KOMATSU PC600-8E0 PC600LC-8E0 PC650-8E0 PC650LC-8E0 PC700LC-8E0 HYDRAULIC EXCAVATOR Field Assembly

GEN00101-02

Field Assembly Instruction

HYDRAULIC EXCAVATOR

PC600 -8E0 PC650 -8E0 PC700LC -8E0 SERIAL NUMBERS

PC600LC -8E0 PC650LC -8E0

65001

and up

FOREWORD Since this machine is large in size, it is divided into some units to meet the transportation conditions and regulations applied to the 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 .................................................................................................................................................

Precautions for Field Assembly ......................................................................................................................

Disposal of Removed Parts ............................................................................................................................

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

KIT Layout Diagram........................................................................................................................................

Transportation ................................................................................................................................................

List of Tools for Field Assembling...................................................................................................................

Tightening Torque ..........................................................................................................................................

Coating Materials ...........................................................................................................................................

Selection of Wire Ropes Used for Assembly ..................................................................................................

1 3 4 5 6 7 12 13 18 20

A. ASSEMBLY OF CHASSIS .........................................................................................................................

A- 1. Installation of Left and Right Track Frames ......................................................................................

A- 2. Installation of Travel Pipe .................................................................................................................

A- 3. Installation of Operator Cab’s Left Handrail......................................................................................

A- 4. Installation of Operator Cab’s Door Stopper and Striker ..................................................................

A- 5. Installation of Rearview Mirror ..........................................................................................................

A- 6. Installation of Handrail ......................................................................................................................

A- 7-1 Installation of Step ..........................................................................................................................

A- 7-2 Installation of Step ..........................................................................................................................

A- 8. Installation of Left Side Step .............................................................................................................

A- 9. Sticking Sheet to Counterweight ......................................................................................................

A-10. Installation of Rear View Camera ....................................................................................................

A-11. Installation of Counterweight ...........................................................................................................

A-12. Installation of Step Light ..................................................................................................................

A-13. Bleeding of Air from Travel Motor ....................................................................................................

A-14-1 Installation of Travel Piping Cover.................................................................................................

A-14-2 Installation of Travel Piping Cover.................................................................................................

A-15. Installation of Travel Motor Guard ...................................................................................................

A-16. Testing Track Shoe Tension............................................................................................................

A-17. Check Fuel, Coolant and Oil Levels ................................................................................................

21 22 27 32 33 35 40 43 44 45 46 47 52 54 56 57 61 64 65 68

B. ASSEMBLING OF WORK EQUIPMENT ...................................................................................................

B- 1. Assembly of Arm Cylinder ................................................................................................................

B- 2. Connection of Arm Cylinder Hoses...................................................................................................

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

B- 4. Installation of Boom Cylinder Hoses.................................................................................................

B- 5. Installation of Boom Foot Dust Seal .................................................................................................

B- 6. Assembly of Boom Assembly ...........................................................................................................

B- 7. Installation of Hoses from Chassis Along Top of Boom....................................................................

B- 8. Connection of Boom Cylinder Head .................................................................................................

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

B-10. Installation of Bucket Cylinder Hoses between Boom and Bucket Cylinder ....................................

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

B-12. Connection of Work Equipment Grease Piping ...............................................................................

B-13. Connection of Work Equipment Wiring............................................................................................

B-14. Greasing after Assembling Work Equipment...................................................................................

B-15. Bleeding Air from Work Equipment Circuit ......................................................................................

B-16. Parts to be Touched up After Field Assembly .................................................................................

71 72 73 74 75 76 77 78 80 81 83 84 87 88 90 91 92

C. Assembling of Work Equipment of Loading Shovel ....................................................................................

C- 1. Releasing residual pressure in hydraulic circuit ................................................................................

C- 2. Pulling out boom foot pin and boom cylinder foot pin........................................................................

C- 3. Installation of boom cylinder foot.......................................................................................................

C- 4. Installation of boom and arm assembly.............................................................................................

C- 5. Installation of boom cylinder hoses ...................................................................................................

C- 6. Installation of boom cylinder rod pin..................................................................................................

C- 7. Installation of boom cylinder..............................................................................................................

C- 8. Installation of arm cylinder hoses ......................................................................................................

C- 9. Installation of bucket cylinder ............................................................................................................

C-10. Installation of bucket cylinder hoses.................................................................................................

C-11. Installation of connecting hoses between chassis and boom top.....................................................

C-12. Installation of bottom dump cylinder hoses ......................................................................................

C-13. Installation of bucket assembly ........................................................................................................

C-14. Installation of working lamps ............................................................................................................

C-15. Installation of work equipment grease piping ...................................................................................

C-16. Greasing after assembling of work equipment .................................................................................

C-17. Bleeding air from work equipment circuit .........................................................................................

C-18. Checking oil level in hydraulic tank and adding oil ...........................................................................

93 94 95 96 97 98 99 100 101 102 103 104 105 106 108 110 111 112 113

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

D- 1. Sticking Sheet to Counterweight .......................................................................................................

D- 2. Adjustment of Shims for Counterweight ............................................................................................

D- 3. Greasing............................................................................................................................................

D- 4. Installation of Counterweight Remover .............................................................................................

D- 5. Installation of Covers.........................................................................................................................

D- 6. Installation of Clamps ........................................................................................................................

D- 7. Installation of Hoses ..........................................................................................................................

D- 8. Bleeding Air from Counterweight Remover Circuit............................................................................

D- 9. Installation of Counterweight .............................................................................................................

D-10. Installation of Accessories................................................................................................................

D-11. Check of Operation ..........................................................................................................................

115 116 117 122 123 124 125 128 129 130 132 133

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

M- 1. Inspection of Oil Level in Hydraulic Tank and Refill..........................................................................

M- 2. Replacement of Return Filter (Standard Filter to Flushing Filter) .....................................................

M- 3. Flushing of Hydraulic Circuit .............................................................................................................

M- 4. Failure code ......................................................................................................................................

M- 5. Operating Method of Monitoring .......................................................................................................

135 136 138 141 143 148

Field Assembly Inspection Report (Backhoe) Field Assembly Inspection Report (Loading Shovel)

SPECIFICATIONS Machine model

PC600-8E0

Weight of machine

kg

Bucket capacity

m3

Engine model Flywheel horsepower

PC600LC-8E0

PC650-8E0

60,200

60,000

59,200

PC650LC-8E0 PC700LC-8E0 61,000

2.7

66,200

2.8

—

KOMATSU SAA6D140E-5

kW/rpm {HP/rpm}

323/1,800 {439/1,800}

Min. ground clearance

mm

780

830

Travel speed (Low/High)

km/h

3.0/4.9

2.8/4.6

Swing speed

rpm

8.3

PC600-8E0

PC650-8E0

1

PC700LC-8E0

2

PRECAUTIONS FOR FIELD ASSEMBLY 1. Selection of work place 1) When selecting a work place, consider the following.

• Is the work place sufficiently wide for loading and unloading the machine? (See the kit layout 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

DISPOSAL OF REMOVED PARTS As described in "FOREWORD", when this machine is transported, it is divided into some units such as the body, undercarriage, cab, work equipment, etc. according to the transportation measure, regulations,etc.

Accordingly, the hydraulic pipings and hydraulic hoses to connect the units, oil inlets and outlets of the hydraulic devices, and parts which must not be damaged are plugged or covered to prevent oil leakage, entry of dirt and dust, and damage during transportation.

In addition, fixing jigs are used to prevent a trouble caused by a fall or a shake during transportation and to facilitate loading, unloading and crane work.

The above plugs, jigs, etc. are removed when the machine is assembled and become unnecessary after completion of the machine. Since they are useful when the machine needs to be transported in future, however, we recommend you to keep them as long as possible.

4

5

Worker

Air compressor

Crane

Assembly unit

Days

25t × 2

· Meeting with all workers

Start of assembling

Leader + 3 mechanics

15 m3/min

0.49 – 0.69 MPa (5 – 7 kg/cm 2)

45t

(Two)

Left track frame Right track frame Axle assembly

Base machine Counterweight Platform group · Inspection of oil level and coolant level

Completion of Installation of unit assembly to body

Upper structure

Completion of body assembling

25t

· Completion of general assembling

Backhoe · Inspection of oil level and coolant level · Air bleeding from work equipment cylinder · Loading shovel- Flushing of hydraulic circuit type excavator · Adjustment of track tension · Performance test Assembling of work equipment

ASSEMBLING PROCEDURES, APPLICABLE EQUIPMENT AND SCHEDULE 4 Divisions

KIT LAYOUT DIAGRAM The dimensions given below are the minimum dimensions needed.

The kit dimensions in the diagram are outline dimensions.

When selecting a place, see “Precautions for Field Assembly”.

Bucket

Tools, facility

Arm cylinder

Arm link

Boom

Boom cylinder

45t crane

Motor cover · handrails

Revolving frame

Counterweight

6

Crawler frame

Crawler frame

Foreword

Left deck

• • •

25t crane

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 (Others)

(Work equipment)

(Upper structure + Undercarriage)

t 4-kit Transportation

(Upper structure)

(Others)

(Work equipment)

(Undercarriage)

t Packing Style of Each Kit (Sizes in drawing are given in millimeters.) • Upper structure + Undercarriage PC650LC- PC700LCPC600LCPC650-8E0 8E0 8E0 8E0

Model

PC600-8E0

A (mm)

6,270

6,440

6,280

6,450

6,490

B (mm)

3,330

3,330

3,460

3,460

3,665

Shoe width (mm) Overall width (mm) Weight (kg)

600

600

600

600

610

3,190

3,190

3,190

3,190

3,485

34,700

35,700

35,000

36,000

40,500

7

•

Upper structure

Model

PC600-8E0

Overall width (mm) Weight (kg)

•

3,170

3,170

3,170

3,170

3,170

17,200

17,400

17,300

17,400

17,500

A (mm)

2,510

2,510

2,630

2,630

2,765

B (mm)

5,064

5,064

5,064

5,064

5,064

C (mm)

585

593

585

593

710

Model

PC600-8E0

Quantity

2

2

2

2

2

A (mm)

1,260

1,260

1,200

1,280

1,440

B (mm)

5,340

5,690

5,360

5,710

5,810

C (mm)

875

875

875

875

980

Undercarriage

Weight (kg)

•

PC600LCPC650LC- PC700LCPC650-8E0 8E0 8E0 8E0

PC600LCPC650LC- PC700LCPC650-8E0 8E0 8E0 8E0

16,300 17,300 16,600 17,500 22,000 (8,150 × 2) (8,650 × 2) (8,300 × 2) (8,750 × 2) (11,000 × 2)

Work equipment (1) Boom

Position of center of gravity 7.6 m

7.3 m

x (mm)

3,590

3,420

y (mm)

680

710

Type

Civil engineering boom

Quarry boom

SE boom

A (mm)

7,930

7,550

6,870

B (mm)

2,010

2,010

2,090

X (mm)

3,780

3,630

3,280

Y (mm)

880

870

920

1,050

1,050

1,050

4,870

4,710

4,810

Overall width (mm) Weight (kg)

8

(2) Arm Civil engineering arm (3.5 m) (4.3 m) (5.2 m)

Type

x: 880 mm y: 220 mm

Quarry arm (3.5 m)

SE arm (2.9 m)

A (mm)

4,870

5,650

6,580

4,870

4,230

B (mm)

1,210

1,220

1,340

1,240

1,490

X (mm)

940

1,190

1,590

940

630

Y (mm)

250

260

260

250

280

460

460

460

460

460

3,740

3,740

4,160

3,330

3,530

Overall width (mm) Weight (kg)

(3) Bucket

Model

PC600-8E0 PC600LC-8E0

PC650-8E0 PC650LC-8E0 PC700LC-8E0

A (mm)

2,150

2,150

B (mm)

1,780

1,780

1,780

1,920

2,430

3,100

Overall width (mm) Weight (kg)

(4) Boom cylinder (for all models)

Weight: 1,000 kg (500 kg × 2 pcs) X: 1,160 mm

9

(5) Arm cylinder

Weight: 727 kg X: 1,400 mm

•

Others (1) Counterweight With counterweight remover PC600-8E0 PC600LC-8E0 PC650-8E0 PC650LC-8E0

Counterweight

Model

PC700LC-8E0

-

A (mm)

830

860

Weight (kg)

10,750

12,204

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

Weight: 37 kg x: 1,150 mm y: 60 mm z: 240 mm

10

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

Weight: 32 kg x: y: z:

11

970 mm 50 mm 250 mm

LIST OF TOOLS FOR FIELD ASSEMBLING

2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

Tool

1

Tool names Equipment

No.

Specifications {7.0kg/cm2}

Engine compressor

Komatsu, 0.69 MPa Class 441 kN {45 ton} Crane truck 245 kN {25 ton} Grease pump Air type Stepladder 5 -stepped- 1500 mm Impact wrench KW10P (for M10) KW12PI (For M12) KW20P (For M16) KW45FS (Spline) Socket for KW45FS Spline × 65 mm Air hose 50 m 16-time wrench 4413 Nm {450 kgm} Socket for 16-time wrench T38.1 × 65 mm T38.1 × 55 mm T38.1 × 50 mm 4-time wrench 25.4, 19 Socket for 4-time wrench T25.4 × 50 mm T25.4 × 55 mm Torque wrench 412 Nm {42 kgm} – T25.4 mm 834 Nm {85 kgm} – T25.4 mm 4118 Nm {420 kgm} – T38.1 mm Standard tool Socket, spanner, wrench Sledge hammer 10 P Bar 1m Hydraulic jack 490 kN {50 ton} (stroke 170)

25

196 kN {20 ton} Waste oil pan

Large, small

27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42

Wooden block Wire

300 × 400 mm ø10 × 3 m ø20 × 5 m ø32 × 5 m ø30 × 5 m SD30 SC18 50 mm wide × 3 m 14.7 – 29.4 kN {1.5 – 3 ton} M12 Brake cleaner EO-10 G2-LI Natural yellow Black gray Bundle

Lubricants

Sling jig

26

Shackle Nylon sling Lever block Eyebolt Detergent liquid Hydraulic oil Grease Repair paint Waste cloth

12

Q’ty 1 1 2 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 sets 1 2 2

Remarks

Work equipment lubrication

For counterweight For counterweight For counterweight For counterweight For track frame For track frame 16-time wrench available 16-time wrench available 16-time wrench available For 16-time wrench For 4-time wrench For counterweight and track frame

Revolving frame pedestal When tightening track frame 1 connecting bolts.

2 each When connecting travel and work equipment piping 4 Revolving frame pedestal 2 For catwalk 2 For boom, arm and bucket 4 For revolving frame and track frame 2 For counterweight 3 4 2 For boom cylinder and arm cylinder 2 2 10 300 l 20 kg Work equipment lubrication 5 5 20 kg For cleaning

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 × Bolt length Thread size diameter (Diameter, pitch, length)

Tool (Socket)

Applicable socket size

Tightening torque

Nm {QQQ kgm}

If tightening torque for a bolt is not specified in the text, tighten it according to Table 1.

Remarks 1. The thread diameter is the nominal diameter. For example, 16 mm is expressed as M16 and 20 mm is expressed as M20.

The pitch in Table 1 is the distance that the bolt advances every turn in the axial direction (Unit: mm).

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

3. The applicable socket size is expressed as 24 mm, 30 mm, etc. Since 24 mm, 30 mm, etc. 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

13

Table 1 Tightening torque for bolts not specified in text Nominal size of thread × pitch a (mm)

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

6×1

10

8 × 1.25

13

10 × 1.5

17

12 × 1.75

19

14 × 2

22

16 × 2

24

18 × 2.5

27

20 × 2.5

30

22 × 2.5

32

24 × 3

36

27 × 3

41

30 × 3

46

33 × 3

50

36 × 3

55

39 × 3

60

Unit: Nm {kgm}

Tightening torque

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

14

Unit: Nm

Unit: {kgm}

12 {1.2} 25 {2.5} 54 {5.5} 89 {9} 137 {14} 230 {23.5} 315 {32} 460 {47} 650 {66.5} 810 {82.5} 1,180 {120} 1,520 {155} 1,960 {200} 2,450 {250} 2,940 {300}

8.8 – 14.7 {0.9 – 1.5} 14.7 – 34 {1.5 – 3.5} 34 – 74 {3.5 – 7.5} 54 – 123 {5.5 – 12.5} 84 – 196 {8.5 – 20} 147 – 309 {15 – 31.5} 201 – 427 {20.5 – 43.5} 319 – 608 {32.5 – 62} 471 – 829 {48 – 84.5} 588 – 1,030 {60 – 105} 883 – 1,470 {90 – 150} 1,130 – 1,910 {115 – 195} 1,470 – 2,450 {150 – 250} 1,860 – 3,040 {190 – 310} 2,260 – 3,630 {230 – 370}

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

3.9 – 6.9 {0.4 – 0.7} 5.9 – 11.8 {0.6 – 1.2} 16.7 – 26.5 {1.7 – 2.7} 32.3 – 52.9 {3.3 – 5.4} 51.0 – 85.3 {5.2 – 8.7} 86.2 – 173.5 {8.8 – 17.7}

2.9 – 5.9 {0.3 – 0.6} 4.9 – 9.8 {0.5 – 1.0} 13.7 – 21.6 {1.4 – 2.2} 26.5 – 43.1 {2.7 – 4.4} 42.1 – 70.6 {4.3 – 7.2} 72.5 – 146.0 {7.4 – 14.9}

2.0 – 3.9 {0.2 – 0.4} 3.9 – 7.8 {0.4 – 0.8} 9.8 – 16.7 {1.0 – 1.7} 19.6 – 32.3 {2.0 – 3.3} 31.4 – 52.9 {3.2 – 5.4} 54.9 – 111.7 {5.6 – 11.4}

Nominal size (in) 1/8 1/4 3/8 1/2 3/4 1

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

16.7 – 29.4 {1.7 – 3.0} 19.6 – 44.1 {2.0 – 4.5} 44.1 – 93.1 {4.5 – 9.5} 98.0 – 188.2 {10.0 – 19.2} 170.5 – 316.5 {17.4 – 32.3} 367.5 – 612.5 {37.5 – 62.5}

9.8 – 19.6 {1.0 – 2.0} 16.7 – 37.2 {1.7 – 3.8} 37.2 – 77.4 3.8 – 7.9} 83.3 – 157.8 {8.5 – 16.1} 141.1 – 247.0 {14.4 – 25.2} 309.7 – 514.5 {31.6 – 52.5}

6.9 – 14.7 {0.7 – 1.5} 12.7 – 28.4 {1.3 – 2.9} 27.4 – 58.8 {2.8 – 6.0} 60.8 – 115.6 {6.2 – 11.8} 105.8 – 186.2 {10.8 – 19.0} 235.2 – 392.0 {24.0 – 40.0}

Nominal size (in) 1/8 1/4 3/8 1/2 3/4 1

15

3. Tightening torque for hydraulic hose connecting nut For the connecting nuts installed to the hydraulic hose adapters in relatively low pressure systems, apply tightening torque in Table 4.1 and 4.2.

