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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





With motor and motor guard

[Remarks]

Full roller guard is optional.

Center of gravity

Top view

When

disassembledto 32 ton

When

disassembledto 27 ton



Z Overall height (mm) 2,920 2,640

W Weight (kg) 31,500 26,500

With 6 hoses to boom

With 4 oil cooler hoses

With grease tank

When disassembled to 27 ton, hydraulic tankassembly and machine (front) assembly are

packed separately.

(Special sling)

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7

(4) Fuel tank assembly

(5) Cab base assembly

(6) Left floor assembly

Top view

Center of gravity


Y Overall width (mm) ,875


W Weight (kg) 2,400

With working lamp

With fuel level sensor

Center of gravity

Top view




W Weight (kg) 2,500

With front and left catwalk

With head lamp and working lamp

Center of gravity

Top view




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





With super hood

With handrail on radiator side

Center of gravity

Top view




W Weight (kg) 1,800

With antenna retracted

With mirrors folded

[Remarks]

Front guard is optional.

Center of gravity

Top view





[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




W Weight (kg) ,550

Center of gravity

Top view

For each catwalk

X Overall length (mm) 2,310Y Overall width (mm) ,545


W Weight (kg) ,260

Center of gravity

Top view



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




W Weight (kg) ,240

Top view

Center of gravity




W Weight (kg) ,390

With grease reel

Center of gravity

Top view

X Overall length (mm) ,715



W Weight (kg) , 90

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11

(16) Cab rear floor assembly

(17) Boom assembly

(18) Arm assembly

Center of gravity

Top view




W Weight (kg) , 70

Center of gravity

Left side view





Left side view

Center of gravity





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





Specifications of standard bucket

for crushed stones

Left side view

Center of gravity




W Weight (kg) , 60

Top view

Center of gravity




W Weight (kg) 1,750

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13

(22) Swing machinery (front) assembly

(23) Cab L.H. catwalk

(24) Cab front catwalk

Top view

Center of gravity

X Overall length (mm) ,775



W Weight (kg) 1,050

Top view

Center of gravity




W Weight (kg) ,220

Top view

Center of gravity




W Weight (kg) ,100

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14

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



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



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



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



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



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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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



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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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



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



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



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



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.


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.


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.


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



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


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


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


1) Take care that dirt will not enter the piping.

2) The hoses are installed to the travel motor.

Name Qty Name Qty




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


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


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


19 mm socket 1

Others

Crawler frame

Travel motor cover

Travel motor guard

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42

Assembly procedure

Installation of travel motor cover (2/2)A-4


. Name Qty Name Qty


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


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


Name Qt Name Qt

For temporary tightening


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


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


46 mm Box 1

Joint 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


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


Name Qty Name Qty


22 mm Socket 1

150 mm Extension 1

41 mm Spanner 1

Pliers 1

Others

Connection


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


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


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



Name Qty Name Qty

Others


Clamp air conditioner hoses

at 4 places marked with .

Clamp PPC hoses

at 2 places marked with .

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Assembly procedure



Name Qty Name Qty

Others

Use split flanges and bolts installed when transported.

07371-32076(16): FLANGE

07375-21240(32): BOLT


Clamp hose.

No. Part No. Q'ty

B-16 07000-B2060 8


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Assembly procedure



Name Qty Name Qty

Others

Use split flanges and bolts installed when transported.

07371-31049(2): FLANGE

07375-21035(4): BOLT


No. Part No. Q'ty

B-17 11Y-62-11980 3

B-18 07000-B3032 1


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Assembly procedure



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 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


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


Name Qty Name Qty

27 mm Spanner 1

32 mm Spanner 1

36 mm Spanner 1

19 mm Socket 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




Name Qty Name Qty

Others


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


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


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


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



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



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


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


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


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


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



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



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



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



Name Qty Name Qty

Others

Approx. 1 mm

2.83 0.28 Nm {0.28 0.03 kgm}


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Assembly procedure

Connection of left floor assembly heater pipingA-17


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




Name Qty Name Qty

Others


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


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


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


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


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


Take care that the O-ring will not be caught. Name Qty Name Qty

Others


07371-32076(14): FLANGE

07375-21240(28): BOLT

Connection

Connection


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


Name Qty Name Qty

Others


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


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


Name Qty Name Qty

Others

Parts to be removed

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Assembly procedure

Connection of delivery piping (2/2)A-25


a Secure the scaffoldings. Name Qty Name Qty

Others

Left of machine

Front of machine


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


Name Qty Name Qty

Others

Left of machine

Front of machine


07371-31049(2): FLANGE

07375-21035(4): BOLT


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


3 Tightening torque for hoseA 177 245 Nm {18 25 kgm}B 128 186 Nm {13 19 kgm}

Name Qty Name Qty

Others


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


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


Name Qty Name Qty

Others

Parts to be removed

M24 (Width across flats: 27)

Container side is female.


Container side is male.


Container side is female.


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


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


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




Name Qty Name Qty

Others


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


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



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


PORTION PART NUMBERSTD

QUANTITIE

armado gen00060-03

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