Komatsu PC1250-7 PC1250LC-7 PC1250SP-7 Hydraulic Excavator Field Assembly Instruction Manual SN 2000

FOREWARD Since this machine is large in size, it is divided into some units to meet the transportation conditions and regulations applied to the transportation 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 protective 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 different languages and customs work together.

The following is a reference supervision system diagram.

(Instruction system) Work leader Work supervisor

Crane director

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 maintain 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 Assembling Procedures, Applicable Equipment and Schedule ..........................................

4 Kit Layout Diagram ............................................................................................................. 5 Transportation.....................................................................................................................

6 List of assembling tools to be brought in field..................................................................... 13 Tightening Torque............................................................................................................... 15 Coating Materials................................................................................................................ 19 List of parts sent individually............................................................................................... 21 A. Assembly of Chassis ......................................................................................................

A- 1. Installation of Track Frame ....................................................................................

A- 2. Supplying Grease to Swing Circle .........................................................................

A- 3. Assembly of Upper Structure and Undercarriage ..................................................

A- 4. Installation of Travel Piping....................................................................................

A- 5. Installation of Travel Piping Cover .........................................................................

A- 6. Installation of Swivel Travel Piping ........................................................................

A- 6. Sticking Sheets (Counterweight) ...........................................................................

A- 7. Installation of Counterweight .................................................................................

A- 8. Installation of Steps ...............................................................................................

A- 9. Installation of Left Side Step (With Handrail) .........................................................

A-10. Installation of Right Side Step ...............................................................................

A-11. Installation of Handrail ...........................................................................................

A-12. Installation of Radiator Cover ................................................................................

A-13. Installation of Intake Air Cap and Muffler Tail Pipe................................................

A-14. Installation of Left Rear-view Mirror.......................................................................

A-15. Installation of Right Rear-view Mirror ....................................................................

A-16. Preparation for Bleeding Air from Travel Motor .....................................................

A-17. Procedure for Bleeding Air from Hydraulic Circuit .................................................

A-18. Tightening Swing Circle Mounting Bolts Permanently...........................................

A-19. Testing and Adjusting Track Link ..........................................................................

A-20. Inspection of Oil Amount and Water Amount ........................................................

A-21. Parts To Be Touched Up After Field Assembly .....................................................

29 30 33 34 35 36 37 38 40 41 42 44 45 46 51 52 53 54 55 56 57 60 62

B. Assembling of work equipment of backhoe....................................................................

B- 1. Boom Foot Pin, Boom Cylinder Foot Pin ...............................................................

B- 2. Installation of Boom Cylinder Foot.........................................................................

B- 3. Installation of Boom Cylinder Hoses......................................................................

B- 4. Installation of Boom Assembly...............................................................................

B- 5. Installation of Boom Cylinder .................................................................................

B- 6. Installation of Boom Hoses (Between Chassis and Boom) ...................................

B- 7. Installation of Arm Cylinder....................................................................................

B- 8. Installation of Arm Cylinder Hoses.........................................................................

B- 9. Installation of Arm Assembly .................................................................................

B-10. Installation of Bucket Cylinder Hoses (Between Boom and Bucket Cylinder) .......

B-11. Installation of Bucket Assembly.............................................................................

B-12. Clearance Standards for Work Equipment Mount .................................................

B-13. Installation of Work Equipment Grease Piping ......................................................

B-14. Procedure for Bleeding Air from Travel Motor .......................................................

B-15. Bleeding Air from Swing Motor ..............................................................................

B-16. Bleeding Air from Cylinder.....................................................................................

B-17. Installation of Work Equipment Electric Wiring......................................................

B-18. Installation of Floor Mat .........................................................................................

B-19. Greasing Assembled Work Equipment..................................................................

63 64 65 66 67 68 69 70 71 72 74 75 77 78 79 81 82 83 84 85

M. Procedure for inspection and maintenance after completion of assembly .....................

M- 1. Reassembly of Return Filter (Standard Part o Flushing Part) ..............................

M- 2. Releasing Pressure from Hydraulic Circuit ............................................................

M- 3. Installation of Work Equipment Flushing Tube ......................................................

M- 4. Flushing Hydraulic Circuit ......................................................................................

M- 5. Reassembly of Pilot Filter (Flushing Part o Standard Part) ..................................

87 88 91 92 94 95

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

C- 1. Installation of Arm Cylinder Bottoms ......................................................................

C- 2. Connection of Boom and Arm ................................................................................

C- 3. Pulling out Boom Foot Pin and Boom Cylinder Foot Pin........................................

C- 4. Installation of Boom and Arm Assembly ................................................................

C- 5. Replacement of Return Filter (Standard Element o Flushing Element) ................

C- 6. Releasing Residual Pressure in Hydraulic Circuit ..................................................

C- 7. Installation of Boom Hoses (Between Chassis and Boom)....................................

C- 8. Installation of Flushing Tube for Boom Cylinder Hoses .........................................

C- 9. Installation of Flushing Tube for Arm Cylinder Hoses ............................................

C-10. Installation of Flushing Tube for Bucket Cylinder Hoses .......................................

C-11. Installation of Hoses Between Boom and Arm (Bottom Dump) .............................

C-12. Installation of Flushing Tube for Bottom Dump Cylinder Hoses ............................

C-13. Flushing of Hydraulic Circuit ..................................................................................

C-14. Replacement of Pilot Filter (Flushing Element o Standard Element)....................

C-15. Installation of Boom Cylinder Bottoms ...................................................................

C-16. Installation of Boom Cylinder Hoses ......................................................................

C-17. Installation of Boom Cylinder Head Pin .................................................................

C-18. Installation of Arm Cylinder Hoses .........................................................................

C-19. Installation of Bucket Cylinder................................................................................

C-20. Installation of Bucket Cylinder Hoses ....................................................................

C-21. Installation of Bucket Assembly .............................................................................

C-22. Installation of Bottom Dump Cylinder Hoses .........................................................

C-23. Maintenance Standard...........................................................................................

C-24. Installation of Working Lamp..................................................................................

C-25. Installation of Work Equipment Greasing Piping....................................................

C-26. Bleeding Air from Work Equipment Circuit.............................................................

