Field Assembly Pc1250lc-8 Gen00055-05

HYDRAULIC
EXCAVATOR
GEN00055-05
PC1250
-8
PC1250LC
-8
PC1250SP
-8
SERIAL NUMBERS
PC1250- 30001
PC1250LC- 30001
PC1250SP- 30001
and up
CONTENTS
Specifications...................................................................................................................... 1
Precautions for Field Assembly .......................................................................................... 3
Assembling Procedures, Applicable Equipment and Schedule.......................................... 4
Kit Layout Diagram............................................................................................................. 5
Transportation..................................................................................................................... 6
List of Tools for Field Assembling....................................................................................... 14
Tightening Torque............................................................................................................... 15
Coating Materials................................................................................................................ 19
List of parts sent individually............................................................................................... 21
A. Assembly of Chassis...................................................................................................... 31
A- 1. Installation of Left and Right Track Frames........................................................... 32
A- 2. Installation of Travel Piping.................................................................................... 35
A- 3. Installation of Travel Piping Covers ....................................................................... 37
A- 4. Installation of Steps ............................................................................................... 39
A- 5. Filling Swing Circle with Grease ............................................................................ 40
A- 6. Assembly of Upper Structure and Undercarriage.................................................. 41
A- 7. Installation of Right Side Steps.............................................................................. 43
A- 8. Installation of Handrails ......................................................................................... 44
A- 9. Installation of Swivel Travel Piping ........................................................................ 45
A-10. Sticking Sheet to Counterweight (EU specification) .............................................. 46
A-11. Installation of Counterweight ................................................................................. 47
A-12. Installation of Left Side Steps (Including handrails)............................................... 48
A-13. Installation of Radiator Cover (Standard specification) ......................................... 51
A-14. Installation of Muffler Tail Pipe .............................................................................. 56
A-15. Changing of Mounting Position of Step Light ........................................................ 57
A-16. Installation of Handrail to the Cab ......................................................................... 58
A-17. Installation of Left Rearview Mirror ........................................................................ 59
A-18. Installation of Right Rearview Mirrors.................................................................... 61
A-19. Preparation for Bleeding Air from Travel Motor ..................................................... 63
A-20. Procedure for Bleeding Air From Hydraulic Circuit ................................................ 64
A-21. Permanent Tightening of Swing Circle Mounting Bolts ......................................... 65
A-22. Testing Track Shoe Tension.................................................................................. 66
A-23. Check Fuel, Coolant and Oil Levels ...................................................................... 69
A-24. Parts to be Touched up after Field Assembly........................................................ 71
B. Assembling of Work Equipment of Backhoe .................................................................. 73
B- 1. Installation of Arm Cylinder.................................................................................... 74
B- 2. Installation of Arm Cylinder Hoses......................................................................... 75
B- 3. Installation of Boom Cylinder Foot ......................................................................... 76
B- 4. Installation of Boom Cylinder Hoses...................................................................... 77
B- 5. Installation of Boom Foot Dust Seal ...................................................................... 78
B- 6. Installation of Boom Assembly............................................................................... 79
B- 7. Installation of Boom Cylinder ................................................................................. 80
B- 8. Installation of Boom Hoses (Between machine and boom) ................................... 81
B- 9. Installation of Arm Assembly ................................................................................. 82
B-10. Installation of Bucket Cylinder Hoses between Boom and Bucket Cylinder.......... 84
B-11. Installation of Bucket Assembly............................................................................. 85
B-12. Clearance Standard for Installation of Work Equipment........................................ 88
B-13. Installation of Work Equipment Grease Piping...................................................... 89
B-14. Procedure for Bleeding Air From Travel Motor...................................................... 90
B-15. Bleeding Air from Swing Motor .............................................................................. 92
B-16. Bleeding Air from Cylinder..................................................................................... 93
B-17. Installation of Work Equipment Wiring................................................................... 94
B-18. Greasing after Assembling Work Equipment......................................................... 95
M. Procedure for Inspection and Maintenance after Completion of Assembly.................... 97
M- 1. Replacement of Return Filter (Standard Filter to Flushing Filter) .......................... 98
M- 2. Relieving Remaining Pressure from Hydraulic Circuit ......................................... 101
M- 3. Installation of Flushing Tubes.............................................................................. 102
M- 4. Flushing of Hydraulic Circuit ................................................................................ 104
M- 5. Replacement of Pilot Filter (Flushing filter o Standard filter) ............................... 105
Field Assembly Inspection Report (Backhoe)
1
SPECIFICATIONS
PC1250-8
PC1250SP-8
Machine model PC1250-8 PC1250SP-8 PC1250LC-8
Weight of machine kg 109,900 111,700 113,500
Bucket capacity m
3
5.2 6.7 5.2
Engine model SAA6D170E-5
Flywheel horsepower kW/rpm {HP/rpm} 502{672}/1,800
Min. ground clearance mm 990
Travel speed (Low/High) km/h 2.1/3.2
Swing speed rpm 5.8
2
PC1250LC-8
3
PRECAUTIONS FOR FIELD ASSEMBLY y
1. Selection of work place
1) When selecting a work place, consider the following.
Is the work place sufficiently wide for loading and unloading the machine? (See the kit layout draw-
ing.)
Is the ground sufficiently hard? (The machine and crane truck must not sink into the ground.)
Is the ground flat? (The ground surface must not be uneven or sloping.)
Is the road to inlet/outlet of the work place sufficient for turning the trailer and crane truck?
2) Take care extremely that dirt or water will not enter the hydraulic circuit while it is assembled.
3) Avoid working outdoors while strong wind is blowing or it is raining.
4) Take measures to protect the machine from sand, dirt and rainwater while the work is stopped.
2. How to do work
The work supervisor or the work leader should not do the work while reading this manual but should read
and understand this manual thoroughly and then start the work.
In particular, write the "Precautions" for each work process in a sheet to explain or stick that sheet to the
work place so that all the workers will observe the precautions.
3. Preparation and check of protective gear, slings and tools
The work supervisor or the work leader must perform the following checks about protective gear, slings and
tools.
1) Are all the workers wearing helmets and other protective gear which they are obliged to wear?
If special protective gear is necessary, check that it is prepared and can be used without problem.
2) Are all the slings and tools prepared? Check in advance that they are ready to be used without prob-
lem. In particular, check wooden blocks for internal decay and cracking.
4. kCheck during actual work
The work supervisor or the work leader must check the following items constantly and make all the workers
observe them.
1) Are the parking brakes of the trailer and crane truck applied securely and are their wheels locked with
chocks during work? Are outriggers, if installed, used securely?
2) Are the temperature and pressure of the engine, hydraulic oil, coolant, etc. lowered sufficiently during
work?
3) Is horn or another signal is made to warn around when the engine is started? In addition, is it checked
that work equipment control lever and other control levers are in neutral and the fuel control dial (or fuel
control lever) is in the low idle position?
4) Is the balance of the slung item checked extremely during sling work with the crane?
5) Is entry prohibition for outsiders to the work place observed?
5. The work supervisor or the work leader is required to hold a meeting with all the workers at the beginning of
every morning and explain the work plan of the day to them and give them instructions to observe the safe
work.
4
ASSEMBLING PROCEDURES,
APPLICABLE EQUIPMENT AND SCHEDULE
D
a
y
s
A
s
s
e
m
b
l
y

u
n
i
t
C
r
a
n
e
A
i
r

c
o
m
p
r
e
s
s
o
r
W
o
r
k
e
r
q

C
e
n
t
e
r

f
r
a
m
e
w

L
e
f
t

a
n
d

r
i
g
h
t

t
r
a
c
k

f
r
a
m
e
s
e

T
r
a
v
e
l

p
i
p
i
n
g

g
r
o
u
p

U
p
p
e
r

s
t
r
u
c
t
u
r
e
r

C
o
u
n
t
e
r
w
e
i
g
h
t
t

P
l
a
t
f
o
r
m

g
r
o
u
p

I
n
s
p
e
c
t
i
o
n

o
f

o
i
l

l
e
v
e
l

a
n
d

c
o
o
l
a
n
t

l
e
v
e
l
B
a
c
k
h
o
e
L
o
a
d
i
n
g

s
h
o
v
e
l
-
t
y
p
e

e
x
c
a
v
a
t
o
r
y

A
s
s
e
m
b
l
i
n
g

o
f

w
o
r
k

e
q
u
i
p
m
e
n
t

I
n
s
p
e
c
t
i
o
n

o
f

o
i
l

l
e
v
e
l

a
n
d

c
o
o
l
a
n
t

l
e
v
e
l

A
i
r

b
l
e
e
d
i
n
g

f
r
o
m

w
o
r
k

e
q
u
i
p
m
e
n
t

c
y
l
i
n
d
e
r

F
l
u
s
h
i
n
g

o
f

h
y
d
r
a
u
l
i
c

c
i
r
c
u
i
t

A
d
j
u
s
t
m
e
n
t

o
f

t
r
a
c
k

t
e
n
s
i
o
n

P
e
r
f
o
r
m
a
n
c
e

t
e
s
t
(
T
w
o
)
4
4
1

k
N

{
4
5
t
}
4
4
1

k
N

{
4
5
t
}
2
4
5

k
N

{
2
5
t
}
0
.
4
9

-
-

0
.
6
9

M
P
a
{
5

-
-

7

k
g
/
c
m
2
}
1
5

m
3
/
m
i
n
L
e
a
d
e
r

+

5

m
e
c
h
a
n
i
c
s
S
t
a
r
t

o
f

a
s
s
e
m
b
l
i
n
g

M
e
e
t
i
n
g

w
i
t
h

a
l
l

w
o
r
k
e
r
s
C
o
m
p
l
e
t
i
o
n

o
f

I
n
s
t
a
l
l
a
t
i
o
n

o
f

u
n
i
t

a
s
s
e
m
b
l
y

t
o

b
o
d
y
C
o
m
p
l
e
t
i
o
n

o
f

b
o
d
y

a
s
s
e
m
b
l
i
n
g

C
o
m
p
l
e
t
i
o
n

o
f

g
e
n
e
r
a
l

a
s
s
e
m
b
l
i
n
g
4 Divisions
5
KIT LAYOUT DIAGRAM
The dimensions given below are the minimum dimensions needed.
The kit dimensions in the diagram are outline dimensions.
When selecting a place, see precautions for FIELD ASSEMBLING.
Bucket
Arm link
Boom
Center
frame
Tools, facility
A
r
m

