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GEN00126-01

HYDRAULIC
EXCAVATOR

PC490LC-11
SERIAL NUMBERS

85001

and up

FOREWORD
3INCETHISMACHINEISLARGEINSIZE ITISDIVIDEDINTOSOMEUNITSTOMEET
THETRANSPORTATIONCONDITIONSANDREGULATIONSAPPLIEDTOTHETRANSPORTA
TIONROUTEWHENSHIPPEDFROMOURFACTORY
4HIS MANUAL DESCRIBES HOW TO ASSEMBLE THE UNITS INTO THE COMPLETE
MACHINEINTHEFIELD7EHOPETHATTHISMACHINEWILLDISPLAYITSQUALITY
ANDYOUWILLUSEITSAFELYACCORDINGTOTHEOPERATIONMANUAL
-ANYUNITSARELARGEINSIZEANDHEAVYINWEIGHTANDMAYBEHANDLED
INADANGEROUSPLACEORPOSTUREANDMANYWORKERSMAYHAVETOWORK
TOGETHERTOSLINGTHEMWITHCRANES
!CCORDINGLY BEFORESTARTINGTHEASSEMBLYWORK THEWORKSUPERVISORIS
REQUIREDTOHOLDASAFETYMEETINGTOOBLIGETHEWORKERSTOPUTONPRO
TECTIVEGEARANDAPPOINTAWORKLEADERANDACRANEWORKSIGNALMAN
ANDALLOTROLESTOALLTHEWORKERSFORSAFEWORK
)NPARTICULAR THEABOVEMEETINGISMOREIMPORTANTWHENWORKEROFDIF
FERENTLANGUAGESANDCUSTOMSWORKTOGETHER
4HEFOLLOWINGISAREFERENCESUPERVISIONSYSTEMDIAGRAM

(Instruction system)
Work leader
Work supervisor

Crane director

Director
and
deputy director

Operator for assembly


Liaison man
Mechanics

Sharing of work

Interpreter

.OTETHATTHISMANUALDOESNOTDESCRIBETHEWHOLESPECIFICATIONOFTHE
MACHINEBUTDESCRIBESONLYTHEBASICSPECIFICATION
)FYOUHAVEANYQUESTIONWHENDIVIDINGANDTRANSPORTINGTHEMACHINE
BYYOURSELFINFUTURE ASKONEOFOURDISTRIBUTORS

CONTENTS
Specifications ......................................................................................................................
Precautions for field assembly ............................................................................................
Disposal of removed parts...................................................................................................
Assembling procedures, applicable equipment and schedule ............................................
Flow of field assembly .........................................................................................................
Kit layout diagram................................................................................................................
Transportation .....................................................................................................................
Tool list for field assembly ...................................................................................................
Tightening torque ................................................................................................................
Coating materials ................................................................................................................
Selection of wire ropes used for assembly..........................................................................
Selection of nylon slings used for assembly........................................................................

1
2
3
4
5
6
7
10
11
16
20
21

A. Assembly of chassis .......................................................................................................


A- 1. Installation of climbing step ....................................................................................
A- 2. Installation of handrail ............................................................................................
A- 3. Installation of mirror................................................................................................
A- 4. Installation of tail pipe, tail pipe cover.....................................................................

23
24
26
28
31

B. Assembling of work equipment .......................................................................................


B- 1. Installation of boom cylinder...................................................................................
B- 2. Releasing remaining pressure in hydraulic circuit ..................................................
B- 3. Installation of boom cylinder hoses ........................................................................
B- 4. Installation of boom cylinder top pin .......................................................................
B- 5. Installation of boom assembly ................................................................................
B- 6. Installation of hoses from chassis along top of boom.............................................
B- 7. Connection of boom cylinder head.........................................................................
B- 8. Installation of arm assembly...................................................................................
B- 9. Installation of bucket cylinder hoses between boom and bucket cylinder ..............
B-10. Installation of bucket..............................................................................................
B-11. Connection of work equipment grease piping .......................................................
B-12. Connection of work equipment wiring ...................................................................
B-13. Greasing after completion of work equipment.......................................................
B-14. Bleeding air from work equipment circuit ..............................................................

33
34
36
37
38
39
43
44
45
47
49
52
54
56
57

C. Increasing and decreasing of track frame gauge, assembling of counterweight ............


C- 1. Increasing and decreasing of track frame gauge ...................................................
C- 2. Installation of steps ................................................................................................
C- 3. Installation of travel piping covers .........................................................................
C- 4. Adjustment of track tension ...................................................................................
C- 5. Sticking sheet to counterweight .............................................................................
C- 6. Installation of camera .............................................................................................
C- 7. Installation of counterweight...................................................................................

59
60
66
67
71
74
75
81

M. Procedure for inspection and maintenance after completion of assembly .....................


M- 1. Replacement of return filter (Standard filter to flushing filter) ................................
M- 2. Flushing of hydraulic circuit ...................................................................................
M- 3. Replacement of return filter (Flushing filter to standard filter)................................
M- 4. Check of oil/coolant level at each part ...................................................................
M- 5. Inspection of oil level in hydraulic tank and refill....................................................
M- 6. Parts to be touched up after field assembly...........................................................
M- 7. Error code ..............................................................................................................

85
86
87
86
91
93
95
96

Mounting bolt torque check sheet


Field assembly inspection report (Backhoe)

Specifications
Machine model

PC490LC-11

Weight of machine

kg

Bucket capacity

m3

1.9

Engine model

KOMATSU SAA6D125E-7

Flywheel
horsepower

SAE J1995 (Gross)


ISO 9249/SAE J1349 (Net)

kW/min-1 {HP/rpm}

47,040

270/1,900{362/1,900}
268/1,900{359/1,900}

Min. ground clearance

mm

700

Travel speed (Low/High)

km/h

3.0/4.2/5.5

Swing speed

rpm

9.1

PC490LC-11

Precautions for field assembly


1. Selection of work place
1) When selecting a work place, consider the following.
Is the work place sufficiently wide for loading and unloading the machine? (See the kit layout drawing.)
Is the ground sufficiently hard? (The machine and crane truck must not sink into the ground.)
Is the ground flat? (The ground surface must not be uneven or sloping.)
Is the road to inlet/outlet of the work place sufficient for turning the trailer and crane truck?
2) Take care extremely that dirt or water will not enter the hydraulic circuit while it is assembled.
3) Avoid working outdoors while strong wind is blowing or it is raining.
4) Take measures to protect the machine from sand, dirt and rainwater while the work is stopped.
2. How to do work
The work supervisor or the work leader should not do the work while reading this manual but should read and
understand this manual thoroughly and then start the work.
In particular, write the "Precautions" for each work process in a sheet to explain or stick that sheet to the work
place so that all the workers will observe the precautions.
3. Preparation and check of protective gear, slings and tools
The work supervisor or the work leader must perform the following checks about protective gear, slings and
tools.
1) Are all the workers wearing helmets and other protective gear which they are obliged to wear? If special
protective gear is necessary, check that it is prepared and can be used without problem.
2) Are all the slings and tools prepared? Check in advance that they are ready to be used without problem.
In particular, check wooden blocks for internal decay and cracking.
4. k Check during actual work
The work supervisor or the work leader must check the following items constantly and make all the workers observe them.
1) Are the parking brakes of the trailer and crane truck applied securely and are their wheels locked with
chocks during work? Are outriggers, if installed, used securely?
2) Are the temperature and pressure of the engine, hydraulic oil, coolant, etc. lowered sufficiently during work?
3) Is horn or another signal is made to warn around when the engine is started? In addition, is it checked that
work equipment control lever and other control levers are in neutral and the fuel control dial (or fuel control
lever) is in the low idle position?
4) Is the balance of the slung item checked extremely during sling work with the crane?
5) Is entry prohibition for outsiders to the work place observed?
5. The work supervisor or the work leader is required to hold a meeting with all the workers at the beginning of
every morning and explain the work plan of the day to them and give them instructions to observe the safe
work.

Disposal of removed parts


As described in "FOREWORD", when this machine is transported, it is divided into some units such as the body,
undercarriage, cab, work equipment, etc. according to the transportation measure, regulations,etc.
Accordingly, the hydraulic pipings and hydraulic hoses to connect the units, oil inlets and outlets of the hydraulic
devices, and parts which must not be damaged are plugged or covered to prevent oil leakage, entry of dirt and
dust, and damage during transportation.
In addition, fixing jigs are used to prevent a trouble caused by a fall or a shake during transportation and to facilitate
loading, unloading and crane work.
The above plugs, jigs, etc. are removed when the machine is assembled and become unnecessary after completion of the machine. Since they are useful when the machine needs to be transported in future, however, we recommend you to keep them as long as possible.

Worker

Air compressor

Crane

Assembly unit

Days

Meeting with all workers

Start of assembling

Leader + 3 mechanics

45t

Unloading parts
Step
Handrail and mirror

Assembly of work
equipment

Increasing of track
frame gauge

Installation of
counterweight

Backhoe

Completion of general
assembling

Inspection of oil level and


coolant level
Air bleeding from work
equipment cylinder
Flushing of hydraulic
circuit
Adjustment of track
tension
Performance test

Assembling procedures,
applicable equipment and schedule
3 Division

Flow of field assembly


*1

*2

Installation of accessories

Installation of boom cylinder

*2*3

Installation of boom

*2*4

*2

Installation of arm

Installation of bucket

Greasing of work equipment

Air bleeding (work equipment)

Increasing of gauge

*5

Installation of counterweight

*6

Installation of sub
counterweight

Installation of accessories

Flushing

Check of oil and coolant levels

Completion inspection

Precautions
*1: Installation of grip, handrail, rear view mirror, tail pipe, and tail pipe cover
*2: Adjustment of shim
*3: Installation of working lamp
*4: Bucket cylinder and link are installed before shipment
*5: Installation of sound absorbing material, backup lamp, and rear view
monitoring camera
*6: Installation of track frame step and travel piping cover

Kit layout diagram

The dimensions given below are the minimum dimensions needed.


The kit dimensions in the diagram are outline dimensions.
When selecting a place, see Precautions for Field Assembly.

Transportation
Packing Style for Transportation
These machines can be divided into three kits for transportation.
Please ask us or our service shop for transportation.
t 3-kit Transportation
(Work equipment)

(Upper structure + Undercarriage)

(Others)

t Packing Style of Each Kit (Sizes in drawing are given in millimeters.)


Upper structure + Undercarriage

Model

PC490LC-11

A (mm)

6,050

B (mm)

3,360

Shoe width
(mm)
Overall width
(mm)
Weight
(kg)

700
3,150
28,930

Packing Style of Each Kit (Sizes in drawing are given in millimeters.)


(1) Boom

Position of center of gravity

Model

PC490LC

A (mm)

7,290

B (mm)

1,725

Overall width
(mm)
Weight
(kg)

780
4,230

Model

PC490LC

A (mm)

4,610

B (mm)

955

(2) Arm

Overall width
(mm)
Weight
(kg)

Position of center of gravity

675
2,210

(3) Boom cylinder

Position of center of gravity

Model

PC490LC

Weight
(kg)

365

(4) Bucket

Model

PC490LC

A (mm)

1,839

B (mm)

1,499

Overall width
(mm)
Weight
(kg)

1,624

Model

PC490LC

Weight (kg)

9,570

1,366

(5) Counterweight

850
3,000

1,165

Tool list for field assembly


1
2
3
4
5
6

Part name
Equipment

No.

