field assembly pc1250lc-8 gen00055-05

8/12/2019 Field Assembly Pc1250lc-8 Gen00055-05

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HYDRAULIC

EXCAVATOR

Field ssembly Instruction

GEN00055-05

PC1250 -8

PC1250LC -8PC1250SP -8

SERIAL NUMBERS

PC1250- 30001

PC1250LC- 30001

PC1250SP- 30001

and up


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M. Procedure for Inspection and Maintenance after Completion of Assembly.................... 97M- 1. Replacement of Return Filter (Standard Filter to Flushing Filter) .......................... 98M- 2. Relieving Remaining Pressure from Hydraulic Circuit ......................................... 101M- 3. Installation of Flushing Tubes.............................................................................. 102

M- 4. Flushing of Hydraulic Circuit ................................................................................ 104M- 5. Replacement of Pilot Filter (Flushing filter o Standard filter) ............................... 105

Field Assembly Inspection Report (Backhoe)


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SPECIFICATIONS

PC1250-8

PC1250SP-8

Machine model PC1250-8 PC1250SP-8 PC1250LC-8

Weight of machine kg 109,900 111,700 113,500

Bucket capacity m3 5.2 6.7 5.2

Engine model SAA6D170E-5

Flywheel horsepower kW/rpm {HP/rpm} 502{672}/1,800

Min. ground clearance mm 990

Travel speed (Low/High) km/h 2.1/3.2

Swing speed rpm 5.8


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PC1250LC-8


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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 workThe 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 checkedthat 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.


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KIT LAYOUT DIAGRAM The dimensions given below are the minimum dimensions needed.

The kit dimensions in the diagram are outline dimensions.

When selecting a place, see precautions for FIELD ASSEMBLING.

Bucket

Arm link

Boom

Center

frame

Tools, facility

Armcylinder

Boom

cylinder

Foreword

Crawlerframe

Crawlerframe

Revolving

frame

Counterweight

Leftd

eck

Motor cover handrails

45t crane

45t crane


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TRANSPORTATION

TRANSPORTATIONThe machine can be divided into seven kits for transportation, so when transporting the machine, please contact your

Komatsu distributor to have the work carried out.

Transportation in seven kits

Posture for each unit

(dimensions in diagram are in mm.)

Upper structure

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

Fuel: Empty

Hydraulic oil: M level

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

Overall width (mm) 3,490

Weight (kg) 26,700

(Upper structure)

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

Boom cylinder, etc.)

(Undercarriage left) (Undercarriage right) (Center frame)


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TRANSPORTATION

Undercarriage

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

do not start the engine.

ItemPC1250-8

PC1250SP-8PC1250LC-8

Qty 2 2

Weight (kg)30,500

(15,250 2 pieces)37,600

(18,800 2 pieces)

LC: 7,400

STD, SP: 6,425

LC: 1,295

STD, SP: 1,222


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TRANSPORTATION

Boom

Item PC1250-8 PC1250SP-8 PC1250LC-8

A (mm) 9,475 8,170 9,475

B (mm) 2,894 3,095 2,894

Overall width (mm) 1,474 1,474 1,474

Weight (kg) 11,200 11,100 11,500


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TRANSPORTATION

Arm

Bucket (excluding side cutter and shroud)

Boom cylinder (same for all models)Weight: 2,400 kg (1200 kg 2 pieces)

Arm cylinder (same for all models)

Weight: 1,500 kg

ItemPC1250-8

PC1250LC-8PC1250SP-8

A (mm) 4,895 4,914

B (mm) 1,626 1,683

Overall width (mm) 890 890

Weight (kg) 6,200 6,400

ItemPC1250-8

PC1250LC-8PC1250SP-8

A (mm) 2,580 2,527

B (mm) 2,276 2,420

Overall width (mm) 2,250 2,520

Weight (kg) 5,500 6,300


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TRANSPORTATION

Center frame

Counterweight

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

Overall width (mm) 3,540

Weight (kg) 9,700

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

Weight (kg) 18,000


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TRANSPORTATION

Others Radiator duct (same for all models)

Radiator duct upper cover (same for all models)

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

Weight (kg) 100

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

Weight (kg) 17


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TRANSPORTATION

Catwalk (right): same for all models

Catwalk (left, front): same for all models

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

Weight (kg) 17

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

Weight (kg) 150


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TRANSPORTATION

Catwalk (left, rear): same for all models

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

Weight (kg) 160


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LIST OF TOOLS FOR FIELD ASSEMBLING

No. Tool names Specifications Qty. Remarks

1

Equipment Engine compressor Komatsu, 0.69 MPa {7.0kg/cm

2} Class 1

2 Crane truck 441 kN {45 ton} 2

2 245 kN {25 ton} 1

3 Grease pump Air type 1 Work equipment lubrication

4 Stepladder 5 -stepped- 1500 mm 2

5

Tool

Impact wrench KW10P (for M10) 1

6 KW12PI (For M12) 17 KW20P (For M16) 1

7 KW380 1

8 KW45FS (Spline) 1 For counterweight

9 Socket for KW45FS Spline 65 mm 1 For counterweight

10 Air hose 50 m 1 For impact wrench

11 16-time wrench 4413 Nm {450 kgm} 1 For counterweight

12 Socket for 16-time wrench T38.1 65 mm 1 For counterweight

13 T38.1 60 mm 1 For track frame

14 T38.1 50 mm 1 For track frame

15 4-time wrench 25.4, 19 1

16 Socket for 4-time wrench T25.4 50 mm 1

17 T25.4 60 mm 1

18 Torque wrench 412 Nm {42 kgm} T25.4 mm 1 For 16-time wrench

19 980 Nm {100 kgm} T25.4 mm 1 For 4-time wrench

20 4118 Nm {420 kgm} T38.1 mm 1 For counterweight and track frame

21 Standard tool Socket, spanner, wrench 2 set

22 Sledge hammer 10 P 1

23 Bar 1 m 2

24 Hydraulic jack 490 kN {50 ton} (stroke 170) 2 Revolving frame pedestal

25 196 kN {20 ton} 1When tightening track frameconnecting bolts.

26 Waste oil pan Large, small 2 eachWhen connecting travel andwork equipment piping

27 Wooden block 300 400 mm 4 Revolving frame pedestal

28

Liftingtool

Wire 10 3 m 2 For catwalk

29 20 5 m 2 For boom, arm and bucket

30 25 5 m 4 For revolving frame and track frame

31 30 5 m 2 For counterweight

32 Shackle SD30 3

33 SC18 4

34 Nylon sling 50 mm wide 3 m 2 For boom cylinder and arm cylinder

34 Nylon sling 25 mm wide 3 m 2 Handrail

35 Pin 50 5 m 2 Track frame

36 Lever block 14.7 29.4 kN {1.5 3 ton} 2

37 Eyebolt M16 2

38 M12 2

39 Detergent liquid Brake cleaner 10

40 Hydraulic oil EO-10 500 l41

Oiland

grease

Grease G2-LI (20 kg) 4 kg Work equipment lubrication, Swing circle

42 Repair paint Natural yellow 5

43 Black gray 5

44 Waste cloth Bundle 20 kg


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TIGHTENING TORQUE

1. Tightening torque for bolts

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

torque.

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

Remarks

1. The thread diameter is the nominal diameter. For example, 16 mm is expressed as M16 and 26

mm is expressed as M20.

The pitch in Table 1 is the distance that the bolt advances every turn in the axial direction (Unit:

mm).

2. The bolt length is dimension c in Fig. 1.

3. The applicable socket size is expressed as 24 mm, 30 mm, etc. Since 24 mm, 30 mm, etc. cor-

respond to dimension b in Fig. 1, an applicable socket can be selected from Table 1, too.

4. Tightening torque is expressed asQQQwwworQQQRR. If the target tightening torque

is set, expression of QQQ RRis applied.

Part No. of bolt TTTTT-TTTTT

Part No. of washer EEEEE-EEEEE

Bolt specification Thread diameter Bolt length

Tool (Socket) Applicable socket size

Tightening torque Nm {QQQkgm}

a : Bolt thread diameter (Nominal diameter)

b : Width across flats of bolt headc : Bolt length

d : Threaded part of bolt

Fig. 1


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aFor symbols a and b in the table, see Fig. 1.