C-27. Checking Oil Level in Hydraulic Tank and Adding Oil............................................

C-28. Greasing After Assembling Work Equipment.........................................................

97 102 103 105 106 107 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 126 127 128 129 130 131 132

Inspection of each part after assembly of loader Field assembly inspection report (Backhoe) Field assembly inspection report (Loading shovel)

SPECIFICATIONS Machine model Weight of machine Bucket capacity Engine model

kg 3

m

PC1250-7

PC1250SP-7

PC1250LC-7

108,700

109,500

113,200

5.2

6.7

5.2

–

SAA6D170E-3

Flywheel horsepower

kW/rpm {HP/rpm}

485{651}/1,800

Min. ground clearance

mm

990

Travel speed (Low/High)

km/h

2.1/3.2

Swing speed

rpm

5.5

PC1250-7

PC1250SP-7

1

PC1250LC-7

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 drawing.)

• 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 problem. 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

ASSEMBLING PROCEDURES, APPLICABLE EQUIPMENT AND SCHEDULE

4

KIT LAYOUT DIAGRAM

5

TRANSPORTATION

TRANSPORTATION

6

TRANSPORTATION

7

TRANSPORTATION

8

TRANSPORTATION

9

TRANSPORTATION

10

TRANSPORTATION

11

TRANSPORTATION

12

LIST OF ASSEMBLING TOOLS TO BE BROUGHT IN FIELD

LIST OF ASSEMBLING TOOLS TO BE BROUGHT IN FIELD

13

LIST OF ASSEMBLING TOOLS TO BE BROUGHT IN FIELD

14

TIGHTENING TORQUE

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. correspond 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 b c d

: Bolt thread diameter (Nominal diameter) : Width across flats of bolt head : Bolt length : Threaded part of bolt

15

TIGHTENING TORQUE

Table 1 Tightening torque for bolts not specified in text Unit: Nm {kgm} Nominal size of thread × pitch a (mm)

Width across flats (= Socket size) b (mm)

6×1

Tightening torque Target

Range

10

12 {1.2}

8.8 – 14.7 {0.9 – 1.5}

8 × 1.25

13

25 {2.5}

14.7 – 34 {1.5 – 3.5}

10 × 1.5

17

54 {5.5}

34 – 74 {3.5 – 7.5}

12 × 1.75

19

89 {9}

54 – 123 {5.5 – 12.5}

14 × 2

22

137 {14}

84 – 196 {8.5 – 20}

16 × 2

24

230 {23.5}

147 – 309 {15 – 31.5}

18 × 2.5

27

315 {32}

201 – 427 {20.5 – 43.5}

20 × 2.5

30

460 {47}

319 – 608 {32.5 – 62}

22 × 2.5

32

650 {66.5}

471 – 829 {48 – 84.5}

24 × 3

36

810 {82.5}

588 – 1030 {60 – 105}

27 × 3

41

1180 {120}

883 – 1470 {90 – 150}

30 × 3

46

1520 {155}

1130 – 1910 {115 – 195}

33 × 3

50

1960 {200}

1470 – 2450 {150 – 250}

36 × 3

55

2450 {250}

1860 – 3040 {190 – 310}

39 × 3

60

2940 {300}

2260 – 3630 {230 – 370}

16

TIGHTENING TORQUE

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

1/8

3.9 – 6.9 {0.4 – 0.7}

2.9 – 5.9 {0.3 – 0.6}

2.0 – 3.9 {0.2 – 0.4}

1/4

5.9 – 11.8 {0.6 – 1.2}

4.9 – 9.8 {0.5 – 1.0}

3.9 – 7.8 {0.4 – 0.8}

3/8

16.7 – 26.5 {1.7 – 2.7}

13.7 – 21.6 {1.4 – 2.2}

9.8 – 16.7 {1.0 – 1.7}

1/2

32.3 – 52.9 {3.3 – 5.4}

26.5 – 43.1 {2.7 – 4.4}

19.6 – 32.3 {2.0 – 3.3}

3/4

51.0 – 85.3 {5.2 – 8.7}

42.1 – 70.6 {4.3 – 7.2}

31.4 – 52.9 {3.2 – 5.4}

1

86.2 – 173.5 {8.8 – 17.7}

72.5 – 146.0 {7.4 – 14.9}

54.9 – 111.7 {5.6 – 11.4}

Nominal size

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

1/8

16.7 – 29.4 {1.7 – 3.0}

9.8 – 19.6 {1.0 – 2.0}

6.9 – 14.7 {0.7 – 1.5}

1/4

19.6 – 44.1 {2.0 – 4.5}

16.7 – 37.2 {1.7 – 3.8}

12.7 – 28.4 {1.3 – 2.9}

3/8

44.1 – 93.1 {4.5 – 9.5}

37.2 – 77.4 {3.8 – 7.9}

27.4 – 58.8 {2.8 – 6.0}

1/2

98.0 – 188.2 {10.0 – 19.2}

83.3 – 157.8 {8.5 – 16.1}

60.8 – 115.6 {6.2 – 11.8}

3/4

170.5 – 316.5 {17.4 – 32.3}

141.1 – 247.0 {14.4 – 25.2}

105.8 – 186.2 {10.8 – 19.0}

1

367.5 – 612.5 {37.5 – 62.5}

309.7 – 514.5 {31.6 – 52.5}

235.2 – 392.0 {24.0 – 40.0}

Nominal size

17

TIGHTENING TORQUE

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} Tightening torque

Outside diameter of hose (mm)

Width across flatse. (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}

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}

Approx. 10

Note : When connecting hoses, take care not to twist them.

18

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

LT-1A

790-129-9030

150 g

Tube

• Used to prevent rubber gaskets, rubber cushions, and cock plug from coming out.

LT-1B

790-129-9050

20 g (2 pcs.)

Polyethylene container

• Used in places requiring an immediately effective, strong adhesive.

Used for plastics (except polyethylene, polyprophylene, tetrafluoroethlene and vinyl chloride), rubber, metal and non-metal.

LT-2

09940-00030

50 g

Polyethylene container

• Features: Resistance to heat and chemicals • Used for anti-loosening and sealant purpose for bolts and plugs.

