PC490LC-11 Komatsu

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HYDRAULIC

EXCAVATOR

GEN00126-01

PC490LC

-11

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FOREWORD

3INCE THE TION 4HIS MACHINE AND -ANY IN TOGETHER !CCORDINGLY REQUIRED TECTIVE AND )N FERENT 4HE .OTE MACHINE )F BY (Instruction system) Work leader

Work supervisor Crane director

Director and deputy director

Liaison man

Operator for assembly

Interpreter

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Specifications ...

1 Precautions for field assembly ...

2 Disposal of removed parts...

3 Assembling procedures, applicable equipment and schedule ...

4 Flow of field assembly ...

5 Kit layout diagram...

6 Transportation ...

7 Tool list for field assembly ...

10 Tightening torque ...

11 Coating materials ...

16 Selection of wire ropes used for assembly...

20 Selection of nylon slings used for assembly...

21 A. Assembly of chassis ...

23 A- 1. Installation of climbing step ...

24 A- 2. Installation of handrail ...

26 A- 3. Installation of mirror...

28 A- 4. Installation of tail pipe, tail pipe cover...

31 B. Assembling of work equipment ...

33 B- 1. Installation of boom cylinder...

34 B- 2. Releasing remaining pressure in hydraulic circuit ...

36 B- 3. Installation of boom cylinder hoses ...

37 B- 4. Installation of boom cylinder top pin ...

38 B- 5. Installation of boom assembly ...

39 B- 6. Installation of hoses from chassis along top of boom...

43 B- 7. Connection of boom cylinder head...

44 B- 8. Installation of arm assembly...

45 B- 9. Installation of bucket cylinder hoses between boom and bucket cylinder ...

47 B-10. Installation of bucket...

49 B-11. Connection of work equipment grease piping ...

52 B-12. Connection of work equipment wiring ...

54 B-13. Greasing after completion of work equipment...

56 B-14. Bleeding air from work equipment circuit ...

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

59 C- 1. Increasing and decreasing of track frame gauge ...

60 C- 2. Installation of steps ...

66 C- 3. Installation of travel piping covers ...

67 C- 4. Adjustment of track tension ...

71 C- 5. Sticking sheet to counterweight ...

74 C- 6. Installation of camera ...

75 C- 7. Installation of counterweight...

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

85 M- 1. Replacement of return filter (Standard filter to flushing filter) ...

86 M- 2. Flushing of hydraulic circuit ...

87 M- 3. Replacement of return filter (Flushing filter to standard filter)...

86 M- 4. Check of oil/coolant level at each part ...

91 M- 5. Inspection of oil level in hydraulic tank and refill...

93 M- 6. Parts to be touched up after field assembly...

95 M- 7. Error code ...

96 Mounting bolt torque check sheet

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Specifications

PC490LC-11

Machine model PC490LC-11

Weight of machine kg 47,040

Bucket capacity m3 _1.9

Engine model — KOMATSU SAA6D125E-7

Flywheel horsepower

SAE J1995 (Gross)

kW/min-1 {HP/rpm} 270/1,900{362/1,900}

ISO 9249/SAE J1349 (Net) 268/1,900{359/1,900}

Min. ground clearance mm 700

Travel speed (Low/High) km/h 3.0/4.2/5.5

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2 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 ob-serve 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.

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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 comple-tion of the machine. Since they are useful when the machine needs to be transported in future, however, we rec-ommend you to keep them as long as possible.

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4 Assembling procedures,

applicable equipment and schedule

Days

Assembly unit Crane Air compressor Worker Unloading parts Step Handrail and mirror

Assembly of work equipment Increasing of track frame gauge Installation of counterweight

Backhoe

·

Inspection of oil level and

coolant

level

·

Air bleeding from work

equipment

cylinder

·

Flushing of hydraulic

circuit · Adjustment of track tension · Performance

test

45t

Leader + 3 mechanics

Start of assembling · Meeting with all workers

· Completion of general assembling

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Flow of field assembly

*1_{Installation of accessories}

*2_{Installation of boom cylinder}

*2•*3_{Installation of boom}

*2•*4_{Installation of arm}

*2_{Installation of bucket}

Greasing of work equipment

Air bleeding (work equipment)

Increasing of gauge

Installation of counterweight *5 Installation of sub

counterweight

*6_{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

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6 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”.

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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

t Packing Style of Each Kit (Sizes in drawing are given in millimeters.) • Upper structure + Undercarriage

(Upper structure + Undercarriage) (Work equipment) _(Others)

Model PC490LC-11 A (mm) 6,050 B (mm) 3,360 Shoe width (mm) 700 Overall width (mm) 3,150 Weight (kg) 28,930

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8

Packing Style of Each Kit (Sizes in drawing are given in millimeters.) (1) Boom (2) Arm (3) Boom cylinder Model PC490LC A (mm) 7,290 B (mm) 1,725 Overall width (mm) 780 Weight (kg) 4,230

