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

June 3, 2018 | Author: Javier Ynga Litano | Category: Axle, Crane (Machine), Elevator, Screw, Mechanical Engineering
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CONTENTS 1 Dividing Process Overview (Major components alone) .......................................................................................... 1 2 Major Components Table of Dimensions ............................................................................................................... 2 3 Work Space Layout ................................................................................................................................................ 4 4 Schedule Table for Field Assembly ........................................................................................................................ 5 5 Facility, Jigs and Tools ........................................................................................................................................... 6 6 List of Oil, Grease and Paints ................................................................................................................................. 9 No. 0010 Oil, grease and coolant 0020 Oil, grease and coolant level 0030 Setting rear frame in place 0040 Setting front frame in place 0050 Joining front and rear frames 0060 Front and rear frames joining procedure 0070 Assembling the steering pin 0080 Assembling the center drive shat (Center support – Transmission) 0090 Connecting the pipes - Part 1 0100 Connecting the pipe - Part 2 0105 Connection of piping (Part 2) (Riotinto specification: If equipped) 0110 Connecting the auto-greasing pipe 0120 Setting the axle in place and assembling the support 0130 Setting the bare machine in place 0140 Assembling the rear axle 0150 Rear axle rear side cover assembling procedure 0160 Connecting the rear axle pipe 0165 Fixing of rear axle piping (Brake cooling specification: If equipped) 0166 Connection of rear axle piping (Riotinto specification: If equipped) 0167 Fixing of rear axle piping (Brake cooling specification: If equipped) 0168 Connection of cooling line piping (Brake cooling specification: If equipped) 0170 Assembling the rear drive shat (Transmission – Rear axle) 0180 Assembling the front axle 0182 Fixing of front axle piping (Brake cooling specification: If equipped) 0185 Connection of front axle piping (Brake cooling specification: If equipped) 0190 Connecting the front axle pipe 0195 Connection of front axle piping (Riotinto specification: If equipped) 0200 Connecting the front drive shat (Front axle – Center support) 0210 Connecting the axle oil temperature sensor (For VHMS specification only) 0220 Assembling the tires 0230 Assembling the fuel tank 0235 Installation of fuel tank (Riotinto specification: If equipped) 0240 Fixing the drain pipe 0245 Fixing of torque converter cooler drain piping (Riotinto specification: If equipped) 0250 Connecting the fuel pipe 0260 Fixing the engine drain hoses 0270 Assembling the hydraulic tank ladder 0280 Assembling the floor and cab assembly 0290 Connecting the air conditioner hose 0300 Connecting the brake line 0310 Connecting the window washer hose 0320 Connecting the PPC line hose 0330 Connecting the floor wiring harness 0333 Connection of floor wiring harness -1 (Riotinto specification: If equipped) 0334 Connection of floor wiring harness -2 (Riotinto specification: If equipped) 0340 Connecting the link for AJSS (For AJSS specification only) 0345 Calibration of the AJSS angle and frame offset angle 0350 Assembling the auto-greasing pump and connecting the pipe (WA900-3E0 North American specification) 0360 Assembling the floor cover 0370 Refilling the window washer 0380 Assembling the battery box Item Page 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 No. 0390 Connecting and fixing the battery wiring Item Page 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 0393 Wiring on right side of battery (Riotinto specification: If equipped) 0394 Wiring on left side of battery -1 (Riotinto specification: If equipped) 0395 Wiring on left side of battery -2 (Riotinto specification: If equipped) 0396 Wiring on left side of battery -3 (Riotinto specification: If equipped) 0397 Connection of ground cable on left side of battery (Riotinto specification: If equipped) 0400 Assembling the battery step 0403 Installation of oil cooler assembly (Brake cooling specification: If equipped) 0404 Installation and connection of oil cooler assembly piping (Brake cooling specification: If equipped) 0406 Installation of oil cooler assembly piping -1 (Brake cooling specification: If equipped) 0407 Installation of oil cooler assembly piping -2 (Brake cooling specification: If equipped) 0410 Assembling the handrail (On the right hand platform) 0411 Installation of handrail (Right platform area) (Brake cooling specification: If equipped) 0420 Assembling the handrail (On the hood top face) 0430 Assembling the handrail (On the right hand battery box) 0440 Assembling the rear access step 0450 Assembling the left handrail (Part 1) 0460 Assembling the left handrail (Part 2) 0461 Installation of left handrail (Part 2) (Brake cooling specification: If equipped) 0470 Assembling the rearview mirror 0471 Installation of rearview mirrors (Brake cooling specification: If equipped) 0480 Assembling the exhaust pipe 0485 Installation of oil cooler guard assembly (Brake cooling specification: If equipped) 0486 Installation of fan motor piping cover -1 (Brake cooling specification: If equipped) 0487 Installation of fan motor piping cover -2 (Brake cooling specification: If equipped) 0490 Applying the counterweight anti-slip 0500 Assembling the counterweight (WA900-3E0 standard specification) 0505 Assembling the counterweight (WA900-3E0 High-lift arm specification) 0510 Assembling the counterweight (WA800-3E0 Overseas general, optional specification and North American specification) 0520 Assembling the counterweight (WA800-3E0 Overseas general standard specification) 0530 Assembling the front axle lamp and connecting the harness 0540 Assembling the front lamp assembly 0550 Assembling the ROPS canopy assembly 0560 Assembling the antenna and work lamp 0570 Assembling the VHMS antenna (For VHMS specification only) 0580 Assembling the floor mat 0590 Assembling the front fender 0600 Engine starting procedure 0610 Bleeding the brake air 0615 Bleeding air from hydraulic circuit 0620 Assembling the lift arm assembly (Part 1) 0630 Assembling the lift arm assembly (Part 2) 0640 Connecting the remote grease tube 0650 Assembling the bucket (Part 1) 0660 Assembling the bucket (Part 2) 0670 Assembling the bucket (Part 3) 0680 Assembling the cover (Bottom of the counterweight) 0690 Feeding the grease 0700 Work equipment hydraulic circuit air bleeding procedure 0710 Adjusting the bucket positioner 0720 Adjusting the new 2 stage (Overseas general standard) 0730 Adjusting the new 2 stage (North American standard specification) 0740 Assembling the lift arm angle sensor 0750 Adjusting the active working system and boom kick-out switch (Overseas general standard and domestic standard) 0760 Touchup work 0770 Applying the decal (For the overseas-directed products only) Appendix: Field assembly inspection report Battery box assembly 17. Ladder assembly 12. Lift arm assembly 8. Floor handrail assembly 11. Rear frame subassembly 3. Front lamp assembly 14. Muffler stack 15. Front axle assembly 4. Front fender 13. Rear axle assembly (With rear axle support) 5. Counterweight 1 . Fuel tank assembly 16.1 Dividing Process Overview (Major components alone) 1. Bucket assembly 7. ROPS canopy assembly 10. Front frame subassembly 2. Floor and cab assembly 9. Wheel and tire assembly 6. 2 Major Components Table of Dimensions Unit name 1 2 3 4 5 6 7 8 9 Floor and cab assembly Front frame subassembly Rear frame subassembly Front axle assembly Rear axle assembly (with axle support) Wheel and tire assembly Bucket assembly Q'ty 1 1 1 1 4 1 1 1 1 1 2 2 2 1 1 1 1 Weight (kg) 11.500 26.425 4400 4400 1200 5200 2300 2500 1820 500 800 800 400 1800 900 3200 375 W: Overall width (mm) 2.600 L: Overall length (mm) 4.380 12.000 8.155 1000 1000 2800 2500 2100 2200 1100 2400 1400 1300 1700 1100 800 600 600 ROPS canopy assembly Floor handrail and rear access step 10 assembly 11 Ladder assembly 12 Front fender 13 Front lamp assembly 14 Muffler stack 15 Fuel tank assembly 16 Battery box assembly 17-1 Counterweight 17-2 Additional counterweight (Dimensions depend on ATT) 2 .500 14.830 6.200 H: Overall height (mm) 3.387 650 60 170 65 50 790 580 2.250 3.514 8.000 1.900 2.150 3.290 1.200 1600 1800 2800 2900 1800 1900 3940 700 1700 700 400 1900 900 1200 3. 155 Style Packing style in transportation by trailer (Application for the Special-purpose Vehicle Passage may be required) Maximum loading mass Loading space length Loading space width Overall length Gooseneck length ton mm mm mm mm 36 6.300 3. fuel tank (including (fuel) and exhaust pipe] 11. loader link. platform.425 3. front axle.900 2. handrail. rear axle (including swivel support).200 11.500 3 . parts around cab and operator's seat.500 4.150 26. tire and rim.200 3. exterior parts (hood grille.250 3. counterweight.830 2.000 6.2 Major Components Table of Dimensions Land transportation Transportation means Front frame assembly in transportation by trailer Rear frame assembly in transportation by trailer Weight (kg) Relevant specifications Overall length Overall width (mm) (mm) Overall height (mm) Provisions required for transportation One 36 ton trailer [For the machine body excluding the following removed parts] Four 15 ton trailers [Bucket. ladder. light support). fender. 3 Work Space Layout (A larger workspace provides better workability.) Tire and wheel assembly Lift arm assembly Bare machine 50 ton crane Front axle assembly Light-weight units storage place Front fender Ladder and muffler stack Front lamp Floor handle Rear axle assembly Front tank Floor and cabin assembly assembly Bucket assembly Counterweight assembly 50 ton crane ROPS canopy assembly Compressor parts Jigs and tools storage place 4 . 25 m × 30 m shown in the figure below is the minimum required space. ROPS. Crane: 50 ton Crane: 50 ton Frame assembly stand Condition of chassis Mount onto counterweight mounting end plate. checking. and adjusting bucket Checking and touchup painting Crane Worker 5 workers 2 workers 5 .4 Day 2nd day 3rd day 1st day Hour Crane: 25 ton Crane: 25 ton Frame assembly stand Mount onto counterweight mounting end plate. and lift arm Installing. Rough assembly work Positioning chassis Coupling frames Positioning axles Installing tires Installing fuel tank and cab Installing step handrails and battery box Crane Schedule Table for Field Assembly Worker 5 workers 5 workers Day 5th day 4th day Hour Condition of chassis Rough assembly work Installing counterweight. 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 For REAR/FRONT(648) For REAR/FRONT(680) (Note) The joint indicated in the figure must be welded at 9 . Quantity For front 2 pieces For rear 2 pieces 6 . 5 × L:41 10 pounds — Large.9 Nm {20 – 140 kgm} 490.4) × L: 68 46T (Entry point 25.4) × L: 82 Entry corner 12. medium and small — Capacity about 300 cc Capacity 1.372. counterweight and ROPS canopy For power wrench For connecting hoses and tubes For connecting hoses and tubes For connecting hoses and tubes Remarks 16 1 each For connecting hoses and tubes For rear axle support cover.1 Nm {2 – 4. 16 time 4 time 60T (Entry point 38.1) × L: 84 36T (Entry point 25.000 cc Inside diameter: ø6.4 × L:160 39.5 kgm} 29.7 × L:150 Entry corner 19 × 12.4 – 68.6 – 44. monkey wrench.2 – 274. 41 196.4) × L: 72 55T (Entry point 38.000 – 2.8 – 411.7 × 9.6 Nm {4 – 28 kgm} 58.5 Facility.4 Nm {50 – 210 kgm} 58. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Tool name List of standard general tools Power wrench Power wrench Socket Socket Socket Socket Socket Extension bar Adapter Extension bar Preset torque wrench (Box type) Head replacement type preset torque wrench Head replacement type preset torque wrench Head replacement type preset torque wrench Head replacement type preset torque wrench (Spanner type) Preset type torque wrench (Box type) Preset type torque wrench (Box type) Preset type torque wrench (Box type) Impact wrench Impact wrench Impact wrench Adapter Adapter Large hammer Air grinder Bar Round mandrel Grease gun (Hand pump type) Oil jack Vinyl hose Head replacement type preset torque wrench Head replacement type preset torque wrench Specification Spanner.1) × L: 82 55T (Entry point 25.8 – 137.9 Nm {6 – 42 kgm} GT-P8M or equivalent GT-P14M or equivalent GT-S22M or equivalent Entry corner 19 × 25.0. 36. etc. ring spanner and box spanner chisel Screwdriver. Jigs and Tools Tools used No.3 – 2.1 Nm {20 kgm} 176. tire and counterweight For fuel tank and counterweight ROPS mount ROPS mount For fuel tank For fuel tank For tire.5 – ø7. counterweight For counterweight For rear axle support cover 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 1 1 1 1 1 1 1 1 1 1 2 each 2 1 1 1 1 1 For tire and ROPS canopy For power wrench and torque wrench For power wrench and torque wrench For adjustment of holes and moving heavy stuff For adjustment of holes For applying grease to pins For bleeding air from brake line For bleeding air from brake line For connecting hoses and tubes For connecting hoses and tubes 7 .4 × L:71 Entry corner 12.7 × L:55 Entry corner 25. hex wrench. hammer.000 – 1.5 Nm {18 kgm} Q’ty 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Front and rear axle mounts.3 Nm {6 – 14 kgm} 19.500 196.059.6 Nm {3 – 7 kgm} Width across flats: 27 (Entry point: ø15) 19 (Entry point: ø12) 22 (Entry point: ø12) 24 (Entry point: ø12).1 – 1. ROPS canopy mount Fuel tank mount For front and rear axle mounts For rear axle support cover. L: 1. 3 in chain diameter)) Floor and cab assembly lifting tool 2 point lift (Sling hook (SL) of L = 2.000 Wire sling Shackle Eyebolt Nylon sling 1.438 (Large) 25 × 250 × 600 400 × 400 × 900 200 × 400 × 800 Capacity: 18l Gauge manifold.000 2.3 in chain diameter)) Nylon sling 150 × 10.250 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 = 5.5 Facility. Fuel tank sling 8.500 Withstand load 11 tons and L = 2. 5 ton.500 and ø16 in chain diameter)) Nylon sling 50 × 2. Rear frame sling Tire lifting tool For removing crossties under machine body (Front lifting) Lift arm lifting tool 2 each Lift arm lifting tool 3.000 and ø6.219 × 2.000 2 point lift Fuel tank lifting tool (Sling hook (SL) of L = 5. Front/Rear axle sling 7. 2 ton Capacity: Min. 32l 1 ton 4 stage (About 1. leak detector Specification Min. 1 2 3 4 5 6 7 8 9 10 11 12 13 Specification 2 point lift Front frame lifting tool (Sling hook (SL) of L = 2. Front frame sling Sling name Q’ty 1 1 1 2 1 1 1 2 2 1 2 1 Remarks See the figure below See the figure below See the figure below Holding axle support and cylinder See the figure below See the figure below See the figure below Withstand load 15 tons and L = 2. 1 2 3 4 5 6 7 8 9 10 11 Crane Forklift Compressor Lever block Footstall (Work table) Steel plate Steel plate Crosstie Air grease gun Air conditioner gas charge Tester Tool name Min. Rear axle sling Chain diameter Chain diameter Chain diameter Chain diameter 5.000 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 m high) (Large) 9 × 1. Jigs and Tools Facilities used Tools and facilities used No.000 and ø6. 50 ton Q’ty 2 1 1 3 3 4 4 14 4 1 1 1 For impact wrench and bleeding air For holding cylinder and drive shaft For work For setting bare machine in place For setting bare machine in place For setting bare machine in place For setting bare machine in place Remarks Lifting tools used No.000 For 2 ton. 10 ton and 15 ton (Top) 2 and (bottom ) 1 25 × 2. Floor and cab assembly sling Chain diameter Chain diameter Chain diameter 8 .5 in chain diameter)) Nylon sling for drive shaft 50 × 5. Grease and Paints Oil.000l Protective gear Work uniform. goggles and rain coat 9 . paints and others No. 1 2 3 4 5 6 Oil. following must be additionally used.200 l) When the front and rear frames were divided. grease. grease and paints Hydraulic oil Specification (KES EO10-CD or equivalent) Quantity 1.6 List of Oil. No. grease and paints Extreme-pressure added with molybdenum disulfide Extreme-pressure added with molybdenum disulfide Fuel Paint for touchup Air conditioner gas Window washer liquid Specification (KES LM-P or equivalent) (KES LM-P or equivalent) Diesel fuel Black R134A gas can (400 g) 1 1l container × 2 Quantity 500 ml 10l Appropriate amount (Full capacity is 1. cotton gloves. 1 Oil. helmet. safety boots. And the amount of replacement oil refers to the amount of oil to be replaced in the inspection and maintenance. Note. adjust the density referencing the section "Cleaning of inside of coolant system" in the Operation and Maintenance Manual. 0010 Oil.. a Whenever starting the engine with atmospheric temperature at 0°C or below. 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. If it went below -10°C...g. 10 .Assembly procedure No. 