Gen00181 03

GEN00181-03
HYDRAULIC PC500LC -10M0

EXCAVATOR
PC500LC -10R
PC500LC- 10M0 95001
SERIAL NUMBERS and up
PC500LC- 10R 100001
FOREWORD　　　
3INCETHISMACHINEISLARGEINSIZEITISDIVIDEDINTOSOMEUNITSTOMEET
THETRANSPORTATIONCONDITIONSANDREGULATIONSAPPLIEDTOTHETRANSPORTA
TIONROUTEWHENSHIPPEDFROMOURFACTORY
4HIS MANUAL DESCRIBES HOW TO ASSEMBLE THEUNITS INTO THE COMPLETE
MACHINEINTHEFIELD7EHOPETHATTHISMACHINEWILLDISPLAYITSQUALITY
ANDYOUWILLUSEITSAFELYACCORDINGTOTHEOPERATIONMANUAL
-ANYUNITSARELARGEINSIZEANDHEAVYINWEIGHTANDMAYBEHANDLED
INADANGEROUSPLACEORPOSTUREANDMANYWORKERSMAYHAVETOWORK
TOGETHERTOSLINGTHEMWITHCRANES
!CCORDINGLYBEFORESTARTINGTHEASSEMBLYWORKTHEWORKSUPERVISORIS
REQUIREDTOHOLDASAFETYMEETINGTOOBLIGETHEWORKERSTOPUTONPRO
TECTIVEGEARANDAPPOINTAWORKLEADERANDACRANEWORKSIGNALMAN
ANDALLOTROLESTOALLTHEWORKERSFORSAFEWORK
)NPARTICULARTHEABOVEMEETINGISMOREIMPORTANTWHENWORKEROFDIF
FERENTLANGUAGESANDCUSTOMSWORKTOGETHER
4HEFOLLOWINGISAREFERENCESUPERVISIONSYSTEMDIAGRAM
(Instruction system)
Work leader
Director
Work supervisor Crane director and
deputy director
Operator for assembly

Liaison man
Mechanics Sharing of work

Interpreter
.OTETHATTHISMANUALDOESNOTDESCRIBETHEWHOLESPECIFICATIONOFTHE
MACHINEBUTDESCRIBESONLYTHEBASICSPECIFICATION
)FYOUHAVEANYQUESTIONWHENDIVIDINGANDTRANSPORTINGTHEMACHINE
BYYOURSELFINFUTUREASKONEOFOURDISTRIBUTORS
CONTENTS
Specifications ...................................................................................................................... 1
Precautions for field assembly ............................................................................................ 2
Disposal of removed parts................................................................................................... 3
Assembling procedures, applicable equipment and schedule ............................................ 4
Flow of field assembly ......................................................................................................... 5
Kit layout diagram ............................................................................................................... 6
Transportation ..................................................................................................................... 7
Tool list for field assembly ................................................................................................... 10
Tightening torque ................................................................................................................ 11
Coating materials ............................................................................................................... 16
Selection of wire ropes used for assembly.......................................................................... 20
Selection of nylon slings used for assembly ....................................................................... 21
A. Assembly of chassis ....................................................................................................... 23

A- 1. Installation of steps ................................................................................................ 24
A- 2. Installation of climbing grip .................................................................................... 25
A- 3. Installation of handrail (if equipped)....................................................................... 26
A- 4. Installation of mirror ............................................................................................... 27
B. Assembling of work equipment ...................................................................................... 31

B- 1. Installation of boom cylinder .................................................................................. 32
B- 2. Releasing remaining pressure in hydraulic circuit ................................................. 34
B- 3. Installation of boom cylinder hoses ....................................................................... 35
B- 4. Installation of boom cylinder top pin ...................................................................... 36
B- 5. Installation of boom assembly ............................................................................... 37
B- 6. Installation of hoses from chassis along top of boom............................................ 39
B- 7. Connection of boom cylinder head ........................................................................ 40
B- 8. Installation of arm assembly .................................................................................. 41
B- 9. Installation of bucket cylinder hoses between boom and bucket cylinder ............. 43
B-10. Installation of bucket............................................................................................. 45
B-11. Connection of work equipment grease piping....................................................... 47
B-12. Connection of work equipment wiring................................................................... 49
B-13. Installation of LED working lamps (if equipped).................................................... 50
B-14. Greasing after completion of work equipment ...................................................... 51
B-15. Bleeding air from work equipment hyd.circuit....................................................... 52
C. Assembling of counterweight and adjustment ................................................................ 53

C- 1. Adjustment of track tension ................................................................................... 54
C- 2. Sticking sheet to revolving frame .......................................................................... 57
C- 3. Sticking sheet to counterweight............................................................................. 58
C- 4. Installation of rear view mirror ............................................................................... 59
C- 5. Installation of camera (if equipped) ....................................................................... 60
C- 6. Installation of counterweight.................................................................................. 68
D. Installation of catwalk ..................................................................................................... 71

D- 1. Installation of side step........................................................................................... 72
D- 2. Installation of hydraulic tank top handrail .............................................................. 73
D- 3. Installation of cab top grip ...................................................................................... 74
M. Procedure for inspection and maintenance after completion of assembly ..................... 77
M- 1. Replacement of return filter (Standard filter to flushing filter)................................ 78
M- 2. Flushing of hydraulic circuit .................................................................................. 80
M- 3. Replacement of return filter (Flushing filter to standard filter) ............................... 82
M- 4. Check of oil/coolant level at each part .................................................................. 84
M- 5. Inspection of oil level in hydraulic tank and refill ................................................... 86
M- 6. Parts to be touched up after field assembly .......................................................... 88
M- 7. Adjust KomVision Camera angle (KomVision Spec.)
(Camera calibration and 12 m visibility check) ...................................................... 89
M- 8. Error code ............................................................................................................. 106
Mounting bolt torque check sheet

Field assembly inspection report (Backhoe)
Specifications
PC500LC PC500LC PC500LC PC500LC
Machine model
-10M0 -10M0 SE spec. -10R -10R SE spec.
Weight of machine kg 49,400 49,300 49,400 49,300
Bucket capacity m3 2.5 4.0 2.5 4.0
Engine model － KOMATSU SAA6D125E-5
Flywheel SAE J1995 (Gross) 270/1,900 {362/1,900}
kW/min-1 {HP/rpm}
horsepower ISO 9249/SAE J1349 (Net) 269/1,900 {360/1,900}
Min. ground clearance mm 570
Travel speed (Low/High) km/h 3.0/4.2/5.5
Swing speed rpm 9.1
PC500LC-10M0, PC500LC-10R
PC500LC-10M0 SE spec., PC500LC-10R SE spec.
1
Precautions for field assembly
1. Selection of work place
1) When selecting a work place, consider the following.
• Is the work place sufficiently wide for loading and unloading the machine? (See the kit layout drawing.)
• Is the ground sufficiently hard? (The machine and crane truck must not sink into the ground.)
• Is the ground flat? (The ground surface must not be uneven or sloping.)
• Is the road to inlet/outlet of the work place sufficient for turning the trailer and crane truck?
2) Take care extremely that dirt or water will not enter the hydraulic circuit while it is assembled.
3) Avoid working outdoors while strong wind is blowing or it is raining.
4) Take measures to protect the machine from sand, dirt and rainwater while the work is stopped.
2. How to do work
The work supervisor or the work leader should not do the work while reading this manual but should read and
understand this manual thoroughly and then start the work.
In particular, write the "Precautions" for each work process in a sheet to explain or stick that sheet to the work
place so that all the workers will observe the precautions.
3. Preparation and check of protective gear, slings and tools

The work supervisor or the work leader must perform the following checks about protective gear, slings and
tools.
1) Are all the workers wearing helmets and other protective gear which they are obliged to wear? If special
protective gear is necessary, check that it is prepared and can be used without problem.
2) Are all the slings and tools prepared? Check in advance that they are ready to be used without problem.
In particular, check wooden blocks for internal decay and cracking.
4. k Check during actual work

The work supervisor or the work leader must check the following items constantly and make all the workers ob-
serve them.
1) Are the parking brakes of the trailer and crane truck applied securely and are their wheels locked with
chocks during work? Are outriggers, if installed, used securely?
2) Are the temperature and pressure of the engine, hydraulic oil, coolant, etc. lowered sufficiently during work?
3) Is horn or another signal is made to warn around when the engine is started? In addition, is it checked that
work equipment control lever and other control levers are in neutral and the fuel control dial (or fuel control
lever) is in the low idle position?
4) Is the balance of the slung item checked extremely during sling work with the crane?
5) Is entry prohibition for outsiders to the work place observed?
5. The work supervisor or the work leader is required to hold a meeting with all the workers at the beginning of
every morning and explain the work plan of the day to them and give them instructions to observe the safe
work.
2
Disposal of removed parts
As described in "FOREWORD", when this machine is transported, it is divided into some units such as the body,
undercarriage, cab, work equipment, etc. according to the transportation measure, regulations,etc.
Accordingly, the hydraulic pipings and hydraulic hoses to connect the units, oil inlets and outlets of the hydraulic
devices, and parts which must not be damaged are plugged or covered to prevent oil leakage, entry of dirt and
dust, and damage during transportation.
In addition, fixing jigs are used to prevent a trouble caused by a fall or a shake during transportation and to facilitate
loading, unloading and crane work.
The above plugs, jigs, etc. are removed when the machine is assembled and become unnecessary after comple-
tion of the machine. Since they are useful when the machine needs to be transported in future, however, we rec-
ommend you to keep them as long as possible.
3
Assembling procedures,
applicable equipment and schedule
3 Division
4
Flow of field assembly
*1 Installation of accessories
*2 Installation of boom cylinder
*2•*3 Installation of boom
*2•*4 Installation of arm
*2 Installation of bucket
Greasing of work equipment
Air bleeding (work equipment)
*5 Sub-assembling of
Installation of counterweight counterweight
Flushing
Check of oil and coolant levels
Completion inspection
Precautions
*1: Installation of track frame step,grip, handrail, rear view mirror,
*2: Adjustment of shim
*3: Installation of working lamp
*4: Bucket cylinder and link are installed before shipment
*5: Installation of sound absorbing material, rear view mirror ,
and rear view monitoring camera(if equipped)
5
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”.
6
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
(Upper structure + Undercarriage) (Work equipment) (Others)
t Packing Style of Each Kit (Sizes in drawing are given in millimeters.)

• Upper structure + Undercarriage
Model PC500LC-10M0 (inc. -10R & SE spec.)
A (mm) 6,070
B B (mm) 3,460
Shoe width 600
(mm)
Overall width 3,340
(mm)
Weight
(kg) 27,300
7
Packing Style of Each Kit (Sizes in drawing are given in millimeters.)
(1) Boom
PC500LC-10M0 (inc. -10R)

Model
STD SE spec.
B A (mm) 7,320 6,290
B (mm) 1,990 1,880
Position of center of gravity Overall width 790

(mm) 790
Weight
(kg) 4,600 4,525
A
(2) Arm
PC500LC-10M0 (inc. -10R)

Model
STD SE spec.
A (mm) 5,530 3,695
B
B (mm) 1,200 1,330
Overall width 720 720

(mm)
Position of center of gravity Weight 2,775 2,690
(kg)
A
(3) Boom cylinder
Model PC500LC-10M0(inc. -10R & SE spec.)
Weight
(kg) 422
Position of center of gravity
8
(4) Bucket
A
Model PC500LC-10M0(inc. -10R & SE spec.)
Bucket capacity(m3) 2.5 4.0
A (mm) 1,930 2,195
B (mm) 1,550 1,895

B Overall width 1,915 1,965
(mm)
Weight 2,425
(kg) 2,450
(5) Counterweight
1,000
3,030 Model PC500LC-10M0(inc. -10R & SE spec.)
Weight (kg) 10,740
1,300
9
Tool list for field assembly
No. Part name Specification Q'ty Remarks
1 Equipment Compressor 7.0kg/cm3 1
2 Crane truck 25 ton 1
3 Grease pump Air supply set 1 For greasing work equipment
4 Stepladder 5-step, 1,500 mm 2
5 M10 bolt 1 Torque capacity: 30-170Nm
Small-sized impact wrench (3.06-17.3 kgf·m)}
6 M12 bolt 1
Medium-sized impact Torque capacity: 200 - 700Nm
7 wrench M14 – M20 bolt 1 (20.4 - 71.4 kgf·m)
8 Large-sized impact M24 – M33 bolt 1 Torque capacity: 1,000 - 2,500Nm
wrench (102 - 255 kgf·m)}
9 Air hose for impact wrench 50 m 1
10 Socket 22 mm width across flats 1
11 Medium-sized impact Socket 24 mm width across flats 1
wrench socket
Large-sized impact
wrench socket
14 Socket 65 mm width across flats 1 Counterweight
15 4 :1 torque
multiplier wrench □25.4(Male), □19(Female) 1
Socket for 4:1 torque
Tool
16 multiplier wrench T25.4 square x Width across flats 65 mm 1 each Counterweight

