Komatsu pc200-8

GEN00060-16
HYDRAULIC PC2000 -8
EXCAVATOR
SERIAL NUMBERS 20001 and up
FOREWORD
Since this machine is large in size, it is divided into some units to meet
the transportation conditions and regulations applied to the transporta-
tion route when shipped from our factory.
This manual describes how to assemble the units into the complete
machine in the field. We hope that this machine will display its quality
and you will use it safely according to the operation manual.
Many units are large in size and heavy in weight and may be handled
in a dangerous place or posture and many workers may have to work
together to sling them with cranes.
Accordingly, before starting the assembly work, the work supervisor is
required to hold a safety meeting to oblige the workers to put on pro-
tective gear and appoint a work leader and a crane work signal man
and allot roles to all the workers for safe work.
In particular, the above meeting is more important when worker of dif-
ferent languages and customs work together.
The following is a reference supervision system diagram.
(Instruction system)
Work leader
Director
Work supervisor Crane director and
deputy director
Operator for assembly

Liaison man
Mechanics Sharing of work

Interpreter
When the work equipment is installed, the engine must be operated.

Accordingly, before installing the work equipment, inspect and main-
tain the machine thoroughly.
Note that this manual does not describe the whole specification of the
machine but describes only the basic specification.
If you have any question when dividing and transporting the machine
by yourself in future, ask one of our distributors.
CONTENTS
SPECIFICATIONS............................................................................................................. 1
PRECAUTIONS FOR FIELD ASSEMBLY ......................................................................... 2
DISPOSAL OF REMOVED PARTS................................................................................... 3
ASSEMBLY PROCEDURE, ASSEMBLY EQUIPMENT AND SCHEDULE ...................... 4
FLOWCHART OF MAIN ASSEMBLY PROCEDURE........................................................ 5
KIT LAYOUT DIAGRAM .................................................................................................... 6
TRANSPORTATION POSTURES..................................................................................... 7
LIST OF PARTS SENT INDIVIDUALLY ............................................................................ 16
TOOLS AND EQUIPMENT TO BE USED FOR LOCAL ASSEMBLY ............................... 37
TIGHTENING TORQUE .................................................................................................... 39
COATING MATERIALS LIST ............................................................................................ 43
A. ASSEMBLY OF CHASSIS ............................................................................................ 45

<Assembly of undercarriage>
A- 1. Assembly of track frame assembly and center frame assembly........................... 46
A- 2. Installation of idler cushion cylinder piping ........................................................... 49
A- 3. Installation of travel motor piping .......................................................................... 50
A- 4. Installation of travel motor cover........................................................................... 51
A- 5. Filling swing circle with grease ............................................................................. 54
A- 6. Assembly of revolving frame assembly and undercarriage .................................. 55
A- 7. Installation of swing machinery (front) assembly (27t)
Installation of swing motor (front) assembly (32t) ................................................. 57
A- 8. Connection of swivel joint piping........................................................................... 58
A- 9. Connection of swing circle grease piping ............................................................. 60
<Assembly of upper structure>
A-10. Installation of hydraulic tank assembly ................................................................. 61
A-11. Installation of fuel tank assembly.......................................................................... 66
A-12. Connection of fuel tank assembly piping and wiring............................................. 67
A-13. Installation of cab base assembly......................................................................... 69
A-14. Installation of emergency escape ladder .............................................................. 71
A-15. Installation of left floor assembly .......................................................................... 72
A-16. Connection of cab base assembly piping ............................................................. 76
A-17. Connection of cab base assembly wiring ............................................................. 79
A-18. Connection of left floor assembly heater piping.................................................... 85
<Coupling of power container>
A-19. Connection of left floor assembly wiring ............................................................... 86
A-20. Installation of tail pipe ........................................................................................... 88
A-21. Installation of power container assembly.............................................................. 89
A-22. Connection of suction piping ................................................................................ 91
A-23. Connection of oil cooler piping and pump drain piping......................................... 93
A-24. Connection of fan motor drain piping.................................................................... 94
A-25. Installation of suction unit undercover .................................................................. 95
A-26. Connection of delivery piping ............................................................................... 96
A-27. Connection of pilot piping and fan motor piping ................................................... 98
A-28. Connection of power container assembly fuel piping ........................................... 99
A-29. Connection of power container assembly air conditioner piping .......................... 101
A-30. Connection of power container assembly heater piping....................................... 102
A-31. Connection of power container assembly wiring .................................................. 103
<Coupling of operator's cab>
A-32. Installation of operator's cab assembly ................................................................ 107
A-33. Installation of rotary lamp (if equipped) ................................................................ 111
A-34. Installation of ORBCOMM antenna (if equipped)................................................. 113
A-35. Connection of operator's cab assembly wiring..................................................... 114
A-36. Connection of operator's cab assembly hydraulic piping ..................................... 117
A-37. Connection of operator's cab assembly window washer hose............................. 119
A-38. Connection of operator's cab assembly air conditioner piping ............................. 120
A-39. Connection of operator's cab assembly heater piping ......................................... 121
A-40. Installation of operator's cab rear floor assembly................................................. 122
A-41. Installation of handrail around operator's cab ...................................................... 123
<Coupling of exterior parts, counterweight, etc.>
A-42. Installation of track frame ladder .......................................................................... 124
A-43. Installation of power container side catwalk assemblies (right and left)............... 125
A-44. Installation of right floor assembly,
grease can cover assembly and center floor........................................................ 126
A-45. Installation of fuel tank right catwalk assembly .................................................... 128
A-46. Installation of fuel tank front catwalk assembly .................................................... 129
A-47. Adjustment of exterior parts clearance................................................................. 130
A-48. Connection of grease reel piping ......................................................................... 131
A-49. Installation of access ladder assembly................................................................. 132
A-50. Installation of counterweight assembly ................................................................ 133
A-51. Installation of deformation preventing stoppers for catwalk assemblies
(left and right) on the side of power container ...................................................... 134
A-52. Installation of handrail on counterweight.............................................................. 135
A-53. Installation of handrail clamps.............................................................................. 136
A-54. Connection of fuel cut wire................................................................................... 139
A-55. Connection of drain piping under power container............................................... 140
A-56. Connection of battery wiring................................................................................. 141
<Starting of engine and inspection and servicing procedures>
A-57. Setting of hydraulic tank strainer.......................................................................... 142
A-58. Starting engine, checking oil and coolant levels, bleeding air from each part,
and adjusting track ............................................................................................... 143
A-59. Permanent tightening of swing circle bolt............................................................. 158
A-60. Parts to be touched up after field assembly (chassis side) .................................. 159
A-61. Connection of engine heater connection port ...................................................... 160
A-62. Installation of optional harness............................................................................. 163
A-63. Installation of rear lamps ...................................................................................... 164
A-64. Installation of rear camera.................................................................................... 169
A-65. Connection of emergency stop switch (if equipped) (at the right below container) 178
A-66. Connection of emergency stop switch (if equipped) (at the left side of ladder).... 179
A-67. Installation of engine oil and PTO oil pipings ....................................................... 180
A-68. Installation of coolant piping................................................................................. 181
A-69. Installation of guard bracket (if equipped) ............................................................ 182
C. ASSEMBLY OF BACKHOE.......................................................................................... 183

<Coupling of boom>
C- 1. Installation of boom cylinder................................................................................. 184
C- 2. Installation of boom cylinder hoses (Serial No. 20095 and up)............................ 186
C- 3. Assembly of boom sub assembly......................................................................... 187
C- 4. Installation of boom assembly.............................................................................. 192
C- 5. Installation of boom cylinder head side ................................................................ 194
<Coupling of arm>
C- 6. Installation of hoses between boom and chassis ................................................. 196
C- 7. Installation of arm assembly ................................................................................. 197
C- 8. Installation of arm cylinder.................................................................................... 200
C- 9. Connection of hoses between boom and arm ...................................................... 201
C-10. Connection of auto grease piping......................................................................... 202
C-11. Connection of wiring between boom and chassis ................................................ 203
<Coupling of bucket>
C-12. Installation of bucket assembly ............................................................................ 204
C-13. Installation of bucket link ...................................................................................... 207
C-14. Bleeding air from cylinders ................................................................................... 209
C-15. Parts to be touched up after field assembly (work equipment side) ..................... 212
C-16. Bleeding air from auto grease circuit.................................................................... 213
LS. ASSEMBLY OF LOADING SHOVEL WORK EQUIPMENT........................................ 217

LS- 1. Installation of arm cylinder bottom parts ............................................................. 218
LS- 2. Installation of boom cylinder to machine body.................................................... 219
LS- 3. Installation of boom cylinder hoses..................................................................... 221
LS- 4. Installation of boom cylinder piping..................................................................... 222
LS- 5. Installation of boom assembly ............................................................................ 223
LS- 6. Installation of boom cylinder head pins............................................................... 224
LS- 7. Installation of hose between machine body and boom....................................... 225
LS- 8. Installation of bucket cylinder assembly ............................................................. 227
LS- 9. Installation of arm assembly ............................................................................... 228
LS-10. Installation of arm cylinder assembly.................................................................. 229
LS-11. Installation of hoses between boom and arm ..................................................... 230
LS-12. Installation of bucket cylinder hoses................................................................... 231
LS-13. Installation of grease feed hose of bucket cylinder............................................. 232
LS-14. Installation of bucket assembly........................................................................... 234
LS-15. Installation of arm cylinder junction hoses.......................................................... 235
LS-16. Installation of bottom dump hose and grease feed hose
between arm and bucket .................................................................................... 236
LS-17. Installation of arm dump cushion (proximity switch) ........................................... 237
M. INSPECTION AND SERVICING PROCEDURES AFTER ASSEMBLY ....................... 239

M- 1. Inspection of oil levels and coolant levels and
using standard of fuel and lubricant ..................................................................... 240
M- 2. Flushing of hydraulic circuit.................................................................................. 242
M- 3. Releasing residual pressure from hydraulic circuit............................................... 245
M- 4. Releasing residual pressure from HIC circuit and check of
gas pressure in HIC accumulator......................................................................... 246
M- 5. Charging air conditioner with refrigerant ............................................................. 247
M- 6. Installed angles of mirrors .................................................................................... 250
M- 7. Installed angles of lights....................................................................................... 253
VHMS CONTOROLLER INITIAL SETTING PROCEDURE .............................................. 257
PC2000-8 Main pump air bleeding check sheet ................................................................ 275
FIELD ASSEMBLY INSPECTION REPORT (BACKHOE)
FIELD ASSEMBLY INSPECTION REPORT (LOADING SHOVEL)

SPECIFICATIONS
Item Unit PC2000-8

Operating weight (including 1 operator) kg 200,000
Backhoe 12.0
Bucket capacity m3
Loading shovel 11.0
Name of engine – Komatsu SAA12V140E-3 diesel engine
Engine horsepower kW{HP}/rpm 728{976}/1,800
Min. ground distance 825
Travel speed (Low/High) km/h 2.7
Swing speed rpm 4.8
PC2000-8 Backhoe
PC2000-8 Loading shovel
1
PRECAUTIONS FOR FIELD ASSEMBLY
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.
2
DISPOSAL OF REMOVED PARTS
As described in "FOREWORD", when this machine is transported, it is divided into some units such as the body,
undercarriage, cab, work equipment, etc. according to the transportation measure, regulations,etc.
Accordingly, the hydraulic pipings and hydraulic hoses to connect the units, oil inlets and outlets of the hydraulic
devices, and parts which must not be damaged are plugged or covered to prevent oil leakage, entry of dirt and
dust, and damage during transportation.
In addition, fixing jigs are used to prevent a trouble caused by a fall or a shake during transportation and to facilitate
loading, unloading and crane work.
The above plugs, jigs, etc. are removed when the machine is assembled and become unnecessary after
completion of the machine. Since they are useful when the machine needs to be transported in future, however,
we recommend you to keep them as long as possible.
3
Day
(Half day)
Units to be
assembled
ASSEMBLY PROCEDURE,
Crane
ASSEMBLY EQUIPMENT AND SCHEDULE
Mobile elevating
4
work platform
Air compressor
Min. 15 m3/min
Workers
Foreman + 6 mechanics Foreman + 6 mechanics Foreman + 6 mechanics Foreman + 2 mechanics
· Start of assembly · Completion of assembly · Completion of total assembly

· Meeting of all workers of chassis
· Start of engine
FLOWCHART OF MAIN ASSEMBLY PROCEDURE
Work necessary to assembly

from 27 ton parts
Assembly of undercarriage
(Coupling of crawler and center)
Coupling of revolving frame Installation of hydraulic tank to

revolving frame
Installation of fuel tank Installation of left floor Installation of machinery

(front)
Installation of cab base Sub-assembly of cab base
Installation of power container
Installation of cab
Installation of external covers

and steps
Installation of counterweight
Motoring
Installation of boom cylinder
Installation of boom Sub-assembly of boom
Installation of arm Sub-assembly of arm
Installation of bucket
5
KIT LAYOUT DIAGRAM
• The dimensions given below are the minimum dimensions needed.
• When selecting a work place, see "Points regarding local assembly".
• When installing the revolving frame, place wooden blocks 700 mm high under it.
Covers
Tubes Tools and equipment Cab
Cab
base
Hoses
Boom cylinder
G reel Covers F tank
Rear floor PA ladder
Front CW Right CW
Bucket Left deck Right deck
Left floor Right floor
Arm link
Crane, 45 ton
Crawler frame
Crawler frame
Front
Center frame
Boom
Revolving
frame
Crane, 45 ton
Power container
C weight
6
TRANSPORTATION POSTURES
For transporting of the machine, ask your Komatsu distributor.
Each dimension in the following figures is rounded up to the next 5 mm and each weight is rounded up to the next 100 kg.
The arrows indicate the hanging points of each assembly.
Values in < > of X, Y and Z indicate the packing dimensions.
t Transportation posture of each kit
(1) Center frame assembly
X Overall length (mm) 3,815 <3,950>

Y Overall width (mm) 3,190 <3,400>
Z Overall height (mm) 2,210 <2,400>
W Weight (kg) 18,100
• With swivel and fixing bar

• With swing circle and grease
piping
• With grease bath (Grease is
packed separately)
• With travel piping tubes Center of gravity
• With HIC piping (Accumulator
has been pressurized)
[Remarks]
Undercover is optional.
Top view
(2) Crawler frame assembly

For each crawler
• With motor and motor guard

[Remarks]
Full roller guard is optional.
Center of gravity
Top view
(3) Revolving frame assembly

(Special sling) When When
disassembled disassembled
to 32 ton to 27 ton
Z Overall height (mm) 2,920 2,640
W Weight (kg) 31,500 26,500
• With 6 hoses to boom
• With 4 oil cooler hoses
• With grease tank
Center of gravity
When disassembled to 27 ton, hydraulic tank

assembly and machine (front) assembly are
packed separately. Top view
7
(4) Fuel tank assembly

Y Overall width (mm) ,875 <1,150>
W Weight (kg) 2,140
• With working lamp (without fuel)
• With fuel level sensor
Center of gravity
Top view
(5) Cab base assembly

W Weight (kg) 2,600
• With head lamp and working lamp
Center of gravity
Top view
(6) Left floor assembly

W Weight (kg) 1,750 <2,011>
• With battery
Center of gravity
8
(7) Power container assembly

• With super hood Center of gravity
• With handrail on radiator side
Top view
(8) Operator's cab assembly

W Weight (kg) 1,900
• With antenna retracted

• With mirrors folded
[Remarks]
Center of gravity
Front guard is optional.
Top view
(9) Counterweight assembly

[Parts packed separately] Center of gravity
Handrail, bolts
Top view
9
(10) Catwalk assembly on power container side
For each catwalk
X Overall length (mm) 2,310
Y Overall width (mm) ,545
Z Overall height (mm) 2,085
W Weight (kg) ,330
[Parts packed separately]
Stopper, shim, bolts
Center of gravity
Top view
(11) Grease can cover assembly

Y Overall width (mm) 1,025
Z Overall height (mm) ,995
W Weight (kg) ,260
Center of gravity
Top view
(12) Switch box assembly
X Overall length (mm) 300

Y Overall width (mm) 200
W Weight (kg) 20
10
(13) Right floor assembly

W Weight (kg) ,240
Center of gravity
Top view
(14) Right catwalk assembly

W Weight (kg) ,390
• With grease reel
Center of gravity
Top view
(15) Front catwalk assembly
X Overall length (mm) ,715

W Weight (kg) , 90
Center of gravity
Top view
11
(16) Cab rear floor assembly

W Weight (kg) , 70
Center of gravity
Top view
(17) Boom assembly

Center of gravity
Left side view
(18) Arm assembly

• With bucket cylinder
Center of gravity
Left side view
12
(19) Bucket assembly
Specifications of standard bucket
for crushed stones
Center of gravity
Left side view
(20) Arm cylinder tube assembly

W Weight (kg) , 60
Center of gravity
Left side view
(21) Hydraulic tank assembly

W Weight (kg) 1,750
Center of gravity
Top view
13
(22) Swing machinery (front) assembly
X Overall length (mm) ,775

W Weight (kg) 1,050
Center of gravity
Top view
(23) Cab L.H. catwalk

W Weight (kg) ,220
Center of gravity
Top view
(24) Cab front catwalk

W Weight (kg) ,100
Center of gravity
Top view
14
• Method of installing chassis hanging jig
15
LIST OF PARTS SENT INDIVIDUALLY (Assembly of undercarriage)
A
Assembly
No. Part No. Part name Q'ty procedure No. Remarks
A-1 21T-30-71160 BOLT 76 A-1
A-2 21T-30-71170 WASHER 76 A-1
A-3 208-30-11850 COVER 1 A-1
A-4 208-30-11861 GASKET 1 A-1
A-5 01024-81225 BOLT 3 A-1
A-6 07000-B3025 O-RING 2 A-2
A-7 07000-B3048 O-RING 4 A-3
A-8 02896-61018 O-RING 2 A-3
A-9 21T-30-32173 COVER 1 A-4
A-10 21T-30-32183 COVER 1 A-4

A-11 01010-82460 BOLT 10 A-4
A-12 17A-54-44130 WASHER 10 A-4
A-13 01010-82460 BOLT 16 A-4
A-14 01643-32460 WASHER 16 A-4
A-15 21T-30-32370 COLLAR 16 A-4
A-16 01010-81660 BOLT 4 A-2
A-17 01643-31645 WASHER 4 A-2
This page is for only the center frame under

A-18 21T-30-18120XC COVER 5 A-4 cover specification.
XC: Paint color; Black gray
A-19 01024-82465 BOLT, SEMS 20 A-4 cover specification.
A-20 01643-32460 WASHER 20 A-4 cover specification.
16
LIST OF PARTS SENT INDIVIDUALLY (Coupling of revolving frame)
B
Assembly
B-1 21T-25-67150 BOLT 60 A-6
B-2 01643-33690 WASHER 60 A-6
B-3 01010-83090 BOLT 14 A-7
B-4 01643-33080 WASHER 14 A-7
B-5 07000-B3032 O-RING 1 A-7
B-6 07000-B3032 O-RING 2 A-7
B-7 02896-61015 O-RING 1 A-7
B-8 02896-61008 O-RING 1 A-7
B-9 01024-81225 BOLT 1 A-7
B-10 11Y-62-11980 O-RING 1 A-8
B-11 02896-61009 O-RING 4 A-8

B-12 07000-B3048 O-RING 4 A-8
B-13 07000-B5230 O-RING 2 A-10
B-14 01011-83010 BOLT 12 A-10
B-15 21T-26-11460 WASHER 12 A-10
B-16 07000-B2060 O-RING 8 A-10
B-17 11Y-62-11980 O-RING 3 A-10
B-18 07000-B3032 O-RING 1 A-10
17
LIST OF PARTS SENT INDIVIDUALLY (Assembly of upper structure)
C
Assembly
C-1 01011-83010 BOLT 20 A-11
C-2 21T-26-11460 WASHER 20 A-11
C-3 04435-52212 CLIP 1 A-12
C-4 02896-61012 O-RING 1 A-12
C-5 02896-61015 O-RING 2 A-12
C-6 02896-61018 O-RING 2 A-12
C-7 01024-81220 BOLT 1 A-12
C-8 04434-52312 CLIP 1 A-12
C-9 04434-51912 CLIP 3 A-12
C-10 01024-81220 BOLT 4 A-12
C-11 01034-81245 BOLT 10 A-13

C-12 01034-81265 BOLT 10 A-13
C-13 21T-54-31140 CLAMP 1 A-13
C-14 21T-54-31150 CLAMP 1 A-13
C-15 01034-81245 BOLT 2 A-13
C-16 01011-82035 BOLT 20 A-13
C-17 01011-82045 BOLT 7 A-13
C-18 567-40-41380 WASHER 27 A-13
C-19 01010-82075 BOLT 24 A-15
C-20 15R-70-16370 WASHER 24 A-15
C-21 21T-53-32271 SHIM 6 A-15
C-22 21T-53-32350 SHIM 10 A-15
C-23 21T-54-33471 COVER 1 A-15
C-24 01034-81230 BOLT 3 A-15
C-25 02896-61012 O-RING 6 A-16
C-26 02896-61018 O-RING 2 A-16
C-27 21T-979-3320 JOINT 2 A-18
18
Assembly
C-28 21T-06-32810 WORK LAMP 2 A-13
C-29 21T-06-32820 WORK LAMP 1 A-13
C-30 04434-51012 CLIP 7 A-13
C-31 01024-81220 BOLT 7 A-13
C-32 01034-81225 BOLT 8 A-14
C-33 01034-81235 BOLT 2 A-14
C-34 01034-81225 BOLT 2 A-14
C-35 01024-81225 BOLT 8 A-14

C35-1 21T-54-37690 BRACKET 1 A-14 　　
C35-2 21T-54-37621 BRACKET 1 A-14
C35-3 21T-54-37661 LADDER 1 A-14

C35-4 21T-54-37681 LADDER 1 A-14
C35-5 21T-53-33141 HANDRAIL 2 A-14
C-36 21T-53-32812 COVER 1 A-15
C-37 01034-81240 PLATE 4 A-15
C-38 21T-53-32820 BOLT 2 A-15
C-39 01034-81240 PLATE 4 A-15
C-40 04435-52112 CLIP 2 A-16 Hydraulic ladder specification only
C-41 01024-81225 BOLT 1 A-16 Hydraulic ladder specification only
C-42 154-979-1480 COLLAR 1 A-16 Hydraulic ladder specification only
C-44 21T-06-32810 WORK LAMP 1 A-17 Hydraulic ladder specification only
C-51 01024-81020 BOLT 1 A-17
C-52 09460-00000 LOCK 1 A-12
C-53 01024-81025 BOLT 1 A-19
C-54 01024-81220 BOLT 1 A-19
C-55 04434-51012 CLIP 1 A-19
19
LIST OF PARTS SENT INDIVIDUALLY (Coupling of power container)
D
Assembly
D-1 21M-01-18130 TAIL PIPE 2 A-20
D-2 01024-81230 BOLT 12 A-20
D-3 6162-14-5640 RAIN CAP 2 A-20
D-4 21T-54-31121 PLATE 4 A-21
D-5 21T-54-31130 BOLT 20 A-21
D-6 01643-34212 WASHER 20 A-21
D-7 07000-B2140 O-RING 2 A-22
D-8 07000-B2100 O-RING 1 A-22
D-9 209-62-41341 CLAMP 4 A-22
D-10 20Y-62-51671 CLAMP 2 A-22
D-11 07000-B2060 O-RING 7 A-23
D-12 07298-02011 HOSE 1 A-23
D-13 07000-B3032 O-RING 1 A-24
D-14 07000-B3048 O-RING 4 A-26
D-15 07000-B3025 O-RING 2 A-27
D-16 07000-B3032 O-RING 1 A-27
D-17 02896-61018 O-RING 2 A-28
D-18 02896-61015 O-RING 1 A-28
D-19 02896-61015 O-RING 1 A-28
D-20 08028-55065 CABLE 2 A-31
D-21 01024-81020 BOLT 2 A-31
20
Assembly
D-22 21T-54-34931 FRAME 1 A-25
D-23 21T-54-34981 COVER 1 A-25
D-24 21T-54-34991 COVER 1 A-25
D-25 21T-54-34971 COVER 1 A-25
D-26 21T-54-34941 COVER 1 A-25
D-27 21T-54-34961 COVER 1 A-25
D-28 21T-54-34951 COVER 1 A-25
D-29 203-54-62670 COLLAR 2 A-25
D-30 01024-81225 BOLT 2 A-25
D-31 01034-81225 BOLT 26 A-25
D-32 08038-10035 CAP 2 A-31
D-33 08038-04030 CAP 2 A-31
D-34 21T-54-34920 COVER 2 A-25
D-35 01024-81225 BOLT 2 A-25
D-36 01034-81225 BOLT 3 A-25
D37 01024-81020 BOLT 4 A-31
21
LIST OF PARTS SENT INDIVIDUALLY (Coupling of operator's cab)
E
Assembly
E-1 21T-54-36661 SHIM 16 A-32
E-2 21T-54-36671 SHIM 8 A-32
E-3 21T-54-35321 CUSHION 8 A-32
E-4 8295-06-1480 LAMP BEACOM 1 A-33
E-5 21T-06-17430 BRACKET 1 A-33
E-6 01024-81225 BOLT 2 A-33
E-7 8295-06-1480 LAMP BEACOM 1 A-33
E-8 21T-06-33610 PLATE 1 A-33
E-9 21T-06-17430 BRACKET 1 A-33
E-10 01024-81225 BOLT 2 A-33
E-11 04434-51012 CLIP 1 A-33
E-12 01024-81220 BOLT 1 A-33
E-13 8A13-10-2100 ANTENNA 1 A-34
E-14 21T-06-64491 BRACKET 1 A-34
E-15 01024-81225 BOLT 1 A-34
E-16 02896-61012 O-RING 10 A-36
E-17 02896-61009 O-RING 2 A-36
E-18 21T-979-4421 SEAL 4 A-38
E-19 08034-20830 BAND 2 A-38
E-20 08034-20830 BAND 3 A-39
E-21 01024-81225 BOLT 14 A-40
E-22 21T-54-33931 HANDRAIL 1 A-41
E-23 01034-81240 BOLT 8 A-41
E-24 203-957-2640 BOLT 2 A-41
E-25 21T-03-11280 WASHER 2 A-41
22
Assembly
E-26 21T-54-34131 COVER 1 A-32
E-27 01034-81225 BOLT 6 A-32
E-28 21T-54-34151 COVER 1 A-32
E-29 01034-81225 BOLT 6 A-32
E-30 21T-54-34141 COVER 1 A-32
E-31 01034-81225 BOLT 6 A-32
E-32 21T-54-34161 COVER 1 A-32
E-33 01034-81225 BOLT 6 A-32
E-34 21T-54-37980 BRACKET 6 A-32
E-35 21T-54-36680 PLATE 9 A-32
E-36 21T-54-36690 PLATE 12 A-32
E-37 01024-81030 BOLT, SEMS 12 A-32
E-38 21T-54-37990 CUSHION 6 A-32
E-39 21T-54-35312 BRACKET 8 A-32

E-40 8230-46-1130 BOLT 16 A-32
E-41 01643-32060 WASHER 16 A-32
E-42 21T-54-35732 PIN 4 A-32
E-43 04020-00514 DOWEL-PIN 8 A-32
E-44 01050-52040 BOLT 4 A-32
E-45 01643-32060 WASHER 4 A-32
E-46 11Y-09-11160 CLIP 4 A-39
E-47 01024-81020 BOLT 1 A-35
E-48 21N-979-8160 COMPRESSOR OIL 1 A-29,A-38
E-49 20Y-979-3310 DRUM 10 M-5 Except EU district (EU specification)
23
LIST OF PARTS SENT INDIVIDUALLY (Coupling of counterweight etc)
F
Assembly
F-1 21T-30-32231 BRACKET 2 A-42
F-2 21T-30-32241 LADDER 2 A-42
F-3 01010-82460 BOLT 8 A-42
F-4 01010-82450 BOLT 8 A-42
F-5 01643-32460 WASHER 16 A-42
F-6 01010-81240 BOLT 16 A-43
F-7 21T-53-32290 SHIM 12 A-43
F-8 01010-82080 BOLT 12 A-44
F-9 01010-82060 BOLT 8 A-44
F-10 01643-32060 WASHER 20 A-44
F-11 21T-53-31550 PLATE 1 A-44

F-12 21T-54-31560 PLATE 1 A-44
F-13 21T-54-33331 STEP 1 A-44
F-14 01034-81250 BOLT 4 A-44
F-15 21T-54-33731 COVER 1 A-44
F-16 21T-54-33781 COVER 1 A-44
F-17 21T-54-33791 COVER 1 A-44
F-18 21T-53-31590 COVER 1 A-44
F-19 01034-81230 BOLT 18 A-44
F-20 01034-81285 BOLT 4 A-44
F-21 01034-81240 BOLT 16 A-45
F-22 01034-81250 BOLT 6 A-46
F-23 21T-53-32491 STEP 1 A-49
F-24 01034-81230 BOLT 4 A-49
F-25 21T-53-33170 LADDER 1 A-49
F-26 01034-81230 BOLT 4 A-49
24
Assembly
4 of 12 bolts are used for installation of
F-27 21T-46-34120 BOLT 12 A-50 transportation jig.
4 of 12 bolts are used for installation of
F-28 209-46-11210 SPACER 12 A-50 transportation jig.
F-29 21T-46-34141 PLATE 2 A-50
F-30 21T-46-34131 PLATE 2 A-50
F-31 01024-81225 BOLT 12 A-50
F-148 21T-53-33640 BRACKET 2 A-51
F-149 21T-53-33650 SHIM 4 A-51
F-150 01024-81255 BOLT 4 A-51
F-32 21T-54-34411 HANDRAIL 1 A-52
F-33 21T-54-34421 HANDRAIL 1 A-52
F-34 01034-81250 BOLT 16 A-52
F-35 21T-54-32911 CLAMP 7 A-53
F-36 21T-54-32921 CLAMP 7 A-53
F-37 01010-D1250 BOLT 14 A-53
F-38 21T-54-37220 CHAIN 1 A-53
F-39 175-54-34170 WASHER 14 A-53
F-40 21T-54-31140 CLAMP 1 A-53
F-41 21T-54-31150 CLAMP 1 A-53
F-42 01010-81245 BOLT 2 A-53
F-43 175-54-34170 WASHER 2 A-53
F-44 21T-54-37220 CHAIN 1 A-54
F-45 04530-10815 BOLT 1 A-54
F-46 21T-04-32180 WIRE ROPE 1 A-54
F-47 21T-01-31471 NIPPLE 1 A-55
F-48 07005-02416 O-RING 1 A-55
F-49 07281-00419 CLAMP 3 A-55
25
Assembly
F-50 01024-81230 BOLT, SEMS 4 A-61
F-51 01024-81020 BOLT, SEMS 2 A-61
F-52 04434-51912 CLIP 1 A-61
F-53 04434-51212 CLIP 1 A-61
F-54 01024-81230 BOLT, SEMS 1 A-61
F-55 04434-51912 CLIP 1 A-61
F-56 04434-51212 CLIP 1 A-61
F-57 195-33-11220 BOLT, SEMS 1 A-61
F-58 01024-81230 BOLT, SEMS 1 A-61
F-59 21T-06-31570 BRACKET 1 A-61
F-60 01024-81230 BOLT, SEMS 4 A-61
F-61 04434-52312 CLIP 2 A-61
F-62 01024-81230 BOLT, SEMS 1 A-61
F-63 04434-51912 CLIP 1 A-61

F-64 01024-81230 BOLT, SEMS 1 A-61
F-65 02896-61015 O-RING 1 A-61
F-66 07281-00419 CLAMP 2 A-61
F-67 21T-06-32810 WORK LAMP ASS'Y 2 A-63
F-68 21T-06-33360 BRACKET 2 A-63
F-69 01024-81225 BOLT 4 A-63
F-70 205-03-71331 COLLAR 4 A-63
F-71 01024-81265 BOLT, SEMS 4 A-63
F-72 01024-81225 BOLT 16 A-63
F-74 04434-51412 CLIP 16 A-63
F-75 01024-81225 BOLT 10 A-63
F-76 04434-51412 CLIP 10 A-63
F-77 203-04-62110 BRACKET 1 A-63
F-78 01024-81255 BOLT, SEMS 1 A-63
F-79 203-62-52110 COVER 1 A-63
F-80 08034-20823 BAND 3 A-63
26
Assembly
F-82 08034-20823 BAND 3 A-63
F-83 203-62-52210 RUBBER 1 A-63
F-84 198-43-15310 COLLAR 1 A-63
F-85 04434-52512 CLIP 2 A-63
F-86 04434-51412 CLIP 2 A-63
F-87 04434-50612 CLIP 3 A-64
F-88 205-03-71331 COLLAR 6 A-64
F-89 01024-81265 BOLT, SEMS 6 A-64
F-90 04434-50612 CLIP 1 A-64
F-91 01024-81225 BOLT 3 A-64
F-92 203-06-61730 BRACKET 3 A-64
F-93 01024-81255 BOLT, SEMS 1 A-64
F-94 04434-53212 CLIP 4 A-64

