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 Assembly............................................................................... 78
B- 6. Installation of Boom Cylinder ................................................................................. 79
B- 7. Installation of Boom Hoses (Between machine and boom) ................................... 80
B- 8. Installation of Arm Assembly ................................................................................. 81
B- 9. Installation of Bucket Cylinder Hoses between Boom and Bucket Cylinder .......... 83
B-10. Installation of Bucket Assembly............................................................................. 84
B-11. Clearance Standard for Installation of Work Equipment........................................ 87
B-12. Installation of Work Equipment Grease Piping ...................................................... 88
B-13. Procedure for Bleeding Air From Travel Motor...................................................... 89
B-14. Bleeding Air from Swing Motor .............................................................................. 91
B-15. Bleeding Air from Cylinder..................................................................................... 92
B-16. Installation of Work Equipment Wiring................................................................... 93
B-17. Greasing after Assembling Work Equipment......................................................... 94
M. Procedure for Inspection and Maintenance after Completion of Assembly.................... 95
M- 1. Replacement of Return Filter (Standard Filter to Flushing Filter) .......................... 96
M- 2. Relieving Remaining Pressure from Hydraulic Circuit ........................................... 99
M- 3. Installation of Flushing Tubes .............................................................................. 100
M- 4. Flushing of Hydraulic Circuit ................................................................................ 102
M- 5. Replacement of Pilot Filter (Flushing filter o Standard filter) ............................... 103

Field Assembly Inspection Report (Backhoe)

SPECIFICATIONS

Machine model PC1250-8 PC1250SP-8 PC1250LC-8

Weight of machine kg 109,900 111,700 113,500
3
Bucket capacity m 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

PC1250-8

PC1250SP-8

1
PC1250LC-8

2
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. k Check during actual work

The work supervisor or the work leader must check the following items constantly and make all the workers
observe them.
1) Are the parking brakes of the trailer and crane truck applied securely and are their wheels locked with
chocks during work? Are outriggers, if installed, used securely?
2) Are the temperature and pressure of the engine, hydraulic oil, coolant, etc. lowered sufficiently during
work?
3) Is horn or another signal is made to warn around when the engine is started? In addition, is it checked
that work equipment control lever and other control levers are in neutral and the fuel control dial (or fuel
control lever) is in the low idle position?
4) Is the balance of the slung item checked extremely during sling work with the crane?
5) Is entry prohibition for outsiders to the work place observed?

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

3
 Days

Backhoe · Inspection of oil level and

4 Divisions

coolant level
· Air bleeding from work
equipment cylinder
·
Loading shovel- Flushing of hydraulic
Assembly unit circuit
type excavator
Upper structure · Adjustment of track
q Center frame r Counterweight tension
w Left and right track frames t Platform group · Performance test
e Travel piping group · Inspection of oil y Assembling of work
ASSEMBLING PROCEDURES,

level and coolant level equipment

(Two)
Crane
APPLICABLE EQUIPMENT AND SCHEDULE

4
441 kN {45t} 441 kN {45t} 245 kN {25t}
0.49 -- 0.69 MPa
{5 -- 7 kg/cm 2}

Air compressor

15 m3/min

Worker

Leader + 5 mechanics

Start of assembling

Completion of body · Completion of general

· Meeting with all workers Completion of Installation of unit assembly to body assembling assembling
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

Tools, facility
Boom
Arm cylinder

Boom 45t crane

cylinder

Foreword
Crawler frame

Crawler frame

Center
Left deck

frame Revolving
frame

Motor cover · handrails Counterweight 45t crane

5
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

(Upper structure) (Undercarriage left) (Undercarriage right) (Center frame)

(Counterweight, Bucket, etc.) (Boom) (Arm, Arm cylinder

Boom cylinder, etc.)

Posture for each unit

(dimensions in diagram are in mm.)

Upper structure

Secure the upper structure to the platform with a chain and block.

Item PC1250-8, PC1250SP-8, PC1250LC-8

Overall width (mm) 3,490
Weight (kg) 26,700

• Fuel: Empty
• Hydraulic oil: M level

6
 TRANSPORTATION

Undercarriage

LC: 7,400 LC: 1,295

STD, SP: 6,425 STD, SP: 1,222

PC1250-8
Item PC1250SP-8 PC1250LC-8

Q’ty 2 2

30,500 37,600
Weight (kg) (15,250 × 2 pieces) (18,800 × 2 pieces)

If any warning tag is attached to the work equipment control levers,

do not start the engine.

7
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

8
 TRANSPORTATION

Arm

Item PC1250-8 PC1250SP-8

PC1250LC-8

A (mm) 4,895 4,914

B (mm) 1,626 1,683

Overall width (mm) 890 890

Weight (kg) 6,200 6,400

Bucket (excluding side cutter and shroud)

PC1250-8
Item 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

Boom cylinder (same for all models)

Weight: 2,400 kg (1200 kg × 2 pieces)

Arm cylinder (same for all models)

Weight: 1,500 kg

9
TRANSPORTATION

Center frame

Item PC1250-8, PC1250SP-8, PC1250LC-8

Overall width (mm) 3,540
Weight (kg) 9,700

Counterweight

Item PC1250-8, PC1250SP-8, PC1250LC-8

Weight (kg) 18,000

10
 TRANSPORTATION

Others
• Radiator duct (same for all models)

Item PC1250-8, PC1250SP-8, PC1250LC-8

Weight (kg) 100

• Radiator duct upper cover (same for all models)

Item PC1250-8, PC1250SP-8, PC1250LC-8

Weight (kg) 17

11
TRANSPORTATION

• Catwalk (right): same for all models

Item PC1250-8, PC1250SP-8, PC1250LC-8

Weight (kg) 17

• Catwalk (left, front): same for all models

Item PC1250-8, PC1250SP-8, PC1250LC-8

Weight (kg) 150

12
 TRANSPORTATION

• Catwalk (left, rear): same for all models

Item PC1250-8, PC1250SP-8, PC1250LC-8

Weight (kg) 160

13
LIST OF TOOLS FOR FIELD ASSEMBLING

No. Tool names Specifications Q’ty. Remarks

1 Equipment Engine compressor Komatsu, 0.69 MPa {7.0kg/cm2} 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 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
Tool

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 1m 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.
When connecting travel and
26 Waste oil pan Large, small 2 each work equipment piping
27 Wooden block 300 × 400 mm 4 Revolving frame pedestal
28 Wire ø10 × 3 m 2 For catwalk
29 ø20 × 5 m 2 For boom, arm and bucket
30 ø25 × 5 m 4 For revolving frame and track frame
31 ø30 × 5 m 2 For counterweight
32 Shackle SD30 3
33 SC18 4
Lifting tool

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 ø50 × 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 Grease G2-LI (20 kg) 4 kg Work equipment lubrication, Swing circle
Oil and
grease