Table 4.1 Hydraulic hose of face seal type Type that uses O-ring at this position

Unit: Nm {kgm} Outside diameter of hose (mm)

Width across flats (mm)

Range

Target

Approx. 6

19

34 – 54 {3.5 – 5.5}

44 {4.5}

Approx. 10

22

54 – 93 {5.5 – 9.5}

74 {7.5}

Approx. 13

27

84 – 132 {8.5 – 13.5}

103 {10.5}

Approx. 16

32

128 – 186 {13.0 – 19.0}

157 {16.0}

Approx. 20

36

177 – 245 {18.0 – 25.0}

216 {22.0}

Tightening torque (Nm {kgm})

Table 4.2 Hydraulic hose of taper seal type

Type that does not use O-ring at this position

Unit: Nm {kgm} Outside diameter of hose (mm)

Width across flats (mm)

Range

Target

Approx. 6

19

34 – 63 {3.5 – 6.5}

44 {4.5}

Approx. 10

24

59 – 98 {6.0 – 10.0}

78 {8.0}

Approx. 13

27

84 – 132 {8.5 – 13.5}

103 {10.5}

Approx. 16

32

128 – 186 {13.0 – 19.0}

157 {16.0}

Approx. 20

36

177 – 245 {18.0 – 25.0}

216 {22.0}

Tightening torque (Nm {kgm})

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

16

4. Proper socket sizes for bolts of M39 and larger (Reference) For the proper sizes of sockets or spanners (= width across flats) for tightening hexagon bolts of M39 and larger, see Table 5.

Table 5 Unit: mm Thread diameter

Proper sizes of sockets or spanners

M42

65

M45

70

M48

75

M52

80

M56

85

M60

90

M64

95

17

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

Category

Komatsu code

Part No.

Q'ty

Container

Main applications, features

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.

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.

Adhesives

Three bond 1735

790-129-9140

• 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

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

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

18

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

19

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)

20

8 9 10 11.2 (12) 12.5 14 16 18 20 22.4 (24) 25 28 30 31.5 33.5 35.5 37.5 40 42.5

Sling angle Angle to vertical line Mode coefficient M Classification of wire rope Outer diameter of wire rope (2)d (mm)

Number of wire ropes

α β

Max. 4.8 {0.49} Max. 6.1 {0.63} Max. 7.6 {0.77} Max. 9.5 {0.97} Max. 10 {1.1} Max. 11 {1.2} Max. 14 {1.5} Max. 19 {1.9} Max. 24 {2.5} Max. 30 {3.1} Max. 38 {3.9} Max. 43 {4.4} Max. 47 {4.8} Max. 59 {6.1} Max. 68 {7.0} Max. 75 {7.7} Max. 85 {8.7} Max. 96 {9.8} Max. 107 {10.9} Max. 122 {12.4} Max. 137 {14.0}

24G

α = 0° β = 0° 1

1 pc.

Max. 5.2 {0.53} Max. 6.6 {0.67} Max. 8.2 {0.83} Max. 10 {1.0} Max. 11 {1.2} Max. 12 {1.3} Max. 16 {1.6} Max. 21 {2.1} Max. 26 {2.7} Max. 32 {3.3} Max. 41 {4.2} — Max. 51 {5.2} Max. 64 {6.5} Max. 73 {7.5} Max. 81 {8.3} Max. 92 {9.4} Max. 103 {10.5} Max. 115 {11.7} Max. 131 {13.4} Max. 148 {15.1}

24A Max. 6.7 {0.68} Max. 8.5 {0.88} Max. 10 {1.0} Max. 13 {1.3} Max. 14 {1.5} Max. 15 {1.6} Max. 19 {2.1} Max. 26 {2.6} Max. 33 {3.5} Max. 42 {4.3} Max. 53 {5.4} Max. 60 {6.1} Max. 65 {6.7} Max. 82 {8.5} Max. 95 {9.8} Max. 105 {10.7} Max. 119 {12.1} Max. 134 {13.7} Max. 149 {15.2} Max. 170 {17.3} Max. 191 {19.6}

24G

α Z 90° β Z 45° 1.4 24A Max. 7.2 {0.74} Max. 9.2 {0.93} Max. 11 {1.1} Max. 14 {1.4} Max. 15 {1.6} Max. 16 {1.8} Max. 22 {2.2} Max. 29 {2.9} Max. 36 {3.7} Max. 44 {4.6} Max. 57 {5.8} — Max. 71 {7.2} Max. 89 {9.1} Max. 102 {10.5} Max. 113 {11.6} Max. 128 {13.1} Max. 144 {14.7} Max. 161 {16.3} Max. 183 {18.7} Max. 207 {21.1}

Annex 2, Table 1 Using loads of 6 × 24 type rope slings.

Select wire ropes to be used for assembly according to the following table.

SELECTION OF WIRE ROPES USED FOR ASSEMBLY

2 pcs.

Max. 4.8 {0.49} Max. 6.1 {0.63} Max. 7.6 {0.77} Max. 9.5 {0.97} Max. 10 {1.1} Max. 11 {1.2} Max. 14 {1.5} Max. 19 {1.9} Max. 24 {2.5} Max. 30 {3.1} Max. 38 {3.9} Max. 43 {4.4} Max. 47 {4.8} Max. 59 {6.1} Max. 68 {7.0} Max. 75 {7.7} Max. 85 {8.7} Max. 96 {9.8} Max. 107 {10.9} Max. 122 {12.4} Max. 137 {14.0}

24G

24A Max. 5.2 {0.53} Max. 6.6 {0.67} Max. 8.2 {0.83} Max. 10 {1.1} Max. 11 {1.2} Max. 12 {1.3} Max. 16 {1.6} Max. 21 {2.1} Max. 26 {2.7} Max. 32 {3.3} Max. 41 {4.2} — Max. 51 {5.2} Max. 64 {6.5} Max. 73 {7.5} Max. 81 {8.3} Max. 92 {9.4} Max. 103 {10.5} Max. 115 {11.7} Max. 131 {13.4} Max. 148 {15.1}

90° < α Z 120° 45° < β Z 60° 1

Unit: kN {tf}

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

Operatorâ&#x20AC;&#x2122;s Left hand seat

Right hand

Left hand

Right hand

Operator's seat

Rear

Sprocket

Sprocket

Rear

21

Assembly procedure

Installation of Left and Right Track Frames (1/4)

A-1 •

Sling the track frame in the posture for “Transportation”.

Hold two boom cylinder bottom pins of the front Upper Structure section for lifting.

Fitting the wire at counterweight portion (Example): Set the wire safely and securely.

Wooden block

Use a shackle for secure connection.

Precautions

Stopper

Necessary tools Name

Never enter under the lifted Upper Structure.

Others

ø 32 × 5000 wire

22

Necessary equipment Q’ty 4

Name

Q’ty

45 ton crane

1

25 ton crane

2

Assembly procedure

Installation of Left and Right Track Frames (2-1/4)

A-1 •

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

Mount the M33 × 3 bolts and tighten them with 200 – 250 kgm torque.

Mount the M36 × 3 bolts and tighten them with 250 – 310 kgm torque.

Right track frame

No. 1 2 3 4 5 6

Left track frame

Precautions

Necessary tools Name

Q’ty 1

Torque wrench (85 kgm)

1

Socket (25 Sq. × 50 mm)

1

Socket (25 Sq. × 55 mm)

1

Others

Q’ty 32 32 8 4 8 8

Necessary equipment

4 time wrench

23

Loose-supply items 15A-78-11270 01643-33380 01011-83630 21M-30-12170 01643-33690 209-30-11330

Name

Q’ty

Assembly procedure

Installation of Left and Right Track Frames (2-2/4)

A-1 For PC700LC only

Mount the M33 × 3 bolts and tighten them with 200 – 250 kgm torque.

Mount the M33 × 3 bolts and tighten them with 200 – 250 kgm torque.

Right track frame

Left track frame

No. 1 2 3 4 5 6

Precautions

Necessary tools Name

Q’ty 1

Torque wrench (85 kgm)

1

Socket (25 Sq. × 50 mm)

1

Socket (25 Sq. × 55 mm)

1

24

Loose-supply items 21M-30-31130 21M-30-31120 21M-30-31130 21M-30-31140 01643-33380 21M-30-31120

Q’ty 32 32 8 4 8 8

Necessary equipment

4 time wrench

Others

•

Name

Q’ty

Assembly procedure

Installation of Left and Right Track Frames (3/4)

A-1 •

Support the center frame bottom with two wooden blocks (300 × 400) at places where they will not interfere with the track frame.

Note: Use sufficiently strong wooden blocks.

•

Lift the Track Frame Assembly and install it on the Center Frame.

Hydraulic jack Decide the sling positions so that the wire ropes will not interfere with the upper structure Place wooden blocks to support

Tighten the bolts lightly, and then lower the jacks to place the track frame on the ground.

Precautions

Necessary tools Name

Necessary equipment Q’ty

Name

Q’ty

Hydraulic jack (50 ton)

2

45 ton crane

1

Wooden block (300 × 400 mm)

4

25 ton crane

2

Wire (ø32 mm, 5000 mm long)

2

Others

•

25

Assembly procedure

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

Name

Necessary equipment Q’ty

4 time wrench

1

Torque wrench (85 kgm)

1

Socket (25 Sq. × 50 mm)

1

Socket (25 Sq. × 55 mm)

1

Others

• Do not remove the shoes before assembling (so as to maintain the tightening torques of the shoe bolts).

• Do not place the washer on the spot facing.

Necessary tools

26

Name

Q’ty

Assembly procedure

Installation of Travel Pipe (1/2)

A-2

Fig. 1

Fig. 2 a Connect the hose having a red band to the upper side of the travel motor.

No. 6 No. 1 2 3 4

Precautions

Name

Q’ty 2

KW12P impact

1

L150 extension

1

M14 socket

1

M19 socket

1

Width across flats 24 spanner

2

Width across flats 36 spanner

2

27

Q’ty 4

Already installed to chassis STD 07098-41030 LC 07098-41032 STD 21M-62-21570 LC 21M-62-21580 STD 02764-00630 LC 02764-00632 STD 02762-00330 LC 02762-00332

Q’ty 2 2 2 2 2 2 2 2

Necessary equipment

Oil pan (small)

Others

• Before removing the oil stopper of each hose, turn the bolt slowly to release the internal pressure.

Necessary tools

Loose-supply items 07000-13032

Name

Q’ty

Assembly procedure

Installation of Travel Pipe (2/2)

A-2-1

Fig. 3

P

Detail P

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

Precautions

Necessary tools

Others

Name

28

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

Name

Qâ&#x20AC;&#x2122;ty

Assembly procedure

Installation of Travel Pipe (1/3)

A-2-2 •

For PC700LC only

No. 1 2 3 4 5

Precautions

Q’ty

Width across flats 32 mm spanner

2

Width across flats 24 mm spanner

2

Width across flats 22 mm spanner

2

KW12P impact

1

L150 extension

1

M17 socket

1

29

Q’ty 2 2 2 2 4

Necessary equipment

Name

Others

• Before removing the oil stopper of each hose, turn the bolt slowly to release the internal pressure.

Necessary tools

Loose-supply items 21M-62-31920 21M-62-31910 02764-00534 02762-00337 07000-13032

Name Oil receiving pan (small)

Q’ty 1

Assembly procedure

Installation of Travel Pipe (2/3)

A-2-2 For PC700LC only

No. 1 2 3 4 5 6 7 8 9 10

Precautions

Necessary tools Name

Others

•

30

Loose-supply items 07094-31024 07095-01035 01010-81290 01643-31232 04434-52312 04434-51512 01010-81250 01643-31232 195-33-11220 08034-20536

Q’ty 4 4 4 4 2 2 2 2 2 4

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

Installation of Travel Pipe (3/3)

A-2-2 •

For PC700LC only

No. 1 2 3 4

Precautions

Necessary tools Name

Others

The hoses are installed on the machine.

31

Loose-supply items 21M-62-31920 21M-62-31910 02764-00534 02762-00337

Q’ty 2 2 2 2

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

Installation of Operator Cab’s Left Handrail

A-3

Mount the grip and its bolts as shown below.

1

2

No. 1 2

Precautions

Necessary tools Name

Others

•

32

Loose-supply items 20Y-53-18870 01435-40825

Q’ty 1 4

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

Installation of Operator Cab’s Door Stopper and Striker (1/2)

A-4

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

Tighten the nuts with the specified torque as shown.

No. 1 2 3 4 Precautions

Necessary tools Name

Others

•

33

Loose-supply items 20Y-53-11320 20Y-53-12940 01584-01008 20Y-53-12661

Q’ty 1 1 2 1

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

Installation of Operator Cab’s Door Stopper and Striker (2/2)

A-4

1. Mounting the door stopper • Mount stoppers, nuts and washers at two positions shown.

• Adjust the stoppers during mounting.

3 2 1

When the door is opened Stopper adjusting instructions Open the door and make the stopper in contact to the door.

Rotate the upper one 5 turns and rotate the lower one 3 turns. Then, fix it by tightening their locknuts.

Precautions

No. 1 2 3

Necessary tools

Others

Name

34

Loose-supply items 20Y-54-11611 01580-11008 01643-31032

Q’ty 2 2 2

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

Installation of Rearview Mirror (1/5)

A-5

(1) Before installing the boom foot pin, remove handrail (6) and bolts and washer (7), (8).

(2) After installing the work equipment, install handrail (6) and bolts and washer (7), (8).

(3) Install parts (1) to (5) to handrail (6).

No. 1 2 3 4 5 6 7 8 9

Precautions

Necessary tools

Others

Name

35

Loose-supply items 421-54-25610 209-54-75350 21M-54-11890 20Y-54-27991 01252-71030 21M-54-31610 01024-81250 01024-81235 04025-00632

Q’ty 1 1 1 3 6 1 6 2 1

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

Installation of Rearview Mirror (2/5)

A-5

Insert pin (5) into the holes of clamps (3), secure mirror (1) with holder (2), tighten screws (4), and check that the mirror does not move.

Insert pin (5) into this hole

Precautions

Necessary tools Name

Others

•

36

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

Installation of Rearview Mirror (3/5)

A-5 WITH TOP GUARD

Install parts (1) to (9) to the handrail at the front of the cab.

Bolt Bolt Clamp Stay Mirror Pin

Support Clamp Bolt

No. 1 2 3 4 5 6 7 8

Precautions

Necessary tools Name

Others

•

37

Loose-supply items 421-54-25610 04025-00632 209-54-45611 20Y-54-35430 01252-A1025 209-54-45660 20Y-54-27991 01024-D1270

Q’ty 1 1 1 1 4 1 1 1

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

Installation of Rearview Mirror (4/5)

A-5 WITHOUT TOP GUARD

Install parts (1) to (9) to the handrail at the front of the cab.

Bolt

Color

Clamp

Bolt

Stay Mirror Pin

Support Clamp Bolt

No. 1 2 3 4 5 6 7 8 9

Precautions

Necessary tools Name

Others

•

38

Loose-supply items 421-54-25610 04025-00632 209-54-45621 20Y-54-35430 01252-A1025 209-54-45660 20Y-54-27991 01024-D1270 20Y-03-11220

Q’ty 1 1 1 1 4 1 1 1 1

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

A-5

Installation of Rearview Mirror (5/5)

ADJUSTING THE REARVIEW MIRROR

k WARNING • Always adjust the rearview mirror in the correct angle before starting the work. If its adjustment is incorrect, the operator may have a poor visual range and a serious personal injury may result.

Loosen screw (2) and bolt (3) of the rearview mirror, and 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 approximately 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 : Mirror mounting position on axis W : Mirror visual range on axis Z (Left side) : Mirror visual range on axis Y (Right side) :

195 mm 75 mm 2500 mm 3100 mm

Mirror A : Must cover shaded area (A).

Mirror B : Must cover shaded area (B).

39

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. 1 2 3 4 5 6 7 8 9 10 11

Precautions

Necessary tools

Others

Name

40

Loose-supply items 21M-54-13611 21M-54-13621 01034-81240 01024-81240 21M-54-33631 01010-81245 21M-54-32970 21M-54-32980 01024-81230 20Y-54-11611 01580-01008

Q’ty 1 1 4 8 1 6 1 2 4 2 2

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

Installation of Handrail (With top guard) (2/3)

A-6 (WITH TOP GUARD)

(1) Install handrail (1) with bolts (2) and spacers (3).

Sling at three points marked with a.

No. 1 2 3 Precautions

Necessary tools Name

Q’ty 1

M19 socket

1

Width across flats 17 spanner

1

Others

Q’ty 1 2 2

Necessary equipment

KW12P impact

41

Loose-supply items 209-54-45570 01010-D1260 195-33-11220

Name

Q’ty

Assembly procedure

Installation of Handrail (Without top guard) (3/3)

A-6

(WITHOUT TOP GUARD) (1) Install handrail (1) with bolts (2).

No. 1 2

Precautions

Necessary tools

Others

Name

42

Loose-supply items 209-54-45580 01024-D1235

Q’ty 1 2

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

Installation of Step

A-7-1

(1) Install step (1) and (2) to 4 places on both sides of the front and rear of the track frame with bolts and washers (3) and (4).

Using 900 mm shoe.

No. 1 2 3 4 5 6 Precautions

Name

Q’ty 1

M24 socket

1

43

Q’ty 4 4 32 32 16 32

Necessary equipment

KW20P impact

Others

Remove the rust prevention plug knocked into the mounting tap hole.

Necessary tools

Loose-supply items 21M-30-12260 21M-30-12210 01010-81640 01643-31645 21M-30-12270 01010-81680

Name

Q’ty

Assembly procedure

Installation of Step

A-7-2 •

For PC700LC only

No. 1 2 3 Precautions

Name

Q’ty 1

M24 socket

1

44

Q’ty 4 16 16

Necessary equipment

KW20P impact

Others

Remove the rust prevention plug knocked into the mounting tap hole.

Necessary tools

Loose-supply items 21M-30-33231 01010-81640 01643-31645

Name

Q’ty

Assembly procedure

Installation of Left Side Step

A-8

a During mounting, adjust the Left Side Step to eliminate a difference between the front and rear steps.