c
y
l
i
n
d
e
r
Boom
cylinder
F
o
r
e
w
o
r
d
C
r
a
w
l
e
r

f
r
a
m
e
C
r
a
w
l
e
r

f
r
a
m
e
Revolving
frame
Counterweight
L
e
f
t

d
e
c
k
Motor cover handrails
45t crane
45t crane
6
TRANSPORTATION
TRANSPORTATION
The machine can be divided into seven kits for transportation, so when transporting the machine, please contact your
Komatsu distributor to have the work carried out.
Transportation in seven kits
Posture for each unit
(dimensions in diagram are in mm.)
Upper structure
Secure the upper structure to the platform with a chain and block.
Fuel: Empty
Hydraulic oil: M level
Item PC1250-8, PC1250SP-8, PC1250LC-8
Overall width (mm) 3,490
Weight (kg) 26,700
(Upper structure)
(Counterweight, Bucket, etc.) (Boom)
(Arm, Arm cylinder
Boom cylinder, etc.)
(Undercarriage left) (Undercarriage right) (Center frame)
7
TRANSPORTATION
Undercarriage
If any warning tag is attached to the work equipment control levers,
do not start the engine.
Item
PC1250-8
PC1250SP-8
PC1250LC-8
Qty 2 2
Weight (kg)
30,500
(15,250 2 pieces)
37,600
(18,800 2 pieces)
LC: 7,400
STD, SP: 6,425
LC: 1,295
STD, SP: 1,222
8
TRANSPORTATION
Boom
Item PC1250-8 PC1250SP-8 PC1250LC-8
A (mm) 9,475 8,170 9,475
B (mm) 2,894 3,095 2,894
Overall width (mm) 1,474 1,474 1,474
Weight (kg) 11,200 11,100 11,500
9
TRANSPORTATION
Arm
Bucket (excluding side cutter and shroud)
Boom cylinder (same for all models)
Weight: 2,400 kg (1200 kg 2 pieces)
Arm cylinder (same for all models)
Weight: 1,500 kg
Item
PC1250-8
PC1250LC-8
PC1250SP-8
A (mm) 4,895 4,914
B (mm) 1,626 1,683
Overall width (mm) 890 890
Weight (kg) 6,200 6,400
Item
PC1250-8
PC1250LC-8
PC1250SP-8
A (mm) 2,580 2,527
B (mm) 2,276 2,420
Overall width (mm) 2,250 2,520
Weight (kg) 5,500 6,300
10
TRANSPORTATION
Center frame
Counterweight
Item PC1250-8, PC1250SP-8, PC1250LC-8
Overall width (mm) 3,540
Weight (kg) 9,700
Item PC1250-8, PC1250SP-8, PC1250LC-8
Weight (kg) 18,000
11
TRANSPORTATION
Others
Radiator duct (same for all models)
Radiator duct upper cover (same for all models)
Item PC1250-8, PC1250SP-8, PC1250LC-8
Weight (kg) 100
Item PC1250-8, PC1250SP-8, PC1250LC-8
Weight (kg) 17
12
TRANSPORTATION
Catwalk (right): same for all models
Catwalk (left, front): same for all models
Item PC1250-8, PC1250SP-8, PC1250LC-8
Weight (kg) 17
Item PC1250-8, PC1250SP-8, PC1250LC-8
Weight (kg) 150
13
TRANSPORTATION
Catwalk (left, rear): same for all models
Item PC1250-8, PC1250SP-8, PC1250LC-8
Weight (kg) 160
14
LIST OF TOOLS FOR FIELD ASSEMBLING
No. Tool names Specifications Qty. Remarks
1
E
q
u
i
p
m
e
n
t
Engine compressor Komatsu, 0.69 MPa {7.0kg/cm
2
} Class 1
2 Crane truck 441 kN {45 ton} 2
2 245 kN {25 ton} 1
3 Grease pump Air type 1 Work equipment lubrication
4 Stepladder 5 -stepped- 1500 mm 2
5
T
o
o
l
Impact wrench KW10P (for M10) 1
6 KW12PI (For M12) 1
7 KW20P (For M16) 1
7 KW380 1
8 KW45FS (Spline) 1 For counterweight
9 Socket for KW45FS Spline 65 mm 1 For counterweight
10 Air hose 50 m 1 For impact wrench
11 16-time wrench 4413 Nm {450 kgm} 1 For counterweight
12 Socket for 16-time wrench T38.1 65 mm 1 For counterweight
13 T38.1 60 mm 1 For track frame
14 T38.1 50 mm 1 For track frame
15 4-time wrench 25.4, 19 1
16 Socket for 4-time wrench T25.4 50 mm 1
17 T25.4 60 mm 1
18 Torque wrench 412 Nm {42 kgm} T25.4 mm 1 For 16-time wrench
19 980 Nm {100 kgm} T25.4 mm 1 For 4-time wrench
20 4118 Nm {420 kgm} T38.1 mm 1 For counterweight and track frame
21 Standard tool Socket, spanner, wrench 2 set
22 Sledge hammer 10 P 1
23 Bar 1 m 2
24 Hydraulic jack 490 kN {50 ton} (stroke 170) 2 Revolving frame pedestal
25 196 kN {20 ton} 1
When tightening track frame
connecting bolts.
26 Waste oil pan Large, small 2 each
When connecting travel and
work equipment piping
27 Wooden block 300 400 mm 4 Revolving frame pedestal
28
L
i
f
t
i
n
g

t
o
o
l
Wire 10 3 m 2 For catwalk
29 20 5 m 2 For boom, arm and bucket
30 25 5 m 4 For revolving frame and track frame
31 30 5 m 2 For counterweight
32 Shackle SD30 3
33 SC18 4
34 Nylon sling 50 mm wide 3 m 2 For boom cylinder and arm cylinder
34 Nylon sling 25 mm wide 3 m 2 Handrail
35 Pin 50 5 m 2 Track frame
36 Lever block 14.7 29.4 kN {1.5 3 ton} 2
37 Eyebolt M16 2
38 M12 2
39 Detergent liquid Brake cleaner 10
40 Hydraulic oil EO-10 500 l
41
O
i
l

a
n
d

g
r
e
a
s
e
Grease G2-LI (20 kg) 4 kg Work equipment lubrication, Swing circle
42 Repair paint Natural yellow 5
43 Black gray 5
44 Waste cloth Bundle 20 kg
15
TIGHTENING TORQUE
1. Tightening torque for bolts
Tightening torque for bolts is indicated in the text as shown below. Tighten each bolt to the specified
torque.
If tightening torque for a bolt is not specified in the text, tighten it according to Table 1.
Remarks
1. The thread diameter is the nominal diameter. For example, 16 mm is expressed as M16 and 26
mm is expressed as M20.
The pitch in Table 1 is the distance that the bolt advances every turn in the axial direction (Unit:
mm).
2. The bolt length is dimension c in Fig. 1.
3. The applicable socket size is expressed as 24 mm, 30 mm, etc. Since 24 mm, 30 mm, etc. cor-
respond to dimension b in Fig. 1, an applicable socket can be selected from Table 1, too.
4. Tightening torque is expressed as QQQ www or QQQ RR. If the target tightening torque
is set, expression of QQQ RR is applied.
Part No. of bolt TTTTT-TTTTT
Part No. of washer EEEEE-EEEEE
Bolt specification Thread diameter Bolt length
Tool (Socket) Applicable socket size
Tightening torque Nm {QQQ kgm}
a : Bolt thread diameter (Nominal diameter)
b : Width across flats of bolt head
c : Bolt length
d : Threaded part of bolt
Fig. 1
16
a For symbols a and b in the table, see Fig. 1.
Table 1 Ti ghtening torque for bolts not specified in text
Nominal size of thread
pitch
a (mm)
Width across flats
(=Socket size)
b (mm)
Tightening torque
Unit : Nm
{1.2 1.5}
11.8 14.7 6 1
{2.8 3.5} 27 34
{6 7.5}
59 74
{10 12.5} 98 123
{15.5 19.5} 153 190
{23.5 29.5} 235 285
{33 41} 320 400
{46.5 58} 455 565
{62.5 78}
610 765
{80 100} 785 980
{118 147} 1150 1440
{155 195} 1520 1910
{200 250} 1960 2450
{250 310} 2450 3040
{295 370}
2890 3630
8 1.25
10 1.5
12 1.75
14 2
16 2
18 2.5
20 2.5
22 2.5
24 3
27 3
30 3
33 3
36 3
39 3
10
13
17
19
22
24
27
30
32
36
41
46
50
55
60
Unit : {kgm}
17
2. Tightening torque for pipe threads
Proper tightening torque for pipe threads depends on combination of the materials of the male screw and
female screw. In this manual, however, select tightening torque from Table 2 and Table 3 on the basis of
the material of the male screw. If tightening torque is specified specially in explanation, however, apply that
tightening torque.
2.1 If the male screw is made of mild steel or cast iron, apply Table 2.
Table 2
Unit: Nm {kgm}
2.2 If the male screw is made of refined steel (heat-treated hard steel), apply Table 3.
Table 3
Unit: Nm {kgm}
Material of female thread
Nominal size (in)
Steel Cast iron Light alloy
1/8
3.9 6.9
{0.4 0.7}
2.9 5.9
{0.3 0.6}
2.0 3.9
{0.2 0.4}
1/4
5.9 11.8
{0.6 1.2}
4.9 9.8
{0.5 1.0}
3.9 7.8
{0.4 0.8}
3/8
16.7 26.5
{1.7 2.7}
13.7 21.6
{1.4 2.2}
9.8 16.7
{1.0 1.7}
1/2
32.3 52.9
{3.3 5.4}
26.5 43.1
{2.7 4.4}
19.6 32.3
{2.0 3.3}
3/4
51.0 85.3
{5.2 8.7}
42.1 70.6
{4.3 7.2}
31.4 52.9
{3.2 5.4}
1
86.2 173.5
{8.8 17.7}
72.5 146.0
{7.4 14.9}
54.9 111.7
{5.6 11.4}
Material of female thread
Nominal size (in)
Steel Cast iron Light alloy
1/8
16.7 29.4
{1.7 3.0}
9.8 19.6
{1.0 2.0}
6.9 14.7
{0.7 1.5}
1/4
19.6 44.1
{2.0 4.5}
16.7 37.2
{1.7 3.8}
12.7 28.4
{1.3 2.9}
3/8
44.1 93.1
{4.5 9.5}
37.2 77.4
{3.8 7.9}
27.4 58.8
{2.8 6.0}
1/2
98.0 188.2
{10.0 19.2}
83.3 157.8
{8.5 16.1}
60.8 115.6
{6.2 11.8}
3/4
170.5 316.5
{17.4 32.3}
141.1 247.0
{14.4 25.2}
105.8 186.2
{10.8 19.0}
1
367.5 612.5
{37.5 62.5}
309.7 514.5
{31.6 52.5}
235.2 392.0
{24.0 40.0}
18
4. Proper socket sizes for bolts of M39 and larger (Reference)
For the proper sizes of sockets or spanners (= width across flats) for tightening hexagon bolts of M39 and
larger, see Table 5.
Table 5
Unit: mm
Thread diameter Proper sizes of sockets or spanners
M42 65
M45 70
M48 75
M52 80
M56 85
M60 90
M64 95
3. Tightening torque for hydraul ic hose connecting nut
For the connecting nuts installed to the hydraulic hose adapters in relatively low pressure systems, apply
tightening torque in Table 4.
Table 4
Note : When connecting hoses, take care not to twist them.
Outside diameter
of hose
(mm)
Width across
flatse.
(mm)
Tightening torque (Nm {kgm})
Range Target
Approx. 6 19 35 63 {3.5 6.5} 44 {4.5}
Approx. 10
22 54 93 {5.5 9.5} 74 {7.5}
24 59 98 {6.0 10.0} 78 {8.0}
Approx. 13 27 84 132 {8.5 13.5} 103 {10.5}
Approx. 16 32 128 186 {13.0 19.0} 157 {16.0}
Approx. 20 36 177 245 {18.0 25.0} 216 {22.0}
19
COATING MATERIALS
a The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly
and assembly are listed below.
a For coating materials not listed below, use the equivalent of products shown in this list.
Category Komatsu code Part No. Q'ty Container Main applications, features
Adhesives
LT-1A 790-129-9030 150 g Tube
Used to prevent rubber gaskets, rub-
ber cushions, and cock plug from
coming out.
LT-1B 790-129-9050
20 g
(2 pcs.)
Polyethylene
container
Used in places requiring an immedi-
ately effective, strong adhesive.
Used for plastics (except polyethyl-
ene, polyprophylene, tetrafluoroeth-
l ene and vinyl chl oride), rubber,
metal and non-metal.
LT-2 09940-00030 50 g
Polyethylene
container
Features: Resistance to heat and
chemicals
Used for anti-loosening and sealant
purpose for bolts and plugs.
LT-3
790-129-9060
(Set of adhesive
and hardening
agent)
Adhesive:
1 kg
Hardening
agent:
500 g
Can
Used as adhesive or sealant for met-
al, glass and plastic.
LT-4 790-129-9040 250 g
Polyethylene
container
Used as sealant for machined holes.
Holtz
MH 705
790-126-9120 75 g Tube
Used as heat-resisting sealant for re-
pairing engine.
Three bond
1735
790-129-9140 50 g
Polyethylene
container
Quick hardening type adhesive
Cure time: within 5 sec. to 3 min.
Used mainly for adhesion of metals,
rubbers, plastics and woods.
Aron-alpha
201
790-129-9130 2 g
Polyethylene
container
Quick hardening type adhesive
Quick cure type (max. strength after
30 minutes)
Used mainly for adhesion of rubbers,
plastics and metals.
Loctite
648-50
79A-129-9110 50 cc
Polyethylene
container
Resistance to heat, chemicals
Used at joint portions subject to high
temperatures.
Gasket
sealant
LG-1 790-129-9010 200 g Tube
Used as adhesive or sealant for gas-
kets and packing of power train case,
etc.
LG-5 790-129-9080 1 kg Can
Used as sealant for various threads,
pipe joints, flanges.
Used as sealant for tapered plugs,
elbows, nipples of hydraulic piping.
LG-6 790-129-9020 200 g Tube
Features: Silicon based, resistance
to heat, cold
Used as sealant for flange surface,
tread.
Used as sealant for oil pan, final
drive case, etc.
LG-7 790-129-9070 1 kg Tube
Features: Silicon based, quick hard-
ening type
Used as sealant for flywheel hous-
ing, intake manifold, oil pan, thermo-
stat housing, etc.
Three bond
1211
790-129-9090 100 g Tube
Used as heat-resisting sealant for re-
pairing engine.
Three bond
1207B
419-15-18131 100 g Tube
Features: Silicone type, heat resist-
ant, vibration resistant, and impact
resistant sealing material
Used as sealing material for transfer
case
20
Category Komatsu code Part No. Q'ty Container Main applications, features
Molybdenum
disulphide
lubricant
LM-G 09940-00051 60 g Can
Used as lubricant for sliding portion
(to prevent from squeaking).
LM-P 09940-00040 200 g Tube
Used to prevent seizure or scuffling
of the thread when press fitting or
shrink fitting.
Used as lubricant for linkage, bear-
ings, etc.
Grease
G2-LI
SYG2-400LI
SYG2-350LI
SYG2-400LI-A
SYG2-160LI
SYGA-160CNLI
Various Various
General purpose type
G2-CA
SYG2-400CA
SYG2-350CA
SYG2-400CA-A
SYG2-160CA
SYGA-160CNCA
Various Various
Used for normal temperature, light
load bearing at places in contact
with water or steam.
Molybdenum
disulphide
grease
LM-G (G2-M)
SYG2-400M
SYG2-400M-A
SYGA-16CNM
400 g 10
400 g 20
16 kg
Bellows type
Bellows type
Can
Used for heavy load portion
Hyper White
Grease G2-T
G0-T (*)
*: For use in cold
district
SYG2-400T-A
SYG2-16CNT
SYG0-400T-A (*)
SYG0-16CNT (*)
400 g
16 kg
Bellows type
Can
Seizure resistance and heat resist-
ance higher than molybdenum di-
sulfide grease
Since this grease is white, it does
not stand out agai nst machine
body.
Biogrease G2B
G2-BT (*)
*: For high
temperature
and large load
SYG2-400B
SYGA-16CNB
SYG2-400BT (*)
SYGA-16CNBT (*)
400 g
16 kg
Bellows type
Can
Since this grease is decomposed
by bacteria in short period, it has
less effects on microorganisms,
animals, and plants.
Primer
SUNSTAR
PAINT PRIMER
580 SUPER
417-926-3910
20 ml
Glass
container
A
d
h
e
s
i
v
e