Position of center of gravity

Model PC490LC A (mm) 4,610 B (mm) 955 Overall width (mm) 675 Weight (kg) 2,210

Position of center of gravity

Model PC490LC

Weight

(kg) 365

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(4) Bucket (5) Counterweight Model PC490LC A (mm) 1,839 B (mm) 1,499 Overall width (mm) 1,624 Weight (kg) 1,366 Model PC490LC Weight (kg) 9,570 850 1,165 3,000

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10 Tool list for field assembly

No. Part name Specification Q'ty Remarks

1

Equ

ipm

en

t _Compressor _7.0kg/cm3 ₁

2 Crane truck 25 ton 1

3 Grease pump Air supply set 1 For greasing work equipment

4 Stepladder 5-step, 1,500 mm 2

5

T

ool

Small-sized impact wrench M10 bolt 1 Torque capacity: 30 – 170Nm

{3.06 – 17.3 kgf

·

m} 6 M12 bolt 1 7 Medium-sized impact wrench M14 – M20 bolt 1 Torque capacity: 200 – 700Nm {20.4 – 71.4 kgf

·

m} 8 Large-sized impact wrench M24 – M33 bolt 1 Torque capacity: 1,000 – 2,500Nm {102 – 255 kgf

·

m}

9 Air hose for impact wrench 50 m 1

10

Medium-sized impact wrench socket

Socket 22 mm width across flats 1

11 Socket 24 mm width across flats 1

12 Socket 30 mm width across flats 1

13

Large-sized impact wrench socket

14 Socket 46 mm width across flats 1 Track frame connecting bolt

15 Socket 65 mm width across flats 1 Counterweight

16 4:1 torque multiplier _wrench 25.4, 19 1

17 Socket for 4:1 torque

multiplier wrench T25.4 square x Width across flats 46 mm

1 each Track frame

18 T25.4 square x Width across flats 65 mm 1 each Counterweight

19

Torque wrench

42 kgm – T25.4 1 35 – 420Nm {3.57 – 42.8 kgf

·

m}

20 85 kgm – T25.4 1 420 – 1,050Nm {42.8 – 107 kgf

·

m}

21 420 kgm – T38.1 1 1,050 – 4,200Nm {107 – 428 kgf_{Counterweight}

·

m}

22 Standard tools Socket, spanner, ring wrench 1 set of _{2 each}

23 Large hammer (plastic) 10 P 1

24 Bar 1 m 2

25 Hydraulic jack 5 – 10 ton 1 For tightening track frame connecting _bolts

26 Oil container Large and small ones 2 each For connecting travel piping and work _{equipment piping}

27

Wooden block

30 × 50 × 150 mm 2 Support of boom cylinder

28 400 × 200 mm 2 For tightening track frame connecting

bolts 29 Sl ing Wire ø10 × 3,000 mm 2 30 ø16 × 3,000 mm 2

31 ø20 × 5,000 mm 2 Boom, arm, bucket

32 ø30 × 3,000 mm 2 Counterweight

33 Shackle SD32 2 Rated load of 6 t for counterweight

34 SC18 4 Rated load of 2 t

35 Nylon sling 50 mm wide x 3,000 mm 2 Boom cylinder, arm cylinder

36 Lever block 1.5 – 3 ton 2 Increase of track frame gauge

37 Eyebolt M12 2 38 Oi l, g rea se, co ns um abl

e Cleaning liquid Brake cleaner spray can 10

39 Hydraulic oil HO56-HE 200 l

40 Grease G2-LI 20 kg For greasing work equipment

41 Touchup paint Natural yellow spray can 5

42 Black gray spray can 5

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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.

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. cor-respond 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.

Part No. of bolt TTTTT-TTTTT

Part No. of washer EEEEE-EEEEE

Bolt specification Thread diameter × Bolt length

Tool (Socket) Applicable socket size

Tightening torque Nm {QQQ kgm}

a : Bolt thread diameter (Nominal diameter) b : Width across flats of bolt head

c : Bolt length

d : Threaded part of bolt Fig. 1

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12

Table 1 Tightening torque for bolts not specified in text

Unit: Nm {kgm}

a For symbols “a” and “b” in the table, see Fig. 1. Nominal size of thread

× pitch a (mm)

Width across flats (= Socket size) b (mm) Tightening torque Target Range M6 × 1 10 _{1.2}12 _{{0.9 – 1.5}}8.8 – 14.7 M8 × 1.25 13 _{2.5}25 _{{1.5 – 3.5}}14.7 – 34 M10 × 1.5 17 _{5.5}54 _{{3.5 – 7.5}}34 – 74 M12 × 1.75 19 _{9}89 _{{5.5 – 12.5}}54 – 123 M14 × 2 22 _{14}137 _{{8.5 – 20}}84 – 196 M16 × 2 24 _{23.5}230 _{{15 – 31.5}}147 – 309 M18 × 2.5 27 _{32}315 _{{20.5 – 43.5}}201 – 427 M20 × 2.5 30 _{47}460 _{{32.5 – 62}}319 – 608 M22 × 2.5 32 _{66.5}650 _{{48 – 84.5}}471 – 829 M24 × 3 36 _{82.5}810 588 – 1,030_{{60 – 105}} M27 × 3 41 1,180_{120} 883 – 1,470_{{90 – 150}} M30 × 3 46 1,520_{155} 1,130 – 1,910_{{115 – 195}} M33 × 3 50 1,960_{200} 1,470 – 2,450_{{150 – 250}} M36 × 3 55 2,450_{250} 1,860 – 3,040_{{190 – 310}} M39 × 3 60 2,940_{300} 2,260 – 3,630_{{230 – 370}}

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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 tight-ening torque.