F-95 07095-00317 CUSHION 3 A-64
F-96 195-33-11220 SPACER 2 A-64
F-97 04434-51812 CLIP 1 A-64
F-98 01024-81250 BOLT, SEMS 2 A-64
F-99 04434-51012 CLIP 1 A-64
F-100 20Y-03-11220 COLLAR 1 A-64
F-101 7835-33-8300 CABLE A. 1 A-64
F-102 7835-33-8200 CABLE A. 2 A-64
F-103 7835-33-8400 CABLE A. 1 A-64
F-104 01024-81260 BOLT, SEMS 1 A-64
F-105 04434-53212 CLIP 2 A-64
F-106 07095-00317 CUSHION 2 A-64
F-107 195-33-11220 SPACER 1 A-64
F-108 04434-51812 CLIP 1 A-64
F-109 01024-81250 CLIP 1 A-64
F-110 08034-20823 BAND 2 A-64
F-111 08017-C2204 CONDUIT 1 A-64
F-112 04434-53212 CLIP 1 A-64
F-113 08017-C2220 CONDUIT 1 A-64
F-114 08034-20823 BAND 16 A-64
F-115 203-62-52210 RUBBER 1 A-64
F-116 198-43-15310 COLLAR 1 A-64
F-117 04434-52512 CLIP 2 A-64
27
Assembly
F-118 04434-51412 CLIP 2 A-64
F-119 01024-81225 BOLT 10 A-64
F-120 203-06-61730 BRACKET 5 A-64
F-121 04434-52512 CLIP 5 A-64
F-122 01024-81225 BOLT 16 A-64
F-123 203-06-61730 BRACKET 8 A-64
F-124 04434-51812 CLIP 10 A-64
F-125 08034-20823 BAND 6 A-64
F-126 08017-C2204 CONDUIT 2 A-64
F-127 08017-C1533 CONDUIT 1 A-64
F-128 08034-20519 BAND 6 A-64
F-129 01024-81220 BOLT 2 A-65
F-130 04434-51012 CLIP 2 A-65

F-131 21T-06-31141 ROPE (RED) 1 A-65
F-132 21T-06-31170 SHACKLE 1 A-65
F-133 21T-06-31131 ROPE (RED) 1 A-66
F-134 21T-06-31170 SHACKLE 1 A-66
F-135 281-01-13180 CLIP 3 A-67
F-136 01024-81225 BOLT 3 A-67
F-137 07281-00419 CLAMP 1 A-67
F-138 07281-00259 CLAMP 1 A-67
F-139 07281-00419 CLAMP 1 A-68
F-140 01024-81250 BOLT, SEMS 1 A-62
F-141 04434-51712 CLIP 1 A-62
F-142 195-33-11220 SPACER 1 A-62
F-143 01024-81220 CLIP 2 A-66
F-144 04434-51912 BOLT, SEMS 3 A-66
F-145 21T-46-31161 BRACKET 1 A-69
F-146 01010-82050 BOLT 4 A-69
F-147 01643-32060 WASHER 4 A-69
28
LIST OF PARTS SENT INDIVIDUALLY (Coupling of boom)
H
Assembly
707-01-XP701 1 For standard specifications

H-1 BOOM CYLINDER(L.H.) C-1
707-H1-X0620 1 For -50°C specifications

H-2 BOOM CYLINDER(R.H.) C-1
H-3 21T-70-31421 SHIM 2 C-1
H-4 21T-70-31470 SHIM 8 C-1
H-5 21T-70-31690 SHIM 8 C-1
H-6 07000-15180 O-RING 4 C-1
H-7 07000-B2060 O-RING 4 C-2
H-8 07000-B3048 O-RING 4 C-2
H-9 21T-64-32970 HOSE 2 C-2
H-10 07083-01417 HOSE 2 C-2
H-11 21T-64-39140 TUBE 1 C-3
H-12 21T-64-39150 TUBE 1 C-3
H-13 21T-64-39160 TUBE 1 C-3
H-14 07000-B3048 O-RING 2 C-3
H-15 07000-B2060 O-RING 7 C-3
H-16 01643-31845 WASHER 12 C-3
H-17 01010-81840 BOLT 4 C-3
H-18 01010-81865 BOLT 16 C-3

H-19 ARM CYLINDER(L.H.) C-3

H-20 ARM CYLINDER(R.H.) C-3
H-21 07000-12140 O-RING 4 C-3
H-22 21T-70-31441 SHIM 4 C-3
H-23 07084-02022 HOSE 2 C-3
H-24 07085-01418 HOSE 1 C-3
H-25 07085-01420 HOSE 1 C-3
H-26 07000-B2060 O-RING 4 C-3
H-27 07000-B3048 O-RING 4 C-3
H-28 07371-51470 FLANGE 4 C-3
H-29 07371-52080 FLANGE 4 C-3
H-30 01643-31445 WASHER 8 C-3
29
Assembly
H-31 01643-31845 WASHER 8 C-3
H-32 01010-81455 BOLT 8 C-3
H-33 01010-81865 BOLT 8 C-3
H-34 21T-06-32810 WORK LAMP A. 4 C-3
H-35 20Y-06-21551 BRACKET 4 C-3
H-36 01643-31445 WASHER 4 C-3
H-37 01010-81430 BOLT 4 C-3
H-38 01024-81225 BOLT 4 C-3
H-39 209-72-11311 SEAL 4 C-3
H-40 21T-70-31480 SHIM 8 C-4
H-41 21T-70-31490 SHIM 16 C-4
H-42 07000-15180 O-RING 4 C-5
H-43 08193-21012 CLIP 4 C-3
H-44 07000-B3048 O-RING 4 C-2
H-45 07371-51470 FLANGE 8 C-2
H-46 01010-81455 BOLT 16 C-2
H-47 01643-31445 WASHER 16 C-2
H-48 21T-64-32980 ADAPTER 4 C-2
H-49 21T-64-32990 BOLT 16 C-2
30
LIST OF PARTS SENT INDIVIDUALLY (Coupling of arm)
I
Assembly
I-1 07000-B2060 O-RING 6 C-6
I-2 21T-70-31290 SEAL 2 C-7
I-3 21N-70-12160 SEAL 4 C-7
I-4 209-72-11261 SEAL 4 C-7
I-5 21T-70-31391 SHIM 2 C-7
I-6 21T-70-31780 SHIM 1 C-7
I-7 21T-70-31810 SHIM 1 C-7
I-8 21T-70-31820 SHIM 1 C-7
I-9 07000-15260 O-RING 2 C-7
I-10 21T-70-32181 SHIM 4 C-8
I-11 07000-12140 O-RING 4 C-8
I-12 07371-51470 FLANGE 4 C-9
I-13 07371-52080 FLANGE 4 C-9
I-14 07084-41427 HOSE 2 C-9
I-15 07084-42026 HOSE 2 C-9
I-16 07000-B3048 O-RING 4 C-9
I-17 07000-B2060 O-RING 4 C-9
I-18 01643-31445 WASHER 8 C-9
I-19 01643-31845 WASHER 8 C-9
I-20 01010-81455 BOLT 8 C-9
I-21 01010-81865 BOLT 8 C-9
I-22 21T-68-31830 TUBE 1 C-10
I-23 203-973-5660 CLAMP 3 C-10
I-24 203-973-5720 SEAT 3 C-10
I-25 01024-81055 BOLT 6 C-10
I-26 21T-70-32330 BRACKET 1 C-10
I-27 01024-81225 BOLT 2 C-10
I-28 07631-20409 HOSE 1 C-10
I-29 04434-51712 CLIP 2 C-11
I-30 01024-81220 BOLT 2 C-11
31
LIST OF PARTS SENT INDIVIDUALLY (Coupling of bucket)
J
Assembly
J-1 209-72-11261 SEAL 4 C-12
J-2 209-70-71370 O-RING 4 C-12
J-3 205-09-61240 BOLT 4 C-12
J-4 01640-20610 WASHER 8 C-12
J-5 01596-00606 NUT 4 C-12
J-6 21T-62-34220 ELBOW 2 C-12
J-7 07000-12011 O-RING 2 C-12
J-8 21T-70-34332 COVER 1 C-12
J-9 07000-15195 O-RING 2 C-12
J-10 01010-83695 BOLT 12 C-12
J-11 01643-33690 WASHER 12 C-12
J-12 21T-70-33171 PIN 2 C-12
J-13 21T-70-34341 COVER 2 C-12
J-14 07000-15175 O-RING 2 C-12
J-15 01010-83685 BOLT 12 C-12
J-16 01643-33690 WASHER 12 C-12
J-17 21T-70-34372 COVER 1 C-12
J-18 21T-70-33250 PIN 2 C-13
J-19 21T-72-73170 STOPPER 2 C-13
J-20 01010-81645 BOLT 6 C-13
J-21 01643-31645 WASHER 6 C-13
J-22 21N-72-11230 SHIM 2 C-13
32
LIST OF PARTS SENT INDIVIDUALLY (Bleeding air from cylinders and hydraulic circuit)
K
Assembly
K-1 209-60-77551 ELEMENT 3 M-2
K-2 21T-60-13730 PLATE 3 M-2
K-3 21T-53-31820 SUPPORT 1 M-6
K-4 21T-53-31791 BRACKET 1 M-6
K-5 21T-53-33860 BRACKET 1 M-6
K-6 21T-53-31841 BRACKET 1 M-6
K-7 21T-53-31850 BRACKET 1 M-6
K-8 07283-53444 SEAT 10 M-6
K-9 07283-33450 CLIP 10 M-6
K-10 01597-01009 NUT 24 M-6
K-11 01643-31032 WASHER 24 M-6
K-12 07283-33442 CLIP 2 M-6

K-13 20Y-54-61630 CLAMP 1 M-6
K-14 01252-71025 BOLT 2 M-6
K-15 01010-81640 BOLT 2 M-6
K-16 21T-72-12620 WASHER 1 M-6
K-17 01643-31645 WASHER 1 M-6
K-18 23S-54-36270 MIRROR 1 M-6
K-19 56B-54-17313 MIRROR A. 1 M-6
K-20 23S-54-36270 MIRROR 2 M-6
K-21 21T-54-34690 SUPPORT 1 M-6
K-22 21T-54-79620 CLAMP 2 M-6
K-23 01252-71025 BOLT 4 M-6
K-24 21T-54-34850 PLATE 1 M-6
K-25 21T-54-34680 PLATE 1 M-6
K-26 07283-32236 CLIP 4 M-6
K-27 01643-31032 WASHER 8 M-6
K-28 01597-01009 NUT 8 M-6
K-29 421-54-25610 MIRROR 1 M-6
K-30 04025-00632 SPRING PIN 1 M-6
K-31 01252-70545 BOLT 4 M-6
K-32 21T-54-36480 SUPPORT 1 M-6
K-33 20Y-54-61630 CLAMP 1 M-6
K-34 01252-71030 BOLT 2 M-6
K-35 21T-06-32810 LAMP A. 1 M-7
K-36 22B-06-11690 LAMP A. 3 M-7
33
LIST OF PARTS SENT INDIVIDUALLY (Assembly of loading shovel)
Assembly
L-1 DM945-438-40 ARM CYLINDER 1 LS-1
L-3 DM945-418-40 BOOM CYLINDER 1 LS-2
L-4 DM945-419-40 BOOM CYLINDER 1 LS-2
L-5 21T-70-31421 SHIM 2 LS-2
L-6 21T-70-31690 SHIM 4 LS-2
L-7 21T-70-31470 SHIM 4 LS-2
L-8 21T-64-39421 HOSE 2 LS-3
L-9 07000-B2060 O-RING 4 LS-3
L-10 07083-01417 HOSE 2 LS-3
L-11 07000-B3048 O-RING 4 LS-3
L-12 DM942-850-40 BOOM 1 LS-5
L-13 21T-70-31690 SHIM 4 LS-5
L-14 21T-70-31470 SHIM 4 LS-5
L-15 07083-01421 HOSE 2 LS-7
L-16 07083-02023 HOSE 2 LS-7
L-17 07084-01419 HOSE 1 LS-7
L-18 07084-01416 HOSE 1 LS-7
L-19 07083-02018 HOSE 3 LS-7
L-20 07000-B3048 O-RING 8 LS-7
L-21 07000-B2060 O-RING 10 LS-7
L-22 07631-20412 HOSE 1 LS-7
L-23 DM905-984-40 BUCKET CYLINDER 2 LS-8
L-24 DM905-742-40 PIN 2 LS-8
L-25 DM905-749-40 PLATE 2 LS-8
L-26 01010-81640 BOLT 4 LS-8
L-27 01643-31645 WASHER 4 LS-8
L-28 DM942-855-40 ARM 1 LS-9
L-29 DM905-739-40 PIN 2 LS-9
L-30 DM905-749-40 PLATE 2 LS-9
L-31 01010-82455 BOLT 4 LS-9
L-32 01643-32460 WASHER 4 LS-9
34
Assembly
L-35 DM908-933-40 PIN 2 LS-10
L-36 DM905-750-40 PLATE 2 LS-10
L-37 01010-81640 BOLT 4 LS-10
L-38 01643-31645 WASHER 4 LS-10
L-39 DM942-888-40 CLAMP A. 2 LS-11
L-40 07085-01430 HOSE 4 LS-11
L-41 07084-02030 HOSE 2 LS-11
L-42 DM490-011-40 HOSE 1 LS-11
L-43 07000-B3048 O-RING 8 LS-11
L-44 01010-81455 BOLT 32 LS-11
L-45 01643-31445 WASHER 32 LS-11

L-46 07000-B2060 O-RING 4 LS-11
L-47 01010-81865 BOLT 16 LS-11
L-48 01643-31845 WASHER 16 LS-11
L-49 07084-01423 HOSE 2 LS-12
L-50 07084-01428 HOSE 2 LS-12
L-51 07000-B3048 O-RING 8 LS-12
L-52 01010-81455 BOLT 32 LS-12
L-53 01643-31445 WASHER 32 LS-12
L-54 DM944-363-40 BUCKET 1 LS-14
L-55 DM620-923-40 RING 4 LS-14
L-56 DM247-091-40 SEAL 4 LS-14
L-57 DM661-196-40 RING 4 LS-14
L-58 DM247-092-40 SEAL 4 LS-14
L-59 DM945-438-40 HOSE 3 LS-15
L-60 DM945-449-40 O-RING 6 LS-15
L-61 07083-41231 HOSE 2 LS-16
L-62 07000-B3038 O-RING 4 LS-16
L-63 01010-81245 BOLT 16 LS-16
L-64 01643-31232 WASHER 16 LS-16
L-65 08034-20536 BAND 4 LS-16
35
Assembly
L-66 21T-06-31281 BRACKET 1 LS-17
L-67 01010-81640 BOLT 1 LS-17
L-68 01643-31645 WASHER 1 LS-17
L-69 21T-06-31271 BRACKET 1 LS-17
L-70 01034-81225 BOLT 2 LS-17
L-71 56B-06-15610 SWITCH 1 LS-17
L-72 21T-72-31990 SPACER 2 LS-12
L-73 01010-81485 BOLT 8 LS-12
L-74 DM940-883-40 SPIRAL COVER 2 LS-13
36
TOOLS AND EQUIPMENT TO BE USED FOR LOCAL ASSEMBLY
No. Part name Specification Q'ty Remarks

1 Engine air compressor 0.7 MPa, 15 m3/min 1 With 200 V, 100 V generator
2 Crane truck 50 ton 2
3 Grease pump Pneumatic 1 For greasing work equipment
4 Mobile elevating work platform 10 m 1 2 workers
Equipment
Substituted by mobile
5 Lift work stand 10 step, 3,000 mm 1
elevating work platform
6 5 step, 1,500 mm 2
Stepladder
7 3 step, 900 mm 2
8 Hydraulic wrench 750 kgm 1 Track frame, power container
9 Hydraulic pump For hydraulic wrench, 200 V 1 Track frame, power container
Tightening capacity (Nm) Note 1) Q'ty Socket installed dimension (mm) Note 2)
10 Up to 196 Nm {Up to 20 kgm} 1 12.7 mm
Air impact wrench
13 Up to 2,940 Nm {Up to 300 kgm} 1 38.1 mm or spline type
14 Up to 6,374 Nm {Up to 650 kgm} 1 Note 3)
Tightening capacity (Nm) Note 1) Q'ty Socket installed dimension (mm) Note 2)
15 588 Nm {60 kgm} 1 12.7 mm
16 Torque wrench 1,370 Nm {140 kgm} 1 12.7 mm
17 2,060 Nm {210 kgm} 1 19.0 mm
18 4,120 Nm {420 kgm} 1 19.0 mm
Width across flats dimensions Q'ty Socket installed dimension (mm) Note 2)
19 17, 19, 22 1 each 12.7 mm 46 for fuel tank
Socket for air impact wrench, 24, 27, 30 65 for counterweight
1 each 19.0 mm 70 for track frame
socket for torque wrench and
socket for hexagonal head bolt 32, 36 1 each 25.4 mm a Match socket installed
dimension to impact
41, 46, 50, 55, 65, 70 1 each 38.1 mm wrench.
14 mm, hexagonal head bolt 1 each
20 For impact wrench, 300 mm long 2
Extension
Tool
21 For impact wrench, 200 mm long 1

22 Impact wrench air hose Inside ø 12, Inside ø 19 50 m each
23 Air coupler For hoses of size 4, 6 2 sets
Unnecessary, if hydraulic
24 16 time wrench 450 kgm 1
wrench is available
25 Width across flats: 30 mm 2
Spanner
29 Standard tool set Sockets, spanners, ring wrenches 2 sets each
30 Large hammer (Plastic) 10 P 1
31 Bar 1m 2
For receiving center frame to
32 50 ton 2
install track frame
Hydraulic jack
For tightening track frame
33 20 ton 1
clamping bolt
For connecting travel piping
34 Oil receiving pan Large and small 2 each
and work equipment piping
35 Drum can oil filler 1
For supporting revolving frame
36 Wooden block 300 × 400 8
and center frame
37
No. Part name Specification Q'ty Remarks
37 M10 × P1.5 1
38 M12 × P1.75 1
39 M14 × P2 1
40 M16 × P2 1
41 M20 × P2.5 1
42 M24 × P3 1
43 Tap M27 × P3 1
44 M30 × P3 1
45 M33 × P3 1
46 M36 × P3 1
47 M39 × P3 1
48 M42 × P3 1
49 M45 × P3 1
50 ø 10 × 3,000 mm 4 Catwalk
51 ø 20 × 5,000 mm 4 Boom, arm and bucket
Wire rope sling Center frame and power
52 ø 30 × 6,000 mm 4
container
Counterweight, revolving
53 ø 40 × 5,000 mm 4
Tool
frame and track frame

54 Chain For 15 ton 2 Track frame
Center frame, boom, arm and
55 5.4 ton 4
power container
56 10 ton 4 Track frame and revolving frame
57 Shackle 20 ton 2 Counterweight
58 2 ton 4 Fuel tank
59 0.9 ton 4 Cabin
60 SB10 2 Travel piping cover
61 50 mm wide × 3,000 mm 2 Boom cylinder
Synthetic fiber sling
62 25 mm wide × 3,000 mm 2 Handrail
63 1.5 ton 3 Left floor assembly
64 Lever block 3.0 ton 2
65 6 ton 2
66 M20 × 2.5 2
67 M16 × 2 4
Eyebolt
68 M12 × 1.75 4
69 M30 × 3 2
70 Pin Pin, ø 50 × 700 mm 2 Track frame
71 Cleaning liquid Brake cleaner spray can 10
72 Hydraulic oil EO10 2400 L
73 Diesel fuel 2000 L
and sub-materials
Fuel, oil, grease
74 Grease G2-LI (20 L can) 5 In grease bath

75 Natural yellow spray can 10
Repair paint
76 Black gray spray can 10
Connecting faces of revolving
77 LG-6 TB1215 1
frame and swing circle
Prepare it only in EU district
78 Air conditioner refrigerant HFC134a (R134a) 2000 g
(EU specification)
79 Cloth 1 bundle 20 kg For cleaning
Note 1) Prepare an impact wrench on the basis of the tightening capacity.

Note 2) The socket installed dimensions are shown for reference. Match the wrench to the socket prepared separately.
Note 3) Hydraulic wrench No. 8 in the previous page may be used for bolts of M27 mm or larger. In this case, splined sockets
must be prepared (1 piece each of sizes 41, 46, 50, 55, 65, and 70 in width across flats).
38
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 size diameter
Thread (Diameter, pitch,
× Bolt length)
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 20
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
39
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) Unit : Nm Unit : {kgm}
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}
a For symbols “a” and “b” in the table, see Fig. 1.
40
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 (in)
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 (in)
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}
41
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
Outside diameter Width across Tightening torque (Nm {kgm})

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.
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
42
COATING MATERIALS LIST
a The coating materials such as adhesives, gasket sealants, and greases used for disassembly and assembly
are listed below.
a For coating materials not listed below, use the equivalent of products shown in this list.
Category Komatsu code Part No. Q'ty Container Main features and applications
• Used to prevent rubber gaskets, rub-

LT-1A 790-129-9030 150 g Tube ber cushions, and cock plugs from
coming out.
• Used for plastic (except polyethyl-
ene, polypropylene, tetrafluoroethyl-
20 g Polyethylene ene and vinyl chloride), rubber,
LT-1B 790-129-9050 (2 pcs.) container metal, and non-metal parts which re-
quire immediate and strong adhe-
sion.
• Features: Resistance to heat and
Polyethylene
LT-2 09940-00030 50 g chemicals
container • Used to fix and seal bolts and plugs.
Adhesive: • Used to stick metal, glass, and plas-
790-129-9060 tics.
1 kg
LT-3 (Set of adhesive Can
Hardener:
and hardener) 500 g
Adhesive Polyethylene • Used to seal plugs.

LT-4 790-129-9040 250 g container
Holtz • Heat-resistant seal used to repair en-

790-126-9120 75 g Tube gines
MH 705
• Quick-setting adhesive
Threebond Polyethylene • Setting time: Within 5 sec. to 3 min.
790-129-9140 50 g
1735 container • Used mainly to stick metals, rubbers,
plastics, and woods.
• Quick-setting adhesive
• Quick-setting type (max. strength is
Aron-alpha Polyethylene
790-129-9130 2g obtained after 30 minutes)
201 container • Used mainly to stick rubbers, plas-
tics, and metals.
• Features: Resistance to heat and
Loctite Polyethylene chemicals
79A-129-9110 50 cc
648-50 container • Used for fitted portions used at high
temperatures.
• Used to stick or seal gaskets and
LG-1 790-129-9010 200 g Tube packings of power train case, etc.
• Used to seal various threaded por-
Polyethylene tions, pipe joints, and flanges.
LG-5 790-129-9080 1 kg container • Used to seal tapered plugs, elbows,
and nipples of hydraulic piping.
• Features: Silicon-based heat and
cold-resistant sealant
• Used to sea flange surfaces and
LG-6 790-129-9020 200 g Tube threaded portions.
• Used to seal oil pan, final drive case,
Gasket etc.
sealant
• Features: Silicon-based quick-set-
ting sealant
LG-7 790-129-9070 1 kg Tube • Used to seal flywheel housing, intake
manifold, oil pan, thermostat hous-
ing, etc.
Three bond • Gasket sealant used to repair engine
790-129-9090 100 g Tube
1211
• Features: Silicon-based, heat and
Three bond cold-resistant, vibration-resistant,
419-15-18131 100 g Tube
1207B impact-resistant sealant
• Used to seal transfer case, etc.
• Used to lubricate sliding portions (to
LM-G 09940-00051 60 g Can prevent squeaking).
Molybdenu • Used to prevent scuffing and seizure
m disulfide of press-fitted portions, shrink-fitted
lubricant LM-P 09940-00040 200 g Tube portions, and threaded portions.
• Used to lubricate linkages, bearings,
etc.
43
Category Komatsu code Part No. Q'ty Container Main applications, features
SYG2-400LI • General purpose type

SYG2-350LI
G2-LI SYG2-400LI-A Various Various
SYG2-160LI
SYGA-160CNLI
SYG2-400CA • Used for bearings used at normal
SYG2-350CA temperature under light load in
G2-CA SYG2-400CA-A Various Various contact with water or steam.
SYG2-160CA
SYGA-160CNCA
Molybdenum • Used for parts under heavy load.
SYG2-400M 400 g × 10 Bellows-type
disulfide
Grease SYG2-400M-A 400 g × 20 container
lubricant SYGA-16CNM 16 kg Can
LM-G (G2-M)
Hyper White • Seizure resistance and heat resist-
SYG2-400T-A ance higher than molybdenum di-
Grease G2-T 400 g Bellows-type
SYG2-16CNT sulfide
G0-T (*) container
SYG0-400T-A (*) 16 kg • Not conspicuous on machine since
*: For cold Can
SYG0-16CNT (*) color is white.
district
Biogrease G2-B, • Since this grease is decomposed
G2-BT (*) SYG2-400B by natural bacteria in short period,
400 g Bellows-type it has less effects on microorgan-
*: For use at high SYGA-16CNB container isms, animals, and plants.
temperature SYG0-400BT (*) 16 kg Can
and under high SYGA-16CNBT (*)
load
SUNSTAR • Used as primer for cab side
Glass (Using limit: 4 months after
PAINT PRIMER 20 ml container date of manufacture)
580 SUPER
417-926-3910
SUNSTAR • Used as primer for glass side
Glass (Using limit: 4 months after
GLASS PRIMER 20 ml container date of manufacture)
580 SUPER
• Used as primer for painted
SUNSTAR Glass surface on cab side
PAINT PRIMER 22M-54-27230 20 ml container (Using limit: 4 months after
435-95
Primer date of manufacture)
• Used as primer for black ce-
ramic-coated surface on
SUNSTAR glass side and for hard poly-
GLASS PRIMER 22M-54-27240 150 ml Can carbonate-coated surface
435-41 (Using limit: 4 months after
date of manufacture)
• Used as primer for sash
SUNSTAR Glass (Almite)
Adhesive for cab glass
SASH PRIMER 22M-54-27250 20 ml container (Using limit: 4 months after

GP-402 date of manufacture)
• "S" is used for high-tempera-
SUNSTAR ture season (April - October)
PENGUINE and "W" for low-temperature
Polyethylene
SEAL 580 417-926-3910 320 ml season (November - April) as
container
SUPER "S" or adhesive for glass.
"W" (Using limit: 4 months after
date of manufacture)
Adhesive
• Used as adhesive for glass.
Sika Japan, Polyethylene
20Y-54-39850 310 ml (Using limit: 6 months after
Sikaflex 256HV container date of manufacture)
SUNSTAR Ecocart • Used as adhesive for glass.
PENGUINE 22M-54-27210 320 ml (Special (Using limit: 6 months after
SUPER 560 container) date of manufacture)
• Used to seal joints of glass
SUNSTAR Polyethylene parts.
PENGUINE 417-926-3920 320 ml container (Using limit: 4 months after
SEAL No. 2505 date of manufacture)
SEKISUI • Used to seal front window.
Caulking Polyethylene (Using limit: 6 months after
SILICONE 20Y-54-55130 333 ml
material container date of manufacture)
SEALANT
• Used to seal joint of glasses.
GE TOSHIBA Translucent white seal. (Us-
SILICONES 22M-54-27220 333 ml Cartridge ing limit: 12 months after date
TOSSEAL 381 of manufacture)
44
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
45
Assembly procedure
Assembly of track frame assembly
A-1 and center frame assembly (1/3)
Track frame assembly (right)
Width across flats
Tightening torque 4413 – 4903 Nm

(450 – 500 kgm)
Apply wooden blocks etc.

to parts which wire ropes
will touch.
Center frame assembly
Track frame assembly (left)
No. Part No. Q'ty

A-1 21T-30-71160 76
A-2 21T-30-71170 76
A-3 208-30-11850 1
A-4 208-30-11861 1
A-5 01024-81225 3
Precautions Tools required Equipment required
a When slinging the center frame, take care Name Q’ty Name Q’ty
not to crush the grease piping of the Power wrench (×16) 1 Hydraulic jack 50t 2
circuit with wires. (21t-98-11120)
Socket 38 × 70 mm 1 Truck crane 45 t 2
(21T-98-11190)
Handle 1 Center frame stand 2
(21T-98-11130)
Socket 70 mm 1
Tap (M45 × 3) 1
Others
46
Assembly procedure
1) Place the left track frame assembly as shown in the figure

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

couple it with the track frames. Left
Center frame assembly
Right
3) Remove the plugs from the coupling surface and clean Rear view
the coupling surface in advance.
4) Insert all the bolts, tighten them temporarily, and support

only the right side of the center frame on a jack.
Use only stands before coupling.
After coupling with left track frame,
5) Sling the right track frame assembly with the 45-ton crane left stand is not necessary any more.
and couple it with the center frame. At this time, the jack
under the center frame should be heightened a little for
20 Pipe
the ease of coupling.
a If you pull in the right track toward the center frame
Grip
with a chain block, you can work easily.
6) Insert all the bolts, tighten them temporarily, and lower

the crane.
7) Remove the jack.
45 t
45 t
Pin (See above figure)
Method of slinging track frame
If 2 cranes are used, holes can be aligned easily.
Precautions
[Before sling by crane]

• Confirm that projecting length (A) of the plunger on hydraulic
idler cushion side is approx. 10 mm.
Hose Oil stopper Tools required Equipment required
Name Q’t Name Q’t
Pin ø50 × 40 mm 2 Crane 45t 2
(Hard steel)
Wire ø40 × 5 m 2
(General purpose)
Plunger on Plunger on hydraulic idler
grease side cushion side
If the projection is not approx. 10 mm, remove the oil stopper of
the hose and discharge hydraulic oil inside the cylinder. Thereaf-
ter, install the oil stopper of the hose again.
• Confirm that projecting length (B) of the plunger on grease side
(when being filled with grease) is approx. 35 mm. If the projection
is not approx. 35 mm, make necessary adjustments by charging
Others
or discharging grease through the grease fitting.
47
Assembly procedure
1) Eliminate the clearance between the mating faces of the track frame and center frame (at the top, bottom, right and left).
Jack up the track frame, if necessary.
2) Coupling bolt
Power wrench (×16) + 36 kgm torque wrench
Mounting bolt size: M45 × P3
Tightening torque: 450 – 500 kgm
20 t
Input: 35 kgm
If input exceeds 35 kgm, power wrench may be broken.
<Tightening order>
When installing the clamping bolts, remove the Name Q’ty Name Q’ty
piping at the rear of the center frame 20t Jack 2
(so that you can use an impact wrench easily).
(See Assembly procedure A-3.)
Others
48
Assembly procedure
Installation of idler cushion cylinder piping
A-2
R.H. side
L.H. side
Bracket and clamp are

installed to piping when
transported.
Tightening torque for U-clamp

11 -- 26 Nm {1.1 -- 2.7 kgm }
Use following parts installed when transported.

07371-30640(4): FLANGE
07395-21035(8): BOLT
This figure shows R.H. side.

No. Part No. Q'ty
A-6 07000-B3025 2
A-16 01010-81660 4
A-17 01643-31645 4
1) When connecting the crawler frame, remove Name Q’ty Name Q’ty
the bolts and bracket marked with ª. 17 mm Socket 1
2) Be careful not to damage tubes during 24 mm Socket 1

connecting work.
3) Be sure to connect L.H. and R.H. sides of

cylinder piping.
Others
49
Assembly procedure
Installation of travel motor piping
A-3
Connect

07371-51470(8): FLANGE
01010-81455(16): BOLT
01643-31445(16): WASHER
Return piping which was removed

when track frame and center frame
were connected.
No. Part No. Q'ty
A-7 07000-B3048 4
A-8 02896-61018 2
1) Take care that dirt will not enter the piping. Name Q’ty Name Q’ty
22 mm Socket 1
2) The hoses are installed to the travel motor.
150 mm Extension 1
300 mm Extension 1
24 mm Spanner 1
32 mm Spanner 1
Others
50
Assembly procedure
Installation of travel motor cover (1/3)
A-4
Travel motor guard

No. Part No. Q'ty
Travel motor cover
A-9 21T-30-32173 1
Crawler frame A-10 21T-30-32183 1
A-11 01010-82460 10
A-12 17A-54-44130 10
A-13 01010-82460 16
A-14 01643-32460 16
A-15 21T-30-32370 16
Travel motor guard is installed to crawler Name Q’ty Name Q’ty

frame assembly when transported.
Travel motor cover is installed temporarily to
crawler frame assembly when transported.
a Before performing this item, bleed air from

the travel motor.
Others
51
Assembly procedure
A-4
Right side
Left side
. Name Q’ty Name Q’ty

Others
52
Assembly procedure
A-4
a This page is for only the center frame under cover speciflcation.
Left of machine
Front of machine
Machine from below
No. Part No. Q'ty

A-18 21T-30-18120XC 5
A-19 01024-82465 20
A-20 01643-32460 20
Install the center frame under cover after Name Q’ty Name Q’ty
adjusting the hydraulic idler cushion.
Others
53
Assembly procedure
Filling swing circle with grease
A-5
1) Fill the swing circle grease bath with grease (G2-LI).
Grease bath seal (all round)
Supply grease near

swing circle gear.
2) Apply grease to the swing circle gear contact faces (Approx. 10 l (9 kg) of 80 l (72 kg)).
3) Fill the grease bath seal with grease.
G2-LI
Grease bath seal
4) Apply gasket sealant LG-6 to the swing circle mounting face.
Apply LG-6 (Gasket sealant)

to swing circle gear side of
outer race mounting bolts.
• Supply 4 × 20 l (18 kg) cans of grease (G2-LI), Name Q’ty Name Q’ty
80 l (72 kg) in total.
• Clean the swing circle mounting face.
• Remove rust preventive.
(If rust preventive is left, the bolt tightening
torque reduces after the bolt is tightened.)
Others
54
Assembly procedure
Assembly of revolving frame assembly
A-6 and undercarriage (1/2)
1) Positioning of crane and revolving frame
2) Method of slinging rear end
When installing revolving frame assembly to

undercarriage, remove transportation jigs.
Sling front and rear ends simultaneously with 2 truck cranes.

