Komatsu PC800-8, PC850-8 Service Manual

CONTENTS

Specifications......................................................................................................................			1
Precautions for Field Assembly ..........................................................................................			2
Assembling Procedures, Applicable Equipment and Schedule ..........................................			3
Kit Layout Diagram .............................................................................................................			4
Transportation.....................................................................................................................			5
List of Tools for Field Assembling.......................................................................................			11
Tightening Torque...............................................................................................................			12
Coating Materials................................................................................................................			16
A. Assembly of Base Machine ............................................................................................			19
A- 1.		Installation of Left and Right Track Frames ...........................................................	20
A-	2.	Installation of Travel Pipe ......................................................................................	24
A- 3.		Installation of Top Guard .......................................................................................	27
A-	4.	Installation of Radiator Cover ................................................................................	28
A-	5.	Installation of Rearview Mirror ...............................................................................	29
A-	6.	Installation of Left Side Step ..................................................................................	33
A-	7.	Installation of Handrail ...........................................................................................	34
A-	8.	Installation of Handrail (With top guard) ................................................................	35
A-	9.	Installation of Muffler Tail Tube..............................................................................	37
A-10. Sticking Sheet to Counterweight ...........................................................................			38
A-11. Installation of Counterweight .................................................................................			39
A-12. Installation of ORBCOMM Antenna (if equipped)..................................................			40
A-13. Installation of Step Light ........................................................................................			41
A-14. Air Bleeding of Travel Motor ..................................................................................			43
A-15. Installation of Travel Piping Cover.........................................................................			44
A-16. Testing Track Shoe Tension..................................................................................			46
A-17. Check Fuel, Coolant and Oil Levels ......................................................................			49
A-18. Parts to be Touched up after Field Assembly........................................................			52
B. Assembling of Work Equipment of Backhoe ..................................................................			53
B- 1.		Assembly of Arm Cylinder .....................................................................................	54
B- 2.		Connection of Arm Cylinder Hoses........................................................................	55
B- 3.		Installation of Boom Cylinder Foot.........................................................................	57
B- 4.		Relieving Remaining Pressure from Hydraulic Circuit ...........................................	58
B- 5.		Installation of Boom Cylinder Hoses......................................................................	59
B- 6.		Assembly of Boom Assembly ................................................................................	60
B- 7.		Hose Connection of Arm and Bucket Circuits........................................................	61
B- 8.		Installation of Quick Return Hose ..........................................................................	62
B- 9.		Installation of Boom Cylinder .................................................................................	63
B-10. Installation of Arm Assembly .................................................................................			64
B-11. Installation of Hose between Boom and Bucket Cylinder......................................			66
B-12. Installation of Bucket Assembly.............................................................................			67
B-13. Lubrication Piping to Work Equipment ..................................................................			68
B-14. Air Bleeding from Cylinder.....................................................................................			69
B-15. Wiring of Work Equipment.....................................................................................			70
B-16. Greasing after Assembling Work Equipment.........................................................			71
M. Procedure for Inspection and Maintenance after Completion of Assembly ...................			73
M- 1. Inspection of Oil Level in Hydraulic Tank and Refill ..............................................			74
M- 2. Replacement of Return Filter (Standard Filter to Flushing Filter)..........................			76
M- 3. Flushing of Hydraulic Circuit .................................................................................			79
M- 4. Error Code.............................................................................................................			81