f
o
r

c
a
b

g
l
a
s
s
Used as primer for cab side
(Expiration date: 4 months)
SUNSTAR
GLASS PRIMER
580 SUPER
20 ml
Glass
container
Used as primer for glass side
Adhesive
SUNSTAR
PENGUINE
SEAL 580
SUPER "S" or
"W"
320 ml
Polyethylene
container
"S" is used for high-tempera-
ture season (April - October)
and "W" for low-temperature
season (November - April) as
adhesive for glass.
Sika Japan,
Sikaflex 256HV
20Y-54-39850 310 ml
Polyethylene
container
Used as adhesive for glass.
Caulking
material
SUNSTAR
PENGUINE
SEAL No. 2505
417-926-3920 320 ml
Polyethylene
container
Used to seal joints of glass
parts.
SEKISUI
SILICONE
SEALANT
20Y-54-55130 333 ml
Polyethylene
container
Used to seal front window.
GE TOSHIBA
SILICONES
TOSSEAL 381
22M-54-27220 333 ml Cartridge
Used to seal joint of glasses.
Translucent white seal.
Paint
Natural yellow SYPA-U03PNY Spray can
Black gray SYPA-U03PBG Spray can
21
LIST OF PARTS SENT INDIVIDUALLY
CHASSIS (STANDARD SPECIFICATION)
No. Parts No. Parts names Qty Remarks Page
1 21N-30-11180 Bolt 40
For connecting track frame 32
2 21N-30-37130 Spacer 40
3 150-74-11140 Bolt 56
For connecting center frame 42
4 01643-33380 Washer 56
5 02896-11009 O-ring 2
For installing travel piping 35
6 02896-11018 O-ring 2
7 07000-B3032 O-ring 4
8 07094-31228 Clamp 8
9 07095-01241 Cushion 8
10 01024-81285 Bolt 8
11 08036-03014 Clip 6
12 04434-52512 Clip 6
13 07095-20318 Cushion 6
14 01024-81225 Bolt 10
15 21N-30-37411 Cover (L.H.) 1
For installing travel piping
cover
37, 38
16 21N-30-37421 Cover (R.H.) 1
17 01024-81225 Bolt 8
18 21N-30-37370 Cover (L.H.) 1
19 21N-30-37381 Cover (R.H.) 1
20 01010-81230 Bolt 8
21 175-54-34170 Washer 8
22 21N-30-37390 Cover 1
23 01010-81230 Bolt 6
24 175-54-34170 Washer 6
25 209-62-52560 Pin 1
For installing swivel and travel
piping
45
26 01641-21626 Washer 1
27 04050-14028 Pin 1
28 02896-11009 O-ring 1
29 07002-12434 O-ring 1
30 07073-01A08 Hose 2
31 07073-01AA7 Hose 2
32 07000-B3032 O-ring 8
22
41 209-09-51170 Bolt 10
For installing counterweight 47
42 209-46-11210 Spacer 10
43 21N-30-37140 Ladder 2
For installing track frame step 39
44 01010-81635 Bolt 8
45 01643-31645 Washer 8
46 21N-53-32132 Step assembly 1
For installing left side step 48, 49
47 01024-81240 Bolt 20
48 21N-53-31362 Step 1
49 01024-81240 Bolt 20
50 01024-81230 Bolt 2
51 21N-53-31982 Bracket 1
52 01024-81230 Bolt 6
53 21N-54-39950 Step 1
54 01024-81240 Bolt 6
55 X21-0878191 Handrail assembly 1
56 01010-81645 Bolt 10
57 01643-31645 Washer 10
59 01010-81645 Bolt 6
60 01643-31645 Washer 6
62 01010-81645 Bolt 6
63 01643-31645 Washer 6
64 8285-54-1570 Chain 1
65 21N-53-32420 Bracket 1
66 01024-D1225 Bolt 1
66-1 08037-01610 Grommet 1
67 21N-54-32490 Ladder 1
50
23
68 21N-54-39661 Step 1
For installing right side step 43
69 01024-81230 Bolt 4
70 21N-54-42430 Step 1
71 01024-81230 Bolt 2
72 21N-54-39640 Step 1
73 01024-81240 Bolt 8
74 21N-54-39650 Handrail 2
75 01024-81235 Bolt 8
76 21N-54-39611 Handrail 1
77 01024-81230 Bolt 4
78 21N-54-39621 Handrail 1
79 01024-81230 Bolt 4
80 21N-54-39631 Handrail 1
81 01024-81230 Bolt 12
82 01024-81240 Bolt 4
83 21N-54-41721 Handrail 1
For installing handrail 44
84 01024-81240 Bolt 8
85 21N-54-41741 Handrail 1
86 01024-81235 Bolt 4
87 21N-54-37241 Handrail 1
88 01024-81230 Bolt 6
89 21N-54-41711 Handrail 1
90 01024-81230 Bolt 10
91 21N-54-39571 Handrail 1
92 01024-81235 Bolt 2
93 21N-54-41351 Duct assembly 1
For installing radiator cover
(STD)
51
94 01024-81230 Bolt 8
95 01011-81220 Bolt 4
96 01643-31232 Washer 4
97 21N-54-41361 Cover 1
98 01011-81200 Bolt 2
99 01643-31232 Washer 2
100 01024-81280 Bolt 3
24
116 X21-1223090 Rain cap assembly 1
For installing exhaust piping 56
117 01024-81235 Bolt 6
117-1 20Y-54-51820 Handrail 1
For installing handrail for cab 58
118 21N-53-32510 Support 1
For installing L.H. rear view
mirror
59
119 20Y-54-35430 Clamp 1
120 01252-71025 Bolt 2
121 421-54-25610 Mirror 1
122 04025-00632 Pin 1
123A 21N-54-41751 Support 1
For installing R.H. rear view
mirror
61
123B 21N-54-42440 Support 1
124 20Y-54-27991 Clamp 2
125 01252-71025 Bolt 4
126 421-54-25610 Mirror 2
127 04025-00632 Pin 2
128 01252-70545 Bolt 8
25
CHASSIS (EU SPECIFICATION)
1 21N-30-11180 Bolt 40
For connecting track frame 32
2 21N-30-37130 Spacer 40
3 150-74-11140 Bolt 56
For connecting center frame 42
4 01643-33380 Washer 56
5 02896-11009 O-ring 2
For installing travel piping 35
6 02896-11018 O-ring 2
7 07000-B3032 O-ring 4
8 07094-31228 Clamp 8
9 07095-01241 Cushion 8
10 01024-81285 Bolt 8
11 08036-03014 Clip 6
12 04434-52512 Clip 6
13 07095-20318 Cushion 6
14 01024-81225 Bolt 10
15 21N-30-37411 Cover (L.H.) 1
For installing travel piping
cover
37, 38
16 21N-30-37421 Cover (R.H.) 1
17 01024-81225 Bolt 8
18 21N-30-37370 Cover (L.H.) 1
19 21N-30-37381 Cover (R.H.) 1
20 01010-81230 Bolt 8
21 175-54-34170 Washer 8
22 21N-30-37390 Cover 1
23 01010-81230 Bolt 6
24 175-54-34170 Washer 6
25 209-62-52560 Pin 1
For installing swivel and travel
piping
45
26 01641-21626 Washer 1
27 04050-14028 Pin 1
28 02896-11009 O-ring 1
29 07002-12434 O-ring 1
30 07073-01A08 Hose 2
31 07073-01AA7 Hose 2
32 07000-B3032 O-ring 8
26
33 01024-81230 Bolt 8
For sticking sheet
(counterweight)
(EU Spec.)
46
34 21N-46-35320 Cover 1
35 21N-46-35310 Cover 1
36 21N-46-35281 Sheet 1
37 21N-46-35271 Sheet 1
38 21N-46-35261 Sheet 1
39 21N-46-35253 Sheet 1
40 21N-46-35211 Sheet 1
41 209-09-51170 Bolt 10
For installing counterweight 47
42 209-46-11210 Spacer 10
43 21N-30-37140 Ladder 2
For installing track frame step 39
44 01010-81635 Bolt 8
45 01643-31645 Washer 8
46 21N-53-32132 Step assembly 1
For installing left side step 48, 49
47 01024-81240 Bolt 20
48 21N-53-31362 Step 1
49 01024-81240 Bolt 20
50 01024-81230 Bolt 2
51 21N-53-31982 Bracket 1
52 01024-81230 Bolt 6
53 21N-54-39950 Step 1
54 01024-81240 Bolt 6
56 01010-81645 Bolt 10
57 01643-31645 Washer 10
59 01010-81645 Bolt 6
60 01643-31645 Washer 6
62 01010-81645 Bolt 6
63 01643-31645 Washer 6
64 8285-54-1570 chain 1
65 21N-53-32420 Bracket 1
66 01024-D1225 Bolt 1
67 21N-54-32490 Ladder 1
50
27
68 21N-54-39661 Step 1
For installing right side step 43
69 01024-81230 Bolt 4
70 21N-54-42430 Step 1
71 01024-81230 Bolt 2
72 21N-54-39640 Step 1
73 01024-81240 Bolt 8
74 21N-54-39650 Handrail 2
75 01024-81235 Bolt 8
76 21N-54-39611 Handrail 1
77 01024-81230 Bolt 4
78 21N-54-39621 Handrail 1
79 01024-81230 Bolt 4
80 21N-54-39631 Handrail 1
81 01024-81230 Bolt 12
82 01024-81240 Bolt 4
83 21N-54-41721 Handrail 1
For installing handrail 44
84 01024-81240 Bolt 8
85 21N-54-41741 Handrail 1
86 01024-81235 Bolt 4
87 21N-54-37241 Handrail 1
88 01024-81230 Bolt 6
89 21N-54-41711 Handrail 1
90 01024-81230 Bolt 10
91 21N-54-39571 Handrail 1
92 01024-81235 Bolt 2
101 01023-10408 Bolt 2
(EU Spec.)
52 - 55
102 20B-54-12210 Spring 1
103 20Y-54-29232 Bar 1
104 195-Z11-2970 Cap 17
105 21N-54-41830 Net 2
106 21N-54-41811 Duct 1
107 21N-54-41880 Seal 4
108 01024-80816 Bolt 8
109 01024-81240 Bolt 14
110 21N-54-41851 Blade 16
111 01024-81020 Bolt 32
112 21N-54-41860 Frame 4
113 01024-80616 Bolt 32
28
114 21N-54-41821 Cover 1
(EU Spec.)
54, 55
115 01024-81235 Bolt 23
116 X21-1223090 Rain cap assembly 1
For installing exhaust piping 56
117 01024-81235 Bolt 6
117-1 20Y-54-51820 Handrail 1
For installing handrail for cab 58
118 21N-53-32510 Support 1
For installing L.H. rear view
mirror
59
119 20Y-54-35430 Clamp 1
120 01252-71025 Bolt 2
121 421-54-25610 Mirror 1
122 04025-00632 Pin 1
123A 21N-54-41751 Support 1
For installing R.H. rear view
mirror
61
123B 21N-54-42440 Support 1
124 20Y-54-27991 Clamp 2
125 01252-71025 Bolt 4
126 421-54-25610 Mirror 2
127 04025-00632 Pin 2
128 01252-70545 Bolt 8
29
WORK EQUIPMENT
129 21N-72-11230 Shim 8
For installing boom cylinder
foot
76
130 07000-13038 O-ring 2
For installing boom cylinder
hose
77
131 07000-13048 O-ring 2
132 21N-72-11210 Shim 3
For installing boom assembly 79
133 21N-72-11220 Shim 3
134 707-01-XZ501 Boom cylinder (L.H.) 1
For installing boom cylinder 80
135 707-01-XZ511 Boom cylinder (R.H.) 1
136 21N-72-11230 Shim 2
137 07099-01218 Hose 2
For installing boom hose 81
138 07000-13038 O-ring 4
139 07099-01418 Hose 4
140 07000-13048 O-ring 10
141 707-01-XZ522 Arm cylinder 1
For installing arm cylinder 74
142 21N-72-11210 Shim 2
143 07098-01418 Hose 3
(For STD boom) 75
07098-01421 Hose 3 (For SE boom)
144 07000-13048 O-ring 6 For installing arm cylinder hose
145 21N-72-11210 Shim 4
82
146 21N-62-38610 Hose 2
For installing bucket cylinder
hose
84
147 07000-13048 O-ring 4
148 21N-62-38620 Hose 2
149 07000-13038 O-ring 4
30
WORK EQUIPMENT
150 21N-70-14220 Bushing 1
