Applicable serial No.

HD2045 : 8775501

HD2045

WARNING
You must read and understand this manual and instruction
manual before operating or servicing this machine.

306431
HD2045 306431
 Introduction (857S-0001-1E)

This manual gives a basic summary of KATO hydraulic excavator and explains the equipment making up the machine,
and the structure, functions, disassembly and assembly, adjustment, maintenance etc. of hydraulic-related equipment.
Improvement in the work rate and the lifetime of the machine are largely controlled by the standards of inspection and
servicing. Refer not just to this manual but also to the separate instruction manual and parts list to gain an understanding
of the structure of the machine and carry out service correctly.
As a general rule, the content of this manual is compiled according to the separate equipment which makes up the
machine, but please understand that the equipment on your machine may differ to some extent for reasons such as
technical improvement. In that case, use this manual as reference material.
This manual does not cover the engine or optional devices. Refer to the separate service manuals.

Serial number and engine serial number (857S-0002-0E)

The serial number and engine serial number will assist in smooth administrative processing of orders for parts and
servicing from your authorised KATO dealer, so please provide these numbers when ordering.

1
MEMO

2
 Table of Contents (877V-0001-0E)

Introduction [1]
Serial number and engine serial number [1]

A Summary

1. How to use this manual 1

2. List of appendix overhaul manuals 2
3. Precautions on inspection and servicing 3
4. Safety parts for periodic replacement 10
5. Inspection and servicing table 11
6. Lubrication 17
7. Tightening torque table 23
8. Judgement of the time for servicing 27

B Specifications

1. External views 31
2. General data 32
3. Working range 33
4. Dimensions and weight 35

C Layout and circuit diagram of equipment

1. Part names 41
2. Hydraulic circuit diagram 45
3. Electrical circuit diagram 46

3
 D Engine unit

1. Engine-related equipment 53
2. Engine control 66
3. Data file 89

E Hydraulic pump equipment

1. Main mechanism 91
2. Hydraulic pump equipment 93
3. Measurement and adjustment of the pressure of pressurised oil 95
4. Equipment related to the hydraulic pump 99
5. Data file 120

F Control equipment

1. Control equipment 127

2. Equipment related to control devices 128
3. Changing procedure for control lever configuration 131

G Front attachment

1. Front attachment 133

2. Removal and mounting of the front attachment 139
3. Data file 161

4
 H Superstructure

1. Swing equipment 171

2. Removal and mounting of swing equipment 173
3. Removal and mounting of equipment in the superstructure 178
4. Data file 188

I Lower structure

1. Lower structure-related equipment 191

2. Travel equipment 193
3. Data file 208

J Electrical equipment

1. Layout of electrical equipment 215

2. Air conditioner 227
3. Battery handling 233
4. Bulb replacement 235
5. Fuse replacement 235
6. High current fuse replacement 236
7. Inspection and replacement of the wiper blade 236
8. Data file 237

5
MEMO

6
 (877V-0002-0E)

A Summary

1. How to use this manual 1

2. List of appendix overhaul manuals 2

3. Precautions on inspection and servicing 3

4. Safety parts for periodic replacement 10

5. Inspection and servicing table 11

6. Lubrication 17
6-1 Precautions on lubrication 17
6-2 Recommended lubricants table 19
6-3 Greasing chart 21
6-4 Oiling chart 22

7. Tightening torque table 23

7-1 Tightening torque for meter screw standard bolt 23
7-2 Tightening torque for designated bolt 23
7-3 Tightening torques for hydraulic and pneumatic related joints 24

8. Judgement of the time for servicing 27

8-1 On-site method for hydraulic oil evaluation 28
8-2 When to disassemble hydraulic equipment 29
8-3 Judgement of the time for servicing each part 30
1. How to use this manual (857S-0005-1E)

(1) Carry out preoperational checks before starting operation.

(2) Check each test item according to the testing schedule of monthly and yearly tests.

If a problem occurs

Refer to each equipment chapter and investigate the location of the problem.
C: Layout and circuit diagram of equipment H: Superstructure
D: Engine unit I: Lower structure
E: Hydraulic pump equipment J: Electrical equipment
F: Control equipment APC100: Refer to the
separate manual.
G: Front attachment

If disassembly of hydraulic units and other devices is required, refer to the "disassembly and assembly
of equipment" section of each equipment chapter.
The manual code of the "overhaul manual" of hydraulic units and other devices required for
disassembly and assembly is printed, so refer to that procedure manual.

When you have repaired any malfunctioning parts, carry out the specified inspections and check that there
is enough oil.
When replacing parts, always check them with reference to the relevant parts list.

Carry out preoperational checks and test-run the equipment unloaded to confirm its safety.

Start work.

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2. List of appendix overhaul manuals (877V-0003-0E)

Device name Part number Manual code

Pilot valve (travel) 669-35000001 800253E
Lock valve 669-65400002 800317E
Rotary seal 689-79700002 800393E
Pilot valve 669-34900001 805171E
Air conditioner unit 709-82700002 805181E
Swing motor assembly 619-00339002 805641E
Plunger motor 619-61900002
Swing motor reduction gear 619-80300001
Hydraulic pump 609-80800010 805651E
Traveling motor assembly 619-00341011 805661E
Hydraulic motor 619-62100011
Traveling motor reduction gear 619-98300003
Control valve 669-27300001 805671E
Boom cylinder 329-16400001 805681E
329-16500001
Arm cylinder 329-19600012 805681E
Bucket cylinder 329-26100001 805681E
Brake valve 639-70800000 805691E
APC100 306211

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3. Precautions on inspection and servicing (0097-1025-3E)

Inspection and servicing are as important as lubrication as they have a great influence on the lifespan of the machine and
are highly significant in maintaining safety. Inspect and service the machine regularly to keep yourself aware of its
condition and preserve its safety and economic performance.
Refer to the inspection and servicing points and methods described below and observe them correctly.

(1) Regular independent inspection

Draw up an inspection and servicing schedule and implement it.

(2) Keeping independent inspection records

The regular independent inspection must be carried out, the
results recorded and preserved.

(3) Repair of broken or malfunctioning parts

If you discover a breakdown or malfunction during an
independent inspection or preoperational check, it must be
repaired immediately.
Operation with such problems unrepaired is highly dangerous.
Never start work before all repairs are complete.

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(4) Park the machine on level ground for inspection and servicing
Choose a work site which is firm, level and free of hazards.
Always lower the bucket to rest on the ground.
Stop the engine and remove the key.
Put the warning tag.
Place chocks to immobilize the track shoes.

(5) Each piece of equipment is rigorously tested and tuned before

shipping. Tuning outside your authorised KATO dealer is
forbidden.
(6) Repairs to the boom and arm require special techniques.
Contact your authorised KATO dealer.

(7) Wear protective clothing and equipment

Wear a helmet, protective goggles, safety boots, gloves etc.
when inspecting and servicing the machine.
Metal splinters can fly off when you are using a hammer or
grinder, so always wear proper protective clothing and
equipment when using these tools.

(8) Supporting attachments

Always rest the attachment on the ground during inspection and
servicing.
It is dangerous to replace or repair hydraulic hoses, joints or
other hydraulic equipment while the attachment is raised in the
air.
It must be lowered to the ground.

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 (9) Relieve hydraulic pressure
Stop the engine and move the control levers for one or two
minutes to relieve pressure.
It is dangerous to replace or repair hydraulic hoses, joints and
equipment without relieving pressure first.

(10) Beware of highly pressurized oil

Hydraulic oil or reduction gear oil at high pressure can cause
serious skin and eye injuries.
Before cutting or opening a hydraulic pipe, always relieve the
pressure inside it.
Oil leakage may not be visible to the eye, so check with thick
paper or wood-shavings. Do not detect oil leakage by naked
hand or finger.
Wear protective goggles to protect your eyes.
If oil penetrates your skin, consult a doctor well experienced
immediately.
(11) Precautions on replacing seals etc.
After you remove an O-ring or other seal, wash the surfaces on
which it was fitted before you fit the replacement.
Before you fit an O-ring or other seal, check that it is
undamaged and cover it with a film of oil. If you find a defective
seal of any kind, do not use it because it could cause oil leakage.

(12) Be careful when you open the radiator cap

When the radiator coolant is hot, it could spray out dangerously
when you take the radiator cap off, possibly causing burns.
If you have to take the radiator cap off, wait until the coolant has
had time to cool and slowly loosen the cap to allow pressure to
dissipate before you remove it. Check the coolant level and top
up with the coolant from the reserve tank.

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(13) Do not allow water to enter when you top up with oil
When you are topping up with fuel or hydraulic oil or replacing
hydraulic oil, take care to avoid the entry of water or dust. If
water gets in, it will cause corrosion and breakdowns.

(14) Use genuine KATO or KATO-approved lubricants and filters

When you top up or replace with lubricants or replace parts such
as filters etc., always use genuine KATO or KATO-approved
products.
If you use any products which are not made or approved by
KATO, we will not be in any way liable for resultant accidents or
breakdowns.

(15) Dispose of waste oil carefully

If you dispose of waste oil, used filters and other waste products
of the machine carelessly, you will cause environmental
pollution.
When you drain waste oil from the hydraulic equipment or oil
reservoir, catch it in a proper container.
Waste oil is environmentally harmful. Dispose of it
thoughtfully.
Never allow it to pour onto the ground or dump it in streams,
rivers or wetlands.
Follow the relevant regulations when you dispose of oil, fuel,
coolant, brake fluid, solvents, filters, batteries or any other
hazardous or potentially hazardous materials.
(16) Always keep cleanliness in mind when you handle the hydraulic
equipment, engine or electrical parts.
The hydraulic equipment, engine and electrical parts are
precisely adjusted. Always do your best to work cleanly.

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(17) Precautions when washing the machine
While washing the machine, you may lose your footing and fall
down, so wear slip-resistant boots while washing the machine.
If you are using high-pressure steam for cleaning, the jet can cut
your skin and mud etc. can splash back into your eyes. Wear all
appropriate protective equipment when using high-pressure
steam.
If you spray water on electrical equipment during washing, it
could break down or malfunction, so work carefully to avoid
wetting the electrical equipment. Take special care to avoid
wetting the "ECU" (Electronic Control Unit) inside the cover in
the rear of the operator's seat.

(18) Precautions when working in high places

When you are working in high places, take precautions to avoid
falling off.
Keep the area you are standing on tidy (no tools scattered
around) and clean (wipe off any spilled oil or grease), and walk
carefully to avoid slipping.
When climbing and descending, use the hand grips and
platforms and always keep yourself adequately supported on at
least three points at any time. Wear a safety harness and other
safety equipment as necessary.

(19) Precaution when climbing on the machine

Always step on the areas with a non-slip treatment.

(20) Stop the engine before inspection and servicing

It is dangerous to inspect and service the machine while it is
moving.
Always stop the engine before you start work unless the task
you are about to perform needs the machine to be moving.

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(21) Servicing with the engine running is a job for two people
Avoid servicing the machine while it is working if at all
possible.
If it is unavoidable, work with at least two people. One of you
must be in the operator's seat to be able to stop the engine at any
time and all those involved must be in constant contact.
If you work near rotating parts, take care not to be trapped or
dragged in.

(22) Precautions when welding

There is a risk of fire when welding due to possible damage to
electrical equipment or generation of gas from hot paint.
Employ a qualified welder for the job and carry it out in a
properly equipped place.

The following are basic precautions before welding.

Turn the starter switch to OFF.
Disconnect the negative side of the battery cable from the terminal.
Cut away the paint from the area to be welded so that it cannot produce gas.
Attach an earth connection within one meter of the weld point with no O-rings or bearings between the weld and
earth points.
Always wear protective equipment and make sure the ventilation is adequate.
Remove flammable materials and place a fire extinguisher nearby.

(8570-0081-1E)

If you don't turn the starter switch to OFF and disconnect the negative side of the battery cable from
the terminal before welding, the electrical or electronic equipment could malfunction or the
batteries could explode dangerously.

(23) Detach the battery cable

When servicing any part of the electrical system or when
welding, there is the risk that a short circuit could occur and
place load on the batteries. The batteries generate flammable
gas causing the risk of an explosion. The battery electrolyte is
dilute sulfuric acid which will burn skin on contact.
Damage to the batteries is extremely dangerous, so always
remove either of the battery cables before servicing any part of
the electrical system or welding. (Always disconnect the battery
cable from the negative terminal.)

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(24) The equipments are hot immediately after the engine stops
The equipments are hot immediately after the engine stops, so
you could be burned if you touch them. In particular the engine,
silencer, oil reservoir, coolant, radiator, sliding parts, hydraulic
equipment, pipes etc. will be very hot.
Wait for all parts to cool before you begin inspection and
servicing.

(25) Illumination
If you are working in poor light, you cannot see well enough
what you are doing, so you could injure yourself.
Before operation, prepare illumination enough to light the
working place.
Do not use a lighter or other flame in place of a lamp to light
dark places. You could start a fire or cause an explosion by
igniting gas generated by the battery.
Use an explosion-preventive type of lamp when looking at the
battery or fuel.
(8270-0160-1E)

The power socket for the lighter on the dashboard in the cab can be used as the 24V power source
for up to 5A.

(26) Do not heat hydraulic equipment or pipes

If you heat hydraulic equipment or pipes or areas near them, it
could generate and ignite flammable vapour or smoke.
Avoid welding, soldering or heating with a torch near hydraulic
equipment or pipes.
If you directly heat pressurized pipes or rubber hoses, they may
rupture suddenly.

(27) Lock all inspection covers

If you leave the inspection covers open, they can swing shut
suddenly when the wind blows and trap fingers etc.
When you open an inspection cover or cab door, always use the
lock bar to lock it securely in the fully open position.
When there is a strong wind, do not open the door or covers.

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4. Safety parts for periodic replacement (9370-0001-1E)

For the long-term safe operation of the machine, we ask you to inspect and service it regularly. However it is difficult to
evaluate the lifespan of parts by external visual inspection, so certain important parts such as the parts related to a fire
should be replaced at set intervals regardless of their apparent condition. If inspection and servicing reveals any
abnormality whatever in these parts, replace them even before their regulation time.
Ask your authorised KATO dealer to carry out the replacement of these safety parts.

Safety parts list

Fuel system: Every 2 years or 4000 hours of operation, whichever reaches sooner.
Fuel hose (fuel tank engine, fuel filter injection pump, fuel pump related)

Hydraulic system: Every 2 years or 4000 hours of operation, whichever reaches sooner.
Pump suction hose (oil reservoir hydraulic pump)
Pump discharge hose (hydraulic pump control valve, tail hose)
Line hose for swing motor (control valve swing motor)
Line hose for boom cylinder (control valve boom cylinder)
Line hose for arm cylinder (control valve boom piping, boom piping arm cylinder)
Line hose for bucket cylinder (control valve boom piping, boom piping bucket cylinder)

Cooling system: Every 2 years or 4000 hours of operation, whichever reaches sooner.
Heater hose (engine heater)

Inside the engine compartment: Every 5 years

Sound absorbing material (urethane)

Others: Every 3 years

Seatbelt
You must also inspect hydraulic hoses and fuel hoses during the following regular inspections.

Inspection interval Inspection item

Preoperational
inspection Oil leakage from the joints and caulked sections of fuel or hydraulic hoses

Monthly inspection Oil leakage from the joints and caulked sections of fuel or hydraulic hoses
Damage to fuel or hydraulic hoses (cracks, wear, tearing)
Oil leakage from the joints and caulked sections of fuel or hydraulic hoses
Yearly inspection Interference, collapse, deterioration, twisting, damage (cracks, wear, tearing) to fuel or
hydraulic hoses
(857E-0001-0E)

(8270-0064-1E)

1. Replace O-rings, gaskets etc. at the same time as you replace hoses.
2. If you find deformation or cracking of hose clamps when you inspect or replace hoses, you
should also replace the affected clamps.

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5. Inspection and servicing table (947V-0004-1E)

Follow the "Inspection and servicing table" to carry out the correct inspection and appropriate servicing necessary for safe
and efficient work.

(8270-0161-2E)

The intervals stated in the inspection and servicing table are based on the elapsed time
indicated by the hour meter.
Follow both the passage of dates and of hours of operation and carry out each inspection item
when one of the times is reached, whichever occurs sooner.
If you discover any damage, breakdown or malfunction, repair it immediately. Do not leave it
for later and do not start work before it is repaired.
For the inspection and replacement methods for the engine, refer to the separate engine
manual.
The inspection intervals for this machine are based on standard operations and working
conditions.
Under severe conditions, the inspection and replacement intervals should be shortened
accordingly.
If any method or interval of inspection and servicing is unclear, contact your authorised
KATO dealer.

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 First oiling/inspection/replacement after delivery of a EO Engine oil
new machine GO Gear oil
Normal operation EG Extreme-pressure bearing grease
*1 Every 2 years
*2 When using KATO recommended hydraulic oil: SG Chassis grease
Every 2000 hours of operation
When using NIPPON OIL HYRANDO WIDE KV32,
KV46, KV68 or KV100: Every 5000 hours of operation
*3 When replacing the hydraulic oil
*4 Every 5 years

defective
Daily Weekly Monthly Every Oil Reference section
Inspection location

When
Part Task Post- or or
Every 6 months Yearly or Part to
and service task Pre- 250h 1000h change Instruction Service
operational operational 60h 100h or 500h
manual manual
Does the engine start 3-4
well? Inspect 6-1

Exhaust gas color Inspect 5

Abnormal noise on
starting, running or Inspect 5
stopping
3-4
Stopping behavior Inspect 6-7
Slack in the exhaust
pipe or silencer Inspect 5 D, 1-2-1

Loose wires, short

Inspect 5
circuits, breakage
Loose or missing
attachment bolts Inspect 5 D, 1

Cylinder head Separate

Engine and Inspect engine manual
retightening
engine
mounting Valve clearance Separate
adjustment Inspect engine manual
Measurement of Separate
compression Inspect
pressure engine manual

Fan belt slack Inspect 5 D, 1-4

Starter motor Separate

turning torque Inspect engine manual
Engine-related

Alternator electricity Separate

generation Inspect engine manual

Separate
Water pump Grease engine manual

Inspect D, 1-2-4
Sound absorbing
material
Replace * D, 1-2-4

Check oil 5
level 4-1-2 D, 1-3
Engine oil
Separate
Oil pan Replace EO engine manual

Filter Separate
Oil filter Replace engine manual
element

Radiator core, fin Inspect and

and tank clean 4-1-5 D, 1-2-3

Check
coolant 5
D, 1-2-3
level 4-1-5
Radiator Coolant
Replace * Coolant 4-1-5 D, 1-2-3

Cracks and damage to

hoses of the cooling Inspect 5 D, 1-2-3
system

Clean 4-1-3 D, 1-2-2

Air cleaner element
Replace Element 4-1-3 D, 1-2-2

(947S-0046-2E)

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 defective
Daily Weekly Monthly Every Oil Reference section
Inspection location

When
Every Yearly or
Part Task or or 6 months Part to Instruction
and service task Pre- Post-
60h 100h 250h or 500h 1000h change
Service
operational operational manual manual

Check oil
level
5

Drain water
Fuel tank and settled 4-1-6 H, 3-3-2
particles
Engine-related

Clean the
Fuel system

cap strainer 1-6

5
Inspect 4-1-4 H, 3-3-5
Water separator
Drain
water 4-1-4 H, 3-3-5

Separate
Fuel filter Replace Element engine manual

Check for
contami- 4-2-1
nation 4-2-3
5
Check oil
4-2-1 E, 4-2-1
level 4-2-3
Hydraulic oil
Drain
water

Oil reservoir Hydraulic

Replace *2 4-2-3 E, 4-2-1
oil

Clean *3 4-2-5 E, 4-1-7

Suction strainer
Strainer,
Replace O-ring 4-2-5 E, 4-1-7

Return filter Replace Element 4-2-6 E, 4-1-8

Oil leakage, 5
Pipe and hose swelling, perishing, Inspect 4-2-1 E, 4-1-1
injuries

Drain filter Replace Cartridge 4-2-7

Hydraulic system-related

E, 4-1-9

Pilot line filter Replace Element 4-2-9 E, 4-1-11

Air breather Element Replace Element 4-2-4 E, 4-1-6

5 Separate
Oil leakage Inspect 4-2-1 805681E

5 Separate
Cylinder Responsivity Inspect 4-2-1 805681E

Separate
Internal leakage Measure 4-2-1 805681E

5
Oil leakage Inspect 4-2-1 E, 4-1-1

Abnormal noise or 5
Inspect 4-2-1 E, 4-1-1
Hydraulic heat
pump
Attachment bolt Inspect E, 4-1-2

Air extraction 4-2-2 E, 4-1-3

5
Oil cooler Oil leakage Inspect 4-2-1 E, 4-1-1

5 Separate
Rotary seal Oil leakage Inspect 4-2-1 800393E

(877V-0004-0E)

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 defective
Daily Weekly Monthly Every Oil Reference section
Inspection location

When
Every Yearly or
Part Task Post- or or 6 months Part to Instruction
and service task Pre-
60h 100h 250h or 500h 1000h change
Service
operational operational manual manual

5
Oil leakage Inspect 4-2-1
system-related
Hydraulic

Hydraulic Relief valve and

valve brake valve function Inspect E, 3

Control valve
function Inspect E, 3

Wear, deformation Inspect I, 2-2

Attachment bolt Inspect I, 2-2

Carrier roller
5
Inspect 4-3-2 I, 2-2
Oil leakage
Oil EO 4-3-2 I, 2-2

Wear, deformation Inspect I, 2-3

Attachment bolt Inspect I, 2-3

Track roller
5
Inspect I, 2-3
4-3-1
Oil leakage
Oil EO 4-3-1 I, 2-3

Wear, deformation Inspect I, 2-6

Driving
tumbler
Attachment bolt Inspect I, 2-6

Inspect and 5
Tension adjust SG 4-3-4 I, 2-1
Travel-related

Cracked links Inspect I, 2-1

Track shoe
Worn pins Inspect I, 2-1

Loose bolts Inspect I, 2-1

Abnormal noise on 5
traveling Inspect 4-2-1 E, 4-1-1
Traveling
motor Check oil
level 4-3-5 I, 2-6-4
reduction gear Reduction gear oil

Replace GO 4-3-5 I, 2-6-4

Wear Inspect I, 2-4

5
Front idler Inspect I, 2-4
4-3-3
Oil leakage
Oil EO 4-3-3 I, 2-4

While traveling Inspect 5

Brake action
While parked Inspect 5

Traveling
Cracks and damage Inspect
frame
(857V-0014-3E)

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 defective
Daily Weekly Monthly Every Oil Reference section
Inspection location

When
Every Yearly or
Part Task Post- or or 6 months Part to Instruction Service
and service task Pre-
60h 100h 250h or 500h 1000h change
operational operational manual manual

Check oil
level 4-4-1 H, 2-5
Swing motor reduction gear
Replace GO 4-4-1 H, 2-5

Abnormal noise on
swinging Inspect 5 H, 2-1
Swing-related

Bearing
Swing gear

Ball contact surface Grease EG 3-3 A, 6-3

Gear Wear, damage Inspect H, 2-1

tooth
surface
Pinion Grease EG 3-3-1 A, 6-3

Swing brake action Inspect

5
Bucket pin Grease EG A, 6-3
3-3
Cylinder pin
(rod and bottom ends) Grease EG 3-3 A, 6-3

Bucket Deformation, cracks Inspect 5 G, 2-1-2

Inspect or
Worn points replace Point 4-5-1 G, 2-1-7

Wear and looseness Inspect or Side 5

of the side cutters replace cutter 4-5-2 G, 2-1-8

Bending, cracks Inspect 5 G, 2-3

Front attachment-related

5
Foot pin Grease EG A, 6-3
3-3
Boom
Cylinder pin
Grease EG 3-3 A, 6-3
(bottom end)
Cylinder pin 5
(rod end) Grease EG 3-3 A, 6-3

Bending, cracks Inspect 5 G, 2-2

Boom and arm 5

Arm connection pin Grease EG 3-3 A, 6-3

Cylinder pin
(rod and bottom ends)
Grease EG 3-3 A, 6-3

Side link pin Grease EG 3-3 A, 6-3

Damage or loss of the bolts and nuts G, 2-1

Inspect G, 2-2
which stop the pins G, 2-3
(877S-0005-1E)

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 defective
Daily Weekly Monthly Every Oil Reference section
Inspection location

When
Every Yearly or
Part Task Post- or or 6 months Part to Instruction
and service task Pre-
60h 100h 250h or 500h 1000h change
Service
operational operational manual manual
Check Battery 5
electrolyte electrolyte 4-6-1 J, 3
volume
Measure
Battery specific 4-6-1 J, 3
gravity

Clean
terminals 4-6-1 J, 3

Check
Horn action
5

Inspect 5 J, 4
Working lamp
Electrical system-related

Replace Bulb 4-6-3 J, 4

Inside the cab Inspect 5 J, 4

Interior lamp
Replace Bulb 4-6-3 J, 4

Inspect 5 J, 7
Wiper
Replace Blade 4-6-6 J, 7

Electrical Condition of
Inspect 5
wiring insulation and slack

Fuse Replace 4-6-4 J, 5

High current fuse Replace 4-6-5 J, 6

Control lever Actions, play, force 3-2

Inspect 5
and pedal for operation
3-3
Monitor display Inspect 3-9
5
Check 3-3
Meter etc. action 5
Cab control system

Every 3-1
Seatbelt Inspect 3 years 5 H, 3-5

3-10
Inspect
5
Washer fluid
Add 3-10

3-1
Action of the door and cover locks Inspect 5

Refrigerant volume Inspect 4-7-4 J, 2-3-4

Inspect and 5
Belt tension adjust 4-7-5 J, 2-3-5
Air conditioner

Air 5
conditioner Inspect 4-7-6 J, 2-3-6
Condenser
Clean 4-7-6 J, 2-3-6

Clean 5
Filter and inspect 4-7-3 J, 2-3-3

(877S-0006-1E)

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6. Lubrication (8170-0064-0E)

Lubrication is essential to ensure safety operation and to increase the lifespan of the machine.
Regular lubrication, done properly, preserves the safety and economic performance of hydraulic equipments, smooth
operation of each part and reduces wear on rotating and sliding parts.

6-1 Precautions on lubrication (8170-0065-2E)

The value of lubrication is greatly reduced if it is not applied correctly. Observe the following precautions strictly and
use correct procedure.
(1) Always follow KATO's instructions and specifications for lubrication. The interval for lubrication is based on the
length of time the machine has been in use or the actual hours of operation as indicated by the hour meter inside the
cab, whichever interval elapses sooner.
However, the lubrication interval specified by KATO is a guideline based on standard fully hydraulic excavator
operating conditions. If the machine is used in harsh conditions, consult your authorised KATO dealer to
determine a suitably-reduced lubrication interval.
(2) Correct lubrication requires application of the right lubricant in the right quantity for each point that requires
lubrication. Choose the lubricant you are going to use from among the types and brands recommended by KATO
for each point and make sure the oil number you select agrees with our selection criteria for the outside
temperatures common in the operating region.
(3) Before filling/injecting with any lubricant, clean around the grease nipple, filler hole etc. to avoid the entry of dirt,
moisture, etc. with the lubricant.
(4) Work in a clean, dry workplace so that dirt, moisture, etc. do not enter the machine during the lubrication process.
(5) If you use lubricants which have not been recommended by KATO or which do not match the selection criteria, or
if you do not observe the lubrication intervals, KATO will not bear any responsibility whatsoever for any resulting
failures.

6-1-1 Precautions on greasing (7670-0190-3E)

Greasing reduces wear to sliding and rotating parts, thus prolonging the lifespan of the machine, and it is also essential
for their smooth action.
Correctly grease each point as necessary, following the precautions listed below.
Refer to the relevant instruction manuals for details of how to grease the engine-related and attachment-related parts.
(1) When greasing bushes and bearings, expel the old grease and fill completely with new grease.
(2) When greasing the boom foot pin and boom cylinder pins, alternate between the greasing position and the jacked
up position and inject grease around each pin.
(3) After greasing the arm and bucket cylinder pin sections, operate each part several times to spread the grease evenly
over the entire surface of the pins.
(4) Grease each part with the type of grease specified by KATO for that part.
(5) The specified greasing intervals only apply where the grease types specified by KATO are applied in the
appropriate locations correctly. If you have no choice but to use a non-recommended grease, consult your
authorised KATO dealer to determine a suitably-reduced greasing interval.

- 17 -
6-1-2 Precautions on oiling (7670-0191-3E)
Observe the following precautions when oiling.
(1) Replace the oil in each device which requires oiling at the interval specified for each device.
The first oil replacement is particularly important when the machine is new and if this oil change is missed, the
lifespan of the device will be drastically reduced. Even more serious consequences such as rapid breakdowns could
also result.
(2) Check the oil level in each device which requires oiling at the interval specified by KATO.
If any oil level is too low, top it up with oil of the same type as that currently in use.
(3) When hydraulic oil has been replaced, extract the air from the pump and wait until all bubbles have disappeared
from the oil reservoir then run the pump unladen at low speed to expel the air from inside the pipes. If there are air
bubbles mixed with the hydraulic oil when you operate the machine, damage to the pump and various other
problems will result.
(4) Replace the air breather element and clean the strainer of the suction strainer at the same time as you change the
hydraulic oil. If the element or strainer is dirty, the hydraulic equipment will be damaged.
(5) When you have changed or added oil, always wipe away any spilled oil or other residues, then test run the engine
and look for any fresh oil leakage.
(6) Order disposal of old oil from a reputable waste disposal company.

- 18 -
6-2 Recommended lubricants table (817E-0022-2E)

To insure proper operation of this machine, all points which require lubrication must be serviced with the correct
lubricants, at proper time interval. All points which require lubrication are shown in the "Greasing chart" and "Oiling
chart".
Maker
NIPPON
Ambient Shell Esso Mobil BP Caltex
OIL
Type Temp.
HYRANDO
32 Tellus Energol Rando Oil
Nuto H32 D.T.E. 24 WIDE
–20°C 20°C ST32 HLP 32 HD 32
KV32
Hydraulic Oil (ISO No.)

HYRANDO
46 Tellus Energol Rando Oil
Nuto H46 D.T.E. 25 WIDE
–10°C 30°C ST46 HLP 46 HD 46
KV46
HO
HYRANDO
68 Tellus Energol Rando Oil
Nuto H68 D.T.E. 26 WIDE
0°C 40°C ST68 HLP 68 HD 68
KV68
HYRANDO
100 Tellus Energol Rando Oil
Nuto H100 D.T.E. 27 WIDE
5°C 50°C 100 HLP 100 HD 100
KV100
Spirax Gear Oil Mobilube Multipurpose
GL-5 class (API No.)

Hypogear
–20°C 30°C EP GX HD Thuban
80W-90
Gear Oil

75W-85 80W-90 80W-90 80W-90

GO
Spirax Gear Oil Mobilube Multipurpose
EPHypogear
0°C 50°C EP GX HD Thuban
85W-140
140 85W-140 85W-140 85W-140
Extreme pressure Alvania
Beacon Mobilux EPEnegrease Multifax
bearing grease EG EP
EP-2 EP-2 LS-EP2 EP2
Grease

(NLG - ) Grease 2
Chassis SAE
grease SG Standard
(NLG - ) Grease
CD, CE class (SAE No.)