C. Assembling of Work Equipment of Loading Shovel.....................................................	83
C- 1. Releasing residual pressure in hydraulic circuit ..................................................	84
C- 2. Pulling out boom foot pin and boom cylinder foot pin .........................................	85
C- 3. Installation of boom and arm assembly...............................................................	86
C- 4. Installation of flushing piping between chassis and boom ..................................	87
C- 5. Installation of flushing piping for boom cylinder and arm cylinder.......................	88
C- 6. Installation of flushing piping for bucket cylinder.................................................	89
C- 7. Installation of flushing piping for bottom dump cylinder ......................................	90
C- 8. Installation of boom cylinder................................................................................	92
C- 9. Installation of boom cylinder foot.........................................................................	93
C-10. Installation of boom cylinder hoses.....................................................................	94
C-11. Installation of boom cylinder rod pin ...................................................................	95
C-12. Installation of arm cylinder hoses........................................................................	96
C-13. Installation of bucket cylinder..............................................................................	97
C-14. Installation of bucket cylinder hose .....................................................................	98
C-15. Installation of connecting hoses between chassis and boom top .......................	99
C-16. Installation of bottom dump cylinder hoses.........................................................	100
C-17. Installation of bucket assembly ...........................................................................	101
C-18. Installation of working lamps...............................................................................	103
C-19. Installation of work equipment grease piping......................................................	104
C-20. Greasing after assembling of work equipment....................................................	105
C-21. Bleeding air from work equipment circuit ............................................................	106
C-22. Checking oil level in hydraulic tank and adding oil..............................................	107
C-23. Replacement of Return Filter (Standard Filter to Flushing Filter) .......................	108
C-24. Flushing of Hydraulic Circuit ...............................................................................	111
Field Assembly Inspection Report (Backhoe)
Field Assembly Inspection Report (Loading Shovel)

SPECIFICATIONS

Machine model		PC800-8	PC800LC-8		PC800SE-8	PC850-8	PC850SE-8
Weight of machine	kg	75,000	77,200		76,000	79,500	79,100
Bucket capacity	m3	3.1	3.1		4.0	3.4	4.3
Engine model	–				SAA6D140E-5
Flywheel horsepower	kW/rpm {HP/rpm}			363/1,800 {486/1,800}
Min. ground clearance	mm			840
Travel speed (Low/High)	km/h			2.8/4.2
Swing speed	rpm			6.8

PC800-8

aThe figures in ( ) show the value when the track width is reduced.

PC850-8

aThe figures in ( ) show the value when the track width is reduced.

1

PRECAUTIONS FOR FIELD ASSEMBLY

1.Selection of workplace

1)When selecting a workplace, consider the following items so that you can load and unload the machine.

•Width

•Hardness

•Flatness

•Access road, place for turn

2)Do not work in a place where dust, rainwater, etc. may enter the hydraulic circuit during assembling work.

3)Do not assemble while a strong wind is blowing or it is raining.

2.Preparation and check of slings and tools

1)Check each sling and tool thoroughly. When using wood blocks, etc., check that their inside is not rotten or broken.

3.Check of actual work

1)Apply the parking brakes of the trailer and crane truck securely and put chocks under their wheels.

2)Before starting the work lower the temperature and pressure of the engine oil, hydraulic oil, cooling water, etc.

3)When starting the engine, make an arranged sign such as sounding of the horn and check that the work equipment control lever and travel lever are in neutral and the fuel control dial (or fuel control lever) is at the low idling position.

4)When using the crane, balance the load.

5)Allow only the persons concerned into the workplace.

4.Before starting the work, read this manual thoroughly and keep the precautions in your mind.

The numbers in circles in the illustrations correspond to the numbers in ( ) in the text. (For example q (1))

5.The supervisor shall write down the precautions for each work process and explain them to the workers.

6.Hold a meeting every morning to check today's work plan and safe work.

2

3

Days

Assembly unit

Crane

Air compressor

Worker

Base machine

q Left track frame w Right track frame e Axle assembly

(Two)

45t 45t

0.49 -- 0.69 MPa (5 -- 7 kg/cm2)

15 m3/min

Leader + 3 mechanics

Start of assembling

· Meeting with all workers

Backhoe

		Loading shovel-
		type excavator
r Upper structure	t Counterweight
	y Platform group
	· Inspection of oil	u Assembling of work
	level and coolant level	equipment

35t

·Inspection of oil level and coolant level

·Air bleeding from work equipment cylinder

·Flushing of hydraulic circuit

·Adjustment of track tension

·Performance test

Divisions 4	AND EQUIPMENT APPLICABLE	PROCEDURES, ASSEMBLING
	SCHEDULE

	Completion of Installation of unit assembly to body	Completion of body	· Completion of general
		assembling	assembling

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 ASSEMBLING”.