LT-3

790-129-9060 (Set of adhesive and hardening agent)

Adhesive: 1 kg Hardening agent: 500 g

Can

LT-4

790-129-9040

250 g

Polyethylene container

Holtz MH 705

790-126-9120

75 g

Tube

• Used as heat-resisting sealant for repairing engine.

Three bond 1735

790-129-9140

50 g

Polyethylene container

• Quick hardening type adhesive • Cure time: within 5 sec. to 3 min.

• Used mainly for adhesion of metals, rubbers, plastics and woods.

• Quick hardening type adhesive • Quick cure type (max. strength after 30 minutes) • Used mainly for adhesion of rubbers, plastics and metals.

Adhesives

• Used as adhesive or sealant for metal, glass and plastic.

• Used as sealant for machined holes.

Aron-alpha 201

790-129-9130

2g

Polyethylene container

Loctite 648-50

79A-129-9110

50 cc

Polyethylene container

• Resistance to heat, chemicals • Used at joint portions subject to high temperatures.

LG-1

790-129-9010

200 g

Tube

• Used as adhesive or sealant for gaskets and packing of power train case, etc.

LG-5

790-129-9080

1 kg

Can

• Used as sealant for various threads, pipe joints, flanges.

• Used as sealant for tapered plugs, elbows, nipples of hydraulic piping.

Tube

• Features: Silicon based, resistance to heat, cold • Used as sealant for flange surface, tread.

• Used as sealant for oil pan, final drive case, etc.

LG-6

790-129-9020

200 g

Gasket sealant LG-7

790-129-9070

1 kg

Tube

• Features: Silicon based, quick hardening type • Used as sealant for flywheel housing, intake manifold, oil pan, thermostat housing, etc.

Three bond 1211

790-129-9090

100 g

Tube

• Used as heat-resisting sealant for repairing engine.

Tube

• Features: Silicone type, heat resistant, vibration resistant, and impact resistant sealing material • Used as sealing material for transfer case

Three bond 1207B

419-15-18131

100 g

19

Category

Molybdenum disulphide lubricant

Grease

Komatsu code

Part No.

Q'ty

Container

Main applications, features

LM-G

09940-00051

60 g

Can

• Used as lubricant for sliding portion (to prevent from squeaking).

Tube

• Used to prevent seizure or scuffling of the thread when press fitting or shrink fitting.

• Used as lubricant for linkage, bearings, etc.

LM-P

09940-00040

G2-LI

SYG2-400LI SYG2-350LI SYG2-400LI-A SYG2-160LI SYGA-160CNLI

G2-CA

SYG2-400CA SYG2-350CA SYG2-400CA-A SYG2-160CA SYGA-160CNCA

Molybdenum disulphide grease LM-G (G2-M)

SYG2-400M SYG2-400M-A SYGA-16CNM

Hyper White Grease G2-T G0-T (*) *: For use in cold district

SYG2-400T-A SYG2-16CNT SYG0-400T-A (*) SYG0-16CNT (*)

Biogrease G2B G2-BT (*) *: For high temperature and large load

SYG2-400B SYGA-16CNB SYG2-400BT (*) SYGA-16CNBT (*)

200 g

• General purpose type Various

Various

Various

Various

400 g × 10 Bellows type 400 g × 20 Bellows type 16 kg Can

400 g 16 kg

400 g 16 kg

• Used for normal temperature, light load bearing at places in contact with water or steam.

• Used for heavy load portion

• Seizure resistance and heat resistance higher than molybdenum diBellows type sulfide grease Can • Since this grease is white, it does not stand out against machine body.

• Since this grease is decomposed by bacteria in short period, it has Bellows type less effects on microorganisms, Can animals, and plants.

SUNSTAR PAINT PRIMER 580 SUPER

20 ml

Glass container

SUNSTAR GLASS PRIMER 580 SUPER

20 ml

Glass container

• Used as primer for cab side (Expiration date: 4 months)

Primer

Caulking material

SUNSTAR PENGUINE SEAL 580 SUPER "S" or "W"

320 ml

Polyethylene container

Sika Japan, Sikaflex 256HV

20Y-54-39850

310 ml

Polyethylene container

SUNSTAR PENGUINE SEAL No. 2505

417-926-3920

320 ml

Polyethylene container

SEKISUI SILICONE SEALANT

20Y-54-55130

333 ml

Polyethylene container

20

Adhesive for cab glass

Adhesive

417-926-3910

• Used as primer for glass side (Expiration date: 4 months) • "S" is used for high-temperature season (April - October) and "W" for low-temperature season (November - April) as adhesive for glass.

(Expiration date: 4 months) • Used as adhesive for glass.

(Expiration date: 6 months) • Used to seal joints of glass parts.

(Expiration date: 4 months) • Used to seal front window.

(Expiration date: 6 months)

LIST OF PARTS SENT INDIVIDUALLY

LIST OF PARTS SENT INDIVIDUALLY

30 30 30 30 30 30 34 34 35 35 35 35 35 35 35 35 35 35 35 35 35 36 36 36 36 36 36 36 36 36 36 37 37 37 37 37 37 37 37 37 37 37

21

LIST OF PARTS SENT INDIVIDUALLY

39A

38 38 38 38 38 38 38 38 39 39 39 39 40 40 41 41 41 41 41 41 41 42 42 42 42 42 42 42 42 42 42 42 42 42 42 42 42 42 42 42 43

22

LIST OF PARTS SENT INDIVIDUALLY

44 44 44 44 44 44 44 44 44 44 44 44 44 44 44 45 45 45 45 45 45 45 45 45 45 46 46 46 46 46 46 46 46

23

LIST OF PARTS SENT INDIVIDUALLY

47 47 47 47 47 47 47 47 47 47 47 47 47 48 48 46 49 49 49 49 49 49 49 50 50 50 51 51 51 51 51 52 52 52 52 52 52 53 53 53 53 53

24

LIST OF PARTS SENT INDIVIDUALLY

65

66 66 66 66 66 66 66 67 67 67 68 68 68 69 69 69 69 69 69 69 70 70 71 71 71 71 71 71 72

25

LIST OF PARTS SENT INDIVIDUALLY

74 74 74 74 74 74 74 74 74 74 75 75 75 75 75 75 78

82 82 82 82

26

LIST OF PARTS SENT INDIVIDUALLY

83 83 83 83 83 83 83 88 88 92 92

95

27

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) (2) (3) (4) (5) (6)

2.

