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EX2500-6 Assembly Manual
EX2500-6 Assembly Manual
ASSEMBLY
PROCEDURE
MANUAL
Foreword
Assembly work is the final touch that gives the machine life. The quality of a machine's
assembly affects its operative performance and service life of the machine.
Because a machine's value is determined by its assembly, those who do this work are
required to have sufficient know-how about assembly.
This manual basically contains assembly know-how such as methods and useful hints for
assembling the EX2500-6 Hydraulic Excavator. Please read this manual carefully and try to
keep it for reference before you engage in assembly or while you work.
This manual is a practical compilation of the following three viewpoints: "the improvement
of work safety", "the improvement of efficiency" and "the enhancement of product quality."
1) Safety: Some hints and information for safe work are provided, such as the
weight of the parts, their lifting points when raised with wire ropes and
their handling procedures.
Work safety is attained with this manual.
2) Quality: Procedures and hints are described for correct machine assembly. They
include the part numbers, tightening torque values of bolts, etc. Correct
assembly is essential to provide the machine with a longer service life at
maximum performance.
3) Efficiency: Tool jigs, the facilities necessary to do the work and the preparation
needed for each work stage are introduced to assure speedy and
effective completion.
We hope this manual will be helpful to you in assembling the machine without a hitch.
i
CONTENTS
Pages
1. Precautions…………………………………………………………………………………………………………… 1
1-1. Safety precautions for servicemen ………………………………………………………………………… 1
1-2. How to use a power wrench………………………………………………………………………………… 17
1-3. Work precautions …………………………………………………………………………………………… 20
2. Workers plan ……………………………………………………………………………………………………… 30
2'. Workers plan ……………………………………………………………………………………………………… 31
2-1. Transportation of Loader Front …………………………………………………………………………… 32
2-1'. Transportation of Backhoe Front…………………………………………………………………………… 33
3. Parts check ………………………………………………………………………………………………………… 41
3-1. Check ………………………………………………………………………………………………………… 41
4. Preparations (loader front) ……………………………………………………………………………………… 42
4'. Preparations (backhoe front) …………………………………………………………………………………… 44
5. Machines, apparatus, tools, and materials necessary for assembly …………………………………… 47
6. Assembly of Undercarriage ……………………………………………………………………………………… 55
6-1. Preparation …………………………………………………………………………………………………… 55
6-2. Connection of track frame and side frames ……………………………………………………………… 57
6-3. Connection of travel motor hoses and adjuster hoses…………………………………………………… 67
6-4. Assembly of motor covers and steps ……………………………………………………………………… 69
6-5. Disassembly procedures for shipment (Procedure, Track)……………………………………………… 71
6-6. Assembly of travel motor guard and mission guard (option) …………………………………………… 73
7. Connection of undercarriage and superstructure …………………………………………………………… 79
7-1. Preparations before connection …………………………………………………………………………… 79
7-2. Preparation of undercarriage ……………………………………………………………………………… 85
7-3. Preparation of base machine ……………………………………………………………………………… 87
7-4. Connection of undercarriage and base machine ………………………………………………………… 89
7-5. Connection of piping to center joint………………………………………………………………………… 97
7-6. Assembly of fuel tank ……………………………………………………………………………………… 99
7-7. Assembly of cab …………………………………………………………………………………………… 102
7-8. Assembly of fenders, steps, handrails, beam, box and covers ……………………………………… 109
7-9. Assembly of engine unit …………………………………………………………………………………… 123
7-10. Mounting the counterweight & installation the reserue tank …………………………………………… 139
7-11. Assembly of air-intake unit / exhaust unit and head lamps, mirror, wroking lamp, etc. …………… 151
7-12. Connection ………………………………………………………………………………………………… 163
7-13. Checking the stop valves and stopcocks………………………………………………………………… 189
7-14. Final check of superstructure……………………………………………………………………………… 195
7-15. Releasing air from main pumps…………………………………………………………………………… 201
7-16. Trial operation of superstructure ………………………………………………………………………… 203
7-17 Disassembly procedures for shipment …………………………………………………………………… 205
7-18. Assembly of option parts ………………………………………………………………………………… 221
ii
8. Mounting procedures for loader front-end attachment …………………………………………………… 235
8-1. Preparation ………………………………………………………………………………………………… 235
8-2. Mounting of loader front …………………………………………………………………………………… 251
8-3. Mounting the bucket ……………………………………………………………………………………… 261
8-4. Adjustment of track link tension…………………………………………………………………………… 271
8-5. Final trial operation check ………………………………………………………………………………… 273
8-6. Disassembly procedures for shipment …………………………………………………………………… 274
8'. Mounting procedures for backhoe front-end attachment ………………………………………………… 281
8'-1. Preparation ………………………………………………………………………………………………… 281
8'-2. Mounting of boom ………………………………………………………………………………………… 291
8'-3. Installation of arm ………………………………………………………………………………………… 303
8'-4. Mounting of bucket ………………………………………………………………………………………… 313
8'-5. Adjustment of track link tension…………………………………………………………………………… 321
8'-6. Final trial operation check ………………………………………………………………………………… 323
8'-7. Assembly of option parts ………………………………………………………………………………… 325
8'-8. Disassembly procedures for shipment …………………………………………………………………… 326
9. Checks after completing the assembly ……………………………………………………………………… 333
10. Checking machine performance ……………………………………………………………………………… 337
iii
EX2500-6 Assembly Process Chart
LOADER FRONT
iv
EX2500-6 Assembly Process Chart
BACKHOE FRONT
v
1. Precautions
1-1 Safety precautions for servicemen
Fig. 1-1
Fig. 1-2
DANGER and WARNING safety signs are located near
specific hazards.
General precautions are listed on CAUTION safety
signs. CAUTION also calls attention to safety items in
this manual.
1
3 FOLLOW SAFETY INSTRUCTIONS
Carefully read and follow all safety signs on the
machine and all safety messages in this manual.
Fig. 1-4
Fig. 1-5
2
6 WEAR PROTECTIVE CLOTHING
Avoid wearing loose clothing, jewelry, or other items
that can catch on control levers or other parts of the
machine.
3
9 ENGINE SAFETY
a) No one should be allowed inside the hydraulic
excavator while it is being operated or during
assembly.
b) Keep hands away from moving parts.
c) Sound the horn as an alert to those nearby before
starting up the engine.
d) Start the engine from the operator's seat and never
while standing on the ground.
e) To avoid injury or possible machine damage, never
start the engine by shorting across the starter
terminals.
Fig. 1-9
Fig. 1-10
11 SAFETY AT HEIGHT
Take adequate measures to avoid falling from high
spots during work. Clean any mud or debris from the
steps, walkways, or work platforms before work, and
use a safety belt during work.
When you get on and off the machine, always face the
machine and maintain a three-point contact with the
steps and handrails. Do not use any controls as
handholds.
Before getting off, be sure to align the cab parallel with
the tracks.
Fig. 1-11
Be careful of slippery conditions on platforms, steps,
and handrails when getting off the machine.
4
12 FUEL SAFETY AND FLAMMABLE
MATERIALS
a) Never smoke while refueling or handling flammable
materials.
b) Shut the engine off while refueling.
c) Exercise caution when refueling while the engine is
still hot.
d) Do not clean parts using opened cans of gasoline
or diesel fuel. Use good, commercial, non-
flammable solvents.
Fig. 1-12
Fig. 1-13-2
5
14 AVOID HIGH-PRESSURE FLUIDS
• Fluids such as diesel fuel or hydraulic oil under
pressure, can penetrate the skin or eyes causing
serious injury, blindness or death.
Fig. 1-14-1
• If an accident occurs, see a doctor familiar with this
type of injury immediately.
Any fluid injected into the skin must be surgically
removed within a few hours, or gangrene may result.
Fig. 1-15
6
16 PROTECT AGAINST NOISE
Prolonged exposure to loud noise can cause
impairment or loss of hearing.
Fig. 1-16
Fig. 1-17
Fig. 1-18
7
19 PRACTICE SAFE MAINTENANCE
Understand service procedures before performing any
work. Keep the work area clean and dry.
8
20 WARN OTHERS OF SERVICE WORK
Unexpected machine movement can cause serious
injury.
Fig. 1-20
Fig. 1-22
9
23 PREVENT AGAINST FLYING PARTS
Grease in the track adjuster is under high pressure.
Do not attempt to remove a GREASE FITTING or
VALVE ASSEMBLY.
Be sure to keep your body and face away from any
valve, as pieces may fly off.
The travel reduction gears are under pressure.
So as to avoid injury from flying parts, be sure to keep
your body and face away from the AIR RELEASE
PLUG.
GEAR OIL is hot. Wait for the GEAR OIL to cool, then Fig. 1-23
24 PREVENT BURNS
Hot spraying fluids:
• After operation, the engine coolant is hot and under
pressure. Also, hot water or steam is contained in the
engine, radiator and heater lines.
Prevent possible injury from hot spraying water.
DO NOT remove the radiator cap until the engine is
cool. When opening, turn the cap slowly to the stop
position.
Allow all pressure to release before removing the
Fig. 1-24-1
cap.
• The hydraulic oil tank is pressurized. Again, be sure
to release all pressure before removing the cap.
Fig. 1-25
10
26 DISPOSE OF WASTE PROPERLY
Improper waste disposal can threaten the environment
and ecology. Potentially harmful waste used with
HITACHI equipment includes such items as oil, fuel,
coolant, brake fluid, filters, and batteries.
Do not pour waste onto the ground, down a drain, or Fig. 1-26
Fig. 1-27
11
29 HANDLE POWER WRENCHES
CORRECTLY
Misuse of power wrenches (part nos. 4093799 and
4229414) may lead to their breakage or personal injury.
Please use power wrenches correctly and in
accordance with this manual.
Fig. 1-28
Fig. 1-32
2
12
30 COMMUNICATION
1) When slinging work is performed on heavy loads, a
predetermined hand signalling method should be
used for trouble-free communication.
Fig. 1-33
Fig. 1-34
13
31 FRONT PIPING PRESSURE-RELEASE PARTS
Front piping pressure-release parts are now available.
• Use these parts when extra large machines are assembled at the work site.
• Install these parts in place after a front attachment is delivered to the work site and before installing it on the base
machine.
Front piping pressure-release parts
Fig. 1-35 For pipe ends
High-pressure pipe
High-pressure hose
14
How to release the pressure
Cap
Breather
1 Install air-release parts 00 to 05 and 06 to 10 on sections from which the pressure should be released (see Figs. 1-
39 and 1-41 on the next page) after a front attachment is delivered to the work site and before it is installed on the
base machine.
Note:
High pressure will be applied to these sections, so the parts must be securely installed.
2 Check that A of the pressure-release part installed in procedure 1 (see Fig. 1-38) is firmly tightened.
3 When the pipes are installed to each location, connect the hose to the breather and place the hose end in an oil
pan first.
4 Gradually loosen part A shown in Fig. 1-38 to release the pressure inside the pipe.
Note:
Do not loosen part A shown in Fig. 1-38 quickly. Doing so is dangerous because the hose may swing violently and
thus be disconnected.
5 After the pressure is released from the pipe, tighten part A shown in Fig. 1-38.
6 Remove the pressure-release parts and proceed with the pipe connection work.
Note:
All of the hydraulic oil is not completely drained out from the pipe even after this pressure-release work has been
done. Place an oil pan before removing the pressure-release parts.
15
Sections from which pressure should be released, size and quantity of pipes
16
1-2 How to use a power wrench
This section describes the correct use of power wrenches. Please note however that, if available, a hydraulic wrench
should be preferred over a power wrench, for reasons of safety and overall quality.
6. Completion of work.
Fig. 1-43 On completion of tightening,
remove the wrench from the nut or
3. Check the positioning of the reaction lever. bolt. Elastic deformation (force) 2
Depending upon the wrench type the reaction lever usually acts between the wrench and bolt can
radially. Due to the large reaction force applied to the reaction lever, the make it difficult to remove the 1
reaction lever should be positioned so that it is both secure and stable. power wrench. In this case,
gradually release the torque on the
ratchet handle and change over
the clutch direction.
Fig. 1-48
Straight type
reaction lever
Fig. 1-44
When using an "L-type" torque wrench, make sure that the distance "L"
between the center of the bolt and support point is at least the figures
shown below. Failing to observe this minimum distance can damage or
break the bolt, or cause the output shaft to become jammed.
Clutch selection
L (counter clockwise)
L type reaction lever R (clockwise)
Model L
8-150P 110
8-300P 130
12-450P 145
12-600P 160
(Unit: mm)
Fig. 1-45
Fig. 1-49
17
2 THE CORRECT HANDLING OF POWER WRENCHES
Misuse of power wrenches (part nos. 4093799 and 4229414) may lead to their breakage or personal injury. Please use
power wrenches correctly and in accordance with this manual.
CAUTION
Ratchet
handle
Fig. 1-50
For your safety, do not enter into the turning circle of the wrench. After
tightening is complete, a torque acting in the opposite direction will be
applied to the wrench. Therefore, do not suddenly let go of the handle,
but let it gently rotate back in the opposite direction until the torque is
zero.
Fig. 1-51
4. After tightening.
It is sometimes difficult to remove the power wrench from a nut or bolt
after tightening.This is generally due to elastic deformation (elastic
force) between the wrench and bolt. Try changing the clutch direction
to L to make the wrench easier to remove. Release the torque on the
ratchet handle gradually since a force will be acting in the opposite 1
direction after changeover of the clutch. If it is not possible to change
over the clutch by hand, do not attempt to use force (a hammer, etc.).
(1666)
(1078)
In selecting a power wrench, give due consideration of the
(784)
differences in power performance between the different
wrench types.
(490)
Input kgf·m
(lbf·ft)
Bolt Power Wrench (N.m) (98) (196) (294) (392) (490) (588) (686) (784) (882)
(6860)
(5880)
(3920)
Output kgf·m (lbf·ft)
(N.m)
(2940)
(1960)
Input kgf·m
(lbf·ft)
(N.m) (137) (176) (216) (255) (294) (333) (372) (412) (451)
6. Torque Specifications
Tightening Torque
No. Component Bolt Dia Wrench Size
(mm) (mm) N·m kgf·m lbf·ft
1 Cab mounting bolt 18
36 27
55 275
245 28
2400 203
1770
2 Cab bed mounting bolt 16 24 205 21 151
3 Swing bearing mounting bolt 48 75 4900 500 2614
4 Counterweight mounting bolt 48 75 4900 500 2614
5 Engine unit mounting bolt 30 46 1420 145 1047
6 Side frame mounting bolt 48 75 4900 500 3614
A 24 36 685 70 505
7 Front pin-retaining mounting bolt B 20 30 390 40 288
C 16 24 265 27 195
19
1-3 Work precautions
Material Composition
White zinc jelly Composition list given on page 29
1:1
Spindle oil Composition list given on page 29
Fig. 1-57
* * * * Base
Face area Face area Thread of the head
Fig. 1-58
Note:
Obtain high tack adhesive/sealant #98D through
the manufacturer detailed on page 29.
3 Connecting hoses.
Fig. 1-60
1 Be careful not to damage the joining surfaces of
the hydraulic components.
2 Make sure that no dust has adhered to the seat
faces of the hoses and adaptors.
3 When connecting hoses, do not twist them or their
service life will be shortened.
4 When connecting the hoses, avoid contact with
other parts.
CAUTION:
Hydraulic ports are sealed with plugs on shipment from
the factory. On removal of these plugs, hydraulic oil will
escape due to the internal hydraulic pressure built up
through transportation, etc.
20
4 Battery earth breaker
This machine is provided with a battery earth breaker.
To break the battery earth circuit for field assembly,
battery replacement, electric system
maintenance/inspection and welding on the machine,
pull breaker lever a down.
REPLACE BATTERIES
Your machine has four 12-volts batteries with negative
(-) ground.
If one of four batteries in a 24-volt system has failed but
the others are still good, replace all the batteries
together with new ones of the same type. For example, Fig. 1-61
replace a failed maintenance-free battery with a new
maintenance-free battery. Different types of batteries
may have different rates of charge. This difference
could overload one of the batteries and cause it to fail.
IMPORTANT:
Do not pull the disconnector lever a down during
operation and the delayed power OFF time after the
key switch is turned off.
All controllers are shut down after the delayed power
OFF time.
Note:
Ground Disconnector
This machine is equipped with a battery ground Fig. 1-62
disconnector located outside of engine unit
compartment on the right side. The battery ground
circuit can be disconnected by pulling
disconnector lever a down before replacing the Breaker lever
a
battery, checking the electrical system, or
performing welding work on the machine.
Fig. 1-63
CAUTION:
Do not replace the battery by physical strength. Use
the crane to replace safely.
21
5 Tightening large-diameter bolts during
assembly
1 It is vital that large-diameter bolts be tightened to
the specified tightening torque during assembly. If
torque specifications are not followed, the
operation of the machine will be affected, with
machine failure, lowering of functionality and
shortening of machine life potentially resulting. Be
careful, therefore, to note the correct tightening
torque at each stage of assembly.
Fig. 1-64
This manual describes use of a power wrench to
achieve the required torque, but a hydraulic
wrench will allow for even more accurate and
efficient tightening work.
CAUTION:
i) If a bolt is too long, you will not be able to fully
tighten it.
ii) If a bolt is too short, you will not be able to be
tighten it sufficiently to secure the parts, possibly
resulting in a serious accident.
Pin
22
7 PRECAUTIONS FOR CONNECTING THE PILOT HOSES
Be sure to observe the following points when connecting the pilot hoses. If the hoses are connected without paying
attention to the precautions described below, contaminants may enter the pilot circuit. If this happens, the contaminants
may cause the pilot valve to malfunction.
Plug
Plug
Fig. 1-68
Adaptor
Fig. 1-69
Adaptor
Step 3
Connect the adaptor and hose fitting. Fitting
Notes:
i) When connecting hoses, do not twist
them, or their service life will be
shortened.
ii) Connect the hoses so as to avoid Detail C
Fig. 1-70
contact with other parts.
iii) Make sure that no dust has adhered to
the seat face of the hoses.
iv) Be careful to not damage the joining
surfaces of the hoses.
23
8 Standards for Hydraulic Joint Work
A ORS joint
Work procedure
1 Check that the O-ring, adapter, hose seat surfaces are free of scars or dirt.
Note:
Visually check their conditions. Wipe off dirt, if any. Do not use any scarred parts.
2 Apply bond to the groove in the adapter, install the O-ring, and apply spray grease High Tack Adhesive/Sealand
98D (Loctite, Ltd) to the screw part of the hose union.
Notes:
i) Remember to handle the O-ring with your bare hands.
ii) Press the entire O-ring with your fingers and install it properly.
iii) Apply the bond uniformly to the groove. Do not overapply. (Otherwise, the bond will seep into the hydraulic
circuit, causing a breakdown.)
Notes:
i) To prevent the O-ring from falling out of place, place the O-ring surface of the adapter and seat surface of the
hose horizontal to each other to keep them immobile.
ii) Tighten the union nut fully with your hands.
iii) If the O-ring is jammed, it will feel differently from when you've tightened it fully with your hands (the torque will
not develop instantaneously and you will feel as though there is something stuck). If you sense any abnormality,
loosen the union nut and make sure to verify the O-ring.
Fig. 1-73
Note:
After the work, carry out a check using a white pen.
24
B Union joint
Work procedure
1 Check that the adapter and hose union seat surfaces are free of scars or dirt.
Note:
Visually check their conditions. Wipe off dirt, if any. Do not use any scarred parts.
Fig. 1-74
Fig. 1-75
2 Apply spray grease to the screw parts of the hose and union.
Note:
Do not overapply.
(When the temperature of the base machine goes up, grease will flow out and this may be mistaken as an oil
leak.)
Note:
Tighten fully using your hands.
(If there are no scars on the thread, you will be able to screw it fully with your hands.)
Fig. 1-76
Notes:
i) After tightening, loosen the union by turning the wrench 2 - 3 times to adapt the seat surface to it.
ii) After the work, carry out a check using a white pen.
25
C Split flange joint
Work procedure
1 Check that the O-ring and hose-seat surfaces are free of scars or dirt.
Notes:
i) Visually check their conditions. Wipe off dirt, if any. Do not use any scarred parts.
ii) Check also the seat surfaces of opposite parts (C/V, pump, etc.) for scars and dirt.
2 Apply bond to the O-ring groove in the hose and flange and install the O-ring High Tack Adhesive/Sealand 98D
(Loctite, Ltd).
Notes:
i) Remember to handle the O-ring with your bare hands.
ii) Apply the bond uniformly to the groove. Do not overapply.
(Otherwise, the bond will seep into the hydraulic circuit, causing a breakdown.)
iii) Press the entire O-ring with your fingers and install it properly.
Note: Notes:
Using your hands, screw in the bolt to about half i) Make sure to insert the hose horizontally to the
its length. installation surface.
ii) Take care so that the O-ring does not fall out of
place.
Pay attention to
the O-ring
26
3) After setting the hose, install the other split flange.
Notes:
i) If the bolt has not been screwed in adequately, the instability of the hose seat surface will increase and the O-ring
may fall off.
ii) After setting the hose, pay attention to the hose installation angle to avoid the hose from being turned.
