GEN00110-02

Field Assembly Instruction

HYDRAULIC
EXCAVATOR

PC360LC -10
SERIAL NUMBERS

70001

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
9
10
15
19
20

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

A- 1. Installation of handrail ............................................................................................
A- 2. Installation of mirror................................................................................................

21
22
24

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

B- 1. Installation of arm assembly...................................................................................
B- 2. Releasing remaining pressure in hydraulic circuit ..................................................
B- 3. Installation of bucket cylinder hoses between boom and bucket cylinder ..............
B- 4. Installation of bucket...............................................................................................
B- 5. Greasing after completion of work equipment........................................................
B- 6. Bleeding air from work equipment circuit ...............................................................

27
28
30
31
32
35
36

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

C- 1. Adjustment of track tension ...................................................................................
C- 2. Sticking sheet to counterweight .............................................................................
C- 3. Installation of camera .............................................................................................
C- 4. Installation of counterweight...................................................................................

37
38
41
42
48

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 (Standard filter to flushing 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 ..............................................................................................................

51
52
53
55
57
59
61
62

Mounting bolt torque check sheet

Field assembly inspection report (Backhoe)

Specifications
Machine model

PC360LC-10

Weight of machine

kg

Bucket capacity

m3

35,140
1.4

Engine model

KOMATSU SAA6D114E-5

Flywheel horsepower

kW/rpm {HP/rpm}

Min. ground clearance

mm

202/1,950

498

Travel speed (Low/Mid/High)

km/h

3.2/4.5/5.5

Swing speed

rpm

9.5

PC360LC-10

{271/1,950}

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
2 Division

Flow of field assembly

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 two kits for transportation.
Please ask us or our service shop for transportation.
t 2-kit Transportation
(Work equipment)

(Upper structure + Undercarriage + Boom)

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

Upper structure + Undercarriage + Boom

Model

PC360LC-10

A (mm)

9,665

B (mm)

3,160

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

700
3,290
25,180

(Counterweight)

 Work equipment
Arm

Civil
engineering
arm

Quarry arm

3.2 m

3.2 m

A (mm)

4,380

4,390

B (mm)

960

970

Overall width
(mm)

600

600

Weight (kg)

1,700

1,900

Type

Position of center of gravity

Others
Counterweight

Model

PC360LC-10

Weight (kg)

7,090

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

10 P
1m

25

Large hammer (plastic)

Bar
Hydraulic jack

26

Oil container

Large and small ones

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
connecting travel piping and work
2 each For
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

27

Q'ty

400 200 mm

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

10

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.

11

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
Material of female thread
Nominal size (in)
1/8
1/4
3/8
1/2
3/4
1

Unit: Nm {kgm}

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}

2.2 If the male screw is made of refined steel (heat-treated hard steel), apply Table 3.
Table 3
Material of female thread
Nominal size (in)

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

Unit: Nm {kgm}

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}

12

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.

13

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

14

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

Can

LT-1B

LT-2

Adhesive

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

LT-3

Set of adhesive
and hardener

Adhesive:
1 kg
Hardener:
500g

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

Three bond
1735

790-129-9140

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

15

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

16

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

SUNSTAR
PAINT
PRIMER 580
SUPER
SUNSTAR
GLASS
PRIMER 580
SUPER

Primer

SUNSTAR
PAINT
PRIMER 43595

SUNSTAR
GLASS
PRIMER 43541
SUNSTAR
SASH
PRIMER GP402

Part No.

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

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

427-12-11871

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

417-926-3910

22M-54-27230

22M-54-27240

22M-54-27250

For gluing cab glass

Category

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)

17

Shown
in this
manual

Adhesive

Caulking
material

Paint

Komatsu code

Part No.

Q'ty

Container

Main features, uses

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

417-926-3910

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)

Sika Japan,
Sikaflex
256HV

20Y-54-39850

310 ml

Polyethylene
container

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)

For gluing cab glass

Category

Used as adhesive for

glass
(Using limit: 6 months after date of manufacture)
Used to seal joints of
glass parts
(Using limit: 4 months after date of manufacture)

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)

GE TOSHIBA
SILICONES
TOSSEAL
381

22M-54-27220

Natural yellow

SYPA-U03SPNY

Spray type

Black gray

SYPA-U03SPBG

Spray type

333 ml

18

Shown
in this
manual

Q
Q

19

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

20

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

21

Assembly procedure

Installation of handrail (1/2)

