Armado GEN00060-03

GEN00060-03
Field Assembly Instruction
HYDRAULIC
EXCAVATOR
PC2000 -8
SERIAL NUMBERS
PC2000-8-20001
and up
FOREWARD
Before starting the engine and assembling the work equipment, you must inspect and service the machine thoroughly. Since
you are frequently obliged to work alone or with other workers in dangerous places or postures, hold a safety meeting in advance and appoint a crane sign maker and a working leader so that all the workers can work safely.
Particularly when working in a foreign country, there are many unsafe factors because of differences in language, customs,
etc. Accordingly, the liaison person and work director in the field must examine the above items fully to secure the safely.
(Instruction system diagram)

Work leader
Work director
Crane sign maker
Regular/Assistant
Operator for assembly

Liaison person
Mechanics
Share of work
(Interpreter)
We hope that all the workers will cooperate to assemble this machine quickly while observing the safety, quality and delivery time.
CONTENTS
SPECIFICATIONS.............................................................................................................
POINTS REGARDING LOCAL ASSEMBLY .....................................................................
ASSEMBLY PROCEDURE, ASSEMBLY EQUIPMENT AND SCHEDULE ......................
FLOWCHART OF MAIN ASSEMBLY PROCEDURE........................................................
KIT LAYOUT DIAGRAM ....................................................................................................
TRANSPORTATION POSTURES.....................................................................................
LIST OF PARTS SENT INDIVIDUALLY ............................................................................
TOOLS AND EQUIPMENT TO BE USED FOR LOCAL ASSEMBLY ...............................
TIGHTENING TORQUE ....................................................................................................
COATING MATERIALS LIST ............................................................................................
1
2
3
4
5
6
15
27
29
33
A. ASSEMBLY OF CHASSIS ............................................................................................

<Assembly of undercarriage>
A- 1. Assembly of track frame assembly and center frame assembly...........................
A- 2. Idler cushion cylinder piping .................................................................................
A- 3. Travel motor piping ...............................................................................................
A- 4. Installation of travel motor cover...........................................................................
A- 5. Filling swing circle with grease .............................................................................
A- 6. Assembly of revolving frame assembly and undercarriage ..................................
A- 7. Installation of swing machinery (front) assembly (27t)
Installation of swing motor (front) assembly (32t) .................................................
A- 8. Connection of swivel joint piping...........................................................................
A- 9. Connection of swing circle grease piping .............................................................
<Assembly of upper structure>
A-10. Installation of hydraulic tank assembly .................................................................
A-11. Installation of fuel tank assembly..........................................................................
A-12. Connection of fuel tank assembly piping and wiring.............................................
A-13. Installation of cab base assembly.........................................................................
A-14. Installation of left floor assembly ..........................................................................
A-15. Connection of cab base assembly piping .............................................................
A-16. Connection of cab base assembly wiring .............................................................
A-17. Connection of left floor assembly heater piping....................................................
A-18. Connection of left floor assembly wiring ...............................................................
<Coupling of power container>
A-19. Installation of tail pipe ...........................................................................................
A-20. Installation of power container assembly..............................................................
A-21. Connection of suction piping ................................................................................
A-22. Connection of oil cooler piping and pump drain piping.........................................
A-23. Connection of fan motor drain piping....................................................................
A-24. Installation of suction unit undercover ..................................................................
A-25. Connection of delivery piping ...............................................................................
A-26. Connection of pilot piping and fan motor piping ...................................................
A-27. Connection of power container assembly fuel piping ...........................................
A-28. Connection of power container assembly air conditioner piping ..........................
A-29. Connection of power container assembly heater piping.......................................
A-30. Connection of power container assembly wiring ..................................................
35
36
39
40
41
43
44
46
47
49
50
55
56
58
60
64
66
71
72
73
74
76
78
79
80
81
83
84
86
87
88
<Coupling of operator's cab>

A-31. Installation of operator's cab assembly ................................................................
A-32. Installation of rotary lamp (if equipped) ................................................................
A-33. Installation of ORBCOMM antenna......................................................................
A-34. Connection of operator's cab assembly wiring.....................................................
A-35. Connection of operator's cab assembly hydraulic piping .....................................
A-36. Connection of operator's cab assembly window washer hose.............................
A-37. Connection of operator's cab assembly air conditioner piping .............................
A-38. Connection of operator's cab assembly heater piping .........................................
A-39. Installation of operator's cab rear floor assembly.................................................
A-40. Installation of handrail around operator's cab ......................................................
<Coupling of exterior parts, counterweight, etc.>
A-41. Installation of track frame ladder ..........................................................................
A-42. Installation of power container side catwalk assemblies (right and left)...............
A-43. Installation of right floor assembly and grease can cover assembly ....................
A-44. Installation of fuel tank right catwalk assembly ....................................................
A-45. Installation of fuel tank front catwalk assembly ....................................................
A-46. Adjustment of exterior parts clearance.................................................................
A-47. Connection of grease reel piping .........................................................................
A-48. Installation of slide ladder assembly ....................................................................
A-49. Installation of counterweight assembly ................................................................
A-50. Installation of handrail on counterweight..............................................................
A-51. Installation of handrail clamps..............................................................................
A-52. Connection of fuel cut wire...................................................................................
A-53. Connection of drain piping under power container...............................................
A-54. Connection of battery wiring.................................................................................
<Starting of engine and inspection and servicing procedures>
A-55. Setting of hydraulic tank strainer..........................................................................
A-56. Starting of engine, inspection of oil levels and coolant levels,
bleeding air and adjustment of track ....................................................................
A-57. Permanent tightening of swing circle bolt.............................................................
A-58. Parts to be touched up after field assembly (chassis side) ..................................
<Extremely cold district specification (if equipped)>
A-59. Connection of engine heater connection port ......................................................
C. ASSEMBLY OF BACKHOE..........................................................................................
<Coupling of boom>
C- 1. Installation of boom cylinder.................................................................................
C- 2. Installation of boom cylinder hoses ......................................................................
C- 3. Assembly of boom sub assembly.........................................................................
C- 4. Installation of boom assembly..............................................................................
C- 5. Installation of boom cylinder.................................................................................
<Coupling of arm>
C- 6. Installation of hoses between boom and chassis.................................................
C- 7. Installation of arm assembly.................................................................................
C- 8. Installation of arm cylinder ...................................................................................
C- 9. Connection of hoses between boom and arm......................................................
C-10. Connection of auto grease piping ........................................................................
C-11. Connection of wiring between boom and chassis................................................
<Coupling of bucket>
C-12. Installation of bucket assembly ............................................................................
C-13. Installation of bucket link......................................................................................
C-14. Bleeding air from cylinders...................................................................................
C-15. Parts to be touched up after field assembly (work equipment side) ....................
C-16. Bleeding air from auto grease circuit ...................................................................
90
93
95
96
97
99
100
101
102
103
104
105
106
107
108
109
110
111
113
114
115
118
119
120
121
122
141
142
143
147
148
150
151
155
157
159
160
163
164
165
166
167
170
172
175
176
LS. ASSEMBLY OF LOADING SHOVEL WORK EQUIPMENT........................................

LS- 1. Installation of arm cylinder bottom parts .............................................................
LS- 2. Installation of boom cylinder to machine body....................................................
LS- 3. Installation of boom cylinder hoses.....................................................................
LS- 4. Installation of boom cylinder piping.....................................................................
LS- 5. Installation of boom assembly ............................................................................
LS- 6. Installation of boom cylinder head pins...............................................................
LS- 7. Installation of hose between machine body and boom.......................................
LS- 8. Installation of bucket cylinder assembly .............................................................
LS- 9. Installation of arm assembly ...............................................................................
LS-10. Installation of arm cylinder assembly..................................................................
LS-11. Installation of hoses between boom and arm .....................................................
LS-12. Installation of bucket cylinder hoses...................................................................
LS-13. Installation of grease feed hose of bucket cylinder.............................................
LS-14. Installation of bucket assembly...........................................................................
LS-15. Installation of bottom dump hose and grease feed hose
between arm and bucket ....................................................................................
179
180
181
183
184
185
186
187
189
190
191
192
193
194
196
M. INSPECTION AND SERVICING PROCEDURES AFTER ASSEMBLY .......................

M- 1. Inspection of oil levels and coolant levels and using standard
of fuel and lubricant..............................................................................................
M- 2. Flushing of hydraulic circuit..................................................................................
M- 3. Releasing residual pressure from hydraulic circuit...............................................
M- 4. Releasing residual pressure from HIC circuit and check
of gas pressure in HIC accumulator.....................................................................
M- 5. Charging air conditioner with refrigerant ..............................................................
M- 6. Installed angles of mirrors ....................................................................................
M- 7. Installed angles of lights.......................................................................................
199
197
200
203
206
207
208
209
211
VHMS CONTOROLLER INITIAL SETTING PROCEDURE .............................................. 215

FIELD ASSEMBLY INSPECTION REPORT (BACKHOE)
FIELD ASSEMBLY INSPECTION REPORT (LOADING SHOVEL)
SPECIFICATIONS
Item
Operating weight (including 1 operator)
Bucket capacity
Backhoe
Loading shovel
Name of engine
Engine horsepower
Unit
PC2000-8
kg
200,000
12.0
m3
11.0
Komatsu SAA12V140E-3 diesel engine
kW{HP}/rpm
728{976}/1,800
Min. ground distance
2,095
Travel speed (Low/High)
km/h
2.7
Swing speed
rpm
4.8
PC2000-8 Backhoe
PC2000-8 Loading shovel
POINTS REGARDING LOCAL ASSEMBLY

1. Selection of work place
1) The work place should be suitable for the machine. The following points should be considered.
Area
Hardness of ground surface
Levelness
Entry/Exit road, turning space
2) Assembly work on the hydraulic circuit must not be carried out in any place where dust or rain can get into the circuit
during the operation.
3) If the work is carried out outside, avoid place where there is rain or strong wind.
2. Preparation and check of lifting tools and jigs

1) Check each lifting tool and jig thoroughly.
In particular, check stands and blocks made of wood to check that the inside is not rotted or cracked.
3. k Check during actual operation

1) Apply the parking brake of the trailer and crane securely, then put chocks under the wheels.
2) Lower the pressure and temperature of the engine, hydraulic oil, and coolant before starting work.
3) When starting the engine, always give an agreed signal, such as blowing the horn, to warn the people around the machine. Check also that the work equipment levers and travel levers are in neutral, and that the fuel control dial (or fuel
control lever) is at the low idle position.
4) Be careful to maintain the balance of parts being lifted by the crane.
5) Do not allow unauthorized persons into the working area.
4 Before starting the operation, read all the instructions, and, in particular, be sure that you understand
the caution items.
The circled numbers in the illustrations are indicated as the numbers in ( ). (Example: q (1))
5. The leader should write out the caution items for each work process, and should explain them to ensure that the workers understand them.
6. Hold a meeting every morning before starting work to confirm the operating plan and operating safety.
Workers
Air compressor
Mobile elevating
work platform
Crane
Units to be
assembled
Day
Start of assembly
Meeting of all workers
Foreman + 6 mechanics
Min. 15 m3/min
Completion of assembly
of chassis
Start of engine
Completion of total assembly
(Half day)
ASSEMBLY PROCEDURE,
ASSEMBLY EQUIPMENT AND SCHEDULE
FLOWCHART OF MAIN ASSEMBLY PROCEDURE
Necessary assembly procedure when disassembling to 27t.
Assembly of
undercarriage
(Crawler, center
frame)
Coupling of
revolving frame
Installation of
hydraulic tank
Connection of
swivel piping
Installation of
front machinery
Installation of
power container
assembly
Installation of
fuel tank
Installation of
grease cover and
ladder
Installation of
exterior parts,
handrail and mirror
Installation of
left floor
Installation of
cab base
Installation of
cab assembly
Installation of
ladder to cab base
Installation of
boom cylinder
Installation of
boom
Installation of
arm
Installation of
bucket
Installation of
counterweight
Motoring
Boom sub
(arm cylinder, tube)
To A
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
Hoses
Boom cylinder
Tools and equipment
Cab
Arm link
Cab
base
F tank
G reel
Covers
Rear floor PA ladder
Front CW Right CW
Left deck Right deck
Left floor Right floor
Bucket
Center frame
Crane, 50 ton
C weight
Crawler frame
Crane, 50 ton
Crawler frame
Boom
Front
Revolving
frame
Power container
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.
t Transportation posture of each kit
(1) Center frame assembly
X
Overall length (mm)
3,815
Overall width (mm)
3,190
Overall height (mm)
2,210
Weight (kg)
18,000
With swivel and fixing bar

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

For each crawler
X
Overall length (mm)
7,435
Overall width (mm)
1,720
Overall height (mm)
1,920
Weight (kg)
26,000
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
Overall length (mm)
7,575
Overall width (mm)
Overall height (mm)
Weight (kg)
3,180
2,920
2,640
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
(4) Fuel tank assembly

X
Overall length (mm)
3,100
Overall width (mm)
,875
Overall height (mm)
2,070
Weight (kg)
2,400
With working lamp

With fuel level sensor
Center of gravity
Top view
(5) Cab base assembly

X
Overall length (mm)
3,660
Overall width (mm)
2,505
Overall height (mm)
2,700
Weight (kg)
2,500
With front and left catwalk

With head lamp and working lamp
Center of gravity
Top view
(6) Left floor assembly

X
Overall length (mm)
2,500
Overall width (mm)
2,100
Overall height (mm)
3,085
Weight (kg)
1,500
With battery
Center of gravity
Top view
(7) Power container assembly

X
Overall length (mm)
5,215
Overall width (mm)
2,455
Overall height (mm)
3,195
Weight (kg)
16,100
With super hood

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

X
Overall length (mm)
2,855
Overall width (mm)
1,880
Overall height (mm)
2,520
Weight (kg)
1,800
With antenna retracted

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

X
Overall length (mm)
6,240
Overall width (mm)
1,115
Overall height (mm)
1,505
Weight (kg)
[Parts packed separately]
Handrail, bolts
24,500
Center of gravity
Top view
(10) Slide ladder assembly

X
Overall length (mm)
3,380
Overall width (mm)
,875
Overall height (mm)
1,255
Weight (kg)
,550
Center of gravity
View Z
(11) Catwalk assembly on power container side

For each catwalk
X
Overall length (mm)
2,310
Overall width (mm)
,545
Overall height (mm)
2,085
Weight (kg)
,260
Center of gravity
Top view
(12) Grease can cover assembly

X
Overall length (mm)
1,030
Overall width (mm)
1,025
Overall height (mm)
,995
Weight (kg)
,260
Center of gravity
Top view
(13) Right floor assembly

X
Overall length (mm)
1,390
Overall width (mm)
1,350
Overall height (mm)
2,085
Weight (kg)
,240
Center of gravity
Top view
(14) Right catwalk assembly

X
Overall length (mm)
3,560
Overall width (mm)
1,300
Overall height (mm)
1,865
Weight (kg)
,390
With grease reel
Center of gravity
Top view
(15) Front catwalk assembly

X
Overall length (mm)
,715
Overall width (mm)
,810
Overall height (mm)
1,540
Weight (kg)
, 90
Center of gravity
Top view
10
(16) Cab rear floor assembly

X
Overall length (mm)
1,470
Overall width (mm)
1,320
Overall height (mm)
,345
Weight (kg)
, 70
Center of gravity
Top view
(17) Boom assembly

X
Overall length (mm)
9,170
Overall width (mm)
2,065
Overall height (mm)
3,195
Weight (kg)
18,430
Center of gravity
Left side view
(18) Arm assembly

X
Overall length (mm)
5,495
Overall width (mm)
1,605
Overall height (mm)
2,055
Weight (kg)
12,900
With bucket cylinder

Center of gravity
Left side view
11
(19) Bucket assembly

Specifications of standard bucket
for crushed stones
Overall length (mm)
5,495
Overall width (mm)
1,605
Overall height (mm)
2,055
Weight (kg)
12,900
Center of gravity
Left side view
(20) Arm cylinder tube assembly

X
Overall length (mm)
1,240
Overall width (mm)
,320
Overall height (mm)
,365
Weight (kg)
, 60
Center of gravity
Left side view
(21) Hydraulic tank assembly

X
Overall length (mm)
1,860
Overall width (mm)
1,115
Overall height (mm)
2,085
Weight (kg)
1,750
Center of gravity
Top view
12
(22) Swing machinery (front) assembly

X
Overall length (mm)
,775
Overall width (mm)
,675
Overall height (mm)
1,335
Weight (kg)
1,050
Center of gravity
Top view
(23) Cab L.H. catwalk

X
Overall length (mm)
3,660
Overall width (mm)
,615
Overall height (mm)
1,355
Weight (kg)
,220
Center of gravity
Top view
(24) Cab front catwalk

X
Overall length (mm)
1,840
Overall width (mm)
,560
Overall height (mm)
Weight (kg)
,100
Center of gravity
Top view
13
11,325
Method of installing chassis hanging jig
14
LIST OF PARTS SENT INDIVIDUALLY (Assembly of undercarriage)

A
No.
Part No.
Part name
Q'ty
Assembly
procedure No.
A-1
21T-30-71160
BOLT
76
A-1
A-2
21T-30-71170
WASHER
76
A-1
A-3
208-30-11850
COVER
A-1
A-4
208-30-11861
GASKET
A-1
A-5
01024-81225
BOLT
A-1
A-6
07000-B3025
O-RING
A-2
A-7
07000-B3048
O-RING
A-3
A-8
02896-61018
O-RING
A-3
A-9
01024-81235
BOLT
A-4
A-10
424-54-14230
COLLAR
A-4
A-11
01024-81230
BOLT
12
A-4
A-12
21N-30-11340
COLLAR
16
A-4
A-13
01641-21223
WASHER
12
A-4
A-14
21T-30-32172
COVER
A-4
A-15
21T-30-32182
COVER
A-4
A-16
01010-82460
BOLT
10
A-4
A-17
17A-54-44130
WASHER
10
A-4
15
Remarks
LIST OF PARTS SENT INDIVIDUALLY (Coupling of revolving frame)

B
Assembly
Q'ty procedure No.
No.
Part No.
Part name
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
A-7
B-6
07000-B3032
O-RING
A-7
B-7
02896-61015
O-RING
A-7
B-8
02896-61008
O-RING
A-7
B-9
01024-81225
BOLT
A-7
B-10
11Y-62-11980
O-RING
A-8
B-11
02896-61009
O-RING
A-8
B-12
07000-B3048
O-RING
A-8
B-13
07000-B5230
O-RING
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
A-10
B-17
11Y-62-11980
O-RING
A-10
B-18
07000-B3032
O-RING
A-10
16
Remarks
LIST OF PARTS SENT INDIVIDUALLY (Assembly of upper structure)

C
No.
Part No.
Part name
Q'ty
Assembly
procedure No.
C-1
01011-83010
BOLT
20
A-11
C-2
21T-26-11460
WASHER
20
A-11
C-3
04435-52212
CLIP
A-12
C-4
02896-61012
O-RING
A-12
C-5
02896-61015
O-RING
A-12
C-6
02896-61018
O-RING
A-12
C-7
01024-81220
BOLT
A-12
C-8
04434-52312
CLIP
A-12
C-9
04434-51912
CLIP
A-12
C-10
01024-81220
BOLT
A-12
C-11
01034-81245
BOLT
10
A-13
C-12
01034-81265
BOLT
10
A-13
C-13
21T-54-31140
CLAMP
A-13
C-14
21T-54-31150
CLAMP
A-13
C-15
01034-81245
BOLT
A-13
C-16
01011-82035
BOLT
20
A-13
C-17
01011-82045
BOLT
A-13
C-18
567-40-41380
WASHER
27
A-13
C-19
01010-82065
BOLT
24
A-14
C-20
01643-32060
WASHER
24
A-14
C-21
21T-53-31530
SHIM
A-14
C-22
21T-53-31540
SHIM
A-14
C-23
21T-54-33471
COVER
A-14
C-24
01034-81230
BOLT
A-14
C-25
02896-61012
O-RING
A-15
C-26
02896-61018
O-RING
A-15
C-27
21T-979-3320
JOINT
A-17
17
Remarks
LIST OF PARTS SENT INDIVIDUALLY (Coupling of power container)

D
Assembly
Q'ty procedure No.
No.
Part No.
Part name
D-1
21M-01-18130
TAIL PIPE
A-19
D-2
01024-81230
BOLT
12
A-19
D-3
6162-14-5640
RAIN CAP
A-19
D-4
21T-54-31121
PLATE
A-20
D-5
21T-54-31130
BOLT
20
A-20
D-6
01643-34212
WASHER
20
A-20
D-7
07000-B2140
O-RING
A-21
D-8
07000-B2100
O-RING
A-21
D-9
209-62-41341
CLAMP
A-21
D-10
20Y-62-51671
CLAMP
A-21
D-11
07000-B2060
O-RING
A-22
D-12
07298-02011
HOSE
A-22
D-13
07000-B3032
O-RING
A-23
D-14
07000-B3048
O-RING
A-25
D-15
07000-B3025
O-RING
A-26
D-16
07000-B3032
O-RING
A-26
D-17
02896-61018
O-RING
A-27
D-18
02896-61015
O-RING
A-27
D-19
02896-61015
O-RING
A-27
D-20
08028-55065
CABLE
A-30
D-21
01024-81020
BOLT
A-30
18
Remarks
LIST OF PARTS SENT INDIVIDUALLY (Coupling of operator's cab)

E
No.
Part No.
Part name
Q'ty
Assembly
procedure No.
E-1
21T-54-36661
SHIM
16
A-31
E-2
21T-54-36671
SHIM
A-31
E-3
21T-54-35321
CUSHION
A-31
E-4
8295-06-1480
LAMP BEACOM
A-32
E-5
21T-06-17430
BRACKET
A-32
E-6
01024-81225
BOLT
A-32
E-7
8295-06-1480
LAMP BEACOM
A-32
E-8
21T-06-33610
PLATE
A-32
E-9
21T-06-17430
BRACKET
A-32
E-11
01024-81225
BOLT
A-32
E-11
04434-51012
CLIP
A-32
E-12
01024-81220
BOLT
A-32
E-13
8A13-10-2100
ANTENNA
A-33
E-14
21T-06-64491
BRACKET
A-33
E-15
01024-81225
BOLT
A-33
E-16
02896-61012
O-RING
10
A-35
E-17
02896-61009
O-RING
A-35
E-18
21T-979-4421
SEAL
A-37
E-19
08034-20830
BAND
A-37
E-20
08034-20830
BAND
A-38
E-21
01024-81225
BOLT
14
A-39
E-22
21T-54-33931
HANDRAIL
A-40
E-23
01034-81245
BOLT
10
A-40
19
Remarks
LIST OF PARTS SENT INDIVIDUALLY (Coupling of counterweight etc)

