Komatsu PC210-11, PC240-11, PC290-11, PC360-11, PC390-11 Service Manual

333514B

Mobile Lubrication Library

Komatsu PC210-11/PC240-11/PC290-11

and PC360-11/ PC390-11/PC490-11

Excavator Installation Instructions

Instructions for installing a Graco automatic lubrication system on a Komatsu PC210-11/PC240-11/PC290-11 and PC360-11/PC390-11/PC490-11 Excavator.

Part No. 17J900

Maximum System Working Pressure: 2750 psi (18.96 MPa, 189.6 bar)

Important Safety Information

Read all warnings and instructions in all Graco related component manuals and all Komatsu equipment manuals. Save all instructions.

Related Graco Component Manuals*

Manual No. Manual Title

332291

G3 Pump

3A2960 GLC2200 Controller

312497 MSP Divider Valves

*Refer to these instruction manuals for additional information related to the installation and operation of system components.

WARNING

FLUID INJECTION HAZARD

Fluid leaks from incorrectly installed or ruptured components, and/or failure to verify the components are properly installed and tested, can result in serious injury such as fluid spraying in the eyes or on skin and fluid injection, or equipment damage. Installation must be done by a qualified professional or Komatsu certified technician and tested prior to use.

The information contained in this document is only a recommendation for an automatic lubrication system and is not intended to replace the installation and maintenance instructions provided by the original equipment manufacturer.

Table of Contents

Table of Contents

Installation Checklist . . . . . . . . . . . . . . . . . . . . . . . . 3

Recommended Tools and Supplies . . . . . . . . . . . . 4

Installation Notes . . . . . . . . . . . . . . . . . . . . . . . . 4

Typical Installation . . . . . . . . . . . . . . . . . . . . . . . . . 5

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Before You Start . . . . . . . . . . . . . . . . . . . . . . . . . 6

Bearing Point Fittings . . . . . . . . . . . . . . . . . . . . . . . 7

MSP Divider Valves . . . . . . . . . . . . . . . . . . . . . . . . 14

MSP Valve Component Identification . . . . . . . . 14

MSP Divider Valve Assembly . . . . . . . . . . . . . . 14

MSP Divider Valve Assembly . . . . . . . . . . . . . . 16

Weld Stud Guidelines . . . . . . . . . . . . . . . . . . . . . . 17

G3 Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

G3 Mounting Bracket Installation . . . . . . . . . . . 23

Remote Fill Installation . . . . . . . . . . . . . . . . . . . . . 24

GLC2200 Controller . . . . . . . . . . . . . . . . . . . . . . . . 28

GLC2200 Controller Wiring . . . . . . . . . . . . . . . . . . 30

Hose Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Hose Assembly Instructions . . . . . . . . . . . . . . . 33

Hose Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Hose Installation . . . . . . . . . . . . . . . . . . . . . . . . 34

Arm and Bucket Valve . . . . . . . . . . . . . . . . . . . . 37

Boom and Swing Circle Valve . . . . . . . . . . . . . . 40

GLC2200 Controller Programming . . . . . . . . . . . . 43

Filling and Purging . . . . . . . . . . . . . . . . . . . . . . . . 46

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Routine Service and Equipment Maintenance . . 47

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 52

2	NOTE: Photographs may include optional equipment.

Installation Checklist

Installation Checklist

The following checklist is provided as a tool to ensure all installation procedures are completed.

Completed	Description	Page
	Walk around the equipment; use a grease gun to verify that all lube points receive grease.	6
	Grease all zerks, before removal	6
	Remove zerks and Komatsu extensions.	6
	Install bearing point fittings	7
	Assemble MSP Divider Valves	14
	Install P-clamp, anchor and MSP valve weld studs	19
	Assemble the G3 pump and fittings	21
	Install G3 pump	22
	Install remote fill	24
	Install and route G3 power cable	25
	Install GLC2200 controller	28
	Wire GLC2200 controller and pump	30
	Route and wrap hoses between divider valves, bearing points and pump	34
	Install P-clamps, zip ties, and other anchors	34
	Program GLC2200 controller	43
	Fill the G3 pump reservoir with grease; purge the main feed lines	46
	Run test program; verify all connections are tight; verify all points are receiving lubricant	47

NOTE: Photographs may include optional equipment.

