armado gen00060-03
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HYDRAULIC
EXCAVATOR
Field ssembly Instruction
GEN00060-03
PC2000 -8
SERIAL NUMBERS PC2000-8-20001 and up
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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 ad-
vance 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.
We hope that all the workers will cooperate to assemble this machine quickly while observing the safety, quality and delivery time.
(Instruction system diagram)
Work leader
Work director Crane sign maker Regular/Assistant
Liaison personOperator for assembly
(Interpreter)
Mechanics Share of work
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CONTENTS
SPECIFICATIONS............................................................................................................. 1POINTS REGARDING LOCAL ASSEMBLY ..................................................................... 2ASSEMBLY PROCEDURE, ASSEMBLY EQUIPMENT AND SCHEDULE ...................... 3
FLOWCHART OF MAIN ASSEMBLY PROCEDURE........................................................ 4KIT LAYOUT DIAGRAM.................................................................................................... 5TRANSPORTATION POSTURES..................................................................................... 6LIST OF PARTS SENT INDIVIDUALLY ............................................................................ 15TOOLS AND EQUIPMENT TO BE USED FOR LOCAL ASSEMBLY............................... 27TIGHTENING TORQUE .................................................................................................... 29COATING MATERIALS LIST ............................................................................................ 33
A. ASSEMBLY OF CHASSIS ............................................................................................ 35A- 1. Assembly of track frame assembly and center frame assembly........................... 36A- 2. Idler cushion cylinder piping ................................................................................. 39A- 3. Travel motor piping ............................................................................................... 40A- 4. Installation of travel motor cover........................................................................... 41A- 5. Filling swing circle with grease ............................................................................. 43A- 6. Assembly of revolving frame assembly and undercarriage .................................. 44A- 7. Installation of swing machinery (front) assembly (27t)
Installation of swing motor (front) assembly (32t) ................................................. 46A- 8. Connection of swivel joint piping........................................................................... 47A- 9. Connection of swing circle grease piping ............................................................. 49
A-10. Installation of hydraulic tank assembly ................................................................. 50A-11. Installation of fuel tank assembly.......................................................................... 55A-12. Connection of fuel tank assembly piping and wiring............................................. 56A-13. Installation of cab base assembly......................................................................... 58A-14. Installation of left floor assembly .......................................................................... 60A-15. Connection of cab base assembly piping............................................................. 64A-16. Connection of cab base assembly wiring ............................................................. 66A-17. Connection of left floor assembly heater piping.................................................... 71A-18. Connection of left floor assembly wiring............................................................... 72
A-19. Installation of tail pipe ........................................................................................... 73A-20. Installation of power container assembly.............................................................. 74A-21. Connection of suction piping ................................................................................ 76A-22. Connection of oil cooler piping and pump drain piping......................................... 78A-23. Connection of fan motor drain piping.................................................................... 79A-24. Installation of suction unit undercover .................................................................. 80A-25. Connection of delivery piping ............................................................................... 81A-26. Connection of pilot piping and fan motor piping ................................................... 83A-27. Connection of power container assembly fuel piping ........................................... 84A-28. Connection of power container assembly air conditioner piping .......................... 86A-29. Connection of power container assembly heater piping....................................... 87A-30. Connection of power container assembly wiring .................................................. 88
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LS. ASSEMBLY OF LOADING SHOVEL WORK EQUIPMENT........................................ 179LS- 1. Installation of arm cylinder bottom parts............................................................. 180LS- 2. Installation of boom cylinder to machine body.................................................... 181LS- 3. Installation of boom cylinder hoses..................................................................... 183LS- 4. Installation of boom cylinder piping..................................................................... 184LS- 5. Installation of boom assembly ............................................................................ 185LS- 6. Installation of boom cylinder head pins............................................................... 186LS- 7. Installation of hose between machine body and boom....................................... 187
LS- 8. Installation of bucket cylinder assembly ............................................................. 189LS- 9. Installation of arm assembly ............................................................................... 190LS-10. Installation of arm cylinder assembly.................................................................. 191LS-11. Installation of hoses between boom and arm..................................................... 192LS-12. Installation of bucket cylinder hoses................................................................... 193LS-13. Installation of grease feed hose of bucket cylinder............................................. 194LS-14. Installation of bucket assembly........................................................................... 196LS-15. Installation of bottom dump hose and grease feed hose
between arm and bucket .................................................................................... 197
M. INSPECTION AND SERVICING PROCEDURES AFTER ASSEMBLY....................... 199
M- 1. Inspection of oil levels and coolant levels and using standardof fuel and lubricant.............................................................................................. 200
M- 2. Flushing of hydraulic circuit.................................................................................. 203M- 3. Releasing residual pressure from hydraulic circuit............................................... 206M- 4. Releasing residual pressure from HIC circuit and check
of gas pressure in HIC accumulator..................................................................... 207M- 5. Charging air conditioner with refrigerant .............................................................. 208M- 6. Installed angles of mirrors.................................................................................... 209M- 7. Installed angles of lights....................................................................................... 211
VHMS CONTOROLLER INITIAL SETTING PROCEDURE .............................................. 215
FIELD ASSEMBLY INSPECTION REPORT (BACKHOE)
FIELD ASSEMBLY INSPECTION REPORT (LOADING SHOVEL)
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1
SPECIFICATIONS
PC2000-8 Backhoe
PC2000-8 Loading shovel
Item Unit PC2000-8
Operating weight (including 1 operator) kg 200,000
Bucket capacityBackhoe
m312.0
Loading shovel 11.0
Name of engine Komatsu SAA12V140E-3 diesel engine
Engine horsepower 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
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2
POINTS REGARDING LOCAL ASSEMBLY
1. Selection of work place1) 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 jigs1) 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 operation1) 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 ma-
chine. 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 en-
sure that the workers understand them.
6. Hold a meeting every morning before starting work to confirm the operating plan and operating safety.
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3
ASSEMBLY PROCEDURE,
ASSEMBLY EQUIPMENT AND SCHEDULE
Day
(Ha
lfday
)
Un
its
tobe
assem
bled
Crane
Mo
bilee
leva
ting
workp
latform
Aircompressor
Min
.15m
3/min
Workers
Foreman
+6mec
han
ics
Foreman
+6mec
han
ics
Foreman
+6mec
han
ics
Foreman
+2mec
han
ics
Starto
fassem
bly
Meetin
go
fa
llworkers
Comp
letion
ofassem
bly
o
fc
hassis
Starto
feng
ine
Comp
letion
oftotalassem
bly
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4
FLOWCHART OF MAIN ASSEMBLY PROCEDURE
To A
A
Necessary assembly procedure when disassembling to 27t.
Assembly ofundercarriage
(Crawler, centerframe)
Installation ofhydraulic tank
Coupling of
revolving frame
Installation offront machinery
Installation ofgrease cover andladder
Installation ofcab base
Installation of
counterweight
Installation ofboom cylinder
Installation ofboom
Installation ofarm
Installation ofbucket
Motoring
Boom sub(arm cylinder, tube)
Installation ofpower container
assembly
Installation ofexterior parts,handrail and mirror
Installation ofcab assembly
Connection of
swivel piping
Installation offuel tank
Installation ofleft floor
Installation ofladder to cab base
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5
KIT LAYOUT DIAGRAM The dimensions given below are the minimum dimensions needed.
When selecting a work place, see "Points regarding local assembly".
When installing the revolving frame, place wooden blocks 700 mm high under it.
Covers
Bucket
Arm
link
Boom
Craw
ler
frame
Craw
ler
frame
G reel
Rear floor
Front CW
Left deck
Left floor
Covers
PA ladder
Right CW
Right deck
Right floor
Cab
Power container
Cabbase
Tubes
Hoses
Tools and equipment
Boom cylinder
Crane, 50 ton
Center frame
C weight
F tank
Front
Revolvingframe
Crane, 50 ton
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6
TRANSPORTATION POSTURESFor 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
(2) Crawler frame assembly
(3) Revolving frame assembly
Center of gravity
Top view
X Overall length (mm) 3,815
Y Overall width (mm) 3,190
Z Overall height (mm) 2,210
W 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.
Top view
Center of gravity
For each crawler
X Overall length (mm) 7,435
Y Overall width (mm) 1,720
Z Overall height (mm) 1,920
W Weight (kg) 26,000
With motor and motor guard
[Remarks]
Full roller guard is optional.
Center of gravity
Top view
When
disassembledto 32 ton
When
disassembledto 27 ton
X Overall length (mm) 7,575
Y Overall width (mm) 3,180
Z Overall height (mm) 2,920 2,640
W Weight (kg) 31,500 26,500
With 6 hoses to boom
With 4 oil cooler hoses
With grease tank
When disassembled to 27 ton, hydraulic tankassembly and machine (front) assembly are
packed separately.
