34
(1) Lift the boom cylinder and adjust it to the frame’s pin holes. (2) Drive in the boom cylinder foot pin.
aInside of pin hole and bushing of boom cylinder boss: Apply LM-P (Only 1st time) [Apply lithium grease for 2nd time and after]
(3) Check the clearance between the pin and chassis and combine and insert adjustment shims (1) so that the clearance on the outside of the chassis will be 1.5 mm or less. Adjust the shims for both right and left cylinders. Insert one piece of 207-70-71251 on the inside of the chassis and insert the other shims on the outside of the chassis.
(4) Push in the boom cylinder foot pin fully and install the lock plate. a Check that the pin lock bolt is not loosened but tightened and check
its torque. Assembly procedure
Installation of boom cylinder (1/2)
B-1
Precautions Necessary tools Necessary equipment
a Assemble so that the grease hole of the boom cylinder bottom will be down.
a Decide the thickness of the adjustment shim by combining shims 1 mm thick (207-70- 71251) and 2 mm thick (207-70-71261). a When pushing in the pin, take care not to break
the dust seal installed to the boom cylinder boss.
Name Q’ty Name Q’ty
Nylon sling 2 25 t crane 1
Socket 19 mm width across flats 1
Small-sized impact wrench 1
Ot
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Outside of machine
Rest of shims 207-70-71251 1 piece
PART P
Inside of machine
(Clearance must be 1.5 mm or less)
No. Loose-supply items Q’ty
1 207-70-71251 6
(5) Insert the boom cylinder supports between each cylinder and revolving frame. * Wooden blocks 30 mm thick may be used instead of the cylinder supports. Assembly procedure
Installation of boom cylinder (2/2)
B-1
Precautions Necessary tools Necessary equipment
Name Q’ty Name Q’ty
Ot h e rs Boom cylinder Support stand Revolving frame
36
When removing the hydraulic piping, be sure to release the remaining pressure according to the following proce- dure.
(1) Lower the work equipment lock lever to the "LOCK" position, and start and run the engine for about 10 seconds, and then stop it.
a Limit the engine speed to low idling.
a Set the work equipment control lever in neutral.
(2) Within 15 seconds after stopping the engine, turn the starting switch to the ON position, set the lock lever to the FREE position, and operate each control lever to the stroke end.
a Repeat the operations of (1) to (2) 3 times. (3) Lower the lock lever to the "LOCK" position.
(4) Remove the oil filler cap of the hydraulic tank to release the pressure in the tank.
kWhen removing the oil filler cap of the hydraulic tank, turn it slowly to release the internal pressure first, and then remove the cap carefully.
(5) After releasing the pressure in the tank, install the oil filler cap of the hydraulic tank to prevent entry of dirt. Assembly procedure
Releasing remaining pressure in hydraulic circuit
B-2
Precautions Necessary tools Necessary equipment
Name Q’ty Name Q’ty
Ot
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(1) Remove the oil stopper plug from the tube at the boom cylinder end.
(2) Set the new O-rings (3) to boom cylinder hoses (1) and (2), 4 pieces in total, and install them to the normal circuit as shown in the figure below.
a Bleed the boom cylinder of air by following Assembly Procedure B-14 “Bleeding Air from Work Equipment Circuit”.
Assembly procedure
Installation of boom cylinder hoses
B-3
Precautions Necessary tools Necessary equipment
1. When removing an oil stopper plug from a hose, slowly loosen its bolts by gradually releasing the internal hydraulic pressure.
2. Keep the removed oil plugs so that they can be reused.
3. When connecting the hoses, take extremely care not to clinch or damage the O-rings. 4. Also, take extremely care not to enter a foreign
material into the hydraulic circuit.
Name Q’ty Name Q’ty
Oil container 2
Socket 14 mm width across flats 1
Small-sized impact wrench 1
Ot
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rs
No. Already installed to Q’ty
1 207-62-52610 2
2 206-62-51650 2
No. Loose-supply items Q’ty
3 07000-13032 4
a Check that the split flange is not loosened but tightened.
a Check that each O-ring is fitted, has not come off, and is not caught.
