PC490LC-11 Komatsu

GEN00126-01
HYDRAULIC
EXCAVATOR
PC490LC-11
SERIAL NUMBERS
85001
and up
FOREWORD
3INCETHISMACHINEISLARGEINSIZEITISDIVIDEDINTOSOMEUNITSTOMEET
THETRANSPORTATIONCONDITIONSANDREGULATIONSAPPLIEDTOTHETRANSPORTA
TIONROUTEWHENSHIPPEDFROMOURFACTORY
4HIS MANUAL DESCRIBES HOW TO ASSEMBLE THE UNITS INTO THE COMPLETE
MACHINEINTHEFIELD7EHOPETHATTHISMACHINEWILLDISPLAYITSQUALITY
ANDYOUWILLUSEITSAFELYACCORDINGTOTHEOPERATIONMANUAL
-ANYUNITSARELARGEINSIZEANDHEAVYINWEIGHTANDMAYBEHANDLED
INADANGEROUSPLACEORPOSTUREANDMANYWORKERSMAYHAVETOWORK
TOGETHERTOSLINGTHEMWITHCRANES
!CCORDINGLYBEFORESTARTINGTHEASSEMBLYWORKTHEWORKSUPERVISORIS
REQUIREDTOHOLDASAFETYMEETINGTOOBLIGETHEWORKERSTOPUTONPRO
TECTIVEGEARANDAPPOINTAWORKLEADERANDACRANEWORKSIGNALMAN
ANDALLOTROLESTOALLTHEWORKERSFORSAFEWORK
)NPARTICULARTHEABOVEMEETINGISMOREIMPORTANTWHENWORKEROFDIF
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
BYYOURSELFINFUTUREASKONEOFOURDISTRIBUTORS
CONTENTS
Specifications ......................................................................................................................
Precautions for field assembly ............................................................................................
Disposal of removed parts...................................................................................................
Assembling procedures, applicable equipment and schedule ............................................
Flow of field assembly .........................................................................................................
Kit layout diagram................................................................................................................
Transportation .....................................................................................................................
Tool list for field assembly ...................................................................................................
Tightening torque ................................................................................................................
Coating materials ................................................................................................................
Selection of wire ropes used for assembly..........................................................................
Selection of nylon slings used for assembly........................................................................
1
2
3
4
5
6
7
10
11
16
20
21
A. Assembly of chassis .......................................................................................................

A- 1. Installation of climbing step ....................................................................................
A- 2. Installation of handrail ............................................................................................
A- 3. Installation of mirror................................................................................................
A- 4. Installation of tail pipe, tail pipe cover.....................................................................
23
24
26
28
31
B. Assembling of work equipment .......................................................................................

B- 1. Installation of boom cylinder...................................................................................
B- 2. Releasing remaining pressure in hydraulic circuit ..................................................
B- 3. Installation of boom cylinder hoses ........................................................................
B- 4. Installation of boom cylinder top pin .......................................................................
B- 5. Installation of boom assembly ................................................................................
B- 6. Installation of hoses from chassis along top of boom.............................................
B- 7. Connection of boom cylinder head.........................................................................
B- 8. Installation of arm assembly...................................................................................
B- 9. Installation of bucket cylinder hoses between boom and bucket cylinder ..............
B-10. Installation of bucket..............................................................................................
B-11. Connection of work equipment grease piping .......................................................
B-12. Connection of work equipment wiring ...................................................................
B-13. Greasing after completion of work equipment.......................................................
B-14. Bleeding air from work equipment circuit ..............................................................
33
34
36
37
38
39
43
44
45
47
49
52
54
56
57
C. Increasing and decreasing of track frame gauge, assembling of counterweight ............

C- 1. Increasing and decreasing of track frame gauge ...................................................
C- 2. Installation of steps ................................................................................................
C- 3. Installation of travel piping covers .........................................................................
C- 4. Adjustment of track tension ...................................................................................
C- 5. Sticking sheet to counterweight .............................................................................
C- 6. Installation of camera .............................................................................................
C- 7. Installation of counterweight...................................................................................
59
60
66
67
71
74
75
81
M. Procedure for inspection and maintenance after completion of assembly .....................

M- 1. Replacement of return filter (Standard filter to flushing filter) ................................
M- 2. Flushing of hydraulic circuit ...................................................................................
M- 3. Replacement of return filter (Flushing filter to standard filter)................................
M- 4. Check of oil/coolant level at each part ...................................................................
M- 5. Inspection of oil level in hydraulic tank and refill....................................................
M- 6. Parts to be touched up after field assembly...........................................................
M- 7. Error code ..............................................................................................................
85
86
87
86
91
93
95
96
Mounting bolt torque check sheet

Field assembly inspection report (Backhoe)
Specifications
Machine model
PC490LC-11
Weight of machine
kg
Bucket capacity
m3
1.9
Engine model
KOMATSU SAA6D125E-7
Flywheel
horsepower
SAE J1995 (Gross)

ISO 9249/SAE J1349 (Net)
kW/min-1 {HP/rpm}
47,040
270/1,900{362/1,900}
268/1,900{359/1,900}
Min. ground clearance
mm
700
Travel speed (Low/High)
km/h
3.0/4.2/5.5
Swing speed
rpm
9.1
PC490LC-11
Precautions for field assembly

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

As described in "FOREWORD", when this machine is transported, it is divided into some units such as the body,
undercarriage, cab, work equipment, etc. according to the transportation measure, regulations,etc.
Accordingly, the hydraulic pipings and hydraulic hoses to connect the units, oil inlets and outlets of the hydraulic
devices, and parts which must not be damaged are plugged or covered to prevent oil leakage, entry of dirt and
dust, and damage during transportation.
In addition, fixing jigs are used to prevent a trouble caused by a fall or a shake during transportation and to facilitate
loading, unloading and crane work.
The above plugs, jigs, etc. are removed when the machine is assembled and become unnecessary after completion of the machine. Since they are useful when the machine needs to be transported in future, however, we recommend you to keep them as long as possible.
Worker
Air compressor
Crane
Assembly unit
Days
Meeting with all workers
Start of assembling
Leader + 3 mechanics
45t
Unloading parts
Step
Handrail and mirror
Assembly of work
equipment
Increasing of track
frame gauge
Installation of
counterweight
Backhoe
Completion of general
assembling
Inspection of oil level and

coolant level
Air bleeding from work
equipment cylinder
Flushing of hydraulic
circuit
Adjustment of track
tension
Performance test
Assembling procedures,
applicable equipment and schedule
3 Division
Flow of field assembly

*1
*2
Installation of accessories
Installation of boom cylinder
*2*3
Installation of boom
*2*4
*2
Installation of arm
Installation of bucket
Greasing of work equipment
Air bleeding (work equipment)
Increasing of gauge
*5
Installation of counterweight
*6
Installation of sub
counterweight
Installation of accessories
Flushing
Check of oil and coolant levels
Completion inspection
Precautions
*1: Installation of grip, handrail, rear view mirror, tail pipe, and tail pipe cover
*2: Adjustment of shim
*3: Installation of working lamp
*4: Bucket cylinder and link are installed before shipment
*5: Installation of sound absorbing material, backup lamp, and rear view
monitoring camera
*6: Installation of track frame step and travel piping cover
Kit layout diagram
The dimensions given below are the minimum dimensions needed.

The kit dimensions in the diagram are outline dimensions.
When selecting a place, see Precautions for Field Assembly.
Transportation
Packing Style for Transportation
These machines can be divided into three kits for transportation.
Please ask us or our service shop for transportation.
t 3-kit Transportation
(Work equipment)
(Upper structure + Undercarriage)
(Others)
t Packing Style of Each Kit (Sizes in drawing are given in millimeters.)

Upper structure + Undercarriage
Model
PC490LC-11
A (mm)
6,050
B (mm)
3,360
Shoe width
(mm)
Overall width
(mm)
Weight
(kg)
700
3,150
28,930
Packing Style of Each Kit (Sizes in drawing are given in millimeters.)

(1) Boom
Position of center of gravity
Model
PC490LC
A (mm)
7,290
B (mm)
1,725
Overall width
(mm)
Weight
(kg)
780
4,230
Model
PC490LC
A (mm)
4,610
B (mm)
955
(2) Arm
Overall width
(mm)
Weight
(kg)
675
2,210
(3) Boom cylinder
Model
PC490LC
Weight
(kg)
365
(4) Bucket
Model
PC490LC
A (mm)
1,839
B (mm)
1,499
Overall width
(mm)
Weight
(kg)
1,624
Model
PC490LC
Weight (kg)
9,570
1,366
(5) Counterweight
850
3,000
1,165
Tool list for field assembly

1
2
3
4
5
6
Part name
Equipment
No.
7
8
9
10
11
12
13
14
15
17
18
19
20
Tool
16
Specification
7.0kg/cm3
25 ton
Air supply set
5-step, 1,500 mm
M10 bolt
Small-sized impact wrench
M12 bolt
Medium-sized impact
M14 M20 bolt
wrench
Large-sized impact
M24 M33 bolt
wrench
Air hose for impact wrench 50 m
Socket 22 mm width across flats
Medium-sized impact
Socket
24 mm width across flats
wrench socket
Large-sized impact
wrench socket
4:1 torque multiplier
25.4, 19
wrench
Socket for 4:1 torque
T25.4 square x Width across flats 46 mm
multiplier wrench
T25.4 square x Width across flats 65 mm
42 kgm T25.4
85
kgm T25.4
Torque wrench
Compressor
Crane truck
Grease pump
Stepladder
420 kgm T38.1
21
Standard tools
Socket, spanner, ring wrench
23
24
Large hammer (plastic)

Bar
Hydraulic jack
10 P
1m
Oil container
Large and small ones
26
27
28
43
Sling
Wire
Oil, grease, consumable
29
30
31
32
33
34
35
36
37
38
39
40
41
42
Shackle
Nylon sling
Lever block
Eyebolt
Cleaning liquid
Hydraulic oil
Grease
Touchup paint
Cloth
1
1
1
1
1
1
1
1
1
Remarks
For greasing work equipment

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

Counterweight
1
1 each
1 each
1
1
Track frame
Counterweight
35 420Nm {3.57 42.8 kgfm}
420 1,050Nm {42.8 107 kgfm}
1,050 4,200Nm {107 428 kgfm}
Counterweight
1 set of
2 each
1
2
10 3,000 mm
16 3,000 mm
20 5,000 mm
30 3,000 mm
SD32
SC18
50 mm wide x 3,000 mm
1.5 3 ton
M12
Brake cleaner spray can
HO56-HE
G2-LI
Natural yellow spray can
Black gray spray can
For tightening track frame connecting

bolts
2 each For connecting travel piping and work
equipment piping
2
Support of boom cylinder
For tightening track frame connecting
2
bolts
2
2
2
Boom, arm, bucket
2
Counterweight
2
Rated load of 6 t for counterweight
4
Rated load of 2 t
2
Boom cylinder, arm cylinder
2
Increase of track frame gauge
2
10
200 l
20 kg For greasing work equipment
5
5
1 bundle
20 kg
5 10 ton
30 50 150 mm
Wooden block
1
1
1
2
1
1
22
25
Q'ty
400 200 mm
10
For cleaning
Tightening torque
1. Tightening torque for bolts
Tightening torque for bolts is indicated in the text as shown below. Tighten each bolt to the specified
torque.
Part No. of bolt
TTTTT-TTTTT
Part No. of washer
EEEEE-EEEEE
Bolt specification
Thread
Bolt
length
Thread
size diameter
(Diameter,
pitch,
length)
Tool (Socket)
Applicable socket size
Tightening torque
Nm {QQQ kgm}
If tightening torque for a bolt is not specified in the text, tighten it according to Table 1.
Remarks
1. The thread diameter is the nominal diameter. For example, 16 mm is expressed as M16 and 20
mm is expressed as M20.
The pitch in Table 1 is the distance that the bolt advances every turn in the axial direction (Unit:
mm).
2. The bolt length is dimension (c) in Fig. 1.
3. The applicable socket size is expressed as 24 mm, 30 mm, etc. Since 24 mm, 30 mm, etc. correspond to dimension (b) in Fig. 1, an applicable socket can be selected from Table 1, too.
4. Tightening torque is expressed as QQQ www or QQQ RR. If the target tightening torque
is set, expression of QQQ RR is applied.
Fig. 1
a
b
c
d
: Bolt thread diameter (Nominal diameter)