42 Repair paint Natural yellow 5

43 Black gray 5
44 Waste cloth Bundle 20 kg

14
TIGHTENING TORQUE

1. Tightening torque for bolts

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

Part No. of bolt TTTTT-TTTTT

Part No. of washer EEEEE-EEEEE
Bolt specification Thread diameter × Bolt length
Tool (Socket) Applicable socket size
Tightening torque Nm {QQQ kgm}

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

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

Fig. 1

a : Bolt thread diameter (Nominal diameter)

b : Width across flats of bolt head
c : Bolt length
d : Threaded part of bolt

15
 Table 1 Tightening torque for bolts not specified in text
Unit: Nm {kgm}

Nominal size of thread Width across flats Tightening torque

× pitch (= Socket size)
a (mm) b (mm) Target Range

12 8.8 – 14.7
6×1 10
{1.2} {0.9 – 1.5}
25 14.7 – 34
8 × 1.25 13
{2.5} {1.5 – 3.5}
54 34 – 74
10 × 1.5 17
{5.5} {3.5 – 7.5}
89 54 – 123
12 × 1.75 19
{9} {5.5 – 12.5}
137 84 – 196
14 × 2 22
{14} {8.5 – 20}
230 147 – 309
16 × 2 24
{23.5} {15 – 31.5}
315 201 – 427
18 × 2.5 27
{32} {20.5 – 43.5}
460 319 – 608
20 × 2.5 30
{47} {32.5 – 62}
650 471 – 829
22 × 2.5 32
{66.5} {48 – 84.5}
810 588 – 1030
24 × 3 36
{82.5} {60 – 105}
1180 883 – 1470
27 × 3 41
{120} {90 – 150}
1520 1130 – 1910
30 × 3 46
{155} {115 – 195}
1960 1470 – 2450
33 × 3 50
{200} {150 – 250}
2450 1860 – 3040
36 × 3 55
{250} {190 – 310}
2940 2260 – 3630
39 × 3 60
{300} {230 – 370}

16
2. Tightening torque for pipe threads
Proper tightening torque for pipe threads depends on combination of the materials of the male screw and
female screw. In this manual, however, select tightening torque from Table 2 and Table 3 on the basis of
the material of the male screw. If tightening torque is specified specially in explanation, however, apply that
tightening torque.

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

Table 2
Unit: Nm {kgm}
Material of female thread
Steel Cast iron Light alloy
Nominal size
3.9 – 6.9 2.9 – 5.9 2.0 – 3.9
1/8
{0.4 – 0.7} {0.3 – 0.6} {0.2 – 0.4}
5.9 – 11.8 4.9 – 9.8 3.9 – 7.8
1/4
{0.6 – 1.2} {0.5 – 1.0} {0.4 – 0.8}
16.7 – 26.5 13.7 – 21.6 9.8 – 16.7
3/8
{1.7 – 2.7} {1.4 – 2.2} {1.0 – 1.7}
32.3 – 52.9 26.5 – 43.1 19.6 – 32.3
1/2
{3.3 – 5.4} {2.7 – 4.4} {2.0 – 3.3}
51.0 – 85.3 42.1 – 70.6 31.4 – 52.9
3/4
{5.2 – 8.7} {4.3 – 7.2} {3.2 – 5.4}
86.2 – 173.5 72.5 – 146.0 54.9 – 111.7
1
{8.8 – 17.7} {7.4 – 14.9} {5.6 – 11.4}

2.2 If the male screw is made of refined steel (heat-treated hard steel), apply Table 3.

Table 3
Unit: Nm {kgm}
Material of female thread
Steel Cast iron Light alloy
Nominal size
16.7 – 29.4 9.8 – 19.6 6.9 – 14.7
1/8
{1.7 – 3.0} {1.0 – 2.0} {0.7 – 1.5}
19.6 – 44.1 16.7 – 37.2 12.7 – 28.4
1/4
{2.0 – 4.5} {1.7 – 3.8} {1.3 – 2.9}
44.1 – 93.1 37.2 – 77.4 27.4 – 58.8
3/8
{4.5 – 9.5} {3.8 – 7.9} {2.8 – 6.0}
98.0 – 188.2 83.3 – 157.8 60.8 – 115.6
1/2
{10.0 – 19.2} {8.5 – 16.1} {6.2 – 11.8}
170.5 – 316.5 141.1 – 247.0 105.8 – 186.2
3/4
{17.4 – 32.3} {14.4 – 25.2} {10.8 – 19.0}
367.5 – 612.5 309.7 – 514.5 235.2 – 392.0
1
{37.5 – 62.5} {31.6 – 52.5} {24.0 – 40.0}

17
3. Tightening torque for hydraulic hose connecting nut
For the connecting nuts installed to the hydraulic hose adapters in relatively low pressure systems, apply
tightening torque in Table 4.

Table 4
Unit: Nm {kgm}

Outside diameter Width across Tightening torque

of hose flatse.
(mm) (mm) Range Target

Approx. 6 19 35 – 63 {3.5 – 6.5} 44 {4.5}

22 54 – 93 {5.5 – 9.5} 74 {7.5}

Approx. 10
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}

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

18
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

• Used to prevent rubber gaskets, rub-

LT-1A 790-129-9030 150 g Tube ber cushions, and cock plug from
coming out.
• Used in places requiring an immedi-
ately effective, strong adhesive.
20 g Polyethylene Used for plastics (except polyethyl-
LT-1B 790-129-9050 (2 pcs.) container ene, polyprophylene, tetrafluoroeth-
lene and vinyl chloride), rubber,
metal and non-metal.
• Features: Resistance to heat and
Polyethylene chemicals
LT-2 09940-00030 50 g container • Used for anti-loosening and sealant
purpose for bolts and plugs.
Adhesive: • Used as adhesive or sealant for met-
790-129-9060 1 kg al, glass and plastic.
LT-3 (Set of adhesive Hardening Can
and hardening agent:
agent) 500 g
Adhesives
Polyethylene • Used as sealant for machined holes.
LT-4 790-129-9040 250 g container

Holtz • Used as heat-resisting sealant for re-

MH 705 790-126-9120 75 g Tube pairing engine.

• Quick hardening type adhesive

Three bond 790-129-9140 50 g Polyethylene • Cure time: within 5 sec. to 3 min.
1735 container • Used mainly for adhesion of metals,
rubbers, plastics and woods.
• Quick hardening type adhesive
• Quick cure type (max. strength after
Aron-alpha 790-129-9130 2g Polyethylene 30 minutes)
201 container • Used mainly for adhesion of rubbers,
plastics and metals.
• Resistance to heat, chemicals
Loctite 79A-129-9110 50 cc Polyethylene • Used at joint portions subject to high
648-50 container temperatures.
• Used as adhesive or sealant for gas-
LG-1 790-129-9010 200 g Tube kets and packing of power train case,
etc.
• Used as sealant for various threads,
LG-5 790-129-9080 1 kg Can pipe joints, flanges.
• Used as sealant for tapered plugs,
elbows, nipples of hydraulic piping.
• Features: Silicon based, resistance
to heat, cold
• Used as sealant for flange surface,
LG-6 790-129-9020 200 g Tube tread.
• Used as sealant for oil pan, final
Gasket drive case, etc.
sealant
• Features: Silicon based, quick hard-
ening type
LG-7 790-129-9070 1 kg Tube • Used as sealant for flywheel hous-
ing, intake manifold, oil pan, thermo-
stat housing, etc.
Three bond • Used as heat-resisting sealant for re-
1211 790-129-9090 100 g Tube pairing engine.