38
Insert the boom cylinder top pin in the boom temporarily.a Weight of boom cylinder top pin: 73 kg a Apply LM-P to the inside of boss. Assembly procedure
Installation of boom cylinder top pin
B-4
Precautions Necessary tools Necessary equipment
Name Q’ty Name Q’ty
Nylon sling 1 25 t crane 1
Ot
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No. Loose-supply items Q’ty
Removal of cover
1. Remove battery case small cover (1). aWeight of battery case small cover: 1.72 kg
2. Open AdBlue/DEF cover.
3. Remove the fuel spray prevention cover.
4. Remove AdBlue/DEF cover.
aWeight of AdBlue/DEF cover: 34.98 kg aWhen removing the cov-
er, take care not to hook the breather in it.
Assembly procedure
Installation of boom assembly (1/4)
B-5
Precautions Necessary tools Necessary equipment
Name Q’ty Name Q’ty
Socket, width across flats: 19 mm 1 Small-sized impact wrench 1
Extension, L: 150 1 Ot h e rs M12 eyebolts may be installed to 2 places to install slings.
No. Parts installed to machine Q’ty
1 208-54-21770 1 2 01024-81225 2 3 208-54-21881 1 4 01034-81225 4 5 01643-51232 4 6 208-54-21602 1 7 01024-81230 4
40
5. Remove the fuel tank front cover. aWeight of fuel tank: 9.87 kg
6. Install the boom foot pin.
aWhen you install the boom foot pin, if the mounting bolts of the filler port bracket and breather bracket are obstacles, remove and place them aside.
• Filler port bracket mounting bolt: (10), (11) • Breather bracket mounting bolt: (12)
7. After installing the boom foot pin, install the cover in the reverse order. Assembly procedure
Installation of boom assembly (2/4)
B-5
Precautions Necessary tools Necessary equipment
Name Q’ty Name Q’ty
Socket, width across flats: 19 mm 1 Small-sized impact wrench 1
Extension, L: 150 1 Ot h e rs
㪏
㪐
InstallIf this is obstacle to installation of boom foot pin, bent it around rubber hose. (Do not remove piping)
Rubber hose
No. Parts installed to machine Q’ty
8 2A7-54-11742 1
9 01024-81230 4
10 01024-81255 1
11 01024-81230 2
(1) Sling the boom assembly with the crane and match it with the pin holes of the machine. a Protect the pin from the sling wires.
(2) Install the boom foot pin.
At this time, balance the boom so that it will be in parallel with the pin holes of the machine. Assembly procedure
Installation of boom assembly (3/4)
B-5
a When slinging boom assembly
(3) Check the clearance in the boom foot all around on the left side of the chassis, then decide and insert the shim quantity so that the minimum clearance will be 1 mm or less.
The following adjustment shims are prepared. (1) (208-70-71611, 3 pieces) t2.0 (2) (208-70-71621, 1 piece) t2.5 (3) (208-70-71631, 1 piece) t3.0 (4) (208-70-71641, 1 piece) t3.5
Assemble these shims to obtain desired thickness.
(Be sure to insert one of (1) on the right side of the machine.) (4) Push in the boom foot pin fully and install the lock plate.
a Inside of pin hole and bushing of boom foot bushing: Apply LM-P (Only 1st time)
[Apply lithium grease for 2nd time and after]
a Check that the pin lock bolt is not loosened but tightened and check its torque.
(Clearance must be 1 mm or less)
No. Loose-supply items Q’ty
1 208-70-71611 3
2 208-70-71621 1
3 208-70-71631 1
4 208-70-71641 1
Precautions Necessary tools Necessary equipment
a When pushing in the pin, take care not to break the dust seal installed to the boom foot as shown below.
a For installation of the grease supply hoses, see Step B-11 "Connesction of grease supply piping of work equipment".
a For the boom and boom cylinder assembly, see next page.