Fig. 1-82
No gap on one
side and too
much gap on the In the case of Should be tightened so that
other side lopsided tightening the gaps are uniform
Fig. 1-84 Fig. 1-85
27
9 When connecting hydraulic hoses and pipes, take A couple of threads left unwrapped
special care to keep seal surfaces free from dirt and to
avoid damaging them. Keep these precautions in mind:
a) Wash hoses, pipes, and the tank interior with a
washing liquid and thoroughly wipe it out before
reconnecting them.
b) Only use O-rings that are free of damage or
defects. Be careful not to damage them during
reassembly.
c) Do not allow high pressure hoses to twist when
Fig. 1-86
connecting them. The life of twisted hoses will be
shortened considerably.
d) When connecting screw type joints, apply seal tape
to the threads of male screw. Be sure to leave a
couple of threads at the male screw top unwrapped,
as shown. Do not overwrap. Apply seal tape around
threads as shown, so that the tape does not loosen
when the female screw is tightened.
e) Carefully tighten low pressure hose clamps to
following torque specifications. Do not overtighten.
T Bolt Clamp:
4.5 N·m (0.45 kgf·m, 3.3 lbf·ft)
Jubilee Clamp:
6.0 to 7.0 N·m Fig. 1-87
(0.6 to 0.7 kgf·m, 4.3 to 5.1 lbf·ft)
f) Carefully tighten nut for bandy pipe to following Pipe Dia. (A) ø8 ø10
torque specifications on the right side. Do not Width across flat (B) (mm) 17 19
overtighten. N·m 35 50
Fastening Torque kgf·m 3.5 5.0
10 When adding hydraulic oil, always use the same brand lbf·ft 26 36
of oil; do not mix brands of oil. As the machine is filled
with Super EX 46HN when it is shipped from the
factory, use it as a general rule. When selecting to use
another brand of oil listed in the table “Bw-Brand
Names of Recommended Hydraulic Oil”, be sure to
completely change the oil in the system.
28
16 For reference
This stiff paste consists primarily of extender pigment and is prepared with specially processed fatty oil.
Ingredients: Extender pigment (calcium carbonate): 84.0%
Color pigment (titanium oxide): 0.5%
Fatty oil (polymerized oil): 14.0%
Solvent (mineral turpentine): 1.5%
Spindle oil
Physical and chemical properties of this oil are as follows. (grade C machine oil)
Appearance: Light brown
Flash point (COC): Above 160°C (320°F)
Density: 0.89 ~ 0.95 g/cm3
Fluid point: Below 10°C (50°F)
Mixture: None
Chemical name and composition: Petroleum system hydrocarbon 100%
Note:
When connecting each connector, remove and
scrap the rubber boots fitted during shipment. Use
rubber packing 13 (P/No. 4392230 PRC24), 12
(P/No. 4392229 DRC40), and 11 (P/No. 4392228
DRC70) supplied.
18 Operation manual
Read the operation manual and this assembly
procedure manual thoroughly to familiarize yourself Fig. 1-90
with the work procedure.
29 (1/3)
19 Example of usage of a chain block or lever block.
By adjusting length “L” on the chain block (or lever block)
connecting the wire ropes, the lifted angle of the load can easily
be adjusted.
Wire rope
L'
Wire rope
L
Chain block
(Lever block)
Chain block
Wire rope
Lever block
Fig. 1-91
Work
Example
The angle of the workpiece in Fig. 1-92 can be
adjusted using chain blocks A .
Workpiece
Chain block
A
Chain block
A
a<b a=b
b
b
a a
Fig. 1-92
29 (2/3)
29 (3/3)
2. Workers plan
LOADER FRONT
Days 1
day
2
day
3
day
4
day
5
day
Fine weather
90 t x 4 days
50 ~ 60 tonnes x 1
(55 ~ 67 US tons) 50 ~ 60 t x 3 days
Cranes
(With operator and assistant)
Tool check
Unloading
Checking parts
Cleaning parts
Assembly of undercarriage
Not required if the oil tank is installed
Mounting counterweight
Mounting front-end
attachment
Workers
Foreman
Touching-up & checks to and four
complete assembly assistant
workers x
5.0 days
Fig. 2-1
This plan varies depending on the job site environment, working conditions, assembly facilities, tools,
and workers’ skills.
30
2'. Workers plan
BACKHOE FRONT
Days 1
day
2
day
3
day
4
day
5
day
Fine weather
90 t x 4 days
Cranes
(With operator and assistant)
Tool check
Unloading
Checking parts
Cleaning parts
Mounting counterweight
Mounting front-end
attachment
Workers
Foreman
Touching-up & checks to and four
complete assembly assistant
workers x
5.0 days
Fig. 2-2
This plan varies depending on the job site environment, working conditions, assembly facilities, tools,
and workers’ skills.
31
2-1 Transportation of Loader Front
3
1
11
10
Fig. 2-3
trailer
20-tonne 20t
trailer
8-tonne 8t
truck
32
2-1' Transportation of Backhoe Front
3
2
1
6
7
8
10
11
Fig. 2-4
30-tonne 30t
trailer
25-tonne 25t
Trailers and trucks
trailer
20-tonne 20t
trailer
11-tonne 11t
truck
8-tonne 8t 8t
truck
33
TRANSPORTATION For EX2500-6
**
**
*
(6'2")
(6'02")
Fender assembly Main frame assembly Handrail Handrail
* (202 lb) ((( (79 200 lb) ( (44 lb) * (20 lb)
*
((( (%
((
((
*
( %
(( (11'6")
(
(1'11")
Fender Fender Fender Fender
(246 lb) (733 lb) (471 lb) (271 lb)
(
*
((
((
(*
*
(
(
((
34
TRANSPORTATION For EX2500-6
UPPERSTRUCTURE
Fuel tank Handrail Step Handrail Cover
Weight : 2 470 kg (5 434 lb) Weight : 31 kg (68 lb) Weight : 121 kg (266 lb) Weight : 7 kg (15 lb) Weight : 19 kg (42 lb)
2 927
1 468
1 916 344
1 942
1 026
332
2 633
1 455
318
1 288
1 701
539
1 500
2 200 790
1 264 782
560
ø508
35
TRANSPORTATION For EX2500-6
# )
# #))
# )
'
$
'#
# )
#
# )
# )
Handrail Handrail Handrail Handrail Handrail
" '* % (34 lb) " #& % (31 lb) " # % (22 lb) " ) % (81 lb) " #& % (31 lb)
# )
# )
# )
# )
'# '(
'$
# *&
#$
$#
" ' (8'2") " # '$ (4'2") " (2")
36
TRANSPORTATION For EX2500-6
UPPERSTRUCTURE
Box Handrail Handrail
Weight : 977 kg (2 150 lb) Weight : 23 kg (51 lb) Weight : 22 kg (48 lb)
462
872
1 026
1 720
1 500
1 073
262
2 431
1 075
1 360
3 144 880
1 046
2 571
1 926 2 699
579
540
1 450
1 007
1 805
37
TRANSPORTATION For EX2500-6
UNDERCARRIAGE
Track center frame assembly Track side frame assembly
(48 100 lb)
(69 200 lb) ×
(1'7") (1'10") (1'10")
38
TRANSPORTATION For EX2500-6
( 12'2")
3 710
3 470
Arm cylinder
10 970
Weight : 2 240 kg (4 930 lb)
Width : 2 600 (8'6")
3 505
3 980 4 475
4 750
BE-arm assembly
Weight : 16 100 kg (35 420 lb)
2 810
2 540
3 480 5 640
39
40
3. Parts check
3-1 Check
Fig. 3-1
41
4. Preparations (loader front)
1 Work site: Select a place where the ground is firm and 3 Cranes: Prepare the following cranes.
flat. 2 × 90 tonnes (100 US tons)
1 × 50 ~ 60 tonnes (55 ~ 67 US tons)
2 Space: Secure a space of 29 m (95 ft) ×26 m (85 ft) or 4 Arrangement of major components: See Figs.
more. 4-1, and 4-2.
Weight Crane
1 Basic machine assembly 36 000 kg ( 79 200 lb) 18 50 ~ 60 t. crane
2 Cab 1 740 kg ( 3 830 lb) 19 90 t. crane
3 Cab bed assembly 2 580 kg ( 5 675 lb)
4 Fenders, handrails and ladders 5 480 kg ( 12 055 lb)
5 Track frame assembly 21 800 kg ( 47 960 lb)
6 Side frame assembly (left) 31 400 kg ( 69 080 lb)
7 Side frame assembly (right) 31 400 kg ( 69 080 lb)
8 Counterweight 29 800 kg ( 65 560 lb)
9 Engine Unit 18 300 kg ( 40 260 lb)
10 Boom assembly 29 000 kg ( 63 800 lb)
11 Boom cylinders 2 960 kg ( 6 510 lb) ×2
12 Arm cylinder 2 240 kg ( 4 930 lb)
13 Bucket cylinders 1 870 kg ( 4 115 lb) ×2
14 Bucket assembly 20 200 kg ( 44 440 lb)
15 Air-intake/ exhaust Unit 880 kg ( 1 935 lb)
16 Fuel tank 2 470 kg ( 5 435 lb)
17 Reserve tank 150 kg ( 330 lb)
42
ARRANGEMENT OF MAJOR COMPONENTS
ft)
(85 29
m 4 m
26 (95
ft)
15
16
6 14
12 10
13 5 8
2 11
7
Fig. 4-1
17
1
16
12 10
13
11
17
Fig. 4-2
43
4'. Preparations (backhoe front)
1 Work site: Select a place where the ground is firm and 3 Cranes: Prepare the following cranes.
flat. 2 × 90 tonnes (100 US tons)
1 × 50 ~ 60 tonnes (55 ~ 67 US tons)
2 Space: Secure a space of 29 m (95 ft) ×26 m (85 ft) or 4 Arrangement of major components: See Figs.
more. 4'-1, and 4'-2.
Weight Crane
1 Basic machine assembly 36 000 kg ( 79 200 lb) 16 50 ~ 60 t. crane
2 Cab 1 740 kg ( 3 830 lb) 17 90 t. crane
3 Cab bed assembly 2 580 kg ( 5 675 lb)
4 Funders, handrails and ladders 5 480 kg ( 12 055 lb)
5 Track frame assembly 21 800 kg ( 47 960 lb)
6 Side frame assembly (left) 31 400 kg ( 69 080 lb)
7 Side frame assembly (right) 31 400 kg ( 69 080 lb)
8 Counterweight 29 800 kg ( 65 560 lb)
9 Engine Unit 18 300 kg ( 40 260 lb)
10 Boom assembly 24 300 kg ( 53 460 lb)
11 Arm assembly 16 100 kg ( 35 420 lb)
12 Boom cylinders 3 120 kg ( 6 865 lb)×2
13 Air-intake/ exhaust Unit 880 kg ( 1 935 lb)
14 Fuel tank 2 470 kg ( 5 435 lb)
15 Reserve tank 150 kg ( 330 lb)
44
ARRANGEMENT OF MAJOR COMPONENTS
ft)
(85 29
m 4 m
26 (95
ft)
14
15
10 6 13
5
12 11 8
2 7
Fig. 4'-1
16
1
15
10
12 11
16
Fig. 4'-2
45
NOTES
46
5. Machines, apparatus, tools, and materials necessary for assembly
Listed below are the machines, apparatus, tools, and materials required for assembling the EX2500-6 hydraulic excavator.
1 Cranes
Two crane of 90 tonne capacity (100 US tons)
One crane of 50 ~ 60 tonne capacity (55 ~ 66 US tons)
2 Wire ropes
36 mmø × 8 000 mm (L) - 2 pcs. 26 mmø × 4 000 mm (L) - 2 pcs. 10 mmø × 5 000 mm (L) - 4 pcs.
(1.4 inø) (312 in L) (1.0 inø) (156 in L) (0.4 inø) (195 in L)
32 mmø × 8 000 mm (L) - 4 pcs. 20 mmø × 3 000 mm (L) - 4 pcs. 10 mmø × 3 000 mm (L) - 4 pcs.
(1.25 inø) (312 in L) (0.8 inø) (117 in L) (0.4 inø) (117 in L)
28 mmø × 8 000 mm (L) - 3 pcs. 12 mmø × 5 000 mm (L) - 1 pc. 8 mmø × 8 000 mm (L) - 1 pc.
(1.1 inø) (312 in L) (0.5 inø) (195 in L) (0.3 inø) (312 in L)
28 mmø × 3 000 mm (L) - 2 pcs. 12 mmø × 3 000 mm (L) - 2 pcs. 8 mmø × 3 000 mm (L) - 4 pcs.
(1.1 inø) (117 in L) (0.5 inø) (117 in L) (0.3 inø) (117 in L)
[ For Loader front ] [ For Backhoe front ]
48 mmø × 10 000 mm (L) - 1 pc. 38 mmø × 6 000 mm (L) - 1 pc.
(1.9 inø) (390 in L) (1.5 inø) (234 in L)
46 mmø × 3 000 mm (L) - 2 pcs. 36 mmø × 12 000 mm (L) - 1 pc.
(1.8 inø) (117 in L) (1.4 inø) (468 in L)
32 mmø × 10 000 mm (L) - 1 pc. 28 mmø × 10 000 mm (L) - 1 pc.
(1.25 inø) (390 in L) (1.1 inø) (390 in L)
32 mmø × 5 000 mm (L) - 2 pcs. 28 mmø × 3 000 mm (L) - 2 pcs.
(1.25 inø) (195 in L) (1.1 inø) (117 in L)
32 mmø × 3 000 mm (L) - 2 pcs. 24 mmø × 8 000 mm (L) - 1 pc.
(1.25 inø) (117 in L) (0.95 inø) (312 in L)
16 mmø × 5 000 mm (L) - 1 pc. 24 mmø × 2 000 mm (L) - 2 pcs.
(0.65 inø) (195 in L) (0.95 inø) (78 in L)
12 mmø × 7 000 mm (L) - 2 pcs. 20 mmø × 5 000 mm (L) - 2 pcs.
(0.5 inø) (273 in L) (0.8 inø) (195 in L)
12 mmø × 3 000 mm (L) - 3 pcs. 12 mmø × 3 000 mm (L) - 2 pcs.
(0.5 inø) (117 in L) (0.8 inø) (117 in L)
12 mmø × 5 000 mm (L) - 1 pc.
(0.5 inø) (195 in L)
10 mmø × 1 000 mm (L) - 2 pcs.
(0.4 inø) (40 in L)
4 Shackles
0.5-ton load- 4 pcs. 2-ton load - 2 pcs. 5-ton load - 4 pcs. 10-ton load - 4 pcs. 20-ton load - 2 pcs.
[ For Loader front ] [ For Backhoe front ]
1.5-ton load - 2 pcs. 15-ton load - 3 pcs.
3-ton load - 2 pcs. 10-ton load - 2 pcs.
12-ton load - 2 pcs.
25-ton load - 4 pcs.
Note:
If the centering work can be performed by methods other than that those shown in 19 on page 29 (2/3), the chain blocks
and lever blocks indicated here are not required.
47
6 Wooden blocks
500 mm (L) × 700 mm (W) × 500 mm (H) - 4 pcs. 2 000 mm (L) × 100 mm (W) × 100 mm (H) - 2 pcs.
(20 in) (30 in) (20 in) (80 in) (4 in) (4 in)
1 000 mm (L) × 500 mm (W) × 1 000 mm (H) - 4 pcs.
(40 in) (20 in) (40 in)
[ For Loader front ] [ For Backhoe front ]
800 mm (L) × 900 mm (W) × 800 mm (H) - 4 pcs. 1 000 mm (L) × 500 mm (W) × 800 mm (H) - 4 pcs.
(30 in) (35 in) (30 in) (40 in) (20 in) (30 in)
300 mm (L) × 300 mm (W) × 1 020 mm (H) - 2 pcs. 1 000 mm (L) × 500 mm (W) × 500 mm (H) - 4 pcs.
(12 in) (12 in) (40 in) (40 in) (20 in) (20 in)
2 600 mm (L) × 300 mm (W) × 200 mm (H) - 1 pc.
(100 in) (12 in) (8 in)
7 Scaffolding
As required - 2 units (2.5 m High) For L/D
(See Fig. 5-1)
As required - 2 units (4.0 m High) For B/H
Ladder (2 ~ 2.5 m High) - 4 pcs.
8 Oil containers
20 liter capacity - 4pcs. 10 liter capacity - 2pcs.
9 Standard tools
Prepare 4 or more sets.
10 Spanner
50 mm: For Fuel hoses/Drain hoses
11 Ratchet handle
12 Crowbar
13 Bar wrench with ball end Scaffolding (example)
4 mm 1 Wiring
14 mm 1 Travel motor hoses
17 mm 3 Front attachment hoses
14 Hydraulic jacks
30 - ton load - 2pcs.
19 Socket wrench
24 mm Number of protectors required to be made: 10 pcs.
30 mm 1 Front attachment pins
Fig. 5-2
36 mm
46 mm 1 Engine units
75 mm 1 Connecting main frame,
counterweight track frame
48
20 Electric power source Headset
22 Headset - 4 sets
(see Fig. 5-3)
Speaker
23 Safety life lines - 5sets
Mike
24 Pressure cleaner (Remove oil/grease)
25 Miscellaneous
Rags Belt
Cleaning detergent
Lubricant
Light & cord reel for work
Battery pack
Grease
Moly coat spray
26 Torque wrench
3.5~90 kgf·m capacity
(35~880 N·m/25.3~650 lbf·ft)
Fig. 5-3
27 Eye Bolt
1.0 - ton load - 4pcs.
49
Note:
For tools which are not available locally, place an
SPECIAL TOOLS order with Hitachi in advance.
P/No. 4093798
Torque wrench Used to tighten
2 1
100 ~ 410 N·m the bolts.
(10 ~ 42 kgf·m/74 ~ 302 lbf·ft)
Fig. 5-5
P/No. 4093800
Used to tighten
Power wrench
3 the side frame
1 470 ~ 4 410 N·m 1 to track frame
150 ~ 450 kgf·m
and swing bearing
1 084 ~ 3 253 lbf·ft
Fig. 5-6
Fig. 5-7
Vacuum pump
Assembly ST6905
Fig. 5-8
50
Note:
For tools which are not available locally, place an
SPECIAL TOOLS order with Hitachi in advance.
6
Fig. 5-9
7
Fig. 5-10
Section A
30- 0.2
0.4
8 # #
# %#
1˚38'
ø36.026
M48×4.0
ø10
A
ø49
70
Fig. 5-12
10 # #
#
Fig. 5-13
51
Note:
For tools which are not available locally, place an
SPECIAL TOOLS order with Hitachi in advance.
15˚
Section A 30˚
16
11
ø30
16
(820)
R8 50
R15 50 (50)
ø10
5
R36
Fig. 5-14
40
ø12
M20×2.5
12 7
17 Fig. 5-15
52
EX2500-6 Assembly Manual
UNDERCARRIAGE
ASSEMBLY OF UNDERCARRIAGE
6. Assembly of Undercarriage
6-1 Preparation
Fig. 1
Parts required
Procedure, track (9205525) 1/2
01 ─── SIDE FRAME ASSEMBLY (L) 1 Side frame (L) and track link
02 ─── SIDE FRAME ASSEMBLY (R) 1 Side frame (R) and track link
09 7040917 SUPPORT 1
10 6020327 COVER 1
11 8061435 STEP 1
13 6017844 COVER 1
14 6016469 COVER 1
15 4344602 HOSE 2 Hose connecting the motor and brake valve, 1.1/2 dia.
55
2/2
16 4344601 HOSE 2 Hose connecting the motor and brake valve, 1.1/2 dia.
17 4401948 HOSE 2 Travel motor drain hose, 3/4 dia.
18 4410984 HOSE 2 Shift speed hose, 1/4 dia.
28 4372448 BOLT 28 For installing the track frame and side frame
29 4372449 SPACER 28 side mounting section
30 4347715 BOLT 40
For installing the track frame and side frame
31 4347723 SPACER 40
32 4510169 O-RING 8
56
Lift
6-2 Connection of track frame and side frames
Step 1
Wire rope
Preparation of the right side frame assembly 36 mmø ×
8 000 mm
c
Wire rope: 2 pcs.
d Fig. 1
36 mmø × 8 000 mm (L)
(1.4 inø) (312 inL) Front
Protector: 8 pcs.
Final drive
2 Place the side frame assembly on the ground with
the final drive toward the rear.
CAUTION: Rear
Never allow any persons to stand directly beneath the Fig. 2
lifted side frame. Detail A
Fig. 3
Detail B
2 Clean the front and rear surfaces (indicated by e
in Fig. 4).
e
3 Check the surfaces for damage or scratches.
Note: e
Repair and/or refinish any damage found.
Fig. 4
57
Step 2 c
00
Preparation of the track frame assembly
d
* Cleaning and finishing
1 Clean all the surfaces of track frame 00 that
will be connected to the side frame. a
(a ~ d ).
Fig. 5
2 Check the surfaces for damage or scratches. b
Detail C
Note:
Repair and/or refinish any damage found.
