Field Assembly PC1250SP-8

GEN00055-08
Field Assembly Instruction
HYDRAULIC PC1250 -8
EXCAVATOR
PC1250LC -8
PC1250SP -8
SERIAL NUMBERS 30001 and up
CONTENTS
Specifications ...................................................................................................................... 1
Precautions for Field Assembly ........................................................................................... 3
Assembling Procedures, Applicable Equipment and Schedule ........................................... 4
Kit Layout Diagram .............................................................................................................. 5
Transportation ..................................................................................................................... 6
List of Tools for Field Assembling ........................................................................................ 14
Tightening Torque ................................................................................................................ 15
Coating Materials ................................................................................................................ 21
List of parts sent individually ................................................................................................ 23
A. Assembly of Chassis ....................................................................................................... 33

A- 1. Installation of Left and Right Track Frames ........................................................... 34
A- 2. Installation of Travel Piping .................................................................................... 37
A- 3. Installation of Travel Piping Covers ....................................................................... 39
A- 4. Installation of Steps ................................................................................................ 41
A- 5. Filling Swing Circle with Grease ............................................................................ 42
A- 6. Assembly of Upper Structure and Undercarriage .................................................. 43
A- 7. Installation of Right Side Steps .............................................................................. 45
A- 8. Installation of Handrails ......................................................................................... 46
A- 9. Installation of Swivel Travel Piping ........................................................................ 47
A-10. Sticking Sheet to Counterweight (EU specification) .............................................. 48
A-11. Installation of Cover board (To the Counterweight) ............................................... 49
A-12. Installation of Counterweight ................................................................................ 50
A-13. Installation of Left Side Steps (Including handrails) .............................................. 51
A-14. Installation of Radiator Cover (Standard specification) ......................................... 54
A-15. Installation of Muffler Tail Pipe .............................................................................. 59
A-16. Changing of Mounting Position of Step Light ........................................................ 60
A-17. Installation of Handrail to the Cab ......................................................................... 61
A-18. Installation of Left Rearview Mirror ....................................................................... 62
A-19. Installation of Right Rearview Mirrors ................................................................... 64
A-20. Installation of Rearview Mirror (On the Counterweight) (EU specification) ........... 66
A-21. Preparation for Bleeding Air from Travel Motor ..................................................... 67
A-22. Procedure for Bleeding Air From Hydraulic Circuit ............................................... 68
A-23. Permanent Tightening of Swing Circle Mounting Bolts ......................................... 69
A-24. Testing Track Shoe Tension .................................................................................. 70
A-25. Check Fuel, Coolant and Oil Levels ..................................................................... 73
A-26. Parts to be Touched up after Field Assembly ........................................................ 75
B. Assembling of Work Equipment of Backhoe ................................................................... 77

B- 1. Installation of Arm Cylinder .................................................................................... 78
B- 2. Installation of Arm Cylinder Hoses ......................................................................... 79
B- 3. Installation of Boom Cylinder Foot ......................................................................... 80
B- 4. Installation of Boom Cylinder Hoses ...................................................................... 81
B- 5. Installation of Boom Foot Dust Seal ...................................................................... 82
B- 6. Installation of Boom Assembly ............................................................................... 83
B- 7. Installation of Boom Cylinder ................................................................................. 84
B- 8. Installation of Boom Hoses (Between machine and boom) ................................... 85
B- 9. Installation of Arm Assembly .................................................................................. 86
B-10. Installation of Bucket Cylinder Hoses between Boom and Bucket Cylinder ......... 88
B-11. Installation of Bucket Assembly ............................................................................ 89
B-12. Clearance Standard for Installation of Work Equipment ....................................... 92
B-13. Installation of Work Equipment Grease Piping ..................................................... 93
B-14. Procedure for Bleeding Air From Travel Motor ..................................................... 94
B-15. Bleeding Air from Swing Motor ............................................................................. 96
B-16. Bleeding Air from Cylinder .................................................................................... 97
B-17. Installation of Work Equipment Wiring .................................................................. 98
B-18. Greasing after Assembling Work Equipment ........................................................ 99
M. Procedure for Inspection and Maintenance after Completion of Assembly .................... 101
M- 1. Replacement of Return Filter (Standard Filter to Flushing Filter) .......................... 102
M- 2. Relieving Remaining Pressure from Hydraulic Circuit ........................................... 105
M- 3. Installation of Flushing Tubes ................................................................................ 106
M- 4. Flushing of Hydraulic Circuit .................................................................................. 108
M- 5. Replacement of Pilot Filter (Flushing filter to Standard filter) ................................. 109
C. Procedure for assembling work equipment of loading shovel ......................................... 111
Field Assembly Inspection Report (Backhoe)
Field Assembly Inspection Report (Loading shovel)

SPECIFICATIONS
Machine model PC1250-8 PC1250-8 PC1250SP-8 PC1250LC-8

(EU specification)
Weight of machine kg 109,900 116,900 111,700 113,500

3
Bucket capacity m 5.2 6.7 5.2
Engine model – SAA6D170E-5
kW/rpm {PS/rpm} 502{672}/1,800
(ISO 9249)
Flywheel horsepower kW/rpm {HP/rpm} 515{700}/1,800
(ISO 14396)
Min. ground clearance mm 990
Travel speed (Low/High) km/h 2.1/3.2
Swing speed rpm 5.5
PC1250-8
PC1250SP-8
1
PC1250LC-8
2
PRECAUTIONS FOR FIELD ASSEMBLY y
1. Selection of work place
1) When selecting a work place, consider the following.
Is the work place sufficiently wide for loading and unloading the machine? (See the kit layout draw-
ing.)
Is the ground sufficiently hard? (The machine and crane truck must not sink into the ground.)
Is the ground flat? (The ground surface must not be uneven or sloping.)
Is the road to inlet/outlet of the work place sufficient for turning the trailer and crane truck?
2) Take care extremely that dirt or water will not enter the hydraulic circuit while it is assembled.
3) Avoid working outdoors while strong wind is blowing or it is raining.
4) Take measures to protect the machine from sand, dirt and rainwater while the work is stopped.
2. How to do work
The work supervisor or the work leader should not do the work while reading this manual but should read
and understand this manual thoroughly and then start the work.
In particular, write the "Precautions" for each work process in a sheet to explain or stick that sheet to the
work place so that all the workers will observe the precautions.
3. Preparation and check of protective gear, slings and tools

The work supervisor or the work leader must perform the following checks about protective gear, slings and
tools.
1) Are all the workers wearing helmets and other protective gear which they are obliged to wear?
If special protective gear is necessary, check that it is prepared and can be used without problem.
2) Are all the slings and tools prepared? Check in advance that they are ready to be used without prob-
lem. In particular, check wooden blocks for internal decay and cracking.
4. k Check during actual work

The work supervisor or the work leader must check the following items constantly and make all the workers
observe them.
1) Are the parking brakes of the trailer and crane truck applied securely and are their wheels locked with
chocks during work? Are outriggers, if installed, used securely?
2) Are the temperature and pressure of the engine, hydraulic oil, coolant, etc. lowered sufficiently during
work?
3) Is horn or another signal is made to warn around when the engine is started? In addition, is it checked
that work equipment control lever and other control levers are in neutral and the fuel control dial (or fuel
control lever) is in the low idle position?
4) Is the balance of the slung item checked extremely during sling work with the crane?
5) Is entry prohibition for outsiders to the work place observed?
5. The work supervisor or the work leader is required to hold a meeting with all the workers at the beginning of
every morning and explain the work plan of the day to them and give them instructions to observe the safe
work.
3
Days
Backhoe · Inspection of oil level and

4 Divisions
coolant level
· Air bleeding from work
equipment cylinder
·
Loading shovel- Flushing of hydraulic
Assembly unit circuit
type excavator
Upper structure · Adjustment of track
q Center frame r Counterweight tension
w Left and right track frames t Platform group · Performance test
e Travel piping group · Inspection of oil y Assembling of work
ASSEMBLING PROCEDURES,
level and coolant level equipment
(Two)
Crane
APPLICABLE EQUIPMENT AND SCHEDULE
4
441 kN {45t} 441 kN {45t} 245 kN {25t}
0.49 -- 0.69 MPa
{5 -- 7 kg/cm 2}
Air compressor
15 m3/min
Worker
Leader + 5 mechanics
Start of assembling
Completion of body · Completion of general

· Meeting with all workers Completion of Installation of unit assembly to body assembling assembling
KIT LAYOUT DIAGRAM
• The dimensions given below are the minimum dimensions needed.
• The kit dimensions in the diagram are outline dimensions.
• When selecting a place, see precautions for “FIELD ASSEMBLING”.
Bucket
Arm link
Tools, facility
Boom
Arm cylinder
Boom 45t crane

cylinder
Foreword
Crawler frame
Crawler frame
Center
Left deck
frame Revolving
frame
Motor cover · handrails Counterweight 45t crane
5
TRANSPORTATION
TRANSPORTATION
The machine can be divided into seven kits for transportation, so when transporting the machine, please contact your
Komatsu distributor to have the work carried out.
Transportation in seven kits
(Upper structure) (Undercarriage left) (Undercarriage right) (Center frame)
(Counterweight, Bucket, etc.) (Boom) (Arm, Arm cylinder

Boom cylinder, etc.)
Posture for each unit

(dimensions in diagram are in mm.)
Upper structure
Secure the upper structure to the platform with a chain and block.
Item PC1250-8, PC1250SP-8, PC1250LC-8

Overall width (mm) 3,490
Weight (kg) 26,700
• Fuel: Empty
• Hydraulic oil: M level
6
TRANSPORTATION
Undercarriage
LC: 7,400 LC: 1,295

STD, SP: 6,425 STD, SP: 1,222
PC1250-8
Item PC1250SP-8 PC1250LC-8
Q’ty 2 2
30,500 37,600
Weight (kg) (15,250 × 2 pieces) (18,800 × 2 pieces)
If any warning tag is attached to the work equipment control levers,

do not start the engine.
7
TRANSPORTATION
Boom
Item PC1250-8 PC1250SP-8 PC1250LC-8

A (mm) 9,475 8,170 9,475
B (mm) 2,894 3,095 2,894
Overall width (mm) 1,474 1,474 1,474
Weight (kg) 11,200 11,100 11,500
8
TRANSPORTATION
Arm
Item PC1250-8 PC1250SP-8

PC1250LC-8
A (mm) 4,895 4,914
B (mm) 1,626 1,683
Overall width (mm) 890 890
Weight (kg) 6,200 6,400
Bucket (excluding side cutter and shroud)

PC1250-8
Item PC1250LC-8 PC1250SP-8
A (mm) 2,580 2,527
B (mm) 2,276 2,420
Overall width (mm) 2,250 2,520
Weight (kg) 5,500 6,300
Boom cylinder (same for all models)

Weight: 2,400 kg (1200 kg × 2 pieces)
Arm cylinder (same for all models)

Weight: 1,500 kg
9
TRANSPORTATION
Center frame
Item PC1250-8, PC1250SP-8, PC1250LC-8

Overall width (mm) 3,540
Weight (kg) 9,700
Counterweight
Item PC1250-8, PC1250SP-8, PC1250LC-8

Weight (kg) 18,000
10
TRANSPORTATION
Others
• Radiator duct (same for all models)
Item PC1250-8, PC1250SP-8, PC1250LC-8

Weight (kg) 100
• Radiator duct upper cover (same for all models)
Item PC1250-8, PC1250SP-8, PC1250LC-8

Weight (kg) 17
11
TRANSPORTATION
• Catwalk (right): same for all models
Item PC1250-8, PC1250SP-8, PC1250LC-8

Weight (kg) 17
• Catwalk (left, front): same for all models
Item PC1250-8, PC1250SP-8, PC1250LC-8

Weight (kg) 150
12
TRANSPORTATION
• Catwalk (left, rear): same for all models
Item PC1250-8, PC1250SP-8, PC1250LC-8

Weight (kg) 160
13
LIST OF TOOLS FOR FIELD ASSEMBLING
No. Tool names Specifications Q’ty. Remarks

1 Equipment Engine compressor Komatsu, 0.69 MPa {7.0kg/cm2} Class 1
2 Crane truck 441 kN {45 ton} 2
2 245 kN {25 ton} 1
3 Grease pump Air type 1 Work equipment lubrication
4 Stepladder 5 -stepped- 1500 mm 2
5 Impact wrench KW10P (for M10) 1
6 KW12PI (For M12) 1
7 KW20P (For M16) 1
7 KW380 1
8 KW45FS (Spline) 1 For counterweight
9 Socket for KW45FS Spline × 65 mm 1 For counterweight
10 Air hose 50 m 1 For impact wrench
11 16-time wrench 4413 Nm {450 kgm} 1 For counterweight
12 Socket for 16-time wrench T38.1 × 65 mm 1 For counterweight
13 T38.1 × 60 mm 1 For track frame
14 T38.1 × 50 mm 1 For track frame
15 4-time wrench 25.4, 19 1
Tool
16 Socket for 4-time wrench T25.4 × 50 mm 1

17 T25.4 × 60 mm 1
18 Torque wrench 412 Nm {42 kgm} – T25.4 mm 1 For 16-time wrench
19 980 Nm {100 kgm} – T25.4 mm 1 For 4-time wrench
20 4118 Nm {420 kgm} – T38.1 mm 1 For counterweight and track frame
21 Standard tool Socket, spanner, wrench 2 set
22 Sledge hammer 10 P 1
23 Bar 1m 2
24 Hydraulic jack 490 kN {50 ton} (stroke 170) 2 Revolving frame pedestal
25 196 kN {20 ton} 1 When tightening track frame
connecting bolts.
When connecting travel and
26 Waste oil pan Large, small 2 each work equipment piping
27 Wooden block 300 × 400 mm 4 Revolving frame pedestal
28 Wire ø10 × 3 m 2 For catwalk
29 ø20 × 5 m 2 For boom, arm and bucket
30 ø25 × 5 m 4 For revolving frame and track frame
31 ø30 × 5 m 2 For counterweight
32 Shackle SD30 3
33 SC18 4
Lifting tool
34 Nylon sling 50 mm wide × 3 m 2 For boom cylinder and arm cylinder

34 Nylon sling 25 mm wide × 3 m 2 Handrail
35 Pin ø50 × 5 m 2 Track frame
36 Lever block 14.7 – 29.4 kN {1.5 – 3 ton} 2
37 Eyebolt M16 2
38 M12 2
39 Detergent liquid Brake cleaner 10
40 Hydraulic oil EO-10 500 l
41 Grease G2-LI (20 kg) 4 kg Work equipment lubrication, Swing circle
Oil and
grease
42 Repair paint Natural yellow 5

43 Black gray 5
44 Waste cloth Bundle 20 kg
14
Tightening Torque
1. Tightening torque for bolts
Tightening torque for bolts is indicated in the text as shown below. Tighten each bolt to the specified
torque.
Part No. of bolt TTTTT-TTTTT

Part No. of washer EEEEE-EEEEE
Bolt specification Thread size diameter
Thread (Diameter, pitch,
× Bolt length)
length
Tool (Socket) Applicable socket size
Tightening torque Nm {QQQ kgm}
If tightening torque for a bolt is not specified in the text, tighten it according to Table 1.
Remarks
1. The thread diameter is the nominal diameter. For example, 16 mm is expressed as M16 and 20
mm is expressed as M20.
The pitch in Table 1 is the distance that the bolt advances every turn in the axial direction (Unit:
mm).
2. The bolt length is dimension (c) in Fig. 1.
3. The applicable socket size is expressed as 24 mm, 30 mm, etc. Since 24 mm, 30 mm, etc. cor-
respond to dimension (b) in Fig. 1, an applicable socket can be selected from Table 1, too.
4. Tightening torque is expressed as QQQ – www or QQQ ± RR. If the target tightening torque
is set, expression of QQQ ± RR is applied.
Fig. 1
a : Bolt thread diameter (Nominal diameter)

b : Width across flats of bolt head
c : Bolt length
d : Threaded part of bolt
15
Table 1 Tightening torque for bolts not specified in text
Unit: Nm {kgm}
Nominal size of thread Width across flats Tightening torque