.
Fix the ropes to the hook securely.
See above.
SC55 shackle = 18 t
(Inside width: 83 mm)
SC40 shackle = 10 t
Take care of the center of gravity of the crane hook.

If the hook is loaded,
the boom lowers a little.
aWhen slinging the revolving frame, adjust it to the horizontal in each
direction with shackles.
Others
aRemove the rust preventive from the mounting faces of the revolving frame
and swing circle and from the inside face of the taps and then clean those
faces. (If any rust preventive is left, the bolt torque will be decreased.)
55
Assembly procedure
Assembly of revolving frame assembly
A-6 and undercarriage (2/2)
1) Clean the mounting surface.
2) Align the dowel pin with the dowel pin hole of the swing circle. Dowel pin
3) Sling and couple the revolving frame.

Take care not to hit it against the swivel joint and grease bath.
4) Tighten all the bolts lightly.

• Retighten them after finishing assembly.
Width across flats

3 Tightening torque :
250 -- 310 kgm
Apply LT-2.
Revolving frame assembly Apply LG-6 (TB1215) all round revolving

frame coupling surface without leaving any
breaks. (Apply to inside of bolt holes.)
2450 -- 3040 Nm {250 -- 300 kgm}
Apply LT-2.
Right Rear
a Sling horizontally so that pinion will not be damaged.
Front Left
5) Tighten 3 bolts each of the right and left sides, 8 bolts on the front side and 3 bolts No. Part No. Q'ty
on the rear side (17 bolts in total) in the drawing to the specified torque. B-1 21T-25-67150 60
B-2 01643-33690 60

Fix the ropes to the hook securely.
a When disassembling to 27 t, install swing 55 mm Socket 1
machinery later.
a When disassembling to 32 t, raise the Tap (M36 × 3) 1
motor.
(Perform this so that the machinery gear
can be rotated freely and its phase can be
set to that of the swing circle.)
See Installation of swing machinery (A-7).
Take care of the center of gravity of the crane hook.
If the hook is loaded,
Others
the boom lowers a little.
56
Assembly procedure
Installation of swing machinery (front) assembly (27t)
A-7 Installation of swing motor (front) assembly (32t)
Swing machinery (front) assembly

1140 kg
155 – 195 kgm
Swing motor (front) assembly
Connection at
5 places
Use split flanges and bolts

installed when transported.
07371-31049(6): FLANGE
07375-21035(12): BOLT
No. Part No. Q'ty

B-3 01010-83090 14
B-4 01643-33080 14
B-5 07000-B3032 1
B-6 07000-B3032 2
B-7 02896-61015 1
Coupling B-8 02896-61008 1
B-9 01024-81225 1
a When connecting the revolving frame to the Name Q’ty Name Q’ty
undercarriage, raise the swing motor 46 mm Socket 1
assembly (front). (200 mm) Joint 1
After connecting the revolving frame to the
undercarriage, reinstall the swing motor 14 mm Socket 1
assembly. (When disassembled to 32 t) 19 mm Set wrench 1
a Take care that the O-ring will not be caught. 19 mm Spanner 1
32 mm Set wrench 1
32 mm Spanner 1
Others
57
Assembly procedure
Connection of swivel joint piping (1/2)
A-8
To drain filter
Connection
No color
mark Red
Green
Blue
Color for distinction of hose
Couple swivel joint lock.
Connection
No. Part No. Q'ty

B-10 11Y-62-11980 1
B-11 02896-61009 4
• Watch your step during work. Name Q’ty Name Q’ty

(Take care not to drop oil around your feet.) 22 mm Socket 1
150 mm Extension 1
41 mm Spanner 1
Pincher or plier 1
Set wrench 1
Others
58
Assembly procedure
Connection of swivel joint piping (2/2)
A-8
If installed angle of
pipe is not proper
when connected,
loosen opposite side
and then install.

07371-51470(8): FLANGE
01010-81455(16): BOLT
01643-31445(16): WASHER
Connection
No. Part No. Q'ty

B-12 07000-B3048 4
• Take care that the O-ring will not be caught. Name Q’ty Name Q’ty
(Check visually.) 22 mm Socket 1
150 mm Extension 1
41 mm Spanner 1
Pincher or plier 1
Others
59
Assembly procedure
Connection of swing circle grease piping
A-9
Connection
L1

Name Q’ty Name Q’ty
17 mm Spanner 1
19 mm Spanner 1
Others
60
Assembly procedure
Installation of hydraulic tank assembly (1/5)
A-10
For disassembly to 27 t
Hydraulic tank assembly

1750 kg
Use bolts and washers installed when

transported.
01024-81235(8): BOLT
1520 -- 1910 Nm {155 -- 195 kgm
Connection
Suction tubes are installed temporarily

to chassis when transported.
3 Tightening torque for U-clamp

35.3 -- 87.2 Nm {3.6 -- 8.9 kgm}
3 Tightening torque for coupling

6.4 -- 7.4 Nm {0.65 -- 0.75 kgm}
No. Part No. Q'ty
B-13 07000-B5230 2
B-14 01011-83010 12
B-15 21T-26-11460 12
a Before connecting the revolving frame to Name Q’ty Name Q’ty

the undercarriage, install the hydraulic
tank.
Others
61
Assembly procedure
A-10
Clamp air conditioner hoses

at 4 places marked with .
Clamp PPC hoses

at 2 places marked with .

Others
62
Assembly procedure
A-10
Use split flanges and bolts installed when transported.

07371-32076(16): FLANGE
07375-21240(32): BOLT
Connection at
5 places
Clamp hose.
No. Part No. Q'ty

B-16 07000-B2060 8

Others
63
Assembly procedure
A-10
Use split flanges and bolts installed when transported.

07371-31049(2): FLANGE
07375-21035(4): BOLT
Connection at
4 places
Rear of main valve

From power container
No. Part No. Q'ty

B-17 11Y-62-11980 3
B-18 07000-B3032 1

Others
64
Assembly procedure
A-10
Clamp wiring harness Clamp wiring harness

(Side of vertical panel of revolving frame). (L-bracket in cab base).
Connect wiring harness connector

(inside of cab base).
Pull wiring harness into cab base

through this grommet.
Precautions to be observed when connecting Name Q’ty Name Q’ty

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

Others
65
Assembly procedure
Installation of fuel tank assembly
A-11
45 t Crane Fuel tank assembly

2350 kg (including 250 L of fuel)
Bolt Collar
No. Part No. Q'ty

C-1 01011-83010 20
C-2 21T-26-11460 20

46 mm Socket 1 45t Crane 1
ø12 × 5 m Wire 2
Eyebolt M30-P3 2
Others
66
Assembly procedure
Connection of fuel tank assembly
A-12 piping and wiring (1/2)
Fuel piping
1. Connection of return and spill lines
1) Remove the blind plugs of the return and spill lines.
2) Connect the return and spill lines marked with ª and fix them with the clamps.
O-ring
Return line
Band marker: Red
Spill line
Band marker: None
Clamp Bolt
2. Connection of drain and supply lines
1) Remove the transportation clamps of the drain line marked with A.
Keep 1 of the 2 clamps to use in 3).
2) Remove the blind plugs of the drain and supply lines.
3) Connect the drain and supply lines marked with w.
O-ring
Delivery line
O-ring
Drain line
Reused clamp
No. Part No. Q'ty

C-3 04435-52212 1
C-4 02896-61012 1
C-5 02896-61015 2
C-6 02896-61018 2
C-7 01024-81220 1
C-52 09460-00000 1

27 mm Spanner 1
32 mm Spanner 1
36 mm Spanner 1
19 mm Socket 1
Others
67
Assembly procedure
Connection of fuel tank assembly
A-12 piping and wiring (2/2)
Electric wiring
Clamp Bolt
1. Clamp the wiring harness to the grease can bracket.

4 places marked with
Clamp Bolt
2. Connect the wiring harness connector marked with .
No. Part No. Q'ty

C-8 04434-52312 1
C-9 04434-51912 3
C-10 01024-81220 4

reconnect it.

Others
68
Assembly procedure
Installation of cab base assembly (1/2)
A-13
Mounting bolt to
cab base assembly
Catwalk in front of cab
Mounting bolt to
Cab base assembly
cab base assembly
2600kg
Catwalk on left of cab
Before installing to cab base,

install working lamp.
No. Part No. Q'ty

C-11 01034-81245 10
C-12 01034-81265 10
C-13 21T-54-31140 1
C-14 21T-54-31150 1
C-15 01034-81245 2
C-28 21T-06-32810 2
C-29 21T-06-32820 1
C-30 04434-51012 7
C-31 01024-81220 7
• For the installed angle of the working lamp, Name Q’ty Name Q’ty
see M-7. 30 mm Socket 1 45t Crane 1
ø12 × 5 m Wire 3
SC14 Shackle 3
Others
69
Assembly procedure
Installation of cab base assembly (2/2)
A-13
C-18 C-16 C-18 C-16
C-18 C-17
No. Part No. Q'ty

C-16 01011-82035 20
C-17 01011-82045 7
C-18 567-40-41380 27

Others
70
Assembly procedure
Installation of emergency escape ladder
Ａ-１４
Mounting bracket of rope ladder
tensioner bracket .
C-35-1
0.35kg
Fixed ladder .C-35-3

assembly 25kg
P Z
Mounting . C-32
Handrail assembly
bolts for C-35-5
fixed ladder (8) Rope ladder
2kg
assembly Q C-35-4
3kg
(2)
Mounting . C-35 (8)

bolts for handrail
assembly
Snap ring (rope ladder) Bracket for
Hook (escape door) adjusting tension
Z
of rope ladder . C-35-2
To be connected Q
with rope ladder
Mounting bolt C-33
of bracket for (2)
adjusting
tension of C-35-5 21T-53-33141 2
rope ladder
C-35-4 21T-54-37681 1
C-35-3 21T-54-37661 1
C-35-2 21T-54-37621 1
Bracket for adjusting tension of rope ladder
C-35-1 21T-54-37690 1
(21T-54-37611；Factory fitted temporaly) 1kg
P C-35 01024-81225 8
C-34 Mounting bolt of bracket for C-34 01034-81225 2
adjusting tension of rope C-33 01034-81235 2
(2)
ladder C-32 01034-81225 8
NO. Parts name Qty
Name Qty Name Qty
a Be sure to fix the rope ladder without 1
looseness. 19mm Socket
150mm Extension 1
a Be sure to install the snap ring of rope
ladder to the hook of the escape door.
Others
71
Assembly procedure
Installation of left floor assembly (1/4)
A-15
Sling position
Install eyebolt.
No. Part No. Q'ty

C-36 21T-53-32812 1
After installing exterior parts, C-37 01034-81240 4
adjust their level difference C-38 21T-53-32820 2
with these shims. (See A-47.) C-39 01034-81240 4
After the work, return the bolts removed to Name Q’ty Name Q’ty
install the eyebolts.
Others
72
Assembly procedure
A-15
C-20 C-19
Part a
C-20 C-19 C-20 C-19
Part b
No. Part No. Q'ty

C-19 01010-82075 24
C-20 15R-70-16370 24
Before tightening the mounting bolts at parts Name Q’ty Name Q’ty
(a) and (b), check that both mating faces are
fitted to each other.
Others
73
Assembly procedure
A-15
Clearance b Clearance a
Shim Shim
t1.2 t1.2
C-21 C-22
(6) (10)
Adjust clearance at this part,

if necessary, by inserting shim Condenser box
under condenser box.
When assembling this

assembly, adjust is so
that it will not interfere
with cab base door.
No. Part No. Q'ty

t1.2 C-21 21T-53-32271 6
t1.2 C-22 21T-53-32350 10
C-23 21T-54-33471 1
C-24 01034-81230 3
Clearance a: 15 mm ± 10 mm Name Q’ty Name Q’ty

(Reduce difference between widest and
narrowest clearances to 3 mm or less)
Clearance b: 17 mm ± 5 mm
(Reduce difference between widest and
narrowest clearances to 3 mm or less)
Others
74
Assembly procedure
A-15
<Adjustment of cab base door>
Adjust the projection of rubber stopper (a) at the door bottom and position of lock bar bracket (c) so that lock bar (b) at the door
top will clasp while rubber stopper (a) is in contact with the side cover.
Lock bar bracket (c)
Lock bar (b)
Rubber stopper (a)
75
Assembly procedure
Connection of cab base assembly piping (1/3)
A-16
Connection (Face seal)
Green
Brown
White
Black
Yellow
Blue
Red
No color mark
Black/Black
Blue/Black
Red/Black
Green/Black
Connection (Quick coupler)
Before connecting, remove hose plug.
No. Part No. Q'ty

C-25 02896-61012 6
Disconnection of quick coupler Connection of quick coupler Name Q’ty Name Q’ty
(1) Push the hose adapter into the adapter. (4) Hold the hose adapter and push it
(2) Push the cap into the adapter. staright into the adapter until it clicks.
(3) Pull the hose straight. After connecting the hose, pull its adapter
lightly to check that it will not come off.
Hose adapter
Hose
Cap
Adapter (Plug or joint)

Others
76
Assembly procedure
A-16
Connection
Connect with L-adapter up.
Right wall in cab base
No. Part No. Q'ty

C-26 02896-61018 2

Others
77
Assembly procedure
A-16
a This page is for only the hydraulic ladder specification.
Band color: Brown
Connect
Right rear in cab base
No. Part No. Q'ty

C-40 04435-52112 2
C-41 01024-81225 1
C-42 154-979-1480 1
C-43 01024-81275 1

Others
78
Assembly procedure
Connection of cab base assembly wiring (1/6)
A-17
Pass wiring harness through hole.
Pass wiring harness

through hole.
Connection
Remove dust proof cap
Cap part No.

Male Female
CN-A05 21T-06-33810 21T-06-33820
CN-A04 21T-06-338A0 21T-06-33830
CN-A22 21T-06-33120 21T-06-33850
08191-00770(4) 08191-00770(4)
• When connecting the DRC multi-pole Name Q’ty Name Q’ty

connector, see "Precautions for connecting
DRC multi-pole connector" on pages 3/6 – 5/6
of this section.
• When connecting the DT, DTP or DTHD

DT, DTP or DTHD connector" on pages 5/6
of this section.
Others
79
Assembly procedure
A-17
Hydraulic ladder
specification Connection
Connection
Loading shovel specification

(if equipped)
Connection
Fix with clamps.
No. Part No. Q'ty

C-51 01024-81020 1
• When connecting the DT, DTP or DTHD Name Q’ty Name Q’ty
DT, DTP or DTHD connector" on pages 5/6
of this section.
• Remove the cover of part X when connecting

the wiring harness and install it again after
the work.
Others
80
Assembly procedure
A-17
"Precautions for connecting DRC multi-pole connector"

Precautions to be observed when connecting DRC multi-pole connector
1. Before connecting
If the seal rubber is broken or deformed,

the connector may not be connected normally.
In this case, replace the connector with new one.
Check the edge for breakage or

17A-06-41830 deformation. If it has any
17A-06-41840 abnormality, replace the whole
connector with new one.
2. Preparation for connection
If the DRC multi-pole connector is at a high place, prepare a work stand so that you can stand stably and connect the con-
nector while checking it visually.

Others
81
Assembly procedure
A-17
3. Connecting method
1) Check that the key ways are aligned and then set the terminals to each other while setting the seal rubber edge to the
receptacle connector edge.
While swinging the connectors up and down and to the right and left so that the terminals will be in position and clear-
ance "a" and "b", and "c" and "d" between the connectors will be the same respectively, tighten the center hexagon
socket head bolt 1 turn.
Receptacle connector edge
Seal rubber edge
Terminal
Up
Left Right
Hexagon socket head bolt

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

Others
82
Assembly procedure
A-17
3) After clearances "a" and "b", and "c" and "d" between the connectors become the same and below 1 mm, tighten the
hexagon socket head bolt to the following torque.
2.83 ± 0.28 Nm {0.28 ± 0.03 kgm}
Approx. 1 mm
4) Check after connection

• Turn the key switch ON and check that the electric parts of the chassis are operating normally. (Observe the condi-
tion for several minutes after turning the key switch ON.)
• Start the engine, move the work equipment, and check that the electric parts (monitors and lights) do not blink
because of vibrations.
If any abnormality is detected by the above 2 checks, disconnect the connector and check it for a problem, and then repeat
steps 1 - 3.
"Precautions for connecting DT, DTP or DTHD connector"
Precautions to be observed when connecting DT, DTP or DTHD connector

• After connecting the connector, check visually that the connector is locked securely.
If the connector is not locked securely, reconnect it.

Others
83
Assembly procedure
A-17
a This page is for only the hydraulic ladder specification.
Switch box assembly
Pass wiring harness through hole

Connect
on side of cab base.
Left rear out of cab base
CH-A38A
CH-A38B
No. Part No. Q'ty
C-44 21T-06-32810 1
Left rear in cab base C-45 01024-81285 4
C-46 04434-51012 1
C-47 04434-51412 3
C-48 04434-51712 2
C-49 04434-51912 2
C-50 01024-81225 8

Others
84
Assembly procedure
Connection of left floor assembly heater piping
A-18
Connection
No. Part No. Q'ty

C-27 21T-979-3320 2
When connecting the hoses, match their Name Q’ty Name Q’ty
identification tape colors.
Others
85
Assembly procedure
Connection of left floor assembly wiring (1/2)
A-19
Front of machine
C-53
Left of machine
(Serial No. 20152 and up:

Seat with 4 holes)
Connection Connection
To cab
This cable is
To air described in A-31.
conditioner
condenser
Right side of battery case
Top of air conditioner condenser
No. Part No. Q'ty

C-53 01024-81025 1

reconnect it.

Others
86
Assembly procedure
Connection of left floor assembly wiring (2/2)
A-19
When emergency stop switch is equipped
Connection
CN-A61A to chassis harness
C-54
C-55
No. Part No. Q'ty

C-54 01024-81220 1
C-55 04434-51012 1

Others
87
Assembly procedure
Installation of tail pipe
A-20
Top of power container
Front of machine Left of machine

No. Part No. Q'ty
D-1 21M-01-18130 2
D-2 01024-81230 12
D-3 6162-14-5640 2
a Before performing this work, connect the Name Q’ty Name Q’ty
container to the revolving frame.
Others
88
Assembly procedure
Installation of power container assembly (1/2)
A-21
Power container assembly

16200 kg
Right rear
Take care that mounting section of

container will not go over guide.
Left rear

Others
89
Assembly procedure
Installation of power container assembly (2/2)
A-21
M42 × 3, L = 350 mm, Width across flats 65 mm

3,430 – 4,212 Nm {350 – 430 kgm}
Nut is welded to
revolving frame.
Plate with nuts
No. Part No. Q'ty

D-4 21T-54-31121 4
D-5 21T-54-31130 20
D-6 01643-34212 20
Retighten the bolts finally after installing the Name Q’ty Name Q’ty
counterweight for safety.
After assembling, check securely that all the

bolts are tightened to the specified torque.
Others
90
Assembly procedure
Connection of suction piping (1/2)
A-22
Use following parts installed

when transported.
01024-81235(4): BOLT Use following parts installed when transported.
Replace band 01010-81660(8): BOLT
(upper). 01643-31645(8): WASHER
(2)
Replace band
(upper).
Suction sub-tank
Connection
Main pump seen from below

No. Part No. Q'ty
D-7 07000-B2140 2
D-8 07000-B2100 1
D-9 209-62-41341 4
D-10 20Y-62-51671 2
• Do not loosen the clamp band on the suction Name Q’ty Name Q’ty
sub-tank side.
Others
91
Assembly procedure
Connection of suction piping (2/2)
A-22
1. Once a MIKALOR clamp is removed, do not use it again but replace it with new one.
2. Install MIKALOR clamp marked as shown below.
(1) Adjust bridge position so that the bridge shoud go into the bottom of band of clamp as shown in the following figure.
(2) Tighten bolt so that dimension (a) should be below figure by using impact wrenchi.
Apply lubricating oil

Bridge
(PANDO 18B made by Three Bond)
on thread of bolt
before tightening a bolt.
Punch hole
The overlap of bridge and band.
No. Clamp part No. Dimension (a)

0
1 209-62-41341 15 -3
0
2 20Y-62-51671 20 -3
92
Assembly procedure
Connection of oil cooler piping and pump drain piping
A-23

07371-32076(14): FLANGE
07375-21240(28): BOLT
Connection
Temporarily
installed to hose Adjust direction of adapter and
then tighten permanently.
Connection at
3 places
Connection
No. Part No. Q'ty

D-11 07000-B2060 7
D-12 07298-02011 1
Take care that the O-ring will not be caught. Name Q’ty Name Q’ty
Others
93
Assembly procedure
Connection of fan motor drain piping
A-24
D-13
07371-31049(2): FLANGE
07375-21035(4): BOLT
Connection
No. Part No. Q'ty

D-13 07000-B3032 1

Others
94
Assembly procedure
Installation of suction unit undercover
A-25
No. Part No. Q'ty

D-22 21T-54-34931 1
D-23 21T-54-34981 1
D-24 21T-54-34991 1
D-25 21T-54-34971 1
D-26 21T-54-34941 1
D-27 21T-54-34961 1
D-28 21T-54-34951 1
D-29 203-54-62670 2
D-30 01024-81225 2
D-31 01034-81225 26
D-34 21T-54-34920 1
D-35 01024-81225 2
D-36 01024-81235 3

Others
95
Assembly procedure
Connection of delivery piping (1/2)
A-26
Before starting this work, remove covers

temporarily. After connecting piping, install
covers again.

Others
96
Assembly procedure
Connection of delivery piping (2/2)
A-26

07371-51470(8): FLANGE
01010-81455(16): BOLT
Connection 01643-31445(16): WASHER
Front end of power container
Left of machine
Front of machine
No. Part No. Q'ty
D-14 07000-B3048 4
a Secure the scaffoldings. Name Q’ty Name Q’ty

Others
97
Assembly procedure
Connection of pilot piping and fan motor piping
A-27
Use following parts installed when transported. Use following parts installed when transported.
D-16 07371-31049(2): FLANGE D-15 07371-30640(4): FLANGE
07375-21035(4): BOLT 07375-21035(8): BOLT
Front end of power container
Connection
Left of machine
No. Part No. Q'ty

Front of machine ª D-15 07000-B3025 2
D-16 07000-B3032 1

Others
98
Assembly procedure
Connection of power container assembly
A-28 fuel piping (1/2)
Spill Delivery 1 Delivery 2
Return Spill
Delivery 1
Return
Delivery 2 (to rear of container)
No. Part No. Q'ty

D-17 02896-61018 2
D-18 02896-61015 1
3 Tightening torque for hose Name Q’ty Name Q’ty

A: 177 – 245 Nm {18 – 25 kgm}
B: 128 – 186 Nm {13 – 19 kgm}
Others
99
Assembly procedure
A-28 fuel piping (2/2)
D-19
Connection
No. Part No. Q'ty

D-19 02896-61015 1

Others
100
Assembly procedure
A-29 air conditioner piping
Parts to be removed
E-48 ‫ڎ‬2
Apply compressor oil to the O-rings.
(to prevent the lowering of sealing performance)
M24 (Width across flats: 27) M24 (Width across flats: 27)
Container side is female. Container side is male.
Tightening torque 30 – 35 Nm Tightening torque 30 – 35 Nm
M22 (Width across flats: 24) M22 (Width across flats: 24)
Container side is female. Container side is male.
Tightening torque 20 – 25 Nm Tightening torque 20 – 25 Nm
‫(ڎ‬GOCNGUKFGKUVQDGHKZGF
Connection
No. Part No. Q’ty

E-48 21N-979-8160 1

1. To prevent moisture and foreign matter from entering the Name Q’ty Name Q’ty
air conditioner piping,
･ Do not perform this work on a rainy day.
･ Always remove each blind plug just before piping work
and perform the work quickly.
･ Never work with cotton work gloves on.
2. Apply compressor oil to the O-rings.

･ Be sure to use compressor oil for refrigerant R134a.
・Never use oil or grease for other refrigerants.
3. Before connecting, check that the contact surfaces of the

O-rings are free from dirt etc.
Others
4. Using two spanners, tighten to the specified torque. (to

prevent the damage of piping)
101
Assembly procedure
A-30 heater piping
Parts to be removed
a Before connecting these hoses, connect Name Q’ty Name Q’ty

all of the other heater hoses.
Others
102
Assembly procedure
A-31 wiring (1/4)
<Caution>
Connect the battery cable after all the
wiring harnesses are connected.
Front of machine
Left of machine
To ground seat of
revolving frame vertical plate
Connection
Fix 2 terminals together.
Connection
Connection
May be connected to either one.
Connection
Fix 2 terminals together.
No. Part No. Q'ty
D-32 08038-10035 2
D-33 08038-04030 2

Others
103
Assembly procedure
A-31 wiring (2/4)
Left of machine
Front of machine
D-20 D-21 D-20 D-21
Pass wiring harness

through hole. Pass wiring harness
through hole.
Connection
No. Part No. Q'ty

D-20 08028-55065 2
D-21 01024-81020 2

reconnect it.

Others
104
Assembly procedure
A-31 wiring (3/4)
a This page is for isolator installed specification only.
Machine left
Machine front
Connection
Install caps.
To revolving frame vertical board

grounding seat (See A-19.)
No. Part No. Q'ty
D-37 01024-81020 4

Others
105
Assembly procedure
A-31 wiring (4/4)
a This page is for jump start installed specification only.
Machine left
Install cap.
Connection
Tighten together with 2 terminals. Machine front
To jump start
receptacle

Others
106
Assembly procedure
Installation of operator's cab assembly (1/4)
A-32
Operator's cab assembly
When installing cab,

remove mount cover
and stopper bracket
(see next page).
No. Part No. Q'ty

E-26 21T-54-34131 1
E-27 01034-81225 6
E-28 21T-54-34151 1
E-29 01034-81225 6
E-30 21T-54-34141 1
E-31 01034-81225 6
E-32 21T-54-34161 1
E-33 01034-81225 6
Take care not to break the mount dowel pin. Name Q’ty Name Q’ty
Others
107
Assembly procedure
A-32
Shims for
adjusting clearance
Z Left of machine
Front of machine
Cab assembly
When riding in cab adjust with shims
so that clearance to be 1.5 to 3 mm.
STD. Quantites of Shim

Portion Part Number Quantities Part Number Quantities
J 21T-54-36690 1 21T-54-36680 1
K 21T-54-36690 1 21T-54-36680 1
L 21T-54-36690 1 21T-54-36680 1 No. Part No. Q'ty
E-34 21T-54-37980 6
M 21T-54-36690 3 t1.6 E-35 21T-54-36680 9
N 21T-54-36690 2 21T-54-36680 1 t3.2 E-36 21T-54-36690 12
E-37 01024-81030 12
P 21T-54-36690 2 21T-54-36680 1 E-38 21T-54-37990 6
Others
108
Assembly procedure
A-32
1) Remove all the stopper brackets installed to the mount.
Cab assembly 130 – 150 mm
2) Lower the cab assembly to 130 – 150 mm above the mount.
3) Raise each mount assembly.

While setting the dowel pin, fix the mount temporarily with the bolt at its center.
Dowel pin
Mount
No. Part No. Q'ty

E-39 21T-54-35312 8
E-40 8230-46-1130 16
E-41 01643-32060 16
Others
109
Assembly procedure
A-32
4) After installing all the mounts temporarily,

lower the cab assembly and tighten the bolt
at the center of each mount.
5) While adjusting the clearance at the stopper,

install the stopper brackets again.
(M20 × 1.5)
(M20 × 2.5)
• Delivered individually with pin assembly

for installation to viscous-mount-less portion.
Adjust so that clearance will be 1.5 – 3 mm

when operator sits in cab seat.
Mounting section (A) – (H)

Standard quantity of shim
Standard cab Cab with front guard
Section
t3.2 t1.6 t3.2 t1.6
A 1 1
B
C 1 1
D 1 2
No. Part No. Q'ty
E 1
t1.6 Shim E-1 21T-54-36661 16
F t3.2 Shim E-2 21T-54-36671 8
G E-3 21T-54-35321 8
E-42 21T-54-35732 4
H 1 1 E-43 01020-00514 8
E-44 01050-52040 4
E-45 01643-32060 4
Others
110
Assembly procedure
Installation of rotary lamp (if equipped) (1/2)
A-33
Left of machine
Front of machine
E-4
E-5
E-6
Connection
No. Part No. Q'ty

E-4 8295-06-1480 1
E-5 21T-06-17430 1
E-6 01024-81225 2

reconnect it.

Others
111
Assembly procedure
Installation of rotary lamp (if equipped) (2/2)
A-33
Front of machine
Left of machine
E-7
E-8
E-9
E-10
Connection
E-11 E-12
No. Part No. Q'ty
E-7 8295-06-1480 1
E-8 21T-06-33610 1
E-9 21T-06-17430 1
E-10 01024-81225 2
E-11 04434-51012 1
E-12 01024-81220 1

reconnect it.

Others
112
Assembly procedure
Installation of ORBCOMM antenna (if equipped)
A-34
Left of machine
To be tightened together
with wiring harness.
Front of machine
E-13
E-14 E-15
No. Part No. Q'ty

E-13 8A13-10-2100 1
E-14 21T-06-64491 1
E-15 01024-81225 1

Others
113
Assembly procedure
Connection of operator's cab assembly wiring (1/3)
A-35
To ORBCOMM antenna
Built-on clamp
CN-A03 (Stamp C)
CN-A02 (Stamp B)
Connection CN-A01 (Stamp A)
Cab base ceiling

Inside right of cab base If you remove this clip temporarily,
you can connect connector easily.
(Inside switch board)

reconnect it.

Others
114
Assembly procedure
A-35 (if equipped)
Connection
CN-A54
to cab harness

Others
115
Assembly procedure
A-35
Front of machine
Left of machine
Connection
Cab seen from below
No. Part No. Q'ty

E-47 01024-81020 1

Others
116
Assembly procedure
Connection of operator's cab assembly
A-36 hydraulic piping (1/2)

Others
117
Assembly procedure
A-36 hydraulic piping (2/2)
Green/Black
Blue
Red/Black
Black/Black
Red
Blue/Black
Blue/White
Red/White
Blue/Blue
Before connecting,
Red remove hose plug.
Connection (Face seal)
Red
No color mark
Blue
White
Black
Green
Brown
Yellow
No. Part No. Q'ty

E-16 02896-61012 10
E-17 02896-61009 2
Disconnection of quick coupler Connection of quick coupler Name Q’ty Name Q’ty
(1) Push the hose adapter into the adapter. (4) Hold the hose adapter and push it
(2) Push the cap into the adapter. staright into the adapter until it clicks.
(3) Pull the hose straight. After connecting the hose, pull its adapter
lightly to check that it will not come off.
Hose adapter
Hose
Cap
Others

118
Assembly procedure
A-37 window washer hose
Connection
Upper washer hose
Lower washer hose
Tanks A and B may
be connected to
either of upper and
lower washer hoses.
A B
Inside right of cab base

Others
119
Assembly procedure
A-38 air conditioner piping
‫ڎ‬ ‫ڎ‬
㪜㪄㪋㪏
Connection (2 pcs.)
Suction line
M24 (Width across flats : 27 )
Bind 2 pieces by 2.
To cab Tightening torque 30 - 35Nm
㪜㪄㪈㪐
㩿㪉㪀
To cab
To compressor
Cab side
Connection (2 pcs.)
Discharge line
Tightening torque 12 - 15Nm
㪜㪄㪈㪏
㩿㪉㪀 After charging with refrigerant,
Connection (2 pcs.) check for its leakage and wind
Liquid line seal (adhesive) around adapter
.
Tightening torque 12 - 15Nm
.
After charging with refrigerant,

㪜㪄㪈㪏 check for its leakage and wind
㩿㪉㪀 seal (adhesive) around adapter
No. Part No. Q'ty

E-18 21T-979-4421 4
E-19 08034-20830 2
E-48 21N-979-8160 1

1. To prevent moisture and foreign matter from entering the Name Q’ty Name Q’ty
air conditioner piping,
･ Do not perform this work on a rainy day.
･ Always remove each blind plug just before piping work
and perform the work quickly.
･ Never work with cotton work gloves on.
2. Apply compressor oil to the O-rings.