2.1 If the male screw is made of mild steel or cast iron, apply Table 2. Table 2

Unit: Nm {kgm}

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 Nominal size (in)

Steel Cast iron Light alloy

1/8 3.9 – 6.9 {0.4 – 0.7} 2.9 – 5.9 {0.3 – 0.6} 2.0 – 3.9 {0.2 – 0.4} 1/4 5.9 – 11.8 {0.6 – 1.2} 4.9 – 9.8 {0.5 – 1.0} 3.9 – 7.8 {0.4 – 0.8} 3/8 16.7 – 26.5 {1.7 – 2.7} 13.7 – 21.6 {1.4 – 2.2} 9.8 – 16.7 {1.0 – 1.7} 1/2 32.3 – 52.9 {3.3 – 5.4} 26.5 – 43.1 {2.7 – 4.4} 19.6 – 32.3 {2.0 – 3.3} 3/4 51.0 – 85.3 {5.2 – 8.7} 42.1 – 70.6 {4.3 – 7.2} 31.4 – 52.9 {3.2 – 5.4} 1 86.2 – 173.5 {8.8 – 17.7} 72.5 – 146.0 {7.4 – 14.9} 54.9 – 111.7 {5.6 – 11.4}

Material of female thread

Nominal size (in) Steel Cast iron Light alloy

1/8 16.7 – 29.4_{{1.7 – 3.0}} _{{1.0 – 2.0}}9.8 – 19.6 _{{0.7 – 1.5}}6.9 – 14.7 1/4 19.6 – 44.1_{{2.0 – 4.5}} 16.7 – 37.2_{{1.7 – 3.8}} 12.7 – 28.4_{{1.3 – 2.9}} 3/8 44.1 – 93.1_{{4.5 – 9.5}} 37.2 – 77.4 _{3.8 – 7.9}} 27.4 – 58.8_{{2.8 – 6.0}} 1/2 _{{10.0 – 19.2}}98.0 – 188.2 83.3 – 157.8_{{8.5 – 16.1}} 60.8 – 115.6_{{6.2 – 11.8}} 3/4 170.5 – 316.5_{{17.4 – 32.3}} 141.1 – 247.0_{{14.4 – 25.2}} 105.8 – 186.2_{{10.8 – 19.0}} 1 367.5 – 612.5_{{37.5 – 62.5}} 309.7 – 514.5_{{31.6 – 52.5}} 235.2 – 392.0_{{24.0 – 40.0}}

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14

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

Unit: Nm {kgm}

Table 4.2 Hydraulic hose of taper seal type

Unit: Nm {kgm}

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

Outside diameter of hose

(mm)

Width across flats (mm) Tightening torque (Nm {kgm}) 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} Outside diameter of hose (mm)

Width across flats (mm) Tightening torque (Nm {kgm}) 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}

Type that uses O-ring at this position (O-ring is fitted to joint side)

Type that does not use O-ring at this position

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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

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16 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

Shown in this manual

Adhesive

LT-1A 790-129-9030 150 g Tube • Used to fix rubber gasket,

rub-ber cushion, or cork plug

LT-1B 790-129-9050 20 g (2-container set) Polyethylene container

• Used to glue resin (excluding polyethylene, polypropylene, ethylene tetrafluoride, vinyl chloride), rubber, metal, or non-metallic material instantane-ously firmly

LT-2 09940-00030 50 g

Polyethylene container

• Features: Heat resistance and chemical resistance

• Used to lock bolts, plugs, etc. and as sealant LT-3 790-129-9060 Set of adhesive and hardener Adhesive: 1 kg Hardener: 500g Can

• Used to glue metal, glass, plas-tic, etc. and as sealant

LT-4 790-129-9040 250 g Polyethylene

container

• Used to glue metal, glass, plas-tic, etc. and as sealant

HOLTS

MH 705 790-129-9120 75 g Tube

• Heat-resistant sealant for re-pairing engine Three bond 1735 790-129-9140 50 g Polyethylene container • Instantaneous adhesive • Adhesion time: 5 sec to 3 min • Mainly used to glue metal,

rub-ber , plastic, and wood

Aron alpha

201 790-129-9130 2 g

• Instantaneous adhesive • Quick-hardening type

(Reach-es max. strength 30 min after) • Mainly used to glue rubber ,

plastic, and metal LOCTITE

648-50 79A-129-9110 50 cc

• Features: Heat resistance and chemical resistance

• Used for gluing parts fitted at high temperature

Liquid gasket

LG-5 790-129-9080 1 kg

• Used as sealant for various threaded portions, pipe joint, and flange

• Used as sealant for taper plug, elbow, nipple, etc.

LG-6 790-129-9160 200 g Tube

• Features: Silicon-based, heat resistance, cold resistance • Used as sealant for flange and

threaded portion

• Used as sealant for oil pan, fi-nal drive case, etc.