A-1

1. Using bolts (3), install handrail (1) and plate (2).

2. Using bolts (6) and (7), install handrail (4) and plate (5).

Weight of handrail (1): 10 kg

Weight of handrail (4): 12 kg

No.
1
2
3
4
5
6
7
Precautions

Qty

Socket 19 mm width across flats

Medium-sized impact wrench

22

Qty
1
1
4
1
1
4
2

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
207-54-41811
207-54-43471
01024-81245
207-54-41821
207-54-43381
01024-81245
01024-81230

Name

Qty

Assembly procedure

Installation of handrail (2/2)

A-1

3. Set plate (2) and plate (3) at part Q, and then install handrail (1) with bolts (4).

Weight of handrail (1): 15 kg

No.
1
2
3
4

Precautions

Qty

Socket 19 mm width across flats

Medium-sized impact wrench

23

Qty
1
1
1
6

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
207-54-41831
207-54-43371
207-54-43851
01024-81245

Name

Qty

Assembly procedure

Installation of mirror (1/3)

A-2

(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

24

Loose-supply items
2A5-54-13420

Qty
1

Necessary equipment
Qty
1
1

Name

Qty

Assembly procedure

Installation of mirror (2/3)

A-2

(2) 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 10).

Necessary tools

25

Loose-supply items
2A5-54-13420
206-54-31190
20Y-54-61630
01252-A1030

Qty
1
1
1
2

Necessary equipment
Qty
1
1

Name

Qty

Assembly procedure

Installation of mirror (3/3)

A-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)

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 10).

Necessary tools

26

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

B. ASSEMBLING OF WORK EQUIPMENT

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

27

Assembly procedure

Installation of arm assembly (1/2)

B-1

(1) Remove lock plate (2) of boom top pin (1) fixed to the boom and pull out top pin (1).
(Boom top pin: 42 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 Combine shims (5), (6), and (7) so that the clearance will be 1 mm or less (Part marked with
(3) Install the stopper (2).

Shim thickness
(5) 207-70-72391
(6) 207-70-72421
(7) 207-70-72431

).

2.0 mm
2.5 mm
3.0 mm

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

Necessary tools

Dust Seal

Name

Qty
2

Lever block 1.5 t

Socket 24 mm width across flats

Medium-sized impact wrench

Large hammer

28

Qty
1
1
2
2
2
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.

Loose-supply items
207-70-72312
207-70-31230
01010-81640
01643-31645
207-70-72391
207-70-72421
207-70-72431

Name
25 t crane

Qty
1

Assembly procedure

Installation of arm assembly (2/2)

B-1

(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: 17 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 Bind the bucket cylinder with wires etc. so that it will not extend when the arm is installed.
a Check that the pin lock bolt is not loosened but tightened and check its torque.

Assemble so that arm

cylinder rod grease hole
will be on upper side.

No.
1
2
3
4
Precautions

Name

Qty
1

Large hammer

Socket 24 mm width across flats

Medium-sized impact wrench

29

Qty
1
1
2
2

Necessary equipment

Nylon sling

Others

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

the dust seal installed to the cylinder boss.

Necessary tools

Loose-supply items
208-70-61241
205-70-66581
01024-81235
207-70-72371

Name
25 t crane

Qty
1

Assembly procedure

B-2

Releasing remaining pressure in hydraulic circuit

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

30

Necessary equipment
Qty

Name

Qty

Assembly procedure

B-3

Installation of bucket cylinder hoses between

boom and bucket cylinder

(1) Remove the hose oil plugs on the bucket cylinder side on the right and left sides of the arm, install new O-ring
(3), and connect bucket cylinder hose (1) and (2).
(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-6 "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
(on both right and left sides)

Installation of hose and O-ring

No.
1
2
3
No.
4
5
Precautions

Name

Qty
2

Socket 14 mm width across flats

Extension L150

Small-sized impact wrench

31

Qty
1
1
4
Qty
8
16

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
207-62-42410
207-62-74190
07000-13032
Already installed to
07371-31049
07375-21035

Name

Qty

Assembly procedure

Installation of bucket (1/3)

B-4

(1) Remove the stoppers of the bucket and arm connecting pin (fixed to the arm) and bucket and link connecting
pin (installed to the link) and remove each pin.
(2) Install bushing (1) to the boss on the bucket side and install O-ring (2) to the position shown below.
a Inside of the bushing: Apply LM-P(Only 1st time)
[lithium grease for 2nd time and after]
(3) Start and run the engine at idle and operate the boom and arm cylinders slowly to match the holes for the bucket and arm connecting pin.
a Weight of bucket assembly: For the weight, see the table of transportation posture.
(4) Push in the arm and bucket connecting pin, check clearance "a" all around and adjust it to 0.5 to 1.0 mm with
shims (3) and (4), and then tighten the stopper mounting bolts (M24).
a For the shim adjustment method, see Step B-4, Installation of bucket assembly (3/3).
(5) Install the lock bolt and nut of the arm and bucket connecting pin.

