Armado de Campo PC600

GEN00101-03
HYDRAULIC PC600 -8E0 PC600LC -8E0

EXCAVATOR PC650 -8E0 PC650LC -8E0
PC700LC -8E0
SERIAL NUMBERS 65001 and up
FOREWORD
Since this machine is large in size, it is divided into some units to meet
the transportation conditions and regulations applied to the transporta-
tion route when shipped from our factory.
This manual describes how to assemble the units into the complete
machine in the field. We hope that this machine will display its quality
and you will use it safely according to the operation manual.
Many units are large in size and heavy in weight and may be handled
in a dangerous place or posture and many workers may have to work
together to sling them with cranes.
Accordingly, before starting the assembly work, the work supervisor is
required to hold a safety meeting to oblige the workers to put on pro-
tective gear and appoint a work leader and a crane work signal man
and allot roles to all the workers for safe work.
In particular, the above meeting is more important when worker of dif-
ferent languages and customs work together.
The following is a reference supervision system diagram.
(Instruction system)
Work leader
Director
Work supervisor Crane director and
deputy director
Operator for assembly

Liaison man
Mechanics Sharing of work

Interpreter
When the work equipment is installed, the engine must be operated.

Accordingly, before installing the work equipment, inspect and main-
tain the machine thoroughly.
Note that this manual does not describe the whole specification of the
machine but describes only the basic specification.
If you have any question when dividing and transporting the machine
by yourself in future, ask one of our distributors.
CONTENTS
SPECIFICATIONS.............................................................................................................. 1
PRECAUTIONS FOR FIELD ASSEMBLY.......................................................................... 3
DISPOSAL OF REMOVED PARTS.................................................................................... 4
ASSEMBLING PROCEDURES, APPLICABLE EQUIPMENT AND SCHEDULE .............. 5
KIT LAYOUT DIAGRAM ..................................................................................................... 6
TRANSPORTATION........................................................................................................... 7
LIST OF TOOLS FOR FIELD ASSEMBLING..................................................................... 12
TIGHTENING TORQUE ..................................................................................................... 13
COATING MATERIALS ...................................................................................................... 18
SELECTION OF WIRE ROPES USED FOR ASSEMBLY ................................................. 20
A. Assembly of Chassis ...................................................................................................... 21

A- 1. Installation of Left and Right Track Frames ........................................................... 22
A- 2. Installation of Travel Pipe ...................................................................................... 27
A- 3. Installation of Operator Cab’s Left Handrail........................................................... 32
A- 4. Installation of Operator Cab's Door Stopper and Striker........................................ 33
A- 5. Installation of Rearview Mirror ............................................................................... 35
A- 6. Installation of Handrail ........................................................................................... 42
A- 7-1. Installation of Step .............................................................................................. 46
A- 7-2. Installation of Step .............................................................................................. 47
A- 8. Installation of Left Side Step .................................................................................. 48
A- 9. Sticking Sheet to Counterweight............................................................................ 49
A-10. Installation of Rear View Camera .......................................................................... 50
A-11. Installation of Counterweight ................................................................................. 55
A-12. Installation of Step Light ........................................................................................ 58
A-13. Bleeding of Air from Travel Motor.......................................................................... 60
A-14-1. Installation of Travel Piping Cover...................................................................... 61
A-14-2. Installation of Travel Piping Cover...................................................................... 65
A-15. Installation of Travel Motor Guard ......................................................................... 68
A-16. Testing Track Shoe Tension.................................................................................. 69
A-17. Check Fuel, Coolant and Oil Levels ...................................................................... 72
B. Assembling of Work Equipment ..................................................................................... 75

B- 1. Assembly of Arm Cylinder ..................................................................................... 76
B- 2. Connection of Arm Cylinder Hoses........................................................................ 77
B- 3. Installation of Boom Cylinder ................................................................................. 78
B- 4. Installation of Boom Cylinder Hoses...................................................................... 79
B- 5. Installation of Boom Foot Dust Seal ...................................................................... 80
B- 6. Assembly of Boom Assembly ................................................................................ 81
B- 7. Installation of Hoses from Chassis Along Top of Boom......................................... 82
B- 8. Connection of Boom Cylinder Head ...................................................................... 84
B- 9. Installation of Arm Assembly ................................................................................. 85
B-10. Installation of Bucket Cylinder Hoses between Boom and Bucket Cylinder.......... 87
B-11. Installation of Bucket ............................................................................................. 88
B-12. Connection of Work Equipment Grease Piping ..................................................... 91
B-13. Connection of Work Equipment Wiring.................................................................. 92
B-14. Greasing after Assembling Work Equipment......................................................... 94
B-15. Bleeding Air from Work Equipment Circuit ............................................................ 95
B-16. Parts to be Touched up After Field Assembly ....................................................... 96
C. Assembling of Work Equipment of Loading Shovel........................................................ 97
C- 1. Releasing residual pressure in hydraulic circuit ..................................................... 98
C- 2. Pulling out boom foot pin and boom cylinder foot pin ............................................ 99
C- 3. Installation of boom cylinder foot............................................................................ 100
C- 4. Installation of boom and arm assembly.................................................................. 101
C- 5. Installation of boom cylinder hoses ........................................................................ 102
C- 6. Installation of boom cylinder rod pin....................................................................... 103
C- 7. Installation of boom cylinder................................................................................... 104
C- 8. Installation of arm cylinder hoses........................................................................... 105
C- 9. Installation of bucket cylinder ................................................................................. 106
C-10. Installation of bucket cylinder hoses ...................................................................... 107
C-11. Installation of connecting hoses between chassis and boom top .......................... 108
C-12. Installation of bottom dump cylinder hoses............................................................ 109
C-13. Installation of bucket assembly .............................................................................. 110
C-14. Installation of working lamps.................................................................................. 112
C-15. Installation of work equipment grease piping......................................................... 114
C-16. Grease after assembling of work equipment ......................................................... 115
C-17. Bleeding air from work equipment circuit ............................................................... 116
C-18. Checking oil level in hydraulic tank and adding oil................................................. 117
D. ASSEMBLING OF COUNTERWEIGHT REMOVER ...................................................... 119

D- 1. Sticking Sheet to Counterweight ............................................................................ 120
D- 2. Adjustment of Shims for Counterweight................................................................. 121
D- 3. Greasing................................................................................................................. 126
D- 4. Installation of Counterweight Remover .................................................................. 127
D- 5. Installation of Covers.............................................................................................. 128
D- 6. Installation of Clamps............................................................................................. 129
D- 7. Installation of Hoses............................................................................................... 132
D- 8. Bleeding Air from Counterweight Remover Circuit................................................. 133
D- 9. Installation of Counterweight.................................................................................. 134
D- 10. Installation of Accessories.................................................................................... 136
D- 11. Check of Operation .............................................................................................. 137
M. Procedure for Inspection and Maintenance after Completion of Assembly.................... 139

M- 1. Inspection of Oil Level in Hydraulic Tank and Refill............................................... 140
M- 2. Replacement of Return Filter (Standard Filter to Flushing Filter) .......................... 142
M- 3. Flushing of Hydraulic Circuit .................................................................................. 143
M- 4. Replacement of Return Filter (Flushing Filter to Standard Filter) .......................... 145
M- 5. Failure code ........................................................................................................... 147
M- 6. Operating Method of Monitoring ............................................................................ 152
Field Assembly Inspection Report (Backhoe)
Field Assembly Inspection Report (Loading Shovel)

SPECIFICATIONS
Machine model PC600-8E0 PC600LC-8E0 PC650-8E0 PC650LC-8E0 PC700LC-8E0
Weight of machine kg 59,200 60,200 60,000 61,000 66,200
Bucket capacity m3 2.7 2.8
Engine model KOMATSU SAA6D140E-5
Flywheel horsepower kW/rpm {HP/rpm} 323/1,800 {43/1,800}
Min. ground clearance mm 780 830
Travel speed (Low/High) km/h 3.0/4.9 2.8/4.6
Swing speed rpm 8.3
PC600-8E0
PC650-8E0
1
PC700LC-8E0
2
PRECAUTIONS FOR FIELD ASSEMBLY
1. Selection of work place
1) When selecting a work place, consider the following.
• Is the work place sufficiently wide for loading and unloading the machine? (See the kit layout draw-
ing.)
• Is the ground sufficiently hard? (The machine and crane truck must not sink into the ground.)
• Is the ground flat? (The ground surface must not be uneven or sloping.)
• Is the road to inlet/outlet of the work place sufficient for turning the trailer and crane truck?
2) Take care extremely that dirt or water will not enter the hydraulic circuit while it is assembled.
3) Avoid working outdoors while strong wind is blowing or it is raining.
4) Take measures to protect the machine from sand, dirt and rainwater while the work is stopped.
2. How to do work
The work supervisor or the work leader should not do the work while reading this manual but should read
and understand this manual thoroughly and then start the work.
In particular, write the "Precautions" for each work process in a sheet to explain or stick that sheet to the
work place so that all the workers will observe the precautions.
3. Preparation and check of protective gear, slings and tools

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

The work supervisor or the work leader must check the following items constantly and make all the workers
observe them.
1) Are the parking brakes of the trailer and crane truck applied securely and are their wheels locked with
chocks during work? Are outriggers, if installed, used securely?
2) Are the temperature and pressure of the engine, hydraulic oil, coolant, etc. lowered sufficiently during
work?
3) Is horn or another signal is made to warn around when the engine is started? In addition, is it checked
that work equipment control lever and other control levers are in neutral and the fuel control dial (or fuel
control lever) is in the low idle position?
4) Is the balance of the slung item checked extremely during sling work with the crane?
5) Is entry prohibition for outsiders to the work place observed?
5. The work supervisor or the work leader is required to hold a meeting with all the workers at the beginning of
every morning and explain the work plan of the day to them and give them instructions to observe the safe
work.
3
DISPOSAL OF REMOVED PARTS
As described in "FOREWORD", when this machine is transported, it is divided into some units such as the body, undercarriage,
cab, work equipment, etc. according to the transportation measure, regulations,etc.
Accordingly, the hydraulic pipings and hydraulic hoses to connect the units, oil inlets and outlets of the hydraulic devices, and
parts which must not be damaged are plugged or covered to prevent oil leakage, entry of dirt and dust, and damage during
transportation.
In addition, fixing jigs are used to prevent a trouble caused by a fall or a shake during transportation and to facilitate loading,
unloading and crane work.
The above plugs, jigs, etc. are removed when the machine is assembled and become unnecessary after completion of the ma-
chine. Since they are useful when the machine needs to be transported in future, however, we recommend you to keep them
as long as possible.
4
Days
Backhoe · Inspection of oil level and

4 Divisions
coolant level
· Air bleeding from work
equipment cylinder
·
Loading shovel- Flushing of hydraulic
Assembly unit Base machine circuit
type excavator
· Adjustment of track
Counterweight tension
Left track frame Upper structure
Platform group · Performance test
Right track frame
Axle assembly
· Inspection of oil Assembling of work
level and coolant level equipment
(Two)
Crane
45t 25t × 2 25t
5
0.49 0.69 MPa
(5 7 kg/cm 2)
Air compressor
15 m3/min
Worker
Leader + 3 mechanics
Start of assembling
Completion of body · Completion of general

Completion of Installation of unit assembly to body
ASSEMBLING PROCEDURES, APPLICABLE EQUIPMENT AND SCHEDULE
· Meeting with all workers assembling assembling

KIT LAYOUT DIAGRAM
The dimensions given below are the minimum dimensions needed.
The kit dimensions in the diagram are outline dimensions.
When selecting a place, see Precautions for Field Assembly.
Bucket
Arm link
Arm cylinder
Tools, facility Boom
Boom
45t crane cylinder
Foreword
Crawler frame
Crawler frame
Revolving
Left deck
frame
Counterweight 25t crane

Motor cover · handrails
6
TRANSPORTATION
Packing Style for Transportation
These machines can be divided into three or four kits for transportation. Please ask us or our service shop for
transportation.
t 3-kit Transportation
(Upper structure + Undercarriage) (Work equipment) (Others)
t 4-kit Transportation
(Upper structure) (Undercarriage) (Work equipment) (Others)
t Packing Style of Each Kit (Sizes in drawing are given in millimeters.)

Upper structure + Undercarriage
PC600LC- PC650LC- PC700LC-

Model PC600-8E0 PC650-8E0
8E0 8E0 8E0
A (mm) 6,270 6,440 6,280 6,450 6,490
B (mm) 3,330 3,330 3,460 3,460 3,665

Shoe width 600 600 600 600 610
(mm)
Overall width 3,190 3,190 3,190 3,190 3,485
(mm)
Weight
(kg) 34,700 35,700 35,000 36,000 40,500
7
Upper structure

Model PC600-8E0 8E0 PC650-8E0 8E0 8E0
Overall width
(mm) 3,170 3,170 3,170 3,170 3,170
Weight 17,200 17,400 17,300 17,400 17,500
(kg)
A (mm) 2,510 2,510 2,630 2,630 2,765
B (mm) 5,064 5,064 5,064 5,064 5,064
C (mm) 585 593 585 593 710
Undercarriage

Model PC600-8E0 8E0 PC650-8E0 8E0 8E0
Quantity 2 2 2 2 2
A (mm) 1,260 1,260 1,200 1,280 1,440
B (mm) 5,340 5,690 5,360 5,710 5,810
C (mm) 875 875 875 875 980

Weight 16,300 17,300 16,600 17,500 22,000
(kg) (8,150 × 2) (8,650 × 2) (8,300 × 2) (8,750 × 2) (11,000 × 2)
Work equipment
(1) Boom
Civil engineer-
Type ing boom Quarry boom SE boom
A (mm) 7,930 7,550 6,870
B (mm) 2,010 2,010 2,090
X (mm) 3,780 3,630 3,280
Position of center of gravity Y (mm) 880 870 920

7.6 m 7.3 m Overall width
(mm) 1,050 1,050 1,050
x (mm) 3,590 3,420
Weight
y (mm) 680 710 (kg) 4,870 4,710 4,810
8
(2) Arm
Civil engineering arm Quarry arm SE arm
Type
(3.5 m) (4.3 m) (5.2 m) (3.5 m) (2.9 m)
A (mm) 4,870 5,650 6,580 4,870 4,230
B (mm) 1,210 1,220 1,340 1,240 1,490
X (mm) 940 1,190 1,590 940 630
x: 880 mm Y (mm) 250 260 260 250 280

y: 220 mm Overall width
(mm) 460 460 460 460 460
Weight
(kg) 3,740 3,740 4,160 3,330 3,530
(3) Bucket
PC650-8E0
Model PC600-8E0 PC650LC-8E0
PC600LC-8E0 PC700LC-8E0
A (mm) 2,150 2,150
B (mm) 1,780 1,780

Overall width
(mm) 1,780 1,920
Weight 2,430 3,100
(kg)
(4) Boom cylinder (for all models)
Weight: 1,000 kg
(500 kg × 2 pcs)
X: 1,160 mm
9
(5) Arm cylinder
Weight: 727 kg
X: 1,400 mm
Others
(1) Counterweight
With counterweight
Counterweight remover
PC600-8E0
PC600LC-8E0
PC650-8E0
Model PC650LC-8E0
PC700LC-8E0 -
A (mm) 830 860
Weight (kg) 10,750 12,204
(2) Catwalk (1) (for PC600 and PC650)
Weight: 37 kg
x: 1,150 mm
y: 60 mm
z: 240 mm
10
(3) Catwalk (2) (for PC600 and PC650)
Weight: 32 kg
x: 970 mm
y: 50 mm
z: 250 mm
11
LIST OF TOOLS FOR FIELD ASSEMBLING
No. Tool names Specifications Qty Remarks

1 Engine compressor Komatsu, 0.69 MPa {7.0kg/cm2} Class 1
Equipment
441 kN {45 ton} 1

2 Crane truck
245 kN {25 ton} 2
3 Grease pump Air type 1 Work equipment lubrication
4 Stepladder 5 -stepped- 1500 mm 2
5 Impact wrench KW10P (for M10) 1
6 KW12PI (For M12) 1
7 KW20P (For M16) 1
8 KW45FS (Spline) 1 For counterweight
9 Socket for KW45FS Spline × 65 mm 1 For counterweight
10 Air hose 50 m 1
11 16-time wrench 4413 Nm {450 kgm} 1 For counterweight
12 Socket for 16-time wrench T38.1 × 65 mm 1 For counterweight
13 T38.1 × 55 mm 1 For track frame
14 T38.1 × 50 mm 1 For track frame
15 4-time wrench 25.4, 19 1 16-time wrench available
16 Socket for 4-time wrench T25.4 × 50 mm 1 16-time wrench available
Tool
17 T25.4 × 55 mm 1 16-time wrench available

18 Torque wrench 412 Nm {42 kgm} T25.4 mm 1 For 16-time wrench
19 834 Nm {85 kgm} T25.4 mm 1 For 4-time wrench
20 4118 Nm {420 kgm} T38.1 mm 1 For counterweight and track frame
21 Standard tool Socket, spanner, wrench 2 sets
22 Sledge hammer 10 P 1
23 Bar 1m 2
24 Hydraulic jack 490 kN {50 ton} (stroke 170) 2 Revolving frame pedestal
When tightening track frame
25 196 kN {20 ton} 1 connecting bolts.
26 Waste oil pan Large, small 2 each When connecting travel and work
equipment piping
27 Wooden block 300 × 400 mm 4 Revolving frame pedestal
28 Wire ø10 × 3 m 2 For catwalk
29 ø20 × 5 m 2 For boom, arm and bucket
30 ø32 × 5 m 4 For revolving frame and track frame
31 ø30 × 5 m 2 For counterweight
Sling jig
32 Shackle SD30 3
33 SC18 4
34 Nylon sling 50 mm wide × 3 m 2 For boom cylinder and arm cylinder
35 Lever block 14.7 29.4 kN {1.5 3 ton} 2
36 Eyebolt M12 2
37 Detergent liquid Brake cleaner 10
38 Hydraulic oil EO-10 300 l
Lubricants
39 Grease G2-LI 20 kg Work equipment lubrication