Rimura Essolube Delvac Vanellus Delo 350 Diesel

–20°C 20°C CT Oil XD-3 Super FE Multigrade CF/DH-1
Engine Oil

10W-30 10W-30 10W-30 10W-30 10W-30 10W-30

EO
Rimura Essolube Delvac Vanellus Delo 600 Diesel
–10°C 40°C CT Oil XD-3 Super C3 Multigrade CF/DH-1
15W-40 15W-40 15W-40 15W-40 15W-40 15W-40
(857E-0012-1E)

(827E-0039-0E)

For replacement with the hydraulic oil which differs in brand from the one in use now, all the
oil confined in the hydraulic circuit including the oil reservoir should be replaced.
The oils and greases recommended above are subject to change due to oil company
circumstances. If there is any difference in the above table, consult your authorised KATO
dealer or oil dealer.

The machine is shipped from the factory with the hydraulic oil conforming to the specification based on the
contract filled. Its brand and ISO VG No. are shown on the nameplate attached to the top of the oil reservoir.
As can be seen from the above table, hydraulic oil is shown as classified by ISO viscosity grade.
- 19 -
(1) Selection of the hydraulic oil
Select the hydraulic oil with reference to the ambient air temperature where the machine will be used and the limit
temperature for appropriate use of the hydraulic oil.
Namely, hydraulic oil is usable between its limit temperature for appropriate use and the lowest ambient air
temperature.

ISO VG No. 32 46 68 100

Ambient air
temperature (°C) –20 +20 –10 +30 0 +40 +5 +50

Limit temperature for

appropriate use +70 +80 +90 +100
(oil temperature °C)
(8270-0167-1E)

Even if the hydraulic oil is of ISO VG No. appropriate to the ambient air temperature, it can exceed the limit
temperature for appropriate use (upper limit) depending on the operating conditions. In such cases use the one
grade higher VG No. oil.

(2) Selection of the gear oil

Select the gear oil with reference to the ambient air temperature where the machine will be used.

SAE No. 90 140

Operating temperature range
(ambient air temperature °C) less than +30 +30 or more
(8270-0168-0E)

(3) Hydraulic oil operating temperature

The operating temperature has a great impact on hydraulic equipment, so if for example you are using hydraulic oil
displaying an ISO viscosity grade number of VG46 listed in the "Recommended lubricants table", pay attention to
the following temperature range.

Operating conditions Temperature range (hydraulic oil) Action

Hazardous start temperature –10°C or less Use oil for cold regions.
Starting and preparation temperature –10°C +10°C Warm-up running
Appropriate operating temperature 30°C 80°C
Appropriate operating limit temperature 95°C Stop the engine to cool it.
(8270-0169-1E)

(8270-0170-1E)

The hydraulic oil monitor displays a message if the oil temperature goes below 10°C or above
95°C. If the oil temperature is low, carry out the enough warm-up running.

- 20 -
6-3 Greasing chart (8270-0044-0E)

- 21 -
6-4 Oiling chart (927E-0017-0E)

GO Gear oil Inspection and topping up

HO Hydraulic oil Replacement for a new machine
EO Engine oil Replacement

*1 When using KATO recommended hydraulic oil: Every 2000 hours of operation
When using NIPPON OIL HYRANDO WIDE KV32, KV46, KV68 or KV100:
Every 5000 hours of operation

- 22 -
7. Tightening torque table (0097-0022-0E)

7-1 Tightening torque for meter screw standard bolt (0097-0023-0E)

[Standard] Units: N m (kgf m) [Fine] Units: N m (kgf m)

7T 7T
Nominal Pitch 4.6 8.8 10.9 12.9 Nominal Pitch 8.8
(reference) (reference)
4 8 10 15 17
M6 1.00
(0.4) (0.8) (1.0) (1.5) (1.7)
9 18 24 35 41 20 26
M8 1.25 M8 1.00
(0.9) (1.9) (2.5) (3.6) (4.2) (2.0) (2.7)
18 37 48 73 85 42 54
M10 1.50 M10 1.25
(1.8) (3.7) (4.9) (7.5) (8.7) (4.2) (5.5)
31 67 87 127 149 74 96
M12 1.75 M12 1.25
(3.2) (6.8) (8.9) (13.0) (15.2) (7.5) (9.8)
52 106 139 204 238 116 151
M14 2.00 M14 1.50
(5.3) (10.9) (14.2) (20.8) (24.3) (11.8) (15.4)
81 166 217 318 371 179 233
M16 2.00 M16 1.50
(8.3) (16.9) (22.1) (32.5) (37.9) (18.2) (23.8)
260 339
M18 1.50
(26.5) (34.6)
159 324 423 621 725 363 474
M20 2.50 M20 1.50
(16.2) (33.0) (43.2) (63.4) (74.0) (37.1) (48.4)
274 560 731 1073 1254 617 805
M24 3.00 M24 2.00
(28.0) (57.1) (74.6) (109.5) (127.9) (62.9) (82.1)
896 1169
M27 2.00
(91.3) (119.3)
546 1116 1456 2139 2498 1248 1629
M30 3.50 M30 2.00
(55.8) (113.8) (148.6) (218.2) (254.9) (127.3) (166.3)
(541D-0152-0E) (541D-0176-0E)

7-2 Tightening torque for designated bolt (8570-0096-0E)

Regarding tightening torques for the bolts related to the track shoe, swing gear, engine mounting and counterweight, abide
by the values shown below.

Track shoe N·m (kgf·m) 1078 (110)

N·m 1227 (125)
Swing gear (kgf·m) 1073 (109.5)
N·m Front 549 (56)
Engine mounting (kgf·m) Rear 981 (100)
Counterweight N·m (kgf·m) 2908 (296.5)
(8770-0019-0E)

- 23 -
7-3 Tightening torques for hydraulic and pneumatic related joints (0097-0024-1E)

(1) The tolerance for the torque values is 10%.

(2) The unit for the torque values is N m (kgf m).
(3) Never allow oil to adhere on the threads or the rotating section of the nut.
(4) When tightening, secure the socket with a spanner so that it does not rotate along with the joint with the female
threads.

(5) Joint with O-ring (made of steel) Units: N m (kgf m)

Screw size (G) 1/8 1/4 3/8 1/2 3/4 1 1 1/4 1 1/2 2
Width across faces (mm) 14 19 22 27 36 41 50 55 (60) 70
25 39 64 98 167 206 255 294 588
Seating surface

Steel
material

Tightening (2.5) (4) (6.5) (10) (17) (21) (26) (30) (60)
torque 15 25 49 59 118 137 153 176 352
Aluminum
(1.5) (2.5) (5) (6) (12) (14) (16) (18) (36)
(541D-0154-0E)

(6) Taper pipe screw (reference values) Units: N m (kgf m)

Screw size (R) 1/8 1/4 3/8 1/2 3/4 1 1 1/4 1 1/2
Width across faces (mm) 14 19 22 27 36 41 50 55 (60)
22 36 59 88 157 196 225 255
Seating surface

Steel
Tightening
material

(2.2) (3.6) (6) (9) (16) (20) (23) (26)

torque 15 25 49 59 118 137 146 165
Aluminum
(1.5) (2.5) (5) (6) (12) (14) (15) (17)
(541D-0155-0E)

(7) Hose joint (Type C, R) Units: N m (kgf m)

Screw size (G) 1/8 1/4 3/8 1/2 3/4 1 1 1/4 1 1/2 2
Width across faces (mm) 14 19 22 27 36 41 50 55 (60) 70
Note 1 34.5MPa 27.5MPa 20.5MPa 17.0MPa 10.5MPa
34 132 316
Seating surface material

15 25 (3.5) 64 (13.5) 196 225 255 (32)

Steel
Tightening Note 2 (1.5) (2.5) 49 (6.5) 157 (20) (23) (26) 412
torque (5) (16) (42)
Note 3 10.5MPa
9 13 21 33
Brass
(0.9) (1.3) (2.1) (3.4)
(541D-0156-2E)

[Note 1] Indicates the application pressure (based on the maximum pressure used for the joint provided in JIS B 8363).
[Note 2] The values in the lower row indicate the torque values stipulated for HD models (corresponding to the
maximum pressure used 34.5MPa).
[Note 3] Indicates the application pressure.

- 24 -
 (8) Adapterless piping (rolled screw type) Units: N m (kgf m)
Screw size (G) 1/4 3/8 1/2 3/4 1
Width across faces (mm) 12 15 19 24 30
25 49 59 118 137
Schedule 80
Tightening (2.5) (5) (6) (12) (14)
torque 23 44 54 108 137
Schedule 40
(2.3) (4.5) (5.5) (11) (14)
(541D-0157-0E)

(9) Flare nut (made of steel) Units: N m (kgf m)

Outer diameter of tube (mm) 4.76 6.35 8.0 10.0 12.0
Screw size M10 1.0 M12 1.0 M14 1.5 M16 1.5 M20 1.5
Width across faces (mm) 14 17 19 22 27
16 20 34 44 69
Seating surface

Steel
Tightening
material

(1.6) (2) (3.5) (4.5) (7)

torque 9 12 25 33 52
Brass
(0.9) (1.2) (2.5) (3.4) (5.3)
(541D-0158-1E)

(10) Split flange (flange head joint)

1) SAE standard (Type I) Units: N m (kgf m)
Inner diameter indication 08 12 16 20 24 32
Hose size 1/2 3/4 1 1 1/4 1 1/2 2
Inner diameter of hose (mm) 12.7 19.0 25.4 31.8 38.1 50.8
Recommendable 34.5 24.0 20.5
pressure used Type I
MPa (kgf/cm2) (350) (245) (210)
23 34 41 54 70 80
Tightening torque
(2.3) (3.5) (4.2) (5.5) (7.1) (8.1)
Bolt used (001-105) M8 1.25 M10 1.5 M10 1.5 M10 1.5 M12 1.75 M12 1.75
(857S-0105-0E)

2) SAE high pressure (Type , ) Units: N m (kgf m)

Inner diameter indication 08 12 16 20 24 32
Hose size 1/2 3/4 1 1 1/4 1 1/2 2
Inner diameter of hose (mm) 12.7 19.0 25.4 31.8 38.1 50.8
34.5
Recommendable Type
(350)
pressure used
MPa (kgf/cm2) 34.5
Type
(350)
23 39 59 88 167 275
Tightening torque
(2.3) (4) (6) (9) (17) (28)
Bolt used (001-105) M8 1.25 M10 1.5 M10 1.5 M12 1.75 M16 2.0 M18 2.5
(857S-0106-1E)

- 25 -
(11) Piping flange Units: N m (kgf m)
Bolt used (001-105) M8 1.25 M10 1.5 M12 1.75 M16 2.0
23 59 88 167
Seating surface
Steel
material
Tightening (2.3) (6) (9) (17)
torque Aluminum 34
Note 1 (3.5)
(541D-0178-0E)

[Note 1] Refers to the attachment flange of the return filter.

(12) Attachment for hydraulic and pneumatic equipments Units: N m (kgf m)

Screw size M6 M8 M10 M12 M14 M20
10 23 59 78 167 275
Tightening torque
(1) (2.3) (6) (8) (17) (28)
(541D-0179-0E)

(8270-0231-0E)

After the first 50 hours of use of a new machine and every month thereafter inspect and
retighten the bolts.
When tightening, clean off any corrosion, earth and debris.

- 26 -
8. Judgement of the time for servicing (817S-0007-4E)

Judgement of the time for disassembly and servicing varies according to several factors and requires a high degree of
technical judgment and observation. For example, for a given device the degree of wear undergone by the parts
comprising the device varies widely according to such factors as the quality of daily servicing, skill of handling and
nature of operation, suitability of lubricating oil and hydraulic oil used, frequency of replacement of the oils, and
environmental conditions on site. In general the method we use to judge the time for servicing is to judge the degree of
wear of hydraulic equipment on the basis of limit of use dimensions of each part drawn from past experience and
records and the degree of deterioration of the hydraulic oil. An alternative method is to carry out servicing at fixed
intervals based on the number of hours the machine is used. With either of the above methods, it is necessary to work
with due consideration of the following points.
(1) Before you start to disassemble and service the machine, test it in operation and carefully inspect its external
appearance. Record your observations in a book kept for the purpose.
(2) Make sure you fully understand the parts you are going to disassemble and what the work involves. Prepare all the
necessary spare parts and tools.
(3) Evaluate hydraulic equipment from its surroundings and external appearance, and if nothing appears to be wrong
with it, do not take it apart.
(4) The table below lists points to check in the visual inspection of hydraulic equipment.

Inspection item Inspection method Evaluation guidelines Action

Externally visible Visual There should be no dents or Repair immediately if the problem
abnormalities cracks. appears likely to affect performance.
There should be no corrosion or Otherwise repair when you carry out
peeling of paint or plating. the regular inspection.
Externally visible Visual Dirt buildup should not be Clean away any excessive dirt
dirt or oil leakage excessive. buildup.
There should be no oil leakage.
Level of oil in the Visual Should be within correct level Replenish oil where necessary.
oil reservoir range.

Oil contamination Visual Check for blockages in Investigate the nature of any
strainers and filters. contamination and replace oil where
necessary.
Vibration, noise or By eye, touch and Should be as normal. If vibration or noise is greater than
abnormal sounds hearing usual or there is an abnormal sound,
find the cause and repair it.
Excessive Touch cautiously Should be as normal. If temperature is higher than usual,
temperature rise with your hand or find the cause and repair it.
use a thermometer.
Pressure From the dial of the The needles of every pressure Repair if pressure variations are larger
maintenance pressure gauge gauge should be indicating than usual.
normal pressure.
There should be no major
fluctuations in pressure.
(767S-0230-1E)

- 27 -
8-1 On-site method for hydraulic oil evaluation (817S-0008-4E)

Evaluate the condition of hydraulic oil by examining the amount and type of material in the filters during regular
inspections, and in the oil reservoir, drained oil etc. in the event of a breakdown.
(1) Discoloration of hydraulic oil
Sample oil regularly in the same way as for evaluation of oil deterioration and leave it undisturbed for a long time
to settle.
1) If you can see precipitates at the bottom of the oil, contamination is severe and the oil should be replaced or
filtered.
2) If there is discoloration other than darkening or browning, i.e. if the transparency of the oil has changed,
investigate for contaminants in a testing laboratory.
(2) Filter blockage
1) If filters blockages occur frequently, you may assume that the oil is heavily contaminated.
2) Take oil from inside the filter case (drain oil) in a transparent container and check for precipitates after allowing
a long time for them to settle.
(3) When you disassemble equipment
1) When you have discovered dirt inside disassembled valves, you may assume that the oil is heavily contaminated.
However, in the first six months of use of a new machine, this is often due to inadequate flushing and does not
necessarily indicate contamination of the entire volume of hydraulic oil.
2) If any pump is seized or abnormally worn, it is possible that the oil is contaminated with a large quantity of
abrasive particles. Investigate the oil using filtration and magnetic analysis etc.
3) If you find any material which could have been produced by corrosion in valves and pipes, investigate it using
magnetic analysis.
4) If you discover any point where contaminants could have entered the hydraulic oil, for example where the top of
the oil reservoir or the filler cap has been left open or a gasket is defective, investigate the oil. Do the same if the
air breather element (the ventilation hole filter) is deformed.
(4) Oil reservoir drain
Open the flange in the top of the oil reservoir and draw some oil from the center of the reservoir. Place it in a
transparent container. If the quantity of precipitates is high, clean the inside of the oil reservoir or filter the oil.
(5) If the oil in the reservoir is turbid (a milky appearance), evaluate using the following method.
1) Place the hydraulic oil in a long, narrow transparent container and leave it undisturbed to settle.
2) Evaluation
If the milkiness is due to air bubbles, it will clear gradually from
the bottom up over a period of 1 2 hours.

- 28 -
 If the oil is contaminated with water, it will only clear to a few
percent of its depth from the top down over a period of 24 hours.
If the milkiness is due to water, replace it immediately.

8-2 When to disassemble hydraulic equipment (817S-0009-0E)

8-2-1 Hydraulic pump (767S-0205-0E)

(1) When the pump gets hot abnormally quickly in use.
(2) When abnormal noises are generated inside the pump.
(3) When the pump's flow rate is reduced.

8-2-2 Hydraulic cylinder (767S-0206-0E)

(1) When a considerable quantity of oil is leaking from the head section.
(2) When operation is hampered by slow response speed.
(3) When stick slip occurs frequently.

8-2-3 Valves etc. (767S-0207-0E)

(1) When the volume of oil leakage becomes large.
(2) When abnormal noise occurs when the valves are operated and the temperature rises.
(3) When the spool does not move correctly.

8-2-4 Hydraulic motor (767S-0208-1E)

(1) When the efficiency of the motor falls.
(2) When the motor casing becomes unusually hot.
(3) When the oil leaks from the motor output shaft.
The above are guidelines for judging when disassembly and servicing is required, but the causes of abnormal noise,
heat generation etc. could lie in other parts of the hydraulic circuit (cavitation etc.). There could even be multiple
causes (oil contamination, air mixture, filter blockage etc.) and a comprehensive evaluation is required to
understand the symptoms.

- 29 -
8-3 Judgement of the time for servicing each part (817S-0010-2E)

8-3-1 Slewing table (767S-0209-0E)

(1) When an inspection of the parts with the boom foot bearing sections, welded joints, etc. on the slewing table
reveals any cracks, deformation or other damage.

8-3-2 Traveling frame (767S-0210-1E)

(1) When the degree of wear on the teeth of the driving tumbler exceeds the allowable limit, when the degree of
deddendum wear exceeds the allowable limit, or when overall wear is extreme. Also when there is a crack or
deformation.
(2) When wear on the outer surface of the front idler, wear in the clearance between the shaft and the bush, between the
shaft and the bearing or in the bearing itself exceeds the allowable limit. Also when there is a crack or deformation.
(3) When wear on the outer surfaces of the carrier and track rollers, in the clearance between the shaft and the bush or
elsewhere exceeds the allowable limit. Also when there is a crack or deformation.
(4) In the track shoe system, when there is wear to the shoes, wear to the links, wear in the clearance between bushes
and links, wear between pins and links or elsewhere which exceeds allowable limits. Also when there is a crack or
deformation.
(5) When an inspection of the parts with bearing attachment sections, welded joints, etc. on the traveling frame
reveals any cracks, deformation or other damage.

8-3-3 Front attachment and related parts (767S-0211-1E)

(1) When the clearance between the pin and the bearing surface exceeds the allowable limit.
(2) When an inspection of the parts with bearing sections, welded joints, etc. on the boom, arm and bucket reveals any
cracks, deformation or other damage.

8-3-4 General precautions concerning servicing (767S-0212-1E)

(1) Premature wear of the engine, hydraulic equipment and units is mainly due to the penetration of dust and grit. The
key to preventing the entry of dust and grit and other foreign bodies to these parts is of course daily servicing with
attention to the air cleaner, fuel filter and oil filter but detached parts and tools must also be kept clean.
(2) Correct daily inspection and servicing coupled with prompt and appropriate treatment of any problems as they
arise will prevent the occurrence of major accidents and breakdowns, prolong the life of the machine and reduce
running costs.
(3) When disassembly and inspection is necessary, decide before you start which parts must be taken apart and what
tools will be required.
(4) Key points of safe repair work
You must have a good idea of the weight of the parts and units you are going to dismount. It is dangerous to
carelessly dismount a heavy part or place it unsteadily. When you lift a heavy object with a jack or crane, you
should quickly support it with a stand or trestle. Use crane sling ropes with care.
You must also use the right tools for the parts you have to disassemble.

- 30 -
 (877V-0058-0E)

B Specifications

1. External views 31

2. General data 32

3. Working range 33
3-1 Standard back-hoeing 33
3-2 BMH back-hoeing 34

4. Dimensions and weight 35

1. External views (877E-0013-0E)

HD2045III

HD2045IIIBMH

0.5m short arm Standard arm 1.5m long arm BMH

Overall height (mm) 3530 3490 3810 3870
Overall length (mm) 11990 11990 12060 11370
(777E-0007-0E)

- 31 -
2. General data (8270-0002-0E)

Name KATO HY-DIG Fully Hydraulic Excavator

Model HD2045 HD2045 BMH
Operating weight 46200kg 46800kg

Overall length
11990mm 11370mm
(in transport position)

Overall height
3490mm 3870mm
(in transport position)

Overall width
3200mm
Dimensions (in transport position)

Overall width
3580mm
(in operation position)

Minimum ground clearance 700mm

Tail swing radius 3625mm
Track shoe width 600mm
Name Mitsubishi 6D24-TLE2A, diesel engine
Type 4-cycle, water cooled, inline, direct injection, exhaust turbocharged with intercooler

Number of cylinders- bore

6-130mm 150mm
Engine stroke

Total displacement 11.94L

Rated output 235kW/2000min-1
Maximum torque 1245N m/1200min-1
Hydraulic pump Variable piston pump 2 + gear pump
Hydraulic
Swing motor Fixed displacement piston motor 2
system
Traveling motor Variable piston motor 2
Boom cylinder 2
Hydraulic
Arm cylinder 1
cylinders
Bucket cylinder 1
Hydraulic oil Total oil volume 610L
Fuel tank Capacity 605L
Swing speed 9.1min-1
Operation
Traveling speed 5.0/3.0/2.2km/h
performance
Grade ability 70%
(877E-0001-0E)

- 32 -
3. Working range (847V-0018-0E)

3-1 Standard back-hoeing (847V-0019-0E)

0.5m short arm Standard arm 1.5m long arm

A. Maximum digging radius (mm) 11640 12080 13430
B. Maximum digging depth (mm) 7260 7760 9250
C. Maximum digging height (mm) 11080 11300 11800
D. Maximum vertical wall (mm) 5880 6630 8120
E. Maximum dumping height (mm) 7800 7970 8480
F. Minimum swing radius (mm) 5050 4860 4840
(7770-0080-0E)

- 33 -
3-2 BMH back-hoeing (777V-0006-0E)

A. Maximum digging radius (mm) 10510

B. Maximum digging depth (mm) 6070
C. Maximum digging height (mm) 10710
D. Maximum vertical wall (mm) 5320
E. Maximum dumping height (mm) 7310
F. Minimum swing radius (mm) 4510
(777E-0009-0E)

- 34 -
4. Dimensions and weight (877E-0012-0E)

(1) Machine body

1) HD2045
Overall width (mm) 3200
Operating weight (ton) 46.2
(7770-0071-0E)

2) HD2045 BMH
Overall width (mm) 3200
Operating weight (ton) 46.8
(777E-0029-0E)

(2) Superstructure + lower structure weight

These figures below do not include the track guard, traveling motor cover, cover under the traveling frame and
piping cover.
1) HD2045
Overall width during retraction
Shoe width (mm) (mm) weight (ton)
600 3200 26.0
700 3200 26.5
(7770-0072-1E)

2) HD2045 BMH
Overall width during retraction
Shoe width (mm) (mm) weight (ton)
600 3200 26.4
(777E-0035-0E)

- 35 -
(3) Superstructure
Overall width (mm) 3200
Weight (ton) 10.0
(8770-0020-0E)

(4) Lower structure

1) HD2045
Overall width during retraction
Shoe width (mm) (mm) weight (ton)
600 3100 17.1
700 3200 17.6
(8770-0021-0E)

2) HD2045 BMH
Overall width during retraction
Shoe width (mm) (mm) weight (ton)
600 3100 17.7
(877E-0014-0E)

(5) Arm + bucket dimensions and weight

1) HD2045
0.5m short arm Standard arm 1.5m long arm
Arm length
2.3m3 bucket 2.0m3 bucket 1.4m3 bucket
Overall length (L)
× overall height (H) 5.93 1.27 1.88 6.44 1.26 1.66 7.94 1.26 1.29
× overall width (W) (m)
Weight (kg) 4310 4370 4390
(8770-0035-0E)

2) HD2045 BMH
Overall length (L)
× overall height (H) 5.35 1.30 1.66
× overall width (W) (m)
Weight (kg) 4200
(777E-0030-1E)

- 36 -
(6) Boom dimensions and weight
1) HD2045
Overall length (L)
× overall height (H) 7.26 1.87 0.91
× overall width (W) (m)
Weight (kg) 4700
(8770-0036-0E)

2) HD2045 BMH
Overall length (L)
× overall height (H) 6.56 1.99 0.91
× overall width (W) (m)
Weight (kg) 4700
(777E-0031-1E)

(7) Arm dimensions and weight

1) HD2045
Arm length 0.5m short arm Standard arm 1.5m long arm
Overall length (L)
× overall height (H) 4.23 1.27 0.68 4.73 1.16 0.68 6.24 1.03 0.68
× overall width (W) (m)
Weight (kg) 2410 2480 2880
(8770-0037-1E)

- 37 -
 2) HD2045 BMH
Overall length (L)
× overall height (H) 3.65 1.30 0.68
× overall width (W) (m)
Weight (kg) 2310
(777E-0032-1E)

(8) Boom cylinder (2 units)

per cylinder
Overall length (L)
× overall height (H) 2600 365 470
× overall width (W) (mm)
Weight (kg) 550
(7770-0076-1E)

(9) Counterweight
Overall length (L)
× overall height (H) 732 1243 3200
× overall width (W) (mm)
Weight (kg) 8800
(7770-0077-1E)

- 38 -
(10) Dimensions and weight of optional attachments
Type Backhoe bucket
Overall length (L)
× overall height (H) 1.81 1.53 1.29 1.81 1.53 1.42 1.81 1.53 1.55 1.81 1.53 1.66
× overall width (W) (m)

Weight (kg) 1400 1510 1605 1780

Bucket capacity (m ) 3 1.4 1.6 1.8 2.0
(877S-0062-0J)

Type Backhoe bucket Skeleton bucket Rock bucket Ripper

Overall length (L)
× overall height (H) 1.81 1.53 1.88 1.85 1.55 1.67 2.13 1.61 1.20 1.89 0.99 0.73
× overall width (W) (m)

Weight (kg) 1790 1930 1870 1290

Bucket capacity (m ) 3 2.3 1.2
(877S-0063-0J)

Backhoe bucket
Skeleton bucket Ripper
Rock bucket

- 39 -
MEMO

- 40 -
 (877V-0059-0E)

C Layout and circuit diagram of equipment

1. Part names 41
1-1 Exterior 41
1-2 Inside the cab 43
1-3 Outside the cab 44

2. Hydraulic circuit diagram 45

3. Electrical circuit diagram 46

1. Part names (7670-0097-1E)

1-1 Exterior (7670-0165-0E)

- 41 -
MEMO

- 42 -
1-2 Inside the cab (877S-0007-1E)
3-1 Inside the cab
1. Door
2. Door lock release lever
3. Key
4. Front window
5. Front lower window
6. Roof window
7. Left window
8. Rear window
9. Operator’s seat
10. Seatbelt
11. Fuse box
12. Engine stop button
13. Hot & cool box
14. Interior lamp
15. Grille (for defroster)
16. Grille (for air conditioner)
17. Fire extinguisher (optional)
18. Ash tray

3-2 Control levers

1. Safety lock lever
2. Console lock levers
3. Horn switch
4. Quick accelerator switch
5. High power switch
6. Traveling control levers
7. Left control lever
8. Right control lever

3-3 Combination monitor

1. Monitor display
2. Engine water temperature gauge
3. Fuel gauge
4. Hour meter
5. Engine preheater indicator lamp
6. Caution lamp
7. Work mode selection switch
8. APC mode selection switch
9. Auto-slow switch
10. Econo mode switch
11. Buzzer stop switch
12. Traveling mode selection switch
13. Working lamp switch
14. Windscreen wiper switch
15. Windscreen washer switch
16. Monitor brightness control switch
17. Monitor selection switch

3-4 Control panel

1. Starter switch
2. Accelerator dial
3. Swing lock release switch
4. Lighter
5. Diagnosis lamp

3-5 Switch panel

1. Cab fan switch (optional)
2. Horn selection switch (optional)
3. Swing warning lamp switch (optional)
4. Travel link alarm switch (optional)
5. Breaker/crusher selection switch (optional)

3-6 APC switch and accelerator backup

switch panel
1. APC switch
2. Accelerator backup switch
3. Accelerator switch

3-7 Radio

3-8 Air conditioner control panel

For details of this page

) Refer to the instruction manual.

- 43 -
1-3 Outside the cab (877S-0008-1E)
3-10 Outside the cab
1. Cover/hood
2. Working lamp
3. Mirror
4. Grease pump
5. Washer tank
6. Aerial

For details of this page

) Refer to the instruction manual.

- 44 -
2. Hydraulic circuit diagram (847E-0009-0E)

- 45 -
3. Electrical circuit diagram (777E-0023-0E)

(1) Applicable serial No.: #5513

- 46 -
- 47 -
- 48 -
(2) Applicable serial No.: #5514

- 49 -
- 50 -
- 51 -
MEMO

- 52 -
 (877V-0009-0E)

D Engine unit

1. Engine-related equipment 53
1-1 Engine inspection and servicing 53
1-2 Removal and mounting of engine accessories 54
1-3 Inspection and replacement of the engine oil 63
1-4 Removal of the engine and hydraulic pump 64

2. Engine control 66
2-1 System blocks for engine control 66
2-2 ECU control 67
2-3 Startup preheat control 74
2-4 ECU trouble diagnosis function 78
2-5 Adjusting the engine control system 87

3. Data file 89
3-1 Engine 89
3-2 Consumable parts guide 90
1. Engine-related equipment (937S-0110-0E)

1-1 Engine inspection and servicing (937S-0105-0E)

Take the engine inspection points from the "Inspection and servicing table".
Take the engine inspection methods from the separate engine manual.
Refer to the separate service manual for APC.

(8270-0172-2E)

Always stop the engine before inspecting it.

If you inspect and service the engine while it
is running, you risk severe injury by trapping
your hands etc. in the cooling fan or fan belt.
When you open the engine hood, always
engage the stopper.
Immediately after the engine stops each part
will be very hot and you risk burns if you
touch it. If you are going to open the engine
hood to inspect the engine, check that it has
cooled sufficiently.
The sound absorbing material in the engine
compartment is designated as a safety part for
periodic replacement.
Inspect it at regular intervals and if any
damaged is discovered, then replace it even if
it is before the scheduled replacement time. If
it falls off, it could cause a fire.

- 53 -
1-2 Removal and mounting of engine accessories (877S-0064-0E)

Remove the cover and any other components which may obstruct your work.
Refer to the section J, 2-3 for the handling of the air conditioner-related parts.

1-2-1 Muffler and exhaust pipe (847S-0014-4E)

(1) Removal of the muffler
1) Remove the bolt and loosen the clamp which joins the exhaust pipe to the muffler.
2) Remove the bands and lift the muffler off.

(2) Inspection and mounting

1) Inspection
Check for rust, corrosion etc. on the muffler and exhaust pipe. Brush any away with a wire brush and repaint
the affected area with heat resisting paint.
Check for cracks, scratches, dents etc. on the muffler and exhaust pipe. Make a welded repair where
necessary.
Check whether the gasket is cracked or broken and whether there is gas leakage. (If it is removed, replace with
new.)
Check for wear and stripped threads on the bands and other threaded parts.
2) Mounting
Reverse the removal procedure to remount the muffler and then check the following point.
Check that the water drain hole and joint section on the muffler are not blocked.

- 54 -
1-2-2 Air cleaner (877S-0010-0E)
(1) Removal
1) Loosen clamp [74] marked with * .
2) Remove bolts [88] and detach the air cleaner.
Loosen clamps [74] and [77] except the clamp marked with * and detach rubber hose [73] and hose [72], if
necessary.