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. see the Operation and Maintenance Manual. Note. 1. a For details of the notes (e. 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.) in the table. EOS0W30 or EOS5W40 must be used for the engine oil pan although the temperature may usually rise up to 10°C or above. 2 . the pipe can be damaged. (Otherwise. be sure to check the level of oil. 0020 Oil. don't try to turn the steering in a large angle. Before the suspension adjustment is complete.Assembly procedure No. grease and coolant.) Cautions Special tool Name Q’ty Necessary Equipment Name Q’ty Others 11 .065 42 360 each 360 each 1.555 337 Volume of replaced oil (l) 130 140 725 31 360 each 360 each — — Volume of refilled oil (l) Caution: Whenever started or stopped the engine. grease and coolant level Lubricating points Engine oil pan Transmission case Hydraulic oil system Brake oil tank Front axle Rear axle Fuel tank Cooling system Types of oil Engine oil Power train oil Hydraulic oil Engine oil Power train oil Axle oil Diesel fuel Super coolant Specified oil level (l) 140 164 1. 2. No. ø20) 1 12 Others .W9E-030) Cautions Special tool Name Q’ty Necessary Equipment Name Q’ty Lifting tool: 2 point lift (L = 2.250. Hitch the lifting tool on the position indicated in the figure and lift rear frame (1). (1) Part No. 0030 Setting rear frame in place 1.Assembly procedure No. 427-46-2295A Part name Q’ty State of part (Parts list No. Set rear frame assembly (1) in place using the steel plate and deck as shown in the figure.) Rear frame assembly 1 Separately packed (No. 250. 3. protect the pins from damage by wrapping a piece of rag around them.000 mm Lumber Deck Steel plate 1. 427-N96-215A Part name Front frame assembly Q’ty State of part (Parts list No. No. 1. Set front frame assembly (1) in place using the deck and lumber as shown in the figure. 2. 0040 Setting front frame in place Wrap the pins with a piece of rag and then hitch the lifting tool on the front frame. When lifting front frame assembly (1).) 1 Separately packed (No. (1) Part No.W9E-040) Cautions Special tool Name Q’ty Necessary Equipment Name Q’ty Lifting tool: 2 point lift (L = 2.Assembly procedure No. Lift front frame assembly (1). ø20) 1 Others 13 . Coating with LM-P Coating with LM-P Coating with LT-2 Tightening torque : 824 – 1. 927.5 427-46-11431 Retainer 01011-63065 Bolt 01643-33080 Washer 01010-62495 Bolt 01643-32460 Washer 427-46-11330 Plate 01010-61025 Bolt 01643-31032 Washer 427-46-11321 Bushing Q’ty 1 1 1 4 6 10 1 1 1 1 1 20 24 1 4 4 10 10 2 4 4 1 Joining front and rear frames State of part (Parts list No.Assembly procedure No.910 Nm {155 – 195 kgm} Cautions Special tool Necessary Equipment Name Q’ty Name Q’ty w Be sure.0060. and 1. Part name 427-46-11161 Shaft 427-46-11190 Retainer 427-46-11440 Bushing 01010-62065 Bolt 01010-62070 Bolt 01643-32060 Washer 427-46-11312 Shaft 01010-63075 Bolt 427-46-11480 Bushing 427-46-11490 Bushing 427-46-11391 Bushing 427-46-11411 Shim t = 0. to apply sufficient 50 ton crane 2 amount of grease to the inside of the bearing. w Touch up the black bolt and the machined sur.715 Nm) Lifting tool (For front frame and rear frame) 1 each with grease until it flows out the dust seal after Jack.030 Nm {84 – 105 kgm} Coating with LT-2 Tightening torque : 1. thickness gauge and copper hammer Air compressor 1 assembly. 14 .) Temporarily installed on the rear frame Temporarily installed on the rear frame Temporarily installed on the rear frame Temporarily installed on the rear frame Temporarily installed on the rear frame Temporarily installed on the rear frame Separately packed (No. #30.W9E-050) Press fitted to the rear frame Press fitted to the rear frame Temporarily installed on the rear frame Temporarily installed on the rear frame Temporarily installed on the rear frame Temporarily installed on the rear frame Temporarily installed on the rear frame Temporarily installed on the rear frame Temporarily installed on the rear frame Temporarily installed on the rear 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 For the front and rear frames joining procedure.W9E-050) Separately packed (No.1 427-46-11421 Shim t = 0. and #46) w Fill the upper hinge and lower hinge shafts Torque wrench (Set 549. in the assembly. #36.520 – 1. Impact wrench (Socket #17. 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. (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15) (16) (17) (18) (19) (20) (21) (22) Part No. see NO. 0050 No.Others face. 11. Be sure to tighten the bolts paying attention to their behavior. 8. 3. 12. Assemble bushing ((3): 427-46-11440) to the upper hinge of the rear frame. tighten the bolts diagonally in the order of 1 o 2 o 3 o 4 o 5 o 6.520 – 1. in the assembly. Assemble bushing ((22): 427-46-11321) to the lower hinge of the front frame. 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. 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}]). Assemble retainer ((2): 427-46-11190) to upper pin ((1): 427-46-11161). (Degrease the threaded and tapped portions completely. to apply sufficient amount of grease to the inside of the bearing. [Caution] a After the work. Cautions Special tool Necessary Equipment Name Q’ty Name Q’ty w Be sure. 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. Impact wrench (Socket #17.910Nm {155 – 195 kgm}. 2.18 mm. a Fill the upper hinge and lower hinge shafts with grease until it flows out the dust seal after assembly. in the assembly. Then tighten them in the order on the circumference. and #46) w Fill the upper hinge and lower hinge shafts Torque wrench (Set 549. Then retighten bolts ((15) and (17)) with M24: 824 – 1. Tightening torque 490 – 608 Nm {50 – 62 kgm} 5. Combine shims in such that the average clearance is adjusted to 0. and then strike the lower pin head 3 – 5 times using the copper hammer. coat them with Locktite #262 and then tighten them with the specified torque. a Be sure.520 – 1.) 14. 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: 1.08 – 0. 7.030 Nm {84 – 105 kgm} and M30: 1. Repeat tightening until they are firmly fixed and don't move. Place the front frame between the rear frame hinges and then insert the upper pin.910 Nm {155 – 195 kgm}. Front and rear frames joining procedure a Front frame and rear frame joining procedure Make sure bushings ((9): 427-46-11480 and (10): 427-46-11490) are press fitted to the rear frame. thickness gauge and copper hammer Air compressor 1 assembly. Pull out bolts ((15) and (17)) one by one. Repeat Step 8 three times so that respective contact regions may fit well. Proceed to Step 8 and 9. #30. 9. #36. 15. And then conduct Step 13 on them. Tightening torque 490 – 608 Nm {50 – 62 kgm} Initially. 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).715 Nm) Lifting tool (For front frame and rear frame) 1 each with grease until it flows out the dust seal after Jack. Note that thickness of the shims must not exceed the thickness of the individual clearances measured.Assembly procedure No. to apply sufficient 50 ton crane 2 amount of grease to the inside of the bearing. using the thickness gauge. Remove the jack from the lower hinge of the front frame. Remove all bolts ((17)) and then measure. w Touch up the black bolt and the machined surface. Others 15 . 927. 13. respectively. Tighten the bolts to the specified torque. namely 1 o 3 o 5 o 2 o 4 o 6 o 1 o . 0060 1. 4. and 1. 10. fix the machine in place with the safety lock bar to prevent articulation. clearance between retainers ((2) and (14)) and frame at three points (in 120° intervals) to calculate the average clearance. Clean the mounting surface of the steering cylinder and pin.3 kgm} set) 16 Others .0 – 43.) 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 Special tool Name Impact wrench Socket (22 mm. Necessary Equipment Q’ty 1 1 each 1 each 1 Name Air compressor Q’ty 1 Torque wrench (385 Nm {39. FITTING (07020-00900) DIRECTION TO BE SYMMETRICAL. 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. Tightening torque : 343 – 427 Nm {35. Make sure the surface is free from foreign substances. Use care not to foul the internal tapered surface with lubricant agent such as grease. For the grease fitting mounting direction. Use care not to foul the internal tapered surface with lubricant agent such as grease. see the figure below. 24 mm) Spanner (10 mm. Make sure the dust seal is assembled being faced outward. 14 mm) Machine center Rear frame Top view of the joint of the front frame and rear frame Cautions 1. Machine front side Steering cylinder No. coat the bushing inner periphery and dust seal lip on the cylinder side with LM-P. (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) Part No. The slit shall be set in the longitudinal direction of the machine body. 0070 Assembling the steering pin The slit shall be set in the longitudinal direction of the machine body.Assembly procedure No.5 kgm} Before assembling the pin. W9E-080) 01050-61895 Bolt 4 Separately packed (No. Mounting surface shall be free from rusts.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. 3. The bolts must be basically tightened diagonally. Cautions 1. No. 30 mm) Torque wrench (385 Nm {39. 2. Sequential tightening of the bolts must be repeated 2 rounds minimum. Must be retightened to the specified torque. Assemble setting the longer side to the transmission Grease nipple position Both the front and rear must be directed in the same direction. Visually inspect the seating face and then apply a check mark using a white felt pen. apply touchup coating on the black bolt to prevent its getting rusty. Make sure the surface is free from foreign substances.0 – 43.Assembly procedure No.0 – 43. Assemble drive shaft (4) as shown in the figure. 4.3 kgm} set) Q’ty 1 1 each 1 Necessary Equipment Name Air compressor Q’ty 1 Others 17 . Tightening torque : 343 – 427 Nm {35. Part name Q’ty State of part (Parts list No. 5. Assemble setting the shorter side to the center support Points to notice 1. Insert 4 bolts temporarily and tighten them temporarily until the seating face is closely contacted. Tightening torque : 343 – 427 Nm {35. After the work. Clean the mounting surface of the drive shaft. pay attention to its direction. Remove (1) and (3) being temporarily installed on the rear frame. Special tool Name Impact wrench Socket (27 mm.W9E-080) Grease nipple position in the spider of 427-20-12211 Coating with LT-2.5 kgm} Part No. Assemble (1) – (3) to their original positions.) 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. foreign substances and dents.W9E-080) 01050-61895 Bolt 4 Separately packed (No. (1) (2) (3) (4) (5) (6) Coating with LT-2.) 3. 2. 2. 0080 Assembling the center drive shat (Center support – Transmission) 1. (When assembling the drive shaft. 2 Impact wrench. 4. (The bolt tightening torque must conform to KES 04. Make sure the O-rings are not damaged.) 1. Don't try to start working on 6 lines at a time. 2 green marks are applied. clean oil being deposited in the surroundings. 3. 0090 Connecting the pipes . For other O-rings. Make sure they are free from foreign substances.Part 1 a A hose is connected (1) – (6) hoses. if any.Assembly procedure No. Special tool Name Impact wrench Socket (19 mm. Connect the hose. (Be sure to implement and complete the following 1 – 4 steps on a line basis. Remove the blind parts on the pipe. 22 mm) Q’ty 1 1 each Necessary Equipment Name Air compressor Q’ty 1 18 Others .) Cautions 1. Note: A single green mark is applied to the O-ring in the connection of (4) alone. 2. After connecting the pipe.123. if any.Part 2 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 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. Be sure to implement Steps (1) – (3) on a line basis. 2. Others 19 . 3. When connecting the hose.5 kgm} Viewed from the machine left side Viewed from the machine right side 1. After connecting the pipe.5 Nm {8 kgm} set) Q’ty 1 each Necessary Equipment Name Q’ty 1. 0100 Connecting the pipe . Make sure they are free from foreign substances. Cautions Special tool Name Torque wrench (49 Nm {5 kgm}.5 – 9.Assembly procedure No. 4. Remove the blind parts on the pipe. 78.5 – 13. clean oil being deposited in the surroundings. Connect the hose. don't try to start the work on (1) – (10) lines at a time. 2. Remove the pipe blocking parts.5 – 9. 0105 Connection of piping (Part 2) (Riotinto specification: If equipped) 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. 78. 4. if there is any.Assembly procedure No. 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 1.5 – 9. Special tool Name Torque wrench (49 Nm {5 kgm}.5 Nm {8 kgm} set) Q’ty 1 each Necessary Equipment Name Q’ty 20 Others . wipe off oil sticking around it.5 kgm} Machine seen from right 1. Connect the hoses. After connecting the piping.5 kgm} Tightening torque 54 – 93 Nm {5. 3.5 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 – Tightening torque 84 – 132 Nm {8.5 – 13. Check that no foreign matter is sticking. Assembly procedure No. 0110 Connecting the auto-greasing pipe 1.5 kgm} set) 1 Necessary Equipment Name Q’ty Others 21 . 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 Name Q’ty Torque wrench (103 Nm {10. 404 kg Setting dimension 5.450 mm Support Lifting load: 300 kg.450 mm space between the wheelbases. (Clean inside of the axle support using a piece of rag and then coat the bushing inner surface with grease (G2-LI)). Fit the rear axle support to the rear axle and then fix it with a wire to prevent its detachment.912 kg Setting the front and rear axles in place Ground level Front axle Steel plate Rear axle Steel plate Setting dimension 5.Assembly procedure No.450 mm Wheelbase 7. Set the front axle assembly and rear axle assembly (with axle support) in the machine body assembling area in the 5. See the figure. 2. 0120 Setting the axle in place and assembling the support 8. (It is needed to prevent its detachment due to vibrations) Special tool Name Q’ty Necessary Equipment Name Q’ty 22 Others . Cautions Q The support must be fixed with a wire and the like. 50 × 2. Clean inside of the axle support and apply grease (G2-LI). 3.000 2 nylon slings 1. ) Details of lifting tool For front frame Lifting Load: 11. lift the bare machine with two 50 ton cranes. 2.Assembly procedure No.500 2.438 × 9 (t) = 2 plates) a Set the machine in a flat place in order to prevent leaning of the machine in the longitudinal direction as much as the situation allows.5 ton Crane: 50 ton 2. 0130 Crane: 50 ton Setting the bare machine in place Crane: 50 ton Ground level Front axle Rear axle 1. Set the bare machine in place by use of the frame deck in such that assembling of the tire and wheel assembly is available. (Dimensions: 1.219 × 2.900 For rear frame Lifting Load: 20 ton Crane: 50 ton 2. Set it secure on the upside of the front and rear axle assembly. 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.850 Cautions Special tool Name Q’ty Necessary Equipment Name Q’ty Others 23 . (Leaned machine makes the pinhole adjustment difficult when installing the lift arm.250 3. Using the lifting eye on the frame. 3. W9E-140) Temporarily installed on the rear axle Temporarily installed on the rear axle Temporarily installed on the rear axle Separately packed (No. Weight = 7.) 3.914 kg When assembling.W9E-140) Temporarily installed on the machine Temporarily installed on the machine Separately packed (No. Assemble rear axle assembly (1). Tightening torque : 824 – 1. After the assembly.170 – 3.030 Nm {84 – 105 kgm} (See 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 Axle support assembly Cautions Special tool Name Power wrench Torque wrench Socket 60 mm Socket 36 mm Q’ty 1 1 1 1 Necessary Equipment Name Q’ty 24 Others . reference No.) Separately packed (No. Tightening torque : 3. care must be exercised not to collapse the brake pipe on both side.) Rear axle assembly 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 Part name Rear axle assy Bolt Washer Nut Cover thrust Bolt Washer Bolt eye Valve Washer thrust Plate thrust Bolt Washer Q’ty 1 4 8 4 1 16 16 1 1 2 1 16 16 State of part (Parts list No. (Hitch the lifting tool in a squeezing manner to lift the axle support horizontally.030 Nm {84 – 105 kgm} Coat the front and rear face of thrust washer (9) with grease (G2-LI). (Space between the frame and rear axle is limited.0150 Rear axle side rear cover assembling procedure. For assembling of cover (5). touch up the lifting traces. (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) Part No.0150) Tightening torque : 824 – 1. 0140 Assembling the rear axle 1.Assembly procedure No.870 Nm {323 – 395 kgm} 4. 5.W9E-140) Separately packed (No. Remove the parts being temporarily installed on the machine and rear axle.0150) (See No. 2. Hitch the lifting tool to rear axle assembly (1) and lift it as shown in the following figure. Assembly procedure No. Aligning position of the hole requires about two workers. Special tool Name Q’ty Necessary Equipment Name Q’ty Others 25 . a Caution • This operation must be carried out carefully exchanging signals with the forklift operator. 