Table 1 Tightening torque for bolts not specified in text

Nominal size of thread

pitcha (mm)

Width across flats

(= Socket size)

b (mm)

Tightening torque

Unit : Nm

{1.2 1.5}11.8 14.76 1

{2.8 3.5}27 34

{6 7.5}59 74

{10 12.5}98 123

{15.5 19.5}153 190

{23.5 29.5}235 285

{33 41}320 400

{46.5 58}455 565

{62.5 78}610 765

{80 100}785 980

{118 147}1150 1440

{155 195}1520 1910

{200 250}1960 2450

{250 310}2450 3040

{295 370}2890 3630

8 1.25

10 1.5

12 1.75

14 2

16 2

18 2.5

20 2.5

22 2.5

24 3

27 3

30 3

33 3

36 3

39 3

10

13

17

19

22

24

27

30

32

36

41

46

50

55

60

Unit : {kgm}


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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 2Unit: Nm {kgm}

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

Table 3

Unit: Nm {kgm}

Material of female thread

Nominal size (in)Steel Cast iron Light alloy

1/83.9 6.9

{0.4 0.7}

2.9 5.9

{0.3 0.6}

2.0 3.9

{0.2 0.4}

1/45.9 11.8

{0.6 1.2}

4.9 9.8

{0.5 1.0}

3.9 7.8

{0.4 0.8}

3/816.7 26.5

{1.7 2.7}

13.7 21.6

{1.4 2.2}

9.8 16.7

{1.0 1.7}

1/232.3 52.9

{3.3 5.4}

26.5 43.1

{2.7 4.4}

19.6 32.3

{2.0 3.3}

3/451.0 85.3

{5.2 8.7}

42.1 70.6

{4.3 7.2}

31.4 52.9

{3.2 5.4}

186.2 173.5

{8.8 17.7}

72.5 146.0

{7.4 14.9}

54.9 111.7

{5.6 11.4}

Material of female thread

Nominal size (in)Steel Cast iron Light alloy

1/816.7 29.4

{1.7 3.0}

9.8 19.6

{1.0 2.0}

6.9 14.7

{0.7 1.5}

1/419.6 44.1

{2.0 4.5}

16.7 37.2

{1.7 3.8}

12.7 28.4

{1.3 2.9}

3/844.1 93.1

{4.5 9.5}

37.2 77.4

{3.8 7.9}

27.4 58.8

{2.8 6.0}

1/298.0 188.2

{10.0 19.2}

83.3 157.8

{8.5 16.1}

60.8 115.6

{6.2 11.8}

3/4170.5 316.5

{17.4 32.3}

141.1 247.0

{14.4 25.2}

105.8 186.2

{10.8 19.0}

1367.5 612.5

{37.5 62.5}

309.7 514.5

{31.6 52.5}

235.2 392.0

{24.0 40.0}


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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 andlarger, see Table 5.

Table 5

Unit: mm

Thread diameter Proper sizes of sockets or spanners

M42 65

M45 70

M48 75

M52 80

M56 85

M60 90

M64 95

3. Tightening torque for 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

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

Outside diameterof hose

(mm)

Width acrossflatse.

(mm)

Tightening torque (Nm {kgm})

Range Target

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

Approx. 10

22 54 93 {5.5 9.5} 74 {7.5}

24 59 98 {6.0 10.0} 78 {8.0}

Approx. 13 27 84 132 {8.5 13.5} 103 {10.5}

Approx. 16 32 128 186 {13.0 19.0} 157 {16.0}

Approx. 20 36 177 245 {18.0 25.0} 216 {22.0}


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COATING MATERIALS

a The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly

and assembly are listed below.

a For coating materials not listed below, use the equivalent of products shown in this list.

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

Adhesives

LT-1A 790-129-9030 150 g Tube Used to prevent rubber gaskets, rub-

ber cushions, and cock plug fromcoming out.

LT-1B 790-129-905020 g

(2 pcs.)Polyethylene

container

Used in places requiring an immedi-ately effective, strong adhesive.Used for plastics (except polyethyl-ene, polyprophylene, tetrafluoroeth-lene and vinyl chloride), rubber,metal and non-metal.

LT-2 09940-00030 50 gPolyethylene

container

Features: Resistance to heat andchemicals

Used for anti-loosening and sealantpurpose for bolts and plugs.

LT-3

790-129-9060(Set of adhesiveand hardening

agent)

Adhesive:1 kgHardening

agent:500 g

Can

Used as adhesive or sealant for met-al, glass and plastic.

LT-4 790-129-9040 250 gPolyethylene

container

Used as sealant for machined holes.

HoltzMH 705

790-126-9120 75 g Tube Used as heat-resisting sealant for re-

pairing engine.

Three bond1735

790-129-9140 50 gPolyethylene

container

Quick hardening type adhesive Cure time: within 5 sec. to 3 min. Used mainly for adhesion of metals,

rubbers, plastics and woods.

Aron-alpha201

790-129-9130 2 gPolyethylene

container

Quick hardening type adhesive Quick cure type (max. strength after

30 minutes) Used mainly for adhesion of rubbers,

plastics and metals.

Loctite648-50

79A-129-9110 50 ccPolyethylene

container

Resistance to heat, chemicals Used at joint portions subject to high

temperatures.

Gasketsealant

LG-1 790-129-9010 200 g Tube Used as adhesive or sealant for gas-

kets and packing of power train case,etc.

LG-5 790-129-9080 1 kg Can

Used as sealant for various threads,pipe joints, flanges.

Used as sealant for tapered plugs,elbows, nipples of hydraulic piping.

LG-6 790-129-9020 200 g Tube

Features: Silicon based, resistanceto heat, cold

Used as sealant for flange surface,tread.

Used as sealant for oil pan, finaldrive case, etc.

LG-7 790-129-9070 1 kg Tube

Features: Silicon based, quick hard-ening type

Used as sealant for flywheel hous-ing, intake manifold, oil pan, thermo-stat housing, etc.

Three bond1211

790-129-9090 100 g Tube Used as heat-resisting sealant for re-

pairing engine.

Three bond1207B

419-15-18131 100 g Tube

Features: Silicone type, heat resist-

ant, vibration resistant, and impactresistant sealing material Used as sealing material for transfer

case


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

Molybdenumdisulphidelubricant

LM-G 09940-00051 60 g Can Used as lubricant for sliding portion

(to prevent from squeaking).

LM-P 09940-00040 200 g Tube

Used to prevent seizure or scufflingof the thread when press fitting orshrink fitting.

Used as lubricant for linkage, bear-ings, etc.

Grease

G2-LI

SYG2-400LISYG2-350LISYG2-400LI-ASYG2-160LISYGA-160CNLI

Various Various

General purpose type

G2-CA

SYG2-400CA

SYG2-350CASYG2-400CA-ASYG2-160CASYGA-160CNCA

Various Various

Used for normal temperature, light

load bearing at places in contactwith water or steam.

MolybdenumdisulphidegreaseLM-G (G2-M)

SYG2-400MSYG2-400M-ASYGA-16CNM

400 g 10400 g 20

16 kg

Bellows typeBellows type

Can

Used for heavy load portion

Hyper WhiteGrease G2-TG0-T (*)*: For use in cold

district

SYG2-400T-ASYG2-16CNTSYG0-400T-A (*)SYG0-16CNT (*)

400 g16 kg

Bellows typeCan

Seizure resistance and heat resist-ance higher than molybdenum di-sulfide grease

Since this grease is white, it doesnot stand out against machinebody.

Biogrease G2BG2-BT (*)*: For high

temperatureand large load

SYG2-400BSYGA-16CNBSYG2-400BT (*)SYGA-16CNBT (*)

400 g16 kg

Bellows typeCan

Since this grease is decomposedby bacteria in short period, it hasless effects on microorganisms,animals, and plants.