For installing bucket assembly 85
151 21N-70-13150 O-ring 2
152 21N-70-14320 Shim 14
153 21N-70-14330 Shim 4
154 21N-72-11230 Shim 3
87
155 07000-16215 O-ring 2
156 07020-00675 Fitting 2
For installing work equipment
lubrication piping
(boom cylinder)
89
157 17A-06-17930 Lamp 2
wiring
94
158 20Y-06-21551 Bracket 2
159 08193-20012 Clip 2
160 01024-81230 Bolt 2
161 209-60-77551 Filter element 2
For assembling return filter
flushing (chassis)
98
162 21T-60-13730 Plate 2
163 21N-62-19370 Tube 4
flushing tube (chassis)
102, 103
164 21N-62-19340 Tee 1
165 424-16-11140 Filter element 1
For assembling pilot filter
flushing (chassis)
105
Parts that are not assembled (kept in tool box as they are)
166 07270-51210 Tube 1
For draing water in fuel tank
167 07281-00167 Clamp 1
For draining
168 07377-01018 Flange 2
For flushing travel piping
169 X211216270 Tool assembly 1
Standard tool
170 209-72-11311 Seal 4
For installing boom foot 78
31
A. ASSEMBLY OF CHASSIS
Remarks
1. In the "drawings" in this manual, parts and places are indicated by 1, 2, 3 ---,
but indicated by (1), (2), (3) --- in the tables and texts.
Example:
2. In some places of this manual, the words of front, rear, right hand and left hand
of machine are used. Those words indicate the directions seen from the opera-
tor's seat with the sprocket at the rear as shown below, unless otherwise speci-
fied.
(1) Plate
(2) Collar
(3) Washer
(4) Bolt
(5) Bolt
(6) Washer
Front
Left hand
Right hand
Operator's seat
Rear
Sprocket
Rear
Front
Left hand Right hand
Operators seat
Sprocket
32
1. Place either track frame assembly on a flat plate.
Weight of track frame assembly (1 piece): 15,250 kg
2. Sling the center frame assembly and position it on the track frame and then install it with mounting bolts (1) and (2) (Tighten
the mounting bolts temporarily with KW20P impact wrench).
Assembly procedure
Installation of Left and Right Track Frames (1/3)
A-1
Precautions Necessary tools Necessary equipment
.
Name Qty Name Qty
30 5000 wire 2 45 ton crane 1
20 5000 wire 4
50 500 pin 2
BC20 shackle 4
KW20P impact wrench 1
M60 socket 1
O
t
h
e
r
s
Center Frame Assembly: 9,700 kg
No. Loose-supply items Qty
1 21N-30-37130 40
2 21N-30-11180 40
33
Secure two points of the center frame of the track by placing a hydraulic jack and a 300 400 mm wooden block at
each point. Make sure that these points do not interfere with the upper structure rotation.
Lift the Track Frame Assembly and install it on the Center Frame.
Assembly procedure
A-1
Name Qty Name Qty
30 5000 wire 2 45 ton crane 1
50 500 pin 2
Wooden block (400 300 mm) 2
50 t jack 2
O
t
h
e
r
s
34
a When tightening bolts, raise the track with a hydraulic jack as shown above so as to get sufficient space for tightening.
a Retighten with a 16 power wrench or a 420 kg torque wrench.
(When using a 420 kg torque wrench, pull it with 1.5 t lever block.)
Assembly procedure
A-1
Do not remove the shoes before assembling
(so as to maintain the tightening torques of
the shoe bolts).
Name Qty Name Qty
16 time wrench 1
Torque wrench (42 kg) 1
M60 Socket 1
Torque wrench (420 kg) 1
20 t jack 1
Wooden block (100 200 mm) 1
1.5 t lever block 1
O
t
h
e
r
s
Thickness of 100 mm
Wooden block
3 Connection bolt of track frame and center frame
2,890 3,630 Nm {295 370 kgm}
35
Assembly procedure
Installation of Travel Piping (1/2)
A-2
1. When connecting the hoses, check that
the mating faces are free from foreign
matter or flaw.
2. Keep the removed flanges and heads so
that they can be reused.
3. When installing a hose, take extreme care
that the O-ring will not be caught.
Name Qty Name Qty
M14 socket 1
L150 extension 1
Spanner, 22 mm width across flats 2
M19 socket 1
Oil receiving pan 2
O
t
h
e
r
s
Fix pilot hose and
drain hose together
with clamps.
1 07094-31228 8
2 07095-01241 8
3 01024-81285 8
4 04434-52512 6
5 07095-20318 6
6 01024-81225 10
7 08036-03014 6
10 07000-B3032 4
11 02896-11009 2
12 02896-11018 2
No. Parts already installed to body Qty
8 07371-31049 8
9 07375-21035 16
(1) Remove the oil plugs of the tubes and hoses on the center frame side and install
new O-rings
(07000-B3032: 4 pieces, 02896-11009: 2 pieces, 02896-11018: 2 pieces).
(2) Connect the 4 main hoses installed on the track frame to the center frame side
and fix them with clamps (1), (2), and (3).
(3) Connect 2 right pilot hoses and 2 left ones to the center frame and fix them with
clamps (4), (5), and (6).
(4) Connect 2 right drain hoses and 2 left ones to the center frame and fix them with
clamps (7) and (6).
a Reuse the split flanges, bolts, etc. used for the oil stopping parts.
36
Assembly procedure
Installation of Travel Piping (2/2)
A-2
Name Qty Name Qty
O
t
h
e
r
s
Hose connection diagram
Main hose
Drain hose
Pilot hose
37
(1) Install travel piping cover (1) with bolts (2) and large washers (3).
(2) Install travel piping covers (4) and (6) with bolts (5).
Assembly procedure
Installation of Travel Piping Covers (1/2)
A-3
Name Qty Name Qty
M19 socket 1
O
t
h
e
r
s
1 21N-30-37390 1
2 01010-81230 6
3 175-54-34170 6
4 21N-30-37421 1
5 01024-81225 8
6 21N-30-37411 1
38
(1) Install travel piping covers (1) and (2) with bolts (3) and large washers (4).
.
Assembly procedure
Installation of Travel Piping Covers (2/2)
A-3
Name Qty Name Qty
M19 socket 1
L150 extension 1
O
t
h
e
r
s
1 21N-30-37381 1
2 21N-30-37370 1
3 01010-81230 8
4 175-54-34170 8
39
(1) Install steps (1) to the right and left track frames with bolts (2) and washers (3).
Assembly procedure
Installation of Steps
A-4
Name Qty Name Qty
M24 socket 1
O
t
h
e
r
s
1 21N-30-37140 2
2 01010-81635 8
3 01643-31645 8
3 Tightening torque for step mounting bolt
245 309 Nm {25 31.5 kgm}
40
1) Pour grease (G2-Ll) in the swing circle grease bath. See Note 1.
2) Apply grease to the swing circle gear contacting surfaces. (Approx. 10 l of above 65 l)
3) Fill the grease bath seal with grease.
Assembly procedure
Filling Swing Circle with Grease
A-5
aDegrease and de-rust the mating faces of the
swing circle and upper structure.
Name Qty Name Qty
O
t
h
e
r
s
4) Apply LG-6.
(Note 1)
Supply grease near swing
circle gear.
41
(1) Clean the mounting face of the swing circle and mating face of the upper structure.
(2) Apply LG-6 to the swing circle.
Assembly procedure
Assembly of Upper Structure and Undercarriage (1/2)
A-6
Name Qty Name Qty
O
t
h
e
r
s
Apply LG-6 to swing circle gear side
of assurance mounting bolts.
(Note 1)
See Note 1.
Clean mating faces.
42
(3) Sling the upper structure and install it with bolts (1) and washers (2).
(Do not hit the upper structure against the center frame or grease bath.)
(4) Tighten all the bolts with the fingers as hard as possible. Retighten them after completing assembly. (Apply LT-2)
Tighten the 4 bolts on the right and left sides permanently.
Assembly procedure
Assembly of Upper Structure and Undercarriage (2/2)
A-6
Name Qty Name Qty
30 5000 wire 4 45 t crane 2
BC36 shackle 2 Special eyebolt 2
KW45F impact wrench 1
M50SP socket 1
O
t
h
e
r
s
1 150-74-11140 56
2 01643-33380 56
3 Tightening torque for bolt
1,960 2,450 Nm {200 250 kgm}
43
(1) Install right front step (1) with bolts (2) and install handrail (3) with bolts (2) and (4).
(2) Install right side steps (5) and (6) with bolts (4) and install right and left handrails (9) with bolts (10).
(3) Install handrails (7) and (8) with bolts (4).
Assembly procedure
Installation of Right Side Steps
A-7
Name Qty Name Qty
KKW12P impact wrench 1
M19 socket 1
L150 extension 1
O
t
h
e
r
s
1 21N-54-39640 1
2 01024-81240 12
3 21N-54-39631 1
4 01024-81230 26
5 21N-54-39661 1
6 21N-54-42430 1
7 21N-54-39611 1
8 21N-54-39621 1
9 21N-54-39650 2
10 01024-81235 8
44
(1) Install handrails (1) and (2) on the fuel tank with bolts (5).
(2) Install handrail (3) on the aftercooler cover with bolts (7).
(3) Install handrail (4) on the side of the hood with bolts (6).
Assembly procedure
Installation of Handrails
A-8
Name Qty Name Qty
M19 socket 1
L150 extension 1
O
t
h
e
r
s
1 21N-54-37241 1
2 21N-54-41711 1
3 21N-54-41721 1
4 21N-54-41741 1
5 01024-81230 16
6 01024-81235 6
7 01024-81240 8
8 21N-54-39571 1
45
1) Install the lock plate to the swivel joint.
2) Remove the oil plugs of the tubes, T-piece, and swivel joint on the revolving frame side and install new O-rings
(07000-B3032: 8 pieces, 07002-12434: 1 piece, 02896-11009: 1 piece)
3) Install the pilot hose and drain hose to the elbow and T-piece.
4) Install the main hoses (4 pieces) to the swivel joint.
Assembly procedure
Installation of Swivel Travel Piping
A-9
1. The lock plate, drain hoses, and pilot hose are
installed to the upper structure.