3 Clean all spot facing surfaces on the track frame. Spot facing
Spot facing
Fig. 6
Fig. 6-a
Step 3
Lift
Lifting of the track frame assembly
Shackle
Shackle 10 ton
Eye-plate
Fig. 8
Fig. 8-a
58
Step 4 Lift & move
Final drive
Brake valves Fig. 9
Detail E
2 Move the track frame assembly horizontally in the
direction of the arrow, and align the centers of the
connecting parts.
Lift & move
Fig. 10
Hold
Fig. 11
59
2 1 Align the bolt holes of the side fame and track Hold
frame, then connect them with bolts 28 and
spacers 29 .
Fig. 12
Detail F
Notes:
i) Be sure to apply a suitable lubricant to bolts 28
before tightening. Use a lubricant made by
mixing white zinc jelly and spindle oil in a 1:1
proportion.
ii) Apply lubricant to each bolt and spacer in the
positions indicated by * in Fig. 14 (the base of
the head and thread of each bolt, and both end 29
faces of the spacers). 28 Fig.13
iii) Place spacers 29 on bolts 28 with the chamfer
directed towards the bolt head.
Detail G
iv) Tighten all bolts until the surfaces engage fully. 29
v) Confirm that there is no gap between the *
surfaces.
*
*
* 0
13
Note:
Be sure to treat all the bolts in the same way.
28 0
25
2 Tighten bolts on the front side following the
28
same procedure as that for the rear side. Fig. 14
CAUTION:
Avoid getting your hand caught by the reaction force
bar of the power wrench.
Fig. 15
60
Lift
Step 5 Detail I
Connecting of the left side frame to the track frame 500 1000
1 Place wooden blocks under the left side of the track 1020
frame as shown in Figs.16 and 16-a.
Wooden block: 2 pcs.
Size: 1 000 mm (L) × 500 mm (W) × 1 000 mm (H) Fig. 16-a
(39 in) (20 in) (40 in)
Note:
Each wooden block must be able to carry at least
Fig. 16
15 000 kg (33 069 lb).
CAUTION:
This method is safer than lifting the track frame assembly
with another crane.
Wooden approx. 1 020 mm
block (39.8 in)
2 1 Clean all screw holes on the side frame 01 using a
tap.
Tap size: M48 × P4.0 Fig. 17
Lift & move
2 Clean the left side frame surfaces to be
connected to the track frame.
Side frame 01
3 1 Lift the left side frame 01 (L) as illustrated in Figs. (left)
18 and 19.
Note:
Apply protectors at a , b , c , and d , indicated by
a
(both sides) to prevent the wire ropes from b
breaking. c
Protector: 8 pcs.
Note:
In lifting the side frame with the wire ropes set as
indicated, the track will sag if the links are loose,
making alignment with the track frame difficult. The
track links should thus be as tight as possible when
carrying out this work.
61
4 Apply a lubricant to the fixing bolts and spacers before
installation, as outlined in the inset detail. Hold
1 Align the bolt hole in the side frame with that of
track frame, then connect them together with bolts
28 and spacers 29 .
Notes:
i) Be sure to apply a suitable lubricant to bolts 28
before tightening. Use a lubricant made by 28 29
mixing white zinc jelly and spindle oil in a 1:1
proportion.
ii) Apply lubricant to each bolt and spacer in the
positions indicated by * in Fig. 21 (the base of
the head and thread of each bolt, and both end
faces of the spacers).
iii) Place spacers 29 on bolts 28 with the chamfer
directed to the bolt head. Fig. 20
iv) Tighten all bolts until the surfaces engage fully.
Detail J
v) Confirm that there is no gap between the 29
surfaces. *
*
13
0
*
25
0
28
Fig. 21
Detail K
29
Note: 28 Fig. 22
Be sure to treat all the bolts in the same way.
Detail L
2 Tighten bolts 28 on the front side following the
same procedure as that for the rear side.
62
Step 6
Fig. 24
Plate
CAUTION:
Hydraulic
Make sure to use a block under each jack, and position jacks:2 pcs.
them securely.
a Block Fig. 25
Fig. 26
Hydraulic
jacks.
a
Fig. 27
63
Step 7
Tightening procedure for the upper side bolts used to
attach the track frame.
Note 1: a
Apply protectors to a , indicated by . a
(Fig. 28)
Fig. 28
2 Loosen valve b at the track adjuster. Do not
touch valve c . (Fig. 29) Detail M
3 Lift the track link using a crane as illustrated in
Fig. 30.
Note 3:
i) Lift the track link to create clearance at the side Detail N
frame's upper face as shown in Fig.32.
ii) Be careful that you do not break the wire rope. Fig. 30
CAUTION:
Place a sleeper between the track link and side frame
so the track link cannot fall from its suspended state.
Fig. 31
2 1 Attach bolts 30 through the clearance made by
lifting the track links. Clearance
2 Apply lubricant to bolts 30 before installation. between
track link
and side
Note: frame
i) Be sure to apply a suitable lubricant to the bolts
before tightening. Use a lubricant made by
mixing white zinc jelly and spindle oil in a 1:1
proportion. Fig.32
ii) Apply lubricant to each bolt and spacer in the
positions indicated by * in Fig. 33 (inset) (the Detail O
base of the head and thread of each bolt, and
both end faces of the spacers).
iii) Place spacers 31 on bolts 30 with the chamfer 30
*
directed towards the bolt head. 30 210 31
iv) Keep the track link lifted until the bolts are *
completely tightened.
*
* 31 Fig. 33
Tighten the bolts at the opposite side again
following the same procedure mentioned above.
64
Step 8
Hold
Retightening of the bolts
Note:
Keep the track link lifted until the bolts are Fig. 34
completely tightened.
Detail P
CAUTION: Power wrench
(4093799)
i) Place a sleeper between the track link and side frame Upper side bolts
so the track link cannot fall from its suspended
state.
Sleeper
ii) Use caution to avoid your hand from being caught
by the reaction force bar.
Fig. 35
Fig. 36
CAUTION:
Power wrench
Use caution to avoid your hand from being caught by (4093799)
the reaction force bar. Fig. 37
Fig. 38
65
66
6-3 Connection of travel motor hoses and adjuster hoses
Step 1
Notes:
i) Clean the surfaces of the travel motor to be
Detail A
connected to the hoses.
ii) Make sure that no dust adheres to the seat
face of each hose. 15
iii) Be careful not to twist the hoses when
connecting them.
iv) Apply sealant #98D to O-rings 32 (P/No.
4510169~12 pcs.) just before installing.
16
Fig. 2
Notes: 18
i) Clean the surfaces of the travel motor to be
connected to the hoses. 17
ii) Make sure that no dust adheres to the seat
face of each hose.
iii) Be careful not to twist the hoses when
connecting them.
Fig.3
67
Front side
D
Notes:
i) Make sure that no dust adheres to the seat face
of the hose nipple. Fig. 4
ii) Be careful not to twist the hoses when
connecting. Detail C
Tightening torque of hose A : 30 N·m A 15 16
(3 kgf·m/22 lbf·ft)
Width across flats: 19 mm
B Band clip
2 Use band clips to secure hoses 16 and 17
together in two positions. Also, secure hoses 15
and 18 in two positions as shown in Fig.5.
17 18 Fig. 5
Notes:
i) Make sure that no dust adheres to the seat face
of the hose nipple.
ii) Be careful not to twist the hose when
connecting.
Connecting
position
Tightening torque of hose a : 30 N·m
(3 kgf·m/22 bf·ft)
Width across flats: 19 mm b Fig. 6
4 Clean the parts carefully after all oil has drained out. Cover
68
6-4 Assembly of motor covers and steps
Detail A
Step 1
Note:
Bolts are being screwed temporarily into the parts to
be installed.
Note:
Bolts are being screwed temporarily into the parts to
be installed.
Notes:
Apply lubricant to the mounting bolts, fit all bolts
in place, then tighten to the specified torque.
69
2 Mounting of the steps Detail C
1 Mount step 11 .
Note:
Bolts are being screwed temporarily into the parts to
be installed.
Note: Fig. 3
Apply lubricant to the mounting bolts, fit all bolts
in place, then tighten to the specified torque. Detail D
Note:
Bolts are being screwed temporarily into the parts to
be installed.
Note: Fig. 4
Apply lubricant to the mounting bolts, fit all bolts
in place, then tighten to the specified torque.
Fig. 5
70
6-5 Disassembly procedures for shipment (Procedure, Track)
Detail A
Fig. 1
EX2500-6 Procedure, Track 9205525
71
6-6 Assembly of motor guards and mission guards (Option)
Until now, the screw seats for the EX2500-6 travel motor guard were welded before they were shipped out. However, starting
from the following serial number models, the screw seats are no longer being welded before the shipment. Some of the reasons
are as follows: difficulties in installing the motor guard during site assembly due to welding distortion of track side frame and
necessity of large quantity of shims. Thus, from now on, screw seats will be welded at the site.
Applicable serial numbers: 1173 and above
Step 1
Procedure of the motor guard Detail A
Note:
Pages 74 and 75 (1/7) show the details of parts and
seats and pages 75 (2/7) and 75 (3/7) show the
welding method for screw seat. The assembly
drawing is given on page 75 (5/7).
Note: /
02 03
If the holes are not properly aligned, use a jack.
/
00 01
3 Mount motor guards 00 / 01 and brackets 02 / 03 in
position as shown.
Fig. 2
Tightening torque of M27 bolt: 1 400 N·m
(Bolt 09 ) (140 kgf·m/1 030 lbf·ft) List of motor guard data
Width across flats: 41 mm
A. Parts required …………………………74, 75 (1/7)
Tightening torque of M16 bolt: 270 N·m B. Butt welding of guard-use screw seat …75 (2/7)
(Bolt 11 ) (27 kgf·m/199 lbf·ft) Welding method for screw sear …………75 (3/7)
Width across flats: 24 mm C. Assembly of motor guard ………………75 (5/7)
Note:
Apply lubricant to the mounting bolts 09 , 11 and
washer 10 , 12 , fit all bolts in place, then tighten to
the specified torque.
73
3 Parts list
00 6017536 GUARD 1
01 6017537 GUARD 1
02 7035028 BRACKET 1
03 7035029 BRACKET 1
04 4393099 SPACER 2
05 4398472 SPACER 2
06 9758513 BRACKET 2
07 4603063 SHIM 4
08 4603014 SHIM 60
09 J932780 BOLT 20
10 4085857 WASHER 20
11 J931680 BOLT 6
12 4087197 WASHER 6
13 J271240 BOLT, SEMS 4
14 4027471 BOLT, EYE 6
4 Installation instructions
5 Remarks
Before welding, remove all flammables (such as grease) and cover all instruments in the vicinity.
74
7 Butt welding of guard-use screw seats
Refer to reference
measurement 1
Fig. 4
Position the screw seat in place and butt weld.
( 01 , 00 , a total of 4 locations)
Procedure
Note:
If there are gaps between the frame and 00 , 01 , use
shim(s) to take up the gaps and then, carry out tack
welding.
75 (2/7)
7 Butt welding of guard-use screw seats
Refer to reference
measurement 1
Fig. 4
Position the screw seat in place and butt weld.
( 01 , 00 , a total of 4 locations)
Procedure
Note:
If there are gaps between the frame and 00 , 01 , use
shim(s) to take up the gaps and then, carry out tack
welding.
75 (2/7)
Detail D
8
Welding method for screw seat (dimensional drawing)
[NOTE]
Common to ,
This drawing shows the additional work of
within the shaded areas EX2500-6 track frame. For dimensions not
specified here, refer to drawing no. 5004649
for track frame.
75 (3/7)
75 (4/7)
9 Assembly of motor guards
Detail E
(Washer)
(Washer)
75 (5/7)
Step 2
Detail A
Fig. 1
EX2500-6 Mission guard XF60000361
75 (6/7)
2 Mounting the mission guards
Installation of the mission guard.
Detail B
Fig. 2
EX2500-6 Mission guard XF60000361
75 (7/7)
EX2500-6 Assembly Manual
SUPERSTRUCTURE
ASSEMBLY OF SUPERSTRUCTURE
7. Connection of undercarriage and superstructure
7-1 Preparations before connection
Fig. 1
Parts required
Procedure, Track (9205525)
Item Part No. Part name Q'ty Remarks
20 8035803 COVER 1
21 4184943 GASKET 1
32 4510169 O-RING 4
33 ─── STOPPER 1
79
Procedure, frame (9289551)
80
Procedure, 2 (9289574)
00 4363484 PIPE 1
01 4446146 PIPE 1
02 4667656 PIPE 1
03 4446148 PIPE 1
04 4446149 PIPE 1
05 4446150 PIPE 1
06 4446151 PIPE 1
07 4446152 PIPE 1
08 4446153 PIPE 1
09 4446154 PIPE 1
62 10 4363494 PIPE 1
11 4363495 PIPE 1
12 4363496 PIPE 1
13 4363497 PIPE 1
14 4363498 PIPE 1
15 4363499 PIPE 1
16 4363500 PIPE 1
17 4363501 PIPE 1
18 4363502 PIPE 1
19 4363503 PIPE 1
20 4363504 PIPE 1
81
Procedure, engine (9289557)
82
Procedure, tank (9274308)
00 4336570 HEAD LAMP 4 Cab, left of the cab at the rear of the step and head lamp.
01 4336570 HEAD LAMP 3 Engine cover back lamp.
02 4336570 HEAD LAMP 1 Refractable stairway.
00 9267369 COUNTERWEIGHT 1
01 7051413 HANDRAIL 1
02 7051412 HANDRAIL 1
03 6024937 STEP 1
04 8106042 HANDRAIL 1
05 6024979 STAND 1
06 8106770 BRACKET 1
07 9766847 HANDRAIL 1
08 8106773 STEP 1
09 ─── BOLT ASSEMBLY 6
10 4660296 STOPPER 2
11 4659756 COVER 2
12 9766763 BRACKET 4
13 8106321 COVER 3
14 7051333 BRACKET 1
15 J271255 BOLT, SEMS 4
16 J271025 BOLT, SEMS 12
17 J271025 BOLT, SEMS 6
18 J281030 BOLT, SEMS 12
83
Spare parts to be delivered (9221389)
Item Part No. Part name Q'ty Remarks
02 A810110 O-RING 3 For the 2-inch suction hose beneath the oil tank and pump
03 A810070 O-RING 2 For the suction pipe beneath the pump (1.1/2 in.)
05 4153543 O-RING 6 Top of the return oil cooler, side of the oil tank, bottom of the butterfly valve
08 4187328 O-RING 1 Beneath the AC motor delivery pump control panel, for ORS
84
7-2 Preparation of undercarriage a
Swing bearing
Step 1
Cleaning and finishing
Note:
If found to be damaged, repair and/or refinish. Fig. 1
Detail A
2 1 Make sure there is no foreign matter or water in
the grease basin (part b indicated by )
inside the internal gear box on the swing bearing. Front side
b
2 Make sure all water has drained out of the basin
through the hole c indicated by .
3 If foreign matter is found to have adhered to the
inside surface of the hole, remove it completely.
4 Install the cover 20 , gasket 21 and bolt, sems over c
the drain hole c . ( 20 , 21 )
Note:
Bolts are being screwed temporarily into the parts to
be installed.
Tightening torque of M12 bolt: 90 N·m Fig. 2
(9 kgf·m/66 lbf·ft)
Width across flats: 19 mm Detail B Knock pin
Note:
Knock pin
Confirm that the knock pins are positioned on the
left and right sides respectively of the swing bearing.
Note:
Soft zone: Hole in swing bearing where ball
bearings are put in. d
Soft zone
4 Fill the oil pan with grease. (Grease volume in the Left side Fig. 3
basin.)
Note:
See the Operation Manual for the type of grease to
be added.
Detail D
Grease
Fig. 5 Fig. 4
85
Step 2
Clean
Fig. 6
86
7-3 Preparation of base machine Detail A
500
Step 1 1000
Note:
Each wooden block must be able to carry at least a 00
10 000 kg (22 000 lb) load. Wooden blocks
Note:
OR
If appropriate wooden blocks are not available,
rest the basic machine on a trailer main frame as
shown in Fig. 3, using the blocks used in
shipment. Trailer
Fig. 3
support a support b
Step 2
Detail B
2 Clean all screw holes in the base machine using a
tap.
Fig. 5
87
Step 3
Swing motors
Releasing of the swing lock valve
Note:
Since the bolts on the swing bearing are to be
tightened while the superstructure is suspended,
the swing lock valve shown here must be
released. This Step is not required when the swing
bearing fixing bolts are to be tightened after
starting the engine.
Fig. 6
Detail C
Front side
swing motor
Rear side
swing motor
1 The procedure below is to be carried out for both of the
two swing motors.
Detail D
a
2 Clean the parts carefully after all oil has drained out.
Fig. 9
88
7-4 Connection of undercarriage and base machine
Step 1
Bolt 09
Attaching of the wire ropes to the base machine
00
2 Attach wire ropes to the base machine as illustrated in
Fig. 2.
Fig. 1
1 Front-side attachment of the wire ropes and chain
block :
Lift
Apply protectors to the pins as shown in Fig. 2.
2 Rear-side attachment of the wire ropes : Wire rope
Apply protectors to the beam of the base machine 28 mmø ×
as shown in Fig. 2. 3 000 mm
00
Fig. 2
Protector
Lift
3 Keep the base machine level during lifting, as
illustrated in Fig. 3.
Note:
Level the main frame by adjusting the preset chain
Lift
blocks.
CAUTION:
When carrying out the joining work on the undercarriage
assembly, station the sub-leaders at each of the front and
rear regions of the base machine, and closely follow the
signals of the leader so as not to damage the component
parts.
CAUTION:
i) Be sure to use protectors to prevent the wire ropes
from breaking.
ii) Never allow anyone to stand directly beneath the
lifted base machine. Fig.3
89
Step 2
Note:
When joining the base machine to the
undercarriage, inserting swing guide pins a (Fig. 7)
into the bearing on the track will allow for smooth Base machine 00 Lower
connection.
Guide ring
1 1 Lift base machine 00 , and align the centers of the
parts to be joined on the undercarriage and base
machine.
Notes:
i) Do not let the base machine touch the grease
basin guide ring on the track frame. Undercarriage Fig. 4
ii) Level the base machine by adjusting the preset
chain blocks.
00
Lower Lower
Fig. 5
Fig. 6
Detail A
b
Guide pins a
Fig. 7
90
Step 3 Hold Hold
Mesh the internal gear on the swing bearing with the pinion
on the swing drive following the procedures below:
Fig. 8
Detail B
Eye level
Fig. 9
Detail C
2 Carefully align the teeth of the two swing drive pinion
Special tools
with the internal gear using the special tools provided (ST3046 and ST3047)
(ST3046 and ST3047).
Note:
Having released the swing lock valve (See Note
on page 88) will make this alignment easier.
Pinion
Internal gear
Fig. 10
Lower Lower
2 Lower the rear side crane little by little so the rear
side pinions mesh with each other.
Fig. 11
91
Note:
If the rear-side gear teeth do not mesh, try to
swing the crane a little in both directions. The gear
teeth should then mesh together.
Hold
30 mm (1.2 in)
approx
Fig. 13
5 Detail D
Align the two knock pins b with the holes in the main
frame.
30 mm (1.2 in)
approx.
Knock pin b
Fig. 14
Lower Lower
6 1 Slowly lower both cranes while keeping the front
and rear of the base machine level. c
Fig. 15
92
Hold Hold
Step 4
Fig. 16
Detail E
1 Fit 10~15 connecting bolts 01 and washers 02 to the
swing bearing from the underneath of the main frame
at the rear and front of the swing bearing respectively.
Notes:
i) Be sure to apply a sultable lubricant to bolts 01
before tightening. Use a lubricant made by
mixing white zinc jelly and spindle oll in a 1:1 01 02
proportion.
ii) Apply lubricant to the screw and under-side of Fig. 17
the bolt head, marked with *, before insertion,
as illustrated in Fig. 18.
Detail F
iii) Place washer 02 on bolt 01 with the chamfer
directed towards the bolt head. 02
02
Chamfer
01
Section a
Fig. 18
93
3 1 Lower both cranes simultaneously until the joining
faces of the undercarriage and main frame contact
uniformly.
Lower Lower
2 Temporarily tighten the remaining connecting
bolts and washers with a ratchet wrench.
Contact
Contact
Fig. 19
Note:
Keep the rear of the base machine lifted as it is.
Fig. 20
Hold
Fig. 21
5 1 Install stopper 33 between the track frame and the
center joint. (Fig. 22) Detail G
Note: Front side Center joint
Bolts are being screwed temporarily into the parts
to be installed.
Fig. 22
94
Step 5
Fig. 23
3 Tighten the 60 base machine connecting bolts 01
using a hydraulic wrench. Detail H
CAUTION: 01 Bolt
Be careful to avoid getting your hand caught by the
reaction force bar on the hydraulic wrench. Hydraulic wrench
Notes:
Fig. 24
i) Mark the heads of the bolts in their final position
after being completely tightened. (See Fig. 25) Detail I
ii) After all the bolts have been tightened
completely, check the tightening torque by re-
tightening 3 or 4 of the bolts which were first
tightened.