Primer

SUNSTARPAINT PRIMER580 SUPER

417-926-3910

20 mlGlass

container

Adhesiveforcabglass

Used as primer for cab side(Expiration date: 4 months)

SUNSTARGLASS PRIMER580 SUPER

20 mlGlass

container

Used as primer for glass side(Expiration date: 4 months)

Adhesive

SUNSTARPENGUINE

SEAL 580SUPER "S" or"W"

320 ml

Polyethylene

container

"S" is used for high-tempera-ture season (April - October)and "W" for low-temperature

season (November - April) asadhesive for glass.(Expiration date: 4 months)

Sika Japan,Sikaflex 256HV

20Y-54-39850 310 mlPolyethylene

container

Used as adhesive for glass.(Expiration date: 6 months)

Caulkingmaterial

SUNSTARPENGUINESEAL No. 2505

417-926-3920 320 mlPolyethylene

container

Used to seal joints of glassparts.(Expiration date: 4 months)

SEKISUISILICONESEALANT

20Y-54-55130 333 mlPolyethylene

container

Used to seal front window.(Expiration date: 6 months)

GE TOSHIBASILICONESTOSSEAL 381

22M-54-27220 333 ml Cartridge

Used to seal joint of glasses.Translucent white seal.

(Expiration date: 12 months)

PaintNatural yellow SYPA-U03PNY Spray can

Black gray SYPA-U03PBG Spray can


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LIST OF PARTS SENT INDIVIDUALLYCHASSIS (STANDARD SPECIFICATION)

No. Parts No. Parts names Qty Remarks Page

1 21N-30-11180 Bolt 40 For connecting track frame 32

2 21N-30-37130 Spacer 40

3 150-74-11140 Bolt 56 For connecting center frame 42

4 01643-33380 Washer 56

5 02896-11009 O-ring 2 For installing travel piping 35

6 02896-11018 O-ring 2

7 07000-B3032 O-ring 4

8 07094-31228 Clamp 8

9 07095-01241 Cushion 8

10 01024-81285 Bolt 8

11 08036-03014 Clip 6

12 04434-52512 Clip 6

13 07095-20318 Cushion 6

14 01024-81225 Bolt 10

15 21N-30-37411 Cover (L.H.) 1 For installing travel pipingcover

37, 38

16 21N-30-37421 Cover (R.H.) 1

17 01024-81225 Bolt 8

18 21N-30-37370 Cover (L.H.) 1

19 21N-30-37381 Cover (R.H.) 1

20 01010-81230 Bolt 8

21 175-54-34170 Washer 8

22 21N-30-37390 Cover 1

23 01010-81230 Bolt 6

24 175-54-34170 Washer 6

25 209-62-52560 Pin 1For installing swivel and travelpiping

45

26 01641-21626 Washer 1

27 04050-14028 Pin 1

28 02896-11009 O-ring 1

29 07002-12434 O-ring 1

30 07073-01A08 Hose 2

31 07073-01AA7 Hose 2

32 07000-B3032 O-ring 8


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CHASSIS (STANDARD SPECIFICATION)


41 209-09-51170 Bolt 10 For installing counterweight 47

42 209-46-11210 Spacer 10

43 21N-30-37140 Ladder 2 For installing track frame step 39

44 01010-81635 Bolt 8

45 01643-31645 Washer 8

46 21N-53-32132 Step assembly 1 For installing left side step 48, 49

47 01024-81240 Bolt 20

48 21N-53-31362 Step 1

49 01024-81240 Bolt 20

50 01024-81230 Bolt 2

51 21N-53-31982 Bracket 1

52 01024-81230 Bolt 6

53 21N-54-39950 Step 1

54 01024-81240 Bolt 6

55 X21-0878191 Handrail assembly 1

56 01010-81645 Bolt 10

57 01643-31645 Washer 10


59 01010-81645 Bolt 6

60 01643-31645 Washer 6


62 01010-81645 Bolt 6

63 01643-31645 Washer 6

64 8285-54-1570 Chain 1

65 21N-53-32420 Bracket 1

66 01024-D1225 Bolt 1

66-1 08037-01610 Grommet 167 21N-54-32490 Ladder 1 50


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68 21N-54-39661 Step 1 For installing right side step 43

69 01024-81230 Bolt 4

70 21N-54-42430 Step 1

71 01024-81230 Bolt 2

72 21N-54-39640 Step 1

73 01024-81240 Bolt 8

74 21N-54-39650 Handrail 2

75 01024-81235 Bolt 8

76 21N-54-39611 Handrail 1

77 01024-81230 Bolt 4

78 21N-54-39621 Handrail 1

79 01024-81230 Bolt 4

80 21N-54-39631 Handrail 1

81 01024-81230 Bolt 12

82 01024-81240 Bolt 4

83 21N-54-41721 Handrail 1 For installing handrail 44

84 01024-81240 Bolt 8

85 21N-54-41741 Handrail 1

86 01024-81235 Bolt 4

87 21N-54-37241 Handrail 1

88 01024-81230 Bolt 6

89 21N-54-41711 Handrail 1

90 01024-81230 Bolt 10

91 21N-54-39571 Handrail 1

92 01024-81235 Bolt 2

93 21N-54-41351 Duct assembly 1 For installing radiator cover(STD)

51

94 01024-81230 Bolt 8

95 01011-81220 Bolt 4

96 01643-31232 Washer 4

97 21N-54-41361 Cover 1

98 01011-81200 Bolt 2

99 01643-31232 Washer 2

100 01024-81280 Bolt 3


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116 X21-1223090 Rain cap assembly 1 For installing exhaust piping 56

117 01024-81235 Bolt 6

117-1 20Y-54-51820 Handrail 1 For installing handrail for cab 58

118 21N-53-32510 Support 1 For installing L.H. rear viewmirror

59

119 20Y-54-35430 Clamp 1

120 01252-71025 Bolt 2

121 421-54-25610 Mirror 1

122 04025-00632 Pin 1

123A 21N-54-41751 Support 1 For installing R.H. rear viewmirror

61

123B 21N-54-42440 Support 1

124 20Y-54-27991 Clamp 2

125 01252-71025 Bolt 4

126 421-54-25610 Mirror 2

127 04025-00632 Pin 2

128 01252-70545 Bolt 8


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CHASSIS (EU SPECIFICATION)


1 21N-30-11180 Bolt 40 For connecting track frame 32

2 21N-30-37130 Spacer 40

3 150-74-11140 Bolt 56 For connecting center frame 42

4 01643-33380 Washer 56

5 02896-11009 O-ring 2 For installing travel piping 35

6 02896-11018 O-ring 2

7 07000-B3032 O-ring 4

8 07094-31228 Clamp 8

9 07095-01241 Cushion 8

10 01024-81285 Bolt 8

11 08036-03014 Clip 6

12 04434-52512 Clip 6

13 07095-20318 Cushion 6

14 01024-81225 Bolt 10

15 21N-30-37411 Cover (L.H.) 1 For installing travel pipingcover

37, 38

16 21N-30-37421 Cover (R.H.) 1

17 01024-81225 Bolt 8

18 21N-30-37370 Cover (L.H.) 1

19 21N-30-37381 Cover (R.H.) 1

20 01010-81230 Bolt 8

21 175-54-34170 Washer 8

22 21N-30-37390 Cover 1

23 01010-81230 Bolt 6

24 175-54-34170 Washer 6

25 209-62-52560 Pin 1For installing swivel and travelpiping

45

26 01641-21626 Washer 1

27 04050-14028 Pin 1

28 02896-11009 O-ring 1

29 07002-12434 O-ring 1

30 07073-01A08 Hose 2

31 07073-01AA7 Hose 2

32 07000-B3032 O-ring 8


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33 01024-81230 Bolt 8 For sticking sheet

(counterweight)

(EU Spec.)

