FOREWARD

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
Field Assembling ................................................................................................................ 2
Assembling Procedures, Applicable Equipment and Schedule .......................................... 3
Kit Layout Diagram ............................................................................................................. 4
Transportation..................................................................................................................... 5
List of Tools for Field Assembling....................................................................................... 10
Standard Tightening Torque ............................................................................................... 11

A. Assembly of Chassis ...................................................................................................... 17

A- 1. Installation of Left and Right Track Frames ........................................................... 18
A- 2. Installation of Travel Pipe ...................................................................................... 22
A- 3. Installation of Operator Cab’s Left Handrail........................................................... 24
A- 4. Installation of Operator Cab’s Door Stopper and Striker ...................................... 25
A- 5. Installation of Rearview Mirror ............................................................................... 27
A- 6. Installation of Handrail ........................................................................................... 31
A- 7. Installation of Step ................................................................................................. 34
A- 8. Installation of Left Side Step .................................................................................. 35
A- 9. Sticking Sheet to Counterweight............................................................................ 36
A-10. Installation of Counterweight ................................................................................. 37
A-11. Installation of Step Light ........................................................................................ 38
A-12. Installation of Travel Piping Cover......................................................................... 40
A-13. Testing Track Shoe Tension.................................................................................. 44
A-14. Check fuel, coolant and oil levels .......................................................................... 47

B. Assembling of Work Equipment ..................................................................................... 51

B- 1. Assembly of Arm Cylinder ..................................................................................... 52
B- 2. Connection of Arm Cylinder Hoses........................................................................ 53
B- 3. Installation of Boom Cylinder ................................................................................. 54
B- 4. Assembly of Boom Assembly ................................................................................ 55
B- 5. Installation of Boom Cylinder Hoses...................................................................... 56
B- 6. Installation of Hoses from Chassis along Top of Boom ......................................... 57
B- 7. Connection of Boom Cylinder Head ...................................................................... 58
B- 8. Installation of Arm Assembly ................................................................................. 59
B- 9. Installation of Bucket Cylinder Hoses between Boom and Bucket Cylinder .......... 61
B-10. Installation of Bucket ............................................................................................. 62
B-11. Connection of Work Equipment Grease Piping ..................................................... 63
B-12. Connection of Work Equipment Wiring.................................................................. 64
B-13. Greasing after Assembling Work Equipment......................................................... 66
B-14. Bleeding Air from Work Equipment Circuit ............................................................ 67
B-15. Parts to be Touched up After Field Assembly ....................................................... 68

M. Procedure for Inspection and Maintenance after Completion of Assembly ................... 69

M- 1. Inspection of Oil Level in Hydraulic Tank and Refill .............................................. 70
M- 2. Replacement of Return Filter (Standard Filter to Flushing Filter).......................... 72
M- 3. Flushing of Hydraulic Circuit ................................................................................. 75
M- 4. Error Code............................................................................................................. 77
M- 5. Operating Method of Monitoring............................................................................ 82

Field Assembly Inspection Report (Backhoe)

SPECIFICATIONS
Machine model PC600-8 PC600LC-8
Weight of machine kg 57,300 58,300
3
Bucket capacity m 2.7
Engine model – KOMATSU SAA6D140E-5
Flywheel horsepower kW/rpm {HP/rpm} 323/1,800 {432/1,800}
Min. ground clearance mm 780
Travel speed (Low/High) km/h 3.0/4.9
Swing speed rpm 8.3

PC600-8

1
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.

2
 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
t Counterweight tension
q Left track frame r Upper structure
y Platform group · Performance test
w Right track frame
· Inspection of oil u Assembling of work
e Axle assembly
level and coolant level equipment

(Two)
ASSEMBLING PROCEDURES,

Crane

3
45t 25t 25t

0.49 -- 0.69 MPa

(5 -- 7 kg/cm2)

Air compressor

15 m3/min
APPLICABLE EQUIPMENT AND SCHEDULE

Worker

Leader + 3 mechanics

Start of assembling

Completion of body · Completion of general

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

Bucket

Arm link

Arm cylinder
Tools, facility Boom

Boom
45t crane cylinder

Foreword
Crawler frame

Crawler frame

Revolving
Left deck

frame

Counterweight 25t crane

Motor cover · handrails

4
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

Model PC600-8 PC600LC-8

A (mm) 6,270 6,440

B (mm) 3,470 3,470

Shoe width
(mm) 600 600
Overall width
(mm) 3,195 3,195
Weight 34,100 35,100
(kg)

5
• Upper structure

Model PC600-8 PC600LC-8

Overall width 3,195 3,195
(mm)
Weight
(kg) 17,800 17,800

A (mm) 2,660 2,660

B (mm) 5,070 5,070

C (mm) 590 590

• Undercarriage

Model PC600-8 PC600LC-8

Quantity 2 2

A (mm) 1,260 1,260

B (mm) 5,340 5,690

C (mm) 875 875

Weight 16,300 17,300
(kg) (8,150 × 2) (8,650 × 2)