Precautions

No. 1 2 3 4 5

Necessary tools Name

Others

Remove the rust prevention plug knocked into the mounting tap hole.

45

Loose-supply items 21M-54-22440 21M-54-22430 21M-54-14690 01024-81245 01024-81235

Q’ty 1 1 5 15 15

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

Sticking Sheet to Counterweight

A-9 •

Stick the sheets to the front side of the counterweight as shown below.

When sticking sheets (1), (2), (3), (4), (5), (6) and (7), set the SG sheet stuck to the side of each sheet up.

Faces without SG sheets

Faces without SG sheets

No. 1 2 3 4 5 6 7 8 Precautions

Necessary tools Name

Others

Remove all oil and rust from the surface where the sheet is to be stuck.

46

Loose-supply items 21M-54-32110 21M-54-22821 21M-54-22830 21M-54-22850 21M-54-22840 21M-54-22860 21M-54-23920 21M-54-23930

Q’ty 1 1 1 1 1 1 1 1

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

Installation of Rear View Camera (1/5)

A-10

(1) Assemble the camera as shown below. (1/2)

Parts marked with are components of this part

Tightening torque 10 – 15 Nm {1.0 – 1.5 kgm} Apply LT-2

Rotation center of camera.

No. 1 2 3 4 5 6 7 8 9 10 11 12 13

Precautions

Necessary tools

Others

Name

47

Loose-supply items 7835-33-1001 7835-33-1100 7835-33-1201 207-06-76431 207-06-76440 20Y-810-1240 01010-80835 01643-30823 04434-53211 07095-00317 01010-81020 01643-31032 08059-00310

Q’ty 1 1 1 1 1 2 2 2 1 1 1 1 2

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

Installation of Rear View Camera (2/5)

A-10

(2) Assemble the camera as shown below. (2/2)

Adjust the camera angle by matching the centers of the camera mounting bolts with the bottom of the 4th line from the lowest one on the scale.

Tightening torque 3 – 5 Nm {0.3 – 0.5 kgm}

Tightening torque 3 – 5 Nm {0.3 – 0.5 kgm}

No. 1 2 3 4 Precautions

Necessary tools

Others

Name

48

Loose-supply items 7835-33-1310 7835-33-1320 7835-33-1330 7835-33-1340

Q’ty 2 4 4 4

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

A-10

Installation of Rear View Camera (3/5)

(2) Install the camera assembled in (1) to the weight and pass the wiring harness through the CW hole.

No. 1 2 3 Precautions

Necessary tools

Others

Name

49

Loose-supply items 207-06-76420 207-06-76451 209-06-45220

Q’ty 1 1 1

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

A-10

Installation of Rear View Camera (4/5)

C

le a

ra n

ce

of

co

nn

ec t io

n

r in

g

an

d

Connection ring Must not use tools for connection ring rotation.

207-06-76451 Installation drawing

re l

ay

ca

bl

e

f la

ng

e.

Hitch claws onto holes

No. 1 2 3 4 Precautions

Necessary tools

Others

Name

50

Loose-supply items 01010-81230 01643-31232 01010-80616 01643-30623

Q’ty 2 2 2 2

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

A-10

Installation of Rear View Camera (5/5)

Remover specification For assembly of the camera, see the standard specification.

For the wiring harness of the camera, see the following figure.

No. 1 2 3 4 5 6 7

Precautions

Necessary tools Name

Others

1.

2.

51

Loose-supply items 21M-06-31210 207-06-76490 04434-51012 195-33-11220 01010-81250 01010-81225 01643-31232

Q’ty 1 1 3 1 1 2 3

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

Installation of Counterweight (1/2)

A-11

(1) Lift the counterweight assembly (1) and install it to the body. a Add one more shackle to the right side to improve the sling balance.

(2) Use the bolt (2) (6 pcs.) and the spacer (3) (6 pcs.) for the installation. a Bolt tightening torque: 3825 ± 392 Nm {390 ± 40 kgm} a If no large torque wrench is available, tighten according to the turning angle below.

1) Initial torque: Tighten to 1470 Nm {150 kgm} 2) After that: Tighten 90° ± 5° a Check the seating condition when tightening the mounting bolts lightly, and then tighten to the specified torque.

4

Counterweight : 10,750 kg

Outer dia 90 mm, 1.0 kg

Tightening torque 3825 ± 392 mm {390 ± 40 kgm}

= 395 mm, 5.1 kg Width across flats 65 mm No. 2 3

Precautions

Name

Q’ty 2

KW45FS impact

1

Width across flats 65S socket

1

Torque wrench (4,118,8 Nm {420 kgm})

1

38sq. × 65 mm socket

1

SD30 shackle

2

52

Q’ty 6 6

Necessary equipment

ø30 x 5000 mm wire

Others

Install the counterweight so that the standard clearance to the revolving frame will be 15 mm and the level differences on the right and left sides will be the same.

Necessary tools

Loose-supply items 21M-46-24210 209-46-11210

Name 45 t crane

Q’ty 1

Assembly procedure

A-11

Installation of Counterweight (2/2)

(3) When installing the counterweight to the machine, remove cover (1) and then install the counterweight, while taking care that the wiring harnesses of the rear working lamp and 2nd camera (if equipped) will not be caught.

Wiring harnesses of rear working lamp and 2nd camera (if equipped)

Precautions

Necessary tools Name

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

Name

Qâ&#x20AC;&#x2122;ty

Others

1

53

Assembly procedure

Installation of Step Light (1/2)

A-12 When installing OPG TOP GUARD 1.

Install step light (1) to the top guard.

2.

When installing the light, remove the bolts marked with bolts marked again.

Note) Tighten the bolts marked with to 7 – 8 Nm.

, remove and tighten the light, and then tighten the

Connector connection position

No. 1 2

Precautions

Necessary tools

Others

Name

54

Loose-supply items 20Y-06-41940 01024-D1020

Q’ty 1 1

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

Installation of Step Light (2/2)

A-12 When not installing OPG TOP GUARD 1.

Install grommet (6) to bracket (3) and install bracket (3) to the cab. Tighten bolt (4) to secure the bracket and rear view mirror together, and tighten bolt (5) to secure the bracket and cab handrail together.

2.

Install step light (1) to bracket (3).

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

again.

No. 1 2 3 4 5 6 Precautions

Necessary tools

Others

Name

55

Loose-supply items 20Y-06-41940 01024-D1020 209-53-24420 01024-D1275 01435-40830 08037-02512

Q’ty 1 1 1 1 1 1

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

A-13 •

Bleeding of Air from Travel Motor

For PC700LC only 1.

Start the engine and run it at low idle.

2.

Loosen air bleeding plug (1) by 1 turn. (Right and left) a Do not loosen the air bleeding plug more than 1 turn.

3.

Travel the machine forward and in reverse 4 – 5 times.

4.

After oil containing no white bubble flows out of air bleeding plug (1), tighten (1).

Precautions

Necessary tools Name

Others

Width across flats 10 spanner

56

Necessary equipment Q’ty 1

Name Oil pan

Q’ty 1

Assembly procedure

A-14-1

Install left travel piping cover.

No. 1 2 3 4 5 6 7 8 9 10 11 12 Precautions

Necessary tools Name

Q’ty 1

L150 extension

1

M19 socket

1

KW20P impact

1

M24 socket

1

57

Loose-supply items 21M-30-28140 01024-81225 21M-30-28120 01024-81230 21M-30-18132 01010-81635 01643-31645 21M-30-28110 01024-81230 21M-30-12340 01010-81640 01643-31645

Q’ty 1 2 1 2 1 4 4 1 4 1 6 6

Necessary equipment

KW12P impact

Others

•

Installation of Travel Piping Cover (1/4)

Name

Q’ty

Assembly procedure

A-14-1

Install left travel piping cover.

No. 1 2

Precautions

Necessary tools Name

Others

•

Installation of Travel Piping Cover (2/4)

58

Loose-supply items 21M-30-28220 01024-81230

Q’ty 1 4

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

A-14-1

Install right travel piping cover.

No. 1 2 3 4 5 6 7 8 9 10 11 12 Precautions

Necessary tools Name

Others

•

Installation of Travel Piping Cover (3/4)

59

Loose-supply items 21M-30-28150 01024-81225 21M-30-28160 01024-81230 21M-30-18182 01010-81635 01643-31645 21M-30-28170 01024-81230 21M-30-12350 01010-81640 01643-31645

Q’ty 1 2 1 2 1 4 4 1 4 1 6 6

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

A-14-1

Install right travel piping cover.

No. 1 2

Precautions

Necessary tools Name

Others

•

Installation of Travel Piping Cover (4/4)

60

Loose-supply items 21M-30-28230 01024-81230

Q’ty 1 4

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

A-14-2 For PC700LC only

No. 1 2 3 4 5 6 7 8 9 10 Precautions

Necessary tools Name

Others

•

Installation of Travel Piping Cover (1/3)

61

Loose-supply items 21M-30-33150 01010-81235 175-54-34170 21M-30-33130 01010-81230 01643-31232 21M-30-33170 01010-81230 01643-31232 175-54-34170

Q’ty 1 2 2 1 2 2 1 2 2 2

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

A-14-2 For PC700LC only

No. 1 2 3 4 5 6 7 8 9 10 Precautions

Necessary tools Name

Others

•

Installation of Travel Piping Cover (2/3)

62

Loose-supply items 21M-30-33150 01010-81235 175-54-34170 21M-30-33130 01010-81230 01643-31232 21M-30-33170 01010-81230 01643-31232 175-54-34170

Q’ty 1 2 2 1 2 2 1 2 2 2

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

A-14-2 For PC700LC only

No. 1 2 3 4 5 6 7 8 9 Precautions

Necessary tools Name

Others

•

Installation of Travel Piping Cover (3/3)

63

Loose-supply items 21M-30-33110 01010-81230 175-54-34170 21M-30-33120 01010-81230 175-54-34170 21M-30-33160 01010-81230 01643-31232

Q’ty 1 4 4 1 4 4 1 4 4

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

A-15 For PC700LC only

Weight of motor guard: 70 kg

No. 1 2 3 4 5 6 Precautions

Necessary tools Name

Others

•

Installation of Travel Motor Guard

64

Loose-supply items 21M-30-33210 01010-81645 01643-31645 21M-30-33220 01010-81645 01643-31645

Q’ty 1 10 10 1 10 10

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

Testing Track Shoe Tension (1/3)

A-16

Precautions

Necessary tools

Others

Name

65

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

Testing Track Shoe Tension (2/3)

A-16

Precautions

Necessary tools

Others

Name

66

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

Testing Track Shoe Tension (3/3)

A-16

Precautions

Necessary tools

Others

Name

67

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

A-17

Check Fuel, Coolant and Oil Levels (1/3)

68

Assembly procedure

Check Fuel, Coolant and Oil Levels (2/3)

A-17

48

13

10.5

7.2

520

58

880

12.68

3.43

2.77

1.9

137.38

15.32

232.50

40

13

10

7.2

360

10.57

3.43

2.64

1.9

95.11

69

Assembly procedure

A-17

Check fuel, coolant and oil levels (3/3)

Precautions

Necessary tools Name

Others

• Non-amine Supercoolant (Blue) is added when shipped. Do not mix coolant of different type with it.

70

Necessary equipment Q’ty

Name

Q’ty

B. ASSEMBLING OF WORK EQUIPMENT â&#x20AC;¢ Clean the mounting pin and pin hole and check them for a flaw.

71

Assembly procedure

Assembly of Arm Cylinder

B-1

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

4 Arm cylinder: 727 kg

4 Arm cylinder foot pin: 36 kg (2) Lift the arm cylinder and adjust it to the boom hole positions.

Adjust the clearance of cylinder foot mounting portion below 1 mm with shim (1).

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

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

(4) Mount the stoppers.

No. 1 Precautions

Necessary tools

Others

Name

72

Loose-supply items 208-70-31310

Q’ty 3

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

Connection of Arm Cylinder Hoses

B-2

(1) Remove the oil stopper plug from the arm cylinder pipe, and replace four O-rings (2) at the hose end with new ones (Part No. 07000-13038).

Then, connect the arm cylinder hoses (1) (PC600, 650: 07085-01214 × 1, 07084-01412 × 1, PC600SE: 21M-62-32760 × 1).

Use existing split flanges (5) and (8) and bolts (6), (7), (9) and (10) of the oil stopper.

See Precaution 1.

7.6 m boom 7.3 m boom 6.6 m boom 7.6 m boom 7.3 m boom 6.6 m boom

Precautions

Necessary tools Name

Others

1. Before starting the hose connection, securely bind the arm cylinder rod using wires so that the rod is not pushed out.

2. Bind to a pipe, etc. so that the dust seal will not be damaged.

3. Remove and store the flange, O-rings and heads so that you can reuse them later.

4. When connecting the hoses, take extremely care not to clinch or damage the O-rings.

5. Also, take extremely care not to enter a foreign material into the hydraulic circuit.

73

No. 1 1 1 2 2 2 3 4 No. 5 6 7 8 9 10

Loose-supply items 07085-01214 07085-01214 21M-62-32760 07084-01413 07084-01412 07084-01415 07000-13038 07000-13048 Parts mounted on the boom 07371-51260 01010-81245 01643-31232 07371-51470 01010-81455 01643-31645

Q’ty 1 1 1 1 1 1 2 2 Q’ty 4 8 8 4 8 8

Necessary equipment Q’ty

Name

Q’ty

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 boom cylinder holding mount between the cylinder and the revolving frame.

(Height: 40 – 50 mm, Width: less than 90 mm)

P

a

Precautions

Name

Necessary equipment Q’ty

50 mm wide, 3000 mm Nylon sling

2

KW20P impact wrench

1

M24 socket

1

Others

a Select an appropriate combination of two 0.8-mm thick shims (Part No. 207-7011360) and two 1.5 mm thick shims (Part No. 207-70-11370) for adjustment of the amount of shims.

Necessary tools

74

Name 25 ton crane

Q’ty

Assembly procedure

Installation of Boom Cylinder Hoses

B-4

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

(2) Install the boom cylinder hoses (07074-01011 × 4) to the correct circuits as shown in the diagram below. a Bleed the boom cylinder of air by following Assembly Procedure B-15 “Bleeding Air from Work Equipment Circuit”.

No. 1 No. 2 Precautions

Name

Q’ty 1

L150 extension

1

M14 socket

1

75

Q’ty 4 Q’ty 4

Necessary equipment

KW10P Impact

Others

1. When removing an oil stopper plug from a hose, slowly loosen its bolts by gradually releasing the internal hydraulic pressure.

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.

Necessary tools

Already installed to chassis 07074-01011 Loose-supply items 07000-13032

Name

Q’ty

Assembly procedure

Installation of Boom Foot Dust Seal

B-5

(1) Install the seal (209-72-11261) to the boom foot

Take care of the direction of its lip.

No. 1 Precautions 1. Take care of the direction of its lip so that the grease can come out from inside.

2. When installing the seal, be careful not to slant it.

Necessary tools Name

Q’ty 1

Template

1

Others

4. Do not hit seal with hammer directly but use template, etc. to hit.

76

Q’ty 2

Necessary equipment

Hammer

3. Insert the seal until it touches the bushing.

Loose-supply items 209-72-11261

Name

Q’ty

Assembly procedure

Assembly of Boom Assembly

B-6

(1) Lift the boom assembly with the crane and bring it to the body pin hole.

(2) Fitting of Boom Foot Pin. When the boom is inclined to the left or right at the time, balance it by using the jib crane.

4 Boom assembly : 4,870 kg

Sling position

(3) Check the clearance between the boom foot and the machine outside, decide the size and quantity of shim so that the clearance becomes below 1 mm and insert the shim between them.

Use the adjustment shims (209-70-71640, 1.0 mm thick, 2 pcs. and 209-70-71650, 1.5 mm thick, 2 pcs.) to decide their combination. (Adjust the clearance with shims at one place outside.)

(4) Insert the boom foot pins fully and fit lockplates there.

2 Inside bushing: Lithium grease No. 1 2 Precautions

Name

Q’ty 2

SD30 shackle

2

Large hammer (plastic)

1

KW20P impact

1

M24 socket

1

77

Q’ty 4 4

Necessary equipment

ø20 × 5000 mm wire

Others

a Two seals are mounted on the boom feet.

Take care not to damage them when inserting the pin.

Necessary tools

Loose-supply items 209-70-71640 209-70-71650

Name 25 ton crane

Q’ty 1

Assembly procedure

Installation of Hoses from Chassis Along Top of Boom (1/2)

B-7

(1) Remove the oil stopping plugs of the tubes on the machine side.

(2) Install arm cylinder hoses (07085-01418: one pc., 07085-01218: one pc.) and bucket cylinder hoses (07085-01217: one pc., 07085-01017: one pc.) to the regular circuit as shown below.

(3) Remove the oil stopping plugs on the boom side and install the hoses. a Bleed the arm cylinder of air by following Assembly Procedure B-15 “Bleeding Air from Work Equipment Circuit”.

No. 1 2 3 4 5 6 7 8 Precautions

Name

Q’ty 1

L150 extension

1

M19 socket

1

M14 socket

1

M22 socket

1

78

Q’ty 1 1 1 1 2 2 2 2

Necessary equipment

KW10P Impact

Others

1. When removing an oil stopper plug from a hose, slowly loosen its bolts by gradually releasing the internal hydraulic pressure.

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.

Necessary tools

Loose-supply items 07085-01418 07085-01218 07085-01217 07085-01017 07000-13048 07000-13038 07000-13038 07000-13032

Name

Q’ty

Assembly procedure

Installation of Hoses from Chassis Along Top of Boom (2/2)

B-7

(1) Remove boom side oil stopper plug.

(2) Install hoses P and T of the arm regeneration valve on the machine side.

Oil stopper plug

Hoses P and T of the arm regeneration valve

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

No. 1 2 3 4

Precautions

Name

Q’ty 1 1 3 2

Necessary equipment Q’ty

Name

Q’ty

KW10P Impact

1

Width across flats 19 mm spanner

1

L150 extension

1

M19 socket

1

Width across flats 32 mm spanner

1

Width across flats 30 mm spanner

1

Width across flats 27 mm spanner

1

Width across flats 22 mm spanner

1

Others

1. When removing an oil stopper plug from a hose, slowly loosen its bolts by gradually releasing the internal hydraulic pressure.

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.

Necessary tools

Loose-supply items 21M-62-31780 21M-62-31551 01024-81225 01024-81240

79

Assembly procedure

Connection of Boom Cylinder Head

B-8

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

4 Boom cylinder: 500 kg

4 Boom cylinder top pin: 104 kg (2) Start the engine and rotate it at the low idle speed.

(3) Sling the cylinder and raise the rod slowly to match the pin holes.