LG-7 790-129-9170 1 kg Tube

• Features: Silicon-based, quick-hardening type

• Used as sealant for flywheel housing, intake manifold, oil pan, thermostat housing, etc. LG-8

ThreeBond 1207B

419-15-18131 100 g Tube

• Features: Silicon-based, heat resistance, vibration resist-ance, impact resistance • Used as sealant for transfer

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Category Komatsu code Part No. Q'ty Container Main features, uses Shown in this manual LG-9 ThreeBond 1206D 790-129-9310 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 surfac-es • 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

transmis-sion case, steering case, etc. ThreeBond

1121 790-129-9090 100 g Tube

• Liquid gasket for repairing en-gine

Molybdenum disulfide lubricant

LM-P 09940-00040 200g Tube

• Used for press fitting, shrink fit-ting, prevention of galling or seizure of screw

• Used as lubricant for linkage, bearing, etc.

Q

– 09995-00250 190 g Can

• Spray type

• Thin molybdenum disulphide film is formed on metal surfac-es to prevent galling between metals

• Used for drive shaft spline, needle bearing, various link pins, bolts, etc.

Anti-seize LC-G

NEVER-SEEZ – – Can

• Feature: Compound consisting of fine metal particles to pre-vent seizure and galling • Used for mounting bolts of

high-temperature parts such as exhaust manifold, turbocharg-er, etc. Grease G2-LI G0-LI(*) *: For cold weather SYG2-400LI SYG2-350LI SYG2-400LI-A SYG2-160LI SYG2-160CNLI SYG0-400LI-A(*) SYG0-16CNLI(*) Various types Various types

• Multi-purpose extreme pres-sure lithium grease

LM-G(G2-M) Molybdenum disulfide grease SYG2-400M SYG2-400M-A SYGA-16CNM 400g × 10 400g × 20 16 kg Bellows can

• Used for high-load portion 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

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18

Category Komatsu code Part No. Q'ty Container Main features, uses

Shown in this manual Hyper White Grease G2-T G0-T (*) *: For cold weather SYG2-400T-A SYG2-16CNT SYG0-400T-A (*) SYG0-16CNT (*) 400 g 16 kg Bellows can

• Has higher seizure resistance, heat resistance, and water re-sistance than molybdenum di-sulphide grease

• Not conspicuous on machine since color is white

Bio grease G2B G2-BT (*) *: For high temperature and high load SYG2-400B SYGA-16CNB SYG0-400BT (*) SYGA-16CNBT (*) 400 g 16 kg Bellows can

• Decomposed by bacteria in na-ture in short period to minimize ef f ect s o n mi cr oo rg an is m, plants, and animals

G2-S ThreeBond 1855

– 200 g Tube

• Feature: Silicon-based, wide using temperature range, high oxidation resistance, preven-tion of deteriorapreven-tion of rubber and plastics

• Used as oil seal for transmis-sion etc.

G2-U-SENS

grease 427-12-11871 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 Primer SUNSTAR PAINT PRIMER 580 SUPER 417-926-3910 20 ml _containerGlass Fo r gl uin g c ab gla s s

• Used as primer for cab side

(Using limit: 4 months af-ter date of manufacture) SUNSTAR GLASS PRIMER 580 SUPER 20 ml Glass container

• Used as primer for glass s i d e ( U s i n g l i m i t : 4 months after date of man-ufacture) SUNSTAR PAINT PRIMER 435-95 22M-54-27230 20 ml Glass container

• Used as paint primer for cab side

(Using limit: 4 months af-ter date of manufacture)

SUNSTAR GLASS PRIMER 435-41 22M-54-27240 150 ml Steel can

• Used as primer for black ceramic-coated surface on glass side and for hard polycarbo nate- co ated surface

(Using limit: 4 months af-ter date of manufacture) SUNSTAR SASH PRIMER GP-402 22M-54-27250 20 ml Glass container

• Used as primer for sash (Almite)

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Category Komatsu code Part No. Q'ty Container Main features, uses Shown in this manual Adhesive SUNSTAR PENGUINE SEAL 580 SUPER "S" or "W" 417-926-3910 320 ml Polyethylene container F o r gl ui n g c ab gl a s s

• "S" is used for high-tem-perature season (April to October) and "W" for low-temperature season (Oc-tober to April) as adhe-sive for glass

(Using limit: 4 months af-ter date of manufacture) Sika Japan,

Sikaflex 256HV

20Y-54-39850 310 ml Polyethylene

container

• Used as adhesive for glass

(Using limit: 6 months af-ter date of manufacture) SUNSTAR PENGUINE SUPER 560 22M-54-27210 320 ml Ecocart (Special container)

• Used as adhesive for glass

Caulking material SUNSTAR PENGUINE SEAL No. 2505 417-926-3920 320 ml Polyethylene _container

• Used to seal joints of glass parts

(Using limit: 4 months af-ter date of manufacture) SEKISUI

SILICONE SEALANT

20Y-54-55130 333 ml Polyethylene

container

• Used to seal front window (Using limit: 6 months af-ter date of manufacture) GE TOSHIBA