F
Assembly
Q'ty procedure No.
No.
Part No.
Part name
F-1
21T-30-32231
BRACKET
A-41
F-2
21T-30-32241
LADDER
A-41
F-3
01010-82460
BOLT
A-41
F-4
01010-82450
BOLT
A-41
F-5
01643-32460
WASHER
16
A-41
F-6
01010-82050
BOLT
16
A-42
F-7
01010-82080
BOLT
12
A-43
F-8
01010-82060
BOLT
A-43
F-9
01643-32060
WASHER
20
A-43
F-10
21T-53-31550
PLATE
A-43
F-11
21T-54-31560
PLATE
A-43
F-12
21T-54-33331
STEP
A-43
F-13
01034-81250
BOLT
A-43
F-14
01034-81235
BOLT
16
A-44
F-15
01034-81250
BOLT
A-45
F-16
01010-82050
BOLT
A-48
F-17
567-40-41380
WASHER
A-48
F-18
21T-46-34120
BOLT
12
A-49
F-19
209-46-11210
SPACER
12
A-49
F-20
21T-46-34141
PLATE
A-49
F-21
21T-46-34131
PLATE
A-49
F-22
01024-81225
BOLT
12
A-49
F-23
21T-54-34411
HANDRAIL
A-50
F-24
21T-54-34421
HANDRAIL
A-50
F-25
01034-81250
BOLT
16
A-50
20
Remarks
No.
Part No.
Part name
Q'ty
Assembly
procedure No.
F-26
21T-54-32911
CLAMP
A-51
F-27
21T-54-32921
CLAMP
A-51
F-28
01034-81245
BOLT
14
A-51
F-29
21T-54-65810
CHAIN
A-51
F-30
21T-54-31140
CLAMP
A-51
F-31
21T-54-31150
CLAMP
A-51
F-32
01034-81245
BOLT
A-51
F-33
21T-01-31471
NIPPLE
A-53
F-34
07005-02416
O-RING
A-53
21
Remarks
LIST OF PARTS SENT INDIVIDUALLY (Coupling of boom)

H
Assembly
Q'ty procedure No.
No.
Part No.
Part name
H-1
707-01-XK750
BOOM CYLINDER(L.H.)
C-1
H-2
707-01-XK760
BOOM CYLINDER(R.H.)
C-1
H-3
21T-70-31421
SHIM
C-1
H-4
21T-70-31470
SHIM
C-1
H-5
21T-70-31690
SHIM
C-1
H-6
07000-15180
O-RING
C-1
H-7
07000-B2060
O-RING
C-2
H-8
07000-B3048
O-RING
C-2
H-9
21T-64-39410
HOSE
C-2
H-10
07083-01417
HOSE
C-2
H-11
21T-64-39140
TUBE
C-3
H-12
21T-64-39150
TUBE
C-3
H-13
21T-64-39160
TUBE
C-3
H-14
07000-B3048
O-RING
C-3
H-15
07000-B2060
O-RING
C-3
H-16
01643-31845
WASHER
32
C-3
H-17
01010-81840
BOLT
C-3
H-18
01010-81865
BOLT
28
C-3
H-19
707-01-XK770
ARM CYLINDER(L.H.)
C-3
H-20
707-01-XK780
ARM CYLINDER(R.H.)
C-3
H-21
07000-12140
O-RING
C-3
H-22
21T-70-31441
SHIM
C-3
H-23
07084-02022
HOSE
C-3
H-24
07085-01418
HOSE
C-3
H-25
07085-01420
HOSE
C-3
H-26
07000-B2060
O-RING
C-3
H-27
07000-B3048
O-RING
C-3
H-28
07371-51470
FLANGE
C-3
H-29
07371-52080
FLANGE
C-3
H-30
01643-31445
WASHER
C-3
22
Remarks
No.
Part No.
Part name
Q'ty
Assembly
procedure No.
H-31
01643-31845
WASHER
C-3
H-32
01010-81455
BOLT
C-3
H-33
01010-81865
BOLT
C-3
H-34
21T-06-32810
WORK LAMP A.
C-3
H-35
20Y-06-21551
BRACKET
C-3
H-36
01643-31445
WASHER
C-3
H-37
01010-81430
BOLT
C-3
H-38
01024-81225
BOLT
C-3
H-39
209-72-11311
SEAL
C-3
H-40
21T-70-31480
SHIM
C-4
H-41
21T-70-31490
SHIM
16
C-4
H-42
07000-15180
O-RING
C-5
23
Remarks
LIST OF PARTS SENT INDIVIDUALLY (Coupling of arm)

I
Assembly
Q'ty procedure No.
No.
Part No.
Part name
I-1
07000-B2060
O-RING
C-6
I-2
21T-70-31290
SEAL
C-7
I-3
21N-70-12160
SEAL
C-7
I-4
209-72-11261
SEAL
C-7
I-5
21T-70-31391
SHIM
C-7
I-6
21T-70-31780
SHIM
C-7
I-7
21T-70-31810
SHIM
C-7
I-8
21T-70-31820
SHIM
C-7
I-9
07000-B5260
O-RING
C-7
I-10
21T-70-32181
SHIM
C-8
I-11
07000-12140
O-RING
C-8
I-12
07371-51470
FLANGE
C-9
I-13
07371-52080
FLANGE
C-9
I-14
07084-41427
HOSE
C-9
I-15
07084-42026
HOSE
C-9
I-16
07000-B3048
O-RING
C-9
I-17
07000-B2060
O-RING
C-9
I-18
01643-31445
WASHER
C-9
I-19
01643-31845
WASHER
C-9
I-20
01010-81455
BOLT
C-9
I-21
01010-81865
BOLT
C-9
I-22
21T-68-31830
TUBE
C-10
I-23
203-973-5660
CLAMP
C-10
I-24
203-973-5720
SEAT
C-10
I-25
01024-81055
BOLT
C-10
I-26
21T-70-75290
BACKET
C-10
I-27
01024-81225
BOLT
C-10
I-28
07631-20409
HOSE
C-10
24
Remarks
LIST OF PARTS SENT INDIVIDUALLY (Coupling of bucket)

J
No.
Part No.
Part name
Q'ty
Assembly
procedure No.
J-1
209-72-11261
SEAL
C-12
J-2
209-70-71370
O-RING
C-12
J-3
205-09-61240
BOLT
C-12
J-4
01640-20610
WASHER
C-12
J-5
01596-00606
NUT
C-12
J-6
21N-72-11230
SHIM
C-13
25
Remarks
LIST OF PARTS SENT INDIVIDUALLY (Bleeding air from cylinders and hydraulic circuit)
K
Assembly
Q'ty procedure No.
No.
Part No.
Part name
K-1
209-60-77551
ELEMENT
M-2
K-2
21T-60-13730
PLATE
M-2
K-3
23S-54-36270
MIRROR
M-6
K-4
21T-54-34690
SUPPORT
M-6
K-5
21T-54-79620
CLAMP
M-6
K-6
01252-71025
BOLT
M-6
K-7
21T-54-34850
PLATE
M-6
K-8
21T-54-34680
PLATE
M-6
K-9
07283-32236
CLIP
M-6
K-10
01643-31032
WASHER
M-6
K-11
01597-01009
NUT
M-6
K-12
421-54-25610
MIRROR
M-6
K-13
04025-00632
SPRING PIN
M-6
K-14
01252-70545
BOLT
M-6
K-15
21T-54-36480
SUPPORT
M-6
K-16
20Y-54-61630
CLAMP
M-6
K-17
01252-71030
BOLT
M-6
26
Remarks
TOOLS AND EQUIPMENT TO BE USED FOR LOCAL ASSEMBLY
Equipment
No.
Part name
Q'ty
Remarks
Engine air compressor
7.0 kg/cm3
Crane truck
50 ton
Grease pump
Pneumatic
For greasing work equipment
Mobile elevating work platform 10 m
Lift work stand
2 workers
Substituted by mobile
elevating work platform
6
7
Stepladder
10 step, 3,000 mm
5 step, 1,500 mm
3 step, 900 mm
With 200 V, 100 V generator
Hydraulic wrench
750 kgm
Track frame, power container
Hydraulic pump
For hydraulic wrench, 200 V
Track frame, power container
10
For M10 mm bolt
(Torque capacity: 10 70 Nm)
11
For M12 mm bolt
For M16 mm bolt
For M36 mm bolt
(Torque capacity: 780 2,900 Nm)
12
Impact wrench
13
14
For M42 mm bolt
(Torque capacity: 1,500 6,300 Nm)
15
Width across flats: 70 mm
Track frame
Counterweight
16
17
Impact wrench socket
18
Fuel tank
19
T 38.1 Width across flats: 70 mm
Track frame
Counterweight
T 38.1 Width across flats: 55mm
T 19 Width across flats 30 mm
20
21
420 kgm
torque wrench socket
22
23
24
25
Tool
Specification
Socket
Extension
For impact wrench, 300 mm long
For impact wrench, 200 mm long
26
Impact wrench air hose
Inside 12, Inside 19
27
Air coupler
For hoses of size 4, 6
28
16 time wrench
450 kgm
29
12 kgm T 19
30
42 kgm T 25.4
For 16 time wrench
85 kgm T 25.4
For 4 time wrench
420 kgm T 38
31
Torque wrench
32
50 m each
2 sets
33
34
35
Spanner
36
2 sets each
37
Standard tool set
Sockets, spanners, ring wrenches
38
Large hammer (Plastic)
10 P
39
Bar
1m
50 ton
20 ton
40
Hydraulic jack
41
42
Oil receiving pan
43
Drum can oil filler
44
Wooden block
Large and small
Unnecessary, if hydraulic
wrench is available
2 each
For receiving center frame to

install track frame
For tightening track frame
clamping bolt
For connecting travel piping
and work equipment piping
1
300 400
27
For supporting revolving frame

and center frame
Tool
No.
Part name
M10 P1.5
46
M12 P1.75
47
M14 P2
48
M16 P2
49
M20 P2.5
50
M24 P3
51
Tap
Remarks
M27 P3
52
M30 P3
53
M33 P3
54
M36 P3
55
M39 P3
56
M42 P3
57
10 3,000 mm
Catwalk
58
20 5,000 mm
30 6,000 mm
40 5,000 mm
For 15 ton
62
5.4 ton
63
10 ton
Boom, arm and bucket

Center frame and power
container
Counterweight, revolving
frame and track frame
Track frame
Center frame, boom, arm and
power container
Track frame and revolving frame
64
20 ton
Counterweight
Wire
60
61
Sling
Q'ty
45
59
Chain
Shackle
65
2 ton
Fuel tank
66
0.9 ton
Cabin
67
SB10
Travel piping cover
68
50 mm wide 3,000 mm
Boom cylinder
25 mm wide 3,000 mm
Handrail
1.5 ton
Left floor assembly
3.0 ton
6 ton
69
Nylon sling
70
71
Lever block
72
73
74
Eyebolt
75
Fuel, oil, grease

and sub-materials
Specification
M20
M16
M12
76
Pin
Pin, 50 40 mm
77
Cleaning liquid
Brake cleaner spray can
78
Hydraulic oil
EO10
79
Diesel fuel
80
Grease
81
82
Repair paint
Track frame
10
2000 L
2000 L
G2-LI (20 L can)
Natural yellow spray can
10
Black gray spray can
10
83
LG-6
TB1215
84
Air conditioner refrigerant
R134a
2000 g
85
Cloth
1 bundle
20 kg
28
In grease bath
Connecting faces of revolving

frame and swing circle
For cleaning
TIGHTENING TORQUE
Remove the various blind plugs and jigs used during transportation. Remove the blind jigs (flange, head, cap, O-ring) used for
the work equipment piping and undercarriage piping, the blind plugs used for the lubrication piping, the jigs used to hold the
cylinders, and the blind plugs used in the tap holes where parts have been removed for transportation. Be careful not to damage these parts, and keep them in a safe place so that they can be used for future transportation. For bolts where the tightening
torque is not separately specified in the maintenance standards, use the tightening torque given in the table below.
1. Tightening torque for bolts
Tighten bolts according to Table 1 when using an impact wrench or spanner.
Apply Table 1 to bolts as a rule. No torque is indicated on drawings as long as Table 1 is applicable.
Table 1
Unit: Nm {kgm}
Thread diameter Pitch
a (mm)
Width across flats

b (mm)
61
Tightening torque
Target
Range
10
12
{1.2}
8.8 - 14.7
{0.9 - 1.5}
8 1.25
13
25
{2.5}
14.7 - 34
{1.5 - 3.5}
10 1.5
17
54
{5.5}
34 - 74
{3.5 - 7.5}
12 1.75
19
89
{9}
54 - 123
{5.5 - 12.5}
14 2
22
137
{14}
84 - 196
{8.5 - 20}
16 2
24
230
{23.5}
147 - 309
{15 - 31.5}
18 2.5
27
315
{32}
201 - 427
{20.5 - 43.5}
20 2.5
30
460
{47}
319 - 608
{32.5 - 62}
22 2.5
32
650
{66.5}
471 - 829
{48 - 84.5}
24 3
36
810
{82.5}
588 - 1030
{60 - 105}
27 3
41
1180
{120}
883 - 1470
{90 - 150}
30 3
46
1520
{155}
1130 - 1910
{115- 195}
33 3
50
1960
{200}
1470 - 2450
{150 - 250}
36 3
55
2450
{250}
1860 - 3040
{190 - 310}
39 3
60
2940
{300}
2260 - 3630
{230 - 370}
29
When using a torque wrench, apply Table 2.

Apply Table 2 when tightening torque must be controlled very strictly.
Table 2
Unit: Nm {kgm}
Thread diameter Pitch
a (mm)
Width across flats

b (mm)
61
Tightening torque
Target
Range
10
13.2
{1.35}
11.8 - 14.7
{1.2 - 1.5}
8 1.25
13
31
{3.2}
27 - 34
{2.8 - 3.5}
10 1.5
17
66
{6.7}
59 - 74
{6.0 - 7.5}
12 1.75
19
113
{11.5}
98 - 123
{10.0 - 12.5}
14 2
22
172
{17.5}
153 - 190
{15.5 - 19.5}
16 2
24
260
{26.5}
235 - 285
{23.5 - 29.5}
18 2.5
27
360
{37.0}
320 - 400
{33.0 - 41.0}
20 2.5
30
510
{52.3}
455 - 565
{46.5 - 58.0}
22 2.5
32
688
{70.3}
610 - 765
{62.5 - 78.0}
24 3
36
883
{90.0}
785 - 980
{80.0 - 100.0}
27 3
41
1295
{132.5}
1150 - 1440
{118.0 - 147.0}
30 3
46
1720
{175.0}
1520 - 1910
{155.0- 195.0}
33 3
50
2210
{225.0}
1960 - 2450
{200.0 - 250.0}
36 3
55
2750
{280.0}
2450 - 3040
{250.0 - 310.0}
39 3
60
3280
{335.0}
2890 - 3630
{295.0 - 370.0}
30
2. Tightening torque for pipe threads

Apply the following standards to the taper male pipe threads of size R1/8 - R1, taper female pipe threads of size Rc1/8 Rc1 and parallel female threads of size Rp1/8 - Rp1 (coated with adhesive). Do not apply them, however, if a tightening
torque is otherwise specified.
2-1. Apply Table 1 to male screws made of SS400, FC or SGP.
Table 1
Unit: Nm {kgm}
Material of female screw
Steel
Cast iron
Light alloy
1/8
3.9 - 6.9
{0.4 - 0.7}
2.9 - 5.9
{0.3 - 0.6}
2.0 - 3.9
{0.2 - 0.4}
1/4
5.9 - 11.8
{0.6 - 1.2}
4.9 - 9.8
{0.5 - 1.0}
3.9 - 7.8
{0.4 - 0.8}
3/8
16.7 - 26.5
{1.7 - 2.7}
13.7 - 21.6
{1.4 - 2.2}
9.8 - 16.7
{1.0 - 1.7}
1/2
32.3 - 52.9
{3.3 - 5.4}
26.5 - 43.1
{2.7 - 4.4}
19.6 - 32.3
{2.0 - 3.3}
3/4
51.0 - 85.3
{5.2 - 8.7}
42.1 - 70.6
{4.3 - 7.2}
31.4 - 52.9
{3.2 - 5.4}
86.2 - 173.5
{8.8 - 17.7}
72.5 - 146.0
{7.4 - 14.9}
54.9 - 111.7
{5.6 - 11.4}
Nominal size
2-2. Apply Table 2 to male screws made of S43C.
Table 2
Unit: Nm {kgm}
Material of female screw
Steel
Cast iron
Light alloy
1/8
16.7 - 29.4
{1.7 - 3.0}
9.8 - 19.6
{1.0 - 2.0}
6.9 - 14.7
{0.7 - 1.5}
1/4
19.6 - 44.1
{2.0 - 4.5}
16.7 - 37.2
{1.7 - 3.8}
12.7 - 28.4
{1.3 - 2.9}
3/8
44.1 - 93.1
{4.5 - 9.5}
37.2 - 77.4
{3.8 - 7.9}
27.4 - 58.8
{2.8 - 6.0}
1/2
98.0 - 188.2
{10.0 - 19.2}
83.3 - 157.8
{8.5 - 16.1}
60.8 - 115.6
{6.2 - 11.8}
3/4
170.5 - 316.5
{17.4 - 32.3}
141.1 - 247.0
{14.4 - 25.2}
105.8 - 186.2
{10.8 - 19.0}
367.5 - 612.5
{37.5 - 62.5}
309.7 - 514.5
{31.6 - 52.5}
235.2 - 392.0
{24.0 - 40.0}
Nominal size
31
3. Tightening torque for hoses (with taper seals or face seals)

Unit: Nm {kgm}
Nominal size
of hose
Width across flats
02
Tightening torque
Range
Target
19
35 - 63 {3.5 - 6.5}
44 {4.5}
22
54 - 93 {5.5 - 9.5}
74 {7.5}
24
59 - 98 {6.0 - 10.0}
78 {8.0}
04
27
84 - 132 {8.5 - 13.5}
103 {10.5}
05
32
128 - 186 {13.0 - 19.0}
157 {16.0}
06
36
177 - 245 {18.0 - 25.0}
216 {22.0}
(10)
41
177 - 245 {18.0 - 25.0}
216 {22.0}
(12)
46
197 - 294 {20.0 - 30.0}
245 {25.0}
(14)
55
246 - 343 {25.0 - 35.0}
294 {30.0}
03
When installing rubber hoses, extremely take care not to twist them.
32
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
Adhesive
Komatsu code
Part No.
Q'ty
Container
Main features and applications
LT-1A
790-129-9030
150 g
Tube
Used to prevent rubber gaskets, rubber cushions, and cock plugs from
coming out.
LT-1B
790-129-9050
20 g
(2 pcs.)
Polyethylene
container
Used for plastic (except polyethylene, polypropylene, tetrafluoroethylene and vinyl chloride), rubber,
metal, and non-metal parts which require immediate and strong adhesion.
LT-2
09940-00030
50 g
Polyethylene
container
Features: Resistance to heat and

chemicals
Used to fix and seal bolts and plugs.
LT-3
790-129-9060
(Set of adhesive
and hardener)
Adhesive:
1 kg
Hardener:
500 g
Can
LT-4
790-129-9040
250 g
Polyethylene
container
Holtz
MH 705
790-126-9120
75 g
Tube
Heat-resistant seal used to repair engines
Threebond
1735
790-129-9140
50 g
Polyethylene
container
Quick-setting adhesive
Setting time: Within 5 sec. to 3 min.
Used mainly to stick metals, rubbers,
plastics, and woods.
2g
Polyethylene
container
Quick-setting adhesive
Quick-setting type (max. strength is
obtained after 30 minutes)
Used mainly to stick rubbers, plastics, and metals.
Features: Resistance to heat and
chemicals
Used for fitted portions used at high
temperatures.
Aron-alpha
201
790-129-9130
Used to seal plugs.
Loctite
648-50
79A-129-9110
50 cc
Polyethylene
container
LG-1
790-129-9010
200 g
Tube
Used to stick or seal gaskets and

packings of power train case, etc.
1 kg
Polyethylene
container
Used to seal various threaded portions, pipe joints, and flanges.

Used to seal tapered plugs, elbows,
and nipples of hydraulic piping.
Tube
Features: Silicon-based heat and

cold-resistant sealant
Used to sea flange surfaces and
threaded portions.
Used to seal oil pan, final drive case,
etc.
Features: Silicon-based quick-setting sealant
Used to seal flywheel housing, intake
manifold, oil pan, thermostat housing, etc.
LG-5
LG-6
790-129-9080
790-129-9020
200 g
Gasket
sealant
Molybdenu
m disulfide
lubricant
Used to stick metal, glass, and plastics.
LG-7
790-129-9070
1 kg
Tube
Three bond
1211
790-129-9090
100 g
Tube
Three bond
1207B
419-15-18131
100 g
Tube
Features: Silicon-based, heat and

cold-resistant, vibration-resistant,
impact-resistant sealant
Used to seal transfer case, etc.
LM-G
09940-00051
60 g
Can
Used to lubricate sliding portions (to

prevent squeaking).
Tube
Used to prevent scuffing and seizure

of press-fitted portions, shrink-fitted
portions, and threaded portions.
Used to lubricate linkages, bearings,
etc.
LM-P
09940-00040
200 g
33
Gasket sealant used to repair engine
Grease
Komatsu code
G2-LI
SYG2-400LI
SYG2-350LI
SYG2-400LI-A
SYG2-160LI
SYGA-160CNLI
G2-CA
SYG2-400CA
SYG2-350CA
SYG2-400CA-A
SYG2-160CA
SYGA-160CNCA
Molybdenum
disulfide
lubricant
LM-G (G2-M)
SYG2-400M
SYG2-400M-A
SYGA-16CNM
Hyper White
Grease G2-T
G0-T (*)
*: For cold
district
SYG2-400T-A
SYG2-16CNT
SYG0-400T-A (*)
SYG0-16CNT (*)
Biogrease G2-B,
G2-BT (*)
*: For use at high
temperature
and under high
load
SYG2-400B
SYGA-16CNB
SYG0-400BT (*)
SYGA-16CNBT (*)
SUNSTAR
PAINT PRIMER
580 SUPER
SUNSTAR
GLASS PRIMER
580 SUPER
Primer
Part No.
Q'ty
Container
General purpose type

Various
Various
Various
Various
400 g 10 Bellows-type
400 g 20
container
16 kg
Can
400 g
16 kg
400 g
16 kg
Used for bearings used at normal

temperature under light load in
contact with water or steam.
Used for parts under heavy load.
Bellows-type
container
Can
Seizure resistance and heat resistance higher than molybdenum disulfide

Not conspicuous on machine since
color is white.
Since this grease is decomposed

by natural bacteria in short period,
Bellows-type
it has less effects on microorgancontainer
isms, animals, and plants.
Can
20 ml
Glass
container
Used as primer for cab side

(Using limit: 4 months after
date of manufacture)
20 ml
Glass
container
Used as primer for glass side

417-926-3910
Used as primer for painted

surface on cab side
Used as primer for black ceramic-coated surface on
glass side and for hard polycarbonate-coated surface
SUNSTAR
PAINT PRIMER
435-95
22M-54-27230
20 ml
Glass
container
SUNSTAR
GLASS PRIMER
435-41
22M-54-27240
150 ml
Can
SUNSTAR
SASH PRIMER
GP-402
22M-54-27250
20 ml
Glass
container
SUNSTAR
PENGUINE
SEAL 580
SUPER "S" or
"W"
417-926-3910
320 ml
Polyethylene
container
Sika Japan,
Sikaflex 256HV
20Y-54-39850
310 ml
Polyethylene
container
SUNSTAR
PENGUINE
SUPER 560
22M-54-27210
320 ml
Ecocart
(Special
container)
SUNSTAR
PENGUINE
SEAL No. 2505
417-926-3920
320 ml
Polyethylene
container
Used to seal joints of glass

parts.
SEKISUI
SILICONE
SEALANT
20Y-54-55130
333 ml
Polyethylene
container
Used to seal front window.

