Вы находитесь на странице: 1из 288

GEN00060-03

Field Assembly Instruction

HYDRAULIC
EXCAVATOR

PC2000 -8
SERIAL NUMBERS

PC2000-8-20001

and up

FOREWARD
Before starting the engine and assembling the work equipment, you must inspect and service the machine thoroughly. Since
you are frequently obliged to work alone or with other workers in dangerous places or postures, hold a safety meeting in advance and appoint a crane sign maker and a working leader so that all the workers can work safely.
Particularly when working in a foreign country, there are many unsafe factors because of differences in language, customs,
etc. Accordingly, the liaison person and work director in the field must examine the above items fully to secure the safely.

(Instruction system diagram)


Work leader
Work director

Crane sign maker

Regular/Assistant

Operator for assembly


Liaison person
Mechanics

Share of work

(Interpreter)

We hope that all the workers will cooperate to assemble this machine quickly while observing the safety, quality and delivery time.

CONTENTS
SPECIFICATIONS.............................................................................................................
POINTS REGARDING LOCAL ASSEMBLY .....................................................................
ASSEMBLY PROCEDURE, ASSEMBLY EQUIPMENT AND SCHEDULE ......................
FLOWCHART OF MAIN ASSEMBLY PROCEDURE........................................................
KIT LAYOUT DIAGRAM ....................................................................................................
TRANSPORTATION POSTURES.....................................................................................
LIST OF PARTS SENT INDIVIDUALLY ............................................................................
TOOLS AND EQUIPMENT TO BE USED FOR LOCAL ASSEMBLY ...............................
TIGHTENING TORQUE ....................................................................................................
COATING MATERIALS LIST ............................................................................................

1
2
3
4
5
6
15
27
29
33

A. ASSEMBLY OF CHASSIS ............................................................................................


<Assembly of undercarriage>
A- 1. Assembly of track frame assembly and center frame assembly...........................
A- 2. Idler cushion cylinder piping .................................................................................
A- 3. Travel motor piping ...............................................................................................
A- 4. Installation of travel motor cover...........................................................................
A- 5. Filling swing circle with grease .............................................................................
A- 6. Assembly of revolving frame assembly and undercarriage ..................................
A- 7. Installation of swing machinery (front) assembly (27t)
Installation of swing motor (front) assembly (32t) .................................................
A- 8. Connection of swivel joint piping...........................................................................
A- 9. Connection of swing circle grease piping .............................................................
<Assembly of upper structure>
A-10. Installation of hydraulic tank assembly .................................................................
A-11. Installation of fuel tank assembly..........................................................................
A-12. Connection of fuel tank assembly piping and wiring.............................................
A-13. Installation of cab base assembly.........................................................................
A-14. Installation of left floor assembly ..........................................................................
A-15. Connection of cab base assembly piping .............................................................
A-16. Connection of cab base assembly wiring .............................................................
A-17. Connection of left floor assembly heater piping....................................................
A-18. Connection of left floor assembly wiring ...............................................................
<Coupling of power container>
A-19. Installation of tail pipe ...........................................................................................
A-20. Installation of power container assembly..............................................................
A-21. Connection of suction piping ................................................................................
A-22. Connection of oil cooler piping and pump drain piping.........................................
A-23. Connection of fan motor drain piping....................................................................
A-24. Installation of suction unit undercover ..................................................................
A-25. Connection of delivery piping ...............................................................................
A-26. Connection of pilot piping and fan motor piping ...................................................
A-27. Connection of power container assembly fuel piping ...........................................
A-28. Connection of power container assembly air conditioner piping ..........................
A-29. Connection of power container assembly heater piping.......................................
A-30. Connection of power container assembly wiring ..................................................

35
36
39
40
41
43
44
46
47
49
50
55
56
58
60
64
66
71
72
73
74
76
78
79
80
81
83
84
86
87
88

<Coupling of operator's cab>


A-31. Installation of operator's cab assembly ................................................................
A-32. Installation of rotary lamp (if equipped) ................................................................
A-33. Installation of ORBCOMM antenna......................................................................
A-34. Connection of operator's cab assembly wiring.....................................................
A-35. Connection of operator's cab assembly hydraulic piping .....................................
A-36. Connection of operator's cab assembly window washer hose.............................
A-37. Connection of operator's cab assembly air conditioner piping .............................
A-38. Connection of operator's cab assembly heater piping .........................................
A-39. Installation of operator's cab rear floor assembly.................................................
A-40. Installation of handrail around operator's cab ......................................................
<Coupling of exterior parts, counterweight, etc.>
A-41. Installation of track frame ladder ..........................................................................
A-42. Installation of power container side catwalk assemblies (right and left)...............
A-43. Installation of right floor assembly and grease can cover assembly ....................
A-44. Installation of fuel tank right catwalk assembly ....................................................
A-45. Installation of fuel tank front catwalk assembly ....................................................
A-46. Adjustment of exterior parts clearance.................................................................
A-47. Connection of grease reel piping .........................................................................
A-48. Installation of slide ladder assembly ....................................................................
A-49. Installation of counterweight assembly ................................................................
A-50. Installation of handrail on counterweight..............................................................
A-51. Installation of handrail clamps..............................................................................
A-52. Connection of fuel cut wire...................................................................................
A-53. Connection of drain piping under power container...............................................
A-54. Connection of battery wiring.................................................................................
<Starting of engine and inspection and servicing procedures>
A-55. Setting of hydraulic tank strainer..........................................................................
A-56. Starting of engine, inspection of oil levels and coolant levels,
bleeding air and adjustment of track ....................................................................
A-57. Permanent tightening of swing circle bolt.............................................................
A-58. Parts to be touched up after field assembly (chassis side) ..................................
<Extremely cold district specification (if equipped)>
A-59. Connection of engine heater connection port ......................................................
C. ASSEMBLY OF BACKHOE..........................................................................................
<Coupling of boom>
C- 1. Installation of boom cylinder.................................................................................
C- 2. Installation of boom cylinder hoses ......................................................................
C- 3. Assembly of boom sub assembly.........................................................................
C- 4. Installation of boom assembly..............................................................................
C- 5. Installation of boom cylinder.................................................................................
<Coupling of arm>
C- 6. Installation of hoses between boom and chassis.................................................
C- 7. Installation of arm assembly.................................................................................
C- 8. Installation of arm cylinder ...................................................................................
C- 9. Connection of hoses between boom and arm......................................................
C-10. Connection of auto grease piping ........................................................................
C-11. Connection of wiring between boom and chassis................................................
<Coupling of bucket>
C-12. Installation of bucket assembly ............................................................................
C-13. Installation of bucket link......................................................................................
C-14. Bleeding air from cylinders...................................................................................
C-15. Parts to be touched up after field assembly (work equipment side) ....................
C-16. Bleeding air from auto grease circuit ...................................................................

90
93
95
96
97
99
100
101
102
103
104
105
106
107
108
109
110
111
113
114
115
118
119
120
121
122
141
142
143
147
148
150
151
155
157
159
160
163
164
165
166
167
170
172
175
176

LS. ASSEMBLY OF LOADING SHOVEL WORK EQUIPMENT........................................


LS- 1. Installation of arm cylinder bottom parts .............................................................
LS- 2. Installation of boom cylinder to machine body....................................................
LS- 3. Installation of boom cylinder hoses.....................................................................
LS- 4. Installation of boom cylinder piping.....................................................................
LS- 5. Installation of boom assembly ............................................................................
LS- 6. Installation of boom cylinder head pins...............................................................
LS- 7. Installation of hose between machine body and boom.......................................
LS- 8. Installation of bucket cylinder assembly .............................................................
LS- 9. Installation of arm assembly ...............................................................................
LS-10. Installation of arm cylinder assembly..................................................................
LS-11. Installation of hoses between boom and arm .....................................................
LS-12. Installation of bucket cylinder hoses...................................................................
LS-13. Installation of grease feed hose of bucket cylinder.............................................
LS-14. Installation of bucket assembly...........................................................................
LS-15. Installation of bottom dump hose and grease feed hose
between arm and bucket ....................................................................................

179
180
181
183
184
185
186
187
189
190
191
192
193
194
196

M. INSPECTION AND SERVICING PROCEDURES AFTER ASSEMBLY .......................


M- 1. Inspection of oil levels and coolant levels and using standard
of fuel and lubricant..............................................................................................
M- 2. Flushing of hydraulic circuit..................................................................................
M- 3. Releasing residual pressure from hydraulic circuit...............................................
M- 4. Releasing residual pressure from HIC circuit and check
of gas pressure in HIC accumulator.....................................................................
M- 5. Charging air conditioner with refrigerant ..............................................................
M- 6. Installed angles of mirrors ....................................................................................
M- 7. Installed angles of lights.......................................................................................

199

197

200
203
206
207
208
209
211

VHMS CONTOROLLER INITIAL SETTING PROCEDURE .............................................. 215


FIELD ASSEMBLY INSPECTION REPORT (BACKHOE)
FIELD ASSEMBLY INSPECTION REPORT (LOADING SHOVEL)

SPECIFICATIONS
Item
Operating weight (including 1 operator)
Bucket capacity

Backhoe
Loading shovel

Name of engine
Engine horsepower

Unit

PC2000-8

kg

200,000
12.0

m3

11.0

Komatsu SAA12V140E-3 diesel engine

kW{HP}/rpm

728{976}/1,800

Min. ground distance

2,095

Travel speed (Low/High)

km/h

2.7

Swing speed

rpm

4.8

PC2000-8 Backhoe

PC2000-8 Loading shovel

POINTS REGARDING LOCAL ASSEMBLY


1. Selection of work place
1) The work place should be suitable for the machine. The following points should be considered.
Area
Hardness of ground surface
Levelness
Entry/Exit road, turning space
2) Assembly work on the hydraulic circuit must not be carried out in any place where dust or rain can get into the circuit
during the operation.
3) If the work is carried out outside, avoid place where there is rain or strong wind.

2. Preparation and check of lifting tools and jigs


1) Check each lifting tool and jig thoroughly.
In particular, check stands and blocks made of wood to check that the inside is not rotted or cracked.

3. k Check during actual operation


1) Apply the parking brake of the trailer and crane securely, then put chocks under the wheels.
2) Lower the pressure and temperature of the engine, hydraulic oil, and coolant before starting work.
3) When starting the engine, always give an agreed signal, such as blowing the horn, to warn the people around the machine. Check also that the work equipment levers and travel levers are in neutral, and that the fuel control dial (or fuel
control lever) is at the low idle position.
4) Be careful to maintain the balance of parts being lifted by the crane.
5) Do not allow unauthorized persons into the working area.

4 Before starting the operation, read all the instructions, and, in particular, be sure that you understand
the caution items.
The circled numbers in the illustrations are indicated as the numbers in ( ). (Example: q (1))

5. The leader should write out the caution items for each work process, and should explain them to ensure that the workers understand them.
6. Hold a meeting every morning before starting work to confirm the operating plan and operating safety.

Workers

Air compressor

Mobile elevating
work platform

Crane

Units to be
assembled

Day

Start of assembly
Meeting of all workers

Foreman + 6 mechanics

Min. 15 m3/min

Completion of assembly
of chassis
Start of engine

Foreman + 6 mechanics

Completion of total assembly

Foreman + 6 mechanics

Foreman + 2 mechanics

(Half day)

ASSEMBLY PROCEDURE,
ASSEMBLY EQUIPMENT AND SCHEDULE

FLOWCHART OF MAIN ASSEMBLY PROCEDURE

Necessary assembly procedure when disassembling to 27t.

Assembly of
undercarriage
(Crawler, center
frame)

Coupling of
revolving frame

Installation of
hydraulic tank

Connection of
swivel piping

Installation of
front machinery

Installation of
power container
assembly

Installation of
fuel tank

Installation of
grease cover and
ladder

Installation of
exterior parts,
handrail and mirror

Installation of
left floor

Installation of
cab base

Installation of
cab assembly

Installation of
ladder to cab base

Installation of
boom cylinder

Installation of
boom

Installation of
arm

Installation of
bucket

Installation of
counterweight

Motoring

Boom sub
(arm cylinder, tube)

To A

KIT LAYOUT DIAGRAM


The dimensions given below are the minimum dimensions needed.
When selecting a work place, see "Points regarding local assembly".
When installing the revolving frame, place wooden blocks 700 mm high under it.

Covers
Tubes
Hoses
Boom cylinder

Tools and equipment

Cab

Arm link

Cab
base
F tank

G reel
Covers
Rear floor PA ladder
Front CW Right CW
Left deck Right deck
Left floor Right floor

Bucket

Center frame

Crane, 50 ton
C weight

Crawler frame

Crane, 50 ton

Crawler frame

Boom

Front
Revolving
frame

Power container

TRANSPORTATION POSTURES
For transporting of the machine, ask your Komatsu distributor.
Each dimension in the following figures is rounded up to the next 5 mm and each weight is rounded up to the next 100 kg.
The arrows indicate the hanging points of each assembly.
t Transportation posture of each kit
(1) Center frame assembly
X

Overall length (mm)

3,815

Overall width (mm)

3,190

Overall height (mm)

2,210

Weight (kg)

18,000

With swivel and fixing bar


With swing circle and grease
piping
With grease bath (Grease is
packed separately)
With travel piping tubes
With HIC piping (Accumulator
has been pressurized)
[Remarks]
Undercover is optional.

Center of gravity

Top view

(2) Crawler frame assembly


For each crawler
X
Overall length (mm)

7,435

Overall width (mm)

1,720

Overall height (mm)

1,920

Weight (kg)

26,000

With motor and motor guard


[Remarks]
Full roller guard is optional.

Center of gravity

Top view

(3) Revolving frame assembly


(Special sling)

When
When
disassembled disassembled
to 32 ton
to 27 ton
Overall length (mm)
7,575

Overall width (mm)

Overall height (mm)

Weight (kg)

3,180
2,920

2,640

31,500

26,500

With 6 hoses to boom


With 4 oil cooler hoses
With grease tank
Center of gravity

When disassembled to 27 ton, hydraulic tank


assembly and machine (front) assembly are
packed separately.

Top view

(4) Fuel tank assembly


X

Overall length (mm)

3,100

Overall width (mm)

,875

Overall height (mm)

2,070

Weight (kg)

2,400

With working lamp


With fuel level sensor

Center of gravity

Top view

(5) Cab base assembly


X

Overall length (mm)

3,660

Overall width (mm)

2,505

Overall height (mm)

2,700

Weight (kg)

2,500

With front and left catwalk


With head lamp and working lamp
Center of gravity

Top view

(6) Left floor assembly


X

Overall length (mm)

2,500

Overall width (mm)

2,100

Overall height (mm)

3,085

Weight (kg)

1,500

With battery
Center of gravity

Top view

(7) Power container assembly


X

Overall length (mm)

5,215

Overall width (mm)

2,455

Overall height (mm)

3,195

Weight (kg)

16,100

With super hood


With handrail on radiator side

Center of gravity

Top view

(8) Operator's cab assembly


X

Overall length (mm)

2,855

Overall width (mm)

1,880

Overall height (mm)

2,520

Weight (kg)

1,800

With antenna retracted


With mirrors folded
[Remarks]
Front guard is optional.

Center of gravity

Top view

(9) Counterweight assembly


X

Overall length (mm)

6,240

Overall width (mm)

1,115

Overall height (mm)

1,505

Weight (kg)
[Parts packed separately]
Handrail, bolts

24,500
Center of gravity

Top view

(10) Slide ladder assembly


X

Overall length (mm)

3,380

Overall width (mm)

,875

Overall height (mm)

1,255

Weight (kg)

,550

Center of gravity

View Z

(11) Catwalk assembly on power container side


For each catwalk
X
Overall length (mm)

2,310

Overall width (mm)

,545

Overall height (mm)

2,085

Weight (kg)

,260

Center of gravity

Top view

(12) Grease can cover assembly


X

Overall length (mm)

1,030

Overall width (mm)

1,025

Overall height (mm)

,995

Weight (kg)

,260

Center of gravity

Top view

(13) Right floor assembly


X

Overall length (mm)

1,390

Overall width (mm)

1,350

Overall height (mm)

2,085

Weight (kg)

,240

Center of gravity

Top view

(14) Right catwalk assembly


X

Overall length (mm)

3,560

Overall width (mm)

1,300

Overall height (mm)

1,865

Weight (kg)

,390

With grease reel

Center of gravity

Top view

(15) Front catwalk assembly


X

Overall length (mm)

,715

Overall width (mm)

,810

Overall height (mm)

1,540

Weight (kg)

, 90

Center of gravity

Top view

10

(16) Cab rear floor assembly


X

Overall length (mm)

1,470

Overall width (mm)

1,320

Overall height (mm)

,345

Weight (kg)

, 70

Center of gravity

Top view

(17) Boom assembly


X

Overall length (mm)

9,170

Overall width (mm)

2,065

Overall height (mm)

3,195

Weight (kg)

18,430

Center of gravity

Left side view

(18) Arm assembly


X

Overall length (mm)

5,495

Overall width (mm)

1,605

Overall height (mm)

2,055

Weight (kg)

12,900

With bucket cylinder


Center of gravity

Left side view

11

(19) Bucket assembly


Specifications of standard bucket
for crushed stones

Overall length (mm)

5,495

Overall width (mm)

1,605

Overall height (mm)

2,055

Weight (kg)

12,900

Center of gravity

Left side view

(20) Arm cylinder tube assembly


X

Overall length (mm)

1,240

Overall width (mm)

,320

Overall height (mm)

,365

Weight (kg)

, 60

Center of gravity

Left side view

(21) Hydraulic tank assembly


X

Overall length (mm)

1,860

Overall width (mm)

1,115

Overall height (mm)

2,085

Weight (kg)

1,750

Center of gravity

Top view

12

(22) Swing machinery (front) assembly


X

Overall length (mm)

,775

Overall width (mm)

,675

Overall height (mm)

1,335

Weight (kg)

1,050

Center of gravity

Top view

(23) Cab L.H. catwalk


X

Overall length (mm)

3,660

Overall width (mm)

,615

Overall height (mm)

1,355

Weight (kg)

,220

Center of gravity

Top view

(24) Cab front catwalk


X

Overall length (mm)

1,840

Overall width (mm)

,560

Overall height (mm)

Weight (kg)

,100

Center of gravity

Top view

13

11,325

Method of installing chassis hanging jig

14

LIST OF PARTS SENT INDIVIDUALLY (Assembly of undercarriage)


A
No.

Part No.

Part name

Q'ty

Assembly
procedure No.

A-1

21T-30-71160

BOLT

76

A-1

A-2

21T-30-71170

WASHER

76

A-1

A-3

208-30-11850

COVER

A-1

A-4

208-30-11861

GASKET

A-1

A-5

01024-81225

BOLT

A-1

A-6

07000-B3025

O-RING

A-2

A-7

07000-B3048

O-RING

A-3

A-8

02896-61018

O-RING

A-3

A-9

01024-81235

BOLT

A-4

A-10

424-54-14230

COLLAR

A-4

A-11

01024-81230

BOLT

12

A-4

A-12

21N-30-11340

COLLAR

16

A-4

A-13

01641-21223

WASHER

12

A-4

A-14

21T-30-32172

COVER

A-4

A-15

21T-30-32182

COVER

A-4

A-16

01010-82460

BOLT

10

A-4

A-17

17A-54-44130

WASHER

10

A-4

15

Remarks

LIST OF PARTS SENT INDIVIDUALLY (Coupling of revolving frame)


B
Assembly
Q'ty procedure No.

No.

Part No.

Part name

B-1

21T-25-67150

BOLT

60

A-6

B-2

01643-33690

WASHER

60

A-6

B-3

01010-83090

BOLT

14

A-7

B-4

01643-33080

WASHER

14

A-7

B-5

07000-B3032

O-RING

A-7

B-6

07000-B3032

O-RING

A-7

B-7

02896-61015

O-RING

A-7

B-8

02896-61008

O-RING

A-7

B-9

01024-81225

BOLT

A-7

B-10

11Y-62-11980

O-RING

A-8

B-11

02896-61009

O-RING

A-8

B-12

07000-B3048

O-RING

A-8

B-13

07000-B5230

O-RING

A-10

B-14

01011-83010

BOLT

12

A-10

B-15

21T-26-11460

WASHER

12

A-10

B-16

07000-B2060

O-RING

A-10

B-17

11Y-62-11980

O-RING

A-10

B-18

07000-B3032

O-RING

A-10

16

Remarks

LIST OF PARTS SENT INDIVIDUALLY (Assembly of upper structure)


C
No.

Part No.

Part name

Q'ty

Assembly
procedure No.

C-1

01011-83010

BOLT

20

A-11

C-2

21T-26-11460

WASHER

20

A-11

C-3

04435-52212

CLIP

A-12

C-4

02896-61012

O-RING

A-12

C-5

02896-61015

O-RING

A-12

C-6

02896-61018

O-RING

A-12

C-7

01024-81220

BOLT

A-12

C-8

04434-52312

CLIP

A-12

C-9

04434-51912

CLIP

A-12

C-10

01024-81220

BOLT

A-12

C-11

01034-81245

BOLT

10

A-13

C-12

01034-81265

BOLT

10

A-13

C-13

21T-54-31140

CLAMP

A-13

C-14

21T-54-31150

CLAMP

A-13

C-15

01034-81245

BOLT

A-13

C-16

01011-82035

BOLT

20

A-13

C-17

01011-82045

BOLT

A-13

C-18

567-40-41380

WASHER

27

A-13

C-19

01010-82065

BOLT

24

A-14

C-20

01643-32060

WASHER

24

A-14

C-21

21T-53-31530

SHIM

A-14

C-22

21T-53-31540

SHIM

A-14

C-23

21T-54-33471

COVER

A-14

C-24

01034-81230

BOLT

A-14

C-25

02896-61012

O-RING

A-15

C-26

02896-61018

O-RING

A-15

C-27

21T-979-3320

JOINT

A-17

17

Remarks

LIST OF PARTS SENT INDIVIDUALLY (Coupling of power container)


D
Assembly
Q'ty procedure No.

No.

Part No.

Part name

D-1

21M-01-18130

TAIL PIPE

A-19

D-2

01024-81230

BOLT

12

A-19

D-3

6162-14-5640

RAIN CAP

A-19

D-4

21T-54-31121

PLATE

A-20

D-5

21T-54-31130

BOLT

20

A-20

D-6

01643-34212

WASHER

20

A-20

D-7

07000-B2140

O-RING

A-21

D-8

07000-B2100

O-RING

A-21

D-9

209-62-41341

CLAMP

A-21

D-10

20Y-62-51671

CLAMP

A-21

D-11

07000-B2060

O-RING

A-22

D-12

07298-02011

HOSE

A-22

D-13

07000-B3032

O-RING

A-23

D-14

07000-B3048

O-RING

A-25

D-15

07000-B3025

O-RING

A-26

D-16

07000-B3032

O-RING

A-26

D-17

02896-61018

O-RING

A-27

D-18

02896-61015

O-RING

A-27

D-19

02896-61015

O-RING

A-27

D-20

08028-55065

CABLE

A-30

D-21

01024-81020

BOLT

A-30

18

Remarks

LIST OF PARTS SENT INDIVIDUALLY (Coupling of operator's cab)


E
No.

Part No.

Part name

Q'ty

Assembly
procedure No.

E-1

21T-54-36661

SHIM

16

A-31

E-2

21T-54-36671

SHIM

A-31

E-3

21T-54-35321

CUSHION

A-31

E-4

8295-06-1480

LAMP BEACOM

A-32

E-5

21T-06-17430

BRACKET

A-32

E-6

01024-81225

BOLT

A-32

E-7

8295-06-1480

LAMP BEACOM

A-32

E-8

21T-06-33610

PLATE

A-32

E-9

21T-06-17430

BRACKET

A-32

E-11

01024-81225

BOLT

A-32

E-11

04434-51012

CLIP

A-32

E-12

01024-81220

BOLT

A-32

E-13

8A13-10-2100

ANTENNA

A-33

E-14

21T-06-64491

BRACKET

A-33

E-15

01024-81225

BOLT

A-33

E-16

02896-61012

O-RING

10

A-35

E-17

02896-61009

O-RING

A-35

E-18

21T-979-4421

SEAL

A-37

E-19

08034-20830

BAND

A-37

E-20

08034-20830

BAND

A-38

E-21

01024-81225

BOLT

14

A-39

E-22

21T-54-33931

HANDRAIL

A-40

E-23

01034-81245

BOLT

10

A-40

19

Remarks

LIST OF PARTS SENT INDIVIDUALLY (Coupling of counterweight etc)


F
Assembly
Q'ty procedure No.

No.

Part No.

Part name

F-1

21T-30-32231

BRACKET

A-41

F-2

21T-30-32241

LADDER

A-41

F-3

01010-82460

BOLT

A-41

F-4

01010-82450

BOLT

A-41

F-5

01643-32460

WASHER

16

A-41

F-6

01010-82050

BOLT

16

A-42

F-7

01010-82080

BOLT

12

A-43

F-8

01010-82060

BOLT

A-43

F-9

01643-32060

WASHER

20

A-43

F-10

21T-53-31550

PLATE

A-43

F-11

21T-54-31560

PLATE

A-43

F-12

21T-54-33331

STEP

A-43

F-13

01034-81250

BOLT

A-43

F-14

01034-81235

BOLT

16

A-44

F-15

01034-81250

BOLT

A-45

F-16

01010-82050

BOLT

A-48

F-17

567-40-41380

WASHER

A-48

F-18

21T-46-34120

BOLT

12

A-49

F-19

209-46-11210

SPACER

12

A-49

F-20

21T-46-34141

PLATE

A-49

F-21

21T-46-34131

PLATE

A-49

F-22

01024-81225

BOLT

12

A-49

F-23

21T-54-34411

HANDRAIL

A-50

F-24

21T-54-34421

HANDRAIL

A-50

F-25

01034-81250

BOLT

16

A-50

20

Remarks

No.

Part No.

Part name

Q'ty

Assembly
procedure No.

F-26

21T-54-32911

CLAMP

A-51

F-27

21T-54-32921

CLAMP

A-51

F-28

01034-81245

BOLT

14

A-51

F-29

21T-54-65810

CHAIN

A-51

F-30

21T-54-31140

CLAMP

A-51

F-31

21T-54-31150

CLAMP

A-51

F-32

01034-81245

BOLT

A-51

F-33

21T-01-31471

NIPPLE

A-53

F-34

07005-02416

O-RING

A-53

21

Remarks

LIST OF PARTS SENT INDIVIDUALLY (Coupling of boom)


H
Assembly
Q'ty procedure No.

No.

Part No.

Part name

H-1

707-01-XK750

BOOM CYLINDER(L.H.)

C-1

H-2

707-01-XK760

BOOM CYLINDER(R.H.)

C-1

H-3

21T-70-31421

SHIM

C-1

H-4

21T-70-31470

SHIM

C-1

H-5

21T-70-31690

SHIM

C-1

H-6

07000-15180

O-RING

C-1

H-7

07000-B2060

O-RING

C-2

H-8

07000-B3048

O-RING

C-2

H-9

21T-64-39410

HOSE

C-2

H-10

07083-01417

HOSE

C-2

H-11

21T-64-39140

TUBE

C-3

H-12

21T-64-39150

TUBE

C-3

H-13

21T-64-39160

TUBE

C-3

H-14

07000-B3048

O-RING

C-3

H-15

07000-B2060

O-RING

C-3

H-16

01643-31845

WASHER

32

C-3

H-17

01010-81840

BOLT

C-3

H-18

01010-81865

BOLT

28

C-3

H-19

707-01-XK770

ARM CYLINDER(L.H.)

C-3

H-20

707-01-XK780

ARM CYLINDER(R.H.)

C-3

H-21

07000-12140

O-RING

C-3

H-22

21T-70-31441

SHIM

C-3

H-23

07084-02022

HOSE

C-3

H-24

07085-01418

HOSE

C-3

H-25

07085-01420

HOSE

C-3

H-26

07000-B2060

O-RING

C-3

H-27

07000-B3048

O-RING

C-3

H-28

07371-51470

FLANGE

C-3

H-29

07371-52080

FLANGE

C-3

H-30

01643-31445

WASHER

C-3

22

Remarks

No.

Part No.

Part name

Q'ty

Assembly
procedure No.

H-31

01643-31845

WASHER

C-3

H-32

01010-81455

BOLT

C-3

H-33

01010-81865

BOLT

C-3

H-34

21T-06-32810

WORK LAMP A.