46

34 21N-46-35320 Cover 1

35 21N-46-35310 Cover 1

36 21N-46-35281 Sheet 1

37 21N-46-35271 Sheet 1

38 21N-46-35261 Sheet 1

39 21N-46-35253 Sheet 1

40 21N-46-35211 Sheet 1

41 209-09-51170 Bolt 10 For installing counterweight 47

42 209-46-11210 Spacer 10

43 21N-30-37140 Ladder 2 For installing track frame step 39

44 01010-81635 Bolt 8

45 01643-31645 Washer 8

46 21N-53-32132 Step assembly 1 For installing left side step 48, 49

47 01024-81240 Bolt 20

48 21N-53-31362 Step 1

49 01024-81240 Bolt 20

50 01024-81230 Bolt 2

51 21N-53-31982 Bracket 1

52 01024-81230 Bolt 6

53 21N-54-39950 Step 1

54 01024-81240 Bolt 6


56 01010-81645 Bolt 10

57 01643-31645 Washer 10


59 01010-81645 Bolt 6

60 01643-31645 Washer 6


62 01010-81645 Bolt 6

63 01643-31645 Washer 6

64 8285-54-1570 chain 1

65 21N-53-32420 Bracket 1

66 01024-D1225 Bolt 1

67 21N-54-32490 Ladder 1 50


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68 21N-54-39661 Step 1 For installing right side step 43

69 01024-81230 Bolt 4

70 21N-54-42430 Step 1

71 01024-81230 Bolt 2

72 21N-54-39640 Step 1

73 01024-81240 Bolt 8

74 21N-54-39650 Handrail 2

75 01024-81235 Bolt 8

76 21N-54-39611 Handrail 1

77 01024-81230 Bolt 4

78 21N-54-39621 Handrail 1

79 01024-81230 Bolt 4

80 21N-54-39631 Handrail 1

81 01024-81230 Bolt 12

82 01024-81240 Bolt 4

83 21N-54-41721 Handrail 1 For installing handrail 44

84 01024-81240 Bolt 8

85 21N-54-41741 Handrail 1

86 01024-81235 Bolt 4

87 21N-54-37241 Handrail 1

88 01024-81230 Bolt 6

89 21N-54-41711 Handrail 1

90 01024-81230 Bolt 10

91 21N-54-39571 Handrail 1

92 01024-81235 Bolt 2

101 01023-10408 Bolt 2 For installing radiator cover(EU Spec.)

52 - 55

102 20B-54-12210 Spring 1

103 20Y-54-29232 Bar 1

104 195-Z11-2970 Cap 17

105 21N-54-41830 Net 2

106 21N-54-41811 Duct 1

107 21N-54-41880 Seal 4

108 01024-80816 Bolt 8

109 01024-81240 Bolt 14

110 21N-54-41851 Blade 16

111 01024-81020 Bolt 32

112 21N-54-41860 Frame 4

113 01024-80616 Bolt 32


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114 21N-54-41821 Cover 1 For installing radiator cover(EU Spec.)

54, 55

115 01024-81235 Bolt 23

116 X21-1223090 Rain cap assembly 1 For installing exhaust piping 56

117 01024-81235 Bolt 6

117-1 20Y-54-51820 Handrail 1 For installing handrail for cab 58

118 21N-53-32510 Support 1 For installing L.H. rear viewmirror

59

119 20Y-54-35430 Clamp 1

120 01252-71025 Bolt 2

121 421-54-25610 Mirror 1

122 04025-00632 Pin 1

123A 21N-54-41751 Support 1 For installing R.H. rear viewmirror

61

123B 21N-54-42440 Support 1

124 20Y-54-27991 Clamp 2

125 01252-71025 Bolt 4

126 421-54-25610 Mirror 2

127 04025-00632 Pin 2

128 01252-70545 Bolt 8


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WORK EQUIPMENT


129 21N-72-11230 Shim 8 For installing boom cylinderfoot

76

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

hose

77

131 07000-13048 O-ring 2

132 21N-72-11210 Shim 3 For installing boom assembly 79

133 21N-72-11220 Shim 3

134 707-01-XZ501 Boom cylinder (L.H.) 1 For installing boom cylinder 80

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

136 21N-72-11230 Shim 2

137 07099-01218 Hose 2 For installing boom hose 81

138 07000-13038 O-ring 4

139 07099-01418 Hose 4

140 07000-13048 O-ring 10

141 707-01-XZ522 Arm cylinder 1 For installing arm cylinder 74

142 21N-72-11210 Shim 2

143 07098-01418 Hose 3 (For STD boom) 75

07098-01421 Hose 3 (For SE boom)

144 07000-13048 O-ring 6 For installing arm cylinder hose

145 21N-72-11210 Shim 4 82

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

hose

84

147 07000-13048 O-ring 4

148 21N-62-38620 Hose 2

149 07000-13038 O-ring 4


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WORK EQUIPMENT


150 21N-70-14220 Bushing 1 For installing bucket assembly 85

151 21N-70-13150 O-ring 2

152 21N-70-14320 Shim 14

153 21N-70-14330 Shim 4

154 21N-72-11230 Shim 3 87

155 07000-16215 O-ring 2

156 07020-00675 Fitting 2 For installing work equipmentlubrication piping(boom cylinder)

89

157 17A-06-17930 Lamp 2 For installing work equipmentwiring

94

158 20Y-06-21551 Bracket 2

159 08193-20012 Clip 2

160 01024-81230 Bolt 2

161 209-60-77551 Filter element 2 For assembling return filterflushing (chassis)

98

162 21T-60-13730 Plate 2

163 21N-62-19370 Tube 4 For installing work equipmentflushing tube (chassis)

102, 103

164 21N-62-19340 Tee 1

165 424-16-11140 Filter element 1 For assembling pilot filterflushing (chassis)

105

Parts that are not assembled (kept in tool box as they are)

166 07270-51210 Tube 1 For draing water in fuel tank

167 07281-00167 Clamp 1 For draining

168 07377-01018 Flange 2 For flushing travel piping

169 X211216270 Tool assembly 1 Standard tool

170 209-72-11311 Seal 4 For installing boom foot 78


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A. ASSEMBLY OF CHASSIS

Remarks

1. In the "drawings" in this manual, parts and places are indicated by1,2,3---,but indicated by (1), (2), (3) --- in the tables and texts.

Example:

2. In some places of this manual, the words of front, rear, right hand and left hand

of machine are used. Those words indicate the directions seen from the opera-

tor's seat with the sprocket at the rear as shown below, unless otherwise speci-

fied.

(1) Plate

(2) Collar

(3) Washer

(4) Bolt

(5) Bolt

(6) Washer

Front

Left hand Right hand

Operator's seat

Rear

SprocketRear

Front

Left hand Right hand

Operators seat

Sprocket


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1. Place either track frame assembly on a flat plate.

Weight of track frame assembly (1 piece): 15,250 kg

2. Sling the center frame assembly and position it on the track frame and then install it with mounting bolts (1) and (2) (Tighten

the mounting bolts temporarily with KW20P impact wrench).

Assembly procedure

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

Precautions Necessary tools Necessary equipment

. Name Qty Name Qty

30 5000 wire 2 45 ton crane 1

20 5000 wire 4

50 500 pin 2

BC20 shackle 4

KW20P impact wrench 1

M60 socket 1

Others

Center Frame Assembly: 9,700 kg

No. Loose-supply i tems Qty

1 21N-30-37130 40

2 21N-30-11180 40


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Secure two points of the center frame of the track by placing a hydraulic jack and a 300 400 mm wooden block at

each point. Make sure that these points do not interfere with the upper structure rotation.

Lift the Track Frame Assembly and install it on the Center Frame.

Assembly procedure



Name Qty Name Qty

30 5000 wire 2 45 ton crane 1

50 500 pin 2

Wooden block (400 300 mm) 2

50 t jack 2

Others


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34

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

a Retighten with a 16 power wrench or a 420 kg torque wrench.

(When using a 420 kg torque wrench, pull it with 1.5 t lever block.)

Assembly procedure



Do not remove the shoes before assembling(so as to maintain the tightening torques ofthe shoe bolts).

Name Qty Name Qty

16 time wrench 1

Torque wrench (42 kg) 1

M60 Socket 1

Torque wrench (420 kg) 1

20 t jack 1

Wooden block (100 200 mm) 1

1.5 t lever block 1

Others

Thickness of 100 mm

Wooden block

3Connection bolt of track frame and center frame2,890 3,630 Nm {295 370 kgm}


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Assembly procedure

Installation of Travel Piping (1/2)A-2


1. When connecting the hoses, check thatthe mating faces are free from foreignmatter or flaw.

2. Keep the removed flanges and heads sothat they can be reused.

3. When installing a hose, take extreme carethat the O-ring will not be caught.

Name Qty Name Qty


M14 socket 1

L150 extension 1

Spanner, 22 mm width across flats 2


M19 socket 1

Oil receiving pan 2

Others

Fix pilot hose and

drain hose together

with clamps.

