GEN00016-01 PC1800-6 Komatsu Service Manual

GEN00016-01
Field Assembly Instruction
HYDRAULIC PC1800 -6
EXCAVATOR
SERIAL NUMBERS 10011,11002 and up
1
2
3
GENERAL
Specifications
4
Points regarding local assembly
5
Bolt tightening torque and bolt tightening tools
6
7
8
Separate units
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
List of parts sent individually
5. LIST OF PARTS SENT INDIVIDUALLY
Loose-supply and assembly-supply items list for harbor assembly
32t
No. Part No. Part name Q'ty Assembly Location
procedure No.
COOLING SUB A 1
F.TANK SUB A 1
H.TANK SUB A 1
SUCTION TUBE SUB A 2
SWING MACHINERY 2
SUB A
HOOD(SMALL) SUB A 1
RIGHT SIDE DOOR
SUB A 1
RIGHT SIDE DUCT
SUB A 1
(*For only +55: specifica-
BATTERY CASE SUB A 1 tion)
1 07289-00095 CLAMP 2 Water hose inlet to engine
2 07289-00080 CLAMP 2 Water hose outlet from

engine
3 07281-00197 CLAMP 2 Engine air vent hose out-
let from engine
4 6212-11-4840 CLAMP 4 Air hose inlet to after
cooler
5 6212-11-4840 CLAMP 4 Air hose inlet to engine
6 01011-83010 BOLT 7 For installation of hydraulic

7 208-30-11971 SPACER 7 tank
For blocking lower hole of

8 175-54-38531 CAP 1 hydraulic tank
9 01024-81235 BOLT 8 For installation of suction

tube
10 21T-62-64171 TUBE 1 Front oil cooler inlet tube

11 01024-81240 BOLT 4 For installation of tube
12 21T-62-64180 TUBE 1 Rear oil cooler inlet tube
14 21T-62-64190 TUBE 1 Rear oil cooler outlet tube
For installation of swing

16 01010-83090 BOLT 28 machinery
29
Assembly
No. Part No. Part name Q'ty procedure No. Location
17 01643-33080 WASHER 28 machinery
18 01024-81225 BOLT 2 machinery drain hose
For installation of drain
19 01024-81225 BOLT 1 hose clamp
Swing brake hose (To
20 21T-64-63180 HOSE 1 swing motor)
For clamping swing brake
21 04434-51312 CLIP 1 hose
22 01010-81230 BOLT 5 For installation of small

hood
23 175-54-34170 WASHER 5 For installation of small
hood
24 21T-54-65411 NET 2 Net above right-hand duct

25 01024-81225 BOLT 16 For installation of net
26 21T-54-65910 SHIM 3 Fitting adjustment shim

27 21T-54-65920 SHIM 3 for right-hand door hinge
28 21T-54-68630 FRAME 1 Front frame of right-hand

door
29 01024-81230 BOLT 4 For installation of frame
30 21T-54-67181 COVER 1 Right-hand door top cover

31 01024-81230 BOLT 9 For installation of cover
Right-hand duct top

32 21T-54-64340 BRACKET 1 bracket (Rear)
33 01024-81230 BOLT 4 For installation of bracket
34 21T-54-64351 BRACKET 1 Right-hand duct top

bracket (Front)
Right-hand duct top
36 21T-54-64360 BRACKET 5 bracket (Center)
38 175-54-34170 WASHER 20 For installation of bracket
39 21T-54-64111 COVER 1 Cooling rear cover
40 01024-81230 BOLT 4 For installation of oil

cooler piping bracket
30
Assembly
Engine compartment rear
41 21T-54-64450 COVER 1 cover
42 01024-81230 BOLT 11 For installation of cover
43 21T-54-64311 COVER 2 Muffler cover
For clamping wiring har-

44 04434-52312 CLIP 1 ness in battery case (*For
only +55: specification)
46 01024-81225 BOLT 1 ness in battery case (*For

only +56: specification

31
Loose-supply items list for standard machine
A
Assembly
Left-hand catwalk of oper-
1 21T-54-69930 FRAME 1 A-12 ator's cab
Left-hand handrail of oper-
2 21T-54-75163 HAND RAIL 1 A-12 ator's cab
3 01010-81235 BOLT 29 A-12
4 175-54-34170 WASHER 31 A-12 For installation
5 01580-11210 NUT 2 A-12
6 21T-54-69780 LADDER 1 A-12 Escape ladder
Handrail of left-hand stairs
7 21T-54-75173 HAND RAIL 1 A-14 (Front)
10 01010-81235 BOLT 10 A-14
For installation
11 175-54-34170 WASHER 10 A-14
Left-hand wiper motor
13 21T-43-67411 COVER 1 A-29 cover
Right-hand wiper motor
14 21T-43-67650 COVER 1 A-29 cover
15 20Y-57-21260 BRACKET 1 A-27
Seat belt bracket
16 20Y-57-21270 BRACKET 1 A-27
For installation of seat belt
17 01024-D1235 BOLT 4 A-27 bracket
19 09409-10001 LAP BELT 1 A-27 78-mm seat belt
20 09409-20000 TETHER BELT 2 A-27 Tether belt
21 09409-00001 BOLT 2 A-27 For installation of belt
22 21T-57-67210 STAND STD 1 A-27 Operator's seat stand
23 21T-54-71851 BRACKET 1 A-27 Right-hand floor foot rest
24 195-54-43210 BOLT 4 A-27
For installation of foot rest
25 198-54-42280 WASHER 4 A-27
26 21T-54-65310 MAT 1 A-27 Floor mat (Front)
27 21T-54-65320 MAT 1 A-27 Floor mat (Rear)
28 01010-81230 BOLT 6 A-27
For installation of floor
29 01010-81235 BOLT 8 A-27 frame
30 01643-31232 WASHER 14 A-27
31 01010-81470 BOLT 16 A-28 For installation of opera-
32 01643-31445 WASHER 16 A-28 tor's cab
33 21T-54-69870 COVER 1 A-12 Escape ladder storage box

assembly
34 01010-81225 BOLT 12 A-12
For installation of storage
35 175-54-34170 WASHER 9 A-12 box
36 01643-31232 WASHER 3 A-12
37 21T-54-69880 COVER 1 A-12 Storage box cover
32
Assembly
38 01010-81225 BOLT 4 A-12 For installation of storage

39 01643-31232 WASHER 4 A-12 box cover
40 21T-54-69450 LOCK 1 A-12 Cover lock
41 01643-30823 WASHER 4 A-12 For installation of cover
42 01580-10806 NUT 4 A-12 lock
43 209-54-31170 LINK 1 A-12 Cover opening stopper
44 202-970-1220 WASHER 1 A-12
45 04050-13018 PIN 2 A-12 For cover opening stopper
46 01641-21016 WASHER 2 A-12
47 21N-54-32670 MIRROR 1 A-12 Cab side mirror
48 21T-54-79611 SUPPORT 1 A-12
49 21T-54-79620 CLAMP 2 A-12 For installation of mirror
50 01252-41025 BOLT 4 A-12
51 21T-54-67480 HAND RAIL 1 A-16 Rear handrail of operator's

cab
52 01010-81235 BOLT 4 A-16
For installation of handrail
53 175-54-34170 WASHER 4 A-16
Installation procedure for
54 21T-98-72180 PLATE 1 A-12 mirror
62 207-57-61200 SEAT 1 A-27 Operator's seat
63 01010-80816 BOLT 2 A-27
64 01252-40820 BOLT 2 A-27 For installation of seat
65 01643-30823 WASHER 2 A-27
66 09049-00002 WASHER 2 A-27
67 09049-00003 NUT 2 A-27 For installation of belt
68 01024-D1045 BOLT 2 A-27
70 175-54-29440 PLATE 2 A-14
Shim
71 195-54-23471 PLATE 1 A-14
73 21T-06-71920 COVER 1 A-27 Electric wire cover at rear

of floor frame
74 21T-06-71860 HARNESS 1 A-27 Wiper wiring harness
75 20M-57-71202 SEAT A. 1 A-27 Sub-seat assembly
76 21T-57-67111 BOX 1 A-27 Box under sub-seat
77 20N-57-21211 BRACKET 1 A-27 Bracket under sub-seat
78 01010-80820 BOLT 4 A-27
For installation of bracket
79 01643-30823 WASHER 4 A-27 under sub-seat
80 01580-10806 NUT 4 A-27
L-bracket under sub-seat
81 21T-57-67130 BRACKET 1 A-27 (Front)
L-bracket under sub-seat
82 21T-57-67120 BRACKET 1 A-27 (Rear)
33
Assembly
83 01010-80820 BOLT 4 A-27 For installation of L-

84 01643-30823 WASHER 4 A-27 bracket under sub-seat
Filter of box under sub-
85 14X-911-7741 FILTER 4 A-27 seat
86 09495-40000 EXTINGUISHER 1 A-27 Fire extinguisher
87 01010-80616 BOLT 6 A-27 For installation of fire
88 01643-30623 WASHER 6 A-27 extinguisher
89 X21-0544722 OPE CAB ASS’Y 1 A-28 Operator's cab assembly
Air conditioner duct at
90 21T-43-67381 DUCT 1 A-28 right front of operator's
cab
91 20Y-979-2160 GRILL 2 A-28 Air outlet
92 20Y-54-14750 BOLT 10 A-28 For installation of air con-
93 01643-70823 WASHER 10 A-28 ditioner duct
94 21T-43-67392 DUCT 1 A-28 Air conditioner duct at left

rear of operator's cab
97 21T-43-67343 COVER 1 A-27 Defroster duct
98 142-979-3221 GRILL 4 A-27 Air outlet of defroster duct
99 01024-D1025 BOLT 3 A-27 For installation of defroster

duct
101 08037-02512 GROMMET 1 A-27
Grommet of defroster duct
102 08037-01610 GROMMET 1 A-27
103 01024-D1016 BOLT 1 A-27 For installation of defroster

duct
104 07281-01159 CLAMP 3 A-39 For A/C discharge hose
A/C discharge hose, A/C
105 21T-979-6270 HOSE 1 A-39 (Front) - Foot/Defroster
106 21T-979-6280 HOSE 1 A-39 (Rear) - Face/Defroster
107 21T-979-6290 HOSE 1 A-39 (Rear) - Right rear pillar
108 07281-01159 CLAMP 3 A-39 For A/C discharge hose
109 07281-02169 CLAMP 4 A-39 For A/C inside air intake

duct hose
110 21T-979-6710 HOSE 2 A-39 A/C inside air intake duct
hose
111 01024-D1230 BOLT 2 A-27 For installation of box
under sub-seat
112 01024-D1230 BOLT 4 A-29 For installation of cover
114 01641-21223 WASHER 2 A-27 For installation of belt
115 21T-54-65511 SEAL 1 A-27
For sealing floor frame
116 21T-54-65651 SEAL 1 A-27
34
Loose-supply items list related to base machine
C
Assembly
For installation of fuel
4 21T-04-71230 SHIM 28 A-25 tank (t1.0)
5 01010-81685 BOLT 8 A-25
For installation of fuel tank
6 21T-72-12620 WASHER 8 A-25
For installation of fuel
13 21T-04-71290 SHIM 28 A-25 tank (t1.0)
14 01010-81650 BOLT 8 A-25
For installation of fuel tank
15 01643-31645 WASHER 8 A-25
19 21T-25-67150 BOLT 60 A-06
For installation of circle
20 01643-33690 WASHER 60 A-06
22 21T-30-71160 BOLT 76 A-01 For installation of crawler
23 21T-30-71170 WASHER 76 A-01 frame
24 21T-30-71194 COVER 1 A-04
Travel motor cover
25 21T-30-71214 COVER 1 A-04
26 01010-81230 BOLT 38 A-04
27 175-54-34170 WASHER 30 A-04
28 01643-31232 WASHER 20 A-04
29 21N-30-11340 COLLAR 16 A-04 For installation of travel
motor cover
30 01011-81210 BOLT 4 A-04
31 424-54-14230 SPACER 4 A-04
32 01010-81235 BOLT 4 A-04
33 21T-46-64240 BOLT 12 A-22 For installation of counter-
34 209-46-11210 SPACER 12 A-22 weight
35 21T-54-75343 LADDER 2 A-09
Step on side of T/F
36 209-30-61851 BRACKET 2 A-09
37 01010-81640 BOLT 16 A-09 For installation of step on
38 01643-31645 WASHER 16 A-09 side of T/F
Front catwalk of opera-
39 21T-54-75433 FRAME 1 A-18 tor's cab
Front handrail of opera-
40 21T-54-75422 HAND RAIL 1 A-18 tor's cab
41 01010-81235 BOLT 26 A-18
43 01580-11210 NUT 2 A-18
44 01580-11210 NUT 4 A-04 For installation of travel

motor cover
45 21T-54-75231 HAND RAIL 1 A-24 Right-hand handrail of
counterweight
35
Assembly
46 01010-81255 BOLT 22 A-24

47 01010-81235 BOLT 10 A-24
48 175-54-34170 WASHER 36 A-24
49 01580-11210 NUT 4 A-24
50 21T-54-67420 FRAME 1 A-11 Right rear catwalk
51 21T-54-69280 FRAME 1 A-11 Right front catwalk
52 01010-81235 BOLT 28 A-11
For installation of catwalk
53 175-54-34170 WASHER 28 A-11
54 21T-54-67440 LADDER 1 A-23 Right-hand ladder (Rear)
55 01010-81230 BOLT 8 A-23 For installation of right-
56 01643-31232 WASEHR 8 A-23 hand ladder (Rear)
57 21T-54-67461 HAND RAIL 1 A-20 Rear handrail of right-hand

catwalk
58 21T-54-75322 HAND RAIL 1 A-20 Front handrail of right-
hand catwalk
59 21T-54-75313 HAND RAIL 1 A-20 Front handrail of
right deck
60 01010-81235 BOLT 42 A-20
62 01580-11210 NUT 2 A-20
63a 21T-54-68651 LADDER 1 A-21 Hydraulic tank ladder
63b 21T-54-65750 LADDER 1 A-21 Hydraulic tank ladder(*For

64 01010-81240 BOLT 8 A-21
65 01643-31232 WASEHR 8 A-21
For installation of ladder
66 01010-81230 BOLT 8 A-21
67 175-54-34170 WASHER 8 A-21
68 01010-81235 BOLT 34 A-27 For installation of cab
69 175-54-34170 WASHER 34 A-27 base
72 21T-68-67610 CUSHION 1 A-21 For grease gun
73 21T-54-67992 HAND RAIL 1 A-30 Handrail of center ladder

(Left-hand)
74 01010-81230 BOLT 8 A-30
75 175-54-34170 WASHER 8 A-30
76 21T-54-67190 HAND RAIL 1 A-30 Upper rear handrail of left-

hand cover
77 01010-81235 BOLT 16 A-30
78 01643-31232 WASHER 16 A-30
79 21T-54-78320 HAND RAIL 1 A-31 Center handrail of hydrau-

lic tank
80 21T-54-78310 HAND RAIL 1 A-31 Rear handrail of hydraulic
tank
36
Assembly
81 07283-33450 CLIP 8 A-31

82 07283-53444 SEAT 8 A-31
83 01599-01011 NUT 16 A-31
84 01643-31032 WASHER 16 A-31
Upper handrail of right-
85 21T-54-68510 HAND RAIL 1 A-31 hand door cover
86 01010-81235 BOLT 10 A-31
87 01011-81210 BOLT 2 A-31 For installation of handrail
88 175-54-34170 WASHER 12 A-31
91 209-68-51240 GREASE REAL A. 1 A-26 Grease reel
92 01010-81030 BOLT 4 A-26 For installation of grease
93 01643-31032 WASHER 4 A-26 reel
94 21T-68-72410 BRACKET 1 A-26 Grease reel bracket
95 01010-81225 BOLT 4 A-26
96 01643-31232 WASHER 4 A-26
97 21T-68-72450 HOSE 1 A-26 Hose wound on reel
99 209-68-11230 GREASE GUN 1 A-26 Grease gun
100 21T-72-17720 HOSE 1 A-26 IN hose
101 08036-01214 CLIP 1 A-26
102 01010-81225 BOLT 1 A-26
For IN hose
103 01643-31232 WASHER 1 A-26
104 21T-68-72390 ELBOW 1 A-26
105 21T-54-75650 GRIP 1 A-14 Handrail grip of left-hand

ladder (Front)
106 01010-81235 BOLT 2 A-14
For installation of grip
107 01643-31232 WASHER 2 A-14
113 21T-54-69360 LADDER(L.H) 1 A-13 Left-hand stairs (Front)
Lower triangle cover of
114 21T-54-75140 COVER 1 A-13 left-hand stairs
115 01010-81230 BOLT 20 A-13
For installation
116 175-54-34170 WASHER 18 A-13
Front upper step of left-
117 21T-54-75520 STEP 1 A-13 hand stairs
118 01643-31232 WASHER 2 A-13 For installation
123 21T-54-64191 LADDER(L.H) 1 A-23 Left-hand stairs (Rear)
124 01010-81230 BOLT 8 A-23 For installation of left-hand
125 01643-31232 WASHER 8 A-23 stairs (Rear)
Left-hand handrail of fuel
126 21T-54-64181 HAND RAIL 1 A-24 tank
Left-hand handrail of
127 21T-54-75221 HAND RAIL 1 A-24 counterweight
Emergency stop switch
136 21T-54-69960 BRACKET 1 A-32 bracket
37
Assembly
137 21T-04-64360 CABLE 1 A-32 Fuel cut lever cable

141 8221-06-1470 SWITCH 1 A-32 Emergency stop switch
Underside plate of switch
142 8253-06-1210 PLATE 1 A-32 box
143 01010-80620 BOLT 2 A-32 For underside plate of
144 01643-30623 WASHER 2 A-32 switch box
145 8253-06-1220 BOX 1 A-32 Switch box
146 01010-81020 BOLT 2 A-32
For switch box
147 01643-31032 WASHER 2 A-32
148 08193-20012 CLIP 1 A-32
For clamping switch wir-
149 01010-81225 BOLT 1 A-32 ing harness connector
150 01643-31232 WASHER 1 A-32
151 21T-06-64330 WIRING HARNESS 1 A-32 Switch wiring harness
152 21T-06-67770 COVER 1 A-32 Switch wiring harness

cover
153 01010-80616 BOLT 6 A-32 For switch wiring har-
154 01643-30623 WASHER 6 A-32 ness cover
155 04434-51012 CLIP 4 A-32
For clamping switch wir-
156 01010-81225 BOLT 4 A-32 ing harness
157 01643-31232 WASHER 4 A-32
158 21N-54-32670 MIRROR 2 A-31 Right mirror
159 21T-54-79631 SUPPORT 2 A-31
160 21T-54-79620 CLAMP 2 A-31 For right mirror
161 01252-41025 BOLT 4 A-31
162 21T-54-69511 HAND RAIL 1 A-33 Radiator top handrail