(4) Knock in the cylinder top pin.

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

P Adjust clearance to 1 mm or less.

P

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. 1 2 3 4 5 Precautions

Necessary tools

Others

Name

80

Loose-supply items 21M-70-11220 21M-70-11280 21M-70-11290 01580-12419 426-70-11280

Q’ty 1 2 2 4 8

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

Installation of Arm Assembly (1/2)

B-9

(1) Remove the stopper of the boom top pin fixed to the boom, then pull out the top pin.

4 Boom top pin: 76 kg

(2) Raise the arm assembly, align the position with the boom hole, insert a shim (209-72-51230) t1.0, then push in the pin.

4 Arm assembly: For the weight, see the table in "Transportation"

a Seals (07145-00125 × 2) are installed to the inside of the bushing at the arm end, but be careful no to damage the seals when inserting the pin.

2 Inside of bushing: Lithium grease (3) Install the stopper.

(4) Remove the stopper of the arm cylinder top pin fixed to the arm, then pull out the top pin.

4 Arm cylinder pin: 32 kg × 1 Be careful of arm cylinder rod greasing hole Assemble so that greasing hole is at top

(5) Start the engine, run at low idle, extend the arm cylinder rod slowly, and align the position of the hole.

When doing this, raise the arm cylinder with a crane and operate the arm cylinder at the same time to align the position.

No. 1 2 Precautions

Necessary tools

Others

Name

81

Loose-supply items 209-72-51230 07145-00125

Q’ty 1 2

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

Installation of Arm Assembly (2/2)

B-9

Precautions

Necessary tools

Others

Name

82

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

Name

Qâ&#x20AC;&#x2122;ty

Assembly procedure

B-10

Installation of Bucket Cylinder Hoses between Boom and Bucket Cylinder

a Bleed the bucket cylinder of air by following Assembly Procedure B-15 “Bleeding Air from Work Equipment Circuit”.

Oil stopper plug

Detail P

No. 1 2 3 4 Precautions

Necessary tools Name

Others

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

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

3. When installing the hoses, take extreme care not to twist them.

(Tighten from the 90° adapter to prevent twisting.)

83

Loose-supply items 07073-21A19 07073-21220 07000-13032 07000-13038

Q’ty 1 1 2 2

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

Installation of Bucket (1/3)

B-11

(1) Remove the stoppers of the bucket and arm connecting pin (fixed to the arm) and bucket and link connecting pin (installed to the link) and remove each pin.

(2) Install bushing (1) and 2 O-rings (2) and (3) to the boss on the bucket side.

(3) Run the engine at idle and operate the boom cylinder and arm cylinder slowly to set the holes for the bucket and arm connecting pin.

4 Weight of bucket assembly: Refer to the section “Transportation”.

(4) Push in the arm and bucket connecting pin, adjust the clearance to 0.5 – 1.0 mm with shims (4) and (5), and tighten cover mounting bolts (M24).

2 Inside of pin hole: Apply lithium grease.

No. 1 2 3 4 5 Precautions

Necessary tools Name

Others

Q’ty 1 1 1 16 4

Necessary equipment Q’ty

Name 25 t crane

84

Loose-supply items 209-70-54160 21M-939-1B51M 21M-939-1B41M 209-70-54181 209-70-54191

Q’ty 1

Assembly procedure

Installation of Bucket (2/3)

B-11

(5) Install O-rings (2) to prevent dirt from entering the bucket and arm connecting pin to the correct positions and then install the pin stopper.

Stopper

Precautions

Necessary tools

Others

Name

85

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

Name

Qâ&#x20AC;&#x2122;ty

Assembly procedure

Installation of Bucket (3/3)

B-11

(6) While slinging the link and operating the bucket cylinder, set the holes for the bucket and link connecting pin. a Operate the cylinder slowly. Do not operate it quickly or to the stroke end. Since there is air in the cylinder, the piston rod may not move for more than 10 seconds. Do not move the lever to the stroke end at this time.

(7) Push in the link and bucket connecting pin and adjust the clearance to below 1 mm with shims (7) 1.0 mm thick.

Install O-rings (6) to prevent entry of dirt to the correct positions and install the pin stopper.

No. 6 7

Precautions

Necessary tools Name

Others

a Since the shape of the link is different from the former link, disassemble and assemble the arm in the vertical posture. If the arm is disassembled in the horizontal posture, in particular, the link jumps up just after the pin is pulled out. Take care extremely.

86

Loose-supply items 21M-939-1B71M 209-72-11220

Qâ&#x20AC;&#x2122;ty 2 1

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

Name

Qâ&#x20AC;&#x2122;ty

Assembly procedure

B-12

Connection of Work Equipment Grease Piping

(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.

87

Assembly procedure

B-13

Connection of Work Equipment Wiring (1/2)

(1) Connect connector (A) (CN-L01) of the working lamp wire to the body wiring harness.

(2) Install the working lamps as shown below.

No. 1 2 3 4 Precautions

Necessary tools

Others

Name

88

Loose-supply items 21T-06-32810 01024-81230 08193-20012 20Y-06-21551

Q’ty 1 2 1 1

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

B-13

Connection of Work Equipment Wiring (2/2)

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

No. 1 2 Precautions

Necessary tools

Others

Name

89

Loose-supply items 04434-51012 01024-81225

Q’ty 1 1

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

B-14

Greasing after Assembling Work Equipment

Precautions

Necessary tools

Others

Name

90

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

B-15

Bleeding Air from Work Equipment Circuit

Precautions

Necessary tools

Others

Name

91

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

B-16

Parts to be Touched up After Field Assembly

Precautions

Necessary tools

Others

Name

92

Necessary equipment Q’ty

Name

Q’ty

C. ASSEMBLING OF WORK EQUIPMENT OF LOADING SHOVEL â&#x20AC;¢ Clean the mounting pin hole and check them for a flaw.

93

Assembly procedure

Releasing residual pressure in hydraulic circuit

C-1

When removing the hydraulic piping, be sure to release the residual pressure according to the following procedure.

(1) Set the lock lever in the FREE position.

(2) Remove the oil filler cap of the hydraulic tank.

(3) Run the engine about 10 seconds, and then stop it. ★ Limit the engine speed to 1,000 rpm. ★ Keep the work equipment control levers in neutral. ★ Raise the hydraulic lock to the FREE position.

(4) Move each work equipment control lever to the stroke end within 5 - 6 seconds after stopping the engine. ★ Repeat steps (3) and (4) 3 times.

When removing the oil filler cap of the hydraulic tank, turn it slowly to release the internal pressure, and then remove it.

(5) After releasing the residual pressure, install the oil filler cap of the hydraulic tank to prevent dirt from entering the tank.

(6) Lower the hydraulic lock to the LOCK position.

Precautions

Necessary tools

Others

Name

94

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

Pulling out boom foot pin and boom cylinder foot pin

C-2

(1) Remove the boom foot pin stopper fixed to the chassis and pull out the pin.

(2) Remove the boom cylinder foot pin stopper fixed to the chassis and pull out the pin. ★ Use forcing screws to pull out the pins.

For boom:(30mm,P=3.0) For boom cylinder:(16mm,P=2.0)

Precautions

Necessary tools

Others

Name

95

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

Installation of boom cylinder foot

C-3

(1) Sling the boom cylinder with the crane and match it to the pin holes.

(2) Apply lithium grease to the pin holes and inside of the bushing.

(3) Check the clearance between the cylinder and chassis (outside of the chassis). Decide the thickness of the shim to be inserted to reduce the clearance to below 1 mm. Adjust the shims for both cylinder.

(Outside of chassis) (4) Push in the boom foot pin completely and install the lock plate.

(5) Install the above parts to both sides similarly. ★ Assemble the parts so that the grease hole of the boom cylinder boom will be on the lower side.

★ Combine the 0.8-mm thick shim (207-70-11360, 4 pieces) and 1.5-mm Thick shim (207-70-11370, 4 pieces) to obtain the necessary thickness.

Precautions

Necessary tools

Others

Name

96

No.

Loose-supply items

Q’ty

1 2

207-70-11360 207-70-11370

4 4

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

Installation of boom and arm assembly

C-4

(1) Install the seals (209-72-11261, 2 pieces) to the boom foot.

(2) Sling the boom and arm assembly with a crane and match it to the pin holes of the chassis.

(3) Apply lithium grease to the pin holes and inside of the bushing.

(4) Install the boom foot pin. (See the figure at right.)

If the boom leans to the right or left at this time, balance it with a jib crane.

Install the seals (209-72-11261, 2 pieces) to the boom foot as shown in the figure below. Take care not to damage those seals when inserting the pin.

Check the clearance at the boom foot on the outside of the chassis and decide the thickness of the shim so that the clearance will be less than 1 mm. Combine the 1.0-mm thick shims (209-72-11180, 2 pieces) and 1.5-mm thick shims (209-72-11190, 2 pieces) to obtain the necessary thickness.

(Adjust the shim at one outside position.)

(5) Push in the boom foot pin completely and install the lock plate.

No.

1 2 3

Precautions

Necessary tools

Others

Name

97

Loose-supply items

209-72-11261 209-72-11190 209-72-11180

Q’ty

2 2 2

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

Installation of boom cylinder hoses

C-5

(1) Remove the tube plug on the boom cylinder.

(2) Install the boom cylinder hoses to the regular circuit as shown below.

No.

1 2

Precautions

Necessary tools

Others

Name

98

Loose-supply items

07085-01009 07085-010A8

Q’ty

2 2

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

Installation of boom cylinder rod pin

C-6

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

(2) Run the engine at low idling.

(3) Sling the cylinder and push the rod slowly to match the pin holes.

(4) Drive in the cylinder top pin.

(5) Install both cylinders according to the same procedure.

(6) Install the stopper. (Tightening torque of M16 bolt : 15 – 31.5 kgm) ★ Move the cylinder slowly. Do not move it quickly or move it to the stroke end.

It may not start for more than 10 seconds at first because of air in it.

Do not move the lever to the stroke end this time.

Precautions

Necessary tools

Others

Name

99

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

Installation of boom cylinder

C-7

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

Boom cylinder : 520 kg Boom cylinder top pin : 104 kg (2) Run the engine at low idling.

(3) Sling the cylinder and push the rod slowly to match the pin holes.

(4) Drive in the cylinder top pin.

Inside of bushing: Apply lithium grease.

★

Move the cylinder slowly. Do not move it quickly or move it to the stroke end. It may not start for more than 10 seconds at first because of air in it. Do not move the lever to the stroke end at this time.

(5) Install the stopper ★ Reduce the clearance between cover (2) and cylinder rod to below 1 mm with shim (5).

No.

1 2 3 4 5

Precautions

Necessary tools

Others

Name

100

Loose-supply items

21M-70-11440 21M-70-11280 21M-70-11290 01580-12419 426-70-11280

Q’ty

1 2 2 4 8

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

Installation of arm cylinder hoses

C-8

(1) Remove the tube oil stopper on the arm cylinder side and that on the boom side.

(2) Install the arm cylinder hoses (07084-21214, 07084-21215) to the regular circuit (See the figure below).

Replace the hose O-rings (07000-13048, 4 pieces) with new ones.

2 3

No.

1 2 3

Precautions

Necessary tools

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

Name

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.

101

Loose-supply items

07000-13048 07084-21214 07084-21215

Q’ty

4 1 1

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

Installation of bucket cylinder

C-9

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

Bucket cylinder : 520 kg Bucket cylinder top pin : 104 kg (2) Run the engine at low idling.

(3) Sling the cylinder and push the rod slowly to match the pin holes.

(4) Drive in the cylinder top pin.

Inside of bushing: Apply lithium grease.

★

Move the cylinder slowly. Do not move it quickly or move it to the stroke end. It may not start for more than 10 seconds at first because of air in it. Do not move the lever to the stroke end at this time.

(5) Install the stopper ★ Reduce the clearance between cover (2) and cylinder rod to below 1 mm with shim (5).

No.

1 2 3 4 5

Precautions

Necessary tools

Others

Name

102

Loose-supply items

21M-72-11291 21M-70-11280 21M-70-11290 01580-12419 426-70-11280

Q’ty

1 2 2 4 8

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

C-10

Installation of bucket cylinder hoses

Installation of bucket cylinder piping. ・ Return the hoses connected for flushing. ・ Replace the hose O-rings (07000-13038, 6 pieces) with new ones.

Plug is installed

07084 21218

Precautions

21M-72 (2)

11730

Necessary tools

Others

Name

103

(2)

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

C-11

Installation of connecting hoses between chassis and boom top

(1) Remove the tube plugs on the boom side.

(2) Hoses for boom, arm cylinder, and bucket cylinder.

(07072-01220, 4 pieces) Hoses for bottom dump cylinder (07072-01218, 2 pieces)

2

1

No.

1 2

Precautions

Necessary tools

Others

Name

104

Loose-supply items

07072-01220 07085-01218

Q’ty

4 2

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

C-12

Installation of bottom dump cylinder hoses

Installation of bottom dump cylinder piping.

(1) When the bucket assembly is installed to the arm as shown at light.

1) Return the bottom dump cylinder hoses (07084-21216, 2 pieces) connected for flushing. Replace the hose O-rings (07000-13038, 4 pieces) with new ones.

2) Return the rear bucket covers (209-72-75170, 2 pieces).

Cover (2) When the bucket assembly is disassembled as shown at right, install the bucket and bucket cylinder according to the procedure shown in the following pages, and then install the bottom dump cylinder hoses (07084-21216, 2 pieces).

Bucket cylinder

・Similarly to (1), replace the O-rings (07000-13038, 4 pieces) with new ones.

Precautions

Necessary tools

Others

Name

105

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

(1/2)

Installation of bucket assembly

C-13

(1) Remove the bucket-arm connecting pins (fixed to the bucket) and bucket-link connecting pins (fixed to the bucket).

(2) Run the engine at low idling and move the boom cylinder and arm cylinders slowly to match the holes for the bucket-arm connecting pins. ・Move the cylinder slowly. Do not move it quickly or move it to the stroke end. ・It may not start for more than 10 seconds at first because of air in it. Do not move the lever to the stroke end at this time.

(3) Keep the arc-level selector switch in the arc digging position.

(Tightening torque: 15-31.5kgm) (4) Install fittings 5 (07020-00000, 2 pieces).

Precautions

Necessary tools

Others

Name

106

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

C-13

(2/2)

Installation of bucket assembly

(5) Match the holes for the bucket cylinder-bucket connecting pins.

(6) Push in bucket cylinder-bucket connecting pins 6 and install plates 7 with bolts 9 and washer 8.

(Tightening torque: 15-31.5kgm)

Precautions

Necessary tools

Others

Name

107

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

(1/2)

Installation of working lamps

C-14

Install lamps 1 (21T-06-32810) with plates 4 (20Y-06-21551), bolts 2 (01010-81430), and washer 3 (01643-31445) and connect the connector. (Install the lamps to both sides of the boom.)

No.

1 2 3 4

Precautions

Necessary tools

Others

Name

108

Loose-supply items

21T-06-32810 01010-81430 01643-31445 20Y-06-21551

Q’ty

2 2 2 2

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

C-14

(2/2)

Installation of working lamps

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

No.

1 2

Precautions

Necessary tools

Others

Name

109

Loose-supply items

04434-51012 01024-81225

Q’ty

1 1

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

Installation of work equipment grease piping

C-15

(1) Install grease fittings (7020-00000, 2 pieces) to the boom cylinder foot.

(2) Install the grease piping of the boom cylinder top and bucket cylinder top to parts (a).

No.

1

Precautions

Necessary tools

Others

Name

110

Loose-supply items

07020-00000

Q’ty

2

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

C-16

Grease after assembling of work equipment

Supply each pin of the work equipment with molybdenum disulfide grease to fit it well for the first 1 month of new machine or until the first grease pail (16 kg) is used up.

(Komatsu genuine grease No. SYGA-16CNM (16 kg)) <Precautions> (1) Do not apply molybdenum disulfide grease to the swing circle bearing.

(Since the balls contact the races by points, they will be worn quickly.)

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

(After the grease in the pin fitting parts dries up, the parts are rusted easily and pins may be fixed.)

Precautions

Necessary tools

Others

Name

111

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

Bleeding air from work equipment circuit

C-17

After assembling the work equipment piping, bleed the air from it.

(1) Run the engine at low idling.

(2) Move each cylinder to about 100 mm before each stroke end 4-5 times.

(3) Keeping the engine speed at low idling, move each cylinder from the point of 100 mm before the stroke end to the stroke end very slowly (taking at least 10 seconds), and then keep the work equipment control lever at the stroke end for 3 minutes.

(Bleed the air from the boom cylinder, arm cylinder, and bucket cylinder at the extraction stroke end, but bleed the air from the bottom dump cylinder at the retraction stroke end (opening end of the bucket).) ★

The cylinder may not start for more than 10 seconds at first because of the much air in the circuit.

Do not move the lever to the stroke end at this time.

(4) Keeping the engine speed at high idling, move each cylinder from the point of 100 mm before the stroke end to the stroke end very slowly (taking at least 10 seconds), and then keep the work equipment control lever at the stroke end for 3 minutes.

(Bleed the air from the boom cylinder, arm cylinder, and bucket cylinder at the extraction stroke end, but bleed the air from the bottom dump cylinder at the retraction stroke end (opening end of the bucket).)

The air in each cylinder is bled by performing steps (2)-(4).

If the engine speed is heightened or each cylinder is moved to the stroke end from the first, the piston packing may be damaged by the air in the cylinder.

Precautions

Necessary tools Name

Others

★ ★

112

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

C-18

Checking oil level in hydraulic tank and adding oil

Checking oil level in hydraulic tank and adding new oil.

(1) Run the engine at low speed, retract the arm cylinder, extract the bucket cylinder, lower the boom until the bucket bottom touches the ground, and stop the engine.

(2) Move the control levers (work equipment and travel) to each stroke end to release the internal pressure.

(3) Check the oil level by sight gauge (G).

(4) If the oil level is below line L of sight gauge (G), add engine oil (CD SAE10W, regardless of the temperature) through oil filter (F). ★ Do not add oil above line H. Before removing the oil filter cap, loosen it gradually and leave it for several minutes to release the air in the tank. After the air pressure in the tank is lowered sufficiently, remove the cap. ★

Since the oil level varies with the oil temperature, note the following. ・When the engine is cold (When the oil temperature is 10 -30 ℃), the oil level should be around the L level. ・When the engine is warmed up (When the oil temperature is 50 – 80 ℃), the oil level should be around the H level.