Tools, facility

45t crane

Left deck

Crawler frame

Motor cover · handrails

Bucket
Arm link
	cylinder
Boom	Arm
	Boom
	cylinder
Foreword
	frame
Revolving	Crawler
frame
Counterweight	45t crane

4

TRANSPORTATION

Packing Style for Transportation

These machines can be divided into three or four kits for transportation. Please ask us or our service shop for transportation.

t 4-kit Transportation

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

•Upper structure (single piece of cab)

		a	Cab convex portion (air intake for air conditioner)	3,219
	Full width	b	Door hinge	3,204
		c	Lock used when the door is opened	3,262
	(mm)
		d	Stopper used when the door is opened	3,287
		e	Handrail	3,220

5

•Upper structure without head guard

Unit: mm

	Equipped				Not equipped
	with cab				with cab
Overall height	H1: 2,840				H2: 2,840
(mm)
	a		3,204
Overall width	b		3,220
	c		3,262	*3,195
(mm)
	d		3,219
	e		3,287
Weight (kg)		25,620		25,080

* Revolving frame

• Upper structure with head guard

Unit: mm
			Equipped				Not equipped
			with cab				with cab
	Overall height		H1: 2,910				H2: 2,840
	(mm)
			a		3,204
	Overall width		b		3,220
			c		3,262	*3,195
	(mm)
			d		3,219
			e		3,287
	Weight (kg)			25,770		25,180
Fix the upper structure on the truck by means of chain block.	* Revolving frame

• Undercarriage

Unit: mm

	Model	PC800-8	PC850-8	PC800LC-8
		PC800SE-8	PC850SE-8
	Quantity	2	2	2
	Weight (kg)	21,500	22,000	23,600
		(10,750×2)	(11,000×2)	(11,800×2)

6

•Work equipment

(1) Boom

	Model	PC800-8	PC800SE-8	PC850-8	PC850SE-8
		PC800LC-8
	A (mm)	8,505	7,405	8,345	7,405
	B (mm)	2,705	2,560	2,695	2,560
	C (mm)	4,387	4,104	4,295	4,104
	D (mm)	1,218	1,098	1,210	1,098
	Overall	1,500	1,500	1,500	1,500
	width (mm)
	Weight	7,510	6,950	7,770	6,950
	(kg)

(2) Arm

	Model	PC800-8	PC800SE-8	PC850-8	PC850SE-8
		PC800LC-8
	A (mm)	5,105	4,075	4,800	4,075
	B (mm)	1,324	1,696	1,410	1,696
	C (mm)	2,459	2,237	2,478	2,237
	D (mm)	577	709	648	709
	Overall	749	753	749	753
	width (mm)
	Weight	3,970	4,880	4,485	4,880
	(kg)

(3) Bucket

	Model	PC800-8	PC800SE-8	PC850-8	PC850SE-8
		PC800LC-8
	A (mm)	2,365	2,200	2,390	2,200
	B (mm)	1,850	1,950	1,880	1,950
	C (mm)	1,052	889	1,118	889
	D (mm)	646	714	599	714
	Overall	1,845	2,105	1,870	2,255
	width (mm)
	Weight	2,960	3,420	3,840	4,245
	(kg)

7

(4) Boom cylinder (for all models)

Weight: 1,550 kg (775 kg × 2 pcs)

(5) Arm cylinder

		PC800-8	PC800SE-8
	Model		PC850-8
		PC800LC-8
			PC850SE-8
	Quantity	1	2
	A (mm)	3,500	2,595
	B (mm)	1,885	1,391
	Weight	870	986 (493 × 2)
	(kg)

•Others

(1) Counterweight

Unit: mm

	Model	PC800-8	PC850-8	PC800LC-8
		PC800SE-8	PC850SE-8	(If equipped)
	A (mm)	451	451	451
	B (mm)	1,689	1,689	1,689
	C (mm)	684	684	684
	Weight	9,740	11,890	13,600
	(kg)

8

(2) Top guard (PC850-8, PC850SE-8 only)

Unit: mm

Weight: 55 kg

(3) Catwalk (1) (for all models)