Plate Collar Washer Bolt Bolt Washer

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 operator's seat with the sprocket at the rear as shown below, unless otherwise specified.

Front Front

Operator’s Left hand seat

Right hand

Left hand

Right hand

Operator's seat

Rear

Sprocket

Sprocket

Rear

29

Assembly procedure

Installation of Track Frame (1/3)

A-1

Precautions

Necessary tools Name Hydraulic jack (490 kN {50 ton} × 170 st)

Necessary equipment Q’ty 2

Name

Q’ty

×12 or ×16 wrench

1

Torque wrench (490 Nm {50 kgm}) Socket for × 12 25.4T × 60

1

T

Others

Socket for × 16 38.1 × 60

×12 wrench: Input torque 304 Nm {31 kgm} ×16 wrench: Input torque 235 Nm {24 kgm}

30

1 1

Assembly procedure

Installation of Track Frame (2/3)

A-1

"

!

Precautions

Necessary tools

Others

Name

31

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

Installation of Track Frame (3/3)

A-1

Precautions

Necessary tools Name

Others

Do not remove the shoe when carrying out this operation (to ensure the quality of the tightening torque for the shoe bolts)

32

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

A-2

Supplying Grease to Swing Circle

Precautions

Necessary tools

Others

Name

33

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

A-3

Assembly of Upper Structure and Undercarriage

Precautions

Necessary tools

Others

Name

34

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

Installation of Travel Piping

A-4

Precautions

Necessary tools Name

Others

Tools for loading and transportation, tools for installation and tightening

35

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

A-5

Installation of Travel Piping Cover

Precautions

Necessary tools

Others

Name

36

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

A-6

Installation of Swivel Travel Piping

Precautions

Necessary tools Name

Others

The lock plate, main hoses, drain hose, and pilot hose are installed to the upper structure.

37

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

A-6

Sticking Sheets (Counterweight) (EU Spec.)

Precautions

Necessary tools Name

Others

Degrease and derust the faces to be covered with the sheets.

38

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

A-6

Sticking Sheets (Counterweight) (+55°C Spec.)

Precautions

Necessary tools Name

Others

Degrease and derust the faces to be covered with the sheets.

39

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

Installation of Counterweight

A-7

Precautions

Name

Necessary equipment Q’ty

×12 or ×16 wrench

1

Torque wrench (490 Nm {50 kgm}) Socket for × 12 25.4T × 60

1

T

Socket for × 16 38.1 × 60

Others

Install the counterweight so that the standard clearance from the revolving frame is 15 mm and the stepped difference on the left and right is equal.

Necessary tools

1 1

×12 wrench: Input torque 353 Nm {36 kgm} ×16 wrench: Input torque 265 Nm {27 kgm}

40

Name

Q’ty

Assembly procedure

Installation of Steps

A-8

Precautions

Necessary tools

Others

Name

41

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

A-9

Installation of Left Side Step (1/2) (With Handrail)

Precautions

Necessary tools

Others

Name

42

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

A-9

Installation of Left Side Step (2/2) (With Handrail)

Precautions

Necessary tools Name

Others

The ladder is not normally used, so lock it with the key.

43

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

Installation of Right Side Step

A-10

Precautions

Necessary tools

Others

Name

44

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

Installation of Handrail

A-11

Precautions

Necessary tools

Others

Name

45

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

A-12

Installation of Radiator Cover (STD Spec.)

Precautions

Necessary tools Name

Others

Adjust to give the standard clearance.

46

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

A-12

Installation of Radiator Cover (EU Spec., R.H. Duct: Different from STD Spec.) (1/2)

Precautions

Necessary tools Name

Others

Adjust to give the standard clearance.

47

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

A-12

Installation of Radiator Cover (EU Spec., R.H. Duct: Different from STD Spec.) (2/2)

Precautions

Necessary tools Name

Others

Adjust to give the standard clearance.

48

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

A-12

Installation of Radiator Cover (+55°C Spec., R.H. Duct: Different from STD Spec.) (1/2)

Precautions

Necessary tools Name

Others

Adjust to give the standard clearance.

49

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

A-12

Installation of Radiator Cover (+55°C Spec., R.H. Duct: Different from STD Spec.) (2/2)

Precautions

Necessary tools Name

Others

Adjust to give the standard clearance.

50

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

A-13

Installation of Intake Air Cap and Muffler Tail Pipe

Precautions

Necessary tools

Others

Name

51

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

A-14

Installation of Left Rear-view Mirror

Precautions

Necessary tools Name

Others

Refer to 209-98-77220 for installation of the mirror.

Adjust the mirror to the most suitable position.

See mirror installing instruction 21N-9831830 for reference.

52

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

A-15

Installation of Right Rear-view Mirror

Precautions

Necessary tools Name

Others

Refer to 209-98-77220 for installation of the mirror.

Adjust the mirror to the most suitable position.

See mirror installing instruction 21N-9831830 for reference.

53

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

A-16

Preparation for Bleeding Air from Travel Motor

Air is to be bled from the travel motor in assembly procedure [A-18]. Before starting the travel motor, loosen the air bleeder and bleed air from the circuit.

Air bleeding vinyl hose The air bleeding vinyl hose is installed when the machine is delivered.

1) Open the hydraulic tank cap.

(Keep the cap placed on the filler lightly to prevent dirt and rain from entering the tank.)

2) Prepare an oil receiver at the vinyl hose end. (Approx. 20 l can/Each side) 3) Loosen air bleeder (5).

Precautions

Necessary tools

Others

Name

54

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

A-17

Procedure for Bleeding Air from Hydraulic Circuit

1. Bleeding air from hydraulic pump group a If a hydraulic pump was removed and installed or a related piping was disconnected and connected, bleed air from the hydraulic pump group according to the following procedure.

1) Loosen air bleeders (1), (2) and (3) 4 turns.

