Asembly EX2600-6 PDF

KO-385-02
ASSEMBLY
PROCEDURE
MANUAL
Foreword
Assembly work is the final touch that gives the machine life. The quality of a machine's
assembly affects its operative performance and service life of the machine.
Because a machine's value is determined by its assembly, those who do this work are
required to have sufficient know-how about assembly.
This manual basically contains assembly know-how such as methods and useful hints for
assembling the EX2600-6 Hydraulic Excavator. Please read this manual carefully and try to
keep it for reference before you engage in assembly or while you work.
This manual is a practical compilation of the following three viewpoints: "the improvement
of work safety", "the improvement of efficiency" and "the enhancement of product quality."
1) Safety: Some hints and information for safe work are provided, such as the
weight of the parts, their lifting points when raised with wire ropes and
their handling procedures.
Work safety is attained with this manual.
2) Quality: Procedures and hints are described for correct machine assembly. They
include the part numbers, tightening torque values of bolts, etc. Correct
assembly is essential to provide the machine with a longer service life at
maximum performance.
3) Efficiency: Tool jigs, the facilities necessary to do the work and the preparation
needed for each work stage are introduced to assure speedy and
effective completion.
We hope this manual will be helpful to you in assembling the machine without a hitch.
i
CONTENTS
Pages
1. Precautions…………………………………………………………………………………………………………… 1
1-1. Safety precautions for servicemen ………………………………………………………………………… 1
1-2. How to use a power wrench………………………………………………………………………………… 17
1-3. Work precautions …………………………………………………………………………………………… 20
2. Workers plan ……………………………………………………………………………………………………… 30
2'. Workers plan ……………………………………………………………………………………………………… 31
2-1. Transportation of Loader Front …………………………………………………………………………… 32
2-1'. Transportation of Backhoe Front…………………………………………………………………………… 33
3. Parts check ………………………………………………………………………………………………………… 41
3-1. Check ………………………………………………………………………………………………………… 41
4. Preparations (loader front) ……………………………………………………………………………………… 42
4'. Preparations (backhoe front) …………………………………………………………………………………… 44
5. Machines, apparatus, tools, and materials necessary for assembly …………………………………… 47
6. Assembly of Undercarriage ……………………………………………………………………………………… 55
6-1. Preparation …………………………………………………………………………………………………… 55
6-2. Connection of track frame and side frames ……………………………………………………………… 57
6-3. Connection of travel motor hoses and adjuster hoses…………………………………………………… 67
6-4. Assembly of motor covers and steps ……………………………………………………………………… 69
6-5. Disassembly procedures for shipment (Procedure, Track)……………………………………………… 71
6-6. Assembly of travel motor guard and mission guard ……………………………………………………… 75
7. Connection of undercarriage and superstructure …………………………………………………………… 85
7-1. Preparations before connection …………………………………………………………………………… 85
7-2. Preparation of undercarriage ……………………………………………………………………………… 91
7-3. Preparation of base machine ……………………………………………………………………………… 97
7-4. Connection of undercarriage and base machine ………………………………………………………… 95
7-5. Connection of piping to center joint ……………………………………………………………………… 103
7-6. Assembly of fuel tank ……………………………………………………………………………………… 105
7-7. Assembly of cab …………………………………………………………………………………………… 109
7-8. Assembly of fenders, steps, handrails, ladder, beam, box and covers ……………………………… 117
7-9. Assembly of engine unit …………………………………………………………………………………… 135
7-10. Mounting the counterweight & installation the reserue tank …………………………………………… 153
7-11. Assembly of intake unit / exhaust unit and head lamps, mirror, wroking lamp, etc. ………………… 165
7-12. Connection ………………………………………………………………………………………………… 177
7-13. Checking the stop valves and stopcocks………………………………………………………………… 211
7-14. Final check of superstructure……………………………………………………………………………… 217
7-15. Releasing air from main pumps…………………………………………………………………………… 223
7-16. Trial operation of superstructure ………………………………………………………………………… 225
7-17. Disassembly procedures for shipment …………………………………………………………………… 227
7-18. Assembly of discharge and back monitors ……………………………………………………………… 245
7-19. Assembly of option parts ………………………………………………………………………………… 255
ii
8. Mounting procedures for loader front-end attachment …………………………………………………… 261
8-1. Preparation ………………………………………………………………………………………………… 261
8-2. Mounting of loader front …………………………………………………………………………………… 277
8-3. Mounting the bucket ……………………………………………………………………………………… 287
8-4. Adjustment of track link tension…………………………………………………………………………… 297
8-5. Final trial operation check ………………………………………………………………………………… 299
8-6. Disassembly procedures for shipment …………………………………………………………………… 300
8'. Mounting procedures for backhoe front-end attachment ………………………………………………… 307
8'-1. Preparation ………………………………………………………………………………………………… 307
8'-2. Mounting of boom ………………………………………………………………………………………… 317
8'-3. Installation of arm ………………………………………………………………………………………… 329
8'-4. Mounting of bucket ………………………………………………………………………………………… 339
8'-5. Adjustment of track link tension…………………………………………………………………………… 347
8'-6. Final trial operation check ………………………………………………………………………………… 349
8'-7. Assembly of option parts ………………………………………………………………………………… 351
8'-8. Disassembly procedures for shipment …………………………………………………………………… 352
9. Checks after completing the assembly ……………………………………………………………………… 361
10. Checking machine performance ……………………………………………………………………………… 365
iii
EX2600-6 Assembly Process Chart
LOADER FRONT
The oil tank may be already installed.
Weight: 249 000 kg (549 000 lb)
iv
EX2600-6 Assembly Process Chart
BACKHOE FRONT
The oil tank may be already installed.
Weight: 254 000 kg (560 000 lb)
v
1. Precautions
1-1 Safety precautions for servicemen
1 RECOGNIZE SAFETY INFORMATION

This is the safety-alert symbol. When you see this
symbol on your machine or in this manual, be alert to
the potential for personal injury.
Follow recommended precautions and safe operating

practices.
Fig. 1-1
2 UNDERSTAND SIGNAL WORDS

Machine safety signs incorporate signal words -
DANGER, WARNING and CAUTION - to designate the
degree or level of hazard.
DANGER indicates an imminently hazardous situation

which, if not avoided, will potentially result in death or
serious injury.
WARNING indicates a potentially hazardous situation

which, if not avoided, could result in death or serious
injury.
CAUTION indicates a potentially hazardous situation

which, if not avoided, may result in minor or moderate
injury.
The NOTE describes cautionary remarks, reference,

etc. for assembly.
Fig. 1-2
DANGER and WARNING safety signs are located near
specific hazards.
General precautions are listed on CAUTION safety
signs. CAUTION also calls attention to safety items in
this manual.
To avoid confusing machine protection with personal

safety messages, IMPORTANT is used to indicate a
situation which, if not avoided, could result in damage
to the machine.
1
3 FOLLOW SAFETY INSTRUCTIONS
Carefully read and follow all safety signs on the
machine and all safety messages in this manual.
Safety signs should be installed, maintained, and

replaced when necessary.
If a safety sign or this manual is damaged or missing,
order a replacement from your Hitachi dealer in the
same way as you order other replacement parts (be
sure to state the machine model and serial number
when ordering.) Fig. 1-3
Learn how to operate the machine and its controls

correctly and safely.
Allow only trained, qualified, authorized personnel to
operate the machine.
Keep your machine in proper working condition.

Unauthorized modifications to the machine may impair
its functions and/or safety, and affect machine life.
The safety messages in this chapter are intended to

illustrate basic safety procedures for hydraulic
excavators. However it is impossible for these safety
messages to cover every hazardous situation you may
encounter. If you have any questions, you should first
consult your supervisor before operating or performing
maintenance work on the machine.
4 DESIGNATE ONE LEADER AND TWO

SUBLEADERS
In order to work with the greatest safety and ease,
designate a foreman and two subleaders as working
partners. When assembling the superstructure, station
the subleaders at the front and rear of the machine.
They should carry out and follow the leader's signals
with utmost care to avoid breakage of components and
personal injury.
Fig. 1-4
5 CLEAN THE MACHINE REGULARLY

Remove any grease, oil or dirt build-up to avoid
possible injury or machine damage.
Do not spray water or steam inside the cab.
Fig. 1-5
2
6 WEAR PROTECTIVE CLOTHING
Avoid wearing loose clothing, jewelry, or other items
that can catch on control levers or other parts of the
machine.
Wear close fitting clothing and safety equipment

appropriate to the job.
You may need:

• Hardhat
• Safety shoes
• Safety glasses, goggles, or a face shield
• Heavy gloves
• Hearing protection
• Reflective clothing
Fig. 1-6
• Wet weather gear
• Respirator or filter mask.
7 PREPARE FOR EMERGENCIES

Be prepared for the eventuality of a fire.
Keep a first aid kit and fire extinguisher handy.
Keep emergency numbers for doctors, ambulance

service, a hospital, and the fire department near your
Fig. 1-7
telephone.
8 PREPARE SUITABLE LIFTING TOOLS

Work with this machine involves lifting heavy and bulky
items with a crane. Pay attention to the following
points:
a) Prepare suitable lifting tools.
b) To prevent unnecessary mishaps due to broken
wire cables, do not use damaged chains or frayed
cables, slings, or ropes. Be sure to use a proper
protector and patch.
c) Before proceeding with the work, agree on specific
signals with the crane operator and the designated
leader/subleader team.
d) Always keep the area directly below any load clear
of people during slinging work.
e) Service personnel and mechanics must check the Fig. 1-8
weights given in this manual, and apply the proper
lifting procedures when removing any components.
f) When using hydraulic excavators for lifting
operations, be sure to comply with all local
regulations.
3
9 ENGINE SAFETY
a) No one should be allowed inside the hydraulic
excavator while it is being operated or during
assembly.
b) Keep hands away from moving parts.
c) Sound the horn as an alert to those nearby before
starting up the engine.
d) Start the engine from the operator's seat and never
while standing on the ground.
e) To avoid injury or possible machine damage, never
start the engine by shorting across the starter
terminals.
Fig. 1-9
10 SUPPORT RAISED EQUIPMENT

Never work under or near a raised bucket. Lower the
bucket to the ground or onto secure blocks.
Fig. 1-10
11 SAFETY AT HEIGHT
Take adequate measures to avoid falling from high
spots during work. Clean any mud or debris from the
steps, walkways, or work platforms before work, and
use a safety belt during work.
Falling is one of the major causes of personal injury.
When you get on and off the machine, always face the
machine and maintain a three-point contact with the
steps and handrails. Do not use any controls as
handholds.
Before getting off, be sure to align the cab parallel with
the tracks.
Never jump on or off the machine. Never mount or

dismount a moving machine.
Fig. 1-11
Be careful of slippery conditions on platforms, steps,
and handrails when getting off the machine.
4
12 FUEL SAFETY AND FLAMMABLE
MATERIALS
a) Never smoke while refueling or handling flammable
materials.
b) Shut the engine off while refueling.
c) Exercise caution when refueling while the engine is
still hot.
d) Do not clean parts using opened cans of gasoline
or diesel fuel. Use good, commercial, non-
flammable solvents.
Fig. 1-12
13 PREVENT BATTERY EXPLOSIONS

Keep sparks, lighted matches, and flame away from
the top of the battery. Battery gas can explode.
Never check the battery charge by placing a metal

object across the posts. Use a voltmeter or hydrometer.
Do not charge a frozen battery - it may explode. Warm

the battery to 16°C (60.8°F).
Disconnect the negative ground cable before working

on the electrical system or making major repairs.
Fig. 1-13-1
Fig. 1-13-2
5
14 AVOID HIGH-PRESSURE FLUIDS
• Fluids such as diesel fuel or hydraulic oil under
pressure, can penetrate the skin or eyes causing
serious injury, blindness or death.
• Avoid this hazard by relieving pressure before

disconnecting hydraulic or other lines.
Relieve the pressure by moving the control levers
several times.
Tighten all connections before pressurizing the
hydraulic system.
• Search for leaks with a piece of cardboard, taking

care to protect your hands and body from high-
pressure fluids. Wear a face shield or safety goggles
for eye protection.
Fig. 1-14-1
• If an accident occurs, see a doctor familiar with this
type of injury immediately.
Any fluid injected into the skin must be surgically
removed within a few hours, or gangrene may result.
Fig. 1-14-2 Fig. 1-14-3 Fig. 1-14-4
15 CHECK EQUIPMENT SAFETY

a) Use a piece of cardboard or paper to safely check
for leaks in all systems, including the following:
Hydraulic system
Fuel system
b) Use the correct testing gauge type when checking
the hydraulic pressure.
c) Check all protective parts on the machine (shields,
guards, pins, etc.). They should be in good
condition and securely fastened.
d) Inspect electrical wiring for worn or frayed
insulation, and install new wiring if damage has
occurred.
Fig. 1-15
6
16 PROTECT AGAINST NOISE
Prolonged exposure to loud noise can cause
impairment or loss of hearing.
Wear a suitable hearing protective device such as

earmuffs or earplugs to protect against objectionable or
uncomfortable loud noises.
Fig. 1-16
17 FASTEN YOUR SEAT BELT

Prior to operating the machine, thoroughly examine the
belt, buckle and attaching hardware. If any item is
damaged or worn, replace the seat belt or component
in question before operating the machine.
Be sure to remain seated with seat belt securely

fastened at all times when the machine is in operation.
Fig. 1-17
18 BEWARE OF EXHAUST FUMES

Prevent asphyxiation. Engine exhaust fumes can cause
sickness or death.
If you must operate in a building, be sure there is

adequate ventilation. Either use an exhaust pipe
extension to remove the exhaust fumes, or open doors
and windows to bring enough fresh air into the area.
Fig. 1-18
7
19 PRACTICE SAFE MAINTENANCE
Understand service procedures before performing any
work. Keep the work area clean and dry.
Never lubricate or service the machine while it is

moving.
Keep hands, feet and clothing away from power-driven
parts.
Before servicing the machine.
• Park the machine on a level surface.

• Lower the bucket to the ground. Fig. 1-19-1
• Turn the auto-idle switch off.
• Run the engine at slow idle speed without load for 3
minutes.
• Turn the ignition OFF to stop the engines.
• Relieve the pressure in the hydraulic system by
moving the control levers several times.
• Remove the key from the ignition.
• Attach a "Do Not Operate" tag to the travel speed
select/pilot control shut-off lever
• Set the travel speed select/pilot control shut-off lever
to the P position.
• Allow the engine to cool.
If a maintenance procedure must be performed with the

engine running, do not leave the machine unattended.
Boom
If the machine must be raised, maintain a 90 to 110˚

Arm
angle between the boom and arm. Securely support
any machine elements that must be raised for service
work. Never work under a machine raised by the boom.
90 to
Inspect certain parts periodically, and repair or replace 110°
as necessary. Refer to the relevant section of the

Operation Manual.
Fig. 1-19-2
Keep all parts in good condition and properly installed.
Fix any damage immediately. Replace worn or broken
parts. Remove any buildup of grease, oil or debris.
Disconnect the battery ground cable (-) before making

adjustments to the electrical system or performing
welding work on the machine.
8
20 WARN OTHERS OF SERVICE WORK
Unexpected machine movement can cause serious
injury.
Before performing any work on the machine, attach a

"DO NOT OPERATE" tag to the travel speed
select/pilot control shut-off lever.
This tag is available from your authorized dealer.
Fig. 1-20
21 REMOVE PAINT BEFORE WELDING OR

HEATING
Hazardous fumes can be generated when paint is
heated by welding, soldering, or using a torch. If
inhaled, these fumes may cause sickness.
Avoid potentially toxic fumes and dust.
Do all such work outside or in a well-ventilated area.

Dispose of paint and solvent properly.
Remove paint before welding or heating:
1 If you sand or grind paint, avoid breathing the

dust. Wear an approved respirator.
2 If you use solvent or paint stripper, remove

stripper with soap and water before welding.
Remove solvent or paint stripper containers and
other flammable material from area. Allow fumes
Fig. 1-21
to disperse at least 15 minutes before welding or
heating.
22 PROTECT AGAINST FLYING DEBRIS

Guard against injury from flying pieces of metal or
debris - wear goggles or safety glasses.
In order to avoid personal injury, keep bystanders away

from the working area when striking any object.
Fig. 1-22
9
23 PREVENT AGAINST FLYING PARTS
Grease in the track adjuster is under high pressure.
Do not attempt to remove a GREASE FITTING or
VALVE ASSEMBLY.
Be sure to keep your body and face away from any
valve, as pieces may fly off.
The travel reduction gears are under pressure.
So as to avoid injury from flying parts, be sure to keep
your body and face away from the AIR RELEASE
PLUG.
GEAR OIL is hot. Wait for the GEAR OIL to cool, then Fig. 1-23
gradually loosen the AIR RELEASE PLUG to release

pressure.
24 PREVENT BURNS
Hot spraying fluids:
• After operation, the engine coolant is hot and under
pressure. Also, hot water or steam is contained in the
engine, radiator and heater lines.
Prevent possible injury from hot spraying water.
DO NOT remove the radiator cap until the engine is
cool. When opening, turn the cap slowly to the stop
position.
Allow all pressure to release before removing the
Fig. 1-24-1
cap.
• The hydraulic oil tank is pressurized. Again, be sure
to release all pressure before removing the cap.
Hot fluids and surfaces:

• Skin contact with escaping hot water or steam can
cause severe burns.
Be sure to stop the engine, and let the engine and
radiator cool. Once the system has cooled, slowly
loosen the radiator cap to release pressure, then
remove it.
• Engine oil, gear oil and hydraulic oil also become hot
during operation.
The engine, hoses, lines and other parts also
Fig. 1-24-2
become hot.
Wait for the oil and components to cool before
starting any maintenance or inspection work.
25 STORE ATTACHMENTS SAFELY

Stored attachments such as buckets, hydraulic
hammers, and blades can fall and cause serious injury
or death.
Securely store attachments and implements to prevent

them falling. Keep playing children and bystanders
away from the storage area.
Fig. 1-25
10
26 DISPOSE OF WASTE PROPERLY
Improper waste disposal can threaten the environment
and ecology. Potentially harmful waste used with
HITACHI equipment includes such items as oil, fuel,
coolant, brake fluid, filters, and batteries.
Use leakproof containers when draining fluids. Do not

use food or beverage containers that may mislead
someone into drinking from them.
Do not pour waste onto the ground, down a drain, or Fig. 1-26
into any water source.
Allowing air conditioning refrigerants to escape into the

air can damage the Earth's atmosphere. Government
regulations may require a certified air conditioning
service center to recover and recycle used air
conditioning refrigerants.
Inquire as to the proper way to recycle or dispose of

waste from your local environmental or recycling
center, or from your HITACHI dealer.
27 SERVICE THE AIR CONDITIONING

SYSTEM SAFELY
Refer to the outside of the freon container for proper
handling procedures when servicing the air
conditioning system.
Use a recovery and recycling system to avoid venting
freon into the atmosphere.
Never let the freon stream make contact with your skin.
Severe frost burns will result.
28 HANDLE CHEMICAL PRODUCTS SAFELY

Direct exposure to hazardous chemicals can cause
serious injury. Potentially hazardous chemicals used
with your machine include such items as lubricants,
coolants, paint, and adhesives.
Fig. 1-27
11
29 HANDLE POWER WRENCHES
CORRECTLY
Misuse of power wrenches (part nos. 4093799 and
4229414) may lead to their breakage or personal injury.
Please use power wrenches correctly and in
accordance with this manual.
1 For your safety, do not enter into the turning circle

of the wrench. After tightening is complete, a
torque acting in the opposite direction will be
applied to the wrench. Therefore, do not suddenly
let go of the handle, but let it gently rotate back in
the opposite direction until the torque is zero.
Fig. 1-28
2 Excessive input torque may cause the output end

or reaction lever to break, causing the wrench to
fall from the machine. The wrench may also fall if
it slips off the reaction member. Secure the
wrench so that it cannot drop, especially when
working on vertical surfaces.
Fig. 1-29 Fig. 1-30
3 It is sometimes difficult to remove the power

wrench from a nut or bolt after tightening.This is
generally due to elastic deformation (elastic force)
between the wrench and bolt. Try changing the
clutch direction to L to make the wrench easier to
remove. Release the torque on the ratchet handle
gradually, since a force will be acting in the
opposite direction after changing over the clutch. If
Fig. 1-31
it is not possible to change the clutch by hand, do
not attempt to use force (a hammer, etc.).
• Try turning the wrench handle slightly in the L

direction to make the clutch easier to change
over.
Fig. 1-32
2
12
30 COMMUNICATION
1) When slinging work is performed on heavy loads, a
predetermined hand signalling method should be
used for trouble-free communication.
2) In order to facilitate long-distance teamwork during

assembly, workers should wear headsets for reliable
communication.
Fig. 1-33
Fig. 1-34
13
31 FRONT PIPING PRESSURE-RELEASE PARTS
Front piping pressure-release parts are now available.
• Use these parts when extra large machines are assembled at the work site.
• Install these parts in place after a front attachment is delivered to the work site and before installing it on the base
machine.
Front piping pressure-release parts
Fig. 1-35 For pipe ends
High-pressure pipe
For 1-1/2 in. pipe For 2 in. pipe

ITEM
PART No. PART NAME QTY PART No. PART NAME QTY
00 4474073 Cover 1 4249893 Cover 1
01 4510169 O-ring 1 4510170 O-ring 1
02 4263446 Reducer, S 1 4263446 Reducer, S 1
03 0643016 Bleeder, air 1 0643016 Bleeder, air 1
(4381187) (4381187)
04 4075854 Flange, split 2 4169565 Flange, split 2
05 M341650 Bolt, socket 4 M342065 Bolt, socket 4
Fig. 1-36 For hose ends
High-pressure hose
For 1-1/2 in. pipe For 2 in. pipe

ITEM
PART No. PART NAME QTY PART No. PART NAME QTY
06 4474075 Cover 1 4474074 Cover 1
07 4510169 O-ring 1 4510170 O-ring 1
08 0643016 Bleeder, air 1 0643016 Bleeder, air 1
(4381187) (4381187)
09 4075854 Flange, split 2 4169565 Flange, split 2
10 M341650 Bolt, socket 4 M342065 Bolt, socket 4
Fig. 1-37 Air-release hose

inside diameter
About ø6.4
ITEM PART No. PART NAME QTY REMARKS

11 4199087 Hose 1 ø6.4 inside diameter, ø14 inside diameter, 2.5m long
12 4235205 Clamp, hose 1
14
How to release the pressure
Cap
Breather
Width across flats:

8 mm
Width across flats:
19 mm
Fig. 1-38
Pressure release
1 Install air-release parts 00 to 05 and 06 to 10 on sections from which the pressure should be released (see Figs. 1-
39 and 1-41 on the next page) after a front attachment is delivered to the work site and before it is installed on the
base machine.
Note:
High pressure will be applied to these sections, so the parts must be securely installed.
2 Check that A of the pressure-release part installed in procedure 1 (see Fig. 1-38) is firmly tightened.
3 When the pipes are installed to each location, connect the hose to the breather and place the hose end in an oil
pan first.
4 Gradually loosen part A shown in Fig. 1-38 to release the pressure inside the pipe.
Note:
Do not loosen part A shown in Fig. 1-38 quickly. Doing so is dangerous because the hose may swing violently and
thus be disconnected.
5 After the pressure is released from the pipe, tighten part A shown in Fig. 1-38.
6 Remove the pressure-release parts and proceed with the pipe connection work.
Note:
All of the hydraulic oil is not completely drained out from the pipe even after this pressure-release work has been
done. Place an oil pan before removing the pressure-release parts.
15
Sections from which pressure should be released, size and quantity of pipes
B/H boom end (for pipe ends)
MODEL 1-1/2 in. 2 in.

EX1900-6 4 ---
EX2500-6
2 2
(EX2600-6)
EX3600-6 2 2
EX5500-6
--- 6 Fig. 1-39
(EX5600-6)
L/D boom end (for hose ends)

(EX3600-6, EX5500-6 only)

EX3600-6 2 5
EX5500-6
--- 8
(EX5600-6) Fig. 1-40
L/D arm ends (for pipe ends)

EX1900-6 2 ---
EX2500-6
2 ---
(EX2600-6)
EX3600-6 2 ---
EX5500-6
--- 2
(EX5600-6) Fig. 1-41
16
1-2 How to use a power wrench
This section describes the correct use of power wrenches. Please note however that, if available, a hydraulic wrench
should be preferred over a power wrench, for reasons of safety and overall quality.
1 METHOD OF USE 4. Input direction selection on the

ratchet handle.
The input direction is set by using
1. Socket selection and mounting.
the changeover lever on the
Select the socket which fits most
ratchet handle.
snugly onto the bolt, and mount the
socket on the wrench. Secure the
socket to the wrench with a 38.1
Changeover lever
mm pin or 25.4 mm bolt.
Fig. 1-46
5. Changeover clutch.
Changeover
Select the input direction by setting clutch
Fig. 1-42
the changeover clutch as detailed
in the figure to right (Fig. 1-47).
2. When accurate torque control is

required.
Set the torque according to the
input/output diagram in Fig. 1-56
(page 19). (Output = input x gear
ratio x efficiency)
Fig. 1-47
6. Completion of work.
Fig. 1-43 On completion of tightening,
remove the wrench from the nut or
3. Check the positioning of the reaction lever. bolt. Elastic deformation (force) 2
Depending upon the wrench type the reaction lever usually acts between the wrench and bolt can
radially. Due to the large reaction force applied to the reaction lever, the make it difficult to remove the 1
reaction lever should be positioned so that it is both secure and stable. power wrench. In this case,
gradually release the torque on the
ratchet handle and change over
the clutch direction.
Fig. 1-48
Straight type
reaction lever
Fig. 1-44
When using an "L-type" torque wrench, make sure that the distance "L"
between the center of the bolt and support point is at least the figures
shown below. Failing to observe this minimum distance can damage or
break the bolt, or cause the output shaft to become jammed.
Clutch selection
L (counter clockwise)
L type reaction lever R (clockwise)
Model L
8-150P 110
8-300P 130
12-450P 145
12-600P 160
(Unit: mm)
Fig. 1-45
Fig. 1-49
17
2 THE CORRECT HANDLING OF POWER WRENCHES
Misuse of power wrenches (part nos. 4093799 and 4229414) may lead to their breakage or personal injury. Please use
power wrenches correctly and in accordance with this manual.
CAUTION
1. Changing the clutch

・ Set the base line of the dial to the R or L marker on the power wrench main body.
Base line
(Select R for clockwise, L for counterclockwise movement.)
Yellow A tightening torque is applied with R and a loosening torque with L. Note that reverse
Direction operation may damage the clutch.
Red
・ The changeover clutch is intended to prevent reverse rotation when the force is released
during a tightening or loosening operation, and is not designed to transmit torque in the
manner of the ratchet handle.
Ratchet
handle
Fig. 1-50
2. Stay away from the ratchet handle

turning circle.
For your safety, do not enter into the turning circle of the wrench. After
tightening is complete, a torque acting in the opposite direction will be
applied to the wrench. Therefore, do not suddenly let go of the handle,
but let it gently rotate back in the opposite direction until the torque is
zero.
Fig. 1-51
3. Don't drop the wrench.

Excessive input torque may cause the output end or reaction
lever to break, causing the wrench to become removed from
the component. The wrench may also become removed if it
slips off the reaction member. Secure the wrench so that it
cannot fall, especially when working on vertical surfaces.
Fig. 1-52 Fig. 1-53
4. After tightening.
It is sometimes difficult to remove the power wrench from a nut or bolt
after tightening.This is generally due to elastic deformation (elastic
force) between the wrench and bolt. Try changing the clutch direction
to L to make the wrench easier to remove. Release the torque on the
ratchet handle gradually since a force will be acting in the opposite 1
direction after changeover of the clutch. If it is not possible to change
over the clutch by hand, do not attempt to use force (a hammer, etc.).
・ Try turning the wrench handle slightly in the L

direction to make the clutch easier to change
over.
Fig. 1-54
Fig. 1-55
2
18
(2548)
5. Power Wrench Input/Output Diagram
Input/Output Diagram (2254)
[Output=input×gear ratio×efficiency]
(1960)
(1666)
Output kgf·m (lbf·ft)

(N.m)
(1372)
(1078)
In selecting a power wrench, give due consideration of the
(784)
differences in power performance between the different
wrench types.
(490)
Input kgf·m
(lbf·ft)
Bolt Power Wrench (N.m) (98) (196) (294) (392) (490) (588) (686) (784) (882)
(6860)
(5880)
Fig. 1-56 (4900)
(3920)
Output kgf·m (lbf·ft)
(N.m)
(2940)
(1960)
Input kgf·m
(lbf·ft)
(N.m) (137) (176) (216) (255) (294) (333) (372) (412) (451)
6. Torque Specifications
Tightening Torque
No. Component Bolt Dia Wrench Size
(mm) (mm) N·m kgf·m lbf·ft
1 Cab mounting bolt 18
36 27
55 275
245 28
2400 203
1770
2 Cab bed mounting bolt 16 24 205 21 151
3 Swing bearing mounting bolt 48 75 5150 525 3798
4 Counterweight mounting bolt 48 75 4900 500 2614
5 Engine unit mounting bolt 30 46 1420 145 1047
6 Side frame mounting bolt 48 75 4900 500 3614
A 24 36 685 70 505
7 Front pin-retaining mounting bolt B 20 30 390 40 288
C 16 24 265 27 195
19
1-3 Work precautions
1 1 Be sure to apply a suitable lubricant to mounting

bolts before tightening. Use lubricant made by
mixing white zinc jelly and spindle oil in 1: 1
proportions.
In the case that these materials are not available,
make up the lubricant from materials of the same White zinc jelly
composition: Spindle oil
Material Composition
White zinc jelly Composition list given on page 29
1:1
Spindle oil Composition list given on page 29
2 Lubricant should be applied to both the bolt and

spacer, in the positions marked ＊ in the diagram
below.
Spacer
Bolt Lubricant
Fig. 1-57
＊＊＊＊ Base
Face area Face area Thread of the head
Fig. 1-58
2 1 Remove the seal fitted to the ports and pipes of

hydraulic components just before assembly, to
High Tack Adhesive/
prevent the ingress of dust. Sealant #98D
2 Oil will come out when removing the seals from
the hydraulic ports. Collect it with a suitable oil
container. Fig. 1-59
3 Lightly apply High Tack Adhesive/Sealant #98D to

the O-ring before hose connection.
Note:
Obtain high tack adhesive/sealant #98D through
the manufacturer detailed on page 29.
3 Connecting hoses.
Fig. 1-60
1 Be careful not to damage the joining surfaces of
the hydraulic components.
2 Make sure that no dust has adhered to the seat
faces of the hoses and adaptors.
3 When connecting hoses, do not twist them or their
service life will be shortened.
4 When connecting the hoses, avoid contact with
other parts.
CAUTION:
Hydraulic ports are sealed with plugs on shipment from
the factory. On removal of these plugs, hydraulic oil will
escape due to the internal hydraulic pressure built up
through transportation, etc.
20
4 Battery earth breaker
This machine is provided with a battery earth breaker.
To break the battery earth circuit for field assembly,
battery replacement, electric system
maintenance/inspection and welding on the machine,
pull breaker lever A down.
REPLACE BATTERIES
Your machine has four 12-volts batteries with negative
(-) ground.
If one of four batteries in a 24-volt system has failed but
the others are still good, replace all the batteries
together with new ones of the same type. For example, Fig. 1-61
replace a failed maintenance-free battery with a new
maintenance-free battery. Different types of batteries
may have different rates of charge. This difference
could overload one of the batteries and cause it to fail.
IMPORTANT:
Do not pull the disconnector lever a down during
operation and the delayed power OFF time after the
key switch is turned off.
All controllers are shut down after the delayed power
OFF time.
Note:
Ground Disconnector
This machine is equipped with a battery ground Fig. 1-62
disconnector located outside of engine unit
compartment on the right side. The battery ground
circuit can be disconnected by pulling
disconnector lever a down before replacing the Breaker lever
a
battery, checking the electrical system, or
performing welding work on the machine.
Fig. 1-63
CAUTION:
Do not replace the battery by physical strength. Use
the crane to replace safely.
21
5 Tightening large-diameter bolts during
assembly
1 It is vital that large-diameter bolts be tightened to
the specified tightening torque during assembly. If
torque specifications are not followed, the
operation of the machine will be affected, with
machine failure, lowering of functionality and
shortening of machine life potentially resulting. Be
careful, therefore, to note the correct tightening
torque at each stage of assembly.
Fig. 1-64
This manual describes use of a power wrench to
achieve the required torque, but a hydraulic
wrench will allow for even more accurate and
efficient tightening work.
2 Be sure to tighten each bolt to the specified torque

using a torque wrench, power wrench, or hydraulic
wrench.
Torque wrench
1) After tightening a bolt to the specified torque,
mark the alignment of the bolt head, spacer and
Fig. 1-65
bolted part. (See Fig. 1-64.)
2) Use only genuine Hitachi bolts.
CAUTION:
i) If a bolt is too long, you will not be able to fully
tighten it.
ii) If a bolt is too short, you will not be able to be
tighten it sufficiently to secure the parts, possibly
resulting in a serious accident.
Pin
6 Notes on inserting pins when affixing the Moly coat spray

Fig. 1-66
front-end attachment.
1 When attaching the front-end attachment,
thoroughly clean away the anticorrosive applied to
the pins and pin holes before inserting the pins,
then regrease them and spray them with Moly coat.
2 Be sure to check the alignment of pin holes when
joining parts. Do not use unreasonable force to Pin
insert pins, and attempt to insert all pins manually
by human strength. If human strength is
insufficient, use a medium-sized hammer to ease
the pin in place.
The use of forklift teeth to force in pins is
absolutely forbidden. Any other unreasonable
force can lead to a pin being deformed and
rendered unusable, and should be avoided. Fig. 1-67
(Fig. 1-67)
22
7 PRECAUTIONS FOR CONNECTING THE PILOT HOSES
Be sure to observe the following points when connecting the pilot hoses. If the hoses are connected without paying
attention to the precautions described below, contaminants may enter the pilot circuit. If this happens, the contaminants
may cause the pilot valve to malfunction.
Plug
Plug
Step 1 The ends of both the valve and hose to be

connected are sealed with plugs.
Detail A
Fig. 1-68
Adaptor
Step 2 1) Remove the plugs. Fitting
2) Thoroughly clean the hose fitting and Remove

adaptor, then connect them, taking care the plugs
to prevent the ingression of any

contaminants. Detail B
Fig. 1-69
Adaptor
Step 3
Connect the adaptor and hose fitting. Fitting
Notes:
i) When connecting hoses, do not twist
them, or their service life will be
shortened.
ii) Connect the hoses so as to avoid Detail C
Fig. 1-70
contact with other parts.
iii) Make sure that no dust has adhered to
the seat face of the hoses.
iv) Be careful to not damage the joining
surfaces of the hoses.
23
8 Standards for Hydraulic Joint Work
A ORS joint
Work procedure
1 Check that the O-ring, adapter, hose seat surfaces are free of scars or dirt.
Note:
Visually check their conditions. Wipe off dirt, if any. Do not use any scarred parts.
Check for dirt and scars
Adapter Hose, union part
O-ring Fig. 1-71
2 Apply bond to the groove in the adapter, install the O-ring, and apply spray grease High Tack Adhesive/Sealand
98D (Loctite, Ltd) to the screw part of the hose union.
Notes:
i) Remember to handle the O-ring with your bare hands.
ii) Press the entire O-ring with your fingers and install it properly.
iii) Apply the bond uniformly to the groove. Do not overapply. (Otherwise, the bond will seep into the hydraulic
circuit, causing a breakdown.)
Handle the O-ring with your bare hands!
Apply spray grease here. Fig. 1-72
3 Screw the hose and union into the adapter.
Notes:
i) To prevent the O-ring from falling out of place, place the O-ring surface of the adapter and seat surface of the
hose horizontal to each other to keep them immobile.
ii) Tighten the union nut fully with your hands.
iii) If the O-ring is jammed, it will feel differently from when you've tightened it fully with your hands (the torque will
not develop instantaneously and you will feel as though there is something stuck). If you sense any abnormality,
loosen the union nut and make sure to verify the O-ring.
Tighten the union nut fully with your hands
Fig. 1-73
4 Tightening the union

• To tighten the union, use a spanner-style torque wrench and control the torque properly.
• Use a specified torque wrench.
Note:
After the work, carry out a check using a white pen.
24
B Union joint
Work procedure
1 Check that the adapter and hose union seat surfaces are free of scars or dirt.
Note:
Visually check their conditions. Wipe off dirt, if any. Do not use any scarred parts.
Adapter seat surfaces Hose union seat surface
Fig. 1-74
Fig. 1-75
Apply spray grease here
2 Apply spray grease to the screw parts of the hose and union.
Note:
Do not overapply.
(When the temperature of the base machine goes up, grease will flow out and this may be mistaken as an oil
leak.)
3 Screw the hose into the adapter.
Note:
Tighten fully using your hands.
(If there are no scars on the thread, you will be able to screw it fully with your hands.)
Tighten the union nut fully with

your hands
Fig. 1-76
4 Tightening the union

• To tighten the union, use a spanner-style torque wrench and control the torque properly.
• Use a specified torque wrench.
Notes:
i) After tightening, loosen the union by turning the wrench 2 - 3 times to adapt the seat surface to it.
ii) After the work, carry out a check using a white pen.
25
C Split flange joint
Work procedure
1 Check that the O-ring and hose-seat surfaces are free of scars or dirt.
Notes:
i) Visually check their conditions. Wipe off dirt, if any. Do not use any scarred parts.
ii) Check also the seat surfaces of opposite parts (C/V, pump, etc.) for scars and dirt.
Check for scars and dirt Fig. 1-77
O-ring Hose, flange
2 Apply bond to the O-ring groove in the hose and flange and install the O-ring High Tack Adhesive/Sealand 98D
(Loctite, Ltd).
Notes:
i) Remember to handle the O-ring with your bare hands.
ii) Apply the bond uniformly to the groove. Do not overapply.
(Otherwise, the bond will seep into the hydraulic circuit, causing a breakdown.)
iii) Press the entire O-ring with your fingers and install it properly.
Handle the O-ring with your bare

hands. Do not overapply the bond. Fig. 1-78
3 Installing the split flange

1) Temporarily install one side of the split flange 2) Confirm the O-ring and set the hose onto the
using the socket bolts. split flange.
Note: Notes:
Using your hands, screw in the bolt to about half i) Make sure to insert the hose horizontally to the
its length. installation surface.
ii) Take care so that the O-ring does not fall out of
place.
Screw in the bolt to

about half its length.
Pay attention to
the O-ring
Fig. 1-79 Fig. 1-80
Split flange Socket bolts
26
3) After setting the hose, install the other split flange.
Notes:
i) If the bolt has not been screwed in adequately, the instability of the hose seat surface will increase and the O-ring
may fall off.
ii) After setting the hose, pay attention to the hose installation angle to avoid the hose from being turned.
Install other split flange