(Special sling)
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(4) Fuel tank assembly
(5) Cab base assembly
(6) Left floor assembly
Top view
Center of gravity
X Overall length (mm) 3,100
Y Overall width (mm) ,875
Z Overall height (mm) 2,070
W Weight (kg) 2,400
With working lamp
With fuel level sensor
Center of gravity
Top view
X Overall length (mm) 3,660
Y Overall width (mm) 2,505
Z Overall height (mm) 2,700
W Weight (kg) 2,500
With front and left catwalk
With head lamp and working lamp
Center of gravity
Top view
X Overall length (mm) 2,500
Y Overall width (mm) 2,100
Z Overall height (mm) 3,085
W Weight (kg) 1,500
With battery
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(7) Power container assembly
(8) Operator's cab assembly
(9) Counterweight assembly
Center of gravity
Top view
X Overall length (mm) 5,215
Y Overall width (mm) 2,455
Z Overall height (mm) 3,195
W Weight (kg) 16,100
With super hood
With handrail on radiator side
Center of gravity
Top view
X Overall length (mm) 2,855
Y Overall width (mm) 1,880
Z Overall height (mm) 2,520
W Weight (kg) 1,800
With antenna retracted
With mirrors folded
[Remarks]
Front guard is optional.
Center of gravity
Top view
X Overall length (mm) 6,240
Y Overall width (mm) 1,115
Z Overall height (mm) 1,505
W Weight (kg) 24,500
[Parts packed separately]
Handrail, bolts
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(10) Slide ladder assembly
(11) Catwalk assembly on power container side
(12) Grease can cover assembly
Center of gravity
View Z
X Overall length (mm) 3,380
Y Overall width (mm) ,875
Z Overall height (mm) 1,255
W Weight (kg) ,550
Center of gravity
Top view
For each catwalk
X Overall length (mm) 2,310Y Overall width (mm) ,545
Z Overall height (mm) 2,085
W Weight (kg) ,260
Center of gravity
Top view
X Overall length (mm) 1,030
Y Overall width (mm) 1,025
Z Overall height (mm) ,995
W Weight (kg) ,260
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(13) Right floor assembly
(14) Right catwalk assembly
(15) Front catwalk assembly
Center of gravity
Top view
X Overall length (mm) 1,390
Y Overall width (mm) 1,350
Z Overall height (mm) 2,085
W Weight (kg) ,240
Top view
Center of gravity
X Overall length (mm) 3,560
Y Overall width (mm) 1,300
Z Overall height (mm) 1,865
W Weight (kg) ,390
With grease reel
Center of gravity
Top view
X Overall length (mm) ,715
Y Overall width (mm) ,810
Z Overall height (mm) 1,540
W Weight (kg) , 90
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(16) Cab rear floor assembly
(17) Boom assembly
(18) Arm assembly
Center of gravity
Top view
X Overall length (mm) 1,470
Y Overall width (mm) 1,320
Z Overall height (mm) ,345
W Weight (kg) , 70
Center of gravity
Left side view
X Overall length (mm) 9,170
Y Overall width (mm) 2,065
Z Overall height (mm) 3,195
W Weight (kg) 18,430
Left side view
Center of gravity
X Overall length (mm) 5,495
Y Overall width (mm) 1,605
Z Overall height (mm) 2,055
W Weight (kg) 12,900
With bucket cylinder
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(19) Bucket assembly
(20) Arm cylinder tube assembly
(21) Hydraulic tank assembly
Left side view
Center of gravity
X Overall length (mm) 5,495
Y Overall width (mm) 1,605
Z Overall height (mm) 2,055
W Weight (kg) 12,900
Specifications of standard bucket
for crushed stones
Left side view
Center of gravity
X Overall length (mm) 1,240
Y Overall width (mm) ,320
Z Overall height (mm) ,365
W Weight (kg) , 60
Top view
Center of gravity
X Overall length (mm) 1,860
Y Overall width (mm) 1,115
Z Overall height (mm) 2,085
W Weight (kg) 1,750
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(22) Swing machinery (front) assembly
(23) Cab L.H. catwalk
(24) Cab front catwalk
Top view
Center of gravity
X Overall length (mm) ,775
Y Overall width (mm) ,675
Z Overall height (mm) 1,335
W Weight (kg) 1,050
Top view
Center of gravity
X Overall length (mm) 3,660
Y Overall width (mm) ,615
Z Overall height (mm) 1,355
W Weight (kg) ,220
Top view
Center of gravity
X Overall length (mm) 1,840
Y Overall width (mm) ,560
Z Overall height (mm) 11,325
W Weight (kg) ,100
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Method of installing chassis hanging jig
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LIST OF PARTS SENT INDIVIDUALLY (Assembly of undercarriage)
A
No. Part No. Part name Q'tyAssembly
procedure No. Remarks
A-1 21T-30-71160 BOLT 76 A-1
A-2 21T-30-71170 WASHER 76 A-1
A-3 208-30-11850 COVER 1 A-1
A-4 208-30-11861 GASKET 1 A-1
A-5 01024-81225 BOLT 3 A-1
A-6 07000-B3025 O-RING 2 A-2
A-7 07000-B3048 O-RING 4 A-3
A-8 02896-61018 O-RING 2 A-3
A-9 01024-81235 BOLT 4 A-4A-10 424-54-14230 COLLAR 4 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 1 A-4
A-15 21T-30-32182 COVER 1 A-4
A-16 01010-82460 BOLT 10 A-4
A-17 17A-54-44130 WASHER 10 A-4
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LIST OF PARTS SENT INDIVIDUALLY (Coupling of revolving frame)
B
No. Part No. Part name Q'tyAssembly
procedure No. Remarks
B-1 21T-25-67150 BOLT 60 A-6
B-2 01643-33690 WASHER 60 A-6
B-3 01010-83090 BOLT 14 A-7
B-4 01643-33080 WASHER 14 A-7
B-5 07000-B3032 O-RING 1 A-7
B-6 07000-B3032 O-RING 2 A-7
B-7 02896-61015 O-RING 1 A-7
B-8 02896-61008 O-RING 1 A-7
B-9 01024-81225 BOLT 1 A-7
B-10 11Y-62-11980 O-RING 1 A-8B-11 02896-61009 O-RING 4 A-8
B-12 07000-B3048 O-RING 4 A-8
B-13 07000-B5230 O-RING 2 A-10
B-14 01011-83010 BOLT 12 A-10
B-15 21T-26-11460 WASHER 12 A-10
B-16 07000-B2060 O-RING 8 A-10
B-17 11Y-62-11980 O-RING 3 A-10
B-18 07000-B3032 O-RING 1 A-10
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LIST OF PARTS SENT INDIVIDUALLY (Assembly of upper structure)
C
No. Part No. Part name Q'tyAssembly
procedure No. Remarks
C-1 01011-83010 BOLT 20 A-11
C-2 21T-26-11460 WASHER 20 A-11
C-3 04435-52212 CLIP 1 A-12
C-4 02896-61012 O-RING 1 A-12
C-5 02896-61015 O-RING 2 A-12
C-6 02896-61018 O-RING 2 A-12
C-7 01024-81220 BOLT 1 A-12
C-8 04434-52312 CLIP 1 A-12
C-9 04434-51912 CLIP 3 A-12
C-10 01024-81220 BOLT 4 A-12
C-11 01034-81245 BOLT 10 A-13
C-12 01034-81265 BOLT 10 A-13
C-13 21T-54-31140 CLAMP 1 A-13
C-14 21T-54-31150 CLAMP 1 A-13
C-15 01034-81245 BOLT 2 A-13
C-16 01011-82035 BOLT 20 A-13
C-17 01011-82045 BOLT 7 A-13
C-18 567-40-41380 WASHER 27 A-13
C-19 01010-82065 BOLT 24 A-14
C-20 01643-32060 WASHER 24 A-14
C-21 21T-53-31530 SHIM 3 A-14
C-22 21T-53-31540 SHIM 3 A-14
C-23 21T-54-33471 COVER 1 A-14
C-24 01034-81230 BOLT 3 A-14
C-25 02896-61012 O-RING 6 A-15
C-26 02896-61018 O-RING 2 A-15
C-27 21T-979-3320 JOINT 2 A-17
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LIST OF PARTS SENT INDIVIDUALLY (Coupling of power container)