7
8
9
10
11
12
13
14
15

17
18
19
20

Tool

16

Specification

7.0kg/cm3
25 ton
Air supply set
5-step, 1,500 mm
M10 bolt
Small-sized impact wrench
M12 bolt
Medium-sized impact
M14 M20 bolt
wrench
Large-sized impact
M24 M33 bolt
wrench
Air hose for impact wrench 50 m
Socket 22 mm width across flats
Medium-sized impact
Socket
24 mm width across flats
wrench socket
Socket 30 mm width across flats
Socket 36 mm width across flats
Large-sized impact
Socket 46 mm width across flats
wrench socket
Socket 65 mm width across flats
4:1 torque multiplier
25.4, 19
wrench
Socket for 4:1 torque
T25.4 square x Width across flats 46 mm
multiplier wrench
T25.4 square x Width across flats 65 mm
42 kgm T25.4
85
kgm T25.4
Torque wrench
Compressor
Crane truck
Grease pump
Stepladder

420 kgm T38.1

21
Standard tools

Socket, spanner, ring wrench

23
24

Large hammer (plastic)


Bar
Hydraulic jack

10 P
1m

Oil container

Large and small ones

26
27
28

43

Sling

Wire

Oil, grease, consumable

29
30
31
32
33
34
35
36
37
38
39
40
41
42

Shackle
Nylon sling
Lever block
Eyebolt
Cleaning liquid
Hydraulic oil
Grease
Touchup paint

Cloth

1
1
1
1
1
1
1
1
1

Remarks

For greasing work equipment


Torque capacity: 30 170Nm
{3.06 17.3 kgfm}
Torque capacity: 200 700Nm
{20.4 71.4 kgfm}
Torque capacity: 1,000 2,500Nm
{102 255 kgfm}

Track frame connecting bolt


Counterweight

1
1 each
1 each
1
1

Track frame
Counterweight
35 420Nm {3.57 42.8 kgfm}
420 1,050Nm {42.8 107 kgfm}
1,050 4,200Nm {107 428 kgfm}
Counterweight

1 set of
2 each
1
2

10 3,000 mm
16 3,000 mm
20 5,000 mm
30 3,000 mm
SD32
SC18
50 mm wide x 3,000 mm
1.5 3 ton
M12
Brake cleaner spray can
HO56-HE
G2-LI
Natural yellow spray can
Black gray spray can

For tightening track frame connecting


bolts
2 each For connecting travel piping and work
equipment piping
2
Support of boom cylinder
For tightening track frame connecting
2
bolts
2
2
2
Boom, arm, bucket
2
Counterweight
2
Rated load of 6 t for counterweight
4
Rated load of 2 t
2
Boom cylinder, arm cylinder
2
Increase of track frame gauge
2
10
200 l
20 kg For greasing work equipment
5
5

1 bundle

20 kg

5 10 ton

30 50 150 mm
Wooden block

1
1
1
2
1
1

22

25

Q'ty

400 200 mm

10

For cleaning

Tightening torque
1. Tightening torque for bolts
Tightening torque for bolts is indicated in the text as shown below. Tighten each bolt to the specified
torque.
Part No. of bolt

TTTTT-TTTTT

Part No. of washer

EEEEE-EEEEE

Bolt specification

Thread
Bolt
length
Thread
size diameter
(Diameter,
pitch,
length)

Tool (Socket)

Applicable socket size

Tightening torque

Nm {QQQ kgm}

If tightening torque for a bolt is not specified in the text, tighten it according to Table 1.
Remarks
1. The thread diameter is the nominal diameter. For example, 16 mm is expressed as M16 and 20
mm is expressed as M20.
The pitch in Table 1 is the distance that the bolt advances every turn in the axial direction (Unit:
mm).
2. The bolt length is dimension (c) in Fig. 1.
3. The applicable socket size is expressed as 24 mm, 30 mm, etc. Since 24 mm, 30 mm, etc. correspond to dimension (b) in Fig. 1, an applicable socket can be selected from Table 1, too.
4. Tightening torque is expressed as QQQ www or QQQ RR. If the target tightening torque
is set, expression of QQQ RR is applied.

Fig. 1

a
b
c
d

: Bolt thread diameter (Nominal diameter)


: Width across flats of bolt head
: Bolt length
: Threaded part of bolt

11

Table 1 Tightening torque for bolts not specified in text


Nominal size of thread
pitch
a (mm)

Tightening torque

Width across flats


(= Socket size)
b (mm)

M6 1

10

M8 1.25

13

M10 1.5

17

M12 1.75

19

M14 2

22

M16 2

24

M18 2.5

27

M20 2.5

30

M22 2.5

32

M24 3

36

M27 3

41

M30 3

46

M33 3

50

M36 3

55

M39 3

60

Unit: Nm {kgm}

a For symbols a and b in the table, see Fig. 1.

12

Target

Range

12
{1.2}
25
{2.5}
54
{5.5}
89
{9}
137
{14}
230
{23.5}
315
{32}
460
{47}
650
{66.5}
810
{82.5}
1,180
{120}
1,520
{155}
1,960
{200}
2,450
{250}
2,940
{300}

8.8 14.7
{0.9 1.5}
14.7 34
{1.5 3.5}
34 74
{3.5 7.5}
54 123
{5.5 12.5}
84 196
{8.5 20}
147 309
{15 31.5}
201 427
{20.5 43.5}
319 608
{32.5 62}
471 829
{48 84.5}
588 1,030
{60 105}
883 1,470
{90 150}
1,130 1,910
{115 195}
1,470 2,450
{150 250}
1,860 3,040
{190 310}
2,260 3,630
{230 370}

2. Tightening torque for pipe threads


Proper tightening torque for pipe threads depends on combination of the materials of the male screw and
female screw. In this manual, however, select tightening torque from Table 2 and Table 3 on the basis of the
material of the male screw. If tightening torque is specified specially in explanation, however, apply that tightening torque.
2.1 If the male screw is made of mild steel or cast iron, apply Table 2.
Table 2

Unit: Nm {kgm}

Material of female thread


Steel

Cast iron

Light alloy

3.9 6.9
{0.4 0.7}
5.9 11.8
{0.6 1.2}
16.7 26.5
{1.7 2.7}
32.3 52.9
{3.3 5.4}
51.0 85.3
{5.2 8.7}
86.2 173.5
{8.8 17.7}

2.9 5.9
{0.3 0.6}
4.9 9.8
{0.5 1.0}
13.7 21.6
{1.4 2.2}
26.5 43.1
{2.7 4.4}
42.1 70.6
{4.3 7.2}
72.5 146.0
{7.4 14.9}

2.0 3.9
{0.2 0.4}
3.9 7.8
{0.4 0.8}
9.8 16.7
{1.0 1.7}
19.6 32.3
{2.0 3.3}
31.4 52.9
{3.2 5.4}
54.9 111.7
{5.6 11.4}

Nominal size (in)


1/8
1/4
3/8
1/2
3/4
1

2.2 If the male screw is made of refined steel (heat-treated hard steel), apply Table 3.
Table 3

Unit: Nm {kgm}

Material of female thread

Steel

Cast iron

Light alloy

16.7 29.4
{1.7 3.0}
19.6 44.1
{2.0 4.5}
44.1 93.1
{4.5 9.5}
98.0 188.2
{10.0 19.2}
170.5 316.5
{17.4 32.3}
367.5 612.5
{37.5 62.5}

9.8 19.6
{1.0 2.0}
16.7 37.2
{1.7 3.8}
37.2 77.4
3.8 7.9}
83.3 157.8
{8.5 16.1}
141.1 247.0
{14.4 25.2}
309.7 514.5
{31.6 52.5}

6.9 14.7
{0.7 1.5}
12.7 28.4
{1.3 2.9}
27.4 58.8
{2.8 6.0}
60.8 115.6
{6.2 11.8}
105.8 186.2
{10.8 19.0}
235.2 392.0
{24.0 40.0}

Nominal size (in)

1/8
1/4
3/8
1/2
3/4
1

13

3. Tightening torque for hydraulic hose connecting nut


For the connecting nuts installed to the hydraulic hose adapters in relatively low pressure systems, apply
tightening torque in Table 4.1 and 4.2.
Table 4.1 Hydraulic hose of face seal type
Type that uses O-ring
at this position
(O-ring is fitted to joint
side)

Unit: Nm {kgm}

Outside diameter
of hose
(mm)

Width across flats


(mm)

Range

Target

Approx. 6

19

34 54 {3.5 5.5}

44 {4.5}

Approx. 10

22

54 93 {5.5 9.5}

74 {7.5}

Approx. 13

27

84 132 {8.5 13.5}

103 {10.5}

Approx. 16

32

128 186 {13.0 19.0}

157 {16.0}

Approx. 20

36

177 245 {18.0 25.0}

216 {22.0}

Tightening torque (Nm {kgm})

Table 4.2 Hydraulic hose of taper seal type

Type that does


not use O-ring
at this position

Unit: Nm {kgm}
Outside diameter
of hose
(mm)

Width across flats


(mm)

Range

Target

Approx. 6

19

34 63 {3.5 6.5}

44 {4.5}

Approx. 10

24

59 98 {6.0 10.0}

78 {8.0}

Approx. 13

27

84 132 {8.5 13.5}

103 {10.5}

Approx. 16

32

128 186 {13.0 19.0}

157 {16.0}

Approx. 20

36

177 245 {18.0 25.0}

216 {22.0}

Tightening torque (Nm {kgm})

Note: When connecting hose, take care not to twist them.

14

4. Proper socket sizes for bolts of M39 and larger (Reference)


For the proper sizes of sockets or spanners (= width across flats) for tightening hexagon bolts of M39 and
larger, see Table 5.
Table 5
Unit: mm
Thread diameter

Proper sizes of sockets or spanners

M42

65

M45

70

M48

75

M52

80

M56

85

M60

90

M64

95

15

Coating materials
a Select adhesives, liquid gaskets, greases, and other coating material used for disassembly and assembly
from the following list.
a

If any coating is not shown in the following list, use the product shown in the manual or equivalent.

Category

Komatsu code

Part No.

Q'ty

Container

Main features, uses

LT-1A

790-129-9030

150 g

Tube

Used to fix rubber gasket, rubber cushion, or cork plug

790-129-9050

20 g
(2container
set)

Polyethylene
container

Used to glue resin (excluding


polyethylene, polypropylene,
ethylene tetrafluoride, vinyl
chloride), rubber, metal, or nonmetallic material instantaneously firmly

09940-00030

50 g

Polyethylene
container

Features: Heat resistance and


chemical resistance
Used to lock bolts, plugs, etc.
and as sealant

790-129-9060
Set of adhesive
and hardener

Adhesive:
1 kg
Hardener:
500g

Can

LT-4

790-129-9040

250 g

Polyethylene
container

Used to glue metal, glass, plastic, etc. and as sealant

HOLTS
MH 705

790-129-9120

75 g

Tube

Heat-resistant sealant for repairing engine

50 g

Polyethylene
container

Instantaneous adhesive
Adhesion time: 5 sec to 3 min
Mainly used to glue metal, rubber , plastic, and wood
Instantaneous adhesive
Quick-hardening type (Reaches max. strength 30 min after)
Mainly used to glue rubber ,
plastic, and metal

LT-1B

LT-2

LT-3

Adhesive

Three bond
1735

790-129-9140

Used to glue metal, glass, plastic, etc. and as sealant

Aron alpha
201

790-129-9130

2g

Polyethylene
container

LOCTITE
648-50

79A-129-9110

50 cc

Polyethylene
container

Features: Heat resistance and


chemical resistance
Used for gluing parts fitted at
high temperature

1 kg

Polyethylene
container

Used as sealant for various


threaded portions, pipe joint,
and flange
Used as sealant for taper plug,
elbow, nipple, etc.

Tube

Features: Silicon-based, heat


resistance, cold resistance
Used as sealant for flange and
threaded portion
Used as sealant for oil pan, final drive case, etc.

Tube

Features: Silicon-based, quickhardening type


Used as sealant for flywheel
housing, intake manifold, oil
pan, thermostat housing, etc.

Tube

Features: Silicon-based, heat


resistance, vibration resistance, impact resistance
Used as sealant for transfer
case etc.

LG-5

LG-6

790-129-9080

790-129-9160

200 g

Liquid gasket

LG-7

LG-8
ThreeBond
1207B

790-129-9170

419-15-18131

1 kg

100 g

16

Shown
in this
manual

Category

Komatsu code

LG-9
ThreeBond
1206D

Part No.

790-129-9310

Q'ty

Container

Main features, uses

200 g

Tube

Used to seal circle gear top


which does not need to be
clamped and fill gaps of welded
parts etc. having rough surfaces
Can be painted

LG-10
ThreeBond
1206E

790-129-9320

200 g

Tube

Used as lubricant and sealant


fro radiator hose
Can be painted

LG-11
ThreeBond
1121

790-129-9330

200 g

Tube

Feature: Can be used with


gasket
Used for covers of transmission case, steering case, etc.

ThreeBond
1121

790-129-9090

100 g

Tube

Liquid gasket for repairing engine

Tube

Used for press fitting, shrink fitting, prevention of galling or


seizure of screw
Used as lubricant for linkage,
bearing, etc.

Can

Spray type
Thin molybdenum disulphide
film is formed on metal surfaces to prevent galling between
metals
Used for drive shaft spline,
needle bearing, various link
pins, bolts, etc.

Can

Feature: Compound consisting


of fine metal particles to prevent seizure and galling
Used for mounting bolts of
high-temperature parts such as
exhaust manifold, turbocharger, etc.

LM-P

09940-00040

200g

Molybdenum
disulfide
lubricant

Anti-seize

LC-G
NEVER-SEEZ

G2-LI
G0-LI(*)
*: For cold
weather

09995-00250

SYG2-400LI
SYG2-350LI
SYG2-400LI-A
SYG2-160LI
SYG2-160CNLI
SYG0-400LI-A(*)
SYG0-16CNLI(*)

190 g

Shown
in this
manual

Multi-purpose extreme pressure lithium grease


Various
types

Various
types

Used for high-load portion

Grease
LM-G(G2-M)
Molybdenum
disulfide
grease

SYG2-400M
SYG2-400M-A
SYGA-16CNM

400g 10
400g 20
16 kg

Bellows can

Caution: Do not use for rolling


bearings and splines such as
swing circle bearing
Apply to work equipment pins
only at assembly time and do
not use after that

17

Category

Komatsu code
Hyper White
Grease
G2-T
G0-T (*)
*: For cold
weather
Bio grease
G2B
G2-BT (*)
*: For high
temperature
and high
load

G2-S
ThreeBond
1855

G2-U-SENS
grease

Part No.