GE TOSHIBA
SILICONES
TOSSEAL 381
22M-54-27220
333 ml
Cartridge
Used to seal joint of glasses.

Translucent white seal. (Using limit: 12 months after date
of manufacture)
Adhesive
Caulking
material
Main applications, features
34
Adhesive for cab glass
Category
Used as primer for sash

(Almite)
"S" is used for high-temperature season (April - October)
and "W" for low-temperature
season (November - April) as
adhesive for glass.
Used as adhesive for glass.
Used as adhesive for glass.
A. ASSEMBLY OF CHASSIS
35
Assembly procedure
A-1
Assembly of track frame assembly

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.
A-1
A-2
A-3
A-4
A-5
Precautions
not to crush the grease piping of the
circuit with wires.
Name
Power wrench (16)
(21t-98-11120)
Socket 38 70 mm
(21T-98-11120)
Handle
(21T-98-11130)
KW45F Impact wrench
Qty
Name
Qty
Hydraulic jack 50t
Truck crane 45 t
Center frame stand
1
1
Tap (M45 3)
36
Q'ty
76
76
1
1
3
Equipment required
Spline socket H70
Others
a When slinging the center frame, take care
Tools required
Part No.
21T-30-71160
21T-30-71170
208-30-11850
208-30-11861
01024-81225
Assembly procedure

A-1
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.
Center frame assembly
Left
3) Remove the plugs from the coupling surface and clean

the coupling surface in advance.
Right
Rear view
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,
left stand is not necessary any more.
5) Sling the right track frame assembly with the 45-ton crane
and couple it with the center frame. At this time, the jack
under the center frame should be heightened a little for
the ease of coupling.
a If you pull in the right track toward the center frame
with a chain block, you can work easily.
20 Pipe
Grip
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 slinging with crane]
Check that projection (A) of the hydraulic cushion cylinder
plunger is approx. 10 mm.
Tools required
Cushion
cylinder
Blind plug
Plunger on grease side
Hose
Plunger on hydraulic cushion side
If the projection is not approx. 10 mm, remove the blind plug from
the hose to drain the oil in the cylinder and then install the blind
plug again.
Check that projection (B) of the plunger on the grease side is
approx. 35 mm (that grease has been supplied). If the projection
is not approx. 35 mm, adjust it by supplying grease through the
grease fitting. (See A-56.).
Name
Pin 50 40 mm
(Hard steel)
Wire 40 5 m
(General purpose)
Others
Yoke
37
Equipment required
Qt
2
2
Name
Crane 45t
Qt
2
Assembly procedure

A-1
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>
Precautions
Name
20t Jack
Equipment required
Qty
2
Others
When installing the clamping bolts, remove the

piping at the rear of the center frame
(so that you can use an impact wrench easily).
(See Assembly procedure A-3.)
Tools required
38
Name
Qty
Assembly procedure
Idler cushion cylinder piping
A-2
Bracket and clamp are

installed to piping when
transported.
3 Tightening torque for U-clamp
11 -- 26 Nm {1.1 -- 2.7 kgm }
Bolts are installed to crawler
frame when transported.
Use following parts installed when transported.

07371-30640(4): FLANGE
07395-21035(8): BOLT
No.
A-6
Precautions
2) When connecting, take care not to break the

tube.
Name
Qty
1
KW12P Impact wrench
17 mm Socket
19 mm Socket
39
Q'ty
2
Equipment required
KW10P Impact wrench
Others
1) When connecting the crawler frame, remove

the bolts and bracket marked with .
Tools required
Part No.
07000-B3025
Name
Qty
Assembly procedure
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.
A-7
A-8
Precautions
Tools required
Name
1) Take care that dirt will not enter the piping.
Qty
1
KW12P Impact wrench
KW14P Impact wrench
17 mm Socket
19 mm Socket
150 mm Extension
300 mm Extension
24 mm Spanner
32 mm Spanner
40
Q'ty
4
2
Equipment required
KW10P Impact wrench
Others
2) The hoses are installed to the travel motor.
Part No.
07000-B3048
02896-61018
Name
Qty
Assembly procedure
A-4
Installation of travel motor cover (1/2)
Crawler frame
Travel motor cover
Travel motor guard
Precautions
Travel motor guard is installed to crawler
frame assembly when transported.
Travel motor cover is installed temporarily to
crawler frame assembly when transported.
Tools required
Name
Equipment required
Qty
KW12P Impact wrench
19 mm socket
a Before performing this item, bleed air from
Others
the travel motor.
41
Name
Qty
Assembly procedure
A-4
Installation of travel motor cover (2/2)
Right side
Left side
No.
A-9
A-10
A-11
A-12
A-13
A-14
A-15
A-16
A-17
Precautions
Tools required
Name
Qty
1
19 mm socket
Others
Q'ty
4
4
12
16
12
1
1
10
10
Equipment required
KW12P Impact wrench
42
Part No.
01024-81235
424-54-14230
01024-81230
21N-30-11340
01641-21223
21T-30-32172
21T-30-32182
01010-82460
17A-54-44130
Name
Qty
Assembly procedure
Filling swing circle with grease
A-5
Grease bath seal (all round)
4) Apply gasket sealant LG-6

to top of swing bearing.
See Note 2.
1) Fill the swing circle grease bath with grease (G2-LI).
See Note 1.
2) Apply grease to the swing circle gear contact faces. (Approx. 10 L in 80 L shown above)
3) Fill the grease bath seal with grease.
(Note 1)
(Note 2)
G2-LI
Apply LG-6 to swing circle gear

side of outer race mounting bolts.
(gasket sealant)
Supply grease near

swing circle gear.
Grease bath seal
Precautions
Tools required
Name
1) Supply grease (G2-LI) of 4

20 l (18 kg) pales = 80 l (72 kg).
2) Clean the swing circle mounting face.
Others
3) Remove the rust preventive.

(If any rust preventive is left, the bolt
torque will be decreased.)
43
Equipment required
Qty
Name
Qty
Assembly procedure
A-6
Assembly of revolving frame assembly

and undercarriage (1/2)
1) Positioning of crane and revolving frame
2) Method of slinging front end

Rear of boom foot pin
3) 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.
Precautions
Tools required
Name
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.
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.)
Others
aWhen slinging the revolving frame, adjust it to the horizontal in each

direction with shackles.
44
Equipment required
Qt
Name
Qt
Assembly procedure
A-6
Assembly of revolving frame assembly

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 to protect the pinion.
Left
Front
No.
B-1
B-2
5) Tighten the 3 bolts on each side, front 8 bolts and rear 3 bolts (17 in total) in figure
to the specified torque.
Precautions
a When disassembling to 27 t, install swing

machinery later.
a When disassembling to 32 t, raise the
motor.
See Installation of swing machinery (A-7).
Take care of the center of

gravity of the crane hook.
If the hook is loaded,
the boom lowers a little.
Name
Qt
KW45F Impact wrench
19 mm Socket
For retightening
KW45FG Impact wrench
55 mm Spline socket
Tap (M36 3)
45
Q'ty
60
60
Equipment required
For temporary tightening
Others
Fix the ropes to the hook securely.
Tools required
Part No.
21T-25-67150
01643-33690
Name
Qt
Assembly procedure
A-7
Installation of swing machinery (front) assembly (27t)

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.
B-3
B-4
B-5
B-6
B-7
B-8
B-9
Coupling
Precautions
Name
KW45F Impact wrench
46 mm Box
Joint
KW10P Impact wrench
14 mm Box
19 mm Set wrench
19 mm Spanner
32 mm Set wrench
32 mm Spanner
Others
a When connecting the revolving frame to the

undercarriage, raise the swing motor
assembly (front). (200 mm)
After connecting the revolving frame to the
undercarriage, reinstall the swing motor
assembly. (When disassembled to 32 t)
Tools required
46
Part No.
01010-83090
01643-33080
07000-B3032
07000-B3032
02896-61015
02896-61008
01024-81225
Q'ty
14
14
1
2
1
1
1
Equipment required
Qty
1
1
1
1
1
1
1
1
1
Name
Qty
Assembly procedure
A-8
Connection of swivel joint piping (1/2)
To drain filter
Connection
Coupling
Connection
No.
B-10
B-11
Precautions
Name
Qty
1
22 mm Socket
150 mm Extension
41 mm Spanner
Pliers
Set wrench
47
Q'ty
1
4
Equipment required
KW14PI Impact wrench
Others
a Connect the travel piping before installing

the swing machinery.
Tools required
Part No.
11Y-62-11980
02896-61009
Name
Qty
Assembly procedure
A-8
Connection of swivel joint piping (2/2)
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.
B-12
Precautions
Tools required
Name
Qty
1
22 mm Socket
150 mm Extension
41 mm Spanner
Pliers
Others
Q'ty
4
Equipment required
48
Part No.
07000-B3048
Name
Qty
Assembly procedure
A-9
Connection of swing circle grease piping
Connection
Precautions
Tools required
Name
Equipment required
Qty
1
19 mm Spanner
Others
17 mm Spanner
49
Name
Qty
Assembly procedure
Installation of hydraulic tank assembly (1/5)
A-10
For disassembly to 27 t
Hydraulic tank assembly

1670 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.
B-13
B-14
B-15
Precautions
Tools required
Name
a Before connecting the revolving frame to
Others
the undercarriage, install the hydraulic

tank.
50
Part No.
07000-B5230
01011-83010
21T-26-11460
Q'ty
2
12
12
Equipment required
Qty
Name
Qty
Assembly procedure
A-10
Clamp air conditioner hoses

at 4 places marked with .
Clamp PPC hoses

at 2 places marked with
Precautions
Tools required
Others
Name
51
Equipment required
Qty
Name
Qty
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.
B-16
Precautions
Tools required
Others
Name
52
Part No.
07000-B2060
Q'ty
8
Equipment required
Qty
Name
Qty
Assembly procedure
A-10
Use split flanges and bolts installed when transported.

07371-31049(2): FLANGE
07375-21035(4): BOLT
Connection at
4 places
No.
B-17
B-18
Precautions
Tools required
Others
Name
53
Part No.
11Y-62-11980
07000-B3032
Q'ty
3
1
Equipment required
Qty
Name
Qty
Assembly procedure
A-10
Clamp wiring harness

(Side of vertical panel of revolving frame).
Clamp wiring harness

(L-bracket in cab base).
Connect wiring harness connector

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

through this grommet.
Precautions
Tools required
Name
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.
When unlocked
Others
When locked
54
Equipment required
Qty
Name
Qty
Assembly procedure
Installation of fuel tank assembly
A-11
Fuel tank assembly
50 t Crane
2,400 kg (including 400 L of fuel)
Bolt
Collar
No.
C-1
C-2
Precautions
Tools required
Name
Qty
1
46 mm Socket
12 5 m Wire
Eyebolt M30-P3
Others
Q'ty
20
20
Equipment required
KW45F Impact wrench
55
Part No.
01011-83010
21T-26-11460
Name
45t Crane
Qty
1
Assembly procedure
A-12
Connection of fuel tank assembly

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 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.
C-3
C-4
C-5
C-6
C-7
Precautions
Tools required
Name
Qty
1
32 mm Spanner
36 mm Spanner
19 mm Socket
Others
Q'ty
1
1
2
2
1
Equipment required
27 mm Spanner
56
Part No.
04435-52212
02896-61012
02896-61015
02896-61018
01024-81220
Name
Qty
Assembly procedure
Connection of fuel tank assembly

piping and wiring (2/2)
A-12
Electric wiring
Clamp
Bolt
1. Clamp the wiring harness to the grease can bracket.

4 places marked with
Clamp
2. Connect the wiring harness connector marked with
Bolt
No.
C-8
C-9
C-10
Precautions
Tools required
Name

reconnect it.
When unlocked
Others
When locked
57
Part No.
04434-52312
04434-51912
01024-81220
Q'ty
1
3
4
Equipment required
Qty
Name
Qty
Assembly procedure
A-13
Installation of cab base assembly (1/2)
Cab front catwark

100 kg
Mounting bolt of
cab base assembly
Cab base assembly

2300 kg
Cab left catwark

220 kg
Mounting bolt of
cab base assembly
No.
C-11
C-12
C-13
C-14
C-15
Precautions
Tools required
Name
a Install the catwalks while the cab base is
Qty
1
30 mm Socket
12 5 m Wire
SC14 Shackle
58
Q'ty
10
10
1
1
2
Equipment required
Others
on the ground.
Part No.
01034-81245
01034-81265
21T-54-31140
21T-54-31150
01034-81245
Name
45t Crane
Qty
1
Assembly procedure
A-13
Installation of cab base assembly (2/2)
C-18
C-18
C-16
C-18
C-17
No.
C-16
C-17
C-18
Precautions
C-16
Tools required
Others
Name
59
Part No.
01011-82025
01011-82045
567-40-41380
Q'ty
20
7
27
Equipment required
Qty
Name
Qty
Assembly procedure
A-14
Installation of left floor assembly (1/4)
Install eyebolt.
Install eyebolt.
Precautions
Sling jig
Install eyebolt.
Tools required
Name
Others
After the work, return the bolts removed to

install the eyebolts.
60
Equipment required
Qty
Name
Qty
Assembly procedure
A-14
C-20
C-19
Part a
C-20
C-19
C-20
C-19
Part b
No.
C-19
C-20
Precautions
Tools required
Name
Others
Before tightening the mounting bolts at parts

(a) and (b), check that both mating faces are
fitted to each other.
61
Part No.
01010-82065
01643-32060
Q'ty
24
24
Equipment required
Qty
Name
Qty
Assembly procedure
A-14
Clearance b
Clearance a
Shim Shim
C-21
Adjust clearance at this part,

if necessary, by inserting shim
under condenser box.
C-22
Condenser box
C-23
t1.2
t1.6
Precautions
Tools required
Name
Clearance a: 15 mm 10 mm
(Reduce difference between widest and
narrowest clearances to 3 mm or less)
Others
Clearance b: 17 mm 5 mm
(Reduce difference between widest and
narrowest clearances to 3 mm or less)
62
No.
C-21
C-22
C-23
C-24
C-24
Part No.
21T-53-31530
21T-53-31540
21T-54-33471
01034-81230
Q'ty
3
3
1
3
Equipment required
Qty
Name
Qty
Assembly procedure
A-14
<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)
63
Assembly procedure
A-15
Connection of cab base assembly piping (1/2)
25
Connection (Face seal)
Green
Brown
White
Black
Yellow
Blue
Red
No color mark
Black/Black
Blue/Black
Red/Black
Green/Black
Connection (Quick coupler)
No.
C-25
Precautions
Tools required
Name
Others
a Remove the hose cap.
64
Part No.
02896-61012
Q'ty
6
Equipment required
Qty
Name
Qty
Assembly procedure
A-15
Connection of cab base assembly piping (2/2)
Connection
Right wall in cab base
No.
C-26
Precautions
Tools required
Others
Name
65
Part No.
02896-61018
Q'ty
2
Equipment required
Qty
Name
Qty
Assembly procedure
A-16
Connection of cab base assembly wiring (1/5)
Pass wiring harness through hole.
Pass wiring harness

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

CN-A05
CN-A04
CN-A22
Precautions
Tools required
Name
When connecting the DRC multi-pole

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

DT, DTP or DTHD connector" on pages 5/5
of this section.
66
Male
21T-06-33810
21T-06-338A0
21T-06-33120
08191-00770(4)
Female
21T-06-33820
21T-06-33830
21T-06-33850
08191-00770(4)
Equipment required
Qty
Name
Qty
Assembly procedure
A-16
Connection
Connection
Connection
Fix with clamps.
Precautions
Tools required
Name
When connecting the DT, DTP or DTHD

DT, DTP or DTHD connector" on pages 5/5
of this section.
Others
Remove the cover of part X when connecting

the wiring harness and install it again after
the work.
67
Equipment required
Qty
Name
Qty
Assembly procedure
A-16
"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

deformation. If it has any
abnormality, replace the whole
connector with new one.
17A-06-41830
17A-06-41840
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 connector while checking it visually.
Precautions
Tools required
Others
Name
68
Equipment required
Qty
Name
Qty
Assembly procedure
A-16
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 clearance "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.
Bottom view
Side view
Precautions
Tools required
Others
Name
69
Equipment required
Qty
Name
Qty
Assembly procedure
A-16
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 condition 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.
When locked
Precautions
When unlocked
Tools required
Others
Name
70
Equipment required
Qty
Name
Qty
Assembly procedure
A-17
Connection of left floor assembly heater piping
27
Distinction tape color: Blue
Connection
Distinction tape color: Red
No.
C-27
Precautions
Tools required
Others
Name
71
Part No.
21T-979-3320
Q'ty
2
Equipment required
Qty
Name
Qty
Assembly procedure
Connection of left floor assembly wiring
A-18
Front of machine
Left of machine
Connection
Connection
To cab
This cable is
described in A-27.
To air
conditioner
condenser
Right side of battery case
Top of air conditioner condenser
Precautions
Tools required
Name

reconnect it.
When unlocked
Others
When locked
72
Equipment required
Qty
Name
Qty
Assembly procedure
Installation of tail pipe
A-19
Top of power container
Front of machine
Left of machine
No.
D-1
D-2
D-3
Precautions
Tools required
Name
a Before performing this work, connect the
Others
container to the revolving frame.
73
Part No.
21M-01-18130
01024-81230
6162-14-5640
Q'ty
2
12
2
Equipment required
Qty
Name
Qty
Assembly procedure
A-20
Installation of power container assembly (1/2)
Power container assembly

16100 kg
Right rear stopper
Left rear stopper
Position container so that container frame will

touch positioning stopper of container mount
of revolving frame.
Precautions
Tools required
Name
a Before connecting the container, remove
Others
the undercover installed temporarily.

(See A-24.)
74
Equipment required
Qty
Name
Qty
Assembly procedure
A-20
Installation of power container assembly (2/2)
M42 3, L = 350 mm, Width across flats 65 mm

3430 -- 4212 Nm (350 -- 430 kgm)
Apply LT-2.
Nut is welded to
revolving frame.
Plate with nuts

4
No.
D-4
D-5
D-6
Precautions
Tools required
Name
Others
Retighten the bolts finally after installing the

counterweight for safety.
75
Part No.
21T-54-31121
21T-54-31130
01643-34212
Q'ty
4
20
20
Equipment required
Qty
Name
Qty
Assembly procedure
Connection of suction piping (1/2)
A-21
Use following parts installed

when transported.
01024-81230(4): BOLT

01010-81640(8): BOLT
01643-31645(8): WASHER
Replace band
(upper).
Replace band
(upper).
Connection
Main pump seen from below

No.
D-7
D-8
D-9
D-10
Precautions
Tools required
Name
Others
Since the suction tube is lowered when

delivered, prepare MIKALOR bands.
(See tightening procedure 2/2.)
76
Part No.
07000-B2140
07000-B2100
209-62-41341
20Y-62-51671
Q'ty
2
1
4
2
Equipment required
Qty
Name
Qty
Assembly procedure
Connection of suction piping (2/2)
A-21
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

(PANDO 18B made by Three Bond)
on thread of bolt
before tightening a bolt.
Bridge
Punch hole
The overlap of bridge and band.
No.
Clamp part No.
Dimension (a)
209-62-41341
15
0
-3
20Y-62-51671
20
0
-3
77
Assembly procedure
Connection of oil cooler piping and pump drain piping
A-22

07371-32076(14): FLANGE
07375-21240(28): BOLT
Connection
Temporarily
installed to hose
Connection at
3 places
Connection
No.
D-11
D-12
Precautions
Tools required
Name
Others
Take care that the O-ring will not be caught.
78
Part No.
07000-B2060
07298-02011
Q'ty
7
1
Equipment required
Qty
Name
Qty
Assembly procedure
A-23
Connection of fan motor drain piping
D-13
07371-31049(2): FLANGE
07375-21035(4): BOLT
Connection
No.
D-13
Precautions
Tools required
Others
Name
79
Part No.
07000-B3032
Q'ty
1
Equipment required
Qty
Name
Qty
Assembly procedure
A-24
Installation of suction unit undercover
Undercover is installed to
container when transported.
When connecting suction unit,

remove undercover, if necessary.
After connecting suction unit,
install undercover again.
Z
Precautions
Tools required
Others
Name
80
Equipment required
Qty
Name
Qty
Assembly procedure
A-25
Connection of delivery piping (1/2)
Remove the covers shown below.
Parts to be removed
Precautions
Tools required
Others
Name
81
Equipment required
Qty
Name
Qty
Assembly procedure
A-25
Connection of delivery piping (2/2)

07371-51470(8): FLANGE
01010-81455(16): BOLT
01643-31445(16): WASHER
Connection
Front end of power container
Left of machine
Front of machine
Precautions
Tools required
Name
Others
a Secure the scaffoldings.
82
No.
D-14
Part No.
07000-B3048
Q'ty
4
Equipment required
Qty
Name
Qty
Assembly procedure
Connection of pilot piping and fan motor piping
A-26
D-16

07371-31049(2): FLANGE
D-15
07375-21035(4): BOLT

07371-30640(4): FLANGE
07375-21035(8): BOLT
Front end of power container
Connection
Left of machine
No.
D-15
Front of machine
Precautions
D-16
Tools required
Others
Name
83
Part No.
07000-B3025
07000-B3032
Q'ty
2
1
Equipment required
Qty
Name
Qty
Assembly procedure
Connection of power container assembly

fuel piping (1/2)
A-27
Connection at
3 places
No.
D-17
D-18
Precautions
Tools required
3 Tightening torque for hose

A 177 245 Nm {18 25 kgm}
B 128 186 Nm {13 19 kgm}
Others
Name
84
Part No.
02896-61018
02896-61015
Q'ty
2
1
Equipment required
Qty
Name
Qty
Assembly procedure
A-27

fuel piping (2/2)
D-19
Connection
No.
D-19
Precautions
Tools required
Others
Name
85
Part No.
02896-61015
Q'ty
1
Equipment required
Qty
Name
Qty
Assembly procedure
A-28

air conditioner piping
Parts to be removed
Coat air conditioner lubrication oil

M24 (Width across flats: 27)
Container side is female.
Tightening torque 29.4 34.3 Nm

Container side is male.