D
No. Part No. Part name Q'tyAssembly
procedure No. Remarks
D-1 21M-01-18130 TAIL PIPE 2 A-19
D-2 01024-81230 BOLT 12 A-19
D-3 6162-14-5640 RAIN CAP 2 A-19
D-4 21T-54-31121 PLATE 4 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 2 A-21
D-8 07000-B2100 O-RING 1 A-21
D-9 209-62-41341 CLAMP 4 A-21
D-10 20Y-62-51671 CLAMP 2 A-21
D-11 07000-B2060 O-RING 7 A-22
D-12 07298-02011 HOSE 1 A-22
D-13 07000-B3032 O-RING 1 A-23
D-14 07000-B3048 O-RING 4 A-25
D-15 07000-B3025 O-RING 2 A-26
D-16 07000-B3032 O-RING 1 A-26
D-17 02896-61018 O-RING 2 A-27
D-18 02896-61015 O-RING 1 A-27
D-19 02896-61015 O-RING 1 A-27
D-20 08028-55065 CABLE 2 A-30
D-21 01024-81020 BOLT 2 A-30
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LIST OF PARTS SENT INDIVIDUALLY (Coupling of operator's cab)
E
No. Part No. Part name Q'tyAssembly
procedure No. Remarks
E-1 21T-54-36661 SHIM 16 A-31
E-2 21T-54-36671 SHIM 8 A-31
E-3 21T-54-35321 CUSHION 8 A-31
E-4 8295-06-1480 LAMP BEACOM 1 A-32
E-5 21T-06-17430 BRACKET 1 A-32
E-6 01024-81225 BOLT 2 A-32
E-7 8295-06-1480 LAMP BEACOM 1 A-32
E-8 21T-06-33610 PLATE 1 A-32
E-9 21T-06-17430 BRACKET 1 A-32
E-11 01024-81225 BOLT 2 A-32
E-11 04434-51012 CLIP 1 A-32E-12 01024-81220 BOLT 1 A-32
E-13 8A13-10-2100 ANTENNA 1 A-33
E-14 21T-06-64491 BRACKET 1 A-33
E-15 01024-81225 BOLT 1 A-33
E-16 02896-61012 O-RING 10 A-35
E-17 02896-61009 O-RING 2 A-35
E-18 21T-979-4421 SEAL 8 A-37
E-19 08034-20830 BAND 2 A-37
E-20 08034-20830 BAND 3 A-38
E-21 01024-81225 BOLT 14 A-39
E-22 21T-54-33931 HANDRAIL 1 A-40
E-23 01034-81245 BOLT 10 A-40
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LIST OF PARTS SENT INDIVIDUALLY (Coupling of counterweight etc)
F
No. Part No. Part name Q'tyAssembly
procedure No. Remarks
F-1 21T-30-32231 BRACKET 2 A-41
F-2 21T-30-32241 LADDER 2 A-41
F-3 01010-82460 BOLT 8 A-41
F-4 01010-82450 BOLT 8 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 8 A-43
F-9 01643-32060 WASHER 20 A-43
F-10 21T-53-31550 PLATE 1 A-43F-11 21T-54-31560 PLATE 1 A-43
F-12 21T-54-33331 STEP 1 A-43
F-13 01034-81250 BOLT 4 A-43
F-14 01034-81235 BOLT 16 A-44
F-15 01034-81250 BOLT 6 A-45
F-16 01010-82050 BOLT 6 A-48
F-17 567-40-41380 WASHER 6 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 2 A-49
F-21 21T-46-34131 PLATE 2 A-49
F-22 01024-81225 BOLT 12 A-49
F-23 21T-54-34411 HANDRAIL 1 A-50
F-24 21T-54-34421 HANDRAIL 1 A-50
F-25 01034-81250 BOLT 16 A-50
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No. Part No. Part name Q'tyAssembly
procedure No. Remarks
F-26 21T-54-32911 CLAMP 7 A-51
F-27 21T-54-32921 CLAMP 7 A-51
F-28 01034-81245 BOLT 14 A-51
F-29 21T-54-65810 CHAIN 1 A-51
F-30 21T-54-31140 CLAMP 1 A-51
F-31 21T-54-31150 CLAMP 1 A-51
F-32 01034-81245 BOLT 2 A-51
F-33 21T-01-31471 NIPPLE 1 A-53
F-34 07005-02416 O-RING 1 A-53
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LIST OF PARTS SENT INDIVIDUALLY (Coupling of boom)
H
No. Part No. Part name Q'tyAssembly
procedure No. Remarks
H-1 707-01-XK750 BOOM CYLINDER(L.H.) 1 C-1
H-2 707-01-XK760 BOOM CYLINDER(R.H.) 1 C-1
H-3 21T-70-31421 SHIM 2 C-1
H-4 21T-70-31470 SHIM 8 C-1
H-5 21T-70-31690 SHIM 8 C-1
H-6 07000-15180 O-RING 4 C-1
H-7 07000-B2060 O-RING 4 C-2
H-8 07000-B3048 O-RING 4 C-2
H-9 21T-64-39410 HOSE 2 C-2
H-10 07083-01417 HOSE 2 C-2
H-11 21T-64-39140 TUBE 1 C-3
H-12 21T-64-39150 TUBE 1 C-3
H-13 21T-64-39160 TUBE 1 C-3
H-14 07000-B3048 O-RING 2 C-3
H-15 07000-B2060 O-RING 7 C-3
H-16 01643-31845 WASHER 32 C-3
H-17 01010-81840 BOLT 4 C-3
H-18 01010-81865 BOLT 28 C-3
H-19 707-01-XK770 ARM CYLINDER(L.H.) 1 C-3
H-20 707-01-XK780 ARM CYLINDER(R.H.) 1 C-3
H-21 07000-12140 O-RING 4 C-3
H-22 21T-70-31441 SHIM 4 C-3
H-23 07084-02022 HOSE 2 C-3
H-24 07085-01418 HOSE 1 C-3
H-25 07085-01420 HOSE 1 C-3
H-26 07000-B2060 O-RING 4 C-3
H-27 07000-B3048 O-RING 4 C-3
H-28 07371-51470 FLANGE 4 C-3
H-29 07371-52080 FLANGE 4 C-3
H-30 01643-31445 WASHER 8 C-3
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No. Part No. Part name Q'tyAssembly
procedure No. Remarks
H-31 01643-31845 WASHER 8 C-3
H-32 01010-81455 BOLT 8 C-3
H-33 01010-81865 BOLT 8 C-3
H-34 21T-06-32810 WORK LAMP A. 4 C-3
H-35 20Y-06-21551 BRACKET 4 C-3
H-36 01643-31445 WASHER 4 C-3
H-37 01010-81430 BOLT 4 C-3
H-38 01024-81225 BOLT 4 C-3
H-39 209-72-11311 SEAL 4 C-3
H-40 21T-70-31480 SHIM 8 C-4
H-41 21T-70-31490 SHIM 16 C-4
H-42 07000-15180 O-RING 4 C-5
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LIST OF PARTS SENT INDIVIDUALLY (Coupling of arm)
I
No. Part No. Part name Q'tyAssembly
procedure No. Remarks
I-1 07000-B2060 O-RING 6 C-6
I-2 21T-70-31290 SEAL 4 C-7
I-3 21N-70-12160 SEAL 4 C-7
I-4 209-72-11261 SEAL 4 C-7
I-5 21T-70-31391 SHIM 2 C-7
I-6 21T-70-31780 SHIM 1 C-7
I-7 21T-70-31810 SHIM 1 C-7
I-8 21T-70-31820 SHIM 1 C-7
I-9 07000-B5260 O-RING 2 C-7
I-10 21T-70-32181 SHIM 4 C-8I-11 07000-12140 O-RING 4 C-8
I-12 07371-51470 FLANGE 4 C-9
I-13 07371-52080 FLANGE 4 C-9
I-14 07084-41427 HOSE 2 C-9
I-15 07084-42026 HOSE 2 C-9
I-16 07000-B3048 O-RING 4 C-9
I-17 07000-B2060 O-RING 4 C-9
I-18 01643-31445 WASHER 8 C-9
I-19 01643-31845 WASHER 8 C-9
I-20 01010-81455 BOLT 8 C-9
I-21 01010-81865 BOLT 8 C-9
I-22 21T-68-31830 TUBE 1 C-10
I-23 203-973-5660 CLAMP 3 C-10
I-24 203-973-5720 SEAT 3 C-10
I-25 01024-81055 BOLT 6 C-10
I-26 21T-70-75290 BACKET 1 C-10
I-27 01024-81225 BOLT 2 C-10
I-28 07631-20409 HOSE 1 C-10
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LIST OF PARTS SENT INDIVIDUALLY (Coupling of bucket)
J
No. Part No. Part name Q'tyAssembly
procedure No. Remarks
J-1 209-72-11261 SEAL 4 C-12
J-2 209-70-71370 O-RING 4 C-12
J-3 205-09-61240 BOLT 4 C-12
J-4 01640-20610 WASHER 8 C-12
J-5 01596-00606 NUT 4 C-12
J-6 21N-72-11230 SHIM 2 C-13
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LIST OF PARTS SENT INDIVIDUALLY (Bleeding air from cylinders and hydraulic circuit)
K
No. Part No. Part name Q'tyAssembly
procedure No. Remarks
K-1 209-60-77551 ELEMENT 3 M-2
K-2 21T-60-13730 PLATE 3 M-2
K-3 23S-54-36270 MIRROR 2 M-6
K-4 21T-54-34690 SUPPORT 1 M-6
K-5 21T-54-79620 CLAMP 2 M-6
K-6 01252-71025 BOLT 4 M-6
K-7 21T-54-34850 PLATE 1 M-6
K-8 21T-54-34680 PLATE 1 M-6
K-9 07283-32236 CLIP 4 M-6
K-10 01643-31032 WASHER 8 M-6
K-11 01597-01009 NUT 8 M-6K-12 421-54-25610 MIRROR 1 M-6
K-13 04025-00632 SPRING PIN 1 M-6
K-14 01252-70545 BOLT 4 M-6
K-15 21T-54-36480 SUPPORT 1 M-6
K-16 20Y-54-61630 CLAMP 1 M-6
K-17 01252-71030 BOLT 2 M-6
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TOOLS AND EQUIPMENT TO BE USED FOR LOCAL ASSEMBLY
No. Part name Specification Q'ty Remarks
Equipment
1 Engine air compressor 7.0 kg/cm3 1 With 200 V, 100 V generator