: Width across flats of bolt head
: Bolt length
: Threaded part of bolt
11
Table 1 Tightening torque for bolts not specified in text

Nominal size of thread
pitch
a (mm)
Tightening torque
Width across flats

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

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

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

1/8
1/4
3/8
1/2
3/4
1
2.2 If the male screw is made of refined steel (heat-treated hard steel), apply Table 3.
Table 3
Unit: Nm {kgm}
Material of female thread
Steel
Cast iron
Light alloy
16.7 29.4
{1.7 3.0}
19.6 44.1
{2.0 4.5}
44.1 93.1
{4.5 9.5}
98.0 188.2
{10.0 19.2}
170.5 316.5
{17.4 32.3}
367.5 612.5
{37.5 62.5}
9.8 19.6
{1.0 2.0}
16.7 37.2
{1.7 3.8}
37.2 77.4
3.8 7.9}
83.3 157.8
{8.5 16.1}
141.1 247.0
{14.4 25.2}
309.7 514.5
{31.6 52.5}
6.9 14.7
{0.7 1.5}
12.7 28.4
{1.3 2.9}
27.4 58.8
{2.8 6.0}
60.8 115.6
{6.2 11.8}
105.8 186.2
{10.8 19.0}
235.2 392.0
{24.0 40.0}
Nominal size (in)
1/8
1/4
3/8
1/2
3/4
1
13
3. Tightening torque for hydraulic hose connecting nut

For the connecting nuts installed to the hydraulic hose adapters in relatively low pressure systems, apply
tightening torque in Table 4.1 and 4.2.
Table 4.1 Hydraulic hose of face seal type
Type that uses O-ring
at this position
(O-ring is fitted to joint
side)
Unit: Nm {kgm}
Outside diameter
of hose
(mm)
Width across flats

(mm)
Range
Target
Approx. 6
19
34 54 {3.5 5.5}
44 {4.5}
Approx. 10
22
54 93 {5.5 9.5}
74 {7.5}
Approx. 13
27
84 132 {8.5 13.5}
103 {10.5}
Approx. 16
32
128 186 {13.0 19.0}
157 {16.0}
Approx. 20
36
177 245 {18.0 25.0}
216 {22.0}
Tightening torque (Nm {kgm})
Table 4.2 Hydraulic hose of taper seal type
Type that does

not use O-ring
at this position
Unit: Nm {kgm}
Outside diameter
of hose
(mm)
Width across flats

(mm)
Range
Target
Approx. 6
19
34 63 {3.5 6.5}
44 {4.5}
Approx. 10
24
59 98 {6.0 10.0}
78 {8.0}
Approx. 13
27
84 132 {8.5 13.5}
103 {10.5}
Approx. 16
32
128 186 {13.0 19.0}
157 {16.0}
Approx. 20
36
177 245 {18.0 25.0}
216 {22.0}
Tightening torque (Nm {kgm})
Note: When connecting hose, take care not to twist them.
14
4. Proper socket sizes for bolts of M39 and larger (Reference)

For the proper sizes of sockets or spanners (= width across flats) for tightening hexagon bolts of M39 and
larger, see Table 5.
Table 5
Unit: mm
Thread diameter
Proper sizes of sockets or spanners
M42
65
M45
70
M48
75
M52
80
M56
85
M60
90
M64
95
15
Coating materials
a Select adhesives, liquid gaskets, greases, and other coating material used for disassembly and assembly
from the following list.
a
If any coating is not shown in the following list, use the product shown in the manual or equivalent.
Category
Komatsu code
Part No.
Q'ty
Container
Main features, uses
LT-1A
790-129-9030
150 g
Tube
Used to fix rubber gasket, rubber cushion, or cork plug
790-129-9050
20 g
(2container
set)
Polyethylene
container
Used to glue resin (excluding

polyethylene, polypropylene,
ethylene tetrafluoride, vinyl
chloride), rubber, metal, or nonmetallic material instantaneously firmly
09940-00030
50 g
Polyethylene
container
Features: Heat resistance and

chemical resistance
Used to lock bolts, plugs, etc.
and as sealant
790-129-9060
Set of adhesive
and hardener
Adhesive:
1 kg
Hardener:
500g
Can
LT-4
790-129-9040
250 g
Polyethylene
container
Used to glue metal, glass, plastic, etc. and as sealant
HOLTS
MH 705
790-129-9120
75 g
Tube
Heat-resistant sealant for repairing engine
50 g
Polyethylene
container
Instantaneous adhesive
Adhesion time: 5 sec to 3 min
Mainly used to glue metal, rubber , plastic, and wood
Instantaneous adhesive
Quick-hardening type (Reaches max. strength 30 min after)
Mainly used to glue rubber ,
plastic, and metal
LT-1B
LT-2
LT-3
Adhesive
Three bond
1735
790-129-9140
Used to glue metal, glass, plastic, etc. and as sealant
Aron alpha
201
790-129-9130
2g
Polyethylene
container
LOCTITE
648-50
79A-129-9110
50 cc
Polyethylene
container
Features: Heat resistance and

chemical resistance
Used for gluing parts fitted at
high temperature
1 kg
Polyethylene
container
Used as sealant for various

threaded portions, pipe joint,
and flange
Used as sealant for taper plug,
elbow, nipple, etc.
Tube
Features: Silicon-based, heat

resistance, cold resistance
Used as sealant for flange and
threaded portion
Used as sealant for oil pan, final drive case, etc.
Tube
Features: Silicon-based, quickhardening type

Used as sealant for flywheel
housing, intake manifold, oil
pan, thermostat housing, etc.
Tube
Features: Silicon-based, heat

resistance, vibration resistance, impact resistance
Used as sealant for transfer
case etc.
LG-5
LG-6
790-129-9080
790-129-9160
200 g
Liquid gasket
LG-7
LG-8
ThreeBond
1207B
790-129-9170
419-15-18131
1 kg
100 g
16
Shown
in this
manual
Category
Komatsu code
LG-9
ThreeBond
1206D
Part No.
790-129-9310
Q'ty
Container
Main features, uses
200 g
Tube
Used to seal circle gear top

which does not need to be
clamped and fill gaps of welded
parts etc. having rough surfaces
Can be painted
LG-10
ThreeBond
1206E
790-129-9320
200 g
Tube
Used as lubricant and sealant

fro radiator hose
Can be painted
LG-11
ThreeBond
1121
790-129-9330
200 g
Tube
Feature: Can be used with

gasket
Used for covers of transmission case, steering case, etc.
ThreeBond
1121
790-129-9090
100 g
Tube
Liquid gasket for repairing engine
Tube
Used for press fitting, shrink fitting, prevention of galling or

seizure of screw
Used as lubricant for linkage,
bearing, etc.
Can
Spray type
Thin molybdenum disulphide
film is formed on metal surfaces to prevent galling between
metals
Used for drive shaft spline,
needle bearing, various link
pins, bolts, etc.
Can
Feature: Compound consisting

of fine metal particles to prevent seizure and galling
Used for mounting bolts of
high-temperature parts such as
exhaust manifold, turbocharger, etc.
LM-P
09940-00040
200g
Molybdenum
disulfide
lubricant
Anti-seize
LC-G
NEVER-SEEZ
G2-LI
G0-LI(*)
*: For cold
weather
09995-00250
SYG2-400LI
SYG2-350LI
SYG2-400LI-A
SYG2-160LI
SYG2-160CNLI
SYG0-400LI-A(*)
SYG0-16CNLI(*)
190 g
Shown
in this
manual
Multi-purpose extreme pressure lithium grease

Various
types
Various
types
Used for high-load portion
Grease
LM-G(G2-M)
Molybdenum
disulfide
grease
SYG2-400M
SYG2-400M-A
SYGA-16CNM
400g 10
400g 20
16 kg
Bellows can
Caution: Do not use for rolling

bearings and splines such as
swing circle bearing
Apply to work equipment pins
only at assembly time and do
not use after that
17
Category
Komatsu code
Hyper White
Grease
G2-T
G0-T (*)
*: For cold
weather
Bio grease
G2B
G2-BT (*)
*: For high
temperature
and high
load
G2-S
ThreeBond
1855
G2-U-SENS
grease
Part No.
SYG2-400T-A
SYG2-16CNT
SYG0-400T-A (*)
SYG0-16CNT (*)
SYG2-400B
SYGA-16CNB
SYG0-400BT (*)
SYGA-16CNBT (*)
427-12-11871
SUNSTAR
PAINT
PRIMER 580
SUPER
Q'ty
400 g
16 kg
400 g
16 kg
Container
Main features, uses
Bellows can
Has higher seizure resistance,

heat resistance, and water resistance than molybdenum disulphide grease
Not conspicuous on machine
since color is white
Bellows can
Decomposed by bacteria in nature in short period to minimize

effects on microorganism,
plants, and animals
Tube
Feature: Silicon-based, wide

using temperature range, high
oxidation resistance, prevention of deterioration of rubber
and plastics
Used as oil seal for transmission etc.
2 kg
Can
Feature:Urea-based (organic)
grease having heat resistance
and long life. Sealed when
used.
Used for rubber in damper,
bearing, oil seal
Caution:Do not mix with lithium
grease
20 ml
Glass
container
Used as primer for cab

side
(Using limit: 4 months after date of manufacture)
20 ml
Glass
container
Used as primer for glass

side (Using limit: 4
months after date of manufacture)
20 ml
Glass
container
200 g
Primer
SUNSTAR
PAINT
PRIMER 43595
SUNSTAR
GLASS
PRIMER 43541
SUNSTAR
SASH
PRIMER GP402
22M-54-27230
22M-54-27240
22M-54-27250
For gluing cab glass
417-926-3910
SUNSTAR
GLASS
PRIMER 580
SUPER
Used as paint primer for

cab side
150 ml
Steel can
Used as primer for black

ceramic-coated surface
on glass side and for hard
polycarbonate-coated
surface
20 ml
Glass
container
Used as primer for sash

(Almite)
18
Shown
in this
manual
Category
Komatsu code
SUNSTAR
PENGUINE
SEAL 580
SUPER "S" or
"W"
Part No.
417-926-3910
Q'ty
Container
Main features, uses
320 ml
Polyethylene
container
"S" is used for high-temperature season (April to

October) and "W" for lowtemperature season (October to April) as adhesive for glass
310 ml
Polyethylene
container
Used as adhesive for

glass
Sika Japan,
Sikaflex
256HV
Caulking
material
20Y-54-39850
For gluing cab glass
Adhesive
Used as adhesive for

glass
SUNSTAR
PENGUINE
SUPER 560
22M-54-27210
320 ml
Ecocart
(Special
container)
SUNSTAR
PENGUINE
SEAL No.
2505
417-926-3920
320 ml
Polyethylene
container
SEKISUI
SILICONE
SEALANT
20Y-54-55130
333 ml
Polyethylene
container
Used to seal front window