Mark
Fig. 25
Remove the
2 Remove the bolts pre-inserted into the main frame wire ropes
to keep the wire ropes in place.
Fig. 26
95
Step 6
Connecting of the grease piping
Note:
The clamp mounting bolts should be tightened
until the rubber is deformed.
Fig. 27
Clamp tightening torque of M10 bolt: 50 N·m
(5 kgf·m/37 lbf·ft)
Width across flats: 17 mm
Detail K
10
00
11
01
12
02 13
03 14
15
04
a b
16
05
17
09
08 07 06 20 19 18
Fig. 28
Notes:
i) Remove the vinyl caps from both ends of each pipe, then install as shown above.
ii) Use the pipe clamps attached to the base machine.
96
7-5 Connection of piping to center joint
Step 1
Notes:
i) Do not twist the hoses when connecting them, or
their service life will be shortened. Fig. 1
ii) Connect the hoses so they do not make contact Detail A
Center joint
with other parts.
Front side
iii) Make sure that no dust has adhered to the seat
face of the hoses.
iv) Be careful not to damage the joining surfaces of
the hoses.
v) Apply a thin layer of sealant #98D to the O-rings
32 (P/No. 4510169~4 pcs.) before installation.
Reuse the O-ring originally fitted to the hoses.
Notes: i
i) Do not twist the hoses when connecting them, or
their service life will be shortened.
ii) Connect the hoses so they do not make contact
with other parts. j
h
iii) Make sure that no dust has adhered to the seat
face of the hoses.
iv) Be careful not to damage the joining surfaces of
g
the hoses.
e
f
Fig. 4
97
Step 2 Detail D
Clean the parts carefully after the oil has drained out.
Fig. 5
98
7-6 Assembly of fuel tank
Fuel tank 30
Step 1
Installation of the fuel tank assembly
Note:
Each wooden block must be able to carry at least a
1 500 kg (3 300 lb) load.
Shackle: 2 pcs.
for 1.5 metric ton (1.65 US ton) load
Lower
Lever block : 1 pc.
for 1.5 metric ton (1.65 US ton) load
30
3 Keep the fuel tank level during lifting, as illustrated
in Fig. 3.
Note:
Level the fuel tank by adjusting the preset chain blocks.
CAUTION!
Never allow anybody to stand directly beneath
the lifted fuel tank.
99
4 1 Connect fuel tank 30 to the main frame with bolts
32 and washers 33 .
2 Tighten the fuel tank mounting bolts 32 using a
hydraulic wrench.
CAUTION!
30
Be careful to avoid getting your hand caught by the
reaction force bar on the hydraulic wrench.
Notes: Fig. 4
i) Be sure to apply a suitable lubricant to the bolts
32 before tightening. Use a lubricant made by
mixing a white zinc jelly and spindle oil in 1:1 Detail A
proportion.
ii) Apply lubricant to the screw and under-side of *
the bolt head, and both ends of the washer, as
33
illustrated by "*" in Fig. 5.
*
Tightening torque of M30 bolt: 1 400 N·m *
(143 kgf·m/1 033 lbf·ft)
Width across flats: 46 mm 32
Fig. 5
Detail B
32 33
Fig. 6
100
Detail C
Assembly of fuel tank
Fig. 7
101
7-7 Assembly of cab
Step 1
49
Installation of the cab bed assembly
Note:
Bolts are being screwed temporarily into the parts 19 20 Fig. 1
to be installed.
c 19
Notes: b
i) Apply lubricant to the bolts before installation.
a
ii) Tighten bolts to the specified torque after first
20
screwing in finger tight.
Fig. 2
Fig. 2-a
Notes:
i) Apply lubricant to the bolts before installation.
ii) Tighten bolts to the specified torque after first
screwing in finger tight.
102
Lift
2 1 Attach wire ropes, a lever block and shackles to
the eye bolts on cab bed assembly 49 , as shown Wire rope Wire rope
in Fig. 3. 10 mmø × 10 mmø × 5 000 mm
3 000 mm
2 Keep the cab bed assembly 49 level during lifting. Lever block
Lever
Note: Wire rope block Eye
Level the cab bed assembly by adjusting the 10 mmø × bolt
3 000 mm
preset lever blocks.
Cab bed assembly 49 weight: 2 870 kg (6 315 lb)
Shackle: 4 pcs.
for 1.0 metric ton (1.1 US ton) load
CAUTION!
Never allow anybody to stand directly beneath the lifted
cab bed assembly.
Lower
Main frame
49
Fig. 4
103
Hold
4 Tighten the bolts a and b .
Note:
Bolts are being screwed temporarily into the parts
to be installed.
Notes:
i) Apply lubricant to the bolts before installation.
ii) Tighten bolts to the specified torque after first
screwing in finger tight.
Fig. 5
Detail A
b Bolt
Plain Spacer
washer
Detail B
a Bolt
Seat screw
Fig. 6
Tighten bolts b
Tighten bolts a
Fig. 7
104
Step 2
Installation of the wiper blade and head lamps on the cab
Notes:
i) Before connecting the electric wires, remove the
anti-corrosive and any rust from the couplers.
ii) Connect the couplers, matching the labels.
08
Fig. 9
Detail C
3 Install the head lamps 00 on the cab.
Notes:
i) Before connecting the electric wires, remove the
anti-corrosive and any rust from the couplers.
ii) Connect the couplers on the labels a b
Fig. 10
105
Step 3 Detail D
Lift
Installation of the cab
Wire rope
10 mmø × 5 000 mm
1 Attach wire ropes and shackles to the cab 04 as shown
in Fig. 11.
Shackle
Cab 04 weight: 1 740 kg
(3 830 lb)
Shackle: 4 pcs.
for 500 kg (1 100 lb) load Fig. 11
CAUTION!
Never allow any persons to stand directly beneath the Lower
lifted cab.
04
Fig. 12
Hold
Fig. 13
Notes:
i) Apply lubricant to the nuts before installation.
Detail E
ii) Tighten all nuts to the specified torque after first Nut
Washer plan
screwing in finger tight.
Cab
floor
Plate
4 Remove the crane wire ropes attached to the cab.
Cab bed
Fig. 14
106
5 Remove the four supports a that are attached to the Detail F
underside of the cab.
Detail G
Support a
Fig. 15
Fig. 16 Detail H
12
During maintenance
Fig. 17
2 Attach the chains 12 to the hook, on the front rail During storage
12
and secure it to the perforated hook after
threading it through the cab handrail a as shown
in Figs. 17 and 18.
Cab handrail
Detail I
12 Cab
handrail a
Fig. 18
Fig. 19
107
7 Install escape device and antenna. Detail J
1 Install bracket 11 .
Note:
Bolts are being screwed temporarily into the parts
to be installed.
Fig. 20
Notes:
i) Apply lubricant to the bolts before installation.
ii) Tighten all bolts to the specified torque after first 05
screwing them in finger tight.
Notes:
i) Before connecting the electric
wires, remove the anti-
corrosive and any rust from Fig. 22 Fig. 21
the couplers.
Detail L
ii) Connect the couplers,
matching the labels.
Notes:
i) For the usage of the satellite communication
antenna, refer to the HCM dealer.
ii) Refer to the drawing of "Kit, GPS parts
(9289888)" (optional) on p. 207.
Note:
Notes:
Bolts are being screwed temporarily into the parts
i) Apply lubricant to the bolts before installation.
to be installed.
ii) Tighten all bolts to the specified torque after first
Tightening torque of M10 bolt: 50 N·m screwing them in finger tight.
(5 kgf·m/37 lbf·ft)
Width across flats: 17 mm
108
7-8 Assembly of fenders, steps, handrails, beam, box, and covers
Step 1
Installation of the fender assembly
Detail A
25
Fig. 1
Detail B
25
Fig. 2
109
Step 2
Installation of the step
Detail C
21
d e
b f
a
Fig. 3
Detail D
Fig. 4-a
21
Fig. 4
110
Step 3
Installation of the beam
Detail E
03
Fig. 5
Detail F
03
Fig. 6
111
Step 4
Installation of the box
Detail G
07
08
09 01 Beam
Fig. 7
Detail H
a
Fig. 8
112
INSTALLATION OF THE BOX Detail I
b
4 1 Place the under-side of the box 01 on wooden a
blocks as shown in Fig. 9.
Note:
Each wooden block must be able to carry at least
a 500 kg (1 100 lb) load.
01
Wooden block: 2 pcs.
Size: 10 mm (L) × 10 mm (W) × 50 mm (H)
(4 in) (4 in) (20 in)
Shackle: 3 pcs.
For 0.4 metric ton (0.44 US ton) load
Fig. 10
Eye bolt: 4 pcs.
For 0.4 metric ton (0.44 US ton) load
Detail K
Lift
CAUTION!
Never allow anybody to stand directly beneath the lifted
Wire rope
box. 8 mmø × 3 000 mm
Note:
Wire rope
Level the box by adjusting the preset chain blocks. 8 mmø × 4 000 mm
Wire rope
Detail L 8 mmø × 4 000 mm
Shackle
Wire rope
8 mmø × 3 000 mm
Shackle
01
Eye bolt
Fig. 12 Fig. 11
113
Lift
5 Installing box 01
Note:
Use the tightening bolts and washers attached to 01
the beam.
Notes:
i) Apply lubricant to the bolts before installation.
ii) Tighten all bolts to the specified torque after first
screwing in finger tight.
01
Detail O
Install cover a over the
Box assembly mounting location shown by the dotted
bolt location line.
Bolt
Washer
Fig. 15
Fig. 16
114
6 Preparing the step for installation
Note:
The rod is fixed to the pin at e . Unfix and reposition
it in the orientation shown below.
Detail Q
rod
Fig. 17
Detail P
box 01 d
a
Pin e b e
Pin e on box 01
f
rod
e Fig. 18
b
a
Fig. 19
Notes:
i) Apply lubricant to the bolts before installation.
ii) Tighten bolts to the specified torque after first
screwing in finger tight. Fig. 20
115
Step 5
Installation of the fender
Detail R
28
Fig. 21
Detail S
28
Fig. 22
116
Step 6
Installation of the fender, handrails, cover and steps
Detail T
54
36 53
38 35 44
37
39
40
41
42 43
Fig. 23
117
4 Shown below is the view once the right-hand fender,
handrails and steps are installed.
Detail U
54 36 35 53
44
40
38
37
41 39
42 43
Fig. 24
Detail V
45
45
Fig. 25-a
Fig. 25
118
Detail W
Nut
Washer
Bolt, sems
Plate
Clamp
a Bolt, sems
Washer After taking up the gap
between 29 and a , tighten
Bolt the bolt by seven turns.
Step Washer
18 Bolt, sems
Bolt
Washer plan
Step
20 Nut
Bolt, sems
Nut Washer Rubber, cushion
Nut
Clip
Washer Bolt Washer
Bracket
Nut Bolt, sems Step Bolt, sems
Bolt, sems
Senser 19 Lamp, working
Washer Plate 13
Plate Bracket
Bracket Bracket
Plate
14
Lamp, head
2 places
00
Step
21
Washer
2 places
Bolt, sems
Nut
Bracket
10 Washer
Device, escape
09 Bolt
Bolt, sems
Bracket
Clip
Bolt, sems
Nut Bolt, sems
Washer
Fig. 26
119
Detail X
120
Assembly of fenders, steps, and handrails
Bracket
Bolt
Washer
Bracket Fender
28
Bolt Bolt
Washer Washer
Bracket
Bolt, sems
Bolt, sems
Nut Step
Bolt, sems
Washer
Step
Bolt, sems Bolt, sems
Pipe Bracket
Fender
25
Bolt
Washer
Fig. 27
Detail Y
Nut
Nut
Washer
Washer
Bolt, sems
Bolt, sems
Plate
Pipe
Bolt, sems
Handrail
36
Washer
Chain Nut
45
Bolt
Bolt, sems
Handrail
44
Bolt, sems
Cover
39
Washer Handrail
35
Bolt, sems
Plate
Fender assembly
37
Nut Step
38 Nut
Washer
Washer
Bolt, sems
Bolt, sems Nut
Plate Chain
Plate Washer 45
Bolt, sems
Bolt, sems
Plate
Handrail
Bolt
Nut
Bolt, sems
Washer
Bracket
Fig. 28
121
122
7-9 Assembly of engine unit
Step 1
d
Notes: c
i) If damaged, repair and/or refinish. Fig. 1
ii) Using guide pins「10」shown on page 51
makes the engine unit easier to install.
Step e
Note:
This step e should be reinstalled when engine unit
assembly has been completed.
Note:
These bolts h will be used to attach the valve
Fig. 2
bracket (See page 171).
Detail A
g
Fig. 3
123
3 1 Place the underside of engine unit 00 on wooden
00
blocks as shown in Fig. 4.
Notes:
Each wooden block must be able to carry at least a
5 000 kg (11 000 lb) load.
124
Step 2
Installation of the handrails, step and fender
2 Parts weight
1 Wire ropes required
Fender 07 weight: 39 kg (86 lb)
Wire rope: 4 pcs. Handrail 08 weight: 12 kg (26 lb)
10 mmø × 3 000 mm (L) Handrail 09 weight: 23 kg (51 lb)
(0.4 inø) (117 in L) Handrail 10 weight: 9 kg (20 lb)
Handrail 12 weight: 14 kg (31 lb)
Handrail 13 weight: 29 kg (64 lb)
3 1 Install handrails 08 , 09 , 10 , 12 , 13 , 14 , 15 , 16 , 20 ,
Handrail 14 weight: 24 kg (53 lb)
21 , 22 , and 23 on the engine unit 00 .
Handrail 15 weight: 14 kg (31 lb)
2 Install fender 07 and step 11 on the engine unit. Handrail 16 weight: 11 kg (24 lb)
Handrail 20 weight: 37 kg (81 lb)
Note: Handrail 21 weight: 14 kg (31 lb)
Bolts are being screwed temporarily into the parts to Handrail 22 weight: 10 kg (22 lb)
be installed. Handrail 23 weight: 5 kg (11 lb)
Step 11 weight: 34 kg (75 lb)
Tightening torque of M12 bolt: 90 N·m
(9 kgf·m/66 lbf·ft)
Width across flats: 19 mm Notes:
i) Apply lubricant to the bolts before installation.
Tightening torque of M16 bolt: 270 N·m
(28 kgf·m/199 lbf·ft) ii) Tighten bolts to the specified torque after first
Width across flats: 24 mm screwing in finger tight.
Detail B
09 12 13
08
22
07 10
20
11
00
21 16
15
14
23
Fig. 5
Detail C
08 10 11 12 13
22 09
07
21 00
14
20
23
16
15
Fig. 6
125
Detail D
126
Assembly of handrails step and fenders
Nut
Washer
Bolt, sems
Pipe
Plate
Bolt, sems
Washer Pipe
Washer
Nut
Washer
Washer
Bolt, sems Bolt
Handrail Bolt, sems
Handrail Fender
22 07 Bolt, sems Step
10 11
Handrail
08
Bolt, sems
Bolt, sems
Handrail
14
Handrail
13
Bolt, sems
Rubber cushion
Fender
Handrail 18
17 Bolt Rubber cushion
Bolt, sems
Bolt, sems
Washer
Bolt, sems
Bolt, sems
Bolt, sems
Plate
Bolt, sems Bolt, sems Bolt, sems Bolt, sems
Nut
Bolt, sems Nut
Washer
Handrail Nut Washer
23
Washer
Bolt, sems
Pipe
Fig. 7
Detail E
Assembly of handrail
Plate
Washer Step
Nut
Bolt, sems
Step
Bolt, sems
Handrail
53
Support
Nut
59 Step
Washer
Bolt, sems
Bolt, sems
Pipe
Handrail
31
Sapport
Bolt, sems
Step
Bolt, sems
Nut
Washer
Bolt, sems
Nut Bolt, sems
Plate Spacer Pipe Pipe
Washer Bracket
Bolt, sems
Bolt, sems
Cover
Rubber
Fig. 8
127
Lift
Step 3
CAUTION! 00
Never allow anybody to stand directly beneath
the lifted engine unit.
Shackle: 4 pcs.
for 5 metric ton (5.5 US ton) load
00
Chain block: 2 pcs.
for 5 metric ton (5.5 US ton) load
Note:
Level the engine unit by adjusting the preset chain
blocks.
Note:
Use guide pins to position the engine unit.
00
Fig. 11
128
Hold
4 1 Connect engine unit 00 to the main frame with
bolts 01 and washers 02 .
Note:
Remove the steps a and b shown below, then
attach bolts 01 . These steps should be reinstalled 00
after tightening bolts 01 as shown in Fig. 14.
2 Tighten the engine unit connecting bolts 01 using
a hydraulic wrench.
CAUTION!
Be careful to avold getting your hand caught by the
reaction force bar on the hydraulic wrench.
Notes:
i) Apply lubricant to the bolts before installation.
ii) Mark the heads of the bolts in their final position
after being completely tightened. Fig. 12
Detail F
Engine Unit 00
01
02
Note:
Be sure to remove the guide pins
if used as outlined on page 123.
Main Frame Fig. 13
Detail G Detail H
Steps
a and b
Hydraulic wrench
Fig. 14 Fig. 15
129
Step 4
Installation of the handrail and step
Detail I
Fuel tank 31
Fig. 16
Detail J
31
Fig. 17
130
Step 5
Installation of the handrail, steps and door
3 1 Install step a .
(This has been disassembled on P123) Notes:
2 Install handrail 58 . i) Apply lubricant to the bolts before installation.
3 Install steps 59 and 60 . ii) Tighten bolts to the specified torque after first
(For the detailed assembly procedure, refer to the screwing in finger tight.
next page.)
4 Install door 03 to the engine unit as shown in Fig
19.
Tightening torque of M14 bolt: 140 N·m Tightening torque of M10 bolt: 50 N·m
(14 kgf·m/103 lbf·ft) (a) (5 kgf·m/37 lbf·ft)
Width across flats: 22 mm Width across flats: 17 mm
Detail K
a 58 60 59
Steps 59 and 60 :
Note:
Bolts are being screwed
temporarily into the parts to be
installed.
Handrail 58 :
Note:
Bolts are being screwed
temporarily into the parts to be
installed.
Fig. 18
Detail L
59
60
Door 03 :
58 03
Note:
Bolts are being screwed
temporarily into the parts to be
installed.
Fig. 19
131
INSTALLATION OF THE STEPS
Notes: Detail M
i) Steps may be already installed on the base
machine. 60
ii) Bolts are being screwed temporarily into the
parts to be installed. 59
Bolt
Step 59 weight: 117 kg (257 lb) Washer
Step 60 weight: 69 kg (152 lb)
Rubber
Tightening torque of M14 bolt: 140 N·m
(14 kgf·m/103 lbf·ft) Spacer
Width across flats: 22 mm
Washer
Note:
59
The step and gauge a may be already installed on
the base machine.
132
Step 6
Installation of the step assembly
Detail O
Lower
00
Fig. 23
Detail P
00
Fig. 24
133
INSTALLATION OF THE STEP ASSEMBLY
Lift Detail Q
4 Slinging step assembly 00 Lift Lift
Protector: 4 pcs.
Detail R
Lift
CAUTION!
Make sure that no one goes directly under the lifting
step assembly 00 . Lower
Detail T Detail S
Hold Hold
Hold
00
00
Fig. 28 Fig. 27
134
Lift
5 Installing step assembly 00
Note:
Apply lubricant to the pins before installation.
01
Fig. 29
Detail U
Notes:
i) Apply lubricant to the bolts before installation.
ii) Tighten all bolts to the specified torque after first Detail V
screwing in finger tight. A
00
B
Step Ass'y 00
Fig. 32
Fig. 31
135
6 Installing the stairway rod a
Detail W
Instoll the rod a
Note:
The measurement of the rod a has been set at the
time of transport, so it can be installed as is.
Fig. 33
Detail X
Tighteming bolt
Rod a
Fig. 34
136
Detail Y
Fig. 35
137
Step 7 Detail A
Note:
Use the tightening pins attached to the fender.
Notes: Detail B
i) Apply a lubricant to the bolts before installing.
ii) After screwing all bolts by hand, tighten them to
the specified torque.
Fig. 37
Notes:
i) Before connecting the electric wires, remove the
anti-corrosive and any rust from the couplers.
ii) Connect couplers with the same marking.
c Fig. 38
138
7-10 Mounting the counterweight & Installation the reserve tank
Step 1 02
Mounting of the counterweight
Note:
Bolts are being screwed temporarily into the parts Fig. 1
to be installed.
Notes:
i) Apply lubricant to the bolts before installation.
ii) Tighten bolts to the specified torque after first
screwing in finger tight.
Shackle: 2 pcs.
Move
for 15 tonne (16.5 US ton) load
Hold
CAUTION!
Do not allow anybody to stand directly beneath
the lifted counterweight.
Rear beam
Fig. 3
139
Hold
5 Connect the counterweight with 6 bolt assemblies 09 ,
incorporating 6 bolts, 6 nuts a , and 12 washers (6
each of b and c ).