2 Crane truck 50 ton 2
3 Grease pump Pneumatic 1 For greasing work equipment
4 Mobile elevating work platform 10 m 1 2 workers
5 Lift work stand 10 step, 3,000 mm 1Substituted by mobileelevating work platform
6Stepladder
5 step, 1,500 mm 2
7 3 step, 900 mm 2
8 Hydraulic wrench 750 kgm 1 Track frame, power container
9 Hydraulic pump For hydraulic wrench, 200 V 1 Track frame, power container
Tool
10
Impact wrench
For M10 mm bolt 1 (Torque capacity: 10 70 Nm)
11 For M12 mm bolt 2 (Torque capacity: 30 170 Nm)
12 For M16 mm bolt 1 (Torque capacity: 150 650 Nm)
13 For M36 mm bolt 1 (Torque capacity: 780 2,900 Nm)
14 For M42 mm bolt 1 (Torque capacity: 1,500 6,300 Nm)
15
Impact wrench socket
Width across flats: 70 mm 1 Track frame
16 Width across flats: 65 mm 1 Counterweight17 Width across flats: 55 mm 1
18 Width across flats: 46 mm 1 Fuel tank
19
420 kgm
torque wrench socket
T38.1 Width across flats: 70 mm 1 Track frame
20 T38.1 Width across flats: 65 mm 1 Counterweight
21 T38.1 Width across flats: 55mm 1
22 T38.1 Width across flats: 50 mm 1
23 Socket T19 Width across flats 30 mm 1
24Extension
For impact wrench, 300 mm long 2
25 For impact wrench, 200 mm long 1
26 Impact wrench air hose Inside 12, Inside 19 50 m each
27 Air coupler For hoses of size 4, 6 2 sets
28 16 time wrench 450 kgm 1Unnecessary, if hydraulicwrench is available
29
Torque wrench
12 kgm T19 1
30 42 kgm T25.4 1 For 16 time wrench
31 85 kgm T25.4 1 For 4 time wrench
32 420 kgm T38 1
33
Spanner
Width across flats: 30 mm 2
34 Width across flats: 32 mm 2
35 Width across flats: 36 mm 2
36 Width across flats: 41 mm 2
37 Standard tool set Sockets, spanners, ring wrenches 2 sets each
38 Large hammer (Plastic) 10 P 1
39 Bar 1 m 2
40Hydraulic jack
50 ton 2For receiving center frame toinstall track frame
41 20 ton 1For tightening track frameclamping bolt
42 Oil receiving pan Large and small 2 eachFor connecting travel pipingand work equipment piping
43 Drum can oil filler 1
44 Wooden block 300 400 8For supporting revolving frameand center frame
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No. Part name Specification Q'ty Remarks
Tool
45
Tap
M10 P1.5 1
46 M12 P1.75 1
47 M14 P2 1
48 M16 P2 1
49 M20 P2.5 1
50 M24 P3 1
51 M27 P3 1
52 M30 P3 153 M33 P3 1
54 M36 P3 1
55 M39 P3 1
56 M42 P3 1
Sling
57
Wire
10 3,000 mm 4 Catwalk
58 20 5,000 mm 4 Boom, arm and bucket
59 30 6,000 mm 4Center frame and powercontainer
60 40 5,000 mm 4Counterweight, revolvingframe and track frame
61 Chain For 15 ton 2 Track frame
62
Shackle
5.4 ton 4Center frame, boom, arm andpower container
63 10 ton 4 Track frame and revolving frame
64 20 ton 2 Counterweight
65 2 ton 4 Fuel tank
66 0.9 ton 4 Cabin
67 SB10 2 Travel piping cover
68Nylon sling
50 mm wide 3,000 mm 2 Boom cylinder
69 25 mm wide 3,000 mm 2 Handrail
70
Lever block
1.5 ton 3 Left floor assembly
71 3.0 ton 2
72 6 ton 2
73
Eyebolt
M20 2
74 M16 4
75 M12 4
76 Pin Pin, 50 40 mm 2 Track frame
Fuel,oil,grease
ands
ub-materials
77 Cleaning liquid Brake cleaner spray can 10
78 Hydraulic oil EO10 2000 L
79 Diesel fuel 2000 L
80 Grease G2-LI (20 L can) 5 In grease bath
81Repair paint
Natural yellow spray can 10
82 Black gray spray can 10
83 LG-6 TB1215 1Connecting faces of revolvingframe and swing circle
84 Air conditioner refrigerant R134a 2000 g
85 Cloth 1 bundle 20 kg For cleaning
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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 dam-
age 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 1Unit: Nm {kgm}
Thread diameter Pitch
a (mm)
Width across flats
b (mm)
Tightening torque
Target Range
6 1 1012
{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 1754
{5.5}
34 - 74
{3.5 - 7.5}
12 1.75 1989
{9}
54 - 123
{5.5 - 12.5}
14 2 22137
{14}
84 - 196
{8.5 - 20}
16 2 24230
{23.5}
147 - 309
{15 - 31.5}
18 2.5 27
315
{32}
201 - 427
{20.5 - 43.5}
20 2.5 30460
{47}
319 - 608
{32.5 - 62}
22 2.5 32650
{66.5}
471 - 829
{48 - 84.5}
24 3 36810
{82.5}
588 - 1030
{60 - 105}
27 3 411180
{120}
883 - 1470
{90 - 150}
30 3 461520
{155}
1130 - 1910
{115- 195}
33 3 501960
{200}
1470 - 2450
{150 - 250}
36 3 552450
{250}
1860 - 3040
{190 - 310}
39 3 602940
{300}
2260 - 3630
{230 - 370}
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When using a torque wrench, apply Table 2.
Apply Table 2 when tightening torque must be controlled very strictly.
Table 2Unit: Nm {kgm}
Thread diameter Pitch
a (mm)
Width across flats
b (mm)
Tightening torque
Target Range
6 1 1013.2
{1.35}
11.8 - 14.7
{1.2 - 1.5}
8 1.25 1331
{3.2}
27 - 34
{2.8 - 3.5}
10 1.5 1766
{6.7}
59 - 74
{6.0 - 7.5}
12 1.75 19113
{11.5}
98 - 123
{10.0 - 12.5}
14 2 22 172{17.5}
153 - 190{15.5 - 19.5}
16 2 24260
{26.5}
235 - 285
{23.5 - 29.5}
18 2.5 27360
{37.0}
320 - 400
{33.0 - 41.0}
20 2.5 30510
{52.3}
455 - 565
{46.5 - 58.0}
22 2.5 32688
{70.3}
610 - 765
{62.5 - 78.0}
24 3 36
883
{90.0}
785 - 980
{80.0 - 100.0}
27 3 411295
{132.5}
1150 - 1440
{118.0 - 147.0}
30 3 461720
{175.0}
1520 - 1910
{155.0- 195.0}
33 3 502210
{225.0}
1960 - 2450
{200.0 - 250.0}
36 3 552750
{280.0}
2450 - 3040
{250.0 - 310.0}
39 3 603280
{335.0}
2890 - 3630
{295.0 - 370.0}
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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 1Unit: Nm {kgm}
2-2. Apply Table 2 to male screws made of S43C.
Table 2
Unit: Nm {kgm}
Material of female screwSteel Cast iron Light alloy
Nominal size
1 / 83.9 - 6.9
{0.4 - 0.7}
2.9 - 5.9
{0.3 - 0.6}
2.0 - 3.9
{0.2 - 0.4}
1 / 45.9 - 11.8
{0.6 - 1.2}
4.9 - 9.8
{0.5 - 1.0}
3.9 - 7.8
{0.4 - 0.8}
3 / 816.7 - 26.5
{1.7 - 2.7}
13.7 - 21.6
{1.4 - 2.2}
9.8 - 16.7
{1.0 - 1.7}
1 / 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 / 451.0 - 85.3
{5.2 - 8.7}
42.1 - 70.6
{4.3 - 7.2}
31.4 - 52.9
{3.2 - 5.4}
186.2 - 173.5
{8.8 - 17.7}
72.5 - 146.0
{7.4 - 14.9}
54.9 - 111.7
{5.6 - 11.4}
Material of female screwSteel Cast iron Light alloy
Nominal size
1 / 816.7 - 29.4
{1.7 - 3.0}
9.8 - 19.6
{1.0 - 2.0}
6.9 - 14.7
{0.7 - 1.5}
1 / 419.6 - 44.1
{2.0 - 4.5}
16.7 - 37.2
{1.7 - 3.8}
12.7 - 28.4
{1.3 - 2.9}
3 / 844.1 - 93.1
{4.5 - 9.5}
37.2 - 77.4
{3.8 - 7.9}
27.4 - 58.8
{2.8 - 6.0}
1 / 298.0 - 188.2
{10.0 - 19.2}
83.3 - 157.8
{8.5 - 16.1}
60.8 - 115.6
{6.2 - 11.8}
3 / 4170.5 - 316.5
{17.4 - 32.3}
141.1 - 247.0
{14.4 - 25.2}
105.8 - 186.2
{10.8 - 19.0}
1367.5 - 612.5
{37.5 - 62.5}
309.7 - 514.5
{31.6 - 52.5}
235.2 - 392.0
{24.0 - 40.0}
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3. Tightening torque for hoses (with taper seals or face seals)
Unit: Nm {kgm}
When installing rubber hoses, extremely take care not to twist them.
