Komatsu Hydraulic Excavator PC750-7 PC750LC-7 PC750SE-7 PC800 PC800SE-7 Field Assembly Instruction M

GEN00014-03

Field Assembly Instruction

HYDRAULIC EXCAVATOR

PC750

-7

PC750LC

-7

PC750SE -7 PC800 SERIAL NUMBERS

-7

PC800SE -7 PC750-20001 PC800-40001

and up

Precautions for Field Assembly Disposal of Removed Parts

Tightening Torque Coating Materials List Chassis

Pulling Out of Boom Foot Pin, and Boom Cylinder Foot Pin Installation of Boom Assembly

B-13 B-14 B-15

Connection of Wiring of Work Equipment Greasing after Assembling Work Equipment Air Bleeding from Hydraulic Cylinder

1 2 3 4 6 6 12 13 17 19 20 23 26 27 28 32 35 36 37 38 39 40 41 43 44 47 50 52 53 54 55 56 57 58 59 60 61 62 64 65 66 67 68 69

71 72 73 74 75 76 77 78 80 81 82 83 84 85 86 87 88 89 91 92 93 94 95 96 Replacement of Return Filter (Standard Filter to Flushing Filter)

98 99

M-4

Replacement of Return Filter (Flushing Filter to Standard Filter)

(Loading Shovel)

101

1

Precautions for field assembly

Precautions for field assembly 1. Selection of work place 1) When selecting a work place, consider the following.

• Is the work place sufficiently wide for loading and unloading the machine? (See the kit layout drawing.)

• Is the ground sufficiently hard? (The machine and crane truck must not sink into the ground.)

• Is the ground flat? (The ground surface must not be uneven or sloping.)

• Is the road to inlet/outlet of the work place sufficient for turning the trailer and crane truck?

2) Take care extremely that dirt or water will not enter the hydraulic circuit while it is assembled.

3) Avoid working outdoors while strong wind is blowing or it is raining.

4) Take measures to protect the machine from sand, dirt and rainwater while the work is stopped.

2. How to do work The work supervisor or the work leader should not do the work while reading this manual but should read and understand this manual thoroughly and then start the work.

In particular, write the "Precautions" for each work process in a sheet to explain or stick that sheet to the work place so that all the workers will observe the precautions.

3. Preparation and check of protective gear, slings and tools The work supervisor or the work leader must perform the following checks about protective gear, slings and tools.

1) Are all the workers wearing helmets and other protective gear which they are obliged to wear?

If special protective gear is necessary, check that it is prepared and can be used without problem.

2) Are all the slings and tools prepared? Check in advance that they are ready to be used without problem. In particular, check wooden blocks for internal decay and cracking.

4. k Check during actual work The work supervisor or the work leader must check the following items constantly and make all the workers observe them.

1) Are the parking brakes of the trailer and crane truck applied securely and are their wheels locked with chocks during work? Are outriggers, if installed, used securely?

2) Are the temperature and pressure of the engine, hydraulic oil, coolant, etc. lowered sufficiently during work?

3) Is horn or another signal is made to warn around when the engine is started? In addition, is it checked that work equipment control lever and other control levers are in neutral and the fuel control dial (or fuel control lever) is in the low idle position?

4) Is the balance of the slung item checked extremely during sling work with the crane?

5) Is entry prohibition for outsiders to the work place observed?

5. The work supervisor or the work leader is required to hold a meeting with all the workers at the beginning of every morning and explain the work plan of the day to them and give them instructions to observe the safe work.

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 completion of the machine. Since they are useful when the machine needs to be transported in future, however, we recommend you to keep them as long as possible.

3

4

Min. 1.5 m3/min

Min. 0.7 MPa

5

Min. 1.5 m3/min

Min. 0.7 MPa

6

7

8

9

10

11

2

Crane truck

Wire rope sling

Synthetic fiber sling

3 divisions: for lifting 343 kN {35 ton}

1

4 divisions: for lifting 343 kN {35 ton}

2

ø10 × 3000 mm ø12 × 3000 mm ø20 × 5000 mm ø25 × 5000 mm ø25 × 8000 mm ø30 × 5000 mm SD30 SC18 1.5 − 3 ton 1/4 ton 50 mm wide × 3000 mm ø50 × 500 mm (for lifting track frame)

Can accept a 50 ton jack at the height of 540 mm and withstands 20 ton.

12

Two 343 kN {35 ton} trucks are required on the first day and one on the second day.

TIGHTENING TORQUE 1. Tightening torque for bolts Tightening torque for bolts is indicated in the text as shown below. Tighten each bolt to the specified torque.