SILICONES TOSSEAL 381

22M-54-27220 333 ml Cartridge

• Used to seal joints of glass parts Translucent white seal

Paint

Natural yellow SYPA-U03SPNY – Spray type

Q

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20 Select

ion

of

wire ro

pes u

sed f

o

r assem

bly

S ele ct w ire ro p es to b e u sed f o r a sse mb ly a cco rd in g t o t h e f o llo w in g t ab le. An nex 2, T a ble 1 Us ing l o ads of 6 × 2 4 ty pe ro pe s ling s . Un it: kN { tf} N u mb er of w ire ro pe s 1 p c. 2 p c s . Sli ng a ngl e  = 0°  Z 90 ° 9 0° <  Z 12 0° Angl e t o v e rti c a l li ne  = 0 °  Z 45 ° 4 5° <  Z 60 ° Mo de co ef fici en t M 11 .41 C las si fic a ti on of w ire ro pe 24 G 2 4A 24 G 24 A 2 4G 24 A O ut e r d iam et e r of wi re ro pe ( 2)d (m m ) 8 9 10 11 .2 (1 2) 12 .5 14 16 18 20 22 .4 (2 4) 25 28 30 31 .5 33 .5 35 .5 37 .5 40 42 .5 M a x . 4. 8 {0. 49} M a x . 6. 1 {0. 63} M a x . 7. 6 {0. 77} M a x . 9. 5 {0. 97} Ma x. 10 {1 .1} M a x. 1 1 {1 .2} Ma x. 14 {1 .5} Ma x. 19 {1 .9} Ma x. 24 {2 .5} Ma x. 30 {3 .1} Ma x. 38 {3 .9} Ma x. 43 {4 .4} Ma x. 47 {4 .8} Ma x. 59 {6 .1} Ma x. 68 {7 .0} Ma x. 75 {7 .7} Ma x. 85 {8 .7} Ma x. 96 {9 .8} M a x . 1 07 {1 0.9 } M a x . 1 22 {1 2.4 } M a x . 1 37 {1 4.0 } Ma x. 5. 2 { 0 .5 3} Ma x. 6. 6 { 0 .6 7} Ma x. 8. 2 { 0 .8 3} Ma x. 10 { 1 .0 } Ma x. 1 1 {1.2 } Ma x. 12 { 1 .3 } Ma x. 16 { 1 .6 } Ma x. 21 { 2 .1 } Ma x. 26 { 2 .7 } Ma x. 32 { 3 .3 } Ma x. 41 { 4 .2 } — Ma x. 51 { 5 .2 } Ma x. 64 { 6 .5 } Ma x. 73 { 7 .5 } Ma x. 81 { 8 .3 } Ma x. 92 { 9 .4 } M ax. 10 3 {10 .5} M a x . 1 1 5 {1 1. 7} M ax. 13 1 {13 .4} M ax. 14 8 {15 .1} M ax. 6.7 {0.6 8} M ax. 8.5 {0.8 8} M ax. 10 {1.0 } M ax. 13 {1.3 } M ax. 14 {1.5 } M ax. 15 {1.6 } M ax. 19 {2.1 } M ax. 26 {2.6 } M ax. 33 {3.5 } M ax. 42 {4.3 } M ax. 53 {5.4 } M ax. 60 {6.1 } M ax. 65 {6.7 } M ax. 82 {8.5 } M ax. 95 {9.8 } Ma x. 1 05 {10. 7} Ma x. 1 19 {1 2.1 } Ma x. 1 34 {13. 7} Ma x. 1 49 {15. 2} Ma x. 1 70 {17. 3} Ma x. 1 91 {19. 6} M ax . 7. 2 { 0 .7 4} M ax . 9. 2 { 0 .9 3} Ma x. 1 1 { 1 .1 } Ma x. 1 4 {1 .4} Ma x. 1 5 {1 .6} Ma x. 1 6 {1 .8} Ma x. 2 2 {2 .2} Ma x. 2 9 {2 .9} Ma x. 3 6 {3 .7} Ma x. 4 4 {4 .6} Ma x. 5 7 {5 .8} — Ma x. 7 1 {7 .2} Ma x. 8 9 {9 .1} M a x . 10 2 {1 0.5 } Ma x. 1 1 3 {1 1 .6} M a x . 12 8 {1 3.1 } M a x . 14 4 {1 4.7 } M a x . 16 1 {1 6.3 } M a x . 18 3 {1 8.7 } M a x . 20 7 {2 1.1 } M a x . 4. 8 {0 .49} M a x . 6. 1 {0 .63} M a x . 7. 6 {0 .77} M a x . 9. 5 {0 .97} Ma x. 1 0 { 1 .1 } M a x . 1 1 {1.2 } Ma x. 1 4 { 1 .5 } Ma x. 1 9 { 1 .9 } Ma x. 2 4 { 2 .5 } Ma x. 3 0 { 3 .1 } Ma x. 3 8 { 3 .9 } Ma x. 4 3 { 4 .4 } Ma x. 4 7 { 4 .8 } Ma x. 5 9 { 6 .1 } Ma x. 6 8 { 7 .0 } Ma x. 7 5 { 7 .7 } Ma x. 8 5 { 8 .7 } Ma x. 9 6 { 9 .8 } M ax . 1 0 7 { 1 0. 9 } M ax . 1 2 2 { 1 2. 4 } M ax . 1 3 7 { 1 4. 0 } Ma x. 5.2 {0.5 3} Ma x. 6.6 {0.6 7} Ma x. 8.2 {0.8 3} Ma x. 10 {1.1 } M a x . 1 1 {1 .2} Ma x. 12 {1.3 } Ma x. 16 {1.6 } Ma x. 21 {2.1 } Ma x. 26 {2.7 } Ma x. 32 {3.3 } Ma x. 41 {4.2 } — Ma x. 51 {5.2 } Ma x. 64 {6.5 } Ma x. 73 {7.5 } Ma x. 81 {8.3 } Ma x. 92 {9.4 } Max . 1 03 {10. 5} M a x. 1 15 {1 1.7} Max . 1 31 {13. 4} Max . 1 48 {15. 1} 18 B 88 17 -199 1

