Manual: Field Assembly

Field
Assembly SEAW002201
Manual
HYDRAULIC EXCAVATOR
SERIAL NUMBERS
8004i 4 0001
PC1 and up
This material is proprietary to Komatsu America International Company and is not to be reproduced, used, or
disclosed except in accordance with written authorization from Komatsu America International Company.
It is our policy to improve our products whenever it is possible and practical to do so. We resewe the right to make
changes or add improvements at any time without incurring any obligation to install such changes on products sold
previously.
Due to this continuous program of research and development, periodic revisions may be made to this publication.
It is recommended that customers contact their distributor for information on the latest revision.
Copyright 2000 Komatsu

OCTOBER 2000
DataKom Publishing Corporation
CONTENTS
Page
GENERAL . .. ... . ...I............................................................................................................................ 5
Specifications ............................................................................................................................ 5
Points regarding local assembly .............................................................................................. 6
Bolt tightening torque and bolt tightening tools .................................................................... 7
Separate units .......................................................................................................................... 10
Transportation style of loading shovel (Work equipment only) ......................................... 23
Lists of parts sent individually ............................................................................................... 24
Assembly procedure, assembly equipment and schedule .................................................. 49
Kit layout diagram ................................................................................................................... 50
Tools and equipment to be used . .. . . .... . .... .. .. .. .. .. ... .. .. .. . .. .. .. . . ... .. .. .. .. ... ... . .. .. .. . .. . .. .. .. .. .. ... .. .. .. .. 51
A . ASSEMBLY OF CHASSIS . .. . .. .. .. .. .. .. .. .. .. .. ... .. .. .. ... .. ... . . ... .. . ... . .. . ... .. .. . .. .. . ... .. .. .. . . ... . . .. . . .. .. .. .. . ... ... 57
A-l Assembly of truck frame and axle ............................................................................ 58
A-2’ Travel motor piping ................................................................................................... 61
A-3’ Idler cushion cylinder piping .................................................................................... 63
A-4’ Installation of travel motor guard and track frame under cover ............................ 64
A-5. Filling swing circuit with grease ............................................................................... 66
A-6. Assembly of revolving frame assebly and assembly ............................................. 67
A-7. Swivel travel piping ................................................................................................... 69
A-8’ Swing circle grease tube piping ............................................................................... 71
A-9. Installing of left and right ladders ............................................................................ 76
A-lb Installation of left catwalk ......................................................................................... 77
A-II’ Installation of right catwalk ....................................................................................... 78
A-12. Installation of catwalk, handrail beside operator’s cab . .. . . ... .. .. .. .. . . .. .. .. ... . .. .. . .. .. .. ... 79
A-13’
A-l 4’ Installation of handrail for getting in and out of operator’s cab .. .. .. .. ... .. . ...I.......... 80
A-l 5.
A-16. Installation of handrail at rear of operator’s cab . . . .. .. .. .. .. . .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. .. . .. . 82
A-17.
A-18’ Operator’s cab front frame, handrail . .. ... .. .. .. .. .. .. . . . .. ... ... .. .. .. .. .. ... . .. . .. . .. .. . .. . . .. . ... . .. .. . . 83
A-19’ Left dheck handrail .. .. .. .. .. .. .. . .. ... .. .. .. .. .. . ... ... . . .. .. . .. ... .. . .. .. .. .. .. .. .. .. .. .. .. . .. . .. . .. .. . . .. . . ... .. .. .. 84
A-20’ Right deck handrail .................................................................................................... 85
A-21’ Installation of ladder on top of hydraulic tank ........................................................ 86
A-22. Insta lation of counterweight .................................................................................... 87
A-23. lnsta lation of counterweight ladder (left and right) ............................................... 88
A-24. lnsta lation of handrail on top of fuel tank, counterweight .................................... 89
A-25. lnsta lation of fuel tank vibration stopper bracket .................................................. 90
A-26’ Insta lation of grease reel, hose, bracket ................................................................. 91
A-27. Insta lation of left cab base assembly . . .. . .. . .. ... .. .. . . .. .. .. .. ... . . .. .. ...*.............................. 92
A-28. Installation of operator’s cab assembly ................................................................... 97
A-29. Installation of wiper motor cover inside opereator’s cab ....................................... 98
A-30. Handrail on boom foot and left pump ..................................................................... 99
A-31. Handrail above the RH door and above the hydraulic oil tank ............................ 100
A-32. . Emergency stop switch, Fuel cutting ..................................................................... 101
A-33A. Handrail above the radiator (Optional) .................................................................. 103
A-33B. Connection of hydraulic piping operator’s cab assembly .................................... 104
A-34. Connection of window washer hose of operator’s cab assembly.. ..................... 107
1
A-35. Connection of air piping of left cab assembly ....................................................... 108
A-36. Connection of grease piping operator’s cab assembly ........................................ 110
A-37. Wire harness (Washer tank, working lamp and operator’s cab base light). ....... 112
A-38. Air conditioner hose, harness and piping .............................................................. 113
A-39. Installation of counterweight lamp (operation) ..................................................... 118
A-40. Start engine .............................................................................................................. 119
A-41. Final tightening of swing circle mounting bolts .................................................... 125
ASSEMBLY OF POWER-ASSISTED LADDER .I.......................................................................... 127

L-l . Power-assisted ladder .. .. .. .. . . ... .. .. . . .. . .. .. .... . .. . .. ... .. ... . .. . .. . .... . .. .. .. . ... . . .. .. .. .... .. ... . . ... .. .. . 130
C. PC1800 INSTALLATION OF BACKHOE WORK EQUIPMENT ..I.......................................... 135

C-l . Installation of boom cylinder to chassis ................................................................ 136
c-2 . installation of boom cylinder piping ...................................................................... 138
c-3 Bleeding air from boom cylinder ............................................................................ 139
c-4. Boom sub-assembly ................................................................................................ 140
c-5’ Installation of boom assembly ............................................................................... 144
C-6.. Installation of boom cylinder top pin ..................................................................... 147
c-7 Connection of arm assembly to boom ................................................................... 149
C-8.. Installation of hoses between boom and chassis ................................................. 152
c-9 Installation of arm cylinder top pin ........................................................................ 154
C-lb Bleeding air from arm cylinder ............................................................................... 156
C-l 1’ Installation of hydraulic between boom and arm ................................................. 157
c-12. Connection of grease piping for boom .................................................................. 158
c-13’ Connection of wiring between boom and chassis ................................................ 161
C-l 4’ Installation of hoses between boom and shassis ................................................. 162
C-l 5.
C-16. Connection of bucket assembly to arm ................................................................. 164
c-17. Installation of bucket link ........................................................................................ 167
C-18.. Bleeding air from bucket cylinder .......................................................................... 169
ASSEMBLY MANUAL FOR LOADING SHOVEL WORK EQUIPMENT ..................................... 171

LS-1. Installation of arm cylinder tubes and hoses ........................................................ 172
LS-2. Installation of bucket hoses .................................................................................... 173
LS-3. Installation of bottom dump hoses and tubes ...................................................... 174
LS-4. Installation of pilot solenoid valve ......................................................................... 175
LS-5. Installation of bottom priority valve . . .. .... .. .. .. .. .... .. . . .. . ... .. . . .. . ...*.............................. 176
LS-6. Installation of arm pilot drain circuit .. . ... .. .. ..I......................................................... 178
LS-7. Installation of control parts .. ... .. .. .. .. .. .. ... .. . . .. .. ... .. ... . .. .. .. ... . . .. . .. . ... ... . . .. .. ... .. . .. .. . . .... . .. 180
LS-8. Installation of horn switch .. ...I................................................................................. 182
LS-9. Change of arm pilot piping . . .. .. ... . . . .. .. .. .. .. .. .. ... .... .. .. . . .. .. .. .. . . .. . . ... .. .. .. .. . .. .... . .. .. .. .. .. ... 183
LS-10. Removal of boom foot handrail .. .. . . .. .. .. ..... . .. . ... ... ... . .. . .. .. .. . . .. . . .. .. .. .. .. .. .. . .. .. .. ... . .. .. . .. . 184
LS-11. Installation of arm cylinder bottom parts .............................................................. 185
LS-12. Installation of boom cylinder to machine body .................................................... 186
LS-13. Installation of boom cylinder piping ...................................................................... 188
LS-14. Installation of boom assembly ............................................................................... 190
LS-15. Installation of boom cylinder head pins ................................................................ 191
LS-16. Installation of grease feed hose between machine body and boom .................. 192
LS-17. Installation of bucket cylinder assembly ................................................................ 193
LS-18. Installation of arm assembly ................................................................................... 194
2
E-19. nsta Iation of arm cylinder assembly .................................................................... 195
LS-20. nsta Iation of hoses between boom and arm ....................................................... 196
LS-21. nsta lation of bucket cylinder hoses ...................................................................... 197
LS-22. nsta Iation of grease feed hose of bucket cylinder .. .. . . .. .. .. ... . ..I........................... 198
LS-23. nsta Iation of bucket assembly . . .. .. .. .. .. .. .. . .. . ... .. . .. . .. ... . .. . .. .. ... .. .. .. .. .. ... .. .. .. . . ... . .. . .. . .. 200
LS-24. nsta Iation of bottom dump hose and grease feed hose
between arm and bucket .. .. .. .. .. .. .. .. . .. . .. . .. .. .. ... .. . ... . ... .. . .. . .. . .... ... .. .. .. ... . .. .. .. . .. .. . ... .. .. 201
M. INSPECTION AND SERVICING PROCEDURES AFTER FINNISHING

ALL THE ASSEMBLY AND INSTALLATION WORKS . .. . .. .. .. . . ... . . .. .. ... ... .. ... . ... .. . .. . ... .. . . .. .. . . 203
M-l. Inspecting the oil level and water level in respective sections and
refilling them .. .. . .. .. .. . .. .. .. ...~.................................................................................... 204
Selection of the appropriate fuel type and lubricating oil type fitting to
the atmospheric temperature range . . .. . .. . .. .. .. . . .. .. ... . .. ... . . .. ... .. ... ... . .. .. .. .. .. .. . .. .. .. .. .. 204
M-2. Flushing of hydraulic circuit .. .. .. . . . ... . .. .. . . .. ...*........................................................... 206
M-3. Releasing residual pressure from hydraulic circuit . . .. .. .. .. ...*.............*.................. 207
3
GENERAL
1. SPECIFICATIONS
PC1800-6
Item Unit PC 1800-6
Operating weight
kg (lb) 180000 (396828)
(including 1 operator, 80 kg)
Bucket capacity BACKHOE m3 (cu.yd) 12 (15.5)

(standard bucket) LOADING SHOVEL m3 (cu.yd) 11 (14.2)
Name of engine Komatsu SAAGDl40 diesel engine x 2
Engine hosepower 338 (454)/l 800
Min.ground distance 1 mm(ftin) 1 2080 (6’10”)
Travel speed 1 km/h (MPH) ( 2.7 (1.7)
Swing speed I rpm I 4.5
17185 6015 _
e
6140
I_ R=6235
-
t- 5055 -1
If?
0
T;t
I-
m
w W
0
m
I-
. 5630 m
LOADING SHOVEL
. 13230 I 6015 ~~ _
.- ~ 6140tR=6235) ) 5055
t
0
al
IL
m
c‘
5
3. BOLT TIGHTENING TORQUE AND BOLT TIGHTENING TOOLS
Remove the various blind plugs and ligs used during transportation. Remove the blind jigs (flange, head, cap,
O-ring) used for the work equipment piping and undercarriage piping, the blind plugs used for the lubrication
piping, the jigs used to hold the cylinders, and the blind plugs used in the tap holes where parts have been removed
for transportation. Be careful not to damage these parts, and keep them in a safe place so that they can be used
for future transportation.
For bolts where the tightening torque is not separately specified in the maintenance standards, use the tightening
torques given in the table below.
1. Tightening torques for bolts

1) Use the figures in Table 1 when using an impact wrench orspanner.
The tightening torque for bolts is basically that given in Table 1, so for bolts which use this torque, no separ-
ate instruction is given.
Table 1 Unit: kgm
6 . I 0.9 - 1.5 I 1.2
8 1.5 - 3.5 2.5

I I
10
I 3.5 - 7.5
I 5.5
12 I 5.5 - 12.5 I 9.0
14 8.5 - 20.0 14.0

I I
16 I 15.0 - 31.5 I 23.5
18 20.5 - 43.5 32.0

I I
20 32.5 - 62.0 47.0
I I
22
I 18.0 - 84.5
I 66.5 -
24 I 60.0 - 105 I 82.5
27 90.0 - 150 120
30 115 - 195 155
33 150 - 250 200
36 190 - 310 250
39 230 - 370 300
7
2) When using a torque wrench, use the figures in Table 2.
These torques are used when a particularly small range of tightening torque is needed.
Table 2 Unit: kgm
Material S43C, SCM 3H, equivalent, or higher
Reference
Range Target
Nominal of
Tension load (kg)
6 1.2 - 1.5 1.35 1150
8 2.8 - 3.5 3.2 2175
10 6 - 7.5 6.7 3355
12 10 - 12.5 11.5 4865
14 16 - 20.0 18 6715
16 25 - 31.5 28.5 9350
18 35 - 43.5 39 11200
20 50 - 62.0 56 ’ 14800
22 67.5 - 84.5 76 18000
24 84 - 105 94.5 20600
27 120 - 150 135 26000
30 155 - 195 175 30100
33 200 - 250’ 225 35800
36 250 - 310 280 40700
39 295 - 370 335 45200
2. Tightening torque for pipe threads

Applicable range:
The tightening torques for pipe threads of nominal size PTl/8 - PTI , PSl/8 - PSl are according to this
standard.
However, this table does not apply if torque is separately specified.
Tightening torque:
1) If the material of the male screw is SS41 .FC.SGP, the tightening torque is as in Table 1.
Table 1 Unit: kgm
Steel Cast iron Light alloy

Nominal
l/4 0.6 - 1.2 0.5 - 1 .O~~~ 0.2 - 0.8

Y I__
318 1.7 - 2.7
I 1.4 - 2.2
I 1.0 - 1.7
l/2 I 3.3 - 5.4 I 2.7 - 4.4 I 2.0 - 3.3
3/4 5.2 - 8.7 4.3 - 7.2 3.2 - 5.4

I I
1 I 8.8 - 17.7 I 7.4 - 14.9 I 5.6 - 11.4
8
2) If the material of the male screw is S43C, the tightening torque is as in Table 2.
Table 2 Unit: kgm
S tee1 Cast iron Light alloy

Nominal
l/4 2.0 - 4.5 1.7 - 3.8 I 1.3 - 2.9

~ ~ I I
318 I 4.5 ‘- 9.5 I 3.8 - 7.9 I 2.8 - 6.0
l/2 10.0 - 19.2 8.5 - 16.1 6.2 - 11.8
3/4 17.4 - 32.3 14.4 - 25.2 10.8 - 19.0
1 37.5 - 62.5 31.6 - 52.5 24.0 - 40.0
3. Tightening torque for rubber hoses with taper seal
Unit: kgm (Nm)
index No. 02 03 04 05 06 10 12 14
Suitable 30*5
25-e0.5 8+2 14k3 18+5 2025 25+5
tightening
(24.5 + 4.9) ,4,“,‘,‘,.6, (78.5 fr 19.6) (137.3 zk 29.4) (176.5249) (196.lt49) (245.2 249) (294.2249)..__
torque
-k Be careful to assembly the rubber hoses without twisting.
list of bolt tightening torque ranges and bolt tightening tools according to KES
Nominal bolt Width Specified torque range

Tightening tools Checking mean Remark
diameter across flats Torque range Target torque
8mm 13 mm 2.8 - 3.5 3.2 8P (Impact wrench)+Torsion bar Torque wrench 13 kgm
10 mm 17 mm 6.0 - 7.5 6.7 IOP (Impact wrench)+Torsion bar Torque wrench 13 kgm
r 12 mm 19 mm 10.0 - 12.5 11.5 12P (Impact wrench)+Torsion bar Torque wrench 13 kgm
14 mm 22 mm 16.0 - 20.0 18.0 14PI (impact wrench) Torque wrench 28 kgm
16 mm 24 mm 25 - 31.5 28.5 20P (Impact wrench) Torque wrench 42 kgm
>
18 mm 27 mm 35 - 43.5 39 20PI (Impact wrench) Torque wrench 56 kgm
I 20 mm 30 mm 50-62 56 32G (Impact wrench) Torque wrench 70 kgm
, 24 mm 36 mm 84- 105 94.5 38G (Impact wrench) Torque wrench 100 kgm
30 mm 46 mm 155 - 195 175 45F (Impact wrench) Torque wrench 13 kgm
+ Power wrench (x4)
9
4. SEPARATE UNITS
(transportation kits)
BACKHOE Short boom, short arm; low cab
Width: 1,998mm ,
Weight: 17,500kg 1 Width: 3,520mm (including swing circle,
Weight: 17,870kg swivel joint, piping)
[Boom cylinded L
...-_ __--_-._
I t
0 x2
Width: 420mm
Weight: 1,900kg x 2 t
Width: 1,714mm (without ladder: 1830 mm),

’ Weight: 25,500kg x 2 (left and right, one each)
(including shoes, rollers, cushion, piping, ladders,
final drive, motor, motor guard, motor cover
Width: 1,460mm (including bucket cylinder,
Weight: I I ,600kg link, pin, piping)
[Arm cylinder 1
f -@[Operator’s cab -}
Width:
Weight: 1,250kg x 2 1‘2’00-7
3510 Width: 1,600mm
lriziik
Weight: 1,230kg
L
s
Ki
0
Width: 2,929m m
Weight: 9,985kg (1 2m3 bucket)
I 87311 Width:
Weight:
7.1Omm
22,OOOkg
@j
r”
Others ‘,
Catwalk, step, handrail,
Width: 3,500mm small removed parts, etc.
Weight: 44,000kg(including right floor frame)
\ I I J
10
2. Short arm assembly
Tightenand
covers temporarily
P&s sent individually

Hose between boom
and arm
‘P
Grease piping
Parts sent individually C-l 2
Both ends of hose:
Both ends of tube:
12
3. Bucket assembly
pins and covers temporarily
Tighten pins and covers temporarily
ZIT-920-6712 - - - 12 m3
Komatsu genuine tooth:

21T-72-74311
13
4. Upper structure (low cab specification) (l/Z)
~-26 ,Grease reel sub-assembly,

El hose- as
_ individual parts
Hose of grease reel
.
With wiper motor cover
n A-29
\r-6;;;;;1 With grease piping -

Rigt
sent as individual 8734 - . .
-, -I
. Fuel tank vibration
.-Foot-rest
- is not included. - _
stopper cushion
It will.- b&shipped
._-
as individual part.
1-G-lElectric wiring to
operator’s cab ass’y
/\ -
/-.
01
‘r-00 1w@
installation’ ,
-0
Grease piping ‘# 37~- ~-A-7(2/2)
I*-* 1 Yy&, Installation
-.. - . Installation of of swivel drain hose _ .
,:..,I___^___
*..I__ (4) of travel hose
14
4. Upper structure (low cab specification) (Z/Z)
hose
I I
Assemble clamp for air conditioner hose

temporarily to hose.
* Transported with right PPC hose connected

Mount of left cab base
15
5. Center frame assembly (14000 kg)
Blind the drain piping Blind the

. travel
__ piping
staliation of elbow and

ing for swivel drain hose
(16) . (32) (32)
--I--/ \ A-8 -1
installation of elbow and adapters for circle grease tube
With dowel pin for swing circle
16
6,7. Track frame assembly (25,500 kg x 2)
With travel motor guard (lower e
7 I
Travel motor guard

mounting bolts are
being supplied in
temporarily
installed state.
, .
Note: Drain the oil from the HIC cylinder and
check that protrusion (A) of the cylinder
plunger is approx. 10 mm.
-AL
Hydraulic cushion’qlinder -..-
17
Left cab base assembly (low cab specification)
with wiper motor

. cover
j(1/211 - j-TGzi-A-27(212)
With left floor frame
1. Operator’s seat,
- --mat, and
right foot rest sent as
individual parts
_
With left foot rest
With air conditioner piping

. .
.
pLzz-j .
r
Air conditioner unit and
wiring harness
*.
. - _: . .
.. .. .
.. . - .
19
9. Counterweight (21,850 kg)
20
10. Others
Weight: 31 kg Weight: 16 kg
(68 lb) (35 lb)
2920
1765
I
AF179400 AE179410
(44 Id, (82 lb)
AEi79420 AE179430
(64 lb) (99 lb)
131
1892 .
I
AW364 370 Aw364 380
21
-
(62 lb) (37 lb)
718. 5
1510
L I w
90
AW364330 rc- AW364340
(18 lb) (18 lb)
AM64350 AW364360
22
TRANSPORTATION STYLE OF LOADING SHOVEL (WORK EQUIPMENT ONLY)
6,400
Bdom
Overall width: 1,740 Weight: 10,800kg
Arm
Overall width: 1,450 Weight: 8,OOOkg’ ’
Arm
cylinder
1,072kg x 2 .
. . .
Overall width: 3,220

Weight: 14,400kg Bucket
cylinder
1,500kg x 2’
23
5. LIST OF PARTS SENT INDIVIDUALLY
BASE MACHINE RELATED PARTS:

LIST OF PARTS SENT INDIVIDUALLY
(Standard parts, excluding exclusive parts for special specifications)
-
J
Assembly
No. Part No. Part name Applications
Q’ty procedure No.
1 209-60-31130 ELEMENT 6
2 2lT-60-13730 PLATE 6 For flushing
3 07000-15180 O-RING 6
4 21T-04-71230 SHIM (tl .O) 28 A-25
5 01010-81685 BOLT 8 A-25
6 2lT-72-12620 WASHER 8 A-25
7 2lT-04-71190 BRACKET 2 A-25
8 2lT-04-71121 BRACKET 2 A-25
9 195-03-41440 CUSHION 2 A-25
10 195-03-41260 PLATE 2 A-25
11 01010-81630 BOLT 2 A-25 Fuel tank vibration stopper

bracket and for installation
12 01643-31645 WASHER 2 A-25
13 2lT-04-71290 SHIM (tl.0) 28 A-25
14 01010-81650 BOLT 8 A-25
15 01643-31645 WASHER 8 A-25
16 209-03-51160 CLAMP 4 A-25
17 01010-82050 BOLT 4 A-25
18 01643-32060 WASHER 4 A-25
19 2lT-25-67150 BOLT 60 A-6 For connection of revolving