C-3

H-35

20Y-06-21551

BRACKET

C-3

H-36

01643-31445

WASHER

C-3

H-37

01010-81430

BOLT

C-3

H-38

01024-81225

BOLT

C-3

H-39

209-72-11311

SEAL

C-3

H-40

21T-70-31480

SHIM

C-4

H-41

21T-70-31490

SHIM

16

C-4

H-42

07000-15180

O-RING

C-5

23

Remarks

LIST OF PARTS SENT INDIVIDUALLY (Coupling of arm)


I
Assembly
Q'ty procedure No.

No.

Part No.

Part name

I-1

07000-B2060

O-RING

C-6

I-2

21T-70-31290

SEAL

C-7

I-3

21N-70-12160

SEAL

C-7

I-4

209-72-11261

SEAL

C-7

I-5

21T-70-31391

SHIM

C-7

I-6

21T-70-31780

SHIM

C-7

I-7

21T-70-31810

SHIM

C-7

I-8

21T-70-31820

SHIM

C-7

I-9

07000-B5260

O-RING

C-7

I-10

21T-70-32181

SHIM

C-8

I-11

07000-12140

O-RING

C-8

I-12

07371-51470

FLANGE

C-9

I-13

07371-52080

FLANGE

C-9

I-14

07084-41427

HOSE

C-9

I-15

07084-42026

HOSE

C-9

I-16

07000-B3048

O-RING

C-9

I-17

07000-B2060

O-RING

C-9

I-18

01643-31445

WASHER

C-9

I-19

01643-31845

WASHER

C-9

I-20

01010-81455

BOLT

C-9

I-21

01010-81865

BOLT

C-9

I-22

21T-68-31830

TUBE

C-10

I-23

203-973-5660

CLAMP

C-10

I-24

203-973-5720

SEAT

C-10

I-25

01024-81055

BOLT

C-10

I-26

21T-70-75290

BACKET

C-10

I-27

01024-81225

BOLT

C-10

I-28

07631-20409

HOSE

C-10

24

Remarks

LIST OF PARTS SENT INDIVIDUALLY (Coupling of bucket)


J
No.

Part No.

Part name

Q'ty

Assembly
procedure No.

J-1

209-72-11261

SEAL

C-12

J-2

209-70-71370

O-RING

C-12

J-3

205-09-61240

BOLT

C-12

J-4

01640-20610

WASHER

C-12

J-5

01596-00606

NUT

C-12

J-6

21N-72-11230

SHIM

C-13

25

Remarks

LIST OF PARTS SENT INDIVIDUALLY (Bleeding air from cylinders and hydraulic circuit)
K
Assembly
Q'ty procedure No.

No.

Part No.

Part name

K-1

209-60-77551

ELEMENT

M-2

K-2

21T-60-13730

PLATE

M-2

K-3

23S-54-36270

MIRROR

M-6

K-4

21T-54-34690

SUPPORT

M-6

K-5

21T-54-79620

CLAMP

M-6

K-6

01252-71025

BOLT

M-6

K-7

21T-54-34850

PLATE

M-6

K-8

21T-54-34680

PLATE

M-6

K-9

07283-32236

CLIP

M-6

K-10

01643-31032

WASHER

M-6

K-11

01597-01009

NUT

M-6

K-12

421-54-25610

MIRROR

M-6

K-13

04025-00632

SPRING PIN

M-6

K-14

01252-70545

BOLT

M-6

K-15

21T-54-36480

SUPPORT

M-6

K-16

20Y-54-61630

CLAMP

M-6

K-17

01252-71030

BOLT

M-6

26

Remarks

TOOLS AND EQUIPMENT TO BE USED FOR LOCAL ASSEMBLY

Equipment

No.

Part name

Q'ty

Remarks

Engine air compressor

7.0 kg/cm3

Crane truck

50 ton

Grease pump

Pneumatic

For greasing work equipment

Mobile elevating work platform 10 m

Lift work stand

2 workers
Substituted by mobile
elevating work platform

6
7

Stepladder

10 step, 3,000 mm
5 step, 1,500 mm

3 step, 900 mm

With 200 V, 100 V generator

Hydraulic wrench

750 kgm

Track frame, power container

Hydraulic pump

For hydraulic wrench, 200 V

Track frame, power container

10

For M10 mm bolt

(Torque capacity: 10 70 Nm)

11

For M12 mm bolt

(Torque capacity: 30 170 Nm)

For M16 mm bolt

(Torque capacity: 150 650 Nm)

For M36 mm bolt

(Torque capacity: 780 2,900 Nm)

12

Impact wrench

13
14

For M42 mm bolt

(Torque capacity: 1,500 6,300 Nm)

15

Width across flats: 70 mm

Track frame

Width across flats: 65 mm

Counterweight

Width across flats: 55 mm

16
17

Impact wrench socket

18

Width across flats: 46 mm

Fuel tank

19

T 38.1 Width across flats: 70 mm

Track frame

T 38.1 Width across flats: 65 mm

Counterweight

T 38.1 Width across flats: 55mm

T 38.1 Width across flats: 50 mm

T 19 Width across flats 30 mm

20
21

420 kgm
torque wrench socket

22
23
24
25

Tool

Specification

Socket
Extension

For impact wrench, 300 mm long

For impact wrench, 200 mm long

26

Impact wrench air hose

Inside 12, Inside 19

27

Air coupler

For hoses of size 4, 6

28

16 time wrench

450 kgm

29

12 kgm T 19

30

42 kgm T 25.4

For 16 time wrench

85 kgm T 25.4

For 4 time wrench

420 kgm T 38

31

Torque wrench

32

50 m each
2 sets

33

Width across flats: 30 mm

34

Width across flats: 32 mm

Width across flats: 36 mm

Width across flats: 41 mm

35

Spanner

36

2 sets each

37

Standard tool set

Sockets, spanners, ring wrenches

38

Large hammer (Plastic)

10 P

39

Bar

1m

50 ton

20 ton

40
Hydraulic jack
41
42

Oil receiving pan

43

Drum can oil filler

44

Wooden block

Large and small

Unnecessary, if hydraulic
wrench is available

2 each

For receiving center frame to


install track frame
For tightening track frame
clamping bolt
For connecting travel piping
and work equipment piping

1
300 400

27

For supporting revolving frame


and center frame

Tool

No.

Part name
M10 P1.5

46

M12 P1.75

47

M14 P2

48

M16 P2

49

M20 P2.5

50

M24 P3

51

Tap

Remarks

M27 P3

52

M30 P3

53

M33 P3

54

M36 P3

55

M39 P3

56

M42 P3

57

10 3,000 mm

Catwalk

58

20 5,000 mm

30 6,000 mm

40 5,000 mm

For 15 ton

62

5.4 ton

63

10 ton

Boom, arm and bucket


Center frame and power
container
Counterweight, revolving
frame and track frame
Track frame
Center frame, boom, arm and
power container
Track frame and revolving frame

64

20 ton

Counterweight

Wire

60
61

Sling

Q'ty

45

59

Chain

Shackle

65

2 ton

Fuel tank

66

0.9 ton

Cabin

67

SB10

Travel piping cover

68

50 mm wide 3,000 mm

Boom cylinder

25 mm wide 3,000 mm

Handrail

1.5 ton

Left floor assembly

3.0 ton

6 ton

69

Nylon sling

70
71

Lever block

72
73
74

Eyebolt

75

Fuel, oil, grease


and sub-materials

Specification

M20

M16

M12

76

Pin

Pin, 50 40 mm

77

Cleaning liquid

Brake cleaner spray can

78

Hydraulic oil

EO10

79

Diesel fuel

80

Grease

81
82

Repair paint

Track frame

10
2000 L
2000 L

G2-LI (20 L can)

Natural yellow spray can

10

Black gray spray can

10

83

LG-6

TB1215

84

Air conditioner refrigerant

R134a

2000 g

85

Cloth

1 bundle

20 kg

28

In grease bath

Connecting faces of revolving


frame and swing circle
For cleaning

TIGHTENING TORQUE
Remove the various blind plugs and jigs used during transportation. Remove the blind jigs (flange, head, cap, O-ring) used for
the work equipment piping and undercarriage piping, the blind plugs used for the lubrication piping, the jigs used to hold the
cylinders, and the blind plugs used in the tap holes where parts have been removed for transportation. Be careful not to damage these parts, and keep them in a safe place so that they can be used for future transportation. For bolts where the tightening
torque is not separately specified in the maintenance standards, use the tightening torque given in the table below.
1. Tightening torque for bolts
Tighten bolts according to Table 1 when using an impact wrench or spanner.
Apply Table 1 to bolts as a rule. No torque is indicated on drawings as long as Table 1 is applicable.

Table 1
Unit: Nm {kgm}
Thread diameter Pitch
a (mm)

Width across flats


b (mm)

61

Tightening torque
Target

Range

10

12
{1.2}

8.8 - 14.7
{0.9 - 1.5}

8 1.25

13

25
{2.5}

14.7 - 34
{1.5 - 3.5}

10 1.5

17

54
{5.5}

34 - 74
{3.5 - 7.5}

12 1.75

19

89
{9}

54 - 123
{5.5 - 12.5}

14 2

22

137
{14}

84 - 196
{8.5 - 20}

16 2

24

230
{23.5}

147 - 309
{15 - 31.5}

18 2.5

27

315
{32}

201 - 427
{20.5 - 43.5}

20 2.5

30

460
{47}

319 - 608
{32.5 - 62}

22 2.5

32

650
{66.5}

471 - 829
{48 - 84.5}

24 3

36

810
{82.5}

588 - 1030
{60 - 105}

27 3

41

1180
{120}

883 - 1470
{90 - 150}

30 3

46

1520
{155}

1130 - 1910
{115- 195}

33 3

50

1960
{200}

1470 - 2450
{150 - 250}

36 3

55

2450
{250}

1860 - 3040
{190 - 310}

39 3

60

2940
{300}

2260 - 3630
{230 - 370}

29

When using a torque wrench, apply Table 2.


Apply Table 2 when tightening torque must be controlled very strictly.

Table 2
Unit: Nm {kgm}
Thread diameter Pitch
a (mm)

Width across flats


b (mm)

61

Tightening torque
Target

Range

10

13.2
{1.35}

11.8 - 14.7
{1.2 - 1.5}

8 1.25

13

31
{3.2}

27 - 34
{2.8 - 3.5}

10 1.5

17

66
{6.7}

59 - 74
{6.0 - 7.5}

12 1.75

19

113
{11.5}

98 - 123
{10.0 - 12.5}

14 2

22

172
{17.5}

153 - 190
{15.5 - 19.5}

16 2

24

260
{26.5}

235 - 285
{23.5 - 29.5}

18 2.5

27

360
{37.0}

320 - 400
{33.0 - 41.0}

20 2.5

30

510
{52.3}

455 - 565
{46.5 - 58.0}

22 2.5

32

688
{70.3}

610 - 765
{62.5 - 78.0}

24 3

36

883
{90.0}

785 - 980
{80.0 - 100.0}

27 3

41

1295
{132.5}

1150 - 1440
{118.0 - 147.0}

30 3

46

1720
{175.0}

1520 - 1910
{155.0- 195.0}

33 3

50

2210
{225.0}

1960 - 2450
{200.0 - 250.0}

36 3

55

2750
{280.0}

2450 - 3040
{250.0 - 310.0}

39 3

60

3280
{335.0}

2890 - 3630
{295.0 - 370.0}

30

2. Tightening torque for pipe threads


Apply the following standards to the taper male pipe threads of size R1/8 - R1, taper female pipe threads of size Rc1/8 Rc1 and parallel female threads of size Rp1/8 - Rp1 (coated with adhesive). Do not apply them, however, if a tightening
torque is otherwise specified.
2-1. Apply Table 1 to male screws made of SS400, FC or SGP.

Table 1
Unit: Nm {kgm}
Material of female screw

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}

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

2-2. Apply Table 2 to male screws made of S43C.

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

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}

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

31

3. Tightening torque for hoses (with taper seals or face seals)


Unit: Nm {kgm}
Nominal size
of hose

Width across flats

02

Tightening torque
Range

Target

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}

04

27

84 - 132 {8.5 - 13.5}

103 {10.5}

05

32

128 - 186 {13.0 - 19.0}

157 {16.0}

06

36

177 - 245 {18.0 - 25.0}

216 {22.0}

(10)

41

177 - 245 {18.0 - 25.0}

216 {22.0}

(12)

46

197 - 294 {20.0 - 30.0}

245 {25.0}

(14)

55

246 - 343 {25.0 - 35.0}

294 {30.0}

03

When installing rubber hoses, extremely take care not to twist them.

32

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

33

Gasket sealant used to repair engine

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

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

34

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

35

Assembly procedure

A-1

Assembly of track frame assembly


and center frame assembly (1/3)

Track frame assembly (right)

Width across flats

Tightening torque 4413 4903 Nm


(450 500 kgm)

Apply wooden blocks etc.


to parts which wire ropes
will touch.

Center frame assembly

Track frame assembly (left)

No.
A-1
A-2
A-3
A-4
A-5
Precautions
not to crush the grease piping of the
circuit with wires.

Name
Power wrench (16)
(21t-98-11120)
Socket 38 70 mm
(21T-98-11120)
Handle
(21T-98-11130)
KW45F Impact wrench

Qty

Name

Qty

Hydraulic jack 50t

Truck crane 45 t

Center frame stand

1
1

Tap (M45 3)

36

Q'ty
76
76
1
1
3

Equipment required

Spline socket H70

Others

a When slinging the center frame, take care

Tools required

Part No.
21T-30-71160
21T-30-71170
208-30-11850
208-30-11861
01024-81225

Assembly procedure

Assembly of track frame assembly


and center frame assembly (2/3)

A-1

1) Place the left track frame assembly as shown in the figure


at right.
2) Sling the center frame assembly with a 45-ton crane and
couple it with the track frames.

Center frame assembly

Left

3) Remove the plugs from the coupling surface and clean


the coupling surface in advance.

Right

Rear view

4) Insert all the bolts, tighten them temporarily, and support


only the right side of the center frame on a jack.
Use only stands before coupling.
After coupling with left track frame,
left stand is not necessary any more.

5) Sling the right track frame assembly with the 45-ton crane
and couple it with the center frame. At this time, the jack
under the center frame should be heightened a little for
the ease of coupling.
a If you pull in the right track toward the center frame
with a chain block, you can work easily.

20 Pipe
Grip

6) Insert all the bolts, tighten them temporarily, and lower


the crane.
7) Remove the jack.

45 t
45 t
Pin (See above figure)

Method of slinging track frame


If 2 cranes are used, holes can be aligned easily.

Precautions
[Before slinging with crane]
Check that projection (A) of the hydraulic cushion cylinder
plunger is approx. 10 mm.
Tools required

Cushion
cylinder
Blind plug

Plunger on grease side

Hose
Plunger on hydraulic cushion side

If the projection is not approx. 10 mm, remove the blind plug from
the hose to drain the oil in the cylinder and then install the blind
plug again.
Check that projection (B) of the plunger on the grease side is
approx. 35 mm (that grease has been supplied). If the projection
is not approx. 35 mm, adjust it by supplying grease through the
grease fitting. (See A-56.).

Name
Pin 50 40 mm
(Hard steel)
Wire 40 5 m
(General purpose)

Others

Yoke

37

Equipment required
Qt
2
2

Name
Crane 45t

Qt
2

Assembly procedure

Assembly of track frame assembly


and center frame assembly (3/3)

A-1

1) Eliminate the clearance between the mating faces of the track frame and center frame (at the top, bottom, right and left).
Jack up the track frame, if necessary.
2) Coupling bolt
Power wrench (16) + 36 kgm torque wrench
Mounting bolt size: M45 P3
Tightening torque: 450 500 kgm

20 t

Input: 35 kgm
If input exceeds 35 kgm, power wrench may be broken.

<Tightening order>

Precautions

Name
20t Jack

Equipment required
Qty
2

Others

When installing the clamping bolts, remove the


piping at the rear of the center frame
(so that you can use an impact wrench easily).
(See Assembly procedure A-3.)

Tools required

38

Name

Qty

Assembly procedure

Idler cushion cylinder piping

A-2

Bracket and clamp are


installed to piping when
transported.
3 Tightening torque for U-clamp
11 -- 26 Nm {1.1 -- 2.7 kgm }
Bolts are installed to crawler
frame when transported.

Use following parts installed when transported.


07371-30640(4): FLANGE
07395-21035(8): BOLT

No.
A-6
Precautions

2) When connecting, take care not to break the


tube.

Name

Qty
1

KW12P Impact wrench

17 mm Socket

19 mm Socket

39

Q'ty
2

Equipment required

KW10P Impact wrench

Others

1) When connecting the crawler frame, remove


the bolts and bracket marked with .

Tools required

Part No.
07000-B3025

Name

Qty

Assembly procedure

Travel motor piping

A-3

Connect

Use following parts installed when transported.


07371-51470(8): FLANGE
01010-81455(16): BOLT
01643-31445(16): WASHER

Return piping which was removed


when track frame and center frame
were connected.
No.
A-7
A-8

Precautions

Tools required
Name

1) Take care that dirt will not enter the piping.

Qty
1

KW12P Impact wrench

KW14P Impact wrench

17 mm Socket

19 mm Socket

150 mm Extension

300 mm Extension

24 mm Spanner

32 mm Spanner

40

Q'ty
4
2

Equipment required

KW10P Impact wrench

Others

2) The hoses are installed to the travel motor.

Part No.
07000-B3048
02896-61018

Name

Qty

Assembly procedure

A-4

Installation of travel motor cover (1/2)

Crawler frame
Travel motor cover

Travel motor guard

Precautions
Travel motor guard is installed to crawler
frame assembly when transported.
Travel motor cover is installed temporarily to
crawler frame assembly when transported.

Tools required
Name

Equipment required
Qty

KW12P Impact wrench

19 mm socket

a Before performing this item, bleed air from

Others

the travel motor.

41

Name

Qty

Assembly procedure

A-4

Installation of travel motor cover (2/2)

Right side
Left side

No.
A-9
A-10
A-11
A-12
A-13
A-14
A-15
A-16
A-17
Precautions

Tools required
Name

Qty
1

19 mm socket

Others

Q'ty
4
4
12
16
12
1
1
10
10

Equipment required

KW12P Impact wrench

42

Part No.
01024-81235
424-54-14230
01024-81230
21N-30-11340
01641-21223
21T-30-32172
21T-30-32182
01010-82460
17A-54-44130

Name

Qty

Assembly procedure

Filling swing circle with grease

A-5

Grease bath seal (all round)

4) Apply gasket sealant LG-6


to top of swing bearing.
See Note 2.

1) Fill the swing circle grease bath with grease (G2-LI).

See Note 1.
2) Apply grease to the swing circle gear contact faces. (Approx. 10 L in 80 L shown above)
3) Fill the grease bath seal with grease.

(Note 1)

(Note 2)

G2-LI

Apply LG-6 to swing circle gear


side of outer race mounting bolts.
(gasket sealant)

Supply grease near


swing circle gear.
Grease bath seal

Precautions

Tools required
Name

1) Supply grease (G2-LI) of 4


20 l (18 kg) pales = 80 l (72 kg).
2) Clean the swing circle mounting face.

Others

3) Remove the rust preventive.


(If any rust preventive is left, the bolt
torque will be decreased.)

43

Equipment required
Qty

Name

Qty

Assembly procedure

A-6

Assembly of revolving frame assembly


and undercarriage (1/2)

1) Positioning of crane and revolving frame

2) Method of slinging front end


Rear of boom foot pin

3) Method of slinging rear end

When installing revolving frame assembly to


undercarriage, remove transportation jigs.

Sling front and rear ends simultaneously with 2 truck cranes.

Precautions

Tools required

Name

Fix the ropes to the hook securely.

See above.
SC55 shackle = 18 t
(Inside width: 83 mm)
SC40 shackle = 10 t
Take care of the center of
gravity of the crane hook.
If the hook is loaded,
the boom lowers a little.

aRemove the rust preventive from the mounting faces of the revolving frame
and swing circle and from the inside face of the taps and then clean those
faces. (If any rust preventive is left, the bolt torque will be decreased.)

Others

aWhen slinging the revolving frame, adjust it to the horizontal in each


direction with shackles.

44

Equipment required
Qt

Name

Qt

Assembly procedure

A-6

Assembly of revolving frame assembly


and undercarriage (2/2)

1) Clean the mounting surface.


2) Align the dowel pin with the dowel pin hole of the swing circle.

Dowel pin

3) Sling and couple the revolving frame.


Take care not to hit it against the swivel joint and grease bath.
4) Tighten all the bolts lightly.
Retighten them after finishing assembly.
Width across flats
3 Tightening torque :
250 -- 310 kgm
Apply LT-2.

Revolving frame assembly

Apply LG-6 (TB1215) all round revolving


frame coupling surface without leaving any
breaks. (Apply to inside of bolt holes.)

3 Tightening torque :
2450 -- 3040 Nm {250 -- 300 kgm}
Apply LT-2.

Right

Rear
a Sling horizontally to protect the pinion.

Left

Front

No.
B-1
B-2

5) Tighten the 3 bolts on each side, front 8 bolts and rear 3 bolts (17 in total) in figure
to the specified torque.

Precautions

a When disassembling to 27 t, install swing


machinery later.
a When disassembling to 32 t, raise the
motor.
See Installation of swing machinery (A-7).

Take care of the center of


gravity of the crane hook.
If the hook is loaded,
the boom lowers a little.

Name

Qt

KW45F Impact wrench

19 mm Socket

For retightening

KW45FG Impact wrench

55 mm Spline socket

Tap (M36 3)

45

Q'ty
60
60

Equipment required

For temporary tightening

Others

Fix the ropes to the hook securely.

Tools required

Part No.
21T-25-67150
01643-33690

Name

Qt

Assembly procedure

A-7

Installation of swing machinery (front) assembly (27t)


Installation of swing motor (front) assembly (32t)

Swing machinery (front) assembly


1140 kg

155 195 kgm

Swing motor (front) assembly


Connection at
5 places

Use split flanges and bolts


installed when transported.
07371-31049(6): FLANGE
07375-21035(12): BOLT

No.
B-3
B-4
B-5
B-6
B-7
B-8
B-9

Coupling
Precautions

Name
KW45F Impact wrench
46 mm Box
Joint
KW10P Impact wrench
14 mm Box
19 mm Set wrench
19 mm Spanner
32 mm Set wrench
32 mm Spanner

Others

a When connecting the revolving frame to the


undercarriage, raise the swing motor
assembly (front). (200 mm)
After connecting the revolving frame to the
undercarriage, reinstall the swing motor
assembly. (When disassembled to 32 t)

Tools required

46

Part No.
01010-83090
01643-33080
07000-B3032
07000-B3032
02896-61015
02896-61008
01024-81225

Q'ty
14
14
1
2
1
1
1

Equipment required
Qty
1
1
1
1
1
1
1
1
1

Name

Qty

Assembly procedure

A-8

Connection of swivel joint piping (1/2)

To drain filter

Connection

Coupling

Connection

No.
B-10
B-11
Precautions

Name

Qty
1

22 mm Socket

150 mm Extension

41 mm Spanner

Pliers

Set wrench

47

Q'ty
1
4

Equipment required

KW14PI Impact wrench

Others

a Connect the travel piping before installing


the swing machinery.

Tools required

Part No.
11Y-62-11980
02896-61009

Name

Qty

Assembly procedure

A-8

Connection of swivel joint piping (2/2)

If installed angle of
pipe is not proper
when connected,
loosen opposite side
and then install.

Use following parts installed when transported.


07371-51470(8): FLANGE
01010-81455(16): BOLT
01643-31445(16): WASHER

Connection

No.
B-12
Precautions

Tools required
Name

Qty
1

22 mm Socket

150 mm Extension

41 mm Spanner

Pliers

Others

Q'ty
4

Equipment required

KW14PI Impact wrench

48

Part No.
07000-B3048

Name

Qty

Assembly procedure

A-9

Connection of swing circle grease piping

Connection

Precautions

Tools required
Name

Equipment required
Qty
1

19 mm Spanner

Others

17 mm Spanner

49

Name

Qty

Assembly procedure

Installation of hydraulic tank assembly (1/5)

A-10

For disassembly to 27 t

Hydraulic tank assembly


1670 kg

Use bolts and washers installed when


transported.
01024-81235(8): BOLT

3 Tightening torque :
1520 -- 1910 Nm {155 -- 195 kgm}
Connection

Suction tubes are installed temporarily


to chassis when transported.
3 Tightening torque for U-clamp
35.3 -- 87.2 Nm {3.6 -- 8.9 kgm}

3 Tightening torque for coupling


6.4 -- 7.4 Nm {0.65 -- 0.75 kgm}
No.
B-13
B-14
B-15
Precautions

Tools required
Name

a Before connecting the revolving frame to

Others

the undercarriage, install the hydraulic


tank.

50

Part No.
07000-B5230
01011-83010
21T-26-11460

Q'ty
2
12
12

Equipment required
Qty

Name

Qty

Assembly procedure

A-10

Installation of hydraulic tank assembly (2/5)

For disassembly to 27 t

Clamp air conditioner hoses


at 4 places marked with .

Clamp PPC hoses


at 2 places marked with

Precautions

Tools required

Others

Name

51

Equipment required
Qty

Name

Qty

Assembly procedure

A-10

Installation of hydraulic tank assembly (3/5)

For disassembly to 27 t

Use split flanges and bolts installed when transported.


07371-32076(16): FLANGE
07375-21240(32): BOLT

Connection at
5 places

Clamp hose.
No.
B-16
Precautions

Tools required

Others

Name

52

Part No.
07000-B2060

Q'ty
8

Equipment required
Qty

Name

Qty

Assembly procedure

A-10

Installation of hydraulic tank assembly (4/5)

For disassembly to 27 t

Use split flanges and bolts installed when transported.


07371-31049(2): FLANGE
07375-21035(4): BOLT
Connection at
4 places

No.
B-17
B-18
Precautions

Tools required

Others

Name

53

Part No.
11Y-62-11980
07000-B3032

Q'ty
3
1

Equipment required
Qty

Name

Qty

Assembly procedure

Installation of hydraulic tank assembly (5/5)

A-10

For disassembly to 27 t

Clamp wiring harness


(Side of vertical panel of revolving frame).

Clamp wiring harness


(L-bracket in cab base).

Connect wiring harness connector


(inside of cab base).

Pull wiring harness into cab base


through this grommet.

Precautions

Tools required
Name

Precautions to be observed when connecting


DT, DTP or DTHD connector
After connecting the connector, check visually
that the connector is locked securely.
If the connector is not locked securely,
reconnect it.

When unlocked

Others

When locked

54

Equipment required
Qty

Name

Qty

Assembly procedure

Installation of fuel tank assembly

A-11

Fuel tank assembly

50 t Crane

2,400 kg (including 400 L of fuel)

Bolt

Collar
No.
C-1
C-2

Precautions

Tools required
Name

Qty
1

46 mm Socket

12 5 m Wire

Eyebolt M30-P3

Others

Q'ty
20
20

Equipment required

KW45F Impact wrench

55

Part No.
01011-83010
21T-26-11460

Name
45t Crane

Qty
1

Assembly procedure

A-12

Connection of fuel tank assembly


piping and wiring (1/2)

Fuel piping
1. Connection of return and spill lines
1) Remove the blind plugs of the return and spill lines.
2) Connect the return and spill lines marked with and fix them with the clamps.

O-ring

Return line
Band marker: Red

Spill line
Band marker: None
Clamp

Bolt

2. Connection of drain and supply lines


1) Remove the transportation clamps of the drain line marked with A.
Keep 1 of the 2 clamps to use in 3).
2) Remove the blind plugs of the drain and supply lines.
3) Connect the drain and supply lines marked with w.
O-ring
Delivery line

O-ring

Drain line
Reused clamp
No.
C-3
C-4
C-5
C-6
C-7
Precautions

Tools required
Name

Qty
1

32 mm Spanner

36 mm Spanner

19 mm Socket

KW14PI Impact wrench

Others

Q'ty
1
1
2
2
1

Equipment required

27 mm Spanner

56

Part No.
04435-52212
02896-61012
02896-61015
02896-61018
01024-81220

Name

Qty

Assembly procedure

Connection of fuel tank assembly


piping and wiring (2/2)

A-12
Electric wiring

Clamp

Bolt

1. Clamp the wiring harness to the grease can bracket.


4 places marked with

Clamp

2. Connect the wiring harness connector marked with

Bolt

No.
C-8
C-9
C-10
Precautions

Tools required
Name

Precautions to be observed when connecting


DT, DTP or DTHD connector
After connecting the connector, check visually
that the connector is locked securely.
If the connector is not locked securely,
reconnect it.