Container side is female.

Container side is male.
Connection
Remove hose dust caps and connect hoses.

M22
M24
Precautions
Tools required
Others
Name
86
Male
21F-979-3250
21F-979-3260
Female
21F-979-3220
21F-979-3230
Equipment required
Qty
Name
Qty
Assembly procedure
A-29

heater piping
Parts to be removed
Precautions
Tools required
Name
a Before connecting these hoses, connect
Others
all of the other heater hoses.
87
Equipment required
Qty
Name
Qty
Assembly procedure

wiring (1/2)
A-30
<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.
CNT02
CNT01
Connection
Connection
May be connected to either one.
Connection
Fix 2 terminals together.
Remove cover and connect terminals in it.
After connecting, install cover again.
Precautions
Tools required
Others
Name
88
Equipment required
Qty
Name
Qty
Assembly procedure

wiring (2/2)
A-30
Left of machine
Front of machine
Pass wiring harness

through hole.
Pass wiring harness

through hole.
Connection
No.
D-19
D-20
Precautions
Tools required
Name

reconnect it.
When unlocked
Others
When locked
89
Part No.
08028-55065
01024-81020
Q'ty
2
2
Equipment required
Qty
Name
Qty
Assembly procedure
Installation of operator's cab assembly (1/3)
A-31
Operator's cab assembly
When installing cab,

remove mount cover
and stopper bracket
(see next page).
Precautions
Tools required
Others
Name
90
Equipment required
Qty
Name
Qty
Assembly procedure
A-31
Left of machine
Front of machine
Stopper bracket is installed

to cab base temporarily.
Adjust so that clearance
will be 1.5 3 mm or less
when operator is seated.
When installing operator's cab assembly, set

dowel pins of viscous mount to mating holes
so that they will not be broken.
Right and left mounts (J) - (P)
No.
E-1
E-2
E-3
Precautions
Tools required
Others
Name
91
Part No.
21T-54-36661
21T-54-36671
21T-54-35321
Q'ty
16
8
8
Equipment required
Qty
Name
Qty
Assembly procedure
A-31
STANDARD QUANTITIES OF SHIM

STD
FG
QUANTITIES QUANTITIES
PORTION
PART NUMBER
21T-54-36671
21T-54-36671
21T-54-36671
21T-54-36671
21T-54-36671
PART NUMBER
STD
FG
QUANTITIES QUANTITIES
F
G
H
Precautions
Tools required
Others
Name
92
Equipment required
Qty
Name
Qty
Assembly procedure
Installation of rotary lamp (if equipped) (1/2)
A-32
Left of machine
Front of machine
E-4
E-5
E-6
Connection
No.
E-4
E-5
E-6
Precautions
Tools required
Name

reconnect it.
When unlocked
Others
When locked
93
Part No.
8295-06-1480
21T-06-17430
01024-81225
Q'ty
1
1
2
Equipment required
Qty
Name
Qty
Assembly procedure
Installation of rotary lamp (if equipped) (2/2)
A-32
Front of machine
Left of machine
E-7
E-8
E-9
E-10
Connection
E-11
E-12
No.
E-7
E-8
E-9
E-10
E-11
E-12
Precautions
Tools required
Name

reconnect it.
When unlocked
Others
When locked
94
Part No.
8295-06-1480
21T-06-33610
21T-06-17430
01024-81225
04434-51012
01024-81220
Q'ty
1
1
1
2
1
1
Equipment required
Qty
Name
Qty
Assembly procedure
A-33
Installation of ORBCOMM antenna
Left of machine
To be tightened together
with wiring harness.
Front of machine
E-13
E-14
No.
E-13
E-14
E-15
Precautions
Tools required
Others
Name
95
E-15
Part No.
8A13-10-2100
21T-06-64491
01024-81225
Q'ty
1
1
1
Equipment required
Qty
Name
Qty
Assembly procedure
Connection of operator's cab assembly wiring
A-34
To ORBCOMM antenna
Built-on clamp
CN-A01 (Stamp A)
CN-A02 (Stamp B)
CN-A03 (Stamp C)
Connection
Cab base ceiling

Inside right of cab base
(Inside switch board)
Precautions
Tools required
Name

reconnect it.
When unlocked
Others
When locked
96
Equipment required
Qty
Name
Qty
Assembly procedure
A-35
Connection of operator's cab assembly

hydraulic piping (1/2)
Precautions
Tools required
Others
Name
97
Equipment required
Qty
Name
Qty
Assembly procedure

hydraulic piping (2/2)
A-35
Red
Blue/Black
Blue/Blue
Red/White
Red
Black/Black
Blue/White
Red/Black
Green/Black
Blue
Brown
Green
Black
White
Yellow
Blue
No color mark
Red
Connection (Face seal)
No.
E-16
E-17
Precautions
Tools required
Others
Name
98
Part No.
02896-61012
02896-61009
Q'ty
10
2
Equipment required
Qty
Name
Qty
Assembly procedure

window washer hose
A-36
Connection
Upper washer hose
Lower washer hose
Tanks A and B may
be connected to
either of upper and
lower washer hoses.
Inside right of cab base
Precautions
Tools required
Others
Name
99
Equipment required
Qty
Name
Qty
Assembly procedure

air conditioner piping
A-37
Bind 2 pieces by 2.
To cab
To cab
To compressor
Cab side
Connection (2 pcs.)
Discharge line
M16 1.5
Connection (2 pcs.)
Liquid line
M16 1.5
Connection (2 pcs.)
Coated with adhesive
Suction line
M24 1.5
After connection, wind seal
onto adapter.
After connection, wind seal onto adapter.
No.
E-18
E-19
Precautions
Tools required
Name
1. Apply compressor oil to the threaded

parts and O-rings.
Others
2. Tightening torque
M24 1.2 1.5 kgm
M16 3.0 3.5 kgm
100
Part No.
21T-979-4421
08034-20830
Q'ty
4
2
Equipment required
Qty
Name
Qty
Assembly procedure
Connection of operator's cab assembly heater piping
A-38
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.
E-20
Precautions
Tools required
Others
Name
101
Part No.
08034-20830
Q'ty
3
Equipment required
Qty
Name
Qty
Assembly procedure
A-39
Installation of operator's cab rear floor assembly
Operator's cab rear floor assembly
Left of machine
E-21
Front of machine
E-21
Clamp air conditioner piping.
No.
E-21
Precautions
Tools required
Others
Name
102
Part No.
01024-81225
Q'ty
14
Equipment required
Qty
Name
Qty
Assembly procedure
A-40
Installation of handrail around operator's cab
No.
E-22
E-23
Precautions
Tools required
Others
Name
103
Part No.
21T-54-33931
01034-81245
Q'ty
1
10
Equipment required
Qty
Name
Qty
Assembly procedure
Installation of track frame ladder
A-41
No.
F-1
F-2
F-3
F-4
F-5
Precautions
Tools required
Others
Name
104
Part No.
21T-30-32231
21T-30-32241
01010-81640
01010-82450
01643-32460
Q'ty
2
2
8
8
16
Equipment required
Qty
Name
Qty
Assembly procedure
A-42
Installation of power container side

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
No.
F-6
Precautions
Tools required
Others
Name
105
Part No.
01034-81235
Q'ty
16
Equipment required
Qty
Name
Qty
Assembly procedure
Installation of right floor assembly

and grease can cover assembly
A-43
Left of machine
Front of machine
F-8
F-7
F-9
F-9
Grease can cover assembly
F-10
F-11
F-13
F-12
Right floor assembly
No.
F-7
F-8
F-9
F-10
F-11
F-12
F-13
Precautions
Tools required
Name
Others
When slinging the grease can cover

assembly, open the top cover and
use the hanging holes in it.
106
Part No.
01010-82080
01010-82060
01643-32060
21T-53-31550
21T-54-31560
21T-54-33331
01034-81250
Q'ty
12
8
20
1
1
1
4
Equipment required
Qty
Name
Qty
Assembly procedure
A-44
Installation of fuel tank right catwalk assembly
Left of machine
Front of machine
F-14
Fuel tank right catwalk assembly
No.
F-14
Precautions
Tools required
Others
Name
107
Part No.
01034-81235
Q'ty
16
Equipment required
Qty
Name
Qty
Assembly procedure
A-45
Installation of fuel tank front catwalk assembly
Left of machine
Front of machine
F-15
(6)
Fuel tank front catwalk assembly
No.
F-15
Precautions
Tools required
Others
Name
108
Part No.
01034-81250
Q'ty
6
Equipment required
Qty
Name
Qty
Assembly procedure
Adjustment of exterior parts clearance
A-46
When and after assembling the exterior parts, adjust each clearance as shown below.
Clearance: 20 5 mm
Clearance: 15 5 mm
Clearance: Max. 30 mm
Clearance: 15 5 mm
Clearance: 20 5 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.
109
Assembly procedure
Connection of grease reel piping
A-47
Left of machine
Front of machine
Connection
Connection
Precautions
Tools required
Others
Name
110
Equipment required
Qty
Name
Qty
Assembly procedure
Installation of slide ladder assembly (1/2)
A-48
Front of machine
Left of machine
Remove right deck

sling bracket in advance.
Slide ladder assembly
No.
F-16
F-17
Precautions
Tools required
Others
Name
111
Part No.
01010-82050
567-40-41380
Q'ty
6
6
Equipment required
Qty
Name
Qty
Assembly procedure
Installation of slide ladder assembly (2/2)
A-48
Clamp wiring harness.
Precautions
Tools required
Name

reconnect it.
When unlocked
Others
When locked
112
Equipment required
Qty
Name
Qty
Assembly procedure
A-49
Installation of counterweight assembly
Counterweight assembly
24500 kg
M42 3, L = 670 mm,

Width across flats 65 mm
3430 -- 4212 Nm
{350 -- 430 kgm}
No.
F-18
F-19
F-20
F-21
F-22
Precautions
Name
Tap (M42 3)
113
Q'ty
12
12
2
2
12
Equipment required
Qty
1
Others
Tighten all the bolts temporarily first, then

tighten them permanently.
Take measures to prevent seizure of the
bolts.
Tools required
Part No.
21T-46-34120
209-46-11210
21T-46-34141
21T-46-34131
01024-81225
Name
Qty
Assembly procedure
A-50
Installation of handrail on counterweight
No.
F-23
F-24
F-25
Precautions
Tools required
Others
Name
114
Part No.
21T-54-34411
21T-54-34421
01034-81250
Q'ty
1
1
16
Equipment required
Qty
Name
Qty
Assembly procedure
A-51
Installation of handrail clamps (1/3)
When installing, use screw

as positioning jig.
Screw
7 places marked with

No.
F-26
F-27
F-28
F-29
Precautions
Tools required
Others
Name
115
Part No.
21T-54-32911
21T-54-32921
01034-81245
21T-54-65810
Q'ty
7
7
14
1
Equipment required
Qty
Name
Qty
Assembly procedure
A-51
Precautions
Tools required
Others
Name
116
Equipment required
Qty
Name
Qty
Assembly procedure
A-51
When installing, use screw

as positioning jig.
No.
F-30
F-31
F-32
Precautions
Tools required
Others
Name
117
Part No.
21T-54-31140
21T-54-31150
01034-81245
Q'ty
1
1
2
Equipment required
Qty
Name
Qty
Assembly procedure
Connection of fuel cut wire
A-52
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
Precautions
Tools required
Others
Name
118
Equipment required
Qty
Name
Qty
Assembly procedure
Connection of drain piping under power container
A-53
Front of machine
Left of machine
128 186 Nm
{13 19 kgm}
F-34
F-33
Clamp
See Note 1.
Clamp
Clamp
Connection
Connection
3.91 4.89 Nm
{0.40 0.50 kgm}
Coolant drain
Engine breather
Muffler drain
Engine oil drain
PTO oil drain
Precautions
Tools required
Name
Note 1
Project the ends of engine breather pipe

and muffler drain pipe 10 mm from
the underside of the revolving frame.
Others
Underside of
revolving frame
119
No.
F-33
F-34
Part No.
21T-01-31471
07005-02416
Q'ty
1
1
Equipment required
Qty
Name
Qty
Assembly procedure
Connection of battery wiring
A-54
See A-30 Connection of power container assembly wiring
Precautions
Tools required
Others
Name
120
Equipment required
Qty
Name
Qty
Assembly procedure
Setting of hydraulic tank strainer
A-55
Remove the suction pipe blind plug in the

hydraulic tank and set the strainer.
Door cover
Flange assembly (2)
(1) Open the hydraulic tank

upper door cover.
(2) Remove the flange

assembly.
(3) (After removal)
Strainer assembly (2)
(4) Pull up the strainer

assembly.
(5) Reverse the strainer

assembly and insert it in
the hydraulic tank again.
Precautions
Tools required
Name
Others
Carry out the above work after installing the

suction piping and hydraulic pump.
Before starting the engine, check that the
strainer is set downward.
121
(6) Install the flange

assembly and close the
door cover.
Equipment required
Qty
Name
Qty
Assembly procedure
A-56
Starting of engine, inspection of oil levels and coolant

levels, bleeding air and adjustment of track (1/19)
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
a If fuel is used up or if a fuel circuit part is removed and
installed, bleed air from the fuel circuit according to the
following procedure.
Reference
The Komatsu genuine fuel filter cartridge employs a
high-efficiency special filter. Always use it.
The common rail fuel injection system used on this
machine consists of more precise parts than the
conventional fuel injection pump and nozzle. If a filter
cartridge other than the Komatsu genuine one is used,
foreign matter may enter the fuel system and may cause
a trouble in the system. Accordingly, never use a
substitute.
When checking or servicing the fuel system, take care of
entry of foreign matter more than ever. If dirt sticks, wash
it off with fuel.
1. Replacing prefilter cartridge or bleeding air from it
1) Pull fuel shut-off lever (1) installed to the front of the
main pump in the pump room to close the fuel supply
circuit from the fuel tank.
122
Assembly procedure
A-56

2) Set a container to receive oil under the fuel prefilter

cartridge.
3) Remove the drain hose (4) of cup (3) of the water
separator.
4) Using the filter wrench, turn filter cartridge (2) to the
left to remove.
5) Turn cup (3) of the water separator installed to the
bottom of the removed cartridge to the left to remove.
(This cup will be reused.)
6) Install removed cup (3) to the new fuel prefilter
cartridge. (At this time, be sure to use a new O-ring.)
3 Cup: 10 Nm {1.0 kgm}
7) Clean the filter stand. Fill the new or reused filter

cartridge with clean fuel, apply oil to the packing
surfaces thinly, and install the cartridge to the filter
stand.
a Add fuel through 8 small holes (a) on the dirty side
without removing cap (b) at the center.
a After adding fuel, remove cap (b) at the center
and install the fuel filter.
a Fill the fuel filter with clean fuel and take care that
dirt will not enter it. Since the center is the clean
side, do not remove cap (b) when adding fuel, and
particularly take care that dirt will not enter it.
123
Assembly procedure
A-56

8) When installing the filter cartridge, tighten it 3/4 turns

after its packing surface touches the seal surface of
the filter stand.
a If the filter cartridge is tightened too much, fuel will
leak because of damage of the packing. If the filter cartridge is not tightened sufficiently, fuel will
also leak through the clearance of the packing.
Accordingly, observe the tightening angle.
When tightening the filter cartridge with the filter
wrench, take care extremely not to scratch or
dent the filter.
9) Install the drain hose.
10) Check that the drain plug at the cup bottom of the
water separator is tightened securely.
3 Drain plug:
0.2 0.45 Nm {0.02 0.046 kgm}
11) When replacing the standard fuel filter cartridge (every 1,000 hours) or bleed air from it, see Replacing
main filter cartridge.
12) Press down fuel cut lever (1) installed to the front of
the main pump in the pump room to supply the fuel.
13) Start the engine and check the filter seal surface and
water separator mounting surface for fuel leakage
and then run the engine at low idle for about 10
minutes.
2. Replacing main filter cartridge or bleeding air from it

1) Replacing main filter cartridge
1] Pull fuel shut-off lever (1) installed to the front of
the main pump in the pump room to close the fuel
supply circuit from the fuel tank.
124
Assembly procedure
A-56

2] Set a container to receive oil under the filter cartridge.

3] Using the filter wrench, turn filter cartridge (5) to
the left to remove.
4] Clean the filter stand. Thinly apply oil to the packing of the new filter cartridge and install the cartridge to the filter stand.
a Do not add fuel to the fuel filter cartridge.
a Remove cap (b) at the center and install the
fuel filter.
5] When installing the filter cartridge, tighten it 3/4
turns after its packing surface touches the seal
surface of the filter stand.
If the filter cartridge is tightened too much, fuel
will leak because of damage of the packing. If the
filter cartridge is not tightened sufficiently, fuel will
also leak through the clearance of the packing.
Accordingly, observe the tightening angle.
When tightening the filter cartridge with the
filter wrench, take care extremely not to
scratch or dent the filter.
6] After replacing filter cartridge (5), loosen its air
bleeding plug (6) and press down fuel shut-off
lever (1) to open the fuel supply circuit from the
fuel tank.
a Open the circuit in the reverse order to closing.
125
Assembly procedure
A-56

2) To bleed air when fuel is used up, perform the following air bleeding procedure taken after replacement of
the main filter cartridge.
3) Bleed air according to the following procedure.
1] Fill the fuel tank with fuel (to the FULL mark of
the fuel level gauge).
2] After replacing filter cartridge (5), loosen air
bleeding plug (6).
3] Remove locknut (8) of priming pump lever (7),
operate priming pump lever (7), and check that
fuel and bubbles flow out of air bleeding plug (6).
4] Tighten air bleeding plug (6).
3 Plug: 4.9 6.9 Nm {0.5 0.7 kgm}
5] Push in priming pump lever (7) and tighten locknut (8) to lock it.
6] After replacing the filter cartridge, start the engine
and check the filter seal surface for fuel leakage.
126
Assembly procedure
A-56

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 to receive oil in oil pan.
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, tighten only bleeder (2) of the
main pump P2 temporarily.
a Keep bleeder (1) of the main pump P1 loose.
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.
a For cranking, idle the engine at low speed for 15
seconds twice.
7) Loosen the bleeder (2) of the main pump P2.
127
Assembly procedure
A-56

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.
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.
13) Loosen plug (5) for the suction tube and make sure that bubble-free oil flows out of it. Then, tighten the plug.
3 Plug : 58.8 78.4Nm {6 8kgm}
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.
these bleeders.
3 Bleeder : 8.8 9.8Nm {0.9 1.0kgm}
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 cylinder 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 procedures 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.
128
Assembly procedure
A-56

(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 circuit 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
bleeder (11). Then, tighten the bleeders.
3 Bleeder : 8.8 9.8Nm {0.9 1.0kgm}
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 circuit 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 bleeders (12). Then, tighten the bleeder.
3 Bleeder : 8.8 9.8Nm {0.9 1.0kgm}
129
Assembly procedure
A-56

(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 wiring harness spring case elbow 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 (13). Then, tighten bleeder.
3 Bleeder : 8.8 9.8 Nm {0.9 1.0 kgm}
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),
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)
130
Assembly procedure
A-56

(7) Air bleeding from control valve 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.
Elbow with bleeders
1) Start the engine and loosen the bleeder (13).

a The bleeders are installed on the wiring harness spring case elbow of the control valve spool (28 places in total).
2) Control each actuator while the engine is idle at low speed.
Make sure that bubble-free oil flows out of bleeder (13). Then, tighten bleeder.
3 Bleeder: 8.8 9.8 Nm {0.9 1.0 kgm}
The operation of each lever should be enough to the extent that each hydraulic switch turns on.
Front side of control valve
Rear side of control valve
Left travel
Right travel
131
Assembly procedure
A-56

(8) 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
no bubbles flows out of bleeder (1), tighten bleeder (1).
3 Bleeder : 8.8 9.8 Nm {0.9 1.0 kgm}
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
no bubbles flows out of bleeder (2), tighten bleeder (2).
3 Bleeder : 8.8 9.8 Nm {0.9 1.0 kgm}
k Operate each lever slightly to a degree that each oil pressure switch is turned ON.
132
Assembly procedure
A-56

(9) Bleeding air from HIC circuit, supplying oil to it, and adjusting track
Since the idler cushion of PC2000-8 uses the hydraulic cylinder and is the closed circuit, bleed air from the circuit.
(Before moving the machine, be sure to bleed air to protect the seals.)
Remaining pressure relief from HIC circuit
k
If the HIC equipment is to be removed or the piping

are to be disconnected, release the remaining pressure from the HIC circuit as follows.
Lower the work equipment completely to the ground,
stop the engine and use the control lever several
times to relieve pressure remaining in the pipe. Then,
loosen the oil filler cap of the hydraulic tank gradually
to relieve pressure in the tank.
1) Loosen stop valves (1) and (2) slowly and relieve
pressure remaining in the circuit.
k Quick loosening will cause a high pressure in
the tank circuit, so be sure to loosen the stop
valves slowly.
a After 1 minute elapsed, the remaining gas will
have been relieved completely.
2) When the remaining pressure is relieved completely,

retighten stop valves (1) and (2).
133
Assembly procedure
A-56

Bleeding air from HIC circuit and supplying oil to it

Before bleeding air from the HIC circuit and supplying grease to the hydraulic grease supply cylinder, be sure to bleed air.
1. Loosen plug (1) of the grease cylinder by 1 turn
(2 places on the right and left).
2. Fully open stop valve (2) at the right inside of the axle.
134
Assembly procedure
A-56

3. Fully open stop valve (3) at the left inside of the axle.
4. Loosen air bleeding plug (4) of the cushion cylinder about

1 turn (2 places on the right and left).
135
Assembly procedure
A-56

5. Remove plug (6) under the block on the side of the relief
valve and loosen air bleeding plug (5) about 1 turn.
6. Run the engine at low idle for 2 3 minutes.
7. When clear oil flows out of air bleeding plugs (4) (at 2
places on the right and left) and the hole for plug (6) under
the block on the side of the relief valve, fully tighten valves
(2) and (3) and plugs (4) and (5).
8. Tighten plugs (1) (at 2 places on the right and left).