If the bolt has not been
screwed in adequately,
the instability of the hose
seat surface will increase,
causing the O-ring to fall
Fig. 1-81 off
Fig. 1-82
4 Tightening the socket bolt

1) Temporary tightening, hose angle adjustment 2) Tightening the bolts
• Make sure to tighten the bolts in the correct • Tighten the bolts using a crisscross
order to avoid lopsided tightening. sequence in the same way as for temporary
• The bolts should be tightened using a tightening.
crisscross sequence. • Be careful not to tighten the bolts lopsidedly.
• The hose should still have movement even • Be careful not to overtighten the bolts with
after the bolts have been tightened. an impact wrench.
• Adjust the hose angle.
3) Checking the torque
1 4 • Use a torque wrench to check that the bolts
are properly tightened.
• Check the bolts in the same crisscross
Bolt tightening sequence sequence as for tightening.
• After the work, carry out a check using a
white pen.
3 2
Fig. 1-83
No gap on one
side and too
much gap on the In the case of Should be tightened so that
other side lopsided tightening the gaps are uniform
Fig. 1-84 Fig. 1-85
27
9 When connecting hydraulic hoses and pipes, take A couple of threads left unwrapped
special care to keep seal surfaces free from dirt and to
avoid damaging them. Keep these precautions in mind:
a) Wash hoses, pipes, and the tank interior with a
washing liquid and thoroughly wipe it out before
reconnecting them.
b) Only use O-rings that are free of damage or
defects. Be careful not to damage them during
reassembly.
c) Do not allow high pressure hoses to twist when
Fig. 1-86
connecting them. The life of twisted hoses will be
shortened considerably.
d) When connecting screw type joints, apply seal tape
to the threads of male screw. Be sure to leave a
couple of threads at the male screw top unwrapped,
as shown. Do not overwrap. Apply seal tape around
threads as shown, so that the tape does not loosen
when the female screw is tightened.
e) Carefully tighten low pressure hose clamps to
following torque specifications. Do not overtighten.
T Bolt Clamp:
4.5 N·m (0.45 kgf·m, 3.3 lbf·ft)
Jubilee Clamp:
6.0 to 7.0 N·m Fig. 1-87
(0.6 to 0.7 kgf·m, 4.3 to 5.1 lbf·ft)
f) Carefully tighten nut for bandy pipe to following Pipe Dia. (A) ø8 ø10
torque specifications on the right side. Do not Width across flat (B) (mm) 17 19
overtighten. N·m 35 50
Fastening Torque kgf·m 3.5 5.0
10 When adding hydraulic oil, always use the same brand lbf·ft 26 36
of oil; do not mix brands of oil. As the machine is filled
with Super EX 46HN when it is shipped from the
factory, use it as a general rule. When selecting to use
another brand of oil listed in the table “Bw-Brand
Names of Recommended Hydraulic Oil”, be sure to
completely change the oil in the system.
11 Do not use hydraulic oils other than those listed in the

table “Bw-Brand Names of Recommended Hydraulic
Oil”.
Fig. 1-88
12 Only 50 to 60 % of the total hydraulic circuit oil on a
large size excavator can be changed at a time.
Accordingly, conduct minimum flushing twice.
13 If any other hydraulic oil (having a different change

interval) is unavoidably used, change the oil in
accordance with the individual change interval
standard.
14 In case the machine is used for dredging operations,

replace the hydraulic oil at a 2000 hour interval
regardless of the oil brand used.
15 Never run the engines without oil in the hydraulic oil

tank.
28
16 For reference
1 Ingredients of the white zinc jelly and spindle oil.
White zinc jelly
This stiff paste consists primarily of extender pigment and is prepared with specially processed fatty oil.
Ingredients: Extender pigment (calcium carbonate): 84.0%
Color pigment (titanium oxide): 0.5%
Fatty oil (polymerized oil): 14.0%
Solvent (mineral turpentine): 1.5%
Spindle oil
Physical and chemical properties of this oil are as follows. (grade C machine oil)
Appearance: Light brown
Flash point (COC): Above 160°C (320°F)
Density: 0.89 ~ 0.95 g/cm3
Fluid point: Below 10°C (50°F)
Mixture: None
Chemical name and composition: Petroleum system hydrocarbon 100%
2 Purchase high tack adhesive/sealant #98D from the following company:

Company Name: Loctite, Ltd.
Part Name: High Tack Adhesive/Sealant #98D
Part No.: 80063 (Loctite Part No.)
17 DRC connector rubber boot handling

precautions
· Rubber boots are fitted to NIHON-DEUTSCH LIMITED- Receptacle plug
made DRC series connectors (24, 40, and 70 poles)
Rubber boots
attached to excavator wiring joints to prevent water and
dust from entering into the connectors.
· These rubber boots are attached to the connectors and
covered with the plate before shipment and should be
stored similarly during disassembly. However, they
may be lost, become removed or flinched during field
assembly.
· To prevent this problem, new connectors and rubber
boots are designed to stick together so that they do not
come apart easily.
· Securely attach the rubber boot to the plug connector
Rubber boots
before assembly, then connect the plug and receptacle
terminals. Take care that the rubber boot is not out of Fig. 1-89
place or pinched during connection.
Note:
When connecting each connector, remove and
scrap the rubber boots fitted during shipment. Use
rubber packing 13 (P/No. 4392230 PRC24), 12
(P/No. 4392229 DRC40), and 11 (P/No. 4392228
DRC70) supplied.
18 Operation manual
Read the operation manual and this assembly
procedure manual thoroughly to familiarize yourself Fig. 1-90
with the work procedure.
29 (1/3)
19 Example of usage of a chain block or lever block.
By adjusting length “L” on the chain block (or lever block)
connecting the wire ropes, the lifted angle of the load can easily
be adjusted.
Wire rope
L'
Wire rope
L
Chain block
(Lever block)
Chain block
Wire rope
Lever block
Fig. 1-91
Work
Example
The angle of the workpiece in Fig. 1-92 can be
adjusted using chain blocks A .
Workpiece
Chain block
A
Chain block
A
a<b a=b
b
b
a a
Fig. 1-92
29 (2/3)
29 (3/3)
2. Workers plan
LOADER FRONT
Days 1
day
2
day
3
day
4
day
5
day
Fine weather
90 t x 4 days
90 tonnes x 2 90 t x 1.5 days

(100 US tons)
50 ~ 60 tonnes x 1
(55 ~ 67 US tons) 50 ~ 60 t x 3 days
Cranes
(With operator and assistant)
Tool check
Unloading
Unpacking major component

parts
Checking parts
Cleaning parts
Assembly of undercarriage
Not required if the oil tank is installed
Mounting basic machine

on undercarriage
Mounting cab on basic machine
Mounting oil tank on basic machine
(It may be already installed)
Assembly of catwalks, handrails
and ladders
Mounting engine unit on

basic machine
Mounting counterweight
Mounting front-end
attachment
Workers
Foreman
Touching-up & checks to and four
complete assembly assistant
workers x
5.0 days
Fig. 2-1
This plan varies depending on the job site environment, working conditions, assembly facilities, tools,
and workers’ skills.
30
2'. Workers plan
BACKHOE FRONT
Days 1
day
2
day
3
day
4
day
5
day
Fine weather
90 t x 4 days
90 tonnes x 2 90 t x 1.5 days

(100 US tons)
50 ~ 60 tonnes x 1
(55 ~ 67 US tons) 50 ~ 60 t x 3 days
Cranes
(With operator and assistant)
Tool check
Unloading
Unpacking major component

parts
Checking parts
Cleaning parts
Assembly of undercarriage Not required if the oil tank is installed
Mounting basic machine

on undercarriage
Mounting cab on basic machine
Mounting oil tank on basic machine
(It may be already installed)
Assembly of catwalks, handrails
and ladders
Mounting engine unit on

basic machine
Mounting counterweight
Mounting front-end
attachment
Workers
Foreman
Touching-up & checks to and four
complete assembly assistant
workers x
5.0 days
Fig. 2-2
This plan varies depending on the job site environment, working conditions, assembly facilities, tools,
and workers’ skills.
31
2-1 Transportation of Loader Front
7 8
11
10
Fig. 2-3
Example : Loader Front (Unit: metric tonne)

1 2 3 4 5 6 7 8 9 10 11
Boom& Handrails Cylinders Cab,
Basic Side frame Side frame Counter- Track Engine and & Cab bed,
arm Bucket
machine assembly (left) (right) weight frame Unit Miscella- Fuel tank
Fenders neous
parts etc.
35-tonne 35t 35t 35t 35t 35t

trailer
25-tonne 25t 25t

Trailers and trucks
trailer
20-tonne 20t
trailer
11-tonne 11t 11t

truck
8-tonne 8t
truck
32
2-1' Transportation of Backhoe Front
3
1 2
6 5
7
8
6
10
11
Fig. 2-4
Example : Backhoe Front (Unit: metric tonne)

1 2 3 4 5 6 7 8 9 10 11
Cylinders
Basic Boom Side frame Side frame Counter- Arm Track Engine Handrails Cab, &
machine assembly (left) (right) weight & frame Unit and Fuel tank Miscella-
with boom Bucket Fenders etc. neous
cylinders parts
35-tonne 35t 35t 35t 35t 35t

trailer
30-tonne 30t
trailer
25-tonne 25t
Trailers and trucks
trailer
20-tonne 20t
trailer
11-tonne 11t
truck
8-tonne 8t 8t
truck
33
TRANSPORTATION For EX2600-6
● Easily assembled owning to local assembling system requiring no welding.

● Overall width of below 3 500 mm (11'6") during transportation.
Unit: mm(ft in)
UPPERSTRUCTURE
Cab assembly Cab bed Reserve tank Hose real
Weight : 1 750 kg (3 850 lb) Weight : 2 580 kg (5 675 lb) Weight : 150 kg (330 lb) Weight : 54 kg (119 lb)
2 828 2 717
1 264
782
ø508
2 524
560
2 910
Width : 1 876 (6'2") Width : 1 835 (6'02") Width : 939 (3'1") Width : 265 (10")
Basic machine Handrail Step

Weight : 37 800 kg (83 160 lb) Weight : 7 kg (15 lb) Weight : 9 kg (20 lb)
8 195
560
1 026
663
3 254
318
Width : 3 500 (11'6")
Step assembly Step assembly Step assembly Step assembly Step

Weight : 71 kg (156 lb) Weight : 74 kg (163 lb) Weight : 77 kg (169 lb) Weight : 65 kg (143 lb) Weight : 153 kg (337 lb)
1 147
1 815
1 713.5 1 820
902
656
711
484
2 658
1 286
1 286
1 285
1 285
1 512
Width : 583 (1'11")
Cover Fender assembly Fender assembly Fender assembly

Weight : 3 kg (7 lb) Weight : 333 kg (733 lb) Weight : 214 kg (471 lb) Weight : 123 kg (271 lb)
2 644
1 605
1 276
1 118
1 100
851
1 657
52
1 937
1 701
1 701
Width : 40 (2")
34

Unit: mm(ft in)
UPPERSTRUCTURE
Fuel tank Handrail assembly Handrail assembly Handrail Handrail
Weight : 2 140 kg (4 708 lb) Weight : 32 kg (70 lb) Weight : 29 kg (34 lb) Weight : 9 kg (20 lb) Weight : 10 kg (22 lb)
2 927
2 039 253 1 883 142 153 307 437

2 780
1 512
1 512
1 227
1 227
Width : 1 302 (4'3")
Fender assembly Fender assembly Handrail Ladder Step assembly

Weight : 191 kg (420 lb) Weight : 478 kg (1 051 lb) Weight : 33 kg (73 lb) Weight : 20 kg (44 lb) Weight : 37 kg (81 lb)
2 720
652 213 1 228 208
1 934 457
1 142
1 500
1 525
985
1 701
2 200 790
Width : 1 309 (4'4")
Step assembly Bracket ~ 2 Bracket ~ 2 Cover Fender Fender assembly

Weight : 140 kg (308 lb) Weight : 10 kg (22 lb) Weight : 14 kg (31 lb) Weight : 1 kg (2 lb) Weight : 72 kg (158 lb) Weight : 86 kg (189 lb)
2 783 1 373
169 285 238 72 1 400 580
564
580
323
593
593
1 030
1 306
1 030
Width : 107 (4") Width : 125 (5")
Intake unit Exhaust unit Step

Weight : 310 kg (682 lb) Weight : 570 kg (1 254 lb) Weight : 8 kg (18 lb)
1 234 1 858
579
1 260
663
1 940
1 280
46
Width : 1 352 (4'5")
35

Unit: mm(ft in)
UPPERSTRUCTURE
Step Handrail Handrail Handrail Handrail
697.5 697.5 2 052 2 052

940
1 007
1 007
1 007
1 007
600
210
Width : 230 (9") Width : 230 (9")
Handrail Handrail Handrail Handrail Handrail

984 2 283.5 2608.5 1241.5 2 563

1 007
1 007
1 007
1 007
1 007
Width : 270 (11") Width : 230 (9") Width : 110 (4")
Step Handrail Handrail Handrail Handrail

740 660 676 284 209 843

1 007
1 007
1 007
834
672
210
Width : 110 (4") Width : 210 (8") Width : 230 (9")
Engine unit Door Door

Weight : 18 100 kg (39 820 lb) Weight : 26 kg (57 lb) Weight : 26 kg (57 lb)
588 598
3 328
1 600
1 600
6 134
Width : 2 500 (8'2") Width : 50 (2") Width : 50 (2")
36

Unit: mm(ft in)
UPPERSTRUCTURE
Box Handrail Handrail
Weight : 977 kg (2 149 lb) Weight : 23 kg (51 lb) Weight : 22 kg (48 lb)
462
872
1 026
1 720
1 500
Width : 1 856 (6'1") Width : 94 (4") Width : 1 030 (3'5")
Bracket Step assembly Beam

Weight : 20 kg (44 lb) Weight : 773 kg (1 701 lb) Weight : 615 kg (1 353 lb)
1 073
262
2 431
1 075
1 360 3 144
879
65
Width : 1 100 (3'7")
Handrail Handrail Handrail

Weight : 35 kg (77 lb) Weight : 33 kg (73 lb) Weight : 3 kg (7 lb) × 2
1 053.5
1 053.5
1 150
65
2 905 2 705
Width : 1 186 (3'11") Width : 1 070 (3'6")
Stopper Counterweight Bolt assembly

Weight : 9 kg (20 lb) × 2 Weight : 29 800 kg (65 560 lb) Weight : 24 kg (53 lb) × 6
32
1 343
87
1 450
420
125
6 696
Width : 1 208 (3'12")
37
Unit: mm(ft in)
UNDERCARRIAGE
Track frame Side frame
Weight : 22 300 kg (49 060 lb) Weight : 31 400 kg (69 080 lb) × 2
2 033
1 560
8 000
3 300
Width : 5 060 (16'7") Width : 2 360 (7'9")
Step Step assembly Support

Weight : 8 kg (18 lb) Weight : 13 kg (29 lb) Weight : 78 kg (172 lb)
Note:
This support is used on undercarriage that does not come
250
attached with a travel motor guards.

150
1 173
410 4 000
490
Width : 200 (8") Width : 603 (1'12") Width : 109 (4")
Cover Cover Cover

Weight : 96 kg (211 lb) Weight : 108 kg (238 lb) Weight : 89 kg (196 lb)
1 246
1 007
1 007
1 965 1 965 1 965
Width : 479 (1'7") Width : 560 (1'10") Width : 560 (1'10")
38
Unit: mm(ft in)
LOADING SHOVEL ATTACHMENTS

Loader bucket (15 m3) Loader
Weight : 20 300 kg (44 660 lb) Weight : 29 000 kg (63 800 lb)
3 240
( 12'2")
3 700
3 440
Arm cylinder
10 970
Weight : 2 240 kg (4 928 lb)
Width : 2 600 (8'6")
3 505
Bucket cylinders Boom cylinders
Weight : 1 870 kg (4 114 lb) × 2 Weight : 2 960 kg (6 512 lb) × 2
3 980 4 475
BACKHOE ATTACHMENTS Boom assembly

Weight : 24 500 kg (53 900 lb)
Boom cylinders
Weight : 3 120 kg (6 864 lb) × 2
3 615
4 750
Bucket assembly : 17.0 m3 9 281

Weight : 15 600 kg (34 320 lb)
Width : 2 240 (7'4")
Arm assembly
Weight : 16 100 kg (35 420 lb)
2 870
2 505
5 305
3 760
Width : 3 600 (11'10") Width : 1 640 (5'5")
39
40
3. Parts check
3-1 Check
1 Unpack the major component parts.
2 Check their quantity against that shown on the packing

list.
3 Check the parts for any damage during transportation.

If there are any missing or damaged parts, take
pictures of the damage and then contact Hitachi or
your Hitachi distributor as soon as possible.
Fig. 3-1
41
4. Preparations (loader front)
1 Work site: Select a place where the ground is firm and 3 Cranes: Prepare the following cranes.
flat. 2 × 90 tonnes (100 US tons)
1 × 50 ~ 60 tonnes (55 ~ 67 US tons)
2 Space: Secure a space of 29 m (95 ft) ×26 m (85 ft) or 4 Arrangement of major components: See Figs.
more. 4-1, and 4-2.
Weight Crane
1 Basic machine assembly 37 800 kg ( 83 160 lb) 19 50 ~ 60 t. crane
2 Cab 1 750 kg ( 3 850 lb) 20 90 t. crane
3 Cab bed assembly 2 580 kg ( 5 675 lb)
4 Fenders, handrails and ladders 4 055 kg ( 8 920 lb)
5 Track frame assembly 22 300 kg ( 49 060 lb)
6 Side frame assembly (left) 31 400 kg ( 69 080 lb)
7 Side frame assembly (right) 31 400 kg ( 69 080 lb)
8 Counterweight 29 800 kg ( 65 560 lb)
9 Engine Unit 18 100 kg ( 39 820 lb)
10 Intake/ exhaust Unit 880 kg ( 1 935 lb)
11 Fuel tank 2 140 kg ( 4 710 lb)
12 Reserve tank 150 kg ( 330 lb)
13 Step assembly 773 kg ( 1 700 lb)
14 Boom assembly 29 000 kg ( 63 800 lb)
15 Boom cylinders 2 960 kg ( 6 510 lb) ×2
16 Arm cylinder 2 240 kg ( 4 930 lb)
17 Bucket cylinders 1 870 kg ( 4 115 lb) ×2
18 Bucket assembly 20 300 kg ( 44 660 lb)
42
ARRANGEMENT OF MAJOR COMPONENTS
ft)
(85 13 29
m 4 m
26 (95
ft)
11
19
7
15 10
14 5
18 8
17
2 6 12
3 16
Fig. 4-1
20
1
19
17
15 14
18
16
20
Fig. 4-2
43
4'. Preparations (backhoe front)
1 Work site: Select a place where the ground is firm and 3 Cranes: Prepare the following cranes.
flat. 2 × 90 tonnes (100 US tons)
1 × 50 ~ 60 tonnes (55 ~ 67 US tons)
2 Space: Secure a space of 29 m (95 ft) ×26 m (85 ft) or 4 Arrangement of major components: See Figs.
more. 4'-1, and 4'-2.
Weight Crane
1 Basic machine assembly 37 800 kg ( 83 160 lb) 18 50 ~ 60 t. crane
2 Cab 1 750 kg ( 3 850 lb) 19 90 t. crane
3 Cab bed assembly 2 580 kg ( 5 675 lb)
4 Funders, handrails and ladders 4 055 kg ( 8 920 lb)
5 Track frame assembly 22 300 kg ( 49 060 lb)
6 Side frame assembly (left) 31 400 kg ( 69 080 lb)
7 Side frame assembly (right) 31 400 kg ( 69 080 lb)
8 Counterweight 29 800 kg ( 65 560 lb)
9 Engine Unit 18 100 kg ( 39 820 lb)
10 Intake/ exhaust Unit 880 kg ( 1 935 lb)
11 Fuel tank 2 140 kg ( 4 710 lb)
12 Reserve tank 150 kg ( 330 lb)
13 Step assembly 773 kg ( 1 700 lb)
14 Boom assembly 24 500 kg ( 53 900 lb)
15 Arm assembly 16 100 kg ( 35 420 lb)
16 Boom cylinders 3 120 kg ( 6 865 lb)×2
17 Bucket assembly 15 600 kg ( 34 320 lb)
44
ARRANGEMENT OF MAJOR COMPONENTS
ft)
(85 13
29
m 4 m
26 (95
ft)
11
18
16
14 7 10
5
17 15 8
2 12
6
Fig. 4'-1
19
1
18
14
17 15
19
Fig. 4'-2
45
NOTES
............................................................... ............................................................... .......................
............................................................... ............................................................... .......................
............................................................... ............................................................... .......................
............................................................... ............................................................... .......................
............................................................... ............................................................... .......................
............................................................... ............................................................... .......................
............................................................... ............................................................... .......................
............................................................... ............................................................... .......................
............................................................... ............................................................... .......................
............................................................... ............................................................... .......................
............................................................... ............................................................... .......................
............................................................... ............................................................... .......................
............................................................... ............................................................... .......................
............................................................... ............................................................... .......................
............................................................... ............................................................... .......................
............................................................... ............................................................... .......................
............................................................... ............................................................... .......................
............................................................... ............................................................... .......................
............................................................... ............................................................... .......................
............................................................... ............................................................... .......................
............................................................... ............................................................... .......................
............................................................... ............................................................... .......................
............................................................... ............................................................... .......................
............................................................... ............................................................... .......................
............................................................... ............................................................... .......................
............................................................... ............................................................... .......................
............................................................... ............................................................... .......................
46
5. Machines, apparatus, tools, and materials necessary for assembly
Listed below are the machines, apparatus, tools, and materials required for assembling the EX2600-6 hydraulic excavator.
1 Cranes
Two crane of 90 tonne capacity (100 US tons)
One crane of 50 ~ 60 tonne capacity (55 ~ 66 US tons)
2 Wire ropes
36 mmø × 8 000 mm (L) - 2 pcs. 26 mmø × 4 000 mm (L) - 2 pcs. 10 mmø × 5 000 mm (L) - 4 pcs.
(1.4 inø) (312 in L) (1.0 inø) (156 in L) (0.4 inø) (195 in L)
28 mmø × 8 000 mm (L) - 3 pcs. 12 mmø × 5 000 mm (L) - 1 pc. 8 mmø × 8 000 mm (L) - 1 pc.
[ For Loader front ] [ For Backhoe front ]
48 mmø × 10 000 mm (L) - 1 pc. 38 mmø × 6 000 mm (L) - 1 pc.
(1.9 inø) (390 in L) (1.5 inø) (234 in L)
46 mmø × 3 000 mm (L) - 2 pcs. 36 mmø × 12 000 mm (L) - 1 pc.
(1.8 inø) (117 in L) (1.4 inø) (468 in L)
32 mmø × 10 000 mm (L) - 1 pc. 28 mmø × 10 000 mm (L) - 1 pc.
(1.25 inø) (390 in L) (1.1 inø) (390 in L)
32 mmø × 5 000 mm (L) - 2 pcs. 28 mmø × 3 000 mm (L) - 2 pcs.
(1.25 inø) (195 in L) (1.1 inø) (117 in L)
32 mmø × 3 000 mm (L) - 2 pcs. 24 mmø × 8 000 mm (L) - 1 pc.
(1.25 inø) (117 in L) (0.95 inø) (312 in L)
16 mmø × 5 000 mm (L) - 1 pc. 24 mmø × 2 000 mm (L) - 2 pcs.
(0.65 inø) (195 in L) (0.95 inø) (78 in L)
(0.5 inø) (273 in L) (0.8 inø) (195 in L)
(0.5 inø) (117 in L) (0.5 inø) (117 in L)
12 mmø × 5 000 mm (L) - 1 pc.
(0.5 inø) (195 in L)
10 mmø × 1 000 mm (L) - 2 pcs.
(0.4 inø) (40 in L)
3 Nylon sling belts

100 mm (W) × 2 000 mm (L) - 2 pcs. 20 mm (W) × 4 000 mm (L) - 2 pcs.
(4.0 in) (78 in) (0.8 in) (156 in)
4 Shackles
0.5-ton load- 4 pcs. 2-ton load - 2 pcs. 5-ton load - 4 pcs. 10-ton load - 4 pcs. 20-ton load - 2 pcs.
1.5-ton load - 2 pcs. 15-ton load - 3 pcs.
3-ton load - 2 pcs. 10-ton load - 2 pcs.
12-ton load - 2 pcs.
5 Chain blocks and lever blocks:

5-ton load - 2 pcs. 0.5-ton load - 1 pc.
Chain blocks
10-ton load - 1 pc. 1.5-ton load - 2 pcs. Lever blocks
2.0-ton load - 1 pc.

1.5-ton load - 2 pcs. 3-ton load - 6 pcs. Lever blocks
3-ton load - 4 pcs. Lever blocks 10-ton load - 1 pc.
Chain blocks
12-ton load - 1 pc. 20-ton load - 1 pc.
Chain blocks
Note:
If the centering work can be performed by methods other than that those shown in 19 on page 29 (2/3), the chain blocks
and lever blocks indicated here are not required.
47
6 Wooden blocks
500 mm (L) × 700 mm (W) × 500 mm (H) - 4 pcs. 2 000 mm (L) × 100 mm (W) × 100 mm (H) - 2 pcs.
(20 in) (30 in) (20 in) (78 in) (4 in) (4 in)
1 000 mm (L) × 500 mm (W) × 1 000 mm (H) - 4 pcs.
(40 in) (20 in) (40 in)
800 mm (L) × 900 mm (W) × 800 mm (H) - 4 pcs. 1 000 mm (L) × 500 mm (W) × 800 mm (H) - 4 pcs.
(30 in) (35 in) (30 in) (40 in) (20 in) (30 in)
300 mm (L) × 300 mm (W) × 1 000 mm (H) - 2 pcs. 1 000 mm (L) × 500 mm (W) × 500 mm (H) - 4 pcs.
(12 in) (12 in) (40 in) (40 in) (20 in) (20 in)
2 600 mm (L) × 300 mm (W) × 200 mm (H) - 1 pc.
(100 in) (12 in) (8 in)
7 Scaffolding
As required - 2 units (2.5 m High) For L/D
(See Fig. 5-1)
As required - 2 units (4.0 m High) For B/H
Ladder (2 ~ 2.5 m High) - 4 pcs.
8 Oil containers
20 liter capacity - 4pcs. 10 liter capacity - 2pcs.
9 Standard tools
Prepare 4 or more sets.
10 Spanner
50 mm: For Fuel hoses/Drain hoses
11 Ratchet handle
12 Crowbar
13 Bar wrench with ball end Scaffolding (example)
4 mm 1 Wiring
14 mm 1 Travel motor hoses
17 mm 3 Front attachment hoses
14 Hydraulic jacks
30 - ton load - 2pcs.
15 Protectors and patches

An example protector is shown in Fig. 5-2
Fig. 5-1
16 Touch-up paint
Protectors
17 Air impact wrenches (with air compressor)

Used tire
4 000 N·m capacity - 1pc. 200 N·m capacity - 1pc.
(408 kgf·m/2 950 lbf·ft) (20 kgf·m/148 lbf·ft)
18 Hand tachometer or digital tachometer
19 Socket wrench
24 mm Number of protectors required to be made: 10 pcs.
30 mm 1 Front attachment pins
Fig. 5-2
36 mm
46 mm 1 Engine units
75 mm 1 Connecting main frame,
counterweight track frame
48
20 Electric power source Headset
21 Bar wrench - 4 mm (For oil tank bleeder)
22 Headset - 4 sets
(see Fig. 5-3)
Speaker
23 Safety life lines - 5sets
Mike
24 Pressure cleaner (Remove oil/grease)
25 Miscellaneous
Rags Belt
Cleaning detergent
Lubricant
Light & cord reel for work
Battery pack
Grease
Moly coat spray
26 Eye Bolt
1.0 - ton load - 4pcs.
Fig. 5-3
27 Special tools (refer to the proceeding pages)
For tools which are not available locally, place an
order with Hitachi in advance.
49
Note:
SPECIAL TOOLS order with Hitachi in advance.
Item Illustration Tool name Q'ty Usage
Tap Tap to be screwed

in bolt hole for
tightening the
1 Tap size 1 side frame,
Side frame M48×P4.0 swing bearing,
Swing bearing P/No. 4370005 oil tank, and
engine unit.
Fuel tank M30×P3.0
Engine unit P/No. 4370003
Fig. 5-4
P/No. 4093798
Torque wrench Used to tighten
2 1
100 ~ 410 N·m the bolts.
(10 ~ 42 kgf·m/74 ~ 302 lbf·ft)
Fig. 5-5
P/No. 4093800
Used to tighten
Power wrench
3 the side frame
1 470 ~ 4 410 N·m 1 to track frame
150 ~ 450 kgf·m
and swing bearing
1 084 ~ 3 253 lbf·ft
Fig. 5-6
P/No. 4229414 Used to tighten

4 Power wrench 1 the side frame
to track frame
Fig. 5-7
Vacuum pump
Assembly ST6905
Vacuum pump ST6440 Used to create a

5
Hose ST6326 1 set vacuum in the
Nipple PT 1/8 ST6066 hydraulic tank
Nipple PT 3/8 ST6068
Fig. 5-8
50
Note:

6

Fig. 5-9

7
Fig. 5-10
Section A
30- 0.2
0.4

8 # #
# %#
1˚38'
ø36.026
M48×4.0
ø10
A
ø49
(50) (100) 23 22.5

15
(400)
Fig. 5-11
9 ! "!#

R ! $#!$
M16×2.0
70
Fig. 5-12

10 # #
#
Fig. 5-13
51
Note:

90˚ 2 45˚
(20)
15˚

Section A 30˚

16
11

ø30
16
(820)
R8 50
R15 50 (50)
ø10
5
R36
Fig. 5-14
40
ø12

M20×2.5

12 7

17 Fig. 5-15
Directions for use of the pin removal/insertion jig
Pin removal Pin insertion
Item no. 12 Item no. 11

Fig. 5-16
52
EX2600-6 Assembly Manual
UNDERCARRIAGE
ASSEMBLY OF UNDERCARRIAGE
6. Assembly of Undercarriage
6-1 Preparation
ASSEMBLY CHART OF UNDERCARRIAGE
Note:
XF60000349 = with motor guard
XF60000358 = without motor guard
Step 1
Parts required
Procedure (track) XF60000349/XF60000358
Part No.
Item Part name Q'ty Remarks
XF60000349 XF60000358
00 XF60001155 XF10001204 TRACK FRAME ASSEMBLY 1 Track frame and swing bearing
01 XF60001156 XF10001205 SIDE FRAME ASSEMBLY (L) 1 Side frame (L) and track link
02 XF60001157 XF10001206 SIDE FRAME ASSEMBLY (R) 1 Side frame (R) and track link
10 6020327 6020327 COVER 1
11 8061435 8061435 STEP 1
12 XF60001158 XF60001207 STEP ASSEMBLY 1 Step, wire rope, and pin
13 6017844 6017844 COVER 1
14 6016469 6016469 COVER 1
15 4344602 4344602 HOSE 2 Hose connecting the motor and brake valve, 1.1/2 dia.
16 4344601 4344601 HOSE 2 Hose connecting the motor and brake valve, 1.1/2 dia.
17 4401948 4401948 HOSE 2 Travel motor drain hose, 3/4 dia.
18 4410984 4410984 HOSE 2 Shift speed hose, 1/4 dia.
28 4372448 4372448 BOLT 28

For installing the track frame and side
29 4372449 4372449 SPACER 28 frame side mounting section
30 4347715 4347715 BOLT 40

For installing the track frame and side
31 4347723 4347723 SPACER 40 frame
32 4510169 4510169 O-RING 8 Note:

35 ─── 7040917 SUPPORT 1 This support is used on undercarriage that
does not come attached with a travel motor
guards.
55
Travel motor guard option (Kit No. XF60000360)
Item Part No. Part name Q'ty Remarks
00 6017536 GUARD (L) 1

01 6017537 GUARD (R) 1
03 7035028 BRACKET (L) 1
04 7035029 BRACKET (R) 1
06 4393099 SPACER 2
07 4398472 SPACER 2
09 J932780 BOLT 20
10 4085857 WASHER 20
12 J931680 BOLT 6
13 4087197 WASHER 6
14 9758513 BRACKET 2
15 J271240 BOLT SEMS 4
18 4027471 BOLT, EYE 6
21 4603063 SHIM 4
22 4603014 SHIM 60
Mission guard option (Kit No. XF60000361)
00 7038666 GUARD (L) 1

01 7038667 GUARD (R) 1
02 8080527 BAND 2
03 M262000 BOLT 8
04 J951020 NUT 16
05 8080560 GUARD (L) 1
06 8080562 GUARD (R) 1
07 8080528 BAND (L) 1
08 8080529 BAND (R) 1
09 M262000 BOLT 8
10 J951020 NUT 16
11 J922465 BOLT 12
12 A590924 WASHER, SPRING 12
13 J222024 WASHER 12
15 8077839 STOPPER 2
16 J922465 BOLT 2
18 J222024 WASHER 2
19 J921850 BOLT 10
21 J222018 WASHER 10
22 8080534 BRACKET 2
56
Lift
6-2 Connection of track frame and side frames
Step 1
Wire rope
Preparation of the right side frame assembly 36 mmø ×
8 000 mm
1 1 Lift right frame assembly (R) 02 as illustrated in

Fig. 1.
a
Note: 02
Apply protectors at a , b , c , and d , indicated
b
by , to prevent the wire ropes from breaking.
Side frame assembly 02 weight: 31 400 kg (69 080 lb)
c
Wire rope: 2 pcs.
d Fig. 1
36 mmø × 8 000 mm (L)
(1.4 inø) (312 inL) Front
Protector: 8 pcs.
Final drive
2 Place the side frame assembly on the ground with
the final drive toward the rear.
CAUTION: Rear
Never allow any persons to stand directly beneath the Fig. 2
lifted side frame. Detail A
2 Cleaning and finishing
1 Clean all screw holes on the side frame using a

tap. (Fig. 3)
Tap size: M48 × P4.0
Fig. 3
Detail B
2 Clean the front and rear surfaces (indicated by e
and f in Fig. 4).
e
3 Check the surfaces for damage or scratches.
Note: f
Repair and/or refinish any damage found.
Fig. 4
57
Step 2 c
00
Preparation of the track frame assembly
d
＊ Cleaning and finishing
1 Clean all the surfaces of track frame 00 that
will be connected to the side frame. a
(a ~ d ).
Fig. 5
2 Check the surfaces for damage or scratches. b
Detail C
Note:
3 Clean all spot facing surfaces on the track frame. Spot facing
Spot facing
Fig. 6
Fig. 6-a
Step 3
Lift
Lifting of the track frame assembly
＊ Lift track frame assembly 00 as shown in Figs.

7, 8 and 8-a.
Track frame assembly 00 weight: 00

22 300 kg (49 060 lb)
Wire rope: 4 pcs.

32 mmø × 8 000 mm (L)
(1.25 inø) (312 inL) Fig. 7
Shackle: 4 pcs. Detail D

for a 10 metric tonne (11 US ton) load
CAUTION: Wire rope

Never allow any persons to stand directly
beneath the lifted track frame. Wire rope
Shackle
Shackle 10 ton
Eye-plate
Fig. 8
Fig. 8-a
58
Step 4 Lift & move
Connecting of the track frame to the right side frame
1 1 Move the track frame assembly horizontally in the

direction of the arrow .
Side frame (right)
Note:
Position the final drive portion of the side frame
assembly and the brake valves on the track frame
assembly to be facing the same direction. (See
Fig.9)
Final drive
Brake valves Fig. 9
Detail E
2 Move the track frame assembly horizontally in the
direction of the arrow, and align the centers of the
connecting parts.
Lift & move
Track frame Side frame (right)
Fig. 10
3 Connect the side frame to the track frame.
Hold
Fig. 11
59
2 1 Align the bolt holes of the side fame and track Hold
frame, then connect them with bolts 28 and
spacers 29 .
Fig. 12
Detail F
Notes:
i) Be sure to apply a suitable lubricant to bolts 28
before tightening. Use a lubricant made by
mixing white zinc jelly and spindle oil in a 1:1
proportion.
ii) Apply lubricant to each bolt and spacer in the
positions indicated by ＊ in Fig. 14 (the base of
the head and thread of each bolt, and both end 29
faces of the spacers). 28 Fig.13
iii) Place spacers 29 on bolts 28 with the chamfer
directed towards the bolt head.
Detail G
iv) Tighten all bolts until the surfaces engage fully. 29
v) Confirm that there is no gap between the ＊
surfaces.
＊
＊
＊ 0
13
Note:
Be sure to treat all the bolts in the same way.
28 0
25
2 Tighten bolts on the front side following the
28
same procedure as that for the rear side. Fig. 14
3 Temporarily tighten using a power wrench.

Detail H
CAUTION:
Avoid getting your hand caught by the reaction force
bar of the power wrench.
The bolts 28 are fully tightened in Step 8.

Power wrench
(4093799)
Fig. 15
60
Lift
Step 5 Detail I
Connecting of the left side frame to the track frame 500 1000
1 Place wooden blocks under the left side of the track 1020
frame as shown in Figs.16 and 16-a.
Wooden block: 2 pcs.
Size: 1 000 mm (L) × 500 mm (W) × 1 000 mm (H) Fig. 16-a
(40 in) (20 in) (40 in)
Note:
Each wooden block must be able to carry at least
Fig. 16
15 000 kg (33 069 lb).
CAUTION:
This method is safer than lifting the track frame assembly
with another crane.
Wooden approx. 1 020 mm
block (39.8 in)
2 1 Clean all screw holes on the side frame 01 using a
tap.
Tap size: M48 × P4.0 Fig. 17
Lift & move
2 Clean the left side frame surfaces to be
connected to the track frame.

Wire rope
Note: 36 mmø × 8 000 mm
Side frame 01
3 1 Lift the left side frame 01 (L) as illustrated in Figs. (left)
18 and 19.
Note:
Apply protectors at a , b , c , and d , indicated by
a
(both sides) to prevent the wire ropes from b
breaking. c
Side frame assembly 01 weight: Fig. 18

31 400 kg (69 080 lb) d
Wire rope: 2 pcs.

Lift & move
36 mmø × 8 000 mm (L)
(1.4 inø) (312 inL)
Protector: 8 pcs.
Note:
In lifting the side frame with the wire ropes set as
indicated, the track will sag if the links are loose,
making alignment with the track frame difficult. The
track links should thus be as tight as possible when
carrying out this work.
2 Move the side frame assembly horizontally in the

direction of the arrow, and align the centers of the
connecting parts.
Fig. 19
61
4 Apply a lubricant to the fixing bolts and spacers before
installation, as outlined in the inset detail. Hold
1 Align the bolt hole in the side frame with that of
track frame, then connect them together with bolts
28 and spacers 29 .
Notes:
i) Be sure to apply a suitable lubricant to bolts 28
before tightening. Use a lubricant made by 28 29
proportion.
positions indicated by ＊ in Fig. 21 (the base of
the head and thread of each bolt, and both end
faces of the spacers).
iii) Place spacers 29 on bolts 28 with the chamfer
directed to the bolt head. Fig. 20
iv) Tighten all bolts until the surfaces engage fully.
Detail J
v) Confirm that there is no gap between the 29
surfaces. ＊
＊
13
0
＊
25
0
28
Fig. 21
Detail K
29
Note: 28 Fig. 22
Be sure to treat all the bolts in the same way.
Detail L
2 Tighten bolts 28 on the front side following the
same procedure as that for the rear side.
3 Temporarily tighten using a hydraulic wrench.
CAUTION: Power wrench

(4093799)
Avoid getting your hand caught by the reaction force
bar on the power wrench.
The bolts 28 are fully tightened in Step 8.