Unit: mm

Weight: 49 kg

(4) Catwalk (2) (for all models)

Unit: mm

Weight: 31 kg

9

(5) Radiator duct (for all models)

Unit: mm

Weight: 81 kg

(6) Travel motor cover (for all models)

Weight: 115 kg × 2

10

LIST OF TOOLS FOR FIELD ASSEMBLING

	No.		Tool names	Specifications	Q’ty.	Remarks
	1	Equipment	Engine compressor	Komatsu, 0.69 MPa {7.0kg/cm2} Class	1
	4		Stepladder	5 -stepped- 1500 mm	2
	2		Crane truck	441 kN {45 ton}, 245 kN {25 ton}	1 each
	3		Grease pump	Air type	1	Work equipment lubrication
	5		Impact wrench	KW10P (for M10)	1
	6			KW12PI (For M12)	1
	7			KW20P (For M16)	1
	8			KW45FS (Spline)	1	For counterweight
	9		Socket for KW45FS	Spline × 65 mm	1	For counterweight
	10		Air hose	50 m	1	For impact wrench
	11		16-time wrench	4413 Nm {450 kgm}	1	For counterweight
	12		Socket for 16-time wrench	T38.1 × 65 mm	1	For counterweight
	13			T38.1 × 55 mm	1	For track frame
	14			T38.1 × 50 mm	1	For track frame
	15		4-time wrench	25.4, 19	1
	16	Tool	Socket for 4-time wrench	T25.4 × 50 mm	1
	17			T25.4 × 55 mm	1
	18		Torque wrench	412 Nm {42 kgm} – T25.4 mm	1	For 16-time wrench
	19			834 Nm {85 kgm} – T25.4 mm	1	For 4-time wrench
	20			4118 Nm {420 kgm} – T38.1 mm	1	For counterweight and track frame
	21		Standard tool	Socket, spanner, wrench	2 set
	22		Sledge hammer	10 P	1
	23		Bar	1 m	2
	24		Hydraulic jack	490 kN {50 ton} (stroke 170)	2	Revolving frame pedestal
	25			196 kN {20 ton}	1	When tightening track frame
						connecting bolts.
	26		Waste oil pan	Large, small	2 each	When connecting travel and
						work equipment piping
	27		Wooden block	300 × 400 mm	4	Revolving frame pedestal
	28		Wire	ø10 × 3 m	2	For catwalk
	29			ø20 × 5 m	2	For boom, arm and bucket
	30			ø25 × 5 m	4	For revolving frame and track frame
	31			ø30 × 5 m	2	For counterweight
	32	tool	Shackle	SD30	3
	33			SC18	4
	34	Lifting	Nylon sling	50 mm wide × 3 m	2	For boom cylinder and arm cylinder
	35		Pin	ø50 × 5 m	2	Track frame
	36		Lever block	14.7 – 29.4 kN {1.5 – 3 ton}	2
	37		Eyebolt	M16	2
	38			M12	2
	39		Detergent liquid	Brake cleaner	10
	40		Hydraulic oil	EO-10	300 l
	41	andOil grease	Grease	G2-LI	20 kg	Work equipment lubrication
	42		Repair paint	Natural yellow	5
	43			Black gray	5
	44		Waste cloth	Bundle	20 kg

11

TIGHTENING TORQUE

Remove the plugging parts (flanges, heads, caps, and O-rings) of the work equipment piping and undercarriage piping, oil stopper plugs of the greasing piping, cylinder fixing jigs, and oil stopper plugs of the tap holes of the loose-supply items which were used for transportation and keep them carefully so that they can be used again for the next transportation.

Tighten the bolts to the torque shown in the following table, unless otherwise specified.

1.Tightening torque of bolts

When tightening the bolts with an impact wrench/spanner, apply Table 1.

Tighten the bolts according to Table 1 as a rule. When this rule is applied, the tightening torque is not shown in the drawing.