(2) Cleaning and replacement procedure

1) Cleaning the outer element

Remove the cover and take the outer element out and clean it using the method described below.
Blow clean, dry compressed air from the inside of the element to the outside along the folds up and down to blow
dust off. Keep the nozzle away from the element 50mm or more and keep the pressure at the nozzle below
0.2MPa (2kgf/cm2). Inspect the filter paper lighting it from the inner side of the element. Replace the element if
there is any damage, pinholes or extremely thinner part is observed on the paper. Also replace it when the
packing is damaged.

- 55 -
 2) After cleaning, put the outer element back in place and attach the cover so that the valve is just under the
cover.
3) When replacing the element, replace the outer element and inner element at the same time.

(7770-0090-1E)

Wear protective goggles when using compressed air.

When using this machine under severe conditions, shorten the cleaning and replacement
intervals accordingly.
If the message indicating air cleaner blockage is displayed on the monitor, you should clean
the element even if it is not yet the scheduled time.
Always stop the engine before cleaning and replacing the element, otherwise foreign bodies
could be drawn in, causing a breakdown or damage.
Always use a genuine KATO or KATO-approved element.
Remove the inner element only when you replace it.

(3) Cleaning and replacement intervals

Cleaning interval Every 250 hours of operation or when called for by the monitor display
Replacement interval Every 1000 hours of operation or yearly
(4) Consumable part number
Refer to the "Consumable parts guide".
(5) Inspection and mounting
1) Inspection
Check for rust, corrosion etc. on the air cleaner.
Check for cracks and deterioration on the rubber hose.
Check for wear and stripped threads on the threaded parts.
2) Mounting
Reverse the removal procedure to remount the air cleaner.

- 56 -
1-2-3 Cooling system (877S-0011-1E)
As the engine runs, corrosion and water scale build up in the water jacket and the radiator, reducing their cooling efficiency
and leading to overheating problems etc. It can also reduce the antifreeze effect of the Long Life Coolant added to the
coolant, risking engine damage due to freezing. It is very important to regularly clean the cooling system and replace the
coolant using the procedure described below.

(1) Intervals for inspection and cleaning of the cooling system and replacement of the coolant
1) Coolant level inspection At the time of preoperational checks
2) Coolant replacement Every 2 years
3) Cooling system cleaning Every time the coolant is replaced.
4) Long Life Coolant KATO Diesel Long Life Coolant (non-amine)
5) Long Life Coolant addition volume Set the coolant freezing temperature 5°C below the lowest recorded
temperature in the operating region and use that temperature to
determine the Long Life Coolant volume to add.
6) Coolant adding Add the coolant through the filler cap on the top of the reserve tank.
7) Water for coolant Use tap water (soft water).
8) Radiator core cleaning Monthly or every 100 hours of operation

- 57 -
(2) Removal of the radiator, oil cooler and intercooler
Drain coolant from the radiator and hydraulic oil from the oil
reservoir before you start work.
1) Remove the hose from the reserve tank and detach the condenser
and receiver drier of the air conditioner.
2) Loosen the couplings and disconnect the piping which is
connected to the oil cooler.
3) Loosen clamps [56] and detach air hoses [21] and [23] from the
engine.
4) Loosen clamps [61], [62] and [70] and detach hoses [17] and
[31] from the engine.
5) Remove stays [7] and [42] from the radiator.
6) Arrange the sling wire rope to the radiator and support it with a
crane then remove bolts [94] and lift off the radiator, oil cooler and
intercooler as an assembly.

(3) Inspection and mounting

1) Inspection
Clean the inside of the radiator.
Check whether any part of the radiator is cracked or broken and whether there is coolant leakage.
Check for splits and deterioration of the hoses and air hoses.
Check for wear and stripped threads on the threaded parts of the bolts.
2) Mounting
Reverse the removal procedure to remount the radiator, oil cooler and intercooler and then check the following
points.
Are any of the radiator mounting bolts loose? Are the couplings of any of the water hoses loose?
Are any of the oil cooler and intercooler mounting bolts loose?
Are the couplings of the oil cooler piping correctly fastened? If the pipe end is not inserted far enough into the
coupling, or if the coupling is not tightly fastened, the pipe can come out of the coupling when in use.
Check for splits and deterioration of the intercooler hose.
Check that the intercooler hose is inserted far enough and that the clamp is not loose.

(4) Adding the coolant

Always check the coolant volume before starting the engine and check that the volume exceeds the "LOW" level of
the reserve tank. Add the coolant if the level is low.
KATO Diesel Long Life Coolant is used in this machine. When adding the coolant, use KATO Diesel Long Life
Coolant and avoid using plain water.

(8570-0099-0E)

When you add the coolant, check that it has cooled sufficiently.

- 58 -
(5) Addition of Long Life Coolant and calculation of its concentration
1) The freezing temperature of the coolant varies greatly with the
concentration of the Long Life Coolant it contains. Set the
coolant freezing temperature 5°C below the lowest recorded
temperature in the operating region and use that temperature to
determine the required concentration of the Long Life Coolant
and therefore the Long Life Coolant volume to add.

Coolant freezing temperature against addition volume of the

Long Life Coolant
Freezing temperature (°C) 15 20 25 30 40

Long Life Coolant concentration (%) 30 35 40 45 55

Long Life Coolant addition volume (L) 14.7 17.2 19.6 22.1 27.0

Water volume (L) 34.3 31.8 29.4 26.9 22.0

Total coolant volume (L) 49

(Using KATO Diesel Long Life Coolant)

(8770-0014-0J)

2) If it is possible that the temperature may be about to drop below the freezing temperature of the coolant currently
in use, add the Long Life Coolant.
Once you have finished adjusting the Long Life Coolant concentration, start the engine and allow it to mix the
coolant fully, then use a hydrometer or concentration gauge to check the actual concentration.
(8570-0083-0E)

Use only genuine KATO Diesel Long Life Coolant. Other brands could cause corrosion of
copper and aluminum components and reduce their lifespan. The freezing temperature might
be different, leaving the risk of freezing and engine damage.
Use the Long Life Coolant within the concentration range between 30 60%. If the
concentration is below 30%, anti-corrosion effect is reduced. If it is 60% or more, the freezing
temperature becomes higher.
If you top up the coolant level with water or repair coolant leakage, always recheck the Long
Life Coolant concentration. If you do not check and adjust the concentration as necessary, the
reduced Long Life Coolant concentration could allow freezing of the coolant which would
damage the engine.

(6) Precautions on handling Long Life Coolant

1) No fire near Long Life Coolant
Long Life Coolant is a hazardous substance and must not be handled near fire or other source of ignition.
(8270-0178-1E)

Long Life Coolant is flammable, so beware of fire.

2) Do not drink Long Life Coolant

Long Life Coolant is poisonous. Never allow it into your mouth even when diluted. If you drink it by accident,
make yourself vomit immediately and consult a doctor.

- 59 -
 3) Never leave Long Life Coolant unattended or improperly stored
If you decant Long Life Coolant into smaller containers for storage, seal the container and clearly label the lid
"COOLANT" respectively. Store them out of direct sunlight and out of the reach of children.
(8570-0106-0E)

If you accidentally get Long Life Coolant in your eye, wash the affected area immediately in
large amounts of clean water and consult a doctor.
When you add or replace the coolant, check that it has cooled sufficiently.

(7) Consumable part number

Refer to the "Consumable parts guide".
(8) Radiator core cleaning procedure
If dust or dead plants build up on the radiator core, oil cooler core or intercooler core, their cooling effect is
drastically reduced and this can cause overheating.
1) Remove the cover that is between the radiator and the oil
cooler.
2) Detach the protector net to clean any dust from the front side of it
using 0.2MPa (2kgf/cm2) or less of water or compressed air, from
a distance of 20 30mm away, and keeping it as perpendicular
as possible.
3) If dead plants etc. are wedged between the fins of the core, use a
thin wire to remove them, taking care not to damage the fins.
Also clean dust or debris off the protector net.
4) Reattach each cover to their original positions.

(8270-0180-1E)

Always wear protective goggles when cleaning.

If you clean using water or compressed air at high pressure, the radiator fins can be deformed,
blocking the flow of air and defeating the object of cooling. Keep an adequate distance
between the nozzle and the core.

(9) Procedure for cleaning the cooling system

When replacing the coolant because its antifreeze performance has declined, always clean the cooling system at
the same time.
Refer to the separate engine manual for the method of cleaning the cooling system.
(8270-0181-2E)

When the radiator coolant is hot, it could spray out dangerously when you take the radiator
cap off, possibly causing burns.
If you have to take the radiator cap off, wait until the coolant has had time to cool and slowly
loosen the cap to allow pressure to dissipate before you remove it. Check the coolant level and
top up with the coolant from the reserve tank.

- 60 -
1-2-4 Inspection and replacement of the sound absorbing material (urethane) (877S-0014-0J)
(8270-0216-0E)

The sound absorbing material (urethane) is designated as a safety part for periodic replacement and
as such it must be replaced every 5 years.
If the material is peeling, falling off or being deteriorated, replace or repair it immediately, even
if it is not yet the scheduled time.

(1) Engine cover

Ref. No. Part name Q'ty Ref. No. Part name Q'ty
23 Lining (sound absorbing material: urethane) 1 47 Lining (sound absorbing material: urethane) 1
27 Lining (sound absorbing material: urethane) 1 48 Lining (sound absorbing material: urethane) 1
32 Lining (sound absorbing material: urethane) 1 49 Lining (sound absorbing material: urethane) 1
33 Lining (sound absorbing material: urethane) 1 50 Lining (sound absorbing material: urethane) 1
34 Lining (sound absorbing material: urethane) 1 51 Lining (sound absorbing material: urethane) 1
37 Lining (sound absorbing material: urethane) 1 52 Lining (sound absorbing material: urethane) 1
38 Lining (sound absorbing material: urethane) 1 53 Lining (sound absorbing material: urethane) 1
39 Lining (sound absorbing material: urethane) 1 54 Lining (sound absorbing material: urethane) 1
40 Lining (sound absorbing material: urethane) 1 55 Lining (sound absorbing material: urethane) 4
41 Lining (sound absorbing material: urethane) 1 56 Lining (sound absorbing material: urethane) 3
43 Lining (sound absorbing material: urethane) 5 57 Lining (sound absorbing material: urethane) 2
44 Lining (sound absorbing material: urethane) 1 62 Lining (sound absorbing material: urethane) 3
45 Lining (sound absorbing material: urethane) 1 95 Lining (sound absorbing material: urethane) 1
46 Lining (sound absorbing material: urethane) 1
(877S-0012-0E)

- 61 -
(2) Slewing table

Ref. No. Part name Q'ty Ref. No. Part name Q'ty
16 Lining (sound absorbing material: urethane) 1 21 Lining (sound absorbing material: urethane) 1
17 Lining (sound absorbing material: urethane) 2 38 Lining (sound absorbing material: urethane) 2
18 Lining (sound absorbing material: urethane) 2 39 Lining (sound absorbing material: urethane) 4
19 Lining (sound absorbing material: urethane) 2 45 Lining (sound absorbing material: urethane) 1
20 Lining (sound absorbing material: urethane) 2 47 Lining (sound absorbing material: urethane) 1
(877S-0013-0E)

- 62 -
1-3 Inspection and replacement of the engine oil (7770-0048-1E)

(1) Inspection procedure

If the position of the oil film on the oil level gauge is below the proper oil level range as shown in the diagram
above, top up with the engine oil.
Take care not to fill with oil beyond the FULL level.

(8670-0078-0E)

After the engine has been running for a long time, the engine oil will be extremely hot, so allow
the engine to cool adequately.

(8570-0082-1E)

If the engine oil is extremely dirty or if the machine is working under severe conditions,
shorten the oil replacement interval appropriately.
The machine should be on level ground when you check the oil level.
Clean around the oil filler hole before you add oil so that no dirt etc. will enter with the oil.
Choose the right engine oil for the outside air temperature in the region.
After adding oil, wait for five or six minutes before checking the oil level. If you check the oil
level immediately after adding, it may show a misleadingly low level, leading to overfilling.
Spilled engine oil can cause fire, so wipe it away immediately.

(2) Inspection and replacement intervals

Inspection interval At the time of preoperational checks
Replacement interval Every 500 hours of operation
After delivery of a new machine, the engine oil should be replaced after 60 hours of
operation.

Refer to the separate engine manual for oil replacement and topping up procedures.
Engine oil volume 49L
Oil pan 45L
Oil filter and others 4L

- 63 -
1-4 Removal of the engine and hydraulic pump (877S-0015-1E)

- 64 -
(1) Removal
1) Disconnect all hoses etc. from the pump. (Fig. )
Note Drain all hydraulic oil from the oil reservoir before you disconnect the suction hose.
2) Detach the stop cable for engine control from the engine. (Fig. )
3) Disconnect the fuel hoses from the engine. (Fig. )
Note Drain all fuel before you detach the fuel hose.
4) Disconnect the air conditioner hoses (heater hoses) from the engine. (Fig. )
5) Remove the bolts which fasten the engine to the slewing table, attach the sling wire rope to the engine and lift it
with a crane clear of the slewing table. (Fig. )
Note 1. Electrical wiring to the engine must be disconnected.
2. Mass
Engine mass: 1100kg (dry mass)
Hydraulic pump mass: 170kg
Pump cover mass: 41kg

(2) Inspection and mounting

1) Inspection
Refer to the engine service manual for inspection and repair procedures for the engine.
2) Mounting
Reverse the removal procedure to remount the engine and then check the following points.
Tightening torque for engine mounting bolts: 549N m (56kgf m) (front side)
981N m (100kgf m) (rear side)
Thoroughly wipe away all traces of oil and grease from the threaded parts of the bolts and always apply
screw-lock compound to them before tightening them.
3) After mounting it, check the following points.
Confirm that the engine stop cable is correctly attached to the engine.
Confirm that the oil pan drain plug on the underside of the engine is not loose and that the washer is in the place.
Confirm for the tension of the fan belt. Confirm that fan belt
pulley is not bent and that the belt is not chafed.

- 65 -
2. Engine control (857S-0130-0E)

The governor and injection timing for this engine is controlled electronically, which can improve the smoke characteristic.
Also the self-diagnosis function is provided to improve service performance.
The control is performed by the diesel engine control unit (hereafter called E/G ECU).

2-1 System blocks for engine control (857S-0131-1E)

The system blocks of the ECU is shown below.

- 66 -
2-2 ECU control (877S-0065-0E)

(1) Fuel injected quantity control

The ECU controls the rack built into the injection pump to optimize the fuel injected quantity in each control
mode, based on various input information including accelerator opening and engine speed.

In each mode, however, a cancellation condition precedes a set condition.

- 67 -
1) Limp home mode
The limp home mode is a backup mode which determines a fuel injected quantity with the PID control that
regards the engine speed as the target value when the actual rack position cannot be fed back due to occurrence
of governor servo system errors or rack sensor errors.
The target engine speed is calculated by interpolation calculation of the limp home mode target engine speed
map based on accelerator opening.

When in the limp home mode, illumination of the diagnosis lamp-2 alerts an operator to abnormality.

2) Start mode
The start mode improves ease of engine start by forcefully increasing a fuel injection amount at the time of
engine start.
The target rack position in the start mode is calculated by interpolation calculation of the start mode rack
position map based on the engine speed and engine coolant temperature.

3) Heat mode
The heat mode activates the rack prior to an engine start.
Target rack position in the heat mode = 3mm

4) Pull-down mode
The pull-down mode stops the engine by pulling back the rack toward the non-injection direction, the instant
either of the following conditions is agreed.
The pull-down mode can securely stop the engine because it pulls back the rack with larger torque than the
normal rack action.

Condition for moving to the pull-down mode Either of the following conditions should be agreed.
Occurrence of severe system failure
Starter SW: OFF position
Engine overrun
Engine reverse rotation

- 68 -
5) Normal control mode
When neither of the aforementioned control modes is set, a mode is set to be a normal control mode.

- 69 -
(2) Fuel injection timing control
The ECU uses various input information, such as engine coolant temperature and engine speed, and optimizes the
fuel injection timing by controlling the timer control valve.

(3) Calculation of accelerator opening

The ECU switches accelerator opening according to the accelerator dial signal and speed control signal.
When the accelerator dial becomes faulty or the accelerator backup switch is switched to the "manual" position, a
backup mode is set that calculates accelerator opening with the accelerator switch.
1) Accelerator dial operation
The opening degree of the accelerator is decided by the voltage
value from the accelerator dial potentiometer only when
"Accelerator dial operation" indicated in the item 2) below is
performed.

- 70 -
2) Switching method of speed control signal
The opening degree of the accelerator is switched by the switch signal inside the APC controller.

3) Accelerator opening with accelerator SW

The opening degree of the accelerator is decided by the accelerator switch when the accelerator dial
malfunctions or the accelerator backup switch is switched to the "MANUAL" position.

- 71 -
(4) Input and output specifications
1) Switch input

(857S-0136-0E)

Input threshold voltage and contact current are ECU's real values, not guaranteed values.

2) Sensor input

- 72 -
3) Load output

(857S-0137-0E)

Output characteristic and current capacity are ECU's real values, not guaranteed values.

4) For sensors + 5V output

- 73 -
2-3 Startup preheat control (857S-0138-0E)

The ECU improves ease of engine start by producing preheat output (air heater, glow) when the engine coolant
temperature is low (below the temperature requiring preheat) before an engine start.

2-3-1 Detail of operation mode (857S-0139-1E)

(1) Engine coolant temperature>temperature requiring preheat
Preheat output is not produced if the engine coolant temperature is higher than the temperature requiring preheat.

(2) Engine coolant temperature temperature requiring preheat [normal start]

When the engine coolant temperature is below the temperature requiring preheat, the engine preheater indicator
lamp and preheat output turn ON after a lapse of preheat signal delay time (ts) after the starter switch is turned ON.
The engine preheater indicator lamp and preheat output turn OFF after a lapse of indicator lamp illumination time
(to) and a lapse of afterheat time (tf), respectively.

When the engine does not stop after a lapse of unnecessary time for re-preheat (ti) after afterheat is completed, the
control is over.

- 74 -
(3) Engine coolant temperature temperature requiring preheat [when the engine is started before the engine
preheater indicator lamp turns OFF]
When the engine is started before the engine preheater indicator lamp turns OFF, the indicator lamp turns OFF
concurrently with engine rotation.

(4) Engine coolant temperature temperature requiring preheat [when the engine is not started]
When the engine is not started after the starter switch turns ON, the engine preheater indicator lamp and preheat
output turn OFF after a lapse of indicator lamp illumination time (to) and a lapse of preheat time (th), respectively.
Thereafter, the control is over after a lapse of unnecessary time for re-preheat (ti).

- 75 -
(5) Engine coolant temperature temperature requiring preheat [when the engine stops just after it is started, and then
is restarted]
When the engine stops (including engine stalling) during afterheat (tf) or unnecessary time for preheat (ti), and the
starter switch turns ON during unnecessary time for preheat (ti), preheat output turns ON (the engine preheater
indicator lamp remains OFF) the moment the starter switch turns ON, and turns OFF after a lapse of afterheat time
(tf).

(6) Engine coolant temperature temperature requiring preheat [when the engine stops just after it is started, and is
not restarted]
When the engine stops (including engine stalling) during afterheat (tf) or unnecessary time for preheat (ti), and the
starter switch does not turn ON after a lapse of unnecessary time for preheat (ti), the engine preheater indicator lamp
and preheat output turn ON the moment unnecessary time for preheat (ti) is over.

If the engine is restarted thereafter, the control is moved to the (2) normal control.

- 76 -
 When the engine is not restarted, the control is moved to the (4) control.

2-3-2 Control constant (857S-0140-0E)

Control constant
Item Remarks
Air heater specs
Temperature requiring preheat 0°C
Temperature requiring afterheat 0°C
Preheat signal delay time (ts) 0.2sec
Engine preheater indicator lamp Varies depending on
engine coolant See Fig. 1
illumination time (to) temperature
Preheat time (th) 20sec
Afterheat time (tf) 20sec
Unnecessary time for re-preheat (ti) 16sec
(877S-0041-0E)

- 77 -
2-4 ECU trouble diagnosis function (857S-0143-1E)

The ECU constantly diagnoses various sensors when the starter switch turns ON. When it judges any sensor to be faulty,
it advises an operator of abnormality by illuminating the diagnosis lamp-1 or lamp-2. At the same time, it stores failures
and enters into the backup mode.
Stored failures can be called up with the diagnosis code or MUT- (optional).

2-4-1 Items illuminated by diagnosis lamps when abnormality is detected (857S-0144-0E)

Diagnosis lamp-1 Diagnosis lamp-2

Remarks
(red) (orange)
1. Error that does not allow
Turns ON Turns OFF
engine stop or engine start

2. Slight failure Turns OFF Turns ON

(857S-0145-1E)

Diagnosis lamp
This lamp lights when there is a malfunction of the fuel injection system.

1) Red lamp: When this lamp lights, you cannot stop or start the engine.
The system is normal if you can restart the engine and the warning lamp goes out after you return
the starter key to "OFF".
2) Orange lamp: This lamp lights when there is a slight malfunction.
This system is normal if the warning lamp goes out when you return the starter key to "OFF" and
restart the engine.
(857S-0146-0E)

If you set the accelerator backup switch to the "MANUAL" position, the "orange lamp" lights
and the accelerator dial cannot be used for control, regardless of any breakdown.
The red lamp is diagnosis lamp-1, and the orange lamp is diagnosis lamp-2.

- 78 -
2-4-2 Method of calling up failures (857S-0147-1E)
Diagnosis codes display failures that are occurring at present or occurred in the past with codes on the diagnosis lamp-1
by operation of the diagnosis display switch and memory clear connector (open circuit or short circuit).

(1) Diagnosis display item

Diagnosis result
Memory clear Diagnosis display Past Normal Normal Failure Failure
connector switch Present Normal Failure Normal Failure
Flashes with Flashes with Flashes
Flashes with a
a code for a code for the with a code
Short circuit Open circuit code for the
normal present for normal
present failure
conditions failure conditions
Flashes Flashes with a
with a code code for the
Open circuit Open circuit
for the past present and
failure past failures
(857S-0155-0E)

(2) Diagnosis code pattern

After the machine is stopped, the starter switch is turned ON, and an open circuit is established in the
diagnosis display switch for one second or more, the code is displayed after the lamp turns OFF for approx.
2.4 seconds.
The code is displayed in a two digit number. The tens place turns ON for 1.2 seconds and turns OFF for 1.2
seconds while the ones place turns ON for 0.4 seconds and turns OFF for 0.4 seconds.
Each code is displayed three times repeatedly, and returns to the first code if there is no new code.
Example 1) If the code is 12,

Example 2) If there are two codes or more (code 12, 13),

- 79 -
2-4-3 Method of erasing failures (857S-0148-0E)
Failures stored in the ECU can be erased by operation of the memory clear connector.
All the failures stored in the ECU can be erased by establishing an open circuit once, and then a short circuit in the
memory clear connector after the starter switch is turned ON.

(857S-0154-0E)

Failures are erased by operation of the memory clear connector only.

If you do not want to erase failures, turn OFF the starter switch with the memory clear
connector left in an open circuit, and establish a short circuit in the memory clear connector.

(1) Checking diagnosis lamps for burned-out bulbs

ECU illuminates the diagnosis lamps-1 and -2 if all of the conditions below are agreed.

<Condition for moving to burned-out bulb check>

All of the following conditions must be agreed.
Engine speed = 0 min-1
Starter switch: ON
Diagnosis display switch: short circuit
No failure occurrence that causes the diagnosis lamps to illuminate

- 80 -
(2) Failure diagnosis item and backup

- 81 -
2-4-4 MUT- (multi-use tester) (optional) (S491-0011-2E)
(1) MUT- communication function
The ECU enables LCD display of various information stored in the ECU on the MUT- by conducting serial
communication with MUT- .

1) List of concerned MUT- parts

- 82 -
(2) MUT- communication items
(ROM PACK in Japanese)

1) Failure
(877S-0066-0E)

Diagnosis code Failure LCD display content (reference)

07 Engine overrun
45 Engine reverse rotation
11 Governor servo system
22 Rack sensor
17 Electronic timer control system
23 Timer control valve
14 Timing sensor
15 NE sensor
24 Accelerator dial
32 Boost sensor
21 Coolant temperature sensor
19 Atmospheric pressure sensor
34 Q-Adjustment resistance
78 Heater relay
33 System error

(S491-0022-0E)

LCD display contents differ depending on ROM PACK specifications.

- 83 -
2) Physical quantity of sensors and switch signals
(877S-0067-0E)

LCD display content (reference) Graphic

Item display
Item Data (reference)
Power supply voltage value V
Engine speed rpm
Accelerator opening (after filter) %
Accelerator opening (before filter) %
Accelerator dial output voltage value V
Target rack position mm
Actual rack position mm
Timer angle difference °CA
Q-Adjustment resistance rank No.
Engine coolant temperature °C
Atmospheric pressure kPa
Boost pressure kPa
Diagnosis display switch ON/OFF
Diagnosis lamp-2 ON/OFF
Diagnosis lamp-1 ON/OFF
Starter switch (M) ON/OFF
Memory clear connector ON/OFF
Governor pull-down signal ON/OFF
Starter switch (ST) ON/OFF
Engine preheater indicator lamp signal ON/OFF
Heater relay ON/OFF

3) Forced drive of actuator

(857S-0135-0E)

Contents of forced drive LCD display

Item Drive method content (reference)
Implement 5 cycles (1 cycle: ON for one
Diagnosis lamp-2
second, and OFF for one second).
Diagnosis lamp-1
Engine preheater indicator lamp signal
Heater relay

(S491-0015-1E)

For an operation method of MUT- and its detailed specifications, refer to the MUT- instruction
manual etc.

- 84 -
(3) Hierarchical level of MUT- operation menu (reference)

(857S-0150-1E)

For an operation method of MUT- and its detailed specifications, refer to the MUT- instruction
manual or service manual.

- 85 -
- 86 -
2-5 Adjusting the engine control system (837S-0017-1E)

Switch the accelerator backup switch to the "AUTO" position to adjust the engine speed according to the following
procedure.

No. Subject Working details Adjustment Data name Rated value

1 Preparation-1 After the accelerator dial has been replaced,
Only follow the procedure below to attach the dial.
applicable Loosen the setscrew and detach the dial.
when the Turn the shaft of the accelerator dial clockwise
accelerator dial until it reaches the stopper.
has been Fit the dial onto the shaft so that the dial pointer
replaced. mark points to the ( ) position then turn the
dial clockwise again until it reaches the stopper.
Tighten the setscrew to fasten the dial securely
onto the shaft.
Turn the accelerator dial fully back
counterclockwise.
2 Power supply Turn the starter switch to the "ON" position.
3 Switch and Set each mode and switch as listed below.
mode settings
Switch or mode name Setting
Work mode Heavy duty
APC mode H
Auto-slow mode OFF
Econo mode OFF
Accelerator backup switch AUTO
(857A-0053-0E)

4 SVAD data Switch to the ADJUST MODE menu. K-L

display A
Select the 1 RCES menu. D
J

(857A-0054-1E)

- 87 -
No. Subject Working details Adjustment Data name Rated value
5 Check Turn the accelerator dial fully clockwise until it
accelerator dial reaches the stopper.
attachment Read the SVAD data on the display and confirm SVAD 4.22
status that it is the rated value. SVAD
Turn the accelerator dial fully 4.75
counterclockwise until it reaches the stopper.
Read the SVAD data on the display and confirm SVAD 0.24
that it is the rated value. SVAD
0.70

[IF NOT]
Adjust the accelerator dial attachment status so
that each rated value is displayed in the items
and above.
6 Check high Turn the accelerator dial fully clockwise until it
idling speed reaches the stopper.
Read the AES data on the display. AES
Set the accelerator switch to the "3" position
and the accelerator backup switch to the
"MANUAL" position. At this time, check that
the displayed AES value is the same as item
above.
[IF NOT]
Check the accelerator dial attachment status.
Return the accelerator backup switch to the
"AUTO" position.
7 Check low Turn the accelerator dial fully
idling speed counterclockwise until it reaches the stopper.
Read the AES data on the display. AES
Set the accelerator switch to the "1" position
and the accelerator backup switch to the
"MANUAL" position. At this time, check that
the displayed AES value is the same as item
above.
[IF NOT]
Check the accelerator dial attachment status.
Return the accelerator backup switch to the
"AUTO" position.
8 Complete Press switch "E" to return to the ADJUST E
adjustment MODE menu.
Press switch "E" again to return to the normal E
mode.
(857A-0055-1E)

- 88 -
3. Data file (817S-0055-0E)

3-1 Engine (937S-0072-1E)

(1) Primary changes

Item HD2045 HD2045
1) Engine name Mitsubishi 6D24-TLE2A diesel engine Mitsubishi 6D24-TCE1 diesel engine
2) Rated output (kW/min ) -1
235/2000 228/2000
3) Maximum torque (N m/min-1) 1245/1200 1187/1400
4) Compression ratio 17.5 16.5
5) Engine dry mass (kg) 1100 1109
6) Governor Electronic control Mechanical centrifugal all-speed control
7) Oil cooler Aluminum Steel
8) Intercooler Air cooled Water cooled
9) Air cleaner Plastic type Sheet metal type
10) Starter 24V-7.0kW 24V-5.5kW
Electronic air heater Electronic air heater
11) Preheating method
22V-2.86kW (Rated at 20 sec) 22V-1.8kW (Rated at 40 sec)
12) Alternator 24V-50A 24V-35A
(877S-0016-0E)

(2) Performance curves

- 89 -
3-2 Consumable parts guide (877S-0060-0E)

Refer to the engine parts list for engine consumable parts such as an element etc.
[Consumable part name] Air cleaner element

Air cleaner assembly: 119-71500000

[Consumable part name] Long Life Coolant

- 90 -
 (877V-0017-0E)

E Hydraulic pump equipment

1. Main mechanism 91

2. Hydraulic pump equipment 93

2-1 Pump circuit 93

3. Measurement and adjustment of the pressure of pressurised oil 95

3-1 Two-step main relief valve 95
3-2 Pilot relief valve for the pilot hydraulic system 97

4. Equipment related to the hydraulic pump 99

4-1 Removal and mounting of the equipment related to the hydraulic pump 99
4-2 Hydraulic oil replacement and flushing 116

5. Data file 120

5-1 Interchangeability of main equipment 120
5-2 Hydraulic pump 121
5-3 Check valve 121
5-4 Control valve 122
5-5 Consumable parts guide 123
1. Main mechanism (837S-0012-2E) 777

This machine is equipped with a diesel engine as power source which drives hydraulic pumps to generate high hydraulic
pressure. The pressurised oil produced passes through a circuit as detailed below to operate hydraulic motors and
cylinders which are used for excavation, travel and swing in this fully hydraulic excavator.