• Features: Silicone type, heat resist-

Three bond ant, vibration resistant, and impact
1207B 419-15-18131 100 g Tube resistant sealing material
• Used as sealing material for transfer
case

19
 Category Komatsu code Part No. Q'ty Container Main applications, features

• Used as lubricant for sliding portion

LM-G 09940-00051 60 g Can (to prevent from squeaking).
Molybdenum • Used to prevent seizure or scuffling
disulphide of the thread when press fitting or
lubricant LM-P 09940-00040 200 g Tube shrink fitting.
• Used as lubricant for linkage, bear-
ings, etc.
SYG2-400LI • General purpose type
SYG2-350LI
G2-LI SYG2-400LI-A Various Various
SYG2-160LI
SYGA-160CNLI
SYG2-400CA • Used for normal temperature, light
SYG2-350CA load bearing at places in contact
G2-CA SYG2-400CA-A Various Various with water or steam.
SYG2-160CA
SYGA-160CNCA

Molybdenum • Used for heavy load portion

disulphide SYG2-400M 400 g × 10 Bellows type
Grease grease SYG2-400M-A 400 g × 20 Bellows type
LM-G (G2-M) SYGA-16CNM 16 kg Can

• Seizure resistance and heat resist-

Hyper White SYG2-400T-A ance higher than molybdenum di-
Grease G2-T SYG2-16CNT 400 g Bellows type sulfide grease
G0-T (*) SYG0-400T-A (*) 16 kg Can • Since this grease is white, it does
*: For use in cold SYG0-16CNT (*) not stand out against machine
district body.
Biogrease G2B • Since this grease is decomposed
SYG2-400B by bacteria in short period, it has
G2-BT (*) SYGA-16CNB 400 g Bellows type
*: For high less effects on microorganisms,
SYG2-400BT (*) 16 kg Can animals, and plants.
temperature SYGA-16CNBT (*)
and large load

SUNSTAR • Used as primer for cab side

Glass (Expiration date: 4 months)
PAINT PRIMER 20 ml container
580 SUPER
Primer
SUNSTAR • Used as primer for glass side
Glass (Expiration date: 4 months)
GLASS PRIMER 20 ml container
580 SUPER 417-926-3910
• "S" is used for high-tempera-
SUNSTAR ture season (April - October)
Adhesive for cab glass

PENGUINE Polyethylene and "W" for low-temperature

SEAL 580 320 ml container season (November - April) as
Adhesive SUPER "S" or adhesive for glass.
"W" (Expiration date: 4 months)
Sika Japan, Polyethylene • Used as adhesive for glass.
20Y-54-39850 310 ml (Expiration date: 6 months)
Sikaflex 256HV container

SUNSTAR • Used to seal joints of glass

Polyethylene parts.
PENGUINE 417-926-3920 320 ml container
SEAL No. 2505 (Expiration date: 4 months)

SEKISUI • Used to seal front window.

Caulking Polyethylene (Expiration date: 6 months)
material SILICONE 20Y-54-55130 333 ml container
SEALANT

GE TOSHIBA • Used to seal joint of glasses.

SILICONES 22M-54-27220 333 ml Cartridge Translucent white seal.
TOSSEAL 381 (Expiration date: 12 months)

Natural yellow SYPA-U03PNY – Spray can

Paint
Black gray SYPA-U03PBG – Spray can

20
LIST OF PARTS SENT INDIVIDUALLY
CHASSIS (STANDARD SPECIFICATION)

No. Parts No. Parts names Q’ty 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 37, 38

cover
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 45

piping
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

21
CHASSIS (STANDARD SPECIFICATION)
No. Parts No. Parts names Q’ty Remarks Page

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

58 X21-0878201 Handrail assembly 1

59 01010-81645 Bolt 6

60 01643-31645 Washer 6

61 X21-0878211 Handrail assembly 1

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

22
CHASSIS (STANDARD SPECIFICATION)

No. Parts No. Parts names Q’ty Remarks Page

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 51

(STD)
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

23
CHASSIS (STANDARD SPECIFICATION)
No. Parts No. Parts names Q’ty Remarks Page

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 59

mirror
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 61

mirror
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

24
CHASSIS (EU SPECIFICATION)

No. Parts No. Parts names Q’ty 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 37, 38

cover
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 45

piping
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

25
CHASSIS (EU SPECIFICATION)
No. Parts No. Parts names Q’ty Remarks Page

33 01024-81230 Bolt 8 For sticking sheet 46

(counterweight)
34 21N-46-35320 Cover 1 (EU Spec.)
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

55 X21-0878191 Handrail assembly 1

56 01010-81645 Bolt 10

57 01643-31645 Washer 10
58 X21-0878201 Handrail assembly 1

59 01010-81645 Bolt 6

60 01643-31645 Washer 6

61 X21-0878211 Handrail assembly 1

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

26
CHASSIS (EU SPECIFICATION)
No. Parts No. Parts names Q’ty Remarks Page

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 For installing radiator cover 52 - 55

(EU Spec.)
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

27
CHASSIS (EU SPECIFICATION)
No. Parts No. Parts names Q’ty Remarks Page

114 21N-54-41821 Cover 1 For installing radiator cover 54, 55

(EU Spec.)
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 59

mirror
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 61

mirror
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

28
WORK EQUIPMENT
No. Parts No. Parts names Q’ty Remarks Page

129 21N-72-11230 Shim 8 For installing boom cylinder 76

foot

130 07000-13038 O-ring 2 For installing boom cylinder 77

hose
131 07000-13048 O-ring 2

132 21N-72-11210 Shim 3 For installing boom assembly 78

133 21N-72-11220 Shim 3

134 707-01-XZ501 Boom cylinder (L.H.) 1 For installing boom cylinder 79

135 707-01-XZ511 Boom cylinder (R.H.) 1

136 21N-72-11230 Shim 2

137 07099-01218 Hose 2 For installing boom hose 80

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 81

146 21N-62-38610 Hose 2 For installing bucket cylinder 83

hose
147 07000-13048 O-ring 4

148 21N-62-38620 Hose 2

149 07000-13038 O-ring 4

29
WORK EQUIPMENT
No. Parts No. Parts names Q’ty Remarks Page

150 21N-70-14220 Bushing 1 For installing bucket assembly 84

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 86

155 07000-16215 O-ring 2

156 07020-00675 Fitting 2 For installing work equipment 88

lubrication piping
(boom cylinder)

157 17A-06-17930 Lamp 2 For installing work equipment 93

wiring
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 96

flushing (chassis)
162 21T-60-13730 Plate 2

163 21N-62-19370 Tube 4 For installing work equipment 100, 101

flushing tube (chassis)
164 21N-62-19340 Tee 1

165 424-16-11140 Filter element 1 For assembling pilot filter 103

flushing (chassis)

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

30
 A. ASSEMBLY OF CHASSIS

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

Example:

(1) Plate
(2) Collar
(3) Washer
(4) Bolt
(5) Bolt
(6) Washer

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.