20 01643-33690 WASHER 60 A-6 frame and swing circle
22 21T-30-71160 BOLT 76 A-l For connection of center

frame and left and right
23 2lT-30-71170 WASHER 76 A-l track frame
24 21T-30-71194 COVER (L.H.) 1 A-4
25 21T-30-71214 COVER (R.H.) 1 A-4
26 01010-81230 BOLT 38 A-4
27 175-54-34170 WASHER 30 A-4
28 01643-31232 WASHER 20 A-4 Travel motor cover
29 21 N-30-1 1340 COLLAR 16 A-4
30 01011-81210 BOLT 4 . A-4
31 424-54- 14230 BOLT 4 A-4
32 01010-81235 SPACER 4 A-4
33 2lT-09-I 1221 BOLT 12 A-22 For installation of counter-

34 209-46-I 1210 WASHER 12 A-22 weight
Parenthesized part numbers are for +55”C specification parts.
24
C
35 1 21T-54-75343 1 LADDER I 2 I A-9
36 209-30-6 185 1 STEP 2 A-9

Left and right ladders
37 01010-81640 BOLT 16 A-9
38 1 01643-31645 / WASHER ’ 1 16 1 A-9
39 / 21T-54-75433 1 FRAME I 1 I A-18

I
40 2lT-54-75422 HAND RAIL 1 A-18
7 Operator’s cab front frame,
41 01010-81235 BOLT 26 A-18 handrail
42 1 175-54-34170 1 WASHER I 26 I A-18 I
43 j 01580-11210 / NUT I 2 I A-18
44 01580-11210 NUT 4 A-4

Travel motor cover
44A 01641-21223 WASHER 8 A-4
45 1 2lT-54-75231 1 HAND RAIL I 1 I A-24 I

46 01010-81255 BOLT 24 A-24
Right top handrail on
47 01010-81235 BOLT 16 A-24 counterweight
48 175-54-34170 WASHER 24 A-24
49 / 01580-11210 1 NUT I 4 I A-24

I
50 21T-54-67420 FRAME (R.H.)
(2 1T-54-69820) Ill A-11 I

51 ( 21T-54-69280 1 FRAME (R.H.) I 1 I A-11 I Right catwalk
52 01010-81235 BOLT 31 A-11
53 175-54-34170 WASHER 31 A-II
54 2 1T-54-67440 LADDER (R.H.) 1 A-23

55 01010-81230 BOLT 8 A-23 Right ladder on counter-
. weight
56 01643-31232 WASHER 8 A-23
57 21T-54-67461 HAND RAIL 1 A-20
(21T-54-69790)
58 2 1T-54-75322 HAND RAIL 1 A-20
59 2lT-54-75312 HAND RAIL 1 A-20 Right handrail
60 01010-81235 BOLT 43 A-20
61 175-54-34170 WASHER 45 A-20
62 01580-I 1210 NUT 2 A-20
Parenthesized part numbers are for +55X specification parts.
25
63 ) ZlT-54-68650 1 LADDER I 1 I A-21 I

64 1 01010-81240 1 BOLT I 8 I A-21 I
65 1 01643-31232 1 WASHER I 8 I A-21 I Ladder on hydraulic tank
66 1 01010-81230 1 BOLT I 8 I A-21 I

67 ) 175-54-34170 1 WASHER I 8 I A-21 I
68 01010-81235 BOLT 34 A-27
For installation of left cab
69 175-54-34170 WASHER 34 A-27 base
7011 21T-54-67491 ( HAND RAIL I 1I A-30 I

71 1 01010-81235 1 BOLT I 12 I A-30 I Boom foot handrail
72 1 175-54-34170 1 WASHER I 12I A-30 I

73 1 21T-54-67991 / HAND RAIL I 1 I A-30 I
74 ( 01010-81230 1 BOLT I 8 I A-30 I Front stairway handrail
75 1 175-54-34170 1 WASHER I 8 I A-30
76 21T-54-67190 HAND RAIL 1 A-30

- Handrail above the LH
77 01010-81235 BOLT 16 A-30
pump
78 01643-31232 WASHER 16 A-30
79 1 21T-54-78320 1 HAND RAIL I 1 I A-31
80 1 21T-54-78310 j HAND RAIL

I 1 I A-31
81 0728333450 CLIP 8 A-31 Handrail on the hydraulic

82 07283-53444 NUT 8 A-31 tank
83 1 01599-01011 1 NUT --I 16 I A-31
84 1 01643-31032 1 WASHER I 16 I A-31
85 1 2lT-54-68510 1 HAND RAIL I 1 I A-31 I

86 01010-81235 BOLT IO A-31
Handrail above the LH door
87 01010-81210 BOLT 2 A-31
88 1 175-54-34170 1 WASHER I 12 I A-31
89 01010-81645 BOLT 4 A-10

For mounting L.H. deck
90 01643-31645 WASHER 4 A-10
91 1 209-68-51240 1 GREESE REEL A. 1 1 1 A-26 I

92 / 01010-81030 1 BOLT I 4 I A-26
93 / 01643-31032 1 WASHER I 4 I A-26 Grease reel, bracket, hose,etc.
94 j 21T-68-72410 1 BRACKET I 1 I A-26
95 1 01010-51225 1 BOLT I 4 I A-26
26
C
Assembly
96 01643-31232 WASHER 4 A-26
97 ZIT-68-72450 HOSE (llm) 1 A-26
99 209-68-I 1230 GREASE BUN 1 A-26
100 ZIT-72-17720 HOSE (400m) 1 A-26

Grease reel, bracket, hose,etc.
101 08036-01214 CLIP 1 A-26
102 01010-51225 BOLT 1 A-26
103 01643-31232 WASHER 1 A-26
104 ZIT-68-72390 ELBOW 1 A-26
105 ZIT-54-75650 GRIP 4 A-14,19, 20
106 01010-81235 BOLT 8 A-l 4,19, 20 Climbing handrail
107 01643-31232 WASHER 8 A-14,19, 20
108 ZIT-54-67411 FRAME 1 A-10
109 ZIT-54-75150 PLATE 1 A-10
110 01010-81235 BOLT 22 A-10 Left catwalk
111 01643-31232 WASHER 2 A-10
112 175-54-75131 WASHER 20 A-10
113 2 1T-54-60360 LADDER (L.H.) 1 A-13
114 ZIT-54-75140 COVER 1 A-13
115 01010-81230 BOLT 20 A-13
116 175-54-75140 WASHER 18 A-13
117 ZIT-54-75520 COVER I A-13 Operator’s cab ladder
118 01643-31232 WASHER 2 A-13
119 2171-54-67451 HAND RAIL 1 A-19
120 01010-81235 BOLT 12 A-19
121 175-54-34170 WASHER 12 A-19
123 ZIT-54-67431 LADDER (L.H.) 1 A-23

124 01010-81230 BOLT 8 A-23 For climbing of counter-
weight
125 01643-31232 WASHER 8 A-23
126 ZIT-54-75211 HAND RAIL (L.H.) :I A-24 Left handrail tank
127 ZIT-54-75221 HAND RAIL (L.H.) I A-24 Left handrail on counterweight
128 08154-12400 LAMP BEACON I A-39
129 ZIT-06-17430 BRACKET 1 A-39 Counterweight lamp
130 01010-81225 BOLT 2 A-39

I
27
C
Assembly
No. Part No. Part name
I I Q’ty procedure No.
Applications
1317 01643-31232 / WASHER I 9 I A-39
132 1 2lT-06-72320 j WIRE HARNESS I 1 I A-39 I

133 1 08036-01014 j CLIP 6 A-39
I I I Counterweight lamp
134 1 08036-00814 ( CLIP I 3 I A-39 I

135 / 01010-81220 / BOLT I 7 I A-39 I
136 2lT-54-69960 BRACKET 1 A-32
137 2 1 T-43-67580 CABLE 1 A-32
141 8221-06-I 470 SWITCH 1 A-32
142 8253-06-I 210 PLATE 1 A-32
143 01010-80620 BOLT 2 A-32
144 01643-30623 WASHER 2 A-32
145 8253-06-I 220 BOX 1 A-32
146 01010-81020 BOLT 2 A-32
147 01643-31020 WASHER 2 A-32 Emergency stop switch,
148 08053-01512 CLIP 1 A-32 Fuel cutting
149 01010-81225 BOLT 1 A-32
150 01643-31232 WASHER 1 A-32
151 2lT-06-67840 WASHER HARNESS 1 A-32
152 ZIT-06-67770 COVER 1 A-32
153 01010-80616 BOLT 6 A-32
154 01643-30623 WASHER 6 A-32
‘155 04434-51012 CLIP 4 A-32
156 01010-81225 BOLT 4 A-32
157 01643-31232 WASHER 4 A-32
158 21 N-54-32670 MIRROR 2 A-31
159 2lT-54-79631 SUPPORT 2 A-31

RH mirror
160 21 N-54-79620 CLAMP 2 A-31
161 01252-41025 BOLT 4 A-31
162 2lT-54-69510 HAND RAIL 1 : A-33A
163 07010-81230 BOLT 12 A-33A

1 Handrail above the radiiator
164 01643-31232 WASHER 12 A-33A (Option)
165 2 7T-54-69520 PLATE 1 A-33A
166 01010-81230 BOLT 5 A-33A
28
C
Assembly
a%’ procedure No.
Applications
167 01643-31232 WASHER 5 A-33A
168 ZOY-54-12990 PLATE 5 A-33A

Handrail above the radiiator
169 ZOY-54-19930 COLLAR 5 A-33A (Option)
170 01010-81230 BOLT 5 A-33A
171 01643-31232 WASHER 5 A-33A
172 (ZIT-54-68641) PLATE 4 A-20
173 (ZOY-54- 12990) PLATE 16 A-20

174 (ZOY-54-19930) COLLOR 16 A-20 . +55”C specification, RH
handrail cover
175 (01010-81230) BOLT 16 A-20
176 (01643-31232) WASHER 16 A-20
177 01010-81230 BOLT 4 A-32
178 01643-32232 WASHER 4 A-32
179 175-06-81610 GROMMET 1 A-32
180 8221-93-1250 PLATE (JAPANESE) 1 A-32 Emergency engine stop

8221-93-I 630 PLATE (ENGLISH) switch decal
181 ZIT-54-68560 BRACKET 1 A-II
182 01010-81230 BOLT 2 A-11 Greasing hose guide
183 01643-31232 WASHER 2 A-11
184 ZIT-30-71251 BRACKET 2 A-4
185 ZIT-30-18120 COVER 5 A-4
186 01010-82465 BOLT 44 A-4
187 01643-32460 WASHER 44 A-4
188 ZIT-30-71280 COVER 2 A-4
189 ZIT-30-71270 COVER 2 A-4
190 01010-82485 BOLT 12 A-4

. Track frame under cover
191 01643-32460 WASHER 12 A-4
192 ZIT-54-75570 PLATE 2 A-30
193 ZIT-54-75560 CLAMP 2 A-30
194 01010-81230 BOLT :2 A-30
195 175-54-34170 WASHER 2 A-30
196 2 1T-54-78390 BRACKET 1 A-31
197 19M-54-13660 BRACKET 4 A-31
198 01010-81235 BOLT 16 A-31
29
C
Assembly
No. Part No. Part name Q’ty procedure No.
Applications
199 175-54-34170 WASHER 16 A-31
200 2 1T-54-69430 FRAME 1 A-II
201 01010-81235 BOLT 8 A-II

. Track frame under cover
202 175-54-34170 WASHER 8 A-11
203 2171-06-25310 LAMP 2 A-11
204 01643-31232 WASHER 4 A-11

205 08036-01014 CLIP 3 A-11 For mounting clamps for R.H.
- head lamp, and mounting
206 01010-81225 BOLT 4 A-11 grounding wire harness

EXCLUSIVE PARTS FOR STANDARD SPECIFICATIONS:
(Low cab)
1 1 ZIT-54-69930 7 FRAME I 1 I A-12 I

2 1 211-54-75163 j HAND RAIL I 1 I A-12 I
3 01010-81235 BOLT 29 A-12
Operator’s cab left catwalk
4 175-54-34170 WASHER 31 A-12
5 / 01580-12210 j NUT I 2 I A-12 I

6 FIT-54-69780 1 LADDER ~~ I---
1 I ~ A-12 ~~ 1
7 ZIT-54-75173 HAND RAIL 1 A-14
. Handrail
10 01010-81235 BOLT 16 A-14
1 (for operator’s cab)
11 175-54-34170 WASHER 16 A-14
13 ZIT-43-67411 COVER 1 A-29 Wiper motor cover inside

14 2 1T-43-67650 COVER 1 A-29 the operator’s cab
15 1 ZOY-57-21260 1 BACKET I 1
I A-27 I
16 j ZOY-57-21270 1 BACKET I 1 I A-27 I
17 1 01010-81235 1 BOLT I 4 I A-27
181 01643-31232 1 WASHER I 4 I-----A-27 1 Seat belt
19A / 09409-60000 1 LAP BELT I 1 I A-27 I

1981 09409-10001 ( LAPBELT I 1 I A-27 I
20 j 09409-20000 1 TETHERBELT I 2 I A-27
21 I 09409-00001 1 BOLT I 2 I A-27 1

22A 1 207-57-61320 j STAND I 1 I A-27 I STD. seat stand
22B 1 207-57-61310 ( STAND I 1 I A-27 I OPT. seat stand

23 1 ZIT-54-71851 / BACKET . I 1 I A-27 T
24 195-54-43210 BOLT 4 A-27
Right foot rest
25 198-54-42280 WASHER 4 A-27
26 j ZIT-54-67741 1 MAT I 1 I A-27
27 1 ZIT-54-67751 j MAT I 1 I A-27 Front floor mat
28 / OlOlO-81230 ( BOLT I 6 I A-27
29 1 01010-81235 ( BOLT I 8 I A-27 I Rear floor mat

30 ( 01643-31232 1 WASHER I ;I4 I A-27
31 01010-51470 BOLT 16 A-28 For connection of left and

32 01643-31445 BOLT 16 A-28 right floos
31
(Low cab)
A
Assembly
33 2 1T-54-69870 COVER 1 A-12
34 01010-81225 BOLT 12 A-12
35 170-54-34170 WASHER 9 A-12
36 01643-31232 WASHER 3 A-12
37 2 1T-54-69880 COVER 1 A-12
38 01010-81225 BOLT 4 A-12
39 01643-31232 WASHER 4 A-12 Escape ladder storing box
40 2 1T-54-69450 LOCK 1 A-12
41 01643-30823 WASHER 1 A-12
42 01580-10806 NUT 1 A-12
43 209-54-31170 LINK 1 A-12
44 202-970-I 220 WASHER 1 A-12
45 04050-13018 PIN 2 A-12
46 01641-21016 WASHER 2 A-12
47 21 N-54-32670 MIRROR 1 A-12
48 ZlT-54-79611 SUPPORT 1 A-12

Operator’s cab side mirror
49 21 T-54-79620 CLAMP 2 A-12
50 01252-41025 BOLT 4 A-12
51 ZIT-54-67480 HAND RAIL 1 A-12

Operator’s cab rear
52 01010-81235 BOLT 4 A-12
. handrail
53 01643-31232 WASHER 4 A-12
55 ZIT-54-67471 HAND RAIL 1 A-12
56 j 01010-81230 / BOLT I 8 I A-12 I

57 01643-31232 WASHER 8 A-12
Handrail at upper front of
58 2 1T-54-75560 CLAMP 1 A-12 the LH door
59 1 2lT54-75570 1 PLATE I 1 I A-12 I

60 ( 01010-81230 1 BOLT I I I A-12 I
61 175-54-34170 WASHER 1 A-12
62 207-57-61200 OP. SEAT 1 : A-27
62 01010-80816 BOLT 2 A-27

Operator’s seat
63 01252-40820 BOLT 2 A-27
64 1 01643-30823 1 WASHER I 2 I A-27 I

32
(Low cab)
A
.
Assembly
65 01641-21223 WASHER 2 A-27
66 09049-00002 WASHER 2 A-27
67 09049-00003 NUT 2 A-27 Seat belt
68 01010-81045 BOLT 2 A-27
69 01602-21030 WASHER 2 A-27
70 175-54-29440 PLATE 2 A-14

For mounting ladder for
71 195-54-23471 PLATE 1 A-14 climbing up and down
72 21T-68-67610 CUSHION 1 A-21 the cab
73 21T-06-71920 COVER 1 A-27 Wire harness cover
74 21T-06-71860 WIRE HARNESS 1 A-27 Wiper harness
75 20M-57-71202 SEAT A. 1 A-27 * Sub seat ass’y (*)
1 76 1 21M-57-67111 1 BOX I 1 I A-27
1 77 1 2ON-57-21211 1 BRACKET I 1 I A-27
I 78 I 01010-80820 I BOLT I 4 I A-27
I 79 I 01643-30823 I WASHER I 4 I A-27 I
I I 80 01580-I 0806 I NUT I 4 I A-27
1 81 1 21T-57-67130 1 BRACKET I 1 I A-27
1 82 1 2171-57-67120 j BRACKET I 1 I A-27
I 83 I 0101 o-80820 I BOLT I 4 I A-27

I
1 84 1 01643-30823 1 WASHER I 4 1 A-27 I
( 85 ( 14X-911-7741 ( FILTER I 4 I A-27 I

I I 09495-00000 I EXTINGUISHER I 1 I A-27 I
I 87 I 01010-80616 I BOLT I 6 I A-27 I

I 88 I 01643-30623 I WASHER ( 6 / ___~A27--1
89 X2 I-0544722 OPE CAB ASS’Y 1 A-28
90 2lT-43-67381 DUCT 1 A-28
91 2OY-979-2160 GRILL 2 A-28
92 2OY-54-14750 BOLT IO A-28
93 01643-70823 WASHER IO A-28
94 21 T-43-67392 DUCT 1 A-28
95 195-54-43210 BOLT IO A-29
96 198-54-42280 WASHER IO A-29
33
(Low cab)
A
Assembly
Applications
97 21T-43-67343 COVER 1 A-27 Defroster
98 142-979-322 1 GRILL 4 A-27
99 1 01010-81025 j BOLT I, 3 I A-27
100 1 01643-31032 / WASHER I 4 I A-27
I-
101 ~~
08037-02512 GROMMET I 1 I A-27
102 / 08037-01610 / GROMMET 1 A-27

I I
103 01010-81016 BOLT 1 A-27
104 07281-01159 CLAMP 3
105 21 T-979-6270 HOSE 1
106 2 1T-979-6280 HOSE 1
107 2 1T-979-6290 HOSE 1
108 07281-01159 CLAMP 3
109 07281-02169 CLAMP 4
110 21T-979-6710 HOSE 2
34
BOOM RELATED PARTS:
(8700 mm)
G
Assembly
“tY procedure No.
1 ZIT-63-X2310 BOOM CYL. A. (L.H.) 1 C-l
Boom cylinder
2 2 1T-63-X2320 BOOM CYL. A. (R.H.) 1 C-l
3 2 1T-63-X2330 ARM CYL. A. (L-H.) 1 c-4

Arm cylinder
4 ZIT-63-X2340 ARM CYL. A. (R.H.) 1 c-4
5 ZIT-70-71260 SHIM (tl .O) 8 c-5
6 ZIT-70-71270 SHIM (tl.5) 16 c-5 Boom foot
7 209-72-I 1311 SEAL 4 c-5
8 ZIT-70-71260 SHIM (tl .O) 8 C-l, 5
9 ZIT-70-71270 SHIM (tl.5) 16 C-l, 5 Boom cylinder bottom
10 178-70-I 2550 SEAL 4 C-l, 5
11 ZIT-70-11240 SEAL 4 C-6
12 07000-05190 O-RING 2 C-6
13 07000-05160 O-RING 2 C-6
14 209-70-I 1340 SEAL 4 c-4

. Arm cylinder bottom
15 07000-05160 O-RING 4 c-4
16 ZIT-70-71650 SHIM (t4.5) 4 c-7
17 ZIT-70-71660 SHIM (t0.5) 12 c-7
18 ZIT-70-71590 SEAL 2 c-7 Boom top
19 07000-05220 O-RING 2 c-7
20 ZIT-70-71670 SHIM (t3.2) 4 c-7
31 2OY-06-25310 WORK LAMP A. 2 c-4
32 2OY-06-Z 1551 BRACKET 2 c-4

Working lamp
33 01010-81430 BOLT 2 c-4
34 01643-31445 WASHER 2 c-4
35 209-70-I 1340 SEAL 4 c-9

- Arm cylinder top
36 07000-05155 O-RING 4 c-9
37 21 N-70-12160 SEAL 4 C-16 Arm top
38 209-72-I 1261 SEAL 4 c-17 Forconnection of front link and bucket
39 ZIN-70-13150 O-RING ;4 C-16
40 ZIT-70-74260 SHIM (tl .O) 32 C-16 Arm top
41 21T-70-74270 SHIM (t0.5) 8 C-16
35
ARM RELATED PARTS:
(3900 mm)
F
Assembly
2 07073-01418 HOSE 8 c-4 Between chassis and boom
3 07073-41425 HOSE 4 c-4 Between boom and arm
4 21T-72-17740 HOSE (800mm) I c-12
5 21T-72-17690 ADAPTER I c-12
6 21T-70-75290 BRACKET 1 c-12
7 01010-51225 BOLT 2 c-12
8 01643-31232 WASHER 2 c-12 Arm greasing
9 21T-72-17620 ADAPTER 1 c-12
IO 21T-70-75740 TUBE 1 c-12
11 07282-I 1048 CLAMP 3 c-12
12 01010-80612 BOLT 6 c-12
13 01643-30623 WASHER 6 c-12
14 07073-01416 HOSE 4 c-4 Arm cylinder hose
36
ARM RELATED PARTS:
(3900 mm)
Assembly
Applications
24 [01643-310321 WASHER 4 A-8
4 [ 07361-204081 HOSE (800mm) ’ 1 c-12
5 [237-60-l 4550 I NIPPLE 2
6 [21T-70-752901 BRACKET 1
7 [OIOIO-812251 BOLT 2
8 [01643-312321 WASHER 2
Arm greasing
10 [21T-68-682901 TUBE 1
1l-l [203-973-56601 CLAMP 3
11-2 [203-973-57201 BOLT 3
12 [OIOIO-810551 BOLT 6
13 [01643-310321 WASHER 6
Part No. in [ ] indicates the LINCOLN specification.
37
SWING CIRCLE GREASING PIPING RELATED PARTS:
H
Assembly
a%’ procedure No.
Applications
1 21T-72-19350 HOSE 1 A-8
2 08036-01214 CLIP 2 A-8
3 01010-81225 BOLT 2 A-8
4 01643-31232 WASHER 2 A-8
6 1 07282-11048 1 CLAMP I 5 I A-8 I