2) Loosen the oil filler cap of the hydraulic tank and leave it for about 10 minutes. a The above time depends on the oil level in the pump case.

3) When oil flows out of air bleeders (1) and (2), tighten air bleeders (1) and (2).

4) Run the engine at low idle. a Set the work equipment lock lever in the lock position to prevent the work equipment from moving.

5) When clear oil flows out of air bleeders (3), tighten air bleeder (3).

Precautions

Necessary tools

Others

Name

55

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

A-18

Tightening Swing Circle Mounting Bolts Permanently

Precautions

Necessary tools

Others

Name

56

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

A-19

Testing and Adjusting Track Link (1/3)

Precautions

Necessary tools

Others

Name

57

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

A-19

Testing and Adjusting Track Link (2/3)

Precautions

Necessary tools

Others

Name

58

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

A-19

Testing and Adjusting Track Link (3/3)

Precautions

Necessary tools

Others

Name

59

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

A-20

Inspection of Oil Amount and Water Amount (1/2)

Precautions

Necessary tools

Others

Name

60

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

A-20

Inspection of Oil Amount and Water Amount (2/2)

Precautions

Necessary tools Name

Others

Check the fuel and water levels, and add if necessary.

61

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

A-21

Parts To Be Touched Up After Field Assembly

, * ++ & %"' ,! % * +"2 !1 * -%" 0 . ,(* "' ,! " % ,(- ! -) ,! (%%(/"' ) *,+ ' *+" ( *(', ' * * ( ((&

' *+" ( *&

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' *+" ( (-', */ " !,

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Precautions

Necessary tools

Others

Name

62

Necessary equipment Q’ty

Name

Q’ty

B. ASSEMBLING OF WORK EQUIPMENT OF BACKHOE • Clean the mounting pin and pin hole and check them for a flaw.

63

Assembly procedure

B-1

Boom Foot Pin, Boom Cylinder Foot Pin

Precautions

Necessary tools Name

Others

1. Clean the pin holes and pins.

2. Check the pin holes and pins for a flaw.

64

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

B-2

Installation of Boom Cylinder Foot

116

Precautions

Necessary tools

Others

Name

65

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

B-3

Installation of Boom Cylinder Hoses

Precautions

Necessary tools Name

1. After removing the flanges, O-rings, and heads, keep 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.

Others

3. When installing the hoses, be extremely careful not to let dirt or dust get into the circuit.

66

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

B-4

Installation of Boom Assembly

67

Assembly procedure

Installation of Boom Cylinder

B-5

Precautions

Necessary tools

Others

Name

68

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

Installation of Boom Hoses (Between Chassis and Boom)

B-6

Precautions

Necessary tools Name

1. After removing the flanges, O-rings, and heads, keep 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.

Others

3. When installing the hoses, be extremely careful not to let dirt or dust get into the circuit.

69

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

Installation of Arm Cylinder

B-7

Precautions

Necessary tools

Others

Name

70

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

B-8

Installation of Arm Cylinder Hoses

Precautions

Necessary tools Name

1. Be careful not to let the arm cylinder rod jump out during operation.

2. After removing the flanges, O-rings, and heads, keep them in a safe place so that they can be used again.

3. When installing the hoses, be extremely careful not to get the O-rings caught.

Others

4. When installing the hoses, be extremely careful not to let dirt or dust get into the circuit.

71

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

B-9

Installation of Arm Assembly (1/2)

Precautions

Necessary tools

Others

Name

72

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

B-9

Installation of Arm Assembly (2/2)

Precautions

Necessary tools

Others

Name

73

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

B-10

Installation of Bucket Cylinder Hoses (Between Boom and Bucket Cylinder)

Precautions

Necessary tools Name

1. After removing the flanges, O-rings, and heads, keep 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.

Others

3. When installing the hoses, be extremely careful not to let dirt or dust get into the circuit.

74

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

B-11

Installation of Bucket Assembly (1/2)

Precautions

Necessary tools

Others

Name

75

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

B-11

Installation of Bucket Assembly (2/2)

Precautions

Name

Others

The shape is different from the conventional link, so always disassemble or assemble with the arm perpendicular. In particular, if disassembly is carried out with the arm horizontal, the link will spring up immediately after the pin is pulled out, so be extremely careful.

Necessary tools

76

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

B-12

Clearance Standards for Work Equipment Mount

Precautions

Necessary tools

Others

Name

77

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

B-13

Installation of Work Equipment Grease Piping

Precautions

Necessary tools

Others

Name

78

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

B-14

Procedure for Bleeding Air from Travel Motor (1/2)

a If the travel motor or swivel joint was removed and installed or a related piping was disconnected and connected, bleed air from the hydraulic pump group according to the following procedure. a Keep air bleeder (5) operated in assembly procedure [A-7] loosened.

1) Run the engine and push up the track shoe on the side to be bled of air by using the work equipment.

2) While running the engine at low idle, perform the following travel operation and rotate the track shoe with no load.

(Operate the travel lever by a half stroke.)

Lever operation pattern and operation time (sec) Unit = sec

Forward Neutral Neutral Reverse Forward Neutral Reverse

Precautions

Necessary tools

Others

Name

79

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

B-14

Procedure for Bleeding Air from Travel Motor (2/2)

3) Check that the oil flowing through the air bleeding hose contains no bubbles and then tighten air bleeder (5).

4) Remove the air bleeding hose and clip from the bleeder.

5) After finishing the following operation, push up the track shoe on the opposite side and bleed air similarly.

6) Remove the air bleeding order tag plate.

(Right and left)

Precautions

Necessary tools

Others

Name

80

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

Bleeding Air from Swing Motor

B-15

a If the swing motor was removed and installed or a related piping was disconnected and connected, bleed air from the swing motor according to the following procedure.

1) While running the engine at slow speed, swing and stop the upper structure several times. a Air is bled from the swing motor automatically by the above operation.

Precautions

Necessary tools

Others

Name

81

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

Bleeding Air from Cylinder

B-16

a If a hydraulic cylinder was removed and installed or a related piping was disconnected and connected, bleed air from the hydraulic cylinder according to the following procedure.

1) Run the engine at idle for about 5 minutes.