17 42 kgm – T25.4 1 35 - 420Nm {(3.57- 42.8 kgf·m)}
18 Torque wrench 85 kgm – T25.4 1 420 - 1,050Nm {(42.8 - 107 kgf·m)}
1,050 - 4,200Nm (107 - 428 kgf·m)}
19 420 kgm – T38.1 1 Counterweight
20 1 set of
Standard tools Socket, spanner, ring wrench 2 each
21 Large hammer (plastic) 10 P 1
22 Bar 1m 2
23 Rectangular bar Approx. 2m length (steel or wood) 1 For adjustment of track tension
24 Tape measure 1 For adjustment of track tension etc.
25 For connecting travel piping and work
Oil container Large and small ones 2 each equipment piping
26 Wooden block 30 x 50 x 150 mm 2 Support of boom cylinder
27 5 mm width across flats 1
Hexagon socket
28 8 mm width across flats 1
29 Wire ø10 × 3,000 mm 2
30 ø16 × 3,000 mm 2
31 ø20 × 5,000 mm 2 Boom, arm, bucket
32 ø30 × 3,000 mm 2 Counterweight
Sling
33 Shackle SD32 2 Rated load of 6 t for counterweight

34 SC18 4 Rated load of 2 t
35 Nylon sling 50 mm wide x 3,000 mm 2 Boom cylinder, arm cylinder
36 Eyebolt M12 2
37 Cleaning liquid Brake cleaner spray can 10
Oil, grease, consumable
38 Hydraulic oil TO10 200 l

39 Grease G2-LI 20 kg For greasing work equipment
40 Touchup paint Natural yellow spray can 5
41 Black gray spray can 5
42 Cloth 1 bundle 20 kg For cleaning
4 types of marker Each one

43
Other
Digital angle gauge 1 For Camera calibration and 12 m

Tripod See 「M-7, Adjust KomVision 1 visibility check
Traffic cone Camera angle」in detail. 2
Tape measure 1
10
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 size (Diameter , Pitch,Bol
, t 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. cor-
respond to dimension (b) in Fig. 1, an applicable socket can be selected from Table 1, too.
4. Tightening torque is expressed as QQQ – www or QQQ ± RR. If the target tightening torque is
set, expression of QQQ ± RR is applied.
Fig. 1
a : Bolt thread diameter (Nominal diameter)

b : Width across flats of bolt head
c : Bolt length
d : Threaded part of bolt
11
Table 1 Tightening torque for bolts not specified in text
Unit: Nm {kgm}
Nominal size of thread Width across flats Tightening torque

× pitch (= Socket size)
a (mm) b (mm) Target Range
12 8.8 – 14.7
M6 × 1 10
{1.2} {0.9 – 1.5}
25 14.7 – 34
M8 × 1.25 13
{2.5} {1.5 – 3.5}
54 34 – 74
M10 × 1.5 17
{5.5} {3.5 – 7.5}
89 54 – 123
M12 × 1.75 19
{9} {5.5 – 12.5}
137 84 – 196
M14 × 2 22
{14} {8.5 – 20}
230 147 – 309
M16 × 2 24
{23.5} {15 – 31.5}
315 201 – 427
M18 × 2.5 27
{32} {20.5 – 43.5}
460 319 – 608
M20 × 2.5 30
{47} {32.5 – 62}
650 471 – 829
M22 × 2.5 32
{66.5} {48 – 84.5}
810 588 – 1,030
M24 × 3 36
{82.5} {60 – 105}
1,180 883 – 1,470
M27 × 3 41
{120} {90 – 150}
1,520 1,130 – 1,910
M30 × 3 46
{155} {115 – 195}
1,960 1,470 – 2,450
M33 × 3 50
{200} {150 – 250}
2,450 1,860 – 3,040
M36 × 3 55
{250} {190 – 310}
2,940 2,260 – 3,630
M39 × 3 60
{300} {230 – 370}
a For symbols “a” and “b” in the table, see Fig. 1.
12
2. Tightening torque for pipe threads
Proper tightening torque for pipe threads depends on combination of the materials of the male screw and
female screw. In this manual, however, select tightening torque from Table 2 and Table 3 on the basis of the
material of the male screw. If tightening torque is specified specially in explanation, however, apply that tight-
ening torque.
2.1 If the male screw is made of mild steel or cast iron, apply Table 2.
Table 2
Unit: Nm {kgm}
Material of female thread
Steel Cast iron Light alloy
Nominal size (in)
3.9 – 6.9 2.9 – 5.9 2.0 – 3.9
1/8
{0.4 – 0.7} {0.3 – 0.6} {0.2 – 0.4}
5.9 – 11.8 4.9 – 9.8 3.9 – 7.8
1/4
{0.6 – 1.2} {0.5 – 1.0} {0.4 – 0.8}
16.7 – 26.5 13.7 – 21.6 9.8 – 16.7
3/8
{1.7 – 2.7} {1.4 – 2.2} {1.0 – 1.7}
32.3 – 52.9 26.5 – 43.1 19.6 – 32.3
1/2
{3.3 – 5.4} {2.7 – 4.4} {2.0 – 3.3}
51.0 – 85.3 42.1 – 70.6 31.4 – 52.9
3/4
{5.2 – 8.7} {4.3 – 7.2} {3.2 – 5.4}
86.2 – 173.5 72.5 – 146.0 54.9 – 111.7
1
{8.8 – 17.7} {7.4 – 14.9} {5.6 – 11.4}
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
Nominal size (in)
16.7 – 29.4 9.8 – 19.6 6.9 – 14.7
1/8
{1.7 – 3.0} {1.0 – 2.0} {0.7 – 1.5}
19.6 – 44.1 16.7 – 37.2 12.7 – 28.4
1/4
{2.0 – 4.5} {1.7 – 3.8} {1.3 – 2.9}
44.1 – 93.1 37.2 – 77.4 27.4 – 58.8
3/8
{4.5 – 9.5} {3.8 – 7.9} {2.8 – 6.0}
98.0 – 188.2 83.3 – 157.8 60.8 – 115.6
1/2
{10.0 – 19.2} {8.5 – 16.1} {6.2 – 11.8}
170.5 – 316.5 141.1 – 247.0 105.8 – 186.2
3/4
{17.4 – 32.3} {14.4 – 25.2} {10.8 – 19.0}
367.5 – 612.5 309.7 – 514.5 235.2 – 392.0
1
{37.5 – 62.5} {31.6 – 52.5} {24.0 – 40.0}
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 Tightening torque (Nm {kgm})
of hose Width across flats
(mm) Range Target
(mm)
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}
Table 4.2 Hydraulic hose of taper seal type
Type that does

not use O-ring
at this position
Unit: Nm {kgm}
Outside diameter Tightening torque (Nm {kgm})
of hose Width across flats
(mm) (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}
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.
Shown
Category Komatsu code Part No. Q'ty Container Main features, uses in this
manual
LT-1A 790-129-9030 150 g Tube • Used to fix rubber gasket, rub-

ber cushion, or cork plug
• Used to glue resin (excluding
20 g polyethylene, polypropylene,
LT-1B 790-129-9050 (2- Polyethylene ethylene tetrafluoride, vinyl
container container chloride), rubber, metal, or non-
set) metallic material instantane-
ously firmly
• Features: Heat resistance and
Polyethylene chemical resistance
LT-2 09940-00030 50 g container • Used to lock bolts, plugs, etc.
and as sealant
790-129-9060 Adhesive: • Used to glue metal, glass, plas-
1 kg tic, etc. and as sealant
LT-3 Can
Set of adhesive Hardener:
and hardener 500g
Adhesive Polyethylene • Used to glue metal, glass, plas-
LT-4 790-129-9040 250 g tic, etc. and as sealant
container
HOLTS • Heat-resistant sealant for re-

790-129-9120 75 g Tube pairing engine
MH 705
• Instantaneous adhesive
Three bond Polyethylene • Adhesion time: 5 sec to 3 min
1735 790-129-9140 50 g container • Mainly used to glue metal, rub-
ber , plastic, and wood
• Instantaneous adhesive
Aron alpha Polyethylene • Quick-hardening type (Reach-
201 790-129-9130 2g container es max. strength 30 min after)
• Mainly used to glue rubber ,
plastic, and metal
• Features: Heat resistance and
LOCTITE Polyethylene chemical resistance
648-50 79A-129-9110 50 cc container • Used for gluing parts fitted at
high temperature
• Used as sealant for various
Polyethylene threaded portions, pipe joint,
LG-5 790-129-9080 1 kg container and flange
• Used as sealant for taper plug,
elbow, nipple, etc.
• Features: Silicon-based, heat
resistance, cold resistance
LG-6 790-129-9160 200 g Tube • Used as sealant for flange and
threaded portion
• Used as sealant for oil pan, fi-
Liquid gasket nal drive case, etc.
• Features: Silicon-based, quick-
hardening type
LG-7 790-129-9170 1 kg Tube • Used as sealant for flywheel
housing, intake manifold, oil
pan, thermostat housing, etc.
• Features: Silicon-based, heat
LG-8 resistance, vibration resist-
ThreeBond 419-15-18131 100 g Tube ance, impact resistance
1207B • Used as sealant for transfer
case etc.
16
Shown
manual
• Used to seal circle gear top
LG-9 which does not need to be
ThreeBond 790-129-9310 200 g Tube clamped and fill gaps of welded
1206D parts etc. having rough surfac-
es
• Can be painted
LG-10 • Used as lubricant and sealant
ThreeBond 790-129-9320 200 g Tube fro radiator hose
1206E • Can be painted
• Feature: Can be used with

LG-11 gasket
ThreeBond 790-129-9330 200 g Tube • Used for covers of transmis-
1121 sion case, steering case, etc.
ThreeBond • Liquid gasket for repairing en-
790-129-9090 100 g Tube gine
1211
• Used for press fitting, shrink fit-
ting, prevention of galling or
LM-P 09940-00040 200g Tube seizure of screw Q
• Used as lubricant for linkage,
bearing, etc.
Molybdenum • Spray type
disulfide • Thin molybdenum disulphide
lubricant film is formed on metal surfac-
– 09995-00250 190 g Can es to prevent galling between
metals
• Used for drive shaft spline,
needle bearing, various link
pins, bolts, etc.
• Feature: Compound consisting
of fine metal particles to pre-
vent seizure and galling
Anti-seize LC-G – – Can • Used for mounting bolts of
NEVER-SEEZ high-temperature parts such as
exhaust manifold, turbocharg-
er, etc.
SYG2-400LI • Multi-purpose extreme pres-
SYG2-350LI sure lithium grease
G2-LI
G0-LI(*) SYG2-400LI-A Various Various
*: For cold SYG2-160LI types types
weather SYG2-160CNLI
SYG0-400LI-A(*)
SYG0-16CNLI(*)
• Used for high-load portion
Grease
Caution: Do not use for rolling
LM-G(G2-M) bearings and splines such as
Molybdenum SYG2-400M 400g × 10
disulfide SYG2-400M-A 400g × 20 Bellows can swing circle bearing Q
grease SYGA-16CNM 16 kg
• Apply to work equipment pins
only at assembly time and do
not use after that
17
Shown
manual
Hyper White • Has higher seizure resistance,
Grease SYG2-400T-A heat resistance, and water re-
G2-T SYG2-16CNT 400 g sistance than molybdenum di-
Bellows can sulphide grease
G0-T (*) SYG0-400T-A (*) 16 kg
*: For cold SYG0-16CNT (*) • Not conspicuous on machine
weather since color is white
Bio grease • Decomposed by bacteria in na-