Name Q’ty Name Q’ty
ø20 × 5,000 mm wire 2 25 t crane 1
ø10 × 3,000 mm wire 1
Lever block 1.5 t 1
Large hammer 1
Socket 30 mm width across flats 1 Medium-sized impact wrench 1
Ot
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Dust seals
42
a Installation of boom and boom cylinder assembly
(1) Sling the boom and boom cylinder assembly with the crane and match them with the pin holes of the chassis. a Protect the pin from the sling wires.
(2) Install the boom foot pin.
At this time, balance the boom so that it will be in parallel with the pin holes of the machine Assembly procedure
Installation of boom assembly (4/4)
B-5
Precautions Necessary tools Necessary equipment
a When pushing in the pin, take care not to break the seals installed to the boom foot as shown below
a For installation of the grease supply hoses, see Step B-11 "Connesction of grease supply piping of work equipment".
Name Q’ty Name Q’ty
ø20 × 5,000 mm wire 2 25 t crane 1
ø10 × 3,000 mm wire 1
Lever block 1.5 t 1
Large hammer 1
Socket 30 mm width across flats 1 Medium-sized impact wrench 1
Ot
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Dust seals
(3) Decide and insert the shim quantity so that the clearance in the boom foot on the left side of the machine will be 1 mm or less.
The following adjustment shims are prepared. (1) (208-70-71611, 3 pieces) t2.0
(2) (208-70-71621, 1 piece) t2.5 (3) (208-70-71631, 1 piece) t3.0 (4) (208-70-71641, 1 piece) t3.5
Assemble these shims to obtain desired thickness. (Be sure to insert one of (1) on the right side of the machine.) (4) Push in the boom foot pin fully and install the lock plate.
a Inside of pin hole and bushing of boom foot bushing: Apply LM-P (Only 1st time)
[Apply lithium grease for 2nd time and after]
a Check that the pin lock bolt is not loosened but tightened and check its torque.
Weight of boom assembly : 4,950 kg
a When sling the boom and cylinder assembly
No. Already installed to chassis Q’ty
1 208-70-71611 3 2 208-70-71621 1 3 208-70-71631 1 4 208-70-71641 1 (Clearance must be 1 mm or less)
(1) Remove the oil stopping plugs of the tubes on the boom side. (2) Install arm cylinder hoses (1), (2), (3), and
bucket cylinder hoses (4) (2 pcs.) to the regular circuit as shown below.
a Bleed the arm cylinder of air by following Assembly Procedure B-14 “Bleeding Air from Work Equipment Circuit”.
a Check that the split flange is not loosened but tightened.
a Check that each O-ring is fitted, has not come off, and is not caught. Assembly procedure
Installation of hoses from chassis along top of boom
B-6
Precautions Necessary tools Necessary equipment
1. When removing an oil stopper plug from a hose, slowly loosen its bolts by gradually releasing the internal hydraulic pressure. 2. Remove and store the flange, O-rings and
heads so that you can reuse them later. 3. When connecting the hoses, take extremely
care not to clinch or damage the O-rings. 4. Also, take extremely care not to enter a foreign
material into the hydraulic circuit.
Name Q’ty Name Q’ty
Oil container 2
Socket 14 mm width across flats 1
Small-sized impact wrench 1
Ot
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No. Already installed to Q’ty
1 208-62-41661 1
2 208-62-41671 1
3 208-62-41682 1
4 208-62-41642 2
No. Loose-supply items Q’ty
44
Clearance “a”
0.5∼1.5mm
Clearance “b”0.5∼1.5mm
(1) Remove the stopper plate (2) fixed to the boom, and remove the boom cylinder top pin. a Boom cylinder: 360 kg / Boom cylinder top pin: 73 kg
(2) Start the engine and rotate it at the low idle speed.