0150 Rear axle rear side cover assembling procedure Portion A View Z a Place bolt (6) and washer (7) beforehand in the hole being drilled when assembling cover (5) (view Z). • Cover weight: 119 kg Cautions a Reasonable care must be exercised in the assembling since the cover weighs 119 kg.) View Y Move the cover to the bottom of the installation position using the forklift and then install it aligning position of the hole. (Installation of the bolt in a later step is unavailable. 5 – 13.Assembly procedure No. Connect the brake line hose to the rear axle side right and left tubes. 1. Connect the breather hose to the rear axle side connector. 2. 0160 Connecting the rear axle pipe Torque converter Rear axle Connect the brake line hose to the rear axle side tube.5 kgm} Connect the breather hose to the rear axle side connector. (2 on both sides) Top view of rear axle Connection tightening torque : 84 – 132 Nm {8. Cautions Special tool Name Q’ty Necessary Equipment Name Q’ty 26 Others . (1) (2) (3) (4) (5) Part No. Rear axle seen from rear 1.Assembly procedure No. 2.) 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 Q’ty Necessary Equipment Name Q’ty Others 27 . Tighten parts (2) – (5) permanently. 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. 0165 Fixing of rear axle piping (Brake cooling specification: If equipped) Fixing: Fix together with axle bolt. Fix plate (1) to the rear axle with the rear axle bolt. No. 0166 Connection of rear axle piping (Riotinto specification: If equipped) Rear frame seen from left View Z: Rear frame seen from above Rear frame seen from left rear. Connect the piping to elbow (1) installed to the rear axle.Assembly procedure No. 1. (1) Part No.) 1 Installed to rear axle Cautions Special tool Name Q’ty Necessary Equipment Name Q’ty 28 Others . No. 427-Z89-3880 Part name Elbow Q’ty State of part (Parts list No. W9E-167) Separately packed (No. 07296-21213 07371-31255 07375-21035 07000-F3038 Part name Hose Flange Bolt. Connect hose (1) installed to the rear axle. sems O-ring Q’ty 1 2 4 1 State of part (Parts list No. 0167 Fixing of rear axle piping (Brake cooling specification: If equipped) Connection To rear axle Lower part of rear axle 1.) Installed to rear axle Separately packed (No.Assembly procedure No. No. W9E-167) Cautions Special tool Name Q’ty Necessary Equipment Name Q’ty Others 29 . W9E-167) Separately packed (No. (1) (2) (3) (4) Part No. (5). 2. 0168 Connection of cooling line piping (Brake cooling specification: If equipped) Connection: Check O-ring. Fixing Connection: Check O-ring. 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. No. (6). (1) (2) (3) (4) (5) (6) (7) (8) (9) Part No. (8) and (9). 02896-21018 07371-31255 07375-21035 07000-F3038 01643-31032 01011-81020 07095-20627 04434-53412 01596-01009 Part name O-ring Flange Bolt. Connect and fix the cooling line with the parts removed in 1 above. (7). Inside of rear frame seen from left 1. Remove temporarily installed parts (2).) 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 Q’ty Necessary Equipment Name Q’ty 30 Others . (3).Assembly procedure No. Insert 4 bolts temporarily and tighten them temporarily until the seating face is closely contacted.W9E-170) Cautions Special tool Name Q’ty Necessary Equipment Name Q’ty Others 31 . When assemble. 2. center and rear drive shafts.000) through the frame center and then lift the shaft from the right platform by use of the crane. 3. clean drive shaft (1) mounting surface. No. Sequential tightening of the bolts must be repeated 2 rounds minimum. Visually inspect the seating face and then apply a check mark using a white felt pen. Mounting surface shall be free from rusts. (When assembling drive shaft (1).) 3. 427-20-12211 01050-61895 Part name Rear drive shaft Bolt Q’ty State of part (Parts list No.) 1 Separately packed (No. Assemble drive shaft (1). 1. 4. foreign substances and dents. set the male side in the front (transmission side). 0170 Assembling the rear drive shat (Transmission – Rear axle) Tightening torque : 343 – 426 Nm {35 – 43. 2. Points to notice 1.Assembly procedure No. Prior to assembling. Feed grease (molybdenum disulfide grease) to the grease fitting for the axle support and drive shaft. pay attention to its direction as well as that of the grease nipple situated in the spider of the front. The bolts must be basically tightened diagonally. (1) (2) Part No. Must be retightened to the specified torque. Then adjust the position and assemble it.5 kgm} Rear axle Grease nipple position in the spider of 427-20-12211 Grease nipple position (Viewed from the machine rear side) Lead the nylon sling (50 × 5.W9E-170) 8 Separately packed (No. 5. 0180 Assembling the front axle Tightening torque : 3. Clean the contact face before assembling the front axle assembly (1). No. 427-22-2020A 427-46-11452 01643-33990 01580-03931 Part name Front axle Bolt Washer Nut Q’ty 1 16 32 16 State of part (Parts list No. Remove (2) – (4) being temporarily installed on the axle skid.) Separately packed (No. 4. (1) (2) (3) (4) Part No.404 kg a Clean the contact face of the mount before assembling the front axle.W9E-180) Temporarily installed on the axle skid Temporarily installed on the axle skid Temporarily installed on the axle skid Cautions Special tool Name Q’ty Necessary Equipment Name Q’ty 32 Others .870 Nm {323 – 395 kgm} Weight = 8. (Lifting load: 8. 5.170 – 3. hitch the lifting tool to it as shown in the figure to the left. When lifting front axle assembly (1). 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.Assembly procedure No.404 kg) 1. touch up the lifting traces. 3. After the assembly. Assemble front axle assembly (1). 2. W9E-182) Separately packed (No. (1) (2) (3) (4) (5) (6) (7) Part No. 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. 0182 Fixing of front axle piping (Brake cooling specification: If equipped) Control valve To mounting position on left inside of front frame Mounting position Left side view of front frame 1.Assembly procedure No. sems Clip Seat Nut Washer Bolt. W9E-182) Separately packed (No. W9E-182) Separately packed (No. 427-S05-3661 01024-81230 07283-33450 07283-53444 01597-01009 01643-31032 01024-81225 Part name Bracket Bolt. Fix the front axle piping. W9E-182) Cautions Special tool Name Q’ty Necessary Equipment Name Q’ty Others 33 . No. Connect front axle piping. 0185 Connection of front axle piping (Brake cooling specification: If equipped) Front frame seen from left Connection: Check O-ring. Front frame seen from above 1. Connection: Check O-ring To right front wheel brake To front axle View Z Cautions Special tool Name Q’ty To left front wheel brake Necessary Equipment Name Q’ty 34 Others .Assembly procedure No. 5 – 13. 2. 3. 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.Assembly procedure No.5 – 13. Fix the hose from the parking brake cylinder with the clip.5 kgm} 1. Cautions Special tool Name Q’ty Necessary Equipment Name Q’ty Others 35 . 0190 Connecting the front axle pipe Connect the hose to the parking cylinder Tightening torque : 84 – 132 Nm {8.5 kgm} Fix it to the clip. Connect the hose from the slack adjuster to the brake tube on the front axle. Connect the hose from the brake valve to the parking brake cylinder. ) 1 Installed to hose Cautions Special tool Name Q’ty Necessary Equipment Name Q’ty 36 Others . Connect the piping to the front axle. Front frame seen from above No.Assembly procedure No. 56B-61-13760 Part name Elbow Q’ty State of part (Parts list No. (1) Part No. 0195 Connection of front axle piping (Riotinto specification: If equipped) Front frame seen from right 1. Prior to assembling the drive shaft.)) 3. 2.W9E-200) Cautions Special tool Name Q’ty Necessary Equipment Name Q’ty Others 37 . Visually inspect the seating face and then apply a check mark using a white felt pen. center and rear drive shafts. Sequential tightening of the bolts must be repeated 2 rounds minimum. Mounting surface shall be free from rusts. Assemble the drive shaft to the front axle. The bolts must be basically tightened diagonally. Feed grease (molybdenum disulfide grease) to the grease fitting for the axle support and drive shaft. Must be retightened to the specified torque.Assembly procedure No. 2. 01050-61895 Part name Bolt Q’ty State of part (Parts list No. 1. 3. (1) Part No. Insert 4 bolts temporarily and tighten them temporarily until the seating face is closely contacted. clean the mounting surface. foreign substances and dents.) 4 Separately packed (No. 0200 Connecting the front drive shat (Front axle – Center support) Center support Tightening torque : 343 – 426 Nm {35 – 43. 5. pay attention to its direction as well as that of the grease nipple situated in the spider of the front. (When assembling drive shaft.5 kgm} Grease nipple position in the spider of 427-20-12211 Front drive shaft Front Axle Grease nipple position (Viewed from the machine rear side) Thicker one is set on the front axle side Points to notice 1. 4. No. ) 2 Temporarily installed on the front axle 2 Temporarily installed on the front axle Special tool Name Impact wrench Socket (17 mm) Q’ty 1 1 Necessary Equipment Name Q’ty 38 Others . (To be tightened along with the mud guard fixing bolt. Connect CN F25. Top view of front frame Connect Front axle Detail of backside of A section View Z No. (1) (2) Part No. Fix the wiring harness of the axle oil temperature sensor. 01024-81055 04434-51010 Cautions Part name Bolt Clip Q’ty State of part (Parts list No. 0210 Connecting the axle oil temperature sensor (For VHMS specification only) a This process is required for the VHMS specification only.Assembly procedure No. 1.) 2. Assembly procedure No. 0220 Assembling the tires 1. Prior to assembling, remove the grease on the stud bolt. 2. Lift a tire using the crane, install on the axle and then assemble the nut to it. (Use care not to damage the tire air injection tube.) 3. Install the tire tightening nut temporarily using the impact wrench. (This process requires working at a high place and also requires tightening many nuts. So it is advisable to use the balance for holding the impact wrench.) 4. Tighten the nut to the specified torque using the torque wrench. 5. Apply chocks to the tires and remove the crossties under the machine. Tightening torque : 736 – 912 Nm {75 – 93 kgm} Assembling of wheel and tire assembly 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 Cautions Q Prior to assembling, remove the grease on the stud bolt. Q Care must be exercised in the positioning of the wheel and tire assembly so that the tire air injection tube may not be damaged. 36 T socket Torque wrench Extension bar Part name Wheel and tire assembly Nut Washer Q’ty State of part (Parts list No.) 4 Separately packed (No.W9E-220) 212 Separately packed (No.W9E-220) 212 Separately packed (No.W9E-220) Special tool Name Q’ty 1 1 1 Necessary Equipment Name Q’ty Others 39 Assembly procedure No. 0230 2) Loosen Assembling the fuel tank 1. Prior to assembling, remove the breather tube. (Be sure to return it to the original position before assembling the fuel tank.) 2. Prior to the assembling, clean the contact face of the mount. 3) Remove beforehand 1) Remove 3. Using a forklift, set the fuel tank assembly under the rear frame. 4. Install the breather tube temporarily while lifting the assembly gradually. 5. Temporarily insert the right side bolt alone to connect and fix the pipe. (See No.0240 – No.0260) 6. After all piping is complete, tighten the bolts to the specified torque. Tightening torque : 1,520 – 1,910 Nm {155 – 195 kgm} Adjust the clearance between the fuel tank and rear frame to 0.5 mm or less. Fuel level sensor Fuel tank View Z No. (1) (2) (3) Part No. 01011-63000 01643-33080 416-855-1190 Cautions Part name Bolt Washer Shim Q’ty State of part (Parts list No.) 6 Temporarily installed on the fuel tank 6 Temporarily installed on the fuel tank 10 Separately packed (No.W9E-230) Special tool Name Impact wrench Power wrench (×4 wrench) Torque wrench (44 Nm set) Extension Socket 46 mm Q’ty 1 1 1 1 1 Connect fuel tank level sensor connector (CN R08) Necessary Equipment Name Q’ty 40 Others Assembly procedure No. 0235 1) Remove. Installation of fuel tank (Riotinto specification: If equipped) 1. Before installing, remove the clips and bolts. (Take care not to lose them. For installation, see No. 0245.) 2. Before installing, clean the mounting face. 3. Position the fuel tank assembly under the rear frame with a forklift etc. 4. While raising the fuel tank gradually, insert only the 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 installing all the pipings, tighten the bolts to the 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 Cautions Part name Bolt Washer Shim Q’ty State of part (Parts list No.) 6 Temporarily installed on the fuel tank 6 Temporarily installed on the fuel tank 10 Separately packed (No.W9E-235) Special tool Name Impact wrench Power wrench (×4 wrench) Torque wrench (44 Nm set) Extension Socket 46 mm Q’ty 1 1 1 1 1 Necessary Equipment Name Q’ty Others 41 Fix the torque converter cooler drain. 4. 0240 Fixing the drain pipe 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. Fix the engine oil pan drain. 2. Fix the torque converter cooler drain pipe and radiator drain pipe.) Temporarily installed on the fuel tank Temporarily installed on the fuel tank Temporarily installed on the fuel tank Temporarily installed on the fuel tank Cautions Special tool Name Q’ty Necessary Equipment Name Q’ty 42 Others . (1) (2) (3) (4) Part No. No.Assembly procedure No. Fix the radiator drain. 3. 01024-81035 01435-01035 08036-20314 01024-81020 Part name Bolt Bolt Clip Bolt Q’ty 2 4 5 5 State of part (Parts list No. No. 0245 Fixing of torque converter cooler drain piping (Riotinto specification: If equipped) Torque converter cooler drain Torque converter oil cooler Fuel tank seen from left 1.) 2 Temporarily installed on the fuel tank 2 Temporarily installed on the fuel tank 2. Open the drain valves. (1) (2) Part No. 424-06-12780 01024-81020 Part name Clip Bolt Q’ty State of part (Parts list No. Fix the torque converter cooler drain piping. • Engine oil pan drain • Torque converter cooler drain • Radiator drain Engine oil pan drain Radiator drain Torque converter cooler drain Rear frame Detail of part P Special tool Name Q’ty Necessary Equipment Name Q’ty Cautions Others 43 .Assembly procedure No. Assembly procedure No. (1 each on the machine right and left sides) 3. (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) Part No. 0250 1. (1 each on the machine right and left sides) Connecting the fuel pipe Connection of the fuel return hose Connection of the spill hose No. Connect and fix the fuel return hose. 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. Connect and fix the fuel spill hose. (2 on the machine right side) 2.) 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 Impact wrench Socket (17 mm) Q’ty 1 1 Necessary Equipment Name Q’ty 44 Others . Connect and fix the suction hose. (1) (2) (3) (4) (5) Part No. Connect the respective drain hoses.Assembly procedure No. 2. 04434-52512 04434-51510 01024-81016 07285-00220 07285-00130 Part name Clip Clip Bolt Clip Clip Q’ty 1 1 2 2 1 State of part (Parts list No. 0260 Fixing the engine drain hoses 1. Connect Machine left side Detail of connection Rear frame viewed from the left side Connect Connect 630 (clamp position) Connect 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. Fix the breather drain hose (on the machine left side) and the muffler drain hose.) 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 Necessary Equipment Cautions Special tool Name Impact wrench Socket (10 mm) Q’ty 1 1 Name Q’ty Others 45 . ) Bolt Washer Bolt Q’ty 1 2 2 2 State of part (Parts list No. Assemble ladder (1).) Separately packed (No. (1) (2) (3) (4) Part No.Assembly procedure No. 427-54-26950 01010-81635 01643-31645 01024-D1225 Part name Ladder (R. 24 mm) Q’ty 1 1 each Necessary Equipment Name Q’ty 46 Others .W9E-270) Temporarily installed on the hydraulic tank Temporarily installed on the hydraulic tank Temporarily installed on the hydraulic tank Cautions Special tool Name Impact wrench Socket (19 mm. 2. Remove (2) – (4) being temporarily installed on the hydraulic tank.H. No. 0270 Assembling the hydraulic tank ladder Hydraulic tank 1. Assembly procedure No. 0280 Assembling the floor and cab assembly Lifting load: 950 kg Lifting tool: 2 point lift × 2 Tightening torque : 245. In cab a Return it to the original position after the piping under the cab is finished. 2.) Separately packed (No. Remove (2) – (4) being temporarily installed on the machine.0 – 308. (1) (2) (3) (4) Part No. Assemble cab assembly (1). 1.5 kgm} a Remove the undercover in the cab rear side beforehand. 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. No.7 Nm {25 – 31.W9E-280) Temporarily installed on the machine Temporarily installed on the machine Temporarily installed on the machine Cautions Special tool Name Q’ty Torque wrench (277 Nm {28.2 kgm} set) 1 Necessary Equipment Name Q’ty Others 47 . Assembly procedure No. Connect the drain hose. (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 Q’ty Necessary Equipment Name Q’ty 48 Others . 