G2B ture in short period to minimize
SYG2-400B effects on microorganism,
G2-BT (*) SYGA-16CNB 400 g
*: For high Bellows can plants, and animals
SYG0-400BT (*) 16 kg
temperature SYGA-16CNBT (*)
and high
load
• Feature: Silicon-based, wide
using temperature range, high
G2-S oxidation resistance, preven-
ThreeBond – 200 g Tube tion of deterioration of rubber
1855 and plastics
• Used as oil seal for transmis-
sion etc.
• Feature:Urea-based (organic)
grease having heat resistance
and long life. Sealed when
G2-U-SENS used.
427-12-11871 2 kg Can • Used for rubber in damper,
grease
bearing, oil seal
Caution:Do not mix with lithium
grease
SUNSTAR • Used as primer for cab
PAINT Glass side
PRIMER 580 20 ml container (Using limit: 4 months af-
SUPER ter date of manufacture)
417-926-3910
SUNSTAR • Used as primer for glass
GLASS Glass side (Using limit: 4
PRIMER 580 20 ml container months after date of man-
SUPER ufacture)
For gluing cab glass
• Used as paint primer for

SUNSTAR cab side
PAINT Glass
22M-54-27230 20 ml container (Using limit: 4 months af-
PRIMER 435-
Primer 95 ter date of manufacture)
• Used as primer for black

ceramic-coated surface
SUNSTAR on glass side and for hard
GLASS 22M-54-27240 polycarbonate-coated
PRIMER 435- 150 ml Steel can
surface
41 (Using limit: 4 months af-
ter date of manufacture)
SUNSTAR • Used as primer for sash
Glass (Almite)
SASH 22M-54-27250 20 ml container
PRIMER GP- (Using limit: 4 months af-
402 ter date of manufacture)
18
Shown
manual
• "S" is used for high-tem-
perature season (April to
SUNSTAR October) and "W" for low-
PENGUINE Polyethylene temperature season (Oc-
SEAL 580 417-926-3910 320 ml container tober to April) as adhe-
SUPER "S" or sive for glass
"W" (Using limit: 4 months af-
Adhesive • Used as adhesive for
Sika Japan, glass
Sikaflex 20Y-54-39850 310 ml Polyethylene
container (Using limit: 6 months af-
256HV
For gluing cab glass

Ecocart • Used as adhesive for
SUNSTAR glass
PENGUINE 22M-54-27210 320 ml (Special
container) (Using limit: 6 months af-
SUPER 560
SUNSTAR • Used to seal joints of
PENGUINE Polyethylene glass parts
417-926-3920 320 ml (Using limit: 4 months af-
SEAL No. container
2505 ter date of manufacture)
SEKISUI • Used to seal front window
Caulking Polyethylene (Using limit: 6 months af-
SILICONE 20Y-54-55130 333 ml container
material SEALANT ter date of manufacture)
• Used to seal joints of
GE TOSHIBA glass parts Translucent
SILICONES 22M-54-27220 333 ml Cartridge white seal
TOSSEAL (Using limit: 12 months af-
381
Natural yellow SYPA-U03SPNY – Spray type Q
Paint
Black gray SYPA-U03SPBG – Spray type Q
19
Selection of wire ropes used for assembly 18
Select wire ropes to be used for assembly according to the following table. B 8817-1991
Annex 2, Table 1 Using loads of 6 × 24 type rope slings.

Unit: kN {tf}
Number of wire ropes 1 pc. 2 pcs.
Sling angle   = 0°  Z 90° 90° <  Z 120°

Angle to vertical line   = 0°  Z 45° 45° <  Z 60°
Mode coefficient M 1 1.4 1
Classification of wire rope
Outer diameter of 24G 24A 24G 24A 24G 24A
wire rope (2)d (mm)
8 Max. 4.8 {0.49} Max. 5.2 {0.53} Max. 6.7 {0.68} Max. 7.2 {0.74} Max. 4.8 {0.49} Max. 5.2 {0.53}
9 Max. 6.1 {0.63} Max. 6.6 {0.67} Max. 8.5 {0.88} Max. 9.2 {0.93} Max. 6.1 {0.63} Max. 6.6 {0.67}
20
10 Max. 7.6 {0.77} Max. 8.2 {0.83} Max. 10 {1.0} Max. 11 {1.1} Max. 7.6 {0.77} Max. 8.2 {0.83}
11.2 Max. 9.5 {0.97} Max. 10 {1.0} Max. 13 {1.3} Max. 14 {1.4} Max. 9.5 {0.97} Max. 10 {1.1}
(12) Max. 10 {1.1} Max. 11 {1.2} Max. 14 {1.5} Max. 15 {1.6} Max. 10 {1.1} Max. 11 {1.2}
12.5 Max. 11 {1.2} Max. 12 {1.3} Max. 15 {1.6} Max. 16 {1.8} Max. 11 {1.2} Max. 12 {1.3}
14 Max. 14 {1.5} Max. 16 {1.6} Max. 19 {2.1} Max. 22 {2.2} Max. 14 {1.5} Max. 16 {1.6}
(24) Max. 43 {4.4} — Max. 60 {6.1} — Max. 43 {4.4} —
Selection of nylon slings used for assembly
Select wires used for assembly according to the following table
tRated load table (WW-1D type)
21
22
A. ASSEMBLY OF CHASSIS
23
C-2. Installation of steps
Assembly procedure
Installation of steps
A-1
• Using bolts (5),(6) and washers (7), install steps (1), (2),(3) and (4) to the 4 places at the front, rear, right,
and left of the track frame.
a When assembling, eliminate clearance between steps (1) and (2),

also in steps (3) and (4).
(Both sides of RH and LH track frame )
No. Loose-supply items Q’ty

1 2A8-30-11331 Step 2
2 2A8-30-11341 Step 2
3 2A8-30-11311 Step 2
4 2A8-30-11321 Step 2
5 01010-81640 Bolt 16
6 01010-81650 Bolt 16
7 01643-31645 Washer 32
Precautions Necessary tools Necessary equipment
a If any clearance is made, the bolts are broken Name Q’ty Name Q’ty
easily when the lower step is deformed. Socket 24 mm width across flats 1
Medium-sized impact wrench 1
Others
24
A-1. Installation of climbing step
Assembly procedure
Installation of climbing grip
A-2
Install grips (1) with bolts (2).

(5 places)

1 208-54-43150 Grip 5
2 01024-81230 Bolt 10
Remove the rust preventive plug from the Name Q’ty Name Q’ty
tapped hole. Socket 19 mm width across flats 1
Small-sized impact wrench 1
Others
25
A-2. Installation of handrail
Assembly procedure
Installation of handrail (if equipped)
A-3
1. Install handrail (1) with bolts (2) ,

and clamps(3)(4) with washer plate(5) and
bolts(6).
a Weight of handrail: (1) ; 14 kg
2. Install handrail (7) with bolts (2).
a Weight of handrail: (7) ; 15 kg

1 2A8-54-11820 Handrail 1
2 01024-81240 Bolt 10
3 2A8-54-11840 Clamp 1
4 2A8-54-11850 Clamp 1
5 20Y-62-13450 Plate 1
6 01024-81230 Bolt 2
7 2A8-54-11831 Handrail 1
a When carrying the handrail, use a crane Name Q’ty Name Q’ty
etc. Socket 19 mm width across flats 1
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)
Others
26
Assembly procedure
Installation of mirror (1/3)
A-4
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 W (=1 m) around the
machine.
(W) ;: 1m
Important for all mirrors

• Tighten the bolts for the brackets
alternately while keeping left and
right clearances (L) and (R) equal.
• If the mounting bolts of mirror and
stay are tightened too strongly, the
bracket may break.
• Tighten them to the specified torque. 1 2A5-54-13421 Mirror 1
Name Q’ty Name Q’ty
Hexagon socket 5 mm width 1
across flats
Others
27
Assembly procedure
A-4
2. Install mirror (1) ,support(2) and clamps(4) with bolts(5).
Tightening torque of mirror(1) mounting bolt: 6.0 to 7.0 Nm (0.61 to 0.71 kgm)
87°
140
420
27°
"KOMATSU" logo
on RH side
9°

1 2A5-54-13421 Mirror 1
2 2A8-54-11252 Support 1
3 20Y-54-61630 Clamp 2
4 01252-A1030 Bolt 4
across flats
across flats
Others
28
Assembly procedure
A-4
3. Install mirror (1), support(2), and clamp(3) , (4).

Tightening torque of mirror(1) mounting bolt: 6.0 to 7.0 Nm
{0.61 to 0.71 kgm}
"KOMATSU" logo on LH side

1 2A5-54-13421 Mirror 1
2 2A5-54-16120 Support 1
3 20Y-54-35430 Clamp 1
4 01252-A1030 Bolt 2
a Tighten bolts (4) according to torque table
1 (page 11). across flats
across flats
Others
29
30
B. ASSEMBLING OF WORK EQUIPMENT
• Clean the mounting pin and pin hole and check them for a flaw.
31
B-1. Installation of boom cylinder
Assembly procedure
Installation of boom cylinder (1/2)
B-1
1. Lift the boom cylinder and adjust it to the pin holes of the chassis.
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.
Outside of machine Inside of machine

<----- ------->
Clearance must be
1.5 mm or less .
1
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 No. Loose-supply items Q’ty
its torque. 1
2A8-70-13670 Shim 6
2A8-70-13660 Shim 2
a Assemble so that the grease hole of the boom Name Q’ty Name Q’ty
cylinder bottom will be down. Nylon sling 2 25 t crane 1
a Decide the thickness of the adjustment shim
Socket 19 mm width across flats 1
by combining shims 0.8mm thick (2A8-70
-13660) and 1.5mm thick (2A8-70-13670). Small-sized impact wrench 1
a When pushing in the pin, take care not to break
the dust seal installed to the boom cylinder
boss.
Others
32
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.
Boom cylinder
Revolving frame

Wooden block (30x50x150mm) 2

Others
33
B-3. Releasing remaining pressure in hydraulic circuit
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 proce-
dure.
1. Lower the work equipment lock lever to the "LOCK" position, and start and run the engine for about 10 seconds,
and then stop it.
a Limit the engine speed to low idling.
a Set the work equipment control lever in neutral.
2. Within 5 to 6 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.
6. Remove the cap from the plug. .........(Fig.1,2,3,4)
7. Connect a hose to the plug and put its other side to the oilpan for drain.
8. Loose the plug slowly about 1/2 turn, and release pressure by oil drain to oil container.
★ Do not turn the plug more than 1/2 . Fig.4<Revo.frame portion (1)>
9. Tighten the plug after oil drain.
★ Tightening torque; 11-15Nm｛1.1-1.5kgm｝
10. Put the cap to the plug after remove the drain hose.
Fig.1
<Bucket cyl. bottom portion> Fig.2 <Boom foot portion>　Fig.3 <Revo.frame portion (2)>
・Do not face/stand to oil release direction. Name Q’ty Name Q’ty
・Be sure to prevent from dust into the plug. Spanner 1
Hose (for oil drain) 1
Oil container 1
<PLUG ass'y>
Cap
Others
34
B-3. Installation of boom cylinder hoses
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. Already installed Q’ty
a Check that each O-ring is fitted, has not come off, and is not 1 206-62-51650 Hose 2
caught. 2 207-62-52610 Hose 2
3 07000-13032 Oring 4
1. When removing an oil stopper plug from a hose, Name Q’ty Name Q’ty
slowly loosen its bolts by gradually releasing the Oil container 2
internal hydraulic pressure.
2. Keep the removed oil plugs so that they can be Socket 14 mm width across flats 1
reused.
3. When connecting the hoses, take extremely Small-sized impact wrench 1
care not to damage the O-rings.
4. Also, take extremely care not to enter foreign
materials into the hyd. circuit.
Others
35
B-4. Installation of boom cylinder top pin
Assembly procedure
Installation of boom cylinder top pin
B-4
Insert the boom cylinder top pin(1) in the boom temporarily.
a Weight of boom cylinder top pin: 89 kg
a Apply LM-P to the inside of boss.

1 2A8-70-13270 Pin 1
Nylon sling 1 25 t crane 1
Others
36
Assembly procedure
Installation of boom assembly (1/2)
B-5
1. Remove the caps(2) from the fuel tank front cover(1).
2. Remove the bolts(3) and the front cover(1).

