Instructions for installing a Graco automatic lubrication system on a Komatsu PC210-11, PC490-11 Excavator

Online PDF Instructions for installing a Graco automatic lubrication system on a Komatsu PC210-11, PC490-11 Excavator

Installation Notes

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

Zerk Fittings
a.Use a clean cloth or rag to remove excessive grease, contaminants and dirt from the work area.
b.Remove all grease zerks and Komatsu extensions from their installation locations.
c.Use a clean cloth or rag to remove any remaining grease, contaminants or dirt from the area around the passage way to the bearing points.
d.If required use 1/8 in. NPT pipe tap to chase the passage threads.
2.Flip over the H-link on the excavator bucket (FIG. 2). (The zerk fittings must face the inside of the arm.) 
3.After the H-link is reversed, manually grease the lube points again to verify grease is being accepted.

Bearing Point Fittings
1.Apply thread sealant to supplied bearing point fittings.
2.Install fittings in bearing points. Refer to FIG. 3 and the Bearing Point Fitting Table, page 8 for installation locations and parts. 
3.Refer to Bearing Point Fitting Table, beginning on page 8, to determine the location of the bearing points on your model.

MSP Divider Valves
The Divider Valve Assembly includes the following components:

  1. MSP divider valve base
  2. MSP divider valve assembly
  3. 1/8 in. x 4 JIC straight outlet fittings
  4. Inlet fittings
  5. Cycle indicators
  6. Performance indicators

Prepare a clean, flat area to assemble the valves.

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

MSP Divider Valve Assembly 
1. The MSP Divider Valves require assembly (FIG. 5). 
NOTE: Refer to the MSP Divider Valve Assembly Table and MSP Divider Valve and Lube Points Assembly reference illustrations, FIG. 12 - FIG. 13 (page 16), to verify assembly orientation.
a.Remove components from packaging.
b.Assemble metering valves to base plates as shown in FIG. 5.

Weld Stud Guidelines

  1. Weld studs are provided in the installation kit. However, the installer may use their own weld studs if preferred.
  2. Specific Weld Stud installation instructions and suggested locations are provided in the respective sections of this manual.
  3. Make sure any welding done is at least 2 inches from any edge, mating surface or existing factory weld.

1.Use a marker or paint pen to mark the weld stud locations.
2.Adjust and clean the surfaces for the weld stud locations as needed before tack welding the weld studs.
3.Tack weld the weld studs.
4.Clean the weld stud with a flap disk or grinding disk.
5.Prime the weld surface with Komatsu primer. When primer has dried, apply a few coats of matching Komatsu colored paint.
Boom and Swing Circle Valve Installation
The Boom and Swing Circle Valve is installed to the right rear side of the boom. It should be centered top to bottom and centered between the fitting block and hose mount on the excavator, see FIG. 14.
1.Mark the location of the first Boom and Swing Circle Valve weld stud location. Then use the Boom and Swing Circle Valve to mark the location of the other weld studs. Make any minor adjustments before installing the weld studs.
2.Set the Boom and Swing Circle Valve aside. Tack weld the weld studs where marked. See the Weld Stud Guidelines.

Arm and Bucket Valve Installation
The Arm and Bucket Valve is installed to the left side of the arm. The weld studs should be installed at least 3 inches (76.2 mm) from the weld, centered below the inlet on the bucket cylinder foot pin.
1.Mark the location of the first Arm and Bucket Valve weld stud location. Then use the Arm and Bucket Valve to mark the location of the other weld studs. Make any minor l adjustments before installing the weld studs.
2.Set the Arm and Bucket Valve aside. Tack weld the weld studs where marked. See the Weld Stud Guidelines.
3.Install Arm and Bucket Valve to the equipment using bolts included in the kit (FIG. 15 - FIG. 16).

P-Clamp Installation
P-Clamps are installed along the arm and on the H-Link on the excavator.

  1. Weld studs for P-Clamp installation should be centered half way across the arm and spaced evenly down the arm as shown in FIG. 17 and FIG. 18.
  2. Only one weld stud is required for P-Clamp installation on the H-Link. It should be installed to the casting protrusion in the middle of the H-Link (FIG. 19).