Cartridge
Used to seal joints of

glass parts Translucent
white seal
Used to seal joints of

glass parts
GE TOSHIBA
SILICONES
TOSSEAL
381
22M-54-27220
Natural yellow
SYPA-U03SPNY
Spray type
Black gray
SYPA-U03SPBG
Spray type
333 ml
Paint
19
Shown
in this
manual
Q
Q
20
8
9
10
11.2
(12)
12.5
14
16
18
20
22.4
(24)
25
28
30
31.5
33.5
35.5
37.5
40
42.5
Sling angle
Angle to vertical line
Mode coefficient M
Classification of wire rope
Outer diameter of
wire rope (2)d (mm)
Number of wire ropes
Max. 4.8 {0.49}

Max. 6.1 {0.63}
Max. 7.6 {0.77}
Max. 9.5 {0.97}
Max. 10 {1.1}
Max. 11 {1.2}
Max. 14 {1.5}
Max. 19 {1.9}
Max. 24 {2.5}
Max. 30 {3.1}
Max. 38 {3.9}
Max. 43 {4.4}
Max. 47 {4.8}
Max. 59 {6.1}
Max. 68 {7.0}
Max. 75 {7.7}
Max. 85 {8.7}
Max. 96 {9.8}
Max. 107 {10.9}
Max. 122 {12.4}
Max. 137 {14.0}
24G
= 0
= 0
1
1 pc.
Max. 5.2 {0.53}

Max. 6.6 {0.67}
Max. 8.2 {0.83}
Max. 10 {1.0}
Max. 11 {1.2}
Max. 12 {1.3}
Max. 16 {1.6}
Max. 21 {2.1}
Max. 26 {2.7}
Max. 32 {3.3}
Max. 41 {4.2}
Max. 51 {5.2}
Max. 64 {6.5}
Max. 73 {7.5}
Max. 81 {8.3}
Max. 92 {9.4}
Max. 103 {10.5}
Max. 115 {11.7}
Max. 131 {13.4}
Max. 148 {15.1}
24A
Max. 6.7 {0.68}
Max. 8.5 {0.88}
Max. 10 {1.0}
Max. 13 {1.3}
Max. 14 {1.5}
Max. 15 {1.6}
Max. 19 {2.1}
Max. 26 {2.6}
Max. 33 {3.5}
Max. 42 {4.3}
Max. 53 {5.4}
Max. 60 {6.1}
Max. 65 {6.7}
Max. 82 {8.5}
Max. 95 {9.8}
Max. 105 {10.7}
Max. 119 {12.1}
Max. 134 {13.7}
Max. 149 {15.2}
Max. 170 {17.3}
Max. 191 {19.6}
24G
Z 90
Z 45
1.4
24A
Max. 7.2 {0.74}
Max. 9.2 {0.93}
Max. 11 {1.1}
Max. 14 {1.4}
Max. 15 {1.6}
Max. 16 {1.8}
Max. 22 {2.2}
Max. 29 {2.9}
Max. 36 {3.7}
Max. 44 {4.6}
Max. 57 {5.8}
Max. 71 {7.2}
Max. 89 {9.1}
Max. 102 {10.5}
Max. 113 {11.6}
Max. 128 {13.1}
Max. 144 {14.7}
Max. 161 {16.3}
Max. 183 {18.7}
Max. 207 {21.1}
Annex 2, Table 1 Using loads of 6 24 type rope slings.
Select wire ropes to be used for assembly according to the following table.
Selection of wire ropes used for assembly
2 pcs.
Max. 4.8 {0.49}

Max. 6.1 {0.63}
Max. 7.6 {0.77}
Max. 9.5 {0.97}
Max. 10 {1.1}
Max. 11 {1.2}
Max. 14 {1.5}
Max. 19 {1.9}
Max. 24 {2.5}
Max. 30 {3.1}
Max. 38 {3.9}
Max. 43 {4.4}
Max. 47 {4.8}
Max. 59 {6.1}
Max. 68 {7.0}
Max. 75 {7.7}
Max. 85 {8.7}
Max. 96 {9.8}
Max. 107 {10.9}
Max. 122 {12.4}
Max. 137 {14.0}
24G
24A
Max. 5.2 {0.53}
Max. 6.6 {0.67}
Max. 8.2 {0.83}
Max. 10 {1.1}
Max. 11 {1.2}
Max. 12 {1.3}
Max. 16 {1.6}
Max. 21 {2.1}
Max. 26 {2.7}
Max. 32 {3.3}
Max. 41 {4.2}
Max. 51 {5.2}
Max. 64 {6.5}
Max. 73 {7.5}
Max. 81 {8.3}
Max. 92 {9.4}
Max. 103 {10.5}
Max. 115 {11.7}
Max. 131 {13.4}
Max. 148 {15.1}
90 < Z 120
45 < Z 60
1
Unit: kN {tf}
18
B 8817-1991
21
tRated load table (WW-1D type)
Select wires used for assembly according to the following table
Selection of nylon slings used for assembly
A. ASSEMBLY OF CHASSIS
23
Assembly procedure
Installation of climbing step (1/2)
A-1
For USA specifications
Install step (1) with bolts (2).
No.
1
2
Precautions
Name
Qty
1
1
24
Qty
1
4
Necessary equipment
Others
Remove the rust preventive plug from the

tapped hole.
Necessary tools
Loose-supply items
208-54-43140
01024-81225
Name
Qty
Assembly procedure
Installation of climbing step (2/2)
A-1
Install grip (1) with bolts (2).
No.
1
2
Precautions
Name
Qty
1
1
25
Qty
1
2
Necessary equipment
Others
Remove the rust preventive plug from the

tapped hole.
Necessary tools
Loose-supply items
208-54-43150
01024-81230
Name
Qty
Assembly procedure
Installation of handrail (1/2)
A-2
1. Set plate (2) and plate (4) at part Q, and then install handrail (1) with bolts (3).
a Weight of handrail: 21 kg
No.
1
2
3
4
Precautions
Qty
Medium-sized impact wrench
26
Qty
1
1
6
1
Necessary equipment
Name
Others
a When carrying the handrail, use a crane

etc.
a Install the handrail to the right side of the
machine first, and then to the left side of
the machine.
When removing the handrail, remove
the left side of the machine first, then
remove the right side.
(Prevention of fall)
Necessary tools
Loose-supply items
208-54-21921
208-54-43120
01024-81245
207-54-43851
Name
Qty
Assembly procedure
Installation of handrail (2/2)
A-2
Using bolts (3), install handrail (1) and plate (2) to the track frame.
a Weight of handrail: 12 kg
No.
1
2
3
Precautions
Qty
27
Qty
1
1
4
Necessary equipment
Name
Others
a When carrying the handrail, use a crane

etc.
a Install the handrail to the right side of the
machine first, and then to the left side of
the machine.
When removing the handrail, remove
the left side of the machine first, then
remove the right side.
(Prevention of fall)
Necessary tools
Loose-supply items
208-54-41833
208-54-43130
01024-81245
Name
Qty
Assembly procedure
Installation of mirror (1/3)
A-3
(1) Install mirror (1).

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

Adjust the mirror so that the operator in the operator
seat can see persons on the ground at 1 m around the
machine.
(W) : 1m
No.
1
Precautions
Necessary tools
Others
Name
Hexagon socket 5 mm width
across flats
across flats
28
Loose-supply items
2A5-54-13420
Qty
1
Necessary equipment
Qty
1
1
Name
Qty
Assembly procedure
A-3
(2) Install mirror (1).

Tightening torque of mirror(1) mounting bolt: 6.0 to 7.0 Nm
{0.61 to 0.71 kgm}
No.
1
Precautions
Necessary tools
Others
Name
across flats
29
Loose-supply items
2A5-54-13420
Qty
1
Necessary equipment
Qty
1
Name
Qty
Assembly procedure
A-3
(3) Install mirror (1), support(2), and clamp(3).

Tightening torque of mirror(1) mounting bolt: 6.0 to 7.0 Nm
{0.61 to 0.71 kgm}
No.
1
2
3
4
Precautions
Name
across flats
across flats
Others
a Tighten bolts (4) according to torque table

1 (page 11).
Necessary tools
30
Loose-supply items
2A5-54-13420
2A5-54-16120
20Y-54-35430
01252-A1030
Qty
1
1
1
2
Necessary equipment
Qty
1
1
Name
Qty
Assembly procedure
Installation of tail pipe and tail pipe cover
A-4
(1) Install tail pipe.
Tightening torque: 11.8 Nm {1.2 kgm}
(2) Install tail pipe cover.
Adjust the cover to equalize the clearance marked with .
No.
1
2
3
4
5
Precautions
Necessary tools
Others
Name
31
Loose-supply items
208-01-21720
6253-11-515A
885-3353-911
208-54-21361
01034-81230
Qty
1
1
1
1
6
Necessary equipment
Qty
Name
Qty
B. ASSEMBLING OF WORK EQUIPMENT

Clean the mounting pin and pin hole and check them for a flaw.
33
Assembly procedure
Installation of boom cylinder (1/2)
B-1
(1) Lift the boom cylinder and adjust it to the frames pin holes.
(2) Drive in the boom cylinder foot pin.
aInside of pin hole and bushing of boom cylinder boss: Apply LM-P (Only 1st time)
[Apply lithium grease for 2nd time and after]
(3) Check the clearance between the pin and chassis and combine and insert adjustment shims (1) so that the
clearance on the outside of the chassis will be 1.5 mm or less. Adjust the shims for both right and left cylinders.
Insert one piece of 207-70-71251 on the inside of the chassis and insert the other shims on the outside of the
chassis.
Outside of machine
Inside of machine
Rest of shims
(Clearance must
be 1.5 mm or less)
207-70-71251 1 piece
PART P
(4) Push in the boom cylinder foot pin fully and install the lock plate.
a Check that the pin lock bolt is not loosened but tightened and check
its torque.
Precautions
Necessary tools
Name
Qty
Nylon sling
2
1
34
Loose-supply items
207-70-71251
207-70-71261
Qty
6
2
Necessary equipment
Others
a Assemble so that the grease hole of the boom

cylinder bottom will be down.
a Decide the thickness of the adjustment shim
by combining shims 1 mm thick (207-7071251) and 2 mm thick (207-70-71261).
a When pushing in the pin, take care not to break
the dust seal installed to the boom cylinder
boss.
No.
Name
25 t crane
Qty
1
Assembly procedure
Installation of boom cylinder (2/2)
B-1
(5) Insert the boom cylinder supports between each cylinder and revolving frame.
* Wooden blocks 30 mm thick may be used instead of the cylinder supports.
Support stand
Boom cylinder
Revolving frame
Precautions
Necessary tools
Others
Name
35
Necessary equipment
Qty
Name
Qty
Assembly procedure
Releasing remaining pressure in hydraulic circuit
B-2
When removing the hydraulic piping, be sure to release the remaining pressure according to the following procedure.
(1) Lower the work equipment lock lever to the "LOCK" position, and start and run the engine for about 10 seconds,
and then stop it.
a Limit the engine speed to low idling.
a Set the work equipment control lever in neutral.
(2) Within 15 seconds after stopping the engine, turn the starting switch to the ON position, set the lock lever to
the FREE position, and operate each control lever to the stroke end.
a Repeat the operations of (1) to (2) 3 times.
(3) Lower the lock lever to the "LOCK" position.
(4) Remove the oil filler cap of the hydraulic tank to release the pressure in the tank.
kWhen removing the oil filler cap of the hydraulic tank, turn it slowly to release the internal pressure first, and
then remove the cap carefully.
(5) After releasing the pressure in the tank, install the oil filler cap of the hydraulic tank to prevent entry of dirt.
Precautions
Necessary tools
Others
Name
36
Necessary equipment
Qty
Name
Qty
Assembly procedure
Installation of boom cylinder hoses
B-3
(1) Remove the oil stopper plug from the tube at the boom cylinder end.
(2) Set the new O-rings (3) to boom cylinder hoses (1) and (2), 4 pieces in total, and install them to the normal
circuit as shown in the figure below.
a Bleed the boom cylinder of air by following Assembly Procedure B-14 Bleeding Air from Work Equipment
Circuit.
a Check that the split flange is not loosened but tightened.
No.
1
2
No.
3
a Check that each O-ring is fitted, has not come off, and is not
caught.
Precautions
Name
Qty
2
37
Qty
2
2
Qty
4
Necessary equipment
Oil container
Others
1. When removing an oil stopper plug from a hose,

slowly loosen its bolts by gradually releasing the
internal hydraulic pressure.
2. Keep the removed oil plugs so that they can be
reused.
3. When connecting the hoses, take extremely
care not to clinch or damage the O-rings.
4. Also, take extremely care not to enter a foreign
material into the hydraulic circuit.
Necessary tools
Already installed to
207-62-52610
206-62-51650
Loose-supply items
07000-13032
Name
Qty
Assembly procedure
Installation of boom cylinder top pin
B-4
Insert the boom cylinder top pin in the boom temporarily.
Weight of boom cylinder top pin: 73 kg