Nominal size
of hoseWidth across flats
Tightening torque
Range Target
02 19 35 - 63 {3.5 - 6.5} 44 {4.5}
03
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}
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COATING MATERIALS LIST
a The coating materials such as adhesives, gasket sealants, and greases used for disassembly and assembly
are listed below.
a For coating materials not listed below, use the equivalent of products shown in this list.
Category Komatsu code Part No. Q'ty Container Main features and applications
Adhesive
LT-1A 790-129-9030 150 g Tube Used to prevent rubber gaskets, rub-
ber cushions, and cock plugs fromcoming out.
LT-1B 790-129-905020 g
(2 pcs.)Polyethylene
container
Used for plastic (except polyethyl-ene, polypropylene, tetrafluoroethyl-ene and vinyl chloride), rubber,metal, and non-metal parts which re-quire immediate and strong adhe-sion.
LT-2 09940-00030 50 gPolyethylene
container
Features: Resistance to heat andchemicals
Used to fix and seal bolts and plugs.
LT-3790-129-9060
(Set of adhesiveand hardener)
Adhesive:1 kg
Hardener:500 g
Can
Used to stick metal, glass, and plas-tics.
LT-4 790-129-9040 250 g Polyethylenecontainer
Used to seal plugs.
HoltzMH 705
790-126-9120 75 g Tube Heat-resistant seal used to repair en-
gines
Threebond1735
790-129-9140 50 gPolyethylene
container
Quick-setting adhesive Setting time: Within 5 sec. to 3 min. Used mainly to stick metals, rubbers,
plastics, and woods.
Aron-alpha201
790-129-9130 2 gPolyethylene
container
Quick-setting adhesive Quick-setting type (max. strength is
obtained after 30 minutes) Used mainly to stick rubbers, plas-
tics, and metals.
Loctite648-50
79A-129-9110 50 cc Polyethylenecontainer
Features: Resistance to heat and
chemicals Used for fitted portions used at high
temperatures.
Gasket
sealant
LG-1 790-129-9010 200 g Tube Used to stick or seal gaskets and
packings of power train case, etc.
LG-5 790-129-9080 1 kgPolyethylene
container
Used to seal various threaded por-tions, pipe joints, and f langes.
Used to seal tapered plugs, elbows,and nipples of hydraulic piping.
LG-6 790-129-9020 200 g Tube
Features: Silicon-based heat andcold-resistant sealant
Used to sea flange surfaces andthreaded portions.
Used to seal oil pan, final drive case,etc.
LG-7 790-129-9070 1 kg Tube
Features: Silicon-based quick-set-ting sealant
Used to seal flywheel housing, intakemanifold, oil pan, thermostat hous-ing, etc.
Three bond1211
790-129-9090 100 g Tube Gasket sealant used to repair engine
Three bond1207B
419-15-18131 100 g Tube
Features: Silicon-based, heat andcold-resistant, vibration-resistant,impact-resistant sealant
Used to seal transfer case, etc.
Molybdenum disulfidelubricant
LM-G 09940-00051 60 g Can Used to lubricate sliding portions (to
prevent squeaking).
LM-P 09940-00040 200 g Tube
Used to prevent scuffing and seizureof press-fitted portions, shrink-fittedportions, and threaded portions.
Used to lubricate linkages, bearings,etc.
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Category Komatsu code Part No. Q'ty Container Main applications, features
Grease
G2-LI
SYG2-400LISYG2-350LISYG2-400LI-ASYG2-160LISYGA-160CNLI
Various Various
General purpose type
G2-CA
SYG2-400CASYG2-350CA
SYG2-400CA-ASYG2-160CASYGA-160CNCA
Various Various
Used for bearings used at normaltemperature under light load in
contact with water or steam.
MolybdenumdisulfidelubricantLM-G (G2-M)
SYG2-400MSYG2-400M-ASYGA-16CNM
400 g 10400 g 20
16 kg
Bellows-typecontainer
Can
Used for parts under heavy load.
Hyper WhiteGrease G2-TG0-T (*)*: For cold
district
SYG2-400T-ASYG2-16CNTSYG0-400T-A (*)SYG0-16CNT (*)
Bellows-typecontainer
Can
Seizure resistance and heat resist-ance higher than molybdenum di-sulfide
Not conspicuous on machine sincecolor is white.
Biogrease G2-B,G2-BT (*)
*: For use at hightemperatureand under highload
SYG2-400B
SYGA-16CNBSYG0-400BT (*)SYGA-16CNBT (*)
Bellows-typecontainerCan
Since this grease is decomposedby natural bacteria in short period,
it has less effects on microorgan-isms, animals, and plants.
Primer
SUNSTARPAINT PRIMER580 SUPER
417-926-3910
20 mlGlass
container
Adhesiveforcabglass
Used as primer for cab side(Using limit: 4 months afterdate of manufacture)
SUNSTARGLASS PRIMER580 SUPER
20 mlGlass
container
Used as primer for glass side(Using limit: 4 months afterdate of manufacture)
SUNSTARPAINT PRIMER435-95
22M-54-27230 20 mlGlass
container
Used as primer for paintedsurface on cab side(Using limit: 4 months afterdate of manufacture)
SUNSTARGLASS PRIMER435-41
22M-54-27240 150 ml Can
Used as primer for black ce-ramic-coated surface onglass side and for hard poly-carbonate-coated surface(Using limit: 4 months afterdate of manufacture)
SUNSTARSASH PRIMERGP-402
22M-54-27250 20 mlGlass
container
Used as primer for sash(Almite)(Using limit: 4 months afterdate of manufacture)
Adhesive
SUNSTARPENGUINESEAL 580SUPER "S" or
"W"
417-926-3910 320 mlPolyethylene
container
"S" is used for high-tempera-ture season (April - October)and "W" for low-temperatureseason (November - April) asadhesive for glass.
(Using limit: 4 months afterdate of manufacture)
Sika Japan,Sikaflex 256HV
20Y-54-39850 310 mlPolyethylene
container
Used as adhesive for glass.(Using limit: 6 months afterdate of manufacture)
SUNSTARPENGUINESUPER 560
22M-54-27210 320 mlEcocart(Special
container)
Used as adhesive for glass.(Using limit: 6 months afterdate of manufacture)
Caulking
material
SUNSTARPENGUINESEAL No. 2505
417-926-3920 320 mlPolyethylene
container
Used to seal joints of glassparts.(Using limit: 4 months afterdate of manufacture)
SEKISUISILICONESEALANT
20Y-54-55130 333 mlPolyethylene
container
Used to seal front window.(Using limit: 6 months after
date of manufacture)
GE TOSHIBASILICONESTOSSEAL 381
22M-54-27220 333 ml Cartridge
Used to seal joint of glasses.Translucent white seal. (Us-ing limit: 12 months after dateof manufacture)
400 g
16 kg
400 g16 kg
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A. ASSEMBLY OF CHASSIS
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Assembly procedure Assembly of track frame assemblyand center frame assembly (1/3)A-1
Precautions Tools required Equipment required
a When slinging the center frame, take carenot to crush the grease piping of thecircuit with wires.
Name Qty Name Qty
Power wrench (16)(21t-98-11120)
1 Hydraulic jack 50t 2
Socket 38 70 mm(21T-98-11120)
1 Truck crane 45 t 2
Handle(21T-98-11130)
1 Center frame stand 2
KW45F Impact wrench 1
Spline socket H70 1
Tap (M45 3) 1
Others
Track frame assembly (right)
Width across flats
4413 4903 Nm
(450 500 kgm)
Tightening torque
Center frame assembly
Track frame assembly (left)
Apply wooden blocks etc.
to parts which wire ropes
will touch.
No. Part No. Q'ty
A-1 21T-30-71160 76
A-2 21T-30-71170 76A-3 208-30-11850 1
A-4 208-30-11861 1
A-5 01024-81225 3
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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.
3) Remove the plugs from the coupling surface and clean
the coupling surface in advance.
4) Insert all the bolts, tighten them temporarily, and support
only the right side of the center frame on a jack.
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.
6) Insert all the bolts, tighten them temporarily, and lower
the crane.
7) Remove the jack.
Assembly procedure Assembly of track frame assemblyand center frame assembly (2/3)A-1
Tools required Equipment required
Name Qt Name Qt
Pin 50 40 mm(Hard steel)
2 Crane 45t 2
Wire 40 5 m(General purpose)
2
Others
Yoke Cushioncylinder
Blind plug
HosePlunger on grease side
Plunger on hydraulic cushion side
Precautions
[Before slinging with crane]
Check that projection (A) of the hydraulic cushion cylinder
plunger is approx. 10 mm.
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.).
Left RightCenter frame assembly
Rear view
Use only stands before coupling.
After coupling with left track frame,
left stand is not necessary any more.