2. Keep the removed flanges and heads so that
they can be reused.
3. When installing a hose, take extreme care that
the O-ring will not be caught.
4. When installing a hose, take extreme care that
dirt will not enter the circuit.
Name Qty Name Qty
KW12P impact wrench 1 Large oil receiving pan 1
L150 extension 1
M14 socket 1
O
t
h
e
r
s
Connect 2 drain hoses.
Connect 4 main hoses.
Connect pilot hose.
Connect lock plate.
1 209-62-52560 1
2 01641-21626 1
3 04050-14028 1
4 02896-11009 1
5 07002-12434 1
6 07073-01A08 2
7 07073-01AA7 2
8 07000-B3032 8
No. Parts already installed to body Qty
9 07371-31049 16
10 07375-21035 32
46
Stick sheets to the surfaces of the counterweight in front of the machine as shown below.
Assembly procedure
Sticking Sheet to Counterweight
(EU specification) A-10
aRemove all oil and rust from the surface
where the sheet is to be stuck.
Name Qty Name Qty
O
t
h
e
r
s
1 21N-46-35261 1
2 21N-46-35310 1
3 21N-46-35271 1
4 21N-46-35281 1
5 21N-46-35320 1
6 21N-46-35253 1
7 21N-46-35211 1
8 01024-81230 8
47
(1) Sling the counterweight assembly with the crane and install it to the upper structure with bolts (1) and spacers (2).
Assembly procedure
Installation of Counterweight
A-11
Install the counterweight so that there will be
the reference space of 15 mm between the
weight and the revolving frame or so that the
left level difference equals to the right one.
Name Qty Name Qty
36 5000 wire 2 45 t crane 1
BC40 shackle 2
KW45SP impact wrench 1
M65SP socket 1
420 kgm torque wrench 1
38.1 square socket,
65 mm width across flats
1
O
t
h
e
r
s
Weight of counterweight assembly: 17,900 kg
1 209-09-51170 10
2 209-46-11210 10
3 Tightening torque for counterweight mounting bolt
3,430 4,212 Nm {350 430 kgm}
48
(1) Install step (1) at front of the cab with bolts (2).
(2) Install step (3) on the side of the cab with bolts (2) and install step (4) with bolts (5).
(3) Install step (6) on the side of the pump with bolts (2) and (5).
Assembly procedure
Installation of Left Side Steps (Including handrails) (1/3)
A-12
aAdjust the level difference between the steps
to 10 mm or less.
Name Qty Name Qty
KW12P impact wrench 1 25 t crane 1
M19 socket 1
L150 extension 1
M12 eyebolt 2
O
t
h
e
r
s
1 21N-54-39950 1
2 01024-81240 46
3 21N-53-31362 1
4 21N-53-31982 1
5 01024-81230 8
6 21N-53-32132 1
49
(5) Install handrails (1), (4), and (5) with bolts (2) and washers (3).
Assembly procedure
A-12
Name Qty Name Qty
KW12P impact wrench 1 25 t crane 1
M19 socket 1
L150 extension 1
25 wide 3,000 nylon sling 2
O
t
h
e
r
s
1 X21-0878211 1
2 01010-81645 22
3 01643-31645 22
4 X21-0878201 1
5 X21-0878191 1
6 8285-54-1570 1
7 21N-53-32420 1
8 01024-D1225 1
9 08037-01610 1
50
(6) Install the maintenance ladder to the step at the rear of the left side.
Install the ladder from the underside of the step.
Open the catch lock.
Put one end of the ladder (upper end of the ladder) on the rack at the front of the step and install the other end to the
hook installed to the catch lock.
Close the catch lock.
Assembly procedure
A-12
Name Qty Name Qty
O
t
h
e
r
s
Catch lock
Install to hook.
1 21N-54-32490 1
51
Install the radiator cover to the machine.
Assembly procedure
Installation of Radiator Cover
(Standard specification) A-13
aEliminate the level difference between the
radiator cover and mounting frame.
Name Qty Name Qty
O
t
h
e
r
s
100
8
(3)
1 21N-54-41351 1
2 01024-81230 8
3 01011-81220 4
4 01643-31232 4
5 21N-54-41361 1
6 01011-81200 2
7 01643-31232 2
8 01024-81280 3
52
(1) Insert net (2) in radiator cover (1) and fix it with bolts (3).
(2) Insert seal (4) in the cover.
Assembly procedure
Installation of Radiator Cover (1/4)
Name Qty Name Qty
O
t
h
e
r
s
1 21N-54-41811 1
2 21N-54-41830 2
3 01024-80816 8
4 21N-54-41880 4
3 Tightening torque for net fixing bolt
14.7 34 Nm {1.5 3.5 kgm}
53
(3) Sling the cover assembly and position it to the machine and then fix with bolts (1).
Assembly procedure
aEliminate the level difference between the
radiator cover and mounting frame.
Name Qty Name Qty
10 3000 wire 2 25 t crane 1
O
t
h
e
r
s
Weight of cover assembly: 150 kg
1 01024-81240 14
3 Tightening torque for cover mounting bolt
54 123 Nm {5.5 12.5 kgm}
54
(4) Fix spring (2) to grille frame (1) with screws (3) and insert bar (4).
(5) Install blade (5) to the frame temporarily with bolts (6), set the holes of plate (7), install bolts (8),
and tighten the bolts permanently.
Assembly procedure
Name Qty Name Qty
O
t
h
e
r
s
1 21N-54-41821 1
2 20B-54-12210 1
3 01023-10408 2
4 20Y-54-29232 1
5 21N-54-41851 16
6 01024-81020 32
7 21N-54-41860 4
8 01024-80616 32
3 Tightening torque for blade mounting bolt
54 123 Nm {5.5 12.5 kgm}
3 Tightening torque for plate mounting bolt
8.8 14.7 Nm {0.9 1.5 kgm}
55
(6) Sling the grille frame assembly, set the bolt holes of the hinge first, and tighten bolt (1).
Adjust the level difference from the cover, close the grille, and tighten the other bolts.
4 Weight of grille frame assembly: 160 kg
(7) After tightening the bolts, insert caps (2).
Assembly procedure
aEliminate the level difference from the cover.
Name Qty Name Qty
10 3000 wire 2 25 t crane 1
O
t
h
e
r
s
1 01024-81235 23
2 195-Z11-2970 17
3 Tightening torque for frame mounting bolt
54 123 Nm {5.5 12.5 kgm}
56
(1) Install muffler tail pipe assembly (1) to the top of the engine hood with bolts (2).
Assembly procedure
Installation of Muffler Tail Pipe
A-14
Name Qty Name Qty
M19 socket 1
O
t
h
e
r
s
54 123 Nm {5.5 12.5 kgm}
57
1) After removing dummy bolt, remove step light, bolt, and washer.
2) Change the mounting position and direction of step light.
Assembly procedure
Changing of Mounting Position of Step Light
A-15
Name Qty Name Qty
O
t
h
e
r
s
During transportation
(Position: On the head guard)
(Direction: Toward the chassis)
After transportation
(Position: Upper side of cab)
(Direction: Obliquely downward to
outside of chassis)
Remove dummy bolt
Spanner
(width across flats 17 mm)
58
1) Remove 4 bolts (01435-40820) installed on the cab and install handrail.
3 Tightening torque: 27 34 Nm {2.8 3.5 kgm}
Assembly procedure
Installation of Handrail to the Cab
A-16
Name Qty Name Qty
O
t
h
e
r
s
1 20Y-54-51820 1
59
(1) Install support (1) to the cabin handrail with clamp (2) and bolts (3) and then set and fix mirror (4) with roll pin (5).
Assembly procedure
Installation of Left Rearview Mirror (1/2)
A-17
For installation of the mirror,
use 209-98-77220.
Adjust the mirror to the best position.
(For the view range, see Installation manual
for mirror 21N-98-41131.)
Name Qty Name Qty
O
t
h
e
r
s
1 21N-53-32510 1
2 20Y-54-35430 1
3 01252-71025 2
4 421-54-25610 1
5 04025-00632 1
60
Pass pin (5) through the hole in ball busing (A), hold the mirror with the holder of mirror (1), then secure in position and
check that the mirror does not move.
Assembly procedure
Installation of Left Rearview Mirror (2/2)
A-17
Name Qty Name Qty
O
t
h
e
r
s
Insert pin (5) in this hole
Holder
Replace the screw (421-54-25660) of the mirror assembly
part with the hexagon head bolt (6) (01252-70545), and
tighten it.
Tightening torque: 1.5 2.0 Nm {0.15 0.2 kgm}
61
(1) Install support (1) to the right front handrail with clamps (3) and bolts (4),
set roll pin (6) to mirror (5), and fix the mirror with bolts (7).
(2) Install support (2) to the right front handrail with clamps (3) and bolts (4),
set roll pin (6) to mirror (5), and fix the mirror with bolts (7).
Assembly procedure
Installation of Right Rearview Mirrors (1/2)
A-18
For installation of the mirror,
use 209-98-77220.
Adjust the mirror to the best position.
(For the view range, see Installation manual
for mirror 21N-98-41131.)
Name Qty Name Qty
O
t
h
e
r
s
1 21N-54-41751 1
2 21N-54-42440 1
3 20Y-54-27991 2
4 01252-71025 4
5 421-54-25610 2
6 04025-00632 2
7 01252-70545 8
62
Pass pin (5) through the hole in ball busing (A), hold the mirror with the holder of mirror (1), then secure in position and
check that the mirror does not move.
Assembly procedure
Installation of Right Rearview Mirrors (2/2)
A-18
Name Qty Name Qty
O
t
h
e
r
s
Insert pin (5) in this hole
Holder
Replace the screw (421-54-25660) of the mirror assembly
part with the hexagon head bolt (6) (01252-70545), and
tighten it.
Tightening torque: 1.5 2.0 Nm {0.15 0.2 kgm}
63
Air is to be bled from the travel motor in assembly procedure [A-19]. Before starting the travel motor, loosen the air bleeder
and bleed air from the circuit.
1) Open the hydraulic tank cap.
(Keep the cap placed on the filler lightly to prevent dirt and rain from entering the tank.)