(*Optional)
163 01010-81230 BOLT 12 A-33
164 175-54-34170 WASHER 12 A-33
165 21T-54-64220 PLATE 1 A-33 (*Optional)
166 01010-81230 BOLT 5 A-33
167 175-54-34170 WASHER 5 A-33
177 01010-81230 BOLT 4 A-32 For emergency stop
178 01643-31232 WASHER 4 A-32 switch bracket
179 175-06-81610 GROMMET 2 A-32 For switch wiring harness
180 8221-93-1630 PLATE (ENGLISH) 1 A-32 Decalcomania of engine

emergency stop switch
181 21T-54-68560 BRACKET 1 A-11
182 01010-81230 BOLT 2 A-11 Grease hose guide
183 01643-31232 WASHER 2 A-11
Center bracket of center
184 21T-30-71251 BRACKET 2 A-04 cover
185 21T-30-18120 COVER 5 A-04 Center of center cover
38
Assembly
186 01010-82465 BOLT 44 A-04 For installation of center

187 01643-32460 WASHER 44 A-04 cover
188 21T-30-71280 COVER 2 A-04
Center cover
189 21T-30-71270 COVER 2 A-04
190 01010-82485 BOLT 12 A-04 For installation of center
191 01643-32460 WASHER 12 A-04 cover
Installing part of hydrau-
196 21T-54-78390 BRACKET 1 A-31 lic tank handrail
Bracket of installing part
197 19M-54-13660 BRACKET 4 A-31 of handrail
198 01010-81235 BOLT 16 A-31
199 01643-31232 WASHER 16 A-31
For prevention of fall from
211 21T-54-65810 CHAIN 1 A-20 front side of right-hand
deck
212 21T-54-65381 BRACKET 1 A-21 Grease gun bracket
213 01010-81230 BOLT 2 A-21 For installation of grease
214 01643-31232 WASHER 2 A-21 gun bracket
215 21T-54-68480 HAND RAIL 1 A-30 Handrail of center stairs

(Right)
216 01010-81230 BOLT 8 A-30
217 175-54-34170 WASHER 8 A-30
218 01010-81235 BOLT 1 A-30
For connection of upper
219 175-54-34170 WASHER 2 A-30 handrail of left cover
220 01580-11210 NUT 1 A-30
221 21T-04-64350 WIRE ROPE 1 A-32 Fuel cut lever stopper
222 07283-31026 CLIP 1 A-32
For fuel cut lever stopper
223 01596-00606 NUT 2 A-32
224 01643-30623 WASHER 2 A-32 For fuel cut lever stopper
225 01641-21223 WASHER 12 A-04 For installation of travel

motor cover
226 21T-54-67471 HAND RAIL 1 A-30 Upper front handrail of
left-hand cover
227 01010-81230 BOLT 8 A-30
228 175-54-34170 WASHER 8 A-30
229 21T-54-75560 CLAMP 1 A-30
230 21T-54-75570 PLATE 1 A-30 For connection of upper
front handrail of left-hand
231 01010-81230 BOLT 1 A-30 cover
232 175-54-34170 WASHER 1 A-30
233 21T-54-75650 GRIP 2 A-20 Front grip of right-hand

catwalk
234 01010-81235 BOLT 4 A-20
235 01643-31232 WASHER 4 A-20
39
Assembly
Right-hand deck front cat-
236 21T-54-75241 FRAME 1 A-11 walk
237 01010-81230 BOLT 6 A-11
238 175-54-34170 WASHER 6 A-11
239 01010-81635 BOLT 2 A-11
240 01643-31645 WASHER 2 A-11
241 20Y-06-25310 LAMP 2 A-11 Right front working lamp
242 01024-81225 BOLT 2 A-11 For installation of work-

ing lamp
243 04434-51012 CLIP 4 A-11 For wiring harness of
244 01024-81225 BOLT 4 A-11 working lamp
245 21T-54-67411 FRAME 1 A-10 Left-hand deck catwalk
246 01010-81235 BOLT 16 A-10
247 175-54-34170 WASHER 16 A-10
248 01010-81645 BOLT 4 A-10
249 01643-31645 WASHER 4 A-10
Left-hand deck catwalk
250 21T-54-75150 PLATE 1 A-10 plate
251 01010-81230 BOLT 2 A-10
For installation of plate
252 01643-31232 WASHER 2 A-10
253 21T-54-67451 HAND RAIL 1 A-10 handrail
254 01010-81235 BOLT 12 A-10
255 175-54-34170 WASHER 12 A-10
256 21T-54-75650 GRIP 1 A-10 grip
257 01010-81235 BOLT 2 A-10
258 01643-31232 WASHER 2 A-10
259 21T-54-65520 SHEET 1 A-34 For blocking floor PPC

hose
For blocking floor lock
260 21T-54-65530 SHEET 1 A-34 lever cable hole
For securing hole blocking
261 08034-20536 BAND 4 A-34 seat
262 21T-54-69820 FRAME 1 A-11 Right-hand rear catwalk

(*+55: specification)
263 01010-81235 BOLT 28 A-11 For installation of catwalk
264 175-54-34170 WASHER 28 A-11 (*+55: specification)
Right front catwalk (*+55:
265 21T-54-65370 FRAME 1 A-11 specification)
Right rear handrail
266 21T-54-69790 HAND RAIL 1 A-11
40
Assembly
Right front handrail (*+55:
269 21T-54-75322 HAND RAIL 1 A-11 specification)
270 01010-81235 BOLT 2 A-11
272 01580-11210 NUT 2 A-11
273 21T-54-68641 PLATE 4 A-11 Handrail lower plate (*+55:

specification)
274 01010-81230 BOLT 32 A-11
275 01643-31232 WASHER 32 A-11 For installation of plate
276 20Y-54-19930 COLLAR 16 A-11 (*+55: specification)
277 20Y-54-12990 PLATE 16 A-11
Right-hand deck front
278 21T-54-65271 HAND RAIL 1 A-11 handrail (Left)
Right-hand deck front
281 21T-54-65281 HAND RAIL 1 A-11 handrail (Right)
282 21T-54-65290 BRACKET 1 A-11
283 01010-81230 BOLT 2 A-11 (*+55: specification)
284 01643-31232 WASHER 2 A-11
Right-hand catwalk grip
285 21T-54-75650 GRIP 2 A-11 (*+55: specification)
286 01010-81230 BOLT 4 A-11 For installation of grip
287 01643-31232 WASHER 4 A-11 (*+55: specification)
For prevention of fall from
288 21T-54-65390 CHAIN 1 A-11 front side of right-hand
deck (*+55: specification)
289 21T-54-68560 BRACKET 1 A-11
290 01010-81230 BOLT 2 A-11 Grease hose guide
291 01643-31232 WASHER 2 A-11
292a 21T-06-64590 SENSOR 1 A-35 NC pressure sensor

NC pressure sensor wiring
292b 21T-06-64392 WIRING HARNESS 1 A-35
harness
293 21T-54-67491 HAND RAIL 1 A-30 Boom rear handrail

294 01010-81230 BOLT 12 A-30
295 175-54-34170 WASHER 12 A-30
296 21T-04-64320 BTACKET 1 A-23

297 21T-04-64330 BRACKET 1 A-23
298 01024-81225 BOLT 4 A-23
41
Loose-supply items list related to arm
F
Assembly
Hose between body to
2 07073-01418 HOSE 8 C-04 boom
3 07073-41425 HOSE 4 C-12 Bucket cylinder hose
4 07631-20408 HOSE 1 C-12
5 237-60-14550 ADAPTER 1 C-12
6 21T-70-75290 BRACKET 1 C-12
7 01010-81225 BOLT 2 C-12
8 01643-31232 WASHER 2 C-12 For greasing between
9 237-60-14550 ADAPTER 1 C-12 boom to arm (LINCOLN)
10 21T-68-68290 TUBE 1 C-12
11 203-973-5720 CLAMP 3 C-12
12 01010-81055 BOLT 6 C-12
13 01643-31032 WASHER 6 C-12
14 07073-01416 HOSE 4 C-12 Arm cylinder hose
15 203-973-5660 CLAMP 3 C-12 For greasing between

boom to arm (LINCOLN)
16 21T-72-17740 HOSE 1 C-12

17 21T-72-17690 ADAPTER 1 C-12
18 21T-70-75290 BRACKET 1 C-12
19 01010-81225 BOLT 2 C-12
20 01643-31232 WASHER 2 C-12 For greasing between
21 21T-72-17620 ADAPTER 1 C-12 boom to arm (NABCO)
22 21T-70-75740 TUBE 1 C-12
23 07282-11048 CLAMP 2 C-12
24 01010-80612 BOLT 4 C-12
25 01602-20619 WASHER 4 C-12
42
Loose-supply items list related to boom
G
Assembly
1 21T-63-X2310 BOOM CYL. L.H 1 C-01 Boom cylinder, left-hand

2 21T-63-X2320 BOOM CYL. R.H 1 C-01 Boom cylinder, right-hand
3 21T-63-X2330 ARM CYL. L.H 1 C-04 Arm cylinder, left-hand
4 21T-63-X2340 ARM CYL. R.H 1 C-04 Arm cylinder, right-hand
5 21T-70-64111 SHIM 8 C-05
6 21T-70-64121 SHIM 16 C-05 Boom foot pin
7 209-72-11311 SEAL 4 C-05
8 21T-70-64111 SHIM 8 C-01
Boom cylinder bottom pin
9 21T-70-64121 SHIM 16 C-01
Boom cylinder bottom
10 178-70-12550 SPACER 4 C-01 spacer
11 21T-70-11240 SEAL 4 C-06
12 07000-15190 O-RING 2 C-06 Boom cylinder top pin
13 07000-15150 O-RING 2 C-06
14 209-70-11340 SEAL 4 C-04
For arm cylinder bottom
15 07000-15160 O-RING 4 C-04
16 21T-70-71650 SHIM 4 C-07
17 21T-70-71660 SHIM 12 C-07
18 21T-70-71590 SEAL 2 C-07 Boom top pin
19 07000-15220 O-RING 2 C-07
20 21T-70-71670 SHIM 4 C-07
31 20Y-06-25310 LAMP 2 C-04 Boom headlamp
32 20Y-06-21551 BRACKET 2 C-04
For installation of head
33 01010-81430 BOLT 2 C-04 lamp
34 01643-31445 WASHER 2 C-04
35 209-70-11340 SEAL 4 C-09
Arm cylinder top pin
36 07000-15155 O-RING 4 C-09
37 21N-70-12160 SEAL 4 C-16 For arm top pin A boss
38 209-72-11261 SEAL 4 C-17 For bucket pin
39 209-70-71370 O-RING 4 C-16 For bucket
40 21T-70-74260 SHIM 32 C-16
For bucket pin
41 21T-70-74270 SHIM 8 C-16
42 205-09-61240 BOLT 4 C-16
43 01640-20610 WASHER 4 C-16
For bucket
44 01580-10605 NUT 4 C-16
45 01640-20610 WASHER 4 C-16
46 07072-01417 HOSE 4 C-02 Boom cylinder hose
43
Loose-supply items list related to swing circle grease piping
H
Assembly
6 07282-11048 CLAMP 4 A-08

7 01010-80612 BOLT 8 A-08
8 01602-20619 WASHER 8 A-08
9 21T-68-68260 TUBE 1 A-08
10 21T-68-68250 TUBE L.H 1 A-08
11 21T-68-68240 TUBE L.H 1 A-08
12 21T-68-68230 TUBE L.H 1 A-08
13 21T-68-68220 TUBE L.H 1 A-08
14 21T-68-68210 TUBE 1 A-08
15 21T-68-68160 TUBE R.H 1 A-08
16 21T-68-68170 TUBE R.H 1 A-08
17 21T-68-68180 TUBE R.H 1 A-08
18 21T-68-68190 TUBE R.H 1 A-08
22 21T-68-67460 CLAMP 2 A-08
23 01010-81035 BOLT 4 A-08
24 01643-31032 WASHER 4 A-08
25 207-70-11740 ELBOW 10 A-08
26 21T-68-67230 TUBE 1 A-08
30 201-62-28540 TEE 6 A-08 Grease piping around
swing circle (LINCOLN)
31 207-70-11730 NIPPLE 20 A-08
32 21T-68-67481 BRACKET 4 A-08
33 01010-81025 BOLT 8 A-08
34 01643-31032 WASHER 8 A-08
35 21T-68-67470 CLAMP 4 A-08
36 01010-81035 BOLT 8 A-08
37 01643-31032 WASHER 8 A-08
38 21T-68-67490 BRACKET 2 A-08
39 01010-81025 BOLT 4 A-08
40 01643-31032 WASHER 4 A-08
41 21T-68-67510 BLOCK 2 A-08
42 01010-81055 BOLT 4 A-08
43 01643-31032 WASHER 4 A-08
44 21T-68-67190 BRACKET 3 A-08
45 01010-80825 BOLT 3 A-08
46 01643-30823 WASHER 3 A-08
47 04435-50808 CLIP 3 A-08
48 01010-80820 BOLT 3 A-08
44
Assembly
49 01643-30823 WASHER 3 A-08

50 21T-68-67410 TUBE L.H 1 A-08
51 21T-68-67420 TUBE L.H 1 A-08
52 21T-68-67430 TUBE 2 A-08 Grease piping around
swing circle (LINCOLN)
53 21T-68-67570 TUBE R.H 1 A-08
54 21T-68-67560 TUBE R.H 1 A-08
55 21T-68-67390 TUBE 4 A-08
106 07282-11048 CLAMP 4 A-08

107 01010-80612 BOLT 8 A-08
108 01602-20619 WASHER 8 A-08
109 21T-68-67450 TUBE 1 A-08
110 21T-68-67310 TUBE L.H 1 A-08
111 21T-68-67320 TUBE L.H 1 A-08
112 21T-68-67330 TUBE L.H 1 A-08
113 21T-68-67340 TUBE L.H 1 A-08
114 21T-68-67440 TUBE 1 A-08
115 21T-68-67350 TUBE R.H 1 A-08
116 21T-68-67360 TUBE R.H 1 A-08
117 21T-68-67370 TUBE R.H 1 A-08
118 21T-68-67380 TUBE R.H 1 A-08
122 21T-68-67460 CLAMP 2 A-08
123 01010-81035 BOLT 4 A-08
124 01643-31032 WASHER 4 A-08 Grease piping around
125 207-70-11740 ELBOW 10 A-08 swing circle (NABCO)
126 21T-68-67230 TUBE 1 A-08
130 201-62-28540 TEE 6 A-08
131 207-70-11730 NIPPLE 20 A-08
132 21T-68-67481 BRACKET 4 A-08
133 01010-81025 BOLT 8 A-08
134 01643-31032 WASHER 8 A-08
135 21T-68-67470 CLAMP 4 A-08
136 01010-81035 BOLT 8 A-08
137 01643-31032 WASHER 8 A-08
138 21T-68-67490 BRACKET 2 A-08
139 01010-81025 BOLT 4 A-08
140 01643-31032 WASHER 4 A-08
141 21T-68-67510 BLOCK 2 A-08
142 01010-81055 BOLT 4 A-08
143 01643-31032 WASHER 4 A-08
45
Assembly
144 21T-68-67190 BRACKET 3 A-08

145 01010-80825 BOLT 3 A-08
146 01643-30823 WASHER 3 A-08
147 04435-50808 CLIP 3 A-08
148 01010-80820 BOLT 3 A-08
149 01643-30823 WASHER 3 A-08 Grease piping around
150 21T-68-67410 TUBE L.H 1 A-08 swing circle (NABCO)
151 21T-68-67420 TUBE L.H 1 A-08
152 21T-68-67430 TUBE 2 A-08
153 21T-68-67570 TUBE R.H 1 A-08
154 21T-68-67560 TUBE R.H 1 A-08
155 21T-68-67390 TUBE 4 A-08
46
Loose-supply items list related to ORBCOMM
J
Assembly
For ORBCOMM antenna
1 362-43-18780 CLIP 3 A-41 line
2 7826-20-9200 ANTENNA 1 A-41 ORBCOMM antenna line
3 7826-20-9300 CABLE 1 A-41 Antenna cable
4 21T-06-64491 BRACKET 1 A-41 Antenna bracket
5 01024-81016 BOLT 2 A-41 For clamping cable
47
Loose-supply items list related to head guard
K
Assembly
1 21T-956-7111 GUARD 1 A-40 Head guard

2 01010-81260 BOLT 8 A-40
For installation of head
3 01010-81225 BOLT 4 A-40 guard
4 01643-31232 WASHER 12 A-40
5 209-00-62160 PLATE 1 A-40 Safety plate
6 04418-13060 SCREW 4 A-40 For installation of plate
48
Loose-supply items list related to
left-hand catwalk and power-assisted ladder
P
Assembly
Power-assisted ladder sub-
1 X21-******* LADDER ASS’Y 1 L-01 assembly
2 01010-81240 BOLT 8 L-01 For installation of power-
assisted ladder sub-assem-
3 175-54-34170 WASHER 8 L-01 bly
Side panel of landing of
4 21T-54-69553 BRACKET 1 L-01 ladder (Front)
For installation of side
5 01024-81225 BOLT 3 L-01 panel of landing
Side panel of landing of
6 21T-54-69543 BRACKET 1 L-01 ladder (Rear)
7 01024-81225 BOLT 3 L-01 For installation of side
8 01024-81225 BOLT 8 L-01 panel of landing
9 21T-54-69460 FRAME 1 L-01 Left-hand catwalk
10 01010-81645 BOLT 29 L-01
11 01643-31645 WASHER 29 L-01 For installation of left-hand
12 01010-81235 BOLT 16 L-01 catwalk
13 175-54-34170 WASHER 16 L-01
14 08037-03614 GROMMET 2 L-01 For ladder wiring harness
15 21T-54-66160 CHAIN 1 L-01 Ladder lowering chain
16 01024-81020 BOLT 2 L-01 For installation of ladder

lowering chain
17 21T-04-64360 CONTROL CABLE 1 L-01 Unlocking cable
18 04434-51212 CLIP 2 L-01 For clamping unlocking
19 01024-81220 BOLT 2 L-01 cable
20 04205-10620 PIN 1 L-01 Cable connecting pin
21 04050-11612 COTTER PIN 1 L-01 For cable connecting pin
22 21T-54-66362 BRACKET 1 L-01 Unlocking lever
Fulcrum bearing of unlock-
23 06124-01616 BEARING 1 L-01 ing lever
24 21T-54-66381 CHAIN 1 L-01 Unlocking chain
25 01024-81020 BOLT 2 L-01 For installation of unlock-

ing chain
26 04205-11645 PIN 1 L-01 Fulcrum pin of unlocking
lever
27 04050-14028 COTTER PIN 1 L-01 For fulcrum pin of unlock-
ing lever
28 21T-54-66421 BRACKET 1 L-01 Cable bracket
For installation of cable
29 01024-81225 BOLT 2 L-01 bracket
30 21T-54-66331 BRACKET 1 L-01 Lock bar
31 170-33-13370 SPRING 1 L-01 For lock bar
49
Assembly
32 21T-54-66430 BRACKET 1 L-01 Lock bar bracket
33 01024-81220 BOLT 2 L-01 For installation of lock bar

bracket
34 04210-21664 YOKE 1 L-01
35 195-49-13840 NUT 1 L-01
For connection of lock bar
36 04205-11645 PIN 1 L-01
37 04050-14028 COTTER PIN 1 L-01
38 21T-54-66391 HAND RAIL 1 L-01 Ladder front small handrail
39 01024-81235 BOLT 4 L-01
40 21T-54-75560 CLAMP 1 L-01 For connection of ladder
41 21T-54-75570 CLAMP 1 L-01 front small handrail
42 01024-81230 BOLT 1 L-01
43 21T-54-69560 HAND RAIL 1 L-01 Ladder rear handrail
44 01010-81230 BOLT 8 L-01 For installation of ladder
45 175-54-34170 WASHER 8 L-01 rear handrail
46 21T-06-64280 WIRING HARNESS 1 L-01 Extension wiring harness
47 01024-81220 BOLT 9 L-01
48 04434-51012 CLIP 8 L-01 For clamping wiring har-
ness
49 08193-20012 CLIP 1 L-01
50 21T-54-66440 BRACKET 1 L-01 Unlocking lever bracket

ing lever bracket
52 04211-20634 YOKE 1 L-01 For installation of unlock-
ing lever bracket
53 21T-54-66450 BRACKET 1 L-01 Unlocking chain offset
bracket
ing chain offset bracket
50
Other loose-supply items list
Z
Assembly
1 209-60-31130 ELEMENT 6 F For flushing in field

