Service News BT04133A Page 1 of 26

1. Preface
To prevent pins and bushings from noising, take care of the following for assembling:
a) Apply the molybdenum disulphide (LM-P) to the inner surfaces of the bushings and
mounting bosses on the work equipment and cylinders.
Be sure to apply LM-P to the inner surface of the boom cylinder head mounting boss
especially.
b) Apply the molybdenum disulphide grease (LM-G) to the pins of the work equipment
before inserting the pins.

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 Service News BT04133A Page 2 of 26

2. State of sub-assembly parts and blank cap position for each part
Fig. 1 shows the state of the sub-assembly parts and the blank cap position for each part.
Remarks In Fig. 1, marked indicate the reused parts at mounting of the hose.

(1) The pin lock is attached in the fixing side.

(2) The bushing is pressed into the bearing. Portion A5
(3) The antirust treatment is applied to the pins and pinholes.
(4) The antirust treatment is applied to the inner surface of the bushing.
(5) The cylinder is filled with oil.
(6) The following parts are packed separately in another box:
Work equipment looseness adjusting shims, boom working lamp, boom cylinder grease
fitting, rearview mirror, track frame gauge extension bar, bolts, washers, and spacers
Portion A2
Portion A2

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Portion A2
Portion B5 Boom cylinder assembly (R.H.)
Portion A2

Boom cylinder assembly (L.H.)

07371 07371

Flange-type rubber hose

07378

Portion B4 01643

07372, 01010, or 01435

07000 07000

07379 07372 or 01010 07370

01643
Type (B) Type (A)
Body assembly

Fig. 1
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3. Treatments before and after assembly

3.1 Treatment before assembly
(1) Secure an indoor workplace that is not affected by wind, rain, dusts, and so on.
(2) Pay attention to safety measures during work. (Secure a flat and appropriately wide
place that causes no trouble for working, and ensure security for crane work during
transport and attachment.
(3) When unpacking, take great care not to cause a damage of piping, wiring, small parts,
and so on.
(4) Check the number of parts and confirm whether they are damaged.
(5) The antirust agent is applied to the inner surface of the pins, pinholes, and bushings.
Wipe it off with Three Bond 2706.
(6) Check that the inner surfaces of pins, pinholes, and bushing are not dusty.
If they are dusty, carefully wipe it off with a waste cloth.
Apply the Komatsu-designated grease (LM-G: molybdenum disulphide grease) to each
pin.
Also apply the molybdenum disulphide (LM-P) to the inner surfaces of the bushings and
mounting bosses.
(7) Loosen the oil filler cap in the hydraulic tank by degrees with the engine stopped, then
bleed the internal pressure of the tank.
(8) Turn the key on with the engine stopped. While keeping the safety lock lever open,

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move the work equipment operation lever with full strokes two or three times backward,
forward, leftward, and rightward, then bleed the residual pressure.

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3.2 Treatment at assembly

(1) For the disassembly/assembly procedures and cautions not described in this service
news, see the shop manual.
(2) Take care that no foreign matter gets into the oil circuit until the hose is attached after
removing the blank cap.
(3) Minimize an oil leakage when removing the blank cap and attaching the hose and
cylinder.
(4) Carefully attach the rubber hose so that it is not twisted.
(5) For attachment, take care not to cause any defect due to dusts, rust, damage, etc.
(6) Properly grease up each portion.
Use the Komatsu-designated grease (LM-G: molybdenum disulphide grease).
(7) To grease up after assembly, use the molybdenum disulphide grease; however, the
viscosity at low temperature (0°C or less) increases depending on brands, so it may be
difficult to grease up.
A remote grease portion especially requires a larger pressure. If it is hard to grease,
follow the steps below.
a) For a remote grease portion, directly attach a fitting to the pin to grease, then re-
assemble the hose. (Hose tightening torque: 0.4 - 0.8 kgm)
b) Heat the grease (50 - 60°C) to reduce the viscosity before greasing.

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 Service News BT04133A Page 5 of 26

(8) See Table 1 for the bolts and nuts with no tightening torque specified.