- 91 -
The main components of this machine are the crawler-type lower structure, superstructure which carries the engine,
pumps, operator's seat etc., and front attachment comprising the boom, arm and bucket.
Each part is operated by pressurised oil sent from two engine-driven pumps P1 and P2. Pressurised oil from pump P1
passes to the control valve in block A and pressurised oil from pump P2 passes to the control valve in block B. The right
control lever controls the boom and bucket cylinders while the left control lever controls the arm cylinder and the swing
motor. The central traveling control levers operate the right and left traveling motors respectively.
The hydraulic circuit of this machine is equipped with the following safety devices to ensure smooth work and
safeguard the hydraulic circuit.
Travel brake valve and parking brake
When the machine is stopped, this automatic braking device operates to prevent the machine moving off down
slopes or slipping on inclined roads, and the mechanical brake works securely when the machine is stopped and
parked.
Swing brake valve
Maintains an appropriate amount of speed reduction of the superstructure to prevent motor damage caused by the
shocks when swinging stops.
Swing parking brake
When swinging stops, this brake operates automatically to prevent the superstructure from swinging spontaneously
on slopes.
Anti-drift valve
Built into the boom cylinder bottom and arm cylinder rod sides of the control valve to reduce spontaneous fall of the
attachments.
Main relief valve
Built into the control valve to prevent damage to hydraulic equipment under overloads and to limit the working
pressure of the hydraulic circuit.
Overload relief valve
Built into the cylinder ports of the control valve to restrict abnormally high pressures inside the cylinders generated
by overloading and protect the cylinders, boom, arm and bucket.

- 92 -
2. Hydraulic pump equipment (857S-0115-1E)

2-1 Pump circuit (837S-0020-0E)

2-1-1 Hydraulic circuit diagram (857S-0030-0E)

- 93 -
2-1-2 Description of the pump circuit (777S-0020-3E)
This pump comprises two identical variable piston pumps, pumps P1 and P2, which are connected in line on a single input
shaft. A pilot gear pump P3 is also attached. They generate three lines of high pressure.
The pressurised oil from pump P1 flows to block A of the control valve and is used for the right traveling motor, swing
motor, speed increase of the boom cylinder extension side, spare and arm cylinder.
The pressurised oil from pump P2 flows to block B of the control valve and is used for the left traveling motor, boom
cylinders, bucket cylinder and speed increase of the arm cylinder.
The pressurised oil from pump P3 is reduced in pressure by an internal relief valve. It then passes through the safety lock
valve to the remote control valves (right), (left) and (travel) for use as pilot pressure for switching the spools of the control
valve.
The pressurised oil from pump P3 also flows to the solenoid block or control valve to operate various controls.
When the spools of the control valve are in the neutral positions, the pressurised oil from pumps P1 and P2 passes
through the central bypass circuit of the control valve, turns the foot relief valve to "on-load" and flows from port R
through the return filter to the oil reservoir. The foot relief valve creates a pressure in the central bypass circuit of the
control valve. By sending this pilot pressure to the pump, the output volume of the pump is minimised when the spools
of the control valve are in the neutral positions.
The return circuit incorporates an oil cooler which prevents excessive temperature rise in the oil flowing in the circuit.
When the oil temperature is low, check valve [10] opens to restrict the oil to bypass the oil cooler, allowing the oil to flow
directly back into the oil reservoir.

- 94 -
3. Measurement and adjustment of the pressure of
pressurised oil (817S-0045-1E)

To ensure the safety of operation and of the hydraulic circuits themselves, the main circuit is fitted with a two-step main
relief valve and the swing circuit is fitted with a swing relief valve. The pilot circuit is fitted with a pilot relief valve.

3-1 Two-step main relief valve (827S-0038-0E)

This is a single main relief valve built into the control valve which
determines the lower pressure setting for use of the front attachment
and the higher pressure setting for use of the traveling motors and high-
power front attachment use.

3-1-1 Pressure measurement method (847S-0028-1E)

(1) Turn the starter switch from "ON" to "START" to "ON" to start the
engine.
(2) Set the work mode to "Heavy duty", the APC mode to "H", the
auto-slow mode to OFF and the econo mode to OFF.
(3) Display the A PUMP1 or B PUMP2 data on the adjust mode menu
screen.
(4) Warm up the engine following the instruction manual until the
hydraulic oil temperature rises to 50 5°C.
Note Hydraulic oil temperature is indicated as H.OIL on the adjust mode screen.
(5) Turn the accelerator dial fully clockwise to the high idling stopper position.
(6) Lift the boom or move the arm lever to full stroke and take readings of the relief pressures P1 and P2. (Low-
pressure measurement)
(7) In this condition, press the high power switch ( ) on the right control lever and take readings of P1 and P2 during
the following ten seconds. (High-pressure measurement)

Indicated pressures MPa (kgf/cm2)

Relief when boom lifted or With the high power switch
When no lever is moved activated in the condition on the
arm operated (low pressure) left. (high pressure)

PUMP1 2.9 4.4 (30 45) 29.4+0.98

0 (300+100 ) 32.9+0.98
0 (335+100 )

PUMP2 2.9 4.4 (30 45) 29.4+0.98

0 (300+100 ) 32.9+0.98
0 (335+100 )
(777S-0026-1E)

- 95 -
3-1-2 Main relief valve adjustment method and its adjustment amount (777S-0027-1E)
On structure, when the high-pressure side pressure of the main relief valve is adjusted, the present pressure set value on
the low-pressure side will also change.
If only the low-pressure side pressure is adjusted, the high-pressure side pressure will not be changed.
(1) Adjustment method and its adjustment amount
1) High-pressure side
Unscrew locknut [A].
Turn plug [B] to adjust the pressure.
One quarter turn (90°) of the plug changes the pressure by 3.22MPa (32.8kgf/cm2).
After adjustment, retighten locknut [A] to the tightening torque indicated below.
Tightening torque: 53.9 7.8N m (550 80kgf cm)
2) Low-pressure side
Unscrew locknut [C].
Turn plug [D] to adjust the pressure.
One quarter turn (90°) of the plug changes the pressure by 3.22MPa (32.8kgf/cm2).
After adjustment, retighten locknut [C] to the tightening torque indicated below.
Tightening torque: 44.1 6.4N m (450 65kgf cm)

- 96 -
3-2 Pilot relief valve for the pilot hydraulic system (857S-0024-1E)

The pilot relief valve is built into the pilot gear pump which is connected in tandem to the main double pump. This
hydraulic system is constantly pressurised to provide the hydraulic pressure for various switching functions.
1. Hydraulic pressure supply for the left and right control pilot valves and travel pilot valve
2. Hydraulic pressure supply through the solenoid valve for the swing parking brake, high power function and travel
transmission switching
3. Hydraulic pressure supply for the direct forward/reverse travel and travel pressure rise signals
4. Hydraulic pressure supply for the boom and arm holding valve release signals
5. Hydraulic pressure supply for the superstructure and travel pressure switches
6. APC proportional reducing valve
Therefore if the pressure in this hydraulic system is too low or too high, it could cause problems.

3-2-1 Pressure measurement method (857S-0025-1E)

(1) Stop the engine and remove the air breather cap (4mm hexagonal key wrench) to relieve air pressure in the oil
reservoir.
(2) Connect the pressure gauge (0 9.8MPa) (0 100kgf/cm2) to the pickup coupler on the outlet of the pilot gear
pump.

- 97 -
 (3) Turn the starter switch from "ON" to "STRAT" to "ON" to start the engine.
(4) Comfirm that there is no oil leakage from the gauge connection.
(5) Set the work mode to "Heavy duty", the APC mode to "H", the auto-slow mode to OFF and the econo mode to
OFF.
(6) Warm up the engine following the instruction manual until the hydraulic oil temperature rises to 50 5°C.
(7) Turn the accelerator dial fully to the low idling and high idling stopper positions and read the each pressure
indicated on the pressure gauge.
Note Pilot relief valve pressure at low idling: 3.14 3.43MPa (32 35kgf/cm2)
Note Pilot relief valve pressure at high idling: 3.43 4.22MPa (35 43kgf/cm2)

3-3-2 Relief valve adjustment method and its adjustment amount (777S-0079-1E)
Use the relief valve which is built into the pilot gear pump to adjust the pressure.
(1) Loosen locknut [A] and turn adjust screw [B] to adjust the
pressure. Tighten locknut [A] to the tightening torque indicated
below.
Note 1. One turn of the adjust screw 1.7MPa (17.4kgf/cm2)
2. Tightening torque: 29.4N m (300kgf cm)

- 98 -
4. Equipment related to the hydraulic pump (937S-0111-0E)

4-1 Removal and mounting of the equipment related to the hydraulic pump
(937S-0112-0E)

- 99 -
4-1-1 Maintenance of hydraulic devices (7670-0202-1E)
This machine is hydraulically powered and uses high-precision hydraulic equipment. Therefore if it is not operated and
maintained correctly, its performance will be reduced and its lifespan shortened with an increased risk of malfunction.
Always carry out the following daily inspections.

(8570-0084-1E)

Always relieve pressure on the oil reservoir before you inspect or service any hydraulic part or
system.
Never interfere with the pump regulator setting and relief settings of the control valve and
brake valve.
The bolts holding hydraulic equipment in place are under an extremely high force, so they are
tightened to the right torque. In case of trouble, contact your authorised KATO dealer.
Special bolts are used for attachment of hydraulic equipment, so you should not use normal
commercially available ones which might cause breakdowns.
If the hydraulic oil is hot, wait for it to cool before carrying out inspection and servicing.
If you start work while the oil is hot, you risk severe burns.
When you have replaced the hydraulic device, return filter or hydraulic oil, you should allow
a running-in period of approximately 10 minutes at engine low speed with the control levers
in their neutral positions (with no load applied).

(1) Daily inspection of hydraulic devices

- 100 -
4-1-2 Pump and pump drive (877S-0061-0E)

(1) Reduction of pressure in the oil reservoir

When taking apart hydraulic piping or changing hydraulic oil, stop the engine and remove the air breather cap.
Start work after pressure has been completely relieved. When you refill with hydraulic oil, remove the cover from
the return filter.
1) How to remove and fit the air breather cap
Insert a hexagonal key wrench (4mm) into the lateral hole in the side block.
Turn the wrench to the outside and slowly turn the cap counterclockwise.
Pressure will be relieved and then you can remove the cap.
To refit the cap, align the projection on the cap with the arrow mark on the case, fit the cap in and turn it
clockwise until it locks.

(7770-0051-0E)

Always use the hexagonal key wrench to release the lock before you try to remove the cap.

- 101 -
 (2) Removal
1) Disconnect all pipes and hoses from the pump.
Note 1. Mark each hose with the name of the corresponding port to prevent mistakes in reassembly.
2. Drain the hydraulic oil from the oil reservoir before you disconnect any hoses.
2) Arrange the sling wire rope to the pump and support it with a crane then undo bolts [7] to detach the pump from
the engine. (Pump assembly mass: 211kg)
3) Remove hexagon socket bolts [2-5] and remove the coupling from the engine.
(3) Inspection and repair
1) Check that there are no cracks or other damage to the coupling.
(4) Mounting
Reverse the removal procedure to mount the pump with particular attention to the following points.
1) Tightening torque for bolts [2-5]: 431 481N m (44 49kgf m)
Always check that you have applied screw-lock compound.
2) Thoroughly wipe away all traces of oil and grease from the threaded parts of bolts [7] and always apply screw-
lock compound to them before tightening them.

4-1-3 Extraction of air from the hydraulic pump (7270-0107-4E)

If you have replaced hydraulic oil or the hydraulic pump itself or removed the pump suction hose, you must go through
the following air extraction procedure to extract air from the pump casing before starting the engine.

(1) Air extraction procedure

1) Fill the oil reservoir with hydraulic oil to the regulation level.
2) Open the drain ports on the top of the pump.
3) Pour hydraulic oil in through both ports to fill the pump casing.
4) Tighten both joints and hoses, and run the pump unloaded at engine low speed.
5) Loosen both joints and hoses a little and extract the air from the pump casing.
6) After confirming that the air is out, tighten both joints and hoses.

(8270-0184-1E)

The pump will be damaged if it is run with air inside the casing. If you have replaced
hydraulic oil or the pump itself or removed the pump suction hose, you must extract air from
the pump casing.
Air extraction from the pump casing and hydraulic circuits must always be done with the
pump unloaded at engine low speed. At engine medium speed or more or with the pump under
load, air can enter the pump and damage it.

- 102 -
4-1-4 Replacement of the pump discharge hose (767S-0224-0E)

(767S-0370-0E)

The pump discharge hose is designated as a safety part for periodic replacement and as such it must
be replaced every 2 years or every 4000 hours of use, whichever occurs sooner.

- 103 -
4-1-5 Control valve (777S-0032-2E)
(1) Removal
1) Disconnect all pipes, hoses and harnesses that are connected to the control valve.
Note 1. Mark each hose with the name of the corresponding port to prevent mistakes in reassembly.
2. Drain the hydraulic oil from the oil reservoir before you disconnect any hoses or pipes.
2) Attach the sling wire rope to the control valve and support it with a crane. Then remove bolts [2] and remove the
valve from the slewing table. (Mass of the valve: 337kg)
(2) Mounting
Reverse the removal procedure to mount the control valve with particular attention to the following points.
1) Tightening torque for control valve mounting bolts [2]: 423N m (43.2kgf m)
2) Thoroughly wipe away all traces of oil and grease from the threaded parts of the bolts and always apply screw-
lock compound to them before tightening them.

- 104 -
4-1-6 Replacement of the air breather element (7770-0052-3E)

(8270-0188-1E)

Relieve pressure in the oil reservoir before you start to replace the air breather element.
The hydraulic oil will be hot immediately after the engine stops, so wait until it cools to 40°C
and less before you start work.

(1) Replacement procedure

1) Insert a hexagonal key wrench (4mm) into the lateral hole in the side block.
2) Turn the wrench to the outside and slowly turn the cap counterclockwise. Pressure will be relieved and then you
can remove the cap.
3) Remove the hexagon socket bolt on the cap, the cap itself and the element in that order.
4) Replace the old element with a new one.
5) Place an O-ring, the element and the cap into the case in that order and fasten it in place with the hexagon socket
bolt.

(2) Replacement interval

Replacement interval At the time of hydraulic oil change and every 1000 hours of operation or yearly
(3) Consumable part number
Refer to the "Consumable parts guide".

- 105 -
4-1-7 Cleaning and replacement of the suction strainer (7670-0206-1E)
(1) Cleaning and replacement procedure
1) Relieve pressure from the oil reservoir.
2) Remove the strainer from inside the oil reservoir.
3) Clean the strainer with a clean, non-flammable solvent and dry it thoroughly.
4) Inspect the strainer and O-ring and replace them if they are damaged.

(2) Cleaning and replacement intervals

Cleaning interval When you change the hydraulic oil
Replacement interval When defective
(3) Consumable part number
Refer to the "Consumable parts guide".

4-1-8 Replacement of the return filter element (8770-0040-0E)

(1) Structure of the KATO return filter
The structure of the KATO return filter is as shown in the diagram
to the right. The hydraulic oil flows from the inside to the outside
of the element to collect the captured dirt into the element, so the
dirt does not flow into the oil reservoir structurally when the
element is replaced to remove the dirt.
If the element is replaced carelessly, the dirt may get in the
hydraulic circuit. Follow the correct procedure and replace the
element with care.

- 106 -
(2) Preparation
Prepare the following for element replacement.
1) Genuine KATO elements
(937S-0077-1E)

The size and number of the filter vary with the type of the machine. If you use the breaker, be sure
to use the high-performance filter. Always use the genuine KATO filter elements. An imitation
element is not guaranteed for performance and durability. If the worst comes to the worst, it
could be damaged early and have an adverse effect on the hydraulic equipment. If an imitation
filter is used, the hydraulic equipment is not guaranteed.

2) Clean tray which is already washed: (300mm 450mm or equivalent)

3) Clean paper or cloth: with no nap
4) Hydraulic oil (cleaning fluid): the same new hydraulic oil as the machine is using
5) Ratchet wrench
6) 19mm box wrench
7) O-ring (for the cover)
(3) Operation before replacement
Before replacing the elements, run the engine at medium speed (1000 1200min-1) and perform traveling, swing,
bucket, arm and boom operation in that order for two minutes respectively to collect the dirt into the return filters
from the hydraulic circuit. Then stop the engine.
(4) Reduction of pressure in the oil reservoir
1) Insert a hexagonal key wrench (4mm) into the lateral hole in the side block.
2) Turn the wrench to the outside and slowly turn the cap counterclockwise.
Pressure will be relieved and then you can remove the cap.

(5) Disassembly procedure

1) Unscrew the four bolts on the filter cover to remove the cover
and O-ring from the filter case.

- 107 -
2) Pull the element assembly out of the filter case.

(937S-0079-0E)

Hold the spring and put the underside of the element on the inside flange of the filter case for about
ten minutes to drain the oil from the filter assembly.

3) After pulling out the element assembly, put the removed cover onto the filter case to prevent entry of dirt or dust
into the reservoir.
(937S-0080-0E)

Do not replace the elements in a dusty workplace.

The wind contains dust, so take an appropriate action for protection against the wind in a windy
workplace before replacing the elements.

4) Put the element assembly from which the oil is drained onto the
tray.

(937S-0081-0E)

Use the washed tray. If the tray is dirty, it makes the lower part of the center bolt of the element
assembly dirty. If the tray is not washed thoroughly, the hydraulic oil could be contaminated by
the dirt, so caution is required.

- 108 -
5) Extract the snap pin from the center bolt on the top of the
element assembly.

6) Unscrew the castle nut to remove the spring from the center bolt.

7) Extract the safety valve from the center bolt.

8) Remove the center bolt from the elements, and separate the two
elements and the retainer.

- 109 -
(6) Cleaning and inspection
1) Thoroughly clean the component parts of the element assembly except the elements using the new hydraulic oil
which is prepared in advance.
2) Cover the washed parts with a cloth etc. which is prepared in advance to prevent dirt adhesion.
3) Check the O-ring. If it is damaged or stretched, replace it with new one.
(7) Assembly of the element assembly
Follow the procedure below to assemble the new elements.
1) Prepare the clean paper or cloth for element assembly.

2) Assemble one element to the center bolt.

3) Attach the retainer onto the assembled element.

(937S-0082-1E)

Do not forget to attach the retainer.

- 110 -
4) Assemble the other element onto the retainer.

5) Attach the safety valve to the elements.

6) Attach the plate spring onto the safety valve. Tighten the castle
nut to the center bolt to the regulation torque (10 15N m).

(8270-0189-1E)

If the tightening force on the castle nut is insufficient, the filter can not work efficiently.
Tighten it to the regulation torque.

7) Insert the snap pin into the center bolt.

- 111 -
 8) Hold the plate spring and store the element assembly into the
filter case.

(937S-0106-0E)

When storing the element assembly into the filter case, keep the elements not to come into contact
with the other parts so that the elements do not get dirty.

9) Check the O-ring for damage again. Then attach the O-ring in
place and put the cover onto the filter case.
10) Attach the washers to the four bolts and tighten the cover to the
filter case to the regulation torque (20 34N m).
(8) Attachment of the air breather cap
To refit the cap, align the projection on the cap with the arrow
mark on the case, fit the cap in and turn it clockwise until it locks.
(9) Element replacement interval
Replacement interval Every 500 hours of operation or six
months
After delivery of a new machine or
right after the hydraulic oil is
changed, the elements should be
replaced after 150 hours of
operation. Also when you change
the hydraulic oil, they should be
replaced.
(10) Consumable part number
Refer to the "Consumable parts guide".
(937V-0018-0E)

You cannot wash the return filter element and reuse it. Always use a new, genuine KATO,
filter element.
If you are using the hydraulic breaker, replace the standard filter element with a high-
performance type.
When you have replaced the return filter, you should allow a running-in period of
approximately 10 minutes at engine low speed with the control levers in their neutral
positions (with no load applied).

- 112 -
4-1-9 Replacement of the drain filter cartridge (7770-0099-3E)
(1) Cartridge replacement procedure
1) Relieve air pressure in the reservoir.
2) Use the specified wrench to remove the cartridge .
3) When fitting a new cartridge, coat the packing surface with clean
hydraulic oil and turn the cartridge through approximately 2/3 of
a turn after the packing contacts the seal surface.
4) Start the engine and check that no oil leaks through the seal
surface.
(2) Cartridge replacement interval
Replacement interval Every 1000 hours of operation or yearly
After delivery of a new machine, the cartridge should be replaced after 150 hours of
operation.
(3) Consumable part number
Refer to the "Consumable parts guide".
(8270-0191-0E)

You cannot wash the cartridge and reuse it.

Always use a new, genuine KATO, filter cartridge.

4-1-10 Recording when replacing the return filter element (7670-0209-2E)

There is a label stuck to the inside of the cab door for you to record when
you replace the filter element. Be sure to stick the sticker when you
change the filter element.

- 113 -
4-1-11 Replacement of the pilot line filter element (7770-0100-3E)
(1) Replacement procedure
Follow this procedure to replace the element.
1) Relieve air pressure in the reservoir.
2) Unscrew the filter case and pull it off downward then turn the
filter element while pulling it off downward.
3) When reassembling, replace the element and O-ring with
new ones.
4) Tighten the filter case to the head assembly at the regulation
torque.
Case tightening torque: 78.4 ± 4.9N·m (8 ± 0.5kgf·m)
(8270-0192-1E)

You cannot wash the filter element and reuse it.

Always replace with a new, genuine KATO, filter element.
When replacing the element, take care that the hydraulic oil will not splash onto the
accelerator actuator.

(2) Element replacement interval

Replacement interval Every 1000 hours of operation or yearly
(3) Consumable part number
Refer to the "Consumable parts guide".

- 114 -
4-1-12 Accumulator handling (7670-0212-2E)

(8270-0193-1E)

In this machine fitted with an accumulator, the front attachment will fall under its own weight if
the control lever is moved for the attachment to lower within a few minutes after the engine has
stopped.
After the engine has stopped, move the safety lock lever to the lock position and lock the optional
attachment control pedal with its lock pin.
High-pressure nitrogen gas is sealed into the accumulator, so any inappropriate handling is
potentially highly dangerous. Strictly observe the following points.
Never pierce the accumulator or bring it near a fire or other source of heat.
Do not weld a boss etc. onto the accumulator.
When disposing of the accumulator, the enclosed gas must be released. Contact your
authorised KATO dealer.

An accumulator is fitted in the control circuit as a pressure-accumulation

device. It allows the control circuit to go on functioning for one or two
minutes after the engine stops.
Therefore if you move the control lever to lower the front attachment, it
is able to move down under its own weight.
You can also release residual pressure in each circuit (boom, bucket,
arm) by moving the control levers in this condition.
The accumulator is fitted as shown in the diagram on the right.

- 115 -
4-2 Hydraulic oil replacement and flushing (857S-0112-0E)

4-2-1 Hydraulic oil replacement (777E-0050-0E)

(1) Oil level check
Check the level of hydraulic oil every day.
The level of oil in the oil reservoir varies with the extension and retraction of the cylinders, so to check the oil level,
first fully retract the arm cylinder and fully extend the bucket cylinder as shown in the diagram and place the
bucket on level ground.

(8270-0185-1E)

If you overfill with hydraulic oil, there will be insufficient air space in the oil reservoir, so when
the oil level rises, the pressure in the oil reservoir will rise excessively, possibly causing breakage
in the pipe system. Keep to the regulation volume.

(2) Reduction of pressure in the oil reservoir

When taking apart hydraulic piping or changing hydraulic oil, stop the engine and remove the air breather cap.
Start work after pressure has been completely relieved. When you refill with hydraulic oil, remove the cover from
the return filter.
1) How to remove and fit the air breather cap
Insert a hexagonal key wrench (4mm) into the lateral hole in the side block.
Turn the wrench to the outside and slowly turn the cap counterclockwise.
Pressure will be relieved and then you can remove the cap.
To refit the cap, align the projection on the cap with the arrow mark on the case, fit the cap in and turn it
clockwise until it locks.

(7770-0051-0E)

Always use the hexagonal key wrench to release the lock before you try to remove the cap.

- 116 -
(3) Hydraulic oil replacement procedure
1) Park the machine on firm, level ground in the hydraulic oil filling position and remove the air breather cap to
relieve pressure in the oil reservoir.
2) Drain hydraulic oil through the drain cock and clean the suction strainer before closing the drain cock.
3) Remove the return filter cover and fill with hydraulic oil to the regulation level on the level gauge.
4) Fit the air breather cap and return filter cover.
5) Extract air from the pump.
6) The oil contains air, so run the engine at idling speed and operate the machine gently for 10 15 minutes,
moving the cylinders evenly, then put the machine in hydraulic oil filling position and recheck the level.
The oil level should lie between the H and L lines on the level gauge. Do not top it up beyond the H level. Do top
it up if it is below the L level.

(8270-0186-1E)

Always top up with new oil of the exact same brand and name. Do not mix with other oil
products.
Always extract air from the pump after changing hydraulic oil.
When you have replaced hydraulic oil, you should allow a running-in period of
approximately 10 minutes at engine low speed with the control levers in their neutral
positions (with no load applied).

(4) Inspection and replacement intervals

Inspection interval At the time of preoperational checks
Replacement interval When using KATO recommended hydraulic oil: Every 2000 hours of operation
or yearly
When using NIPPON OIL HYRANDO WIDE KV32, KV46, KV68 or KV100:
Every 5000 hours of operation
Oil filling volume 329L
Total oil volume 610L
(8270-0187-0E)

Hydraulic oil will deteriorate naturally even if the machine is not being operated, so if the machine
is stored for a long period, thoroughly inspect the condition of the hydraulic oil, and replace it if
necessary, before starting to work.

- 117 -
4-2-2 Flushing (937S-0083-1E)
(1) Precautions when changing hydraulic oil
Flushing when you change hydraulic oil is very important. Hydraulic oil is replaced when the periodic replacement
interval has expired, when it has deteriorated extremely, when it is contaminated with water or different type of oil,
or when it contains large quantities of metal fragments, debris or other foreign bodies. In special cases it may also
be changed when the machine is to be left unused for prolonged periods.
In any case flushing is an absolutely necessary part of the oil changing procedure. Its purpose is to eliminate
decomposed oil, corrosion, anti-corrosion paint, insoluble impurities and other materials which may be clinging to
the inner surfaces of pumps, valves and pipes, as well as foreign bodies which may have sunk to the bottom of the
oil reservoir. The oil in the system must also be eliminated to remove water and different oil types which have
mixed with the oil. These foreign substances cause foaming of the oil and corrosion of metal parts. Occasionally
they can also cause gaskets to expand, causing severe damage to hydraulic equipment.
Furthermore if decomposed oil is left in the system, the lifespan of new oil is greatly reduced and residual moisture
causes clouding and corrosion. To avoid such problems, take great care to drain all oil from the pipes and hydraulic
equipment.
(2) Flushing after replacing the return filter elements
Be sure to flush (wash) after replacing the elements. Even if the elements are replaced carefully, dirt can get in the
oil reservoir. Flush to filter the dirt through the return filters.
Follow the procedure below to perform the flushing process.
1) Start the engine and run it at low speed for about one or two minutes.
Wait until the return filters are filled with hydraulic oil. Flush at engine medium speed for about ten minutes.

(937S-0084-0E)

Never move the levers during the flushing process.

If any lever is moved, dirt could get in the hydraulic circuit.

(3) After replacing hydraulic equipment

1) After replacing the hydraulic pump or control valve, perform the flushing process in the same way as "(2)
Flushing after replacing the return filter elements" above.
2) After replacing the hydraulic cylinder, start the engine and move the replaced cylinder through five strokes or
more without reaching the stroke end at engine medium speed.
3) After replacing the hydraulic motor (swing or travel), start the engine, lock the motor and operate the levers
halfway at engine low speed to relieve pressure for about one minute. Then move the replaced motor at engine
medium speed with the least possible load in either direction respectively for ten seconds at least three times.

- 118 -
(4) After attaching the additional optional hydraulic pipes
1) Bypass the connection hose to the attachment to flush the additional pipes.
From the status above, start the engine and move the lever at engine medium speed so that the hydraulic oil can
flow to the additional pipes to perform flushing process for about one minute.
2) Connect the bypass hose to the hydraulic equipment of the attachment and perform the flushing process as
indicated in "(3) After replacing hydraulic equipment".
(5) After replacing the optional hydraulic attachment
1) If the hydraulic breaker is mounted, never move the boom, arm and bucket cylinders simultaneously. If you use
the hydraulic breaker, use the high-performance filter to filter fine dirt. If you do not do so, the lifespans of the
hydraulic pump or other hydraulic devices will be shortened.
2) If the cylinder attachment such as a hydraulic crusher is mounted, move the machine to the place the attachment
can be moved sufficiently before operating the attachment.
Move the attachment cylinder through full stroke at least five times to perform the flushing process. At this time,
never move the boom, arm and bucket cylinders simultaneously.
3) If the motor attachment such as a hydraulic piler is mounted, move the machine to the place the attachment can
be moved sufficiently before operating the attachment.
Then move the attachment motor for one minute or more to perform the flushing process. At this time, never
move the boom, arm and bucket cylinders simultaneously.

- 119 -
5. Data file (817S-0055-0E)

5-1 Interchangeability of main equipment (937S-0085-0J)

Interchangeability
Classification Device Notes (interchangeable conditions)
HD2045 HD2045
Engine
Pump coupling
Radiator
Superstructure

Oil cooler
Swing gear
Battery
Cab
Operator's seat
Water separator
Sprocket
Front idler
Lower structure

Adjuster cylinder
Track roller
Carrier roller
Track shoe
Track link
Suction hose
Can be used if regulator settings are
Pump
changed.
Control valve
Swing motor
Traveling motor
Boom cylinder
Arm cylinder
Hydraulic equipment

Bucket cylinder
Rotary seal
Pilot valve (upper)
Pilot valve (travel)
Solenoid block
Lock valve
Pressure switch
Shuttle valve
Accumulator
Check valve (back pressure)
Check valve (bypass)
Air breather
Abbreviations : Two-way interchangeable : Not interchangeable (877S-0018-1E)

: Conditionally interchangeable : One-way interchangeable

- 120 -
 Interchangeability
Classification Device Notes (interchangeable conditions)
HD2045 HD2045
Boom
Arm
Front

Bucket
Side link
Tipping link
Return filter
Drain filter
Element

Fuel filter
Suction strainer
Pilot line filter
Engine oil filter
Air cleaner element
(877S-0019-0E)
Abbreviations : Two-way interchangeable : Not interchangeable
: Conditionally interchangeable : One-way interchangeable

5-2 Hydraulic pump (937S-0126-0E)

Part No. 609-80800010

Rated pressure 32.9MPa (335kgf/cm2)
Main pump

Delivery 185cm3/rev 2
Maximum flow 370L/min 2
Direction of rotation Clockwise (as viewed from shaft end)
Rated pressure 3.6MPa (37kgf/cm2)
Gear pump

Delivery 15cm3/rev
Maximum flow 30L/min
Direction of rotation Clockwise (as viewed from shaft end)
Mass 211kg
(877S-0020-0E)

5-3 Check valve (937S-0128-0E)

Back pressure Bypass

Part No. 669-69600001 669-61200001
0.3 0.1
Cracking pressure 0.15 0.03MPa (1.5 kgf/cm2) 0.6 0.01MPa (6.0 kgf/cm2)
Mass Approx. 0.16kg Approx. 0.16kg
(877S-0021-0E)

- 121 -
5-4 Control valve (877S-0022-0E)

Part No. 669-27300001

Type KMX32N/B45002
Boom, Arm, Bucket 29.4MPa (300kgf/cm2)
pressure

Main relief
Rated

When traveling and pressurising 32.9MPa (335kgf/cm2)

Overload relief Arm, Boom, Bucket, Option 34.3MPa (350kgf/cm2)
Mass Approx. 337kg
(877S-0023-0E)

- 122 -
5-5 Consumable parts guide (837S-0035-1E)

[Consumable part name] Air breather element

Air breather assembly: 689-17400004

[Consumable part name] Suction strainer

Suction strainer assembly: 689-12800003

- 123 -
 [Consumable part name] Return filter element

Return filter assembly: 689-42900001

689-43100001

[Consumable part name] Drain filter cartridge

Drain filter assembly: 689-25100001

- 124 -
 [Consumable part name] Pilot line filter element

Pilot line filter assembly: 689-29300004

- 125 -
MEMO

- 126 -
 (877V-0024-0E)

F Control equipment

1. Control equipment 127

1-1 Control equipment circuit 127

2. Equipment related to control devices 128

2-1 Pilot valves (boom, arm, bucket, swing) 130

3. Changing procedure for control lever configuration 131

1. Control equipment (877S-0068-0E)

Control devices are located in the cab, under the floor and on the slewing table and are connected by pilot hoses. They
comprise the pilot valve, solenoid valve, lock valve, shuttle valve etc.