× pitch (= Socket size)
a (mm) b (mm) Unit: Nm Unit: {kgm}
6×1 10 12 8.8 – 14.7

{1.2} {0.9 – 1.5}
25 14.7 – 34
8 × 1.25 13 {2.5} {1.5 – 3.5}
54 34 – 74
10 × 1.5 17 {5.5} {3.5 – 7.5}
12 × 1.75 19 89 54 – 123
{9} {5.5 – 12.5}
137 84 – 196
14 × 2 22 {14} {8.5 – 20}
230 147 – 309
16 × 2 24 {23.5} {15 – 31.5}
18 × 2.5 27 315 201 – 427
{32} {20.5 – 43.5}
460 319 – 608
20 × 2.5 30 {47} {32.5 – 62}
650 471 – 829
22 × 2.5 32 {66.5} {48 – 84.5}
24 × 3 36 810 588 – 1,030
{82.5} {60 – 105}
1,180 883 – 1,470
27 × 3 41 {120} {90 – 150}
1,520 1,130 – 1,910
30 × 3 46 {155} {115 – 195}
33 × 3 50 1,960 1,470 – 2,450
{200} {150 – 250}
2,450 1,860 – 3,040
36 × 3 55 {250} {190 – 310}
2,940 2,260 – 3,630
39 × 3 60 {300} {230 – 370}
a For symbols “a” and “b” in the table, see Fig. 1.
16
2. Tightening torque for pipe threads
Proper tightening torque for pipe threads depends on combination of the materials of the male screw and
female screw. In this manual, however, select tightening torque from Table 2 and Table 3 on the basis of the
material of the male screw. If tightening torque is specified specially in explanation, however, apply that tight-
ening torque.
2.1 If the male screw is made of mild steel or cast iron, apply Table 2.
Table 2
Unit: Nm {kgm}
Material of female thread
Steel Cast iron Light alloy
Nominal size (in)
3.9 – 6.9 2.9 – 5.9 2.0 – 3.9
1/8 {0.4 – 0.7} {0.3 – 0.6} {0.2 – 0.4}
1/4 5.9 – 11.8 4.9 – 9.8 3.9 – 7.8
{0.6 – 1.2} {0.5 – 1.0} {0.4 – 0.8}
16.7 – 26.5 13.7 – 21.6 9.8 – 16.7
3/8 {1.7 – 2.7} {1.4 – 2.2} {1.0 – 1.7}
32.3 – 52.9 26.5 – 43.1 19.6 – 32.3
1/2 {3.3 – 5.4} {2.7 – 4.4} {2.0 – 3.3}
3/4 51.0 – 85.3 42.1 – 70.6 31.4 – 52.9
{5.2 – 8.7} {4.3 – 7.2} {3.2 – 5.4}
86.2 – 173.5 72.5 – 146.0 54.9 – 111.7
1 {8.8 – 17.7} {7.4 – 14.9} {5.6 – 11.4}
2.2 If the male screw is made of refined steel (heat-treated hard steel), apply Table 3.
Table 3
Unit: Nm {kgm}
Material of female thread
Steel Cast iron Light alloy
Nominal size (in)
1/8 16.7 – 29.4 9.8 – 19.6 6.9 – 14.7
{1.7 – 3.0} {1.0 – 2.0} {0.7 – 1.5}
19.6 – 44.1 16.7 – 37.2 12.7 – 28.4
1/4 {2.0 – 4.5} {1.7 – 3.8} {1.3 – 2.9}
44.1 – 93.1 37.2 – 77.4 27.4 – 58.8
3/8 {4.5 – 9.5} 3.8 – 7.9} {2.8 – 6.0}
1/2 98.0 – 188.2 83.3 – 157.8 60.8 – 115.6
{10.0 – 19.2} {8.5 – 16.1} {6.2 – 11.8}
170.5 – 316.5 141.1 – 247.0 105.8 – 186.2
3/4 {17.4 – 32.3} {14.4 – 25.2} {10.8 – 19.0}
1 367.5 – 612.5 309.7 – 514.5 235.2 – 392.0
{37.5 – 62.5} {31.6 – 52.5} {24.0 – 40.0}
17
3. Tightening torque for hydraulic hose connecting nut
For the connecting nuts installed to the hydraulic hose adapters in relatively low pressure systems, apply
tightening torque in Table 4.1 and 4.2.
Table 4.1 Hydraulic hose of face seal type
Type that uses

O-ring at this
position
Unit: Nm {kgm}
Outside diameter Tightening torque (Nm {kgm})
of hose Width across flats
(mm) (mm) Range Target
Approx. 6 19 34 – 54 {3.5 – 5.5} 44 {4.5}
Approx. 10 22 54 – 93 {5.5 – 9.5} 74 {7.5}
Approx. 13 27 84 – 132 {8.5 – 13.5} 103 {10.5}
Approx. 16 32 128 – 186 {13.0 – 19.0} 157 {16.0}
Approx. 20 36 177 – 245 {18.0 – 25.0} 216 {22.0}
Table 4.2 Hydraulic hose of taper seal type
Type that does

not use O-ring
at this position
Unit: Nm {kgm}
Outside diameter Tightening torque (Nm {kgm})
of hose Width across flats
(mm) (mm) Range Target
Approx. 6 19 34 – 63 {3.5 – 6.5} 44 {4.5}
Approx. 10 24 59 – 98 {6.0 – 10.0} 78 {8.0}
Approx. 13 27 84 – 132 {8.5 – 13.5} 103 {10.5}
Approx. 16 32 128 – 186 {13.0 – 19.0} 157 {16.0}
Approx. 20 36 177 – 245 {18.0 – 25.0} 216 {22.0}
Note: When connecting hose, take care not to twist them.
18
4. Proper socket sizes for bolts of M39 and larger (Reference)
For the proper sizes of sockets or spanners (= width across flats) for tightening hexagon bolts of M39 and
larger, see Table 5.
Table 5
Unit: mm
Thread diameter Proper sizes of sockets or spanners
M42 65
M45 70
M48 75
M52 80
M56 85
M60 90
M64 95
19
COATING MATERIALS
a The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly
and assembly are listed below.
a For coating materials not listed below, use the equivalent of products shown in this list.
Category Komatsu code Part No. Q'ty Container Main applications, features
• Used to prevent rubber gaskets, rub-

LT-1A 790-129-9030 150 g Tube ber cushions, and cock plug from
coming out.
• Used in places requiring an immedi-
ately effective, strong adhesive.
20 g Polyethylene Used for plastics (except polyethyl-
LT-1B 790-129-9050 (2 pcs.) container ene, polyprophylene, tetrafluoroeth-
lene and vinyl chloride), rubber,
metal and non-metal.
• Features: Resistance to heat and
Polyethylene chemicals
LT-2 09940-00030 50 g container • Used for anti-loosening and sealant
purpose for bolts and plugs.
Adhesive: • Used as adhesive or sealant for met-
790-129-9060 1 kg al, glass and plastic.
LT-3 (Set of adhesive Hardening Can
and hardening agent:
agent) 500 g
Adhesives
Polyethylene • Used as sealant for machined holes.
LT-4 790-129-9040 250 g container
Holtz • Used as heat-resisting sealant for re-

MH 705 790-126-9120 75 g Tube pairing engine.
• Quick hardening type adhesive

Three bond 790-129-9140 50 g Polyethylene • Cure time: within 5 sec. to 3 min.
1735 container • Used mainly for adhesion of metals,
rubbers, plastics and woods.
• Quick hardening type adhesive
• Quick cure type (max. strength after
Aron-alpha 790-129-9130 2g Polyethylene 30 minutes)
201 container • Used mainly for adhesion of rubbers,
plastics and metals.
• Resistance to heat, chemicals
Loctite 79A-129-9110 50 cc Polyethylene • Used at joint portions subject to high
648-50 container temperatures.
• Used as adhesive or sealant for gas-
LG-1 790-129-9010 200 g Tube kets and packing of power train case,
etc.
• Used as sealant for various threads,
LG-5 790-129-9080 1 kg Can pipe joints, flanges.
• Used as sealant for tapered plugs,
elbows, nipples of hydraulic piping.
• Features: Silicon based, resistance
to heat, cold
• Used as sealant for flange surface,
LG-6 790-129-9020 200 g Tube tread.
• Used as sealant for oil pan, final
Gasket drive case, etc.
sealant
• Features: Silicon based, quick hard-
ening type
LG-7 790-129-9070 1 kg Tube • Used as sealant for flywheel hous-
ing, intake manifold, oil pan, thermo-
stat housing, etc.
Three bond • Used as heat-resisting sealant for re-
1211 790-129-9090 100 g Tube pairing engine.
• Features: Silicone type, heat resist-

Three bond ant, vibration resistant, and impact
1207B 419-15-18131 100 g Tube resistant sealing material
• Used as sealing material for transfer
case
21
Category Komatsu code Part No. Q'ty Container Main applications, features
• Used as lubricant for sliding portion

LM-G 09940-00051 60 g Can (to prevent from squeaking).
Molybdenum • Used to prevent seizure or scuffling
disulphide of the thread when press fitting or
lubricant LM-P 09940-00040 200 g Tube shrink fitting.
• Used as lubricant for linkage, bear-
ings, etc.
SYG2-400LI • General purpose type
SYG2-350LI
G2-LI SYG2-400LI-A Various Various
SYG2-160LI
SYGA-160CNLI
SYG2-400CA • Used for normal temperature, light

SYG2-350CA load bearing at places in contact
G2-CA SYG2-400CA-A Various Various with water or steam.
SYG2-160CA
SYGA-160CNCA
Molybdenum • Used for heavy load portion

disulphide SYG2-400M 400 g × 10 Bellows type
Grease grease SYG2-400M-A 400 g × 20 Bellows type
LM-G (G2-M) SYGA-16CNM 16 kg Can
• Seizure resistance and heat resist-

Hyper White SYG2-400T-A ance higher than molybdenum di-
Grease G2-T SYG2-16CNT 400 g Bellows type sulfide grease
G0-T (*) SYG0-400T-A (*) 16 kg Can • Since this grease is white, it does
*: For use in cold SYG0-16CNT (*) not stand out against machine
district body.
Biogrease G2B • Since this grease is decomposed
SYG2-400B by bacteria in short period, it has
G2-BT (*) SYGA-16CNB 400 g Bellows type
*: For high less effects on microorganisms,
SYG2-400BT (*) 16 kg Can animals, and plants.
temperature SYGA-16CNBT (*)
and large load
SUNSTAR • Used as primer for cab side

Glass (Expiration date: 4 months)
PAINT PRIMER 20 ml container
580 SUPER
Primer
SUNSTAR • Used as primer for glass side
Glass (Expiration date: 4 months)
GLASS PRIMER 20 ml container
580 SUPER 417-926-3910
• "S" is used for high-tempera-
SUNSTAR ture season (April - October)
Adhesive for cab glass
PENGUINE Polyethylene and "W" for low-temperature

SEAL 580 320 ml container season (November - April) as
Adhesive SUPER "S" or adhesive for glass.
"W" (Expiration date: 4 months)
Sika Japan, Polyethylene • Used as adhesive for glass.
20Y-54-39850 310 ml (Expiration date: 6 months)
Sikaflex 256HV container
SUNSTAR • Used to seal joints of glass

Polyethylene parts.
PENGUINE 417-926-3920 320 ml container
SEAL No. 2505 (Expiration date: 4 months)
SEKISUI • Used to seal front window.

Caulking Polyethylene (Expiration date: 6 months)
material SILICONE 20Y-54-55130 333 ml container
SEALANT
GE TOSHIBA • Used to seal joint of glasses.

SILICONES 22M-54-27220 333 ml Cartridge Translucent white seal.
TOSSEAL 381 (Expiration date: 12 months)
Natural yellow SYPA-U03PNY – Spray can

Paint
Black gray SYPA-U03PBG – Spray can
22
LIST OF PARTS SENT INDIVIDUALLY
CHASSIS (STANDARD SPECIFICATION)
No. Part No. Part name Q’ty Remarks Page
1 21N-30-11180 Bolt 40 For connecting track frame 34
2 21N-30-37130 Spacer 40
3 150-74-11140 Bolt 56 For connecting center frame 44
4 01643-33380 Washer 56
5 02896-11009 O-ring 2 For installing travel piping 37
6 02896-11018 O-ring 2
7 07000-B3032 O-ring 4
8 07094-31228 Clamp 8
9 07095-01241 Cushion 8
10 01024-81285 Bolt 8
11 08036-03014 Clip 6
12 04434-52512 Clip 6
13 07095-20318 Cushion 6
14 01024-81225 Bolt 10
15 21N-30-37411 Cover (L.H.) 1 For installing travel piping cover 39,40
16 21N-30-37421 Cover (R.H.) 1

17 01024-81225 Bolt 8
18 21N-30-37370 Cover (L.H.) 1
19 21N-30-37381 Cover (R.H.) 1
20 01010-81230 Bolt 8
21 175-54-34170 Washer 8
22 21N-30-37390 Cover 1
23 01010-81230 Bolt 6
24 175-54-34170 Washer 6
25 209-62-52560 Pin 1 For installing swivel and travel 47

piping
26 01641-21626 Washer 1
27 04050-14028 Pin 1
28 02896-11009 O-ring 1
29 07002-12434 O-ring 1
30 07073-01A08 Hose 2
31 07073-01AA7 Hose 2
32 07000-B3032 O-ring 8
23
41 209-09-51170 Bolt 10 For installing counterweight 50
42 209-46-11210 Spacer 10
43 21N-30-37140 Ladder 2
44 01010-81645 Bolt 8 For installing track frame step 41
45 01643-31645 Washer 8
46 21N-53-32132 Step assembly 1 For installing left side step 51,52
47 01024-81240 Bolt 20
48 21N-53-31362 Step 1
49 01024-81240 Bolt 20
50 01024-81230 Bolt 2
51 21N-53-31982 Bracket 1
52 01024-81230 Bolt 6
53 21N-54-39950 Step 1
54 01024-81240 Bolt 6
55 X21-0878191 Handrail assembly 1
56 01010-81645 Bolt 10
57 01643-31645 Washer 10
59 01010-81645 Bolt 6
60 01643-31645 Washer 6
62 01010-81645 Bolt 6
63 01643-31645 Washer 6
64 8285-54-1570 Chain 1
65 21N-53-32420 Bracket 1
66 01024-D1225 Bolt 1
66-1 08037-01610 Grommet 1
67 21N-54-32490 Ladder 1 53
24
68 21N-54-39661 Step 1 For installing right side step 45
69 01024-81230 Bolt 4
70 21N-54-42430 Step 1
71 01024-81230 Bolt 2
72 21N-54-39640 Step 1
73 01024-81240 Bolt 8
74 21N-54-39650 Handrail 2
75 01024-81235 Bolt 8
76 21N-54-39611 Handrail 1
77 01024-81230 Bolt 4
78 21N-54-39621 Handrail 1
79 01024-81230 Bolt 4
80 21N-54-39631 Handrail 1
81 01024-81230 Bolt 12
82 01024-81240 Bolt 4
83 21N-54-41721 Handrail 1 For installing handrail 46
84 01024-81240 Bolt 8
85 21N-54-41741 Handrail 1
86 01024-81235 Bolt 4
87 21N-54-37241 Handrail 1
88 01024-81230 Bolt 6
89 21N-54-41711 Handrail 1
90 01024-81230 Bolt 10
91 21N-54-39571 Handrail 1
92 01024-81235 Bolt 2
93 21N-54-41351 Duct assembly 1 For installing radiator cover (STD) 54
94 01024-81230 Bolt 8
95 01011-81220 Bolt 4
96 01643-31232 Washer 4
97 21N-54-41361 Cover 1
98 01011-81200 Bolt 2
99 01643-31232 Washer 2
100 01024-81280 Bolt 3
25
116 X21-1223090 Rain cap assembly 1 For installing exhaust piping 59
117 01024-81235 Bolt 6
117-1 20Y-54-51820 Handrail 1 For installing handrail for cab 61
118 21N-53-32510 Support 1 For installing L.H. rear view mirror 62
119 20Y-54-35430 Clamp 1

120 01252-71025 Bolt 2
121 421-54-25610 Mirror 1
122 04025-00632 Pin 1
123A 21N-54-41751 Support 1 For installing R.H. rear view mirror 64
123B 21N-54-42440 Support 1

124 20Y-54-27991 Clamp 2
125 01252-71025 Bolt 4
126 421-54-25610 Mirror 2
127 04025-00632 Pin 2
128 01252-70545 bolt 8
26
CHASSIS (EU SPECIFICATION)
1 21N-30-11180 Bolt 40 For connecting track frame 34
2 21N-30-37130 Spacer 40
3 150-74-11140 Bolt 56 For connecting center frame 44
4 01643-33380 Washer 56
5 02896-11009 O-ring 2 For installing travel piping 37
6 02896-11018 O-ring 2
7 07000-B3032 O-ring 4
8 07094-31228 Clamp 8
9 07095-01241 Cushion 8
10 01024-81285 Bolt 8
11 08036-03014 Clip 6
12 04434-52512 Clip 6
13 07095-20318 Cushion 6
14 01024-81225 Bolt 10
15 21N-30-37411 Cover (L.H.) 1 For installing travel piping cover 39,40
16 21N-30-37421 Cover (R.H.) 1