7 01010-80612 BOLT 5 A-8
8 01643-30623 WASHER 5 A-8
9 2 1T-68-67450 TUBE 1 A-8
10 21T-68-67310 TUBE 1 A-8 Swing circle greasing
11 21 T-68-67320 TUBE 1 A-8
12 2 1T-68-67330 TUBE 1 A-8
13 2 1T-68-67340 TUBE 1 A-8
14 2 1T-68-67440 TUBE 1 A-8
15 2 1T-68-67350 TUBE 1 A-8
16 2 1T-68-67360 TUBE 1 A-8
17 21T-68-67370 TUBE 1 A-8
18 21T-68-67380 TUBE 1 A-8
19 21T-68-67550 BRACKET 2 A-8
20 01010-81025 BOLT 4 A-8
‘arenthesized part numbers are for +55”C specification parts.
38
H
Assembly
“tv procedure No.
9 [21T-68682601 TUBE 1 A-8
10 [21T-68-682501 TUBE 1 A-8
11 [21T-68-682401 TUBE 1 A-8
12 [2lT-68-682301 TUBE 1 A-8
13 [21T-68-682201 TUBE 1 A-8
14 [21T-68-682101 TUBE 1 A-8
15 [21T-68-681601 TUBE 1 A-8 Swing circle greasing
16 [21T-68-681701 TUBE I A-8
17 [21T-68-681801 TUBE 1 A-8
18 [21T-68-681901 TUBE 1 A-8
22 [21T-68-674601 CLAMP 2 A-8
23 [OIOIO-810351 BOLT 4 A-8
Part No. in [ ] indicates the LINCOLN specification.
39
Assembly
Applications
24 01643-31032 WASHER 4 A-8
25 207-70-I 1740 ELBOW IO A-8
26 21 T-68-67230 TUBE I A-8

,
30 20 I-62-28540 TEE 6 A-8
31 1 207-70-11730 ) NIPPLE I 20 I A-8
32 j ZIT-68-67481 1 BRACKET 141 A-8

33 1 01010-81025 1 BOLT I 8 I A-8 I
34 ( 01643-31032 1 WASHER I 8 I A-8
35 1 21T-68-67470 1 CLAMP I 4 I A-8
36 1 01010-81035 1 BOLT I 8 I A-8 I

37 1 01643-31032 1 WASHER 181 --A-8 1
38 1 21T-68-67490 1 BRACKET I 2 I A-8 I

39 / 01010-81025 1 BOLT I 4
I A-8
40 1 01643-31032 1 WASHER I 4 I A-8
41 ( 211-68-67510 / BLOCK I 2
I A-8 Swing circle greasing
42 1 01010-81055 1 BOLT I 8 I A-8
43 1 01643-31032 / WASHER 181 A-8

44 21T-68-67190 BRACKET 3 A-8
45 01010-80815 BOLT 3 A-8

46 01643-30823 WASHER 3 A-8
47 04435-50808 CLIP 3 A-8
48 j 01010-80820 1 BOLT I 3
I A-8 I
49 1 01643-30823 1 WASHER I 3 I A-8 I
50 1 21T-68-67410 1 TUBE Ill -=--I
51 / 21T-68-67420 1 TUBE
I 1
I A-8
52 2lT-68-67430 TUBE 2 A-8
53 2 1T-68-67570 TUBE 1 A-8
54 / 21T-68-67560 / TUBE I 1 I A-8
55 1 21T-68-67390 1 TUBE I 4 I A-8

PARTS TO BE REMOVED WHEN KIT FOR MODIFICATION OF
BACKHOE INTO LOADING SHOVEL IS INSTALLED
LS
Assembly
Applications
Right-hand 5-spool valve bucket
a 2 1T-62-76690 TUBE 1 LS-5 dump PPC tube
Right-hand 5-spool valve bottom
b 2 1T-62-74820 TUBE 1 LS-5 dump PPC tube
Right-hand 4-spool valve arm
c ZIT-62-75740 TUBE 1 LS-6 bottom dump PPC tube
1 Right-hand 4-spool valve arm
d 2 1T-62-74580 ELBOW I LS-6 bottom dump PPC elbow
Right-hand 4-spool valve straight
e 07235-I 0315 TUBE I LS-6 travel T-port elbow
f ZIT-43-67610 LEVER 1 LS-8 Left-hand control lever
g 2 1T-43-67620 LEVER 1 LS-8 Right-hand control lever
h ZOY-06-21350 WIRING HARNESS 1 LS-8 Right-hand control lever horn harnes
Only #IO001 - #IO006

k ZIT-54-67491 WASHER 1 LS-IO
41
LIST OF LOADING SHOVEL UNIT KIT PARTS
LS
Assembly
1 2 1T-62-69240 TUBE 3 LS-1
2 ZIT-62-69250 BOLT 1 LS-1
3 07000-B3048 O-RING 4 LS-1
4 01010-81455 BOLT 16 LS-1
5 01643-31445 WASHER 16 LS-I
6 1 2lT-62-69261 ) BRACKET I 1 I LS-1
7 1 ZIT-62-69271 1 BRACKET I I I LS-1
8 / 01010-81290 [ BOLT I 8 I LS-1
9 1 01643-31232 1 WASHER I 8 I LS-1

I
1 IO 1 176-61-41330 1 CLAMP I 4 I LS-1 Bottom dump line
I 11 I 01010-81250
I
I WASHER I 8 I LS-1
12 01643-31232 BRACKET 8 LS-1
I 13 I 07072-01421 I HOSE I 4 I LS-1
I 14 I 07000-B3048 O-RING I 8 I LS-1
15 1 07371-51470 1 FLANGE I 16 I LS-1
16) 01010-81455 1 BOLT I 32 I LS-l
17 01643-31445 WASHER 32 LS-1
18 ZIN-62-12210 FLANGE 4 LS-I
19 07000-B3048 O-RING 4 LS-1
20 01010-81455 BOLT 16 LS-1

1
! 21 I 01643-31445 WASHER I I6 I LS-1 I
I 22 I 07073-01418 HOSE I 4 I LS-2
23 ( 07000-B3048 1 O-RING I 8 I LS-2 I

24 1 07371-51470 1 FLANGE I 16 I LS-2 I Bucket hose
25 / 01010-81455 / BOLT I 32 I LS-2
26 1 01643-31445 1 WASHER LS-2

I 32 I
27 1 ZIT-62-67560 / BLOCK -1 1 I LS-3
28 1 07000-B3048 1 O-RING I 13 I LS-3
29 1 ZIT-62-67570 1 TUBE I 1 I; LS-3
30 01011-81415 BOLT 4 LS-3

Bottom dump piping
31 01643-31445 WASHER 4 LS-3
32 1 07073-01416 1 HOSE I 1 I LS-3 I

33 1 07073-01418 1 HOSE I 1 I LS-3
34 / 07371-51470 j FLANGE I 8 I LS-3 I
42
LS
Assembly
35 01010-81455 CONNECTOR 48 LS-3
36 01643-31445 NIPPLE 48 LS-3
37 21T-62-67590 TUBE I LS-3
38 720-68-I 5910 PLUG 1 LS-3

I Bottom dump piping
39 720-68-I 5260 SEAL 1 LS-3
40 2 1 T-62-67 480 TUBE 1 LS-3
41 21T-62-67490 TUBE 1 LS-3
42 21T-62-67510 TUBE 1 LS-3
43 209-60-I 2830 SOL. VALVE 1 LS-4
44 12H-49-11170 NIPPLE 2 LS-4
45 21T-62-77410 NIPPLE 2 LS-4
46 2 1 T-06-67990 WIRING HARNESS 1 LS-4
47 2lT-06-12530 CONNECTOR 1 LS-4
48 01252-40535 BOLT 4 LS-4
49 01601-20513 WASHER 4 LS-4
50 207-62-56230 NIPPLE 2 LS-4
51 07002-l 2034 O-RING 2 LS-4
52 2OY-06-2 17 IO SWITCH A. 2 LS-4 Pilot line
53 2lT-06-681 IO WIRING HARNESS 1 LS-4
54 207-979-6180 BRACKET 1 LS-4
55 08053-01512 CLIP 1 LS-4
56 01010-81225 BOLT 1 LS-4
57 01643-31232 BOLT 1 LS-4
58 04435-51410 CLIP 1 LS-4
59 07 184-00307 HOSE 2 LS-4
60 07221-20315 NUT 2 LS-4
61 07222-00312 PLUG 2 LS-4
62 706-75-87 100 VALVE A. I LS-5
63 21 T-62-76550 PLATE 1 LS-5
64 07000-12010 O-RING 3 LS-5
65 0101 o-80880 BOLT 2 LS-5 Main valve pilot line
66 01010-81025 BOLT 2 LS-5
67 01643-31032 WASHER 4 LS-5
68 2lT-62-76560 PLATE I LS-5

A *
43
LS
Assembly
“tY procedure No.
69 07000-I 2016 O-RING 1 LS-5
70 0101 o-80835 BOLT 4 LS-5
71 01643-30823 WASHER 4 LS-5
72 07213-51013 NIPPLE 3 LS-5
73 ZIT-62-76540 TUBE 1 LS-5 Main valve pilot line
74 ZIT-62-76530 TUBE 1 LS-5
75 ZIT-62-76790 TUBE 1 LS-5
76 07 102-20206 HOSE 1 LS-5
77 07236-I 0210 ELBOW 1 LS-5
78 07002-I 1423 O-RING 1 LS-5
79 ZIT-62-69480 TUBE 1 LS-6
80 209-62-572 10 TEE 1 LS-6

4-spool valve arm head
81 07235-I 0315 ELBOW 1 LS-6 PPC drain circuit
82 07002-I 2034 O-RING 2 LS-6
83 07 184-003A5 HOSE 1 LS-6
84 2 1T-43-67760 LEVER A. L.H 1 LS-7
85 2 1T-43-67770 LEVER A. R.H 1 LS-7
86 ZIT-06-71710 WIRING HANESS 3 LS-7 Control lever in cab
87 ZOY-54-13440 CLIP 4 LS-7
88 08034-00519 BAND 8 LS-7
89 ZIT-06-11901 SWITCH A. 1 LS-8
90 01010-80812 BOLT 2 LS-8
91 01643-30823 WASHER 2 LS-8 Foot horn switch
92 208-72-68880 WIRING HANESS 1 LS-8
93 ZIT-06-71940 COVER 2 LS-8

LIST OF LOOSE-SUPPLY MACHINE BODY PARTS RELATED TO LOADING SHOVEL
( * : KMG PARTS)
LS
~No. Part No. Part name Applications
1 94 1 21T-960-1400 1 BOOM CYL. L.H I 1 I LS-12
95 21T-940-1500 BOOM CYL. R.H 1 LS-12

Boom cylinder
96 21T-72-71260- SHIM tl.0 4 LS-12
97 1 21T-72-71270 1 SHIM t1.5 I 4 I LS-12
98 1 07072-01417 1 HOSE I 4 I LS-13 Boom cylinder hose
99 1 21T-960-1100 1 BOOM A. I I I LS-14 Loading shovel boom
100(21T-72-71260 1 sHiM ti.0 I 4 I LS-14 assembly
101 1 2lT-72-71270 ( SHIM t1.5 I 4 I LS-14 I

Grease feed hose between
102 07633-20412 HOSE I LS-16 machine body and boom
103 21T-960-1200 BACKET CYL. A. 2 LS-17
104 21T-960-1680 PIN 2 LS-17

Installation of bucket
105 21T-960-21 IO PLATE 2 LS-17
cylinder assembly
106 1 DM905 748 40 1 WASHER [ 4 1 LS-17 ( (Included in boom assembly)
107 1 01010-81640 1 BOLT I 4 I LS-17 I
108 ( 01643-31645 1 WASHER I 4 I LS-17 I
109 / 2lT-960-2600 1 ARM A. I 1
I LS-18 I
110 1 21T-960-1670 / PIN I 2 I LS-18
ll I FIT-960-2140 / PLATE I 2 I LS-18 I Installation of arm assembly
112 / DM905 747 40 1 WASHER I 4 I LS-18 I (Included in boom assembly)
113 / 01010-82455 1 BOLT I 4 I LS-18 I

114 / 01643-32460 / WASHER I 4 I LS-18 I
115 1 21T-960-2300 1 ARM CYL. A. L.H I 1 I LS-19 I
116 2lT-960-2400 ARM CYL. A. R.H 1 LS-19
Installation of arm cylinder
117 21T-960-2130 PIN 2 LS-19 assembly
118 21N-70-11210 PLATE 2 LS-19 (Included in arm cylinder

assembly)
119 01010-81640 BOLT 4 LS-19
120 1 01643-31645 / WASHER I 4 I LS-19 I

121 1 21T-960-1690 1 HOSEA. I I I LS-20 I
122 07000-B3048 O-RING :I2 LS-20 Installation of hose between
123 01010-81455 BOLT 48 LS-20 boom and arm
124 1 01643-31445 1 WASHER I 48 I LS-20
45
LIST OF LOOSE-SUPPLY MACHINE BODY PARTS RELATED TO LOADING SHOVEL
( * : KMG PARTS)
LS
Assembly
125 07073-01423 HOSE 2 LS-2 1
126 07073-01428 HOSE 2 LS-2 1

- Bottom dump bottom line
122 07000-83048 O-RING 8 LS-2 1 hose
123 01010-81455 BOLT 32 LS-2 1
124 01643-31445 WASHER 32 LS-2 1
127 2 1T-960-2700 BUCKET A. 1 LS-23

128 DM620 923 40 SEAL A. 4 LS-23 Bottom dump bucket
assembly
129 DM661 196 40 SEAL A. 4 LS-23
130 07072-01231 HOSE 2 LS-24
131 07000-B3038 O-RING 4 LS-24

InstalIatioI 1 VI UULLUIII
132 01010-81245 BOLT 16 LS-24 dump hose between
I
arm and bucket

133 01643-31232 WASHER 16 LS-24
134 1 08034-20536 1 BAND I 4 I LS-24
46
LIST OF LOOSE-SUPPLY PARTS OF POWER-ASSISTED LADDER

I I “ty
Assembly
procedure No.
Applications
1 1 X210665680 1 LADDER ASS’Y L-l 1 Power-assisted ladder
I 2 I 21T-54-69551 I BRACKET I 1 I L-l I

3 2171-54-69541 BRACKET 1 L-l
I 4 I 01010-81225 I BOLT 181 L-1 I

I I 5 01643-31232 WASHER I 8 I L-l I
I 6 I 01010-81225 BOLT I 6 I L-l I
I 7 I 01643-31232 WASHER I 6 I L-l I
I 8 I 01010-81240 BOLT
I 8 I L-l
I
1 9 1 175-54-34170 1 WASHER I 8 I L-l
1 10 ( 21T-54-69460 / FLAME 1 L-l

I I I
1 II I 01010-81645 I BOLT 1291 L-l I
I 12 I 01643-31645 I WASHER I 29 I L-l I

I 13 I 01010-81235 BOLT I 16 I L-l I
1 14 j 175-54-34170 j WASHER I 16 I L-l I
I 15 I 08037-03614 GROMMET I 2 I L-l I
1 16 ( ZlT-54-66370 1 CONTROLCABLE 1 1 1 L-l I Unlocking cable
I 17 I 04434-50812 I CLIP I 2 I L-l I