40 Repair paint Natural yellow 5
41 Black gray 5
42 Waste cloth Bundle 20 kg For cleaning
12
TIGHTENING TORQUE
1. Tightening torque for bolts
Tightening torque for bolts is indicated in the text as shown below. Tighten each bolt to the specified
torque.
Part No. of bolt TTTTT-TTTTT

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

b : Width across flats of bolt head
c : Bolt length
d : Threaded part of bolt
13
Table 1 Tightening torque for bolts not specified in text
Unit: Nm {kgm}
Nominal size of thread Width across flats Tightening torque

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

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

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

not use O-ring
at this position
Unit: Nm {kgm}
Outside diameter Tightening torque (Nm {kgm})
of hose Width across flats
(mm) (mm) Range Target
Approx. 6 19 34 63 {3.5 6.5} 44 {4.5}
Approx. 10 24 59 98 {6.0 10.0} 78 {8.0}
Approx. 13 27 84 132 {8.5 13.5} 103 {10.5}
Approx. 16 32 128 186 {13.0 19.0} 157 {16.0}
Approx. 20 36 177 245 {18.0 25.0} 216 {22.0}
Note: When connecting hose, take care not to twist them.
16
4. Proper socket sizes for bolts of M39 and larger (Reference)
For the proper sizes of sockets or spanners (= width across flats) for tightening hexagon bolts of M39 and
larger, see Table 5.
Table 5
Unit: mm
Thread diameter Proper sizes of sockets or spanners
M42 65
M45 70
M48 75
M52 80
M56 85
M60 90
M64 95
17
COATING MATERIALS
a The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly
and assembly are listed below.
a For coating materials not listed below, use the equivalent of products shown in this list.
Category Komatsu code Part No. Q'ty Container Main applications, features
Used to prevent rubber gaskets, rub-
LT-1A 790-129-9030 150 g Tube ber cushions, and cock plug from
coming out.
Used in places requiring an immedi-
ately effective, strong adhesive.
LT-1B 790-129-9050 20 g Polyethylene Used for plastics (except polyethyl-
(2 pcs.) container ene, polyprophylene, tetrafluoroeth-
lene and vinyl chloride), rubber,
metal and non-metal.
Features: Resistance to heat and
Polyethylene chemicals
LT-2 09940-00030 50 g container Used for anti-loosening and sealant
purpose for bolts and plugs.
Adhesive: Used as adhesive or sealant for met-
790-129-9060 al, glass and plastic.
(Set of adhesive 1 kg
LT-3 and hardening Hardening Can
agent) agent:
Adhesives 500 g
Polyethylene Used as sealant for machined holes.
LT-4 790-129-9040 250 g
container
Holtz Used as heat-resisting sealant for re-

790-126-9120 75 g Tube pairing engine.
MH 705
Quick hardening type adhesive
Three bond Polyethylene Cure time: within 5 sec. to 3 min.
1735 790-129-9140 50 g container Used mainly for adhesion of metals,
rubbers, plastics and woods.
Quick hardening type adhesive
Aron-alpha Polyethylene Quick cure type (max. strength after
201 790-129-9130 2g container 30 minutes)
Used mainly for adhesion of rubbers,
plastics and metals.
Resistance to heat, chemicals
Loctite 79A-129-9110 50 cc Polyethylene Used at joint portions subject to high
648-50 container temperatures.
Used as adhesive or sealant for gas-
LG-1 790-129-9010 200 g Tube kets and packing of power train case,
etc.
Used as sealant for various threads,
LG-5 790-129-9080 1 kg Can pipe joints, flanges.
Used as sealant for tapered plugs,
elbows, nipples of hydraulic piping.
Features: Silicon based, resistance
to heat, cold
LG-6 790-129-9020 200 g Tube Used as sealant for flange surface,
tread.
Used as sealant for oil pan, final
Gasket drive case, etc.
sealant
Features: Silicon based, quick hard-
ening type
LG-7 790-129-9070 1 kg Tube Used as sealant for flywheel hous-
ing, intake manifold, oil pan, thermo-
stat housing, etc.
Three bond Used as heat-resisting sealant for re-
790-129-9090 100 g Tube pairing engine.
1211
Features: Silicone type, heat resist-
Three bond ant, vibration resistant, and impact
1207B 419-15-18131 100 g Tube resistant sealing material
Used as sealing material for transfer
case
18
Category Komatsu code Part No. Q'ty Container Main applications, features
Used as lubricant for sliding portion
LM-G 09940-00051 60 g Can (to prevent from squeaking).
Molybdenum Used to prevent seizure or scuffling
disulphide of the thread when press fitting or
lubricant LM-P 09940-00040 200 g Tube shrink fitting.
Used as lubricant for linkage, bear-
ings, etc.
SYG2-400LI General purpose type
SYG2-350LI
G2-LI SYG2-400LI-A Various Various
SYG2-160LI
SYGA-160CNLI
SYG2-400CA Used for normal temperature, light
SYG2-350CA load bearing at places in contact
G2-CA SYG2-400CA-A Various Various with water or steam.
SYG2-160CA
SYGA-160CNCA
Molybdenum Used for heavy load portion
disulphide SYG2-400M 400 g × 10 Bellows type
Grease grease SYG2-400M-A 400 g × 20 Bellows type
LM-G (G2-M) SYGA-16CNM 16 kg Can
Seizure resistance and heat resist-

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

Glass (Expiration date: 4 months)
PAINT PRIMER 20 ml container
580 SUPER
Primer
SUNSTAR Used as primer for glass side
Glass (Expiration date: 4 months)
GLASS PRIMER 20 ml container
580 SUPER 417-926-3910
Adhesive for cab glass
"S" is used for high-tempera-

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

Polyethylene parts.
PENGUINE 417-926-3920 320 ml container
SEAL No. 2505 (Expiration date: 4 months)
Caulking
material Used to seal front window.
SEKISUI Polyethylene
SILICONE 20Y-54-55130 333 ml (Expiration date: 6 months)
container
SEALANT
19
SELECTION OF WIRE ROPES USED FOR ASSEMBLY
Select wire ropes to be used for assembly according to the following table.
Annex 2, Table 1 Using loads of 6 × 24 type rope slings.

Unit: kN {tf}
Number of wire ropes 1 pc. 2 pcs.
SELECTION OF WIRE ROPES USED FOR ASSEMBLY
Sling angle D D = 0° D Z 90° 90° < D Z 120°

Angle to vertical line E E = 0° E Z 45° 45° < E Z 60°
Mode coefficient M 1 1.4 1
Classification of wire rope
Outer diameter of 24G 24A 24G 24A 24G 24A
wire rope (2)d (mm)
8 Max. 4.8 {0.49} Max. 5.2 {0.53} Max. 6.7 {0.68} Max. 7.2 {0.74} Max. 4.8 {0.49} Max. 5.2 {0.53}
9 Max. 6.1 {0.63} Max. 6.6 {0.67} Max. 8.5 {0.88} Max. 9.2 {0.93} Max. 6.1 {0.63} Max. 6.6 {0.67}
20
10 Max. 7.6 {0.77} Max. 8.2 {0.83} Max. 10 {1.0} Max. 11 {1.1} Max. 7.6 {0.77} Max. 8.2 {0.83}
11.2 Max. 9.5 {0.97} Max. 10 {1.0} Max. 13 {1.3} Max. 14 {1.4} Max. 9.5 {0.97} Max. 10 {1.1}
(12) Max. 10 {1.1} Max. 11 {1.2} Max. 14 {1.5} Max. 15 {1.6} Max. 10 {1.1} Max. 11 {1.2}
12.5 Max. 11 {1.2} Max. 12 {1.3} Max. 15 {1.6} Max. 16 {1.8} Max. 11 {1.2} Max. 12 {1.3}
14 Max. 14 {1.5} Max. 16 {1.6} Max. 19 {2.1} Max. 22 {2.2} Max. 14 {1.5} Max. 16 {1.6}
(24) Max. 43 {4.4} Max. 60 {6.1} Max. 43 {4.4}
A. ASSEMBLY OF CHASSIS
Remarks
1. In the "drawings" in this manual, parts and places are indicated by 1, 2, 3 ---,
but indicated by (1), (2), (3) --- in the tables and texts.
Example:
(1) Plate
(2) Collar
(3) Washer
(4) Bolt
(5) Bolt
(6) Washer
2. In some places of this manual, the words of front, rear, right hand and left hand
of machine are used. Those words indicate the directions seen from the opera-
tor's seat with the sprocket at the rear as shown below, unless otherwise speci-
fied.
Front
Front
Operator’s
Left hand seat Right hand
Left hand Right hand
Operator's seat
Sprocket
Sprocket
Rear
Rear
21
INSTALLATION OF LEFT AND RIGHT TRACK FRAMES
Assembly procedure
Installation of Left and Right Track Frames (1/4)
A-1
Sling the track frame in the posture for Transportation.
Hold two boom cylinder

bottom pins of the front
Upper Structure section
for lifting.
Fitting the wire at

counterweight portion (Example):
Set the wire safely and securely.
Wooden block
Use a shackle for Stopper
secure connection.
Precautions Necessary tools Necessary equipment
Never enter under the lifted Upper Structure. Name Qty Name Qty
ø 32 × 5000 wire 4 45 ton crane 1
25 ton crane 2
Others
22
Assembly procedure
Installation of Left and Right Track Frames (2-1/4)
A-1
Lower the Upper Structure by two cranes and install it on the Track Frames as shown.
Mount the M33 × 3 bolts and tighten them

with 200 250 kgm torque.
Mount the M36 × 3 bolts

and tighten them with
250 310 kgm torque.
Right track frame
No. Loose-supply items Qty

1 15A-78-11270 32
2 01643-33380 32
3 01011-83630 8
4 21M-30-12170 4
Left track frame 5 01643-33690 8
6 209-30-11330 8

Name Qty Name Qty
4 time wrench 1
Torque wrench (85 kgm) 1
Socket (25 Sq. × 50 mm) 1
Others
23
Assembly procedure
Installation of Left and Right Track Frames (2-2/4)
A-1
For PC700LC only
Mount the M33 × 3 bolts and tighten them with

200 250 kgm torque.
Mount the M33 × 3 bolts

and tighten them with
200 250 kgm torque.
Right track frame
Left track frame

1 21M-30-31130 32
2 21M-30-31120 32
3 21M-30-31130 8
4 21M-30-31140 4
5 01643-33380 8
6 21M-30-31120 8

Name Qty Name Qty
4 time wrench 1
Torque wrench (85 kgm) 1
Others
24
Assembly procedure
A-1
Support the center frame bottom with two wooden blocks (300 × 400) at places where they will not interfere with the
track frame.
Note: Use sufficiently strong wooden blocks.
Lift the Track Frame Assembly and install it on the Center Frame.
Hydraulic jack
Decide the sling positions so that the wire

ropes will not interfere with the upper structure
Place wooden blocks to support
Tighten the bolts lightly, and then lower the jacks to place the track frame on the ground.

Name Qty Name Qty
Hydraulic jack (50 ton) 2 45 ton crane 1
Wooden block (300 × 400 mm) 4 25 ton crane 2
Wire (ø32 mm, 5000 mm long) 2
Others
25
Assembly procedure
A-1
Thickness of 100 mm
Wooden block
a When tightening bolts, raise the track with a hydraulic jack as shown above so as to get sufficient space for tightening.
3 M33 × P3 bolt: 1,961.3 2,451.7 Nm {200 250 kgm}
M36 × P3 bolt: 2,451.7 3,040.7 Nm {250 310 kgm}
Do not remove the shoes before Name Qty Name Qty

assembling (so as to maintain the 4 time wrench 1
tightening torques of the shoe bolts).
Do not place the washer on the spot Torque wrench (85 kgm) 1
facing.
Others
26
INSTALLATION OF TRAVEL PIPE
Assembly procedure
Installation of Travel Pipe (1/2)
A-2
Fig. 1
Fig. 2
a Connect the hose having a red band to the upper side of the travel motor.

6 07000-13032 4
No. Already installed to chassis Qty

STD 07098-41030 2
1
LC 07098-41032 2
STD 21M-62-21570 2
2
LC 21M-62-21580 2
STD 02764-00630 2
3
LC 02764-00632 2
STD 02762-00330 2
4
LC 02762-00332 2
Before removing the oil stopper of each Name Qty Name Qty
hose, turn the bolt slowly to release the Oil pan (small) 2
internal pressure.
KW12P impact 1
L150 extension 1
M14 socket 1
M19 socket 1
Width across flats 24 spanner 2
Others
27
Assembly procedure
A-2-1
Fig. 3
Detail P
a After the hose connection, bleed the travel pipes of air by loosening the air bleeding plug of the travel motor.

Name Qty Name Qty
Others
28
INSTALLATION OF TRAVEL PIPE
Assembly procedure
A-2-2
For PC700LC only

1 21M-62-31920 2
2 21M-62-31910 2
3 02764-00534 2
4 02762-00337 2
5 07000-13032 4
Before removing the oil stopper of each Name Qty Name Qty
hose, turn the bolt slowly to release the Width across flats 32 mm spanner 2 Oil receiving pan (small) 1
internal pressure.
Width across flats 24 mm spanner 2
KW12P impact 1
L150 extension 1
M17 socket 1
Others
29
Assembly procedure
A-2-2
For PC700LC only

1 07094-31024 4
2 07095-01035 4
3 01010-81290 4
4 01643-31232 4
5 04434-52312 2
6 04434-51512 2
7 01010-81250 2
8 01643-31232 2
9 195-33-11220 2
10 08034-20536 4

Name Qty Name Qty
Others
30
Assembly procedure
A-2-2
For PC700LC only

1 21M-62-31920 2
2 21M-62-31910 2
3 02764-00534 2
4 02762-00337 2
The hoses are installed on the machine. Name Qty Name Qty
Others
31
INSTALLATION OF OPERATOR CAB’S LEFT HANDRAIL
Assembly procedure
Installation of Operator Cabs Left Handrail
A-3
Mount the grip and its bolts as shown below.

1 20Y-53-18870 1
2 01435-40825 4

Name Qty Name Qty
Others
32
INSTALLATION OF OPERATOR CAB'S DOOR STOPPER AND STRIKER
Assembly procedure
Installation of Operator Cabs
A-4 Door Stopper and Striker (1/2)
1. Mounting the striker

Mount the striker, plate, nut and cover as shown below.
Tighten the nuts with the specified torque as shown.

1 20Y-53-11320 1
2 20Y-53-12940 1
3 01584-01008 2
4 20Y-53-12661 1

Name Qty Name Qty
Others
33
Assembly procedure
Installation of Operator Cabs
A-4 Door Stopper and Striker (2/2)
1. Mounting the door stopper

Mount stoppers, nuts and washers at two positions shown.
Adjust the stoppers during mounting.
3
2
1
When the door

is opened
Stopper adjusting instructions
Open the door and make the

stopper in contact to the door.
Rotate the upper one 5 turns
and rotate the lower one 3 1 20Y-54-11611 2
turns. Then, fix it by 2 01580-11008 2
tightening their locknuts. 3 01643-31032 2

Name Qty Name Qty
Others
34
INSTALLATION OF REARVIEW MIRROR
Assembly procedure
Installation of Rearview Mirror (1/7)
A-5
(1) Before installing the boom foot pin, remove handrail (6) and bolts and washer (7), (8).
(2) After installing the work equipment, install handrail (6) and bolts and washer (7), (8).
(3) Install parts (1) to (5), (9) and (10) to handrail (6).
No. Loose-supply items Q’ty

1 421-54-25610 1
2 209-54-75350 1
21M-54-11890 (for PC600) 1
3
21M-54-31890 (for PC700) 1
4 20Y-54-27991 3
5 01252-A1030 6
6 21M-54-31610 1
7 01024-81250 6
8 01024-81235 2
9 04025-00632 1
10 01252-A0545 4

Name Q’ty Name Q’ty
Others
35
Assembly procedure
A-5 (ISO2867-2011 correspondence specification)
(1) Before installing the boom foot pin, remove handrail (6) and bolts and washer (7), (8).
(2) After installing the work equipment, install handrail (6) and bolts and washer (7), (8).
(3) Install parts (1) to (5), (9) and (10) to handrail (6).
㻢㻣㻤
㻝㻥㻝㻜
㻞㻠㻡
㻣㻜
䚷䚷㻌
䚷䚷䚷䚷
䚷䚷䚷䚷
䚷䚷䚷䚷

㻟㻠㻡
1 421-54-25610 1
2 21M-54-32150 1
21M-54-31830 (for PC600) 1
3
21M-54-31820 (for PC700) 1
4 20Y-54-61630 3
5 01252-A1030 6
6 21M-54-31620 1
7 01024-81240 4
8 01024-81250 4
9 04025-00632 1
10 01252-A0545 4

Others
36
Assembly procedure
Installation of Rearview Mirror (/)
A-5
Insert pin (5) into the holes of clamps (3), secure mirror (1) with holder (2), tighten screws (4), and check that the mir-
ror does not move.
Insert pin (5) into this hole

Name Qty Name Qty
Others
37
Assembly procedure
Installation of Rearview Mirror (/)
A-5
WITH TOP GUARD

Install parts (1) to (9) to the handrail at the front of the cab.
Bolt
Bolt
Clamp
Stay
Mirror
Pin
Support
Clamp
Bolt

1 421-54-25610 1
2 04025-00632 1
3 209-54-45611 1
4 20Y-54-35430 1
5 01252-A1025 4
6 209-54-45660 1
7 20Y-54-27991 1
8 01024-D1270 1

Name Qty Name Qty
Others
38
Assembly procedure
Installation of Rearview Mirror ()
A-5
WITHOUT TOP GUARD

Install parts (1) to (9) to the handrail at the front of the cab.
Bolt
Color
Clamp
Bolt
Stay
Mirror
Pin
Support
Clamp
Bolt

1 421-54-25610 1
2 04025-00632 1
3 209-54-45621 1
4 20Y-54-35430 1
5 01252-A1025 4
6 209-54-45660 1
7 20Y-54-27991 1
8 01024-D1270 1
9 20Y-03-11220 1

Name Qty Name Qty
Others
39
Assembly procedure
Installation of Rearview Mirror ( /)
A-5
ADJUSTING THE REARVIEW MIRROR

k WARNING
Always adjust the rearview mirror in the correct angle
before starting the work. If its adjustment is incorrect, the
operator may have a poor visual range and a serious
personal injury may result.
Loosen screw (2) and bolt (3) of the rearview mirror, and ad-
just the mirror angle so that you can have the best view from
the operators seat.
Adjust the mirror angle so that you can see a person who
is standing at the right or left rear end position of the
machine (or an object having the diameter of approxi-
mately 30 cm and the height of approximately 1 meter).
The figure right shows the reference mirror mounting

position. Also, the following defines the reference mirror
visual range.
Mirror mounting position on axis X : 195 mm

Mirror mounting position on axis W : 75 mm
Mirror visual range on axis Z (Left side) : 2500 mm
Mirror visual range on axis Y (Right side) : 3100 mm
Mirror A : Must cover shaded area (A).