2 21T-60-13730 PLATE 6 F
3 07000-15180 O-Ring 6 F
4 07063-51210 FILETER 6 F For installation after flush-

ing
5 04530-13045 EYE-BOLT 2 F
6 04530-13655 EYE-BOLT 2 F
7 04530-14265 EYE-BOLT 1 F
8 07287-01415 HOSE 2 F
9 21T-98-11490 COUPLING A. 1 F
10 21T-98-71160 BRACKET 4 F
11 07285-00180 CLIP 2 F
51
52
53
54
55
56
57
58
(Half day)
assembled
Units to be
1 Connection of track frame assem- 1 Assembly of left and right catwalks 1 Assembly of bucket assembly
bly and axle 2 Installation of counterweight 2 Installation of bucket cylinder link
2 Assembly of travel piping 3 Installation of operator's cab assembly 3 Assembly of work equipment piping
3 Filling swing circle grease bath (for high cab, operator's cab + (7) (between bucket and arm) Checking performance
with grease assembly) 4 Bleeding air (including completion check and
4 Assembly of revolving frame as- 4 Wiring, piping related to operator's cab 5 Adjustment of microcomputer repair of paintwork)
sembly 5 Assembly of boom, arm assembly s Adjustment of track
5 Assembly of swivel travel piping 6 Work equipment piping, piping bet- s Flushing hydraulic
6 Assembly of swing circle grease ween revolving frame and boom circuit
Assembly procedure
piping s Checking oil and water levels
s Bleeding air
Assembly procedure, assembly equipment and schedule
Kit layout diagram
Use wood blocks so that the underside of the

revolving frame assembly will be at least 700 mm
above the ground level (See view X). Place the
front wood block so that it will not be an obstacle
to removal of the front transportation jig.
59
Tools and equipment to be used
61
62
(2) Equipment and tools for local assembly
No. Part name Specification Q’ty Remarks

1 Air compressor 7.0 kg/cm3 class 1
2 Crane truck For 45-ton load 2 Including operator
KW10P (For M10) 2
KW12PI (For M12) 2
KW14PI (For M14) 1
3 Pneumatic impact wrench KW20P (For M16) 1
KW20PI (For M20) 1
KW38G (For M24) 1
KW45FG 1
4 16-time wrench 450 kgm 1 With reaction receiver
5 Socket for 16-time wrench 38To55 mm, 60 mm, 65 mm, 70 mm 1 each
6 Socket adapter 1 12 1 3
4 (inch) 1 each
Swing circle Counter weight Axle
7 Spline socket 55 mm 65 mm 70 mm 1 each
8 Socket wrench set 200M (ISO) 1
9 Torque wrench 36 kgm, 72 kgm 1 each
70 mm, 55 mm, 50 mm, 27 mm 1 each
10 Spanner 46 mm, 41 mm, 36 mm, 32 mm, 30 mm,
2 each
24 mm, 22 mm
11 Ring wrench 60 mm, 70 mm 1 each
o
12 Pipe For retightening 50 o/ x 2 m 1 each
30 / x 1 m
13 Hammer 10 lb 2
14 Bar 1 m, 1.5 m 2, 1
15 Hammer 4 lb 2
Abrasive wheel diameter
16 Pneumatic grinder 180 mm, 100 mm 1 each
17 Pneumatic pencil grinder NTB-48 1
GWP-400
18 Water pump pliers 1 each
GWP-300
Input: 19 mm square
19 4-time wrench Output: 25 mm square 25 mm – 60 mm square socket 1 each
t 2 mm, 3 mm, 4 mm, 5 mm, 6 mm, 8 mm,
20 Hexagonal wrench set 1
10 mm, 12 mm
21 Standard tool set 3
12 o/ x 5 m 4
16 o/ x 2 m 4
20 o/ x 5 m 4
22 Wire
20 o/ x 3 m 2
30 o/ x 3 m 4
30 o/ x 5 m 4
25 mm wide, 3 m long 2
23 Nylon sling
50 mm wide, 3 m long 2
SD22, SC55 4, 2 See following page.
24 Shackle SC40, SC34 4 each See following page.
SC30, SC14 4 each See following page.
SPK-24, 32, 36 1 each
25 Set wrench Width across flats:
1 each
41 mm, 46 mm (Made-to-order)
26 Brush and cleaning tools Brush, paper, etc. —
27 Pad for wire Must be made of metal 4
M42-P3 2 See following page.
28 Eyebolt
M30-P3 2
63
No. Part name Specification Q’ty Remarks
6-ton 2
3-ton 1
29 Lever block
1.5-ton 2
3/4-ton 1
30 Pin (Hard) 50 o/ x 400 mm 2
31 Air hose 4, 6 50 m each
32 Air coupler 4, 6 for hose 5 set
Height H = 3 m 1
33 Lift work stand H = 1.5 m 2
H = 0.9 m 1
34 Special axle stand H = 470 mm 2
50-ton 3
35 Hydraulic jack
10-ton 1
36 Lighting equipment (Matched to power source) 1 set 500 W, 5 pieces
37 Oil receiver Large, medium, small 2 each
Natural yellow 12
Black gray 12
38 Repair paint
For touching up machined
Rust-preventive clear 2
surface
39 Protective goggles For gas work and grinding 2 each
40 Adhesive For synthetic rubber (in tube) 1
SAE10W-CD 1,000 l For hydraulic tank
41 Oil
SAE30-CD 60 l
42 Diesel fuel oil 600 l For refilling
2
43 Welding rod LB26 or equivalent (40 kg/mm class) 40 kg
44 Cleaning oil 200 l
20-liter can (Pail can) 7
Grease G2-LI
45 Komatsu cartridge 5 Including hand pump
Grease MOBIL TAC81S 20-liter can (Pail can) 3
Leather gloves, cotton gloves, rainwear (L)
46 Protective gears
Safety rope for work at high place 3 set
5 pieces,
47 Safety rope Keep-out notice, rope
50 m
64
66
67
68
Components to be assembled in harbor
Components to be assembled
Component
COOLING SUB ASS’Y
FUEL TANK SUB ASS’Y
HYDRAULIC TANK SUB ASS’Y
SUCTION TUBE SUB ASS’Y
OIL COOLER LINE
SWING MACHINERY SUB ASS’Y
HOOD (SMALL) SUB ASS’Y
RIGHT SIDE DOOR SUB ASS’Y
RIGHT SIDE DUCT SUB ASS’Y
PARTITION COVER
MUFFLER COVER
BATTERY CASE SUB ASS’Y (1/3) (*For only +55: specification)
Precautions
(1) After checking that the engine starts, disconnect the battery cables from the battery.
Disconnect cables and insulate

the cable terminals and battery
terminals securely with tapes, etc.
(2) Do not connect the controllers to which wiring harnesses are not connected (VHMS
controller and ORBCOMM controller) in the harbor.
69
COOLING SUB ASS’Y
̪ Installation of cooling sub-assembly to the body
Cooling sub-assembly
Installed
temporarily to
right deck of
body
70
# JOIN HOSE FROM RADIATOR UPPER TANK TO PORT WITHOUT DENT ON SUB TANK.
# AFTER INSTALLING FAN V-BELT. SCREW STOPPER

BOLT TO BE IN CONTACT WITH TENSIONER
AND TIGHTEN 2 REVOLUTIONS FURTHERMORE
AND TIGHTEN LOCK NUT.
# ADJUST FAN PULLEY ALIGNMENT SO THAT GAP

BETWEEN NO.1 GROOVE OF FAN PULLEY AND
NO.1 GROOVE OF ENGINE PULLEY (CRANK
PULLEY AND TENSION PULLEY) TO BE WITHIN
3mm.
# INSERT LENGTH OF AFTER COOLER AIR HOSE
TO BE 50mm MIN.
71
COOLING SUB ASS’Y
Installation of fan belts
Fan belts are hung on

fan pulley of cooling
sub-assembly.
72
COOLING SUB ASS’Y (WATER HOSE)
q Connection of water hoses
Engine side
For water hose

(Upper)
3 9 0 0.5Nm {90 0 5kgcm}
For water hose (Lower) For bleeding air

3 9 0 0.5Nm {90 0 5kgcm} 3 3.4 0 0.5Nm {35 0 5kgcm}
73
Loose-supply items list for cooling sub-assembly
COOLING SUB ASS’Y (WATER HOSE)

Assembly
2 07289-00095 CLAMP 2
7 07281-00197 CLAMP 2
10 07289-00080 CLAMP 2
74
COOLING SUB ASS’Y (AIR HOSE)
q Connection of air hoses
Engine side of body
For air hose (Inlet)
For air hose (Outlet)
e Tightening torque of parts marked with .

9.8 0 0.5Nm {100 0 5kgcm}
Revolving frame e Check tightening torque of all parts marked with .

side of body
e Fit every air hose by 50 mm or more.
75
Loose-supply items list for cooling sub-assembly
COOLING SUB ASS’Y (AIR HOSE)

Assembly
17 6112-11-4840 CLAMP 4
19 6212-11-4840 CLAMP 4
76
COOLING SUB ASS’Y (SUB TANK HOSE)
̪ Connection of sub-tank hoses
Body side
Connection
Clips, bolts, and

washers marked
with # are installed
temporarily to engine
hood on body side.
77
COOLING SUB ASS’Y (TENSION PULLY LUBRICATION HOSE)
̪ Connection of tension pulley lubrication hose
%QQNKPIUWDCUUGODN[
%QPPGEVVGPUKQPRWNNG[
NWDTKECVKQPJQUGVQGPIKPGUKFG
78
COOLING SUB ASS’Y (TENSION PULLY LUBRICATION HOSE)
̪ Connection of tension pulley lubrication hose
Connect tension pulley

lubrication hose to
engine side.
Part disconnected
when 32t is Air conditioner
disassembled compressor bracket
(Installed to rear
engine)
79
FUEL TANK SUB ASS’Y
̪ Installation of fuel tank
Installed temporarily
to revolving frame
side of body
Do not install
counterweight in harbor.
80
FUEL TANK SUB ASS’Y (FUEL HOSE)
̪ Connection of fuel hoses
Connection
Body side
81
Connection
Body side
82
Connect fuel hoses to parts marked with # (4 places).
83
̪ Connection of fuel emergency cut line
Connect level gauge

wiring harness.
Body side Connection
84
FUEL TANK SUB ASS’Y (FUEL EMAGENCY CUT LINE)
̪ Connection of fuel emergency cut line
Body side
Connection
85
̪ Installation of hydraulic tank
Body side
86
Loose-supply items list for hydraulic tank sub-assembly

Assembly
8 01011-83010 BOLT 7
9 208-30-11971 SPACER 7
87
Connection
88
Connection
89
90
Loose-supply items list for hydraulic tank sub-assembly

Assembly
1 175-54-38531 CAP 1
91
̪ Connection of suction tubes
Body side
Suction tube
sub-assembly
Loose-supply suction
flange mounting bolt
92
Loose-supply items list for suction tube sub-assembly

Assembly
2 01010-81235 BOLT 8
3 01643-31232 WASHER 8
93
OIL COOLER LINE
̪ Connection of oil cooler line
Body side
Connection
94
Loose-supply items list for oil cooler sub-assembly
OIL COOLER LINE

Assembly
19 21T-62-64171 TUBE 1
20 01024-81240 BOLT 4
95
OIL COOLER LINE
Body side
Connection
Connection
Oil cooler tube bracket

sub-assembly
Connection
96
Loose-supply items list for oil cooler sub-assembly
OIL COOLER LINE

Assembly
18 21T-62-64180 TUBE 1
19 21T-62-64190 TUBE 1
20 01024-81240 BOLT 8
97
HYDRAULIC TANK SUB ASS’Y (RETURN LINE L. H)
̪ Connection of return line
Connection
Body side
98
HYDRAULIC TANK SUB ASS’Y (RETURN LINE R. H)
Connection
Body side
99
Swing machinery
(Rear) sub-assembly
̪ Installation of swing machinery
Swing machinery
(Front) sub-assembly
100
Loose-supply items list for swing machinery sub-assembly

Assembly
1 01024-81225 BOLT 3
5 01010-83090 BOLT 28
6 01643-33080 WASHER 28
101
SWING MACHINERY SUB ASS’Y (SWING LINE)
Connection
Swing machinery
(Rear) sub-assembly
Body side
Swing machinery
102
SWING MACHINERY SUB ASS’Y (BRAKE HOSE)
Swing machinery
(Rear) sub-assembly
Connection
Connection
Swing machinery
103
Loose-supply items list for swing machinery sub-assembly
SWING MACHINERY SUB ASS’Y (BRAKE HOSE)

Assembly
13 21T-64-63180 HOSE, 1900MM 1

14 04434-51312 CLIP 1
104
SWING MACHINERY SUB ASS’Y (SOLENOID VALVE LINES)
Connection
105
̪ Installation of small hood
Small hood
sub-assembly
Body
106
Loose-supply items list for hood (small) sub-assembly

Assembly
19 01010-81230 BOLT 5
20 175-54-34170 WASHER 5
107
Radiator top fan net
108
Loose-supply items list for hood (small) sub-assembly

Assembly
40 21T-54-65411 NET 2
41 01024-81225 BOLT 16
109
̪ Installation of right side door
Fitting
adjustment
shim
Right side door

sub-assembly
to right deck on
body side
110
Loose-supply items list for right side door sub-assembly

Assembly
44 21T-54-65910 SHIM 3
45 21T-54-65920 SHIM 3
111
RIGHT SIDE DOOR SUB ASS’Y (BRACKET)
Installed
temporarily to
right side door
cover sub-
assembly
112
RIGHT SIDE DOOR SUB ASS’Y (BRACKET)

Assembly
13 21T-54-68630 BRACKET 1
14 01024-81230 BOLT 6
16 21T-54-73321 BRACKET 1
17 01024-81230 BOLT 6
113
RIGHT SIDE DOOR SUB ASS’Y (MACHINE COVER)
114
RIGHT SIDE DOOR SUB ASS’Y (MACHINE COVER)

Assembly
7 21T-54-67181 COVER 1
8 01024-81230 BOLT 9
115
̪ Installation of ducts
Duct sub-assembly
to right deck on
body side
116
RIGHT SIDE COVER
Oil cooler tube bracket

sub-assembly Installed temporarily
to right deck
117
Loose-supply items list for right side cover sub-assembly
RIGHT SIDE COVER

Assembly
19 01024-81230 BOLT 4
21 21T-54-64110 COVER 1
118
̪ Installation of parts around right duct
119
Loose-supply items list for right side duct sub-assembly

Assembly
24 21T-54-64340 BRACKET 1
27 21T-54-64351 BRACKET 1
28 01024-81230 BOLT 8
30 21T-54-64360 BRACKET 5
31 01010-81230 BOLT 20
32 175-54-34170 WASHER 20
120
PARTITION COVER
121
Loose-supply items list for partition cover sub-assembly
PARTITION COVER
Assembly
24 21T-54-64450 COVER 1
25 01024-81230 BOLT 11
122
MUFFLER COVER
̪ Installation of muffler cover
Installed temporarily to muffler

to engine hood
on body side
Muffler cover
To be installed to engine hood.
Body side
Body side
123
Loose-supply items list for muffler cover sub-assembly
MUFFLER COVER
Assembly
20 21T-54-64311 COVER 2
124
BATTERY CASE SUB ASS’Y (1/3)
̪ Installation of battery case

sub-assembly
Do not install steps and

handrails in harbor.
Battery case
sub-assembly
Body side
125
Fog lamp Case A and mounting

wiring harness bolts are installed
(Optional) temporarily to front side
of right deck.
Wiring harness
to head lamp
126
Fog lamp
wiring harness
(Optional)
Since this is not used Hydraulic Tank
for B40, bind it to
other wiring harnesses.
Wiring harness to fog lamp
127
Loose-supply items list for battery case sub-assembly
BATTERY CASE SUB ASS’Y

Assembly
1 04434-52112 CLIP 2
2 01024-81025 BOLT 2
3 04434-52312 CLIP 1
4 04434-51012 CLIP 1
5 01643-21232 WASHER 1
6 04434-51012 CLIP 3
7 01024-81225 BOLT 3
128
Procedure for slinging battery assembly
Keep cover open.
(Note)
When slinging the battery
case assembly, be sure to
use the taps on the frame
side as shown in this
figure, since the battery
case is not strong.
Frame
From body
1. Install eyebolts (M12) to 4 places to sling the battery case assembly.