Front
Front

Operator’s
Left hand seat Right hand

Left hand Right hand

Operator's seat
Sprocket

Sprocket
Rear
Rear

31
 Assembly procedure
Installation of Left and Right Track Frames (1/3)
A-1

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).

Center Frame Assembly: 9,700 kg

No. Loose-supply items Q’ty

1 21N-30-37130 40
2 21N-30-11180 40

Precautions Necessary tools Necessary equipment

. Name Q’ty Name Q’ty

ø 30 × 5000 wire 2 45 ton crane 1
ø 20 × 5000 wire 4
ø 50 × 500 pin 2
BC20 shackle 4
KW20P impact wrench 1
M60 socket 1
Others

32
Assembly procedure
Installation of Left and Right Track Frames (2/3)
A-1

• 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.

Precautions Necessary tools Necessary equipment

Name Q’ty Name Q’ty
ø 30 × 5000 wire 2 45 ton crane 1
ø 50 × 500 pin 2
Wooden block (400 × 300 mm) 2
50 t jack 2
Others

33
 Assembly procedure
Installation of Left and Right Track Frames (3/3)
A-1

Thickness of 100 mm
Wooden block

a When tightening bolts, raise the track with a hydraulic jack as shown above so as to get sufficient space for tightening.

3 Connection bolt of track frame and center frame

2,890 – 3,630 Nm {295 – 370 kgm}

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.)

Precautions Necessary tools Necessary equipment

Do not remove the shoes before assembling Name Q’ty Name Q’ty
(so as to maintain the tightening torques of 16 time wrench 1
the shoe bolts).
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
Others

34
 Assembly procedure
Installation of Travel Piping (1/2)
A-2

Fix pilot hose and

drain hose together
with clamps.

(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
No. Loose-supply items Q’ty
and fix them with clamps (1), (2), and (3). 1 07094-31228 8
2 07095-01241 8
(3) Connect 2 right pilot hoses and 2 left ones to the center frame and fix them with 3 01024-81285 8
clamps (4), (5), and (6). 4 04434-52512 6
5 07095-20318 6
6 01024-81225 10
(4) Connect 2 right drain hoses and 2 left ones to the center frame and fix them with 7 08036-03014 6
clamps (7) and (6). 10 07000-B3032 4
11 02896-11009 2
a Reuse the split flanges, bolts, etc. used for the oil stopping parts. 12 02896-11018 2
No. Parts already installed to body Q’ty
8 07371-31049 8
9 07375-21035 16

Precautions Necessary tools Necessary equipment

1. When connecting the hoses, check that Name Q’ty Name Q’ty
the mating faces are free from foreign KW12P impact wrench 1
matter or flaw.
M14 socket 1
2. Keep the removed flanges and heads so
L150 extension 1
that they can be reused.
Spanner, 22 mm width across flats 2
3. When installing a hose, take extreme care
that the O-ring will not be caught. Spanner, 36 mm width across flats 2
M19 socket 1
Oil receiving pan 2
Others

35
Assembly procedure
Installation of Travel Piping (2/2)
A-2

Hose connection diagram

Main hose

Drain hose

Pilot hose

Precautions Necessary tools Necessary equipment

Name Q’ty Name Q’ty
Others

36
Assembly procedure
Installation of Travel Piping Covers (1/2)
A-3

(1) Install travel piping cover (1) with bolts (2) and large washers (3).

(2) Install travel piping covers (4) and (6) with bolts (5).

No. Loose-supply items Q’ty

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

Precautions Necessary tools Necessary equipment

Name Q’ty Name Q’ty
KW12P impact wrench 1
M19 socket 1
Others

37
Assembly procedure
Installation of Travel Piping Covers (2/2)
A-3

(1) Install travel piping covers (1) and (2) with bolts (3) and large washers (4).
.

No. Loose-supply items Q’ty

1 21N-30-37381 1
2 21N-30-37370 1
3 01010-81230 8
4 175-54-34170 8

Precautions Necessary tools Necessary equipment

Name Q’ty Name Q’ty
KW12P impact wrench 1
M19 socket 1
L150 extension 1
Others

38
Assembly procedure
Installation of Steps
A-4

(1) Install steps (1) to the right and left track frames with bolts (2) and washers (3).

3 Tightening torque for step mounting bolt

245 – 309 Nm {25 – 31.5 kgm}

No. Loose-supply items Q’ty

1 21N-30-37140 2
2 01010-81635 8
3 01643-31645 8

Precautions Necessary tools Necessary equipment

Name Q’ty Name Q’ty
KW20P impact wrench 1
M24 socket 1
Others

39
 Assembly procedure
Filling Swing Circle with Grease
A-5

4) Apply LG-6.

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.

(Note 1)

Supply grease near swing

circle gear.

Precautions Necessary tools Necessary equipment

a Degrease and de-rust the mating faces of the Name Q’ty Name Q’ty
swing circle and upper structure.
Others

40
Assembly procedure
Assembly of Upper Structure and Undercarriage (1/2)
A-6

(1) Clean the mounting face of the swing circle and mating face of the upper structure.

(2) Apply LG-6 to the swing circle.

See Note 1.

Clean mating faces.

Precautions Necessary tools Necessary equipment

Name Q’ty Name Q’ty

(Note 1)
Others

Apply LG-6 to swing circle gear side

of assurance mounting bolts.

41
Assembly procedure
Assembly of Upper Structure and Undercarriage (2/2)
A-6

(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.

3 Tightening torque for bolt

1,960 – 2,450 Nm {200 – 250 kgm}

No. Loose-supply items Q’ty

1 150-74-11140 56
2 01643-33380 56

Precautions Necessary tools Necessary equipment

Name Q’ty Name Q’ty
ø 30 × 5000 wire 4 45 t crane 2
BC36 shackle 2 Special eyebolt 2
KW45F impact wrench 1
M50SP socket 1
Others

42
Assembly procedure
Installation of Right Side Steps
A-7

(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).

No. Loose-supply items Q’ty

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

Precautions Necessary tools Necessary equipment

Name Q’ty Name Q’ty
KKW12P impact wrench 1
M19 socket 1
L150 extension 1
Others

43
Assembly procedure
Installation of Handrails
A-8

(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).

No. Loose-supply items Q’ty

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

Precautions Necessary tools Necessary equipment

Name Q’ty Name Q’ty
KW12P impact wrench 1
M19 socket 1
L150 extension 1
Others

44
 Assembly procedure
Installation of Swivel Travel Piping
A-9

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.

a Reuse the split flanges, bolts, etc. used for the oil stopping parts.