2) Prepare an oil receiver at the vinyl hose end. (Approx. 20 l can/Each side)
3) Loosen air bleeder (5).
(The air bleeding vinyl hose is installed when the machine is delivered.)
a Keep the air bleeder loosened and opened during the work equipment assembly work.
(Check the air bleeding oil level occasionally and take care that the oil will not spill.)
Assembly procedure
Preparation for Bleeding Air from Travel Motor
A-19
Name Qty Name Qty
O
t
h
e
r
s
Air bleeding vinyl hose
64
1. Bleeding air from hydraulic pump group
a If a hydraulic pump was removed and installed or a related piping was disconnected and connected, bleed air from the
hydraulic pump group according to the following procedure.
1) Loosen air bleeders (1), (2) and (3) 4 turns.
2) Loosen the oil filler cap of the hydraulic tank and leave it for about 10 minutes.
a The above time depends on the oil level in the pump case.
3) When oil flows out of air bleeders (1) and (2), tighten air bleeders (1) and (2).
4) Run the engine at low idle.
a Set the work equipment lock lever in the lock position to prevent the work equipment from moving.
5) When clear oil flows out of air bleeders (3), tighten air bleeder (3).
Assembly procedure
Procedure for Bleeding Air From Hydraulic Circuit
A-20
Name Qty Name Qty
O
t
h
e
r
s
65
In the procedure for assembly of the upper structure and undercarriage, only 4 of the 56 revolving frame and swing circle mounting
bolts were tightened permanently and the other 52 bolts were tightened temporarily. Tighten those 52 bolts in this step.
(1) Start the engine.
(2) Swing the upper structure to set the bolts to the places (right and left) marked with * in the figure and tighten the bolts to
the specified torque.
Assembly procedure
Permanent Tightening of Swing Circle Mounting Bolts
A-21
aWhile swinging the upper structure and tight-
ening the bolts, make signs securely.
Name Qty Name Qty
KW45F impact wrench 1
M50 socket 1
O
t
h
e
r
s
Width across flats 50
3 Tightening torque for bolt
1960 2450 Nm {200 250 kgm}
66
Assembly procedure
Testing Track Shoe Tension (1/3)
A-22
Name Qty Name Qty
O
t
h
e
r
s
67
Assembly procedure
A-22
Name Qty Name Qty
O
t
h
e
r
s
Grease cylinder
68
Assembly procedure
A-22
Name Qty Name Qty
O
t
h
e
r
s
Dont stand at the front.
Dont look inside.
k Warning
69
Assembly procedure
Check Fuel, Coolant and Oil Levels (1/2)
A-23
Name Qty Name Qty
O
t
h
e
r
s
70
Assembly procedure
Check Fuel, Coolant and Oil Levels (2/2)
A-23
Non-amine Supercoolant (Blue) is added
when shipped. Do not mix coolant of
different type with it.
Name Qty Name Qty
O
t
h
e
r
s
71
Assembly procedure
Parts to be Touched up after Field Assembly
A-24
Name Qty Name Qty
O
t
h
e
r
s
73
B. ASSEMBLING OF WORK EQUIPMENT
OF BACKHOE
Clean the mounting pin and pin hole and check them for a flaw.
74
(1) Remove the lock plate fixed to the boom and remove the arm cylinder foot pin.
4Arm cylinder foot pin: 92.9 kg (Standard boom)
: 101.3 kg (SE boom)
(2) Sling the arm cylinder and set it to the hole of the boom.
Adjust shim (1) (21N-72-11210) so that the clearance in the foot will be 2 mm 3 mm.
4Weight of arm cylinder: 1,500 kg
(3) Drive in the arm cylinder foot pin.
2Inside of pin hole: Apply lithium grease.
(4) Install the lock plate.
Tightening torque for plate mounting bolt: 824 1030 Nm {84 105 kgm}
Assembly procedure
Installation of Arm Cylinder
B-1
1. When working, bind the arm cylinder rod
to prevent it from coming out.
that dirt will not enter the circuit.
Name Qty Name Qty
50 wide 3,000 nylon sling 2 25 t crane 1
KW380 impact wrench 1 5 step stepladder 1
M36 socket 1
Sledge hammer 1
O
t
h
e
r
s
Lock plate
Arm cylinder foot pin
1 21N-72-11210 2
2 707-01-XZ522 1
75
(1) Remove the oil plugs from the arm cylinder and from the tubes on the boom side and install new O-rings
(07000-13048, 6 pieces).
(2) Install arm cylinder hoses (1) (3 pieces) as shown below.
Assembly procedure
Installation of Arm Cylinder Hoses
B-2
1. When working, bind the arm cylinder rod
to prevent it from coming out.
Name Qty Name Qty
KW12P impact wrench 1 5 step stepladder 1
L150 extension 1
M22 socket 1
O
t
h
e
r
s
For standard boom
For SE boom
1 07098-01418 3
2 07000-13048 6
No. Parts installed to boom Qty
3 07371-51470 12
4 01010-81455 24
5 01643-31445 24
76
(1) Remove the boom cylinder foot pin lock plate fixed to the machine body and pull out the pin.
(2) Sling the boom cylinder and position it to the machine body and then adjust shim (1) so that the clearance
(on the outside of the machine body) between the boom cylinder and revolving frame will be 2 mm 3 mm.
4Weight of boom cylinder (each): 1,200 kg
(3) Insert wooden blocks between the cylinder and revolving frame to support the boom cylinder.
(Height: 40 50 mm, Width: Max. 90 mm)
(4) Push in the boom cylinder foot pin fully and install the lock plate.
Assembly procedure
Installation of Boom Cylinder Foot
B-3
Name Qty Name Qty
KW20P impact wrench 1 Wooden block 2
M24 socket 1
O
t
h
e
r
s
Wooden blocks
to support boom
cylinder
3 Tightening torque for lock plate bolt
147 309 Nm {15 31.5 kgm}
1 21N-72-11230 8
77
(1) Remove the oil plugs from the tubes on the boom cylinder side and from the hoses on the revolving frame side and install
new O-rings (07000-13038: 2 pieces, 07000-13048: 2 pieces).
(2) Install boom cylinder hoses (1) and (5) (4 pieces) as shown below.
a The boom cylinder hoses are installed to the upper structure (machine body).
Assembly procedure
Installation of Boom Cylinder Hoses
B-4
Name Qty Name Qty
KW12P impact wrench 1 Oil receiving pan (small) 2
L150 extension 1
M19 socket 1
M22 socket 1
O
t
h
e
r
s
No. Parts installed to machine body Qty
1 07099-01216 2
2 07371-51260 4
3 01024-81245 8
5 07099-01416 2
6 07371-51470 4
7 01010-81455 8
8 01643-31445 8
4 07000-13038 2
9 07000-13048 2
78
(1) Install the seal (209-72-11311) to the boom foot
Assembly procedure
Installation of Boom Foot Dust Seal
B-5
1. Take care of the direction of its lip so that
the grease can come out from inside.
2. When installing the seal, be careful not to
slant it.
3. Insert the seal until it touches the bushing.
4. Do not hit seal with hammer directly but
use template, etc. to hit.
Name Qty Name Qty
Hammer 1
Template 1
O
t
h
e
r
s
Take care of the
direction of its lip.
Take care of the
direction of its lip.
170
170
1 209-72-11311 4
79
(1) Sling the boom assembly with the crane and set it to the pin holes of the machine.
4 Weight of boom assembly: 12,700 kg.
(2) Push the boom foot pin (which has been installed to the revolving frame) into either pin hole until it stops and then set its
opposite end into the other pin hole. If the boom slants to the right or left at this time, adjust it with a lever block.
a Adjust the clearance at the boom foot on the outside of the machine to 1 mm or less with the shim.
Combine the shims 1.0 mm thick (21N-72-11210, 3 pieces) and 1.5 mm thick (21N-72-11220, 3 pieces) to obtain proper
thickness. (Adjust the shim at only 1 place on the outside of the boom.)
(3) Push in the right and left boom foot pins fully and install the lock plates.
Assembly procedure
Installation of Boom Assembly
B-6
a Inside of pin hole: Apply lithium grease.
a When inserting the pins, take care not to dam-
age the seal (209-72-11311)
installed to the boom foot (Align the pins se-
curely).
Name Qty Name Qty
30 5000 wire 2 25 t crane 1
SD32 shackle 2 5 step stepladder 1
KW20 impact wrench 1
M24 socket 1
Sledge hammer 1
O
t
h
e
r
s
When operating crane, install ropes to
boom assembly end to prevent boom
assembly from swinging.
1 21N-72-11210 3
2 21N-72-11220 3
245 309 Nm {25 31.5 kgm}
80
(1) Remove the lock plate fixed to the boom and remove the boom cylinder top pin.
4 Boom cylinder top pin: 43.8 kg 2 pieces
(2) Start the engine and run it at low idle.
(3) Sling the cylinder, push the rod slowly, set the pin holes, and check the clearance between cylinder boss end and boom
boss end. Insert a proper number of shims so that the clearance will be 2 3 mm, push in the pin, and install the lock plate.
2Inside of pin hole: Apply lithium grease.
Assembly procedure
Installation of Boom Cylinder
B-7
aBefore connecting the boom cylinder, bleed
air. See the section of bleeding air from cylin-
der.
Name Qty Name Qty
M24 socket 1
Sledge hammer 1
O
t
h
e
r
s
Lock plate
Boom
cylinder
top pin
245 309 Nm {25 31.5 kgm}
1 707-01-XZ501 1
2 707-01-XZ511 1
3 21N-72-11230 2
81
(1) Remove the oil plugs from the tubes on the boom side and revolving frame side and install new O-rings
(07000-13048: 10 pieces, 07000-13038: 4 pieces).
(2) Install the boom hoses (7 pieces) as shown below.