• Work equipment
(1) Boom

Model PC600-8 PC600LC-8

A (mm) 7,920 7,920

B (mm) 2,040 2,040

Position of center of gravity
Overall width
(mm) 1,190 1,190
7.6 m 7.3 m
Weight 4,820 4,820
x (mm) 3,590 3,420 (kg)
y (mm) 680 710

6
(2) Arm

Model PC600-8 PC600LC-8

A (mm) 4,870 4,870

B (mm) 1,210 1,210

Overall width 480 480
(mm)
x: 880 mm
Weight 3,250 3,250
y: 220 mm (kg)

(3) Bucket

Model PC600-8 PC600LC-8

A (mm) 2,150 2,150

B (mm) 1,780 1,780

Overall width
(mm) 1,780 1,780
Weight 2,430 2,430
(kg)

(4) Boom cylinder (for all models)

Weight : 990 kg
(495 kg × 2 pcs)

X : 1,160 mm

7
 (5) Arm cylinder

Weight: 735 kg

X : 1,400 mm

• Others
(1) Counterweight

Model PC600-8 PC600LC-8

PC600LC-8 (For USA)
Weight
(kg) 10,750 13,500

(2) Catwalk (1) (for all models)

Weight: 37 kg

x : 1,150 mm
y: 60 mm
z : 240 mm

8
(3) Catwalk (2) (for all models)

Weight: 32 kg

x: 970 mm
y: 50 mm
z: 250 mm

9
LIST OF TOOLS FOR FIELD ASSEMBLING
No. Tool names Specifications Q’ty. Remarks
1 Engine compressor Komatsu, 0.69 MPa {7.0kg/cm2} Class 1
2 Crane truck 441 kN {45 ton}, 245 kN {25 ton} 1 each
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 For impact wrench
11 16-time wrench 4413 Nm {450 kgm} 1 For counterweight
12 Socket for 16-time wrench T38.1 × 65 mm 1 For counterweight
13 T38.1 × 55 mm 1 For track frame
14 T38.1 × 50 mm 1 For track frame
15 4-time wrench 25.4, 19 1
16 Socket for 4-time wrench T25.4 × 50 mm 1
17 T25.4 × 55 mm 1
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 set
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 ø25 × 5 m 4 For revolving frame and track frame
31 ø30 × 5 m 2 For counterweight
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
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

10
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 diameter × Bolt 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 26
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

11
 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) Target Range

12 8.8 – 14.7
6×1 10
{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}
89 54 – 123
12 × 1.75 19
{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}
315 201 – 427
18 × 2.5 27
{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}
810 588 – 1030
24 × 3 36
{82.5} {60 – 105}
1180 883 – 1470
27 × 3 41
{120} {90 – 150}
1520 1130 – 1910
30 × 3 46
{155} {115 – 195}
1960 1470 – 2450
33 × 3 50
{200} {150 – 250}
2450 1860 – 3040
36 × 3 55
{250} {190 – 310}
2940 2260 – 3630
39 × 3 60
{300} {230 – 370}

12
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
tightening 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
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}
5.9 – 11.8 4.9 – 9.8 3.9 – 7.8
1/4
{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}
51.0 – 85.3 42.1 – 70.6 31.4 – 52.9
3/4
{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
16.7 – 29.4 9.8 – 19.6 6.9 – 14.7
1/8
{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}
98.0 – 188.2 83.3 – 157.8 60.8 – 115.6
1/2
{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}
367.5 – 612.5 309.7 – 514.5 235.2 – 392.0
1
{37.5 – 62.5} {31.6 – 52.5} {24.0 – 40.0}

13
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.

Table 4
Unit: Nm {kgm}

Outside diameter Width across Tightening torque

of hose flatse.
(mm) (mm) Range Target

Approx. 6 19 35 – 63 {3.5 – 6.5} 44 {4.5}

22 54 – 93 {5.5 – 9.5} 74 {7.5}

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 hoses, take care not to twist them.

14
COATING MATERIALS
a The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly
and assembly are listed below.
a For coating materials not listed below, use the equivalent of products shown in this list.

Category Komatsu code Part No. Q'ty Container Main applications, features

• Used to prevent rubber gaskets, rub-

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

Holtz • Used as heat-resisting sealant for re-

MH 705 790-126-9120 75 g Tube pairing engine.

• Quick hardening type adhesive

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

• Features: Silicone type, heat resist-

Three bond ant, vibration resistant, and impact
1207B 419-15-18131 100 g Tube resistant sealing material
• Used as sealing material for transfer
case

15
 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

16
 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

17
 Assembly procedure
Installation of Left and Right Track Frames (1/4)
A-1

• Before transportation, the Upper Structure (also called the “Revolving Frame Assembly”) was rotated 90° from its
original position. Start the engine and return the Upper Structure to its original position by slowly rotating it 90°
as follows.