When unlocked

Others

When locked

57

Part No.
04434-52312
04434-51912
01024-81220

Q'ty
1
3
4

Equipment required
Qty

Name

Qty

Assembly procedure

A-13

Installation of cab base assembly (1/2)

Cab front catwark


100 kg
Mounting bolt of
cab base assembly

Cab base assembly


2300 kg

Cab left catwark


220 kg
Mounting bolt of
cab base assembly

No.
C-11
C-12
C-13
C-14
C-15
Precautions

Tools required
Name

a Install the catwalks while the cab base is

Qty
1

30 mm Socket

12 5 m Wire

SC14 Shackle

58

Q'ty
10
10
1
1
2

Equipment required

KW20PI Impact wrench

Others

on the ground.

Part No.
01034-81245
01034-81265
21T-54-31140
21T-54-31150
01034-81245

Name
45t Crane

Qty
1

Assembly procedure

A-13

Installation of cab base assembly (2/2)

C-18

C-18

C-16

C-18

C-17

No.
C-16
C-17
C-18
Precautions

C-16

Tools required

Others

Name

59

Part No.
01011-82025
01011-82045
567-40-41380

Q'ty
20
7
27

Equipment required
Qty

Name

Qty

Assembly procedure

A-14

Installation of left floor assembly (1/4)

Install eyebolt.

Install eyebolt.

Precautions

Sling jig

Install eyebolt.

Tools required
Name

Others

After the work, return the bolts removed to


install the eyebolts.

60

Equipment required
Qty

Name

Qty

Assembly procedure

Installation of left floor assembly (2/4)

A-14

C-20

C-19

Part a

C-20

C-19

C-20

C-19

Part b
No.
C-19
C-20
Precautions

Tools required
Name

Others

Before tightening the mounting bolts at parts


(a) and (b), check that both mating faces are
fitted to each other.

61

Part No.
01010-82065
01643-32060

Q'ty
24
24

Equipment required
Qty

Name

Qty

Assembly procedure

Installation of left floor assembly (3/4)

A-14

Clearance b

Clearance a

Shim Shim
C-21

Adjust clearance at this part,


if necessary, by inserting shim
under condenser box.

C-22

Condenser box

C-23

t1.2
t1.6

Precautions

Tools required
Name

Clearance a: 15 mm 10 mm
(Reduce difference between widest and
narrowest clearances to 3 mm or less)

Others

Clearance b: 17 mm 5 mm
(Reduce difference between widest and
narrowest clearances to 3 mm or less)

62

No.
C-21
C-22
C-23
C-24

C-24

Part No.
21T-53-31530
21T-53-31540
21T-54-33471
01034-81230

Q'ty
3
3
1
3

Equipment required
Qty

Name

Qty

Assembly procedure

A-14

Installation of left floor assembly (4/4)

<Adjustment of cab base door>


Adjust the projection of rubber stopper (a) at the door bottom and position of lock bar bracket (c) so that lock bar (b) at the door
top will clasp while rubber stopper (a) is in contact with the side cover.

Lock bar bracket (c)


Lock bar (b)

Rubber stopper (a)

63

Assembly procedure

A-15

Connection of cab base assembly piping (1/2)

25

Connection (Face seal)

Green
Brown
White
Black
Yellow
Blue
Red
No color mark
Black/Black
Blue/Black
Red/Black
Green/Black
Connection (Quick coupler)

No.
C-25
Precautions

Tools required
Name

Others

a Remove the hose cap.

64

Part No.
02896-61012

Q'ty
6

Equipment required
Qty

Name

Qty

Assembly procedure

A-15

Connection of cab base assembly piping (2/2)

Connection

Right wall in cab base

No.
C-26
Precautions

Tools required

Others

Name

65

Part No.
02896-61018

Q'ty
2

Equipment required
Qty

Name

Qty

Assembly procedure

A-16

Connection of cab base assembly wiring (1/5)

Pass wiring harness through hole.

Pass wiring harness


through hole.
Connection

Remove dust proof cap

Cap part No.


CN-A05
CN-A04
CN-A22
Precautions

Tools required
Name

When connecting the DRC multi-pole


connector, see "Precautions for connecting
DRC multi-pole connector" on pages 3/5 5/5
of this section.

Others

When connecting the DT, DTP or DTHD


connector, see "Precautions for connecting
DT, DTP or DTHD connector" on pages 5/5
of this section.

66

Male
21T-06-33810
21T-06-338A0
21T-06-33120
08191-00770(4)

Female
21T-06-33820
21T-06-33830
21T-06-33850
08191-00770(4)

Equipment required
Qty

Name

Qty

Assembly procedure

A-16

Connection of cab base assembly wiring (2/5)

Connection

Connection

Connection

Fix with clamps.

Precautions

Tools required
Name

When connecting the DT, DTP or DTHD


connector, see "Precautions for connecting
DT, DTP or DTHD connector" on pages 5/5
of this section.

Others

Remove the cover of part X when connecting


the wiring harness and install it again after
the work.

67

Equipment required
Qty

Name

Qty

Assembly procedure

A-16

Connection of cab base assembly wiring (3/5)

"Precautions for connecting DRC multi-pole connector"


Precautions to be observed when connecting DRC multi-pole connector
1. Before connecting

If the seal rubber is broken or deformed,


the connector may not be connected normally.
In this case, replace the connector with new one.

Check the edge for breakage or


deformation. If it has any
abnormality, replace the whole
connector with new one.

17A-06-41830
17A-06-41840

2. Preparation for connection


If the DRC multi-pole connector is at a high place, prepare a work stand so that you can stand stably and connect the connector while checking it visually.

Precautions

Tools required

Others

Name

68

Equipment required
Qty

Name

Qty

Assembly procedure

Connection of cab base assembly wiring (4/5)

A-16

3. Connecting method
1) Check that the key ways are aligned and then set the terminals to each other while setting the seal rubber edge to the
receptacle connector edge.
While swinging the connectors up and down and to the right and left so that the terminals will be in position and clearance "a" and "b", and "c" and "d" between the connectors will be the same respectively, tighten the center hexagon
socket head bolt 1 turn.

Receptacle connector edge


Seal rubber edge

Terminal

Up

Left

Right
Hexagon socket head bolt

Down
2) While swinging the connectors up and down and to the right and left again to adjust them finely so that clearance "a"
and "b", and "c" and "d" between the connectors will be the same respectively, tighten the bolt gradually. Repeat this
work several times.

Bottom view

Side view
Precautions

Tools required

Others

Name

69

Equipment required
Qty

Name

Qty

Assembly procedure

A-16

Connection of cab base assembly wiring (5/5)

3) After clearances "a" and "b", and "c" and "d" between the connectors become the same and below 1 mm, tighten the
hexagon socket head bolt to the following torque.

2.83 0.28 Nm {0.28 0.03 kgm}

Approx. 1 mm
4) Check after connection
Turn the key switch ON and check that the electric parts of the chassis are operating normally. (Observe the condition for several minutes after turning the key switch ON.)
Start the engine, move the work equipment, and check that the electric parts (monitors and lights) do not blink
because of vibrations.
If any abnormality is detected by the above 2 checks, disconnect the connector and check it for a problem, and then repeat
steps 1 - 3.

"Precautions for connecting DT, DTP or DTHD connector"


Precautions to be observed when connecting DT, DTP or DTHD connector
After connecting the connector, check visually that the connector is locked securely.
If the connector is not locked securely, reconnect it.

When locked

Precautions

When unlocked

Tools required

Others

Name

70

Equipment required
Qty

Name

Qty

Assembly procedure

A-17

Connection of left floor assembly heater piping

27

Distinction tape color: Blue

Connection

Distinction tape color: Red

No.
C-27
Precautions

Tools required

Others

Name

71

Part No.
21T-979-3320

Q'ty
2

Equipment required
Qty

Name

Qty

Assembly procedure

Connection of left floor assembly wiring

A-18

Front of machine

Left of machine

Connection

Connection

To cab

This cable is
described in A-27.

To air
conditioner
condenser

Right side of battery case

Top of air conditioner condenser

Precautions

Tools required
Name

Precautions to be observed when connecting


DT, DTP or DTHD connector
After connecting the connector, check visually
that the connector is locked securely.
If the connector is not locked securely,
reconnect it.

When unlocked

Others

When locked

72

Equipment required
Qty

Name

Qty

Assembly procedure

Installation of tail pipe

A-19

Top of power container

Front of machine

Left of machine
No.
D-1
D-2
D-3

Precautions

Tools required
Name

a Before performing this work, connect the

Others

container to the revolving frame.

73

Part No.
21M-01-18130
01024-81230
6162-14-5640

Q'ty
2
12
2

Equipment required
Qty

Name

Qty

Assembly procedure

A-20

Installation of power container assembly (1/2)

Power container assembly


16100 kg

Right rear stopper

Left rear stopper

Position container so that container frame will


touch positioning stopper of container mount
of revolving frame.

Precautions

Tools required
Name

a Before connecting the container, remove

Others

the undercover installed temporarily.


(See A-24.)

74

Equipment required
Qty

Name

Qty

Assembly procedure

A-20

Installation of power container assembly (2/2)

M42 3, L = 350 mm, Width across flats 65 mm


3 Tightening torque :
3430 -- 4212 Nm (350 -- 430 kgm)
Apply LT-2.

Nut is welded to
revolving frame.

Plate with nuts


4

No.
D-4
D-5
D-6
Precautions

Tools required
Name

Others

Retighten the bolts finally after installing the


counterweight for safety.

75

Part No.
21T-54-31121
21T-54-31130
01643-34212

Q'ty
4
20
20

Equipment required
Qty

Name

Qty

Assembly procedure

Connection of suction piping (1/2)

A-21

Use following parts installed


when transported.
01024-81230(4): BOLT

Use following parts installed when transported.


01010-81640(8): BOLT
01643-31645(8): WASHER

Replace band
(upper).

Replace band
(upper).

Connection

Main pump seen from below


No.
D-7
D-8
D-9
D-10
Precautions

Tools required
Name

Others

Since the suction tube is lowered when


delivered, prepare MIKALOR bands.
(See tightening procedure 2/2.)

76

Part No.
07000-B2140
07000-B2100
209-62-41341
20Y-62-51671

Q'ty
2
1
4
2

Equipment required
Qty

Name

Qty

Assembly procedure

Connection of suction piping (2/2)

A-21

1. Once a MIKALOR clamp is removed, do not use it again but replace it with new one.
2. Install MIKALOR clamp marked

as shown below.

(1) Adjust bridge position so that the bridge shoud go into the bottom of band of clamp as shown in the following figure.
(2) Tighten bolt so that dimension (a) should be below figure by using impact wrenchi.

Apply lubricating oil


(PANDO 18B made by Three Bond)
on thread of bolt
before tightening a bolt.

Bridge

Punch hole
The overlap of bridge and band.

No.

Clamp part No.

Dimension (a)

209-62-41341

15

0
-3

20Y-62-51671

20

0
-3

77

Assembly procedure

Connection of oil cooler piping and pump drain piping

A-22

Use following parts installed when transported.


07371-32076(14): FLANGE
07375-21240(28): BOLT

Connection

Temporarily
installed to hose
Connection at
3 places

Connection

No.
D-11
D-12
Precautions

Tools required
Name

Others

Take care that the O-ring will not be caught.

78

Part No.
07000-B2060
07298-02011

Q'ty
7
1

Equipment required
Qty

Name

Qty

Assembly procedure

A-23

Connection of fan motor drain piping

D-13
Use following parts installed when transported.
07371-31049(2): FLANGE
07375-21035(4): BOLT

Connection

No.
D-13
Precautions

Tools required

Others

Name

79

Part No.
07000-B3032

Q'ty
1

Equipment required
Qty

Name

Qty

Assembly procedure

A-24

Installation of suction unit undercover

Undercover is installed to
container when transported.

When connecting suction unit,


remove undercover, if necessary.
After connecting suction unit,
install undercover again.

Z
Precautions

Tools required

Others

Name

80

Equipment required
Qty

Name

Qty

Assembly procedure

A-25

Connection of delivery piping (1/2)

Remove the covers shown below.

Parts to be removed

Precautions

Tools required

Others

Name

81

Equipment required
Qty

Name

Qty

Assembly procedure

A-25

Connection of delivery piping (2/2)

Use following parts installed when transported.


07371-51470(8): FLANGE
01010-81455(16): BOLT
01643-31445(16): WASHER

Connection

Front end of power container

Left of machine

Front of machine

Precautions

Tools required
Name

Others

a Secure the scaffoldings.

82

No.
D-14

Part No.
07000-B3048

Q'ty
4

Equipment required
Qty

Name

Qty

Assembly procedure

Connection of pilot piping and fan motor piping

A-26

D-16

Use following parts installed when transported.


07371-31049(2): FLANGE
D-15
07375-21035(4): BOLT

Use following parts installed when transported.


07371-30640(4): FLANGE
07375-21035(8): BOLT

Front end of power container

Connection

Left of machine

No.

D-15

Front of machine
Precautions

D-16

Tools required

Others

Name

83

Part No.
07000-B3025
07000-B3032

Q'ty
2
1

Equipment required
Qty

Name

Qty

Assembly procedure

Connection of power container assembly


fuel piping (1/2)

A-27

Connection at
3 places
No.
D-17
D-18
Precautions

Tools required

3 Tightening torque for hose


A 177 245 Nm {18 25 kgm}
B 128 186 Nm {13 19 kgm}

Others

Name

84

Part No.
02896-61018
02896-61015

Q'ty
2
1

Equipment required
Qty

Name

Qty

Assembly procedure

A-27

Connection of power container assembly


fuel piping (2/2)

D-19

Connection

No.
D-19
Precautions

Tools required

Others

Name

85

Part No.
02896-61015

Q'ty
1

Equipment required
Qty

Name

Qty

Assembly procedure

A-28

Connection of power container assembly


air conditioner piping

Parts to be removed

Coat air conditioner lubrication oil


M24 (Width across flats: 27)
Container side is female.
Tightening torque 29.4 34.3 Nm

M24 (Width across flats: 27)


Container side is male.
Tightening torque 29.4 34.3 Nm

M22 (Width across flats: 24)


Container side is female.
Tightening torque 19.6 24.5 Nm

M22 (Width across flats: 24)


Container side is male.
Tightening torque 19.6 24.5 Nm

Connection

Remove hose dust caps and connect hoses.


M22
M24
Precautions

Tools required

Others

Name

86

Male
21F-979-3250
21F-979-3260

Female
21F-979-3220
21F-979-3230

Equipment required
Qty

Name

Qty

Assembly procedure

A-29

Connection of power container assembly


heater piping

Parts to be removed

Connection (Quick coupler)

Precautions

Tools required
Name

a Before connecting these hoses, connect

Others

all of the other heater hoses.

87

Equipment required
Qty

Name

Qty

Assembly procedure

Connection of power container assembly


wiring (1/2)

A-30

<Caution>
Connect the battery cable after all the
wiring harnesses are connected.

Front of machine
Left of machine

To ground seat of
revolving frame vertical plate

Connection
Fix 2 terminals together.

CNT02
CNT01

Connection

Connection
May be connected to either one.

Connection
Fix 2 terminals together.
Remove cover and connect terminals in it.
After connecting, install cover again.

Precautions

Tools required

Others

Name

88

Equipment required
Qty

Name

Qty

Assembly procedure

Connection of power container assembly


wiring (2/2)

A-30

Left of machine

Front of machine

Pass wiring harness


through hole.

Pass wiring harness


through hole.

Connection
No.
D-19
D-20
Precautions

Tools required
Name

Precautions to be observed when connecting


DT, DTP or DTHD connector
After connecting the connector, check visually
that the connector is locked securely.
If the connector is not locked securely,
reconnect it.

When unlocked

Others

When locked

89

Part No.
08028-55065
01024-81020

Q'ty
2
2

Equipment required
Qty

Name

Qty

Assembly procedure

Installation of operator's cab assembly (1/3)

A-31

Operator's cab assembly

When installing cab,


remove mount cover
and stopper bracket
(see next page).

Precautions

Tools required

Others

Name

90

Equipment required
Qty

Name

Qty

Assembly procedure

Installation of operator's cab assembly (2/3)

A-31

Left of machine

Front of machine

Stopper bracket is installed


to cab base temporarily.
Adjust so that clearance
will be 1.5 3 mm or less
when operator is seated.

When installing operator's cab assembly, set


dowel pins of viscous mount to mating holes
so that they will not be broken.

Right and left mounts (J) - (P)

No.
E-1
E-2
E-3
Precautions

Tools required

Others

Name

91

Part No.
21T-54-36661
21T-54-36671
21T-54-35321

Q'ty
16
8
8

Equipment required
Qty

Name

Qty

Assembly procedure

Installation of operator's cab assembly (3/3)

A-31

STANDARD QUANTITIES OF SHIM


STD
FG
QUANTITIES QUANTITIES

PORTION

PART NUMBER

21T-54-36671

21T-54-36671

21T-54-36671

21T-54-36671

21T-54-36671

PART NUMBER

STD
FG
QUANTITIES QUANTITIES

F
G
H

Precautions

Tools required

Others

Name

92

Equipment required
Qty

Name

Qty

Assembly procedure

Installation of rotary lamp (if equipped) (1/2)

A-32

Left of machine

Front of machine

E-4

E-5

E-6

Connection

No.
E-4
E-5
E-6
Precautions

Tools required
Name

Precautions to be observed when connecting


DT, DTP or DTHD connector
After connecting the connector, check visually
that the connector is locked securely.
If the connector is not locked securely,
reconnect it.

When unlocked

Others

When locked

93

Part No.
8295-06-1480
21T-06-17430
01024-81225

Q'ty
1
1
2

Equipment required
Qty

Name

Qty

Assembly procedure

Installation of rotary lamp (if equipped) (2/2)

A-32

Front of machine

Left of machine

E-7
E-8
E-9

E-10

Connection

E-11

E-12
No.
E-7
E-8
E-9
E-10
E-11
E-12
Precautions

Tools required
Name

Precautions to be observed when connecting


DT, DTP or DTHD connector
After connecting the connector, check visually
that the connector is locked securely.
If the connector is not locked securely,
reconnect it.

When unlocked

Others

When locked

94

Part No.
8295-06-1480
21T-06-33610
21T-06-17430
01024-81225
04434-51012
01024-81220

Q'ty
1
1
1
2
1
1

Equipment required
Qty

Name

Qty

Assembly procedure

A-33

Installation of ORBCOMM antenna

Left of machine
To be tightened together
with wiring harness.

Front of machine

E-13

E-14

No.
E-13
E-14
E-15
Precautions

Tools required

Others

Name

95

E-15

Part No.
8A13-10-2100
21T-06-64491
01024-81225

Q'ty
1
1
1

Equipment required
Qty

Name

Qty

Assembly procedure

Connection of operator's cab assembly wiring

A-34

To ORBCOMM antenna

Built-on clamp

CN-A01 (Stamp A)
CN-A02 (Stamp B)
CN-A03 (Stamp C)

Connection

Cab base ceiling


Inside right of cab base
(Inside switch board)

Precautions

Tools required
Name

Precautions to be observed when connecting


DT, DTP or DTHD connector
After connecting the connector, check visually
that the connector is locked securely.
If the connector is not locked securely,
reconnect it.

When unlocked

Others

When locked

96

Equipment required
Qty

Name

Qty

Assembly procedure

A-35

Connection of operator's cab assembly


hydraulic piping (1/2)

Precautions

Tools required

Others

Name

97

Equipment required
Qty

Name

Qty

Assembly procedure

Connection of operator's cab assembly


hydraulic piping (2/2)

A-35

Red

Blue/Black
Blue/Blue

Red/White

Red

Black/Black
Blue/White

Red/Black

Green/Black

Blue

Connection (Quick coupler)

Brown

Green

Black

White

Yellow

Blue

No color mark

Red

Connection (Face seal)

No.
E-16
E-17

Precautions

Tools required

Others

Name

98

Part No.
02896-61012
02896-61009

Q'ty
10
2

Equipment required
Qty

Name

Qty

Assembly procedure

Connection of operator's cab assembly


window washer hose

A-36

Connection
Upper washer hose
Lower washer hose
Tanks A and B may
be connected to
either of upper and
lower washer hoses.

Inside right of cab base

Precautions

Tools required

Others

Name

99

Equipment required
Qty

Name

Qty

Assembly procedure

Connection of operator's cab assembly


air conditioner piping

A-37

Bind 2 pieces by 2.
To cab
To cab
To compressor

Cab side

Connection (2 pcs.)
Discharge line
M16 1.5
Connection (2 pcs.)
Liquid line
M16 1.5

Connection (2 pcs.)
Coated with adhesive
Suction line
M24 1.5
After connection, wind seal
onto adapter.

After connection, wind seal onto adapter.

No.
E-18
E-19

Precautions

Tools required
Name

1. Apply compressor oil to the threaded


parts and O-rings.

Others

2. Tightening torque
M24 1.2 1.5 kgm
M16 3.0 3.5 kgm

100

Part No.
21T-979-4421
08034-20830

Q'ty
4
2

Equipment required
Qty

Name

Qty

Assembly procedure

Connection of operator's cab assembly heater piping

A-38

Insert coolant drain hoses


(2 pcs).

Connection (4 pcs.)

Bind cables in fours.

Bind cables in twos

Bind cables in twos

Rear of cab seen from below

White tape Red tape


No.
E-20
Precautions

Tools required

Others

Name

101

Part No.
08034-20830

Q'ty
3

Equipment required
Qty

Name

Qty

Assembly procedure

A-39

Installation of operator's cab rear floor assembly

Operator's cab rear floor assembly

Left of machine

E-21

Front of machine

E-21

Clamp air conditioner piping.

No.
E-21
Precautions

Tools required

Others

Name

102

Part No.
01024-81225

Q'ty
14

Equipment required
Qty

Name

Qty

Assembly procedure

A-40

Installation of handrail around operator's cab

No.
E-22
E-23
Precautions

Tools required

Others

Name

103

Part No.
21T-54-33931
01034-81245

Q'ty
1
10

Equipment required
Qty

Name

Qty

Assembly procedure

Installation of track frame ladder

A-41

No.
F-1
F-2
F-3
F-4
F-5
Precautions

Tools required

Others

Name

104

Part No.
21T-30-32231
21T-30-32241
01010-81640
01010-82450
01643-32460

Q'ty
2
2
8
8
16

Equipment required
Qty

Name

Qty

Assembly procedure

A-42

Installation of power container side


catwalk assemblies (right and left)

Front of machine
Power container side
catwalk assembly

Left of machine

Right assembly:
Without wiring
harness bracket on
underside

Left assembly:
With wiring harness
bracket on underside

No.
F-6
Precautions

Tools required

Others

Name

105

Part No.
01034-81235

Q'ty
16

Equipment required
Qty

Name

Qty

Assembly procedure

Installation of right floor assembly


and grease can cover assembly

A-43

Left of machine

Front of machine

F-8

F-7

F-9

F-9

Grease can cover assembly

F-10

F-11

F-13

F-12
Right floor assembly

No.
F-7
F-8
F-9
F-10
F-11
F-12
F-13
Precautions

Tools required
Name

Others

When slinging the grease can cover


assembly, open the top cover and
use the hanging holes in it.

106

Part No.
01010-82080
01010-82060
01643-32060
21T-53-31550
21T-54-31560
21T-54-33331
01034-81250

Q'ty
12
8
20
1
1
1
4

Equipment required
Qty

Name

Qty

Assembly procedure

A-44

Installation of fuel tank right catwalk assembly

Left of machine

Front of machine

F-14

Fuel tank right catwalk assembly

No.
F-14
Precautions

Tools required

Others

Name

107

Part No.
01034-81235

Q'ty
16

Equipment required
Qty

Name

Qty

Assembly procedure

A-45

Installation of fuel tank front catwalk assembly

Left of machine
Front of machine

F-15
(6)

Fuel tank front catwalk assembly

No.
F-15
Precautions

Tools required

Others

Name

108

Part No.
01034-81250

Q'ty
6

Equipment required
Qty

Name

Qty

Assembly procedure

Adjustment of exterior parts clearance

A-46

When and after assembling the exterior parts, adjust each clearance as shown below.

Clearance: 20 5 mm
Clearance: 15 5 mm
Clearance: Max. 30 mm
Clearance: 15 5 mm

Clearance: 20 5 mm
Reduce the level difference between the outside surfaces of adjacent exterior covers to 5 mm or less.
Reduce the level difference between the underside surfaces of adjacent exterior covers to 7 mm or less.

109

Assembly procedure

Connection of grease reel piping

A-47

Left of machine
Front of machine

Connection

Connection

Precautions

Tools required

Others

Name

110

Equipment required
Qty

Name

Qty

Assembly procedure

Installation of slide ladder assembly (1/2)

A-48

Front of machine

Left of machine

Remove right deck


sling bracket in advance.

Slide ladder assembly

No.
F-16
F-17
Precautions

Tools required

Others

Name

111

Part No.
01010-82050
567-40-41380

Q'ty
6
6

Equipment required
Qty

Name

Qty

Assembly procedure

Installation of slide ladder assembly (2/2)

A-48

Clamp wiring harness.

Precautions

Tools required
Name

Precautions to be observed when connecting


DT, DTP or DTHD connector
After connecting the connector, check visually
that the connector is locked securely.
If the connector is not locked securely,
reconnect it.

When unlocked

Others

When locked

112

Equipment required
Qty

Name

Qty

Assembly procedure

A-49

Installation of counterweight assembly

Counterweight assembly
24500 kg

M42 3, L = 670 mm,


Width across flats 65 mm
3 Tightening torque :
3430 -- 4212 Nm
{350 -- 430 kgm}

No.
F-18
F-19
F-20
F-21
F-22
Precautions

Name
Tap (M42 3)

113

Q'ty
12
12
2
2
12

Equipment required
Qty
1

Others

Tighten all the bolts temporarily first, then


tighten them permanently.
Take measures to prevent seizure of the
bolts.

Tools required

Part No.
21T-46-34120
209-46-11210
21T-46-34141
21T-46-34131
01024-81225

Name

Qty

Assembly procedure

A-50

Installation of handrail on counterweight

No.
F-23
F-24
F-25
Precautions

Tools required

Others

Name

114

Part No.
21T-54-34411
21T-54-34421
01034-81250

Q'ty
1
1
16

Equipment required
Qty

Name

Qty

Assembly procedure

A-51

Installation of handrail clamps (1/3)

When installing, use screw


as positioning jig.

Screw

7 places marked with


No.
F-26
F-27
F-28
F-29
Precautions

Tools required

Others

Name

115

Part No.
21T-54-32911
21T-54-32921
01034-81245
21T-54-65810

Q'ty
7
7
14
1

Equipment required
Qty

Name

Qty

Assembly procedure

A-51

Installation of handrail clamps (2/3)

Precautions

Tools required

Others

Name

116

Equipment required
Qty

Name

Qty

Assembly procedure

A-51

Installation of handrail clamps (3/3)

When installing, use screw


as positioning jig.
No.
F-30
F-31
F-32
Precautions

Tools required

Others

Name

117

Part No.
21T-54-31140
21T-54-31150
01034-81245

Q'ty
1
1
2

Equipment required
Qty

Name

Qty

Assembly procedure

Connection of fuel cut wire

A-52

Fuel cut wire

<Procedure>
(1) Remove the cotter pin of the fuel
cut wire connecting pin and then
remove the wire.
Step

(2) Pass the wire through the hole of


the step and connect it to the pin
again. Reuse the cotter pin.

Fuel cut wire

Precautions

Tools required

Others

Name

118

Equipment required
Qty

Name

Qty

Assembly procedure

Connection of drain piping under power container

A-53

Front of machine

Left of machine

3 Tightening torque :
128 186 Nm
{13 19 kgm}

F-34

F-33

Clamp
See Note 1.
Clamp

Clamp
Connection

Connection

3 Tightening torque :
3.91 4.89 Nm
{0.40 0.50 kgm}

Coolant drain
Engine breather
Muffler drain

Engine oil drain

PTO oil drain

Precautions

Tools required
Name

Note 1

Project the ends of engine breather pipe


and muffler drain pipe 10 mm from
the underside of the revolving frame.

Others

Underside of
revolving frame

119

No.
F-33
F-34

Part No.
21T-01-31471
07005-02416

Q'ty
1
1

Equipment required
Qty

Name

Qty

Assembly procedure

Connection of battery wiring

A-54

See A-30 Connection of power container assembly wiring

Precautions

Tools required

Others

Name

120

Equipment required
Qty

Name

Qty

Assembly procedure

Setting of hydraulic tank strainer

A-55

Remove the suction pipe blind plug in the


hydraulic tank and set the strainer.