Table 1

				Unit: Nm {kgm}
Nominal size of thread	Width across flats		Tightening torque
pitch
	b (mm)	Target		Range
a (mm)
6 1	10	12		8.8 - 14.7
		{1.2}		{0.9 - 1.5}
8 1.25	13	25		14.7 - 34
		{2.5}		{1.5 - 3.5}
10 1.5	17	54		34 - 74
		{5.5}		{3.5 - 7.5}
12 1.75	19	89		54 - 123
		{9}		{5.5 - 12.5}
14 2	22	137		84 - 196
		{14}		{8.5 - 20}
16 2	24	230		147 - 309
		{23.5}		{15 - 31.5}
18 2.5	27	315		201 - 427
		{32}		{20.5 - 43.5}
20 2.5	30	460		319 - 608
		{47}		{32.5 - 62}
22 2.5	32	650		471 - 829
		{66.5}		{48 - 84.5}
24 3	36	810		588 - 1030
		{82.5}		{60 - 105}
27 3	41	1180		883 - 1470
		{120}		{90 - 150}
30 3	46	1520		1130 - 1910
		{155}		{115195}
33 3	50	1960		1470 - 2450
		{200}		{150 - 250}
36 3	55	2450		1860 - 3040
		{250}		{190 - 310}
39 3	60	2940		2260 - 3630
		{300}		{230 - 370}

12

When tightening the bolts with a torque wrench, apply Table 2.

Apply Table 2 when the proper tightening torque range is particularly narrow.

Table 2

						Unit: Nm {kgm}
Nominal size of thread	Width across flats			Tightening torque
pitch
	b (mm)	Target			Range
a (mm)
6 1	10	13.2			11.8	- 14.7
		{1.35}			{1.2 - 1.5}
8 1.25	13	31			27	- 34
		{3.2}			{2.8 - 3.5}
10 1.5	17	66			59	- 74
		{6.7}			{6.0 - 7.5}
12 1.75	19	113			98 - 123
		{11.5}			{10.0 - 12.5}
14 2	22	172			153	- 190
		{17.5}			{15.5 - 19.5}
16 2	24	260			235	- 285
		{26.5}			{23.5 - 29.5}
18 2.5	27	360			320	- 400
		{37.0}			{33.0 - 41.0}
20 2.5	30	510			455	- 565
		{52.3}			{46.5 - 58.0}
22 2.5	32	688			610	- 765
		{70.3}			{62.5 - 78.0}
24 3	36	883			785	- 980
		{90.0}			{80.0 - 100.0}
27 3	41	1295			1150	- 1440
		{132.5}			{118.0 - 147.0}
30 3	46	1720			1520	- 1910
		{175.0}			{155.0- 195.0}
33 3	50	2210			1960	- 2450
		{225.0}			{200.0 - 250.0}
36 3	55	2750			2450	- 3040
		{280.0}			{250.0 - 310.0}
39 3	60	3280			2890	- 3630
		{335.0}			{295.0 - 370.0}

13

2.Tightening torque of pipe threads

Tighten taper male pipe threads of nominal sizes of R1/8 - R1 and Rc1/8 - Rc1 and parallel female pipe threads of nominal size of Rp1/8 - Rp1 (coated with adhesive) according to the following standard.

If tightening torque is specified particularly, however, do not apply the following standard.

2-1. If the material of male threads is SS400, FC, or SGP, apply Table 1.

Table 1

Unit: Nm {kgm}

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

2-2. If the material of male threads is S43C, apply Table 2.

Table 2

Unit: Nm {kgm}

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

14

3. Tightening torque of hoses (with taper/face seal)

Unit: Nm {kgm}

Nominaldiameter	Width across				Tightening torque
of hose	flatse.		Range			Target
02	19	35 - 63		{3.5 - 6.5}		44	{4.5}
03	22	54 - 93		{5.5 - 9.5}		74	{7.5}
	24	59 - 98 {6.0 - 10.0}				78	{8.0}
04	27	84	- 132	{8.5 - 13.5}		103	{10.5}
05	32	128	- 186	{13.0 - 19.0}		157	{16.0}
06	36	177	- 245	{18.0 - 25.0}		216	{22.0}
{10}	41	177	- 245 {18.0 - 25.0}			216	{22.0}
{12}	46	197	- 294 {20.0 - 30.0}			245	{25.0}
{14}	55	246	- 343 {25.0 - 35.0}			294	{30.0}

When connecting hoses, take care not to twist them.