No. Loose-supply items Qty

1 07094-31228 8

2 07095-01241 8

3 01024-81285 8

4 04434-52512 6

5 07095-20318 6

6 01024-81225 10

7 08036-03014 6

10 07000-B3032 4

11 02896-11009 2

12 02896-11018 2No. Parts already installed to body Qty

8 07371-31049 8

9 07375-21035 16

(1) Remove the oil plugs of the tubes and hoses on the center frame side and install

new O-rings

(07000-B3032: 4 pieces, 02896-11009: 2 pieces, 02896-11018: 2 pieces).

(2) Connect the 4 main hoses installed on the track frame to the center frame side

and fix them with clamps (1), (2), and (3).

(3) Connect 2 right pilot hoses and 2 left ones to the center frame and fix them with

clamps (4), (5), and (6).

(4) Connect 2 right drain hoses and 2 left ones to the center frame and fix them with

clamps (7) and (6).

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


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36

Assembly procedure

Installation of Travel Piping (2/2)A-2


Name Qty Name Qty

Others

Hose connection diagram

Main hose

Drain hose

Pilot hose


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37

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

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

Assembly procedure

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


Name Qty Name Qty


M19 socket 1

Others


1 21N-30-37390 1

2 01010-81230 6

3 175-54-34170 6

4 21N-30-37421 1

5 01024-81225 8

6 21N-30-37411 1


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

Assembly procedure

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


Name Qty Name Qty


M19 socket 1

L150 extension 1

Others


1 21N-30-37381 12 21N-30-37370 1

3 01010-81230 8

4 175-54-34170 8


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

Assembly procedure

Installation of StepsA-4


Name Qty Name Qty


M24 socket 1

Others

No. Loose-supply i tems Qty1 21N-30-37140 2

2 01010-81635 8

3 01643-31645 8

3Tightening torque for step mounting bolt245 309 Nm {25 31.5 kgm}


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1) Pour grease (G2-Ll) in the swing circle grease bath. See Note 1.

2) Apply grease to the swing circle gear contacting surfaces. (Approx. 10 lof above 65 l)

3) Fill the grease bath seal with grease.

Assembly procedure

Filling Swing Circle with GreaseA-5


a Degrease and de-rust the mating faces of the

swing circle and upper structure.

Name Qty Name Qty

Others

4) Apply LG-6.

(Note 1)

Supply grease near swing

circle gear.


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

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

Assembly procedure

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


Name Qty Name Qty

OthersApply LG-6 to swing circle gear side

of assurance mounting bolts.

(Note 1)

See Note 1.

Clean mating faces.


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(3) Sling the upper structure and install it with bolts (1) and washers (2).

(Do not hit the upper structure against the center frame or grease bath.)

(4) Tighten all the bolts with the fingers as hard as possible. Retighten them after completing assembly. (Apply LT-2)

Tighten the 4 bolts on the right and left sides permanently.

Assembly procedure

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


Name Qty Name Qty

30 5000 wire 4 45 t crane 2

BC36 shackle 2 Special eyebolt 2

KW45F impact wrench 1

M50SP socket 1

Others


1 150-74-11140 56

2 01643-33380 56

3Tightening torque for bolt1,960 2,450 Nm {200 250 kgm}


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(1) Install right front step (1) with bolts (2) and install handrail (3) with bolts (2) and (4).

(2) Install right side steps (5) and (6) with bolts (4) and install right and left handrails (9) with bolts (10).

(3) Install handrails (7) and (8) with bolts (4).

Assembly procedure

Installation of Right Side StepsA-7


Name Qty Name Qty

KKW12P impact wrench 1

M19 socket 1

L150 extension 1

Others


1 21N-54-39640 1

2 01024-81240 12

3 21N-54-39631 1

4 01024-81230 26

5 21N-54-39661 1

6 21N-54-42430 1

7 21N-54-39611 1

8 21N-54-39621 1

9 21N-54-39650 2

10 01024-81235 8


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(1) Install handrails (1) and (2) on the fuel tank with bolts (5).

(2) Install handrail (3) on the aftercooler cover with bolts (7).

(3) Install handrail (4) on the side of the hood with bolts (6).

Assembly procedure

Installation of HandrailsA-8


Name Qty Name Qty


M19 socket 1

L150 extension 1

Others


1 21N-54-37241 1

2 21N-54-41711 1

3 21N-54-41721 1

4 21N-54-41741 1

5 01024-81230 166 01024-81235 6

7 01024-81240 8

8 21N-54-39571 1


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1) Install the lock plate to the swivel joint.

2) Remove the oil plugs of the tubes, T-piece, and swivel joint on the revolving frame side and install new O-rings

(07000-B3032: 8 pieces, 07002-12434: 1 piece, 02896-11009: 1 piece)

3) Install the pilot hose and drain hose to the elbow and T-piece.

4) Install the main hoses (4 pieces) to the swivel joint.


Assembly procedure

Installation of Swivel Travel PipingA-9


1. The lock plate, drain hoses, and pilot hose are

installed to the upper structure.

2. Keep the removed flanges and heads so that

they can be reused.

3. When installing a hose, take extreme care that

the O-ring will not be caught.

4. When installing a hose, take extreme care that

dirt will not enter the circuit.

Name Qty Name Qty

KW12P impact wrench 1 Large oil receiving pan 1

L150 extension 1

M14 socket 1



Others

Connect 2 drain hoses.

Connect 4 main hoses.

Connect pilot hose.

Connect lock plate.


1 209-62-52560 1

2 01641-21626 1

3 04050-14028 1

4 02896-11009 1

5 07002-12434 16 07073-01A08 2

7 07073-01AA7 2

8 07000-B3032 8

No. Parts already installed to body Qty

9 07371-31049 16

10 07375-21035 32


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

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


a Remove all oil and rust from the surface

where the sheet is to be stuck.

Name Qty Name Qty

Others


1 21N-46-35261 1

2 21N-46-35310 1

3 21N-46-35271 1

4 21N-46-35281 1

5 21N-46-35320 16 21N-46-35253 1

7 21N-46-35211 1

8 01024-81230 8


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

Assembly procedure

Installation of CounterweightA-11


Install the counterweight so that there will bethe reference space of 15 mm between theweight and the revolving frame or so that theleft level difference equals to the right one.

Name Qty Name Qty

36 5000 wire 2 45 t crane 1

BC40 shackle 2

KW45SP impact wrench 1

M65SP socket 1

420 kgm torque wrench 1

38.1 square socket,65 mm width across flats

1

Others

Weight of counterweight assembly: 17,900 kg


1 209-09-51170 10

2 209-46-11210 10

3Tightening torque for counterweight mounting bolt3,430 4,212 Nm {350 430 kgm}


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(1) Install step (1) at front of the cab with bolts (2).

(2) Install step (3) on the side of the cab with bolts (2) and install step (4) with bolts (5).

(3) Install step (6) on the side of the pump with bolts (2) and (5).

Assembly procedure

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


aAdjust the level difference between the steps

to 10 mm or less.

Name Qty Name Qty

KW12P impact wrench 1 25 t crane 1

M19 socket 1

L150 extension 1

M12 eyebolt 2

Others


1 21N-54-39950 1

2 01024-81240 46

3 21N-53-31362 14 21N-53-31982 1

5 01024-81230 8

6 21N-53-32132 1


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

Assembly procedure



Name Qty Name Qty

KW12P impact wrench 1 25 t crane 1

M19 socket 1

L150 extension 1

25 wide 3,000 nylon sling 2

Others


1 X21-0878211 1

2 01010-81645 22

3 01643-31645 22

4 X21-0878201 1

5 X21-0878191 1

6 8285-54-1570 17 21N-53-32420 1

8 01024-D1225 1

9 08037-01610 1


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(6) Install the maintenance ladder to the step at the rear of the left side.

Install the ladder from the underside of the step.

Open the catch lock.

Put one end of the ladder (upper end of the ladder) on the rack at the front of the step and install the other end to the

hook installed to the catch lock. Close the catch lock.

Assembly procedure



Name Qty Name Qty

Others

Catch lock

Install to hook.