20 Pipe
Grip
45 t45 t
Pin (See above figure)
Method of slinging track frame
If 2 cranes are used, holes can be aligned easily.
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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 wrenchMounting bolt size: M45 P3
Tightening torque: 450 500 kgm
Assembly procedure Assembly of track frame assemblyand center frame assembly (3/3)A-1
Precautions Tools required Equipment required
When installing the clamping bolts, remove thepiping at the rear of the center frame(so that you can use an impact wrench easily).(See Assembly procedure A-3.)
Name Qty Name Qty
20t Jack 2
Others
Input: 35 kgm
If input exceeds 35 kgm, power wrench may be broken.
20 t
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Assembly procedure
Idler cushion cylinder pipingA-2
Precautions Tools required Equipment required
1) When connecting the crawler frame, removethe bolts and bracket marked with .
2) When connecting, take care not to break thetube.
Name Qty Name Qty
KW10P Impact wrench 1
KW12P Impact wrench 1
17 mm Socket 1
19 mm Socket 1
Others
Bracket and clamp are
installed to piping when
transported.
3Tightening torque for U-clamp11 -- 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. Part No. Q'ty
A-6 07000-B3025 2
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Assembly procedure
Travel motor pipingA-3
Precautions Tools required Equipment required
1) Take care that dirt will not enter the piping.
2) The hoses are installed to the travel motor.
Name Qty Name Qty
KW10P Impact wrench 1
KW12P Impact wrench 1
KW14P Impact wrench 1
17 mm Socket 1
19 mm Socket 1
150 mm Extension 1
300 mm Extension 1
24 mm Spanner 1
32 mm Spanner 1
Others
Use following parts installed when transported.
07371-51470(8): FLANGE
01010-81455(16): BOLT
01643-31445(16): WASHER
Connect
Return piping which was removed
when track frame and center frame
were connected.
No. Part No. Q'ty
A-7 07000-B3048 4
A-8 02896-61018 2
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Assembly procedure
Installation of travel motor cover (1/2)A-4
Precautions Tools required Equipment required
Travel motor guard is installed to crawlerframe assembly when transported.Travel motor cover is installed temporarily tocrawler frame assembly when transported.
a Before performing this item, bleed air fromthe travel motor.
Name Qty Name Qty
KW12P Impact wrench 1
19 mm socket 1
Others
Crawler frame
Travel motor cover
Travel motor guard
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Assembly procedure
Installation of travel motor cover (2/2)A-4
Precautions Tools required Equipment required
. Name Qty Name Qty
KW12P Impact wrench 1
19 mm socket 1
Others
Right side
Left side
No. Part No. Q'ty
A-9 01024-81235 4
A-10 424-54-14230 4
A-11 01024-81230 12
A-12 21N-30-11340 16
A-13 01641-21223 12
A-14 21T-30-32172 1A-15 21T-30-32182 1
A-16 01010-82460 10
A-17 17A-54-44130 10
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Assembly procedure
Filling swing circle with greaseA-5
Precautions Tools required Equipment required
1) Supply grease (G2-LI) of 4 20 l(18 kg) pales = 80 l(72 kg).
2) Clean the swing circle mounting face.
3) Remove the rust preventive.(If any rust preventive is left, the bolttorque will be decreased.)
Name Qty Name Qty
Others
Grease bath seal (all round)
1) Fill the swing circle grease bath with grease (G2-LI).
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.
4) Apply gasket sealant LG-6to top of swing bearing.See Note 2.
See Note 1.
(Note 1) (Note 2)
Grease bath seal
Supply grease near
swing circle gear.
Apply LG-6 to swing circle gear
side of outer race mounting bolts.
G2-LI
(gasket sealant)
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1) Positioning of crane and revolving frame 2) Method of slinging front end
Rear of boom foot pin
3) Method of slinging rear end
Sling front and rear ends simultaneously with 2 truck cranes.
Assembly procedure Assembly of revolving frame assemblyand undercarriage (1/2)A-6
Precautions Tools required Equipment required.
aWhen slinging the revolving frame, adjust it to the horizontal in eachdirection with shackles.
aRemove the rust preventive from the mounting faces of the revolving frameand swing circle and from the inside face of the taps and then clean thosefaces. (If any rust preventive is left, the bolt torque will be decreased.)
Name Qt Name Qt
See above.
SC55 shackle = 18 t(Inside width: 83 mm)
SC40 shackle = 10 t
Others
Fix the ropes to the hook securely.
Take care of the center of
gravity of the crane hook.
If the hook is loaded,the boom lowers a little.
When installing revolving frame assembly to
undercarriage, remove transportation jigs.
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Assembly procedure Assembly of revolving frame assemblyand undercarriage (2/2)A-6
Precautions Tools required Equipment required
Name Qt Name Qt
For temporary tightening
KW45F Impact wrench 1
19 mm Socket 1
For retightening 1
KW45FG Impact wrench 1
55 mm Spline socket 1
Tap (M36 3) 1
Others
Fix the ropes to the hook securely.
Take care of the center of
gravity of the crane hook.If the hook is loaded,
the boom lowers a little.
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).
Dowel pin
Width across flats
3Tightening torque :250 -- 310 kgm
Apply LT-2.
Revolving frame assembly Apply LG-6 (TB1215) all round revolving
frame coupling surface without leaving anybreaks. (Apply to inside of bolt holes.)
3Tightening torque :2450 -- 3040 Nm {250 -- 300 kgm}
Apply LT-2.
Right
LeftFront
Rear
aSling horizontally to protect the pinion.
No. Part No. Q'ty
B-1 21T-25-67150 60
B-2 01643-33690 60
1) Clean the mounting surface.
2) Align the dowel pin with the dowel pin hole of the swing circle.
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.
5) Tighten the 3 bolts on each side, front 8 bolts and rear 3 bolts (17 in total) in figure
to the specified torque.
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Assembly procedure Installation of swing machinery (front) assembly (27t)Installation of swing motor (front) assembly (32t)A-7
Precautions Tools required Equipment required
a When connecting the revolving frame to theundercarriage, raise the swing motorassembly (front). (200 mm)After connecting the revolving frame to theundercarriage, reinstall the swing motorassembly. (When disassembled to 32 t)
Name Qty Name Qty
KW45F Impact wrench 1
46 mm Box 1
Joint 1
KW10P Impact wrench 1
14 mm Box 1
19 mm Set wrench 1
19 mm Spanner 132 mm Set wrench 1
32 mm Spanner 1
Others
Swing machinery (front) assembly
Swing motor (front) assembly
155 195 kgm
1140 kg
Connection at5 places
Coupling
Use split flanges and bolts
installed when transported.
07371-31049(6): FLANGE
07375-21035(12): BOLT
No. Part No. Q'ty
B-3 01010-83090 14
B-4 01643-33080 14
B-5 07000-B3032 1
B-6 07000-B3032 2B-7 02896-61015 1
B-8 02896-61008 1
B-9 01024-81225 1
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Assembly procedure
Connection of swivel joint piping (1/2)A-8
Precautions Tools required Equipment required
a Connect the travel piping before installingthe swing machinery.
Name Qty Name Qty
KW14PI Impact wrench 1
22 mm Socket 1
150 mm Extension 1
41 mm Spanner 1
Pliers 1
Set wrench 1
Others
Connection
Connection
Coupling
No. Part No. Q'ty
B-10 11Y-62-11980 1
B-11 02896-61009 4
To drain filter
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Assembly procedure
Connection of swivel joint piping (2/2)A-8
Precautions Tools required Equipment required
Name Qty Name Qty
KW14PI Impact wrench 1
22 mm Socket 1
150 mm Extension 1
41 mm Spanner 1
Pliers 1
Others
Connection
Use following parts installed when transported.
07371-51470(8): FLANGE01010-81455(16): BOLT
01643-31445(16): WASHER
If installed angle ofpipe is not proper
when connected,
loosen opposite side
and then install.
No. Part No. Q'ty
B-12 07000-B3048 4
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Assembly procedure
Connection of swing circle grease pipingA-9
Precautions Tools required Equipment required
Name Qty Name Qty
17 mm Spanner 1
19 mm Spanner 1
Others
Connection
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Assembly procedure
Installation of hydraulic tank assembly (1/5)A-10
Precautions Tools required Equipment required
a Before connecting the revolving frame tothe undercarriage, install the hydraulictank.
Name Qty Name Qty
Others
Hydraulic tank assembly
1670 kg
Use bolts and washers installed when
transported.
01024-81235(8): BOLT
3Tightening torque :1520 -- 1910 Nm {155 -- 195 kgm}
Connection
Suction tubes are installed temporarily
to chassis when transported.
3Tightening torque for U-clamp35.3 -- 87.2 Nm {3.6 -- 8.9 kgm}
3Tightening torque for coupling6.4 -- 7.4 Nm {0.65 -- 0.75 kgm}
No. Part No. Q'tyB-13 07000-B5230 2
B-14 01011-83010 12
B-15 21T-26-11460 12
For disassembly to 27 t
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Assembly procedure
Installation of hydraulic tank assembly (2/5)A-10
Precautions Tools required Equipment required
Name Qty Name Qty
Others
For disassembly to 27 t
Clamp air conditioner hoses
at 4 places marked with .