3

Recommended Tools and Supplies

Recommended Tools and Supplies

	Size/Description
Tool
	US		Metric
Combination wrench*	1/4 in. - 3/4 in.		6 mm - 20 mm
Socket set, standard and deep well with ratchet*	3/8 in. - 3/4 in.		9.5 mm - 20 mm
Screwdrivers: standard and Phillips	1 short; 1 long
Adjustable wrench	1 small; 1 medium
High speed drill (corded or cordless)
Drill bit - steel, high quality	5/16 in., 11/16 in.
Center punch	fine point
Pipe taper tap	1/8 in. NPT
Hammer
Angle grinder
Grinding disc	Heavy grade grinding disc
Flap disc	60 - 80 grit
Cutoff disc	High quality disc
Cutting blade / knife	Razor blade cutting tool
Standard pliers	Rubber handle
Needle nose pliers	Rubber handle
Side cut pliers (diagonal cutters)	Rubber handle
Slip joint pliers	Rubber handle
Locking pliers	Small or medium
Electrician’s wire striper / crimper	General duty wire striper / crimper
Soldering iron	30 watt minimum
Electrical solder
Soldering flux
Shrink tubing	Various sizes
Electrical tape	Black, small roll
Thread sealant	Liquid thread sealant such as Loctite® 656
Multi-tester / voltmeter	Must test DC/AC/Ohms
Electrical connectors	Ring connectors (14 gauge)
Tape measure	Standard / metric
Komatsu primer and paint	Color should match the Komatsu equipment
Documentation / writing implements	Small note pad, pen, pencil, marker

*Both US and Metric sizes of these tools are recommended.

Loctite® is a registered trademark of the Henkel Corporation.

All other Trademarks used herein are the property of their respective owners.

Installation Notes

• Do not use PTFE tape on fitting threads. Liquid pipe	• Prime and paint all bare metal surfaces prior to
sealant is recommended for use in lubrication sys-	installation with matching Komatsu primer and paint.
tems to eliminate the potential for contamination. If
you must use PTFE tape, always skip the first two
threads on the fitting.
• Refer to the Installation Checklist provided on page
3 to ensure all installation procedures have been
completed.

4	NOTE: Photographs may include optional equipment.

Typical Installation

Typical Installation

A

B

D

C

Key

AGLC2200 Controller

BG3 Automatic Lubrication Pump

CMSP Divider Valve - Boom and Swing Circle Valve

DMSP Divider Valve - Arm and Bucket Valve

Run Time

MODEL	Pump ON Time	Pump OFF Time
PC210-11/PC240-11	1 minutes and 45 seconds	1 hour
PC290-11/PC360-11	2 minutes	1 hour
PC390-11/PC490-11	2 minutes and 10 seconds	1 hour

NOTE: Photographs may include optional equipment.

5

Installation

Installation

Before You Start

WARNING

Disconnect battery before installing the lubrication equipment. Installing lubrication equipment on powered machinery could result in serious injury from skin injection or parts moving unexpectedly.

FIG. 1: Battery Disconnect

1.Walk around the machine with a grease gun and verify that every bearing point is accepting grease. (Refer to FIG. 3, page 7 to identify lubrication points). This will ensure that the valves can dispense grease to the bearing points by identifying potentially blocked passages from the grease zerk to the bearing point.

Zerk Fittings

a.Use a clean cloth or rag to remove excessive grease, contaminants and dirt from the work area.

b.Remove all grease zerks and Komatsu extensions from their installation locations.

c.Use a clean cloth or rag to remove any remaining grease, contaminants or dirt from the area around the passage way to the bearing points.

d.If required use 1/8 in. NPT pipe tap to chase the passage threads.

2.Flip over the H-link on the excavator bucket (FIG. 2). (The zerk fittings must face the inside of the arm.)

3.After the H-link is reversed, manually grease the lube points again to verify grease is being accepted.