2. Apply cloths to the battery case so that the battery case will not be
damaged.
129
A. ASSEMBLY OF CHASSIS
131
A-1: Assembly of track frame and axle
Width across flats
Tightening torque
450 – 500kgm
Axle
Track Frame
132
A-1: Assembly of track frame and axle (2/3)
133
A-1: Assembly of track frame and axle (3/3)
134
A-2: Travel motor piping
135
A-2: Travel motor piping (2/2)
136
A-3: Idler cushion cylinder piping
137
A-4: Installation of travel motor guard
138
A-4: Installation of travel motor guard (2/2)
A-4: (2/2)
Track frame under cover
Parts sent individually

No. Part No. Q'ty
C184 21T-30-71251 2
C185 21T-30-18120 5
C186 01010-82465 44
C187 01643-32460 44
C188 21T-30-71280 2
C189 21T-30-71270 2
C190 01010-82485 12
C191 01643-32460 12
Precautions Tools and equipment required

Name Q'ty Name Q'ty
Others
139
A-5: Filling swing circle with grease
(Note 1) (Note 2)
G2-L1
Apply LG-6 to swing circle

Supply grease near gear side of outer race
swing circle gear. mounting bolts.
140
A-6: Assembly of revolving frame assembly and axle assembly
141
A-6: Assembly of revolving frame assembly and axle assembly (2/2)
142
A-7: Swivel travel piping
143
A-7: Swivel travel piping (Drain hose) (2/2)
A-7: Swivel travel piping (Drain hose) (2/2)
Connection of swivel drain hose
Connection

Name Q'ty Name Q'ty
41 mm Spanner 1
Others
144
A-8: Swing circle grease tube piping
A-8: Swing circle grease tube piping (1/4)
LINCOLN

No. Part No. Q'ty
25 207-70-11740 4
50 21T-68-67410 1
51 21T-68-67420 1
55 21T-68-67390 4

Name Q'ty Name Q'ty
14 mm Spanner 1
Others
145
A-8: Swing circle grease tube piping (2/4) L
LINCOLN

No. Part No. Q'ty
9 21T-68-68260 1
10 21T-68-68250 1
11 21T-68-68240 1
12 21T-68-68230 1
13 21T-68-68220 1
14 21T-68-68210 1
15 21T-68-68160 1
16 21T-68-68170 1
17 21T-68-68180 1
18 21T-68-68190 1
22 21T-68-67460 2
23 01010-81035 4
24 01643-31032 4
25 207-70-11740 2

Name Q'ty Name Q'ty
14 mm Spanner 1
Others
146
LINCOLN

No. Part No. Q'ty
6 07282-11048 8
7 01010-80612 16
8 01602-20619 16
25 207-70-11740 2
26 21T-68-67230 1
30 201-62-28540 4
31 207-70-11730 16

Name Q'ty Name Q'ty
14 mm Spanner 1
Others
147
LINCOLN

No. Part No. Q'ty
30 201-02-28540 2
31 207-70-11730 4
32 21T-68-67481 4
33 01010-81025 8
34 01643-31032 8
35 21T-68-67470 4
36 01010-81035 8
37 01643-31032 8
38 21T-68-67490 2
39 01010-81025 4
40 01643-31032 4
41 21T-68-67510 2
42 01010-81055 4
43 01643-31032 4
44 21T-68-67190 3
45 01010-80825 3
46 01643-30823 3
47 04435-50808 3
48 01010-80820 3
49 01643-30823 3
52 21T-68-67430 2
53 21T-68-67570 1
54 21T-68-67560 1

Name Q'ty Name Q'ty
14 mm Spanner 1
Others
148
A-8: Swing circle grease tube piping (1/4) N
NABCO

No. Part No. Q'ty
125 207-70-11740 4
132 21T-68-67481 4
133 01010-81025 8
134 01643-31032 8
135 21T-68-67470 4
136 01010-08135 8
137 01643-31032 8
150 21T-68-67410 1
151 21T-68-67420 1
155 21T-68-67390 4

Name Q'ty Name Q'ty
14 mm Spanner 1
Others
149
NABCO

No. Part No. Q'ty
16 07282-11048 5
17 01010-80612 10
18 01642-20619 10
19 21T-68-67450 1
110 21T-68-67310 1
111 21T-68-67320 1
112 21T-68-67330 1
113 21T-68-67340 1
114 21T-68-67440 1
115 21T-68-67350 1
116 21T-68-67360 1
117 21T-68-67370 1
118 21T-68-67380 1
122 21T-68-67460 2
123 01010-81025 4
124 01643-31032 4

Name Q'ty Name Q'ty
14 mm Spanner 1
Others
150
NABCO

No. Part No. Q'ty
125 207-70-11740 4
126 21T-68-67230 1
130 201-62-28540 4
131 207-70-11730 16

Name Q'ty Name Q'ty
14 mm Spanner 1
Others
151
NABCO

No. Part No. Q'ty
130 201-02-28540 2
131 207-70-11730 4
138 21T-68-67490 2
139 01010-81025 4
140 01643-31032 4
141 21T-68-67510 2
142 01010-81055 4
143 01643-31032 4
144 21T-68-67190 3
145 01010-80825 3
146 01643-30823 3
147 04435-50808 3
148 01010-80820 3
149 01643-30823 3
152 21T-68-67430 2
153 21T-68-67570 1
154 21T-68-67560 1

Name Q'ty Name Q'ty
14 mm Spanner 1
Others
152
A-9: Installation of left and right ladders
153
A-10: Installation of left catwalk (STD)
154
A-11: Installation of right catwalk
155
A-12: Installation of catwalk, handrail beside operator’s cab
156
A-13: Installation of operator’s cab ladder
157
A-14: Installation of operator’s cab handrail
158
A-16: Installation of handrail at rear of operator’s cab
159
A-18: Operator’s cab front frame, handrail
160
A-20: Right deck handrail
A-1:

No. Part No. Q'ty

Name Q'ty Name Q'ty
Others
161
A-21: Installation of ladder on top of hydraulic tank
A-1:

No. Part No. Q'ty
(q1)
(q2)
(q1) STD Specification

(q2) +55: Specification

Name Q'ty Name Q'ty
Others
162
A-22: Installation of counterweight
Counterweight 20,900 kg

No. Part No. Q'ty
C33 21T-46-64240 12
C34 209-46-11210 12

Name Q'ty Name Q'ty
KW45FG Impact wrench 1 SC40 about sheckle 2
Spline socket 65 1
Power wrench (X 16) 1
Ratchet handle 1

38 -- 65 mm socket 1
36 kgm Torque wrench 1
φ30, 5 m Wire 2
Others
163
A-23: Installation of counterweight ladders (left and right)
A-1:

No. Part No. Q'ty
C296 21T-04-64320 1
C297 21T-04-64330 1
C298 01024-81225 4

Name Q'ty Name Q'ty
Others
164
A-24: Installation of handrail on top of fuel tank, counterweight
165
A-25: Installation of fuel tank vibvration stopper bracket
166
A-26: Installation of grease reel, hose, bracket
167
A-27: Installation of left cab base assembly
A-1: (1/5)
Right floor frame

(set on revolving
frame assembly)
Left floor frame

Control stand
(set on left cab
base assembly)
Adjust installation. Parts sent individually

(See precautions.) No. Part No. Q'ty
C68 01010-81235 34
C69 175-54-34170 34
A28 01010-81230 6
A29 01010-81235 8
A30 01643-31232 14
A115 21T-54-65651 1
A116 21T-54-65651 1
Left, cab base assembly

Name Q'ty Name Q'ty
Adjust installation so that
the control stand will
not interfere with its
rear cover when it is
slid (on both sides). Secure
clearance.
Others
168
A-27: Installation of left cab base assembly (2/5)
169
A-1: (3/5)
Seat Belt

No. Part No. Q'ty
A15 20Y-57-21260 1
A16 20Y-57-21270 1
A17 01024-01235 4
A19 09409-10001 1
A20 09409-20000 2
A21 09409-00001 2
A114 01641-21223 2
A66 09049-00002 2
A67 09049-00003 2
A68 01024-D1045 2

Name Q'ty Name Q'ty
Others
170
A-1: (4/5)
Sub sheat assembly

No. Part No. Q'ty
A75 20M-57-71202 1
A76 21T-57-67111 1
A77 20N-57-21211 1
A78 01010-80820 4
A79 01643-30823 4
A80 01580-10806 4
A81 21T-57-67130 1
A82 21T-57-67120 1
A83 01010-80820 4
A84 01643-30823 4
A85 14X-911-7741 4
A86 09495-40000 1
A87 01010-80616 6
A88 01643-30623 6
A111 01024-D1230 2

Name Q'ty Name Q'ty
Others
171
A-1: (5/5)
Defroster

No. Part No. Q'ty
A97 21T-43-67343 1
A98 142-979-3221 4
A99 01024-D1025 3
A101 08037-02512 1
A102 08037-01610 1
A103 01024-D1016 1

Name Q'ty Name Q'ty
Others
172
A-28: Installation of operator’s cab assembly
A-1:

No. Part No. Q'ty
A31 01010-81470 16
A32 01643-31445 16
A89 X210544722 1
A90 21T-43-67381 1
A91 20Y-979-2160 2
A92 20Y-54-14750 10
A93 01643-70823 10
A94 21T-43-67392 1

Name Q'ty Name Q'ty
Others
173
A-29: Installation of wiper motor cover inside operator’s cab
A-1:
Install as shown in
diagram on left.
Bolts to mount
on cab

No. Part No. Q'ty
A13 21T-43-67411 1
A14 21T-43-67650 1
A112 01024-D1230 4
: Being shipped in assembled state to the cab base.

Name Q'ty Name Q'ty
Others
174
A-30: Installation of upper handrail of left-hand door cover
A-30: Installation of upper handrail of left-hand door cover (1/2)

No. Part No. Q'ty

Name Q'ty Name Q'ty
KWI2P Impact wrench 1
19 mm Socket 1
150 mm Extension 1
φ12, 5m Wire 4
Others
175
A-30: Installation of upper handrail of left-hand door cover (2/2)

No. Part No. Q'ty

Name Q'ty Name Q'ty
Others
176
A-31: Installation above the RH door and above the hydraulic oil tank
177
A-32: Emergency stop switch, Fuel cut lever
06
178
A-32: Emergency stop switch, Fuel cuttiing (2/2)
179
A-33: Handrail above the radiator
A-33: Handrail above the radiator

No. Part No. Q'ty
162 21T-54-69511 1
163 01010-81230 12
164 175-54-34170 12
165 21T-54-64220 1
166 01010-81230 5
167 175-54-34170 5

Name Q'ty Name Q'ty
Others
180
A-34: Connection of hydraulic piping operator’s cab assembly
181
A-34: Connection of hydraulic piping operator’s cab assembly (2/5)
182
A-34: Connection of hydraulic piping operator’s cab assembly (PPC pilot piping) (3/5)
A-34: Connection of hydraulic piping operator's cab assembly (PPC pilot piping) (3/5)
(Connection circut for PPC Piping)

No. Part No. Q'ty

Name Q'ty Name Q'ty
Others
183
A-34: Connection of hydraulic piping operator's cab assembly (4/5)
Adjustment of travel PPC control linkage

1. Adjust the linkage bar so that the travel lever will be in neutral (the lever base axis will be
directed up vertically) when the travel PPC valve is in neutral. Take care that the levers on both
sides will be in the same position. At this time, adjust the yoke of the linkage marked with *
so that the clearance between the pin and oblong hole will be 0 - 0.5 mm when the PPC
valve is in neutral. Adjust stopper bolts "a" and "b" according to the following procedure.
1) Move the pedal or lever to the forward travel stroke end and press stopper bolt "a" against
the lever.
2) Return the lever to the neutral position, and then return the bolts about 1/3 turn and secure
it with the nut.
3) Adjust bolt "b" on the reverse travel side similarly.
(See 5/5.)
Connection and adjustment of safety lock cable

1. Adjust installation of the safety lock cable according to the following procedure.
1) Set the selector valve in the free position and install the cable on the valve side to the valve.
2) Bring the lock lever in contact with the stopper and return its end about 14 mm, and then
install the cable. (The clearance between the lock lever and stopper is 1.5 - 2.0 mm under
this condition.)
2. Adjust the safety lock lever according to the following procedure.
1) Adjust the push-pull cable, yoke, and nut so that the distance
between the lock lever end and floor top (without the floor
mat) will be about 115 mm when the spool of the safety Parts sent individually
lock valve is pulled out (to the locking position). No. Part No. Q'ty
2) Tighten the nut so that the clearance at the bolt tip will be
1.5 - 2.0 mm when the lever is raised and the spool of the
lock valve is pushed in by 15 mm (to the stroke end).
(See 5/5.)

Name Q'ty Name Q'ty
Others
184
A-34: Connection of hydraulic piping operator's cab assembly (5/5)
Free
Lock
Directed up vertically
in neutral

No. Part No.
- 2.0
: 1.5
ance
Clear

Name Q'ty Name Q'ty
Others
185
A-35: Connection of window washer hose of operator’s cab assembly
186
A-36: Connection of air piping of left cab assembly
A-36: Connection of air piping of left cab base assembly
Air hose
Sleeve Sleeve nut
Width across flats: 17

Tightening torque: 0.70 - 1.00 kgm
Connect hose at this position.

Horn valve

No. Part No. Q'ty
Clips, bolts, and washers at places marked with are

installed to cab base assembly temporarily

Name Q'ty Name Q'ty
Others
187
A-37: Connection of grease piping operator’s cab assembly
A-37: Connection of grease piping of operation's cab assembly (1/4)
Connection of hydraulic piping for grease pump

Hydraulic pump
Filter (Cab base assembly)
To hydraulic tank
Connect hose
at this position.
From pump

No. Part No. Q'ty
Grease pump
(Cab base assembly)
Clips marked with : Installed to cab base assembly temporarily

Clips marked with : Installed to body temporarily

Name Q'ty Name Q'ty
Others
188
A-37: Connection of grease piping operator’s cab assembly (2/4)
Connection of grease piping Hydraulic pump

Connect hose
at this position.
To auto grease distributor
To grease gun
Pressure switch
(Cab base assembly)
Connect hose
at this position.
Pressure switch Connect hose

(Cab base assembly) at this position.

No. Part No. Q'ty


Name Q'ty Name Q'ty
Others
189
Connection of grease pump wiring harness

Hydraulic pump
Body side
Cab base
assembly side
Connect hose
at this position.
No. Part No. Q'ty

Name Q'ty Name Q'ty
Others
190

Connection of grease piping
To auto grease distributor Connect hose at

this position.
To grease gun
Pressure gauge
(Cab base assembly)
Connect hose From air tank

at this position.
Connect hose
at this position.

No. Part No. Q'ty
Air hose
Sleeve Sleeve nut

(07831-00612) (07832-00614)
Width across flats: 17 mm
Tightening torque: 0.70 - 1.00 kgm


Name Q'ty Name Q'ty
Others
191
A-38: Connection of wiring harness in cab base
A-38: Connection of wiring harness in cab base
Wiring harness (Washer fluid tank, working lamp, CAB base lamp)
Window
Air Grease
Connect
VHMS controller wiring harness

Connect wiring harness of VHMS controller in cab base.

Name Q'ty Name Q'ty
Others
192
A-39: Piping of air conditioner discharge hose
A-39: Piping of air conditioner discharge hose (1/5)
(In left-hand CAB base)

Revolving frame
Pillar at left front of operator
Foot area/
Defroster
Tightening torque
6.8v0.49 kgm
Pillar at right
rear of operator

No. Part No. Q'ty
104 07281-01159 3
r
filte
air
sh
Fre
Rear air conditioner: View from above

Name Q'ty Name Q'ty
Do not pass air conditioner discharge
piping over fresh air filter of rear air KW12PI impact 1
conditioner unit. 19-mm socket 1
7-mm spanner 1
Install clamp marked with as
shown in figure. Flat-head screwdriver 1
150-mm extension 1
Others
193
Air conditioner discharge hose (Right-hand CAB base)
From rear air

conditioner (Front) Parts sent individually
No. Part No. Q'ty
From front air
conditioner (Rear) From rear A108 07281-01159 3
air conditioner (Rear) A107 21T-97H-6290 1
A106 21T-979-6280 1
A105 21T-979-6270 1

Name Q'ty Name Q'ty
Others
194
Air conditioner wiring harness (In left-hand CAB base)
Front air Rear air

conditioner conditioner

No. Part No. Q'ty
Connect
Connect

Name Q'ty Name Q'ty
Others
195
Inside air intake duct hose of air conditioner
In cab base

No. Part No. Q'ty
A110 21T-979-6710 2
Front
air A109 07281-02169 4
Rear
conditioner air
conditioner

Name Q'ty Name Q'ty
Others
196

Air conditioner piping
Connect
Connect
Connect

No. Part No. Q'ty

Name Q'ty Name Q'ty
Others
197
A-40: Installation of head guard
A-40: Installation of head guard

No. Part No. Q'ty
K1 21T-956-7111 1
K2 01010-81260 8
K3 01010-81225 4
K4 01643-31232 12
K5 209-00-62160 1
K6 04418-13060 4

Name Q'ty Name Q'ty
Others
198
A-41: Installation of Orbcom antenna
A-41: Installation of ORBCOMM antenna
Clamp this part and

stopper bracket
together.
4-claw clip
4 places
Clamp this part and

head guard together.

No. Part No. Q'ty
J1 362-43-18780 3
J2 7826-20-9200 1
J3 7826-20-9300 1
J4 21T-06-64491 1
J5 01024-81016 2

Name Q'ty Name Q'ty
Others
199
A-42: Connection of battery cable
A-42: Connection of battery cable
Connect battery cable

to battery terminals.

No. Part No. Q'ty

Name Q'ty Name Q'ty
Others
200
A-43: Start engine
A-43: Start engine (1/8)
1. Check before starting.

r Check cooling water level, add water
r Check level of oil in engine oil pan, add oil
r Check fuel level See operation manual.
r Check level of oil in hydraulic tank, add oil
r Check level of oil in PTO case, add oil
r Check level of oil in swing machinery case, add oil
r Check level of oil in final drive case, add oil
2. Check for oil leakage.
3. Bleed air from hydraulic pump.
4. Start engine (slow).
5. Bleed air from travel PPC line.
6. Bleed air from swing brake line.
7. Bleed air from swing motor.
8. Bleed air from travel motor.
9. Bleed air from HIC circuit, fill with pressurized oil, adjust track.
10. Stop the engine and refill hydraulic oil.

11. Check for oil leakage.
No. Part No. Q'ty

Name Q'ty Name Q'ty
Others
201
Air bleeding from hydraulic pump --- Execute before starting engine
s See the shop manual, TESTING AND ADJUSTING, Air bleeding from each component.

Name Q'ty Name Q'ty
10 mm Spanner 1
Others
202
Air bleeding from travel PPC circuit

Name Q'ty Name Q'ty
10 mm Spanner 1
Others
203
Air bleeding from swing holding brake circuit

Name Q'ty Name Q'ty
10 mm Spanner 1
Others
204
Air bleeding from travel and swing motors

Name Q'ty Name Q'ty
10 mm Spanner 1
Others
205
Bleeding air from HIC circuit and supplying hydraulic oil
Since the idler cushion of PC1800 uses hydraulic cylinders and its circuit is closed, bleed air from
the circuit.
(Bleed air to prevent seizure of the seals before moving the travel system.)
1. Release residual pressure in the HIC circuit.

a Loosen stop valves (4) and (5) gradually to release
the residual pressure in the circuit.
k If the stop valves are loosened quickly, high
pressure will be generated in the tank circuit.

Accordingly, loosen them gradually.
a After 1 minute, the residual pressure is released
completely.
2. Loosen grease valves (1) of the right and left grease

cylinders by 1 turn.
k Since the valve may jump out because of the high-
pressure grease, do not loosen it more than 1 turn.
3. Loosen air bleeding plugs (2) of the right and left

cylinders about 1 turn.
4. Loosen air bleeding plug (3) of the relief valve about 1

turn.
5. Run the engine at low idling for 2 – 3 minutes.
6. When oil containing no bubbles flows out of air

bleeding plugs (2), tighten stop valve (4).
7. While running the engine at low idling, move the right

travel lever to the forward position 2 – 3 times.
8. When oil containing no bubbles flows out of air

bleeding plugs (2) and (3), tighten air bleeding plugs
(2) and (3) and stop valve (5).
9. Tighten grease valves (1) of the right and left grease

cylinders and check that projection "a" of plunger (6)
is normal.
• Projection "a": 135 ± 5 mm
206
HIC circuit
Width across flats: 24

Tightening torque
6 – 9kgm
Bleeding air from

HIC circuit 2 places marked with
Air bleeding plug
Pressure
reducing valve
Right
travel
Stop valve
Forward
Swivel joint
Air bleeding plug
Stop valve Relief valve

Name Q'ty Name Q'ty
Others
207
Testing and adjusting track tension

Testing
1. Run the engine at low idling and move the
machine forward by the length of track on
ground and stop slowly.
2. Place a square bar (3) longer than the distance
between second roller (1) and third roller (2) on
the track.
3. Measure the maximum distance between the top
of the track and underside of the square bar.
e Standard distance
If distance "a" is 10 -- 30 mm, the track
tension is normal.
Adjusting
If the track tension is abnormal, adjust the HIC
cylinder and grease cylinder, referring to the
operation manual.