Fig. 23
62
Step 6
Removing of the wooden blocks Wooden block
Fig. 24
1 1 Lower the crane.

2 Place hydraulic jacks a (indicated by ) at
the front and rear of the underside beam on the
track frame. Lower
3 Extend the jacks at the front and rear sides Wooden block
simultaneously.
4 Jack up the track frame high enough to remove
the wooden blocks.
Hydraulic jack: 2 pcs.

for 30 tonne (33 US ton) load
Plate
CAUTION:
Hydraulic
Make sure to use a block under each jack, and position jacks:2 pcs.
them securely.
a Blocks Fig. 25
2 1 Remove the wooden blocks
Fig. 26
2 Lower the 2 hydraulic jacks a (indicated by

) simultaneously to ground the track frame.
Hydraulic
jacks.
a
Fig. 27
63
Step 7
Tightening procedure for the upper side bolts used to
attach the track frame.
1 1 Attach the wire rope as indicated in Fig. 28. Track link
Note 1: b
Apply protectors to a and b , indicated by . a
(Fig. 28)
Fig. 28
2 Loosen valve c at the track adjuster. Do not
touch valve d . (Fig. 29) Detail M
3 Lift the track link using a crane as illustrated in
Fig. 30.
Track link weight: Approx. 10 000 kg (22 000 lb)
Wire rope: 1 pc. CAUTION

Grease
36 mmø × 8 000 mm (L) outlet Do not touch d
(1.4 inø) (312 inL) c
Protector: 2 pcs. Lift

d
Note 2: Fig. 29
Grease will come out of valve d when lifting the
track link. Track link
Collect the grease with the vinyl bag provided.
Notes 3:
i) Lift the track link to create clearance at the side Detail N
frame's upper face as shown in Fig.32.
ii) Be careful that you do not break the wire rope. Fig. 30
CAUTION:
Place a sleeper between the track link and side frame
so the track link cannot fall from its suspended state.
Fig. 31
2 1 Attach bolts 30 through the clearance made by
lifting the track links. Clearance
2 Apply lubricant to bolts 30 before installation. between
track link
and side
Notes: frame
i) Be sure to apply a suitable lubricant to the bolts
proportion. Fig.32
positions indicated by ＊ in Fig. 33 (inset) (the Detail O
base of the head and thread of each bolt, and
both end faces of the spacers).
iii) Place spacers 31 on bolts 30 with the chamfer 30
＊
directed towards the bolt head. 30 210 31
iv) Keep the track link lifted until the bolts are ＊
completely tightened.
＊
3 Attach the remaining bolts on the opposite side frame

90
using the same procedure.
＊ 31 Fig. 33
Tighten the bolts at the opposite side again
following the same procedure mentioned above.
64
Step 8
Hold
Retightening of the bolts
1 Retighten the upper side bolts.

Tighten these bolts to the specified torque using a
power wrench.
Tightening torque of M48 bolt: 4 900 N·m
(499 kgf·m/3 614 lbf·ft)
Width across flats: 75 mm
Note:
Keep the track link lifted until the bolts are Fig. 34
completely tightened.
Detail P
CAUTION: Power wrench
(4093799)
i) Place a sleeper between the track link and side frame Upper side bolts
so the track link cannot fall from its suspended
state.
Sleeper
ii) Use caution to avoid your hand from being caught
by the reaction force bar.
Fig. 35
Fig. 36
2 Tighten the side bolts installed temporarily in Step 4 Detail Q

and Step 5 to the specified torque, using a power wrench. Side bolts

(499 kgf·m/3 614 lbf·ft)
CAUTION:
Power wrench
Use caution to avoid your hand from being caught by (4093799)
the reaction force bar. Fig. 37
Fig. 38
65
3 Removal of the sleeper.
Left
Slightly lift the trak link and remove the sleeper that in
placed between the side frame and track link.
Fig. 39
Detail Q
Sleeper
Fig. 40
66
6-3 Connection of travel motor hoses and adjuster hoses
Step 1
Connection of the travel motor hoses
1 1 Connect travel motor hoses 15 and 16 (on the

right side).
Hose 15 weight: 18 kg (40 lb)

Hose 16 weight: 16 kg (35 lb)
Tightening torque of M16 bolt : 15 and 16

210 N·m (21 kgf·m/155 lbf·ft)
Socket size: 14 mm
Fig. 1
Notes:
i) Clean the surfaces of the travel motor to be
Detail A
connected to the hoses.
ii) Make sure that no dust adheres to the seat
face of each hose. 15
iii) Be careful not to twist the hoses when
connecting them.
iv) Apply sealant #98D to O-rings 32 (P/No.
4510169~8 pcs.) just before installing.
16
Fig. 2
2 Connect pilot hoses 17 and drain hoses 18 . Detail B
Tightening torque of hose unions:

(Hose 17 ) 180 N·m (18 kgf·m/133 lbf·ft)
(Hose ) 30 N·m
18 (3 kgf·m/22 lbf·ft)
Notes: 18
i) Clean the surfaces of the travel motor to be
connected to the hoses. 17
ii) Make sure that no dust adheres to the seat
face of each hose.
iii) Be careful not to twist the hoses when
connecting them.
Fig.3
67
Front side
D
2 1 Connect the hoses a and b as shown in Fig. 5.
Notes:
i) Make sure that no dust adheres to the seat face
of the hose nipple. Fig. 4
ii) Be careful not to twist the hoses when
connecting. Detail C
Tightening torque of hose a : 30 N·m a 15 16
(3 kgf·m/22 lbf·ft)
Tightening torque of hose b : 180 N·m

b Band clip
2 Use band clips to secure hoses 16 and 17
together in two positions. Also, secure hoses 15
and 18 in two positions as shown in Fig.5.
17 18
Band clip Fig. 5
3 Connect the adjuster hoses c and d after removing

the cover, as shown in Figs. 6 and 7. View D
The cover should be reinstalled after completing the
connection. c
Notes:
i) Make sure that no dust adheres to the seat face
of the hose nipple.
ii) Be careful not to twist the hose when
connecting.
Connecting
position
Tightening torque of hose c : 30 N·m
(3 kgf·m/22 bf·ft)
Width across flats: 19 mm d Fig. 6
Tightening torque for hose d : 95 N·m

(10 kgf·m/70 lbf·ft) Detail E
Tightening torque for cover bolt : 50 N·m

4 Clean the parts carefully after all oil has drained out. Cover
Connect the hoses on the other side using the

same procedure. Fig. 7
68
6-4 Assembly of motor covers and steps
Detail A
Step 1
Mounting of the travel motor covers and step
1 1 Put the supports 35 assembly in place.
Note:
This support 35 is used on undercarriage that does
not come attached with a travel motor guards.
Note: 35
Bolts are being screwed temporarily into the parts to Fig. 1
be installed.
Detail B
Support 35 weight: 78 kg (172 lb)
Tightening torque of M16 bolt: 210 N·m

2 Mount covers 10 , 13 , 14 in position.
Note: 14
Bolts are being screwed temporarily into the parts to
be installed.
Cover 10 weight: 108 kg (238 lb)

10
13 Fig. 2
Tightening torque of M12 bolt: 90 N·m Detail C

14
Note:
Apply lubricant to the mounting bolts, fit all bolts
in place, then tighten to the specified torque.
10
13
Fig. 3
69
2 Mounting of the steps Detail D
1 Mount step 11 .
Note:
be installed.
Step 11 weight: 8 kg (18 lb)
Tightening torque of M12 bolt: 90 N·m 11

Note: Fig. 4
in place, then tighten to the specified torque. Detail E
2 Mount step assembly 12 .
Note:
be installed.
Step assembly 12 weight: 13 kg (29 lb)

Width across flats: 19 mm 12
Note: Fig. 5
in place, then tighten to the specified torque.
3 Check all bolts on the undercarriage and confirm that

they are securely tightened. Detail F
Fig. 6
70
6-5 Disassembly procedures for shipment (Procedure, Track)
6-5-1 With motor guard

Detail A
Fig. 1
EX2600-6 Procedure, Track XF60000349
71
6-5-2 Without motor guard
Detail B
Fig. 2
EX2600-6 Procedure, Track XF60000358
73
6-6 Assembly of motor guards and mission guards (Option)
Until now, the screw seats for the EX2600-6 travel motor guard were welded before they were shipped out. However, starting
from the following serial number models, the screw seats are no longer being welded before the shipment. Some of the reasons
are as follows: difficulties in installing the motor guard during site assembly due to welding distortion of track side frame and
necessity of large quantity of shims. Thus, from now on, screw seats will be welded at the site.
Applicable serial numbers: 2007 and above
Step 1
Procedure of the motor guard Detail A
Note:
Pages 76 and 77 show the details of parts and seats
and pages 78 and 79 show the welding method for
screw seat. The assembly drawing is given on page
81 (1/3).
1 Mounting the travel motor guard /

02 03
1 Place guards 00 / 01 and brackets 02 / 03 in position

as shown.
Wire rope: 2 pcs.

24 mmø × 6 000 mm (L)
/
00 01 Fig. 1
(0.95 inø) (234 in L) Detail B
Guard 00 weight: 540 kg (1 200 lb)

Bracket 02 weight: 450 kg (990 lb)
Guard 01 weight: 540 kg (1 200 lb)
2 Lift the guard and align the bolt holes.
Note: /
02 03
If the holes are not properly aligned, use a jack.
/
00 01
3 Mount motor guards 00 / 01 and brackets 02 / 03 in
position as shown.
Fig. 2
(Bolt 09 ) (140 kgf·m/1 030 lbf·ft) List of motor guard data
A. Parts required ………………………………76, 77
Tightening torque of M16 bolt: 270 N·m B. Butt welding of guard-use screw seat ………78
(Bolt 11 ) (27 kgf·m/199 lbf·ft) Welding method for screw sear ………………79
Width across flats: 24 mm C. Assembly of motor guard ………………81 (1/3)
Note:
Apply lubricant to the mounting bolts 09 , 11 and
washer 10 , 12 , fit all bolts in place, then tighten to
the specified torque.
2 Install the motor guard on the opposite side in the

same way.
75
3 Parts list
Kit No. YA60010184

Kit No. YA6001080 (MOTOR GUARD)
00 6017536 GUARD 1
01 6017537 GUARD 1
02 7035028 BRACKET 1
03 7035029 BRACKET 1
04 4393099 SPACER 2
05 4398472 SPACER 2
06 9758513 BRACKET 2
07 4603063 SHIM 4
08 4603014 SHIM 60
09 J932780 BOLT 20
10 4085857 WASHER 20
11 J931680 BOLT 6
12 4087197 WASHER 6
13 J271240 BOLT, SEMC 4
14 4027471 BOLT, EYE 6
Kit No. YA6001081 (SEAT SCREW)
00 4385751 SEAT SCREW 4

01 4385752 SEAT SCREW 4
4 Installation instructions
1 Welding the screw seat

1) Butt-weld the screw seat as outlined below.
*Temporarily assemble the motor guard.
*Temporarily install the seat by using the butt welding method. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 78
*Remove the motor guard and then, carry out regular welding (refer to drawing no. 8069264).
2) If butt welding is not possible (taking into account the site conditions)
*Refer to additional work drawing no. 8069264 for frame to carry out additional machining. . . . . . . . . . .Page 79
Caution: Sometimes you can find it difficult to assemble the motor guard due to welding error and
distortion. Or else, large quantity of shims may be necessary.
2 Installing the motor guard

*Assemble the parts while referring to drawing no. YA00014763 for guard. . . . . . . . . . . . . . . . . . . . . . .Page 81(1/3)
5 Remarks
Before welding, remove all flammables (such as grease) and cover all instruments in the vicinity.
76
Detail C
6
Details of parts
P/No. P/No.
Spacer Spacer
P/No. P/No.
Guard Guard
P/No. P/No.
Shim Shim
P/No. P/No.
Bolt Bolt
P/No. P/No.
Bracket Bracket
P/No. P/No.
Bolt, sems Bolt, eye P/No. P/No.
Seat, screw Seat, screw
Parts to be welded
Apply anti-rust lubricant in screw holes
P/No. P/No.
Washer
NOTE
Washer
1. 00 shows the parts contained in guard kit no. YA60010180.
P/No.
Bracket 2. 01 shows the parts contained in screw seat kit no. YA60010181.
Parts to be installed
Apply anti-rust lubricant to all parts
EX2600-6 Guard YA60010184

Fig. 3
77
7 Butt welding of guard-use screw seats
Refer to reference
measurement 1
Fig. 4
Position the screw seat in place and butt weld.
( 01 , 00 , a total of 4 locations)
Procedure
1 Assemble the guard refer to 81 (1/3).
2 Install the guard to the side frame screw seat and

temporarily tighten the bolts (J931680, 932780).
Fig. 5
Note:
Adjust by inserting the necessary number of shims so that
the guard does not become crooked during installation.
(To adjust, refer to reference measurement 1.)
3 Temporarily tighten bolt J932780 to install 00 and

01 to the guard and tack weld to the frame.
Note:
If there are gaps between the frame and 00 , 01 , use
shim(s) to take up the gaps and then, carry out tack
welding.
4 Remove the guard and carry out regular welding.
This drawing shows the additional work of EX2600-6 track frame
78
Detail D
8
Welding method for screw seat (dimensional drawing)
[NOTE]
Common to ,
This drawing shows the additional work of
within the shaded areas EX2600-6 track frame. For dimensions not
specified here, refer to drawing no. 5004649
for track frame.
EX2600-6 Rework drawing, frame 8069264

Fig. 6
79
80
9 Assembly of motor guards
Detail E
(Washer)
Tightening torque: 1400 N·m
(Guard) (Bracket) (Bracket)
(Guard) (Bolt, sems) (Bracket)

(Bolt) (M16X80)
(Washer)
(Spacer) Tightening torque: 1400 N·m

(Bolt) (M27X80)
(Spacer)
(Washer)

(Bolt) (M27X80) NOTE
1. This drawing shows the travel motor on the left side. Assemble the
(Washer) travel motor on the right side symmetrically.
2. When installing the motor guard, use shims 07 , 08 as required.
EX2600-6 Guard YA00014763

Fig. 7
81 (1/3)
Step 2
1 1 Parts required the mission guards (option)
Detail A
Fig. 1
EX2600-6 Mission guard XF60000361
81 (2/3)
2 Mounting the mission guards
Installation of the mission guard.
Detail B
Fig. 2
EX2600-6 Mission guard XF60000361
81 (3/3)
SUPERSTRUCTURE
ASSEMBLY OF SUPERSTRUCTURE
7. Connection of undercarriage and superstructure
7-1 Preparations before connection
ASSEMBLY CHART OF SUPERSTRUCTURE
Fig. 1
Parts required
Procedure (Track) XF60000349/XF6000358
20 8035803 COVER 1
21 4184943 GASKET 1
33 ─── STOPPER 1
85
Procedure (frame) XF60000229
00 XF10000636 BASE MACHINE 1 With frame and oil tank

01 4707224 BOLT 60 For installing the swing bearing and track frame
02 4345655 WASHER 60 (For connecting the track to the swing bearing)
04 XF10000637 CAB ASSEMBLY 1
05 4123177 ANTENNA 1
07 XF10000638 MIRROR ASSEMBLY 1
08 4639249 WIPER BLADE 1
09 4626135 DEVICE, ESCAPE 1
10 9751682 BRACKET 1 For fixing the escape device in place
11 9751610 BRACKET 1
12 4652389 CHAIN 2
13 XF10000639 LAMP, WORKING 1 Rotary lamp on the stairway
14 3120851 BRACKET 1
15 YA00001191 DISPLAY 1
17 XF10000640 STEP ASSEMBLY 1 Front of the cab
18 XF10000641 STEP ASSEMBLY 1 Left front of the cab
19 XF10000642 STEP ASSEMBLY 1 Left rear of the cab
20 XF10000643 STEP ASSEMBLY 1 Rear of the cab
21 6028845 STEP 1 Step at the rear of the cab
23 8106697 STEP 1
25 XF10000644 FENDER ASSEMBLY 1 Left fender with a set of the fuel filters
26 4623477 HOSE 1 Fuel filter IN
27 4671862 HOSE 1 Fuel filter OUT
28 XF10000645 FENDER ASSEMBLY 1 Left fender
30 XF10000646 TANK, FUEL 1 With Wiggins vacuum pipe and return pipe
31 XF10000647 HANDRAIL ASSEMBLY 1 Top of the fuel tank
32 XF10000655 HANDRAIL ASSEMBLY 1
33 J833080 BOLT 16 For installing the fuel tank
34 4114408 WASHER 16 For installing the fuel tank
35 YA400001243 COVER 1 Top of the right steps
36 4621705 CHAIN 1 Top of the right steps
37 XF10000648 FENDER ASSEMBLY 1 Right steps
38 XF1000649 FENDER ASSEMBLY 1
40 4446902 CHAIN 2 Beneath the right bed
41 XF10000651 HOSE REEL 1
42 8125413 STEP 1
44 XF10001407 PIPE ASSEMBLY 1
45 XA00007506 COVER, PIPE 1
46 4053698 CLAMP, PIPE 5
47 XF10001408 BRACKET ASSEMBLY 1
49 XF10000652 CAB BED 1
50 4353353 CLAMP 3 For the air conditioner duct
51 4625795 CLAMP 1 For the air conditioner duct
53 XF10001049 STEP ASSEMBLY 1
54 YA40000188 HANDRAIL 1 Above the oil tank
55 YA40000187 HANDRAIL 1
56 YA40000387 LAVDDER 1
58 4446902 CHAIN 2
59 4721667 PIPE 1
62 XF60000381 PROCEDURE 1 Grease piping
65 XF10000653 HANDLER 1 For fuel filter replacement-use
67 4103398 FLANGE, SPLIT 2
68 M341250 BOLT, SOCKET 4
69 J271270 BOLT, SEMS 5
70 M341236 BOLT, SOCKET 4
86
Procedure XF60000381
00 4363484 PIPE 1
01 4446146 PIPE 1
02 4667656 PIPE 1
03 4446148 PIPE 1
04 4446149 PIPE 1
05 4446150 PIPE 1
06 4446151 PIPE 1
07 4446152 PIPE 1
08 4446153 PIPE 1
09 4446154 PIPE 1
62 10 4363494 PIPE 1
11 4363495 PIPE 1
12 4363496 PIPE 1
13 4363497 PIPE 1
14 4363498 PIPE 1
15 4363499 PIPE 1
16 4363500 PIPE 1
17 4363501 PIPE 1
18 4363502 PIPE 1
19 4363503 PIPE 1
20 4363504 PIPE 1
87
Procedure (engine) XF60000228
00 XF10000632 ENGINE UNIT 1

01 J833080 BOLT 30 For installing the engine bed to the frame
02 4114408 WASHER 30 For installing the engine bed to the frame
03 4660021 DOOR 1 Door next to the fuel tank
04 4729777 DOOR 1
05 3120674 BRACKET 1 Light mounting bracket
07 YA40000308 STEP 1 Above the engine unit, at the front fuel tank fender
08 YA40000168 HANDRAIL 1 Above the engine unit, at the front fuel tank fender
09 YA40000169 HANDRAIL 1 Front center on the engine unit
10 YA40000209 HANDRAIL 1 Above the front oil tank step on the engine unit
11 YA40000170 HANDRAIL 1 Above the engine unit, at the front oil tank step
12 8106666 HANDRAIL 1 Right front side on the engine unit
13 8106666 HANDRAIL 1 Right side of the engine unit
14 8106667 HANDRAIL 1 Left side of the engine unit
15 YA40000205 HANDRAIL 1 Above the counterweight-side radiator on the engine unit
16 YA40000206 HANDRAIL 1 Above the engine unit, left on the counterweight side
17 8106665 HANDRAIL 1 Above the counterweight-side stairway on the engine unit
18 YA40000163 HANDRAIL 1 Above the engine unit, stairway fender on the counterweight side
19 8108582 HANDRAIL 1 Above the counterweight-side stairway on the engine unit
20 YA40000208 HANDRAIL 1 Above the engine unit, right on the counterweight side
21 YA40000210 STEP 1 Above the engine unit, left front
25 XF10000633 INTAKE UNIT 1
26 XF10000634 EXHAUST UNIT 1
27 4701885 HOSE 2
28 4504199 CLAMP, HOSE 4 For the dust ejector
29 4447520 TUBE 2
30 4348845 GASKET 2 Exhaust pipe-use gasket
32 4673113 HOSE 1 Return pipe above O/C
33 4729826 HOSE 1 Return pipe above O/C
37 4658713 HOSE 1 For returning fuel
42 XF10000635 PIPE ASSEMBLY 1 Reserve tank pipe assembly
43 J271020 BOLT, SEMS 6 For installing 42
45 4433444 HOSE 1
46 YA00002846 HOSE 1
50 XF10001045 STEP ASSEMBLY 1
51 YA40000520 FENDER 1
53 8108437 BRACKET 2
54 YA40000464 BRACKET 2
55 YA40002897 COVER 1
57 A40007542 BRACKET 1
58 A40007543 BRACKET 1
88
Procedure (tank) XF60000347
00 XF10001154 RESERE TANK 1
Procedure (HID) lamp XF60000328
00 4336570 LAMP HEAD 3 Cab rear ~ 1 pc./left step rear of cab ~ 1 pc. /Refractable stairway ~ 1 pc.
01 4696127 LAMP WORKING 5 Cab front ~ 2 pcs./Engine unit back ~ 2 pcs./Engine unit left ~ 1 pc.
Procedure (counterweight) XF60000310
00 9325232 COUNTERWEIGHT 1
01 7060737 HANDRAIL 1
03 9773663 HANDRAIL 2
04 9766762 BOLT ASSEMBLY 6
05 4660296 STOPPER 2
06 4659756 COVER 2
07 9766763 BRACKET 4
08 8106321 COVER 3
09 7051333 BRACKET 1
10 YA40003577 BRACKET 1
12 J271255 BOLT, SEMS 4
13 J271025 BOLT, SEMS 14
14 J281030 BOLT, SEMS 12
Procedure (step) XF60000311
00 XF10000911 STEP, ASSEMBLY 1

01 XF10000912 BOX 1
02 XF10000913 LAMP; WORKING 1
03 XF10000914 BEAM 1
05 3120851 BRACKET 1
07 7053743 BRACKET 1
08 7051481 HANDRAIL 1
09 7052387 HANDRAIL 1
89
Spare parts to be delivered (XF60000401)
00 4292384 O-RING 4 For the center joint spindle
01 4292385 O-RING 5 For the delivery hoses
02 A810110 O-RING 3 For the 2-inch suction hose beneath the pump
03 A810070 O-RING 2 For the suction pipe beneath the pump (1.1/2 in.)
04 4293250 O-RING 5 For the return hose beneath the oil cooler
05 4153541 O-RING 3 For the return oil tank
06 4153534 O-RING 1 For the drain oil tank
07 4187329 O-RING 2 For the drain oil cooler, for ORS
08 4187328 O-RING 2 Beneath the AC motor delivery pump control panel, for ORS
11 4392228 PACKING;RUBBER 10 For the DRC70
90
7-2 Preparation of undercarriage a
Swing bearing
Step 1
Cleaning and finishing
1 1 Clean the surfaces ( a ) of the swing

bearing mounted on the track frame.
Note:
If found to be damaged, repair and/or refinish. Fig. 1
Detail A
2 1 Make sure there is no foreign matter or water in
the grease basin (part b indicated by )
inside the internal gear box on the swing bearing. Front side
b
2 Make sure all water has drained out of the basin
through the hole c indicated by .
3 If foreign matter is found to have adhered to the
inside surface of the hole, remove it completely.
4 Install the cover 20 , gasket 21 and bolt, sems over c
the drain hole c . ( 20 , 21 )
Note:
be installed.
Tightening torque of M12 bolt: 90 N·m Fig. 2
Width across flats: 19 mm Detail B Knock pin
3 Turn the bearing and be sure to position the "Soft

zone" ( d indicated by ) of the swing bearing to
the left side of the track frame.
Note:
Knock pin
Confirm that the knock pins are positioned on the
left and right sides respectively of the swing bearing.
Note:
Soft zone: Hole in swing bearing where ball
bearings are put in. d
Soft zone
4 Fill the oil pan with grease. (Grease volume in the Left side Fig. 3
basin.)
Grease capacity: 200 liters (52 US gal)

Detail C
Grease
Note:
See the Operation Manual for the type of grease to
be added.
Detail D
Grease
Fig. 5 Fig. 4
91
Step 2
Cleaning of the contact surface

Detail E
Clean the bolt contact surface at the bottom of the swing
bearing.
Clean
Fig. 6
92
7-3 Preparation of base machine Detail A
500
Step 1 1000
Preparation of the base machine assembly

1000
＊ Place the under-side of base machine 00 on wooden

blocks as shown in Figs. 1 and 2.
Fig. 1
Note:
Each wooden block must be able to carry at least a 00
10 000 kg (22 000 lb) load. Wooden blocks

Size: 1 000 mm (L) × 500 mm (W) × 1 000 mm (H)
(40 in) (20 in) (40 in)
Base machine 00 wight: 37 800 kg

(83 160 lb) 1 000 mm (40 in) Fig. 2
Note:
OR
If appropriate wooden blocks are not available,
rest the basic machine on a trailer main frame as
shown in Fig. 3, using the blocks used in
shipment.
Trailer
Fig. 3
support a support b
Step 2
Cleaning and finishing

Fig. 4
＊ 1 Remove the supports a and bthat are attached
to the underside of the bass machine (Fig. 4).
Detail B
2 Clean all screw holes in the base machine using a
tap.
3 Clean the underside of the main frame (indicated

by c in Fig.5).
4 Check surfaces for damage or scratches.

c
Note:
If damaged, repair and/or refinish.
Fig. 5
93
Step 3
Swing motors
Releasing of the swing lock valve
Note:
Since the bolts on the swing bearing are to be
tightened while the superstructure is suspended,
the swing lock valve shown here must be
released. This Step is not required when the swing
bearing fixing bolts are to be tightened after
starting the engine.
Fig. 6
Detail C
Front side
swing motor
Rear side
swing motor
1 The procedure below is to be carried out for both of the
two swing motors.
1 Remove the plug a from the top of each swing Fig. 7

motor. (Fig. 8)
Detail D
a
2 Pull up the piston by screwing a M16 x 2.0 bolt b Fig. 8

with a 70 mm nominal length into the hole from
which the plug was removed in step 1 . (Fig. 9)
b
(Now the swing lock valve should be released.)
2 Clean the parts carefully after all oil has drained out.
Fig. 9
94
7-4 Connection of undercarriage and base machine
Step 1
Bolt 09
Attaching of the wire ropes to the base machine
1 1 Prepare two 90 metric tonne (100 US ton) crane

for lifting the base machine 00 .
2 Pre-insert bolts 09 (For counterweight) into the
beam holes in the main frame to prevent the wire Beam
rope from coming off, as illustrated in Fig. 1.
2 Attach wire ropes to the base machine as illustrated in 00

Fig. 2.
Fig. 1
1 Front-side attachment of the wire ropes and chain
block :
Lift
Apply protectors to the pins as shown in Fig. 2.
2 Rear-side attachment of the wire ropes :
Apply protectors to the beam of the base machine Wire rope
28 mmø ×
as shown in Fig. 2. 3 000 mm
Lift
Base machine 00 weight: 37 800 kg (83 160 lb)
Chain block
Wire rope
Wire rope: 8 pcs. 28 mmø ×
28 mmø × 6 000 mm (L): 4 pcs. Protector 3 000 mm
(1.1 inø) (234 inL)
28 mmø × 3 000 mm (L): 4 pcs.
Wire rope Chain block
(1.1 inø) (117 inL) 28 mmø ×
6 000 mm
Wire rope
Protector: 8 pcs. 28 mmø ×
6 000 mm
Chain block : 4 pcs.
for 10 metric tonne (11 US ton) load
00
Fig. 2
Protector
3 Keep the base machine level during lifting, as Lift

illustrated in Fig. 3.
Note:
Level the main frame by adjusting the preset chain Lift
blocks.
CAUTION:
When carrying out the joining work on the undercarriage
assembly, station the sub-leaders at each of the front and
rear regions of the base machine, and closely follow the
signals of the leader so as not to damage the component
parts.
CAUTION:
i) Be sure to use protectors to prevent the wire ropes
from breaking.
ii) Never allow anyone to stand directly beneath the
lifted base machine. Fig.3
95
Step 2
Connection of the base machine to the undercarriage

Lower
Note:
When joining the base machine to the
undercarriage, inserting swing guide pins a (Fig. 7)
00 Lower
into the bearing on the track will allow for smooth Base machine
connection.
Guide ring
1 1 Lift base machine 00 , and align the centers of the
parts to be joined on the undercarriage and base
machine.
2 Lower the base machine while keeping it level.
Notes:
i) Do not let the base machine touch the grease
basin guide ring on the track frame. Undercarriage Fig. 4
ii) Level the base machine by adjusting the preset
chain blocks. 00
Lower Lower
Fig. 5
200 mm (7.8 in)

approx.
2 Stop crane operation once the clearance between the
joining faces of the undercarriage and base machine is
about 200 mm (7.8 in) ( b indicated by ).
b
Fig. 6
Detail A
200 mm (7.8 in)

approx.
b
Guide pins a
Fig. 7
96
Step 3 Hold Hold
Mesh the internal gear on the swing bearing with the pinion
on the swing drive following the procedures below:
1 Bring the base machine down by lowering the front

crane a little.
Fig. 8
Detail B
Eye level
Fig. 9
Detail C
2 Carefully align the teeth of the two swing drive pinion
Special tools
with the internal gear using the special tools provided (ST3046 and ST3047)
(ST3046 and ST3047).
Note:
Having released the swing lock valve (See Note
on page 94) will make this alignment easier.
Pinion
Internal gear
Fig. 10
3 1 After joining the front-side pinion teeth to the

internal gear, lower the front side crane a little
more to mesh the pinions with the internal gear.
Lower Lower
2 Lower the rear side crane little by little so the rear
side pinions mesh with each other.
3 After joining the rear-side pinion teeth to the

internal gear, lower the rear side crane a little
Eye level
more to mesh the pinions with the internal gear.
Fig. 11
97
Hold
Note:
If the rear-side gear teeth do not mesh, try to
swing the crane a little in both directions. The gear
teeth should then mesh together.
4 1 Slowly lower both cranes while keeping the front

Sway
and rear of the base machine horizontal.
2 Stop crane operation once the clearance between

the joining faces on the undercarriage and
superstructure is about 30 mm (1.2 in) ( a
indicated by ). Fig. 12
Hold
30 mm (1.2 in)
approx
Fig. 13
5 Detail D
Align the two knock pins b with the holes in the main
frame.
30 mm (1.2 in)
approx.
Knock pin b
Fig. 14
Lower Lower
6 1 Slowly lower both cranes while keeping the front
and rear of the base machine level. c
2 Stop crane operation once the clearance between

the joining faces on the undercarriage and base
machine is about 2 ~ 3 mm (0.08 ~ 0.12 in) 2 ~ 3 mm
(0.08 ~0.12 in)
( c indicated by ).
Fig. 15
98
Hold Hold
Step 4
Mounting the connecting bolts on the undercarriage and

base machine
Fig. 16
Detail E
1 Fit 10~15 connecting bolts 01 and washers 02 to the
swing bearing from the underneath of the main frame
at the rear and front of the swing bearing respectively.
Notes:
i) Be sure to apply a sultable lubricant to bolts 01
mixing white zinc jelly and spindle oll in a 1:1 01 02
proportion.
ii) Apply lubricant to the screw and under-side of Fig. 17
the bolt head, marked with ＊, before insertion,
as illustrated in Fig. 18.
Detail F
iii) Place washer 02 on bolt 01 with the chamfer
directed towards the bolt head. 02
02
Chamfer
01
Section a
Fig. 18
2 Remove the guide pin fitted in step 2 .
99
3 1 Lower both cranes simultaneously until the joining
faces of the undercarriage and main frame contact
uniformly.
Lower Lower
2 Temporarily tighten the remaining connecting
bolts and washers with a ratchet wrench.
Contact
Contact
Fig. 19
Remove crane Hold

4 Remove the crane wire rope used in lifting the front of wire rope.
the base machine.
Note:
Keep the rear of the base machine lifted as it is.
Fig. 20
Hold
Fig. 21
5 1 Install stopper 33 between the track frame and the
center joint. (Fig. 22) Detail G
Note: Front side Center joint
Bolts are being screwed temporarily into the parts
to be installed.
2 Tighten the three mounting bolts.
Stopper 33 weight: 12 kg (26 lb)

33
Fig. 22
100
Step 5
Swing
Tightening the connecting bolts on the undercarriage and
base machine
Finish tightening the bolts that were fastened

( temporarily in Step 4. )
1 1 Tighten the bolts at the soft zone position of the

swing bearing first.
2 While swinging the base machine a little at a time

by way of the crane holding the rear, as illustrated
in Fig. 23, fit the connecting bolts as shown in Fig.
24.
Fig. 23
3 Tighten the 60 base machine connecting bolts 01
using a hydraulic wrench. Detail H

(525 kgf·m/3 798 lbf·ft)
CAUTION: 01 Bolt
Be careful to avoid getting your hand caught by the
reaction force bar on the hydraulic wrench. Hydraulic wrench
Notes:
Fig. 24
i) Mark the heads of the bolts in their final position
after being completely tightened. (See Fig. 25) Detail I
ii) After all the bolts have been tightened
completely, check the tightening torque by re-
tightening 3 or 4 of the bolts which were first
tightened.
Mark
Fig. 25
2 1 Remove the final crane wire ropes attached to the

base machine.
Remove the
2 Remove the bolts pre-inserted into the main frame wire ropes
to keep the wire ropes in place.
Fig. 26
101
Step 6
Connecting of the grease piping
1 Connect grease pipes 00 ~ 20 between the main frame

Detail J
and swing bearing as indicated.
Grease pipe tightening torque: 35 N·m
2 Secure the grease pipes with clamps a and b ,

indicated by .
Note:
The clamp mounting bolts should be tightened
until the rubber is deformed.
Fig. 27
Clamp tightening torque of M10 bolt: 50 N·m
3 After the grease has completely drained out, clean the

parts carefully.
Detail K
10
00
11
01
12
02 13
03 14
15
04
a b
16
05
17
09
08 07 06 20 19 18
Fig. 28
Notes:
i) Remove the vinyl caps from both ends of each pipe, then install as shown above.
ii) Use the pipe clamps attached to the base machine.
102
7-5 Connection of piping to center joint
Step 1
Installation of the hoses to the center joint Center joint
1 Connect the travel hoses a , b , c and d to the

center joint as illustrated in Figs. 2 and 3.

Socket size: 14 mm
Notes:
i) Do not twist the hoses when connecting them, or
their service life will be shortened. Fig. 1
ii) Connect the hoses so they do not make contact Detail A
Center joint
with other parts.
Front side
iii) Make sure that no dust has adhered to the seat
face of the hoses.
iv) Be careful not to damage the joining surfaces of
the hoses.
v) Apply a thin layer of sealant #98D to the O-rings
00 (P/No. 4292384~4 pcs.) before installation.
Reuse the O-ring originally fitted to the hoses.
2 1 Connect the adjuster hose e to the center joint as

B
2 Connect the pilot hose h , i to the pilot pipe as Fig. 2

Detail B
Tightening torque: ( e , h , i ) 30 N·m
3 Connect the pilot hose f , and adjuster hose g to

the center joint as illustrated in Fig. 4. a
Tightening torque: ( f , g ) 40 N·m

b d
4 Connect the pilot hose j to the pilot pipe as
c
Tightening torque: ( j ) 180 N·m Fig. 3
Width across flats: 36 mm Detail C
Notes: i
i) Do not twist the hoses when connecting them, or
their service life will be shortened.
ii) Connect the hoses so they do not make contact
with other parts. j
h
face of the hoses.
g
the hoses.
e
f
Fig. 4
103
Step 2 Detail D
Cleaning of the parts
Clean the parts carefully after the oil has drained out.
Fig. 5
104
7-6 Assembly of fuel tank
Fuel tank 30
Step 1
Installation of the fuel tank assembly
1 1 Place the under-side of fuel tank 30 on wooden

blocks as shown in Fig. 1.
Fuel tank 30 weight: 2 140 kg (4 708 lb)
Note:
Each wooden block must be able to carry at least a
1 500 kg (3 300 lb) load.

Support a Support b
Size: 500 mm (L) × 800 mm (W) × 500 mm (H)
(20 in) (30 in) (20 in) Wooden block
Fig. 1
2 Clean all screw holes in the fuel tank 30 using a
Lift
tap.
Wire rope
3 Clean the underside of the fuel tank 30 . 12 mmø × 3 000 mm
4 Check all surfaces for damage or scratches.
Lever block
Note:
Wire rope
If damaged, repair and/or refinish. 12 mmø ×
Wire rope 10 000 mm
5 Remove the supports a and b that are attached 12 mmø × 3 000 mm
to the underside of the base machine (Fig. 1).
Shackle
2 1 Attach wire ropes and shackles to the hooks on

fuel tank 30 .
2 Lift with a crane as shown Fig. 2. Fuel tank 30
Fuel tank 30 weight: 2 140 kg (4 708 lb)
Wire rope: 3 pcs.

12 mmø × 3 000 mm (L) × 2
(0.5 inø) (117 in L)
12 mmø ×10 000 mm (L) × 1
(0.5 inø) (390 in L) Fig. 2
Shackle: 2 pcs.
for 1.5 metric ton (1.65 US ton) load
Lower
Lever block : 1 pc.
30
3 Keep the fuel tank level during lifting, as illustrated
in Fig. 3.
Note:
Level the fuel tank by adjusting the preset chain blocks.
CAUTION!
Never allow anybody to stand directly beneath
the lifted fuel tank.
3 Move fuel tank to the main frame as shown in Fig. 3.