Assembly procedure
Installation of Boom Hoses (Between machine and boom)
B-8
Name Qty Name Qty
KW12P impact wrench 1 Oil receiving pan 1
L150 extension 1
M19 socket 1
M22 socket 1
O
t
h
e
r
s
No. Parts installed to machine body Qty
2 07371-51470 20
3 01010-81455 40
4 01643-31445 40
7 07371-51260 8
8 01024-81245 16
1 07099-01418 5
5 07000-13048 10
6 07099-01218 2
9 07000-13038 4
82
(1) Remove the boom top pin lock plate installed to the boom and pull out the top pin.
4 Boom top pin: 168.6 kg
(2) Sling the arm assembly and set it to the holes of the boom.
Insert shim (21N-72-11210) 1.0 mm thick to reduce the clearance to below 1.0 mm and push in the pin.
4 Weight of arm assembly: 6,200 kg
2Inside of bushing: Apply grease.
2Pin: Apply grease.
Assembly procedure
Installation of Arm Assembly (1/2)
B-9
a When inserting the pin, take care not to dam-
age the seal (209-72-11311) installed in the
bushing on the arm side.
Name Qty Name Qty
25 5000 wire 2 25 t crane 1
SD32 shackle 2 5 step stepladder 1
Sledge hammer 1
M24 socket 1
O
t
h
e
r
s
Lock plate
Lock plate
Take care of grease hole
of arm cylinder rod.
Set grease hole to top.
Boom
Arm
Boom
top pin
Arm assembly top pin
245 309 Nm {25 31.5 kgm}
1 21N-72-11210 4
83
(4) Remove the arm cylinder top pin lock plate installed to the arm and pull out the top pin.
4 Weight of arm cylinder top pin: 97.9 kg
(5) Run the engine at idle and extend the arm cylinder piston rod slowly to set it to the pin hole.
(At this time, sling the arm cylinder with the crane and position the piston rod while operating.)
(6) Set the arm cylinder top hole to the arm hole, insert shim (21N-72-11210) 1.0 mm thick to adjust the clearance to 2 3 mm,
and push in the pin.
2 Inside of pin hole: Apply lithium grease.
a 1) Operate the cylinder lever slowly. Do not operate it quickly or to the stroke end. Since there is air in the cylinder, the
piston rod may not move for more than 10 seconds. Do not move the lever to the stroke end at this time.
2) When installing the arm, take care that the bucket cylinder rod will not come out.
Assembly procedure
Installation of Arm Assembly (2/2)
B-9
a Before connecting the arm cylinder, bleed air.
See the section of bleeding air from cylinder.
Name Qty Name Qty
Sledge hammer 1 5 step stepladder 1
M24 socket 1
O
t
h
e
r
s
245 309 Nm {25 31.5 kgm}
84
(1) Remove the oil plugs from the bucket cylinder and from the tubes on the boom side and install new O-rings
(07000-13038: 4 pieces, 07000-13048: 4 pieces).
(2) Install bucket cylinder hoses (1) and (5) (4 pieces) as shown below.
a When assembling, take care that the protection wires installed to the hoses will not come off the hose adapters.
Assembly procedure
Installation of Bucket Cylinder Hoses
between Boom and Bucket Cylinder B-10
1. Keep the removed flanges and heads so that
they can be reused.
Name Qty Name Qty
KW12P impact wrench 1 5 step stepladder 1
L150 extension 1 Oil receiving pan 1
M19 socket 1
M22 socket 1
O
t
h
e
r
s
Inside hoses
Outside hoses
Connect hoses in
parallel with cylinder.
1 21N-62-38620 2
2 07000-13038 4
5 21N-62-38610 2
6 07000-13048 4
No. Parts installed to boom/arm Qty
3 07371-51260 8
4 01024-81245 16
7 07371-51470 8
8 01010-81455 16
9 01643-31445 16
85
(1) Remove the stoppers of the bucket and arm connecting pin (fixed to the arm) and bucket and link connecting pin (installed
to the link) and remove each pin.
(2) Install bushing (1) and 2 O-rings (2) to the boss on the bucket side.
(3) Run the engine at idle and operate the boom cylinder and arm cylinder slowly to set the holes for the bucket and arm con-
necting pin.
2 Weight of bucket assembly: 5,100 kg
(4) Push in the arm and bucket connecting pin, adjust the clearance to 0.5 1.0 mm with shims (3) and (4), and tighten cover
mounting bolts (M30).
2 Inside of pin hole: Apply lithium grease.
Assembly procedure
Installation of Bucket Assembly (1/3)
B-11
Name Qty Name Qty
KW45F impact wrench 1 25 t crane 1
M46 socket 1
O
t
h
e
r
s
1130 1910 Nm {115 195 kgm}
1 21N-70-14220 1
2 21N-70-13150 2
3 21N-70-14320 14
4 21N-70-14330 4
86
(5) Install O-rings (2) to prevent dirt from entering the bucket and arm connecting pin to the correct positions and then install
the pin stopper.
Assembly procedure
B-11
Name Qty Name Qty
O
t
h
e
r
s
Stopper
3 Tightening torque for stopper mounting bolt
588 1030 Nm {60 105 kgm}
87
(6) While slinging the link and operating the bucket cylinder, set the holes for the bucket and link connecting pin.
a Operate the cylinder lever slowly. Do not operate it quickly or to the stroke end. Since there is air in the cylinder, the piston
rod may not move for more than 10 seconds. Do not move the lever to the stroke end at this time.
(7) Push in the link and bucket connecting pin and adjust the clearance to below 1 mm with shims (6) 1.0 mm thick.
Install O-rings (5) to prevent entry of dirt to the correct positions and install the pin stopper.
Assembly procedure
B-11
Name Qty Name Qty
O
t
h
e
r
s
a Since the shape of the link is
different from the former link,
disassemble and assemble
the arm in the vertical pos-
ture. If the arm is disassem-
bled in the horizontal posture,
in particular, the link jumps up
just after the pin is pulled out.
Take care extremely.
3 Tightening torque for stopper mounting bolt
588 1030 Nm {60 105 kgm}
5 07000-16215 2
6 21N-72-11230 3
88
Assembly procedure
Clearance Standard for Installation of Work Equipment
B-12
Name Qty Name Qty
O
t
h
e
r
s
Unit: mm
No. Item Criterion
Clearance limit
(A) (9)
Clearance between revolving frame
and boom cylinder
Adjust clearance to 2 3 mm
with shim.
(B) (10)
Clearance between revolving frame
and boom
Adjust clearance to below 1 mm
with shim.
(C) (11)
Clearance between boom and boom
cylinder
with shim.
(D) (12)
Clearance between boom and arm
cylinder
with shim.
(E) (13) Clearance between boom and arm
with shim.
(K) (18) Clearance between bucket and arm
Adjust clearance to 0.5 1 mm
with shim.
(J) (19) Clearance between bucket and link
with shim.
(F) (20)
Clearance between arm and arm
cylinder
with shim.
Standard shim
thickness: 8
Adjusting clearance
of bucket and link
Adjusting clearance
of bucket and arm
89
(1) Remove the oil plugs on the cylinder side of boom cylinder grease hoses (2 pieces) at part (a) and those on the hose nipple
side. Remove the nipples from the hoses and install them to the cylinder, and then connect the hoses.
(2) Remove the oil plugs on the cylinder side of arm cylinder foot grease hose at part (b) and that on the hose elbow side.
Remove the elbow from the hose and install it to the cylinder, and then connect the hose.
(3) Remove the oil plugs on the cylinder side of arm cylinder top grease hose at part (c) and that on the hose elbow side. Re-
move the elbow from the hose and install it to the cylinder, and then connect the hose.
(4) Remove the oil plugs on the right and left cylinder sides of boom cylinder foot grease fittings (07020-00675, 2 pieces) and
install the fittings.
Assembly procedure
Installation of Work Equipment Grease Piping
B-13
Name Qty Name Qty
O
t
h
e
r
s
1 07020-00675 2
90
a If the travel motor or swivel joint was removed and installed
or a related piping was disconnected and connected, bleed
air from the hydraulic pump group according to the following
procedure.
a Keep air bleeder (5) operated in assembly procedure
[A-10] loosened.
1) Run the engine and push up the track shoe on the side to
be bled of air by using the work equipment.
2) While running the engine at low idle, perform the following
travel operation and rotate the track shoe with no load.
(Operate the travel lever by a half stroke.)
Lever operation pattern and operation time (sec)
Assembly procedure
Procedure for Bleeding Air From Travel Motor (1/2)
B-14
Name Qty Name Qty
O
t
h
e
r
s
Unit = sec
Forward
Forward
Neutral
Neutral
Neutral
Reverse
Reverse
91
3) Check that the oil flowing through the air bleeding hose
contains no bubbles and then tighten air bleeder (5).
4) Remove the air bleeding hose and clip from the bleeder.
5) After finishing the following operation, push up the track
shoe on the opposite side and bleed air similarly.
6) Remove the air bleeding order tag plate. (Right and left)
Assembly procedure
Procedure for Bleeding Air From Travel Motor (2/2)
B-14
Name Qty Name Qty
O
t
h
e
r
s
92
a If the swing motor was removed and installed or a re-
lated piping was disconnected and connected, bleed
air from the swing motor according to the following
procedure.
1) While running the engine at slow speed, swing and
stop the upper structure several times.