Part No. of bolt

TTTTT-TTTTT

Part No. of washer

EEEEE-EEEEE

Bolt specification

Thread × Bolt length Thread size diameter (Diameter, pitch, length)

Tool (Socket)

Applicable socket size

Tightening torque

Nm {QQQ kgm}

If tightening torque for a bolt is not specified in the text, tighten it according to Table 1.

Remarks 1. The thread diameter is the nominal diameter. For example, 16 mm is expressed as M16 and 20 mm is expressed as M20.

The pitch in Table 1 is the distance that the bolt advances every turn in the axial direction (Unit: mm).

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

3. The applicable socket size is expressed as 24 mm, 30 mm, etc. Since 24 mm, 30 mm, etc. correspond to dimension (b) in Fig. 1, an applicable socket can be selected from Table 1, too.

4. Tightening torque is expressed as QQQ – www or QQQ ± RR. If the target tightening torque is set, expression of QQQ ± RR is applied.

Fig. 1

a b c d

: Bolt thread diameter (Nominal diameter) : Width across flats of bolt head : Bolt length : Threaded part of bolt

13

Table 1 Tightening torque for bolts not specified in text Unit: Nm {kgm} Width across flats (= Socket size) b (mm)

Unit : Nm

Unit : {kgm}

6×1

10

11.8 – 14.7

{1.2 – 1.5}

8 × 1.25

13

27 – 34

{2.8 – 3.5}

10 × 1.5

17

59 – 74

{6 – 7.5}

12 × 1.75

19

98 – 123

{10 – 12.5}

14 × 2

22

153 – 190

{15.5 – 19.5}

16 × 2

24

235 – 285

{23.5 – 29.5}

18 × 2.5

27

320 – 400

{33 – 41}

20 × 2.5

30

455 – 565

{46.5 – 58}

22 × 2.5

32

610 – 765

{62.5 – 78}

24 × 3

36

785 – 980

{80 – 100}

27 × 3

41

1150 – 1440

{118 – 147}

30 × 3

46

1520 – 1910

{155 – 195}

33 × 3

50

1960 – 2450

{200 – 250}

36 × 3

55

2450 – 3040

{250 – 310}

39 × 3

60

2890 – 3630

{295 – 370}

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

14

Tightening torque

Nominal size of thread × pitch a (mm)

2. Tightening torque for pipe threads Proper tightening torque for pipe threads depends on combination of the materials of the male screw and female screw. In this manual, however, select tightening torque from Table 2 and Table 3 on the basis of the material of the male screw. If tightening torque is specified specially in explanation, however, apply that tightening torque.

2.1 If the male screw is made of mild steel or cast iron, apply Table 2.

Table 2 Unit: Nm {kgm} Material of female thread

Steel

Cast iron

Light alloy

1/8

3.9 – 6.9 {0.4 – 0.7}

2.9 – 5.9 {0.3 – 0.6}

2.0 – 3.9 {0.2 – 0.4}

1/4

5.9 – 11.8 {0.6 – 1.2}

4.9 – 9.8 {0.5 – 1.0}

3.9 – 7.8 {0.4 – 0.8}

3/8

16.7 – 26.5 {1.7 – 2.7}

13.7 – 21.6 {1.4 – 2.2}

9.8 – 16.7 {1.0 – 1.7}

1/2

32.3 – 52.9 {3.3 – 5.4}

26.5 – 43.1 {2.7 – 4.4}

19.6 – 32.3 {2.0 – 3.3}

3/4

51.0 – 85.3 {5.2 – 8.7}

42.1 – 70.6 {4.3 – 7.2}

31.4 – 52.9 {3.2 – 5.4}

1

86.2 – 173.5 {8.8 – 17.7}

72.5 – 146.0 {7.4 – 14.9}

54.9 – 111.7 {5.6 – 11.4}

Nominal size (in)

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

1/8

16.7 – 29.4 {1.7 – 3.0}

9.8 – 19.6 {1.0 – 2.0}

6.9 – 14.7 {0.7 – 1.5}

1/4

19.6 – 44.1 {2.0 – 4.5}

16.7 – 37.2 {1.7 – 3.8}

12.7 – 28.4 {1.3 – 2.9}

3/8

44.1 – 93.1 {4.5 – 9.5}

37.2 – 77.4 {3.8 – 7.9}

27.4 – 58.8 {2.8 – 6.0}

1/2

98.0 – 188.2 {10.0 – 19.2}

83.3 – 157.8 {8.5 – 16.1}

60.8 – 115.6 {6.2 – 11.8}

3/4

170.5 – 316.5 {17.4 – 32.3}

141.1 – 247.0 {14.4 – 25.2}

105.8 – 186.2 {10.8 – 19.0}

1

367.5 – 612.5 {37.5 – 62.5}

309.7 – 514.5 {31.6 – 52.5}

235.2 – 392.0 {24.0 – 40.0}

Nominal size (in)

15

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.