0290 1. Connecting the air conditioner 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. 2. Connect the hot water hose. Connect the air conditioner hose. 3. 5 kgm} Connect Tightening torque : 177 – 245 Nm {18.0 kgm} Connect Routed to the rear brake Tightening torque : 84 – 132 Nm {8.5 – 13.5 kgm} Cautions Special tool Name Torque wrench Q’ty 1 Necessary Equipment Name Q’ty Others 49 .0 kgm} Cab viewed from the left side Connect Tightening torque : 84 – 132 Nm {8. 2.0 – 25.5 – 13.5 kgm} Connect Routed to the front brake Tightening torque : 84 – 132 Nm {8. Connecting the brake line Connect Tightening torque : 177 – 245 Nm {18. Connect 1 hose to the tube to be routed to the PPC pump.5 – 13. Connect 3 hoses to the tube to be routed to the component box.0 – 25. 3. 0300 1.Assembly procedure No. Connect 2 hoses to the joint hose to be routed to the front brake and rear brake. 0310 Connecting the window washer hose Cab viewed from the top Front washer hose (Red taping) Connect (Match the color) Rear washer hose View Z 1. (Confirm the red tape attached on the front washer hose.) Cautions Special tool Name Q’ty Necessary Equipment Name Q’ty 50 Others . Connect the washer hose (for the front and rear) being exit from the cab bottom to the frame side hose.Assembly procedure No. (P1. 0320 Connecting the PPC line hose PPC control valve of ide t s hine n Fro mac Connect Connect Connect Connect Frame connection viewed from the top 1.Assembly procedure No. P2. 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 Q’ty Necessary Equipment Name Q’ty Others 51 . 2. Connect a hose from the PPC relief valve. Connect 4 PPC line hoses. Make sure the Nos. P3 and P4) are matching the band colors. 3. (Before connecting the cable. Part No.) 3. 2. check the connection for paint and rusts. remove it before connecting the cable. CN L27) Ground cable Connect Top view of the floor frame No. 0330 Connecting the floor wiring harness 1. If present. Part name Q’ty Bolt Clip Bolt Clip Bolt 1 1 1 2 1 (1) 01024-81016 (2) 04434-51410 (3) 01024-81020 (4) 04434-51010 (5) 01024-81020 State of part (Parts list No. Connect the connectors.Assembly procedure No. Remove (1) – (5) being temporarily installed on the floor support. Fix the steering lock switch harness. (CN L39. Connect the ground cable.) 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 Connect View X Connect Connect Connect Connect View Z Cautions Special tool Name Q’ty Necessary Equipment Name Q’ty 52 Others . 4. CN CB1) Cautions Special tool Name Q’ty Necessary Equipment Name Q’ty Others 53 . Connect the connectors. 0333 Connection of floor wiring harness -1 (Riotinto specification: If equipped) Floor Connection: CN CAB Connection: CN CB1 Floor seen from rear 1.Assembly procedure No. (CN CAB. 2. Remove parts (1) – (3) installed to the cab. 421-877-2250 04434-51010 01024-81060 Part name Spacer Clip Bolt. (CN RF) No. Fix the wiring harness with parts (1) – (3).) 3 Temporarily installed on the machine 3 Temporarily installed on the machine 3 Temporarily installed on the machine Cautions Special tool Name Q’ty Necessary Equipment Name Q’ty 54 Others . (1) (2) (3) Part No. Connect the connector. 3. 0334 Connection of floor wiring harness -2 (Riotinto specification: If equipped) Marked : 3 places Connection: CN RF Cab seen from rear 1. sems Q’ty State of part (Parts list No.Assembly procedure No. Assembly procedure No. 1.0345. 2. No.) 1 Temporarily installed on the lever 1 Temporarily installed on the lever Cautions Special tool Name Q’ty Necessary Equipment Name Q’ty Others 55 .0 – 20.0 kgm} For calibration procedure of the AJSS lever angle and frame offset angle.9 – 196.1 Nm {16. 3. Connect the coupling rod connecting the front frame. (1) (2) Part No. see No. Tightening torque : 48 – 62 Nm {4. 0340 Connecting the link for AJSS (For AJSS specification only) a This process is required for the AJSS specification only.8 – 6. Connect the joint connecting the floor. Remove (1) and (2) being temporarily installed on the lever.3 kgm} Front frame Tightening torque : 156. 01643-31445 01595-01411 Part name Washer Nut Q’ty State of part (Parts list No. 40 – 2.) 4. Stop the engine (set the starting switch to the OFF position) and set the steering lock lever to the lock position. 0345 Calibration of the AJSS angle and frame offset angle Adjusting connector Front side of machine Front side of the right hand console 1.60 V. the adjustment is completed. 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. (See the figure above.) Cautions Special tool Name Q’ty Necessary Equipment Name Q’ty 56 Others . Connect the connector JL3 for the neutral position adjustment. 6. a Don't try to operate the steering lever as long as the operations of Steps 4 – 6 are continued.Assembly procedure No. 2. If beep of the buzzer is heard 1 second after. Pull out connector JL3 for neutral position adjustment situated in the right hand console. (If the adjustment did not end normally. Set the machine and steering lever to the straight-travel state. Start the engine setting the starting switch to the 1st stage ON. 3. 5. Assemble the grease pump. Grease pump Top view of the left platform Connect Connect Section A-A No. 2.) 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 Q’ty Necessary Equipment Name Q’ty Others 57 . (1) (2) (3) (4) (5) (6) Part No. 0350 Assembling the auto-greasing pump and connecting the pipe (WA900-3E0 North American specification) 1. Remove (2) – (6) being temporarily installed on the platform. Connect 4 pipes.Assembly procedure 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. 3. (1) (2) (3) (4) (5) (6) (7) (8) Part No. Remove (2) and (5) – (8) being temporarily installed on the floor.) Bolt Washer Cover Bolt Q’ty 1 4 1 1 6 6 1 7 State of part (Parts list No. Assemble floor covers (3) and (4). 427-54-24311 01024-81020 427-54-24321 427-54-24331 01024-81025 424-09-12650 427-S95-5250 01024-81020 Cautions Part name Cover Bolt Cover (L. 3.H.) Separately packed (No.) Cover (R.H.W9E-360) Temporarily installed on the floor Temporarily installed on the floor Temporarily installed on the floor Temporarily installed on the floor Special tool Necessary Equipment Q’ty 1 1 Name Q’ty Name Impact wrench Socket (17 mm) 58 Others . Floor support No. 0360 Assembling the floor cover Floor frame 1.W9E-360) Separately packed (No.W9E-360) Temporarily installed on the floor Separately packed (No. 2.Assembly procedure No. Assemble floor cover (1). Assembly procedure No. Cautions Special tool Name Q’ty Necessary Equipment Name Q’ty Others 59 . 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. 0370 Refilling the window washer Washer tank position (In the bulkhead) Water filler port 1. Assemble battery box assemblies (1) and (2) to the frame. battery box.H.) Separately packed (No. 2. R. Assemble bolt (6) situated in the disaster prevention cover.Assembly procedure No. 36 mm) Q’ty 1 1 each Necessary Equipment Name Q’ty 60 Others .H.W9E-380) Temporarily installed on the rear frame Temporarily installed on the rear frame Temporarily installed on the rear frame Separately packed (No. Bolt Bolt Washer Bolt Q’ty 1 1 4 4 8 4 State of part (Parts list No. Remove (3) – (5) being temporarily installed on the rear frame. 427-06-2463A 427-06-2464A 01011-62450 01011-62470 01643-32460 01024-D1225 Cautions Part name Battery box. (1) (2) (3) (4) (5) (6) Part No. 0380 Assembling the battery box 1. 3. View X Rear frame View Z No.W9E-380) Special tool Name Impact wrench Socket (19 mm.W9E-380) Separately packed (No. L. 0390 Connecting and fixing the battery wiring 1. connect it to the battery just before starting the engine. 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 View B State of part (Parts list No.) Separately packed (No. Referencing the following figure. (1) (2) (3) (4) (5) (6) (7) Part No.Assembly procedure No. 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 and fix the wiring in the battery box.W9E-390) Temporarily installed on the battery box Temporarily installed on the battery box Temporarily installed on the battery box Temporarily installed on the battery box Temporarily installed on the battery box Temporarily installed on the battery box Others 61 . and then clamp and connect it to the correct position. Connection: CN RA1 Connection: CN RA3 L. 0393 Wiring on right side of battery (Riotinto specification: If equipped) Connection: Check mark "4".H.H.) 1 Temporarily installed on the machine 1 Temporarily installed on the machine 1 Temporarily installed on the machine Cautions 1. battery box Fixing: Use bolts and clips installed temporarily. Detail of part P View Z 1. battery box View X Detail of R. 08038-00035 04434-51710 01024-81020 Part name Cap Clip Bolt. Connection: Check mark "2". Connect the wiring on the right side of the battery. Install each wiring harnesses so that it will not cross other wiring harnesses. Removal of boot and connection: Check mark "1".H. Wiring harness Connection R. sems Q’ty State of part (Parts list No. Special tool Name Q’ty Necessary Equipment Name Q’ty 62 Others . No. (1) (2) (3) Part No. battery box Connection: Check mark "6".Assembly procedure No. Check mark "4". and then clamp and connect it to the correct position. 6151-53-8280 01024-81020 Part name Clip Bolt. Pull the wiring into the battery on the left side. battery box Longer end Pull cable into L. battery box Shorter end L. sems Q’ty State of part (Parts list No. View Z: Machine seen from below 1.H.) 4 Temporarily installed on the machine 4 Temporarily installed on the machine Cautions 1. Install each wiring harnesses so that it will not cross other wiring harnesses. 0394 Wiring on left side of battery -1 (Riotinto specification: If equipped) Pull wiring harness into L. No.H. Special tool Name Q’ty Necessary Equipment Name Q’ty Others 63 . Check mark "2". Check mark "3".Assembly procedure No. Check mark "5". battery box Marked : 4 places Check mark "1".H. (1) (2) Part No. Fixing: Use bolt and clip installed temporarily. Removal and connection of boot: Check mark "2". battery box Removal and connection of boot: Check mark "1". Connect the wiring in the L. and then clamp and connect it to the correct position. Fixing: Use bolt and clip installed temporarily. Special tool Name Q’ty Necessary Equipment Name Q’ty 64 Others . Fixing: Use bolt and clip installed temporarily. 1.H. Install each wiring harnesses so that it will not cross other wiring harnesses. Removal and connection of boot: Check mark "5". 0395 Wiring on left side of battery -2 (Riotinto specification: If equipped) L. Detail Section A-A Fixing: Use bolt and clip installed temporarily.Assembly procedure No. battery. Removal and connection of boot: Check mark "4". Connection: CN RA4 Connection: CN RA2 Connection: CN R09 Fixing: Use bolt and clip installed temporarily. Removal and connection of boot: Check mark "3".H. View Z Cautions 1. sems Q’ty State of part (Parts list No.Assembly procedure No. Install each wiring harnesses so that it will not cross other wiring harnesses.) 2 Temporarily installed on the machine 2 Temporarily installed on the machine Cautions 1.H. Connect the wiring on the left side of the battery No. Special tool Name Q’ty Necessary Equipment Name Q’ty Others 65 . 6151-53-8280 01024-81020 Part name Clip Bolt. and then clamp and connect it to the correct position. battery box Connection: CN V101 Black (–) Connection: CN V102 Red (+) Connection: CN EM41 Connection: CN EM42 Section A-A 1. battery box L. 0396 Wiring on left side of battery -3 (Riotinto specification: If equipped) R. (1) (2) Part No.H. H. 01024-81020 Part name Bolt. Connect the ground cable on the left side of the battery. 0397 Connection of ground cable on left side of battery (Riotinto specification: If equipped) View Z: Machine seen from below L. and clamp and connect it to the correct position. Special tool Name Q’ty Necessary Equipment Name Q’ty 66 Others . 2. battery box seen from rear 1. sems Q’ty State of part (Parts list No. No. Install each wiring harnesses so that it will not cross other wiring harnesses.) 2 Temporarily installed on the machine Cautions 1. (1) Part No.Assembly procedure No. The ground cable connecting areas must be free from dirt and paint. 427-54-26770 427-54-26780 01024-D1235 01024-D1245 427-54-2933A 01024-81235 Cautions Part name Step (R.H. Assemble the step to the right side of the machine.Assembly procedure No.W9E-400) Separately packed (No. (1) (2) (3) (4) (5) (6) Part No. fuel tank and battery box.H.H. 2.) Bolt Bolt Step assembly Bolt Q’ty 1 1 6 2 2 8 State of part (Parts list No.W9E-400) Temporarily installed on the rear frame Temporarily installed on the fuel tank Separately packed (No. Assemble the step to the left side of the machine. 0400 Assembling the battery step 1. Battery box L. Remove (3). Battery box R. Fuel tank 3. (4) and (6) being temporarily installed on the rear frame.H.) Separately packed (No.W9E-400) Temporarily installed on the battery box Special tool Necessary Equipment Q’ty 1 1 Name Q’ty Name Impact wrench Socket (19 mm) Others 67 . Fuel tank No.) Step (L. 5 kgm} 1. W9E-403) Bolt.Assembly procedure No. No.5 – 12. (1) (2) (3) Part No.5 kgm} Oil cooler Tightening torque 54 – 123 Nm {5.) Oil cooler assembly 1 Separately packed (No. W9E-403) Cautions Special tool Name Q’ty Necessary Equipment Name Q’ty 68 Others . sems 2 Separately packed (No. W9E-403) Bolt. 427-S05-489A 01024-81245 01024-81235 Part name Q’ty State of part (Parts list No.5 kgm} Tightening torque 54 – 123 Nm {5.5 – 12.5 – 12. 0403 Installation of oil cooler assembly (Brake cooling specification: If equipped) Tightening torque 54 – 123 Nm {5. Install oil cooler assembly (1) to the right platform. sems 4 Separately packed (No. 07000-F3035 01024-81035 07371-31255 07375-21035 Part name O-ring Bolt. (1) (2) (3) (4) Part No. No. Connection: Check O-ring. Connect the oil cooler assembly piping.Assembly procedure No. 0404 Installation and connection of oil cooler assembly piping (Brake cooling specification: If equipped) Connection: Check O-ring. sems Flange Bolt. W9E-404) Temporarily installed on the 4 oil cooler assembly 8 Temporarily installed on the oil cooler assembly Cautions Special tool Name Q’ty Necessary Equipment Name Q’ty Others 69 . sems Q’ty State of part (Parts list No. View Z 1.) 2 Separately packed (No. W9E-404) 4 Separately packed (No. (1) (2) (3) (4) (9) Part No. W9E-406) Separately packed (No. 0406 Connection: O-ring Installation of oil cooler assembly piping -1 (Brake cooling specification: If equipped) Connection: Check O-ring. W9E-406) Separately packed (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.Assembly procedure No. W9E-406) Cautions Special tool Name Q’ty Necessary Equipment Name Q’ty 70 Others .) Separately packed (No. Bulkhead Right platform Rear frame seen from right Oil cooler Connection Rear frame seen from front 1. W9E-406) Installed to machine Separately packed (No. No. Connect the oil cooler assembly piping. Connection: Check O-ring. Cautions Special tool Name Q’ty Necessary Equipment Name Q’ty Others 71 . Check mark (white tape). Connect the oil cooler assembly piping. 0407 Installation of oil cooler assembly piping -2 (Brake cooling specification: If equipped) a Connect each tube (8 places in total).Assembly procedure No. Connection (4 pieces): Check O-ring. 1. W9E-410) Temporarily installed on the right platform Separately packed (No.Assembly procedure No. (1) (2) (3) (4) (5) (6) (7) (8) Part No.) Separately packed (No. Remove the parts being temporarily installed. 427-54-29270 01024-D1235 427-54-25861 01024-D1235 426-54-42310 426-54-35220 426-54-35320 23S-07-11160 Cautions 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. Assemble handrails (1) and (3) to the right side of the machine. 2. No. 3. 0410 Assembling the handrail (On the right hand platform) Rear frame 1.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) Special tool Name Impact wrench Socket (19 mm) Q’ty 1 1 Necessary Equipment Name Q’ty 72 Others . Hitch the cable on handrail (1). W9E-411) Temporarily installed on the right platform Separately packed (No. Install handrails (1) and (3) to the right side of the machine. 2. W9E-411) Temporarily installed on the right platform Separately packed (No.Assembly procedure 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 Cautions Part name Handrail Bolt. Remove the parts installed temporarily. 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) Special tool Name Q’ty Necessary Equipment Name Q’ty Others 73 . No. (1) (2) (3) (4) (5) (6) (7) (8) (9) Part No. 3. Hook the cable to handrail (1).) Separately packed (No. sems Bolt. 0411 Installation of handrail (Right platform area) (Brake cooling specification: If equipped) 1. sems Handrail Bolt. sems Hose Cable Joint Catcher Q’ty 1 11 1 2 2 1 1 1 1 State of part (Parts list No. 2. Using (3) – (6). 3.Assembly procedure No. 19 mm) Q’ty 1 1 each Necessary Equipment Name Q’ty 74 Others . 