• Lift the Upper Structure by two cranes and position it on the Track Frames as shown.

Weight of rear section: Weight of front section:

Approx. 8,000 kg (8 tons) Approx. 9,000 kg (9 tons)

Weight of Upper Structure: 17,900 kg

Slowly rotate 90°

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 Q’ty Name Q’ty
ø 25 × 5000 wire 4 45 ton crane 1
SD30 shackle 1 25 ton crane 1
Others

18
Assembly procedure
Installation of Left and Right Track Frames (2/4)
A-1

• Lower the Upper Structure by two cranes and install it on the Track Frames as shown.

Mount the M36 × 3 bolts and tighten them

with 250 to 310 kgm torque.

Mount the M33 × 3 bolts

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

No. Loose-supply items Q’ty

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

Precautions Necessary tools Necessary equipment

Name Q’ty Name Q’ty
4 time wrench 1
Torque wrench (85 kg) 1
Socket (25.4 Sq. × 50 mm) 1
Socket (25.4 Sq. × 55 mm) 1
Others

19
Assembly procedure
Installation of Left and Right Track Frames (3/4)
A-1

• Secure two points of the center frame of the track by placing a hydraulic jack and a 300 × 400 mm wooden block at
each point. Make sure that these points do not interfere with the upper structure rotation.
• Lift the Track Frame Assembly and install it on the Center Frame.

Weight of a single side of Track Frame

Assembly: 8,200 kg

Precautions Necessary tools Necessary equipment

Name Q’ty Name Q’ty
Hydraulic jack (50 ton) 2 45 ton crane 1
Wooden block (300 × 400 mm) 2
Wire (ø25 mm, 5000 mm long) 2
Others

20
 Assembly procedure
Installation of Left and Right Track Frames (4/4)
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}

Precautions Necessary tools Necessary equipment

Do not remove the shoes before assembling Name Q’ty Name Q’ty
(so as to maintain the tightening torques of 4 time wrench 1
the shoe bolts).
Torque wrench (85 kg) 1
Socket (25.4 Sq. × 50 mm) 1
Socket (25.4 Sq. × 55 mm) 1
Others

21
 Assembly procedure
Installation of Travel Pipe (1/2)
A-2

a Connect the hose having a red band to the upper side of the travel motor.

No. Loose-supply items Q’ty

6 07000-13032 4

No. Already installed to chassis Q’ty

STD 07098-41030 2
1
LC 07098-41032 2
STD 21M-62-2157 2
2
LC 21M-62-2158 2
STD 02764-00630 2
3
LC 02764-00632 2
STD 02762-00330 2
4
LC 02762-00332 2

Precautions Necessary tools Necessary equipment

• Before removing the oil stopper of each Name Q’ty Name Q’ty
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
Width across flats 36 spanner 2
Others

22
Assembly procedure
Installation of Travel Pipe (2/2)
A-2

Red band

Red band

a After the hose connection, bleed the travel pipes of air by loosening the air bleeding plug of the travel motor.

Precautions Necessary tools Necessary equipment

Name Q’ty Name Q’ty
Others

23
Assembly procedure
Installation of Operator Cab’s Left Handrail
A-3

• Mount the grip and its bolts as shown below.

No. Loose-supply items Q’ty

1 20Y-54-51820 1
2 01435-40820 4

Precautions Necessary tools Necessary equipment

Name Q’ty Name Q’ty
Others

24
Assembly procedure
Installation of Operator Cab’s
A-4 Door Stopper and Striker (1/2)

1. Mounting the door stopper

• Mount stoppers, nuts and washers at two positions shown.
• Adjust the stoppers during mounting.

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
turns. Then, fix it by
tightening their locknuts.
No. Loose-supply items Q’ty
1 20Y-54-11611 2
2 01580-11008 2
3 01643-31032 2

Precautions Necessary tools Necessary equipment

Name Q’ty Name Q’ty
Others

25
Assembly procedure
Installation of Operator Cab’s
A-4 Door Stopper and Striker (2/2)

2. Mounting the striker

• Mount the striker, plate, nut and cover as shown below.

• Tighten the nuts with the specified torque as shown.