Table 1
At use of torque wrench
Material S43C, SCN435H, or better
Nominal diameter Range
of thread (mm) Unit Nm Unit kgm
6 11.8 - 14.7 { 1.2 - 1.5 }
8 27 - 34 { 2.8 - 3.5 }
10 59 - 74 { 6 - 7.5 }
12 98 - 123 { 10 - 12.5 }
14 157 - 196 { 16 - 20 }
16 245 - 309 { 25 - 31.5 }
18 343 - 427 { 35 - 43.5 }
20 490 - 608 { 50 - 62 }
22 662 - 829 { 67.5 - 84.5 }
24 824 - 1030 { 84 - 105 }
27 1180 - 1470 { 120 - 150 }

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30 1520 - 1910 { 155 - 195 }
33 1960 - 2450 { 200 - 250 }
36 2450 - 3040 { 250 - 310 }
39 2890 - 3630 { 295 - 370 }

3.3 Treatment after assembly

(1) Check the following items:
a) Whether the hydraulic tank cap is fastened securely
b) Whether the quantity of the hydraulic oil is as specified. If it does not reach the
specified level, add the Komatsu-designated oil.
(See the operation and maintenance manual.)

(2) Bleed air from each cylinder.

a) With the engine running at low idle, slowly extend and contract each cylinder the first
four or five times to about 100 mm before the stroke end is reached.
b) Move the boom cylinder to the stroke end the next three or four times.
When the arm and bucket cylinders move to the stroke end, they may interfere with
the boom depending on their types.

(3) Check whether the quantity of the hydraulic oil is as specified.

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Field-Installation Procedure
Packaging at shipment
No. Description Remarks
1 Main body Excluding operation cab
2 Weight
3 Boom and arm ASSY's Pipe boom unit, arm unit, arm cylinder, bucket cylinder
4 Bucket ASSY Bucket unit, pin
5 Others (Mirror, handrail, etc.) Including operator's cab, boom cylinder and garnish

List of parts to attach and work flow Application by manufactured region

Manufactured
Manufactured Manufactured
No. Description in North Others
in Japan in Europe
America
1 Attaching the sound absorbing material at front surface of
the weight.
2 Attaching the boom cylinder.
3 Connecting the boom working lamp wires.
4 Removing the boom cylinder rod pin.
5 Attaching the weight.

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6 Attaching the boom and arm ASSY's to the main body.
7 Attaching the boom cylinder rod to the boom.
8 Connecting the boom pipe to the main valve.
9 Attaching the pipe to the bucket.
10 Attaching the bucket to the arm.
11 Connecting the bucket open/close pipe.
12 Checking the hydraulic oil level and greasing up.
13 Attaching the mirrors (left and right) and handrail.
14 Extending the variable gauge
- -
(For machines based on variable gauge specifications).
15 Attaching the pipe cover
- -
(For machines based on variable gauge specifications).
16 Attaching the riding step.

Weight list by specifications

Civil engineering
Fixed gauge Variable gauge
STD LC STD LC Shoe: 600 mm
Main body 1 23,900 24,900 25,200 26,000 Crawler integral type
Main body 2 - - 13,200 13,200 Crawler separate type
Crawler ASSY - - 12,000 12,800
Weight 9,200 9,200 9,200 9,200 Common to all domestic specifications Fig. 2
Boom arm ASSY 5,600 5,600 5,600 5,600
Bucket ASSY 3,700 3,700 3,700 3,700
Others 700 700 700 700 (Boom cylinder, mirror, handrail, etc.)

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1. Attaching the sound absorbing materials to front surface of the weight

1 Adhere four sound absorbing materials. (Note 1)

(Note 1) Remove grease and rust on the adhesive surface.

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No. Part No. Part name Q'ty Specifications

1 208-46-74251 SHEET 1 (AUF, t50) EU
208-46-74150 SHEET 1 (PET, t35) Japan, N.A.
2 208-46-74231 SHEET 1 (AUF, t50) EU
208-46-74130 SHEET 1 (PET, t35) Japan, N.A.
3 208-46-74241 SHEET 1 (AUF, t50) EU
208-46-74141 SHEET 1 (PET, t35) Japan, N.A.
4 208-46-74260 SHEET 1 (AUF, t50) EU
208-46-74160 SHEET 1 (PET, t35) Japan, N.A.

