FA WA800,900-3E0 70001,80001 up GEN00056-01

CONTENTS 1

Dividing Dividing Process Process Overview Overview (Major components components alone) alone) ........... ................. ............ ............ ............ ............ ........... ........... ............ ............ ............ ............ ........... ........... ......... ... 1

2

Major Major Component Components s Table of Dimensions Dimensions ............ ................. ........... ............ ............ ............ ............ ........... ........... ............ ............ ............ ........... ........... ........... ........... ........... ........... ........ .. 2

3

Work Space Space Layout Layout ........... ................. ............ ........... ........... ............ ............ ............ ............ ........... ........... ............ ............ ............ ........... ........... ............ ........... ........... ........... ........... ............ ............ ........... ....... 4

4

Schedule Schedule Table for Field Assembly Assembly ........... ................. ............ ............ ............ ............ ............ ........... ........... ............ ............ ............ ............ ............ ........... ........... ........... ........... ............ .......... .... 5

5

Facility, Facility, Jigs and Tools ............ ................. ........... ............ ............ ........... ........... ............ ............ ............ ........... ........... ............ ............ ............ ........... .......... ........... ........... ........... ............ ............ ........... ....... .. 6

6

List of Oil, Grease and Paints............ Paints.................. ............ ............ ........... ........... ............ ............ ............ ........... ........... ............ ............ ............ ............ ......... ......... ............ ............ ........... ........... ......... ... 9 No.

Item

Page

0010 Oil, grease and coolant

10

0020 Oil, grease and coolant level

11

0030 Setting rear frame in place

12

0040 Setting front frame in place

13

0050 Joining front and rear frames

14

0060 Fr Front and rear frames joining procedure

15

0070 Assembling the steering pin

16

0080 Assembling the center drive shat (Center support – Transmission)

17

0090 Connecting the pipes - Part 1

18

0100 Connecting the pipe - Part 2

19

0105 Connection of piping (Part 2) (Riotinto specification: If equipped)

20

0110 Connecting the auto-greasing pipe

21

0120 Setting the axle in place and assembling the support

22

0130 Setting the bare machine in place

23

0140 Assembling the rear axle

24

0150 Rear axle rear side cover assembling procedure

25

0160 Connecting the rear axle pipe

26

0165 Fixing of rear axle piping (Brake cooling specification: If equipped)

27

0166 Connection of rear axle piping (Riotinto specification: If equipped)

28

0167 Fixing of rear axle piping (Brake cooling specification: If equipped)

29

0168 Connection of cooling line piping (Brake cooling specification: If equipped)

30

0170 Assembling the rear drive shat (Transmission – Rear axle)

31

0180 Assembling the front axle

32

0182 Fixing of front axle piping (Brake cooling specification: If equipped)

33

0185 Connection of front axle piping (Brake cooling specification: If equipped)

34

0190 Connecting the front axle pipe

35

0195 Connection of front axle piping (Riotinto specification: If equipped)

36

0200 Connecting the front drive shat (Front axle – Center support)

37

0210 Connecting the axle oil temperature sensor (For VHMS specification only)

38

0220 Assembling the tires

39

0230 Assembling the fuel tank

40

0235 Installation of fuel tank (Riotinto specification: If equipped)

41

0240 Fixing the drain pipe

42

0245 Fixing of torque converter cooler drain piping (Riotinto specification: If equipped)

43

0250 Connecting the fuel pipe

44

0260 Fixing the engine drain hoses

45

0270 Assembling the hydraulic tank ladder

46

0280 As Assembling the floor and cab assembly

47

0290 Connecting the air conditioner hose

48

0300 Connecting the brake line

49

0310 Connecting the window washer hose

50

0320 Connecting the PPC line hose

51

0330 Connecting the floor wiring harness

52

0333 Connection of floor wiring harness -1 (Riotinto specification: If equipped)

53

0334 Connection of floor wiring harness -2 (Riotinto specification: If equipped)

54

0340 Connecting the link for AJSS (For AJSS specification only)

55

0345 Calibration of the AJSS angle and frame offset angle

56

0350 Assembling the auto-greasing pump and connecting the pipe (WA900-3E0 North American specification)

57

0360 Assembling the floor cover

58

0370 Refilling the window washer

59

0380 Assembling the battery box

60

No.

Item

Page

0390 Co Connecting and fixing the battery wiring

61

0393 Wiring on right side of battery (Riotinto specification: If equipped)

62

0394 Wiring on left side of battery -1 (Riotinto specification: If equipped)

63


64


65

0397 Connection of ground cable on left side of battery (Riotinto specification: If equipped)

66

0400 Assembling the battery step

67

0403 Installation of oil cooler assembly (Brake cooling specification: If equipped)

68

0404 Instal la lati on on an and co connect io ion of of oi oil co cooler as as se sembl y pi pi pi ng ng (B (Brak e co ol oli ng ng sp speci fific at ation: If If eq equi pp pped)

69

0406 Installation of oil cooler assembly piping -1 (Brake cooling specification: If equipped)

70

0407 Installation of oil cooler assembly piping -2 (Brake cooling specification: If equipped)

71

0410 Assembling the handrail (On the right hand platform)

72

0411 Installation of handrail (Right platform area) (Brake cooling specification: If equipped)

73

0420 Assembling the handrail (On the hood top face)

74

0430 Assembling the handrail (On the right hand battery box)

75

0440 Assembling the rear access step

76

0450 Assembling the left handrail (Part 1)

77

0460 Assembling the left handrail (Part 2)

78

0461 Installation of left handrail (Part 2) (Brake cooling specification: If equipped)

79

0470 Assembling the rearview mirror

80

0471 Installation of rearview mirrors (Brake cooling specification: If equipped)

81

0480 Assembling the exhaust pipe

82

0485 Installation of oil cooler guard assembly (Brake cooling specification: If equipped)

83

0486 Installation of fan motor piping cover -1 (Brake cooling specification: If equipped)

84

0487 Installation of fan motor piping cover -2 (Brake cooling specification: If equipped)

85

0490 Applying the counterweight anti-slip

86

0500 Assembling the counterweight (WA900-3E0 standard specification)

87

0505 Assembling the counterweight (WA900-3E0 High-lift arm specification)

88

0510 Assembling the counterweight (WA800-3E0 Overseas general, optional specification and North American specification)

89

0520 Assembling the counterweight (WA800-3E0 Overseas general standard specification)

90

0530 Assembling the front axle lamp and connecting the harness

91

0540 Assembling the front lamp assembly

92

0550 Assembling the ROPS canopy assembly

93

0560 Assembling the antenna and work lamp

94

0570 Assembling the VHMS antenna (For VHMS specification only)

95

0580 Assembling the floor mat

96

0590 Assembling the front fender

97

0600 Engine starting procedure

98

0610 Bleeding the brake air

99

0615 Bleeding air from hydraulic circuit

100

0620 As A ssembling the lift arm assembly (Part 1)

101

0630 As A ssembling the lift arm assembly (Part 2)

102

0640 Connecting the remote grease tube

103

0650 Assembling the bucket (Part 1)

104


105


106

0680 Assembling the cover (Bottom of the counterweight)

107

0690 Feeding the grease

108

0700 Work equipment hydraulic circuit air bleeding procedure

109

0710 Adjusting the bucket positioner

110

0720 Adjusting the new 2 stage (Overseas general standard)

111 111

0730 Adjusting the new 2 stage (North American standard specification)

112

0740 Assembling the lift arm angle sensor

113

0750 Adjusting the active working system and boom kick-out switch (Overseas general standard and domestic standard)

114

0760 Touchup work

115

0770 Applying the decal (For the overseas-directed products only)

116

Appendix: Field assembly inspection report

1

Dividing Process Overview (Major components alone)

1. Front frame subassembly

2. Rear frame subassembly

4. Rear axle assembly (With rear axle support)

5. Wheel and tire assembly

7. Lift arm assembly

10. Floor handrail assembly

14. Muffler stack

3. Front axle assembly

8. Floor and cab assembly

11. Ladder assembly

15. Fuel tank assembly

6. Bucket assembly

9. ROPS canopy assembly

12. Front fender

16. Battery box assembly

13. Front lamp assembly

17. Counterweight

1

2

Major Components Table of Dimensions

1

Front frame subassembly

1

Weight (kg) 11,500

2

Rear frame subassembly

1

26,000

6,425

3,200

3,155

3

1

8,514

4400

1600

1000

1

8,500

4400

1800

1000

5

Front axle assembly Rear axle assembly (with axle support) Wheel and tire assembly

4

14,380

1200

2800

2800

6

Bucket assembly

1

12,290

5200

2900

2500

Floor and cab assembly

1

1,000

2300

1800

2100

Unit name

4

Q'ty

L: Overall length (mm) 4,830

W: Overall width (mm) 2,250

H: Overall height (mm) 3,150

7 8 9

ROPS canopy assembly Floor handrail and rear access step 10 assembly 11 Ladder assembly

1

1,387

2500

1900

2200

1

650

1820

3940

1100

1

60

500

700

2400

12 Front fender

2

170

800

1700

1400

13 Front lamp assembly

2

65

800

700

1300

14 Muffler stack

2

50

400

400

1700

15 Fuel tank assembly

1

790

1800

1900

1100

16 Battery box assembly

1

580

900

900

800

1

2,900

3200

1200

600

1

2,600

375

3,200

600

17-1 Counterweight Additional counterweight 17-2 (Dimensions depend on ATT)

2

2

Major Components Table of Dimensions

Land transportation Transportation means

Weight (kg)

Relevant specifications Overall length Overall width (mm) (mm)

Provisions required for transportation

Overall height (mm)

Front frame assembly in transportation by trailer

11,500

4,830

2,250

3,150

Rear frame assembly in transportation by trailer

26,000

6,425

3,200

3,155

One 36 ton trailer [ For the machine body excluding the following removed parts] Four 15 ton trailers [Bucket, loader link, front axle, rear axle (including swivel support), tire and rim, parts around cab and operator's seat, exterior parts (hood grille, fender, ladder, platform, handrail, light support), counterweight, fuel tank (including (fuel) and exhaust pipe]

Style Packing style in transportation by trailer (Application for the Special-purpose Vehicle Passage may be required)

Maximum loading mass

ton

36

Loading space length

mm

6,300

Loading space width

mm

3,200

Overall length

mm

11,900

Gooseneck length

mm

2,500

3

3

Work Space Layout

(A larger workspace provides better workability. 25 m × 30 m shown in the figure below is the minimum required space.)

Tire and wheel assembly

Lift arm assembly

50 ton crane

Bare machine

Front axle assembly

Light-weight units storage place Front fender Ladder and muffler stack Front lamp Floor handle

Front tank Floor and cabin assembly assembly

Rear axle assembly

Counterweight assembly

e n a r c n o t 0 5

Bucket assembly

ROPS canopy assembly

Compressor parts Jigs and tools storage place

4

4

Schedule Table for Field Assembly

s l i a r d n a h x o p b e t s y r e g t t n i a l b l a t s d n n I a

y a d d r 3

k n a t l e u f g b n a i l l a c t s d n n I a

y a d d n 2 n o t 0 5 : e n a r C

t d d h n n g i o e a t t e g s n w o r i n y t . l t t e n n b n e u u t e u m o o a l o e m c m p s M a r s F a

d t d n h g n i a t o e t e s n w g y o r i n l t t e . b t n e e m n n u u t e o u a l o o n m s a M c m p o r s t F a 0 5 : e n a r C n o t 5 2 : e n a r C

y r a u o D H

y a d h t 5

f o s n i o s i t i s a d h n c o C

s e m a r f g n i l p u o C

, t h g i e w r m r e a t t n f i u l o d c n g a n , i l l S a P t s O n R I

s r e k r o w 5

e n a r C

r e k r o W

s r e k r o w 2

, t e g k n c i u k b c e g h i n c t , s g j n u i l l d a a t s d n n I a

y a d h t 4

s i s s a h c g n i n o i t i s o P k r o h w y g l u b o m R e s s a

g n i t n i a p p u h c u o t d n a g n i k c e h C

s r e k r o w 5

s e l x a g n i n o i t i s o P

n o t 5 2 : e n a r C

y a d t s 1

s e r i t g n i l l a t s n I

y r a u o D H

f o s n i o s i t s i a d h n c o C

k r o h w y g l u b o m R e s s a

s r e k r o w 5

e n a r C

r e k r o W

5

5

Facility, Jigs and Tools

Drawing of frame deck Drill hole of 4-22 (Machining is not necessarily required)

Either above or a component made of welded t12 flat steel is acceptable

) 8 4 6 ( T N O R F / R A E R r o F

(Note) The joint indicated in the figure must be welded at 9

6

) 0 8 6 ( T N O R F / R A E R r o F

.

Quantity For front 2 pieces For rear 2 pieces

5


Tools used No.

Tool name

Specification Spanner, ring spanner and box spanner chisel Screwdriver, hammer, monkey wrench, hex wrench, etc.

Q’ty

Remarks

1

List of standard general tools

2

Power wrench

16 time

1

3

Power wrench

4 time

1

4

Socket

60T (Entry point 38.1) × L: 84

1

5

Socket


1

6

Socket


1

For front and rear axle mounts For rear axle support cover, tire and counterweight For fuel tank and counterweight

7

Socket


1

ROPS mount

8

Socket


1

ROPS mount

9

Extension bar

Entry corner 12.7 × L:150

1

For fuel tank

10

Adapter

Entry corner 19 × 12.7 × L:55

1

11

Extension bar

Entry corner 25.4 × L:160

1

12

Preset torque wrench (Box type) Head replacement type preset torque wrench Head replacement type preset torque wrench Head replacement type preset torque wrench

39.2 – 274.6 Nm {4 – 28 kgm}

1

For fuel tank For tire, counterweight and ROPS canopy For power wrench

58.8 – 137.3 Nm {6 – 14 kgm}

1

For connecting hoses and tubes

19.6 – 44.1 Nm {2 – 4.5 kgm}

1


29.4 – 68.6 Nm {3 – 7 kgm}

1


Width across flats: 27 (Entry point: ø15) 19 (Entry point: ø12) 22 (Entry point: ø12) 24 (Entry point: ø12), 36, 41

1 each


13 14 15

16

Head replacement type preset torque wrench (Spanner type)

2 Front and rear axle mounts, ROPS canopy mount Fuel tank mount

196.1 – 1,372.9 Nm {20 – 140 kgm}

1

For rear axle support cover, counterweight

490.3 – 2,059.4 Nm {50 – 210 kgm}

1

For counterweight

58.8 – 411.9 Nm {6 – 42 kgm}

1

For rear axle support cover

20

Preset type torque wrench (Box type) Preset type torque wrench (Box type) Preset type torque wrench (Box type) Impact wrench

GT-P8M or equivalent

1

21

Impact wrench

GT-P14M or equivalent

1

22

Impact wrench

GT-S22M or equivalent

1

23

Adapter

Entry corner 19 × 25.4 × L:71

1

24

Adapter

Entry corner 12.7 × 9.5 × L:41

1

25

Large hammer

10 pounds

1

26

Air grinder

27

Bar

28

Round mandrel

29

Grease gun (Hand pump type)

30

Oil jack

31

Vinyl hose

17 18 19

32 33

Head replacement type preset torque wrench Head replacement type preset torque wrench

—

For tire and ROPS canopy For power wrench and torque wrench For power wrench and torque wrench

1

2

For adjustment of holes and moving heavy stuff For adjustment of holes

Capacity about 300 cc

1

For applying grease to pins

Capacity 1,000 – 2,000 cc Inside diameter: ø6.5 – ø7.0, L: 1,000 – 1,500

1

For bleeding air from brake line

1

For bleeding air from brake line

196.1 Nm {20 kgm}

1


176.5 Nm {18 kgm}

1


Large, medium and small —

2 each

7

5


Facilities used Tools and facilities used No.

Tool name

Specification

Q’ty

Remarks

1

Crane

Min. 50 ton

2

2

Forklift

Min. 2 ton

1

3

Compressor

Capacity: Min. 32l

1

For impact wrench and bleeding air

4

Lever block

1 ton

3

For holding cylinder and drive shaft

5

Footstall (Work table)

4 stage (About 1.5 m high)

3

For work

6

Steel plate

(Large) 9 × 1,219 × 2,438

4

For setting bare machine in place

7

Steel plate

(Large) 25 × 250 × 600

4


8

Crosstie

400 × 400 × 900

14


200 × 400 × 800

4


9

Air grease gun

Capacity: 18l

1

10

Air conditioner gas charge

Gauge manifold, leak detector

1

11

Tester

1

Lifting tools used No.

Sling name

Specification

9

2 point lift (Sling hook (SL) of L = 2,250 and ø20 in chain diameter)) Balance 2 point lift Rear frame lifting tool (Sling hook (SL) of ø20 in chain diameter)) 2 point lift Rear axle lifting tool (Club hook (G) of L = 5,500 and ø16 in chain diameter)) Nylon sling 50 × 2,000 Balance 2 point lift (Sling hook (SL) of ø16 in chain diameter)) Front and Rear axle lifting tool Balance 2-point lift (Club hook (G) of ø12.5 in chain diameter)) Nylon sling for drive shaft 50 × 5,000 2 point lift Fuel tank lifting tool (Sling hook (SL) of L = 5,000 and ø6.3 in chain diameter)) 2 point lift Floor and cab assembly lifting tool (Sling hook (SL) of L = 2,000 and ø6.3 in chain diameter)) Nylon sling 150 × 10,000

10

Wire sling

1 2 3 4 5 6 7 8

Front frame lifting tool

1

See the figure below

1


2

Holding axle support and cylinder

1 See the figure below 1 1


2


2 1

Withstand load 11 tons and L = 2,000

1

For 2 ton, 5 ton, 10 ton and 15 ton

12

Eyebolt

(Top) 2 and (bottom ) 1

13

Nylon sling

25 × 2,000

Chain diameter


2

Shackle

2. Rear frame sling

Remarks

1

Withstand load 15 tons and L = 2,500

11

1. Front frame sling

Q’ty

Tire lifting tool For removing crossties under machine body (Front lifting) Lift arm lifting tool

2 each Lift arm lifting tool

3. Rear axle sling

Chain diameter Chain diameter

Chain diameter

5. Front/Rear axle sling

7. Fuel tank sling 8. Floor and cab assembly sling

Chain diameter Chain diameter

Chain diameter

8

6

List of Oil, Grease and Paints

Oil, grease, paints and others No.

3

Oil, grease and paints Extreme-pressure added with molybdenum disulfide Extreme-pressure added with molybdenum disulfide Fuel

4

Paint for touchup

Black

5

Air conditioner gas

R134A gas can (400 g)

6

Window washer liquid

1 2

Specification

Quantity

(KES LM-P or equivalent)

500 ml

(KES LM-P or equivalent)

10l

Diesel fuel

Appropriate amount (Full capacity is 1,200 l) 1 1l container × 2

When the front and rear frames were divided, following must be additionally used. No. 1

Oil, grease and paints Hydraulic oil

Specification (KES EO10-CD or equivalent)

Quantity 1,000l

Protective gear Work uniform, safety boots, helmet, cotton gloves, goggles and rain coat

9

Assembly procedure

No. 0010

Oil, grease and coolant

Selective use of fuel and lubricating oil depending on the given atmospheric temperature t Fuel and oil Use them selectively depending on the given atmospheric temperature. a The specified oil level denotes the total volume of oil used on the machine including that is contained in the pipes of respective equipment. And the amount of replacement oil refers to the amount of oil to be replaced in the inspection and maintenance. a Whenever starting the engine with atmospheric temperature at 0°C or below, EOS0W30 or EOS5W40 must be used for the engine oil pan although the temperature may usually rise up to 10°C or above. t Coolant Since the Komatsu genuine Super Coolant (AF-NAC) is added to the coolant, change of the coolant is unnecessary as long as atmospheric temperature remains at -10°C or above. If it went below -10°C, adjust the density referencing the section "Cleaning of inside of coolant system" in the Operation and Maintenance Manual.

a

10

For details of the notes (e.g., Note. 1, Note. 2 ...) in the table, see the Operation and Maintenance Manual.