SYG2-400T-A
SYG2-16CNT
SYG0-400T-A (*)
SYG0-16CNT (*)

SYG2-400B
SYGA-16CNB
SYG0-400BT (*)
SYGA-16CNBT (*)

427-12-11871

SUNSTAR
PAINT
PRIMER 580
SUPER

Q'ty

400 g
16 kg

400 g
16 kg

Container

Main features, uses

Bellows can

Has higher seizure resistance,


heat resistance, and water resistance than molybdenum disulphide grease
Not conspicuous on machine
since color is white

Bellows can

Decomposed by bacteria in nature in short period to minimize


effects on microorganism,
plants, and animals

Tube

Feature: Silicon-based, wide


using temperature range, high
oxidation resistance, prevention of deterioration of rubber
and plastics
Used as oil seal for transmission etc.

2 kg

Can

Feature:Urea-based (organic)
grease having heat resistance
and long life. Sealed when
used.
Used for rubber in damper,
bearing, oil seal
Caution:Do not mix with lithium
grease

20 ml

Glass
container

Used as primer for cab


side
(Using limit: 4 months after date of manufacture)

20 ml

Glass
container

Used as primer for glass


side (Using limit: 4
months after date of manufacture)

20 ml

Glass
container

200 g

Primer

SUNSTAR
PAINT
PRIMER 43595

SUNSTAR
GLASS
PRIMER 43541

SUNSTAR
SASH
PRIMER GP402

22M-54-27230

22M-54-27240

22M-54-27250

For gluing cab glass

417-926-3910
SUNSTAR
GLASS
PRIMER 580
SUPER

Used as paint primer for


cab side
(Using limit: 4 months after date of manufacture)

150 ml

Steel can

Used as primer for black


ceramic-coated surface
on glass side and for hard
polycarbonate-coated
surface
(Using limit: 4 months after date of manufacture)

20 ml

Glass
container

Used as primer for sash


(Almite)
(Using limit: 4 months after date of manufacture)

18

Shown
in this
manual

Category

Komatsu code

SUNSTAR
PENGUINE
SEAL 580
SUPER "S" or
"W"

Part No.

417-926-3910

Q'ty

Container

Main features, uses

320 ml

Polyethylene
container

"S" is used for high-temperature season (April to


October) and "W" for lowtemperature season (October to April) as adhesive for glass
(Using limit: 4 months after date of manufacture)

310 ml

Polyethylene
container

Used as adhesive for


glass
(Using limit: 6 months after date of manufacture)

Sika Japan,
Sikaflex
256HV

Caulking
material

20Y-54-39850

For gluing cab glass

Adhesive

Used as adhesive for


glass
(Using limit: 6 months after date of manufacture)

SUNSTAR
PENGUINE
SUPER 560

22M-54-27210

320 ml

Ecocart
(Special
container)

SUNSTAR
PENGUINE
SEAL No.
2505

417-926-3920

320 ml

Polyethylene
container

SEKISUI
SILICONE
SEALANT

20Y-54-55130

333 ml

Polyethylene
container

Used to seal front window


(Using limit: 6 months after date of manufacture)

Cartridge

Used to seal joints of


glass parts Translucent
white seal
(Using limit: 12 months after date of manufacture)

Used to seal joints of


glass parts
(Using limit: 4 months after date of manufacture)

GE TOSHIBA
SILICONES
TOSSEAL
381

22M-54-27220

Natural yellow

SYPA-U03SPNY

Spray type

Black gray

SYPA-U03SPBG

Spray type

333 ml

Paint

19

Shown
in this
manual

Q
Q

20

8
9
10
11.2
(12)
12.5
14
16
18
20
22.4
(24)
25
28
30
31.5
33.5
35.5
37.5
40
42.5

Sling angle
Angle to vertical line
Mode coefficient M
Classification of wire rope
Outer diameter of
wire rope (2)d (mm)

Number of wire ropes

Max. 4.8 {0.49}


Max. 6.1 {0.63}
Max. 7.6 {0.77}
Max. 9.5 {0.97}
Max. 10 {1.1}
Max. 11 {1.2}
Max. 14 {1.5}
Max. 19 {1.9}
Max. 24 {2.5}
Max. 30 {3.1}
Max. 38 {3.9}
Max. 43 {4.4}
Max. 47 {4.8}
Max. 59 {6.1}
Max. 68 {7.0}
Max. 75 {7.7}
Max. 85 {8.7}
Max. 96 {9.8}
Max. 107 {10.9}
Max. 122 {12.4}
Max. 137 {14.0}

24G

= 0
= 0
1

1 pc.

Max. 5.2 {0.53}


Max. 6.6 {0.67}
Max. 8.2 {0.83}
Max. 10 {1.0}
Max. 11 {1.2}
Max. 12 {1.3}
Max. 16 {1.6}
Max. 21 {2.1}
Max. 26 {2.7}
Max. 32 {3.3}
Max. 41 {4.2}

Max. 51 {5.2}
Max. 64 {6.5}
Max. 73 {7.5}
Max. 81 {8.3}
Max. 92 {9.4}
Max. 103 {10.5}
Max. 115 {11.7}
Max. 131 {13.4}
Max. 148 {15.1}

24A
Max. 6.7 {0.68}
Max. 8.5 {0.88}
Max. 10 {1.0}
Max. 13 {1.3}
Max. 14 {1.5}
Max. 15 {1.6}
Max. 19 {2.1}
Max. 26 {2.6}
Max. 33 {3.5}
Max. 42 {4.3}
Max. 53 {5.4}
Max. 60 {6.1}
Max. 65 {6.7}
Max. 82 {8.5}
Max. 95 {9.8}
Max. 105 {10.7}
Max. 119 {12.1}
Max. 134 {13.7}
Max. 149 {15.2}
Max. 170 {17.3}
Max. 191 {19.6}

24G

Z 90
Z 45
1.4
24A
Max. 7.2 {0.74}
Max. 9.2 {0.93}
Max. 11 {1.1}
Max. 14 {1.4}
Max. 15 {1.6}
Max. 16 {1.8}
Max. 22 {2.2}
Max. 29 {2.9}
Max. 36 {3.7}
Max. 44 {4.6}
Max. 57 {5.8}

Max. 71 {7.2}
Max. 89 {9.1}
Max. 102 {10.5}
Max. 113 {11.6}
Max. 128 {13.1}
Max. 144 {14.7}
Max. 161 {16.3}
Max. 183 {18.7}
Max. 207 {21.1}

Annex 2, Table 1 Using loads of 6 24 type rope slings.

Select wire ropes to be used for assembly according to the following table.

Selection of wire ropes used for assembly

2 pcs.

Max. 4.8 {0.49}


Max. 6.1 {0.63}
Max. 7.6 {0.77}
Max. 9.5 {0.97}
Max. 10 {1.1}
Max. 11 {1.2}
Max. 14 {1.5}
Max. 19 {1.9}
Max. 24 {2.5}
Max. 30 {3.1}
Max. 38 {3.9}
Max. 43 {4.4}
Max. 47 {4.8}
Max. 59 {6.1}
Max. 68 {7.0}
Max. 75 {7.7}
Max. 85 {8.7}
Max. 96 {9.8}
Max. 107 {10.9}
Max. 122 {12.4}
Max. 137 {14.0}

24G

24A
Max. 5.2 {0.53}
Max. 6.6 {0.67}
Max. 8.2 {0.83}
Max. 10 {1.1}
Max. 11 {1.2}
Max. 12 {1.3}
Max. 16 {1.6}
Max. 21 {2.1}
Max. 26 {2.7}
Max. 32 {3.3}
Max. 41 {4.2}

Max. 51 {5.2}
Max. 64 {6.5}
Max. 73 {7.5}
Max. 81 {8.3}
Max. 92 {9.4}
Max. 103 {10.5}
Max. 115 {11.7}
Max. 131 {13.4}
Max. 148 {15.1}

90 < Z 120
45 < Z 60
1

Unit: kN {tf}

18
B 8817-1991

21

tRated load table (WW-1D type)

Select wires used for assembly according to the following table

Selection of nylon slings used for assembly

A. ASSEMBLY OF CHASSIS

23

Assembly procedure

Installation of climbing step (1/2)

A-1
For USA specifications
Install step (1) with bolts (2).

No.
1
2
Precautions

Name

Qty

Socket 19 mm width across flats

1
1

24

Qty
1
4

Necessary equipment

Small-sized impact wrench

Others

Remove the rust preventive plug from the


tapped hole.

Necessary tools

Loose-supply items
208-54-43140
01024-81225

Name

Qty

Assembly procedure

Installation of climbing step (2/2)

A-1

Install grip (1) with bolts (2).

No.
1
2

Precautions

Name

Qty

Socket 19 mm width across flats

1
1

25

Qty
1
2

Necessary equipment

Small-sized impact wrench

Others

Remove the rust preventive plug from the


tapped hole.

Necessary tools

Loose-supply items
208-54-43150
01024-81230

Name

Qty

Assembly procedure

Installation of handrail (1/2)

A-2

1. Set plate (2) and plate (4) at part Q, and then install handrail (1) with bolts (3).
a Weight of handrail: 21 kg

No.
1
2
3
4

Precautions

Qty

Socket 19 mm width across flats

Medium-sized impact wrench

26

Qty
1
1
6
1

Necessary equipment

Name

Others

a When carrying the handrail, use a crane


etc.
a Install the handrail to the right side of the
machine first, and then to the left side of
the machine.
When removing the handrail, remove
the left side of the machine first, then
remove the right side.
(Prevention of fall)

Necessary tools

Loose-supply items
208-54-21921
208-54-43120
01024-81245
207-54-43851

Name

Qty

Assembly procedure

Installation of handrail (2/2)

A-2

Using bolts (3), install handrail (1) and plate (2) to the track frame.
a Weight of handrail: 12 kg

No.
1
2
3

Precautions

Qty

Socket 19 mm width across flats

Medium-sized impact wrench

27

Qty
1
1
4

Necessary equipment

Name

Others

a When carrying the handrail, use a crane


etc.
a Install the handrail to the right side of the
machine first, and then to the left side of
the machine.
When removing the handrail, remove
the left side of the machine first, then
remove the right side.
(Prevention of fall)

Necessary tools

Loose-supply items
208-54-41833
208-54-43130
01024-81245

Name

Qty

Assembly procedure

Installation of mirror (1/3)

A-3

(1) Install mirror (1).


Tightening torque of mirror mounting bolt: 6.0 to 7.0 Nm
{0.61 to 0.71 kgm}

View from right of machine


Adjust the mirror so that the operator in the operator
seat can see persons on the ground at 1 m around the
machine.
(W) : 1m

No.
1
Precautions

Necessary tools

Others

Name
Hexagon socket 5 mm width
across flats
Hexagon socket 8 mm width
across flats

28

Loose-supply items
2A5-54-13420

Qty
1

Necessary equipment
Qty
1
1

Name

Qty

Assembly procedure

Installation of mirror (2/3)

A-3

(2) Install mirror (1).


Tightening torque of mirror(1) mounting bolt: 6.0 to 7.0 Nm
{0.61 to 0.71 kgm}

No.
1
Precautions

Necessary tools

Others

Name
Hexagon socket 5 mm width
across flats

29

Loose-supply items
2A5-54-13420

Qty
1

Necessary equipment
Qty
1

Name

Qty

Assembly procedure

Installation of mirror (3/3)

A-3

(3) Install mirror (1), support(2), and clamp(3).


Tightening torque of mirror(1) mounting bolt: 6.0 to 7.0 Nm
{0.61 to 0.71 kgm}

No.
1
2
3
4
Precautions

Name
Hexagon socket 5 mm width
across flats
Hexagon socket 8 mm width
across flats

Others

a Tighten bolts (4) according to torque table


1 (page 11).

Necessary tools

30

Loose-supply items
2A5-54-13420
2A5-54-16120
20Y-54-35430
01252-A1030

Qty
1
1
1
2

Necessary equipment
Qty
1
1

Name

Qty

Assembly procedure

Installation of tail pipe and tail pipe cover

A-4
(1) Install tail pipe.

Tightening torque: 11.8 Nm {1.2 kgm}

(2) Install tail pipe cover.

Adjust the cover to equalize the clearance marked with .

No.
1
2
3
4
5
Precautions

Necessary tools

Others

Name

31

Loose-supply items
208-01-21720
6253-11-515A
885-3353-911
208-54-21361
01034-81230

Qty
1
1
1
1
6

Necessary equipment
Qty

Name

Qty

B. ASSEMBLING OF WORK EQUIPMENT


Clean the mounting pin and pin hole and check them for a flaw.