Fig. 3
105
4 1 Connect fuel tank 30 to the main frame with bolts
33 and washers 34 .
2 Tighten the fuel tank mounting bolts 33 using a
hydraulic wrench.
CAUTION!
30
Be careful to avoid getting your hand caught by the
reaction force bar on the hydraulic wrench.
Notes: Fig. 4
33 before tightening. Use a lubricant made by
mixing a white zinc jelly and spindle oil in 1:1 Detail A
proportion.
ii) Apply lubricant to the screw and under-side of ＊
the bolt head, and both ends of the washer, as
34
illustrated by "＊" in Fig. 5.
＊
Tightening torque of M30 bolt: 1 450 N·m ＊
(148 kgf·m/1 069 lbf·ft)
Fig. 5
Detail B
32 33
Fig. 6
106
5 Installation of the fender assembly
1 Wire ropes required 2 Parts weight
Wire rope: 4 pcs. Step 23 weight: 8 kg (18 lb)

10 mmø × 3 000 mm (L)
(0.4 inø) (117 in L)
3 Install step 23 on the base machine. Notes:

i) Apply lubricant to the bolts before installation.
Note:
ii) Tighten bolts to the specified torque after first
screwing in finger tight.
to be installed.
Detail C
23
Fig. 7
Detail D
23
Fig. 8
107
Detail E
108
Assembly of fuel tank
Fig. 9
7-7 Assembly of cab
Step 1
49
Installation of the cab bed assembly
1 1 Place cab bed 49 on wooden blocks as shown in 17

Fig. 1.
Cab bed 49 weight: 2 580 kg (5 675 lb)
2 Install steps 17 , 18 , 19 and 20 , on the cab bed 49 .
Note:
Bolts are being screwed temporarily into the parts 18
to be installed.
Wire rope: 2 pcs.

19 20
10 mmø × 3 000 mm (L) Fig. 1
(0.4 inø) (117 in L)

12
17

(9 kgf·m/66 lbf·ft) 18
c 19
Notes: b
a
20
Fig. 2
Fig. 2-a
3 Install the two plates a to the handrails b and c

as shown in Fig. 2-a.
4 Install chains 12 on the cab front handrail of step
17 .
Chain 12 weight: 0.9 kg (2 lb) × 2
Notes:
109
Lift
2 1 Attach wire ropes, a lever block and shackles to
the eye bolts on cab bed assembly 49 , as shown Wire rope Wire rope
in Fig. 3. 10 mmø × 10 mmø × 5 000 mm
3 000 mm
2 Keep the cab bed assembly 49 level during lifting. Lever block
Lever
Note: Wire rope block Eye
Level the cab bed assembly by adjusting the 10 mmø × bolt
3 000 mm
preset lever blocks.
3 Remove the supports a and b that are attached

to the underside of the cab bed (Fig. 3). Fig. 3-a
Cab bed assembly 49 weight: 2 870 kg (6 315 lb)
Wire rope: 6 pcs. Wire rope

10 mmø × 5 000 mm (L) : 2 pcs. 10 mmø × 49
(0.4 inø) (195 in L) 3 000 mm
10 mmø × 3 000 mm (L) : 4 pcs.
(0.4 inø) (117 in L)
Fig. 3
Eye bolt: 4 pcs. a
b
Lever block: 2 pcs.
Shackle: 4 pcs.
4 Lift with a crane as shown Fig. 3.
CAUTION!
Never allow anybody to stand directly beneath the lifted
cab bed assembly.
3 Move cab bed assembly 49 to the main frame Move

as shown in FIg. 4.
Lower
Main frame
49
Fig. 4
110
Hold
4 Tighten the bolts a and b .
Note:
to be installed.
1 Temporarily tighten all the bolts a and spacer.

2 Temporarily tighten all bolts b , washer, seat
screw and then securely tighten all bolts a and
b.

Notes:
Fig. 5
Detail A
a Bolt
Detail B
Cab bed assembly
Spacer
Washer
b Bolt
Seat screw
Fig. 6
a Bolt
Spacer
Washer Seat screw
b Bolt
Fig. 7
5 Remove the crane wire ropes attached to the cab bed.
111
Step 2
Installation of the wiper blade and head lamps on the cab
1 Preparation of the cab 04 as shown in Fig. 8.
Cab 04 weight: 1 750 kg (3 850 lb)

04
2 Install the wiper blade 08 on the cab.

Support
Fig. 8
1 Mount wiper blade 08 on the wiper motors.
2 Connect electric wire couplers for the wiper blade.
Notes:
i) Before connecting the electric wires, remove the
anti-corrosive and any rust from the couplers.
ii) Connect the couplers, matching the labels.
08
Fig. 9
Detail C
3 Install the head lamps 01 on the cab.
01 01
1 Install head lamps 01 .
2 Connect electric wire couplers.
Notes:
i) Before connecting the electric wires, remove the 08
ii) Connect the couplers on the labels
Fig. 10
112
Step 3 Detail D
Lift
Installation of the cab
Wire rope
10 mmø × 5 000 mm
1 Attach wire ropes and shackles to the cab 04 as shown
in Fig. 11.
Shackle
Cab 04 weight: 1 750 kg
(3 850 lb)
Wire rope: 4 pcs.

04
10 mmø × 5 000 mm (L)
(0.4 inø) (195 in L)
Shackle: 4 pcs.
for 500 kg (1 100 lb) load Fig. 11
CAUTION!
Never allow any persons to stand directly beneath the Lower
lifted cab.
04
2 1 Keep the cab 04 level during lifting, as illustrated

in Fig. 12.
2 Sling cab 04 , lower it slowly, and then place it on
the cab bed.
Fig. 12
Hold
3 1 Install the cab 04 on the cab bed.

2 Tighten the cab connecting nuts, washer plans
and plates.
04
Note:
Nuts are being screwed temporarily into the parts
to be installed.

Fig. 13
Notes:
i) Apply lubricant to the nuts before installation.
Detail E
ii) Tighten all nuts to the specified torque after first Nut
Washer plan
Cab
floor
Plate
4 Remove the crane wire ropes attached to the cab.
Cab bed
Fig. 14
113
5 Remove the four supports a that are attached to the Detail F
underside of the cab.
Detail G
Support a
Fig. 15
Detail H
Fig. 16
12
During maintenance
6 The placement of chains
1 Install the 2 chains 12 during maintenance, as shown.
Fig. 17
2 Attach the chains 12 to the hook, on the front rail During storage
12
and secure it to the perforated hook after
threading it through the cab handrail a as shown
in Figs. 17 and 18.
Cab handrail
Detail I
12 Cab
handrail a
Fig. 18
Fig. 19
114
7 Install escape device and antenna. Detail J
1 Install bracket 11 .
Note:
to be installed.

Fig. 20
Notes:
ii) Tighten all bolts to the specified torque after first 05
screwing them in finger tight.
FOR RADIO ANTENNA

Detail K
2 -a. Install antenna 05 and
connect the cords.
FOR OPTIONAL GPS 05

ANTENNA 4441588
2 -b. Install antenna (kit, GPS ( Kit No.

9289888 )
parts) 05 and connect the
cords.
Notes:
i) Before connecting the electric
wires, remove the anti-
corrosive and any rust from Fig. 22 Fig. 21
the couplers.
Detail L
ii) Connect the couplers,
matching the labels.
Notes:
i) For the usage of the satellite communication
antenna, refer to the HCM dealer.
ii) Refer to the drawing of "Kit, GPS parts
(9289888)" (optional) on peges 255 ~ 257.
3 Install escape device 09 (evacuation equipment 09

box). 10
Escape device 09 weight: 9 kg (20 lb)
Fig. 23
4 Install escape device box bracket 10 on the cab
side fender.
Note:
Notes:
to be installed.
ii) Tighten all bolts to the specified torque after first
Tightening torque of M10 bolt: 50 N·m screwing them in finger tight.
115
116
7-8 Assembly of fenders, steps, handrails, ladder, beam, box, and covers
Step 1
Installation of the fender assembly
Wire rope: 4 pcs. Fender assembly 25 weight: 478 kg (1 052 lb)

10 mmø × 3 000 mm (L)
(0.4 inø) (117 in L)
3 Install fender assembly 25 on the base machine. Notes:

Note:
to be installed.
Detail A
25
Fig. 1
Detail B
25
Fig. 2
117
Step 2
Installation of the step

8 mmø × 3 000 mm (L)
(0.3 inø) (117 in L)
3 1 Install step 21 on the fender. Notes:

Note:
to be installed.
2 Install plates a to the handrail b and step c as
shwn in Fig. 4-a.
3 Install pipes d to the handrail e and step f as
shwn in Fig. 4-a.
Detail C
21
d e
b f
a
Fig. 3
Detail D
Fig. 4-a
21
Fig. 4
118
Step 3
Installation of the beam
Wire rope: 4 pcs. Beam 03 weight: 615 kg (1 353 lb)

8 mmø × 3 000 mm (L)
(0.3 inø) (117 in L)
3 Install beam 03 on the bese machine.

Notes:
Note:
to be installed.
(beam 03 ) (77 kgf·m/553 lbf·ft)
Detail E
03
Fig. 5
Detail F
03
Fig. 6
119
Step 4
Installation of the box
1 Wire ropes required 3 Install box assembly a on the beam.
Wire rope: 4 pcs. Note:

8 mmø × 3 000 mm (L) Bolts are being screwed temporarily into the parts
(0.3 inø) (117 in L)
to be installed.
2 Assembly of the box a Box assembly a 01 weight:

1 042 kg ( 2 290 lb)
1 Bracket 07 to the box 01 .
2 Handrail 08 and 09 to the box 01 . (box 01 ) (56 kgf·m/406 lbf·ft)
Note:
Bolts are being screwed temporarily into the parts Notes:
to be installed. i) Apply lubricant to the bolts before installation.
Box 01 weight: 977 kg ( 2 149 lb) screwing in finger tight.
Bracket 07 weight: 20 kg ( 44 lb)
Handrail 08 weight: 22 kg ( 48 lb) iii) For detailed instructions for installing box 01 ,
Handrail 09 weight: 23 kg ( 51 lb) refer to pages 121 to 123.
Detail G
07
08
09 01 Beam
Fig. 7
Detail H
a
Fig. 8
120
INSTALLATION OF THE BOX Detail I
b
4 1 Place the under-side of the box 01 on wooden a
Box 01 weight: 1 042 kg (2 290 lb)
Note:
a 500 kg (1 100 lb) load.
01
Size: 2 000 mm (L) × 100 mm (W) × 50 mm (H)
(78 in) (4 in) (2 in)
2 Remove the steps a and b that is fitted inside

box 01 . Wooden
blok
Fig. 9
3 Hook wire ropes, chain block, eye bolts and
shackles to box 01 for suspension, as shown in
the photos Figs. 10 and 11. Detail J
Lift
Box 01 weight: 1 042 kg (2 290 lb)
Wire rope: 4 pcs.

8 mmø × 4 000 mm (L) : 2 pcs. 03
(0.3 inø) (156 in L)
8 mmø × 3 000 mm (L) : 2 pcs.
(0.3 inø) (117 in L)
Chain block: 1 pc.

For 0.4 metric ton (0.44 US ton) load
Shackle: 3 pcs.
Fig. 10
Eye bolt: 4 pcs.
Detail K
Lift
CAUTION!
Wire rope
box. 8 mmø × 3 000 mm
4 Keep the lifting box 01 level. Chain block
Note:
Wire rope
Level the box by adjusting the preset chain blocks. 8 mmø × 4 000 mm
Wire rope
Detail L 8 mmø × 4 000 mm
Shackle
Wire rope
8 mmø × 3 000 mm
Shackle
01
Eye bolt
Fig. 12 Fig. 11
121
Lift
5 Installing box 01
ve
Mo
1 Lift up box 01 as shown, and move it to just

beside the frame connection part.
Box 01 weight: 1 042 kg (2 290 lb)
2 Lift box 01 , slide it sideways and connect it to the

beam.
01
3 Remove the cover found at the space for
tightening the box mounting bolt.
Fig. 13
4 Secure box 01 in place by tightening bolt and Detail M

Lift
washer.
Note:
Use the tightening bolts and washers attached to 01
the beam.

Notes:
5 After bolting box 01 , install the cover a that was

removed in 3 on the location shown by the dotted
line in Figs. 15 and 16. Fig. 14
Tightening torque of M10 bolt: 50 N·m Detail N

(5 kgf·m/37 lbf·ft) Hold
01
Detail O
Install cover a over the
Box assembly mounting location shown by the dotted
bolt location line.
Bolt
Washer
Fig. 15
Fig. 16
122
6 Preparing the step for installation
Remove the pins a ~ f from box 01 that was

assembled in step 5 .
The link on the pin e should be facing upward at this
time. (Fig. 19)
Note:
The rod is fixed to the pin at e . Unfix and reposition
it in the orientation shown below.
Detail Q
rod
Fig. 17
Detail P
box 01 d
a
Pin e b e
Pin e on box 01
f
rod
e Fig. 18
b
a
Fig. 19
7 Reinstall steps a and b .

Notes:
screwing in finger tight. Fig. 20
123
Step 5
Installation of the fender
Wire rope: 4 pcs. Fender assembly 28 weight: 191 kg (420 lb)

8 mmø × 3 000 mm (L)
(0.3 inø) (117 in L)
Notes:
3 Install fender assembly 28 on the base machine.
Note: screwing in finger tight.
to be installed.

Detail R
28
Fig. 21
Detail S
28
Fig. 22
124
Step 6
Installation of the fender, step, ladder and handrails
Wire rope: 4 pcs. Step assembly 53 weight: 37 kg (81 lb)

8 mmø × 3 000 mm (L) Handrail 54 weight: 9 kg (20 lb)
(0.3 inø) (117 in L) Handrail 55 weight: 33 kg (72 lb)
Ladder 56 weight: 20 kg (44 lb)
Handrail 57 weight: 10 kg (22 lb)
3 1 Install step assembly 53 , Handrail 54 , 55 on the oil Chain 58 weight: 0.5 kg (1 lb)× 2
tank. Pipe 59 weight: 1 kg (2 lb)
2 Install ladder 56 and pipe 59 on the oil tank.
3 Install 2 chains 58 as shown in Fig 24. Notes:
Note: ii) Tighten bolts to the specified torque after first
Bolts are being screwed temporarily into the parts screwing in finger tight.
to be installed.
Tightening torque of M16 bolt: 270 N·m Tightening torque of M12 bolt: 90 N·m
(28 kgf·m/199 lbf·ft) (9 kgf·m/66 lbf·ft)
Width across flats: 24 mm Width across flats: 19 mm
Detail T
57 55 54
53
56
59 58
Fig. 23
Detail U
57 55 54
53
58
59
56
Fig. 24
125
Step 7
Installation of the fenders, handrail, cover and step
1 Wire ropes required 2 1 Parts weight
Wire rope: 4 pcs. Cover 35 weight: 3 kg (7 lb)

8 mmø × 3 000 mm (L) Fender assembly 37 weight: 333 kg (733 lb)
(0.3 inø) (117 in L) Fender assembly 38 weight: 214 kg (471 lb)
Fender assembly 39 weight: 123 kg (271 lb)
Step 42 weight: 9 kg (20 lb)
3 1 Install cover 35 .
2 Install fenders 37 , 38 and 39 .
3 Install step 42 . Notes:
Note: ii) Tighten bolts to the specified torque after first
Bolts are being screwed temporarily into the parts screwing in finger tight.
to be installed.
Tightening torque of M16 bolt: 270 N·m 2 Parts required

Width across flats: 24 mm Chain 36 weight: 0.3 kg(0.7 lb)× 1
Chain 40 weight: 0.3 kg(0.7 lb)× 2
Detail V
42
35 36
40
37
38 39
Fig. 25
126
4 Shown below is the view once the right-hand fender,
handrails and steps are installed.
Detail W
42
39
38
39
Fig. 26
5 1 Install 3 chains 36 and 40 as shown in Fig. 27-a. 2 Parts weight
Chain 36 weight: 0.3 kg (0.7 lb)× 1

Chain 40 weight: 0.3 kg (0.7 lb)× 2
Detail X
36
40
Fig. 27-a
Fig. 27
127
Detail Y
128
Assembly of handrail and chaims
〔Washer〕
〔Bolt〕
〔Chain〕
12 〔Step〕
17
〔Bolt, sems〕
〔Handrail〕
17
〔Nut〕
〔Washer〕
〔Bolt, sems〕
〔Plate〕
〔Plate〕
〔Bolt, sems〕
Fig. 28
Detail Z
〔Bolt, sems〕
Assembly of handrails and steps 〔Handrail〕

20
〔Clamp〕
〔Bolt, sems〕
〔Nut〕
〔Washer〕〔Washer〕
〔Bolt, sems〕〔Bolt〕

〔Bolt, sems〕
〔Step〕
18 〔Washer〕〔Washer, plan〕
〔Plate〕
〔Bolt〕
2 places 〔Nut〕
〔Step〕
〔Bolt, sems〕〔Rubber, cushion〕
〔Nut〕〔Washer〕〔Nut〕
〔Clip〕
〔Washer〕〔Bolt〕〔Washer〕
〔Bracket〕〔Lamp, working〕〔Bolt, sems〕
〔Bolt, sems〕〔Bolt, sems〕〔Step〕 13
〔Bolt, sems〕
〔Senser〕 19 〔Bracket〕
〔Plate〕〔Handrail〕
19 〔Plate〕
〔Bolt, sems〕
〔Washer, plan〕
〔Bracket〕
〔Bracket〕
14
〔Lamp, head〕
00
3 places
21 〔Step〕
〔Bolt, sems〕
〔Handrail〕
18
〔Nut〕
〔Bolt, sems〕
〔Washer〕
〔Bracket〕
10 〔Bolt〕
〔Device, escape〕
09
〔Bolt, sems〕
〔Bracket〕
〔Clip〕
〔Bolt, sems〕
〔Nut〕〔Bolt, sems〕
〔Washer〕
129
Detail A
130
〔Washer〕
Assembly of fenders
〔Bolt〕
〔Bracket〕
〔Washer〕
〔Bolt〕
〔Support〕
28 Fender
〔Bracket〕
〔Bracket〕
〔Bolt, sems〕
〔Bracket〕
〔Cover〕
〔Bracket〕
〔Bolt, sems〕
〔Bracket〕
〔Bracket〕〔Bolt〕
〔Bolt, sems〕〔Washer〕
〔Bracket〕〔Bracket〕
〔Bolt, sems〕
〔Bolt, sems〕
〔Handrail〕
〔Nut〕
〔Bolt, sems〕〔Step〕
〔Washer〕
〔Step〕
〔Bolt, sems〕
〔Bolt, sems〕
〔Bracket〕
〔Pipe〕
〔Fender〕
25 28 Fender
〔Bolt〕
〔Washer〕
Fig. 30
Detail B
〔Plte〕
Assembly of handrails step and beam
〔Bolt, sems〕
〔Washer〕
〔Nut〕
Handrail 09
〔Bolt, sems〕
〔Bracket〕
08 Handrail 05
〔Lamp head〕
00
〔Plate〕
〔Beam〕〔Bolt, sems〕〔Washer〕

03
〔Nut〕
〔Bolt, sems〕
〔Plate〕〔Washer〕
〔Clip〕
〔Nut〕
〔Bolt, sems〕
〔Step assembly〕
00
〔Bolt, sems〕
〔Step〕
〔Bolt, sems〕
〔Bolt〕
〔Bracket〕
07
〔Washer〕
〔Clamp〕
〔Box, switch〕
〔Bolt, sems〕
〔Bolt〕
〔Bolt, sems〕
〔Washer, plan〕
〔Nut〕
〔Handrail〕
〔Rubber, cushion〕 08
〔Bolt, sems〕〔Bolt〕
〔Lamp, working〕
〔Bolt, sems〕
02 〔Step〕〔Spacer〕
〔Bracket〕
01
〔Bolt〕
〔Washer, plan〕
〔Bracket〕
〔Bracket〕〔Washer〕
〔Bolt, sems〕
3 places
Fig. 31
131
Detail C
132
〔Washer, plan〕
〔Washer, plan〕
〔Washer, spring〕
〔Washer, spring 〕
〔Bolt〕
〔Bolt〕
Assembly of handrails and fenders
〔Bracket〕
〔Bracket〕
〔Washer, plan〕
〔Washer, spring 〕
〔Bolt〕
〔Bracket〕
〔Bolt, sems〕
〔Bracket〕
〔Step〕
〔Bolt〕 42
〔Nut〕
〔Washer〕
〔Washer, plan〕
〔Bolt, sems〕
〔Pipe〕
〔Chain〕
36
39 Fender
〔Step〕
38 Fender
〔Bolt, sems〕
37 Fender
〔Nut〕〔Nut〕
〔Bolt, sems〕〔Bolt, sems〕〔Bolt, sems〕〔Bolt, sems〕〔Bolt, sems〕
〔Bolt, sems〕
〔Step〕〔Handrail〕〔Plate〕〔Handrail〕〔Plate〕
37 38 〔Chain〕〔Handrail〕
40 39
〔Bolt, sems〕
〔Handrail〕
39
〔Bolt, sems〕
35 〔Cover〕
〔Fender〕〔Fender〕〔Fender〕

37 38 39
〔Bolt〕〔Bolt〕〔Bolt〕
〔Washer〕〔Washer〕〔Washer〕

〔Working lamp〕
〔Clip〕
〔Bolt, sems〕
Fig. 32
Detail D
Assembly of ladder and handrails

〔Nut〕
〔Washer〕
〔Plate〕
〔Bolt, sems〕
〔Bolt, sems〕
〔Plate〕
〔Washer〕
〔Nut〕
〔Stopper, rubber〕
〔Pipe〕
59
〔Bolt, sems〕〔Bolt, sems〕
〔Bolt, sems〕
〔Handrail〕〔Handrail〕
53 54 〔Bolt〕〔Handrail〕
55
〔Washer, plan〕
〔Bolt, sems〕
〔Nut〕
〔Handrail〕
57
〔Chain〕
58
〔Step〕
〔Bolt〕
〔Washer〕
〔Bolt, sems〕
〔Ladder〕
56
Fig. 33
133
134
7-9 Assembly of engine unit
Step 1
Preparation of the engine unit
1 Cleaning and finishing
1 Clean all screw holes in the base machine using

a tap.
Tap size: M30 × P3.0 b
2 Clean the engine mounting surfaces of the main a

frame (indicated by a ~ d ).
d
Notes: c
i) If damaged, repair and/or refinish. Fig. 1
ii) Using guide pins「10」shown on page 51
makes the engine unit easier to install.
Step e
2 Remove the step e .
Note:
This step e should be reinstalled when engine unit
assembly has been completed.
Fig. 2
135
3 1 Place the underside of engine unit 00 on wooden
00
Engine unit 00 weight: 18 100 kg (39 820 lb)
Note:
5 000 kg (11 000 lb) load.

Size: 500 mm (L) × 800 mm (W) × 500 mm (H)
(20 in) (30 in) (20 in)
a
2 Clean the underside of the engine unit (indicated (Opposite side)
by a and b ).

b
(Opposite side) Fig. 3
Note: Wooden block
If damaged, repair and/or refinish.
136
Step 2
Installation of the handrails, step and fender
2 Parts weight
1 Wire ropes required

10 mmø × 3 000 mm (L) Handrail 08 weight: 13 kg (29 lb)
(0.4 inø) (117 in L) Handrail 09 weight: 34 kg (75 lb)
3 1 Install handrails 08 , 09 , 10 , 11 , 12 , 13 , 14 , 15 , 16 , Handrail 11 weight: 14 kg (31 lb)
17 , 18 , 19 , 20 and step 21 on the engine unit 00 . Handrail 12 weight: 27 kg (59 lb)
2 Install fender 07 and step 21 on the engine unit. Handrail 13 weight: 27 kg (59 lb)
Note: Handrail 15 weight: 33 kg (73 lb)
Bolts are being screwed temporarily into the parts to Handrail 16 weight: 35 kg (77 lb)
be installed. Handrail 17 weight: 18 kg (40 lb)
Tightening torque of M12 bolt: 90 N·m Handrail 19 weight: 5 kg (11 lb)
(9 kgf·m/66 lbf·ft) Handrail 20 weight: 12 kg (26 lb)
Width across flats: 19 mm Step 21 weight: 39 kg (86 lb)

(28 kgf·m/199 lbf·ft) Notes:
Width across flats: 24 mm i) Apply lubricant to the bolts before installation.
Detail A screwing in finger tight.
3 Attach the handrail to the upper part of the engine
09 21 10 20 11 13 unit and then, use the plate to connect the
handrails.
08 Width across flats: 19 mm
Detail B
18
07 18 09 10 21 20 11 13
07
17 08
12 17
12
16
19
15
16
19 14
15
14
Fig. 4 Fig. 5
137
Detail C
138
Assembly of handrails and steps
〔Handrail〕
11
〔Bolt, sems〕
〔Plate〕〔Plate〕
〔Bolt, sems〕〔Plate〕

〔Bolt, sems〕
〔Washer〕〔Bolt, sems〕

〔Washer〕〔Handrail〕〔Handrail〕
〔Nut〕
17 09 〔Washer〕
〔Nut〕〔Bolt, sems〕〔Bolt, sems〕
〔Nut〕
〔Bolt, sems〕〔Bolt〕〔Bolt〕〔Bolt, sems〕

〔Bolt, sems〕
〔Handrail〕〔Step〕〔Step〕〔Handrail〕
18 07 〔Handrail〕 21 20
10
〔Handrail〕
08
〔Bolt, sems〕
〔Handrail〕
12 〔Handrail〕
13
〔Bolt, sems〕
〔Bolt, sems〕
〔Nut〕
〔Bolt, sems〕
〔Washer〕
〔Handrail〕
19 〔Plate〕〔Bolt, sems〕
〔Plate〕〔Bolt, sems〕〔Bolt, sems〕〔Bolt, sems〕〔Bolt, sems〕
〔Bolt, sems〕〔Pipe〕
〔Bolt, sems〕〔Handrail〕〔Handrail〕〔Plate〕〔Handrail〕
14 15 16
〔Washer〕
〔Washer〕
〔Nut〕
〔Nut〕
Fig. 6
Lift
Step 3
Installation of the engine unit Wire rope

20 mmø × 3 000 mm
Wire rope Chain
26 mmø × block
1 1 Attach wire ropes, chain blocks, and shackles to 6 000 mm
Wire rope
the hooks on engine unit 00 , as shown in Fig. 7.
20 mmø ×
6 000 mm
CAUTION! 00
Never allow anybody to stand directly beneath
the lifted engine unit.
Engine unit 00 weight: 18 435 kg (40 560 lb) Fig. 7

shackle
Wire rope: 6 pcs.
Hold
26 mmø × 6 000 mm (L) × 2
(1.0 inø) (234 in L)
20 mmø × 3 000 mm (L) × 2
(0.8 inø) (117 in L)
20 mmø × 6 000 mm (L) × 2
(0.8 inø) (234 in L) Move
Shackle: 4 pcs.
for 5 metric ton (5.5 US ton) load
00
Chain block: 2 pcs.
for 5 metric ton (5.5 US ton) load
Note:
Level the engine unit by adjusting the preset chain
blocks.
2 1 Keep the engine unit 00 level during lifting, as

shown in Fig. 8.
2 Move engine unit 00 to the main frame as shown
in Fig. 8.
Fig. 8
3 Connect engine unit 00 to the main frame. Lower
Note:
Use guide pins to position the engine unit.
00
Fig. 9
139
Hold
4 1 Connect engine unit 00 to the main frame with
bolts 01 and washers 02 .
Note:
Remove the steps a and b shown below, then
attach bolts 01 . These steps should be reinstalled 00
after tightening bolts 01 as shown in Fig. 12.
2 Tighten the engine unit connecting bolts 01 using
a hydraulic wrench.
CAUTION!
Be careful to avold getting your hand caught by the
reaction force bar on the hydraulic wrench.
Notes:
ii) Mark the heads of the bolts in their final position
after being completely tightened. Fig. 10

(148 kgf·m/1 069 lbf·ft)
3 Reinstall the steps a and b .
Detail D
Engine Unit 00
01
02
Note:
Be sure to remove the guide pins
if used as outlined on page 139.
Main Frame Fig. 11
Detail E Detail F
Steps
a and b
Hydraulic wrench
Fig. 12 Fig. 13
140
Step 4
Installation of the step, fenders and cover
Wire rope: 4 pcs. Step assembly 50 weight: 140 kg (308 lb)

8 mmø × 3 000 mm (L) Fender 51 weight: 72 kg (158 lb)
(0.3 inø) (117 in L) Fender assembly 52 weight: 86 kg (189 lb)
3 Install step assembly 50 fenders 51 , 52 , brackets 53 , Bracket 54 weight: 10 kg (22 lb)
54 and cover 55 on the engine unit and bese machine. Cover 55 weight: 1 kg (2 lb)
Note:
Notes:
to be installed.
Tightening torque of M14 bolt: 140 N·m screwing in finger tight.

Detail G
50
53
52
54
54
51 53
Fig. 14
Detail H
50
52
51
55
Fig. 15
141
Step 5
Installation of the handrails
Wire rope: 4 pcs. Handrail assembly 31 weight: 32 kg (70 lb)

8 mmø × 3 000 mm (L) Handrail assembly 32 weight: 29 kg (64 lb)
(0.3 inø) (117 in L)
3 Install handrails 31 and 32 on the fuel tank.

Notes:
Note:
to be installed.
Tightening torque: M12 bolt 9 kgf·m

(90 N·m/66 lbf·ft)
Detail I
32
31
Fig. 16
Detail J
32
31
Fig. 17
142
Step 6
Installation of the doors
Wire rope: 4 pcs. Door 03 weight: 26 kg (57 lb)

8 mmø × 3 000 mm (L) Door 04 weight: 26 kg (57 lb)
(0.3 inø) (117 in L)
3 1 Install step a . Notes:

(This has been disassembled on page 135) i) Apply lubricant to the bolts before installation.
2 Install doors 03 and 04 to the engine unit as
shown in Fig 19.
(a) (5 kgf·m/37 lbf·ft) Note:
Width across flats: 17 mm Check to be sure that door (04) on the oil cooler
Tightening torque of M8 bolt: 20 N·m side will open and shut without touching the return
(doors 03 and 04 )(2 kgf·m/15 lbf·ft) hose as stated on page 187.
Detail K
a 03
04
Fig. 18
Detail L
a (Inside) 03 (Inside)
04
Fig. 19
143
Detail M
144
Assembly of handrail, step, fender, brackets and covers
〔Bracket〕
〔Bolt, sems〕
54 〔Bracket〕
〔Bolt〕
〔Washer〕
〔Bolt, sems〕
〔Bolt, sems〕
〔Washer〕
〔Cover〕
52 〔Bolt〕
〔Support〕
53 〔Bracket〕 53 〔Bracket〕
〔Bolt〕〔Bolt〕
〔Step〕
〔Nut〕
50
〔Bolt〕
〔Washer〕〔Nut〕
〔Washer〕
〔Bolt, sems〕
〔Plate〕
〔Bolt, sems〕
〔Plate〕
50 〔Handrail〕
〔Washer〕
〔Bolt〕
〔Bracket〕
54
NOTE
1. Pay attention to the installation direction of the bolt
at the handrail joint (make sure that the bolt head
faces the catwalk).
2. If there is a difference in level at ☆ when 42 is
installed, make adjustments so that the
measurements at that are shown below are
equal to each other.
〔Cover〕
〔Fender〕
55
51
〔Bolt〕
〔Washer〕〔Bolt, sems〕
Fig. 20
Detail N
Assembly of handrails
〔Nut〕
〔Washer〕
〔Bolt, sems〕
2 places
〔Handrail〕
31
〔Bolt, sems〕
〔Handrail〕
32
〔Bolt, sems〕
〔Plate〕
05
〔Bolt, sems〕
2 places
〔Washer〕
〔Nut〕
〔Bolt, sems〕
〔Pipe〕
〔Step〕
Fig. 21
145
Detail O
146
〔Cover〕〔Stopper, rubber〕
〔Bolt, sems〕
〔Cover〕
〔Bolt, sems〕
〔Bolt, sems〕
〔Cover〕
〔Cover〕
〔Bolt, sems〕
10 places
〔Cover〕
〔Bolt, sems〕
〔Cover〕〔Door〕〔Door〕〔Cover〕
〔Bolt, sems〕〔Bolt, sems〕〔Bolt, sems〕〔Bolt, sems〕

〔Door〕
03 〔Door〕
04
〔Bolt, sems〕 Assembly of doors
〔Grill〕
〔Bolt, sems〕
〔Grill〕
〔Cover〕
〔Cover〕
〔Bolt, sems〕
〔Bolt, sems〕
〔Cover〕〔Cover〕
〔Bolt, sems〕
〔Cover〕
〔Bracket〕
〔Bolt, sems〕〔Bolt, sems〕〔Bolt, sems〕〔Bolt, sems〕〔Bolt, sems〕〔Bolt, sems〕
〔Bolt, sems〕
〔Door〕〔Cover〕〔Door〕〔Door〕〔Door〕〔Door〕
〔Cover〕
〔Bolt, sems〕
〔Bolt, sems〕
〔Sensor〕〔Nut〕〔Cover〕
〔Clip〕
〔Bolt, sems〕
〔Bolt, sems〕
〔Door〕
3 places
Fig. 22
Step 7
Installation of the step assembly
Wire rope: 4 pcs. Step assembly 00 weight: 773 kg (1 700 lb)

8 mmø × 4 000 mm (L)
(0.3 inø) (156 in L)
3 Install step assembly 00 . Notes:

Note:
to be installed.
iii) For detailed instructions for installing step
Tightening torque of M16 bolt: 205 N·m assembly 00 , refer to pages 148 to 150.
Detail P
Lower
00
Fig. 23
Detail Q
00
Fig. 24
147
INSTALLATION OF THE STEP ASSEMBLY
Lift Detail R
4 Slinging step assembly 00 Lift Lift
11 Prepare step assembly

00 for the slinging work.
(Main hoist hook) (Auxiliary hoist hook)
2 Release the transport-
posture of step assembly
00 .
3 Sling the ladder by hooking

Fig. 25-a 00
the wire ropes to the both sides. The main
Above the
hoist hook of the crane should be positioned step
above the step assembly and the auxiliary hoist assembly
hook should be positioned under the step

assembly 00 . Under the
Block for step step
Step assembly 00 weight: 773 kg (1 700 lb) assembly
Wire rope: 4 pcs. Fig. 25

8 mmø × 4 000 mm (L)
(0.3 inø) (156 in L)
Protector: 4 pcs.
Detail S
Lift
CAUTION!
Make sure that no one goes directly under the lifting
step assembly 00 . Lower
4 Next, suspend both the main hoist hook and

auxiliary hoist hook simultaneously at a fixed
height and lift step assembly 00 from the ground.
00
Use the auxiliary hoist hook to balance one side of
step assembly 00 and next, suspend the main
hoist hook to let step assembly 00 stand as shown
in Figs. 26 and 27.
5 Step assembly 00 should be perpendicular when

lifted.
Fig. 26
Detail U Detail T
Hold Hold
Hold
00
00
Fig. 28 Fig. 27
148
Lift
5 Installing step assembly 00
1 Lift up step assembly 00 as shown, and move it to

directly above the box assembly connection part.
Step assembly 00 weight: 773 kg (1 700 lb)
2 Lower step assembly 00 , connect it to the box 01

and insert three pins A ~ C into each side as 00
shown in Fig. 32.
Note:
Apply lubricant to the pins before installation.
01
Fig. 29
Detail V
3 Tighten the pin locking bolts.

Fig. 30
Notes:
ii) Tighten all bolts to the specified torque after first Detail W
screwing in finger tight. A
00
B
Box 01
Fig. 32
Fig. 31
149
6 Installing the stairway rod a
Detail X
Instoll the rod a
■ After installing the step assembly, install the rod

a as shown at right.
Note:
The measurement of the rod a has been set at the
time of transport, so it can be installed as is.

Fig. 33
Detail Y
Tighteming bolt
Rod a
Fig. 34
150
Detail Z
Installation of the Stairway
Fig. 35
151
Step 8 Detail A
Installation of the hose reel. 41
※ Install the hose reel 41 .
Note:
Use the tightening pins attached to the fender.
Hose reel 41 weight: 54 kg (119 lb) Bolt

Fig. 36
Notes: Detail B
i) Apply a lubricant to the bolts before installing.
ii) After screwing all bolts by hand, tighten them to
the specified torque.
Fig. 37
152
7-10 Mounting the counterweight & Installation the reserve tank
Step 1 02
Mounting of the counterweight 03
1 Install the handrail on the counterweight. 01
1 Prepare the wire ropes below.
Wire rope: 2 pcs.

8 mmø × 3 000 mm (L)
(0.3 inø) (117 in L)
2 Install handrails 02 and 03 on the counterweight 00 .

Counterweight 00
3 Install handrails 03 to the handrails 02 and 03 .
Note: Fig. 1
to be installed.
Handrail 01 weight: 33 kg (73 lb) × 1 Hold
Handrail 02 weight: 35 kg (77 lb) × 1
Handrail 03 weight: 3 kg (7 lb) × 2
Wire rope
36 mmø ×
Nut tightening torque of M12 bolt: 90 N·m 8 000 mm
Notes:
00
2 Attach wire ropes with shackles to the eye plates Shackle

provided on counterweight 00 , as shown in Fig. 2.
Counterweight 00 weight: 29 800 kg

(65 560 lb)
Wire rope: 2 pcs.

36 mmø × 8 000 mm (L) Fig. 2
(1.4 inø) (312 in L)
Shackle: 2 pcs.
Move
for 15 tonne (16.5 US ton) load
Hold
3 Lift the counterweight 00 while keeping it horizontal, as

CAUTION!
Do not allow anybody to stand directly beneath
the lifted counterweight.
4 1 Move the counterweight 00 to the rear beam.

2 Lower the counterweight 00 onto the rear beam. 00
Rear beam
Fig. 3
153
Hold
5 Connect the counterweight with 6 bolt assemblies 04 ,
incorporating 6 bolts, 6 nuts a , and 12 washers (6
each of b and c ).
Bolt assembly 04 weight: 24 kg (53 lb)
Notes:
00
mixing a white zinc jelly and spindle oil in a 1:1
proportion.
ii) Apply lubricant to the underside of the bolt head
and screw, marked with ＊, before insertion, as
1 Install 6 bolts 04 and 6 washers c on the

Fig. 4
counterweight as shown in Figs. 5 and 7.
Detail B Detail A
2 Install washers b Washer c
and nuts a to the Bolt 04
underside of the
counterweight.
Notes: 04
i) Install washer b
so that the
grooved side will
face downwards.
Counterwight
ii) Temporarily
tighten the nuts by Fig. 6 Fig. 5
hand.
Detail D Detail C
For washer b ,
Washer b
use the grooved
washer. Note that
the second,
b
ungrooved Grooved
washer should be side
attached to the
bolt before
insertion.
a
Fig. 7
Fig. 8
Detail E
3 Install the stoppers 05 and bolts 12 .