Assembly procedure

Oil, grease and coolant level

No. 0020

Lubricating points

Types of oil

Specified oil level (l)

Volume of replaced oil (l)

Engine oil pan

Engine oil

140

130

Transmission case

Power train oil

164

140

1,065

725

42

31

360 each

360 each

360 each

360 each

Hydraulic oil system Brake oil tank Front axle Rear axle

Hydraulic oil Engine oil Power train oil Axle oil

Fuel tank

Diesel fuel

1,555

—

Cooling system

Super coolant

337

—

Volume of refilled oil (l)

Caution: Whenever started or stopped the engine, be sure to check the level of oi l, grease and coolant. Before the suspension adjustment is complete, don't try to turn t he steering in a large angle. (Otherwise, the pipe can be damaged.)

Cautions

Special tool Name

Necessary Equipment Q’ty

Name

Q’ty

s r e h t O

11

Assembly procedure

Setting rear frame in place

No. 0030

1. Hitch the lifting tool on the position indicated in the figure and lift rear frame (1). 2. Set rear frame assembly (1) in place using the steel plate and deck as shown in the figure. No. (1)

Part No. 427-46-2295A

Part name Q’ty State of part (Parts list No.) Rear frame as sembl y 1 S eparatel y packed (No.W 9E- 03 0)

Cautions

Special tool Name

s r e h t O

12


Name

Q’ty

Lifting tool: 2 point lift (L = 2,250, ø20)

1

Assembly procedure

Setting front frame in place

No. 0040

Wrap the pins with a piece of rag and then hitch the lifting tool on the front frame.

Lumber

1,000 mm

Deck

Steel plate

1. When lifting front frame assembly (1), protect the pins from damage by wrapping a piece of rag around them. 2. Lift front frame assembly (1). 3. Set front frame assembly (1) in place using the deck and lumber as shown in the figure. No. (1)

Part No. 427-N96-215A

Part name Front frame as sembly

Q’ty State of part (Parts list No.) 1 S eparately pack ed (No. W9E-040)

Cautions

Special tool Name


Name

Q’ty

Lifting tool: 2 point lift (L = 2,250, ø20)

1

s r e h t O

13

Assembly procedure

Joining front and rear frames

No. 0050 No. (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15) (16) (17) (18) (19) (20) (21) (22)

Part No. Part name Q’ty State of part (Parts list No.) 427-46-11161 Shaft 1 Temporarily installed on the rear frame 427-46-11190 Retainer 1 Temporarily installed on the rear frame 427-46-11440 Bushing 1 Temporarily installed on the rear frame 01010-62065 Bolt 4 Temporarily installed on the rear frame 01010-62070 Bolt 6 Temporarily installed on the rear frame 01643-32060 Washer 10 Temporarily installed on the rear frame 427-46-11312 Shaft 1 Separately packed (No.W9E-050) 01010-63075 Bolt 1 Separately packed (No.W9E-050) 427-46-11480 Bushing 1 Press fitted to the rear frame 427-46-11490 Bushing 1 Press fitted to the rear frame 427-46-11391 Bushing 1 Temporarily installed on the rear frame 427-46-11411 Shim t = 0.1 20 Temporarily installed on the rear frame 427-46-11421 Shim t = 0.5 24 Temporarily installed on the rear frame 427-46-11431 Retainer 1 Temporarily installed on the rear frame 01011-63065 Bolt 4 Temporarily installed on the rear frame 01643-33080 Washer 4 Temporarily installed on the rear frame 01010-62495 Bolt 10 Temporarily installed on the rear frame 01643-32460 Washer 10 Temporarily installed on the rear frame 427-46-11330 Plate 2 Temporarily installed on the front frame 01010-61025 Bolt 4 Temporarily installed on the front frame 01643-31032 Washer 4 Temporarily installed on the front frame 427-46-11321 Bushing 1 Temporarily installed on the front frame

For the front and rear frames joining procedure, see NO.0060.

Coating with LT-2 Tightening torque : 490 – 608 Nm {50 – 62 kgm}

Use care not to foul the internal tapered portion with lubricant agent such as grease. Coating with LM-P

Coating with LM-P

Coating with LT-2

Coating with LT-2

Tightening torque : 824 – 1,030 Nm {84 – 105 kgm}

Cautions w w

w

Be sure, in the assembly, to apply sufficient amount of grease to the inside of the bearing. Fill the upper hinge and lower hinge shafts with grease until it flows out the dust seal after assembly. Touch up the black bolt and the machined surface.

14

Tightening torque : 1,520 – 1,910 Nm {155 – 195 kgm}

Special tool Name


Name

Q’ty

Impact wrench (Socket #17, #30, #36, and #46)

50 ton crane

Torque wrench (Set 549, 927, and 1,715 Nm)

Lifting tool (For front frame and rear frame) 1 each

Jack, thickness gauge and copper hammer

Air compressor

Others

2 1

Assembly procedure

No. 0060

Front and rear frames joining procedure

Front frame and rear frame joining procedure 1. 2. 3. 4.

Make sure bushings ((9): 427-46-11480 and (10): 427-46-11490) are press fitted to the rear frame. Assemble bushing ((22): 427-46-11321) to the lower hinge of the front frame. Assemble bushing ((3): 427-46-11440) to the upper hinge of the rear frame. Assemble retainer ((2): 427-46-11190) to upper pin ((1): 427-46-11161). Tightening torque 490 – 608 Nm {50 – 62 kgm} 5. Place the front frame between the rear frame hinges and then insert the upper pin. Tightening torque 490 – 608 Nm {50 – 62 kgm} Initially, tighten the bolts diagonally in the order of 1 o 2 o 3 o 4 o 5 o 6. Then tighten them in the order on the circumference, namely 1 o 3 o 5 o 2 o 4 o 6 o 1 o . Be sure to tighten the bolts paying attention to their behavior. Tighten the bolts to the specified torque. Repeat tightening until they are firmly fixed and don't move. 6. Insert lower pin ((7): 427-46-11312) and bushing ((11): 427-46-11391) to the lower hinge and then install retainer ((14): 427-46-11431). 7. Set the jack under the lower hinge of the front frame to contact the rear frame and bushing closely to each other by removing the clearance between them. 8. Tighten retainer mounting bolts ((15): 01011-63065 and (17):01010-62495) of the lower hinge with M24: 824 – 1,030 Nm {84 – 105 kgm} and M30: 1,520 – 1,910Nm {155 – 195 kgm}, respectively, and then strike the lower pin head 3 – 5 times using the copper hammer. 9. Repeat Step 8 three times so that respective contact regions may fit well. Then retighten bolts ((15) and (17)) with M24: 824 – 1,030 Nm {84 – 105 kgm} and M30: 1,520 – 1,910 Nm {155 – 195 kgm}. 10. Remove all bolts ((17)) and then measure, using the thickness gauge, clearance between retainers ((2) and (14)) and frame at three points (in 120° intervals) to calculate the average clearance. Combine shims in such that the average clearance is adjusted to 0.08 – 0.18 mm. Note that thickness of the shims must not exceed the t hickness of the individual clearances measured. 11. Remove bolts ((15) and (17)) from the front frame while holding it in place and then insert the shims being combined in Step 10 above. 12. Proceed to Step 8 and 9. 13. Pull out bolts ((15) and (17)) one by one, coat them with Locktite #262 and then tighten them with the specified torque. (Degrease the threaded and tapped portions completely.) 14. Conduct Steps 8 and 9 on the upper pin bolts ((4): 01010-62065 and (5): 01010-62070) (tightening torque used in this case should be that for M20 [490 – 608 Nm {50 – 62 kgm}]). And then conduct Step 13 on them. 15. Remove the jack from the lower hinge of the front frame. [Caution] a After the work, fix the machine in place with the safety lock bar to prevent articulation. a Be sure, in the assembly, to apply sufficient amount of grease to the inside of the bearing. a Fill the upper hinge and lower hinge shafts with grease until it flows out the dust seal after assembly.

Cautions w w

w

Special tool

Necessary Equipment

Name Q’ty Name Q’ty Be sure, in the assembly, to apply sufficient amount of grease to the inside of the bearing. Impact wrench (Socket #17, #30, #36, and #46) 50 ton crane 2 Fill the upper hinge and lower hinge shafts Torque wrench (Set 549, 927, and 1,715 Nm) Lifting tool (For front frame and rear frame) 1 each with grease until it flows out the dust s eal after Jack, thickness gauge and copper hammer Air compressor 1 assembly. Touch up the black bolt and the machined surface.

s r e h t O

15

Assembly procedure

Assembling the steering pin

No. 0070

The slit shall be set in the longitudinal direction of the machine body. Use care not to foul the internal tapered surface with lubricant agent such as grease.

The slit shall be set in the longitudinal direction of the machine body. Use care not to foul the internal tapered surface with lubricant agent such as grease.

Tightening torque : 343 – 427 Nm {35.0 – 43.5 kgm} Before assembling the pin, coat the bushing inner periphery and dust seal lip on the cylinder side with LM-P. For the grease fitting mounting direction, see the figure below.

Make sure the dust seal is assembled being faced outward.

FITTING (07020-00900) DIRECTION TO BE SYMMETRICAL. Machine front side

Steering cylinder

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

Part No. 427-46-12410 427-46-12420 427-46-12430 427-46-12440 427-46-12450 421-70-11331 01010-81475 01643-31445 01010-81635 01643-31645 421-70-11280 6141-55-5630 07020-00900

Part name Q’ty State of part (Parts list No.) Shaft 2 Temporarily installed on the rear frame Plate 2 Temporarily installed on the rear frame Plate 2 Temporarily installed on the rear frame Bushing 2 Temporarily installed on the rear frame Bushing 2 Temporarily installed on the rear frame Shim 16 Temporarily installed on the rear frame Bolt 12 Temporarily installed on the rear frame Washer 12 Temporarily installed on the rear frame Bolt 2 Temporarily installed on the rear frame Washer 4 Temporarily installed on the rear frame Washer 2 Temporarily installed on the rear frame Nipple 2 Temporarily installed on the rear frame Fitting 2 Temporarily installed on the rear frame

Cautions 1. Clean the mounting surface of the steering cylinder and pin. Make sure the surface is free from foreign substances.

Machine center Rear frame

Top view of the joint of the front frame and rear frame

Special tool Name Impact wrench

Q’ty 1

Socket (22 mm, 24 mm)

1 each

Spanner (10 mm, 14 mm)

1 each

Torque wrench (385 N m {39.3 kgm} set)

s r e h t O

16

Necessary Equipment

1

Name Air compressor

Q’ty 1

Assembly procedure

No. 0080

Assembling the center drive shat (Center support – Transmission)

1. Remove (1) and (3) being temporarily installed on the rear frame. 2. Assemble drive shaft (4) as shown in the figure. (When assembling the drive shaft, pay attention to its direction.) 3. Assemble (1) – (3) to their original positions. No. (1) (2) (3) (4) (5) (6)

Part No. Part name Q’ty State of part (Parts list No.) 427-46-22531 Guard 1 Temporarily installed on the rear frame 01010-82045 Bolt 2 Temporarily installed on the rear frame 01643-32060 Washer 2 Temporarily installed on the rear frame 427-20-12211 Shaft 1 Separately packed (No.W9E-080) 01050-61895 Bolt 4 Separately packed (No.W9E-080) 01050-61895 Bolt 4 Separately packed (No.W9E-080)

Coating with LT-2. Tightening torque : 343 – 427 Nm {35.0 – 43.5 kgm}

Grease nipple position in the spider of 427-20-12211

Coating with LT-2. Tightening torque : 343 – 427 Nm {35.0 – 43.5 kgm}

Grease nipple position (Viewed from the machine rear side) Center support Grease nipple position Both the front and rear must be directed in the same direction. Assemble setting the longer side to the transmission Grease nipple position

Assemble setting the shorter side to the center support

Both the front and rear must be directed in the same direction.

Points to notice 1. Mounting surface shall be free from rusts, foreign substances and dents. 2. Insert 4 bolts temporarily and tighten them temporarily until the seating face is closely contacted. 3. The bolts must be basically tightened diagonally. Sequential tightening of the bolts must be repeated 2 rounds minimum. 4. Must be retightened to the specified torque. 5. Visually inspect the seating face and then apply a check mark using a white felt pen.

Cautions 1. Clean the mounting surface of the drive shaft. Make sure the surface is free from foreign substances. 2. After the work, apply touchup coating on the black bolt to pr event its getting rusty.

Special tool Name Impact wrench Socket (27 mm, 30 mm)


Necessary Equipment Q’ty 1

Name Air compressor

Q’ty 1

1 each

1

s r e h t O

17

Assembly procedure

Connecting the pipes - Part 1

No. 0090

a

A hose is connected (1) – (6) hoses.

(Be sure to implement and complete the following 1 – 4 steps on a line basis. Don't try to start working on 6 lines at a time.) 1. Remove the blind parts on the pipe. 2. Make sure they are free from foreign substances. 3. Make sure the O-rings are not damaged. Note: A single green mark is applied to the O-ring in the connection of (4) alone. For other O-rings, 2 green marks are applied. 4. Connect the hose. (The bolt tightening torque must conform to KES 04.123.2 Impact wrench.)

Cautions 1. After connecting the pipe, clean oil being deposited in the surroundings, if any.


s r e h t O

18

Necessary Equipment Q’ty 1 1 each

Name Air compressor

Q’ty 1

Assembly procedure

Connecting the pipe - Part 2

No. 0100

PPC control valve (P4) line Yellow band PPC control valve (P2) line Red band PPC control valve (P1) line Orange band PPC control valve (P3) line Blue band S/T (L) line S/T (R) line

(1) – (6) Tightening torque : 54 – 93 Nm {5.5 – 9.5 kgm} Viewed from the machine right side

Brake (Slack adjuster A) line Brake (Slack adjuster) line

Brake (Valve T) line Brake (Valve P) line

(7) – (10) Tightening torque : 84 – 132 Nm {8.5 – 13.5 kgm}

Viewed from the machine left side

Viewed from the machine right side

1. 2. 3. 4.

Remove the blind parts on the pipe. Make sure they are free from foreign substances. Connect the hose. When connecting the hose, don't try to start the work on (1) – (10) lines at a time. Be sure to implement Steps (1) – (3) on a line basis. Cautions

1. After connecting the pipe, clean oil being deposited in the surroundings, if any.

Special tool Name Torque wrench (49 Nm {5 kgm}, 78.5 Nm {8 kgm} set)


Name

Q’ty

1 each

s r e h t O

19

Assembly procedure

Connection of piping (Part 2) (Riotinto specification: If equipped)

No. 0105

PPC control valve (P4) line Yellow band PPC control valve (P2) line Red band PPC control valve (P1) line Orange band PPC control valve (P3) line Blue band Steering (L) line Steering (R) line

–

Tightening torque 54 – 93 Nm {5.5 – 9.5 kgm}

Machine seen from right

Breather remote line Brake (Slack adjuster A) line Brake (Slack adjuster) line

Brake (Valve T) line Brake (Valve P) line

–



Machine seen from right 1. 2. 3. 4.

Remove the pipe blocking parts. Check that no foreign matter is sticking. Connect the hoses. Do not connect the hoses of all lines (1) – (11) at a time but perform work 1 – 3 securely for them one by one. Cautions

1. After connecting the piping, wipe off oil sticking around it, if there is any.

Special tool Name Torque wrench (49 Nm {5 kgm}, 78.5 Nm {8 kgm} set) s r e h t O

20

Necessary Equipment Q’ty 1 each

Name

Q’ty

Assembly procedure

No. 0110

Connecting the auto-greasing pipe

1. Connect the auto-greasing pipe from the front frame to the tube on the rear frame.

Connect

Frame connection viewed from the left side

Connect

View Z Cautions

Special tool

Necessary Equipment

Name

Q’ty


1

Name

Q’ty

s r e h t O

21

Assembly procedure

Setting the axle in place and assembling the support

No. 0120

Setting dimension 5,450 mm Wheelbase

8,404 kg

Setting the front and rear axles in place

7,912 kg

Steel plate Ground level

Steel plate

Front axle

Rear axle

Setting dimension 5,450 mm

Support Lifting load: 300 kg,

50 × 2,000 2 nylon slings

1. Set the front axle assembly and rear axle assembly (with axle support) in the machine body assembling area in the 5,450 mm space between the wheelbases. See the figure. 2. Clean inside of the axle support and apply grease (G2-LI). (Clean inside of the axle support using a piece of rag and then coat the bushing inner surface with grease (G2-LI)). 3. Fit the rear axle support to the rear axle and then fix it with a wire to prevent its detachment.

Cautions Q

Special tool Name

The support must be fixed with a wire and the like. (It is needed to prevent its detachment due to vibrations)

s r e h t O

22


Name

Q’ty

Assembly procedure

Setting the bare machine in place

No. 0130 Crane: 50 ton

Crane: 50 ton

Ground level Front axle

Rear axle

1. Using the lifting eye on the frame, lift the bare machine with two 50 ton cranes. 2. Set it secure on the upside of the front and rear axle assembly. 3. Set the bare machine in place by use of the frame deck in such that assembling of the tire and wheel assembly is available. When setting it on the ground, spread steel plates under the crossties to prevent leaning of the machine due to depression of the ground surface. (Dimensions: 1,219 × 2,438 × 9 (t) = 2 plates) a

Set the machine in a flat place in order to prevent leaning of t he machine in the longitudinal direction as much as the situation allows. (Leaned machine makes the pinhole adjustment difficult when installing the l ift arm.)

Details of lifting tool For front frame Lifting Load: 11.5 ton Crane: 50 ton

2,250

3,900 For rear frame Lifting Load: 20 ton Crane: 50 ton

Cautions

0 0 5 , 2

2,850

Special tool Name


Name

Q’ty

s r e h t O

23

Assembly procedure

Assembling the rear axle

No. 0140

1. Remove the parts being temporarily installed on the machine and rear axle. 2. Hitch the lifting tool to rear axle assembly (1) and lift it as shown in the following figure. (Hitch the lifting tool in a squeezing manner to lift the axle support horizontally.) 3. Assemble rear axle assembly (1). Tightening torque : 3,170 – 3,870 Nm {323 – 395 kgm} 4. For assembling of cover (5), reference No.0150 Rear axle side rear cover assembling procedure. 5. After the assembly, touch up the lifting traces. Tightening torque : 824 – 1,030 Nm {84 – 105 kgm}

(See No.0150)

(See No.0150)

Tightening torque : 824 – 1,030 Nm {84 – 105 kgm} Coat the front and rear face of thrust washer (9) with grease (G2-LI). Weight = 7,914 kg When assembling, care must be exercised not to collapse the brake pipe on both side. (Space between the frame and rear axle is limited.)