Door cover

Flange assembly (2)

(1) Open the hydraulic tank


upper door cover.

(2) Remove the flange


assembly.

(3) (After removal)

Strainer assembly (2)

(4) Pull up the strainer


assembly.

(5) Reverse the strainer


assembly and insert it in
the hydraulic tank again.

Precautions

Tools required
Name

Others

Carry out the above work after installing the


suction piping and hydraulic pump.
Before starting the engine, check that the
strainer is set downward.

121

(6) Install the flange


assembly and close the
door cover.

Equipment required
Qty

Name

Qty

Assembly procedure

A-56

Starting of engine, inspection of oil levels and coolant


levels, bleeding air and adjustment of track (1/19)

1. Inspection and addition of each oil and coolant --- See the M1 and Operation and Maintenance Manual for each item.
Inspection and addition of coolant
Inspection and addition of oil in engine oil pan
Inspection of fuel
Inspection and addition of oil in hydraulic tank
Inspection and addition of oil in PTO case
Inspection and addition of oil in swing machinery case
Inspection and addition of oil in final drive case
2. Check for oil leakage
3. Bleeding air from fuel circuit
a If fuel is used up or if a fuel circuit part is removed and
installed, bleed air from the fuel circuit according to the
following procedure.
Reference
The Komatsu genuine fuel filter cartridge employs a
high-efficiency special filter. Always use it.
The common rail fuel injection system used on this
machine consists of more precise parts than the
conventional fuel injection pump and nozzle. If a filter
cartridge other than the Komatsu genuine one is used,
foreign matter may enter the fuel system and may cause
a trouble in the system. Accordingly, never use a
substitute.
When checking or servicing the fuel system, take care of
entry of foreign matter more than ever. If dirt sticks, wash
it off with fuel.
1. Replacing prefilter cartridge or bleeding air from it
1) Pull fuel shut-off lever (1) installed to the front of the
main pump in the pump room to close the fuel supply
circuit from the fuel tank.

122

Assembly procedure

A-56

Starting of engine, inspection of oil levels and coolant


levels, bleeding air and adjustment of track (2/19)

2) Set a container to receive oil under the fuel prefilter


cartridge.
3) Remove the drain hose (4) of cup (3) of the water
separator.
4) Using the filter wrench, turn filter cartridge (2) to the
left to remove.
5) Turn cup (3) of the water separator installed to the
bottom of the removed cartridge to the left to remove.
(This cup will be reused.)
6) Install removed cup (3) to the new fuel prefilter
cartridge. (At this time, be sure to use a new O-ring.)
3 Cup: 10 Nm {1.0 kgm}

7) Clean the filter stand. Fill the new or reused filter


cartridge with clean fuel, apply oil to the packing
surfaces thinly, and install the cartridge to the filter
stand.
a Add fuel through 8 small holes (a) on the dirty side
without removing cap (b) at the center.
a After adding fuel, remove cap (b) at the center
and install the fuel filter.
a Fill the fuel filter with clean fuel and take care that
dirt will not enter it. Since the center is the clean
side, do not remove cap (b) when adding fuel, and
particularly take care that dirt will not enter it.

123

Assembly procedure

A-56

Starting of engine, inspection of oil levels and coolant


levels, bleeding air and adjustment of track (3/19)

8) When installing the filter cartridge, tighten it 3/4 turns


after its packing surface touches the seal surface of
the filter stand.
a If the filter cartridge is tightened too much, fuel will
leak because of damage of the packing. If the filter cartridge is not tightened sufficiently, fuel will
also leak through the clearance of the packing.
Accordingly, observe the tightening angle.
When tightening the filter cartridge with the filter
wrench, take care extremely not to scratch or
dent the filter.
9) Install the drain hose.
10) Check that the drain plug at the cup bottom of the
water separator is tightened securely.
3 Drain plug:
0.2 0.45 Nm {0.02 0.046 kgm}
11) When replacing the standard fuel filter cartridge (every 1,000 hours) or bleed air from it, see Replacing
main filter cartridge.
12) Press down fuel cut lever (1) installed to the front of
the main pump in the pump room to supply the fuel.
13) Start the engine and check the filter seal surface and
water separator mounting surface for fuel leakage
and then run the engine at low idle for about 10
minutes.

2. Replacing main filter cartridge or bleeding air from it


1) Replacing main filter cartridge
1] Pull fuel shut-off lever (1) installed to the front of
the main pump in the pump room to close the fuel
supply circuit from the fuel tank.

124

Assembly procedure

A-56

Starting of engine, inspection of oil levels and coolant


levels, bleeding air and adjustment of track (4/19)

2] Set a container to receive oil under the filter cartridge.


3] Using the filter wrench, turn filter cartridge (5) to
the left to remove.
4] Clean the filter stand. Thinly apply oil to the packing of the new filter cartridge and install the cartridge to the filter stand.
a Do not add fuel to the fuel filter cartridge.
a Remove cap (b) at the center and install the
fuel filter.
5] When installing the filter cartridge, tighten it 3/4
turns after its packing surface touches the seal
surface of the filter stand.
If the filter cartridge is tightened too much, fuel
will leak because of damage of the packing. If the
filter cartridge is not tightened sufficiently, fuel will
also leak through the clearance of the packing.
Accordingly, observe the tightening angle.
When tightening the filter cartridge with the
filter wrench, take care extremely not to
scratch or dent the filter.
6] After replacing filter cartridge (5), loosen its air
bleeding plug (6) and press down fuel shut-off
lever (1) to open the fuel supply circuit from the
fuel tank.
a Open the circuit in the reverse order to closing.

125

Assembly procedure

A-56

Starting of engine, inspection of oil levels and coolant


levels, bleeding air and adjustment of track (5/19)

2) To bleed air when fuel is used up, perform the following air bleeding procedure taken after replacement of
the main filter cartridge.
3) Bleed air according to the following procedure.
1] Fill the fuel tank with fuel (to the FULL mark of
the fuel level gauge).
2] After replacing filter cartridge (5), loosen air
bleeding plug (6).
3] Remove locknut (8) of priming pump lever (7),
operate priming pump lever (7), and check that
fuel and bubbles flow out of air bleeding plug (6).
4] Tighten air bleeding plug (6).
3 Plug: 4.9 6.9 Nm {0.5 0.7 kgm}
5] Push in priming pump lever (7) and tighten locknut (8) to lock it.
6] After replacing the filter cartridge, start the engine
and check the filter seal surface for fuel leakage.

126

Assembly procedure

A-56

Starting of engine, inspection of oil levels and coolant


levels, bleeding air and adjustment of track (6/19)

4. Air bleeding from each component


(1) Air bleeding from hydraulic pump

a After removing and installing the hydraulic pump or


changing hydraulic oil, bleed air from the hydraulic pump
according to the following procedures.
k If air was not bled or air was bled insufficiently, the
pump may be broken. So, be sure to bleed air strictly
according to the procedures.
1) Loosen bleeders (1) (3) of all hydraulic pump 1 or 2
turns at the same time.
a Connect a tube [1] to each bleeder to prevent oil
from being scattered and to receive oil in oil pan.
2) Feed hydraulic oil up to the specified level.
a Even after feeding oil to the hydraulic tank, keep
the oil filler cap removed.
3) After oil flew out from bleeder (3) of the fan pump PF,
tighten bleeder (3) temporarily.
4) After bleeders (1) and (2) of the main pumps P1 and
P2 stop bleeding air, tighten only bleeder (2) of the
main pump P2 temporarily.
a Keep bleeder (1) of the main pump P1 loose.
5) Loosen plug (5) for suction tube and check that oil
flows out. Then, tighten the plug temporarily.
6) Crank the engine and make sure that oil flows out
from bleeder (1) of the main pump P1. Then, tighten
the bleeder temporarily.
a For cranking, idle the engine at low speed for 15
seconds twice.
7) Loosen the bleeder (2) of the main pump P2.

127

Assembly procedure

A-56

Starting of engine, inspection of oil levels and coolant


levels, bleeding air and adjustment of track (7/19)

8) Crank the rear engine and make sure that oil flows out of the bleeder (2) of the main pump P2. Then, tighten the bleeder
temporarily.
a For cranking, idle the engine at low speed for 15 seconds twice.
9) Start the engine and keep it idle at low speed.
10) Loosen the bleeders (1) (3) of all hydraulic pumps and make sure that bubble-free oil flows out of them. Then, tighten
these bleeders temporarily.
11) Close the oil filler caps of the hydraulic tank.
12) Keep the engine idling at low speed, raise the work equipment from the ground and swing the upper structure 180.
a After the swing, lower the work equipment completely to the ground.
13) Loosen plug (5) for the suction tube and make sure that bubble-free oil flows out of it. Then, tighten the plug.
3 Plug : 58.8 78.4Nm {6 8kgm}
14) Loosen the bleeders (1) (3) of all hydraulic pumps and make sure that bubble-free oil flows out of them. Then, tighten
these bleeders temporarily.
a This work is the same as in the above Step 10.
15) Keep the engine idling at low speed, raise the work equipment from the ground and swing the upper structure 180.
a Swing the upper structure in the reverse direction from the one in the above Step 12. After the swing, lower the work
equipment completely to the ground.
16) Loosen the bleeders (1) (3) of all hydraulic pumps and make sure that bubble-free oil flows out of them. Then, tighten
these bleeders.
3 Bleeder : 8.8 9.8Nm {0.9 1.0kgm}
17) Stop the engine.
18) Loosen the oil filler cap of the hydraulic tank slowly and remove it. Relieve pressure from the hydraulic tank and feed
hydraulic oil up to the specified level.
(2) Air bleeding from work equipment cylinder circuit
a When removing and installing the work equipment cylinder or when disconnecting and connecting the cylinder
circuit piping, bleed air from the work equipment cylinder
according to the following procedures.
k If air was not bled or air was bled insufficiently, the
cylinder piston ring may be broken. So, be sure to
bleed air strictly according to the procedures.
1) Start the engine and idle it at low speed for about 5
minutes.
2) Repeat raising and lowering the boom 4 or 5 times at
the low idle.
a Stop the piston rod about 100mm before the
stroke end and be careful not to relieve it.
3) Execute Step 2) at high idle.
4) Bring the piston rod to the stroke end at low idle and
relieve it.
5) Execute Steps 2) 4) for the arm and the bucket.
a When the cylinder was replaced, execute the procedures before connecting the work equipment.
Especially, when the boom cylinder was installed
to the work equipment, the lowering side does not
move to the stroke end.

128

Assembly procedure

A-56

Starting of engine, inspection of oil levels and coolant


levels, bleeding air and adjustment of track (8/19)

(3) Air bleeding from swing motor circuit (Swing motor)


a When removing and installing the swing motor or when
disconnecting and connecting the swing motor main circuit pipes, bleed air from the swing motor according to the
following procedures.
k If air was not bled or air was bled insufficiently, the
swing motor may be damaged. So, be sure to bleed
air strictly according to the procedures.
1) Start the engine and operate it while the engine is
idling at low speed.
2) Repeat operations of swing, start, and stop 5 or 6
times.

(4) Air bleeding from swing motor circuit (Parking brake circuit)
a When removing and installing the swing motor or when
disconnecting and connecting the swing holding brake
circuit piping, bleed air from the brake circuit according to
the following procedures.
k If air was not bled or air was bled insufficiently, the
swing holding brake may be dragged. So, be sure to
bleed air strictly according to the procedures.
1) Start the engine and loosen bleeder (11).
a The bleeder is mounted on the front and rear
swing motors.
2) Turn off the swing lock switch.
3) Swing the motor while the engine is idling at low
speed and make sure that bubble-free oil flows out of
bleeder (11). Then, tighten the bleeders.
3 Bleeder : 8.8 9.8Nm {0.9 1.0kgm}
a The swing operation may be as faintly as the
swing oil pressure switch turns on.
(5) Air Bleeding from travel motor circuit (Travel motor)
a When removing and installing the travel motor or when
disconnecting and connecting the travel motor main circuit pipes, bleed air from the travel motor according to the
following procedures.
k If air was not bled or air was bled insufficiently, the
travel motor may be damaged. So, be sure to bleed
air strictly according to the procedures.
1) Start the engine and loosen bleeder (12).
a The bleeder is mounted on the LH and RH travel
motors.
2) Make sure that bubble-free oil flows out of the bleeders (12). Then, tighten the bleeder.
3 Bleeder : 8.8 9.8Nm {0.9 1.0kgm}

129

Assembly procedure

A-56

Starting of engine, inspection of oil levels and coolant


levels, bleeding air and adjustment of track (9/19)

(6) Air bleeding from PPC circuit


a When removing and installing the control valve or when disconnecting and connecting PPC hose, bleed air from the PPC
circuit according to the following procedures.
k

If air was not bled or air was bled insufficiently, time lag or abnormal sound may occur. So, be sure to bleed air
strictly according to the procedures.
1) Start the engine and loosen the bleeder (13).
a The bleeders are installed on the wiring harness spring case elbow of the control valve spool (28 places in total).
2) Control each actuator while the engine is idle at low speed.
3) Make sure that bubble-free oil flows out of bleeder (13). Then, tighten bleeder.
3 Bleeder : 8.8 9.8 Nm {0.9 1.0 kgm}
k The operation of each lever should be enough to the extent that each hydraulic switch turns on.
4) The circuits and places to be bled are as follows.
A : Arm IN circuit (3 places),
Q : Boom RAISE circuit (3 places),
T : Bucket CURL circuit (4 places),
U: Travel REVERSE circuit (4 places),
a : Arm OUT circuit (4 places),
q : Boom LOWER circuit (2 places),
t : Bucket DUMP circuit (4 places),
u: Travel FORWARD circuit (4 places)

130

Assembly procedure

A-56

Starting of engine, inspection of oil levels and coolant


levels, bleeding air and adjustment of track (10/19)

(7) Air bleeding from control valve PPC circuit


a When removing and installing the control valve or when
disconnecting and connecting PPC hose, bleed air from
the PPC circuit according to the following procedures.
k

If air was not bled or air was bled insufficiently, time lag or
abnormal sound may occur. So, be sure to bleed air
strictly according to the procedures.

Elbow with bleeders

1) Start the engine and loosen the bleeder (13).


a The bleeders are installed on the wiring harness spring case elbow of the control valve spool (28 places in total).
2) Control each actuator while the engine is idle at low speed.
Make sure that bubble-free oil flows out of bleeder (13). Then, tighten bleeder.
3 Bleeder: 8.8 9.8 Nm {0.9 1.0 kgm}

The operation of each lever should be enough to the extent that each hydraulic switch turns on.

Front side of control valve

Rear side of control valve

Left travel

Right travel

131

Assembly procedure

A-56

Starting of engine, inspection of oil levels and coolant


levels, bleeding air and adjustment of track (11/19)

(8) Bleeding air from pilot selector valve circuit

Pilot selector valve PV1

Pilot service valve PV2

a If the pilot selector valve circuit was disconnected and connected, bleed air from it according to the following procedure.
k

If the air bleeding operation is not performed or all air is not bled, the work equipment speed may decrease during
compound operation. Therefore, be sure to bleed air according to the specified procedure.
1) Start the engine and loosen bleeders (1) and (2).
a Pilot selector valves PV1 and PV2 have 1 bleeder each.
2) While running the engine at low idle, move the arm in and curl or dump the bucket simultaneously. When oil containing
no bubbles flows out of bleeder (1), tighten bleeder (1).
3 Bleeder : 8.8 9.8 Nm {0.9 1.0 kgm}
k Operate each lever slightly to a degree that each oil pressure switch is turned ON.
3) Turn swing lock switch ON.
4) While running the engine at low idle, raise the boom and swing the upper structure simultaneously. When oil containing
no bubbles flows out of bleeder (2), tighten bleeder (2).
3 Bleeder : 8.8 9.8 Nm {0.9 1.0 kgm}
k Operate each lever slightly to a degree that each oil pressure switch is turned ON.

132

Assembly procedure

A-56

Starting of engine, inspection of oil levels and coolant


levels, bleeding air and adjustment of track (12/19)

(9) Bleeding air from HIC circuit, supplying oil to it, and adjusting track
Since the idler cushion of PC2000-8 uses the hydraulic cylinder and is the closed circuit, bleed air from the circuit.
(Before moving the machine, be sure to bleed air to protect the seals.)
Remaining pressure relief from HIC circuit
k

If the HIC equipment is to be removed or the piping


are to be disconnected, release the remaining pressure from the HIC circuit as follows.
Lower the work equipment completely to the ground,
stop the engine and use the control lever several
times to relieve pressure remaining in the pipe. Then,
loosen the oil filler cap of the hydraulic tank gradually
to relieve pressure in the tank.
1) Loosen stop valves (1) and (2) slowly and relieve
pressure remaining in the circuit.
k Quick loosening will cause a high pressure in
the tank circuit, so be sure to loosen the stop
valves slowly.
a After 1 minute elapsed, the remaining gas will
have been relieved completely.

2) When the remaining pressure is relieved completely,


retighten stop valves (1) and (2).

133

Assembly procedure

A-56

Starting of engine, inspection of oil levels and coolant


levels, bleeding air and adjustment of track (13/19)

Bleeding air from HIC circuit and supplying oil to it


Before bleeding air from the HIC circuit and supplying grease to the hydraulic grease supply cylinder, be sure to bleed air.
1. Loosen plug (1) of the grease cylinder by 1 turn
(2 places on the right and left).

2. Fully open stop valve (2) at the right inside of the axle.

134

Assembly procedure

A-56

Starting of engine, inspection of oil levels and coolant


levels, bleeding air and adjustment of track (14/19)

3. Fully open stop valve (3) at the left inside of the axle.

4. Loosen air bleeding plug (4) of the cushion cylinder about


1 turn (2 places on the right and left).

135

Assembly procedure

A-56

Starting of engine, inspection of oil levels and coolant


levels, bleeding air and adjustment of track (15/19)

5. Remove plug (6) under the block on the side of the relief
valve and loosen air bleeding plug (5) about 1 turn.
6. Run the engine at low idle for 2 3 minutes.

7. When clear oil flows out of air bleeding plugs (4) (at 2
places on the right and left) and the hole for plug (6) under
the block on the side of the relief valve, fully tighten valves
(2) and (3) and plugs (4) and (5).

8. Tighten plugs (1) (at 2 places on the right and left).


9. Tighten plug (6).
3 Plug: 81.3 6.9 Nm {8.3 0.7 kgm}
a Be sure to tighten plug (1) last.
a Fully close the stop valves and air bleeding plugs.
a After bleeding air, test and adjust the track shoe tension.
For details, see Testing and adjusting track shoe tension. in the shop manual.

136

Assembly procedure

Starting of engine, inspection of oil levels and coolant


levels, bleeding air and adjustment of track (16/19)

A-56
HIC system

1.
2.
3.
4.
5.
6.
7.
8.
9.

10. Stop valve


11. Pressure reducing valve
12. Check valve
13. Right travel valve
14. Center swivel joint
15. Control valve (R.H.)
16. Line oil filter
17. Hydraulic pump (front)

Idler
Yoke
Plunger A
Plunger B
Cylinder
Stop valve
Relief-check valve
Accumulator
Check valve

Testing and adjusting track shoe tension


Testing
1. Run the engine at low idle and drive the machine forward
by the length of track on ground, and then stop slowly.
2. Place steel bar (b) on the track shoe between 2nd carrier
roller (1) and 3rd carrier roller (2).
3. Measure the maximum clearance between the track shoe
top and the steel bar.
Maximum clearance (a): 10 30 mm

137

Assembly procedure

A-56

Starting of engine, inspection of oil levels and coolant


levels, bleeding air and adjustment of track (17/19)

Adjusting
If the track shoe tension is abnormal, adjust it according to the
following procedure.
1. Adjusting HIC cylinder
1) Check that stop valve (4) at the right inside of the axle
is fully closed.

2) Open stop valve (5) at the left inside of the axle.

138

Assembly procedure

A-56

Starting of engine, inspection of oil levels and coolant


levels, bleeding air and adjustment of track (18/19)

3) Turn the fuel control dial to the medium position and


run the engine at medium speed.
4) Operate the right travel lever in the forward and reverse directions intermittently (2 3 seconds) 5 6
times.
a Do not perform this operation on a slippery place
(steel plate etc.)
a Even if projection (a) of the hydraulic cushion cylinder is normal, the hydraulic cushion charge
pressure may be low. Accordingly, perform the
operation in 4) securely.
5) Check that projection (a) of the plunger of hydraulic
cushion cylinder (7) is 135 5 mm on each side.
6) If projection (a) is not 135 5 mm, perform the operation in 4) again to set projection (a) in the specified
range.
a If projection (a) cannot be set to 135 5 mm, too
much grease may be in grease cylinder (6). In this
case, discharge the grease according to 2. Adjusting grease cylinder.
7) Fully close stop valve (5).
2. Adjusting grease cylinder
When tension is low
1) Add grease through plug (8).
2) To check that the tension is normal, move the machine forward slowly.
3) Check the track shoe tension again. If it is not proper,
adjust it again.

4) You may adjust the track shoe tension by adding


grease until projection (b) of grease cylinder (9) becomes 35 190 mm.
a If the tension is still low, the pins and bushings
may be worn much.

139

Assembly procedure

A-56

Starting of engine, inspection of oil levels and coolant


levels, bleeding air and adjustment of track (19/19)

When tension is too high


1) Loosen plug (8) gradually to discharge grease.
k Do not loosen the valve more than 1 turn. If it is
loosened more, it may jump out because of the
high-pressure grease in it.
k If the grease is not discharged well, move the machine forward and in reverse and then check the
track shoe tension.
2) Tighten plug (8).
3) To check that the tension is normal, move the machine forward and in reverse.
4) Check the track shoe tension again. If it is not proper,
adjust it again.

140

Assembly procedure

A-57

Permanent tightening of swing circle bolt

In assembly procedure No. A-6, 7 of the 60 mounting bolts of the revolving frame and swing circle were tightened.
Tighten the other 43 bolts.
[Procedure]
(1) Start the engine (Follow the procedure given in assembly procedure A-56).
(2) Swing the upper structure and tighten the bolts when they come to either one of the places marked (54 bolts).

Width across flats: 55


3 Tightening torque :
2,452 3,040 Nm
{250 310 kgm}

Tighten this bolt.


Apply LT-2.

Precautions

Name
KW45FG Impact wrench
55 mm spline socket

Others

Make sure to bleed air from each part


before swinging the upper structure.

Tools required

141

Equipment required
Qty

Name

Qty

Assembly procedure

A-58

Parts to be touched up after field assembly


(chassis side)

After assembling the large-sized hydraulic excavator in the field, touch up the following parts.

Underside of counterweight

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-preventive clear paint for touching up the machined surfaces etc.
(Recommended brand: KOMATSU genuine rust-preventive clear paint)

Precautions

Tools required

Others

Name

142

Equipment required
Qty

Name

Qty

Assembly procedure

A-59

Connection of engine heater connection port (1/3)

No.
01
02
03
04
05
06
07
08
09
Precautions

Tools required
Name

Qty
1

KW12P Impact wrench

17 mm Socket

19 mm Socket

250 mm Extension

22 mm Spanner

27 mm Spanner

Others

Q'ty
4
2
1
1
1
1
1
1
1

Equipment required

KW10P Impact wrench

143

Part No.
01024-81230
01024-81020
04434-51912
04434-51212
01024-81230
04434-51912
04434-51212
195-33-11220
01024-81230

Name

Qty

Assembly procedure

A-59

Connection of engine heater connection port (2/3)

Color of hose distingush tape: white

Connection (face seal)


1 point
No.
10
11
12
13
14
15
16
17

Connection
2 points

Precautions

Tools required

Others

Name

144

Part No.
21T-06-31570
01024-81230
04434-52312
01024-81230
04434-51912
01024-81230
02896-61015
07281-00419

Q'ty
1
4
2
1
1
1
1
2

Equipment required
Qty

Name

Qty

Assembly procedure

A-59

Connection of engine heater connection port (3/3)

(1) Confirm that the 5 valves (a mark) of connection ports are closed.

Open
Close

Close

Close

Turn the knob clockwise to close the valves.

Connection port

(2) Open 2 valves (A mark) around the engine.

Engine left front side

Turn the knob counterclockwise


to open the valves.

Engine right side

Precautions

Tools required
Name

Others

Note) After the procedure (1) is finished,


perform the procedure (2).

145

Equipment required
Qty

Name

Qty

C. ASSEMBLY OF BACKHOE

147

Assembly procedure

C-1

Installation of boom cylinder (1/2)

Method of slinging boom cylinder for installation

Boom cylinder
Weight: 2,400 kg/each

Precautions

Tools required
Name

Equipment required
Qty

Hammer

36 mm Socket

KW38G Impact wrench

12, 5 m Wire

2
1

SC14 Shackle

8 t Crane

Others

16, 5 m Wire

148

Name

Qty

Assembly procedure

Installation of boom cylinder (2/2)

C-1

[Procedure]
(1) Remove the parts marked with A which are installed
to the revolving frame temporarily.
(2) Clean the pins and inside of the bushings.
(3) Sling the cylinder and position it to the pin hole.
(4) Set the shims and spacer and install the parts
marked with A.
Reduce the clearance marked with to 1 mm or
less.
(5) Perform this procedure for the right and left boom
cylinder feet.

Boom cylinder

Left Right

H = 2000

O-ring

Side of center of machine

Pin, weight: 93.8 kg


(2 places)

Clearance between pin and


revolving frame bushing:
0.128 0.28 mm
Clearance between pin and
boom cylinder bushing hole:
0.243 0.366m

Plate, bolt, washer

Bushing
(has been press fitted)
(outside)

Bushing
(has been press fitted)
(inside)

(2 places)

(2 places)

Left side
Right side
Shim

Shim

Shim

Precautions

Tools required
Name

Others

1. There are bushings press fitted to the


revolving frame, and the parts marked
with A are installed temporarily for
transportation.
2. Before inserting the pin, apply grease to
the pin hole (inside surface of the
bushing).
a When installing the plate, hold it with
wires etc. so that your fingers will not be
caught.

149

No.
H-1
H-2
H-3
H-4
H-5
H-6

Part No.
707-01-XK750
707-01-XK760
21T-70-31421
21T-70-31470
21T-70-31690
07000-15180

Q'ty
1
1
2
8
8
4

Equipment required
Qty

Name

Qty

Assembly procedure

Installation of boom cylinder hoses

C-2

Remove the blind plugs from the boom cylinder piping and revolving frame piping,
and then install the 4 hoses as shown in the
following figure.
Use the split flanges, bolts, O-rings, etc.
used to install the blind plugs (on the chassis hose side) as they are.
Parts to install blind plugs (on cylinder side)
#20 Hose
07371-52080 (Flange) 8 pcs.:
Reuse
01010-81865 (Bolt) 16 pcs.:
Reuse
01643-81845 (Washer) 16 pcs.: Reuse
07000-B2060 (O-ring) 4 pcs.:
Keep
07378-12010 (Head) 4 pcs.:
Keep
#14 Hose
07371-51470 (Flange) 8 pcs.:
01010-81455 (Bolt) 16 pcs.:
01643-81445 (Washer) 16 pcs.:
07000-B3048 (O-ring) 4 pcs.:
07378-11410 (Head) 4 pcs.:

H-10

H-8

H-7
O-ring
Hose inside

Reuse
Reuse
Reuse
Keep
Keep

H-9

O-ring
Hose outside

No.
H-7
H-8
H-9
H-10
Precautions

Name

Qty
1

27 mm Socket

KW14PI Impact wrench

150 mm Extension

150

Q'ty
4
4
2
2

Equipment required

22 mm Socket

Others

1. Take care not to twist the hoses when


installing.
2. Take care not to catch the O-rings in the
parts (Apply grease to them before
installing).
3. After connecting the hoses, bleed air from
the boom cylinder.
a Tighten the hoses from the revolving
frame side (to prevent them from
twisting).

Tools required

Part No.
07000-B2060
07000-B3048
21T-64-39410
07083-01417

Name

Qty

Assembly procedure

Assembly of boom sub assembly (1/4)

C-3

1. Installation of work equipment piping (tubes)

Remove the blind plugs


marked with and connect
the tubes (7 places).

Tube

O-ring

Washer

Bolt

Tube

Tube

O-ring

Washer

O-ring

O-ring

Washer

Bolt

Washer

Bolt

Bolt

Arm cylinder tube assembly

O-ring

Washer

Bolt

No.
H-11
H-12
H-13
H-14
H-15
H-16
H-17
H-18
Precautions

Name

Qty
1

22 mm Socket

27 mm Socket

KW14PI Impact wrench

650 mm Extension

150 mm Extension

151

Q'ty
1
1
1
2
7
32
4
28

Equipment required

19 mm Socket

Others

1. Take care not to catch the O-rings in the


parts (Apply grease to them before
installing).
a Securely take measures to prevent the
arm cylinder from projecting.