17 01024-81225 Bolt 8
18 21N-30-37370 Cover (L.H.) 1
19 21N-30-37381 Cover (R.H.) 1
20 01010-81230 Bolt 8
21 175-54-34170 Washer 8
22 21N-30-37390 Cover 1
23 01010-81230 Bolt 6
24 175-54-34170 Washer 6
25 209-62-52560 Pin 1 For installing swivel and travel 47

piping
26 01641-21626 Washer 1
27 04050-14028 Pin 1
28 02896-11009 O-ring 1
29 07002-12434 O-ring 1
30 07073-01A08 Hose 2
31 07073-01AA7 Hose 2
32 07000-B3032 O-ring 8
27
33 01024-81230 Bolt 8 For sticking sheet 48
(counterweight)
34 21N-46-35320 Cover 1 (EU Spec.)
35 21N-46-35310 Cover 1
36 21N-46-35281 Sheet 1
37 21N-46-35271 Sheet 1
38 21N-46-35261 Sheet 1
39 21N-46-35253 Sheet 1
40 21N-46-35211 Sheet 1
41 209-09-51170 Bolt 10 For installing counterweight 50
42 209-46-11210 Spacer 10
43 21N-30-37140 Ladder 2 For installing track frame step 41
44 01010-81645 Bolt 8
45 01643-31645 Washer 8
46 21N-53-32132 Step assembly 1 For installing left side step 51,52
47 01024-81240 Bolt 20
48 21N-53-31362 Step 1
49 01024-81240 Bolt 20
50 01024-81230 Bolt 2
51 21N-53-31982 Bracket 1
52 01024-81230 Bolt 6
53 21N-54-39950 Step 1
54 01024-81240 Bolt 6
56 01010-81645 Bolt 10
57 01643-31645 Washer 10
59 01010-81645 Bolt 6
60 01643-31645 Washer 6
62 01010-81645 Bolt 6
63 01643-31645 Washer 6
64 8285-54-1570 Chain 1
65 21N-53-32420 Bracket 1
66 01024-D1225 Bolt 1
66-1 08037-01610 Grommet 1
67 21N-54-32490 Ladder 1 53
28
68 21N-54-39661 Step 1 For installing right side step 45
69 01024-81230 Bolt 4
70 21N-54-42430 Step 1
71 01024-81230 Bolt 2
72 21N-54-39640 Step 1
73 01024-81240 Bolt 8
74 21N-54-39650 Handrail 2
75 01024-81235 Bolt 8
76 21N-54-39611 Handrail 1
77 01024-81230 Bolt 4
78 21N-54-39621 Handrail 1
79 01024-81230 Bolt 4
80 21N-54-39631 Handrail 1
81 01024-81230 Bolt 12
82 01024-81240 Bolt 4
83 21N-54-41721 Handrail 1 For installing handrail 46
84 01024-81240 Bolt 8
85 21N-54-41741 Handrail 1
86 01024-81235 Bolt 4
87 21N-54-37241 Handrail 1
88 01024-81230 Bolt 6
89 21N-54-41711 Handrail 1
90 01024-81230 Bolt 10
91 21N-54-39571 Handrail 1
92 01024-81235 Bolt 2
101 01023-10408 Bolt 2 For installing radiator cover 55 - 58

(EU Spec.)
102 20B-54-12210 Spring 1
103 20Y-54-29232 Bar 1
104 195-Z11-2970 Cap 17
105 21N-54-41830 Net 2
106 21N-54-41811 Duct 1
107 21N-54-41880 Seal 4
108 01024-80816 Bolt 8
109 01024-81240 Bolt 14
110 21N-54-41851 Blade 16
111 01024-81020 Bolt 32
112 21N-54-41860 Frame 4
113 01024-80616 Bolt 32
29
114 21N-54-41821 Cover 1 For installing radiator cover 57,58
(EU Spec.)
115 01024-81235 Bolt 23
116 X21-1223090 Rain cap assembly 1 For installing exhaust piping 59
117 01024-81235 Bolt 6
117-1 20Y-54-51820 Handrail 1 For installing handrail for cab 61
118 21N-53-32510 Support 1 For installing L.H. rear view mirror 62
119 20Y-54-35430 Clamp 1

120 01252-71025 Bolt 2
121 421-54-25610 Mirror 1
122 04025-00632 Pin 1
123A 21N-54-41751 Support 1 For installing R.H. rear view mirror 64
123B 21N-54-42440 Support 1

124 20Y-54-27991 Clamp 2
125 01252-71025 Bolt 4
126 421-54-25610 Mirror 2
127 04025-00632 Pin 2
128 01252-70545 Bolt 8
30
WORK EQUIPMENT
129 21N-72-11230 Shim 8 For installing boom cylinder foot 80
130 07000-13038 O-ring 2 For installing boom cylinder hose 81
131 07000-13048 O-ring 2
132 21N-72-11210 Shim 3 For installing boom assembly 83
133 21N-72-11220 Shim 3
134 707-01-XZ501 Boom cylinder (L.H.) 1 For installing boom cylinder 84
135 707-01-XZ511 Boom cylinder (R.H.) 1

136 21N-72-11230 Shim 2
137 07099-01218 Hose 2 For installing boom hose 85
138 07000-13038 O-ring 4

139 07099-01418 Hose 5
140 07000-13048 O-ring 10
141 707-01-XZ522 Arm cylinder 1 For installing arm cylinder 78
142 21N-72-11210 Shim 2
143 07098-01418 Hose 3 (For STD boom) 79
07098-01421 Hose 3 (For SE boom)

144 07000-13048 O-ring 6 For installing arm cylinder hose
145 21N-72-11210 Shim 4 86
146 21N-62-38610 Hose 2 For installing bucket cylinder hose 88
147 07000-13048 O-ring 4

148 21N-62-38620 Hose 2
149 07000-13038 O-ring 4
31
WORK EQUIPMENT
150 21N-70-14220 Bushing 1 For installing bucket assembly 89
151 21N-70-13150 O-ring 2

152 21N-70-14320 Shim 14
153 21N-70-14330 Shim 4
154 21N-72-11230 Shim 3 91
155 07000-16215 O-ring 2
156 07020-00675 Fitting 2 For installing work equipment 93

lubrication piping
(boom cylinder)
157 17A-06-17930 Lamp 2 For installing work equipment wiring 98
158 20Y-06-21551 Bracket 2

159 08193-20012 Clip 2
160 01024-81230 Bolt 2
161 209-60-77551 Filter element 2 For assembling return filter flushing 102
(chassis)
162 21T-60-13730 Plate 2
163 21N-62-19370 Tube 4 For installing work equipment 106,107

flushing tube (chassis)
164 21N-62-19340 Tee 1
165 424-16-11140 Filter element 1 For assembling pilot filter flushing 109
(chassis)
Parts that are not assembled (kept in tool box as they are)
166 07270-51210 Tube 1 For draining water in fuel tank

167 07281-00167 Clamp 1 For draining
168 07377-01018 Flange 2 For flushing travel piping
169 X21-1216270 Tool assembly 1 Standard tool
170 209-72-11311 Seal 4 For installing boom foot 82
32
A. ASSEMBLY OF CHASSIS
Remarks
1. In the "drawings" in this manual, parts and places are indicated by 1, 2, 3 ---,
but indicated by (1), (2), (3) --- in the tables and texts.
Example:
(1) Plate
(2) Collar
(3) Washer
(4) Bolt
(5) Bolt
(6) Washer
2. In some places of this manual, the words of front, rear, right hand and left hand
of machine are used. Those words indicate the directions seen from the opera-
tor's seat with the sprocket at the rear as shown below, unless otherwise speci-
fied.
Front
Front
Operator’s
Left hand seat Right hand
Left hand Right hand
Operator's seat
Sprocket
Sprocket
Rear
Rear
33
Assembly procedure
Installation of Left and Right Track Frames (1/3)
A-1
1. Place either track frame assembly on a flat plate.

Weight of track frame assembly (1 piece): 15,250 kg
2. Sling the center frame assembly and position it on the track frame and then install it with mounting bolts (1) and (2) (Tighten
the mounting bolts temporarily with KW20P impact wrench).
Center Frame Assembly: 9,700 kg
No. Loose-supply items Q’ty

1 21N-30-37130 40
2 21N-30-11180 40
Precautions Necessary tools Necessary equipment
. Name Q’ty Name Q’ty

ø 30 × 5000 wire 2 45 ton crane 1
ø 20 × 5000 wire 4
ø 50 × 500 pin 2
BC20 shackle 4
KW20P impact wrench 1
M60 socket 1
Others
34
Assembly procedure
A-1
• Secure two points of the center frame of the track by placing a hydraulic jack and a 300 × 400 mm wooden block at
each point. Make sure that these points do not interfere with the upper structure rotation.
• Lift the Track Frame Assembly and install it on the Center Frame.

Name Q’ty Name Q’ty
ø 30 × 5000 wire 2 45 ton crane 1
ø 50 × 500 pin 2
Wooden block (400 × 300 mm) 2
50 t jack 2
Others
35
Assembly procedure
A-1
Thickness of 100 mm
Wooden block
a When tightening bolts, raise the track with a hydraulic jack as shown above so as to get sufficient space for tightening.
3 Connection bolt of track frame and center frame

2,890 – 3,630 Nm {295 – 370 kgm}
a Retighten with a 16 power wrench or a 420 kg torque wrench.

(When using a 420 kg torque wrench, pull it with 1.5 t lever block.)
Do not remove the shoes before assembling Name Q’ty Name Q’ty
(so as to maintain the tightening torques of 16 time wrench 1
the shoe bolts).
Torque wrench (42 kg) 1
M60 Socket 1
Torque wrench (420 kg) 1
20 t jack 1
Wooden block (100 × 200 mm) 1
1.5 t lever block 1
Others
36
Assembly procedure
Installation of Travel Piping (1/2)
A-2
Fix pilot hose and

drain hose together
with clamps.
(1) Remove the oil plugs of the tubes and hoses on the center frame side and install
new O-rings
(07000-B3032: 4 pieces, 02896-11009: 2 pieces, 02896-11018: 2 pieces).
(2) Connect the 4 main hoses installed on the track frame to the center frame side
and fix them with clamps (1), (2), and (3). 1 07094-31228 8
2 07095-01241 8
(3) Connect 2 right pilot hoses and 2 left ones to the center frame and fix them with 3 01024-81285 8
clamps (4), (5), and (6). 4 04434-52512 6
5 07095-20318 6
6 01024-81225 10
(4) Connect 2 right drain hoses and 2 left ones to the center frame and fix them with 7 08036-03014 6
clamps (7) and (6). 10 07000-B3032 4
11 02896-11009 2
a Reuse the split flanges, bolts, etc. used for the oil stopping parts. 12 02896-11018 2
No. Parts already installed to body Q’ty
8 07371-31049 8
9 07375-21035 16
1. When connecting the hoses, check that Name Q’ty Name Q’ty
the mating faces are free from foreign KW12P impact wrench 1
matter or flaw.
M14 socket 1
2. Keep the removed flanges and heads so
that they can be reused. L150 extension 1
Spanner, 22 mm width across flats 2
3. When installing a hose, take extreme care
that the O-ring will not be caught. Spanner, 36 mm width across flats 2
M19 socket 1
Oil receiving pan 2
Others
37
Assembly procedure
Installation of Travel Piping (2/2)
A-2
Hose connection diagram

Main hose
Drain hose
Pilot hose

Others
38
Assembly procedure
Installation of Travel Piping Covers (1/2)
A-3
(1) Install travel piping cover (1) with bolts (2) and large washers (3).
(2) Install travel piping covers (4) and (6) with bolts (5).

1 21N-30-37390 1
2 01010-81230 6
3 175-54-34170 6
4 21N-30-37421 1
5 01024-81225 8
6 21N-30-37411 1

M19 socket 1
Others
39
Assembly procedure
Installation of Travel Piping Covers (2/2)
A-3
(1) Install travel piping covers (1) and (2) with bolts (3) and large washers (4).
.

1 21N-30-37381 1
2 21N-30-37370 1
3 01010-81230 8
4 175-54-34170 8

M19 socket 1
L150 extension 1
Others
40
Assembly procedure
Installation of Steps
A-4
(1) Install steps (1) to the right and left track frames with bolts (2) and washers (3).
3 Tightening torque for step mounting bolt

245 – 309 Nm {25 – 31.5 kgm}

1 21N-30-37140 2
2 01010-81635 8
3 01643-31645 8

M24 socket 1
Others
41
Assembly procedure
Filling Swing Circle with Grease
A-5
4) Apply LG-6.
1) Pour grease (G2-Ll) in the swing circle grease bath. See Note 1.
2) Apply grease to the swing circle gear contacting surfaces. (Approx. 10 l of above 65 l)
3) Fill the grease bath seal with grease.
(Note 1)
Supply grease near swing

circle gear.
a Degrease and de-rust the mating faces of the Name Q’ty Name Q’ty
swing circle and upper structure.
Others
42
Assembly procedure
Assembly of Upper Structure and Undercarriage (1/2)
A-6
(1) Clean the mounting face of the swing circle and mating face of the upper structure.
(2) Apply LG-6 to the swing circle.
See Note 1.
Clean mating faces.

(Note 1)
Apply LG-6 to swing circle gear side

Others
of assurance mounting bolts.
43
Assembly procedure
Assembly of Upper Structure and Undercarriage (2/2)
A-6
(3) Sling the upper structure and install it with bolts (1) and washers (2).
(Do not hit the upper structure against the center frame or grease bath.)
(4) Tighten all the bolts with the fingers as hard as possible. Retighten them after completing assembly. (Apply LT-2)
Tighten the 4 bolts on the right and left sides permanently.
3 Tightening torque for bolt

1,960 – 2,450 Nm {200 – 250 kgm}

1 150-74-11140 56
2 01643-33380 56

ø 30 × 5000 wire 4 45 t crane 2
BC36 shackle 2 Special eyebolt 2
KW45F impact wrench 1
M50SP socket 1
Others
44
Assembly procedure
Installation of Right Side Steps
A-7
(1) Install right front step (1) with bolts (2) and install handrail (3) with bolts (2) and (4).
(2) Install right side steps (5) and (6) with bolts (4) and install right and left handrails (9) with bolts (10).
(3) Install handrails (7) and (8) with bolts (4).

1 21N-54-39640 1
2 01024-81240 12
3 21N-54-39631 1
4 01024-81230 26
5 21N-54-39661 1
6 21N-54-42430 1
7 21N-54-39611 1
8 21N-54-39621 1
9 21N-54-39650 2
10 01024-81235 8

M19 socket 1
L150 extension 1
Others
45
Assembly procedure
Installation of Handrails
A-8
(1) Install handrails (1) and (2) on the fuel tank with bolts (5).
(2) Install handrail (3) on the aftercooler cover with bolts (7).
(3) Install handrail (4) on the side of the hood with bolts (6).

1 21N-54-37241 1
2 21N-54-41711 1
3 21N-54-41721 1
4 21N-54-41741 1
5 01024-81230 16
6 01024-81235 6
7 01024-81240 8
8 21N-54-39571 1

M19 socket 1
L150 extension 1
Others
46
Assembly procedure
Installation of Swivel Travel Piping
A-9
1) Install the lock plate to the swivel joint.
2) Remove the oil plugs of the tubes, T-piece, and swivel joint on the revolving frame side and install new O-rings
(07000-B3032: 8 pieces, 07002-12434: 1 piece, 02896-11009: 1 piece)
3) Install the pilot hose and drain hose to the elbow and T-piece.
4) Install the main hoses (4 pieces) to the swivel joint.
a Reuse the split flanges, bolts, etc. used for the oil stopping parts.
Connect 2 drain hoses.
Connect 4 main hoses.
Connect lock plate.

Connect pilot hose. 1 209-62-52560 1
2 01641-21626 1
3 04050-14028 1
4 02896-11009 1
5 07002-12434 1
No. Parts already installed to body Q’ty 6 07073-01A08 2
9 07371-31049 16 7 07073-01AA7 2
10 07375-21035 32 8 07000-B3032 8
1. The lock plate, drain hoses, and pilot hose are Name Q’ty Name Q’ty
installed to the upper structure. KW12P impact wrench 1 Large oil receiving pan 1
2. Keep the removed flanges and heads so that
L150 extension 1
they can be reused.
3. When installing a hose, take extreme care that M14 socket 1
the O-ring will not be caught.
Spanner, 22 mm width across flats 2
4. When installing a hose, take extreme care that
dirt will not enter the circuit. Spanner, 36 mm width across flats 2
Others
47
Assembly procedure
Sticking Sheet to Counterweight
A-10 (EU specification)
• Stick sheets to the surfaces of the counterweight in front of the machine as shown below.

1 21N-46-35261 1
2 21N-46-35310 1
3 21N-46-35271 1
4 21N-46-35281 1
5 21N-46-35320 1
6 21N-46-35253 1
7 21N-46-35211 1
8 01024-81230 8
a Remove all oil and rust from the surface Name Q’ty Name Q’ty
where the sheet is to be stuck.
Others
48
Assembly procedure
Installation of Cover board (To the Counterweight)
A-11
• Install the Cover board in Counterweight as shown below.