Mirror B : Must cover shaded area (B).
40
Assembly procedure
ADJUSTING THE REARVIEW MIRROR

k WARNING
Always adjust the rearview mirror in the correct angle
before starting the work. If its adjustment is incorrect, the
operator may have a poor visual range and a serious
personal injury may result.
Loosen screw (2) and bolt (3) of the rearview mirror, and ad-
just the mirror angle so that you can have the best view from
the operators seat.
Adjust the mirror angle so that you can see a person who
is standing at the right or left rear end position of the
machine (or an object having the diameter of approxi-
mately 30 cm and the height of approximately 1 meter).
The figure right shows the reference mirror mounting

position. Also, the following defines the reference mirror
visual range.
Mirror mounting position on axis X : mm

Mirror mounting position on axis W : 75 mm
Mirror visual range on axis Z (Left side) : 2500 mm
Mirror visual range on axis Y (Right side) : 3100 mm
Mirror A : Must cover shaded area (A).

Mirror B : Must cover shaded area (B).

Others
41
INSTALLATION OF HANDRAIL
Assembly procedure
Installation of Handrail (1/)
A-6
(1) Install handrails (1) and (2) with bolts (4).
(2) Install brackets (5) and (7) with bolts (3) and (6).
(3) Adjust stopper (10) with nut (11), then install to the face of the hydraulic tank.
(4) Adjust step (8) with bolts (9).

1 21M-54-13611 1
2 21M-54-13621 1
3 01034-81240 4
4 01024-81240 8
5 21M-54-33631 1
6 01010-81245 6
7 21M-54-32970 1
8 21M-54-32980 2
9 01024-81230 4
10 20Y-54-11611 2
11 01580-01008 2

Name Qty Name Qty
Others
42
Assembly procedure
Installation of Handrail (With top guard) (2/)
A-6
(WITH TOP GUARD)

(1) Install handrail (1) with bolts (2) and spacers (3).
Sling at three points marked with a.

1 209-54-45570 1
2 01010-D1260 2
3 195-33-11220 2

Name Qty Name Qty
KW12P impact 1
M19 socket 1
Others
43
Assembly procedure
Installation of Handrail (Without top guard) (3/)
A-6
(WITHOUT TOP GUARD)

(1) Install handrail (1) with bolts (2).

1 209-54-45580 1
2 01024-D1235 2

Name Qty Name Qty
Others
44
Assembly procedure
Installation of Handrail (4/4)
1. Install handrails (1), (2) and (3) with bolts (7).
2. Install foot barriers (4), (5) and (6) with bolts (8).
㻟㻣
㻞㻣
㻝㻣
㻡㻤
㻤㻠㻢㻤
㻠㻤
㻡㻤

1 21M-54-31940 1
2 21M-54-31950 1
3 21M-54-31960 1
4 21M-54-31970 2
5 21M-54-32130 2
6 21M-54-31990 1
7 01024-81240 26
8 01024-81230 10

Others
45
INSTALLATION OF STEP
Assembly procedure
Installation of Step
A-7-1
(1) Install step (1) and (2) to 4 places on both sides of the front and rear of the track frame with bolts and
washers (3) and (4).
Using 900 mm shoe.

1 21M-30-12260 4
2 21M-30-12210 4
3 01010-81640 32
4 01643-31645 32
5 21M-30-12270 16
6 01010-81680 32
Remove the rust prevention plug knocked Name Qty Name Qty
into the mounting tap hole. KW20P impact 1
M24 socket 1
Others
46
INSTALLATION OF STEP
Assembly procedure
Installation of Step
A-7-2
For PC700LC only

1 21M-30-33231 4
2 01010-81640 16
3 01643-31645 16
into the mounting tap hole. KW20P impact 1
M24 socket 1
Others
47
INSTALLATION OF LEFT SIDE STEP
Assembly procedure
Installation of Left Side Step
A-8
a During mounting, adjust the Left Side Step to eliminate a difference No. Loose-supply items Qty
between the front and rear steps. 1 21M-54-22440 1
2 21M-54-22430 1
3 21M-54-14690 5
4 01024-81245 15
5 01024-81235 15
into the mounting tap hole.
Others
48
STICKING SHEET TO COUNTERWEIGHT
Assembly procedure
Sticking Sheet to Counterweight
A-9
Stick the sheets to the front side of the counterweight as shown below.
When sticking sheets (1), (2), (3), (4), (5), (6) and (7), set the SG sheet stuck to the side of each sheet up.
Faces Faces
without SG sheets without SG sheets

1 21M-54-32110 1
2 21M-54-22821 1
3 21M-54-22830 1
4 21M-54-22850 1
5 21M-54-22840 1
6 21M-54-22860 1
7 21M-54-23920 1
8 21M-54-23930 1
Remove all oil and rust from the surface Name Qty Name Qty
where the sheet is to be stuck.
Others
49
INSTALLATION OF REAR VIEW CAMERA
Assembly procedure
Installation of Rear View Camera (1/5)
A-10
(1) Assemble the camera as shown below. (1/2)
Parts marked with

are components of this part
Tightening torque
10 15 Nm {1.0 1.5 kgm}
Apply LT-2
Rotation center
of camera.

1 7835-33-1001 1
2 7835-33-1100 1
3 7835-33-1201 1
4 207-06-76431 1
5 207-06-76440 1
6 20Y-810-1240 2
7 01010-80835 2
8 01643-30823 2
9 04434-53211 1
10 07095-00317 1
11 01010-81020 1
12 01643-31032 1
13 08059-00310 2

Name Qty Name Qty
Others
50
Assembly procedure
A-10
(2) Assemble the camera as shown below. (2/2)
Adjust the camera angle by matching the centers of the camera mounting bolts with the bottom of the
4th line from the lowest one on the scale.
Tightening torque
3 5 Nm {0.3 0.5 kgm}
Tightening torque
3 5 Nm {0.3 0.5 kgm}

1 7835-33-1310 2
2 7835-33-1320 4
3 7835-33-1330 4
4 7835-33-1340 4

Name Qty Name Qty
Others
51
Assembly procedure
A-10
(2) Install the camera assembled in (1) to the weight and pass the wiring harness through the CW hole.

1 207-06-76420 1
2 207-06-76451 1
3 209-06-45220 1

Name Qty Name Qty
Others
52
Assembly procedure
A-10
C
le
a ra
n ce
of
co
nn
ec
t io
n
r in
g
an
d
re
l ay
ca
bl
e
Connection ring f la
ng
e.
Must not use tools for connection ring rotation.
207-06-76451
Installation drawing
Hitch claws onto holes

1 01010-81230 2
2 01643-31232 2
3 01010-80616 2
4 01643-30623 2

Name Qty Name Qty
Others
53
Assembly procedure
A-10
Remover specification
1. For assembly of the camera, see the standard specification.
2. For the wiring harness of the camera, see the following figure.

1 21M-06-31210 1
2 207-06-76490 1
3 04434-51012 3
4 195-33-11220 1
5 01010-81250 1
6 01010-81225 2
7 01643-31232 3

Name Qty Name Qty
Others
54
INSTALLATION OF COUNTERWEIGHT
Assembly procedure
Installation of Counterweight (1/)
A-11
(1) Lift the counterweight assembly (1) and install it to the body.
a Add one more shackle to the right side to improve the sling balance.
(2) Use the bolt (2) (6 pcs.) and the spacer (3) (6 pcs.) for the installation.
a Bolt tightening torque: 3825 ± 392 Nm {390 ± 40 kgm}
a If no large torque wrench is available, tighten according to the turning angle below.
1) Initial torque: Tighten to 1470 Nm {150 kgm}
2) After that: Tighten 90° ± 5°
a Check the seating condition when tightening the mounting bolts lightly, and then tighten to the
specified torque.
4 Counterweight : 10,750 kg
Outer dia 90 mm, 1.0 kg
Tightening torque = 395 mm, 5.1 kg

3825 ± 392 mm Width across flats
{390 ± 40 kgm} 65 mm

2 21M-46-24210 6
3 209-46-11210 6
Install the counterweight so that the standard Name Qty Name Qty
clearance to the revolving frame will be ø30 x 5000 mm wire 2 45 t crane 1
15 mm and the level differences on the right
and left sides will be the same. KW45FS impact 1
Width across flats 65S socket 1
Torque wrench (4,118,8 Nm {420 kgm}) 1
38sq. × 65 mm socket 1
SD30 shackle 2
Others
55
Assembly procedure
Installation of Counterweight (2/3)
(1) Lift the counterweight assembly (1) and install it to the body.
a Add one more shackle to the right side to improve the sling balance.
(2) Use the bolt (2) (6 pcs.) and the spacer (3) (6 pcs.) for the installation.
a Bolt tightening torque: 3825 ± 392 Nm {390 ± 40 kgm}
a If no large torque wrench is available, tighten according to the turning angle below.
1) Initial torque: Tighten to 1470 Nm {150 kgm}
2) After that: Tighten 90° ± 5°
a Check the seating condition when tightening the mounting bolts lightly, and then
tighten to the specified torque.
㻼
4 Counterweight: 10,850 kg
Outer dla f90 mm, 1.0 kg
Tightening torque l = 395 mm, 5.1 kg

3825 ± 392 mm
Width across flats
{390 ± 40 kgm} No. Loose-supply items Q’ty
65mm
2 21M-46-24210 6
3 209-46-11210 6
Install the counterweight so that the standard Name Q’ty Name Q’ty
clearance to the revolving frame will be 15 ø30 x 5000 mm wire 2 45 t crane 1 1
mm and the level differences on the right and
left sides will be the same. KW45FS impact 1
Width across flats 65S socket 1
Torque wrench (4,118,8 Nm {420 kgm}) 1
38sq. × 65 mm socket 1
SD30 shackle 2
Others
56
Assembly procedure
Installation of Counterweight (/)
A-11
(3) When installing the counterweight to the machine, remove cover (1) and then install the counter-
weight, while taking care that the wiring harnesses of the rear working lamp and 2nd camera
(if equipped) will not be caught.
Wiring harnesses of rear

working lamp and 2nd
camera (if equipped)

Name Qty Name Qty
1
Others
57
INSTALLATION OF STEP LIGHT
Assembly procedure
Installation of Step Light (1/2)
A-12
When installing OPG TOP GUARD

1. Install step light (1) to the top guard.
2. When installing the light, remove the bolts marked with , remove and tighten the light, and then tighten the
bolts marked again.
Note) Tighten the bolts marked with to 7 8 Nm.
Connector connection position

1 20Y-06-41940 1
2 01024-D1020 1

Name Qty Name Qty
Others
58
Assembly procedure
Installation of Step Light (2/2)
A-12
When not installing OPG TOP GUARD

1. Install grommet (6) to bracket (3) and install bracket (3) to the cab. Tighten bolt (4) to secure the bracket and
rear view mirror together, and tighten bolt (5) to secure the bracket and cab handrail together.
2. Install step light (1) to bracket (3).
When installing the light, remove the bolts marked with ,

remove and tighten the light, and then tighten the bolts marked again.
Note) Tighten the bolts marked with to 7 8 Nm.

1 20Y-06-41940 1
2 01024-D1020 1
3 209-53-24420 1
4 01024-D1275 1
5 01435-40830 1
6 08037-02512 1

Name Qty Name Qty
Others
59
BLEEDING OF AIR FROM TRAVEL MOTOR
Assembly procedure
Bleeding of Air from Travel Motor
A-13
For PC700LC only

1. Start the engine and run it at low idle.
2. Loosen air bleeding plug (1) by 1 turn. (Right and left)
a Do not loosen the air bleeding plug more than 1 turn.
3. Travel the machine forward and in reverse 4 5 times.
4. After oil containing no white bubble flows out of air bleeding plug (1), tighten (1).

Name Qty Name Qty
Width across flats 10 spanner 1 Oil pan 1
Others
60
INSTALLATION OF TRAVEL PIPING COVER
Assembly procedure
Installation of Travel Piping Cover (1/4)
A-14-1
Install left travel piping cover.

1 21M-30-28140 1
2 01024-81225 2
3 21M-30-28120 1
4 01024-81230 2
5 21M-30-18132 1
6 01010-81635 4
7 01643-31645 4
8 21M-30-28110 1
9 01024-81230 4
10 21M-30-12340 1
11 01010-81640 6
12 01643-31645 6

Name Qty Name Qty
KW12P impact 1
L150 extension 1
M19 socket 1
KW20P impact 1
M24 socket 1
Others
61
Assembly procedure
A-14-1
Install left travel piping cover.

1 21M-30-28220 1
2 01024-81230 4

Name Qty Name Qty
Others
62
Assembly procedure
A-14-1
Install right travel piping cover.

1 21M-30-28150 1
2 01024-81225 2
3 21M-30-28160 1
4 01024-81230 2
5 21M-30-18182 1
6 01010-81635 4
7 01643-31645 4
8 21M-30-28170 1
9 01024-81230 4
10 21M-30-12350 1
11 01010-81640 6
12 01643-31645 6

Name Qty Name Qty
Others
63
Assembly procedure
A-14-1
Install right travel piping cover.

1 21M-30-28230 1
2 01024-81230 4

Name Qty Name Qty
Others
64
INSTALLATION OF TRAVEL PIPING COVER
Assembly procedure
A-14-2
For PC700LC only

1 21M-30-33150 1
2 01010-81235 2
3 175-54-34170 2
4 21M-30-33130 1
5 01010-81230 2
6 01643-31232 2
7 21M-30-33170 1
8 01010-81230 2
9 01643-31232 2
10 175-54-34170 2

Name Qty Name Qty
Others
65
Assembly procedure
A-14-2
For PC700LC only

1 21M-30-33150 1
2 01010-81235 2
3 175-54-34170 2
4 21M-30-33130 1
5 01010-81230 2
6 01643-31232 2
7 21M-30-33170 1
8 01010-81230 2
9 01643-31232 2
10 175-54-34170 2

Name Qty Name Qty
Others
66
Assembly procedure
A-14-2
For PC700LC only

1 21M-30-33110 1
2 01010-81230 4
3 175-54-34170 4
4 21M-30-33120 1
5 01010-81230 4
6 175-54-34170 4
7 21M-30-33160 1
8 01010-81230 4
9 01643-31232 4

Name Qty Name Qty
Others
67
INSTALLATION OF TRAVEL MOTOR GUARD
Assembly procedure
Installation of Travel Motor Guard
A-15
For PC700LC only
Weight of motor guard: 70 kg

1 21M-30-33210 1
2 01010-81645 10
3 01643-31645 10
4 21M-30-33220 1
5 01010-81645 10
6 01643-31645 10

Name Qty Name Qty
Others
68
TESTING TRACK SHOE TENSION
Assembly procedure
Testing Track Shoe Tension (1/3)
A-16

Name Qty Name Qty
Others
69
Assembly procedure
A-16

Name Qty Name Qty
Others
70
Assembly procedure
A-16

Name Qty Name Qty
Others
71
CHECK FUEL, COOLANT AND OIL LEVELS
Assembly procedure
Check Fuel, Coolant and Oil Levels (1/3)
A-17
72
Assembly procedure
Check Fuel, Coolant and Oil Levels (2/3)
A-17
48 13 10.5 7.2 520 58 880

12.68 3.43 2.77 1.9 137.38 15.32 232.50
40 13 10 7.2 360
10.57 3.43 2.64 1.9 95.11
73
Assembly procedure
Check fuel, coolant and oil levels (3/3)
A-17
Non-amine Supercoolant (Blue) is added when Name Qty Name Qty

shipped. Do not mix coolant of different type
with it.
Others
74
B. ASSEMBLING OF WORK EQUIPMENT
• Clean the mounting pin and pin hole and check them for a flaw.
75
ASSEMBLY OF ARM CYLINDER
Assembly procedure
Assembly of Arm Cylinder
B-1
(1) Remove the stoppers from the boom and remove the arm cylinder foot pins.
4 Arm cylinder: 727 kg
4 Arm cylinder foot pin: 36 kg
(2) Lift the arm cylinder and adjust it to the boom hole positions.
Adjust the clearance of cylinder foot mounting portion below 1 mm with shim (1).
(3) Insert the arm cylinder foot pins into holes.