・Weight of the front cover ; 12kg
3. Remove the bolts(3) and step(4).
4. Install the boom foot pin.
5. After installing the boom foot pin, install the cover in the reverse order. No. Already installed Q’ty
1 2A8-54-11411 Cover 1
2 195-54-42990 Cap 4
3 01024-81230 Bolt 8
4 2A5-54-13410 Step 1
Socket, width across flats: 19 mm 1
Extension, L: 150 1
Others
37
Assembly procedure
Installation of boom assembly (2/2)
B-5
6. 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.
7. 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.
When slinging boom assembly
Weight of boom assembly :
4,610 kg
Lever block
When slinging boom assembly with

boom cyl.
Weight of boom assembly with boom cyl. :
5,460 kg
★Protect cyl. piping from the wire

8. 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 less than 1 mm .
The following adjustment shims are prepared.
(1) (2A8-70-13680, 1 piece) t 0.8 mm
(2) (2A8-70-13690, 4 pieces ) t 1.5 mm
9. Push in the boom foot pin fully and install the lock plate.
a Inside of pin hole and bushing of boom foot bushing: Apply
LM-P (Only 1st time)
[Apply lithium grease for 2nd time and after]
a Check that the pin lock bolt is not loosened but tightened No. Loose-supply items Q’ty
and check its torque. 1 2A8-70-13680 Shim 1
2 2A8-70-13690 Shim 4
a When pushing in the pin, take care not to break the
dust seal installed to the boom foot as shown below. Name Q’ty Name Q’ty
Φ20 x 5,000 mm wire 2 25 t crane 1
Dust seals
Φ10 x 3,000 mm wire 1
Lever block 1.5 t 1
Large hammer 1
a For installation of the grease supply hoses, see Step

Others
B-11 "Connection of grease supply piping of work

equipment".
38
B-6. Installation of hoses from chassis along top of boom
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 hyd. circuit”.
a Check that the split flange is not loosened but tightened. 1 208-62-41661 Hose 1
a Check that each O-ring is fitted, has not come off, and is not caught. 2 208-62-41671 Hose 1
3 208-62-41682 Hose 1
4 208-62-41642 Hose 2
5 07000-13032 O-ring 5
1. When removing an oil stopper plug from a
hose, slowly loosen its bolts by gradually Oil container 2
releasing the internal hydraulic pressure.
2. Remove and store the flange, O-rings and Socket 14 mm width across flats 1
heads so that you can reuse them later.
3. When connecting the hoses, take extremely Small-sized impact wrench 1
care not to damage the O-rings.
4. Also, take extremely care not to enter foreign Extension L150 1
materials into the hyd. circuit.
Others
39
B-7. Connection of boom cylinder head
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 (1).
a Boom cylinder: 422 kg / Boom cylinder top pin: 89 kg
2. Start the engine and keep 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 the stopper plate(2) and adjusting clearance"a" with shims (5), (6) , and fix with bolts(3) and nuts(4).
Clearance “b”
0.5～1.5mm
1 2A8-70-13270 Pin 1
Part marked with A (2 portions) 2 2A8-70-13440 Plate 2
P
3 21M-70-11290 Bolt 2
4 01580-12419 Nut 4
5 2A8-70-13640 Shim 1
6 2A8-70-13650 Shim 5
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 Nylon sling 1 25 t crane 1
air in the cylinder and the cylinder may not move for
the first 10 seconds. In such case, do not operate the Socket 36 mm width across flats 1
control lever to the end of its stroke.
a Check the clearance between plate(2) and cylinder Spanner 36 mm width across flats 1
rod all around and combine shims 0.8 mm thick
(2A8- 70-13640) and 1.5 mm thick Large-sized impact wrench 1
(2A8-70-13650) so that clearance"a"will be less
than 1.0mm. (Portion marked with ※)
a Adjust clearance"b" between the plate and double
nut to 0.5 to 1.5 mm (2 portions marked with ☆ ).
a Before operating the cylinders, check that the flushing
filter is installed to capture dirt in hyd. circuit.
a For installation of the grease supply hoses, see Step
Others
B-11 "Connesction of work equipment grease

piping".
40
B-8. Installation of arm assembly
Assembly procedure
Installation of arm assembly (1/2)
B-8
1. Remove lock plate (2) ,bolts(3) and washers(4) of boom top pin (1) fixed to the boom, and pull out top pin (1).
(Boom top pin: 71 kg)
2. Raise the arm assembly, align the position with the boom hole, insert shims, then push in the pin.
(Arm assembly: For the weight, see the table in "Transportation")
a Dust seals (2A8-70-13410 ×2) are installed to the inside of the bushing at the arm end. Be careful not 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), so that the clearance will be less than 1 mm.
(Portion of ※ )
3. Install the lock plate (2).
Shim thickness
(5) 2A8-70-13580 ;1.5 mm
(6) 2A8-70-13590 ;0.8 mm

1 2A8-70-13290 Pin 1
2 2A8-70-13720 Plate 1
3 01010-82045 Bolt 2
a Check that the pin lock bolt is not loosened but tightened and 4 01643-32060 Washer 2
5 2A8-70-13580 Shim 3
check its torque. 6 2A8-70-13590 Shim 1
a When pushing in the pin, take care not to break Name Q’ty Name Q’ty
the dust seal installed to the arm boss as Nylon sling 2 25 t crane 1
shown below.
Lever block 1.5 t 1
Large hammer 1
Others
41
Assembly procedure
Installation of arm assembly (2/2)
B-8
4. Remove lock plate (2) and bolts(3) of arm cylinder top pin (1) fixed to the arm and pull out top pin (1).
(Arm cylinder top pin: 28 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)
a Check the clearance all around and combine shims (4), (5), so that the clearance will be less than 1 mm.
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.

1 208-70-61241 Pin 1
2 205-70-66581 Plate 1
3 01024-81235 Bolt 2
4 207-70-11340 Shim 1
5 207-70-11350 Shim 3
a For installation of the grease supply hoses, Name Q’ty Name Q’ty
see Step B-11 "Connection of grease supply Nylon sling 1 25 t crane 1
piping of work equipment".
Large hammer 1
a When pushing in the pin, take care not to break
the dust seal installed to the cylinder boss. Socket 19 mm width across flats 1
Others
42
B-9. Installation of bucket cylinder hoses between boom and bucket cylinder
Assembly procedure
Installation of bucket cylinder hoses between
B-9 boom and bucket cylinder (1/2)
1. Remove the tube oil plug(factory fitted) on the bucket cylinder side on the left side of the arm, and
install new O-ring (2), and connect bucket cylinder hose (1) with flanges(3) and bolts(4) .
2. Remove the tube oil plug on the boom side, install new O-ring (2), and connect bucket cylinder hose (1)
with flanges(3) and bolts(4) .
a Reuse the oil stop parts as the split flange, bolts, etc.
a Bleed air from the bucket cylinder. For details, see B-14 "Bleeding air from work equipment hyd. circuit".
a Check that the split flange is not loosened but tightened.
a Check that each O-ring is fitted, has not come off, and is not caught.

1 207-62-54680 Hose 1
2 07000-13032 O-ring 2
3 07371-31049 Flange 4
4 07375-21035 Bolt 8
1. Keep the oil plugs used for component so that Name Q’ty Name Q’ty
you can reuse them later. Oil container 2
2. When installing the hose take extreme care
not to damage O-rings. Socket 14 mm width across flats 1
3. When installing the hoses, take extreme care
not to twist them. Extension L150 1
(Tighten from the 90° adapter to prevent
twisting.) Small-sized impact wrench 1
4. While installing the hose, take extreme care
not to enter foreign materials into
the hyd. circuit.
Others
43
Assembly procedure
Installation of bucket cylinder hoses between
B-9 boom and bucket cylinder (2/2)
3. Similarly, connect bucket cylinder hose (1) on the right side of the arm.

1 207-62-54680 Hose 1
2 07000-13032 O-ring 2
3 07371-31049 Flange 4
4 07375-21035 O-ring 8
1. Keep the oil plugs used for component so that
you can reused them later. Oil container 2
2. When installing the hose take extreme care
not to damage O-rings. Socket 14 mm width across flats 1
3. When installing the hoses, take extreme care
not to twist them. Extension L150 1
(Tighten from the 90° adapter to prevent
twisting.) Small-sized impact wrench 1
4. While installing the hose, take extreme care
not to enter foreign materials into
the hyd. circuit.
Others
44
B-10. Installation of bucket
Assembly procedure
Installation of bucket assembly (1/2)
B-10
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(1). (Apply lithium grease at the 2nd time
and after)
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, and adjust clearance by shims (3),
(4) between 0.5 mm to 1 mm, then install the cover with bolts (M24).
Pin
O-ring position
O-ring(2) position
Bolt (On the bucket
before connecting
Cover to arm, for easy
connecting)
5. Install the O-ring(2) to the correct position, and install the stopper with bolts.
O-ring(2) position
between bucket and arm
Bolt

1 2A8-70-13350 Bushing 1
2 2A8-70-81110 O-ring 2
3 2A8-70-13550 Shim 18
4 2A8-70-13560 Shim 4
Nylon sling 1 25t crane 1
Sledge hammer 1
Socket, width across flats: 36 mm 1
Spanner, width across flats: 36 mm 1
Ring spanner, width across flats: 36 mm 1
Large-sized impact wrench 1
Torque wrench: 85 kgm 1
Others
45
Assembly procedure
Installation of bucket (2/2)
B-10
6. 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.
7. Push in the link-bucket connecting pin(8), install O-rings (5) to the correct positions to prevent entry of
dirt, and then install the bolt(6) with nuts(7) to fix the pin (8) .
Q P
(5)
between bucket and link
Q
5 207-70-33181 O-ring 2
6 208-70-73160 Bolt 1
7 01580-12419 Nut 2
8 2A7-70-13250 Pin 1
Sledge hammer 1 25t crane 1
Spanner, width across flats: 36 mm 2
Others
46
B-11. Connection of work equipment grease piping
Assembly procedure
Connection of work equipment grease piping (1/2)
B-11
1. At portion (a)
Remove the oil stopper plug at the cylinder end and the oil stopper plug at the hose nipple end, remove the
nipple(1) from the hose, then assemble it to the boom cylinder at first . And connect greasing hose at portion (a)
to the nipple . (LH and RH)
2. At portion (b)
Remove the oil stopper plug at the cylinder end and the oil stopper plug at the hose nipple end, remove the
nipple(1) from the hose, then assemble it to the arm cylinder bottom at first. And connect greasing
hose at portion (b) to the nipple , and supply grease to portion (a) and (b) and connect the arm ass`y.
3. At portion (c)
Remove the oil stopper plug at the cylinder end and the oil stopper plug at the hose elbow end, remove the
elbow(2) from the hose(3), then assemble it to the arm cylinder top at first . And connect greasing
hose(3) at portiion (c) to the elbow(2), and supply grease to the portion (c).
ｃｂ
Tightening torque of
greasing hose ;
5.9 to 11.8 Nm
(0.6 to 1.2 kgm) 　　 .
a (2 places) No. Loose-supply items Q’ty

1 205-70-51390 Nipple 2
a After installing the boom and boom cylinder, Name Q’ty Name Q’ty
supply grease to parts (a) and (b), and then in- Spanner 19 mm width across flats 2 Grease pump (LM-G) 1
stall the arm.
a After installing the arm, supply grease to part
(c), and then install the bucket.
Others
47
Assembly procedure
Connection of work equipment grease piping (2/2)
B-11
Tightening torque of grease hose

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

3 . 5.9 to 11.8 Nm (0.6 to 1.2 kgm)
c No.
1
2
Loose-supply items
205-70-51390 Nipple
205-70-65780 Elbow
Q’ty
1
1
3 2A8-70-12210 Hose 1
Spanner 19 mm width across flats 2
Others
48
B-12. Connection of work equipment wiring
Assembly procedure
Connection of work equipment wiring
B-12
1. Install working lamp (1) and bracket (2) with bolts (3) and washers (4).
★ Working lamp nut (1) tightening 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, and fix with clip (5)
and bolt (6) (portion P), and also connect connector (b)(CN-A13) to the working lamp wiring harness,
and fix with clip (7) and bolt (8). (portion Q)
Work lamp wiring harness to pass through

underneath grease tube to avoid from interference.