2) While running the engine at slow speed, extend and retract the cylinder 4 – 5 times. a Move the piston rod to about 100 mm before each stroke end and never relieve the pressure.

3) While running the engine at slow speed, move the piston rod very slowly (taking at least 10 seconds) from a position about 100 mm before the extension stroke end to the stroke end and relieve the pressure for 3 minutes.

4) While running the engine at full throttle, move the piston rod very slowly (taking at least 10 seconds) from a position about 100 mm before the extension stroke end to the stroke end and relieve the pressure for 1 minutes.

Precautions

Necessary tools

Others

Name

82

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

B-17

Installation of Work Equipment Electric Wiring

Precautions

Necessary tools

Others

Name

83

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

Installation of Floor Mat

B-18

Precautions

Necessary tools

Others

Name

84

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

B-19

Greasing Assembled Work Equipment

Apply molybdenum disulfide grease to each pin of the work equipment to fit the pin well for the first month of the new machine or until the first grease pail (16 kg) is used up. (Komatsu Item No. SYGA16CNM (16kg pail)) <Precautions> (1) Do not apply molybdenum disulfide grease to the swing circle bearing.

(Since the balls are in contact with the races by points, they are worn quickly.)

(2) Do not apply molybdenum disulfide grease to the pin holes when assembling the work equipment.

(After the grease at the pin fixing parts dries up, those parts are rusted easily and the pin may be fixed.)

Precautions

Necessary tools

Others

Name

85

Necessary equipment Qâ&#x20AC;&#x2122;ty

Name

Qâ&#x20AC;&#x2122;ty

M.PROCEDURE FOR INSPECTION AND MAINTENANCE AFTER COMPLETION OF ASSEMBLY

87

Assembly procedure

Reassembly of Return Filter (1/3) (Standard Part o Flushing Part)

M-1

Precautions

Necessary tools Name

Others

The standard parts that are removed (element, strainer, valve) are used again after the completion of flushing, so keep them in a safe place and be careful not to damage them.

88

Necessary equipment Qâ&#x20AC;&#x2122;ty

Name

Qâ&#x20AC;&#x2122;ty

Assembly procedure

M-1

Replacement of Return Filter (Flushing Filter to Standard Filter) (2/3)

Precautions

Necessary tools

Others

Name

89

Necessary equipment Qâ&#x20AC;&#x2122;ty

Name

Qâ&#x20AC;&#x2122;ty

Assembly procedure

Reassembly of Return Filter (3/3) (Standard Part o Flushing Part)

M-1

Precautions

Necessary tools Name

After completion of flushing, remove the special flushing element and discard it.

Others

The plate is removed and used again, so keep it in a safe place.

90

Necessary equipment Qâ&#x20AC;&#x2122;ty

Name

Qâ&#x20AC;&#x2122;ty

Assembly procedure

M-2

Releasing Pressure from Hydraulic Circuit

Precautions

Necessary tools

Others

Name

91

Necessary equipment Qâ&#x20AC;&#x2122;ty

Name

Qâ&#x20AC;&#x2122;ty

Assembly procedure

M-3

Installation of Work Equipment Flushing Tube (1/2)

Precautions

Necessary tools

Others

Name

92

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

M-3

Installation of Work Equipment Flushing Tube (2/2)

Precautions

Necessary tools Name

1. After removing the flushing tube and tee, keep them in a safe place so that they can be used again.

2. When connecting the hoses, be extremely careful not to get any parts caught.

Others

3. Be extremely careful that there is no interference or twisting of the hoses when installing.

93

Necessary equipment Qâ&#x20AC;&#x2122;ty

Name

Qâ&#x20AC;&#x2122;ty

Assembly procedure

Flushing Hydraulic Circuit

M-4 After finishing assembly, flush the hydraulic circuit.

(1) Set the levers in neutral and run the engine at low idle for 30 minutes.

(2) Set the levers in neutral and run the engine at medium speed for 30 minutes.

(3) While running the engine at speed of about 1,700 rpm, repeat the following lever operation pattern 4 times (Keep each operation for 1 minute – 1 minute 30 seconds).

The operation pattern for flushing is as follows.

(4) After finishing the above work, return the flushing tube and tee and perform the following flushing.

After finishing the general assembly, flush the hydraulic circuit. a Run the engine at low idle (E mode) with the lever in neutral and perform flushing for 15 minutes according to the following procedure.

(5) Flushing of Swing Circuit Right swing and left swing for 3 minutes each

(6) Flushing of Travel Circuit Press the ground with the work equipment as illustrated here to raise one side of the machine, and operate the travel lever as follows: •

Forward travel and backward travel to the right For 3 minutes each

•

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

Precautions

Necessary tools Name

Others

If the flushing is performed with the engine at full throttle, the filter element may be broken since the relief valve of the filter is closed.

94

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

Reassembly of Pilot Filter (Flushing Part o Standard Part)

M-5

Precautions

Necessary tools

Others

Name

95

Necessary equipment Qâ&#x20AC;&#x2122;ty

Name

Qâ&#x20AC;&#x2122;ty

C. PROCEDURE FOR ASSEMBLING WORK EQUIPMENT OF LOADING SHOVEL

CONTENTS Transportation posture (only work equipment)....................................................................

List of parts sent individually ...............................................................................................

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

C- 1. Installation of Arm Cylinder Bottoms ......................................................................

C- 2. Connection of Boom and Arm ................................................................................

C- 3. Pulling out Boom Foot Pin and Boom Cylinder Foot Pin........................................

C- 4. Installation of Boom and Arm Assembly ................................................................

C- 5. Replacement of Return Filter (Standard Element o Flushing Element) ................

C- 6. Releasing Residual Pressure in Hydraulic Circuit ..................................................

C- 7. Installation of Boom Hoses (Between Chassis and Boom)....................................

C- 8. Installation of Flushing Tube for Boom Cylinder Hoses .........................................

C- 9. Installation of Flushing Tube for Arm Cylinder Hoses ............................................

C-10. Installation of Flushing Tube for Bucket Cylinder Hoses .......................................

C-11. Installation of Hoses Between Boom and Arm (Bottom Dump) .............................