Notes:
05
screwing in finger tight. 12 Fig. 9
154
4 Tighten the bolts. Detail F
Note:
Tighten with a power wrench as shown in Fig. 10.
Nut tightening torque of M48 bolt: 4 900 N·m

(500 kgf·m/3 614 lbf·ft)
CAUTION!
Fig. 10
Do not let your hand get caught by the reaction
force bar on the power wrench.
5 Mark the heads of the bolts in their final position Remove the
wire ropes
after being completely tightened.
6 Remove the wire ropes holding the counterweight.
Fig. 11
7 Install brackets 07 and covers 06 with bolts 13 on the
counterweight.
06
Cover 06 weight: 7 kg (15 lb) × 2 13
Bracket 07 weight: 2 kg (4 lb) × 4

(5 kgf·m/37 lbf·ft) 07
Notes: 13

ii) After screwing in all bolts by hand, tighten them
to the specified torque.
Fig. 12
155
Step 2
Installation of the reserve tank Detail G

Reserve tank 00
1 Slinging reserve tank 00 .
1 Prepare reserve tank 00 for the slinging work.
2 Release the transport-posture of reserve tank 00 .
Fig. 13
Detail H
Hold
3 Hook the wire rope and shackle to reserve tank 00
for suspension, as shown in the photo Fig. 14.
Shackle
Reserve tank 00 weight: 150 kg (330 lb)
Wire rope: 2 pcs.

8 mmø × 4 000 mm (L) Wire rope
(0.3 inø) (156 in L)
00
Shackle: 2 pcs.
CAUTION!
Make sure that no one goes directly under the lifting
reserve tank 00 .
4 Keep the lifting reserve tank 00 level.

Fig. 14
Detail I
Lift
Wire rope
8 mmø ×
4 000 mm
Shackle
00
Fig. 15
156
Lift
2 Installing reserve tank 00 .
1 Lift up reserve tank 00 as shown, and move it to

directly above the counterweight connection part.
Reserve tank 00 weight: 150 kg (330 lb)
2 Lift up reserve tank 00 and install it on the

counterweight.
3 Secure reserve tank 00 in place by tightening the 00

bolts.
Fig. 16
Note:
to be installed.

Notes:
Fig. 17
Detail J Detail K
Right-hand reserve tank and handrail installation locations Left-hand reserve tank and handrail installation locations
Reserve tank
mounting bolt
Reserve tank
mounting bolt
Fig. 18 Fig. 19
157
3 Detail L
1 Installing the pipe assembly 42 with bolts 43 .
Pipe assembly 42 weight: 10 kg (22 lb)

(Bolt 43 ) (5 kgf·m/37 lbf·ft)
Notes:
43
Reserve tank Fig. 20
Detail M
2 Connect hoses a ~ d for reserve tank.
Tightening torque of hose: 160 N·m

(Hose a , c , d ) (16 kgf·m/118 lbf·ft)
c
a
Tightening torque of hose: 80 N·m d
b
(Hose b ) (8 kgf·m/59 lbf·ft)
Notes:
i) Connect both hoses so they do not come in
contact with other parts. Fig. 21
ii) Make sure that no dust has adhered to the seat
faces of the hoses.
iii) Do not damage the joining surfaces of the
hoses.
iv) Do not twist hoses when connecting them
together. Their service life will be shortened.
Fig. 22
158
4 Installing the hoses for reserve tank 00 .
Detail N
Connect air hoses 26 ~ 29 for reserve tank. 00

Put number tags on respective ports and hoses.
Connect the hoses, matching the wire numbers.

27
( 26 , 28 , 29 ) (16 kgf·m/118 lbf·ft)
Width across flats: 36 mm 29 26

( 27 ) (8 kgf·m/59 lbf·ft)
28
Fig. 23
Notes:
i) Connect both hoses so they do not come in
Detail O
contact with other parts. 00
ii) Make sure that no dust has adhered to the seat 29 27
faces of the hoses.
iii) Do not damage the joining surfaces of the
hoses. 26
together. Their service life will be shortened. 28
Fig. 24
159
5 Connecting the reserve tank electric wire couple. Detail P
1 Installing the bracket 10 as shown in Fig 25.
Note: 10
to be installed.

Fig. 25
Notes:
i) Apply lubricant to the bolts before installation. Detail Q
2 Connect electric wire coupler a .
Notes:
ii) Connect couplers of identical marking.
a a
Fig. 26
Detail R
a
Fig. 27
3 Clamps wire harness b and c as shown in Detail S

Fig 28.

b c
Fig. 28
160
6 Installing the bracket 09 with bolts 13 . Detail T

Width across flats: 17 mm 13 09
Notes:
Fig. 29
7 Installing the covers 08 with bolts 14 . Detail U
Covers 08 weight: 7 kg (15 lb) × 3 14 08

Notes:
Fig. 30
Fig. 31
161
Detail V
162
Assembly of handrails
Nut
Washer, plan
Bolt, sems
Nut
Washer, plan
Bolt, sems
4 places
4 places
Handrail
03
Handrail Pipe
02 Handrail
01
Bolt, sems
Cover
06
Bracket
07
Bolt M48
Tightening toque 4900N･m
04
Washer
04
Nut, u
04
Washer
04
Fig. 32
Detail W
Assembly of pipings and coves
Return Suction
Oil pan
75
Suction
59
Return
Bolt, sems
Hose 14
(Suction) Cover
Hose
08
Bolt, sems
(Return) 13
Bracket
09
Hose
Clanp, pipe
Bolt, sems
Pipe Pipe Pipe

Pipe
Adapter, s Adapter, s Adapter

Adapter, s
Elbow, s Clamp, pipe

O-ring
O-ring Bolt, sems
Clamp, pipe
Bolt, sems
Bracket
Bolt, sems
Fig. 33
163
164
7-11 Assembly of intake unit / exhaust unit and head lamps, mirror, wroking lamp, etc.
Step 1
Installation of the intake unit / Exhaust unit
1 Place the under-side of exhaust unit 26 on wooden

blocks as shown in Fig. 1. 26
Exhaust unit 26 weight: 570 kg (1 255 lb)
Note:
300 kg (660 lb) load.

Size: 500 mm (L) × 800 mm (W) × 500 mm (H)
Wooden block
(20 in) (30 in) (20 in) Fig. 1
2 1 Remove vinyl covers a and b , used to seal the 26 b

pipes on exhaust unit 26 .
2 Remove covers c and d , used to seal the pipes
on ehaust unit 26 .
d
Fig. 2
3 Place the under-side of intake unit 25 on wooden 25

Intake unit 25 weight: 310 kg (680 lb)
Note:
100 kg (220 lb) load.

Wooden block
Size: 300 mm (L) × 500 mm (W) × 300 mm (H)
Fig. 3
(12 in) (20 in) (12 in)
25
4 Remove vinyl covers and clamps e used to seal the

pipes on intake unit 25 .
Clamp
e
Cover
Fig. 4
165
5 1 Remove covers a , b , c and d from the engine Detail A
c
cover.
a d
b
Engine cover
Fig. 5
2 Remove the vinyl covers e and f from the air- Detail B

intake unit-use pipe.
f
Vinyl cover e
Fig. 6
Detail C
3 Remove covers g and h from the inside top of
the engine.
Note: j
The gaskets i , bolts j and nuts k installed on the
covers will be reused to install the tube.
g h
i k
4 Install tubes 29 to the top of the engine. Fig. 7
Tube 29 weight: 8 kg (18 lb) × 2 Detail D

Notes:
i) To install the tube, use the gaskets i bolts j
and nuts k that have been removed in 3 above. j
ii) AApply lubricant to the bolts before installation.
iii) Tighten all bolts to the specified torque after first
screwing them in finger tight. 29 k
i
iv) Use two spanners to lock the double nut.
Fig. 8
166
Lift
6 1 Attach wire ropes, a lever block and shackles to
the eye bolts on exhaust unit 26 .
2 Lift with a crane as shown Fig. 9. Wire rope
8 mmø × 3 000 mm Wire rope
Exhaust unit 26 weight: 570 kg (1 255 lb) 8 mmø × 8 000 mm
Lever block
Wire rope: 5 pcs.
8 mmø × 3 000 mm (L) × 2
(0.3 inø) (117 in L) Wire rope
8 mmø × 8 000 mm (L) × 2 8 mmø × 6 000 mm
(0.3 inø) (312 in L)
8 mmø × 6 000 mm (L) × 2
(0.3 inø) (234 in L)
Shackles
Shackle: 4 pcs.
26
Lever block: 2 pcs.

for 0.3 metric ton (0.33 US ton) load Fig. 9
3 Keep the exhaust unit 26 level during lifting, as Hold
Note:
Level the exhaust unit by adjusting the preset lever
block. 26
CAUTION!
exhaust unit.
7 1 Sling exhaust unit 26 , and lower it slowly onto the

engine unit (Fig. 10).
2 Install exhaust unit 26 on the engine unit.
Note:
Use the tightening bolts attached to the engine unit.
(9 kgf·m/66 lbf·ft) Fig. 10
Notes:
3 Connect the exhaust tube a .
Note:
Make sure to fit the gaskets 30 (P/No. 4348845~2)
when installing exhaust unit 26 .
Detail E
Fig. 11
30
a
Notes:
Tube
iii) Use two spanners to lock the double nut.
Fig. 12
167
Lift
8 1 Attach wire ropes, and shackles to the eye bolts
on intake unit 25 .
Intake unit 25 weight: 310 kg (680 lb)
Wire rope: 2 pcs.

8 mmø × 3 000 mm (L) Wire rope
8 mmø × 3 000 mm (L)
(0.3 inø) (117 in L)
Shackle: 2 pcs.
25
Shackles
3 Keep the intake unit 25 level during lifting, as

CAUTION! Fig. 13

intake unit.
25
9 Sling intake unit 25 , and lower it slowly onto the engine
Lower
unit (Fig. 14).
Fig. 14
168
Hold
10 1 Assemble two hoses 27 and four clamps 28 on
the pipes for exhaust unit 26 , as shown in Fig. 16. 26
2 Suspend intake unit 25 to fit it to the hoses

assembled on the exhaust unit and at the same
time, bring it close to the bolt hole in the
installation location of air-intake unit 25 .
3 Connect exhaust unit 26 and intake unit 25 by
hoses 27 and screw the mounting bolt into air-
intake unit 25 .
4 Secure hoses 27 by tightening clamps 28 .
Tightening torque: 6~7 N·m

(1 kgf·m/4~5 lbf·ft) 25
Fig. 15
5 Install intake unit 25 on the engine unit.
Detail F
Exhaust unit 26
Note:
Intake Lift
Bolts are being screwed temporarily into the parts to unit 25
Move
be installed.
Notes:
6 Connect the intake piping a . as shown in Fig. 20.
Clamp 28
(1 kgf·m/4 lbf·ft) Hose 27 Fig. 16
Detail G
27
28 Fig. 17
Detail H
Intake piping
a
Fig. 18
Fig. 19
169
Detail I
170
Installation of air-intake unit & exhaust device unit
Fig. 20
Step 2 Detail J
Installation of the display
(Front in the cab)
＊ 1 Install display 15 in the cab inside.
15
Notes:
i) Bolts are being screwed temporarily into the
parts to be installed. Fig. 22
ii) Apply luburicant to the bolts before installation.
iii) Tighten all the bolts to the specified torque after Detail K
first screwing in finger tight. 15
2 Connect electric wire coupler a and b .
Bolt
Notes:
ii) Connect the couplers, matching the labels.
Note: a b
For details, refer to the assembly drawing shown in
Figs. 22 and 23.
Fig. 23
Detail L
15 Display
L&M
Fig. 24
Fig. 21 Detail M
15 Display
Fig. 25
171
172
Step 3 Head lamp at the rear of the cab Head lamp on the fender at Stairway-use switch box
00 14 00 the left side of the cab
Installation of the head lamps, mirror, switch box and working
Switch box c
lamps, motion alarm.
Notes:
1 Cautionary remarks for tightening the bolts
ii) Tighten bolts to the specified torque after first screwing connector joint a connector joint b
in finger tight.
Fig. 27-a Fig. 27-b
2 Cautionary remarks for connecting the wire harnesses 1 Install head lamp 00 . 1 Install bracket 14 .
i) Before connecting the electric wires, remove the anti- 2 Connector joint a . 2 Install head lamp 00 .
corrosive and any rust from the couplers. 3 Connector joint b . From the base machine
ii) Connect couplers with the same marking.
Detail O
The switch box c is found
inside the base machine. Take
it from the base machine and
install it on the bracket.
07
Fig. 27-c
198
Front
Motion alarm
Fig. 27-i
1 Install mirror 07 on the handrail. The installation
dimension is as shown above.
ambient temperature sensor a
Motion alarm d
connector joint h Motion alarm

Fig. 27-h
1 Install temperature sensor a . Fig. 27
2 Connector joint h . (ambient temperature sensor)
Working lamp on the handrail at the left side of the cab Working lamp on the stairway Head lamp on the stairway
d
02
13
05 00
Clamp
connector joint Clamp

g
connector joint f
connecter joint e
Fig. 27-g Fig. 27-f Fig. 27-e Fig. 27-d
1 Install working lamp 13 . 1 Install working lamp 02 . 1 Install bracket 05 . 1 Pull out the motion alarm harness that is banded on
2 Pull out the wire harness from the cab bed and 2 Pull out the wire harness from the cab bed and 2 Install head lamp 00 . the base machine.
connect it to g . After connection, secure the connect it to f . After connection, secure the 3 Connector joint e . 2 Connector joint d .
harness with the clamp. harness with the clamp.
173
Step 4
Greasing (1)
Detail P
This machine is equipped with a hydraulic lubrication

device, with a hose reel and grease gun connected.
Perform lubrication according to the following
procedure.
a
1 Manual lubrication procedure:
b
1 Connect coupler b to hose a .
2 Place automatic lubrication switch c in the upper
(manual) position.
3 Hold grease gun d and pull the hose out from the Fig. 28
hose reel e .
4 Stop pulling the hose when it has been pulled out
Detail Q
as far as needed. The reel will click, automatically
securing the hose in place.
5 Connect grease gun d to the grease fitting to be
lubricated and pull the trigger. Grease will be
supplied hydromechanically.
c
IMPORTANT:
Set the engine to run at neutral or higher speed during
lubrication with the lubrication device.
2 Start the engine. Fig. 29
3 Supply grease to the 22 locations f shown in Fig. 32.

Detail R
Notes:
i) Increase the engine speed to higher than neutral
when using the lubrication device.
e
ii) If the optional automatic lubrication system is not
fitted, use a standard air grill gun to manually
d
lubricate the front pins.
iii) Insufficient lubrication may cause the pins to
wear. Sufficiently lubricate the necessary
locations.
Fig. 30
Detail S
Fig. 31 Fig. 32
175
4 After completing the lubrication Detail T
1 Slightly pull the hose out from the hose reel e .
The lock will be released and the grease hose
automatically withdrawn back onto hose reel e .
e
2 Remove coupler b from hose a .

Fig. 33
IMPORTANT:
Before storing, make sure to release any residual Detail U
air in the hose reel by use of the grease gun. This will
prevent damage being done to the pump.
Note:
Leaving the device in a state of manual lubrication a
will cause the automatic lubrication warning lamp
on the cab instrument panel to light up. b
Fig. 34
Step 5
Releasing of the transport-posture for the outside

temperature sensor
＊ The outside temperature sensor have been masked

with paper tape before shipment.
Remove the paper tape.
1 In front of the oil coolar on the right engine unit

(2 place) (Figs. 35 and 36)
2 Lower left side of the left fender of the cab
(Figs. 35 and 36) Fig. 35
3 In front of the radiator on the left engine unit
(1 places) (Figs. 37 and 38)
Remove the paper masking tape
from the slanted area.
Fig. 36
Detail V
Remove the paper masking tape

from the slanted area.
Fig. 38
Fig. 37 Detail W
176
7-12 Connection
1. Connecting the piping (1/2)

（Including some wire harnesses）
Step Location Remarks Page No.
Step 1 Top side of the oil tank Release of air pressure 179
Step 2 Right rear of the fuel tank Connection of the fuel pipe-use coupling 180
and electric wire
Step 3 Beneath the fuel cooler and on Connection of the fuel line hoses 181
the fuel tank side
Step 4 Beneath the pump transmission Connection of the suction hoses and 182
transmission drain hoses
Step 5 • From the top side of the transmission Connection of the delivery hoses 183
to the top side of the oil tank
• From the rear of the control valve to
the lower front of the engine unit
A Top side of the transmission – Connection of the delivery hoses 183
top side of the oil tank
B Rear of the control valve – Connection of the delivery hose 184
lower front of the engine unit
Step 6 • From the top side of the oil tank to 185

the top side of the oil cooler Connection of the return hose,
• Beneath the oil cooler drain hose and pilot hose
A Top side of the oil tank Installation of the pipe assembly/connection 185
of the drain hose and pilot hose
Top side of the oil tank – Connection of the return hoses 186
top side of the oil cooler
B Beneath the oil cooler Connection of the return hoses 188
Beneath the oil cooler Installation of the bracket assembly 189
Step 7 From the top side of the oil tank to Connection of the drain hoses 190
the top side of the oil cooler
Step 8 Stairway system Connection of the stairway hoses and 191

wire harnesses
A Box on the stairway Connection of the stairway hoses and 191
wire harness (1)
B Stairway Connection of the stairway hoses and 192
wire harness (2)
177
1. Connecting the piping (2/2)
Step 9 Fuel filter (stage 1 filter) at the lower Connection of the fuel filter hoses 193
part of the left step
Step 10 Lower part of the engine Connection of the coolant pipes and 194
quick filling system hoses
Step 11 • Lower part of the pump transmission Connection of the pilot primary pressure 195
• Lower part of the engine delivery hose, air conditioner delivery
hose, pilot delivery hose, fuel suction
hose and oil pan drain hose
A Lower part of the pump transmission Connection of the pilot primary pressure 195
delivery hose, air conditioner delivery
hose and pilot delivery hose
B Lower part of the engine Connection of the fuel suction hose and 196
oil pan drain hose
178
Step 1 Detail A
AIR BREATHER
Release of air pressure
(Top side of the oil tank) 1
Cap a
1 Seal the air breather as shown in Figs. 2 ~ 5.
Note:
Use a hexagon wrench to remove the hydraulic oil
tank air breather.
1 Remove the cap a from the breather. Fig. 2
2 Remove the filter b .

3 Wind with tape c .
2
Filter b
Fig. 3
Tape c
3
Fig. 4
Detail B
Fig. 1
2 Release the air pressure in the oil tank by using the

Oil tank
quick exhaust valve. To prevent oil leakage, create a
vacuum in the tank using a vacuum pump, as shown in
Fig.5.
Note:
Hoses will be connected to the oil tank in the next Vacuum pump
step. Since the oil tank has been filled with
hydraulic oil before shipment, use a vacuum
device or drain the oil to the hose installing port
level to prevent the oil from gushing out when
connecting the hoses.
Fig. 5
179
Step 2
Connection of the fuel pipe-use coupling and electric wire
(Right rear of the fuel tank)
1 1 Use fuel pipe-use coupling a for connection. Notes:

i) Make sure that no dust has adhered to the seat
Note: faces of the piping.
For coupling installation instructions, see Fig. 2-a. ii) Do not damage the joining surfaces of the piping.
Tightening torque of coupling: 90 N·m

2 Clean the parts carefully after all oil has drained

out.
2 Connect the electric wire harness b . See Fig. 2-b.
Notes:
Fig. 1
Detail A
Front
side
Fuel tank
Insert the bolt

from the top. a
Parallel to
each other
Fig. 2-a b Fig. 2-b

Fig. 2
180
Step 3
Connection of the fuel line hoses
Notes:
(Beneach the fuel cooler and on the fuel tank side)
i) Do not twist hoses when connecting them
1 1 Connect the fuel line return hose 37 .
with other parts.
(20 kgf·m/148 lbf·ft) iii) Make sure that no dust has adhered to the seat
Width across flats: 41 mm faces of the hoses.
iv) Do not damage the joining surfaces of the hoses.
2 Connect the fuel line hose a .

2 Clean the parts carefully after all oil has

drained out.
Detail A
Fig. 1
37
Detail B
Fuel tank
Front
Fig. 2
Fig. 3
181
Step 4
Connection of the suction hoses and transmission drain hoses
(Beneath the pump transmission)
1 Use block b to secure the transmission drain hose a

(Tag No. 9 ) to the frame.
Connect the hoses, matching the wire numbers. B

Width across flats: 36 mm A
2 Connect the suction hoses c ~ g . Fig. 1
Detail A
Socket size: 10 mm
Notes:
i) Connect the hoses so they do not make contact
a
with other parts.
(Tag No. 9 )
faces of the hoses.
iii) Do not damage the joining surfaces of the hoses.
b
iv) Apply a thin layer of sealant #98D to the O-rings
Fig. 2
02(A810110~3 pcs.), 03 (A810070~2 pcs.),
before installation. Note:
The transmission drain hose a is found inside the
3 Clean the parts carefully after all oil has engine unit. Pull out it from the engine unit and
drained out. connect.
Detail B
03 O-ring
02 O-ring
c
d
e
Fig. 3
182
Step 5
Connection of the delivery hoses
(From the top side of the transmission to the top side of the oil tank)
(From the rear of the control valve to the lower front of the engine unit)
A Connection of the delivery hoses

1 Connect of the delivery hoses 45 and 46 .
(Top side of the transmission - Top side of the oil tank)

Socket size: 17 mm
Notes:
with other parts.
faces of the hoses.
v) Apply a thin layer of sealant #98D to the O-ring
01 (4292385~4 pcs.) before installation.

drained out.
Fig. 1
Detail A
01
01
01 O-ring
01 46 46 45 45
Front
Fig. 2
183
B Connection of the delivery hose
1 Connect of the delivery hose a .
(Rear of the control valve - lower front of the
engine unit)

Socket size: 17 mm
Notes:
with other parts.
faces of the hoses.
01 (4292385~1 pc.) before installation.

Fig. 3
drained out.
Detail B
Front
a
a Control valve
01 O-ring
Fig. 4
184
Step 6
Connection of the return hose, drain hose and pilot hose
(From the top side of the oil tank to the top side of the oil cooler)
(Beneath the oil cooler)
A Installation of the pipe assembly/connection of the 2 Connect of the drain hose a and pilot hose b .
drain hose and pilot hose. (Top side of the oil tank)
1 Using five pipe clamps 46 and five sems bolts 69 , Tightening torque of hose a : 210 N·m
install pipe assembly 44 to the upper part of the oil (21 kgf·m/155 lbf·ft)
tank. Width across flats: 41 mm
Use O-ring 06 on part noted by a *2) during
installation. Tightening torque of hose b : 160 N·m
Pipe assembly 44 weight: 13 kg (29 lb) Width across flats: 36 mm
Tightening torque of pipe assembly 44 : 90 N·m
Notes:
*1) Width across flats: 19 mm i) Do not twist hoses when connecting them
*2) Socket size: 10 mm together. Their service life will be shortened.
2 Install of the cover 43 on the oil tank. with other parts.
Note: faces of the hoses.
Bolts are being screwed temporarily into the parts to iv) Do not damage the joining surfaces of the hoses.
be installed. v) Apply a thin layer of sealant #98D to the O-ring
06 (4153534~1 pc.) and 08 (4187328~1 pc.)
Tightening torque of M10 bolt: 50 N·m O-ring (ORS) before installation.
(Cover 43 ) (5 kgf·m/37 lbf·ft)
Width across flats: 17 mm 3 Clean of the parts carefully after all oil
has drained out.
43 *2)
06 O-ring
Detail A
Fig. 2-a
Detail B
44
46
69
46
Fig. 1
69
to drain piping Clamp pipe 46

*1)
a Bolt, sems 69 44 Pipe assembly 46 46
b
69 69
a b
08
O-ring
(ORS)
to pilot piping
Fig. 2
185
4 Install the pipe assembly 39 and hose 32 .
(Top side of the oil tank – top side of the oil cooler)
Note:
Use split flange 67 and sems bolt 68 on ＊-marked
area of pipe assembly 39 .
In addition, use bolt 70 on ☆-marked area of hose
32 .
Tightening torque of hose 39 : 90 N·m

(＊ mark) (9 kgf·m/66 lbf·ft) Fig. 3
Socket size: 10 mm
Detail D
(☆ mark) (11 kgf·m/81 lbf·ft)
Socket size: 10 mm
Notes:
with other parts. Photograph once the hose is installed
iii) Make sure that no dust has adhered to the seat (example of interference)
faces of the hoses.
05 (P/No.4153541~1 pc.) and
Note (1):
04 (P/No.4293250~3 pcs.) before installation. Install hoses 32 and 39 in such way so that the
clearance at the door is larger than 30mm and the
5 Clean the parts carefully after all oil has clearacne at the step is 5mm.
drained out. Note (1):
Section a
Detail C
Fig. 4
Detail E
04
05
O-ring
32
39 Note (1)
04 04 O-ring
Oil cooler Front
Note (2):
Note (1)
Check the clearance
between the hose
and door.
Oil tank As viewed from the inside of the door Fig. 5

(example of interference)
Detail F
＊
67
☆
68 70
Note (3):
Check the clearance
between the hose
and door.
As viewed from the outside of the door Fig. 6

Fig. 7 (example of interference)
186
6 When opening or shutting the oil cooler-side door,
confirm that it does not thouch the return hose
(★).
Fig. 8
Detail G
(★)
Door
Fig. 9
187
B Connection of the return hoses
(Beneath the oil cooler)
1 Connect the return hoses 34 and 35 .

Socket size: 10 mm
Notes:
with other parts.
faces of the hoses.
04 (P/No.4293250~2 pcs.) and Fig. 10
05 (P/No.4153541~2 pcs.) before installation.

drained out.
Detail H
04 O-ring 04 05
34 35 05 O-ring
Fig. 11
188
3 Install the bracket assembly 47 . View I
(Beneath the oil tank) a
Note:
be installed.
Bracket assembly 47 weight: 6 kg (13 lb)
b
Tightening torque of M10 bolt a : 50 N·m
Tightening torque of M12 bolt b : 90 N·m

Notes:
i) Apply lubricant to the bolts before installation. Fig. 12

Detail J
47 Bracket assembly
Fig. 13
189
Step 7 Detail A
(★)
Connection of the drain hoses
Drain hose 33
(From the top side of the oil tank to the top side of the oil cooler)
1 1 Connect the drain hose 33 .

Door
Notes: Fig. 1
with other parts.
faces of the hoses.
v) Apply a thin layer of sealant #98D to the ORS
O-ring 07 (P/No.4187229~2 pcs.) before
installation.
2 When opening or shutting the oil cooler-side door,

confirm that it does not thouch the return hose
(★) as shown in Fig.1.

drained out.
Fig. 2
Detail B
Front
Oil tank
07 O-ring 07
(ORS)
33
Oil cooler
Fig. 3
190
Step 8
Connection of the stairway hoses and wire harnesses
Notes:
(Stairway system)
A Connection of the stairway hoses and wire harness (1) together. Their service life will be shortened.
(Box on the stairway) ii) Connect the hoses so they do not make contact
Pull out three hoses a , b ( 3 ), c ( 2 ), d ( 1 ) and with other parts.
wire harnesses e , f , g and h from the base iii) Make sure that no dust has adhered to the seat
machine and connect them in place. faces of the hoses.
1 1 Connect the hose a .
2 Install the clamp i .
Width across flats:

50 mm ( After connecting the hoses a , b , c and d ,
install the clamp i )
2 Connect the hose b (Tag No. 3 ). Tightening torque of M10 bolt: 50 N·m
Tightening torque of hose: 95 N·m Width across flats: 17 mm
3 Connect the hoses c (Tag No. 2 ) and d drained out.
(Tag No. 1 ).

4 Connect electric wire couplers e , f and g , h .
Notes:
Detail A
Pull out the hoses a ,

b , c and d from the Fig. 1
base machine and i
connect them.
Pull out the harnesses e , f ,
Rear side g and h from the base
d c b a machine and connect it.
Tag No. 1 2 3
e f
g h
g h
Tag No. 1 2 3 e f
d c b a
Fig. 2
191
B Connection of the stairway hoses and wire harness (2)
(Stairway)
1 1 Pull out the hose a , hose b and wire harness c

from the box and connect them.
2 Connect the stairway hoses a and b .

(Inner side of the stairway-use ladder)

Notes:
i) Connect both hoses so they do not come in Fig. 3
contact with other parts.
faces of the hoses.
iii) Do not damage the joining surfaces of the hoses.
together. Their service life will be shortened. Detail B
3 Allow all oil to drain from the parts before

cleaning them carefully.
2 Connect limit switch electric wire coupler c .
Notes:
Fig. 4
Detail D Detail C
Connecter joint
c
a
b
Fig. 6 Fig. 5
192
Step 9
Connection of the fuel filter hoses
(Fuel filter (stage 1 filter) at the lower part of the left step)
1 Connect the fuel filter hoses 26 and 27 .

Notes:
with other parts.
faces of the hoses.

drained out.
Fig. 1
Detail A
Front
Hose 26
4623477~1 27
Hose
4671862~1
Fig. 2
193
Step 10
Connection of the coolant pipes and quick filling system hoses
(Lower part of the engine)
1 1 Connect the 4 hoses a (Tag. No. 4 ), b (Tag.

No. 5 ), c (Tag. No. 6 ) and d (Tag. No. 7 ).
Connect the hoses, matcing the wire numbers.
A
( a and d ) (8 kgf·m/59 lbf·ft)
( b and c ) (18 kgf·m/133 lbf·ft)
Fig. 1
2 Connect the hoses e , f (Tag. No. 24 ) and g Detail A
(Tag. No. 25 ).

Width across flats: 36 mm Front
Notes:
with other parts.
faces of the hoses.
iv) Do not damage the joining surfaces of
the hoses.
Detail B
c (Tag No. 6 )
(Tag No. 5 ) b
d (Tag No. 7 )
(Tag No. 4 ) a
180 N·m
d (Tag No. 7 ) (18 kgf·m/133 lbf·ft)
(Tag No. 4 ) a
e
c (Tag No. 6 )
(Tag No. 5 ) b
Radiator
outlet pipe
g (Tag No. 25 )
(Tag No. 24 ) f
(Tag No. 4 ) a
d (Tag No. 7 )
b (Tag No. 5 ) c (Tag No. 6 )

Fig. 2
COOLANT PIPING, OIL/DRAIN PIPING 2 Clean the parts carefully after all oil has
Fig. 3 drained out.
194
Step 11
Connection of the pilot primary pressure delivery hose, air
conditioner delivery hose, pilot delivery hose, fuel suction
hose and oil pan drain hose
(Lower part of the pump transmission)
A Connection of the pilot primary pressure delivery hose,

air conditioner delivery hose and pilot delivery hose
(Lower part of the pump transmission)
1 Connect the pilot primary pressure delivery
hose a .
Fig. 1
2 Connect the air conditioner deilivery hose b .
Tightening torque: 210 N·m Detail A
3 Connect the pilot delivery hose c .
Notes:
with other parts.
faces of the hoses. a b
v) Apply a thin layer of sealant #98D to the ORS
O-ring 08 (P/No.4187328~1 pc.) before
08 O-ring
installation.
(ORS)
4 Clean the parts carefully after all oil has c
drained out.
Detail B
Fig. 2
Pilot primary pressure

delivery hose
a
Air conditioner
Pilot delivery hose delivery hose a
08 O-ring
(ORS)
b
c c
LOWER SIDE OF THE PUMP CONTROL PANEL Fig. 3
195
B Connection of the fuel suction hose and oil pan drain hose
1 Connect the fuel suction hose a . 3 Clean the parts carefully after all oil has
drained out.
2 Connect the oil pan drain hose b (Tag. No. 8 ).

Notes:
with other parts.
faces of the hoses.
Fig. 4
Detail A
b (Tag No. 8 )
ENG. Oil pan
Fuel suction hose

from the base machine
Oil pan drain
FUEL PIPING (ENGINE SUCTION HOSE)

Fig. 5
196
2. Connecting the wire harnesses
(Including some hoses)
Precautions DRC connector rubber boot handling 198

precautions
Step 1 Cab bed interior Connection of the air conditioner hoses 199
Step 2 Cab bed interior Connection of the air conditioner heater 200
hoses, A/C motor drive hoses and A/C
motor drain hoses
Step 3 Lower part of the fuel filter (stage 1 Connection of the fuel filter wire harness 201
filter) at the lower part of the left step
Step 4 • Engine area Connection of the electric wire couplers 202

• Tail frame at the lower rear of the engine
A Engine area Connection of the engine electric wires 202
B Tail frame at the lower rear of the engine Connection of the electric wire couplers 203
Step 5 Cab bed interior Connection of the electric wire couplers 204
Step 6 Upper right front in the cab bed Connection of the window washer hose 204
Step 7 Control panel inside the cab bed Connection of the electric instrument box 205
wires and ambient temperature sensor
wires
Step 8 • Inner front of the right fender Connection of the wire harnesses 206
• Lower part of the engine
A Inner front of the right fender Connection of the electric wire couplers 206
B Lower part of the engine Connection of the electric wire 207
Step 9 Inside the cab bed Connection of the grunding wire harness 208
Step 10 Inside the cab bed Photographs of wire harnesses 209

connected inside the cab bed
197
DRC CONNECTOR RUBBER BOOT HANDLING PRECAUTIONS
Notes:
DRC connector rubber boot handling precautions
· Rubber boots are fitted to NIHON-DEUTSCH-

LIMITED-made DRC series connectors (24, 40,
and 70 poles), attached to excavator wiring joints,
to prevent water and dust from entering into the Detail A
connector.
Receptacle plug
· These rubber boots are attached to the connectors Rubber boot

and covered with the plate before shipment and
should be stored similarly during disassembly.
However, they may be lost, become removed or
jammed during field assembly.
· To prevent this problem, new connectors and

rubber boots are designed to stick together so that
they do not come apart easily.
· Securely attach the rubber boot to the plug

connector before assembly, then connect the plug
Rubber boot
and receptacle terminals. Take care that the rubber
boot is not out of place or jammed during Fig. 1
connection.
Note:
When connecting each connector, remove and scrap
the rubber boots fitted during shipment. Use rubber
packing 13 (P/No. 4392230 ~ DRC24), 12 (P/No.
4392229 ~ DRC40), 11 (P/No. 4392228 ~ DRC70).
Note:
Tighten the DRC connector screw to the specified
torque.
Note:
A gap should be provided here after tightening
the screw.
Recommended torque:
=2.82 ± 0.25 [N·m]
=28.8 ± 2.88 [kgf·cm]
=25 ± 2.5 [in·lbs]
Receptacle
Plug
To fit the connector smoothly, tighten the screw

while shaking the plug and connector.
Wire seal Note:

Rubber boot Too weak tightening torque can result in poor
Fig. 2
water resistance. Too strong tightening torque
Note: can cause the interface seal to be crushed and
Check that the plug and receptacle are parallel to break.
each other before and after tightening the screw.
198
Step 1
Connection of the air conditioner hoses
(Cab bed interior)
Notes:
1 Remove the vinyl covers from the cab side and cab i) Do not twist hoses when connecting them
bed side of the four air conditioner vent duct (inside air together. Their service life will be shortened.
intake duct), totaling eight covers. ii) Connect the hoses so they do not make contact
with other parts.
2 1 Connect the air conditioner hoses a , b , c ,
and d . faces of the hoses.
Tightening torque of hose: 6~7 N·m

(1.0 kgf·m/4~5 lbf·ft)
2 Clamp the clamps 50 ~ 3 pcs. and 51 ~ 1 pc. in

the positions marked with ＊ in Fig 3-a and 3-b.
Tightening torque of clamp: 50 N·m

Notes:
ii) Tighten all the bolts to the specified torque
after first screwing in finger tight. Fig. 1
Detail A
Front side
c
＊ 50
＊ 50
a
b
＊
＊
50
51 Fig. 3-a
50 or 51
Clamping method
＊
Fig. 3-b
Fig. 2 Fig. 3
199
Step 2
Connection of the air conditioner heater hoses, A/C motor
drive hoses and A/C motor drain hoses Notes:
(Cab bed interior) i) Put number tags on respective ports and hoses.
Connect the hoses, matching the wire numbers.
1 1 Connect the air conditioner heater hoses labeled ii) Do not twist hoses when connecting them
Tag No. 13 and 14 . together. Their service life will be shortened.
iii) Connect the hoses so they do not make contact
with other parts.
Width across flats: 36 mm iv) Make sure that no dust has adhered to the seat
faces of the hoses.
2 Connect the A/C motor drive hoses labeled Tag v) Do not damage the joining surfaces of the hoses.
No. 11 and Tag No. 12 .

3 Connect the A/C motor drain hose labeled Tag

No. 10 .

2 Clean the parts carefully after all oil has drained out.
Fig. 1
Detail A
Tag No. 13 Tag No. 13

From the base machine
Tag No. 14
Out
In Tag No. 14
AIR CONDITIONER HEATER HOSES SECTIONAL SIDE VIEW OF THE CAB BED
Tag No. 11 Tag No. 11 Tag No. 10

Tag No. 10
AC motor
drain hose
From the base

From the base Tag No. 12 From the cab bed
machine
machine
From the cab
Tag No. 12 bed
AIR CONDITIONER MOTOR HOSES Fig. 2
200
Step 3
Connection of the fuel filter wire harness
(Lower part of the fuel filter (stage 1 filter)

at the lower part of the left step )
＊ 1 Pull out the wire harness a from the base
machine and connect them.
2 Connect the electric wire coupler a .
Notes:
Fig. 1
Detail A
Fuel filter
Fig. 2-a

a
Fig. 2-b
a
a DT4
FUEL FILTER HARNESS

Fig. 2
201
Step 4
Connection of the electric wire couplers
(Engine area)
(Tail frame at the lower rear of the engine)
A Connection of the engine electric wires

(Engine area)
Connect the 14 electric wire couplers Tag No. 30 ~ 43

as illustrated in Fig. 2.
A number tag is put on each port and wires.
Connect the wires, matching the wire numbers.
A
Notes:
iii) Do not twist wires when connecting them
iv) Connect the wires so they do not make contact
with other parts.
Fig. 1
Detail A
For the pre-lube pressure switch
Tag No. 40
Tag No. 42
For the engine data link

Rotary pick-up sensor
Tag No. 41
Tag No. 37

Starter-use
upper step
Starter-use
lower step
Tag No. 43 For the

DT4 pre-lube
For the alternator
Tag No. 35 Oil pan-use level sensor

For the pre-lube Starter-use upper step
Tag No. 31
Tag No. 36
Starter-use lower step
Tag No. 33
Tag No. 34
ELECTRICAL WIRING FOR ENGINE

Fig. 2
202
B Connection of the electric wire couplers
(Tail frame at the lower rear of the engine)
1 Connect the 3 electric wires couplers a , b

and c as illustrated in Fig. 4.
2 Connect the electric wire coupler d .
Notes:
Fig. 3
Detail B
a DT4 a From the engine unit
From the base machine c DT12 (B type)

From the engine a
unit
c
b DT12 (A type)
b
Harness beneath the left-hand frame Fig. 4-a
d
From the engine unit d

d
DRC70-pole connector beneath the pump room
Fig. 4-b
BASE MACHINE-ENGINE UNIT HARNESS/FUEL FILTER HARNESS

Fig. 4
203
Step 5
Connection of the electric wire couplers
(Cab bed interior)
1 Connect the electric wire harness a .
(Item 11 : DRC70)
2 Connect the electric wire harness b .