I 18 I 01010-81220 I BOLT I21 L-l I
19 1 01643-31232 ( WASHER I 2 I L-l I
20 1 04205-10516 1 PIN I 1 I L-l I
21 1 04050-11210 1 COTTER PIN I 1I L-l I
22 1 21T-54-66360 1 BRACKET I 1I L-l I Unlocking
~ lever
~~~ ~
23 1 06124-01616 1 BEARING I 7I L-l
24 1 21T-54-66380 1 CHAIN I 1 I L-l Unlocking chain
25 1 01010-81020 1 BOLT 121 L-l -1
26 ( 01643-31032 1 WASHER I 2 I L-l
27 1 04205-11645 1 PIN I 1I L-I I

28 / 04050-14028 1 COTTER PIN I 1I L-l
29 ) 2lT-54-66420 1 BRACKET I i1 I L-l I Cable bracket
30 01010-81225 BOLT 2 L-l
31 01643-31232 WASHER 2 L-l
32 / 21T-54-66330 1 BRACKET I 1I L-1 I Lock bar
33 / 170-33-13370 1 SPRING
34 1 21T-54-66430 1 BRACKET I 1 I L-l I
47
LIST OF LOOSE-SUPPLY PARTS OF POWER-ASSISTED LADDER
35 [ 01010-81220 v I 2 I L-l I
36 1 01643-31232 1 WASHER I 2 I L-l I
37 1 04210-21664 ) YOKE Ill L-l I
38 195-49-l 3840 NUT 1 L-l
39 1 04205-11845 1 PIN I 1 I L-l I

40 / 04050-14028 / COTTER PIN I 1 I L-l I
41 1 21T-54-66390 1 HAND RAIL III L-1 I
42 1 01010-81235 1 BOLT I 4 I L-l I
43 1 01643-31232 1 WASHER I 4 I L-l I
44 2 1 T-54-69560 HAND RAIL 1 L-l
45 01010-81230 BOLT 8 L-l
46 175-54-34170 WASHER 8 L-l
47 2 1 T-06-68220 WIRING HARNESS 1 L-l
48 21T-06-68210 WIRING HARNESS 1 L-l
49 01010-81220 BOLT 11 L-l
50 01643-31232 WASHER 11 L-l
51 04434-51012 CLIP 11 L-l
52 08053-01512 CLIP 1 L-l
53 21 N-06-31 390 LAMP 1 L-l
54 2 1T-00-67330 PLATE 1 L-l
55 2171-54-66160 CHAIN 1 L-l
56 01010-81020 BOLT 2 L-l
57 01643-31032 WASHER 2 L-l
48
0)
.
Day D
cn
cn
m
3
W
I-
<
Units to be assembled
w
n
0
c)
m
u
C
n
Assembly Procedure No. qm
Maintenance Procedure No.
D
cn
cn
m
Crane
3
W
I
4
Air compcestzor m
0
C
F
3
m
2
-I
D
2
’ I Fo;Bman -I- 5 rnecha~c~ Foreman + 2 machanics
u
cn
c)
Forklift I:
m
u
Starl ol asembly Complstioa. of assembfy of chassis Completion of total assenlbly C
Meeting of all workecs Start errgirre
I-
m
1
7. KIT LAYOUT DIAGRAM
The dimensions given below are the minimum dimensions needed.

When selecting a place, see A-l. Precautions for Local Assembly.
(6)
/
I
Tools,
parts sent
individually
(7)
(8)
3M
-
(1)
(2)
Left track frame assembly
Right track frame assembly
(5) Counterweight
(6) Handrail group
assembly
I(9) Arm, bucket assembly
(10) Crane, 45 ton
(3) Axle assembly (7) Operator’s cab assembly (11) Crane, 45 ton
(4) Upper structure assembly (8) Boom assembly (12) Tools, parts sent individually
50
(1) STANDARD TOOLS SUPPLIED WITH MACHINE
(2) EQUIPMENT AND TOOLS FOR LOCAL ASSEMBLY
51
(1) Standard tools supplied with machine (Legend)
% _Tools used in Japan (Standard only in Japan
* : Essential tools (Standard in Japan and overseas)
@ : Essential spare parts (Standard both in Japan and overseas)
% % *
.
f.I
h.
-
R 49
%
m
H
PUMP GREASE
‘.
G. CARTRIGE SPANNER SET

09055-05513 07952-80002 07950-90403 09000-30006
s zy ;’ %
DRIVER PLIERS HAMMER

09020-I 0284 09033-00190 09036-00150 09039-00150
%
. .’ - . .-.
. . . 1’f
_. ax+
- /Y E _@:. s &_ z
: -. .
. f
-.?s. . . : --.
SOCKET WRENCH FILTER
DRAIN HOSE
NOZZLE THICKNESS GAUGE BLEEDING COUPLER
09054-00000
52
(2) Equipment and tools for local assembly
No. Fart Name Specification Q’ty Remarks No. Part Name Specification Q’ty Remarks
1 Engine compressor Made by KOMATSU, 7.0 kg/cm2class 1 Lease 28 Eyebolts M42-P3 2 See separate sheet
2 Truck crane 45 ton capacity 2 Including operator M30-P3 2 See separate sheet
29 Lever block 6 ton 2
5 Forklift I,5 ton class (useful if available) 1 Lease 3 ton 2
6 Air impact wrence KWIOP (For MIO) 2 1.5 ton 2
(Made by KUKEN) KWl2PI (For M12) 2 314 ton 2
KW14PI (For M14) 1 30 Pin (hard material) 50ex400mm 2 Pin
KW2OP (For Ml6) 1 31 Air hose 4, 6 50meach
KW20PI (For M20) 1 32 Air coupler For 4,6 hose 5 set
KW38G (For M24) 1 Match with impact wrench and compressor
KW45FG 1 33 Stands for work in high places Height: 3 m 1
7 Wrench (x 16) Made by TONE, 450 kgm 1 With reactionabsorbe Height: 1.5 m 2
8 Socket for wrench (x 16) 38%55,60,65,70 mm 1 each Height: 0.9 m 1
9 Socket adapter I-1/2~1++3/4 inch 1 each 34 Axle stand Height: 470 mm 2
10 Spline socket 55 mm (S/C), 65 mm (CW), 70mm (Ax) 1 each 35 Hydraulic jack 50 ton 3
11 Socket wrench set Made by TONE, 200 M (ISO) 1' . 10 ton 1
12 Torque wrench 36 kgm, 72 kgm 1 each 36 Lighting (Match with power source) 1 set 500 W x 5
13 Spanner 70,55,50,27 mm 1 each 37 Drum can valve 1
46,41,36,32,30,24, 22 mm 2 each 38 I Drum can scanner I I 1I I
14 Ring wrench 60,70 mm 1 each 39 Oil catcher 1 box
15 Pipe For extra tightening 50@x 2 m,30@ x 1 m 1 each 40 Waste oil drum 200 e drum, 18 e drum 113
_.
16 Large hammer 10 pound 2 41 Pipe wrench Handle Length = 400 mm or equivalent 2
17 Bar Im 2 42 Oil containers Large, Medium, Small 12 each
1.5 m 1 43 Grease pump For nail can (air tvoe) 1
18 Hammer 4 pound 2 44 Hand pump For supplying oil 1
19 Air grinder Diameter of grinder: 180 mm, 100 mm 1 each 45 Extra paint Komatsu Yellow spray can 12
20 Air pencil grinder NTB-48, Made by NPK 1 Komatsu Space blue spray can 12
21 Water pump pliers Made by SANKO, GWP-400, GWP-300 1 each 46 Air conditioner gas charger 1 set
21-1 Wrench (x 4)(lnput:19 Output:25) 25O - 60 mm Socket 1 each 47 Protective glasses For gas, for grinder 2 each
22 Hexagonal wrench set 2, 3, 4, 5, 6,8, 10, 12 mm 1 48 Wateroroof sheet 5mx5m 2
23 Standard tool set Made by TONE, 700A or equivalent 3 49 Nail remover 2
24 Wire 12Qx5m 4 50 Thread tightener For synthetic rubber (in tube) 1
16ox2m 4 51 Hydraulic oil ENG OIL EO-10 lOOO&! For adding
20qx5m 4 52 Diesel oil 6001 For adding
2O$x3m 2 t_
3O$x3m 4 54 Detergent Trichlorethane 2001
30Qx5m 4 55 Grease G2-LI 20 J! can (pail can) 7
25 Nylon sling 25mm(W)x3m 2 , Komatsu cartridge I 5 , Including hand puml;l
50mm(W)x3m 2 Grease Mobil TAC81C 20 liter can (pail can) 3
26 Shackle SD22, SC55 4, 2 See separate sheet 56 Cleaning tools White cloth, bamboo broom, etc, 20 kg, 3
sc40, SC34 4 each See separate sheet 57 Protective clothes and equipment Leather gloves, Thick gloves 2,5 (doz)
sc30, SC14 4 each See separate sheet Raincoat (L) 7
26-1 Set wrench (Made by CANON) SPK-24,32,36 1 each Safety rope for high places 3 set
Width across flat: 41,46 mm (Special order) 1 each 58 Safety rope Keep out signs, rope 5,50m
26-2 Brush, cleaning tools Brush, paper, etc 1 59 Notice board Magnetic board, felt pens 1 set
27 Block for contact with wire Only metal blocks 4 60 Engine oil EO-30 6Oe
(NEW) JIS TYPE SHACKLES
l Dimensions of the SC shackle body (Unit: mm)

Nominal
Shackle
codes
t d B D dl thread dia- Ll
meters (dz)
14 14 14 24 36 18 Ml6 56
30 30 30 45 75 37 M36 120
34 34 34 50 85 41 M39 136
40 40 40 60 100 49 M48 160
55 55 55 83 138 67 M64 220
SC shackle body
l Dimensions of the SD shackle body (Unit: mm)

t Nom in al
Shackle
01 B .D dl thread dia- Ll
codes
d meters (dz)
22 22 44 50 28 M27 88
SD shackle body
54
HEXAGON HEADED BOLTS, EYEBOLTS AND EYENUTS
. 4
a
z
Q
w -_
t.
.-- .
of flat point
P-m
b
-.-__-._
- --
Oval
Hexagon headed bolts l Upper

. iGit: mm
Nominal thread diameters (d) 4~ k s e dkt r d, z

S6&rd _A---
Standard S&&rd
Coarse thread ’ Fine thread
size
Tolerance Toterawe Tolera_n,ce Approx. A$rox. ‘#Mih. ‘Max. Approx.
_-.-. size size
.
? 3 I G5 64 I;fi 01 96 of;
--
- (M 3.5j
---. _ 1 13.5 i-41 * 0.1 i’ ii: 9 ;: i 0: 1 i i 0: 6
--_-M 4 4 0 2.8 .7 0 8. 1 6.8 0.2 4.7 0.8.
(M 4.5) 4.5* -0.1 3. 2 8 -0.2 . g-2 7.8 0.2 5. 2 0. 8
M5- - 5 3.5 8 9.2 7.8 0.2 5.7 0.9
M 6 6 * 4 * 0.15 10 11.5 9.8 0. 25 6.8 1
55
Shape, dimensions and applicable loads for eyebolts
Tapped hole shape
Always round
the under
Vertical
head section 45” hoisting
hoisting
at a radius of
rl or more.
JL Unit: mm
I
Nominal thread H ~ Applicable loads
diameters
I I e 9 YI da ri k
:Veftical, ;45%istingr). .
--I--- ,(Per2eyebofts),
I ’hoisting
(d (Reference) \ (Min.) (Min.)1 &ax.) (Approx.) (Appm kN kN
M8 32.6 3 6 1 9.2 4 1.2 0.785 0.785 *
Ml0 41 41.5 18
Ml2 5 9.4 1.4 14.2 6 2

M 16 60 60 27 5 13 1.6 18.2 6 2
M20 72 6.18 1 6.18

M24 90 90 38
M30
M36 22_,6 1 22.6
M42 65
h148
M64
. M8Ox6 263 105
(M9ox6)
~1100x6 340
Shape, dimensions and applicable loads for eyenuts

a
+I
Verticalhoisting 45”hoisting
Unit: mm
Nominal thread a h c D I /I iI . c-i’ Applicableloads

diameters (Reference) (AXIAL.)
Vertical .45”hoisIing
(‘)
(d) hoisting (Per2eyebofts)
kN kN
M8 32.6 20 6.3 16 12 23 39-3 8 8.5 0.783 (I _785
M 10 4.1 25 8 20 15 28 48.5 10 10.6 1 _3.7 I .17
M 12 50 30 10 25 19 36 61 12 12.5 2.16 2.16
M 16 60 35 12.5 30 23 42 72 14 17 4.41 4.41
M 20 72 40 16 35 28 50 86 16 21.2 6.18 6.18
M 24. 90 50 20 4.5 38 66 111 25 25 9.32 9.32
M 30 110 60 25 60 46 80 135 30 31.5 14.7 14.T
M 36 133 70 31.5 70 55 95 161.5 35 37.5 22.6 22.6
M 42 151 80 35.5 no 64 109 184..5 40 45 33.3 33.3
hl 48 170 90 4.0 90 73 123 208 45 SO 44. 1 1.4. I

*--
hl 64 210 II0 SO 110 90 151 256 50 67 H8.2 lllj _2
hl 80x6 2w 14.0 03 I 30 108 18.1. 317 00 f1S 137 I :I7
56
ASSEMBLING PROCEDURES
A. ASSEMBLY OF CHASSIS
Assemble the machine body according to the instructions given on the following
pages.
57
A-1: Assembly of track frame and axle (I/3)
Track frame ass’y (RH)
Track frame pss’y (Ltf)
Precautions Tools and equipment required
Install the travel motor guard (bottom) to the Name Qw Name Q’ty
trackframe at this point. Power wrench (Xl 6) 1 Hydraulic jack 50t 2
(21T-98-11120) Truck crane 45t 2
Socket 3FX 70 mm 1 Axle stand 2
(21T-98-11190)
Handle (21T-98-11130) 1
KW45F Impact wrench 1
Spline socket 70 mm 1
Others
58
A-I: Assembly of track frame and axle (Z/3)
1)Place
the left trackframe assembly as shown in the diagram on
the left.
2) Raise the axle assembly with a 45ton crane and joint it.
3) Before doing this, remove the plugs from the connection SW
View from roar face and make the surface clean.
4) After inserting all the bolts, tighten them temporarily and sup-
port the right side only with a jack.
5) Raise the right track frame assembly with a 45ton crane and
connect it. When doing this, the assembly is easier if the jack un-
der the axle is made slightly higher.
6) After inserting all the bolts, tighten them temporarily, and tower
the crane.
7) Remove the jack.
BeroLe join, IJ& dnly stands.
After connectingleft track frame, left stand is not
needed.
200
Pipe *
500
Method for slinging track frame
It is easy to align the holes if two cranes are used to sling the track
frame.

efore raising with crane] 0376-00600 Name Q’ty Name Q’tj
Check that protrusion (A) of the HIC
Blind plug Pin 500 X 400 mm 2 Crane 45t 1
cylinder plunger is approx. 10 mm. \ /
(Hard steel) Crane 45t 1
wire 300 X 8 m 2
(general use)
the protrusion is not approx. 10 mm, Others

rmove the blind plug from the hose and
*ain the oil inside the cylinder. After doing this,
stall the blind plug in the hose again.
59
A-1: Assembly of track frame and axle (3/3)
1) Make the clearance between the track frame and axle zero. If necessary, jack up the
track frame.
2) Tighten the connecting bolts fully.
Power wrench (x16) + 36 kgm torque wrench
Input: 30 kgm
Parts sent individually

Note: If more than 35 kgm input is applied, the power wrench may break.
No. 1 Part No. 1Q’ty
- (Order for tightening>
Precautions 1 Tools and equipment required
I Name Name
50 ton jack 1
Others
k
60
A-2: Travel motor piping (l/Z)
I Parts sent individually
1 I
Connect to the place

marked m .
Precautions 1 I Took and equipment required
Be careful not to let any dirt get in Name -7 ctvl Name

1 KWl2PI Impact wrench 1 1 ]
1 KW14PI Impact wrench 1 1 ) I
1 19 mm, 22 mm Sacker-11 WCII/*
] 150,300 mm Extension (1 each\
I Others 1
A-2: Travel motor piping (drain piping) (2/z)

marked m .
Width BWOSS flats : 32

Portion P

Name Q’ty Name
KVVIOPImpact wrench 1
17 mm Socket 1
24,32 mm Spanner 1 each
,
Others
62
.
A-3: Idler cushion cylinder piping
When connecting the parts

marked w , use blind
plugs when assembling.
Tightening torque: 2.8-3.5 kgm

(Width across fiats: 13 mm)
(M8)
with the bolts and washers

nto the track frame.

Name Q’ty Name cYt\
KWlOP Impact wrench 1
KM/l 2PI Impact wrench 1
17 mm Socket 1
19 mm Socket 1
Others
63
A-4: Installation of travel motor guard and track frame under cover (l/Z)
44 01580-11210 4
44A 01641-21223 12

Name Q’w Name Q%
KWIZPI lnpactwrench 1
19mm Socket 1
Others
64
A-5: Filling swing circle with grease
4)Coat with LG-6.
1) Fill swing circle grease bath with 170 liters of grease (G2-11).
2) Coat grease on swing circle gear contact surface.
3) Fill grease bath seal with grease.
G2-LI
Precautions Took and equipment required

Name Q’W Name Q't y
Others
66
A-6: Assembly of revolving frame assembly and axle assembly (l/2)
1)Position for crane, revolving
frame
2) Method of slinging front end

__.-
Rear of boom foot pin
300 X 8 m General wire x 2
- SC40 shackle
or equivalent
- SC55 shackle
or equivalent
3) Method of slinging rear
Fit wires to this part of the revolving

frame
rear in the same way as at the
Use two truck cranes at the front and rear, and lift together-
Make sure that the wire is fixed properly to the Name Q’ty Name Q’ty
hook ! As given above
SC55 shackle - 18 t
(inside width: 83 mm)
SC40 shackle - 10 t
Be careful of the center

of gravity of the crane
Others
(When load is applied, *
the boom will bend.
slightly.)
67
A-6: Assembly of revolving frame assembly and axle assembly (Z/Z)
1) Clean mount surface.

Dowel pin
2) Align with dowel pin hole of circle.
3) Raise revolving frame and connect.
. Do not let the center swivel hit the grease bath.
4) Temporarily tighten all bolts as far as they will go.
. Tighten fully after completion of assembly.
36 X 3
21T-25-67150
’ Tightening torque
250 - 310 kgm
Coat with LT-2A
t the whole connecting surface of the revolving Parts sent individually

I No- I Part No.
1 Cl9 1 21T-25-67150 I 60 I
1 C20 1 01643-33690 I 60 I
Tightening torque
5) Tighten 3 bolts each (total

6) at the places marked
m’ in the diagram
(left and right} to the speci-
fied tightening torque.
I

Name IO’WI Name )Q’ty
When tightening temporarily
KW45F Impact wrench 1
1-55 mm Socket 1
When tightening fully
I KVV45FG Impact wrench I I / I I

I- 55 mm Spline socket I 1 I I I
Others
68
A-7: Swivel travel piping (l/Z)
1) Remove the blind plugs from the

hoses marked * and the blind plugs
from the swivel at the points marked
w before connecting.
(Blind plugs are used at 4 places.)
2) Install the swivel stopper plate.
(The part is temporarily is installed to
the revolving frame and swivel.}
201-60-l 1230
Blind plug at swivel end

0737811410 (4)
07371-51470 (8)
01010-51455 (16)
01643-31445 (16) Tightening torque: 16.0 - 20.0 k&l
07000-l 3048 (4) Width across fiats: 22 mm
Be careful of the o-rings. Name Q’ty Name Q’ty

KW14PI Impact wrench 1
22 mm socket 1
150 mm Extension 1
Pincers or pliers 1
Others
69
A-7: Swivel travel piping (Drain hose) (2/2)
1) Connect swivel drain hoses. (2 places}

(The parts marked * are installed to the swivel.)
Instailed to revolving
frame assemblv
A- -
,Blindplug at hose end 07376-50628
Hose 07102-20607
,Hose 07102-20311 I _
07222-00616 (1)
at swivel end
. .

Name Q’ty Name Q’tj
24 mm Spanner 1
1 36 mm Spanner I 1 I I
t I 1
Others
70
A-8: Swing circle grease tube piping
1)Remove the blind plugs at the places marked

@j=’ before connecting. (4 places}
l The parts marked * are installed to the swing circle.

l The grease tube is included in the revolving frame assembly.

Name Qw Name Q’ty
14 mm Spanner 1
Others
Part sent individually Part sent individually
No. I Part No. I Q'ty No. I Part No. 1 1 Q’ty

1 I 21T-72-19350 I 1 26 I 2 1T-68-67230 I 2
2 *I 08036-01214 Tmm 2 27 I 21T-70-71460 I 2
3 I 01010-81225 I 2 28 I 07002-03034 I 2
01643-31232 I 29 I 21T-68-71140 I 2
5 I 2 1T-68-72290 I 1 3o I 20 l-62-28540 I 6
6 I 07282-l 1048 I 5 31 I 207-70- 11730 I 20

7 I 01010-80612 I 6 .32 I 21T-68-67480 I 4
8 I 0 1642-206 19 I 7 33 I 01010-81025 I 8
9 I 21T-68-67450 1 1 34 I 01643-31032 1 8
10 I 2lT-68-67310 1 1 35 I 21T-68-67470 1 4
l1 I 21T-68-67320 I 1 36 I 01010-81035 I 8
l2 I 21T-68-67330 I 1 37 I 01643-31032 I 8
l3 I 21T-68-67340 I 1 38 I 21T-68-67490 I 2
14 2 1T-68-67440 1 39 01010-81025 4
15 21T-68-67350 1 40 01643-31032 4
16 21T-68-67360 1 41 21T-68-67510 2
17 2 1T-68-67370 1 42 01010-81055 4
18 21T-68-67380 1 43 01643-31032 4
19 21T-68-67550 2 44 21T-68-67190 3
20 01010-81025 4 45 01010-80825 3
21 01643-31032 4 46 0 1643030823 3
22 2 1T-68-67460 2 47 04435-50808 3
23 01010-81035 4 48 01010-80820 3
24 01643-31032 4 49 01643-30823 3
25 I 207-70-11740 I 10 I I
72
73
-----my-
L__ L__--------- -______ - -_-mm
------_-__-______-__-~--
‘\
74
A-9: Installation of left and right ladders
Install ladders to left and right track frame.

Name Q’ty Name wty
KVV12P Impact wrench 1
24 mm Socket 1
150 mm Extension 1
012, 5 m Wire 2
Others
76
A-10: Installation of left-hand catwalk
Transport parts
marked with *
without removing
them from catwalk

Name Qw Name Q’ty
KW12PI impact wrench 1
19-mm socket 1
012.5-m: wire 4 pcs.
Others
A-l I: Installation of right-hand catwalk
200 2 IT-54-69430 1
201 01010-81235 8

Name Q’ty Name CYty
19-mm socket 1
@12.5-m wire , 4 PCS.
Others
78
A-12: Installation of catwalk and handrail by side of operator’s cab
No. Part No. O’ty
38 01010-81225 4
39 01643-31232 4
40 2 1T-54-69450 1
41 01643-30823 4
42 01580-10806 4

No.
47 21 N-54-32670
48 2lT-54-79611
49 2lT-54-79620
50 01252-41025
54 2lT-98-72180 Parts sent individually
Q’ty
1 2 1T-54-69930 1
2 2lT-54-75163 1
3 01010-81235 29
4 175-54-34170 31
For installation
of catwalk 5 01580-11210 2
6 2lT-54-69780 1
33 2lT-54-69870 1
34 01010-81225 12
35 175-54-34170 9
36 01643-31232 3
37 2lT-54-69880 1

Name o’ty Name Q’ty
KWl2PI impact wrench 1
1g-mm socket 1
#I 2.5-m. wire 4 pcs.

No. Part No. Qw
43 209-54-31170 1
44 202-970-I 220 1 Others
45 04050-13018 2
46 01641-21016 2
79
A-14: Installation of handrail for getting in and out of operator’s cab
Precautions 1 I Tools and equipment required

Name I Q’w I Name -l-K
1 KWIZPI impactwrench 1 1 1
( 1%mm socket I 1 I I
1 pr12.5-m wire 14PCS.1
k
Others
80
A-14: Installation of operator’s cab handrail
(Low cab specification)
Operatix’s
cab frame
O’IOIO-81230 I IO
1 All ! 175-54-34170 I IO
/Al05 1 21T-54-75650 I -l
IA706j 07010-81235 I 2 i
ro/i 01643-31232 . 1 i-1
t 1-
Name Q’ty Name Q’ty
19 mm Socket 1
012, 5 m Wire 4 *
Others
81
A-16: Installation of handrail at rear of operator’s cab
29.7 kg

I No*I Part No. 1Q’w
1A51 1 2171-54-67480 11
1 A521 01010-81235 1 4
] A531 175-54-34170 1 4

Name IQw Name IQ-Y
1 KWI2PI k-n&t wrench / 1 1
19 mm Socket 1
012, 5 m Wire 4
I Others 1
82
A-18: Operator’s cab front frame, handrail

KYVl2PIImpact wrench 1
19 mm Socket 1
012, 5 m Wire 4 ’
Others
83
A-19: Left deck handrail
29 kg

Name Q’tY Name

19 mm Socket 1
pIl2,5 m Wire 4
Others
84
A-20: Right deck handrail
Parenthesized part numbers are

+55OC specification parts.

Name Qw Name
KWIZPI Impact wrench 1
19 mm Socket 1
@12,5 m Wire 4
Others
85
A-21: Installation of ladder for climbing up and down hydraulic tank

Part No. bY
1 63 1 ZIT-54-68650 I 1
1 64 1 01010-81240 18
1 65 1 01643-31232 I 8
1 66 1 01010-81230 18
I 67 I 175-54-34170 I 8
1 72 1 21T-68-67610 1 1
Precautions I Tools and equipment required

Name Name
1 KW12PI impact wrench- 1 1 1

1 19-mm socket
I 150-mm extension I 1 I I
@12.5-m wire 14pcs.I
1 Others
86
<Tightening procedure>
(I) Tighten with KW45FG impact wrench Low-cab standard work
and +65-mm spline socket. equipment
(Approx. 250 kgm) l/T_& - 6716so. -

(2) Retighten with 16-time wrench to speci-
fied torque.
(Input: 30 kgm)
Tightening torque: 350 - 450 kgm

Apply LT-2.
Width across flats of bolt = 65

Name alty Name Q’ty
Precaution for applying LT-2 KW45FG impact wrench 1 Shackle equivalent to SC40 2
Before applying LT-2, remove all rust-
Spline socket, 65 1
preventive grease from tap holes.
Power wrench, 16 times
Ratchet handle
38-mm0 - 65-mm socket
36-kgm torque wrench
030, 5-m wire 2 pcs.
Others
87
A-23: Installation of counterweight ladders (left and right)

No. Part No. Q’ty
Cl23 21T-54-67431 I
Cl24 01010-81230 8
Cl25 01643-31232 8
C54 21T-54-67440 1
C55 01010-81230 8
C56 01643-31232 8

Name O’ty Name Q’ty
KVVI2PI Impact wrench 1
19 mm Socket 1
150 mm Extension 1
012, 5 m Wire 4
Others
88
Name Qw Name Q’ty
19-mm socket 1
150-mrrj extension 1
@12.5-m wire 4 pcs.
19 spaner
I
Others
89
A-25: Installation of fuel tank vibration stopper bracket
Shim

No. Part No. WY
c4 21 T-04-7 1230 28
1 c5 1 01010-81685 I 8
Ice I 21 T-72-l 2620 I 8
1 C7 f 21T-04-71190 1 2
Ia I 21T-04-71121 I 2
] Cl0 1 195-03-41260 1 2
fCl1 ] 01010-81630 j 2
1Cl2 1 01643-31645 I2
1Cl3 t 2lT-0171290 1 28
/Cl4'( 01010-81650 18
1615 1 0X43-31645 1 8
y/2* 1 Cl 6 1 209-03-51160 I 4
CD 1Cl7 1 01011-82050 I 4
For the partssent individually,
transport the parts marked * as ] Cl8 1 01643-32-60 I 4
a su b-asem bly.

Name IQ’WI Name 1Q’tj
1 Kw2OP Impact wrench1 1 T I
1 KVV2OPI Impact wrench 1 1 1 I
1 24 mm Socket I 1 I I
30 mm Socket.,
I Others 1
90
A-26: Installation of grease reel, hose, and bracket
Included in
revolving frame A

Send (91), (92), (93), (971, (98), and (99)
KWIOP impact wrench 1
in sub-assembly.
KWIZPI impact wrench 1
17-mm socket 1
19-mm socket 1
Others
91
A-27: Installation of left cab base assembly (l/5)
(LOWcab specification)
f(Egg_ 1) Installation of cab base

lnstali with parts marked *.
2) Connection of left and right floor

frames
lS3
Connect with parts marked *.
Rigtrtfltor frame
(set on revolving frame assembh)
6 z
b3
1 A *X\..
z9
Left floor frame
30 k
(set on left cab base assembly)
8
. - .

Name Q’w Name Q’ty
Others
92
(1) Install right-hand
(Set to left-hand
cab base A.) _
Others
93
A-27: Seat belt (315)
No. Part No. Q’ty
68 07010-81045 2
69 01602-21030 2
66 09049-00002 2
67 09049-00003 2

Others
94
A-27: Sub-seat assembly (4/5)
No. Part No. Q%
86 09495-40000 I
09495-00000 1
87 01010-80616 6
88 0 1643-30623 6
84 01643-30823 4
85 14X-911-7741 4

Name Qw Name Q’ty
Others
95
A-27: Defroster (515)

Name O’ty Name Q’tj
Others
96
A-28: Installation of operator’s cab
Operator’s cab

Name IQWI Name I Q’ty
Above parts for high-cab specification
included in operator’s cab A.
are
1 KWl4PI impact wrench l 11 I
1 22-mm socket I 1 I I
I 150-mm extension I 1 I I
Others
t- A
97
A-29: Installation of wiper motor cover inside operator’s cab
Install as shown in diagram on left.
. . .
No. / Part No.
.. .
*: Being shipped in assembled state to the cab base.

1 1 I
For the high cab specification, the above parts ,
are included in the operator’s cab assembly. KWl2PI Impact wrench 1
19 mm Socket ‘I
Others
I
98
. ,
A-30: )
.._ ._ _’ .-.-.-C.-.+ &_
A-31: Handrails above the RH door and above the hydraulic oil tank

No. j Part No. j Q’ty
/ ?lT-54-78320 1
80 / ZIT-54-78310 1
1 84 / 01643-31032 I 16
1 85 1 ZIT-54-68510 I1
158 ZIN-54-32670 2
159 ZlT-54-79631 2

A-32: Emergency stop switch and emergency fuel cut (l/2)

No. Part No. Q’ty
136 ZIT-54-69960 1
137 21T-54-67580 1
141 8221-06-1470 1
142 8253-06-1210 1
143 01010-80620 2
144 01643-30623 2
145 8253-06-1220 1
146 01010-81020 2
147 01643-31032 2
.b 148 08053-01512 1
i
149 01010-81225 1
L
I I_
I
t

Name Qw Name CYty
Others
101
A-32: Emergency stop switch and emergency fuel cut (212)

Others
A
102
A-33A: Handrail above the radiator (Optional)

No. Pat-t No. Q’ty
162 2171-54-68510 1
163 OIOIO-81230 12
164 01643-31232 12
] 165 1 2'lT-54-69520 11
1 766 1 01010-81230 I 5
) 167 ) 01643-31232 ] 5
168 2OY-54-12990 5
169 2OY-54-19930 5
1 170 1 01010-81230 / 5
1 171 ) 01643-31232 1 5

Name I Q’w I Name / arty
Others
I
A-33B: Connection of hydraulic piping operator’s cab assembly (l/3)
~~~ ~__ ~~ ~
Connection of PPC pirot piping
Left PPC valve (arm, swing) a
Connect the PPC piIping between the left
/ hCrCI
bau
Lcrnnassemory
uaat:
AA-- ’ ’ and the right cab base
assembly and revolving frame assembly
at the place marked w .
PPC vralve for
Part No. I O’ty
Remove the blind plug marked m , and

connect the hose to the elbow and union of the
PPC valve.
Use 12 hoses (03) and 6 hoses (04). .
Name (Uty/ Name / Q’ty

24 mm Spanner 1
27 mm Spanner 1
I Others I
A-33B: Connection of hydraulic piping operator’s cab assembly (z/3)
Pipingsfor the travel PPC valve and LH PIT valve
Pipings for the travel PPC valve
--
ightward backing travel (Blue)
ard backing travel (Green/Black)
Rightward forward travel (Green)
Leftward forward travel (Red/Black)
Pipings for the LH PPC valve
(An-nswing)
port “T” tBlue/Blue)

Others
105
A-33B: Connection of hydraulic piping operator’s cab assembly
(PPC pilot piping)(3/3)
Connection circuit for PPC piping

Others
106
A-34: Connection of window washer hose of operator% cab
assembly
Connect to check valve

marked w .