Coat the inner surface of the pin hole with lithium grease.
(4) Mount the stoppers.

1 208-70-31310 3

Name Qty Name Qty
Others
76
CONNECTION OF ARM CYLINDER HOSES
Assembly procedure
Connection of Arm Cylinder Hoses
B-2
(1) Remove the oil stopper plug from the arm cylinder pipe, and replace four O-rings (2) at the hose end with new ones
(Part No. 07000-13038).
Then, connect the arm cylinder hoses (1) (PC600, 650: 07085-01214 × 1, 07084-01412 × 1, PC600SE: 21M-62-32760 × 1).
Use existing split flanges (5) and (8) and bolts (6), (7), (9) and (10) of the oil stopper.
See Precaution 1.

7.6 m boom 1 07085-01214 1
7.3 m boom 1 07085-01214 1
6.6 m boom 1 21M-62-32760 1
7.6 m boom 2 07084-01413 1
7.3 m boom 2 07084-01412 1
6.6 m boom 2 07084-01415 1
3 07000-13038 2
4 07000-13048 2
No. Parts mounted on the boom Qty
5 07371-51260 4
6 01010-81245 8
7 01643-31232 8
8 07371-51470 4
9 01010-81455 8
10 01643-31645 8
1. Before starting the hose connection, Name Qty Name Qty

securely bind the arm cylinder rod using
wires so that the rod is not pushed out.
2. Bind to a pipe, etc. so that the dust seal
will not be damaged.
3. Remove and store the flange, O-rings and
heads so that you can reuse them later.
4. When connecting the hoses, take
extremely care not to clinch or damage
the O-rings.
5. Also, take extremely care not to enter a
foreign material into the hydraulic circuit.
Others
77
INSTALLATION OF BOOM CYLINDER
Assembly procedure
Installation of Boom Cylinder
B-3
(1) Lift the boom cylinder and adjust it to the frames pin holes.
(2) Coat the inner surface of the pin hole with lithium grease.
(3) Check the clearance between the cylinder pins and the track frame (outside of the track), determine the amount of shim,
and mount the boom cylinder. Then, adjust the amount of the shim at the right and left cylinders (outside of the track).
(4) Fully insert the boom foot pin and mount the lock plate.
(5) Insert the boom cylinder holding mount between the cylinder and the revolving frame.
(Height: 40 50 mm, Width: less than 90 mm)
a Select an appropriate combination of two Name Qty Name Qty

0.8-mm thick shims (Part No. 207-70- 50 mm wide, 3000 mm Nylon sling 2 25 ton crane
11360) and two 1.5 mm thick shims (Part
No. 207-70-11370) for adjustment of the KW20P impact wrench 1
amount of shims.
M24 socket 1
Others
78
INSTALLATION OF BOOM CYLINDER HOSES
Assembly procedure
Installation of Boom Cylinder Hoses
B-4
(1) Remove the oil stopper plug from the tube at the boom cylinder end.
(2) Install the boom cylinder hoses (07074-01011 × 4) to the correct circuits as shown in the diagram below.
a Bleed the boom cylinder of air by following Assembly Procedure B-15 Bleeding Air from Work Equipment Circuit.
No. Already installed to chassis Qty

1 07074-01011 4
2 07000-13032 4
1. When removing an oil stopper plug from a Name Qty Name Qty
hose, slowly loosen its bolts by gradually KW10P Impact 1
releasing the internal hydraulic pressure.
2. Remove and store the flange, O-rings and L150 extension 1
M14 socket 1
extremely care not to clinch or damage
the O-rings.
4. Also, take extremely care not to enter a
Others
79
INSTALLATION OF BOOM FOOT DUST SEAL
Assembly procedure
Installation of Boom Foot Dust Seal
B-5
(1) Install the seal (209-72-11261) to the boom foot
Take care of the

direction of its lip.

1 209-72-11261 2
1. Take care of the direction of its lip so that Name Qty Name Qty
the grease can come out from inside. Hammer 1
2. When installing the seal, be careful not to
slant it. Template 1
3. Insert the seal until it touches the bushing.

4. Do not hit seal with hammer directly but
use template, etc. to hit.
Others
80
ASSEMBLY OF BOOM ASSEMBLY
Assembly procedure
Assembly of Boom Assembly
B-6
(1) Lift the boom assembly with the crane and bring it to the body pin hole.
(2) Fitting of Boom Foot Pin.

When the boom is inclined to the left or right at the time, balance it by using the jib crane.
4 Boom assembly : 4,870 kg
Sling position
(3) Check the clearance between the boom foot and the ma-
chine outside, decide the size and quantity of shim so that
the clearance becomes below 1 mm and insert the shim be-
tween them.
Use the adjustment shims (209-70-71640, 1.0 mm thick,
2 pcs. and 209-70-71650, 1.5 mm thick, 2 pcs.) to decide
their combination. (Adjust the clearance with shims at one
place outside.)
(4) Insert the boom foot pins fully and fit lockplates there.
2 Inside bushing: Lithium grease

1 209-70-71640 4
2 209-70-71650 4
a Two seals are mounted on the boom feet. Name Qty Name Qty
Take care not to damage them when in- ø20 × 5000 mm wire 2 25 ton crane 1
serting the pin.
SD30 shackle 2
Large hammer (plastic) 1
KW20P impact 1
M24 socket 1
Others
81
INSTALLATION OF HOSES FROM CHASSIS ALONG TOP OF BOOM
Assembly procedure
Installation of Hoses from Chassis Along Top of Boom
B-7 (1/2)
(1) Remove the oil stopping plugs of the tubes on the machine side.
(2) Install arm cylinder hoses (07085-01418: one pc., 07085-01218: one pc.) and
bucket cylinder hoses (07085-01217: one pc., 07085-01017: one pc.) to the regular circuit as shown below.
(3) Remove the oil stopping plugs on the boom side and install the hoses.
a Bleed the arm cylinder of air by following Assembly Procedure B-15 Bleeding Air from Work Equipment Circuit.

1 07085-01418 1
2 07085-01218 1
3 07085-01217 1
4 07085-01017 1
5 07000-13048 2
6 07000-13038 2
7 07000-13038 2
8 07000-13032 2
hose, slowly loosen its bolts by gradually KW10P Impact 1
M19 socket 1
extremely care not to clinch or damage M14 socket 1
the O-rings.
4. Also, take extremely care not to enter a M22 socket 1
Others
82
Assembly procedure
Installation of Hoses from Chassis Along Top of Boom
B-7 (2/2)
(1) Remove boom side oil stopper plug.
(2) Install hoses P and T of the arm regeneration valve on the machine side.
Oil stopper plug
Hoses P and T of the

arm regeneration valve
(3) Install the oil spray prevention caps to the bucket circuit.
a Bleed the arm cylinder of air by following Assembly Procedure B-15 Bleeding Air from Work Equipment Circuit.

1 21M-62-31780 1
2 21M-62-31551 1
3 01024-81225 3
4 01024-81240 2
hose, slowly loosen its bolts by gradually KW10P Impact 1 Width across flats 19 mm spanner 1
M19 socket 1
extremely care not to clinch or damage Width across flats 32 mm spanner 1
the O-rings.
4. Also, take extremely care not to enter a Width across flats 30 mm spanner 1
Others
83
CONNECTION OF BOOM CYLINDER HEAD
Assembly procedure
Connection of Boom Cylinder Head
B-8
(1) Remove the stopper plate fixed to the boom, and remove the boom cylinder top pin.
4 Boom cylinder: 500 kg
4 Boom cylinder top pin: 104 kg

(2) Start the engine and rotate it at the low idle speed.
(3) Sling the cylinder and raise the rod slowly to match the pin holes.
(4) Knock in the cylinder top pin.

Coat the inner surface of the pin hole with lithium grease.
P
Adjust clearance to 1 mm
or less.
a When operating the cylinder, extend it slowly. Do not operate the cylinder suddenly and do not operate it to the end of its
stroke. In the first operation, there is an air in the cylinder and the cylinder may not move for the first 10 seconds. In such
case, do not operate the control lever to the end of its stroke.
(5) Mount and fix the stopper plate.
a Using shim (5), adjust the clearance between cover (2) and the cylinder rod within 1 mm.

1 21M-70-11220 1
2 21M-70-11280 2
3 21M-70-11290 2
4 01580-12419 4
5 426-70-11280 8

Name Qty Name Qty
Others
84
INSTALLATION OF ARM ASSEMBLY
Assembly procedure
Installation of Arm Assembly (1/2)
B-9
(1) Remove the stopper of the boom top pin fixed to the boom, then pull out the top pin.
4 Boom top pin: 76 kg
(2) Raise the arm assembly, align the position with the boom hole, insert a shim (209-72-51230) t1.0, then push in the pin.
4 Arm assembly: For the weight, see the table in "Transportation"
a Seals (07145-00125 × 2) are installed to the inside of the bushing at the arm end, but be careful no to damage the seals
when inserting the pin.
2 Inside of bushing: Lithium grease
(3) Install the stopper.
(4) Remove the stopper of the arm cylinder top pin fixed to the arm, then pull out the top pin.
4 Arm cylinder pin: 32 kg × 1
Be careful of arm cylinder

rod greasing hole
Assemble so that greasing
hole is at top
(5) Start the engine, run at low idle, extend the arm cylinder rod slowly, and align the position of the hole.
When doing this, raise the arm cylinder with a crane and operate the arm cylinder at the same time to align the position.

1 209-72-51230 1
2 07145-00125 2

Name Qty Name Qty
Others
85
Assembly procedure
Installation of Arm Assembly (2/2)
B-9

Name Qty Name Qty
Others
86
INSTALLATION OF BUCKET CYLINDER HOSES BETWEEN BOOM AND BUCKET CYLINDER
Assembly procedure
Installation of Bucket Cylinder Hoses between
B-10 Boom and Bucket Cylinder
a Bleed the bucket cylinder of air by following Assembly Procedure B-15 Bleeding Air from Work
Equipment Circuit.
Oil stopper plug
Detail P

1 07073-21A19 1
2 07073-21220 1
3 07000-13032 2
4 07000-13038 2
1. After removing the flanges, O-rings, and Name Qty Name Qty
heads, keep them in a safe place so that
they can be used again.
2. When installing the hoses, be extremely
careful not to get the O-rings caught.
3. When installing the hoses, take extreme
care not to twist them.
(Tighten from the 90° adapter to prevent
twisting.)
Others
87
INSTALLATION OF BUCKET
Assembly procedure
Installation of Bucket (1/3)
B-11
(1) Remove the stoppers of the bucket and arm connecting pin (fixed to the arm) and bucket and link connecting pin (installed
to the link) and remove each pin.
(2) Install bushing (1) and 2 O-rings (2) and (3) to the boss on the bucket side.
(3) Run the engine at idle and operate the boom cylinder and arm cylinder slowly to set the holes for the bucket and arm con-
necting pin.
4 Weight of bucket assembly: Refer to the section Transportation.
(4) Push in the arm and bucket connecting pin, adjust the clearance to 0.5 1.0 mm with shims (4) and (5), and tighten cover
mounting bolts (M24).
2 Inside of pin hole: Apply lithium grease.

1 209-70-54160 1
2 21M-939-1B51M 1
3 21M-939-1B41M 1
4 209-70-54181 16
5 209-70-54191 4

Name Qty Name Qty
25 t crane 1
Others
88
Assembly procedure
B-11
(5) Install O-rings (2) to prevent dirt from entering the bucket and arm connecting pin to the correct positions and then install
the pin stopper.
Stopper

Name Qty Name Qty
Others
89
Assembly procedure
B-11
(6) While slinging the link and operating the bucket cylinder, set the holes for the bucket and link connecting pin.
a Operate the cylinder slowly. Do not operate it quickly or to the stroke end. Since there is air in the cylinder, the piston rod
may not move for more than 10 seconds. Do not move the lever to the stroke end at this time.
(7) Push in the link and bucket connecting pin and adjust the clearance to below 1 mm with shims (7) 1.0 mm thick.
Install O-rings (6) to prevent entry of dirt to the correct positions and install the pin stopper.

6 21M-939-1B71M 2
7 209-72-11220 1
a Since the shape of the link is Name Qty Name Qty

different from the former link,
disassemble and assemble the
arm in the vertical posture. If
the arm is disassembled in the
horizontal posture, in particular,
the link jumps up just after the
pin is pulled out. Take care
extremely.
Others
90
CONNECTION OF WORK EQUIPMENT GREASE PIPING
Assembly procedure
Connection of Work Equipment Grease Piping
B-12
(1) Remove the oil stopper plug at the cylinder end and the oil stopper plug at the hose nipple end, remove the nipple from the
hose, then assemble the boom cylinder greasing hoses (2 places) at porting (a) to the cylinder end, and connect.
(2) Remove the oil stopper plug at the cylinder end and the oil stopper plug at the hose elbow end, remove the elbow from the
hose, then assemble the arm cylinder top greasing hose at porting (b) to the cylinder end, and connect.
(3) Remove the oil stopper plug at the cylinder end and the oil stopper plug at the hose elbow end, remove the elbow from the
hose, then assemble the arm cylinder bottom greasing hose at porting (c) to the cylinder end, and connect.
91
CONNECTION OF WORK EQUIPMENT WIRING
Assembly procedure
Connection of Work Equipment Wiring (1/2)
B-13
(1) Connect connector (A) (CN-L01) of the working lamp wire to the body wiring harness.
(2) Install the working lamps as shown below.

1 21T-06-32810 1
2 01024-81230 2
3 08193-20012 1
4 20Y-06-21551 1

Name Qty Name Qty
Others
92
Assembly procedure
Connection of Work Equipment Wiring (2/2)
B-13
(3) Connect connector (A) (CN-A13) of the boom wiring harness to the body wiring harness.

1 04434-51012 1
2 01024-81225 1

Name Qty Name Qty
Others
93
GREASING AFTER ASSEMBLING WORK EQUIPMENT
Assembly procedure
Greasing after Assembling Work Equipment
B-14

Name Qty Name Qty
Others
94
BLEEDING AIR FROM WORK EQUIPMENT CIRCUIT
Assembly procedure
Bleeding Air from Work Equipment Circuit
B-15

Name Qty Name Qty
Others
95
PARTS TO BE TOUCHED UP AFTER FIELD ASSEMBLY
Assembly procedure
Parts to be Touched up After Field Assembly
B-16

Name Qty Name Qty
Others
96
C. ASSEMBLING OF WORK EQUIPMENT
OF LOADING SHOVEL
• Clean the mounting pin hole and check them for a flaw.
97
RELEASING RESIDUAL PRESSURE IN HYDRAULIC CIRCUIT
98
PULLING OUT BOOM FOOT PIN AND BOOM CYLINDER FOOT PIN
99
INSTALLATION OF BOOM CYLINDER FOOT
100
INSTALLATION OF BOOM AND ARM ASSEMBLY
101
INSTALLATION OF BOOM CYLINDER HOSES
102
INSTALLATION OF BOOM CYLINDER ROD PIN
103
INSTALLATION OF BOOM CYLINDER
104
INSTALLATION OF ARM CYLINDER HOSES
105
INSTALLATION OF BUCKET CYLINDER
106
INSTALLATION OF BUCKET CYLINDER HOSES
107
INSTALLATION OF CONNECTING HOSES BETWEEN CHASSIS AND BOOM TOP
108
INSTALLATION OF BOTTOM DUMP CYLINDER HOSES
109
INSTALLATION OF BUCKET ASSEMBLY
110
111
INSTALLATION OF WORKING LAMPS
112
113
INSTALLATION OF WORK EQUIPMENT GREASE PIPING
114
GREASE AFTER ASSEMBLING OF WORK EQUIPMENT
115
BLEEDING AIR FROM WORK EQUIPMENT CIRCUIT
116
CHECKING OIL LEVEL IN HYDRAULIC TANK AND ADDING OIL
117
D. ASSEMBLING OF COUNTERWEIGHT REMOVER
119
STICKING SHEET TO COUNTERWEIGHT
Assembly procedure
Sticking Sheet to Counterweight
D-1
Stick the sheets to the front side of the counterweight as shown below.
When sticking sheets (2), (3), (4), (5), (6), (7) and (10), set the SG sheet stuck to the side of each sheet up.
2 Sheets (1), (8), (9) and (11) : LT-1A (24 hours hardening)
Shall be bonded using LT-1A. Shall be bonded using LT-1A. Shall be bonded using LT-1A.
Surface Surface
without SG sheet. without SG sheet.
Shall be bonded using LT-1A.

1 21M-54-14390 2
2 21M-54-32110 1
3 21M-54-22850 1
4 21M-54-22860 1
5 21M-54-23290 1
6 21M-54-23350 1
7 21M-54-23360 1
8 21M-54-23581 1
9 21M-54-23660 1
10 21M-54-23670 1
11 21M-54-23680 1
Remove all oil and rust from the surface Name Qty Name Qty
where the sheet is to be stuck.
Others
120
ADJUSTMENT OF SHIMS FOR COUNTERWEIGHT
Assembly procedure
Adjustment of Shims for Counterweight (1/5)
D-2
(1) Sling counterweight assembly (1) and install it to the machine.
(2) Check that bolts (2) (6 pieces) can be installed.