Rear axle assembly

Axle support assembly

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

Cautions

Part No. 427-23-20200 427-46-12130 01643-33990 01580-03931 427-46-12180 01011-82400 01643-32460 04530-11018 07029-00000 427-46-12161 427-46-12171 01011-82420 01643-32460

Q’ty 1 4 8 4 1 16 16 1 1 2 1 16 16

Special tool Name

State of part (Parts list No.) Separately packed (No.W9E-140) Temporarily installed on the rear axle Temporarily installed on the rear axle Temporarily installed on the rear axle Separately packed (No.W9E-140) Temporarily installed on the machine Temporarily installed on the machine Separately packed (No.W9E-140) Separately packed (No.W9E-140) Temporarily installed on the rear axle Temporarily installed on the rear axle Temporarily installed on the rear axle Temporarily installed on the rear axle


Power wrench

1

Torque wrench

1

Socket 60 mm

1

Socket 36 mm

1

s r e h t O

24

Part name Rear axle assy Bolt Washer Nut Cover thrust Bolt Washer Bolt eye Valve Washer thrust Plate thrust Bolt Washer

Name

Q’ty

Assembly procedure

No. 0150

Rear axle rear side cover assembling procedure

Portion A

View Z a

Place bolt (6) and washer (7) beforehand in the hole being dri lled when assembling cover (5) (view Z). (Installation of the bolt in a later step is unavailable.)

View Y

Move the cover to the bottom of the installation position using the forklift and t hen install it aligning position o f the hole. Aligning position of the hole requires about two workers. a

Caution • This operation must be carried out carefully exchanging signals with the forklift operator. • Cover weight: 119 kg

Cautions

Special tool Name

a Reasonable

care must be exercised in the assembling since the cover weighs 119 kg.


Name

Q’ty

s r e h t O

25

Assembly procedure

Connecting the rear axle pipe

No. 0160

Torque converter

Rear axle

Connect the brake line hose to the rear axle side tube. (2 on both sides)

Top view of rear axle

Connection tightening torque : 84 – 132 Nm {8.5 – 13.5 kgm}

Connect the breather hose to the rear axle side connector.

1. Connect the brake line hose to the rear axle side right and left tubes. 2. Connect the breather hose to the rear axle side connector.

Cautions

Special tool Name

s r e h t O

26


Name

Q’ty

Assembly procedure

Fixing of rear axle piping (Brake cooling specification: If equipped)

No. 0165

Fixing: Fix together with axle bolt. Rear axle seen from rear

1. Fix plate (1) to the rear axle with the rear axle bolt. 2. Tighten parts (2) – (5) permanently. No. (1) (2) (3) (4) (5)

Part No. 427-S05-6250 07283-33450 07283-53444 01597-01009 01643-31032

Part name Plate Clip Seat Nut Washer

Q’ty 1 2 2 4 4

State of part (Parts list No.) Temporarily installed on the machine Temporarily installed on the machine Temporarily installed on the machine Temporarily installed on the machine Temporarily installed on the machine

Cautions

Special tool Name


Name

Q’ty

s r e h t O

27

Assembly procedure

Connection of rear axle piping (Riotinto specification: If equipped)

No. 0166

View Z: Rear frame seen from above

Rear frame seen from left

Rear frame seen from left rear.

1. Connect the piping to elbow (1) installed to the rear axle. No. (1)

Part No. 427-Z89-3880

Part name Elbow

Q’ty State of part (Parts list No.) 1 Installed to rear axle

Cautions

Special tool Name

s r e h t O

28


Name

Q’ty

Assembly procedure

Fixing of rear axle piping (Brake cooling specification: If equipped)

No. 0167

Connection

To rear axle

Lower part of rear axle

1. Connect hose (1) installed to the rear axle. No. (1) (2) (3) (4)

Part No. 07296-21213 07371-31255 07375-21035 07000-F3038

Part name Hose Flange Bolt, sems O-ring

Q’ty 1 2 4 1

State of part (Parts list No.) Installed to rear axle Separately packed (No. W9E-167) Separately packed (No. W9E-167) Separately packed (No. W9E-167)

Cautions

Special tool Name


Name

Q’ty

s r e h t O

29

Assembly procedure

Connection of cooling line piping (Brake cooling specification: If equipped)

No. 0168

Connection: Check O-ring.

Fixing


Inside of rear frame seen from left

1. Remove temporarily installed parts (2), (3), (5), (6), (7), (8) and (9). 2. Connect and fix the cooling line with the parts removed in 1 above. No. (1) (2) (3) (4) (5) (6) (7) (8) (9)

Part No. 02896-21018 07371-31255 07375-21035 07000-F3038 01643-31032 01011-81020 07095-20627 04434-53412 01596-01009

Part name O-ring Flange Bolt, sems O-ring Washer Bolt Cushion Clip Nut

Q’ty 1 2 4 1 1 1 1 1 1

State of part (Parts list No.) Installed to machine Temporarily installed on the machine Temporarily installed on the machine Installed to machine Temporarily installed on the machine Temporarily installed on the machine Temporarily installed on the machine Temporarily installed on the machine Temporarily installed on the machine

Cautions

Special tool Name

s r e h t O

30


Name

Q’ty

Assembly procedure

Assembling the rear drive shat (Transmission – Rear axle)

No. 0170


Rear axle

Tightening torque : 343 – 426 Nm {35 – 43.5 kgm}

Grease nipple position (Viewed from the machine rear side)

Lead the nylon sling (50 × 5,000) through the frame center and then lift the shaft from the right platform by use of the crane. Then adjust the position and assemble it. When assemble, set the male side in the front (transmission side).


1. Prior to assembling, clean drive shaft (1) mounting surface. 2. Assemble drive shaft (1). (When assembling drive shaft (1), pay attention to its direction as well as that of t he grease nipple situated in the spider of the front, center and rear drive shafts.) 3. Feed grease (molybdenum disulfide grease) to the grease fitting for the axle support and drive shaft. No. (1) (2)

Part No. 427-20-12211 01050-61895

Part name Rear drive shaft Bolt

Q’ty State of part (Parts list No.) 1 Separately packed (No.W9E-170) 8 Separately packed (No.W9E-170)

Cautions

Special tool Name


Name

Q’ty

s r e h t O

31

Assembly procedure

Assembling the front axle

No. 0180


Weight = 8,404 kg

a Clean

the contact face of the mount before assembling the front axle.

Position of lifting tool Note: Hitch the lifting tool in the squeezing manner Lift the front axle in such that the axle pad is set horizontal. (Lifting load: 8,404 kg)

1. Remove (2) – (4) being temporarily installed on the axle skid. 2. Clean the contact face before assembling the front axle assembly (1). 3. When lifting front axle assembly (1), hitch the lifting tool to it as shown in the figure to the left. 4. Assemble front axle assembly (1). 5. After the assembly, touch up the lifting traces.

No. (1) (2) (3) (4)

Part No. 427-22-2020A 427-46-11452 01643-33990 01580-03931

Part name Front axle Bolt Washer Nut

Q’ty 1 16 32 16

Cautions

State of part (Parts list No.) Separately packed (No.W9E-180) Temporarily installed on the axle skid Temporarily installed on the axle skid Temporarily installed on the axle skid

Special tool Name

s r e h t O

32


Name

Q’ty

Assembly procedure

Fixing of front axle piping (Brake cooling specification: If equipped)

No. 0182

Control valve

To mounting position on left inside of front frame

Mounting position Left side view of front frame 1. Fix the front axle piping. No. (1) (2) (3) (4) (5) (6) (7)

Part No. 427-S05-3661 01024-81230 07283-33450 07283-53444 01597-01009 01643-31032 01024-81225

Part name Bracket Bolt, sems Clip Seat Nut Washer Bolt, sems

Q’ty 1 2 1 1 2 2 2

State of part (Parts list No.) Installed to machine Installed to machine Separately packed (No. W9E-182) Separately packed (No. W9E-182) Separately packed (No. W9E-182) Separately packed (No. W9E-182) Separately packed (No. W9E-182)

Cautions

Special tool Name


Name

Q’ty

s r e h t O

33

Assembly procedure

No. 0185

Connection of front axle piping (Brake cooling specification: If equipped)

Front frame seen from left


Front frame seen from above

1. Connect front axle piping.

Connection: Check O-ring

To right front wheel brake To front axle

View Z Cautions

Special tool Name

s r e h t O

34

To left front wheel brake Necessary Equipment Q’ty

Name

Q’ty

Assembly procedure

Connecting the front axle pipe

No. 0190

Connect the hose to the parking cylinder Tightening torque : 84 – 132 Nm {8.5 – 13.5 kgm}

Fix it to the clip.

Front view of front axle

Connect the hose to the front axle brake tube (1 each on both sides) Tightening torque : 84 – 132 Nm {8.5 – 13.5 kgm}

1. Connect the hose from the slack adjuster to the brake tube on the front axle. 2. Connect the hose from the brake valve to the parking brake cylinder. 3. Fix the hose from the parking brake cylinder with the clip.

Cautions

Special tool Name


Name

Q’ty

s r e h t O

35

Assembly procedure

Connection of front axle piping (Riotinto specification: If equipped)

No. 0195

Front frame seen from right

1. Connect the piping to the front axle.

Front frame seen from above

No. (1)

Part No. 56B-61-13760

Part name Elbow

Q’ty State of part (Parts list No.) 1 Installed to hose

Cautions

Special tool Name

s r e h t O

36


Name

Q’ty

Assembly procedure

Connecting the front drive shat (Front axle – Center support)

No. 0200

Center support

Tightening torque : 343 – 426 Nm {35 – 43.5 kgm}


Grease nipple position (Viewed from the machine rear side)

Front drive shaft Front Axle

Thicker one is set on the front axle side


1. Prior to assembling the drive shaft, clean the mounting surface. 2. Assemble the drive shaft to the front axle. (When assembling drive shaft, pay attention to its direction as well as that of th e grease nipple situated in the spider of the front, center and rear drive shafts.)) 3. Feed grease (molybdenum disulfide grease) to the grease fitting for the axle support and drive shaft. No. (1)

Part No. 01050-61895

Part name Bolt

Q’ty State of part (Parts list No.) 4 Separately packed (No.W9E-200)

Cautions

Special tool Name


Name

Q’ty

s r e h t O

37

Assembly procedure

Connecting the axle oil temperature sensor (For VHMS specification only)

No. 0210 a

This process is required for the VHMS specification only.

1. Fix the wiring harness of the axle oil temperature sensor, (To be tightened along with the mud guard fixing bolt.) 2. Connect CN F25.

Top view of front frame

Connect

Front axle

Detail of backside of A section

View Z No. (1) (2)

Part No. 01024-81055 04434-51010

Part name Bolt Clip

Q’ty State of part (Parts list No.) 2 Temporarily installed on the front axle 2 Temporarily installed on the front axle

Cautions

Special tool Name

Q’ty

Impact wrench

1

Socket (17 mm)

1

s r e h t O

38

Necessary Equipment Name

Q’ty

Assembly procedure

Assembling the tires

No. 0220

1. Prior to assem assembling, bling, remov remove e the grease grease on the the stud stud bolt. 2. Lift a tire tire using using the crane, crane, install install on the the axle axle and then then assemble the nut to it. (Use care not to damage the tire air injection tube.)

Assembling of wheel and tire assembly

3. Install Install the tire tire tightening tightening nut nut temporaril temporarily y using using the impact impact wrench. (This process requires working at a high place and also requires tightening many nuts. So it i s advisable to use the balance for holding the impact wrench.)

4. Tighten Tighten the nut to the the specifie specified d torque using using the torque torque wrench wrench.. 5. Apply chock chocks s to the tires and and remove remove the crosstie crossties s under the the machine. Tightening torque : 736 – 912 Nm {75 – 93 kgm}

Lifting a tire Hitch the lifting tool on the tire and lift it in such that the tire is hung flat.

Hitch in the squeezing manner Nylon sling (150 × 10,000)

(Weight of tire and wheel assembly: 3,500 kg) No. (1) (2) (3)

Part No. 427-30-1240A 426-22-12930 01643-32460

Part name Wheel an and titire as assembly Nut Washer

Q’ty State of part (Parts list No.) 4 Separately pa packed (N (No.W9E-220) 212 Separately packed (No.W9E-220) 212 Separately packed (No.W9E-220)

Cautions Q Q

Prior to assembling, remove the grease on the stud bolt. Care must be exercised in the positioning of the wheel and tire assembly so that the tire air injection tube may not be damaged.

Special tool Name


36 T socket

1

Torque wrench

1

Extension bar

1

Name

Q’ty

s r e h t O

39

Assembly procedure

Assembling the fuel tank

No. 0230 2) Loosen

1. Prior to to assembl assembling, ing, remove remove the breather breather tube. tube. (Be sure to return it to the original position before assembling the fuel tank.) 1) Remove

2. Prior to the assembl assembling, ing, clean clean the contac contactt face of of the mount. mount. 3) Remove beforehand

3. Using a forklif forklift, t, set the fuel fuel tank assemb assembly ly under under the rear frame. frame. 4. Install Install the breather breather tube temporar temporarily ily while lifting lifting the assembly assembly gradual gradually. ly. 5. Temporari Temporarily ly insert insert the right side side bolt alone alone to connect connect and and fix the pipe. pipe. (See No.0240 – No.0260) 6. After all all piping is comple complete, te, tighten tighten the bolts bolts to the specifie specified d torque. torque.


Adjust the clearance between the fuel tank and rear frame to 0.5 mm or less.

Fuel tank

Fuel level sensor

Connect fuel tank level sensor connector (CN R08)

View Z No. (1) (2) (3)

Part No. 01011-63000 01643-33080 416-855-1190

Part name Bolt Washer S h im

Q’ty State of part (Parts list No.) 6 Temporarily installed on the fuel tank 6 Temporarily installed on the fuel tank 10 Separately pa packed (N (No.W9E-230)

Cautions

Special tool Name

Q’ty

Impact wrench

1

Power wrench (×4 wrench)

1

Torque wrench (44 Nm set)

1

Extension

1

Socket 46 mm

1

s r e h t O

40


Q’ty

Assembly procedure

Installation of fuel tank (Riotinto specification: If equipped)

No. 0235 1) Remove.

1. Before Before installin installing, g, remove remove the the clips clips and and bolts. bolts. (Take care not to lose lose them. For installation, see No. 0245.) 0245.) 2. Before Before installi installing, ng, clean clean the mounting mounting face. face. 3. Position Position the fuel fuel tank assem assembly bly under under the rear frame frame with a forklift forklift etc. 4. While raisin raising g the fuel fuel tank gradual gradually, ly, insert insert only the bolts bolts on the right side and connect and fix the piping (Do not tighten the bolts at this time). (See No. 0245, No. 0250 and No. 0260.) 5. After instal installing ling all the pipings pipings,, tighten the the bolts to the the specified specified torque.

Tightening torque 1,520 – 1,910 Nm {155 – 195 kgm}

Adjust so that clearance between fuel tank and rear frame will be 0.5 mm or less.

Fuel level sensor

Fuel tank

View Z Connect fuel level sensor connector (CN R08). No. (1) (2) (3)

Part No. 01011-63000 01643-33080 416-855-1190

Part name Bolt Washer S h im

Q’ty State of part (Parts list No.) 6 Temporarily installed on the fuel tank 6 Temporarily installed on the fuel tank 10 Separately pa packed (N (No.W9E-235)

Cautions

Special tool Name


Impact wrench

1


1

Torque wrench (44 Nm set)

1

Extension

1

Socket 46 mm

1

Name

Q’ty

s r e h t O

41

Assembly procedure

Fixing the drain pipe

No. 0240

Engine oil pan drain Fuel tank viewed from the left side

Torque converter oil cooler Radiator

Torque converter cooler drain

Radiator drain

Fuel tank viewed from the left side

1. 2. 3. 4.

Fix the engine oil pan drain. Fix the torque converter cooler drain. Fix the radiator drain. Fix the torque converter cooler drain pipe and radiator drain pipe.

Cautions

No. (1) (2) (3) (4)

Part No. 01024-81035 01435-01035 08036-20314 01024-81020

Special tool Name

s r e h t O

42

Part name Bolt Bolt Clip Bolt

Q’ty 2 4 5 5

State of part (Parts list No.) Temporarily installed on the fuel tank Temporarily installed on the fuel tank Temporarily installed on the fuel tank Temporarily installed on the fuel tank


Name

Q’ty

Assembly procedure

Fixing of torque converter cooler drain piping (Riotinto specification: If equipped)

No. 0245

Torque converter oil cooler


Fuel tank seen from left

1. Fix the torque converter cooler drain piping. No. (1) (2)

Part No. 424-06-12780 01024-81020

Part name Clip Bolt

Q’ty State of part (Parts list No.) 2 Temporarily installed on the fuel tank 2 Temporarily installed on the fuel tank

2. Open the drain valves. • Engine oil pan drain • Torque converter cooler drain • Radiator drain

Engine oil pan drain Radiator drain


Detail of part P

Rear frame

Cautions

Special tool Name


Name

Q’ty

s r e h t O

43

Assembly procedure

Connecting the fuel pipe

No. 0250 1. Connect and fix the suction hose. (2 on the machine right side) 2. Connect and fix the fuel spill hose. (1 each on the machine right and left sides)

Connection of the spill hose

Connection of the fuel return hose

3. Connect and fix the fuel return hose. (1 each on the machine right and left sides)

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

Part No. 04434-52110 07095-20314 04434-51410 01024-81020 04434-53412 07095-20625 04434-52712 04434-52110 07095-20314 01024-81020

Part name Clip Cushion Clip Bolt Clip Cushion Clip Clip Cushion Bolt

Q’ty 2 2 2 3 2 2 3 2 2 4

State of part (Parts list No.) Temporarily installed on the frame Temporarily installed on the frame Temporarily installed on the frame Temporarily installed on the frame Temporarily installed on the frame Temporarily installed on the frame Temporarily installed on the frame Temporarily installed on the frame Temporarily installed on the frame Temporarily installed on the frame

Engine viewed from the left side

Connection of the suction hose

Connection of the suction hose

Connection of the spill hose

Connection of the fuel return hose

Engine viewed from the right side

Cautions

Special tool Name

Q’ty

Impact wrench

1

Socket (17 mm)

1

s r e h t O

44


Q’ty

Assembly procedure

Fixing the engine drain hoses

No. 0260

1. Fix the breather drain hose (on the machine left side) and the muffler drain hose. 2. Connect the respective drain hoses.

Connect

Connect

Machine left side Detail of connection Rear frame viewed from the left side Connect

Connect

630 (clamp position)

290 (clamp position)

Machine right side Detail of connection

Fuel tank Breather drain (Machine right side) Breather drain (Machine left side) Muffler drain (Machine left side)

Detail of rear side

No. (1) (2) (3) (4) (5)

Cautions

Part No. 04434-52512 04434-51510 01024-81016 07285-00220 07285-00130

Part name Clip Clip Bolt Clip Clip

Q’ty 1 1 2 2 1

Special tool Name

State of part (Parts list No.) Temporarily installed on the rear frame Temporarily installed on the rear frame Temporarily installed on the rear frame Temporarily installed on the drain hose Temporarily installed on the drain hose


Impact wrench

1

Socket (10 mm)

1

Name

Q’ty

s r e h t O

45

Assembly procedure

Assembling the hydraulic tank ladder

No. 0270

Hydraulic tank

1. Remove (2) – (4) being temporarily installed on the hydraulic tank. 2. Assemble ladder (1). No. (1) (2) (3) (4)

Part No. 427-54-26950 01010-81635 01643-31645 01024-D1225

Part name Ladder (R.H.) Bolt Washer Bolt

Q’ty 1 2 2 2

State of part (Parts list No.) Separately packed (No.W9E-270) Temporarily installed on th e hydraulic tank Temporarily installed on th e hydraulic tank Temporarily installed on th e hydraulic tank

Cautions


s r e h t O

46


Name

Q’ty

Assembly procedure

Assembling the floor and cab assembly

No. 0280

Lifting load: 950 kg Lifting tool: 2 point lift × 2

Tightening torque : 245.0 – 308.7 Nm {25 – 31.5 kgm}

a Remove

the undercover in the cab rear side beforehand.

a Return

it to the original position after the piping under the cab is finished.