Notes:
i) Be sure to apply a suitable lubricant to the bolts
00
before tightening. Use a lubricant made by
mixing a white zinc jelly and spindle oil in a 1:1
proportion.
ii) Apply lubricant to the underside of the bolt head
and screw, marked with *, before insertion, as
illustrated in Fig. 6.
Detail B Detail A
2 Install washers b Washer c
and nuts a to the Bolt 09
underside of the
counterweight.
Notes: 09
i) Install washer b
so that the
grooved side will
face downwards.
Counterwight
ii) Temporarily
Fig. 5
tighten the nuts by Fig. 6
hand.
Detail D Detail C
For washer b ,
Washer b
use the grooved
washer. Note that
the second,
b
ungrooved Grooved
washer should be side
attached to the
bolt before
insertion.
a
Fig. 7
Fig. 8
Detail E
Notes:
i) Apply lubricant to the bolts before installation.
10
ii) Tighten bolts to the specified torque after first
screwing in finger tight. 15 Fig. 9
140
4 Tighten the bolts. Detail F
Note:
Tighten with a power wrench as shown in Fig. 10.
CAUTION!
Fig. 10
Do not let your hand get caught by the reaction
force bar on the power wrench.
5 Mark the heads of the bolts in their final position Remove the
wire ropes
after being completely tightened.
Fig. 11
7 Install brackets 12 and covers 11 with bolts 16 on the
counterweight.
11
Tightening torque of M10 bolt: 50 N·m 16
(5 kgf·m/37 lbf·ft)
Width across flats: 17 mm
Notes: 12
i) Apply lubricant to the bolts before installation.
ii) After screwing in all bolts by hand, tighten them 16
to the specified torque.
Fig. 12
141
Step 2
Fig. 13
Detail H
Hold
3 Hook the wire rope and shackle to reserve tank 00
for suspension, as shown in the photo Fig. 14.
Shackle
Reserve tank 00 weight: 150 kg (330 lb)
CAUTION!
Make sure that no one goes directly under the lifting
reserve tank 00 .
Detail I
Lift
Wire rope
8 mmø ×
4 000 mm
Shackle
00
Fig. 15
142
Lift
2 Installing reserve tank 00 .
Notes:
i) Apply lubricant to the bolts before installation.
ii) Tighten all bolts to the specified torque after first
screwing in finger tight.
Fig. 17
Detail J Detail K
Right-hand reserve tank and handrail installation locations Left-hand reserve tank and handrail installation locations
Reserve tank
mounting bolt
Reserve tank
mounting bolt
Fig. 18 Fig. 19
143
3 Detail L
1 Installing the pipe assembly 42 with bolts 43 .
Notes:
i) Apply lubricant to the bolts before installation.
ii) Tighten bolts to the specified torque after first
screwing in finger tight.
43
Reserve tank Fig. 20
Detail M
2 Connect hoses a ~ d for reserve tank.
Fig. 22
144
4 Installing the hoses for reserve tank 00 .
Detail N
Notes:
i) Connect both hoses so they do not come in
contact with other parts. 28
ii) Make sure that no dust has adhered to the seat Fig. 23
faces of the hoses.
iii) Do not damage the joining surfaces of the Detail O
hoses. 00
iv) Do not twist hoses when connecting them 29 27
together. Their service life will be shortened.
26
28
Fig. 24
Notes:
i) Before connecting the electric wires, remove the
anti-corrosive and any rust from the couplers.
00
ii) Connect couplers of identical marking.
Detail Q
a
b c
Fig. 26
145
6 Installing the bracket 14 with bolts 17 . Detail R
Notes:
i) Apply lubricant to the bolts before installation.
ii) Tighten bolts to the specified torque after first
screwing in finger tight.
Fig. 27
Notes:
i) Apply lubricant to the bolts before installation.
ii) Tighten bolts to the specified torque after first
screwing in finger tight.
Fig. 28
Fig. 29
146
Step 3
2 Parts weight
Installation of the stand, fender steps and handrails.
Stand 05 weight: 75 kg (165 lb)
Step 03 weight: 137 kg (301 lb)
1 Wire ropes required Step 08 weight: 9 kg (20 lb)
Handrail 17 weight: 16 kg (35 lb)
Wire rope: 4 pcs. Handrail 19 weight: 14 kg (31 lb)
10 mmø × 3 000 mm (L) × 2 pcs. Handrail 04 weight: 19 kg (42 lb)
(0.4 inø) (117 in L) Handrail 07 weight: 2 kg (4 lb)
Bracket 06 weight: 16 kg (35 lb)
3 1 Install stand 05 on the counterweight. Fender 18 weight: 24 kg (53 lb)
2 Install bracket 06 on the counterweight.
3 Install steps 03 and 08 on the stand and Notes:
counterweight. i) Apply lubricant to the bolts before installation.
4 Install handrails 17 , 19 , 04 , 07 and fender 18 . ii) Tighten bolts to the specified torque after first
screwing in finger tight.
Tightening torque of M16 bolt: 270 N·m
Detail T
(28 kgf·m/199 lbf·ft)
19
Width across flats: 24 mm 18
03
Tightening torque of M12 bolt: 90 N·m
17
(9 kgf·m/66 lbf·ft)
Width across flats: 19 mm
08
Tightening torque of M12 bolt: 110 N·m
( 08 ) (11 kgf·m/81 lbf·ft) 04
Width across flats: 19 mm
Detail U 07
06
05
Fig. 30
Note:
Bolts are being
screwed temporarily
into the parts to be
installed.
Fig. 31
Detail V
17 18 19
03
08
06
07
04 05
Fig. 32
147
4 Tightening torque of M12 bolt: 90 N·m
1 Install plates a and rubber cushions b to the
(9 kgf·m/66 lbf·ft)
handrails c and d as shown in Fig. 35.
Width across flats: 19 mm
2 Inatall plates e and rubber cushions f to the
handrails g and h as shown in Fig. 36.
Notes:
Note: i) Apply lubricant to the bolts before installation.
Bolts are being screwed temporarily into the parts to ii) Tighten bolts to the specified torque after first
be installed. screwing in finger tight.
Detail W
Fig. 33
Detail Y
h
g
Detail X
c e
f
d Fig. 36
Fig. 34
a
Fig. 35
148
Detail Z
Nut
Bolt, sems
Washer
Step
08 Bolt
Plate
2 places
Bolt, sems
Washer
Nut
Plate
Bolt, sems
2 places
Washer
Nut
Bolt, sems
Handrail
04
Bolt
Nut
Washer
Washer
Bracket
Bolt
06
Washer
Washer
Bolt
09 Bolt, assembly
Nut
Washer
Fig. 37
149
150
7-11 Assembly of air-intake unit / exhaust unit and head lamps, mirror, wroking lamp, etc.
Step 1
Installation of the air-intake unit / Exhaust unit
Note:
Each wooden block must be able to carry at least a
300 kg (660 lb) load.
d
Fig. 2
Note:
Each wooden block must be able to carry at least a
100 kg (220 lb) load.
25
Clamp
e
Cover
Fig. 4
151
5 1 Remove covers a , b , c and d from the engine Detail A
c
cover.
a d
b
Engine cover
Fig. 5
f
Vinyl cover e
Fig. 6
Detail C
3 Remove covers g and h from the inside top of
the engine.
Note: j
The gaskets i , bolts j and nuts k installed on the
covers will be reused to install the tube.
g h
i k
Notes:
i) To install the tube, use the gaskets i bolts j
and nuts k that have been removed in 3 above. j
ii) AApply lubricant to the bolts before installation.
iii) Tighten all bolts to the specified torque after first
screwing them in finger tight. 29 k
i
iv) Use two spanners to lock the double nut.
Fig. 8
152
Lift
6 1 Attach wire ropes, a lever block and shackles to
the eye bolts on exhaust unit 26 .
2 Lift with a crane as shown Fig. 9. Wire rope
8 mmø × 3 000 mm Wire rope
Exhaust unit 26 weight: 570 kg (1 255 lb) 8 mmø × 8 000 mm
Lever block
Wire rope: 5 pcs.
8 mmø × 3 000 mm (L) × 2
(0.3 inø) (117 in L) Wire rope
8 mmø × 8 000 mm (L) × 2 8 mmø × 6 000 mm
(0.3 inø) (312 in L)
8 mmø × 6 000 mm (L) × 2
(0.3 inø) (234 in L)
Shackles
Shackle: 4 pcs.
26
for 0.3 metric ton (0.33 US ton) load
Note:
Level the exhaust unit by adjusting the preset lever
block. 26
CAUTION!
Never allow anybody to stand directly beneath the lifted
exhaust unit.
Note:
Use the tightening bolts attached to the engine unit.
Tightening torque of M12 bolt: 90 N·m
(9 kgf·m/66 lbf·ft) Fig. 10
Width across flats: 19 mm
Notes:
i) Apply lubricant to the bolts before installation.
ii) Tighten all bolts to the specified torque after first
screwing them in finger tight.
3 Connect the exhaust tube a .
Note:
Make sure to fit the gaskets 30 (P/No. 4348847~2)
when installing exhaust unit 26 .
Tightening torque of M10 bolt: 50 N·m
(5 kgf·m/37 lbf·ft)
Width across flats: 17 mm
Detail E
Fig. 11
30
a
Notes:
i) Apply lubricant to the bolts before installation.
ii) Tighten all bolts to the specified torque after first
screwing them in finger tight.
Tube
iii) Use two spanners to lock the double nut.
Fig. 12
153
Lift
8 1 Attach wire ropes, and shackles to the eye bolts
on air-intake unit 25 .
2 Lift with a crane as shown Fig. 13.
Shackle: 2 pcs.
for 0.2 metric ton (0.22 US ton) load
25
Shackles
CAUTION! Fig. 13
25
9 Sling air-intake unit 25 , and lower it slowly onto the
Lower
engine unit (Fig. 14).
Fig. 14
154
Hold
10 1 Assemble two hoses 27 and four clamps 28 on
26
the pipes for exhaust unit 26 , as shown in Fig. 16.
Notes:
i) Apply lubricant to the bolts before installation.
ii) Tighten all bolts to the specified torque after first
screwing them in finger tight.
6 Connect the air-intake piping a . as shown in Fig. 20.
Clamp 28
Tightening torque: 6 N·m
(1 kgf·m/4 lbf·ft) Hose 27 Fig. 16
Width across flats: 11 mm
Detail G
27
Detail H
27
28 Fig. 17
28 Fig. 18
Detail I
Air-intake piping
a
Fig. 19
Fig. 20
155
Detail J
156
Installation of air-intake unit & exhaust device unit
Fig. 21
Step 2 Detail K
Installation of the display
(Front in the cab)
15
Tightening torque of M10 bolt: 50 N·m
(5 kgf·m/37 lbf·ft)
Width across flats: 17 mm
Notes:
i) Bolts are being screwed temporarily into the
parts to be installed. Fig. 23
ii) Apply luburicant to the bolts before installation.
iii) Tighten all the bolts to the specified torque after Detail L
first screwing in finger tight. 15
2 Connect electric wire coupler a and b .
Bolt
Notes:
i) Before connecting the electric wires, remove the
anti-corrosive and any rust from the couplers.
ii) Connect the couplers, matching the labels.
Note: a b
For details, refer to the assembly drawing shown in
Figs. 94 and 95.
Fig. 24
Detail M
15 Display
M&N
Fig. 25
Fig. 22 Detail N
15 Display
Fig. 26
157
158
Step 3 Head lamp at the rear of the cab Head lamp on the fender at Stairway-use switch box
00 14 00 the left side of the cab
Installation of the head lamps, mirror, switch box and work
Switch box c
lamps.
Notes:
1 Cautionary remarks for tightening the bolts
i) Apply lubricant to the bolts before installation.
ii) Tighten bolts to the specified torque after first screwing connector joint a connector joint b
in finger tight.
Fig. 27-a Fig. 27-b
2 Cautionary remarks for connecting the wire harnesses 1 Install head lamp 00 . 1 Install bracket 14 .
i) Before connecting the electric wires, remove the anti- 2 Connector joint a . 2 Install head lamp 00 .
corrosive and any rust from the couplers. 3 Connector joint b . From the base machine
ii) Connect couplers with the same marking.
Detail O
The switch box c is found
inside the base machine. Take
it from the base machine and
install it on the bracket.
07
Fig. 27-c
198
Head lamp at the right rear 01
of the engine unit 04
Fig. 27-k
1 Install mirror 07 on the handrail. The installation
dimension is as shown above. connector joint d
connector joint j
04
Fig. 27-j Fig. 27
connector joint e
1 Connector joint j . (ambient temperature senser)
Fig. 27-e
1 Install bracket 04 .
Working lamp on the handrail at the left side of the cab Working lamp on the stairway
2 Install head lamp 01 .
Head lamp on the stairway
3 Connector joint e .
02
13
Head lamp at the left rear 01
Clamp side of the engine unit 04
04 02
connector joint Clamp
i
connector joint h
connector joint f
159
Step 4
Greasing (1)
Detail P
c
IMPORTANT:
Set the engine to run at neutral or higher speed during
lubrication with the lubrication device.
Detail S
Fig. 31 Fig. 32
161
4 After completing the lubrication Detail T
1 Slightly pull the hose out from the hose reel e .
The lock will be released and the grease hose
automatically withdrawn back onto hose reel e .
e
IMPORTANT:
Before storing, make sure to release any residual Detail U
air in the hose reel by use of the grease gun. This will
prevent damage being done to the pump.
Note:
Leaving the device in a state of manual lubrication a
will cause the automatic lubrication warning lamp
on the cab instrument panel to light up. b
Fig. 34
Step 5
Fig. 36
Fig. 37 Fig. 38
162
7-12 Connection
Step 2 Right rear of the fuel tank Connecting the fuel pipe-use coupling 165
and electric wire
Step 3 Beneath the pump transmission Connecting the suction / return hoses 166
and drain hoses
Step 4 Beneath the fuel cooler and on Connecting the fuel line return hose 167
the fuel tank side
Step 5 A Box on the stairway Connecting the stairway hoses & 168
wire harnesses (1)
B Stairway Connecting the stairway hoses & 169
wire harness (2)
Step 6 Fuel filter (stage 1 filter) at the lower Connecting the fuel filter hoses 170
part of the left step
Step 7 Rear of the oil tank Connecting the return and delivery 171
piping
Step 8 Lower part of the engine Connecting the quick filling system hoses 173
163
Step 1 Detail A
AIR BREATHER
Release of the air pressure
(Top of the oil tank) 1
Cap a
Note:
Use a hexagon wrench to remove the hydraulic oil
tank air breather.
Fig. 2
Tape c
3
Fig. 3
Detail B
Vacuum pump
Oil tank
2 Release the air pressure in the oil tank by using the
quick exhaust valve. To prevent oil leakage, create a
vacuum in the tank using a vacuum pump, as shown in
Fig.4.
Note:
Hoses will be connected to the oil tank in the next
Breather
step. Since the oil tank has been filled with
hydraulic oil before shipment, use a vacuum
device or drain the oil to the hose installing port
level to prevent the oil from gushing out when
connecting the hoses.
Fig. 4
164
Step 2
Connecting the fuel pipe-use coupling and electric wire
(Right rear of the fuel tank)
Notes:
i) Before connecting the electric wires, remove the
anti-corrosive and any rust from the couplers.
Fig. 5
ii) Connect couplers with the same marking.
Detail C
Fuel tank
Insert the bolt
from the top. a
Parallel to
each other
b
Fig. 6-a Fig. 6-b
Front
side
Fuel tank
a
Fig. 6
165
Step 3
Connecting the suction / return hoses and drain hoses.
(Beneath the pump transmission)
D
2 1 Connect the suction hoses c ~ g .
Detail E
h
c 35
i
d
Fig. 9
166
Step 4
Connecting the fuel line return hose
Notes:
(Beneach the fuel cooler and on the fuel tank side)
i) Do not twist hoses when connecting them
together. Their service life will be shortened.
1 1 Connect fuel line hose 37 .
ii) Connect the hoses so they do not make contact
with other parts.
Tightening torque of hose: 210 N·m
(21 kgf·m/155 lbf·ft) iii) Make sure that no dust has adhered to the seat
Width across flats: 14 mm faces of the hoses.
iv) Do not damage the joining surfaces of the hoses.
2 Connect the fuel line hose a .
Detail F
Fig. 10
37
Front
side
Fig. 11
Fig. 12
167
Step 5
Connecting the stairway hoses and wire harnesses
(Stairway system) Notes:
i) Do not twist hoses when connecting them
A Connecting the stairway hoses & wire harnesses (1)
together. Their service life will be shortened.
(Box on the stairway)
ii) Connect the hoses so they do not make contact
Pull out three hoses a , b ( 3 ), c ( 2 ), d ( 1 ) and
with other parts.
wire harnesses e , f , g and h from the base
iii) Make sure that no dust has adhered to the seat
machine and connect them in place.
faces of the hoses.
1 1 Connect hose a . iv) Do not damage the joining surfaces of the hoses.
v) Apply a thin layer of sealant #98D to the O-ring
Tightening torque of hose: 330 N·m before installation.
(34 kgf·m/243 lbf·ft)
Width across flats: 50 mm
Tightening torque of hose: 40 N·m 3 Clean the parts carefully after all oil has
(4 kgf·m/30 lbf·ft) drained out.
Width across flats: 22 mm
Notes:
i) Before connecting the electric wires, remove the
anti-corrosive and any rust from the couplers.
ii) Connect couplers with the same marking.
Detail H
e f
g h
g h
Tag No. 1 2 3 e f
d c b a
Fig. 14
168
B Connecting the stairway hoses & wire harness (2)
(Stairway)
Notes:
i) Connect both hoses so they do not come in
contact with other parts.
ii) Make sure that no dust has adhered to the seat
Fig. 15
faces of the hoses.
iii) Do not damage the joining surfaces of the hoses.
iv) Do not twist hoses when connecting them
together. Their service life will be shortened. Detail I
Notes:
i) Before connecting the electric wires, remove the
anti-corrosive and any rust from the couplers.
ii) Connect couplers with the same marking.
Fig. 16
Detail K Detail J
Connecter joint
c
a
b
Fig. 18 Fig. 17
169
Step 6
Connecting the fuel filter hoses
(Fuel filter (stage 1 filter) at the lower part of the left step)
Notes:
i) Do not twist hoses when connecting them
together. Their service life will be shortened.
ii) Connect the hoses so they do not make contact
with other parts.
iii) Make sure that no dust has adhered to the seat
faces of the hoses.
iv) Do not damage the joining surfaces of the hoses.
Fig. 19
Detail L
26 27
Fuel filter
Fuel filter
Fig. 20
170
Step 7
Connecting the return and delivery piping
(Rear of the oil tank)
3 Connect pipe 40 .
Tightening torque of M20 socket bolt: 400 N·m
(41 kgf·m/295 lbf·ft)
f
Socket size: 17 mm
5 Connect hose f . 40
2 Clean the parts carefully after all oil has drained out.
Fig. 22-a
171
Step 8 Detail N
Connecting the quick filling system hoses
(Lower part of the engine)
95 N·m
(10 kgf·m/70 lbf·ft)
1 1 Connect hoses a and b . a
Notes:
i) Do not twist hoses when connecting them
together. Their service life will be shortened.
ii) Connect the hoses so they do not make contact
with other parts.
iii) Make sure that no dust has adhered to the seat
faces of the hoses.
iv) Do not damage the joining surfaces of the hoses.
v) Apply a thin layer of sealant #98D to the O-ring
before installation.
180 N·m
(18 kgf·m/133 lbf·ft)
c
180 N·m
(18 kgf·m/133 lbf·ft) d (Tag No. 25 )
180 N·m
(18 kgf·m/133 lbf·ft) e (Tag No. 24 )
Fig. 23 Fig. 24
173
2. Connecting the wire harnesses
(Including some hoses)
Step 1 Cab bed interior Connecting the air conditioner hoses 177
Step 2 Cab bed interior Connecting the air conditioner heater 178
hoses, AC motor drive hoses and AC
motor drain hoses.
Step 3 Lower part of the fuel filter (stage 1 Connecting the fuel filter wire harness. 179
filter) at the lower part of the left step
Step 4 Lower part of the pump transmission Connecting the pilot, air deliver
conditioner, pilot delivery hoses and
electric wireing.
1 Lower part of the engine Connecting the pilot, air conditioner 180
delivery, pilot delivery hoses and electric
wire.
3 Front side of the engine Connecting the fuel suction hose and 182
electric wire harness.
5 Tail frame at the lower rear of the engine Connecting the electric wire couplers. 184
Step 5 Cab bed interior Connecting the electric wire couplers. 185
Step 6 Upper right front in the cabbed Connecting the window washer hose. 185
Step 7 Control panel inside the cab bed Connecting the electric instrument box 186
wires and ambient temperature sensor
wires.
175
DRC connector rubber boot handling precautions
Note:
DRC connector rubber boot handling precautions
Note:
When connecting each connector, remove and scrap
the rubber boots fitted during shipment. Use rubber
packing 1 (P/No. 4392230 ~ DRC24), 12 (P/No.
4392229 ~ DRC40), 11 (P/No. 4392228 ~ DRC70).