No. Part No. Q'ty

Name Q'ty Name Q'ty
Do not adjust the track tension by only
supplying grease to the grease cylinder
without adjusting it with the HIC
cylinder. If it is adjusted so, excessive
loads may be applied to the
undercarriage to breakage.
Others
208
A-44: Final tightening of swing circle mounting bolts
A-44: Final tightening of swing circle mounting bolts
In assembly procedure No.A-6, only 6 of the 60 mountig bolts for the revolving frame and swing
circle were tightened fully. The remaining 54 bolts were tightened partially, so tighten these
remaining 54 bolts.
[Procedure]
1) Start the engine. (Follow the procedure given in assembly procedure A-43)
2) Swing the upper structure and tighten the bolts when they come to one of the places
marked (54 bolts)

No. Part No. Q'ty

Name Q'ty Name Q'ty
KW45FG Impact wrench 1
55 mm spline socket 1
Others
209
4: Final tightening of swing circle mounting bolts
210
L-1: Installation of left-hand catwalk and power-assisted ladder
L-1: Installation of left-hand catwalk and power-assisted ladder (1/3)
Parts sent individually Parts sent individually

No. Part No. Q'ty No. Part No. Q'ty
P1 X21******* 1 P13 175-54-34170 16
P2 01010-81240 8 P15 21T-54-66160 1
P3 175-54-34170 8 P16 01024-81020 2
P4 21T-54-69553 1 P38 21T-54-66391 1
P5 01024-81225 3 P39 01024-81235 4
P6 21T-54-69543 1 P40 21T-54-75560 1
P7 01024-81225 3 P41 21T-54-75570 1
P8 01024-81225 8 P42 01024-81230 1
P9 21T-54-69460 1 P43 21T-54-69560 1
P10 01010-81645 29 P44 01010-81230 8
P11 01643-31645 29 P45 175-54-34170 8
P12 01010-81235 16
Name Q'ty Name Q'ty
Others
211
Parts sent individually Parts sent individually Parts sent individually

No. Part No. Q'ty No. Part No. Q'ty No. Part No. Q'ty
P14 08037-03614 1 P25 01024-81020 2 P34 04210-21664 1
P17 21T-04-64360 1 P26 04205-11645 1 P35 195-49-13840 1
P18 04434-51212 2 P27 04050-14028 1 P36 04205-11645 1
P19 01024-81220 2 P28 21T-54-66421 1 P37 04050-14028 1
P20 04205-10620 1 P29 01024-81225 2 P50 21T-54-66440 1
P21 04050-11612 1 P30 21T-54-66331 1 P51 01024-81230 2
P22 21T-54-66362 1 P31 170-33-13370 1 P52 04211-20634 1
P23 06124-01616 1 P32 21T-54-66430 1 P53 21T-54-66450 1
P24 21T-54-66381 1 P33 01024-81220 2 P54 01024-81025 2
Name Q'ty Name Q'ty
Others
212
Ladder
Detail A
Detail B
To main harness

No. Part No. Q'ty
P14 08037-03614 1
P46 21T-06-64280 1
P47 01024-81220 9
P48 04434-51012 8
P49 08193-20012 1
Detail C

Name Q'ty Name Q'ty
Others
213
C. INSTALLATION PROCEDURES
Precaution: Before inserting the work equipment pin, apply lithium grease to the inside
of the pin hole.
215
C-1: Installation of boom cylinder to chassis
216
C-1: Installation of boom cylinder to chassis (2/2)
Clearance between pin and

revolving frame hole. 0.095 – 0.223
[Procedure]
(1) Remove the parts marked with
Boom which are installed to the revolving
cylinder
frame temporarily.
(2) Sling the cylinder and position it to

the pin hole.
(3) Set the shims and spacer and install

the parts marked with . Adjust the
Shim Shim clearance marked with to 1 mm
Wood block
or less.
Spacer
(4) If you fit the wood block marked with

in the above figure to secure the
Pin cylinder, you can easily install the
parts marked with .
(5) Perform this procedure for the right

Center side and left boom cylinder foot.
of chassis
Plate, bolt, washer
Bushing Bushing
(Press fitted) (Press fitted)
217
C-2: Installation of boom cylinder piping
218
C-3: Bleeding air from boom cylinder
219
C-4: Boom sub-assembly
220
C-4: Boom sub-assembly (2/4)
[2] Installation of working lamp
Working lamp
1) Install the working lamp as shown
in the diagram on the left.

2) Connect the wiring at the place
marked .
PLATE (The wire (q) is clamped to the boom.)
q
Harness
M14 Parts sent individually

No. Part No. Q'ty
G31 20y-06-25310 2
G32 20y-06-21551 2
G33 01010-81430 2
G34 01643-31445 2

Name Q'ty Name Q'ty
22 mm Socket 1
KW14PI Impact wrench 1
Others
221
[3] Installation of hydraulic hoses
4 places Hose
Blind plug
Connect at the marked
(12 places) .
07371-01400 (3)
Blind plug
07378-11410 (4)
07371-51470 (8) q
01010-51455 (16) q The split flange is
01643-31445 (16) q 07371-51470
07000-13048 (4) q Use M14 mounting bolts.
Hose

No. Part No. Q'ty
F2 07073-01418 8
F14 07073-01416 4
Use the blind parts of the split flange, bolts, O-ring,

etc. as they are (Parts marked with q).

Name Q'ty Name Q'ty
Be careful of the O-rings. 22 mm Socket 1
Others
222
223
C-5: Installation of boom assembly
224
C-5: Installation of boom assembly (2/3)
225
C-5: Installation of boom assembly (3/3)
226
C-6: Installation of boom cylinder top pin
227
C-6: Installation of boom cylinder top pin (2/2)
228
C-7: Connectin of arm assembly to boom
229
C-7: Connection of arm assembly to boom (2/3)
1)
2)
3)
4)
5)
6)
7)
230
C-7: Connection of arm assembly to boom (3/3)
231
C-8: Installation of hoses between boom and chassis
232
C-8: Installation of hoses between boom and chasis (2/2)
233
C-9: Installation of arm cylinder top pin
234
C-9: Installation of arm cylinder top pin (2/2)
235
C-10: Bleedin air from arm cylinder
236
C-11: Installation of hydraulic hoses between boom and arm
237
C-12: Connection of grease piping
C-12: Connection of grease piping (1/5)
Auto grease system

[1] Between boom and chassis manufactured by
LINCOLN
Connect grease hose at

this position. (Hose is
installed to body when
shipped.) Parts sent individually
From grease pump No. Part No. Q'ty
on body side

Name Q'ty Name Q'ty
19-mm spanner 1
Others
238
Auto grease system

[2] Between boom and arm manufactured by
LINCOLN
Detail A

No. Part No. Q'ty
F4 07631-20408 1
Detail B
F5 237-60-14550 1
F6 21T-70-75290 1
F7 01010-81225 2
F8 01643-31232 2
F9 237-60-14550 1
F10 21T-68-68290 1
F15 203-973-5660 3
F11 203-973-5720 3
F12 01010-81055 6
F13 01643-31032 6

Name Q'ty Name Q'ty
Others
239
Auto grease system

[1] Between boom and chassis manufactured by
NABCO
Common to long and
short booms

(1) Connect the adapter to the
hose marked with .
Hose adapter
Blind Plug Parts sent individually

209-98-11960
No. Part No. Q'ty
Hose
21T-72-17730
sBlock (Length: 700 mm)
21T-68-72250 sAdapter
Blind Plug
21T-72-17690 Hose
21T-98-71140 (2)
21T-72-17740
(Length: 800 mm)

Name Q'ty Name Q'ty
1. Parts marked with s are contained 19-mm spanner 1
in revolving frame when shipped.
Others
240
Auto grease system

[2] Boom top manufactured by
NABCO
Common to long and
short booms

(1) Connect the parts marked with
. (3 places)
sAdapter sHose l=700 (2) Parts marked with s are

21T-72-17690 21T-72-17730 contained in boom sub
assembly.

No. Part No. Q'ty
sHose
21T-72-19410 (2)
Boom top
pin cover

Name Q'ty Name Q'ty
19-mm spanner 1
Others
241
Auto grease system

[3] Between boom and arm manufactured by
Male Female NABCO
- Standard (Short) boom -
Both ends
Boom
assembly
Adapter Plug
Hose 209-98-1196
Adapter
21T-72-17690
Boom top
Blind plug pin cover
Clamp Bolt Washer 21T-98-71140 (2)
(1) Assemble parts as shown in

this figure.

(2) Couple with boom assembly at
part marked with .
Contained in Adapter
arm assembly
Adapter Parts sent individually

21T-72-17620
No. Part No. Q'ty
Male Female 16 21T-72-17740 1
1.8 kg
Blind plug Bracket 17 21T-72-17690 1
21T-98-71140 18 21T-70-75290 1
Tube Bolt
19 01010-81225 2
20 01643-31232 2
21 21T-72-17620 1
Washer
22 21T-70-75740 1
23 07282-11048 2
Blind plug 24 01010-80612 4
209-98-11460 25 01602-20619 4

Name Q'ty Name Q'ty
19-mm spanner 1
19-mm socket 1
Ratchet handle 1
KW12PI impact wrench 1
150-mm extension 1
10-mm socket 1
Others
242
C-13: Connection of wiring between boom and chassis
243
C-14: Installation of hoses between boom and chassis
244
C-14: Installation of hoses between boom and chassis (2/2)
245
C-16: Connection of bucket assembly to arm
246
C-16: Connection of bucket assembly to arm (2/3)
247
C-16: Connection of bucket assembly to arm (3/3)
C-16: Connection of bucket assembly and arm (3/3)
Arm, bucket connecting pin 1) Adjust with shims so that clear-

ance a (each side, 2 places) is
0.25 - 0.5.
2) Carry this out on the left and

right.
s Cover 22kg O-ring
21T-70-74251 (2) See below.
Press fit bushing s

s Stopper cover (11.3 kg) 21T-70-74280 (2)
21T-70-74290 (2)
s
bucket
Center
Bolt, washer
M16
s Bolt (M30)
01011-83070 (2)
s Collar
Clear- Clear-
21T-70-74310 (2) ance a ance a
s s s
s 01011-83615 (12)
sRibbed bushing Pin (81.4 kg) Cover
01643-33690 (12) 21N-70-14220 (2) 21T-72-73141 (2) 21T-72-73170 (2)

No. Part No. Q'ty
G37 21N-70-12160 4
G40 21T-70-74260 32
G41 21T-70-74270 8
G39 209-70-71370 4
G42 205-09-61240 4
G43 01640-20610 4
G44 01580-10605 4
G45 01640-20610 4
O-ring

Name Q'ty Name Q'ty
1. Be careful of the seals and O-rings. 24 mm Socket 1 Hammer 1
2. Assemble the seal (G37) and O-ring 46 mm Socket 1
(G39) when temporarily assembling 55 mm Socket 1
the pin for transportation. 150 mm Extension 1
Ratchet handle 1
KW45FG Impact wrench 1
Others
248
C-17: Installation of bucket link
249
C-17: Installation of bucket link (2/2)
250
C-18: Bleeding air from bucket cylinder
251
252
253
254
255
256
257
258
259
260
261
262
263
264
265
266
267
268
269
270
271
272
273
274
275
276
277
278
279
280
281
282
283
M. INSPECTION AND SERVICING PROCEDURES
284
M-1: Inspecting the oil level and water level
M-1:
1. Inspecting the oil level and water level in respective sections and refilling them.
(1) Inspecting the cooling water level and refilling it

(2) Inspecting the oil quantity in the engine oil pan and refilling the engine oil when deemed necessary
(3) Checking and confirming the fuel level
(4) Inspecting the oil level in the hydraulic oil tank and refilling the oil when deemed necessary
(5) Inspecting the oil level in the P.T.O. case and refilling the oil when deemed necessary
(6) Inspecting the oil level in the swing machinery case and refilling the oil when deemed necessary
(7) Inspecting the oil level in the final drive assembly and refilling the oil when deemed necessary
Since information on these matters are given in the Operation and Maintenance Manual, refer to the
manual.
2. Selection of the appropriate fuel type and lubrication oil type fitting to the atmospheric
temperature range
(1) Fuel and oil

Select the appropriate fuel and oil types fitting to the atmospheric temperature range.
AMBIENT TEMPERATURE CAPACITY

KIND OF
RESERVOIR
FLUID -22 -4 14 32 50 68 86 104 122fF Specified Refill
-30 -20 -10 0 10 20 30 40 50fC
SAE 30 61 liters 55 liters

Engine oil pan (Front & rear) (Front & rear)
16.12 US gal 13.42 US gal
SAE 10W
SAE 10W-30 20 liters 20 liters

PTO case (Front & rear) (Front & rear)
SAE 15W-40
30 liters 30 liters
Swing machinery case Engine oil (Front & rear) (Front & rear)
SAE 30
85 liters 85 liters
Final drive case 22.46 US gal 22.46 US gal
(each) (each)
2400 liters 1500 liters

Hydraulic system HO46HM (q1) 634.08 US gal 396.30 US gal
2750 liters
ASTM D975 No.2 726.55 US gal
Diesel fuel (if equipped: -
Fuel tank (q2) 3300 liters
q3 871.86 US gal)
NLGL No.2
18 liters 18 liters
Auto-Grease Grease 4.76 US gal 4.76 US gal
NLGL No.0
85 liters
Cooling system Water Add antifreeze (Front & rear) -
22.46 US gal
q1: For HO46-HM, use the oil recommended by komatsu.

q2: Use only diesel fuel.
q3: ASTM D975 No.1
285
M-1: Inspecting the oil level and water level
M-1:
(2) Anti-freezing solution

When the atmospheric temperature drops below 0fC, add an anti-freezing solution.
Add an anti-freezing solution to the cooling water to prevent freezing of the cooling water while the
machine is in standstill.
e Determine the ratio between the anti-fteezing solution and cooling water checking the minimum
temperature recorded in the past and referring to the mixture ratio table given below.
Actually, determine the mixture ratio assuming an about 10?o? C lower atmospheric temperature.
Mixing rate of water and antifreeze
Cleaning inside of cooling system

Kind of coolant and changing coolant Adding corrosion resistor agent KI
Permanent type anti- Every year (autumn) or every 2000

freese (All season type) hours whichever comes first
Non permanent type Every 1000 hours and when

Every 6 months (spring, autumn)
antifreeze containing cleaning the inside of the cooling
(Drain antifreeze in spring, add
ethylene glycol (winter, system and when changing cool-
antifreeze in autumn)
one season type) ant.
When not using anti- Every 6 months or every 1000

freeze hours whichever comes first
s The quantity figures in the above table are for an engine on one side.
Total quantity should therefore be double the above quantities.
k Since anti-freezing solutions are inflammable, be careful with fire when handling them.
s As the anti-freezing solutions, use a corrosion-proof all-season anti-freezing solution (AF-ACL) or all-
season anti-freezing solution (AF-PTL). Do not use an alcohol type anti-freezing solution.
s Prescribed oil quantity means the total quantity of oil including the part remaining in circuit pipings
for respective equipment and changing oil quantity means the quantity of oil to change at times of
ordinary inspections servicing.
s When starting the engine under atmospheric temperature environments of less than 0fC, always use
SAE10W or SAE10W-30 even if daytime temerature is expected to rise upto around 10fC.
s Use city water as the cooling water. When using substitute source water (such as river water and
well water) for an unavoidable reason, contact our office or our designated service shops.
286
M-1: Komatsu genuine oil
M-1:
3. Komatsu genuine oil
The performance of the Komatsu genuine oil is assured by the severe KES (Komatsu's standard), thus it is
applicable to machines of every type.
Working efficiency is heightened by using reliable Komatsu genuine oil to maintain your machines under the
best condition.
s Quality of oil and grease cannot be judged by checking their appearance. Accordingly, replace them
periodically and securely.
s Various types of Komatsu genuine oil and grease are prepared as shown in the following table. Use
the oil and grease specified in TESTING AND ADJUSTING.
Type of oil SAE No.
10W
Engine oil 30
10W/30
Gear oil 90
Torque converter oil
Compressor oil
Brake fluid
Antifreeze
Grease
287
M-2: Flushing of hydraulic circuit
M-2: Flushing of hydraulic circuit
Flush the hydraulic circuit according to the following procedure.
1. Bypass the work equipment piping at the cylinders.
2. Replace the return filter element with the flushing element (accessory).
3. Replace the relief valve of the return filter with the plate (accessory).
4. Run the engine at low idling with the lever in the N position for 30 minutes.
5. Run the engine at a medium speed with the lever in the N position for 30 minutes.
6. Run the engine at 1,700 rpm and repeat the following lever operation pattern 4 times.
Keep the lever at each operation position for 1 minute - 1 minute 30 seconds.
Operation pattern
(Raise boom) m (Lower boom) m (Extend arm) m (Retract arm)
m (Extend bucket) m (Retract bucket)
7. Replace the return filter relief valve and element with the normal ones.
8. Correct the work equipment piping (connect it to the cylinders).

s If the "Filter clogged" caution lamp on the monitor in the operator's cab lights up while
the hydraulic cylinder is flushed, stop the engine immediately and replace the flushing
element. If a new flushing element is not available, use a new genuine element (07063-
01210).
qSpare parts
Flushing element ............. 209-60-31130
Absolute filter mesh size: 6um
(Filter mesh size of genuine element is 30um)
Plate ................................ 21T-60-13730
288
M-3: Releasing residual pressure from hydraulic circuit
M-3: Releasing residual pressure from hydraulic circuit
When disconnecting the hydraulic piping, be sure to release the residual pressure according
to the following procedure.
1. Pull the safety lock lever to the "FREE" position. FREE

LOCK
2. Remove the hydraulic tank cap.
3. Replace the relief valve of the return filter with the

plate (accessory).
s Limit the engine speed to 1,000 rpm.
s Keep the work equipment control levers in neutral.
4. Operate each work equipment control lever to the stroke end in 5 - 6 seconds after
stopping the engine.
s Perform the operations in 3 - 4 above by 3 times.
Loosen the oil filler cap of the hydraulic tank slowly to release the residual pressure, and
then remove it.
5. After releasing the residual pressure, install the oil filler cap of the hydraulic tank.
6. Push the safety lock lever to the "LOCK" position.