1-1 Control equipment circuit (857S-0029-0E)

1-1-1 Hydraulic circuit diagram (857S-0020-0E)

- 127 -
2. Equipment related to control devices (857S-0031-1E)

- 128 -
- 129 -
2-1 Pilot valves (boom, arm, bucket, swing) (777S-0080-1E)

(1) Removal
1) Remove 12 screws (left and right) from the cover and lift the boot to unscrew the locknut of the control lever.
2) Disconnect the wiring cord from the control lever and detach the control lever from the pilot valve while turning
it.
3) Remove the pilot valve attachment bolts and disconnect the hoses connected to the pilot valve with the pilot
valve slightly raised.
Mark each hose with the name of the corresponding port to prevent mistakes in reassembly.

(2) Attachment
Reverse the removal procedure to attach the pilot valve with particular attention to the following points.
1) Tightening torque for the locknut of the control lever: 41.2N m (420kgf cm)
2) Secure the boot by using the cover to clamp it from the side.
3) Tighten the screws to the tightening torque about 0.39N m (4kgf cm). Do not over tighten the screws as this may
crack the cover.
4) Put a bundle of wires into the "U" groove of the valve to press it down using the boot.

- 130 -
3. Changing procedure for control lever configuration (877S-0069-0E)

Switch the hoses at the shuttle valve hose connections located under the operator's seat.

(877S-0081-0E)

Be careful of the swing pressure switch, located forward of the shuttle valve, and the swing control
pressure signal hose, located toward the rear.

- 131 -
MEMO

- 132 -
 (877V-0025-0E)

G Front attachment

1. Front attachment 133

1-1 Boom circuit 133
1-2 Arm circuit 135
1-3 Bucket circuit 137

2. Removal and mounting of the front attachment 139

2-1 Bucket 140
2-2 Arm 151
2-3 Boom 156

3. Data file 161

3-1 Data for front attachment mounting 161
3-2 Service standards 162
1. Front attachment (857S-0033-1E)

1-1 Boom circuit (837S-0021-0E)

1-1-1 Hydraulic circuit diagram (857S-0030-0E)

- 133 -
1-1-2 Description of the boom circuit (777S-0021-2E)
The two boom cylinders are operated by No. 3 spool of the control valve (block A) and No. 3 spool of the control valve
(block B). When the boom spools are in the neutral positions, the boom cylinders are at rest. When the boom lever is moved
forward or backward, the boom cylinders extend or retract.
The boom 1 spool houses the overload relief valve that prevents outside pressure causing abnormal high pressure in the
circuit when the spool is in the neutral position. When the boom spools are switched to the extension side, the pressurised
oil from pump P1 and P2 merges inside the control valve to flow to the boom cylinder bottom side.
If the boom spools are switched to the retraction side, the boom 2 spool is in neutral and the only pressurised oil from pump
P2 flows to the boom cylinder rod side.
(1) Boom recycling circuit
The retraction side of the boom 1 spool is equipped with a recycling mechanism so that the returning oil from the
cylinder bottom side flows to the rod side again.
(2) Boom raising priority circuit
When boom raised and bucket crowded
The pressurised oil from pump P1 passes through the parallel channel in the control valve (block A) to the
boom cylinder bottom side.
The pressurised oil from pump P2 is supplied to the boom and bucket spools through the parallel channel in
the control valve (block B), but a pilot pressure (PAcs) acts to regulate the stroke of the bucket spool so that it
does not move to full stroke. Thus the channel is constricted and pressure is maintained for the boom raising
operation.
When boom and swing operations are performed simultaneously
The pressurised oil from pump P2 passes through the parallel channel in the control valve (block B) to the
boom cylinder bottom side.
The pressurised oil from pump P1 is supplied to the boom and swing spools through the parallel channel in the
control valve (block A), but a pilot pressure of boom 2 acts on the boom raising priority spool at the same time
which constricts the swing oil channel to supply oil to the boom in priority.
(3) Boom anti-drift valve
There is an anti-drift valve on the boom cylinder bottom side to
minimize leakage from the boom cylinders and reduce boom
gravity lowering.
(4) Slow operation mode
When the work mode is switched to the slow operation mode, the
lowering pilot pressure acts on (PAbs) through the solenoid block.
This restricts the spool stroke and maintains the range of slow
operation to improve the lowering operation.

- 134 -
1-2 Arm circuit (837S-0022-0E)

1-2-1 Hydraulic circuit diagram (857S-0030-0E)

- 135 -
1-2-2 Description of the arm circuit (777S-0022-3E)
The arm cylinder is operated by No. 1 spool of the control valve (block A) and No. 1 spool of the control valve (block
B). When the arm spools are in the neutral positions, the arm cylinder is at rest. When the arm lever is moved forward
or backward, the arm cylinder extends or retracts. Each port of the arm 1 spool houses the overload relief valve.
When the arm spools are switched, the pressurised oil from pump P1 flows through the arm 1 of the control valve (block
A) to the arm cylinder.
The pressurised oil from pump P2 passes through the arm 2 of the control valve (block B) and merges with the
pressurised oil from the arm 1 inside the control valve to flow to the arm cylinder. The arm 2 is connected in tandem, but
in one section inside the control valve it is in parallel connection to improve ease of control during simultaneous
operation.
When the mode is switched to the fine control mode, the pilot pressure acting on the control valve (block B) is blocked
by the solenoid block. At this time the pressurised oil only from pump P1 flows to the arm cylinder bottom side to
improve the arm operation.
(1) Arm recycling circuit
The arm 1 spool extension side is equipped with a recycling mechanism so that the returning oil from the arm
cylinder rod side flows to the bottom side again.
(2) Arm anti-drift valve
There is an anti-drift valve on the arm cylinder rod side to minimize leakage from the cylinder and reduce for the
cylinder to extend with load.

- 136 -
1-3 Bucket circuit (837S-0023-0E)

1-3-1 Hydraulic circuit diagram (857S-0030-0E)

- 137 -
1-3-2 Description of the bucket circuit (777S-0023-1E)
The bucket cylinder is operated by No. 2 spool of the control valve (block B). When the bucket spool is in the neutral
position, the bucket cylinder is at rest. When the bucket lever is moved left or right, the bucket cylinder extends or
retracts. Each port of the bucket spool houses the overload relief valve.
When the bucket spool is switched, the pressurised oil from pump P2 flows to the bucket cylinder. The bucket spool is
fitted with an orifice in the return circuit to regulate the fall of the bucket to an appropriate speed.
(1) Bucket merging circuit
When the bucket spool is switched to the extension side, the pilot pressure is simultaneously applied to the cut
spool of the control valve (block A).
The pressurised oil from pump P1 passes through the central bypass channel of the control valve (block A) and join
the flow from pump P2 at the bucket spool of the control valve (block B) to flow to the bucket cylinder bottom side.

- 138 -
2. Removal and mounting of the front attachment (857S-0041-0E)

(777S-0083-0E)

When you hit a pin with a hammer, metal splinters can fly off which could cause severe eye
injuries.
Before you start work, always put on protective goggles, helmet, gloves etc.
Store each detached attachment so that it cannot fall over and place barriers so that no
unauthorised personnel can approach it.
Carry out the process in a workplace with secure footing.
When carrying out team operations such as pin insertion and cylinder extension/retraction, take
care to work safely with good exchange of signals and communication between all those
concerned.

(1) Preparations for disassembly

When you remove the hydraulic cylinder, do the followings before detaching the connected hoses. Rest the
attachment on the ground, turn the engine off and work each pilot valve within the next 1 2 minutes to relieve
pressure from each hose. Relieve all excess air pressure in the oil reservoir completely and remove the air breather
cap.

- 139 -
2-1 Bucket (767S-0150-0E)

2-1-1 Removal (8570-0075-2E)

(1) Rest the bucket to be replaced on firm, level ground. (Fig. )
When you are extracting the pins, make sure that the bucket is only resting lightly on the ground. If it is pressed
strongly against the ground, the resistance on the pins will be increased making them harder to extract.
(2) Roll the pin seal O-rings onto the bosses of the bucket. (Fig. )
(3) Remove the retaining nuts and bolts and extract bucket pins and . (Fig. )
(4) Raise the boom slightly and separate the bucket from the arm. (Fig. )
(5) Remove the pin seal O-rings.

2-1-2 Inspection and repair (857S-0043-1E)

After disassembly, inspect the following points and make repairs as necessary.
(1) Check for cracks, damage, deformation, corrosion etc. in each part of the bucket and repair cracks and damage by
welding where necessary. Remove corrosion with a wire brush and repaint the affected areas.
(2) Check for worn or missing bucket teeth. Use calipers to measure wear to the inner diameters of pin holes and
bushes, bending, damage and wear to pins etc. and replace any which exceeds wear limits. (Refer to "Service
standards".)

- 140 -
 (8270-0143-4E)

Take care not to get grit or mud on the extracted pins.

Thoroughly wipe the grease, grit and mud off the extracted O-rings. If any O-ring is damaged,
deformed or hardened, replace it.
The arm tip and tipping link have dust seals fitted on both ends, so take care not to damage
them.

2-1-3 Mounting (9370-0012-3E)

(1) Ready the bucket for mounting
(2) Clean and grease all pins and holes.
(3) Start the engine and leave it at idling speed.
(4) Fit the pin seal O-rings onto the inside of the bosses of bucket holes , and insert the steel bushes into the holes.
Line the arm tip holes up with the bucket holes which have the steel bushes inside and insert bucket pin .
(Fig. )
The fit is good enough to ensure that the pin can be inserted as long as the centers of the holes are aligned, so do
not hit the pin or otherwise apply excessive force.
Line the pin up with the rotation stopper hole and check the pin's orientation before you insert it.

(5) Fit the pin seal O-rings onto the inside of the bosses of bucket holes , and raise the boom or the arm to lift the
bucket. Then adjust the cylinders so that bucket pin can be easily inserted into the bucket holes . (Fig. )
(6) After inserting each pin, line them up with their rotation stopper holes and fasten the bolts in place. (Fig. )
(7) Set the pin seal O-rings in the "V" grooves. (Fig. )
(8) Adjust the play on the bucket.
(9) Grease each pin and stop the engine. Bucket attachment is complete.

- 141 -
 (8270-0145-1E)

When aligning the pin holes, do not put your hand or fingers into the holes. If the bucket moves,
your hand or finger could be severed.

(777S-0084-1E)

When attaching the bucket, check to ensure

that the steel bushes are fitted in place.
The arm tip and tipping link have dust seals
fitted on both ends, so take care not to
damage them when inserting the pin.
When attaching the locknuts, leave a gap of
2mm.

2-1-4 Adjustment method of bucket play (8170-0048-2E)

This machine is equipped with a mechanism for adjusting play on the
bucket. (This mechanism uses the successive insertion of shims to
eliminate the play in the connection between the arm and the bucket
which builds up due to wear.)
This has the multiple effect of maintaining the sealing condition of the
O-rings and delaying the advance of wear, increasing the longevity of
bushes, pins etc.

(1) Adjustment method

Unscrew the bolt and remove the plate. Insert shim(s) to equal the amount of play (the amount of wear) in the
connection and fix the plate back into place using the bolt.
Inserting shim(s) pushes on the steel bushes and reduces the amount of play in the connection.
Play of 0.5 1.0mm is suitable.

- 142 -
2-1-5 Removal and attachment of the link (777S-0039-2E)
(1) Removal
1) Angle the bucket cylinder to be perpendicular to the ground. (Fig. )
Note When you are working with the arm raised, place a block of wood between the bucket cylinder and the arm or
arrange the sling wire rope to the bucket cylinder to support it with a crane.
2) Arrange the sling wire rope to the link to support it with a crane then remove bolts [43] and extract the bucket cylinder
pin (rod end). (Fig. )
3) Remove bolt [36] and extract the side link pin. (Fig. )
After you finish work, fully retract the bucket cylinder.

(2) Inspection and repair

After disassembly, inspect the following points and make repairs as necessary.
1) Check for cracks, damage, deformation, corrosion etc. in each part of the link and repair cracks and damage by
welding where necessary. Remove corrosion with a wire brush and repaint the affected areas.
2) Use calipers to measure wear to the inner diameters of pin holes and bushes, bending, damage and wear to pins
etc. and replace any which exceeds wear limits. (Refer to "Service standards".)
3) Inspect all pipes and hoses for damage, cracks, dents, bending, crumbling, deformation and wear of the screw
threads. Replace any worn or defective parts.
4) Replace all O-rings and seals with new ones.

- 143 -
(3) Attachment
1) Use the side link pin to fasten the side links to the arm. After inserting the pin, attach bolt [36] to prevent the pin
from rotating. (Fig. )
2) Arrange the sling wire rope to the link to support it with a crane and align the centers of the attachment holes. Use
the bucket cylinder pin (rod end) to attach the link and side links to the rod hole of the bucket cylinder. (Fig. )
After inserting the pin, attach bolts [43] to prevent the pin from rotating.

(777S-0085-1E)

When aligning the pin holes, do not put your hand or fingers into the holes. If the cylinder moves,
your hand or finger could be severed.

(777S-0086-1E)

Insert an appropriate thickness of shims (those marked in the diagram) to reduce the lateral
clearance in each boss to 1.0mm or less. Place the shims carefully, locating them so as to
avoid applying excessive force to the cylinder.
The arm tip and tipping link have dust seals
fitted on both ends, so take care not to
damage them when inserting the pin.
When you attach the locknuts, leave a gap of
2mm.

- 144 -
2-1-6 Removal and mounting of the bucket cylinder and hoses (777S-0087-2E)
(1) Removal
1) Disconnect the hoses connected to the cylinder. (Fig. )
(767S-0309-0E)

The bucket cylinder line hose is designated as a safety part for periodic replacement and as such
it must be replaced every 2 years or every 4000 hours of use, whichever occurs sooner.

Note 1. Attach the flanges to the openings exposed by hose disconnection to prevent hydraulic oil leakage.
2. If the grease supply hose is connected to the bottom end of the cylinder, remove it in advance.
2) Arrange the sling wire rope around the center of gravity of the cylinder to support it with a crane then remove bolt
[38] and extract the pin. (Fig. )

(2) Inspection and repair

After disassembly, inspect the following points and make repairs as necessary.
1) Check for cracks, damage, deformation, corrosion etc. in each part of the bucket cylinder and repair cracks and
damage by welding where necessary. Remove corrosion with a wire brush and repaint the affected areas.
2) Inspect all pipes and hoses for damage, cracks, dents, bending, crumbling, deformation and wear of the screw
threads. Replace any worn or defective parts.
3) Replace all O-rings and seals with new ones.

- 145 -
(3) Mounting
1) Arrange the sling wire rope around the center of gravity of the cylinder and support it with a crane. Align the
centers of the attachment holes and insert the pin into the bottom end of the cylinder. After inserting the pin, fix
it with bolt [38].
(777S-0088-1E)

Insert an appropriate thickness of shims (those marked in the diagram) to reduce the lateral
clearance in each boss to 1.0mm or less. Place the shims carefully, locating them so as to
avoid applying excessive force to the cylinder.
The cylinder is fitted with the dust seal. Insert the pin carefully to avoid damaging the seal.

2) Connect the hoses to the cylinder.

Note If the grease supply hose needs connecting to the bottom end of the cylinder, connect the hose.
3) Raise the boom and arm until the cylinder is approximately horizontal and gradually supply pressurised oil.
Move the cylinder between its stroke ends several times to drive air out.

- 146 -
2-1-7 Bucket point inspection and replacement procedure (8470-0047-2E)

(8270-0203-1E)

Metal fragments can fly off and cause injuries, so always wear protective clothing including
protective goggles and a helmet.

(1) Structure

(2) Parts and tools

1) Locking pin extraction

Use the short side of the pin extractor jig. Place it against the top
end of the pin and strike it with a hammer.

- 147 -
2) Locking pin extraction
When the short side has pushed all the way in, turn to the long
side and continue to strike it.

3) Removal of the point

Twist the point to the left as you pull it off.

4) Preparation for attaching the point

Clean the tooth tip.
If the tip is muddy etc., you will not be able to push the point all
the way on and then it will be impossible to knock the pin in.

5) Point attachment
Twist the point to the right while slowly fitting it into place.
Push the point on until it contacts the tooth tip.

6) Locking pin insertion

Push the point firmly onto the tooth then check the pin
orientation before pushing it into place.

- 148 -
 7) Knocking the locking pin into place
Strike the pin with a hammer until it is flush with the top of the
point.

8) Locking pin is completely in place.

The pin can be inserted easily from above or below.

After inserting the pin, knock the point up, down, left and right several times with a hammer. If the pin is not
properly in place, it will drop out, so reinsert it properly.
If the point is worn on one side, you can change it from left to right or its orientation between up and down. This
makes wear even and improves digging efficiency.
If the points do not wear equally, you can improve digging efficiency by selecting points which are equally worn
for use.

(3) Limit of wear

The limit is reached when a small hole appears in the point.

- 149 -
2-1-8 Inspection and replacement of the side cutters (9370-0017-0E)
(1) Inspection procedure
The limit of use is as shown in the diagram.

(2) Replacement procedure

1) Clean away any earth etc. which is stuck around the attachment
bolts.
2) Unscrew the attachment bolts and remove the side cutters. If the
bolts are corroded in place and cannot be removed, melt them
away to cut down.

3) Clean and smooth the attachment surfaces and attach new side
cutters. Use new bolts, nuts and spring washers.
Side cutter attachment bolt tightening torque:
621N·m (63.4kgf·m) 3%

2-1-9 Lifting hook inspection (optional) (7670-0222A1E)

Inspect the hook for wear, cracks and deformation, the hook mounting for
cracks, the rope retainer (latch, spring, pin, spring pin) for damage, and
check the overall function.
If the hook has any problem, repair or replace it.

- 150 -
2-2 Arm (767S-0199-0E)

2-2-1 Removal (877S-0026-0E)

(1) Retract the arm and boom cylinders to bring the arm tip close to the ground. (Fig. )
(2) Disconnect the hoses connected to the bucket cylinder. (Fig. )
Note Attach the flanges to the openings exposed by hose disconnection to prevent hydraulic oil leakage.
(3) Arrange the sling wire rope to the arm cylinder and support it with a crane to remove bolt [38] and extract the arm
cylinder pin (rod end). (Fig. )
Lower the arm cylinder on the back of the boom and fully retract it.
Note If the grease supply hose is connected to the rod end of the cylinder, remove it in advance.

(4) Pass iron bars etc. of adequate strength through the bucket attachment hole and cylinder attachment holes of the
arm and attach the sling wire ropes to the iron bars. Support the arm with a crane then undo the castle nut and
extract the boom and arm connection pin. (Fig. )

- 151 -
2-2-2 Inspection and repair (857S-0036-1E)
After disassembly, inspect the following points and make repairs as necessary.
(1) Check for cracks, damage, deformation, corrosion etc. in each part of the arm and repair cracks and damage by
welding where necessary. Remove corrosion with a wire brush and repaint the affected areas.
(2) Use calipers to measure wear to the inner diameters of pin holes and bushes, bending, damage and wear to pins etc.
and replace any which exceeds wear limits. (Refer to "Service standards".)
(3) Inspect all pipes and hoses for damage, cracks, dents, bending, crumbling, deformation and wear of the screw
threads. Replace any worn or defective parts.
(4) Replace all O-rings and seals with new ones.

2-2-3 Mounting (877S-0027-0E)

(1) Pass iron bars etc. of adequate strength through the bucket attachment hole and cylinder attachment holes of the
arm and attach the sling wire ropes to the iron bars. Support the arm with a crane and align the centers of the
attachment holes then use the boom and arm connection pin to attach the arm to the boom. After inserting the pin,
attach the castle nut. (Fig. )

(777S-0088-1E)

Insert an appropriate thickness of shims (those marked in the diagram) to reduce the lateral
clearance in each boss to 1.0mm or less. Place the shims carefully, locating them so as to
avoid applying excessive force to the cylinder.
The boom and arm connecting section has dust seals fitted on both ends, so take care not to
damage them when inserting the pin.

Note After you have tightened the castle nut by hand without using any tools, unscrew it one groove to you and insert
a split pin to prevent rotation.

- 152 -
(2) Arrange the sling wire rope to the arm cylinder and support it with a crane. Align the centers of the attachment
holes and insert the arm cylinder pin (rod end) to join the rod end of the cylinder to the arm. After inserting the pin,
fix it with bolt [38]. (Fig. )
(3) Connect the hoses to the bucket cylinder. (Fig. )
Note If the grease supply hose needs connecting to the rod end of the cylinder, connect the hose.
(4) Raise the boom and arm until the bucket cylinder is approximately horizontal and gradually supply pressurised oil.
Move the cylinder between its stroke ends several times to drive air out.

(777S-0088-1E)

Insert an appropriate thickness of shims (those marked in the diagram) to reduce the lateral
clearance in each boss to 1.0mm or less. Place the shims carefully, locating them so as to
avoid applying excessive force to the cylinder.
The cylinder is fitted with the dust seal. Insert the pin carefully to avoid damaging the seal.

- 153 -
2-2-4 Removal and mounting of the arm cylinder and hoses (877S-0071-0E)
(1) Removal
1) Disconnect the arm cylinder piping from the control valve (Fig. ) and the hoses connected to the cylinder.
(Fig. )
(767S-0310-0E)

The arm cylinder hose is designated as a safety part for periodic replacement and as such it must
be replaced every 2 years or every 4000 hours of use, whichever occurs sooner.

Note 1. Attach the flanges to the openings from which you have disconnected the piping and hoses to prevent
hydraulic oil leakage.
2. If the grease supply hose is connected to the cylinder, remove it in advance.
2) Arrange the sling wire rope around the center of gravity of the cylinder and support it with a crane then remove
bolt [37] and extract the arm cylinder pin (bottom end).

(2) Inspection and repair

After disassembly, inspect the following points and repair as necessary.
1) Check for cracks, damage, deformation, corrosion etc. in each part of the arm cylinder and repair cracks and
damage by welding where necessary. Remove corrosion with a wire brush and repaint the affected area.
2) Inspect all pipes and hoses for damage, cracks, dents, bending, crumbling, deformation and wear of the screw
threads. Replace any worn or defective parts.
3) Replace all O-rings and seals with new ones.

- 154 -
(3) Mounting
1) Arrange the sling wire rope around the center of gravity of the cylinder and support it with a crane. Align the
centers of the attachment holes and insert the arm cylinder pin (bottom end) into the bottom end of the cylinder.
After inserting the pin, fix it with bolt [37].

(777S-0088-1E)

Insert an appropriate thickness of shims (those marked in the diagram) to reduce the lateral
clearance in each boss to 1.0mm or less. Place the shims carefully, locating them so as to
avoid applying excessive force to the cylinder.
The cylinder is fitted with the dust seal. Insert the pin carefully to avoid damaging the seal.

2) Connect the hoses to the cylinder and the arm cylinder piping to the control valve.
Note If the grease supply hose needs connecting to the cylinder, connect the hose.
3) Raise the boom so that the cylinder is approximately horizontal. Gradually supply pressurised oil to move the
cylinder between its stroke ends several times to drive air out.

- 155 -
2-3 Boom (767S-0151-0E)

2-3-1 Removal (877S-0028-0E)

(1) Place the boom top onto the ground. (Fig. )
(767S-0311-1E)

Be sure to mark the shims (detached when removing the pin) left and right to avoid mistakes in
reassembly.

(2) Arrange the sling wire rope to the boom cylinder and support it with a crane then remove the end plates and extract
the boom cylinder pin (rod end). (Fig. )
Note If the grease supply hose is connected to the rod end of the cylinder, remove it in advance.

(3) Fully retract the boom cylinders and lower them slowly onto the bench so that the rod ends are approximately
horizontal. (Fig. )
(4) Pass iron bars etc. of adequate strength through the boom cylinder attachment hole and the arm attachment holes.
Attach the sling wire ropes to the iron bars and support the boom with a crane. (Fig. )
(5) Disconnect the hoses at the boom foot. (Fig. )
Note 1. Attach the flanges to the openings exposed by hose disconnection to prevent hydraulic oil leakage.
2. Also disconnect the wires for the working lamp.

- 156 -
 (6) Remove plate [60] and extract the boom foot pin. (Fig. )
(767S-0311-1E)

Be sure to mark the shims (detached when removing the pin) left and right to avoid mistakes in
reassembly.

2-3-2 Inspection and repair (857S-0120-1E)

After disassembly, inspect the following points and make repairs as necessary.
(1) Check for cracks, damage, deformation, corrosion etc. in each part of the boom and repair cracks and damage by
welding where necessary. Remove corrosion with a wire brush and repaint the affected areas.
(2) Use calipers to measure wear to the inner diameters of pin holes and bushes, bending, damage and wear to pins etc.
and replace any which exceeds wear limits. (Refer to "Service standards".)
(3) Inspect all pipes and hoses for damage, cracks, dents, bending, crumbling, deformation and wear of the screw
threads. Replace any worn or defective parts.
(4) Replace all O-rings and seals with new ones.

2-3-3 Mounting (877S-0029-0E)

(1) Pass iron bars etc. of adequate strength through the boom cylinder attachment hole and the arm attachment holes.
Attach the sling wire ropes to the iron bars and support the boom with a crane. Align the centers of the attachment
holes and insert the boom foot pin to join the boom foot to the slewing table. After inserting the pin, attach plate
[60]. (Fig. )
(777S-0091-1E)

Be sure to attach the shims (detached when removing the pin) left and right correctly in
reassembly.
Insert an appropriate thickness of shims (those marked in the diagram) to reduce the lateral
clearance in the boom boss to 2.0mm. Place the shims carefully, locating them so as to avoid
applying excessive force to the cylinders etc.
The boom foot section has dust seals fitted on both ends, so take care not to damage them
when inserting the pin.

- 157 -
(2) Reconnect the hoses at the boom foot. (Fig. )
Note Before you attach the boom cylinders to the boom, supply pressurised oil to the cylinders while they are
horizontal or with the bottom ends lowered and extract air through the bottom of the cylinders.

(3) Transfer the sling wire rope to the boom cylinder to support it with a crane and align the centers of the attachment
holes then insert the boom cylinder pin (rod end) to attach the rod ends of the cylinders to the boom.
After inserting the pin, attach the end plates. (Fig. )
(777S-0092-1E)

Be sure to attach the shims (detached when removing the pin) left and right correctly in
reassembly.
Insert an appropriate thickness of shims (those marked in the diagram) to reduce the lateral
clearance in each boss to 1.0mm or less. Place the shims carefully, locating them so as to
avoid applying excessive force to the cylinders.
The cylinder is fitted with the dust seal. Insert the pin carefully to avoid damaging the seal.

Note If the grease supply hose needs connecting to the rod end of the cylinder, connect the hose.

- 158 -
2-3-4 Removal and mounting of the boom cylinders and hoses (777S-0093-2E)
(1) Removal
1) Disconnect all hoses from the cylinders. (Fig. )
(767S-0313-0E)

The boom cylinder hose is designated as a safety part for periodic replacement and as such it must
be replaced every 2 years or every 4000 hours of use, whichever occurs sooner.

Note Attach the flanges to the openings exposed by hose disconnection to prevent hydraulic oil leakage.
2) Arrange the sling wire rope around the center of gravity of the cylinder and support it with a crane then remove
plate [22] and extract the boom cylinder pin (bottom end). (Fig. )

(2) Inspection and repair

After disassembly, inspect the following points and repair as necessary.
1) Check for cracks, damage, deformation, corrosion etc. in each part of the boom cylinders and repair cracks and
damage by welding where necessary. Remove corrosion with a wire brush and repaint the affected area.
2) Inspect all pipes and hoses for damage, cracks, dents, bending, crumbling, deformation and wear of the screw
threads. Replace any worn or defective parts.
3) Replace all O-rings and seals with new ones.

- 159 -
(3) Mounting
1) Arrange the sling wire rope around the center of gravity of the cylinder and support it with a crane. Align the
centers of the attachment holes and insert the boom cylinder pin (bottom end) into the bottom end of the
cylinder. After inserting the pin, attach plate [22].
(777S-0094-1E)

Never fit the clearance adjuster shim on the bottom end of the cylinders.
The cylinder is fitted with the dust seal. Insert the pin carefully to avoid damaging the seal.

2) Connect the hoses to the cylinders.

3) Set the cylinders horizontal. Gradually supply pressurised oil to move the cylinders between the stroke ends
several times to drive air out.

- 160 -
3. Data file (817S-0055-0E)

3-1 Data for front attachment mounting (877S-0072-0E)

Maximum output pressure 32.9MPa (335kgf/cm2)

Maximum output flow 370L/min
Bucket cylinder
Bore diameter 170mm Rod diameter 120mm
Full retraction length 1971mm Stroke 1278mm
Rod pin diameter 110mm Rod boss width 140mm
Rod boss outside diameter 200mm
Side link length 730mm
Tipping link length 700mm
Dimensions for each location

- 161 -
3-2 Service standards (937S-0034-0E)
3-2-1 Front attachment shaft and bush (877S-0030-0E)

(1) Boom, arm, bucket and link Units: mm

Alphabet
Standard
Shaft Hole Clearance
in the
dimensions Standard Standard Recommended Limit Standard Recommended Limit
Action
figure
Part No. tolerance Part No. Type tolerance replacement of use tolerance replacement of use
0.150 0.335
0.085 777-41616001 Boom bush 0.100 126 126.5 0.185 1 1.5 Replace bush
M1 125 777-41602002 0.150 0.335
0.185 777-40203001 Table bush 0.100 126 126.5 0.185 1 1.5 Replace bush
0.150 0.309
0.072 Table hole 0.100 116 116.5 0.172 1 1.5 Build up metal
M2 115 527-41603003 0.250 0.409
0.159 329-16402101 Cylinder bush 0.050 116 116.5 0.122 1 1.5 Replace bush
0.150 0.335
0.085 777-41604001 Boom bush 0.120 126 126.5 0.185 1 1.5 Replace bush
M3 125 777-41603001 0.250 0.435
0.185 329-16402201 Cylinder bush 126 126.5 1 1.5 Replace bush
0.050 0.135
0.150 0.335
0.085 Boom hole 0.100 126 126.5 0.185 1 1.5 Build up metal
M4 125 777-42008002 0.250 0.435
0.185 329-19602101 Cylinder bush 0.050 126 126.5 0.135 1 1.5 Replace bush
0.100 0.285
0.085 527-41609002 Boom bush 0.050 126 126.5 0.135 1 1.5 Replace bush
M5 125 527-41606002 0.150 0.335
0.185 777-42010001 Arm bush 0.100 126 126.5 0.185 1 1.5 Replace bush
0.150 0.335
0.085 Arm hole 0.100 126 126.5 0.185 1 1.5 Build up metal
M6 125 777-42008002 0.250 0.435
0.185 329-19602101 Cylinder bush 0.050 126 126.5 0.135 1 1.5 Replace bush
0.150 0.309
0.072 Arm hole 0.100 111 111.5 0.172 1 1.5 Build up metal
M7 110 527-42008002 0.250 0.409
0.159 329-19202101 Cylinder bush 0.050 111 111.5 0.122 1 1.5 Replace bush
0.150 0.309
0.072 Side link hole 0.100 101 101.5 0.172 1 1.5 Build up metal
M8 100 777-42005002 0.150 0.309
0.159 527-42010003 Arm bush 0.100 101 101.5 0.172 1 1.5 Replace bush
0.150 0.309
Bucket hole 0 106 106.5 0.072 1 1.5 Build up metal
0.072 0.150 0.309
M9 105 777-42012001 527-85006003 Bucket bush 0.100 106 106.5 0.172 1 1.5 Replace bush
0.159 0.150 0.309
777-42007003 Arm bush 0.100 106 106.5 0.172 1 1.5 Replace bush
0.150 0.309
527-42011002 Side link bush 0.100 111 111.5 0.172 1 1.5 Replace bush
0.072 0.150 0.309
M10 110 527-42006001 527-42012002 Link bush 0.100 111 111.5 0.172 1 1.5 Replace bush
0.159 0.250 0.409
329-19202101 Cylinder bush 0.050 111 111.5 0.122 1 1.5 Replace bush
0.150 0.309
0.072 Bucket hole 0.100 106 106.5 0.172 1 1.5 Build up metal
M11 105 777-42012001 0.200 0.359
0.159 527-42009003 Link bush 0.150 106 106.5 0.222 1 1.5 Replace bush
(877S-0031-0E)

Note 1. The limit of use dimension for shafts indicates wear amounting to 5% of shaft diameter. Beyond this limit
replace with a new shaft.
2. The tolerance for the bush is the dimension after it has been pressed into place.