1 20Y-06-43230 Lamp A. 1
2 20Y-06-21551 Bracket 1
3 01010-81430 Bolt 1
4 01643-31445 Washer 1
5 08193-20012 Clip 1
6 01024-81220 Bolt 1
7 04434-51012 Clip 1
8 01024-81225 Bolt 1
Others
49
Assembly procedure
Installation of LED working lamps (if equipped)
B-13
1. Install working lamp (1) and bracket (2) with bolts (3) and washers (4).
★ Working lamp nut (1) tightening torque: 55 ± 10 Nm (5.6 ± 1.0 kgm)
2. Connect connector (a)(CN-L01A) and (b)(CN-L01B) of the working lamp wire to the body wiring
harness, and fix with bracket (5), clip (6) and bolt (7).
No Loose-supply items Q'ty

1 20Y-06-43230 Lamp A. 2
2 2A8-06-11160 Bracket 2
3 01010-81430 Bolt 2
4 01643-31445 Washer 2
5 20Y-06-48260 Bracket 1
6 08193-20012 Clip 1
7 01024-81220 Bolt 2

Others
50
B-13. Greasing after completion of work equipment
Assembly procedure
Greasing after completion of work equipment
B-14
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.

Grease pump (LM-G) 1
Others
51
B-14. Bleeding air from work equipment circuit
Assembly procedure
Bleeding air from work equipment hyd. circuit
B-15
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.
a Before operating the cylinder, check that the Name Q’ty Name Q’ty
flushing filter is installed (to capture dirt in the
circuit).
a After the assembly work is completed, perform
the final check of the hydraulic tank oil level re-
ferring to the Assembly procedure M-5 "In-
spection of oil level in hydraulic tank and refill".
Others
52
C. Assembling of counterweight and adjustment
53
C-4. Adjustment of track tension
Assembly procedure
Adjustment of track tension (1/3)
C-1
Testing and adjusting track tension
k Warning
This work must be done by 2 persons. The operator

shall move the machine according to the signs from the
worker.
Since the wear condition of the pins and bushings of the undercarriage varies with the working condition and
soil type, check the track tension occasionally and keep it at the standard.
Test and adjust the track tension on a level and hard place.
Testing
1. Stop the machine on a level and firm place.
2.
3. Place a rectangular bar (3) which is longer than

the distance between idler (1) and carrier roller
(2) on the track.
4. Measure the maximum slack between the top of
the track and the underside of the rectangular
bar.
Standard slack ; 16 to 34 mm

Rectangular bar
1
(Approx. 2m length, steel or wood)
Tape measure 1
Others
54
Assembly procedure
C-1
If the track tension is out of the standard, adjust it according to the following procedure.
Adjusting
k Warning
Do not loosen the plug more than 1 turn. If it is loosened

more, it may jump out because of the internal high-pres-
sure 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.

Rectangular bar Grease pump 1
1
Tape measure 1
Others
55
Assembly procedure
C-1
Decreasing track tension
k Warning
It is very dangerous to discharge grease by a method

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

2. Do not loosen the plug (1) more than 1 turn.
3. If the grease does not come out, move the ma-
chine 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.

Extension L150 1
Rectangular bar
1
Tape measure 1
Others
56
Assembly procedure
Sticking sheet to revolving frame
C-2
• Stick the sheets to the rear side of revolving frame as shown below.
䚷
(250)
36
䚷
(95)
35.5
(169) (635)
1 2
No. Loose-supply items Q'ty

1 208-46-72410 1
2 2A8-46-11370 1
Remove all oil and rust from the surface Name Q’ty Name Q’ty
where the sheet is to be stuck.
Others
57
C-5. Sticking sheet to counterweight
Assembly procedure
Sticking sheet to counterweight
C-3
• Stick the sheets to the front side of the counterweight as shown below. When
sticking sheets (1) and (2), direct the faces having no black cover down.
Direct the faces having no black

cover down.
1 208-46-41721 Sheet 1
2 208-46-41731 Sheet 1
Remove all oil and rust from the surface Name Q’ty Name Q’ty
where the sheet is to be stuck.
Others
58
Assembly procedure
Installation of rear view mirror
C-4
1. Install bracket (1) with bolts (2) on the counterweight, and fix mirror (3) with bolts attached to the mirror.
Bolt tightening torque; 4.0 - 5.4 Nm (0.41 - 0.55 kgm)
★ Check the visibility; Adjust the mirror angle so that the area (W) shown in the fig below is reflected in it
at operator's eye - point in the operator cab.
2. Install cover (4) with bolts (5) .
3. Install caps (6) .
P
60°
29
14°
P
W =1m
1 2A8-54-17941 Bracket 1
2 01024-81230 Bolt 4
3 207-
207-54-77 Mirror 1
4 207-
207-54-26 Cover 1
5 01024-81025 Bolt 2
6 11Y-54-13630 Cap 2

Hexagon wrench 5mm width across flats 1

Others
59
C-6. Installation of camera
Assembly procedure
Installation of camera (if equipped) (1/8)
C-5
1. Pass wiring harness (1) through the hole of the counterweight.
P No. Loose-supply items

1 2A8-06-1
2A8-06-14231
Q’ty
1
Others
60
Assembly procedure
Installation of camera (if equipped)　　(2/8)
C-5
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

1 -- amera A. 1
2 01024-
01024-81025 2

Others
61
Assembly procedure
Installation of camera (if equipped) (3/8)
C-5
3. Install cover (1) with bolts(3) and shims (2) as shown below.
Adjust shim (2) so that ※ marked

clearance difference will be 2 mm
max. at points a, b, and c.

1 2A5-06-11821 Cover 1
2 2A5-06-12240 Shim 3
3 01024-80616 Bolt 2
Others
62
Assembly procedure
Installation of camera (if equipped)　　　(4/8)
C-5
4. Install cover (1) as shown below.

1 207-06-76451 Cover 1
Others
63
Assembly procedure
C-5
5. Remove the double-sided adhesive tape and stick sheet (1) as shown below.
Then, connect the clips on the wiring harness side and counterweight side (6 places).
Install clips (6 places)

4 places at ※ : Counterweight
2 places at u: Machine frame

1 2A5-06
2A5-06-11860 1
Others
64
Assembly procedure
C-5
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 Counterweight

Others
65
Assembly procedure
C-5-1
1. Install camera Ass'y (1) shown as below.

1 - Camera Ass'y 2
2 01024-81230 Bolt 8

Others
66
Assembly procedure
C-5-2
1. Connect connectors (CN-A76, CN-A78) of wiring harness (1).
Connect the clips on the wiring harness side and counter weight side (14 places).

1 2A8-06-14441 wiring harness 1
2 08057-14012 clip 2
3 01024-81220 bolt 3
4 04435-51012 clip 1

Others
67
C-7. Installation of counterweight
Assembly procedure
Installation of counterweight (1/3)
C-6
1. Sling counterweight assembly (1) and install it to the machine.

2. Install by using mounting bolts (2) (6 pieces) and washers (3) (6 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 : 10,740 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 Shims(4) are for adjusting clearance and level difference. No. Loose-supply items Q’ty
1 -- (Counterweight A.) 1
208-46-52260: 1.0 mm thick
2 21M-46-14210 Bolt 6
208-46-52270: 0.5 mm thick 3 01643-34212 Washer 6
208-46-52260 Shim 4
4
208-46-52270 Shim 4
a Do not insert any shim basically for adjusting Name Q’ty Name Q’ty
clearance or level difference.
If adjustment is necessary,observe the follow- ø30 × 3,000 mm wire 2 25 t crane 1
ing.
a) Adjust by inserting a shim only in the Shackle SD32 2
backward and forward directions.
Example: No shim in both front holes and Socket 65 mm width across flats 1
shims 1 mm thick in both rear holes.
b) Limit the adjustment quantity with shim to 2 Large-sized impact wrench 1
mm.
Torque wrench 420 kgm 1
a For adjustment after assembling the counter-
weight, see 3/3.
a Dimension of hanging hole of counterweight

ø42 mm
Others
68
Assembly procedure
C-6
3. Only for camera if equipped.

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 (2 places at ◆) and connect connector (CN-A40) from the left
machine compartment door.
4. Only for KomVision camera if equipped.

Install clips (3 places at ■) and connect connector (CN-A80).

a When installing, do not enter between
the revolving frame and counterweight
but open the left side door and check
that the wiring harness is not caught.
Others
69
Assembly procedure
C-6
5. 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.
.
Level difference "e":
Clearance "c": 10 ± 5 mm
0 to 5 mm
(Difference between
points T and S : 0 to 3 mm)
Clearance "a": 10 ± 5 mm

Others
70
Ｄ. Installation of catwalk
71
Assembly procedure
Installation of side step
D-1
1. Install ladder (1) by using plates (2) and bolts (3).
2. If ladder (1) leans, adjust it by using shims (4) and (5).
3. Install brackets (6) by using plates (7) and bolts (8). (5 places)
4. Install steps (9) and (10) by using bolts (11).
5. If steps (9) and (10) tilt, adjust them by using shims (12) and (13).
1 4 5
B A
B A
3
A-A
9 10
12 13

1 2A8-54-11891 1
2 208-54-25230 4
3 01024-81260 8
4 208-54-25260 2
5 208-54-25270 2
6 2A8-54-14251 5
7 2A8-54-14290 10
7 8 6 11 8 01024-81275 20
9 2A8-54-14261 1
B-B 10 2A8-54-14271 1
11 01024-81235 20
12 208-54-25240 5
13 208-54-25250 5

a Remove rust prevention plugs from the
tapped mounting holes in advance. Small impact wrench 1
Socket 19 mm in width across flats 1
Extension 150 mm long 1
Others
72
Assembly procedure
Installation of hydraulic tank top handrail
D-2
1. Remove the hydraulic tank top cover and transportation bolts (2 pieces).
Hydraulic tank top cover
Transportation bolt (2 pcs.)
2. Install handrail (1) by using bolts (2) and (3). 1

3. Install handrail (4) by using bolts (5).
3 5 4
4. Install the hydraulic tank top cover.
Hydraulic tank top cover

1 2A8-54-11871 1
2 01024-81235 3
3 01024-81255 2
4 2A8-54-11861 1
5 01024-81240 6
1. Remove the rust prevention plugs from the Name Q’ty Name Q’ty
tapped mounting holes in advance. Socket 19 mm in width across flats 1 1
2. Use a crane, etc. to carry the handrail.
Medium impact wrench 1
Others
73
Assembly procedure
Installation of cab top grip (1/2)
D-3
a When top guard is not installed
1. Remove the rust prevention plugs (2 places) on the cab top.

Rust prevention plug
2. Install grip (1) by using bolts (2).

1 209-54-45580 1
2 01024-D1235 2

Socket 19 mm in width across flats 1
Medium impact wrench 1
Others
74
Assembly procedure
Installation of cab top grip (2/2)
D-3
a When top guard is installed
1. Install grip (1) by using collars (2), washers (3), and bolts (4).
Rust prevention plug Top guard

4

1 208-54-25321 1
2 2A5-954-1130 2
3 01643-71232 2
4 01011-D1260 2

a Use a crane, etc. to carry the top guard.
Others
75
76
M. PROCEDURE FOR INSPECTION AND MAINTENANCE AFTER
COMPLETION OF ASSEMBLY
77
M-1. Replacement of return filter (Standard filter to flushing filter)
Assembly procedure
Replacement of return filter (1/2)
M-1 (Standard filter to flushing filter)
Replace the bypass valve sensor ass`y (2) , strainer (3) and hydraulic oil return filter element (4) of standard
items with cover (5), spring (6) , plate (7) and hydraulic oil flushing element (8).
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.

1 01024-81230 Bolt 6
2 - Valve A. 1
3 07069-25400 Strainer 1
4 208-60-71124 Element 1

5 2A8-60-11341 Cover 1
6 07069-34075 Spring 1
7 21T-60-13730 Plate 1
8 208-60-71170 Element 1
a Store the removed bypass valve sensor Name Q’ty Name Q’ty
ass`y (2) , strainer (3) and standard
element(4), because they are used Socket 19 mm width across flats 1
again after flushing.
a Replace before starting the assembly work.