Connect 2 drain hoses.

Connect 4 main hoses.

Connect lock plate.

No. Loose-supply items Q’ty

Connect pilot hose. 1 209-62-52560 1
2 01641-21626 1
3 04050-14028 1
4 02896-11009 1
5 07002-12434 1
No. Parts already installed to body Q’ty 6 07073-01A08 2
9 07371-31049 16 7 07073-01AA7 2
10 07375-21035 32 8 07000-B3032 8

Precautions Necessary tools Necessary equipment

1. The lock plate, drain hoses, and pilot hose are Name Q’ty Name Q’ty
installed to the upper structure. KW12P impact wrench 1 Large oil receiving pan 1
2. Keep the removed flanges and heads so that
L150 extension 1
they can be reused.
3. When installing a hose, take extreme care that M14 socket 1
the O-ring will not be caught.
Spanner, 22 mm width across flats 2
4. When installing a hose, take extreme care that
dirt will not enter the circuit. Spanner, 36 mm width across flats 2
Others

45
 Assembly procedure
Sticking Sheet to Counterweight
A-10 (EU specification)

• Stick sheets to the surfaces of the counterweight in front of the machine as shown below.

No. Loose-supply items Q’ty

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

Precautions Necessary tools Necessary equipment

a Remove all oil and rust from the surface Name Q’ty Name Q’ty
where the sheet is to be stuck.
Others

46
 Assembly procedure
Installation of Counterweight
A-11

(1) Sling the counterweight assembly with the crane and install it to the upper structure with bolts (1) and spacers (2).

Weight of counterweight assembly: 17,900 kg

3 Tightening torque for counterweight mounting bolt

3,430 – 4,212 Nm {350 – 430 kgm}

No. Loose-supply items Q’ty

1 209-09-51170 10
2 209-46-11210 10

Precautions Necessary tools Necessary equipment

Install the counterweight so that there will be Name Q’ty Name Q’ty
the reference space of 15 mm between the ø 36 × 5000 wire 2 45 t crane 1
weight and the revolving frame or so that the
left level difference equals to the right one. BC40 shackle 2
KW45SP impact wrench 1
M65SP socket 1
420 kgm torque wrench 1
38.1 square × socket, 1
65 mm width across flats
Others

47
 Assembly procedure
Installation of Left Side Steps (Including handrails) (1/3)
A-12

(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).

No. Loose-supply items Q’ty

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

Precautions Necessary tools Necessary equipment

a Adjust the level difference between the steps Name Q’ty Name Q’ty
to 10 mm or less. KW12P impact wrench 1 25 t crane 1
M19 socket 1
L150 extension 1
M12 eyebolt 2
Others

48
Assembly procedure
Installation of Left Side Steps (Including handrails) (2/3)
A-12

(5) Install handrails (1), (4), and (5) with bolts (2) and washers (3).

No. Loose-supply items Q’ty

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

Precautions Necessary tools Necessary equipment

Name Q’ty Name Q’ty
KW12P impact wrench 1 25 t crane 1
M19 socket 1
L150 extension 1
25 wide × 3,000 nylon sling 2
Others

49
Assembly procedure
Installation of Left Side Steps (Including handrails) (3/3)
A-12

(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.

Catch lock

Install to hook.

No. Loose-supply items Q’ty

1 21N-54-32490 1

Precautions Necessary tools Necessary equipment

Name Q’ty Name Q’ty
Others

50
 Assembly procedure
Installation of Radiator Cover
A-13 (Standard specification)

Install the radiator cover to the machine.

100

8
(3)

No. Loose-supply items Q’ty

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

Precautions Necessary tools Necessary equipment

a Eliminate the level difference between the Name Q’ty Name Q’ty
radiator cover and mounting frame.
Others

51
Assembly procedure
Installation of Radiator Cover (1/4)
A-13 (EU specification)

(1) Insert net (2) in radiator cover (1) and fix it with bolts (3).

(2) Insert seal (4) in the cover.

3 Tightening torque for net fixing bolt

14.7 – 34 Nm {1.5 – 3.5 kgm}

No. Loose-supply items Q’ty

1 21N-54-41811 1
2 21N-54-41830 2
3 01024-80816 8
4 21N-54-41880 4

Precautions Necessary tools Necessary equipment

Name Q’ty Name Q’ty
Others

52
 Assembly procedure
Installation of Radiator Cover (2/4)
A-13 (EU specification)

(3) Sling the cover assembly and position it to the machine and then fix with bolts (1).

Weight of cover assembly: 150 kg

3 Tightening torque for cover mounting bolt

54 – 123 Nm {5.5 – 12.5 kgm}

No. Loose-supply items Q’ty

1 01024-81240 14

Precautions Necessary tools Necessary equipment

a Eliminate the level difference between the Name Q’ty Name Q’ty
radiator cover and mounting frame. ø 10 × 3000 wire 2 25 t crane 1
Others

53
Assembly procedure
Installation of Radiator Cover (3/4)
A-13 (EU specification)

(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.

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}

No. Loose-supply items Q’ty

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

Precautions Necessary tools Necessary equipment

Name Q’ty Name Q’ty
Others

54
 Assembly procedure
Installation of Radiator Cover (4/4)
A-13 (EU specification)

(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).

3 Tightening torque for frame mounting bolt

54 – 123 Nm {5.5 – 12.5 kgm}

No. Loose-supply items Q’ty

1 01024-81235 23
2 195-Z11-2970 17

Precautions Necessary tools Necessary equipment

a Eliminate the level difference from the cover. Name Q’ty Name Q’ty
ø 10 × 3000 wire 2 25 t crane 1
Others

55
Assembly procedure
Installation of Muffler Tail Pipe
A-14

(1) Install muffler tail pipe assembly (1) to the top of the engine hood with bolts (2).

3 Tightening torque for cover mounting bolt

54 – 123 Nm {5.5 – 12.5 kgm}

Precautions Necessary tools Necessary equipment

Name Q’ty Name Q’ty
KW12P impact wrench 1
M19 socket 1
Others

56
Assembly procedure
Changing of Mounting Position of Step Light
A-15

1) After removing dummy bolt, remove step light, bolt, and washer.
2) Change the mounting position and direction of step light.

During transportation
(Position: On the head guard)
(Direction: Toward the chassis)

Remove dummy bolt

Spanner
(width across flats 17 mm)

After transportation
(Position: Upper side of cab)
(Direction: Obliquely downward to
outside of chassis)

Precautions Necessary tools Necessary equipment

Name Q’ty Name Q’ty
Others

57
Assembly procedure
Installation of Handrail to the Cab
A-16

3 Tightening torque: 27 – 34 Nm {2.8 – 3.5 kgm}

1) Remove 4 bolts (01435-40820) installed on the cab and install handrail.

No. Loose-supply items Q’ty

1 20Y-54-51820 1

Precautions Necessary tools Necessary equipment

Name Q’ty Name Q’ty
Others

58
 Assembly procedure
Installation of Left Rearview Mirror (1/2)
A-17

(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).