427-54-25870 01024-D1235 207-62-54770 01024-D1030 01643-31032 01580-11008 427-54-29370 01024-D1235 427-54-25880 01024-D1235 Cautions 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. Remove the parts being temporarily installed.W9E-420) Temporarily installed on the machine Special tool Name Impact wrench Socket (17 mm. Rear frame 1.W9E-420) Temporarily installed on the machine Separately packed (No. fix handrail (1) and handrail (7) as shown in the figure above. No. 4.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.) Separately packed (No. 0420 Assembling the handrail (On the hood top face) Insert handrail (7) to handrail (9). Insert handrail (7) to handrail (9) as shown in the figure above and then assemble them. Assemble handrail (1). (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) Part No. 0430 Assembling the handrail (On the right hand battery box) Rear frame 1. No. 2. Remove the parts being temporarily installed.W9E-430) Temporarily installed on the right battery box Cautions Special tool Name Impact wrench Socket (19 mm) Q’ty 1 1 Necessary Equipment Name Q’ty Others 75 .Assembly procedure No. Bolt Bolt Handrail R. Bolt Q’ty 1 4 4 1 4 State of part (Parts list No. Assemble handrails (1) and (4) as shown in the figure above. 427-54-25821 01024-D1230 01024-D1235 427-54-25180 01024-D1235 Part name Handrail R.H.) Separately packed (No.H.W9E-430) Temporarily installed on the right battery box Temporarily installed on the right battery step and rear frame Separately packed (No. (1) (2) (3) (4) (5) Part No. Assembly procedure No. 0440 Assembling the rear access step 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 No. (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) 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 01024-81225 124-54-26540 01024-81220 1. Remove (2) and (3) being temporarily installed on the machine. 2. Assemble floor assembly (1) using (2) and (3). 3. Remove (5) – (8) being temporarily installed on step assembly (4). 4. Remove (9) and (10) being temporarily Part name Q’ty State of part (Parts list No.) installed on the left hand battery box. Floor assembly 1 Separately packed (No.W9E-440) Bolt 8 Temporarily 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 Separately packed (No.W9E-440) referencing the figure above. Bracket 1 Temporarily installed on the step assembly (4) 6. Remove (14) being temporarily 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 (12) and (13) being temporarily 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 cover (11) using (12) and (13). Cover 1 Separately packed (No.W9E-440) 9. Fix cover (11) and step assembly (4) cover Bolt 6 Temporarily installed on the machine and floor assembly (1) to each other using bolt (14). Washer Bolt 6 6 Temporarily installed on the machine and floor assembly (1) Temporarily installed on the step assembly (4) Cautions Special tool Name Impact wrench Socket (19 mm, 22 mm) Q’ty 1 1 each Necessary Equipment Name Q’ty 76 Others Assembly procedure No. 0450 Assembling the left handrail (Part 1) View Z 1. Remove (2) being temporarily installed on the machine. Detail of A 2. Assemble handrail (1). 3. Remove (7), (8), (9), (11) and (12) being temporarily installed on the machine and bracket (see detail of A). 4. Assemble handrail (6) using (7) and (8) (for the assembling position, see view Z). 5. Fix handrail (6) using (9) – (12). (See detail of A) 6. Assemble mudguard (4) using (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 Cautions 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 packed (No.W9E-450) Temporarily installed on the machine Separately packed (No.W9E-450) Separately packed (No.W9E-450) Separately packed (No.W9E-450) Separately packed (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 Special tool Necessary Equipment Q’ty 1 1 each Name Q’ty Name Impact wrench Socket (17 mm, 19 mm) Others 77 Assembly procedure No. 0460 Assembling the left handrail (Part 2) Detail of B (2 places) 1. Remove (2) being temporarily installed on the machine. 2. Assemble handrail (1) using (2). 3. Remove (4) being temporarily installed on the machine. 4. Assemble handrail (3) using (4). 5. Remove (6) being temporarily installed on the machine. 6. Assemble handrail (5) using (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 Cautions 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-460) Temporarily installed on the machine Separately packed (No.W9E-460) Temporarily installed on the machine Separately packed (No.W9E-460) Temporarily installed on the machine Special tool Name Impact wrench Socket (19 mm) Q’ty 1 1 Necessary Equipment Name Q’ty 78 Others Assembly procedure No. 0461 Installation of left handrail (Part 2) (Brake cooling specification: If equipped) Detail of B (2 places) 1. Remove part (2) installed to the machine. 2. Install handrail (1) with part (2). 3. Remove part (4) installed to the machine. 4. Install handrail (3) with part (4). 5. Remove part (6) installed to the 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 Cautions 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 packed (No.W9E-461) Temporarily installed on the machine Separately packed (No.W9E-461) Temporarily installed on the machine Special tool Name Impact wrench Socket (19 mm) Q’ty 1 1 Necessary Equipment Name Q’ty Others 79 Assembly procedure No. 0470 Assembling the rearview mirror Detail of the mirror adjustment 1. Remove (3) and (4) being temporarily installed on the cab. 2. Assemble right and left mirror stays (1) and (2) using (3) and (4). 3. Assemble mirror (5) to the assembled mirror stay and then fix them using (6). 4. Adjust the mirror angle referencing the detail of mirror adjustment (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 packed (No.W9E-470) Separately packed (No.W9E-470) Cautions Special tool Name Spanner (17 mm) Q’ty Necessary Equipment Name Q’ty 80 Others W9E-471) 4 Accessory to part (1) 4 Accessory to part (1) Cautions Special tool Name Spanner (24 mm) Q’ty 1 Necessary Equipment Name Q’ty Others 81 . Install rearview mirror (1) to the handrail and fix it with parts (2) and (3). 56B-54-17311 (56B-54-17311) (56B-54-17311) Part name Mirror Nut Washer Q’ty State of part (Parts list No. Adjust the mirror angle. 1. Remove parts (2) and (3) installed to rearview mirror (1). (Work on the right and left sides similarly. 0471 Installation of rearview mirrors (Brake cooling specification: If equipped) a Work on right and left sides similarly.) 2 Separately packed (No. 2. (1) (2) (3) Part No. No.Assembly procedure No.) 3. Remove (2) being temporarily installed on the hood. Assemble exhaust pipe (1) using (2). 427-02-21140 01024-81240 Part name Exhaust pipe Bolt Q’ty State of part (Parts list No. No.W9E-480) 12 Temporarily installed on the front hood Cautions Special tool Name Impact wrench Socket (19 mm) Q’ty 1 1 Necessary Equipment Name Q’ty 82 Others .) 2 Separately packed (No. 2. (1) (2) Part No.Assembly procedure No. 0480 Assembling the exhaust pipe 1. Install the cover removed in 1 again. 2. sems Q’ty State of part (Parts list No.) 1 Separately packed (No. 3. (1) (2) Part No. Install the oil cooler guard assembly with bolts (2).5 Nm {5. 41F-S05-173A 01024-81225 Part name Guard assembly Bolt.5 – 12. W9E-485) 6 Separately packed (No.Assembly procedure No. 0485 Installation of oil cooler guard assembly (Brake cooling specification: If equipped) Tightening torque: 54 – 122. W9E-485) Cautions Special tool Name Q’ty Necessary Equipment Name Q’ty Others 83 . Remove the front cover of the oil cooler guard assembly. No.5 kgm} 1. (1) (2) (3) (4) (5) Part No. Install the oil cooler piping cover. sems Bolt. W9E-486) Separately packed (No. 0486 Installation of fan motor piping cover -1 (Brake cooling specification: If equipped) 1. W9E-486) Cautions Special tool Name Q’ty Necessary Equipment Name Q’ty 84 Others . 427-S05-3410 427-S05-3391 427-S05-3441 01024-81225 01024-81230 Part name Cover Cover Cover Bolt. W9E-486) Separately packed (No. sems Q’ty 1 1 1 12 4 State of part (Parts list No. No.) Separately packed (No.Assembly procedure No. W9E-486) Separately packed (No. W9E-486) Separately packed (No. 5 – 7.5 kgm} 1. 0487 Installation of fan motor piping cover -2 (Brake cooling specification: If equipped) Tightening torque: 34 – 74 Nm {3. W9E-487) Separately packed (No.5 kgm} Tightening torque: 34 – 74 Nm {3.) Separately packed (No. W9E-487) Cautions Special tool Name Q’ty Necessary Equipment Name Q’ty Others 85 . W9E-487) Separately packed (No. No.Assembly procedure No. sems Cover Bolt. W9E-487) Separately packed (No. (1) (2) (3) (4) Part No. sems Q’ty 1 8 1 4 State of part (Parts list No.5 – 7. Install the cover to the right platform bottom. 427-S05-5190 01024-D1025 41F-S05-1491 01024-D1225 Part name Cover Bolt. using a felt pen. 4.Assembly procedure No.) 4 Separately packed (No. Use care when applying it so that fingers may not touch the adhesive. on the application position. Apply the anti-slip decal. If the surface if fouled with oil. 417-06-11321 Part name Plate Q’ty State of part (Parts list No. 3. (1) Part No. press the anti-slip plate using a roller from the center of the plate toward the brim. too. Remove the protective cover on the backside. clean it off using detergent.W9E-490) Cautions Special tool Name Q’ty Necessary Equipment Name Q’ty 86 Others . Sufficiently clean the application surface and dry it. It is advisable to give a mark. 6. 5. Apply adhesive "LT-1A" in the perimeter of the anti-slip plate. In order to paste it up securely. 0490 Applying the counterweight anti-slip 1. 2. No. W9E-500) Temporarily installed on the rear part of the rear frame Separately packed (No. 0500 Assembling the counterweight (WA900-3E0 standard specification) Tightening torque: 1. Insert pin (9).520 – 1. Assemble counterweight (1) using (2) and (3). 5.) Separately packed (No. 4. 3. Assemble counterweight (4) using (5) and (6). Assemble cover (7) using (8).Assembly procedure No.910 Nm {155 – 195 kgm} Rear frame 2.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. (1) (2) (3) (4) (5) (6) (7) (8) (9) Part 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.890 kg 1. Remove (2). (5). 2. 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.890 kg 2. (3).W9E-500) Cautions Special tool Name Torque wrench Socket 46 mm Extension Impact wrench (for M30) Q’ty 1 1 1 1 Necessary Equipment Name Q’ty Others 87 . (6) and (8) being temporarily installed in the rear part of the rear frame. No. (9).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.600 kg 1. 5. (8). (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) Part No. 0505 2. Insert pin (11). 6. Remove (2). Assemble spacer (8). Assemble cover (12) using (13).298 kg Rear frame 1.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. Assemble counterweight (4) using (5) and (6). No. 4. Assemble counterweight (1) using (2) and (3).Assembly procedure No.890 kg Assembling the counterweight (WA900-3E0 High-lift arm specification) 1. (3). Assemble counterweight (7) using (9) and (10). (10) and (13) being temporarily installed in the rear part of the rear frame. 3. 4.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.) Separately packed (No. (6). 2. (5).W9E-505) Temporarily installed on the rear part of the rear frame Temporarily installed on the rear part of the rear frame Necessary Equipment Q’ty Name Q’ty Cautions Special tool Name 88 Others . 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 Q’ty 1 4 4 1 6 6 1 4 4 4 1 1 2 State of part (Parts list No. Assemble counterweight (1) using (2) and (3). Insert pin (8).890 kg 1.) Separately packed (No. 5. Assemble counterweight (4) using (6) and (7).520 – 1. No.910 Nm {155 – 195 kgm} Tightening torque: 823 – 1. 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.600 kg Tightening torque: 1. Assemble spacer (5). 2. (5). 3.Assembly procedure 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. optional specification and North American specification) 1.W9E-510) Cautions Special tool Name Torque wrench Socket 46 mm Extension Impact wrench (for M30) Q’ty 1 1 1 1 Necessary Equipment Name Q’ty Others 89 .5 kgm} Rear frame 2. (3). (6) and (7) being temporarily installed in the rear part of the rear frame. Remove (2).030 Nm {84 – 94. (1) (2) (3) (4) (5) (6) (7) (8) Part No. 4. 0510 Assembling the counterweight (WA800-3E0 Overseas general.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. 0520 Assembling the counterweight (WA800-3E0 Overseas general standard specification) Tightening torque: 1.W9E-520) Cautions Special tool Name Torque wrench Socket 46 mm Extension Impact wrench (for M30) Q’ty 1 1 1 1 Necessary Equipment Name Q’ty 90 Others .520 – 1. Insert pin (4).910 Nm {155 – 195 kgm} Rear frame 2. Remove (2) and (3) being temporarily installed in the rear part of the rear frame.Assembly procedure No.) Separately packed (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. 2.W9E-520) Temporarily installed on the rear frame Temporarily installed on the rear frame Separately packed (No.890 kg 1. No. 3. Assemble counterweight (1) using (2) and (3). W9E-530) 4 Temporarily installed on the front frame Cautions Special tool Name Q’ty Necessary Equipment Name Q’ty Others 91 . Assemble front axle lamp assembly (1) using (2). 3. 427-06-2525A 01024-81225 Part name Work lamp Bolt Q’ty State of part (Parts list No.) 1 Separately packed (No. (1) (2) Part No. Referencing view Z. 0530 Assembling the front axle lamp and connecting the harness Front frame Connect CN FAR View Z Connect CN FAL 1. 2. No. connect the harness.Assembly procedure No. Remove (2) being temporarily installed on the front frame. CN HF1 Fix here Fix here Connect CN F03. 0540 Assembling the front lamp assembly 1. 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.Assembly procedure No. CN HF2 Connect CN F02. Connect CN F01.W9E-540) 8 Temporarily installed on the right and left of front frame Cautions Special tool Name Impact wrench Socket (19 mm) Q’ty 1 1 Necessary Equipment Name Q’ty 92 Others . CN HF2 Front frame viewed from the inner right side Front frame viewed from the inner left side No. 2.W9E-540) 1 Separately packed (No.) 1 Separately packed (No. Assemble right and left front lamp assemblies (1) and (2) using (3). Fix the harness of the front lamp and then connect the connector referencing the figure below. Remove (3) being temporarily installed on the front frame. 3. CN HF1 Connect CN F04. (1) (2) (3) Part No. Clean the contact face of ROPS canopy assembly (3) mount.) Temporarily installed on the machine Temporarily installed on the machine Separately packed (No. Remove cover (1) being temporarily installed on the machine using (2). 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 State of part (Parts list No. assemble cover (1) currently being removed to the original position.450 – 3. a Clean the contact face of the mount before assembling. 5.040 Nm {250 – 310 kgm} 1. Assemble ROPS canopy (3) using (4) and (5).Natural yellow WA900-3E0 .42 t) (The lifting tool used for the tool and cab assembly is also used here) Tightening torque : 2. Using (2). 2. 3. Remove (4) and (5) being temporarily installed on the machine.Black gray Lifting tool: 2 point lift (Lifting load: 1.Assembly procedure No. 4. (1) (2) (3) (4) (5) Part No. No.W9E-550) Temporarily installed on the machine Temporarily installed on the machine Cautions Special tool Name Power wrench (×16 wrench) Socket (55 mm) Extension Torque wrench Q’ty 1 1 1 1 Necessary Equipment Name Q’ty Others 93 . 0550 Assembling the ROPS canopy assembly 2 different colors are used for the ROPS canopy WA800-3E0 . 8 – 2. Lead the harness on the cab ceiling to connect it to the lamp.Assembly procedure No. 2. 22B-06-11690 Cautions Part name Lamp assembly Q’ty State of part (Parts list No. Remove the antenna being temporarily installed on the cab and assemble it to the ROPS. (1) Part No. Assemble lamp (1) and tighten it to the specified torque. No.W9E-560) Special tool Name Q’ty Necessary Equipment Name Q’ty 94 Others .0 kgm} Assembled to the bracket being already assembled to the cab assembly Extend the antenna line from the cab Install it setting the slit at the bottom and then coat the entire perimeter with Cemedine 366E or equivalent. 0560 Assembling the antenna and work lamp Remove the antenna being temporarily installed on the cab and assemble it to the canopy.6 – 19.) 3 Separately packed (No. Connect CN C17 1. 3.6 Nm {1. Step lamp (Backside of upper left side of ROPS) Lamp assembly Tightening torque : 17. 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. 5. 2.W9E-570) Separately packed (No.Assembly procedure No.W9E-570) Temporarily installed on the ROPS canopy assembly Cautions Special tool Name Impact wrench Socket (17 mm) Q’ty 1 1 Necessary Equipment Name Q’ty Others 95 . 0570 Assembling the VHMS antenna (For VHMS specification only) Connect 7 places with mark View Z Cab viewed from the left side 1. 4. Assemble bracket (4) using (5) as shown in the view Z. Connecting the VHMS harness to the antenna. No. Fix the VHMS antenna harness as shown in the figure above. (1) (2) (3) (4) (5) Part No. Fix antenna (3) to the bucket. 