･ Be sure to use compressor oil for refrigerant R134a.
・Never use oil or grease for other refrigerants.
3. Before connecting, check that the contact surfaces of the

O-rings are free from dirt etc.
Others
4. Using two spanners, tighten to the specified torque. (to

prevent the damage of piping)
120
Assembly procedure
Connection of operator's cab assembly heater piping
A-39
Insert coolant drain hoses

(2 pcs).
Connection (4 pcs.)
Bind cables in fours.
Bind cables in twos
Bind cables in twos
Rear of cab seen from below
White tape Red tape No. Part No. Q'ty

E-20 08034-20830 3
E-46 11Y-09-11160 4

Others
121
Assembly procedure
Installation of operator's cab rear floor assembly
A-40
Operator's cab rear floor assembly Left of machine Front of machine
E-21 E-21
Clamp air conditioner piping.
No. Part No. Q'ty

E-21 01024-81225 14

Others
122
Assembly procedure
Installation of handrail around operator's cab
A-41
No. Part No. Q'ty

E-22 21T-54-33931 1
E-23 01034-81240 8
E-24 203-957-2640 2
E-25 21T-03-11280 2

Others
123
Assembly procedure
Installation of track frame ladder
A-42
No. Part No. Q'ty

F-1 21T-30-32231 2
F-2 21T-30-32241 2
F-3 01010-81640 8
F-4 01010-82450 8
F-5 01643-32460 16
Perform this step after adjusting the track Name Q’ty Name Q’ty
tension to avoid interference with the track.
Others
124
Assembly procedure
Installation of power container side
A-43 catwalk assemblies (right and left)
Front of machine
Power container side

catwalk assembly
Left of machine
Right assembly:
Without wiring harness
bracket on underside
Left assembly:
With wiring harness bracket
on underside
After installing exterior

parts, adjust their level
difference with these
shims. (See A-47.)
F-7
No. Part No. Q'ty

F-6 01034-81240 16
F-7 21T-53-32290 12

Others
125
Assembly procedure
Installation of right floor assembly,
A-44 grease can cover assembly and center floor (1/2)
Left of machine
Front of machine
F-9 F-10 F-8 F-10
Grease can cover assembly
F-11 F-12
F-13 F-14
Right floor assembly

No. Part No. Q'ty
F-8 01010-82080 12
F-9 01010-82060 8
F-10 01643-32060 20
F-11 21T-53-31550 1
F-12 21T-54-31560 1
F-13 21T-54-33331 1
F-14 01034-81250 4

When slinging the grease can cover
assembly, open the top cover and
use the hanging holes in it.
Others
126
Assembly procedure
Installation of right floor assembly,
A-44 grease can cover assembly and center floor (2/2)
F-19 F-19 F-20 F-19
F-15 F-16 F-18 F-17
No. Part No. Q'ty

F-15 21T-54-33731 1
F-16 21T-54-33781 1
F-17 21T-54-33791 1
F-18 21T-53-31590 1
F-19 01034-81230 18
F-20 01034-81285 4

Others
127
Assembly procedure
Installation of fuel tank right catwalk assembly
A-45
Left of machine
Front of machine
F-21
Fuel tank right catwalk assembly
No. Part No. Q'ty

F-21 01034-81240 16

Others
128
Assembly procedure
Installation of fuel tank front catwalk assembly
A-46
Left of machine
Front of machine
F-22
(6) Fuel tank front catwalk assembly
No. Part No. Q'ty

F-22 01034-81250 6

Others
129
Assembly procedure
Adjustment of exterior parts clearance
A-47
When and after assembling the exterior parts, adjust each clearance as shown below.
Adjust the clearance finally after installing the counterweight.
Clearance: 20 ± 5 mm
Clearance: Max. 30 mm
Reduce the level difference between the outside surfaces of adjacent exterior covers to 5 mm or less.
Reduce the level difference between the underside surfaces of adjacent exterior covers to 7 mm or less.
130
Assembly procedure
Connection of grease reel piping
A-48
Left of machine
Front of machine
Connection
Connection

Others
131
Assembly procedure
Installation of access ladder assembly
A-49
a For hydraulic ladder specification (option)
The ladder unit is installed to the left deck assembly when transported.
Install the left deck assembly to the machine and hang the ladder and then install the parts in the following figure.
F-23
F-24
No. Part No. Q'ty

F-23 21T-53-32491 1
F-24 01034-81230 4
F-25 21T-53-33170 1
F-26 01034-81230 4

Others
132
Assembly procedure
Installation of counterweight assembly
A-50
Counterweight assembly
24,500 kg
M42 × 3, L = 670 mm,

Width across flats 65 mm
3430 -- 4212 Nm
{350 -- 430 kgm}
F-27 F-28
4 bolts and 4 washers are

used to install transportation
jigs during transportation.
F-30 F-31
F-31 F-29
No. Part No. Q'ty

F-27 21T-46-34120 12
F-28 209-46-11210 12
F-29 21T-46-34141 2
F-30 21T-46-34131 2
F-31 01024-81225 12
Tighten the counterweight mounting bolts Name Q’ty Name Q’ty

permanently after tightening all the bolts Tap (M42 × 3) 1
temporarily.
(Prevention of seizure of the bolts)
Others
133
Assembly procedure
Installation of deformation preventing stoppers for catwalk
A-51 assemblies (left and right) on the side of power container
Adjust the clearance to

F-149 F-148 F-150
5 ± 2.5 mm by using shims.
Clearance: 5 ± 2.5 mm
(2 places on the right and left sides) No. Part No. Q'ty
F-148 21T-53-33640 2
F-149 21T-53-33650 4
F-150 01024-81255 4
After adjusting the clearances of exterior Name Q’ty Name Q’ty

parts in (A-47), adjust the clearance of the
stopper. (2 places on the right and left sides)
Others
134
Assembly procedure
Installation of handrail on counterweight
A-52
F-34 F-32
F-34 F-33
No. Part No. Q'ty

F-32 21T-54-34411 1
F-33 21T-54-34421 1
F-34 01034-81250 16

Others
135
Assembly procedure
Installation of handrail clamps (1/3)
A-53
F-39 F-37 F-36 F-35

(14)
When installing, use screw

as positioning jig.
Screw
F-38
7 places marked with
No. Part No. Q'ty

F-35 21T-54-32911 7
F-36 21T-54-32921 7
F-37 01010-D1250 14
F-38 21T-54-37220 1
F-39 175-54-34170 14

Others
136
Assembly procedure
A-53

Others
137
Assembly procedure
A-53
F-40 F-41 F-42 F-43
When installing, use screw

as positioning jig.
No. Part No. Q'ty
F-40 21T-54-31140 1
F-41 21T-54-31150 1
F-42 01010-81245 2
F-43 175-54-34170 2

Others
138
Assembly procedure
Connection of fuel cut wire
A-54
F-44 Chain
F-45
F-46
Fuel cut wire
<Procedure>
(1) Remove the cotter pin of the fuel
cut wire connecting pin and then
remove the wire.
Step (2) Pass the wire through the hole of

the step and connect it to the pin
again. Reuse the cotter pin.
Fuel cut wire
No. Part No. Q'ty

F-44 21T-54-37220 1
F-45 04530-10815 1
F-46 21T-04-32180 1

Others
139
Assembly procedure
Connection of drain piping under power container
A-55
Front of machine
Left of machine
128 – 186 Nm
{13 – 19 kgm}
F-48 F-47
Clamp
See Note 1.
F-49
F-34
F-49 3.91 – 4.89 Nm
Connection {0.40 – 0.50 kgm}
Connection
Coolant drain
Engine breather No. Part No. Q'ty

F-47 21T-01-31471 1
Muffler drain PTO oil drain Engine oil drain F-48 07005-02416 1
F-49 07281-00419 3

Note 1
Underside of
revolving frame
Project the ends of engine breather pipe

and muffler drain pipe 10 mm from
Others
the underside of the revolving frame.
140
Assembly procedure
Connection of battery wiring
A-56
See A-31 Connection of power container assembly wiring

Others
141
Assembly procedure
Setting of hydraulic tank strainer
A-57
Remove the suction pipe blind plug in the

hydraulic tank and set the strainer.
Door cover Flange assembly (2)
(1) Open the hydraulic tank (2) Remove the flange (3) (After removal)
upper door cover. assembly.
Strainer assembly (2)
(4) Pull up the strainer (5) Reverse the strainer (6) Install the flange
assembly. assembly and insert it in assembly and close the
the hydraulic tank again. door cover.
• Carry out the above work after installing the Name Q’ty Name Q’ty
suction piping and hydraulic pump.
• Before starting the engine, check that the
strainer is set downward.
a Set in normal position (5) when shipped

from the factory.
Others
142
Assembly procedure
Starting engine, checking oil and coolant levels,
A-58 bleeding air from each part, and adjusting track (1/15)
1. Inspection and addition of each oil and coolant --- See the M1 and Operation and Maintenance Manual for each item.
• Inspection and addition of coolant
• Inspection and addition of oil in engine oil pan
• Inspection of fuel
• Inspection and addition of oil in hydraulic tank
• Inspection and addition of oil in PTO case
• Inspection and addition of oil in swing machinery case
• Inspection and addition of oil in final drive case
2. Check for oil leakage
3. Bleeding air from fuel circuit

1) Fill the fuel tank with fuel (to the FULL level of the fuel
level gauge).
2) Check that fuel shut-off lever (1) is pushed down and

then loosen air bleeding plug (2).
143
Assembly procedure
3) Remove locknut (4) of priming pump lever (3),

operate priming pump lever (3), and check that
bubbles are discharged from the air bleeding plug (2)
and then fuel flows out of the plug.
3 Plug: 4.9 – 6.9 Nm {0.5 – 0.7 kgm}

4) Tighten air bleeding plug (2).
5) Push in priming pump lever (3) and tighten locknut (4)

to fix priming pump lever (3).
6) Before starting the engine, perform following steps

4. (1) – (5).
7) Start the engine and check each part for fuel leak and
oil leak, and then keep the engine running at low idle
for about 10 minutes.
144
Assembly procedure
4. Air bleeding from each component
(1) Air bleeding from hydraulic pump
a After removing and installing the hydraulic pump or

changing hydraulic oil, bleed air from the hydraulic pump
according to the following procedures.
k If air was not bled or air was bled insufficiently, the
pump may be broken. So, be sure to bleed air strictly
according to the procedures.
1) Loosen bleeders (1) – (3) of all hydraulic pump 1 or 2
turns at the same time.
a Connect a tube [1] to each bleeder to prevent oil
from being scattered and making the machine
dirty, and receive the oil in oil pan or others.
2) Feed hydraulic oil up to the specified level.
a Even after feeding oil to the hydraulic tank, keep
the oil filler cap removed.
3) After oil flew out from bleeder (3) of the fan pump PF,
tighten bleeder (3) temporarily.
4) After bleeders (1) and (2) of the main pumps P1 and
P2 stop bleeding air, keep bleeder (1) of main pump
P1 loosened, and tighten only bleeder (2) of the main
pump P2 temporarily.
5) Loosen plug (5) for suction tube and check that oil
flows out. Then, tighten the plug temporarily.
6) Crank the engine and make sure that oil flows out
from bleeder (1) of the main pump P1. Then, tighten
the bleeder temporarily.
Note) Bleeding all air takes time.
a For cranking, idle the engine at low speed for 15
seconds twice.
145
Assembly procedure
7) Loosen the bleeder (2) of the main pump P2.

8) Crank the rear engine and make sure that oil flows out of the bleeder (2) of the main pump P2. Then, tighten the bleeder
temporarily.
Note) Bleeding all air takes time.
a For cranking, idle the engine at low speed for 15 seconds twice.
9) Start the engine and keep it idle at low speed.
10) Loosen the bleeders (1) – (3) of all hydraulic pumps and make sure that bubble-free oil flows out of them. Then, tighten
these bleeders temporarily.
11) Close the oil filler caps of the hydraulic tank.
12) Keep the engine idling at low speed, raise the work equipment from the ground and swing the upper structure 180°.
a After the swing, lower the work equipment completely to the ground.
3 Plug : 58.8 – 78.4Nm {6 – 8kgm}

13) Loosen plug (5) for the suction tube and make sure that bubble-free oil flows out of it. Then, tighten the plug.
these bleeders temporarily.
a This work is the same as in the above Step 10.
15) Keep the engine idling at low speed, raise the work equipment from the ground and swing the upper structure 180°.
a Swing the upper structure in the reverse direction from the one in the above Step 12. After the swing, lower the work
equipment completely to the ground.
3 Bleeder : 8.8 – 9.8Nm {0.9 – 1.0kgm}

these bleeders.
17) Stop the engine.

18) Loosen the oil filler cap of the hydraulic tank slowly and remove it. Relieve pressure from the hydraulic tank and feed
hydraulic oil up to the specified level.
(2) Air bleeding from work equipment cylinder circuit
a When removing and installing the work equipment cylin-

der or when disconnecting and connecting the cylinder
circuit piping, bleed air from the work equipment cylinder
according to the following procedures.
cylinder piston ring may be broken. So, be sure to
bleed air strictly according to the procedures.
1) Start the engine and idle it at low speed for about 5
minutes.
2) Repeat raising and lowering the boom 4 or 5 times at
the low idle.
a Stop the piston rod about 100mm before the
stroke end and be careful not to relieve it.
3) Execute Step 2) at high idle.
4) Bring the piston rod to the stroke end at low idle and
relieve it.
5) Execute Steps 2) – 4) for the arm and the bucket.
a When the cylinder was replaced, execute the pro-
cedures before connecting the work equipment.
Especially, when the boom cylinder was installed
to the work equipment, the lowering side does not
move to the stroke end.
146
Assembly procedure
(3) Air bleeding from swing motor circuit (Swing motor)
a When removing and installing the swing motor or when

disconnecting and connecting the swing motor main cir-
cuit pipes, bleed air from the swing motor according to the
following procedures.
swing motor may be damaged. So, be sure to bleed
air strictly according to the procedures.
1) Start the engine and operate it while the engine is
idling at low speed.
2) Repeat operations of swing, start, and stop 5 or 6
times.
(4) Air bleeding from swing motor circuit (Parking brake circuit)
a When removing and installing the swing motor or when

disconnecting and connecting the swing holding brake
circuit piping, bleed air from the brake circuit according to
the following procedures.
swing holding brake may be dragged. So, be sure to
bleed air strictly according to the procedures.
1) Start the engine and loosen bleeder (11).
a The bleeder is mounted on the front and rear
swing motors.
2) Turn off the swing lock switch.
3) Swing the motor while the engine is idling at low
speed and make sure that bubble-free oil flows out of
3 Bleeder : 8.8 – 9.8Nm {0.9 – 1.0kgm}

bleeder (11). Then, tighten the bleeders.
a The swing operation may be as faintly as the

swing oil pressure switch turns on.
(5) Air Bleeding from travel motor circuit (Travel motor)
a When removing and installing the travel motor or when

disconnecting and connecting the travel motor main cir-
cuit pipes, bleed air from the travel motor according to the
following procedures.
travel motor may be damaged. So, be sure to bleed
air strictly according to the procedures.
1) Start the engine and loosen bleeder (12).
a The bleeder is mounted on the LH and RH travel
motors.
2) Make sure that bubble-free oil flows out of the bleed-
3 Bleeder : 8.8 – 9.8Nm {0.9 – 1.0kgm}

ers (12). Then, tighten the bleeder.
147
Assembly procedure
(6) Air bleeding from PPC circuit
a When removing and installing the control valve or when disconnecting and connecting PPC hose, bleed air from the PPC
circuit according to the following procedures.
k If air was not bled or air was bled insufficiently, time lag or abnormal sound may occur. So, be sure to bleed air
strictly according to the procedures.
1) Start the engine and loosen the bleeder (13).
a The bleeders are installed on the elbow of the return
spring case of the control valve spool. (28 places in total)
2) Control each actuator while the engine is idle at low speed.
3) Make sure that bubble-free oil flows out of bleeder
3 Bleeder : 8.8 – 9.8 Nm {0.9 – 1.0 kgm}

(13). Then, tighten bleeder.
k The operation of each lever should be enough to

the extent that each hydraulic switch turns on.
4) The circuits and places to be bled are as follows.
A : Arm IN circuit (3 places),
Q : Boom RAISE circuit (3 places),
T : Bucket CURL circuit (4 places), Elbow with bleeders
U: Travel REVERSE circuit (4 places),
a : Arm OUT circuit (4 places),
q : Boom LOWER circuit (2 places),
t : Bucket DUMP circuit (4 places),
u: Travel FORWARD circuit (4 places)
• Front side of control valve
• Rear side of control valve
Left travel Right travel
148
Assembly procedure
(7) Bleeding air from pilot selector valve circuit
• Pilot selector valve PV1 • Pilot service valve PV2
a If the pilot selector valve circuit was disconnected and connected, bleed air from it according to the following procedure.
k If the air bleeding operation is not performed or all air is not bled, the work equipment speed may decrease during
compound operation. Therefore, be sure to bleed air according to the specified procedure.
1) Start the engine and loosen bleeders (1) and (2).
a Pilot selector valves PV1 and PV2 have 1 bleeder each.
2) While running the engine at low idle, move the arm in and curl or dump the bucket simultaneously. When oil containing
3 Bleeder : 8.8 – 9.8 Nm {0.9 – 1.0 kgm}

no bubbles flows out of bleeder (1), tighten bleeder (1).
k Operate each lever slightly to a degree that each oil pressure switch is turned ON.
3) Turn swing lock switch ON.
4) While running the engine at low idle, raise the boom and swing the upper structure simultaneously. When oil containing
3 Bleeder : 8.8 – 9.8 Nm {0.9 – 1.0 kgm}

no bubbles flows out of bleeder (2), tighten bleeder (2).
k Operate each lever slightly to a degree that each oil pressure switch is turned ON.
149
Assembly procedure
5. Air bleeding from HIC (Hydraulic Idler Cushion) circuit, filling of pressurized oil, and adjustment of track shoe ten-
sion
Hydraulic idler cushions will be abbreviated as HIC.
k Idler cushion on PC2000-8 is designed hydraulic. Do not adjust the tension of the track shoe by filling grease into
grease cylinder only without adjusting by HIC cylinder.
If the hydraulic idler cushion is adjusted defectively, excessive force applies on undercarriage parts and they may
break.
If the track shoe is to be tensioned right after assembly in the field, follow the procedures below.
Bleeding air from HIC circuit
Filling of oil with pressure into HIC circuit
Adjusting the tension of track shoe by using grease cylinder
(1) HIC system configuration figure
HIC cylinder
Section Q
Section P
Enlarged view of the Enlarged view of the
section P section Q
No. Part Name Part No. Remarks

4 Valve 07959-30000 For Grease Cylinder
6 Plug 198-30-14420 For Cushion Cylinder
150
Assembly procedure
HIC piping
No. Part No. Part Name Remarks

7 709-90-74401 Safety valve
8 21T-60-31510 Relief valve with check valve
9 21T-60-12221 Accumulator
10 21T-62-74420 Check valve block
11 209-60-52170 Check valve
12 21T-60-12251 Drain valve
13 21T-60-72120 Pressure reducing valve
14 209-60-52170 Check valve
151
Assembly procedure
HIC (Hydraulic Idler Cushion) System
1. Idler 11. Check valve

2. Yoke (grease cylinder) 12. Drain valve (stop valve)
3. Plunger (grease cylinder) 13. Pressure reducing valve
4. Plug (for grease) 14. Check valve
5. Cushion cylinder (hydraulic cylinder) 15. Air bleeding plug
5-1 Plunger (cushion cylinder) 16. Plug
6. Plug (for cushion cylinder) 17. Travel motor (right)
7. Safety valve 18. Swivel joint
8. Relief valve with check valve 19. Control valve
9. Accumulator 20. Inline filter
10. Check valve block 21. Main pump
Operation
• For filling of oil with pressure to hydraulic circuit, it is started • The cracking pressure (opening pressure) of relief valve
to fill oil to forward circuit of right travel motor through with check valve is 25.7 MPa {262 kg/cm2} (cracking
check valve (14) and pressure reducing valve (13). pressure of relief valve : 8.0 MPa {81.6 kg/cm2} (when
By pressure reducing valve (13), the pressure of filled oil back-pressure is 0 MPa {0 kg/cm2}) + back-pressure :
is set to 17.7 MPa {180 kg/cm2}, and oil is filled in cush- 17.7 MPa {180 kg/cm2} = 25.7 MPa {262 kg/cm2}).
ion cylinder (5), so the plunger (5-1) stretches to stroke
• Oil pushed out by plunger (5-1) flows into accumulator
end. At the same time, oil is filled into accumulator (9) to
(9) after relief valve with check valve (8) opens, and
pressurize the nitrogen pressure gas sealed inside, from
nitrogen gas in the accumulator is pressed, raising the
13.2 MPa to 17.7 MPa {135 kg/cm2 to 180 kg/cm2}.
inner pressure.
• As the forward circuit of right travel motor is always con-
• If the exterior force on the idler is released, the pressure
nected, if the pressure in the circuit is lower than set
will push the oil reversely, returning the oil to cushion cyl-
pressure, 17.7 MPa {180 kg/cm2}, because of gas leak
inder (5) through the check valve in relief valve with
of the accumulator, or if right forward travelling pressure
check valve (8). Therefore the inner pressure reduces
is higher than 17.7 MPa {180 kg/cm2}, hydraulic pres-
while idler (1) moves forward, and the system returns to
sure will be supplied.
the original condition.
Therefore, the pressure in the circuit is kept at 17.7 MPa
{180 kg/cm2} all the time. • If there is abnormal high pressure in the circuit when
idler (1) withdraws under exterior force because of gas
• Yoke (2) works as grease cylinder, and grease is filled
leak in accumulator (9) or abnormality in relief valve with
inside plunger (3).
check valve (8), safety valve (7) will be operated to pre-
• If idler (1) withdraw under exterior force, plunger (5-1) of vent accidents, such as breakage of piping, etc.
cushion cylinder (5) is pushed back and the inner pres-
sure of the cylinder rises. If this pressure rises higher
than the cracking pressure of relief valve with check
valve (8), this valve will open and the oil will flow into
accumulator (9).
152
Assembly procedure
(1) Bleeding of air from idler cushion circuit
a Be sure to bleed air from idler cushion circuit before

grease is filled into grease cylinder.
1) Loosen plug (4) of grease cylinder for one turn .

(2 places in left and right sides)
2) Completely open drain valve (12) on the inner side of

the center frame.
View Z
Z Rear of the machine
3) Loosen air bleeding plug (6) of the cushion cylinder

about one turn. (2 places in left and right sides)
4) Remove plug (16) on the bottom of check valve block

(10), and loosen air bleeding plug (15) on the side for
about one turn .
5) Run the engine at low idle for 2 to 3 minutes.
6) Completely close drain valve (12) when clean oil

flows out from the holes of air bleeding plug (6) and
plug (16).
7) After that, tighten air bleeding plugs (15), (6) (2 places

in left and right sides). Upper
8) Tighten plug (16).
9) Tighten plugs (4) (2 places in the right and left sides).
10) Finally, tighten drain valve (12).

No. Tightening torque
4
6 58.8 – 88.3 Nm {6 – 9 kgm}
15 Lower
16 3.9 – 6.9 Nm {0.4 – 0.7 kgm}
View Z
Rear of the machine
153
Assembly procedure
(2) Procedure for filling of oil with pressure into HIC circuit
1) Run the engine at medium speed.
a Before working, confirm that drain valve (12) is

tightened.
2) In order to increase the filled oil pressure in HIC cir-

cuit, keep the bucket teeth upright and lowered into
the ground to prevent the machine from travelling,
and obtain a hydraulic relief for 4 to 5 seconds
through directional operations of R.H. travel lever.
Repeat these operations 5 or 6 times.
a Do not carry out these directional operations on

any slippery surface (such as steel plate).
a Even when projecting length (a) of the hydraulic

cushion cylinder plunger is within the specified
values, occasionally the charging pressure of oil
in HIC circuit is low.
3) Confirm that projecting length (a) of the hydraulic

cushion cylinder plunger is 135 ± 5mm on both L.H.
and R.H. sides.
4) If projecting length (a) has not become 135 ± 5mm,

carry out the operations in (2) described above once
again and be sure to obtain the specified dimension
of (a).
a In case the length of 135 ± 5mm cannot be ob-

tained, it is supposed that some excessive grease
is contained in the grease cylinder. Discharge
such excessive grease in accordance with the
item "Adjusting grease cylinder" in the next page.
• Protrusion amount (A): 135 ± 5 mm

<Check point>
If the front edge of hydraulic cushion cylinder plunger
is located near the center of the inspection hole on
the side face of crawler frame, the projecting length is
approximately within the specified values.
(3) Testing and adjusting track shoe tension
Testing
1. Run the engine at low idle and drive the machine forward
by the length of track on ground, and then stop slowly.
2. Place steel bar (b) on the track shoe between 2nd carrier
roller (1) and 3rd carrier roller (2).
3. Measure the maximum clearance between the track shoe

top and the steel bar.
• Maximum clearance (a): 10 – 30 mm
154
Assembly procedure
(4) Adjusting of grease cylinder

Adjust grease cylinder after adjusting hydraulic cushion cylinder.
k Do not loosen plug (4) for more than one turn.

If the plug is loosened for more than one turn , plug (4) may fly out by inside high pressured grease, so parts
other than plug (4) should not be loosened. Keep face away from the mounting direction of plug (4).
a Before injecting grease, confirm that protrusion

amount (A) of plunger (a) of hydraulic cushion cylin-
der (5) is 135 ± 5 mm on both left and right sides. Con-
firm the protrusion amount of hydraulic cushion
cylinder again after injecting grease, and if the
amount is not in this range, loosen plug (4) for one
turn, eject the grease, and fill oil with pressure again
into HIC circuit in accordance with procedure (2).
k Avoid adjusting the tension of the track shoe by filling grease into grease cylinder without adjusting hydraulic
cushion cylinder. Extreme force may apply on the undercarriage, causing breakage.
• When increasing tension

Prepare grease pump.
1) Inject grease into cylinder through the plug (4)
with a grease gun.
2) To check that the tension is normal, move the ma-

chine forward slowly.
3) Check the track shoe tension again, and if the ten-

sion is not proper, adjust it again.
4) Adjust the track shoe tension by adding grease

until protrusion amount (B) of grease cylinder (3)
becomes 35 to 190 mm (*).
If the tension is still not enough, the track shoe
may be extremely worn, so it is necessary to re-
verse or replace pins, bushing pins and bushings.
a (*) The amount is 30 to 45 mm when the machine

is delivered from the plant.
155
Assembly procedure
• When reducing tension
k If eject grease other than following procedure, it may be great danger. Never fail to forget the above.
1) Loosen plug (4) gradually to eject the grease.
2) Turn plug (4) a maximum of one turn.
3) If the grease does not come out smoothly, move

the machine backwards and forwards a short dis-
tance.
4) Tighten plug (4).
5) To check that the proper tension has been achieved,

move the machine backwards and forwards.
6) Check the track shoe tension again, and if the ten-

sion is not proper, adjust it again.
(5) Procedures for releasing the remaining pressure in HIC circuit
HIC circuit is closed circuit filled with highly pressurized oil, so if the HIC devices are removed or piping is disconnected,
release the remaining oil pressure in the circuit following the procedures below.
Lower the work equipment completely to the ground, operate the work equipment control lever several times to release the
remaining pressure in piping after stopping the engine, and then release the internal pressure of the hydraulic tank by grad-
ually loosening the oil filler cap of the tank.
1) Loosen drain valve (12) slowly and relieve pressure

remaining in the circuit.
k If the valve is loosened too fast, high pressure

may be generated in the tank circuit, so loosen
drain valve (12) slowly. The remaining pressure
will be completely released after more than one
minute.
2) After completion of releasing the remaining pressure,

tighten drain valve (12).
Z
View Z
Rear of the machine
156
Assembly procedure
Bleeding air from hydraulic ladder cylinder
1. Raise and lower the ladder 5 – 6 times in a range (B) where the ladder automatic pressing system does not work.
2. Hold the ladder in the ladder storage position (A) for 3 minutes. Keep the engine running in this period.
Automatic pressing range

5°
Lower ladder
Raise ladder
Moveable range
152°
Switch box
1. While the ladder is not in the storage Name Q’ty Name Q’ty
position (While the upper proximity switch
is not ON), the control lever is locked
(hydraulically) and the machine cannot be
operated. When operating the machine
(travelling or swinging the machine or
operating the work equipment), store the
ladder.
2. When the cylinder piping needs to be

removed, release the pressure in the
circuit according to the following
procedure, and then remove the piping.
Others
• With the ladder lowered, hold down the

LOWER button for 5 seconds.
157
Assembly procedure
Permanent tightening of swing circle bolt
A-59
In assembly procedure No. A-6 of the 60 mounting bolts of the revolving frame and swing circle were tightened.
Tighten the other 17 bolts.
[Procedure]
(1) Start the engine (Follow the procedure given in assembly procedure A-56).
(2) Swing the upper structure and tighten the bolts when they come to either one of the places marked (43 bolts).
Width across flats: 55

2,452 – 3,040 Nm
{250 – 310 kgm}
Tighten this bolt.