Fig. 3

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2. Attaching the boom cylinder

1 Apply LM-P to the inner surfaces of the boom cylinder (bottom/head) bushings.
(4 portions)
2 Apply LM-P to the inner surfaces of the boom cylinder mounting bracket bosses (left and
right).
3 Mount the right boom cylinder in the boom foot unit.
4 Insert shims in the pin insertion side. -> Insert shims in both sides of the boss.
5 Insert the cylinder bottom pin.
6 Fit shims in both ends of the cylinder boss. (Note 1)
7 Attach the fixing plate and fasten the bolt.
8 Perform the same procedure in the left side.
9 Remove the cap of the hydraulic hose, and mount the split flanges. (Notes 2 to 4)
(Note 1) Determine the number of shims so that the clearance between both ends is
1.5 mm or less.
(Note 2) Take care of the left and right of the pipe and cylinder.
(Note 3) To install the split flanges, take care not to twist the hose.
(If the hose is twisted outward, it may interfere with the revolving frame at the
maximum excavation.)
(Note 4) Bleed the residual pressure before connecting the pipe. (For the procedure, see
page 14.)

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1 2

8
7
Determine the
number of shims so
that the clearance is
8
1.0 mm or less. 3
4
5 6
No. Part No. Part name Q'ty
1 707-01-XT330 CYLINDER (L.H.) 1
2 707-01-XT340 CYLINDER (R.H.) 1
3 208-70-61210 PIN 2
4 205-70-66580 PLATE 2
5 01643-31232 WASHER 4
6 01010-81235 BOLT 4
7 207-70-11340 SPACER (t1.5) 2 Fig. 4
8 207-70-11350 SPACER (t0.8) 6
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3. Connecting the boom working lamp wires

1 Attach the working lamp and bracket. (Note 1)

2 Connect the working lamp wiring connectors. (2 portions)
(Note 1) Fasten the earth cable together.

4. Removing the boom cylinder top pin

1 Temporarily remove the pin indicated by A in Figure 5.

1
34
5 6

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No. Part No. Part name Q'ty

1 20Y-06-25310 WORK LUMP ASS'Y 1
2 20Y-06-21551 BRACKET 1
3 01010-81430 BOLT 1
4 01643-31445 WASHER 1
5 01010-81220 BOLT 1
6 01643-31232 WASHER 1

Fig. 5

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5. Attaching the weight

1 Fasten four mount bolts.

Tightening torque: 3430 Nm - 4212 Nm (350 - 430 kgm)
(Note 1) Insert shims to fair the facing.
(Reference) Counter weight: Approx. 9,220 kg (for Japan and EU)
Approx. 9,500 kg (for N.A.)

For this work, keep the traveling body

in the lower side parallel with the swing
body in the upper side.

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(DxP)
42x3
Width across flat: 65

No. Part No. Part name Q'ty

1 208-46-74121 BOLT 4
2 01643-34212 WASHER 4
3 208-46-52260 SHIM (t1) 4
208-46-52270 SHIM (t0.5) 4

Fig. 6

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6. Attaching the boom and arm ass'y to the main body

0 Press the dust seal into the boom foot, taking care of the direction.
1 Remove four bolts, then remove the front cover of the fuel tank. (The lower side is cut in
a U shape.)
2 Apply LM-P to the inner surfaces of the boom foot bushings. (3 portions)
3 Apply LM-P to the inner surfaces of the boom foot bracket bosses (left and right).
4 Temporarily insert the boom foot pin in either side of the revolving frame.
5 Hoist the boom ass'y with a crane to meet the boom foot hole to it.
6 Insert shims in both the left and right. (Note 1) -> Important
7 Press the pin into the foot part.
8 Attach the lock plate and fasten the bolts.
9 Attach the front cover of the fuel tank. (4 bolts)
(Note 1) Adjust the number of shims so that the clearance between the boom foot edge
and bracket is 1 mm or less.
(Note 2) Bleed the residual pressure before connecting the pipe. (For the procedure, see
page 14.)
1 Front cover of
fuel tank
5
3
4 2

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Determine the number of
shims so that the clearance
is 1 mm or less.
5
5
5
F 6
7
Take care of the
lip direction.