No. Loose-supply items Q’ty

1 21N-53-32510 1
2 20Y-54-35430 1
3 01252-71025 2
4 421-54-25610 1
5 04025-00632 1

Precautions Necessary tools Necessary equipment

For installation of the mirror, Name Q’ty Name Q’ty

use 209-98-77220.
Adjust the mirror to the best position.
(For the view range, see “Installation manual
for mirror” 21N-98-41131.)
Others

59
Assembly procedure
Installation of Left Rearview Mirror (2/2)
A-17

• 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.

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}

Precautions Necessary tools Necessary equipment

Name Q’ty Name Q’ty
Others

60
 Assembly procedure
Installation of Right Rearview Mirrors (1/2)
A-18

(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).

No. Loose-supply items Q’ty

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

Precautions Necessary tools Necessary equipment

For installation of the mirror, Name Q’ty Name Q’ty

use 209-98-77220.
Adjust the mirror to the best position.
(For the view range, see “Installation manual
for mirror” 21N-98-41131.)
Others

61
Assembly procedure
Installation of Right Rearview Mirrors (2/2)
A-18

• 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.

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}

Precautions Necessary tools Necessary equipment

Name Q’ty Name Q’ty
Others

62
Assembly procedure
Preparation for Bleeding Air from Travel Motor
A-19

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.

Air bleeding vinyl hose

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.)

Precautions Necessary tools Necessary equipment

Name Q’ty Name Q’ty
Others

63
Assembly procedure
Procedure for Bleeding Air From Hydraulic Circuit
A-20

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).

Precautions Necessary tools Necessary equipment

Name Q’ty Name Q’ty
Others

64
 Assembly procedure
Permanent Tightening of Swing Circle Mounting Bolts
A-21

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.

3 Tightening torque for bolt

1960 – 2450 Nm {200 – 250 kgm}

Width across flats 50

Precautions Necessary tools Necessary equipment

a While swinging the upper structure and tight- Name Q’ty Name Q’ty
ening the bolts, make signs securely. KW45F impact wrench 1
M50 socket 1
Others

65
Assembly procedure
Testing Track Shoe Tension (1/3)
A-22

Precautions Necessary tools Necessary equipment

Name Q’ty Name Q’ty
Others

66
Assembly procedure
Testing Track Shoe Tension (2/3)
A-22

Grease cylinder

Precautions Necessary tools Necessary equipment

Name Q’ty Name Q’ty
Others

67
Assembly procedure
Testing Track Shoe Tension (3/3)
A-22

k Warning
• Don’t stand at the front.
• Don’t look inside.

Precautions Necessary tools Necessary equipment

Name Q’ty Name Q’ty
Others

68
Assembly procedure
Check Fuel, Coolant and Oil Levels (1/2)
A-23

Precautions Necessary tools Necessary equipment

Name Q’ty Name Q’ty
Others

69
 Assembly procedure
Check Fuel, Coolant and Oil Levels (2/2)
A-23

Precautions Necessary tools Necessary equipment

• Non-amine Supercoolant (Blue) is added Name Q’ty Name Q’ty

when shipped. Do not mix coolant of
different type with it.
Others

70
Assembly procedure
Parts to be Touched up after Field Assembly
A-24

Precautions Necessary tools Necessary equipment

Name Q’ty Name Q’ty
Others

71
B. ASSEMBLING OF WORK EQUIPMENT
OF BACKHOE

• Clean the mounting pin and pin hole and check them for a flaw.

73
 Assembly procedure
Installation of Arm Cylinder
B-1

(1) Remove the lock plate fixed to the boom and remove the arm cylinder foot pin.

4 Arm 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.

4 Weight of arm cylinder: 1,500 kg

(3) Drive in the arm cylinder foot pin.

2 Inside of pin hole: Apply lithium grease.

(4) Install the lock plate.

Tightening torque for plate mounting bolt: 824 – 1030 Nm {84 – 105 kgm}

Lock plate

Arm cylinder foot pin

No. Loose-supply items Q’ty

1 21N-72-11210 2
2 707-01-XZ522 1

Precautions Necessary tools Necessary equipment

1. When working, bind the arm cylinder rod Name Q’ty Name Q’ty
to prevent it from coming out. 50 wide × 3,000 nylon sling 2 25 t crane 1
2. Keep the removed flanges and heads so
that they can be reused. KW380 impact wrench 1 5 step stepladder 1
3. When installing a hose, take extreme care
M36 socket 1
that the O-ring will not be caught.
4. When installing a hose, take extreme care Sledge hammer 1
that dirt will not enter the circuit.
Others

74
 Assembly procedure
Installation of Arm Cylinder Hoses
B-2

(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.

a Reuse the split flanges, bolts, etc. used for the oil stopping parts.

For standard boom

For SE boom

No. Loose-supply items Q’ty

1 07098-01418 3
2 07000-13048 6
No. Parts installed to boom Q’ty
3 07371-51470 12
4 01010-81455 24
5 01643-31445 24

Precautions Necessary tools Necessary equipment

1. When working, bind the arm cylinder rod Name Q’ty Name Q’ty
to prevent it from coming out. KW12P impact wrench 1 5 step stepladder 1
2. Keep the removed flanges and heads so
that they can be reused. L150 extension 1
3. When installing a hose, take extreme care
M22 socket 1
that the O-ring will not be caught.
4. When installing a hose, take extreme care
that dirt will not enter the circuit.
Others

75
Assembly procedure
Installation of Boom Cylinder Foot
B-3

(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.

4 Weight 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.

3 Tightening torque for lock plate bolt

147 – 309 Nm {15 – 31.5 kgm}

Wooden blocks
to support boom
cylinder

No. Loose-supply items Q’ty

1 21N-72-11230 8

Precautions Necessary tools Necessary equipment

Name Q’ty Name Q’ty
25 wide × 3,000 nylon sling 1 25 t crane 1
KW20P impact wrench 1 Wooden block 2
M24 socket 1
Others

76
 Assembly procedure
Installation of Boom Cylinder Hoses
B-4

(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).
a Reuse the split flanges, bolts, etc. used for the oil stopping parts.

No. Parts installed to machine body Q’ty

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
No. Loose-supply items Q’ty
4 07000-13038 2
9 07000-13048 2

Precautions Necessary tools Necessary equipment

1. Keep the removed flanges and heads so Name Q’ty Name Q’ty
that they can be reused. KW12P impact wrench 1 Oil receiving pan (small) 2
2. When installing a hose, take extreme care
that the O-ring will not be caught. L150 extension 1
3. When installing a hose, take extreme care
M19 socket 1
that dirt will not enter the circuit.
M22 socket 1
Others

77
 Assembly procedure
Installation of Boom Assembly
B-5

(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.

When operating crane, install ropes to

boom assembly end to prevent boom
assembly from swinging.

(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.