Apply LT-2.
• Make sure to bleed air from each part Name Q’ty Name Q’ty
before swinging the upper structure. 55 mm Socket
Others
158
Assembly procedure
Parts to be touched up after field assembly
A-60 (chassis side)
After assembling the large-sized hydraulic excavator in the field, touch up the following parts.
Underside of counterweight
When the machine is used on the seashore etc. where it is rusted easily, touch up the following parts, too.
Unpainted parts of machined surfaces of flanges after installing piping
Grease tubes
Metallic hose bands, etc.
Use rust-preventive clear paint for touching up the machined surfaces etc.
(Recommended brand: KOMATSU genuine rust-preventive clear paint)

Others
159
Assembly procedure
Connection of engine heater connection port (1/3)
A-61
F-50 F-51
No. Part No. Q'ty

F-50 01024-81230 4
F-51 01024-81020 2
F-52 04434-51912 1
F-53 04434-51212 1
F-54 01024-81230 1
F-55 04434-51912 1
F-52 F-53 F-54 F-55 F-56 F-57 F-58 F-56 04434-51212 1
F-57 195-33-11220 1
F-58 01024-81230 1

KW10P Impact wrench 1
KW12P Impact wrench 1
17 mm Socket 1
19 mm Socket 1
250 mm Extension 1
22 mm Spanner 1
27 mm Spanner 1
Others
160
Assembly procedure
A-61
F-59 F-60
F-63 F-64
Color of hose distingush tape: white
F-65
F-61 F-62
Connection (face seal)

1 point
No. Part No. Q'ty

F-59 21T-06-31570 1
F-60 01024-81230 4
F-61 04434-52312 2
F-62 01024-81230 1
F-63 04434-51912 1
F-64 01024-81230 1
F-66 Connection F-65 02896-61015 1
2 points F-66 07281-00419 2

Others
161
Assembly procedure
A-61
(1) Confirm that the 5 valves (a mark) of connection ports are closed.
Open
Close Close
Close
• Turn the knob clockwise to close the valves.
Connection port
(2) Open 2 valves (A mark) around the engine.
• Turn the knob counterclockwise

Engine left front side Engine right side to open the valves.
Note) After the procedure (1) is finished, Name Q’ty Name Q’ty
perform the procedure (2).
Others
162
Assembly procedure
Installation of optional harness
A-62
Connect CN-A56
Connect CN-A57
F-140
F-141
F-142
No. Part No. Q'ty

F-140 01024-81250 1
F-141 04434-51712 1
F-142 195-33-11220 1
Do not use in a cold district.(below -30°C) Name Q’ty Name Q’ty

Others
163
Assembly procedure
Installation of rear lamps (1/5)
A-63
Installation of rear lamp

Rear lamp (left)
Rear lamp (right)
Rear camera Rear camera Rear camera Rear camera

not equipped equipped not equipped equipped
No. Part No. Q'ty

F-67 21T-06-32810 2
F-68 21T-06-33360 2
F-69 01024-81225 4
F-70 205-03-71331 4
Rear lamp (right) Rear lamp (left) F-71 01024-81265 4

Others
164
Assembly procedure
A-63
Installation of rear lamp wiring (when rear camera is not installed)
No. Part No. Q'ty

F-72 01024-81225 16
F-73 21T-06-32810 1
F-74 04434-51412 16

Others
165
Assembly procedure
A-63
Wind CR cover onto

through hole portion.
No. Part No. Q'ty

F-75 01024-81225 10
F-76 04434-51412 10
F-77 203-04-62110 1
F-78 01024-81255 1
F-79 203-62-52110 1
F-80 08034-20823 3
166
Assembly procedure
A-63
<<Precautions>>
When installing the rear
camera, clamp its wiring and
rear lamp wiring along the
same route. F-81
To be clamped.
To be clamped.
Same positions as those Same positions as those

on previous page on previous page
No. Part No. Q'ty

F-81 21T-06-32810 1
167
Assembly procedure
A-63
Rear lamp wiring

harness clip
Wind CR cover onto

through hole portion
(3)
See installation of rear camera on page A-63 (3/9).
No. Part No. Q'ty

F-82 08034-20823 3
F-83 203-62-52210 1
F-84 198-43-15310 1
F-85 04434-52512 2
F-86 04434-51412 2

Others
168
Assembly procedure
Installation of rear camera (1/9)
A-64
Explanation of delivered parts
Rear camera assembly 3 pcs.
F-89
Installation of rear camera
F-88
F-87
Rear camera assembly
Rear camera R.H.
Rear camera (C)
Rear camera L.H.
No. Part No. Q'ty

F-87 04434-50612 3
F-88 205-03-71331 6
F-89 01024-81265 6

Others
169
Assembly procedure
A-64
Installation of rear camera cable (1)
Tighten together
with bracket.
Fix with 4 claws and

Fix with 4 claws.
tie and secure wires together.
Rear camera (R.H.)
Rear camera (C)

Fix with 4 claws.
No. Part No. Q'ty

Fix with 4 claws. F-90 04434-50612 1
F-91 01024-81225 3
F-92 203-06-61730 3
F-93 01024-81255 1
Rear camera (L.H.) F-94 04434-53212 4
F-95 07095-00317 3
F-96 195-33-11220 2
F-97 04434-51812 1
F-98 01024-81250 2
F-99 04434-51012 1
Assemble temporarily according to this page. Name Q’ty Name Q’ty

Perform the procedures in A-63 (3/9) – A63
(6/9) to assemble and adjust the wiring.
Then, connect the camera cable connector
and fix it finally with the cushions in A63
(5/9).
Others
170
Assembly procedure
A-64
Mark band color: Red

Previous page
Rear lamp
Mark band color: Yellow
Previous page
<<Precautions>>
When installing the rear
camera, clamp its wiring
and rear lamp wiring along
the same route.
Previous page
Rear lamp
Mark band color: Blue
Put wires in conduit and

secure them by winding
band onto them.
No. Part No. Q'ty

F-100 20Y-03-11220 1
F-101 7835-33-8300 1
F-102 7835-33-8200 2
F-103 7835-33-8400 1
F-104 01024-81260 1
F-105 04434-53212 2
F-106 07095-00317 2
F-107 195-33-11220 1
F-108 04434-51812 1
F-109 01024-81250 1
F-110 08034-20823 2
F-111 08017-C2204 1
When installing the rear camera, clamp its Name Q’ty Name Q’ty
wiring and rear lamp wiring along the same
route.
Others
171
Assembly procedure
A-64
Put wires in conduit and secure

them by winding band onto them.
F-118
F-117
F-114
F-116
F-113
F-118
F-117
F-115 Wind CR cover onto

through hole portion.
F-112 F-114
To be clamped.
To be clamped.
Fix with connector

To be clamped.
Mark band color: Blue
Adjust wiring length Mark band color: Yellow
here as shown. F-114 Mark band color: Red
No. Part No. Q'ty

F-112 04434-53212 1
F-113 08017-C2220 1
F-114 08034-20823 16
F-115 203-62-52210 1
F-116 198-43-15310 1
F-117 04434-52512 2
F-118 04434-51412 2
Assemble temporarily according to A-63 (3/9) – Name Q’ty Name Q’ty

A63 (6/9). After assembling and adjusting the
wiring, fix it finally.
Others
172
Assembly procedure
A-64
F-120
F-121
F-119
No. Part No. Q'ty

F-119 01024-81225 10
F-120 203-06-61730 5
F-121 04434-52512 5

Others
173
Assembly procedure
A-64

F-125
F-124
F-126
F-123
F-122
F-124
F-127

No. Part No. Q'ty

F-122 01024-81225 16
F-123 203-06-61730 8
F-124 04434-51812 10
F-125 08034-20823 6
F-126 08017-C2204 2
F-127 08017-C1533 1

Others
174
Assembly procedure
A-64
Fix with 4 claws.
Tighten together with main wiring harness.
F-128
From operator cab
(Red)
(Yellow)
(Blue)
Mark band color
From machine
F-128
No. Part No. Q'ty

F-128 08034-20519 6

Others
175
Assembly procedure
A-64
Setting rear camera monitor
The rear camera is set when shipped from the plant.

Basically, the work in this page does not need to be performed.
(1) Select "06 Initialize" and ( ) (2) Select "04 Set camera" and ( )
(3) Set the rear camera for reversed image.
Rear camera (L.H.)
Rear camera (C)
Rear camera (R.H.)

Others
176
Assembly procedure
A-64
Adjustment of rear camera
Adjust the rear camera angle so that the images from the rear camera will be as follows.
(Recommendation) Adjust so that a little part of counterweight end will be in the image, and you see easily if there is distance
between a rock etc. and the machine.
Rear camera (R.H.) Rear camera (L.H.)
Rear camera (C)
Loosen camera fixing bolts

and adjust camera angle.
Rear camera assembly 3 pcs.
177
Assembly procedure
Connection of emergency stop switch (if equipped)
A-65 (at the right below container)
Machine left
Machine front
Connection
No. Part No. Q'ty

F-129 01024-81220 2
F-130 04434-51012 2
F-131 21T-06-31141 1
F-132 21T-06-31170 1

Others
178
Assembly procedure
Connection of emergency stop switch (if equipped)
A-66 (at the left side of ladder)
Machine front
Machine left
F-134
mark
F-143
F-144
F-133
F-144
Pass the cord
through the clip. Tighten together with harness
No. Part No. Q'ty

F-133 21T-06-31131 1
F-134 21T-06-31170 1
F-143 01024-81220 2
F-144 04434-51912 3

Others
179
Assembly procedure
Installation of engine oil and PTO oil pipings
A-67
a This page is for service center installed machine.
mark position
Tighten engine oil hose

together with PTO oil hose.
Tightening torque:
3.91 – 4.89 Nm {0.4 – 0.5 kgm}
Tightening torque:
3.91 – 4.89 Nm {0.4 – 0.5 kgm}
(1) Clamp the engine oil hose fixed at the power container to revolving frame and install the tip of the hose to service center port.
(2) Install the tip of PTO oil hose fixed at the revolving frame to PTO valve.
No. Part No. Q'ty

F-135 281-01-13180 3
F-136 01024-81225 3
F-137 07281-00419 1
F-138 07281-00259 1

19 mm socket 1
Screwdriver 1
Others
180
Assembly procedure
Installation of coolant piping
A-68
a This page is for service center installed machine.
Tightening torque:
3.91 – 4.89 Nm {0.40 – 0.50 kgm}
Install the coolant hose fixed at the revolving frame to radiator lower piping valve.

Screwdriver 1
Others
181
Assembly procedure
Installation of guard bracket (if equipped)
A-69
a This item is for service center specification only
Left of machine
Front of machine
F-146
F-147
F-145 Seen from below
No. Part No. Q'ty

F-145 21T-46-31161 1
F-146 01010-82050 4
F-147 01643-32060 4

Screwdriver 1
Others
182
C. ASSEMBLY OF BACKHOE
183
Assembly procedure
Installation of boom cylinder (1/2)
C-1
Method of slinging boom cylinder for installation
Pay attention to the mounting direction

of the boom cylinder!
-----------------------------------------
The tube on the cylinder bottom side
------------------------------
must be on the upper side.
Boom cylinder weight

2,400 kg /each
Since you can install the boom cylinder in Name Q’ty Name Q’ty
reverse without realizing, check its direction Hammer 1
before installing it.
36 mm Socket 1
ø12, 5 m Wire 2
ø16, 5 m Wire 1
SC14 Shackle 1
8 t Crane 1
Others
184
Assembly procedure
Installation of boom cylinder (2/2)
C-1
Boom cylinder
[Procedure]
(1) Remove the parts marked with A which are installed
Left Right to the revolving frame temporarily.
(2) Clean the pins and inside of the bushings.
(3) Sling the cylinder and position it to the pin hole.
(4) Install the O-ring to the cylinder bushing.
(5) Set the shims and spacer and install the parts
marked with A.
H = 2000 Reduce the clearance marked with to 1 mm or
less.
(6) Perform this procedure for the right and left boom
cylinder feet.
O-ring Clearance between pin and
revolving frame bushing:
0.098 – 0.310 mm
Clearance between pin and
Outside Side of center boom cylinder bushing hole:
of machine of machine 0.043 – 0.131 mm
Pin, weight: 93.8 kg

(2 places) Shim (H-3, H-4 ,H-5)
a
Plate, bolt, washer a=185mm
䠾= 365mm
Bushing Bushing
(has been press fitted) (has been press fitted) b
(outside) (inside)
(2 places) (2 places)
No. Part No. Q'ty

STD Spec. 707-01-XP701 1
H-1
-50°C Spec. 707-H1-X0620 1
STD Spec. 707-01-XP711 1
H-2
-50°C Spec. 707-H1-X0630 1
H-3 21T-70-31421 2
Install only the shims 16 mm thick on inside of the H-4 21T-70-31470 8
machine and adjust the clearance by changing the H-5 21T-70-31690 8
quantity of the shims on outside of the machine. H-6 07000-15180 4
1. The bushings are press fitted to the Name Q’ty Name Q’ty
revolving frame and the parts marked with
A are tightened temporarily when the
machine is shipped.
2. Before inserting the pins, apply grease to
the pin holes (inside of the bushings).
a When installing the plates, hold them with
wires etc. so that you will not catch your
fingers in them..
Others
185
Assembly procedure
Installation of boom cylinder hoses
C-2 (Serial No. 20095 and up)
Remove the oil stopper from the boom cylinder piping and revolving frame piping, and then install the 4 hoses as shown in the
following figure.
a When removing the oil stopper, take care that oil may spout out.
Use the split flanges, bolts, etc. used to install the oil stopper (on the machine hose side) as they are.
Parts to install blind plugs (on cylinder side)
#20 Hose
07371-52080 (Flange) × 8 pcs.: Reuse
01010-81865 (Bolt) × 16 pcs.: Reuse
01643-81845 (Washer) × 16 pcs.: Reuse
07000-B2060 (O-ring) × 4 pcs.: Keep
07378-12010 (Head) × 4 pcs.: Keep
#14 Hose
07371-51470 (Flange) × 8 pcs.: Reuse
01010-81455 (Bolt) × 16 pcs.: Reuse
01643-81445 (Washer) × 16 pcs.: Reuse
07000-B3048 (O-ring) × 4 pcs.: Keep
07378-11410 (Head) × 4 pcs.: Keep
Tightening torque :
343 – 425 Nm {35 – 43.5 kgm}
O-ring O-ring
Hose inside Hose outside
No. Part No. Q'ty

H-44 07000-B3048 4
H-45 07371-51470 8 No. Part No. Q'ty
H-46 01010-81455 16 H-7 07000-B2060 4
H-47 01643-31445 16 H-8 07000-B3048 4
H-48 21T-64-32980 4 H-9 21T-64-32970 2
H-49 21T-64-32990 16 H-10 07083-01417 2
1. Take care not to twist the hoses when Name Q’ty Name Q’ty
installing. 22 mm Socket 1
2. Take care not to catch the O-rings in the
parts (Apply grease to them before 27 mm Socket 1
installing).
150 mm Extension 1
3. After connecting the hoses, bleed air from
the boom cylinder.
4. Tighten the hoses from the revolving
frame side (to prevent them from
twisting).
Others
186
Assembly procedure
Assembly of boom sub assembly (1/5)
C-3
1. Installation of work equipment piping (tubes)
Remove the blind plugs

marked with and connect
the tubes (7 places).
Tube O-ring Washer Bolt

Washer Bolt
O-ring
Arm cylinder tube assembly
O-ring
No. Part No. Q'ty

H-11 21T-64-39140 1
H-12 21T-64-39150 1
H-13 21T-64-39160 1
H-14 07000-B3048 2
H-15 07000-B2060 7
H-16 01643-31845 16
H-17 01010-81840 4
H-18 01010-81865 12
1. Take care not to catch the O-rings in the Name Q’ty Name Q’ty
parts (Apply grease to them before 19 mm Socket 1 Lift work stand 1
installing).
22 mm Socket 1
2. Securely take measures to prevent the
arm cylinder from projecting. 27 mm Socket 1
3. Use some split flanges, bolts, etc. used to 650 mm Extension 1

install the oil stopper (on the machine
hose side) as they are. 150 mm Extension 1
Others
187
Assembly procedure
C-3
2. Installation of arm cylinder
Fix the arm cylinder rod securely so that it will not come out during work.
Arm cylinder
Left Right
[Procedure]
(1) Remove the pin from the boom.
(2) Clean the pin and inside of the bushing.
(4) Sling the bushing and set it to the pin hole.
(5) Set the shim and install the pin.
(6) Perform the above procedure for the right and left arm
cylinders.
Plates, bolts and washers
O-ring
Set shims on both inside and outside.
No. Part No. Q'ty

STD 707-01-XP723 1
H-19
-50°C Spec. 707-H1-X0641 1
STD 707-01-XP733 1
H-20
-50°C Spec. 707-H1-X0651 1
H-21 07000-12140 4
H-22 21T-70-31441 4
Pin
188
Assembly procedure
C-3
3. Installation of work equipment piping (hoses)
Hose Flange on Washer on Bolt on

#14 O-ring cylinder side cylinder side cylinder side
Hose Flange on Washer on Bolt on
H-24 H-27 H-28 H-30 H-32 #20 O-ring cylinder side cylinder side cylinder side
H-23 H-26 H-29 H-31 H-33
Remove the blind plugs from the boom pip-

ing (tubes) and arm cylinder piping, and
then install the 4 hoses as shown in the fol-
lowing figure.
Connecting parts: 8 places marked with ª
Use the split flanges, bolts, etc. used to in-

stall the blind plugs on the tube side as they
are.
Parts to install blind plugs (on tube side)

#20 Hose
07371-52080 (Flange) × 4 pcs.: Reuse
01010-81865 (Bolt) × 8 pcs.: Reuse
01643-31845 (Washer) × 8 pcs.: Reuse
H-25 H-27 H-28 H-30 H-32 07000-B2060 (O-ring) × 2 pcs.: Keep
Hose 07378-12010 (Head) × 2 pcs.: Keep
#14 O-ring Flange on Washer on Bolt on
cylinder side cylinder side cylinder side
#14 Hose
07371-51470 (Flange) × 4 pcs.: Reuse
01010-81455 (Bolt) × 8 pcs.: Reuse
01643-31445 (Washer) × 8 pcs.: Reuse
07000-B3048 (O-ring) × 2 pcs.: Keep
07378-11410 (Head) × 2 pcs.: Keep
No. Part No. Q'ty

H-28 07371-51470 4 No. Part No. Q'ty
H-29 07371-52080 4 H-23 07084-02022 2
H-30 01643-31445 8 H-24 07085-01418 1
H-31 01643-31845 8 H-25 07085-01420 1
H-32 01010-81455 8 H-26 07000-B2060 4
H-33 01010-81865 8 H-27 07000-B3048 4
parts (Apply grease to them before
installing).
2. Securely take measures to prevent the
arm cylinder from projecting.
3. Adjust the hoses so that they will not be
twisted.
Others
189
Assembly procedure
C-3
4. Installation of working lamps
See page (5/5)
Working lamp
Install work equipment lamps as
shown at left and connect their wires.
4 places on right and left of boom.
Bracket Washer Bolt
Bolt Clip
No. Part No. Q'ty

H-34 21T-06-32810 4
H-35 20Y-06-21551 4
H-36 01643-31445 4
H-37 01010-81430 4
H-38 01024-81225 4
H-39 209-72-11311 4
H-43 08193-21012 4
a When installing the seal (209-72-11311), Name Q’ty Name Q’ty

take care of the direction of its lip so that
the grease can come out from inside.
Others
190
Assembly procedure
C-3
Install the seal as seen in figure below.

4 places on right and left of boom.
Seal
191
Assembly procedure
Installation of boom assembly (1/2)
C-4
1. Slinging method
45 t Crane
30 × 5 m wire × 4 pcs.
+
Apply wooden blocks
SB55 shackle × 4 pcs.
(about 100 mm square)
to protect grease piping
and wiring harness.
Hook hole diameter: 80
a Sling horizontally.
Boom assembly
Weight: 20,900 kg
1. Appoint a worker to act as a signalman for Name Q’ty Name Q’ty

the crane operator. Hammer 1 Lift work stand 1
2. Do not go under a raised load.
3. Check that the wires are fitted properly to 36 mm Socket 1
the hook.
4. When working, securely fix the arm ø30, 5 m Wire 4
cylinder rod to prevent it from projecting. SB55 Shackle 4
a Take care that wooden blocks will not be 45t Crane 1
driven out.
Others
192
Assembly procedure
Installation of boom assembly (2/2)
C-4
2. Installation of boom foot pin
Bushing (has been press fitted) (outside)

(2 places) Boom assembly
Bushing (has been press fitted) (inside)

(2 places)
Pin, Weight: 87.9 kg

(2 places)
Plate, bolt, washer

(2 places)
Bushing (has been press fitted) (boom foot)

Revolving frame
H-41 H-40 Insert shims on only outside of machine.
Shim Shim
[Procedure]
(1) Remove the parts marked with * which are installed to the revolving frame temporarily.
(3) Set the boom as shown above so that the clearances at the parts marked with on the right and left sides will
be even and then decide the thickness and quantity of the shims to reduce the clearance to 1 mm or less.
(4) Assemble the shims and pins.
Clearance between pin and revolving frame bushing: 0.128 – 0.278 mm
Clearance between pin and boom foot bushing hole: 0.386 – 0.562 mm
(5) Perform this procedure for the right and left boom feet.
No. Part No. Q'ty

H-40 21T-70-31480 8
H-41 21T-70-31490 16
1. There are bushings press fitted to the Name Q’ty Name Q’ty
revolving frame and boom, and the parts
marked with ª are installed temporarily for
transportation.
2. Insert the pin from the lower side of the
ground.
3. Take care not to catch the seals in the
parts.
4. Before inserting the pin, apply grease to
the inside of the bushing.
Others
193
Assembly procedure
Installation of boom cylinder head side (1/2)
C-5
45 t Crane
16 × 5 m Wire
Boom cylinder
Boom cylinder top pin
Boom top
G.L. (Ground level)
[Procedure]
(1) After inserting the boom foot pin, lower the boom with the crane until its top touches the ground.
(2) Remove the ropes from the boom assembly.
(3) Sling the cylinder with the wire as shown above.
(4) Start the engine. (Low idle)
1. When slinging the boom cylinder, do not Name Q’ty Name Q’ty
install the wire directly to its rod or body. Hammer 1
(Protection of rod)
2. Bleed air from the cylinder. (See C-14.) 36 mm Socket 1
150 mm Extension 1
ø2, 5 m Wire 1
ø16, 5 m Wire 2
45t Crane 1
Others
194
Assembly procedure
Installation of boom cylinder head side (2/2)
C-5
Bushing, press fitted already (outside)

21T-70-31240 (2 places)
Bushing, press fitted already (inside)

21T-70-31250 (2 places)
Plates, bolts Pin, Weight: 98.4 kg

and washers 21T-70-31181 (2 places)
21T-70-71490 (2)
01643-32460 (4)
01010-82455 (4)
O-ring
[Procedure]
(5) Remove parts marked with ª from the boom.
(6) Clean the pin and inside of the bushing.
(7) Sling the cylinder with wires. While extending and retracting it hydraulically, adjust the pin holes.
(8) Install the seal, O-ring and pin and then install the cover.
(Since the pin is heavy, sling it with a crane, taking care of safety.)
Fit of pin and boom bushing
---- Clearance: 0.106 – 0.298 mm
Fit of pin and boom cylinder
---- Clearance: 0.043 – 0.131 mm
(9) Perform the above procedure for the right and left of the boom cylinder top.
No. Part No. Q'ty

H-42 07000-15180 4
1. The bushings are press fitted to the boom Name Q’ty Name Q’ty
assembly and the parts marked with ª are
tightened temporarily when the machine
is shipped.
2. When inserting each pin, check that the
O-ring of the cylinder is not caught.
3. Check that pins and inside of the
bushings are clean.
4. Extend and retract the boom cylinder
carefully with the engine at low idle. Do
not operate a lever other than the boom
control lever.
5. Before inserting each pin, apply grease to
Others
the pin hole (inside of the bushing).
195
Assembly procedure
Installation of hoses between boom and chassis
C-6
I-1
Blind plugs
Tube side Hose side O-ring
ª 07071-52080 (12) 07371-52080 (12)

ª 01643-31845 (24) 01643-31845 (24)
ª 01010-81835 (24) 01010-81865 (24)
07000-B2060 (6) 07000-B2060 (6)
07378-12010 (6) 21T-64-39620 (6)
[Procedure]
Arm B
Arm H
Bucket B
Bucket B
Bucket H
Arm B
(1) Remove the blind plugs from the hoses and tubes.
The parts marked with ª will be reused to connect the hoses and tubes.
(2) Connect the hoses and tubes (6 places).
No. Part No. Q'ty

I-1 07000-B2060 6
parts. 22 mm Socket 1
(Apply grease to them before installing.)
2. When the oil stopper is removed, oil 27 mm Socket 1
spouts out. Take care.
3. Adjust the hoses so that they will not be 150 mm Extension 1
twisted.
4. Connect the bucket cylinder pipings
(marked with a) in Connection of bucket
cylinder (C-9).
Others
196
Assembly procedure
Installation of arm assembly (1/3)
C-7
1. Preparation
45 t Crane 45 t Crane
30 × 5 m wire × 2 pcs.
+
SB55 shackle × 2 pcs.
[Procedure]
(1) Remove the parts marked with ª which are installed to
the boom top temporarily.
(3) Press fit the seals to arm top, link and boom connect-
ing bushing.
Fix the link section securely so that

bucket cylinder will not be
extended when assembly is slung.
Arm assembly
Weight: 12,900 kg
• Before inserting the pin, apply grease to Name Q’ty Name Q’ty
the inside of the bushing. Hammer 1
• Fix the link securely so that the bucket
cylinder will not extend. 36 mm Socket 1
150 mm Extension 1
ø30, 5 m Wire 2
SB55 Shackle 2
45 t Crane 1
Others
197
Assembly procedure
C-7
No. Part No. Q'ty

I-2 21T-70-31290 2
I-3 21N-70-12160 4
I-4 209-72-11261 4
Install the seals so that they will not slant. Name Q’ty Name Q’ty
Others
198
Assembly procedure
C-7
2. Installation of arm assembly
45 t Crane
[Procedure]
(1) Raise and lower the boom several times. After the boom cylinder be-
comes easy to control finely, lower the boom slowly to align the holes.
(2) Install the nylon sling to the pin and lift it up.
(3) Set the arm as shown in the above figure and install it as shown in the
figure below.
Clearance between pin and boom bushing: 0.710 – 0.854 mm
Clearance between pin and arm bushing: 0.520 – 0.703 mm
(4) Adjust the clearance between the boom and arm to 1 mm or less with
shims.
Cover, bolt, washer
Pin
Bushing No. Part No. Q'ty

(has been press fitted) t12 I-5 21T-70-31391 2
21T-70-32151 (2 places) t9 I-6 21T-70-31780 1
Shim Shim Shim Shim
t1 I-7 21T-70-31810 1
t = 1.5 t=1 t = 9 t = 12 O-ring t1.5 I-8 21T-70-31820 1
I-9 07000-15260 2
1. Take care not to catch the O-rings and Name Q’ty Name Q’ty
seals in the parts. Hammer 1
(Before fitting the O-rings, apply grease to
them.) 36 mm Socket 1
2. There are bushings press fitted to the arm
assembly and boom assembly, and the 150 mm Extension 1
parts marked with ª are installed ø30, 5 m Wire 2
temporarily for transportation.
3. Insert the shims in the right and left sides SB55 Shackle 2
evenly.
45t Crane 1
Nylon sling 1
Others
199
Assembly procedure
Installation of arm cylinder
C-8
[Procedure]
(1) Remove the parts marked with ª which
are installed to the arm cylinder top tem-
Arm cylinder porarily.
12 × 5 m Wire (2) Clean the pins and inside of the bush-
ings.
(4) Install the wire to the left arm cylinder
assembly as shown in the figure at left.
Boom (5) Remove the rod fixing wire of only the
Arm cylinder top left cylinder.
(6) Give the operator directions to operate
the arm.
(7) Raise or lower the crane and extend or
retract the arm cylinder to align the
holes.
If the stroke is short, raise the boom a lit-
tle.
Arm (8) Set the seal, insert the pin, and install
the O-ring and cover.
(9) Perform this procedure similarly for the
right arm cylinder top.
Section of arm cylinder top

Shim Pin
O-ring Lockplate, washer, bolt
(2 places)
I-11 I-10
arm bushing: 0.503 – 0.629 mm
arm cylinder: 0.243 – 0.369 mm
Bushing (has been press fitted)
(4 places)
No. Part No. Q'ty

I-10 21T-70-32181 4
I-11 07000-B2140 4

1. After connecting the hose, bleed air from the arm
cylinder. Hammer 1
2. Limit the engine speed to low idle and do not
move the cylinder to the stroke end. 36 mm Socket 1
3. Take care of the seals and O-rings. (Apply
grease before fitting) 150 mm Extension 1
4. Align the holes carefully and do not put your
hand/finger in the holes. ø12, 5 m Wire 1
5. There are bushings press fitted to the arm
assembly, and the parts marked with ª are 45 t Crane 1
installed temporarily for transportation.
6. When slinging the arm cylinder, do not install the
wire directly to its rod or body.
7. When extending and retracting the arm cylinder,
limit the engine speed to low idle and operate the
lever carefully. Do not operate the bucket.
8. Before inserting the pin, apply grease to the
Others
inside of the bushing.

9. Insert the shims in the inside and outside evenly.
200
Assembly procedure
Connection of hoses between boom and arm
C-9
\
Remove the blind plugs from the boom pip-
ing (tubes) and bucket cylinder piping, and
then install the 4 hoses as shown in the fol-
lowing figure.
Connecting parts: 8 places marked with ª
Use the split flanges, bolts, etc. used to in-

stall the blind plugs on the tube side as they
are.
Parts to install blind plugs (on tube side)

#20 Hose
07371-52080 (Flange) × 4 pcs.: Reuse
01010-81865 (Bolt) × 8 pcs.: Reuse
01643-31845 (Washer) × 8 pcs.: Reuse
07000-B2060 (O-ring) × 2 pcs.: Keep
07378-12010 (Head) × 2 pcs.: Keep
#14 Hose
07371-51470 (Flange) × 4 pcs.: Reuse
01010-81455 (Bolt) × 8 pcs.: Reuse
01643-31445 (Washer) × 8 pcs.: Reuse
07000-B3048 (O-ring) × 2 pcs.: Keep
07378-11410 (Head) × 2 pcs.: Keep
Hose O-ring Flange on Washer on Bolt on Hose O-ring Flange on Washer on Bolt on
#20 cylinder side cylinder side cylinder side #14 cylinder side cylinder side cylinder side
No. Part No. Q'ty No. Part No. Q'ty

I-17 07000-B2060 4 I-12 07371-51470 4
I-18 01643-31445 8 I-13 07371-52080 4
I-19 01643-31845 8 I-14 07084-41427 2
I-20 01010-81455 8 I-15 07084-42026 2
I-21 01010-81865 8 I-16 07000-B3048 4
parts (Apply grease to them before 22 mm Socket 1
installing).
2. After connecting the hoses, bleed air from 27 mm Socket 1
the bucket cylinder securely.
3. When the oil stopper is removed, oil 150 mm Extension 1
spouts out. Take care.
Others
201
Assembly procedure
Connection of auto grease piping
C-10
Connection between chassis and boom

(Connecting parts of revolving frame and boom seen from rear upper direction of machine)
Remove the oil stopping parts

marked with ª and connect the
hoses and T-pieces.
Oil stopping parts

Hose side
07376-50422 (Plug)
T-piece side
07222-00414 (Plug)
07221-20422 (Nut)
Connection between boom and arm (Connecting parts of boom and arm seen from right of machine)
Remove the oil stopping parts

marked with A and connect the
hoses and T-pieces (2 places).
Oil stopping parts

Boom side
07222-00414 (Plug)
07221-20422 (Nut)
Arm side
07222-00414 (Plug)
07221-20422 (Nut)
No. Part No. Q'ty

I-22 21T-68-31830 1
I-23 203-973-5660 3
I-24 203-973-5720 3
I-25 01024-81055 6
I-26 21T-70-75290 1
I-27 01024-81225 2
I-28 07631-20409 1
• Grease pipings can be installed before Name Q’ty Name Q’ty

the connection of the arm. 27 mm Spanner 1
32 mm Spanner 1
Others
202
Assembly procedure
Connection of wiring between boom and chassis
C-11
Wiring harness clamp

(Side of cab base)
Connection
(1) Remove the connector plug.
(2) Clamp the wiring harness on the side of the cab base. (2 places)
(3) Pass the wiring harness through the hole on the side of the cab base and connect it
to connector CN-A13 in the cab base.
No. Part No. Q'ty

I-29 04434-51712 2
I-30 01024-81220 2

Others
203
Assembly procedure
Installation of bucket assembly (1/3)
C-12
45 t Crane
20 × 5 m Wire × 2 pcs.
[Procedure]
(1) Install the wire to the bucket assembly as
shown in the figure and place it on a level
ground.
(2) Clean the pin and the inside of the bushing.
(3) Coupling with arm
Wooden block
1) Align the holes by operating the boom
and arm.
2) Install the pins.
3) Adjust the shims.
4) Install the covers.
5) Supply grease.
1. Bushings are press fitted to the arm Name Q’ty Name Q’ty
assembly and bucket assembly. Hammer 1 ø20, 5 m Wire 2
2. Put a block under the bucket to prevent
the latter from falling back down. 19 mm Socket 1
55 mm Socket 1
10 mm Spanner 2
10 mm Hexagonal wrench 1
45 t Crane 1
Others
204
Assembly procedure
C-12
Detail of arm and bucket connecting pins
Seal
Pin (bucket side)
O-ring: See following figure.
Bushing, press Bushing, press Bushing, press

fitted already fitted already fitted already
Fit of pin and arm bushing --- Clearance: 0.382 – 0.527 mm

Fit of pin and bucket bushing (outside) --- Clearance: 0.255 – 0.390 mm
• Stamps on pin covers Fit of pin and bucket bushing (inside) --- Clearance: 0.298 – 0.419 mm
LH: For lefthand
RH: For righthand Nut Washer Bolt
M6 × 1 piece, width across flats 10 mm
O-ring
O-ring section No. Part No. Q'ty

J-1 209-72-11261 4
J-2 209-70-71370 4
J-3 205-09-61240 4
J-4 01640-20610 8
J-5 01596-00606 4
J-6 21T-62-34220 2
J-7 07000-12011 2
J-8 21T-70-34332 1
J-9 07000-15195 2
J-10 01010-83695 12
: L.H. : R.H. J-11 01643-33690 12
J-12 21T-70-33171 2
J-13 21T-70-34341 2
J-14 07000-15175 2
J-15 01010-83685 12
J-16 01643-33690 12
J-17 21T-70-34372 1
1. Take care of the seals and O-rings. Name Q’ty Name Q’ty
2. Before inserting each pin, apply grease to
the pin hole (inside of the bushing).
3. Tightening torque of elbow (J-6):
19.6 – 39.2 Nm {2.0 – 4.0 kgm}
Others
205
Assembly procedure
C-12
[Procedure]
(1) Remove the right and left covers.
(2) Connect the hoses.
3 Tightening torque of hose: 19.6 – 39.2 Nm {2.0 – 4.0 kgm}
(3) Install the right and left covers.
Be careful not to catch the hose.
Hose
Cover
a Be careful not to catch the hose.
Cover
206
Assembly procedure
Installation of bucket link (1/2)
C-13
Connection of bucket link
[Procedure]
(1) Clean the connection parts.
(2) Align the holes by operating the bucket.
a If the arm angle is as shown in the left figure below, you must press the link strongly in the direction of the arrow and
cannot assemble easily. Take care.
(3) Install the pins.
(4) Install the covers.
(5) Supply grease.
Press
Bucket link
connecting pin

1. Since air has not been bled from the Name Q’ty Name Q’ty
bucket cylinder, limit the engine speed to
low idle and do not move the cylinder to the Hammer (large) 1
stroke end.
2. Set the arm angle carefully so that you can 24 mm Socket 1
work easily.
3. A bushing is press fitted to the link 150 mm Extension 1
assembly. ø12, 5 m Wire 1
4. When moving the bucket cylinder, set the
engine speed slow and operate the lever 45t Crane 1
carefully.
5. If the bucket cylinder is moved to near
either stroke end while the bucket is not
installed, the grease hose will be broken.
a Take care when bleeding air from the
Others
bucket cylinder.
207
Assembly procedure
Installation of bucket link (2/2)
C-13
Bucket link connecting pin
Shim
t1.0
Adjust clearance to 1 mm or less.
Bushing
(has been press fitted)
Pin
Clearance between pin and link bushing: 0.363 – 0.507 mm

Clearance between pin and bucket: 0.043 – 0.306 mm
No. Part No. Q'ty

J-18 21T-70-33250 2
J-19 21T-72-73170 2
J-20 01010-81645 6
J-21 01643-31645 6
J-22 21N-72-11230 2
1. Take care of the seals. Name Q’ty Name Q’ty

2. Before inserting the pin, apply grease to
the inside of the bushing.
Others
208
Assembly procedure
Bleeding air from cylinders (1/3)
C-14
Bleeding air from boom cylinder
When assembling the boom, you must align the boom cylinder top pin holes by extending or retracting the boom cylinder.
Accordingly, perform the following air bleeding operation after assembling the boom cylinder.
(1) Before installing the boom, set the boom cylinder in the horizontal position and perform following steps (2) and (3).
(2) While running the engine at low idle, extend and retract the boom cylinder 5 – 6 times, stopping it at about 100 – 200
mm before each stroke end.
a At the first operation, the cylinder does not move for more than 10 seconds since much air is in the circuit.
Do not move the control lever to the stroke end, however.
a Do not set the engine speed high or move the cylinder to a stroke end from the first.
(Air in the cylinder may damage the piston packing etc.)
a After starting the engine, warm it up sufficiently to fit all the parts.
(3) Extend the boom cylinder to the stroke end and keep the boom control lever at the stroke end for 3 minutes.
(4) After installing the boom, perform above steps (2) and (3).
(5) Keep the engine speed similarly to (3) for 1 minute.
(6) Bleed air from boom, arm and bucket cylinders immediately after installing each of them.