Outside

No. Part No. Part name Q'ty

1 208-70-71590 PIN 1
2 205-70-61560 PLATE 1
3 01010-82045 BOLT 2
4 01643-32060 WASHER 2
5 208-70-51310 SPACER (t1.5) 4
6 208-70-31290 SPACER (t0.8) 1 Fig. 7
7 07145-00120 DUSTSEAL 2
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 Service News BT04133A Page 12 of 26

3. Attaching the boom cylinder rod to the boom

1 Apply LM-P to the inner surfaces of the boom cylinder head mounting bracket bosses (two portions
in all).
2 Grease the boom cylinder top pin and temporarily insert the pin in the boom.
3 Start the engine and turn the safety lock lever off (in work).
4 Keep the engine in the low idle mode.
5 Bleed air from each cylinder. (For the procedure, see page 14.)
6 Carefully move the boom cylinder head in the extension direction (boom up), holding it with the
crane.
7 Stop the crane at the pin position, then knock in the pin with a hammer.
8 Insert shims and fix the spatulate part with a plate.
9 In the same way, insert shims and fix them with a plate in the opposite side. (Note 1)
10 Attach the grease hose to the boom grease block.
11 Attach the grease elbow to the boom cylinder top.
12 Connect the grease hose to the grease elbow.

(Note 1) Determine the number of shims so that the clearance is 1.0 mm or less.

3.4 2
Fix the spatulate part
with a plate again.
1
Pin removed in step 5

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5
6 Adjust the number of
Angle of grease shims so that the
elbow: 30° clearance is 1.0 mm
or less.

7
No. Part No. Part name Q'ty
1 208-70-31210 PIN 2
2 205-70-66580 PLATE 2
3 01010-81235 BOLT 4
4 01643-31232 WASHER 4
5 207-70-31340 SPACER (t0.8) 6
6 205-70-65780 ELBOW 2 Fig. 8
7 205-70-51360 HOSE 2
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7. Connecting the arm and bucket bottom pipes

1 Bleed the residual pressure. For details, see the procedure below.
2 Connect the hydraulic hose of the arm and bucket bottom.
3 Grease up the parts other than the bucket attachment part.
4 After assembly, bleed air of the boom cylinder, arm cylinder, and bucket cylinder.
<For air bleeding, see the procedure below.>

(Note 1) For assembly, take care not to twist the high-pressure rubber hose.
(Note 2) For assembly, take care not to cause a damage due to dusts, rust, flaw, and so
on.
(Note 3) For the bolt tightening torque, see Table 1.
Take care of the residual pressure when removing the blind plate.
<<Residual pressure bleeding procedure>>
1. Start the engine.
2. Stop the engine.
3. Turn the key on.
4. Turn the safety lock off.
5. Carefully move the operation lever; the residual pressure is bled.
<<Cylinder air bleeding procedure>>
1. Run the engine at low idle, then extend/contract each cylinder four to five times

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(stop this action about 100 mm before the stroke end is reached), taking care not to
work it to the stroke end.
2. Move each cylinder to the stroke end three to four times.
3. Also move each cylinder to the stroke end four to five times to completely bleed air.
Note) When bleeding the air from the bucket cylinder, keep the Bucket installed.
If the bucket cylinder is moved to the stroke end without the bucket installed, the
arm and the cylinder will interfere and the cylinder will be damaged.

F
G
B
D C

E A
F
G
A B C D E
A: Arm cylinder bottom 1 (Extended)
B: Arm cylinder bottom 2 (Extended)
C: Bucket cylinder head (Contracted)
D: Bucket cylinder bottom (Extended)
E: Arm cylinder head (Contracted)
F: Bottom cylinder bottom (Extended (Bucket close)) Fig. 9
G: Bottom cylinder head (Contracted (Bucket open))
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7. Connecting the arm bucket bottom pipes

4 3
2
1
1

3 3
2 2
1 1

2 3
1
(This figure shows only the arm and bucket pipings.)

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5

7
8

6
(This figure shows only the bottom piping.)