Table 4 Tightening torque (Nm {kgm})

Outside diameter of hose (mm)

Width across flatse. (mm)

Range

Target

Approx. 6

19

35 – 63 {3.5 – 6.5}

44 {4.5}

22

54 – 93 {5.5 – 9.5}

74 {7.5}

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}

Approx. 10

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

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

16

Thread diameter

Proper sizes of sockets or spanners

M42

65

M45

70

M48

75

M52

80

M56

85

M60

90

M64

95

COATING MATERIALS LIST a The coating materials such as adhesives, gasket sealants, and greases used for disassembly and assembly are listed below. a For coating materials not listed below, use the equivalent of products shown in this list.

Category

Adhesive

Komatsu code

Part No.

Q'ty

Container

Main features and applications

LT-1A

790-129-9030

150 g

Tube

• Used to prevent rubber gaskets, rubber cushions, and cock plugs from coming out.

LT-1B

790-129-9050

20 g (2 pcs.)

Polyethylene container

• Used for plastic (except polyethylene, polypropylene, tetrafluoroethylene and vinyl chloride), rubber, metal, and non-metal parts which require immediate and strong adhesion.

LT-2

09940-00030

50 g

Polyethylene container

• Features: Resistance to heat and chemicals • Used to fix and seal bolts and plugs.

LT-3

790-129-9060 (Set of adhesive and hardener)

Adhesive: 1 kg Hardener: 500 g

Can

LT-4

790-129-9040

250 g

Polyethylene container

Holtz MH 705

790-126-9120

75 g

Tube

• Heat-resistant seal used to repair engines

Threebond 1735

790-129-9140

50 g

Polyethylene container

• Quick-setting adhesive • Setting time: Within 5 sec. to 3 min.

• Used mainly to stick metals, rubbers, plastics, and woods.

2g

Polyethylene container

• Quick-setting adhesive • Quick-setting type (max. strength is obtained after 30 minutes) • Used mainly to stick rubbers, plastics, and metals.

• Features: Resistance to heat and chemicals • Used for fitted portions used at high temperatures.

Aron-alpha 201

790-129-9130

• Used to seal plugs.

Loctite 648-50

79A-129-9110

50 cc

Polyethylene container

LG-1

790-129-9010

200 g

Tube

• Used to stick or seal gaskets and packings of power train case, etc.

1 kg

Polyethylene container

• Used to seal various threaded portions, pipe joints, and flanges.

• Used to seal tapered plugs, elbows, and nipples of hydraulic piping.

Tube

• Features: Silicon-based heat and cold-resistant sealant • Used to sea flange surfaces and threaded portions.

• Used to seal oil pan, final drive case, etc.

• Features: Silicon-based quick-setting sealant • Used to seal flywheel housing, intake manifold, oil pan, thermostat housing, etc.

LG-5

LG-6

790-129-9080

790-129-9020

200 g

Gasket sealant

Molybdenu m disulfide lubricant

• Used to stick metal, glass, and plastics.

LG-7

790-129-9070

1 kg

Tube

Three bond 1211

790-129-9090

100 g

Tube

Three bond 1207B

419-15-18131

100 g

Tube

• Features: Silicon-based, heat and cold-resistant, vibration-resistant, impact-resistant sealant • Used to seal transfer case, etc.

LM-G

09940-00051

60 g

Can

• Used to lubricate sliding portions (to prevent squeaking).

Tube

• Used to prevent scuffing and seizure of press-fitted portions, shrink-fitted portions, and threaded portions.

• Used to lubricate linkages, bearings, etc.

LM-P

09940-00040

200 g

• Gasket sealant used to repair engine

17

Grease

Komatsu code

G2-LI

SYG2-400LI SYG2-350LI SYG2-400LI-A SYG2-160LI SYGA-160CNLI

G2-CA

SYG2-400CA SYG2-350CA SYG2-400CA-A SYG2-160CA SYGA-160CNCA

Molybdenum disulfide lubricant LM-G (G2-M)

SYG2-400M SYG2-400M-A SYGA-16CNM

Hyper White Grease G2-T G0-T (*) *: For cold district

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

Biogrease G2-B, G2-BT (*) *: For use at high temperature and under high load

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

SUNSTAR PAINT PRIMER 580 SUPER SUNSTAR GLASS PRIMER 580 SUPER

Primer

Part No.