Others
209
Assembly procedure
C-14
Bleeding air from arm cylinder (Carry out this operation before installing the bucket)
After assembling the arm and arm cylinder, bleed air from the arm cylinder according to the following procedure.
(1) While running the engine at low idle, extend and retract the arm cylinder 5 - 6 times, stopping it at about 100 - 200 mm
before each stroke end.
(2) Run the engine at full throttle and perform step (1).
a Do not move the cylinder to the stroke end.

Others
210
Assembly procedure
C-14
Bleeding air from bucket cylinder
After assembling the bucket, bleed air from the bucket cylinder according to the following procedure.
(1) While running the engine at low idle, extend and retract the bucket cylinder 5 - 6 times, stopping it at about 100 - 200
mm before each stroke end.
(2) Run the engine at full throttle and perform step (1).
a Do not move the cylinder to the stroke end.
(3) After bleeding air, add hydraulic oil to the specified level.
Bleed air with the bucket installed. Name Q’ty Name Q’ty
If the bucket cylinder is moved to near either
stroke end while the bucket is not installed,
the auto-grease hose will be broken.
Others
211
Assembly procedure
Parts to be touched up after field assembly
C-15 (work equipment side)
After assembling the large-sized hydraulic excavator in the field, touch up the following parts.
(1) Front and rear underside of boom
(2) Underside of arm
(3) Underside of bucket
When the machine is used on the seashore etc. where it is rusted easily, touch up the following parts, too.
Unpainted parts of machined surfaces of flanges after installing piping
Grease tubes
Metallic hose bands, etc.
Use rust-preventive clear paint for touching up the machined surfaces etc.
(Recommended brand: KOMATSU genuine rust-preventive clear paint)

Others
212
Assembly procedure
Bleeding air from auto grease circuit (1/3)
C-16
• After assembling the whole machine, bleed air from the grease circuit according to the following procedure.
(1) Remove the 3 plugs (581-96-19590, marked with a) from the injector assembly manifold one by one from the one nearest
to the pump. Then, operate the auto grease unit continuously in the manual mode and check that pressurized grease
comes out. After checking, install the plugs again.
Order of check: Revolving frame front face ➞ Boom top face ➞ Arm top face
(2) Supply grease with the grease gun through the service nipple of the injector and check that grease comes out of each
greasing point.
Discharge adjustment screw Locknut

Indicator pin 3 Tightening torque :
Service nipple 19.6 -- 24.5 Nm {2.0 -- 2.5 kgm}
Plug (581-96-19590)
19.6 -- 29.4 Nm {2.0 -- 3.0 kgm}
Manifold
Injector assembly
A Do not use molybdenum disulfide grease Name Q’ty Name Q’ty

to the bearings of the swing circle etc.
Bushing:Molybdenum disulfide grease
may be used.
Bearing: Use lithium grease.
Others
213
Assembly procedure
C-16
Boom cylinder bottom, right Circle Boom cylinder bottom, left
Plug (581-96-19590)
19.6 -- 29.4 Nm {2.0 -- 3.0 kgm}
Revolving frame front face
Boom foot, right

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

Plug (581-96-19590) Boom top, right
3 Tightening torque : Boom cylinder head, right
19.6 -- 29.4 Nm {2.0 -- 3.0 kgm} Boom foot, right
Boom top face
214
Assembly procedure
C-16
Arm B boss, right

Arm A boss, right
Bucket, right
Bucket cylinder head, right
Bucket cylinder bottom, right
Arm cylinder head, right Bucket cylinder head, left
Arm cylinder head, left Bucket, left
Bucket cylinder bottom, left Arm A boss, left
Arm C boss Arm B boss, left
When adjusting injector,

remove piping cover.
After adjusting, install again.
Front link + Bucket, left

Front link + Wrist link, left
Front link + Wrist link, left
Front link + Bucket, right Plug (581-96-19590)

Front link + Wrist link, right Arm top face 3 Tightening torque :
Front link + Wrist link, right 19.6 -- 29.4 Nm {2.0 -- 3.0 kgm}
215
LS. ASSEMBLY OF LOADING SHOVEL
WORK EQUIPMENT
217
Assembly procedure
Installation of arm cylinder bottom parts
LS-1
(1) Remove the lock piece fixed to the boom and remove the arm cylinder bottom pins.
(2) Lay the 2 arm cylinders in parallel on wood blocks.
(3) Sling the boom with a crane and push in the pins, matching the pinhole of the boom to the holes of the arm cylinder bottoms.
(4) Install both arm cylinders similarly.
(5) Install the lock piece.
(6) Using a nylon sling, secure the arm cylinders with the lever block.
Boom assembly: 11,000 kg
Nylon slling
(R.H.) (L.H.)
Pin: 28 kg × 2
Arm cylinder:
1,072 kg × 2
Arm cylinder
Cold district
STD specification
Left: DM945 438 40 DM945 468 40
Right: DM945 449 40 DM945 469 40
No. Part No. Q'ty

L-1 DM945-438-40 1
L-2 DM945-449-40 1
1. Apply grease (GL-LI) to the inside of the Name Q’ty Name Q’ty
bushings.
2. Install the arm cylinder bottom parts with
the piping ports down.
Others
218
Assembly procedure
Installation of boom cylinder to machine body (1/2)
LS-2
Slinging method of boom cylinder for installation
Rod stopper wire
Boom cylinder
Cold district
STD specification
Left: DM945 418 40 DM945 462 40
Right: DM945 419 40 DM945 463 40

Others
219
Assembly procedure
Installation of boom cylinder to machine body (2/2)
LS-2
[Procedure]
(1) Remove the parts marked A and
installed to the revolving frame.
Boom cylinder (2) Clean the pin and inside of the
Left Right bushing.
(3) Sling the cylinder and position it to the
pin hole.
(4) Set the shim and spacer and install
the parts marked .
Adjust the marked clearance to 1 mm
or less.
(5) Work on the right and left boom
cylinder bottoms.
H = 2,000
Body center side

Pin weight: 93.8 kg
21T-72-31190 (2 places)
Plate, bolt, washer

21T-70-71490 (2)
01643-32460 (4)
01010-82455 (4)
Bushing which has

been installed (Inside)
Bushing which has
been installed (Outside) 21T-70-31230 (2 places)
21T-70-31220 (2 places)
Shim No. Part No. Q'ty

t=16
L-3 DM945-418-40 1
Shim Shim L-4 DM945-419-40 1
t=1.0 t=1.5
L-5 21T-70-31421 2
L-6 21T-70-31690 4
L-7 21T-70-31470 4
• The machine is transported with the parts Name Q’ty Name Q’ty
marked with A installed temporarily. Hammer 1 45 t crane 1
• Check that the pins and inside of the 36 mm socket 1

bushings are cleaned.
KW38G impact wrench 1
ø12, 5 m wire 2
Others
220
Assembly procedure
Installation of boom cylinder hoses
LS-3
Remove the oil stoppers of the boom cylinder piping and revolving frame piping and install the 4 hoses as shown in the
following figure.
a When removing the oil stoppers, take care of spout of oil.
Reuse the split flanges, bolts and washers used to install the oil stoppers (on the machine hose side) as they are.
Parts used to install oil stoppers

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

#14 #20
No. Part No. Q'ty

L-8 21T-64-39421 2
L-9 07000-B2060 4
L-10 07083-01417 2
L-11 07000-B3048 4
1. When installing the hoses, take care not to Name Q’ty Name Q’ty
twist them. 22 mm socket 1
2. Take care not to damage the O-rings.
(Before installing, apply grease.) 27 mm socket 1
3. After connecting the hoses, bleed air from
the boom cylinder. KW14PI impact wrench 1
150 mm extension 1
Others
221
Assembly procedure
Installation of boom cylinder piping
LS-4
When the boom is installed, the boom cylinders are extracted and retracted to position the holes
of the boom cylinder top pins. Accordingly, bleed air according to the following procedure after
installing the boom cylinders.
Bleeding air from boom cylinders

(1) Run the engine at the low idle speed and extract and retract the boom cylinders 5 – 6 times without moving them to the
stroke ends (stop them about 100 – 200 mm before each stroke end).
a Since there is much air in the circuit, the work equipment does not move for more than 10 seconds when the control
lever is operated for the first time. Do not move the control lever to the stroke end at this time, however.
a If the engine speed is increased high or the cylinder is moved to the stroke end from the first, the piston packing may
be damaged by the air in the cylinder.
a After starting the engine, warm it up sufficiently to fit each part.
(2) Next, extract the boom cylinders to the stroke end and keep the control lever at the stroke end for 3 minutes.
(3) Run the engine at the full speed and keep the control lever similarly to (2) for 1 minute.

Others
222
Assembly procedure
Installation of boom assembly
LS-5
(1) Sling the boom assembly with a crane and position the boom foot pinholes.
(2) Install the boom foot pins.

a Push in either boom foot pin first until it stops and then position the pinhole on the other side. If the boom leans to the
right or left at this time, correct it with a jib crane.
a Decide the number of the adjustment shims so that the clearance of the boom foot pin out of the machine body will be
below 1 mm.
Combine the following adjustment shims properly to adjust the clearance.

(21T-70-31470) t1.5: 4 pcs.
(21T-72-31690) t1.0: 4 pcs.
(Adjust the shims at 1 place on the left outside of the boom.)
Work equipment assembly: 13,000 kg
(3) Push in both boom foot pins to the end and

install the lock plates.
Seal
Right side (DM908 60 140) Left side
Boom foot pin
L-13 L-14
Shim Shim
t=1.0 t=1.5 No. Part No. Q'ty
L-12 DM942 850 40 1
L-13 21T-70-31690 4
L-14 21T-70-31470 4
• When pushing in the pin, take care not to Name Q’ty Name Q’ty
break the seal.
Others
223
Assembly procedure
Installation of boom cylinder head pins
LS-6
(1) Remove the pin lock pieces from the boom cylinder and then remove the boom cylinder top pins.
4 Boom cylinder top pin: 61 kg
(2) Start and run the engine at the low idle speed.
(3) Sling each cylinder and extract its rod slowly to match the pinhole and push in the pin.
(4) Install both cylinders similarly.
(5) Install the pin lock pieces (Tightening torque of M24 bolt: 60 – 105 kgm).
Inside of bushings: Apply grease (GL-LI).
a Extract the cylinder slowly.

Do not move it quickly or move it to the stroke end.
Since there is much air in the circuit, the work equipment may not move for more than 10 seconds when the control
lever is operated for the first time. Do not move the control lever to the stroke end at this time, however.
Pin

Others
224
Assembly procedure
Installation of hose between
LS-7 machine body and boom (1/2)
(1) Remove the oil stopping parts of the tubes and blocks.
(2) Install the hoses. (10 pcs.)

Reuse the split flanges, bolts and washers (marked a) used to stop oil as they are.
Bucket line
#20
Bottom dump bottom

#14
Bottom dump head

#14
Arm cylinder head

#14
No. Part No. Q'ty

L-15 07083-01421 2
L-16 07083-02023 2
Arm cylinder bottom
L-17 07084-01419 1
#20 L-18 07084-01416 1
L-19 07083-02018 3
L-20 07000-B3048 8
L-21 07000-B2060 10

Others
225
Assembly procedure
Installation of hose between
LS-7 machine body and boom (2/2)
(1) Install the grease hose. (Tightening torque: 84 – 132 Nm {8.5 – 13.5 kgm})
No. Part No. Q'ty

L-22 07631-20412 1

Others
226
Assembly procedure
Installation of bucket cylinder assembly
LS-8
(1) Sling each bucket cylinder with a crane. At this time, lean it about 45° with the rod side up.
(2) Insert the pin boss on the rod side in the bracket of the boom.
(3) Insert pin in the pinhole and secure the cylinder.
(4) Install the pin lock plate.
Note). When reassembling, remove the pins, lock plates, bolts, and washers from the boom assembly.
No. Part No. Q'ty

L-23 DM905 984 40 2
L-24 DM905 742 40 2
L-25 DM905 749 40 2
L-26 01010-81640 4
L-27 01643-31645 4

Bucket cylinder
Cold district
STD
specification
Right and Left DM905 984 40 DM923 854 40
Others
227
Assembly procedure
Installation of arm assembly
LS-9
(1) Install wires to the hooks of arm assembly and sling it with a crane.
(2) Insert the boss on the boom side of the arm assembly in the pin bracket of the boom.
(3) Insert pins and secure the arm assembly.
(4) Install pin lock plates.
Note). When reassembling, remove the pins, lock plates, bolts, and washers from the boom assembly.
No. Part No. Q'ty

L-28 DM942 855 40 1
L-29 DM905 739 40 2
L-30 DM905 749 40 2
L-31 01010-82455 4
L-32 01643-32460 4

Others
228
Assembly procedure
Installation of arm cylinder assembly
LS-10
(1) Install chains to the hooks of arm cylinder under the boom and sling them.
(2) Extracting each arm cylinder, match the center of the cylinder rod end boss to the cylinder bracket of the arm.
(3) Insert pin in the pinhole to secure the cylinder.
(4) Install pin lock plate.
Note). When reassembling, remove the pins, lock plates, bolts, and washers from the cylinder assembly.
No. Part No. Q'ty

L-33 DM945 438 40 1
L-34 DM945 449 40 1
L-35 DM908 933 40 2
L-36 DM905 750 40 2
L-37 01010-81640 4
L-38 01643-31645 4

Others
229
Assembly procedure
Installation of hoses between boom and arm
LS-11
(1) Install hose assembly between the boom and arm.
#14 ×4
#20 ×2
No. Part No. Q'ty

L-39 DM942 888 40 2
L-40 07085-01430 4
L-41 07084-02030 2
L-42 DM490 011 40 1
L-43 07000-B3048 8
L-44 01010-81455 32
L-45 01643-31445 32
L-46 07000-B2060 4
L-47 01010-81865 16
L-48 01643-31845 16
• When installing the hoses and tubes, take Name Q’ty Name Q’ty
care extremely not to catch the O-rings.
• Take care extremely not to let dust in the
hydraulic circuit.
Others
230
Assembly procedure
Installation of bucket cylinder hoses
LS-12
(1) Install bucket cylinder hoses.
No. Part No. Q'ty

L-49 07084-01423 2
L-50 07084-01428 2
L-51 07000-B3048 8
L-52 01010-81455 32
L-53 01643-31445 32
L-72 21T-72-31990 2
L-73 01010-81485 8
hydraulic circuit.
Others
231
Assembly procedure
Installation of grease feed hose
LS-13 of bucket cylinder (1/2)
(1) Unwind the grease feed hose from the tube of the arm assembly and install it along the bucket cylinder hose to the grease
fitting of the bucket cylinder rod end boss.
(2) Unwind the grease feed hose from the body of the arm assembly and install it along the bucket cylinder hose and connect
to the bottom grease feed hose installed to the bucket cylinder assembly.
Note). Adjust the grease feed hoses to proper length by the following method.
(3) Wind spiral covers onto the grease feed tubes and bucket cylinder hose as shown below.
Bucket cylinder rod end grease feed hose

(To be unwound and installed along hydraulic hose)
Grease
feed hose
Grease feed hose
Hydraulic hose
Bucket cylinder
hydraulic hose
Spiral cover
A–A No. Part No. Q'ty
L=2100 L-74 DM940-883-40 2

Others
232
Assembly procedure
Installation of grease feed hose
LS-13 of bucket cylinder (2/2)
(1) Unwind the grease feed hose from the tube of the arm assembly and install it along the bucket cylinder hose to the grease
fitting of the bucket cylinder rod end boss.
(2) Unwind the grease feed hose from the body of the arm assembly and install it along the bucket cylinder hose and connect
to the bottom grease feed hose installed to the bucket cylinder assembly.
Note). Adjust the grease feed hoses to proper length by the following method.
(3) Wind spiral covers onto the grease feed tubes and bucket cylinder hose as shown below.
Connect to
hose on
cylinder side
at this point.
Grease feed hose
Hydraulic
hose
Spiral cover
No. Part No. Q'ty

L=2600 L-75 DM907-344-40 2

Others
233
Assembly procedure
Installation of bucket assembly
LS-14
(1) Install bucket assembly.
Note). When reassembling, remove the pins, lock plates, bolts, and washers from the bucket assembly.
(2) Install the pin seal assembly.
No. Part No. Q'ty

L-54 DM944 363 40 1
L-55 DM620 923 40 4
L-56 DM247 091 40 4
L-57 DM661 196 40 4
L-58 DM247 092 40 4

Others
234
Assembly procedure
Installation of arm cylinder junction hoses
LS-15
Remove the oil stoppers from the head port and bottom port of the arm cylinder and connect the 3 hoses as shown in the fol-
lowing figure.
a When removing the oil stoppers, take care of the spouting oil.
Reuse the oil stopper mounting parts such as the split flanges, bolts, etc.
Use the clamps installed to the cylinder to clamp the hoses.
Parts to install blind plugs
07371-31049 (Flange) × 12 pcs.: Reuse
07372-21035 (Bolt) × 24 pcs.: Reuse
01643-31032 (Washer) × 24 pcs.: Reuse
07000-B3025 (O-ring) × 6 pcs.: Keep
07378-10600 (Head) × 6 pcs.: Keep
No. Part No. Q'ty

L-59 07085-006A9 3
L-60 07000-B3025 6
1. When connecting each hose, take care Name Q’ty Name Q’ty
not to twist it. 14 mm socket 1
2. Take care that the O-rings will not be
caught. (Apply grease to the O-rings 19 mm socket 1
before fitting.)
3. Take care extremely that dirt will not enter
the hydraulic circuit.
Others
235
Assembly procedure
Installation of bottom dump hose and
LS-16 grease feed hose between arm and bucket
(1) Install bottom dump hydraulic hoses between the arm and bucket.
Note). Reuse the bolts and washers used for the blind cover.
(2) Unwind the grease feed hose from the arm and connect it to the bottom dump grease feed hose on the bucket side.
(3) Wind spiral covers onto the grease feed tubes and bottom dump cylinder hoses.
Grease feed hose
L-61
Hydraulic hose
L-63
L-65 L-64
Grease feed hoses Hydraulic hose No. Part No. Q'ty

L-62 L-61 07083-41231 2
L-62 07000-B3038 4
L-63 01010-81245 16
L-64 01643-31232 16
L-65 08034-20536 4
L=2900 L-76 DM940-884-40 2
hydraulic circuit.
Others
236
Assembly procedure
Installation of arm dump cushion (proximity switch)
LS-17
Work 1. Move the work equipment so that the arm cylinder will be retracted to the end and then lower the bucket to the ground
with the arm cylinder retracted to the end.
Work 2. Install the sensor plates to the arm. (1), (2) and (3)
Work 3. Install proximity switch (6) to proximity switch fixing bracket (4). [Tighten lightly]
Work 4. Install proximity switch bracket (4) to the boom so that proximity switch (6) installed in Work 3 will be set to the dimen-
sions in Fig. 1.
Work 5. Adjust the position of proximity switch (6) so that the distance between the proximity switch and sensor plate (1) will
be 5 mm and then tighten the proximity switch. [Tightening torque: 2.5 kgm – 3.5 kgm (Width across flats: 36 mm)
Work 6. Connect the wiring harness connector to the proximity switch connector.
Proximity switch
Sensor plate Fixing bracket Proximity switch
L–69
No. Part No. Q'ty

L-66 21T-06-31281 1
From proximity switch center to sensor plate end: 25 mm L-67 01010-81640 1
Fig. 1 (From periphery of proximity switch thread to sensor plate end: 10 mm) L-68 01643-31645 1
L-69 21T-06-31271 1
L-70 01034-81225 2
L-71 56B-06-15610 1

19 mm socket 1
24 mm socket 1
36 mm ring wrench 1
36 mm spanner 1
Others
237
M. INSPECTION AND SERVICING PROCEDURES
AFTER ASSEMBLY
239
Assembly procedure
Inspection of oil levels and coolant levels and
M-1 using standard of fuel and lubricant (1/2)
240
Assembly procedure
Inspection of oil levels and coolant levels and
M-1 using standard of fuel and lubricant (2/2)
241
Assembly procedure
Flushing of hydraulic circuit (1/3)
M-2
Flush the hydraulic circuit according to the following procedure.
1. Bypass the work equipment piping at the cylinders.
Bypass
Bypass
Boom cylinder bottom
Bypass
Bypass Bypass
Bypass
Arm cylinder bottom Bucket cylinder bottom

Others
242
Assembly procedure
M-2
2. Replace the return filter element with the flushing element (accessory).
3. Replace the relief valve of the return filter with the plate (accessory).
a When replacing the element, lift it up carefully so that the dirt sticking to it will not fall in the case.
Remove the dirt remaining in the case with the hand.
Replace relief valve with

Valve
this plate only when flushing.
Strainer
Special element for flushing

Absolute filtration rating: 6 µ
FR1F080A001A
manufactured YAMASHIN
KOGYO or equivalent
No. Part No. Q'ty

K-1 209-60-77551 3
K-2 21T-60-13730 3
Keep the removed standard parts (element, Name Q’ty Name Q’ty
strainer, valve) carefully, since they will be
used again after flushing.
Others
243
Assembly procedure
M-2
4. Run the engine at low idle with the lever in the N position for 30 minutes.
5. Run the engine at a medium speed with the lever in the N position for 30 minutes.
6. Run the engine at 1,700 rpm and repeat the following lever operation pattern 4 times.
Keep the lever at each operation position for 1 minute - 1 minute 30 seconds.
Operation pattern
(Raise boom) (Lower boom) (Extend arm) (Retract arm) (Extend bucket) (Retract bucket)
7. Replace the return filter relief valve and element with the regular ones.
8. Correct the work equipment piping (connect it to the cylinders).
a If the "Filter clogged" caution lamp on the monitor in the operator's cab lights up during the flushing operation, stop the
engine immediately and replace the flushing element. If a new flushing element is not available, use a new genuine
element.
Installation condition of element
Fig. 1 Good condition Fig. 2 Bad condition
a Do not install the element with its bottom on the elevated part of the case bottom as shown in Fig. 2. In particular, if
the filter case is filled with oil, it is difficult to see if the element is installed normally. In this case, turn the element with
your hand. If you can turn it smoothly, it is installed normally.

Others
244
Assembly procedure
Releasing residual pressure from hydraulic circuit
M-3
When disconnecting the hydraulic piping, be sure to release the residual pressure according to the following procedure.
1. Set the lock lever to the "FREE" position.
2. Remove the hydraulic tank cap.

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

Others
245
Assembly procedure
Releasing residual pressure from HIC circuit and
M-4 check of gas pressure in HIC accumulator
For check of the gas pressure in the HIC accumulator, see PC2000-8 Shop Manual, "Testing and adjusting".

Others
246
Assembly procedure
Charging air conditioner with refrigerant (1/3)
M-5
Using the tool kit in the following table, charge the air conditioner with gas.
Symbol Part No. Part name Remarks
1 799-703-1200 Service tool kit For HFC134a (R134a)
For HFC134a (R134a)
799-703-1100 Vacuum pump (100 V)
N
For HFC134a (R134a)
2 799-703-1111 Vacuum pump (220 V)
For HFC134a (R134a)
799-703-1121 Vacuum pump (240 V)
O 799-703-1401 Gas leak detector
N2: Vacuum pump O: Gas leak detector N1: Service tool

Charge the air conditioner gas according to the follow- a Since PC2000-8 is equipped with two air conditioners, charge
ing procedure. them one by one, checking A and B shown in the figure.
For detail, see pages 186+1 and after.
Type of air conditioner gas: HFC134a (R134a)
Amount of charge: Front compressor (A): 950 ± 50 g
1. Start vacuuming Rear compressor (B): 950 ± 50 g
Approx. 30 min
-100 kPa {-750 mmHg} or below
Charge them with refrigerant in five each of 200g air conditioner
Stop vacuuming Check/Repair gas can (20Y-979-3310) through the compressors of A and B.
Leave for connected portions Use the air conditioner gas supplied loose from the plant. Do not
5 min use any other gas.
There is pressure fluctuation
2. Check air tightness However, it cannot be supplied loose in the EU district (for the
(There is leakage)
㩷㪦㪢 machines of EU specification). Accordingly, prepare and use
3. Charge refrigerant the same product locally. ENGINE UNIT
COMPRESSER
4. Check through A B
sight glass
5. Check gas leakage

RECIEVER TANK
A/C㩷UNIT CONDENCER B
B
A B A B A
A
CONTROL㩷PANEL
OPERATOR'S CAB. CONDENCER BOX
If refrigerant gas gets in your eyes, you may Name Q’ty Name Q’ty
lose your sight. Accordingly, when adding it,
put on protective goggles.
Gas must be collected and charged by a

specialist.
For details of refrigerant charging procedure,

see the instruction manual for the tool kit.
Be sure to observe the amount of air

conditioner gas to be charged.
If automatic charging machine is used, be
Others
sure to follow its operation manual to charge

specified amount (950 g)
247
Assembly procedure
M-5
Refrigerant charge work
1. Using the vacuum pump, vacuum the refrigerant piping to -100 kPa {750 mmHg} or below.
Air and moisture are removed from the refrigerant piping by vacuuming.
2. After vacuuming, leave for five minutes and check that the gauge pressure does not change. If the pressure has changed,
air tightness is low. In this case, check the piping joints again and repair, and then perform the procedure again from 1.
3. Charging of refrigerant
3-1) With the engine stopped, charge 200 g of the air conditioner gas (one can) from the high pressure side.
(Never operate the air conditioner while no refrigerant gas is in it.)
3-2) Close the high pressure valve of the tool kit, and then start the engine.
3-3) To operate only the control panel corresponding to the compressor being charged with the gas,
turn on only the air conditioner switch of panel A (left side) while A (front side) is being charged, and
turn on only the air conditioner switch of panel B (right side) while B (rear side) is being charged.
Circuit Compressor Control panel Receiver tank

A Front side of machine Left side of machine Left side of machine
B Rear side of machine Right side of machine Right side of machine
3-4) While running the engine at low idle, charge the 800 g of the rest of the air conditioner gas (200 g x 4) from the low pressure
side.
B Rear compressor
Charging valve on
A high pressure side
B Charging valve on
low pressure side
A˴Front compressor
Charging valve on
high pressure side
OPERATOR'S CAB.
CONTROL PANEL Charging valve on
ENGINE ASS'Y low pressure side
No. Part No. Q'ty

A/C SWITCH E-49 20Y-979-3310 10

If refrigerant gas gets in your eyes, you may Name Q’ty Name Q’ty
lose your sight. Accordingly, when adding it,
put on protective goggles.
Refrigerant gas must be collected and added

by a qualified person.
For details of refrigerant charging procedure,

see the instruction manual for the tool kit.
If the compressor is operated while the high

pressure valve of the tool kit is open, the
refrigerant flows back, and it is dangerous.
If the refrigerant is charged from the low
Others
pressure side first, the compressor may be

broken by liquid compression.
248
Assembly procedure
M-5
4. While running the engine at high idle, check the amount of charged refrigerant through the sight glass
on the top of the receiver tank.
If the amount is proper, few bubbles are seen through the sight glass while the air conditioner is operated.
If the refrigerant seems milky, the amount of the refrigerant is insufficient. In this case, check gas leakage,
repair the leaking portion, and then charge the refrigerant again.
★ When adding refrigerant while how much refrigerant has been charged is unknown, add until few bubbles
are seen, and then add 200 g (one can) as spare, and the total amount is proper.
A 㪪㫀㪾㪿㫋㩷㪾㫃㪸㫊㫊
Amount
䋨B) SHORTAGE 䋨A) GOOD AMOUNT (C) OVER CHARGE
condition
5. Finally, while operating the air conditioner,
check the piping joints for gas leakage with Condition of Many bubble Intermittent
Clear
the detector. sight glass bubble
㪧㫉㫆㪹㪼
Condition of OUT Spare
Receiver tank IN amount
inner
AC GAS Pressure
Receiver tank
Bubble capasity
disuppear
★ Check gas leakage in a well ventilated point
place. Additional charge 200g

Characteristic of
★ Apply the probe not at one point but all gas charge
from bubble disupper
around the joint.