3 Tightening torque for plate mounting bolt

245 – 309 Nm {25 – 31.5 kgm}

No. Loose-supply items Q’ty

1 21N-72-11210 3
2 21N-72-11220 3

Precautions Necessary tools Necessary equipment

a Inside of pin hole: Apply lithium grease. Name Q’ty Name Q’ty
a When inserting the pins, take care not to dam- ø 30 × 5000 wire 2 25 t crane 1
age the seal (209-72-11311)
SD32 shackle 2 5 step stepladder 1
installed to the boom foot (Align the pins se-
curely). KW20 impact wrench 1
M24 socket 1
Sledge hammer 1
Others

78
 Assembly procedure
Installation of Boom Cylinder
B-6

(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.

2 Inside of pin hole: Apply lithium grease.

3 Tightening torque for plate mounting bolt

245 – 309 Nm {25 – 31.5 kgm}

Boom
cylinder
Lock plate top pin

No. Loose-supply items Q’ty

1 707-01-XZ501 1
2 707-01-XZ511 1
3 21N-72-11230 2

Precautions Necessary tools Necessary equipment

aBefore connecting the boom cylinder, bleed Name Q’ty Name Q’ty
air. See the section of bleeding air from cylin- 25 wide × 3,000 nylon sling 1 25 t crane 1
der.
KW20P impact wrench 1
M24 socket 1
Sledge hammer 1
Others

79
 Assembly procedure
Installation of Boom Hoses (Between machine and boom)
B-7

(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.

a Reuse the split flanges, bolts, etc. used for the oil stopping parts.

No. Parts installed to machine body Q’ty

2 07371-51470 20
3 01010-81455 40
4 01643-31445 40
7 07371-51260 8
8 01024-81245 16
No. Loose-supply items Q’ty
1 07099-01418 5
5 07000-13048 10
6 07099-01218 2
9 07000-13038 4

Precautions Necessary tools Necessary equipment

1. Keep the removed flanges and heads so Name Q’ty Name Q’ty
that they can be reused. KW12P impact wrench 1 Oil receiving pan 1
2. When installing a hose, take extreme care
that the O-ring will not be caught. L150 extension 1
3. When installing a hose, take extreme care
M19 socket 1
that dirt will not enter the circuit.
M22 socket 1
Others

80
 Assembly procedure
Installation of Arm Assembly (1/2)
B-8

(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

2 Inside of bushing: Apply grease.

2 Pin: Apply grease.

(3) Install the lock plate.

3 Tightening torque for plate mounting bolt

245 – 309 Nm {25 – 31.5 kgm}

Take care of grease hole

of arm cylinder rod.
Boom
Set grease hole to top.

Arm assembly top pin

Arm
Boom
top pin

Lock plate
Lock plate
No. Loose-supply items Q’ty
1 21N-72-11210 4

Precautions Necessary tools Necessary equipment

a When inserting the pin, take care not to dam- Name Q’ty Name Q’ty
age the seal (209-72-11311) installed in the ø 25 × 5000 wire 2 25 t crane 1
bushing on the arm side.
SD32 shackle 2 5 step stepladder 1
Sledge hammer 1
KW20P impact wrench 1
M24 socket 1
Others

81
 Assembly procedure
Installation of Arm Assembly (2/2)
B-8

(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.

(7) Install the lock plate.

3 Tightening torque for plate mounting bolt

245 – 309 Nm {25 – 31.5 kgm}

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.

Precautions Necessary tools Necessary equipment

a Before connecting the arm cylinder, bleed air. Name Q’ty Name Q’ty
See the section of bleeding air from cylinder. 25 wide × 3,000 nylon sling 1 25 t crane 1
Sledge hammer 1 5 step stepladder 1
KW20P impact wrench 1
M24 socket 1
Others

82
 Assembly procedure
Installation of Bucket Cylinder Hoses
B-9 between Boom and Bucket Cylinder

(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.

a Reuse the split flanges, bolts, etc. used for the oil stopping parts.

Outside hoses

Connect hoses in
parallel with cylinder.

Inside hoses

No. Loose-supply items Q’ty

1 21N-62-38620 2
2 07000-13038 4
5 21N-62-38610 2
6 07000-13048 4
No. Parts installed to boom/arm Q’ty
3 07371-51260 8
4 01024-81245 16
7 07371-51470 8
8 01010-81455 16
9 01643-31445 16

Precautions Necessary tools Necessary equipment

1. Keep the removed flanges and heads so that Name Q’ty Name Q’ty
they can be reused. KW12P impact wrench 1 5 step stepladder 1
2. When installing a hose, take extreme care
L150 extension 1 Oil receiving pan 1
that the O-ring will not be caught.
3. When installing a hose, take extreme care M19 socket 1
that dirt will not enter the circuit.
M22 socket 1
Others

83
Assembly procedure
Installation of Bucket Assembly (1/3)
B-10

(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.

3 Tightening torque for cover mounting bolt

1130 – 1910 Nm {115 – 195 kgm}

No. Loose-supply items Q’ty

1 21N-70-14220 1
2 21N-70-13150 2
3 21N-70-14320 14
4 21N-70-14330 4

Precautions Necessary tools Necessary equipment

Name Q’ty Name Q’ty
KW45F impact wrench 1 25 t crane 1
M46 socket 1
Others

84
Assembly procedure
Installation of Bucket Assembly (2/3)
B-10

(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.

Stopper

3 Tightening torque for stopper mounting bolt

588 – 1030 Nm {60 – 105 kgm}

Precautions Necessary tools Necessary equipment

Name Q’ty Name Q’ty
Others

85
 Assembly procedure
Installation of Bucket Assembly (3/3)
B-10

(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.

3 Tightening torque for stopper mounting bolt

588 – 1030 Nm {60 – 105 kgm}

No. Loose-supply items Q’ty

5 07000-16215 2
6 21N-72-11230 3

Precautions Necessary tools Necessary equipment

Name Q’ty Name Q’ty
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.
Others

86
Assembly procedure
Clearance Standard for Installation of Work Equipment
B-11

Adjusting clearance
of bucket and link
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

and boom
between revolving frame Adjust clearance to below 1 mm
with shim. Adjusting clearance
(C) (11) Clearance
cylinder
between boom and boom Adjust clearance to 2 – 3 mm
with shim.
of bucket and arm

(D) (12) Clearance

cylinder
between boom and arm Adjust clearance to 2 – 3 mm
with shim.
Adjust clearance to below 1 mm
(E) (13) Clearance between boom and arm with shim.
Adjust clearance to 0.5 – 1 mm
(K) (18) Clearance between bucket and arm with shim.
Standard shim
Adjust clearance to below 1 mm thickness: 8
(J) (19) Clearance between bucket and link with shim.

(F) (20) Clearance

cylinder
between arm and arm Adjust clearance to 2 – 3 mm
with shim.

Precautions Necessary tools Necessary equipment

Name Q’ty Name Q’ty
Others

87
Assembly procedure
Installation of Work Equipment Grease Piping
B-12

(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.