(3) Sling the right cylinder, raise the rod slowly, and match the pin holes while extending and retracting the cylinder. (4) Knock in the cylinder top pin.
a Inside of pin hole and bushing of boom cylinder bushing: Apply LM-P (Only 1st time) [Apply lithium grease for 2nd time and after]
(5) Mount fixed the stopper plate and adjusting shims (5), (6). Assembly procedure
Connection of boom cylinder head
B-7
Precautions Necessary tools Necessary equipment
a When operating the cylinder, extend it slowly. Do not operate the cylinder suddenly and do not operate it to the end of its stroke. In the first operation, there is an air in the cylinder and the cylinder may not move for the first 10 seconds. In such case, do not operate the control lever to the end of its stroke.
a Check the clearance between cover (2) and cylinder rod all around and combine shims 1 mm thick (208- 70-71561) and 2 mm thick (208-70-71571) so that clearance "a" will be 0.5 – 1.5 mm. (Portions of ) a Adjust clearance "b" between the plate and double
nut to 0.5 to 1.5 mm. (Part marked with A )
a Before operating the cylinder, check that the flushing filter is installed (to capture dirt in the circuit). a For installation of the grease supply hoses, see Step
B-11 "Connesction of grease supply piping of work equipment".
Name Q’ty Name Q’ty
Nylon sling 1 25 t crane 1
Socket 36 mm width across flats 1
Spanner 36 mm width across flats 1 Large-sized impact wrench 1
Ot
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No. Loose-supply items Q’ty
1 208-70-61860 1 2 208-70-31242 2 3 207-70-13340 2 4 01580-12419 4 5 208-70-71561 4 6 208-70-71571 2
(1) Remove lock plate (2) of boom top pin (1) fixed to the boom and pull out top pin (1). (Boom top pin: 54 kg)
(2) Raise the arm assembly, align the position with the boom hole, insert a shim, then push in the pin. (Arm assembly: For the weight, see the table in "Transportation")
a Seals (07145-00120 × 2) are installed to the inside of the bushing at the arm end, but be careful no to dam- age the seals when inserting the pin.
a Inside of pin hole and bushing of arm bushing: Apply LM-P (Only 1st time) [Apply lithium grease for 2nd time and after]
a Check the clearance all around and combine shims (5), (6), and (7) so that the clearance will be 1 mm or less (Portion of ).
(3) Install the stopper (2). Assembly procedure
Installation of arm assembly (1/2)
B-8
Precautions Necessary tools Necessary equipment
a When pushing in the pin, take care not to break the dust seal installed to the arm boss as shown below.
Name Q’ty Name Q’ty
Nylon sling 2 25 t crane 1
Lever block 1.5 t 1
Socket 30 mm width across flats 1 Medium-sized impact wrench 1
Large hammer 1
Ot
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No. Loose-supply items Q’ty
1 208-70-71580 1 2 208-70-71670 1 3 01010-82045 2 4 01643-32060 2 5 208-70-71531 3 6 208-70-71541 1 7 208-70-71551 1 Shim thickness (5) 208-70-71531 2.0 mm (6) 208-70-71541 2.5 mm (7) 208-70-71551 3.0 mm
a Check that the pin lock bolt is not loosened but tightened and check its torque.
46
(4) Remove lock plate (2) of arm cylinder top pin (1) fixed to the arm and pull out top pin (1). (Arm cylinder top pin: 23 kg)
(5) Start the engine, run at low idle, extend the arm cylinder rod slowly, and align the position of the hole.
When doing this, raise the arm cylinder with a crane and operate the arm cylinder at the same time to align the position.