(Item 13 : DRC24)
Notes:
Fig. 1
Detail A
Window washer piping
a
c
Fig. 2-a O
Pull out from the cab.
11 : DRC70
a
a
b SECTIONAL SIDE VIEW OF THE CAB BED

b
13 : DRC24 Pull out from the cab bed.
SECTION O
Fig. 2
Step 6
Connection the window washer hose
(Upper right front in cab bed) Notes:
i) Connect the hose so it does not make contact
＊ Connect window washer hose c . with other parts.
face of the hose.
204
Step 7
Connection of the electric instrument box wires and Notes:
ambient temperature sensor wires
i) A number tag is put on each port and wires.
(Control panel inside the cab bed)
Connection the wires, matching the wire
1 Connect the electric wire harness a numbers.
( 11 : DRC70 ~ 1pc.) ii) Before connecting the electric wires, remove the
2 Connect the 4 electric wire harnesses b anti-corrosive and any rust from the couplers.
(Tag. No. 15 ~ 18 ). ( 11 : DRC70 ~ 4pcs.) iii) Connect couplers with the same marking.
3 Connect the electric wire harnesses c

(Tag. No. 23 ). ( 12 : DRC40 ~ 1pc.)
4 Connect the electric wire harnesses d

(Tag. No. 19 ~ 22 ). (L-shaped connector 4 pcs.)
5 Connect the electric wire harnesses f and g .
Fig. 1
Detail A
11 : DRC70
a a From the cab bed
f
g f
g
c DRC40 : 12
Tag No. 18
(Tag No. 23 )
Tag No. 17
DRC70 b
Tag No. 16
Tag No. 15
c (Tag No. 23 ) Tag No. 19
Tag No. 20
Cab harness from the cab d L-shaped
Tag No. 21 connector
Tag No. 15 from the base
Tag No. 22 machine
Tag No. 16
b
Tag No. 17
Tag No. 18
From the cab frame harness

ELECTRIC INSTRUMENT BOX WIRING
Fig. 2
205
Step 8 Detail A
Connection of the wire harnesses

(Inner front of the right fender)
A Connection of the electric wire couplers

Connect the 2 electric wire couplers a as illustrated in
Figs. 1 and 2. (Item DT2)
(Inner front of the right fender)
Notes:
anti-corrosive and any rust from the couplers. Fig. 1
Detail B
a
To base machine
DT2-pole
Main frame
To right fender light
Fig. 2
206
B Connection of the electric wire
Connect the electric wire coupler a .

(Item 11 : DRC70)
Notes:
Fig. 3
Detail D Detail C
Detail E
Fig. 5 Fig. 4
Pull out from the engine bed
11 : DRC70 connector
a
Electric wiring
a
Fig. 6
Detail F
LOWER SIDE OF THE PUMP CONTROL PANEL Fig. 7
207
Step 9
Connection of the grounding wire harness
(Inside the cab bed)
■ Conect the grounding wire harness a .
1) Remove the paint on the installation surface.
2) Tighten the grounding harness-use bolt.

Notes:
Fig. 1
Detail A
a Grounding wire harnesses
SECTION
A
Front
A
Inner left side of cab bed B

SECTION
B
Fig. 2
208
Step 10 Detail A
Photographs of wire harnesses connected inside the cab bed
(Inside the cab bed)
Fig. 9
Fig. 2
Fig. 10
Fig. 3
Fig. 11
Fig. 4
Fig. 1
Inside the cab bed
Fig. 5 Fig. 12
Fig. 6 Fig. 7 Fig. 8 Fig. 13
209
7-13 Checking the stop valves and stopcocks
1 Open the Stop Valves. Detail A

The stop valves should be opened Closed Open
before supplying hydraulic oil.
1 Verify that the stop valve on the Stop valve
suction pipe is open as shown in
Figs. 2 and 3.
2 Verify that the stop valves on the Stop
valve
return pipes are open as shown in
Fig. 4.
3 Verify that the heater hose stopcock
under the radiator is open as shown
in Fig. 5.
Fig. 2 Fig. 3
Detail B
Fig. 1
Stop valve Stop valve

Open Open Fig. 4
Detail C
Stopcock
Open
Fig. 5
211
2 Open the stopcocks.
The stopcocks on the AC heater line should be
opened.
1 Verify that the six A/C heater hose stopcocks a

under the cab bed are open as shown in Fig. 7. Fig. 6
Detail D
Stopcock
(6 pcs.) a
Open
Fig. 7
2 Verify that the heater hose stopcocks b under the

engine are open as shown in Fig. 9.
Fig. 8
Detail E
Open the stopcock b
Fig. 9
212
3 Open the stopcock.
The stopcocks on the fuel line and oil tank line should
be opened.
■ Verify that the fuel hose stopcock a behind the

engine is open as shown in Figs. 11 and 12. Fig. 10
Detail G Detail F
Stopcock
Stopcock a
Open
Fig. 12 Fig. 11

The stopcock on the oil tank line should be opened.
■ Verify that the oil tank stopcock b behind the

engine is open as shown in Figs. 14 and 15. Fig. 13
Detail I Detail H
Stopcock
Open
Fig. 15 Fig. 14
213
5 Open the stopcocks.
The stopcocks on the fuel filter line should be opened.
1 Verify that the stopcock a on the fuel filter line is

open as shown in Figs. 17, 18 and 19.
Note:
Shown here is the closed stopcock. Fig. 16
View K Detail J
Stopcock a
Fig. 18 Fig. 17
Detail L
Stopcock
Open
Fig. 19
2 Verify that the stopcock b on the fuel tank is

open as shown in Figs. 21 and 22. Fig. 20
Detail N Detail M
Fuel tank
Stopcock
Open
Stopcock b
Fig. 22 Fig. 21
214
The stopcock on the stairway line should be opened.
Verify that the stopcock a on the stairway is open as

shown in Figs. 24, 25 and 26.
Note: Fig. 23
Shown here is the closed stopcock.
Detail P Detail O
Stopcock
Open the stopcock a
Fig. 25
Detail Q
Open the stopcock

Open
Fig. 26
Fig. 24
215
The stopcocks on the coolant line and reserve tank line
should be opened.
■ Verify that the coolant line stopcock a behind the

engine is open as shown in Fig. 28. Fig. 27
Detail R
Radiator outlet
pipe
Stopcock a
Open
Fig. 28

The stopcock on the reserve tank line should be
opened.
■ Verify that the reserve tank hose stopcock b

behind the engine is open as shown in Figs. 30 Fig. 29
and 31.
Detail S
Reserve tank
Detail T
Stopcock b
Open
Stopcock b
Fig. 31 Fig. 30
216
7-14 Final check of superstructure
Step 1
Checking the fluid levels
Detail A
Note:
The person in charge of assembly must confirm the
check items in this step. Incorrect operation will
damage the equipment.
a
1 Check the water level a in the radiator (See Fig. 1).

If the level is low, refill through the water filler ports on
the radiator.
Refer to the OPERATION MANUAL for details.
Fig. 1
Detail B
2 Check the oil levels b in all reduction gears for swing

reduction devices.
CAUTION: b
The machine will be hot immediately after operation.
Allow the machine to cool adequately before checking
the oil levels.
Fig. 2
Detail C
3 Check the oil level c in the engine oil pan.
CAUTION:
the oil levels.
4 Check the oil levels d in the final drives.

c Fig. 3
Detail D
IMPORTANT:
Never stand in front of the final drives when doing this
work.
Loosen the plug by 2 to 3 turns to allow any residual d
pressure in the travel device to escape, before fully
removing the plug.
If the plug is removed without letting residual pressure
escape, the plug and gear oil may gush from the
machine, causing injury. Do not stand or place your Fig. 4
face directly in front of the plug.
217
5 1 Turn key switch to the on position. Detail E
2 Check the fuel levels a and b in the fuel tank.

CAUTION!
Handle fuel carefully. Shut the engine off before
fueling. Do not smoke while you fill the fuel tank or
work on the fuel system.
Check fuel level gauge a or fuel gauge b on the

monitor panel. Add fuel via the fill cap c if necessary. Fig. 5
Fuel capacity is approximately 3200 liters (845 US gal).
Detail G Detail F
Fig. 7 a Fig. 6
Detail H
Fig. 8
Detail I
6 Check the transmission oil level.

1 Remove the dipstick d . Oil must be between the

marks. d
2 If necessary, add oil after returning the dipstick to
its original position.
CAUTION:
Fig. 9
the oil levels.
218
Note: Detail J
The person in charge of assembly must confirm the Oil tank
check items in this step. Incorrect operation will
damage the equipment.
7 Checking the hydraulic oil level.

Check that the level of oil in the hydraulic tank is above
the range indicated in the oil level gauge.
Fig. 10
Note: Detail K
Release the air from the main pump at the same
time you add hydraulic oil. (See page 209 for air
release procedure.)
Check that the level of oil in
the hydraulic tank is above
the range indicated in the oil
level gauge.
Fig. 11
Step 2
Connecting the battery cables to the batteries

Fig. 12
1 Clean all anticorrsive and any rust from the Detail L

connections before connecting the battery cables.
Note:
Reconnect the battery earth (−) removed at the
beginning of the work.
Connect
00
Fig. 13
219
2 Set the battery switch to "ON" (Figs. 14, 15 and 16).
Fig. 14
Detail M
Fig. 15
Detail N
ON
Fig. 16
220
Swing motors
Step 3
Checking the swing motors
Note:
Be sure that the person in charge of assembly
confirms the check items in this step. Incorrect
operation will damage equipment.
Fig. 17
Detail O
Front side
swing motor
Rear side
swing motor
Fig. 18
Detail P
a
1 1 Remove the 70 mm nominal length M16 bolts a

inserted on page 96.
Fig. 19
b
2 Insert the plugs b .
Fig. 20
2 Check that all the tightening bolts of the superstructure
are securely tightened.
Fig. 21
Detail Q
Check all tightening bolts.
Fig. 22
221
Step 4
Remove the plate locking the arm of the quick filling system
(Quick filling system option)
Fig. 23
Detail R
Quick filling system
Fig. 24
Detail S
Plate
Fig. 25
Fig. 26
CAUTION! Confirm that this plate

has been removed.
Note that the quick filling system will be damaged if you
operate it with the plate still attached.
222
7-15 Releasing air from main pumps
IMPORTANT : If the hydraulic pump is not filled with oil, it Detail A

will be damaged when the engine is started.
1 1 Loosen connector a of the six pumps to release

trapped air. Retighten connector a when air
stops and oil flows from the connector a . a
2 Loosen pipe connector b on the outlet line of fan
drive pump to release trapped air. Retighten pipe
connector b when air stops and oil flows from
pipe connector b .
a Fig. 1
3 Start the engine and run at slow idle.
4 Purge air from the hydraulic system by running the

engine at slow idle and operating the control
levers slowly and smoothly for 15 minutes.
5 Position the machine as illustrated in the oil level

checking procedure.
6 Lower the bucket to the ground.
7 Turn the auto-idle switch off.
8 Stop the engine. Remove the key from the key

switch.
9 Pull the pilot control shut-off lever to the LOCK

posi-tion.
10 Check the hydraulic oil tank gauge. Add oil if nec-

Fig. 2
essary.
Detail B
CAUTION!
This operation must be done slowly. Avoid abrupt
operation!
b
2 Check the hydraulic oil tank gauge c . Add oil if
necessary.
Fig. 3
Detail D Detail C
Oil tank
c Level check
Fig. 5 Fig. 4
223
224
7-16 Trial operation of superstructure
FRONT
SWING RIGHT FORWARD

Trial operation
1 1 Start the engine.

SWING LEFT REVERSE
2 Check the operation of the gauges. Fig. 1
3 Check the travel and swing functions.
CAUTION!
This operation must be done slowly. Avoid abrupt
operation!
4 Check for oil leakage. Confirm that there is no oil

SWING
leaking from the assembled areas.
5 Check the amount of oil in the hydraulic tank. If
the oil level is low, add more through the oil filler
port on the hydraulic tank.
Fig. 2
CAUTION!
Before starting the excavator, make sure there is no
person other than the operator in the machine.
Forward Reverse Fig. 3

travel travel
2 Confirm that machine noise is maintained at specified

levels.
Fig. 4
225
226
7-17 Disassembly procedures for shipment
1. Procedure (engine) 1/2 XF60000228 (1/2) •••••••••••••••••••••••••••• 229
Procedure (engine) 2/2 XF60000228 (2/2) •••••••••••••••••••••••••••• 231
2. Procedure (frame) 1/2 XF60000229 (1/2) •••••••••••••••••••••••••••• 233
Procedure (frame) 2/2 XF60000229 (2/2) •••••••••••••••••••••••••••• 235
3. Procedure (tank) XF60000347 ••••••••••••••••••••••••••••••••• 237
4. Procedure (weight) XF60000310 ••••••••••••••••••••••••••••••••• 239
5. Procedure (step) XF60000311 ••••••••••••••••••••••••••••••••• 241
6. Procedure (lamp) XF60000328 ••••••••••••••••••••••••••••••••• 243
227
228
Detail A
1. Procedure (engine) 1/2
Light mounting bracket (YA40007542)-1 Light mounting bracket (YA40007543)-1

Install the mounting bolts to the engine unit. Install the mounting bolts to the engine unit.
Fig. 1
EX2600-6 Procedure (engine) XF60000228 (1/2)
229
Detail B
1. Procedure (engine) 2/2
Fig. 2
EX2600-6 Procedure (engine) XF60000228 (2/2)
231
Detail C
2. Procedure (frame) 1/2
Fig. 3
EX2600-6 Procedure (frame) XF60000229 1/2
233
Detail D
2. Procedure (frame) 2/2
2140kg
Fig. 4
EX2600-6 Procedure (frame) XF60000229 2/2
235
Detail E
3. Procedure (tank)
Fig. 5
EX2600-6 Procedure (tank) XF60000347
237
Detail F
4. Procedure (weight)
Fig. 6
EX2600-6 Procedure (weight) XF60000310
239
Detail G
5. Procedure (step)
Fig. 7
EX2600-6 Procedure (step) XF60000311
241
Detail H
6. Procedure (lamp)
EX2600-6 Procedure (lamp) XF60000328

Fig. 8
243
244
7-18 Assembly of discharge lamps and back monitors
Contents
Step 1 Parts list •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 245 ~ 247

Step 2 Assembly of the dischage lamps and back monitors • • • • • • • • • • • • • • • • • • • • • • 249 ~ 253
Step 1
1 Preparation of the parts
■ PROCEDURE MONITOR : XF60000348
00 4662521 CAMERA 4
01 YA60006521 MONITOR 2
05 3091772 BRACKET 2
06 4659177 BRACKET 4
07 4698228 BRACKET 4
10 4698362 HARNESS; WIRE 1
16 4055312 CLIP; BAND 20
17 4121859 CLIP; BAND 20
■ DISCHARGE LAMP : XF60000328
01 4696127 LAMP; WORKING 5
245
246
2 Procedure, monitor (XF60000348)
Detail B
EX2600-6 Procedure, monitor XF60000348

Fig.1
247
Step 2
Assembly of the discharge lamps and back monitors
1 Installation of the back monitors Notes:

Cautionary remarks for connecting the wire
1 Install two monitors 01 on the left front of the cab harnesses
as shown in Figs. 1 and 3. i) Before connecting the electric wires, remove
2 Connect the power lines and camera cables as the anticorrosive and any rust from the
shown in Fig. 2. couplers.
3 Fix the cables in place with band clips 16 and 17 ii) Connect couplers with the same marking.
as shown in Fig. 1.
Detail A
a
Note:
For installation instructions, refer to pages 251 and
253.
Fix the cobles

with 16 17 clips.
Fig. 1
Detail C
Plug terminal
21
Unused Camera connector (black)
Power connector (white) WITOCO 272FCW-8P
MITSUBISHI CABLE
C02M-W Four camera cables
Connect the power

harness that branches
off from the main
harness.
Band all unused

camera cables
with a repeat tie.
Interior of cab
Main harness
Fig. 2
Detail C
Monitor 01
20-pole connector B
AMP 174047-2
16-pole connector A
AMP 174046-2
20-pole connector B
AMP 174047-2
16-pole connector A
AMP 174046-2
Fig. 3
249
250
2 Installation of the cameras and working lamps
Lamp, working 01 Working lamp at the right
00 rear of the engine unit
00 00
Notes:
1 Cautionary remarks for tightening the bolts
i) Apply lubricant to the bolts before installation. 01
07
ii) Tighten bolts to the specified torque after first screwing
Bracket 58
in finger tight.
2 Cautionary remarks for connecting the wire harnesses
i) Before connecting the electric wires, remove the anti- 06 1 Install bracket 58 and bolts. 1 Install camera 00 with brackets 58 , 06
corrosive and any rust from the couplers. 05 2 Install working lamp 01 . and 07 .
Fig. 5-a
ii) Connect couplers with the same marking. 3 Lead connector. 2 Lead connector.
3 When connecting lamp, working harness 00 (4696127),

1 Install camera 00 with brackets 58 , 06 and 07 . 58 06
pay attention to the following points. Fig. 6-e does not
2 Lead connector.
need the harness attachment.
Detail D
00
07
Fig. 6-f Fig. 5-b
Lamp, working 01 Working lamp at the left

rear of the engine unit
01
00
00
Fig. 5
Bracket 57
1 Install bracket 57 and bolts. 1 Install camera 00 with brackets 57 , 06

2 Install working lamp 01 . and 07 .
1 Install camera 00 with brackets 58 , 06 and 07 . 3 Lead connector. 2 Lead connector.
3 Lead connector.
e 00 57
Working lamp at the left 06
06 side of the engine unit Lamp, working 01
01
07
05
00
Bracket 05
07
Fig. 6-c
1 Install bracket 58 and bolts.

2 Install working lamp 01 .
Fig. 5-e 3 Lead connector. Fig. 5-d Fig. 5-c
251
3 Procedure (Monitor) (YA60003624)
Detail E
00
06
07
00
07
06
YA60006521
06
57
58
00
07
00
EX2600-6 Monitor YA60003624

Fig. 6
253
7-19 Assembly of option parts
1. Kit, GPS parts 9289888 ••••••••••••••••••••••••••••••• 256 ~ 257
255
1. Kit, GPS parts (9289888)
00 4635318 Controller 1
01 4654204 Bracket 1
02 J680612 Screw, sems 4
03 J260814 Bolt, sems 2
05 4441588 Antenna 1
06 4441572 Connector 1
07 J460316 Screw, sems 4
08 4457076 Cable 1
256
Kit, GPS DWG. (9289888)
Detail A
EX2600-6 Kit, GPS parts 9289888

Fig. 1
257
MOUNTING PROCEDURES FOR

LOADER FRONT-END ATTACHMENT
ATTACHMENT
8. Mounting procedures for loader front-end attachment
8-1 Preparation
MOUNTING CHART OF LOADER FRONT
Fig. 1
Step 1
Parts required
PROCEDURE, LINKAGE (XF60000389) 1/2
00 XF10001288 LOADER 1
07 4433056 HOSE 11
08 4357729 HOSE 2
09 4357730 HOSE 2
10 4180363 HOSE 2
11 4357725 HOSE 2
12 4357726 HOSE 2
13 4180360 HOSE 2
14 4357723 HOSE 2
16 4358925 HOSE 1
17 4358924 HOSE 1
20 XF10001289 CLAMP ASS'Y 2
261
2/2
22 4489557 CYL., BOOM 2

23 4402129 CYL., ARM 1
24 4418071 CYL., BUCKET (R) 1
25 4418072 CYL., BUCKET (L) 1
34 3074037 PIPE 2
35 3074038 PIPE 1
46 4510170 O-RING 34
47 4510169 O-RING 16
PROCEDURE, LOADER BUCKET (XF60000378)
00 XF10001287 BUCKET LOADER 1

04 4487594 O-RING 2
262
Detail A'
Step 2 Bracket
Installation of the arm cylinder
1 1 Place wooden blocks under loader boom 00 as

shown in Figs. 2-a and 2-b. Fig. 2-a
Loadr boom 00 weight: 29 000 kg (63 800 lb) b

800 00
Wooden block: 4 pcs. 800 900

Size: 800 mm (L) × 900 mm (W) × 800 mm (H) a
(30 in) (35 in) (30 in)
Note:
800
8 000 kg (17 600 lb).
a
800 900
2 Clean the pin holes a on the boom foot indicated
by . Fig. 2
3 Clean the pins b (located on both sides of boom) Detail A
on the boom top.
4 Extract the pins b on the boom top.
Bracket
Fig. 2-b
263
2 Preparation of arm cylinder.
Detail B
Lever block
1 Use a lever block and wire ropes on the rod ends
of arm cylinder 23 so that they do not extend.
(Figs. 3 and 4)
a
Wire rope: 2 pcs.

Wire rope
10 mmø × 3 000 mm (L) : 1 pc. 10 mmø × 3 000 mm
(0.4 inø) (117 in L)
10 mmø × 6 000 mm (L) : 1 pc. b
(0.4 inø) (234 in L) 23
Fig. 3
Lever block: 1 pc. Detail C

for 1.0 tonne (1.1 US ton) load
Wire rope attachment method
Lever block
2 Clean pin holes a and b in the arm cylinder.
Wire rope
Note:
In particular, the area surrounding the bearing
should be carefully cleaned.
Fig. 4
3 Installation arm cylinder.
Arm cylinder 23
1 Have a pallet ready and place wooden blocks e Lower
and d on it.

e Size:800 mm (L)× 600 mm (W)× 600 mm (H) Wooden block e Wooden block d
(30 in) (23 in) (23 in)
d Size:800 mm (L)× 300 mm (W)× 300 mm (H) 300 600
(30 in) (12 in) (12 in)
Fig. 5
Pallet
Note: Hold
1 500 kg (3 300 lb).
2 Attach wire ropes to the arm cylinder 23 .
Arm cylinder 23 weight: 2 240 kg (4 930 lb)
Wire rope: 2 pcs.

12 mmø ×8 000 mm (L) : 1 pc.
(0.5 inø) (312 in L)
12 mmø × 6 000 mm (L) : 1 pc. Fig. 6
(0.5 inø) (234 in L) Detail D
3 Lift the arm cylinder as shown in Fig. 5.

Pallet
4 Place wooden blocks under the arm cylinder as
shown in Figs. 6 and 7.
Note:
Firmly secure the wooden blocks to prevent the level Wooden block d
cylinder from toppling over. 23
Wooden block e
Fig. 7
264
4 Moving the arm cylinder.
1 Use a forklift to move arm cylinder 23 that was

installed in 3 to the under side of the boom.
23
Fig. 8
23
Fig. 9
2 Install arm cylinder 23 so that its pin hole a is
aligned with the pin hole b in the boom.
23
b
Fig. 10
265
5 Install the arm cylinder.
Fig. 11
1 Align pin hole a with pin hole b .
2 Install the arm cylinder.

1) Lift the bottom of the arm cylinder by attaching
a chain block, wire ropes, and shackles to the
eye plate on the bottom of the boom.
Arm cylinder 23 weight: 2 240 kg

(4 930 lb)
Wire rope: 2 pcs. a b

10 mmø × 4 000 mm (L)
(0.4 inø) (156 in L)
Shackle: 4 pcs.
for a 1 metric tonne (1.1 US ton) load
Chain block: 1 pc. Fig. 12

for a 1 metric tonne (1.1 US ton) load
2) Bring pin hole a in the boom near pin hole b

in the arm cylinder.
3) Align pin hole a with pin hole b .
3 Bring pin hole a in the arm cylinder near pin hole

b in the boom.
266
4 Align pin hole a with pin hole b in order to insert
the pin.
5 Grease the pin before insertion.
6 Tighten the pin with 2 bolts, 2 washers and 1 plate.
a b
Note:
Apply lubricant to the bolts before installation.

(71 kgf·m/516 lbf·ft) Fig. 13
Section E
Bolt &
Washer
Plate
Pin
Fig. 14
c d
Pallet
7 Secure the arm cylinders under the boom using
wire ropes, shackles and a lever block.
Fig. 15
Wire rope: 2 pcs.
12 mmø × 3 000 mm (L)
(0.5 inø) (117 in L) Detail F
Shackle: 2 pcs. Lever block

for a 1.5 metric tonne (1.65 US ton) load
Shackle
Lever block: 4 pcs.
for a 1.5 metric tonne (1.65 US ton) load
Wire rope
8 Remove wooden blocks c , d and pallet under
the arm cylinder as shown in Fig. 15.
Arm cylinder Fig. 16
267
9 Connect arm cylinder grease hose a (Fig. 17). Detail G
Notes:
i) Do not twist hose when connecting them
ii) Connect the hose so they do not contact other
a
parts.
Fig. 17
faces of the hose.
iv) Do not damage the joining surfaces of the hose.
10 After the grease has drained out, clean

the parts carefully.
Fig. 18
268
Step 3 Detail H
22 Wire rope
10 mmø × 3 000 mm
Installation of the boom cylinders
Wire rope
10 mmø × 6 000 mm
1 Preparation of the boom cylinders.
1 Use lever blocks and wire ropes on the rod ends b

of boom cylinders 22 so that they do not extend. a
(Figs. 19 and 20)
Lever block
3 ton
Wire rope: 4 pcs. Fig. 19
10 mmø × 3 000 mm (L) : 2
(0.4 inø) (117 in L) Detail I
10 mmø × 6 000 mm (L) : 2 Wire rope attachment method
(0.4 inø) (234 in L)
Wire rope
Lever block: 2 pc.

2 Clean pin holes a and b in the boom cylinders.

Lever block
Fig. 20
Detail J Hold
Note:
In particular, the area surrounding the bearing
Wire rope Wire rope
16 mmø × 12 mmø ×
5 000 mm 3 000 mm
2 Lifting the boom cylinder.

Lever block
3 ton
1 Attach wire ropes and a lever block to the boom
cylinder as shown in Fig. 21.
Boom cylinder 22 weight: 2 960 kg (6 510 lb)

Wire rope
12 mmø ×
22 5 000 mm
Wire rope: 3 pcs.
16 mmø × 5 000 mm (L) : 1
(0.65 inø) (195 in L)
12 mmø × 3 000 mm (L) : 1
(0.5 inø) (117 in L)
12 mmø × 5 000 mm (L) : 1
(0.5 inø) (195 in L)
Fig. 21
Lever block: 1 pc. Hold

2 Lift the boom cylinder as shown in Fig. 22.

3 Move the boom cylinder to the pin hole b on the
b
boom.
22
Fig. 22
269
3 1 Align the pin holes a and b and insert the pin,
as shown in Fig. 23.
Notes:
i) The pin holes can be aligned by controlling the Lever block
lever block.
ii) Before installing the spacer, make sure that its
a b
chamfered side is aligned facing towards the
cylinder.
iii) Grease the pin before inserting.
2 Tighten the pin with 2 bolts, 2 washers, 1 plate

and 1 spacer.
Note: Fig. 23
Apply lubricant to the bolts before installing. Detail K cylinder
Tightening torque of M24 bolt: 700 N·m Pin
Width across flats: 36 mm OUT facing IN facing
side side
Bolt &
Washer
Plate Spacer
Pay attention to the

chamfered side of the spacer. Fig. 24
4 1 Support the rod side of each boom cylinder using

one lever block and wire rope, as shown in Fig.
26.
Lever block: 2 pcs.

for 1.5 tonne (1.65 US ton) load Fig. 25
Detail L
Wire rope: 2 pcs.
12 mmø × 3 000 mm(L)
(0.5 inø) (117 in L)
Shackle
Shackle: 2 pcs. Lever block
for 1.5 tonne (1.65 US ton) load 1.5 ton
2 Remove the crane wire ropes and chain block Wire rope
12 mmø ×
holding the boom cylinder. 3 000 mm
The second boom cylinder should be installed in

the same manner as described above.
Fig. 26
270
5 1 Connect boom cylinder hoses 10 and 13 .
(both sides)
Tightening torque of M20 socket bolt: 400 N·m

(hose 10 ) (41 kgf·m/295 lbf·ft)
Socket size: 17 mm

(hose )13 (21 kgf·m/155 lbf·ft)
Socket size: 14 mm
Notes:
with other parts. Fig. 27
faces of the hoses.
iv) Do not damage the joining surfaces of the Detail M
hoses. 10 ~2 pcs.
46 (P/No. 4510170~4 pcs.) and 47 (P/No.
4510169~4 pcs.) before installation.
13 ~2 pcs.
2 After the oil has drained out, clean the parts

carefully.
Fig. 28
The set of boom cylinder hoses for the opposite

cylinder should be installed in the same manner
as described above.
271
6 Connect the grease hoses.
1 Connect grease hoses a (Fig. 30). (both sides)
Tightening torque of hose a : 30 N·m

Notes:
with other parts.
faces of the hoses. Fig. 29
iv) Do not damage the joining surfaces of the Detail N

hoses.
Boom
Cylinder
The grease hose for the opposite cylinder should
be installed in the same manner as described
above.
a
Fig. 30
2 Connect grease pipes 34 (2 pcs.) and 35 (1 pc.).
Tightening torque of pipe: 30 N·m Detail O

( 34 and 35 ) (3 kgf·m/22 lbf·ft)
Tightening torque of M10 clamp bolt: 50 N·m

Clamp
Notes: bolt
i) Make sure that no dust has adhered to the seat
2 pcs.
faces of the pipes.
34
ii) Do not damage the joining surfaces of the pipes.
3 After the grease has drained out, clean the parts 35

carefully.
Clamp
Clamp
CAUTION: bolt
After connecting the hoses, install the pressure-release
parts described on pages 14 to 16. These parts must Install pressure-
release parts here.
be installed since this area will be highly pressurized.
Use them to release the pressure during installation,
ensuring safe operation.
Fig. 31
272
Step 4
Installation of the bucket cylinders
1 1 Position bucket cylinder (L) 25 (or 24 ) beneath the

front of the boom. c
b
2 Clean a and b on the bucket cylinder (L) 25 .
Bucket
cylinder (L) 25
Note:
The left and right sides of the bucket cylinder are not a
of the same shape. Take care when positioning it
beneath the boom.
3 Pull out the boom bucket cylinder mounting pin c Fig. 32

halfway.
Detail P
4 Clean pin c . 24 or 25
5 Use a lever block to secure the bucket cylinder in

an unextended state (Fig. 33). Wire rope
Wire rope: 2 pcs.

10 mmø × 1 000 mm (L)
(0.4 inø) (40 in L) Lever block
Fig. 33
Lever block: 1 pc. Lift Wire rope

12 mmø × 7 000 mm × 2 pcs.
2 1 Suspend the bucket cylinder by two wire ropes on

the rod end and lift it up with a crane.
Bucket cylinder 24 or 25 weight:

1 870 kg (4 115 lb)
Wire rope: 2 pcs.

12 mmø × 7 000 mm (L)
(0.5 inø) (273 in L)
2 With the bucket cylinder lifted, secure the bucket

cylinder tube to the arm eye plate with a wire rope
and lever block as shown.
Fig. 34
Note:
This work is required to align the pin holes of the Detail Q
bucket cylinder. Wire rope
Lever block
Wire rope: 1 pc. Shackle

10 mmø × 5 000 mm (L)
(0.4 inø) (195 in L)
Lever block: 1pc.

for a 1.5 tonne (1.65 US ton) load
Shackle: 1pc.
for a 3 tonne (3.3 US ton) load
Fig. 35
273
Lift
3 Align the pin hole on the rod end of the bucket cylinder
with the boom mounting pin hole, while controlling (A)
(lifted up by the crane) and (B) (held by the lever
block). (A)
(B)
Lever block (B)
1 Align the pin holes a and b , then insert the pin.

Fig. 36
Note: S
Grease the pin before inserting.
2 Tighten the pin with 2 bolts, 2 spring washers and

a
1 plate. b
Note:
Apply lubricant to the bolts before installing.

Width across flats: 36 mm Fig. 37
Detail R
Bucket
Plate cylinder
Bolt &
Washer
Pin
Fig. 38
3 Use shackles and lever blocks between the eye Detail S

bolt on the bottom of the bucket cylinder and eye
plate on the arm to secure the bottom of the
bucket cylinder. Eye plate
Lever block: 1 pc.

Shackle
Shackle: 1 pc. Lever block

Eye bolt
The second bucket cylinder 24 (or 25 ) should be

installed in the same manner as described above.
Fig. 39
274
4 1 Remove the blind covers from the pipe ends.
(both sides)
2 Connect bucket cylinder hoses 09 and 12 .

Socket size: 17 mm

Socket size: 14 mm
Notes:
together. Their service life will be shortened. Fig. 40

Detail T
with other parts.
faces of the hoses.
iv) Do not damage the joining surfaces of the
hoses.
v) Apply a thin layer of sealant #98D to the O-rings 09
46 (P/No. 4510170~4 pcs.) and 47 (P/No.
4510169~4 pcs.) before installation. Reuse the 12
O-ring originally fitted to the hoses.

carefully. Fig. 41
The bucket cylinder hoses for the opposite

as described above.
275
276
8-2 Mounting of loader front Detail A
a
Step 1
a
Mounting of the boom
1 1 Clean the anticorrosive off the pins inserted into

the boom-joint section of the main frame.
2 Extract the 2 pins a from the main frame.
3 Apply grease to the pin holes.
Fig. 1
Wire rope
32 mmø ×
5 000 mm
Wire rope Wire rope

48 mmø × 46 mmø ×
10 000 mm 3 000 mm
Chain block
Chain block
25 ton
25 ton
2 1 Clean the pin holes b in the boom.
Wire rope
2 Put shackles on the eye-plate provided on the Wire rope
32 mmø ×
46 mmø ×
boom, and attach wire ropes and a chain block as 3 000 mm
3 000 mm
Shackle Shackle
Note:
Level the boom by adjusting the preset chain blocks. 00
CAUTION! b
boom.
Loader boom 00 weight: 40 900 kg

(89 980 lb)
Wire rope: 7 pcs. b

48 mmø × 10 000 mm (L) : 1 pc. Fig. 2
(1.9 inø) (390 in)
32 mmø × 5 000 mm (L) : 2 pcs. Lift
(1.25 inø) (195 in)
32 mmø × 3 000 mm (L) : 2 pcs.
(1.25 inø) (117 in)
46 mmø × 3 000 mm (L) : 2 pcs.
(1.8 inø) (117 in) 90°
Shackle: 4 pcs.
Chain block: 3 pcs.

for 25 tonne (27.5 US ton) load b
3 Lift with a crane as shown in Fig. 3.

4 Lift the boom so that pin holes b remain
horizontal. Fig. 3
277
Lift & move
3 Move the boom to the pin holes a in the main frame.
Cab
Notes:
i) When moving the front attachment, be careful
that it does not touch the cab.
ii) It is safe to attach a rope on the section indicated a
by ★ in order to guide it. ★
Hold
Rope
Rope: 1 pc. 8 mmø × 5 000 mm b
8 mmø × 5 000 mm (L)
(0.3 inø) (195 in L)
Fig. 4
Hold
B
4 1 Align the pin holes a and b in order to insert the
pins.
2 Grease the pins before inserting.
b
a
Notes:
i) The height to the arm end should be about 3 170
mm (124 in). 3170
ii) Align the left pin holes first, then the right pin (124 in)
holes. The right ones should align easily. This
can be done by controlling the chain block. Fig. 5
3 Tighten the pins with a total of 4 bolts, 4 washers Detail B

and 2 plates. Shim Plate
Notes:
i) A shim is attached to the pin on the base Bolt &
machine. Insert this shim as it is. Washer
ii) Apply lubricant to the bolts before installation.

Width across flats: 36 mm Pin
Fig. 6
5 1 Place one wooden block for each arm end, about

1 000 mm (40 in) in height, on the ground so that
the arm can rest on top of them.

300 mm (L) × 300 mm (W) × 1 000 mm (H)
Wooden
(12 in) (12 in) (40 in)
block
2 Lower the front end so that the arm top rests on

the top of the wooden blocks.
1000
(40 in)
Fig. 7
6 Remove the wire ropes and chain blocks lifting the
boom assembly.
278
Step 2
Connection of the hoses to base machine and boom
1 1 Release the pressure in the hydraulic tank.

2 Remove the blind covers from the pipe ends on
the base machine and boom.
Detail C Detail D
07
07
Fig. 8 Fig. 9
Boom side Base machine side
3 Connect the 11 hoses 07 between the base

machine and boom.

Boom side
Socket size: 17 mm
Notes:
i) Do not twist hoses when connecting them. Their
ii) Connect the hoses so they do not make contact Base
machine side
with other parts.
Fig. 10
faces of the hoses.
iv) Do not damage the joining surfaces of the Detail E
Bolt 12 mm
hoses.
Reuse the O-ring which has been fitted on the 20
hoses.
2 1 Secure 2 clamps 20 (with the 24 bolts, 12 plates,

and 24 washers connected to it) at the midpoint of
the hoses.
Fig. 11
Tightening torque of M12 lock nut: 9 kgf·m
(90 N·m/66 lbf·ft) Detail F
2 After the oil has drained out from the hoses, clean
the parts carefully.
20
Fig. 12
279
Step 3
Connection of the arm cylinder hoses
1 1 Remove the blind covers from the pipe ends.
2 Connect the 4 hoses 08 and 11 (2 pcs. each) to

the piping.