Precautions

Necessary tools

Others

Name

113

Necessary equipment Q’ty

Name

Q’ty

D. ASSEMBLING OF COUNTERWEIGHT REMOVER

115

Assembly procedure

Sticking Sheet to Counterweight

D-1 •

Stick the sheets to the front side of the counterweight as shown below.

When sticking sheets (2), (3), (4), (5), (6), (7) and (10), set the SG sheet stuck to the side of each sheet up.

2 Sheets (1), (8), (9) and (11) : LT-1A (24 hours hardening)

Shall be bonded using LT-1A.

Shall be bonded using LT-1A.

Surface without SG sheet.

Shall be bonded using LT-1A.

Surface without SG sheet.

Shall be bonded using LT-1A.

No. 1 2 3 4 5 6 7 8 9 10 11

Precautions

Necessary tools Name

Others

Remove all oil and rust from the surface where the sheet is to be stuck.

116

Loose-supply items 21M-54-14390 21M-54-32110 21M-54-22850 21M-54-22860 21M-54-23290 21M-54-23350 21M-54-23360 21M-54-23581 21M-54-23660 21M-54-23670 21M-54-23680

Q’ty 2 1 1 1 1 1 1 1 1 1 1

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

Adjustment of Shims for Counterweight (1/5)

D-2

(1) Sling counterweight assembly (1) and install it to the machine.

(2) Check that bolts (2) (6 pieces) can be installed.

(Tighten the bolts with the fingers. You do not need to tighten them securely at this time.)

Weight of counterweight assembly: 12,200 kg

No. 2 3

Precautions

Necessary tools Name

Q’ty 2

SD30 shackle

2

Others

Q’ty 6 6

Necessary equipment

ø300 × 5,000 mm wire

117

Loose-supply items 21M-46-24210 209-46-11210

Name 45 t crane

Q’ty 1

Assembly procedure

Adjustment of Shims for Counterweight (2/5)

D-2

(3) Decide the thickness of shims (2), (3) and (4) at the 4 places so that the clearance between the revolving frame and plate (1) will be 2 mm.

(4) Remove the counterweight mounting bolts and lift the counterweight assembly down from the revolving frame.

(5) Install plate (1) and shims (2), (3) and (4) decided by step (3) above to the counterweight with bolts (5).

Clearance: 2 mm

Shim installing place

No. 1 2 3 4 5 Precautions

Necessary tools

Others

Name

118

Loose-supply items 21M-46-24491 21M-46-24511 21M-46-24521 21M-46-24541 01024-81235

Q’ty 4 8 8 4 8

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

Adjustment of Shims for Counterweight (3/5)

D-2

a If a crane is not available, adjust the shims for the counterweight according to the following procedure.

(1) Measure distances A (L.H.) and A (R.H.) between the center of the counterweight mounting hole of the revolving frame and outside end of the revolving frame top plate.

Precautions

Necessary tools

Others

Name

119

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

Name

Qâ&#x20AC;&#x2122;ty

Assembly procedure

Adjustment of Shims for Counterweight (4/5)

D-2

(2) Measure distances B (L.H.) and B (R.H.) between the center of the counterweight hole and end of plate (1).

Precautions

Necessary tools

Others

Name

120

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

Name

Qâ&#x20AC;&#x2122;ty

Assembly procedure

Adjustment of Shims for Counterweight (5/5)

D-2

(3) Decide the thickness of shims (2), (3) and (4) at the 4 places so that B (L.H.) – A (L.H.) and B (R.H.) – A (R.H.) will be 2 mm respectively.

(4) Install plate (1) and shims (2), (3) and (4) decided by step (3) above to the counterweight with bolts (5).

Clearance: 2 mm

Shim installing place

No. 1 2 3 4 5

Precautions

Necessary tools

Others

Name

121

Loose-supply items 21M-46-24491 21M-46-24511 21M-46-24521 21M-46-24541 01024-81235

Q’ty 4 8 8 4 8

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

Greasing

D-3

Before assembling the counterweight remover assembly, grease each pin.

Precautions

Necessary tools Name

Others

•

122

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

Installation of Counterweight Remover

D-4

1) Sling counterweight remover assembly (1) and install it to the machine.

2) Fix the counterweight remover assembly with mounting bolts (2) (6 pieces) and washers (3) (6 pieces).

Weight of counterweight remover assembly: 1,300 kg

No. 2 3 Precautions

Necessary tools Name

Q’ty 2

4:1 torque multiplier

1

85 kgm torque wrench

1

T 25 × socket, 55 mm width across flats

1

Others

Q’ty 6 6

Necessary equipment

50 × 3,000 mm nylon sling

123

Loose-supply items 01011-83625 01643-33690

Name 25 t crane

Q’ty 1

Assembly procedure

Installation of Covers

D-5

Install covers (1), (2), bracket (3), and bolts and washers (4), (5) and (6).

㽵㽲 㽶㽳 㽷㽴

Precautions

Necessary tools Name

Others

•

124

No.

Loose-supply items

Q’ty

1

21M-46-24371

1

2

21M-46-24550

1

3

21M-46-24430

1

4

01024-81225

4

5

01024-81225

4

6

01024-81230

2

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

Installation of Clamps (1/3)

D-6

• Install clamps (1), cushions (2), and bolts and washers (3).

No. 1 2 3 Precautions

Necessary tools

Others

Name

125

Loose-supply items 07094-10417 07095-00420 01024-81265

Q’ty 4 2 2

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

Installation of Clamps (2/3)

D-6

• Install clamps (1), cushions (2), and bolts and washers (3).

No. 1 2 3 Precautions

Necessary tools

Others

Name

126

Loose-supply items 07094-10417 07095-00420 01024-81265

Q’ty 4 2 2

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

Installation of Clamps (3/3)

D-6

• Install clamps (1), cushions (2) and bolts and washer (3).

No. 1 2 3 Precautions

Necessary tools

Others

Name

127

Loose-supply items 07094-30417 07095-00420 01024-81265

Q’ty 2 2 1

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

Installation of Hoses

D-7

• Remove the oil plugs of the chassis side and those of the hoses and connect hoses at the remover side to the joint at the chassis side.

Blue

White

Green

Brown

Yellow Red

Precautions

Name

Necessary equipment Q’ty

Oil receiving pan (small)

1

Spanner, 19 mm width across flats

2

Spanner, 22 mm width across flats

2

Others

1. When removing each oil plug, loosen it slowly to release the internal pressure and then remove it carefully.

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

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

Necessary tools

128

Name

Q’ty

Assembly procedure

Bleeding Air from Counterweight Remover Circuit

D-8

a After assembling the piping, bleed air from the counterweight remover circuit.

(1) Run the engine at low idle.

(2) Extend and retract each cylinder 4 â&#x20AC;&#x201C; 5 times, stopping it at about 100 mm before each stroke end.

(3) While running the engine at low idle, extend each cylinder from 100 mm before each stroke end to the stroke end very slowly (taking at least 10 seconds) and then keep the remover control lever at the stroke end for 4 minutes. a At the first operation, the remover link does not move for more than 10 seconds since much air is in the circuit. Do not move the lever to the stroke end, however. a The air in the cylinder is bled by operations (1) to (3). a If each cylinder is moved to the stroke end from the first operation, the air in the cylinder may damage the piston packing, etc.

Precautions

Necessary tools

Others

Name

129

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

Name

Qâ&#x20AC;&#x2122;ty

Assembly procedure

Installation of Counterweight (1/2)

D-9

(1) Set the pin holes of the link to those of the counterweight by operating the counterweight remover and then install counterweight pins (1) and lock plates (2) with bolts (3), washers (4) and nuts (5).

No. 1 2 3 4 5 Precautions

Necessary tools

Others

Name

130

Loose-supply items 21M-46-24360 21M-46-24570 01011-81250 01643-31232 01580-11210

Q’ty 2 2 2 4 4

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

Installation of Counterweight (2/2)

D-9

(2) Place the counterweight on the revolving frame by operating the counterweight remover.

(3) Install bolts (1) (6 pieces) and spacers (2) (6 pieces). a If a large torque wrench is not available, tighten the bolts by the following angle tightening method.

(1) Tighten the bolts to 1,471 Nm {150 kgm} first.

(2) Tighten the bolts by 90 ± 5°. a Check the seating condition when tightening the mounting bolts lightly, and then tighten to the specified torque.

Outside diameter: f90 mm, 1.0 kg

3 Tightening torque 3,825 ± 392 Nm {390 ± 40 kgm}

L = 395 mm, 5.0 kg Width across flats: 65 mm

No. 1 2 Precautions

Name

Q’ty 1

Socket, 65 mm width across flats

1

420 kgm torque wrench

1

T 38 × socket, 65 mm width across flats

1

131

Q’ty 6 6

Necessary equipment

KW45FS impact wrench

Others

Install the counterweight so that there will be the reference space of 15 mm between the weight and the revolving frame or so that the left level difference equals to the right one.

Necessary tools

Loose-supply items 21M-46-24210 209-46-11210

Name

Q’ty

Assembly procedure

Installation of Accessories

D-10

After tightening counterweight mounting bolt, install cover (1) and bolt (2).

㽳㽲

Note) Install the cover (1) at last since it can interfere with the counterweight remover when the latter is operated.

Precautions

Necessary tools Name M19 socket

132

No.

Loose-supply items

1

209-46-42222

Q’ty 1

2

01024-81225

2

Necessary equipment Q’ty 1

Others

•

Name

Q’ty

Assembly procedure

Check of Operation

D-11

• After assembling the counterweight remover, check the following 3 items.

(1) The cylinders move as operated with the levers.

(2) No oil is leaking.

(3) No parts interfere with each other.

Precautions

Necessary tools

Others

Name

133

Necessary equipment Q’ty

Name

Q’ty

M. PROCEDURE FOR INSPECTION AND MAINTENANCE AFTER COMPLETION OF ASSEMBLY

135

Assembly procedure

M-1

Inspection of Oil Level in Hydraulic Tank and Refill (1/2)

Inspection of oil level in hydraulic tank and refill

Precautions

Necessary tools

Others

Name

136

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

Name

Qâ&#x20AC;&#x2122;ty

Assembly procedure

M-1

Inspection of Oil Level in Hydraulic Tank and Refill (2/2)

Precautions

Necessary tools

Others

Name

137

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

Name

Qâ&#x20AC;&#x2122;ty

Assembly procedure

M-2

Replacement of Return Filter (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). a When replacing the element, take out the element slowly so that refuses adhered to the element do not fall inside. Also, take out refuses by hand from the case

Replace the relief valve with this plate only at the flushing time.

Replacement

Valve

Strainer

Special element for flushing, Absolute filter mesh size: 6 µ

No. 1 2 Precautions

Necessary tools Name

Others

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

138

Loose-supply items 209-60-77551 21T-60-13730

Q’ty 1 1

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

M-2

Replacement of Return Filter (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. a When replacing the element, take out the element slowly so that refuses adhered to the element do not fall inside. Also, take out refuses by hand from the case

Replacement Valve (3)

Strainer (2)

Standard element (1)

Precautions

Necessary tools

Others

Name

139

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

Name

Qâ&#x20AC;&#x2122;ty

Assembly procedure

M-2

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

Precautions

Necessary tools

Others

Name

140

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

Name

Qâ&#x20AC;&#x2122;ty

Assembly procedure

Flushing of Hydraulic Circuit (1/2)

M-3

Precautions

Necessary tools Name

Others

Full operation may damage the filter element since the relief valve of the filter is closed.

141

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

Name

Qâ&#x20AC;&#x2122;ty

Assembly procedure

M-3

Flushing of Hydraulic Circuit (2/2)

Precautions

Necessary tools

Others

Name

142

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

Failure 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 failure code have been generated.

Function for Abnormality Record [02] The monitor panel records failures that occurred on the machines in the past after classifying them into failures in the electric system and those in the mechanical system.

Information on them can be displayed through the following operation.

1) Selection of menu Select "02 Abnormality Record" in the initial display of Service Menu and depress [F6] switch.

2) Selection of Submenu Select an appropriate item from Submenu in the Abnormality Record display and depress [F6] switch.

No.

Abnormality Record Submenu

01

Mechanical Systems

02

Electrical Systems

03

Air-conditioner Systems

3) Information shown in display of Abnormality Record in the mechanical system (a): Order from newest one/Number of all records (b): Failure Code (c): Contents of failure code (d): Number of occurrences (Display range: 0 â&#x20AC;&#x201C; 65,535) (e): Time elapsed since the occurrence of the first failure (f): Service meter reading at latest occurrence a

Refer to "Table for error code No. and failure code No." in Operator's Menu.

4) Information shown in display of Abnormality Record in the electrical systems (a): Order from newest one/Number of all records (b): Failure Code (c): Contents of failure (d): Number of occurrences (Display range: 0 â&#x20AC;&#x201C; 65,535) (e): Time elapsed since the occurrence of the first failure (f): Service meter reading at latest occurrence a

Refer to "Table for error code No. and failure code No." in Operator's Menu.

143

Assembly procedure

Failure code (2/5)

M-4 a Failure code table for mechanical system

Failure code for mechanical system No. 1

Display Failure code Eng. Hi Out of Std

Code

Server

CA234

ENG/M

2

Eng. Lo Out of Std

A000KX

â&#x20AC;&#x201D;

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

7

Eng. Water Lvl Low

B@BCZK

MON

8

Aircleaner Clogging

AA10NX

MON

MON PUMP

9

Charge Voltage Low

AB00KE

MON

10

Crane Ope. Overload

989EKX

PUMP

11

Auto. Lub. Abnormal.

DA80MA

PUMP

144

Assembly procedure

Failure code (3/5)

M-4 a Failure code table for electrical system User code — — — — — — — E0E — — E03 — — — — — —

DY2DKB DY2EKB DY2CKB DY20KA DY20MA DY2GKM DY2FMA DAFRMC DGH2KB DW48KB DE45KB DWK0KB DW43KB DWK0KA DW43KA DA2SKG DV20KB

—

DHPAMA

— E02 E07 E0E E0E E02 E02 — — — — — E11 E11 — — —

DHPBMA

Display Failure code Wiper Drive (Fwd) Short Circuit Wiper Drive (Rev) Short Circuit Washer Drive Short Circuit Wiper Working Abnormality Wiper Parking Abnormality Wiper Select Abnormality Upper Wiper Working Abnormality CAN Discon (Monitor Detected) Hyd Oil Sensor Short CO Cancel Sol Short Circuit Swing Brake Sol short Circuit 2-stage Relief Sol Short Circuit Travel Speed Sol Short Circuit 2-Stage Relief Sol Open Circuit Travel Speed Sol Open Circuit Model selection Abnormality Travel Alarm Short Circuit F Pump Press Sensor Abnormality Pump Press Sensor Abnormality R Pump Press Sensor Abnormality

DA25KP

SV Sensor l Power Abnormality

DA2RMC DA22KK DXA0KB DXA0KA D195KB D195KA DW4XKB DW4XKA D110KB DX16KA DX16KB DW7BKA DX7BKB DGE5KB DAFGMC D862KA D19JKZ 989N00 989M00 989L00 DAF8KB CA441 CA442 CA111 CA757 CA342 CA689 CA342 CA689 CA115 CA731

CAN Discon (Pump Con Detected) Pump Solenoid Power Low Error TVC Sol Short Circuit TVC Sol Open Circuit Step Light Relay Short Circuit Step Light Relay Open Circuit Bucket Curl Hi Cancel Sol Short Circuit Bucket Curl Hi Cancel Sol Open Circuit Battery Relay Drive Short Circuit Fan Pump EPC Sol Open Circuit Fan Pump EPC Sol Short Circuit Fan Reverse Sol Open Circuit Fan Reverse Sol Short Circuit Ambi. Temp Sensor Short Circuit GPS Module Error GPS Antenna open Circuit Personal Code Relay Abnormality Engine Controller Lock Caution 3 Engine Controller Lock Caution 2 Engine Controller Lock Caution 1 Camera Power Supply Short Circuit Battery Voltage Low Error Battery Voltage High Error ECM Critical Internal Failure All Critical Internal Failure Calibration Code Incompatibility Eng Ne and Bkup Speed Sens Error Eng Ne Speed Sensor Error Eng Ne and Bkup Speed Sensor Error Eng Bkup Speed Sensor Error Eng Bkup Speed Sens Phase Error

E01

E10 E10 E10 E10 E10 E10 E15 E10 E15 E15

145

Assembly procedure

Failure code (4/5)

M-4 User code E14 E14 E15 E15 E11 E11 E15 E15 E0E E10 E10 E10 E10 E11 E11 E11 E11 E15 E15 E11 E10 E11 E11 E11 E11 E11 E11 E15 E15 E15 E15 E15 E14 E14 E15 E15 E15 E15 E11 E11 E15 E15 E15 E15 E11 E11 E11 E11 E15 E11 E15 E11 E11 E11 E11 E11

CA131 CA132 CA144 CA145 CA122 CA123 CA263 CA265 CA1633 CA271 CA273 CA272 CA274 CA451 CA452 CA554 CA449 CA553 CA559 CA2249 CA351 CA322 CA331 CA324 CA332 CA323 CA325 CA352 CA386 CA187 CA227 CA238 CA2186 CA2185 CA135 CA141 CA153 CA154 CA221 CA222 CA2555 CA2556 CA1653 CA1642 CA2271 CA2272 CA1631 CA1632 CA1228 CA1625 CA1628 CA1629 CA2351 CA2352 CA1626 CA1627

Display Failure code Throttle Sensor High Error Throttle Sensor Low Error Coolant Temp Sens High Error Coolant Temp Sens Low Error Chg Air Press Sensor High Error Chg Air Press Sensor Low Error Fuel Temp Sensor High Error Fuel Temp Sensor Low Error KOMNET Datalink Timeout Error IMV/PCV1 Short Error PCV2 Short Error IMV/PCV1 Open Error PCV2 Open Error Rail Press Sensor High Error Rail Press Sensor Low Error Rail Press Sensor In Range Error Rail Press Very High Error Rail Press High Error Rail Press Low Error Rail Press Very Low Error Injectors Drive Circuit Error Inj #1(L#1) Open/Short Error Inj #2(L#2) Open/Short Error Inj #3(L#3) Open/Short Error Inj #4(L#4) Open/Short Error Inj #5(L#5) Open/Short Error Inj #6(L#6) Open/Short Error Sens Supply 1 Volt Low Error Sens Supply 1 Volt High Error Sens Supply 2 Volt Low Error Sens Supply 2 Volt High Error Ne Speed Sens Supply Volt Error Throt Sens Sup Volt Low Error Throt Sens Sup Volt High Error Eng Oil Press Sensor High Error Eng Oil Press Sensor Low Error Chg Air Temp Sensor High Error Chg Air Temp Sensor Low Error Ambient Press Sens High Error Ambient Press Sens Low Error Grid Htr Relay Volt Low Error Grid Htr Relay Volt High Error EGR Inlet Press Sens High Error EGR Inlet Press Sens Low Error EGR Valve Pos Sens High Error EGR Valve Pos Sens Low Error BP Valve Pos Sens High Error BP Valve Pos Sens Low Error EGR Valve Servo Error 1 EGR Valve Servo Error 2 Bypass Valve Servo Error 1 Bypass Valve Servo Error 2 EGR Valve Sol Current High Error EGR Valve Sol Current Low Error BP Valve Sol Current High Error BP Valve Sol Current Low Error

146

Assembly procedure

Failure code (5/5)

M-4 5) Resetting Electrical Systems a Resetting the Abnormality Record (deletion) is possible only with the electrical system. The Abnormality Record in the mechanical system cannot be reset. a For resetting any specific or all information in the Electrical Systems, follow the operation explained below. i) Through the following switch operation, call the resetting display in the display of Electrical Systems.