9. Tighten plug (6).
3 Plug: 81.3 6.9 Nm {8.3 0.7 kgm}
a Be sure to tighten plug (1) last.
a Fully close the stop valves and air bleeding plugs.
a After bleeding air, test and adjust the track shoe tension.
For details, see Testing and adjusting track shoe tension. in the shop manual.
136
Assembly procedure

A-56
HIC system
1.
2.
3.
4.
5.
6.
7.
8.
9.
10. Stop valve

11. Pressure reducing valve
12. Check valve
13. Right travel valve
14. Center swivel joint
15. Control valve (R.H.)
16. Line oil filter
17. Hydraulic pump (front)
Idler
Yoke
Plunger A
Plunger B
Cylinder
Stop valve
Relief-check valve
Accumulator
Check valve
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
137
Assembly procedure
A-56

Adjusting
If the track shoe tension is abnormal, adjust it according to the
following procedure.
1. Adjusting HIC cylinder
1) Check that stop valve (4) at the right inside of the axle
is fully closed.
2) Open stop valve (5) at the left inside of the axle.
138
Assembly procedure
A-56

3) Turn the fuel control dial to the medium position and

run the engine at medium speed.
4) Operate the right travel lever in the forward and reverse directions intermittently (2 3 seconds) 5 6
times.
a Do not perform this operation on a slippery place
(steel plate etc.)
a Even if projection (a) of the hydraulic cushion cylinder is normal, the hydraulic cushion charge
pressure may be low. Accordingly, perform the
operation in 4) securely.
5) Check that projection (a) of the plunger of hydraulic
cushion cylinder (7) is 135 5 mm on each side.
6) If projection (a) is not 135 5 mm, perform the operation in 4) again to set projection (a) in the specified
range.
a If projection (a) cannot be set to 135 5 mm, too
much grease may be in grease cylinder (6). In this
case, discharge the grease according to 2. Adjusting grease cylinder.
7) Fully close stop valve (5).
2. Adjusting grease cylinder
When tension is low
1) Add grease through plug (8).
2) To check that the tension is normal, move the machine forward slowly.
3) Check the track shoe tension again. If it is not proper,
adjust it again.
4) You may adjust the track shoe tension by adding

grease until projection (b) of grease cylinder (9) becomes 35 190 mm.
a If the tension is still low, the pins and bushings
may be worn much.
139
Assembly procedure
A-56

When tension is too high

1) Loosen plug (8) gradually to discharge grease.
k Do not loosen the valve more than 1 turn. If it is
loosened more, it may jump out because of the
high-pressure grease in it.
k If the grease is not discharged well, move the machine forward and in reverse and then check the
track shoe tension.
2) Tighten plug (8).
3) To check that the tension is normal, move the machine forward and in reverse.
4) Check the track shoe tension again. If it is not proper,
adjust it again.
140
Assembly procedure
A-57
Permanent tightening of swing circle bolt
In assembly procedure No. A-6, 7 of the 60 mounting bolts of the revolving frame and swing circle were tightened.
Tighten the other 43 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 (54 bolts).
Width across flats: 55

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

Apply LT-2.
Precautions
Name
55 mm spline socket
Others
Make sure to bleed air from each part

before swinging the upper structure.
Tools required
141
Equipment required
Qty
Name
Qty
Assembly procedure
A-58
Parts to be touched up after field assembly

(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)
Precautions
Tools required
Others
Name
142
Equipment required
Qty
Name
Qty
Assembly procedure
A-59
Connection of engine heater connection port (1/3)
No.
01
02
03
04
05
06
07
08
09
Precautions
Tools required
Name
Qty
1
KW12P Impact wrench
17 mm Socket
19 mm Socket
250 mm Extension
22 mm Spanner
27 mm Spanner
Others
Q'ty
4
2
1
1
1
1
1
1
1
Equipment required
KW10P Impact wrench
143
Part No.
01024-81230
01024-81020
04434-51912
04434-51212
01024-81230
04434-51912
04434-51212
195-33-11220
01024-81230
Name
Qty
Assembly procedure
A-59
Color of hose distingush tape: white
Connection (face seal)

1 point
No.
10
11
12
13
14
15
16
17
Connection
2 points
Precautions
Tools required
Others
Name
144
Part No.
21T-06-31570
01024-81230
04434-52312
01024-81230
04434-51912
01024-81230
02896-61015
07281-00419
Q'ty
1
4
2
1
1
1
1
2
Equipment required
Qty
Name
Qty
Assembly procedure
A-59
(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.
Engine left front side
Turn the knob counterclockwise

to open the valves.
Engine right side
Precautions
Tools required
Name
Others
Note) After the procedure (1) is finished,

perform the procedure (2).
145
Equipment required
Qty
Name
Qty
C. ASSEMBLY OF BACKHOE
147
Assembly procedure
C-1
Installation of boom cylinder (1/2)
Method of slinging boom cylinder for installation
Boom cylinder
Weight: 2,400 kg/each
Precautions
Tools required
Name
Equipment required
Qty
Hammer
36 mm Socket
KW38G Impact wrench
12, 5 m Wire
2
1
SC14 Shackle
8 t Crane
Others
16, 5 m Wire
148
Name
Qty
Assembly procedure
C-1
[Procedure]
(1) Remove the parts marked with A which are installed
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) Set the shims and spacer and install the parts
marked with A.
Reduce the clearance marked with to 1 mm or
less.
(5) Perform this procedure for the right and left boom
cylinder feet.
Boom cylinder
Left Right
H = 2000
O-ring
Side of center of machine
Pin, weight: 93.8 kg

(2 places)
Clearance between pin and

revolving frame bushing:
0.128 0.28 mm
boom cylinder bushing hole:
0.243 0.366m
Plate, bolt, washer
Bushing
(has been press fitted)
(outside)
Bushing
(inside)
(2 places)
(2 places)
Left side
Right side
Shim
Shim
Shim
Precautions
Tools required
Name
Others
1. There are bushings press fitted to the

revolving frame, and the parts marked
with A are installed temporarily for
transportation.
2. Before inserting the pin, apply grease to
the pin hole (inside surface of the
bushing).
a When installing the plate, hold it with
wires etc. so that your fingers will not be
caught.
149
No.
H-1
H-2
H-3
H-4
H-5
H-6
Part No.
707-01-XK750
707-01-XK760
21T-70-31421
21T-70-31470
21T-70-31690
07000-15180
Q'ty
1
1
2
8
8
4
Equipment required
Qty
Name
Qty
Assembly procedure
Installation of boom cylinder hoses
C-2
Remove the blind plugs from the boom cylinder piping and revolving frame piping,
and then install the 4 hoses as shown in the
following figure.
Use the split flanges, bolts, O-rings, etc.
used to install the blind plugs (on the chassis 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.:
01010-81455 (Bolt) 16 pcs.:
01643-81445 (Washer) 16 pcs.:
07000-B3048 (O-ring) 4 pcs.:
07378-11410 (Head) 4 pcs.:
H-10
H-8
H-7
O-ring
Hose inside
Reuse
Reuse
Reuse
Keep
Keep
H-9
O-ring
Hose outside
No.
H-7
H-8
H-9
H-10
Precautions
Name
Qty
1
27 mm Socket
150 mm Extension
150
Q'ty
4
4
2
2
Equipment required
22 mm Socket
Others
1. Take care not to twist the hoses when

installing.
2. Take care not to catch the O-rings in the
parts (Apply grease to them before
installing).
3. After connecting the hoses, bleed air from
the boom cylinder.
a Tighten the hoses from the revolving
frame side (to prevent them from
twisting).
Tools required
Part No.
07000-B2060
07000-B3048
21T-64-39410
07083-01417
Name
Qty
Assembly procedure
Assembly of boom sub assembly (1/4)
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
Tube
Tube
O-ring
Washer
O-ring
O-ring
Washer
Bolt
Washer
Bolt
Bolt
Arm cylinder tube assembly
O-ring
Washer
Bolt
No.
H-11
H-12
H-13
H-14
H-15
H-16
H-17
H-18
Precautions
Name
Qty
1
22 mm Socket
27 mm Socket
650 mm Extension
150 mm Extension
151
Q'ty
1
1
1
2
7
32
4
28
Equipment required
19 mm Socket
Others

installing).
a Securely take measures to prevent the
arm cylinder from projecting.
Tools required
Part No.
21T-64-39140
21T-64-39150
21T-64-39160
07000-B3048
07000-B2060
01643-31845
01010-81840
01010-81865
Name
Lift work stand
Qty
1
Assembly procedure
C-3
2. Installation of arm cylinder

Fix the arm cylinder rod securely so that it will not project during the work.
Arm cylinder
Left
Right
[Procedure]
(1) Remove the pins installed to the boom temporarily.
(2) Clean the pins and inside surface of the bushings.
(3) Sling the cylinder and position it to the pin holes.
(4) Set the shim and install the pin.
(5) Perform the above procedure for both right and left
arm cylinder bottoms.
Plate, bolt, washer
O-ring
Pin
Shim t11
152
No.
H-19
H-20
H-21
H-22
Part No.
707-01-XK770
707-01-XK780
07000-12140
21T-70-31441
Q'ty
1
1
4
4
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
H-24 H-27 H-28 H-30 H-32
Hose
#20
H-23
Flange on
Washer on
Bolt on
O-ring cylinder side cylinder side cylinder side

H-26
H-29
H-33
H-31
Remove the blind plugs from the boom piping (tubes) and arm cylinder piping, and
then install the 4 hoses as shown in the following figure.
Connecting parts: 8 places marked with
Use the split flanges, bolts, etc. used to install the blind plugs on the tube side as they
are.
H-25
H-27
Hose
#14
O-ring Flange on
H-28
H-30
H-32
Washer on Bolt on
cylinder side cylinder side cylinder side
No.
H-28
H-29
H-30
H-31
H-32
H-33
Precautions
Part No.
07371-51470
07371-52080
01643-31445
01643-31845
01010-81455
01010-81865
Parts to install blind plugs (on tube side)

#20 Hose
07371-52080 (Flange) 4 pcs.:
Reuse
01010-81865 (Bolt) 8 pcs.:
Reuse
07000-B2060 (O-ring) 2 pcs.:
Keep
07378-12010 (Head) 2 pcs.:
Keep
#14 Hose
07371-51470 (Flange) 4 pcs.:
01010-81455 (Bolt) 8 pcs.:
01643-31445 (Washer) 8 pcs.:
07000-B3048 (O-ring) 2 pcs.:
07378-11410 (Head) 2 pcs.:
Q'ty
4
4
8
8
8
8
Tools required
Name
Others

installing).
a Securely take measures to prevent the
arm cylinder from projecting.
153
No.
H-23
H-24
H-25
H-26
H-27
Reuse
Reuse
Reuse
Keep
Keep
Part No.
07084-02022
07085-01418
07085-01420
07000-B2060
07000-B3048
Q'ty
2
1
1
4
4
Equipment required
Qty
Name
Qty
Assembly procedure
C-3
3. Installation of working lamps
Install the working lamps

as shown in the figure at left.
4 place on right and
left side of boom
Connect the wires at

places marked with .
4 place on right and
left side of boom
Seal
Working lamp Bracket Washer
Bolt
Ground bolt
No.
H-34
H-35
H-36
H-37
H-38
H-39
Precautions
Tools required
Others
Name
154
Part No.
21T-06-32810
20Y-06-21551
01643-31445
01010-81430
01024-81225
209-72-11311
Q'ty
4
4
4
4
4
4
Equipment required
Qty
Name
Qty
Assembly procedure
Installation of boom assembly (1/2)
C-4
1. Slinging method
50 t Crane
30 5 m wire 4 pcs.
+
SB55 shackle 4 pcs.
Apply wooden blocks

(about 100 mm square)
to protect grease piping
and wiring harness.
Hook hole diameter: 80
a Sling horizontally.
Boom assembly
Weight: 20,900 kg
Precautions
a Take care that wooden blocks will not be

driven out.
Name
Equipment required
Qty
Hammer
36 mm Socket
KW38G Impact wrench
30, 5 m Wire
SB55 Shackle
50t Crane
Others
1. Appoint a worker to act as a signalman for

the crane operator.
2. Do not go under a raised load.
3. Check that the wires are fitted properly to
the hook.
4. When working, securely fix the arm
cylinder rod to prevent it from projecting.
Tools required
155
Name
Lift work stand
Qty
1
Assembly procedure
Installation of boom assembly (2/2)
C-4
2. Installation of boom foot pin
Bushing (has been press fitted) (outside)
Boom assembly
(2 places)
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-40
Shim
H-41
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.
H-40
H-41
Precautions
Tools required
Name
Others

revolving frame and boom, and the parts
marked with 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.
the inside of the bushing.
156
Part No.
21T-70-31480
21T-70-31490
Q'ty
8
16
Equipment required
Qty
Name
Qty
Assembly procedure
C-5
50 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)
Precautions
Name
Equipment required
Qty
Hammer
36 mm Socket
KW38G Impact wrench
150 mm Extension
2, 5 m Wire
16, 5 m Wire
50t Crane
Others
1. When slinging the boom cylinder, do not

install the wire directly to its rod or body.
(Protection of rod)
Tools required
157
Name
Qty
Assembly procedure
C-5
Bushing (has been press fitted) (inside)
Bushing (has been press fitted) (outside)
21T-70-31250 (2 places)
21T-70-31240 (2 places)
Plate, bolt, washer

21T-70-71490 (2)
Pin, Weight: 98.4 kg
01643-32460 (4)
21T-70-31181 (2 places)
01010-82455 (4)
H-42
O-ring
[Procedure]
(5) Remove the parts marked with which are installed to the boom temporarily.
(7) Sling the cylinder with the wire and align the pin holes by extending or retracting the rod.
(8) Fit the O-ring and pin and install the plate.
(Since the pin is heavy, sling it with the crane carefully.)
Clearance between pin and boom bushing: 0.380 0.508 mm
Clearance between pin and boom cylinder: 0.243 0.366 mm
(9) Perform this procedure for the right and left boom cylinder tops.
No.
H-42
Precautions
Name
Others

boom assembly, and the parts marked
with are installed temporarily for
transportation.
2. When inserting the pin, check that the Oring is not caught in it.
3. Check that the pin and inside of the
bushing are clean.
4. Extend and retract the boom cylinder
carefully while running the engine at low
idle. Operate only the boom control lever.
Tools required
158
Part No.
07000-B5180
Q'ty
4
Equipment required
Qty
Name
Qty
Assembly procedure
C-6
Installation of hoses between boom and chassis
I-1
Blind plugs
Tube side
07071-52080
01643-31845
01010-81835
07000-B2060
07378-12010
(12)
(24)
(24)
(6)
(6)
Hose side
07371-52080
01643-31845
01010-81865
07000-B2060
21T-64-39620
O-ring
(12)
(24)
(24)
(6)
(6)
Arm B
Arm H
Bucket B
Bucket B
Bucket H
Arm B
[Procedure]
(1) Remove the blind plugs from the hoses and tubes.
The parts marked with will be reused to connect the hoses and tubes.
(2) Connect the hoses and tubes (6 places).
No.
I-1
Precautions
Name
Qty
1
27 mm Socket
150 mm Extension
159
Q'ty
6
Equipment required
22 mm Socket
Others

parts.
(Apply grease to them before installing.)
2. When the oil stopper is removed, oil
spouts out. Take care.
Tools required
Part No.
07000-B2060
Name
Qty
Assembly procedure
Installation of arm assembly (1/3)
C-7
1. Preparation
50 t Crane
50 t Crane
[Procedure]
(1) Remove the parts marked with which are installed
to the boom top temporarily.
(3) Press fit the seals to arm top, link and boom connecting bushing.
30 5 m wire 2 pcs.
+
SB55 shackle 2 pcs.
Arm assembly
Weight: 12,900 kg
Precautions
Before inserting the pin, apply grease to

Fix the link securely so that the bucket
cylinder will not extend.
Name
Equipment required
Qty
Hammer
36 mm Socket
KW38G Impact wrench
150 mm Extension
30, 5 m Wire
SB55 Shackle
50t Crane
Others
Tools required
160
Name
Qty
Assembly procedure
C-7
No.
I-2
I-3
I-4
Precautions
Tools required
Name
Others
Install the seals so that they will not slant.
161
Part No.
21T-70-31290
21N-70-12160
209-72-11261
Q'ty
2
4
4
Equipment required
Qty
Name
Qty
Assembly procedure
C-7
2. Installation of arm assembly
50 t Crane
[Procedure]
(1) Raise and lower the boom several times. After the boom cylinder becomes 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.
Bushing
t12
t9
t1
t1.5
21T-70-32151 (2 places)
Shim
t = 1.5
Shim
t=1
Shim Shim
t = 9 t = 12
O-ring
Precautions
Name
Qty
1
36 mm Socket
KW38G Impact wrench
150 mm Extension
30, 5 m Wire
SB55 Shackle
50t Crane
Nylon sling
162
Part No.
21T-70-31391
21T-70-31780
21T-70-31810
21T-70-31820
07000-B5260
Q'ty
2
1
1
1
2
Equipment required
Hammer
Others
1. Take care not to catch the O-rings and

seals in the parts.
(Before fitting the O-rings, apply grease to
them.)
2. There are bushings press fitted to the arm
assembly and boom assembly, and the
parts marked with are installed
temporarily for transportation.
Tools required
No.
I-5
I-6
I-7
I-8
I-9
Name
Qty
Assembly procedure
Installation of arm cylinder
C-8
Arm cylinder
12 5 m Wire
Boom
Arm cylinder top
Arm
[Procedure]
(1) Remove the parts marked with which
are installed to the arm cylinder top temporarily.
(3) Install the wire to the left arm cylinder
assembly as shown in the figure at left.
(4) Remove the rod fixing wire of only the
left cylinder.
(5) Give the operator directions to operate
the arm.
(6) 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 little.
(7) Set the seal, insert the pin, and install
the O-ring and cover.
(8) Perform this procedure similarly for the
right arm cylinder top.
Section of arm cylinder top

Pin
Shim
O-ring
Lockplate, washer, bolt
(2 places)
I-10
I-11

arm bushing: 0.503 0.629 mm
arm cylinder: 0.243 0.369 mm
Bushing (has been press fitted)

(4 places)
No.
I-10
I-11
Precautions
Tools required
Name
Qty
1
36 mm Socket
KW38G Impact wrench
150 mm Extension
12, 5 m Wire
50t Crane
163
Q'ty
4
4
Equipment required
Hammer
Others
1. After connecting the hose, bleed air from the

arm cylinder.
2. Limit the engine speed to low idle and do not
move the cylinder to the stroke end.
3. Take care of the seals and O-rings. (Apply
grease before fitting)
4. Align the holes carefully and do not put your
hand/finger in the holes.
assembly, and the parts marked with are
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
inside of the bushing.
Part No.
21T-70-32181
07000-B2140
Name
Qty
Assembly procedure
Connection of hoses between boom and arm
C-9
\
Remove the blind plugs from the boom piping (tubes) and bucket cylinder piping, and
then install the 4 hoses as shown in the following figure.
Connecting parts: 8 places marked with
Use the split flanges, bolts, etc. used to install 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
07000-B2060 (O-ring) 2 pcs.:
Keep
07378-12010 (Head) 2 pcs.:
Keep
#14 Hose
07371-51470 (Flange) 4 pcs.:
01010-81455 (Bolt) 8 pcs.:
01643-31445 (Washer) 8 pcs.:
07000-B3048 (O-ring) 2 pcs.:
07378-11410 (Head) 2 pcs.:
I-15
Hose
#20
I-17
I-13
I-19
I-21
O-ring Flange on Washer on Bolt on

cylinder side cylinder side cylinder side
Precautions
I-18
I-20
I-14
I-16
Hose
#20
O-ring
Flange on Washer on
cylinder side cylinder side
No.
I-17
I-18
I-19
I-20
I-21
Part No.
07000-B2060
01643-31445
01643-31845
01010-81455
01010-81865
Bolt on
cylinder side
Q'ty
4
8
8
8
8
Tools required
Name
Qty
1
27 mm Socket
150 mm Extension
164
No.
I-12
I-13
I-14
I-15
I-16
Part No.
07371-51470
07371-52080
07084-41427
07084-42026
07000-B3048
Q'ty
4
4
2
2
4
Equipment required
22 mm Socket
Others

installing).
the bucket cylinder.
3. When the oil stopper is removed, oil
spouts out. Take care.
I-12
Reuse
Reuse
Reuse
Keep
Keep
Name
Qty
Assembly procedure
C-10
Connection of auto grease piping
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 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.
I-22
I-23
I-24
I-25
I-26
I-27
I-28
Precautions
Tools required
Name
Qty
1
32 mm Spanner
Others
Q'ty
1
3
3
6
1
2
1
Equipment required
27 mm Spanner
165
Part No.
21T-68-31830
203-973-5660
203-973-5720
01024-81055
21T-70-75290
01024-81225
07631-20409
Name
Qty
Assembly procedure
C-11
Connection of wiring between boom and chassis
Remove the blind plugs and connect to CN-A13 in the cab base.
Blind plugs
08191-00770 (Plug) 4 pcs.
08192-14100 (Connector) 1 pc.
Precautions
Tools required
Others
Name
166
Equipment required
Qty
Name
Qty
Assembly procedure
Installation of bucket assembly (1/3)
C-12
50 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) Remove the parts marked with (pins, covers, etc.) and clean the pins and inside of the
bushings. (For details, see 2/2.)
(3) Coupling with arm
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.
Wooden block
Precautions
Name
Equipment required
Qty
Hammer
19 mm Socket
55 mm Socket
10 mm Spanner
10 mm Hexagonal wrench
KW20P Impact wrench
50t Crane
Others

assembly and bucket assembly, and the
parts marked with are installed
temporarily for transportation.
2. Put a block under the bucket to prevent
the latter from falling back down.
Tools required
167
Name
20, 5 m Wire
Qty
2
Assembly procedure
C-12
Detail of arm and bucket connecting pins
Cover, O-ring, bolt, swivel
Cover, O-ring, bolt, washer (outside)
Cover, O-ring, bolt, washer (inside)
O-ring: See following figure.
Pin
Bushing
Bushing
Take care of installed direction of cover.