No. Part No. wty
*
Check
19597
I I
Revolving Flame
I
J
I
*
Washer hose - - - - - - - -
21T-06-11411

Parts marked * are common for both the low
cab and high cab specification.
(Left cab base assembly)
Others
107
A-35: Connection of piping of left cab assembly (l/2)
Air piping (Air horn)

marked m
Width across flats: 17

Tightening torque: 0.70 - 1.00 kgm

Name Q’tv Name Q’ty
Others
A-35: Connection of piping of left cab assembly (2/2)

Others
109
A-36: Connection of grease piping of operator’s cab assembly
(operator’s cab + high cab base) (1) (l/Z)
(Common for high cab specification and low cab specification)
ro main distributor on boom
Cqnnect 4 hoses
marked m .
Wind end of hose

19 -(Width across flats)
Upper structure ass’y
These parts form an assembly with the uper Name a’tv Name Q’ty
structure. 19 mm Spanner 1
Others
110
A-36: Connection of grease piping of operator’s cab assembly
(operator’s cab + high cab base) (2) (2/i?) i
Install
to operator’s cab assembly
Connect 1 h&e at part

marked w’ .
PFl I4
19 (Width across flats)

21 T-72-1 7690
Grease pressure gauge mounting position for low cab
partssent individually for high cab
!Q - -..
2700)_
Wind end of hose with
white tape
21 T-98-71 140
(High cab) Left cab base assembly
For the low cab, these parts are still connected Name QW Name Q’ty
to the left cab base assembly. KWI 2PI impact wrench 1
19 mm Socket 1
19 mm Spanner 1
I50 mm Extension. 1
Others
111
A-37: Wire harnesses
(Washer tank, working lamp and operator’s cab base light)
Make this connection.

No. f Part No. / QW

Others
112
A-38: Air conditioner discharge hose piping (I/5)
(Inside of left-hand cab base)
nt pillar of operator
Rear air conditioner: View from above

Name Q’ty Name
Air conditioner discharge piping must not
KWIZPI lnpact wrench 1
be installed over fresh air filter of rear air
conditioner unit. 19mm Socket 1
7mm spaner 1
- driver 1
150mm extension 1
Others
113
A-38: Air conditioner discharge hose (Right-hand cab base) (215)
From front air From rear air

conditioner
conditioner
(Rear) (Rear)
1107 1 21T-979-6290 I1
I108 1 07281-07159 I 3

Name Q’ty Name Q’t\
Others
114
A-38: Air conditioner hose, harness and piping (3/5)
(Harness)
(Inside the LH operator’s cab base)
conditioner
Make these
Make these
connections.
connections.

Name Qw Name Qw
Others
115
A-38: Air conditioner inside air suction duct hose (4/5)
Inside of cab base

Part No.
109 07281-02169 4
1 IO 21T-979-6710 2
Precautions ] I
c
Tools and equipment required
I
Others
116
A-38: Air conditioner hose, harness and piping (5/5)
(Piping)
Tools and equipment required

Name lQw/ Name I
Others
A-39: Installation of counterweight lamp (option)
1) Mount the rotating lamp and bracket

with three M8 nuts (01580-00806).
2) Install clips (133) and (134) with Ml 2.
Rotating lamp (yellow)

This applies when installing the rotating lamp .
on the top surface of the counterweight as an 13 mm Spanner 1
option.
KWl2PI Impact wrench 1
19 mm Socket 1
Others
118
A-40: Start engine (I /6)
1. Check before starting. \

l Check cooling water level, add water
l Check level of oil in engine oil pan, add oil
l Check fuel level Refer to M-l Inspection and
l Check level of oil in hydraulic tank, add oil servicing procedures.
l Check level of oil in PTO case, add oil
l Check level of oil in swing machinery case, add oil
/
2. Check for oil leakage.
3. Bleed air from main pump (see next page).
4. Start engine (slow).
5. Bleed air from swing motor.
6. Bleed air from travel motor.
7. Bleed air from HIC circuit, fill with pressurized oil, adjust track.
8. Stop the engine and refill hydraulic oil.
9. Check for oil leakage.

Name Q’ty Name CYty
Others
119
A-40: Start engine (Z/6)
Bleeding air from main pump - Bleed the air before starting the engine.
1 Bleeding air from pump
Before starting the engine after completion of local assembly, bled the air as follows.
1) Check that the hydraulic oil is at the specified level.
2) Loosen drain plug (A) of the swing pump 1 - 2 turns, and bleed the air until no more bubbles
come out.
3) After this, start the engine and run it at low idling. (Do not raise the engine speed until the bleeding
of the air is completed.) Continue to bleed the air until no more bubbles come out from the air
bleed plug. (Carry out this procedure for the engine front pump and rear Pump.)
4) After completion of bleeding the air, tighten plug (A).
(Tightening torque of plug: 0.8 - 10.0 kgm)
5) Raise the engine speed to 1500 rpm and run the engine for 5 minutes.
(Do not raise the engine speed above 1500 rpm until the bleeding of the air is completed.)
6) After bleeding the air, add hydraulic oil to the specified level.
7) Carry out this procedure for both the front and rear engines.
+~~dthacrOssflaB: 10 1
Bleeder (ZOB-27-11210)

10 mm Spanner 1
Others
120
A-40: Start engine (3/6)
Bleeding air from swing and travel motors

Bleeding air from motors
1. Travel motor
U2982
Start the engine and run at low idling. Loosen bleeder (B) of the swing mo-
tor 1 - 2 turns.
Loosen bleders (A) of the travel mo-
tor 1 - 2 turns. Start the engine and run at low idling.
* Loosen the bleeders for all four Bleed the air until no more white
motors. cloudy oil comes out from bleeder
(B).
Bleed the air until no more white
cloudy oil comes outfrom bleder (A). After completing bleeding the air,
tighten bleeder (B).
Parts sent individuafIy
After completing bleeding the air,
tighten bleeder {A}. * Tightening torque: 0.9 +, 0.1 No- Part NO. Q’ty
kgm
* Tightening torque: 0.9 + 0.1
kgm * Carry out the same procedure for
the two motors at the front and
rear.
Bleeder (206-27-l 1210): Same for both

swing and travef

Name Io’tyI Name Q’ty
IO mm Spanner 1
10 mm Socket 1
Ratchet handle 4 *
Others
121
A-40: Start engine M/6)
Bleeding air HIC circuit and filling with pressurized oil

The idler cushion on the PC1800 uses a hydraulic cylinder. The forms a closed circuit, SO please bleed the airfrom
inside the circuit.
(To prevent burning and damage of the seal, bleed the air before moving the machine.)
1) Loosen stop valve @ and drain valve 0.

2) Loosen air bleed plugs @ (left and right, 2 places) and @ .
3) Start the engine and run at idling for 2 - 3 minuts. Bleeding air
4) After checking that oil comes out from air bleed plugs @I (2 places) and @ I tighten
drain valve @ and air bleed plugs @ (2 places) and @ . I
5) Operate the right travel lever four times in turn to the FORWARD and REVERSE posi-
tions (2 - 3 seconds).
Filling with pressurized oil
6) Check that hydraulic cushion cylinder rod @ moves out 135 Z!Z5 mm.
7) Tighten stop valve @ . t
8) Raise the chassis with the boom and arm, and pump in grease through grease fitting
Adjusting the track shoe
@until there is a clearance of 150 - 200 mm between the roller tread surface and the 1
J
assemblies
track link at the 4th track roller from the sprocket.
* If the track tension is adjusted by pumping in grease without adjusting the hydraulic
pressure, an excessive load will act on the undercarriage and may cause it to break.

Name QW Name Q’ty
I} See the circuits on the next page.
2) When turning the stop valve and drain 209-98-l 1140 . 1
valve, use the special tool (handle: 209-
24 mm Spanner 1
98-1 1140).
3) When bleeding the air or filling with pres- 19 mm Spanner 1
surized oil, loosen grease fitting (lubrica-
tor) (6) one turn. After finishing filling with ’
pressurized oil, tighten the lubricator.
(Refer to page 6/6.)
Others
122
A-40: Start engine (516)
HICcircuit
Width across flats: 24.
Bleeding air from HIC circuit Air bleed plug @
(2 places)
198-30-l 4420
across flats: 24
ming torque:
6 - 9 kgn
RIGHT
TRAVEL
FORWARD
L’T(F)a\ - rla ._ __ _...
////////////////////A I
L-,-d
/ ----A Y\ Drain valve @
Swivel joint 21 T-60-1 2250
703-l 573200
21T-60-12250 (2)
-e
-l
209X50-31 110 \ Air bleed plug @I
198-30-l 4420 .
(cf... HIC circuit of PC1506) I Parts sent individually

Part No.
m2
0 kg/cmL 198-30- 14420
I Others 1
123
A-40: Start engine (616)
Supplement to “Adjusting the track shoe assemblies”
1. When increasing the tension of the track shoe assembly, press-fit

grease through the lubricator (07959-30000).
i - -7
Z.When alleviating the tension of the track shoe assembly, loosen the
. ! -
lubricator by a turn to discharge grease. (Refer to the Operation and
.*
.
Maintenance Manual regarding the track shoe assembly adjusting
procedures.)
L
Lubricator
3.Do not loosen the lubricator by any more then a single turn.
Also, do not loosen other parts than the lubricator. Since the internal
space if being filled by highly pressurized grease, negligent loosen-
ing of the lubricator is very dangerous.
4.After finishing the adjustment work, be sure to tighten the lubricator

securely.
-
02 .
Tightening
,Width
torque:
across fiats: 19
6 - 9kgm

Name QW Name Q’ty
(cf.)
PC1500 is equipped with the discharge plug (198-
30-1 4420) and lubricator (07959-30000).
Others
124
A-41: Final tightening of swing circle mounting bolts
In assembly procedure No. A-6, only 6 of the 60 mounting bolts for the revolving frame and swing circle were tigh-
tened fully. The remaining 54 bolts were tightened partially, so tighten these remaining 54 bolts.
(Procedure]
1) Start the engine. (Follow the procedure given in assembly procedure B-40)
2) Swing the upper structure and tighten the bolts when they come to one of the places marked mS (54 bolts)
l@dth across flats: 55

Tightening torque:
01 250 - 310 kgm
M 36
.
Coat the whole circumference of the revolving frame connecting
surface with LG-6 (TB1215) without le
(Coat the inside of the bolt h&s.)
Tighten this bolt

KW45FG Impact wrench 1
55 mm spline socket 1
Others
125
ASSEMBLY OF POWER-ASSISTED LADDER
127
Left side view of machine with power-assisted ladder
Top view of machine with power-assisted ladder
E
_P. -
128
PARTS TO BE REMOVED FROM STANDARD MODEL FOR INSTALLATION OF
POWER-ASSISTED LADDER
Catwalk and handrail on left side of machine body

Name Q-Y Name Q’ty
Others
129
L-l : Power-assisted ladder (l/4)

I
No. Part No. Q‘tv
0/fJ 88I/
42
I3
/ I
v-
*.
-
1
2
3
X2 10665680
2 IT-54-69551
21T-54-69541
I
1
1
4 01010-81225 8
5 01643-31232 8
6 01010-81225 6
7 01643-31232 6

130
L-l: Power-assisted ladder (Z/4)
To page 130

4
Name Q’ty Name O’ty

No. Part No. O’ty
27 04205 17 645 1
28 04050-14028 1
29 2 IT-54-66420 1 Others
30 01010-81225 2
31 01643-31232 2
131
L-l : Power-assisted ladder (3/4)
To page130

Part No. IQ ‘t 1
1 32 1 ZIT-54-66330 I1
( 33 I 170-33-13370 I 1
f 34 1 ZIT-54-66430 1 1
1 35 t 01010-81220 1 2
] 36 1 01643-31232 1 2
1 38 1 195-49-13840 1 1
) 39 1 04205-11645 1 1
1 40 1 04050-14028 I 1
41 2lT-54-66390 1
42 01010-81235 4

Part No. IQWI
43 1 01643-31232 I 4 I
) Others I
32
L-l : Power-assisted ladder (4/4)
To CN-B57
Inside of 6p&-ator’s cab 53 UN-06-31390 1

53 ZIT-00-67330 1

Others
133
INSTALLATION PROCEDURES
C. PC1800
INSTALLATION OF BACKHOE WORK EQUIPMENT
In case of backhoe specification machines, make the installation works following

the designations in this procedures manual.
PRECAUTIONS:
I. Apply LM-P to the inside surfaces of all the shims and insert them carefully paying attention not
to damage the sealing.
2After finishing assemblies and installations and before connecting the greasing pipings, seal-in
molybdenum disulfide grease (LM-G).
135
C-l: Installation of boom cylinder to chassis (I/Z)
Method for sliding when installing boom cylinder
Wire to
Boom cyfnder /
Left: 2 1T-63-X23 10
Right: 2 1T-63-X2320
Both standard (short) and long are same.

Others
136
C-l: Installation of boom cylinder to chassis (2/2)
(Fitting of pin and revolving frame

(Clearance: 0.095 - 0.223)
hole)
[Procedure]
1) Remove the parts marked
* tightened to the revolv-
ing frame.
2) Raise the cylinder and set
in position at the pin hole.
3) Set the shim and spacer in
position and assemble the
parts marked *.
{Adjust the clearance at
places w so that it
is less than 1 mm.)
parts marked 6, fit the

wooden block marked *.
This holds the parts in po-
sition and makes assem-
36

1. There is a bushing press fitted to the re- _
volving frame, and the parts marked * are Hammer 1 45t Crane 1
temporarily installed for transportation.
36mm Socket 1
2. Clean and check the pin and inside surface
of the bushing. KW38G lnpact wrench 1
012, 5m Wire 2
016, 2m Wire 1
SC14 Shackle 1
Others
137
C-2: Installation of boom cylinder piping
For standard (short) boom

Remove the blind plugs from the revolving
frame piping and boom cylinder piping, then
install the 4 hoses as shown in the diagram
below.
Continue to use the split flanges, bolts, and

O-rings (marked *) used to install the biind
plugs.
I No*I Part No. I Q’tv
Temporarily assemble to __
chassis when transporting.
I. Be careful not to twist the hoses when in- Name IQWI Name I Q’ty
stalling. 1 22mm Socket I 1 I I
2. Be careful of the O-rings.
1 KVV14PIImpact wrench 1 1 1
Others
138
C-3: Bleeding air from boom cylinder
When assembling the boom, it is necessary to retract and extend the boom cylinder to align the position of the
boom cylinder top pin. Therefore, after assembling the boom cylinder, bleed the air as follows.
Bleeding air from boom cylinder

1) Run the engine at low idling, and extend and reract the boom cylinder 5 or 6
times without going to the end of its stroke.
(Stop approx. 100 - 200 mm before the end of iti stroke.)
Y%At first there is a large amount of air inside the cylinder, so the work equip-
ment may not move for the first ten seconds. However, do not operate the
lever to the end of its travel.
2) Next, extend the boom cylinder to the end of its stroke, and hold the control
lever at the full stroke position for 3 minutes.
3) Then, run the engine at high idling, repeat the operation in Step (2), and hold
the control lever at the full stroke position for 1 minute.

Name Qw Name Q’ty
Others
139
C-4: Boom sub-assembly (l/4)
[I] Installation of arm cylinder
Arm cylinder
[Procedure]
1) Remove the parts marked * temporarily
tightened to the boom.
Using forcing screws (Ml6), pull out the
ribbed bushing (*) approx. 20 mm.
(To prevent damage to the seal)
2) Raise the arm cylinder, and

align the pin hole position.
(The method of raising is the
same as for the boom cylin-
der. See C-l (l/2))
3) Set (14) and (15) in position,
1 ‘----+------._.. . then push in the ribbed bush-
--- - _. ing, and assemble the parts
marked $Y- .
) To protect the cylinder, put wooden
Wooden block
blocks under it.
5) Carry out the same procedure for the arm
cylinder foot on the left and right.
(6 x 4 places - 2
Section C-_c
(Do not press-fit these bushings.)
Transition-fit these bushings.
08
*+
l-l ie
Assemble the
when temporarily
transportation.
assembling the
O-ring (Gl5)
pin for

Name Q’W Name Q’ty
1. Check that the inside surface of the bushing
and pin are clean. 24 mm Socket 1 45t Crane 1
2. Be careful of the seals and O-rings.
KW2OP Impact wrench 1
Hammer 1
012, 5 m Wire 2
016, 2.m Wire 1
SC14 Shackle 1
Others
140
C-4: Boom sub-assembly (Z/4)
[Z] Installation of working lamp
1) Install the working lamp as shown in the

diagram on the left.
2) Connect the wiring at the place marked
uzF_
(The wire (*) is clamped to the boom.)
1. Parts sent individually
I No=I Part No. I Q’tY

1 G31 1 2OY-06-25310 I 2
1 G32 ] 2OY-06-21551 -17
1 G33 ( 01010-51430 ( 2
] G34 1 01643-31445 1 2
Precautions Tools and equipment required I

Name Q’ty Name Q’ty i
I
22 mm Socket 1
KVV14PI Impact wrench 1
Others
141
C-4: Boom sub-assembly (S/4)
[3]Installation of hydraulic hoses

Standard (short) boom
1) Connect at the places makred m - (12 places)
Continue to use the split flanges, boIs, and O-rings (marked
*) used to install the blind plugs.
r Blind plugs
07378-I 1410 (4)
The split flange is
07371-51470 (8) *
07000-13048 (4) * 07371-V 470.
Use Ml4 mounting bolts.
01 O-l O-51 455 (16) *
01643-31445 (16)*
22
l-lose

Part No.
1 F 2 107073~Wl418 8
F14 107073-01416 I 4

Name Q’ty Name Q’t
Be careful of the O-rings. I
22 mm Socket
I Others 1
142
C-4: Boom sub-assembly (414)
[4] Installation of hydraulic hoses
1) JnstaJl
4 bucket circuit hydraulic hoses between the boom and arm. (Place
marked ( m ))
2) Continue to use the blind
plug parts marked *
07371-51470 WI*
01010-51455 (16)*
1 01643-31445 (16)*
The split flange is
07371-51470.
Use Ml4 mounting bob
I,
2.2

Name Q’W Name Q’tj
22 mm Socket 1
Ratchet handle 1
KVV14PIImpact wrench 1
150 mm Extension 1
Others
143
C-5: Installation of boom assembly (l/3)
[I] Method of slinging
- Pr30 x 3 m Wire x 2
030 x 5 m Wire x 2
Precautions Tools and equipment required .

Name Q-Y Name Q’tj
1. Select one worker to act as a signalman for
the crane operator. No other person must 030 x 3 r-n 2 45t crane 1
give any signals.
030 x 5 m 2
2. Do not go under a raised load.
3. Check that the wire is fitted properly on the SC55 Shackle 2
hook!
Others
144
C-5: Installation of boom assembly (213)
[Z] Installation of boom foot pin
Right
-_
7
I
.I
I
11According to the levelness of the ground surface, install the lower end first (the end which
is aligned first with the hoie when lowered directly from above). (The right side in the dia-
gram above).
2) tower the crane slightly, and align the hole on the left side. No. ] Part No.
(Never use your fingers to align the holes.)
3) Push in the left pin.
4) Adjust the shim.
5) Install the pin cover.

Name Name Q’ty
-Be- careful
--- ---. -._- __set
not to J”
vnur finoe, rs caught?
, _-. . . . . a’
Keep strictly to the agreed signals for the 1 Eyebolt M42-P3 I 2 I I I

crane.
Pipe 500 x 2M 1
-Others 1 I
145
C-5: Installation of boom assembly (313)
[Z] Installation of boom foot pin
tl .O shim t1.5 shim
Boom
When press fitting the

bushing, the end
. face of the bushing
(Procedure]
1) Remove the parts marked * temporarily tightened to the revolving frame.

cf.(Fitting of pin and revolving frame
Clearance: 0.095 - 0.223
Pin and boom foot hole
Clearance: 0.405 - 0.534)
2) Set the boom as shown in the diagram above and measure clearance 6 when the clear-
ance at the place marked w is equal on the left and right.
3) Decide the type and number of shims to make clearance 6 within 1 mm.
4) Assemble the shim, seal and pin.
(Clearance at place marked m 6 5 1)
5) Carry out the same procedure for the boom foot on the left and right.