(6) Insert shims (4) on both sides and push in arm cylinder top pin (1).
a Inside of pin hole and bushing of arm cylinder bushing: Apply LM-P (Only 1st time) [Apply lithium grease for 2nd time and after]
(7) Install lock plate (2).
a Operate the cylinder slowly. Do not operate it quickly and do not bring it to the stroke end. Since air gathers inside the cylinder at the first time, it may not move for aver 10 seconds, but do not move the lever to the full stroke.
a When installing the arm, extreme caution should be exercised so that the bucket cylinder rod does not jump out.
a Check that the pin lock bolt is not loosened but tightened and check its torque. Assembly procedure
Installation of arm assembly (2/2)
B-8
Precautions Necessary tools Necessary equipment
a For installation of the grease supply hoses, see Step B-11 "Connection of grease supply piping of work equipment".
a When pushing in the pin, take care not to break the dust seal installed to the cylinder boss.
Name Q’ty Name Q’ty
Nylon sling 1 25 t crane 1
Large hammer 1
Ot
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No. Loose-supply items Q’ty
1 208-70-61220 1
2 205-70-66580 1
3 01024-81235 2
Assembly procedure
Installation of bucket cylinder hoses between
boom and bucket cylinder (1/2)
B-9
Precautions Necessary tools Necessary equipment
1. Keep the oil plugs used for component so that they can be reused.
2. When installing the hose take extreme care not to catch the O-ring.
3. When installing the hoses, take extreme care not to twist them.
(Tighten from the 90° adapter to prevent twisting.)
4. While installing the hose, take extreme care not to allow dirt in the circuit.
Name Q’ty Name Q’ty
Oil container 2
Socket 14 mm width across flats 1
Extension L150 1
Small-sized impact wrench 1
Ot
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(1) Remove the tube oil plug on the bucket cylinder side on the left side of the arm, install new O-ring (2), and connect bucket cylinder hose (1).
(2) Remove the tube oil plug on the machine side, install new O-ring (2), and connect bucket cylinder hose (1). a Reuse the oil stop parts as the split flange, bolts, etc.
a Bleed air from the bucket cylinder. For details, see B-14 "Bleeding air from work equipment circuit". a Check that the split flange is not loosened but tightened.
a Check that each O-ring is fitted, has not come off, and is not caught.
No. Loose-supply items Q’ty
1 207-62-54680 1
2 07000-13032 2
No. Already installed to Q’ty
3 07371-31049 4
4 07375-21035 8
Installation of hose and O-ring
PART A
48
(3) Similarly, connect bucket cylinder hose (1) on the right side of the arm.
Assembly procedure
Installation of bucket cylinder hoses between
boom and bucket cylinder (2/2)
B-9
Precautions Necessary tools Necessary equipment
1. Keep the oil plugs used for component so that they can be reused.
2. When installing the hose take extreme care not to catch the O-ring.
3. When installing the hoses, take extreme care not to twist them.
(Tighten from the 90° adapter to prevent twisting.)
4. While installing the hose, take extreme care not to allow dirt in the circuit.
Name Q’ty Name Q’ty
Oil container 2
Socket 14 mm width across flats 1
Extension L150 1
Small-sized impact wrench 1 Ring wrench 14 mm width across
flats 1
Ot
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No. Loose-supply items Q’ty
1 207-62-54680 1
2 07000-13032 2
No. Already installed to Q’ty
3 07371-31049 4
4 07375-21035 8
[Preparation for installation]
1. Remove the stoppers of the bucket-arm connecting pin (fixed to the arm) and bucket-link connecting pin (fixed to the link), and remove those pins.
2. Lightly install bushing (1) to the boss on the bucket side, and install O-rings (2) to the places shown below. a Apply LM-P (1st time only) to the inside surface of the bushing (apply lithium grease at the 2nd time and
after).
[Installation]
3. Run the engine at low idle and operate the boom cylinder and arm cylinder slowly to set the holes for the bucket and arm connecting pin.
a Weight of bucket assembly: For the weight, see the packing style table for transportation. 4. Install the arm-bucket connecting pin and the lock bolt and nut for the pin, without inserting shim.