Standard amout of
PC2000
750 950
AC GAS AMOUNT[g]

Check the amount of the Name Q’ty Name Q’ty
charged air conditioner gas Relationship between ambient
temperature and refrigerant pressure
through the sight glass. Refrigerant is
Gauge pressure
charged too much
★ Do not check the amount of

the charged air conditioner 㪧㫉㫆㫇㪼㫉
gas by only the gauge pressure Refrigerant is insufficient
since it varies largely with the

Ambient temperature
ambient temperature.
Others
249
Assembly procedure
Installed angles of mirrors (1/3)
M-6
Right step mirror
Left rear mirror

Operator's cab mirror
Left step mirror
Right
Front
<Right step mirror> (Loose-supply item)
No. Part No. Q'ty

K-3 21T-53-31820 1
K-4 21T-53-31791 1
K-5 21T-53-33860 1
K-6 21T-53-31841 1
K-7 21T-53-31850 1
K-8 07283-53444 10
K-9 07283-33450 10
K-10 01597-01009 24
K-11 01643-31032 24
K-12 07283-33442 2
K-13 20Y-54-61630 1
K-14 01252-71025 2
K-15 01010-81640 2
K-16 21T-72-12620 1
K-17 01643-31645 1
K-18 23S-54-36270 1
K-19 56B-54-17313 1
While sitting in the operator's seat and Name Q’ty Name Q’ty
checking the visibility, adjust the angle of
each mirror.
Others
250
Assembly procedure
M-6
<Left rear mirror> (Sent individually)
Front
Left
No. Part No. Q'ty

K-20 23S-54-36270 2
K-21 21T-54-34690 1
K-22 21T-54-79620 2
K-23 01252-71025 4
K-24 21T-54-34850 1
K-25 21T-54-34680 1
K-26 07283-32236 4
K-27 01643-31032 8
K-28 01597-01009 8
each mirror.
Others
251
Assembly procedure
M-6
<Operator's cab left mirror> (Installed to side of of operator's cab when machine is shipped)
<Left step mirror> (Loose-supply item)
Front
Left
No. Part No. Q'ty

K-29 421-54-25610 1
K-30 04025-00632 1
K-31 01252-70545 4
K-32 21T-54-36480 1
K-33 20Y-54-61630 1
K-34 01252-71030 2
each mirror.
Others
252
Assembly procedure
Installed angles of lights (1/3)
M-7
<Light above operator's cab>
Right
Front
K-35
<Light above fuel tank>

Right
Front
K-36
(3)
No. Part No. Q'ty

K-35 21T-06-32810 1
K-36 22B-06-11690 3
checking the lighting direction, adjust the
light angles.
Others
253
Assembly procedure
M-7
<Left step light>
Left
Front
Bottom view of left step
a For the part No. of the light, see A-13.
254
Assembly procedure
M-7
<Work equipment (Boom) light>
Up
Front
Left side (Right side is similar)

Others
255
VHMS CONTOROLLER INITIAL SETTING PROCEDURE
257
1
VHMS controller initial setting procedure 1
a Equipment used for VHMS controller initial set- 1. Confirmation of machine information,
ting engine information, transmission controller
information and controller information
Symbol Part No. Part name a This confirmation procedure is targeted at
the entire machine.
799-608-3211 Diskette
1 Confirm and record the machine informa-
799-608-3220 Wiring harness tion, engine information, VHMS controller
W Note type PC information and ORBCOMM terminal
Commercially
2 (Windows 98/2000/Me/XP), information.
available
with RS232C terminal
No. Information to be confirmed
a Initial setting of VHMS controller shall be done
according to the following procedure. This 1 Model name
operation is needed prior to a full-scale opera- 2 Machine serial No.
tion of a machine being delivered and assem- 3 Current service meter hour
bled in the field, or prior to resumption of its
4 Engine serial No.
operation after a long time of storage.
a Machine data collected with VHMS controller 5 VHMS controller serial No.
are stored and managed on WebCARE data- ORBCOM terminal serial No.
6
base. In order to endure smooth data process- [Only for machines equipped with ORBCOMM]
ing on WebCARE , consistency must be
provided among the settings done on VHMS a VHMS controller (1) and ORBCOMM ter-
controller. Inconsistencies in the settings minal (2) are installed in the cab base
obstruct loading of data to WebCARE, ham- inner the distribution board.
pering appropriate use of VHMS data. The ini-
tial setting, therefore, is a must.
a For the installation procedure of the VHMS ini-
tial setting program to a PC, refer to the opera-
tion and maintenance manual being bundled
with the service kit W1.
a In the procedure, service menus of the
machine monitor are used. Thus, it is advis-
able to reference the information contained in
the Special functions of machine monitor to
understand their procedure beforehand.
a The initial setting procedure is described in the
ORBCOMM installation specification and the
ORBCOMM-less specification. When using
the ORBCOMM installation specification,
implement the procedures needed for VHMS
alone, bypassing those prepared only for ORB-
COMM installation specification.
a Check each step of the setting work referenc-
ing the VHMS initial setting work check
sheet.
a Information such as models shown in the fig-
ures may not be identical with actual ones.
258
2. Connecting a PC 3. Confirming VHMS controller operation and
a This work is done inside the cab. confirming satellite capturing state
1) Make sure the starting switch is at OFF a This work is done inside the cab.
position. a Confirmation of capturing of the satellite is
k Before connecting or disconnect- done for [ORBCOMM installation specifi-
ing a PC, be sure to turn off the cation].
starting switch. 1) Turn the starting switch ON.
2) Using harness [1] of service kit W1, con- 2) Check the controller for normal operation
nect the PC W2 and download connector referencing 7-segment LED of VHMS con-
C53. troller.
a Then connect the PC to RS232C ter- a VHMS controller is fed with switch
minal. power supply. Thus, its operation is
judged normal if its 7-segment LED
starts flashing while rotating as the
starting switch is turned on and then if
the controller starts counting in the
ascending order.
a Download connector C53 is installed

in the back side of the left stand of
operator seat.
3) Among the 7-segment LED situated in the

right side of VHMS controller, refer to the
one that represents the decimal point to
check whether or not ORBCOMM control-
ler has captured the communication satel-
lite. [ORBCOMM installation specification]
a Check whether or not ORBCOMM
controller is capturing the communi-
cation satellite from VHMS controller.
a It is successfully capturing the satel-
lite when the LED representing the
decimal point in the right side 7-seg-
ment LED is flashing.
259
a It can be checked with monitoring
function of the machine monitor, too.
4. Starting the VHMS initial setting tool

a This work is done inside the cab (from PC).
1) Turn on the PC power and start the OS.
2) Operating [VHMS initial setting tool] icon on
the PC, start up the VHMS initial setting tool.
Important
a Appearance of the setup screen of
the VHMS setting tool depends its
tool.
5. Initial setting of VHMS controller (Ver. 3. 5.
a When using Ver.3.5.2.1 or older ver-
2. 1 or older version)
sion (CD-ROM), the setting proce-
a This work is done inside the cab (from
dure shall conform to that described
PC).
in Section 5.
a It is prohibited in the initial setting to mod-
a When using an update version
ify the data of service meter [SMR].
(Ver.3.5.2.1 or after), the procedure in
[Machine Information]
Section 6 shall be used.
1) Open [Machine Information] tab.
a It is recommended to download the
a [Data clear and Set up] menu displays
latest VHMS version from WebCARE
[Machine Information] tab first.
to update the currently used version.
2) Check every data for correctness.
(Related material: PARTS & SER-
V IC E O PE RAT IO N T IP S S EK N-
5052)
3) Enter the 10-digit service ID to [Service ID].
a Service ID: 7826117000
4) Select [Data clear and Set up] from
[Select Function] item.
5) Click [OK] button to proceed to the setup
screen.
260
3) When [Date/Time] information is not appro- 5) As every data in [Machine Information]
priate, correct it in the following manner. has been checked and corrected, press
1] Press [Edit] button in the lower right [Apply] button to settle the setting.
side of [Date/Time] box to display the a As [Apply] button is pressed, a mes-
correction screen. sage confirming above setting will
2] After correcting it to the correct infor- appear on the screen. Check the set-
mation, press [OK] button. ting again and, if the setting is correct,
press [OK] button.
a ORBCOMM installation specification
requires the settlement operation after
[Communication Setting] is completed.
4) When [Machine Information] information is

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

specification only]
a This setting shall be implemented after the
request for station opening has been made
and station of ORBCOMM has been opened.
6) Open [Communication Setting] tab.
7) Check every data for correctness.
261
8) When modifying the setting of [SHORT 10) When modifying the setting of [Satellite
FAULT HISTORY], employ the following Setting], employ the following procedure.
procedure. 1] Press [Edit] button in the [Satellite
1] Select [SHORT FAULT HISTORY] from Setting] block to display the correc-
the screen and then press [Edit] button tion screen.
in the lower left side of [File Transfer 2] Set the GCC code to the region
Setting] block to display the setup applied and, as setting is completed,
screen. press [OK] button.
2] Correct the setting and, as it is com-
pleted, press [OK] button.
a In the initial setting, select [Occur-
rence] from [Timing] item and then
set the function to ON.
GCC codes and applicable regions

Code Applicable region Code Applicable region
1 America 122 Korea
120 Italy 130 Japan
121 Malaysia
9) When modifying the setting of [SHORT
TREND ANALYSIS], employ the following 11) As every data in [Communication Setting]
procedure. has been checked and corrected, press
1] Select [SHORT TREND ANALYSIS] [Apply] button to settle the setting.
from the screen and then press [Edit] a As [Apply] button is pressed, a mes-
button in the lower left side of [File sage confirming above setting will
Transfer Setting] block to display the appear on the screen. Check the set-
setup screen. ting again and, if the setting is correct,
2] Correct the setting and, as it is com- press [OK] button.
pleted, press [OK] button.
a In the initial setting, enter [20h] to
[SMR] and then set the function to
ON.
262
12) As every data in [Machine Information]
and [Communication Setting] has been
checked and corrected, press [Exit] button
to end [VHMS initial setting tool].
13) After the initial setting of the VHMS con-

troller is completed, initialize the machine
monitor maintenance information, too.
q Maintenance information initialization pro-
cedure
1] While the ordinary screen is dis- 2] When the service menu screen
played, perform the following opera- appears, move the yellow cursor onto
tion with the numeral input switches. "04 Maintenance Mode Change"
q Switch operations: While pressing using [F3] or [F4] and then press [F6].
[4], perform [4] + [1] o [2] o [3] in
order.
a This operation of the switches is
accepted only while the ordinary
screen is displayed.
263
3] When the maintenance mode change 6. Initial setting of VHMS controller (Ver. 3. 5.
screen appears, move the yellow cur- 2. 1 or later version)
sor onto "99 Use Default Value" using a This work is done inside the cab (from PC).
[F3] or [F4] and then press [F6]. a It is prohibited in the initial setting to mod-
ify the data of service meter [SMR].
1) Select [VHMS Setting] and then press
[Next] button.
2) Select [Set up & All clear] and press [Next]

button.
4] The maintenance information is ini-

tialized.
264
3) Confirm the machine information and, if 4) Select the time zone.
they are correct, press [Next] button. 5) Enter the local time.
6) When DST (Daylight Saving Time) (or
summer time) is currently used, press
[Next] button.
a Selecting DST advances the clock by
an hour. Thus, correction of the time
is needed again.
a When VHMS has been installed later,

it is required to enter the information
such as [Serial No.].
7) Set the GCC code to the target region of

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

Code Applicable region Code Applicable region
1 America 122 Korea
120 Italy 123 Brazil
121 Malaysia 130 Japan
265
8) If there is no problem in the setting dis- 7. Performing Quick Pm
played last, press [Apply] button. a Perform the following procedure in the cab.
a The Quick Pm means the Pm clinic per-
formed by using the snap shot (manual)
function of the machine monitor.
1) Run the engine at low idle and set the
machine in the following position.
q Swing the boom 90° to right
(with the idler on the front side).
q Set the arm vertically.
q Lower the bucket bottom to the ground
and set it horizontally.
2) Set the switches and lever in the following
positions.
q Working mode switch: P-mode
q Heavy lift switch: ON
q Auto-decelerator switch: ON
q Swing lock switch: OFF
9) A screen message will confirm whether or q PCC lock lever: Free
not the data before the setting is to be 3) Set the machine monitor to display the
saved. If the data is not necessary, select service menu.
[NO]. a For the operating method, see Spe-
cial function of machine monitor.
4) On the initial screen of the service menu,

select 10 Snap shot menu.
10) As correction of the first setting is com-

pleted, press [OK] button to end the pro-
gram.
266
5) Press the [F1] switch to start the snap shot
operation.
a Before starting the snap shot opera-
tion, understand the operating proce-
dure for the Quick Pm by referring to
Operating procedure for Quick Pm.
a The data of 48 items are recorded
and saved for 7 minutes 30 seconds
after the [F1] switch on the machine
monitor is pressed.
a The data are recorded at the intervals
of 10 seconds for the first 5 minutes
and at the intervals of 1 second for
the 2 minutes 20 seconds after the 5
minutes.
a To interrupt the snap shot operation,
press the switch.
a If the snap shot operation is inter-
rupted, the data collected up to now
are not recorded. In this case, repeat
the operation from the first.
6) Operate the fuel dial, swing lock switch,
both work equipment control levers, and
both travel levers according to the Oper-
at i n g pr o c ed u r e f o r Q u i c k P m a n d
elapsed time.
a The elapsed time is displayed on the
machine monitor.
k Since the operator must operate
the work equipment, swing the
boom, and drive the machine actu-
ally for the Quick Pm, take extreme
care of safety around the machine
during the work.
7) After 5 seconds passes since the bar

graph is completed (7 minutes 30 seconds
passes after the snap shot is starts), the
initial screen of the service menu is dis-
played again.
267
Operating procedure for Quick Pm
*: Operation mode (P)
Time on Fuel Swing lock Data read in Pm clinic after data
No. Elapsed time Operation of lever
snap data dial switch are downloaded
Start 0:00 330.00 Engine speed (Low idle)
MIN
1 O O O OFF Set all levers in neutral. Engine oil pressure (Low idle)
(Low)
Finish 0:30 300.00 Ambient temperature
Engine speed (High idle)
Start 0:30 300.00 Engine oil pressure (High idle)
MAX Set all levers in neutral
2 O O O OFF J/S differential pressure
(High) (Turn decelerator on).
Finish 1:00 270.00 Pump oil pressure
Fan pump oil pressure
Start 1:00 270.00
MAX Move levers finely [Note]
3 O O O OFF Engine speed (Auto deceleration)
(High) (Turn decelerator off).
Finish 1:30 240.00
Start 1:30 240.00 Raise right-hand track
MAX Pump pressure
4 O O O OFF shoe and drive it idle
(High) (actuating pressure)
Finish 2:30 180.00 (Set lever to stroke end).
Swing 180°.
Start 2:30 180.00
MAX Raise left-hand track shoe Pump pressure
5 O O O OFF
(High) and drive it idle (Set lever (actuating pressure)
Finish 3:30 120.00
to stroke end).
Start 3:30 120.00
MAX Swing oil pressure
6 O O O ON R.H. swing relief.
(High) (relief pressure)
Finish 4:00 090.00
Start 4:00 090.00
MAX Swing oil pressure
7 O O O ON L.H. swing relief.
(High) (relief pressure)
Finish 4:30 060.00
Start 4:30 060.00
MAX
8 O O O ON Arm OUT relief. Arm OUT oil pressure
(High)
Finish 5:00 030.00
Start 5:00 030.00
MAX
9 O O O ON Bucket DUMP relief. Bucket DUMP oil pressure
(High)
Finish 5:30 000.00
Start 5:30 000.00
MAX
10 O O O ON Bucket CURL relief. Bucket CURL oil pressure
(High)
Finish 6:00 030.00
Start 6:00 030.00
MAX
11 O O O ON Arm IN relief. Arm IN oil pressure
(High)
Finish 6:30 060.00
Start 6:30 060.00
MAX
12 O O O ON Boom RAISE relief. Boom RAISE oil pressure
(High)
Finish 7:00 090.00
Start 7:00 090.00 Set all levers in neutral
MAX Engine speed
13 O O O ON (1st deceleration o 2nd
(High) (1st deceleration speed)
Finish 7:30 120.00 deceleration)
MIN
14 7:30 120.00 ON Finish
(Low)
Note: To turn off the decelerator and set the engine speed to high idle, move one of both work equipment control
levers and both travel levers to a degree that the work equipment does not move or the machine does not
swing or travel. (If the PPC oil pressure switch is turned ON, the auto-decelerator is turned OFF.)
268
Snap shot item table
No. Item Unit No. Item Unit
Sampling time sec 43 Arm throttle selector valve L
1 Engine speed rpm 44 Arm throttle selector valve R
2 Fuel injection rate mm3/st 45 Swing brake valve
3 Blow-by pressure kPa 46 Swing priority selector valve
4 Left-bank front exhaust temperature °C 47 Travel back pressure valve
5 Left-bank rear exhaust temperature °C 48 Swing back pressure valve
6 Right-bank front exhaust temperature °C
7 Right-bank rear exhaust temperature °C
8 Engine oil pressure MPa
9 engine oil temperature °C
10 Engine coolant temperature °C
11 Intake air pressure kPa
12 Intake air temperature °C
13 Ambient temperature °C
14 Pump 1F oil pressure MPa
15 Pump 1R oil pressure MPa
16 Pump 2F oil pressure MPa
17 Pump 2R oil pressure MPa
18 Fan pump F pressure MPa
19 Fan pump R pressure MPa
20 Hydraulic oil temperature °C
21 Pump 1F control current mA
22 Pump 1R control current mA
23 Pump 2F control current mA
24 Pump 2R control current mA
25 Engine speed command value V
26 Auto-deceleration command value V
27 Fuel injection timing deg
28 Fuel injection pressure MPa
29 PTO oil temperature °C
30 Boom raise oil pressure MPa
31 Boom lower oil pressure MPa
32 Arm in oil pressure MPa
33 Arm out oil pressure MPa
34 Bucket curl oil pressure MPa
35 Bucket dump oil pressure MPa
36 Right travel oil pressure switch
37 Left travel oil pressure switch
38 Right swing oil pressure MPa
39 Left swing oil pressure MPa
40 Service valve pressure switch
41 Straight travel valve
42 2-stage main relief signal
269
8. Download of setting data a Enter [User Name] and [Password].
1) Using harness [1] of service kit W1, con- a For the operating procedure, see the
nect PC W2 to download connector C53 in VHMS analysis tool operation and
the cab or download connector VDL on maintenance manual.
the ground.
3) Using [Download] function, download the

data currently recorded on VHMS to PC.
a For the operating procedure, see the
a Download connector C53 in the cab is VHMS analysis tool operation and
installed in the back side of the left maintenance manual.
stand of operator seat. a After making sure the download is
complete, proceed to the next step.
9. Confirmation of download data

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

end [VHMS analysis tool].
270
10. Disconnecting the PC 11. Report to Komatsu
1) Make sure the starting switch is at OFF As steps 1 9 are completed, send VHMS/
position. WebCARE setting report to VHMS/WebCARE
k Before connecting or disconnect- Support Center in Komatsu Headquarters.
ing a PC, be sure to turn off the a This report is a must since setting on the
starting switch. receiving end in the satellite communica-
2) End the OS of PC W2 and then turn off the tion must be done by Komatsu.
PC power. a In this case, send VHMS data via Notes
(LAN) or E-mail (WAN).
Komatsu VHMS/WebCARE Support Center
2-3-6, Akasaka Minato-Ku Tokyo, Japan
FAX: 81-3-5561-4766 (from outside of Japan)

FAX: 03-5561-4766 (Domestic user)
E-mail: [email protected]
3) When the data was download into the cab,

disconnect harness [1] of service kit W1
from download connector C53.
271
[For storage] Date of setting:
DB/branch
VHMS initial setting work check sheet office name
Data entered by:
Setup step Check item Result
Model name
Confirmation of machine body and Serial No.
1
component nameplates Engine serial No.
VHMS controller serial No.
Connection between PC and VHMS

2 Is the connection secure? yes no
controller
Is it operating normally?
VHMS controller check for normal
3 (Displays counting in ascending-order succeeding to yes no
operation
rotation)
Is Data Clear and Set up selected for the setting tool
4 Starting of VHMS initial setting tool yes no
mode?
Is model name identical with machine body? yes no

Initial setting of VHMS controller
Is machine body serial No. correctly entered? yes no
(Setting of machine body informa- Is engine serial No. correctly entered? yes no
5 tion)
In this step, basic machine body Is today's date entered? yes no
information are set on VHMS con- Is current time entered? yes no
troller Is SMR correctly entered? yes no
6 Saving of settings Is LED (7-segment) turned off? yes no
7 Confirmation of VHMS function Is LED operation normal? yes no
Is service mode SNAPSHOT turned on and is the

8 Execution of quick Pm yes no
switch hit?
9 Data storing operation on VHMS Is LED (7-segment) turned off? yes no
10 Download Is LED operation normal? yes no
Are all files downloaded? yes no

Hour,
The time downloaded (Reference wrist watch)
minute:
[Confirmation of data]
11 Confirmation of download data
Is [MFA0] error present in Fault History? yes no
Are SMR and time in Fault History consistent with set-
yes no
tings?
Is any data missing in Snap Shot0? yes no
12 Data storing operation on VHMS Is LED (7-segment) turned off? yes no
272
[For storage] Date of setting:
DB/branch
ORBCOMM station opening work office name
check sheet Data entered by:
Setup step Check item Result
Model name
Serial No.
Confirmation of machine body and
1 Engine serial No.
component nameplates
VHMS controller serial No.
ORBCOMM terminal serial No.
Connection between PC and VHMS

2 Is the connection secure? yes no
controller
Is it operating normally?
VHMS controller check for normal
3 (Displays counting in ascending-order succeeding to yes no
operation
rotation)
4 Starting of VHMS initial setting tool Is Set up selected for the setting tool mode? yes no
Entry of setting to S.Fault History

Initial setting of VHMS controller Presence/absence of communication On Off
1. Setting of communication
(Setting of machine body infor- Number of cases (Default is 8 cases)
mation and PLM are completed) Entry of setting of S.Trend Analysis setting
Presence/absence of communication On Off
Interval (Default is 20H)
5
Entry of setting of S.Payload data
Presence/absence of communication On Off
Tabulation start time
Interval of tabulation (in days) day
2. Setting for start of communica-
Is GCC code set? (130 for Japan) yes no
tion
6 Saving of settings Is LED (7-segment) turned off after data was stored? yes no
How is decimal point display in VHMS monitor

ORBCOMM controller performance
7 (7-segment)? yes no
check
(OFF, ON, long/short flashing)
273
274
PC2000-8 Main pump air bleeding check sheet
1. Purpose
(1) When the hydraulic pump is removed and installed or the hydraulic oil is Date of check
replaced, bleed air according to Field assembly manuals A-57 and C-14 and
Serial No.
enter the contents of the bleeding work performed in this check sheet. (Make
Jobsite
a copy of this page for the record.)
(2) If the air is not bled at all or bled insufficiently, the pump may be broken.
Accordingly, be sure to bleed air according to the given procedure.
2. Air bleeding check

Air bleeding
Shop Manual Engine speed Operation Check result Consumed time Checked by
portion
A-57 Pages Main pump Stopped Add hydraulic oil to specified level
2/16 – 4/16 Fan pump
Loosen pump bleeders (1), (2) and (3)
Add hydraulic oil to specified level
Check that oil flows out of fan pump bleeder (3)
Check that oil flows out of main pump bleeders (1) and (2)
Loosen suction tube plug (5) and check that oil flows out of it
Crank for 15
Check that oil flows out of bleeder (2)
sec twice
Check that oil containing no bubble flows out of bleeders
(1), (2) and (3)
Tighten hydraulic tank cap
Raise work equipment from ground and swing upper struc-
ture 180°
Start and run Loosen suction tube plug (5) and check that oil containing
at low idle no bubble flows out
Raise work equipment from ground and swing upper struc-
ture 180° in opposite direction
Loosen suction tube plug (5) and check that oil containing
no bubble flows out
Check that oil containing no bubble flows out of bleeders
(1), (2) and (3)
Remove hydraulic tank cap and add hydraulic oil to speci-
Stopped
fied level
A-57 Page Swing motor Low idle Start and stop winging 5 – 6 times over
5/16 circuit
Check that oil containing no bubble flows out of swing
motor bleeder (11)
Travel motor Check that oil containing no bubble flows out of travel
Low idle
circuit motor bleeder (12)
Page Check that oil containing no bubble flows out of PPC
A-57 PPC circuit Low idle
6/16 bleeder (13)
Page Check that oil containing no bubble flows out of PV1 and
A-57 Pilot valve Low idle
7/16 PV2 bleeders
A-57 Page Work Start o
Keep for 5 minutes
4/16 equipment Low idle
C-14 Pages cylinder Raise and lower boom 4 – 5 times (Stop at 100 mm before
1/3 – 3/3 Low idle
stroke end and do not relieve)
Raise and lower arm 4 – 5 times (Stop at 100 mm before
Low idle
Raise and lower bucket 4 – 5 times (Stop at 100 mm
Low idle
before stroke end and do not relieve)
Low idle Relieve boom at stroke end
Low idle Relieve arm at stroke end
Low idle Relieve bucket at stroke end
Raise and lower boom 4 – 5 times (Stop at 100 mm before
High idle
Raise and lower arm 4 – 5 times (Stop at 100 mm before
High idle
Raise and lower bucket 4 – 5 times (Stop at 100 mm
High idle
before stroke end and do not relieve)
275
Backhoe specification 1/13
Report No.
FIELD ASSEMBLY INSPECTION REPORT

After completion of assembling a machine, make inspections according to these check sheets for assuring machine performance.
After checking, send these check sheets to the Osaka plant.
[E-mail address] [email protected]
Model - Type Machine serial No. User unit No. Engine model Engine serial No.
PC2000-8 SAA12V140E-3
Backhoe spec.
Service meter reading Date of inspection Attachment
1 2
Location of machine at inspection Manufacturer
Model
Distributor's name
Serial No.
Customer's name Address: Name:

Delivery
report No.
Date :
Inspector's comments:
Inspector's name:
KOMATSU USE ONLY:
Title: Check sheet receiving date:

By:
Signature:
Remark:
Check sheets filling instructions:
1. Use following indexes for entry of judgment.

.......... Normal .......... Correction made on abnormal point
.......... Abnormal .......... Not applied
2. Enter measured values in parentheses. [ ]
Notes:
(1) Criteria area based on the standards when the machine is shipped out of the factory.
(2) This FEIELD ASSEMBLY INSPECTION REPORT is for "A" specification.
At local At ___
Category
Revision Check item assembly operating Criterion

time hours
Oil and coolant levels Measured value

Radiator coolant level Sub tank coolant level
Max. 25 mm
Radiator coolant
level
[ ]
Coolant Soft water
Sub tank coolant
level
[ ]
Added/
[ ]
Not added
Antifreeze
(A, B, C, D, E) A: -50 – -40 °C D:-20 – -10 °C
Freezing
[ ] B: -40 – -30 °C E:-10 – 0 °C
point
Check before assembly
C: -30 – -20 °C (Not necessary in summer)

E010W30-DH L – H +5
Engine oil [ ]
E015W40-DH (In 10 minutes after stopping engine)
T010 L +5 – H
PTO oil [ ]
T030 (In 10 minutes after stopping engine)
Front T030
Swing machinery L +5 – H +10
[ ]
case oil (In 10 minutes after stopping engine)
Rear T030
Right T030 [ ]
Final drive gear
0 – -10 mm from level plug bottom
case oil
Left T030 [ ]
T010
Hydraulic oil [ ] Between H – L (Posture: Max. reach)
H046HM
Battery electrolyte — [ ] Max. 13 mm from filler bottom
Engine No. [ ]
When accepted After check
Service meter[ h] [ h]
Loosened or untightened connecting pin lock bolt Must not be detected.
Loosened or untightened work equipment piping split flange Must not be detected.
Uninstalled, lost or caught work equipment piping O-ring Must not be detected.
Loosened or twisted grease piping joint Must not be detected.

Max. 1 mm
Shim adjustment for work equipment pin
(For shim position, see assembly manual)
Check during assembly
Cylinder bottom side tube must be on

the upper side.
Confirm the mounting direction of the boom cylinder
Improperly inserted or un-inserted wiring Must not be detected.
Loosened or untightened ladder mounting bolt Must not be detected.

At local At ___
Category

time hours
Loosened or untightened counterweight mounting bolt Must not be detected.
Clearance or level difference between counterweight and frame Max. 15 mm
Loosened or untightened operator's cab mounting bolt Must not be detected.
Loosened or untightened cab base mounting bolt Must not be detected.
Loosened or untightened container base mounting bolt Must not be detected.
Loosened or untightened hydraulic tank mounting bolt Must not be detected.
Loosened or untightened fuel tank mounting bolt Must not be detected.
Loosened or untightened center frame mounting bolt Must not be detected.
Loosened or untightened travel system piping bolt/joint Must not be detected.
Uninstalled, lost or caught travel system piping O-ring Must not be detected.
Loosened or untightened track frame mounting bolt Must not be detected.
Loosened or untightened travel motor cover bolt Must not be detected.
Uninstalled part (Rearview mirror, etc.) Must not be detected.

Bleeding air from hydraulic pump As per assembly manual
Bleeding air from travel motor
Bleeding air from swing holding brake circuit
Bleeding air from work equipment cylinder circuit
Adjustment of track tension
Flushing hydraulic circuit
Grease all parts.

Greasing each part of work equipment
Check that grease comes out.
Addition of hydraulic oil Add to between L – H.
Addition of fuel and window washing fluid Fill tank.

Check of charged air conditioner gas
a Use the air conditioner gas supplied loose from the plant. Do
not use any other gas. Check that few bubbles are seen through sight
However, it cannot be supplied loose in the EU district (for the glass on top of receiver tank while air
machines of EU specification). Accordingly, prepare and use conditioner is operated
the same product locally.
Proper Gas amount Overcharge

is insufficient or
empty
At local At ___
Category

time hours
Monitor display
1. Check of monitor function
When the starting switch is turned ON, all of the gauge section,
check-before-starting section and monitor section must light up
and alarm buzzer must sound.
2. Check of gauge section and check-before-starting section
All lamps must go off about 3 seconds after the starting switch is
Display must be as shown on left.
turned ON (all lamps are ON), then only the gauge section is
displayed and the check-before-starting section and monitor
section are kept OFF.
3. Check of monitor section
After the engine is started, the caution lamps must not light up
and the alarm buzzer must not sound in the range between low
idle and high idle.
Service meter must be free from flaw, blur and
Operation of service meter
uneven operation.
Initialization must be executed.
Initialization of VHMS
(Pm clinic, downloading, application for start of use).
Monitor
Check of monitor
X (1/2): Ordinary work screen (1/2), X (2/2): Ordinary work screen (2/2)
• Screens X (1/2) and X (2/2) are displayed alternately each time function switch F1 (7) is pressed.
(1) Window washer switch (17) Clock/Service meter

(2) Wiper selector switch (18) Auto-decelerator monitor
(3) Alarm buzzer cancel switch (19) Working mode monitor
(4) Heavy lift switch (20) Heavy lift monitor
(5) Working mode selector switch (21) Truck counter 1
(6) Auto-decelerator selector switch (22) Truck counter 2
(7) Function switches (F1 – F7) (23) ECO gauge
(8) Engine coolant temperature monitor (24) Fuel level gauge
(9) Engine coolant temperature gauge (25) Fuel level monitor
(10) Hydraulic oil temperature monitor (26) PTO oil temperature gauge
(11) Hydraulic oil temperature gauge (27) PTO oil temperature monitor
(12) Wiper monitor (28) Engine oil temperature gauge
(13) Swing lock switch (29) Engine oil temperature monitor
(14) Preheater monitor (30) Engine oil pressure gauge
(15) Auto grease unit operation monitor (31) Engine oil pressure monitor
(16) Engine stop monitor (32) Numeral key (0 – 9)
At local At ___
Category

time hours
Check of switches and levers
(1) VHMS download connector (10) Foot rest

(2) 12V outlet (11) Travel pedal
(3) Cigarette lighter (24V outlet) (12) Travel lever
(4) AM/FM radio (13) Lock lever
(5) Air conditioner panel 2 (14) Horn switch
(6) Air conditioner panel 1 (15) Control lever (right)
(7) Control lever (left) (16) Starting switch
(8) Truck counter switch (2 pcs.) (17) Fuel control dial
(9) Machine monitor
If the switch is pressed, the horn sounds and

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

time hours
Ladder must be raised and lowered smoothly.
When ladder is lowered:
Machine cannot swing.
Operation of power-assisted ladder Warning lamp lights up.
When ladder is raised:
Machine can swing.
Warning lamp goes off.
If the switch is pressed when the engine is
Operation of emergency engine stop switch
started, engine must stop.
Switch is installed to front and rear of engine compartment and
While the engine is stopped in an emergency,
front of fuel tank (3 places in total).
warning lamp lights up.
Lighting of P: For heavy load work
Lighting of E: For lower fuel consumption
Operation of working mode selector switch
If the switch is operated, the monitor changes
and the operator can select.
Lamp ON: Auto-decelerator is operated.
Lamp OFF: Auto-decelerator is reset.
Operation of auto-decelerator switch
Each time the switch is pressed, the monitor
changes and the operator can select.
During single boom raise operation, if the
Operation of heavy lift switch switch is turned ON, the boom raise force is
increased.
Lighting of INT lamp:
Intermittent operation of wiper

Lighting of ON (Continuous) lamp:
Continuous operation of wiper
Operation of wiper switch Lighting of ON (Continuous upper) lamp:
Continuous operation of only upper wiper

If the switch is pressed, the window washing
Operation of window washer switch fluid spouts against the front glass.
(Wiper operation is linked.)
If the switch is pressed, alarm buzzer for
Operation of buzzer cancel switch
warning item is stopped.
ON position: Room lamp lights up.
Operation of room lamp switch
OFF position: Room lamp goes off.
ON position: Auxiliary lamp lights up.
Operation of auxiliary lamp switch
OFF position: Auxiliary lamp goes off.
ON position: Working lamp lights up.
Operation of working lamp switch
OFF position: Working lamp goes off.
• If the switch is pressed, the step light is
turned ON for about 90 seconds.
Operation of step light switch • Even if the starting switch is OFF, if the
switch is pressed, the step light is turned ON
for about 90 seconds.
ON position: Rotary lamp lights up.
Operation of rotary lamp switch
OFF position: Rotary lamp goes off.
MANUAL position:
Grease must be supplied manually.
Operation of greasing mode switch
AUTO position:
Grease is supplied automatically.
Low pressure setting: Boom thrust force is low.
Operation of machine push-up switch High pressure setting: Boom thrust force is
increased.
If the switch is turned ON, work equipment
Operation of boom shockless control switch
shakes less when boom is stopped.
At local At ___
Category

time hours
When the switch is turned ON, the air
Operation of air conditioner
conditioner starts.
When the switch is turned ON, the radio
Operation of radio
sounds.
If the lighter is pushed in, it is heated red and
Operation of cigarette lighter
returns automatically several seconds after.
If the switch (1 or 2) is pressed, the
Operation of truck counter switch confirmation buzzer sounds and the monitor
counts.
Forward: Lever is pushed forward.

(Pedal is angled forward)
Operation of travel lever Reverse: Lever is pushed back.