(Tighten the bolts with the fingers. You do not need to tighten them securely at this time.)
Weight of counterweight assembly: 12,200 kg

2 21M-46-24210 6
3 209-46-11210 6

Name Qty Name Qty
ø300 × 5,000 mm wire 2 45 t crane 1
SD30 shackle 2
Others
121
Assembly procedure
D-2
(3) Decide the thickness of shims (2), (3) and (4) at the 4 places so that the clearance between the revolving frame and plate
(1) will be 2 mm.
(4) Remove the counterweight mounting bolts and lift the counterweight assembly down from the revolving frame.
(5) Install plate (1) and shims (2), (3) and (4) decided by step (3) above to the counterweight with bolts (5).
Clearance:
2 mm
Shim installing place

1 21M-46-24491 4
2 21M-46-24511 8
3 21M-46-24521 8
4 21M-46-24541 4
5 01024-81235 8

Name Qty Name Qty
Others
122
Assembly procedure
D-2
a If a crane is not available, adjust the shims for the counterweight according to the following procedure.
(1) Measure distances A (L.H.) and A (R.H.) between the center of the counterweight mounting hole of the revolving frame and
outside end of the revolving frame top plate.

Name Qty Name Qty
Others
123
Assembly procedure
D-2
(2) Measure distances B (L.H.) and B (R.H.) between the center of the counterweight hole and end of plate (1).

Name Qty Name Qty
Others
124
Assembly procedure
D-2
(3) Decide the thickness of shims (2), (3) and (4) at the 4 places so that B (L.H.) A (L.H.) and B (R.H.) A (R.H.) will be 2 mm
respectively.
(4) Install plate (1) and shims (2), (3) and (4) decided by step (3) above to the counterweight with bolts (5).
Clearance:
2 mm
Shim installing place

1 21M-46-24491 4
2 21M-46-24511 8
3 21M-46-24521 8
4 21M-46-24541 4
5 01024-81235 8

Name Qty Name Qty
Others
125
GREASING
Assembly procedure
Greasing
D-3
• Before assembling the counterweight remover assembly, grease each pin.

Others
126
INSTALLATION OF COUNTERWEIGHT REMOVER
Assembly procedure
Installation of Counterweight Remover
D-4
1) Sling counterweight remover assembly (1) and install it to the machine.
2) Fix the counterweight remover assembly with mounting bolts (2) (6 pieces) and washers (3) (6 pieces).
Weight of counterweight remover assembly: 1,300 kg

2 01011-83625 6
3 01643-33690 6

Name Qty Name Qty
50 × 3,000 mm nylon sling 2 25 t crane 1
4:1 torque multiplier 1
85 kgm torque wrench 1
T 25 × socket, 55 mm 1
width across flats
Others
127
INSTALLATION OF COVERS
Assembly procedure
Installation of Covers
D-5
• Install covers (1), (2), bracket (3), and bolts and washers (4), (5) and (6).
㽵㽲
㽶㽳
㽷㽴

1 21M-46-24371 1
2 21M-46-24550 1
3 21M-46-24430 1
4 01024-81225 4
5 01024-81225 4
6 01024-81230 2

Others
128
INSTALLATION OF CLAMPS
Assembly procedure
Installation of Clamps (1/3)
D-6
Install clamps (1), cushions (2), and bolts and washers (3).

1 07094-10417 4
2 07095-00420 2
3 01024-81265 2

Name Qty Name Qty
Others
129
Assembly procedure
D-6
Install clamps (1), cushions (2), and bolts and washers (3).

1 07094-10417 4
2 07095-00420 2
3 01024-81265 2

Name Qty Name Qty
Others
130
Assembly procedure
D-6
Install clamps (1), cushions (2) and bolts and washer (3).

1 07094-30417 2
2 07095-00420 2
3 01024-81265 1

Name Qty Name Qty
Others
131
INSTALLATION OF HOSES
Assembly procedure
Installation of Hoses
D-7
Remove the oil plugs of the chassis side and those of the hoses and connect hoses at the remover side to the joint at the
chassis side.
Blue
White
Green
Brown
Yellow
Red
1. When removing each oil plug, loosen it Name Qty Name Qty
slowly to release the internal pressure Oil receiving pan (small) 1
and then remove it carefully.
2. When installing each hose, take extreme Spanner, 19 mm width across flats 2
care that the O-ring will not be caught.
Spanner, 22 mm width across flats 2
3. When installing each hose, take extreme
care that dirt will not enter the circuit.
Others
132
BLEEDING AIR FROM COUNTERWEIGHT REMOVER CIRCUIT
Assembly procedure
Bleeding Air from Counterweight Remover Circuit
D-8
a After assembling the piping, bleed air from the counterweight remover circuit.
(1) Run the engine at low idle.
(2) Extend and retract each cylinder 4 5 times, stopping it at about 100 mm before each stroke end.
(3) While running the engine at low idle, extend each cylinder from 100 mm before each stroke end to the stroke end very
slowly (taking at least 10 seconds) and then keep the remover control lever at the stroke end for 4 minutes.
a At the first operation, the remover link does not move for more than 10 seconds since much air is in the circuit. Do
not move the lever to the stroke end, however.
a The air in the cylinder is bled by operations (1) to (3).
a If each cylinder is moved to the stroke end from the first operation, the air in the cylinder may damage the piston
packing, etc.

Name Qty Name Qty
Others
133
INSTALLATION OF COUNTERWEIGHT
Assembly procedure
D-9
(1) Set the pin holes of the link to those of the counterweight by operating the counterweight remover and then install
counterweight pins (1) and lock plates (2) with bolts (3), washers (4) and nuts (5).

1 21M-46-24360 2
2 21M-46-24570 2
3 01011-81250 2
4 01643-31232 4
5 01580-11210 4

Name Qty Name Qty
Others
134
Assembly procedure
D-9
(2) Place the counterweight on the revolving frame by operating the counterweight remover.
(3) Install bolts (1) (6 pieces) and spacers (2) (6 pieces).

a If a large torque wrench is not available, tighten the bolts by the following angle tightening method.
(1) Tighten the bolts to 1,471 Nm {150 kgm} first.
(2) Tighten the bolts by 90 ± 5°.
a Check the seating condition when tightening the mounting bolts lightly, and then tighten to the specified torque.
Outside diameter: f90 mm, 1.0 kg
3 Tightening torque
3,825 ± 392 Nm L = 395 mm, 5.0 kg
{390 ± 40 kgm} Width across flats: 65 mm

1 21M-46-24210 6
2 209-46-11210 6
Install the counterweight so that there will be Name Qty Name Qty
the reference space of 15 mm between the KW45FS impact wrench 1
weight and the revolving frame or so that the
left level difference equals to the right one. Socket, 65 mm width across flats 1
420 kgm torque wrench 1
T 38 × socket, 1
65 mm width across flats
Others
135
Installation of Accessories
Assembly procedure
Installation of Accessories
D-10
• After tightening counterweight mounting bolt, install cover (1) and bolt (2).
㽳㽲
Note) Install the cover (1) at last since it can interfere with the counterweight
remover when the latter is operated.

1 209-46-42222 1
2 01024-81225 2

M19 socket 1
Others
136
CHECK OF OPERATION
Assembly procedure
Check of Operation
D-11
After assembling the counterweight remover, check the following 3 items.
(1) The cylinders move as operated with the levers.
(2) No oil is leaking.
(3) No parts interfere with each other.

Name Qty Name Qty
Others
137
M. PROCEDURE FOR INSPECTION AND MAINTENANCE
AFTER COMPLETION OF ASSEMBLY
139
INSPECTION OF OIL LEVEL IN HYDRAULIC TANK AND REFILL
Assembly procedure
Inspection of Oil Level in Hydraulic Tank and Refill (1/2)
M-1
Inspection of oil level in hydraulic tank and refill

Name Qty Name Qty
Others
140
Assembly procedure
Inspection of Oil Level in Hydraulic Tank and Refill (2/2)
M-1

Name Qty Name Qty
Others
141
REPLACEMENT OF RETURN FILTER (STANDARD FILTER TO FLUSHING FILTER)
Assembly procedure
Replacement of Return Filter
M-2 (Standard Filter to Flushing Filter)
Replace the hydraulic oil return filter element, valve and strainer of standard items
with hydraulic oil flushing element (1) and plate (2).
a When replacing the element, take out the element

slowly so that refuses adhered to the element do not
fall inside. Also, take out refuses by hand from the
case
Replace the relief valve with this

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

Absolute filter mesh size: 6 μ

1 209-60-77551 1
2 21T-60-13730 1
Store the removed standard element Name Qty Name Qty

(209-60-77530), strainer (20Y-60-31140) and
valve (20Y-60-31131) in order because they
are used again after flushing.
Others
142
FLUSHING OF HYDRAULIC CIRCUIT
Assembly procedure
Flushing of Hydraulic Circuit (1/2)
M-3
a Rotate the engine at the low idle (in the E

mode) with the lever in the neutral position for
15 minutes, and follow the procedures below.

Full operation may damage the filter element
since the relief valve of the filter is closed.
Others
143
Assembly procedure
Flushing of Hydraulic Circuit (2/2)
M-3
(4) Confirmation
After flushing, replace the standard element with
flushing element referring to step M-4.
While doing above, check the collected dusts in
the flushing element if they are not unusual.
If uncertain, contact your distributor.

Others
144
REPLACEMENT OF RETURN FILTER (FLUSHING FILTER TO STANDARD FILTER)
Assembly procedure
M- ( Filter to Filter) (/ )
Reassemble hydraulic oil return filter element (1), strainer (2) and valve (3) which you have removed in the previous step.
a When replacing the element, take out the element

slowly so that refuses adhered to the element do not
fall inside. Also, take out refuses by hand from the
case
Replacement
Valve (3)
Strainer (2)
Standard element (1)

Name Qty Name Qty
Others
145
Assembly procedure
M- ( Filter to Filter) ( )
a After completion of flushing, check the Name Qty Name Qty

flushing element referring to the
caution in M-3, and discard it. Obey
the local rule for discarding.
a Store the strainer, valve and replaced
plate, because they can be used
again.
Others
146
FAILURE CODE
Assembly procedure
Failure code (1/5)
M-
Turn the starting switch ON, operate on the multi-monitor panel in the following procedure, and make sure that no failure
code have been generated.
Function for Abnormality Record [02]

The monitor panel records failures that occurred on the
machines in the past after classifying them into failures in
the electric system and those in the mechanical system.
Information on them can be displayed through the follow-
ing operation.
1) Selection of menu
Select "02 Abnormality Record" in the initial display of
Service Menu and depress [F6] switch.
2) Selection of Submenu
Select an appropriate item from Submenu in the Ab-
normality Record display and depress [F6] switch.
No. Abnormality Record Submenu
01 Mechanical Systems
02 Electrical Systems
03 Air-conditioner Systems
3) Information shown in display of Abnormality Record in

the mechanical system
(a): Order from newest one/Number of all records
(b): Failure Code
(c): Contents of failure code
(d): Number of occurrences (Display range: 0
65,535)
(e): Time elapsed since the occurrence of the first
failure
(f): Service meter reading at latest occurrence
a Refer to "Table for error code No. and failure
code No." in Operator's Menu.
4) Information shown in display of Abnormality Record in

the electrical systems
(a): Order from newest one/Number of all records
(b): Failure Code
(c): Contents of failure
(d): Number of occurrences (Display range: 0
65,535)
(e): Time elapsed since the occurrence of the first
failure
(f): Service meter reading at latest occurrence
a Refer to "Table for error code No. and failure

code No." in Operator's Menu.
147
Assembly procedure
Failure code (2/5)
M-
a Failure code table for mechanical system
Failure code for mechanical system

Display
No.
Failure code Code Server
1 Eng. Hi Out of Std CA234 ENG/M
2 Eng. Lo Out of Std A000KX
3 Eng. Water Overheat B@BCNS ENG/M
4 Eng. Oil Press. Low B@BAZG ENG/M
5 Eng. Oil Level Low B@BAZK MON
MON
6 Hydr. Oil Overheat B@HANS
PUMP
7 Eng. Water Lvl Low B@BCZK MON
8 Aircleaner Clogging AA10NX MON
9 Charge Voltage Low AB00KE MON
10 Crane Ope. Overload 989EKX PUMP
11 Auto. Lub. Abnormal. DA80MA PUMP
148
Assembly procedure
Failure code (3/5)
M-
a Failure code table for electrical system

Display
User code Failure code
DY2DKB Wiper Drive (Fwd) Short Circuit
DY2EKB Wiper Drive (Rev) Short Circuit
DY2CKB Washer Drive Short Circuit
DY20KA Wiper Working Abnormality
DY20MA Wiper Parking Abnormality
DY2GKM Wiper Select Abnormality
DY2FMA Upper Wiper Working Abnormality
E0E DAFRMC CAN Discon (Monitor Detected)
DGH2KB Hyd Oil Sensor Short
DW48KB CO Cancel Sol Short Circuit
E03 DE45KB Swing Brake Sol short Circuit
DWK0KB 2-stage Relief Sol Short Circuit
DW43KB Travel Speed Sol Short Circuit
DWK0KA 2-Stage Relief Sol Open Circuit
DW43KA Travel Speed Sol Open Circuit
DA2SKG Model selection Abnormality
DV20KB Travel Alarm Short Circuit
F Pump Press Sensor Abnormality
DHPAMA
Pump Press Sensor Abnormality
DHPBMA R Pump Press Sensor Abnormality
E02 DA25KP SV Sensor l Power Abnormality
E07
E0E DA2RMC CAN Discon (Pump Con Detected)
E0E DA22KK Pump Solenoid Power Low Error
E02 DXA0KB TVC Sol Short Circuit
E02 DXA0KA TVC Sol Open Circuit
D195KB Step Light Relay Short Circuit
D195KA Step Light Relay Open Circuit
DW4XKB Bucket Curl Hi Cancel Sol Short Circuit
DW4XKA Bucket Curl Hi Cancel Sol Open Circuit
D110KB Battery Relay Drive Short Circuit
E11 DX16KA Fan Pump EPC Sol Open Circuit
E11 DX16KB Fan Pump EPC Sol Short Circuit
DW7BKA Fan Reverse Sol Open Circuit
DX7BKB Fan Reverse Sol Short Circuit
DGE5KB Ambi. Temp Sensor Short Circuit
DAFGMC GPS Module Error
D862KA GPS Antenna open Circuit
E01 D19JKZ Personal Code Relay Abnormality
989N00 Engine Controller Lock Caution 3
989M00 Engine Controller Lock Caution 2
989L00 Engine Controller Lock Caution 1
DAF8KB Camera Power Supply Short Circuit
E10 CA441 Battery Voltage Low Error
E10 CA442 Battery Voltage High Error
E10 CA111 ECM Critical Internal Failure
E10 CA757 All Critical Internal Failure
E10 CA342 Calibration Code Incompatibility
E10 CA689 Eng Ne and Bkup Speed Sens Error
E15 CA342 Eng Ne Speed Sensor Error
E10 CA689 Eng Ne and Bkup Speed Sensor Error
E15 CA115 Eng Bkup Speed Sensor Error
E15 CA731 Eng Bkup Speed Sens Phase Error
149
Assembly procedure
Failure code (4/5)
M-
Display
User code Failure code
E14 CA131 Throttle Sensor High Error
E14 CA132 Throttle Sensor Low Error
E15 CA144 Coolant Temp Sens High Error
E15 CA145 Coolant Temp Sens Low Error
E11 CA122 Chg Air Press Sensor High Error
E11 CA123 Chg Air Press Sensor Low Error
E15 CA263 Fuel Temp Sensor High Error
E15 CA265 Fuel Temp Sensor Low Error
E0E CA1633 KOMNET Datalink Timeout Error
E10 CA271 IMV/PCV1 Short Error
E10 CA273 PCV2 Short Error
E10 CA272 IMV/PCV1 Open Error
E10 CA274 PCV2 Open Error
E11 CA451 Rail Press Sensor High Error
E11 CA452 Rail Press Sensor Low Error
E11 CA554 Rail Press Sensor In Range Error
E11 CA449 Rail Press Very High Error
E15 CA553 Rail Press High Error
E15 CA559 Rail Press Low Error
E11 CA2249 Rail Press Very Low Error
E10 CA351 Injectors Drive Circuit Error
E11 CA322 Inj #1(L#1) Open/Short Error
E15 CA352 Sens Supply 1 Volt Low Error
E15 CA386 Sens Supply 1 Volt High Error
E15 CA187 Sens Supply 2 Volt Low Error
E15 CA227 Sens Supply 2 Volt High Error
E15 CA238 Ne Speed Sens Supply Volt Error
E14 CA2186 Throt Sens Sup Volt Low Error
E14 CA2185 Throt Sens Sup Volt High Error
E15 CA135 Eng Oil Press Sensor High Error
E15 CA141 Eng Oil Press Sensor Low Error
E15 CA153 Chg Air Temp Sensor High Error
E15 CA154 Chg Air Temp Sensor Low Error
E11 CA221 Ambient Press Sens High Error
E11 CA222 Ambient Press Sens Low Error
E15 CA2555 Grid Htr Relay Volt Low Error
E15 CA2556 Grid Htr Relay Volt High Error
E15 CA1653 EGR Inlet Press Sens High Error
E15 CA1642 EGR Inlet Press Sens Low Error
E11 CA2271 EGR Valve Pos Sens High Error
E11 CA2272 EGR Valve Pos Sens Low Error
E11 CA1631 BP Valve Pos Sens High Error
E11 CA1632 BP Valve Pos Sens Low Error
E15 CA1228 EGR Valve Servo Error 1
E11 CA1625 EGR Valve Servo Error 2
E15 CA1628 Bypass Valve Servo Error 1
E11 CA1629 Bypass Valve Servo Error 2
E11 CA2351 EGR Valve Sol Current High Error
E11 CA2352 EGR Valve Sol Current Low Error
E11 CA1626 BP Valve Sol Current High Error
E11 CA1627 BP Valve Sol Current Low Error
150
Assembly procedure
Failure code (5/5)
M-
5) Resetting Electrical Systems

a Resetting the Abnormality Record (deletion) is
possible only with the electrical system. The Ab-
normality Record in the mechanical system can-
not be reset.
a For resetting any specific or all information in the
Electrical Systems, follow the operation ex-
plained below.
i) Through the following switch operation, call the
resetting display in the display of Electrical Sys-
tems.
Switch operation (While pressing [4], per-
form the operation in order):
[4] + [1] o [2] o [3]
a This is the same switch operation in chang-
ing the display to Service Menu.
ii) Check that the screen display is set in the reset

mode, then reset the information items one by
one or all of them with the function switches.
a If [CLEAR] is displayed in [F2], the screen
display is set in the clear mode.
[F2]: Clear all information items
[F3]: Select lower item
[F4]: Select upper item
[F5]: Return to abnormality record screen
[F6]: Reset individual information items
a When resetting individual information items:
Select an item to be reset with [F3] or [F4]
and press [F6], and that item is reset.
a When resetting all information items: Press
[F2], and all the items are reset without ref-
erence to selected item.
a If [E] is displayed on the left of a failure
code, the deleting operation is accepted
but the information is not deleted.
a The figure at right shows the screen display
when the individual information items are
reset. If all the information items are reset
with [F2], "Reset?" is displayed.
iii) If a selected item is cleared, the message of