- 162 -
3-2-2 Bucket: 777-88100001 (877S-0032-0E)
(1) Lip: 777-88102000
Units: mm

Alphabet in Standard Recommended replacement Limit of use

the figure dimensions Action Action
Metal buildup
A 50 30 by welding 25 Replace
Metal buildup
B 36 29 by welding 25 Replace
Metal buildup
C 0 35 by welding 45 Replace
Metal buildup
D 0 35 by welding 50 Replace
(877S-0073-0E)

(2) Point: 527-88104000

Note If the point is overused to the extent of wearing, a hole in the point wear will proceed to the tooth and it will
become impossible to fit a new point onto the worn tooth.

(3) Side cutter: 144-85006000 (R), 144-85007000 (L)

- 163 -
3-2-3 Cylinder (877S-0033-0E)
(1) Boom cylinder
(R): 329-16400001
(L): 329-16500001

- 164 -
 Ref. No. Part name Q'ty Ref. No. Part name Q'ty
1 Cylinder tube kit 1 2-2 Pin bush 1
1-1 Cylinder tube 1 2-3 Wiper ring 2
1-2 Pin bush 1 3 Cylinder head 1
1-3 Wiper ring 2 4 Bush 1
1-4 Pipe 1 5 Snap ring 1
1-5 Pipe 1 6 Buffer ring 1
1-6 O-ring 1 7 U-ring 1
1-7 Hexagon socket bolt 4 8 Backup ring 1
1-8 O-ring 1 9 Slide ring 1
1-9 Hexagon socket bolt 4 10 Wiper ring 1
1-10 Band 1 11 O-ring 1
1-11 Band 1 12 Backup ring 1
1-12 Band 2 13 Hexagon socket bolt 8
1-13 Bolt 4 14 Cushion bearing 1
1-14 Washer 4 15 Cushion seal 1
1-15 Pipe holder 2 16 Piston 1
1-16 Bolt 1 17 Seal ring 1
1-17 Spring washer 1 18 Slide ring 2
1-18 Pipe holder 1 19 Slide ring 2
1-19 Bolt 1 20 Shim 1
1-20 Spring washer 1 21 Nut 1
1-21 Grease nipple 1 22 Setscrew 1
2 Piston rod kit 1 23 Steel ball 1
2-1 Piston rod 1
(777S-0121-0E)

Part No. 329-16400001, 329-16500001

Output Dimensions

Cylinder bore 180mm

Boom cylinder

Rod diameter 130mm

Stroke 1683mm
Extension side 748kN/29.4MPa (76300kgf/300kgf/cm2)
Retraction side 358kN/29.4MPa (36500kgf/300kgf/cm2)
Mass 546kg
(877S-0034-0E)

- 165 -
(2) Arm cylinder
329-19600012

- 166 -
 Ref. No. Part name Q'ty Ref. No. Part name Q'ty
1 Cylinder tube kit 1 4 Bush 1
1-1 Cylinder tube 1 5 Snap ring 1
1-2 Pin bush 1 6 Buffer ring 1
1-3 Wiper ring 2 7 U-ring 1
1-4 Pipe 1 8 Backup ring 1
1-5 Pipe 1 9 Slide ring 1
1-6 O-ring 2 10 Wiper ring 1
1-7 Hexagon socket bolt 8 11 O-ring 1
1-8 Band 2 12 Backup ring 1
1-9 Band 2 13 Hexagon socket bolt 8
1-10 Bolt 4 14 Cushion bearing 1
1-11 Washer 4 16 Piston 1
1-12 Pipe holder 2 17 Seal ring 1
1-13 Bolt 2 18 Slide ring 2
1-14 Spring washer 2 19 Slide ring 2
2 Piston rod kit 1 20 Nut 1
2-1 Piston rod 1 21 Shim 1
2-2 Pin bush 1 22 Steel ball 1
2-3 Wiper ring 2 23 Setscrew 1
3 Cylinder head 1
(777S-0203-0E)

Part No. 329-19600012

Output Dimensions

Cylinder bore 190mm

Arm cylinder

Rod diameter 130mm

Stroke 1990mm
Extension side 834kN/29.4MPa (85000kgf/300kgf/cm2)
Retraction side 443kN/29.4MPa (45200kgf/300kgf/cm2)
Mass 666kg
(877S-0035-0E)

- 167 -
(3) Bucket cylinder
329-26100001

- 168 -
 Ref. No. Part name Q'ty Ref. No. Part name Q'ty
1 Cylinder tube kit 1 3 Cylinder head 1
1-1 Cylinder tube 1 4 Bush 1
1-2 Pin bush 1 5 Snap ring 1
1-3 Wiper ring 2 6 Buffer ring 1
1-4 Pipe 1 7 U-ring 1
1-5 Joint 1 8 Backup ring 1
1-6 O-ring 2 9 Slide ring 1
1-7 Hexagon socket bolt 8 10 Wiper ring 1
1-8 Band 2 11 O-ring 1
1-9 Band 2 12 Backup ring 1
1-10 Bolt 4 13 Hexagon socket bolt 8
1-11 Washer 4 14 Cushion bearing 1
1-12 Pipe holder 2 15 Piston 1
1-13 Bolt 2 16 Seal ring 1
1-14 Spring washer 2 17 Slide ring 2
2 Piston rod kit 1 18 Slide ring 2
2-1 Piston rod 1 19 Nut 1
2-2 Pin bush 1 20 Steel ball 1
2-3 Wiper ring 2 21 Setscrew 1
2-4 Grease nipple 1
(777S-0201-0E)

Part No. 329-26100001

Output Dimensions

Cylinder bore 170mm

Bucket cylinder

Rod diameter 120mm

Stroke 1278mm
Extension side 667kN/29.4MPa (68000kgf/300kgf/cm2)
Retraction side 335kN/29.4MPa (34100kgf/300kgf/cm2)
Mass 394kg
(877S-0036-0E)

- 169 -
MEMO

- 170 -
 (877V-0037-0E)

H Superstructure

1. Swing equipment 171

1-1 Swing circuit 171

2. Removal and mounting of swing equipment 173

2-1 Swing motor 173
2-2 Swing motor relief valve 174
2-3 Replacement of the swing motor line hose 175
2-4 Rotary seal 176
2-5 Oiling the swing motor reduction gear 177

3. Removal and mounting of equipment in the superstructure 178

3-1 Superstructure and swing gear 178
3-2 Counterweight 181
3-3 Disassembly and assembly of fuel system 182
3-4 Oil reservoir 186
3-5 Seatbelt 187

4. Data file 188

4-1 Swing motor 188
4-2 Service standards 189
4-3 Consumable parts guide 189
1. Swing equipment (767S-0142-2E)

The swing mechanism, which is mounted between the traveling frame and the slewing table, includes a swing bearing
including an internal gear and a swing motor equipped with a pinion gear.

1-1 Swing circuit (747S-0031-0E)

1-1-1 Hydraulic circuit diagram (857S-0020-0E)

- 171 -
1-1-2 Description of the swing circuit (777S-0024-1E)
The swing motors are driven by No. 4 spool of the control valve (block A).
Pressure in the circuit is regulated by the relief valves built into the swing motors.
When the swing spool is in the neutral position, the swing motors are at rest. When the swing lever is moved left or right,
the swing motors run forward or in reverse to swing the superstructure left or right respectively.
A relief valve for cushioning, a cavitation prevention makeup valve and a reactionless valve to prevent lateral swing when
swing operation stops are all built into the cover above the motor.
(1) Swing priority circuit
When swinging occurs simultaneously with arm excavation operation, the circuit gives priority of oil supply to the
swing motors.
The pressurised oil from pump P2 passes through the central bypass circuit of the control valve (block B) to flow
to the arm 2.
The pressurised oil from pump P1 flows to the swing and arm spools of the control valve (block A), but the swing
pilot pressure is simultaneously applied to the swing priority spool and constricts the oil channel to the arm to
maintain pressure for driving the swing motors.
(2) Swing parking brake
When the lever is in the neutral position, the swing parking brake automatically acts. Operation of non-traveling
levers applies a pilot pressure through the solenoid block to release the brake.

- 172 -
2. Removal and mounting of swing equipment (857S-0123-0E)

2-1 Swing motor (857S-0050-0E)

2-1-1 Removal (877S-0038-0E)

(1) Disconnect all hoses from above the swing motor before you remove the motor.
(2) Disconnect all hoses from the swing motor before you remove the motor.
(3) Remove the bolts then attach the sling wire rope to the swing motor and lift it off the slewing table using a crane.
(Mass of the swing motor assembly: 331kg)

2-1-2 Inspection and repair (857S-0052-0E)

(1) Inspect the meshing of the pinion gear, which should exhibit no severe pitching. Check that the gear is not cracked
or damaged.
(2) Inspect all parts of the pinion for wear with reference to the service standards.

2-1-3 Mounting (877S-0039-0E)

Reverse the removal procedure to remount the swing motor with particular attention to the following points.
(1) Bolt tightening torque: 533N m (54.4kgf m)
(2) Thoroughly wipe away all traces of oil and grease from the threaded parts of the bolts and always apply screw-lock
compound to them before tightening them.

- 173 -
2-2 Swing motor relief valve (777S-0028-0E)

Two relief valves for right swing and left swing are built into the swing
motor. These are for overload relief, and swing relief is done by the main
relief valve of the control valve.

2-2-1 Pressure measurement method (777S-0029-1E)

(1) Turn the starter switch from "ON" to "START" to "ON" to start the engine.
(2) Set the work mode to "Heavy duty", the APC mode to "H", the auto-slow mode to OFF and the econo mode to
OFF.
(3) Display the A PUMP1 or B PUMP2 data on the adjust mode menu screen.
(4) Warm up the engine following the instruction manual until the
hydraulic oil temperature rises to 50 5°C.
Note Hydraulic oil temperature is indicated as H.OIL on the adjust
mode screen.
(5) Turn the accelerator dial fully clockwise to the high idling stopper
position.
(6) With the machine in the maximum reach position, place the side of
the bucket against a wall and gradually move the swing control
lever until it reaches the end. Follow this procedure for both right
and left swing and note the P1 and P2 pressure readings in each case.
1.5 15
PUMP 1, 2 29.4 0 MPa (300 0 kgf/cm2)

2-2-2 Relief valve adjustment method and its adjustment amount (777S-0073-1J)
Unscrew locknut [A] and turn plug [B] to adjust the pressure.
Tighten locknut [A] to the tightening torque indicated below.
Note 1. One turn of the plug = 10MPa (102kgf/cm2)
2. Tightening torque: 117.7 9.8N m (1200 100kgf cm)

- 174 -
2-3 Replacement of the swing motor line hose (767S-0381-1E)

(767S-0303-0E)

The swing motor line hose is designated as a safety part for periodic replacement and as such it must
be replaced every 2 years or every 4000 hours of use, whichever occurs sooner.

- 175 -
2-4 Rotary seal (857S-0124-0E)

(1) Removal
1) Disconnect all piping from the rotary seal.
Note Mark each hose with the name of the corresponding port to prevent mistakes in reassembly.
2) After removing the link, remove bolts [4] and lift the rotary seal from the traveling frame.

- 176 -
2-5 Oiling the swing motor reduction gear (7770-0059-2E)

(8270-0202-0E)

Immediately after operating the machine, the swing motor, reduction gear and other parts are hot,
so do not start to work before all parts have cooled sufficiently.

(8570-0090-1E)

If you replace the swing motor reduction gear oil and the drained oil contains the metal dust etc.,
the reduction gear may need to be overhauled. Contact your authorised KATO dealer.

(1) Oiling method

1) Remove the level gauge, pour gear oil in through the oil filler
hole and use the level gauge to check that oil is at the regulation
level.

Refer to the recommended lubricants table for the brand of gear oil.
You may use any brand of gear oil, but you should use one brand consistently and avoid mixing different brands.
(2) Inspection and replacement intervals
Inspection interval Every 250 hours of operation
Replacement interval Every 1000 hours of operation or yearly
After delivery of a new machine, the gear oil should be
replaced after 250 hours of operation.
Oil volume (per swing motor reduction gear) 11.3L

- 177 -
3. Removal and mounting of equipment in the superstructure
(817S-0069-0E)

3-1 Superstructure and swing gear (767S-0155-0E)

3-1-1 Removal (777S-0045-2E)

(1) Remove the front attachment.
(2) Remove the counterweight.
(3) Disconnect the hoses and link from the casing of the rotary seal. (Fig. )
(4) Remove the swing motors. (Fig. )
(5) Arrange the sling wire ropes to the superstructure and support it with a crane.
Remove bolts [2] and [3] which attach the superstructure to the outer race of the swing gear bearing and lift the
superstructure off the lower structure. (Fig. )
(6) Remove bolts [4] which attach the inner race of the swing gear bearing to the lower structure and remove the swing
gear from the lower structure. (Fig. )
Note Mass of the superstructure: approx. 9000kg (excluding the hydraulic oil and fuel)

- 178 -
3-1-2 Inspection and repair (767S-0297-1E)
Replace the internal gear if it shows signs of damage or deterioration. Measure the displacement over a given number of
the internal gear teeth and replace it if the limit of use is exceeded. (Refer to "Service standards".)

3-1-3 Mounting (777S-0046-2E)

(1) After cleaning the swing gear bearing, degrease and wash the screw threads of all the bolts and dry it with
compressed air.
(2) Arrange the wire rope slings to the swing gear, lift it with a crane and lower it into position for remounting on the
lower structure.

(847S-0054-0E)

When remounting the swing gear onto the

lower structure, position it so that the soft
zone (marked "S") on the inner race of the
swing gear bearing is positioned as shown in
the diagram relative to the lower structure.
If the surface, the swing gear is to be bolted
onto, is rough or scarred, you must grind it
smooth before mounting the swing gear.

(3) First provisionally bolt the swing gear bearing to the lower
structure with four bolts [4] at diagonally opposite positions. Then
fasten all the bolts provisionally on diagonally-opposite pairs
before finally tightening them evenly to the correct torque.
Note 1. Bolts must be degreased, washed, dried and coated with
screw-lock compound.
2. Tightening torque for bolts [4]: 1073N m (109.5kgf m)
(4) Arrange the sling wire ropes to the superstructure and use a crane
to lift and support it in the correct position for mounting on the lower
structure.
(767S-0321-1E)

When remounting the superstructure onto the

swing gear, position it so that the soft zone
(marked "S") on the outer race of the swing gear
bearing is positioned as shown in the diagram
relative to the superstructure.

Note At this stage if you insert two metal bars into bolt attachment holes on the swing gear bearing, it will be easier to
position the superstructure correctly.

- 179 -
(5) First provisionally bolt the swing gear bearing to the superstructure with four bolts [2] and [3] at diagonally
opposite positions. Then fasten all the bolts provisionally on diagonally-opposite pairs before finally tightening
them evenly to the correct torque.
Note 1. Bolts must be degreased, washed, dried and coated with
screw-lock compound.
2. Tightening torque for bolts [2] and [3]: 1227N m (125kgf m)

(6) Mount the swing motors.

(7) Connect the hoses and link to the rotary seal.
(8) Mount the counterweight.
(9) Mount the front attachment.

- 180 -
3-2 Counterweight (777S-0047-0E)

3-2-1 Removal (777S-0199-2E)

(1) Attach the sling wire ropes to the counterweight and support it with a crane then remove the counterweight
mounting bolts and lift the counterweight off the slewing table.
Mass of the counterweight: 8800kg

3-2-2 Inspection and repair (767S-0253-2E)

(1) Check that the counterweight mounting bolts are not bent, damaged or abnormally worn and replace any defective
bolts.

3-2-3 Mounting (777S-0048-2E)

Reverse the removal procedure to mount the counterweight with particular attention to the following points.
(1) Thoroughly wipe away all traces of oil and grease from the threaded parts of the counterweight mounting bolts and
always apply screw-lock compound (Loctite #262) to them before tightening them.
Tightening torque for the counterweight mounting bolts: 2908N m (285kgf m)
(2) Tighten the counterweight mounting bolts at the rear end first.

- 181 -
3-3 Disassembly and assembly of fuel system (837S-0045-0E)

3-3-1 Fuel tank (777S-0096-2E)

(1) Removal
1) Open the drain cock on the underside of the fuel tank and drain all fuel out.
2) Disconnect all hoses from the fuel tank, then remove bolts [15].
3) Arrange the sling wire rope to the fuel tank with the hoisting bolt (M16) screwed in and lift it off the slewing
table with a crane.
4) Remove the fuel sending unit, screen etc.

(2) Inspection and repair

1) Clean the inside of the tank and dry it with compressed air.
2) Check for rust and corrosion in each part of the tank. Brush any away with a wire brush and repaint the affected
area.
3) Check that there are no cracks in the welded parts of the tank and no damage or breakage in any part. Make
welded repairs where necessary.
Note If you make a welded repair, treat the inside of the tank against corrosion.
4) Replace any defective parts with new ones.

(3) Mounting
Reverse the removal procedure to remount the fuel tank.

- 182 -
3-3-2 Draining water from the fuel tank (7670-0201-1E)
(1) Water drainage procedure
Loosen the drain cock in the bottom of the fuel tank to drain water
out.
Close the drain cock after draining the water.

(2) Water drainage interval

Water drainage interval Every 500 hours of operation or 6 months

(8270-0182-0E)

Diesel fuel is used in this machine as fuel. It is highly flammable and therefore very dangerous,
so handle with care.

3-3-3 Fuel hose (767S-0383-0E)

(767S-0324-0E)

The fuel hose is designated as a safety part for periodic replacement and as such it must be replaced
every 2 years or every 4000 hours of use, whichever occurs sooner.

- 183 -
3-3-4 Fuel hose (optional filter) (877S-0040-0E)
(1) Mounting
1) Attach filter [6] to bracket [2] and mount them onto the slewing table.
2) Remove the hose that is between the feed pump and engine filter.
3) Use hoses [3] and [11] to connect the feed pump to filter [6] and filter [6] to the engine filter.
Be careful of which way the hoses face, etc., and tighten the connection sections. The tightening torque is 34N m
(3.5kgf m).
4) Make sure that hoses [3] and [11] do not touch other parts, except at connections.

(877S-0041-0E)

Hoses [3] and [11] are designated as safety parts for periodic replacement and as such they must
be replaced every 2 years or every 4000 hours of use, whichever occurs sooner.

- 184 -
3-3-5 Water separator inspection (827E-0014-2E)
(1) Inspection procedure
Check whether the ring is above the red line. If water has accumulated inside the separator, drain it through the
drain plug.

(2) Water drainage procedure

1) Unscrew the drain plug to drain out accumulated water.
2) Once all water has been drained out, tighten the plug again.
3) Check that there is no fuel leakage.

(8270-0175-1E)

When the ring has reached the red line, you must drain water out immediately.
Handle the fuel with care.
If the fuel is leaking, a fire could result.

(3) Intervals for inspection and water drainage

Inspection interval Daily before starting the engine
Water drainage interval When the ring has reached the red line
(4) Consumable part number
Refer to the "Consumable parts guide".

- 185 -
3-4 Oil reservoir (857S-0059-2E)

3-4-1 Removal (877S-0042-0E)

(1) Extract the pressurised air inside the oil reservoir and remove the air breather cap. Then remove the drain plug from
the underside of the oil reservoir to drain the hydraulic oil.
Units: L

Oil reservoir capacity Hydraulic oil Total hydraulic oil

replacement volume volume
329 585 610
(777S-0050-1E)

(2) Disconnect all the rubber hose [1] and pipes from the oil reservoir then remove bolts [11].
(3) Attach the sling wire rope to the oil reservoir with the hoisting bolt (M16) screwed in and lift it off the slewing table
with a crane.
(4) Remove the return filters, air breather, suction strainer, cover etc.

(767S-0323-1E)

Rubber hose [1] is designated as a safety part for periodic replacement and as such it must be
replaced every 2 years or every 4000 hours of use, whichever occurs sooner.

- 186 -
3-4-2 Inspection and repair (857S-0126-1E)
(1) Clean the inside of the reservoir and dry it with compressed air.
(2) Check for rust and corrosion in each part of the reservoir. Brush any away with a wire brush and repaint the
affected area.
(3) Check that there are no cracks in the welded parts of the reservoir and no damage or breakage in any part. Make
welded repairs where necessary.
Note If you make a welded repair, treat the inside of the reservoir against corrosion.
(4) Replace any defective parts and all O-rings with new ones.

3-4-3 Mounting (877S-0043-0E)

Reverse the removal procedure to remount the reservoir with particular attention to the following points.
(1) Tightening torque for bolts [11]: 217N m (22.1kgf m)
(2) Tightening torque for clamps: 6.4N m (65kgf cm)
(3) Thoroughly wipe away all traces of oil and grease from the threaded parts of bolts [11] and always apply
screw-lock compound to them before tightening them.

3-5 Seatbelt (767S-0159-0E)

(767S-0326-0E)

The seatbelt is designated as a safety part for periodic replacement and as such it must be replaced
every 3 years.

- 187 -
4. Data file (817S-0055-0E)

4-1 Swing motor (937S-0097-0E)

Part No. 619-00339002

Type M5X180CHB-10A-10C/315-149-RG16S21D16
Rated pressure 29.4MPa (300kgf/cm2)
Capacity 148.5cm3/rev
Maximum torque 14685N m (1497kgf m)
Brake torque 846N m (86.3kgf m)
Brake release pressure 2.4MPa (24.5kgf/cm2)
Reduction gear ratio 21.12
Reactionless valve Attached
Mass 331kg
(877S-0044-0E)

- 188 -
4-2 Service standards (767S-0160-0E)

(1) Gear

Units: mm
Alphabet Dimensions Displacement over a given number of teeth
in the Part No. Tooth form Action
figure Module The number Tooth
of teeth
The given Standard Recommended
width number of teeth dimensions replacement Limit of use

G1 527-20201000 Spur gear 14 15 90 2 67.809 66.6 65.1 Replace

G2 777-20208000 Spur gear 14 101 89 14 592.685 589 588 Replace

(777S-0053-2E)

4-3 Consumable parts guide (937S-0052-0E)

[Consumable part name] Water separator

Water separator assembly: 119-50300002

- 189 -
MEMO

- 190 -
 (877V-0045-0E)

I Lower structure

1. Lower structure-related equipment 191

1-1 Travel circuit 191

2. Travel equipment 193

2-1 Track shoe 193
2-2 Carrier roller 196
2-3 Track roller 200
2-4 Front idler 202
2-5 Disassembly and assembly of the adjuster cylinder 204
2-6 Driving tumbler 206

3. Data file 208

3-1 Traveling motor 208
3-2 Service standards 209
1. Lower structure-related equipment (857S-0128-0E)

1-1 Travel circuit (747S-0032-0E)

1-1-1 Hydraulic circuit diagram (857S-0030-0E)

- 191 -
1-1-2 Description of the travel circuit (777S-0025-2E)
The right traveling motor is driven by No. 5 spool of the control valve (block A) while the left traveling motor is driven
by No. 4 spool of the control valve (block B).
When the travel spools are in the neutral positions, the traveling motors are at rest while moving the traveling levers
(pedals) forward or backward causes the traveling motors to turn forward or in reverse for forward or reverse travel. At
this time, the travel pilot signal channel is blocked to generate a pressure.
(1) Direct forward/reverse travel function
When only the travel spools are operating, the pressurised oil from pumps P1 and P2 passes to the left and right
traveling motors respectively for direct forward or reverse travel.
When spools other than the travel spools are used, for example the swing and travel spools, simultaneously, the
pilot signal circuit for travel and superstructure in the control valve is blocked to generate a pilot pressure which
switches the direct forward/reverse travel spool.
The pressurised oil from pump P2 is supplied with priority for swinging while the pressurised oil from pump P1
flows to the left and right traveling motors to allow multiple operations with direct forward or reverse travel. (The
same applies for other operations than swinging.)
(2) High speed, medium speed and low speed
You can choose between three traveling speeds by pressing the traveling mode selection switch on the combination
monitor.
By switching the solenoid valve to apply pilot pressure, the inclination of the variable swash plates in the traveling
motors is altered to vary the traveling speed between medium and high. For low speed, the flow volume of
pressurised oil to the traveling motors is altered to change the traveling speed. When the switch is set for high
speed, the pressures of pumps P1 and P2 are reported to the APC100 controller by pressure sensors. If travel operation
pressure exceeds the rated value, the solenoid valve switches to block pilot pressure and traveling speed switches
to medium speed to generate high torque. When it drops below rated pressure, the solenoid valve switches to apply
pilot pressure which causes the speed to revert to high speed.

- 192 -
2. Travel equipment (767S-0162-1E)

The swing gear is mounted in the upper part of the traveling frame and the rotary seal is located at the center of rotation
of the superstructure. Two hydraulic traveling motors with reduction gears drive the right and left track shoes. Torque is
transmitted from the motors to the track shoes through reduction gears and driving tumblers.

2-1 Track shoe (767S-0163-0E)

2-1-1 Removal (777S-0099-2E)

(1) The grease drain plug of the adjustment window is located on the outside front of the lower structure. Loosen it by
turning it to the left (do not unscrew it by more than one turn) to loosen the track shoe. (Fig. )
(2) Move the master pin to the side of the front idler then extract it to open the track link. (Fig. )
(3) Turn the superstructure to face the side on which the track shoe is to be removed and use the front attachment to lift
that side of the machine. (Fig. )
(4) Run the traveling motor until one end of the track shoe is above the driving tumbler then attach the sling wire rope
to the track shoe and lift it with a crane to pull it off the underside of the machine. (Fig. )
(5) If necessary, remove bolts [2] to remove the shoe from the link. (Fig. )

- 193 -
2-1-2 Inspection and repair (777S-0100-1E)
(1) Inspect for cracks and breakages on the track shoe and link.
(2) Measure wear on each part of the track shoe. (Refer to "Service standards".)
(3) Measure the inner diameters of the link pin holes. (Refer to "Service standards".)
(4) Inspect the master pin and master bush for abnormal wear, bending, damage etc.
(5) Measure the outer diameters of the track pins and master pin. Any which are worn beyond the limit of use should
be replaced with oversize pins. (Refer to "Service standards".)

2-1-3 Mounting (777S-0101-2E)

Reverse the removal procedure to return the track shoe to its position.
After you have mounted the track shoe in position, you must follow the procedure below to adjust its tension.

2-1-4 Tension inspection and adjustment (777S-0055-0E)

Track shoes are adjusted by using the adjuster cylinders to move the front idlers backward or forward.
(1) Measuring the amount of slack
When you are adjusting track shoe tension, jack up each side separately and slightly drive the jacked up side shoe
to measure the amount of slack. Adjust so that the amount of dimension A between the underside of the traveling
frame and the top of the track shoes is 340mm (or dimension B between the track link top and the underside of the
track rollers is 80mm).
If you are working on ground which is likely to clog around the track links and pins, make the volume of slack
slightly greater so that there is no tension on the track links.
Turn the track links backward and measure with the upper track shoes under tension.

- 194 -
(2) Adjustment procedure
1) To increase track shoe tension
Use a high-pressure grease pump to inject grease into the
adjuster cylinder through the grease nipple in the adjustment
window on the outside front of the lower structure.
2) To reduce track shoe tension
Unscrew the grease drain plug of the adjustment window by
turning it to the left. Grease will escape under its own pressure,
increasing slack on the track shoe. After adjustment, screw the
drain plug in. (Tightening torque: 196N·m (20kgf·m))

(8270-0195-2E)

If you loosen the plug too much, it could fly under the high pressure of the grease inside. Do
not unscrew the plug by more than one turn.
Do not face towards the plug as you fit it.
If the track shoe did not loosen, order a repair from your authorised KATO dealer.

(3) To check whether the track shoe tension is correct, travel the machine forward and backward and then re-inspect
the track link tension.
(7770-0057-1E)

When dimension A falls below the limit of use, the length of adjuster cylinder rod remaining inside
the cylinder becomes too short, risking damage to the seal of the adjuster cylinder.

Unit: mm

Dimension A on new machine Dimension A at limit of use

108 0

- 195 -
2-2 Carrier roller (767S-0165-0E)

2-2-1 Removal and disassembly (777S-0056-2E)

(1) Remove bolts [2] to remove the carrier roller from the traveling frame. (Fig. )
(2) If it is necessary to disassemble the carrier roller, follow the procedure below. (Fig. )
1) Remove plug [1-9].
2) Remove bolts [1-16].
3) Remove cover [1-7].

- 196 -
 4) Turn the cover side of the roller downward to remove oil.
5) Remove bolts [1-15] to remove plate [1-3].
6) Turn the cover side of the roller upward and clamp the roller in a
vise. Place a narrow bar against the center of shaft [1-2] and tap
it gently to push it down. Take care not to damage the shaft tip in
doing so. (Fig. )
7) Remove floating seal [1-11] from the roller and the bracket.

8) Turn the cover side of the roller downward. Insert a bar with a
diameter 5mm shorter than the shaft and tap it against bush [1-4]
on the cover side to push it down. (Fig. )

9) Turn the bracket side of the roller downward. Push bush [1-5] on
the bracket side down in the same way as the item 8) above.
(Fig. )

10) Remove shaft [1-2] from bracket [1-10] by pressing it down with
a hydraulic press.

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2-2-2 Inspection and repair (777S-0057-1E)
(1) Measure wear on each part of the carrier roller. (Refer to "Service standards".)
(2) Measure the inner diameters of the bushes. (Refer to "Service standards".)
(3) Check that there is no abnormal wear, seizure marks or other damage on the shaft.
(4) Check that there is no abnormal wear, damage, crack or other defect on the floating seal. Also check the O-rings.
(5) Replace any parts which are defective or worn beyond the limit of use.