15

COATING MATERIALS

a The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly and assembly are listed below.

a For coating materials not listed below, use the equivalent of products shown in this list.

Category	Komatsu code	Part No.	Q'ty	Container		Main applications, features
	LT-1A	790-129-9030	150 g	Tube	• Used to prevent rubber gaskets, rub-
						ber cushions, and cock plug from
						coming out.
					• Used in places requiring an immedi-
			20 g	Polyethylene		ately effective, strong adhesive.
	LT-1B	790-129-9050				Used for plastics (except polyethyl-
			(2 pcs.)	container		ene, polyprophylene, tetrafluoroeth-
						lene and vinyl chloride), rubber,
						metal and non-metal.
				Polyethylene	•	Features: Resistance to heat and
	LT-2	09940-00030	50 g			chemicals
				container	•	Used for anti-loosening and sealant
						purpose for bolts and plugs.
		790-129-9060	Adhesive:		•	Used as adhesive or sealant for met-
			1 kg			al, glass and plastic.
	LT-3	(Set of adhesive	Hardening	Can
		and hardening
			agent:
		agent)
Adhesives			500 g
	LT-4	790-129-9040	250 g	Polyethylene	•	Used as sealant for machined holes.
				container
	Holtz	790-126-9120	75 g	Tube	•	Used as heat-resisting sealant for re-
	MH 705					pairing engine.
	Three bond			Polyethylene	• Quick hardening type adhesive
		790-129-9140	50 g		•	Cure time: within 5 sec. to 3 min.
	1735			container	•	Used mainly for adhesion of metals,
						rubbers, plastics and woods.
					• Quick hardening type adhesive
	Aron-alpha			Polyethylene	• Quick cure type (max. strength after
		790-129-9130	2 g			30 minutes)
	201			container
					• Used mainly for adhesion of rubbers,
						plastics and metals.
	Loctite			Polyethylene	• Resistance to heat, chemicals
		79A-129-9110	50 cc		•	Used at joint portions subject to high
	648-50			container
						temperatures.
	LG-1	790-129-9010	200 g	Tube	• Used as adhesive or sealant for gas-
						kets and packing of power train case,
						etc.
					• Used as sealant for various threads,
	LG-5	790-129-9080	1 kg	Can		pipe joints, flanges.
					•	Used as sealant for tapered plugs,
						elbows, nipples of hydraulic piping.
					•	Features: Silicon based, resistance
					•	to heat, cold
	LG-6	790-129-9020	200 g	Tube		Used as sealant for flange surface,
						tread.
					•
Gasket						Used as sealant for oil pan, final
						drive case, etc.
sealant
					• Features: Silicon based, quick hard-
	LG-7	790-129-9070	1 kg	Tube	•	ening type
						Used as sealant for flywheel hous-
						ing, intake manifold, oil pan, thermo-
						stat housing, etc.
	Three bond	790-129-9090	100 g	Tube	•	Used as heat-resisting sealant for re-
	1211					pairing engine.
					•	Features: Silicone type, heat resist-
	Three bond					ant, vibration resistant, and impact
		419-15-18131	100 g	Tube		resistant sealing material
	1207B
					• Used as sealing material for transfer
						case