Apply LM-P to the inside of boss.
No.
1
Precautions
Necessary tools
Name
Nylon sling
38
Loose-supply items
208-70-61860
Qty
1
Necessary equipment
Qty
1
Others
a
a
Name
25 t crane
Qty
1
Assembly procedure
Installation of boom assembly (1/4)
B-5
Removal of cover
1. Remove battery case small cover (1).
aWeight of battery case small cover: 1.72 kg
2. Open AdBlue/DEF cover.
3. Remove the fuel spray prevention cover.
4. Remove AdBlue/DEF cover.

aWeight of AdBlue/DEF cover: 34.98 kg
aWhen removing the cover, take care not to hook
the breather in it.
M12 eyebolts may be

installed to 2 places to
install slings.
No.
1
2
3
4
5
6
7
Precautions
Necessary tools
Name
Qty
1
Extension, L: 150
Others
Qty
1
2
1
4
4
1
4
Necessary equipment
Socket, width across flats: 19 mm
39
Parts installed to
machine
208-54-21770
01024-81225
208-54-21881
01034-81225
01643-51232
208-54-21602
01024-81230
Name
Qty
Assembly procedure
B-5
5. Remove the fuel tank front cover.
a Weight of fuel tank: 9.87 kg
6. Install the boom foot pin.

a When you install the boom foot pin, if the
mounting bolts of the filler port bracket and
breather bracket are obstacles, remove
and place them aside.
Filler port bracket mounting bolt: (10), (11)
Breather bracket mounting bolt: (12)
Install
If this is obstacle to installation
of boom foot pin, bent it
around rubber hose.
(Do not remove piping)
Rubber hose
No.
8
9
10
11
12
7. After installing the boom foot pin, install the cover in the reverse order.
Precautions
Necessary tools
Name
Qty
1
Extension, L: 150
Others
Qty
1
4
1
2
2
Necessary equipment
40
Parts installed to
machine
2A7-54-11742
01024-81230
01024-81255
01024-81230
01024-81230
Name
Qty
Assembly procedure
B-5
(1) Sling the boom assembly with the crane and match it with the pin holes of the machine.
a Protect the pin from the sling wires.
(2) Install the boom foot pin.
At this time, balance the boom so that it will be in parallel with the pin holes of the machine.
Weight of boom assembly : 4,230 kg
a When slinging boom assembly
(3) Check the clearance in the boom foot all around on the left
side of the chassis, then decide and insert the shim quantity
so that the minimum clearance will be 1 mm or less.
The following adjustment shims are prepared.
(1) (208-70-71611, 3 pieces) t2.0
(2) (208-70-71621, 1 piece) t2.5
(3) (208-70-71631, 1 piece) t3.0
(4) (208-70-71641, 1 piece) t3.5
Assemble these shims to obtain desired thickness.
(Be sure to insert one of (1) on the right side of the machine.)
(Clearance must be
1 mm or less)
(4) Push in the boom foot pin fully and install the lock plate.
a Inside of pin hole and bushing of boom foot bushing: Apply
LM-P (Only 1st time)
a Check that the pin lock bolt is not loosened but tightened
and check its torque.
Precautions
Dust seals
a For installation of the grease supply hoses, see Step

B-11 "Connesction of grease supply piping of work
equipment".
a For the boom and boom cylinder assembly, see next
page.
Necessary tools
Name
Qty
2
10 3,000 mm wire
Lever block 1.5 t
Large hammer
41
Loose-supply items
208-70-71611
208-70-71621
208-70-71631
208-70-71641
Qty
3
1
1
1
Necessary equipment
20 5,000 mm wire
Others
a When pushing in the pin, take care not to break the

dust seal installed to the boom foot as shown below.
No.
1
2
3
4
Name
25 t crane
Qty
1
Assembly procedure
B-5
a Installation of boom and boom cylinder assembly

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

and cylinder assembly
(3) Decide and insert the shim quantity so that the clearance in
the boom foot on the left side of the machine will be 1 mm or
less.
The following adjustment shims are prepared.
(1) (208-70-71611, 3 pieces) t2.0
(2) (208-70-71621, 1 piece) t2.5
(3) (208-70-71631, 1 piece) t3.0
(4) (208-70-71641, 1 piece) t3.5
Assemble these shims to obtain desired thickness.
(Be sure to insert one of (1) on the right side of the machine.)
(Clearance must be
1 mm or less)
(4) Push in the boom foot pin fully and install the lock plate.
a Inside of pin hole and bushing of boom foot bushing: Apply
LM-P (Only 1st time)
a Check that the pin lock bolt is not loosened but tightened
and check its torque.
Precautions
Dust seals
a For installation of the grease supply hoses, see Step

equipment".
Necessary tools
Name
Qty
2
10 3,000 mm wire
Lever block 1.5 t
Large hammer
42
Already installed to chassis

208-70-71611
208-70-71621
208-70-71631
208-70-71641
Qty
3
1
1
1
Necessary equipment
20 5,000 mm wire
Others
a When pushing in the pin, take care not to

break the seals installed to the boom foot as
shown below
No.
1
2
3
4
Name
25 t crane
Qty
1
Assembly procedure
Installation of hoses from chassis along top of boom
B-6
(1) Remove the oil stopping plugs of the tubes on the boom side.
(2) Install arm cylinder hoses (1), (2), (3), and
bucket cylinder hoses (4) (2 pcs.) to the regular circuit as shown below.
a Bleed the arm cylinder of air by following Assembly Procedure B-14

Bleeding Air from Work Equipment Circuit.
a Check that the split flange is not loosened but tightened.
a Check that each O-ring is fitted, has not come off, and is not caught.
Precautions
Name
Qty
2
43
208-62-41661
208-62-41671
208-62-41682
208-62-41642
Loose-supply items
07000-13032
Qty
1
1
1
2
Qty
5
Necessary equipment
Oil container
Others
1. When removing an oil stopper plug from a

hose, slowly loosen its bolts by gradually
releasing the internal hydraulic pressure.
2. Remove and store the flange, O-rings and
heads so that you can reuse them later.
3. When connecting the hoses, take extremely
care not to clinch or damage the O-rings.
4. Also, take extremely care not to enter a foreign
material into the hydraulic circuit.
Necessary tools
No.
1
2
3
4
No.
5
Name
Qty
Assembly procedure
Connection of boom cylinder head
B-7
(1) Remove the stopper plate (2) fixed to the boom, and remove the boom cylinder top pin.
a Boom cylinder: 360 kg / Boom cylinder top pin: 73 kg
(2) Start the engine and rotate it at the low idle speed.
(3) Sling the right cylinder, raise the rod slowly, and match the pin holes while extending and retracting the cylinder.
(4) Knock in the cylinder top pin.
a Inside of pin hole and bushing of boom cylinder bushing: Apply LM-P (Only 1st time)
(5) Mount fixed the stopper plate and adjusting shims (5), (6).
0.51.5mm
Clearance a
0.51.5mm
Clearance b
No.
1
2
3
4
5
6
Part marked with A (2 points)
Precautions
a
a
a
When operating the cylinder, extend it slowly. Do not

operate the cylinder suddenly and do not operate it to
the end of its stroke. In the first operation, there is an
air in the cylinder and the cylinder may not move for
the first 10 seconds. In such case, do not operate the
control lever to the end of its stroke.
Check the clearance between cover (2) and cylinder
rod all around and combine shims 1 mm thick (20870-71561) and 2 mm thick (208-70-71571) so that
clearance "a" will be 0.5 1.5 mm. (Portions of )
Adjust clearance "b" between the plate and double
nut to 0.5 to 1.5 mm.
(Part marked with A )
Before operating the cylinder, check that the flushing
filter is installed (to capture dirt in the circuit).
For installation of the grease supply hoses, see Step
equipment".
Necessary tools
Name
Qty
Nylon sling
1
1
Spanner 36 mm width across flats
Large-sized impact wrench
44
Qty
1
2
2
4
4
2
Necessary equipment
Others
Loose-supply items
208-70-61860
208-70-31242
207-70-13340
01580-12419
208-70-71561
208-70-71571
Name
25 t crane
Qty
1
Assembly procedure
Installation of arm assembly (1/2)
B-8
(1) Remove lock plate (2) of boom top pin (1) fixed to the boom and pull out top pin (1).
(Boom top pin: 54 kg)
(2) Raise the arm assembly, align the position with the boom hole, insert a shim, then push in the pin.
(Arm assembly: For the weight, see the table in "Transportation")
a Seals (07145-00120 2) are installed to the inside of the bushing at the arm end, but be careful no to damage the seals when inserting the pin.
a Inside of pin hole and bushing of arm bushing: Apply LM-P (Only 1st time)
a Check the clearance all around and combine shims (5), (6), and (7) so that the clearance will be 1 mm or
less (Portion of
).
(3) Install the stopper (2).
Shim thickness
(5) 208-70-71531
(6) 208-70-71541
(7) 208-70-71551
No.
1
2
3
4
5
6
7
a Check that the pin lock bolt is not loosened but tightened and
check its torque.
Precautions
Name
Qty
2
Lever block 1.5 t
Large hammer
45
Loose-supply items
208-70-71580
208-70-71670
01010-82045
01643-32060
208-70-71531
208-70-71541
208-70-71551
Qty
1
1
2
2
3
1
1
Necessary equipment
Nylon sling
Others

the dust seal installed to the arm boss as
shown below.
Necessary tools
2.0 mm
2.5 mm
3.0 mm
Name
25 t crane
Qty
1
Assembly procedure
Installation of arm assembly (2/2)
B-8
(4) Remove lock plate (2) of arm cylinder top pin (1) fixed to the arm and pull out top pin (1).
(Arm cylinder top pin: 23 kg)
(5) Start the engine, run at low idle, extend the arm cylinder rod slowly, and align the position of the hole.
When doing this, raise the arm cylinder with a crane and operate the arm cylinder at the same time to align the
position.
(6) Insert shims (4) on both sides and push in arm cylinder top pin (1).
a Inside of pin hole and bushing of arm cylinder bushing: Apply LM-P (Only 1st time)
(7) Install lock plate (2).
a Operate the cylinder slowly. Do not operate it quickly and do not bring it to the stroke end. Since air gathers
inside the cylinder at the first time, it may not move for aver 10 seconds, but do not move the lever to the
full stroke.
a When installing the arm, extreme caution should be exercised so that the bucket cylinder rod does not jump
out.
a Check that the pin lock bolt is not loosened but tightened and check its torque.
No.
1
2
3
4
Precautions
Name
Qty
Nylon sling
1
1
46
Qty
1
1
2
2
Necessary equipment
Large hammer
Others
a For installation of the grease supply hoses,