Tightening torque:
25 -- 34 Nm {2.6 -- 3.5 kgm}

No. Loose-supply items Q’ty

1 20Y-54-51321 1
2 20Y-54-51341 1
3 01584-01008 2
4 20Y-54-51490 1

Precautions Necessary tools Necessary equipment

Name Q’ty Name Q’ty
Others

26
Assembly procedure
Installation of Rearview Mirror (1/4)
A-5

No. Loose-supply items Q’ty

1 421-54-25610 1
2 209-54-75350 1
3 21M-54-11890 1
4 20Y-54-27991 3
5 01252-71030 6
6 21M-54-19141 1
7 01024-81250 6
8 01024-81235 2
9 04025-00632 1

Precautions Necessary tools Necessary equipment

Name Q’ty Name Q’ty
Others

27
Assembly procedure
Installation of Rearview Mirror (2/4)
A-5

Bolt

Bolt
Clamp
Stay

Mirror

No. Loose-supply items Q’ty

1 20Y-54-28911 1
2 209-53-13630 1
3 01024-D1235 2
4 20Y-54-35430 1
5 01252-71025 2

Precautions Necessary tools Necessary equipment

Name Q’ty Name Q’ty
Others

28
Assembly procedure
Installation of Rearview Mirror (3/4)
A-5

Washer
Bolt

Mirror

Bolt
Clamp
Stay

No. Loose-supply items Q’ty

1 20Y-54-28911 1
2 209-53-13691 1
3 20Y-54-35430 1
4 01252-71025 2
5 01024-D1245 1
6 208-01-11270 1

Precautions Necessary tools Necessary equipment

Name Q’ty Name Q’ty
Others

29
Assembly procedure
Installation of Rearview Mirror (4/4)
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 nut (1), screw (2) and bolt (3) of the rearview mirror,
and adjust the mirror angle so that you can have the best view
from the operator’s 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).

30
Assembly procedure
Installation of Handrail (1/3)
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).

No. Loose-supply items Q’ty

1 21M-54-13611 1
2 21M-54-13621 1
3 01034-81240 4
4 01024-81240 8
5 21M-54-21160 1
6 01024-81245 6
7 21M-54-12971 1
8 209-54-63481 2
9 01024-81230 4
10 20Y-54-11611 2
11 01580-01008 2

Precautions Necessary tools Necessary equipment

Name Q’ty Name Q’ty
Others

31
Assembly procedure
Installation of Handrail (With top guard) (2/3)
A-6

No. Loose-supply items Q’ty

1 209-53-13640 1
2 01010-D1260 2
3 01643-71232 2
4 195-33-11220 2

Precautions Necessary tools Necessary equipment

Name Q’ty Name Q’ty
KW12P impact 1
M19 socket 1
Width across flats 17 spanner 1
Others

32
Assembly procedure
Installation of Handrail (Without top guard) (3/3)
A-6

(1) Install handrails (1) with bolts (2), (4) and pipes (3), (5)

No. Loose-supply items Q’ty

1 209-53-13640 1
2 01024-D1260 1
3 20Y-954-4240 1
4 01024-D1275 1
5 20Y-954-4230 1

Precautions Necessary tools Necessary equipment

Name Q’ty Name Q’ty
Others

33
 Assembly procedure
Installation of Step
A-7

No. Loose-supply items Q’ty

1 21M-30-12260 4
2 21M-30-12210 4
Using 900 mm shoe. 3 01010-81640 32
4 01643-31645 32
5 21M-30-12270 16
6 01010-81680 32

Precautions Necessary tools Necessary equipment

Remove the rust prevention plug knocked Name Q’ty Name Q’ty
into the mounting tap hole. KW20P impact 1
M24 socket 1
Others

34
 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 Q’ty
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

Precautions Necessary tools Necessary equipment

Remove the rust prevention plug knocked Name Q’ty Name Q’ty
into the mounting tap hole.
Others

35
 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), (3), (4), (5), (6) and (7), set the SG sheet stuck to the side of each sheet up.

No. Loose-supply items Q’ty

1 21M-54-22810 1
2 21M-54-22821 1
3 21M-54-22830 1
4 21M-54-22840 1
5 21M-54-22850 1
6 21M-54-22860 1
7 21M-54-23290 1

Precautions Necessary tools Necessary equipment

Remove all oil and rust from the surface Name Q’ty Name Q’ty
where the sheet is to be stuck.
Others

36
 Assembly procedure
Installation of Counterweight
A-10

4 Counterweight : 10,750 kg

Outer dia 90 mm 1.0 kg

Tightening torque = 385 mm 5.0 kg

3825 ± 392 mm Width across flats
65mm
(390 ± 40 kg)

No. Loose-supply items Q’ty

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

Precautions Necessary tools Necessary equipment

Install the counterweight so that there will be Name Q’ty Name Q’ty
the reference space of 15 mm between the ø30 x 5000 mm wire 2 45 t crane
weight and the revolving frame or so that the
left level difference equals to the right one. SD30 shackle 2
KW45FS impact 1
Width across flats 65S socket 1
Torque wrench (4,118,8 Nm {420 kgm}) 1
38sq. × 65 mm socket 1
Others

37
Assembly procedure
Installation of Step Light (1/2)
A-11

Connect step light

connector.

Take out connector.

Install grommet.

Taping
Apply silicone seal
all round grommet.