In cab

1. Remove (2) – (4) being temporarily installed on the machine. 2. Assemble cab assembly (1). No. (1) (2) (3) (4)

Part No. 427-56-2130A 421-54-23260 01596-01615 425-70-11290

Part name Cab assembly Plate Nut lock Washer

Q’ty 1 4 4 4

State of part (Parts list No.) Separately packed (No.W9E-280) Temporarily installed on the machine Temporarily installed on the machine Temporarily installed on the machine

Cautions

Special tool

Necessary Equipment

Name

Q’ty


1

Name

Q’ty

s r e h t O

47

Assembly procedure

Connecting the air conditioner hose

No. 0290 1. Connect the hot water hose. 2. Connect the air conditioner hose. 3. Connect the drain hose.

Inside of the rear frame viewed from the side face

Air conditioner unit

Connect the heater hose IN and OUT (match the color) Remove the joint parts on which IN and OUT are bypassed as the shipping parts. (To be discarded)

Detail of A section

Drain hose

To be fixed with the welded clip in 3 places

Note: Confirm the hose size

Connect the air conditioner coupler

View Z Cautions

Special tool Name

s r e h t O

48


Name

Q’ty

Assembly procedure

Connecting the brake line

No. 0300 1. Connect 3 hoses to the tube to be routed to the component box. 2. Connect 2 hoses to the joint hose to be routed to the front brake an d rear brake. 3. Connect 1 hose to the tube to be routed to the PPC pump.

Connect Tightening torque : 177 – 245 Nm {18.0 – 25.0 kgm}

Cab viewed from the left side



Connect Routed to the rear brake Tightening torque : 84 – 132 Nm {8.5 – 13.5 kgm}

Connect Routed to the front brake Tightening torque : 84 – 132 Nm {8.5 – 13.5 kgm}

Cautions

Special tool Name Torque wrench


Name

Q’ty

1

s r e h t O

49

Assembly procedure

No. 0310

Connecting the window washer hose

Cab viewed from the top

Front washer hose (Red taping)

Rear washer hose

Connect (Match the color)

View Z 1. Connect the washer hose (for the front and rear) being exit from the cab bottom to the frame side hose. (Confirm the red tape attached on the front washer hose.)

Cautions

Special tool Name

s r e h t O

50


Name

Q’ty

Assembly procedure

Connecting the PPC line hose

No. 0320

PPC control valve f e o d i s n e i n t c h o r F m a

Connect

Frame connection viewed from the top

Connect Connect

Connect 1. Connect 4 PPC line hoses. Make sure the Nos. (P1, P2, P3 and P4) are matching the band colors. 2. Connect a hose from the PPC relief valve. 3. Connect a hose from the hydraulic oil cooler.

View X

Connect From hydraulic oil cooler

Connect From PPC relief valve

View Z

Cautions

Special tool Name


Name

Q’ty

s r e h t O

51

Assembly procedure

Connecting the floor wiring harness

No. 0330

1. Remove (1) – (5) being temporarily installed on the floor support. 2. Connect the ground cable. (Before connecting the cable, check the connection for paint and rusts. If present, remove it before connecting the cable.) 3. Fix the steering lock switch harness. 4. Connect the connectors. (CN L39, CN L27)

Ground cable Connect Top view of the floor frame

No.

Part No.

Part name Q’ty

(1) 01024-81016

Bolt

1

(2) 04434-51410

Clip

1

(3) 01024-81020

Bolt

1

(4) 04434-51010

Clip

2

(5) 01024-81020

Bolt

1

State of part (Parts list No.) Installed temporarily on the floor support Installed temporarily on the floor support Installed temporarily on the floor support Installed temporarily on the floor support Installed temporarily on the floor support

Connect

Connect

View X

Connect Connect

Connect Connect

Connect

View Z

Cautions

Special tool Name

s r e h t O

52


Name

Q’ty

Assembly procedure

No. 0333

Connection of floor wiring harness -1 (Riotinto specification: If equipped)

Floor

Connection: CN CAB

Connection: CN CB1

Floor seen from rear

1. Connect the connectors. (CN CAB, CN CB1)

Cautions

Special tool Name


Name

Q’ty

s r e h t O

53

Assembly procedure

Connection of floor wiring harness -2 (Riotinto specification: If equipped)

No. 0334

Marked

: 3 places

Connection: CN RF

Cab seen from rear

1. Remove parts (1) – (3) installed to the cab. 2. Fix the wiring harness with parts (1) – (3). 3. Connect the connector. (CN RF) No. (1) (2) (3)

Part No. 421-877-2250 04434-51010 01024-81060

Part name Spacer Clip Bolt, sems

Q’ty State of part (Parts list No.) 3 Temporarily installed on the machine 3 Temporarily installed on the machine 3 Temporarily installed on the machine

Cautions

Special tool Name

s r e h t O

54


Name

Q’ty

Assembly procedure

Connecting the link for AJSS (For AJSS specification only)

No. 0340 a

This process is required for the AJSS specification only.

Tightening torque : 48 – 62 Nm {4.8 – 6.3 kgm}

Tightening torque : 156.9 – 196.1 Nm {16.0 – 20.0 kgm}

Front frame

For calibration procedure of the AJSS lever angle and frame offset angle, see No.0345. 1. Remove (1) and (2) being temporarily installed on the lever. 2. Connect the coupling rod connecting the front frame. 3. Connect the joint connecting the floor. No. (1) (2)

Part No. 01643-31445 01595-01411

Part name Washer Nut

Q’ty State of part (Parts list No.) 1 Temporarily installed on the lever 1 Temporarily installed on the lever

Cautions

Special tool Name


Name

Q’ty

s r e h t O

55

Assembly procedure

No. 0345

Calibration of the AJSS angle and frame offset angle

Adjusting connector Front side of machine

Front side of the right hand console

1. Set the machine and steering lever to the straight-travel state. 2. Stop the engine (set the starting switch to the OFF position) and set the steering lock lever to the lock position. 3. Pull out connector JL3 for neutral position adjustment situated in the right hand console. (See the figure above.) 4. Start the engine setting the starting switch to the 1st stage ON. 5. Connect the connector JL3 for the neutral position adjustment. 6. If beep of the buzzer is heard 1 second after, the adjustment is completed. a Don't try to operate the steering lever as long as the operations of Steps 4 – 6 are continued. (If the adjustment did not end normally, repeat from Step 1 again after making sure that the output voltage from both the steering lever angle sensor and the frame angle sensor is between 2.40 – 2.60 V.)

Cautions

Special tool Name

s r e h t O

56


Name

Q’ty

Assembly procedure

Assembling the auto-greasing pump and connecting the pipe (WA900-3E0 North American specification)

No. 0350

1. Remove (2) – (6) being temporarily installed on the platform. 2. Assemble the grease pump. 3. Connect 4 pipes.

Grease pump

Top view of the left platform

Connect

Connect

Section A-A

No. (1) (2) (3) (4) (5) (6)

Part No. 427-S95-A24A 01435-01045 415-64-13120 415-64-13130 421-62-18560 419-43-17930

Part name Q’ty State of part (Parts list No.) Hydraulic pump assembly 1 Separately packed (No.W9E-350) Bolt 4 Temporarily installed on the platform Washer 8 Temporarily installed on the platform Cushion 4 Temporarily installed on the platform Spacer 4 Temporarily installed on the platform Cushion 4 Temporarily installed on the platform

Cautions

Special tool Name


Name

Q’ty

s r e h t O

57

Assembly procedure

Assembling the floor cover

No. 0360

Floor frame

1. Remove (2) and (5) – (8) being temporarily installed on the floor. 2. Assemble floor cover (1).

Floor support

3. Assemble floor covers (3) and (4).

No. (1) (2) (3) (4) (5) (6) (7) (8)

Part No. 427-54-24311 01024-81020 427-54-24321 427-54-24331 01024-81025 424-09-12650 427-S95-5250 01024-81020

Part name Cover Bolt Cover (L.H.) Cover (R.H.) Bolt Washer Cover Bolt

Q’ty 1 4 1 1 6 6 1 7

State of part (Parts list No.) Separately packed (No.W9E-360) Temporarily installed on the floor Separately packed (No.W9E-360) Separately packed (No.W9E-360) Temporarily installed on the floor Temporarily installed on the floor Temporarily installed on the floor Temporarily installed on the floor

Cautions

Special tool Name

Q’ty

Impact wrench

1

Socket (17 mm)

1

s r e h t O

58


Q’ty

Assembly procedure

Refilling the window washer

No. 0370

Washer tank position (In the bulkhead)

Water filler port

1. Open the cover in the front side of the bulkhead, and then pour 2l of washer liquid (KES product) and tap water (soft water) to the window washer tank.

Cautions

Special tool Name


Name

Q’ty

s r e h t O

59

Assembly procedure

Assembling the battery box

No. 0380

1. Remove (3) – (5) being temporarily installed on the rear frame. 2. Assemble battery box assemblies (1) and (2) to the frame. 3. Assemble bolt (6) situated in the disaster prevention cover.

View X

Rear frame

View Z No. (1) (2) (3) (4) (5) (6)

Part No. 427-06-2463A 427-06-2464A 01011-62450 01011-62470 01643-32460 01024-D1225

Part name Battery box, L.H. battery box, R.H. Bolt Bolt Washer Bolt

Q’ty 1 1 4 4 8 4

Cautions

State of part (Parts list No.) Separately packed (No.W9E-380) Separately packed (No.W9E-380) Temporarily installed on the rear frame Temporarily installed on the rear frame Temporarily installed on the rear frame Separately packed (No.W9E-380) Special tool Name

Impact wrench Socket (19 mm, 36 mm)

s r e h t O

60


Name

Q’ty

Assembly procedure

Connecting and fixing the battery wiring

No. 0390

1. Referencing the following figure, connect and fix the wiring in the battery box.

Left side of the battery box

Right side of the battery box

Connect Connect

View X

View Y

View A Cautions Q

After wiring the ground cable, connect it to the battery just before starting the engine.

View B No. (1) (2) (3) (4) (5) (6) (7)

Part No. 08038-00035 424-09-12530 04434-51410 04434-51710 04434-51910 04434-52310 01024-81020

Part name Cap Cap Clip Clip Clip Clip Bolt

Q’ty 2 2 3 1 3 1 6

State of part (Parts list No.) Separately packed (No.W9E-390) Temporarily installed on t he battery box Temporarily installed on t he battery box Temporarily installed on t he battery box Temporarily installed on t he battery box Temporarily installed on t he battery box Temporarily installed on t he battery box

s r e h t O

61

Assembly procedure

Wiring on right side of battery (Riotinto specification: If equipped)

No. 0393

Connection: Check mark "4". Removal of boot and connection: Check mark "1".

Connection: Check mark "2". Wiring harness

Connection R.H. battery box

View X Detail of R.H. battery box

Connection: CN RA1

Connection: CN RA3

Connection: Check mark "6".

L.H. battery box

Fixing: Use bolts and clips installed temporarily.

Detail of part P

View Z

1. Connect the wiring on the right side of the battery. No. (1) (2) (3)

Part No. 08038-00035 04434-51710 01024-81020

Part name Cap Clip Bolt, sems

Q’ty State of part (Parts list No.) 1 Temporarily installed on the machine 1 Temporarily installed on the machine 1 Temporarily installed on the machine

Cautions

Special tool Name

1. Install each wiring harnesses so that it will not cross other wiring harnesses, and then clamp and connect it to the correct position.

s r e h t O

62


Name

Q’ty

Assembly procedure

Wiring on left side of battery -1 (Riotinto specification: If equipped)

No. 0394

Pull wiring harness into L.H. battery box

Shorter end

L.H. battery box Longer end

Pull cable into L.H. battery box

Marked : 4 places

Check mark "1". Check mark "2". Check mark "3".

Check mark "4". Check mark "5".

View Z: Machine seen from below

1. Pull the wiring into the battery on the left side. No. (1) (2)

Part No. 6151-53-8280 01024-81020

Part name Clip Bolt, sems

Q’ty State of part (Parts list No.) 4 Temporarily installed on the machine 4 Temporarily installed on the machine

Cautions

Special tool Name


Name

Q’ty


s r e h t O

63

Assembly procedure


No. 0395

L.H. battery box

Removal and connection of boot: Check mark "1". Removal and connection of boot: Check mark "2".

Fixing: Use bolt and clip installed temporarily.

Fixing: Use bolt and clip installed temporarily.

Connection: CN RA4 Connection: CN RA2

Connection: CN R09 Fixing: Use bolt and clip installed temporarily.

Detail

Section A-A Fixing: Use bolt and clip installed temporarily.

Fixing: Use bolt and clip installed temporarily. Removal and connection of boot: Check mark "4". Removal and connection of boot: Check mark "3".

1. Connect the wiring in th e L.H. battery.

View Z

Removal and connection of boot: Check mark "5".

Cautions

Special tool Name


s r e h t O

64


Name

Q’ty

Assembly procedure


No. 0396

R.H. battery box

L.H. battery box

Connection: CN V101 Black (–)

Connection: CN V102 Red (+)

Connection: CN EM41 Connection: CN EM42

Section A-A 1. Connect the wiring on the left side of the battery No. (1) (2)

Part No. 6151-53-8280 01024-81020

Part name Clip Bolt, sems

Q’ty State of part (Parts list No.) 2 Temporarily installed on the machine 2 Temporarily installed on the machine

Cautions

Special tool Name


Name

Q’ty


s r e h t O

65

Assembly procedure

No. 0397

Connection of ground cable on left side of battery (Riotinto specification: If equipped)

View Z: Machine seen from below

L.H. battery box seen from rear

1. Connect the ground cable on the left side of the battery. No. (1)

Part No. 01024-81020

Part name Bolt, sems

Q’ty State of part (Parts list No.) 2 Temporarily installed on the machine

Cautions

Special tool Name

1. Install each wiring harnesses so that it will not cross other wiring harnesses, and clamp and connect it to the correct position. 2. The ground cable connecting areas must be free from dirt and paint.

s r e h t O

66


Name

Q’ty

Assembly procedure

Assembling the battery step

No. 0400

1. Remove (3), (4) and (6) being temporarily installed on the rear frame, fuel tank and battery box. 2. Assemble the step to the right side of the machine.

Battery box R.H. Fuel tank

3. Assemble the step to the left side of the machine.

Battery box L.H.

Fuel tank

No. (1) (2) (3) (4) (5) (6)

Part No. 427-54-26770 427-54-26780 01024-D1235 01024-D1245 427-54-2933A 01024-81235

Part name Step (R.H.) Step (L.H.) Bolt Bolt Step assembly Bolt

Q’ty 1 1 6 2 2 8

State of part (Parts list No.) Separately packed (No.W9E-400) Separately packed (No.W9E-400) Temporarily installed on the rear frame Temporarily installed on the fuel tank Separately packed (No.W9E-400) Temporarily installed on the battery box

Cautions

Special tool Name


Impact wrench

1

Socket (19 mm)

1

Name

Q’ty

s r e h t O

67

Assembly procedure

Installation of oil cooler assembly (Brake cooling specification: If equipped)

No. 0403


Oil cooler

Tightening torque 54 – 123 Nm {5.5 – 12.5 kgm} Tightening torque 54 – 123 Nm {5.5 – 12.5 kgm}

1. Install oil cooler assembly (1) to the right platform. No. (1) (2) (3)

Part No. 427-S05-489A 01024-81245 01024-81235

Part name Q’ty State of part (Parts list No.) Oil cooler assembly 1 Separately packed (No. W9E-403) Bolt, sems 4 Separately packed (No. W9E-403) Bolt, sems 2 Separately packed (No. W9E-403)

Cautions

Special tool Name

s r e h t O

68


Name

Q’ty

Assembly procedure

No. 0404

Installation and connection of oil cooler assembly piping (Brake cooling specification: If equipped)

Connection: Check O-ring. Connection: Check O-ring.

View Z

1. Connect the oil cooler assembly piping. No. (1) (2)

Part No. 07000-F3035 01024-81035

Part name O-ring Bolt, sems

Q’ty State of part (Parts list No.) 2 Separately packed (No. W9E-404) 4 Separately packed (No. W9E-404)

(3)

07371-31255

Flange

4

Temporarily installed on the oil cooler assembly

(4)

07375-21035

Bolt, sems

8

Temporarily installed on the oil cooler assembly

Cautions

Special tool Name


Name

Q’ty

s r e h t O

69

Assembly procedure

Installation of oil cooler assembly piping -1 (Brake cooling specification: If equipped)

No. 0406 Connection: O-ring



Bulkhead Right platform

Rear frame seen from right Oil cooler

Connection

Rear frame seen from front

1. Connect the oil cooler assembly piping. No. (1) (2) (3) (4) (9)

Part No. 427-S05-5630 427-S05-5590 427-S05-5650 427-S05-5580 02896-21018

Part name Tube Tube Tube Tube O-ring

Q’ty 1 1 1 1 3

State of part (Parts list No.) Separately packed (No. W9E-406) Separately packed (No. W9E-406) Separately packed (No. W9E-406) Installed to machine Separately packed (No. W9E-406)

Cautions

Special tool Name

s r e h t O

70


Name

Q’ty

Assembly procedure

No. 0407

Installation of oil cooler assembly piping -2 (Brake cooling specification: If equipped)

a

Connect each tube (8 places in total).

Connection (4 pieces): Check O-ring.

Check mark (white tape).

1. Connect the oil cooler assembly piping.

Cautions

Special tool Name


Name

Q’ty

s r e h t O

71

Assembly procedure

No. 0410

Assembling the handrail (On the right hand platform)

Rear frame

1. Remove the parts being temporarily installed. 2. Assemble handrails (1) and (3) to the right side of the machine. 3. Hitch the cable on handrail (1). No. (1) (2) (3) (4) (5) (6) (7) (8)

Part No. 427-54-29270 01024-D1235 427-54-25861 01024-D1235 426-54-42310 426-54-35220 426-54-35320 23S-07-11160

Part name Handrail Bolt Handrail Bolt Hose Cable Joint Catcher

Q’ty 1 11 1 11 1 1 1 1

State of part (Parts list No.) Separately packed (No.W9E-410) Temporarily installed on the right platform Separately packed (No.W9E-410) Temporarily installed on the right platform Temporarily installed on the handrail (3) Temporarily installed on the handrail (3) Temporarily installed on the handrail (3) Temporarily installed on the handrail (3)

Cautions

Special tool Name

Q’ty

Impact wrench

1

Socket (19 mm)

1

s r e h t O

72


Q’ty

Assembly procedure

Installation of handrail (Right platform area) (Brake cooling specification: If equipped)

No. 0411

1. Remove the parts installed temporarily. 2. Install handrails (1) and (3) to the right side of the machine. 3. Hook the cable to handrail (1). No. (1) (2) (3) (4) (5) (6) (7) (8) (9)

Part No. 427-54-2952A 01024-D1235 427-S05-5790 01024-D1235 01024-D1235 426-54-42310 426-54-35220 426-54-35320 23S-07-11160

Part name Handrail Bolt, sems Handrail Bolt, sems Bolt, sems Hose Cable Joint Catcher

Q’ty 1 11 1 2 2 1 1 1 1

State of part (Parts list No.) Separately packed (No. W9E-411) Temporarily installed on the right platform Separately packed (No. W9E-411) Temporarily installed on the right platform Separately packed (No. W9E-411) Temporarily installed on the handrail (3) Temporarily installed on the handrail (3) Temporarily installed on the handrail (3) Temporarily installed on the handrail (3)

Cautions

Special tool Name


Name

Q’ty

s r e h t O

73

Assembly procedure

No. 0420

Assembling the handrail (On the hood top face) Insert handrail (7) to handrail (9).