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. 3. Remove (1) and (2) being temporarily installed on the ROPS canopy assembly.) Temporarily installed on the ROPS canopy assembly Temporarily installed on the ROPS canopy assembly Separately packed (No. 0580 Assembling the floor mat 1.Assembly procedure No.W9E-580) Cautions Special tool Name Q’ty Necessary Equipment Name Q’ty 96 Others . No. 427-54-26480 427-54-26460 Part name Sheet Mat Q’ty State of part (Parts list No. 2.) 1 Separately packed (No. Fit in sheet (1) to the floor frame as shown in the above figure.W9E-580) 1 Separately packed (No. Spread floor mat (2) as shown in the above figure. (1) (2) Part No. Remove (3) – (9) being temporarily installed on the front frame. 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. 81. 24 mm) Q’ty 1 1 each Name Q’ty Others 97 .) 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. (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) Part No.) Bracket (R. 0590 Assembling the front fender 1.H.) Fender (R.6 kg 5. 81.H.Assembly procedure No. 3. Assemble (12) to the original position. 2. Assemble right and left front fenders (1) and (2) to the front frame using (3) and (4).6 kg No. Assemble right and left brackets (5) and (6) to the front fender using (7) – (11).) Bolt Washer Bracket (L.W9E-590) Separately packed (No.W9E-590) 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 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) View Z (Detail of bolts assembling position) Necessary Equipment Cautions Special tool Name Impact wrench Socket (19 mm.H.H.) Separately packed (No. 4. Remove (10) – (12) being temporarily installed on right and left front fenders (1) and (2). 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 For the gauge position and the standard oil and coolant level. 4. a Stop the engine immediately if a trouble such as oil leakage and abnormal noise is detected. a Check the engine for oil leakage a Check and supply oil and coolant to respective components Cautions Special tool Name Q’ty Necessary Equipment Name Q’ty 98 Others . (See No. thus supply of hydraulic oil is necessary. Make sure that 40l of coolant is contained in the sub-tank after the radiator has been filled up. For the starting procedure. Fill oil up to the center of the upper sight gauge. 3. Bleed air. Check the current oil and coolant level and supply them to respective components • Amount of coolant 1. Reference (Tank capacity: 1. 2. Confirm the oil level constantly while starting the engine. Make sure oil is filled up to the center of the sight gauge in the state of “3” above.0610) 3. Check the engine after it has been stopped. 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.Assembly procedure No. Reference (Tank capacity: 1. Supply coolant until the radiator is 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. 2. • Amount of fuel Supply fuel. Fully charge the accumulator. 2. 0600 Engine starting procedure 1. reference the Operation and Maintenance Manual. a And also confirm the engine stop procedure in the Operation and Maintenance Manual. a The axle and cab are shipped after being disassembled. see the Operation and Maintenance Manual.604l) • Amount of hydraulic oil Supply oil up to the top of the sight gauge. (4) until the air is completely bled through the bleeding plug and the flowing out oil is free from bubbles. (7) Make sure in this state that oil is filled up to the center of the sight gauge. Then loosen the bleeding plug and then step down the brake pedal again to repeat step (3) above.Assembly procedure No.) (6) Run the engine at low idle for about 2 minutes in order to fully charge the accumulator. (3) Feed brake oil by stepping down the brake pedal and then drain air from the bleeding plug.) Bleeding plug Slack adjuster (2 places in the front and rear) Axle (2 places in the front and rear) (Bleeding on the axle is conducted in the complete machine assembling process. (5) Repeat (2) . Cautions Special tool Name Q’ty Necessary Equipment Name Q’ty Others 99 .) (4) Tighten the bleeding plug and release the brake pedal. (2) Loosen the air bleeding plug (in the axle brake chamber). 0610 Bleeding the brake air (1) Start the engine and fill up the accumulator chamber with oil. (Feed the brake oil constantly to maintain the chamber being filled up. (Keep the brake pedal being stepped down. (5) Check that all air has been bled through the plug and oil has started flowing out. and then tighten the plug. 0615 Bleeding air from hydraulic circuit (1) Before starting the engine. (6) Run the engine at low idle for about 5 minutes to check each part for oil leakage.Assembly procedure No. add new hydraulic oil to the specified level and loosen the plug installed to the top of the piston pump. loosen the plug installed to the suction tube. (8) Close the oil filler cap of the hydraulic tank. Switching pump Loader pump Steering pump (2) Check that all air has been bled through the plug and oil has started flowing out. Check that oil flows out and then tighten the plug. (7) Loosen the plug at the top of the piston pump. Cautions Special tool Name Q’ty Necessary Equipment Name Q’ty 100 Others . (3) Leave the machine for 10 minutes as it is so that the pump will be filled with hydraulic oil. and then tighten the plug. (4) If the hydraulic oil level is low. ) 5. (If the rust retardant is left unwashed.5 mm max. Lift the lift arm assembly using the crane and then move it over the front frame (see Fig.3) 7. Part name Q’ty State of part (Parts list No. coat the entire inner surface of the bushing with the molybdenum disulfide lubricating oil in paste form (KES. 6. 0620 Assembling the lift arm assembly (Part 1) [1] Assembling of the lift arm assembly 1. a When inserting the pin. 4. Clearance on the right and left side must be equal. Assemble pin (4). coat the seal with grease to protect it from damage. make sure the rust retardant on the bushing inner surface is washed off. Shim Shim Front frame Clearance 1.2).5 mm or less using the shims. For the adjustment procedure using shims. after the positioning.Assembly procedure No.0 mm 2 Separately packed (No. lift the dump and lift cylinders. 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.1) 2. Fig. adjust the clearance to 1.) (1) 427-N42-209A Lift arm assembly 1 Separately packed (No. Q When aligning the pinhole. 6 ton) Q’ty 1 each 3 2 1 Others 101 . 1 ton) Nylon sling (Withstand load min. (See Fig. (See Fig.W9E-620) (2) 427-70-11460 Shim 1. 4 Adjustment using shims Before inserting the pin. Special tool Name Impact wrench Socket (36 mm) Large hammer Q’ty 1 1 1 Necessary Equipment Name Cranes 10 ton. molybdenum component does not adhere on the bushing surface and the oil loses its effect as an anti-scuffing measure. insert the lift arm hinge pin.W9E-620) (3) 427-70-11470 Shim 3. (See Fig.5 mm 4 Separately packed (No.1) 3. a Prior to coating. don't try to insert a finger in the pinhole. No. Hold the dump and lift cylinders in the current position using the lever block. 2 Fig. 1 Fig. 50 kg) Nylon sling (Withstand load min. coat the seal with grease to protect it from damage. Part No.W9E-620) (4) 427-70-11993 Pin 2 Temporarily installed on the front frame pivot Temporarily installed on the front (5) 01010-82450 Bolt 2 frame pivot (6) 427-70-11480 Washer 2 Temporarily installed on the front frame pivot Temporarily installed on the lift (7) 07049-01620 Plug 6 arm assembling pin Nylon sling Hinge it on the lifting eye Lever block of the cabin Hold the cylinder using the square timber Fig.LM-P or equivalent). 3 Cautions Q Before inserting the pin. Q When inserting the pin. Then. Using the nylon sling (crane 10-ton). 4. 25 ton Nylon sling (Withstand load min. Before assembling pin (2). Eliminate and clean the grease and paint deposited in the pinhole. see Fig. molybdenum component does not adhere on the bushing surface and the oil loses its effect as an anti-scuffing measure. Name Impact wrench Torque wrench Socket (30 mm) Large hammer . coat the seal with grease to protect it from damage.) 3.W9E-630) Separately packed (No. lift the lift arm and adjust the pinhole position. Care must be exercised to Fig. Adjust the position of the lift arm assembly and the lift cylinder and then insert lift cylinder head pin (1) to them. 1) 1. Q When inserting the pin.LM-P or equivalent). coat the entire inner surface of the bushing with the molybdenum disulfide lubricating oil in paste form (KES. coat the seal with grease to protect it from damage.Assembly procedure No. Fig.W9E-630) Temporarily installed on the lift cylinder assembling pin Separately packed (No. Before assembling pin (1). 0630 Assembling the lift arm assembly (Part 2) [2] Assembling of the lift cylinder to the lift arm assembly (see Fig. (If the rust retardant is left unwashed. a Prior to coating. a Prior to coating. coat the entire inner surface of the bushing with the molybdenum disulfide lubricating oil in paste form (KES.) (If the rust retardant is left unwashed. a Start the engine. 2.) Separately packed (No. 500 kg) Nylon sling (Withstand load min. 1 2. [3] Assembling of the bucket cylinder to the lift arm assembly (Assembling of the bell crank) (See Fig. (1) (2) (3) (4) (5) (6) (7) (8) Part No. Lift the cylinder head using the crane and then insert bucket cylinder pin (5) while adjusting the cylinder head position.) 3. Q When aligning the pinhole. Eliminate and clean the grease and paint deposited in the pinhole.W9E-630) Separately packed (No.W9E-630) Separately packed (No. 50kg) Q’ty 1 2 2 102 Others Q Before inserting the pin. make sure the rust retardant on the bushing inner surface is washed off. Before assembling pin (1). make sure the rust retardant on the bushing inner surface is washed off. 2 No.W9E-630) Separately packed (No. 427-70-11972 01010-82035 427-70-11290 07049-01620 427-70-11942 01010-82035 427-70-11290 07049-01620 Cautions 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. molybdenum component does not adhere on the bushing surface and the oil loses its effect as an anti-scuffing measure. molybdenum component does not adhere on the bushing surface and the oil loses its effect as an anti-scuffing measure. don't try to insert a finger in the pinhole. Q Care must be exercised to prevent assembling a lift cylinder pin or bucket cylinder 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.LM-P or equivalent). Bucket cylinder Bell crank Care must be exercised to prevent assembling a wrong pin. a When inserting the pin. Eliminate and clean the grease and paint deposited in the pinhole.W9E-630) Temporarily installed on the bucket cylinder assembling pin Special tool Necessary Equipment Q’ty 1 1 1 1 Name Crane 25 ton Nylon sling (Withstand load min. (If the rust retardant is left unwashed. Lift arm Lift cylinder prevent assembling a wrong pin. 2) 1. Note: This process is not required when the auto-greasing specification is employed Cautions Special tool Name Q’ty Necessary Equipment Name Q’ty Others 103 . 0640 Connecting the remote grease tube 1.Assembly procedure No. 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. W9E-650) (3) 01596-00606 Nut 4 Separately packed (No. 3 Cross section of bucket hinge pin section (Cross section A-A) Cautions Special tool Name Impact wrench Socket (10 mm) Spanner 10 mm Q’ty 1 1 1 Necessary Equipment Name Crane 25 ton Fig.W9E-650) Bucket assembly 1) Installation of the cord ring 1. two 4. Align the hole of the right and left hinge pins on the bucket to the pinholes on the lift arm. 4 Q’ty 1 1 2 Wire sling (Withstand load 11 ton. Place cord ring (O-ring) (1) on the lift arm boss 1. Coat the entire perimeter of the cord ring assembling-groove sufficiently with LM-G (molybdenum disulfide lithium grease). Part name Q’ty State of part (Parts list No. (See Fig. Lift the bucket assembly using a 25 ton crane. Cord ring assembling groove Bucket assembly viewed from the left side Fig. Part No. L=2.2) 2. a Don't try to insert a finger into the pin inserting pivot. (See Fig.000) Shackle: 5 ton 104 Others . Lifting tool: Wire sling (Withstand load 11 tons.W9E-650) 427-70-11450 Shim (3. Coat the entire inner surface 3 of the dust tool lip with LM-G (molybdenum disulfide lithium grease).W9E-650) (4) 01640-20610 Washer 8 Separately packed (No. (Adjust clearance (T) to 1.2) 3. Place the cord ring 2 in the groove after assembling of the bucket and adjustment with shims are complete.600 kg Fig. 1 Cross section of bucket hinge pin section (Cross section A-A) Fig. Select shim (5) in such that clearance (T) in the right and left side becomes even.W9E-650) (5) 427-70-11440 Shim (1. (See Fig. 2 Bucket assembly Weight: 8.W9E-650) (2) 426-09-11150 Bolt 4 Separately packed (No. 0650 Assembling the bucket (Part 1) No.5 mm) 6 Separately packed (No.) 1-2. 3) Selecting of shims for the bucket hinge pin section 1.Assembly procedure No.0 mm) 4 Separately packed (No.000 mm slings are used for lifting) Shackle: For 5 tons 2. Shim-based adjustment procedure 1-1.2) 4.5 mm max.) (1) 427-N42-1140 (O-ring) cord ring 4 Separately packed (No. (See Fig.2) 2) Alignment of hinge pin holes on the bucket assembly 1. Use a screwdriver (-) for holding the shim. coat it with grease. Care must be exercised when inserting bucket hinge pin (6) not to damage the dust seal. Part No. Before inserting the pin. 50 kg) Crane 10 ton Q’ty 1 1 Others 105 . (6) 427-N42-1161 (7) 01010-82035 (8) 427-70-11290 Part name Pin Bolt Washer Q’ty State of part (Parts list No. 6) Place cord ring (1) in the groove.8 kg 5) Assembling of the bucket hinge pin 1. Weight: 112. 2.Assembly procedure No. Assemble the shim being selected in 3) above. Assemble bucket hinge pin (6) using bolt (7) and washer (8). No. 0660 Assembling the bucket (Part 2) 4) Insertion of bucket hinge pin 1. After coating.) 2 Separately packed (No.W9E-660) 2 Separately packed (No.W9E-660) 2 Separately packed (No.W9E-660) Cross section of bucket hinge pin section (Cross section A-A) Cautions Special tool Name Impact wrench Socket (30 mm) Spanner 30 mm Large hammer Q’ty 1 1 1 1 Necessary Equipment Name Nylon sling (Withstand load min. place the pin in the groove. align the pinhole and then insert the buck hinge pin. ) No.W9E-670) Separately packed (No.W9E-670) Separately packed (No.0660).) Install the bucket link in the same procedure as 1) – 6) (See No. 1.Assembly procedure No.W9E-670) Separately packed (No. a After feeding the grease. 30 mm) Q’ty 1 1 Necessary Equipment Name Nylon sling (Withstand load min.W9E-670) 9) Feed LM-G (molybdenum disulfide lithium grease) to the bucket hinge pin and bucket link pin (See Fig. 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. Select the shim in such that the clearance on both sides is even and adjusted to max.W9E-670) Separately packed (No.W9E-670) Separately packed (No.0650 and No. Fig.) Separately packed (No.0 mm) Shim (1. 2 Fig.W9E-670) 2 Separately packed (No. (1) (2) (3) (4) (5) (6) (7) (8) (9) Part No.) 9 Separately packed (No.2).) • Assembling to the bucket hinge pin (See Fig. 1. No.5 mm. 50 kg) Crane 10 ton Q’ty 1 1 106 Others . 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 (3.5 mm) Ring Bolt Nut Washer Q’ty 1 1 1 2 4 2 2 2 4 State of part (Parts list No. (10) (11) Part No. 3. 2. Use a flat-blade screwdriver for holding the shim. 0670 Assembling the bucket (Part 3) Fig. 3 Grease position Bucket link Bucket hinge (2 places) Cautions Special tool Name Torque wrench Socket (10 mm. 1.) 8) Assembling of the grease nipple and plug • Assembling to the bucket link pin (See Fig. (Don't try to insert a finger into the pin-inserting pivot.W9E-670) Separately packed (No. 07049-01620 07020-00000 Part name Plug Fitting Q’ty State of part (Parts list No.W9E-670) Separately packed (No.W9E-670) a Shim-based adjustment procedure 1. 1 7) Installation of bucket link pin (See Fig.W9E-670) Separately packed (No. Assemble cover (1) using (2) and (3). No. (1) (2) (3) Part No. 0680 Assembling the cover (Bottom of the counterweight) 1. 2. Remove (2) and (3) being temporarily installed on the rear frame. 427-46-25341 01010-82045 01643-32060 Part name Cover Bolt Washer Q’ty State of part (Parts list No.W9E-680) 4 Temporarily installed on the rear frame 4 Temporarily installed on the rear frame Cautions Special tool Name Impact wrench Socket (30 mm) Q’ty 1 1 Necessary Equipment Name Q’ty Others 107 .) 1 Separately packed (No.Assembly procedure No. 0690 Feeding the grease 1. 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) Q’ty 1 Necessary Equipment Name Q’ty 108 Others .Assembly procedure No. After the assembly. 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. feed molybdenum disulfide lubricating agent (KES LM-G) until the grease spills out of the joint. 0700 1. (2) Set the bucket control lever to "Dump" and lift arm control lever to "Raise". Maintain the cylinder at its stroke end for 1 minute. Bleeding of air from the cylinder Work equipment hydraulic circuit air bleeding procedure (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.Assembly procedure No. Air bleeding from the PPC circuit (1) Set the bucket control lever to "Tilt" and lift arm control lever to "Float". Cautions Spanner Special tool Name Q’ty 1 Necessary Equipment Name Q’ty Others 109 . Maintain the cylinder at its stroke end for 1 minute. 