NOTICE

It may be necessary to rotate the pins while greasing to get the grease to purge.

H-Link

FIG. 2

6	NOTE: Photographs may include optional equipment.

Bearing Point Fittings

Bearing Point Fittings

1.Apply thread sealant to supplied bearing point fittings.

2.Install fittings in bearing points. Refer to FIG. 3 and the Bearing Point Fitting Table, page 8 for installation locations and parts.

3.Refer to Bearing Point Fitting Table, beginning on page 8, to determine the location of the bearing points on your model.

4

5

3

6

13

13 6

10
11
12	8
10	9

FIG. 3

NOTE: Photographs may include optional equipment.

7

Bearing Point Fittings

Bearing Point Fittings Table: PC210-11/PC240-11 Models

NOTE: Before starting a lube cycle, set the machine to the greasing posture. If you are unsure of this procedure, see the Komatsu Excavator instruction manual.

Ref
No.	Location	Part No.	Description
1	Boom cylinder rod	17K062	Adapter, long, BSPT x NPT
	pins (2 places)	556763	Elbow, JIC 90° 1/8 inch x 4
2	Arm cylinder foot pin	17K062	Adapter, long, BSPT x NPT
	(1 place)	556763	Elbow, JIC 90° 1/8 inch x 4
3	Boom and arm con-	17G422	Adapter, short, BSPT x NPT
	nection pin (1 place)	556763	Elbow, JIC 90° 1/8 inch x 4
4†	Arm cylinder rod	556763	Elbow, JIC 90° 1/8 inch x 4
	end (1 place)
5	Bucket cylinder foot	17G422	Adapter, short, BSPT x NPT
	pin (1 place)	556763	Elbow, JIC 90° 1/8 inch x 4
6	Boom cylinder foot	17G422	Adapter, short, BSPT x NPT
	pins (2 places)	556763	Elbow, JIC 90° 1/8 inch x 4
7		17K062	Adapter, long, BSPT x NPT
		556763	Elbow, JIC 90° 1/8 inch x 4
	Boom foot pins (2
	places)	17K062	Adapter, long, BSPT x NPT	7
7*		17K061	Adapter, street elbow, BSPT x NPT	7
		555749	Connector, #4, JIC, 1/8 PM

8	NOTE: Photographs may include optional equipment.

Bearing Point Fittings

8	Arm and link con-	17K061	Adapter, street elbow, BSPT x NPT
	nection pin (1 place)	555749	Connector, #4, JIC, 1/8 PM
9	Arm and bucket con-	17K061	Adapter, street elbow, BSPT x NPT
	nection pin (1 place)	555749	Connector, #4, JIC, 1/8 PM
10	H-Link connecting	17G422	Adapter, short, BSPT x NPT
	pins (2 places)	556763	Elbow, JIC 90° 1/8 inch x 4
11	Bucket cylinder rod	17K061	Adapter, street elbow, BSPT x NPT
	pin (1 place)	555749	Connector, #4, JIC, 1/8 PM
12	Bucket and link con-	17G422	Adapter, short, BSPT x NPT
	nection pin (1 place)	556763	Elbow, JIC 90° 1/8 inch x 4
13	Swing circle (2	17K062	Adapter, long, BSPT x NPT
	places)	556763	Elbow, JIC 90° 1/8 inch x 4

†Tap rod end with 1/8 NPT tap. Rod end may need to be flipped over to allow clearance for fittings during articulation

Grind slot in cap around zerk wide enough to tighten fittings approximately 1-1/4 inch wide.

NOTE: Photographs may include optional equipment.

9

Bearing Point Fittings

Bearing Point Fittings Table: PC290-11/PC360-11 Models

NOTE: Before starting a lube cycle, set the machine to the greasing posture. If you are unsure of this procedure, see the Komatsu Excavator instruction manual.