No. Loose-supply items Q’ty

1 07020-00675 2

Precautions Necessary tools Necessary equipment

Name Q’ty Name Q’ty
Others

88
Assembly procedure
Procedure for Bleeding Air From Travel Motor (1/2)
B-13

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)

Forward Unit = sec

Neutral
Neutral

Reverse

Forward
Neutral
Reverse

Precautions Necessary tools Necessary equipment

Name Q’ty Name Q’ty
Others

89
Assembly procedure
Procedure for Bleeding Air From Travel Motor (2/2)
B-13

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)

Precautions Necessary tools Necessary equipment

Name Q’ty Name Q’ty
Others

90
Assembly procedure
Bleeding Air from Swing Motor
B-14

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.

Precautions Necessary tools Necessary equipment

Name Q’ty Name Q’ty
Others

91
Assembly procedure
Bleeding Air from Cylinder
B-15

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.

Precautions Necessary tools Necessary equipment

Name Q’ty Name Q’ty
Others

92
Assembly procedure
Installation of Work Equipment Wiring
B-16

(1) Install the lights to both sides of the boom.

(2) Connect the lights to the wires on the boom side.

Detail of mounting portion

Connect to wire
on boom side.

Connect to wire
on machine side.

No. Loose-supply items Q’ty

1 17A-06-17930 2
2 20Y-06-21551 2
3 08193-20012 2
4 01024-81230 2

Precautions Necessary tools Necessary equipment

Name Q’ty Name Q’ty
Others

93
Assembly procedure
Greasing after Assembling Work Equipment
B-17

Precautions Necessary tools Necessary equipment

Name Q’ty Name Q’ty
Others

94
M. PROCEDURE FOR INSPECTION AND MAINTENANCE
AFTER COMPLETION OF ASSEMBLY

95
 Assembly procedure
Replacement of Return Filter
M-1 (Standard Filter to Flushing Filter) (1/3)

Replace the relief valve with this Valve

plate only at the flushing time.
Strainer

Special element for flushing,

Absolute filter mesh size: 6 µ

No. Loose-supply items Q’ty

1 209-60-77551 2
2 21T-60-13730 2

Precautions Necessary tools Necessary equipment

Store the removed standard element (209- Name Q’ty Name Q’ty
60-75531)., strainer (20Y-60-31140). and
valve (20Y-60-31131) 2 pcs.
in order because they are used again after
flushing.
Others

96
 Assembly procedure
Replacement of Return Filter
M-1 (Flushing Filter to Standard Filter) (2/3)

Replacement
Valve

Strainer

Standard element

Precautions Necessary tools Necessary equipment

This work is performed after the flushing end. Name Q’ty Name Q’ty
Others

97
 Assembly procedure
Replacement of Return Filter
M-1 (Standard Filter ↔ Flushing Filter) (3/3)

Precautions Necessary tools Necessary equipment

The flushing filter must be discarded after use. Name Q’ty Name Q’ty
The flushing filter is not allowed to be reused.
Others

98
Assembly procedure
Relieving Remaining Pressure from Hydraulic Circuit
M-2

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.

k When 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.

Precautions Necessary tools Necessary equipment

Name Q’ty Name Q’ty
Others

99
Assembly procedure
Installation of Flushing Tubes (1/2)
M-3

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.

Flushing tube

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.

a Reuse the installed flanges, mounting bolts, etc.

Flushing T-piece

Precautions Necessary tools Necessary equipment

Name Q’ty Name Q’ty
Others

100
 Assembly procedure
Installation of Flushing Tubes (2/2)
M-3

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 Reuse the installed flanges, mounting bolts, etc.

Flushing tube

a After finishing flushing, return the removed hoses.

(Remove the flushing tubes and T-pieces.)

Precautions Necessary tools Necessary equipment

1. Keep the removed flushing tubes and flush- Name Q’ty Name Q’ty
ing T-pieces so that they can be reused.
2. When installing a hose, take extreme care
that any part will not be caught.
3. When installing a hose, take extreme care
that the hose will not interfere with or catch
another part.
Others

101
 Assembly procedure
Flushing of Hydraulic Circuit
M-4

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

Precautions Necessary tools Necessary equipment

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

102
Assembly procedure
Replacement of Pilot Filter
M-5 (Flushing filter o Standard filter)

(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.
Pilot filter
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.

Element Filter assembly

Drain plug
Bolt

Precautions Necessary tools Necessary equipment

Name Q’ty Name Q’ty
Others

103
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
 (10) Ashtray
(11) Machine monitor
(12) Horn switch
(13) R.H. work equipment control lever
(14) Cigarette lighter
(15) Starting switch
(1) Radio (16) Step light switch
(2) Large capacity airflow air conditioner blower switch (if equipped) (17) Fuel control dial
(3) Revolving warning lamp switch (if equipped) (18) Lamp switch
(4) Lower wiper switch (machines equipped with fixed front window cab) (19) Swing lock switch
(5) Air conditioner control panel (20) Machine push-up siwtch
(6) Lock lever (21) Boom shockless control switch
(7) L.H. work equipment control lever (22) Swing parking brake release switch
(8) Travel pedals (23) Emergency pump drive switch
(9) Travel levers (24) Room lamp switch
 P

: Check in monitoring mode “01006”

High idling (Operate lever a little) 1950 – 2050 rpm

High idling (Do not operate lever) 1700 – 1800 rpm

Speed at boom raise relief

[ rpm ]
(Heavy lift: OFF)
Speed at boom raise relief
[ rpm ]
(Heavy lift: ON)

Check in service mode “55”

2. Rediator fan speed (Fan rotation 100% fixed mode)
975 ± 50 rpm
Speed at engine rated speed [ rpm ]
(Engine at full throttle, Oil temperature at 50 °C)

3. Measurement of oil pressure Check in monitoring mode Swing pump “09000”,

F pump: “01100”, R pump: “01101”
Control valve main MPa 31.4 +1.0
--1.5 MPa
F pump
set pressure {kg/cm2} {320 +10
--15 kg/cm2}
Control valve main MPa 31.4 +1.0
--1.5 MPa
R pump
set pressure {kg/cm2} {320 +10
--15 kg/cm2}
Control valve main MPa 33.3 +1.0
--1.5 MPa
F pump
set pressure (Increase of pressure) {kg/cm2} {340 +10
--15 kg/cm2}
+1.0
Control valve main MPa 33.3 --1.5 MPa
R pump
set pressure (Increase of pressure) {kg/cm2} {340 +10
--15 kg/cm2}
Control valve main MPa 31.4 +1.0
--1.5 MPa At engine high idling,
Swing pump boom raise and P mode,
set pressure {kg/cm2} {320 +10
--15 kg/cm2} heavy lift off relief
+5
Pilot relief valve set pressure
MPa 31.4 +0.5
0 MPa {32 0 kg/cm2}
{kg/cm2}

When boom is raised When boom is raised

In neutral (Heavy: OFF) In neutral (Heavy: OFF)
1.13
11.5

1.13
11.5

When boom is raised When boom is raised

In neutral (Heavy: OFF) In neutral (Heavy: OFF)
GEN00055-04