Remove Connection in connector

When not rubber cap.
installed
A-A (1:2)

No. Loose-supply items Q’ty

1 209-53-14430 1
2 01024-D1020 1

Precautions Necessary tools Necessary equipment

Name Q’ty Name Q’ty
Others

38
Assembly procedure
Installation of Step Light (2/2)
A-11

Connect step light

connector.
Install grommet.
Take out connector.

Taping
Apply silicone seal
all round grommet.
Remove Remove grommet and
When not rubber cap. connect connector inside cab
installed
C-C (1:2)

No. Loose-supply items Q’ty

1 209-53-14430 1
2 01024-D1020 1
3 209-53-14421 1
4 01024-D1220 1

Precautions Necessary tools Necessary equipment

Name Q’ty Name Q’ty
Others

39
Assembly procedure
Installation of Travel Piping Cover (1/4)
A-12

• Install left travel piping cover.

No. Loose-supply items Q’ty

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

Precautions Necessary tools Necessary equipment

Name Q’ty Name Q’ty
KW12P impact 1
L150 extension 1
M19 socket 1
KW20P impact 1
M24 socket 1
Others

40
Assembly procedure
Installation of Travel Piping Cover (2/4)
A-12

• Install left travel piping cover.

No. Loose-supply items Q’ty

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

Precautions Necessary tools Necessary equipment

Name Q’ty Name Q’ty
Others

41
Assembly procedure
Installation of Travel Piping Cover (3/4)
A-12

• Install right travel piping cover.

No. Loose-supply items Q’ty

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

Precautions Necessary tools Necessary equipment

Name Q’ty Name Q’ty
Others

42
Assembly procedure
Installation of Travel Piping Cover (4/4)
A-12

• Install right travel piping cover.

No. Loose-supply items Q’ty

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

Precautions Necessary tools Necessary equipment

Name Q’ty Name Q’ty
Others

43
Assembly procedure
Testing Track Shoe Tension (1/3)
A-13

Precautions Necessary tools Necessary equipment

Name Q’ty Name Q’ty
Others

44
Assembly procedure
Testing Track Shoe Tension (2/3)
A-13

Precautions Necessary tools Necessary equipment

Name Q’ty Name Q’ty
Others

45
Assembly procedure
Testing Track Shoe Tension (3/3)
A-13

Precautions Necessary tools Necessary equipment

Name Q’ty Name Q’ty
Others

46
Assembly procedure
Check Fuel, Coolant and Oil Levels (1/3)
A-14

47
Assembly procedure
Check Fuel, Coolant and Oil Levels (2/3)
A-14

48 13 10.5 7.2 520 58 880

12.68 3.43 2.77 1.9 137.38 14.80 232.50
40 13 10 7.2 360
10.57 3.43 2.64 1.9 95.11

48
 Assembly procedure
Check fuel, coolant and oil levels (3/3)
A-14

Precautions Necessary tools Necessary equipment

• Non-amine Supercoolant (Blue) is added when Name Q’ty Name Q’ty

shipped. Do not mix coolant of different type
with it.
Others

49
B. ASSEMBLING OF WORK EQUIPMENT

• Clean the mounting pin and pin hole and check them for a flaw.

51
Assembly procedure
Assembly of Arm Cylinder
B-1

(1) Remove the stoppers from the arm and remove the arm cylinder foot pins.

4 Arm cylinder : 735 kg

4 Arm cylinder foot pin: 36 kg

(2) Lift the arm cylinder and adjust it to the boom hole positions.

(3) Insert the arm cylinder foot pins into holes.

Coat the inner surface of the pin hole with lithium grease.

(4) Mount the stoppers.

No. Loose-supply items Q’ty

1 208-70-31310 3

Precautions Necessary tools Necessary equipment

Name Q’ty Name Q’ty
50 mm wide, 3000 mm Nylon sling 2 25 ton crane 1
KW20P impact wrench 1
M24 socket 1
Others

52
 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) (07084-01213 × 2). Use existing split flange (3) and bolts (4)
and (5) of the oil stopper.

See Precaution 1.

No. Loose-supply items Q’ty

7.6 meter boom 1 07084-01213 2
7.3 meter boom 1 07084-012A9 2
6.6 meter boom 1 07084-01215 2
2 07000-13038 4
No. Parts mounted on the boom Q’ty
3 07371-51260 8
4 01010-81245 16
5 01643-31232 16

Precautions Necessary tools Necessary equipment

1. Before starting the hose connection, Name Q’ty Name Q’ty

securely bind the arm cylinder rod using
wires so that the rod is not pushed out.
2. Remove and store the flange, O-rings and
heads so that you can reuse them later.
3. When connecting the hoses, take
extremely care not to clinch or damage
the O-rings.
4. Also, take extremely care not to enter a
foreign material into the hydraulic circuit.
Others

53
 Assembly procedure
Installation of Boom Cylinder
B-3

(1) Lift the boom cylinder and adjust it to the frame’s 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 frame cylinder holding mount between the cylinder and the revolving frame.
(Height: 40 – 50 mm, Width: less than 90 mm)