	Ref
	No.	Location	Part No.	Description
	1	Boom cylinder rod	17K062	Adapter, long, BSPT x NPT
		pins (2 places)	556763	Elbow, JIC 90° 1/8 inch x 4
	2	Arm cylinder foot pin	17K062	Adapter, long, BSPT x NPT
		(1 place)	556763	Elbow, JIC 90° 1/8 inch x 4
	3	Boom and arm con-	17K061	Adapter, street elbow, BSPT x NPT
		nection pin (1 place)	555749	Connector, #4, JIC, 1/8 PM
	4†	Arm cylinder rod	556763	Elbow, JIC 90° 1/8 inch x 4
		end (1 place)
	5	Bucket cylinder foot	17G422	Adapter, short, BSPT x NPT
		pin (1 place)	556763	Elbow, JIC 90° 1/8 inch x 4
	6	Boom cylinder foot	17G422	Adapter, short, BSPT x NPT
		pins (2 places)	556763	Elbow, JIC 90° 1/8 inch x 4
		Boom foot pins (2	17K062	Adapter, long, BSPT x NPT
	7	places)
			556763	Elbow, JIC 90° 1/8 inch x 4	7
					7

10	NOTE: Photographs may include optional equipment.

Bearing Point Fittings

8	Arm and link con-	17K061	Adapter, street elbow, BSPT x NPT
	nection pin (1 place)	555749	Connector, #4, JIC, 1/8 PM
9	Arm and bucket con-	17K061	Adapter, street elbow, BSPT x NPT
	nection pin (1 place)	555749	Connector, #4, JIC, 1/8 PM
10	H-Link connecting	17G422	Adapter, short, BSPT x NPT
	pins (2 places)	556763	Elbow, JIC 90° 1/8 inch x 4
11	Bucket cylinder rod	17K061	Adapter, street elbow, BSPT x NPT
	pin (1 place)	555749	Connector, #4, JIC, 1/8 PM
12	Bucket and link con-	17K062	Adapter, long, BSPT x NPT
	nection pin (1 place)	556763	Elbow, JIC 90° 1/8 inch x 4
13	Swing circle (2	17K062	Adapter, long, BSPT x NPT
	places)	556763	Elbow, JIC 90° 1/8 inch x 4

† Tap rod end with 1/8 NPT tap. Rod end may need to be flipped over to allow clearance for fittings during articulation.  Remove plug from cylinder end and install plug on opposite side of cylinder where zerk was located.

 Grind slot in cap around zerk wide enough to tighten fittings approximately 1-1/4 inch wide.

NOTE: Photographs may include optional equipment.

11

Bearing Point Fittings

Bearing Point Fittings Table: PC390-11/PC490-11 Models

NOTE: Before starting a lube cycle, set the machine to the greasing posture. If you are unsure of this procedure, see the Komatsu Excavator instruction manual.

	Ref
	No.	Location	Part No.	Description
	1	Boom cylinder rod	17K062	Adapter, long, BSPT x NPT
		pins (2 places)	556763	Elbow, JIC 90° 1/8 inch x 4
	2	Arm cylinder foot pin	17K062	Adapter, long, BSPT x NPT
		(1 place)	556763	Elbow, JIC 90° 1/8 inch x 4
	3	Boom and arm con-	17K061	Adapter, street elbow, BSPT x NPT
		nection pin (1 place)	555749	Connector, #4, JIC, 1/8 PM
			17K062	Adapter, long, BSPT x NPT
	4	Arm cylinder rod	15K783	Elbow, street
		end (1 place)
			555749	Connector, #4, JIC, 1/8 PM
	5	Bucket cylinder foot	17G422	Adapter, short, BSPT x NPT
		pin (1 place)	556763	1/8 inch x 4 JIC 90° elbow
	6	Boom cylinder foot	17G422	Adapter, short, BSPT x NPT
		pins (2 places)	556763	Elbow, JIC 90° 1/8 inch x 4
	7	Boom foot pins (2	17K062	Adapter, long, BSPT x NPT
		places)	556763	Elbow, JIC 90° 1/8 inch x 4	7
					7