1 21N-54-44120 1
2 01024-81225 4
a Execute it before installing the Counterweight Name Q’ty Name Q’ty

to the machine.
Others
49
Assembly procedure
Installation of Counterweight
A-12
(1) Sling the counterweight assembly with the crane and install it to the upper structure with bolts (1) and spacers (2).
Weight of counterweight assembly: 17,900 kg
3 Tightening torque for counterweight mounting bolt

3,430 – 4,212 Nm {350 – 430 kgm}

1 209-09-51170 10
2 209-46-11210 10
Install the counterweight so that there will be Name Q’ty Name Q’ty
the reference space of 15 mm between the ø 36 × 5000 wire 2 45 t crane 1
weight and the revolving frame or so that the
left level difference equals to the right one. BC40 shackle 2
KW45FS impact wrench 1
M65SP socket 1
420 kgm torque wrench 1
38.1 square × socket, 1
65 mm width across flats
Others
50
Assembly procedure
Installation of Left Side Steps (Including handrails) (1/3)
A-13
(1) Install step (1) at front of the cab with bolts (2).
(2) Install step (3) on the side of the cab with bolts (2) and install step (4) with bolts (5).
(3) Install step (6) on the side of the pump with bolts (2) and (5).

1 21N-54-39950 1
2 01024-81240 46
3 21N-53-31362 1
4 21N-53-31982 1
5 01024-81230 8
6 21N-53-32132 1
a Adjust the level difference between the steps Name Q’ty Name Q’ty
to 10 mm or less. KW12P impact wrench 1 25 t crane 1
M19 socket 1
L150 extension 1
M12 eyebolt 2
Others
51
Assembly procedure
A-13
(5) Install handrails (1), (4), and (5) with bolts (2) and washers (3).

1 X21-0878211 1
2 01010-81645 22
3 01643-31645 22
4 X21-0878201 1
5 X21-0878191 1
6 8285-54-1570 1
7 21N-53-32420 1
8 01024-D1225 1
9 08037-01610 1

KW12P impact wrench 1 25 t crane 1
M19 socket 1
L150 extension 1
25 wide × 3,000 nylon sling 2
Others
52
Assembly procedure
A-13
(6) Install the maintenance ladder to the step at the rear of the left side.
• Install the ladder from the underside of the step.
• Open the catch lock.
• Put one end of the ladder (upper end of the ladder) on the rack at the front of the step and install the other end to the
hook installed to the catch lock.
• Close the catch lock.
Catch lock
Install to hook.

1 21N-54-32490 1

Others
53
Assembly procedure
Installation of Radiator Cover
A-14 (Standard specification)
Install the radiator cover to the machine.
100
8
(3)

1 21N-54-41351 1
2 01024-81230 8
3 01011-81220 4
4 01643-31232 4
5 21N-54-41361 1
6 01011-81200 2
7 01643-31232 2
8 01024-81280 3
a Eliminate the level difference between the Name Q’ty Name Q’ty
radiator cover and mounting frame.
Others
54
Assembly procedure
Installation of Radiator Cover (1/4)
(1) Insert net (2) in radiator cover (1) and fix it with bolts (3).
(2) Insert seal (4) in the cover.
3 Tightening torque for net fixing bolt

14.7 – 34 Nm {1.5 – 3.5 kgm}

1 21N-54-41811 1
2 21N-54-41830 2
3 01024-80816 8
4 21N-54-41880 4

Others
55
Assembly procedure
(3) Sling the cover assembly and position it to the machine and then fix with bolts (1).
Weight of cover assembly: 150 kg
3 Tightening torque for cover mounting bolt

54 – 123 Nm {5.5 – 12.5 kgm}

1 01024-81240 14
a Eliminate the level difference between the Name Q’ty Name Q’ty
radiator cover and mounting frame. ø 10 × 3000 wire 2 25 t crane 1
Others
56
Assembly procedure
(4) Fix spring (2) to grille frame (1) with screws (3) and insert bar (4).
(5) Install blade (5) to the frame temporarily with bolts (6), set the holes of plate (7), install bolts (8),
and tighten the bolts permanently.
3 Tightening torque for blade mounting bolt

54 – 123 Nm {5.5 – 12.5 kgm}
3 Tightening torque for plate mounting bolt

8.8 – 14.7 Nm {0.9 – 1.5 kgm}

1 21N-54-41821 1
2 20B-54-12210 1
3 01023-10408 2
4 20Y-54-29232 1
5 21N-54-41851 16
6 01024-81020 32
7 21N-54-41860 4
8 01024-80616 32

Others
57
Assembly procedure
(6) Sling the grille frame assembly, set the bolt holes of the hinge first, and tighten bolt (1).
Adjust the level difference from the cover, close the grille, and tighten the other bolts.
4 Weight of grille frame assembly: 160 kg
(7) After tightening the bolts, insert caps (2).
3 Tightening torque for frame mounting bolt

54 – 123 Nm {5.5 – 12.5 kgm}

1 01024-81235 23
2 195-Z11-2970 17
a Eliminate the level difference from the cover. Name Q’ty Name Q’ty
ø 10 × 3000 wire 2 25 t crane 1
Others
58
Assembly procedure
Installation of Muffler Tail Pipe
A-15
(1) Install muffler tail pipe assembly (1) to the top of the engine hood with bolts (2).

54 – 123 Nm {5.5 – 12.5 kgm}

M19 socket 1
Others
59
Assembly procedure
Changing of Mounting Position of Step Light
A-16
1) After removing dummy bolt, remove step light, bolt, and washer.
2) Change the mounting position and direction of step light.
During transportation
(Position: On the head guard)
(Direction: Toward the chassis)
Remove dummy bolt

Spanner
(width across flats 17 mm)
After transportation
(Position: Upper side of cab)
(Direction: Obliquely downward to
outside of chassis)

Others
60
Assembly procedure
Installation of Handrail to the Cab
A-17
3 Tightening torque: 27 – 34 Nm {2.8 – 3.5 kgm}

1) Remove 4 bolts (01435-40820) installed on the cab and install handrail.

1 20Y-54-51820 1

Others
61
Assembly procedure
Installation of Left Rearview Mirror (1/2)
A-18
(1) Install support (1) to the cabin handrail with clamp (2) and bolts (3) and then set and fix mirror (4) with roll pin (5).

1 21N-53-32510 1
2 20Y-54-35430 1
3 01252-71025 2
4 421-54-25610 1
5 04025-00632 1
For installation of the mirror, Name Q’ty Name Q’ty

use 209-98-77220.
Adjust the mirror to the best position.
(For the view range, see “Installation manual
for mirror” 21N-98-41131.)
Others
62
Assembly procedure
Installation of Left Rearview Mirror (2/2)
A-18
• Pass pin (5) through the hole in ball busing (A), hold the mirror with the holder of mirror (1), then secure in position and
check that the mirror does not move.
Insert pin (5) in this hole
Holder
Replace the screw (421-54-25660) of the mirror assembly

part with the hexagon head bolt (6) (01252-70545), and
tighten it.
Tightening torque: 1.5 – 2.0 Nm {0.15 – 0.2 kgm}

Others
63
Assembly procedure
Installation of Right Rearview Mirrors (1/2)
A-19
(1) Install support (1) to the right front handrail with clamps (3) and bolts (4),
set roll pin (6) to mirror (5), and fix the mirror with bolts (7).
(2) Install support (2) to the right front handrail with clamps (3) and bolts (4),
set roll pin (6) to mirror (5), and fix the mirror with bolts (7).

1 21N-54-41751 1
2 21N-54-42440 1
3 20Y-54-27991 2
4 01252-71025 4
5 421-54-25610 2
6 04025-00632 2
7 01252-70545 8
For installation of the mirror, Name Q’ty Name Q’ty

use 209-98-77220.
Adjust the mirror to the best position.
(For the view range, see “Installation manual
for mirror” 21N-98-41131.)
Others
64
Assembly procedure
Installation of Right Rearview Mirrors (2/2)
A-19
• Pass pin (5) through the hole in ball busing (A), hold the mirror with the holder of mirror (1), then secure in position and
check that the mirror does not move.
Insert pin (5) in this hole
Holder
Replace the screw (421-54-25660) of the mirror assembly

part with the hexagon head bolt (6) (01252-70545), and
tighten it.
Tightening torque: 1.5 – 2.0 Nm {0.15 – 0.2 kgm}

Others
65
Assembly procedure
Installation of Rearview Mirror
A-20 (On the Counterweight) (EU specification)
Mirror D must be able to see hatched area (D)
• If rear view mirror D does not move smoothly when

adjusting its angle, loosen mirror securing screw (4).
Tightening torque of screw (4): 0.98-1.47 Nm (0.10-0.15
kgm)
• When installing mirror D make sure to leave clearance (V)

to prevent contact between mirror and mirror stay.
(V) = min. 10 mm.
66
Assembly procedure
Preparation for Bleeding Air from Travel Motor
A-21
Air is to be bled from the travel motor in assembly procedure [B-14]. Before starting the travel motor, loosen the air bleeder
and bleed air from the circuit.
Air bleeding vinyl hose
1) Open the hydraulic tank cap.

(Keep the cap placed on the filler lightly to prevent dirt and rain from entering the tank.)
2) Prepare an oil receiver at the vinyl hose end. (Approx. 20 l can/Each side)
3) Loosen air bleeder (5).

(The air bleeding vinyl hose is installed when the machine is delivered.)
a Keep the air bleeder loosened and opened during the work equipment assembly work.
(Check the air bleeding oil level occasionally and take care that the oil will not spill.)

Others
67
Assembly procedure
Procedure for Bleeding Air From Hydraulic Circuit
A-22
1. Bleeding air from hydraulic pump group
a If a hydraulic pump was removed and installed or a related piping was disconnected and connected, bleed air from the
hydraulic pump group according to the following procedure.
1) Loosen air bleeders (1), (2) and (3) 4 turns.
2) Loosen the oil filler cap of the hydraulic tank and leave it for about 10 minutes.
a The above time depends on the oil level in the pump case.
3) When oil flows out of air bleeders (1) and (2), tighten air bleeders (1) and (2).
4) Run the engine at low idle.
a Set the work equipment lock lever in the lock position to prevent the work equipment from moving.
5) When clear oil flows out of air bleeders (3), tighten air bleeder (3).

Others
68
Assembly procedure
Permanent Tightening of Swing Circle Mounting Bolts
A-23
In the procedure for assembly of the upper structure and undercarriage, only 4 of the 56 revolving frame and swing circle mounting
bolts were tightened permanently and the other 52 bolts were tightened temporarily. Tighten those 52 bolts in this step.
(1) Start the engine.
(2) Swing the upper structure to set the bolts to the places (right and left) marked with * in the figure and tighten the bolts to
the specified torque.
3 Tightening torque for bolt

1960 – 2450 Nm {200 – 250 kgm}
Width across flats 50
a While swinging the upper structure and tight- Name Q’ty Name Q’ty
ening the bolts, make signs securely. KW45F impact wrench 1
M50 socket 1
Others
69
Assembly procedure
Testing Track Shoe Tension (1/3)
A-24

Others
70
Assembly procedure
A-24
Grease cylinder

Others
71
Assembly procedure
A-24
k Warning
• Don’t stand at the front.
• Don’t look inside.

Others
72
Assembly procedure
Check Fuel, Coolant and Oil Levels (1/2)
A-25

Others
73
Assembly procedure
Check Fuel, Coolant and Oil Levels (2/2)
A-25
• Non-amine Supercoolant (Blue) is added Name Q’ty Name Q’ty

when shipped. Do not mix coolant of
different type with it.
Others
74
Assembly procedure
Parts to be Touched up after Field Assembly
A-26

Others
75
B. ASSEMBLING OF WORK EQUIPMENT
OF BACKHOE
• Clean the mounting pin and pin hole and check them for a flaw.
77
Assembly procedure
Installation of Arm Cylinder
B-1
(1) Remove the lock plate fixed to the boom and remove the arm cylinder foot pin.
4 Arm cylinder foot pin: 92.9 kg (Standard boom)

: 101.3 kg (SE boom)
(2) Sling the arm cylinder and set it to the hole of the boom.
Adjust shim (1) (21N-72-11210) so that the clearance in the foot will be 2 mm – 3 mm.
4 Weight of arm cylinder: 1,500 kg
(3) Drive in the arm cylinder foot pin.
2 Inside of pin hole: Apply lithium grease.
(4) Install the lock plate.

Tightening torque for plate mounting bolt: 824 – 1030 Nm {84 – 105 kgm}
Lock plate
Arm cylinder foot pin

1 21N-72-11210 2
2 707-01-XZ522 1
1. When working, bind the arm cylinder rod Name Q’ty Name Q’ty
to prevent it from coming out. 50 wide × 3,000 nylon sling 2 25 t crane 1
that they can be reused. KW380 impact wrench 1 5 step stepladder 1
that the O-ring will not be caught. M36 socket 1
4. When installing a hose, take extreme care Sledge hammer 1
that dirt will not enter the circuit.
Others
78
Assembly procedure
Installation of Arm Cylinder Hoses
B-2
(1) Remove the oil plugs from the arm cylinder and from the tubes on the boom side and install new O-rings
(07000-13048, 6 pieces).
(2) Install arm cylinder hoses (1) (3 pieces) as shown below.
For standard boom
For SE boom

1 07098-01418 3
2 07000-13048 6
No. Parts installed to boom Q’ty
3 07371-51470 12
4 01010-81455 24
5 01643-31445 24
1. When working, bind the arm cylinder rod Name Q’ty Name Q’ty
to prevent it from coming out. KW12P impact wrench 1 5 step stepladder 1
that they can be reused. L150 extension 1
that the O-ring will not be caught. M22 socket 1
Others
79
Assembly procedure
Installation of Boom Cylinder Foot
B-3
(1) Remove the boom cylinder foot pin lock plate fixed to the machine body and pull out the pin.
(2) Sling the boom cylinder and position it to the machine body and then adjust shim (1) so that the clearance
(on the outside of the machine body) between the boom cylinder and revolving frame will be 2 mm – 3 mm.
4 Weight of boom cylinder (each): 1,200 kg
(3) Insert wooden blocks between the cylinder and revolving frame to support the boom cylinder.
(Height: 40 – 50 mm, Width: Max. 90 mm)
(4) Push in the boom cylinder foot pin fully and install the lock plate.
3 Tightening torque for lock plate bolt

147 – 309 Nm {15 – 31.5 kgm}
Wooden blocks
to support boom
cylinder

1 21N-72-11230 8

25 wide × 3,000 nylon sling 1 25 t crane 1
KW20P impact wrench 1 Wooden block 2
M24 socket 1
Others
80
Assembly procedure
Installation of Boom Cylinder Hoses
B-4
(1) Remove the oil plugs from the tubes on the boom cylinder side and from the hoses on the revolving frame side and install
new O-rings (07000-13038: 2 pieces, 07000-13048: 2 pieces).
(2) Install boom cylinder hoses (1) and (5) (4 pieces) as shown below.
a The boom cylinder hoses are installed to the upper structure (machine body).
No. Parts installed to machine body Q’ty

1 07099-01216 2
2 07371-51260 4
3 01024-81245 8
5 07099-01416 2
6 07371-51470 4
7 01010-81455 8
4 01643-31445 8
8 07000-13038 2
9 07000-13048 2
1. Keep the removed flanges and heads so Name Q’ty Name Q’ty
that they can be reused. KW12P impact wrench 1 Oil receiving pan (small) 2
that the O-ring will not be caught. L150 extension 1
that dirt will not enter the circuit. M19 socket 1
M22 socket 1
Others
81
Assembly procedure
Installation of Boom Foot Dust Seal
B-5
(1) Install the seal (209-72-11311) to the boom foot
170
Take care of the

170
direction of its lip.
Take care of the No. Loose-supply items Q’ty

direction of its lip. 1 209-72-11311 4
1. Take care of the direction of its lip so that Name Q’ty Name Q’ty
the grease can come out from inside. Hammer 1
2. When installing the seal, be careful not to
Template 1
slant it.
3. Insert the seal until it touches the bushing.
4. Do not hit seal with hammer directly but
use template, etc. to hit.
Others
82
Assembly procedure
Installation of Boom Assembly
B-6
(1) Sling the boom assembly with the crane and set it to the pin holes of the machine.
4 Weight of boom assembly: 12,700 kg.
When operating crane, install ropes to

boom assembly end to prevent boom
assembly from swinging.
(2) Push the boom foot pin (which has been installed to the revolving frame) into either pin hole until it stops and then set its
opposite end into the other pin hole. If the boom slants to the right or left at this time, adjust it with a lever block.
a Adjust the clearance at the boom foot on the outside of the machine to 1 mm or less with the shim.
Combine the shims 1.0 mm thick (21N-72-11210, 3 pieces) and 1.5 mm thick (21N-72-11220, 3 pieces) to obtain proper
thickness. (Adjust the shim at only 1 place on the outside of the boom.)
(3) Push in the right and left boom foot pins fully and install the lock plates.