Rear frame

1. Remove the parts being temporarily installed. 2. Insert handrail (7) to handrail (9) as shown in the figure above and then assemble them. 3. Assemble handrail (1). 4. Using (3) – (6), fix handrail (1) and handrail (7) as shown in the figure above. No. (1) (2) (3) (4) (5) (6) (7) (8) (9) (10)

Part No. 427-54-25870 01024-D1235 207-62-54770 01024-D1030 01643-31032 01580-11008 427-54-29370 01024-D1235 427-54-25880 01024-D1235

Part name Handrail Bolt Clamp Bolt Washer Nut Handrail Bolt Handrail Bolt

Q’ty 1 6 2 1 1 1 2 16 1 12

State of part (Parts list No.) Separately packed (No.W9E-420) Temporarily installed on the machine Temporarily installed on the handrail Temporarily installed on the handrail Temporarily installed on the handrail Temporarily installed on the handrail Separately packed (No.W9E-420) Temporarily installed on the machine Separately packed (No.W9E-420) Temporarily installed on the machine

Cautions


s r e h t O

74


Name

Q’ty

Assembly procedure

Assembling the handrail (On the right hand battery box)

No. 0430

Rear frame

1. Remove the parts being temporarily installed. 2. Assemble handrails (1) and (4) as shown in the figure above. No. (1) (2) (3) (4) (5)

Part No. 427-54-25821 01024-D1230 01024-D1235 427-54-25180 01024-D1235

Part name Handrail R.H. Bolt Bolt Handrail R.H. Bolt

Q’ty 1 4 4 1 4

State of part (Parts list No.) Separately packed (No.W9E-430) Temporarily installed on the right battery box Temporarily installed on the right battery step and rear frame Separately packed (No.W9E-430) Temporarily installed on the right battery box

Cautions

Special tool Name


Impact wrench

1

Socket (19 mm)

1

Name

Q’ty

s r e h t O

75

Assembly procedure

Assembling the rear access step

No. 0440

Detail of the bolts assembling in the floor and step connections

(They are tightened together with bracket (5).)

8 places

Fix the covers to each other Detail of the bolts assembling in the step and battery box connections View from the bottom

1. Remove Remove (2) (2) and (3) (3) being being tempor temporari arily ly installed on the machine. 2. Assembl Assemble e floor floor assembl assemblyy (1) using using (2) (2) and (3). (3). 3. Remove Remove (5) (5) – (8) being being tempo temporarily rarily installed installed on step assembly (4). 4. Remove Remove (9) and (10) being temporari temporarily ly Part name Q’ty State of part (Parts list No.) installed on the left hand battery box. Floor assembly 1 Separ Separat atel ely y packed packed (No. (No.W9 W9E-4 E-440 40)) Bolt 8 Temporarily in installed on the machine 5. Assemble step assembly (4) using (6) – (10). Washer 8 Temporarily installed on the machine In this step, assemble bracket (5), too, Step assembly 1 Separ Separat atel ely y packed packed (No. (No.W9 W9E-4 E-440 40)) referencing the figure above. Bracket 1 Temporarily installed on the step assembly (4) 6. Remove Remove (14) (14) being being tempo temporarily rarily installed installed on Bolt 8 Temporarily installed on the step assembly (4) step assembly (4) cover. Bolt 2 Temporarily installed on the step assembly (4) 7. Remove Remove (12) (12) and (13) (13) being temporaril temporarily y Washer 10 Temporarily installed on the step assembly (4) installed on the machine and floor assembly Bolt 6 Temporarily installed on the left battery box (1). Washer 6 Temporarily installed on the left battery box 8. Assemble Assemble cover cover (11) (11) using using (12) (12) and (13). Cover 1 Separately packed (No.W9E-440) 9. Fix cover cover (11) and and step step assembly assembly (4) cover cover Temporarily installed on the machine Bolt 6 and floor assembly (1) to each other using bolt (14).

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

Part No. 427-54-2592A 01010-81435 01643-31445 427-54-2475A 427-54-25340 01010-81435 01010-81445 01643-31445 01010-81635 01643-31645 427-54-24191

(12)

01024-81225

(13)

124-54-26540

Washer

6

Temporarily installed on the machine and floor assembly (1)

(14)

01024-81220

Bolt

6

Temporarily installed on the step assembly (4)

Cautions

Special tool Name Impact wrench Socket (19 mm, 22 mm) s r e h t O

76


Name

Q’ty

Assembly procedure

Assembling the left handrail (Part 1)

No. 0450

View Z

1. Remove Remove (2) being being temporari temporarily ly installed installed on on the machine. machine.

Detail of A

2. Assem Assemble ble handra handrail il (1). (1). 3. Remove Remove (7), (8), (8), (9), (11) (11) and (12) (12) being being temporaril temporarily y installed installed on the machine and bracket (see detail of A). 4. Assemble Assemble handrail handrail (6) using (7) and (8) (8) (for the assembling position, see view Z). 5. Fix handrai handraill (6) using using (9) – (12). (12). (See (See detail detail of A) 6. Assemble Assemble mudguard mudguard (4) (4) using using (3) (3) and (5).

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

Part No. 427-54-25170 01024-D1235 427-54-21560 427-54-21571 01024-D1025 427-54-29280 01024-D1230 01024-D1235 07283-33450 07283-53444 01597-01009 01643-31032

Part name Handrail Bolt Plate Rubber Bolt Handrail Bolt Bolt Clip Seat Nut Washer

Q’ty 1 4 1 1 3 1 2 6 1 1 2 2

State of part (Parts list No.) Separately pa packed (N (No.W9E-450) Temporarily installed on the machine Separately packed (No.W9E-450) Separately pa packed (N (No.W9E-450) Separately packed (No.W9E-450) Separately pa packed (N (No.W9E-450) Separately packed (No.W9E-450) Temporarily installed on the machine Temporarily installed on the bracket Separately packed (No.W9E-450) Temporarily installed on the bracket Temporarily installed on the bracket

Cautions



Name

Q’ty

1 1 each

s r e h t O

77

Assembly procedure

Assembling the left handrail (Part 2)

No. 0460

Detail of B (2 places)

1. Remove Remove (2) being being tempora temporarily rily install installed ed on the machin machine. e. 2. Assem Assemble ble handr handrail ail (1) (1) using using (2). (2). 3. Remove Remove (4) being being tempora temporarily rily install installed ed on the machin machine. e. 4. Assem Assemble ble handr handrail ail (3) (3) using using (4). (4). 5. Remove Remove (6) being being tempora temporarily rily install installed ed on the machin machine. e. 6. Assem Assemble ble handr handrail ail (5) (5) using using (6). (6). No. (1) (2) (3) (4) (5) (6)

Part No. 427-54-29260 01024-D1235 427-54-25851 01024-D1235 427-54-25811 01024-D1230

Part name Handrail Bolt Handrail Bolt Handrail Bolt

Q’ty 1 10 1 22 1 14

State of part (Parts list No.) Separately pa packed (N (No.W9E-460) Temporarily installed on the machine Separately pa packed (N (No.W9E-460) Temporarily installed on the machine Separately pa packed (N (No.W9E-460) Temporarily installed on the machine

Cautions

Special tool Name

Q’ty

Impact wrench

1

Socket (19 mm)

1

s r e h t O

78


Q’ty

Assembly procedure

Installation Installation of left handrail (Part 2) (Brake cooling specification: If equipped)

No. 0461

Detail of B (2 places)

1. Remove part (2) installed to th e machine. 2. Install handrail (1) with part (2). 3. Remove part (4) installed to th e machine. 4. Install handrail (3) with part (4). 5. Remove part (6) installed to th e machine. 6. Install handrail (5) with part (6). No. (1) (2) (3) (4) (5) (6)

Part No. 427-54-2951A 01024-D1235 427-54-25851 01024-D1235 427-54-25811 01024-D1230

Part name Handrail Bolt Handrail Bolt Handrail Bolt

Q’ty 1 10 1 22 1 14

State of part (Parts list No.) Separately packed (No.W9E-461) Temporarily installed on the machine Separately pa packed (N (No.W9E-461) Temporarily installed on the machine Separately pa packed (N (No.W9E-461) Temporarily installed on the machine

Cautions

Special tool Name


Impact wrench

1

Socket (19 mm)

1

Name

Q’ty

s r e h t O

79

Assembly procedure

Assembling the rearview mirror

No. 0470

Detail of the mirror adjustment

1. Remove Remove (3) and and (4) being being temporar temporarily ily installed installed on the cab. cab. 2. Assemble Assemble right right and left left mirror mirror stays (1) (1) and (2) using using (3) and (4). (4). 3. Assemble Assemble mirror mirror (5) to the assemble assembled d mirror stay stay and then fix them them using using (6). 4. Adjust Adjust the mirror mirror angle referen referencing cing the the detail of mirror mirror adjustm adjustment ent (figure to the left).

Detail of the mirror adjustment No. (1) (2) (3) (4) (5) (6)

Part No. 426-54-25710 426-54-25720 01435-01025 363-54-31450 421-54-25610 04025-00632

Part name Stay (L.H.) Stay (R.H.) Bolt Cap Mirror Spring pin

Q’ty 1 1 8 8 2 2

State of part (Parts list No.) Separately packed (No.W9E-470) Separately packed (No.W9E-470) Temporarily installed on the cab Temporarily installed on the cab Separately pa packed (N (No.W9E-470) Separately packed (No.W9E-470)

Cautions

Special tool Name Spanner (17 mm)

s r e h t O

80


Name

Q’ty

Assembly procedure

Installation of rearview mirrors (Brake cooling specification: If equipped)

No. 0471

a

Work on right and left sides similarly.

1. Remove parts (2) and (3) installed to rearview mirror (1). 2. Install rearview mirror (1) to the handrail and fix it with parts (2) and (3). (Work on the right and left sides similarly.) 3. Adjust the mirror angle. No. (1) (2) (3)

Part No. 56B-54-17311 (56B-54-17311) (56B-54-17311)

Part name Mirror Nut Washer

Q’ty State of part (Parts list No.) 2 Separately packed (No. W9E-471) 4 Accessory to part (1) 4 Accessory to part (1)

Cautions

Special tool Name Spanner (24 mm)


Name

Q’ty

1

s r e h t O

81

Assembly procedure

Assembling the exhaust pipe

No. 0480

1. Remove (2) being temporarily installed on the hood. 2. Assemble exhaust pipe (1) using (2). No. (1) (2)

Part No. 427-02-21140 01024-81240

Part name Exhaust pipe Bolt

Q’ty State of part (Parts list No.) 2 Separately packed (No.W9E-480) 12 Temporarily installed on the front hood

Cautions

Special tool Name

Q’ty

Impact wrench

1

Socket (19 mm)

1

s r e h t O

82


Q’ty

Assembly procedure

No. 0485

Installation of oil cooler guard assembly (Brake cooling specification: If equipped)

Tightening torque: 54 – 122.5 Nm {5.5 – 12.5 kgm}

1. Remove the front cover of the oil cooler guard assembly. 2. Install the oil cooler guard assembly with bolts (2). 3. Install the cover removed in 1 again. No. (1) (2)

Part No. 41F-S05-173A 01024-81225

Part name Guard assembly Bolt, sems

Q’ty State of part (Parts list No.) 1 Separately packed (No. W9E-485) 6 Separately packed (No. W9E-485)

Cautions

Special tool Name


Name

Q’ty

s r e h t O

83

Assembly procedure

Installation of fan motor piping cover -1 (Brake cooling specification: If equipped)

No. 0486

1. Install the oil cooler piping cover. No. (1) (2) (3) (4) (5)

Part No. 427-S05-3410 427-S05-3391 427-S05-3441 01024-81225 01024-81230

Part name Cover Cover Cover Bolt, sems Bolt, sems

Q’ty 1 1 1 12 4

State of part (Parts list No.) Separately packed (No. W9E-486) Separately packed (No. W9E-486) Separately packed (No. W9E-486) Separately packed (No. W9E-486) Separately packed (No. W9E-486)

Cautions

Special tool Name

s r e h t O

84


Name

Q’ty

Assembly procedure

Installation of fan motor piping cover -2 (Brake cooling specification: If equipped)

No. 0487

Tightening torque: 34 – 74 Nm {3.5 – 7.5 kgm} Tightening torque: 34 – 74 Nm {3.5 – 7.5 kgm}

1. Install the cover to the right platform bottom. No. (1) (2) (3) (4)

Part No. 427-S05-5190 01024-D1025 41F-S05-1491 01024-D1225

Part name Cover Bolt, sems Cover Bolt, sems

Q’ty 1 8 1 4

State of part (Parts list No.) Separately packed (No. W9E-487) Separately packed (No. W9E-487) Separately packed (No. W9E-487) Separately packed (No. W9E-487)

Cautions

Special tool Name


Name

Q’ty

s r e h t O

85

Assembly procedure

Applying the counterweight anti-slip

No. 0490

1. Sufficiently clean the application surface and dry it. If the surface if fouled with oil, clean it off using detergent, too. 2. It is advisable to give a mark, using a felt pen, on the application position. 3. Remove the protective cover on the backside. 4. Apply the anti-slip decal. Use care when applying it so that fingers may not touch the adhesive. 5. In order to paste it up securely, press the anti-slip plate using a roller from the center of the plate toward the brim. 6. Apply adhesive "LT-1A" in the perimeter of the anti-slip plate. No. (1)

Part No. 417-06-11321

Part name Plate


Cautions

Special tool Name

s r e h t O

86


Name

Q’ty

Assembly procedure

Assembling the counterweight (WA900-3E0 standard specification)

No. 0500

Tightening torque: 1,520 – 1,910 Nm {155 – 195 kgm}

2,890 kg

Rear frame

2,890 kg 1. Remove (2), (3), (5), (6) and (8) being temporarily installed in the rear part of the rear frame. 2. Assemble counterweight (1) using (2) and (3). 3. Assemble counterweight (4) using (5) and (6). 4. Assemble cover (7) using (8). 5. Insert pin (9). No. (1) (2) (3) (4) (5) (6) (7) (8) (9)

Part No. 427-46-25311 427-46-25150 01643-33080 427-46-25321 198-30-37320 01643-33080 427-54-25332 01024-D1230 427-46-13120

Part name Counterweight Bolt Washer Counterweight Bolt Washer Cover Bolt Pin

Q’ty 1 4 4 1 6 6 1 4 1

State of part (Parts list No.) Separately packed (No.W9E-500) Temporarily installed on the rear part of the rear frame Temporarily installed on the rear part of the rear frame Separately packed (No.W9E-500) Temporarily installed on the rear part of the rear frame Temporarily installed on the rear part of the rear frame Separately packed (No.W9E-500) Temporarily installed on the rear part of the rear frame Separately packed (No.W9E-500)

Cautions

Special tool Name


Torque wrench

1

Socket 46 mm

1

Extension

1

Impact wrench (for M30)

1

Name

Q’ty

s r e h t O

87

Assembly procedure

Assembling the counterweight (WA900-3E0 High-lift arm specification)

No. 0505

1,600 kg

2,890 kg

1,298 kg Rear frame

1. Remove (2), (3), (5), (6), (8), (9), (10) and (13) being temporarily installed in the rear part of the rear frame. 2. Assemble counterweight (1) using (2) and (3). 3. Assemble counterweight (4) using (5) and (6). 4. Assemble spacer (8). 4. Assemble counterweight (7) using (9) and (10). 5. Insert pin (11). 6. Assemble cover (12) using (13).

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

Part No. 427-46-25370 425-974-1171 01643-33080 427-46-25321 427-T88-1131 01643-33080 427-975-2110 427-97-51120 419-09-11180 426-09-11510 427-46-13120 427-46-25350 01024-D1225

Part name Counterweight Bolt Washer Counterweight Bolt Washer Counterweight Spacer Bolt Washer Pin Cover Bolt

Cautions

Q’ty 1 4 4 1 6 6 1 4 4 4 1 1 2

State of part (Parts list No.) Separately packed (No.W9E-505) Temporarily installed on the rear part of the rear frame Temporarily installed on the rear part of the rear frame Separately packed (No.W9E-505) Temporarily installed on the rear part of the rear frame Temporarily installed on the rear part of the rear frame Separately packed (No.W9E-505) Temporarily installed on the rear part of the rear frame Temporarily installed on the rear part of the rear frame Temporarily installed on the rear part of the rear frame Separately packed (No.W9E-505) Temporarily installed on the rear part of the rear frame Temporarily installed on the rear part of the rear frame

Special tool Name

s r e h t O

88


Name

Q’ty

Assembly procedure

No. 0510

Assembling the counterweight (WA800-3E0 Overseas general, optional specification and North American specification)


1,600 kg

Tightening torque: 823 – 1,030 Nm {84 – 94.5 kgm}

Rear frame

2,890 kg 1. Remove (2), (3), (5), (6) and (7) being temporarily installed in the rear part of the rear frame. 2. Assemble counterweight (1) using (2) and (3). 3. Assemble spacer (5). 4. Assemble counterweight (4) using (6) and (7). 5. Insert pin (8). No. (1) (2) (3) (4) (5) (6) (7) (8)

Part No. 427-46-25321 198-30-37320 01643-33080 427-975-2110 427-975-1120 419-09-11180 426-09-11510 427-46-13120

Part name Counterweight Bolt Washer Counterweight Spacer Bolt Washer Pin

Q’ty 1 6 6 1 4 4 4 1

State of part (Parts list No.) Separately packed (No.W9E-510) Temporarily installed on the rear part of the rear frame Temporarily installed on the rear part of the rear frame Separately packed (No.W9E-510) Temporarily installed on the rear part of the rear frame Temporarily installed on the rear part of the rear frame Temporarily installed on the rear part of the rear frame Separately packed (No.W9E-510)

Cautions

Special tool Name


Torque wrench

1

Socket 46 mm

1

Extension

1


1

Name

Q’ty

s r e h t O

89

Assembly procedure

Assembling the counterweight (WA800-3E0 Overseas general standard specification)

No. 0520


Rear frame

2,890 kg

1. Remove (2) and (3) being temporarily installed in the rear part of the rear frame. 2. Assemble counterweight (1) using (2) and (3). 3. Insert pin (4). No. (1) (2) (3) (4)

Part No. 427-46-25321 198-30-37320 01643-33080 427-46-13120

Part name Counterweight Bolt Washer Pin

Q’ty 1 6 6 1

State of part (Parts list No.) Separately packed (No.W9E-520) Temporarily installed on the rear frame Temporarily installed on the rear frame Separately packed (No.W9E-520)

Cautions

Special tool Name

Q’ty

Torque wrench

1

Socket 46 mm

1

Extension

1


1

s r e h t O

90


Q’ty

Assembly procedure

Assembling the front axle lamp and connecting the harness

No. 0530

Front frame

Connect CN FAR

Connect CN FAL

View Z

1. Remove (2) being temporarily installed on the front frame. 2. Assemble front axle lamp assembly (1) using (2). 3. Referencing view Z, connect the harness. No. (1) (2)

Part No. 427-06-2525A 01024-81225

Part name Work lamp Bolt

Q’ty State of part (Parts list No.) 1 Separately packed (No.W9E-530) 4 Temporarily installed on the front frame

Cautions

Special tool Name


Name

Q’ty

s r e h t O

91

Assembly procedure

Assembling the front lamp assembly

No. 0540

1. Remove (3) being temporarily installed on the front frame. 2. Assemble right and left front lamp assemblies (1) and (2) using (3). 3. Fix the harness of the front lamp and then connect the connector referencing the figure below.