Installed position of O-ring (2)

No.
1
2
3
4

Clearance a
(0.5 1.0 mm)
Precautions

Necessary tools
Name

Qty
1

Large hammer

Socket 36 mm width across flats

Spanner 36 mm width across flats

Large-sized impact wrench

Others

32

Qty
1
2
20
4

Necessary equipment

Nylon sling

When tightening, adjust the clearance between

the double nut and stopper to 0.5 to 1.5 mm. (Part
marked with )

Loose-supply items
207-70-34230
207-70-33181
207-70-34250
207-70-34260

Name
25 t crane

Qty
1

Assembly procedure

Installation of bucket (2/3)

B-4

(6) While slinging the link and operating the bucket cylinder, set the holes for the bucket and link connecting pin.
a Operate the cylinder slowly. Do not operate it quickly or to the stroke end. Since there is air in the cylinder,
the piston rod may not move for more than 10 seconds. Do not move the lever to the stroke end at this time.
(7) Push in the link and bucket connecting pin, install soil entry prevention O-ring (1) to the normal position, and
then install the bolt and nut of the pin lock plate.

Correct position of O-ring

No.
1
Precautions

Necessary tools
Name

Qty
1

Socket 36 mm width across flats

Spanner 36 mm width across flats

Large-sized impact wrench

Others

Qty
2

Necessary equipment

Large hammer

33

Loose-supply items
205-70-73280

Name

Qty

Assembly procedure

Installation of bucket (3/3)

B-4
a Adjustment method of bucket shim

1. Install the arm and bucket connecting pin with no shim as shown below.

2. Measure clearance at portion marked with .

a Measure while there is no clearance on both sides of the arm end.

Position of O-ring for shim adjustment

3. Set the total shim thickness 0.5 to 1.0 mm larger than the measured clearance at portion marked with

Precautions

Necessary tools

Others

Name

34

Necessary equipment
Qty

Name

Qty

Assembly procedure

B-5

Greasing after completion of work equipment

(1) Supply grease to each part.

Use grease LM-G.
1) Arm and link connecting pin (1 place)
2) Arm and bucket connecting pin (1 place)
3) Link connecting pin (2 places)
4) Bucket cylinder rod end (1 place)
5) Bucket and link connecting pin (1 place)
6) Arm cylinder foot pin (1 place)
7) Boom and arm connecting pin (1 place)
8) Arm cylinder rod end (1 place)
9) 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

35

Qty
1

Assembly procedure

B-6

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.

Precautions

Necessary tools
Name

Others

a Before operating the cylinder, check that the

flushing filter is installed (to capture dirt in the
circuit).

36

Necessary equipment
Qty

Name

Qty

C. INCREASING AND DECREASING OF TRACK FRAME GAUGE,

ASSEMBLING OF COUNTERWEIGHT

37

Assembly procedure

Adjustment of track tension (1/3)

C-1
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) Drive forward by the length of track on ground
with engine speed at low idle, and then stop slowly.
(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 10 to 30 mm, it is normal.

Precautions

Necessary tools

Others

Name

38

Necessary equipment
Qty

Name

Qty

Assembly procedure

Adjustment of track tension (2/3)

C-1

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

39

Qty
1

Assembly procedure

Adjustment of track tension (3/3)

C-1
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

40

Name

Qty

Assembly procedure

Sticking sheet to counterweight

C-2

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.

41

Loose-supply items
207-46-41711
207-46-41771
207-46-41721
207-46-41731
207-46-41741

Qty
1
1
1
1
1

Necessary equipment
Qty

Name

Qty

Assembly procedure

Installation of camera (1/6)

C-3

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

Connector(CN-A45)

No.
1
Precautions

Necessary tools

Others

Name

42

Loose-supply items
207-06-41130

Qty
1

Necessary equipment
Qty

Name

Qty

Assembly procedure

Installation of camera (2/6)

C-3

(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

43

Loose-supply items
Camera A.
01024-81025

Qty
1
2

Necessary equipment
Qty

Name

Qty

Assembly procedure

Installation of camera (3/6)

C-3
(4) Install cover (1) as shown below.