(To capture dirt during the hose connecting
work and in the work equipment circuit)
Others
78
Assembly procedure Replacement of return filter (2/2)

M-1 (Standard filter to flushing filter)
Check the state of filter element, after installation as follows.
a Do not install the element with its bottom on the elevated part of the case bottom as shown in Fig. 2.
When the filter case is filled with oil, it is difficult to check if the element is inserted correctly.
Turn the element by hand after inserting it in the case.
When it turns smoothly, judge that it is inserted correctly.
<Installed state of element>
(Fig. 1 ) Good state (Fig. 2) Bad state
Check the used filter element according to Name Q’ty Name Q’ty
"Inspection and maintenance procedure",
then discard it. Discard according to local
laws.
The flushing filter parts are reusable. It is

recommended to keep them for the next
flushing.
Others
79
M-2. Flushing of hydraulic circuit
Assembly procedure
Flushing of hydraulic circuit (1/2)
M-2
After completion of assembling ,flush the hydraulic

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
Full operation may damage the filter element Name Q’ty Name Q’ty
since the relief valve of the filter is closed.
Others
80
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.

Since the bypass valve sensor is
removed during flushing, open circuit
failure code ”DDPAKA” is displayed,
but this is no problem.
After connecting the bypass valve

sensor ,delete the failure records.
Others
81
Assembly procedure
Replacement of return filter (1/2)
M-3 (Flushing filter to standard filter)
Replace the cover (5), spring (6) , plate (7) and hydraulic oil flushing element (8) with the bypass valve sensor
ass`y (2) , strainer (3) and hydraulic oil return filter element (4) of standard items.
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.

1 01024-81230 Bolt 6
2 - Valve A. 1
3 07069-25400 Strainer 1
4 208-60-71124 Element 1

5 2A8-60-11341 Cover 1
6 07069-34075 Spring 1
7 21T-60-13730 Plate 1
8 208-60-71170 Element 1
a Store the removed cover (5), spring (6) , Name Q’ty Name Q’ty
and plate (7) , because they are reused
again for flushing next time.
Others
82
Assembly procedure Replacement of return filter (2/2)

M-3 (Flushing filter to standard filter)
Check the state of filter element, after installation as follows.
a Do not install the element with its bottom on the elevated part of the case bottom as shown in Fig. 2.
When the filter case is filled with oil, it is difficult to check if the element is inserted correctly.
Turn the element by hand after inserting it in the case.
When it turns smoothly, judge that it is inserted correctly.
<Installed state of element>
(Fig. 1 ) Good state (Fig. 2) Bad state
The flushing filter element must be Name Q’ty Name Q’ty

discarded after use, and not allowed to
be reused.
Others
83
M-4. Check of oil/coolant level at each part
Assembly procedure
Check of oil/coolant level at each part (1/2)
M-4
a For details of the notes (Note 1, 2, 3, 4, 5) in the table, see the "Operation and Maintenance Manual".
For details of the recommended genuine oil, see the "Operation and Maintenance Manual", too.
KES ; Komatsu Engineering Standard
84
Assembly procedure
Check of oil/coolant level at each part (2/2)
M-4
Final
Swing drive case
Engine Damper Hydraulic Cooling
machin- (Each of Fuel tank
oil pan case oil system system
ery case right and
left)
Specified capacity
46 19 9.5 1.6 507 48 640
(l)
Refill capacity
37 17 9 1.6 279 45 –
(l)
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
-15 -20 -25 -30 -35 -40
Quantity -10
(l)
Coolant 13.5 16.2 18.5 20.7 22.5 24.3 26.1
Water 31.5 28.8 26.5 24.3 22.5 20.7 18.9
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.
• When the machine is delivered, it is filled with Name Q’ty Name Q’ty
Supercoolant (blue) containing no amine. Do
not add coolant of different type.
Others
85
M-5. Inspection of oil level in hydraulic tank and refill
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 in-
ternal pressure.
3. Open the door on the left side of the machine
and check the sight gauge (G). When the oil lev-
el is between the H and L lines, the level is ap-
propriate.
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 hydrau-
lic circuit may be damaged or oil may burst out.

Others
86
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 under-
cover (1) or (2) and drain excessive oil
through drain plug (P) or (A).After drain-
ing 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 30°C).
• The oil level shall be around the H level during
normal operation (when the oil temperature
ranges from 50 to 80°C).

Others
87
M-6. Parts to be touched up after field assembly
Assembly procedure
Parts to be touched up after field assembly
M-6
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
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)

Touch-up paint (Spray can)
・Natural yellow 5　
・Black gray 5　
Others
88
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89
Assembly procedure
Adjust KomVision Camera angle (KomVision Spec.)
M-7 (Camera calibration and 12 m visibility check) (2/17)
• Shift: Images cross each other on yellow reference line

(ground level)
SETTING OF KomVision (CAMERA CALIBRATION)

Testing tools for KomVision (camera calibration)
Symbol Part No. Part name Q'ty Remarks
A - Angle setting calibration marker 1
B - Position setting calibration marker 1
Commercially
C Tripod 1
available
Commercially
D Traffic cone 2 Height : Approx. 70 cm
available
Test this item under the following conditions.

• On a flat and level ground, there are not any obstacles within 4 to 5 m of the machine
• Dust free environment (Avoid a place where the camera lens may get dirty during work).
Adjust each parameter to compose the multiple camera images.
METHOD FOR SETTING OF KomVision (CAMERA CALIBRATION)

NOTICE
Perform “angle calibration” first, then perform “position calibration”.
Operation of “angle calibration”

1. Make the angle setting calibration marker A.
REMARK
• Make an enlarged photocopy of the angle setting calibration marker A in Fig. 1 found at the end of this
section.
• Ensure the figure size to be large enough to read on the machine monitor screen. The recommended
size is A3.
2. Fix the angle setting calibration marker A to the tripod C.
90
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91
Assembly procedure
6. Select “Camera Calibration” with the function switches on

“KomVision Adjustment Menu” screen.
F1: The screen returns to “Service Menu” screen.
F3: Moves the selection downward.
F4: Moves the selection upward.
F5: Selection is canceled. The screen returns to “Adjust-
ment” screen.
F6: Enters the selected item.
7. Select “Angle Calibration” with the function switches on

“CAMERA CALIBRATION” screen.
F5: Selection is canceled. The screen returns to “KomVi-
sion Adjustment Menu” screen.
8. Select the camera to be adjusted with the function

switches on “Camera Selection (Angle Calibration)”
screen.
F5: Selection is canceled. The screen returns to “CAMERA
CALIBRATION” screen.
REMARK
“Bird's-eye Image Rate” and “Camera Image Size Rate”
can be adjusted with the function switches.
9. Check that the angle setting calibration marker A installed
in Step 1 is displayed in the box (b) when the angle cali-
bration screen for the selected camera is displayed.
REMARK
Adjust the position of the angle setting calibration marker A
or the angle of the camera if the angle setting calibration
marker A is not displayed.
92
Assembly procedure
10. Select and enter “Camera Pitch Angle” with the function
switches.
The back ground color of icon (c) turns yellow when the
selected item is entered.
11. Match the center of the angle setting calibration marker A
and the vertical direction position of the camera marker
with the function switches.
A: Angle setting calibration marker A
x: Camera marker
F3: Moves the camera image downward
F4: Moves the camera image upward
F5: Cancels the calibration item / Cancels the change. The
screen returns to “KomVision Adjustment Menu” screen.
F6: Enters the calibration item/Enters the change
12. Select and enter “Camera Yaw Angle” with the function
switches.
The back ground color of icon (d) turns yellow when the
93
Assembly procedure
13. Match the center of the angle setting calibration marker A

and the lateral position of the camera marker with the func-
tion switches.
x: Camera marker
F3: Moves the camera image to the left
F4: Moves the camera image to the right
14. Select and enter “Camera Roll Angle” with the function
switches.
The back ground color of icon (e) turns yellow when the
15. Match the angle setting calibration marker A and the rota-
tion direction position of the camera marker with the func-
tion switches.
x: Camera marker
F3: Rotates the camera image counterclockwise
F4: Rotates the camera image clockwise
94
Assembly procedure
Adjust KomVision Camera angle (KomVision
M-7 Spec.)(Camera calibration and 12 m visibility check) (7/17)
• Example of matching
x: Camera marker
• Example of not matched

x: Camera marker
16. Select “Save” with the function switches when the angle
calibration marker A and the camera marker match. Press
F6 to save the setting.
Perform Step 1 to Step 16 for each camera.

REMARK
• Perform calibration for all cameras always when the controller is replaced or when the specification is
changed.
• Perform only the necessary calibrations relevant to the camera which has been replaced.
NOTICE
Perform "Camera Calibration" according to the table always when the camera angle, etc. is adjusted af-
ter camera image check.
Item to be performed
Adjusted camera Angle calibration
Rear camera Rear R.H. camera Front R.H. camera Rear L.H. camera
Rear camera ○ - - -
Rear R.H. camera - ○ - -
Front R.H. camera - - ○ -
Rear L.H. camera - - - ○
Operation of “position calibration”

1. Make the position setting calibration marker B.
REMARK
• Make the position setting calibration marker B accord-
ing to the figure.
• Stick some 50 mm wide black tapes on a board when
making the calibration marker.
2. Set the position setting calibration marker B according to the Table 1.
95
Assembly procedure
NOTICE
Start with the rear R.H. camera for performing “position calibration”. Then, perform in the order of
the right rear, right front, and left rear) when 4 cameras are installed.
REMARK
Perform “Position calibration” by each camera.
B: Position setting calibration marker B
y: Machine
Table 1
Dimension, angle Positive value
a 1 to 1.5 m (From upper structure end)
b 1 to 1.5 m (From counterweight end)
c 1 to 1.5 m (From upper structure end)
d Center between 2 cameras
θ 90 °
3. Check on the machine monitor that the position setting calibration marker B is reflected in the image cap-
tured by 2 adjacent cameras.
4. Select “Adjustment” on “Service Menu” screen.
REMARK
See “METHOD FOR OPERATING SERVICE MODE” in
“SERVICE MODE” for selecting method.
5. Select “KomVision Adjustment” with the function switches

or numeral input switches on “Adjustment” screen.
REMARK
See “METHOD FOR OPERATING SERVICE MODE” in
“SERVICE MODE” for selecting method.
96
Assembly procedure
6. Select “Camera Calibration” with the function switches on

“KomVision Adjustment Menu” screen.
F5: Selection is canceled. The screen returns to “Adjust-
ment” screen.
7. Select “Position Calibration” with the function switches on

“CAMERA CALIBRATION” screen.
F5: Selection is canceled. The screen returns to “KomVi-
sion Adjustment Menu” screen.
8. Select the camera to be adjusted with the function

switches on “Camera Selection (Position Calibration)”
screen.
REMARK
Table 2 describes the calibrations target of cameras. The
calibration target changes depending on which camera is
selected on “Camera Selection (Position Calibration)”
screen.
Table 2
Selected item Standard camera Camera to be adjusted
Rear R.H. camera Rear camera Rear R.H. camera
Front R.H. camera Rear R.H. camera Front R.H. camera
Rear L.H. camera Rear camera Rear L.H. camera
9. Check that the position setting calibration marker B instal-
led in Step 1 is displayed in the box (f) when the position
calibration screen for the selected camera is displayed.
REMARK
• Check that the calibration marker is on both rear cam-
era image and R.H. camera image.
• Adjust “Bird's-eye Image Rate” or reinstall the position
setting calibration marker B if the position setting cali-
bration marker B is not displayed.
97
Assembly procedure
10. Select and enter “Camera Lateral Position” with the func-
tion switches.
The back ground color of icon (g) turns yellow when the
11. Align the marker of the target camera and the lateral posi-
tion of the calibration marker B for position setting with the
function switches.
z: Marker of camera to be adjusted
F3: Moves the camera image to the left
F4: Moves the camera image to the right
F5: Cancels the calibration item/the Cancels the changed
item. The screen returns to “Camera Selection (Position
Calibration)” screen.
12. Select and enter “Camera longitude Posit” with the func-
tion switches.
The back ground color of icon (h) turns yellow when the
98
Assembly procedure
13. Align the marker of the target camera and the longitudinal
position of the calibration marker B for position setting with
the function switches.
F3: Moves the camera image downward
F4: Moves the camera image upward
F5: Cancels the calibration item/the Cancels the changed
item. The screen returns to “Camera Selection (Position
Calibration)” screen.
• Example of matching
• Example of not matched

14. Select “Save” with the function switches when the position
calibration marker B and the camera marker match. Press
F6 to save the setting.
Return the screen to the standard screen after completing
the calibration process. Check that the failure code is not
displayed.
Perform Step 1 to Step 14 for each camera.
15. See the camera image to check the following items.
1) Check that the line (a), (b), or (c) is not displayed.
When the line (a) is displayed:
The rear R.H. camera is tilted upward out of the speci-
fied angle. Adjust the camera mounting angles to be
within the specified angle by referring to “METHOD
FOR ADJUSTING KomVision CAMERA ANGLE”.
When the line (b) is displayed:
The rear L.H. camera is tilted upward out of the speci-
fied angle. Adjust the camera mounting angles to be
99
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100
Assembly procedure
3) Check that the images (i) are aligned correctly.