(26)

Select

ion

of

nylo

n slin

gs u

sed f

o

r assem

bly

S ele ct w ires u sed f o r ass emb ly a cco rd in g t o t h e fo llo w in g t ab le t Ra te d loa d ta ble ( WW-1 D ty pe )

(27)

(28)

(29)

24

For USA specifications

• Install step (1) with bolts (2). Assembly procedure

Installation of climbing step (1/2)

A-1

Precautions Necessary tools Necessary equipment

Remove the rust preventive plug from the tapped hole.

Name Q’ty Name Q’ty

Small-sized impact wrench 1

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No. Loose-supply items Q’ty

1 208-54-43140 1

(30)

• Install grip (1) with bolts (2).

Assembly procedure

Installation of climbing step (2/2)

A-1

Remove the rust preventive plug from the tapped hole.

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1 208-54-43150 1

(31)

26

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

Assembly procedure

Installation of handrail (1/2)

A-2

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)

Medium-sized impact wrench 1

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1 208-54-21921 1

2 208-54-43120 1

3 01024-81245 6

(32)

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

Assembly procedure

Installation of handrail (2/2)

A-2

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)

Medium-sized impact wrench 1

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1 208-54-41833 1

2 208-54-43130 1

(33)

28

Assembly procedure

Installation of mirror (1/3)

A-3

Hexagon socket 5 mm width

across flats 1

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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

View from right of machine

(1) Install mirror (1).

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

(34)

Assembly procedure

Installation of mirror (2/3)

A-3

across flats 1

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1 2A5-54-13420 1

(2) Install mirror (1).

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

(35)

30

Assembly procedure

Installation of mirror (3/3)

A-3

a Tighten bolts (4) according to torque table 1 (page 11).

across flats 1

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1 2A5-54-13420 1

2 2A5-54-16120 1

3 20Y-54-35430 1

4 01252-A1030 2

(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}

(36)

Assembly procedure

Installation of tail pipe and tail pipe cover

A-4

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1 208-01-21720 1

2 6253-11-515A 1

3 885-3353-911 1

4 208-54-21361 1

5 01034-81230 6

(1) Install tail pipe.

(2) Install tail pipe cover.

Adjust the cover to equalize the clearance marked with ※ . Tightening torque: 11.8 Nm {1.2 kgm}

(37)

(38)

B. ASSEMBLING OF WORK EQUIPMENT

(39)

34

(1) Lift the boom cylinder and adjust it to the frame’s 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.

(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. Assembly procedure

Installation of boom cylinder (1/2)

B-1

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 (207-70-71251) 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.

Nylon sling 2 25 t crane 1

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Outside of machine

Rest of shims _{207-70-71251 1 piece}

PART P

Inside of machine

(Clearance must be 1.5 mm or less)

1 207-70-71251 6

(40)

(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. Assembly procedure

Installation of boom cylinder (2/2)

B-1

Ot h e rs Boom cylinder Support stand Revolving frame

(41)

36

When removing the hydraulic piping, be sure to release the remaining pressure according to the following proce-dure.

(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. Assembly procedure

Releasing remaining pressure in hydraulic circuit

B-2

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(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”.

Assembly procedure

Installation of boom cylinder hoses

B-3

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.

Oil container 2

Ot

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No. Already installed to Q’ty

1 207-62-52610 2

2 206-62-51650 2

3 07000-13032 4

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.

(43)

38

Insert the boom cylinder top pin in the boom temporarily.

a Weight of boom cylinder top pin: 73 kg a Apply LM-P to the inside of boss. Assembly procedure

Installation of boom cylinder top pin

B-4

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(44)

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

cov-er, take care not to hook the breather in it.

Assembly procedure

Installation of boom assembly (1/4)

B-5

Socket, width across flats: 19 mm 1 Small-sized impact wrench 1

Extension, L: 150 1 Ot h e rs M12 eyebolts may be installed to 2 places to install slings.