Assembly procedure
Installation of bucket assembly (1/3)
B-10
Precautions Necessary tools Necessary equipment
Name Q’ty Name Q’ty
Nylon sling 1 25t crane 1
Sledge hammer 1
Socket, width across flats: 36 mm 1 Spanner, width across flats: 36 mm 1
Ring spanner, width across flats: 36 mm 1 Large-sized impact wrench 1
Torque wrench: 85 kgm 1 Ot h e rs
㪉
㪈
O-ring positionNo. Loose-supply items Q’ty
1 208-70-34230 1
50
[Adjustment of shim]
5. Lightly tighten the stopper bolt (M24), measure clearance "a", and then decide the number of shims so that their total thickness is the measured value +0.5 to +1.0 mm.
a Measure when there is no clearance on both sides of the arm end.
6. Install shims (1) and (2).
7. Lightly tighten the stopper bolt (M24), check clearance "b" between the arm and bushing is 0.5 to 1.0 mm all round, and then install the O-rings to the correct positions (both sides of arm end).
8. Install lock bolt. Assembly procedure
Installation of bucket (2/3)
B-10
Precautions Necessary tools Necessary equipment
When tightening, adjust the clearance between the double nut and stopper to 0.5 to 1.5 mm. (Clearance marked with *)
Name Q’ty Name Q’ty
Sledge hammer 1
Socket, width across flats: 36 mm 1
Spanner, width across flats: 36 mm 1 Ring spanner, width across flats: 36 mm 1
Large-sized impact wrench 1
Torque wrench: 85 kgm 1 Ot h e rs O-ring position Clearance "a" O-ring
Correct position of O-ring
Clearance "b" (0.5 to 1.0 mm)
No. Loose-supply items Q’ty 1 208-70-34250 18
[Installation of link]
9. Fit O-ring (1) to prevent entry of soil and sand.
10. While operating the bucket cylinder, align the holes for the bucket-link connecting pin.
a Operate the cylinder slowly. Do not operate it quickly or to the stroke end. In the first operation, there is an air in the cylinder and the cylinder may not move for the first 10 seconds. In such case, do not operate the control lever to the end of its stroke.
11. Push in the link-bucket connecting pin, install O-rings (1) to the correct positions to prevent entry of dirt, and then install the pin stopper.
Assembly procedure
Installation of bucket (3/3)
B-10
Precautions Necessary tools Necessary equipment
When tightening, adjust the clearance between the double nut and stopper to 0.5 to 1.5 mm. (Clearance marked with *)
Name Q’ty Name Q’ty
Sledge hammer 1
Socket, width across flats: 36 mm 1
Spanner, width across flats: 36 mm 1 Ring spanner, width across flats: 36 mm 1
Large-sized impact wrench 1
Torque wrench: 85 kgm 1 Ot h e rs
㪈㪈
Correct position of O-ring
No. Loose-supply items Q’ty
52
(1) Remove the oil stopper plug at the cylinder end and the oil stopper plug at the hose nipple end, remove the nipple from the hose, then assemble the boom cylinder greasing hoses (2 places) at porting (a) to the cylinder end, and connect.
(2) Remove the oil stopper plug at the cylinder end and the oil stopper plug at the hose elbow end, remove the elbow from the hose, then assemble the arm cylinder bottom greasing hose at porting (b) to the cylinder end, and connect.
(3) Remove the oil stopper plug at the cylinder end and the oil stopper plug at the hose elbow end, remove the elbow from the hose, then assemble the arm cylinder top greasing hose at porting (c) to the cylinder end, and connect.
Assembly procedure
Connection of work equipment grease piping (1/2)
B-11
Precautions Necessary tools Necessary equipment
a After installing the boom and boom cylinder, supply grease to parts (a) and (b), and then in- stall the arm.
a After installing the arm, supply grease to part (c), and then install the bucket.
Name Q’ty Name Q’ty
Spanner 19 mm width across flats 2