REMARK
• Person's upper body may be doubly displayed in
blend area (i) since KomVision corrects the error
between the mounted cameras on the basis of
ground level (by position calibration).
• The targets on machine side (k) from the red refer-
ence line within the blend area (i), their images
may be doubly displayed.
• The targets out side (m) of the red reference line
within the blend area (i), images from both cam-
eras may be separately displayed.
4) Place the traffic cones D at the following positions,

and check that they can be seen in the camera image.
a: 1.0 to 1.5 m from upper structure end
b: 1.0 to 1.5 m from counterweight end
c: 1.0 to 1.5 m from upper structure end
d: Center between 2 cameras
Perform “Camera Calibration” again if the object is not
seen in the camera image by referring to “METHOD
FOR SETTING OF KomVision (CAMERA CALIBRA-
TION)”. Adjust the angles of the camera by referring to
“METHOD FOR ADJUSTING KomVision CAMERA
ANGLE” when the image quality is still poor after per-
forming “Camera Calibration”.
NOTICE
Make sure to perform “Camera Calibration” ac-
cording to the Table 3 after the camera angle, etc.
is adjusted as a result of camera image check.
Table 3
Item to be performed
“Angle Calibration” “Position Calibration”
Adjusted camera
Rear Rear R.H. Front R.H. Rear L.H. Rear R.H. Front R.H. Rear L.H.
Camera camera camera camera camera camera camera
Rear camera ○ - - - ○ ○ ○
Rear R.H. camera - ○ - - ○ ○ -
Front R.H. camera - - ○ - - ○ -
Rear L.H. camera - - - ○ - - ○
101
Assembly procedure
Fig. 1
102
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103
Assembly procedure
3. Check that the mark is correctly seen on the screen.

REMARK
Judge according to the figure.
OK: Marker is on the line.
NG: Marker is out of the line.
1) Check that the mark A is at position [2] (rear side) on

the reference line B.
REMARK
Perform camera calibration if the judgment result is
NG ,by referring to the above “ADJUST KomVision
CAMERA ANGLE”.
2) Swing the upper structure to the left so that the marker

A is displayed at position [3] (left side). Check that the
marker A is at position [3] (left side) on the reference
line.
REMARK
CAMERA ANGLE”.
3) Check that the marker A comes to the position [4]

(right side) on the reference line according to the
same procedure.
REMARK
CAMERA ANGLE”.
4. Install the marker B on the ground on a circumference of

12000 mm from the center of swing.
(5): Center of swing
(6): 12000 mm
(c): 1500 mm
(d): 1500 mm
104
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105
M-7. Error code
Assembly procedure
Error code
M-8
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.
106
1/4
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}
Bolt size: M12 Bolt size: M20

No. Torque No. Torque
1 3
2 4
107
2/4
Boom foot lock plate
Tightening torque: M20、 455 to 565 Nm {46.5 to 58 kgm}
No. Torque
1
2
108
3/4
Boom cylinder bottom lock plate
Tightening torque: M12、 98 to 123 Nm {10 to 12.5 kgm}
Right side of chassis Left side of chassis

No. Torque No. Torque
1 3
2 4
109
4/4
Counterweight mounting bolt
Tightening torque: M42、 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
5
6
110
Backhoe 1/13
Report No.
FIELD ASSEMBLY INSPECTION REPORT

After completion of assembling a machine, make inspections according to these check sheets for assuring machine performance
and quality. After inspection, these check sheets must be submitted through EQP CARE system , or please send the copy
of these check sheets to E-mail address below.
[E-mail adress] osaka_qa@komatsu.co.jp

Model-Type
PC500LC-10M0 □ Machine Serial No. User Unit No. Engine Model Engine Serial No.
PC500LC-10R
Backhoe spec.
□ SAA6D125E-5
Service Meter Reading Date of Inspection

Attachment
1 2
Location of Machine at Inspection Manufacturer
Model
Distributor's Name
Serial No.
Customer's Name Address: Signature: Delivery Report

No. attached
Date:
Inspector's Comments
Inspector's Name: KOMATSU USE ONLY :
C. Sheet Receiving Date :

Title
By :
Signature:
Remark:
Check sheets filling instructions:
1. Use following indexes for entry of judgement
T..... Normal T ..... Correction made on abnormal point

T..... Abnormal T ..... Not applied
2. Enter actually measured values in parenthese, [ ].
Notes:
(1) Criteria are based on the standards when the machine is shipped out of the factory.
(2) This FIELD ASSEMBLY INSPECTION REPORT is for “A” specification.
SUBMITTANCE OF THIS REPORT (AND CHECK SHEETS) TO KOMATSU IS ONE OF THE CONDITIONS OF WARRANTY VALIDATION,
COPY FOR KOMATSU SHALL BE FORWARDED TO THE KOMATSU REGIONAL OFFICE TOGETHER WITH THE COPY OF DELIVERY
SERVICE REPORT.
Category 2/13
Revision
Local After
Check item assembly hours of Judgement standard
time operation
Oil and water levels Actual measurement
RESERVE TANK
Coolant Soft water [ ]
A: -50 to -40°C D: -20 to -10°C

Engine coolant Density of
[ ] B: -40 to -30°C E: -10 to 0°C
(A, B, C, D, E) anti-freeze
C: -30 to -20°C
L to H (At least 15 minutes after
Engine oil EO10W30-DH [ ]
engine stops)
Damper case oil TO30 [ ] To lower rim of damper case plug hole
Checks before assembly
Swing machinery gear

case oil TO30 [ ] L to H
Right TO30 [ ]
Final drive gear
case oil Bottom edge of level plug: 0 to -10 mm
Left TO30 [ ]
H to L (Posture: Max. reach)
Hydraulic oil Center between H and L:
TO10 [ ]
Oil temperature is 10 to 30°C
Near H: Oil temperature is 50 to 80°C
Battery electrolyte – [ ] Check that level is between UPPER
LEVEL and LOWER LEVEL
Fuel tank Full
Enigne No. [ ]
When accepted After check
Service meter [ ] [ ]
Loose, untightened lock bolts for connecting pins There must be none.
Loose, untightened split flange bolts for work equipment piping There must be none.
Forgotten, missing, catching O-rings for work equipment piping There must be none.
Checks during assembly
Loose, twisted connections for grease piping There must be none.
Shim adjustment for work equipment pins Max. 1 mm (for locations, see assembly
procedure manual)
Improperly inserted wiring, unconnected wiring There must be none.

Category 3/13
Revision
Local After
time operation
Loose, untightened counterweight bolts There must be none.
Stepped clearance between counterweight and frame 5 to 15 mm
Loose, untightened operator's cab mounting bolts There must be none.
Loose, untightened operator's seat mounting bolts There must be none.
Loose, untightened mounting bolts and joints for travel There must be none.
Forgotten, missing, catching O-ring for travel There must be none.
Loose, untightened bolts for travel motor cover There must be none.
Checks during assembly
Are there any other parts not yet installed (rear view There must be none.
mirror, etc.)?
Follow instructions in assembly procedure

Bleed air from hydraulic pump manual.
Bleed air from travel motor
manual.

Flush hydraulic circuit manual.

Bleed air from work equipment cylinder circuit
manual.
Grease all parts of work equipment All locations must be greased.
Add to between L and H marks at inspection

Add hydraulic oil posture
Add fuel, washer fluid Fill tank.
Dirty oil on paintwork, damage to paintwork at any part Clean, repair damaged paintwork
4/13
Revision
Category
Local After
Check item assembly hours of Judgment standard
time operation
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
As per left.
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 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 to high idling.
There should be no scratches or misting
Operation of service meter
of the lens or variation in operation.
MONITOR (Quoted from operation & maintenance manual)
Check monitor
AA: Standard screen

BB: Check before starting screen
CC: Maintenance time warming screen
(1) Wiper switch (21) Radiator coolant level caution lamp

(2) Buzzer cancel switch (22) Seat belt caution lamp
(3) Auto-deceleration switch (23) Engine stop pilot lamp
(4) Service meter/clock (24) Lock lever pilot lamp
(5) Engine coolant temperature caution lamp (25) Message display
(6) ECO gauge (26) Air conditioner pilot lamp
(7) Engine coolant temperature gauge (27) Wiper pilot lamp
(8) Hydraulic oil temperature gauge (28) Swing lock pilot lamp
(9) Hydraulic oil temperature caution lamp (29) Engine preheating pilot lamp or One-touch power maximizing pilot
(10) Working mode display lamp
(11) Travel speed display (30) Auto-deceleration pilot lamp
(12) Fuel gauge (31) Engine oil level caution lamp
(13) Fuel level caution lamp (32) Air cleaner clogging caution lamp
(14) Fuel consumption gauge (33) Water separator caution lamp
(15) Working mode selector switch (34) Function switches (F1 to F6)
(16) Travel speed selector switch (35) Maintenance time caution lamp
(17) Window washer switch (36) Camera switch display
(18) Air conditioner control switch (37) Camera direction display
(19) Engine oil pressure caution lamp (38) Service meter
(20) Charge level caution lamp (39) Clock
Category 5/13
Revision
Local After
time operation
Check of switches, control levers
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.
Operation of fuel control dial MAX: Full speed
MIN: Low idle
Category 6/13
Revision
Local After
time operation
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 lifting work
Lighting of B: For breaker work
Monitor display changes, synchronizing
with switch
Full throttle speed of engine changes
When engine is started, P mode is
selected automatically
Operation of auto-deceleration switch ON lights up: Auto-deceleration is
actuated.
OFF: Auto-deceleration is
canceled.
Each time the switch is pressed, the

auto-deceleration is actuated or
canceled.
Operation of travel speed switch Lo lights up: Low speed travel
Mid lights up: Middle speed travel
Hi lights up: High speed travel
When the engine is started, the travel

speed is automatically set to Lo.
Operation of wiper switch ON lights up: Wiper moves continuously
INT lights up: Wiper moves intermittently
OFF: Wiper stops
If switch is held down, window washer
Operation of window washer switch liquid spouts out.
(Interlocked with wiper)
Operation of cigarette lighter If lighter is pushed in, it is heated red
and returned to original position in
several seconds.
Operation of lamp switch This switch is used to turn on the front
lamps working lamps, additional lamp at
the top front of the cab, and monitor
lighting.
Operation of swing lock switch 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.
Operation of machine push-up switch Low pressure setting:
The boom thrust force is weak.
High pressure setting:
The boom thrust force becomes
more powerful.
Operation of room lamp switch ON position: Room lamp lights up.
Operation of emergency pump drive switch Normal state:

Switch is in "LOWER" position
While monitor is indicating "Pump control error", if switch is in If switch is set to "UPPER" position,
"UP" position, emergency pump can be driven alarm buzzer sounds.
7/13
Category
Revision
Local After
time operation
Operation of lock lever auto lock cancel switch When normal: Switch is in "Lower"
position.
When this switch is set in "Upper" position, the lock lever auto
lock function is disabled. If the switch is set to "Upper" position,
When the lock lever is released while the control lever or the lock lever lock switch cancel monitor
pedal is operated, the work equipment or machine moves. lighting up.
Operation of swing brake cancel switch Normal state:
Switch is in "LOWER" position
While monitor is indicating "L03 swing brake error", if switch
is in "UP" position, brake is cancelled and upper structure can If switch is set to "UPPER" position,
swing. alarm buzzer sounds and swing
However, swing brake is kept cancelled. lock symbol flashes
Operation of alarm buzzer stop switch This is used to stop alarm buzzer if it
sounds to warn of an abnormality during
operation.
Operation of travel levers 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.
Operation of left work equipment control lever This lever is used to operate the arm
(with auto-deceleration device) 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.
Operation of right work equipment control lever This lever is used to operate the boom
(with auto-deceleratiom device) 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.
Confirmation of failure history Check there is no abnormality, then
(Both electrical and mechanical) delete abnormality record. When
finishing inspection, check again there is
no abnormality record.
Operation of power max. switch When the switch on the LH work
equipment control lever is pushed, the
digging power increases.
Check function of rotation lamp switch
(option) ON: Rotary lamp lights up
Category 8/13
Revision
Local After
time operation
Swing operation running in: Engine high idle speed.
(Work equipment posture: Max. reach)
Right Left
Constant swing speed [ rpm] [ rpm] 9.1 +/- 0.9 rpm
Swing performance
Brake angle Max. 140° (Max. reach with no load)
Swing variation, hunting There must be none.
Abnormal noise, irregular swing There must be none.
Travel operation running in: Engine high idle speed.
(Work equipment posture: Travel posture)
There must be no abnormal noise or

Abnormal noise, heat from carrier roller, track roller, idler
abnormal heat.
Must brake securely without pulling
Operation of travel brake to one side.
Abnormal noise, irregular travel There must be none.