No. Parts installed to _machine Q’ty

1 208-54-21770 1 2 01024-81225 2 3 208-54-21881 1 4 01034-81225 4 5 01643-51232 4 6 208-54-21602 1 7 01024-81230 4

(45)

40

5. Remove the fuel tank front cover. aWeight of fuel tank: 9.87 kg

6. Install the boom foot pin.

aWhen 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)

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

Installation of boom assembly (2/4)

B-5

Socket, width across flats: 19 mm 1 Small-sized impact wrench 1

Extension, L: 150 1 Ot h e rs

㪏

㪐

Install

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

Rubber hose

No. Parts installed to _machine Q’ty

8 2A7-54-11742 1

9 01024-81230 4

10 01024-81255 1

11 01024-81230 2

(46)

(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. Assembly procedure

Installation of boom assembly (3/4)

B-5

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.) (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.

(Clearance must be 1 mm or less)

1 208-70-71611 3

2 208-70-71621 1

3 208-70-71631 1

4 208-70-71641 1

a When pushing in the pin, take care not to break the dust seal installed to the boom foot as shown below.

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.

ø20 × 5,000 mm wire 2 25 t crane 1

ø10 × 3,000 mm wire 1

Lever block 1.5 t 1

Large hammer 1

Socket 30 mm width across flats 1 Medium-sized impact wrench 1

Ot

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Dust seals

(47)

42

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 Assembly procedure

Installation of boom assembly (4/4)

B-5

a When pushing in the pin, take care not to break the seals installed to the boom foot as shown below

a For installation of the grease supply hoses, see Step B-11 "Connesction of grease supply piping of work equipment".

ø20 × 5,000 mm wire 2 25 t crane 1

ø10 × 3,000 mm wire 1

Lever block 1.5 t 1

Large hammer 1

Ot

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Dust seals

(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.) (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]

Weight of boom assembly : 4,950 kg

a When sling the boom and cylinder assembly

No. Already installed to chassis Q’ty

1 208-70-71611 3 2 208-70-71621 1 3 208-70-71631 1 4 208-70-71641 1 (Clearance must be 1 mm or less)

(48)

(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. Assembly procedure

Installation of hoses from chassis along top of boom

B-6

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.

Oil container 2

Ot

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1 208-62-41661 1

2 208-62-41671 1

3 208-62-41682 1

4 208-62-41642 2

(49)

44 Clearance “a”

0.5 ∼1.5mm

Clearance “b”

0.5∼1.5mm

(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). Assembly procedure

Connection of boom cylinder head

B-7

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.

a Check the clearance between cover (2) and cylinder rod all around and combine shims 1 mm thick (208-70-71561) and 2 mm thick (208-70-71571) so that clearance "a" will be 0.5 – 1.5 mm. (Portions of ) a Adjust clearance "b" between the plate and double

nut to 0.5 to 1.5 mm. (Part marked with A )

a Before operating the cylinder, check that the flushing filter is installed (to capture dirt in the circuit). a For installation of the grease supply hoses, see Step

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

Spanner 36 mm width across flats 1 Large-sized impact wrench 1

Ot

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1 208-70-61860 1 2 208-70-31242 2 3 207-70-13340 2 4 01580-12419 4 5 208-70-71561 4 6 208-70-71571 2

(50)

(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 dam-age 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). Assembly procedure

Installation of arm assembly (1/2)

B-8

a When pushing in the pin, take care not to break the dust seal installed to the arm boss as shown below.

Lever block 1.5 t 1

Large hammer 1

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1 208-70-71580 1 2 208-70-71670 1 3 01010-82045 2 4 01643-32060 2 5 208-70-71531 3 6 208-70-71541 1 7 208-70-71551 1 Shim thickness (5) 208-70-71531 2.0 mm (6) 208-70-71541 2.5 mm (7) 208-70-71551 3.0 mm

(51)

46

(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. Assembly procedure

Installation of arm assembly (2/2)

B-8

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.

Large hammer 1

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1 208-70-61220 1

2 205-70-66580 1

3 01024-81235 2

(52)

Assembly procedure

_{Installation of bucket cylinder hoses between}

boom and bucket cylinder (1/2)

B-9

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.

Oil container 2

Extension L150 1

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(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 Reuse the oil stop parts as the split flange, bolts, etc.

a Bleed air from the bucket cylinder. For details, see 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.

1 207-62-54680 1

2 07000-13032 2

3 07371-31049 4

4 07375-21035 8

Installation of hose and O-ring

PART A

(53)

48

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

Assembly procedure

_{Installation of bucket cylinder hoses between}

boom and bucket cylinder (2/2)

B-9

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.

Oil container 2

Extension L150 1

Small-sized impact wrench 1 Ring wrench 14 mm width across

flats 1

Ot

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1 207-62-54680 1

2 07000-13032 2

3 07371-31049 4

4 07375-21035 8

(54)

[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).

[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.

Assembly procedure

Installation of bucket assembly (1/3)

B-10

Nylon sling 1 25t crane 1

Sledge hammer 1

Socket, width across flats: 36 mm 1 Spanner, width across flats: 36 mm 1

Ring spanner, width across flats: 36 mm 1 Large-sized impact wrench 1

Torque wrench: 85 kgm 1 Ot h e rs

㪉

㪈

O-ring position

1 208-70-34230 1

(55)

50

[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.