Socket size: 17 mm

(hose 11 ) (21 kgf·m/155 lbf·ft) Fig. 13
Detail G
Socket size: 14 mm
08
Notes:
with other parts.
iii) Make sure that no dust has adhered to the seat 11
faces of the hoses.
hoses.
46 (P/No. 4510170~4 pcs.) and 47 (P/No.
Fig. 14
4510169~4 pcs.) before installation. Reuse the
O-ring which has been fitted on the hoses.

carefully.
Fig. 15
Detail H
2 Remove the stoppers a and b which lock the level
cylinder so it cannot retract. a
b
Fig. 16
280
Step 4
Installation of the boom cylinder to base machine
1 1 Extract each pin from part a (both sides)

indicated by .
2 Carefully clean the pin holes a and b .
3 Cut the wires used to fasten the boom
cylinders at the time of shipping.
4 Remove the lever block fitted to prevent the boom
cylinder rod from extending.
b
2 1 Lower the boom cylinder slowly with a lever block a

Fig. 17
until the pin hole of the boom cylinder rod b
aligns with a on the main frame.
2 Start the engine and extend the rod end of the

boom cylinder.
Lever block
a
Fig. 18
Note:
Operate the boom cylinder carefully, an inch at a
time, during this work.
3 1 Align the pin holes a and b and insert the pins.
Note:
Grease each pin before inserting.
a b
Fig. 19
2 Tighten the pin with 2 bolts, 2 spring washers and

1 plate. Detail I
Plate
Note:
Bolt &
Tightening torque of M24 bolt: 950 N·m Spring washer
4 Perform the same work on the apposite side. Pin
Fig. 20
281
Step 5
Connection of the grease hoses
1 1 Connect the hose 16 ( a ) between the

base machine and boom. (Automatic greasing
type only)
Detail J Fig. 21
a
16
Boom
Fig. 22
Fig. 23
Notes:
i) Do not twist hose when connecting them
ii) Connect the hose so they do not make contact
with other parts.
faces of the hose.
iv) Do not damage the joining surfaces of the hose.
2 After the grease has drained out, clean the

parts carefully.
2 1 Connect the grease hoses b and c . Fig. 24

(3 kgf·m/22 lbf·ft) Detail K
Notes:
with other parts.
iii) Make sure that no dust has adhered to the seat b c
faces of the hoses.
iv) Do not damage the joining surfaces of the Fig. 25
hoses.
2 After the grease has drained out, clean the

parts carefully.
282
Step 6
Installation of the arm cylinder

Boom cylinder
1 1 Place a plate of about 20 mm (0.8 in) thickness at
the end of the arm to replace the blocks.
2 Retract the boom cylinder and lower the arm onto

the plate.
Block
Note:
The boom cylinder should be retracted to the stroke
end.
20 mm (0.8 in) Fig. 26
Arm cylinder
Fig. 27
2 1 Extend the arm cylinder to align the pin hole on Detail L

the cylinder rod with that of the arm bracket.
Lever block
Shackle
Wire rope
Arm cylinder Fig. 28
Detail M
2 To align the arm bracket pin holes while extending
the arm cylinder, adjust the lever block vertically, Lever block
as shown.
Bracket
Fig. 29
283
3 1 The pin hole in the arm cylinder cannot be aligned
with that of the arm bracket in its current
condition. Operating the boom cylinder at the
stroke end to retract it further will cause the level
cylinder to retract, sliding the arm inward on the
ground.
2 Align the pin holes on the cylinder in the manner a

described above.
CAUTION! Fig. 30
At this time, loosen chain block a , shown in Fig. 30,
as much as possible. Doing this work with the chain
block tightened will cause the chain block or a part
of the chain block assembly to break, potentially
leading to a serious accident.
4 1 Insert the pin when the pin holes are aligned.
Note:
Grease the pin before inserting.
2 Tighten the pin with 2 bolts, 2 washers and

1 plate. Fig. 31
Note:
Apply lubricant to the bolts before installing. Detail N

Plate
Width across flats: 36 mm Bolt &
Washer
Pin
3 Connect grease hose b .

Fig. 32
Detail O
Notes:
i) Connect the hose so it does not make contact
with other parts.
faces of the hose.
iii) Do not damage the joining surfaces of the hose.
b
Fig. 33
4 After the grease has drained out, clean the parts
carefully.
284
Extend
CAUTION! Raise
Do not operate any of the cylinders before attaching
the bucket. If the cylinders are accidentally operated,
the bucket cylinder, suspended by a shackle on the Retract
arm, may move, potentially resulting in a serious
Lower
machine failure or injury.
Fig. 34
CAUTION
Fig. 35
CAUTION
CAUTION!
Never extend or retract the bucket cylinder rod when
removing the eye bolts. The eye bolts will break,
potentially leading to serious damage.
Fig. 36
285
286
8-3 Mounting the bucket
Step 1
Mounting of the bucket

c
a
1 1 Remove the 4 pins at a and b from the bucket
00
00 .
2 Clean parts a , b , c and d .
d
3 Apply grease to parts a , b , c and d . b
Fig. 1
4 Raise the arm 1 740 mm (68 in) above the

ground.
1 740 mm
(68 in)
Fig. 2
2 1 Put shackles on the eye plates provided on the Detail A

bucket 00 , then attach wire ropes and a chain Hold
block.
2 Lift the bucket as illustrated in Fig. 3.
Note:
Level the bucket by adjusting the preset chain
blocks.
Wire rope
32 mmø ×
CAUTION! 3 000 mm
bucket. Wire rope
32 mmø ×
10 000 mm
Bucket 00 weight: 20 300 kg (44 660 lb)
Chain block
12 ton
Wire rope: 3 pcs.
32 mmø × 10 000 mm (L) : 1 pc.
(1.25 inø) (390 in L)
Wire rope
32 mmø × 3 000 mm (L) : 2 pcs.
32 mmø ×
(1.25 inø) (117 in L) 3 000 mm
Chain block: 1 pc.

00
for 12 tonne (13.2 US ton) load Shackle
Shackle: 2 pcs.
Fig. 3
287
3 Lift the bucket 00 such that pin holes a are kept
level. Lift & move
4 Move the bucket to the arm top pin hole b . a
00
3 1 Align the centers of pin holes a and b in order to

Fig. 4
insert the pins.
Notes: Lift
i) A shim is attached to the pin on the base
machine. Insert this shim as it is.
ii) Apply grease to the pins before installation.
a
2 Tighten the pins with 4 bolts, 4 washers and b
2 stoppers.
Note:
B
Tightening torque of M20 bolt: 400 N·m Fig. 5
Width across flats: 30 mm Section B
3 After inserting the pins, position 2 O-rings 04 in Stopper

Pin
the groove and tighten their nuts. Bolt &
Washer
Tightening torque:
Assemble so that no gap is provided here.
Width across flats: 8 mm Detail C
Note:
Carefully seat 2 O-rings 04 on the boss arm and 04
bucket as shown in Figs. 7 and 7-a. Fig. 6
Note:
To ease the assembly, the bolt has been made
slightly long. After assembly, cut the bolt to ☆ 10 ~
20 mm for usage.
(Bolt size: M5) Fig. 7
☆ 10 ~ 20 Slit ☆ 10 ~ 20
Hold
Double nut Double nut
04
Assemble so that no
gap is provided here. Fig. 7-a
Fig. 8
288
CAUTION
CAUTION!
Never extend or retract the bucket cylinder rod
when removing the eye bolts. The eye bolts will
break, leading to serious damage.
Fig. 9
4 1 Lower the bucket with the crane so that the

bottom of the bucket rests on the ground.
Take off the crane wire ropes
and chain blocks
2 Remove the wire ropes and chain blocks lifting the
bucket.
Fig. 10
289
Step 2
Extend the bucket cylinders to align the pin holes with the Chain block
bucket pin holes in order to insert the pins
Bucket cylinder
1 Extend the bucket cylinders in the direction of the arrow
to align the centers of the bucket cylinder lower pin
holes a and the bucket pin holes b , as shown in Fig.
11.
a Fig. 11
Note: b
Align the pin holes by operating the chain block Detail D
supporting the bucket cylinder.
Bucket
cylinder
2 1 Align the centers of pin holes a and b on the

bucket cylinders and bucket. Fig. 12
2 Grease the pins.
3 Insert the pins.
Bucket cylinder
Fig. 13
a b
3 1 Secure the pins with 4 bolts, 4 washers and
1 stoppers.
Note:
Apply lubricant to the bolts before installation

Width across flats: 30 mm E Fig. 14
a b
Section E
Stopper
Pin
Bolt &
Washer
2 Remove the chain blocks holding the bucket

cylinders. Fig. 15
290
Step 3
Connection of the dump cylinder (open/close) hoses
CAUTION:
Perform operation after releasing the high pressure
from the pressure-release parts that have been
installed as outlined on page 272.
1 1 Connect the end of hoses 14 to the pipe end of

the arm. (Fig. 17)
Tightening torque of M16 socket bolt: 210 N·m Fig. 16
Socket size: 14 mm Detail F
17 14
2 Connect the grease hose 17 .

Notes:
with other parts.
faces of the hoses. Fig. 17
hoses.
Detail G
Reuse the O-ring originally fitted to the hoses.
2 After the oil has drained out, clean the parts carefully.
3 Connect the grease hoses a (both sides).
Tightening torque of hose a : 30 N·m a

Fig. 18
Notes:
with other parts.
Detail H
faces of the hoses.
hoses.
4 After the grease has drained out clean the parts

carefully.
5 Check that all the bolts on the loader front attachment

are tightened to the indicated torques.
Fig. 19
291
Step 4 Detail I
Greasing (2)

device, with a hose reel and a fitted grease gun. Carry
out lubrication according to the following procedure. a
b
1 Manual lubrication:
1 Connect coupler b to hose a . Fig. 20
(manual) position. Detail J
3 Hold grease gun d and pull the hose out from the
hose reel e .
c
Fig. 21
IMPORTANT: Detail K
Set the engine to run at neutral or higher speed during
lubrication with the lubrication device.
e
2 Start the engine.
3 1 Apply grease to the 2 locations f shown in Fig. 24.

d
2 Apply grease to the 9 locations g shown in Fig. 25.
Fig. 22
Notes:
provided, use a standard air grill gun to manually
wear.
Fig. 23
Detail L Detail M
f
Fig. 24 g
Fig. 25
292
3 Apply grease to the 6 locations a shown in Figs.
27 and 27-a.
Notes:
wear.
Fig. 26
Detail N
ARM-BUCKET JOINT (R)

BOOM-ARM JOINT (R)
LEVEL CYL. ROD
ARM CYL. ROD
BOOM-ARM JOINT (L)
ARM-BUCKET JOINT (L) Fig. 27-a
Fig. 27
4 Apply grease to the 8 locations b shown in Figs.
29 and 29-a.
Notes:
wear.
Fig. 28
Detail O
BUCKET CYL. BOTTOM (L)

DUMP CYL. BOTTOM (L)
DUMP CYL. ROD (L)
BUCKET F.-R. JOINT (L)
BUCKET F.-R. JOINT (R)
DUMP CYL. ROD (R)
Fig. 29
DUMP CYL. BOTTOM (R)
BUCKET CYL. BOTTOM (R) Fig. 29-a
293
4 After completing the lubrication Detail P
1 Gently pull the hose out from hose reel c .

automatically withdrawn back onto hose reel c . c
2 Remove coupler b from hose a .
d
IMPORTANT:
Before storing, make sure to release any residual air in
Fig. 30
the hose reel by way of the grease gun d . This will
prevent damage being done to the pump.
Detail Q
Note:
Leaving the device in the manual lubrication
setting will cause the automatic lubrication warning
lamp on the cab instrument panel to light up. a
Fig. 31
294
Step 5
Air bleeding for boom, arm, dump and bucket cylinder Raise
Extend
Tilt-in
1 1 Start the engine. Open
CAUTION!
Be sure that nobody other than the operator is in or on Close Retract Lower
the hydraulic excavator. Tilt-out
2 Idle the engine sufficiently to release the air in the

hydraulic system. Fig. 32
3 Check for unusual vibration or noise.

4 Operate each cylinder a few times to bleed the air
in the hydraulic system, according to the following
procedure.
Note:
The engine speed should be kept as low as
possible.
PROCEDURE
Action
1 Start the engine.
Note:
Run the engine at low speed.
2 Move each cylinder back and forth five times

using the lever movement shown in the illustration
above.
Notes:
i) Avoid moving the cylinder suddenly or quickly,
or the seals may be burnt.
ii) Stop the cylinder 100 mm before the cylinder
rod hits the stroke end during the first four
cycles.
iii) Move the cylinder at full stroke on the fifth cycle.
3 Hold the cylinder at the stroke end for a minute to

apply relief pressure and bleed the air from the
cylinder. Repeat the procedure twice.
4 Stop the engine.
Bleeding Locations & Cylinder Positions for Bleeding Air (Refer to Fig. 33 on next page.)
295
2 Bleeding locations.
CAUTION!
Take all reasonable precautions because this work is to be conducted high above the ground.
1 Set the front-end attachment on the ground as illustrated below.
2 Stop the engine.
CAUTION!
Take care to prevent anybody from starting the engine during the work.
3 Follow the procedures outlined below to release air from the cylinders from each of the bleeders
indicated by .
1) Remove the rubber cap.

2) Loosen the plug.
3) A mixture of air and hydraulic air will escape
from the bleeder.
4) Continue bleeding until only oil escapes.
5) Tighten the plug securely.
6) Replace the rubber cap.
Fig. 33
Detail R
Oil tank
Fig. 34
Detail S
Level check
3 Recheck the oil level in the hydraulic tank.
If the oil level is low, refill the tank.
Fig. 35
296
8-4 Adjustment of track link tension
1 Loosen the track link. Detail A
Note:
The inside of the adjuster cylinder is under high
pressure. Loosening valve a excessively or
suddenly is dangerous, because it may cause the
grease to gush out. Keep your face away from valve
a and loosen the valve little by little. Never loosen
grease fitting b .
Fig. 1
1 Drain out the grease by loosening valve a
gradually, the track link will be loosened.
Detail B
2 Note that valve a needs to be loosened only by 1

to 1.5 turns.
a
3 If the grease is not smoothly drained out, float the
track link to be loosened and slightly rotate it.
4 When the grease is no more drained out from the

b
grease drain hole, tighten valve a to the original
state.
Fig. 2
Tightening torque of M16 valve: 150 N·m
Detail C
Grease outlet
CAUTION
a Never touch valve b
b
Fig. 3
2 Start the engine, move the front attachment and thrust

the bucket tip to the ground.
3 Set the travel lever to forward and travel for about

30 seconds (to send pressure to the adjuster
cylinder). Bucket
driven into
(The actual pressure is sent from the travel right
the ground
forward line.)
Fig. 4
297
4 Tensioning the track link.
1 Swing the upperstructure 90 degrees to float the

track link as shown at right.
Securely support the machine using a block c or
similar material during this work.
2 Use the lubricator (manual) to feed grease to D

adjuster cylinder fitting b inside the side frame.
Fig. 5
The track link will be tensioned. c
3 After feeding grease, race the track link once, and

then measure the amount of tension, L, shown at
Detail D
right.
4 When the correct tension listed below is achieved,

adjust the tension of the right side in the same
way as for the left side.
If L is outside the correct tension, repeat
procedures 2 and 3 .
Fig. 6
Size: 500 mm (L)× 1 000 mm (W) × 1 000 mm (H)
Detail E
(20 in) (40 in) (40 in)
Crawler belt sag (L):

a
465 ~ 535 mm (18 ~ 20 in)
Fig. 7
Detail F
Grease outlet
CAUTION
b
Fig. 8
298
8-5 Final trial operation check
＊ 1 Adjust the track link tension to an appropriate

figure. (See pages 297 and 298, "Adjustment of
track link tension.")
2 Check all functions of the machine. (See pages

361 to 371 "Checks after completing the
assembly.")
3 Recheck the oil level in the hydraulic tank. If the

oil is low, refill the tank through the oil filler port.
Fig. 1
CAUTION!
Before starting the excavator, make sure there is no
person other than the operator in the machine.
Note:
After the above procedures are completed, work at
60% to 70% power for the first 50 hours of
operation, and then begin full-power operation.
Forward Reverse
travel travel
R Swing
Swing
Forward Reverse
travel travel
Fig. 2
Raise
Extend
Tilt-in
Open
Close Lower
Retract
Tilt-out
Fig. 3
299
8-6 Disassembly procedures for shipment
1. Procedure, linkage XF60000379 ••••••••••••••••••••••••••••••••• 301
2. Procedure, bucket XF60000378 ••••••••••••••••••••••••••••••••• 303
300
Detail A
1. Procedure, linkage
Procedure,
Fig. 1
EX2600-6 linkage XF60000379
301
Detail B
2. Procedure, loader bucket
Procedure,
Fig. 2
EX2600-6 loader bucket XF60000378
303
MOUNTING PROCEDURES FOR

BACKHOE FRONT-END ATTACHMENT
ATTACHMENT
8'. Mounting procedures for backhoe front-end attachment
8'-1 Preparation
MOUNTING CHART BACKHOE FRONT
Step 1
Parts required
Fig. 1
PROCEDURE, BOOM (XF60000363)
00 XF10001210 BOOM ASSEMBLY 1

02 4433056 HOSE 13
03 XF10001211 CLAMP ASSEMBLY 2
08 4371893 HOSE 1
09 4292385 O-RING 26
11 4436678 CYL, BOOM 2
13 4357725 HOSE 2
14 4180363 HOSE 2
16 4510170 O-RING 4
17 4510169 O-RING 4
PROCEDURE, ARM (XF60000362)

00 XF10001208 ARM ASSEMBLY 1

02 4386556 HOSE 2
03 4386555 HOSE 2
04 XF10001209 JOINT 2
15 4485894 O-RING 4
16 4487586 O-RING 4
17 4292385 O-RING 4
18 4292384 O-RING 4
PROCEDURE, BUCKET (XF60000380)

00 XF10001290 BUCKET (17m3) 1
307
Step 2 Detail A' Detail A
0 10
Installation of the boom cylinders 50 00
1 1 Place wooden blocks under boom 00 as shown in

Fig. 2. Bracket
800
Boom 00 weight: 24 500 kg (53 900 lb) Fig. 2-a

Size: 1 000 mm (L) × 500 mm (W) × 800 mm (H) Fig. 2-b
(40 in) (20 in) (30 in)
00
Note:
Each wooden block must be able to carry a load of
b a
at least 7 000 kg (15 400 lb).
2 Clean boom foot pin holes a . c
Fig. 2
3 Clean boom top pin holes b .
4 Clean boom cylinder rod pin holes c .
2 Preparation of the boom cylinders. Detail B

11 Wire rope
10 mmø × 3 000 mm
1 Use lever blocks and wire ropes on the rod ends
Wire rope
of boom cylinders 11 so that they do not extend. 10mmø × 6 000 mm
(Figs. 3 and 4)
e
Wire rope: 4 pcs. d
10 mmø × 3 000 mm (L) : 2 pcs.
(0.4 inø) (117 in L)
10 mmø × 6 000 mm (L) : 2 pcs. Lever block
(0.4 inø) (234 in L)
Fig. 3
Lever block: 2 pc. Detail C

for 3 tonne (3.3 US ton) load Wire rope attachment method
Wire rope
2 Clean pin holes d and e in the boom cylinders.
Note: Lever block

In particular, the area surrounding the bearing Fig. 4
308
3 Lifting the boom cylinder. Detail D Hold
1 Attach wire ropes and a lever block to the boom

cylinder as shown in Fig. 5. Wire rope Wire rope
16 mmø × 12 mmø ×
5 000 mm 3 000 mm
Boom cylinder 11 weight: 3 120 kg (6 865 lb)
Wire rope: 3 pcs. Lever block

16 mmø × 5 000 mm (L) : 1 3 ton
(0.65 inø) (195 in L)
12 mmø × 3 000 mm (L) : 1
(0.5 inø) (117 in L)
12 mmø × 5 000 mm (L) : 1 Wire rope
(0.5 inø) (195 in L) 12 mmø ×
5 000 mm
Lever block: 1 pc.

for a 3 tonne (3.3 US ton) load 11
2 Lift the boom cylinder as shown in Fig. 6.

3 Move the boom cylinder to the pin hole a on the
boom. Fig. 5
Hold
11
Fig. 6
309
Hold
4 1 Align the pin holes a and b and insert the pin,
as shown in Fig. 7.
Notes:
i) The pin holes can be aligned by controlling the Lever block
lever block.
ii) Before installing the spacer, make sure that its
chamfered side is aligned facing towards the
cylinder.
iii) Grease the pin before inserting. a b
2 Tighten the pin with 2 bolts, 2 spring washers,

1 plate and 1 spacer.
Note: Fig. 7
Apply lubricant to the bolts before installing. Detail E
Spacer
Pin
Bolt &
Sprig washer
Fig. 8
Hold
5 1 Support the rod side of each boom cylinder using

one lever block and wire rope, as shown in Fig. 10.
Lever block: 2 pcs.

Fig. 9
Wire rope: 2 pcs. Detail F
12 mmø × 3 000 mm(L)
(0.5 inø) (117 in L)
Shackle: 2 pcs. Shackle

for 1.5 tonne (1.65 US ton) load Lever block
1.5 ton
2 Remove the crane wire ropes and chain block

holding the boom cylinder. Wire rope
12 mmø ×
3 000 mm
The second boom cylinder should be installed in

the same manner as described above.
Fig. 10
310
6 1 Connect boom cylinder hoses 13 and 14 .
(both sides)

Socket size: 14 mm

Socket size: 17 mm
Notes:
with other parts. Fig. 11
faces of the hoses.
iv) Do not damage the joining surfaces of the Detail G
hoses.
16 (P/No. 4510170~4 pcs.) and 17 (P/No.
4510169~4 pcs.) before installation. Reuse the
O-ring originally fitted to the hoses.

carefully.
The set of boom cylinder hoses for the opposite

as described above. 14 ~ 2 pccs.
13 ~ 2 pccs.
Fig. 12
311
7 Connect bucket cylinder hoses 02 and 03 (both sides).
02
Tightening torque of M20 socket bolt: 400 N·m 03
Socket size: 17 mm

(hose 03 ) (21 kgf·m/155 lbf·ft) Fig. 13
Socket size: 14 mm
Detail H
Notes:
i) Apply a thin layer of sealant #98D to O-rings 17 03 Out-side
(P/No. 4292385~2 pcs.) and 18 (4292384~2
pcs.)before installation. 02 In-side
ii) Make sure the no dust has adhered to the seat
faces of the hoses.
iii) Be careful not to damage the joining surfaces.
Fig. 14
312
8 1 Installing the air-release parts.
Arm cylinder
CAUTION:
After connecting the hoses, install the pressure-release
parts described on pages 14 to 16. These parts must
be installed since this area will be highly pressurized.
Use them to release the pressure during installation,
ensuring safe operation.
2 Fix both arm cylinders with wire ropes and a lever

block as shown in Figs. 15 and 16.
Fig. 15
Install pressure-
release parts here.
Detail I
Wire rope
Wire rope: 4 pcs.
Lever block
10 mmø × 5 000 mm (L)
(0.4 inø) (195 in L)
Lever block: 2 pcs.

Wire rope
CAUTION:
Securing this wire rope and lever block in place
prevents the cylinder rods from being stretched. Be
sure to secure them, otherwise the cylinder may be
stretched suddenly, causing a serious accident.
Fig. 16
Note:
The lever block secures the arm cylinders and
prevents the cylinder rod from extending during the
work.
313
Step 3
Preparation of the arm

00
1 Place wooden blocks under arm 00 as shown in Fig. 17.
Arm 00 weight: 16 100 kg (35 420 lb)

Size: 1 000 mm (L) × 500 mm (W) × 500 mm (H) Wooden
(40 in) (20 in) (20 in) block
Note:
Fig. 17
Each wooden block must be able to carry a load of
at least 5 000 kg (11 000 lb).
2 1 Remove pins a , b and c from the arm.

a
b
2 Clean pin holes and pins a , b and c .
Fig. 18
Bucket cylinder
3 Fix both bucket cylinders with wire ropes and a lever

block as shown in Figs. 19 and 20.
Wire rope: 4 pcs.

10 mmø × 5 000 mm (L)
(0.4 inø) (195 in L)
Lever block: 2 pcs.

Fig. 19
CAUTION: Detail J
Securing this wire rope and lever block in place Wire rope
Lever block
prevents the cylinder rods from being stretched. Be
sure to secure them, otherwise the cylinder may be Wire rope
stretched suddenly, causing a serious accident.
Note:
The lever block secures the bucket cylinders and
prevents the cylinder rod from extending during the
work.
Fig. 20
314
Step 4 c
b
Preparation of the bucket
1 1 Position bucket 00 .
2 Remove the 2 cover a , as shown in Fig. 22. 00
3 Extract pins b from the bucket.
4 Clean pin holes c and pins b .
Fig. 21
View K
00
Pin b
Cover a
Fig. 22
View L
2 Set link pin b and bucket pin d , removed from the

Pin d
arm end as outlined on the previous page, as shown in
Fig. 23.
Pin b
Fig. 23
View M
Apply grease
f
3 Apply grease to bucket pin holes e and f and the e
connecting surfaces of the arm end (a total of 8 Apply grease
locations).
Fig. 24
315
316
8'-2 Mounting of boom Detail A
a
Step 1
a
Mounting of the boom
1 1 Clean the anticorrosive off the pins inserted into

the boom-joint section of the main frame.
2 Extract the 2 pins a from the main frame.
3 Apply grease to the pin holes.
Main Frame
Fig. 1
A
Hold
The total length of one

wire rope can be changed Wire rope
Wire rope
by adjusting the length at 36 mmø × 28 mmø × 3 000 mm
A. 12 000 mm
Wire rope
28 mmø ×
10 000 mm
Chain block
20 tonne
Fig. 2-a
2 1 Clean boom pin holes b . Wire rope
28 mmø ×
2 Put shackles on the eye-plate provided on the 3 000 mm
boom 00 , and attach wire ropes, shackles and a Shackle
chain block as illustrated in Fig. 2. Shackle
Eye plate
Loader boom 00 weight: 30 740 kg

(67 630 lb) Eye plate
Wire rope: 4 pcs.

28 mmø × 10 000 mm (L) : 1 pc.
(1.1 inø) (390 in)
28 mmø × 3 000 mm (L) : 2 pcs.
b
(1.1 inø) (117 in)
36 mmø × 12 000 mm (L) : 1 pc. 00
(1.4 inø) (468 in)
Shackle: 3 pcs.
Lift Fig. 2
b
Chain block: 1 pc.
3 Lift with a crane as shown in Fig. 3.
Note:
Level the boom by adjusting the preset chain blocks
b
and wire ropes (36 mmø).
CAUTION!
boom.
4 Lift the boom so that pin holes b remain

horizontal.
Fig. 3
317
3 Move the boom to the pin holes a in the main frame.
Lift & move
Notes:
i) When moving the front attachment, be careful Cab
that it does not touch the cab.
ii) In interests of safety, a rope can be attached to
the section indicated by ★ in order to guide it to b a
the boom.
★
Rope: 1 pc.
10 mmø × 5 000 mm (L)
(0.4 inø) (195 in L)
Rope
10 mmø × 5 000 mm
Fig. 4
Lift
4 1 Align the pin holes a and b in order to insert the
pins.
2 Grease the pins before inserting.
Notes: B
i) The height to the arm end should be about
3 000 mm (117 in). b
a
ii) Align the left pin holes first, then the right pin
holes. The right holes should align easily.
Perform the alignment with use of the chain
block.
3 000 mm
(117 in)
3 Tighten the pins with a total of 4 bolts, 4 spring
washers and 2 plates. Fig. 5
Notes:
i) A shim is attached to the pin on the base
machine. Insert this shim as it is.
ii) Apply lubricant to the bolts before installation.
Section B
Plate

Bolt &
Width across flats: 36 mm Spring washer
Pin
Shim Fig. 6
318
5 1 Place 1 wooden block a , about 200 mm (8 in) in
height, on the ground to support the boom top.
Lower
Wooden block : 1 pc.
Size: 2 600 mm (L) × 300 mm (W) × 200 mm (H)
(100 in) (12 in) (8 in)
2 Lower the front so that the arm top rests on the

wooden block.
Fig. 7
Wooden
200 mm (8 in) block a
Remove the crane wire ropes

and chain blocks
6 Remove the crane wire ropes and chain blocks used to
lift the boom assembly.
Fig. 8
319
Step 2
Connection of the hoses to base machine and boom (1)

Detail C
Note: Hoses 02
Do not connect the 4 hoses for the bucket when

connecting hoses between the base machine and
Boom side
boom. If the bucket hoses are connected at this
point, operating the levers will cause oil to escape
from the bucket circuit.

2 Remove the blind covers from the pipe ends
on the base machine and boom. Base machine side
Fig. 9
Detail D Detail E
02
02
Connected in
a later step. Connected in
Fig. 10 a later step. Fig. 11
Boom side Base machine side

machine and boom.

Socket size: 17 mm
Notes:
i) When connecting the hoses, do not twist them,
or their service life will be shortened.
with other parts.
faces of the hoses.
the hoses.
v) Apply a thin layer of sealant #98D to O-rings 09
(P/No. 4292385~18 pcs.) before installation.
2 After the oil has drained from the hoses, clean all
surrounding parts carefully.
320
Step 3
Installation of the boom cylinder to base machine
1 1 Extract the pin from location a indicated by

(both sides). a
2 Carefully clean pin holes a and b .
3 Cut the wires used to fasten the boom
cylinders at the time of shipping.
4 Remove the lever block fitted to prevent
the boom cylinder rod from extending. b
Fig. 12
2 1 Lower the boom cylinder slowly with a lever block

until the pin hole of the boom cylinder rod aligns
with a on the main frame.
2 Start the engine and extend the rod end of the

boom cylinder.
Lever block
a Fig. 13
Note:
Operate the boom cylinder carefully, an inch at a
time, when aligning the pin holes.
3 Align pin holes a and b .
Lever block
b
a Fig. 14
Fig. 15
321
3 1 Align pin holes a and b and insert the pins.
Note:
Grease each pin before inserting. a
b
2 Secure the pin with 2 bolts, 2 spring washers and

1 plate. Fig. 16
Note:

a b
Fig. 17
Section F
Plate
Bolt &
Spring washer
Pin Fig. 18
4 Perform the same work on the opposite side.
322
Step 4
Connection of the grease hoses
1 1 Connect hoses a and b to the boom cylinder

rod pins (see Fig. 20).
Notes:
ii) Connect the hoses so as not to make contact
with other parts.
Fig. 19
faces of the hoses.
the hoses.
Detail G
2 After the grease has drained from the hoses,

clean all surrounding parts carefully.
2 1 Connect grease hose 08 ( c and d )

between the base machine and boom. a b
Fig. 20
Notes:
i) When connecting the hose, do not twist it, or its
ii) Connect the hose so as not to make contact with
other parts.
faces of the hose.
the hose.
2 After the grease has drained from the hose,

Fig. 21
Detail H
Detail I
d c
08
c Boom
08
Fig. 22
Fig. 23
323
3 1 Remove the lever block used to fix the arm Detail J Wire rope
cylinders in "Step 2- 8 " on page 313. Lever block
2 Cut wire a used to fasten the arm cylinder at the

time of shipping (see Fig. 24). Wire rope
a Wire
Fig. 24
324
Step 5
Greasing (2)
Detail K

procedure. a
1 Manual lubrication procedure: b

1 Connect coupler b to hose a .
(manual) position.
Fig. 25
3 Hold grease gun d and pull the hose out from
hose reel e .
4 Stop pulling the hose when it has been pulled out Detail L
lubricated, and pull the trigger. Grease will be
c
IMPORTANT:
Set the engine to run at neutral or higher speed
during lubrication with the lubrication device. Fig. 26
2 Start the engine.

Detail M
3 Supply grease to the 2 locations f and g shown in
Figs. 28 and 29.
e
CAUTION!
i) Increase the engine speed to higher than neutral d
lubricate the front pins. Fig. 27
iii) Insufficient lubrication may cause the pins to wear.
Sufficiently lubricate the necessary locations.
Detail N
f g
Fig. 28 Fig. 29
325
4 Supply grease to the 6 locations a shown in Figs. 30,
31 and 31-a.
CAUTION!
Sufficiently lubricate the necessary locations. Detail O
Detail P
Fig. 30
Fig. 31
BOOM FOOT (L)

ARM CYL. BOTTOM (L)
BOOM CYL. BOTTOM (L)
BOOM CYL. BOTTOM (R)
ARM CYL. BOTTOM (R)
BOOM FOOT (R) Fig. 31-a
326
Step 6
Raise
Air bleeding of the boom and arm cylinders
Boom cylinder
CAUTION:
Before starting the engine, make sure that no person
Lower
other than the operator is in the hydraulic excavator.
2 Let the engine idle to sufficiently release the air in

the hydraulic circuit.
3 Check for unusual vibration or noise. Fig. 32
4 Operate each cylinder a few times to bleed the air Arm cylinder
from the hydraulic circuit. Follow the procedure
t
below. ou
oll-
R
in
ll-
Note: Ro
Reduce the engine speed as low as
possible during the bleeding procedure.
Procedure:
Fig. 33
Order of items
1 Move boom and arm cylinder back and forth five

times as shown in Figs. 32 and Fig. 33.
Notes:
i) Avoid moving the cylinders suddenly or quickly,
as it can cause the seals to burn.
ii) Stop the cylinder 100 mm before the cylinder rod
hits the stroke end, for the first four times.
iii) Move the cylinder in full stroke on the fifth
repitition.

cylinder. Repeat this procedure twice.
3 Stop the engine.
Breather Locations & Cylinder Positions for Bleeding Air (Refer to Fig. 27 on page 346.)
Detail Q
2 Recheck the oil level in the hydraulic tank. If there is
insufficient oil, refill the tank through the oil filter port.
Level check
Fig. 34
327
328
8'-3 Installation of arm
Step 1
Installation of the arm a
1 1 Clean pin holes a , b and c .
3 020 mm
2 Apply grease to pin holes a , b and c . (118 in)
3 Raise the boom top about 3 020 mm (118 in) b

above the ground. Fig. 1
c
2 Set two sets of scaffolding about 2 500 mm (98 in) in

height on either side of the boom top.
Scaffolding: 2 sets, 2 500 mm (98 in) high

Scaffolding
2 500 mm
3 Put shackles on the eye-plates provided for lifting arm (98 in)
00 , and attach chain blocks and wire ropes to the
shackles as shown in Fig. 3.
Fig. 2
Arm 00 weight: 16 100 kg (35 420 lb) Detail A
Wire rope
Wire rope: 4 pcs. 24 mmø × 2 000 mm
38 mmø × 6 000 mm (L) : 1 pc.
(1.5 inø) (234 in L) Chain block 10 t
24 mmø × 2 000 mm (L) : 2 pcs. Wire rope
38 mmø × 6 000 mm
(0.95 inø) (78 in L) Wire rope
24 mmø × 2 000 mm
Shackle
Chain block: 1 pc.
for 10 tonne (11 US ton) load 00
Shackle: 2 pcs.
Fig. 3
4 1 Lift the arm, keeping pin holes c horizontal.
Note: Lift & move
Level the arm by adjusting the preset chain blocks.
CAUTION:
arm.
2 Move the arm to the pin holes a on the boom.
c a
Fig. 4
329
5 1 Align the centers of pin holes a and b , and Hold
insert the pins.
Notes:
i) Use the scaffolding when aligning pin holes a
and b .
ii) All following work involving parts a and b
should be done using the scaffolding.
CAUTION: a b
Be especially aware of safety measures as the work is Scaffolding
done at a height.
Fig. 5
2 Install the arm joint pins, as shown in Fig. 6.

Section B
Bolt &
Note: Spring Washer
Grease each pin before inserting.
Pin
Plate
Fig. 6
3 Tighten the 2 plates with 8 bolts and 8 spring

washers.
Note:
Apply lubricant to the bolts before installing.
Lower
Wooden block
6 1 Place a wooden block on the ground underneath
the arm top. Fig. 7
200 mm (8 in)
2 Simultaneously lower the crane and boom so that

the arm top rests on the wooden block.
Remove the wire ropes
Wooden block: 1 pc. and chain blocks.
Size: 2 600 mm (L) × 300 mm (W) × 200 mm (H)
(100 in) (12 in) (8 in)
3 Remove the wire ropes and chain blocks used to

lift the arm.
Fig. 8
330
Step 2 Detail C Lift
Installation of the arm cylinders
Arm cylinder Lift
1 Secure the arm cylinders with the 2 cranes.
Wire rope: 2 pcs.

20 mmø × 5 000 mm (L) Arm cylinder
(0.8 inø) (195 in L)
Fig. 9
2 Marginally lift the arm cylinders with the crane.
b
3 Install the 2 arm cylinders, one at a time.
1 Lift the arm cylinders a little further so that the

center of the pin hole of the arm cylinder rod and
that of the arm bracket, indicated by a and b a
respectively, are aligned.
2 Extend the arm cylinder rod slowly in the direction

of the arrow .
3 Align the center of the pin holes of the arm

cylinder rod and the arm bracket, a and b Fig. 10
respectively.
Hold
4 Align the pin holes a and b in order to insert the
pins. Arm
cylinder
Lower
5 Grease the pin and insert.
Notes: b
i) Place 2 spacers at the eye end of the cylinder
rod of the arm cylinder (see Fig. 12).
ii) If there is a gap between the cylinder rod and
a
arm, insert shim(s).
Section D
Pin
Bolt & Fig. 11

Spring
washer
Hold
Hold
Shim
Spacer
Plate
Fig. 12
a b
6 Tighten the 2 pins with 4 bolts, 4 spring washers,
2 plates and spacers.
Note:
Apply lubricant to the bolts before tightening.

(71 kgf·m/516 lbf·ft) D
4 Install the second arm cylinder in the same manner.

Fig. 13
331
Detail E
CAUTION:
Perform operation after releasing the high pressure
from the pressure-release parts that have been
installed as outlined on page 313.
5 1 Connect hydraulic hoses 02 and 03 from the

bucket cylinder to a (see Fig. 14).
(both sides) 02 a
03
Socket size: 17 mm
Fig. 14
Socket size: 14 mm
Notes:
ii) Connect the hoses so as not to contact other
parts.
faces of the hoses.
the hoses.
v) Apply grease to O-rings 17 (P/No. 4292385~2
pcs.) and 18 (P/No. 4292384~2 pcs.) just before
installation. Replace the O-rings attached to the
hoses prior to shipment.
Fig. 15
The hoses for the second bucket cylinder should

be connected in the same manner as above.

332
Step 3
Connection of the hoses to base machine and boom (2)
Note:
The 4 bucket hoses not installed on page 320 are
installed in this step.
Note:
Use O-rings 09 , split flanges, and socket bolts to
connect the hoses on the base machine side.
2 Remove the blind covers from the pipe ends on
the base machine and boom. Detail G
Detail F
02
02 02 Fig. 17
02 Base machine side
Fig. 16
Boom side

machine and boom.
02
Tightening torque of M20 socket belt: 400 N·m Boom side

Socket size: 17 mm
Notes:
i) When connecting the hoses, do not twist then, or
02
Base machine side
with other parts.
Fig. 18
faces of the hoses. Detail H
iv) Be careful not to damage the joining surfaces of Bolt 12mm
the hoses.
v) Apply a thin layer of sealant #98D to O-rings 09
(P/No. 4292385~8 pcs.) before installation.
2 1 Secure 2 clamps 03 (with, bolts, plates, clamps,

and washers connected to it) at the midpoint of
the hoses.
Fig. 19
Tightening torque of M12 lock nut: 90 N·m Detail I
2 After the oil has drained out the hoses, clean all
surrounding parts carefully.
03
03
Fig. 20
333
3 1 Connect grease hoses at location a and b (see
Figs. 21 and 22).
Tightening torque of hose a : 30 N·m

(3 kgf·m/22 lbf·ft) J
Tightening torque of hose b : 180 N·m

Notes:
i) When connecting hoses, do not twist them, or
parts.
Fig. 21
faces of the hoses.

View J
b
a
Fig. 22
334
4 1 Connect grease hoses at location a and b (see
Figs. 23 and 24). K
Notes:
parts.
faces of the hoses.

Fig. 23
View K
Fig. 24
335
5 1 Remove the lever block used to fix the bucket Detail L
cylinders in "Step 3- 3 " on page 314.
Lever block
2 Cut wires a and b used to fasten the bucket
cylinder at the time of shipping (see Fig. 25).
Wire rope
a
b
Wire
Fig. 25
336
Step 4 Detail M
Greasing (3)

Perform lubrication according to the following a
procedure.

