M 8x1.00 6 13 23 33 39
M 10x1.00 8 17 48 70 82
M 12x1.25 10 19 81 119 139
M 14x1.50 12 22 127 187 219
M 16x1.50 14 24 191 280 330
M 18x2.00 14 27 270 385 450
M 20x2.00 17 30 380 540 630
M 22x2.00 17 32 510 720 850
M 24x2.00 19 36 680 960 1130
M 27x2.00 19 41 990 1410 1650
M 30x2.00 22 46 1380 1960 2300
M 33x2.00 24 50 1850 2650 3100
M 36x3.00 27 55 2300 3250 3850
M 39x3.00 60 3000 4200 4950
M 42x3.00 32 65 3750 5300 6200
M 45x3.00 70 4600 6600 7700
M 48x3.00 35 75 5700 8100 9500

M 52x3.00 80 7300 10400 12100
M 56x4.00 41 85 8900 12600 14800
M 60x4.00 90 11000 15600 18300
M 64x4.00 46 95 13300 19000 22200
M 68x4.00 100 16100 22900 27000

The torque indications on the chart attached are valid only when the bolts are
manufactured according to DIN.
Threads and bolt heads must be greased carefully with grease KP2K.
The surfaces of contact which should screwed together have to be free of grease.
Divergencing torques: Bolts at excavator slew rings (see Service Bulletin AH00511b).
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PC5500AS rev2 104

Edition 04/2005
PC5500AS rev2 105

Edition 04/2005
- Service Information -
Buscherhofstr. 10
40599 Düsseldorf
Phone +49 (0)211 7109 0
Fax +49 (0)211 74 33 07
PC5500AS rev2 106

Edition 04/2005

Procedimiento de Armado PC5500E-6

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General Assembly Procedure

Hydraulic Mining Shovel PC5500

All stated information corresponds

Delivery of the Excavator

ã Personnel entrusted with work on the machine must have

) • If the excavator is equipped with a fire suppression system,

• Before assembling/disassembling, lifting or transporting this

Assembling of the Excavator

• Assembling of the excavator must be carried out only by

Transportation and Lifting

Diesel drive Electric drive

Average assembly and commissioning time schedule* (Diesel drive)

Average assembly and commissioning time schedule* (Electric drive)

1. Assembly of the Undercarriage.................................................................................. 21

Assembly Site Requirements

Qty. Specification Designation

Qty. Specification Designation

Space and Placing Requirements

Service Weight Crawler Assembly*

Dimensions and weights have been designed to allow transportation within

Excavator with backhoe attachment

Dimensions and weights have been designed to allow transportation within

Excavator with bucket attachment

Configuration of Components on Erection Site.

1. Assembly of the Undercarriage (Z 24016a, Z 24018a)

) • Do not remove the protective coating on the flange plates.

*Insert the 2 measuring bolts(1) at the upper corners!

) • Insert the corresponding lines for the chain tensioning system

) • Do not remove the protective coating on the flange plates.

8. Insert the bolts (2 x 39 pieces + 2 measuring bolts(1)* with a resilient

*Insert the 2 measuring bolts(1) at the upper corner - refer to

1.2 Determination of the tightening torque (Z24019a, Z 24020a)

Procedure to determine the tightening torque for the first assembly

Procedure to determine the tightening torque for inspection after 1000

Measuring Device (PN 92847640) (Z 24020a)

Position Part name Part No. Number

1.3 Final works (Z24021a)

1.1 Track tensioning system (Z23037)

1. Working position: Closed

) • The valve position (open or closed) is not depend on the

2. Assembly of the Cable Reel Unit (Z21885)

1. Lift cable reel unit and align with the undercarriage.

3. Assembly of the Superstructure Platform

) • For slew ring assembling refer to Service Bulletin AH00511

) • If approx. 10 bolts (front and rear) are tightened the

4. Assembly of the Prime Drive Unit to the

4. a Mounting of the hydraulic access ladder (Z21136)

) • Connect ladder platform(02) and ladder(01) with the

1. Connect hinged ladder(01) to the platform (02) with the

Tightening torque of self locking nuts (06)

3. Connect ladder lifting cylinder (03);

Bullclam bucket attachment

1. Lift up the boom.

5.a. Assembly of the Boom (Z21889a)

1. Lift the boom with boom and stick cylinders attached.

) • If necessary lower or raise the boom for easier alignment.

Diesel drive version

) • Remove the pull eyes “A” before mounting the

Electric drive version

6. Assembly of the Counterweight (Z21891; Z21891a)

1. Lift the counterweight.

7. Mounting of the Fuel Tank (Z 21892) or

1. Lift the fuel tank.