No. Part No. Part name Q'ty

1 07000-13032 O-RING 5
2 07371-31049 FLANGE 10
3 07372-21035 BOLT 20
4 01643-31032 WASHER 20
5 07000-13025 O-RING 2
6 07371-30640 FLANGE 4
7 07372-21035 BOLT 8
8 01643-31032 WASHER 8

Fig. 10

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9. Connecting the bucket bottom pipes

1 Remove the bucket covers B and C.

2 Remove the blind plug of the hydraulic block, then connect the hose.
(Reuse the split flanges, blots, and so on.)
3 Install covers B and C again.

C B Do not remove the dust

protective cap.

1 2

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No. Part No. Part name Q'ty

1 208-72-56620 HOSE 2
2 07000-13025 O-RING 2

Fig. 11

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10. Attaching the bucket

1 Press the dust seal in the arm and bucket link, taking care of the direction. (4 portions x 2)
2 Remove the pin from the bucket.
3 Apply LM-P to the inner surface of the bushing in the arm and bucket link connection part.
4 Fit the arm to the bucket hole.
5 Align the link hole and the bucket hole.
6 Attach the greased pin.
7 Apply the grease from the grease nipple.

Take care of the

(Do not attach shims to the bucket.)
lip direction.

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No. Part No. Part name Q'ty

1 208-72-11150 SEAL 4
2 207-72-13150 SEAL 4

Fig. 12

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10. Attaching the bucket hose

1 Remove the blind plate of the arm pipe. (Reuse the split flanges and bolts.)
2 Attach the hose.
3 Bleed air from the bottom cylinder.
4 After assembly, flash all the piping circuits.

Bottom view of arm + bucket

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Hose connection destinations

Arm piping in left of machine ----- Lower bucket hose
1
Arm piping in right of machine --- Upper bucket hose

No. Part No. Part name Q'ty

1 07000-13025 O-RING 2

Fig. 13

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12. Checking the hydraulic oil level and greasing up

1 Run the engine at low speed; pull in the arm cylinder;

extend the bucket cylinder; and lower the boom to
ground the bottom of the bucket. Then stop the engine.
2 Shift each operation lever in each direction with a full
stroke, and bleed the inner pressure.
3 Remove the cap of the hydraulic tank, and bleed the
inner pressure of the tank. (Loosen the cap by degrees,
and leave it for a few minutes before opening it.)
4 When the hydraulic oil level is not between H and L, add
the hydraulic oil.
5 Grease up: Grease each part.
Use LM-G as the grease.
1) Boom cylinder foot pin (2 pieces)
2) Boom foot pin (2 pieces)
3) Boom cylinder top pin (2 pieces)
4) Boom cylinder bottom pin (1 piece)
Fig. 14
5) Boom-arm connection pin (2 pieces)
6) Bucket cylinder bottom pin (2 pieces)

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7) Arm cylinder top pin (1 piece)
8) Arm (link connection) (2 pieces)
9) Bucket-link connection pin (2 pieces)
10) Arm top pin (2 pieces)
11) Bucket - bucket cylinder top connection pin (2 pieces)
12) Bucket open-close pin (2 pieces)
13) Bottom cylinder pin (Head: 2 pieces, Bottom: 2 pieces)
5-1. Grease each part while holding position B.
5-2. Carefully move the arm and bucket three to four times, and return the body to position
A. Then grease them again. (Excluding the boom part)
5-3. Carefully move the boom up and down three to four times, and return the body to
position C. Then grease the boom part again.
5-4. Open and close the bucket three to four times, then grease the bucket open-close pin
again while keeping the bucket open.

Position B

Position A
Position C

Position A

Fig. 15
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11. Attaching the mirrors and handrail

(1) Attach the support and mirror according to the rearview mirror attachment (right) figure.

(Note 1) For attachment of the rearview mirror, see the Mirror Attachment procedures
(209-98-77220 and 207-54-71863).

(Note 1)

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No. Part No. Part name Q'ty

1 207-54-71840 SUPPORT 1
2 20Y-54-61630 CLAMP 1
3 01252-71030 BOLT 2
4 421-54-25610 MIRROR 1
5 04025-00632 PIN 1
6 01252-70545 BOLT 4

Fig. 16

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Pass pin <5> through the hole of clamp <3>; clip mirror <1> with holder <2>; secure it
with screw <4>; then confirm that the mirror is fixed.