"Reset!" is displayed. If all the items are reset,
the message of "All reset!" is displayed.
After the message is displayed for a while in ei-
ther case, the message of "No Error" is dis-
played.
151
OPERATING METHOD OF MONITORING
Assembly procedure
Operating Method of Monitoring (1/6)
M-
To enter the System Monitoring mode, turn the starting switch ON, operate on the multi-monitor panel in the following procedure.
OPERATION AND DISPLAY OF SERVICE MENU

Way of switching to Service Menu
a When using Service Menu, change the display to Ser-
vice Menu display through the following special oper-
ation.
1) Confirmation of display
Confirm that the display of ordinary items is shown.
a Changing to Service Menu cannot be made from
displays other than this.
2) Switch operation
Operate the switches as follows.
Switch operation (Press the following switches
in order while pressing [4]):
[4] + [1] o [2] o [3]
3) Showing Service Menu display

The display is changed to the initial display of service
menu program. Select an appropriate item from
among the menu.
No. Service Menu
01 Monitoring
02 Abnormality Record
03 Maintenance Record
04 Maintenance Mode Change
05 Phone Number Entry
06 AAAA/Default
07 Adjustment
4) Termination of Service Menu function

To finish the service menu screen, press [F5], and the
screen returns to the ordinary screen (operator
mode).
152
Assembly procedure
M-
Function of Monitoring [01]

The machine monitor can monitor the machine condition
in real time by the signals of various switches, sensors,
and actuators installed to each part of the machine and
the information from the controller which control those
parts.
1) Selection of menu
On the service menu screen, select "01 Monitoring"
and press the [F6] switch.
2) Setting of monitoring item

After the monitoring selection menu screen is dis-
played, select an item to be monitored with the func-
tion switches or numeral input switches.
[F1]: Move to next page (screen)
[F2]: Move to previous page (screen)
[F3]: Select lower item
[F4]: Select upper item
[F5]: Clear input value/Return to service menu
screen
[F6]: Confirm selection
a Selection with function switches: Select an item

with [F3] or [F4], then confirm with [F6].
a Selection with numeral input switches: Input a 5-
digit code, and the item of that code is selected
directly. Confirm with [F6].
a If the color of the selected box changes from yel-
low to red, selection of the item of that box is
confirmed.
a Up to six monitoring items can be selected si-
multaneously. However, six items may not be
able to be set, depending on their display styles.
a Execution with function switch: Double-click or
hold down [F6]. (About 2 seconds)
a For example, when monitoring only two items,
select each of them and confirm with [F6]. If [F6]
is pressed after completing selection, monitoring
is started.
a If monitoring items are selected up to the select-
able number, monitoring is started automatically.
a For detailed information, display unit, etc. of the
monitoring items, see the monitoring item table.
153
Assembly procedure
M-
3) Monitoring operation
Call the monitoring information display and confirm
the monitored information, while operating the ma-
chine.
4) Function of holding monitoring information

The monitoring information can be held and holding
can be reset with the function switches.
[F3]: Reset holding
[F4]: Hold information (Displayed data is fixed)
[F5]: Return to monitoring selection menu screen
5) Function of changing machine setting mode

When changing the working mode, travel speed, or
auto-deceleration during monitoring, operate the cor-
responding switch under the current condition, and
the mode setting screen appears.
a After completing change of the setting, press
[F6] to return to the monitoring information dis-
play screen.
a If the setting is changed during monitoring, it is
maintained even when the screen returns to the
ordinary screen after monitoring is finished.
a For the monitoring item list, see the following pages.
154
Assembly procedure
M-
a Monitoring item table

Monitoring item Unit
Monitoring Remark
ID English (1) Default (2) Meter (3) Inch
SI unit
00200 Controller Model Select Select the supported controller model code.
00201 Machine ID
01002 Engine Speed r/min rpm rpm 0 to 4000 rpm
01601 2nd Eng. Speed Command r/min rpm rpm
01100 F Pump Pressure MPa kg/cm2 psi The MPa unit system is used in expression A.
01101 R Pump Pressure MPa kg/cm2 psi The MPa unit system is used in expression A.
01102 Travel FW L PPC Pressure MPa kg/cm2 psi
40 to +210°C.
04107 Coolant Temperature C °C °F As Model CM850 has low-temperature sensors only, the
monitoring information of only Engine Water Temp. is displayed.
The low-temperature ID is used as it is.
14200 Fuel Temperature °C °C °F 40 to +210 °C.
04401 Hydr. Oil Temperature °C °C °F (For only B33, display range is 3/0)
37502 Ambient Temperature °C °C °F The setup range is unknown. A negative value may be accepted.
01300 TVC Sol. Curr. mA mA mA
31623 Fan Pump EPC Sol. Curr. mA mA mA
03200 Battery Voltage V V V
03203 Battery Power Supply V V V 0.0 to 480.0 V
04300 Battery Charge Vol. V V V 0.0 to approx. 28.0 V
37200 Engine Oil Pressure kPa kg/cm2 psi 999.9 to +999.9 kPa (if MPa unit system is used in expression A)
36400 Rail Pressure MPa kg/cm2 psi 0 to 400 MPa
37400 Ambient Pressure kPa kg/cm2 psi 999.9 to +999.9 kPa (if MPa unit system is used in expression A)
18400 Intake Temperature °C °C °F 50 to +200 °C.
18500 Charge Temperature °C °C °F 50 to +200 °C.
36500 Boost Pressure kPa kg/cm2 psi 999.9 to +999.9 kPa (MPa*1000) (*3)
18000 EGR Inlet Pressure-A kPa kg/cm2 psi 999.9 to +999.9 kPa
18100 EGR Valve Position mm mm in 0.00 to 99.00 mm
18200 BPS Valve Position mm mm in 0.00 to 99.00 mm
36700 Engine Torque Ratio % % % 0 to 100%
18700 Engine Output Torque Nm kgm lbft 24000 to +24000 Nm
01112 F Pump Pres. Snesor Vol. V V V
01113 R Pump Pres. Snesor Vol. V V V
03000 Fuel Dial Pos Sens Volt V V V 0.00 to 5.00 V
04200 Fuel Level Sensor Vol. V V V
04105 Eng. Water Temp. Vol. Lo V V V 0.00 to 5.00 V
14201 Fuel Temp. Sensor Vol. V V V 0.00 to 5.00 V
04402 Hydr. Temp. Sonser Vol. V V V 0.00 to 5.00 V
37503 Ambi. Temp. Sensor Vol. V V V
37201 Eng Oil Press Sens Volt V V V 0.00 to 5.00 V
37401 Ambient Press Sens Volt V V V 0.00 to 5.00 V
18401 Intake Temp Sens Volt V V V 0.00 to 5.00 V
18501 Charge Temp Sens Volt V V V
36501 Charge Press Sens Volt V V V 0.00 to 5.00 V
36401 Rail Pressure Sens Volt V V V 0.00 to 5.00 V
18001 EGR In Press Sens Volt V V V 0.00 to 5.00 V
18101 EGR Valve Pos Sens Volt V V V 0.00 to 5.00 V
18201 BPS Valve Pos Sens Volt V V V 0.00 to 5.00 V
17201 PCV Close Timing CA CA CA 180.0 to +180.0 CA (*2)
17500 Engine Power Mode Display of digits 0 to 4
31701 Throttle Position % % % 0 to 100%
31706 Final Throttle Position % % % 0 to 100%
18600 Inject Fueling Command mg/st mg/st mg/st 0 to 1000 mg/st
36200 Rail Press Command MPa kg/cm2 psi 0 to 400 MPa
36300 Injection Timing Command CA CA CA 180.0 to +180.0 CA (*2)
37300 Fuel Rate l /h l /h gal/h 0.0 to 9999.9 h (in units of 0.1 l/h)
01602 2nd Eng. Speed Command % % % Throttle opening (%) is appropriate because the engine power is
controlled based on the fan rotation speed control.
13113 Main Pump Absorb Torque Nm kgm lbft
13114 Fan Pump Absorb Torque Nm kgm lbft
13112 Total Pump Absorb Torque Nm kgm lbft
155
Assembly procedure
M-

Monitoring Remark
SI unit
01900 Pressure Switch 1
Swing
Travel (B81: R.H. Travel)
Boom Lower ON/OFF Display
Boom Raise
Arm Curl
Arm Dump
01901 Pressure Switch 2
Bucket Curl
ON/OFF Display
Bucket Dump
Service
02300 Solenoid Valve 1
(B81) Travel Junction
Swing Brake
2-Stage Relief ON/OFF Display
Travel Speed
CO Cancel
Swing Priority
02300 Solenoid Valve 1
(C12) Bucket Hi Cancel
Swing Brake
2-Stage Relief ON/OFF Display
Travel Speed
Fan Reverse
CO Cancel
02200 Switch Input 1
Lever Sw.
ON/OFF Display
Swing Release Sw
Swing Brake Sw.
Model Select 1
Model Select 2
Model Select 3 ON/OFF Display
Model Select 4
Model Select 5
Overload Alarm
ON/OFF Display
Key Switch (ACC)
Step Light Sw. ON/OFF Display
Horn Sw.
Window Limit SW.
ON/OFF Display
Upper wiper P Limit SW.
Upper wiper W Limit SW.
Upper wiper P Limit SW.
Lower wiper SW. ON/OFF Display
Lower wiper active SW.
Lower wiper Select
05500 Sensor Input 1
Over Load Sensor ON/OFF Display
Auto Greasing
03700 Controller Output 1
ON/OFF Display
Batt. Relay Dr.
03701 Controller Output 2
Step L. Relay
ON/OFF Display
Flash L. Relay
Travel Alarm
04500 Monitor Input 1
Key Switch
Start
ON/OFF Display
Preheat
Light
Rad. Level
156
Assembly procedure
M-

Monitoring Remark
SI unit
Aircleaner
ON/OFF Display
Eng. Oil Level
Battery Charge
(C09) ON/OFF Display
Swing Brake Sw.
04503 Monitor Function Switch
F1
F2
F3 ON/OFF Display
F4 F4 cannot be monitored
F5
F6
04504 Monitor 1st & 2nd Row Switches
SW1
SW2
SW3 ON/OFF Display
SW4
SW5
SW6
04505 Monitor 3rd & 4th Row Switches
SW7
SW8
SW9 ON/OFF Display
SW10
SW11
SW12
04506 Monitor 5th Row Switches
SW13
ON/OFF Display
SW14
SW15
20216 ECM Build Version
20217 ECM CAL Data Ver
18900 ECM Internal Temp °C °C °F 40 to +210 °C.
20400 ECM Serial No 0 to 49999999
20227 Monitor Ass'y P/N
20402 Monitor Serial No
20228 Monitor Prog. P/N
20229 Pump Con. Ass'y P/N
20403 Pump Con. Serial No
20230 Pump Con. Prog. P/N
(*2): Unit "CA" is an abbreviation for "Crank Angle" and its actual unit is "deg".
However, do not put " ° " or "deg" as a unit but put only "CA".
(*3): Although the received data has the MPa unit system, the data is dis-
played in kPa as its value is small.
157
Backhoe 1/13
Report No.
FIELD ASSEMBLY INSPECTION REPORT
After completion of assembling a machine, make inspections according to these check sheets for assuring machine performance and quality.
Model - Type Machine Serial No. User Unit No. Engine Model Engine Serial No.
Backhoe spec. SAA6D140E-5
Service Meter Reading Date of Inspection

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

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

□ ……Abnormal □ ……Not applied
2. Enter actually measured values in parentheses, [ ].
Notes :
(1) Criteria are based on the standards when the machine is shipped out of the factory
(2) This FIELD ASSEMBLY INSPECTION REPORT is for “A” specification.
2/13
Category
Revision
Local After
Check item assembly hours of Judgment standard
time operation
Actual
Oil and water levels
measuremet
Cooling water Soft water [ ]
Anti-freeze Density of A : -50 to -40 °C D: -20 to -10 °C

[ ] B : -40 to -30 °C E: -10 to 0 °C
(A, B, C, D, E) anti-freeze
C : -30 to -20 °C (Not necessary in summer)
EO10W30-DH L to H+5 mm (10 minutes after stopping

Engine oil [ ]
EO15W40-DH engine)
Checks before assembly
TO10 L+5 mm to H (10 minutes after stopping

PTO oil [ ]
TO30 engine)
Swing machinery TO30 [ ] L+5 mm to H+10 mm(10 minutes after stopping

gear case oil engine)
Right TO30 [ ]
Final drive gear Bottom edge of level plug : 0 to -10 mm
case oil
Left TO30 [ ]
Hydraulic oil TO10 [ ] Between the H and L marks
Battery electrolyte – [ ] Within 13 mm from bottom surface of filler

port
Engine No. [ ]
When accepted After check
Service meter [ ] [ ]
Loose, untightened lock bolts for connecting pins There must be none.
Loose, untightened split flange bolts for work equipment piping There must be none.
Forgotten, missing, catching O-rings for work equipment piping There must be none.
Checks during assembly
Loose, twisted connections for grease piping There must be none.
Shim adjustment for work equipment pins Max. 1mm (for locations, see assembly
procedure manual)
Improperly inserted wiring, unconnected wiring There must be none.
Loose, untightened ladder mounting bolts There must be none.

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

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

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

Add hydraulic oil
posture.
Add fuel, washer fluid Fill tank.
Dirty oil on paintwork, damage to paintwork at any part Clean, repair damaged paintwork
4/13
Category
Revision
Local After
time operation
Monitor display
1. Check of monitor function
When the starting switch is turned ON, the gauges,
CHECK items, and all display items on the monitor should
light up. At the same the alarm buzzer should sound.
2. Check of gauges and CHECK items
When starting switch is turned to ON (all lamps on), all Display should be as on left.
display lamps should go out after approx. 3 sec.
For another 2 seconds, only the gauges are displayed, and
the CHECK and monitor items disappear.
3. Check of monitor items
After starting the engine, the caution lamps should not light
up and the alarm buzzer should not sound when the
engine speed is low idle – high idle.
There should be no scratches or misting of
Operation of service meter the lens or variation in operation.
MONITOR
AA: Screen for standard
BB: Screen with all lamps lighted up
CC: Maintenance time warning screen
(1) Wiper switch
(2) Buzzer cancel switch
(3) Auto-deceleration switch
(4) Engine coolant temperature monitor
Check monitor
(5) Engine coolant temperature gauge

(6) Hydraulic oil temperature gauge
(7) Service meter, Clock
(8) Hydraulic oil temperature monitor
(9) Working mode monitor
(10) Travel speed monitor
(11) Fuel gauge
(12) ECO gauge
(13) Fuel level monitor
(14) Working mode selector switch
(15) Travel speed selector switch
(16) Window washer switch
(17) Air conditioner control switches
(18) Engine oil pressure monitor
(19) Charge level monitor
(20) Radiator coolant level monitor
(21) Message monitor
(22) Air conditioner monitor
(23) Wiper monitor
(24) Swing lock monitor
(25) Engine pre-heating monitor or One-touch power max.
monitor
(26) Auto-deceleration monitor
(27) Engine oil level monitor
(28) Air cleaner clogging monitor
(29) Function switches (F1 to F6)
(30) Maintenance interval monitor
5/13
Category
Revision Local After

time operation
Check of switches, control levers
(1) Radio (12) Fuel control dial

(2) Lock lever (13) Lamp switch
(3) Left work equipment control lever (14) Swing lock switch
(4) One-touch power max. switch (15) Machine push-up switch
(5) Travel pedals (16) Wiper switch (if equipped)
(6) Travel levers (17) Revolving warning lamp switch (if equipped)
(7) Horn switch (18) Heated operator seat switch (if equipped)
(8) Machine monitor (19) Room lamp switch
(9) Cigarette lighter (20) Emergency pump drive switch
(10) Right work equipment control lever (21) Swing parking brake release switch
(11) Starting switch (22) Step lamp switch (if equipped)
Operation of horn switch Press the switch to sound the horn.