Tools required

Part No.
21T-64-39140
21T-64-39150
21T-64-39160
07000-B3048
07000-B2060
01643-31845
01010-81840
01010-81865

Name
Lift work stand

Qty
1

Assembly procedure

C-3

Assembly of boom sub assembly (2/4)

2. Installation of arm cylinder


Fix the arm cylinder rod securely so that it will not project during the work.

Arm cylinder
Left

Right

[Procedure]
(1) Remove the pins installed to the boom temporarily.
(2) Clean the pins and inside surface of the bushings.
(3) Sling the cylinder and position it to the pin holes.
(4) Set the shim and install the pin.
(5) Perform the above procedure for both right and left
arm cylinder bottoms.

Plate, bolt, washer

O-ring

Pin

Shim t11

152

No.
H-19
H-20
H-21
H-22

Part No.
707-01-XK770
707-01-XK780
07000-12140
21T-70-31441

Q'ty
1
1
4
4

Assembly procedure

Assembly of boom sub assembly (3/4)

C-3

3. Installation of work equipment piping (hoses)

Hose
Flange on Washer on Bolt on
#14 O-ring cylinder side cylinder side cylinder side
H-24 H-27 H-28 H-30 H-32

Hose
#20
H-23

Flange on

Washer on

Bolt on

O-ring cylinder side cylinder side cylinder side


H-26
H-29
H-33
H-31

Remove the blind plugs from the boom piping (tubes) and arm cylinder piping, and
then install the 4 hoses as shown in the following figure.
Connecting parts: 8 places marked with
Use the split flanges, bolts, etc. used to install the blind plugs on the tube side as they
are.

H-25

H-27

Hose
#14

O-ring Flange on

H-28

H-30

H-32

Washer on Bolt on
cylinder side cylinder side cylinder side

No.
H-28
H-29
H-30
H-31
H-32
H-33
Precautions

Part No.
07371-51470
07371-52080
01643-31445
01643-31845
01010-81455
01010-81865

Parts to install blind plugs (on tube side)


#20 Hose
07371-52080 (Flange) 4 pcs.:
Reuse
01010-81865 (Bolt) 8 pcs.:
Reuse
01643-31845 (Washer) 8 pcs.: Reuse
07000-B2060 (O-ring) 2 pcs.:
Keep
07378-12010 (Head) 2 pcs.:
Keep
#14 Hose
07371-51470 (Flange) 4 pcs.:
01010-81455 (Bolt) 8 pcs.:
01643-31445 (Washer) 8 pcs.:
07000-B3048 (O-ring) 2 pcs.:
07378-11410 (Head) 2 pcs.:
Q'ty
4
4
8
8
8
8

Tools required
Name

Others

1. Take care not to catch the O-rings in the


parts (Apply grease to them before
installing).
a Securely take measures to prevent the
arm cylinder from projecting.

153

No.
H-23
H-24
H-25
H-26
H-27

Reuse
Reuse
Reuse
Keep
Keep

Part No.
07084-02022
07085-01418
07085-01420
07000-B2060
07000-B3048

Q'ty
2
1
1
4
4

Equipment required
Qty

Name

Qty

Assembly procedure

Assembly of boom sub assembly (4/4)

C-3
3. Installation of working lamps

Install the working lamps


as shown in the figure at left.
4 place on right and
left side of boom

Connect the wires at


places marked with .
4 place on right and
left side of boom

Seal
Working lamp Bracket Washer

Bolt

Ground bolt

No.
H-34
H-35
H-36
H-37
H-38
H-39
Precautions

Tools required

Others

Name

154

Part No.
21T-06-32810
20Y-06-21551
01643-31445
01010-81430
01024-81225
209-72-11311

Q'ty
4
4
4
4
4
4

Equipment required
Qty

Name

Qty

Assembly procedure

Installation of boom assembly (1/2)

C-4
1. Slinging method

50 t Crane

30 5 m wire 4 pcs.
+
SB55 shackle 4 pcs.

Apply wooden blocks


(about 100 mm square)
to protect grease piping
and wiring harness.

Hook hole diameter: 80

a Sling horizontally.
Boom assembly
Weight: 20,900 kg

Precautions

a Take care that wooden blocks will not be


driven out.

Name

Equipment required
Qty

Hammer

36 mm Socket

KW38G Impact wrench

30, 5 m Wire

SB55 Shackle

50t Crane

Others

1. Appoint a worker to act as a signalman for


the crane operator.
2. Do not go under a raised load.
3. Check that the wires are fitted properly to
the hook.
4. When working, securely fix the arm
cylinder rod to prevent it from projecting.

Tools required

155

Name
Lift work stand

Qty
1

Assembly procedure

Installation of boom assembly (2/2)

C-4
2. Installation of boom foot pin

Bushing (has been press fitted) (outside)

Boom assembly

(2 places)

Bushing (has been press fitted) (inside)


(2 places)

Pin, Weight: 87.9 kg


(2 places)

Plate, bolt, washer


(2 places)

Bushing (has been press fitted) (boom foot)

Revolving frame

H-40
Shim

H-41
Shim

[Procedure]
(1) Remove the parts marked with * which are installed to the revolving frame temporarily.
(2) Clean the pins and inside of the bushings.
(3) Set the boom as shown above so that the clearances at the parts marked with on the right and left sides will
be even and then decide the thickness and quantity of the shims to reduce the clearance to 1 mm or less.
(4) Assemble the shims and pins.
Clearance between pin and revolving frame bushing: 0.128 0.278 mm
Clearance between pin and boom foot bushing hole: 0.386 0.562 mm
(5) Perform this procedure for the right and left boom feet.

No.
H-40
H-41
Precautions

Tools required
Name

Others

1. There are bushings press fitted to the


revolving frame and boom, and the parts
marked with are installed temporarily for
transportation.
2. Insert the pin from the lower side of the
ground.
3. Take care not to catch the seals in the
parts.
4. Before inserting the pin, apply grease to
the inside of the bushing.

156

Part No.
21T-70-31480
21T-70-31490

Q'ty
8
16

Equipment required
Qty

Name

Qty

Assembly procedure

Installation of boom cylinder (1/2)

C-5

50 t Crane

16 5 m Wire

Boom cylinder
Boom cylinder top pin

Boom top

G.L. (Ground level)

[Procedure]
(1) After inserting the boom foot pin, lower the boom with the crane until its top touches the ground.
(2) Remove the ropes from the boom assembly.
(3) Sling the cylinder with the wire as shown above.
(4) Start the engine. (Low idle)

Precautions

Name

Equipment required
Qty

Hammer

36 mm Socket

KW38G Impact wrench

150 mm Extension

2, 5 m Wire

16, 5 m Wire

50t Crane

Others

1. When slinging the boom cylinder, do not


install the wire directly to its rod or body.
(Protection of rod)

Tools required

157

Name

Qty

Assembly procedure

Installation of boom cylinder (2/2)

C-5

Bushing (has been press fitted) (inside)

Bushing (has been press fitted) (outside)

21T-70-31250 (2 places)

21T-70-31240 (2 places)

Plate, bolt, washer


21T-70-71490 (2)

Pin, Weight: 98.4 kg

01643-32460 (4)

21T-70-31181 (2 places)

01010-82455 (4)

H-42
O-ring

[Procedure]
(5) Remove the parts marked with which are installed to the boom temporarily.
(6) Clean the pins and inside of the bushings.
(7) Sling the cylinder with the wire and align the pin holes by extending or retracting the rod.
(8) Fit the O-ring and pin and install the plate.
(Since the pin is heavy, sling it with the crane carefully.)
Clearance between pin and boom bushing: 0.380 0.508 mm
Clearance between pin and boom cylinder: 0.243 0.366 mm
(9) Perform this procedure for the right and left boom cylinder tops.

No.
H-42
Precautions

Name

Others

1. There are bushings press fitted to the


boom assembly, and the parts marked
with are installed temporarily for
transportation.
2. When inserting the pin, check that the Oring is not caught in it.
3. Check that the pin and inside of the
bushing are clean.
4. Extend and retract the boom cylinder
carefully while running the engine at low
idle. Operate only the boom control lever.
5. Before inserting the pin, apply grease to
the inside of the bushing.

Tools required

158

Part No.
07000-B5180

Q'ty
4

Equipment required
Qty

Name

Qty

Assembly procedure

C-6

Installation of hoses between boom and chassis

I-1
Blind plugs
Tube side
07071-52080
01643-31845
01010-81835
07000-B2060
07378-12010

(12)
(24)
(24)
(6)
(6)

Hose side
07371-52080
01643-31845
01010-81865
07000-B2060
21T-64-39620

O-ring

(12)
(24)
(24)
(6)
(6)

Arm B
Arm H
Bucket B
Bucket B
Bucket H
Arm B

[Procedure]
(1) Remove the blind plugs from the hoses and tubes.
The parts marked with will be reused to connect the hoses and tubes.
(2) Connect the hoses and tubes (6 places).

No.
I-1
Precautions

Name

Qty
1

27 mm Socket

KW14PI Impact wrench

150 mm Extension

159

Q'ty
6

Equipment required

22 mm Socket

Others

1. Take care not to catch the O-rings in the


parts.
(Apply grease to them before installing.)
2. When the oil stopper is removed, oil
spouts out. Take care.

Tools required

Part No.
07000-B2060

Name

Qty

Assembly procedure

Installation of arm assembly (1/3)

C-7
1. Preparation

50 t Crane

50 t Crane
[Procedure]
(1) Remove the parts marked with which are installed
to the boom top temporarily.
(2) Clean the pins and inside of the bushings.
(3) Press fit the seals to arm top, link and boom connecting bushing.

30 5 m wire 2 pcs.
+
SB55 shackle 2 pcs.

Arm assembly
Weight: 12,900 kg

Precautions

Before inserting the pin, apply grease to


the inside of the bushing.
Fix the link securely so that the bucket
cylinder will not extend.

Name

Equipment required
Qty

Hammer

36 mm Socket

KW38G Impact wrench

150 mm Extension

30, 5 m Wire

SB55 Shackle

50t Crane

Others

Tools required

160

Name

Qty

Assembly procedure

Installation of arm assembly (2/3)

C-7

No.
I-2
I-3
I-4
Precautions

Tools required
Name

Others

Install the seals so that they will not slant.

161

Part No.
21T-70-31290
21N-70-12160
209-72-11261

Q'ty
2
4
4

Equipment required
Qty

Name

Qty

Assembly procedure

Installation of arm assembly (3/3)

C-7
2. Installation of arm assembly

50 t Crane

[Procedure]
(1) Raise and lower the boom several times. After the boom cylinder becomes easy to control finely, lower the boom slowly to align the holes.
(2) Install the nylon sling to the pin and lift it up.
(3) Set the arm as shown in the above figure and install it as shown in the
figure below.
Clearance between pin and boom bushing: 0.710 0.854 mm
Clearance between pin and arm bushing: 0.520 0.703 mm
(4) Adjust the clearance between the boom and arm to 1 mm or less with
shims.

Bushing
(has been press fitted)

t12
t9
t1
t1.5

21T-70-32151 (2 places)
Shim
t = 1.5

Shim
t=1

Shim Shim
t = 9 t = 12

O-ring

Precautions

Name

Qty
1

36 mm Socket

KW38G Impact wrench

150 mm Extension

30, 5 m Wire

SB55 Shackle

50t Crane

Nylon sling

162

Part No.
21T-70-31391
21T-70-31780
21T-70-31810
21T-70-31820
07000-B5260

Q'ty
2
1
1
1
2

Equipment required

Hammer

Others

1. Take care not to catch the O-rings and


seals in the parts.
(Before fitting the O-rings, apply grease to
them.)
2. There are bushings press fitted to the arm
assembly and boom assembly, and the
parts marked with are installed
temporarily for transportation.

Tools required

No.
I-5
I-6
I-7
I-8
I-9

Name

Qty

Assembly procedure

Installation of arm cylinder

C-8

Arm cylinder
12 5 m Wire

Boom
Arm cylinder top

Arm

[Procedure]
(1) Remove the parts marked with which
are installed to the arm cylinder top temporarily.
(2) Clean the pins and inside of the bushings.
(3) Install the wire to the left arm cylinder
assembly as shown in the figure at left.
(4) Remove the rod fixing wire of only the
left cylinder.
(5) Give the operator directions to operate
the arm.
(6) Raise or lower the crane and extend or
retract the arm cylinder to align the
holes.
If the stroke is short, raise the boom a little.
(7) Set the seal, insert the pin, and install
the O-ring and cover.
(8) Perform this procedure similarly for the
right arm cylinder top.

Section of arm cylinder top


Pin

Shim
O-ring

Lockplate, washer, bolt

(2 places)

I-10

I-11

Clearance between pin and


arm bushing: 0.503 0.629 mm
Clearance between pin and
arm cylinder: 0.243 0.369 mm

Bushing (has been press fitted)


(4 places)

No.
I-10
I-11

Precautions

Tools required
Name

Qty
1

36 mm Socket

KW38G Impact wrench

150 mm Extension

12, 5 m Wire

50t Crane

163

Q'ty
4
4

Equipment required

Hammer

Others

1. After connecting the hose, bleed air from the


arm cylinder.
2. Limit the engine speed to low idle and do not
move the cylinder to the stroke end.
3. Take care of the seals and O-rings. (Apply
grease before fitting)
4. Align the holes carefully and do not put your
hand/finger in the holes.
5. There are bushings press fitted to the arm
assembly, and the parts marked with are
installed temporarily for transportation.
6. When slinging the arm cylinder, do not install
the wire directly to its rod or body.
7. When extending and retracting the arm
cylinder, limit the engine speed to low idle
and operate the lever carefully. Do not
operate the bucket.
8. Before inserting the pin, apply grease to the
inside of the bushing.

Part No.
21T-70-32181
07000-B2140

Name

Qty

Assembly procedure

Connection of hoses between boom and arm

C-9
\

Remove the blind plugs from the boom piping (tubes) and bucket cylinder piping, and
then install the 4 hoses as shown in the following figure.
Connecting parts: 8 places marked with
Use the split flanges, bolts, etc. used to install the blind plugs on the tube side as they
are.
Parts to install blind plugs (on tube side)
#20 Hose
07371-52080 (Flange) 4 pcs.:
Reuse
01010-81865 (Bolt) 8 pcs.:
Reuse
01643-31845 (Washer) 8 pcs.: Reuse
07000-B2060 (O-ring) 2 pcs.:
Keep
07378-12010 (Head) 2 pcs.:
Keep
#14 Hose
07371-51470 (Flange) 4 pcs.:
01010-81455 (Bolt) 8 pcs.:
01643-31445 (Washer) 8 pcs.:
07000-B3048 (O-ring) 2 pcs.:
07378-11410 (Head) 2 pcs.:

I-15
Hose
#20

I-17

I-13

I-19

I-21

O-ring Flange on Washer on Bolt on


cylinder side cylinder side cylinder side

Precautions

I-18

I-20

I-14

I-16

Hose
#20

O-ring

Flange on Washer on
cylinder side cylinder side

No.
I-17
I-18
I-19
I-20
I-21

Part No.
07000-B2060
01643-31445
01643-31845
01010-81455
01010-81865

Bolt on
cylinder side

Q'ty
4
8
8
8
8

Tools required
Name

Qty
1

27 mm Socket

KW14PI Impact wrench

150 mm Extension

164

No.
I-12
I-13
I-14
I-15
I-16

Part No.
07371-51470
07371-52080
07084-41427
07084-42026
07000-B3048

Q'ty
4
4
2
2
4

Equipment required

22 mm Socket

Others

1. Take care not to catch the O-rings in the


parts (Apply grease to them before
installing).
2. After connecting the hoses, bleed air from
the bucket cylinder.
3. When the oil stopper is removed, oil
spouts out. Take care.

I-12

Reuse
Reuse
Reuse
Keep
Keep

Name

Qty

Assembly procedure

C-10

Connection of auto grease piping

Connection between chassis and boom


(Connecting parts of revolving frame and boom seen from rear upper direction of machine)

Remove the oil stopping parts


marked with and connect the
hoses and T-pieces.
Oil stopping parts
Hose side
07376-50422 (Plug)
T-piece side
07222-00414 (Plug)
07221-20422 (Nut)

Connection between boom and arm (Connecting parts of boom and arm seen from right of machine)

Remove the oil stopping parts


marked with A and connect the
hoses and T-pieces (2 places).
Oil stopping parts
Boom side
07222-00414 (Plug)
07221-20422 (Nut)
Arm side
07222-00414 (Plug)
07221-20422 (Nut)

No.
I-22
I-23
I-24
I-25
I-26
I-27
I-28
Precautions

Tools required
Name

Qty
1

32 mm Spanner

Others

Q'ty
1
3
3
6
1
2
1

Equipment required

27 mm Spanner

165

Part No.
21T-68-31830
203-973-5660
203-973-5720
01024-81055
21T-70-75290
01024-81225
07631-20409

Name

Qty

Assembly procedure

C-11

Connection of wiring between boom and chassis

Remove the blind plugs and connect to CN-A13 in the cab base.
Blind plugs
08191-00770 (Plug) 4 pcs.
08192-14100 (Connector) 1 pc.

Precautions

Tools required

Others

Name

166

Equipment required
Qty

Name

Qty

Assembly procedure

Installation of bucket assembly (1/3)

C-12

50 t Crane

20 5 m Wire 2 pcs.

[Procedure]
(1) Install the wire to the bucket assembly as
shown in the figure and place it on a level
ground.
(2) Remove the parts marked with (pins, covers, etc.) and clean the pins and inside of the
bushings. (For details, see 2/2.)
(3) Coupling with arm
1) Align the holes by operating the boom
and arm.
2) Install the pins.
3) Adjust the shims.
4) Install the covers.
5) Supply grease.

Wooden block

Precautions

Name

Equipment required
Qty

Hammer

19 mm Socket

55 mm Socket

10 mm Spanner

10 mm Hexagonal wrench

KW20P Impact wrench

KW45FG Impact wrench

50t Crane

Others

1. There are bushings press fitted to the arm


assembly and bucket assembly, and the
parts marked with are installed
temporarily for transportation.
2. Put a block under the bucket to prevent
the latter from falling back down.

Tools required

167

Name
20, 5 m Wire

Qty
2

Assembly procedure

Installation of bucket assembly (2/3)

C-12
Detail of arm and bucket connecting pins
Cover, O-ring, bolt, swivel

Cover, O-ring, bolt, washer (outside)

Cover, O-ring, bolt, washer (inside)

O-ring: See following figure.

Pin

Bushing
(has been press fitted)

Bushing
(has been press fitted)

Take care of installed direction of cover.


If right and left are mistaken, grease hose will be broken.

Bushing
(has been press fitted)

J-1

Seal (bucket side)

Clearance between pin and arm bushing: 0.382 0.527 mm


Clearance between pin and bucket bushing (outside): 0.043 0.306 mm
Clearance between pin and bucket bushing (inside): 0.163 0.290 mm

If right and left are mistaken,


grease hose will be broken.

Washer

Nut

Bolt

O-ring

O-ring section

Precautions

Tools required
Name

Others

1. Take care of the seals and O-rings


2. Before inserting the pin, apply grease to
the inside of the bushing.

168

No.
J-1
J-2
J-3
J-4
J-5

Part No.
209-72-11261
209-70-71370
205-09-61240
01640-20610
01596-00606

Q'ty
4
4
4
8
4

Equipment required
Qty

Name

Qty

Assembly procedure

C-12

Installation of bucket assembly (3/3)

[Procedure]
(1) Remove the right and left covers.
(2) Connect the hoses.
(3) Install the right and left covers.

Hose
Cover

Cover

169

Assembly procedure

Installation of bucket link (1/2)

C-13
Connection of bucket link

[Procedure]
(1) Remove the parts marked with which are installed temporarily to the bucket joint of the bucket link. (For details, see 2/2.)
(2) Clean the joints.
(3) Align the holes by operating the bucket.
a If the arm angle is as shown in the left figure below, you must press the link strongly in the direction of the arrow and
cannot assemble easily. Take care.
(4) Install the pins.
(5) Install the covers.
(6) Supply grease.

Press
Bucket link
connecting ping

Precautions

Name

Equipment required
Qty

Hammer (large)

24 mm Socket

KW20P Impact wrench

150 mm Extension

12, 5 m Wire

50t Crane

Others

1. Since air has not been bled from the


bucket cylinder, limit the engine speed to
low idle and do not move the cylinder to the
stroke end.
2. Set the arm angle carefully so that you can
work easily.
3. There are bushings press fitted to the link
assembly, and the parts marked with * are
installed temporarily for transportation.
4. When moving the bucket cylinder, set the
engine speed slow and operate the lever
carefully.
5. If the bucket cylinder is moved to near
either stroke end while the bucket is not
installed, the grease hose will be broken.
a Take care when bleeding air from the
bucket cylinder.

Tools required

170

Name

Qty

Assembly procedure

Installation of bucket link (2/2)

C-13
Bucket link connecting pin

Shim
t1.0

Adjust clearance to 1 mm or less.


Cover, O-ring, bolt, washer (inside)

Bushing
(has been press fitted)
Pin
Clearance between pin and link bushing: 0.363 0.507 mm
Clearance between pin and bucket: 0.043 0.306 mm

No.
J-6
Precautions

Tools required
Name

Others

1. Take care of the seals.


2. Before inserting the pin, apply grease to
the inside of the bushing.

171

Part No.
21N-72-11230

Q'ty
2

Equipment required
Qty

Name

Qty

Assembly procedure

Bleeding air from cylinders (1/3)

C-14
Bleeding air from boom cylinder

When assembling the boom, you must align the boom cylinder top pin holes by extending or retracting the boom cylinder.
Accordingly, perform the following air bleeding operation after assembling the boom cylinder.
(1) While running the engine at low idle, extend and retract the boom cylinder 5 - 6 times, stopping it at about 100 - 200
mm before each stroke end.
a At the first operation, the cylinder does not move for more than 10 seconds since much air is in the circuit. Do not move
the control lever to the stroke end, however.
a If the engine speed is set high or the cylinder is moved to the stroke end from the first operation, the air in the cylinder
may damage the piston packing etc.
a After starting the engine, warm it up sufficiently to fit all the parts.
(2) Extend the boom cylinder to the stroke end and keep the boom control lever at the stroke end for 3 minutes.
(3) Run the engine at full throttle and keep the boom control lever in the same position as (2) for 1 minute.

Precautions

Tools required

Others

Name

172

Equipment required
Qty

Name

Qty

Assembly procedure

Bleeding air from cylinders (2/3)

C-14

Bleeding air from arm cylinder (Carry out this operation before installing the bucket)
After assembling the arm and arm cylinder, bleed air from the arm cylinder according to the following procedure.
(1) While running the engine at low idle, extend and retract the arm cylinder 5 - 6 times, stopping it at about 100 - 200 mm
before each stroke end.
(2) Run the engine at full throttle and perform step (1).
a Do not move the cylinder to the stroke end.
a If the engine speed is set high or the cylinder is moved to the stroke end from the first operation, the air in the cylinder may damage the piston packing etc.
a After starting the engine, warm it up sufficiently to fit all the parts.

Precautions

Tools required

Others

Name

173

Equipment required
Qty

Name

Qty

Assembly procedure

Bleeding air from cylinders (3/3)

C-14
Bleeding air from bucket cylinder

After assembling the bucket, bleed air from the bucket cylinder according to the following procedure.
(1) While running the engine at low idle, extend and retract the bucket cylinder 5 - 6 times, stopping it at about 100 - 200
mm before each stroke end.
(2) Run the engine at full throttle and perform step (1).
a Do not move the cylinder to the stroke end.
a If the engine speed is set high or the cylinder is moved to the stroke end from the first operation, the air in the cylinder may damage the piston packing etc.
a After starting the engine, warm it up sufficiently to fit all the parts.
(3) After bleeding air, add hydraulic oil to the specified level.

Precautions

Tools required
Name

Others

Bleed air with the bucket installed.


If the bucket cylinder is moved to near either
stroke end while the bucket is not installed,
the auto-grease hose will be broken.

174

Equipment required
Qty

Name

Qty

Assembly procedure

C-15

Parts to be touched up after field assembly


(work equipment side)

After assembling the large-sized hydraulic excavator in the field, touch up the following parts.

(1) Front and rear underside of boom

(2) Underside of arm

(3) 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-preventive clear paint for touching up the machined surfaces etc.
(Recommended brand: KOMATSU genuine rust-preventive clear paint)

Precautions

Tools required

Others

Name

175

Equipment required
Qty

Name

Qty

Assembly procedure

C-16

Bleeding air from auto grease circuit (1/3)

After assembling the whole machine, bleed air from the grease circuit according to the following procedure.
(1) Remove the 3 plugs (581-96-19590, marked with a) from the injector assembly manifold one by one from the one nearest
to the pump. Then, operate the auto grease unit continuously in the manual mode and check that pressurized grease
comes out. After checking, install the plugs again.
Order of check: Revolving frame front face Boom top face Arm top face
(2) Supply grease with the grease gun through the service nipple of the injector and check that grease comes out of each
greasing point.

Discharge adjustment screw


Indicator pin

Locknut
3 Tightening torque :
19.6 -- 24.5 Nm {2.0 -- 2.5 kgm}

Service nipple

Plug (581-96-19590)
3 Tightening torque :
19.6 -- 29.4 Nm {2.0 -- 3.0 kgm}
Manifold

Injector assembly

Precautions

Tools required
Name

Others

A Do not use molybdenum disulfide grease


to the bearings of the swing circle etc.
Bushing: Molybdenum disulfide grease
may be used.
Bearing: Use lithium grease.

176

Equipment required
Qty

Name

Qty

Assembly procedure

C-16

Bleeding air from auto grease circuit (2/3)

Boom cylinder bottom, right

Circle

Boom cylinder bottom, left

Plug (581-96-19590)
3 Tightening torque :
19.6 -- 29.4 Nm {2.0 -- 3.0 kgm}

Revolving frame front face

Boom foot, right


Boom cylinder head, right
Boom top, right
Arm cylinder bottom, right

Arm cylinder bottom, right


Boom top, right
Boom cylinder head, right
Boom foot, right

Plug (581-96-19590)
3 Tightening torque :
19.6 -- 29.4 Nm {2.0 -- 3.0 kgm}

Boom top face

177

Assembly procedure

C-16

Bleeding air from auto grease circuit (3/3)

Arm B boss, right


Arm A boss, right
Bucket, right
Bucket cylinder head, right
Bucket cylinder bottom, right
Bucket cylinder head, left

Arm cylinder head, right

Bucket, left

Arm cylinder head, left


Bucket cylinder bottom, left

Arm A boss, left

Arm C boss

Arm B boss, left


When adjusting injector,
remove piping cover.
After adjusting, install again.

Front link + Bucket, left


Front link + Wrist link, left
Front link + Wrist link, left
Front link + Bucket, right
Front link + Wrist link, right
Front link + Wrist link, right

Plug (581-96-19590)

Arm top face

178

3 Tightening torque :
19.6 -- 29.4 Nm {2.0 -- 3.0 kgm}

LS. ASSEMBLY OF LOADING SHOVEL


WORK EQUIPMENT

179

Assembly procedure

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

Installation of arm cylinder bottom parts

Remove the lock piece fixed to the boom and remove the arm cylinder bottom pins.
Lay the 2 arm cylinders in parallel on wood blocks.
Sling the boom with a crane and push in the pins, matching the pinhole of the boom to the holes of the arm cylinder bottoms.
Install both arm cylinders similarly.
Install the lock piece.
Using a nylon sling, secure the arm cylinders with the lever block.

Boom assembly: 11,000 kg

Nylon slling

(R.H.) (L.H.)
Pin: 28 kg 2
Arm cylinder:
1,072 kg 2
Arm cylinder

Left:

DM945 438 40

Cold district
specification
DM945 468 40

Right:

DM945 449 40

DM945 469 40

STD

No.
01
02
Precautions

Tools required
Name

Others

1. Apply grease (GL-L1) to the inside of the


bushings.
2. Install the arm cylinder bottom parts with
the piping ports down.