<1>

Insert pin <5> in the

<3> hole.

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<4>
<5>

Fig. 17

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(2) Attach the left rearview mirror and grip (used to help you to get in and out the machine)
Attach the support and mirror according to the figure below.

(Note 2) For attachment of the rearview mirror, see the Mirror Attachment Procedure
(207-54-71863).

2
4
3
1

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5
6

Remove the cork plug.

No. Part No. Part name Q'ty

1 08174-13118 MIRROR 1
2 20Y-54-35420 SUPPORT 1
3 20Y-54-35430 CLAMP 1
4 01252-41030 BOLT 2
5 207-54-66120 SUPPORT 1
6 01024-81225 BOLT, SEMS 2

Fig. 18

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13. Extending the variable gauge (For machine based on variable gauge specifications)

1 Remove center frame attachment bolt <2> (eight pieces front and rear in each side) front
and rear of the track frame to be extended.
2 Turn the upper swing body so that it is at a right angle with track frame (A) to be
extended.
3 Put a square log <3> ( 100 - 150) inside crawler track (B) of track frame (A) to be
extended.
4 Move the upper swing body using the work equipment; the track frame moves outside the
machine, using corner (C) of the square log as a support point.
5 Repeat steps 3 and 4 to extend the body until it reaches the stopper bolt. Then carefully
take down the body on the land, and fasten bolt <1> (16 pieces front and rear in each
side).
Tightening torque: 155 - 195 kg·m (1520 - 1910 N·m)
6 In the same way, treat the opposite track frame.
(Note 1) The track frame gauge width must be extended/shortened on the horizontal and
solid ground.
(Note 2) Do not perform a quick operation for each cylinder while extending/shortening the
track frame gauge width.
(Note 3) To shorten the gauge width, put square log <3> outside the crawler track (D). The
others are the same as the extension steps.

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Center frame

<2>

Track frame
(A)
Center frame
<1>

<1>
(C)
Move up and down
-

Track frame

<3>
(D) (B)
No. Part No. Part name Q'ty
1 208-30-12130 BOLT 36
2 208-30-75390 WASHER 36

Fig. 19
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Notes on extending/shortening the variable gauge

(for machine based on variable gauge specifications)
The bolts must be attached according to the four places indicated by *; so first screw
the bolts at the four places.

* *

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* *
Fig. 20

Fig. 21

To fasten the bolts, use a hydraulic jack to jack up the crawler track as shown above,
and secure an enough space to fasten them.

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<<Remarks>> Notes on driving motor piping when extending the variable gauge
1. After extending the gauge, adjust the slack pipe for driving
In this case, pull the hose to the (B) direction, then secure the lower and
upper clearances with the center frame in portion (A) below 20 mm or more.

* Attach the driving pipe cover, then check the clearances again.
(This is because the hose may return to the inside of the center frame when
the cover is pressed.)

Secure a clearance with the

center frame in portion (A)
20 mm or more.

(B)

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Fig. 22

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14. Attaching the driving pipe cover (for machine based on variable gauge specifications)

1 Extend the track frame gauge, then attach the driving pipe cover.

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No. Part No. Part name Q'ty

1 208-30-75311 COVER 1
2 208-30-75321 COVER 1
3 01010-81635 BOLT 6
4 01643-31645 WASHER 6
5 208-30-75332 COVER 1
6 208-30-75342 COVER 1
7 01010-81640 BOLT 4
8 01643-31645 WASHER 4
9 208-30-75351 COVER (L.H) 1
10 208-30-75361 COVER (R.H) 1
11 01010-81635 BOLT 8
12 418-18-31160 WASHER 8
13 208-30-58230 BRACKET 2
14 01010-81635 BOLT 8
15 01643-31645 WASHER 8

Fig. 23
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15. Lifting step

1 Attach four steps.

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No. Part No. Part name Q'ty

1 208-30-71260 BRACKET 4
2 01010-81640 BOLT 16
3 01643-31645 WASHER 16

Fig. 24

BT04133A