Precautions Necessary tools Necessary equipment

a Select an appropriate combination of two Name Q’ty Name Q’ty

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

54
 Assembly procedure
Assembly of Boom Assembly
B-4

4 Boom assembly : 4,820 kg

No. Loose-supply items Q’ty

1 209-72-11180 4
2 209-72-11190 4
3 209-72-11261 2

Precautions Necessary tools Necessary equipment

a Two seals (Part No. 209-72-11261) are Name Q’ty Name Q’ty
mounted on the boom feet. Take care not ø20 × 5000 mm wire 2 25 ton crane 1
to damage them when inserting the pin.
SD30 shackle 2
Large hammer (plastic) 1
KW20P impact 1
M24 socket 1
Others

55
 Assembly procedure
Installation of Boom Cylinder Hoses
B-5

(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-14 “Bleeding Air from Work Equipment Circuit”.

No. Already installed to chassis Q’ty

1 07074-01011 4
No. Loose-supply items Q’ty
2 07000-13032 4

Precautions Necessary tools Necessary equipment

1. When removing an oil stopper plug from a Name Q’ty Name Q’ty
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
heads so that you can reuse them later.
M14 socket 1
3. When connecting the hoses, take
extremely care not to clinch or damage
the O-rings.
4. Also, take extremely care not to enter a
foreign material into the hydraulic circuit.
Others

56
 Assembly procedure
Installation of Hoses from Chassis Along Top of Boom
B-6

(1) Remove the oil stopper plug from the tube at the boom end.

(2) Install the arm cylinder and bucket cylinder hoses (07072-01020 × 1, 07072-01220 × 3) on the top of the boom to the correct
circuits shown in the diagram below.

a Bleed the arm cylinder of air by following Assembly Procedure B-14 “Bleeding Air from Work Equipment Circuit”.

Oil stopper plug

Top of boom

No. Already installed to chassis Q’ty

1 07072-01020 1
2 07072-01220 3
No. Loose-supply items Q’ty
3 07000-13032 1
4 07000-13038 3

Precautions Necessary tools Necessary equipment

1. When removing an oil stopper plug from a Name Q’ty Name Q’ty
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
heads so that you can reuse them later.
M19 socket 1
3. When connecting the hoses, take
extremely care not to clinch or damage M14 socket 1
the O-rings.
4. Also, take extremely care not to enter a
foreign material into the hydraulic circuit.
Others

57
Assembly procedure
Connection of Boom Cylinder Head
B-7

(1) Remove the stopper plate fixed to the boom, and remove the boom cylinder top pin.

4 Boom cylinder : 495 kg

4 Boom cylinder top pin : 104 kg

(2) Start the engine and rotate it at the low idle speed.

(3) Lift the boom cylinder, extend the rod slowly, and align the pin holes.

(4) Knock in the cylinder top pin.

Coat the inner surface of the pin hole with lithium grease.

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.

No. Loose-supply items Q’ty

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

Precautions Necessary tools Necessary equipment

Name Q’ty Name Q’ty
Others

58
Assembly procedure
Installation of Arm Assembly (1/2)
B-8

No. Loose-supply items Q’ty

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

Precautions Necessary tools Necessary equipment

Name Q’ty Name Q’ty
Others

59
Assembly procedure
Installation of Arm Assembly (2/2)
B-8

Precautions Necessary tools Necessary equipment

Name Q’ty Name Q’ty
Others

60
 Assembly procedure
Installation of Bucket Cylinder Hoses between
B-9 Boom and Bucket Cylinder

a Bleed the bucket cylinder of air by following Assembly Procedure B-14 “Bleeding Air from Work
Equipment Circuit”.

Oil stopper plug

Detail P

No. Loose-supply items Q’ty

1 07073-21A19 1
2 07073-21220 1
3 07000-13032 2
4 07000-13038 2

Precautions Necessary tools Necessary equipment

1. After removing the flanges, O-rings, and Name Q’ty Name Q’ty
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, be extremely
careful not to let dirt or dust get into the
circuit.
Others

61
Assembly procedure
Installation of Bucket
B-10

Adjust so that
clearance a is 0.5 - 1 mm.

Clearance a

Standard shim thickness 8

No. Loose-supply items Q’ty

1 209-70-54181 16
2 209-70-54191 4
3 209-70-53150 2
4 209-72-11220 1
5 208-70-33181 2

Precautions Necessary tools Necessary equipment

Name Q’ty Name Q’ty
Others

62
Assembly procedure
Connection of Work Equipment Grease Piping
B-11

(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.

63
Assembly procedure
Connection of Work Equipment Wiring (1/2)
B-12

No. Loose-supply items Q’ty

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

Precautions Necessary tools Necessary equipment

Name Q’ty Name Q’ty
Others

64
Assembly procedure
Connection of Work Equipment Wiring (2/2)
B-12

(3) Connect connector (A) (CN-A13) of the boom wiring harness to the body wiring harness.