180

Part No.
DM945-438-40
DM945-449-40

Q'ty
1
1

Equipment required
Qty

Name

Qty

Assembly procedure

Installation of boom cylinder to machine body (1/2)

LS-2

Slinging method of boom cylinder for installation

Rod stopper wire

Boom cylinder

Left:

DM945 418 40

Cold district
specification
DM945 462 40

Right:

DM945 419 40

DM945 463 40

STD

Precautions

Tools required

Others

Name

181

Equipment required
Qty

Name

Qty

Assembly procedure

Installation of boom cylinder to machine body (2/2)

LS-2

[Procedure]
(1) Remove the parts marked A and
installed to the revolving frame.
(2) Clean the pin and inside of the
bushing.

Boom cylinder
Left

Right

(3) Sling the cylinder and position it to the


pin hole.
(4) Set the shim and spacer and install
the parts marked
.
Adjust the marked clearance to 1 mm
or less.
(5) Work on the right and left boom
cylinder bottoms.

H = 2,000

Body center side


Pin weight: 93.8 kg
(2 places)

Plate, bolt, washer

Bushing which has


been installed (Inside)

Bushing which has


been installed (Outside)

(2 places)

(2 places)

Shim
Shim

Precautions

The machine is transported with the parts


marked with A installed temporarily.
Check that the pins and inside of the
bushings are cleaned.

Tools required
Name

Qty
1

36 mm socket

KW38G impact wrench

12, 5 m wire

182

Part No.
DM945-418-40
DM945-419-40
21T-70-31421
21T-70-31690
21T-70-31470

Q'ty
1
1
2
4
4

Equipment required

Hammer

Others

No.
01
02
03
04
05

Shim

Name
45 t crane

Qty
1

Assembly procedure

Installation of boom cylinder hoses

LS-3

Remove the oil stoppers of the boom cylinder piping and revolving frame piping and install the 4 hoses as shown in the
following figure.
a When removing the oil stoppers, take care of spout of oil.
Reuse the split flanges, bolts and washers used to install the oil stoppers (on the machine hose side) as they are.

Parts used to install oil stoppers


Hose #20
07371-52080 (Flange) 8 pcs.
01010-81865 (Bolt)
16 pcs.
01643-81845 (Washer) 16 pcs.
07000-B2060 (O-ring) 4 pcs.
07378-12010 (Head) 4 pcs.
Hose #14
07371-51470 (Flange) 8 pcs.
01010-81455 (Bolt)
16 pcs.
01643-81445 (Washer) 16 pcs.
07000-B3048 (O-ring) 4 pcs.
07378-11410 (Head) 4 pcs.

Reuse
Reuse
Reuse
Store
Store
Reuse
Reuse
Reuse
Store
Store

Inside hose
#14

Outside hose
#20

No.
01
02
03
04
Precautions

Name

Qty
1

27 mm socket

KW14PI impact wrench

150 mm extension

183

Q'ty
2
4
2
4

Equipment required

22 mm socket

Others

1. When installing the hoses, take care not to


twist them.
2. Take care not to damage the O-rings.
(Before installing, apply grease.)
3. After connecting the hoses, bleed air from
the boom cylinder.

Tools required

Part No.
21T-64-39421
07000-B2060
07083-01417
07000-B3048

Name

Qty

Assembly procedure

LS-4

Installation of boom cylinder piping

When the boom is installed, the boom cylinders are extracted and retracted to position the holes
of the boom cylinder top pins. Accordingly, bleed air according to the following procedure after
installing the boom cylinders.
Bleeding air from boom cylinders
(1) Run the engine at the low idling speed and extract and retract the boom cylinders 5 6 times without moving them to the
stroke ends (stop them about 100 200 mm before each stroke end).
A Since there is much air in the circuit, the work equipment does not move for more than 10 seconds when the control
lever is operated for the first time. Do not move the control lever to the stroke end at this time, however.
A If the engine speed is increased high or the cylinder is moved to the stroke end from the first, the piston packing may
be damaged by the air in the cylinder.
A After starting the engine, warm it up sufficiently to fit each part.
(2) Next, extract the boom cylinders to the stroke end keep the control lever at the stroke end for 3 minutes.
(3) Run the engine at the full speed and keep the control lever similarly to (2) for 1 minute.

Precautions

Tools required

Others

Name

184

Equipment required
Qty

Name

Qty

Assembly procedure

Installation of boom assembly

LS-5

(1) Sling the boom assembly with a crane and position the boom foot pinholes.
(2) Install the boom foot pins.
A Push in either boom foot pin first until it stops and then position the pinhole on the other side. If the boom leans to the
right or left at this time, correct it with a jib crane.
A Decide the number of the adjustment shims so that the clearance of the boom foot pin out of the machine body will be
below 1 mm.
Combine the following adjustment shims properly to adjust the clearance.
(21T-70-31470) t1.5: 4 pcs.
(21T-72-31690) t1.0: 4 pcs.
(Adjust the shims at 1 place on the left outside of the boom.)

Work equipment assembly: 13,000 kg

(3) Push in both boom foot pins to the end and


install the lock plates.

Seal
(DM908 60 140)

Right side

Left side

Boom foot pin

Shim Shim

Precautions

Name

When pushing in the pin, take care not to


break the seal.

Others

Tools required

185

No.
01
02
03

Part No.
DM942 850 40
21T-70-31690
21T-70-31470

Q'ty
1
4
4

Equipment required
Qty

Name

Qty

Assembly procedure

Installation of boom cylinder head pins

LS-6

(1) Remove the pin lock pieces from the boom cylinder and then remove the boom cylinder top pins.
4 Boom cylinder top pin: 61 kg

(2) Start and run the engine at the low idling speed.
(3) Sling each cylinder and extract its rod slowly to match the pinhole and push in the pin.
(4) Install both cylinders similarly.
(5) Install the pin lock pieces (Tightening torque of M24 bolt: 60 105 kgm).
Inside of bushings: Apply grease (GL-L1).
A Extract the cylinder slowly.
Do not move it quickly or move it to the stroke end.
Since there is much air in the circuit, the work equipment may not move for more than 10 seconds when the control
lever is operated for the first time. Do not move the control lever to the stroke end at this time, however.

Pin

Precautions

Tools required

Others

Name

186

Equipment required
Qty

Name

Qty

Assembly procedure

Installation of hose between


machine body and boom (1/2)

LS-7

(1) Remove the oil stopping parts of the tubes and blocks.
(2) Install the hoses. (10 pcs.)
Reuse the split flanges, bolts and washers (marked a) used to stop oil as they are.

Bucket line
#20
Bottom dump bottom
#14
Bottom dump head
#14

Arm cylinder head


#14

Arm cylinder bottom


#20

Precautions

Tools required

Others

Name

187

No.
01
02
03
04
05
06
07

Part No.
07083-01421
07083-02023
07084-01419
07084-01416
07083-02018
07000-B3048
07000-B2060

Q'ty
2
2
1
1
3
8
10

Equipment required
Qty

Name

Qty

Assembly procedure

Installation of hose between


machine body and boom (2/2)

LS-7

(1) Install the grease hose. (Tightening torque: 84 132 Nm {8.5 13.5 kgm})

No.
01
Precautions

Tools required

Others

Name

188

Part No.
07631-20412

Q'ty
1

Equipment required
Qty

Name

Qty

Assembly procedure

Installation of bucket cylinder assembly

LS-8

(1) Sling each bucket cylinder with a crane. At this time, lean it about 45 with the rod side up.
(2) Insert the pin boss on the rod side in the bracket of the boom.
(3) Insert pin in the pinhole and secure the cylinder.
(4) Install the pin lock plate.
Note). When reassembling, remove the pins, lock plates, bolts, and washers from the boom assembly.

No.
01
02
03
04
05
Precautions

Tools required
Name

Bucket cylinder
STD

Cold district
specification

Others

Right and Left DM905 984 40 DM923 854 40

189

Part No.
DM905 984 40
DM905 742 40
DM905 749 40
01010-81640
01643-31645

Q'ty
2
2
2
4
4

Equipment required
Qty

Name

Qty

Assembly procedure

Installation of arm assembly

LS-9

(1) Install wires to the hooks of arm assembly and sling it with a crane.
(2) Insert the boss on the boom side of the arm assembly in the pin bracket of the boom.
(3) Insert pins and secure the arm assembly.
(4) Install pin lock plates.
Note). When reassembling, remove the pins, lock plates, bolts, and washers from the boom assembly.

No.
01
02
03
04
05
Precautions

Tools required

Others

Name

190

Part No.
DM942 855 40
DM905 739 40
DM905 749 40
01010-82455
01643-32460

Q'ty
1
2
2
4
4

Equipment required
Qty

Name

Qty

Assembly procedure

LS-10

Installation of arm cylinder assembly

(1) Install chains to the hooks of arm cylinder under the boom and sling them.
(2) Extracting each arm cylinder, match the center of the cylinder rod end boss to the cylinder bracket of the arm.
(3) Insert pin in the pinhole to secure the cylinder.
(4) Install pin lock plate.
Note). When reassembling, remove the pins, lock plates, bolts, and washers from the cylinder assembly.

No.
01
02
03
04
05
06
Precautions

Tools required

Others

Name

191

Part No.
DM945 438 40
DM945 449 40
DM908 933 40
DM905 750 40
01010-81640
01643-31645

Q'ty
1
1
2
2
4
4

Equipment required
Qty

Name

Qty

Assembly procedure

Installation of hoses between boom and arm

LS-11

(1) Install hose assembly between the boom and arm.

#14 4
#20 2

No.
01
02
03
04
05
06
07
08
09
10
Precautions
When installing the hoses and tubes, take
care extremely not to catch the O-rings.

Take care extremely not to let dust in the


hydraulic circuit.

Name

Others

Tools required

192

Part No.
DM942 888 40
07085-01430
07084-02030
DM490 011 40
07000-B3048
01010-81455
01643-31445
07000-B2060
01010-81865
01643-31845

Q'ty
2
4
2
1
8
32
32
4
16
16

Equipment required
Qty

Name

Qty

Assembly procedure

LS-12

Installation of bucket cylinder hoses

(1) Install bucket cylinder hoses.

No.
01
02
03
04
05
Precautions
When installing the hoses and tubes, take
care extremely not to catch the O-rings.

Take care extremely not to let dust in the


hydraulic circuit.

Name

Others

Tools required

193

Part No.
07084-01423
07084-01428
07000-B3048
01010-81455
01643-31445

Q'ty
2
2
8
32
32

Equipment required
Qty

Name

Qty

Assembly procedure

Installation of grease feed hose


of bucket cylinder (1/2)

LS-13

(1) Unwind the grease feed hose from the tube of the arm assembly and install it along the bucket cylinder hose to the grease
fitting of the bucket cylinder rod end boss.
(2) Unwind the grease feed hose from the body of the arm assembly and install it along the bucket cylinder hose and connect
to the bottom grease feed hose installed to the bucket cylinder assembly.
Note). Adjust the grease feed hoses to proper length by the following method.
(3) Wind spiral covers onto the grease feed tubes and bucket cylinder hose as shown below.

Bucket cylinder rod end grease feed hose


(To be unwound and installed along hydraulic hose)
Grease
feed hose
Grease feed hose
Hydraulic hose
Bucket cylinder
hydraulic hose
Spiral cover

AA

Precautions

Tools required

Others

Name

194

Equipment required
Qty

Name

Qty

Assembly procedure

Installation of grease feed hose


of bucket cylinder (2/2)

LS-13

(1) Unwind the grease feed hose from the tube of the arm assembly and install it along the bucket cylinder hose to the grease
fitting of the bucket cylinder rod end boss.
(2) Unwind the grease feed hose from the body of the arm assembly and install it along the bucket cylinder hose and connect
to the bottom grease feed hose installed to the bucket cylinder assembly.
Note). Adjust the grease feed hoses to proper length by the following method.
(3) Wind spiral covers onto the grease feed tubes and bucket cylinder hose as shown below.

Connect to
hose on
cylinder side
at this point.

Grease feed hose

Hydraulic
hose
Spiral cover

Precautions

Tools required

Others

Name

195

Equipment required
Qty

Name

Qty

Assembly procedure

Installation of bucket assembly

LS-14
(1) Install bucket assembly.

Note). When reassembling, remove the pins, lock plates, bolts, and washers from the bucket assembly.
(2) Install the pin seal assembly.

No.
01
02
03
04
05
Precautions

Tools required

Others

Name

196

Part No.
DM944 363 40
DM620 923 40
DM247 091 40
DM661 196 40
DM247 092 40

Q'ty
1
4
4
4
4

Equipment required
Qty

Name

Qty

Assembly procedure

LS-15

Installation of bottom dump hose and


grease feed hose between arm and bucket

(1) Install bottom dump hydraulic hoses between the arm and bucket.
Note). Reuse the bolts and washers used for the blind cover.
(2) Unwind the grease feed hose from the arm and connect it to the bottom dump grease feed hose on the bucket side.
(3) Wind spiral covers onto the grease feed tubes and bottom dump cylinder hoses.

Grease feed hose


Spiral band

Hydraulic hose

Grease feed hoses


Hydraulic hose

Precautions
When installing the hoses and tubes, take
care extremely not to catch the O-rings.

Take care extremely not to let dust in the


hydraulic circuit.

Name

Others

Tools required

197

No.
01
02
03
04
05

Part No.
07083-41231
07000-B3038
01010-81245
01643-31232
08034-20536

Q'ty
2
4
16
16
4

Equipment required
Qty

Name

Qty

M. INSPECTION AND SERVICING PROCEDURES


AFTER ASSEMBLY

199

Assembly procedure

M-1

Inspection of oil levels and coolant levels and


using standard of fuel and lubricant (1/3)

Selection of fuels and lubricants according to ambient temperature and Komatsu genuine oils
Since the Komatsu genuine oils are manufactured under standards higher than the common standards to increase the reliability and durability of construction machinery, they are most suitable to the Komatsu construction machines. Recommend
the customers to use the oils, greases and coolants of Komatsu shown in this manual to keep the machines under the best
condition for long years.
If these recommended lubricants and coolants are not used, the service lives of the engine, power train and cooling system
may be shortened and their parts may be worn extremely.
The oil additives on the market may lower the oil performance. We do not recommend any oil additives on the market.
Select fuels and oils as shown in the following table, depending on the ambient temperature.
The rated capacity is the total quantity of oil in each device and its piping. The refill capacity is the quantity of oil replaced
for inspection or maintenance.
When starting the engine at a temperature below 0C, do not use SAE30DH but use another multi-grade oil in the table,
even if the temperature rises to about 10C during the daytime.

IMPORTANT
Be sure to use recommended diesel fuel.
The engine of this machine employs the high-pressure fuel injection unit controlled electronically to obtain higher fuel
efficiency and better exhaust gas characteristics. This fuel injection unit requires high parts precision and lubrication
performance. If a low-viscosity fuel having low lubrication performance is used, the durability of the engine may be
decreased extremely.

Precautions

Tools required

Others

Name

200

Equipment required
Qty

Name

Qty

Assembly procedure

M-1

Inspection of oil levels and coolant levels and


using standard of fuel and lubricant (2/3)

201

Assembly procedure

Inspection of oil levels and coolant levels and


using standard of fuel and lubricant (3/3)

M-1

Engine oil pan

PTO case

Specified
capacity
(l)

128

36

Refill capacity
(l)

120

36

Swing
machinery
case

Final drive
case

Hydraulic
system

Fuel tank

Cooling system

Grease

(Each of front (Each of right


and left)
and rear)
85
30

2400

3400

180

200

(Each of front (Each of right


and rear)
and left)
30
85

1300

200

Note 1: HTHS (High-Temperature High-Shear Viscosity 150C), specified by ASTM D4741 must be equal to or higher than
3.5 mPa-S. Komatsu EOS0W30 and EOS5W40 are the most suitable oils.
Note 2: Powertrain oil has different properties from engine oil. Be sure to use the recommended oils.
Note 3: If the automatic greasing system is installed, see "Operation and maintenance manual".
Note 4: Hyper grease (G2-T, G2-TE) has a high performance.
When it is necessary to improve the lubricating ability of the grease in order to prevent squeaking of pins and bushings,
the use of G2-T or G2-TE is recommended.
Note 5: Supercoolant (AF-NAC)
1) Coolant has the important function of anticorrosion as well as antifreeze.
Even in the areas where freezing is not an issue, the use of antifreeze coolant is essential.
Komatsu machines are supplied with Komatsu Supercoolant AF-NAC. Komatsu Supercoolant AF-NAC has excellent anticorrosion, antifreeze and cooling properties and can be used continuously for 2 years or 4000 hours.
Komatsu Supercoolant AF-NAC is strongly recommended wherever available.
2) For details of the ratio when diluting super coolant with water, see "Operation and maintenance manual".
Supercoolant AF-NAC may be supplied in premix. In this case, always top off with premix solution.
(never dilute with water)
3) To maintain the anticorrosion properties of Supercoolant AF-NAC, always keep the density of Supercoolant between 30%
and 68%.
Features of greases (Reference)
Grease

High load Wear


resistance resistance

Lubrication of rolling bearing


(Fretting resistance)

Heat
Water
Biodegrad
resistance resistance ability

Molybdenum disulfide
grease

Lithium grease

Bio-grease

wExcellent QGood EFair Bad

202

Remarks
Do not use molybdenum
disulfide grease to rolling
bearings.

Synthetic biodegradable
lithium grease

Assembly procedure

Flushing of hydraulic circuit (1/3)

M-2

Flush the hydraulic circuit according to the following procedure.


1. Bypass the work equipment piping at the cylinders.

Bypass
Bypass

Boom cylinder bottom

Bypass
Bypass

Bypass

Bypass

Arm cylinder bottom

Precautions

Bucket cylinder bottom

Tools required

Others

Name

203

Equipment required
Qty

Name

Qty

Assembly procedure

Flushing of hydraulic circuit (2/3)

M-2

2. Replace the return filter element with the flushing element (accessory).
3. Replace the relief valve of the return filter with the plate (accessory).
a When replacing the element, lift it up carefully so that the dirt sticking to it will not fall in the case.
Remove the dirt remaining in the case with the hand.

Replace relief valve with

Valve

this plate only when flushing.

Strainer

Special element for flushing


Absolute filtration rating: 6
FR1F080A001A
manufactured YAMASHIN
KOGYO or equivalent

No.
K-1
K-2
Precautions

Tools required
Name

Others

Keep the removed standard parts (element,


strainer, valve) carefully, since they will be
used again after flushing.

204

Part No.
209-60-77551
21T-60-13730

Q'ty
3
3

Equipment required
Qty

Name

Qty

Assembly procedure

Flushing of hydraulic circuit (3/3)

M-2

4. Run the engine at low idle with the lever in the N position for 30 minutes.
5. Run the engine at a medium speed with the lever in the N position for 30 minutes.
6. Run the engine at 1,700 rpm and repeat the following lever operation pattern 4 times.
Keep the lever at each operation position for 1 minute - 1 minute 30 seconds.
Operation pattern
(Raise boom) (Lower boom) (Extend arm) (Retract arm) (Extend bucket) (Retract bucket)
7. Replace the return filter relief valve and element with the regular ones.
8. Correct the work equipment piping (connect it to the cylinders).
a If the "Filter clogged" caution lamp on the monitor in the operator's cab lights up during the flushing operation, stop the
engine immediately and replace the flushing element. If a new flushing element is not available, use a new genuine
element.

Installation condition of element

Fig. 1 Good condition

Fig. 2 Bad condition

a Do not install the element with its bottom on the elevated part of the case bottom as shown in Fig. 2. In particular, if
the filter case is filled with oil, it is difficult to see if the element is installed normally. In this case, turn the element with
your hand. If you can turn it smoothly, it is installed normally.

Precautions

Tools required

Others

Name

205

Equipment required
Qty

Name

Qty

Assembly procedure

M-3

Releasing residual pressure from hydraulic circuit

When disconnecting the hydraulic piping, be sure to release the residual pressure according to the following procedure.
1. Set the lock lever to the "FREE" position.
2. Remove the hydraulic tank cap.
3. Run the engine for about 10 seconds, and then stop it.
a Limit the engine speed to 1,000 rpm.
a Keep the work equipment control levers in neutral.
4. Operate each work equipment control lever to the stroke end in 5 - 6 seconds after stopping the engine.
a Perform the operations in 3 4 above by 3 times.
a Loosen the oil filler cap of the hydraulic tank slowly to release the residual pressure, and then remove it.
5. After releasing the residual pressure, install the oil filler cap of the hydraulic tank.
6. Set the lock lever to the "LOCK" position.

LOCK

FREE

Precautions

Tools required

Others

Name

206

Equipment required
Qty

Name

Qty

Assembly procedure

M-4

Releasing residual pressure from HIC circuit and


check of gas pressure in HIC accumulator

For check of the gas pressure in the HIC accumulator, see PC2000-8 Shop Manual, "Testing and adjusting".

Precautions

Tools required

Others

Name

207

Equipment required
Qty

Name

Qty

Assembly procedure

Charging air conditioner with refrigerant

M-5

Service tool kit


(100 V)

799-703-1100

Vacuum pump

799-703-1111

Vacuum pump
(220 V)
Vacuum pump
(240 V)

Gas leak detector

799-703-1121
799-703-1401

Part name

Sketch

Q'ty

799-703-1200

Part No.

New/Remodel

Necessity

Using the tool kit in the following table, charge the air conditioner with refrigerant.

Type of refrigerant: R134a


Quantity: Front compressor: 950 50 g
Rear compressor: 950 50 g
Supply the refrigerant through the charging valves shown in the following figure.

Rear compressor
Charging valve on
high pressure side
Charging valve on
low pressure side

Front compressor
Charging valve on
high pressure side

Engine assembly

Precautions

Tools required
Name

If refrigerant gas (R134a) gets in your eyes,


you may lose your sight. Accordingly, when
adding it, put on protective goggles.
Refrigerant gas must be collected and added
by a qualified person.

Others

For details of refrigerant charging procedure,


see the instruction manual for the tool kit.
For the method of checking the quantity in
the air conditioner, see the Operation and
Maintenance Manual for the machine.

Charging valve on
low pressure side

208

Equipment required
Qty

Name

Qty

Assembly procedure

Installed angles of mirrors (1/2)

M-6

<Right step mirror> (Installed on the step handrail during transportation)

Right
Right step mirror

Left rear mirror

Front

<Left rear mirror> (Sent individually)


Front
Left

Operators cab
mirror
Left step mirror

No.
K-3
K-4
K-5
K-6
K-7
K-8
K-9
K-10
K-11
Precautions

Tools required
Name

Others

While sitting in the operator's seat and


checking the view, adjust the mirror angles.

209

Part No.
23S-54-36270
21T-54-34690
21T-54-79620
01252-71025
21T-54-34850
21T-54-34680
07283-32236
01643-31032
01597-01009

Q'ty
2
1
2
4
1
1
4
8
8

Equipment required
Qty

Name

Qty

Assembly procedure

Installed angles of mirrors (2/2)

M-6

Front

<Operator's cab left mirror>


(Installed on the operator
cab during transportation)

Left

<Left step mirror>


(Sent indiviually)

No.
K-12
K-13
K-14
K-15
K-16
K-17
Tools required

Others

Name

210

Part No.
421-54-25610
04025-00632
01252-70545
21T-54-36480
20Y-54-61630
01252-71030

Q'ty
1
1
4
1
1
2

Equipment required
Qty

Name

Qty

Assembly procedure

Installed angles of lights (1/3)

M-7

<Light above operator's cab>


Right
Front

<Light above fuel tank>


Right
Front

Precautions

Tools required
Name

Others

While sitting in the operator's seat and


checking the lighting direction, adjust the
light angles.

211

Equipment required
Qty

Name

Qty

Assembly procedure

M-7

Installed angles of lights (2/3)

<Left step light>

Left
Front

Bottom view of left step

212

Assembly procedure

Installed angles of lights (3/3)

M-7

<Work equipment (Boom) light>

Up
Front

Left side (Right side is similar)

Precautions

Tools required

Others

Name

213

Equipment required
Qty

Name

Qty

VHMS CONTOROLLER INITIAL SETTING PROCEDURE

215

1
VHMS controller initial setting
procedure
a

1
ZB
2

a
a

Equipment used for VHMS controller initial setting

Symbol

1.

Part No.

Part name

799-608-3211 Diskette
799-608-3220 Wiring harness
Note type PC
Commercially
(Windows 98/2000/Me/XP),
available
with RS232C terminal

Confirmation of machine information,


engine information, transmission controller
information and controller information
a This confirmation procedure is targeted at
the entire machine.
Confirm and record the machine information, engine information, VHMS controller
information and ORBCOMM terminal
information.
No.

Initial setting of VHMS controller shall be done


according to the following procedure. This
operation is needed prior to a full-scale operation of a machine being delivered and assembled in the field, or prior to resumption of its
operation after a long time of storage.
Machine data collected with VHMS controller
are stored and managed on WebCARE database. In order to endure smooth data processing on WebCARE , consistency must be
provided among the settings done on VHMS
controller. Inconsistencies in the settings
obstruct loading of data to WebCARE, hampering appropriate use of VHMS data. The initial setting, therefore, is a must.
For the installation procedure of the VHMS initial setting program to a PC, refer to the operation and maintenance manual being bundled
with the service kit ZB1.
In the procedure, service menus of the
machine monitor are used. Thus, it is advisable to reference the information contained in
the Special functions of machine monitor to
understand their procedure beforehand.
The initial setting procedure is described in the
ORBCOMM installation specification and the
ORBCOMM-less specification. When using the
ORBCOMM installation specification, implement the procedures needed for VHMS alone,
bypassing those prepared only for ORBCOMM
installation specification.
Check each step of the setting work referencing the VHMS initial setting work check sheet.
Information such as models shown in the figures may not be identical with actual ones.

Model name

Machine serial No.

Current service meter hour

Engine serial No.

VHMS controller serial No.

ORBCOM terminal serial No.


[Only for machines equipped with ORBCOMM]

216

Information to be confirmed

VHMS controller (1) and ORBCOMM terminal (2) are installed in the rear under the
operator seat.

2.

3.

Connecting a PC
a This work is done inside the cab.
1) Make sure the starting switch is at OFF
position.
k Before connecting or disconnecting a PC, be sure to turn off the
starting switch.
2) Using harness [1] of service kit ZB1, connect the PC ZB2 and download connector
VH13.
a Then connect the PC to RS232C terminal.

Confirming VHMS controller operation and


confirming satellite capturing state
a This work is done inside the cab.
a Confirmation of capturing of the satellite is
done for [ORBCOMM installation specification].
1) Turn the starting switch ON.
2) Check the controller for normal operation
referencing 7-segment LED of VHMS controller.
a VHMS controller is fed with switch
power supply. Thus, its operation is
judged normal if its 7-segment LED
starts flashing while rotating as the
starting switch is turned on and then if
the controller starts counting in the
ascending order.

Download
connector
VH13
is
installed in the front side of the right
stand of operator seat.
3)

217

Among the 7-segment LED situated in the


right side of VHMS controller, refer to the
one that represents the decimal point to
check whether or not ORBCOMM controller has captured the communication satellite. [ORBCOMM installation specification]
a Check whether or not ORBCOMM
controller is capturing the communication satellite from VHMS controller.
a It is successfully capturing the satellite when the LED representing the
decimal point in the right side 7-segment LED is flashing.

4.

5.

Starting the VHMS initial setting tool


a This work is done inside the cab (from PC).
1) Turn on the PC power and start the OS.
2) Operating [VHMS initial setting tool] icon on
the PC, start up the VHMS initial setting tool.

3)
4)
5)

Important
a Appearance of the setup screen of
the VHMS setting tool depends its
tool.
a When using Ver.3.5.2.1 or older version (CD-ROM), the setting procedure shall conform to that described
in Section 5.
a When using an update version
(Ver.3.5.2.1 or after), the procedure in
Section 6 shall be used.
a It is recommended to download the
latest VHMS version from WebCARE
to update the currently used version.
(Related material: PARTS & SERV IC E O PE RAT IO N T IP S S EK N5052)
Enter the 10-digit service ID to [Service ID].
a Service ID: 7826143000
Select [Data clear and Set up] from
[Select Function] item.
Click [OK] button to proceed to the setup
screen.

218

Initial setting of VHMS controller (Ver. 3. 5. 2. 1


or older version)
a This work is done inside the cab (from
PC).
a It is prohibited in the initial setting to modify the data of service meter [SMR].
[Machine Information]
1) Open [Machine Information] tab.
a [Data clear and Set up] menu displays
[Machine Information] tab first.
2) Check every data for correctness.

3)

When [Date/Time] information is not appropriate, correct it in the following manner.


1] Press [Edit] button in the lower right
side of [Date/Time] box to display the
correction screen.
2] After correcting it to the correct information, press [OK] button.