Q'ty

Container

• General purpose type Various

Various

Various

Various

400 g × 10 Bellows-type 400 g × 20 container 16 kg Can

400 g 16 kg

400 g 16 kg

18

• Used for bearings used at normal temperature under light load in contact with water or steam.

• Used for parts under heavy load.

• Bellows-type container • Can

Seizure resistance and heat resistance higher than molybdenum disulfide Not conspicuous on machine since color is white.

• Since this grease is decomposed by natural bacteria in short period, Bellows-type it has less effects on microorgancontainer isms, animals, and plants.

Can

20 ml

Glass container

• Used as primer for cab side (Using limit: 4 months after date of manufacture)

20 ml

Glass container

• Used as primer for glass side (Using limit: 4 months after date of manufacture)

417-926-3910

• Used as primer for painted surface on cab side (Using limit: 4 months after date of manufacture) • Used as primer for black ceramic-coated surface on glass side and for hard polycarbonate-coated surface (Using limit: 4 months after date of manufacture)

SUNSTAR PAINT PRIMER 435-95

22M-54-27230

20 ml

Glass container

SUNSTAR GLASS PRIMER 435-41

22M-54-27240

150 ml

Can

SUNSTAR SASH PRIMER GP-402

22M-54-27250

20 ml

Glass container

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

417-926-3910

320 ml

Polyethylene container

Sika Japan, Sikaflex 256HV

20Y-54-39850

310 ml

Polyethylene container

SUNSTAR PENGUINE SUPER 560

22M-54-27210

320 ml

Ecocart (Special container)

SUNSTAR PENGUINE SEAL No. 2505

417-926-3920

320 ml

Polyethylene container

• Used to seal joints of glass parts.

(Using limit: 4 months after date of manufacture)

SEKISUI SILICONE SEALANT

20Y-54-55130

333 ml

Polyethylene container

• Used to seal front window.

(Using limit: 6 months after date of manufacture)

GE TOSHIBA SILICONES TOSSEAL 381

22M-54-27220

333 ml

Cartridge

• Used to seal joint of glasses.

Translucent white seal. (Using limit: 12 months after date of manufacture)

Adhesive

Caulking material

Main applications, features

Adhesive for cab glass

Category

• Used as primer for sash (Almite) (Using limit: 4 months after date of manufacture) • "S" is used for high-temperature season (April - October) and "W" for low-temperature season (November - April) as adhesive for glass.

(Using limit: 4 months after date of manufacture) • Used as adhesive for glass.

(Using limit: 6 months after date of manufacture) • Used as adhesive for glass.

(Using limit: 6 months after date of manufacture)

A. ASSEMBLY OF CHASSIS Remarks 1. In the "drawings" in this manual, parts and places are indicated by 1, 2, 3 ---, but indicated by (1), (2), (3) --- in the tables and texts.

Example:

(1) (2) (3) (4) (5) (6)

2.

Plate Collar Washer Bolt Bolt Washer

In some places of this manual, the words of front, rear, right hand and left hand of machine are used. Those words indicate the directions seen from the operator's seat with the sprocket at the rear as shown below, unless otherwise specified.

Front Front

Operator’s Left hand seat

Right hand

Left hand

Right hand

Operator's seat

Rear

Sprocket Rear

Sprocket

19

a

Cranes must be the same model.

Place the washer (5) on the plate (4).

When installing spacer (2), be careful not to slant it to the spot facing, etc.

209-30-41630

20

21

22

23

24

25

26

27

28

29

30

31

32

33

34

35

36

37

38

39

40

a OPG: Operator Protective Guard

41

42

43

44

45

46

47

48

49

Assembly Procedure No. A-17. Inspection of Oil Amount and Water Amount (1/2)

For details of the recommended oils, see Operation and Maintenance Manual.

50

Assembly Procedure No. A-17. Inspection of Oil Amount and Water Amount (2/2)

51

#1"/ 00"* )&+$ 1%" ) /$" 0&7"! %6!/ 2)& "5 3 1,/ &+ 1%" #&")! 1,2 % 2- 1%" #,)),4&+$ - /10 +!"/0&!" ,# #/,+1 +! /" / ,# ,,*

+!"/0&!" ,# /*

,- , 1 ,# "+! ,# ),+$ ,,* "1 -/,'" 1"! #/,* 1/ &)"/ -"")0 ,##

+!"/0&!" ,# ,2+1"/4"&$%1

+!"/0&!" ,# 2 ("1

%"+ 1%" * %&+" &0 20"! ,+ 1%" 0" 0%,/" "1 4%"/" &1 &0 /201"! " 0&)6 1,2 % 2- 1%" #,)),4&+$ - /10 1,, +- &+1"! - /10 ,# * %&+"! 02/# "0 ,# #) +$"0 #1"/ &+01 ))&+$ -&-&+$ /" 0" 12 "0 "1 ))& %,0" +!0 "1 0" /201 -/"3"+1 )" / - &+1 #,/ 1,2 %&+$ 2- 1%" * %&+"! 02/# "0 "1 " ,**"+!"! / +! $"+2&+" /201 -/"3"+1&3" )" / - &+1 /" 21&,+0

,,)0 20"! ,,) *"

, ,,0" 02--)6 &1"*0 816 , ,,0" 02--)6 &1"*0 816

1%"/0

52

.2&-*"+1 20"!