Name Q’ty Name wty
1. There is a bushing press fitted to the re- ,
volving frame, and the parts marked * are Hammer I
temporarily installed for transportation.
36 mm Socket 1
2. Clean and check the pin and inside surface
of the bushing. KW38G Impact wrench 1
Others
146
C-6: Installation of boom cylinder top pin (l/Z)
Installation of boom cylinder top pin
[Procedure]
1) After inserting the boom foot pin, low-

er the crane until the boom top con-
tacts the ground.
2) Remove the wires holding the boom
assembly.
3) Sling the boom cylinder with wires as
shown in the diagram on the left.
(Use different cranes for the left and
right.)
oom cylinder top pin
4) Start the engine.

(Bleedingoftheair from the boom cylinder was completed in assembly procedure
C-3.)

016, 5 m Wire 2 45t crane 2
Others
147
C-6: Installation of boom cylinder top pin (Z/Z)
[Procedure]
1) Remove the parts marked *

temporarily installed to the
boom.
2) With the ribbed bushing
1
cf. Fitting of bushing and boom
021.5 HWh7
+0.072 0
0 AI.046
Clearance: 0 - 0.026
N
3) Sling the cylinder with wire, and extend or retract the cylinder with hydraulic
pressure to align the position of the pin hole.
4) Assemble seal, O-rings, and pin, and install cover.
(The pins are heavy, so use a crane to lift them, and pay attention to safety.)
5) Carry out the same procedure for the boom cylinder top on the left and right.
Assemble the seal (Gil) and O-ring (G12), (GW

when temporarily assembling the pin for trans-
portation.

Name UtY Name Q’ty
1. There is a bushing press fitted to the boom
assembly, and the parts marked * or *-are 24 mm Socket 1 45t crane 2
temporarily installed.
150 mm Extension 1
3. Clean and check the pin and inside surface KW2OP Impact wrench 1
of the bushing. Hammer 1
012, 5m Wire
Others
148
C-7: Connectin of arm assembly to boom (l/3)
[I] Preparation for installation of arm assembly

1) Remove th parts marked * temporarily fitted to the boom top. (p.3/3)
2) Clean the connection surface.
3) Turn over the arm assembly.
i) Sling the arm cylinder top pin with wire as shown
in the figure on the left.
ii) Wind in the 36-ton crane until the load comes off
the ground.
iii) Sling the bucket pin hole as show! in the diagram
on the left, and wind in with the other crane.
iv) Lower the 45ton crane slowly to turn over.
v) After turning over, set portion A on a wooden
block.
300x 8m Wire
4) Start the engine
Install wire t0 St0

vibration of link.
TooIs and equipment required

Name Qw Name Q’tj
030 x 8 m Wire 2 45t Crane 2
016~ 2 m Wire 2
Others
ld?
C-7: Connection of arm assembly to boom (Z/3)
[2] Installation of arm assembly

[Procedure]
1) Select operator.
2) With the ribbed bushing marked+(p.3/3), keep the bushing at least5 mmfrom
the end face of the boss as shown in the diagram on the right.
(After inserting the pin, assemble together with the cover.)
3) Raise and lower the boom several times, and when the fine control of the boom
cylinder becomes better, lower the boom slowly and align the holes.
4) Sling the pin with a nylon sling. (330 kg)
‘5) Without assembling shims, assemble the ribbed-bushing and pin, and measure least
clearance 6. mm
6) Select a shim thick- -Y
ness of (6 + 3) mm for
one side, and pull out
the bushing.
7) Assemble the seal, O-ring, cover,
and shim.
8) Remove the sling.
30s x 8m Wire
Precautions TooIs and equipment required

Name alty Name o’ty
030 X 8 m Wire 2 49 Crane 1
Others
150
C-7: Connection of arm assembly to boom (3/3)
[Z] Installation of arm assembly
cf. Fitting of pin and bushing

cf. Fitting of pin and bushing
Clearance: 0.526 - 0.718
cf. Fitting of bushing and boom

8200 A&B
t +0.732 -0.056
-I+.660 -0.137
Clearance: 0.716 - 0.669
Assemble the O-ring (Gl9) when

temporarily assembling the pin for
transportation. ti

There is a bushing press fitted to the arm .
assembly, and the parts marked* oreare 24 mm Spanner 1
temporarily installed.
27 mm Spanner 1
Others
151
C-8: Installation of hoses between boom and chassis (I/Z)

1No. 1 Part No. I Q’ty
l,-,’ .
.- &
-.
1.._ Exa
-- . _
.
Connect the 4 hoses (arm cir&it} from the place marked w to
the revolving frame.
See page 313.

Name Qw Name Q’t
Others
152
C-8: Installation of hoses between boom arid chasis (2/2)
Installation of arm circuit hoses
1) Connect the 4 hoses at the

place marked m
2) Continue to use the blind plug

parts marked *.
Blind plug
The split flange is 07371-51470.
07371-51470 (8) * Use Ml 4 mounting bolts.
07000-13048(4) *
01010-51455(16) *
01643 -31445 (16)*

Be careful of the O-rings. Name Q’W Name Q’ty
22 mm Socket 1
150 mm extension 1
KWl4PI Impact wrench 1
Others
153
C-9: Installation of arm cylinder top pin (l/2)
[Procedure]
,120X5mWire Remove the parts marked * temporarily

.f I- / . installed to the arm cylinder top.
Clean the connection surface.
Wire to prevent rod from coming out With the ribbed bushing marked * (p.2/2),
keep the bushing at least 5 mm from the
end face of the boss as shown in the dia-
gram below.
(After inserting the pin, assemble together
with the cover.}
I No- I Part No.
Sling the left arm cylinder as shown in the diagram above.
Remove the wire fitted to prevent the rod from coming out from the left
cylinder only.
Instruct the operator to move the arm.
The air has not yet been bled from the arm
Name ; Q’W Name Q’ty
cylinder, so run the engine at low idling and

do not operate the cylinder to the end of its
stroke.
I Others 1
154
C-9: Installation of arm cylinder top pin (212)
-Cover 7) Raise and lower the crane, and extend and re-
+ 121T-91 g-7270) tract the arm cylinder to align the hole.
+ 21 T-72-l 5190 (If the stroke is insufficient, raise the boom
Bott, washer
slightly.)
Ml6 24
Pin 21 T-72-l 2210

8) Set the seal in position, insert the pin, then
assemble the O-ring and cover.
9} Repeat the same procedure for the right arm

cylinder top.
cf. Fittingof cylinder and pin

0140 +0.263 ,f8
cf. Fitting with pin
s140A8/f8 I Clea r&%P” a 0.243 - 0.369 1
+0.523 -0.043
+0&o -0.106
Clearance: 0.503 - 0.629
1 I
[ cf-~;f;;;o_la /
Assemble the . O-ring (G36) ,

when temporarily assembling the pin for
transportation.

I
Name Qw Name Q’ty

1) Be careful of the seals and O-rings.
2) Align the hole carefully, and never put 24 mm Socket 1
your fingers inside the hole.
012X5mWire 1
1*Ratchet handle 1
Others
155
C-IO: Bleeding air from arm cylinder
After assembling the arm and arm cylinder, bleed the air from
the arm cylinder as follows.
Bleeding air from arm cylinder (Bleed the air before assembling the bucket.)
1) Run the engine at low idling, and extend and retract the arm cylinder 5 or 6 times
without going to the end of its stroke. (Stop approx. 100 - 200 mm before the end
of its stroke)
2) Next, run the engine at high idling, and repeat the operation in Step (1).
* Do not let the cylinder hit at the end of its stroke.

Others
156
C-II: Installation of hydraulic hoses between boom and arm
Installation of bucket circuit

hydraulic hoses

1) Connect at the place marked w .
2) Continue to use the blind plug parts marked **

Assembly of this
part was coinpleted in
c-4
l Blind plugs 0
@
, 07371-51470 (8)
1,
22

22 mm Socket 1
Ratchet handle l
KWI 4PI Impact wrench 1
150 mm Extension 1
Others .
157
C-12: Connection of grease piping for boom (l/3)
Common for long and short boom
[I] Between boom and chassis

1) connect adapter and hose
marked w .
Hose connector
C-~~19

No. ( Part No.
Block 211
21 T-68-72250
The parts marked fiare included with the Name lQw( Name 1
revolving frame for transpostation. f 19 mm Spanner I ’ I I
Others
158
C-12: Connection of grease piping for boom P/3)
Common for short (standard) and long
[Z] Boom top
1) connect 3 places marked m .
2) the parts markedbare included In

PF1/4 the boom subasetibly.
U-
Li!.i!.
00 ,’
19
Hose I - 700
21 T-72-l 7730
r-

Name Qw Name
19 mm Spanner 1
Others
C-12: Connection of grease piping for boom (3/3)
Standard (short)boom
[3] Between boom and arm 1) Assemble the individual parts as shown in the dia-
gram.
2) Join to the boom assembly at the palce
PT1/4 PF1/4 ,9
Male Female
Adapter
M6
7 Blind pluge
21 T-98-71 140 (2)
I
Included in I No-I Part No. 1Qw

arm assembly 1 F4 1 2lT-72-17740 I 1
IF5 I 21T-72-l 7690 I 1
IF7 I 01010-81225 I 2
1 f8 --I 01643-31232 I 2
1 F9 1 2lT-72-17620 I 1
21 T-98-71 140
1 FlO ] 2lT-70-75740 1 1
1 Fl 1 1 07282-l 1048 I 2
( F12 1 01010-50612 I 4
1 F13 1 01602-20619 1 4
PF1/4
PFl/4 .

Name IQWI Name I Q’ty
j 19 mm Spanner
1 19 mm Socket
I Ratchet handle
I ~~12~1 Impact wrench I I l
I 150 mm Extension
I IO mm Socket
k
Others
160
C-13: Connection of wiring between boom and chassis
Short (Standard) boom

No. 1 Part No. IQW
(This bracket is included

in the boom assembly)
Connect to the connector “CN-C20” of

the chassis harness of the section
passing inside the operator’s cab base.
Temporarily assemble to
the bracket when transporting.

Name Qw Name
19 mm Socket 1
150 mm Extension 1
Ratchet handle 1
Others
I
161
C-14: Installation of hoses between boom and chassis (112)
Installation of bucket circuit hoses
07073-01418 (4)
Connect 4 hoses (bucket circuit) from the place marked w

to the revolving frame.

I
Others
162
C-14: Installation of hoses between boom and chassis (Z/Z)
Common for short (standard) and long boom
Installation of bucket circuit hoses

1) Connect 4 hoses at the places
marked m
2) continue to use the blind plug

parts marked *


Name Qw Name
Be careful of the’ O-rings.
22 mm Socket I
150 mm Extension 1
KWl4PI Impact wrench 1 *
.
Others
163
C-16: connection of bucket assembly to arm (l/3)
1. Preparation for connection of arm and bucket
1) sling the bucket assembly as shown in the diagram and

place it on as level ground as possible.
2) Remove the parts marked * (pin, cover, etc.), and clean the
pin and inside surface of the bushing.
(The parts marked *(p_ 3/3) are temporarily tightened and
included with the bucket for transportation.)
3) Join to the arm (go to next page).

200 X 5 m Wire 2
19 O-24 mm Socket 1 *
19 ORatchet handle 1
‘\
Others
164
C-16: Connection of bucket assembly to arm (Z/3)
2. Connection of arm and bucket
1) Operate the boom and arm to align the holes.
2) Insert the pin.
3) Adjust the shims.
5) Apply grease.
For datails, see p. 313.

Name cr’ty Name
1) Be careful noi to-get your fingers cau&t!-
KVV2OPIImpact wrench I
2) The Operator must follow the instructions IF-24 mm Socket 1
from the signal man.
WRatchet handle 1
Others
165
C-16: Connection of bucket assembly and arm (3/3)
Arm, bucket connecting pin
1) Adjust with shims so that cfear-

ante a (each side, 2 places) is
0.25 - 0.5.
2) Carry this out on the left and

right.
t1 .O to.5
Shim Shim
.- v-y
-Cover 22 kg
2,T __ - __:._.
I
-70-74251 (2)
.)” O-ring
Ribbed bushin
Press fit bushing (with rib) Fitting of bushing and pin

2 1T-70-74280 (2)
+O.l2C
Clearance: 0.163 - 0.29
4~44 hen-n I-1 4%

J IV I _l_-CNUN
:C \Lj
WV..“. 21T-70-731 41 (2) I 17
M3U CT-70-7431 0 (21 81.4 kg (21 T-9l9-72901
y; .
0701l-8361 5
01643-33690
!@-p$
Fitting of pin and bushing at arm side
M36 .n A’13
. ~~~r~~~~~~-O518 _ ~
Assemble the seal (G37j and O-ring (G39)
when temporarrly assemblrng the prn for
transportation.
Precautions I Tools and equipment reauired

Name I Q’tv I Name I Q’w
1 24 mm Socket 1 1 1 Hammer 1
46 mm Socket 1
55 mm Socket 1
1 150 mm Extension I 1 I I
I Ratchet handle Ill ~ 1
1 KW20PI Impact wrench 1 1 / I
1 KW45FG impact wrench l 1 l I
Others
I
166
C-17: Installation of bucket link (l/Z)
l7
Connecting link
Operate the bucket to align the holes.
With the arm angle shown in the diagram the link must be pushed strongly in the di-
rection of the arrow; so it is not easy to assemble.
3) Insert the pin.
4) Adjust the shims.
6) App ty grease.
The air has not been bled from the bucket Name IQW Name IQ%I
cylinder, so run the engine at low idling
and do not move the cylinder to the end of
its stroke.
Be careful to ensure that the angle of the

arm is suitable to make the operation easi-
er.
Others
167
C-17: Installation of bucket link (Z/Z)
Link connecting pin
Remove the parts marked * temporarily tightened to the

bucket, and align the bucket hole.
Seal
Clearance: 0.043 - 0.306
cf. Fitting of pin and press fit bushing
Be careful of the seals. Name Q‘W Name Q’ty

24 mm Socket 1
KVV2OPIImpact wrench 1
150 mm Extension 1 .
Others
168
C-18: Bleeding air from bucket cylinder
After completion of asembly of the bucket, bleed the air from

the bucket cylinder as follows.
Bleeding air from bucket cylinder
1) Run the engine at low idling, and extend and retract the bucket cylinder 5
or 6 times without going to the end of its stroke (stop approx. 100 - 200
mm before the end of the stroke).
2) Next, run the engine at high idling, and repeat the operation in Step 1).
* Do not let the cylinder hit at the end of its stroke.
* If this operation is carried out from the first with the engine running at
high speed or with the cylinder operated to the end of its stroke, the
air contained inside the cylinder may cause damage to the piston pack-
ing.
* After starting the engine, warm it up fully to settle all parts.
3) After completion of bleeding of the

air, add hydraulic oil to the specifi-
ed level.

Name Q’tv Name Q’ty
Others
169
ASSEMBLY MANUAL FOR LOADING SHOVEL
WORK EQUIPMENT
<Note>
LS-1 - LS-8 show the procedure to modify the backhoe into the loading shovel with the loading
shovel unit kit.
171
LS-1: Installation of arm cylinder tubes and hoses
(For assembly of loading shovel kit in field)
1). Remove the blind plugs at the places marked with % on the underside of the boom foot block and install
tubes (I) (3 pieces) and (2) (1 piece).
2). Tighten brackets (6) and (7) together to the boom cylinder line tube clamp and secure the arm tube with
clamp (IO).
3). Install arm cylinder hoses (13) (07072-01421,4 pieces) to the piping and cylinder with the 45-degree adapt-
ers on the machine body side.
4). Plug the arm ports on the front side of the block with (18) (21N-62-12210).
10 176-61-41330 4
11 01010-81250 8

l Perform steps 1,2), and 4) for only modi-
fication of the backhoe.
l When installing the hoses and tubes, take
care extremely not to catch the O-rings.
l Take care extremely not to let dust in the
hydraulic circuit.
Others
I
172
LS-2: Installation of bucket hoses
I). Remove the blind plugs at the places marked with * on the front side of the boom foot block and install
hoses (22) (4 pieces).

8
I No-I Part No. IQtv
1 22 1 07073-01418 1 4
1 23 1 07000-B3048 I 8
1 24 1 07371-51470 1 16
1 25 1 0101081455 I 32
1 26 ] 01643-31445 I 32

l When installing the hoses and tubes, take _
hydraulic circuit.
Others
173
LS-3: Installation of bottom dump hoses and tubes
1). Remove the blind plugs at the places marked with * on the front side of the boom foot block and install
block (27) and tube (29).
2). Install hoses (32) and (331, 1 piece each.
3). Install tube(37).
4). Install couplers (38) and (39).
5). Install tubes (40), (41), and (42) between the main valve and boom foot block.
I No-1 Part No. IQ ty

1 38 1 720-68-15910 1 1
1 391 720-68-15260 1 1
1 40 1 21T-62-67480 I 1
RK
I
‘8
1 41 ] 21T-62-67490 1
1
I N4 Part No. IQW

1 27 1 21T-62-67560 I 1
] 28 1 07000-B3048 I 13~
LK
1 29 1 21T-62-67570 I 1
1 30 1 01011-81415 1 4
1 31 1 01643-31445 I 4
32 07073-01416 1
33 07073-01418 1
I 34 I 07371-51470 I 8
35 01010-81455 48
36 01643-31445 48
37 21T-62-67590 1

hydraulic circuit.
I Others I
174
LS-4: Installation of pilot solenoid valve
IL Install nipples (44) and (55) and harness (46) to solenoid valve (43).
2). Install the solenoid valve assembly in 1) above to the bracket.
3). Connect the solenoid valve harness to machine body harness connector “CN-BIS”.
4). Install nipple (50) and switch (52) to the solenoid valve assembly.
5). Install harness (53).
6). Connect P-line and T-line of the solenoid valve by hose (59).
7). Remove bottom opening and closing A-line and B-line from the pilot T-line tubes
and connect them to the solenoid valve. (A: Blue, yellow, B: No colors)
(Close the tubes with plugs (60) and (6’l)J - To main valve
P

I
Part No. IQtY
1 43 1 209-60-12830 1 1
( 44 ( IZH-49-11170 I 2
tube
1 45 ( ZIT-62-77410 I 2
1 46 1 ZIT-06-67990 I 1
1 47 1 ZIT-06-12530 I 1
1 48 1 01252-40535 I 4
seeFIuffl&d1-o3Ao 1 49 1 01601-20513 ~ I 4
63 P P-line tube 1 50 1 207-62-56230 1 2
1 51 1 07002-12034 ] 2
w 1 52 1 ZOY-06-21710 I 2
1 53 1 ZIT-06-68110 1 1
1 54 1 207-979-6180 I 1
1 55 1 08053-01512 1 1
1 56 1 01010-81225 I ‘1
1 57 1 01643-31232 I 1
1 58 1 04435-51410 1 1
PORT
1 59 1 07184-00307 1 2
1 60 1 07221-20315 I 2
1 61 1 07222-00312 1 2
.. .
BOT’(OM BUMi’ OPEN
.
Precautions 1

hydraulic circuit.
Connection of solenoid valve harness
LS-5: Installation of bottom priority valve (l/Z)
1). Remove tubes (a) and (b).
2). Install priority valve (62) and valve plates (63) and (68) to the main valve bracket.
(Keep nipples (72) and elbow (77) installed to the valve plate.)
3). Install tubes (731, (741, and (75) and hose (76).
69 07000-12016 1
70 01010-80835 4

hydraulic circuit.
*
Others
176
LS-6: Installation of arm pilot drain circuit (l/Z)
1). Remove tube (c) and elbows (d) and (e). (Right-hand 4-spool valve arm pulling circuit, straight travel “T”
circuit)
2). Install tube (791, t-piece (801, and elbow (81).
3). Install hose (83).

No. Part No. O’ty
c 21T-62-75740 I
d 2 1T-62-74580 1
e 07235-10315 1
79 2 1T-62-69480 1
80 209-62-572 IO 1
81 07235-10315 1
82 07002-I 2034 2
83 07 184-003A5 1
Precautions j Tools and equipment required

hydraulic circuit.
178
LS-6: Installation of arm pilot drain circuit (2/2)
(For assembly of loading shovel kit in field) (Arm pulling pilot circuit)

Name a’ty Name a’ty
Others
LS-7: Installation of control parts (l/2)
1). Remove control levers (f) and (g) and harness (h).
2). Install control levers (84) and (85) to harnesses (86).
3). Connect the right-hand lever harness to cab harnesses CN-C43 and -C44 by extenuation cable (86).
4). Connect the left-hand lever harness to cab harnesses CN-C40 and -C41 by extenuation cable (86).
5). Secure the harnesses to the floor and pilot hose with clips (87) and bands (88).

Others
180
LS-7: Installation of control parts (2/2)
CM-l423
!
j; _-y
d_-.._O
L-.~_~~-~_-~__-I-~~-..~~~~.~-~~~~.
. _¶_-__q -_I-__--_____ .._. _
181
LS-8: Installation of horn switch
1). Install horn switch (89) to the right-hand footrest.
2). Connect the horn switch to cab harness CN-M23 by harness (92).
3). Secure the harness to the floor with cover (93).
Precautions I I Tools and equipment required

Name Name
--”
Others
182
LS-9: Change of arm pilot piping
(For modification of backhoe into loading shovel in field)
1). Change the head and bottom lines on the PPC valve side of the arm circuit at the junction block of the PPC
line.
(The colors of the hose identification bands before and after the junction block are as follows.)
To be changed.
Piping for I oading shovel
Red \ Yfi?llow
/
Piping for backhoe 5?
Red II tt Yellow
II I
II I
II I
III
II I
A
Red / Yellow
\
To be changed.
183
LS-IO: Removal of boom foot handrail
(For modification of backhoe into loading shovel in field)
1). Remove handrail (k) of the boom foot. (#IO001 - #10006)
l Remove the handrail before installing the

Name IQd Name
boom assembly.
I Others )
184
LS-11: Installation of arm cylinder bottom parts
1). Remove the lock piece fixed to the boom and remove the arm cylinder bottom pins.
2). Lay the 2 arm cylinders in parallel on wood blocks.
3). Sling the boom with a crane and push in the pins, matching the pinhole of the boom to the holes of the arm
cylinder bottoms.
4). Install both arm cylinders similarly.
5). Install the lock piece.
6). Using a nylon sling, secure the arm cylinders with the lever block.
Arm cylinder
Bk 10724~x.2

l Apply grease (GL-Ll) to the inside of the
bushings.
l Install the arm cylinder bottom parts with
the piping ports down.
I
Others
185
LS-12: Installation of boom cylinder to machine body (l/2)
Slinging method of boom cylinder for installation
@I2 x 5 m Wire
Rod
_-stopper wire -
Left &+$%7J+%7
Apply this method to both standard (short)

and long types.
I
Name Qw Name Q’ty
Others
LS-12: Installation of boom cylinder to machine body (2/2)
[Procedures]
Fining clearance between pin and i (1) Remove the parts
revolving frame hole: 0.095 - 0.223 which are marked
. with * and installed
. to the revolving
(4) When installing the

parts marked with
block marked with

z in the above
figure to secure
of machine body revolving frame for
the ease of work.
(5) Perform the above
work for both
boom cylinder feet.