Name Q'ty Name Q'ty
Others
289
INITIALIZATION PROCEDURES FOR VHMS CONTROLLER
s Initialization Tools for VHMS Controller 1. Check of Machine Information, Engine Infor-
mation
Symbol Part Number Part Name s This step applies to works on the whole ma-
799-608-3101 Service kit chine.
1 799-608-3210 Diskette Check and record machine information, engine
information, VHMS controller information and
799-608-3220 Wiring harness ORBCOMM controller information.
Notebook type
Commercial personal computer Information to be checked
2
L article (OS : Windows98/ No. Information Remarks
2000)
1 Machine name
Coupling assem-
2 Machine serial number 5 digits
21T-06-64590 bly (Accessory
3 tool) 3 Current service meter time Unit 0.1h
Harness (Acces- 4 Front engine serial number 6 digits
21T-06-64392
sory tool) 5 Rear engine serial number 6 digits
s Before starting operation after completion of

VHMS controller serial num-
6 5 digits
ber
local assembly or before resuming operation ORBCOMM controller serial
after storage for a long period, initialize the 7 number (For only specification 11 digits
VHMS Controller according to the following with ORBCOMM)
procedures.
s Data collected with the VHMS controller as
s The above No. is the same as in the check
WebCARE database are accumulated and man-
sheet.
aged. To process data smoothly on the Web-
CARE, it is necessary to set the VHMS controller
consistently. If it is not set correctly, data will not
be taken into the WebCARE and data in the
VHMS controller may not be utilized. So, be sure
to carry out the initialization.
s For the installing method of the VHMS Initializa-
tion Program in the personal computer, refer to
the Operation and Maintenance Manual con-
tained in the package of the service kit L1.
s In the procedures, it is necessary to use the
service menu on the CGC monitor. Refer to the
paragraph of Function and Operation of CGC
Monitor and fully understand the operating
procedures.
s The initialization procedures cover both "ORB-
• (1) Front engine
• (2) Rear engine
COMM Specification" and "ORBCOMMLESS • (3) VHMS controller
Specification." In case of "ORBCOMMLESS • (4) ORBCOMM controller
Specification", omit the procedures necessary • (5) Machine monitor (reference)
for "ORBCOMM Specification" only.
s During the initialization work, make necessary
• (6) CGC monitor (reference)
• (7) Pump controller (reference)
confirmations for each work according to the • (8) Front engine controller (reference)
"VHMS Initialization Work Checklist". • (9) Rear engine controller (reference)
290
2. Operation Check of ORBCOMM Controller 3. Connection of Personal Computer
(ORBCOMM Specification only) s This step applies works in the cab.
s This step applies to works in the cab and the 1) Make sure that the starting switch is set to
cab under room. the OFF position.
1) Make sure that the starting switch is set to k Be sure to connect and disconnect the
the OFF position. personal computer when the starting
2) Check that the ORBCOMM controller green switch is set to the OFF position.
LED is ON, and make sure that the 2) Connect the personal computer L2 and the
controller is operating. download connector C53 with the wiring
s Since the power is supplied to the ORB- harness [1] of the service kit L1.
COMM controller all the time, the con- s The download connector C53 is con-
troller is normal when the green LED is nected to the left side face of CGC mon-
ON while the starting switch is turned off. itor.
s Connect the personal computer to the
RS232C terminal.
291
4. Performance Check of VHMS Controller 5. Startup of VHMS Initialization Tool
s This step applies to works in the cab and the s This step applies to works in the cab (for the
cab under room. personal computer).
1) Set the starting switch to the ON position. 1) Switch on the personal computer and start
2) Check the 7-segment LED of the VHMS the OS.
controller and make sure that the controller 2) Click the icon of [VHMS Setting Tool] on the
is operating normally. personal computer screen to start the
s Since the switch power is supplied to the VHMS initialization tool.
VHMS controller, it is normal if the 7- 3) Input the 10-digit service ID in [Service ID].
segment LED flashes in rotation after the s Service ID : 7826101001
starting switch is turned on and, then, it s The Service ID is the same as that to be
counts up. used in the service menu on the CGC
monitor.
4) Select [Data clear and Set up] in the [Select
Function] column.
5) Press the [OK] button to shift to the setup
screen.
292
6. Initialization of VHMS Controller 4) When information in the [Machine Informa-
s This step applies to works in the cab (for the tion] box is not correct, change it according
personal computer). to the following procedures:
s At the time of initialization, never change i) Press the [Edit] button on the right lower
data of the service meter (SMR). part of the [Machine Information] box to
[Machine Information] display the correction screen.
1) Open the [Machine Information] tab. ii) Change the information to the correct
s The [Machine Information] tab is dis- one and then press the [OK] button.
played first in the [Data clear and Set up]
menu.
2) Check all the data.
5) After having checked and changed all data

in [Machine Information], press the [Apply]
button to settle the setting.
s Press the [Apply] button, and the screen
for checking the setting will appear.
Check the setting again and press the
[OK] button when the setting is correct.
s In case of the ORBCOMM Specification,
3) When information in the [Date/Time] box is execute [Communication Setting] and
not correct, change it according to the fol- settle it.
lowing procedures:
i) Press the [Edit] button on the right lower
part of the [Date/Time] box to display
the correction screen.
ii) Change the information to the correct
one and then press the [OK] button.
293
[Communication Setting] (ORBCOMM Specifi- ii) Change the setting and then press the
cation only) [OK] button.
6) Open the [Communication Setting] tab. s At initialization, select [20h] at [SMR]
7) Check all the data. screen, and set the function to [ON].

in [Communication Setting], press the
[Apply] button to settle the setting.
8) To change setting in [SHORT FAULT s Press the [Apply] button, and the screen
HISTRY], follow the procedures below: for checking the setting will appear.
i) Select [SHORT FAULT HISTRY] on the Check the setting again and then press
screen and press the [Edit] button on the [OK] button when it is correct.
the left lower part of the [File Transfer
Setting] block to display the setting
screen.
ii) Change the setting and then press the
[OK] button.
s At initialization, select [Occurrence]
at [Timing] screen, and set the
function to [ON].
9) To change setting in [SHORT TREND

ANALYSIS], follow the procedures below:
i) Select [SHORT TREND ANALYSIS] on
the screen and press the [Edit] button
o n t h e l e ft l o w e r pa r t o f t h e [ F i l e
Transfer Setting] block to display the
setting screen.
294
[Exit] 7. Check of Storage Operation of VHMS
11) After having check and changed all data in Controller
[Machine Information] and [Communication s This step applies to works in the cab and the
Setting], press the [Exit] button on the right cab under room
lower part of the screen to terminate [VHMS 1) Set the starting switch to the OFF position.
Initialization Tool]. 2) Check the 7-segment LED of the VHMS
controller and make sure that the controller
power has been completely cut off.
s The VHMS controller records and up-
dates data when the starting switch is
turned OFF.
s The controller power is retained for stor-
age operation for several seconds after
the starting switch is turned OFF. So,
make sure that the 7-segment LED of
the controller has completely gone out.
295
8. Performance Check of VHMS Controller 9. Execution of Quick PM Clinic
s This step applies to works in the cab and the s This step applies to works in the cab.
cab under room. 1) Start the engine and idle it low.
1) Set the starting switch to the ON position. 2) Set the operation mode to the DH Mode and
2) Check the 7-segment LED of the VHMS bring the safety lock lever to the release
controller and make sure that the controller position.
is operating normally. 3) Let the CGC monitor display the service
s Since the switch power is supplied to the menu select screen.
VHMS controller, it is normal when the 7- s See the paragraph of "Function and Op-
segment LED blinks in rotating after the eration of CGC Monitor".
starting switch is turned on and, then, it 4) Select [Snapshot].
counts up.
5) Keep operating the screen and start SNAP-

SHOT.
s Press the [START] button on the screen
below, and the confirmation message
will appear.
s Before staring SNAPSHOT, fully under-
stand the SNAPSHOT procedures.
296
6) Operate switches and levers for each run s Execute the quick PM clinic twice, i.e., once
time according to "Quick PM Clinic Opera- for the front engine system and once for the
tion Procedures" in the table below. rear engine system.
s Run times are displayed on the machine s One set of the coupling assembly, L3, for
control monitor (CGC). measuring NC pressure is available in the
k Since the work equipment and travel toolbox. Connect it to respective measuring
have to be operated practically in the couplers according to the measurement
quick PM clinic, pay sufficient attention procedures.
to safety around during the operation. • NC Pressure Measuring Coupler on the front
engine side
F: No.1 and 2 front pumps NC pressure
R: No.1 and 2 rear pumps NC pressure
S: Front swing pump NC pressure
• NC Pressure Measuring Coupler on the rear

engine side
S: Rear swing pump NC pressure
297
Quick PM Clinic Operation Procedures
(each engine)
Switch NC pres-
Time in
Se- Work- Auto- sure
Run time snap data Fuel dial Heavy Swing Control lever Data read to PM clinic
quence ing decel- sensor
(sec.) lift lock
Mode eration position
0 sec. –300.00 . Engine speed (Low idling
Low
1 ↓ ↓ DH OFF OFF OFF — All neutral . Engine oil pressure (Low idling)
(MIN)
30 sec. –270.00 . Ambient temperature
. Engine speed (High idling
. Engine oil pressure (High idling)
30 sec. –270.00
High . Control pump oil pressure
2 ↓ ↓ ↑ ↑ ↑ ↑ All neutral
(MAX) . TVC valve output pressure
1 min. 30 sec. –210.00
. NC valve output pressure
. Swing NC valve output pressure
1 min. 30 sec. –210.00
. Engine speed
3 ↓ ↓ ↑ ↑ ON ↑ ↑ All neutral
(Auto-deceleration)
2 min. –180.00
2 min. –180.00 s Lift the R.H track with the work
R.H. travel operation
4 ↓ ↓ ↑ ↑ ↑ ↑ ↑ F equipment first.
(R.H. travel full idling)
3 min. 30 sec. –90.00 . Front NC valve output pressure
3 min. 30 sec. –90.00 s Lift the L.H track with the work
L.H. travel operation
5 ↓ ↓ ↑ ↑ ↑ ↑ ↑ R equipment first.
(L.H. travel full idling)
5 min. 0.00 . Rear NC valve output pressure
5 min. 0.00
Swing operation
6 ↓ ↓ ↑ ↑ ↑ ↑ ON S . Swing pump oil pressure
(Swing relief)
5 min. 30 sec. 30.00
5 min. 30 sec. 30.00
Boom RAISE opera- . Engine speed (Relief)
7 ↓ ↓ ↑ ↑ ↑ ↑ ↑
tion (RAISE relief) . TVC valve output pressure
5 min. 45 sec. 45.00
. Engine speed (Relief)
5 min. 45 sec. 45.00
Boom RAISE opera- . Blow-by pressure
8 ↓ ↓ ↑ ↑ ↑ ON ↑
tion (RAISE relief) . Exhaust gas temperature
6 min. 60.00
. TVC valve output pressure
6 min. 60.00
Arm IN operation (IN . Main pump oil pressure
9 ↓ ↓ ↑ ↑ ↑ ↑ ↑
relief) . Boost pressure
6 min. 30 sec. 90.00
6 min. 30 sec. 90.00
Arm OUT operation
10 ↓ ↓ ↑ ↑ ↑ ↑ ↑
(OUT relief)
6 min. 50 sec. 110.00
6 min. 50 sec. 110.00
Bucket DUMP opera-
11 ↓ ↓ ↑ ↑ ↑ ↑ ↑
tion (DUMP relief)
7 min. 10 sec. 130.00
7 min. 10 sec. 130.00
Bucket digging opera-
12 ↓ ↓ ↑ ↑ ↑ ↑ ↑
tion (Digging relief)
7 min. 30 sec. 150.00
Low
13 7 min. 30 sec. 150.00 ↑ ↑ ↑ ↑ End
(MIN)
• NC Pressure Measuring Coupler on Front • NC Pressure Measuring Coupler on Rear Engine

Engine Side Side
298
10. Check of Record of VHMS Controller 11. Downloading of Set Data
s This step applies to works in the cab and the s This step applies to works in the cab (on the
cab under room personal computer).
1) Set the starting switch to the OFF position. 1) Set the starting switch to the ON position.
2) Check the 7-segment LED of the VHMS 2) Click the icon of [VHMS Technical Analysis
controller and make sure that the controller Tool] on the personal computer to start the
power has been completely cut off. VHMS analysis tool.
s The VHMS controller records and up- s Input [User Name] and [Password].
dates data when the starting switch is s For the operation procedures, refer to
turned off. the Operation and Maintenance Manual
s The controller power is retained for stor- for VHMS Technical Analysis Tool.
the starting switch is turned off. So, con-
firm that the 7-segment LED of the con-
troller has completely gone out.
3) Use the [Download] function to download

the data recorded in the VHMS controller to
the personal computer.
s For the operation procedures, refer to
the Operation and Maintenance Manual
for VHMS Technical Analysis Tool.
s Make sure that the downloading has
completed before proceeding to the next
step.
299
12. Check of Downloaded Data 13. Setting for Satellite Communication
s This step applies to works in the cab (on the (ORBCOMM specification only)
personal computer). s This step applies to works in the cab (on the
1) Check the set data with the [View] function. personal computer).
s For the operation procedures, refer to 1) See the procedures in "5. Startup of VHMS
the Operation and Maintenance Manual "Setting Tool" and start the VHMS Setting
for VHMS Technical Analysis Tool. tool.
s Make sure that the [MFA0] code at the s [Select Function] selects [Set up].
time of quick snapshot is displayed in
[Failure History]
s Make sure that the SNAPSHOT data
has been recorded.
2) After having check the set data, terminate

[VHMS Technical Analysis Tool].
2) Open the [Communication Setting] tab.

3) Check the setting of [Satellite Setting].
300
4) To change the setting of [Satellite Setting], 14. Check of Storage Operation of VHMS Con-
follow the procedures below: troller
i) Press the [Edit] button in the [Satellite s This step applies to works in the cab and the
Setting] block to display the setting cab under room
screen. 1) Set the starting switch to the OFF position.
ii) Bring GCC Code to the applicable area 2) Check the 7-segment LED of the VHMS
and then press the [OK] button. controller and make sure that the controller
turned off.
GCC Code and Application Area

Code Applicable Area
1 U.S.A.
120 Italy
121 Malaysia
122 Korea
123 Brazil
130 Japan
301
15. Disconnection of Personal Computer 16. Communication to Komatsu
s This step applies to works in the cab. After having completed Steps 1 to 15 success-
1) Make sure that the starting switch is set to fully, please send the checklist and the VHMS
the OFF position. data to VHMS/WebCARE Support Center of
k Be sure to turn off the starting switch Komatsu, Tokyo.
before connecting and disconnecting the s Komatsu, Tokyo, has to arrange the setting
personal computer. for satellite communication on the receive
2) Terminate the OS of the personal computer side, please be sure to inform Komatsu of
L2, and switch off the personal computer. the completion of the setting.
3) Disconnect the wiring harness [1] of the s Fax the checklist to Komatsu.
service kit L1, from the download connector s Send the VHMS data by Notes (LAN) or E-
C53. mail (WAN).
Contact VHMS/WebCARE Support Center by

Telephone : 81-3-5561-2765
FAX : 81-3-5561-4766
E-mail : webcare@komatsu.co.jp
302
To : VHMS/WebCARE Support Team, Komatsu, Tokyo Set date :
Fax date :
PC1800-6 DB/ Branch name :
VHMS Initialization Work Checklist Person in charge :
Setting Step Check Item Result
1 Machine name
2 Machine serial number (5 digits)
3 Current service meter time (in 0.1h)
Check of Machine Information,
1 4 Front engine serial number (6 digits)
Engine Information and Controller
Information 5 Rear engine serial number (6 digits)
(*:ORBCOMM specification only) 6 VHMS controller serial number (5 digits)
7 ORBCOMM controller serial number (11 digits)[*]
Performance Check of ORBCOMM

2 Is the green LED on? yes no
Controller (ORBCOMM specification only)
3 Connection of Personal Computer Is it connected correctly? yes no
4 Performance Check of VHMS Controller Is the 7-segment LED operating normally? yes no
5 Startup of VHMS Initialization Tool Is [Data clear and Set up] selected as the function of the initialization tool? yes no
Is Date (mm/dd/yyyy) set correctly? yes no

Date/Time Is the Time set correctly? yes no
[Local Time]Is the Time Zone set correctly? yes no
Is the DST (Summer Time) set correctly? yes no
SMR Is the SMR (h) set correctly? No change allowed
Is the Product Group set correctly? yes no
Is the Machine Model set correctly? yes no
Initialization of VHMS Controller Machine Is the Type set correctly? yes no

6 Is the Variation Code set correctly? yes no
(Items marked with * are for Is the Serial No. set correctly? yes no
the ORBCOMM specification only.)
Is the Engine Model set correctly? yes no
Engine Is the Engine Serial No. 1 set correctly? yes no
Is the Engine Serial No. 2 set correctly? yes no
SHORT FAULT Which is the Send set to? On Off
HISTY[*] Is the Number (Default : 10) set?
SHORT TREND Which is the Send set to? On Off
ANALYSIS[*] Is the Number (Default : 10) set? (SMR)
7 Check of Storage Operation of VHMS Controller Did the 7-segment LED go out? yes no
9 Execution of Quick PM Clinic Have you arranged the snap shot as per the procedures? yes no
11 Downloading of Set Data Have you completed the downloading? yes no
Could you download all files? yes no

What time did you download (by your wrist watch)? Time
12 Check of Downloaded Data Is the [MFAO] code displayed in the Fault History? yes no
Data Check Do SMR and Time match with the set values in the Fault History? yes no
Is no data missing in the Snapshot? yes no
Setting for Satellite Communication

13 Did you set the GCC Code? yes no
(ORBCOMM specification only)
15 Disconnection of Personal Computer Did you disconnect it correctly? yes no
Contact VHMS/WebCARE Support Team, Komatsu, Tokyo by

• Telephone : 03-5561-2765 (Nation Code 81)
16 Communication to Komatsu • FAX:03-5561-4766 (Nation Code 81)
• E-mail:webcare@komatsu.co.jp
303
SETTING PROCEDURES FOR REPLACING VHMS CONTROLLER
s Setting Tools for Replacing VHMS Controller Preparatory Work for Replacing VHMS
Controller
Symbol Part No. Part Name s Steps 1–4 apply to works with the current con-
799-608-3101 Service kit troller before replacing the VHMS controller.
1 799-608-3210 • Diskette
1. Connection of Personal Computer
799-608-3220 • Wiring harness s This step applies works in the cab.
L Notebook personal 1) Make sure that the starting switch is set to
Commercial computer the OFF position.
k Be sure to connect and disconnect the
2
article (OS : Windows98/
2000) personal computer when the starting
switch is set to the OFF position.
2) Connect the personal computer, L2, and the
s When it has become necessary to replace the download connector, C53, with the wiring
harness [1] of the service kit, L1.
s The download connector, C53, is con-
VHMS controller, set the controller according to
the following procedures before and after the re-
placement. nected to the left side face of the ma-
s Accumulate and manage machine data collected chine control monitor (CGC).
with the VHMS controller as WebCARE data- s Connect the personal computer to the
base. To process data smoothly on the Web- RS232C terminal.
CARE, set the VHMS controller consistently. If it
is not set correctly, data will not be taken in the
WebCARE and data in the VHMS controller may
not be utilized. So, be sure to set the controller at
the time of replacement.
s For the installing method of the VHMS Initializa-
tion Program in the personal computer, refer to
the "Operation and Maintenance Manual" con-
tained in the package of the service kit, L1.
s In the procedures, use the service menu on the
CGC monitor. See the paragraph of "Function
and Operation of CGC Monitor" and fully under-
stand the operating procedures in advance.
s The setting procedures for replacement cover
both "ORBCOM specification" and "ORBCOMM-
LESS specification". In case of "ORBCOMM-
LESS specification", omit the procedures
necessary for "ORBCOMM specification" only.
s During the setting work, make necessary confir-
mations for each work according to the "VHMS
Initialization Work Checklist".
304
2. Performance Check of VHMS Controller 3. Downloading of Remaining Data
s This step applies to works in the cab and the s This step applies to works in the cab (on the
cab under room. personal computer).
1) Set the starting switch to the ON position. 1) Set the starting switch to the ON position.
2) Check the 7-segment LED of the VHMS 2) Switch on the personal computer and start
controller and make sure that the controller the OS.
is operating normally. 3) Click the icon of [VHMS Technical Analysis
s Since the switch power is supplied to the Tool] on the personal computer to start the
VHMS controller, it is normal when the 7- VHMS analysis tool.
segment LED blinks in rotating after the s Input [User Name] and [Password].
starting switch is turned on and, then, it s For the operation procedures, refer to
counts up. the Operation and Maintenance Manual

the remaining data recorded in the VHMS
controller to the personal computer.
step.
5) Terminate the VHMS Technical Analysis