816

*"

816

53

Assembly Procedure No. B-1. Pulling Out of Boom Foot Pin, and Boom Cylinder Foot Pin

54

Assembly Procedure No. B-2. Installation of Boom Assembly

55

56

57

m oo fb ro nte Ce

top

pin

58

59

60

61

62

63

64

a Refer to the Maintenance standard for the clearance of the connection.

65

66

Assembly Procedure No. B-13. Connection of Wiring of Work Equipment

67

Assembly Procedure No. B-14. Greasing after Assembling Work Equipment

68

Assembly Procedure No. B-15. Air Bleeding from Hydraulic Cylinder

69

8# 6HH:B7A>C< D; LDG@ :FJ>EB:CI D; AD69>C< H=DK:A &OHDQ WKH PRXQWLQJ SLQ KROH DQG FKHFN WKHP IRU D ÀDZ

71

72

73

74

%RWK HQGV DUH SOXJJHG

%RRP VHHQ IURP DERYH

3 VHHQ IURP VLGH

75

+RVH WR EH UHPRYHG

+RVH WR EH UHPRYHG %RRP VHHQ IURP EHORZ

76

%XFNHW ERWWRP

+RVH WR EH UHPRYHG

%XFNHW KHDG

%XFNHW KHDG %XFNHW ERWWRP

+RVH WR EH UHPRYHG

77

$UP VHHQ IURP EHORZ

6KRUW FLUFXLW VWDWH 5HXVH WKH UHPRYHG VSOLW Ã&#x20AC;DQJHV EROWV ZDVKHUV DQG 2 ULQJV

78

79

>chiVaa Wdi] h^YZ Xna^cYZgh Vh hVbZ egdXZYjgZ#

80

81

82

83

2LO VWRSSHUV DUH LQVWDOOHG

$UP F\OLQGHU

%RRP VHHQ IURP EHORZ

84

2LO VWRSSHUV DUH LQVWDOOHG

85

Cylinder bottom side angle : 75 degrees

q

Cylinder head side angle : 90 degrees

q

Plug is installed

86

2LO VWRSSHUV DUH LQVWDOOHG RQ ERWK VLGHV

87

88

89

90

91

%XFNHW F\OLQGHU SRUWLRQ

'HWDLO D

92

%RRP F\OLQGHU SRUWLRQ

93

C-21 Bleeding air from hydraulic cylinder

94

95

Inspection and Maintenance Procedure No. M-1.

Inspection of Oil Level in Hydraulic Tank and Refill (1/2)

96

Inspection and Maintenance Procedure No. M-1.

Inspection of Oil Level in Hydraulic Tank and Refill (2/2)

97

Inspection and Maintenance Procedure No. M-2.

Replacement of Return Filter (Standard Filter to Flushing Filter)

98

Inspection and Maintenance Procedure No. M-3.

Flushing of Hydraulic Circuit (1/2)

If the flushing is performed with the engine at full throttle, the filter element may be broken since the relief valve of the filter is closed.

99

Inspection and Maintenance Procedure No. M-3.

Flushing of Hydraulic Circuit (2/2)

(4)

100

Confirmation After flushing, replace the standard element with flushing element referring to step M-4.

While doing above, check the collected dusts in the flushing element if they are not unusual.

If uncertain, contact your distributor.

Inspection and Maintenance Procedure No. M-4.

Replacement of Return Filter (Flushing Filter to Standard Filter) (1/2)

101

Inspection and Maintenance Procedure No. M-4.

Replacement of Return Filter (Flushing Filter to Standard Filter) (2/2)

After completion of flushing, check the flushing element referring to the caution in M-3, and discard it.

Store the strainer, valve and replaced plate because they can be used again.

102

After completion of assembling a machine, make inspections according to these check sheets for assuring machine performance.

After checking, send these check sheets to the Osaka plant.

After completion of assembling a machine, make inspections according to these check sheets for assuring machine performance.

After checking, send these check sheets to the Osaka plant.