At the same time, the flashing light (if
equipped) at the bottom front of the cab
will flash for approx. 5 seconds.
Operation of lock lever Push down the lever to apply the lock.
Engine can be started but all work
equipment control levers do not move.
Push up the lever to release the lock.
Engine cannot be started but all work
equipment levers move.
Operation of fuel control dial MAX: Full speed
MIN: Low idle
Operation of preheating pilot Rotate the key at the preheating position so
that the monitor display shows "preheating
ON". The preheating pilot will flash after
approx. 30 seconds to indicate the
completion of preheating.
6/13
Category
Revision
Local After
time operation
Operation of working mode selector switch P lights up: Heavy-duty operations

E lights up: Fuel-efficient operations
Monitor display changes in synchronous with

the switch operation.
Engine switches to or from the full operation.
When starting the engine, P (heavy-duty
operation) mode is automatically selected.
Operation of auto-deceleration switch ON lights up: Auto-deceleration is actuated.
OFF: Auto-deceleration is cancelled.
Each time the switch is pressed, the monitor

display changes so that ON or OFF state can
be selected.
Operation of travel speed switch Lo lights up: Low speed travel
Hi lights up: High speed travel

the switch operation. When the engine is
started, the travel speed is automatically set
to Lo.
Operation of wiper switch ON lights up: Wiper moves continuously
INT lights up: Wiper moves intermittently
OFF: Wiper stops

display changes so that any state can be
selected.
Operation of window washer switch Window washer fluid is sprayed out to the
front glass (in combination with wiper) when
the switch is pressed continuously.
Operation of cigarette lighter This is used to light cigarettes. To use, push
the lighter in. After a few seconds it will spring
back and glow.
Operation of lamp switch This switch is used to turn on the front lamps,
working lamps, additional lamp at the top front
of the cab, and monitor lighting.
Operation of swing lock switch ON position (actuated):
The swing lock is always applied, and the
upper structure will not swing even if the
swing is operated. In this condition, the
swing lock monitor lights up.
OFF position (canceled):
Swing operation is possible. In this
condition,the swing lock monitor goes off.
Operation of machine push-up switch Low pressure setting:
The boom thrust force is weak.
High pressure setting:
The boom thrust force becomes more
powerful.
Operation of boom shockless control switch (if equipped) ON: While the boom stop operation, shock of
the boom is controlled.
Operation of step lamp switch (if equipped) • When the switch is pressed, the step light
will light up for approx. 60 seconds.
• Even if the starting switch key is at the
OFF position, the step light will light up for
approx. 60 seconds when the switch is
pressed.
Operation of room lamp switch ON position: Room lamp lights up
OFF position: Room lamp lights off
Even if the starting switch key is at the OFF

position, the room lamp will light up when the
switch is pressed.
Operation of emergency pump drive switch When normal: Switch is pushed down.
When the monitor display shows E02 (TVC valve system error), When switch is pushed up, alarm buzzer
sounds.
move the switch "up" to make it possible to perform work
7/13
Category
Revision
Local After
time operation
Operation of swing brake cancel switch When normal: Switch is pushed down.
When the monitor display shows E03 (Swing brake system error), When switch is pushed up, alarm buzzer
move the switch "up" to cancel the brake, and it becomes possible to sounds, and swing lock symbol flashes
actuate the swing. However, the swing brake remains released.
This is used to stop alarm buzzer if it
Operation of alarm buzzer stop switch sounds to warn of an abnormality of
warning item during engine operation.
ON: Lower wiper moves.
Operation of lower wiper switch (if equipped)
OFF: Lower wiper stops.
Operation of travel levers FORWARD:
The lever is pushed forward.
(The pedal is angled forward)
REVERSE:
The lever is pulled back.
(The pedal is angled back)
N(Neutral):
The machine stops.
Operation of left work equipment control lever This lever is used to operate the arm and
(with auto-deceleration device) upper structure.
Arm operation Swing operation
(a) Arm OUT (c) Swing to right
(b) Arm IN (d) Swing to leftt
N (Neutral):
When the lever is in this position, the
upper structure and the arm will be
retained in the position in which they stop.
Operation of right work equipment control lever This lever is used to operate the boom and
(with auto-deceleration device) bucket.
Boom operation Bucket operation
(a) RAISE (c) DUMP
(b) LOWER (d) CURL
N (Neutral):
boom and the bucket will be retained in the
position in which they stop.
Confirmation of failure history See M-4. Error Code.
(Both electrical and mechanical)
When the switch on the LH work equipment
Operation of power max. switch control lever is pushed, the digging power
increases.
Check function of rotation lamp switch
ON: Rotary lamp lights up
(if equipped)
Check function of large capacity air conditioner blower switch ON: Blower actuated
(if equipped) OFF: Blower stopped
8/13
Category

time operation
Swing operation running in: Engine high idle speed.
(Work equipment posture: Max. reach)
Right Left
8.3 ± 0.4 rpm
Constant swing speed [ rpm] [ rpm]
Swing performance
Brake angle Max. 79° (feeling)
Swing variation, hunting There must be none.
Abnormal noise, irregular swing There must be none.
Travel operation running in: Engine high idle speed.
(Work equipment posture: Travel posture)
Abnormal noise, heat from carrier roller, track roller, idler There must be no abnormal noise or
abnormal heat.
Operation of travel brake Must brake securely without pulling to one
side.
Abnormal noise, irregular travel There must be none.
Travel deviation (feeling) There must be no abnormal deviation from

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

considered that Low Max. 200 mm / 20 m
[ ] [ ]
speed
there is abnormality.) mm / 20 m mm / 20 m
Travel performance
Track rotating
High Forward Reverse P mode
speed speed [ ] [ ] 40.3 ± 5.4 sec / 5 turns
- Right sec sec Difference between left and right: 1.2 sec
High Forward Reverse

speed [ ] [ ]
- Left (PC700LC: 48 ± 5 sec / 5 turns)
sec sec
Low Forward Reverse P mode

speed [ ] [ ] 63.0 ± 6 sec / 5 turns
- Right sec sec Difference between left and right: 1.2 sec
Low Forward Reverse

speed [ ] [ ]
- Left (PC700LC: 77.3 ± 8 sec / 5 turns)
sec sec
Righ Left
Track tension [ ] [ ]
mm mm
9/13
Note: All judgment standard values for speeds are the values in P mode.
Category

time operation
Work equipment operation running in: Engine high idle speed,

(Note: Boom cylinder to ground level)
Pressurized: each port relief 2 minutes, shock 20 times (except BOOM LOWER)
Work equipment posture
Work equip- RAISE sec LOWER sec

ment speed RAISE: 5.1 ± 0.5 sec.
Boom [ ] [ ] LOWER: 3.6 ± 0.4 sec.
OUT sec IN sec IN: 5.5 ± 0.5 sec.

Arm [ ] [ ] OUT: 3.8 ± 0.4 sec.
CURL sec DUMP sec CURL: 3.2 ± 0.3 sec.

Bucket [ ] [ ] DUMP: 3.2 ± 0.3 sec.
Work equip- LOWER sec

ment time lag Boom [ ] Max. 6 sec.
(Engine low Only when there is considered to be abnormality.
idle)
IN sec
Arm [ ] Max. 5 sec.
Work equipment performance
Only when there is considered to be abnormality.

DUMP sec
Bucket [ ] Max. 4 sec.
There must be no abnormality during

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

Engine partial performance under no load, there must be no stalling of
engine even at low idle and relief.
Fine control performance Must operate smoothly.

There must be no escape of boom, arm, or
Operation when raising chassis bucket.
Abnormal noise, grating noise from work equipment There must be none.
Cushion must be fully effective.

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

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

Operating force of control lever when each actuator is
During operation
ation.
actuated.
• Must return naturally to neutral.
Feeling and noise of vibration in operator’s cab There must be none.
Vibration noise from frame, guard, ladder There must be none.
Movement of doors and windows Must move smoothly.

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

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

Contact of link tread
or missing or broken parts.
Oil leakage There must be none.
Center swivel, pump, solenoid valve, relief valve, control

valve, PPC valve, swing motor, brake valve, shuttle valve,
swing machinery, hydraulic tank, piping
There must be none.

Leakage of fuel
(Fuel tank, engine, piping)
Around chassis
Leakage of water from engine cooling water system There must be none.
Leakage of oil from engine lubrication system There must be none.
Leakage of gas from engine gas system There must be none.
Movement of covers Must move smoothly.
Cover locks Must lock securely.

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

Around chassis
Position for passing electrical wiring through

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

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

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

There must be none.
when turning over
12/13
Note: If the operation or function is defective, measure as necessary. All judgment standard values for speeds are the values in P mode.
Category
Revision
Local After
time operation
1. Engine speed: Check in monitoring mode “01006”
Low idle [ rpm] 800 ± 50 rpm
High idle (Operate lever a little) 1950 ± 50 rpm

Monitoring mode ID
High idle “01002”
(When lever is not operated), (Auto-deceleration: canceled) 1750 ± 50 rpm
Speed at arm OUT [ rpm] 1850 ± 50 rpm

at P mode
Speed at arm IN [ rpm] Min. 1780 rpm
2. Radiator fan speed

1430 ± 50 rpm
Speed at engine high idle speed[ rpm] Check in service mode “55”
(Fan rotation 100% fixed mode)
Check in monitoring mode

3. Oil pressure measurement Swing pump “09000”,
Main measurement items
F pump: “01100”, R pump: “01101”

Control valve main +1.5 At engine high idle, arm
set pressure 4-spool valve MPa 31.9 -1.0 MPa
OUT, P mode and Heavy
(R pump) {kg/cm²} {320 +15
-10 kg/cm²}
lift OFF, relief
Control valve main
5-spool valve MPa 34.3 +1.5
-1.0 MPa
set pressure +15 At power max. switch ON
(F pump) {kg/cm²} {350 -10 kg/cm²}
Travel relief set

Right travel MPa 35.3 ± 1.5 MPa
pressure
(F pump) {kg/cm²} {360 ± 15 kg/cm²}
Relieved on one side
Travel relief set at P mode
Left travel MPa 35.3 ± 1.5 MPa
pressure
(R pump) {kg/cm²} {360 ± 15 kg/cm²}
Swing relief set

MPa 29.9 ± 1.0 MPa At engine high idle,
pressure F pump
{kg/cm²} {305 ± 10 kg/cm²} swing and P mode, relief
Pilot relief valve set +0.39 +4

pressure MPa 3.14 0 MPa {32 0 kg/cm²}
{kg/cm²} (At engine high idle, neutral)
In neutral When boom is raised

(Heavy: OFF)
NC valve output Max.
pressure (at top surface MPa MPa Engine
of NC valve) No.1 pump, 1.10 MPa
{kg/cm²} {kg/cm²} high idle
No.2 pump {11.2 kg/cm²}
P mode
Note: Measure the following J/S differential pressure only if

the NC valve output pressure does not pass the test.
At neutral At relief
J/S differential pressure At
Max.
(differential pressure at Engine engine
MPa MPa 1.8 ± 0.2 MPa 0.2 MPa
input and output ports of high high
{kg/cm²} {kg/cm²} {18 ± 2 kg/cm²} idle {2kg/cm²}
jet sensor) No.1 pump, idle, no
No.2 pump load
P mode
13/13
Category
Revision
Local After
time operation
4. Hydraulic drift of work equipment

(bucket unloaded, 50 ± 5°C)
Bucket tooth tip [ mm] Max. 600 mm / 15 minutes
Note: Measure the hydraulic drift of the following cylinders
only if the hydraulic drift at the bucket tooth tip does
not pass the test.
Boom cylinder [ mm] Max. 7 mm/minute
Arm cylinder [ mm] Max. 7 mm/minute
Bucket cylinder [ mm] Max. 7 mm/minute
5. Operation force, travel

Boom lever RAISE N LOWER N
Operating 15.7 ± 3.9 N
force {kg} {kg} {1.6 ± 0.4 kg}
RAISE LOWER PLAY Stroke: 85 ± 10 mm

Stroke
[ mm] [ mm] [ mm] Play: Max. 10 mm
Swing lever RIGHT N LEFT N

force {kg} {kg} {1.3 ± 0.3 kg}
RIGHT LEFT PLAY Stroke: 85 ± 10 mm

Stroke
Bucket DUMP N
Operating CURL N 12.7 ± 2.9 N
lever
force {kg} {kg} {1.3 ± 0.3 kg}
CURL DUMP PLAY Stroke: 85 ± 10 mm

Stroke
At engine high
Arm lever IN N OUT N idle, relief
force {kg} {kg} {1.6 ± 0.4 kg}
IN OUT PLAY Stroke: 85 ± 10 mm

Stroke
Right travel FOR- N RE- N

lever Operating WARD VERSE
24.5 ± 5.9 N
force {kg} {kg} {2.5 ± 0.6 kg}
FORWARD REVERSE PLAY Stroke: 115 ± 12 mm

Stroke
Left travel FOR- N RE- N

24.5 ± 5.9 N
force {kg} {kg} {2.5 ± 0.6 kg}
FORWARD REVERSE PLAY Stroke:115 ± 12 mm

Stroke
Measure the travel of the lever at the center of the lever tip
Loading shovel 1/13
Report No.
FIELD ASSEMBLY INSPECTION REPORT
After completion of assembling a machine, make inspections according to these check sheets for assuring machine performance and quality.
Model - Type Machine Serial No. User Unit No. Engine Model Engine Serial No.
Loading shovel spec. SAA6D140E-5
Service Meter Reading Date of Inspection

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

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

□ ……Abnormal □ ……Not applied
2. Enter actually measured values in parentheses, [ ].
Notes :
(1) Criteria are based on the standards when the machine is shipped out of the factory
(2) This FIELD ASSEMBLY INSPECTION REPORT is for “A” specification.
2/13
Category
Revision
Local After
time operation
Actual
Oil and water levels
measuremet
Cooling water Soft water [ ]
Anti-freeze Density of A : -50 to -40 °C D: -20 to -10 °C

[ ] B : -40 to -30 °C E: -10 to 0 °C
(A, B, C, D, E) anti-freeze
C : -30 to -20 °C (Not necessary in summer)
EO10W30-DH L to H+5 mm (10 minutes after stopping

Engine oil [ ]
EO15W40-DH engine)
Checks before assembly
TO10 L+5 mm to H (10 minutes after stopping

PTO oil [ ]
TO30 engine)
Swing machinery TO30 [ ] L+5 mm to H+10 mm (10 minutes after

gear case oil stopping engine)
Right TO30 [ ]
Final drive gear Bottom edge of level plug : 0 to -10 mm
case oil
Left TO30 [ ]
Hydraulic oil TO10 [ ] Between the H and L marks
Battery electrolyte – [ ] Within 13 mm from bottom surface of filler

port
Engine No. [ ]
When accepted After check
Service meter [ ] [ ]
Loose, untightened lock bolts for connecting pins There must be none.
Loose, untightened split flange bolts for work equipment piping There must be none.
Forgotten, missing, catching O-rings for work equipment piping There must be none.
Loose, twisted connections for grease piping There must be none.
Shim adjustment for work equipment pins Max. 1mm (for locations, see assembly
procedure manual)
Improperly inserted wiring, unconnected wiring There must be none.
Loose, untightened ladder mounting bolts There must be none.

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

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

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

Add hydraulic oil
posture.
Add fuel, washer fluid Fill tank.
Dirty oil on paintwork, damage to paintwork at any part Clean, repair damaged paintwork
4/13
Category
Revision
Local After
time operation
Monitor display
1. Check of monitor function
When the starting switch is turned ON, the gauges,
CHECK items, and all display items on the monitor should
light up. At the same the alarm buzzer should sound.
2. Check of gauges and CHECK items
When starting switch is turned to ON (all lamps on), all Display should be as on left.
display lamps should go out after approx. 3 sec.
For another 2 seconds, only the gauges are displayed, and
the CHECK and monitor items disappear.
3. Check of monitor items
After starting the engine, the caution lamps should not light
up and the alarm buzzer should not sound when the
engine speed is low idle – high idle.
There should be no scratches or misting of
Operation of service meter the lens or variation in operation.
MONITOR
AA: Screen for standard
BB: Screen with all lamps lighted up
CC: Maintenance time warning screen
(1) Wiper switch
(2) Buzzer cancel switch
(3) Auto-deceleration switch
(4) Engine coolant temperature monitor
Check monitor
(5) Engine coolant temperature gauge

(6) Hydraulic oil temperature gauge
(7) Service meter, Clock
(8) Hydraulic oil temperature monitor
(9) Working mode monitor
(10) Travel speed monitor
(11) Fuel gauge
(12) ECO gauge
(13) Fuel level monitor
(14) Working mode selector switch
(15) Travel speed selector switch
(16) Window washer switch
(17) Air conditioner control switches
(18) Engine oil pressure monitor
(19) Charge level monitor
(20) Radiator coolant level monitor
(21) Message monitor
(22) Air conditioner monitor
(23) Wiper monitor
(24) Swing lock monitor
(25) Engine pre-heating monitor or One-touch power max.
monitor
(26) Auto-deceleration monitor
(27) Engine oil level monitor
(28) Air cleaner clogging monitor
(29) Function switches (F1 to F6)
(30) Maintenance interval monitor
5/13
Category

time operation
(1) Radio (12) Fuel control dial

(2) Lock lever (13) Lamp switch
(3) Left work equipment control lever (14) Swing lock switch
(4) Bottom dump switch (15) Machine push-up switch
(5) Travel pedals (16) Wiper switch (if equipped)
(6) Travel levers (17) Revolving warning lamp switch (if equipped)
(7) Horn switch (18) Heated operator seat switch (if equipped)
(8) Machine monitor (19) Room lamp switch
(9) Cigarette lighter (20) Emergency pump drive switch
(10) Right work equipment control lever (21) Swing parking brake release switch
(11) Starting switch (22) Step lamp switch (if equipped)
Operation of horn switch Press the switch to sound the horn.