1 427-43-19233 Tightening torque: 14. relation between the bucket angle and cylinder length is 8.W9E-710) Temporarily installed on the cylinder Temporarily installed on the plate Temporarily installed on the plate Temporarily installed on the plate Sensor sensing surface Section A-A Protector 3–5 Bucket positioner adjusting procedure (1) Lower the bucket on the ground and set it horizontal. (1) (2) (3) (4) (5) (6) (7) (8) (9) Part No. ª Confirm magnitude of the displacement.) (2) Adjust the proximity switch in such that its sensing surface is pulled in ª0. 0710 Adjusting the bucket positioner Bucket cylinder (1.5 – 1. 1/2 displacement should be present No. 1.Assembly procedure No. See Fig. Then fix the proximity switch.W9E-710) Temporarily installed on the cylinder Temporarily installed on the cylinder Temporarily installed on the cylinder Separately packed (No.7 mm/1°. 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. 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.) Separately packed (No.032) Detection bar 2 in nominal clearance Detection bar Proximity switch mounting bracket Fig. adjust the clearance along the entire passing surface to 3 – 5 mm.5 – 2. (3) Since the detection bar moves laterally to the switch sensing-surface.) Cautions Special tool Name Impact wrench Socket 19 mm Torque wrench Spanner Q’ty 1 1 1 1 Necessary Equipment Name Q’ty 110 Others .500 rpm) and activate the positioner.) (5) When the positioner is activated and the bucket is set near the ground surface.6 Nm {1. (When the bucket is set horizontal near the ground surface. (Make sure the displacement is 1/2 minimum.0 mm from the protector end.7 – 19.0 kgm} Min. (4) Run the engine at mid speed (1. fluctuation due to the engine speed shall be 4° maximum. (The ground surface must be even. 6 Nm {1.7 – 19. Distance between the switch center and sensor plate top end is 0 – 5 mm When the bucket is set horizontal When raised to the highest position Position of the plate when the lift arm was raised to the highest position Front frame Cautions Special tool Name Impact wrench Socket (17mm. 427-43-29110 01435-01020 428-43-29210 01435-01225 56B-06-15610 08193-21012 01435-01020 01643-31032 01580-11008 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. (1) (2) (3) (4) (5) (6) (7) (8) (9) Part No.5 – 2.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 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. 19 mm) Torque wrench Spanner Q’ty 1 1 each 1 1 Necessary Equipment Name Q’ty Others 111 . 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.Assembly procedure No.) Separately packed (No. (2) Fix the switch in such that the clearance between the switch sensing surface and plate in horizontal direction becomes 3 – 5 mm.W9E-720) Separately packed (No.0 kgm} View Z No. 7 – 19.) 1 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. 427-62-21330 01435-01220 56B-06-15610 Part name Bracket Bolt Switch Q’ty State of part (Parts list No. (1) (2) (3) Part No. Cautions Special tool Name Impact wrench Socket (19 mm) Q’ty 1 1 Necessary Equipment Name Q’ty 112 Others . 0730 Adjusting the new 2 stage (North American standard specification) Clearance between the switch sensing surface and plate in horizontal direction is 3 – 5 mm Tightening torque: 14.Assembly procedure No.W9E-730) 2 Separately packed (No.5 – 2.6 Nm {1.0 kgm} View Z No. 0740 View A Assembling the lift arm angle sensor Connect CN FB4 Front lamp assembly Assemble the respective parts to the assembled bracket. Lift arm assembly Detail of assembling No. Remove (9) being temporarily installed on lever (1). 3.W9E-740) Assemble (1) – (11) as show in the detail of Shim t = 0.Assembly procedure No. (1) (2) (3) (4) (5) (6) Part No. 1. 4. Temporarily installed on the lift arm (13) 427-43-28212 Cover 1 assembly and front frame Temporarily installed on the lift arm (14) 01024-81230 Bolt 1 assembly and front frame Temporarily installed on the front (15) 04434-51010 Clip 1 lamp assembly Temporarily installed on the front (16) 01024-81016 Bolt 1 lamp assembly 113 . (8) 01023-10412 Screw 2 Temporarily installed on the front frame Screw 2 Temporarily installed on the lever (1) Fix the harness using (15) and (16) as shown (9) 01315-20812 (10) 419-S30-2510 Plate 1 Temporarily installed on the front frame in view A.1 Temporarily installed on the front frame meter installed on the front lamp assembly. Clip and bolt already assembled Fix the harness here. Bearing 1 Temporarily installed on the front frame Case 1 Temporarily installed on the front frame Assemble (12) – (14) as show in the detail of Shaft 1 Temporarily installed on the front frame the assembling. 5. 427-43-28221 421-64-15140 06124-01416 425-S31-2120 421-S30-2250 427-S33-3190 Part name Q’ty State of part (Parts list No. (11) 01024-81025 Bolt 3 Temporarily installed on the front frame Fix and connect the harness to the clip Temporarily installed on the lift arm (12) 01024-81225 Bolt 4 assembly and front frame already being assembled. 6. 2.5 1 Temporarily installed on the front frame the assembling.) Lever 1 Separately packed (No. 7. Remove (2) – (8) and (10) – (14) being temporarily installed on the lift arm assembly of the front frame. Spring 1 Temporarily installed on the front frame Remove (15) and (16) being temporarily (7) 56B-06-11630 Sensor potentio. ) 1 Separately packed (No. 427-62-21330 01435-01220 56B-06-15610 Part name Bracket Bolt Switch Q’ty State of part (Parts list No. 0750 Adjusting the active working system and boom kick-out switch (Overseas general standard and domestic standard) Clearance between the switch sensing surface and plate in horizontal direction is 3 – 5 mm Tightening torque: 14. No.Assembly procedure No.0 kgm} 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. (1) (2) (3) Part No.5 – 2.6 Nm {1.7 – 19.W9E-750) 2 Separately packed (No.W9E-750) 1 Temporarily installed on the front frame When raised to the highest position 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 Impact wrench Socket (19 mm) Q’ty 1 1 Necessary Equipment Name Q’ty 114 Others . Assembly procedure No. 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. 115 . touch up the location where paint is peeled off. (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. Bolts and washers in the external bare portion shall be painted in the same color as the exterior parts.) (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. Following lists the places and number of the nipples used. touch up the damaged portions. (Touchup in the following (1) – (10) sections is a must. 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. Except the sections where face coating is provided. Black gray Black heat resistant paint Natural yellow 2. Grease nipple shall be painted in red. For other sections. Paint color shall conform to the following. 0760 Touchup work 1. 0770 Applying the decal (For the overseas-directed products only) 1. (1) Part No.) 2 Separately packed (No.Assembly procedure No.W9E-770) Special tool Name Q’ty Necessary Equipment Name Q’ty 116 Others . 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. 09807-C1683 Cautions Part name Mark Q’ty State of part (Parts list No. 1/9 1/9 WA800-3E0 WA900-3E0 KOMATSU SAA12V140E-3 GEN00056-01 . . operation. With the measurement gauge 10 hours later after the engine stopped. the buzzer sounds. the [CHECK] lamp Function of centralized inspection lamp does not go on. The density shall satisfy the standard. Turn the key switch ON. the buzzer stops sounding. When the starting switch is set to ON. the engine does not start. start the engine to check the level. (Example: ) Check Maintenance Remarks Judgment procedures and criteria Recording the Serial No. With the measurement gauge 5 minutes later after the engine started. (Check the level after the engine stopped. Inspection items Finish H 2/9 List of check marks for inspection results : Acceptable ( ) : Enter numeric values. A 7 8 9 10 Coolant level Electrolyte level Window washer level Check of antifreeze density in coolant The level shall be above the middle between Full and Low on the sub tank. a Check the level more than 60 minutes later after the engine stopped. The level shall be at 10 – 12 mm above the polar plate.a Carefully read the Operation and Maintenance Manual in advance to understand safety. shall be satisfied. (The engine does not start when the transmission is set to other than neutral.) 4 Brake oil level (When the check is difficult while the engine is at a stop.) 16 Safety function of transmission neutral 17 Safety function of steering lever set to neutral .) (When the lever is returned to the N position. Date of Inspection Inspector Service meter Start H No. : Unacceptable Empty column : Uninspected : No check is required. machine operations and controls.) 3 Engine oil level (while the engine is at a stop.) When the joystick lever is lowered to the right or left. the engine does not start. : Not applicable Check relevant items after maintenance. (Check the level by comparing it with the stamp [ENGINE STOPPED] on the dipstick more than 15 minutes later after the engine stopped. the pilot lamp blinks Function of emergency steering pilot lamp (and goes out after the engine starts). (Check safety around in advance so that everything is in order even if the engine starts. circle any of the above marks. Stamp 1 Lift arm No. Also. (Check them before starting the engine. The level shall be at the ENGINE RUNNING level.) The level shall be at the ENGINE STOP level.) Check the safety function at the start of engine. (When the lever is set to other than neutral. when the lever is lowered. which can be found after the monitor panel and the lunch box are removed. 2 Checking oil and water levels. Area A: -33 – -43°C Areas B: -24 – -34°C Areas C: -14 – -24°C Measured value ( ) °C Before the machine inspection. The number is stamped on the right upper part of the lift arm.) The level shall be in the range between (H) and (L). When the result is acceptable. The level shall be above the 2/3 level of the tank capacity. 5 Hydraulic oil level Lower the bucket on the ground. When the starting switch is set to ON. And the level shall be in the range of the inspection window. Check the antifreeze density. Preparation before function check 11 Satisfaction of failure code. the failure code on the display.) 6 Transmission oil level The level shall be in the range A at the ENGINE STOP position of the level gauge. of built-in parts. The sound volume is satisfactory without vibrating tone Function of horn (sensory). the buzzer sounds for Valve check function of main monitor and sub-monitor a second and the lamps of the main monitor and the submonitor go on. 12 13 14 15 When the starting switch is set to ON. Even when key switch is set to START by using the transmission rear and forward switch F or R of the joystick lever. and then carry out the following inspections. the engine does not start. level it. . (4) Set the lever to the [Lower] position. and the lift arm rises. a When the kick-out height is adjusted as requested by user. Standard: 2. (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. Initial setting a Do not move lever during procedures No. When no pip sound in (7) is heard. set the transmission lever to F3 speed and step down the accelerator pedal.020 – 2. 22 (2) Stop engine (Turn starting switch OFF) and set steering lock lever in LOCK position. Start each measurement only after warning-up run. For recording only. release the parking brake. (Sensory evaluation) No abnormal noise is heard. 1. Before measuring the engine speed. Inspection items Judgment procedures and criteria Check Maintenance Remarks Start the engine. refer to the paragraph of [Measurement of Engine Speed] in Part: “Testing and adjusting” in the Shop Manual. apply the parking brake. (3) Disconnect neutral position adjustment connector "JL3" <<Caution>> in right console. (5) Set the lever to the [Float] position. the lift arm cylinder stroke shall be within 5 mm. 23 Make checks related to the work equipment. order. carry out the initial setting again.170 – 2. (6) Set the lift lever to the [Float] position. Then. The accelerator pedal shall be free from double stepping and counter bounce and return smoothly. Is the exhaust color satisfactory at a sudden acceleration (Li o Hi). (3) Bring the lever to the [Hold] position. For recording only. the lever works at the height. release the accelerator pedal and set the secondary switch to ON. step on the brake pedal. and the work equipment is not released. apply the parking brake and step on the accelerator pedal.220 rpm Measure value of high idle speed: ( ) rpm Before measuring the speed.) 18 19 20 21 Function of centralized warning lamp Function of accelerator pedal Exhaust color Abnormal noise of engine When the engine starts.940 – 2. (4) – (7) at right. Standard: 820 – 910 rpm Measure value of low idle (secondary) speed: ( ) rpm Before measuring the speed. Measured value of engine speed at full stall: ( ) rpm Measuring the engine speed. If the pip sound does not occur even after re-initial setting. the [CAUTION] lamp does not blink. (Sensory check) Check low idle and high idle at each stall. (2) Pull the lever further from the [Raise] position. sensor and frame angle sensor are 2. (4) Turn starting switch to ON position and start engine.220 rpm (WA900) Measured value of engine speed at stalling T/C: ( ) rpm Before measuring the speed. Standard: 1. 24 Function of lift arm control lever .3/9 No. and the lever returns to the [Hold] position at the same time. release the work equipment and step on the accelerator pedal. Measured value of engine speed at ) rpm stalling the work equipment: ( Before measuring the speed. release the accelerator pedal and set the secondary switch to OFF. the joystick steering is out of (5) Connect neutral position adjustment connector "JL3". (Check that both output voltages of steering angle (6) Reset steering lock lever. (1) Set machine and steering in straight travel position. Standard: 620 – 710 rpm ) rpm Measure value of low idle speed: ( Before measuring the speed. bring the lift arm to the position adjusted with the kick-out. release the parking brake. Initial setting of AJSS (joystick steering) ª Check each function after the initial setting. step on the brake pedal. and the lever is clutched at the notch and stops there. apply the parking brake.) completed. set the transmission lever to F3 speed. step on the accelerator pedal and release the work equipment. (Check safety around and then start the engine. Troubleshoot it and carry out the initial setting. apply the parking brake.60 V (7) After 1 second.40 – 2. (1) Set the lever to the [Raise] position. buzzer beeps 3 times and adjustment is and then repeat procedures from No. and the lift arm keeps staying at the position where it stopped. and the lift arm falls and the work equipment is released at the lowest position.140 rpm (WA800) 2. 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 When the engine speed measuring method is not clear. the lever is clutched at the notch and the lift arm can freely move as external force is applied. . and the bucket moves in the dump direction. Function of bucket control lever (4) Set the lever to the [Dump] position. and the bucket moves in the tilt direction. 45 – 55 °C) Measured value: ( ) sec.) Standard lever dumping: 2. 30 Proximity switch for active mode Measurement of solenoid voltage 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 dump cylinder rod 15 minutes later. Inspection items Judgment procedures and criteria Check Maintenance Remarks 25 26 27 28 29 (1) Set the lever to the [Tilt] position. work equipment is released. Bucket tilted back time (Measure the time without load at the lift arm highest position. and the bucket keeps staying at the position where it stopped. side of the dashboard to Normal Loading Measured value: ( ) sec. (2) Pull the lever further from the [Tilt] position when the bucket is dumped. and start the measurement. the work equipment does not lower even if the (for work equipment control lever) work equipment control lever is moved.1 sec. Measurement of work equipment speed in the Lift arm raising time (without load) Standard lever raising: 9.9 – 10. and the lift arm comes down. (Oil temperature: 45 – 55 °C) Standard value: 30 mm/15 minutes Measured value: ( ) mm 31 Check of lift arm hydraulic drift (without load) Check of bucket natural dump (without load) 32 Posture for measuring hydraulics drift . (3) Bring the lever to the [Hold] position. (Work equipment speed and oil temperature: Lift arm lowering time (without load) Standard lever lowering: 4. start the measurement 5 minutes later after the engine stopped and measure the fall of the lift cylinder rod 15 minutes later. When a metal piece is stuck to the proximity switch for Set the Active Working Switch on the right powerful mode (and fixed with rubber tape) at the lift arm side of the dashboard to Normal Loading highest position. Measured value: ( ) sec. (Note that a poor switch adjustment causes the bucket to be released from the notch before the working position sometimes.3 – 5.) a When the bucket positioner is adjusted as requested by user.9 sec.) Set the Active Working Switch on the right Standard lever tilting: 3. the loader pump solenoid has the voltage of 24 V.5 – 4. The pilot lamp of the proximity switch for powerful mode goes Check of active mode on at the lift arm hinge pin height of 1. Stop the engine after an engine high idle and lower the lift Function of work equipment accumulator arm control lever. Bucket dumping time (Measure the time without load at the lift arm highest position. make the bucket bottom horizontal with the ground. the bucket shall work at the position. the transmission is set to F3 speed and the and start the measurement.0 m. normal mode Measured value: ( ) sec. Does the remote positioner switch enable to set the Down Function of remote positioner 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 Function of lock lever lowered).4/9 No. (5) The bucket positioner has been adjusted so that the bucket is level with the ground or is slightly tilted down forward.8 sec. 