245 – 309 Nm {25 – 31.5 kgm}

1 21N-72-11210 3
2 21N-72-11220 3
a Inside of pin hole: Apply lithium grease. Name Q’ty Name Q’ty
a When inserting the pins, take care not to dam- ø 30 × 5000 wire 2 25 t crane 1
age the seal (209-72-11311)
SD32 shackle 2 5 step stepladder 1
installed to the boom foot (Align the pins se-
curely). KW20 impact wrench 1
M24 socket 1
Sledge hammer 1
Others
83
Assembly procedure
Installation of Boom Cylinder
B-7
(1) Remove the lock plate fixed to the boom and remove the boom cylinder top pin.
4 Boom cylinder top pin: 43.8 kg × 2 pieces
(2) Start the engine and run it at low idle.
(3) Sling the cylinder, push the rod slowly, set the pin holes, and check the clearance between cylinder boss end and boom
boss end. Insert a proper number of shims so that the clearance will be 2 – 3 mm, push in the pin, and install the lock plate.

245 – 309 Nm {25 – 31.5 kgm}
Boom
cylinder
Lock plate top pin

1 707-01-XZ501 1
2 707-01-XZ511 1
3 21N-72-11230 2
aBefore connecting the boom cylinder, bleed Name Q’ty Name Q’ty
air. See the section of bleeding air from cylin- 25 wide × 3,000 nylon sling 1 25 t crane 1
der.
M24 socket 1
Sledge hammer 1
Others
84
Assembly procedure
Installation of Boom Hoses (Between machine and boom)
B-8
(1) Remove the oil plugs from the tubes on the boom side and revolving frame side and install new O-rings (7) and (9)
(07000-13048: 10 pieces, 07000-13038: 4 pieces).
(2) Install the boom hoses (6) and (8) (7 pieces) as shown below.
No. Parts installed to machine body Q’ty

1 07371-51470 20
2 01010-81455 40
3 01643-31445 40
4 07371-51260 8
5 01024-81245 16
6 07099-01418 5
7 07000-13048 10
8 07099-01218 2
9 07000-13038 4
1. Keep the removed flanges and heads so Name Q’ty Name Q’ty
that they can be reused. KW12P impact wrench 1 Oil receiving pan 1
that the O-ring will not be caught. L150 extension 1
that dirt will not enter the circuit. M19 socket 1
M22 socket 1
Others
85
Assembly procedure
Installation of Arm Assembly (1/2)
B-9
(1) Remove the boom top pin lock plate installed to the boom and pull out the top pin.
4 Boom top pin: 168.6 kg
(2) Sling the arm assembly and set it to the holes of the boom.
Insert shim (21N-72-11210) 1.0 mm thick to reduce the clearance to below 1.0 mm and push in the pin.
4 Weight of arm assembly: 6,200 kg
2 Inside of bushing: Apply grease.
2 Pin: Apply grease.

245 – 309 Nm {25 – 31.5 kgm}
Take care of grease hole

of arm cylinder rod.
Boom
Set grease hole to top.
Arm assembly top pin

Arm
Boom
top pin
Lock plate
Lock plate
1 21N-72-11210 4
a When inserting the pin, take care not to dam- Name Q’ty Name Q’ty
age the seal (209-72-11311) installed in the ø 25 × 5000 wire 2 25 t crane 1
bushing on the arm side.
SD32 shackle 2 5 step stepladder 1
Sledge hammer 1
M24 socket 1
Others
86
Assembly procedure
Installation of Arm Assembly (2/2)
B-9
(4) Remove the arm cylinder top pin lock plate installed to the arm and pull out the top pin.
4 Weight of arm cylinder top pin: 97.9 kg
(5) Run the engine at idle and extend the arm cylinder piston rod slowly to set it to the pin hole.
(At this time, sling the arm cylinder with the crane and position the piston rod while operating.)
(6) Set the arm cylinder top hole to the arm hole, insert shim (21N-72-11210) 1.0 mm thick to adjust the clearance to 2 – 3 mm,
and push in the pin.

245 – 309 Nm {25 – 31.5 kgm}
a 1) Operate the cylinder lever slowly. Do not operate it quickly or to the stroke end. Since there is air in the cylinder, the
piston rod may not move for more than 10 seconds. Do not move the lever to the stroke end at this time.
2) When installing the arm, take care that the bucket cylinder rod will not come out.
a Before connecting the arm cylinder, bleed air. Name Q’ty Name Q’ty
See the section of bleeding air from cylinder. 25 wide × 3,000 nylon sling 1 25 t crane 1
Sledge hammer 1 5 step stepladder 1
M24 socket 1
Others
87
Assembly procedure
Installation of Bucket Cylinder Hoses
B-10 between Boom and Bucket Cylinder
(1) Remove the oil plugs from the bucket cylinder and from the tubes on the boom side and install new O-rings
(07000-13038: 4 pieces, 07000-13048: 4 pieces).
(2) Install bucket cylinder hoses (1) and (5) (4 pieces) as shown below.
a When assembling, take care that the protection wires installed to the hoses will not come off the hose adapters.
Outside hoses
Connect hoses in
parallel with cylinder.
Inside hoses

1 21N-62-38620 2
2 07000-13038 4
5 21N-62-38610 2
6 07000-13048 4
No. Parts installed to boom/arm Q’ty
3 07371-51260 8
4 01024-81245 16
7 07371-51470 8
8 01010-81455 16
9 01643-31445 16
1. Keep the removed flanges and heads so that Name Q’ty Name Q’ty
they can be reused. KW12P impact wrench 1 5 step stepladder 1
L150 extension 1 Oil receiving pan 1
that the O-ring will not be caught.
3. When installing a hose, take extreme care M19 socket 1
M22 socket 1
Others
88
Assembly procedure
Installation of Bucket Assembly (1/3)
B-11
(1) Remove the stoppers of the bucket and arm connecting pin (fixed to the arm) and bucket and link connecting pin (installed
to the link) and remove each pin.
(2) Install bushing (1) and 2 O-rings (2) to the boss on the bucket side.
(3) Run the engine at idle and operate the boom cylinder and arm cylinder slowly to set the holes for the bucket and arm con-
necting pin.
2 Weight of bucket assembly: 5,100 kg
(4) Push in the arm and bucket connecting pin, adjust the clearance to 0.5 – 1.0 mm with shims (3) and (4), and tighten cover
mounting bolts (M30).

1130 – 1910 Nm {115 – 195 kgm}

1 21N-70-14220 1
2 21N-70-13150 2
3 21N-70-14320 14
4 21N-70-14330 4

KW45F impact wrench 1 25 t crane 1
M46 socket 1
Others
89
Assembly procedure
B-11
(5) Install O-rings (2) to prevent dirt from entering the bucket and arm connecting pin to the correct positions and then install
the pin stopper.
Stopper
3 Tightening torque for stopper mounting bolt

588 – 1030 Nm {60 – 105 kgm}

Others
90
Assembly procedure
B-11
(6) While slinging the link and operating the bucket cylinder, set the holes for the bucket and link connecting pin.
a Operate the cylinder lever slowly. Do not operate it quickly or to the stroke end. Since there is air in the cylinder, the piston
rod may not move for more than 10 seconds. Do not move the lever to the stroke end at this time.
(7) Push in the link and bucket connecting pin and adjust the clearance to below 1 mm with shims (6) 1.0 mm thick.
Install O-rings (5) to prevent entry of dirt to the correct positions and install the pin stopper.
3 Tightening torque for stopper mounting bolt

588 – 1030 Nm {60 – 105 kgm}

5 07000-16215 2
6 21N-72-11230 3

a Since the shape of the link is
different from the former link,
disassemble and assemble
the arm in the vertical pos-
ture. If the arm is disassem-
bled in the horizontal posture,
in particular, the link jumps up
just after the pin is pulled out.
Take care extremely.
Others
91
Assembly procedure
Clearance Standard for Installation of Work Equipment
B-12
Adjusting clearance
of bucket and link
Unit: mm
No. Item Criterion
Clearance limit
(A) (9) Clearance between revolving frame

and boom cylinder
Adjust clearance to 2 – 3 mm
with shim.
(B) (10) Clearance

and boom
between revolving frame Adjust clearance to below 1 mm
with shim. Adjusting clearance
(C) (11) Clearance
cylinder
between boom and boom Adjust clearance to 2 – 3 mm
with shim.
of bucket and arm
(D) (12) Clearance

cylinder
between boom and arm Adjust clearance to 2 – 3 mm
with shim.
Adjust clearance to below 1 mm
(E) (13) Clearance between boom and arm with shim.
Adjust clearance to 0.5 – 1 mm
(K) (18) Clearance between bucket and arm with shim.
Standard shim
Adjust clearance to below 1 mm thickness: 8
(J) (19) Clearance between bucket and link with shim.
(F) (20) Clearance

cylinder
between arm and arm Adjust clearance to 2 – 3 mm
with shim.

Others
92
Assembly procedure
Installation of Work Equipment Grease Piping
B-13
(1) Remove the oil plugs on the cylinder side of boom cylinder grease hoses (2 pieces) at part (a) and those on the hose nipple
side. Remove the nipples from the hoses and install them to the cylinder, and then connect the hoses.
(2) Remove the oil plugs on the cylinder side of arm cylinder foot grease hose at part (b) and that on the hose elbow side.
Remove the elbow from the hose and install it to the cylinder, and then connect the hose.
(3) Remove the oil plugs on the cylinder side of arm cylinder top grease hose at part (c) and that on the hose elbow side. Re-
move the elbow from the hose and install it to the cylinder, and then connect the hose.
(4) Remove the oil plugs on the right and left cylinder sides of boom cylinder foot grease fittings (07020-00675, 2 pieces) and
install the fittings.

1 07020-00675 2

Others
93
Assembly procedure
Procedure for Bleeding Air From Travel Motor (1/2)
B-14
a If the travel motor or swivel joint was removed and installed

or a related piping was disconnected and connected, bleed
air from the hydraulic pump group according to the following
procedure.
a Keep air bleeder (5) operated in assembly procedure

[A-20] loosened.
1) Run the engine and push up the track shoe on the side to
be bled of air by using the work equipment.
2) While running the engine at low idle, perform the following

travel operation and rotate the track shoe with no load.
(Operate the travel lever by a half stroke.)
Lever operation pattern and operation time (sec)
Forward Unit = sec

Neutral
Neutral
Reverse
Forward
Neutral
Reverse

Others
94
Assembly procedure
Procedure for Bleeding Air From Travel Motor (2/2)
B-14
3) Check that the oil flowing through the air bleeding hose
contains no bubbles and then tighten air bleeder (5).
4) Remove the air bleeding hose and clip from the bleeder.
5) After finishing the following operation, push up the track

shoe on the opposite side and bleed air similarly.
6) Remove the air bleeding order tag plate. (Right and left)

Others
95
Assembly procedure
Bleeding Air from Swing Motor
B-15
a If the swing motor was removed and installed or a re-

lated piping was disconnected and connected, bleed
air from the swing motor according to the following
procedure.
1) While running the engine at slow speed, swing and

stop the upper structure several times.
a Air is bled from the swing motor automatically by the

above operation.

Others
96
Assembly procedure
Bleeding Air from Cylinder
B-16
a If a hydraulic cylinder was removed and installed or a re-

lated piping was disconnected and connected, bleed air
from the hydraulic cylinder according to the following pro-
cedure.
1) Run the engine at idle for about 5 minutes.
2) While running the engine at slow speed, extend and re-

tract the cylinder 4 – 5 times.
a Move the piston rod to about 100 mm before each stroke

end and never relieve the pressure.
3) While running the engine at slow speed, move the piston

rod very slowly (taking at least 10 seconds) from a posi-
tion about 100 mm before the extension stroke end to the
stroke end and relieve the pressure for 3 minutes.
4) While running the engine at full throttle, move the piston

rod very slowly (taking at least 10 seconds) from a posi-
tion about 100 mm before the extension stroke end to the
stroke end and relieve the pressure for 1 minutes.

Others
97
Assembly procedure
Installation of Work Equipment Wiring
B-17
(1) Install the lights to both sides of the boom.
(2) Connect the lights to the wires on the boom side.
Detail of mounting portion
Connect to wire
on boom side.
Connect to wire
on machine side.

1 17A-06-17930 2
2 20Y-06-21551 2
3 08193-20012 2
4 01024-81230 2

Others
98
Assembly procedure
Greasing after Assembling Work Equipment
B-18

Others
99
M. PROCEDURE FOR INSPECTION AND MAINTENANCE
AFTER COMPLETION OF ASSEMBLY
101
Assembly procedure
Replacement of Return Filter
M-1 (Standard Filter to Flushing Filter) (1/3)
Replace the relief valve with this Valve

plate only at the flushing time.
Strainer
Special element for flushing,

Absolute filter mesh size: 6 µ

1 209-60-77551 2
2 21T-60-13730 2
Store the removed standard element (209- Name Q’ty Name Q’ty
60-75531)., strainer (20Y-60-31140). and
valve (20Y-60-31131) 2 pcs.
in order because they are used again after
flushing.
Others
102
Assembly procedure
M-1 (Flushing Filter to Standard Filter) (2/3)
Replacement
Valve
Strainer
Standard element
This work is performed after the flushing end. Name Q’ty Name Q’ty
Others
103
Assembly procedure
M-1 (Standard Filter ↔ Flushing Filter) (3/3)
The flushing filter must be discarded after use. Name Q’ty Name Q’ty
The flushing filter is not allowed to be reused.
Others
104
Assembly procedure
Relieving Remaining Pressure from Hydraulic Circuit
M-2
When removing hydraulic pipes, be sure to relieve remaining

pressure in accordance with the following procedures:
(1) Remove the cap from the hydraulic oil tank.
k When removing the cap from the oil it slowly to relieve

pressure in the tank and remove it carefully.
(2) Lower the lock lever and keep it locked.
(3) Start the engine, operate it for about 10 seconds and stop
the engine.
a Do not increase the engine speed to over 1,000 rpm.
a Keep the control lever of the work equipment neutral.
(4) Turn the starting switch to ON, set the lock lever to “Free”
and set the control lever of each work equipment to Full
Stroke within 5 to 6 seconds after stopping the engine.
a Repeat the procedures (2) to (4) three times.
(5) After relieving remaining pressure, set the cap to the oil
filler port of the hydraulic oil tank so that dust do not enter
the tank.
(6) Lower the lock lever and keep it locked.

Others
105
Assembly procedure
Installation of Flushing Tubes (1/2)
M-3
Install the flushing tubes to flush the work equipment piping.
1. Boom cylinder hoses (Right and left)

(1) Remove the hoses on the boom cylinder side and install the flushing tubes.
(2) Install the oil plugs to the tube on the boom cylinder side.
Flushing tube
a Reuse the installed flanges, mounting bolts, etc.
2. Arm cylinder hose

(1) Remove the hose on the arm cylinder side and install the flushing T-piece.
(2) Install the oil plug to the arm cylinder.
Flushing T-piece

Others
106
Assembly procedure
Installation of Flushing Tubes (2/2)
M-3
3. Bucket cylinder hoses (Right and left)

(1) Remove the hoses on the bucket cylinder side and install the flushing tubes.
(2) Install the oil plugs to the tube on the bucket cylinder side.
Flushing tube
a After finishing flushing, return the removed hoses.

(Remove the flushing tubes and T-pieces.)
1. Keep the removed flushing tubes and flush- Name Q’ty Name Q’ty
ing T-pieces so that they can be reused.
that any part will not be caught.
that the hose will not interfere with or catch
another part.
Others
107
Assembly procedure
Flushing of Hydraulic Circuit
M-4
After finishing assembly, flush the hydraulic circuit.
(1) Set the levers in neutral and run the engine at low idle for 30 minutes.
(2) Set the levers in neutral and run the engine at medium speed for 30 minutes.
(3) While running the engine at speed of about 1,700 rpm, repeat the following lever operation pattern 4 times
(Keep each operation for 1 minute – 1 minute 30 seconds).
The operation pattern for flushing is as follows.
(4) After finishing the above work, return the flushing tube and tee and perform the following flushing.
After finishing the general assembly, flush the hydraulic circuit.
a Run the engine at low idle (E mode) with the lever in neutral and perform flushing for 15 minutes according to the following
procedure.
(5) Flushing of Swing Circuit

Right swing and left swing for 3 minutes each
(6) Flushing of Travel Circuit

Press the ground with the work equipment as illustrated
here to raise one side of the machine, and operate the
travel lever as follows:
• Forward travel and backward travel to the right

For 3 minutes each
• Forward travel and backward travel to the left

For 3 minutes each
If the flushing is performed with the engine at Name Q’ty Name Q’ty
full throttle, the filter element may be broken
since the relief valve of the filter is closed.
Others
108
Assembly procedure
Replacement of Pilot Filter
M-5 (Flushing filter o Standard filter)
(1) After finishing flushing, replace the pilot filter element etc.
(2) Replacement procedure
1) Open the front cover of the engine hood.
2) Remove drain plug (1) from the bottom of the pilot

filter assembly to drain the oil from the filter case.
Pilot filter
3) Loosen bolt (2) at the bottom of pilot filter assembly
(3) and remove the filter assembly.
4) Remove filter element (4) and install new filter

element (4).
5) Install drain plug (1).
6) Install filter assembly (3) with bolt (2).