Clamp PPC hoses
at 2 places marked with .
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Assembly procedure
Installation of hydraulic tank assembly (3/5)A-10
Precautions Tools required Equipment required
Name Qty Name Qty
Others
Use split flanges and bolts installed when transported.
07371-32076(16): FLANGE
07375-21240(32): BOLT
Connection at5 places
Clamp hose.
No. Part No. Q'ty
B-16 07000-B2060 8
For disassembly to 27 t
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Assembly procedure
Installation of hydraulic tank assembly (4/5)A-10
Precautions Tools required Equipment required
Name Qty Name Qty
Others
Use split flanges and bolts installed when transported.
07371-31049(2): FLANGE
07375-21035(4): BOLT
Connection at4 places
No. Part No. Q'ty
B-17 11Y-62-11980 3
B-18 07000-B3032 1
For disassembly to 27 t
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Assembly procedure
Installation of hydraulic tank assembly (5/5)A-10
Precautions Tools required Equipment required
Precautions to be observed when connectingDT, DTP or DTHD connectorAfter connecting the connector, check visually
that the connector is locked securely.If the connector is not locked securely,reconnect it.
Name Qty Name Qty
Others
When locked When unlocked
For disassembly to 27 t
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.
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Assembly procedure
Installation of fuel tank assemblyA-11
Precautions Tools required Equipment required
Name Qty Name Qty
KW45F Impact wrench 1 45t Crane 1
46 mm Socket 1
12 5 m Wire 2
Eyebolt M30-P3 2
Others
50 t Crane Fuel tank assembly2,400 kg (including 400 L of fuel)
Bolt Collar
No. Part No. Q'ty
C-1 01011-83010 20
C-2 21T-26-11460 20
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Fuel piping1. 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 withand fix them with the clamps.
2. Connection of drain and supply lines
1) Remove the transportation clamps of the drain line marked withA.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 withw.
Assembly procedure Connection of fuel tank assemblypiping and wiring (1/2)A-12
Precautions Tools required Equipment required
Name Qty Name Qty
27 mm Spanner 1
32 mm Spanner 1
36 mm Spanner 1
19 mm Socket 1
KW14PI Impact wrench 1
Others
Return line
Band marker: Red
Spill line
Band marker: None
O-ring
BoltClamp
O-ring
Delivery line
O-ring
Drain line
Reused clamp
No. Part No. Q'ty
C-3 04435-52212 1
C-4 02896-61012 1C-5 02896-61015 2
C-6 02896-61018 2
C-7 01024-81220 1
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Electric wiring
Assembly procedure Connection of fuel tank assemblypiping and wiring (2/2)A-12
Precautions Tools required Equipment required
Precautions to be observed when connectingDT, DTP or DTHD connectorAfter connecting the connector, check visually
that the connector is locked securely.If the connector is not locked securely,reconnect it.
Name Qty Name Qty
Others
When locked When unlocked
Clamp
Clamp
Bolt
Bolt
1. Clamp the wiring harness to the grease can bracket.
4 places marked with
2. Connect the wiring harness connector marked with .
No. Part No. Q'tyC-8 04434-52312 1
C-9 04434-51912 3
C-10 01024-81220 4
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Assembly procedure
Installation of cab base assembly (1/2)A-13
Precautions Tools required Equipment required
a Install the catwalks while the cab base ison the ground.
Name Qty Name Qty
KW20PI Impact wrench 1 45t Crane 1
30 mm Socket 1
12 5 m Wire 3
SC14 Shackle 3
Others
Cab base assembly
Cab front catwark
100 kg
Cab left catwark
220 kg
2300 kgMounting bolt ofcab base assembly
Mounting bolt ofcab base assembly
No. Part No. Q'ty
C-11 01034-81245 10
C-12 01034-81265 10C-13 21T-54-31140 1
C-14 21T-54-31150 1
C-15 01034-81245 2
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Assembly procedure
Installation of cab base assembly (2/2)A-13
Precautions Tools required Equipment required
Name Qty Name Qty
Others
C-18
C-18 C-17
C-16 C-18 C-16
No. Part No. Q'ty
C-16 01011-82025 20
C-17 01011-82045 7
C-18 567-40-41380 27
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Assembly procedure
Installation of left floor assembly (1/4)A-14
Precautions Tools required Equipment required
After the work, return the bolts removed toinstall the eyebolts.
Name Qty Name Qty
Others
Install eyebolt. Install eyebolt.
Install eyebolt. Sling jig
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Assembly procedure
Installation of left floor assembly (2/4)A-14
Precautions Tools required Equipment required
Before tightening the mounting bolts at parts(a) and (b), check that both mating faces arefitted to each other.
Name Qty Name Qty
Others
Part a
Part b
C-20 C-19
C-20 C-19C-20 C-19
No. Part No. Q'ty
C-19 01010-82065 24
C-20 01643-32060 24
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Assembly procedure
Installation of left floor assembly (3/4)A-14
Precautions Tools required Equipment required
Clearance a: 15 mm 10 mm(Reduce difference between widest andnarrowest clearances to 3 mm or less)
Clearance b: 17 mm 5 mm(Reduce difference between widest andnarrowest clearances to 3 mm or less)
Name Qty Name Qty
Others
C-23 C-24
Clearance b
Adjust clearance at this part,
if necessary, by inserting shim
under condenser box.Condenser box
Clearance a
Shim Shim
C-21 C-22
No. Part No. Q'ty
t1.2 C-21 21T-53-31530 3
t1.6 C-22 21T-53-31540 3
C-23 21T-54-33471 1
C-24 01034-81230 3
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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.
Assembly procedure
Installation of left floor assembly (4/4)A-14
Lock bar bracket (c)
Lock bar (b)
Rubber stopper (a)
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Assembly procedure
Connection of cab base assembly piping (1/2)A-15
Precautions Tools required Equipment required
a Remove the hose cap. Name Qty Name Qty
Others
Connection (Face seal)
Connection (Quick coupler)
Green
Brown
White
Black
Yellow
Blue
Red
No color mark
Black/Black
Blue/Black
Red/Black
Green/Black
25
No. Part No. Q'ty
C-25 02896-61012 6
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Assembly procedure
Connection of cab base assembly piping (2/2)A-15
Precautions Tools required Equipment required
Name Qty Name Qty
Others
Connection
Right wall in cab base
No. Part No. Q'ty
C-26 02896-61018 2
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Assembly procedure
Connection of cab base assembly wiring (1/5)A-16
Precautions Tools required Equipment required
When connecting the DRC multi-poleconnector, see "Precautions for connectingDRC multi-pole connector" on pages 3/5 5/5of this section.
When connecting the DT, DTP or DTHDconnector, see "Precautions for connectingDT, DTP or DTHD connector" on pages 5/5of this section.
Name Qty Name Qty
Others
Pass wiring harness through hole.
Pass wiring harness
through hole.
Remove dust proof cap
Connection
Male Female
CN-A05 21T-06-33810 21T-06-33820CN-A04 21T-06-338A0 21T-06-33830
CN-A2221T-06-33120
08191-00770(4)21T-06-33850
08191-00770(4)
Cap part No.
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Assembly procedure
Connection of cab base assembly wiring (2/5)A-16
Precautions Tools required Equipment required
When connecting the DT, DTP or DTHDconnector, see "Precautions for connectingDT, DTP or DTHD connector" on pages 5/5of this section.
Remove the cover of part X when connectingthe wiring harness and install it again afterthe work.
Name Qty Name Qty
Others
Connection
Connection
Connection
Fix with clamps.
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"Precautions for connecting DRC multi-pole connector"Precautions to be observed when connecting DRC multi-pole connector
1. Before connecting
2. Preparation for connection
If the DRC multi-pole connector is at a high place, prepare a work stand so that you can stand stably and connect the con-
nector while checking it visually.
Assembly procedure
Connection of cab base assembly wiring (3/5)A-16
Precautions Tools required Equipment required
Name Qty Name Qty
Others
If the seal rubber is broken or deformed,
the connector may not be connected normally.
In this case, replace the connector with new one.
17A-06-41830
17A-06-41840
Check the edge for breakage or
deformation. If it has any
abnormality, replace the whole
connector with new one.
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3. Connecting method
1) Check that the key ways are aligned and then set the terminals to each other while setting the seal rubber edge to the
receptacle connector edge.
While swinging the connectors up and down and to the right and left so that the terminals will be in position and clear-
ance "a" and "b", and "c" and "d" between the connectors will be the same respectively, tighten the center hexagonsocket head bolt 1 turn.
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.
Assembly procedure
Connection of cab base assembly wiring (4/5)A-16
Precautions Tools required Equipment required
Name Qty Name Qty
Others
Receptacle connector edge
Seal rubber edge
Terminal
Up
Down
Left Right
Hexagon socket head bolt
Side view Bottom view
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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.
4) Check after connection
Turn the key switch ON and check that the electric parts of the chassis are operating normally. (Observe the condi-
tion for several minutes after turning the key switch ON.)
Start the engine, move the work equipment, and check that the electric parts (monitors and lights) do not blink
because of vibrations.