a Air is bled from the swing motor automatically by the
above operation.
Assembly procedure
Bleeding Air from Swing Motor
B-15
Name Qty Name Qty
O
t
h
e
r
s
93
a If a hydraulic cylinder was removed and installed or a re-
lated piping was disconnected and connected, bleed air
from the hydraulic cylinder according to the following pro-
cedure.
1) Run the engine at idle for about 5 minutes.
2) While running the engine at slow speed, extend and re-
tract the cylinder 4 5 times.
a Move the piston rod to about 100 mm before each stroke
end and never relieve the pressure.
3) While running the engine at slow speed, move the piston
rod very slowly (taking at least 10 seconds) from a posi-
tion about 100 mm before the extension stroke end to the
stroke end and relieve the pressure for 3 minutes.
4) While running the engine at full throttle, move the piston
rod very slowly (taking at least 10 seconds) from a posi-
tion about 100 mm before the extension stroke end to the
stroke end and relieve the pressure for 1 minutes.
Assembly procedure
Bleeding Air from Cylinder
B-16
Name Qty Name Qty
O
t
h
e
r
s
94
(1) Install the lights to both sides of the boom.
(2) Connect the lights to the wires on the boom side.
Assembly procedure
Installation of Work Equipment Wiring
B-17
Name Qty Name Qty
O
t
h
e
r
s
Connect to wire
on boom side.
Connect to wire
on machine side.
Detail of mounting portion
1 17A-06-17930 2
2 20Y-06-21551 2
3 08193-20012 2
4 01024-81230 2
95
Assembly procedure
Greasing after Assembling Work Equipment
B-18
Name Qty Name Qty
O
t
h
e
r
s
97
M. PROCEDURE FOR INSPECTION AND MAINTENANCE
AFTER COMPLETION OF ASSEMBLY
98
Assembly procedure
Replacement of Return Filter
(Standard Filter to Flushing Filter) (1/3) M-1
Store the removed standard element (209-
60-75531)., strainer (20Y-60-31140). and
valve (20Y-60-31131) 2 pcs.
in order because they are used again after
flushing.
Name Qty Name Qty
O
t
h
e
r
s
Valve
Strainer
Replace the relief valve with this
plate only at the flushing time.
Special element for flushing,
Absolute filter mesh size: 6
1 209-60-77551 2
2 21T-60-13730 2
99
Assembly procedure
(Flushing Filter to Standard Filter) (2/3) M-1
This work is performed after the flushing end.
Name Qty Name Qty
O
t
h
e
r
s
Valve
Strainer
Standard element
Replacement
100
Assembly procedure
(Standard Filter Flushing Filter) (3/3) M-1
The flushing filter must be discarded after use.
The flushing filter is not allowed to be reused.
Name Qty Name Qty
O
t
h
e
r
s
101
When removing hydraulic pipes, be sure to relieve remaining
pressure in accordance with the following procedures:
(1) Remove the cap from the hydraulic oil tank.
kWhen removing the cap from the oil it slowly to relieve
pressure in the tank and remove it carefully.
(2) Lower the lock lever and keep it locked.
(3) Start the engine, operate it for about 10 seconds and stop
the engine.
a Do not increase the engine speed to over 1,000 rpm.
a Keep the control lever of the work equipment neutral.
(4) Turn the starting switch to ON, set the lock lever to Free
and set the control lever of each work equipment to Full
Stroke within 5 to 6 seconds after stopping the engine.
a Repeat the procedures (2) to (4) three times.
(5) After relieving remaining pressure, set the cap to the oil
filler port of the hydraulic oil tank so that dust do not enter
the tank.
(6) Lower the lock lever and keep it locked.
Assembly procedure
Relieving Remaining Pressure from Hydraulic Circuit
M-2
Name Qty Name Qty
O
t
h
e
r
s
102
Install the flushing tubes to flush the work equipment piping.
1. Boom cylinder hoses (Right and left)
(1) Remove the hoses on the boom cylinder side and install the flushing tubes.
(2) Install the oil plugs to the tube on the boom cylinder side.
a Reuse the installed flanges, mounting bolts, etc.
2. Arm cylinder hose
(1) Remove the hose on the arm cylinder side and install the flushing T-piece.
(2) Install the oil plug to the arm cylinder.
Assembly procedure
Installation of Flushing Tubes (1/2)
M-3
Name Qty Name Qty
O
t
h
e
r
s
Flushing tube
Flushing T-piece
103
3. Bucket cylinder hoses (Right and left)
(1) Remove the hoses on the bucket cylinder side and install the flushing tubes.
(2) Install the oil plugs to the tube on the bucket cylinder side.
a After finishing flushing, return the removed hoses.
(Remove the flushing tubes and T-pieces.)
Assembly procedure
Installation of Flushing Tubes (2/2)
M-3
1. Keep the removed flushing tubes and flush-
ing T-pieces so that they can be reused.
that any part will not be caught.
that the hose will not interfere with or catch
another part.
Name Qty Name Qty
O
t
h
e
r
s
Flushing tube
104
After finishing assembly, flush the hydraulic circuit.
(1) Set the levers in neutral and run the engine at low idle for 30 minutes.
(2) Set the levers in neutral and run the engine at medium speed for 30 minutes.
(3) While running the engine at speed of about 1,700 rpm, repeat the following lever operation pattern 4 times
(Keep each operation for 1 minute 1 minute 30 seconds).
The operation pattern for flushing is as follows.
(4) After finishing the above work, return the flushing tube and tee and perform the following flushing.
After finishing the general assembly, flush the hydraulic circuit.
a Run the engine at low idle (E mode) with the lever in neutral and perform flushing for 15 minutes according to the following
procedure.
(5) Flushing of Swing Circuit
Right swing and left swing for 3 minutes each
(6) Flushing of Travel Circuit
Press the ground with the work equipment as illustrated
here to raise one side of the machine, and operate the
travel lever as follows:
Forward travel and backward travel to the right
For 3 minutes each
Forward travel and backward travel to the left
For 3 minutes each
Assembly procedure
Flushing of Hydraulic Circuit
M-4
If the flushing is performed with the engine at
full throttle, the filter element may be broken
since the relief valve of the filter is closed.
Name Qty Name Qty
O
t
h
e
r
s
105
(1) After finishing flushing, replace the pilot filter element etc.
(2) Replacement procedure
1) Open the front cover of the engine hood.
2) Remove drain plug (1) from the bottom of the pilot
filter assembly to drain the oil from the filter case.
3) Loosen bolt (2) at the bottom of pilot filter assembly
(3) and remove the filter assembly.
4) Remove filter element (4) and install new filter
element (4).
5) Install drain plug (1).
6) Install filter assembly (3) with bolt (2).
Tightening torque for bolt (2): 6.6 9.0 kgm
a When replacing, if oil spills, clean around thoroughly.
a When draining the oil through drain plug (1), use a waste
oil receiving pan.
Assembly procedure
Replacement of Pilot Filter
(Flushing filter o Standard filter) M-5
Name Qty Name Qty
O
t
h
e
r
s
Pilot filter
Bolt
Element Filter assembly
Drain plug
E010W30-DH
E030-DH
T010
T030
T030
T030
T030
H046-HM
MONITOR
AA: Screen with all lamps lighted up
BB: Screen for standard
CC: Maintenance time warning screen
(1) User mode adjustment switch
(2) Working mode selector switch (basic switch)
(3) Alarm buzzer stop switch
(4) Wiper monitor
(5) Engine pre-heating monitor
(6) Swing lock monitor
(7) Engine coolant temperature monitor
(8) Engine oil pressure monitor
(9) Engine coolant temperature gauge
(10) Charge level monitor
(11) Radiator coolant level monitor
(12) Working mode monitor
(13) Service meter
(14) Travel speed monitor
(15) Engine oil level monitor
(16) Air cleaner clogging monitor
(17) Fuel gauge
(18) Fuel level monitor
(19) Auto-deceleration monitor
(20) Liquid crystal monitor adjustment switch
(21) Input confirmation switch
(22) Window washer switch
(23) Wiper switch
(24) Maintenance switch
(25) Travel speed selector switch (selection switch)
(26) Auto-deceleration switch (selection switch)
(27) Hydraulic oil temperature monitor
(28) Hydraulic oil temperature gauge
(29) Maintenance interval monitor
(1) Radio
(2) Large capacity airflow air conditioner blower switch (if equipped)
(3) Revolving warning lamp switch (if equipped)
(4) Lower wiper switch (machines equipped with fixed front window cab)
(5) Air conditioner control panel
(6) Lock lever
(7) L.H. work equipment control lever
(8) Travel pedals
(9) Travel levers
(10) Ashtray
(11) Machine monitor
(12) Horn switch
(13) R.H. work equipment control lever
(14) Cigarette lighter
(15) Starting switch
(16) Step light switch
(17) Fuel control dial
(18) Lamp switch
(19) Swing lock switch
(20) Machine push-up siwtch
(21) Boom shockless control switch
(22) Swing parking brake release switch
(23) Emergency pump drive switch
(24) Room lamp switch
P
1950 2050 rpm
1700 1800 rpm
High idling
2. Rediator fan speed
: Check in monitoring mode 01006
3. Measurement of oil pressure
High idling
[ rpm ]
[ rpm ]
[ rpm ]
Speed at boom raise relief
(Heavy lift: OFF)
Check in service mode 55
(Fan rotation 100% fixed mode)
Check in monitoring mode Swing pump 09000,
F pump: 01100, R pump: 01101
Speed at boom raise relief
(Heavy lift: ON)
Speed at engine rated speed
975 50 rpm
(Engine at full throttle, Oil temperature at 50 C)
Control valve main
set pressure
F pump
MPa
{kg/cm
2
}
R pump
F pump
R pump
Swing pump
Control valve main
set pressure
Control valve main
set pressure (Increase of pressure)
Control valve main
set pressure (Increase of pressure)
Control valve main
set pressure
Pilot relief valve set pressure
In neutral
When boom is raised
(Heavy: OFF) In neutral
When boom is raised
(Heavy: OFF)
In neutral
When boom is raised
(Heavy: OFF) In neutral
When boom is raised
(Heavy: OFF)
(Operate lever a little)
(Do not operate lever)
MPa
{kg/cm
2
}
MPa
{kg/cm
2
}
MPa
{kg/cm
2
}
MPa
{kg/cm
2
}
MPa
{kg/cm
2
}
31.4
+1.0
--1.5
MPa
{320
+10
--15
kg/cm
2
}
{320
+10
--15
kg/cm
2
}
{340
+10
--15
kg/cm
2
}
{340
+10
--15
kg/cm
2
}
31.4
+1.0
--1.5
MPa
33.3
+1.0
--1.5
MPa
33.3
+1.0
--1.5
MPa
{320
+10
--15
kg/cm
2
}
{32
+5
0 0 kg/cm
2
}
31.4
+1.0
--1.5
MPa
31.4
+0.5
MPa
At engine high idling,
boom raise and P mode,
heavy lift off relief
1.13
1.13
11.5
11.5

Field Assembly Pc1250lc-8 Gen00055-05

Încărcat de

Informații document

Descriere originală:

Drepturi de autor

Formate disponibile

Partajați acest document

Partajați sau inserați document

Opțiuni de partajare

Vi se pare util acest document?

Este necorespunzător acest conținut?

Drepturi de autor:

Formate disponibile

Field Assembly Pc1250lc-8 Gen00055-05

Încărcat de

Drepturi de autor:

Formate disponibile

HYDRAULIC

S-ar putea să vă placă și