Adjust shim (2) so that the vertical clearance

between the cover (1) and counterweight
(part marked with
) varies less than 2 mm
all around.
Cover (1) and counterweight must not interfere with each other.

No.
1
2
3
Precautions

Necessary tools

Others

Name

44

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-3
(5) Install cover (1) as shown below.

Hitch hooks to holes

No.
1
Precautions

Necessary tools

Others

Name

45

Loose-supply items
207-06-76451

Qty
1

Necessary equipment
Qty

Name

Qty

Assembly procedure

Installation of camera (5/6)

C-3

(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
(Mark :6 places)

No.
1
Precautions

Necessary tools

Others

Name

46

Loose-supply items
2A5-06-11860

Qty
1

Necessary equipment
Qty

Name

Qty

Assembly procedure

Installation of camera (6/6)

C-3

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

47

Counterweight

Necessary equipment
Qty

Name

Qty

Assembly procedure

C-4

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 : 7,100 kg

Tightening torque

a Parts (4) are shims for adjusting

clearance and level difference
207-46-32150: 1 mm thick
207-46-32140: 0.5mm thick

Precautions

Name

Qty
2

Large-sized impact wrench

Socket 55 mm width across flats

Shackle SD32

Torque wrench 1050 to 4200 Nm

48

Loose-supply items
207-46-41810
01643-33690
207-46-32140
207-46-32150

Qty
4
4
4
4

Necessary equipment

30 3,000 mm wire

Others

a Do not insert any shim basically for adjusting

clearance or level difference.
If adjustment is necessary observe the following.
a) Adjust only the inclination in the backward
and forward directions by inserting a shim.
b) Always adjust the same quantity on the right
and left sides of the machine.
Example) Both rear holes: 2 mm Both front
holes: 0 mm
c) Limit the adjustment quantity with shim to 2
mm.
a For adjustment after assembling the counterweight, see 3/3.
a Dimension of hanging hole of counterweight:
42 mm

Necessary tools

No.
2
3

Name
25 t crane

Qty
1

Assembly procedure

C-4

Installation of counterweight (2/3)

(1) When installing the counterweight to the machine, take care not to catch the wiring harness of the rear view
monitoring camera.
After installing, connect connector (CN-A40).

Connector
(CN-A40)

a Take care not to catch

wiring harness of rear
view monitoring camera

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.

49

Necessary equipment
Qty

Name

Qty

Assembly procedure

Installation of counterweight (3/3)

C-4

(4) Adjustment method of assembled counterweight

Counterweight

Level difference "d":

9 4mm

Level difference "e":

0 to 5 mm

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 9 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.

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

(Difference between
points T and S: 0 to 4 mm)
Left and right
door

Level difference "b":

0 to 5 mm
Counterweight
Level difference "b": 0 to 5 mm

Clearance "a": 10 5 mm

Precautions

Necessary tools

Others

Name

50

Necessary equipment
Qty

Name

Qty

M. PROCEDURE FOR INSPECTION AND MAINTENANCE AFTER

COMPLETION OF ASSEMBLY

51

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

(207-60-71182), strainer (20Y-60-31140) and
valve (20Y-60-31131) 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)

52

Loose-supply items
22U-60-21370
22U-60-21380

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.

53

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

54

Necessary equipment
Qty

Name

Qty

Assembly procedure

M-3

Replacement of return filter

(Standard filter to flushing 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

Valve

Replacement

Strainer

Standard element

Precautions

Necessary tools

Others

Name

55

Necessary equipment
Qty

Name

Qty

Assembly procedure

Replacement of return filter

(Standard filter to flushing filter) (2/2)

M-3
State of inserted 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

56

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) in the table, see the "Operation and Maintenance Manual".
For details of the recommended genuine oil, see the "Operation and Maintenance Manual", too.

57

Assembly procedure

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

M-4

Engine
oil pan

Swing
machinery
case

Final drive
case
(Each of
right and
left)

Damper
case

Hydraulic
oil system

Cooling
system

Fuel tank

Specified capacity (l)

35

16.5

9.0

1.3

365

37

605

Refill capacity
(l)

35

13.7

9.0

1.3

188

37

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

10.5

12.6

14.4

16.1

17.5

18.9

20.3

Water

24.5

22.4

20.6

18.9

17.5

16.1

14.7

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.