33

Assembly procedure

Installation of boom cylinder (1/2)

B-1

(1) Lift the boom cylinder and adjust it to the frames pin holes.
(2) Drive in the boom cylinder foot pin.
aInside of pin hole and bushing of boom cylinder boss: Apply LM-P (Only 1st time)
[Apply lithium grease for 2nd time and after]
(3) Check the clearance between the pin and chassis and combine and insert adjustment shims (1) so that the
clearance on the outside of the chassis will be 1.5 mm or less. Adjust the shims for both right and left cylinders.
Insert one piece of 207-70-71251 on the inside of the chassis and insert the other shims on the outside of the
chassis.

Outside of machine

Inside of machine

Rest of shims

(Clearance must
be 1.5 mm or less)

207-70-71251 1 piece

PART P

(4) Push in the boom cylinder foot pin fully and install the lock plate.
a Check that the pin lock bolt is not loosened but tightened and check
its torque.
Precautions

Necessary tools
Name

Qty

Nylon sling

2
1

Small-sized impact wrench

34

Loose-supply items
207-70-71251
207-70-71261

Qty
6
2

Necessary equipment

Socket 19 mm width across flats

Others

a Assemble so that the grease hole of the boom


cylinder bottom will be down.
a Decide the thickness of the adjustment shim
by combining shims 1 mm thick (207-7071251) and 2 mm thick (207-70-71261).
a When pushing in the pin, take care not to break
the dust seal installed to the boom cylinder
boss.

No.

Name
25 t crane

Qty
1

Assembly procedure

Installation of boom cylinder (2/2)

B-1

(5) Insert the boom cylinder supports between each cylinder and revolving frame.
* Wooden blocks 30 mm thick may be used instead of the cylinder supports.

Support stand

Boom cylinder

Revolving frame

Precautions

Necessary tools

Others

Name

35

Necessary equipment
Qty

Name

Qty

Assembly procedure

Releasing remaining pressure in hydraulic circuit

B-2

When removing the hydraulic piping, be sure to release the remaining pressure according to the following procedure.
(1) Lower the work equipment lock lever to the "LOCK" position, and start and run the engine for about 10 seconds,
and then stop it.
a Limit the engine speed to low idling.
a Set the work equipment control lever in neutral.
(2) Within 15 seconds after stopping the engine, turn the starting switch to the ON position, set the lock lever to
the FREE position, and operate each control lever to the stroke end.
a Repeat the operations of (1) to (2) 3 times.
(3) Lower the lock lever to the "LOCK" position.
(4) Remove the oil filler cap of the hydraulic tank to release the pressure in the tank.
kWhen removing the oil filler cap of the hydraulic tank, turn it slowly to release the internal pressure first, and
then remove the cap carefully.
(5) After releasing the pressure in the tank, install the oil filler cap of the hydraulic tank to prevent entry of dirt.

Precautions

Necessary tools

Others

Name

36

Necessary equipment
Qty

Name

Qty

Assembly procedure

Installation of boom cylinder hoses

B-3

(1) Remove the oil stopper plug from the tube at the boom cylinder end.
(2) Set the new O-rings (3) to boom cylinder hoses (1) and (2), 4 pieces in total, and install them to the normal
circuit as shown in the figure below.
a Bleed the boom cylinder of air by following Assembly Procedure B-14 Bleeding Air from Work Equipment
Circuit.

a Check that the split flange is not loosened but tightened.

No.
1
2
No.
3

a Check that each O-ring is fitted, has not come off, and is not
caught.

Precautions

Name

Qty
2

Socket 14 mm width across flats

Small-sized impact wrench

37

Qty
2
2
Qty
4

Necessary equipment

Oil container

Others

1. When removing an oil stopper plug from a hose,


slowly loosen its bolts by gradually releasing the
internal hydraulic pressure.
2. Keep the removed oil plugs so that they can be
reused.
3. When connecting the hoses, take extremely
care not to clinch or damage the O-rings.
4. Also, take extremely care not to enter a foreign
material into the hydraulic circuit.

Necessary tools

Already installed to
207-62-52610
206-62-51650
Loose-supply items
07000-13032

Name

Qty

Assembly procedure

Installation of boom cylinder top pin

B-4

Insert the boom cylinder top pin in the boom temporarily.

Weight of boom cylinder top pin: 73 kg


Apply LM-P to the inside of boss.

No.
1
Precautions

Necessary tools
Name
Nylon sling

38

Loose-supply items
208-70-61860

Qty
1

Necessary equipment
Qty
1

Others

a
a

Name
25 t crane

Qty
1

Assembly procedure

Installation of boom assembly (1/4)

B-5

Removal of cover
1. Remove battery case small cover (1).
aWeight of battery case small cover: 1.72 kg

2. Open AdBlue/DEF cover.

3. Remove the fuel spray prevention cover.

4. Remove AdBlue/DEF cover.


aWeight of AdBlue/DEF cover: 34.98 kg
aWhen removing the cover, take care not to hook
the breather in it.

M12 eyebolts may be


installed to 2 places to
install slings.

No.
1
2
3
4
5
6
7
Precautions

Necessary tools
Name

Qty
1

Small-sized impact wrench

Extension, L: 150

Others

Qty
1
2
1
4
4
1
4

Necessary equipment

Socket, width across flats: 19 mm

39

Parts installed to
machine
208-54-21770
01024-81225
208-54-21881
01034-81225
01643-51232
208-54-21602
01024-81230

Name

Qty

Assembly procedure

Installation of boom assembly (2/4)

B-5
5. Remove the fuel tank front cover.
a Weight of fuel tank: 9.87 kg

6. Install the boom foot pin.


a When you install the boom foot pin, if the
mounting bolts of the filler port bracket and
breather bracket are obstacles, remove
and place them aside.
Filler port bracket mounting bolt: (10), (11)
Breather bracket mounting bolt: (12)

Install
If this is obstacle to installation
of boom foot pin, bent it
around rubber hose.
(Do not remove piping)

Rubber hose
No.
8
9
10
11
12

7. After installing the boom foot pin, install the cover in the reverse order.

Precautions

Necessary tools
Name

Qty
1

Small-sized impact wrench

Extension, L: 150

Others

Qty
1
4
1
2
2

Necessary equipment

Socket, width across flats: 19 mm

40

Parts installed to
machine
2A7-54-11742
01024-81230
01024-81255
01024-81230
01024-81230

Name

Qty

Assembly procedure

Installation of boom assembly (3/4)

B-5

(1) Sling the boom assembly with the crane and match it with the pin holes of the machine.
a Protect the pin from the sling wires.
(2) Install the boom foot pin.
At this time, balance the boom so that it will be in parallel with the pin holes of the machine.
Weight of boom assembly : 4,230 kg
a When slinging boom assembly

(3) Check the clearance in the boom foot all around on the left

side of the chassis, then decide and insert the shim quantity
so that the minimum clearance will be 1 mm or less.
The following adjustment shims are prepared.
(1) (208-70-71611, 3 pieces) t2.0
(2) (208-70-71621, 1 piece) t2.5
(3) (208-70-71631, 1 piece) t3.0
(4) (208-70-71641, 1 piece) t3.5
Assemble these shims to obtain desired thickness.
(Be sure to insert one of (1) on the right side of the machine.)

(Clearance must be
1 mm or less)

(4) Push in the boom foot pin fully and install the lock plate.
a Inside of pin hole and bushing of boom foot bushing: Apply
LM-P (Only 1st time)
[Apply lithium grease for 2nd time and after]
a Check that the pin lock bolt is not loosened but tightened
and check its torque.
Precautions

Dust seals

a For installation of the grease supply hoses, see Step


B-11 "Connesction of grease supply piping of work
equipment".
a For the boom and boom cylinder assembly, see next
page.

Necessary tools
Name

Qty
2

10 3,000 mm wire

Lever block 1.5 t

Large hammer

Socket 30 mm width across flats

Medium-sized impact wrench

41

Loose-supply items
208-70-71611
208-70-71621
208-70-71631
208-70-71641

Qty
3
1
1
1

Necessary equipment

20 5,000 mm wire

Others

a When pushing in the pin, take care not to break the


dust seal installed to the boom foot as shown below.

No.
1
2
3
4

Name
25 t crane

Qty
1

Assembly procedure

B-5

Installation of boom assembly (4/4)

a Installation of boom and boom cylinder assembly


(1) Sling the boom and boom cylinder assembly with the crane and match them with the pin holes of the chassis.
a Protect the pin from the sling wires.
(2) Install the boom foot pin.
At this time, balance the boom so that it will be in parallel with the pin holes of the machine
Weight of boom assembly : 4,950 kg

a When sling the boom


and cylinder assembly

(3) Decide and insert the shim quantity so that the clearance in
the boom foot on the left side of the machine will be 1 mm or
less.
The following adjustment shims are prepared.
(1) (208-70-71611, 3 pieces) t2.0
(2) (208-70-71621, 1 piece) t2.5
(3) (208-70-71631, 1 piece) t3.0
(4) (208-70-71641, 1 piece) t3.5
Assemble these shims to obtain desired thickness.
(Be sure to insert one of (1) on the right side of the machine.)

(Clearance must be
1 mm or less)

(4) Push in the boom foot pin fully and install the lock plate.
a Inside of pin hole and bushing of boom foot bushing: Apply
LM-P (Only 1st time)
[Apply lithium grease for 2nd time and after]
a Check that the pin lock bolt is not loosened but tightened
and check its torque.
Precautions

Dust seals

a For installation of the grease supply hoses, see Step


B-11 "Connesction of grease supply piping of work
equipment".

Necessary tools
Name

Qty
2

10 3,000 mm wire

Lever block 1.5 t

Large hammer

Socket 30 mm width across flats

Medium-sized impact wrench

42

Already installed to chassis


208-70-71611
208-70-71621
208-70-71631
208-70-71641

Qty
3
1
1
1

Necessary equipment

20 5,000 mm wire

Others

a When pushing in the pin, take care not to


break the seals installed to the boom foot as
shown below

No.
1
2
3
4

Name
25 t crane

Qty
1

Assembly procedure

Installation of hoses from chassis along top of boom

B-6

(1) Remove the oil stopping plugs of the tubes on the boom side.
(2) Install arm cylinder hoses (1), (2), (3), and
bucket cylinder hoses (4) (2 pcs.) to the regular circuit as shown below.

a Bleed the arm cylinder of air by following Assembly Procedure B-14


Bleeding Air from Work Equipment Circuit.
a Check that the split flange is not loosened but tightened.
a Check that each O-ring is fitted, has not come off, and is not caught.

Precautions

Name

Qty
2

Socket 14 mm width across flats

Small-sized impact wrench

43

Already installed to
208-62-41661
208-62-41671
208-62-41682
208-62-41642
Loose-supply items
07000-13032

Qty
1
1
1
2
Qty
5

Necessary equipment

Oil container

Others

1. When removing an oil stopper plug from a


hose, slowly loosen its bolts by gradually
releasing the internal hydraulic pressure.
2. Remove and store the flange, O-rings and
heads so that you can reuse them later.
3. When connecting the hoses, take extremely
care not to clinch or damage the O-rings.
4. Also, take extremely care not to enter a foreign
material into the hydraulic circuit.

Necessary tools

No.
1
2
3
4
No.
5

Name

Qty

Assembly procedure

Connection of boom cylinder head

B-7

(1) Remove the stopper plate (2) fixed to the boom, and remove the boom cylinder top pin.
a Boom cylinder: 360 kg / Boom cylinder top pin: 73 kg
(2) Start the engine and rotate it at the low idle speed.
(3) Sling the right cylinder, raise the rod slowly, and match the pin holes while extending and retracting the cylinder.
(4) Knock in the cylinder top pin.
a Inside of pin hole and bushing of boom cylinder bushing: Apply LM-P (Only 1st time)
[Apply lithium grease for 2nd time and after]
(5) Mount fixed the stopper plate and adjusting shims (5), (6).

0.51.5mm
Clearance a

0.51.5mm
Clearance b

No.
1
2
3
4
5
6

Part marked with A (2 points)

Precautions

a
a
a

When operating the cylinder, extend it slowly. Do not


operate the cylinder suddenly and do not operate it to
the end of its stroke. In the first operation, there is an
air in the cylinder and the cylinder may not move for
the first 10 seconds. In such case, do not operate the
control lever to the end of its stroke.
Check the clearance between cover (2) and cylinder
rod all around and combine shims 1 mm thick (20870-71561) and 2 mm thick (208-70-71571) so that
clearance "a" will be 0.5 1.5 mm. (Portions of )
Adjust clearance "b" between the plate and double
nut to 0.5 to 1.5 mm.
(Part marked with A )
Before operating the cylinder, check that the flushing
filter is installed (to capture dirt in the circuit).
For installation of the grease supply hoses, see Step
B-11 "Connesction of grease supply piping of work
equipment".