4)

When [Machine Information] information is


not appropriate, correct it in the following
manner.
1] Press [Edit] button in the lower right
side of [Machine Information] dialog
box to display the correction screen.
2] After correcting it to the correct information, press [OK] button.

5)

As every data in [Machine Information]


has been checked and corrected, press
[Apply] button to settle the setting.
a As [Apply] button is pressed, a message confirming above setting will
appear on the screen. Check the setting again and, if the setting is correct,
press [OK] button.
a ORBCOMM installation specification
requires the settlement operation after
[Communication Setting] is completed.

[Communication Setting] [ORBCOMM installation


specification only]
a This setting shall be implemented after the
request for station opening has been made
and station of ORBCOMM has been opened.
6) Open [Communication Setting] tab.
7) Check every data for correctness.

8)

219

When modifying the setting of [SHORT


FAULT HISTORY], employ the following
procedure.
1] Select [SHORT FAULT HISTORY] from
the screen and then press [Edit] button
in the lower left side of [File Transfer
Setting] block to display the setup
screen.
2] Correct the setting and, as it is completed, press [OK] button.
a In the initial setting, select [Occurrence] from [Timing] item and then
set the function to ON.

When modifying the setting of [SHORT


TREND ANALYSIS], employ the following
procedure.
1] Select [SHORT TREND ANALYSIS]
from the screen and then press [Edit]
button in the lower left side of [File
Transfer Setting] block to display the
setup screen.
2] Correct the setting and, as it is completed, press [OK] button.
a In the initial setting, enter [20h] to
[SMR] and then set the function to
ON.

11) As every data in [Communication Setting]


has been checked and corrected, press
[Apply] button to settle the setting.
a As [Apply] button is pressed, a message confirming above setting will
appear on the screen. Check the setting again and, if the setting is correct,
press [OK] button.

10) When modifying the setting of [Satellite


Setting], employ the following procedure.
1] Press [Edit] button in the [Satellite
Setting] block to display the correction screen.
2] Set the GCC code to the region
applied and, as setting is completed,
press [OK] button.

12) As every data in [Machine Information]


and [Communication Setting] has been
checked and corrected, press [Exit] button
to end [VHMS initial setting tool].

9)

GCC codes and applicable regions


Code

Applicable region

Code

Applicable region

America

122

Korea

120

Italy

123

Brazil

121

Malaysia

130

Japan

220

6.

3)

Initial setting of VHMS controller (Ver. 3. 5. 2. 1


or later version)
a This work is done inside the cab (from PC).
a It is prohibited in the initial setting to modify the data of service meter [SMR].
1) Select [VHMS Setting] and then press
[Next] button.

Confirm the machine information and, if


they are correct, press [Next] button.

2)

Select [Set up & All clear] and press [Next]


button.

221

When VHMS has been installed later,


it is required to enter the information
such as [Serial No.].

4)
5)
6)

7)

Select the time zone.


Enter the local time.
When DST (Daylight Saving Time) (or
summer time) is currently used, press
[Next] button.
a Selecting DST advances the clock by
an hour. Thus, correction of the time
is needed again.

8)

If there is no problem in the setting displayed last, press [Apply] button.

9)

A screen message will confirm whether or


not the data before the setting is to be
saved. If the data is not necessary, select
[NO].

Set the GCC code to the target region of


application and, as setting is completed,
press [Next] button.
GCC codes and applicable regions

Code

Applicable region

Code

Applicable region

America

122

Korea

120

Italy

123

Brazil

121

Malaysia

130

Japan

10) As correction of the first setting is completed, press [OK] button to end the program.

222

7.

Performing Quick Pm
a Perform the following procedure in the cab.
a The Quick Pm means the Pm clinic performed by using the snap shot (manual)
function of the machine monitor.
1) Run the engine at low idle and set the
machine in the following position.
q
Swing the boom 90 to right
(with the idler on the front side).
q
Set the arm vertically.
q
Lower the bucket bottom to the ground
and set it horizontally.
2) Set the switches and lever in the following
positions.
q
Working mode switch: P-mode
q
Heavy lift switch: ON
q
Auto-decelerator switch: ON
q
Swing lock switch: OFF
q
PCC lock lever: Free
3) Set the machine monitor to display the
service menu.
a For the operating method, see Special function of machine monitor.
4) On the initial screen of the service menu,
select 10 Snap shot menu.

5)

6)

Press the [ ] switch to start the snap shot


operation.
a Before starting the snap shot operation, understand the operating procedure for the Quick Pm by referring to
Operating procedure for Quick Pm.
a The data of 35 items are recorded
and saved for 7 minutes 30 seconds
after the switch on the machine
monitor is pressed.
a The data are recorded at the intervals
of 10 seconds for the first 5 minutes
and at the intervals of 1 second for
the 2 minutes 20 seconds after the 5
minutes.
a To interrupt the snap shot operation,
press the switch.

223

If the snap shot operation is interrupted, the data collected up to now


are not recorded. In this case, repeat
the operation from the first.

Operate the fuel dial, swing lock switch,


both work equipment control levers, and
both travel levers according to the Opera t i n g p r oc e d u r e f or Q u i c k P m a n d
elapsed time.
a The elapsed time is displayed on the
machine monitor.
k Since the operator must operate
the work equipment, swing the
boom, and drive the machine actually for the Quick Pm, take extreme
care of safety around the machine
during the work.

7)

If the following screen appears 7 minutes


30 seconds after the snap shot is started,
the snap shot is finished.
a The initial screen of the service menu
appears automatically 5 seconds after
the snap shot operation is finished.

224

Operating procedure for Quick Pm


No.

Elapsed time

Time on
snap data

Fuel
dial

Swing lock
switch

Data read in Pm clinic after data


are downloaded

Operation of lever

Start
O
Finish

0:00
O
0:30

330.00
O
300.00

MIN
(Low)

OFF

Set all levers in neutral.

Start
O
Finish

0:30
O
1:00

300.00
O
270.00

MAX
(High)

OFF

Set all levers in neutral


(Turn decelerator on).

Engine speed
(2nd deceleration speed)

Start
O
Finish

1:00
O
1:30

270.00
O
240.00

MAX
(High)

OFF

Move levers finely [Note]


(Turn decelerator off).

Start
O
Finish

1:30
O
2:30

240.00
O
180.00

MAX
(High)

OFF

Raise right-hand track


shoe and drive it idle
(Set lever to stroke end).

Start
O
Finish

2:30
O
3:30

180.00
O
120.00

MAX
(High)

OFF

Swing 180.
Raise left-hand track shoe Rear pump oil pressure
and drive it idle (Set lever
(Hydraulic pressure)
to stroke end).

Start
O
Finish

3:30
O
4:00

120.00
O
090.00

MAX
(High)

ON

R.H. swing relief.

Swing pump oil pressure


(Relief pressure)

Start
O
Finish

4:00
O
4:30

090.00
O
060.00

MAX
(High)

ON

L.H. swing relief.

Swing pump oil pressure


(Relief pressure)

Start
O
Finish

4:30
O
5:00

060.00
O
030.00

MAX
(High)

ON

Arm OUT relief.

Front, rear, swing pump oil pressure


(Low relief pressure)

Start
O
Finish

5:00
O
5:30

030.00
O
000.00

MAX
(High)

ON

Bucket DUMP relief.

Front, rear pump oil pressure


(Low relief pressure)

10

Start
O
Finish

5:30
O
6:00

000.00
O
030.00

MAX
(High)

ON

Bucket CURL relief.

Front, rear, swing pump oil pressure


(Low relief pressure)

11

Start
O
Finish

6:00
O
6:30

030.00
O
060.00

MAX
(High)

ON

Arm IN relief.

Front, rear, swing pump oil pressure


(Low relief pressure)

12

Start
O
Finish

6:30
O
7:00

060.00
O
090.00

MAX
(High)

ON

Boom RAISE relief.

Front, rear, swing pump oil pressure


(High relief pressure)
Engine speed
Blow-by pressure, exhaust
temperature, PTO oil temperature

13

Start
O
Finish

7:00
O
7:30

090.00
O
120.00

MAX
(High)

ON

Set all levers in neutral


(1st deceleration o 2nd
deceleration)

Engine speed
(1st deceleration speed)

14

7:30

120.00

MIN
(Low)

ON

Finish

Engine speed (Low idle)


Engine oil pressure (Low idle)
Engine coolant temperature
Hydraulic oil temperature
Outside temperature
Control pump pressure (Low idle)

Engine speed (High idle)


Engine oil pressure (High idle)
Control pump pressure (High idle)
Fan pump pressure
(Cooling fan, aftercooler fan)

Front pump oil pressure


(Hydraulic pressure)

Note: To turn off the decelerator and set the engine speed to high idle, move one of both work equipment control
levers and both travel levers to a degree that the work equipment does not move or the machine does not
swing or travel. (If the PPC oil pressure switch is turned ON, the auto-decelerator is turned OFF.)

225

8.

a
a

Download of setting data


1) Using harness [1] of service kit ZB1, connect PC ZB2 to download connector DLF
in the cab or download connector VDL on
the ground.

3)

Download connector VH13 in the cab


is installed in the front side of the right
stand of operator seat.

9.

2)

Operating [VHMS analysis tool] on PC,


start up the VHMS analysis tool.

Using [Download] function, download the


data currently recorded on VHMS to PC.
a For the operating procedure, see the
VHMS analysis tool operation and
maintenance manual.
a After making sure the download is
complete, proceed to the next step.

Confirmation of download data


1) Check the setting data using [View] function.
a For the operating procedure, see the
VHMS analysis tool operation and
maintenance manual.
a Make sure that [MFA0] code, which
was used in the quick snapshot, is
indicated in [Fault History].
a Make sure the snap shot data are
recorded.

2)

226

Enter [User Name] and [Password].


For the operating procedure, see the
VHMS analysis tool operation and
maintenance manual.

As check of the setting data is finished,


end [VHMS analysis tool].

11. Report to Komatsu


As steps 1 9 are completed, send VHMS/
WebCARE setting report to VHMS/WebCARE
Support Center in Komatsu Headquarters.
a This report is a must since setting on the
receiving end in the satellite communication must be done by Komatsu.
a In this case, send VHMS data via Notes
(LAN) or E-mail (WAN).

10. Disconnecting the PC


1) Make sure the starting switch is at OFF
position.
k Before connecting or disconnecting a PC, be sure to turn off the
starting switch.
2) End the OS of PC ZB2 and then turn off
the PC power.

Komatsu VHMS/WebCARE Support Center

2-3-6, Akasaka Minato-Ku Tokyo, Japan


FAX: 81-3-5561-4766 (from outside of Japan)
FAX: 03-5561-4766 (Domestic user)
E-mail: webcare@komatsu.co.jp

3)

When the data was download into the cab,


disconnect harness [1] of service kit ZB1
from download connector VH13.

227

[For storage]
VHMS initial setting work check sheet

Date of setting:
DB/branch
office name
Data entered by:

Setup step

Check item

Result

Model name
1

Confirmation of machine body and


component nameplates

Serial No.
Engine serial No.
VHMS controller serial No.

Connection between PC and VHMS


controller

Is the connection secure?

yes

no

VHMS controller check for normal


operation

Is it operating normally?
(Displays counting in ascending-order succeeding to
rotation)

yes

no

Is "Data Clear and Set up" selected for the setting tool
mode?

yes

no

Is model name identical with machine body?

yes

no

Is machine body serial No. correctly entered?

yes

no

4 Starting of VHMS initial setting tool

Initial setting of VHMS controller


(Setting of machine body informa5 tion)
In this step, basic machine body
information are set on VHMS controller

Is engine serial No. correctly entered?

yes

no

Is today's date entered?

yes

no

Is current time entered?

yes

no

Is SMR correctly entered?

yes

no

6 Saving of settings

Is LED (7-segment) turned off?

yes

no

7 Confirmation of VHMS function

Is LED operation normal?

yes

no

8 Execution of quick Pm

Is service mode "SNAPSHOT" turned on and is the


switch hit?

yes

no

9 Data storing operation on VHMS

Is LED (7-segment) turned off?

yes

no

10 Download

Is LED operation normal?

yes

no

Are all files downloaded?

yes

no

The time downloaded (Reference wrist watch)


11 Confirmation of download data

12 Data storing operation on VHMS

Hour,
minute:

[Confirmation of data]
Is [MFA0] error present in Fault History?

yes

no

Are SMR and time in Fault History consistent with settings?

yes

no

Is any data missing in Snap Shot0?

yes

no

Is LED (7-segment) turned off?

yes

no

228

[For storage]
ORBCOMM station opening work
check sheet

Date of setting:
DB/branch
office name
Data entered by:

Setup step

Check item

Result

Model name
Confirmation of machine body and
1
component nameplates

Serial No.
Engine serial No.
VHMS controller serial No.
ORBCOMM terminal serial No.

Connection between PC and VHMS


controller

Is the connection secure?

yes

no

VHMS controller check for normal


operation

Is it operating normally?
(Displays counting in ascending-order succeeding to
rotation)

yes

no

Is "Set up" selected for the setting tool mode?

yes

no

On

Off

On

Off

On

Off

4 Starting of VHMS initial setting tool

Entry of setting to S.Fault History


Initial setting of VHMS controller
1. Setting of communication
(Setting of machine body information and PLM are completed)

Presence/absence of communication
Number of cases (Default is 8 cases)
Entry of setting of S.Trend Analysis setting
Presence/absence of communication
Interval (Default is 20H)

Entry of setting of S.Payload data


Presence/absence of communication
Tabulation start time
Interval of tabulation (in days)
2. Setting for start of communication

6 Saving of settings
7

ORBCOMM controller performance


check

day

Is GCC code set? (130 for Japan)

yes

no

Is LED (7-segment) turned off after data was stored?

yes

no

How is decimal point display in VHMS monitor


(7-segment)?
(OFF, ON, long/short flashing)

yes

no

229

230

Backhoe specification 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.
After checking, send these check sheets to the chassis plant.
Model - Type

Machine serial No.

User unit No.

Engine model

PC2000-8

Engine serial No.

SAA12V140E-3

Backhoe spec.
Service meter reading

Date of inspection

Attachment
1

Location of machine at inspection

Manufacturer

Model
Distributor's name
Serial No.

Customer's name

Address:

Name:

Date :

Inspector's comments:

Inspector's name:

KOMATSU USE ONLY:


Check sheet receiving date:

Title:

By:
Signature:

Remark:

Check sheets filling instructions:


1.

Use following indexes for entry of judgment.


.......... Normal
.......... Correction made on abnormal point
.......... Abnormal

2. Enter measured values in parentheses. [

.......... Not applied

Notes:
(1) Criteria area based on the standards when the machine is shipped out of the factory.
(2) This FEIELD ASSEMBLY INSPECTION REPORT is for "A" specification.

Delivery
report No.

Revision

Category

Backhoe specification 2/13


At local
At ___
assembly operating
time
hours

Check item
Oil and coolant levels

Criterion

Measured value
Radiator coolant level

Sub tank coolant level

Max. 25 mm

Coolant

Soft water

Check before assembly

Antifreeze
(A, B, C, D, E)

]
]

Added/
Not added

Freezing
point

SAE10WCD
[
SAE30CD
SAE10WCD
[
SAE30CD

Engine oil
PTO oil
Swing machinery
case oil

Front

]
]

SAE30CD
[

Rear SAE30CD

A: -50 -40 C D:-20 -10 C


B: -40 -30 C E:-10 0 C
C: -30 -20 C (Not necessary in summer)
L H +5
(In 10 minutes after stopping engine)
L +5 H
(In 10 minutes after stopping engine)
L +5 H +10
(In 10 minutes after stopping engine)

Right

SAE30CD

Left

SAE30CD

Hydraulic oil

SAE10WCD [

Between H L (Posture: Max. reach)

Battery electrolyte

Max. 13 mm from filler bottom

Final drive gear


case oil

Engine No.

0 -10 mm from level plug bottom

When accepted
Service meter[
h]

Check during assembly

Radiator coolant
level
[
Sub tank coolant
level
[

]
After check
[

h]

Loosened or untightened connecting pin lock bolt

Must not be detected.

Loosened or untightened work equipment piping split flange

Must not be detected.

Uninstalled, lost or caught work equipment piping O-ring

Must not be detected.

Loosened or twisted grease piping joint

Must not be detected.

Shim adjustment for work equipment pin

Max. 1 mm
(For shim position, see assembly manual)

Improperly inserted or un-inserted wiring

Must not be detected.

Loosened or untightened ladder mounting bolt

Must not be detected.

Check during assembly

Revision

Category

Backhoe specification 3/13

Check item

At local
At ___
assembly operating
time
hours

Criterion

Loosened or untightened counterweight mounting bolt

Must not be detected.

Clearance or level difference between counterweight and frame

Max. 15 mm

Loosened or untightened operator's cab mounting bolt

Must not be detected.

Loosened or untightened cab base mounting bolt

Must not be detected.

Loosened or untightened container base mounting bolt

Must not be detected.

Loosened or untightened hydraulic tank mounting bolt

Must not be detected.

Loosened or untightened fuel tank mounting bolt

Must not be detected.

Loosened or untightened center frame mounting bolt

Must not be detected.

Loosened or untightened travel system piping bolt/joint

Must not be detected.

Uninstalled, lost or caught travel system piping O-ring

Must not be detected.

Loosened or untightened track frame mounting bolt

Must not be detected.

Loosened or untightened travel motor cover bolt

Must not be detected.

Uninstalled part (Rearview mirror, etc.)

Must not be detected.

Bleeding air from hydraulic pump

As per assembly manual

Bleeding air from travel motor


Bleeding air from swing holding brake circuit
Bleeding air from work equipment cylinder circuit
Bleeding air from HIC circuit
Adjustment of track tension
Flushing hydraulic circuit

Greasing each part of work equipment

Grease all parts.


Check that grease comes out.

Addition of hydraulic oil

Add to between L H.

Addition of fuel and window washing fluid

Fill tank.

Revision

Category

Backhoe specification 4/13

Check item

At local
At ___
assembly operating
time
hours

Monitor display
1. Check of monitor function
When the starting switch is turned ON, all of the gauge section,
check-before-starting section and monitor section must light up
and alarm buzzer must sound.
2. Check of gauge section and check-before-starting section
All lamps must go off about 3 seconds after the starting switch is
turned ON (all lamps are ON), then only the gauge section is
displayed and the check-before-starting section and monitor
section are kept OFF.
3. Check of monitor section
After the engine is started, the caution lamps must not light up
and the alarm buzzer must not sound in the range between low
idle and high idle.

Criterion

Display must be as shown on left.

Service meter must be free from flaw, blur and


uneven operation.
Initialization must be executed.
(Pm clinic, downloading, application for start of use).

Operation of service meter


Initialization of VHMS

Check of monitor

Monitor

X (1/2): Ordinary work screen (1/2), X (2/2): Ordinary work screen (2/2)
Screens X (1/2) and X (2/2) are displayed alternately each time function switch F1 (7) is pressed.
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)

Window washer switch


Wiper selector switch
Alarm buzzer cancel switch
Heavy lift switch
Working mode selector switch
Auto-decelerator selector switch
Function switches (F1 F7)
Engine coolant temperature monitor
Engine coolant temperature gauge
Hydraulic oil temperature monitor
Hydraulic oil temperature gauge
Wiper monitor
Swing lock switch
Preheater monitor
Auto grease unit operation monitor
Engine stop monitor

(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
(28)
(29)
(30)
(31)
(32)

Clock/Service meter
Auto-decelerator monitor
Working mode monitor
Heavy lift monitor
Truck counter 1
Truck counter 2
ECO gauge
Fuel level gauge
Fuel level monitor
PTO oil temperature gauge
PTO oil temperature monitor
Engine oil temperature gauge
Engine oil temperature monitor
Engine oil pressure gauge
Engine oil pressure monitor
Numeral key (0 9)

Revision

Check item

At local
At ___
assembly operating
time
hours

Criterion

Check of switches and levers

Category

Backhoe specification 5/13

(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)

VHMS download connector


12V outlet
Cigarette lighter (24V outlet)
AM/FM radio
Air conditioner panel 2
Air conditioner panel 1
Control lever (left)
Truck counter switch (2 pcs.)
Machine monitor

Operation of horn switch

Operation of hydraulic lock lever

Operation of swing lock switch

(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)

Foot rest
Travel pedal
Travel lever
Lock lever
Horn switch
Control lever (right)
Starting switch
Fuel control dial

If the switch is pressed, the horn sounds and


flashlight (if equipped) at the front of the cab
blinks for about 5 seconds.
Lever down: Lock
Engine can be started.
No work equipment moves.
Lever up: Unlock
Engine cannot be started.
All work equipment moves.
ON position (Operation):
When swing operation is performed,
machine does not swing. At this time, swing
lock monitor lights up.
OFF position (Reset):
Machine can swing. At this time, swing lock
monitor goes off.

Revision

Category

Backhoe specification 6/13

Check item

Operation of power-assisted ladder

Operation of emergency engine stop switch


Switch is installed to front and rear of engine compartment and
front of fuel tank (3 places in total).

At local
At ___
assembly operating
time
hours

Criterion
Ladder must be raised and lowered smoothly.
When ladder is lowered:
Machine cannot swing.
Warning lamp lights up.
When ladder is raised:
Machine can swing.
Warning lamp goes off.
If the switch is pressed when the engine is
started, engine must stop.
While the engine is stopped in an emergency,
warning lamp lights up.
Lighting of P: For heavy load work
Lighting of E: For lower fuel consumption

Operation of working mode selector switch


If the switch is operated, the monitor changes
and the operator can select.
Lamp ON: Auto-decelerator is operated.
Lamp OFF: Auto-decelerator is reset.
Operation of auto-decelerator switch

Check of switches and levers

Operation of heavy lift switch

Operation of wiper switch

Operation of window washer switch


Operation of buzzer cancel switch
Operation of room lamp switch
Operation of auxiliary lamp switch
Operation of working lamp switch

Operation of step light switch

Operation of rotary lamp switch

Operation of greasing mode switch

Operation of machine push-up switch


Operation of boom shockless control switch

Each time the switch is pressed, the monitor


changes and the operator can select.
During single boom raise operation, if the
switch is turned ON, the boom raise force is
increased.
Lighting of INT lamp:
Intermittent operation of wiper
Lighting of ON (Continuous) lamp:
Continuous operation of wiper
Lighting of ON (Continuous upper) lamp:
Continuous operation of only upper wiper
Each time the switch is pressed, the monitor
changes and the operator can select.
If the switch is pressed, the window washing
fluid spouts against the front glass.
(Wiper operation is linked.)
If the switch is pressed, alarm buzzer for
warning item is stopped.
ON position: Room lamp lights up.
OFF position: Room lamp goes off.
ON position: Auxiliary lamp lights up.
OFF position: Auxiliary lamp goes off.
ON position: Working lamp lights up.
OFF position: Working lamp goes off.
If the switch is pressed, the step light is
turned ON for about 90 seconds.
Even if the starting switch is OFF, if the
switch is pressed, the step light is turned ON
for about 90 seconds.
ON position: Rotary lamp lights up.
OFF position: Rotary lamp goes off.
MANUAL position:
Grease must be supplied manually.
AUTO position:
Grease is supplied automatically.
Low pressure setting: Boom thrust force is low.
High pressure setting: Boom thrust force is
increased.
If the switch is turned ON, work equipment
shakes less when boom is stopped.

Revision

Category

Backhoe specification 7/13

Check item
Operation of air conditioner
Operation of radio
Operation of cigarette lighter
Operation of truck counter switch

At local
At ___
assembly operating
time
hours

Criterion
When the switch is turned ON, the air
conditioner starts.
When the switch is turned ON, the radio
sounds.
If the lighter is pushed in, it is heated red and
returns automatically several seconds after.
If the switch (1 or 2) is pressed, the
confirmation buzzer sounds and the monitor
counts.

Check of switches and levers

Forward:
Operation of travel lever

Operation of left work equipment control lever


(With auto-deceleration function)
Operation of right work equipment control lever
(With auto-deceleration function)
Operation of bottom dump switch
Check of fault history (electrical system and mechanical system)

Lever is pushed forward.


(Pedal is angled forward)
Reverse: Lever is pushed back.
(Pedal is angled back)
N (Neutral):Machine stops.
This lever is used to operate the upper
structure and arm.
N (Neutral):Upper structure and arm are fixed.
This lever is used to operate the boom and
bucket.
N (Neutral):Boom and bucket are fixed.
Check that no abnormality is displayed and
then delete the fault history. After finishing all
the checks, check again that there is no fault
history.

Operation of emergency pump prolix switch

When normal: Switch is set "down".

While monitor is displaying E07 (Pump EPC solenoid system


error), operation can be continued with this switch set "up".
Operation of swing holding brake prolix switch

If the switch is set "up", the alarm buzzer


sounds and the monitor displays E07 error.
When normal: Switch is set "down".

While monitor is displaying E03 (Swing holding brake system


error), brake can be released and machine can swing with this
switch set "up". Swing brake is kept released, however.

If the switch is set "up", the monitor displays


E03 error.

Revision

Category

Backhoe specification 8/13


At local
At ___
assembly operating
time
hours

Check item

Criterion

Swing operation running in: Engine at high idle


(Work equipment posture: Max. reach)

Travel
performance

Swing performance

Normal swing speed

Right

sec]

Left

sec]

Empty

P mode: 11.6 13.6 sec/turn


E mode: 12.0 14.3 sec/turn

Brake angle

Max. 55 (Sensory)

Unevenness and hunting of swing

Must not be detected.

Abnormal sound and shakiness in swing

Must not be detected.

Travel operation running in: Engine at high idle


(Work equipment posture: Max. reach)

Abnormal sound and heating in track roller, carrier roller and idler

Abnormal sound and heating must not be


detected.

Operation of travel brake

Must operate securely without dragging.

Abnormal sound in travel and shakiness in swing

Must not be detected.

Travel deviation (Sensory)

Must be free from abnormal travel deviation in


the range from fine control to stroke end
(Sensory).

Travel deviation
(To be measured only
when abnormal)

Forward
mm/20m

Track rotation speed


Right

Left

Track tension

Stroke of
HIC cylinder
(Elongation)

Reverse

Forward
sec
Forward

sec

Right
mm

Right
mm

Reverse

sec

Reverse

sec

Left

mm

]
20.3 2.0 sec/turn
(P mode, full throttle)
]

Stroke of HIC cylinder


135 5 mm

Left

Max. 200 mm/20 m

mm/20m

mm

Revision

Category

Backhoe specification 9/13


At local
At ___
assembly operating
Criterion
time
hours
Work equipment running in: Engine at high idle (Note: Lower boom cylinder to ground level)
Pressurization: Relieve each port for 2 minutes and give shock 20 times (excluding boom lower operation).
Check item

Boom

Work equipment
posture
A mode

Arm

Empty

Raise

Work equipment
speed (including
cushion working time)

Boom

Arm

In

Work equipment performance

P mode
Engine: Full throttle
8.7 m boom
3.9 m arm
12 m3 bucket

Work equipment
time lag
Engine: Low
When normal:
Sensory
When abnormal:
Measure

Curl

Bucket [

Arm

Empty

Empty

sec

Lower

sec

Out

sec

Dump

Lower

Boom

Bucket

In

Dump

Bucket [

Raise: 7.5 0.8 sec

sec

Lower: 5.0 0.5 sec

In: 7.3 0.7 sec

sec

Out: 5.2 0.5 sec

Curl: 5.0 0.5 sec

sec

sec

Dump: 3.9 0.4 sec

Max. 6.0 sec

Max. 5.0 sec

sec

sec

Max. 4.0 sec

Abnormal sound from hydraulic pump and PTO

Must be free from abnormality during no-load


operation and when relieved.

Heating of PTO

Must be free from abnormal heating.

Partial engine output performance

Engine must not hunt in any gear speed during


no-load operation and must not stall when
hydraulic circuit is relieved at low idle.

Fine control performance

Work equipment must operate smoothly.

Machine push-up operation (including machine push-up function)

Boom, arm and bucket must not escape.

Abnormal sound or creak from work equipment

Must not be detected.

Shock at cylinder stroke end


(Shock at boom raise and arm in stroke ends)

Cushion must work sufficiently.

Function of accumulator

Immediately after engine is stopped, with key


switch ON, boom cylinder must be retracted
from extension stroke end to ground level
(when arm is at max. reach).

Revision

Category

Backhoe specification 10/13

Check item

At local
At ___
assembly operating
time
hours

Criterion

Around operator's seat

During operation

Check of each part


Operating effort of control lever when each actuator is operated

Lever must not be hitched during operation.


Lever must return to neutral by itself.

Shaking and beat noise of operator's cab

Must not be detected.