C-12. Installation of Flushing Tube for Bottom Dump Cylinder Hoses ............................

C-13. Flushing of Hydraulic Circuit ..................................................................................

C-14. Replacement of Pilot Filter (Flushing Element o Standard Element)....................

C-15. Installation of Boom Cylinder Bottoms ...................................................................

C-16. Installation of Boom Cylinder Hoses ......................................................................

C-17. Installation of Boom Cylinder Head Pin .................................................................

C-18. Installation of Arm Cylinder Hoses .........................................................................

C-19. Installation of Bucket Cylinder................................................................................

C-20. Installation of Bucket Cylinder Hoses ....................................................................

C-21. Installation of Bucket Assembly .............................................................................

C-22. Installation of Bottom Dump Cylinder Hoses .........................................................

C-23. Maintenance Standard...........................................................................................

C-24. Installation of Working Lamp..................................................................................

C-25. Installation of Work Equipment Greasing Piping....................................................

C-26. Bleeding Air from Work Equipment Circuit.............................................................

C-27. Checking Oil Level in Hydraulic Tank and Adding Oil............................................

C-28. Greasing After Assembling Work Equipment.........................................................

Inspection of each part after assembly of loader.................................................................

98 99 102 102 103 105 106 107 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 126 127 128 129 130 131 132 133

<Note> This manual describes only the assembly procedure for work equipment different from the backhoe specification model.

For the procedures for assembling the base machine, flushing the hydraulic circuit, bleeding air from the hydraulic circuit, adjusting the track link, and checking the oil, water, and fuel, see the backhoe specification model.

97

TRANSPORTATION POSTURE (ONLY WORK EQUIPMENT)

TRANSPORTATION POSTURE (ONLY WORK EQUIPMENT)

98

LIST OF PARTS SENT INDIVIDUALLY (WORK EQUIPMENT)

LIST OF PARTS SENT INDIVIDUALLY (WORK EQUIPMENT)

102 102 103 103 103

106 106 106

110 110 110 110 110 110 110 112 112 112 112 112 112 112 112 112 113 113 113 113 113 113 113 113 113

99

LIST OF PARTS SENT INDIVIDUALLY (WORK EQUIPMENT)

114 114 114 114 115 115 115 115 118 118 118, 120 122 122 122, 125 123 123 123 123 123 123 123 123 123 124 128 128 128 128 128 129 129

100

LIST OF PARTS SENT INDIVIDUALLY (CHASSIS AND WORK EQUIPMENT)

(CHASSIS AND WORK EQUIPMENT)

107 107 111-113 115 117

101

Assembly procedure

C-1

Installation of Arm Cylinder Bottoms

Precautions

Necessary tools Name

1. Apply lithium grease to the inside walls of the pin holes.

Others

2. Install the arm cylinder bottoms with the piping ports down.

102

Necessary equipment Qâ&#x20AC;&#x2122;ty

Name

Qâ&#x20AC;&#x2122;ty

Assembly procedure

C-2

Connection of Boom and Arm (1/2)

Precautions

Necessary tools Name

1. When installing the pins, do not damage the seals.

Others

2. Apply lithium grease to the inside walls of the pin holes.

103

Necessary equipment Qâ&#x20AC;&#x2122;ty

Name

Qâ&#x20AC;&#x2122;ty

Assembly procedure

C-2

Connection of Boom and Arm (2/2)

Precautions

Necessary tools Name

Others

Apply lithium grease to the inside walls of the pin holes.

104

Necessary equipment Qâ&#x20AC;&#x2122;ty

Name

Qâ&#x20AC;&#x2122;ty

Assembly procedure

C-3

Pulling out Boom Foot Pin and Boom Cylinder Foot Pin

Precautions

Necessary tools Name

1. Clean the pin holes and pins.

Others

2. Check the pin holes and pins for a flaw.

105

Necessary equipment Qâ&#x20AC;&#x2122;ty

Name

Qâ&#x20AC;&#x2122;ty

Assembly procedure

C-4

Installation of Boom and Arm Assembly

Precautions

Necessary tools Name

Others

When inserting the pins, take care not to damage seals (209-72-11311, 4 pieces).

106

Necessary equipment Qâ&#x20AC;&#x2122;ty

Name

Qâ&#x20AC;&#x2122;ty

Assembly procedure

C-5

Replacement of Return Filter (1/2) (Standard Element o Flushing Element)

Precautions

Necessary tools Name

Others

Keep the removed standard parts (filter element, strainer, and valve) carefully since they will be reused after flushing is finished.

107

Necessary equipment Qâ&#x20AC;&#x2122;ty

Name

Qâ&#x20AC;&#x2122;ty

Assembly procedure

C-5

Replacement of Return Filter (2/2) (Standard Element o Flushing Element)

Precautions

Necessary tools Name

After finishing flushing, discard the removed flushing element.

Others

Keep the removed plate, however, since it will be reused.

108

Necessary equipment Qâ&#x20AC;&#x2122;ty

Name

Qâ&#x20AC;&#x2122;ty

Assembly procedure

C-6

Releasing Residual Pressure in Hydraulic Circuit

Precautions

Necessary tools

Others

Name

109

Necessary equipment Qâ&#x20AC;&#x2122;ty

Name

Qâ&#x20AC;&#x2122;ty

Assembly procedure

Installation of Boom Hoses (Between Chassis and Boom)