2-2-3 Assembly and mounting (777S-0058-2E)

Reverse the removal procedure to mount the carrier roller. If you have disassembled the carrier roller, follow the
procedure below to reassemble it before mounting.
(1) Clean the parts (roller body, shaft, bracket, bush, cover).
(2) Press shaft [1-2] into bracket [1-10].
Apply a thin coating of oil to the parts of the bracket and shaft that push together. Use a hydraulic press or hydraulic
jack to press them together.

(777S-0102-1E)

Press the shaft into the bracket so that the oiling hole is horizontal to the bracket.

(3) Fully press flanged bush [1-4] on the cover side into the roller
body.
(4) Press bush [1-5] on the bracket side to the rated position in the
roller body.
(5) Insert floating seal [1-11] into the bracket.
(6) Insert floating seal [1-11] on the bracket side into the roller body.
Fit the roller to shaft [1-2].

(857S-0065-0E)

Refer to "2-2-4 Assembly method of the floating seal" for the reassembly procedure for the floating
seal.

- 198 -
 (7) Fit plate [1-3] from the cover side of roller [1-1] and tighten it with bolts [1-15]. [Tightening torque: 73N m
(7.5kgf m)]
(8) Fit O-ring [1-14] to cover [1-7]. Fit the cover onto the body.
(9) Tighten cover [1-7] with bolts [1-16]. [Tightening torque: 73N m (7.5kgf m)]
(10) Pour engine oil in. (0.2L)
(11) Insert plug [1-9].

(777S-0103-2E)

Thoroughly wipe away all traces of oil and grease from the threaded parts of bolts [1-15] and [1-
16] and always apply screw-lock compound to them before tightening them.

2-2-4 Assembly method of the floating seal (777S-0104-2E)

(1) Points to inspect before assembly
1) Separate the O-rings from the floating seal and check that there are no cracks or scratches in any part.
2) If there are any significant irregularities inside the housing, these should be smoothed out with a file or
sandpaper.
3) Make sure that there is no cloth, loose fibers, grit, metal filings, paint flakes or other foreign materials inside the
housing. Ideally you should blow out the inside with compressed air to expel such materials. If no compressed air
is available, wipe the inside with a cloth soaked in lubricating or cleaning oil and then with a dry cloth.
(2) Assembly method
1) Fit the O-rings into their positions on the floating seal. Take care not to twist the O-rings as you fit them.
2) Fit the floating seal with O-rings attached into place. At this
stage, it is very important that the end face of the seal cover (A),
the O-ring (B) and the sliding face of the floating seal (C) should
all be fitted to lie parallel to each other as shown in Fig. 1.
If (A) and (C) are parallel but (B) alone is not, an eccentric load
on the periphery will cause abnormal wear or deformation and
break the O-ring, considerably shortening the lifetime of the
seal. Always take care in fitting the floating seal and O-ring into
the seal cover and check after assembly that all parts are properly
arranged.
Fig. 1 The O-ring (B) and the floating seal (C) are fitted into the seal cover (A) in parallel.
Fig. 2 The O-ring (B) is fitted into the seal cover (A) in parallel, but the floating seal (C) is aslant fitted
into it.
Fig. 3 The floating seal (C) is fitted into the seal cover (A) in parallel, but the O-ring (B) is aslant fitted
into it.
3) The position of the floating seal inside the O-rings may make it difficult to fit them into the opening of the seal
cover, but do not lubricate the seal cover, O-ring contact faces on the floating seal, and O-rings. Torque is
transmitted through them, and if they are lubricated, the O-rings will slip. When they are fitted into each seal
cover, wipe the sliding faces clean and check that there are no foreign bodies on them, then apply a little
lubricating oil (lubricating oil sealed into the seal).

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2-3 Track roller (767S-0166-0E)

2-3-1 Removal and disassembly (777S-0105-2E)

(1) Retract the adjuster cylinder to allow more slack in the track shoe then use the boom to raise the body on the side
from which the track roller is to be removed.
Note If this operation is difficult, remove the track shoe altogether.
(2) Remove bolts [2] and remove the track roller from the traveling frame. (Fig. )
(3) If it is necessary to disassemble the track roller, follow the procedure below. (Fig. )
1) Remove wire clip [1-9] from the outside of the shaft and pin [1-7] from the inside to remove collars [1-2] and
[1-3] from the both sides of shaft [1-4].
Note Remove plug [1-10] and drain oil out before doing this work.
2) Remove floating seals [1-6] from the collars and roller.
3) Remove O-rings [1-8] from the shaft.
4) Remove roller [1-1] with bushes [1-5] from the shaft.

- 200 -
2-3-2 Inspection and repair (777S-0106-1E)
(1) Measure wear on each part of the track roller. (Refer to "Service standards".)
(2) Measure the inner diameters of the bushes. (Refer to "Service standards".)
(3) Check that there is no abnormal wear, seizure marks or other damage on the roller shaft.
(4) Check that there is no abnormal wear, damage, crack or other defect on the floating seals. Also check the O-rings.
(5) Replace any parts which are defective or worn beyond the limit of use.

2-3-3 Assembly and mounting (877S-0074-0E)

Reverse the removal and disassembly procedures to reassemble and mount the track roller.
Note 1. Refer to "2-2-4 Assembly method of the floating seal" for the reassembly procedure for the floating seals.
2. After assembly, use an oiling nozzle to pour engine oil into the track roller. (0.41L)
3. Tightening torque for bolts [2]: 790N m (86.7kgf m)

- 201 -
2-4 Front idler (767S-0167-0E)

2-4-1 Removal and disassembly (777S-0107-2E)

(1) Separate the track shoe at the front idler position then pull the front idler off the traveling frame. (Fig. )
Note Refer to "2-1-1 Removal" for removal of the track shoe.
(2) If it is necessary to disassemble the front idler, follow the procedure below. (Fig. )
1) Remove bolts [3] and remove spring assembly [2] from yoke [1-3].
2) Remove bolts [1-12] and detach the yoke from bearings [1-4] and [1-5].
3) Remove pin [1-2] and snap ring [1-10] then take bearings [1-4] and [1-5] from both ends of the shaft.
Note Remove plug [1-11] and drain oil out before doing this work.
4) Remove floating seals [1-8] from bearings [1-4] and [1-5], and idler [1-6].
5) Remove O-rings [1-9] from shaft [1-1].
6) Remove idler [1-6] with bushes [1-7] from the shaft.
(3) If necessary, disassemble spring assembly [2]. (Fig. )

- 202 -
2-4-2 Inspection and repair (777S-0108-1E)
(1) Inspect each part of the front idler for damage, cracks, breakages etc.
(2) Measure wear on each part of the front idler. If the allowable value is exceeded, build up metal by welding. (Refer
to "Service standards".)
(3) Measure the inner diameters of the bearings.
(4) Check that there is no abnormal wear, seizure marks or other damage on the shaft.
(5) Check that there is no weakening, damage, crack or other defect in the spring.
(6) Replace any parts which are defective or worn beyond the limit of use.

2-4-3 Assembly and mounting (777S-0061-2E)

Reverse the removal and disassembly procedures to reassemble and mount the idler with particular attention to the
following points.
(1) Do not disassemble the spring assembly unless it is necessary.
If you have done so unavoidably, you will need a hydraulic jack to
reassemble it.
Note When you reset the spring, the attachment length (A) and set
load are as follows.

(2) Refer to "2-2-4 Assembly method of the floating seal" for the reassembly procedure for the floating seals.
(3) Assemble the front idler so that the shaft oiling holes are faced to the front of the machine.
(4) After assembly, pour engine oil into the front idler. (0.5L)
(5) Refer to "2-1-4 Tension inspection and adjustment" to adjust track shoe tension after mounting is complete.

- 203 -
2-5 Disassembly and assembly of the adjuster cylinder (767S-0168-0E)

2-5-1 Structure and function (777S-0109-0E)

Inject grease to this single-action cylinder to adjust track shoe tension by exerting pressure on the front idler.

2-5-2 Disassembly (777S-0062-2E)

(1) Tools required
1) Ring pliers [for shaft, 95]
2) Socket wrench #19
3) Shockless hammer 51 108
4) Grease pump
5) Punch jig for wiper ring
(2) Use the socket wrench to remove plug [6] from cylinder [1].
Note Remember that grease will come out through the plug hole. Remove grease nipple [11] and setscrew [9] from the
plug and take out spring [8] and steel ball [7].
(3) Screw in the hoisting bolt (M8) on the top end of piston rod [2]. Then extract the piston rod from cylinder [1].
(4) Use a screwdriver or spatula to remove wiper ring [5].
Note Take care not to damage the inner and outer peripheral lips of the wiper ring when you remove it.
(5) Stand piston rod [2] with the mounting side of packing [3] up and fix it in place.
(6) Remove snap ring [10] and detach packing [3] and backup ring [4] from piston rod [2].

2-5-3 Assembly (777S-0110-2E)

(1) Moisten each part with grease or hydraulic oil before reassembly.
(2) Stand piston rod [2] upright and hold it in place. Insert backup ring [4] and push packing [3] onto the rod.
(3) Apply grease to the top of packing [3] and fix the above components in place with snap ring [10].

- 204 -
 (4) Apply grease to the upper face of piston rod [2].
(5) Stand cylinder [1] upright and squeeze grease into the tube.
Note Insert grease until the piston rod reaches the bottom of the cylinder.
(6) Insert piston rod [2] into cylinder [1].
(7) Place wiper ring [5] onto piston rod [2] and mount the punch jig for wiper ring onto piston rod [2].
(8) Use a shockless hammer to tap the jig evenly until wiper ring [5] is fitted to cylinder [1].
(9) Assemble plug [6] and attach it to cylinder [1].

2-5-4Extracting air (777S-0111-0E)

When you are overhauling the travel system such as the track shoes etc.
or in any other case when it is necessary to remove the adjuster cylinder
and extract air from it, follow the procedure below.
(1) Unscrew the grease drain plug and fully retract the cylinder rod.
(2) Inject grease so that the rod extends by 15 20mm.
(3) Face the drain plug upward and again fully retract the cylinder rod.
This completes the air extraction procedure. Finish by screwing the
plug in.
Tightening torque: 196N m (20kgf m)

2-5-5 Inspection after assembly (777S-0063-0E)

(1) Unladen operation test
Place the cylinder in a horizontal position unladen and apply pressure to the extension port to move the piston rod
five times to check that it moves correctly. (Extract air at the same time.) There is nothing to limit the extension of
this cylinder, so do not allow it to extend through a stroke of more than 158mm. A longer stroke could cause the rod
to fly out.
(2) Pressure resistance test
1) Apply a pressure of 29.4MPa (300kgf/cm2) to the extension port for three minutes and confirm that there is no
leakage around the rod etc. and there is no permanent deformation. Keep stroke within 158mm and never run a
pressure resistance test beyond 158mm of stroke.
2) Eliminate all air from the cylinder before you conduct the tests. There is the risk of heat damage to the gasket in
the presence of air.

2-5-6 Other precautions (877S-0046-0E)

(1) Clean the gasket etc. with petroleum-based hydraulic oil. Other types of oil will severely shorten the lifespan of the
gasket etc.
(2) After prolonged disuse, work the cylinder slowly three or four times unladen before applying load. This is because
the film of oil over sliding surfaces can break over long periods and sudden loaded operation in this condition can
cause damage to the gasket.
(3) You only need to remove wiper ring [5] for replacement, so the old ring can be broken or deformed during removal
if necessary.

- 205 -
2-6 Driving tumbler (767S-0169-0E)

2-6-1 Removal (777S-0112-2E)

(1) Separate the track shoe and remove it from the driving tumbler.
(Refer to "2-1-1 Removal" for removal of the track shoe.)
(2) Attach the sling wire rope to the sprocket and support it with a crane. Then remove bolts [2] to lift the sprocket off
the motor assembly. (Fig. ) (Mass of the sprocket: 87kg)
(3) Remove the cover. (Fig. )
(4) Disconnect all piping and brake valve from the motor. (Fig. )
(5) Attach the sling wire rope to the motor assembly and support it with a crane. Then remove bolts [3] to lift the motor
assembly off the traveling frame. (Fig. ) (Mass of the motor assembly: 613kg)

2-6-2 Inspection and repair (767S-0274-0E)

(1) Examine the sprocket for defects, cracks, damage etc.
(2) Investigate the degree of wear to the sprocket. (Refer to "Service standards".)
(3) Examine the brake valve, motor and reduction gear for damage.
- 206 -
2-6-3 Mounting (877S-0075-0E)
Reverse the removal procedure to mount the driving tumbler with particular attention to the following points.
(1) When you remove parts, pay attention to the orientation of ports and the way they are assembled so you can
reassemble them quickly and accurately.
(2) Replace all O-rings once you remove them regardless of their apparent condition.
(3) When mounting the motor assembly onto the traveling frame, you must not strike the area marked A in Fig. .
(4) Thoroughly wipe away all traces of oil and grease from the threaded parts of bolts [2] and [3] and always apply
screw-lock compound to them before tightening them.
Note Tightening torque for bolts [2] and [3]: 838N m (85.5kgf m)

2-6-4 Oiling and inspecting the traveling motor reduction gear (8770-0015-1E)

(8270-0197-1E)

Immediately after the traveling motor has stopped, the motor, shoes and other parts are hot, so
do not start to work before all parts have cooled sufficiently.
Residual pressure inside the traveling motor reduction gear may cause the plug or oil to fly
out. Loosen the plug slowly to relieve pressure before proceeding.
(8570-0089-1E)

If you replace the traveling motor reduction gear oil and the drained oil contains the metal dust etc.,
the reduction gear may need to be overhauled. Contact your authorised KATO dealer.

(1) Oiling method

1) Place the traveling motor reduction gear as shown in the
diagram.
2) Remove the oil filler hole and level plugs.
3) Pour gear oil in through the oil filler hole until it pours out from
the level hole.
4) Wrap sealing tape around the plugs to prevent oil leakage and
then screw them back in.
Tightening torque: 98N·m (10kgf·m)
Refer to the recommended lubricants table for the brand of gear oil.
Allow at least ten minutes after traveling before you measure the oil volume.
You may use any brand of gear oil, but you should use one brand consistently and avoid mixing different brands.
The standard temperature of the reduction gear casing is normal hydraulic oil temperature + 20°C in continuous
operation.
(2) Inspection and replacement intervals
Inspection interval Every 250 hours of operation
Replacement interval Every 1000 hours of operation or yearly
After delivery of a new machine, the gear oil should be replaced after 500 hours of
operation.
Oil volume (per traveling motor reduction gear) 21L

- 207 -
3. Data file (817S-0055-0E)

3-1 Traveling motor (937S-0098-0E)

Part No. 619-00341011

Type DNB80A4072G
Rated pressure 30.9MPa (315kgf/cm2)
Capacity 256/146cm3/rev
Maximum torque 77.4kN m (7891kgf m)
Reduction gear ratio 72.33
Mass 613kg
(877S-0047-0E)

- 208 -
3-2 Service standards (767S-0170-0E)

3-2-1 Track shoe (767S-0380-0E)

Units: mm
Part No. 527-51000003
Alphabet in
the figure Inspection items Evaluation standards Action
Recommended
Standard dimensions replacement Limit of use
A Link pitch Replace
215.9 219 224

B Link height 126 121 117 Build up metal or replace

C Height of triple grouser 36 21 10 Lug weld or replace

Tolerance Standard
Standard
dimensions
clearance and Limit of use Action
Shaft Hole interference

Interference of track bush +0.40 +0.17

D 71 0.3 0.18 0.1 Replace
and link +0.35 +0.10

Interference of track pin +0.60 +0.35

E 47 0.37 0.22 0.1 Replace
and link +0.57 +0.30

Interference of master bush +0.40 +0.17

F 71 0.3 0.18 0.1 Replace
and link +0.35 +0.10

Interference of master pin +0.67 +0.35

G 47 0.37 0.22 Replace
and link +0.57 +0.30

Clearance between track +0.67 +1.67

H 47 0.3 1.1 4.8 Replace
pin and track bush +0.57 +0.97

Clearance between collar 0.2 +0.1 Repair or

I 72 0.1 0.5
and link 0.4 0.1 replace

Clearance between master +0.3 +1.67 Repair or

J 47 0.67 1.47 4.8
pin and master bush +0.2 +0.97 replace
Standard
dimensions Limit of service Reverse or
K Track bush 67
71 68 replace
(777S-0065-2E)

- 209 -
3-2-2 Carrier roller (767S-0277-0E)

Units: mm
Part No. 107-50600120
Alphabet in Standard
the figure Inspection items dimensions Limit of use Action
Diameter of
A 170 160 Build up or replace
flange
Diameter of
B 140 130 Build up or replace
outer surface
Width of outer
C 52 56 Build up or replace
surface

D Width of flange 100 92 Build up or replace

(877S-0076-0E)

- 210 -
3-2-3 Track roller (767S-0278-0E)

Units: mm
Part No. 527-50800102
Alphabet
Inspection items Standard dimensions Limit of use Action
in the figure

Build up or
A Diameter of flange 220 210 replace
Diameter of outer Build up or
B surface 180 165 replace
Width of outer Build up or
C surface 58 63 replace
Build up or
D Width of flange 16.5 10 replace
Clearance of track Standard clearance Limit of use
E roller in shaft Replace
direction 0.4 1.3 1.5
Standard Tolerance Standard Limit of
clearance and
dimensions Shaft Hole interference use
Clearance between 0 +0.40 0.30
F track roller shaft 70 0.445 1.0 Replace
and bush 0.045 +0.30
Interference of track +0.13 +0.03 0.07
G 78 +0.10 0 0.13 0 Replace
roller and bush
(877S-0077-0E)

- 211 -
3-2-4 Front idler (777S-0113-0E)
(1) Shaft and bush

Units: mm
Part No. 527-50400102
Alphabet
Inspection items Standard dimensions Limit of use Action
in the figure

Diameter of raised Build up or

A section 675 replace
Diameter of outer Build up or
B surface 630 620 replace
Width of raised Build up or
C section 102 92 replace
Build up or
D Overall width 204 replace
Width of outer Build up or
E surface 51 46 replace
Standard Tolerance Standard Limit of
clearance and
dimensions Shaft Hole interference use
Clearance between 0.012 +0.2 0.112
F shaft and bush 105 1.0 Replace bush
0.047 +0.1 0.247
Clearance between +0.012 +0.035 0.012
G shaft and bearing 105 1.0 Replace
+0.047 0 0.082
Overall width of idler
H (After push-insertion 216 213 Replace bush
of bush)
(877S-0078-1E)

- 212 -
 (2) Bearing

Units: mm
Part No. 527-50407001, 527-50408001
Alphabet Standard Recommended
in the figure dimensions replacement Limit of use Action

Build up and finish

A 159 157 155 with a shaper
Build up and finish
B 75 77 79 with a shaper
(877S-0079-0E)

3-2-5 Adjuster cylinder (937S-0125-0E)

Part No. 777-32600001

Dimensions

Cylinder bore 120mm

Rod diameter 120mm
Stroke 158mm
Pressure test load (extension side) 554.6kN/49.0MPa 56500kgf/500kgf/cm2
Mass 54kg
(877S-0048-0E)

- 213 -
3-2-6 Sprocket (777S-0200-0E)

Units: mm
Part No. 527-50201005
Standard dimensions for
Standard dimensions Amount of Limit of use
tooth form
wear (A) on Action
The number Tooth Pitch sprocket tooth Outer Tooth
Pitch A B C D E form diameter width (B)
of teeth width diameter
Build up
215.9 23 92 800.2 10 36.0 215.9 60° 820 6 812 84
or replace
(877S-0080-0E)

A: Amount of wear on sprocket tooth form

Measure in at least four areas around the sprocket with a gauge which can measure across three or more teeth. If the
allowable value is exceeded, build up metal by welding or replace the sprocket.

B: Sprocket tooth width

Measure in at least four areas around the sprocket.

- 214 -
 (877V-0049-0E)

J Electrical equipment

1. Layout of electrical equipment 215

1-1 Inside the cab 215
1-2 Superstructure 216
1-3 Layout of connectors (inside the cab) 225

2. Air conditioner 227

2-1 Air conditioner body 227
2-2 Air conditioner pipes 228
2-3 Air conditioner-related 229

3. Battery handling 233

4. Bulb replacement 235

5. Fuse replacement 235

6. High current fuse replacement 236

7. Inspection and replacement of the wiper blade 236

8. Data file 237

8-1 Consumable parts guide 237
1. Layout of electrical equipment (817S-0089-0E)

1-1 Inside the cab (817S-0090-0E)

Ref. No. Part name Ref. No. Part name Ref. No. Part name
1 Wire harness 20 Wire harness 42 Wire harness
3 Control unit 21 Wire harness 43 Curl cord
4 Relay 22 Wire harness 47 Grommet
5 Wire harness 23 Wire harness 66 Resistor (41 )
6 Fuse box 24 Wire harness 67 Swing brake release switch
7 Starter switch 25 Wire harness 71 Fuse (15A)
8 Diode 26 Door switch 72 Fuse (10A)
9 Diode 28 Relay 73 Fuse (5A)
10 Relay board 29 Module 77 Fuse (4A)
11 Volume switch 31 Interior lamp 78 Fuse (3A)
12 APC backup switch 32 Relay 79 Fuse (2A)
16 Switch 35 Key 80 Fuse (1A)
17 Lighter 40 Wire harness 90 Switch
18 Accelerator dial 41 Wire harness 93 Resistor unit
(877S-0050-1E)
- 215 -
1-2 Superstructure (837S-0056-1E)

Ref. No. Part name Ref. No. Part name Ref. No. Part name
1 Wire harness 26 Battery cord 44 High current fuse
2 Wire harness 31 Battery relay 45 High current fuse
3 Wire harness 32 Battery cord 46 High current fuse
5 Earth cord 35 Diode 47 Oil pressure switch
7 Battery cord 36 Thermo sending unit 48 Thermal switch
8 Wire harness 37 Safety relay 49 Pressure sensor
10 Resistor 39 Dust indicator 50 Pressure switch
19 Unit thermo sensor 40 Working lamp 51 Pressure switch
22 Battery cord 41 Working lamp 52 Pressure switch
24 Tachometer sensor 42 Horn 53 Oil bypass switch
25 Heater relay 43 Horn 54 Revolution sensor
(877S-0051-0E)

- 216 -
(1) Wire harness
Location of use: Engine No. Size Color From To
1 0.85 GB MC3-2 CN13 Engine water temperature gauge
1) Applicable serial No.: #5513
2 0.85 Br MC3-3 Engine water temperature switch
3 0.85 Br MC3-5 CN16 Hydraulic oil temperature
4 0.85 RG MC3-6 CN20 Harness under the cab
5 0.85 YB MC3-7 CN20 Harness under the cab
6 0.85 L MC3-18 CN21 Swing pressure switch
7 0.85 RL MC3-9 CN14 Engine oil pressure
8 0.85 R MC3-10 CN17 Air cleaner
9 0.85 YR MC3-11 Return filter
10 0.85 GW MC3-12 CN18 Reserve tank
11 0.85 Y MC3-13 CN41'
12 0.85 B CN21 Swing pressure switch Earth (dashboard)
13 0.5 RW MC3-15 Heater indicator relay 3
14 0.85 BrW MC3-16 Engine oil bypass
15 0.85 B MC3-19 Earth (dashboard)
16 0.85 Br CN4 Dashboard harness CN43 Starter relay
17 0.85 LW CN4 Dashboard harness Heater relay
18 3.0 R CN4 Dashboard harness CN67 High current fuse
19 0.85 BrW CN4 Dashboard harness Battery relay ( )
20 5.0 W CN60 Dashboard harness CN69 High current fuse
21 3.0 R CN22 Dashboard harness
22 0.85 G CN22 CN23 Air conditioner receiver drier
23 0.85 WL CN10 Safety relay CN43 Starter relay
24 0.85 Y CN11 Alternator L
25 0.85 WG CN11 Alternator R
26 0.85 B CN10 Safety relay Alternator E
27 0.85 WY CN10 Safety relay CN12 Alternator P
28 20.0 R Heater relay ( ) RLY ( )
29 20.0 B Heater relay Air heater
30 8.0 W Alternator B CN70 High current fuse
31 8.0 B Alternator E Earth (dashboard)
32 0.85 B Water thermo switch Earth (dashboard)
33 0.85 B CN18 Reserve tank Earth (dashboard)
34 0.85 G CN23 Air conditioner receiver drier Air conditioner compressor
35 0.85 B CN17 Air cleaner Earth (dashboard)
36 0.85 WG CN10 Safety relay Diode
37 0.85 G MC3-17 CN20 Left lever switch (spare)
38 0.85 Y CN41 CN10 Safety relay
39 0.85 BrW Battery relay ( ) Diode
40 0.85 B Battery relay ( ) Diode
41 0.85 B Battery relay ( )
42 0.85 LW Diode
43 0.85 B Diode
44 0.85 B Heater relay
45 0.85 WG Diode Battery relay ( )
46 0.5 OB CN57 Outside air temperature sensor CN56 Air conditioner harness
47 0.5 BY CN57 Outside air temperature sensor CN56 Air conditioner harness
48 1.25 R Fuel pump
49 2.0 RW CN67 High current fuse RLY ( )
50 2.0 BW CN68 High current fuse RLY ( )
51 5.0 BW CN69 High current fuse RLY ( )
52 8.0 WR CN70 High current fuse RLY ( )
53 2.0 W Lubricator ( ) CN68 High current fuse
54 0.85 Br Diode
55 0.85 WL Diode
(877S-0052-1E)

- 217 -
2) Applicable serial No.: #5514 No. Size Color From To
1 0.85 GB MC3-2 CN13 Engine water temperature gauge

2 0.85 Br MC3-3 Engine water temperature switch

3 0.85 Br MC3-5 CN16 Hydraulic oil temperature
4 0.85 RG MC3-6 CN20 Harness under the cab
5 0.85 YB MC3-7 CN20 Harness under the cab
6 0.85 L MC3-18 CN21 Swing pressure switch
7 0.85 RL MC3-9 CN14 Engine oil pressure
8 0.85 R MC3-10 CN17 Air cleaner
9 0.85 YR MC3-11 Return filter
10 0.85 GW MC3-12 CN18 Reserve tank
11 0.85 Y MC3-13 CN41'
12 0.85 B CN21 Swing pressure switch Earth (dashboard)
13 0.5 RW MC3-15 Heater indicator relay 3
14 0.85 BrW MC3-16 Engine oil bypass
15 0.85 B MC3-19 Earth (dashboard)
16 0.85 Br CN4 Dashboard harness CN43 Starter relay
17 0.85 LW CN4 Dashboard harness Heater relay
18 3.0 R CN4 Dashboard harness CN67 High current fuse
19 0.85 BrW CN4 Dashboard harness Battery relay ( )
20 5.0 W CN60 Dashboard harness CN69 High current fuse
21 3.0 R CN22 Dashboard harness
22 0.85 G CN22 CN23 Air conditioner receiver drier
23 0.85 WL CN10 Safety relay CN43 Starter relay
24 0.85 Y CN11 Alternator L
25 0.85 WG CN11 Alternator R
26 0.85 B CN10 Safety relay Alternator E
27 0.85 WY CN10 Safety relay CN12 Alternator P
28 20.0 R Heater relay ( ) RLY ( )
29 20.0 B Heater relay Air heater
30 8.0 W Alternator B CN70 High current fuse
31 8.0 B Alternator E Earth (dashboard)
32 0.85 B Water thermo switch Earth (dashboard)
33 0.85 B CN18 Reserve tank Earth (dashboard)
34 0.85 G CN23 Air conditioner receiver drier Air conditioner compressor
35 0.85 B CN17 Air cleaner Earth (dashboard)
36 0.85 WG CN10 Safety relay Diode
37 0.85 G MC3-17 CN20 Left lever switch (spare)
38 0.85 Y CN41 CN10 Safety relay
39 0.85 BrW Battery relay ( ) Diode
40 0.85 B Battery relay ( ) Diode
41 0.85 B Battery relay ( )
42 0.85 LW Diode
43 0.85 B Diode
44 0.85 B Heater relay
45 0.85 WG Diode Battery relay ( )
46 0.5 OB CN57 Outside air temperature sensor CN56 Air conditioner harness
47 0.5 BY CN57 Outside air temperature sensor CN56 Air conditioner harness
48 1.25 R Fuel pump
49 3.0 RW CN67 High current fuse RLY ( )
50 3.0 BW CN68 High current fuse RLY ( )
51 5.0 BW CN69 High current fuse RLY ( )
52 8.0 WR CN70 High current fuse RLY ( )
53 3.0 W Lubricator ( ) CN68 High current fuse
54 0.85 Br Diode
55 0.85 WL Diode
(877V-0052-0E)

- 218 -
(2) Wire harness
Location of use: Under the cab
1) Applicable serial No.: #5513

- 219 -
No. Size Color From To No. Size Color From To
1 61 2-core shielded wire Pump proportional valve Earth 3
2 62 2.0 W Lubricator ( ) Engine harness
3 63 2.0 B Lubricator Earth
4 0.85 G MC4-4 CN27 C/V pressure switch 64
5 0.85 B MC4-5 CN27 C/V pressure switch 65
6 0.85 B MC4-6 CN29 SOL pressure switch 66
7 0.85 GY MC4-7 CN29 SOL pressure switch 67
8 68
9 0.5 WY MC4-9 Lever switch R 69
10 0.5 RW MC4-10 Lever switch R 70
11 0.5 G CN20 Lever switch L 71 2-core shielded wire CN35 Accelerator dial Earth 1
12 0.85 WR MC2-1 CN30 SL1 72 0.5 W CC5-6 CN35 Accelerator dial 2
13 0.85 L MC2-2 CN34 SL5 73 0.5 B CC5-7 CN35 Accelerator dial 1
14 0.85 LR MC2-3 CN33 SL4 74 0.85 Y CC5-8 CN40 Dashboard harness
15 0.85 Y MC2-5 CN31 SL2 75 0.5 W CC5-9 CN36 Revolution sensor ( )
16 0.85 LW MC2-6 CN32 SL3 76 0.5 B CC5-10 CN36 Revolution sensor
17 0.5 LR RC2-6 CN24 Windscreen washer 77 2-core shielded wire CN36 Revolution sensor Earth 1
18 0.5 R CN28 78 0.5 R CC6-1 CN37 P1 pressure sensor
19 0.5 RL RC2-5 79 0.5 W CC6-2 CN37 P1 pressure sensor
20 0.85 RL RC2-14 Cab top working lamp R 80 0.5 B CC6-3 CN37 P1 pressure sensor
21 0.85 LW CN28 81 3-core shielded wire CN37 P1 pressure sensor Earth 2
22 0.85 R RC2-4 Boom working lamp 82 3-core shielded wire CN38 P2 pressure sensor Earth 2
23 0.5 R RC2-13 83 0.5 B CC6-6 CN38 P2 pressure sensor
24 84 0.5 W CC6-7 CN38 P2 pressure sensor
25 85 0.5 R CC6-8 CN38 P2 pressure sensor
26 86 0.5 R Resistor CN6-3
27 87 0.5 W Accelerator error relay 9 CN6-2
28 0.85 RW CN1 SOL power source CN31 SL2 88 0.5 B CN6-1
29 0.85 RY CN1 SOL power source CN34 SL5 89 3-core shielded wire CN6 Earth 1
30 0.85 R CN1 SOL power source CN32 SL3 90
31 0.85 RB CN1 SOL power source CN33 SL4 91
32 0.85 RG CN1 SOL power source CN30 SL1 92
33 0.85 B Lever switch R Earth 93 0.5 WR CC6-14 AC2-1
34 0.85 B Lever switch L Earth 94 0.5 RY CC6-15 AC2-2
35 0.85 B Toolbox working lamp Earth 95 0.5 G CC6-13 CN40 Dashboard harness
36 0.85 B CN26' Horn L Earth 96 0.5 R Resistor CN35 Accelerator dial 3
37 0.85 B CN25' Horn R Earth 97 0.5 R CN66-1 Accelerator error relay 14
38 0.85 B Boom working lamp Earth 98 0.5 B CN66-2 Accelerator error relay 1
39 0.85 B CN24 Windscreen washer Earth 99 0.5 BR AC2-3 Accelerator error relay 13
40 100 0.5 L Accelerator error relay 5
41 0.85 B Cab top working lamp L Earth 101 0.5 LW Accelerator error relay 5 Accelerator error relay 8
42 0.85 B Cab top working lamp R Earth 102 0.5 B Accelerator error relay 1 Accelerator error relay 4
43 0.85 RW CN28 Toolbox working lamp 103 0.5 WR Accelerator error relay 9 Accelerator error relay 12
44 0.85 RL Cab top working lamp L 104 0.5 BW Heater indicator relay 5 CN66-3
45 0.85 GW CN26 Horn L CN25 Horn R 105 0.5 R Accelerator error relay 14 Heater indicator relay 4
46 0.85 GW RC2-1 CN26 Horn L 106 0.5 R Heater indicator relay 4 Heater indicator relay 1
47 0.5 B RC2-12 Pump proportional valve ( ) (877S-0053-1E)
48 0.5 W RC2-11 Pump proportional valve ( )
49 0.5 GR RC2-10 Male terminal for optional horn
50 0.5 LB RC2-7 Wiper B
51 0.85 LR RC4-4 CN28
52 0.5 LR RC4-1
53 0.5 LW RC4-3 Wiper S
54 0.5 BW RC4-2 Wiper P
55 0.5 B RC4-5 Earth
56
57 0.5 GR Female terminal for optional horn Horn switch
58 0.85 RG CN20 CN19 Fuel level S
59 0.85 YB CN20 CN19 Fuel level G
60 0.85 B CN19 Fuel level E Earth