see Step B-11 "Connection of grease supply
piping of work equipment".
the dust seal installed to the cylinder boss.
Necessary tools
Loose-supply items
208-70-61220
205-70-66580
01024-81235
208-70-71651
Name
25 t crane
Qty
1
Assembly procedure
B-9
Installation of bucket cylinder hoses between

boom and bucket cylinder (1/2)
(1) Remove the tube oil plug on the bucket cylinder side on the left side of the arm, install new O-ring (2), and
connect bucket cylinder hose (1).
(2) Remove the tube oil plug on the machine side, install new O-ring (2), and connect bucket cylinder hose (1).
a
a
a
a
Reuse the oil stop parts as the split flange, bolts, etc.
Bleed air from the bucket cylinder. For details, see B-14 "Bleeding air from work equipment circuit".
Check that the split flange is not loosened but tightened.
Check that each O-ring is fitted, has not come off, and is not caught.
PART A
Installation of hose and O-ring
No.
1
2
No.
3
4
Precautions
Name
Qty
2
Extension L150
47
Qty
1
2
Qty
4
8
Necessary equipment
Oil container
Others
1. Keep the oil plugs used for component so that

they can be reused.
2. When installing the hose take extreme care
not to catch the O-ring.
3. When installing the hoses, take extreme care
not to twist them.
(Tighten from the 90 adapter to prevent
twisting.)
4. While installing the hose, take extreme care
not to allow dirt in the circuit.
Necessary tools
Loose-supply items
207-62-54680
07000-13032
07371-31049
07375-21035
Name
Qty
Assembly procedure
B-9
Installation of bucket cylinder hoses between

boom and bucket cylinder (2/2)
(3) Similarly, connect bucket cylinder hose (1) on the right side of the arm.
PART B
No.
1
2
No.
3
4
Precautions
Name
Qty
2
Extension L150
Ring wrench 14 mm width across

flats
48
Qty
1
2
Qty
4
8
Necessary equipment
Oil container
Others
1. Keep the oil plugs used for component so that

they can be reused.
2. When installing the hose take extreme care
not to catch the O-ring.
3. When installing the hoses, take extreme care
not to twist them.
(Tighten from the 90 adapter to prevent
twisting.)
4. While installing the hose, take extreme care
not to allow dirt in the circuit.
Necessary tools
Loose-supply items
207-62-54680
07000-13032
07371-31049
07375-21035
Name
Qty
Assembly procedure
Installation of bucket assembly (1/3)
B-10
[Preparation for installation]

1. Remove the stoppers of the bucket-arm connecting pin (fixed to the arm) and bucket-link connecting pin (fixed
to the link), and remove those pins.
2. Lightly install bushing (1) to the boss on the bucket side, and install O-rings (2) to the places shown below.
a Apply LM-P (1st time only) to the inside surface of the bushing (apply lithium grease at the 2nd time and
after).
O-ring position
[Installation]
3. Run the engine at low idle and operate the boom cylinder and arm cylinder slowly to set the holes for the bucket
and arm connecting pin.
a Weight of bucket assembly: For the weight, see the packing style table for transportation.
4. Install the arm-bucket connecting pin and the lock bolt and nut for the pin, without inserting shim.
No.
1
2
Precautions
Necessary tools
Name
Qty
1
Sledge hammer
Spanner, width across flats: 36 mm
Ring spanner, width across flats: 36 mm
Torque wrench: 85 kgm
Others
Qty
1
2
Necessary equipment
Nylon sling
49
Loose-supply items
208-70-34230
208-70-33181
Name
25t crane
Qty
1
Assembly procedure
Installation of bucket (2/3)
B-10
[Adjustment of shim]
5. Lightly tighten the stopper bolt (M24), measure clearance "a", and then decide the number of shims so that
their total thickness is the measured value +0.5 to +1.0 mm.
a Measure when there is no clearance on both sides of the arm end.
O-ring position
Clearance "a"
6. Install shims (1) and (2).
7. Lightly tighten the stopper bolt (M24), check clearance "b" between the arm and bushing is 0.5 to 1.0 mm all
round, and then install the O-rings to the correct positions (both sides of arm end).
O-ring
Correct position of O-ring
Clearance "b"
(0.5 to 1.0 mm)
No.
1
2
8. Install lock bolt.

Precautions
Necessary tools
Name
Qty
1
50
Qty
18
4
Necessary equipment
Sledge hammer
Others
When tightening, adjust the clearance

between the double nut and stopper to 0.5 to
1.5 mm. (Clearance marked with *)
Loose-supply items
208-70-34250
208-70-34260
Name
Qty
Assembly procedure
Installation of bucket (3/3)
B-10
[Installation of link]
9. Fit O-ring (1) to prevent entry of soil and sand.
10. While operating the bucket cylinder, align the holes for the bucket-link connecting pin.
a Operate the cylinder slowly. Do not operate it quickly or to the stroke end. In the first operation, there is an
air in the cylinder and the cylinder may not move for the first 10 seconds. In such case, do not operate the
control lever to the end of its stroke.
11. Push in the link-bucket connecting pin, install O-rings (1) to the correct positions to prevent entry of dirt, and
then install the pin stopper.
Correct position of O-ring
No.
1
Precautions
Necessary tools
Name
Qty
1
51
Qty
2
Necessary equipment
Sledge hammer
Others
When tightening, adjust the clearance

between the double nut and stopper to 0.5 to
1.5 mm. (Clearance marked with *)
Loose-supply items
207-70-33181
Name
Qty
Assembly procedure
B-11
Connection of work equipment grease piping (1/2)
(1) Remove the oil stopper plug at the cylinder end and the oil stopper plug at the hose nipple end, remove the
nipple from the hose, then assemble the boom cylinder greasing hoses (2 places) at porting (a) to the cylinder
end, and connect.
(2) Remove the oil stopper plug at the cylinder end and the oil stopper plug at the hose elbow end, remove the
elbow from the hose, then assemble the arm cylinder bottom greasing hose at porting (b) to the cylinder end,
and connect.
(3) Remove the oil stopper plug at the cylinder end and the oil stopper plug at the hose elbow end, remove the
elbow from the hose, then assemble the arm cylinder top greasing hose at porting (c) to the cylinder end, and
connect.
Tightening torque of hose

5.9 to 11.8 Nm (0.6 to 1.2 kgm)
(2places)
No.
1
Precautions
Qty
52
Qty
2
Necessary equipment
Name
Others
a After installing the boom and boom cylinder,

supply grease to parts (a) and (b), and then install the arm.
a After installing the arm, supply grease to part
(c), and then install the bucket.
Necessary tools
Loose-supply items
205-70-51390
Name
Qty
Assembly procedure
B-11
Connection of work equipment grease piping (2/2)
Tightening torque of hose

5.9 to 11.8 Nm (0.6 to 1.2 kgm)
PART
PART
Precautions
No.
1
2
3
Necessary tools
Qty
Others
Qty
1
1
1
Necessary equipment
Name
53
Loose-supply items
205-70-51390
205-70-51380
208-70-65770
Name
Qty
Assembly procedure
Connection of work equipment wiring (1/2)
B-12
(1) Install working lamp (1) and bracket (2).

a Working lamp nut tighteing torque: 17.6 to 19.6 Nm (1.8 to 2.0 kgm)
(2) Connect connector (a) (CN-L01) of the working lamp wire to the body wiring harness.
No.
1
2
3
4
5
6
PART A
Precautions
Necessary tools
Qty
Others
Qty
1
1
1
1
1
1
Necessary equipment
Name
54
Loose-supply items
20Y-06-43230
20Y-06-21551
01010-81430
01643-31445
08193-20012
01024-81220
Name
Qty
Assembly procedure
B-12
Connection of work equipment wiring (2/2)
(3) Connect connector (b) (CN-A13) of the boom wiring harness to the body wiring harness.
a Pass the wiring under the grease tube.
PART B
No.
1
2
Precautions
Necessary tools
Name
Qty
1
Others
Qty
1
1
Necessary equipment
55
Loose-supply items
04434-51012
01024-81225
Name
Qty
Assembly procedure
B-13
Greasing after completion of work equipment
(1) Supply grease to each part.

Use grease LM-G.
1) Boom cylinder foot pin (2 places)
2) Boom foot pin (2 places)
3) Arm and link connecting pin (1 place)
4) Arm and bucket connecting pin (1 place)
5) Link connecting pin (2 places)
6) Bucket cylinder rod end (1 place)
7) Bucket and link connecting pin (1 place)
8) Boom cylinder rod end (2 places)
9) Arm cylinder foot pin (1 place)
10)Boom and arm connecting pin (1 place)
11)Arm cylinder rod end (1 place)
12)Bucket cylinder foot pin (1 place)
Note 1 : Slowly move the boom up and down 3 to 4 times, and then supply LM-G through the fittings.
Note 2 : When assembly, take care extremely that dirt, rust, flaw, etc. will not cause trouble.
Be sure to perform Notes 1 which are important for prevention of galling of the pins.
Precautions
Necessary tools
Name
Necessary equipment
Qty
Name
Others
Grease pump
56
Qty
1
Assembly procedure
B-14
Bleeding air from work equipment circuit
After assembling the work equipment piping, bleed the air from it.
(1) Run the engine at low idle.
(2) Move each clinder to about 100 mm before each stroke end 4 - 5 times.
(3) Keeping the engine speed at low idle, move each cylinder from the point of 100 mm before the stroke end to
the stroke end very slowly (taking at least 10 seconds), and then keep the work equipment control lever at the
stroke end for 3 minutes.
[Bleed the air from the boom cylinder, arm cylinder, and bucket cylinder at the extraction stroke end.]
aThe cylinder may not start for more than 10 seconds at first because of the much air in the circuit. Do not
move the lever to the stroke end at this time.
aIf the engine speed is heightened or each cylinder is moved to the stroke end from the first, the piston packing
may be damaged by the air in the cylinder.
aEach time air is bled from each cylinder, retract the cylinder to the stroke end and check the sight gauge of
the hydraulic tank. If the oil level is below L-level, add hydraulic oil through the oil filler port.
Precautions
Necessary tools
Name
Others
a Before operating the cylinder, check that the

flushing filter is installed (to capture dirt in the
circuit).
a After the assembly work is completed, perform
the final check of the hydraulic tank oil level referring to the Assembly procedure M-5 "Inspection of oil level in hydraulic tank and refill".
57
Necessary equipment
Qty
Name
Qty
C. INCREASING AND DECREASING OF TRACK FRAME GAUGE,

ASSEMBLING OF COUNTERWEIGHT
59
Assembly procedure
Increasing and decreasing of track frame gauge (1/6)
C-1
Increasing of track frame gauge (1/3)

(1) Remove front and rear center frame mounting bolts (1) and colors (2) on the side to be extended. (4
pieces each at the front and rear)
(2) Swing the upper structure to a right angle to crawler frame (3) to be extended, connect bucket (4) and
crawler frame (3) to be extended by chain block (5), and raise crawler frame (3) by using the work
equipment.
(two pieces at both ends of crawler frame)
Tooth side
Precautions
Name
Necessary equipment
Qty
10 3,000 mm wire
20 5,000 mm wire
Lever block 3 ton
Others
a Limit the raising height (H) of the crawler frame

to 20 mm.
(If the crawler frame is raised too high, the
stopper bolt will be pried and bent.)
a When pulling the crawler frames with the lever
blocks, pull them so that the wires will be as
level as possible.
a When decreasing the gauge, see C-1 Decreasing of track frame gauge (4/6) to (6/6).
Necessary tools
60
Crawler side
Name
Qty
Assembly procedure
C-1

(3) Extend crawler frame (3) until it reaches stopper (6), lower the machine slowly to the ground, and
install bolts (1) and collars (2) (9 pieces each at the front and rear).
Tightening torque: 1,520 to 1,910 Nm (155 to 195 kgm)
a Install the bolts of the four positions marked with

the base of those bolts.
first, since other bolts are installed on
No.
1
2
(4) Work on the crawler frame on the opposite side similarly.