Tightening torque for bolt (2): 6.6 – 9.0 kgm
a When replacing, if oil spills, clean around thoroughly.
a When draining the oil through drain plug (1), use a waste
oil receiving pan.
Element Filter assembly
Drain plug
Bolt

Others
109
C. PROCEDURE FOR ASSEMBLING WORK EQUIPMENT
OF LOADING SHOVEL
CONTENTS
Transportation posture (only work equipment) .................................................................. 112
List of parts sent individually .............................................................................................. 113
C. Procedure for assembling work equipment of loading shovel ....................................... 116
C- 1. Installation of Arm Cylinder Bottoms .................................................................... 116
C- 2. Connection of Boom and Arm .............................................................................. 117
C- 3. Pulling out Boom Foot Pin and Boom Cylinder Foot Pin ..................................... 119
C- 4. Installation of Boom and Arm Assembly .............................................................. 120
C- 5. Replacement of Return Filter (Standard Element → Flushing Element) ............ 121
C- 6. Releasing Residual Pressure in Hydraulic Circuit ............................................... 123
C- 7. Installation of Boom Hoses (Between Chassis and Boom) ................................. 124
C- 8. Installation of Flushing Tube for Boom Cylinder Hoses ....................................... 125
C- 9. Installation of Flushing Tube for Arm Cylinder Hoses .......................................... 126
C-10. Installation of Flushing Tube for Bucket Cylinder Hoses .................................... 127
C-11. Installation of Hoses Between Boom and Arm (Bottom Dump) .......................... 128
C-12. Installation of Flushing Tube for Bottom Dump Cylinder Hoses ......................... 129
C-13. Installation of Hydraulic Circuit ........................................................................... 130
C-14. Replacement of Pilot Filter (Flushing Element → Standard Element) ............... 131
C-15. Installation of Boom Cylinder Bottoms ................................................................ 132
C-16. Installation of Boom Cylinder Hoses ................................................................... 133
C-17. Installation of Boom Cylinder Head Pin .............................................................. 134
C-18. Installation of Arm Cylinder Hoses ...................................................................... 135
C-19. Installation of Bucket Cylinder ............................................................................ 136
C-20. Installation of Bucket Cylinder Hoses ................................................................. 137
C-21. Installation of Bucket Assembly .......................................................................... 138
C-22. Installation of Bottom Dump Cylinder Hoses ...................................................... 140
C-23. Maintenance Standard ........................................................................................ 141
C-24. Installation of Working Lamp .............................................................................. 142
C-25. Installation of Work Equipment Greasing Piping ................................................ 143
C-26. Bleeding Air from Work Equipment Circuit ......................................................... 144
C-27. Checking Oil Level in Hydraulic Tank and Adding Oil ......................................... 145
C-28. Greasing After Assembling Work Equipment ...................................................... 146
Inspection of each part after assembly of loader .............................................................. 147
<Note> This manual describes only the assembly procedure for work equipment different from the backhoe
specification model.
For the p rocedures for a ssembling the base ma chine, flushing the hydrauli c circuit, bleeding air
from the hyd raulic circuit, adjusting the track lin k, and checking the oil, wate r, and fuel, se e the
backhoe specification model.
111
TRANSPORTATION POSTURE (ONLY WORK EQUIPMENT)
TRANSPORTATION POSTURE (ONLY WORK EQUIPMENT)
112
LIST OF PARTS SENT INDIVIDUALLY (WORK EQUIPMENT)
1 21N-63-X3121 Arm cylinder (L.H.) 1 For installation of arm cylinder 116
2 21N-63-X3131 Arm cylinder (R.H.) 1
3 209-72-11311 Seal 4 Arm foot portion 117
4 21N-72-11210 Shim 3
5 21N-72-11220 Shim 4
6 209-72-11311 Seal 4 Boom foot portion 120
7 21N-72-11210 Shim 3
8 21N-72-11220 Shim 3
9 07371-51470 Flange 10 For installation of work equipment assembly 124
10 01010-81455 Bolt 20
11 01643-31445 Washer 20
12 07000-13048 O-ring 5
13 07371-51260 Flange 8
14 01024-81245 Bolt 16
15 07000-13038 O-ring 4
16 07097-01213 Hose 2 For installation of arm cylinder flushing tube 126
17 07371-51260 Flange 8
18 01024-81245 Bolt 16
19 07000-13038 O-ring 4
20 07097-01415 Hose 2
21 07371-51470 Flange 8
22 01010-81455 Bolt 16
23 01643-31445 Washer 16
24 07000-13048 O-ring 4
25 07099-21225 Hose 2 For installation of bucket cylinder flushing 127

tube
26 07371-51260 Flange 8
27 01024-81245 Bolt 16
28 07000-13038 O-ring 4
29 07099-21425 Hose 2
30 07371-51470 Flange 8
31 01010-81455 Bolt 16
32 01643-31445 Washer 16
33 07000-13048 O-ring 4
113
34 07099-21222 Hose 2 For installation of hoses between boom and 128
arm
35 07371-51260 Flange 8
36 01024-81245 Bolt 16
37 07000-13038 O-ring 4
38 07099-21217 Hose 2 129
39 07371-51260 Flange 8 For installation of hoses between arm and

40 01024-81245 Bolt 16 bucket
41 07000-13038 O-ring 4
42 21N-63-X3100 Boom cylinder (L.H.) 1 For installation of boom cylinder 132
43 21N-63-X3110 Boom cylinder (R.H.) 1

44 21N-72-11230 Shim 10 132,134
45 707-01-XE920 Bucket cylinder (L.H.) 1 For installation of bucket cylinder 136
46 707-01-XE930 Bucket cylinder (R.H.) 1

47 07000-12130 O-ring 8 136,139
48 07099-21222 Hose 2 For installation of bucket cylinder flushing tube 137
49 07371-51260 Flange 8
50 01024-81245 Bolt 16
51 07000-13038 O-ring 4
52 07099-21422 Hose 2
53 07371-51470 Flange 8
54 01010-81455 Bolt 16
55 01643-31445 Washer 16
56 07000-13048 O-ring 4
57 209-72-11311 Seal 4 For arm top 138
58 17A-06-17930 Lamp 2 For installation of work equipment wiring 142
59 20Y-06-21551 Bracket 2
60 08193-20012 Clip 2
61 01024-81230 Bolt 2
62 04434-51212 Clip 2
63 07020-00675 Fitting 2 For installation of grease piping 143
64 07020-00000 Fitting 4
114
(CHASSIS AND WORK EQUIPMENT)
65 209-60-77551 Filter element 2 For rearrangement of return filter flushing 121
circuit (chassis)
66 21T-60-13730 Plate 2
67 21N-62-19370 Tube 6 For installation of work equipment flushing 125-127
68 21N-62-19320 Flange 1 tube (work equipment) 129
For rearrangement of pilot filter flushing

69 424-16-11140 Filter element 1 131
circuit (chassis)
115
Assembly procedure
Installation of Arm Cylinder Bottoms
C-1
recautions Necessary tools Necessary equipment
1. Apply lithium grease to the inside walls of Name Q’ty Name Q’ty
the pin holes.
2. Install the arm cylinder bottoms with the
piping ports down.
Others
116
Assembly procedure
Connection of Boom and Arm (1/2)
C-2
1. When installing the pins, do not damage Name Q’ty Name Q’ty
the seals.
2. Apply lithium grease to the inside walls of
the pin holes.
Others
117
Assembly procedure
Connection of Boom and Arm (2/2)
C-2
Apply lithium grease to the inside walls of the Name Q’ty Name Q’ty
pin holes.
Others
118
Assembly procedure
Pulling out Boom Foot Pin and Boom Cylinder Foot Pin
C-3
1. Clean the pin holes and pins. Name Q’ty Name Q’ty
2. Check the pin holes and pins for a flaw.
Others
119
Assembly procedure
Installation of Boom and Arm Assembly
C-4
When inserting the pins, take care not to Name Q’ty Name Q’ty
damage seals (209-72-11311, 4 pieces).
Others
120
Assembly procedure
Replacement of Return Filter (1/2)
C-5 (Standard Element o Flushing Element)
77551
Keep the removed standard parts (filter Name Q’ty Name Q’ty
element, strainer, and valve) carefully since
they will be reused after flushing is finished.
Others
121
Assembly procedure
Replacement of Return Filter (2/2)
C-5 (Standard Element o Flushing Element)
After finishing flushing, discard the removed Name Q’ty Name Q’ty
flushing element.
Keep the removed plate, however, since it
will be reused.
Others
122
Assembly procedure
Releasing Residual Pressure in Hydraulic Circuit
C-6

Others
123
Assembly procedure
Installation of Boom Hoses
C-7 (Between Chassis and Boom)
1. Keep the removed flanges, O-rings, and Name Q’ty Name Q’ty
heads so that they can be reused.
2. When connecting each hose, take
extreme care that the O-rings will not be
caught.
extreme care that dirt will not enter the
circuit.
Others
124
Assembly procedure
Installation of Flushing Tube for Boom Cylinder Hoses
C-8
caught.
circuit.
Others
125
Assembly procedure
Installation of Flushing Tube for Arm Cylinder Hoses
C-9
caught.
circuit.
Others
126
Assembly procedure
Installation of Flushing Tube for Bucket Cylinder Hoses
C-10
caught.
circuit.
Others
127
Assembly procedure
Installation of Hoses Between Boom and Arm
C-11 (Bottom Dump)
caught.
circuit.
Others
128
Assembly procedure
Installation of Flushing Tube for
C-12 Bottom Dump Cylinder Hoses
caught.
circuit.
Others
129
Assembly procedure
Flushing of Hydraulic Circuit
C-13

Others
130
Assembly procedure
Replacement of Pilot Filter
C-14 (Flushing Element o Standard Element)

Others
131
Assembly procedure
Installation of Boom Cylinder Bottoms
C-15

Others
132
Assembly procedure
Installation of Boom Cylinder Hoses
C-16
1. When connecting each hose, take Name Q’ty Name Q’ty

caught.
circuit.
Others
133
Assembly procedure
Installation of Boom Cylinder Head Pin
C-17

Others
134
Assembly procedure
Installation of Arm Cylinder Hoses
C-18

caught.
circuit.
Others
135
Assembly procedure
Installation of Bucket Cylinder
C-19

Others
136
Assembly procedure
Installation of Bucket Cylinder Hoses
C-20

caught.
circuit.
Others
137
Assembly procedure
C-21

Others
138
Assembly procedure
C-21

Others
139
Assembly procedure
Installation of Bottom Dump Cylinder Hoses
C-22

Others
140
Assembly procedure
Maintenance Standard
C-23

Others
141
Assembly procedure
Installation of Working Lamp
C-24

Others
142
Assembly procedure
Installation of Work Equipment Greasing Piping
C-25

Others
143
Assembly procedure
Bleeding Air from Work Equipment Circuit
C-26

Others
144
Assembly procedure
Checking Oil Level in Hydraulic Tank and Adding Oil
C-27

Others
145
Assembly procedure
Greasing After Assembling Work Equipment
C-28

Others
146
INSPECTION OF EACH PART AFTER ASSEMBLY OF LOADER
(For the inspection of the chassis, see the backhoe specification model.)
147
Backhoe 1/13
Report No.
FIELD ASSEMBLY INSPECTION REPORT
After completion of assembling a machine, make inspections according to these check sheets for assuring machine performance and quality.
Model - Type Machine Serial No. User Unit No. Engine Model Engine Serial No.
Backhoe spec. SAA6D170E-5
Service Meter Reading Date of Inspection

Attachment
1 2
Location of Machine at Inspection Manufacture
Model
Distributor’s Name
Serial No.
Delivery
Customer’s Name Address： Signature： Report
No. attached
Date：
Inspector’s Comments：
Inspector’s Name： KOMATSU USE ONLY：

C. Sheet Receiving Date：
Title：
By：
Signature： Remark：
Check sheet filling instructions：
1. Use following indexes for entry of judgment
□ ……Normal □……Correction made on abnormal point

□ ……Abnormal □……Not applied
2. Enter actually measured values in parentheses, [ ].
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.
SUBMITTANCE OF 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 COPY OF DELIVERY
SERVICE REPORT.
2/13
Revision
Category
Local After
Check item assembly hours of Judgment standard
time operation
Actual
Oil and water levels
measurement
Cooling water Soft water 〔〕
Yes/No 〔〕
Anti-freeze
Ａ：-50－-40℃ Ｄ：-20－-10℃
（Ａ，Ｂ，Ｃ，Ｄ，Ｅ） Density of
anti-freeze
〔〕Ｂ：-40－-30℃ Ｅ：-10－0℃
Ｃ：-30－-20℃ (Not necessary in summer)
+5mm
Engine oil EO10W30-DH Ｌ－Ｈ（10 minutes after stopping
EO30-DH 〔〕 engine）
For selection by
Checks before assembly
atmospheric
temperature, see +5
operation manual. TO10 Ｌ－Ｈ（10 minutes after stopping
PTO oil 〔〕 engine）
TO30
+5 +10
Swing machinery Ｌ－Ｈ（10 minutes after stopping
TO30 〔〕 engine）
gear case oil
Right TO30 〔〕
Final drive gear
Bottom edge of level plug:0 to －10mm
case oil
Left TO30 〔〕
Hydraulic oil HO46-HM 〔〕 Between the H and L marks
Within 13 mm from bottom surface of filler

Battery electrolyte －〔〕
port
Engine No. 〔〕
When accepted After check

Service meter 〔〕〔〕
Revolving frame No. 〔〕 Must match Serial No.
Loose, untightened lock bolts for connecting pins There must be none.
Loose, untightened split flange bolts for work equipment piping There must be none.
Forgotten, missing, catching O-rings for work equipment piping There must be none.
Checks during assembly
Loose, twisted connections for grease piping There must be none.
Max. 1mm （for locations, see assembly

Shim adjustment for work equipment pins
procedure manual）
Improperly inserted wiring, unconnected wiring There must be none.
Loose, untightened ladder mounting bolts There must be none.

3/13
Revision
Category
Local After
time operation
Loose, untightened counterweight bolts There must be none.
Stepped clearance between counterweight and frame Max. 15mm
Loose, untightened operator’s cab mounting bolts There must be none.
Loose, untightened operator’s seat mounting bolts There must be none.
Loose, untightened mounting bolts and joints for travel There must be none.
Forgotten, missing, catching O-rings for travel There must be none.
Loose, untightened track frame mounting bolts There must be none.
Loose, untightened bolts for travel motor cover There must be none.
Are there any other parts not yet installed (rear view mirror, etc.)? There must be none.
Follow instructions in assembly procedure

Bleed air from pump
manual.
Bleed air from travel motor
manual.

Flush hydraulic circuit
manual.