No. Loose-supply items Q’ty

1 04434-51012 1
2 01024-81225 1

Precautions Necessary tools Necessary equipment

Name Q’ty Name Q’ty
Others

65
Assembly procedure
Greasing after Assembling Work Equipment
B-13

Precautions Necessary tools Necessary equipment

Name Q’ty Name Q’ty
Others

66
Assembly procedure
Bleeding Air from Work Equipment Circuit
B-14

Precautions Necessary tools Necessary equipment

Name Q’ty Name Q’ty
Others

67
Assembly procedure
Parts to be Touched up After Field Assembly
B-15

Precautions Necessary tools Necessary equipment

Name Q’ty Name Q’ty
Others

68
M. PROCEDURE FOR INSPECTION AND MAINTENANCE
AFTER COMPLETION OF ASSEMBLY

69
Assembly procedure
Inspection of Oil Level in Hydraulic Tank and Refill (1/2)
M-1

Precautions Necessary tools Necessary equipment

Name Q’ty Name Q’ty
Others

70
Assembly procedure
Inspection of Oil Level in Hydraulic Tank and Refill (2/2)
M-1

Precautions Necessary tools Necessary equipment

Name Q’ty Name Q’ty
Others

71
 Assembly procedure
Replacement of Return Filter
M-2 (Standard Filter to Flushing Filter) (1/3)

Replace the hydraulic oil return filter element, valve and strainer of standard items
with hydraulic oil flushing element (1) and plate (2).

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

No. Loose-supply items Q’ty

1 209-60-77551 1
2 21T-60-13730 1

Precautions Necessary tools Necessary equipment

Store the removed standard element (209- Name Q’ty Name Q’ty
60-77530), strainer (20Y-60-31140) and
valve (20Y-60-31131) in order because they
are used again after flushing.
Others

72
Assembly procedure
Replacement of Return Filter
M-2 (Standard Filter to Flushing Filter) (2/3)

Reassemble hydraulic oil return filter element (1), strainer (2) and valve (3) which you have removed in the previous step.

Replacement

Valve (3)

Strainer (2)

Standard element (1)

Precautions Necessary tools Necessary equipment

Name Q’ty Name Q’ty
Others

73
Assembly procedure
Replacement of Return Filter
M-2 (Standard Filter to Flushing Filter) (3/3)

Precautions Necessary tools Necessary equipment

Name Q’ty Name Q’ty
Others

74
 Assembly procedure
Flushing of Hydraulic Circuit (1/2)
M-3

Precautions Necessary tools Necessary equipment

Full operation may damage the filter element Name Q’ty Name Q’ty
since the relief valve of the filter is closed.

Do not relieve any circuits !

Others

75
Assembly procedure
Flushing of Hydraulic Circuit (2/2)
M-3

Precautions Necessary tools Necessary equipment

Name Q’ty Name Q’ty
Others

76
Assembly procedure
Error Code (1/5)
M-4

Turn the starting switch ON, operate on the multi-monitor panel in the following procedure, and make sure that no error codes
have been generated.

77
Assembly procedure
Error Code (2/5)
M-4

a Failure code table for electrical system

Display
User code Failure code
— DY2DKB Wiper Drive (For) S/C
— DY2EKB Wiper Drive (Rev) S/C
— DY2CKB Washer Drive S/C
— DY20KA Wiper Working Abnormality
— DY20MA Wiper Parking Abnormality
E0E DAFRMC Monitor Comm. Abnormality
— DGH2KB Hydr. Oil Temp. Sensor S/C
— DW48KB CO Cancel Sol. S/C
E03 DW45KB Swing Brake Sol. S/C
— DWK0KB 2-stage Relief Sol. S/C
— DW43KB Travel Speed Sol. S/C
— D163KB Flash Light Relay S/C
— DW48KA CO Cancel Sol. Disc.
E03 DW45KA Swing Brake Sol. Disc.
— DWK0KA 2-stage Relief Sol. Disc.
— DW43KA Travel Speed Sol. Disc.
— DA2SKQ Model selection Abnormality
— DV20KB Travel Alarm S/C
— DHPAMA F Pump P.Sensor Abnormality
— DHPBMA R Pump P.Sensor Abnormality
E0E DA2RMC Pump Comm. Abnormality
E0E DA22KK Pump Solenoid Power Low Error
E02 DXA0KB TVC Sol. S/C
E02 DXA0KA TVC Sol. Disc.
— D195KB Step Light Relay S/C
— DW4XKB Bucket Curl Hi Cancel Sol. S/C
— DW4XKA Bucket Curl Hi Cancel Sol.Disc.
— D110KB Battery Relay Drive S/C
E11 DX16KA Fan Pump EPC Sol. Disc.
E11 DX16KB Fan Pump EPC Sol. S/C
— DW7BKA Fan Reverse Sol. Disc.
— DW7BKB Fan Reverse Sol. S/C
— DGE5KB Ambi. Temp. Sensor S/C
E10 CA441 Battery voltage low error
E10 CA442 Battery voltage high error
E10 CA111 ECM Critical Internal Failure
E10 CA757 All Persistent Data Lost Error
E10 CA342 Calibration Code Incompatibility
E15 CA689 Eng Ne Speed Sensor Error
E10 CA115 Eng Ne and Bkup Speed Sens Error
E15 CA778 Eng Bkup Speed Sensor Error
E15 CA731 Eng Bkup Speed Sens Phase Error
— CA234 Eng Overspeed
— B@BCNS COOLANT_TEMPERATURE_FUELING_ERROR
B@BAZG OIL_PRESSURE_FUELING_ERROR
—
B@BAZG OIL_PRESSURE_RPM_ERROR
E14 CA131 Throttle Sensor High Error
E14 CA132 Throttle Sensor Low Error