Travel deviation There must be no abnormal deviation
from fine control range to full stroke
range (feeling).
Travel Forward Reverse
High
deviation [ ] [ ] Max. 200 mm/20m
speed
(measured) mm/20m mm/20m
(Only when it is
considered that Low Forward Reverse
Max. 200 mm/20m
Travel performance
there is speed [ ] [ ]
abnormality.) mm/20m mm/20m
High Forward Reverse

Track rotating speed [ ] [ ]
36.7 +/-3.6 sec
speed - Right sec sec
(Time required to make 5 turns of
High Forward Reverse
speed [ ] [ ] track shoe after 1 turn)
- Left sec sec
Low Forward Reverse
speed [ ] [ ]
67.3 +/-13.5 sec
- Right sec sec
(Time required to make 5 turns of
Low Forward Reverse
speed [ ] [ ] track shoe after 1 turn)
- Left sec sec
Right Left
Track tension [ ] [ ]
mm mm
Category 9/13
Revision
Local After
time operation
Work equipment operation running in: Engine high idle speed. (Note: Boom cylinder to ground level)
Pressurized; each port relief 2 minutes, shock 20 times (except BOOM LOWER).
Work equipment posture
At P mode
Work
equipmet
speed RAISE sec LOWER sec RAISE: 4.2 +/-0.4 sec.
(Incl. Boom [ ] [ ] LOWER: 3.1 +/- 0.3 sec.
cushion
actuating
time)
IN sec OUT sec IN: 4.6 +/-0.5 sec.
Arm [ ] [ ] OUT: 3.7 +/-0.4 sec.
CURL sec DUMP sec CURL: 3.5 +/-0.4 sec.

Bucket [ ] [ ] DUMP: 2.9 +/-0.3 sec.
Work
equipment Boom LOWER sec
[ ] Max. 3.0 sec
time lag
(Engine Only when there is considered to be abnormality.
low idle)
Work equipment performance
IN sec
Arm [ ] Max. 3.0 sec
Only when there is considered to be abnormality.
DUMP sec
Bucket [ ] Max. 3.0 sec
Only when there is considered to be abnormality.
There must be no abnormality

Abnormal noise from hydraulic pump during operation under no load
and during relief.
There must be no hunting at any

speed under no load, there must
Engine partial performance be no stalling of engine even at
low idle and relief.
Fine control performance Must idle smoothly.
There must be no escape of
boom, arm, or bucket
Operation when raising chassis
ON: Machine is pushed up
OFF: Machine is not pushed up
Abnormal noise, grating noise from work equipment There must be none.
Shock at end of cylinder stroke

Cushion must be fully effective.
(Shock at end of stroke for BOOM RAISE and ARM IN)
Immediately after engine is

stopped, boom cylinder must
Function of accumulator move from fully extended position
to ground level. (Arm at max.
reach)
Category 10/13
Revision
Local After
time operation
Check all parts

• There must be no catching dur-
During operation
Operating force of control lever when each actuator is actuated. ing operation.
• Must return naturally to neutral.
Feeling and noise of vibration in operator's cab There must be none.
Vibration noise from frame, guard There must be none.

Around operator’s cab
Movement of doors and windows Must move smoothly
Door, window locks Must lock securely.
Must be possible to make all

Adjustment of operator's seat
adjustments.
Oil leakage There must be none.

(Idler, roller, sprocket, final drive gear case, motor)
Undercarriage
Interference at any part There must be none.
Looseness of track shoe bolt There must be none.

There must be no overlapping,
Contact of link tread separation, or missing or broken
parts.
Oil leakage There must be none.
( Center swivel, pump, solenoid valve, relief valve, control valve,

PPC valve, swing motor, brake valve, shuttle valve, swing
(
machinery, hydraulic tank, piping
Leakage of fuel
[Fuel tank, engine, piping] There must be none.
Around chassis
Leakage of water from engine cooling water system There must be none.
Leakage of oil from engine lubrication system There must be none.
Leakage of gas from engine gas system There must be none.
Movement of covers Must move smoothly
Cover locks Must lock securely.

Category 11/13
Revision
Local After
time operation
Looseness, insufficient insertion of electric wiring terminals There must be none.
There must be a clearance of at least 10 mm

Position for passing electrical wiring throuth
from any moving part or edge.
Around chassis
Leakage of air from air system There must be none.
Interference at any part There must be none.
Oil leakage
[Cylinder, piping, block] There must be none.
Around work equipment
Grease leakage from grease piping There must be none.
Interference of work equipment There must be none.
Looseness of work equipment piping clamps, play in piping There must be none.
Twisting of hydraulic hoses and operation of work

equipment when turning over There must be none.
12/13
Note: If the operation or function is defective, measure as necessary. All judgement standard values for speeds are the values in P mode.
Category
Local After
Revision

time operation
1. Engine speed
1000 +/- 25 rpm When auto- decele-

Low idle speed rpm ]
ration switch is OFF
High idle speed rpm ] 1770 +/- 50rpm
Speed at arm OUT rpm ] When mode is P

1720 +/-100 rpm and swing lock is ON
Speed at arm IN rpm ] When mode is P

1720 +/-100 rpm and swing lock is ON
2. Readiator fan speed
Speed at engine high idle speed rpm ] 1815 +/- 100 rpm
When oil temperature is 50 oC and fan
rotation is 100%%
3. Oil pressure measurment (measure at pump outlet port)
RAISE 34.8 (+1.47 / -1.18)MPa

Measurement items
｛353 (+15 / -12)kg/cm2}

Boom
*37.3 (+1.47 / -1.18)MPa
• Hydraulic oil temperature : Within opera-
tion range
｛380 (+15 / -12)kg/cm2}
34.8 (+1.47 / -1.18)MPa

Arm
• Engine at high idle 　｛353 (+15 / -12)kg/cm2}
• Working mode: P mode * 37.3 (+1.47 / -1.18)MPa

Bucket
｛ 380 (+15 / -12)kg/cm2}
• Hydraulic pump output pressure with all
measurement circuits relieved
29.9 (+1.47 / -1.96)MPa
Swing • Values indside parenthesis :
Hydraulic oil pressure with power max.
｛305 (+15 / -20)kg/cm2}
switch in ON mode
(reference only) 37.3 (+2.94 / -0.98)MPa
Travel
｛ 380 (+30 / -10)kg/cm2}
• Hydraulic oil temperature: Within opera- 3.24 +/- 0.2 MPa
tion range
｛33 +/- 2 kg/cm2}
Control circuit source • Engine at high idle
pressure
• Self pressure reducing valve output pres-
sure with all control levers in NEUTRAL
position
• Hydraulic oil temper-
ature: Within operat- When all control 4.2 +/-1.0 MPa
ing range levers in NEUTRAL
• Engine at high idle position {42 +/-10 kg/cm2}
• Working mode: P
LS differential pressure mode
• Traveling speed: Hi
When traveling at 2.65 +/- 0.1 MPa
• Hydraulic oil pump
｛27 +/1 kg/cm2}
half stroke
pressure-LS pres- (At idling)
sure
13/13
Category
Local After
Revision

time operation
4. Hydrauric drift of work equipment

(Bucket load: 3,960 kg, hydraulic oil temperature 50 +/-5°C)
Bucket tooth tip [ 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.
Boom cylinder [ mm ] Max. 25 mm/ 15minutes
Arm cylinder [ mm ] Max. 136 mm/ 15minutes
Bucket cylinder [ mm ] Max. 30 mm/ 15minutes
5. Operation force, travel
Boom  RISE N  LOWER N  

lever Operating 15.7 +/-3.9 N
force     
 (kg)    {1.6 +/- 0.4 kg}
(kg) 

RISE LOWER PLAY Stroke: 85 +/-10 mm

Stroke
(Play: Max. 15mm) 
[ mm] [ mm] [ mm]

Swing
 RIGHT N  LEFT N  
lever 12.7 +/-2.9 N
Operating
    
force 
Main measurement items
 (kg)   (kg)  {1.3 +/-0.3 kg}


RIGHT LEFT PLAY Stroke: 85 +/-10 mm 
Stroke 
[ mm] [ mm] [ mm] (Play: Max. 15mm) 

Bucket  CURL N  DUMP N  12.7 +/-2.9 N 
lever Operating
force     
 (kg)    {1.3 +/- 0.3 kg}
(kg) 

CURL DUMP PLAY Stroke: 85 +/-10 mm At engine high

Stroke idling, relief
(Play: Max. 15mm) 
[ mm] [ mm] [ mm]

Arm lever 
 IN N  OUT N  15.7 +/-3.9 N 
Operating
force     
 (kg)   (kg)  { 1.6 +/- 0.4 kg}

IN OUT PLAY Stroke: 85 +/-10 mm 
Stroke 
[ mm] [ mm] [ mm] (play: Max. 15mm) 

Right  FOR– N  RE– N  
travel Operating 24.5 +/- 5.9 N
lever force  WARD   VERSE
 
 (kg)   (kg)  {2.5 +/-0.6 kg} 

FORWARD REVERSE PLAY Stroke: 115 +/-12mm 
Stroke 
[ mm] [ mm] [ mm] ( Play: Max. 20mm) 
Left travel

 FOR– N  RE– N  24.5 +/-5.9 N 
lever Operating WARD VERSE
force     
 (kg)   (kg)  {2.5 +/- 0.6 kg}

Stroke: 115 +/-12 mm

FORWARD REVERSE PLAY
Stroke 
(Play: Max. 20mm) 
[ mm] [ mm] [ mm]
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GEN00181-03

HYDRAULIC PC500LC -10M0

Operator for assembly

Mechanics Sharing of work

A. Assembly of chassis ....................................................................................................... 23

B. Assembling of work equipment ...................................................................................... 31

C. Assembling of counterweight and adjustment ................................................................ 53

D. Installation of catwalk ..................................................................................................... 71

Mounting bolt torque check sheet

PC500LC-10M0 SE spec., PC500LC-10R SE spec.

3. Preparation and check of protective gear, slings and tools

4. k Check during actual work

*2 Installation of boom cylinder

*2•*3 Installation of boom

*2•*4 Installation of arm

Greasing of work equipment

Air bleeding (work equipment)

Check of oil and coolant levels

These machines can be divided into three kits for transportation.

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

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

Model PC500LC-10M0 (inc. -10R & SE spec.)

PC500LC-10M0 (inc. -10R)

B (mm) 1,990 1,880

Position of center of gravity Overall width 790

PC500LC-10M0 (inc. -10R)

Overall width 720 720

(3) Boom cylinder

Model PC500LC-10M0(inc. -10R & SE spec.)

B (mm) 1,550 1,895

Position of center of gravity

Weight (kg) 10,740

Position of center of gravity

16 multiplier wrench T25.4 square x Width across flats 65 mm 1 each Counterweight

33 Shackle SD32 2 Rated load of 6 t for counterweight

38 Hydraulic oil TO10 200 l

42 Cloth 1 bundle 20 kg For cleaning

4 types of marker Each one

Digital angle gauge 1 For Camera calibration and 12 m

Part No. of bolt TTTTT-TTTTT

2. The bolt length is dimension (c) in Fig. 1.

a : Bolt thread diameter (Nominal diameter)

Nominal size of thread Width across flats Tightening torque

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

Table 4.1 Hydraulic hose of face seal type

Type that uses O-ring

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}

Table 4.2 Hydraulic hose of taper seal type

Type that does

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}

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

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

HOLTS • Heat-resistant sealant for re-

• Feature: Can be used with

Bio grease • Decomposed by bacteria in na-

• Used as paint primer for

2•3 Installation of boom

2•4 Installation of arm