Note:
Tighten the DRC connector screw to the specified
torque.
Note:
A gap should be provided here after tightening
the screw.
Recommended torque:
=2.82 ± 0.25 [N·m]
=28.8 ± 2.88 [kgf·cm]
=25 ± 2.5 [in·lbs]
Receptacle
Plug
176
Step 1
Connecting the air conditioner hoses.
(Cab bed interior)
Notes:
1 Remove the vinyl covers from the cab side and cab i) Do not twist hoses when connecting them
bed side of the four air conditioner vent duct (inside air together. Their service life will be shortened.
intake duct), totaling eight covers. ii) Connect the hoses so they do not make contact
with other parts.
2 1 Connecting the air conditioner hoses a , b , c ,
iii) Make sure that no dust has adhered to the seat
and d . faces of the hoses.
Notes:
i) Apply lubricant to the bolts before
installation.
ii) Tighten all the bolts to the specified Fig. 2
torque after first screwing in finger
Detail B
tight.
Front side
c
* 50
* 50
a
b
*
*
50
51 Fig. 4-a
50 or 51
Clamping method
*
Fig. 4-b
Fig. 3 Fig. 4
177
Step 2
Connecting the air conditioner hearer hoses, AC motor
drive hoses and AC motor drain hoses Notes:
(Cab bed interior) i) Put number tags on respective ports and hoses.
Connect the hoses, matching the wire numbers.
1 1 Connect the air conditioner heater hoses labeled ii) Do not twist hoses when connecting them
Tag No. 13 and 14 . together. Their service life will be shortened.
iii) Connect the hoses so they do not make contact
Tightening torque of hose: 210 N·m
with other parts.
(21 kgf·m/155 lbf·ft)
Width across flats: 36 mm iv) Make sure that no dust has adhered to the seat
faces of the hoses.
2 Connect the AC motor drive hoses labeled Tag v) Do not damage the joining surfaces of the hoses.
No. 11 and Tag No. 12 .
2 Clean the parts carefully after all oil has drained out.
Fig. 5
Detail C
Tag No. 14
Out
In
Tag No. 14
AC motor AC motor
drive hoses drain hose
178
Step 3
Connecting the fuel filter wire harness
Notes:
i) Before connecting the electric wires, remove the
anti-corrosive and any rust from the couplers.
ii) Connect couplers with the same marking.
Fig. 7
Detail F
Fuel filter
Fig. 8-a
Fig. 8-b
a
a DT4
179
Step 4
Connecting the pilot, air deliver conditioner, pilot delivery
hoses and electric wireing
(Lower part of the pump transmission)
4 Clean the parts carefully after all oil has
1 Connecting the pilot, air conditioner delivery, pilot drained out.
delivery hoses and electric wire.
(Lower part of the engine) 5 Connect electric wire coupler d . (Item 11 : DRC70)
Notes:
i) Do not twist hoses when connecting them
together. Their service life will be shortened.
ii) Connect the hoses so they do not make contact
with other parts.
iii) Make sure that no dust has adhered to the seat Fig. 9
faces of the hoses.
iv) Do not damage the joining surfaces of the hoses.
Detail G
d
Pilot delivery hose a
a Air conditioner
delivery hose Pull out from the engine bed
DRC70 connector
b
b d
c c Electric wiring
Pull out the pilot hose
from the base machine
d
Fig. 10-a
180
2 Connecting the engine electric wires.
(Engine area)
Notes:
i) Before connecting the electric wires, remove the
anti-corrosive and any rust from the couplers.
ii) Connect couplers with the same marking.
I
iii) Do not twist wires when connecting them
together. Their service life will be shortened.
iv) Connect the wires so they do not make contact
with other parts.
Fig. 11
Detail I
For the pre-lube pressure switch
Tag No. 40
Tag No. 42
Tag No. 41
Tag No. 37
Starter-use
lower step
181
3 Connecting the fuel suction hose and oil pan drainhose.
(Front side of the engine)
1 Connect the fuel suction hose a . 3 Connect the oil pan drain hose b (Tag. No. 8 ).
Notes:
i) Do not twist hoses when connecting them
together. Their service life will be shortened.
ii) Connect the hoses so they do not make contact
with other parts.
iii) Make sure that no dust has adhered to the seat
faces of the hoses.
iv) Do not damage the joining surfaces of the hoses.
Fig. 13
Detail K
FUEL PIPING (ENGINE SUCTION HOSE)
b (Tag No. 8 )
a A
Suction hose
from the base machine ENG. Oil pan
VIEW A
Fig. 14
182
4 Connecting the coolant pipes and oil/drain pipes
(Lower side of the engine)
2 Clean the parts carefully after all oil has
1 Connect the 4 hoses a (Tag. No. 4 ), b (Tag. drained out.
No. 5 ), c (Tag. No. 6 ) and d (Tag. No. 7 ).
Put number tags on respective ports and hoses.
Connect the hoses, matcing the wire numbers.
Notes:
i) Do not twist hoses when connecting them
together. Their service life will be shortened.
ii) Connect the hoses so they do not make contact
with other parts.
iii) Make sure that no dust has adhered to the seat
faces of the hoses.
iv) Do not damage the joining surfaces of the hoses. Fig. 15
Detail L
Radiator
outlet pipe
Fig. 16
183
5 Connecting the electric wire couplers.
(Tail frame at the lower rear of the engine)
Notes:
i) Before connecting the electric wires, remove the
anti-corrosive and any rust from the couplers.
ii) Connect couplers with the same marking.
Fig. 17
Detail M
a DT4 a From the engine unit
c
From the base machine
b DT12 (A type)
b
Harness beneath the left-hand frame Fig. 18-a
d
184
Step 5
Connecting the electric wire couplers.
(Cab bed interior)
1 Connect the electric wire harness a .
(Item 11 : DRC70)
Notes:
i) Before connecting the electric wires, remove the
anti-corrosive and any rust from the couplers.
ii) Connect couplers with the same marking.
Fig. 19
Detail N
Window washer piping
a
c
Fig. 20-a O
Pull out from the cab.
11 : DRC70
a
a
SECTION O
Fig. 20
Step 6
Connection the window washer hose
(Upper right front in cab bed) Notes:
i) Connect the hose so it does not make contact
* Connect window washer hose c . with other parts.
ii) Make sure that no dust has adhered to the seat
face of the hose.
185
Step 7
Connecting the electric instrument box wires and ambient Notes:
temperature sensor wires
i) A number tag is put on each port and wires.
(Control panel inside the cab bed)
Connection the wires, matching the wire
1 Connect the electric wire harness a numbers.
ii) Before connecting the electric wires, remove the
2 Connect the 4 electric wire harnesses b
anti-corrosive and any rust from the couplers.
3 Connect the electric wire harnesses c iii) Connect couplers with the same marking.
(Tag. No. 23 ). ( 12 : DRC40 ~ 1pcs.)
Fig. 21
Detail P
DRC70
a a From the cab bed
e
f
g f
g
c DRC40
Tag No. 18
(Tag No. 23 )
Tag No. 17
DRC70 b
Tag No. 16
Tag No. 15
Tag No. 20
Cab harness from the cab d L-shaped
Tag No. 21 connector
Tag No. 15 from the base
Tag No. 22 machine
Tag No. 16
b
Tag No. 17
Tag No. 18
186
Step 8 Detail Q
Photographs of wire harnesses connected inside the cab bed
(inside the cab bed)
Fig. 23
187
7-13 Checking the stop valves and stopcocks
4 and 5.
3 Verify that the heater hose stopcock
under the radiator is open as shown
in Fig. 6.
Fig. 2 Fig. 3
Detail B
Stop Closed
valve
B
A
Fig. 4
Stop valve
Open
Fig. 1
Fig. 5
Detail C
Stopcock
Open
Fig. 6
189
2 Open the stopcocks.
The stopcocks should be opened before heater line.
Detail D
Stop cock
Open
(6 pcs.)
Fig. 8
Fig. 9
Detail E
Open the stopcock b
Fig. 10
190
3 Open the stopcock.
The stopcock should be opened before neater line.
Detail F
Fig. 12
191
4 Open the stopcocks.
The stopcocks should be opened before fuel filter link.
Note:
Shown here is the closed stopcock. Fig. 13
Detail H Detail G
Stopcock
Detail I
Fig. 16
Detail J
192
5 Open the stopcock.
The stopcock should be opened before stairway line.
Note: Fig. 19
Shown here is the closed stopcock.
Detail L Detail K
Stopcock
Fig. 21
Detail M
Fig. 22
Fig. 20
193
194
7-14 Final check of superstructure
Step 1
Checking the fluid levels
Detail A
Note:
The person in charge of assembly must confirm the
check items in this step. Incorrect operation will
damage the equipment.
a
Detail B
CAUTION: b
The machine will be hot immediately after operation.
Allow the machine to cool adequately before checking
the oil levels.
Fig. 2
Detail C
3 Check the oil level c in the engine oil pan.
Refer to the OPERATION MANUAL for details.
CAUTION:
The machine will be hot immediately after operation.
Allow the machine to cool adequately before checking
the oil levels.
Detail D
IMPORTANT:
Never stand in front of the final drives when doing this
work.
Loosen the plug by 2 to 3 turns to allow any residual d
pressure in the travel device to escape, before fully
removing the plug.
If the plug is removed without letting residual pressure
escape, the plug and gear oil may gush from the
machine, causing injury. Do not stand or place your Fig. 4
195
5 1 Turn key switch to the on position. Detail E
CAUTION!
Handle fuel carefully. Shut the engine off before
fueling. Do not smoke while you fill the fuel tank or
work on the fuel system.
Detail G Detail F
Fig. 7 a Fig. 6
Detail H
Fig. 8
Detail I
CAUTION:
Fig. 9
The machine will be hot immediately after operation.
Allow the machine to cool adequately before checking
the oil levels.
196
Note: Detail J
The person in charge of assembly must confirm the
check items in this step. Incorrect operation will
damage the equipment.
Fig. 10
Note: Detail K
Release the air from the main pump at the same
time you add hydraulic oil. (See page 136 for air
release procedure.)
Check that the level of oil in
the hydraulic tank is above
the range indicated in the oil
level gauge.
Fig. 11
Step 2
Note:
Reconnect the battery earth (−) removed at the
beginning of the work.
Connect
00
Fig. 13
197
2 Set the battery switch to "ON" (Figs. 13, 14 and 15).
Fig. 14
Detail M
Fig. 15
Detail N
ON
Fig. 16
198
Swing motors
Step 3
Checking the swing motors
Note:
Be sure that the person in charge of assembly
confirms the check items in this step. Incorrect
operation will damage equipment.
Fig. 17
Detail O
Front side
swing motor
Rear side
swing motor
Fig. 18
Detail P
a
Fig. 20
2 Check that all the tightening bolts of the superstructure
are securely tightened.
Fig. 21
Detail Q
Fig. 22
199
Step 4
Remove the plate locking the arm of the quick filling system
(Quick filling system option)
Fig. 23
Detail R
Fig. 24
Detail S
Plate
Fig. 25
Fig. 26
200
7-15 Releasing air from main pumps
Detail B
CAUTION!
This operation must be done slowly. Avoid abrupt
operation!
b
2 Check the hydraulic oil tank gauge c . Add oil if
necessary.
Fig. 3
Detail D Detail C
c Level check
Fig. 5 Fig. 4
201
202
7-16 Trial operation of superstructure
FRONT
CAUTION!
This operation must be done slowly. Avoid abrupt
operation!
Fig. 2
CAUTION!
Make sure nobody other than the operator is in the
hydraulic excavator before starting the operation.
Fig. 4
203
204
7-17 Disassembly procedures for shipment
205
206
Detail A
1. Procedure, engine
Fig. 1
EX2500-6 Procedure, engine 9289557
207
Detail B
Fig. 2
EX2500-6 Procedure, frame 9289551 1/2
209
Detail C
oil tank
Fig. 3
EX2500-6 Procedure, frame 9289551 2/2
211
Detail D
3. Procedure, tank
Fig. 4
EX2500-6 Procedure, tank 9274308
213
Detail E
4. Procedure, weight
Fig. 5
EX2500-6 Procedure, weight 9289591
215
Detail F
5. Procedure, step
1 2 3
1 2 3
With mounting
bolt
Fig. 6
EX2500-6 Procedure, step 9289600
217
Detail G
219
220
7-18 Assembly of option parts
221
1. Kit, GPS parts (9289888)
00 4635318 Controller 1
01 4654204 Bracket 1
02 J680612 Screw, sems 4
03 J260814 Bolt, sems 2
05 4441588 Antenna 1
06 4441572 Connector 1
07 J460316 Screw, sems 4
08 4457076 Cable 1
222
1. Kit, GPS parts (9289888)
Detail A
223
2. Procedure, monitor (9289508)
00 4660608 Camera 4
01 4679750 Monitor 2
03 8077959 Bracket 1
04 8077961 Bracket 1
05 3091772 Bracket 2
07 4659177 Bracket 4
09 4680002 Wire harness 1
10 4680002 Wire harness 1
11 4670759 Wire harness 1
12 4670760 Wire harness 1
14 ─── Manual 1
16 4055312 Clip band 1
17 4121859 Clip band 1
225
226
2. Procedure, monitor (9289508)
Detail B
227
3. Monitor (9288761)
04 4679750 Monitor 2
08 8077961 Bracket 1
09 8077959 Bracket 1
10 J271030 Bolt, sems 8
11 4660608 Camera 4
12 4659177 Bracket 4
13 J460512 Screw, sems 22
15 8112271 Bracket 1
16 J271045 Bolt, sems 2
17 4190124 Clamp, pipe 2
19 3091772 Bracket 2
20 J271230 Bolt, sems 4
22 J281020 Bolt, sems 2
23 4146559 Bushing, rubber 2
25 4055312 Clip, band 20
26 4121859 Clip, band 20
27 4190261 Clip 43
28 4192018 Clip 13
29 4190277 Clip 14
30 4190263 Clip 3
31 4190273 Clip 4
35 J271025 Bolt, sems 72
37 4680002 Harness, wire 2
38 4670759 Harness, wire 1
39 3670760 Harness, wire 1
41 4679994 Procedure 2
43 J222006 Washer 12
44 A590105 Washer, plane 12
47 J271020 Bolt, sems 3
229
230
3. Monitor (9288761)
Detail C
231
EX2500-6 Assembly Manual
ATTACHMENT
8. Mounting procedures for loader front-end attachment
8-1 Preparation
Fig. 1
Step 1
Parts required
Procedure for loader front (9154908) 1/2
00 ─── LOADER 1
07 4433056 HOSE 11
08 4357729 HOSE 2
09 4357730 HOSE 2
10 4180363 HOSE 2
11 4357725 HOSE 2
12 4357726 HOSE 2
13 4180360 HOSE 2
14 4357723 HOSE 2
16 4358925 HOSE 1
17 4358924 HOSE 1
20 ─── CLAMP ASS'Y 2
235
2/2
00 ─── BUCKET 1
04 4487594 O-RING 2
236
Detail A'
Step 2 Bracket
Note:
Each wooden block must be able to carry at least
800
8 000 kg (17 600 lb).
a
800 900
2 Clean the pin holes a on the boom foot indicated
by . Fig. 2
3 Clean the pins b (located on both sides of boom) Detail A
on the boom top.
4 Extract the pins b on the boom top.
Bracket
Fig. 2-b
237
2 Preparation of arm cylinder.
Detail B
Lever block
1 Use a lever block and wire ropes on the rod ends
of arm cylinder 23 so that they do not extend.
(Figs. 3 and 4)
a
Note:
In particular, the area surrounding the bearing
should be carefully cleaned.
Fig. 4
Arm cylinder 23
1 Have a pallet ready and place wooden blocks e Lower
and d on it.
Note: Hold
Each wooden block must be able to carry at least
1 500 kg (3 300 lb).
Note:
Firmly secure the wooden blocks to prevent the level Wooden block d
cylinder from toppling over. 23
Wooden block e
Fig. 7
238
4 Moving the arm cylinder.
23
Fig. 8
23
Fig. 9
2 Install arm cylinder 23 so that its pin hole a is
aligned with the pin hole b in the boom.
23
b
Fig. 10
239
5 Install the arm cylinder.
Fig. 11
Shackle: 4 pcs.
for a 1 metric tonne (1.1 US ton) load
240
4 Align pin hole a with pin hole b in order to insert
the pin.
5 Grease the pin before insertion.
6 Tighten the pin with 2 bolts, 2 washers, and 1 plate.
a b
Note:
Apply lubricant to the bolts before installation.
Section E
Bolt &
spring washer
Plate
Pin
Fig. 14
c d
Pallet
7 Secure the arm cylinders under the boom using
wire ropes, shackles and a lever block.
Fig. 15
Wire rope: 2 pcs.
12 mmø × 3 000 mm (L)
(0.5 inø) (117 in L) Detail F
Wire rope
8 Remove wooden blocks c , d and pallet under
the arm cylinder as shown in Fig. 15.
Arm cylinder Fig. 16
241
9 Connect arm cylinder grease hose a (Fig. 17). Detail G
Tightening torque of hose: 30 N·m
(3 kgf·m/22 lbf·ft)
Width across flats: 19 mm
Notes:
i) Do not twist hose when connecting them
together. Their service life will be shortened.
ii) Connect the hose so they do not contact other
a
parts.
iii) Make sure that no dust has adhered to the seat
Fig. 17
faces of the hose.
iv) Do not damage the joining surfaces of the hose.
Fig. 18
242
Step 3 Detail H
22 Wire rope
10 mmø × 3 000 mm
Installation of the boom cylinders
Wire rope
10 mmø × 6 000 mm
1 Preparation of the boom cylinders.
Detail J Hold
Note:
In particular, the area surrounding the bearing
should be carefully cleaned.
Wire rope Wire rope
16 mmø × 12 mmø ×
5 000 mm 3 000 mm
22
Fig. 22
243
3 1 Align the pin holes a and b and insert the pin,
as shown in Fig. 23.
Notes:
i) The pin holes can be aligned by controlling the Lever block
lever block.
ii) Before installing the spacer, make sure that its
a b
chamfered side is aligned facing towards the
cylinder.
iii) Grease the pin before inserting.
Note: Fig. 23
Apply lubricant to the bolts before installing. Detail K cylinder
Tightening torque of M24 bolt: 700 N·m Pin
(71 kgf·m/516 lbf·ft)
Width across flats: 36 mm OUT facing IN facing
side side
Bolt
Spring washer
Plate Spacer
2 Remove the crane wire ropes and chain block Wire rope
12 mmø ×
holding the boom cylinder. 3 000 mm
244
5 1 Connect boom cylinder hoses 10 and 13 .
(both sides)
Notes:
i) Do not twist hoses when connecting them
together. Their service life will be shortened.
ii) Connect the hoses so they do not make contact
with other parts. Fig. 27
iii) Make sure that no dust has adhered to the seat
faces of the hoses.
iv) Do not damage the joining surfaces of the Detail M
hoses. 10 ~2 pcs.
v) Apply a thin layer of sealant #98D to the O-rings
46 (P/No. 4510170~4 pcs.) and 47 (P/No.
4510169~4 pcs.) before installation.
13 ~2 pcs.
Fig. 28
245
6 Connect the grease hoses.
Notes:
i) Do not twist hoses when connecting them
together. Their service life will be shortened.
ii) Connect the hoses so they do not make contact
with other parts.
iii) Make sure that no dust has adhered to the seat
faces of the hoses. Fig. 29
Fig. 30
2 Connect grease pipes 34 (2 pcs.) and 35 (1 pc.).
Clamp
Notes: bolt
i) Make sure that no dust has adhered to the seat
2 pcs.
faces of the pipes.
34
ii) Do not damage the joining surfaces of the pipes.
Fig. 31
246
Step 4
b
2 Clean a and b on the bucket cylinder (L) 25 .
Bucket
cylinder (L) 25
Note:
The left and right sides of the bucket cylinder are not a
of the same shape. Take care when positioning it
beneath the boom.
Fig. 34
Note:
This work is required to align the pin holes of the Detail Q
bucket cylinder. Wire rope
Lever block
Shackle: 1pc.
for a 3 tonne (3.3 US ton) load
Fig. 35
247
Lift
3 Align the pin hole on the rod end of the bucket cylinder
with the boom mounting pin hole, while controlling (A)
(lifted up by the crane) and (B) (held by the lever
block). (A)
(B)
Note: S
Grease the pin before inserting.
Note:
Apply lubricant to the bolts before installing.
Bucket
Plate cylinder
Bolt
Spring washer
Pin
Fig. 38
248
4 1 Remove the blind covers from the pipe ends.
(both sides)
Notes:
i) Do not twist hoses when connecting them
together. Their service life will be shortened. Fig. 40
249
250
8-2 Mounting of loader front Detail A
a
Step 1
a
Mounting of the boom
Fig. 1
Wire rope
32 mmø ×
5 000 mm
Chain block
Chain block
25 ton
25 ton
2 1 Clean the pin holes b in the boom.
Wire rope
2 Put shackles on the eye-plate provided on the Wire rope
32 mmø ×
46 mmø ×
boom, and attach wire ropes and a chain block as 3 000 mm
3 000 mm
illustrated in Fig. 2.