Beat noise of frame, guard and ladder

Must not be detected.

Movement of doors and windows

Must move smoothly.

Locks of doors and windows

Must work securely.

Adjustment of operator's seat

All adjustment must be possible.

Must not be detected.

Undercarriage

Oil leakage
(Idler, track roller, sprocket,
final drive gear case, motor, brake valve)

Interference of each part

Must not be detected.

Looseness of track shoe bolt

Must not be detected.

Contact of link tread

Must be free from overlapping, flaking and


breakage.

Must not be detected.

Around chassis

Oil leakage
(Center swivel joint, pump, solenoid valve, relief valve,
control valve, PPC valve, swing motor, brake valve,
shuttle valve, swing machinery, hydraulic tank, piping)

Fuel leakage
(Fuel tank, engine, piping)

Must not be detected.

Water leakage from engine cooling system

Must not be detected.

Oil leakage from engine lubrication system

Must not be detected.

Gas leakage from engine gas system

Must not be detected.

Operation of covers

Must move smoothly.

Locks of covers

Must work securely.

Around chassis

Revision

Category

Backhoe specification 11/13

Check item

Criterion

Operation of grease pump

Must operate smoothly.

Looseness and insufficient insertion of electric wiring terminals

Must not be detected.

Electric wiring route

Clearance of at least 10 mm must be made


around moving part and edge.

Air leakage from air system

Must not be detected.

Interference of each part

Must not be detected.

Oil leakage
(Cylinder, piping, block)

Around work equipment

At local
At ___
assembly operating
time
hours

Must not be detected.

Grease leakage from grease piping

Must not be detected.

Interference of work equipment

Must not be detected.

Looseness of work equipment piping clamp and play of piping

Must not be detected.

Twist of hydraulic hose and operation of work equipment at


reverse

Must not be detected.

Backhoe specification 12/13

Revision

Category

Note: If the operation or function is defective, measure as necessary.


Check item

The speeds in the criteria column are the values in P mode.


At local
At ___
assembly operating
Criterion
time
hours
P mode

1. Engine speed: Check in monitoring mode "01002".


Low idle

rpm]

825 50 rpm

High idle

rpm]

1980 50 rpm

rpm]

1750 50 rpm

rpm]

1800 50 rpm

Boom raise relieve speed


(Heavy lift: OFF)
Boom raise relieve speed
(Heavy lift: ON)

2. Oil pressure measurement: Check in monitoring mode "01002".


1F pump: "01124 1R pump: "01125"
2F pump: "01126 2R pump: "01127"
1F [
1R [
Control valve main set pressure
2F [
2R [

MPa]
MPa]
MPa]
MPa]

29.4 1.0 MPa

At engine high idle, boom


raise, P mode, heavy lift
OFF and relief

1F [
Control valve main set pressure 1R [
(Boosted pressure)
2F [
2R [

MPa]
MPa]
MPa]
MPa]

31.4 1.0 MPa

At engine high idle, boom


raise, P mode, heavy lift ON
and relief
At engine high idle, swing, P
mode and relief

Swing relief set pressure

1F [Right
1F [Left

MPa]
MPa]

28.4 2.0 MPa

Pilot relief valve set pressure

MPa]

3.2 + 0.2/-0 MPa At engine high idle

3. Current and voltage measurement


EPC current: Check in monitoring mode.
1F pump: "01307 1R pump: "01309"
2F pump: "01311 2R pump: "01313"

Pump EPC current

1F [
1R [
2F [
2R [

mA]
mA]
mA]
mA]

280 50 mA

At engine high idle, lever


neutral and P mode

1F [
1R [
2F [
2R [

mA]
mA]
mA]
mA]

470 100 mA

At engine high idle, boom


raise, P mode, heavy lift
OFF and relief

J/S differential pressure output voltage: Check in monitoring mode.


1F pump: "13808 1R pump: "13809"
2F pump: "13810 2R pump: "13811"

J/S differential pressure


output voltage

1F [
1R [
2F [
2R [

V]
V]
V]
V]

Min. 3.2 V

At engine high idle, lever


neutral and P mode

1F [
1R [
2F [
2R [

V]
V]
V]
V]

Max. 1.2 V

At engine high idle, arm in,


P mode, and relief

Revision

Category

Backhoe specification 13/13


At local
At ___
assembly operating
time
hours

Check item

Criterion

4. Work equipment hydraulic drift


(Bucket: No load, Hydraulic oil temperature: 50 5 C)
Bucket tooth tip

mm]

Max. 1,200 mm/15 min

Note: Only when the hydraulic drift of the bucket tooth tip is not
acceptable, measure the hydraulic drift of the following
cylinders.
Boom cylinder

mm]

Max. 17 mm/min (250 mm/15 min)

Arm cylinder

mm]

Max. 23 mm/min (350 mm/15 min)

Bucket cylinder

mm]

9 mm/min (140 mm/15 min)

5. Operating effort and stroke


Boom
control lever

Operating Raise
effort

Main measurement items

Stroke
Swing
control lever

Arm
control lever

N
{kg}

Right
Left
[
mm] [

Operating Curl
effort
Stroke

N
{kg}

Curl
[

N
{kg}

In
[

Out
mm] [

Right travel lever Operating Forward


effort
Stroke
Left travel lever

N
{kg}

N
{kg}

N
{kg}

mm]
N
{kg}

Play
mm] [
Dump

Out

mm]
N
{kg}

mm]
N
{kg}

Play
mm] [
Reverse

Forward
Reverse
Play
[
mm] [
mm] [

Operating Forward
effort
Stroke

Left

Dump
Play
mm] [
mm] [

Operating In
effort
Stroke

Lower

Raise
Lower
Play
[
mm] [
mm] [

Operating Right
effort
Stroke

Bucket
control lever

N
{kg}

Reverse

Forward
Reverse
Play
[
mm] [
mm] [

mm]
N
{kg}

mm]
N
{kg}

mm]

15.7 4.9 N
{1.6 0.5 kg}
Stroke: 85 10 mm
Play: Max. 10 mm
12.8 3.9 N
{1.3 0.4 kg}
Stroke: 85 10 mm
Play: Max. 10 mm
12.8 3.9 N
{1.3 0.4 kg}
Stroke: 85 10 mm
Play: Max. 10 mm
15.7 4.9 N
{1.6 0.5 kg}
Stroke: 85 10 mm
Play: Max. 10 mm
24.5 5.9 N
{2.5 0.6 kg}
Stroke: 115 15 mm
Play: Max. 10 mm
24.5 5.9 N
{2.5 0.6 kg}
Stroke: 115 15 mm
Play: Max. 10 mm

Serial No. of controllers and monitor

Serial No. Confirm with monitoring mode or visual check.


Engine controller (L-BANK)

Engine controller (R-BANK)

Pump controller (UPPER)

Pump controller (LOWER)

VHMS controller

ORBCOMM controller

Monitor

At engine
high idle and
relief

Loading shovel specification 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.
After checking, send these check sheets to the chassis plant.
Model - Type

Machine serial No.

User unit No.

Engine model

PC2000-8

Engine serial No.

SAA12V140E-3

Loading Shovel spec.


Service meter reading

Date of inspection

Attachment
1

Location of machine at inspection

Manufacturer

Model
Distributor's name
Serial No.

Customer's name

Address:

Name:

Date :

Inspector's comments:

Inspector's name:

KOMATSU USE ONLY:


Check sheet receiving date:

Title:

By:
Signature:

Remark:

Check sheets filling instructions:


1.

Use following indexes for entry of judgment.


.......... Normal
.......... Correction made on abnormal point
.......... Abnormal

2. Enter measured values in parentheses. [

.......... Not applied

Notes:
(1) Criteria area based on the standards when the machine is shipped out of the factory.
(2) This FEIELD ASSEMBLY INSPECTION REPORT is for "A" specification.

Delivery
report No.

Revision

Category

Loading shovel specification 2/13


At local
At ___
assembly operating
time
hours

Check item
Oil and coolant levels

Criterion

Measured value
Radiator coolant level

Sub tank coolant level

Max. 25 mm

Coolant

Soft water

Check before assembly

Antifreeze
(A, B, C, D, E)

]
]

Added/
Not added

Freezing
point

E010W30-DH
[
E015W40-DH
T010
[
T030

Engine oil
PTO oil
Swing machinery
case oil

Front

]
]

T030
[

Rear T030

A: -50 -40 C D:-20 -10 C


B: -40 -30 C E:-10 0 C
C: -30 -20 C (Not necessary in summer)
L H +5
(In 10 minutes after stopping engine)
L +5 H
(In 10 minutes after stopping engine)
L +5 H +10
(In 10 minutes after stopping engine)

Right

T030

Left

T030

Hydraulic oil

T010
H046HM

Between H L (Posture: Max. reach)

Battery electrolyte

Max. 13 mm from filler bottom

Final drive gear


case oil

Engine No.

0 -10 mm from level plug bottom

When accepted
Service meter[
h]

Check during assembly

Radiator coolant
level
[
Sub tank coolant
level
[

]
After check
[

h]

Loosened or untightened connecting pin lock bolt

Must not be detected.

Loosened or untightened work equipment piping split flange

Must not be detected.

Uninstalled, lost or caught work equipment piping O-ring

Must not be detected.

Loosened or twisted grease piping joint

Must not be detected.

Shim adjustment for work equipment pin

Max. 1 mm
(For shim position, see assembly manual)

Improperly inserted or un-inserted wiring

Must not be detected.

Loosened or untightened ladder mounting bolt

Must not be detected.

Check during assembly

Revision

Category

Loading shovel specification 3/13

Check item

At local
At ___
assembly operating
time
hours

Criterion

Loosened or untightened counterweight mounting bolt

Must not be detected.

Clearance or level difference between counterweight and frame

Max. 15 mm

Loosened or untightened operator's cab mounting bolt

Must not be detected.

Loosened or untightened cab base mounting bolt

Must not be detected.

Loosened or untightened container base mounting bolt

Must not be detected.

Loosened or untightened hydraulic tank mounting bolt

Must not be detected.

Loosened or untightened fuel tank mounting bolt

Must not be detected.

Loosened or untightened center frame mounting bolt

Must not be detected.

Loosened or untightened travel system piping bolt/joint

Must not be detected.

Uninstalled, lost or caught travel system piping O-ring

Must not be detected.

Loosened or untightened track frame mounting bolt

Must not be detected.

Loosened or untightened travel motor cover bolt

Must not be detected.

Uninstalled part (Rearview mirror, etc.)

Must not be detected.

Bleeding air from hydraulic pump

As per assembly manual

Bleeding air from travel motor


Bleeding air from swing holding brake circuit
Bleeding air from work equipment cylinder circuit
Bleeding air from HIC circuit
Adjustment of track tension
Flushing hydraulic circuit

Greasing each part of work equipment

Grease all parts.


Check that grease comes out.

Addition of hydraulic oil

Add to between L H.

Addition of fuel and window washing fluid

Fill tank.

Revision

Category

Loading shovel specification 4/13

Check item

At local
At ___
assembly operating
time
hours

Monitor display
1. Check of monitor function
When the starting switch is turned ON, all of the gauge section,
check-before-starting section and monitor section must light up
and alarm buzzer must sound.
2. Check of gauge section and check-before-starting section
All lamps must go off about 3 seconds after the starting switch is
turned ON (all lamps are ON), then only the gauge section is
displayed and the check-before-starting section and monitor
section are kept OFF.
3. Check of monitor section
After the engine is started, the caution lamps must not light up
and the alarm buzzer must not sound in the range between low
idle and high idle.

Criterion

Display must be as shown on left.

Service meter must be free from flaw, blur and


uneven operation.
Initialization must be executed.
(Pm clinic, downloading, application for start of use).

Operation of service meter


Initialization of VHMS

Check of monitor

Monitor

X (1/2): Ordinary work screen (1/2), X (2/2): Ordinary work screen (2/2)
Screens X (1/2) and X (2/2) are displayed alternately each time function switch F1 (7) is pressed.
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)

Window washer switch


Wiper selector switch
Alarm buzzer cancel switch
Heavy lift switch
Working mode selector switch
Auto-decelerator selector switch
Function switches (F1 F7)
Engine coolant temperature monitor
Engine coolant temperature gauge
Hydraulic oil temperature monitor
Hydraulic oil temperature gauge
Wiper monitor
Swing lock switch
Preheater monitor
Auto grease unit operation monitor
Engine stop monitor

(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
(28)
(29)
(30)
(31)
(32)

Clock/Service meter
Auto-decelerator monitor
Working mode monitor
Heavy lift monitor
Truck counter 1
Truck counter 2
ECO gauge
Fuel level gauge
Fuel level monitor
PTO oil temperature gauge
PTO oil temperature monitor
Engine oil temperature gauge
Engine oil temperature monitor
Engine oil pressure gauge
Engine oil pressure monitor
Numeral key (0 9)

Revision

Check item

At local
At ___
assembly operating
time
hours

Criterion

Check of switches and levers

Category

Loading shovel specification 5/13

(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)

VHMS download connector


12V outlet
Cigarette lighter (24V outlet)
AM/FM radio
Air conditioner panel 2
Air conditioner panel 1
Control lever (left)
Truck counter switch (2 pcs.)
Machine monitor

Operation of horn switch

Operation of hydraulic lock lever

Operation of swing lock switch

(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)

Foot rest
Travel pedal
Travel lever
Lock lever
Horn switch
Control lever (right)
Starting switch
Fuel control dial

If the switch is pressed, the horn sounds and


flashlight (if equipped) at the front of the cab
blinks for about 5 seconds.
Lever down: Lock
Engine can be started.
No work equipment moves.
Lever up: Unlock
Engine cannot be started.
All work equipment moves.
ON position (Operation):
When swing operation is performed,
machine does not swing. At this time, swing
lock monitor lights up.
OFF position (Reset):
Machine can swing. At this time, swing lock
monitor goes off.

Revision

Category

Loading shovel specification 6/13

Check item

Operation of power-assisted ladder

Operation of emergency engine stop switch


Switch is installed to front and rear of engine compartment and
front of fuel tank (3 places in total).

At local
At ___
assembly operating
time
hours

Criterion
Ladder must be raised and lowered smoothly.
When ladder is lowered:
Machine cannot swing.
Warning lamp lights up.
When ladder is raised:
Machine can swing.
Warning lamp goes off.
If the switch is pressed when the engine is
started, engine must stop.
While the engine is stopped in an emergency,
warning lamp lights up.
Lighting of P: For heavy load work
Lighting of E: For lower fuel consumption

Operation of working mode selector switch


If the switch is operated, the monitor changes
and the operator can select.
Lamp ON: Auto-decelerator is operated.
Lamp OFF: Auto-decelerator is reset.
Operation of auto-decelerator switch

Check of switches and levers

Operation of heavy lift switch

Operation of wiper switch

Operation of window washer switch


Operation of buzzer cancel switch
Operation of room lamp switch
Operation of auxiliary lamp switch
Operation of working lamp switch

Operation of step light switch

Operation of rotary lamp switch

Operation of greasing mode switch

Operation of machine push-up switch


Operation of boom shockless control switch

Each time the switch is pressed, the monitor


changes and the operator can select.
During single boom raise operation, if the
switch is turned ON, the boom raise force is
increased.
Lighting of INT lamp:
Intermittent operation of wiper
Lighting of ON (Continuous) lamp:
Continuous operation of wiper
Lighting of ON (Continuous upper) lamp:
Continuous operation of only upper wiper
Each time the switch is pressed, the monitor
changes and the operator can select.
If the switch is pressed, the window washing
fluid spouts against the front glass.
(Wiper operation is linked.)
If the switch is pressed, alarm buzzer for
warning item is stopped.
ON position: Room lamp lights up.
OFF position: Room lamp goes off.
ON position: Auxiliary lamp lights up.
OFF position: Auxiliary lamp goes off.
ON position: Working lamp lights up.
OFF position: Working lamp goes off.
If the switch is pressed, the step light is
turned ON for about 90 seconds.
Even if the starting switch is OFF, if the
switch is pressed, the step light is turned ON
for about 90 seconds.
ON position: Rotary lamp lights up.
OFF position: Rotary lamp goes off.
MANUAL position:
Grease must be supplied manually.
AUTO position:
Grease is supplied automatically.
Low pressure setting: Boom thrust force is low.
High pressure setting: Boom thrust force is
increased.
If the switch is turned ON, work equipment
shakes less when boom is stopped.

Revision

Category

Loading shovel specification 7/13

Check item
Operation of air conditioner
Operation of radio
Operation of cigarette lighter
Operation of truck counter switch

At local
At ___
assembly operating
time
hours

Criterion
When the switch is turned ON, the air
conditioner starts.
When the switch is turned ON, the radio
sounds.
If the lighter is pushed in, it is heated red and
returns automatically several seconds after.
If the switch (1 or 2) is pressed, the
confirmation buzzer sounds and the monitor
counts.

Check of switches and levers

Forward:
Operation of travel lever

Operation of left work equipment control lever


(With auto-deceleration function)
Operation of bottom dump switch
Operation of right work equipment control lever
(With auto-deceleration function)
Operation of bottom dump switch
Check of fault history (electrical system and mechanical system)

Lever is pushed forward.


(Pedal is angled forward)
Reverse: Lever is pushed back.
(Pedal is angled back)
N (Neutral):Machine stops.
This lever is used to operate the upper
structure and arm.
N (Neutral):Upper structure and arm are fixed.
This lever is used to operate the boom and
bucket.
N (Neutral):Boom and bucket are fixed.
Check that no abnormality is displayed and
then delete the fault history. After finishing all
the checks, check again that there is no fault
history.

Operation of emergency pump prolix switch

When normal: Switch is set "down".

While monitor is displaying E07 (Pump EPC solenoid system


error), operation can be continued with this switch set "up".
Operation of swing holding brake prolix switch

If the switch is set "up", the alarm buzzer


sounds and the monitor displays E07 error.
When normal: Switch is set "down".

While monitor is displaying E03 (Swing holding brake system


error), brake can be released and machine can swing with this
switch set "up". Swing brake is kept released, however.

If the switch is set "up", the monitor displays


E03 error.

Revision

Category

Loading shovel specification 8/13


At local
At ___
assembly operating
time
hours

Check item

Criterion

Swing operation running in: Engine at high idle


(Work equipment posture: Max. reach)

Travel
performance

Swing performance

Normal swing speed

Right

sec]

Left

sec]

Empty

P mode: 11.5 13.6 sec/turn


E mode: 12.2 14.6 sec/turn

Brake angle

Max. 55 (Sensory)

Unevenness and hunting of swing

Must not be detected.

Abnormal sound and shakiness in swing

Must not be detected.

Travel operation running in: Engine at high idle


(Work equipment posture: Max. reach)

Abnormal sound and heating in track roller, carrier roller and idler

Abnormal sound and heating must not be


detected.

Operation of travel brake

Must operate securely without dragging.

Abnormal sound in travel and shakiness in swing

Must not be detected.

Travel deviation (Sensory)

Must be free from abnormal travel deviation in


the range from fine control to stroke end
(Sensory).

Travel deviation
(To be measured only
when abnormal)

Forward
mm/20m

Track rotation speed


Right

Left

Track tension

Stroke of
HIC cylinder
(Elongation)

Reverse

Forward
sec
Forward

sec

Right
mm

Right
mm

Reverse

sec

Reverse

sec

Left

mm

]
20.1 2.0 sec/turn
(P mode, full throttle)
]

Stroke of HIC cylinder


135 5 mm

Left

Max. 200 mm/20 m

mm/20m

mm

Revision

Category

Loading shovel specification 9/13


At local
At ___
assembly operating
Criterion
time
hours
Work equipment running in: Engine at high idle (Note: Lower boom cylinder to ground level)
Pressurization: Relieve each port for 2 minutes and give shock 20 times (excluding boom lower operation).
Check item

Work
equipment
posture

Boom

Arm

Bucket

Empty
Empty

Empty

Work equipment
speed (including
Boom
cushion working time)

P mode
Engine: Full throttle

Raise

In

Arm

Curl

sec

Open

Work equipment performance

Bottom
dump [

Engine: Low
When normal:
Sensory
When abnormal:
Measure

Lower

sec

Out

sec

Bucket [

Work equipment
time lag

Bottom dump

Dump

sec

Close

Lower

Boom

Arm

In

Dump

Bucket [

Empty

Raise: 8.3 0.8 sec

sec

Lower: 6.4 0.6 sec

In: 5.3 0.5 sec

sec

Out: 3.2 0.4 sec

Curl: 4.2 0.5 sec

sec

Dump: 2.9 0.4 sec

Open: 2.2 0.2 sec

sec

sec

]
sec

]
sec

Close: 2.2 0.2 sec

Max. 6.0 sec

Max. 5.0 sec

Max. 4.0 sec

Abnormal sound from hydraulic pump and PTO

Must be free from abnormality during no-load


operation and when relieved.

Heating of PTO

Must be free from abnormal heating.

Partial engine output performance

Engine must not hunt in any gear speed during


no-load operation and must not stall when
hydraulic circuit is relieved at low idle.

Fine control performance

Work equipment must operate smoothly.

Machine push-up operation (including machine push-up function)

Boom, arm and bucket must not escape.

Abnormal sound or creak from work equipment

Must not be detected.

Shock at cylinder stroke end


(Shock at boom raise and arm in stroke ends)

Cushion must work sufficiently.

Function of accumulator

Immediately after engine is stopped, with key


switch ON, boom cylinder must be retracted
from extension stroke end to ground level
(when arm is at max. reach).

Revision

Category

Loading shovel specification 10/13

Check item

At local
At ___
assembly operating
time
hours

Criterion

Around operator's seat

During operation

Check of each part


Operating effort of control lever when each actuator is operated

Lever must not be hitched during operation.


Lever must return to neutral by itself.

Shaking and beat noise of operator's cab

Must not be detected.

Beat noise of frame, guard and ladder

Must not be detected.

Movement of doors and windows

Must move smoothly.

Locks of doors and windows

Must work securely.

Adjustment of operator's seat

All adjustment must be possible.

Must not be detected.

Undercarriage

Oil leakage
(Idler, track roller, sprocket,
final drive gear case, motor, brake valve)

Interference of each part

Must not be detected.

Looseness of track shoe bolt

Must not be detected.

Contact of link tread

Must be free from overlapping, flaking and


breakage.

Must not be detected.

Around chassis

Oil leakage
(Center swivel joint, pump, solenoid valve, relief valve,
control valve, PPC valve, swing motor, brake valve,
shuttle valve, swing machinery, hydraulic tank, piping)

Fuel leakage
(Fuel tank, engine, piping)

Must not be detected.

Water leakage from engine cooling system

Must not be detected.

Oil leakage from engine lubrication system

Must not be detected.

Gas leakage from engine gas system

Must not be detected.

Operation of covers

Must move smoothly.

Locks of covers

Must work securely.

Around chassis

Revision

Category

Loading shovel specification 11/13

Check item

Criterion

Operation of grease pump

Must operate smoothly.

Looseness and insufficient insertion of electric wiring terminals

Must not be detected.

Electric wiring route

Clearance of at least 10 mm must be made


around moving part and edge.

Air leakage from air system

Must not be detected.

Interference of each part

Must not be detected.

Oil leakage
(Cylinder, piping, block)

Around work equipment

At local
At ___
assembly operating
time
hours

Must not be detected.

Grease leakage from grease piping

Must not be detected.

Interference of work equipment

Must not be detected.

Looseness of work equipment piping clamp and play of piping

Must not be detected.

Twist of hydraulic hose and operation of work equipment at


reverse

Must not be detected.

Loading shovel specification 12/13

Revision

Category

Note: If the operation or function is defective, measure as necessary.


Check item

The speeds in the criteria column are the values in P mode.


At local
At ___
assembly operating
Criterion
time
hours
P mode

1. Engine speed: Check in monitoring mode "01002".


Low idle

rpm]

825 50 rpm

High idle

rpm]

1980 50 rpm

rpm]

1780 50 rpm

rpm]

1780 50 rpm

Boom raise relieve speed


(Heavy lift: OFF)
Boom raise relieve speed
(Heavy lift: ON)

2. Oil pressure measurement: Check in monitoring mode "01002".


1F pump: "01124 1R pump: "01125"
2F pump: "01126 2R pump: "01127"
1F [
1R [
Control valve main set pressure
2F [
2R [

MPa]
MPa]
MPa]
MPa]

29.4 1.0 MPa

At engine high idle, boom


raise, P mode, heavy lift
OFF and relief

1F [
Control valve main set pressure 1R [
(Boosted pressure)
2F [
2R [

MPa]
MPa]
MPa]
MPa]

31.4 1.0 MPa

At engine high idle, boom


raise, P mode, heavy lift ON
and relief
At engine high idle, swing, P
mode and relief

Swing relief set pressure

1F [Right
1F [Left

MPa]
MPa]

28.4 2.0 MPa

Pilot relief valve set pressure

MPa]

3.2 + 0.2/-0 MPa At engine high idle

3. Current and voltage measurement


EPC current: Check in monitoring mode.
1F pump: "01307" 1R pump: "01309"
2F pump: "01311" 2R pump: "01313"

Pump EPC current

1F [
1R [
2F [
2R [

mA]
mA]
mA]
mA]

220 60 mA

At engine high idle, lever


neutral and P mode

1F [
1R [
2F [
2R [

mA]
mA]
mA]
mA]

460 60 mA

At engine high idle, boom


raise, P mode, heavy lift
OFF and relief

J/S differential pressure output voltage: Check in monitoring mode.


1F pump: "13808" 1R pump: "13809"
2F pump: "13810" 2R pump: "13811"

J/S differential pressure


output voltage

1F [
1R [
2F [
2R [

V]
V]
V]
V]

Min. 3.2 V

At engine high idle, lever


neutral and P mode

1F [
1R [
2F [
2R [

V]
V]
V]
V]

Max. 1.4 V

At engine high idle, arm in,


P mode, and relief

Revision

Category

Loading shovel specification 13/13


At local
At ___
assembly operating
time
hours

Check item

Criterion

4. Work equipment hydraulic drift


(Bucket: No load, Hydraulic oil temperature: 50 5 C)
Bucket tooth tip

mm]

Max. 1,200 mm/15 min

Note: Only when the hydraulic drift of the bucket tooth tip is not
acceptable, measure the hydraulic drift of the following
cylinders.
Boom cylinder

mm]

Max. 17 mm/min (250 mm/15 min)

Arm cylinder

mm]

Max. 23 mm/min (350 mm/15 min)

Bucket cylinder

mm]

9 mm/min (140 mm/15 min)

5. Operating effort and stroke


Boom
control lever

Operating Raise
effort

Main measurement items

Stroke
Swing
control lever

Arm
control lever

N
{kg}

Right
Left
[
mm] [

Operating Curl
effort
Stroke

N
{kg}

Curl
[

N
{kg}

In
[

Out
mm] [

Right travel lever Operating Forward


effort
Stroke
Left travel lever

N
{kg}

N
{kg}

N
{kg}

mm]
N
{kg}

Play
mm] [
Dump

Out

mm]
N
{kg}

mm]
N
{kg}

Play
mm] [
Reverse

Forward
Reverse
Play
[
mm] [
mm] [

Operating Forward
effort
Stroke

Left

Dump
Play
mm] [
mm] [

Operating In
effort
Stroke

Lower

Raise
Lower
Play
[
mm] [
mm] [

Operating Right
effort
Stroke

Bucket
control lever

N
{kg}

Reverse

Forward
Reverse
Play
[
mm] [
mm] [

mm]
N
{kg}

mm]
N
{kg}

mm]

16.7 4.2 N
{1.6 0.5 kg}
Stroke: 85 10 mm
Play: Max. 10 mm
13.7 3.4 N
{1.4 0.4 kg}
Stroke: 85 10 mm
Play: Max. 10 mm
13.7 3.4 N
{1.4 0.4 kg}
Stroke: 85 10 mm
Play: Max. 10 mm
13.7 3.4 N
{1.4 0.4 kg}
Stroke: 85 10 mm
Play: Max. 10 mm
25.5 6.4 N
{2.5 0.6 kg}
Stroke: 135 14 mm
Play: Max. 10 mm
25.5 6.4 N
{2.5 0.6 kg}
Stroke: 135 14 mm
Play: Max. 10 mm

Serial No. of controllers and monitor

Serial No. : Confirm with monitoring mode or visual check.


Engine controller (L-BANK)

Engine controller (R-BANK)

Pump controller (UPPER)

20403

Pump controller (LOWER)

20407

VHMS controller

ORBCOMM controller

Monitor

20402

At engine
high idle and
relief

GEN00060-03

Похожие интересы