C-7

Precautions

Necessary tools Name

1. Keep the removed flanges, O-rings, and heads so that they can be reused.

2. When connecting each hose, take extreme care that the O-rings will not be caught.

Others

3. When connecting each hose, take extreme care that dirt will not enter the circuit.

110

Necessary equipment Qâ&#x20AC;&#x2122;ty

Name

Qâ&#x20AC;&#x2122;ty

Assembly procedure

C-8

Installation of Flushing Tube for Boom Cylinder Hoses

Precautions

Necessary tools Name

1. Keep the removed flanges, O-rings, and heads so that they can be reused.

2. When connecting each hose, take extreme care that the O-rings will not be caught.

Others

3. When connecting each hose, take extreme care that dirt will not enter the circuit.

111

Necessary equipment Qâ&#x20AC;&#x2122;ty

Name

Qâ&#x20AC;&#x2122;ty

Assembly procedure

C-9

Installation of Flushing Tube for Arm Cylinder Hoses

Precautions

Necessary tools Name

1. Keep the removed flanges, O-rings, and heads so that they can be reused.

2. When connecting each hose, take extreme care that the O-rings will not be caught.

Others

3. When connecting each hose, take extreme care that dirt will not enter the circuit.

112

Necessary equipment Qâ&#x20AC;&#x2122;ty

Name

Qâ&#x20AC;&#x2122;ty

Assembly procedure

C-10

Installation of Flushing Tube for Bucket Cylinder Hoses

Precautions

Necessary tools Name

1. Keep the removed flanges, O-rings, and heads so that they can be reused.

2. When connecting each hose, take extreme care that the O-rings will not be caught.

Others

3. When connecting each hose, take extreme care that dirt will not enter the circuit.

113

Necessary equipment Qâ&#x20AC;&#x2122;ty

Name

Qâ&#x20AC;&#x2122;ty

Assembly procedure

C-11

Installation of Hoses Between Boom and Arm (Bottom Dump)

Precautions

Necessary tools Name

1. Keep the removed flanges, O-rings, and heads so that they can be reused.

2. When connecting each hose, take extreme care that the O-rings will not be caught.

Others

3. When connecting each hose, take extreme care that dirt will not enter the circuit.

114

Necessary equipment Qâ&#x20AC;&#x2122;ty

Name

Qâ&#x20AC;&#x2122;ty

Assembly procedure

Installation of Flushing Tube for Bottom Dump Cylinder Hoses

C-12

Precautions

Necessary tools Name

1. Keep the removed flanges, O-rings, and heads so that they can be reused.

2. When connecting each hose, take extreme care that the O-rings will not be caught.

Others

3. When connecting each hose, take extreme care that dirt will not enter the circuit.

115

Necessary equipment Qâ&#x20AC;&#x2122;ty

Name

Qâ&#x20AC;&#x2122;ty

Assembly procedure

Flushing of Hydraulic Circuit

C-13

Precautions

Necessary tools

Others

Name

116

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

C-14

Replacement of Pilot Filter (Flushing Element o Standard Element)

Precautions

Necessary tools

Others

Name

117

Necessary equipment Qâ&#x20AC;&#x2122;ty

Name

Qâ&#x20AC;&#x2122;ty

Assembly procedure

C-15

Installation of Boom Cylinder Bottoms

Precautions

Necessary tools

Others

Name

118

Necessary equipment Qâ&#x20AC;&#x2122;ty

Name

Qâ&#x20AC;&#x2122;ty

Assembly procedure

C-16

Installation of Boom Cylinder Hoses

Precautions

Necessary tools Name

1. When connecting each hose, take extreme care that the O-rings will not be caught.

Others

2. When connecting each hose, take extreme care that dirt will not enter the circuit.

119

Necessary equipment Qâ&#x20AC;&#x2122;ty

Name

Qâ&#x20AC;&#x2122;ty

Assembly procedure

C-17

Installation of Boom Cylinder Head Pin

Precautions

Necessary tools

Others

Name

120

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

C-18

Installation of Arm Cylinder Hoses

Precautions

Necessary tools Name

1. When connecting each hose, take extreme care that the O-rings will not be caught.

Others

2. When connecting each hose, take extreme care that dirt will not enter the circuit.

121

Necessary equipment Qâ&#x20AC;&#x2122;ty

Name

Qâ&#x20AC;&#x2122;ty

Assembly procedure

Installation of Bucket Cylinder

C-19

Precautions

Necessary tools

Others

Name

122

Necessary equipment Qâ&#x20AC;&#x2122;ty

Name

Qâ&#x20AC;&#x2122;ty

Assembly procedure

C-20

Installation of Bucket Cylinder Hoses

Precautions

Necessary tools Name

1. When connecting each hose, take extreme care that the O-rings will not be caught.

Others

2. When connecting each hose, take extreme care that dirt will not enter the circuit.

123

Necessary equipment Qâ&#x20AC;&#x2122;ty

Name

Qâ&#x20AC;&#x2122;ty

Assembly procedure

C-21

Installation of Bucket Assembly (1/2)

Precautions

Necessary tools

Others

Name

124

Necessary equipment Qâ&#x20AC;&#x2122;ty

Name

Qâ&#x20AC;&#x2122;ty

Assembly procedure

C-21

Installation of Bucket Assembly (2/2)

Precautions

Necessary tools

Others

Name

125

Necessary equipment Qâ&#x20AC;&#x2122;ty

Name

Qâ&#x20AC;&#x2122;ty

Assembly procedure

C-22

Installation of Bottom Dump Cylinder Hoses

Precautions

Necessary tools

Others

Name

126

Necessary equipment Qâ&#x20AC;&#x2122;ty

Name

Qâ&#x20AC;&#x2122;ty

Assembly procedure

Maintenance Standard

C-23

Precautions

Necessary tools

Others

Name

127

Necessary equipment Qâ&#x20AC;&#x2122;ty

Name

Qâ&#x20AC;&#x2122;ty

Assembly procedure

Installation of Working Lamp

C-24

Precautions

Necessary tools

Others

Name

128

Necessary equipment Qâ&#x20AC;&#x2122;ty

Name

Qâ&#x20AC;&#x2122;ty

Assembly procedure

C-25

Installation of Work Equipment Greasing Piping

Precautions

Necessary tools

Others

Name

129

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

C-26

Bleeding Air from Work Equipment Circuit

Precautions

Necessary tools

Others

Name

130

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

C-27

Checking Oil Level in Hydraulic Tank and Adding Oil

Precautions

Necessary tools

Others

Name

131

Necessary equipment Qâ&#x20AC;&#x2122;ty

Name

Qâ&#x20AC;&#x2122;ty

Assembly procedure

C-28

Greasing After Assembling Work Equipment

Precautions

Necessary tools

Others

Name

132

Necessary equipment Q’ty

Name

Q’ty

INSPECTION OF EACH PART AFTER ASSEMBLY OF LOADER (For the inspection of the chassis, see the backhoe specification model.)

133

GEN00015-03