Precautions
Necessary tools
Name
Qty
1
Torque wrench (420 kgm)
Others
Qty
20
20
Necessary equipment
61
Loose-supply items
208-30-12130
208-30-41390
Name
Qty
Assembly procedure
C-1
Wooden block
a When tightening the bolts, raise the track shoe by the level portion with jacks or wooden blocks as
shown above to secure a space for the tightening work.
Precautions
Name
Necessary equipment
Qty
5 t Hydraulic jack
Torque wrench 420 kgm
Wooden block 400 200 mm
Others
Do not remove the shoe during the above

work.
(For securing the tightening torque of the
shoe bolts.)
Each collar must not ride over the spot facing.
Necessary tools
62
Name
Qty
Assembly procedure
C-1
Decreasing of track frame gauge (1/3)

(1) Remove front and rear center frame mounting bolts (1) on the side to be retracted. (9 pieces each
at the front and rear)
(2) Swing the upper structure to a right angle to crawler frame (2) to be retracted, connect right and
left crawler frames (2) and (3) by chain block (4), and raise crawler frame (2) by using the work
equipment and pull it with chain block (4) to decrease the gauge.
Precautions
Necessary tools
Name
Others
Limit the raising height (H) of the crawler

frame to 50 mm.
(If the crawler frame is raised too high, the
stopper bolt will be pried and bent.)
63
Necessary equipment
Qty
Name
Qty
Assembly procedure
C-1

(3) Retract crawler frame (2) until it reaches stopper (5), lower the machine slowly to the ground, and
install bolts (1) and collars (2) (4 pieces each at the front and rear).
Tightening torque: 1,520 to 1,910 Nm (155 to 195 kgm)
Guide plate
(4) Work on the crawler frame on the opposite side similarly.
Precautions
Necessary tools
Name
Others
a When decreasing the gauge, loosen the track.

(Loosening quantity is 30 to 50 mm. See
Step C-4, "Adjustment of track tension".)
After increasing the gauge, tense the
track.
(To prevent wear of the guide plate.)
a When decreasing the gauge, do not travel the
machine for a long time.
64
Necessary equipment
Qty
Name
Qty
Assembly procedure
C-1
Wooden block
a When tightening the bolts, raise the track shoe by the level portion with jacks or wooden blocks as
shown above to secure a space for the tightening work.
Precautions
Necessary tools
Name
Others
Do not remove the shoe during the above work.

(For securing the tightening torque of the
shoe bolts.)
Each collar must not ride over the spot facing.
65
Necessary equipment
Qty
Name
Qty
Assembly procedure
Installation of steps
C-2
Using bolts and washers (3) and (4), install steps (1) and (2) to the 4 places at the front, rear, right, and left
of the track frame.
a When assembling, eliminate

clearance in steps (1) and (2).
(All places)
No.
1
2
3
4
Precautions
Name
Qty
1
66
Qty
4
4
32
32
Necessary equipment
Others
a If any clearance is made, the bolts are broken

easily when the lower step is deformed.
Necessary tools
Loose-supply items
208-30-41611
208-30-41621
01010-81640
01643-31645
Name
Qty
Assembly procedure
Installation of travel piping covers (1/4)
C-3
(1) Installation of left travel piping cover
No.
1
2
3
4
5
6
Precautions
Name
Qty
1
67
Qty
1
3
3
1
4
4
Necessary equipment
Others
a Install all the covers (both right and left ones)

temporarily and adjust the clearance and level
difference, and then tighten them permanently.
Necessary tools
Loose-supply items
208-30-41311
01643-31645
01010-81635
208-30-75351
418-18-31160
01010-81635
Name
Qty
Assembly procedure
C-3
(2) Installation of left travel piping cover
No.
1
2
3
4
5
6
Precautions
Name
Qty
1
68
Qty
1
2
2
1
4
4
Necessary equipment
Others
a Clearances "a" and "b" in the cover must be

the same on the right and left sides.
Necessary tools
Loose-supply items
208-30-75332
01643-31645
01010-81640
208-30-58230
01643-31645
01010-81635
Name
Qty
Assembly procedure
C-3
(3) Installation of right travel piping cover
No.
1
2
3
4
5
6
Precautions
Necessary tools
Name
Qty
1
Others
Qty
1
3
3
1
4
4
Necessary equipment
69
Loose-supply items
208-30-41321
01643-31645
01010-81635
208-30-75361
418-18-31160
01010-81635
Name
Qty
Assembly procedure
C-3
(4) Installation of right travel piping cover
No.
1
2
3
4
5
6
Precautions
Name
Qty
1
70
Qty
1
2
2
1
4
4
Necessary equipment
Others
a Clearances "a" and "b" in the cover must be

the same on the right and left sides.
Necessary tools
Loose-supply items
208-30-75342
01643-31645
01010-81640
208-30-58230
01643-31645
01010-81635
Name
Qty
Assembly procedure
Adjustment of track tension (1/3)
C-4
Testing and adjusting track tension
k Warning
This work must be done by 2 persons. The operator

shall move the machine according to the signs from the
worker.
Since the wear condition of the pins and bushings of the
undercarriage varies with the working condition and soil
type, check the track tension occasionally and keep it at
the standard.
Test and adjust the track tension on a level and hard
place.
Testing
(1) Stop the machine on a level and firm place.
(2) Place a rectangular bar (3) which is longer than
the distance between idler (1) and carrier roller
(2) on the track.
(3) Measure the maximum slack between the top of
the track and the underside of the rectangular
bar.
Standard slack
If slack "a" is 16 to 34 mm, it is normal.
a When delivered, the slack is set to 30 to 50 mm

so that the gauge can be extended easily.
Precautions
Necessary tools
Others
Name
71
Necessary equipment
Qty
Name
Qty
Assembly procedure
C-4
If the track tension is out of the standard, adjust it according to the following procedure.
Adjusting
k Warning
Do not loosen the plug more than 1 turn. If it is loosened

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

(1) Add grease through plug (1) with the grease
pump.
(2) Move the machine forward and backward to
check that the track tension is proper.
(3) Check the track tension again. If it is not proper,
adjust it again.
(4) You may supply grease until (S) is 0 mm. If the
tension is still low, the pin and bushing are worn
excessively. In this case, turn over or replace the
pin and bushing. Consult your Komatsu distributor.
Precautions
Necessary tools
Name
Necessary equipment
Qty
Name
Others
Grease pump
72
Qty
1
Assembly procedure
C-4
Decreasing track tension
k Warning
It is very dangerous to discharge grease by a method

other than the following procedure.
(1) Loosen plug (1) slowly to discharge the grease.

(2) Do not loosen the plug (1) more than 1 turn.
(3) If the grease does not come out, move the machine back and forward a little.
(4) Tighten plug (1).
(5) Move the machine forward and backward to
check that the track tension is proper.
(6) Check the track tension again. If it is not proper,
adjust it again.
Precautions
Necessary tools
Name
Necessary equipment
Qty
1
Extension L150
Others
73
Name
Qty
Assembly procedure
Sticking sheet to counterweight
C-5
Stick the seats to the front side of the counterweight as shown below.
When sticking seats (1), (2), (3), (4), and (5), direct the faces having no black cover down.
Direct the faces having no black

cover down.
No.
1
2
3
4
5
Precautions
Necessary tools
Name
Others
Remove all oil and rust from the surface

where the sheet is to be stuck.
74
Loose-supply items
208-46-41711
208-46-41721
208-46-41731
208-46-41741
208-46-41761
Qty
1
1
1
1
1
Necessary equipment
Qty
Name
Qty
Assembly procedure
Installation of camera (1/6)
C-6
(1) Pass wiring harness (1) through the hole of the counterweight.
No.
1
Precautions
Necessary tools
Others
Name
75
Loose-supply items
208-06-24230
Qty
1
Necessary equipment
Qty
Name
Qty
Assembly procedure
C-6
(2) Connect connector (CN-A45) as shown below and install camera A (1) with bolts (2).
Face A
Match line of camera with angle of bracket
Top of camera must be in parallel with face A
No.
1
2
Precautions
Necessary tools
Others
Name
76
Loose-supply items
Camera A.
01024-81025
Qty
1
2
Necessary equipment
Qty
Name
Qty
Assembly procedure
C-6
(4) Install cover (1) as shown below.
Adjust shim (2) so that marked

clearance difference will be 2 mm
max. at points a, b, and c.
No.
1
2
3
Precautions
Necessary tools
Others
Name
77
Loose-supply items
2A5-06-11821
2A5-06-12240
01024-80616
Qty
1
3
2
Necessary equipment
Qty
Name
Qty
Assembly procedure
C-6
(5) Install cover (1) as shown below.
No.
1
Precautions
Necessary tools
Others
Name
78
Loose-supply items
207-06-76451
Qty
1
Necessary equipment
Qty
Name
Qty
Assembly procedure
C-6
(6) Remove the double-sided adhesive tape and stick seat (1) as shown below.
Then, connect the clips on the wiring harness side and counterweight side (6 places).
Install clips (6 places)

5 places at : Counterweight
1 place at u: Machine frame
No.
1
Precautions
Necessary tools
Others
Name
79
Loose-supply items
2A5-06-11860
Qty
1
Necessary equipment
Qty
Name
Qty
Assembly procedure
C-6
After installing, watch the monitor screen and check "how the counterweight is displayed".
"Monitor screen"
"If dimension L is out of the following range, adjust the installed angle of
the camera"
L: Must be in range from 4.5 to 13 mm
Precautions
Necessary tools
Others
Name
80
Counterweight
Necessary equipment
Qty
Name
Qty
Assembly procedure
C-7
Installation of counterweight (1/3)
(1) Sling counterweight assembly (1) and install it to the machine.