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).

8. Install lock bolt. Assembly procedure

Installation of bucket (2/3)

B-10

When tightening, adjust the clearance between the double nut and stopper to 0.5 to 1.5 mm. (Clearance marked with *)

Sledge hammer 1

Socket, width across flats: 36 mm 1

Spanner, width across flats: 36 mm 1 Ring spanner, width across flats: 36 mm 1

Large-sized impact wrench 1

Torque wrench: 85 kgm 1 Ot h e rs O-ring position Clearance "a" O-ring

Correct position of O-ring

Clearance "b" (0.5 to 1.0 mm)

No. Loose-supply items Q’ty 1 208-70-34250 18

(56)

[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.

Assembly procedure

Installation of bucket (3/3)

B-10

When tightening, adjust the clearance between the double nut and stopper to 0.5 to 1.5 mm. (Clearance marked with *)

Sledge hammer 1

Socket, width across flats: 36 mm 1

Spanner, width across flats: 36 mm 1 Ring spanner, width across flats: 36 mm 1

Large-sized impact wrench 1

Torque wrench: 85 kgm 1 Ot h e rs

㪈㪈

Correct position of O-ring

(57)

52

(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.

Assembly procedure

Connection of work equipment grease piping (1/2)

B-11

a After installing the boom and boom cylinder, supply grease to parts (a) and (b), and then in-stall the arm.

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

Spanner 19 mm width across flats 2

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(2places)

Tightening torque of hose 5.9 to 11.8 Nm (0.6 to 1.2 kgm)

(58)

Assembly procedure

Connection of work equipment grease piping (2/2)

B-11

Spanner 19 mm width across flats 2

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1 205-70-51390 1

2 205-70-51380 1

3 208-70-65770 1

PART

Tightening torque of hose 5.9 to 11.8 Nm (0.6 to 1.2 kgm)

(59)

54

(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. Assembly procedure

Connection of work equipment wiring (1/2)

B-12

Spanner 22 mm width across flats 1 Socket 19 mm width across flats 1

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1 20Y-06-43230 1 2 20Y-06-21551 1 3 01010-81430 1 4 01643-31445 1 5 08193-20012 1 6 01024-81220 1

PART A

(60)

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

Assembly procedure

Connection of work equipment wiring (2/2)

B-12

Socket 19 mm width across flats 1 Small-sized impact wrench 1

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1 04434-51012 1

2 01024-81225 1

(61)

56

(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. Assembly procedure

Greasing after completion of work equipment

B-13

Grease pump 1

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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.

Assembly procedure

Bleeding air from work equipment circuit

B-14

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 re-ferring to the Assembly procedure M-5 "In-spection of oil level in hydraulic tank and refill".

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(64)

C. INCREASING AND DECREASING OF TRACK FRAME GAUGE,

ASSEMBLING OF COUNTERWEIGHT

(65)

60

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)

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 De-creasing of track frame gauge (4/6) to (6/6).

ø10 × 3,000 mm wire 2

ø20 × 5,000 mm wire 2

Lever block 3 ton 2

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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 first, since other bolts are installed on the base of those bolts.

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

Torque wrench (420 kgm) 1

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No. Loose-supply items Q’ty 1 208-30-12130 20 2 208-30-41390 20

PC490LC-11 Komatsu

HYDRAULIC

EXCAVATOR

GEN00126-01

PC490LC

-11

FOREWORD

CONTENTS

Specifications ...

1

Precautions for field assembly ...

2

Disposal of removed parts...

3

Assembling procedures, applicable equipment and schedule ...

4

Flow of field assembly ...

5

Kit layout diagram...

6

Transportation ...

7

Tool list for field assembly ...

10

Tightening torque ...

11

Coating materials ...

16

Selection of wire ropes used for assembly...

20

Selection of nylon slings used for assembly...

21

A. Assembly of chassis ...

23

A- 1. Installation of climbing step ...

24

A- 2. Installation of handrail ...

26

A- 3. Installation of mirror...

28

A- 4. Installation of tail pipe, tail pipe cover...

31

B. Assembling of work equipment ...

33

B- 1. Installation of boom cylinder...

34

B- 2. Releasing remaining pressure in hydraulic circuit ...

36

B- 3. Installation of boom cylinder hoses ...

37

B- 4. Installation of boom cylinder top pin ...

38

B- 5. Installation of boom assembly ...

39

B- 6. Installation of hoses from chassis along top of boom...

43

B- 7. Connection of boom cylinder head...

44

B- 8. Installation of arm assembly...

45

B- 9. Installation of bucket cylinder hoses between boom and bucket cylinder ...

47

B-10. Installation of bucket...

49

B-11. Connection of work equipment grease piping ...

52

B-12. Connection of work equipment wiring ...

54

B-13. Greasing after completion of work equipment...

56

B-14. Bleeding air from work equipment circuit ...

57

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

59

C- 1. Increasing and decreasing of track frame gauge ...

60

C- 2. Installation of steps ...

66

C- 3. Installation of travel piping covers ...

67