16

Category	Komatsu code	Part No.	Q'ty	Container			Main applications, features
	LM-G	09940-00051	60 g	Can	• Used as lubricant for sliding portion
						(to prevent from squeaking).
Molybdenum
					• Used to prevent seizure or scuffling
disulphide	LM-P	09940-00040	200 g	Tube		of the thread when press fitting or
lubricant						shrink fitting.
					• Used as lubricant for linkage, bear-
						ings, etc.
		SYG2-400LI			•	General purpose type
	G2-LI	SYG2-350LI	Various	Various
		SYG2-400LI-A
		SYG2-160LI
		SYGA-160CNLI
		SYG2-400CA			• Used for normal temperature, light
	G2-CA	SYG2-350CA	Various	Various		load bearing at places in contact
		SYG2-400CA-A				with water or steam.
		SYG2-160CA
		SYGA-160CNCA
	Molybdenum	SYG2-400M	400 g × 10	Bellows type	• Used for heavy load portion
	disulphide
Grease		SYG2-400M-A	400 g × 20	Bellows type
	grease
	LM-G (G2-M)	SYGA-16CNM	16 kg	Can
	Hyper White				• Seizure resistance and heat resist-
		SYG2-400T-A				ance higher than molybdenum di-
	Grease G2-T
		SYG2-16CNT	400 g	Bellows type		sulfide grease
	G0-T (*)
		SYG0-400T-A (*)	16 kg	Can	•	Since this grease is white, it does
	*: For use in cold
		SYG0-16CNT (*)				not stand out against machine
	district
						body.
	Biogrease G2B	SYG2-400B			•	Since this grease is decomposed
	G2-BT (*)		400 g	Bellows type		by bacteria in short period, it has
	*: For high	SYGA-16CNB				less effects on microorganisms,
	temperature	SYG2-400BT (*)	16 kg	Can		animals, and plants.
	and large load	SYGA-16CNBT (*)
	SUNSTAR		20 ml	Glass			•	Used as primer for cab side
	PAINT PRIMER							(Expiration date: 4 months)
	580 SUPER			container
Primer
	SUNSTAR		20 ml	Glass			• Used as primer for glass side
	GLASS PRIMER							(Expiration date: 4 months)
	580 SUPER	417-926-3910		container
					glass
	SUNSTAR						•	"S" is used for high-tempera-
	PENGUINE				cab			ture season (April - October)
			320 ml	Polyethylene				and "W" for low-temperature
	SEAL 580
	SUPER "S" or			container	for			season (November - April) as
Adhesive								adhesive for glass.
	"W"
					Adhesive			(Expiration date: 4 months)
	Sika Japan,	20Y-54-39850	310 ml	Polyethylene			• Used as adhesive for glass.
	Sikaflex 256HV			container				(Expiration date: 6 months)
	SUNSTAR	417-926-3920	320 ml	Polyethylene			•	Used to seal joints of glass
	PENGUINE							parts.
Caulking	SEAL No. 2505			container				(Expiration date: 4 months)
material	SEKISUI	20Y-54-55130	333 ml	Polyethylene			• Used to seal front window.
	SILICONE							(Expiration date: 6 months)
	SEALANT			container

17

A. ASSEMBLY OF BASE MACHINE

19

	Assembly procedure	Installation of Left and Right Track Frames (1/4)
	A-1

•Before transportation, the Upper Structure (also called the “Revolving Frame Assembly”) was rotated 90° from its original position. Start the engine and return the Upper Structure to its original position by slowly rotating it 90° as follows.

•Lift the Upper Structure by two cranes and position it on the Track Frames as shown.

Weight of Upper Structure: 25,800 kg

Slowly rotate 90°

Fitting the wire at counterweight portion (Example):

Set the wire safely and securely.

Wooden block
				Stopper
		Use a shackle for
		secure connection.

Precautions		Necessary tools		Necessary equipment
Never enter under the lifted Upper Structure.		Name	Q’ty	Name	Q’ty
	ø 25 × 5000 wire		4	45 ton crane	1
	SD30 shackle		1
	Others

20

	Assembly procedure	Installation of Left and Right Track Frames (2/4)
	A-1

•Lower the Upper Structure by two cranes and install it on the Track Frames as shown.

Mount the M36 × 3 bolts and tighten them with 250 to 310 kgm torque.

Mount the M33 × 3 bolts Right track frame and tighten them with

200 to 250 kgm torque.

Left track frame

No.	Loose-supply items	Q’ty
1	209-09-11310	8
2	209-30-61120	8
3	209-09-51110	8
4	209-30-71121	2
5	01643-33690	8
6	209-30-11330	8
7	209-09-51110	32
8	209-30-61120	32

Precautions		Necessary tools		Necessary equipment
		Name	Q’ty	Name	Q’ty
	4 time wrench		1	45 ton crane	2
	Torque wrench (100 kg)		1
	Socket (25.4 Sq. × 55 mm)		1
	Torque wrench (4,200 kg)		1
	Others

21

	Assembly procedure	Installation of Left and Right Track Frames (3/4)
	A-1

•Secure two points of the center frame of the track by placing a hydraulic jack and a 300 × 400 mm wooden block at each point. Make sure that these points do not interfere with the upper structure rotation.