1 21N-54-32490 1


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Install the radiator cover to the machine.

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


a Eliminate the level difference between the

radiator cover and mounting frame.

Name Qty Name Qty

Others

100

8(3)


1 21N-54-41351 1

2 01024-81230 8

3 01011-81220 4

4 01643-31232 4

5 21N-54-41361 1

6 01011-81200 2

7 01643-31232 2

8 01024-81280 3


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

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

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


Name Qty Name Qty

Others


1 21N-54-41811 12 21N-54-41830 2

3 01024-80816 8

4 21N-54-41880 4

3Tightening torque for net fixing bolt14.7 34 Nm {1.5 3.5 kgm}


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



a Eliminate the level difference between the

radiator cover and mounting frame.

Name Qty Name Qty

10 3000 wire 2 25 t crane 1

Others

Weight of cover assembly: 150 kg


1 01024-81240 14

3Tightening torque for cover mounting bolt54 123 Nm {5.5 12.5 kgm}


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(4) Fix spring (2) to grille frame (1) with screws (3) and insert bar (4).

(5) Install blade (5) to the frame temporarily with bolts (6), set the holes of plate (7), install bolts (8),

and tighten the bolts permanently.



Name Qty Name Qty

Others


1 21N-54-41821 1

2 20B-54-12210 1

3 01023-10408 2

4 20Y-54-29232 1

5 21N-54-41851 16

6 01024-81020 32

7 21N-54-41860 4

8 01024-80616 32

3Tightening torque for blade mounting bolt54 123 Nm {5.5 12.5 kgm}

3Tightening torque for plate mounting bolt8.8 14.7 Nm {0.9 1.5 kgm}


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(6) Sling the grille frame assembly, set the bolt holes of the hinge first, and tighten bolt (1).

Adjust the level difference from the cover, close the grille, and tighten the other bolts.

4Weight of grille frame assembly: 160 kg

(7) After tightening the bolts, insert caps (2).



a Eliminate the level difference from the cover. Name Qty Name Qty

10 3000 wire 2 25 t crane 1

Others


1 01024-81235 23

2 195-Z11-2970 17

3Tightening torque for frame mounting bolt54 123 Nm {5.5 12.5 kgm}


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

Assembly procedure

Installation of Muffler Tail PipeA-14


Name Qty Name Qty


M19 socket 1

Others

3Tightening torque for cover mounting bolt54 123 Nm {5.5 12.5 kgm}


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1) After removing dummy bolt, remove step light, bolt, and washer.

2) Change the mounting position and direction of step light.

Assembly procedure

Changing of Mounting Position of Step LightA-15


Name Qty Name Qty

Others

During transportation

(Position: On the head guard)

(Direction: Toward the chassis)

After transportation

(Position: Upper side of cab)

(Direction: Obliquely downward to

outside of chassis)

Remove dummy bolt

Spanner

(width across flats 17 mm)


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

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

Assembly procedure

Installation of Handrail to the CabA-16


Name Qty Name Qty

Others


1 20Y-54-51820 1


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(1) Install support (1) to the cabin handrail with clamp (2) and bolts (3) and then set and fix mirror (4) with roll pin (5).

Assembly procedure

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


For installation of the mirror,use 209-98-77220.Adjust the mirror to the best position.(For the view range, see Installation manualfor mirror 21N-98-41131.)

Name Qty Name Qty

Others


1 21N-53-32510 1

2 20Y-54-35430 1

3 01252-71025 2

4 421-54-25610 1

5 04025-00632 1


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Pass pin (5) through the hole in ball busing (A), hold the mirror with the holder of mirror (1), then secure in position and

check that the mirror does not move.

Assembly procedure

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


Name Qty Name Qty

Others

Insert pin (5) in this hole

Holder

Replace the screw (421-54-25660) of the mirror assembly

part with the hexagon head bolt (6) (01252-70545), and

tighten it.

Tightening torque: 1.5 2.0 Nm {0.15 0.2 kgm}


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(1) Install support (1) to the right front handrail with clamps (3) and bolts (4),

set roll pin (6) to mirror (5), and fix the mirror with bolts (7).

(2) Install support (2) to the right front handrail with clamps (3) and bolts (4),

set roll pin (6) to mirror (5), and fix the mirror with bolts (7).

Assembly procedure

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


For installation of the mirror,use 209-98-77220.Adjust the mirror to the best position.(For the view range, see Installation manualfor mirror 21N-98-41131.)

Name Qty Name Qty

Others


1 21N-54-41751 1

2 21N-54-42440 1

3 20Y-54-27991 2

4 01252-71025 4

5 421-54-25610 26 04025-00632 2

7 01252-70545 8


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Pass pin (5) through the hole in ball busing (A), hold the mirror with the holder of mirror (1), then secure in position and

check that the mirror does not move.

Assembly procedure

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


Name Qty Name Qty

Others

Insert pin (5) in this hole

Holder

Replace the screw (421-54-25660) of the mirror assemblypart with the hexagon head bolt (6) (01252-70545), andtighten it.Tightening torque: 1.5 2.0 Nm {0.15 0.2 kgm}


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Air is to be bled from the travel motor in assembly procedure [A-19]. Before starting the travel motor, loosen the air bleeder

and bleed air from the circuit.

1) Open the hydraulic tank cap.

(Keep the cap placed on the filler lightly to prevent dirt and rain from entering the tank.)

2) Prepare an oil receiver at the vinyl hose end. (Approx. 20 lcan/Each side)

3) Loosen air bleeder (5).

(The air bleeding vinyl hose is installed when the machine is delivered.)

a Keep the air bleeder loosened and opened during the work equipment assembly work.

(Check the air bleeding oil level occasionally and take care that the oil will not spill.)

Assembly procedure

Preparation for Bleeding Air from Travel MotorA-19


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Others

Air bleeding vinyl hose


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1. Bleeding air from hydraulic pump group

a If a hydraulic pump was removed and installed or a related piping was disconnected and connected, bleed air from the

hydraulic pump group according to the following procedure.

1) Loosen air bleeders (1), (2) and (3) 4 turns.

2) Loosen the oil filler cap of the hydraulic tank and leave it for about 10 minutes.

a The above time depends on the oil level in the pump case.

3) When oil flows out of air bleeders (1) and (2), tighten air bleeders (1) and (2).

4) Run the engine at low idle.

a Set the work equipment lock lever in the lock position to prevent the work equipment from moving.

5) When clear oil flows out of air bleeders (3), tighten air bleeder (3).

Assembly procedure

Procedure for Bleeding Air From Hydraulic CircuitA-20


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In the procedure for assembly of the upper structure and undercarriage, only 4 of the 56 revolving frame and swing circle mounting

bolts were tightened permanently and the other 52 bolts were tightened temporarily. Tighten those 52 bolts in this step.

(1) Start the engine.

(2) Swing the upper structure to set the bolts to the places (right and left) marked with * in the figure and tighten the bolts to

the specified torque.

Assembly procedure

Permanent Tightening of Swing Circle Mounting BoltsA-21


a While swinging the upper structure and tight-

ening the bolts, make signs securely.

Name Qty Name Qty

KW45F impact wrench 1

M50 socket 1

Others

Width across flats 50

3Tightening torque for bolt1960 2450 Nm {200 250 kgm}


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Assembly procedure

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


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Others


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Assembly procedure



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Grease cylinder


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Assembly procedure



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Dont stand at the front.

Dont look inside.

Warning


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Assembly procedure

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


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Others


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Assembly procedure

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


Non-amine Supercoolant (Blue) is addedwhen shipped. Do not mix coolant ofdifferent type with it.

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Others


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Assembly procedure

Parts to be Touched up after Field AssemblyA-24


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Others


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B. ASSEMBLING OF WORK EQUIPMENTOF BACKHOE

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


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

4 Arm cylinder foot pin: 92.9 kg (Standard boom): 101.3 kg (SE boom)

(2) Sling the arm cylinder and set it to the hole of the boom.

Adjust shim (1) (21N-72-11210) so that the clearance in the foot will be 2 mm 3 mm.

4 Weight of arm cylinder: 1,500 kg

(3) Drive in the arm cylinder foot pin.