Connect CN F01, CN HF1 Connect CN F04, CN HF1

Fix here Fix here

Connect CN F02, CN HF2

Connect CN F03, CN HF2

Front frame viewed from the inner right side

Front frame viewed from the inner left side No. (1) (2) (3)

Part No. 427-06-2311A 427-06-2312A 01024-81245

Part name Left front lamp Right front lamp Bolt

Q’ty State of part (Parts list No.) 1 Separately packed (No.W9E-540) 1 Separately packed (No.W9E-540) 8 Temporarily installed on the right and left of front frame

Cautions

Special tool Name

Q’ty

Impact wrench

1

Socket (19 mm)

1

s r e h t O

92


Q’ty

Assembly procedure

Assembling the ROPS canopy assembly

No. 0550

2 different colors are used for the ROPS canopy WA800-3E0 - Natural yellow WA900-3E0 - Black gray Lifting tool: 2 point lift (Lifting load: 1.42 t) (The lifting tool used for the tool and cab assembly is also used here)


1. Remove cover (1) being temporarily installed on the machine using (2). 2. Remove (4) and (5) being temporarily installed on the machine. 3. Clean the contact face of ROPS canopy assembly (3) mount. 4. Assemble ROPS canopy (3) using (4) and (5). 5. Using (2), assemble cover (1) currently being removed to the original position.

a Clean

No. (1) (2) (3) (4) (5)

Part No. 427-54-25951 01024-D1230 427-921-229A 01011-63650 01643-33690

Part name Cover Bolt ROPS canopy Bolt Washer

Q’ty 2 8 1 20 20

the contact face of the mount before assembling.

State of part (Parts list No.) Temporarily installed on the machine Temporarily installed on the machine Separately packed (No.W9E-550) Temporarily installed on the machine Temporarily installed on the machine

Cautions

Special tool Name



1

Socket (55 mm)

1

Extension

1

Torque wrench

1

Name

Q’ty

s r e h t O

93

Assembly procedure

Assembling the antenna and work lamp

No. 0560

Remove the antenna being temporarily installed on the cab and assemble it to the canopy.

Extend the antenna line from the cab

Step lamp (Backside of upper left side of ROPS)

Install it setting the slit at the bottom and then coat the entire perimeter with Cemedine 366E or equivalent.

Lamp assembly Tightening torque : 17.6 – 19.6 Nm {1.8 – 2.0 kgm} Assembled to the bracket being already assembled to the cab assembly

Side lamp (On both side of ROPS) Assembled to the bracket being already assembled to the cab assembly

Connect CN SL5

Lead the harness on the cab ceiling to connect it to the lamp.

Connect CN C17

1. Assemble lamp (1) and tighten it to the specified torque. 2. Lead the harness on the cab ceiling to connect it to the lamp. 3. Remove the antenna being temporarily installed on the cab and assemble it to the ROPS. No. (1)

Part No. 22B-06-11690

Part name Lamp assembly


Cautions

Special tool Name

s r e h t O

94


Name

Q’ty

Assembly procedure

Assembling the VHMS antenna (For VHMS specification only)

No. 0570

Connect

7 places with mark

View Z

Cab viewed from the left side 1. Remove (1) and (2) being temporarily installed on the ROPS canopy assembly. 2. Fix the VHMS antenna harness as shown in the figure above. 3. Assemble bracket (4) using (5) as shown in the view Z. 4. Fix antenna (3) to the bucket. 5. Connecting the VHMS harness to the antenna. No. (1) (2) (3) (4) (5)

Part No. 04434-50810 01024-81020 8A13-10-2100 7826-21-1210 01024-81020

Part name Clip Bolt Antenna sat Bracket Bolt

Q’ty 7 7 1 1 2

State of part (Parts list No.) Temporarily installed on the ROPS canopy assembly Temporarily installed on the ROPS canopy assembly Separately packed (No.W9E-570) Separately packed (No.W9E-570) Temporarily installed on the ROPS canopy assembly

Cautions

Special tool Name


Impact wrench

1

Socket (17 mm)

1

Name

Q’ty

s r e h t O

95

Assembly procedure

Assembling the floor mat

No. 0580

1. Fit in sheet (1) to the floor frame as shown in the above figure. 2. Spread floor mat (2) as shown in the above figure. No. (1) (2)

Part No. 427-54-26480 427-54-26460

Part name Sheet Mat


Cautions

Special tool Name

s r e h t O

96


Name

Q’ty

Assembly procedure

Assembling the front fender

No. 0590

1. Remove (3) – (9) being temporarily installed on the front frame. 2. Remove (10) – (12) being temporarily installed on right and left front fenders (1) and (2). 3. Assemble right and left front fenders (1) and (2) to the front frame using (3) and (4). 4. Assemble right and left brackets (5) and (6) to the front fender using (7) – (11). 5. Assemble (12) to the original position.

81.6 kg

81.6 kg No. (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12)

Part No. 427-54-26810 427-54-26820 01010-81635 01643-31645 427- 54- 13380 427- 54-13410 01010-81245 01010-81230 01643-31232 01010-81230 124-54-26540 09415-05016

Part name Fender (L.H.) Fender (R.H.) Bolt Washer B rac ket (L.H.) B rack et (R.H.) Bolt Bolt Washer Bolt Washer Cap

Q’ty 1 1 6 6 1 1 4 4 8 16 16 6

State of part (Parts list No.) Separately packed (No.W9E-590) Separately packed (No.W9E-590) Temporarily installed on the front frame Temporarily installed on the front frame Tempor ari ly instal led on the front fr ame Tempor ari ly instal led on the front fr ame Temporarily installed on the front frame Temporarily installed on the front frame Temporarily installed on the front frame Temporarily installed on the front fender (right and left) Temporarily installed on the front fender (right and left) Temporarily installed on the front fender (right and left)

Cautions


View Z

(Detail of bolts assembling position) Necessary Equipment

Q’ty

Name

Q’ty

1 1 each

s r e h t O

97

Assembly procedure

Engine starting procedure

No. 0600

1. Check the current oil and coolant level and supply them to respective components • Amount of coolant 1. Supply coolant until the radiator is filled up. 2. Make sure that 40l of coolant is contained in the sub-tank after the radiator has been filled up. • Amount of oil in the engine oil pan and brake oil tank Reference: Total amount of lubricating oil: When engine is stopped Low level: 118l High level: 138l Lubricating oil refill capacity: When engine is stopped Low level: 110l High level: 130l • Amount of oil in the brake tank 1. Fill oil up to the center of the upper sight gauge. 2. Bleed air. (See No.0610) 3. Fully charge the accumulator. 4. Make sure oil is filled up to the center of the sight gauge in the state of “3” above. • Amount of fuel Supply fuel. Reference (Tank capacity: 1,604l) • Amount of hydraulic oil Supply oil up to the top of the sight gauge. Reference (Tank capacity: 1,065l) • Amount of oil in transmission (Specified oil level 164l) Refill capacity 140l Atmospheric temperature 0°C or above: TO30 Atmospheric temperature 10°C or below: TO10 a a

For the gauge position and the standard oil and coolant level, see the Operation and Maintenance Manual. The axle and cab are shipped after being disassembled, thus supply of hydraulic oil is necessary. Confirm the oil level constantly while starting the engine.

2. For the starting procedure, reference the Operation and Maintenance Manual. a And also confirm the engine stop procedure in the Operation and Maintenance Manual. a Run the engine at low idle for 10 minutes a Don't try to operate the control lever as long as the engine is run. a Stop the engine immediately if a trouble such as oil leakage and abnormal noise is detected. 3. Check the engine after it has been stopped. a Check the engine for oil le akage a Check and supply oil and coolant to respective components

Cautions

Special tool Name

s r e h t O

98


Name

Q’ty

Assembly procedure

Bleeding the brake air

No. 0610

(1) Start the engine and fill up the accumulator chamber with oil. (2) Loosen the air bleeding plug (in the axle brake chamber). (3) Feed brake oil by stepping down the brake pedal and then drain air from the bleeding plug. (Keep the brake pedal being stepped down.) (4) Tighten the bleeding plug and release the brake pedal. Then loosen the bleeding plug and then step down the brake pedal again to repeat step (3) above. (5) Repeat (2) - (4) until the air is completely bled through the bleeding plug and the flowing out oil is free from bubbles. (Feed the brake oil constantly to maintain the chamber being filled up.)

Bleeding plug

Axle (2 places in the front and rear)

Slack adjuster (2 places in the front and rear)

(Bleeding on the axle is conducted in the complete machine assembling process.) (6) Run the engine at low idle for about 2 minutes in order to fully charge the accumulator. (7) Make sure in this state that oil is filled up to the center of the sight gauge.

Cautions

Special tool Name


Name

Q’ty

s r e h t O

99

Assembly procedure

No. 0615

Bleeding air from hydraulic circuit

(1) Before starting the engine, loosen the plug installed to the suction tube.

Switching pump

Loader pump

Steering pump

(2) Check that all air has been bled through the plug and oil has started flowing out, and then tighten the plug. (3) Leave the machine for 10 minutes as it is so that the pump will be filled with hydraulic oil. (4) If the hydraulic oil level is low, add new hydraulic oil to the specified level and loosen the plug installed to the top of the piston pump.

(5) Check that all air has been bled through the plug and oil has started flowing out, and then tighten the plug. (6) Run the engine at low idle for about 5 minutes to check each part for oil leakage. (7) Loosen the plug at the top of the piston pump. Check that oil flows out and then tighten the plug. (8) Close the oil filler cap of the hydraulic tank.

Cautions

Special tool Name

s r e h t O

100


Name

Q’ty

Assembly procedure

Assembling the lift arm assembly (Part 1)

No. 0620

[1] Assembling of the lift arm assembly 1. Using the nylon sling (crane 10-ton), lift the dump and lift cylinders. (See Fig.1)

Nylon sling

Hinge it on the lifting eye Lever block of the cabin

2. Hold the dump and lift cylinders in the current position using the lever block. (See Fig.1) 3. Eliminate and clean the grease and paint deposited in the pinhole. 4. Before assembling pin (2), coat the entire inner surface of the bushing with the molybdenum disulfide lubricating oil in paste form (KES.LM-P or equivalent). a Prior to coating, make sure the rust retardant on the bushing inner surface is washed off. (If the rust retardant is left unwashed, molybdenum component does not adhere on the bushing surface and the oil loses its effect as an anti-scuffing measure.) 5. Lift the lift arm assembly using the crane and then move it over the front frame (see Fig.2). Then, after the positioning, insert the lift arm hinge pin.

Hold the cylinder using the square timber

Fig. 1

6. Assemble pin (4). a When inserting the pin, coat the seal with grease to protect it from damage. (See Fig.3) 7. For the adjustment procedure using shims, see Fig. 4. State of part (Parts list No.) No. Part No. Part name Q’ty (1) 427-N42-209A Lift arm assembly 1 Separately packed (No.W9E-620) (2) 427-70-11460 Shim 1.5 mm 4 Separately packed (No.W9E-620) (3) 427-70-11470 Shim 3.0 mm 2 Separately packed (No.W9E-620) Temporarily installed on the front (4) 427-70-11993 Pin 2 frame pivot Temporarily installed on the front (5) 01010-82450 Bolt 2 frame pivot Temporarily installed on the front (6) 427-70-11480 Washer 2 frame pivot Temporarily installed on the lift (7) 07049-01620 Plug 6 arm assembling pin

Fig. 4 Adjustment using shims

Shim

Fig. 2

Front frame

Shim

Before inserting the pin, adjust the clearance to 1.5 mm or less using the shims. Clearance on the right and left side must be equal. Fig. 3

Clearance 1.5 mm max.

Cautions Q

Before inserting the pin, clean the pin and entire internal perimeter of the pinhole using a piece of rag and then coat that portion with molybdenum disulfide LM-P in paste form.

Q

When inserting the pin, coat the seal with grease to protect it from damage.

Q

When aligning the pinhole, don't try to insert a finger in the pinhole.

Special tool Name


Name

Q’ty 1 each

Impact wrench

1

Cranes 10 ton, 25 ton

Socket (36 mm)

1

Nylon sling (Withstand load min. 1 ton)

3

Large hammer

1

Nylon sling (Withstand load min. 50 kg)

2

Nylon sling (Withstand load min. 6 ton)

1

s r e h t O

101

Assembly procedure

Assembling the lift arm assembly (Part 2)

No. 0630

[2] Assembling of the lift cylinder to the lift arm assembly (see Fig. 1) 1. Eliminate and clean the grease and paint deposited in the pinhole.

Lift arm

2. Before assembling pin (1), coat the entire inner surface of the bushing with the molybdenum disulfide lubricating oil in paste form (KES.LM-P or equivalent).

Lift cylinder

a

Prior to coating, make sure the rust retardant on the bushing inner surface is washed off. (If the rust retardant i s left unwashed, molybdenum component does not adhere on the bushing surface and the oil loses its effect as an anti-scuffing measure.) 3. Adjust the position of the lift arm assembly and the lift cylinder and then insert lift cylinder head pin (1) to them. Care must be exercised to

Fig. 1

prevent assembling a wrong pin. [3] Assembling of the bucket cylinder to the lift arm assembly (Assembling of the bell crank) (See Fig. 2) 1. Eliminate and clean the grease and paint deposited in the pinhole.

2. Before assembling pin (1), coat the entire inner surface of the bushing with the molybdenum disulfide lubricating oil in paste form (KES.LM-P or equivalent). Prior to coating, make sure the rust retardant on the bushing inner surface is washed off. (If the rust retardant is left unwashed, molybdenum component does not adhere on the bushing surface and the oil loses its effect as an anti-scuffing measure.) (If the rust retardant i s left unwashed, molybdenum component does not adhere on the bushing surface and the oil loses its effect as an anti-scuffing measure.)

Bucket cylinder

a

Bell crank

Care must be exercised to prevent assembling a wrong pin. Fig. 2

3. Lift the cylinder head using the crane and then insert bucket cylinder pin (5) while adjusting the cylinder head position. a

a

No. (1) (2) (3) (4) (5) (6) (7) (8)

When inserting the pin, coat the seal with grease to protect it from damage. Start the engine, lift the lift arm and adjust the pinhole position.

Part No. 427-70-11972 01010-82035 427-70-11290 07049-01620 427-70-11942 01010-82035 427-70-11290 07049-01620

Part name Pin Bolt Washer Plug Pin Bolt Washer Plug

Q’ty 2 2 2 6 1 1 1 3

State of part (Parts list No.) Separately packed (No.W9E-630) Separately packed (No.W9E-630) Separately packed (No.W9E-630) Temporarily installed on the lift cylinder assembling pin Separately packed (No.W9E-630) Separately packed (No.W9E-630) Separately packed (No.W9E-630) Temporarily installed on the bucket cylinder assembling pin

Cautions Q

Q Q Q

Before inserting the pin, clean the pin and entire internal perimeter of the pinhole using a piece of rag and then coat that portion with molybdenum disulfide LM-P in paste form. When inserting the pin, coat the seal with grease to protect it from damage. When aligning the pinhole, don't try to insert a finger in the pinhole. Care must be exercised to prevent assembling a lift cylinder pin or bucket cylinder pin.

102

Special tool Name


Name

Q’ty

Impact wrench

1

Crane 25 ton

1

Torque wrench

1


2

Socket (30 mm)

1

Nylon sling (Withstand load min. 50kg)

2

Large hammer

1

s r e h t O

Assembly procedure

Connecting the remote grease tube

No. 0640

1. Connect the remote grease tube in 5 places

Connect

Connect Connect Connect

Connect

Feed grease (KES LM-G) to the grease feed fitting for the pins on the lift arm. Note: This process is not required when the auto-greasing specification is employed

Cautions

Special tool Name


Name

Q’ty

s r e h t O

103

Assembly procedure

Assembling the bucket (Part 1)

No. 0650

State of part (Parts list No.) No. Part No. Part name Q’ty (1) 4 27-N42-1140 ( O-r ing) co rd ri ng 4 Separately packed (No.W9E-650) (2) 426-09-11150 Bolt 4 Separately packed (No.W9E-650) (3) 01596-00606 Nut 4 Separately packed (No.W9E-650) (4) 01640-20610 Washer 8 Separately packed (No.W9E-650) 427-70-11450 Shim (3.0 mm) 4 Separately packed (No.W9E-650) (5) 427-70-11440 Shim (1.5 mm) 6 Separately packed (No.W9E-650)

Bucket assembly

1) Installation of the cord ring 1. Place cord ring (O-ring) (1) on the lift arm boss1. (See Fig.2) 2. Coat the entire perimeter of the cord ring assembling-groove sufficiently with LM-G (molybdenum disulfide lithium grease). (See Fig.2)

Bucket assembly viewed from the left side

Fig. 1

3. Place the cord ring 2 in the groove after assembling of the bucket and adjustment with shims are complete. (See Fig.2) 4. Coat the entire inner surface 3 of the dust tool lip with LM-G (molybdenum disulfide lithium grease). (See Fig.2) Cord ring assembling groove

2) Alignment of hinge pin holes on the bucket assembly 1. Lift the bucket assembly using a 25 ton crane. Lifting tool: Wire sling (Withstand load 11 tons, two 4,000 mm slings are used f or lifting) Shackle: For 5 tons

Cross section of bucket hinge pin section (Cross section A-A)

Fig. 2

2. Align the hole of the right and left hinge pins on the bucket to the pinholes on the lift arm. 3) Selecting of shims for the bucket hinge pin section 1. Shim-based adjustment procedure 1-1. Select shim (5) in such that clearance (T) in the right and left side becomes even. (Adjust clearance (T) to 1.5 mm max.) 1-2. Use a screwdriver (-) for holding the shim. a Don't try to insert a finger into the pin inserting pivot.

Bucket assembly Weight: 8,600 kg Fig. 3


Cautions

Special tool Name


Name

Q’ty

Impact wrench

1

Crane 25 ton

1

Socket (10 mm)

1

Wire sling (Withstand load 11 ton, L=2,000)

1

Spanner 10 mm

1

Shackle: 5 ton

2

s r e h t O

104

Fig. 4

Assembly procedure


No. 0660

4) Insertion of bucket hinge pin 1. Assemble the shim being selected in 3) above, align the pinhole and then insert the buck hinge pin. Before inserting the pin, coat it with grease. 2. Care must be exercised when inserting bucket hinge pin (6) not to damage the dust seal. After coating, place the pin in the groove.

Weight: 112.8 kg

5) Assembling of the bucket hinge pin 1. Assemble bucket hinge pin (6) using bolt (7) and washer (8).

6) Place cord ring (1) in the groove.