(2) Install by using mounting bolts (2) (4 pieces) and washers (3) (4 pieces).
Lightly tighten the bolts with a hand wrench or a small-sized impact
wrench until each installation face of the counterweight is seated,
and then tighten them to the specified torque.
a Check that the bolts are not loosened but tightened and check their torque.
Weight of counterweight assembly : 9,570 kg
Tightening torque:
3430 to 4212 Nm
(350 to 430 kgm)
Since these are important bolts, tighten them to
the center value of the specified torque range.
Center value of tightening torque:
3,820 Nm (390 kgm)
a Parts (4) are shims for adjusting

clearance and level difference
208-46-52260: 1 mm thick
208-46-52270: 0.5mm thick
No.
2
3
4
Precautions
a Do not insert any shim basically for adjusting
clearance or level difference.
If adjustment is necessary observe the following.
a) Adjust by inserting a shim only in the
backward and forward directions.
Example: No shim in both front holes and
shims 1 mm thick in both rear holes.
b) Limit the adjustment quantity with shim to 2
mm.
Necessary tools
Name
Qty
2
Shackle SD32
Torque wrench 420 kgm
Others
a Dimension of hanging hole of counterweight

42 mm
81
Qty
4
4
4
4
Necessary equipment
30 3,000 mm wire
a For adjustment after assembling the counterweight, see 3/3.
Loose-supply items
208-46-41610
01643-34212
208-46-52260
208-46-52270
Name
25 t crane
Qty
1
Assembly procedure
C-7
(3) When installing the counterweight to the machine, take care not to catch the wiring harness of the rear view
monitoring camera.
After installing, install harness clips (one place at u) and connect connector (CN-A40).
a Take care not to catch

wiring harness of rear
view monitoring camera
Connector (CN-A40)
Precautions
Necessary tools
Name
Others
a When installing, do not enter between the

revolving frame and counterweight but
open the left door and check that the wiring is not caught.
82
Necessary equipment
Qty
Name
Qty
Assembly procedure
C-7
(4) Adjustment method of assembled counterweight

a) Clearance to revolving frame must be 10 5 mm on both right and left sides.
b) Level difference from revolving frame must be 5mm or less on both right and left sides.
c) Clearance to exterior door must be 10 5 mm on both right and left sides.
d) Level difference from exterior door must be 8 4mm or less on both right and left sides.
e) Level difference from top of exterior door must be 5mm or less on both right and left sides.
Left door
Left door side
Level difference: 8 4 mm
(Difference between points T and S: 0 to 4 mm)
Level difference "e":
0 to 5 mm
Counterweight
Clearance "c": 10 5 mm
(Difference between points T and S: 0 to 3 mm)
Counterweight
Level difference "d":
8 4mm
Counterweight
Level difference "b":

0 to 5 mm
Right door
Clearance "a": 10 5 mm
Right door side
Counterweight
Level difference "b": 0 to 5 mm
Precautions
Necessary tools
Others
Name
83
Necessary equipment
Qty
Name
Qty
M. PROCEDURE FOR INSPECTION AND MAINTENANCE AFTER

COMPLETION OF ASSEMBLY
85
Assembly procedure
Replacement of return filter

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

plate only at the flushing time.
Replacement
Special element for flushing,

Absolute filter mesh size: 6 m
No.
1
2
Precautions
Necessary tools
Name
Others
a Store the removed standard element

(208-60-71123), strainer (07069-25400) and
valve (208-60-71160) in order because they
are used again after flushing.
a Replace before starting the assembly work.
(To capture dirt during the hose connecting
work and in the work equipment circuit)
86
Loose-supply items
208-60-71170
21T-60-13730
Qty
1
1
Necessary equipment
Qty
Name
Qty
Assembly procedure
Flushing of hydraulic circuit (1/2)
M-2
After completion of assembling flush the hydrau

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

minutes.
(c)
Extension and contraction of boom cylinder for

5 minutes
Precautions
Necessary tools
Name
Others
Full operation may damage the filter element

since the relief valve of the filter is closed.
87
Necessary equipment
Qty
Name
Qty
Assembly procedure
Flushing of hydraulic circuit (2/2)
M-2
(2) Flushing of Swing Circult

Right swing and left swing for 3 minutes each
(3) Flushing of Travel Circuit
Press the ground with the work equipment

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

For 3 minutes each
Forward travel and backward travel to the left

For 3 minutes each
(4) Check
After finishing flushing, replace the flushing filter with the standard one according to "Replacement of return
filter (2/2)".
At this time, check that the dirt captured in the flushing element has no problem. If the dirt seems to have
problem, consult your Komatsu distributor.
Precautions
Necessary tools
Others
Name
88
Necessary equipment
Qty
Name
Qty
Assembly procedure
M-3

(Flushing filter to standard filter) (1/2)
Reassemble hydraulic oil return filter element (1), strainer (2) and valve (3) which you have removed in the previous step.
a When replacing the element, take out the element slowly so that refuses adhered to the element do not fall inside. Also, take out refuses by
hand from the case
Replacement
Valve (3)
Valve (2)
Standard element (1)
Precautions
Necessary tools
Others
Name
89
Necessary equipment
Qty
Name
Qty
Assembly procedure

(Flushing filter to standard filter) (2/2)
M-3
State of inserted element
Element
Fig. 1 Correct state
Do not insert the element so that it stands on the step at the bottom of the case as shown in Fig.
2.When the filter case is filled with oil, it is difficult to check if the element is inserted correctly,
so turn the element by hand after inserting it in the case. When it turns smoothly, it is considered
to be inserted correctly.
Precautions
Necessary tools
Name
Others
Fig. 2 Incorrect state
90
Necessary equipment
Qty
Name
Qty
Assembly procedure
M-4
Check of oil/coolant level at each part (1/2)
a For details of the notes (Note 1, 2, 3, 4, 5, 6) in the table, see the "Operation and Maintenance Manual".
For details of the recommended genuine oil, see the "Operation and Maintenance Manual", too.
91
Assembly procedure
Check of oil/coolant level at each part (2/2)
M-4
Engine
oil pan
Final
drive case
Swing
(Each of
machinery case right and
left)
Damper
case
Hydraulic
oil system
Cooling
system
Fuel tank
AdBlue
/DEF
Specified capacity (l)
42
20
11
1.6
472
44
650
60
Refill capacity
(l)
38
20
11
1.6
248
44
Decide the mixing proportion of the coolant to the water according to the past minimum temperature and the
following mixing proportion table.
Actually, set the proportion for a temperature about 10 C lower than the past minimum temperature.
Mixing proportion of water and coolant
Min. temperature
(C)
Above
-10
-15
-20
-25
-30
-35
-40
Coolant
13.2
15.8
18.0
20.2
22.0
23.8
25.5
Water
30.8
28.2
26.0
23.8
22.0
20.2
18.5
Quantity
(l)
k Waring
Coolant is flammable. So keep it away from
open flame.
Use city water to dilute.
Adjust the control proportion by using an antifreeze concentration meter.
k Waring
When removing the drain plug, take care that
the coolant and water mixture will not be
splashed over you.
Precautions
Necessary tools
Name
Others
When the machine is delivered, it is filled with

Supercoolant (blue) containing no amine. Do
not add coolant of different type.
92
Necessary equipment
Qty
Name
Qty
Assembly procedure
Inspection of oil level in hydraulic tank and refill (1/2)
M-5
Inspection of oil level in hydraulic tank and refill
k Warning
When removing the cap from the oil filler port,

turn it slowly to relieve the internal pressure so
that the oil will not burst out.
(1) If the machine is not in the state illustrated here,

start the engine, rotate it at a low speed, reduce
the arm and the bucket cylinder, lower the boom
slowly so that the bucket teeth touch the
ground, and then stop the engine.
(2) Set the start switch to the ON position with in 5
to 6 seconds after stopping the engine and set
each control lever (work equipment and travel)
to the full stroke in each direction to relieve internal pressure.
(3) Open the door on the left side of the machine
and check the sight gauge (G). When the oil level is between the H and L lines, the level is appropriate.
(4) When the oil level is below the L Iine, supply oil
through the oil filter port (F).
For applicable oil, "Check of oil/coolant level at
each part M-4 ".
Notice:
Do not supply oil, beyond the H line, but the hydraulic circuit may be damaged or oil may burst out.
Precautions
Necessary tools
Others
Name
93
Necessary equipment
Qty
Name
Qty
Assembly procedure
Inspection of oil level in hydraulic tank and refill(2/2)
M-5
k Warning
If the oil level is higher than level H, stop

the engine, wait until the hydraulic oil
cools down, and then remove undercover (1) or (2) and drain excessive oil
through drain plug (P) or (A).After draining the oil, tighten the drain plug and
install the undercover.
Supplementary Explanation:
Since the oil level changes as the oil temperature
changes, check the oil level noting the following
as guides:
The oil level shall be around the L level before

operation (when the oil temperature ranges
from 10 to 30C).
The oil level shall be around the H level during

normal operation (when the oil temperature
ranges from 50 to 80C).
Precautions
Necessary tools
Others
Name
94
Necessary equipment
Qty
Name
Qty
Assembly procedure
M-6
Parts to be touched up after field assembly
After assembling the large-sized hydraulic excavator in the field, touch up the following parts.
(1) Underside of front and rear of boom
(2) Underside of arm
(3) Underside of counterweight
(4) Underside of bucket
(5) Track frame (Flaws made during increasing/

decreasing of gauge, unpainted parts)
(Right and left sides, 4 places in total)
When the machine is used on the seashore, etc. where it is rusted easily, touch up the following
parts, too.
Unpainted parts of machined surfaces of flanges after installing piping Grease tubes
Metallic hose bands, etc.
Use rust-prevent clear paint for touching up the machined surfaces, etc.
(Recommended brand: KOMATSU genuine rust-preventive clear paint)
Precautions
Necessary tools
Others
Name
95
Necessary equipment
Qty
Name
Qty
Assembly procedure
Error code
M-7
Turn the key switch to the ON position and check that no error code is displayed on the monitor.
If any error code is displayed, consult your Komatsu distributor.
96
Arm cylinder lock plate

Boom top lock plate
Tightening torque: M12 98 to 123 Nm {10 to 12.5 kgm}
M20 455 to 565 Nm {46.5 to 58 kgm}
No.
Bolt size: M12

Torque
No.
97
Bolt size: M20

Torque
Boom foot lock plate

Tightening torque: M20 455 to 565 Nm {46.5 to 58 kgm}
No.
Torque
1
2
98
Boom cylinder bottom lock plate

Tightening torque: M12 98 to 123 Nm {10 to 12.5 kgm}
No.
Right side of chassis

Torque
No.
99
Left side of chassis

Torque
Counterweight mounting bolt

Tightening torque: 3,430 to 4,212 Nm {350 to 430 kgm}
Since these are important bolts, tighten them to the center value of the specified torque range.
Center value of tightening torque: 3,820 Nm (390 kgm)
No.
Torque
1
2
3
4
100
Center frame x crawler frame

Tightening torque: 1,520 to 1,910 Nm {155 to 195 kgm}
Front of chassis
Left of chassis
Right of chassis
Rear of chassis
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
Right side of chassis

Torque
No.
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
101
Left side of chassis

Torque
Revision
Category
4/13
Check item
Local After
assembly hours of
time
operation
Judgement standard
Monitor display
1. Check of monitor function
When the starting switch is turned ON, the gauges,
CHECK items, and all display items on the monitor should
light up. At the same the alarm buzzer should sound.
2. Check of gauges and CHECK items
When starting switch is turned to ON (all lamps on), all
display lamps should go out after approx. 3 sec.
For another 2 seconds, only the gauges are displayed,
and the CHECK and monitor items disappear.
3. Check of monitor items
After starting the engine, the caution lamps should not
light up and the alarm buzzer should not sound when the
engine speed is low idling high idling.
As per left
Operation of service meter
There should be no scratches or misting

of the lens or variation in operation.
MONITOR
Check monitor
Ordinal display
Display of meter only
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
(28)
(29)
(30)
(31)
(32)
(33)
(34)
(35)
(36)
(37)
(38)
(39)
(40)
Wiper switch
Buzzer cancel switch
Auto-deceleration switch
Service meter, Clock
ECO gauge
Camera direction monitor
Hydraulic oil temperature gauge
Hydraulic oil temperature monitor
Engine coolant temperature gauge
Engine coolant temperature monitor
Fuel gauge
Fuel level monitor
Ad/Blue/DEF level gauge
Ad/Blue/DEF level monitor
Fuel consumption gauge
Working mode selector switch
Travel speed selector switch
Window washer switch
Air conditioner control switches
Seatbelt fixing monitor
Engine stop monitor
Lock lever monitor
KDPF regeneration monitor
KDPF regeneration stop monitor
Message monitor
Air conditioner monitor
Wiper monitor
Swing lock monitor
Engine pre-heating monitor or
One-touch power max. monitor
Auto-deceleration monitor
Working mode monitor
Travel speed monitor
Radiator coolant level monitor
Air cleaner clogging monitor
Engine oil level monitor
Charge level monitor
Ad/Blue/DEF system monitor
Engine oil pressure monitor
Function switches (F1 to F6)
Maintenance interval monitor
Check of switches, control levers
Revision
Category
5/13
Check item
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
Radio
Lock lever
Left work equipment control lever
One-touch power max. switch
Travel pedals
Travel levers
Horn switch
Machine monitor
Right work equipment control lever
Starting switch
Fuel control dial
Lamp switch
Swing lock switch
Local After
assembly hours of
time
operation
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
Judgement standard
Machine push-up switch

Ceiling window wiper switch (if equipped)
Revolving warning lamp switch (if equipped)
Attachment control pedal (if equipped)
Attachment control pedal (if equipped)
Cigarette lighter
Room lamp switch
Heated seat switch (if equipped)
Engine shut down secondary switch
Secondary pump drive switch
Swing brake cancel switch
Lock lever auto release switch
Operation of horn switch
If the switch is pushed, the horn sounds.
Operation of lock lever
Push down the lever to apply the lock.