Necessary tools
Name

Qty

Nylon sling

1
1

Spanner 36 mm width across flats

Large-sized impact wrench

44

Qty
1
2
2
4
4
2

Necessary equipment

Socket 36 mm width across flats

Others

Loose-supply items
208-70-61860
208-70-31242
207-70-13340
01580-12419
208-70-71561
208-70-71571

Name
25 t crane

Qty
1

Assembly procedure

Installation of arm assembly (1/2)

B-8

(1) Remove lock plate (2) of boom top pin (1) fixed to the boom and pull out top pin (1).
(Boom top pin: 54 kg)
(2) Raise the arm assembly, align the position with the boom hole, insert a shim, then push in the pin.
(Arm assembly: For the weight, see the table in "Transportation")
a Seals (07145-00120 2) are installed to the inside of the bushing at the arm end, but be careful no to damage the seals when inserting the pin.
a Inside of pin hole and bushing of arm bushing: Apply LM-P (Only 1st time)
[Apply lithium grease for 2nd time and after]
a Check the clearance all around and combine shims (5), (6), and (7) so that the clearance will be 1 mm or
less (Portion of
).
(3) Install the stopper (2).

Shim thickness
(5) 208-70-71531
(6) 208-70-71541
(7) 208-70-71551

No.
1
2
3
4
5
6
7

a Check that the pin lock bolt is not loosened but tightened and
check its torque.
Precautions

Name

Qty
2

Lever block 1.5 t

Socket 30 mm width across flats

Medium-sized impact wrench

Large hammer

45

Loose-supply items
208-70-71580
208-70-71670
01010-82045
01643-32060
208-70-71531
208-70-71541
208-70-71551

Qty
1
1
2
2
3
1
1

Necessary equipment

Nylon sling

Others

a When pushing in the pin, take care not to break


the dust seal installed to the arm boss as
shown below.

Necessary tools

2.0 mm
2.5 mm
3.0 mm

Name
25 t crane

Qty
1

Assembly procedure

Installation of arm assembly (2/2)

B-8

(4) Remove lock plate (2) of arm cylinder top pin (1) fixed to the arm and pull out top pin (1).
(Arm cylinder top pin: 23 kg)
(5) Start the engine, run at low idle, extend the arm cylinder rod slowly, and align the position of the hole.
When doing this, raise the arm cylinder with a crane and operate the arm cylinder at the same time to align the
position.
(6) Insert shims (4) on both sides and push in arm cylinder top pin (1).
a Inside of pin hole and bushing of arm cylinder bushing: Apply LM-P (Only 1st time)
[Apply lithium grease for 2nd time and after]
(7) Install lock plate (2).
a Operate the cylinder slowly. Do not operate it quickly and do not bring it to the stroke end. Since air gathers
inside the cylinder at the first time, it may not move for aver 10 seconds, but do not move the lever to the
full stroke.
a When installing the arm, extreme caution should be exercised so that the bucket cylinder rod does not jump
out.
a Check that the pin lock bolt is not loosened but tightened and check its torque.

No.
1
2
3
4
Precautions

Name

Qty

Nylon sling

1
1

46

Qty
1
1
2
2

Necessary equipment

Large hammer

Others

a For installation of the grease supply hoses,


see Step B-11 "Connection of grease supply
piping of work equipment".
a When pushing in the pin, take care not to break
the dust seal installed to the cylinder boss.

Necessary tools

Loose-supply items
208-70-61220
205-70-66580
01024-81235
208-70-71651

Name
25 t crane

Qty
1

Assembly procedure

B-9

Installation of bucket cylinder hoses between


boom and bucket cylinder (1/2)

(1) Remove the tube oil plug on the bucket cylinder side on the left side of the arm, install new O-ring (2), and
connect bucket cylinder hose (1).
(2) Remove the tube oil plug on the machine side, install new O-ring (2), and connect bucket cylinder hose (1).
a
a
a
a

Reuse the oil stop parts as the split flange, bolts, etc.
Bleed air from the bucket cylinder. For details, see B-14 "Bleeding air from work equipment circuit".
Check that the split flange is not loosened but tightened.
Check that each O-ring is fitted, has not come off, and is not caught.

PART A

Installation of hose and O-ring

No.
1
2
No.
3
4
Precautions

Name

Qty
2

Socket 14 mm width across flats

Extension L150

Small-sized impact wrench

47

Qty
1
2
Qty
4
8

Necessary equipment

Oil container

Others

1. Keep the oil plugs used for component so that


they can be reused.
2. When installing the hose take extreme care
not to catch the O-ring.
3. When installing the hoses, take extreme care
not to twist them.
(Tighten from the 90 adapter to prevent
twisting.)
4. While installing the hose, take extreme care
not to allow dirt in the circuit.

Necessary tools

Loose-supply items
207-62-54680
07000-13032
Already installed to
07371-31049
07375-21035

Name

Qty

Assembly procedure

B-9

Installation of bucket cylinder hoses between


boom and bucket cylinder (2/2)

(3) Similarly, connect bucket cylinder hose (1) on the right side of the arm.

PART B
No.
1
2
No.
3
4
Precautions

Name

Qty
2

Socket 14 mm width across flats

Extension L150

Small-sized impact wrench

Ring wrench 14 mm width across


flats

48

Qty
1
2
Qty
4
8

Necessary equipment

Oil container

Others

1. Keep the oil plugs used for component so that


they can be reused.
2. When installing the hose take extreme care
not to catch the O-ring.
3. When installing the hoses, take extreme care
not to twist them.
(Tighten from the 90 adapter to prevent
twisting.)
4. While installing the hose, take extreme care
not to allow dirt in the circuit.

Necessary tools

Loose-supply items
207-62-54680
07000-13032
Already installed to
07371-31049
07375-21035

Name

Qty

Assembly procedure

Installation of bucket assembly (1/3)

B-10

[Preparation for installation]


1. Remove the stoppers of the bucket-arm connecting pin (fixed to the arm) and bucket-link connecting pin (fixed
to the link), and remove those pins.
2. Lightly install bushing (1) to the boss on the bucket side, and install O-rings (2) to the places shown below.
a Apply LM-P (1st time only) to the inside surface of the bushing (apply lithium grease at the 2nd time and
after).

O-ring position

[Installation]
3. Run the engine at low idle and operate the boom cylinder and arm cylinder slowly to set the holes for the bucket
and arm connecting pin.
a Weight of bucket assembly: For the weight, see the packing style table for transportation.
4. Install the arm-bucket connecting pin and the lock bolt and nut for the pin, without inserting shim.

No.
1
2
Precautions

Necessary tools
Name

Qty
1

Sledge hammer

Socket, width across flats: 36 mm

Spanner, width across flats: 36 mm

Ring spanner, width across flats: 36 mm

Large-sized impact wrench

Torque wrench: 85 kgm

Others

Qty
1
2

Necessary equipment

Nylon sling

49

Loose-supply items
208-70-34230
208-70-33181

Name
25t crane

Qty
1

Assembly procedure

Installation of bucket (2/3)

B-10

[Adjustment of shim]
5. Lightly tighten the stopper bolt (M24), measure clearance "a", and then decide the number of shims so that
their total thickness is the measured value +0.5 to +1.0 mm.
a Measure when there is no clearance on both sides of the arm end.

O-ring position

Clearance "a"

6. Install shims (1) and (2).

7. Lightly tighten the stopper bolt (M24), check clearance "b" between the arm and bushing is 0.5 to 1.0 mm all
round, and then install the O-rings to the correct positions (both sides of arm end).
O-ring

Correct position of O-ring

Clearance "b"
(0.5 to 1.0 mm)
No.
1
2

8. Install lock bolt.


Precautions

Necessary tools
Name

Qty
1

Socket, width across flats: 36 mm

Spanner, width across flats: 36 mm

Ring spanner, width across flats: 36 mm

Large-sized impact wrench

Torque wrench: 85 kgm

50

Qty
18
4

Necessary equipment

Sledge hammer

Others

When tightening, adjust the clearance


between the double nut and stopper to 0.5 to
1.5 mm. (Clearance marked with *)

Loose-supply items
208-70-34250
208-70-34260

Name

Qty

Assembly procedure

Installation of bucket (3/3)

B-10

[Installation of link]
9. Fit O-ring (1) to prevent entry of soil and sand.
10. While operating the bucket cylinder, align the holes for the bucket-link connecting pin.
a Operate the cylinder slowly. Do not operate it quickly or to the stroke end. In the first operation, there is an
air in the cylinder and the cylinder may not move for the first 10 seconds. In such case, do not operate the
control lever to the end of its stroke.
11. Push in the link-bucket connecting pin, install O-rings (1) to the correct positions to prevent entry of dirt, and
then install the pin stopper.

Correct position of O-ring

No.
1
Precautions

Necessary tools
Name

Qty
1

Socket, width across flats: 36 mm

Spanner, width across flats: 36 mm

Ring spanner, width across flats: 36 mm

Large-sized impact wrench

Torque wrench: 85 kgm

51

Qty
2

Necessary equipment

Sledge hammer

Others

When tightening, adjust the clearance


between the double nut and stopper to 0.5 to
1.5 mm. (Clearance marked with *)

Loose-supply items
207-70-33181

Name

Qty

Assembly procedure

B-11

Connection of work equipment grease piping (1/2)

(1) Remove the oil stopper plug at the cylinder end and the oil stopper plug at the hose nipple end, remove the
nipple from the hose, then assemble the boom cylinder greasing hoses (2 places) at porting (a) to the cylinder
end, and connect.
(2) Remove the oil stopper plug at the cylinder end and the oil stopper plug at the hose elbow end, remove the
elbow from the hose, then assemble the arm cylinder bottom greasing hose at porting (b) to the cylinder end,
and connect.
(3) Remove the oil stopper plug at the cylinder end and the oil stopper plug at the hose elbow end, remove the
elbow from the hose, then assemble the arm cylinder top greasing hose at porting (c) to the cylinder end, and
connect.

Tightening torque of hose


5.9 to 11.8 Nm (0.6 to 1.2 kgm)

(2places)

No.
1
Precautions

Qty

Spanner 19 mm width across flats

52

Qty
2

Necessary equipment

Name

Others

a After installing the boom and boom cylinder,


supply grease to parts (a) and (b), and then install the arm.
a After installing the arm, supply grease to part
(c), and then install the bucket.

Necessary tools

Loose-supply items
205-70-51390

Name

Qty

Assembly procedure

B-11

Connection of work equipment grease piping (2/2)

Tightening torque of hose


5.9 to 11.8 Nm (0.6 to 1.2 kgm)

PART

PART

Precautions

No.
1
2
3

Necessary tools
Qty

Spanner 19 mm width across flats

Others

Qty
1
1
1

Necessary equipment

Name

53

Loose-supply items
205-70-51390
205-70-51380
208-70-65770

Name

Qty

Assembly procedure

Connection of work equipment wiring (1/2)

B-12

(1) Install working lamp (1) and bracket (2).


a Working lamp nut tighteing torque: 17.6 to 19.6 Nm (1.8 to 2.0 kgm)
(2) Connect connector (a) (CN-L01) of the working lamp wire to the body wiring harness.

No.
1
2
3
4
5
6

PART A

Precautions

Necessary tools
Qty

Spanner 22 mm width across flats

Socket 19 mm width across flats

Small-sized impact wrench

Others

Qty
1
1
1
1
1
1

Necessary equipment

Name

54

Loose-supply items
20Y-06-43230
20Y-06-21551
01010-81430
01643-31445
08193-20012
01024-81220

Name

Qty

Assembly procedure

B-12

Connection of work equipment wiring (2/2)

(3) Connect connector (b) (CN-A13) of the boom wiring harness to the body wiring harness.
a Pass the wiring under the grease tube.

PART B

No.
1
2

Precautions

Necessary tools
Name

Qty
1

Small-sized impact wrench

Others

Qty
1
1

Necessary equipment

Socket 19 mm width across flats

55

Loose-supply items
04434-51012
01024-81225

Name

Qty

Assembly procedure

B-13

Greasing after completion of work equipment

(1) Supply grease to each part.


Use grease LM-G.
1) Boom cylinder foot pin (2 places)
2) Boom foot pin (2 places)
3) Arm and link connecting pin (1 place)
4) Arm and bucket connecting pin (1 place)
5) Link connecting pin (2 places)
6) Bucket cylinder rod end (1 place)
7) Bucket and link connecting pin (1 place)
8) Boom cylinder rod end (2 places)
9) Arm cylinder foot pin (1 place)
10)Boom and arm connecting pin (1 place)
11)Arm cylinder rod end (1 place)
12)Bucket cylinder foot pin (1 place)
Note 1 : Slowly move the boom up and down 3 to 4 times, and then supply LM-G through the fittings.
Note 2 : When assembly, take care extremely that dirt, rust, flaw, etc. will not cause trouble.
Be sure to perform Notes 1 which are important for prevention of galling of the pins.