Shackle Shackle
Note:
Level the boom by adjusting the preset chain blocks. 00
CAUTION! b
Never allow anybody to stand directly beneath the lifted
boom.
Shackle: 4 pcs.
for 25 tonne (27.5 US ton) load
251
Lift & move
3 Move the boom to the pin holes a in the main frame.
Cab
Notes:
i) When moving the front attachment, be careful
that it does not touch the cab.
ii) It is safe to attach a rope on the section indicated a
by ★ in order to guide it. ★
Hold
Rope
Rope: 1 pc. 8 mmø × 5 000 mm b
8 mmø × 5 000 mm (L)
(0.3 inø) (195 in L)
Fig. 4
Hold
B
4 1 Align the pin holes a and b in order to insert the
pins.
2 Grease the pins before inserting.
b
a
Notes:
i) The height to the arm end should be about 3 170
mm (124 in). 3170
ii) Align the left pin holes first, then the right pin (124 in)
holes. The right ones should align easily. This
can be done by controlling the chain block. Fig. 5
Notes:
i) A shim is attached to the pin on the base Bolt
machine. Insert this shim as it is. Spring washer
ii) Apply lubricant to the bolts before installation.
Fig. 7
6 Remove the wire ropes and chain blocks lifting the
boom assembly.
252
Step 2
Detail C Detail D
07
07
Notes:
i) Do not twist hoses when connecting them. Their
service life will be shortened.
ii) Connect the hoses so they do not make contact Base
machine side
with other parts.
Fig. 10
iii) Make sure that no dust has adhered to the seat
faces of the hoses.
iv) Do not damage the joining surfaces of the Detail E
Bolt 12 mm
hoses.
v) Apply a thin layer of sealant #98D to the O-ring
46 (P/No. 4510170~22 pcs.) before installation.
Reuse the O-ring which has been fitted on the 20
hoses.
2 After the oil has drained out from the hoses, clean
the parts carefully.
20
Fig. 12
253
Step 3
08
Notes:
i) Do not twist hoses when connecting them. Their
service life will be shortened.
ii) Connect the hoses so they do not make contact
with other parts.
iii) Make sure that no dust has adhered to the seat 11
faces of the hoses.
iv) Do not damage the joining surfaces of the
hoses.
v) Apply a thin layer of sealant #98D to the O-rings
46 (P/No. 4510170~4 pcs.) and 47 (P/No.
Fig. 14
4510169~4 pcs.) before installation. Reuse the
O-ring which has been fitted on the hoses.
Fig. 15
Detail H
2 Remove the stoppers a and b which lock the level
cylinder so it cannot retract. a
b
Fig. 16
254
Step 4
Lever block
a
Fig. 18
Note:
Operate the boom cylinder carefully, an inch at a
time, during this work.
Notes:
Grease each pin before inserting.
a b
Fig. 19
Bolt
Tightening torque of M24 bolt: 700 N·m Spring washer
(71 kgf·m/516 lbf·ft)
Width across flats: 36 mm
Fig. 20
255
Step 5
Detail J Fig. 21
a
16
Boom
Fig. 22
Fig. 23
Notes:
i) Do not twist hose when connecting them
together. Their service life will be shortened.
ii) Connect the hose so they do not make contact
with other parts.
iii) Make sure that no dust has adhered to the seat
faces of the hose.
iv) Do not damage the joining surfaces of the hose.
Notes:
i) Do not twist hoses when connecting them
together. Their service life will be shortened.
ii) Connect the hoses so they do not make contact
with other parts.
iii) Make sure that no dust has adhered to the seat b c
faces of the hoses.
iv) Do not damage the joining surfaces of the Fig. 25
hoses.
256
Step 6
Block
Note:
The boom cylinder should be retracted to the stroke
end.
Arm cylinder
Fig. 27
Shackle
Wire rope
Detail M
2 To align the arm bracket pin holes while extending
the arm cylinder, adjust the lever block vertically, Lever block
as shown.
Bracket
Fig. 29
257
3 1 The pin hole in the arm cylinder cannot be aligned
with that of the arm bracket in its current
condition. Operating the boom cylinder at the
stroke end to retract it further will cause the level
cylinder to retract, sliding the arm inward on the
ground.
CAUTION! Fig. 30
At this time, loosen chain block a , shown in Fig. 30,
as much as possible. Doing this work with the chain
block tightened will cause the chain block or a part
of the chain block assembly to break, potentially
leading to a serious accident.
Note:
Grease the pin before inserting.
Note:
Apply lubricant to the bolts before installing. Detail N
Pin
Notes:
i) Connect the hose so it does not make contact
with other parts.
ii) Make sure that no dust has adhered to the seat
faces of the hose.
iii) Do not damage the joining surfaces of the hose.
b
Fig. 33
4 After the grease has drained out, clean the parts
carefully.
258
Extend
CAUTION! Raise
Do not operate any of the cylinders before attaching
the bucket. If the cylinders are accidentally operated,
the bucket cylinder, suspended by a shackle on the
Retract
arm, may move, potentially resulting in a serious
machine failure or injury. Lower
Fig. 34
CAUTION
Fig. 35
CAUTION
CAUTION!
Never extend or retract the bucket cylinder rod when
removing the eye bolts. The eye bolts will break,
potentially leading to serious damage.
Fig. 36
259
260
8-3 Mounting the bucket
Step 1
Fig. 1
1 740 mm
(68 in)
Fig. 2
Note:
Level the bucket by adjusting the preset chain
blocks.
Wire rope
32 mmø ×
CAUTION! 3 000 mm
Never allow anybody to stand directly beneath the lifted
bucket. Wire rope
32 mmø ×
10 000 mm
Bucket 00 weight: 20 200 kg (44 440 lb)
Chain block
12 ton
Wire rope: 3 pcs.
32 mmø × 10 000 mm (L) : 1 pc.
(1.25 inø) (390 in L)
Wire rope
32 mmø × 3 000 mm (L) : 2 pcs.
32 mmø ×
(1.25 inø) (117 in L) 3 000 mm
Shackle: 2 pcs.
for 12 tonne (13.2 US ton) load
Fig. 3
261
3 Lift the bucket 00 such that pin holes a are kept
level. Lift & move
00
Notes: Lift
i) A shim is attached to the pin on the base
machine. Insert this shim as it is.
ii) Apply grease to the pins before installation.
a
2 Tighten the pins with 4 bolts, 4 spring washers, b
and 2 plates.
Note:
Apply lubricant to the bolts before installation.
B
Tightening torque of M20 bolt: 400 N·m Fig. 5
(41 kgf·m/295 lbf·ft)
Width across flats: 30 mm Section B
Note:
Carefully seat 2 O-rings 04 on the boss arm and 04
bucket as shown in Figs. 7 and 7-a. Fig. 6
Note:
To ease the assembly, the bolt has been made
slightly long. After assembly, cut the bolt to ☆ 10 ~
20 mm for usage.
(Bolt size: M5) Fig. 7
☆ 10 ~ 20 Slit ☆ 10 ~ 20
Hold
Double nut Double nut
04
Assemble so that no
gap is provided here. Fig. 7-a
Fig. 8
262
CAUTION
CAUTION!
Never extend or retract the bucket cylinder rod
when removing the eye bolts. The eye bolts will
break, leading to serious damage.
Fig. 9
Fig. 10
263
Step 2
Extend the bucket cylinders to align the pin holes with the Chain block
bucket pin holes in order to insert the pins
Bucket cylinder
1 Extend the bucket cylinders in the direction of the arrow
to align the centers of the bucket cylinder lower pin
holes a and the bucket pin holes b , as shown in Fig.
11.
a Fig. 11
Note: b
Align the pin holes by operating the chain block Detail D
supporting the bucket cylinder.
Bucket
cylinder
Bucket cylinder
Fig. 13
a b
3 1 Secure the pins with 4 bolts, 4 spring washers,
and 1 stopper.
Note:
Apply lubricant to the bolts before installation
Section E
Plate
Pin
Bolt
spring
washer
264
Step 3
CAUTION:
Perform operation after releasing the high pressure
from the pressure-release parts that have been
installed as outlined on page 246.
Notes:
i) Do not twist hoses when connecting them. Their
service life will be shortened.
ii) Connect the hoses so they do not make contact
with other parts.
iii) Make sure that no dust has adhered to the seat
faces of the hoses. Fig. 17
iv) Do not damage the joining surfaces of the
hoses.
Detail G
v) Apply a thin layer of sealant #98D to the O-ring
47 (P/No. 4510169~4 pcs.) before installation.
Reuse the O-ring originally fitted to the hoses.
2 After the oil has drained out, clean the parts carefully.
265
Step 4 Detail I
Greasing (2)
IMPORTANT: Detail K
Set the engine to run at neutral or higher speed during
lubrication with the lubrication device.
e
Notes:
i) Increase the engine speed to higher than neutral
when using the lubrication device.
ii) If the optional automatic lubrication system is not
provided, use a standard air grill gun to manually
lubricate the front pins.
iii) Insufficient lubrication may cause the pins to
wear.
Fig. 23
Detail L Detail M
f
Fig. 24 g
Fig. 25
266
3 Apply grease to the 6 locations a shown in Figs.
27 and 27-a.
Notes:
i) Increase the engine speed to higher than neutral
when using the lubrication device.
ii) If the optional automatic lubrication system is not
provided, use a standard air grill gun to manually
lubricate the front pins.
iii) Insufficient lubrication may cause the pins to
wear.
Fig. 26
Detail N
Notes:
i) Increase the engine speed to higher than neutral
when using the lubrication device.
ii) If the optional automatic lubrication system is not
provided, use a standard air grill gun to manually
lubricate the front pins.
iii) Insufficient lubrication may cause the pins to
wear.
Fig. 28
Detail O
267
4 After completing the lubrication Detail P
IMPORTANT:
Before storing, make sure to release any residual air in
Fig. 30
the hose reel by way of the grease gun d . This will
prevent damage being done to the pump.
Detail Q
Note:
Leaving the device in the manual lubrication
setting will cause the automatic lubrication warning
lamp on the cab instrument panel to light up. a
Fig. 31
268
Step 5
Air bleeding for boom, arm, dump and bucket cylinder Raise
Extend
Tilt-in
1 1 Start the engine. Open
CAUTION!
Be sure that nobody other than the operator is in or on Close Retract Lower
the hydraulic excavator. Tilt-out
Note:
The engine speed should be kept as low as
possible.
PROCEDURE
Action
Note:
Run the engine at low speed.
Notes:
i) Avoid moving the cylinder suddenly or quickly,
or the seals may be burnt.
ii) Stop the cylinder 100 mm before the cylinder
rod hits the stroke end during the first four
cycles.
iii) Move the cylinder at full stroke on the fifth cycle.
Bleeding Locations & Cylinder Positions for Bleeding Air (Refer to Fig. 33 on next page.)
269
2 Bleeding locations.
CAUTION!
Take all reasonable precautions because this work is to be conducted high above the ground.
CAUTION!
Take care to prevent anybody from starting the engine during the work.
3 Follow the procedures outlined below to release air from the cylinders from each of the bleeders
indicated by .
Fig. 33
Detail R
Fig. 34
Detail S
Level check
3 Recheck the oil level in the hydraulic tank.
If the oil level is low, refill the tank.
Fig. 35
270
8-4 Adjustment of track link tension
Note:
The inside of the adjuster cylinder is under high
pressure. Loosening valve a excessively or
suddenly is dangerous, because it may cause the
grease to gush out. Keep your face away from valve
a and loosen the valve little by little. Never loosen
grease fitting b .
Fig. 1
1 Drain out the grease by loosening valve a
gradually, the track link will be loosened.
Detail B
Grease outlet
CAUTION
a Never touch valve b
b
Fig. 3
Fig. 4
271
4 Tensioning the track link.
Fig. 6
Wooden block: 2 pcs.
Size: 500 mm (L)× 1 000 mm (W) × 1 000 mm (H)
Detail E
(20 in) (40 in) (40 in)
Fig. 7
Detail F
Grease outlet
CAUTION
a Never touch valve b
b
Fig. 8
272
8-5 Final trial operation check
CAUTION!
Before starting the excavator, make sure there is no
person other than the operator in the machine.
Note:
After the above procedures are completed, work at
60% to 70% power for the first 50 hours of
operation, and then begin full-power operation.
Forward Reverse
travel travel
R Swing
Swing
Forward Reverse
travel travel
Fig. 2
Raise
Extend
Tilt-in
Open
Close Lower
Retract
Tilt-out
Fig. 3
273
8-6 Disassembly procedures for shipment
274
Detail A
Procedure for
Fig. 1
EX2500-6 loader front 9154908
275
Detail B
Procedure for
Fig. 2
EX2500-6 loader bucket 9207467
277
EX2500-6 Assembly Manual
ATTACHMENT
8'. Mounting procedures for backhoe front-end attachment
8'-1 Preparation
Fig. 1
Step 1
Parts required
PROCEDURE, BOOM (9205595)
Item Part No. Part name Q'ty Remarks
00 ─── BUCKET 1
281
Step 2 Detail A' Detail A
0 10
Installation of the boom cylinders 50 00
Fig. 2
3 Clean boom top pin holes b .
b
Wire rope: 4 pcs. a
10 mmø × 3 000 mm (L) : 2 pcs.
(0.4 inø) (117 in L)
10 mmø × 6 000 mm (L) : 2 pcs. Lever block
(0.4 inø) (234 in L)
Fig. 3
Wire rope
2 Clean pin holes a and b in the boom cylinders.
282
3 Lifting the boom cylinder. Detail D Hold
Hold
11
Fig. 6
283
Hold
4 1 Align the pin holes a and b and insert the pin,
as shown in Fig. 7.
Notes:
i) The pin holes can be aligned by controlling the Lever block
lever block.
ii) Before installing the spacer, make sure that its
chamfered side is aligned facing towards the
cylinder.
iii) Grease the pin before inserting. a b
Note: Fig. 7
Apply lubricant to the bolts before installing. Detail E
Spacer
Tightening torque of M24 bolt: 700 N·m
(71 kgf·m/516 lbf·ft)
Width across flats: 36 mm
Pin
Bolt &
Sprig washer
Fig. 8
Hold
284
6 1 Connect boom cylinder hoses 13 and 14 .
(both sides)
Notes:
i) Do not twist hoses when connecting them
together. Their service life will be shortened.
ii) Connect the hoses so they do not make contact
with other parts. Fig. 11
iii) Make sure that no dust has adhered to the seat
faces of the hoses.
iv) Do not damage the joining surfaces of the Detail G
hoses.
v) Apply a thin layer of sealant #98D to the O-rings
16 (P/No. 4510170~8 pcs.) and 17 (P/No.
4510169~8 pcs.) before installation. Reuse the
O-ring originally fitted to the hoses.
14 ~ 2 pccs.
Fig. 12
285
7 Connect bucket cylinder hoses 02 and 03 (both sides).
02
Tightening torque of M20 socket bolt: 400 N·m 03
(hose 02 ) (41 kgf·m/295 lbf·ft)
Socket size: 17 mm
Fig. 14
286
8 1 Installing the air-release parts.
Arm cylinder
CAUTION:
After connecting the hoses, install the pressure-release
parts described on pages 14 to 16. These parts must
be installed since this area will be highly pressurized.
Use them to release the pressure during installation,
ensuring safe operation.
Fig. 15
Install pressure-
release parts here.
Detail I
Wire rope
Wire rope: 4 pcs.
Lever block
10 mmø × 5 000 mm (L)
(0.4 inø) (195 in L)
CAUTION:
Securing this wire rope and lever block in place
prevents the cylinder rods from being stretched. Be
sure to secure them, otherwise the cylinder may be
stretched suddenly, causing a serious accident.
Fig. 16
Note:
The lever block secures the arm cylinders and
prevents the cylinder rod from extending during the
work.
287
Step 3
Note:
Fig. 17
Each wooden block must be able to carry a load of
at least 5 000 kg (11 000 lb).
Fig. 18
Bucket cylinder
CAUTION: Detail J
Securing this wire rope and lever block in place Wire rope
Lever block
prevents the cylinder rods from being stretched. Be
sure to secure them, otherwise the cylinder may be Wire rope
stretched suddenly, causing a serious accident.
Note:
The lever block secures the bucket cylinders and
prevents the cylinder rod from extending during the
work.
Fig. 20
288
Step 4 c
b
Preparation of the bucket
1 1 Position bucket 00 .
2 Remove the 2 cover a , as shown in Fig. 22. 00
3 Extract pins b from the bucket.
4 Clean pin holes c and pins b .
Fig. 21
View K
00
Pin b
Cover a
Fig. 22
View L
2 Set link pin d and bucket pin e , removed from the Pin d
arm end as outlined on the previous page, as shown in
Fig. 23.
Pin e
Fig. 23
View M
Apply grease
f
3 Apply grease to bucket pin holes f and g and the g
connecting surfaces of the arm end (a total of 8 Apply grease
locations).
Fig. 24
289
290
8'-2 Mounting of boom Detail A
a
Step 1
a
Mounting of the boom
Chain block
20 tonne
Fig. 2-a
2 1 Clean boom pin holes b . Wire rope
28 mmø ×
2 Put shackles on the eye-plate provided on the 3 000 mm
boom 00 , and attach wire ropes, shackles and a Shackle
chain block as illustrated in Fig. 2. Shackle
Eye plate
Shackle: 3 pcs.
Lift Fig. 2
for 15 tonne (16.5 US ton) load
b
Chain block: 1 pc.
for 20 tonne (22.0 US ton) load
Note:
Level the boom by adjusting the preset chain blocks
b
and wire ropes (36 mmø).
CAUTION!
Never allow anybody to stand directly beneath the lifted
boom.
291
3 Move the boom to the pin holes a in the main frame.
Lift & move
Notes:
i) When moving the front attachment, be careful Cab
that it does not touch the cab.
ii) In interests of safety, a rope can be attached to
the section indicated by ★ in order to guide it to b a
the boom.
★
Rope: 1 pc.
10 mmø × 5 000 mm (L)
(0.4 inø) (195 in L)
Rope
10 mmø × 5 000 mm
Fig. 4
Lift
4 1 Align the pin holes a and b in order to insert the
pins.
2 Grease the pins before inserting.
Notes: B
i) The height to the arm end should be about
3 000 mm (117 in). b
a
ii) Align the left pin holes first, then the right pin
holes. The right holes should align easily.
Perform the alignment with use of the chain
block.
3 000 mm
(117 in)
3 Tighten the pins with a total of 4 bolts, 4 spring
washers, and 2 plates. Fig. 5
Notes:
i) A shim is attached to the pin on the base
machine. Insert this shim as it is.
ii) Apply lubricant to the bolts before installation.
Section B
Plate
Pin
Shim Fig. 6
292
5 1 Place 1 wooden block a , about 200 mm (8 in) in
height, on the ground to support the boom top.
Lower
Wooden block : 1 pc.
Size: 2 600 mm (L) × 300 mm (W) × 200 mm (H)
(100 in) (12 in) (8 in)
Fig. 7
Wooden
200 mm (8 in) block a
Fig. 8
293
Step 2
Note: Hoses 02
Fig. 9
Detail D Detail E
02
02
Connected in
Connected in
a later step.
a later step.
Boom side Fig. 10 Base machine side Fig. 11
Notes:
i) When connecting the hoses, do not twist them,
or their service life will be shortened.
ii) Connect the hoses so they do not make contact
with other parts.
iii) Make sure that no dust has adhered to the seat
faces of the hoses.
iv) Be careful not to damage the joining surfaces of
the hoses.
v) Apply a thin layer of sealant #98D to O-rings 09
(P/No. 4292385~18 pcs.) before installation.
2 After the oil has drained from the hoses, clean all
surrounding parts carefully.
294
Step 3
Fig. 12
Lever block
a Fig. 13
Note:
Operate the boom cylinder carefully, an inch at a
time, when aligning the pin holes.
Lever block
b
a Fig. 14
Fig. 15
295
3 1 Align pin holes a and b and insert the pins.
Note:
Grease each pin before inserting. a
b
Note:
Apply lubricant to the bolts before installation.
a b
Fig. 17
Section F
Plate
Bolt
Spring washer
Pin Fig. 18
296
Step 4
Notes:
i) When connecting the hoses, do not twist them,
or their service life will be shortened.
ii) Connect the hoses so as not to make contact
with other parts.
iii) Make sure that no dust has adhered to the seat
Fig. 19
faces of the hoses.
iv) Be careful not to damage the joining surfaces of
the hoses.
Detail G
Tightening torque of hose: 30 N·m
(3 kgf·m/22 lbf·ft)
Width across flats: 19 mm
Notes:
i) When connecting the hose, do not twist it, or its
service life will be shortened.
ii) Connect the hose so as not to make contact with
other parts.
iii) Make sure that no dust has adhered to the seat
faces of the hose.
iv) Be careful not to damage the joining surfaces of
the hose.