If right and left are mistaken, grease hose will be broken.
Bushing
J-1
Seal (bucket side)
Clearance between pin and arm bushing: 0.382 0.527 mm

Clearance between pin and bucket bushing (outside): 0.043 0.306 mm
Clearance between pin and bucket bushing (inside): 0.163 0.290 mm
If right and left are mistaken,

grease hose will be broken.
Washer
Nut
Bolt
O-ring
O-ring section
Precautions
Tools required
Name
Others
1. Take care of the seals and O-rings

168
No.
J-1
J-2
J-3
J-4
J-5
Part No.
209-72-11261
209-70-71370
205-09-61240
01640-20610
01596-00606
Q'ty
4
4
4
8
4
Equipment required
Qty
Name
Qty
Assembly procedure
C-12
[Procedure]
(1) Remove the right and left covers.
(2) Connect the hoses.
(3) Install the right and left covers.
Hose
Cover
Cover
169
Assembly procedure
Installation of bucket link (1/2)
C-13
Connection of bucket link
[Procedure]
(1) Remove the parts marked with which are installed temporarily to the bucket joint of the bucket link. (For details, see 2/2.)
(2) Clean the joints.
(3) 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.
(4) Install the pins.
(5) Install the covers.
(6) Supply grease.
Press
Bucket link
connecting ping
Precautions
Name
Equipment required
Qty
Hammer (large)
24 mm Socket
KW20P Impact wrench
150 mm Extension
12, 5 m Wire
50t Crane
Others
1. Since air has not been bled from the

bucket cylinder, limit the engine speed to
low idle and do not move the cylinder to the
stroke end.
2. Set the arm angle carefully so that you can
work easily.
3. There are bushings press fitted to the link
assembly, and the parts marked with * are
installed temporarily for transportation.
4. When moving the bucket cylinder, set the
engine speed slow and operate the lever
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
bucket cylinder.
Tools required
170
Name
Qty
Assembly procedure
Installation of bucket link (2/2)
C-13
Bucket link connecting pin
Shim
t1.0
Adjust clearance to 1 mm or less.

Cover, O-ring, bolt, washer (inside)
Bushing
Pin
Clearance between pin and link bushing: 0.363 0.507 mm
Clearance between pin and bucket: 0.043 0.306 mm
No.
J-6
Precautions
Tools required
Name
Others
1. Take care of the seals.

171
Part No.
21N-72-11230
Q'ty
2
Equipment required
Qty
Name
Qty
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) 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 If the engine speed is set high or the cylinder is moved to the stroke end from the first operation, the air in the cylinder
may damage the piston packing etc.
a After starting the engine, warm it up sufficiently to fit all the parts.
(2) Extend the boom cylinder to the stroke end and keep the boom control lever at the stroke end for 3 minutes.
(3) Run the engine at full throttle and keep the boom control lever in the same position as (2) for 1 minute.
Precautions
Tools required
Others
Name
172
Equipment required
Qty
Name
Qty
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.
a If the engine speed is set high or the cylinder is moved to the stroke end from the first operation, the air in the cylinder may damage the piston packing etc.
Precautions
Tools required
Others
Name
173
Equipment required
Qty
Name
Qty
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.
a If the engine speed is set high or the cylinder is moved to the stroke end from the first operation, the air in the cylinder may damage the piston packing etc.
(3) After bleeding air, add hydraulic oil to the specified level.
Precautions
Tools required
Name
Others
Bleed air with the bucket installed.

If the bucket cylinder is moved to near either
stroke end while the bucket is not installed,
the auto-grease hose will be broken.
174
Equipment required
Qty
Name
Qty
Assembly procedure
C-15
Parts to be touched up after field assembly

(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)
Precautions
Tools required
Others
Name
175
Equipment required
Qty
Name
Qty
Assembly procedure
C-16
Bleeding air from auto grease circuit (1/3)
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

Indicator pin
Locknut
19.6 -- 24.5 Nm {2.0 -- 2.5 kgm}
Service nipple
Plug (581-96-19590)
19.6 -- 29.4 Nm {2.0 -- 3.0 kgm}
Manifold
Injector assembly
Precautions
Tools required
Name
Others
A Do not use molybdenum disulfide grease

to the bearings of the swing circle etc.
Bushing: Molybdenum disulfide grease
may be used.
Bearing: Use lithium grease.
176
Equipment required
Qty
Name
Qty
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

Boom top, right
Boom cylinder head, right
Boom foot, right
Plug (581-96-19590)
19.6 -- 29.4 Nm {2.0 -- 3.0 kgm}
Boom top face
177
Assembly procedure
C-16
Arm B boss, right

Arm A boss, right
Bucket, right
Bucket cylinder head, right
Bucket cylinder bottom, right
Bucket cylinder head, left
Arm cylinder head, right
Bucket, left
Arm cylinder head, 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
Front link + Wrist link, right
Front link + Wrist link, right
Plug (581-96-19590)
Arm top face
178
19.6 -- 29.4 Nm {2.0 -- 3.0 kgm}
LS. ASSEMBLY OF LOADING SHOVEL

WORK EQUIPMENT
179
Assembly procedure
LS-1
(1)
(2)
(3)
(4)
(5)
(6)
Installation of arm cylinder bottom parts
Remove the lock piece fixed to the boom and remove the arm cylinder bottom pins.
Lay the 2 arm cylinders in parallel on wood blocks.
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.
Install both arm cylinders similarly.
Install the lock piece.
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
Left:
DM945 438 40
Cold district
specification
DM945 468 40
Right:
DM945 449 40
DM945 469 40
STD
No.
01
02
Precautions
Tools required
Name
Others
1. Apply grease (GL-L1) to the inside of the

bushings.
2. Install the arm cylinder bottom parts with
the piping ports down.
180
Part No.
DM945-438-40
DM945-449-40
Q'ty
1
1
Equipment required
Qty
Name
Qty
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
Left:
DM945 418 40
Cold district
specification
DM945 462 40
Right:
DM945 419 40
DM945 463 40
STD
Precautions
Tools required
Others
Name
181
Equipment required
Qty
Name
Qty
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.
(2) Clean the pin and inside of the
bushing.
Boom cylinder
Left
Right
(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
(2 places)
Plate, bolt, washer
Bushing which has

been installed (Inside)
Bushing which has

been installed (Outside)
(2 places)
(2 places)
Shim
Shim
Precautions
The machine is transported with the parts

marked with A installed temporarily.
Check that the pins and inside of the
bushings are cleaned.
Tools required
Name
Qty
1
36 mm socket
KW38G impact wrench
12, 5 m wire
182
Part No.
DM945-418-40
DM945-419-40
21T-70-31421
21T-70-31690
21T-70-31470
Q'ty
1
1
2
4
4
Equipment required
Hammer
Others
No.
01
02
03
04
05
Shim
Name
45 t crane
Qty
1
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.
01010-81865 (Bolt)
16 pcs.
01643-81845 (Washer) 16 pcs.
07000-B2060 (O-ring) 4 pcs.
07378-12010 (Head) 4 pcs.
Hose #14
07371-51470 (Flange) 8 pcs.
01010-81455 (Bolt)
16 pcs.
01643-81445 (Washer) 16 pcs.
07000-B3048 (O-ring) 4 pcs.
07378-11410 (Head) 4 pcs.
Reuse
Reuse
Reuse
Store
Store
Reuse
Reuse
Reuse
Store
Store
Inside hose
#14
Outside hose
#20
No.
01
02
03
04
Precautions
Name
Qty
1
27 mm socket
KW14PI impact wrench
150 mm extension
183
Q'ty
2
4
2
4
Equipment required
22 mm socket
Others
1. When installing the hoses, take care not to

twist them.
2. Take care not to damage the O-rings.
(Before installing, apply grease.)
the boom cylinder.
Tools required
Part No.
21T-64-39421
07000-B2060
07083-01417
07000-B3048
Name
Qty
Assembly procedure
LS-4
Installation of boom cylinder piping
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 idling 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 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.
Precautions
Tools required
Others
Name
184
Equipment required
Qty
Name
Qty
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
(DM908 60 140)
Right side
Left side
Boom foot pin
Shim Shim
Precautions
Name
When pushing in the pin, take care not to

break the seal.
Others
Tools required
185
No.
01
02
03
Part No.
DM942 850 40
21T-70-31690
21T-70-31470
Q'ty
1
4
4
Equipment required
Qty
Name
Qty
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 idling 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-L1).
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
Precautions
Tools required
Others
Name
186
Equipment required
Qty
Name
Qty
Assembly procedure
Installation of hose between

machine body and boom (1/2)
LS-7
(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
Arm cylinder bottom

#20
Precautions
Tools required
Others
Name
187
No.
01
02
03
04
05
06
07
Part No.
07083-01421
07083-02023
07084-01419
07084-01416
07083-02018
07000-B3048
07000-B2060
Q'ty
2
2
1
1
3
8
10
Equipment required
Qty
Name
Qty
Assembly procedure
Installation of hose between

machine body and boom (2/2)
LS-7
(1) Install the grease hose. (Tightening torque: 84 132 Nm {8.5 13.5 kgm})
No.
01
Precautions
Tools required
Others
Name
188
Part No.
07631-20412
Q'ty
1
Equipment required
Qty
Name
Qty
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.
01
02
03
04
05
Precautions
Tools required
Name
Bucket cylinder
STD
Cold district
specification
Others
Right and Left DM905 984 40 DM923 854 40
189
Part No.
DM905 984 40
DM905 742 40
DM905 749 40
01010-81640
01643-31645
Q'ty
2
2
2
4
4
Equipment required
Qty
Name
Qty
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.
01
02
03
04
05
Precautions
Tools required
Others
Name
190
Part No.
DM942 855 40
DM905 739 40
DM905 749 40
01010-82455
01643-32460
Q'ty
1
2
2
4
4
Equipment required
Qty
Name
Qty
Assembly procedure
LS-10
Installation of arm cylinder assembly
(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.
01
02
03
04
05
06
Precautions
Tools required
Others
Name
191
Part No.
DM945 438 40
DM945 449 40
DM908 933 40
DM905 750 40
01010-81640
01643-31645
Q'ty
1
1
2
2
4
4
Equipment required
Qty
Name
Qty
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.
01
02
03
04
05
06
07
08
09
10
Precautions
When installing the hoses and tubes, take
care extremely not to catch the O-rings.
Take care extremely not to let dust in the

hydraulic circuit.
Name
Others
Tools required
192
Part No.
DM942 888 40
07085-01430
07084-02030
DM490 011 40
07000-B3048
01010-81455
01643-31445
07000-B2060
01010-81865
01643-31845
Q'ty
2
4
2
1
8
32
32
4
16
16
Equipment required
Qty
Name
Qty
Assembly procedure
LS-12
Installation of bucket cylinder hoses
(1) Install bucket cylinder hoses.
No.
01
02
03
04
05
Precautions

hydraulic circuit.
Name
Others
Tools required
193
Part No.
07084-01423
07084-01428
07000-B3048
01010-81455
01643-31445
Q'ty
2
2
8
32
32
Equipment required
Qty
Name
Qty
Assembly procedure
Installation of grease feed hose

of bucket cylinder (1/2)
LS-13
(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
AA
Precautions
Tools required
Others
Name
194
Equipment required
Qty
Name
Qty
Assembly procedure
Installation of grease feed hose

of bucket cylinder (2/2)
LS-13
(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
Precautions
Tools required
Others
Name
195
Equipment required
Qty
Name
Qty
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.
01
02
03
04
05
Precautions
Tools required
Others
Name
196
Part No.
DM944 363 40
DM620 923 40
DM247 091 40
DM661 196 40
DM247 092 40
Q'ty
1
4
4
4
4
Equipment required
Qty
Name
Qty
Assembly procedure
LS-15
Installation of bottom dump hose and

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

Spiral band
Hydraulic hose
Grease feed hoses

Hydraulic hose
Precautions

hydraulic circuit.
Name
Others
Tools required
197
No.
01
02
03
04
05
Part No.
07083-41231
07000-B3038
01010-81245
01643-31232
08034-20536
Q'ty
2
4
16
16
4
Equipment required
Qty
Name
Qty
M. INSPECTION AND SERVICING PROCEDURES

AFTER ASSEMBLY
199
Assembly procedure
M-1
Inspection of oil levels and coolant levels and

using standard of fuel and lubricant (1/3)
Selection of fuels and lubricants according to ambient temperature and Komatsu genuine oils
Since the Komatsu genuine oils are manufactured under standards higher than the common standards to increase the reliability and durability of construction machinery, they are most suitable to the Komatsu construction machines. Recommend
the customers to use the oils, greases and coolants of Komatsu shown in this manual to keep the machines under the best
condition for long years.
If these recommended lubricants and coolants are not used, the service lives of the engine, power train and cooling system
may be shortened and their parts may be worn extremely.
The oil additives on the market may lower the oil performance. We do not recommend any oil additives on the market.
Select fuels and oils as shown in the following table, depending on the ambient temperature.
The rated capacity is the total quantity of oil in each device and its piping. The refill capacity is the quantity of oil replaced
for inspection or maintenance.
When starting the engine at a temperature below 0C, do not use SAE30DH but use another multi-grade oil in the table,
even if the temperature rises to about 10C during the daytime.
IMPORTANT
Be sure to use recommended diesel fuel.
The engine of this machine employs the high-pressure fuel injection unit controlled electronically to obtain higher fuel
efficiency and better exhaust gas characteristics. This fuel injection unit requires high parts precision and lubrication
performance. If a low-viscosity fuel having low lubrication performance is used, the durability of the engine may be
decreased extremely.
Precautions
Tools required
Others
Name
200
Equipment required
Qty
Name
Qty
Assembly procedure
M-1

201
Assembly procedure

M-1
Engine oil pan
PTO case
Specified
capacity
(l)
128
36
Refill capacity
(l)
120
36
Swing
machinery
case
Final drive
case
Hydraulic
system
Fuel tank
Cooling system
Grease
(Each of front (Each of right

and left)
and rear)
85
30
2400
3400
180
200
(Each of front (Each of right

and rear)
and left)
30
85
1300
200
Note 1: HTHS (High-Temperature High-Shear Viscosity 150C), specified by ASTM D4741 must be equal to or higher than
3.5 mPa-S. Komatsu EOS0W30 and EOS5W40 are the most suitable oils.
Note 2: Powertrain oil has different properties from engine oil. Be sure to use the recommended oils.
Note 3: If the automatic greasing system is installed, see "Operation and maintenance manual".
Note 4: Hyper grease (G2-T, G2-TE) has a high performance.
When it is necessary to improve the lubricating ability of the grease in order to prevent squeaking of pins and bushings,
the use of G2-T or G2-TE is recommended.
Note 5: Supercoolant (AF-NAC)
1) Coolant has the important function of anticorrosion as well as antifreeze.
Even in the areas where freezing is not an issue, the use of antifreeze coolant is essential.
Komatsu machines are supplied with Komatsu Supercoolant AF-NAC. Komatsu Supercoolant AF-NAC has excellent anticorrosion, antifreeze and cooling properties and can be used continuously for 2 years or 4000 hours.
Komatsu Supercoolant AF-NAC is strongly recommended wherever available.
2) For details of the ratio when diluting super coolant with water, see "Operation and maintenance manual".
Supercoolant AF-NAC may be supplied in premix. In this case, always top off with premix solution.
(never dilute with water)
3) To maintain the anticorrosion properties of Supercoolant AF-NAC, always keep the density of Supercoolant between 30%
and 68%.
Features of greases (Reference)
Grease
High load Wear

resistance resistance
Lubrication of rolling bearing

(Fretting resistance)
Heat
Water
Biodegrad
resistance resistance ability
Molybdenum disulfide
grease
Lithium grease
Bio-grease
wExcellent QGood EFair Bad
202
Remarks
Do not use molybdenum
disulfide grease to rolling
bearings.
Synthetic biodegradable
lithium grease
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
Precautions
Bucket cylinder bottom
Tools required
Others
Name
203
Equipment required
Qty
Name
Qty
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
FR1F080A001A
manufactured YAMASHIN
KOGYO or equivalent
No.
K-1
K-2
Precautions
Tools required
Name
Others
Keep the removed standard parts (element,

strainer, valve) carefully, since they will be
used again after flushing.
204
Part No.
209-60-77551
21T-60-13730
Q'ty
3
3
Equipment required
Qty
Name
Qty
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.
Precautions
Tools required
Others
Name
205
Equipment required
Qty
Name
Qty
Assembly procedure
M-3
Releasing residual pressure from hydraulic circuit
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.
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.
a Loosen the oil filler cap of the hydraulic tank slowly to release the residual pressure, and then remove it.
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
Precautions
Tools required
Others
Name
206
Equipment required
Qty
Name
Qty
Assembly procedure
M-4
Releasing residual pressure from HIC circuit and

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".
Precautions
Tools required
Others
Name
207
Equipment required
Qty
Name
Qty
Assembly procedure
Charging air conditioner with refrigerant
M-5
Service tool kit

(100 V)
799-703-1100
Vacuum pump
799-703-1111
Vacuum pump
(220 V)
Vacuum pump
(240 V)
Gas leak detector
799-703-1121
799-703-1401
Part name
Sketch
Q'ty
799-703-1200
Part No.
New/Remodel
Necessity
Using the tool kit in the following table, charge the air conditioner with refrigerant.
Type of refrigerant: R134a

Quantity: Front compressor: 950 50 g
Rear compressor: 950 50 g
Supply the refrigerant through the charging valves shown in the following figure.
Rear compressor
Charging valve on
high pressure side
Charging valve on
low pressure side
Front compressor
Charging valve on
high pressure side
Engine assembly
Precautions
Tools required
Name
If refrigerant gas (R134a) gets in your eyes,

you may lose your sight. Accordingly, when
adding it, put on protective goggles.
Refrigerant gas must be collected and added
by a qualified person.
Others
For details of refrigerant charging procedure,

see the instruction manual for the tool kit.
For the method of checking the quantity in
the air conditioner, see the Operation and
Maintenance Manual for the machine.
Charging valve on
low pressure side
208
Equipment required
Qty
Name
Qty
Assembly procedure
Installed angles of mirrors (1/2)
M-6
<Right step mirror> (Installed on the step handrail during transportation)
Right
Right step mirror
Left rear mirror
Front
<Left rear mirror> (Sent individually)

Front
Left
Operators cab
mirror
Left step mirror
No.
K-3
K-4
K-5
K-6
K-7
K-8
K-9
K-10
K-11
Precautions
Tools required
Name
Others
While sitting in the operator's seat and

checking the view, adjust the mirror angles.
209
Part No.
23S-54-36270
21T-54-34690
21T-54-79620
01252-71025
21T-54-34850
21T-54-34680
07283-32236
01643-31032
01597-01009
Q'ty
2
1
2
4
1
1
4
8
8
Equipment required
Qty
Name
Qty
Assembly procedure
Installed angles of mirrors (2/2)
M-6
Front
<Operator's cab left mirror>

(Installed on the operator
cab during transportation)
Left
<Left step mirror>

(Sent indiviually)
No.
K-12
K-13
K-14
K-15
K-16
K-17
Tools required
Others
Name
210
Part No.
421-54-25610
04025-00632
01252-70545
21T-54-36480
20Y-54-61630
01252-71030
Q'ty
1
1
4
1
1
2
Equipment required
Qty
Name
Qty
Assembly procedure
Installed angles of lights (1/3)
M-7
<Light above operator's cab>

Right
Front
<Light above fuel tank>

Right
Front
Precautions
Tools required
Name
Others
While sitting in the operator's seat and

checking the lighting direction, adjust the
light angles.
211
Equipment required
Qty
Name
Qty
Assembly procedure
M-7
<Left step light>
Left
Front
Bottom view of left step
212
Assembly procedure
M-7
<Work equipment (Boom) light>
Up
Front
Left side (Right side is similar)
Precautions
Tools required
Others
Name
213
Equipment required
Qty
Name
Qty
VHMS CONTOROLLER INITIAL SETTING PROCEDURE
215
1
VHMS controller initial setting
procedure
a
1
ZB
2
a
a
Equipment used for VHMS controller initial setting
Symbol
1.
Part No.
Part name
799-608-3211 Diskette
799-608-3220 Wiring harness
Note type PC
Commercially
(Windows 98/2000/Me/XP),
available
with RS232C terminal
Confirmation of machine information,

engine information, transmission controller
information and controller information
a This confirmation procedure is targeted at
the entire machine.
Confirm and record the machine information, engine information, VHMS controller
information and ORBCOMM terminal
information.
No.
Initial setting of VHMS controller shall be done

according to the following procedure. This
operation is needed prior to a full-scale operation of a machine being delivered and assembled in the field, or prior to resumption of its
operation after a long time of storage.
Machine data collected with VHMS controller
are stored and managed on WebCARE database. In order to endure smooth data processing on WebCARE , consistency must be
provided among the settings done on VHMS
controller. Inconsistencies in the settings
obstruct loading of data to WebCARE, hampering appropriate use of VHMS data. The initial setting, therefore, is a must.
For the installation procedure of the VHMS initial setting program to a PC, refer to the operation and maintenance manual being bundled
with the service kit ZB1.
In the procedure, service menus of the
machine monitor are used. Thus, it is advisable to reference the information contained in
the Special functions of machine monitor to
understand their procedure beforehand.
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 ORBCOMM
installation specification.
Check each step of the setting work referencing the VHMS initial setting work check sheet.
Information such as models shown in the figures may not be identical with actual ones.
Model name
Machine serial No.
Current service meter hour
Engine serial No.
VHMS controller serial No.
ORBCOM terminal serial No.

[Only for machines equipped with ORBCOMM]
216
Information to be confirmed
VHMS controller (1) and ORBCOMM terminal (2) are installed in the rear under the
operator seat.
2.
3.
Connecting a PC
a This work is done inside the cab.
1) Make sure the starting switch is at OFF
position.
k Before connecting or disconnecting a PC, be sure to turn off the
starting switch.
2) Using harness [1] of service kit ZB1, connect the PC ZB2 and download connector
VH13.
a Then connect the PC to RS232C terminal.
Confirming VHMS controller operation and

confirming satellite capturing state
a This work is done inside the cab.
a Confirmation of capturing of the satellite is
done for [ORBCOMM installation specification].
1) Turn the starting switch ON.
2) Check the controller for normal operation
referencing 7-segment LED of VHMS controller.
a VHMS controller is fed with switch
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.
Download
connector
VH13
is
installed in the front side of the right
stand of operator seat.
3)
217
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 controller has captured the communication satellite. [ORBCOMM installation specification]
a Check whether or not ORBCOMM
controller is capturing the communication satellite from VHMS controller.
a It is successfully capturing the satellite when the LED representing the
decimal point in the right side 7-segment LED is flashing.
4.
5.
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.
3)
4)
5)
Important
a Appearance of the setup screen of
the VHMS setting tool depends its
tool.
a When using Ver.3.5.2.1 or older version (CD-ROM), the setting procedure shall conform to that described
in Section 5.
a When using an update version
(Ver.3.5.2.1 or after), the procedure in
Section 6 shall be used.
a It is recommended to download the
latest VHMS version from WebCARE
to update the currently used version.
(Related material: PARTS & SERV IC E O PE RAT IO N T IP S S EK N5052)
Enter the 10-digit service ID to [Service ID].
a Service ID: 7826143000
Select [Data clear and Set up] from
[Select Function] item.
Click [OK] button to proceed to the setup
screen.
218
Initial setting of VHMS controller (Ver. 3. 5. 2. 1

or older version)
a This work is done inside the cab (from
PC).
a It is prohibited in the initial setting to modify the data of service meter [SMR].
[Machine Information]
1) Open [Machine Information] tab.
a [Data clear and Set up] menu displays
[Machine Information] tab first.
2) Check every data for correctness.
3)
When [Date/Time] information is not appropriate, correct it in the following manner.