Precautions

Necessary tools
Name

Necessary equipment
Qty

Name

Others

Grease pump

56

Qty
1

Assembly procedure

B-14

Bleeding air from work equipment circuit

After assembling the work equipment piping, bleed the air from it.
(1) Run the engine at low idle.
(2) Move each clinder to about 100 mm before each stroke end 4 - 5 times.
(3) Keeping the engine speed at low idle, move each cylinder from the point of 100 mm before the stroke end to
the stroke end very slowly (taking at least 10 seconds), and then keep the work equipment control lever at the
stroke end for 3 minutes.
[Bleed the air from the boom cylinder, arm cylinder, and bucket cylinder at the extraction stroke end.]
aThe cylinder may not start for more than 10 seconds at first because of the much air in the circuit. Do not
move the lever to the stroke end at this time.
aIf the engine speed is heightened or each cylinder is moved to the stroke end from the first, the piston packing
may be damaged by the air in the cylinder.
aEach time air is bled from each cylinder, retract the cylinder to the stroke end and check the sight gauge of
the hydraulic tank. If the oil level is below L-level, add hydraulic oil through the oil filler port.

Precautions

Necessary tools
Name

Others

a Before operating the cylinder, check that the


flushing filter is installed (to capture dirt in the
circuit).
a After the assembly work is completed, perform
the final check of the hydraulic tank oil level referring to the Assembly procedure M-5 "Inspection of oil level in hydraulic tank and refill".

57

Necessary equipment
Qty

Name

Qty

C. INCREASING AND DECREASING OF TRACK FRAME GAUGE,


ASSEMBLING OF COUNTERWEIGHT

59

Assembly procedure

Increasing and decreasing of track frame gauge (1/6)

C-1

Increasing of track frame gauge (1/3)


(1) Remove front and rear center frame mounting bolts (1) and colors (2) on the side to be extended. (4
pieces each at the front and rear)

(2) Swing the upper structure to a right angle to crawler frame (3) to be extended, connect bucket (4) and
crawler frame (3) to be extended by chain block (5), and raise crawler frame (3) by using the work
equipment.
(two pieces at both ends of crawler frame)
Tooth side

Precautions

Name

Necessary equipment
Qty

10 3,000 mm wire

20 5,000 mm wire

Socket 46 mm width across flats

Lever block 3 ton

Others

a Limit the raising height (H) of the crawler frame


to 20 mm.
(If the crawler frame is raised too high, the
stopper bolt will be pried and bent.)
a When pulling the crawler frames with the lever
blocks, pull them so that the wires will be as
level as possible.
a When decreasing the gauge, see C-1 Decreasing of track frame gauge (4/6) to (6/6).

Necessary tools

60

Crawler side

Name

Qty

Assembly procedure

Increasing and decreasing of track frame gauge (2/6)

C-1

Increasing of track frame gauge (2/3)


(3) Extend crawler frame (3) until it reaches stopper (6), lower the machine slowly to the ground, and
install bolts (1) and collars (2) (9 pieces each at the front and rear).

Tightening torque: 1,520 to 1,910 Nm (155 to 195 kgm)

a Install the bolts of the four positions marked with


the base of those bolts.

first, since other bolts are installed on

No.
1
2

(4) Work on the crawler frame on the opposite side similarly.


Precautions

Necessary tools
Name

Qty
1

Torque wrench (420 kgm)

Others

Qty
20
20

Necessary equipment

Socket 46 mm width across flats

61

Loose-supply items
208-30-12130
208-30-41390

Name

Qty

Assembly procedure

Increasing and decreasing of track frame gauge (3/6)

C-1

Increasing of track frame gauge (3/3)

Wooden block

a When tightening the bolts, raise the track shoe by the level portion with jacks or wooden blocks as
shown above to secure a space for the tightening work.

Precautions

Name

Necessary equipment
Qty

5 t Hydraulic jack

Torque wrench 420 kgm

Wooden block 400 200 mm

Others

Do not remove the shoe during the above


work.
(For securing the tightening torque of the
shoe bolts.)
Each collar must not ride over the spot facing.

Necessary tools

62

Name

Qty

Assembly procedure

Increasing and decreasing of track frame gauge (4/6)

C-1

Decreasing of track frame gauge (1/3)


(1) Remove front and rear center frame mounting bolts (1) on the side to be retracted. (9 pieces each
at the front and rear)

(2) Swing the upper structure to a right angle to crawler frame (2) to be retracted, connect right and
left crawler frames (2) and (3) by chain block (4), and raise crawler frame (2) by using the work
equipment and pull it with chain block (4) to decrease the gauge.

Precautions

Necessary tools
Name

Others

Limit the raising height (H) of the crawler


frame to 50 mm.
(If the crawler frame is raised too high, the
stopper bolt will be pried and bent.)

63

Necessary equipment
Qty

Name

Qty

Assembly procedure

Increasing and decreasing of track frame gauge (5/6)

C-1

Decreasing of track frame gauge (2/3)


(3) Retract crawler frame (2) until it reaches stopper (5), lower the machine slowly to the ground, and
install bolts (1) and collars (2) (4 pieces each at the front and rear).

Tightening torque: 1,520 to 1,910 Nm (155 to 195 kgm)

Guide plate

(4) Work on the crawler frame on the opposite side similarly.

Precautions

Necessary tools
Name

Others

a When decreasing the gauge, loosen the track.


(Loosening quantity is 30 to 50 mm. See
Step C-4, "Adjustment of track tension".)
After increasing the gauge, tense the
track.
(To prevent wear of the guide plate.)
a When decreasing the gauge, do not travel the
machine for a long time.

64

Necessary equipment
Qty

Name

Qty

Assembly procedure

Increasing and decreasing of track frame gauge (6/6)

C-1

Decreasing of track frame gauge (3/3)

Wooden block

a When tightening the bolts, raise the track shoe by the level portion with jacks or wooden blocks as
shown above to secure a space for the tightening work.

Precautions

Necessary tools
Name

Others

Do not remove the shoe during the above work.


(For securing the tightening torque of the
shoe bolts.)
Each collar must not ride over the spot facing.

65

Necessary equipment
Qty

Name

Qty

Assembly procedure

Installation of steps

C-2

Using bolts and washers (3) and (4), install steps (1) and (2) to the 4 places at the front, rear, right, and left
of the track frame.

a When assembling, eliminate


clearance in steps (1) and (2).
(All places)

No.
1
2
3
4
Precautions

Name

Qty
1

Medium-sized impact wrench

66

Qty
4
4
32
32

Necessary equipment

Socket 24 mm width across flats

Others

a If any clearance is made, the bolts are broken


easily when the lower step is deformed.

Necessary tools

Loose-supply items
208-30-41611
208-30-41621
01010-81640
01643-31645

Name

Qty

Assembly procedure

Installation of travel piping covers (1/4)

C-3

(1) Installation of left travel piping cover

No.
1
2
3
4
5
6
Precautions

Name

Qty
1

Medium-sized impact wrench

67

Qty
1
3
3
1
4
4

Necessary equipment

Socket 24 mm width across flats

Others

a Install all the covers (both right and left ones)


temporarily and adjust the clearance and level
difference, and then tighten them permanently.

Necessary tools

Loose-supply items
208-30-41311
01643-31645
01010-81635
208-30-75351
418-18-31160
01010-81635

Name

Qty

Assembly procedure

Installation of travel piping covers (2/4)

C-3

(2) Installation of left travel piping cover

No.
1
2
3
4
5
6
Precautions

Name

Qty
1

Medium-sized impact wrench

68

Qty
1
2
2
1
4
4

Necessary equipment

Socket 24 mm width across flats

Others

a Clearances "a" and "b" in the cover must be


the same on the right and left sides.

Necessary tools

Loose-supply items
208-30-75332
01643-31645
01010-81640
208-30-58230
01643-31645
01010-81635

Name

Qty

Assembly procedure

Installation of travel piping covers (3/4)

C-3

(3) Installation of right travel piping cover

No.
1
2
3
4
5
6
Precautions

Necessary tools
Name

Qty
1

Medium-sized impact wrench

Others

Qty
1
3
3
1
4
4

Necessary equipment

Socket 24 mm width across flats

69

Loose-supply items
208-30-41321
01643-31645
01010-81635
208-30-75361
418-18-31160
01010-81635

Name

Qty

Assembly procedure

Installation of travel piping covers (4/4)

C-3

(4) Installation of right travel piping cover

No.
1
2
3
4
5
6
Precautions

Name

Qty
1

Medium-sized impact wrench

70

Qty
1
2
2
1
4
4

Necessary equipment

Socket 24 mm width across flats

Others

a Clearances "a" and "b" in the cover must be


the same on the right and left sides.

Necessary tools

Loose-supply items
208-30-75342
01643-31645
01010-81640
208-30-58230
01643-31645
01010-81635

Name

Qty

Assembly procedure

Adjustment of track tension (1/3)

C-4
Testing and adjusting track tension
k Warning

This work must be done by 2 persons. The operator


shall move the machine according to the signs from the
worker.
Since the wear condition of the pins and bushings of the
undercarriage varies with the working condition and soil
type, check the track tension occasionally and keep it at
the standard.
Test and adjust the track tension on a level and hard
place.
Testing
(1) Stop the machine on a level and firm place.
(2) Place a rectangular bar (3) which is longer than
the distance between idler (1) and carrier roller
(2) on the track.
(3) Measure the maximum slack between the top of
the track and the underside of the rectangular
bar.
Standard slack
If slack "a" is 16 to 34 mm, it is normal.

a When delivered, the slack is set to 30 to 50 mm


so that the gauge can be extended easily.

Precautions

Necessary tools

Others

Name

71

Necessary equipment
Qty

Name

Qty

Assembly procedure

Adjustment of track tension (2/3)

C-4

If the track tension is out of the standard, adjust it according to the following procedure.
Adjusting

k Warning

Do not loosen the plug more than 1 turn. If it is loosened


more, it may jump out because of the internal high-pressure grease.
At this time, do not loosen any part other than the plug.
Do not direct your face in the installed direction of the
plug.

Increasing track tension


(1) Add grease through plug (1) with the grease
pump.
(2) Move the machine forward and backward to
check that the track tension is proper.
(3) Check the track tension again. If it is not proper,
adjust it again.
(4) You may supply grease until (S) is 0 mm. If the
tension is still low, the pin and bushing are worn
excessively. In this case, turn over or replace the
pin and bushing. Consult your Komatsu distributor.

Precautions

Necessary tools
Name

Necessary equipment
Qty

Name

Others

Grease pump

72

Qty
1

Assembly procedure

Adjustment of track tension (3/3)

C-4
Decreasing track tension
k Warning

It is very dangerous to discharge grease by a method


other than the following procedure.

(1) Loosen plug (1) slowly to discharge the grease.


(2) Do not loosen the plug (1) more than 1 turn.
(3) If the grease does not come out, move the machine back and forward a little.
(4) Tighten plug (1).
(5) Move the machine forward and backward to
check that the track tension is proper.
(6) Check the track tension again. If it is not proper,
adjust it again.

Precautions

Necessary tools
Name

Necessary equipment
Qty
1

Extension L150

Others

Socket 19 mm width across flats

73

Name

Qty

Assembly procedure

Sticking sheet to counterweight

C-5

Stick the seats to the front side of the counterweight as shown below.
When sticking seats (1), (2), (3), (4), and (5), direct the faces having no black cover down.

Direct the faces having no black


cover down.
No.
1
2
3
4
5

Precautions

Necessary tools
Name

Others

Remove all oil and rust from the surface


where the sheet is to be stuck.

74

Loose-supply items
208-46-41711
208-46-41721
208-46-41731
208-46-41741
208-46-41761

Qty
1
1
1
1
1

Necessary equipment
Qty

Name

Qty

Assembly procedure

Installation of camera (1/6)

C-6

(1) Pass wiring harness (1) through the hole of the counterweight.

No.
1
Precautions

Necessary tools

Others

Name

75

Loose-supply items
208-06-24230

Qty
1

Necessary equipment
Qty

Name

Qty

Assembly procedure

Installation of camera (2/6)

C-6

(2) Connect connector (CN-A45) as shown below and install camera A (1) with bolts (2).

Face A
Match line of camera with angle of bracket
Top of camera must be in parallel with face A

No.
1
2

Precautions

Necessary tools

Others

Name

76

Loose-supply items
Camera A.
01024-81025

Qty
1
2

Necessary equipment
Qty

Name

Qty

Assembly procedure

Installation of camera (3/6)

C-6
(4) Install cover (1) as shown below.

Adjust shim (2) so that marked


clearance difference will be 2 mm
max. at points a, b, and c.