G3 Pump
The G3 Pump includes the following components:

  1. Pump with attached reservoir
  2. Pressure relief valve (required to protect system from damage)
  3. Pressure gauge (used to monitor system performance and to assist with troubleshooting).
  4. Mounting bracket and hardware
  5. CPC power cable
  6. Zip ties
  7. •Pump element spacers 
  8. •Washers - 4 total
  9. •Nuts - 4 total

1. Remove all components from the packaging and place all parts on a clean, flat surface.
2. Assemble the pressure relief valve.
a. Apply thread sealant (user supplied) to threads of pressure relief valve (a) (FIG. 22).
b.Install pressure relief valve (a) into banjo fitting (b). Wrench tighten (FIG. 22).
c.Install one washer (c) over end banjo bolt (d). Then install banjo fitting (b) on banjo bolt, followed by the second washer (c) (FIG. 23).
3. Install banjo bolt (d) into pump element (e) (FIG. 24). 
4.Use two wrenches to tighten banjo fitting. Place one wrench on the pump element (e) and the second wrench over the end of the banjo bolt (d). ONLY tighten the banjo bolt (d) while holding the pump element (e) securely in place. Torque banjo bolt (d) to 35 ft. lbs (45.7 N•m) (FIG. 25). Take care to not over-tighten.

G3 Mounting Bracket Installation 

  1. For the PC210-11/PC240-11/PC290-11 models: Install the pump to the platform on the left-hand side of the equipment behind the cab, near the handrails as shown in FIG. 31.
  2. For the PC360-11/PC390-11/PC490-11 models: Install the pump to the platform on the right-hand side of the equipment, near the handrails as shown in FIG. 32.

1.For PC210-11/PC240-11/PC290-11 Models: Install the pump bracket behind the cab on the left side of the machine. Slide the pump bracket up next to the kick-plate as far as it will go (FIG. 31).
For PC360-11/PC390-11/PC490-11 models: On the right hand side of the machine, center the mounting bracket between the hand rail and the engine cover.
Measure in approximately 2.5 inches (63.5 mm) from the outside edge of the platform. Use a marker or pen to mark the location of the first mounting hole (FIG. 29).
2.Square and align the bracket over the mark made in Step 1. Use a marker or paint pen to mark the locations of the remaining mounting holes in the bracket (FIG. 30). 
3.Use a drill to drill the mounting holes in the platform.
4.Secure G3 pump to mounting bracket.
5.Align mounting bracket with the drilled holes in the platform. 
6.Insert bolts through holes in the bracket and platform. Thread the nuts over the end of the bolts and tighten nuts to hold the bracket securely to platform (FIG. 32).

Installing and Routing G3 Power Cable
NOTE: Before the pump wiring can be installed, the excavator must be rotated 90° so that the boom and arm are facing over the track. See the Komatsu Excavator instruction manual for these instructions.
1. Remove the metal access panel located below the cab.
2.Wrap the G3 pump CPC power cable with the 1/4 in. cable loom.
3.Connect the end of the power cable to the G3 pump.
4.Route the power cable through the mounting bracket and into the engine compartment as shown in FIG. 37 and FIG. 40.

Hose Routing 
Routing hose lines takes time. It is easier when there are two people working on the installation together.

  1. Identify the internal and external swing circle points to ensure proper hose lengths are applied. If hoses are too short, they will bind and eventually break. If hoses are too long, they can easily get snagged on external debris, or pinched in the machine and break.
  2. Care must be taken to ensure hoses are installed to move with the machine. To make the lube system part of the machine consideration must be given to the many swing circle, oscillation, extension and pinch point areas of a equipment. Before cutting and securing hoses, have a qualified technician move the various parts of the machine to ensure proper routing is achieved.
  3. Look for access points. Utilize grommets, supports, or cutouts in equipment’s frame. Routing hoses through these areas keeps the hoses inside the machine and provides protection. It will also provide a cleaner, more professional looking installation.
Online PDF Instructions for installing a Graco automatic lubrication system on a Komatsu PC210-11, PC490-11 Excavator

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