1] Press [Edit] button in the lower right
side of [Date/Time] box to display the
correction screen.
2] After correcting it to the correct information, press [OK] button.
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 information, press [OK] button.
5)
As every data in [Machine Information]

has been checked and corrected, press
[Apply] button to settle the setting.
a As [Apply] button is pressed, a message confirming above setting will
appear on the screen. Check the setting again and, if the setting is correct,
press [OK] button.
a ORBCOMM installation specification
requires the settlement operation after
[Communication Setting] is completed.
[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.
8)
219
When modifying the setting of [SHORT

FAULT HISTORY], employ the following
procedure.
1] Select [SHORT FAULT HISTORY] from
the screen and then press [Edit] button
in the lower left side of [File Transfer
Setting] block to display the setup
screen.
2] Correct the setting and, as it is completed, press [OK] button.
a In the initial setting, select [Occurrence] from [Timing] item and then
set the function to ON.
When modifying the setting of [SHORT

TREND ANALYSIS], employ the following
procedure.
1] Select [SHORT TREND ANALYSIS]
from the screen and then press [Edit]
button in the lower left side of [File
Transfer Setting] block to display the
setup screen.
2] Correct the setting and, as it is completed, press [OK] button.
a In the initial setting, enter [20h] to
[SMR] and then set the function to
ON.
11) As every data in [Communication Setting]

has been checked and corrected, press
[Apply] button to settle the setting.
a As [Apply] button is pressed, a message confirming above setting will
appear on the screen. Check the setting again and, if the setting is correct,
press [OK] button.
10) When modifying the setting of [Satellite

Setting], employ the following procedure.
1] Press [Edit] button in the [Satellite
Setting] block to display the correction screen.
2] Set the GCC code to the region
applied and, as setting is completed,
press [OK] button.
12) As every data in [Machine Information]

and [Communication Setting] has been
checked and corrected, press [Exit] button
to end [VHMS initial setting tool].
9)
GCC codes and applicable regions

Code
Applicable region
Code
Applicable region
America
122
Korea
120
Italy
123
Brazil
121
Malaysia
130
Japan
220
6.
3)
Initial setting of VHMS controller (Ver. 3. 5. 2. 1

or later version)
a This work is done inside the cab (from PC).
a It is prohibited in the initial setting to modify the data of service meter [SMR].
1) Select [VHMS Setting] and then press
[Next] button.
Confirm the machine information and, if

they are correct, press [Next] button.
2)
Select [Set up & All clear] and press [Next]

button.
221
When VHMS has been installed later,

it is required to enter the information
such as [Serial No.].
4)
5)
6)
7)
Select the time zone.

Enter the local time.
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.
8)
If there is no problem in the setting displayed last, press [Apply] button.
9)
A screen message will confirm whether or

not the data before the setting is to be
saved. If the data is not necessary, select
[NO].
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
America
122
Korea
120
Italy
123
Brazil
121
Malaysia
130
Japan
10) As correction of the first setting is completed, press [OK] button to end the program.
222
7.
Performing Quick Pm
a Perform the following procedure in the cab.
a The Quick Pm means the Pm clinic performed 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
q
PCC lock lever: Free
3) Set the machine monitor to display the
service menu.
a For the operating method, see Special function of machine monitor.
4) On the initial screen of the service menu,
select 10 Snap shot menu.
5)
6)
Press the [ ] switch to start the snap shot

operation.
a Before starting the snap shot operation, understand the operating procedure for the Quick Pm by referring to
Operating procedure for Quick Pm.
a The data of 35 items are recorded
and saved for 7 minutes 30 seconds
after the 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.
223
If the snap shot operation is interrupted, the data collected up to now

are not recorded. In this case, repeat
the operation from the first.
Operate the fuel dial, swing lock switch,

both work equipment control levers, and
both travel levers according to the Opera t i n g p r oc e d u r e f or 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 actually for the Quick Pm, take extreme
care of safety around the machine
during the work.
7)
If the following screen appears 7 minutes

30 seconds after the snap shot is started,
the snap shot is finished.
a The initial screen of the service menu
appears automatically 5 seconds after
the snap shot operation is finished.
224
Operating procedure for Quick Pm

No.
Elapsed time
Time on
snap data
Fuel
dial
Swing lock
switch
Data read in Pm clinic after data

are downloaded
Operation of lever
Start
O
Finish
0:00
O
0:30
330.00
O
300.00
MIN
(Low)
OFF
Set all levers in neutral.
Start
O
Finish
0:30
O
1:00
300.00
O
270.00
MAX
(High)
OFF
Set all levers in neutral

(Turn decelerator on).
Engine speed
(2nd deceleration speed)
Start
O
Finish
1:00
O
1:30
270.00
O
240.00
MAX
(High)
OFF
Move levers finely [Note]

(Turn decelerator off).
Start
O
Finish
1:30
O
2:30
240.00
O
180.00
MAX
(High)
OFF
Raise right-hand track

shoe and drive it idle
(Set lever to stroke end).
Start
O
Finish
2:30
O
3:30
180.00
O
120.00
MAX
(High)
OFF
Swing 180.
Raise left-hand track shoe Rear pump oil pressure
and drive it idle (Set lever
(Hydraulic pressure)
to stroke end).
Start
O
Finish
3:30
O
4:00
120.00
O
090.00
MAX
(High)
ON
R.H. swing relief.
Swing pump oil pressure

(Relief pressure)
Start
O
Finish
4:00
O
4:30
090.00
O
060.00
MAX
(High)
ON
L.H. swing relief.
Swing pump oil pressure

(Relief pressure)
Start
O
Finish
4:30
O
5:00
060.00
O
030.00
MAX
(High)
ON
Arm OUT relief.
Front, rear, swing pump oil pressure

(Low relief pressure)
Start
O
Finish
5:00
O
5:30
030.00
O
000.00
MAX
(High)
ON
Bucket DUMP relief.
Front, rear pump oil pressure

10
Start
O
Finish
5:30
O
6:00
000.00
O
030.00
MAX
(High)
ON
Bucket CURL relief.

11
Start
O
Finish
6:00
O
6:30
030.00
O
060.00
MAX
(High)
ON
Arm IN relief.

12
Start
O
Finish
6:30
O
7:00
060.00
O
090.00
MAX
(High)
ON
Boom RAISE relief.

(High relief pressure)
Engine speed
Blow-by pressure, exhaust
temperature, PTO oil temperature
13
Start
O
Finish
7:00
O
7:30
090.00
O
120.00
MAX
(High)
ON
Set all levers in neutral

(1st deceleration o 2nd
deceleration)
Engine speed
(1st deceleration speed)
14
7:30
120.00
MIN
(Low)
ON
Finish
Engine speed (Low idle)

Engine oil pressure (Low idle)
Engine coolant temperature
Hydraulic oil temperature
Outside temperature
Control pump pressure (Low idle)
Engine speed (High idle)

Engine oil pressure (High idle)
Control pump pressure (High idle)
Fan pump pressure
(Cooling fan, aftercooler fan)
Front pump oil pressure

(Hydraulic pressure)
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.)
225
8.
a
a
Download of setting data

1) Using harness [1] of service kit ZB1, connect PC ZB2 to download connector DLF
in the cab or download connector VDL on
the ground.
3)
Download connector VH13 in the cab

is installed in the front side of the right
stand of operator seat.
9.
2)
Operating [VHMS analysis tool] on PC,

start up the VHMS analysis tool.
Using [Download] function, download the

data currently recorded on VHMS to PC.
a For the operating procedure, see the
VHMS analysis tool operation and
maintenance manual.
a After making sure the download is
complete, proceed to the next step.
Confirmation of download data

1) Check the setting data using [View] function.
a For the operating procedure, see the
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)
226
Enter [User Name] and [Password].

For the operating procedure, see the
maintenance manual.
As check of the setting data is finished,

end [VHMS analysis tool].
11. Report to Komatsu

As steps 1 9 are completed, send VHMS/
WebCARE setting report to VHMS/WebCARE
Support Center in Komatsu Headquarters.
a This report is a must since setting on the
receiving end in the satellite communication must be done by Komatsu.
a In this case, send VHMS data via Notes
(LAN) or E-mail (WAN).
10. Disconnecting the PC

1) Make sure the starting switch is at OFF
position.
k Before connecting or disconnecting a PC, be sure to turn off the
starting switch.
2) End the OS of PC ZB2 and then turn off
the PC power.
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: webcare@komatsu.co.jp
3)
When the data was download into the cab,

disconnect harness [1] of service kit ZB1
from download connector VH13.
227
[For storage]
VHMS initial setting work check sheet
Date of setting:
DB/branch
office name
Data entered by:
Setup step
Check item
Result
Model name
1
Confirmation of machine body and

component nameplates
Serial No.
Engine serial No.
Connection between PC and VHMS

controller
Is the connection secure?
yes
no
VHMS controller check for normal

operation
Is it operating normally?
(Displays counting in ascending-order succeeding to
rotation)
yes
no
Is "Data Clear and Set up" selected for the setting tool
mode?
yes
no
Is model name identical with machine body?
yes
no
Is machine body serial No. correctly entered?
yes
no
4 Starting of VHMS initial setting tool
Initial setting of VHMS controller

(Setting of machine body informa5 tion)
In this step, basic machine body
information are set on VHMS controller
Is engine serial No. correctly entered?
yes
no
Is today's date entered?
yes
no
Is current time entered?
yes
no
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
8 Execution of quick Pm
Is service mode "SNAPSHOT" turned on and is the

switch hit?
yes
no
9 Data storing operation on VHMS
yes
no
10 Download
Is LED operation normal?
yes
no
Are all files downloaded?
yes
no
The time downloaded (Reference wrist watch)

11 Confirmation of download data
12 Data storing operation on VHMS
Hour,
minute:
[Confirmation of data]
Is [MFA0] error present in Fault History?
yes
no
Are SMR and time in Fault History consistent with settings?
yes
no
Is any data missing in Snap Shot0?
yes
no
yes
no
228
[For storage]
ORBCOMM station opening work
check sheet
Date of setting:
DB/branch
office name
Data entered by:
Setup step
Check item
Result
Model name
Confirmation of machine body and
1
component nameplates
Serial No.
Engine serial No.
ORBCOMM terminal serial No.
Connection between PC and VHMS

controller
Is the connection secure?
yes
no
VHMS controller check for normal

operation
Is it operating normally?
(Displays counting in ascending-order succeeding to
rotation)
yes
no
Is "Set up" selected for the setting tool mode?
yes
no
On
Off
On
Off
On
Off
4 Starting of VHMS initial setting tool
Entry of setting to S.Fault History

Initial setting of VHMS controller
1. Setting of communication
(Setting of machine body information and PLM are completed)
Presence/absence of communication
Number of cases (Default is 8 cases)
Entry of setting of S.Trend Analysis setting
Interval (Default is 20H)
Entry of setting of S.Payload data

Tabulation start time
Interval of tabulation (in days)
2. Setting for start of communication
6 Saving of settings
7
ORBCOMM controller performance

check
day
Is GCC code set? (130 for Japan)
yes
no
Is LED (7-segment) turned off after data was stored?
yes
no
How is decimal point display in VHMS monitor

(7-segment)?
(OFF, ON, long/short flashing)
yes
no
229
230
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 chassis plant.
Model - Type
Machine serial No.
User unit No.
Engine model
PC2000-8
Engine serial No.
SAA12V140E-3
Backhoe spec.
Service meter reading
Date of inspection
Attachment
1
Location of machine at inspection
Manufacturer
Model
Distributor's name
Serial No.
Customer's name
Address:
Name:
Date :
Inspector's comments:
Inspector's name:
KOMATSU USE ONLY:

Check sheet receiving date:
Title:
By:
Signature:
Remark:
Check sheets filling instructions:

1.
Use following indexes for entry of judgment.

.......... Normal
.......... Correction made on abnormal point
.......... Abnormal
2. Enter measured values in parentheses. [
.......... Not applied
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.
Delivery
report No.
Revision
Category

At local
At ___
assembly operating
time
hours
Check item
Oil and coolant levels
Criterion
Measured value
Radiator coolant level
Sub tank coolant level
Max. 25 mm
Coolant
Soft water
Check before assembly
Antifreeze
(A, B, C, D, E)
]
]
Added/
Not added
Freezing
point
SAE10WCD
[
SAE30CD
SAE10WCD
[
SAE30CD
Engine oil
PTO oil
Swing machinery
case oil
Front
]
]
SAE30CD
[
Rear SAE30CD
A: -50 -40 C D:-20 -10 C

B: -40 -30 C E:-10 0 C
C: -30 -20 C (Not necessary in summer)
L H +5
(In 10 minutes after stopping engine)
L +5 H
L +5 H +10
Right
SAE30CD
Left
SAE30CD
Hydraulic oil
SAE10WCD [
Between H L (Posture: Max. reach)
Battery electrolyte
Max. 13 mm from filler bottom
Final drive gear

case oil
Engine No.
0 -10 mm from level plug bottom
When accepted
Service meter[
h]
Check during assembly
Radiator coolant
level
[
Sub tank coolant
level
[
]
After check
[
h]
Loosened or untightened connecting pin lock bolt
Must not be detected.
Loosened or untightened work equipment piping split flange
Uninstalled, lost or caught work equipment piping O-ring
Loosened or twisted grease piping joint
Shim adjustment for work equipment pin
Max. 1 mm
(For shim position, see assembly manual)
Improperly inserted or un-inserted wiring
Loosened or untightened ladder mounting bolt
Revision
Category
Check item
At local
At ___
assembly operating
time
hours
Criterion
Loosened or untightened counterweight mounting bolt
Clearance or level difference between counterweight and frame
Max. 15 mm
Loosened or untightened operator's cab mounting bolt
Loosened or untightened cab base mounting bolt
Loosened or untightened container base mounting bolt
Loosened or untightened hydraulic tank mounting bolt
Loosened or untightened fuel tank mounting bolt
Loosened or untightened center frame mounting bolt
Loosened or untightened travel system piping bolt/joint
Uninstalled, lost or caught travel system piping O-ring
Loosened or untightened track frame mounting bolt
Loosened or untightened travel motor cover bolt
Uninstalled part (Rearview mirror, etc.)
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
Bleeding air from HIC circuit
Adjustment of track tension
Flushing hydraulic circuit
Greasing each part of work equipment
Grease all parts.

Check that grease comes out.
Addition of hydraulic oil
Add to between L H.
Addition of fuel and window washing fluid
Fill tank.
Revision
Category
Check item
At local
At ___
assembly operating
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
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.
Criterion
Display must be as shown on left.
Service meter must be free from flaw, blur and

uneven operation.
Initialization must be executed.
(Pm clinic, downloading, application for start of use).
Operation of service meter

Initialization of VHMS
Check of monitor
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)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
Window washer switch

Wiper selector switch
Alarm buzzer cancel switch
Heavy lift switch
Working mode selector switch
Auto-decelerator selector switch
Function switches (F1 F7)
Engine coolant temperature monitor
Engine coolant temperature gauge
Hydraulic oil temperature monitor
Hydraulic oil temperature gauge
Wiper monitor
Swing lock switch
Preheater monitor
Auto grease unit operation monitor
Engine stop monitor
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
(28)
(29)
(30)
(31)
(32)
Clock/Service meter
Auto-decelerator monitor
Working mode monitor
Heavy lift monitor
Truck counter 1
Truck counter 2
ECO gauge
Fuel level gauge
Fuel level monitor
PTO oil temperature gauge
PTO oil temperature monitor
Engine oil temperature gauge
Engine oil temperature monitor
Engine oil pressure gauge
Engine oil pressure monitor
Numeral key (0 9)
Revision
Check item
At local
At ___
assembly operating
time
hours
Criterion
Check of switches and levers
Category
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
VHMS download connector

12V outlet
Cigarette lighter (24V outlet)
AM/FM radio
Air conditioner panel 2
Control lever (left)
Truck counter switch (2 pcs.)
Machine monitor
Operation of horn switch
Operation of hydraulic lock lever
Operation of swing lock switch
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
Foot rest
Travel pedal
Travel lever
Lock lever
Horn switch
Control lever (right)
Starting switch
Fuel control dial
If the switch is pressed, the horn sounds and

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.
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
lock monitor lights up.
OFF position (Reset):
Machine can swing. At this time, swing lock
monitor goes off.
Revision
Category
Check item
Operation of power-assisted ladder
Operation of emergency engine stop switch

Switch is installed to front and rear of engine compartment and
front of fuel tank (3 places in total).
At local
At ___
assembly operating
time
hours
Criterion
Ladder must be raised and lowered smoothly.
When ladder is lowered:
Machine cannot swing.
Warning lamp lights up.
When ladder is raised:
Machine can swing.
Warning lamp goes off.
If the switch is pressed when the engine is
started, engine must stop.
While the engine is stopped in an emergency,
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
Operation of heavy lift switch
Operation of wiper switch
Operation of window washer switch

Operation of buzzer cancel switch
Operation of room lamp switch
Operation of auxiliary lamp switch
Operation of working lamp switch
Operation of step light switch
Operation of rotary lamp switch
Operation of greasing mode switch
Operation of machine push-up switch

Operation of boom shockless control switch
Each time the switch is pressed, the monitor

changes and the operator can select.
During single boom raise operation, if the
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
Lighting of ON (Continuous upper) lamp:
Continuous operation of only upper wiper
If the switch is pressed, the window washing
fluid spouts against the front glass.
(Wiper operation is linked.)
If the switch is pressed, alarm buzzer for
warning item is stopped.
ON position: Room lamp lights up.
OFF position: Room lamp goes off.
ON position: Auxiliary lamp lights up.
OFF position: Auxiliary lamp goes off.
ON position: Working lamp lights up.
OFF position: Working lamp goes off.
If the switch is pressed, the step light is
turned ON for about 90 seconds.
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.
OFF position: Rotary lamp goes off.
MANUAL position:
Grease must be supplied manually.
AUTO position:
Grease is supplied automatically.
Low pressure setting: Boom thrust force is low.
High pressure setting: Boom thrust force is
increased.
If the switch is turned ON, work equipment
shakes less when boom is stopped.
Revision
Category
Check item
Operation of air conditioner
Operation of radio
Operation of cigarette lighter
Operation of truck counter switch
At local
At ___
assembly operating
time
hours
Criterion
When the switch is turned ON, the air
conditioner starts.
When the switch is turned ON, the radio
sounds.
If the lighter is pushed in, it is heated red and
returns automatically several seconds after.
If the switch (1 or 2) is pressed, the
confirmation buzzer sounds and the monitor
counts.
Forward:
Operation of travel lever
Operation of left work equipment control lever

(With auto-deceleration function)
Operation of right work equipment control lever
Operation of bottom dump switch
Check of fault history (electrical system and mechanical system)
Lever is pushed forward.

(Pedal is angled forward)
Reverse: Lever is pushed back.
(Pedal is angled back)
N (Neutral):Machine stops.
This lever is used to operate the upper
structure and arm.
N (Neutral):Upper structure and arm are fixed.
This lever is used to operate the boom and
bucket.
N (Neutral):Boom and bucket are fixed.
Check that no abnormality is displayed and
then delete the fault history. After finishing all
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

error), operation can be continued with this switch set "up".
Operation of swing holding brake prolix switch
If the switch is set "up", the alarm buzzer

sounds and the monitor displays E07 error.
While monitor is displaying E03 (Swing holding brake system

error), brake can be released and machine can swing with this
switch set "up". Swing brake is kept released, however.
If the switch is set "up", the monitor displays

E03 error.
Revision
Category

At local
At ___
assembly operating
time
hours
Check item
Criterion
Swing operation running in: Engine at high idle

(Work equipment posture: Max. reach)
Travel
performance
Swing performance
Normal swing speed
Right
sec]
Left
sec]
Empty
P mode: 11.6 13.6 sec/turn

E mode: 12.0 14.3 sec/turn
Brake angle
Max. 55 (Sensory)
Unevenness and hunting of swing
Abnormal sound and shakiness in swing
Travel operation running in: Engine at high idle

Abnormal sound and heating in track roller, carrier roller and idler
Abnormal sound and heating must not be

detected.
Operation of travel brake
Must operate securely without dragging.
Abnormal sound in travel and shakiness in swing
Travel deviation (Sensory)
Must be free from abnormal travel deviation in

the range from fine control to stroke end
(Sensory).
Travel deviation
(To be measured only
when abnormal)
Forward
mm/20m
Track rotation speed

Right
Left
Track tension
Stroke of
HIC cylinder
(Elongation)
Reverse
Forward
sec
Forward
sec
Right
mm
Right
mm
Reverse
sec
Reverse
sec
Left
mm
]
20.3 2.0 sec/turn
(P mode, full throttle)
]
Stroke of HIC cylinder

135 5 mm
Left
Max. 200 mm/20 m
mm/20m
mm
Revision
Category

At local
At ___
assembly operating
Criterion
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).
Check item
Boom
Work equipment
posture
A mode
Arm
Empty
Raise
Work equipment
speed (including
cushion working time)
Boom
Arm
In
Work equipment performance
P mode
Engine: Full throttle
8.7 m boom
3.9 m arm
12 m3 bucket
Work equipment
time lag
Engine: Low
When normal:
Sensory
When abnormal:
Measure
Curl
Bucket [
Arm
Empty
Empty
sec
Lower
sec
Out
sec
Dump
Lower
Boom
Bucket
In
Dump
Bucket [
Raise: 7.5 0.8 sec
sec
Lower: 5.0 0.5 sec
In: 7.3 0.7 sec
sec
Out: 5.2 0.5 sec
Curl: 5.0 0.5 sec
sec
sec
Dump: 3.9 0.4 sec
Max. 6.0 sec
Max. 5.0 sec
sec
sec
Max. 4.0 sec
Abnormal sound from hydraulic pump and PTO
Must be free from abnormality during no-load

operation and when relieved.
Heating of PTO
Must be free from abnormal heating.
Partial engine output performance
Engine must not hunt in any gear speed during

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
Shock at cylinder stroke end

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

switch ON, boom cylinder must be retracted
from extension stroke end to ground level
(when arm is at max. reach).
Revision
Category
Check item
At local
At ___
assembly operating
time
hours
Criterion
Around operator's seat
During operation
Check of each part

Operating effort of control lever when each actuator is operated
Lever must not be hitched during operation.