Tool.
305
4. Check of Set Information
s This step applies to works in the cab (on the
personal computer).
s Checking the setting in [Communication
Setting] is for ORBCOMM specification only.
1) Click the icon of [VHMS Setting Tool] on the
personal computer to start the VHMS Set-
ting Tool.
2) Input the 10-digit service ID in [Service ID].
s Service ID : 7826101001
s The Service ID is the same as the one
used in the service menu of the machine
control monitor (CGC).
Function] column.
4) Press the [OK] button and move to the set-
ting screen.
6) Open the [Communication Setting] tab and
check all information.
7) After having check and recorded all informa-

tion, press the [Exit] button on the right
lower part of the screen to terminate [VHMS
Setting Tool].
5) Open the [Machine Information] tab, and

check and record all information.
s In the [Data clear and Set up] menu, the
[Machine Information] is displayed first.
306
8) Terminate the OS of the personal computer Work after Replacement of VHMS Controller
and switch off the personal computer. s The steps 5–18 apply to works on the new VHMS
9) Set the starting switch to the OFF position. controller after the replacement.
k When replacing the VHMS controller, it
is acceptable that the personal computer 5. Performance Check of ORBCOMM controller
is connected, but be sure to switch off (ORBCOMM specification only)
the personal computer and to turn off the s This step applies to works in the cab and the
starting switch. cab under room.
1) Make sure that the starting switch is set to
the OFF position.
2) Check the green LED of the ORBCOMM
is operating.
s Since the power is supplied to the ORB-
COMM controller all the time, the con-
troller is normal when the green LED is
ON while the starting switch is turned off.
307
6. Connection Check of Personal Computer 7. Performance Check of VHMS Controller
s This step applies to works in the cab. s This step applies to works in the cab and the
s When disconnecting the personal computer cab under room.
during the work, connect it again referring to 1) Set the starting switch to the ON position.
"1. Connection of Personal Computer". 2) Check the 7-segment LED of the VHMS
1) Make sure that the starting switch is set to controller and make sure that the controller
the OFF position. is operating normally.
k Be sure to check the connection of the s Since the switch power is supplied to the
personal computer only when the start- VHMS controller, it is normal when the 7-
ing switch is set to the OFF position. segment LED blinks in rotating after the
2) Make sure that the personal computer and starting switch is turned on and, then, it
the download connector C53 are connected counts up.
the wiring harness (1).
308
8. Startup of VHMS Setting Tool 9. Resetting of VHMS Controller
s This step applies to works in the cab (on the s This step applies to works in the cab (on the
personal computer). personal computer).
1) Switch on the personal computer and start [Machine Information]
the OS. 1) Open the [Machine Information] tab.
2) Click the icon of [VHMS Setting Tool] on the s The [Machine Information] tab is dis-
personal computer to start the VHMS Set- played first in the [Data clear and Set up]
ting tool. menu.
3) Input the 10-digit service ID in [Service ID]. 2) Change all the data to the latest one or to
s Service ID : 7826101001 the data recorded before the replacement.
s The Service ID is the same as that to be
used in the service menu on the
machine control monitor (CGC).
Function] column.
3) When correcting information in [Date/Time],

follow the procedures below:
s Change the data in [Date/Time] except
for [Time Zone] to the correct data at the
time of correction.
part of the [Date/Time] box to display
the correction screen.
ii) Change the information to the correct
one and then press the [OK] button.
309
4) When correcting the information in [SMR], 6) After having checked and changed all data
follow the procedures below: in [Machine Information], press the [Apply]
s Be sure to set the value obtained by add- button to settle the setting.
ing 0.1h to the data recorded before the s Press the [Apply] button, and the screen
replacement to the service meter. for checking the setting will appear.
Example : Check the setting again and press the
123.4h (before replacement)⇒ [OK] button when the setting is correct.
123.5h (for resetting) s In case of the ORBCOMM specification,
s If an incorrect value is set to the service execute [Communication Setting] and
meter, data will come not to be managed settle it.
on the WebCARE database. So, be sure
to set correct values.
Delete the value in the [SMR (h)] and input
the new value to be set.
5) When correcting information in the [Machine

Information], follow the procedures below:
part of the [Machine Information] box to
display the correction screen.
ii) Change the information to the one
recorded before the replacement and
then press the [OK] button.
310
[Communication Setting] 10) To change setting in [SHORT TREND
(ORBCOMM specification only) ANALYSIS], follow the procedures below:
7) Open the [Communication Setting] tab. i) Select [SHORT TREND ANALYSIS] on
8) Change all the data to the one recorded the screen and press the [Edit] button
before the replacement. on the left lower part of the [File Trans-
fer Setting] block to display the setting
screen.
ii) Change the setting to the one recorded
before the replacement and then press
the [OK] button.
9) To change setting in [SHORT FAULT

HISTRY], follow the procedures below:
i) Select [SHORT FAULT HISTRY] on the
screen and press the [Edit] button on
in [Communication Setting], press the
the left lower part of the [File Transfer
[Apply] button to settle the setting.
s Press the [Apply] button, and the screen
Setting] block to display the setting
screen.
for checking the setting will appear.
ii) Change the setting to the one recorded
Check the setting again and then press
before the replacement and then press
the [OK] button when the setting is
the [OK] button.
correct.
311
[Exit] 10. Check of Storage Operation of VHMS
12) After having changed all the data in Controller
[Machine Information] and [Communication s This step applies to works in the cab and the
Setting], press the [Exit] button on the right cab under room
lower part of the screen to terminate [VHMS 1) Set the starting switch to the OFF position.
Initialization Tool]. 2) Check the 7-segment LED of the VHMS
turned off.
s The controller power is retained for
storage operation for several seconds
after the starting switch is turned off. So,
make sure that the 7-segment LED of
the controller has completely gone out.
312
11. Performance Check of VHMS Controller 12. Execution of Quick PM Clinic
s This step applies to works in the cab and the s This step applies to works in the cab.
cab under room. 1) Start the engine and idle it low.
1) Set the starting switch to the ON position. 2) Set the operation mode to the DH Mode and
2) Check the 7-segment LED of the VHMS bring the safety lock lever to the release
controller and make sure that the controller position.
is operating normally. 3) Let the CGC monitor display the service
s Since the switch power is supplied to the menu select screen.
VHMS controller, it is normal when the 7- s See the paragraph of "Function and Op-
segment LED blinks in rotating after the eration of CGC Monitor".
starting switch is turned on and, then, it 4) Select [Snapshot].
counts up.
5) Keep operating the screen and start snap-

shooting.
s Press the [Start] button on the screen
below, and the confirmation message
will appear.
s Before staring snapshooting, fully under-
stand the snapshooting procedures.
313
6) Operate switches and levers for each run s Execute the quick PM clinic twice, i.e., once for
time according to "Quick PM Clinic Opera- the front engine system and once for the rear en-
tion Procedures" in the table below. gine system.
s Run times are displayed on the machine s One NC pressure sensor is available in the tool-
control monitor (CGC). box. Connect it to respective measuring couplers
k Since the work equipment and travel according to the measurement procedures.
have to be operated practically in the • NC Pressure Measuring Coupler on the front en-
quick PM clinic, pay sufficient attention gine side
to safety around during the operation. F: No.1 and 2 front pumps NC pressure
S: Front swing pump NC pressure
• NC Pressure Measuring Coupler on the rear

engine side
S: Rear swing pump NC pressure
314
Quick PM Clinic Operation Procedures
(For each engine)
Switch NC pres-
Time in
Se- Work- Auto- sure
Run time snap data Fuel dial Heavy Swing Control lever Data read to PM clinic
quence ing decel- sensor
(sec.) lift lock
Mode eration position
0 sec. –300.00 . Engine speed (Low idling
Low
1 ↓ ↓ DH OFF OFF OFF — All neutral . Engine oil pressure (Low idling)
(MIN)
30 sec. –270.00 . Ambient temperature
. Engine speed (High idling
. Engine oil pressure (High idling)
30 sec. –270.00
High . Control pump oil pressure
2 ↓ ↓ ↑ ↑ ↑ ↑ All neutral
(MAX) . TVC valve output pressure
1 min. 30 sec. –210.00
. NC valve output pressure
. Swing NC valve output pressure
1 min. 30 sec. –210.00
. Engine speed
3 ↓ ↓ ↑ ↑ ON ↑ ↑ All neutral
(Auto-deceleration)
2 min. –180.00
2 min. –180.00 s Lift the R.H track with the work
R.H. travel operation
4 ↓ ↓ ↑ ↑ ↑ ↑ ↑ F equipment first.
(R.H. travel full idling)
3 min. 30 sec. –90.00 . Front NC valve output pressure
3 min. 30 sec. –90.00 s Lift the L.H track with the work
L.H. travel operation
5 ↓ ↓ ↑ ↑ ↑ ↑ ↑ R equipment first.
(L.H. travel full idling)
5 min. 0.00 . Rear NC valve output pressure
5 min. 0.00
Swing operation
6 ↓ ↓ ↑ ↑ ↑ ↑ ON S . Swing pump oil pressure
(Swing relief)
5 min. 30 sec. 30.00
5 min. 30 sec. 30.00
Boom RAISE opera- . Engine speed (Relief)
7 ↓ ↓ ↑ ↑ ↑ ↑ ↑
tion (RAISE relief) . TVC valve output pressure
5 min. 45 sec. 45.00
. Engine speed (Relief)
5 min. 45 sec. 45.00
Boom RAISE opera- . Blow-by pressure
8 ↓ ↓ ↑ ↑ ↑ ON ↑
tion (RAISE relief) . Exhaust gas temperature
6 min. 60.00
. TVC valve output pressure
6 min. 60.00
Arm IN operation (IN . Main pump oil pressure
9 ↓ ↓ ↑ ↑ ↑ ↑ ↑
relief) . Boost pressure
6 min. 30 sec. 90.00
6 min. 30 sec. 90.00
Arm OUT operation
10 ↓ ↓ ↑ ↑ ↑ ↑ ↑
(OUT relief)
6 min. 50 sec. 110.00
6 min. 50 sec. 110.00
Bucket DUMP opera-
11 ↓ ↓ ↑ ↑ ↑ ↑ ↑
tion (DUMP relief)
7 min. 10 sec. 130.00
7 min. 10 sec. 130.00
Bucket digging opera-
12 ↓ ↓ ↑ ↑ ↑ ↑ ↑
tion (Digging relief)
7 min. 30 sec. 150.00
Low
13 7 min. 30 sec. 150.00 ↑ ↑ ↑ ↑ End
(MIN)
• NC Pressure Measuring Coupler on Front • NC Pressure Measuring Coupler on Rear Engine

Engine Side Side
315
13. Check of Storage Operation of VHMS 14. Downloading of Set Data
Controller s This step applies to works in the cab (on the
s This step applies to works in the cab and the personal computer).
cab under room 1) Set the starting switch to the ON position.
1) Set the starting switch to the OFF position. 2) Click the icon of [VHMS Technical Analysis
2) Check the 7-segment LED of the VHMS Tool] on the personal computer to start the
controller and make sure that the controller VHMS Technical Analysis Tool.
power has been completely cut off. s Input [User Name] and [Password].
s The VHMS controller records and up- s For the operation procedures, refer to
dates data when the starting switch is the Operation and Maintenance Manual
turned off. for VHMS Technical Analysis Tool.

the data recorded in the VHMS controller to
the personal computer.
step.
316
15. Check of Downloaded Data 16. Setting for Satellite Communication
s This step applies to works in the cab (on the (ORBCOMM specification only)
personal computer). s This step applies to works in the cab (on the
1) Check the set data with the [View] function. personal computer).
s For the operation procedures, refer to 1) See the procedures in "5. Startup of VHMS
the Operation and Maintenance Manual Setting Tool" and start the VHMS Setting
for VHMS Technical Analysis Tool. tool.
s Make sure that the [MFA0] code at the s [Select Function] selects [Set up].
time of quick snapshot is displayed in
[Fault History]
s Make sure that the snapshot data has
been recorded.
2) After having check the set data, terminate

[VHMS Technical Analysis Tool].
2) Open the [Communication Setting] tab.

3) Change the setting of [Satellite Setting] to
the setting recorded before the replace-
ment.
317
4) To change the setting of [Satellite Setting], 17. Check of Storage Operation of VHMS
follow the procedures below: Controller
i) Press the [Edit] button in the [Satellite s This step applies to works in the cab and the
Setting] block to display the setting cab under room
screen. 1) Set the starting switch to the OFF position.
ii) Bring GCC Code to the applicable area 2) Check the 7-segment LED of the VHMS
and then press the [OK] button. controller and make sure that the controller
turned off.
GCC Code and Application Area

Code Applicable Area
1 U.S.A.
120 Italy
121 Malaysia
122 Korea
123 Brazil
130 Japan
318
18. Disconnection of Personal Computer 19. Communication to Komatsu
s This step applies to works in the cab. A f t e r h a v i n g c o m p l e t e d St e p s 1 t o 1 7
1) Make sure that the starting switch is set to successfully, please send the checklist and the
the OFF position. VHMS data to Komatsu, Tokyo.
k Be sure to turn off the starting switch Komatsu, Tokyo, has to arrange the setting for
before connecting and disconnecting the satellite communication on the receive side,
personal computer. please be sure to inform Komatsu of the
2) Terminate the OS of the personal computer, completion of the setting.
L2, and switch off the personal computer. s Fax the checklist to Komatsu.
3) Disconnect the wiring harness (1) of the s Send the VHMS data by Notes (LAN) or E-
service kit, L1, from the download connec- mail (WAN).
tor, C53.
Contact VHMS/WebCARE Support Center by
Telephone : 81-3-5561-2765
FAX : 81-3-5561-4766
E-mail : webcare@komatsu.co.jp
319
To : VHMS/WebCARE Support Team, Komatsu, Tokyo Set date :
Fax date :
PC1800-6 DB/ Branch name :
VHMS Initialization Work Checklist Person in charge :
Setting Step Check Item Result
1 Connection of Personal Computer Is it connected correctly? yes no
3 Downloading of remaining data Did the downloading complete? yes no
Date(mm/dd/yyyy)
Date/Time Time
[Local Time] Time zone GMT+
DST(Summer Time) On Off
SMR SMR(h)
Product Group
Machine Model
Check of set information Machine Type
4 Variation code
(Items marked with * are for Serial No.
ORBCOMM specification only.)
Engine Model
Engine Engine Serial No.1
Engine Serial No.2
SHORT FAULT Send On Off
HISTY[*] Number (Default : 10)
SHORT TREND Send On Off
ANALYSIS[*] Interval (Default : 180) (SMR)
Performance check of ORBCOMM controller

5 Is the green LED on? yes no
6 Connection check of personal computer Is it connected correctly? yes no
7 Performance check of VHMS controller Is the 7-segment LED operating normally? yes no
8 Startup of VHMS initialization tool Is [Data clear and Set up] selected as the function of the initialization tool? yes no
Date/Time yes no
Did you match the setting with the record before the replacement?
[Local Time]
SMR Did you add 0.1h to the record before the replacement for the setting? yes no
Resetting of VHMS controller Machine Did you match the setting with the record before the replacement? yes no
9 Engine Did you match the setting with the record before the replacement? yes no
(Items marked with * are for SHORT FAULT
ORBCOMM specification only.) Did you match the setting with the record before the replacement? yes no
HISTY[*]
SHORT TREND
Did you match the setting with the record before the replacement? yes no
ANALYSIS[*]
12 Execution of Quick PM Clinic Have you arranged the snap shot as per the procedures? yes no
14 Downloading of Set Data Have you completed the downloading? yes no
Could you download all files? yes no

What time did you download (by your wrist watch)? Time
15 Check of Downloaded Data Is the [MFAO] code displayed in the Fault History yes no
Data Check Do SMR and Time match with the set values in the Fault History yes no
Is no data missing in the Snapshot? yes no
Setting for Satellite Communication yes no

16 Did you match the setting with the record before the replacement?
18 Disconnection of Personal Computer Did you disconnect it correctly? yes no
Contact VHMS/WebCARE Support Team, Komatsu, Tokyo by

• Telephone : 03-5561-2765 (Nation Code 81)
19 Communication to Komatsu
• FAX:03-5561-4766 (Nation Code 81)
• E-mail:webcare@komatsu.co.jp
320
1/13
1 Report No.
FIELD ASSEMBLY INSPECTION REPORT
After completion of assembling a machine, make inspections according to these check sheets for assuring machine performance and quality.
Model - Type Machine Serial No. User Unit No. Engine Model Engine Serial No.
Backhoe spec. SAA6D140E-3
Service Meter Reading Date of Inspection

Attachment
1 2
Location of Machine at Inspection

Manufacture
Model
Distributor's Name
Serial No.
Customer's Name Address: Signature: Delivery

Report
No. attached
Date:
Inspector's Comments:
Inspector's Name: KOMATSU USE ONLY :

C. Sheet Receiving Date :
Title
By :
Signature:
Remark:
Check sheets filling instructions:
1. Use following indexes for entry of judgement
...........Nomal ...........Correction made on abnormal point

...........Abnormal ...........Not applied
2. Enter actually measured values in parenthese, [ ].
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.
321
279
2/13
Category
Revision
Local After
Check item assembly hours of Judgement standard
time operation
Oil and water levels Actual measurement
Cooling water Soft water [ ]
Yes/No [ ]
Anti-freeze
(A, B, C, D, E) A: -50 - -40fC D: -20 - -10fC
Density of [ ] B: -40 - -30fC E: -10 - 0fC
anti-freeze
C: -30 - -20fC (Not necessary in summer)
EO10W +5mm (10 minutes after stopping
Engine oil [ ] L-H
Checks before assembly
EO30 engine)
EO10W (10 minutes after stopping
PTO oil [ ] L+5-H engine)
EO30
Swing machinery +5 +10 (10 minutes after stopping
gear case oil
EO30 [ ] L -H engine)
Right EO30 [ ]
Final drive gear
case oil Bottom edge of level plug: 0 to -10mm
Left EO30 [ ]
Hydraulic oil EO10W [ ] Between the H and L marks.
Battery electrolyte - [ ] Within 13 mm from bottom surface of

filler port
Engine No. [ ]
When accepted After check

Service meter [ ] [ ]
Revolving frame No. [ ] 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, cahtching O-rings for work equipment piping There must be none.
Checks during assembly
Loose, twisted connections for grease piping There must be none.