Name Q’ty Name alty
l The machine is transported with the parts
Hammer 1 45 t crane 1
marked with * installed temporarily.
1
l Check that the pins and inside of the 36-mm ‘Ocket
bushings are cleaned. KW38G Jnpact wrench 1
l When modifying the backhoe into the @12I 5-m wire 2
loading shovel, remove the bushings
@16,2-m wire 1
from the revolving frame.
Shackle equivalent to SCM 1
Others
187
LS-13: Installation of boom cylinder piping (l/2)
1. Remove the blind plugs from

the revolving frame piping
and boom cylinder piping and
install the hoses (4 pieces) as
shown in the following figure.
2. Reuse the split flanges, bolts,

O-rings, etc. (the parts marked
with %) used to install the
blind plugs.
When transporting the machine,

keep the parts marked with $2
installed.
b73Tl -Slq-‘1”
Split flange mounting bolt

Name Q’ty Name O’ty
l When installing the hoses, take care not yz2 mm socket
1
to twist them.
l Take care not to damage the O-rings. KW14PI lnpact wrench 1
Others
188
LS-13: Installation of boom cylinder piping (2/2)
When the boom is installed, the boom cylinders are extracted and retracted to position the holes of the boom
cylinder top pins. Accordingly, bleed air according to the following procedure after installing the boom cylinders.
Bleeding air from boom cylinders

(I) Run the engine at the low idling speed and extract and retract the boom cylinders 5 - 6 times without
moving them to the stroke ends (stop them about 100 - 200 mm before each stroke end).
* Since there is much air in the circuit,.the work equipment does not move for more than IO seconds
when the control lever is operated for the first time. Do not move the control lever to the stroke end at
this time, however.
(2) Next, extract the boom cylinders to the stroke end and keep the control lever at the stroke end for 3 minutes.
(3) Run the engine at the full speed and keep the control lever similarly to (2) for 1 minute.
I--- Parts sent individually 1

No. Part No. O’ty
Precautions ) Tools and equipment required

Name alty Name
I Others 1
189
LS-14: Installation of boom assembly
1). Sling the boom assembly with a crane and position the boom foot pinholes.
2) Install the boom foot pins.
Push in either boom foot pin first until it stops and then position the pinhole on the other side. If the boom leans
to the right or left at this time, correct it with a jib crane.
Decide the number of the adjustment shims so that the clearance of the boom foot pin out of the machine body
will be below 1 mm. Decide the total thickness of the shims by combining the shims 1.5 mm thick (ZIT-72-71270)
and 1.0 mm thick (21T-72-71260), prepared 4 pieces each. (Adjust the shims at 1 place on the left outside of the
boom.)
Work equipment
assembly: 13,000 kg
3) Push in both boom foot pins

to the end and install the lock
plates.
Inside of bushings: Apply
grease (GL-Ll).
side
Boom foot pin
Precautions ] Parts sent individually

No. Part No. Q’ty
l When inserting the pins, take care not to
99 21T-960-1100 1
damage the seals (21T-72-71240, 4 pieces).
l When modifying the backhoe into the loading 100 21T-72-71260 4
shovel, remove the bushings from the 101 21T-72-71270 4
revolving frame.
190
LS-15: Installation of boom cylinder head pins
1). Remove the pin lock pieces from the boom and then remove the boom cylinder top pins.
& kg Boom cylinder top pin: 61 kg

2) Start and run the engine at the low idling speed.
3) Sling each cylinder and extract its rod slowly to match the pinhole and push in the pin.
4) Install both cylinders similarly.
5) Install the pin lock pieces (Tightening torque of M24 bolt: 60 - 105 kgm).
Inside of bushings: Apply grease (GL-Ll).
* Extract the cylinder slowly.
Do not move it quickly or move it to the stroke end.
Since there is much air in the circuit, the work equipment may not move for more than IO seconds when
the control lever is operated for the first time. Do not move the control lever to the stroke end at this
time, however.
-14,16
Pin
191
LS-16: Installation of grease feed hose between machine body and boom
1).Install grease feed hose (102). (Tightening torque: 58.8 - 97/l Nm)

Others
192
LS-17: Installation of bucket cylinder assembly
1). Sling each bucket cylinder (103) with a crane. At this time, lean it about 45 degrees with the rod side up.
2). Insert the pin boss on the rod side in the bracket of the boom.
3). Insert pin (104) in the pinhole and secure the cylinder.
4). Install the pin lock plate (105).
Note). When reassembling, remove the pins, lock plates, bolts, and washers from the boom assembly.
0/bs
(002 072 79)

Name Q’ty Name QW
Others
193
LS-18: Installation of arm assembly
1). Install wires to the hooks of arm assembly (109) and sling it with a crane.
2). Insert the boss on the boom side of the arm assembly in the pin bracket of the boom.
3). Insert pins (1 IO) and secure the arm assembly.
4). Install pin lock plates (111).
Note). When reassembling, remove the pins, lock plates, bolts, and washers from the boom assembly.

NO. Part No. my
109 21T-960-2600 1
( 1 (905610 40) 1
1 110 1 21T-960-1670 I 2
(905 739 40)
111 21T-960-2140 2
1 112 1 DM905 747 40 I 4
1 1 (002 027 79) 1
194
LS-19: Installation of arm cylinder assembly
I). Install chains to the hooks of arm cylinders (I 15) and (116) under the boom and sling them.
2). Extracting each arm cylinder, match the center of the cylinder rod end boss to the cylinder bracket of the
arm.
3). Insert pin (I 17) in the pinhole to secure the cylinder.
4). Install pin lock plate (118).
Note). When reassembling, remove the pins, lock plates, bolts, and washers from the cylinder assembly.

1
No. Part No. )Q’ty
I115 1 2lT-960-2300 I_ 1
1 1 (908-128-40) 1
I116 1 2lT-960-2400 I 1
1 1 (908 129 40) 1
I117 1 2lT-960-2130 I 2
1 1 (908 933 40) 1
1118 1 2lN-70-11210 I 2
I 1 (905 749 40) I
( 119 1 01010-81640 I 4
1 1 (307 824 99) 1
(120 1 01643-31645 ( 4
I I (002 072 79)

I I
195
LS-20: Installation of hoses between boom and arm
1).Install hose assembly (121) between the boom and arm.
Precautions Parts sent individually

No. Part No. Q’ty
121 1
l Take care extremely not to let dust in 121-I ZlT-960-1690 1
the hydraulic circuit. (905 751 40)
121-2 07073-01430 2
121-3 07074-01430 4
121-7 21T-960-2150 1
(515 307 40)
122 07000-B3048 12
(514 014 98)
123 01010-81455 48
(308 430 99)
124 01643-31445 48
(002 135 79)
196
LS-21: Installation of bucket cylinder hoses
I). Install bucket cylinder hoses (125) and (126).

No. Part No. Q’tY
122 07000-B3048 8
(514 014 98)
123 01010-81455 32
(308 430 99)
124 01643-31445 32
(002 135 79)
Precautions 125 07073-01423 2
(910 286 40)
+ When installing the hoses and tubes, take
care extremely not to catch the O-rings. 126 07073-01428 2
l Take care extremely not to let dust in (516 107 98)
the hydraulic circuit.
197
LS-22: Installation of grease feed hose of bucket cylinder (l/2)
1). Unwind the grease feed hose from the tube of the arm assembly and install it along the bucket cylinder hose
to the grease fitting of the bucket cylinder rod end boss.
2). Unwind the grease feed hose from the body of the arm assembly and install it along the bucket cylinder
hose and connect to the bottom grease feed hose installed to the bucket cylinder assembly.
Note). Adjust the grease feed hoses to proper length by the following method.
3). Wind spiral covers onto the grease feed tubes and bucket cylinder hose as shown below.
Grease feed hose
Hydrau lit hose
Bucket cylinder
hydraulic hose
Spiral cover
A-A
198
1). Unwind the grease feed hose from the tube of the arm assembly and install it along the bucket cylinder hose
to the grease fitting of the bucket cylinder rod end boss.
2). Unwind the grease feed hose from the body of the arm assembly and install it along the bucket cylinder
hose and connect to the bottom grease feed hose installed to the bucket cylinder assembly.
Note). Adjust the grease feed hoses to proper length by the following method.
3). Wind spiral covers onto the grease feed tubes and bucket cylinder hose as shown below.
hose on cylinder
Others
199
LS-23: Installation of bucket assembly
IL Install bucket assembly (127).
Note). When reassembling, remove the pins, lock plates, bolts, and washers from the bucket assembly.
2). lnsIall pin seal assemr,iies \ ILUII ana
3). Wind spiral covers onto the grease feed tubes and bottom dump cylinder hose as shown below.
x /

No. j Part No. )my
ib.zv \ \
1127) 2
(128-I 1 DM247 091 40 [ 2

Y a- l
I - Y ’
I I129 1 DM661 19640 1 4
1129-I1 DM247-092 40 1 2
200
LS_24: Installation of bottom dump hose and grease feed hose between arm and bucket
‘I). Install bottom dump hydraulic hoses (130) between the arm and bucket.
Note). Reuse the bolts and washers used for the blind cover.
2). Unwind the grease feed hose from the arm and connect it to the bottom dump grease feed hose on the
bucket side.
3). Wind spiral covers onto the grease feed tubes and bottom dump cylinder hoses.
Grease feed hose
Q
t34
,Bands
Grease feed hoses
it’* .
No. Part No. Q’ty
’ =V@
130 07072-01231 2
P
4I 0
0 (910 287 40)
GIY 131 07000-B3038 4
ij-@
t (006 725 98)
Hydraulic hose
132 01010-81245 16
Precautions (308 603 99)
133 01643-31232 16
(003 229 79)
. Take care extremely not to let dust in the 134 08034-20536 4
hydraulic circuit.
201
INSPECTION AND SERVICING PROCEDURES
M. INSPECTION AND SERVICING PROCEDURES

AFTER FINISHING ALL THE ASSEMBLY AND
INSTALLATION WORKS
1. Perform inspections and servicing referring to this procedures manual and read it for working
sequence and precautions.
2.For general information when performing servicing works, refer to the Operation and Mainte-
nance Manual.
203
M-l
1. Inspecting the oil level and water level in respective sections and refilling them.
(1) Inspecting the cooling water level and refilling it

(2) Inspecting the oil quantity in the engine oil pan and refilling the engine oil when deemed necessary
(3) Checking and confirming the fuel level
(4) Inspecting the oil level in the hydraulic oil tank and refilling the oil when deemed necessary
(5)lnspecting the oil level in the P-T-0. case and refilling the oil when deemed necessary
(6) Inspecting the oil level in the swing machinery case and refilling the oil when deemed necessary
(7) Inspecting the oil level in the final drive assembly and refilling the oil when deemed necessary
Since information on these matters are given in the Operation and Maintenance Manual, refer to the manual.
2. Selection of the appropriate fuel type and lubricating oil type fitting to the atmospheric tem-
perature range
(1) Fuel and oil
Select the appropriate fuel and oil types fitting to the atmospheric temperature range.
Engine oil pan
PTO case - ----_
Swing machinery case
Final drive case
Hydraulic system
Fuel tank
Grease fitting
Cooling system Add antifreeze
.
% ASTM 0975 No. 1
M-l
(2) Anti-freezing solution

When the atmospheric temperature drops below OOC, add an anti-freezing solution.
Add an anti-freezing solution to the cooling water to prevent freezing of the cooling water while the machine
is in standstill_
l Determine the ratio between the anti-freezing solution and cooling water checking the minimum tempera-
ture recorded in the past and referring to the mixture ratio table given below.
Actually, determine the mixture ratio assuming an about lO?o? C lower atmospheric temperature.
Mixing rate of water and antifreeze

-
Min. OC -5 -10 -15 -20 -25 -30
atmospheric -
temperature “F 23 14 5 -4 -13 -22
Amount of
I ~~~
4Y I l&S 1 25.5 1 30-5 1 34.8 1 39.0 1 42.5
antifreeze 1 US gal I 5.2 1 6~3 I 8.1 I 9.2 I 10.3 I 11.2
UK gal 4.3 5.6 -6.7 7.7 8.6 9.4
f? 65.5 59.5 54.5 50.2 46.0 42.5

Amount of
water US gal 17.3 15.7 14.4 13.3 12.2 11.2
UK gal 14.4 13.1 12.0 11.0 10.1 9.4
* The quantity figures in the above table are for an engine on one side.
Total quantity should therefore be double the above quantities.
A Since anti-freezing solutions are inflammable, be careful with fire when handling them.
* AS the anti-freezing solution, use a corrosion-proof all-season anti-freezing solution (AF-ACL) or all-season
anti-freezing solution (AF-PTL). Do not use an alcohol type anti-freezing solution.
* Prescribed oil quantity means the total quantity of oil including the part remaining in circuit pipings for
respective equipment and changing oil quantity means the quantity of oil to change at times of ordinary
inspections and servicing.
* When starting the engine under atmospheric temperature environments of less than OOC, always use
SAEIOW or SAEIOW-30 even if daytime temperature is expected to rise upto around 10°C.
* Use city water as the cooling water. When using substitute source water (such as river water and well
water) for an unavoidable reason, contact our office or our designated service shops.
205
M-2 Flushing of hydraulic circuit
FLUSH THE HYDRAULIC CIRCUIT ACCORDING TO THE FOLLOWING PROCEDURE.
I). Short the work equipment piping at the cylinders.

2). Replace the return filter element with the flushing element {Accessory).
3). Replace the return filter relief valve with the plate (Accessory).
4). Run the engine at the low idling speed with the lever at the N position for 30 minutes.
5). Run the engine at a medium speed with the lever at the N position for 30 minutes.
6). Run the engine at 1700 rpm and repeat the follotving lever operation pattern 4 times (Keep each lever at
the operating position for 1 minute - 1 minute 30 seconds).
0 Backhoe specification
(Raise boom) + (Lower boom) + (Arm out) + (Arm in) + (Dump bucket) + (Tilt bucket)
. Loading specification
l (Arm in) + (Arm out) + (Tilt bucket) -+ (Dump bucket) -+ (Open bottom) -+ (Close bottom)
7). Replace the flushing parts with the normal return filter relief valve and element.
8). Replace the work equipment piping with the normal circuit (Connect to the cylinders).
* If the “Filter clogged” caution lamp on the monitor in the operator’s cab lights up during flushing
operation, stop the engine immediately and replace the flushing element.
If the flushing element is short, use a new genuine element (07063-01210).
* Spare parts
Flushing element . . . . . . . . 209-60-31130
Absolute filtration particle size: 6pm
(Genuine filter: 30pm)
Plate . . . . . . . . ZIT-60-13730

Name O’ty Name o’ty
I Others 1
206
M-3 Releasing residual pressure from hydraulic circuit
WHEN DISCONNECTING THE HYDRAULIC PIPING, BE SURE TO RELEASE THE RESIDUAL PRES-
SURE ACCORDING TO THE FOLLOWING PROCEDURE.
I). Pull the safety lock fever to the “Free” position.

2). Remove the hydraulic tank cap.
3). Start and run the engine for about IO seconds, then stop it.
J, Do not raise the engine speed above 1,000 rpm.
* Keep the work equipment control levers at the neutral position.
4). Operate each work equipment control lever to the stroke end within
5 - 6 seconds after stopping the engine.
* Perform steps 3 and 4 repeatedly 3 times.
A When removing the hydraulic tank cap, turn it slowly to release
the pressure safely and then remove it.
5). After releasing the residual pressure, install the hydraulic tank cap
to prevent dust from entering the tank.
6). Push the safety lock lever to the “Lock” position.

Name O’ty Name O’ty
Others
Backhoe l/l 3
KOHR~RB Report No.
FIELD ASSEMBLY INSPECTION REPORT
After completion of assembling a machine, make inspections according to these check sheets for assuring machine performance and quality.
Model - Type Machine Serial No. User Unit No. Engine Model Engine Serial No.
PC 1800-6
SAAGD140E-2
Backhoe spec.
Service Meter Reading Date of inspection

Attachment
Location of Machine at Inspection
Distributor’s Name
Customer’s Name Address: Signature:
Date:
Inspector’s Comments:
Inspector’s Name: KOMATSU USE ONLY :

C. Sheet Receiving Date :
Title
.
BY
Signature:
Remark:
Check sheets fillinq instructions:
1. Use following indexes for entry of judgement
clV ..._....... Normal IIzl .._.__.. Correction made on abnormal point

Ix1 ........... Abnormal 171.._...._...Not applied
jf
2. Enter actually measured values in parenthese, [ l-
Notes:
(1) Criteria are based on the standards when the machine is shipped out of the factory.
(2) This FIELD ASSEMBLY INSPECTION REPORT is for “A” specification.
SUBMIT-TANCEOF THIS REPORT (AND CHECK SHEETS) TO KOMATSU IS ONE OF THE CONDITIONS OF WARRANTY VALIDATION,
COPY FOR KOMATSU SHALL BE FORWARDED TO THE KOMATSU REGIONAL OFFICE TOGETHER WITH THE COPY OF DELIVERY
SERVICE REPORT.
@ Komatsu copy
2f13
2
g
5
.-cn
Local After
Ql Check item assembly hours of Judgement standard
Z Z
0 CfI time operation
Oil and water levels Actual measurement
RESERVE TANK
FULL
Cooling water Soft water [ I
LOW
etween Full and
OW ‘eve’ SUP05505
Yes/No [ 3
. 1Anti-freeze
A: -50 - -40°C D: -20 - -10°C
(A, B, C, D, E) Density of
anti-freeze [ I B: -40 - -30°C E: -10 - 0°C
C: -30 - -20°C (Not necessary in summer)
> ’
z EOl ow L_H+5mm (10 minutes after stopping
E Engine oil E I
ZZ E030 engine)
Z EOlOW +5 (10 minutes after stopping
g PTO oil I I L -H
,o E030 engine)
2 Swing machinery +5_H+1 0 (10 minutes after stopping
y” gear case oil
E030 [ I L
engine)
g -
5 Right E030 [ 1
, Final drive gear Bottom edge of level plug: 0 to -10 mm
case oil
Left E030 [ 1
Between the H and L marks.
Loose, twisted connections for grease piping There must be none.
must be none.
@ Komatsu copy
Check item Judgement standard
I I Loose, untightened counterweight bolts 1 1 1 I ITheremustbenone.
I I ,
Forgotten, missing, catching O-rings for travel There must be none.
I I Loose, untightened track frame mounting bolts / / )There must be none.
Loose, untightened bolts for travel motor cover There must be none.
Add fuel, washer fluid Fill tank.
I I Dirty oil on paintwork, damage to paintwork at any part

I I I I I Clean, repair damaged paintwork
@ Komatsu copy
4/l 3
Local After
Check item assembly hours of Judgement standard
time operation
Monitor display
I. Check of monitor function
When the starting switch is turned ON, the gauges, CHECK items,
and all display itemson the monitorshouldlightup. At the same
~ the alarm buzzer shouldsound.
?. Check of gauges and CHECK items
When starting switch is turned to ON (all lamps on), all display
lamps should go out after approx. 3 sec. For another 2 seconds, Display should be as on left.
only the gauges are displayed, and the CHECK and monitor items
disaooear.
3. Check of monitor items
After starting the engine, the caution lamps should not light up and
the alarm buzzer should not sound when the engine speed is low
idling - high idling.
There should be no scratches or misting of
Operation of service meter the lens or variation in operation.
MONITOR
(Clock & troubleshooting)
Coolant and hydraulic oil temp. gauge

\
Service meter
Coolant and hydraulic oil temp. mo
Battery charge monitor (F. engine

Fuel level monitor
Engine oil pressure monitor (F. e
Hydraulic oil clogging monitor
Air cleaner clogging monito
(F. engine)
’ Coolant level monitor
Battery charge monitor (R. engin
Engine oil pressure monitor

(R. engine)
Air cleaner I Engine oil level monitor
--. clogging
(R. engine)
Working mode selector

Auto-deceleration switch
Heavy lift switch ’
/ k
Coolant and hydraulic oil temp.’
indicator change-over switch
@ Komatsu copy
5/l 3
Local After
time I operation I
Travel levers
1 1
_--w_--.
Monitor
.
L)__ 0
__ _ 0 o’--------l “- __ vwork.equipment lever
RH
Machine control monitor

Starting switch
LH work
equipment lever Fuel control dial (F. engine)
Starting motor change-over SWriteh
Fuel control dial (R. engine)
Swing lock switch
Lamp switch
Safety lock fever Step light switch
Machine push-up switch
Room lamp switch
Fog lamp switch (option)
Boom shockless control switch
Rotation lamp switch (option)
Alarm buzzer stop switch

Wiper switch
1holding
__..
! switch
0
brake
II
Operation of working mode selector switch DH lights up: Powerful operation for short
time during heavy-duty
operations
H lights up: Heavy-duty operations
G lights up: Normal operations
When starting the engine, Ii (heavy-duty

ooeration)mode is automatically selected.
Operation of auto-deceleration switch I ON lights up: Autodeceleration is
actuated.
OFF: Auto-deceleration is canceled.
Each time the switch is pressed, the auto-

deceleration is actuated or canceled.
Operation of heavy lift switch When the switch is turned ON during
independent operations of the boom, the
boom liftino power is increased.
@ Komatsu copy
5
&
5
v,
Local After
zz Check item assembly hours of Judgement standard
5
s a time operation
Operation of starting switch OFF position: Engine is stopped

ON position: Electric current flows in the
charging and lamp circuits.
START position: Engine is started.
Operation of fuel control dial MAX: Full speed
MIN: Low idling
Operation of cigarette lighter This is used to light cigarettes. To use, push
the lighter in. After a few seconds it will
spring back.
Operation of swing lock switch ON position (actuated):
The swing lock is always applied, and the
upper structure will not swing even if the
swing is operated. In this condition, the
swing lock lamp lights up.
OFF position (canceled):
The swing lock is applied only when all
work equipment control levers are at
neutral; when any work equipment
control lever is operated, it is canceled.
The swing lock is actuated approx. 4
seconds after all work equipment control
lever is placed in neutral.
Operation of wiper switch 0 OFF: Wiper stops
@ ON: Wiper moves continuously
@ Window washer fluid is sprayed out.
When switch is released it returns to
position @_
@ ON: Wiper moves intermittenly
position @.
Operation of lamp switch This switch is used to turn on the front lamps
z working lamps, additional lamp at the top
z front of the cab, rear lamps, and monitor
z?
lighting.
2
E Operation of alarm buzzer stop switch This is used to stop alarm buzzer if it sounds
g to warn of an abnormality during operation.
z? Operation of car heater fan switch (option) ON: Fan is started.
c
c0 OFF: Fan is stopped.
3 ’
cn
Operation of machine push-up switch Low pressure setting:
73
The boom thrust force is weak.
5
a> High pressure setting:
6 The boom thrust force becomes more
powerful.
Operation of boom shockless control switch When the switch is at the ON position and
the boom is stopped, the shaking is not felt.
Operation of horn switch Press the switch on the right work equipment
control lever to sound the horn.
At the same time, the flashing light (option)
at the top front of the cab will flash for
approx. 5 seconds.
Operation of room lamp switch ON position: Room lamp lights up.
Operation of pump prolix switch When normal:

Switch is pushed down.
When abnormal:
1 When the monitor display shows E02
(n/C valve system error), move the
switch up to make it possible to carry out
work. .-._ . -.. -- .
,
@ Komatsu copy
2
5
5cn Local After
5 Check item assembly hours of Judgement standard
t;j time operation
0 I?
Operation of swing prolix switch When normal:
When abnormal:
When the monitor display shows E03
(Swing brake system error), the brake is
canceled, and it becomes possible to
actuate the swing and carry out normal
operations. However, the swing brake
remains released.
Operation of step light switch l When the switch is pressed, the step
light will light up for approx. 60 seconds.
l Even if the starting switch key is at the
OFF position, the step light will light up
for approx. 60 seconds when the switch
is pressed.
Operation of safety lock lever Pull the lever up to apply the lock.
This lock lever is a hydraulic lock, so even if
it is in the lock position, the work equipment
control lever and travel lever will move, but
the work equipment, travel motor, and swing
motor will not work.
Operation of travel levers FORWARD:
The lever is pushed forward.
(The pedal is angled forward)
REVERSE:
The lever is pulled back.
(The pedal is angled back)
% N (Neutral):
2
The machine stops.
:
6 Operation of left work equipment control lever This lever is used to operate the arm and
(with auto-deceleration device) upper structure.
Arm operation Swing operation
@ ArmOUT @ Swing to right
@ ArmIN @ Swing to left
N (Neutral):
When the lever in this position, the
upper structure and the arm will be
retained in the position in which they
stop.
Operation of right work equipment control lever This lever is used to operate the boom and
(with autodeceleratiom device) bucket.
Boom operation Bucket operation
0 RAISE @ DUMP
@ LOWER @ CURL
N (Neutral):
When the lever in this position, the boom
and the bucket will be retained in the
position in which they stop.
@ Komatsu copy
8/13
(Work equipment posture: Max. reach)
(Work equipment posture: Travel posture)
Travel deviation
considered that
Track rotating Hi
@ Komatsu copy
9/l 3
Note: All judgement standard values for speeds are the values in DH mode.
Work equipment operation running in: Engine high idling speed,

(Note: Boom cylinder to ground level)
Pressurized; each port relief 2 minutes, shock 20 times (except BOOM LOWER).
Work equipment posture Bucket
BKPOOlll BKPOOl12 BKP00113
ment time lag Boom
Arm
end of cylinder stroke

t end of stroke for BOOM RAISE and ARM OUT)
cylinder must move from fully extended

position to ground level. (Arm at max. reach)
@ Komatsu copy
IO/13
Check all parts
l There must be no catching during

Operating force of control lever when each actuator is actuated. operation.
l Must return naturally to neutral.
Feeling and noise of vibration in operator’s cab There must be none.
Vibration noise from frame, guard, ladder There must be none.
(Idler, roller, sprocket, final drive gear case, motor, brake valve)
1 ( 1 (
I ILooseness of track shoe bolt IThere must be none.
pping, separation, or
Contact of link tread
Center swivel, pump, solenoid valve, relief valve, control valve,

PPC valve, swing motor, brake valve, shuttle valve, swing
machinery, hydraulic tank, piping)
6
z I I Leakage of oil from engine lubrication system )There must be none.
Leakage of gas from engine gas system There must be none.
Movement of covers Must move smoothly.
Cover locks Must lock securely.
@ Komatsu copy
II/13
Oil leakage
There must be none.
[Cylinder, piping, block]
Grease leakage from grease piping There must be none.
Interference of work equipment There must be none.
I
1Looseness of wo& equipment piping clamps, play in piping ( 1 1 1 1There must be none.
45
P Twisting of hydraulic hoses and operation of work equipment when
There must be none.
turning over
@ Komatsu copy
Note: lf the operation or function is defective, measure as necessary- All judgement standard values for speeds are the values in OH mode.
1. Engine speed
Low idling speed 1 rpmI
Speed at boom raise relief

I I (Heavy lift: OFF) E rpmI
I I Speed at boom raise relief

(Heavy lift: ON) 1 rpm
I I i i 1800 2 100 rpm 1
1050/l 150 rpm at 1800 rpm
R.H4-spool
I IControl valve main Swina 4-sood I I I
I set pressure valve 1
I I Travel relief
set pressure
Travel reiief
Right
travel
Left MPa
I
MPa \ 6Hmode
I
set pressure travel (kg/cm21 I
MPa 30.4 z;:; MPa At engine high idfing,
Swing relief set pressure swing and DH mode, relic
I (310 ?$ kg/cm*}
I I Pilot relief valve set pressure

1
3.1 4+y4 MPa (32 +ts kg!cm*}
(At engine high idling, neutral)
I I At neutral
NC valve output pressure (at top
II surfaceof NC valve) No.1 and

No.2 pump
NCvalve output.pressure (at top

MPa
{Wm2)1I
MPa MPa
surface of NC valve) No.3 pump wcm2) I[ Wcm2~
I I
0.39 MPa
(4 kg/cm*}
:’
I I valve output pressure does not pass the test. F,,&
J/S differential pressure (differential

pressure at input and output ports of
jet sensor) No.1 and No.2 pump
1 J/S differential pressure (differential

MPa MPa
MmP Wcm2~ wcm*1
@ Komatsu copy
13/13
I- I-4. Hydrauric
~~ drift
~ of w
Max. 1200 mm/l5 minutes
Note: Measure the hydraulic drift of the following cylinders only if the
hydraulic drift at the bucket tooth tip does not pass the test.
Max. 17 mm/minutes
Max. 23 mm/minutes
1Bucket cylinder Max. 9 mm/minutes
I I5. Operation force, travel

16.7 k 4.9 N
Boom lever (1.7 + 0.5 kg}
Stroke:85 f IO mm
[ mm11 mm1 [ mm1 Play:Max. 10 mm
Operating RIGHT N LEFT 13.7 2 3.9 N
Swing lever force
1 {kg1 1I tk: I (1.4 + 0.4 kg)
RIGHT LEFT PLAY
Stroke
[ mm11 I I
1Bucket Operating 1CURL N1 [DUMP NlI 1
1lever force (1.4 2 0.4 kg)
Stroke: 85 * 10 mm
Plav: Max. 10 mm At engine high
idling, relief
uperatrng IN 16.7 4 4.9 N
El 1Arm lever I-_-_ I (1.7 e 0.5 kg}
=I I Stroke
IN OUT PLAY Stroke: 85 f 10 mm
mm1 [ mm1 [ mm1 I I Play: Max. 10 mm
1Right Operation f FOR- N1 (RE- VI I 25.5 + 5.9 N
(2.6 k 0.6 kg)
I I Left
travel lever
N RE-
1I
VERSE
N
II I (2.6 t 0.6 kg)
I I Stroke
FORWARD
mm1 [
REVERSE PLAY
mm1 I I
I IMeasure the travel of the lever at the center of the lever tip
@ Komatsu copy
Roading shovel 1/I 3
KOMA!!U Report No.
FIELD ASSEMBLY INSPECTION REPORT
After completion of assembling a machine, make inspections according to these check sheets for assuring machine performance and quality.
Model - Type Machine Serial No. User Unit No. Engine Model Engine Serial No.
PC1 800-6
SAA~DUOE-z
Roading shovel spec.
Service Meter Reading Date of Inspection

Attachment
1 2
Location of Machine at Inspection

Manufacture
Model
Distributor’s Name
Serial No.
q
Customer’s Name Address: Signature: Delivery
Report
No. attached
Date:
inspector’s Comments:
Inspector’s Name: KOMATSU USE ONLY :

C. Sheet Receiving Date :
.
BY
I _~~
Signature:
Remark:
/
Check sheets fillina instructions:
1. Use following indexes for entry of judgement
lz ....._. Normal IEI........... Correction made on abnormal point

lxl ........... Abnormal 171_.__.__
._..Not applied
2. Enter actually measured values in parenthese, f 3.
Notes:
(1) Criieria are based on the standards when the machine is shipped out of the factory.
(2) This FIELD ASSEMBLY INSPECTION REPORT is for “A” specification.
SUBMllTANCE OFTHIS REPORT (AND CHECK SHEETS) TO KOMATSU IS ONE OF THE CONDITIONS OF WARRANP/ VALtDATfON,
COPY FOR KOMATSU SHALL BE FORWARDED TO THE KOMATSU REGIONAL OFFICE TOGETHER WITH THE COPY OF DELIVERY
SERVICE REPORT
@ Komatsu copy
2/13
p 5 Local After
$ -G
‘5 Check item assembly hours of Judgement standard
$ : time operation
Oil and water levels Actual measurement
RESERVE TANK
FULL
Cooling water Soft water [ I
LOW
Between Full and
Low Ieve’ SUP05505
Yes/No 1 I
Anti-freeze
A: -50 - -40°C D: -20 - -10°C
(A, B, C, D, E) Density of [ B: -40 - -30°C E: -10 - 0°C
anti-freeze 1
C: -30 - -20°C (Not necessary in summer)
).
z? EOI OW L_H+5mm (10 minutes after stopping
E Engine oil 1 I
% E030 engine)
Z EOlOW (10 minutes after stopping
? PTO oil 1 1 L+?f-i
g E030 engine)
Z Swing machinery +5_H+1 0 (10 minutes after stopping
gear case oil
E030 c I L
engine)
$
Bottom edge of level plug: 0 to -10 mm
Improperly inserted wiring, unconnected wiring There must be none.
Loose, untightened ladder mounting bolts There must be none.
@ Komatsu copy
3/l 3
I I Loose, untightened counterweight bolts 1 ) / 1 ITheremustbenone.
missing, catching O-rings for travel ] There must be none.
I I Loose, untightened track frame mounting bolts 1There must benone.
I I Add fuel, washer fluid / ( 1Fill tank.
I- I Dirty oil on paintwork, damage to paintwork at any part

I I I -1 I Clean, repair damaged paintwork
@ Komatsu copy
4/I 3
Local After
time operation
Monitor display
1. Check of monitor function
When the starting switch is turned ON, the gauges, CHECK items,
and all display items on the monitor should light up. At the same
the alamr buzzer shouldsound.
2. Check of gauges and CHECK items
When starting switchis turned to ON (all lamps on), all display
lamps should go out after approx. 3 sec. For another 2 seconds, Display should be as on left.
only the gauges are displayed,and the CHECK and monitor items
disappear.
3. Check of monitor items
After starting the engine, the caution lamps should not light up and
the alarm buzzer should not sound when the engine speed is low
idling - high idling.
There shouldbe no scratchesor mistingof
Operation of service meter
the lens or variation in operation.
MONITOR
(Clock & troubleshooting)
Coolant and hydraulic oil temp. gauge

\ T-y
Service meter
Coolant and hydraulic oil temp. monitor

XT]:_ - Fuel gauge
Battery charge monitor (F. enq ine)_ WI1
Fuel level monitor
Engine oil pressure monitor (F. e
Hydraulic oil clogging moni to1
Air cleaner clogging monito
(F. engine) Hydraulic oil level monitor
Coolant level monitor

arrery w~d~ye: IIIUIIILUI \I\. GIIYIIIGI
Preheat monitor
Engine oil pressure monitor
(R. enaine) Swing lock monitor
Air cleaner clogging monitor ’ Engine oil level monitor

(R. engine)
Working mode selector switch

Auto-deceleration switch
Coolant and hydraulic oil temp.’

indicator change-over switch
@ Komatsu copy
Local After
time operation
Travel levers’
RH work .equipment lever
Machine control monitor
LH work
equipment lever Fuel control dial (F. engine)
Starting motor change-over switch
Fuel control dial (R. engine)
Swing lock switch
Safety lock lever

Step light switch
Machine push-up switch
Room lamp switch
Fog lamp switch (option)
Boom shockless control switch
Rotation lamp switch (option)
Alarm buzzer stop switch
holding
- -_ brake
switch
0
II
3peration of working mode selector switch DH lights up: Powerful operation for short
time during heavy-duty .
operations
H lights up: Heavy-duty operations
G lights up: Normal operations
When starting the engine, H (heavy-duty

ooeration) mode is automatically selected. ’
Iperation of auto-decelerationswitch 2 ON lights up: Auto-deceleration is
actuated.
OFF: Auto-deceleration is canceled
Each time the switch is pressed, the auto-

deceleration
.__-___.-_ is- actuated or canceled.
Operation of heavy lift switch When the switch is turned ON during
independent operations of the boom, the
@ Komatsu copy
6/l 3
Local After
time operation
I- Operation of starting switch OFF position:

ON position:
Engine is stopped
Electric current flows in the
charging and lamp circuits.
START position: Engine is started.
Operation of fuel control dial MAX: Full speed
MIN: Low idling
Operation of cigarette lighter This is used to light cigarettes. To use, push
the lighter in. After a few seconds it will
sorina back.
Operation of swing lock switch ON position (actuated):
The swing lock is always applied, and the
upper structure will not swing even if the
swing is operated. In this condition, the
swing lock lamp lights up.
OFF position (canceled):
The swing lock is applied only when all
work equipment control levers are at
neutral; when any work equipment
control lever is operated, it is canceled.
The swing lock is actuated approx. 4
seconds after all work equipment control
lever is Dlaced in neutral.
Operation of wiper switch 0 OFF: Wiper stops
@ ON: Wiper moves continuously
position @_
@ ON: Wiper moves intermittenly
position @.
Operation of lamp switch This switch is used to turn on the front lamps
!!? working lamps, additional lamp at the top
!Z front of the cab, rear lamps, and monitor
-Q)
lighting.
%? .
E Operation of alarm buzzer stop switch This is used to stop alarm buzzer if it sounds
g to warn of an abnormality during operation.
Z Operation of car heater fan switch (option) ON: Fan is started
5
= OFF: Fan is stoooed.
3
fn .
Operation of machine push-up switch Low pressure setting:
5
Y The boom thrust force is weak.
g High pressure setting:
if The boom thrust force becomes more
I I I I powerful.
Operation of boom shockless control switch When the switch is at the ON position and
the boom is stopped, the shaking is not felt.
Operation of horn switch Press the switch on the right work equipmenl
control lever to sound the horn.
At the same time, the flashing light (option)
at the top front of the cab will flash for
aporox. 5 seconds.
I I Operation of room lamp switch

I I I
ON position: Room lamp lights up.
Operation of pump prolix switch When normal:

When abnormal:
(TVC valve system error), move the
switch up to make it possible to carry out
work. _-- _-_ - .
@ Komatsu copy
*
g
=
.g Local After
2 5 Check item assembly hours of Judgement standard
6 ; time operation
Operation of swing prolix switch When normal:

When abnormal:
(Swing brake system error), the brake is
canceled, and it becomes possible to
actuate the swing and carry out normal
operations. However, the swing brake
remains released.
Operation of step light switch l When the switch is pressed, the step
light will light up for approx. 60 seconds.
l Even if the starting switch key is at the
OFF position, the step light will light up
for approx. 60 seconds when the switch
is pressed.
Operation of safety lock lever Pull the lever up to apply the lock_
This lock lever is a hydraulic lock, so even if
it is in the lock position, the work equipment
control lever and travel lever will move, but
the work equipment, travel motor, and swing
motor will not work.
Operation of travel levers FORWARD:
The lever is pushed forward.
(The pedal is angled forward)
REVERSE:
The lever is pulled back.
(The pedal is angled back)
N (Neutral):
The machine stops.
Operation of left work equipment control lever This lever is used to operate the arm and
(with auto-deceleration device) upper structure.
Arm operation Swing operation
@ ArmOUT @ Swing to right
@I ArmiN @I Swing to left
N (Neutral):
When the lever in this position, the
upper structure and the arm will be
retained in the position in which they
stop.
Operation of right work equipment control lever This lever is used to operate the boom and
(with autodeceleratiom device) bucket.
Boom operation Bucket operation
@ RAISE @ DUMP
@ LOWER @ CURL
N (Neutral):
When the lever in this position, the boom
and the bucket will be retained in the
position in which they stop.
@ Komatsu copy
8/13
(Work equipment posture: Max. reach)
(Work equipment posture: Travel posture)
Max. 200 mml20m
considered that
there is abnormality.)
Track rotating H
@ Komatsu copy
9/l 3
Note: All jut
Work equipment operation running in: Engine high idling speed,

(Note: Boom cylinder to ground level)
Pressurized; each port relief 2 minutes, shock 20 times (except BOOM LOWER).
Work equipment posture
eooa
under no load, there must be no stalling
Abnormal noise, grating noise from work equipment There must be none.
Immediately after engine is stopped, boom

cylinder must move from fully extended
position to ground level. (Arm at max. reach)
@ Komatsu copy
l There must be no catching during

Operating force of control lever when each actuator is actuated. operation.
l Must return naturally to neutral.
Feeling and noise of vibration in operator’s cab There must be none.
2
I rVibration noise from frame, guard, ladder 1Theremust be none.
Movement of doors and windows
(Idler, roller, sprocket, final drive gear case, motor, brake valve)
I ILooseness of track shoe bolt 1There must be none.
I I Oil leakage
) 1 I I ITberemustbenone.
Center swivel, pump, solenoid valve, relief valve, control valve,
IPPC valve, swing motor, brake valve, shuttle valve, swing

machinery, hydraulic tank, piping)
Leakage of fuel
There must be none.
[Fuel tank, engine, piping]
Leakage of water from engine cooling water system There must be none.
Leakage of oil from engine lubrication system There must be none.

!
Leakage of gas from engine gas system There must be none.
Movement of covers Must move smoothly.
Cover locks Must lock securely.
@ Komatsu copy
11/13
1Operation of grease pump 1 Must work smoothly.
Looseness, insufficient insertion of electric wiring terminals 1There must be none.
There must be a clearance of at least 10 m

Position for passing electrical wiring throuth
from any moving part or edge.
Leakage of air from air system There must be none.
Interference between bucket and arm stopper
Contact between front bucket and rear bucket stopper

I I I I When one side contacts, other side
clearance: Max. 10 mm
@ Komatsu copy
Note: lf the operation or function is defective, measure as necessary. Ali judgement standard values for speeds are the values in OH mode.
Local After
time operation
1. Engine speed
Low idling speed
I I High idling speed

I I
I I Speed at boom RAISE relief

(Heavy lift: OFF) l 1850 2 700 rpm
Speed at boom RAISE relief

I I (Heavy lift: ON) [ rpmI I I
1 1800 -e 100 rpm 1
2. Rediator fan’speed
Speed at engine rated speed
13. Oil pressure measurement (measure at pump outlet port)
3wulg 4spo01
set pressure valve I
_I I II I I
z
Control valve main L.H5-spool
5 set pressure valve I Mpf1
{kglcm kg/ant)
Travel relief Right MPa
set pressure travel W& 1 Relieved on one
Travel relief Left MPa 131.4 -‘::5” MPa
L
Iset pressure travel I Wcm21 I,
MPa
Swing relief5et pressure
Wcm21 I
NC valve output pressure(at top Max.

surface of NC valve) No.1 and 0.39 MPa I
No.2Dump
II NC valve output pressure (at top

surfaceof NC valve) No.3pump
MPa
{Wm2) I1 MPa
Vwm21
j/ I I0.39 MPa
{4 k&m*)
Note: Measure the following J/S differential pressure only if the NC
H valve output pressure does not pass the test.
At neutral At relief
J/s differentialpressure (differential
MPa
jet sensor) No.1 and No.2 pump W4/cm21
r 1 J/Sdifferential pressure (differential
@ Komatsu copy
13113
Check item
hydraulic drift at the bucket tooth tip does not pass the test.
Max. 17 mm/minute
@ Komatsu copy

Manual: Field Assembly

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Manual: Field Assembly

Uploaded by

Copyright:

Available Formats

Field

Copyright 2000 Komatsu

ASSEMBLY OF POWER-ASSISTED LADDER .I.......................................................................... 127

C. PC1800 INSTALLATION OF BACKHOE WORK EQUIPMENT ..I.......................................... 135

ASSEMBLY MANUAL FOR LOADING SHOVEL WORK EQUIPMENT ..................................... 171

M. INSPECTION AND SERVICING PROCEDURES AFTER FINNISHING

Item Unit PC 1800-6

Bucket capacity BACKHOE m3 (cu.yd) 12 (15.5)

1. Tightening torques for bolts

Table 1 Unit: kgm

6 . I 0.9 - 1.5 I 1.2

8 1.5 - 3.5 2.5

12 I 5.5 - 12.5 I 9.0

14 8.5 - 20.0 14.0

18 20.5 - 43.5 32.0

27 90.0 - 150 120

30 115 - 195 155

33 150 - 250 200

36 190 - 310 250

39 230 - 370 300

Table 2 Unit: kgm

Material S43C, SCM 3H, equivalent, or higher

6 1.2 - 1.5 1.35 1150

8 2.8 - 3.5 3.2 2175

10 6 - 7.5 6.7 3355

12 10 - 12.5 11.5 4865

16 25 - 31.5 28.5 9350

22 67.5 - 84.5 76 18000

24 84 - 105 94.5 20600

27 120 - 150 135 26000

30 155 - 195 175 30100

33 200 - 250’ 225 35800

36 250 - 310 280 40700

39 295 - 370 335 45200

2. Tightening torque for pipe threads

Table 1 Unit: kgm

Steel Cast iron Light alloy

l/4 0.6 - 1.2 0.5 - 1 .O~~~ 0.2 - 0.8

l/2 I 3.3 - 5.4 I 2.7 - 4.4 I 2.0 - 3.3

3/4 5.2 - 8.7 4.3 - 7.2 3.2 - 5.4

Table 2 Unit: kgm

S tee1 Cast iron Light alloy

l/4 2.0 - 4.5 1.7 - 3.8 I 1.3 - 2.9

l/2 10.0 - 19.2 8.5 - 16.1 6.2 - 11.8

3/4 17.4 - 32.3 14.4 - 25.2 10.8 - 19.0

1 37.5 - 62.5 31.6 - 52.5 24.0 - 40.0

3. Tightening torque for rubber hoses with taper seal

Unit: kgm (Nm)

-k Be careful to assembly the rubber hoses without twisting.

Nominal bolt Width Specified torque range

BACKHOE Short boom, short arm; low cab

Width: 1,714mm (without ladder: 1830 mm),

3510 Width: 1,600mm

P&s sent individually

Both ends of tube:

pins and covers temporarily

Tighten pins and covers temporarily

Komatsu genuine tooth:

~-26 ,Grease reel sub-assembly,

\r-6;;;;;1 With grease piping -

Assemble clamp for air conditioner hose

* Transported with right PPC hose connected

Blind the drain piping Blind the