58

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) Within 15 seconds after stopping the engine,
turn the starting switch to the ON position and
operate each control lever (work equipment and
travel) to the stroke end in each direction to release the 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) Whenthe 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-1 ".

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

59

Necessary equipment
Qty

Name

Qty

Assembly procedure

M-5

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

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 (3) 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

60

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 boom end

(2) Underside of arm

(3) Underside of counterweight

(4) Underside of bucket

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

61

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.

62

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}

M16 235 to 285 Nm {23.5 to 29.5 kgm}

No.

Bolt size: M12

Torque

No.

63

Bolt size: M16

Torque

Mounting bolt torque check sheet

Counterweight mounting bolt

Tightening torque: 2,450 to 3,040 Nm {250 to 310 kgm}

No.

Torque

1
2
3
4

64

Revision

Category

4/13

Local After
assembly hours of
time
operation

Check item

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.
There should be no scratches or misting
of the lens or variation in operation.

Operation of service meter

Check monitor

MONITOR

(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)

Wiper switch
Buzzer cancel switch
Auto-deceleration switch
Engine coolant temperature monitor
Engine coolant temperature gauge
Hydraulic oil temperature gauge
Service meter, Clock
Hydraulic oil temperature monitor
Working mode monitor
Travel speed monitor
Fuel gauge
ECO gauge
Fuel level monitor
Working mode selector switch
Travel speed selector switch
Window washer switch
Air conditioner control switches
Engine oil pressure monitor
Charge level monitor

(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
(28)
(29)
(30)
(31)
(32)
(33)
(34)
(35)

Radiator coolant level monitor

Message monitor
Air conditioner monitor
Wiper monitor
Swing lock monitor
Engine pre-heating monitor or One-touch power
max. monitor
Auto-deceleration monitor
Engine oil level monitor
Air cleaner clogging monitor
Water separator monitor
Function switches (F1 to F6)
Maintenance interval monitor
Seatbelt monitor
Engine stop monitor
KDPF regeneration monitor or KDPF
regeneration stop monitor
Fuel consumption gauge

Check of switches, control levers

Revision

Category

5/13

Check item

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

Radio
Lock lever
L.H. work equipment control lever
One-touch power max. switch
Travel pedals
Travel levers
Horn switch
Machine monitor
Cigarette lighter
R.H. work equipment control lever
Starting switch
Fuel control dial

Operation of horn switch

Operation of lock lever

Operation of fuel control dial

Local After
assembly hours of
time
operation

(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)

Judgement standard

Lamp switch
Swing lock switch
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)
Room lamp switch
Emergency pump drive switch
Swing brake cancel switch
Engine shutdown secondary switch
Heated seat switch (if equipped)
Press the switch on the right work
equipment control lever to sound the
horn. At the same time, the flashing light
(option) at the bottom front of the cab
will flash for approx. 5 seconds.
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

Revision

Category

6/13

Check item

Operation of working mode selector switch

Operation of auto-deceleration switch

Check of switches, control levers

Operation of travel speed switch

Operation of wiper switch

Operation of window washer switch

Operation of cigarette lighter
Operation of lamp switch

Operation of swing lock switch

Operation of machine push-up switch

Local After
assembly hours of
time
operation

Judgement standard
Lighting of P: For heavy load work
(ATT/P)
Lighting of E: For economical work
(ATT/E)
Lighting of L: For lifting work
Lighting of B: For breaker work
Monitor display changes, synchronizing
with switch
Full throttle speed of engine changes
When engine is started, P mode is
selected automatically
ON lights up: Auto-deceleration is
actuated.
OFF:
Auto-deceleration is
canceled.
Each time the switch is pressed, the
auto-deceleration is actuated or
canceled.
This is used to select the two travel
speeds.
Lo lights up: Low speed travel
Mid lights up: Middle speed travel
Hi lights up: High speed travel
When the engine is started, the travel
speed is automatically set to Lo.
ON lights up: Wiper moves continuously
INT lights up: Wiper moves intermittently
OFF: Wiper stops
If switch is held down, window washer
liquid spouts out.
(Interlocked with wiper)
If lighter is pushed in, it is heated red
and returned to original position in
several seconds.
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 room lamp switch

ON position: Room lamp lights up.