• Switch operation (While pressing [4], perform the operation in order): [4] + [1] o [2] o [3] a This is the same switch operation in changing the display to Service Menu. ii)

Check that the screen display is set in the reset mode, then reset the information items one by one or all of them with the function switches. a If [CLEAR] is displayed in [F2], the screen display is set in the clear mode.

• [F2]: Clear all information items • [F3]: Select lower item • [F4]: Select upper item • [F5]: Return to abnormality record screen • [F6]: Reset individual information items a When resetting individual information items: Select an item to be reset with [F3] or [F4] and press [F6], and that item is reset. a When resetting all information items: Press [F2], and all the items are reset without reference to selected item. a If [E] is displayed on the left of a failure code, the deleting operation is accepted but the information is not deleted. a The figure at right shows the screen display when the individual information items are reset. If all the information items are reset with [F2], "Reset?" is displayed.

iii)

If a selected item is cleared, the message of "Reset!" is displayed. If all the items are reset, the message of "All reset!" is displayed.

After the message is displayed for a while in either case, the message of "No Error" is displayed.

147

Assembly procedure

Operating Method of Monitoring (1/6)

M-5

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

OPERATION AND DISPLAY OF SERVICE MENU Way of switching to Service Menu a When using Service Menu, change the display to Service Menu display through the following special operation.

1) Confirmation of display Confirm that the display of ordinary items is shown. a Changing to Service Menu cannot be made from displays other than this.

2) Switch operation Operate the switches as follows. â&#x20AC;˘ Switch operation (Press the following switches in order while pressing [4]): [4] + [1] o [2] o [3]

3) Showing Service Menu display The display is changed to the initial display of service menu program. Select an appropriate item from among the menu.

No.

Service Menu

01

Monitoring

02

Abnormality Record

03

Maintenance Record

04

Maintenance Mode Change

05

Phone Number Entry

06

AAAA/Default

07

Adjustment

4) Termination of Service Menu function To finish the service menu screen, press [F5], and the screen returns to the ordinary screen (operator mode).

148

Assembly procedure

M-5

Operating Method of Monitoring (2/6)

Function of Monitoring [01] The machine monitor can monitor the machine condition in real time by the signals of various switches, sensors, and actuators installed to each part of the machine and the information from the controller which control those parts.

1) Selection of menu On the service menu screen, select "01 Monitoring" and press the [F6] switch.

2) Setting of monitoring item After the monitoring selection menu screen is displayed, select an item to be monitored with the function switches or numeral input switches.

• [F1]: Move to next page (screen) • [F2]: Move to previous page (screen) • [F3]: Select lower item • [F4]: Select upper item • [F5]: Clear input value/Return to service menu screen • [F6]: Confirm selection a a

a

a

a a

a a

Selection with function switches: Select an item with [F3] or [F4], then confirm with [F6].

Selection with numeral input switches: Input a 5digit code, and the item of that code is selected directly. Confirm with [F6].

If the color of the selected box changes from yellow to red, selection of the item of that box is confirmed.

Up to six monitoring items can be selected simultaneously. However, six items may not be able to be set, depending on their display styles.

Execution with function switch: Double-click or hold down [F6]. (About 2 seconds) For example, when monitoring only two items, select each of them and confirm with [F6]. If [F6] is pressed after completing selection, monitoring is started.

If monitoring items are selected up to the selectable number, monitoring is started automatically.

For detailed information, display unit, etc. of the monitoring items, see the monitoring item table.

149

Assembly procedure

M-5

Operating Method of Monitoring (3/6)

3) Monitoring operation Call the monitoring information display and confirm the monitored information, while operating the machine.

4) Function of holding monitoring information The monitoring information can be held and holding can be reset with the function switches. â&#x20AC;˘ [F3]: Reset holding â&#x20AC;˘ [F4]: Hold information (Displayed data is fixed) â&#x20AC;˘ [F5]: Return to monitoring selection menu screen

5) Function of changing machine setting mode When changing the working mode, travel speed, or auto-deceleration during monitoring, operate the corresponding switch under the current condition, and the mode setting screen appears. a After completing change of the setting, press [F6] to return to the monitoring information display screen. a If the setting is changed during monitoring, it is maintained even when the screen returns to the ordinary screen after monitoring is finished. a For the monitoring item list, see the following pages.

150

Assembly procedure

Operating Method of Monitoring (4/6)

M-5 a Monitoring item table Monitoring ID

Monitoring item English

00200 00201 01002 01601 01100 01101 01102

Controller Model Select Machine ID Engine Speed 2nd Eng. Speed Command F Pump Pressure R Pump Pressure Travel FW L PPC Pressure

04107

Coolant Temperature

14200 04401 37502 01300 31623 03200 03203 04300 37200 36400 37400 18400 18500 36500 18000 18100 18200 36700 18700 01112 01113 03000 04200 04105 14201 04402 37503 37201 37401 18401 18501 36501 36401 18001 18101 18201 17201 17500 31701 31706 18600 36200 36300 37300

Fuel Temperature Hydr. Oil Temperature Ambient Temperature TVC Sol. Curr.

Fan Pump EPC Sol. Curr.

Battery Voltage Battery Power Supply Battery Charge Vol. Engine Oil Pressure Rail Pressure Ambient Pressure Intake Temperature Charge Temperature Boost Pressure EGR Inlet Pressure-A EGR Valve Position BPS Valve Position Engine Torque Ratio Engine Output Torque F Pump Pres. Snesor Vol. R Pump Pres. Snesor Vol. Fuel Dial Pos Sens Volt Fuel Level Sensor Vol. Eng. Water Temp. Vol. Lo Fuel Temp. Sensor Vol. Hydr. Temp. Sonser Vol. Ambi. Temp. Sensor Vol. Eng Oil Press Sens Volt Ambient Press Sens Volt Intake Temp Sens Volt Charge Temp Sens Volt Charge Press Sens Volt Rail Pressure Sens Volt EGR In Press Sens Volt EGR Valve Pos Sens Volt BPS Valve Pos Sens Volt PCV Close Timing Engine Power Mode Throttle Position Final Throttle Position Inject Fueling Command Rail Press Command Injection Timing Command Fuel Rate

01602 13113 13114 13112

Unit (1) Default (2) Meter SI unit – – – – r/min rpm r/min rpm MPa kg/cm2 MPa kg/cm2 MPa kg/cm2

Remark

(3) Inch – – rpm rpm psi psi psi

C

°C

°F

°C °C °C mA mA V V V kPa MPa kPa °C °C kPa kPa mm mm % Nm V V V V V V V V V V V V V V V V V CA

°C °C °C mA mA V V V kg/cm2 kg/cm2 kg/cm2 °C °C kg/cm2 kg/cm2 mm mm % kgm V V V V V V V V V V V V V V V V V CA

°F °F °F mA mA V V V psi psi psi °F °F psi psi in in % lbft V V V V V V V V V V V V V V V V V CA

% % mg/st MPa CA l /h

% % mg/st kg/cm2 CA l /h

% % mg/st psi CA gal/h

2nd Eng. Speed Command

%

%

%

Main Pump Absorb Torque Fan Pump Absorb Torque Total Pump Absorb Torque

Nm Nm Nm

kgm kgm kgm

lbft lbft lbft

151

Select the supported controller model code.

0 to 4000 rpm The MPa unit system is used in expression A. The MPa unit system is used in expression A. –40 to +210°C. As Model CM850 has low-temperature sensors only, the monitoring information of only “Engine Water Temp.” is displayed.

The low-temperature ID is used as it is.

–40 to +210 °C. (For only B33, display range is 3/0) The setup range is unknown. A negative value may be accepted.

0.0 to 480.0 V 0.0 to approx. 28.0 V –999.9 to +999.9 kPa (if MPa unit system is used in expression A) 0 to 400 MPa –999.9 to +999.9 kPa (if MPa unit system is used in expression A) –50 to +200 °C. –50 to +200 °C. –999.9 to +999.9 kPa (MPa*1000) (*3) –999.9 to +999.9 kPa 0.00 to 99.00 mm 0.00 to 99.00 mm 0 to 100% –24000 to +24000 Nm

0.00 to 5.00 V 0.00 to 5.00 V 0.00 to 5.00 V 0.00 to 5.00 V 0.00 to 5.00 V 0.00 to 5.00 V 0.00 to 5.00 V 0.00 to 5.00 V 0.00 to 5.00 V 0.00 to 5.00 V 0.00 to 5.00 V 0.00 to 5.00 V –180.0 to +180.0 CA (*2) Display of digits 0 to 4 0 to 100% 0 to 100% 0 to 1000 mg/st 0 to 400 MPa –180.0 to +180.0 CA (*2) 0.0 to 9999.9 h (in units of 0.1 l/h) Throttle opening (%) is appropriate because the engine power is controlled based on the fan rotation speed control.

Assembly procedure

Operating Method of Monitoring (5/6)

M-5 Monitoring ID 01900

01901

02300 (B81)

02300 (C12)

02200

02201

02202 02203

02204

02209

05500

03700 03701

04500

Monitoring item English Pressure Switch 1 Swing Travel (B81: R.H. Travel) Boom Lower Boom Raise Arm Curl Arm Dump Pressure Switch 2 Bucket Curl Bucket Dump Service Solenoid Valve 1 Travel Junction Swing Brake 2-Stage Relief Travel Speed CO Cancel Swing Priority Solenoid Valve 1 Bucket Hi Cancel Swing Brake 2-Stage Relief Travel Speed Fan Reverse CO Cancel Switch Input 1 Lever Sw. Swing Release Sw Swing Brake Sw. Switch Input 2 Model Select 1 Model Select 2 Model Select 3 Model Select 4 Model Select 5 Overload Alarm Switch Input 3 Key Switch (ACC) Switch Input 4 Step Light Sw. Horn Sw. Switch Input 5 Window Limit SW. Upper wiper P Limit SW. Upper wiper W Limit SW. Switch Input 6 Upper wiper P Limit SW. Lower wiper SW. Lower wiper active SW. Lower wiper Select Sensor Input 1 Over Load Sensor Auto Greasing Controller Output 1 Batt. Relay Dr. Controller Output 2 Step L. Relay Flash L. Relay Travel Alarm Monitor Input 1 Key Switch Start Preheat Light Rad. Level

Unit (1) Default (2) Meter SI unit

(3) Inch

ON/OFF Display

ON/OFF Display

ON/OFF Display

ON/OFF Display

ON/OFF Display

ON/OFF Display

ON/OFF Display

ON/OFF Display

ON/OFF Display

ON/OFF Display

ON/OFF Display

ON/OFF Display

ON/OFF Display

ON/OFF Display

152

Remark

Assembly procedure

Operating Method of Monitoring (6/6)

M-5 Monitoring ID

Monitoring item English

04501

Unit (1) Default (2) Meter SI unit

Monitor Input 2 Aircleaner Eng. Oil Level Battery Charge

04502 (C09) 04503

04504

04505

04506

20216 20217 18900 20400 20227 20402 20228 20229 20403 20230

Remark

(3) Inch

Monitor Input 3 Swing Brake Sw. Monitor Function Switch F1 F2 F3 F4 F5 F6 Monitor 1st & 2nd Row Switches SW1 SW2 SW3 SW4 SW5 SW6 Monitor 3rd & 4th Row Switches SW7 SW8 SW9 SW10 SW11 SW12 Monitor 5th Row Switches SW13 SW14 SW15 ECM Build Version ECM CAL Data Ver ECM Internal Temp ECM Serial No Monitor Ass'y P/N Monitor Serial No Monitor Prog. P/N Pump Con. Ass'y P/N Pump Con. Serial No Pump Con. Prog. P/N

ON/OFF Display

ON/OFF Display

ON/OFF Display F4 cannot be monitored

ON/OFF Display

ON/OFF Display

ON/OFF Display

– – °C –

– – °C –

– – °F –

–40 to +210 °C. 0 to 49999999

(*2): Unit "CA" is an abbreviation for "Crank Angle" and its actual unit is "deg".

However, do not put " ° " or "deg" as a unit but put only "CA". (*3): Although the received data has the “MPa” unit system, the data is displayed in “kPa” as its value is small.

153

Loading shovel 1/13

Report No.

FIELD ASSEMBLY INSPECTION REPORT After completion of assembling a machine, make inspections according to these check sheets for assuring machine performance and quality.

Machine Serial No.

Model - Type

User Unit No.

Engine Model

Engine Serial No.

SAA6D140E-5

Backhoe spec.

Service Meter Reading

Date of Inspection

Attachment 1

Location of Machine at Inspection

2

Manufacture

Model Distributor’s Name Serial No.

Address：

Customer’s Name

Signature： Date：

Inspector’s Comments：

KOMATSU USE ONLY：

Inspector’s Name：

C. Sheet Receiving Date： Title：

By： Remark：

Signature：

Check sheet filling instructions： 1. Use following indexes for entry of judgment

□ ……Normal

□……Correction made on abnormal point

□ ……Abnormal

□……Not applied

2. Enter actually measured values in parentheses, [

].

Notes： (1) Criteria are based on the standards when the machine is shipped out of the factory (2) This FIELD ASSEMBLY INSPECTION REPORT is for “A” specification.

Delivery Report No. attached

Revision

Category

2/13

Local assembly time

Check item

Checks before assembly

Judgment standard

Actual measurement

Oil and water levels

Cooling water

Soft water

〔

〕

Anti-freeze (A, B, C, D, E）

Density of anti-freeze

〔

〕

Engine oil

EO10W30-DH EO15W40-DH

〔

〕

L－H+5mm

PTO oil

TO10 TO30

〔

〕

L+5mm －H

Swing machinery gear case oil

TO30

〔

〕

Right

TO30

〔

〕

Left

TO30

〔

〕

Hydraulic oil

TO10

〔

〕

Between the H and L marks

Battery electrolyte

－

〔

〕

Within 13 mm from bottom surface of filler port

Final drive gear case oil

Engine No. Service meter

A：-50－-40℃ D：-20－-10℃ B：-40－-30℃ E：-10－0℃ C：-30－-20℃ (Not necessary in summer)

(10 minutes after stopping engine)

(10 minutes after stopping engine)

L

+5mm

+10mm

－H

(10 minutes after stopping engine)

Bottom edge of level plug:0 to －10mm

〔 〔

〕 〕

〔

Revolving frame No. 〔

Checks during assembly

After hours of operation

〕 〕

Must match Serial No.

Loose, untightened lock bolts for connecting pins

There must be none.

Loose, untightened split flange bolts for work equipment piping

There must be none.

Forgotten, missing, catching O-rings for work equipment piping

There must be none.

Loose, twisted connections for grease piping

There must be none.

Shim adjustment for work equipment pins

Max. 1mm （for locations, see assembly procedure manual）

Improperly inserted wiring, unconnected wiring

There must be none.

Loose, untightened ladder mounting bolts

There must be none.

Checks during assembly

Revision

Category

3/13

Check item

Local assembly time

After hours of operation

Judgment standard

Loose, untightened counterweight bolts

There must be none.

Stepped clearance between counterweight and frame

Max. 15mm

Loose, untightened operatorâ&#x20AC;&#x2122;s cab mounting bolts

There must be none.

Loose, untightened operatorâ&#x20AC;&#x2122;s seat mounting bolts

There must be none.

Loose, untightened mounting bolts and joints for travel

There must be none.

Forgotten, missing, catching O-rings for travel

There must be none.

Loose, untightened track frame mounting bolts

There must be none.

Loose, untightened bolts for travel motor cover

There must be none.

Are there any other parts not yet installed (rear view mirror, etc.)?

There must be none.

Bleed air from pump

Follow instructions in assembly procedure manual.

Bleed air from travel motor

Follow instructions in assembly procedure manual.

Flush hydraulic circuit

Follow instructions in assembly procedure manual.

Bleed air from work equipment cylinder circuit

Follow instructions in assembly procedure manual.

Grease all parts of work equipment

All locations must be greased.

Adjust work equipment potentiometer (boom, arm)

Add hydraulic oil

Add to between L and H marks at inspection posture.

Add fuel, washer fluid

Fill tank.

Dirty oil on paintwork, damage to paintwork at any part

Clean, repair damaged paintwork

Revision

Category

4/13

Check item

Local assembly time

After hours of operation

Judgment standard

Monitor display 1.Check of monitor function When the starting switch is turned ON, the gauges, CHECK items, and all display items on the monitor should light up. At the same the alarm buzzer should sound.

2.Check of gauges and CHECK items When starting switch is turned to ON (all lamps on), working mode and travel speed monitors appear after approx. 3 sec.

For another 2 seconds, only the gauges are displayed, and the CHECK and monitor items disappear.

Display should be as on left.

3.Check monitor items After starting the engine, the caution lamps should not light up and the alarm buzzer should not sound when the engine speed is low idling â&#x20AC;&#x201C; high idling.

There should be no scratches or misting of the lens or variation in operation.