No. Part No. (6) 427-N42-1161 (7) 01010-82035 (8) 427-70-11290

Part name Pin Bolt Washer

Q’ty State of part (Parts list No.) 2 Separately packed (No.W9E-660) 2 Separately packed (No.W9E-660) 2 Separately packed (No.W9E-660)


Cautions

Special tool Name


Name

Q’ty

Impact wrench

1


1

Socket (30 mm)

1

Crane 10 ton

1

Spanner 30 mm

1

Large hammer

1

s r e h t O

105

Assembly procedure


No. 0670

7) Installation of bucket link pin (See Fig. 1.) Install the bucket link in the same procedure as 1) – 6) (See No.0650 and No.0660). No. (1) (2) (3) (4) (5) (6) (7) (8) (9)

Part No. 427-N42-1151 01010-82035 427-70-11290 427-70-11450 427-70-11440 427-N42-1140 426-09-11150 01596-00606 01640-20610

Part name Pin Bolt Washer Shim (3.0 mm) Shim (1.5 mm) Ring Bolt Nut Washer

Q’ty 1 1 1 2 4 2 2 2 4

Fig. 1

State of part (Parts list No.) Separately packed (No.W9E-670) Separately packed (No.W9E-670) Separately packed (No.W9E-670) Separately packed (No.W9E-670) Separately packed (No.W9E-670) Separately packed (No.W9E-670) Separately packed (No.W9E-670) Separately packed (No.W9E-670) Separately packed (No.W9E-670)

Shim-based adjustment procedure 1. Select the shim in such that the clearance on both sides is even and adjusted to max. 1.5 mm. 2. Use a flat-blade screwdriver for holding the shim. (Don't try to insert a finger into the pin-inserting pivot.) a

8) Assembling of the grease nipple and plug • Assembling to the bucket link pin (See Fig. 1.) • Assembling to the bucket hinge pin (See Fig. 3.) No. (10) (11)

Part No. 07049-01620 07020-00000

Part name Plug Fitting


9) Feed LM-G (molybdenum disulfide lithium grease) to the bucket hinge pin and bucket link pin (See Fig.2). a After feeding the grease, run the engine at low idle and then repeat lift arm LOW – Hi and bucket tilt – dump 2 – 3 times to spread the grease evenly on the pin.

Fig. 2

Fig. 3

Grease position Bucket link

Bucket hinge (2 places)

Cautions

Special tool Name

Q’ty

Name

Q’ty

Torque wrench

1


1

Socket (10 mm, 30 mm)

1

Crane 10 ton

1

s r e h t O

106

Necessary Equipment

Assembly procedure

No. 0680

Assembling the cover (Bottom of the counterweight)

1. Remove (2) and (3) being temporarily installed on the rear frame. 2. Assemble cover (1) using (2) and (3). No. (1) (2) (3)

Part No. 427-46-25341 01010-82045 01643-32060

Part name Cover Bolt Washer

Q’ty State of part (Parts list No.) 1 Separately packed (No.W9E-680) 4 Temporarily installed on the rear frame 4 Temporarily installed on the rear frame

Cautions

Special tool Name


Impact wrench

1

Socket (30 mm)

1

Name

Q’ty

s r e h t O

107

Assembly procedure

Feeding the grease

No. 0690

1. After the assembly, feed molybdenum disulfide lubricating agent (KES LM-G) until the grease spills out of the joint. Front frame: 6 places

Front frame

Detail of A portion (Rear right side of the front frame)

2. After the assembly, feed molybdenum disulfide lubricating agent (KES LM-G) until the grease spills out of the joint. Rear frame: 4 places

Rear frame

Detail of B portion (Front left side of the rear frame)

Cautions

Special tool Name Grease gun (Hand pump type)

s r e h t O

108

Necessary Equipment Q’ty 1

Name

Q’ty

Assembly procedure

No. 0700

Work equipment hydraulic circuit air bleeding procedure

1. Bleeding of air from the cylinder (1) Engine at low idle and cylinder up to 100 mm in front of the stroke end: 3 – 4 times of reciprocating motion (2) Engine at mid idle and cylinder up to 100 mm in front of the stroke end: 3 – 4 times of reciprocating motion (3) Engine at high idle and cylinder up to 100 mm in front of the stroke end: 3 – 4 times of reciprocating motion (4) Engine at low idle and cylinder relieved at 100 mm in front of the stroke end: 3 – 4 times of reciprocating motion (5) Engine at mid idle and cylinder relieved at 100 mm in front of the stroke end: 3 – 4 times of reciprocating motion (6) Engine at high idle and cylinder relieved at 100 mm in front of the stroke end: 3 – 4 times of reciprocating motion

2. Air bleeding from the PPC circuit (1) Set the bucket control lever to "Tilt" and lift arm control lever to "Float". Maintain the cylinder at its stroke end fo r 1 minute. (2) Set the bucket control lever to "Dump" and lift arm control lever to "Raise". Maintain the cylinder at its stroke end fo r 1 minute.

Cautions

Special tool Name Spanner


Name

Q’ty

1

s r e h t O

109

Assembly procedure

Adjusting the bucket positioner

No. 0710

Bucket cylinder

(1,032) Detection bar

2 in nominal clearance

Detection bar Proximity switch mounting bracket Fig. 1

427-43-19233 Tightening torque: 14.7 – 19.6 Nm {1.5 – 2.0 kgm}

Min. 1/2 displacement should be present No. (1) (2) (3) (4) (5) (6) (7) (8) (9)

Part No. 427-43-19233 01435-01245 01596-01211 01643-31232 427-44-11113 01024-81225 56B-06-15610 08193-20010 01435-01025

Part name Plate Bolt Nut Washer Support Bolt Switch Clip Bolt

Q’ty 1 2 2 2 1 4 1 1 1

State of part (Parts list No.) Separately packed (No.W9E-710) Temporarily installed on the cylinder Temporarily installed on the cylinder Temporarily installed on the cylinder

Sensor sensing surface

Separately packed (No.W9E-710) Temporarily installed on the cylinder

Temporarily installed on the plate Temporarily installed on the plate Temporarily installed on the plate

Section A-A Protector

3–5

Bucket positioner adjusting procedure (1) Lower the bucket on the ground and set it horizontal. (The ground surface must be even.) (2) Adjust the proximity switch in such that its sensing surface is pulled in ª0.5 – 1.0 mm from the protector end. Then fix the proximity switch. (3) Since the detection bar moves laterally to the switch sensing-surface, adjust the clearance along the entire passing surface to 3 – 5 mm. (4) Run the engine at mid speed (1,500 rpm) and activate the positioner. Then adjust the proximity switch mounting bracket (427-43-19233) in such that the bucket angle is set downward by 0 – 1° when the bucket was placed on the ground. (When the bucket is set horizontal near the ground surface, relation between the bucket angle and cylinder length is 8.7 mm/1°.) (5) When the positioner is activated and the bucket is set near the ground surface, fluctuation due to the engine speed shall be 4° maximum. ª Confirm magnitude of the displacement. (Make sure the displacement is 1/2 minimum. See Fig. 1.)

Cautions

Special tool Name

Q’ty

Impact wrench

1

Socket 19 mm

1

Torque wrench

1

Spanner

1

s r e h t O

110


Q’ty

Assembly procedure

No. 0720

Adjusting the new 2 stage (Overseas general standard)

Clearance between the switch sensing surface and plate in horizontal direction is 3 – 5 mm

Tightening torque: 14.7 – 19.6 Nm {1.5 – 2.0 kgm}

View Z No. (1) (2) (3) (4) (5) (6) (7) (8) (9)

Boom kick out adjusting procedure (1) Raise the lift arm to the highest position and then fix the sensor plate in such that the distance between the switch center and sensor plate top end becomes 0 – 5 mm. (2) Fix the switch in such that the clearance between the switch sensing surface and plate in horizontal direction becomes 3 – 5 mm. Distance between the switch center and sensor plate top end is 0 – 5 mm

Part No. 427-43-29110 01435-01020 428-43-29210 01435-01225 56B-06-15610 08193-21012 01435-01020 01643-31032 01580-11008

When raised to the highest position

Part name Bracket Bolt Bracket Bolt Switch Clip Bolt Washer Nut

Q’ty 1 2 1 2 1 2 2 2 2

State of part (Parts list No.) Separately packed (No.W9E-720) Separately packed (No.W9E-720) Temporarily installed on the front frame Temporarily installed on the front frame Temporarily installed on the front frame Temporarily installed on the front frame Temporarily installed on the front frame Temporarily installed on the front frame Temporarily installed on the front frame

Position of the plate when the lift arm was raised to the highest position

When the bucket is set horizontal

Front frame

Cautions

Special tool Name Impact wrench Socket (17mm, 19 mm)


Name

Q’ty

1 1 each

Torque wrench

1

Spanner

1

s r e h t O

111

Assembly procedure

No. 0730

Adjusting the new 2 stage (North American standard specification)



View Z No. (1) (2) (3)

Part No. 427-62-21330 01435-01220 56B-06-15610

Part name Bracket Bolt Switch

Q’ty State of part (Parts list No.) 1 Separately packed (No.W9E-730) 2 Separately packed (No.W9E-730) 1 Temporarily installed on the front frame

When raised to the highest position When the bucket is set horizontal

Front frame

Adjustment of boom kick out (1) Fix the switch in such that the clearance between the switch sensing surface and plate in horizontal direction becomes 3 – 5 mm. Cautions

Special tool Name

Q’ty

Impact wrench

1

Socket (19 mm)

1

s r e h t O

112


Q’ty

Assembly procedure

No. 0740

Assembling the lift arm angle sensor

View A

Connect CN FB4

Front lamp assembly

Assemble the respective parts to the assembled bracket. Clip and bolt already assembled Fix the harness here.

1. Remove (2) – (8) and (10) – (14) being temporarily installed on the lift arm assembly of the front frame.

Lift arm assembly

Detail of assembling

2. Remove (9) being temporarily installed on lever (1).

No. (1) 3. Assemble (1) – (11) as show in the detail of (2) the assembling. (3) 4. Assemble (12) – (14) as show in the detail of (4) (5) the assembling. (6)

5. Remove (15) and (16) being temporarily installed on the front lamp assembly.

(7)

7. Fix and connect the harness to the clip already being assembled.

(12)

(8) 6. Fix the harness using (15) and (16) as shown (9) (10) in view A. (11)

(13) (14) (15) (16)

Part name Q’ty State of part (Parts list No.) Lever 1 Separately packed (No.W9E-740) Shim t = 0.5 1 Temporarily installed on the front frame Bearing 1 Temporarily installed on the front frame Case 1 Temporarily installed on the front frame Shaft 1 Temporarily installed on the front frame Spring 1 Temporarily installed on the front frame Sensor potentio56B-06-11630 1 Temporarily installed on the front frame meter 01023-10412 Screw 2 Temporarily installed on the front frame 01315-20812 Screw 2 Temporarily installed on the lever (1) 419-S30-2510 Plate 1 Temporarily installed on the front frame 01024-81025 Bolt 3 Temporarily installed on the front frame Temporarily installed on the lift arm 01024-81225 Bolt 4 assembly and front frame Temporarily installed on the lift arm 427-43-28212 Cover 1 assembly and front frame Temporarily installed on the lift arm 01024-81230 Bolt 1 assembly and front frame Temporarily installed on the front 04434-51010 Clip 1 lamp assembly Temporarily installed on the front 01024-81016 Bolt 1 lamp assembly Part No. 427-43-28221 421-64-15140 06124-01416 425-S31-2120 421-S30-2250 427-S33-3190

113

Assembly procedure

No. 0750

Adjusting the active working system and boom kick-out switch (Overseas general standard and domestic standard)



View Z

Adjustment of the active working system and boom kick-out switch (1) Raise the lift arm to the highest position and then fix the sensor plate in such that the distance between the switch center and sensor plate bottom end becomes 115 mm. (2) Fix the switch in such that the clearance between the switch sensing surface and plate in horizontal direction becomes 3 – 5 mm.

No. (1) (2) (3)

Part No. 427-62-21330 01435-01220 56B-06-15610

Part name Bracket Bolt Switch

When raised to the highest position

State of part (Parts list No.) Q’ty 1 Separately packed (No.W9E-750) 2 Separately packed (No.W9E-750) 1 Temporarily installed on the front frame

Position of the plate when the lift arm was raised to the highest position

Distance between the switch center and sensor plate bottom end is 115 mm

Front frame

Cautions

Special tool Name

Q’ty

Impact wrench

1

Socket (19 mm)

1

s r e h t O

114


Q’ty

Assembly procedure

Touchup work

No. 0760

1. Paint can be peeled off in the sections where lifting tools were used as well as machined sections and dented sections. If such is recognized, touch up the damaged portions. (Touchup in the following (1) – (10) sections is a must. For other sections, touch up the location where paint is peeled off.) (1) (2) (3) (4) (5) (6) (7) (8) (9) (10)

Lift arm: The section where the nylon sling was used for lifting Lift arm: The section where dents from assembling of the pin are left Lift cylinder: The section where the nylon sling was used for lifting Lift cylinder: The section where dents from assembling of the pin are left Bucket cylinder: The section where the nylon sling was used for lifting Bucket cylinder: The section where dents from assembling of the pin are left Bell crank: The section where the nylon sling was used for lifting Bell crank: The section where dents from assembling of the pin are left Machined portion on the tires Counterweight section Right and left Right and left

Right and left

View Z Cautions 1. Paint color shall conform to the following. Except the sections where face coating is provided.

Black gray

Black heat resistant paint

Natural yellow

2. Grease nipple shall be painted in red. Following lists the places and number of the nipples used. (1) Loader linkage 13 places (4) Drive shaft 7 places (2) Center pin 2 places (5) Rear axle support 2 places (3) Steering cylinder 4 places 3. Bare outside sections: Following hose for hydraulic tank shall not be painted (1) Hose from the front plate exit of the front frame to the bucket cylinder (2 pieces) (2) Hose to the lift arm cylinder (4 pieces both right and left) (3) Hose for the 3-spool valve on the right and left lift arm plates (2 pieces) 4. Bolts and washers in the external bare portion shall be painted in the same color as the exterior parts.

115

Assembly procedure

Applying the decal (For the overseas-directed products only)

No. 0770

1. Apply the decal to the lift arm top end (Caution for falling off of the work equipment) (( o) in the figure indicates the upward direction of the decal)

Top view of the lift arm

The same process is employed for both the right and left side

View Z

No. (1)

Part No. 09807-C1683

Part name Mark


Cautions

Special tool Name

s r e h t O

116


Name

Q’ty

1/9

WA800-3E0 WA900-3E0

KOMATSU SAA12V140E-3

GEN00056-01

a

Carefully read the Operation and Maintenance Manual in advance to understand safety, operation, machine operations and controls, and then carry out the following inspections.

Date of Inspection

Inspector

Start

Finish H

No.

H

Inspection items

: Acceptable (

) : Enter numeric values.

: Unacceptable Empty column : Uninspected

: Not applicable

Service meter

2/9

List of check marks for inspection results

: No check is required.

Check relevant items after maintenance. When the result is acceptable, circle any of the above marks. (Example: )

Judgment procedures and criteria

Check

Maintenance

Remarks

Recording the Serial No. of built-in parts. The number is stamped on the right upper part of the lift arm. Stamp

1

Lift arm No.

2 Checking oil and water levels. (Check them before starting the engine.)

3

Engine oil level (while the engine is at a stop.)

4

Brake oil level (When the check is difficult while the engine is at a stop, start the engine to check the level.)

5

Hydraulic oil level

6

Transmission oil level

The level shall be in the range between (H) and (L). (Check the level by comparing it with the stamp [ENGINE STOPPED] on the dipstick more than 15 minutes later after the engine stopped.) The level shall be at the ENGINE STOP level. The level shall be at the ENGINE RUNNING level.

With the measurement gauge 10 hours later after the engine stopped. With the measurement gauge 5 minutes later after the engine started.

Lower the bucket on the ground, level it. And the level shall be in the r ange of the inspection window. (Check the level after the engine stopped.) The level shall be in the range A at the ENGINE STOP position of the level gauge.

A

a Check

the level more than 60 minutes later after the engine stopped.

7

Coolant level

The level shall be above the middle between Full and Low on the sub tank.

8

Electrolyte level

The level shall be at 10 – 12 mm above the polar plate.

9

Window washer level

The level shall be above the 2/3 level of the tank capacity.

Check of antifreeze density in coolant

Check the antifreeze density. The density shall satisfy the standard. Area A: -33 – -43°C Areas B: -24 – -34°C Areas C: -14 – -24°C Measured value ( ) °C

10

Preparation before function check 11

Satisfaction of failure code.

Before the machine inspection, the failure code on the display, which can be found after the monitor panel and the lunch box are removed, shall be satisfied.

Turn the key switch ON. 12 13 14 15

When the starting switch is set to ON, the buzzer s ounds for Valve check function of main monitor and sub-monitor a second and the lamps of the main monitor and the submonitor go on. When the starting switch is set to ON, the [CHECK] lamp Function of centralized inspection lamp does not go on. When the starting switch is set to ON, the pilot lamp blinks Function of emergency steering pilot lamp (and goes out after the engine starts). The sound volume is satisfactory without vibrating tone Function of horn (sensory).

Check the safety function at the start of engine. (Check safety around in advance so that everything is in order even if the engine starts.)

16

Safety function of transmission neutral

17

Safety function of steering lever set to neutral

Even when key switch is set to START by using the transmission rear and forward switch F or R of the joystick lever, the engine does not start. (The engine does not start when the transmission is set to other than neutral.) When the joystick lever is lowered to the right or left, the engine does not start. Also, when the lever is lowered, the buzzer sounds. (W hen the lever is set to other than neutral, the engine does not start.) (When the lever is returned to the N position, the buzzer stops sounding.)

3/9 No.

Inspection items


Start the engine. (Check safety around and then start the engine. Start each measurement only after warning-up run.) 18

Function of centralized warning lamp

19

Function of accelerator pedal

20

Exhaus t c olor

21

Abnormal noise of engine

Initial setting of AJSS (joystick steering)

The accelerator pedal shall be free from double stepping and counter bounce and r eturn smoothly. Is the exhaust color satisfactory at a sudden acceleration (Li o Hi). (Sensory evaluation) No abnormal noise is heard. (Sensory check) Check low idle and high idle at each stall. ª

Check each function after the initial setting.

Initial setting a

22

When the engine starts, the [CAUTION] lamp does not blink.

Do not move lever during procedures No. (4) – (7) at right.

<> When no pip sound in (7) is heard, carry out the initial setting again. If the pip sound does not occur even after re-initial setting, the joystick steering is out of order. Troubleshoot it and carry out the initial setting. (Check that both output voltages of steering angle sensor and frame angle sensor are 2.40 – 2.60 V and then repeat procedures from No. 1.)

(1) Set machine and steering in straight travel position. (2) Stop engine (Turn starting switch OFF) and set steering lock lever in LOCK position. (3) Disconnect neutral position adjustment connector "JL3" in right console. (4) Turn starting switch to ON position and start engine. (5) Connect neutral position adjustment connector "JL3". (6) Reset steering lock lever. (7) After 1 second, buzzer beeps 3 times and adjustment is completed.

Measuring the engine speed. Engine revolution (Measuring conditions) ª Engine coolant temperature: Within the green range ª Engine oil temperature: 80 – 90 °C ª Torque converter oil temperature: 60 – 80 °C ª Work equipment oil temperature: 45 – 55 °C

ª

23

When the engine speed measuring method is not clear, refer to the paragraph of [Measurement of Engine Speed] in Part: “Testing and adjusting” in the Shop Manual.