Engine can be started but all work
equipment control levers do not move.
Push up the lever to release the lock.
Engine cannot be started but all work
equipment levers move.
MAX: Full speed
MIN: Low idle
Operation of fuel control dial
Revision
Category
6/13
Check item
Judgement standard
Operation of working mode selector switch
Lighting of P: For heavy load work

(ATT/P)
Lighting of E: For economical work
(ATT/E)
Lighting of L: For inching operation
Lighting of B: For breaker work
Monitor display changes, synchronizing
with switch
Full throttle speed of engine changes
Operation of auto-deceleration switch
ON lights up: Auto-deceleration is

actuated.
OFF:
Auto-deceleration is
canceled.
Operation of travel speed switch
Local After
assembly hours of
time
operation
Operation of wiper switch
Each time the switch is pressed, the

auto-deceleration is actuated or
canceled.
La lights up: Low speed travel
Mi lights up: Middle speed travel
Hi lights up: High speed travel
When the engine is started, the travel
speed is automatically set to Lo.
OFF: Wiper stops
ON lights up: Wiper moves continuously
INT lights up: Wiper moves intermittently
Each time switch is pressed, monitor
display changes and can be selected.
Operation of window washer switch
Window washer fluid is sprayed out.
Operation of cigarette lighter
This is used to light cigarettes. To use,

push the lighter in. After a few seconds
it will spring back.
This switch is used to turn on the front
lamps working lamps, additional lamp at
the top front of the cab, and monitor
lighting.
ON position (actuated):
The swing lock is always applied,
and the upper structure will not
swing even if the swing is
operated. In this condition, the
swing lock lamp lights up.
OFF position (canceled):
Swing operation is possible. Swing
lock monitor goes off.
Low pressure setting:
The boom thrust force is weak.
High pressure setting:
The boom thrust force becomes
more powerful.
Operation of lamp switch
Operation of swing lock switch
Operation of machine push-up switch
Operation of room lamp switch
ON position: Room lamp lights up.
Operation of secondary pump drive switch
Normal state:
Switch is in "LOWER" position
If switch is set to "UPPER" position,
alarm buzzer sounds.
While monitor is indicating "L03 pump control error", if switch

is in "UP" position, emergency pump can be driven
Revision
Category
7/13
Check item
Operation of lock lever auto lock cancel switch
Judgement standard
When normal: Switch is in "Lower"
position.
When this switch is set in "Upper" position, the lock lever auto
lock function is disabled.
When the lock lever is released while the control lever or
pedal is operated, the work equipment or machine moves.
Operation of swing brake cancel switch
If the switch is set to "Upper" position,

the lock lever lock switch cancel monitor
lighting up.
While monitor is indicating "L03 swing brake error", if switch

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

alarm buzzer sounds and swing
lock symbol flashes
Operation of lower wiper switch (option)

Operation of travel levers
Operation of left work equipment control lever

(with auto-deceleration device)
Local After
assembly hours of
time
operation
Operation of right work equipment control lever

(with auto-deceleratiom device)
Confirmation of failure history

(Both electrical and mechanical)
Operation of power max. switch
Check function of rotation lamp switch
(option)
Normal state:
Switch is in "LOWER" position
This is used to stop alarm buzzer if it

sounds to warn of an abnormality during
operation.
ON: Lower wiper moves.
OFF: Lower wiper stops.
FORWARD:
The lever is pushed forward.
(The pedal is angled forward)
REVERSE:
The lever is pulled back.
(The pedal is angled back)
N (Neutral):
The machine stops.
This lever is used to operate the arm
and upper structure.
Arm operation
Swing operation
N (Neutral):
When the lever in this position, the
upper structure and the arm will be
retained in the position in which
they stop.
This lever is used to operate the boom
and bucket.
Boom operation
Bucket operation
N (Neutral):
When the lever in this position,
the boom and the bucket will be
retained in the position in which
they stop.
Check there is no abnormality, then
delete abnormality record. When
finishing inspection, check again there is
no abnormality record.
When the switch on the LH work
equipment control lever is pushed, the
digging power increases.
ON: Rotary lamp lights up
Leakage of AdBlue/DEF from each part

(AdBlue/DEF tank, pump, injector piping)
There must be none.
12/13
Revision
Category
Note: If the operation or function is defective, measure as necessary. All judgement standard values for speeds are the values in P mode.
Local
After
assembly hours of
time
operation
Check item
Judgement standard
1. Engine speed
Low idle speed
rpm ]
1000 50 rpm
High idle speed
rpm ]
1930 50rpm
Speed at arm OUT
rpm ]
1930 100 rpm
at P mode
Speed at arm IN
rpm ]
1830 100 rpm
When mode is P and

swing lock is ON
rpm ]
1270 50 rpm
When oil temperature is 50 oC and fan
rotation is 100%
2. Readiator fan speed

Speed at engine high idle
speed
Measurement items
3. Oil pressure measurment (measure at pump outlet port)

RAISE
{355 (+15 / -12)kg/cm3}
Boom
*37.3 (+1.47 / -1.18)MPa

Hydraulic oil temperature : Within operation range
{355 (+15 / -12)kg/cm3}
Engine at high idle

Working mode: P mode
Hydraulic pump output pressure with all
measurement circuits relieved
Swing
Travel
Values indside parenthesis :

Hydraulic oil pressure with power max.
switch in ON mode
(reference only)
*37.3 (+1.47 / -1.18)MPa

{380 (+15 / -12)kg/cm3}
30.9 (+1.47 / -2.65)MPa
{315 (+15 / -20)kg/cm3}
37.3 (+2.94 / -1.13)MPa
{380 (+30 / -10)kg/cm3}
Hydraulic oil temperature: Within operation range
Control circuit source

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

34.8 (+1.47 / -1.18)MPa
Arm
Bucket
34.8 (+1.47 / -1.18)MPa
3.24 0.2 MPa

{33 2 kg/cm3}
Engine at high idle

Self pressure reducing valve output pressure with all control levers in NEUTRAL
position
LS differential pressure
Hydraulic oil temperature: Within operating range

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

levers in NEUTRAL
position
4.2 1.0 MPa
When traveling at
half stroke
(At idling)
2.65 0.1 MPa
{42 10 kg/cm3}
{27 1 kg/cm3}
Revision
Category
13/13
Local
After
assembly hours of
time
operation
Check item
Measure in
posture at right
4. Hydrauric drift of work equipment

(Bucket load: 3,060 kg, hydraulic oil temperature 50 5C)
Bucket tooth tip
Judgement standard
mm ]
Max. 600 mm/15 minutes
Note: Measure the hydraulic drift of the following cylinders only if

the hydraulic drift at the bucket tooth tip does not pass the test.
Measure retraction distance of each of following cylinders.
Boom cylinder
mm ]
Max. 29 mm/ minutes
Arm cylinder
mm ]
Max. 100 mm/ minutes
Bucket cylinder
mm ]
Max. 35 mm/ minutes
5. Operation force, travel

Boom
lever
Operating
force
RISE

(kg)
N
RISE
LOWER
LOWER
(kg)
N
15.7 3.9 N
{1.6 0.4 kg}
Stroke: 85 10 mm
PLAY
Stroke
Measurement items
[
Swing
lever
Operating
force
mm]
mm]
RIGHT

(kg)
RIGHT
LEFT
mm]
(kg)
LEFT
PLAY
Play: Max. 15mm

12.7 2.9 N
{1.3 0.3 kg}
Stroke: 85 10 mm
Stroke
[
Bucket
lever
Operating
force
mm]
CURL
mm]

(kg)
N
CURL
mm]
(kg)
DUMP
DUMP
Play: Max. 15mm

12.7 2.9 N
{1.3 0.3 kg}
Stroke: 85 10 mm
PLAY
Stroke
[
Arm lever
Operating
force
mm]
IN
mm]

(kg)
N
IN
mm]
(kg)
OUT
OUT
PLAY
Play: Max. 15mm

15.7 3.9 N
{1.6 0.4 kg}
Stroke: 85 10 mm
Stroke
[
Right
travel
lever
Operating
force
mm]
FOR
WARD
mm]

(kg)
N
FORWARD
mm]
RE
VERSE
REVERSE
(kg)
N
Play: Max. 15mm

24.5 5.9 N
{2.5 0.6 kg}
Stroke: 115 15 mm
PLAY
Stroke
[
Left travel
lever
Operating
force
mm]
FOR
WARD
mm]

(kg)
N
FORWARD
mm]
RE
VERSE
REVERSE
(kg)
N
Play: Max. 20mm

24.5 5.9 N
{2.5 0.6 kg}
Stroke: 115 15 mm
PLAY
Stroke
[
mm]
mm]
mm]
Play: Max. 20mm
At engine high
idling, relief

PC490LC-11 Komatsu

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PC490LC-11 Komatsu

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GEN00126-01

Operator for assembly

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

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

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

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

Mounting bolt torque check sheet

SAE J1995 (Gross)

Min. ground clearance

Travel speed (Low/High)

Precautions for field assembly

Disposal of removed parts

Meeting with all workers

Inspection of oil level and

Flow of field assembly

Installation of boom cylinder

Greasing of work equipment

Air bleeding (work equipment)

Check of oil and coolant levels

Kit layout diagram

The dimensions given below are the minimum dimensions needed.

(Upper structure + Undercarriage)

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

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

Position of center of gravity

Position of center of gravity

(3) Boom cylinder

Position of center of gravity

Tool list for field assembly

420 kgm T38.1

Socket, spanner, ring wrench

Large hammer (plastic)

Large and small ones

Oil, grease, consumable

For greasing work equipment

Track frame connecting bolt

For tightening track frame connecting

Part No. of washer

Applicable socket size

: Bolt thread diameter (Nominal diameter)

Table 1 Tightening torque for bolts not specified in text

Width across flats

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

2. Tightening torque for pipe threads

Material of female thread

Nominal size (in)

Material of female thread

Nominal size (in)

3. Tightening torque for hydraulic hose connecting nut

Width across flats

84 132 {8.5 13.5}

128 186 {13.0 19.0}

177 245 {18.0 25.0}

Tightening torque (Nm {kgm})

Table 4.2 Hydraulic hose of taper seal type

Type that does

Width across flats

84 132 {8.5 13.5}

128 186 {13.0 19.0}

177 245 {18.0 25.0}

Tightening torque (Nm {kgm})

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

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

Proper sizes of sockets or spanners