Operation of emergency pump drive switch

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

While monitor is indicating "Pump control error", if switch is in

"UP" position, emergency pump can be driven

Revision

Category

7/13

Check item
Operation of swing brake cancel switch
While monitor is indicating "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
Operation of lower wiper switch (option)
Operation of travel levers

Check of switches, control levers

Operation of left work equipment control lever

(with auto-deceleration device)

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)
Check function of large capacity air conditioner blower switch
(option)

Local After
assembly hours of
time
operation

Judgement standard
Normal state:
Switch is in "LOWER" position
If switch is set to "UPPER" position,
alarm buzzer sounds and swing lock
symbol flashes
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
ON: Blower actuated
OFF: Blower stopped

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 A mode.

Local
After
assembly hours of
time
operation

Check item

Judgement standard

1. Engine speed
Low idle speed

rpm ]

1000 25 rpm
Auto-decelerator cancelled,
Monitoring
lever in neutral

High idle speed

rpm ]

Swing lock OFF: 1,900 rpm

mode ID
[01002]

Swing lock ON : 2,050 rpm

Speed at arm IN

rpm ]

1750 100 rpm at P mode swing

lock ON

Main Measurement items

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

34.81 (+1.47 / -1.18)MPa

RAISE

Boom

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

*37.26 (+1.47 / -1.18)MPa
{380 (+15 / -12)kg/cm3}

Arm

Bucket

Hydraulic oil temperature : Within

operating range

34.81 (+1.47 / -1.18)MPa

Engine at high idle

*37.26 (+1.47 / -1.18)MPa

Working mode: P mode

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

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

30.87 (+1.47 / -2.45)MPa

Swing

Hydraulic pump output pressure

when measured circuits is
relieved

Travel

Mark * indicates oil pressure

when one-touch power max.
function is ON (Reference)

37.27 (+2.94 / -0.98)MPa

Hydraulic oil temperature: Within

operating range

3.23 0.2 MPa

Control circuit source

pressure

Engine at high idle

Outlet pressure of self-pressure
reducing valve when all control
levers are in neutral

{315 (+15 / -25)kg/cm3}

{380 (+30 / -10)kg/cm3}

{33 2 kg/cm3}

Revision

Category

13/13

Local
After
assembly hours of
time
operation

Check item

Judgement standard

3. Hydrauric drift of work equipment

(Bucket load: 2,160 kg, hydraulic oil temperature 50 5C)
Bucket tooth tip

mm ]

Max.500 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.
Boom cylinder

mm ]

Max. 30 mm/ minutes

Arm cylinder

mm ]

Max.165 mm/ minutes

Bucket cylinder

mm ]

Max.25 mm/ minutes

4. Operation force, travel

Boom
lever

Operating
force

RISE

(kg)
N

RISE

LOWER

LOWER

(kg)
N

Main measurement items

Swing
lever

Operating
force

mm]

mm]

RIGHT

(kg)

RIGHT

LEFT

mm]

(kg)

LEFT

PLAY

Stroke
[
Bucket
lever

Operating
force

mm]

CURL

mm]

(kg)
N

CURL

mm]

(kg)

DUMP

DUMP

Arm lever

Operating
force

Stroke

Operating
force

Stroke

Operating
force

Stroke

mm]

(kg)

OUT

OUT
mm]

FOR

WARD

(kg)

mm]

FOR

WARD

FORWARD

mm]

RE

mm]

(kg)
N

VERSE

{1.3 0.3 kg}

Stroke: 85 10 mm
Play: Max. 15mm
12.7 2.9 N
{1.3 0.3 kg}

Play: Max. 15mm

15.7 3.9 N
{1.6 0.4 kg}
Stroke: 85 10 mm
Play: Max. 15mm
24.5 5.9 N
{2.5 0.6 kg}

Play: Max. 20mm

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

PLAY
[

12.7 2.9 N

Stroke: 115 15 mm

PLAY

REVERSE
[

(kg)
N

VERSE

mm]

(kg)

mm]

RE

REVERSE

mm]

PLAY
mm]

FORWARD

mm]

IN

[
Left travel
lever

(kg)

IN

[
Right
travel
lever

mm]

Play: Max. 15mm

Stroke: 85 10 mm

PLAY

Stroke
[

{1.6 0.4 kg}

Stroke: 85 10 mm

PLAY

Stroke
[

15.7 3.9 N

mm]

Play: Max. 20mm

At engine high
idling, relief