12	NOTE: Photographs may include optional equipment.

Bearing Point Fittings

8	Arm and link con-	17K062	Adapter, long, BSPT x NPT
	nection pin (1 place)	556763	Elbow, JIC 90° 1/8 inch x 4
9	Arm and bucket con-	17K061	Adapter, street elbow, BSPT x NPT
	nection pin (1 place)	555749	Connector, #4, JIC, 1/8 PM
10	H-Link connecting	17K062	Adapter, long, BSPT x NPT
	pins (2 places)	556763	Elbow, JIC 90° 1/8 inch x 4
11	Bucket cylinder rod	17K061	Adapter, street elbow, BSPT x NPT
	pin (1 place)	555749	Connector, #4, JIC, 1/8 PM
12	Bucket and link con-	17K062	Adapter, long, BSPT x NPT
	nection pin (1 place)	556763	Elbow, JIC 90° 1/8 inch x 4
13	Swing circle (2	17K062	Adapter, long, BSPT x NPT
	places)	556763	Elbow, JIC 90° 1/8 inch x 4

 Remove plug from cylinder end and install plug on opposite side of cylinder where zerk was located.

 Grind slot in cap around zerk wide enough to tighten fittings approximately 1-1/4 inch wide.

NOTE: Photographs may include optional equipment.

13

MSP Divider Valves

MSP Divider Valves

The Divider Valve Assembly includes the following components:

•MSP divider valve base

•MSP divider valve assembly

•1/8 in. x 4 JIC straight outlet fittings

•Inlet fittings

•Cycle indicators

•Performance indicators

Prepare a clean, flat area to assemble the valves.

MSP Divider Valve Assembly

1.The MSP Divider Valves require assembly (FIG. 5).

NOTE: Refer to the MSP Divider Valve Assembly Table and MSP Divider Valve and Lube Points Assembly reference illustrations, FIG. 12 - FIG. 13 (page 16), to verify assembly orientation.

a.Remove components from packaging.

b.Assemble metering valves to base plates as shown in FIG. 5.

MSP Valve Component Identification

NOTE: The MSP Divider Valves shown in FIG. 4 - FIG. 10 are provided for reference only. The MSP Divider Valves used in your installation may include fewer or more blocks and appear slightly different than those shown in the reference figures.

B

A

FIG. 5

C

D

E

FIG. 4

Key:

AValve Section

BInlet Section

CIndicator / Port Plug

DEnd Plug

EEnd Section

14	NOTE: Photographs may include optional equipment.

2.Install inlet fitting assembly in ports (FIG. 6).

•Inlet fitting assembly includes: a 1/4 inch tee, a 1/4 x 4 JIC and a zerk fitting

•Orient zerk fitting so it is always easily accessible (see FIG. 6 and FIG. 7).

FIG. 6

MSP Divider Valves

5.Install 1500 psi (10.34 bar, 103.4 MPa) performance indicators in ports (FIG. 9):

NOTE: Refer to the MSP Divider Valve Assembly (page 16) to verify assembly orientation.

Performance

Indicator

FIG. 9

6.Install cycle indicators in valves (FIG. 10).

• Magnetic Cycle indicators (quantity 2)

Cycle Indicator

FIG. 7

3. Install grease zerk fittings and zerk cover (FIG. 8).

zerk

FIG. 8

4.Remove end plugs and indicator port plugs before installing performance and cycle indicators in the MSP Divider Valve assembly.

FIG. 10

7.Install outlet plugs in all open ports as shown in the MSP Divider Valve Assembly reference illustrations (FIG. 12 and FIG. 13, page 16.

8.Install outlet fittings in all ports (FIG. 11).

•All outlets use 1/8 in. x 4 JIC straight fittings (included in kit).

Outlet

Port

FIG. 11

NOTE: Photographs may include optional equipment.

15

MSP Divider Valves

MSP Divider Valve Assembly

Boom and Swing			Arm and
Circle Valve			Bucket Valve
(FIG. 12)			(FIG. 13)
		Plug
10T			10S
40T			20T
40T			40T
40T			40T
20S	Plug		40T

MSP Divider Valve and Lube Points Assembly

Boom and Swing Circle Valve (FIG. 12)

FIG. 12

Arm and Bucket Valve (FIG. 13)

FIG. 13

16	NOTE: Photographs may include optional equipment.