At the same time, the flashing light (if
equipped) at the bottom front of the cab
will flash for approx. 5 seconds.
Operation of lock lever Push down the lever to apply the lock.
Engine can be started but all work
equipment control levers do not move.
Push up the lever to release the lock.
Engine cannot be started but all work
equipment levers move.
Operation of fuel control dial MAX: Full speed
MIN: Low idle
Operation of preheating pilot Rotate the key at the preheating position so
that the monitor display shows "preheating
ON". The preheating pilot will flash after
approx. 30 seconds to indicate the
completion of preheating.
6/13
Category
Revision
Local After
time operation
Operation of working mode selector switch P lights up: Heavy-duty operations

E lights up: Fuel-efficient operations

the switch operation.
Engine switches to or from the full operation.
When starting the engine, P (heavy-duty
operation) mode is automatically selected.
Operation of auto-deceleration switch ON lights up: Auto-deceleration is actuated.
OFF: Auto-deceleration is cancelled.

display changes so that ON or OFF state can
be selected.
Operation of travel speed switch Lo lights up: Low speed travel
Hi lights up: High speed travel

the switch operation. When the engine is
started, the travel speed is automatically set
to Lo.
Operation of wiper switch ON lights up: Wiper moves continuously
INT lights up: Wiper moves intermittently
OFF: Wiper stops

display changes so that any state can be
selected.
Operation of window washer switch Window washer fluid is sprayed out to the
front glass (in combination with wiper) when
the switch is pressed continuously.
Operation of cigarette lighter This is used to light cigarettes. To use, push
the lighter in. After a few seconds it will spring
back and glow.
Operation of lamp switch This switch is used to turn on the front lamps,
working lamps, additional lamp at the top front
of the cab, and monitor lighting.
Operation of swing lock switch ON position (actuated):
The swing lock is always applied, and the
upper structure will not swing even if the
swing is operated. In this condition, the
swing lock monitor lights up.
OFF position (canceled):
Swing operation is possible. In this
condition,the swing lock monitor goes off.
Operation of machine push-up switch Low pressure setting:
The boom thrust force is weak.
High pressure setting:
The boom thrust force becomes more
powerful.
Operation of boom shockless control switch (if equipped) ON: While the boom stop operation, shock of
the boom is controlled.
Operation of step lamp switch (if equipped) • When the switch is pressed, the step light
will light up for approx. 60 seconds.
• Even if the starting switch key is at the
OFF position, the step light will light up for
approx. 60 seconds when the switch is
pressed.
Operation of room lamp switch ON position: Room lamp lights up
OFF position: Room lamp lights off
Even if the starting switch key is at the OFF

position, the room lamp will light up when the
switch is pressed.
Operation of emergency pump drive switch When normal: Switch is pushed down.
When the monitor display shows E02 (TVC valve system error), When switch is pushed up, alarm buzzer
sounds.
move the switch "up" to make it possible to perform work
7/13
Category
Revision
Local After
time operation
Operation of swing brake cancel switch When normal: Switch is pushed down.
When the monitor display shows E03 (Swing brake system error), When switch is pushed up, alarm buzzer
move the switch "up" to cancel the brake, and it becomes possible to sounds, and swing lock symbol flashes
actuate the swing. However, the swing brake remains released.
This is used to stop alarm buzzer if it
Operation of alarm buzzer stop switch sounds to warn of an abnormality of
warning item during engine operation.
ON: Lower wiper moves.
Operation of lower wiper switch (if equipped)
OFF: Lower wiper stops.
Operation of travel levers FORWARD:
The lever is pushed forward.
(The pedal is angled forward)
REVERSE:
The lever is pulled back.
(The pedal is angled back)
N(Neutral):
The machine stops.
Operation of left work equipment control lever This lever is used to operate the arm and
(with auto-deceleration device) upper structure.
Arm operation Swing operation
(a) Arm OUT (c) Swing to right
(b) Arm IN (d) Swing to leftt
N (Neutral):
upper structure and the arm will be
retained in the position in which they stop.
Operation of right work equipment control lever This lever is used to operate the boom and
(with auto-deceleration device) bucket.
Boom operation Bucket operation
(a) RAISE (c) DUMP
(b) LOWER (d) CURL
N (Neutral):
boom and the bucket will be retained in the
position in which they stop.
Confirmation of failure history See M-4. Error Code.
(Both electrical and mechanical)
R.H.: Bottom opens
Operation of bottom dump switch
L.H.: Bottom closes
Check function of rotation lamp switch
ON: Rotary lamp lights up
(if equipped)
Check function of large capacity air conditioner blower switch ON: Blower actuated
(if equipped) OFF: Blower stopped
8/13
Category

time operation
Swing operation running in: Engine high idle speed.
(Work equipment posture: Max. reach)
Right Left
6.8 ± 0.4 rpm
Constant swing speed [ rpm] [ rpm]
Swing performance
Brake angle Max. 79° (feeling)
Swing variation, hunting There must be none.
Abnormal noise, irregular swing There must be none.
Travel operation running in: Engine high idle speed.
(Work equipment posture: Travel posture)
Abnormal noise, heat from carrier roller, track roller, idler There must be no abnormal noise or
abnormal heat.
Operation of travel brake Must brake securely without pulling to one
side.
Abnormal noise, irregular travel There must be none.
Travel deviation (feeling) There must be no abnormal deviation from

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

considered that Low Max. 200 mm / 20 m
[ ] [ ]
speed
there is abnormality.) mm / 20 m mm / 20 m
Travel performance
Track rotating
speed speed [ ] [ ]
- Right sec sec
P mode
53.6 ± 5.4 sec / 5 turns
speed [ ] [ ]
- Left sec sec
Low Forward Reverse

speed [ ] [ ]
- Right sec sec
P mode
82.0 ± 8 sec / 5 turns
Low Forward Reverse
speed [ ] [ ]
- Left sec sec
Righ Left
Track tension [ ] [ ]
mm mm
9/13
Note: All judgment standard values for speeds are the values in P mode.
Category

time operation
Work equipment operation running in: Engine high idle speed,

(Note: Boom cylinder to ground level)
Pressurized: each port relief 2 minutes, shock 20 times (except BOOM LOWER)
Work equipment posture
Work equip- RAISE sec LOWER sec

ment speed RAISE: 6.1 ± 0.6 sec.
Boom [ ] [ ] LOWER: 4.8 ± 0.5 sec.
OUT sec IN sec IN: 4.1 ± 0.4 sec.

Arm (arc) [ ] [ ] OUT: 2.5 ± 0.3 sec.
CURL sec DUMP sec CURL: 4.6 ± 0.5 sec.

Bucket [ ] [ ] DUMP: 4.0 ± 0.4 sec.
OPEN sec CLOSE sec OPEN: 1.6 ± 0.3 sec.

Bottom [ ] [ ] CLOSE: 1.8 ± 0.3 sec.
Work equip- LOWER sec

ment time lag Boom [ ] Max. 3 sec.
(Engine low Only when there is considered to be abnormality.
idle)
IN sec
Arm [ ] Max. 3 sec.
Work equipment performance

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

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

Engine partial performance under no load, there must be no stalling of
engine even at low idle and relief.
Fine control performance Must operate smoothly.

There must be no escape of boom, arm, or
Operation when raising chassis bucket.
Abnormal noise, grating noise from work equipment There must be none.
Cushion must be fully effective.

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

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

Operating force of control lever when each actuator is
During operation
ation.
actuated.
• Must return naturally to neutral.
Feeling and noise of vibration in operator’s cab There must be none.
Vibration noise from frame, guard, ladder There must be none.
Movement of doors and windows Must move smoothly.

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

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

Contact of link tread
or missing or broken parts.
Oil leakage There must be none.
Center swivel, pump, solenoid valve, relief valve, control

valve, PPC valve, swing motor, brake valve, shuttle valve,
swing machinery, hydraulic tank, piping
There must be none.

Leakage of fuel
(Fuel tank, engine, piping)
Around chassis
Leakage of water from engine cooling water system There must be none.
Leakage of oil from engine lubrication system There must be none.
Leakage of gas from engine gas system There must be none.
Movement of covers Must move smoothly.
Cover locks Must lock securely.

11/13
Category
Revision
Local After
time operation
Operation of grease pump Must move smoothly.
Looseness, insufficient insertion of electric wiring

terminals There must be none.
There must be a clearance of at least 10

Around chassis
Position for passing electrical wiring through mm from any moving part or edge.
Leakage of air from air system There must be none.
There must be none.

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

Around work equipment
One side in contact, clearance at other

(CURL side) side within 5 mm.
Contact between bucket and arm
stopper One side in contact, clearance at other
(DUMP side) side within 5 mm.
One side in contact, clearance at other
Contact between front bucket and rear stopper side within 10 mm.
12/13
Note: If the operation or function is defective, measure as necessary. All judgment standard values for speeds are the values in P mode.
Category
time operation
1. Engine speed: Check in monitoring mode “01006”
Low idle [ rpm] 800 ± 50 rpm
High idle (Operate lever a little) 1950 ± 50 rpm

Monitoring mode ID
High idle “01002”
(When lever is not operated), (Auto-deceleration: canceled) 1750 ± 50 rpm
Speed at arm OUT [ rpm] 1850 ± 50 rpm

at P mode
Speed at arm IN [ rpm] Min. 1780 rpm
2. Radiator fan speed

1430 ± 50 rpm
Speed at engine high idle speed[ rpm] Check in service mode “55”
(Fan rotation 100% fixed mode)
Check in monitoring mode

3. Oil pressure measurement Swing pump “09000”,
F pump: “01100”, R pump: “01101”
Control valve main +1.5 At engine high idle, arm

set pressure 4-spool valve MPa 31.9 -1.0 MPa
OUT, P mode and Heavy
(R pump) {kg/cm²} {320 +15
-10 kg/cm²}
lift OFF, relief
Control valve main
5-spool valve MPa 34.3 +1.5
-1.0 MPa
set pressure +15 At power max. switch ON
(F pump) {kg/cm²} {350 -10 kg/cm²}
Travel relief set

Right travel MPa 35.3 ± 1.5 MPa
pressure
(F pump) {kg/cm²} {360 ± 15 kg/cm²}
Relieved on one side
Travel relief set at P mode
Left travel MPa 35.3 ± 1.5 MPa
pressure
(R pump) {kg/cm²} {360 ± 15 kg/cm²}
Swing relief set

MPa 29.9 ± 1.0 MPa At engine high idle,
pressure F pump
{kg/cm²} {305 ± 10 kg/cm²} swing and P mode, relief
Pilot relief valve set +0.39 +4

pressure MPa 3.14 0 MPa {32 0 kg/cm²}
{kg/cm²} (At engine high idle, neutral)
In neutral When boom is raised

(Heavy: OFF)
NC valve output Max.
pressure (at top surface MPa MPa Engine
of NC valve) No.1 pump,
1.10 MPa
{kg/cm²} {kg/cm²} high idle
No.2 pump {11.2 kg/cm²}
P mode
Note: Measure the following J/S differential pressure only if

the NC valve output pressure does not pass the test.
At neutral At relief
J/S differential pressure At
Max.
(differential pressure at Engine engine
MPa MPa 1.8 ± 0.2 MPa 0.2 MPa
input and output ports of high high
{kg/cm²} {kg/cm²} {18 ± 2 kg/cm²} idle {2kg/cm²}
jet sensor) No.1 pump, idle, no
No.2 pump load
P mode
13/13
Category
Revision
Local After
time operation
4. Hydraulic drift of work equipment

(bucket unloaded, 50 ± 5°C)
Bucket tooth tip [ mm] Max. 600 mm / 15 minutes
Note: Measure the hydraulic drift of the following cylinders
only if the hydraulic drift at the bucket tooth tip does
not pass the test.
Boom cylinder [ mm] Max. 7 mm/minute
Arm cylinder [ mm] Max. 7 mm/minute
Bucket cylinder [ mm] Max. 7 mm/minute
5. Operation force, travel

Boom lever RAISE N LOWER N
force {kg} {kg} {1.7 ± 0.4 kg}
RAISE LOWER PLAY Stroke: 85 ± 10 mm

Stroke
Swing lever RIGHT N LEFT N

force {kg} {kg} {1.4 ± 0.3 kg}
RIGHT LEFT PLAY Stroke: 85 ± 10 mm

Stroke
Bucket DUMP N
Operating CURL N 13.7 ± 2.9 N
lever
force {kg} {kg} {1.4 ± 0.3 kg}
CURL DUMP PLAY Stroke: 85 ± 10 mm

Stroke
At engine high
Arm lever IN N OUT N idle, relief
force {kg} {kg} {1.7 ± 0.4 kg}
IN OUT PLAY Stroke: 85 ± 10 mm

Stroke
Right travel FOR- N RE- N

24.5 ± 5.9 N
force {kg} {kg} {2.5 ± 0.6 kg}
FORWARD REVERSE PLAY Stroke: 115 ± 12 mm

Stroke
Left travel FOR- N RE- N

24.5 ± 5.9 N
force {kg} {kg} {2.5 ± 0.6 kg}
FORWARD REVERSE PLAY Stroke:115 ± 12 mm

Stroke
Measure the travel of the lever at the center of the lever tip

Armado de Campo PC600

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Armado de Campo PC600

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GEN00101-03

HYDRAULIC PC600 -8E0 PC600LC -8E0

Operator for assembly

Mechanics Sharing of work

When the work equipment is installed, the engine must be operated.

A. Assembly of Chassis ...................................................................................................... 21

B. Assembling of Work Equipment ..................................................................................... 75

D. ASSEMBLING OF COUNTERWEIGHT REMOVER ...................................................... 119

M. Procedure for Inspection and Maintenance after Completion of Assembly.................... 139

Field Assembly Inspection Report (Backhoe)

Field Assembly Inspection Report (Loading Shovel)

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

4. k Check during actual work

Backhoe · Inspection of oil level and

Completion of body · Completion of general

· Meeting with all workers assembling assembling

Counterweight 25t crane

(Upper structure + Undercarriage) (Work equipment) (Others)

(Upper structure) (Undercarriage) (Work equipment) (Others)

t Packing Style of Each Kit (Sizes in drawing are given in millimeters.)

PC600LC- PC650LC- PC700LC-

B (mm) 3,330 3,330 3,460 3,460 3,665

PC600LC- PC650LC- PC700LC-

B (mm) 5,064 5,064 5,064 5,064 5,064

C (mm) 585 593 585 593 710

PC600LC- PC650LC- PC700LC-

A (mm) 1,260 1,260 1,200 1,280 1,440

B (mm) 5,340 5,690 5,360 5,710 5,810

C (mm) 875 875 875 875 980

A (mm) 7,930 7,550 6,870

B (mm) 2,010 2,010 2,090

X (mm) 3,780 3,630 3,280

Position of center of gravity Y (mm) 880 870 920

B (mm) 1,210 1,220 1,340 1,240 1,490

X (mm) 940 1,190 1,590 940 630

x: 880 mm Y (mm) 250 260 260 250 280

B (mm) 1,780 1,780

(4) Boom cylinder (for all models)

A (mm) 830 860

Weight (kg) 10,750 12,204

(2) Catwalk (1) (for PC600 and PC650)

No. Tool names Specifications Qty Remarks

441 kN {45 ton} 1

17 T25.4 × 55 mm 1 16-time wrench available

39 Grease G2-LI 20 kg Work equipment lubrication

Part No. of bolt TTTTT-TTTTT

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

a : Bolt thread diameter (Nominal diameter)

Nominal size of thread Width across flats Tightening torque

6×1 10 12 8.8  14.7

a For symbols a and b in the table, see Fig. 1.

Table 4.1 Hydraulic hose of face seal type

Type that uses

Approx. 6 19 34  54 {3.5  5.5} 44 {4.5}

Approx. 10 22 54  93 {5.5  9.5} 74 {7.5}

Approx. 13 27 84  132 {8.5  13.5} 103 {10.5}

Approx. 16 32 128  186 {13.0  19.0} 157 {16.0}

Approx. 20 36 177  245 {18.0  25.0} 216 {22.0}

Table 4.2 Hydraulic hose of taper seal type

Type that does

Approx. 6 19 34  63 {3.5  6.5} 44 {4.5}

Approx. 10 24 59  98 {6.0  10.0} 78 {8.0}

Approx. 13 27 84  132 {8.5  13.5} 103 {10.5}

No. Tool names Specifications Qty Remarks

6×1 10 12 8.8 14.7

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

Approx. 6 19 34 54 {3.5 5.5} 44 {4.5}

Approx. 10 22 54 93 {5.5 9.5} 74 {7.5}

Approx. 13 27 84 132 {8.5 13.5} 103 {10.5}

Approx. 16 32 128 186 {13.0 19.0} 157 {16.0}

Approx. 20 36 177 245 {18.0 25.0} 216 {22.0}

Approx. 6 19 34 63 {3.5 6.5} 44 {4.5}

Approx. 10 24 59 98 {6.0 10.0} 78 {8.0}

Approx. 13 27 84 132 {8.5 13.5} 103 {10.5}

Approx. 16 32 128 186 {13.0 19.0} 157 {16.0}

Approx. 20 36 177 245 {18.0 25.0} 216 {22.0}

Holtz Used as heat-resisting sealant for re-

Seizure resistance and heat resist-

SUNSTAR Used as primer for cab side

"S" is used for high-tempera-

SUNSTAR Used to seal joints of glass

Sling the track frame in the posture for Transportation.

No. Loose-supply items Qty

For PC700LC only

No. Loose-supply items Qty

Do not remove the shoes before Name Qty Name Qty

No. Loose-supply items Qty

No. Already installed to chassis Qty

For PC700LC only

No. Loose-supply items Qty

For PC700LC only

No. Loose-supply items Qty

For PC700LC only

No. Loose-supply items Qty

Mount the grip and its bolts as shown below.

No. Loose-supply items Qty

Tighten the nuts with the specified torque as shown.

No. Loose-supply items Qty

No. Loose-supply items Qty

No. Loose-supply items Qty

The figure right shows the reference mirror mounting