Operation of service meter

MONITOR

Check monitor

AA: Screen with all lamps lighted up BB: Screen for standard CC: Maintenance time warning screen

(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15) (16) (17) (18) (19) (20) (21) (22) (23) (24) (25) (26) (27) (28) (29) (30)

Wiper switch Buzzer cancel switch Auto-deceleration switch Engine coolant temperature monitor Engine coolant temperature gauge Hydraulic oil temperature gauge Service meter, Clock Hydraulic oil temperature monitor Working mode monitor Travel speed monitor Fuel gauge ECO gauge Fuel level monitor Working mode selector switch Travel speed selector switch Window washer switch Air conditioner control switches Engine oil pressure monitor Charge level monitor Radiator coolant level monitor Message monitor Air conditioner monitor Wiper switch Swing lock monitor Engine pre-heating monitor or One-touch power max. monitor Auto-deceleration monitor Engine oil level monitor Air cleaner clogging monitor Function switches (F1 to F6) Maintenance interval monitor

Check of switches, control levers

Revision

Category

5/13

Check item

(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11)

Radio Lock lever Left work equipment control lever One-touch power max. switch Travel pedals Travel levers Horn switch Machine monitor Cigarette lighter Right work equipment control lever Starting switch

Operation of horn switch

Operation of lock lever

Operation of fuel control dial

Operation of preheating pilot

Local assembly time

After hours of operation

(12) (13) (14) (15) (16) (17) (18) (19) (20) (21) (22)

Judgment standard

Fuel control dial Lamp switch Swing lock switch Machine push-up switch Wiper switch (if equipped) Revolving warning lamp switch (if equipped) Heated operator seat switch (if equipped) Room lamp switch Emergency pump drive switch Swing parking brake release switch Step lamp switch (if equipped)

Press the switch on the right work equipment control lever to sound the horn.

At the same time, the flashing light (option) at the bottom front of the cab will flash for approx. 5 seconds.

Push down the lever to apply the lock.

Engine can be started but all work equipment control levers do not move.

Push up the lever to release the lock.

Engine cannot be started but all work equipment levers move.

MAX: Full speed MIN: Low idling Rotate the key at the preheating position so that the monitor display shows "preheating ON". The preheating pilot will flash after approx. 30 seconds to indicate the completion of preheating.

Revision

Category

6/13

Check item

Operation of mode selector switch

Local assembly time

After hours of operation

Judgment standard

P light up: Heavy-duty operations E light up: Fuel-efficient operations When starting the engine, P (heavy-duty operation) mode is automatically selected.

Operation of auto-deceleration switch

ON light up: OFF:

Auto-deceleration is actuated.

Auto-deceleration is canceled.

Each time the switch is pressed, the autodeceleration is actuated or canceled.

Operation of travel speed switch

This is used to select the two travel speeds.

Lo light up: Low speed travel Hi light up: High speed travel

Check of switches, control levers

When the engine is started, the travel speed is automatically set to Lo. Operation of wiper switch

OFF: Wiper stops ON light up: Wiper moves continuously INT light up: Wiper moves intermittently

Operation of window washer switch

Window washer fluid is sprayed out.

Operation of cigarette lighter

This is used to light cigarettes. To use, push the lighter in. After a few seconds it will spring back.

Operation of lamp switch

Operation of swing lock switch

Operation of machine push-up switch

Operation of boom shockless control switch (option)

Operation of step light switch (option)

Operation of room lamp switch Operation of emergency pump drive switch

This switch is used to turn on the front lamps, working lamps, additional lamp at the top front of the cab, and monitor lighting.

ON position (actuated): The swing lock is always applied, and the upper structure will not swing even if the swing is operated. In this condition, the swing lock lamp lights up.

OFF position (canceled): Swing operation is possible. Swing lock monitor goes off.

Low pressure setting: The boom thrust force is weak.

High pressure setting: The boom thrust force becomes more powerful.

ON: While the boom stop operation, shock of the boom is controlled. ă&#x192;ť When the switch is pressed, the step light will light up for approx. 60 seconds. ă&#x192;ť Even if the starting switch key is at the OFF position, the step light will light up for approx. 60 seconds when the switch is pressed.

ON position: Room lamp lights up.

When normal: Switch is pushed down.

When abnormal: When the monitor display shows E02 (TVC valve system error), move the switch up to make it possible to carry out work.

Revision

Category

7/13

Check item

Operation of swing holding brake release swtich

Local assembly time

After hours of operation

Judgment standard

When normal: Switch is pushed down.

When abnormal: When the monitor display shows E03 (Swing brake system error), the brake is canceled, and it becomes possible to actuate the swing and carry out normal operations. However, the swing brake remains released.

Operation of alarm buzzer stop switch

This is used to stop alarm buzzer if it sounds to warn of an abnormality during operation.

Operation of lower wiper switch (option)

ON: Lower wiper moves.

OFF: Lower wiper stops.

Operation of travel levers

Check of switches, control levers

Operation of left work equipment control lever (with auto-deceleration device)

FORWARD: The lever is pushed forward.

(The pedal is angled forward) REVERSE: The lever is pulled back.

(The pedal is angled back) N(Neutral): The machine stops.

This lever is used upper structure.

Arm operation (a) Arm OUT (b) Arm IN

to operate the arm and Swing operation (c) Swing to right (d) Swing to left

N(neutral): When the lever in this position, the upper structure and the arm will be retained in the position in which they stop.

Operation of right work equipment control lever (with auto-deceleration device)

This lever is used to operate the boom and bucket.

Boom operation Bucket operation (a) RAISE (c) DUMP (b) LOWER (d) CURL

N(neutral): When the lever in this position, the boom and the bucket will be retained in the position in which they stop.

Confirmation of failure history (Both electrical and mechanical)

See M-4. Error Code.

Operation of power max. switch

When the switch on the LH work equipment control lever is pushed, the digging power increases.

Check function of rotation lamp switch (option)

ON: Rotary lamp lights up

Check function of large capacity air conditioner blower switch (option)

ON: Blower actued OFF: Blower stopped

Revision

Category

8/13

Local assembly time

Check item

After hours of operation

Judgment standard

Swing operation running in: Engine high idling speed.

(Work equipment posture: Max. reach)

Right

Left

Swing performance

Constant swing speed [

rpm]

[

8.3 ± 0.4 rpm

rpm]

Brake angle

Max. 79° (feeling)

Swing variation, hunting

There must be none.

Abnormal noise, irregular swing

There must be none.

Travel operation running in: Engine high idling speed.

Travel performance

(Work equipment posture: Max. reach)

Abnormal noise, heat from carrier roller, track roller, idler

There must be no abnormal noise or abnormal heat.

Operation of travel brake

Must brake securely without pulling to one side.

Abnormal noise, irregular travel

There must be none.

Travel deviation (feeling)

There must be no abnormal deviation from fine control range to full stroke range (feeling).

Travel deviation (measured)

High speed

(Only when it is considered that there is abnormality.)

Low speed

Track rotating speed

High speed - Right High speed - Left Low speed - Right Low speed - Left

Track tension

Forward [

]

Reverse [

mm/20m

Forward [

]

Reverse [

mm/20m

Forward [

]

Reverse [

]

Reverse [ Reverse [

sec

]

(PC700LC: 48 ± 5 sec / 5 turns)

]

P mode 63.0 ± 6 sec / 5 turns Difference between left and right: 1.2 sec

]

(PC700LC: 77.3 ± 8 sec / 5 turns)

sec

]

Reverse [

sec

Right [

P mode 40.3 ± 5.4 sec / 5 turns Difference between left and right:

sec

]

Forward [

] sec

sec

Forward [

Max. 200 mm / 20 m

]

mm/20m

sec

Forward [

Max. 200 mm / 20 m

]

mm/20m

sec

] mm

Left [

] mm

9/13

Revision

Category

Note: All judgment standard values for speeds are the values in P mode.

Local assembly time

Check item

After hours of operation

Judgment standard

Work equipment operation running in: Engine high idling speed, (Note: Boom cylinder to ground level) Pressurized: each port relief 2 minutes, shock 20 times (except BOOM LOWER) Work equipment posture

Work equipment speed

Work equipment time lag (Engine low idling)

Boom

RAISE [

Arm

OUT [

Bucket

CURL [

Boom

sec ] sec ] sec ]

LOWER [

sec ]

RAISE: 5.1 ± 0.5 sec.

LOWER: 3.6 ± 0.4 sec.

IN [

sec ]

IN: OUT:

DUMP [

sec ]

CURL: 3.2 ± 0.3 sec.

DUMP: 3.2 ± 0.3 sec.

LOWER [

5.5 ± 0.5 sec.

3.8 ± 0.4 sec.

sec ]

Max. 6 sec.

Only when there is considered to be abnormality.

Arm

IN [

sec ]

Max. 5 sec.

Work equipment performance

Only when there is considered to be abnormality.

Bucket

DUMP [

sec ]

Max. 4 sec

Only when there is considered to be abnormality.

Abnormal noise from pump, PTO Generation of heat by PTO

There must be no abnormality during operation under no load and during relief.

There must be no abnormal generation of heat.

Engine partial performance

There must be no hunting at any speed under no load, there must be no stalling of engine even at low idling and relief.

Fine control performance

Must operate smoothly.

Operation when raising chassis

There must be no escape of boom, arm, or bucket.

Abnormal noise, grating noise from work equipment

There must be none.

Shock at end of cylinder stroke (Shock at end of stroke for BOOM RAISE and ARM OUT)

Function of accumulator

Cushion must be fully effective.

Immediately after engine is stopped, boom cylinder must move from fully extend position to ground level. (Arm at Max. reach)

Revision

Category

10/13

Check item

Local assembly time

After hours of operation

Judgment standard

During operation

Operating force of control lever when each actuator is actuated.

・ There must be no catching during operation. ・ Must return naturally to neutral.

Feeling and noise of vibration in operator’s cab

There must be none.

Vibration noise from frame, guard, ladder

There must be none.

Around operator’s cab

Check all parts

Movement of doors and windows

Must move smoothly.

Door, window locks

Must lock securely.

Adjustment of operator’s seat

Must be possible to make all adjustments.

There must be none.

Undercarriage

Oil leakage (Idler, roller, sprocket, final drive gear case, motor, brake valve)

Interference at any part

There must be none.

Looseness of track shoe bolt

There must be none.

Contact of link tread

There must be no overlapping, separation, or missing or broken parts.

Oil leakage

There must be none.

Center swivel, pump, solenoid valve, relief valve, control valve, PPC valve, swing motor, brake valve, shuttle valve, swing machinery, hydraulic tank, piping

Around chassis

Leakage of fuel

There must be none.

(Fuel tank, engine, piping) Leakage of water from engine cooling water system

There must be none.

Leakage of oil from engine lubrication system

There must be none.

Leakage of gas from engine gas system

There must be none.

Movement of covers

Must move smoothly.

Cover locks

Must lock securely.

Around chassis

Revision

Category

11/13

Check item

Local assembly time

After hours of operation

Judgment standard

Operation of grease pump

Must move smoothly.

Looseness, insufficient insertion of electric wiring terminals

There must be none.

Position for passing electrical wiring through

There must be a clearance of at least 10 mm from any moving part or edge.

Leakage of air from air system

There must be none.

Interference at any part

There must be none.

Oil leakage

There must be none.

Around work equipment

(Cylinder, piping, block) Grease leakage from grease piping

There must be none.

Interference of work equipment

There must be none.

Looseness of work equipment piping clamps, play in piping

There must be none.

Twisting of hydraulic hoses and operation of work equipment when turning over

There must be none.

12/13

Revision

Category

Note: If the operation or function is defective, measure as necessary. All judgment standard values for speeds are the values in P mode.

Local assembly time

Check item

After hours of operation

Judgment standard

1. Engine speed: Check in monitoring mode “01006” Low idling High idling

[

rpm]

(Operate lever a little)

800 ± 50 rpm 1950 ± 50 rpm

High idling (When lever is not operated), (Auto-deceleration: canceled)

1750 ± 50 rpm

Speed at arm OUT

[

rpm]

1850 ± 50 rpm

Speed at arm IN

[

rpm]

Min. 1780 rpm

Monitoring mode ID “01002”

at P mode

2. Radiator fan speed 1430 ± 50 rpm Main measurement items

Speed at engine high idle speed

3. Measurement of oil pressure

[

rpm]

Check in service mode “55” (Fan rotation 100% fixed mode)

Check in monitoring mode Swing pump “09000”, F pump: “01100”, R pump: “01101”

Control valve main set pressure

4-spool valve (R pump)

Control valve main set pressure

5-spool valve (F pump)

Travel relief set pressure

Right travel (F pump)

Travel relief set pressure

Left travel (R pump)

Swing relief set pressure

F pump

31.9 ｛320

+1.5 MPa -1.0 +15 kg/㎠｝ -10

MPa {kg/㎠}

34.3 ｛350

+1.5 MPa -1.0 +15 kg/㎠｝ -10

MPa {kg/㎠} MPa {kg/㎠} MPa {kg/㎠} MPa {kg/㎠}

Pilot relief valve set pressure

35.3±1.5 MPa {360±15 kg/㎠} 35.3±1.5 MPa {360±15 kg/㎠}

At engine high idling, arm OUT, P mode and Heavy lift OFF, relief

At power max. switch ON

Relieved on one side at P mode

At engine high idling, swing 29.9±1.0 MPa and P mode, relief {305±10 kg/㎠} +4 3.14 +0.39 MPa ｛32 0 kg/㎠} 0 (At engine high idling, neutral)

When boom is raised (Heavy: OFF)

In neutral NC valve output pressure (at top surface of NC valve) No.1 pump, No.2 pump

MPa {kg/㎠}

MPa {kg/㎠}

MPa {kg/㎠}

Max. 1.10 MPa {11.2 kg/㎠}

Engine high idling P mode

Note: Measure the following J/S differential pressure only if the NC valve output pressure does not pass the test.

At neutral J/S differential pressure (differential pressure at input and output ports of jet sensor) No.1 pump, No.2 pump

At relief MPa {kg/㎠}

MPa {kg/㎠}

1.8 ± 0.2 MPa {18 ± 2{kg/㎠}

Engine high idling P mode

Max. 0.2 MPa {2kg/㎠}

At engine high idling no load

Revision

Category

13/13

Local assembl y time

Check item

After hours of operation

Judgment standard

4. hydraulic drift of work equipment (bucket unloaded, 50±5℃） Bucket tooth up

[

mm]

Max. 600 mm / 15 minutes

Note: Measure the hydraulic drift of the following cylinders only if the hydraulic drift at the bucket tooth tip does not pass the test.

Boom cylinder

[

mm]

Max. 7 mm/minute

Arm cylinder

[

mm]

Max. 7 mm/minute

Bucket cylinder

[

mm]

Max. 7 mm/minute

5. operation force, travel Boom lever

Operating force

RAISE

N

RAISE Stroke

Main measurement items

Swing lever

Operating force Stroke

Bucket lever

Operating force Stroke

Arm lever

Operating force Stroke

Right travel lever

Operating force Stroke

Left travel lever

Operating force Stroke

LOWER

N

{kg}

[

{kg}

LOWER mm] [

RIGHT

PLAY mm] [

N

mm]

LEFT

N

{kg} RIGHT [ CURL

{kg}

LEFT mm] [ N

PLAY mm] [ DUMP

mm] N

{kg} CURL [ IN

{kg}

DUMP mm] [ N

PLAY mm] [ OUT

mm] N

{kg} IN [ FOR-

mm] [ N

WARD

{kg}

FORWARD [ FOR-

PLAY mm] [ REVERSE

REVERSE

mm] [ N

WARD

{kg}

FORWARD [

{kg}

OUT

mm] [

mm] N {kg} PLAY

mm] [ REVERSE

REVERSE

mm] N {kg} PLAY

mm] [

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

mm]

15.7±3.9N {1.6±0.4kg} Stroke:85±10mm Play: Max. 10mm 12.7±2.9N {1.3±0.3kg} Stroke:85±10mm Play: Max. 10mm 12.7±2.9N {1.3±0.3kg} Stroke:85±10mm Play: Max. 10mm 15.7±3.9N {1.6±0.4kg} Stroke:85±10mm Play: Max. 10mm 24.5±5.9N {2.5±0.6kg} Stroke:115±12mm Play: Max. 10mm 24.5±5.9N {2.5±0.6kg} Stroke:115±12mm Play: Max. 10mm

At engine high idling, relief

Loading shovel 1/13

Report No.

FIELD ASSEMBLY INSPECTION REPORT After completion of assembling a machine, make inspections according to these check sheets for assuring machine performance and quality.

Machine Serial No.

Model - Type

User Unit No.

Engine Model

SAA6D140E-5

Loading shovel spec.

Service Meter Reading

Engine Serial No.

Date of Inspection

Attachment 1

Location of Machine at Inspection

2

Manufacture

Model Distributor’s Name Serial No.

Address：

Customer’s Name

Signature： Date：

Inspector’s Comments：

KOMATSU USE ONLY：

Inspector’s Name：

C. Sheet Receiving Date： Title：

By： Remark：

Signature：

Check sheet filling instructions： 1. Use following indexes for entry of judgment

□ ……Normal

□……Correction made on abnormal point

□ ……Abnormal

□……Not applied

2. Enter actually measured values in parentheses, [

].

Notes： (1) Criteria are based on the standards when the machine is shipped out of the factory (2) This FIELD ASSEMBLY INSPECTION REPORT is for “A” specification.

Delivery Report No. attached

Revision

Category

2/13

Local assembly time

Check item

Checks before assembly

Judgment standard

Actual measurement

Oil and water levels

Cooling water

Soft water

〔

〕

Anti-freeze (A, B, C, D, E）

Density of anti-freeze

〔

〕

Engine oil

EO10W30-DH EO15W40-DH

〔

〕

L－H+5mm

PTO oil

TO10 TO30

〔

〕

L+5mm －H

Swing machinery gear case oil

TO30

〔

〕

Right

TO30

〔

〕

Left

TO30

〔

〕

Hydraulic oil

TO10

〔

〕

Between the H and L marks

Battery electrolyte

－

〔

〕

Within 13 mm from bottom surface of filler port

Final drive gear case oil

Engine No. Service meter

A：-50－-40℃ D：-20－-10℃ B：-40－-30℃ E：-10－0℃ C：-30－-20℃ (Not necessary in summer)

(10 minutes after stopping engine)

(10 minutes after stopping engine)

L

+5mm

+10mm

－H

(10 minutes after stopping engine)

Bottom edge of level plug:0 to －10mm

〔 〔

〕 〕

〔

Revolving frame No. 〔

Checks during assembly

After hours of operation

〕 〕

Must match Serial No.

Loose, untightened lock bolts for connecting pins

There must be none.

Loose, untightened split flange bolts for work equipment piping

There must be none.

Forgotten, missing, catching O-rings for work equipment piping

There must be none.

Loose, twisted connections for grease piping

There must be none.

Shim adjustment for work equipment pins

Max. 1mm （for locations, see assembly procedure manual）

Improperly inserted wiring, unconnected wiring

There must be none.

Loose, untightened ladder mounting bolts

There must be none.