•Lift the Track Frame Assembly and install it on the Center Frame.

Weight of a single side of Track Frame

Assembly: 11,000 kg

Precautions		Necessary tools		Necessary equipment
		Name	Q’ty	Name	Q’ty
	Hydraulic jack (50 ton)		2	45 ton crane	1
	Wooden block (300 × 400 mm)		2
	Wire (ø30 mm, 5000 mm long)		2
	Pin (ø50 mm, 500 mm)		2
	Others

22

	Assembly procedure	Installation of Left and Right Track Frames (4/4)
	A-1

Thickness of 100 mm

Wooden block

a When tightening bolts, raise the track with a hydraulic jack as shown above so as to get sufficient space for tightening.

Precautions		Necessary tools		Necessary equipment
Do not remove the shoes before assembling		Name	Q’ty	Name	Q’ty
(so as to maintain the tightening torques of	4 time wrench		1
the shoe bolts).
	Torque wrench (100 kg)		1
	Socket (25.4 Sq. × 55 mm)		1
	Torque wrench (4,200 kg)		1
	Others

23

	Assembly procedure	Installation of Travel Pipe (1/3)
	A-2

Fig. 1

L.H. R.H.

Fig. 2

					No.		Parts already installed to body	Q’ty
					1		209-64-12131	2
					2		209-64-12141	2
					3		209-62-42610	2
					4		209-62-42520	1
					5		209-62-42510	1
					No.		Loose-supply items	Q’ty
					6		07000-13032	4
Precautions		Necessary tools				Necessary equipment
• Before removing the oil stopper of each		Name	Q’ty				Name		Q’ty
hose, turn the bolt slowly to release the	Width across flats 32 spanner		2
internal pressure.
	Width across flats 24 spanner		2
	Width across flats 22 spanner		2
	KW12P impact		1
	L150 extension		1
	M17 socket		1
	Others

24

	Assembly procedure	Installation of Travel Pipe (2/3)
	A-2

L.H. R.H.

Fig. 3

				No.		Parts already installed to body		Q’ty
				1		209-64-12131		2
				2		209-64-12141		2
				3		209-62-42610		2
				4		209-62-42520		1
				5		209-62-42510		1
				No.		Loose-supply items		Q’ty
				6		07000-13032		4
Precautions	Necessary tools				Necessary equipment
	Name	Q’ty				Name			Q’ty

Others

25

	Assembly procedure	Installation of Travel Pipe (3/3)
	A-2

(1)Arrange the pilot hoses (4) (L.H.), (5) (R.H.) for selecting machine speed and the drain hoses (3) (Figs 1,2 and 3)

(2)Arrange the main hoses (1) and (2) on the travel motor side (Figs 1,2 and 3). Use new O-rings (6) out of the loose-supply items and use split flange, bolt and washer out of the travel motor parts.

				No.		Parts already installed to body		Q’ty
				1		209-64-12131		2
				2		209-64-12141		2
				3		209-62-42610		2
				4		209-62-42520		1
				5		209-62-42510		1
				No.		Loose-supply items		Q’ty
				6		07000-13032		4
Precautions	Necessary tools				Necessary equipment
	Name	Q’ty				Name			Q’ty

Others

26

	Assembly procedure	Installation of Top Guard
	A-3
	.

				No.		Loose-supply items		Q’ty
				1		209-954-4211		1
				2		195-Z11-2970		6
				3		01011-81220		2
				4		01643-31232		4
				5		130-43-64260		6
				6		01024-81280		2
				7		01024-81295		2
				8		01024-01220		2
				9		20Y-954-4220		2
				10		20Y-954-4240		2
				11		20Y-954-4230		2
Precautions	Necessary tools				Necessary equipment
	Name	Q’ty				Name			Q’ty

Others

27