2 Inside of pin hole: Apply lithium grease.

(4) Install the lock plate.

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

Assembly procedure

Installation of Arm CylinderB-1


1. When working, bind the arm cylinder rodto prevent it from coming out.



4. When installing a hose, take extreme carethat dirt will not enter the circuit.

Name Qty Name Qty

50 wide 3,000 nylon sling 2 25 t crane 1

KW380 impact wrench 1 5 step stepladder 1

M36 socket 1

Sledge hammer 1

Others

Lock plate

Arm cylinder foot pin


1 21N-72-11210 2

2 707-01-XZ522 1


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(1) Remove the boom cylinder foot pin lock plate fixed to the machine body and pull out the pin.

(2) Sling the boom cylinder and position it to the machine body and then adjust shim (1) so that the clearance

(on the outside of the machine body) between the boom cylinder and revolving frame will be 2 mm 3 mm.

4 Weight of boom cylinder (each): 1,200 kg

(3) Insert wooden blocks between the cylinder and revolving frame to support the boom cylinder.

(Height: 40 50 mm, Width: Max. 90 mm)

(4) Push in the boom cylinder foot pin fully and install the lock plate.

Assembly procedure

Installation of Boom Cylinder FootB-3


Name Qty Name Qty


KW20P impact wrench 1 Wooden block 2

M24 socket 1

Others

Wooden blocks

to support boom

cylinder

3Tightening torque for lock plate bolt147 309 Nm {15 31.5 kgm}


1 21N-72-11230 8


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(1) Remove the oil plugs from the tubes on the boom cylinder side and from the hoses on the revolving frame side and install

new O-rings (07000-13038: 2 pieces, 07000-13048: 2 pieces).

(2) Install boom cylinder hoses (1) and (5) (4 pieces) as shown below.

a The boom cylinder hoses are installed to the upper structure (machine body).


Assembly procedure

Installation of Boom Cylinder HosesB-4





Name Qty Name Qty

KW12P impact wrench 1 Oil receiving pan (small) 2

L150 extension 1

M19 socket 1

M22 socket 1

Others

No. Parts installed to machine body Qty

1 07099-01216 2

2 07371-51260 4

3 01024-81245 8

5 07099-01416 2

6 07371-51470 4

7 01010-81455 8

8 01643-31445 8No. Loose-supply items Qty

4 07000-13038 2

9 07000-13048 2


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(1) Install the seal (209-72-11311) to the boom foot

Assembly procedure

Installation of Boom Foot Dust SealB-5


1. Take care of the direction of its lip so thatthe grease can come out from inside.

2. When installing the seal, be careful not toslant it.

3. Insert the seal until it touches the bushing.

4. Do not hit seal with hammer directly butuse template, etc. to hit.

Name Qty Name Qty

Hammer 1

Template 1

Others

Take care of the

direction of its lip.

Take care of the

direction of its lip.

170

170


1 209-72-11311 4


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(1) Sling the boom assembly with the crane and set it to the pin holes of the machine.

4Weight of boom assembly: 12,700 kg.

(2) Push the boom foot pin (which has been installed to the revolving frame) into either pin hole until it stops and then set its

opposite end into the other pin hole. If the boom slants to the right or left at this time, adjust it with a lever block.

a Adjust the clearance at the boom foot on the outside of the machine to 1 mm or less with the shim.

Combine the shims 1.0 mm thick (21N-72-11210, 3 pieces) and 1.5 mm thick (21N-72-11220, 3 pieces) to obtain properthickness. (Adjust the shim at only 1 place on the outside of the boom.)

(3) Push in the right and left boom foot pins fully and install the lock plates.

Assembly procedure

Installation of Boom AssemblyB-6


a Inside of pin hole: Apply lithium grease.

a When inserting the pins, take care not to dam-

age the seal (209-72-11311)

installed to the boom foot (Align the pins se-

curely).

Name Qty Name Qty

30 5000 wire 2 25 t crane 1

SD32 shackle 2 5 step stepladder 1

KW20 impact wrench 1

M24 socket 1

Sledge hammer 1

Others

When operating crane, install ropes to

boom assembly end to prevent boom

assembly from swinging.


1 21N-72-11210 3

2 21N-72-11220 3

3Tightening torque for plate mounting bolt245 309 Nm {25 31.5 kgm}


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

4Boom cylinder top pin: 43.8 kg 2 pieces

(2) Start the engine and run it at low idle.

(3) Sling the cylinder, push the rod slowly, set the pin holes, and check the clearance between cylinder boss end and boom

boss end. Insert a proper number of shims so that the clearance will be 2 3 mm, push in the pin, and install the lock plate.


Assembly procedure

Installation of Boom CylinderB-7


aBefore connecting the boom cylinder, bleed

air. See the section of bleeding air from cylin-

der.

Name Qty Name Qty



M24 socket 1

Sledge hammer 1

Others

Lock plate

Boom

cylindertop pin


No. Loose-supply i tems Qty1 707-01-XZ501 1

2 707-01-XZ511 1

3 21N-72-11230 2


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(1) Remove the oil plugs from the tubes on the boom side and revolving frame side and install new O-rings

(07000-13048: 10 pieces, 07000-13038: 4 pieces).

(2) Install the boom hoses (7 pieces) as shown below.


Assembly procedure

Installation of Boom Hoses (Between machine and boom)B-8





Name Qty Name Qty

KW12P impact wrench 1 Oil receiving pan 1

L150 extension 1

M19 socket 1

M22 socket 1

Others

No. Parts installed to machine body Qty

2 07371-51470 20

3 01010-81455 40

4 01643-31445 40

7 07371-51260 8

8 01024-81245 16


1 07099-01418 55 07000-13048 10

6 07099-01218 2

9 07000-13038 4


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(1) Remove the boom top pin lock plate installed to the boom and pull out the top pin.

4Boom top pin: 168.6 kg

(2) Sling the arm assembly and set it to the holes of the boom.

Insert shim (21N-72-11210) 1.0 mm thick to reduce the clearance to below 1.0 mm and push in the pin.

4Weight of arm assembly: 6,200 kg2 Inside of bushing: Apply grease.2 Pin: Apply grease.


Assembly procedure

Installation of Arm Assembly (1/2)B-9


a When inserting the pin, take care not to dam-

age the seal (209-72-11311) installed in the

bushing on the arm side.

Name Qty Name Qty

25 5000 wire 2 25 t crane 1

SD32 shackle 2 5 step stepladder 1

Sledge hammer 1


M24 socket 1

Others

Lock plateLock plate

Take care of grease holeof arm cylinder rod.Set grease hole to top.

Boom

Arm

Boomtop pin

Arm assembly top pin



1 21N-72-11210 4


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(4) Remove the arm cylinder top pin lock plate installed to the arm and pull out the top pin.

4Weight of arm cylinder top pin: 97.9 kg

(5) Run the engine at idle and extend the arm cylinder piston rod slowly to set it to the pin hole.

(At this time, sling the arm cylinder with the crane and position the piston rod while operating.)

(6) Set the arm cylinder top hole to the arm hole, insert shim (21N-72-11210) 1.0 mm thick to adjust the clearance to 2 3 mm,

and push in the pin.



a 1) Operate the cylinder lever slowly. Do not operate it quickly or to the stroke end. Since there is air in the cylinder, the

piston rod may not move for more than 10 seconds. Do not move the lever to the stroke end at this time.2) When installing the arm, take care that the bucket cylinder rod will not come out.

Assembly procedure

Installation of Arm Assembly (2/2)B-9


a Before connecting the arm cylinder, bleed air.

See the section of bleeding air from cylinder.

Name Qty Name Qty


Sledge hammer 1 5 step stepladder 1


M24 socket 1

Others



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(1) Remove the oil plugs from the bucket cylinder and from the tubes on the boom side and install new O-rings

(07000-13038: 4 pieces, 07000-13048: 4 pieces).

(2) Install bucket cylinder hoses (1) and (5) (4 pieces) as shown below.

a When assembling, take care that the protection wires installed to the hoses will not come off the hose adapters.


Assembly procedure Installation of Bucket Cylinder Hosesbetween Boom and Bucket CylinderB-10


1. Keep the removed flanges and heads so that

they can be reused.