Checks during assembly

Revision

Category

3/13

Check item

Local assembly time

After hours of operation

Judgment standard

Loose, untightened counterweight bolts

There must be none.

Stepped clearance between counterweight and frame

Max. 15mm

Loose, untightened operatorâ&#x20AC;&#x2122;s cab mounting bolts

There must be none.

Loose, untightened operatorâ&#x20AC;&#x2122;s seat mounting bolts

There must be none.

Loose, untightened mounting bolts and joints for travel

There must be none.

Forgotten, missing, catching O-rings for travel

There must be none.

Loose, untightened track frame mounting bolts

There must be none.

Loose, untightened bolts for travel motor cover

There must be none.

Are there any other parts not yet installed (rear view mirror, etc.)?

There must be none.

Bleed air from pump

Follow instructions in assembly procedure manual.

Bleed air from travel motor

Follow instructions in assembly procedure manual.

Flush hydraulic circuit

Follow instructions in assembly procedure manual.

Bleed air from work equipment cylinder circuit

Follow instructions in assembly procedure manual.

Grease all parts of work equipment

All locations must be greased.

Adjust work equipment potentiometer (boom, arm)

Add hydraulic oil

Add to between L and H marks at inspection posture.

Add fuel, washer fluid

Fill tank.

Dirty oil on paintwork, damage to paintwork at any part

Clean, repair damaged paintwork

Revision

Category

4/13

Check item

Local assembly time

After hours of operation

Judgment standard

Monitor display 1.Check of monitor function When the starting switch is turned ON, the gauges, CHECK items, and all display items on the monitor should light up. At the same the alarm buzzer should sound.

2.Check of gauges and CHECK items When starting switch is turned to ON (all lamps on), working mode and travel speed monitors appear after approx. 3 sec.

For another 2 seconds, only the gauges are displayed, and the CHECK and monitor items disappear.

Display should be as on left.

3.Check monitor items After starting the engine, the caution lamps should not light up and the alarm buzzer should not sound when the engine speed is low idling â&#x20AC;&#x201C; high idling.

There should be no scratches or misting of the lens or variation in operation.

Operation of service meter

MONITOR

Check monitor

AA: Screen with all lamps lighted up BB: Screen for standard CC: Maintenance time warning screen

(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15) (16) (17) (18) (19) (20) (21) (22) (23) (24) (25) (26) (27) (28) (29) (30)

Wiper switch Buzzer cancel switch Auto-deceleration switch Engine coolant temperature monitor Engine coolant temperature gauge Hydraulic oil temperature gauge Service meter, Clock Hydraulic oil temperature monitor Working mode monitor Travel speed monitor Fuel gauge ECO gauge Fuel level monitor Working mode selector switch Travel speed selector switch Window washer switch Air conditioner control switches Engine oil pressure monitor Charge level monitor Radiator coolant level monitor Message monitor Air conditioner monitor Wiper switch Swing lock monitor Engine pre-heating monitor or One-touch power max. monitor Auto-deceleration monitor Engine oil level monitor Air cleaner clogging monitor Function switches (F1 to F6) Maintenance interval monitor

Check of switches, control levers

Revision

Category

5/13

Check item

(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11)

Radio Lock lever Left work equipment control lever Bottom dump switch Travel pedals Travel levers Horn switch Machine monitor Cigarette lighter Right work equipment control lever Starting switch

Operation of horn switch

Operation of lock lever

Operation of fuel control dial

Operation of preheating pilot

Local assembly time

After hours of operation

(12) (13) (14) (15) (16) (17) (18) (19) (20) (21) (22)

Judgment standard

Fuel control dial Lamp switch Swing lock switch Machine push-up switch Wiper switch (if equipped) Revolving warning lamp switch (if equipped) Heated operator seat switch (if equipped) Room lamp switch Emergency pump drive switch Swing parking brake release switch Step lamp switch (if equipped)

Press the switch on the right work equipment control lever to sound the horn.

At the same time, the flashing light (option) at the bottom front of the cab will flash for approx. 5 seconds.

Push down the lever to apply the lock.

Engine can be started but all work equipment control levers do not move.

Push up the lever to release the lock.

Engine cannot be started but all work equipment levers move.

MAX: Full speed MIN: Low idling Rotate the key at the preheating position so that the monitor display shows "preheating ON". The preheating pilot will flash after approx. 30 seconds to indicate the completion of preheating.

Revision

Category

6/13

Check item

Operation of mode selector switch

Local assembly time

After hours of operation

Judgment standard

P light up: Heavy-duty operations E light up: Fuel-efficient operations When starting the engine, P (heavy-duty operation) mode is automatically selected.

Operation of auto-deceleration switch

ON light up: OFF:

Auto-deceleration is actuated.

Auto-deceleration is canceled.

Each time the switch is pressed, the autodeceleration is actuated or canceled.

Operation of travel speed switch

This is used to select the two travel speeds.

Lo light up: Low speed travel Hi light up: High speed travel

Check of switches, control levers

When the engine is started, the travel speed is automatically set to Lo. Operation of wiper switch

OFF: Wiper stops ON light up: Wiper moves continuously INT light up: Wiper moves intermittently

Operation of window washer switch

Window washer fluid is sprayed out.

Operation of cigarette lighter

This is used to light cigarettes. To use, push the lighter in. After a few seconds it will spring back.

Operation of lamp switch

Operation of swing lock switch

Operation of machine push-up switch

Operation of boom shockless control switch (option)

Operation of step light switch (option)

Operation of room lamp switch Operation of emergency pump drive switch

This switch is used to turn on the front lamps, working lamps, additional lamp at the top front of the cab, and monitor lighting.

ON position (actuated): The swing lock is always applied, and the upper structure will not swing even if the swing is operated. In this condition, the swing lock lamp lights up.

OFF position (canceled): Swing operation is possible. Swing lock monitor goes off.

Low pressure setting: The boom thrust force is weak.

High pressure setting: The boom thrust force becomes more powerful.

ON: While the boom stop operation, shock of the boom is controlled. ă&#x192;ť When the switch is pressed, the step light will light up for approx. 60 seconds. ă&#x192;ť Even if the starting switch key is at the OFF position, the step light will light up for approx. 60 seconds when the switch is pressed.

ON position: Room lamp lights up.

When normal: Switch is pushed down.

When abnormal: When the monitor display shows E02 (TVC valve system error), move the switch up to make it possible to carry out work.

Revision

Category

7/13

Check item

Operation of swing holding brake release swtich

Local assembly time

After hours of operation

Judgment standard

When normal: Switch is pushed down.

When abnormal: When the monitor display shows E03 (Swing brake system error), the brake is canceled, and it becomes possible to actuate the swing and carry out normal operations. However, the swing brake remains released.

Operation of alarm buzzer stop switch

This is used to stop alarm buzzer if it sounds to warn of an abnormality during operation.

Operation of lower wiper switch (option)

ON: Lower wiper moves.

OFF: Lower wiper stops.

Operation of travel levers

Check of switches, control levers

Operation of left work equipment control lever (with auto-deceleration device)

FORWARD: The lever is pushed forward.

(The pedal is angled forward) REVERSE: The lever is pulled back.

(The pedal is angled back) N(Neutral): The machine stops.

This lever is used upper structure.

Arm operation (a) Arm OUT (b) Arm IN

to operate the arm and Swing operation (c) Swing to right (d) Swing to left

N(neutral): When the lever in this position, the upper structure and the arm will be retained in the position in which they stop.

Operation of right work equipment control lever (with auto-deceleration device)

This lever is used to operate the boom and bucket.

Boom operation Bucket operation (a) RAISE (c) DUMP (b) LOWER (d) CURL

N(neutral): When the lever in this position, the boom and the bucket will be retained in the position in which they stop.

Confirmation of failure history (Both electrical and mechanical)

See M-4. Error Code.

Operation of bottom dump switch

R.H.: Bottom opens L.H.: Bottom closes

Check function of rotation lamp switch (option)

ON: Rotary lamp lights up

Check function of large capacity air conditioner blower switch (option)

ON: Blower actued OFF: Blower stopped

Revision

Category

8/13

Local assembly time

Check item

After hours of operation

Judgment standard

Swing operation running in: Engine high idling speed.

(Work equipment posture: Max. reach)

Right

Left

Swing performance

Constant swing speed [

rpm]

[

6.8 ± 0.4 rpm

rpm]

Brake angle

Max. 70° (feeling)

Swing variation, hunting

There must be none.

Abnormal noise, irregular swing

There must be none.

Travel operation running in: Engine high idling speed.

Travel performance

(Work equipment posture: Max. reach) Abnormal noise, heat from carrier roller, track roller, idler

There must be no abnormal noise or abnormal heat.

Operation of travel brake

Must brake securely without pulling to one side.

Abnormal noise, irregular travel

There must be none.

Travel deviation (feeling)

There must be no abnormal deviation from fine control range to full stroke range (feeling).

Travel deviation (measured)

High speed

(Only when it is considered that there is abnormality.)

Low speed

Track rotating speed

High speed - Right High speed - Left Low speed - Right Low speed - Left

Track tension

Forward [

]

Reverse [

mm/20m

Forward [

]

Reverse [

mm/20m

Forward [

]

Reverse [

]

Reverse [

]

Reverse [

sec

] sec

]

Reverse [

sec

Right [

P mode 53.6 ± 5.4 sec / 5 turns

sec

]

Forward [

] sec

sec

Forward [

Max. 200 mm / 20 m

]

mm/20m

sec

Forward [

Max. 200 mm / 20 m

]

mm/20m

] sec

] mm

Left [

] mm

P mode 82.0 ± 8 sec / 5 turns

9/13

Revision

Category

Note: All judgment standard values for speeds are the values in P mode.

Local assembly time

Check item

After hours of operation

Judgment standard

Work equipment operation running in: Engine high idling speed, (Note: Boom cylinder to ground level) Pressurized: each port relief 2 minutes, shock 20 times (except BOOM LOWER) Work equipment posture

Work equipment speed

Work equipment time lag (Engine low idling)

Boom

RAISE [

Arm (arc)

OUT [

Bucket

CURL [

sec

Bottom

OPEN [

sec ]

Boom

sec ] sec ] ]

LOWER [

sec ]

RAISE: 6.1 ± 0.6 sec.

LOWER: 4.8 ± 0.5sec.

IN [

sec ]

IN: OUT:

DUMP [

sec ]

CURL: 4.6 ± 0.5 sec.

DUMP: 4.0 ± 0.4 sec.

CLOSE [

sec ]

OPEN: 1.6 ± 0.3 sec.

CLOSE: 1.8 ± 0.3 sec.

LOWER [

4.1 ± 0.4 sec.

2.5 ± 0.3 sec.

sec ]

Max. 3 sec.

Only when there is considered to be abnormality.

Arm

IN [

sec ]

Max. 3 sec.

Work equipment performance

Only when there is considered to be abnormality.

Bucket

DUMP [

sec ]

Max. 3 sec

Only when there is considered to be abnormality.

Bottom

CLOSE [

sec ]

Max. 3 sec

Only when there is considered to be abnormality.

Abnormal noise from pump, PTO Generation of heat by PTO

There must be no abnormality during operation under no load and during relief.

There must be no abnormal generation of heat.

Engine partial performance

There must be no hunting at any speed under no load, there must be no stalling of engine even at low idling and relief.

Fine control performance

Must operate smoothly.

Operation when raising chassis

There must be no escape of boom, arm, or bucket.

Abnormal noise, grating noise from work equipment

There must be none.

Shock at end of cylinder stroke (Shock at end of stroke for BOOM RAISE and ARM OUT)

Function of accumulator

Cushion must be fully effective.

Immediately after engine is stopped, boom cylinder must move from fully extend position to ground level. (Arm at Max. reach)

Revision

Category

10/13

Check item

Local assembly time

After hours of operation

Judgment standard

During operation

Operating force of control lever when each actuator is actuated.

・ There must be no catching during operation. ・ Must return naturally to neutral.

Feeling and noise of vibration in operator’s cab

There must be none.

Vibration noise from frame, guard, ladder

There must be none.

Around operator’s cab

Check all parts

Movement of doors and windows

Must move smoothly.

Door, window locks

Must lock securely.

Adjustment of operator’s seat

Must be possible to make all adjustments.

There must be none.

Undercarriage

Oil leakage (Idler, roller, sprocket, final drive gear case, motor, brake valve)

Interference at any part

There must be none.

Looseness of track shoe bolt

There must be none.

Contact of link tread

There must be no overlapping, separation, or missing or broken parts.

Oil leakage

There must be none.

Center swivel, pump, solenoid valve, relief valve, control valve, PPC valve, swing motor, brake valve, shuttle valve, swing machinery, hydraulic tank, piping

Around chassis

Leakage of fuel

There must be none.

(Fuel tank, engine, piping) Leakage of water from engine cooling water system

There must be none.

Leakage of oil from engine lubrication system

There must be none.

Leakage of gas from engine gas system

There must be none.

Movement of covers

Must move smoothly.

Cover locks

Must lock securely.

Around chassis

Revision

Category

11/13

Local assembly time

Check item

After hours of operation

Judgment standard

Operation of grease pump

Must move smoothly.

Looseness, insufficient insertion of electric wiring terminals

There must be none.

Position for passing electrical wiring through

There must be a clearance of at least 10 mm from any moving part or edge.

Leakage of air from air system

There must be none.

Interference at any part

There must be none.

There must be none.

Oil leakage (Cylinder, piping, block)

There must be none.

Around work equipment

Grease leakage from grease piping

(CURL side)

One side in contact,, clearance at other side within 5 mm.

(DUMP side)

One side in contact,, clearance at other side within 5 mm.

Contact between bucket and arm stopper

Contact between front bucket and rear stopper

One side in contact,, clearance at other side within 10 mm.

12/13

Revision

Category

Note: If the operation or function is defective, measure as necessary. All judgment standard values for speeds are the values in P mode.

Local assembly time

Check item

After hours of operation

Judgment standard

1. Engine speed: Check in monitoring mode “01006” Low idling High idling

[

rpm]

(Operate lever a little)

800 ± 50 rpm 1950 ± 50 rpm

High idling (When lever is not operated), (Auto-deceleration: canceled)

1750 ± 50 rpm

Speed at arm OUT

[

rpm]

1850 ± 50 rpm

Speed at arm IN

[

rpm]

Min. 1780 rpm

Monitoring mode ID “01002”

at P mode

2. Radiator fan speed 1430 ± 50 rpm Main measurement items

Speed at engine high idle speed

3. Measurement of oil pressure

[

rpm]

Check in service mode “55” (Fan rotation 100% fixed mode)

Check in monitoring mode Swing pump “09000”, F pump: “01100”, R pump: “01101”

Control valve main set pressure

4-spool valve (R pump)

Control valve main set pressure

5-spool valve (F pump)

Travel relief set pressure

Right travel (F pump)

Travel relief set pressure

Left travel (R pump)

Swing relief set pressure

F pump

31.9 ｛320

+1.5 MPa -1.0 +15 kg/㎠｝ -10

MPa {kg/㎠}

34.3 ｛350

+1.5 MPa -1.0 +15 kg/㎠｝ -10

MPa {kg/㎠} MPa {kg/㎠} MPa {kg/㎠} MPa {kg/㎠}

Pilot relief valve set pressure

35.3±1.5 MPa {360±15 kg/㎠} 35.3±1.5 MPa {360±15 kg/㎠}

At engine high idling, arm OUT, P mode and Heavy lift OFF, relief

At power max. switch ON

Relieved on one side at P mode

At engine high idling, swing 29.9±1.0 MPa and P mode, relief {305±10 kg/㎠} +4 3.14 +0.39 MPa ｛32 0 kg/㎠} 0 (At engine high idling, neutral)

When boom is raised (Heavy: OFF)

In neutral NC valve output pressure (at top surface of NC valve) No.1 pump, No.2 pump

MPa {kg/㎠}

MPa {kg/㎠}

MPa {kg/㎠}

Max. 1.10 MPa {11.2 kg/㎠}

Engine high idling P mode

Note: Measure the following J/S differential pressure only if the NC valve output pressure does not pass the test.

At neutral J/S differential pressure (differential pressure at input and output ports of jet sensor) No.1 pump, No.2 pump

At relief MPa {kg/㎠}

MPa {kg/㎠}

1.8 ± 0.2 MPa {18 ± 2{kg/㎠}

Engine high idling P mode

Max. 0.2 MPa {2kg/㎠}

At engine high idling no load

Revision

Category

13/13

Local assembl y time

Check item

After hours of operation

Judgment standard

4. hydraulic drift of work equipment (bucket unloaded, 50±5℃） Bucket tooth up

[

mm]

Max. 600 mm / 15 minutes

Note: Measure the hydraulic drift of the following cylinders only if the hydraulic drift at the bucket tooth tip does not pass the test.

Boom cylinder

[

mm]

Max. 7 mm/minute

Arm cylinder

[

mm]

Max. 7 mm/minute

Bucket cylinder

[

mm]

Max. 7 mm/minute

5. operation force, travel Boom lever

Operating force

RAISE

N

RAISE Stroke

Main measurement items

Swing lever

Operating force Stroke

Bucket lever

Operating force Stroke

Arm lever

Operating force Stroke

Right travel lever

Operating force Stroke

Left travel lever

Operating force Stroke

LOWER

N

{kg}

[

{kg}

LOWER mm] [

RIGHT

PLAY mm] [

N

mm]

LEFT

N

{kg} RIGHT [ CURL

{kg}

LEFT mm] [ N

PLAY mm] [ DUMP

mm] N

{kg} CURL [ IN

{kg}

DUMP mm] [ N

PLAY mm] [ OUT

mm] N

{kg} IN [ FOR-

mm] [ N

WARD

{kg}

FORWARD [ FOR-

PLAY mm] [ REVERSE

REVERSE

mm] [ N

WARD

{kg}

FORWARD [

{kg}

OUT

mm] [

mm] N {kg} PLAY

mm] [ REVERSE

REVERSE

mm] N {kg} PLAY

mm] [

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

mm]

16.7±3.9N {1.7±0.4kg} Stroke:85±10mm Play: Max. 10mm 13.7±2.9N {1.4±0.3kg} Stroke:85±10mm Play: Max. 10mm 13.7±2.9N {1.4±0.3kg} Stroke:85±10mm Play: Max. 10mm 16.7±3.9N {1.7±0.4kg} Stroke:85±10mm Play: Max. 10mm 24.5±5.9N {2.5±0.6kg} Stroke:115±12mm Play: Max. 10mm 24.5±5.9N {2.5±0.6kg} Stroke:115±12mm Play: Max. 10mm

At engine high idling, relief