Bleed air from work equipment cylinder circuit
manual.
Grease all parts of work equipment All locations must be greased.
Add to between L and H marks at inspection

Add hydraulic oil
posture.
Add fuel, washer fluid Fill tank.
Dirty oil on paintwork, damage to paintwork at any part Clean, repair damaged paintwork
4/13
Revision
Category
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 alarm buzzer should sound.
2.Check of gauges and CHECK items

When starting switch is turned to ON (all lamps on), working
mode and travel speed monitors appear after approx. 3 sec. Display should be as on left.
For another 2 seconds, only the gauges are displayed, and
the CHECK and monitor items disappear.
3.Check 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

Operation of service meter
of the lens or variation in operation.
MONITOR
AA: Screen with all lamps lighted up
BB: Screen for standard
CC: Maintenance time warning screen
(1) User mode adjustment switch

(2) Working mode selector switch (basic switch)
(3) Alarm buzzer stop switch
Check monitor
(4) Wiper monitor

(5) Engine pre-heating monitor
(6) Swing lock monitor
(7) Engine coolant temperature monitor
(8) Engine oil pressure monitor
(9) Engine coolant temperature gauge
(10) Charge level monitor
(11) Radiator coolant level monitor
(12) Working mode monitor
(13) Service meter
(14) Travel speed monitor
(15) Engine oil level monitor
(16) Air cleaner clogging monitor
(17) Fuel gauge
(18) Fuel level monitor
(19) Auto-deceleration monitor
(20) Liquid crystal monitor adjustment switch
(21) Input confirmation switch
(22) Window washer switch
(23) Wiper switch
(24) Maintenance switch
(25) Travel speed selector switch (selection switch)
(26) Auto-deceleration switch (selection switch)
(27) Hydraulic oil temperature monitor
(28) Hydraulic oil temperature gauge
(29) Maintenance interval monitor
Checking error code (Electrical system/Mechanical system) No error codes must be displayed.
(If any error code is displayed,
check and eliminate it.)
5/13
Revision
Category
Local After
time operation
(10) Ashtray
(11) Machine monitor
(12) Horn switch
(13) R.H. work equipment control lever
(14) Cigarette lighter
(15) Starting switch
(1) Radio
(16) Step light switch
(2) Large capacity airflow air conditioner blower switch (if equipped)
(17) Fuel control dial
(3) Revolving warning lamp switch (if equipped)
(18) Lamp switch
(4) Lower wiper switch (machine equipped with front window cab)
(19) Swing lock switch
Check of switches, control levers
(5) Air conditioner control panel

(20) Machine push-up switch
(6) Lock lever
(21) Boom shockless control switch
(7) L.H. work equipment control lever
(22) Swing parking brake release switch
(8) Travel pedals
(23) Emergency pump drive switch
(9) Travel levers
(24) Room lamp switch
P light up: Heavy-duty operations
Operation of mode selector switch E light up: Fuel-efficient operations
When starting the engine, P (heavy-duty

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

deceleration is actuated or canceled.
This is used to select the two travel speeds.
Operation of travel speed switch Lo light up: Low speed travel
Hi light up: High speed travel
When the engine is started, the travel speed

is automatically set to Lo.
When the switch is turned ON during
Operation of heavy lift switch independent operations of the boom, the
boom lifting power is increased.
When ON lights up: Effective for
Operation of swing priority mode switch 180°swing and loading
When ON goes out: For normal operations
(90° swing and loading)
Operation of alarm buzzer stop switch This is used to stop alarm buzzer if it sounds
to warn of an abnormality during operation.
OFF position: Engine is stopped
Operation of starting switch 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
This is used to light cigarettes. To use, push
Operation of cigarette lighter the lighter in. After a few seconds it will
spring back.
6/13
Revision
Category
Local After
time operation
ON position (actuated):
Operation of swing lock switch 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. 11
seconds after all work equipment control
lever is placed in neutral.
OFF: Wiper stops
Operation of wiper switch ON light up: Wiper moves continuously
INT light up: Wiper moves intermittently
Operation of window washer switch Window washer fluid is sprayed out.
This switch is used to turn on the front

Operation of lamp switch lamps, working lamps, additional lamp at the
top front of the cab, and monitor lighting.
Low pressure setting:
Operation of machine push-up switch The boom thrust force is weak.
High pressure setting:

The boom thrust force becomes more
powerful.
When the switch is at the ON position and
Operation of shockless boom control switch
the boom is stopped, the shaking is not felt.
Press the switch on the right work
Operation of horn switch 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 light up.
When normal:
Operation of pump prolix switch Switch is pushed down.
When abnormal:
When the monitor display shows E02
(TVC valve system error), move the
switch up to make it possible to carry out
work.
When normal:
Operation of swing prolix switch Switch is pushed down.
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.
・ When the switch is pressed, the step light
Operation of step light switch will light up for approx. 60 seconds.
・ 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.
ON: Lower wiper moves.

Operation of lower wiper switch
OFF: Lower wiper stops.
7/13
Revision
Category
Local After
time operation
Push down the lever up to apply the lock.

Operation of lock lever 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.
FORWARD:
Operation of travel levers 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.
This lever is used to operate the arm and
Operation of left work equipment control lever upper structure.
(with auto-deceleration device) Arm operation Swing operation
(a) Arm OUT (c) Swing to right

(b) Arm IN (d) 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.
This lever is used to operate the boom and
Operation of right work equipment control lever bucket.
(with auto-deceleration device) Boom operation Bucket operation
(a) RAISE (c) DUMP
(b) LOWER (d) CURL
N(neutral):
When the lever in this position, the boom
and the bucket will be retained in the
position in which they stop.
8/13
Revision
Category
Local After
time operation
Swing operation running in: Engine high idling speed.
(Work equipment posture: Max. reach)
Right Left
Constant swing speed [ rpm] [ rpm] P mode : 5.8 ± 0.3 rpm
Swing performance
Brake angle Max. 60° (feeling)
Swing variation, hunting There must be none.
Abnormal noise, irregular swing There must be none.
Travel operation running in: Engine high idling speed.
There must be no abnormal noise or

Abnormal noise, heat from carrier roller, track roller, idler
abnormal heat.
Must brake securely without pulling to one
Operation of travel brake
side.
Abnormal noise, irregular travel There must be none.
There must be no abnormal deviation from

Travel deviation (feeling) fine control range to full stroke range
(feeling).
Forward Reverse
Travel deviation High
[ ] [ ] Max. 200 mm / 20 m
(measured) speed
mm/20m mm/20m
Forward Reverse
Travel performance
(Only when it is
Low
considered that [ ] [ ] Max. 200 mm / 20 m
there is abnormality.) speed
mm/20m mm/20m
Forward Reverse P mode

Track rotating High speed 73 ± 8 sec / 5 turns
[ ] [ ]
speed - Right
sec sec
Forward Reverse
High speed
[ ] [ ]
- Left
sec sec

Low speed 105 ± 11 sec / 5 turns
[ ] [ ]
- Right
sec sec
Forward Reverse
Low speed
[ ] [ ]
- Left
sec sec
Right Left
Track tension [ ] [ ]
mm mm
9/13
Note: All judgment standard values for speeds are the values in P mode.
Revision
Category
Local After
time operation
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
Work equip- RAISE sec LOWER sec RAISE:6.0±0.6sec.(STD)6.4±0.7sec.(SP)

Boom LOWER:4.0±0.4sec.(STD)4.4±0.4sec.(SP)
P mode
ment speed [ ] [ ]
IN sec LOWER sec IN : 5.0±0.5 sec.
Arm OUT:4.0±0.4 sec.
P mode
[ ] [ ]
CURL sec DUMP sec CURL:3.3±0.4sec.(STD)

Bucket 3.5±0.4sec.(SP)
[ ] [ ] P mode
DUMP:2.9±0.4sec.(STD)
3.1±0.4sec.(SP)
Work equip-
ment time lag LOWER sec
(Engine low Boom [ ] Max. 5 sec.
idling) Only when there is considered to be abnormality.
IN sec
Arm [ ] Max. 2 sec.
Only when there is considered to be abnormality.
Work equipment performance
DUMP sec
Bucket [ ] Max. 2 sec
There must be no abnormality during

Abnormal noise from pump, PTO
operation under no load and during relief.
There must be no abnormal generation of
Generation of heat by PTO
heat.
There must be no hunting at any speed

Engine partial performance under no load, there must be no stalling of
engine even at low idling and relief.
Fine control performance Must operate smoothly.
There must be no escape of boom, arm, or
Operation when raising chassis
bucket.
Abnormal noise, grating noise from work equipment There must be none.
Cushion must be fully effective.

Shock at end of cylinder stroke
(Shock at end of stroke for BOOM RAISE and ARM OUT)
Immediately after engine is stopped, boom

Function of accumulator cylinder must move from fully extend
position to ground level. (Arm at Max. reach)
10/13
Revision
Category
Local After
time operation
Check all parts
・ There must be no catching during

Operating force of control lever when each actuator is
During operation
operation.
actuated.
・ 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.
Movement of doors and windows Must move smoothly.

Around operator’s cab
Door, window locks Must lock securely.
Adjustment of operator’s seat Must be possible to make all adjustments.
There must be none.

Oil leakage
(Idler, roller, sprocket, final drive gear case, motor, brake
valve)
Undercarriage
Interference at any part There must be none.
Looseness of track shoe bolt There must be none.
There must be no overlapping, separation,

Contact of link tread
or missing or broken parts.
Oil leakage There must be none.

Center swivel, pump, solenoid valve, relief valve, control
valve, PPC valve, swing motor, brake valve, shuttle valve,
swing machinery, hydraulic tank, piping
There must be none.

Leakage of fuel
(Fuel tank, engine, piping)
Around chassis
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.

11/13
Revision
Category
Local After
time operation
Operation of grease pump Must move smoothly.
Looseness, insufficient insertion of electric wiring terminals There must be none.
There must be a clearance of at least 10

Around chassis
Position for passing electrical wiring through

mm from any moving part or edge.
Leakage of air from air system There must be none.
There must be none.

Oil leakage
(Cylinder, piping, block)
Grease leakage from grease piping There must be none.

Around work equipment
Interference of work equipment There must be none.
Looseness of work equipment piping clamps, play in piping There must be none.
Twisting of hydraulic hoses and operation of work equipment

There must be none.
when turning over
12/13
Note: If the operation or function is defective, measure as necessary. All judgment standard values for speeds are the values in P mode.
Revision
Category
Local After
time operation
1. Engine speed: Check in monitoring mode “01006”
Low idling [ rpm] 850 – 950 rpm (P mode)
High idling (Operate lever a little) 1950 – 2050 rpm
High idling (Do not operate lever) 1700 – 1800 rpm
Speed at boom raise relief

[ rpm] Min 1700 rpm
(Heavy lift: OFF)
[ rpm]
(Heavy lift: ON)
2. Radiator fan speed Check in service mode “55”

(Fan rotation 100% fixed mode)
975 ± 50 rpm
Speed at engine rated speed [ rpm]
(Engine at full throttle, Oil temperature at 50℃)
Main measurement items
Check in monitoring mode

3. Measurement of oil pressure Swing pump “09000”,
F pump: “01100”, R pump: “01101”
Control valve main set MPa 31.4 +1.0
-1.5 MPa
F pump {kg/㎠} +10 kg/㎠｝ At engine high idling, arm
pressure ｛320 -15
OUT, P mode and Heavy
-1.5 MPa lift OFF, relief
R pump {kg/㎠}
pressure ｛320 +10 kg/㎠｝
-15
Control valve main set pressure MPa 33.3 +1.0

-1.5 MPa
F pump
(Increase of pressure) {kg/㎠} ｛340 +10 kg/㎠｝
-15
Relieved on one side
MPa 33.3 +1.0
MPa
at P mode
Control valve main set pressure -1.5
R pump
-15

-1.5 MPa At engine high idling, swing
Swing pump
pressure {kg/㎠} ｛320 +10 kg/㎠｝
-15
and P mode, relief
+5
MPa 3.14 +0.5 MPa ｛32 0 kg/㎠}
Pilot relief valve set pressure 0
{kg/㎠} (At engine high idling, neutral)
In neutral When boom is raised When boom is raised

(Heavy: OFF) In neutral (Heavy: OFF)
NC valve output pressure Max.
1.13±0.2 MPa
(at top surface of NC MPa MPa 0.25 MPa Engine {11.5±2.0 kg/㎠}
valve) No.1 Front pump {kg/㎠} {kg/㎠} {2.6 kg/㎠} high idling
1.13±0.2 MPa
(at top surface of NC MPa MPa 0.25 MPa
P mode {11.5±2.0 kg/㎠}
valve) No.1 Rear pump {kg/㎠} {kg/㎠} {2.6 kg/㎠}
Note: Measure the following J/S differential pressure only if

the NC valve output pressure does not pass the test.
When boom is raised When boom is raised

In neutral (Heavy: OFF) In neutral (Heavy: OFF)
J/S differential pressure At
Min. Max.
(differential pressure at input MPa MPa engine
1.77±0.2MPa 0.2 MPa
and output ports of jet Engine high
sensor) No.1 Front pump
{kg/㎠} {kg/㎠} {Min. 18±2{kg/㎠} {2kg/㎠}
idling
high idling
J/S differential pressure turn
Min. Max.
(differential pressure at input MPa MPa P mode with no
1.77±0.2MPa 0.2 MPa
and output ports of jet load
sensor) No.1 Rear pump
{kg/㎠} {kg/㎠} {Min. 18±2{kg/㎠} {2kg/㎠}
13/13
Revision
Category
Local After
Check item assembl hours of Judgment standard
y time operation
4. hydraulic drift of work equipment

(bucket unloaded, 50±5℃）
Bucket tooth up [ mm] Max. 650 mm / 15 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.
Boom cylinder [ mm] Max. 55 mm / 15 minutes
Arm cylinder [ mm] Max. 70 mm / 15 minutes
Bucket cylinder [ mm] Max. 45 mm / 15 minutes
5. operation force, travel

Boom lever Operating RAISE N LOWER N 15.7±4.9N
force {kg} {kg} {1.6±0.5kg}
RAISE LOWER PLAY
Stroke:85±10mm
Stroke
[ mm] [ mm] [ mm] Play: Max. 10mm
Swing lever Operating RIGHT N LEFT N 12.7±3.9N
RIGHT LEFT PLAY Stroke:85±10mm
Stroke
Bucket Operating CURL N DUMP N 12.7±3.9N

lever force {kg} {kg} {1.3±0.4kg}
CURL DUMP PLAY Stroke:85±10mm
Stroke At engine high
idling, relief
Arm lever Operating IN N OUT N 15.7±4.9N
IN OUT PLAY Stroke:85±10mm
Stroke
Right travel Operating FOR- N RE- N 21.5±5.9N
lever force {2.2±0.6kg}
WARD {kg} VERSE {kg}
FORWARD REVERSE PLAY Stroke:112±15mm
Stroke
Left travel Operating FOR- N RE- N 21.5±5.9N
Stroke
Measure the travel of the lever at the center of the lever tip
Loading shovel 1/13
Report No.
FIELD ASSEMBLY INSPECTION REPORT
After completion of assembling a machine, make inspections according to these check sheets for assuring machine performance and quality.
Model - Type Machine Serial No. User Unit No. Engine Model Engine Serial No.
Loading shovel spec. SAA6D170E-5
Service Meter Reading Date of Inspection

Attachment
1 2
Location of Machine at Inspection Manufacture
Model
Distributor’s Name
Serial No.
Delivery
Customer’s Name Address： Signature： Report
No. attached
Date：
Inspector’s Comments：
Inspector’s Name： KOMATSU USE ONLY：

C. Sheet Receiving Date：
Title：
By：
Signature： Remark：
Check sheet filling instructions：
1. Use following indexes for entry of judgment
□ ……Normal □……Correction made on abnormal point

□ ……Abnormal □……Not applied
2. Enter actually measured values in parentheses, [ ].
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.
SUBMITTANCE OF 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 COPY OF DELIVERY
SERVICE REPORT.
2/13
Revision
Category
Local After
time operation
Actual
Oil and water levels
measurement
Cooling water Soft water 〔〕
Yes/No 〔〕
Anti-freeze
Ａ：-50－-40℃ Ｄ：-20－-10℃
（Ａ，Ｂ，Ｃ，Ｄ，Ｅ） Density of
anti-freeze
〔〕Ｂ：-40－-30℃ Ｅ：-10－0℃
Ｃ：-30－-20℃ (Not necessary in summer)
+5mm
Engine oil EO10W30-DH Ｌ－Ｈ（10 minutes after stopping
EO30-DH 〔〕 engine）
For selection by
Checks before assembly
atmospheric
temperature, see +5
operation manual. TO10 Ｌ－Ｈ（10 minutes after stopping
PTO oil 〔〕 engine）
TO30
+5 +10
Swing machinery Ｌ－Ｈ（10 minutes after stopping
TO30 〔〕 engine）
gear case oil
Right TO30 〔〕
Final drive gear
Bottom edge of level plug:0 to －10mm
case oil
Left TO30 〔〕
Hydraulic oil HO46-HM 〔〕 Between the H and L marks
Within 13 mm from bottom surface of filler

Battery electrolyte －〔〕
port
Engine No. 〔〕
When accepted After check

Service meter 〔〕〔〕
Revolving frame No. 〔〕 Must match Serial No.
Loose, untightened lock bolts for connecting pins There must be none.
Loose, untightened split flange bolts for work equipment piping There must be none.
Forgotten, missing, catching O-rings for work equipment piping There must be none.
Loose, twisted connections for grease piping There must be none.
Max. 1mm （for locations, see assembly

Shim adjustment for work equipment pins
procedure manual）
Improperly inserted wiring, unconnected wiring There must be none.
Loose, untightened ladder mounting bolts There must be none.

3/13
Revision
Category
Local After
time operation
Loose, untightened counterweight bolts There must be none.
Stepped clearance between counterweight and frame Max. 15mm
Loose, untightened operator’s cab mounting bolts There must be none.
Loose, untightened operator’s seat mounting bolts There must be none.
Loose, untightened mounting bolts and joints for travel There must be none.
Forgotten, missing, catching O-rings for travel There must be none.
Loose, untightened track frame mounting bolts There must be none.
Loose, untightened bolts for travel motor cover There must be none.
Are there any other parts not yet installed (rear view mirror, etc.)? There must be none.

Bleed air from pump
manual.
Bleed air from travel motor
manual.

Flush hydraulic circuit
manual.