Detail H
Detail I
d c
08
c Boom
08
Fig. 22
Fig. 23
297
3 1 Remove the lever block used to fix the arm Detail J Wire rope
cylinders in "Step 2- 8 " on page 287. Lever block
a Wire
Fig. 24
298
Step 5
Greasing (2)
Detail K
IMPORTANT:
Set the engine to run at neutral or higher speed
during lubrication with the lubrication device. Fig. 26
e
CAUTION!
i) Increase the engine speed to higher than neutral d
when using the lubrication device.
ii) If the optional automatic lubrication system is not
fitted, use a standard air grill gun to manually
lubricate the front pins. Fig. 27
iii) Insufficient lubrication may cause the pins to wear.
Sufficiently lubricate the necessary locations.
Detail N
f g
Fig. 28 Fig. 29
299
4 Supply grease to the 6 locations a shown in Figs. 30,
31 and 31-a.
CAUTION!
i) Increase the engine speed to higher than neutral
when using the lubrication device.
ii) If the optional automatic lubrication system is not
fitted, use a standard air grill gun to manually
lubricate the front pins.
iii) Insufficient lubrication may cause the pins to wear.
Sufficiently lubricate the necessary locations. Detail O
Detail P
Fig. 30
Fig. 31
300
Step 6
Raise
Air bleeding of the boom and arm cylinders
Boom cylinder
1 1 Start the engine.
CAUTION:
Before starting the engine, make sure that no person
Lower
other than the operator is in the hydraulic excavator.
4 Operate each cylinder a few times to bleed the air Arm cylinder
from the hydraulic circuit. Follow the procedure
t
below. ou
oll-
R
in
ll-
Note: Ro
Reduce the engine speed as low as
possible during the bleeding procedure.
Procedure:
Fig. 33
Order of items
Notes:
i) Avoid moving the cylinders suddenly or quickly,
as it can cause the seals to burn.
ii) Stop the cylinder 100 mm before the cylinder rod
hits the stroke end, for the first four times.
iii) Move the cylinder in full stroke on the fifth
repitition.
Breather Locations & Cylinder Positions for Bleeding Air (Refer to Fig. 27 on page 320.)
Detail Q
2 Recheck the oil level in the hydraulic tank. If there is
insufficient oil, refill the tank through the oil filter port.
Level check
Fig. 34
301
302
8'-3 Installation of arm
Step 1
3 020 mm
2 Apply grease to pin holes a , b and c . (118 in)
2 500 mm
3 Put shackles on the eye-plates provided for lifting arm (98 in)
00 , and attach chain blocks and wire ropes to the
shackles as shown in Fig. 3.
Fig. 2
Arm 00 weight: 16 100 kg (35 420 lb) Detail A
Wire rope
Wire rope: 4 pcs. 24 mmø × 2 000 mm
38 mmø × 6 000 mm (L) : 1 pc.
(1.5 inø) (234 in L) Chain block 10 t
24 mmø × 2 000 mm (L) : 2 pcs. Wire rope
38 mmø × 6 000 mm
(0.95 inø) (78 in L) Wire rope
24 mmø × 2 000 mm
Shackle
Chain block: 1 pc.
for 10 tonne (11 US ton) load 00
Shackle: 2 pcs.
for 10 tonne (11 US ton) load
Fig. 3
CAUTION:
Never allow anybody to stand directly beneath the lifted
arm.
c a
Fig. 4
303
5 1 Align the centers of pin holes a and b , and Hold
insert the pins.
Notes:
i) Use the scaffolding when aligning pin holes a
and b .
ii) All following work involving parts a and b
should be done using the scaffolding.
CAUTION: a b
Be especially aware of safety measures as the work is Scaffolding
done at a height.
Fig. 5
Pin
Plate
Fig. 6
Note:
Apply lubricant to the bolts before installing.
Lower
Tightening torque of M20 bolt: 400 N·m
(41 kgf·m/295 lbf·ft)
Width across flats: 30 mm
Wooden block
6 1 Place a wooden block on the ground underneath
the arm top. Fig. 7
200 mm (8 in)
Fig. 8
304
Step 2 Detail C Lift
Installation of the arm cylinders
Arm cylinder Lift
Fig. 9
2 Marginally lift the arm cylinders with the crane.
b
3 Install the 2 arm cylinders, one at a time.
Notes: b
i) Place 2 spacers at the eye end of the cylinder
rod of the arm cylinder (see Fig. 12).
ii) If there is a gap between the cylinder rod and
a
arm, insert shim(s).
Section D
Pin
Bolt Fig. 11
Spring
Washer
Hold
Hold
Shim
Spacer
Plate
Fig. 12
a b
6 Tighten the 2 pins with 4 bolts, 4 spring washers,
and 2 plates.
Note:
Apply lubricant to the bolts before tightening.
305
Detail E
CAUTION:
Perform operation after releasing the high pressure
from the pressure-release parts that have been
installed as outlined on page 287.
Notes:
i) When connecting the hoses, do not twist them,
or their service life will be shortened.
ii) Connect the hoses so as not to contact other
parts.
iii) Make sure that no dust has adhered to the seat
faces of the hoses.
iv) Be careful not to damage the joining surfaces of
the hoses.
v) Apply grease to O-rings 17 (P/No. 4292385~4
pcs.) and 18 (P/No. 4292384~4 pcs.) just before
installation. Replace the O-rings attached to the
hoses prior to shipment.
Fig. 15
306
Step 3
Connection of the hoses to base machine and boom (2)
Note:
The 4 bucket hoses not installed on page 288 are
installed in this step.
Note:
Use O-rings 09 , split flanges, and socket bolts to
1 1 Release the pressure in the hydraulic tank.
connect the hoses on the base machine side.
2 Remove the blind covers from the pipe ends on
the base machine and boom. Detail G
Detail F
02
02 02
02 Base machine side Fig. 17
Boom side Fig. 16
Notes:
i) When connecting the hoses, do not twist then, or
02
their service life will be shortened.
Base machine side
ii) Connect the hoses so they do not make contact
with other parts.
Fig. 18
iii) Make sure that no dust has adhered to the seat
faces of the hoses. Detail H
iv) Be careful not to damage the joining surfaces of Bolt 12mm
the hoses.
v) Apply a thin layer of sealant #98D to O-rings 09
(P/No. 4292385~8 pcs.) before installation.
2 After the oil has drained out the hoses, clean all
surrounding parts carefully.
03
03
Fig. 20
307
3 1 Connect grease hoses at location a and b (see
Figs. 21 and 22).
Notes:
i) When connecting hoses, do not twist them, or
their service life will be shortened.
ii) Connect the hoses so as not to contact other
parts.
Fig. 21
iii) Make sure that no dust has adhered to the seat
faces of the hoses.
View J
b
a
Fig. 22
308
4 1 Connect grease hoses at location a and b (see
Figs. 23 and 24). K
Tightening torque of hose: 30 N·m
(3 kgf·m/22 lbf·ft)
Width across flats: 19 mm
Notes:
i) When connecting hoses, do not twist them, or
their service life will be shortened.
ii) Connect the hoses so as not to contact other
parts.
iii) Make sure that no dust has adhered to the seat
faces of the hoses.
View K
Fig. 24
309
5 1 Remove the lever block used to fix the bucket Detail L
cylinders in "Step 3- 3 " on page 288.
Lever block
2 Cut wires a and b used to fasten the bucket
cylinder at the time of shipping (see Fig. 25).
Wire rope
a
b
Wire
Fig. 25
310
Step 4 Detail M
Greasing (3)
Fig. 27
IMPORTANT:
Set the engine to run at neutral or higher speed Detail O
during lubrication with the lubrication device.
CAUTION!
i) Increase the engine speed to higher than neutral
when using the lubrication device.
ii) If the optional automatic lubrication system is not
fitted, use a standard air grill gun to manually
lubricate the front pins. Fig. 28
iii) Insufficient lubrication may cause the pins to wear.
Sufficiently lubricate the necessary locations. Detail P
Fig. 29
311
Step 5
CAUTION:
Make sure that no person other than the operator is in Roll in
the hydraulic excavator during the work.
Fig. 30
4 Operate each cylinder a few times to bleed the air
from the hydraulic circuit. Follow the procedure
below.
Note:
Reduce the engine speed as low as possible
during the bleeding procedure.
Procedure:
Order of items
Notes:
i) Avoid moving the cylinder suddenly or quickly,
as it can cause the seals to burn.
ii) Stop the cylinder 100 mm before the cylinder rod
hits the stroke end, for the first four times.
iii) Move the cylinder at full stroke on the fifth
repitition.
Bleeding Locations & Cylinder Positions for Bleeding Air (Refer to Fig. 27 on page 320.)
Detail Q
2 Recheck the oil level in the hydraulic tank.
If there is insufficient oil, refill the tank through the oil
filler port.
Level check
Fig. 31
312
8'-4 Mounting of bucket
Step 1
b
Mounting of the bucket
c
1 1 Clean pins and pin holes a , b , c and d . d
Detail A Hold
d c
Wire rope: 3 pcs.
24 mmø × 2 000 mm (L) : 2 pcs.
(0.95 inø) (78 in) Shackle
24 mmø × 8 000 mm (L) : 1 pc.
(0.95 inø) (312 in)
3 500 mm
(136 in)
Fig. 3
4 Lift the bucket so that the pin holes c become Lift & move
level with a .
Note: c
Level the bucket by adjusting the preset chain
blocks.
CAUTION!
Never allow anybody to stand directly beneath the lifted a
bucket.
Fig. 4
313
Hold
3 1 Align the centers of pin holes a and c and insert
the pins.
Note:
Grease the pins before inserting.
a
2 Tighten the 2 covers with 24 bolts and 24 spring
c
washers. (both sides)
Note:
Apply lubricant to the bolts before installation.
O-ring 15
Note: Fig. 6
Carefully seat 4 O-rings 15
Fig. 7
on the boss arm and bucket
as shown in Figs. 7 and 7-a.
Remove wire ropes
Note:
To ease the assembly, the bolt has been made
slightly long. After assembly, cut the bolt to ☆ 10 ~
20 mm for usage.
(Bolt size: M5)
Lower
☆ 10 ~ 20 Slit ☆ 10 ~ 20
15
Assemble so that no Fig. 8
gap is provided here. Fig. 7-a
2 Remove the wire ropes and chain blocks used to 120° to 140°
Fig. 9
314
6 Install of the link and bucket.
Note:
Apply lubricant to the bolts before tightening.
Note:
Carefully seat 4 O-rings 16 on the boss arm and
bucket as shown in Figs. 15 and 15-a.
Note:
To ease the assembly, the bolt has been made
slightly long. After assembly, cut the bolt to ☆ 10 ~
20 mm for usage.
(Bolt size: M5)
F
☆ 10 ~ 20 Slit ☆ 10 ~ 20
16
Assemble so that no Section F
gap is provided here. Fig. 15-a
Pin
Bolt
Section G Washer
16
16 O-ring
Fig. 14
Fig. 15
315
7 1 Install joints 04 in the bucket boss side.
2 Connect grease hoses at location a and b (see
Fig. 17).
Notes:
i) When connecting hoses, do not twist them, or
their service life will be shortened.
ii) Connect the hoses so as not to contact other
parts.
iii) Make sure that no dust has adhered to the seat Fig. 16
Detail H
3 After the grease has drained from the hoses,
clean all surrounding parts carefully.
b Joint 04
Fig. 17
〔OPTION PARTS〕
Detail I
4 Install guard 00 with bolt 01 and to the bucket
boss side.
00
01
Fig. 18
316
Step 2 Detail J
Greasing (4)
IMPORTANT:
Fig. 20
Set the engine to run at neutral or higher speed
during lubrication with the lubrication device.
ARM-LINK B (L)
ARM TOP PIN (L)
ARM TOP PIN (R)
ARM-LINK B (R)
Fig. 21-a
Notes:
i) Increase the engine speed to higher than neutral
when using the lubrication device.
e
ii) If the optional automatic lubrication system is not
fitted, use a standard air grill gun to manually
f
lubricate the front pins.
iii) Insufficient lubrication may cause the pins to
wear. Sufficiently lubricate the necessary g
locations.
Fig. 22
317
4 After completing the lubrication Detail M
1 Slightly pull the hose out from the hose reel a .
The lock will be released and the grease hose
automatically withdrawn back onto hose reel a .
2 Remove coupler d from hose c . a
IMPORTANT:
Before storing, make sure to release any residual air in Fig. 23
the hose reel by use of the grease gun b . This will
prevent damage being done to the pump. Detail N
Note:
Leaving the device in a state of manual lubrication
will cause the automatic lubrication warning lamp
c
on the cab instrument panel to light up.
d
Fig. 24
Detail O
318
Step 3
CAUTION:
Roll-out
Before starting, make sure that no person other than
Roll-in
the operator is in the hydraulic excavator.
Note:
Reduce the engine speed as low as possible
during the bleeding procedure.
Procedure:
Order of items
Notes:
i) Avoid moving the cylinder suddenly or quickly,
as it can cause the seals to burn.
ii) Stop the cylinder 100 mm before the cylinder rod
hits the stroke end, for the first four times.
iii) Move the cylinder at full stroke on the fifth
repitition.
Breather Locations & Cylinder Positions for Bleeding Air (Refer to Fig. 27 on page 314)
319
2 Bleeding locations for bleeding air from the cylinders
CAUTION:
As this work is to be conducted at a height, take due safety precautions.
1 Set the front-end attachment on the ground in the position illustrated below (Fig. 27).
CAUTION:
Take care to prevent anybody from starting the engine during the work.
3 Following the procedure outlined below, release the air from the cylinders through the bleeding locations indicated
by in Fig. 25.
1) Remove the rubber cap.
2) Loosen the plug.
3) Air and hydraulic oil will escape together.
4) Continue bleeding until only oil escapes.
5) Tighten the plug securely to its original position.
6) Replace the rubber cap.
Arm cyl.
Arm cyl.
Bucket cyl.
Bucket cyl.
Boom cyl.
Boom cyl.
Fig. 27
Detail P
Level check
Fig. 29
320
8'-5 Adjustment of track link tension
Note:
The inside of the adjuster cylinder is under high
pressure. Loosening valve a excessively or
suddenly is dangerous, because it may cause the
grease to gush out. Keep your face away from valve
a and loosen the valve little by little. Never loosen
grease fitting b .
Fig. 1
1 Drain out the grease by loosening valve a
gradually, the track link will be loosened.
Detail B
Grease outlet
CAUTION
a Never touch valve b
Fig. 3
321
4 Tensioning the track link.
D
3 After feeding grease, race the track link once, and
then measure the amount of tension, L, shown at
Fig. 5
right. c
Fig. 7
Detail F
Grease outlet
CAUTION
a Never touch valve b
Fig. 8
322
8'-6 Final trial operation check
Note:
After the above procedures 1 and 2 are
completed, carry out work at 60% to 70% of full
power for the first 50 operating hours, before
commencing full-power operation.
Forward Reverse
travel travel
R
Swing
Swing
Forward Reverse
travel travel
Fig. 2
Raise
Roll-out
Roll-out Roll-in
Lower
Roll-in
Fig. 3
323
324
8'-7 Assembly of option parts
Detail A
1 Parts reguired
00 8085125 Guard 2
01 J271235 Bolt, aems 8
00
01
Fig. 1
325
8'-8 Disassembly procedures for shipment
326
Detail A
1. Procedure, boom
Fig. 1
EX2500-6 Procedure, boom 9205595
327
Detail B
2. Procedure, arm
Fig. 2
EX2500-6 Procedure, arm 9233042
329
EX2500-6 Assembly Manual
CHECKS
&
PERFORMANCE STANDARDS
CHECKING
9. Checks after completing the assembly
Transmission
Fuel Tank
Check Oil Level
Check Fuel Level
Final Drive
Check Oil Level Engine
(Both sides) Check Oil Level
Fig. 1
Radiator
Check Coolant Level
1 Electrical system
Check for worn or frayed wires and loose
connections.
2 Boom, bucket, arm, frame, and tracks
Check for deformed, broken, or missing parts.
3 Hardware
Check for loose or missing parts.
4 Hydraulic system
Check for leaks, kinked hoses and lines, or hoses
that rub against each other or other parts.
5 Lubrication
Check the lubrication points listed in the
Operation Manual.
6 Protective devices
Check guards and fenders.
7 Check that the parts are correctly reassembled.
8 Apply touch-up paint if necessary, after
completing assembly. Fig. 2
333
3 Check the instruments immediately after starting the
engine.
Detail A
IMPORTANT: MONITOR
DISPLAY
If a gauge does not operate correctly as shown below,
STOP THE ENGINE IMMEDIATELY and take all
necessary measures.
1- Model Name
2- Hydraulic Oil Temperature Gauge
3- Front Type
4- Coolant Temperature Gauge
5- Control Lever Pattern
6- Tachometer
7- Hour Meter
8- Engine Oil Pressure Gauge
9- Engine Oil Temperature Gauge Fig. 3
10- Clock
11- Battery Voltage Gauge
12- Fuel Gauge
Detail B
13- Ambient Temperature
14- Alternator Indicator
15- Engine Stop Indicator
16- Coolant Overheat Indicator
17- Exhaust Temperature Indicator
18- Fuel Temperature Indicator
19- Engine Warning Indicator
20- Prelub Indicator
21- Hydraulic Oil Level Indicator
22- Auto-Lubrication Indicator
23- Hydraulic Oil Overheat Indicator
24- Stairway Position Indicator
25- Fast Filling Indicator
26- Tension Indicator
27- Auto-Idle Indicator
28- Travel Mode Indicator
29- Electric Lever Indicator
30- Emergency Engine Stop Indicator Fig. 4
Fig. 5
334
4 Measurement of engine revolutions
Detail D
Determination
Standard
Item for new
machine
Detail E
Fig. 7
335
NOTES
336
10. Checking machine performance
The figures and tolerances listed below are for new machines.
The measurements should be performed under the following Note:
conditions: Measure each actuator speed after sufficiently operating
・Engine speed: Maximum the machine.
・Hydraulic oil temperature: 50° ± 5°C
・Site: Firm level ground
1 Preparation
Fig. 1 Fig. 2
2 Measurement
Bring machine to rest Test run 20 m Preliminary run Machine at rest Fig. 3
over (65.6 ft) 7~9m
7~9m (23 ~ 30 ft)
(23 ~ 30 ft)
3 Determination
Unit: sec
Item Standard
20m(Low) 45 ± 2
20m(High) 31 ± 2
337
TRACK LINK SPEED FOR 3 FULL TURNS
1 Preparation
90° ~ 110°
90° ~ 110°
Fig. 4 Fig. 5
1 Mark any one of the track shoes on the side where this test is
to be performed.
2 Jack up the track to be tested. (Fig. 10-4 and Fig. 10-5)
2 Measurement
1 Accelerate the engine to maximum speed. Fig. 6
2 Measure the time required to make three full
turns.
3 Repeat this test for both tracks in the forward and
reverse directions.
3 Determination
Unit: sec.
Item Standard
338
SWING SPEED FOR 3 TURNS
1 Preparation
Fig. 7 Fig. 8
2 Measurement
1 Set the swing control lever to full stroke.
2 Measure the time required for three full turns at a
constant speed.
Fig. 9
3 Determination
Unit: sec.
Item Standard
339
AMOUNT OF COAST DURING SWING
1 Preparation
Fig. 10 Fig. 11
2 Measurement
1 Set the swing control lever to full stroke.
Amount of coasting
2 At 180°, return the lever to the neutral position.
3 Measure the amount of coasting.
Swing stop
180° swing
Fig. 12
3 Determination
Unit: mm (in)
Item Standard
Less than
R
Amount of 740 (29.13)
coast
Less than
L
740 (29.13)
340
CYLINDER SPEED (Loader front)
1 Action
Boom cylinder
Fig. 13
Level luffing
Arm cylinder
Fig. 14
Dump cylinder
Bucket cylinder
Fig. 15 Fig. 16
2 Repeat the time measurement at least 3 times for each
item and record the average time.
Note:
For machines with a bucket tilt controller (an option) ,
be sure to turn the bucket control switch to OFF when
measuring the boom raise speed.
3 Determination
Unit: sec.
Item Loader Front
341
CYLINDER SPEED (Backhoe front)
1 Action
Raise
Lower
Fig. 17
Bucket
Roll-out
Bucket
Roll-in Fig. 19
3 Determination
Unit: sec.
Application 9.0 m Boom
Item Backhoe Front
4.2 m Arm
Raise 7.7 ± 0.7
Boom cylinder 15.0 m3 Bucket
Lower 4.7 ± 0.5
342
AMOUNT OF HYDRAULIC CYLINDER CREEP
1 Preparation
2 000 mm 2 000 mm
(80 in) (80 in)
Fig. 20 Fig. 21
B A
Fig. 22
3 Determination
Unit: mm (in)
Item Loader Front Backhoe Front
A−B = Natural lowering
Boom cylinder, mm/5min Less than 30 (1.17) Less than 30 (1.17)
Mark
Mark
B
A
Fig. 23
343
NOTES
344
Head Office: 5-1, Koraku 2-chome, Bunkyo-ku,
Tokyo 112-0004 Japan
Telephone: Tokyo (03) 3830-8050
Facsimile: Tokyo (03) 3830-8202
Printed in Japan KG