2. When installing a hose, take extreme care

that the O-ring will not be caught.

3. When installing a hose, take extreme care

that dirt will not enter the circuit.

Name Qty Name Qty

KW12P impact wrench 1 5 step stepladder 1

L150 extension 1 Oil receiving pan 1

M19 socket 1

M22 socket 1

Others

Inside hoses

Outside hoses

Connect hoses in

parallel with cylinder.


1 21N-62-38620 2

2 07000-13038 4

5 21N-62-38610 2

6 07000-13048 4

No. Parts installed to boom/arm Qty

3 07371-51260 8

4 01024-81245 16

7 07371-51470 8

8 01010-81455 16

9 01643-31445 16


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(1) Remove the stoppers of the bucket and arm connecting pin (fixed to the arm) and bucket and link connecting pin (installed

to the link) and remove each pin.

(2) Install bushing (1) and 2 O-rings (2) to the boss on the bucket side.

(3) Run the engine at idle and operate the boom cylinder and arm cylinder slowly to set the holes for the bucket and arm con-

necting pin.

2Weight of bucket assembly: 5,100 kg

(4) Push in the arm and bucket connecting pin, adjust the clearance to 0.5 1.0 mm with shims (3) and (4), and tighten cover

mounting bolts (M30).


Assembly procedure

Installation of Bucket Assembly (1/3)B-11


Name Qty Name Qty

KW45F impact wrench 1 25 t crane 1

M46 socket 1

Others

3Tightening torque for cover mounting bolt1130 1910 Nm {115 195 kgm}


1 21N-70-14220 1

2 21N-70-13150 2

3 21N-70-14320 14

4 21N-70-14330 4


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(5) Install O-rings (2) to prevent dirt from entering the bucket and arm connecting pin to the correct positions and then install

the pin stopper.

Assembly procedure



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Stopper

3Tightening torque for stopper mounting bolt588 1030 Nm {60 105 kgm}


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(6) While slinging the link and operating the bucket cylinder, set the holes for the bucket and link connecting pin.

a Operate the cylinder lever slowly. Do not operate it quickly or to the stroke end. Since there is air in the cylinder, the piston

rod may not move for more than 10 seconds. Do not move the lever to the stroke end at this time.

(7) Push in the link and bucket connecting pin and adjust the clearance to below 1 mm with shims (6) 1.0 mm thick.

Install O-rings (5) to prevent entry of dirt to the correct positions and install the pin stopper.

Assembly procedure



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Others

a Since the shape of the link is

different from the former link,

disassemble and assemble

the arm in the vertical pos-

ture. If the arm is disassem-

bled in the horizontal posture,

in particular, the link jumps up

just after the pin is pulled out.

Take care extremely.

3Tightening torque for stopper mounting bolt588 1030 Nm {60 105 kgm}


5 07000-16215 2

6 21N-72-11230 3


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Assembly procedure

Clearance Standard for Installation of Work EquipmentB-12


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Unit: mm

No. Item Criterion

Clearance limit

(A) (9) Clearance between revolving frameand boom cylinder

Adjust clearance to 2 3 mmwith shim.

(B) (10) Clearance between revolving frameand boom

Adjust clearance to below 1 mmwith shim.

(C) (11) Clearance between boom and boomcylinder


(D) (12) Clearance between boom and armcylinder


(E) (13) Clearance between boom and arm Adjust clearance to below 1 mmwith shim.

(K) (18) Clearance between bucket and armAdjust clearance to 0.5 1 mmwith shim.

(J) (19) Clearance between bucket and linkAdjust clearance to below 1 mmwith shim.

(F) (20) Clearance between arm and armcylinder


Standard shim

thickness: 8

Adjusting clearanceof bucket and link

Adjusting clearanceof bucket and arm


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(1) Remove the oil plugs on the cylinder side of boom cylinder grease hoses (2 pieces) at part (a) and those on the hose nipple

side. Remove the nipples from the hoses and install them to the cylinder, and then connect the hoses.

(2) Remove the oil plugs on the cylinder side of arm cylinder foot grease hose at part (b) and that on the hose elbow side.

Remove the elbow from the hose and install it to the cylinder, and then connect the hose.

(3) Remove the oil plugs on the cylinder side of arm cylinder top grease hose at part (c) and that on the hose elbow side. Re-

move the elbow from the hose and install it to the cylinder, and then connect the hose.

(4) Remove the oil plugs on the right and left cylinder sides of boom cylinder foot grease fittings (07020-00675, 2 pieces) and

install the fittings.

Assembly procedure

Installation of Work Equipment Grease PipingB-13


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Others


1 07020-00675 2


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a If the travel motor or swivel joint was removed and installed

or a related piping was disconnected and connected, bleed

air from the hydraulic pump group according to the followingprocedure.

a Keep air bleeder (5) operated in assembly procedure

[A-10] loosened.

1) Run the engine and push up the track shoe on the side to

be bled of air by using the work equipment.

2) While running the engine at low idle, perform the following

travel operation and rotate the track shoe with no load.

(Operate the travel lever by a half stroke.)

Lever operation pattern and operation time (sec)

Assembly procedure

Procedure for Bleeding Air From Travel Motor (1/2)B-14


Name Qty Name Qty

Others

Unit = secForward

Forward

Neutral

Neutral

Neutral

Reverse

Reverse


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3) Check that the oil flowing through the air bleeding hose

contains no bubbles and then tighten air bleeder (5).

4) Remove the air bleeding hose and clip from the bleeder.

5) After finishing the following operation, push up the track

shoe on the opposite side and bleed air similarly.

6) Remove the air bleeding order tag plate. (Right and left)

Assembly procedure

Procedure for Bleeding Air From Travel Motor (2/2)B-14


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Others


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a If the swing motor was removed and installed or a re-

lated piping was disconnected and connected, bleed

air from the swing motor according to the following

procedure.

1) While running the engine at slow speed, swing and

stop the upper structure several times.

a Air is bled from the swing motor automatically by the

above operation.

Assembly procedure

Bleeding Air from Swing MotorB-15


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Others


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a If a hydraulic cylinder was removed and installed or a re-

lated piping was disconnected and connected, bleed air

from the hydraulic cylinder according to the following pro-

cedure.

1) Run the engine at idle for about 5 minutes.

2) While running the engine at slow speed, extend and re-

tract the cylinder 4 5 times.

a Move the piston rod to about 100 mm before each stroke

end and never relieve the pressure.

3) While running the engine at slow speed, move the piston

rod very slowly (taking at least 10 seconds) from a posi-

tion about 100 mm before the extension stroke end to the

stroke end and relieve the pressure for 3 minutes.

4) While running the engine at full throttle, move the piston

rod very slowly (taking at least 10 seconds) from a posi-

tion about 100 mm before the extension stroke end to the

stroke end and relieve the pressure for 1 minutes.

Assembly procedure

Bleeding Air from CylinderB-16


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Others


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

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

Assembly procedure

Installation of Work Equipment WiringB-17


Name Qty Name Qty

Others

Connect to wire

on boom side.

Connect to wireon machine side.

Detail of mounting portion


1 17A-06-17930 22 20Y-06-21551 2

3 08193-20012 2

4 01024-81230 2


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Assembly procedure

Greasing after Assembling Work EquipmentB-18


Name Qty Name Qty

Others


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M. PROCEDURE FOR INSPECTION AND MAINTENANCEAFTER COMPLETION OF ASSEMBLY


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


Store the removed standard element (209-60-75531)., strainer (20Y-60-31140). andvalve (20Y-60-31131) 2 pcs.in order because they are used again afterflushing.

Name Qty Name Qty

Others

Valve

Strainer

Replace the relief valve with this

plate only at the flushing time.

Special element for flushing,

Absolute filter mesh size: 6


1 209-60-77551 2

2 21T-60-13730 2


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


This work is performed after the flushing end. Name Qty Name Qty

Others

Valve

Strainer

Standard element

Replacement


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Assembly procedure Replacement of Return Filter(Standard FilterFlushing Filter) (3/3)M-1


The flushing filter must be discarded after use.The flushing filter is not allowed to be reused.

Name Qty Name Qty

field assembly pc1250lc-8 gen00055-05

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