Bleed air from work equipment cylinder circuit
manual.
Grease all parts of work equipment All locations must be greased.
Adjust work equipment potentiometer (boom, arm)
Add to between L and H marks at inspection

Add hydraulic oil
posture.
Add fuel, washer fluid Fill tank.
Dirty oil on paintwork, damage to paintwork at any part Clean, repair damaged paintwork
4/13
Revision
Category
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 alarm buzzer should sound.
2.Check of gauges and CHECK items

When starting switch is turned to ON (all lamps on), working
mode and travel speed monitors appear after approx. 3 sec. Display should be as on left.
For another 2 seconds, only the gauges are displayed, and
the CHECK and monitor items disappear.
3.Check 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

Operation of service meter
of the lens or variation in operation.
MONITOR
AA: Screen with all lamps lighted up
BB: Screen for standard
CC: Maintenance time warning screen
(1) User mode adjustment switch

(2) Working mode selector switch (basic switch)
(3) Alarm buzzer stop switch
Check monitor
(4) Wiper monitor

(5) Engine pre-heating monitor
(6) Swing lock monitor
(7) Engine coolant temperature monitor
(8) Engine oil pressure monitor
(9) Engine coolant temperature gauge
(10) Charge level monitor
(11) Radiator coolant level monitor
(12) Working mode monitor
(13) Service meter
(14) Travel speed monitor
(15) Engine oil level monitor
(16) Air cleaner clogging monitor
(17) Fuel gauge
(18) Fuel level monitor
(19) Auto-deceleration monitor
(20) Liquid crystal monitor adjustment switch
(21) Input confirmation switch
(22) Window washer switch
(23) Wiper switch
(24) Maintenance switch
(25) Travel speed selector switch (selection switch)
(26) Auto-deceleration switch (selection switch)
(27) Hydraulic oil temperature monitor
(28) Hydraulic oil temperature gauge
(29) Maintenance interval monitor
Checking error code (Electrical system/Mechanical system) No error codes must be displayed.
(If any error code is displayed,
check and eliminate it.)
5/13
Revision
Category
Local After
time operation
(12) Horn switch

(13) R.H. work equipment control lever
(14) Cigarette lighter
(15) Starting switch
(1) Radio
(16) Step light switch
(2) Large capacity air conditioner blower switch (if equipped)
(17) Fuel control dial
(3) Revolving warning lamp switch (if equipped)
(18) Lamp switch
(4) Lower wiper switch (machines equipped with fixed front window cab)
(19) Swing lock switch
(5) Air conditioner control switch
(20) Machine push-up switch
(6) Lock lever
(21) Boom shockless control switch
(7) L.H. work equipment control lever
(22) Swing parking brake release switch

(8) Travel pedals
(23) Emergency pump drive switch
(9) Travel levers
(24) Room lamp switch
(10) Ashtray
(25) L.H. bottom dump switch
(11) Machine monitor
(26) R.H. bottom dump switch
P light up: Heavy-duty operations

Operation of mode selector switch E light up: Fuel-efficient operations
When starting the engine, P (heavy-duty

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

deceleration is actuated or canceled.
This is used to select the two travel speeds.
Operation of travel speed switch Lo light up: Low speed travel
Hi light up: High speed travel
When the engine is started, the travel speed

is automatically set to Lo.
When the switch is turned ON during
Operation of heavy lift switch independent operations of the boom, the
boom lifting power is increased.
When ON lights up: Effective for
Operation of swing priority mode switch 180°swing and loading
When ON goes out: For normal operations
(90° swing and loading)
Operation of alarm buzzer stop switch This is used to stop alarm buzzer if it sounds
to warn of an abnormality during operation.
OFF position: Engine is stopped
Operation of starting switch 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
This is used to light cigarettes. To use, push
Operation of cigarette lighter the lighter in. After a few seconds it will
spring back.
6/13
Revision
Category
Local After
time operation
ON position (actuated):
Operation of swing lock switch 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. 11
seconds after all work equipment control
lever is placed in neutral.
OFF: Wiper stops
Operation of wiper switch ON light up: Wiper moves continuously
INT light up: Wiper moves intermittently
Operation of window washer switch Window washer fluid is sprayed out.
This switch is used to turn on the front

Operation of lamp switch lamps, working lamps, additional lamp at the
top front of the cab, and monitor lighting.
Low pressure setting:
Operation of machine push-up switch The boom thrust force is weak.
High pressure setting:

The boom thrust force becomes more
powerful.
When the switch is at the ON position and
Operation of shockless boom control switch
the boom is stopped, the shaking is not felt.
Press the switch on the right work
Operation of horn switch 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 light up.
When normal:
Operation of pump prolix switch Switch is pushed down.
When abnormal:
(TVC valve system error), move the
switch up to make it possible to carry out
work.
When normal:
Operation of swing prolix switch Switch is pushed down.
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.
・ When the switch is pressed, the step light
Operation of step light switch will light up for approx. 60 seconds.
・ 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.
ON: Lower wiper moves.

Operation of lower wiper switch
OFF: Lower wiper stops.
7/13
Revision
Category
Local After
time operation
Push down the lever up to apply the lock.

Operation of lock lever 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.
FORWARD:
Operation of travel levers 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.
This lever is used to operate the arm and
Operation of left work equipment control lever upper structure.
(with auto-deceleration device) Arm operation Swing operation
(a) Arm OUT (c) Swing to right

(b) Arm IN (d) 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.
This lever is used to operate the boom and
Operation of right work equipment control lever bucket.
(with auto-deceleration device) Boom operation Bucket operation
(a) RAISE (c) DUMP
(b) LOWER (d) CURL
N(neutral):
When the lever in this position, the boom
and the bucket will be retained in the
position in which they stop.
R.H.: Bottom opens
Operation of bottom dump switch
L.H.: Bottom closes
8/13
Revision
Category
Local After
time operation
Swing operation running in: Engine high idling speed.
Right Left
Constant swing speed [ rpm] [ rpm] 5.8 ± 0.3 rpm
Swing performance
Brake angle Max. 60° (feeling)
Swing variation, hunting There must be none.
Abnormal noise, irregular swing There must be none.
Travel operation running in: Engine high idling speed.
There must be no abnormal noise or

Abnormal noise, heat from carrier roller, track roller, idler
abnormal heat.
Must brake securely without pulling to one
Operation of travel brake
side.
Abnormal noise, irregular travel There must be none.
There must be no abnormal deviation from

Travel deviation (feeling) fine control range to full stroke range
(feeling).
Forward Reverse
Travel deviation High
[ ] [ ] Max. 200 mm / 20 m
(measured) speed
mm/20m mm/20m
(Only when it is Forward Reverse

Travel performance
Low
considered that [ ] [ ] Max. 200 mm / 20 m
there is abnormality.) speed
mm/20m mm/20m

Track rotating High speed 73 ± 8 sec / 5 turns
[ ] [ ]
speed - Right
sec sec
Forward Reverse
High speed
[ ] [ ]
- Left
sec sec

Low speed 105 ± 11 sec / 5 turns
[ ] [ ]
- Right
sec sec
Forward Reverse
Low speed
[ ] [ ]
- Left
sec sec
Right Left
Track tension [ ] [ ]
mm mm
9/13
Note: All judgment standard values for speeds are the values in P mode.
Revision
Category
Local After
time operation
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
Work equip- RAISE sec LOWER sec RAISE: 6.9 ± 0.7 sec.
Boom
ment speed [ ] [ ] LOWER: 4.8 ± 0.5sec.
OUT sec IN sec IN: 4.0 ± 0.5 sec.
Arm (arc)
[ ] [ ] OUT: 3.1 ± 0.4 sec.
CURL sec DUMP sec CURL: 3.9 ± 0.4 sec.
Bucket
[ ] [ ] DUMP: 3.3 ± 0.4 sec.
OPEN sec CLOSE sec OPEN: 2.3 ± 0.3 sec.
Bottom
[ ] [ ] CLOSE: 3.0 ± 0.4sec.
Work equip-
ment time lag LOWER sec
(Engine low Boom [ ] Max. 5 sec.
idling) Only when there is considered to be abnormality.
IN sec
Arm [ ] Max. 2 sec.
DUMP sec
Work equipment performance
Bucket [ ] Max. 2 sec

CLOSE sec
Bottom [ ] Max. 3 sec
There must be no abnormality during

Abnormal noise from pump, PTO
operation under no load and during relief.
There must be no abnormal generation of
Generation of heat by PTO
heat.
There must be no hunting at any speed

Engine partial performance under no load, there must be no stalling of
engine even at low idling and relief.
Fine control performance Must operate smoothly.
There must be no escape of boom, arm, or
Operation when raising chassis
bucket.
Abnormal noise, grating noise from work equipment There must be none.
Cushion must be fully effective.

Shock at end of cylinder stroke
(Shock at end of stroke for BOOM RAISE and ARM OUT)
Immediately after engine is stopped, boom

Function of accumulator cylinder must move from fully extend
position to ground level. (Arm at Max. reach)
10/13
Revision
Category
Local After
time operation
Check all parts
・ There must be no catching during

Operating force of control lever when each actuator is
During operation
operation.
actuated.
・ 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.
Movement of doors and windows Must move smoothly.

Around operator’s cab
Door, window locks Must lock securely.
Adjustment of operator’s seat Must be possible to make all adjustments.
There must be none.

Oil leakage
(Idler, roller, sprocket, final drive gear case, motor, brake
valve)
Undercarriage
Looseness of track shoe bolt There must be none.
There must be no overlapping, separation,

Contact of link tread
or missing or broken parts.
Oil leakage There must be none.

Center swivel, pump, solenoid valve, relief valve, control
valve, PPC valve, swing motor, brake valve, shuttle valve,
swing machinery, hydraulic tank, piping
There must be none.

Leakage of fuel
(Fuel tank, engine, piping)
Around chassis
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.

11/13
Revision
Category
Local After
time operation
Operation of grease pump Must move smoothly.
Looseness, insufficient insertion of electric wiring terminals There must be none.
There must be a clearance of at least 10

Around chassis
Position for passing electrical wiring through

mm from any moving part or edge.
Leakage of air from air system There must be none.
There must be none.

Oil leakage
(Cylinder, piping, block)
Grease leakage from grease piping There must be none.

Around work equipment
One side in contact,, clearance at other side

(CURL side)
within 5 mm.
Contact between bucket and arm stopper
(DUMP side)
within 5 mm.
Contact between front bucket and rear stopper
within 10 mm.
12/13
Note: If the operation or function is defective, measure as necessary. All judgment standard values for speeds are the values in P mode.
Revision
Category
Local After
time operation
1. Engine speed: Check in monitoring mode “01006”
Low idling [ rpm] 900 ± 50 rpm
High idling (Operate lever a little) 2000 ± 50 rpm

[ rpm] Min 1700 rpm
(Heavy lift: OFF)
[ rpm]
(Heavy lift: ON)
2. Radiator fan speed Check in service mode “55”

(Fan rotation 100% fixed mode)
975 ± 50 rpm
Speed at engine rated speed [ rpm]
(Engine at full throttle, Oil temperature at 50℃)
Check in monitoring mode

3. Measurement of oil pressure Swing pump “09000”,
F pump: “01100”, R pump: “01101”
-1.5 MPa
F pump {kg/㎠} +10 kg/㎠｝ At engine high idling, arm
pressure ｛320 -15
OUT, P mode and Heavy
-1.5 MPa lift OFF, relief
R pump {kg/㎠}
pressure ｛320 +10 kg/㎠｝
-15
Control valve main set pressure MPa 34.3 +1.0

-1.5 MPa
F pump
-15
Relieved on one side
MPa 34.3 +1.0
MPa
at P mode
Control valve main set pressure -1.5
R pump
-15
Swing relief set MPa 31.4 +1.0

-1.5 MPa At engine high idling, swing
Swing pump
pressure {kg/㎠} ｛320 +10 kg/㎠｝
-15
and P mode, relief
+5
MPa 3.14 +0.5 MPa ｛32 0 kg/㎠}
Pilot relief valve set pressure 0
{kg/㎠} (At engine high idling, neutral)
In neutral When boom is raised

(Heavy: OFF)
(at top surface of NC MPa MPa 0.25 MPa Engine
valve) No.1 Front pump {kg/㎠} {kg/㎠} {2.6 kg/㎠} high idling
(at top surface of NC MPa MPa 0.25 MPa
P mode
valve) No.1 Rear pump {kg/㎠} {kg/㎠} {2.6 kg/㎠}
Note: Measure the following J/S differential pressure only if

the NC valve output pressure does not pass the test.
When boom is raised When boom is raised

In neutral (Heavy: OFF) In neutral (Heavy: OFF)
J/S differential pressure At
Max.
(differential pressure at input MPa MPa Min. 1.5MPa engine
0.2 MPa
and output ports of jet {Min. 15{kg/㎠} Engine high
sensor) No.1 Front pump
{kg/㎠} {kg/㎠} {2kg/㎠}
idling
high idling
J/S differential pressure turn
Max.
(differential pressure at input MPa MPa Min. 1.5MPa P mode with no
0.2 MPa
and output ports of jet {Min. 15{kg/㎠} load
sensor) No.1 Rear pump
{kg/㎠} {kg/㎠} {2kg/㎠}
13/13
Revision
Category
Local After
Check item assembl hours of Judgment standard
y time operation
4. hydraulic drift of work equipment

(bucket unloaded, 50±5℃）
Bucket tooth up [ mm] Max. 700 mm / 15 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.
Boom cylinder [ mm]
Arm cylinder [ mm]
Bucket cylinder [ mm]
5. operation force, travel

Boom lever Operating RAISE N LOWER N 16.7±4.9N
RAISE LOWER PLAY
Stroke:79±10mm
Stroke
Swing lever Operating RIGHT N LEFT N 13.7±3.9N
RIGHT LEFT PLAY Stroke:79±10mm
Stroke
Bucket Operating CURL N DUMP N 13.7±3.9N

lever force {kg} {kg} {1.4±0.4kg}
CURL DUMP PLAY Stroke:79±10mm
Stroke At engine high
idling, relief
Arm lever Operating IN N OUT N 16.7±4.9N
IN OUT PLAY Stroke:79±10mm
Stroke
Right travel Operating FOR- N RE- N 24.5±5.9N
Stroke
Left travel Operating FOR- N RE- N 24.5±5.9N
Stroke
Measure the travel of the lever at the center of the lever tip

Field Assembly PC1250SP-8

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GEN00055-08

Field Assembly Instruction

A. Assembly of Chassis ....................................................................................................... 33

B. Assembling of Work Equipment of Backhoe ................................................................... 77

C. Procedure for assembling work equipment of loading shovel ......................................... 111

Field Assembly Inspection Report (Backhoe)

Field Assembly Inspection Report (Loading shovel)

Machine model PC1250-8 PC1250-8 PC1250SP-8 PC1250LC-8

Weight of machine kg 109,900 116,900 111,700 113,500

3. Preparation and check of protective gear, slings and tools

4. k Check during actual work

Backhoe · Inspection of oil level and

level and coolant level equipment

Completion of body · Completion of general

Boom 45t crane

Motor cover · handrails Counterweight 45t crane

Transportation in seven kits

(Upper structure) (Undercarriage left) (Undercarriage right) (Center frame)

(Counterweight, Bucket, etc.) (Boom) (Arm, Arm cylinder

Posture for each unit

Item PC1250-8, PC1250SP-8, PC1250LC-8

LC: 7,400 LC: 1,295

If any warning tag is attached to the work equipment control levers,

Item PC1250-8 PC1250SP-8 PC1250LC-8

Item PC1250-8 PC1250SP-8

A (mm) 4,895 4,914

B (mm) 1,626 1,683

Overall width (mm) 890 890

Weight (kg) 6,200 6,400

Bucket (excluding side cutter and shroud)

A (mm) 2,580 2,527

B (mm) 2,276 2,420

Overall width (mm) 2,250 2,520

Weight (kg) 5,500 6,300

Boom cylinder (same for all models)

Arm cylinder (same for all models)

Item PC1250-8, PC1250SP-8, PC1250LC-8

Item PC1250-8, PC1250SP-8, PC1250LC-8

Item PC1250-8, PC1250SP-8, PC1250LC-8

• Radiator duct upper cover (same for all models)

Item PC1250-8, PC1250SP-8, PC1250LC-8

• Catwalk (right): same for all models

Item PC1250-8, PC1250SP-8, PC1250LC-8

• Catwalk (left, front): same for all models

Item PC1250-8, PC1250SP-8, PC1250LC-8

• Catwalk (left, rear): same for all models

Item PC1250-8, PC1250SP-8, PC1250LC-8

No. Tool names Specifications Q’ty. Remarks

16 Socket for 4-time wrench T25.4 × 50 mm 1

34 Nylon sling 50 mm wide × 3 m 2 For boom cylinder and arm cylinder

42 Repair paint Natural yellow 5

Part No. of bolt TTTTT-TTTTT

2. The bolt length is dimension (c) in Fig. 1.

a : Bolt thread diameter (Nominal diameter)

Nominal size of thread Width across flats Tightening torque

6×1 10 12 8.8 – 14.7

a For symbols “a” and “b” in the table, see Fig. 1.

Table 4.1 Hydraulic hose of face seal type