1 Place automatic lubrication switch a in the upper Fig. 26
(manual) position.
2 Hold grease gun c and pull the hose out from Detail N
hose reel b .
securing the hose in place. b
4 Connect grease gun c to the grease fitting to be
lubricated, and pull the trigger. Grease will be c
Fig. 27
IMPORTANT:
Set the engine to run at neutral or higher speed Detail O
during lubrication with the lubrication device.
2 Start the engine.
3 Supply grease to the 4 locations d shown in Figs. 28,

29 and 29-a.
CAUTION!
lubricate the front pins. Fig. 28
Sufficiently lubricate the necessary locations. Detail P
ARM CYL. ROD (L)

BOOM-ARM JOINT (L)
BOOM-ARM JOINT (R)
ARM CYL. ROD (R) Fig. 29-a
Fig. 29
337
Step 5
Air bleeding of the arm and bucket cylinders Roll out Roll in
1 1 Start the engine. Roll out
Roll in
CAUTION:
Make sure that no person other than the operator is in
the hydraulic excavator during the work.

hydraulic circuit.
3 Check for abnormal vibration or noise.
Fig. 30
from the hydraulic circuit. Follow the procedure
below.
Note:
Reduce the engine speed as low as possible
during the bleeding procedure.
Procedure:
Order of items
1 Move arm cylinder back and forth five times as

shown in Fig. 30.
Notes:
iii) Move the cylinder at full stroke on the fifth
repitition.

3 Stop the engine.
Bleeding Locations & Cylinder Positions for Bleeding Air (Refer to Fig. 27 on page 346.)
Detail Q
2 Recheck the oil level in the hydraulic tank.
If there is insufficient oil, refill the tank through the oil
filler port.
Level check
Fig. 31
338
8'-4 Mounting of bucket
Step 1
b
Mounting of the bucket
c
1 1 Clean pins and pin holes a , b , c and d . d
2 Apply grease to pins and pin holes a , b , c and a

d.
Fig. 1
Detail A Hold
2 1 Put shackles on the eye-plate provided on the Wire rope

bucket 00 , and attach wire ropes and a chain 24 mmø × 8 000 mm
Wire rope
block as illustrated in Fig. 2. 24 mmø × 2 000 mm
2 Lift the bucket as illustrated in Figs. 2 and 3. Chain block

10 tonne
Bucket 00 weight: 15 600 kg Wire rope

(34 320 lb) 24 mmø × 2 000 mm
d c
Wire rope: 3 pcs.
24 mmø × 2 000 mm (L) : 2 pcs.
(0.95 inø) (78 in) Shackle
24 mmø × 8 000 mm (L) : 1 pc.
(0.95 inø) (312 in)
Chain block: 1 pc.

00
Fig. 2
Shackle: 2 pcs.
Lift
Arm
3 Raise the arm top 3 500 mm (136 in) above the c

ground.
150° ~ 160°
3 500 mm
(136 in)
Fig. 3
4 Lift the bucket so that the pin holes c become Lift & move
level with a .
Note: c
Level the bucket by adjusting the preset chain
blocks.
CAUTION!
Never allow anybody to stand directly beneath the lifted a
bucket.
5 Move the bucket to pin hole a .
Fig. 4
339
Hold
3 1 Align the centers of pin holes a and c and insert
the pins.
Note:
Grease the pins before inserting.
a
2 Tighten the 2 covers with 24 bolts and 24 spring
c
washers. (both sides)
Note:

B
Width across flats: 19 mm Fig. 5
3 After inserting the pins, position 4 O-rings 15 in

the groove and tighten their nuts. Section B
Tightening torque:
Cover Pin
Width across flats: 8 mm Bolt &
Spring
Section C washer
15
O-ring 15
Note: Fig. 6
Carefully seat 4 O-rings 15
Fig. 7
on the boss arm and bucket
as shown in Figs. 7 and 7-a.
Remove wire ropes
Note:
20 mm for usage.
(Bolt size: M5)
Lower
☆ 10 ~ 20 Slit ☆ 10 ~ 20
Double nut Double nut
15
Assemble so that no Fig. 8
4 1 Use the crane to lower the bucket so that the

bottom almost rests on the ground.
2 Remove the wire ropes and chain blocks used to 120° to 140°
lift the bucket.
5 Set the arm at 120° to 140°.
Fig. 9
340
6 Install of the link and bucket.
1 Extend the bucket cylinder in the direction of

arrow to align the centers of the link pin
hole a and the bucket pin hole b , as shown
in Figs. 11 and 12.
2 Align the centers of the pin holes of the link and

bucket. Fig. 10
3 Grease the pins and insert.

Detail D Detail E
4 To prevent the 2 pins from coming out, secure Bucket cylinder

them with 2 stoppers, 8 bolts and 8 spring
washers (see Fig. 14).
Note:
Apply lubricant to the bolts before tightening.

(21 kgf·m/155 lbf·ft) a
b
5 After inserting the pins, position 4 O-rings 16 a
in the groove and tighten their nuts. b
Tightening torque:
Width across flats: 8 mm Fig. 11 Fig. 12
Note:
Carefully seat 4 O-rings 16 on the boss arm and
bucket as shown in Figs. 15 and 15-a.
Note:
20 mm for usage.
(Bolt size: M5)
F
☆ 10 ~ 20 Slit ☆ 10 ~ 20
Double nut Double nut Fig. 13
16
Assemble so that no Section F
Pin
Bolt &
Spring
Section G washer
16
16 O-ring
Fig. 14
Fig. 15
341
7 1 Install joints 04 in the bucket boss side.
2 Connect grease hoses at location a and b (see
Fig. 17).

H
Notes:
parts.
iii) Make sure that no dust has adhered to the seat Fig. 16
faces of the hoses.
Detail H
b Joint 04
Fig. 17
〔OPTION PARTS〕
Detail I
4 Install guard 00 with bolt 01 and to the bucket
boss side.

00
01
Fig. 18
342
Step 2 Detail J
Greasing (4)

procedure. a

1 Place automatic lubrication switch a in the upper
(manual) position.
2 Hold grease gun c and pull the hose out from the Fig. 19
hose reel b .
Detail K
4 Connect grease gun c to the grease fitting to be
b
c
IMPORTANT:
Fig. 20
Set the engine to run at neutral or higher speed
during lubrication with the lubrication device.
ARM-LINK B (L)
ARM TOP PIN (L)
ARM TOP PIN (R)
ARM-LINK B (R)
Fig. 21-a
2 Start the engine.
3 1 Supply grease to the 4 locations and d shown in

Figs. 21 and 21-a.
2 Supply grease to the 12 locations and e , f and Fig. 21
g shown in Fig. 22.
Detail L
Notes:
e
f
wear. Sufficiently lubricate the necessary g
locations.
Fig. 22
343
4 After completing the lubrication Detail M
1 Slightly pull the hose out from the hose reel a .
automatically withdrawn back onto hose reel a .
2 Remove coupler d from hose c . a
IMPORTANT:
Before storing, make sure to release any residual air in Fig. 23
the hose reel by use of the grease gun b . This will
prevent damage being done to the pump. Detail N
Note:
Leaving the device in a state of manual lubrication
will cause the automatic lubrication warning lamp
c
on the cab instrument panel to light up.
d
Fig. 24
Detail O
5 After the grease has drained out clean the parts

carefully.
6 Check that all the bolts on the loader front attachment

are tightened to the indicated torques.
Fig. 25
344
Step 3
Air bleeding of the bucket cylinder
CAUTION:
Roll-out
Before starting, make sure that no person other than
Roll-in
the operator is in the hydraulic excavator.

Fig. 26
hydraulic circuit.
3 Check for unusual vibration or noise.

from the hydraulic circuit according to the
following procedure.
Note:
Reduce the engine speed as low as possible
during the bleeding procedure.
Procedure:
Order of items
1 Move bucket cylinder back and forth five times as

shown in Fig. 26.
Notes:
iii) Move the cylinder at full stroke on the fifth
repitition.

3 Stop the engine.
Breather Locations & Cylinder Positions for Bleeding Air (Refer to Fig. 27 on page 346)
345
2 Bleeding locations for bleeding air from the cylinders
CAUTION:
As this work is to be conducted at a height, take due safety precautions.
1 Set the front-end attachment on the ground in the position illustrated below (Fig. 27).
2 Stop the engine.
CAUTION:
Take care to prevent anybody from starting the engine during the work.
3 Following the procedure outlined below, release the air from the cylinders through the bleeding locations indicated
by in Fig. 27.
1) Remove the rubber cap.
2) Loosen the plug.
3) Air and hydraulic oil will escape together.
4) Continue bleeding until only oil escapes.
5) Tighten the plug securely to its original position.
6) Replace the rubber cap.
Arm cyl.
Arm cyl.
Bucket cyl.
Bucket cyl.
Boom cyl.
Boom cyl.
Fig. 27
Detail P
Level check
3 Recheck the oil level in the hydraulic tank. If there is

insufficient oil, refill the tank through the oil filler port.
Position the front-end attachment as illustrated in Fig. Fig. 28
29 when checking the oil level.
Fig. 29
346
8'-5 Adjustment of track link tension
1 Loosen the track link. Detail A
Note:
The inside of the adjuster cylinder is under high
pressure. Loosening valve a excessively or
suddenly is dangerous, because it may cause the
grease to gush out. Keep your face away from valve
a and loosen the valve little by little. Never loosen
grease fitting b .
Fig. 1
1 Drain out the grease by loosening valve a
gradually, the track link will be loosened.
Detail B
2 Note that valve a needs to be loosened only by 1

to 1.5 turns.
a
3 If the grease is not smoothly drained out, float the
track link to be loosened and slightly rotate it.
4 When the grease is no more drained out from the

grease drain hole, tighten valve a to the original b
state.
Fig. 2
Tightening torque of M16 valve: 150 N·m
(15 kgf·m/111 lbf·ft) Detail C
Grease outlet
CAUTION
Fig. 3
2 Start the engine, move the front attachment and thrust

the bucket tip to the ground.
3 Set the travel lever to forward and travel for about 30

seconds (to send pressure to the adjuster cylinder).
(The actual pressure is sent from the travel right
forward line.)
Drive the
bucket into
the ground
Fig. 4
347
4 Tensioning the track link.
1 Swing the upperstructure 90 degrees to float the

track link as shown at right.
Securely support the machine using a block c or
similar material during this work.
2 Use the lubricator (manual) to feed grease to

90° ~ 110°
adjuster cylinder fitting b inside the side frame.
The track link will be tensioned.
D
3 After feeding grease, race the track link once, and
then measure the amount of tension, L, shown at
Fig. 5
right. c
4 When the correct tension listed below is achieved, View D

adjust the tension of the right side in the same
way as for the left side.
If L is outside the correct tension, repeat
procedures 2 and 3 .

Size: 500 mm (L)× 1 000 mm (W) × 1 000 mm (H) L
(20 in) (40 in) (40 in) Fig. 6
Crawler belt sag (L):

Detail E
465 ~ 535 mm (18 ~ 20 in)
Fig. 7
Detail F
Grease outlet
CAUTION
Fig. 8
348
8'-6 Final trial operation check
＊ 1 Adjust the track link tension appropriately. (See

pages 347 and 348 "Adjustment of track link
tension".)
2 Check all functions of the machine. (See "Checks

after completing the assembly")
3 Recheck the oil level in the hydraulic tank. If there

is insufficient oil, refill the tank through the oil filler
port.
Fig. 1
CAUTION:
Before starting, make sure there is no person other
than the operator in the hydraulic excavator.
Note:
After the above procedures 1 and 2 are
completed, carry out work at 60% to 70% of full
power for the first 50 operating hours, before
commencing full-power operation.
Forward Reverse
travel travel
R Swing
Swing
Forward Reverse
travel travel
Fig. 2
Raise
Roll-out
Roll-out Roll-in
Lower
Roll-in
Fig. 3
349
350
8'-7 Assembly of option parts
Detail A
＊ Guard option (9229325)
1 Parts reguired
Item Part No. Part name Q'ty
00 8085125 Guard 2
01 J271235 Bolt, aems 8
2 Install guard 00 with bolt sems 02 to the bucket

boss side.
00
01
Fig. 1
351
8'-8 Disassembly procedures for shipment
1. Procedure, boom XF60000363 ••••••••••••••••••••••••••••••••• 353
2. Procedure, arm XF60000362 ••••••••••••••••••••••••••••••••• 355
3. Procedure, bucket XF60000380 ••••••••••••••••••••••••••••••••• 357
352
Detail A
1. Procedure, boom
Fig. 1
EX2600-6 Procedure, boom XF60000363
353
Detail B
2. Procedure, arm
Fig. 2
EX2600-6 Procedure, arm XF60000362
355
Detail C
3. Procedure, Bucket
Fig. 3
EX2600-6 Procedure, Bucket XF60000380
357
CHECKS
&
PERFORMANCE STANDARDS
CHECKING
9. Checks after completing the assembly
1 After assembly, clean and wipe each part

thoroughly with a rag.
2 Inspect the excavator before starting

the engine. Swing Reduction Device
Check Oil Level
Hydraulic Oil tank

Check Oil Level
Transmission
Fuel Tank
Check Oil Level
Check Fuel Level
Final Drive
Check Oil Level Engine
(Both sides) Check Oil Level
Fig. 1
Radiator
Check Coolant Level
Checks after completing the assembly
1 Electrical system
Check for worn or frayed wires and loose
connections.
2 Boom, bucket, arm, frame, and tracks
Check for deformed, broken, or missing parts.
3 Hardware
Check for loose or missing parts.
4 Hydraulic system
Check for leaks, kinked hoses and lines, or hoses
that rub against each other or other parts.
5 Lubrication
Check the lubrication points listed in the
Operation Manual.
6 Protective devices
Check guards and fenders.
7 Check that the parts are correctly reassembled.
8 Apply touch-up paint if necessary, after
completing assembly. Fig. 2
361
3 Check the instruments immediately after starting the
engine.
Detail A
IMPORTANT: MONITOR
DISPLAY
If a gauge does not operate correctly as shown below,
STOP THE ENGINE IMMEDIATELY and take all
necessary measures.
1- Model Name
2- Hydraulic Oil Temperature Gauge
3- Front Type
4- Coolant Temperature Gauge
5- Control Lever Pattern
6- Tachometer
7- Hour Meter
8- Engine Oil Pressure Gauge
9- Engine Oil Temperature Gauge Fig. 3
10- Clock
11- Battery Voltage Gauge
12- Fuel Gauge
Detail B
13- Ambient Temperature
14- Alternator Indicator
15- Engine Stop Indicator
16- Coolant Overheat Indicator
17- Exhaust Temperature Indicator
18- Fuel Temperature Indicator
19- Engine Warning Indicator
20- Prelub Indicator
21- Hydraulic Oil Level Indicator
22- Auto-Lubrication Indicator
23- Hydraulic Oil Overheat Indicator
24- Stairway Position Indicator
25- Fast Filling Indicator
26- Tension Indicator
27- Auto-Idle Indicator
28- Travel Mode Indicator
29- Electric Lever Indicator
30- Emergency Engine Stop Indicator Fig. 4
31- Electlical Equipment Box Indicator

32- Pump Contamination Indicator
Detail C
33- Stop Valve Indicator
34- Air Cleaner Restriction Indicator
35- Engine Over Run Indicator
36- Coolant Level Indicator
37- Engine Oil Pressure Indicator
38- Pump Transmission Oil Level Indicator
Fig. 5
362
4 Measurement of engine revolutions
Detail D
Determination
Standard
Item for new
machine
Low-speed idling 780 ± 50

Engine
revolutions Auto idling 1400 ± 50
(rpm)
High-speed idling 1950 ± 50
Fig. 6
Detail E
Fig. 7
363
NOTES
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364
10. Checking machine performance
The figures and tolerances listed below are for new machines.
The measurements should be performed under the following Note:
conditions: Measure each actuator speed after sufficiently operating
･Engine speed: Maximum the machine.
･Hydraulic oil temperature: 50° ± 5°C
･Site: Firm level ground
TRAVEL SPEED (20M TEST RUN)
1 Preparation
Fig. 1 Fig. 2
2 Measurement
Bring machine to rest Test run 20 m Preliminary run Machine at rest Fig. 3
over (65.6 ft) 7~9m
7~9m (23 ~ 30 ft)
(23 ~ 30 ft)
3 Determination
Unit: sec
Item Standard
20m(Low) 45 ± 2
20m(High) 31 ± 2
365
TRACK LINK SPEED FOR 3 FULL TURNS
1 Preparation
90° ~ 110°
90° ~ 110°
Fig. 4 Fig. 5
1 Mark any one of the track shoes on the side where this test is
to be performed.
2 Jack up the track to be tested. (Fig. 10-4 and Fig. 10-5)
2 Measurement
1 Accelerate the engine to maximum speed. Fig. 6
2 Measure the time required to make three full
turns.
3 Repeat this test for both tracks in the forward and
reverse directions.
3 Determination
Unit: sec.
Item Standard
Track link speed/

109 ± 5
Forward 3 rev. (Low)
speed
Track link speed/
77 ± 4
3 rev. (High)
Track link speed/

109 ± 5
3 rev. (Low)
Reverse
speed Track link speed/
3 rev. (High) 77 ± 4
366
SWING SPEED FOR 3 TURNS
1 Preparation
Fig. 7 Fig. 8
2 Measurement
1 Set the swing control lever to full stroke.
2 Measure the time required for three full turns at a
constant speed.
Three full turns
Fig. 9
3 Determination
Unit: sec.
Item Standard
Swing speed/3 rev. R 44 ± 5
Swing speed/3 rev. L 44 ± 5
367
AMOUNT OF COAST DURING SWING
1 Preparation
Fig. 10 Fig. 11
1 The arm cylinder should be fully retracted.

2 The bucket cylinder should be fully extended.
3 Place an aligning mark between the swing frame
and the track frame.
4 Swing the superstructure so that the swing frame
is at 90° to the track frame.
2 Measurement
1 Set the swing control lever to full stroke.
Amount of coasting
2 At 180°, return the lever to the neutral position.
3 Measure the amount of coasting.
Swing stop
180° swing
Fig. 12
3 Determination
Unit: mm (in)
Item Standard
Less than
R
Amount of 740 (29.13)
coast
Less than
L
740 (29.13)
368
CYLINDER SPEED (Loader front)
1 Action
Boom cylinder
Fig. 13
Level luffing
Arm cylinder
Fig. 14
Dump cylinder
Bucket cylinder
Fig. 15 Fig. 16
2 Repeat the time measurement at least 3 times for each
item and record the average time.
Note:
For machines with a bucket tilt controller (an option) ,
be sure to turn the bucket control switch to OFF when
measuring the boom raise speed.
3 Determination
Unit: sec.
Item Loader Front
Raise 8.2 ± 0.7

Boom cylinder
Lower 5.0 ± 0.5
Retract 3.4 ± 0.5

Arm cylinder
Extend 4.2 ± 0.5
Tilt-in 4.0 ± 0.5

Bucket cylinder
Tilt-out 2.9 ± 0.4
Open 2.1 ± 0.4

Dump cylinder
Close 2.5 ± 0.4
369
CYLINDER SPEED (Backhoe front)
1 Action
Raise
Lower
Fig. 17
Arm Roll-out Arm Roll-in

Fig. 18
Bucket
Roll-out
Bucket
Roll-in Fig. 19
2 Repeat the time measurement at least 3 times for each

item and record the average time.
3 Determination
Unit: sec.
Application 9.0 m Boom
Item Backhoe Front
4.2 m Arm
Raise 7.7 ± 0.7
Boom cylinder 15.0 m3 Bucket
Lower 4.6 ± 0.5
Roll-in 7.1 ± 0.5

Arm cylinder
Roll-out 6.5 ± 0.5
Roll-in 4.4 ± 0.5

Bucket cylinder
Roll-out 3.5 ± 0.5
370
AMOUNT OF HYDRAULIC CYLINDER CREEP
1 Preparation
2 000 mm 2 000 mm
(80 in) (80 in)
Fig. 20 Fig. 21
With a full load in the bucket, set the front-end

attachment as shown above.
2 Measurement Mark Mark

1 Stop the engine.
2 Measure the amount of creep over 5 minutes.
B A
Fig. 22
3 Determination
Unit: mm (in)
Item Loader Front Backhoe Front
A−B = Natural lowering
Boom cylinder, mm/5min Less than 25 (0.97) Less than 30 (1.17)
Arm cylinder, mm/5min Less than 25 (0.97) Less than 60 (2.53)
Bucket cylinder, mm/5min Less than 20 (0.78) Less than 20 (0.78)
＊ Apply touch-up paint if necessary.
Mark
Mark
B
A
Fig. 23
371
NOTES
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372
373
FORWORD
These completed assembly check sheets are intended for use in

checking whether the machine has been assembled correctly and
completely.
All components requiring field assembly are illustrated in
perspective view, so that even an inexperienced serviceman will
be able to verify the assembly procedure easily.
We recommend that you use these check sheets to check all field
assembled sections.
Building up product quality Maintaining machine quality through

at the field assembly stage correct preventive maintenance
374
Report No. 01
COMPLETED ASSEMBLY CHECK

REPORT FOR THE EX2600-6
D / M / Y
Inspection date
Country: Machine Serial No.:

Customer name: Engine Serial No.:
Dealer name:
Inspected by :
Specifications
Front att. Date of Date of
Front att. Capacity Hour meter Inspection
S/No. Delivery
Boom m D/M/Y D/M/Y
□ Loader front Arm m
□ Backhoe front Bucket m3 Hours
(Hitachi use) (Hitachi use)
Type of work □ Mining ( □ Coal □ Coal Overburden □ Gold □ Other )

□ Stone Crushing □ Quarry
□ Civil Engineering Work □ Road Building □ Land Development
□ Pipelaying □ Other
□ Dredging
□ Other
ANY COMMENTS
375
Report No. 02
EX2600-6 ASSEMBLY CHECK SHEET (1/7)

SATISFACTORY
UNSATISFACTORY
CORRECTED
Inspected by:
UNDERCARRIAGE (1/1)
6-2. Connection of track frame and side frames

No. Step Page Checking item Mark
1 1 57 Preparation of the right side frame assembly
2 2 58 Preparation of the track frame assembly
3 3 58 Lifting of the track frame assembly
4 4 59 〜 60 Connecting of the track frame to the right side frame
5 5 61 〜 62 Connecting of the left side frame to the track frame
6 6 63 Removing of the wooden blocks
7 7 64 Tightening procedure for the upper side bolts used to attach the track frame
8 8 65 〜 66 Retightening of the bolts
6-3. Connection of travel motor HOSES and adjuster HOSES

9 1 67 〜 68 Connection of the travel motor hoses
6-4. Assembly of MOTOR COVERS AND STEPS

10 1 69 〜 70 Mounting of the travel motor covers and step
ANY COMMENTS
376
Report No. 03

SATISFACTORY
UNSATISFACTORY
CORRECTED
Inspected by:
SUPERSTRUCTURE (1/4)
7-2. Preparation of undercarriage

1 1 91 Cleaning and finishing
2 2 92 Cleaning of the contact surface
7-3. Preparation of BASE MACHINE

3 1 93 Preparation of the base machine assembly
4 2 93 Cleaning and finishing
5 3 94 Releasing of the swing lock valve
7-4. Connection of undercarriage and BASE MACHINE

6 1 95 Attaching of the wire ropes to the base machine
7 2 96 Connection of the base machine to the undercarriage
8 3 97 〜 98 Mesh the internal gear on the swing bearing with the pinionon on the swing drive
following the procedure below:
9 4 99 〜 100 Mounting the connecting bolts on the undercarriage and base machine
10 5 101 Tightening the connecting bolts on the undercarriage and base machine
11 6 102 Connecting of the grease piping
7-5. Connection of piping to center joint

12 1 103 Installation of the hoses to the center joint
13 2 104 Cleaning of the parts
7-6. Assembly of FUEL TANK

14 1 105 〜 108 Installation of the fuel tank assembly
7-7. Assembly of CAB

15 1 109 〜 111 Installation of the cab bed assembly
16 2 112 Installation of the wiper blade and head lamps on the cab
17 3 113 〜 115 Installation of the cab
ANY COMMENTS
377
Report No. 04

SATISFACTORY
UNSATISFACTORY
CORRECTED
Inspected by:
7-8. Assembly of FENDRERS, STEPS, HANDRAILS, LADDER, BEAM, BOX AND COVERS
18 1 117 Installation of the fender assembly
19 2 118 Installation of the step
20 3 119 Installation of the beam
21 4 120 〜 123 Installation of the box
22 5 124 Installation of the fender
23 6 125 Installation of the fender, step, ladder and handrails
24 7 126 〜 127 Installation of the fenders, handrail, cover and step
7-9. Assembly of engine unit

25 1 135 〜 136 Preparation of the engine unit
26 2 137 〜 138 Installation of the handrails, step and fender
27 3 139 〜 140 Installation of the engine unit
28 4 141 Installation of the step, fenders and cover
29 5 142 Installation of the handrails
30 6 143 Installation of the doors
31 7 147 〜 151 Installation of the step assembly
32 8 152 Installation of the hose reel
7-10. MOUNTING THE COUNTERWEIGHT & INSTALLATION THE RESERVE TANK

33 1 153 〜 155 Mounting of the counterweight
34 2 156 〜 161 Installation of the reserve tank
7-11. ASSEMBLY OF INTAKE UNIT/EXHAUST UNIT AND HEAD LAMPS, MIRROR, WORKING LAMP, ETC.
35 1 165 〜 170 Installation of the intake unit / exhaust unit
36 2 171 Installation of the display
37 3 173 Installation of the head lamps, mirror, switch box and working lamps
38 4 175 〜 176 Greasing (1)
39 5 176 Releasing of the transport-posture for the outside temperature sensor
ANY COMMENTS
378
Report No. 05

SATISFACTORY
UNSATISFACTORY
CORRECTED
Inspected by:
7-12. Connection
1. Connecting the piping (Including some wire harnesses)
40 1 179 Release of air pressure
41 2 180 Connection of the fuel pipe-use coupling and electric wire
42 3 181 Connection of the fuel line hoses
43 4 182 Connection of the suction hoses and transmission drain hoses
44 5-A 183 Connection of the delivery hoses
45 5-B 184 Connection of the delivery hose
46 6-A 185 〜 187 Installation of the pipe assembly/connection of the drain hose and pilot hose
47 6-B 188 〜 189 Connection of the return hoses
48 7 190 Connection of the drain hoses
49 8-A 191 Connection of the stairway hoses and wire harness (1)
50 8-B 192 Connection of the stairway hoses and wire harness (2)
51 9 193 Connection of the fuel filter hoses
52 10 194 Connection of the coolant pipes and quick filling system hoses
53 11-A 195 Connection of the pilot primary pressure delivery hose, air conditioner delivery
hose and pilot delivery hose
54 11-B 196 Connection of the fuel suction hose and oil pan drain hose
2. Connecting the wire harnesses (Including some hoses)

55 1 199 Connection of the air conditioner hoses
56 2 200 Connection of the air conditioner heater hoses, A/C motor drive hoses and A/C
motor drain hoses
57 3 201 Connection of the fuel filter wire harness
58 4-A 202 Connection of the engine electric wires
59 4-B 203 Connection of the electric wire couplers
60 5 204 Connection of the electric wire couplers
61 6 204 Connection the window washer hose
62 7 205 Connection of the electric instrument box wires and ambient temperature sensor
wires
63 8-A 206 Connection of the electric wire couplers
64 8-B 207 Connection of the electric wire
65 9 209 Photographs of wire harnesses connected inside the cab bed
ANY COMMENTS
379
Report No. 06

SATISFACTORY
UNSATISFACTORY
CORRECTED
Inspected by:
7-13. CHCKING THE STOP VALVES AND STOPCOCKS

66 1-1 211 Suction pipe stop valve
67 1-2 211 Return pipe stop valves (2 pcs.)
68 1-3 211 Heater hose stopcock
69 2-1 212 A/C heater hose stopcocks (6 pcs.)
70 2-2 212 Heater hose stopcocks (2 pcs.)
71 3 213 Fuel hose stopcock
72 4 213 Oil tank stopcock
73 5-1 214 Fuel filter line stopcock
74 5-2 214 Fuel tank stopcock
75 6 215 Stairway stopcock
76 7 216 Coolant line stopcock
77 8 216 Reserve tank hose stopcock
7-14. FINAL CHECK OF SUPERSTRUCTURE

78 1-1 217 Check the water level in the radiator
79 1-2 217 Check the oil level in reduction gears for swing reduction devices
80 1-3 217 Check the oil level in the engine oil pan
81 1-4 217 Check the oil level in the final drives
82 1-5 218 Check the fuel level in the fuel tank
83 1-6 218 Check the transmission oil level
84 1-7 219 Check the hydraulic oil level in the hydraulic tank
85 2-1 219 Check the batttery cables to the batteries
86 2-2 220 Set battery switch to "ON"
87 3-1 221 Check the swing motors (Insert the plugs)
88 3-2 221 Check that all the tightening bolts of the superstructure are securely tightened
89 4 222 Remove plate locking the arm of the quick filling system
7-15. RELEASING AIR FROM MAIN PUMPS

90 − 223 Releasing air from main pumps
7-16. TRIAL OPERATION OF SUPERSTRUCTURE

91 − 225 Trial operation of superstructure
ANY COMMENTS
380
Report No. 07

SATISFACTORY
UNSATISFACTORY
CORRECTED
Inspected by:
LODER FRONT (1/1)
8-1. PREPARATION
1 2 263 〜 268 Installation of the arm cylinder
2 3 269 〜 272 Installation of the boom cylinders
3 4 273 〜 275 Installation of the bucket cylinders
8-2. MOUNTING OF LOADER BOOM

4 1 277 〜 278 Mounting of the boom
5 2 279 Connection of the hoses to base machine and boom
6 3 280 Connection of the arm cylinder hoses
7 4 281 Installation of the boom cylinder to base machine
8 5 282 Connection of the grease hoses
9 6 283 〜 285 Installation of the arm cylinder
8-3. MOUNTING OF BUCKET

10 1 287 〜 289 Mounting the bucket
11 2 290 Extend the bucket cylinders to align the pin holes with the bucket pin holes in
order to insert the pins
12 3 291 Connection of the dump cylinders (open/close) hoses
13 4 292 〜 294 Greasing (2)
14 5 295 〜 296 Air bleeding for boom, arm, dump and bucket cylinder
8-4. ADJUSTMENT OF TRACK LINK TENSION

15 − 297 〜 298 Adjustment of track link tension
8-5. FINAL TRAIAL OPERATION CHECK

16 − 299 Final trial operation check
ANY COMMENTS
381
Report No. 08

SATISFACTORY
UNSATISFACTORY
CORRECTED
Inspected by:
BACKHOE FRONT (1/1)
8'-1. PREPARATION
1 2 308 〜 313 Installation of the boom cylinders
2 3 314 Preparation of the arm
3 4 315 Preparation of the bucket
8'-2. MOUNTING OF BOOM

4 1 317 〜 319 Mounting the boom
5 2 320 Connection of the hoses to base machine and boom (1)
6 3 321 〜 322 Installation of the boom cylinder to base machine
7 4 323 〜 324 Connection of the grease hoses
8 5 325 〜 326 Greasing (2)
9 6 327 Air bleeding of the boom and arm cylinders
8'-3. INSTALLATION OF ARM

10 1 329 〜 330 Installation of the arm
11 2 331 〜 332 Installation of the arm cylinders
12 3 333 〜 336 Connection of the hoses to base machine and boom (2)
13 4 337 Greasing (3)
14 5 338 Air bleeding of the bucket cylinders
8'-4. MOUNTING OF BUCKET

15 1 339 〜 342 Mounting of the bucket
16 2 343 〜 344 Greasing (4)
17 3 345 〜 346 Air bleeding of the arm and bucket cylinders
8'-5. ADJUSTMENT OF TRACK LINK TENSION

18 − 347 〜 348 Adjustment of track link tension
8'-6. FINAL TRIAL OPERATION CHECK

19 − 349 Final trial operation check
8'-7. ASSEMBLY OPTION PARTS

20 − 351 Guard option parts
ANY COMMENTS
382
Report No. 09
SATISFACTORY
IMPLEMENT SPEEDS
UNSATISFACTORY
CORRECTED
Inspected by:
The figures and tolerances listed below are for new machines.
For machines already in operation, a certain allowance is
permitted according to working conditions and the hourmeter
reading on the machine.
The measurements should be performed under the following
conditions:
1. TEST CONDITIONS
Item Condition Test Result

Road Surface Level
Hydraulic Oil Temperature 50°C ± 5°C (122°F ± 41°F) °C (°F )
Low idling 780 ± 50
Auto idling 1400 ± 50
Engine Speed (rpm)
High idling 1950 ± 50
383
Report No. 10
SATISFACTORY
UNSATISFACTORY
CORRECTED
Inspected by:
2. TRACK LINE SPEED/3 TURNS
90° ~ 110°
90° ~ 110°
Unit: sec
Working Time
Item Criterion Evaluation
1 2 3 Avg.
TRACK LINK
109 ± 5
SPEED/3 rev. (Low)
Forward
TRACK LINK
77 ± 4
SPEED/3 rev. (High)
R
TRACK LINK
109 ± 5
SPEED/3 rev. (Low)
Backward
TRACK LINK
77 ± 4
SPEED/3 rev. (High)
Travel
TRACK LINK
109 ± 5
SPEED/3 rev. (Low)
Forward
TRACK LINK
77 ± 4
SPEED/3 rev. (High)
L
TRACK LINK
109 ± 5
SPEED/3 rev. (Low)
Backward
TRACK LINK
77 ± 4
SPEED/3 rev. (High)
384
Report No. 11
SATISFACTORY
UNSATISFACTORY
CORRECTED
3. SWING SPEED/3 TURNS
Inspected by:
Three full turns
Unit: sec
Working Time
1 2 3 Avg.
R 44 ± 5
Swing Speed/3 turns
L 44 ± 5
4. AMOUNT OF COAST WHEN SWINGING
Amount of
coast
Swing stop Swing start
180° swing
Unit: mm (in)
Coasting Amount
1 2 3 Avg.
Less than
R 740 (29.13)
Amount of Coast
Less than
L 740 (29.13)
385
Report No. 12
SATISFACTORY
UNSATISFACTORY
CORRECTED
Inspected by:
5. CYLINDER SPEEDS (Loader front)
Unit: sec
Working Time
Criterion Evaluation
1 2 3 Avg.
Boom Cylinder
Raise 8.2 ± 0.7
Lower 5.0 ± 0.5
Arm Cylinder
Retract 3.4 ± 0.5

Level luffing
Extend 4.2 ± 0.5
Bucket Cylinder
Tilt-in 4.0 ± 0.5
Tilt-out 2.9 ± 0.4
Bucket Open/Close Cylinder

Dump cylinder
Open 2.1 ± 0.4
Close 2.5 ± 0.4
ANY COMMENTS
386
Report No. 13
SATISFACTORY
UNSATISFACTORY
CORRECTED
Inspected by:
6. CYLINDER SPEEDS (Backhoe front)
Unit: sec
Working Time
Criterion Evaluation
1 2 3 Avg.
Raise
Raise 7.7 ± 0.7
Lower Lower 4.6 ± 0.5
Roll-in 7.1 ± 0.5
Arm Roll-in
6.5 ± 0.5
Arm Roll-out
Roll-out
Roll-in 4.4 ± 0.5
Bucket
Bucket Roll-in
Roll-out Roll-out 3.5 ± 0.5
ANY COMMENTS
387
Report No. 14
SATISFACTORY
UNSATISFACTORY
CORRECTED
Inspected by:
7. DEGREE OF CYLINDER CREEP (Loader front)
2 000 mm
(80 in)
Unit: mm (in)
Measured Data
1 2 3 Avg.
Boom Cylinder
Less than 30 (1.17)
mm/5 min
Arm Cylinder
Less than 60 (2.53)
mm/5 min
Bucket Cylinder
Less than 20 (0.78)
mm/5 min
8. DEGREE OF CYLINDER CREEP (Backhoe front)
2 000 mm
(80 in)
Unit: mm (in)
Measured Data
1 2 3 Avg.
Boom Cylinder
Less than 25 (0.97)
mm/5 min
Arm Cylinder
Less than 25 (0.97)
mm/5 min
Bucket Cylinder
Less than 20 (0.78)
mm/5 min
388
Head Office: 5-1, Koraku 2-chome, Bunkyo-ku,
Tokyo 112-0004 Japan
Telephone: Tokyo (03) 3830-8050
Facsimile: Tokyo (03) 3830-8202
Printed in Japan KG

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KO-385-02

The oil tank may be already installed.

Weight: 249 000 kg (549 000 lb)

The oil tank may be already installed.

Weight: 254 000 kg (560 000 lb)

1 RECOGNIZE SAFETY INFORMATION

Follow recommended precautions and safe operating

2 UNDERSTAND SIGNAL WORDS

DANGER indicates an imminently hazardous situation

WARNING indicates a potentially hazardous situation

CAUTION indicates a potentially hazardous situation

The NOTE describes cautionary remarks, reference,

To avoid confusing machine protection with personal

Safety signs should be installed, maintained, and

Learn how to operate the machine and its controls

Keep your machine in proper working condition.

The safety messages in this chapter are intended to

4 DESIGNATE ONE LEADER AND TWO

5 CLEAN THE MACHINE REGULARLY

Do not spray water or steam inside the cab.

Wear close fitting clothing and safety equipment

You may need:

7 PREPARE FOR EMERGENCIES

Keep a first aid kit and fire extinguisher handy.

Keep emergency numbers for doctors, ambulance

8 PREPARE SUITABLE LIFTING TOOLS

10 SUPPORT RAISED EQUIPMENT

Falling is one of the major causes of personal injury.

Never jump on or off the machine. Never mount or

13 PREVENT BATTERY EXPLOSIONS

Never check the battery charge by placing a metal

Do not charge a frozen battery - it may explode. Warm

Disconnect the negative ground cable before working

• Avoid this hazard by relieving pressure before

• Search for leaks with a piece of cardboard, taking

Fig. 1-14-2 Fig. 1-14-3 Fig. 1-14-4

15 CHECK EQUIPMENT SAFETY

Wear a suitable hearing protective device such as

17 FASTEN YOUR SEAT BELT

Be sure to remain seated with seat belt securely

18 BEWARE OF EXHAUST FUMES

If you must operate in a building, be sure there is

Never lubricate or service the machine while it is

Before servicing the machine.

• Park the machine on a level surface.

If a maintenance procedure must be performed with the

If the machine must be raised, maintain a 90 to 110˚

as necessary. Refer to the relevant section of the

Disconnect the battery ground cable (-) before making

Before performing any work on the machine, attach a

21 REMOVE PAINT BEFORE WELDING OR

Avoid potentially toxic fumes and dust.

Do all such work outside or in a well-ventilated area.

Remove paint before welding or heating:

1 If you sand or grind paint, avoid breathing the

2 If you use solvent or paint stripper, remove

22 PROTECT AGAINST FLYING DEBRIS

In order to avoid personal injury, keep bystanders away

gradually loosen the AIR RELEASE PLUG to release

Hot fluids and surfaces:

25 STORE ATTACHMENTS SAFELY

Securely store attachments and implements to prevent

Use leakproof containers when draining fluids. Do not