Before measuring the engine speed, apply t he parking brake, release the accelerator pedal and set the secondary switch to OFF. Standard: 620 – 710 rpm Measure value of low idle speed: ( ) rpm Before measuring the speed, apply the parking brake, release the accelerator pedal and set the secondary switch to ON. Standard: 820 – 910 rpm Measure value of low idle (secondary) speed: ( ) rpm Before measuring the speed, apply the parking brake and step on the accelerator pedal. Standard: 2,170 – 2,220 rpm Measure value of high idle speed: ( ) rpm Before measuring the speed, step on the brake pedal, release the parking brake, set the transmission lever to F3 speed and step down the accelerator pedal. Standard:1,940 – 2,140 rpm (WA800) 2,020 – 2,220 rpm (WA900) Measured value of engine speed at stalling T/C: ( ) rpm Before measuring the speed, apply the parking brake, step on the accelerator pedal and release the work equipment. For recording only, Measured value of engine speed at stalling the work equipment: ( ) rpm Before measuring the speed, step on the brake pedal, release the parking brake, set the transmission lever to F3 speed, release the work equipment and step on the accelerator pedal. For recording only, Measured value of engine speed at full stall: ( ) rpm

Make checks related to the work equipment. (1) Set the lever to the [Raise] position, and the lift arm rises.

24

Function of lift arm control lever

(2) Pull the lever further from the [Raise] position, and the lever is clutched at the notch and stops there. Then, bring the lift arm to the position adjusted with the kick-out, and the lever returns to the [Hold] position at the same time. (3) Bring the lever to the [Hold] position, and the lift arm keeps staying at the position where it stopped. (4) Set the lever to the [Lower] position, and the lift arm falls and the work equipment is released at the lowest position. (5) Set the lever to the [Float] position, the lever is clutched at the notch and the lift arm can freely move as external force is applied. (6) Set the lift lever to the [Float] position, and the work equipment is not released. (7) When the lever is released from the notch as the lift arm is kicked out and the lever is pulled further to the [Raise] position until the work equipment is released, the lift arm cylinder stroke shall be within 5 mm. a When the kick-out height is adjusted as requested by user, the lever works at the height.

Check

Maintenance

Remarks

4/9 No.

Inspection items


25

Function of bucket control lever

26

Function of remote positioner

27

Function of lock lever (for work equipment control lever)

28

Function of work equipment accumulator Measurement of work equipment speed in the normal mode (Work equipment speed and oil temperature: 45 – 55 °C)

29

Set the Active Working Switch on the right side of the dashboard to Normal Loading and start the measurement.

Check of active mode Set the Active Working Switch on the right side of the dashboard to Normal Loading and start the measurement.

(1) Set the lever to the [Tilt] position, and the bucket moves in the tilt direction. (2) Pull the lever further from the [Tilt] position when the bucket is dumped, and the lever is clutched at the notch and stops there and then returns to the [Hold] position at the same time when the bucket comes to the position adjusted with the bucket posi tioner. (3) Bring the lever to the [Hold] position, and the bucket keeps staying at the position where it stopped. (4) Set the lever to the [Dump] position, and the bucket moves in the dump direction. (5) The bucket positioner has been adjusted so that the bucket is level with the ground or is slightly tilted down forward. (Note that a poor switch adjustment causes the bucket to be released from the notch before the working position sometimes.) a When the bucket positioner is adjusted as requested by user, the bucket shall work at the position. Does the remote positioner switch enable to set the Down Position and the UP Position freely? Does the remote positioner return automatically to neutral at the set position? When the work equipment lock lever is set to ON (the lever is lowered), the work equipment does not lower even if the work equipment control lever is moved. Stop the engine after an engine high idle and lower the lift arm control lever, and the lift arm comes down. Lift arm raising time (without load) Standard lever raising: 9.9 – 10.9 sec. Measured value: ( ) sec. Lift arm lowering time (without load) Standard lever lowering: 4.3 – 5.3 sec. Measured value: ( ) sec. Bucket tilted back time (Measure the time without load at the lift arm highest position.) Standard lever tilting: 3.5 – 4.1 sec. Measured value: ( ) sec. Bucket dumping time (Measure the time without load at the lift arm highest position.) Standard lever dumping: 2.2 – 2.8 sec. Measured value: ( ) sec. The pilot lamp of the proximity switch for powerful mode goes on at the lift arm hinge pin height of 1.4 – 2.0 m. When a metal piece is stuck to the proximity switch for powerful mode (and fixed with rubber tape) at the lift arm highest position, the transmission is set to F3 speed and the work equipment is released, the loader pump solenoid has the voltage of 24 V.

30 Proximity switch for active mode

Measurement of solenoid voltage

31

Check of lift arm hydraulic drift (without load)

Check of bucket natural dump (without load)

32

Make the lift arm hinge pin and the bucket mounting pin horizontal with the ground, start the measurement 5 minutes later after the engine stopped and measure the fall of the lift cylinder rod 15 minutes later. (Oil temperature: 45 – 55 °C) Standard value: 50 mm/15 minutes Measured value: ( ) mm Make the lift arm hinge pin and the bucket mounting pin horizontal with the ground and also, make the bucket bottom horizontal with the ground. Start the measurement 5 minutes later after the engine stopped and measure the fall of the dump cylinder rod 15 minutes later. (Oil temperature: 45 – 55 °C) Standard value: 30 mm/15 minutes Measured value: ( ) mm

Posture for measuring hydraulics drift

Check

Maintenance

Remarks

5/9 No.

Inspection items


Making checks related to the steering. 33

34

35

36

37

Bring the steering lock lever to the lock position after starting the engine and lower the joystick lever to the right or left, and the buzzer sounds but the steering is not disengaged. Lower the joystick lever to the right, and the machine turns to the right. Lower the joystick lever to the left, and the machine turns to Function of steering the left. The steering angle changes only as much as the joystick lever is moved. Bring the joystick lever to the stroke end while idle the engine at low speed, and there occurs the clearance of 20 – 30 mm Check of adjustment of steering stopper bolt between the front frame and the rear one. (Check the clearance on both the right and left sides.) Measure the full stroke time in idle the engine at high speed. Standard left swing: 3.2 – 4.3 sec. Measured value: ( ) Measurement of steering operation time Measure the full stroke time in idle the engine at high speed. Standard right swing: 3.2 – 4.3 sec. (Work equipment speed and oil temperature: 45 – 55°C) Measured value: ( ) The above measured swing times do not differ more than 10% on the right and the left sides. When the engine stopped while traveling downhill, the Function of emergency steering steering angle changes. (Check it on both the right and left sides.) Safety function of joystick steering lock lever

Making checks of travel and brake. 38

39

40

41

42

43

44

45

46

Set the transmission to F or R at the locked position, and the buzzer sounds and the machine does not travel. Set the forward-reverse selector switch of the joystick lever to the F position, and the machine travels forward. Set the forward-reverse selector switch of the joystick lever to the R position, and the machine travels backward. Set the forward-reverse selector switch of the joystick lever Transmission control function of joystick lever to the N position, and the machine does not travel. Press the shift-up switch (+) of the joystick lever, and the transmission speed increases. Press the shift-down switch (-) of the joys tick lever, and the transmission speed decreases. Change the machine travel direction to forward or backward Shock to and time lag of transmission at the 1st or 2nd speed, and the transmission does not get any shock nor cause any time lag. Press the switch on the head of the lift arm control lever while traveling the machine at the F2 speed, the machine comes to Function of kick-down switch travel at the 1st speed. Set the transmission to reverse travel (R), and the machine returns to the 2nd speed. Set the transmission cut-off switch on the main monitor panel to ON, the pilot lamp of the transmission cut-off switch on the Function of transmission cut-off switch monitor goes on. Step on the left brake, and the transmission is set to neutral. Set the selector switch on the main monitor to ON (to turn on the pilot lamp), and the transmission gets in the manual shift mode. Set the selector switch to OFF (to turn off the pilot Auto and manual shift changeover function of lamp), and the transmission gets in the auto shift mode. transmission When the transmission is in the auto shift mode, the indicator lamp on the left dashboard for the selected automatic transmission maximum speed gear goes on. (In the manual shift mode, the pilot lamp does not go on.) The shift display on the monitor panel agrees with the gear Function of transmission manual shift mode shift selected with the transmission shift up/down switch. The lighted transmission indicator lamp agrees with the automatic gear shift range and the machine starts traveling at the 2nd speed when the forward and backward travels are changed over. (1st speed pilot lamp o Automatic gear shift to 1st speed, 2nd speed pilot lamp o Automatic gear shift to 2nd speed, 3rd speed pilot lamp o Automatic gear shift to 2nd speed - 3rd speed) Function of transmission auto shift mode When the F3 speed is changed over to R3 speed while the engine is idle at high speed, pip sounds occurs. Press the switch on the head of the lift arm control lever while traveling the machine at the F2 speed, the machine comes to travel at F1 speed, and returns to the 2nd speed about 4 seconds later (in the auto shift mode only). When the transmission in the auto shift mode, press the switch beside the lift arm lever knob, the transmission is fixed to the gear shift being displayed with the transmission Function of hold switch indicator on the main monitor and the hold indication on the main monitor goes on. Press the switch once again, and the hold is released and the display disappears. Safety function of joystick steering lock lever

Check

Maintenance

Remarks

6/9 No.

Inspection items

47

Heat accumulation in brake disc

48 49

50

51

52

53

54


After traveling the machine, touch the brake chamber by hand. No abnormal heat can be felt (on the four wheels). Turn on the parking switch, set the joystick lever T/M Safety function of parking brake forward-reverse switch to F or R, and the centralized warning lamp blinks and the warning buzzer sounds. This brake enables to stop the machine on slopes of 1/5 Function of parking brake gradient. Apply the brake suddenly at the initi al speed of 20 km/h, and the machine stops within 7.5 m. Braking force of service brake Step on the brake while the engine is idle at high speed or at the F2 speed, and the machine does not start. Travel the machine at more than 20 km/h and apply the Pul l of brake brake suddenly, and the machine stops one a strai ght line. When the pressure in the accumulator drops, the parking brake works automatically. (The engine stops, the starting switch gets set to ON and the parking brake works.) Step on the service brake pedal several times, and the accumulator Check of emergency brake pressure drops and the parking brake works.) When the emergency brake works, the parking brake pilot lamp goes on. Step on the brake pedal to sound the caution buzzer for oil pressure drop. Then, idle the engine at high speed until the Check of the time when the brake accumulator accumulator is fully charged. Stop the engine and restart the pressure drops engine 30 minutes later, and the caution lamp for the oil pressure of the brake accumulator does not go on. Standard F1 speed: 6 – 8 km/h Measured value: ( ) km/h Check of travel speed Standard F2 speed: 11 – 13 km/h Measured value: ( ) km/h When the bucket is empty, check the travel speed at each gear speed with the Standard F3 speed: 26 – 30 km/h machine-mounted meter on the main Measured value: ( ) km/h monitor. Standard R1 speed: 6 – 8 km/h Measured value: ( ) km/h Since F3 and R3 require long approach Standard R2 speed: 11 – 13 km/h distance, they are regarded as reference Measured value: ( ) km/h values. Standard R3 speed: 26 – 30 km/h Measured value: ( ) km/h

Checking all lamps. 55

Internal lighting of main monitor and sub monitor

56

Function of clearance lamp

57

Function of head lamp

58

Function of turn signal lamp

59

Function of hazard lamp

60

Function of tail lamp

61

Function of back-up lamp

62

Function of brake lamp

63

Function of working lamp

64

Function of step lamp

65

Function of room lamp

66

Function of back-up buzzer

Set the lamp switches (on the 1st and 2nd stages) to ON, and the internal lightings go on. Set the light switches (on the 1st and 2nd stages) to ON, and the right and left front lights go on. Set the lamp switches (on the 2nd stages) to ON, and the head lamps (2 lamps each on the right and left sides) go on. Move the turn signal lever, and the front and rear turn signal lamps corresponding to the intended direction blink. Set the hazard switch to ON, and the right and left turn s ignal lamps and the pilot lamp (arrow) inside the cab blink. Set the light switches (on the 1st and 2nd stages) to ON, and the right and left rear lights go on. Set the transmission shift lever to R, and the back-up lamp goes on. Step on the brake pedal, and the red brake lamps (right and left) go on. Set the light switches to ON and apply the brake, and brightness of the brake lamp changes. (The lamp becomes brighter.) Set the light switches (on the 1st and 2nd stages) to ON and set the F working light switch to O N, and the pilot lamp F goes on and the working light on the cab front head goes on. Set the light switches (on the 1st and 2nd stages) to ON and set the R working light switch to ON, and the pilot lamp goes on and the rear right and left working lights on the radiator grille go on. Set the light switches (on the 1st and 2nd stages) to ON and set the R working light switch to ON, and the pilot lamp goes on, the right and left working lights on the roll- over protective structure and on the radiator guard go on. Set the switch to ON, and the light goes on and goes out automatically about a minute later. Set the switch to ON, and the light goes on. Also, the lights at the doors light when the cab door are opened. The sound volume is satisfactory without vibrating tone. (Sensory)

Check

Maintenance

Remarks

7/9 No.

Inspection items


Check gauge performance. 67 68 69

Function of torque converter oil temperature gauge

During operation, the gauge indicates any point in the green range. During operation, the gauge indicates any point in the green Function of engine coolant temperature gauge range. During operation, the gauge indicates the exact level in the Function of fuel gauge fuel tank.

Checking the power window

70

Function of power window

L. H. side: Press the switch front, and the window glass lowers. Press its rear side, and the window glass rises. R. H. side: Press the switch front, and the window glass lowers. Press its rear side, and the window glass rises.

Checking the windshield wiper

71

Function of windshield wiper

Press the push-button on the side of the switch, and the washer liquid is sprayed over the front glass and the front wiper interlocks. Turn the rotary switch, and the front wiper corresponds to [OFF], [INT], [Low Speed] and [High Speed] in this order. Turn the wiper switch lever backward, and the rear washer liquid is sprayed. Turn it forward to the 1st step, and the rear wiper works, turn it forward to the 2nd step, and the rear washer and the rear wiper interlock.

Checking air conditioner The air flow rate corresponds to that on the fan switch.

Function of air conditioner 72

Since the air conditioner does not work when the temperature in the cab is low, warm the air inside the cab before starting the check.

Press the external/internal air changeover switch, and the indicator lamp on the upper side of the switch goes on. The mode selector switch corresponds to the wind spurtingout position. When the level indicator of the temperature adjustment switch shows green, you can get cool wind, and when it shows red, you can get warm wind. Press the air conditioner switch, and the indicator l amp on the upper side of the switch goes on. The capacitor fan is rotating during operation of the air conditioner.

Checking the AM/FM radio cassette stereo

73

Function of AM/FM radio cassette stereo

Turn the power switch to the right, and the radio is switched on. Keep turning it, and the speaker volume increases. What is effective are auto store, preset scanner, tone (low and high), loudness, manual tuning, seek tuning, band changeover and manual memory. After inserting a cassette tape (arranging the side where the tape can be seen to the right), replay, rapid forwarding and rewinding can be made s moothly. Display the clock (by pressi ng the DIPS button) and check that it shows the correct time.

Checking cigarette lighter 74

Check of cigarette lighter

The cigarette lighter is heated red and returns to where it was several second later.

Checking tire air pressure

75

Tire size and criteria

Measured value: Front left ( Measured value: Front right (

) kg/cm2 ) kg/cm2

45/65-45-46PR L-5 Standard value: 5.25 kg/cm 2

Measured value: Rear left ( Measured value: Rear right (

) kg/cm2 ) kg/cm2

Checking failure code 76

Check of failure code

Make sure that no failure code is dis played on the monitor panel after completion of the function c heck. Check of failure code ( )

Check

Maintenance

Remarks

8/9 No.

Inspection items


Carry out inspection of every part. Cab lining is free from flaw and stain. 77

Chec k of cab Cab glass is free from flaw. Mounting bolts are free from looseness and scuffing.

78

Check of ROPS structure

79

Inspection around machine upper side

The antenna is installed tightly, and the screws are f ree from scuffing. Side working lights and step lights are installed tightly, and the harness is fixed to the clip. Mounting bolts of each handrail are tightened together with washers. Mounting bolts of each handrail are tightened certainly and are free from scuffing. Harness connectors below the floor are certainly locked to the claws, and harnesses do not sway. The throttle cable is connected straight and tightly.

Inspection of loader link and bucket

80

Ф180

Mounting pin bolts of the loader link and bucket are tightened certainly and are free from scuffing. Mounting pins of the loader link and bucket are greased certainly. Bell crank upper pins and lift arm c ylinder pins (on the rod side) are assembled correctl y.

Pin on bell crank side

44 5

Ф180

Pin on lift arm cylinder side

43 5 Their diameters are the same but their lengths are different by 10 mm.

81

Inspection around front axle

Front axle mounting bolts are free from looseness and scuffing. No oil leakage is detected in the brake syst em.

82

Inspection of light support

83

Inspection of front fender

84

Inspection around center pin

Light support mounting bolts are lightened certainly and are free from scuffing. (Check them on both the right and left sides.) Front fender mounting bolts are tightened certainly and are free from scuffing. (Check them on both the right and left sides.) Center pin mounting bolts are tightened certainly and are free from scuffing. (Check both upper and lower pins.) There is some clearance between the upper center pin lock plate and the rear frame. Center pins are greased c ertainly. (Check both the upper and lower pins.) Steering cylinder mounting pin bolts are tightened certainly and are free from scuffing. (Check them on both the right and left sides.) Steering cylinder mounting pins are greased certainly. (Check them on both the right and left sides.) No oil leakage is detected in the hydraulic l ine, steering line and brake line systems. The PPC valve hose connecting portion is no t loose. At the time or right swing, there is not interference between the steering link and the harness to the front. Floor frame mounting bolts are tightened certainly and are free from scuffing.

Check

Maintenance

Remarks

9/9 No.

Inspection items


85

Inspection of exterior parts

Cab skirt panel mounting bolts are tightened certainly and are free from scuffing. Access ladder mounting bolts are tightened certainly and are free from scuffing.

86

Inspection around engine

No oil leakage nor water leakage are detected.

87

Inspection around battery box

88

Inspection of fuel tank

Battery box mounting pin bolts are tightened certainly and are free from looseness and scuffing. (Check the boxes on both the right and left sides.) Battery holder is mounted tightly. (Check it on both the right and left sides.) Battery cables are tightly connected. (Check them on both the right and left sides.) Step mounting bolts on the battery box front side are tightened certainly and are free f rom scuffing. (R. H. side) Belt step mounting bolts are tightened certainly and are free from scuffing. (Check them on both the right and left sides.) Fuel tank mounting bolts are free from looseness and scuffing. The breather tube is not deformed. No fuel leakage is detected from the fuel tank.

89

Inspection around rear axle

Rear axle mounting bolts are free from looseness and scuffing. No oil leakage is detected in the brake syst em.

90

Inspection of counterweight

91

Inspection around hydraulic tank

Counterweight mounting bolts are free from looseness and scuffing. Lift ladder mounting bolts are tightened cer tainly and are free from scuffing. No oil leakage is detected.

92

Inspection of tire and wheel

93

Inspection of lower parts

Hub nuts are mounted tightly and are free from scuffing. (Check them on the four wheels.) Tires are free from flaw and tear. (Check them on the four wheels.) Air valve caps are installed certainly. (Check them on the four wheels.) No oil leakage is detected from the transmission and the torque converter. Front drive shaft mounting bolts are tightened certainly and are free from looseness and scuffing. Rear drive shaft mounting bolts are tightened certainly and are free from looseness and scuffing. There is no clearance at the drive shaft yoke mounting portion. Rear axle rear cover mounting bolts are tightened certainly and are free from scuffing. The rear axle support is greased certainly. No oil leakage is detected in the brake system and hydraulic system.

Check

Maintenance

Remarks

FA WA800,900-3E0 70001,80001 up GEN00056-01

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