(Pedal is angled back)
N (Neutral):Machine stops.
This lever is used to operate the upper
Operation of left work equipment control lever
structure and arm.
(With auto-deceleration function)
N (Neutral):Upper structure and arm are fixed.
Operation of right work equipment control lever This lever is used to operate the boom and
(With auto-deceleration function) bucket.
Operation of bottom dump switch N (Neutral):Boom and bucket are fixed.
Check that no abnormality is displayed and
then delete the fault history. After finishing all
Check of fault history (electrical system and mechanical system)
the checks, check again that there is no fault
history.
Operation of emergency pump prolix switch When normal: Switch is set "down".
While monitor is displaying E07 (Pump EPC solenoid system If the switch is set "up", the alarm buzzer
error), operation can be continued with this switch set "up". sounds and the monitor displays E07 error.
Operation of swing holding brake prolix switch When normal: Switch is set "down".
While monitor is displaying E03 (Swing holding brake system If the switch is set "up", the monitor displays
error), brake can be released and machine can swing with this E03 error.
switch set "up". Swing brake is kept released, however.
At local At ___
Category

time hours
Swing operation running in: Engine at high idle
(Work equipment posture: Max. reach) Empty
Right Left
Normal swing speed [ sec] [ sec] P mode: 11.5 – 13.6 sec/turn
E mode: 12.2 – 14.6 sec/turn

Swing performance
Brake angle Max. 55° (Sensory)
Unevenness and hunting of swing Must not be detected.
Abnormal sound and shakiness in swing Must not be detected.

performance
Travel operation running in: Engine at high idle

Travel
(Work equipment posture: Max. reach)
Abnormal sound and heating must not be

Abnormal sound and heating in track roller, carrier roller and idler
detected.
Operation of travel brake Must operate securely without dragging.
Abnormal sound in travel and shakiness in swing Must not be detected.

Must be free from abnormal travel deviation in
Travel deviation (Sensory) the range from fine control to stroke end
(Sensory).
Travel deviation Forward Reverse
(To be measured only [ ] [ ] Max. 200 mm/20 m
when abnormal) mm/20m mm/20m
Track rotation speed Forward Reverse

[ ] [ ]
Right sec sec
20.1 ± 2.0 sec/turn
Forward Reverse
(P mode, full throttle)
[ ] [ ]
Left sec sec
Right Left
Track tension [ ] [ ]
mm mm
a Travel forward and in reverse on a flat ground and then stop slowly
Stroke
Right Left
Stroke of A[ ] [ ] 135 ± 5 mm
HIC cylinder mm mm
(Elongation)
Grease cylinder B[ ] [ ]
mm mm
At local At ___
Category

time hours
Work equipment running in: Engine at high idle (Note: Lower boom cylinder to ground level)
Pressurization: Relieve each port for 2 minutes and give shock 20 times (excluding boom lower operation).
Work equipment Boom Arm Bucket

posture
A mode Empty
Empty Empty
Raise sec Lower sec Raise: 7.5 ± 0.8 sec

Boom [ ] [ ]
Work equipment Lower: 5.3 ± 0.5 sec
speed (Including
cushion working time)
In sec Out sec In: 7.5 ± 0.8 sec

Arm [ ] [ ]
P mode Out: 5.2 ± 0.5 sec
Engine: Full throttle
8.7 m boom
3.9 m arm
Curl sec Dump sec Curl: 5.0 ± 0.5 sec
12 m3 bucket
Bucket [ ] [ ]
Dump: 3.9 ± 0.4 sec
Lower sec
Work equipment Max. 6.0 sec
Work equipment performance
time lag Boom [ ]
In sec
Engine: Low Arm [ ] Max. 5.0 sec
When normal:
Sensory
When abnormal: Dump sec
Measure Max. 4.0 sec
Bucket [ ]
Must be free from abnormality during no-load

Abnormal sound from hydraulic pump and PTO
operation and when relieved.
Heating of PTO Must be free from abnormal heating.
Engine must not hunt in any gear speed during

Partial engine output performance no-load operation and must not stall when
hydraulic circuit is relieved at low idle.
Fine control performance Work equipment must operate smoothly.
Machine push-up operation (including machine push-up function) Boom, arm and bucket must not escape.
Abnormal sound or creak from work equipment Must not be detected.

Shock at cylinder stroke end
Cushion must work sufficiently.
(Shock at boom raise and arm in stroke ends)
Immediately after engine is stopped, with key

switch ON, boom cylinder must be retracted
Function of accumulator
from extension stroke end to ground level
(when arm is at max. reach).
At local At ___
Category

time hours
Check of each part

During operation
• Lever must not be hitched during operation.

Operating effort of control lever when each actuator is operated
• Lever must return to neutral by itself.
Shaking and beat noise of operator's cab Must not be detected.
Beat noise of frame, guard and ladder Must not be detected.

Around operator's seat
Movement of doors and windows Must move smoothly.
Locks of doors and windows Must work securely.
Adjustment of operator's seat All adjustment must be possible.
Must not be detected.

Oil leakage
(Idler, track roller, sprocket,
final drive gear case, motor, brake valve)
Undercarriage
Interference of each part Must not be detected.
Looseness of track shoe bolt Must not be detected.

Must be free from overlapping, flaking and
Contact of link tread
breakage.
Oil leakage
(Center swivel joint, pump, solenoid valve, relief valve,
control valve, PPC valve, swing motor, brake valve,
shuttle valve, swing machinery, hydraulic tank, piping)

Fuel leakage
(Fuel tank, engine, piping)
Around chassis
Water leakage from engine cooling system Must not be detected.
Oil leakage from engine lubrication system Must not be detected.
Gas leakage from engine gas system Must not be detected.
Operation of covers Must move smoothly.
Locks of covers Must work securely.

At local At ___
Category

time hours
Operation of grease pump Must operate smoothly.
Looseness and insufficient insertion of electric wiring terminals Must not be detected.
Clearance of at least 10 mm must be made
Around chassis
Electric wiring route

around moving part and edge.
Air leakage from air system Must not be detected.

Oil leakage
(Cylinder, piping, block)
Grease leakage from grease piping Must not be detected.
Interference of work equipment Must not be detected.
Looseness of work equipment piping clamp and play of piping Must not be detected.
Twist of hydraulic hose and operation of work equipment at
Around work equipment

reverse
Cylinder bottom side tube must be on
the upper side.
Confirm the mounting direction of the boom cylinder
Note: If the operation or function is defective, measure as necessary. The speeds in the criteria column are the values in P mode.
At local At ___
Category

time hours
1. Engine speed: Check in monitoring mode "01002". P mode
Low idle [ rpm] 825 ± 50 rpm
High idle [ rpm] 1980 ± 50 rpm

Boom raise relieve speed
[ rpm] 1780 ± 50 rpm
(Heavy lift: OFF)
[ rpm] 1780 ± 50 rpm
(Heavy lift: ON)
2. Oil pressure measurement: Check in monitoring mode "01002".

1F pump: "01124 1R pump: "01125"
2F pump: "01126 2R pump: "01127"
1F [ MPa]
1R [ MPa] At engine high idle, boom
Control valve main set pressure 29.4 ± 1.0 MPa raise, P mode, heavy lift
2F [ MPa] OFF and relief
2R [ MPa]
1F [ MPa]
At engine high idle, boom
Control valve main set pressure 1R [ MPa]
31.4 ± 1.0 MPa raise, P mode, heavy lift ON
(Boosted pressure) 2F [ MPa] and relief
2R [ MPa]
1F [Right MPa] At engine high idle, swing, P
Swing relief set pressure 28.4 ± 2.0 MPa
1F [Left MPa] mode and relief
Pilot relief valve set pressure [ MPa] 3.2 + 0.2/-0 MPa At engine high idle
3. Current and voltage measurement

EPC current: Check in monitoring mode.
1F pump: "01307 1R pump: "01309"
2F pump: "01311 2R pump: "01313"
1F [ mA]
1R [ mA] At engine high idle, lever
220 ± 60 mA
2F [ mA] neutral and P mode
2R [ mA]
Pump EPC current
1F [ mA]
1R [ mA] At engine high idle, boom
460 ± 60 mA raise, P mode, heavy lift
2F [ mA] OFF and relief
2R [ mA]
J/S differential pressure output voltage: Check in monitoring mode.
1F pump: "13808 1R pump: "13809"
2F pump: "13810 2R pump: "13811"
1F [ V]
1R [ V] At engine high idle, lever
Min. 3.2 V
2F [ V] neutral and P mode
J/S differential pressure 2R [ V]
output voltage 1F [ V]
1R [ V] At engine high idle, arm in,
Max. 1.4 V
2F [ V] P mode, and relief
2R [ V]
At local At ___
Category

time hours
4. Work equipment hydraulic drift
(Bucket: No load, Hydraulic oil temperature: 50 ± 5 °C)
Bucket tooth tip [ mm] Max. 1,200 mm/15 min
Note: Only when the hydraulic drift of the bucket tooth tip is not
acceptable, measure the hydraulic drift of the following
cylinders.
Boom cylinder [ mm] Max. 17 mm/min (250 mm/15 min)
Arm cylinder [ mm] Max. 23 mm/min (350 mm/15 min)
Bucket cylinder [ mm] 9 mm/min (140 mm/15 min)
5. Operating effort and stroke
Boom Operating Raise N Lower N 15.7 ± 4.9 N

control lever effort {kg} {kg} {1.6 ± 0.5 kg}
Stroke Raise Lower Play Stroke: 85 ± 10 mm

[ mm] [ mm] [ mm] Play: Max. 10 mm
Main measurement items
Swing Operating Right N Left N 12.8 ± 3.9 N

Stroke Right Left Play Stroke: 85 ± 10 mm

Bucket Operating Curl N Dump N 12.8 ± 3.9 N

Stroke Curl Dump Play Stroke: 85 ± 10 mm

[ mm] [ mm] [ mm] Play: Max. 10 mm At engine
high idle and
Arm Operating In N Out N 15.7 ± 4.9 N relief
Stroke In Out Play Stroke: 85 ± 10 mm

Right travel lever Operating Forward N Reverse N 24.5 ± 5.9 N

effort {kg} {kg} {2.5 ± 0.6 kg}
Stroke Forward Reverse Play Stroke: 115 ± 15 mm

Left travel lever Operating Forward N Reverse N 24.5 ± 5.9 N

effort {kg} {kg} {2.5 ± 0.6 kg}

Serial No. Confirm with monitoring mode or visual check.

Serial No. of controllers and monitor
Engine controller (L-BANK) [ ] Visual check
Engine controller (R-BANK) [ ] Visual check
Pump controller (UPPER) [ ] [20403]
Pump controller (LOWER) [ ] [20407]
VHMS controller [ ] Visual check
ORBCOMM controller [ ] Visual check
Monitor [ ] [20402]
Loading shovel specification 1/13
Report No.
FIELD ASSEMBLY INSPECTION REPORT

After completion of assembling a machine, make inspections according to these check sheets for assuring machine performance.
After checking, send these check sheets to the Osaka plant.
Model - Type Machine serial No. User unit No. Engine model Engine serial No.
PC2000-8 SAA12V140E-3
Loading Shovel spec.
Service meter reading Date of inspection Attachment
1 2
Location of machine at inspection Manufacturer
Model
Distributor's name
Serial No.
Customer's name Address: Name:

Delivery
report No.
Date :
Inspector's comments:
Inspector's name:
KOMATSU USE ONLY:
Title: Check sheet receiving date:

By:
Signature:
Remark:
Check sheets filling instructions:
1. Use following indexes for entry of judgment.

.......... Normal .......... Correction made on abnormal point
.......... Abnormal .......... Not applied
2. Enter measured values in parentheses. [ ]
Notes:
(1) Criteria area based on the standards when the machine is shipped out of the factory.
(2) This FEIELD ASSEMBLY INSPECTION REPORT is for "A" specification.
At local At ___
Category

time hours
Oil and coolant levels Measured value

Radiator coolant level Sub tank coolant level
Max. 25 mm
Radiator coolant
level
[ ]
Coolant Soft water
Sub tank coolant
level
[ ]
Added/
[ ]
Not added
Antifreeze
(A, B, C, D, E) A: -50 – -40 °C D:-20 – -10 °C
Freezing
[ ] B: -40 – -30 °C E:-10 – 0 °C
point
Check before assembly
C: -30 – -20 °C (Not necessary in summer)

E010W30-DH L – H +5
Engine oil [ ]
E015W40-DH (In 10 minutes after stopping engine)
T010 L +5 – H
PTO oil [ ]
T030 (In 10 minutes after stopping engine)
Front T030
Swing machinery L +5 – H +10
[ ]
case oil (In 10 minutes after stopping engine)
Rear T030
Right T030 [ ]
Final drive gear
0 – -10 mm from level plug bottom
case oil
Left T030 [ ]
T010
Hydraulic oil [ ] Between H – L (Posture: Max. reach)
H046HM
Battery electrolyte — [ ] Max. 13 mm from filler bottom
Engine No. [ ]
When accepted After check
Service meter[ h] [ h]
Loosened or untightened connecting pin lock bolt Must not be detected.
Loosened or untightened work equipment piping split flange Must not be detected.
Uninstalled, lost or caught work equipment piping O-ring Must not be detected.
Loosened or twisted grease piping joint Must not be detected.

Max. 1 mm
Shim adjustment for work equipment pin
(For shim position, see assembly manual)
Improperly inserted or un-inserted wiring Must not be detected.
Loosened or untightened ladder mounting bolt Must not be detected.

At local At ___
Category

time hours
Loosened or untightened counterweight mounting bolt Must not be detected.
Clearance or level difference between counterweight and frame Max. 15 mm
Loosened or untightened operator's cab mounting bolt Must not be detected.
Loosened or untightened cab base mounting bolt Must not be detected.
Loosened or untightened container base mounting bolt Must not be detected.
Loosened or untightened hydraulic tank mounting bolt Must not be detected.
Loosened or untightened fuel tank mounting bolt Must not be detected.
Loosened or untightened center frame mounting bolt Must not be detected.
Loosened or untightened travel system piping bolt/joint Must not be detected.
Uninstalled, lost or caught travel system piping O-ring Must not be detected.
Loosened or untightened track frame mounting bolt Must not be detected.
Loosened or untightened travel motor cover bolt Must not be detected.
Uninstalled part (Rearview mirror, etc.) Must not be detected.

Bleeding air from hydraulic pump As per assembly manual
Bleeding air from travel motor
Bleeding air from swing holding brake circuit
Bleeding air from work equipment cylinder circuit
Adjustment of track tension
Flushing hydraulic circuit
Grease all parts.

Greasing each part of work equipment
Check that grease comes out.
Addition of hydraulic oil Add to between L – H.
Addition of fuel and window washing fluid Fill tank.

Check of charged air conditioner gas
a Use the air conditioner gas supplied loose from the plant. Do
not use any other gas. Check that few bubbles are seen through sight
However, it cannot be supplied loose in the EU district (for the glass on top of receiver tank while air
machines of EU specification). Accordingly, prepare and use conditioner is operated
the same product locally.
Proper Gas amount Overcharge

is insufficient or
empty
At local At ___
Category

time hours
Monitor display
1. Check of monitor function
When the starting switch is turned ON, all of the gauge section,
check-before-starting section and monitor section must light up
and alarm buzzer must sound.
2. Check of gauge section and check-before-starting section
All lamps must go off about 3 seconds after the starting switch is
Display must be as shown on left.
turned ON (all lamps are ON), then only the gauge section is
displayed and the check-before-starting section and monitor
section are kept OFF.
3. Check of monitor section
After the engine is started, the caution lamps must not light up
and the alarm buzzer must not sound in the range between low
idle and high idle.
Service meter must be free from flaw, blur and
Operation of service meter
uneven operation.
Initialization must be executed.
Initialization of VHMS
(Pm clinic, downloading, application for start of use).
Monitor
Check of monitor
X (1/2): Ordinary work screen (1/2), X (2/2): Ordinary work screen (2/2)
• Screens X (1/2) and X (2/2) are displayed alternately each time function switch F1 (7) is pressed.
(1) Window washer switch (17) Clock/Service meter

(2) Wiper selector switch (18) Auto-decelerator monitor
(3) Alarm buzzer cancel switch (19) Working mode monitor
(4) Heavy lift switch (20) Heavy lift monitor
(5) Working mode selector switch (21) Truck counter 1
(6) Auto-decelerator selector switch (22) Truck counter 2
(7) Function switches (F1 – F7) (23) ECO gauge
(8) Engine coolant temperature monitor (24) Fuel level gauge
(9) Engine coolant temperature gauge (25) Fuel level monitor
(10) Hydraulic oil temperature monitor (26) PTO oil temperature gauge
(11) Hydraulic oil temperature gauge (27) PTO oil temperature monitor
(12) Wiper monitor (28) Engine oil temperature gauge
(13) Swing lock switch (29) Engine oil temperature monitor
(14) Preheater monitor (30) Engine oil pressure gauge
(15) Auto grease unit operation monitor (31) Engine oil pressure monitor
(16) Engine stop monitor (32) Numeral key (0 – 9)
At local At ___
Category

time hours
(1) VHMS download connector (10) Foot rest

(2) 12V outlet (11) Travel pedal
(3) Cigarette lighter (24V outlet) (12) Travel lever
(4) AM/FM radio (13) Lock lever
(5) Air conditioner panel 2 (14) Horn switch
(6) Air conditioner panel 1 (15) Control lever (right)
(7) Control lever (left) (16) Starting switch
(8) Truck counter switch (2 pcs.) (17) Fuel control dial
(9) Machine monitor
If the switch is pressed, the horn sounds and

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

time hours
Ladder must be raised and lowered smoothly.
When ladder is lowered:
Machine cannot swing.
Operation of power-assisted ladder Warning lamp lights up.
When ladder is raised:
Machine can swing.
Warning lamp goes off.
If the switch is pressed when the engine is
Operation of emergency engine stop switch
started, engine must stop.
Switch is installed to front and rear of engine compartment and
While the engine is stopped in an emergency,
front of fuel tank (3 places in total).
warning lamp lights up.
Lighting of P: For heavy load work
Lighting of E: For lower fuel consumption
Operation of working mode selector switch
If the switch is operated, the monitor changes
and the operator can select.
Lamp ON: Auto-decelerator is operated.
Lamp OFF: Auto-decelerator is reset.
Operation of auto-decelerator switch
During single boom raise operation, if the
Operation of heavy lift switch switch is turned ON, the boom raise force is
increased.
Lighting of INT lamp:
Intermittent operation of wiper

Lighting of ON (Continuous) lamp:
Continuous operation of wiper
Operation of wiper switch Lighting of ON (Continuous upper) lamp:
Continuous operation of only upper wiper

If the switch is pressed, the window washing
Operation of window washer switch fluid spouts against the front glass.
(Wiper operation is linked.)
If the switch is pressed, alarm buzzer for
Operation of buzzer cancel switch
warning item is stopped.
ON position: Room lamp lights up.
Operation of room lamp switch
OFF position: Room lamp goes off.
ON position: Auxiliary lamp lights up.
Operation of auxiliary lamp switch
OFF position: Auxiliary lamp goes off.
ON position: Working lamp lights up.
Operation of working lamp switch
OFF position: Working lamp goes off.
• If the switch is pressed, the step light is
turned ON for about 90 seconds.
Operation of step light switch • Even if the starting switch is OFF, if the
switch is pressed, the step light is turned ON
for about 90 seconds.
ON position: Rotary lamp lights up.
Operation of rotary lamp switch
OFF position: Rotary lamp goes off.
MANUAL position:
Grease must be supplied manually.
Operation of greasing mode switch
AUTO position:
Grease is supplied automatically.
Low pressure setting: Boom thrust force is low.
Operation of machine push-up switch High pressure setting: Boom thrust force is
increased.
If the switch is turned ON, work equipment
Operation of boom shockless control switch
shakes less when boom is stopped.
At local At ___
Category

time hours
When the switch is turned ON, the air
Operation of air conditioner
conditioner starts.
When the switch is turned ON, the radio
Operation of radio
sounds.
If the lighter is pushed in, it is heated red and
Operation of cigarette lighter
returns automatically several seconds after.
If the switch (1 or 2) is pressed, the
Operation of truck counter switch confirmation buzzer sounds and the monitor
counts.
Forward: Lever is pushed forward.

(Pedal is angled forward)
Operation of travel lever Reverse: Lever is pushed back.

(Pedal is angled back)
N (Neutral):Machine stops.
Operation of left work equipment control lever This lever is used to operate the upper
(With auto-deceleration function) structure and arm.
Operation of bottom dump switch N (Neutral):Upper structure and arm are fixed.
Operation of right work equipment control lever This lever is used to operate the boom and
(With auto-deceleration function) bucket.
Operation of bottom dump switch N (Neutral):Boom and bucket are fixed.
Check that no abnormality is displayed and
then delete the fault history. After finishing all
Check of fault history (electrical system and mechanical system)
the checks, check again that there is no fault
history.
Operation of emergency pump prolix switch When normal: Switch is set "down".
While monitor is displaying E07 (Pump EPC solenoid system If the switch is set "up", the alarm buzzer
error), operation can be continued with this switch set "up". sounds and the monitor displays E07 error.
Operation of swing holding brake prolix switch When normal: Switch is set "down".
While monitor is displaying E03 (Swing holding brake system If the switch is set "up", the monitor displays
error), brake can be released and machine can swing with this E03 error.
switch set "up". Swing brake is kept released, however.
At local At ___
Category

time hours
Swing operation running in: Engine at high idle
(Work equipment posture: Max. reach) Empty
Right Left
Normal swing speed [ sec] [ sec] P mode: 11.5 – 13.6 sec/turn
E mode: 12.2 – 14.6 sec/turn

Swing performance
Brake angle Max. 55° (Sensory)
Unevenness and hunting of swing Must not be detected.
Abnormal sound and shakiness in swing Must not be detected.

performance
Travel operation running in: Engine at high idle

Travel
(Work equipment posture: Max. reach)
Abnormal sound and heating must not be

Abnormal sound and heating in track roller, carrier roller and idler
detected.
Operation of travel brake Must operate securely without dragging.
Abnormal sound in travel and shakiness in swing Must not be detected.

Must be free from abnormal travel deviation in
Travel deviation (Sensory) the range from fine control to stroke end
(Sensory).
Travel deviation Forward Reverse
(To be measured only [ ] [ ] Max. 200 mm/20 m
when abnormal) mm/20m mm/20m
Track rotation speed Forward Reverse

[ ] [ ]
Right sec sec
20.1 ± 2.0 sec/turn
Forward Reverse
(P mode, full throttle)
[ ] [ ]
Left sec sec
Right Left
Track tension [ ] [ ]
mm mm
Stroke of HIC cylinder

Stroke of Right Left
135 ± 5 mm
HIC cylinder [ ] [ ]
mm mm
(Elongation)
At local At ___
Category

time hours
Work equipment running in: Engine at high idle (Note: Lower boom cylinder to ground level)
Pressurization: Relieve each port for 2 minutes and give shock 20 times (excluding boom lower operation).
Boom Arm Bucket Bottom dump
Work
equipment
posture Empty
Empty Empty Empty
Work equipment Raise sec Lower sec Raise: 8.3 ± 0.8 sec
speed (including Boom [ ] [ ]
cushion working time) Lower: 6.4 ± 0.6 sec
P mode In sec Out sec In: 5.3 ± 0.5 sec

Engine: Full throttle Arm [ ] [ ]
Out: 3.2 ± 0.4 sec
Curl sec Dump sec Curl: 4.2 ± 0.5 sec

Bucket [ ] [ ]
Dump: 2.9 ± 0.4 sec
Open sec Close sec Open: 2.2 ± 0.2 sec

Bottom
dump [ ] [ ]
Close: 2.2 ± 0.2 sec
Work equipment performance
Lower sec
Work equipment Max. 6.0 sec
time lag Boom [ ]
In sec
Engine: Low Max. 5.0 sec
Arm [ ]
When normal:
Sensory
When abnormal: Dump sec
Measure Max. 4.0 sec
Bucket [ ]
Must be free from abnormality during no-load

Abnormal sound from hydraulic pump and PTO
operation and when relieved.
Heating of PTO Must be free from abnormal heating.
Engine must not hunt in any gear speed during

Partial engine output performance no-load operation and must not stall when
hydraulic circuit is relieved at low idle.
Fine control performance Work equipment must operate smoothly.
Machine push-up operation (including machine push-up function) Boom, arm and bucket must not escape.
Abnormal sound or creak from work equipment Must not be detected.

Shock at cylinder stroke end
Cushion must work sufficiently.
(Shock at boom raise and arm in stroke ends)
Immediately after engine is stopped, with key

switch ON, boom cylinder must be retracted
Function of accumulator
from extension stroke end to ground level
(when arm is at max. reach).
At local At ___
Category

time hours
Check of each part

During operation
• Lever must not be hitched during operation.

Operating effort of control lever when each actuator is operated
• Lever must return to neutral by itself.
Shaking and beat noise of operator's cab Must not be detected.
Beat noise of frame, guard and ladder Must not be detected.

Around operator's seat
Movement of doors and windows Must move smoothly.
Locks of doors and windows Must work securely.
Adjustment of operator's seat All adjustment must be possible.

Oil leakage
(Idler, track roller, sprocket,
final drive gear case, motor, brake valve)
Undercarriage
Looseness of track shoe bolt Must not be detected.

Must be free from overlapping, flaking and
Contact of link tread
breakage.
Oil leakage
(Center swivel joint, pump, solenoid valve, relief valve,
control valve, PPC valve, swing motor, brake valve,
shuttle valve, swing machinery, hydraulic tank, piping)

Fuel leakage
(Fuel tank, engine, piping)
Around chassis
Water leakage from engine cooling system Must not be detected.
Oil leakage from engine lubrication system Must not be detected.
Gas leakage from engine gas system Must not be detected.
Operation of covers Must move smoothly.
Locks of covers Must work securely.

At local At ___
Category

time hours
Operation of grease pump Must operate smoothly.
Looseness and insufficient insertion of electric wiring terminals Must not be detected.
Clearance of at least 10 mm must be made
Around chassis
Electric wiring route

around moving part and edge.
Air leakage from air system Must not be detected.

Oil leakage
(Cylinder, piping, block)
Grease leakage from grease piping Must not be detected.

Around work equipment
Interference of work equipment Must not be detected.
Looseness of work equipment piping clamp and play of piping Must not be detected.
Twist of hydraulic hose and operation of work equipment at
reverse
Note: If the operation or function is defective, measure as necessary. The speeds in the criteria column are the values in P mode.
At local At ___
Category

time hours
1. Engine speed: Check in monitoring mode "01002". P mode
Low idle [ rpm] 825 ± 50 rpm
High idle [ rpm] 1980 ± 50 rpm

[ rpm] 1780 ± 50 rpm
(Heavy lift: OFF)
[ rpm] 1780 ± 50 rpm
(Heavy lift: ON)
2. Oil pressure measurement: Check in monitoring mode "01002".

1F pump: "01124 1R pump: "01125"
2F pump: "01126 2R pump: "01127"
1F [ MPa]
1R [ MPa] At engine high idle, boom
Control valve main set pressure 29.4 ± 1.0 MPa raise, P mode, heavy lift
2F [ MPa] OFF and relief
2R [ MPa]
1F [ MPa]
At engine high idle, boom
Control valve main set pressure 1R [ MPa]
31.4 ± 1.0 MPa raise, P mode, heavy lift ON
(Boosted pressure) 2F [ MPa] and relief
2R [ MPa]
1F [Right MPa] At engine high idle, swing, P
Swing relief set pressure 28.4 ± 2.0 MPa
1F [Left MPa] mode and relief
Pilot relief valve set pressure [ MPa] 3.2 + 0.2/-0 MPa At engine high idle
3. Current and voltage measurement

EPC current: Check in monitoring mode.
1F pump: "01307" 1R pump: "01309"
2F pump: "01311" 2R pump: "01313"
1F [ mA]
1R [ mA] At engine high idle, lever
220 ± 60 mA
2F [ mA] neutral and P mode
2R [ mA]
Pump EPC current
1F [ mA]
1R [ mA] At engine high idle, boom
460 ± 60 mA raise, P mode, heavy lift
2F [ mA] OFF and relief
2R [ mA]
J/S differential pressure output voltage: Check in monitoring mode.
1F pump: "13808" 1R pump: "13809"
2F pump: "13810" 2R pump: "13811"
1F [ V]
1R [ V] At engine high idle, lever
Min. 3.2 V
2F [ V] neutral and P mode
J/S differential pressure 2R [ V]
output voltage 1F [ V]
1R [ V] At engine high idle, arm in,
Max. 1.4 V
2F [ V] P mode, and relief
2R [ V]
At local At ___
Category

time hours
4. Work equipment hydraulic drift
(Bucket: No load, Hydraulic oil temperature: 50 ± 5 °C)
Bucket tooth tip [ mm] Max. 1,200 mm/15 min
Note: Only when the hydraulic drift of the bucket tooth tip is not
acceptable, measure the hydraulic drift of the following
cylinders.
Boom cylinder [ mm] Max. 17 mm/min (250 mm/15 min)
Arm cylinder [ mm] Max. 23 mm/min (350 mm/15 min)
Bucket cylinder [ mm] 9 mm/min (140 mm/15 min)
5. Operating effort and stroke
Boom Operating Raise N Lower N 16.7 ± 4.2 N

Stroke Raise Lower Play Stroke: 85 ± 10 mm

Main measurement items
Swing Operating Right N Left N 13.7 ± 3.4 N

Stroke Right Left Play Stroke: 85 ± 10 mm

Bucket Operating Curl N Dump N 13.7 ± 3.4 N

Stroke Curl Dump Play Stroke: 85 ± 10 mm

[ mm] [ mm] [ mm] Play: Max. 10 mm At engine
high idle and
Arm Operating In N Out N 13.7 ± 3.4 N relief
Stroke In Out Play Stroke: 85 ± 10 mm

Right travel lever Operating Forward N Reverse N 25.5 ± 6.4 N

effort {kg} {kg} {2.5 ± 0.6 kg}

Left travel lever Operating Forward N Reverse N 25.5 ± 6.4 N

effort {kg} {kg} {2.5 ± 0.6 kg}

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

Engine controller (L-BANK) [ ]
Serial No. of controllers and monitor
Engine controller (R-BANK) [ ]
Pump controller (UPPER) [ ] “20403”
Pump controller (LOWER) [ ] “20407”
VHMS controller [ ]
ORBCOMM controller [ ]
Monitor [ ] “20402”
GEN00060-16

Komatsu pc200-8

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GEN00060-16

Operator for assembly

Mechanics Sharing of work

When the work equipment is installed, the engine must be operated.

A. ASSEMBLY OF CHASSIS ............................................................................................ 45

C. ASSEMBLY OF BACKHOE.......................................................................................... 183

LS. ASSEMBLY OF LOADING SHOVEL WORK EQUIPMENT........................................ 217

M. INSPECTION AND SERVICING PROCEDURES AFTER ASSEMBLY ....................... 239

VHMS CONTOROLLER INITIAL SETTING PROCEDURE .............................................. 257

PC2000-8 Main pump air bleeding check sheet ................................................................ 275

FIELD ASSEMBLY INSPECTION REPORT (BACKHOE)

FIELD ASSEMBLY INSPECTION REPORT (LOADING SHOVEL)

Item Unit PC2000-8

PC2000-8 Loading shovel

1. Selection of work place

3. Preparation and check of protective gear, slings and tools

4. k Check during actual work

Foreman + 6 mechanics Foreman + 6 mechanics Foreman + 6 mechanics Foreman + 2 mechanics

· Start of assembly · Completion of assembly · Completion of total assembly

Work necessary to assembly

Coupling of revolving frame Installation of hydraulic tank to

Installation of fuel tank Installation of left floor Installation of machinery

Installation of cab base Sub-assembly of cab base

Installation of power container

Installation of external covers

Installation of boom cylinder

Installation of boom Sub-assembly of boom

Installation of arm Sub-assembly of arm

X Overall length (mm) 3,815 <3,950>

• With swivel and fixing bar

(2) Crawler frame assembly

• With motor and motor guard

(3) Revolving frame assembly

When disassembled to 27 ton, hydraulic tank

X Overall length (mm) 3,100 <3,350>

(5) Cab base assembly

X Overall length (mm) 2,100 <2,300>

(6) Left floor assembly

X Overall length (mm) 2,500 <3,070>

X Overall length (mm) 5,215 <5,300>

(8) Operator's cab assembly

X Overall length (mm) 2,855 <3,100>

• With antenna retracted

(9) Counterweight assembly

X Overall length (mm) 6,240 <6,300>

(11) Grease can cover assembly

X Overall length (mm) 1,030

(12) Switch box assembly

X Overall length (mm) 300

X Overall length (mm) 1,390

(14) Right catwalk assembly

X Overall length (mm) 3,560

• With grease reel

(15) Front catwalk assembly

X Overall length (mm) ,715

X Overall length (mm) 1,470

(17) Boom assembly

X Overall length (mm) 9,170 <9,200>

Left side view