No.
1
2
3
Precautions

Necessary tools

Others

Name

77

Loose-supply items
2A5-06-11821
2A5-06-12240
01024-80616

Qty
1
3
2

Necessary equipment
Qty

Name

Qty

Assembly procedure

Installation of camera (4/6)

C-6
(5) Install cover (1) as shown below.

No.
1
Precautions

Necessary tools

Others

Name

78

Loose-supply items
207-06-76451

Qty
1

Necessary equipment
Qty

Name

Qty

Assembly procedure

Installation of camera (5/6)

C-6

(6) Remove the double-sided adhesive tape and stick seat (1) as shown below.
Then, connect the clips on the wiring harness side and counterweight side (6 places).

Install clips (6 places)


5 places at : Counterweight
1 place at u: Machine frame

No.
1
Precautions

Necessary tools

Others

Name

79

Loose-supply items
2A5-06-11860

Qty
1

Necessary equipment
Qty

Name

Qty

Assembly procedure

Installation of camera (6/6)

C-6

After installing, watch the monitor screen and check "how the counterweight is displayed".

"Monitor screen"

"If dimension L is out of the following range, adjust the installed angle of
the camera"
L: Must be in range from 4.5 to 13 mm

Precautions

Necessary tools

Others

Name

80

Counterweight

Necessary equipment
Qty

Name

Qty

Assembly procedure

C-7

Installation of counterweight (1/3)

(1) Sling counterweight assembly (1) and install it to the machine.


(2) Install by using mounting bolts (2) (4 pieces) and washers (3) (4 pieces).
Lightly tighten the bolts with a hand wrench or a small-sized impact
wrench until each installation face of the counterweight is seated,
and then tighten them to the specified torque.
a Check that the bolts are not loosened but tightened and check their torque.
Weight of counterweight assembly : 9,570 kg

Tightening torque:
3430 to 4212 Nm
(350 to 430 kgm)
Since these are important bolts, tighten them to
the center value of the specified torque range.
Center value of tightening torque:
3,820 Nm (390 kgm)

a Parts (4) are shims for adjusting


clearance and level difference
208-46-52260: 1 mm thick
208-46-52270: 0.5mm thick

No.
2
3
4

Precautions
a Do not insert any shim basically for adjusting
clearance or level difference.
If adjustment is necessary observe the following.
a) Adjust by inserting a shim only in the
backward and forward directions.
Example: No shim in both front holes and
shims 1 mm thick in both rear holes.
b) Limit the adjustment quantity with shim to 2
mm.

Necessary tools
Name

Qty
2

Shackle SD32

Socket 65 mm width across flats

Large-sized impact wrench

Torque wrench 420 kgm

Others

a Dimension of hanging hole of counterweight


42 mm

81

Qty
4
4
4
4

Necessary equipment

30 3,000 mm wire

a For adjustment after assembling the counterweight, see 3/3.

Loose-supply items
208-46-41610
01643-34212
208-46-52260
208-46-52270

Name
25 t crane

Qty
1

Assembly procedure

Installation of counterweight (2/3)

C-7

(3) When installing the counterweight to the machine, take care not to catch the wiring harness of the rear view
monitoring camera.
After installing, install harness clips (one place at u) and connect connector (CN-A40).

a Take care not to catch


wiring harness of rear
view monitoring camera

Connector (CN-A40)

Precautions

Necessary tools
Name

Others

a When installing, do not enter between the


revolving frame and counterweight but
open the left door and check that the wiring is not caught.

82

Necessary equipment
Qty

Name

Qty

Assembly procedure

Installation of counterweight (3/3)

C-7

(4) Adjustment method of assembled counterweight


a) Clearance to revolving frame must be 10 5 mm on both right and left sides.
b) Level difference from revolving frame must be 5mm or less on both right and left sides.
c) Clearance to exterior door must be 10 5 mm on both right and left sides.
d) Level difference from exterior door must be 8 4mm or less on both right and left sides.
e) Level difference from top of exterior door must be 5mm or less on both right and left sides.

Left door
Left door side

Level difference: 8 4 mm
(Difference between points T and S: 0 to 4 mm)
Level difference "e":
0 to 5 mm

Counterweight

Clearance "c": 10 5 mm
(Difference between points T and S: 0 to 3 mm)

Counterweight
Level difference "d":
8 4mm

Counterweight

Level difference "b":


0 to 5 mm

Right door

Clearance "a": 10 5 mm

Right door side

Counterweight
Level difference "b": 0 to 5 mm

Precautions

Necessary tools

Others

Name

83

Necessary equipment
Qty

Name

Qty

M. PROCEDURE FOR INSPECTION AND MAINTENANCE AFTER


COMPLETION OF ASSEMBLY

85

Assembly procedure

Replacement of return filter


(Standard filter to flushing filter)

M-1

Replace the hydraulic oil return filter element, valve and strainer of standard items
with hydraulic oil flushing element (1) and plate (2).
a When replacing the element, take out the element slowly so that refuses adhered to the element do not fall inside. Also, take out refuses by
hand from the case

Replace the relief valve with this


plate only at the flushing time.

Replacement

Special element for flushing,


Absolute filter mesh size: 6 m

No.
1
2
Precautions

Necessary tools
Name

Others

a Store the removed standard element


(208-60-71123), strainer (07069-25400) and
valve (208-60-71160) in order because they
are used again after flushing.
a Replace before starting the assembly work.
(To capture dirt during the hose connecting
work and in the work equipment circuit)

86

Loose-supply items
208-60-71170
21T-60-13730

Qty
1
1

Necessary equipment
Qty

Name

Qty

Assembly procedure

Flushing of hydraulic circuit (1/2)

M-2

After completion of assembling flush the hydrau


lic circuit as follows:
a Run the engine at low idle (at the minimum throttle)
with the levers in neutral for 15 minutes, and then
perform the following.
(1) Flushing of Work Equipment Pipes
Extend and contract each cylinder for several
minutes without reaching them to the stroke end.
(a) Extension and contraction of bucket cylinder
for 5 minutes

(b) Extension and contraction of arm cylinder for 5


minutes.

(c)

Extension and contraction of boom cylinder for


5 minutes

Precautions

Necessary tools
Name

Others

Full operation may damage the filter element


since the relief valve of the filter is closed.

87

Necessary equipment
Qty

Name

Qty

Assembly procedure

Flushing of hydraulic circuit (2/2)

M-2

(2) Flushing of Swing Circult


Right swing and left swing for 3 minutes each

(3) Flushing of Travel Circuit

Press the ground with the work equipment


as illustrated here to raise one side of the
machine, and operate the travel lever as folows:

Forward travel and backward travel to the right


For 3 minutes each

Forward travel and backward travel to the left


For 3 minutes each

(4) Check
After finishing flushing, replace the flushing filter with the standard one according to "Replacement of return
filter (2/2)".
At this time, check that the dirt captured in the flushing element has no problem. If the dirt seems to have
problem, consult your Komatsu distributor.

Precautions

Necessary tools

Others

Name

88

Necessary equipment
Qty

Name

Qty

Assembly procedure

M-3

Replacement of return filter


(Flushing filter to standard filter) (1/2)

Reassemble hydraulic oil return filter element (1), strainer (2) and valve (3) which you have removed in the previous step.
a When replacing the element, take out the element slowly so that refuses adhered to the element do not fall inside. Also, take out refuses by
hand from the case

Replacement
Valve (3)

Valve (2)
Standard element (1)

Precautions

Necessary tools

Others

Name

89

Necessary equipment
Qty

Name

Qty

Assembly procedure

Replacement of return filter


(Flushing filter to standard filter) (2/2)

M-3
State of inserted element

Element

Fig. 1 Correct state

Do not insert the element so that it stands on the step at the bottom of the case as shown in Fig.
2.When the filter case is filled with oil, it is difficult to check if the element is inserted correctly,
so turn the element by hand after inserting it in the case. When it turns smoothly, it is considered
to be inserted correctly.

Precautions

Necessary tools
Name

Others

Fig. 2 Incorrect state

90

Necessary equipment
Qty

Name

Qty

Assembly procedure

M-4

Check of oil/coolant level at each part (1/2)

a For details of the notes (Note 1, 2, 3, 4, 5, 6) in the table, see the "Operation and Maintenance Manual".
For details of the recommended genuine oil, see the "Operation and Maintenance Manual", too.

91

Assembly procedure

Check of oil/coolant level at each part (2/2)

M-4

Engine
oil pan

Final
drive case
Swing
(Each of
machinery case right and
left)

Damper
case

Hydraulic
oil system

Cooling
system

Fuel tank

AdBlue
/DEF

Specified capacity (l)

42

20

11

1.6

472

44

650

60

Refill capacity
(l)

38

20

11

1.6

248

44

Decide the mixing proportion of the coolant to the water according to the past minimum temperature and the
following mixing proportion table.
Actually, set the proportion for a temperature about 10 C lower than the past minimum temperature.
Mixing proportion of water and coolant
Min. temperature
(C)

Above
-10

-15

-20

-25

-30

-35

-40

Coolant

13.2

15.8

18.0

20.2

22.0

23.8

25.5

Water

30.8

28.2

26.0

23.8

22.0

20.2

18.5

Quantity
(l)

k Waring
Coolant is flammable. So keep it away from
open flame.
Use city water to dilute.
Adjust the control proportion by using an antifreeze concentration meter.
k Waring
When removing the drain plug, take care that
the coolant and water mixture will not be
splashed over you.

Precautions

Necessary tools
Name

Others

When the machine is delivered, it is filled with


Supercoolant (blue) containing no amine. Do
not add coolant of different type.

92

Necessary equipment
Qty

Name

Qty

Assembly procedure

Inspection of oil level in hydraulic tank and refill (1/2)

M-5

Inspection of oil level in hydraulic tank and refill

k Warning

When removing the cap from the oil filler port,


turn it slowly to relieve the internal pressure so
that the oil will not burst out.

(1) If the machine is not in the state illustrated here,


start the engine, rotate it at a low speed, reduce
the arm and the bucket cylinder, lower the boom
slowly so that the bucket teeth touch the
ground, and then stop the engine.
(2) Set the start switch to the ON position with in 5
to 6 seconds after stopping the engine and set
each control lever (work equipment and travel)
to the full stroke in each direction to relieve internal pressure.
(3) Open the door on the left side of the machine
and check the sight gauge (G). When the oil level is between the H and L lines, the level is appropriate.
(4) When the oil level is below the L Iine, supply oil
through the oil filter port (F).
For applicable oil, "Check of oil/coolant level at
each part M-4 ".
Notice:
Do not supply oil, beyond the H line, but the hydraulic circuit may be damaged or oil may burst out.

Precautions

Necessary tools

Others

Name

93

Necessary equipment
Qty

Name

Qty

Assembly procedure

Inspection of oil level in hydraulic tank and refill(2/2)

M-5

k Warning

If the oil level is higher than level H, stop


the engine, wait until the hydraulic oil
cools down, and then remove undercover (1) or (2) and drain excessive oil
through drain plug (P) or (A).After draining the oil, tighten the drain plug and
install the undercover.

Supplementary Explanation:
Since the oil level changes as the oil temperature
changes, check the oil level noting the following
as guides:

The oil level shall be around the L level before


operation (when the oil temperature ranges
from 10 to 30C).

The oil level shall be around the H level during


normal operation (when the oil temperature
ranges from 50 to 80C).

Precautions

Necessary tools

Others

Name

94

Necessary equipment
Qty

Name

Qty

Assembly procedure

M-6

Parts to be touched up after field assembly

After assembling the large-sized hydraulic excavator in the field, touch up the following parts.
(1) Underside of front and rear of boom

(2) Underside of arm

(3) Underside of counterweight

(4) Underside of bucket

(5) Track frame (Flaws made during increasing/


decreasing of gauge, unpainted parts)

(Right and left sides, 4 places in total)

When the machine is used on the seashore, etc. where it is rusted easily, touch up the following
parts, too.
Unpainted parts of machined surfaces of flanges after installing piping Grease tubes
Metallic hose bands, etc.
Use rust-prevent clear paint for touching up the machined surfaces, etc.
(Recommended brand: KOMATSU genuine rust-preventive clear paint)

Precautions

Necessary tools

Others

Name

95

Necessary equipment
Qty

Name

Qty

Assembly procedure

Error code

M-7

Turn the key switch to the ON position and check that no error code is displayed on the monitor.
If any error code is displayed, consult your Komatsu distributor.

96

Mounting bolt torque check sheet

Arm cylinder lock plate


Boom top lock plate
Tightening torque: M12 98 to 123 Nm {10 to 12.5 kgm}
M20 455 to 565 Nm {46.5 to 58 kgm}

No.

Bolt size: M12


Torque

No.

97

Bolt size: M20


Torque

Mounting bolt torque check sheet

Boom foot lock plate


Tightening torque: M20 455 to 565 Nm {46.5 to 58 kgm}

No.