If any abnormality is detected by the above 2 checks, disconnect the connector and check it for a problem, and then repeat
steps 1 - 3.
"Precautions for connecting DT, DTP or DTHD connector"
Precautions to be observed when connecting DT, DTP or DTHD connector
After connecting the connector, check visually that the connector is locked securely.
If the connector is not locked securely, reconnect it.
Assembly procedure
Connection of cab base assembly wiring (5/5)A-16
Precautions Tools required Equipment required
Name Qty Name Qty
Others
Approx. 1 mm
2.83 0.28 Nm {0.28 0.03 kgm}
When locked When unlocked
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Assembly procedure
Connection of left floor assembly heater pipingA-17
Precautions Tools required Equipment required
Name Qty Name Qty
Others
Distinction tape color: Blue
Connection
Distinction tape color: Red
27
No. Part No. Q'ty
C-27 21T-979-3320 2
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Assembly procedure
Connection of left floor assembly wiringA-18
Precautions Tools required Equipment required
Precautions to be observed when connectingDT, DTP or DTHD connectorAfter connecting the connector, check visually
that the connector is locked securely.If the connector is not locked securely,reconnect it.
Name Qty Name Qty
Others
When locked When unlocked
Front of machine
Left of machine
ConnectionConnection
To cab
This cable isdescribed in A-27.To air
conditionercondenser
Right side of battery case
Top of air condit ioner condenser
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Assembly procedure
Installation of tail pipeA-19
Precautions Tools required Equipment required
a Before performing this work, connect thecontainer to the revolving frame.
Name Qty Name Qty
Others
Top of power container
Front of machine Left of machine
No. Part No. Q'ty
D-1 21M-01-18130 2D-2 01024-81230 12
D-3 6162-14-5640 2
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Assembly procedure
Installation of power container assembly (1/2)A-20
Precautions Tools required Equipment required
a Before connecting the container, removethe undercover installed temporarily.(See A-24.)
Name Qty Name Qty
Others
Power container assembly
Right rear stopper
Left rear stopper
16100 kg
Position container so that container frame will
touch positioning stopper of container mount
of revolving frame.
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Assembly procedure
Installation of power container assembly (2/2)A-20
Precautions Tools required Equipment required
Retighten the bolts finally after installing thecounterweight for safety.
Name Qty Name Qty
Others
M42 3, L = 350 mm, Width across flats 65 mm
3Tightening torque :3430 -- 4212 Nm (350 -- 430 kgm)
Apply LT-2.
Nut is welded to
revolving frame.
Plate with nuts
4
No. Part No. Q'ty
D-4 21T-54-31121 4
D-5 21T-54-31130 20
D-6 01643-34212 20
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Assembly procedure
Connection of suction piping (1/2)A-21
Precautions Tools required Equipment required
Since the suction tube is lowered whendelivered, prepare MIKALOR bands.(See tightening procedure 2/2.)
Name Qty Name Qty
Others
Use following parts installed
when transported.
01024-81230(4): BOLT Use following parts installed when transported.
01010-81640(8): BOLT
01643-31645(8): WASHER
Main pump seen from below
Connection
Replace band(upper).
Replace band
(upper).
No. Part No. Q'ty
D-7 07000-B2140 2D-8 07000-B2100 1
D-9 209-62-41341 4
D-10 20Y-62-51671 2
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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.
Assembly procedure
Connection of suction piping (2/2)A-21
BridgeApply lubricating oil
(PANDO 18B made by Three Bond)
on thread of bolt
before tightening a bolt.
Punch hole
The overlap of bridge and band.
No.
1 209-62-41341 15 0-3
2 20Y-62-51671 20 0-3
Clamp part No. Dimension (a)
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Assembly procedure
Connection of oil cooler piping and pump drain pipingA-22
Precautions Tools required Equipment required
Take care that the O-ring will not be caught. Name Qty Name Qty
Others
Use following parts installed when transported.
07371-32076(14): FLANGE
07375-21240(28): BOLT
Connection
Connection
Connection at3 places
Temporarily
installed to hose
No. Part No. Q'ty
D-11 07000-B2060 7
D-12 07298-02011 1
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Assembly procedure
Connection of fan motor drain pipingA-23
Precautions Tools required Equipment required
Name Qty Name Qty
Others
Use following parts installed when transported.
07371-31049(2): FLANGE
07375-21035(4): BOLT
Connection
D-13
No. Part No. Q'ty
D-13 07000-B3032 1
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Assembly procedure
Installation of suction unit undercoverA-24
Precautions Tools required Equipment required
Name Qty Name Qty
Others
Undercover is installed to
container when transported.
When connecting suction unit,
remove undercover, if necessary.
After connecting suction unit,
install undercover again.
Z
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Remove the covers shown below.
Assembly procedure
Connection of delivery piping (1/2)A-25
Precautions Tools required Equipment required
Name Qty Name Qty
Others
Parts to be removed
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Assembly procedure
Connection of delivery piping (2/2)A-25
Precautions Tools required Equipment required
a Secure the scaffoldings. Name Qty Name Qty
Others
Left of machine
Front of machine
Use following parts installed when transported.
07371-51470(8): FLANGE
01010-81455(16): BOLT
01643-31445(16): WASHER
Front end of power container
Connection
No. Part No. Q'ty
D-14 07000-B3048 4
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Assembly procedure
Connection of pilot piping and fan motor pipingA-26
Precautions Tools required Equipment required
Name Qty Name Qty
Others
Left of machine
Front of machine
Use following parts installed when transported.
07371-31049(2): FLANGE
07375-21035(4): BOLT
Use following parts installed when transported.
07371-30640(4): FLANGE
07375-21035(8): BOLT
Front end of power container
Connection
D-16 D-15
No. Part No. Q'ty
D-15 07000-B3025 2
D-16 07000-B3032 1
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Assembly procedure Connection of power container assemblyfuel piping (1/2)A-27
Precautions Tools required Equipment required
3 Tightening torque for hoseA 177 245 Nm {18 25 kgm}B 128 186 Nm {13 19 kgm}
Name Qty Name Qty
Others
Connection at3 places
No. Part No. Q'tyD-17 02896-61018 2
D-18 02896-61015 1
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Assembly procedure Connection of power container assemblyfuel piping (2/2)A-27
Precautions Tools required Equipment required
Name Qty Name Qty
Others
Connection
D-19
No. Part No. Q'ty
D-19 02896-61015 1
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Assembly procedure Connection of power container assemblyair conditioner pipingA-28
Precautions Tools required Equipment required
Name Qty Name Qty
Others
Parts to be removed
M24 (Width across flats: 27)
Container side is female.
M24 (Width across flats: 27)
Container side is male.
M22 (Width across flats: 24)
Container side is female.
M22 (Width across flats: 24)
Container side is male.
Connection
Tightening torque 29.4 34.3 Nm Tightening torque 29.4 34.3 Nm
Tightening torque 19.6 24.5 Nm Tightening torque 19.6 24.5 Nm
Coat air conditioner lubrication oil
Male Female
M22 21F-979-3250 21F-979-3220
M24 21F-979-3260 21F-979-3230
Remove hose dust caps and connect hoses.
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Assembly procedure Connection of power container assemblyheater pipingA-29
Precautions Tools required Equipment required
a Before connecting these hoses, connectall of the other heater hoses.
Name Qty Name Qty
Others
Parts to be removed
Connection (Quick coupler)
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Assembly procedure Connection of power container assemblywiring (1/2)A-30
Precautions Tools required Equipment required
Name Qty Name Qty
Others
Connect the battery cable after all the
wiring harnesses are connected.
Front of machine
Left of machine
To ground seat ofrevolving frame vertical plate
Connection
Fix 2 terminals together.
Connection
May be connected to either one.
Connection
Fix 2 terminals together.
Connection
Remove cover and connect terminals in it.After connecting, install cover again.
CNT02CNT01
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Assembly procedure Connection of power container assemblywiring (2/2)A-30
Precautions Tools required Equipment required
Precautions to be observed when connectingDT, DTP or DTHD connectorAfter connecting the connector, check visually
that the connector is locked securely.If the connector is not locked securely,reconnect it.
Name Qty Name Qty
Others
When locked When unlocked
Left of machine
Front of machine
Pass wiring harness
through hole.
Pass wiring harness
through hole.
Connection
No. Part No. Q'ty
D-19 08028-55065 2
D-20 01024-81020 2
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Assembly procedure
Installation of operator's cab assembly (1/3)A-31
Precautions Tools required Equipment required
Name Qty Name Qty
Others
Operator's cab assembly
When installing cab,remove mount coverand stopper bracket(see next page).
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Assembly procedure
Installation of operator's cab assembly (2/3)A-31
Precautions Tools required Equipment required
Name Qty Name Qty
Others
Left of machine
Front of machine
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)
Stopper bracket is installed
to cab base temporarily.
No. Part No. Q'tyE-1 21T-54-36661 16
E-2 21T-54-36671 8
E-3 21T-54-35321 8
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STANDARD QUANTITIES OF SHIM
Assembly procedure
Installation of operator's cab assembly (3/3)A-31
PORTION PART NUMBERSTD
QUANTITIE
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