- 220 -
2) Applicable serial No.: #5514

- 221 -
No. Size Color From To No. Size Color From To
1 61 2-core shielded wire Pump proportional valve Earth 3
2 62 3.0 W Lubricator ( ) Engine harness
3 63 3.0 B Lubricator Earth
4 0.85 G MC4-4 CN27 C/V pressure switch 64
5 0.85 B MC4-5 CN27 C/V pressure switch 65
6 0.85 B MC4-6 CN29 SOL pressure switch 66
7 0.85 GY MC4-7 CN29 SOL pressure switch 67
8 68
9 0.5 WY MC4-9 Lever switch R 69
10 0.5 RW MC4-10 Lever switch R 70
11 0.5 G CN20 Lever switch L 71 2-core shielded wire CN35 Accelerator dial Earth 1
12 0.85 WR MC2-1 CN30 SL1 72 0.5 W CC5-6 CN35 Accelerator dial 2
13 0.85 L MC2-2 CN34 SL5 73 0.5 B CC5-7 CN35 Accelerator dial 1
14 0.85 LR MC2-3 CN33 SL4 74 0.85 Y CC5-8 CN40 Dashboard harness
15 0.85 Y MC2-5 CN31 SL2 75 0.5 W CC5-9 CN36 Revolution sensor ( )
16 0.85 LW MC2-6 CN32 SL3 76 0.5 B CC5-10 CN36 Revolution sensor
17 0.5 LR RC2-6 CN24 Windscreen washer 77 2-core shielded wire CN36 Revolution sensor Earth 1
18 0.5 R CN28 78 0.5 R CC6-1 CN37 P1 pressure sensor
19 0.5 RL RC2-5 79 0.5 W CC6-2 CN37 P1 pressure sensor
20 0.85 RL RC2-14 Cab top working lamp R 80 0.5 B CC6-3 CN37 P1 pressure sensor
21 0.85 LW CN28 81 3-core shielded wire CN37 P1 pressure sensor Earth 2
22 0.85 R RC2-4 Boom working lamp 82 3-core shielded wire CN38 P2 pressure sensor Earth 2
23 0.5 R RC2-13 83 0.5 B CC6-6 CN38 P2 pressure sensor
24 84 0.5 W CC6-7 CN38 P2 pressure sensor
25 85 0.5 R CC6-8 CN38 P2 pressure sensor
26 86 0.5 R Resistor CN6-3
27 87 0.5 W Accelerator error relay 9 CN6-2
28 0.85 RW CN1 SOL power source CN31 SL2 88 0.5 B CN6-1
29 0.85 RY CN1 SOL power source CN34 SL5 89 3-core shielded wire CN6 Earth 1
30 0.85 R CN1 SOL power source CN32 SL3 90
31 0.85 RB CN1 SOL power source CN33 SL4 91
32 0.85 RG CN1 SOL power source CN30 SL1 92
33 0.5 B Lever switch R Earth 93 0.5 WR CC6-14 AC2-1
34 0.5 B Lever switch L Earth 94 0.5 RY CC6-15 AC2-2
35 0.85 B Toolbox working lamp Earth 95 0.5 G CC6-13 CN40 Dashboard harness
36 0.85 B CN26' Horn L Earth 96 0.5 R Resistor CN35 Accelerator dial 3
37 0.85 B CN25' Horn R Earth 97 0.5 R CN66-1 Accelerator error relay 14
38 0.85 B Boom working lamp Earth 98 0.5 B CN66-2 Accelerator error relay 1
39 0.85 B CN24 Windscreen washer Earth 99 0.5 BR AC2-3 Accelerator error relay 13
40 100 0.5 L Accelerator error relay 5
41 0.85 B Cab top working lamp L Earth 101 0.5 LW Accelerator error relay 5 Accelerator error relay 8
42 0.85 B Cab top working lamp R Earth 102 0.5 B Accelerator error relay 1 Accelerator error relay 4
43 0.85 RW CN28 Toolbox working lamp 103 0.5 WR Accelerator error relay 9 Accelerator error relay 12
44 0.85 RL Cab top working lamp L 104 0.5 BW Heater indicator relay 5 CN66-3
45 0.85 GW CN26 Horn L CN25 Horn R 105 0.5 R Accelerator error relay 14 Heater indicator relay 4
46 0.85 GW RC2-1 CN26 Horn L 106 0.5 R Heater indicator relay 4 Heater indicator relay 1
47 0.5 B RC2-12 Pump proportional valve ( ) (877V-0053-0J)
48 0.5 W RC2-11 Pump proportional valve ( )
49 0.5 GR RC2-10 Male terminal for optional horn
50 0.5 LB RC2-7 Wiper B
51 0.85 LR RC4-4 CN28
52 0.5 LR RC4-1
53 0.5 LW RC4-3 Wiper S
54 0.5 BW RC4-2 Wiper P
55 0.5 B RC4-5 Earth
56
57 0.5 GR Female terminal for optional horn Horn switch
58 0.85 RG CN20 CN19 Fuel level S
59 0.85 YB CN20 CN19 Fuel level G
60 0.85 B CN19 Fuel level E Earth

- 222 -
(3) Wire harness No. Size Color From To
14 0.5 RB AC3-3 EC2-49
Location of use: Engine control 15
1) Applicable serial No.: #5513 16 0.5 LG AC3-5 EC3-86
17 0.5 LB AC3-6 EC3-81
18 0.5 WB AC3-7 EC3-70
19 0.5 B CN6-1 EC3-83
20 0.5 W CN6-2 EC3-73
21 0.5 R CN6-3 EC3-62
22 0.5 WL CN63-1
23 0.85 R CN63-3 EC4-92
24 0.5 WL CN63-4 EC4-98
25 0.5 WL EC4-104
26 0.5 BrW CN64-1
27 0.5 Y CN64-4 EC1-1
28 0.5 W EC1-4 GC4-1
29 0.5 B EC1-17 GC5-3
30 0.5 YL EC1-6 GC3-4
31 0.5 GW EC1-9 GC1-8
32 0.5 B EC1-15 GC4-2
33 0.5 YB EC1-18 GC3-3
34 0.5 GB EC1-22 GC1-10
35 0.5 YR EC1-27 GC3-2
36 0.5 B EC1-28 GC3-5
37 0.5 W EC2-33 GC1-1
38 0.5 B EC2-34 GC2-11
39 0.5 LY EC2-35 GC1-3
40 0.5 WG EC2-36 GC1-5
41 0.5 Y EC2-37 G-ADJUST (SIG)
42 0.5 W GC5-4 EC1-5
43 0.5 B EC2-42 Earth
44 0.5 LR EC2-43 GC1-4
45 0.5 GR EC2-44 GC2-13
46 0.5 BrW EC2-45 GC2-15
47 0.5 B EC-26 G-ADJUST (GND)
48 0.5 W EC2-51 GC1-2
49 0.5 B EC2-52 GC2-12
50 0.5 BW EC2-53 GC1-6
51 0.85 B EC2-54 Shielded
52 0.5 RB EC2-56 MUT- -7
53 0.5 B EC3-58 MUT- -1
54 0.5 BrW EC3-60
55 0.5 BrW EC3-61
56 0.5 BrW GC6-3
57 0.5 BrY EC3-75 GC3-1
58 0.85 B EC3-87 Earth
59 0.5 BrW GC6-1
60 0.85 R EC4-93
No. Size Color From To 61 0.85 B EC4-99 Earth
1 0.85 BrW CN7-1 CN64-2 62 0.85 B EC4-100 Earth
2 0.85 LW CN7-2 CN64-3 63 2-core shielded wire GC4
3 0.85 Br CN7-3 EC3-65 64 2-core shielded wire GC1, GC2
4 0.85 WL CN7-4 CN63-2 65 2-core shielded wire GC1, GC2
5 0.5 R CN7-5 66 0.5 R CN66-1
6 0.5 RG CN7-6 EC3-82 67 0.5 B CN66-2 Earth
7 0.5 RY CN7-8 EC3-71 68 0.5 B CN7-7 Earth
8 0.5 LR CN7-10 EC2-40 69 3-core shielded wire CN6
9 0.5 LY CN7-11 EC4-91 70 0.5 GY GC2-14
10 0.5 WR CN7-12 EC2-57 71 0.5 WL EC1-25 GC6-4
11 0.5 WG CN7-13 EC4-97 72 0.5 LR EC1-26 GC6-2
12 0.5 RL AC3-1 EC2-39 73 0.5 BW EC3-85 CN66-3
13 0.5 RW AC3-2 EC3-67 74 2-core shielded wire GC5
(877S-0054-0E)
- 223 -
 No. Size Color From To
14 0.5 RB AC3-3 EC2-49
15
2) Applicable serial No.: #5514 16 0.5 LG AC3-5 EC3-86
17 0.5 LB AC3-6 EC3-81
18 0.5 WB AC3-7 EC3-70
19 0.5 B CN6-1 EC3-83
20 0.5 W CN6-2 EC3-73
21 0.5 R CN6-3 EC3-62
22 0.5 WL CN63-1
23 0.85 R CN63-3 EC4-92
24 0.5 WL CN63-4 EC4-98
25 0.5 WL EC4-104
26 0.5 BrW CN64-1
27 0.5 Y CN64-4 EC1-1
28 0.5 W EC1-4 GC4-1
29 0.5 B EC1-17 GC5-3
30 0.5 YL EC1-6 GC3-4
31 0.5 GW EC1-9 GC1-8
32 0.5 B EC1-15 GC4-2
33 0.5 YB EC1-18 GC3-3
34 0.5 GB EC1-22 GC1-10
35 0.5 YR EC1-27 GC3-2
36 0.5 B EC1-28 GC3-5
37 0.5 W EC2-33 GC1-1
38 0.5 B EC2-34 GC2-11
39 0.5 LY EC2-35 GC1-3
40 0.5 WG EC2-36 GC1-5
41 0.5 Y EC2-37 G-ADJUST (SIG)
42 0.5 W GC5-4 EC1-5
43 0.5 B EC2-42 Earth
44 0.5 LR EC2-43 GC1-4
45 0.5 GR EC2-44 GC2-13
46 0.5 BrW EC2-45 GC2-15
47 0.5 B EC-26 G-ADJUST (GND)
48 0.5 W EC2-51 GC1-2
49 0.5 B EC2-52 GC2-12
50 0.5 BW EC2-53 GC1-6
51 0.85 B EC2-54 Shielded
52 0.5 RB EC2-56 MUT- -7
53 0.5 B EC3-58 MUT- -1
54 0.5 BrW EC3-60
55 0.5 BrW EC3-61
56 0.5 R GC6-3
57 0.5 BrY EC3-75 GC3-1
58 0.85 B EC3-87 Earth
59 0.5 R GC6-1
60 0.85 R EC4-93
No. Size Color From To 61 0.85 B EC4-99 Earth
1 0.85 BrW CN7-1 CN64-2 62 0.85 B EC4-100 Earth
2 0.85 LW CN7-2 CN64-3 63 2-core shielded wire GC4
3 0.85 Br CN7-3 EC3-65 64 2-core shielded wire GC1, GC2
4 0.85 WL CN7-4 CN63-2 65 2-core shielded wire GC1, GC2
5 0.5 R CN7-5 66 0.5 R CN66-1
6 0.5 RG CN7-6 EC3-82 67 0.5 B CN66-2 Earth
7 0.5 RY CN7-8 EC3-71 68 0.5 B CN7-7 Earth
8 0.5 LR CN7-10 EC2-40 69 3-core shielded wire CN6
9 0.5 LY CN7-11 EC4-91 70 0.5 GY GC2-14
10 0.5 WR CN7-12 EC2-57 71 0.5 WL EC1-25 GC6-4
11 0.5 WG CN7-13 EC4-97 72 0.5 LR EC1-26 GC6-2
12 0.5 RL AC3-1 EC2-39 73 0.5 BW EC3-85 CN66-3
13 0.5 RW AC3-2 EC3-67 74 2-core shielded wire GC5
(877V-0054-0E)
- 224 -
 Connector Circuit name Connector Circuit name

1-3 Layout of connectors (inside the cab) (857S-0077-1J) MC1 Travel signal, swing signal, monitor power source, CN22 High current fuse fuse box

Monitor panel
windscreen wiper, windscreen washer, lamp Air conditioner receiver drier
MC2 High power, boom slow, H/L travel, swing lock CN23 Receiver drier pressure switch
MC3 Water temperature, engine oil, air cleaner, filter, charge CN24 Windscreen washer
MC4 Proportional valve, pressure switch, high power CN25 Horn (H)
MC5 RX1, TX1 CN26 Horn (L)
CC1 APC, accelerator, proportional valve, speed control CN27 (Superstructure signal) control valve, pressure switch (PS1)

CC2 Speaker, voice, speed control CN28 Swing lock switch, radio ILL, working lamp

APC
CC4 RX1, TX1 CN29 Solenoid pressure switch (PS2)
CC5 Accelerator dial, key OFF, revolution sensor CN30 Solenoid valve, high power (P)
CC6 Pump AV, APC backup, swing lock CN31 Solenoid valve, travel H/L (T)
RC1 Speaker, radio, working lamp, APC backup, OHM CN32 Solenoid valve, swing lock (S)
for manual operation CN33 Solenoid valve, arm (A)
RC2 Windscreen washer, working lamp, horn, windscreen CN34 Solenoid valve, boom (B)

Relay board
wiper, accelerator, proportional valve CN35 Accelerator dial
RC3 Working lamp, windscreen washer, windscreen wiper CN36 Revolution sensor
RC4 Wiper motor CN37 Control valve, pressure sensor (P1)
RC5 APC, accelerator, proportional valve, speaker, voice CN38 Control valve, pressure sensor (P2)
RC6 Windscreen washer, key OFF, working lamp, APC, CN40 Engine key OFF, swing lock release
monitor, windscreen wiper, horn CN41 For hour meter stop
GC1 RED-4 electronic governor CN42 Starter switch
GC2 RED-4 electronic governor CN43 Starter relay L, SW

Engine
GC3 Water temperature sensor, boost sensor CN44 Radio
GC4 NE sensor 1 CN45 Speaker R L
GC5 NE sensor 2 CN47 Heater power source (OP)
GC6 Timer control valve CN48 OP1 switch (fan)
EC1 Heater relay, NE sensor, boost sensor CN49 OP2 switch
EC2 RED-4, Q-Adjustment resistance, diagnosis lamp-1 CN50 OP3 switch

ECU
EC3 Starter switch, accelerator dial, memory clear, CN51 Wiper motor
preheater lamp CN52 Swing lock release switch
EC4 ECU power source, diagnosis lamp-2 CN53 Lighter
AC1 APC, accelerator backup switch CN54 OP horn switch (OP4)
AC2 APC, accelerator backup switch CN55 Door switch
AC3 Accelerator, accelerator backup switch CN56 Outside air temperature sensor
CN1 Fuse box solenoid valve power source CN57 Outside air temperature sensor
CN4 Battery relay starter switch CN59 Electric lubricator
CN5 Air conditioner power source CN60 High current fuse fuse box
CN6 Accelerator dial CN61 Memory clear
CN7 Diagnosis, memory clear, speed control CN62 Diagnosis switch
CN9 Travel signal, swing signal CN63 ECU power source relay
CN10 Safety relay CN64 Heater relay
CN11 Alternator L, R safety relay CN66 Accelerator error relay, heater indicator relay
CN12 Alternator P safety relay CN67 High current fuse 30A
CN13 Thermo sending unit Battery relay fuse box
CN14 Engine oil pressure CN68 High current fuse 30A
CN16 Oil reservoir oil temperature Battery relay electric lubricator
CN17 Air cleaner sensor CN69 High current fuse 45A
CN18 Water level sensor (reserve tank) Battery relay fuse box
CN19 Fuel level sensor CN70 High current fuse 65A
CN20 Fuel level, left lever spare Battery relay alternator
CN21 Swing pressure switch (PS3)
(877S-0055-1E)
- 225 -
MEMO

- 226 -
2. Air conditioner (817S-0092-0E)

2-1 Air conditioner body (767S-0201-0E)

Ref. No. Part name Q'ty Ref. No. Part name Q'ty
1 Duct 1 23 Hose clamp 2
2 Control panel 1 24 Tape 1
3 Bracket 1 25 Clamp 1
4 Bracket 1 26 Grille 2
5 Lining 1 27 Washer 5
6 Sensor 1 28 Hose clamp 1
7 Sensor 1 29 Hose 1
8 Clamp 1 30 Hose clamp 2
9 Base 1 31 Air conditioner unit 1
10 Hose 2 32 Bolt 2
11 Spring nut 2 33 Bolt 2
12 Tapping screw 2 34 Bolt 3
13 Duct 1 35 Bolt 2
14 Bend duct 1 36 Machine screw 2
15 Hose 1 37 Screw 4
16 Hose 1 38 Spring washer 4
17 Grille duct 2 39 Spring washer 2
18 Grille 4 40 Spring washer 5
19 Hose 1 41 Washer 2
20 Screw 4 42 Hose band 4
21 Screw 8 43 Binder 1
22 Nut 8 44 Binder 1
(777S-0116-0E)
- 227 -
2-2 Air conditioner pipes (767S-0202-0E)

Ref. No. Part name Q'ty Ref. No. Part name Q'ty Ref. No. Part name Q'ty
1 Hose S 1 20 Hose 1 42 Spring washer 1
2 Hose D 1 21 Hose 1 43 Spring washer 13
3 Hose L 1 22 Hose 5 44 Spring washer 4
4 V-belt 1 23 Joint 1 45 Washer 8
5 Bracket 1 25 Bolt 4 46 Washer 4
8 Sensor 1 26 Adjusting bolt 1 47 Nut 1
9 Tapping screw 1 27 Nut 4 48 Nut 9
10 Hose L 1 28 Water cock 1 49 Binder 18
11 Receiver drier 1 29 Hose clamp 4 50 Clamp 1
12 Clamp 5 30 Bolt 4 52 Joint 1
13 Clamp 4 31 Condenser 1 53 Pulley 1
14 Bolt 2 32 Drier bracket 1 54 Slide shaft 1
15 Bolt 2 33 Compressor 1 55 Nut 1
16 Bolt 2 34 Bolt 8 56 Stopper 1
17 Bolt 2 39 Flange nut 2 57 Locknut 1
18 Washer 2 40 Spring washer 8
19 Cover 1 41 Spring washer 1
(877S-0056-0E)
- 228 -
2-3 Air conditioner-related (8370-0037-4E)

Have the air conditioner inspected and serviced regularly to maintain it at full performance.

(857E-0014-0E)

If the air conditioner malfunctions, switch it OFF and contact your authorised KATO dealer.
Filling with refrigerant (gas) and other service tasks require special tools and instruments and
should only be attempted in a properly equipped KATO dealer.
The refrigerant used for this air conditioner is R134a. Do not loosen the piping or compressor
section before extracting refrigerant (gas) in a properly equipped place.

Note Even in seasons when the air conditioner is not used, run
it in cooling mode for a few minutes two or three times a
month to circulate oil to all parts of the compressor and
maintain their oil coating.
At the same time, check whether refrigerant has leaked out.
If the air conditioner is left for a long period with refrigerant
leaking, corrosion can form on internal parts.

2-3-1 Inspection and servicing table (7670-0229-0E)

Inspection and servicing interval

Inspection and servicing item Preoperational Every 6 Replacement
check Monthly months interval (years)
Filter Blockage, dirt 2

Blockage, dirt
Condenser
Clean

Belt Slack, damage

Refrigerant Filled volume

Connection Looseness, damage,
piping gas leakage
Receiver
drier Replace 2
(8270-0211-3E)

(8270-0212-1E)

When filling with the refrigerant, refer to the separate service manual to confirm the refrigerant
volume and the method of filling.

- 229 -
4-7-2 Removal and attachment of the inspection cover (7670-0230-3E)
In machines fitted with an air conditioner, inspection and cleaning of the filters, inspection of the belts, inspection for
blockage of the condenser are necessary.
The air conditioner unit of this machine is fitted inside the inspection cover at the rear of the seat. Remove the cover to
inspect and clean the internal air filter and outside air filter.
(1) Removal
Turn the turn fasteners (7 locations) 90° to pull them out. Hold the
handle on the cover top to slightly pull toward you and remove the
cover by taking it up.
(2) Attachment
Align the attaching holes of the cover to those of the air
conditioner.
Fix the turn fasteners back into the place and turn them 90°.

2-3-3 Filter inspection, cleaning and replacement (7770-0093-3E)

This air conditioner unit is fitted with the filters to prevent lint, paper scraps etc. from clogging the evaporator heater core
etc. Remove the filters to inspect occasionally and clean them by blowing with compressed air or tapping gently on a
hard surface. Replace the filter if there are any blockages you cannot remove without damaging the filter. Filter
blockages reduce the performance of the air conditioner.
(1) Removal and mounting of the filter
Before detaching the internal and outside air filters, remove the cover located at the rear of the cab.
1) Internal air filter
Removal: Gently lift the hook of the filter and draw it
toward you.
Mounting: Reverse the removal procedure.
2) Outside air filter
Removal: Pull the two (upper and lower) NI-latch plungers and
remove the filter cover. Next, draw the outside air
filter out toward you, keeping the fold part.
Mounting: Reverse the removal procedure.
(2) Consumable part number
Refer to the "Consumable parts guide".

- 230 -
2-3-4 Inspection of refrigerant (gas) volume (7670-0232-1E)
The refrigerant for this air conditioner is HFC-134a.
Never fill the air conditioner with any other refrigerant.
(1) Conditions for evaluating refrigerant volume
Engine speed: Low idling
Air volume switch: Strong
Temperature setting switch: Maximum cooling
Pressure on high-pressure side: 1.37 1.57MPa
(14 16kgf/cm2)
(Block the front of the condenser by the right amount to produce a pressure in this
range.)
Door: Fully open
Windows: Fully open
(2) Evaluation guidelines
Compare the state of bubbling visible through the sight glass with the diagrams below.

2-3-5 Belt inspection (7670-0233-2E)

Check that the compressor belt and fan belt are not slack or worn. If the
compressor belt is loose and slips, cooling performance will be
reduced. If the fan belt is loose, it can cause overheating and battery
depletion.

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2-3-6 Inspection for blockage in the radiator and condenser (937V-0015-1E)
If the radiator and condenser are clogged with mud, insects etc., the
passage of air will be obstructed, causing overheating and reduced
cooling performance. Clean them regularly according to the section "D,
1-2-3 Cooling system, (8) Radiator core cleaning procedure".

2-3-7 Display of malfunctions (7670-0235-1E)

When a malfunction is indicated on the temperature setting display, it can be one of the following three types.

HL.* Multiple sensors have malfunctioned, including the internal air temperature sensor (where *
is a number from 0 9).
All AUTO control functions are deactivated and the output air is heated in proportion to the
number * on the temperature setting switch.
(This is equivalent to manual operation. In other words, all the air outlet temperature, airflow
volume and compressor control functions are selected manually.)

**.E A sensor other than the internal air temperature sensor and solar radiation sensor has
malfunctioned, or the motor actuator has malfunctioned (where ** is a number from 18
32).
The temperature setting can be increased or decreased by 1°C and the control system does
not use the problem sensor or actuator.
(For example, if the evaporation sensor has malfunctioned, the compressor control can no
longer be turned ON.)

HL.E The internal air temperature sensor has malfunctioned in conjunction with the motor actuator
for the hot water flow regulator valve. All AUTO control functions are deactivated. It is no
longer possible to adjust how much the output air is heated or the temperature setting.

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3. Battery handling (827E-0026-3E)

This machine uses two 12V batteries connected in series with a 24V negative earth. Observe the following precautions
when handling the batteries.

(541D-0137-5E)

1) The battery electrolyte used is dilute sulfuric acid, so keep it away from your eyes, skin,
clothing and any metal components. If it comes into contact with any of them, wash it away
with large amounts of water. (In case of personal contact, consult a doctor after washing.)
2) The batteries generate flammable hydrogen, so do not use flame or other source of ignition
near the batteries.
In particular take care when welding.
3) Before inspecting, servicing or charging the batteries or servicing the electrical system, turn
the starter key to the "OFF" position and detach the battery cable from the negative terminal
for safety.
4) When detaching the battery cable, always begin with the negative terminal and when
reattaching the battery cable, begin with the positive terminal. Take care to connect the
terminals correctly.
5) Handle the batteries with care. In particular do not charge them near flame or a source of
ignition and do not dispose of them in fire as an explosion could result.
6) Never take the batteries apart or make holes in the casing.
Any resulting leakage could cause dangerous corrosion and personal injury.
7) When recharging the batteries, dismount them from the machine, remove all bungs and
place them in a well-ventilated area.

(1) Battery electrolyte level inspection

(8270-0206-1E)

When performing the preoperational checks, be sure to check the batteries for the electrolyte level
and refill if they are insufficient. If the electrolyte level is below "LOWER", the battery could
explode when starting the engine.

The battery electrolyte level should be between the "UPPER" and

"LOWER" level lines.
If it is below the "LOWER" level, top it up with battery electrolyte
or distilled water to the "UPPER" level.
Do not top up beyond the UPPER level.

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(2) Battery terminal inspection
Check for loose terminals and clean away dirt and corrosion.
1) If the terminals are covered with whitish powdery corrosion,
wash it with away with boiling water.
If corrosion is severe, use a wire brush or sandpaper to scrape it
away.
2) After cleaning the terminals, coat them in a thin layer of grease.
3) Specific gravity inspection Full charge 1.28 (at 20°C)
Half charge 1.22
You must recharge the battery if the specific gravity is at or below 1.22.
(3) Inspection and cleaning intervals for the batteries
Battery electrolyte level inspection At the time of preoperational checks
Specific gravity inspection Every 250 hours of operation
Terminal cleaning Every 250 hours of operation

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4. Bulb replacement (7670-0225-1E)

Always switch the starter switch and lamp switches "OFF" before you start to replace the bulb.
Only use bulbs of the correct rated voltage and wattage.
(8270-0208-1E)

Always replace the bulb with that of the specified capacity. If you use the bulb in excess of the rated
capacity, the excess power consumption will cause accidents by blowing the fuse, burning to
damage the relay or igniting electrical insulation.

(1) Consumable part number

Refer to the "Consumable parts guide".

5. Fuse replacement (7670-0226-1E)

The fuse box is located inside a panel in the cab.

If a fuse blows, investigate its cause, turn off the power (turn off the starter
switch), repair the damaged place and then replace the fuse with a new
one with same capacity. When removing the fuse, use the "fuse
extractor" of the cover.

(8270-0086-1E)

Never use fuses of other than the rated capacity, or wire etc.
In the event of a power surge the wiring and electrical devices will not be protected from burning
out.

(1) Consumable part number

Refer to the "Consumable parts guide".

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6. High current fuse replacement (9470-0015-0E)

(8770-0033-1E)

Disconnect the negative side of the battery cable from the terminal before removing the high
current fuse.
If the battery cable is not disconnected from the negative terminal, battery voltage may be
constantly applied on the high current fuses dangerously.
When the fuse has blown, investigate the cause carefully and repair the problem completely
before attaching the fuse.
Be sure to use the fuse with the designated ampere.

High current fuses are placed to blow and protect the circuit if a large current flows in the circuit between the batteries
and the fuse box due to a short circuit or other problem.
If there is no abnormality in the fuses and a problem occurs in the electrical system, the high current fuse has blown.
Contact your authorised KATO dealer and replace the high current fuse after the problem has been repaired.

(1) Consumable part number

Refer to the "Consumable parts guide".

7. Inspection and replacement of the wiper blade (7670-0228-1E)

Inspect the wiper blade and replace if it is worn or damaged.

(1) Consumable part number
Refer to the "Consumable parts guide".

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8. Data file (817S-0055-0E)

8-1 Consumable parts guide (877S-0057-0E)

[Consumable part name] Bulb

No. Type of lamp Assembly No. Bulb/lamp No. Bulb capacity Q'ty Notes
1 Interior lamp 709-24700001 709-24701001 24V 6W 1
2 Working lamp 709-22000003 709-22007002 24V 70W 2 H3
3 Working lamp 709-31600001 709-23906000 24V 70W 1 H3

[Consumable part name] Fuse

Fuse 1A : 719-11033001
2A : 719-11032001
3A : 719-11031001
4A : 719-11030001
5A : 719-11040001
10A : 719-11034001
15A : 719-11035001

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 [Consumable part name] High current fuse

High current fuse 30A: 719-11045001

45A: 719-11046001
65A: 719-11047001

[Consumable part name] Wiper blade

Wiper blade: 709-47101001

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 [Consumable part name] Internal air filter and outside air filter

Internal air filter: 709-82613001

Outside air filter: 709-82614003

[Consumable part name] Receiver drier

Receiver drier: 817-76205000

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 [Consumable part name] Refrigerant

Refrigerant = R134a 200g: 709-82598001

R134a 250g: 709-82599001

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HEAD OFFICE : 9-37, Higashi-ohi 1-chome,
(OVERSEAS MARKETING DEPT.) Shinagawa-ku, Tokyo, 140-0011 Japan
Telephone : Tokyo (03) 3458-1111
Telex Number : 222-4519 (CRKATO J)
Cable Address : CRANEKATO TOKYO