(for locations, see assembly
Shim adjustment for work equipment pins Max. 1 mm procedure manual)
Improperly inserted writing, unconnected wiring There must be none.
Loose, untightened ladder mounting bolts There must be none.
323
281
3/13
Category
Revision
Local After
time operation
Loose, untightened counterweight bolts There must be none.
Stepped clearance between counterweight and frame Max. 15 mm
Loose, untightened operator's cab mounting bolts There must be none.
Loose, untightened operator's seat mounting bolts There must be none.
Loose,untightened mounting bolts and joints for travel There must be none.
Forgotten, missing, catching O-rings for travel There must be none.
Loose, untightened track frame mounting bolts There must be none.
Loose, untightened bolts for travel motor cover There must be none.
Checks during assembly
Are there any other parts not yet installed (rear view mirror, etc.)? There must be none.
Follow instructions in assembly procedure

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

Flush hydraulic circuit
manual.

Bleed air from work equipment cylinder circuit
manual.
Greese all parts of work equipment All locations must be greased.
Add to between L and H marks at

Add hydraulic oil
inspection posture
Add fuel, washer flued Fill tank.
Dirty oil on paintwork, damage to paintwork at any part Clean, repair damaged paintwork
325
283
4/13
Category
Revision
Local After
time operation
Monitor display
1. Check of monitor function
When the starting switch is turned ON, the gauges, CHECK
items, and all display items on the monitor should light up, At
the same the alarm buzzer should sound.
2. Check of guages and CHECK items
When the starting switch is turned to ON (all lamps on), all
display lamps should go out after approx. 3 sec. For another 2 Display should be as on left.
seconds, only the gauges are displayed, and the CHECK and
monitor items disappear.
3. Check of monitor items
After starting the engine, the caution lamps should not light up
and the alarm buzzer should not sound when the engine speed
is low idling -- high idling.
Operation of service meter There should be no scratches or misting

of the lens or variation in operation.
Checks monitor
327
285
5/13
Category
Revision
Local After
time operation
Checks of switches, control levers
1. Air control panel 2 17. Engine emergency stop lamp

2. Greasing switch 18. Auto grease caution lamp
3. Safety lock lever 19. Ladder warning lamp
4. Air control panel 1 20. Track counter lamp
5. Swing lock switch 21. Fuel control dial (For front engine)
6. Cigarette lighter 22. Starting selector switch
7. Track counter switch (2 pieces) 23. Fuel control dial (For rear engine)
8. Left work equipment control lever 24. Lamp (Front) switch
9. Car radio 25. Step light switch
10. Horn switch 26. Rotary lamp switch
11. Right work equipment control lever 27. Machine pushup switch
12. Starting switch 28. Fog lamp switch (Optional)
13. Travel lever 29. Rotary lamp (Optional)
14. Machine monitor 30. Boom shockless control switch
15. Machine control monitor 31. Warning buzzer stop switch
16. Preheater switch 32. Wiper switch
329
287
6/13
Category
Revision
Local After
time operation
Operation of working mode selector switch DH lights up: Powerful operation for short
time during heavy-duty
operations
H lights up: Heavy-duty operations
G lights up: Normal operations
When starting the engine, H (heavy-duty

operation) mode is automatically selected.
Operation of auto-deceleration switch ON lights up: Auto-deceleration is actuated.
OFF: Auto-deceleration is
canceled.
Each time the switch is pressed, the

autodeceleration is actuated or canceled.
Operation of heavy lift switch When the switch is turned ON during
independent operations of the boom, the
boom lifting power is increased.
Operation of starting switch OFF position: Engine is stopped
ON position: Electric current flows in the
charging and lamp circuits.
START position: Engine is started.
Operation of fuel control dial MAX: Full speed
MIN: Low idling
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 swing lock switch ON position (actuated):
The swing lock is always applied, and

the upper structure will not swing even if
the swing is operated. In this condition,
the swing lock lamp lights up.
OFF position (canceled):
The swing lock is applied only when all
work equipment control levers are at
neutral; when any work equipment control
lever is operated, it is canceled. The
swing lock is actuated approx. 4 seconds
after all work equipment control lever is
placed in neutal.
Operation of wiper switch 1 OFF: Wiper stops
2 ON: Wiper moves continuously
3 Window washer fluid is sprayed out.
When switch is released it returns to
position 2.
4 ON: Wiper moves intermittenly
5 Window washer fluid is sprayed out.
When switch is released it returns to
posision 4.
Operation of lamp switch This switch is used to turn on the front
lamps, working lamps, additional lamp at
the top front of the cab, rear lamps, and
monitor lighting.
Operation of alarm buzzer stop switch This is used to stop alarm buzzer if it sounds
to warm of an abnormality during operation.
Operation of air conditioner ON: Fan is started.
OFF: Fan is stopped.
Operation of machine push-up switch Low pressure setting:
The boom thrust force is weak.
High pressure setting:
The boom thrust force becomes more
powerful.
Operation of boom shockless control switch When the switch is at the ON position and
the boom is stopped, the shaking is not felt.
Operation of horn switch Press the switch on the right work
equipment control lever to sound the horn.
At the same time, the flashing light (option)
at the top front of the cab will flash for
approx. 5 seconds.
331
289
7/13
Category
Revision
Local After
time operation
Operation of room lamp switch
ON position: Room lamp lights up.
Operation of pump prolix switch 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.
Operation of swing prolix switch 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
barake remains released.
Operation of step light switch e When the switch is pressed, the step
light will light up for approx. 60
seconds.
e Even if the starting switch key is at
the OFF position, the step light will
light up for approx. 60 seconds when
the switch is pressed.
Operation of safety lock lever Pull the lever up to apply the lock.
This lock lever is a hydraulic lock, so
even if it is in the lock position, the

work equipment control lever and travel
lever will move, but the work equipment,
travel motor, and swing motor will not
work.
Operation of travel levers FORWARD:
The lever is pushed forward.
(The pedal is angled forward)
REVERSE:
The lever is pulled back.
(The pedal is angled back)
N (Neutral):
The machine stops.
Operation of left work equipment control lever This lever is used to operate the arm
(with auto-deceleration device) and upper structure.
Arm operation Swing operation
A Arm OUT C Swing to right
B Arm IN 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 This lever is used to operate the boom
(with auto-deceleration device) and bucket.
Boom operation Bucket operation
1 RAISE 3 DUMP
2 LOWER 4 CURL
N (Neutral):
When the lever in this position, the
boom and the bucket will be retained
in the position in which they stop.
Operation of track counter switch If switch (1 or 2) is pressed, the
counter lamp lights up and the control
333
291
8/13
Category
Revision
Local After
time operation
Swing operation running in: Engine high idling speed.
(Work equipment posture: Max. reach)
Right Left
Constant swing speed [ rpm] [ rpm] 4.5 v 0.3 rpm
Swing performance
Brake angle
Max. 55f (Feeling)
Swing variation, hunting

There must be none.
Abnormal noise, irregular swing
There must be none.
Travel operation running in: Engine high idling speed.
(Work equipment posture: Travel posture)
Abnormal noise, heat from carrier roller, track roller, idler There must be no abnormal noise or
abnormal heat.
Operation of travel brake Must brake securely without pulling to
one side.
Abnormal noise, irregular travel There must be none.
Travel deviation (feeling) There must be no abnormal deviation

from fine control range to full stroke
range (feeling).
Forward Reverse
Travel deviation Hight
[ ] [ ] Max. 200 mm/20m
(measured) speed
mm/20m mm/20m
(Only when it is
Travel performance
considered that
there is abnormality.)
Travel rotating Hight speed

Forward Reverse 93.5 - 113.5 sec/5 turns
[ ] [ ] Difference between left and right:
speed - Right
sec sec
Forward Reverse
Hight speed
[ ] [ ]
- Left
sec sec
Right Left
Travel tension [ ] [ ]
mm mm
335
293
9/13
Category
Revision
Local After
time operation
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 equip- RAISE sec LOWER sec RAISE: 7.5 v 0.7 sec. (STD)
ment speed. Boom [ ] [ ] LOWER: 5.2 v 0.5 sec. (STD)
IN sec OUT sec IN: 7.7 v 0.8 sec.
Arm [ ] [ ] OUT: 5.5 v 0.5 sec.
CURL sec DUMP sec CURL: 5.5 v 0.5 sec. (STD)

Bucket [ ] [ ] DUMP: 4.4 v 0.4 sec. (STD)
Work equip- LOWER sec

ment time Boom [ ] Max. 6 sec.
lag. (Engine Only when there is considered to be abnormality.
low idling) IN sec
Arm [ ] Max. 5 sec.
Only when there is considered to be abnormality.
DUMP sec
Bucket [ ] Max. 4 sec.
Work equipment performance
Only when there is considered to be abnormality.
There must be no abnormality during

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

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

Operation when raising chassis 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 IN) Cushion must be fully effective.
Immediately after engine is stopped,

Function of accumulator boom cylinder must move from fully
extended position to ground level.
(Arm at max. reach)
337
295
10/13
Category
Revision
Local After
time operation
Check all parts

e There must be no catching during
During operation
Operating force of control lever when each actuator is actuated. operation.

e Must return naturally to netral.
Feeling and noise of vabration in operator's cab There must be none.
Vibration noise from frame, guard, ladder There must be none.
Movement of doors and windows Must move smoothly.

Around operation cab
Door, window locks Must look securely
Adjustment of operator's seat Must be possible to make all adjustments.
Oil leakage
(Idler, roller, sprocket, final drive gear case, motor, barke, valve) There must be none.
Undercarriage
Interference at any part There must be none.
Looseness of track shoe bolt There must be none.
There must be no overlapping,

Contact of link tread
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 )
Leakage of fuel
There must be none.
[Fuel tank, engine, piping]
Around chassis
Leakage of water from engine cooling water system There must be none.
Leakage of oil from engine lubrication system There must be none.
Leakage of gas from engine gas system There must be none.
Movement of covers Must move smoothly.
Cover locks Must lock securely.
339
297
11/13
Category
Revision
Local After
time operation
Operation of grease pump Must work smoothly.
Looseness, insufficient insertion of electric wiring terminals There must be none.
There must be a clearance of at least

Around chassis
Position for passing electrical wiring throuth

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.
[Cylinder, piping, block]
Grease leakage from grease piping There must be none.

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

There must be none.
tuming over.
341
299
12/13
Note: If the operation or function is defective, measure as necessary. All judgement standard values for speeds are the values in DH mode.
Category
Revision
Local After
time operation
1. Engine speed
Low idling speed [ rpm ] 825 v 25 rpm
High idling speed [ rpm ] 1980 v 50 rpm
Speed at boom raise relief

[ rpm ] 1750 v 100 rpm
(Heavy lift: OFF)
at DH mode
Speed at boom raise relief
(Heavy lift: ON) [ rpm ] 1750 v 100 rpm
2. Rediator fan speed
1050/1150 rpm at 1800 rpm

Speed at engine rated speed [ rpm ]
(STD/55f spec.)
3. Oil pressure measurement (Measure at pump outlet port)

R.H 4-spool 29.4 +1.0
Control valve main
set pressure
Swing 4-spool
valve [ MPa
{kg/cm2} ] -1.5
{300 +10
-15
MPa
kg/cm2}
At engine high idling,
arm OUT, DH mode
Main measurement itmes
29.4 +1.0 and Heavy lift OFF,

Control valve main
set pressure
L.H 5-spool
valve [ MPa
{kg/cm2} ] -1.5
{300 +10
-15
MPa
kg/cm2} relief
31.4 +1.0
Travel relief
set pressure
Right
travel [ MPa
{kg/cm2} ] -1.5
{320 +10
-15
MPa
kg/cm2} Relieved on one
side at
31.4 +1.0
Travel relief
set pressure
Left
travel [ MPa
{kg/cm2} ] -1.5
{320 +10
-15
MPa
kg/cm2}
DH mode
28.4 +1.0
Swing relief set pressure [ MPa
{kg/cm2} ] -1.9 MPa
{290 +10 2
-20 kg/cm }
At engine high idling,
swing and DH mode, relief
3.14 +0.34 +0.35 2
Pilot relief valve set pressure [ MPa
{kg/cm2} ] 0 MPa {32 0 kg/cm }
(At engine high idling, neutral)
At neutral Boom RAISE

Nc valve output pressure (at Max.
top surface of NC valve)
and No.2 pump
No.1 [ MPa
{kg/cm2} ][ MPa
{kg/cm2} ] 0.39 MPa
{4 kg/cm2} Engine
Nc valve output pressure (at Max. high idling
top surface of NC valve)
pump
No.3 [ MPa
{kg/cm2} ][ MPa
{kg/cm2} ] 0.39 MPa
{4 kg/cm2}
Note: Measure the following J/S differential pressure only if the

NC valve output pressure does not pass the test.
At neutral Boom relief

J/S differential pressure
1.8 v 0.2 MPa
(diferential pressure at input and
output ports of jet sensor) No.1
and No.2 pump
[ MPa
{kg/cm2} ][ MPa
{kg/cm2} ] {18 v 2 kg/cm2} Engine
J/S differential pressure
high idling
1.8 v 0.2 MPa DH mode
(diferential pressure at input and
output ports of jet sensor) No.3
pump
[ MPa
{kg/cm2} ][ MPa
{kg/cm2} ] {18 v 2 kg/cm2}
343
301
13/13
Category
Revision
Local After
time operation
4. Hydrauric drift of work equipment
(bucket unloaded, 50 v 5fC)
Bucket tooth tip [ cc ] Max. 1200 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 [ cc ] Max. 17 mm/minutes
Arm cylinder [ cc ] Max. 23 mm/minutes
Bucket cylinder [ cc ] Max. 9 mm/minutes
5. Operation force, travel
Operationg 16.7 v 4.9 N

Boom lever
force [ RAISE N
{kg} ] [ LOWER N
{kg} ] {17 v 0.5 kg}
Stroke
RAISE LOWER PLAY Stroke: 85 v 10 mm
[ mm] [ mm] [ mm] Play: Max. 10 mm
Swing lever
force [ RIGHT N
{kg} ] [ LEFT N
{kg} ] {1.4 v 0.4 kg}
Stroke
RIGHT LEFT PLAY Stroke: 85 v 10 mm
Main measurement itmes

Bucket
lever force [ CURL N
{kg} ] [ DUMP N
{kg} ] {1.4 v 0.4 kg}
Stroke
CURL DUMP PLAY Stroke: 85 v 10 mm
[ mm] [ mm] [ mm] Play: Max. 10 mm At engine high
Operationg 16.7 v 4.9 N idling, relief
Arm lever
force [ IN N
{kg} ][ OUT N
{kg} ] {1.7 v 0.5 kg}
Stroke
IN OUT PLAY Stroke: 85 v 10 mm
Right
travel lever force [ FOR-
WARD
N RE-
{kg}
VERSE ][ N
{kg} ] {2.6 v 0.6 kg}
Stroke
FORWARD REVERSE PLAY Stroke: 135 v 15 mm
Left
travel lever force [ FOR-
WARD
N RE-
{kg}
VERSE ][ N
{kg} ] {2.6 v 0.6 kg}
Stroke
FORWARD REVERSE PLAY Stroke: 135 v 15 mm
Measure the travel of the lever at the center of the lever tip.
9JH03109
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GEN00016-01

Field Assembly Instruction

5. LIST OF PARTS SENT INDIVIDUALLY

Loose-supply and assembly-supply items list for harbor assembly

2 07289-00080 CLAMP 2 Water hose outlet from

6 01011-83010 BOLT 7 For installation of hydraulic

For blocking lower hole of

9 01024-81235 BOLT 8 For installation of suction

10 21T-62-64171 TUBE 1 Front oil cooler inlet tube

For installation of swing

22 01010-81230 BOLT 5 For installation of small

24 21T-54-65411 NET 2 Net above right-hand duct

26 21T-54-65910 SHIM 3 Fitting adjustment shim

28 21T-54-68630 FRAME 1 Front frame of right-hand

30 21T-54-67181 COVER 1 Right-hand door top cover

Right-hand duct top

34 21T-54-64351 BRACKET 1 Right-hand duct top

39 21T-54-64111 COVER 1 Cooling rear cover

40 01024-81230 BOLT 4 For installation of oil

43 21T-54-64311 COVER 2 Muffler cover

For clamping wiring har-

For clamping wiring har-

For clamping wiring har-

33 21T-54-69870 COVER 1 A-12 Escape ladder storage box

38 01010-81225 BOLT 4 A-12 For installation of storage

51 21T-54-67480 HAND RAIL 1 A-16 Rear handrail of operator's

73 21T-06-71920 COVER 1 A-27 Electric wire cover at rear

83 01010-80820 BOLT 4 A-27 For installation of L-

94 21T-43-67392 DUCT 1 A-28 Air conditioner duct at left

99 01024-D1025 BOLT 3 A-27 For installation of defroster

103 01024-D1016 BOLT 1 A-27 For installation of defroster

109 07281-02169 CLAMP 4 A-39 For A/C inside air intake

44 01580-11210 NUT 4 A-04 For installation of travel

46 01010-81255 BOLT 22 A-24

57 21T-54-67461 HAND RAIL 1 A-20 Rear handrail of right-hand

63b 21T-54-65750 LADDER 1 A-21 Hydraulic tank ladder(*For

73 21T-54-67992 HAND RAIL 1 A-30 Handrail of center ladder

76 21T-54-67190 HAND RAIL 1 A-30 Upper rear handrail of left-

79 21T-54-78320 HAND RAIL 1 A-31 Center handrail of hydrau-

81 07283-33450 CLIP 8 A-31

105 21T-54-75650 GRIP 1 A-14 Handrail grip of left-hand

137 21T-04-64360 CABLE 1 A-32 Fuel cut lever cable

152 21T-06-67770 COVER 1 A-32 Switch wiring harness

162 21T-54-69511 HAND RAIL 1 A-33 Radiator top handrail

180 8221-93-1630 PLATE (ENGLISH) 1 A-32 Decalcomania of engine

186 01010-82465 BOLT 44 A-04 For installation of center

215 21T-54-68480 HAND RAIL 1 A-30 Handrail of center stairs

225 01641-21223 WASHER 12 A-04 For installation of travel

233 21T-54-75650 GRIP 2 A-20 Front grip of right-hand

242 01024-81225 BOLT 2 A-11 For installation of work-

259 21T-54-65520 SHEET 1 A-34 For blocking floor PPC

262 21T-54-69820 FRAME 1 A-11 Right-hand rear catwalk

273 21T-54-68641 PLATE 4 A-11 Handrail lower plate (*+55:

292a 21T-06-64590 SENSOR 1 A-35 NC pressure sensor

293 21T-54-67491 HAND RAIL 1 A-30 Boom rear handrail

296 21T-04-64320 BTACKET 1 A-23

15 203-973-5660 CLAMP 3 C-12 For greasing between

16 21T-72-17740 HOSE 1 C-12

1 21T-63-X2310 BOOM CYL. L.H 1 C-01 Boom cylinder, left-hand

6 07282-11048 CLAMP 4 A-08

49 01643-30823 WASHER 3 A-08

106 07282-11048 CLAMP 4 A-08