Lever must return to neutral by itself.
Shaking and beat noise of operator's cab
Beat noise of frame, guard and ladder
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.
Undercarriage
Oil leakage
(Idler, track roller, sprocket,
final drive gear case, motor, brake valve)
Interference of each part
Looseness of track shoe bolt
Contact of link tread
Must be free from overlapping, flaking and

breakage.
Around chassis
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)
Water leakage from engine cooling system
Oil leakage from engine lubrication system
Gas leakage from engine gas system
Operation of covers
Must move smoothly.
Locks of covers
Must work securely.
Around chassis
Revision
Category
Check item
Criterion
Operation of grease pump
Must operate smoothly.
Looseness and insufficient insertion of electric wiring terminals
Electric wiring route
Clearance of at least 10 mm must be made

around moving part and edge.
Air leakage from air system
Oil leakage
(Cylinder, piping, block)
Around work equipment
At local
At ___
assembly operating
time
hours
Grease leakage from grease piping
Interference of work equipment
Looseness of work equipment piping clamp and play of piping
Twist of hydraulic hose and operation of work equipment at

reverse
Revision
Category
Note: If the operation or function is defective, measure as necessary.

Check item
The speeds in the criteria column are the values in P mode.

At local
At ___
assembly operating
Criterion
time
hours
P mode
1. Engine speed: Check in monitoring mode "01002".

Low idle
rpm]
825 50 rpm
High idle
rpm]
1980 50 rpm
rpm]
1750 50 rpm
rpm]
1800 50 rpm
Boom raise relieve speed

(Heavy lift: OFF)
(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 [
1R [
Control valve main set pressure
2F [
2R [
MPa]
MPa]
MPa]
MPa]
29.4 1.0 MPa
At engine high idle, boom

raise, P mode, heavy lift
OFF and relief
1F [
Control valve main set pressure 1R [
(Boosted pressure)
2F [
2R [
MPa]
MPa]
MPa]
MPa]
31.4 1.0 MPa

raise, P mode, heavy lift ON
and relief
At engine high idle, swing, P
mode and relief
Swing relief set pressure
1F [Right
1F [Left
MPa]
MPa]
28.4 2.0 MPa
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"
Pump EPC current
1F [
1R [
2F [
2R [
mA]
mA]
mA]
mA]
280 50 mA
At engine high idle, lever

neutral and P mode
1F [
1R [
2F [
2R [
mA]
mA]
mA]
mA]
470 100 mA

OFF and relief
J/S differential pressure output voltage: Check in monitoring mode.

1F pump: "13808 1R pump: "13809"
2F pump: "13810 2R pump: "13811"
J/S differential pressure

output voltage
1F [
1R [
2F [
2R [
V]
V]
V]
V]
Min. 3.2 V

neutral and P mode
1F [
1R [
2F [
2R [
V]
V]
V]
V]
Max. 1.2 V
At engine high idle, arm in,

P mode, and relief
Revision
Category

At local
At ___
assembly operating
time
hours
Check item
Criterion
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]
Bucket cylinder
mm]
9 mm/min (140 mm/15 min)
5. Operating effort and stroke

Boom
control lever
Operating Raise
effort
Main measurement items
Stroke
Swing
control lever
Arm
control lever
N
{kg}
Right
Left
[
mm] [
Operating Curl
effort
Stroke
N
{kg}
Curl
[
N
{kg}
In
[
Out
mm] [
Right travel lever Operating Forward

effort
Stroke
Left travel lever
N
{kg}
N
{kg}
N
{kg}
mm]
N
{kg}
Play
mm] [
Dump
Out
mm]
N
{kg}
mm]
N
{kg}
Play
mm] [
Reverse
Forward
Reverse
Play
[
mm] [
mm] [
Operating Forward
effort
Stroke
Left
Dump
Play
mm] [
mm] [
Operating In
effort
Stroke
Lower
Raise
Lower
Play
[
mm] [
mm] [
Operating Right
effort
Stroke
Bucket
control lever
N
{kg}
Reverse
Forward
Reverse
Play
[
mm] [
mm] [
mm]
N
{kg}
mm]
N
{kg}
mm]
15.7 4.9 N
{1.6 0.5 kg}
Stroke: 85 10 mm
Play: Max. 10 mm
12.8 3.9 N
{1.3 0.4 kg}
Stroke: 85 10 mm
Play: Max. 10 mm
12.8 3.9 N
{1.3 0.4 kg}
Stroke: 85 10 mm
Play: Max. 10 mm
15.7 4.9 N
{1.6 0.5 kg}
Stroke: 85 10 mm
Play: Max. 10 mm
24.5 5.9 N
{2.5 0.6 kg}
Stroke: 115 15 mm
Play: Max. 10 mm
24.5 5.9 N
{2.5 0.6 kg}
Stroke: 115 15 mm
Play: Max. 10 mm
Serial No. of controllers and monitor
Serial No. Confirm with monitoring mode or visual check.

Engine controller (L-BANK)
Engine controller (R-BANK)
Pump controller (UPPER)
Pump controller (LOWER)
VHMS controller
ORBCOMM controller
Monitor
At engine
high idle and
relief
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 chassis plant.
Model - Type
Machine serial No.
User unit No.
Engine model
PC2000-8
Engine serial No.
SAA12V140E-3
Loading Shovel spec.

Service meter reading
Date of inspection
Attachment
1
Location of machine at inspection
Manufacturer
Model
Distributor's name
Serial No.
Customer's name
Address:
Name:
Date :
Inspector's comments:
Inspector's name:
KOMATSU USE ONLY:

Check sheet receiving date:
Title:
By:
Signature:
Remark:
Check sheets filling instructions:

1.
Use following indexes for entry of judgment.

.......... Normal
.......... Correction made on abnormal point
.......... Abnormal
2. Enter measured values in parentheses. [
.......... Not applied
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.
Delivery
report No.
Revision
Category

At local
At ___
assembly operating
time
hours
Check item
Oil and coolant levels
Criterion
Measured value
Radiator coolant level
Sub tank coolant level
Max. 25 mm
Coolant
Soft water
Check before assembly
Antifreeze
(A, B, C, D, E)
]
]
Added/
Not added
Freezing
point
E010W30-DH
[
E015W40-DH
T010
[
T030
Engine oil
PTO oil
Swing machinery
case oil
Front
]
]
T030
[
Rear T030
A: -50 -40 C D:-20 -10 C

B: -40 -30 C E:-10 0 C
C: -30 -20 C (Not necessary in summer)
L H +5
L +5 H
L +5 H +10
Right
T030
Left
T030
Hydraulic oil
T010
H046HM
Between H L (Posture: Max. reach)
Battery electrolyte
Max. 13 mm from filler bottom
Final drive gear

case oil
Engine No.
0 -10 mm from level plug bottom
When accepted
Service meter[
h]
Radiator coolant
level
[
Sub tank coolant
level
[
]
After check
[
h]
Loosened or untightened connecting pin lock bolt
Loosened or untightened work equipment piping split flange
Uninstalled, lost or caught work equipment piping O-ring
Loosened or twisted grease piping joint
Shim adjustment for work equipment pin
Max. 1 mm
(For shim position, see assembly manual)
Improperly inserted or un-inserted wiring
Loosened or untightened ladder mounting bolt
Revision
Category
Check item
At local
At ___
assembly operating
time
hours
Criterion
Loosened or untightened counterweight mounting bolt
Clearance or level difference between counterweight and frame
Max. 15 mm
Loosened or untightened operator's cab mounting bolt
Loosened or untightened cab base mounting bolt
Loosened or untightened container base mounting bolt
Loosened or untightened hydraulic tank mounting bolt
Loosened or untightened fuel tank mounting bolt
Loosened or untightened center frame mounting bolt
Loosened or untightened travel system piping bolt/joint
Uninstalled, lost or caught travel system piping O-ring
Loosened or untightened track frame mounting bolt
Loosened or untightened travel motor cover bolt
Uninstalled part (Rearview mirror, etc.)
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
Bleeding air from HIC circuit
Adjustment of track tension
Flushing hydraulic circuit
Greasing each part of work equipment
Grease all parts.

Check that grease comes out.
Addition of hydraulic oil
Add to between L H.
Addition of fuel and window washing fluid
Fill tank.
Revision
Category
Check item
At local
At ___
assembly operating
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
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.
Criterion
Display must be as shown on left.
Service meter must be free from flaw, blur and

uneven operation.
Initialization must be executed.
(Pm clinic, downloading, application for start of use).
Operation of service meter

Initialization of VHMS
Check of monitor
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)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
Window washer switch

Wiper selector switch
Alarm buzzer cancel switch
Heavy lift switch
Working mode selector switch
Auto-decelerator selector switch
Function switches (F1 F7)
Engine coolant temperature monitor
Engine coolant temperature gauge
Hydraulic oil temperature monitor
Hydraulic oil temperature gauge
Wiper monitor
Swing lock switch
Preheater monitor
Auto grease unit operation monitor
Engine stop monitor
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
(28)
(29)
(30)
(31)
(32)
Clock/Service meter
Auto-decelerator monitor
Working mode monitor
Heavy lift monitor
Truck counter 1
Truck counter 2
ECO gauge
Fuel level gauge
Fuel level monitor
PTO oil temperature gauge
PTO oil temperature monitor
Engine oil temperature gauge
Engine oil temperature monitor
Engine oil pressure gauge
Engine oil pressure monitor
Numeral key (0 9)
Revision
Check item
At local
At ___
assembly operating
time
hours
Criterion
Category
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
VHMS download connector

12V outlet
Cigarette lighter (24V outlet)
AM/FM radio
Control lever (left)
Truck counter switch (2 pcs.)
Machine monitor
Operation of horn switch
Operation of hydraulic lock lever
Operation of swing lock switch
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
Foot rest
Travel pedal
Travel lever
Lock lever
Horn switch
Control lever (right)
Starting switch
Fuel control dial
If the switch is pressed, the horn sounds and

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.
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
lock monitor lights up.
OFF position (Reset):
Machine can swing. At this time, swing lock
monitor goes off.
Revision
Category
Check item
Operation of power-assisted ladder
Operation of emergency engine stop switch

Switch is installed to front and rear of engine compartment and
front of fuel tank (3 places in total).
At local
At ___
assembly operating
time
hours
Criterion
Ladder must be raised and lowered smoothly.
When ladder is lowered:
Machine cannot swing.
Warning lamp lights up.
When ladder is raised:
Machine can swing.
Warning lamp goes off.
If the switch is pressed when the engine is
started, engine must stop.
While the engine is stopped in an emergency,
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
Operation of heavy lift switch
Operation of wiper switch
Operation of window washer switch

Operation of buzzer cancel switch
Operation of room lamp switch
Operation of auxiliary lamp switch
Operation of working lamp switch
Operation of step light switch
Operation of rotary lamp switch
Operation of greasing mode switch
Operation of machine push-up switch

Operation of boom shockless control switch

During single boom raise operation, if the
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
Lighting of ON (Continuous upper) lamp:
Continuous operation of only upper wiper
If the switch is pressed, the window washing
fluid spouts against the front glass.
(Wiper operation is linked.)
If the switch is pressed, alarm buzzer for
warning item is stopped.
ON position: Room lamp lights up.
OFF position: Room lamp goes off.
ON position: Auxiliary lamp lights up.
OFF position: Auxiliary lamp goes off.
ON position: Working lamp lights up.
OFF position: Working lamp goes off.
If the switch is pressed, the step light is
turned ON for about 90 seconds.
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.
OFF position: Rotary lamp goes off.
MANUAL position:
Grease must be supplied manually.
AUTO position:
Grease is supplied automatically.
Low pressure setting: Boom thrust force is low.
High pressure setting: Boom thrust force is
increased.
If the switch is turned ON, work equipment
shakes less when boom is stopped.
Revision
Category
Check item
Operation of air conditioner
Operation of radio
Operation of cigarette lighter
Operation of truck counter switch
At local
At ___
assembly operating
time
hours
Criterion
When the switch is turned ON, the air
conditioner starts.
When the switch is turned ON, the radio
sounds.
If the lighter is pushed in, it is heated red and
returns automatically several seconds after.
If the switch (1 or 2) is pressed, the
confirmation buzzer sounds and the monitor
counts.
Forward:
Operation of travel lever
Operation of left work equipment control lever

Operation of right work equipment control lever
Check of fault history (electrical system and mechanical system)
Lever is pushed forward.

(Pedal is angled forward)
Reverse: Lever is pushed back.
(Pedal is angled back)
N (Neutral):Machine stops.
This lever is used to operate the upper
structure and arm.
N (Neutral):Upper structure and arm are fixed.
This lever is used to operate the boom and
bucket.
N (Neutral):Boom and bucket are fixed.
Check that no abnormality is displayed and
then delete the fault history. After finishing all
the checks, check again that there is no fault
history.
Operation of emergency pump prolix switch
While monitor is displaying E07 (Pump EPC solenoid system

error), operation can be continued with this switch set "up".
Operation of swing holding brake prolix switch
If the switch is set "up", the alarm buzzer

sounds and the monitor displays E07 error.
While monitor is displaying E03 (Swing holding brake system

error), brake can be released and machine can swing with this
switch set "up". Swing brake is kept released, however.
If the switch is set "up", the monitor displays

E03 error.
Revision
Category

At local
At ___
assembly operating
time
hours
Check item
Criterion
Swing operation running in: Engine at high idle

Travel
performance
Swing performance
Normal swing speed
Right
sec]
Left
sec]
Empty
P mode: 11.5 13.6 sec/turn

E mode: 12.2 14.6 sec/turn
Brake angle
Max. 55 (Sensory)
Unevenness and hunting of swing
Abnormal sound and shakiness in swing
Travel operation running in: Engine at high idle

Abnormal sound and heating in track roller, carrier roller and idler
Abnormal sound and heating must not be

detected.
Operation of travel brake
Must operate securely without dragging.
Abnormal sound in travel and shakiness in swing
Travel deviation (Sensory)
Must be free from abnormal travel deviation in

the range from fine control to stroke end
(Sensory).
Travel deviation
(To be measured only
when abnormal)
Forward
mm/20m
Track rotation speed

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

135 5 mm
Left
Max. 200 mm/20 m
mm/20m
mm
Revision
Category

At local
At ___
assembly operating
Criterion
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).
Check item
Work
equipment
posture
Boom
Arm
Bucket
Empty
Empty
Empty
Work equipment
speed (including
Boom
cushion working time)
P mode
Engine: Full throttle
Raise
In
Arm
Curl
sec
Open
Work equipment performance
Bottom
dump [
Engine: Low
When normal:
Sensory
When abnormal:
Measure
Lower
sec
Out
sec
Bucket [
Work equipment
time lag
Bottom dump
Dump
sec
Close
Lower
Boom
Arm
In
Dump
Bucket [
Empty
Raise: 8.3 0.8 sec
sec
Lower: 6.4 0.6 sec
In: 5.3 0.5 sec
sec
Out: 3.2 0.4 sec
Curl: 4.2 0.5 sec
sec
Dump: 2.9 0.4 sec
Open: 2.2 0.2 sec
sec
sec
]
sec
]
sec
Close: 2.2 0.2 sec
Max. 6.0 sec
Max. 5.0 sec
Max. 4.0 sec
Abnormal sound from hydraulic pump and PTO
Must be free from abnormality during no-load

operation and when relieved.
Heating of PTO
Must be free from abnormal heating.
Partial engine output performance
Engine must not hunt in any gear speed during

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
Shock at cylinder stroke end

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

switch ON, boom cylinder must be retracted
from extension stroke end to ground level
(when arm is at max. reach).
Revision
Category
Check item
At local
At ___
assembly operating
time
hours
Criterion
Around operator's seat
During operation
Check of each part

Operating effort of control lever when each actuator is operated
Lever must not be hitched during operation.

Lever must return to neutral by itself.
Shaking and beat noise of operator's cab
Beat noise of frame, guard and ladder
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.
Undercarriage
Oil leakage
(Idler, track roller, sprocket,
final drive gear case, motor, brake valve)
Looseness of track shoe bolt
Contact of link tread
Must be free from overlapping, flaking and

breakage.
Around chassis
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)
Water leakage from engine cooling system
Oil leakage from engine lubrication system
Gas leakage from engine gas system
Operation of covers
Must move smoothly.
Locks of covers
Must work securely.
Around chassis
Revision
Category
Check item
Criterion
Operation of grease pump
Must operate smoothly.
Looseness and insufficient insertion of electric wiring terminals
Electric wiring route
Clearance of at least 10 mm must be made

around moving part and edge.
Air leakage from air system
Oil leakage
(Cylinder, piping, block)
Around work equipment
At local
At ___
assembly operating
time
hours
Grease leakage from grease piping
Interference of work equipment
Looseness of work equipment piping clamp and play of piping
Twist of hydraulic hose and operation of work equipment at

reverse
Revision
Category
Note: If the operation or function is defective, measure as necessary.

Check item
The speeds in the criteria column are the values in P mode.

At local
At ___
assembly operating
Criterion
time
hours
P mode
1. Engine speed: Check in monitoring mode "01002".

Low idle
rpm]
825 50 rpm
High idle
rpm]
1980 50 rpm
rpm]
1780 50 rpm
rpm]
1780 50 rpm

(Heavy lift: OFF)
(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 [
1R [
Control valve main set pressure
2F [
2R [
MPa]
MPa]
MPa]
MPa]
29.4 1.0 MPa

OFF and relief
1F [
Control valve main set pressure 1R [
(Boosted pressure)
2F [
2R [
MPa]
MPa]
MPa]
MPa]
31.4 1.0 MPa

raise, P mode, heavy lift ON
and relief
At engine high idle, swing, P
mode and relief
Swing relief set pressure
1F [Right
1F [Left
MPa]
MPa]
28.4 2.0 MPa
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"
Pump EPC current
1F [
1R [
2F [
2R [
mA]
mA]
mA]
mA]
220 60 mA

neutral and P mode
1F [
1R [
2F [
2R [
mA]
mA]
mA]
mA]
460 60 mA

OFF and relief
J/S differential pressure output voltage: Check in monitoring mode.

1F pump: "13808" 1R pump: "13809"
2F pump: "13810" 2R pump: "13811"
J/S differential pressure

output voltage
1F [
1R [
2F [
2R [
V]
V]
V]
V]
Min. 3.2 V

neutral and P mode
1F [
1R [
2F [
2R [
V]
V]
V]
V]
Max. 1.4 V
At engine high idle, arm in,

P mode, and relief
Revision
Category

At local
At ___
assembly operating
time
hours
Check item
Criterion
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]
Arm cylinder
mm]
Bucket cylinder
mm]
9 mm/min (140 mm/15 min)
5. Operating effort and stroke

Boom
control lever
Operating Raise
effort
Main measurement items
Stroke
Swing
control lever
Arm
control lever
N
{kg}
Right
Left
[
mm] [
Operating Curl
effort
Stroke
N
{kg}
Curl
[
N
{kg}
In
[
Out
mm] [
Right travel lever Operating Forward

effort
Stroke
Left travel lever
N
{kg}
N
{kg}
N
{kg}
mm]
N
{kg}
Play
mm] [
Dump
Out
mm]
N
{kg}
mm]
N
{kg}
Play
mm] [
Reverse
Forward
Reverse
Play
[
mm] [
mm] [
Operating Forward
effort
Stroke
Left
Dump
Play
mm] [
mm] [
Operating In
effort
Stroke
Lower
Raise
Lower
Play
[
mm] [
mm] [
Operating Right
effort
Stroke
Bucket
control lever
N
{kg}
Reverse
Forward
Reverse
Play
[
mm] [
mm] [
mm]
N
{kg}
mm]
N
{kg}
mm]
16.7 4.2 N
{1.6 0.5 kg}
Stroke: 85 10 mm
Play: Max. 10 mm
13.7 3.4 N
{1.4 0.4 kg}
Stroke: 85 10 mm
Play: Max. 10 mm
13.7 3.4 N
{1.4 0.4 kg}
Stroke: 85 10 mm
Play: Max. 10 mm
13.7 3.4 N
{1.4 0.4 kg}
Stroke: 85 10 mm
Play: Max. 10 mm
25.5 6.4 N
{2.5 0.6 kg}
Stroke: 135 14 mm
Play: Max. 10 mm
25.5 6.4 N
{2.5 0.6 kg}
Stroke: 135 14 mm
Play: Max. 10 mm
Serial No. of controllers and monitor
Serial No. : Confirm with monitoring mode or visual check.

Engine controller (L-BANK)
Engine controller (R-BANK)
Pump controller (UPPER)
20403
Pump controller (LOWER)
20407
VHMS controller
ORBCOMM controller
Monitor
20402
At engine
high idle and
relief
GEN00060-03

Armado GEN00060-03

Transféré par

Informations du document

Copyright

Formats disponibles

Partager ce document

Partager ou intégrer le document

Options de partage

Avez-vous trouvé ce document utile ?

Ce contenu est-il inapproprié ?

Droits d'auteur :

Formats disponibles

Armado GEN00060-03

Transféré par

Droits d'auteur :

Formats disponibles

GEN00060-03

Field Assembly Instruction

(Instruction system diagram)

Crane sign maker

Operator for assembly

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

<Coupling of operator's cab>

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

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

VHMS CONTOROLLER INITIAL SETTING PROCEDURE .............................................. 215

Komatsu SAA12V140E-3 diesel engine

Min. ground distance

Travel speed (Low/High)

PC2000-8 Loading shovel

POINTS REGARDING LOCAL ASSEMBLY

2. Preparation and check of lifting tools and jigs

3. k Check during actual operation

Completion of total assembly

FLOWCHART OF MAIN ASSEMBLY PROCEDURE

Necessary assembly procedure when disassembling to 27t.

KIT LAYOUT DIAGRAM

Tools and equipment

Overall length (mm)

Overall width (mm)

Overall height (mm)

With swivel and fixing bar

(2) Crawler frame assembly

Overall width (mm)

Overall height (mm)

With motor and motor guard

(3) Revolving frame assembly

Overall width (mm)

Overall height (mm)

With 6 hoses to boom

When disassembled to 27 ton, hydraulic tank

(4) Fuel tank assembly

Overall length (mm)

Overall width (mm)

Overall height (mm)

With working lamp

(5) Cab base assembly

Overall length (mm)

Overall width (mm)

Overall height (mm)

With front and left catwalk

(6) Left floor assembly

Overall length (mm)

Overall width (mm)

Overall height (mm)

(7) Power container assembly

Overall length (mm)

Overall width (mm)

Overall height (mm)

With super hood

(8) Operator's cab assembly

Overall length (mm)

Overall width (mm)

Overall height (mm)

With antenna retracted

(9) Counterweight assembly

Overall length (mm)

Overall width (mm)

Overall height (mm)

(10) Slide ladder assembly