Torque

1
2

98

Mounting bolt torque check sheet

Boom cylinder bottom lock plate


Tightening torque: M12 98 to 123 Nm {10 to 12.5 kgm}

No.

Right side of chassis


Torque

No.

99

Left side of chassis


Torque

Mounting bolt torque check sheet

Counterweight mounting bolt


Tightening torque: 3,430 to 4,212 Nm {350 to 430 kgm}
Since these are important bolts, tighten them to the center value of the specified torque range.
Center value of tightening torque: 3,820 Nm (390 kgm)

No.

Torque

1
2
3
4

100

Mounting bolt torque check sheet

Center frame x crawler frame


Tightening torque: 1,520 to 1,910 Nm {155 to 195 kgm}

Front of chassis

Left of chassis

Right of chassis

Rear of chassis

No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18

Right side of chassis


Torque

No.
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36

101

Left side of chassis


Torque

Revision

Category

4/13

Check item

Local After
assembly hours of
time
operation

Judgement standard

Monitor display
1. Check of monitor function
When the starting switch is turned ON, the gauges,
CHECK items, and all display items on the monitor should
light up. At the same the alarm buzzer should sound.
2. Check of gauges and CHECK items
When starting switch is turned to ON (all lamps on), all
display lamps should go out after approx. 3 sec.
For another 2 seconds, only the gauges are displayed,
and the CHECK and monitor items disappear.
3. Check of monitor items
After starting the engine, the caution lamps should not
light up and the alarm buzzer should not sound when the
engine speed is low idling high idling.

As per left

Operation of service meter

There should be no scratches or misting


of the lens or variation in operation.

MONITOR

Check monitor

Ordinal display

Display of meter only

(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
(28)
(29)
(30)
(31)
(32)
(33)
(34)
(35)
(36)
(37)
(38)
(39)
(40)

Wiper switch
Buzzer cancel switch
Auto-deceleration switch
Service meter, Clock
ECO gauge
Camera direction monitor
Hydraulic oil temperature gauge
Hydraulic oil temperature monitor
Engine coolant temperature gauge
Engine coolant temperature monitor
Fuel gauge
Fuel level monitor
Ad/Blue/DEF level gauge
Ad/Blue/DEF level monitor
Fuel consumption gauge
Working mode selector switch
Travel speed selector switch
Window washer switch
Air conditioner control switches
Seatbelt fixing monitor
Engine stop monitor
Lock lever monitor
KDPF regeneration monitor
KDPF regeneration stop monitor
Message monitor
Air conditioner monitor
Wiper monitor
Swing lock monitor
Engine pre-heating monitor or
One-touch power max. monitor
Auto-deceleration monitor
Working mode monitor
Travel speed monitor
Radiator coolant level monitor
Air cleaner clogging monitor
Engine oil level monitor
Charge level monitor
Ad/Blue/DEF system monitor
Engine oil pressure monitor
Function switches (F1 to F6)
Maintenance interval monitor

Check of switches, control levers

Revision

Category

5/13

Check item

(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)

Radio
Lock lever
Left work equipment control lever
One-touch power max. switch
Travel pedals
Travel levers
Horn switch
Machine monitor
Right work equipment control lever
Starting switch
Fuel control dial
Lamp switch
Swing lock switch

Local After
assembly hours of
time
operation

(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)

Judgement standard

Machine push-up switch


Ceiling window wiper switch (if equipped)
Revolving warning lamp switch (if equipped)
Attachment control pedal (if equipped)
Attachment control pedal (if equipped)
Cigarette lighter
Room lamp switch
Heated seat switch (if equipped)
Engine shut down secondary switch
Secondary pump drive switch
Swing brake cancel switch
Lock lever auto release switch

Operation of horn switch

If the switch is pushed, the horn sounds.

Operation of lock lever

Push down the lever to apply the lock.


Engine can be started but all work
equipment control levers do not move.
Push up the lever to release the lock.
Engine cannot be started but all work
equipment levers move.
MAX: Full speed
MIN: Low idle

Operation of fuel control dial

Revision

Category

6/13

Check item

Judgement standard

Operation of working mode selector switch

Lighting of P: For heavy load work


(ATT/P)
Lighting of E: For economical work
(ATT/E)
Lighting of L: For inching operation
Lighting of B: For breaker work
Monitor display changes, synchronizing
with switch
Full throttle speed of engine changes

Operation of auto-deceleration switch

ON lights up: Auto-deceleration is


actuated.
OFF:
Auto-deceleration is
canceled.

Operation of travel speed switch

Check of switches, control levers

Local After
assembly hours of
time
operation

Operation of wiper switch

Each time the switch is pressed, the


auto-deceleration is actuated or
canceled.
La lights up: Low speed travel
Mi lights up: Middle speed travel
Hi lights up: High speed travel
When the engine is started, the travel
speed is automatically set to Lo.
OFF: Wiper stops
ON lights up: Wiper moves continuously
INT lights up: Wiper moves intermittently
Each time switch is pressed, monitor
display changes and can be selected.

Operation of window washer switch

Window washer fluid is sprayed out.

Operation of cigarette lighter

This is used to light cigarettes. To use,


push the lighter in. After a few seconds
it will spring back.
This switch is used to turn on the front
lamps working lamps, additional lamp at
the top front of the cab, and monitor
lighting.
ON position (actuated):
The swing lock is always applied,
and the upper structure will not
swing even if the swing is
operated. In this condition, the
swing lock lamp lights up.
OFF position (canceled):
Swing operation is possible. Swing
lock monitor goes off.
Low pressure setting:
The boom thrust force is weak.
High pressure setting:
The boom thrust force becomes
more powerful.

Operation of lamp switch

Operation of swing lock switch

Operation of machine push-up switch

Operation of room lamp switch

ON position: Room lamp lights up.

Operation of secondary pump drive switch

Normal state:
Switch is in "LOWER" position
If switch is set to "UPPER" position,
alarm buzzer sounds.

While monitor is indicating "L03 pump control error", if switch


is in "UP" position, emergency pump can be driven

Revision

Category

7/13

Check item
Operation of lock lever auto lock cancel switch

Judgement standard
When normal: Switch is in "Lower"
position.

When this switch is set in "Upper" position, the lock lever auto
lock function is disabled.
When the lock lever is released while the control lever or
pedal is operated, the work equipment or machine moves.
Operation of swing brake cancel switch

If the switch is set to "Upper" position,


the lock lever lock switch cancel monitor
lighting up.

While monitor is indicating "L03 swing brake error", if switch


is in "UP" position, brake is cancelled and upper structure can
swing.
However, swing brake is kept cancelled.
Operation of alarm buzzer stop switch

If switch is set to "UPPER" position,


alarm buzzer sounds and swing
lock symbol flashes

Operation of lower wiper switch (option)


Operation of travel levers

Operation of left work equipment control lever


(with auto-deceleration device)

Check of switches, control levers

Local After
assembly hours of
time
operation

Operation of right work equipment control lever


(with auto-deceleratiom device)

Confirmation of failure history


(Both electrical and mechanical)
Operation of power max. switch
Check function of rotation lamp switch
(option)

Normal state:
Switch is in "LOWER" position

This is used to stop alarm buzzer if it


sounds to warn of an abnormality during
operation.
ON: Lower wiper moves.
OFF: Lower wiper stops.
FORWARD:
The lever is pushed forward.
(The pedal is angled forward)
REVERSE:
The lever is pulled back.
(The pedal is angled back)
N (Neutral):
The machine stops.
This lever is used to operate the arm
and upper structure.
Arm operation
Swing operation

N (Neutral):
When the lever in this position, the
upper structure and the arm will be
retained in the position in which
they stop.
This lever is used to operate the boom
and bucket.
Boom operation
Bucket operation

N (Neutral):
When the lever in this position,
the boom and the bucket will be
retained in the position in which
they stop.
Check there is no abnormality, then
delete abnormality record. When
finishing inspection, check again there is
no abnormality record.
When the switch on the LH work
equipment control lever is pushed, the
digging power increases.
ON: Rotary lamp lights up

Leakage of AdBlue/DEF from each part


(AdBlue/DEF tank, pump, injector piping)

There must be none.

12/13

Revision

Category

Note: If the operation or function is defective, measure as necessary. All judgement standard values for speeds are the values in P mode.

Local
After
assembly hours of
time
operation

Check item

Judgement standard

1. Engine speed
Low idle speed

rpm ]

1000 50 rpm

High idle speed

rpm ]

1930 50rpm

Speed at arm OUT

rpm ]

1930 100 rpm

at P mode

Speed at arm IN

rpm ]

1830 100 rpm

When mode is P and


swing lock is ON

rpm ]

1270 50 rpm
When oil temperature is 50 oC and fan
rotation is 100%

2. Readiator fan speed


Speed at engine high idle
speed

Measurement items

3. Oil pressure measurment (measure at pump outlet port)


RAISE

{355 (+15 / -12)kg/cm3}

Boom

*37.3 (+1.47 / -1.18)MPa


Hydraulic oil temperature : Within operation range

{355 (+15 / -12)kg/cm3}

Engine at high idle


Working mode: P mode
Hydraulic pump output pressure with all
measurement circuits relieved

Swing

Travel

Values indside parenthesis :


Hydraulic oil pressure with power max.
switch in ON mode
(reference only)

*37.3 (+1.47 / -1.18)MPa


{380 (+15 / -12)kg/cm3}
30.9 (+1.47 / -2.65)MPa
{315 (+15 / -20)kg/cm3}
37.3 (+2.94 / -1.13)MPa
{380 (+30 / -10)kg/cm3}

Hydraulic oil temperature: Within operation range

Control circuit source


pressure

{380 (+15 / -12)kg/cm3}


34.8 (+1.47 / -1.18)MPa

Arm

Bucket

34.8 (+1.47 / -1.18)MPa

3.24 0.2 MPa


{33 2 kg/cm3}

Engine at high idle


Self pressure reducing valve output pressure with all control levers in NEUTRAL
position

LS differential pressure

Hydraulic oil temperature: Within operating range


Engine at high idle
Working mode: P
mode
Traveling speed: Hi
Hydraulic oil pump
pressure-LS pressure

When all control


levers in NEUTRAL
position

4.2 1.0 MPa

When traveling at
half stroke
(At idling)

2.65 0.1 MPa

{42 10 kg/cm3}

{27 1 kg/cm3}

Revision

Category

13/13

Local
After
assembly hours of
time
operation

Check item

Measure in
posture at right

4. Hydrauric drift of work equipment


(Bucket load: 3,060 kg, hydraulic oil temperature 50 5C)

Bucket tooth tip

Judgement standard

mm ]

Max. 600 mm/15 minutes

Note: Measure the hydraulic drift of the following cylinders only if


the hydraulic drift at the bucket tooth tip does not pass the test.
Measure retraction distance of each of following cylinders.
Boom cylinder

mm ]

Max. 29 mm/ minutes

Arm cylinder

mm ]

Max. 100 mm/ minutes

Bucket cylinder

mm ]

Max. 35 mm/ minutes

5. Operation force, travel


Boom
lever

Operating
force

RISE



(kg)
N

RISE

LOWER

LOWER

(kg)
N

15.7 3.9 N
{1.6 0.4 kg}
Stroke: 85 10 mm

PLAY

Stroke

Measurement items

[
Swing
lever

Operating
force

mm]

mm]

RIGHT



(kg)

RIGHT

LEFT

mm]

(kg)

LEFT

PLAY

Play: Max. 15mm


12.7 2.9 N
{1.3 0.3 kg}
Stroke: 85 10 mm

Stroke
[
Bucket
lever

Operating
force

mm]

CURL

mm]



(kg)
N

CURL

mm]

(kg)

DUMP

DUMP

Play: Max. 15mm


12.7 2.9 N
{1.3 0.3 kg}
Stroke: 85 10 mm

PLAY

Stroke
[
Arm lever
Operating
force

mm]

IN

mm]



(kg)
N

IN

mm]

(kg)

OUT

OUT

PLAY

Play: Max. 15mm


15.7 3.9 N
{1.6 0.4 kg}
Stroke: 85 10 mm

Stroke
[
Right
travel
lever

Operating
force

mm]

FOR

WARD

mm]



(kg)
N

FORWARD

mm]

RE
VERSE

REVERSE

(kg)
N

Play: Max. 15mm


24.5 5.9 N
{2.5 0.6 kg}
Stroke: 115 15 mm

PLAY

Stroke
[
Left travel
lever

Operating
force

mm]

FOR

WARD

mm]



(kg)
N

FORWARD

mm]

RE
VERSE

REVERSE

(kg)
N

Play: Max. 20mm


24.5 5.9 N
{2.5 0.6 kg}
Stroke: 115 15 mm

PLAY

Stroke
[

mm]

mm]

mm]

Play: Max. 20mm

At engine high
idling, relief