78
Assembly procedure
Error Code (3/5)
M-4

Display
User code Failure code
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 CA273 PCV2 Short Error
E11 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
E11 CA331 Inj #2(L#2) Open/Short Error
E11 CA324 Inj #3(L#3) Open/Short Error
E11 CA332 Inj #4(L#4) Open/Short Error
E11 CA323 Inj #5(L#5) Open/Short Error
E11 CA325 Inj #6(L#6) 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

79
Assembly procedure
Error Code (4/5)
M-4

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 — — —
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
6 Hydr. Oil Overheat B@HANS MON
7 Eng. Water Lvl Low B@BCZK MON
8 Aircleaner Clogging AA10NX MON
9 Charge Voltage Low AB00KE MON
10 — — —
11 Auto. Lub. Abnormal. DA80MA PUMP

80
Assembly procedure
Error Code (5/5)
M-4

81
Assembly procedure
Operating Method of Monitoring (1/5)
M-5

To enter the System Monitoring mode, turn the starting switch ON, operate on the multi-monitor panel in the following procedure.

82
Assembly procedure
Operating Method of Monitoring (2/5)
M-5

83
Assembly procedure
Operating Method of Monitoring (3/5)
M-5

a For the monitoring item list, see the following pages.

84
Assembly procedure
Operating Method of Monitoring (4/5)
M-5

a Monitoring item table

Monitoring item Unit
Monitoring
(1) Default Remark
ID English (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.
04107 Coolant Temperature C °C °F -40 to +210 °C. As Model CM850 has low-temperature sensors
14200 Fuel Temperature °C °C °F -40 to +210 °C.
04401 Hydr. Oil Temperature °C °C °F
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
01006 Engine Speed r/min rpm rpm
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) (Note 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
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
37300 Fuel Rate l /h l /h gal/h 0.0 to 9999.9 h (in units of 0.1 l /h)
Throttle opening (%) is appropriate because the engine power is
01602 2nd Eng. Speed Command % % %
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
01900 Pressure Switch 1
Swing
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
Backet Hi Cancel
Swing Brake
2-Stage Relief ON/OFF Display
Travel Speed
Fan Reverse
CO Cancel

85
Assembly procedure
Operating Method of Monitoring (5/5)
M-5

Monitoring item Unit

Monitoring Remark
ID English (1) Default (2) Meter (3) Inch
SI unit
02200 Switch Input 1
Lever Sw.
ON/OFF Display
Swing Release Sw
Swing Brake Sw.
02201 Switch Input 2
Model Select 1
Model Select 2
Model Select 3
ON/OFF Display
Model Select 4
Model Select 5

Overload Alarm
02202 Switch Input 3
ON/OFF Display
Key Switch(ACC)
02203 Switch Input 4
Step Light Sw. ON/OFF Display
Horn Sw.
05500 Sensor Input 1
Over Load Sensor ON/OFF Display
Auto Greacing
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
04501 Monitor Input 2
Aircleaner
Eng. Oil Level ON/OFF Display

Battery Charge
04502 Monitor Input 3
Swing Brake Sw.
Bzzr Cancel Sw. (*6)
Window Limit Sw. ON/OFF Display
W Limit Sw.
Upper P Limit Sw. (:P Limit Sw.) Dual wiper model of large machines.
Lower P Limit Sw.
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
20200 Monitor Prog. Version – – –
20212 Pump Con. Prog. Version – – – Software version only for prototyping (Note 1)

Note 1. The software version data is delivered during prototype operations. (The data consists of 4-digit entire version, 4-digit
program section version, and 4-digit data section version.)

Note 3. Although the received data has the “MPa” unit system, the data is displayed in “kPa” as its value is small.

Note 6. The “buzzer” is shorted to “bzzr” due to insufficient display space. Up to 16 characters can be set in this field.

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