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 positioner.3 sec.2 – 2.4 – 2. (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. . Change the machine travel direction to forward or backward at the 1st or 2nd speed. Set the selector switch to OFF (to turn off the pilot lamp). and there occurs the clearance of 20 – 30 mm Check of adjustment of steering stopper bolt between the front frame and the rear one. The steering angle changes only as much as the joystick lever is moved.2 – 4. the machine comes to travel at F1 speed.3 sec. 33 Safety function of joystick steering lock lever Bring the steering lock lever to the lock position after starting the engine and lower the joystick lever to the right or left. (Check it on both the right and left sides. (1st speed pilot lamp o Automatic gear shift to 1st speed. 38 Safety function of joystick steering lock lever 39 Transmission control function of joystick lever 40 Shock to and time lag of transmission 41 Function of kick-down switch 42 Function of transmission cut-off switch 43 Auto and manual shift changeover function of transmission 44 Function of transmission manual shift mode 45 Function of transmission auto shift mode 46 Function of hold switch .5/9 No. the indicator lamp on the left dashboard for the selected automatic transmission maximum speed gear goes on. the transmission is fixed to the gear shift being displayed with the transmission indicator on the main monitor and the hold indication on the main monitor goes on. Press the shift-down switch (-) of the joystick lever. Set the forward-reverse selector switch of the joystick lever to the F position. and the transmission speed decreases.) Measure the full stroke time in idle the engine at high speed. the pilot lamp does not go on. (Check the clearance on both the right and left sides. 2nd speed pilot lamp o Automatic gear shift to 2nd speed. Set the transmission to reverse travel (R). the pilot lamp of the transmission cut-off switch on the monitor goes on. and the buzzer sounds and the machine does not travel. and the buzzer sounds but the steering is not disengaged. and the machine turns to Function of steering the left. (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.) The shift display on the monitor panel agrees with the gear shift selected with the transmission shift up/down switch. and the hold is released and the display disappears. 34 35 36 37 Making checks of travel and brake. 3rd speed pilot lamp o Automatic gear shift to 2nd speed . and the machine turns to the right. Set the forward-reverse selector switch of the joystick lever to the N position. Set the transmission cut-off switch on the main monitor panel to ON. and the machine returns to the 2nd speed. Lower the joystick lever to the left. Set the forward-reverse selector switch of the joystick lever to the R position. press the switch beside the lift arm lever knob. and the transmission does not get any shock nor cause any time lag. Inspection items Judgment procedures and criteria Check Maintenance Remarks Making checks related to the steering. Press the shift-up switch (+) of the joystick lever. When the engine stopped while traveling downhill. Press the switch on the head of the lift arm control lever while traveling the machine at the F2 speed. Press the switch on the head of the lift arm control lever while traveling the machine at the F2 speed.2 – 4. and the transmission is set to neutral. Lower the joystick lever to the right. When the transmission in the auto shift mode. pip sounds occurs. and the transmission speed increases. When the transmission is in the auto shift mode. Measured value: ( ) Measurement of steering operation time Measure the full stroke time in idle the engine at high speed. Step on the left brake. (In the manual shift mode. and the machine travels backward. Bring the joystick lever to the stroke end while idle the engine at low speed. Press the switch once again. the Function of emergency steering steering angle changes. and the transmission gets in the manual shift mode. Standard left swing: 3. and the transmission gets in the auto shift mode. Standard right swing: 3.3 sec. and returns to the 2nd speed about 4 seconds later (in the auto shift mode only).) Set the transmission to F or R at the locked position. the machine comes to travel at the 1st speed. 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.3rd speed) When the F3 speed is changed over to R3 speed while the engine is idle at high speed. and the machine travels forward. Set the selector switch on the main monitor to ON (to turn on the pilot lamp). and the machine does not travel. . (The engine stops. and the internal lightings go on. Standard F1 speed: 6 – 8 km/h Measured value: ( ) km/h Check of travel speed Standard F2 speed: 11 – 13 km/h ) km/h When the bucket is empty. the parking brake pilot lamp goes on. the starting switch gets set to ON and the parking brake works. and brightness of the brake lamp changes. and the light goes on and goes out automatically about a minute later. Standard R3 speed: 26 – 30 km/h Measured value: ( ) km/h Internal lighting of main monitor and sub monitor Function of clearance lamp Function of head lamp Function of turn signal lamp Function of hazard lamp Function of tail lamp Function of back-up lamp Set the lamp switches (on the 1st and 2nd stages) to ON. and the caution lamp for the oil pressure of the brake accumulator does not go on. Apply the brake suddenly at the initial speed of 20 km/h. the lights at the doors light when the cab door are opened. idle the engine at high speed until the Check of the time when the brake accumulator accumulator is fully charged. Turn on the parking switch. and the machine stops within 7. Also. and the back-up lamp goes on. 55 56 57 58 59 60 61 62 Function of brake lamp 63 Function of working lamp 64 65 66 Function of step lamp Function of room lamp Function of back-up buzzer . and the right and left rear lights go on. the right and left working lights on the roll-over protective structure and on the radiator guard go on. and the red brake lamps (right and left) go on. (Sensory) Checking all lamps. Step on the brake pedal to sound the caution buzzer for oil pressure drop. Set the light switches (on the 1st and 2nd stages) to ON.) When the emergency brake works. Step on the brake pedal. Set the transmission shift lever to R. check the travel Measured value: ( 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.) Step on the service brake pedal several times. Set the light switches to ON and apply the brake. Set the switch to ON. Set the light switches (on the 1st and 2nd stages) to ON and set the R working light switch to ON. This brake enables to stop the machine on slopes of 1/5 Function of parking brake gradient. Braking force of service brake Step on the brake while the engine is idle at high speed or at the F2 speed. the parking brake works automatically. No abnormal heat can be felt (on the four wheels). Set the switch to ON. and the right and left front lights go on. and the light goes on. and the machine stops one a straight line. and the centralized warning lamp blinks and the warning buzzer sounds. 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. and the pilot lamp goes on. 47 48 49 50 51 Inspection items Heat accumulation in brake disc Judgment procedures and criteria Check Maintenance Remarks 52 53 54 After traveling the machine.5 m. Move the turn signal lever. touch the brake chamber by hand. and the right and left turn signal lamps and the pilot lamp (arrow) inside the cab blink. and the head lamps (2 lamps each on the right and left sides) go on.) Set the light switches (on the 1st and 2nd stages) to ON and set the F working light switch to ON. (The lamp becomes brighter. and the pilot lamp goes on and the rear right and left working lights on the radiator grille go on. and the pilot lamp F goes on and the working light on the cab front head goes on. When the pressure in the accumulator drops. Then. set the joystick lever T/M Safety function of parking brake forward-reverse switch to F or R. Set the light switches (on the 1st and 2nd stages) to ON and set the R working light switch to ON. Set the hazard switch to ON. Set the light switches (on the 1st and 2nd stages) to ON. The sound volume is satisfactory without vibrating tone. Stop the engine and restart the pressure drops engine 30 minutes later. and the front and rear turn signal lamps corresponding to the intended direction blink. Travel the machine at more than 20 km/h and apply the Pull of brake brake suddenly. Set the lamp switches (on the 2nd stages) to ON. they are regarded as reference Measured value: ( ) km/h values. and the machine does not start.6/9 No. and the accumulator Check of emergency brake pressure drops and the parking brake works. . 67 68 69 During operation. side: Press the switch front. the gauge indicates any point in the green Function of engine coolant temperature gauge range. and the window glass rises. you can get warm wind. Function of air conditioner 72 Since the air conditioner does not work when the temperature in the cab is low. The cigarette lighter is heated red and returns to where it was several second later. seek tuning.25 kg/cm2 Measured value: Front left ( Measured value: Front right ( Measured value: Rear left ( Measured value: Rear right ( ) kg/cm2 ) kg/cm2 ) kg/cm2 ) kg/cm2 Checking failure code 76 Check of failure code Make sure that no failure code is displayed on the monitor panel after completion of the function check. tone (low and high). Press its rear side. and the speaker volume increases. H. replay. turn it forward to the 2nd step. and the radio is switched on. and the washer liquid is sprayed over the front glass and the front wiper interlocks. Checking the AM/FM radio cassette stereo 73 Function of AM/FM radio cassette stereo Checking cigarette lighter 74 Check of cigarette lighter Checking tire air pressure Tire size and criteria 75 45/65-45-46PR L-5 Standard value: 5. Inspection items Judgment procedures and criteria Check Maintenance Remarks Check gauge performance. R. and the window glass lowers. the gauge indicates any point in the green range. preset scanner. L. you can get cool wind. warm the air inside the cab before starting the check. Turn it forward to the 1st step. and the indicator lamp on the upper side of the switch goes on. and the rear washer and the rear wiper interlock. [INT]. When the level indicator of the temperature adjustment switch shows green. loudness. Press the air conditioner switch. manual tuning. rapid forwarding and rewinding can be made smoothly. and the window glass lowers. and the rear wiper works. side: Press the switch front. and the indicator lamp on the upper side of the switch goes on. Display the clock (by pressing the DIPS button) and check that it shows the correct time. [Low Speed] and [High Speed] in this order. During operation. the gauge indicates the exact level in the Function of fuel gauge fuel tank. Turn the wiper switch lever backward. Press its rear side. and when it shows red. and the front wiper corresponds to [OFF]. Function of torque converter oil temperature gauge Checking the power window 70 Function of power window Checking the windshield wiper 71 Function of windshield wiper Checking air conditioner The air flow rate corresponds to that on the fan switch. Keep turning it. Turn the power switch to the right. and the window glass rises. What is effective are auto store. After inserting a cassette tape (arranging the side where the tape can be seen to the right). During operation. H. Turn the rotary switch. The capacitor fan is rotating during operation of the air conditioner. Press the push-button on the side of the switch. Press the external/internal air changeover switch. band changeover and manual memory. The mode selector switch corresponds to the wind spurtingout position.7/9 No. and the rear washer liquid is sprayed. Check of failure code ( ) . . Side working lights and step lights are installed tightly. 78 Check of ROPS structure The antenna is installed tightly. (Check them on both the right and left sides. Inspection items Judgment procedures and criteria Check Maintenance Remarks Carry out inspection of every part. The PPC valve hose connecting portion is not loose. Mounting bolts are free from looseness and scuffing.) There is some clearance between the upper center pin lock plate and the rear frame. and the harness is fixed to the clip. Front axle mounting bolts are free from looseness and scuffing.8/9 No. Mounting bolts of each handrail are tightened certainly and are free from scuffing. and the screws are free from scuffing. 79 Inspection around machine upper side Inspection of loader link and bucket Mounting pin bolts of the loader link and bucket are tightened certainly and are free from scuffing. 82 83 Inspection of light support Inspection of front fender Light support mounting bolts are lightened certainly and are free from scuffing. Bell crank upper pins and lift arm cylinder pins (on the rod side) are assembled correctly.) Steering cylinder mounting pins are greased certainly. (Check them on both the right and left sides. The throttle cable is connected straight and tightly. there is not interference between the steering link and the harness to the front. Harness connectors below the floor are certainly locked to the claws. (Check both the upper and lower pins. 81 Inspection around front axle 84 Inspection around center pin . (Check them on both the right and left sides. 80 Ф180 44 5 Pin on bell crank side Ф180 43 5 Pin on lift arm cylinder side Their diameters are the same but their lengths are different by 10 mm.) No oil leakage is detected in the hydraulic line. Mounting pins of the loader link and bucket are greased certainly. Mounting bolts of each handrail are tightened together with washers. steering line and brake line systems. At the time or right swing. Floor frame mounting bolts are tightened certainly and are free from scuffing.) Front fender mounting bolts are tightened certainly and are free from scuffing.) Center pin mounting bolts are tightened certainly and are free from scuffing.) Steering cylinder mounting pin bolts are tightened certainly and are free from scuffing. and harnesses do not sway. (Check them on both the right and left sides. 77 Check of cab Cab glass is free from flaw. Center pins are greased certainly. (Check both upper and lower pins. Cab lining is free from flaw and stain. No oil leakage is detected in the brake system. . side) Belt step mounting bolts are tightened certainly and are free from scuffing. H.) Fuel tank mounting bolts are free from looseness and scuffing. 92 Inspection of tire and wheel 93 Inspection of lower parts . No oil leakage nor water leakage are detected. The breather tube is not deformed. No oil leakage is detected in the brake system. No oil leakage is detected in the brake system and hydraulic system. 87 Inspection around battery box 88 Inspection of fuel tank 89 90 91 Inspection around rear axle Inspection of counterweight Inspection around hydraulic tank Rear axle mounting bolts are free from looseness and scuffing. 85 86 Inspection items Inspection of exterior parts Inspection around engine Judgment procedures and criteria Check Maintenance Remarks Cab skirt panel mounting bolts are tightened certainly and are free from scuffing.) Air valve caps are installed certainly. Front drive shaft mounting bolts are tightened certainly and are free from looseness and scuffing. Hub nuts are mounted tightly and are free from scuffing.9/9 No. Rear axle rear cover mounting bolts are tightened certainly and are free from scuffing. Rear drive shaft mounting bolts are tightened certainly and are free from looseness and scuffing.) Tires are free from flaw and tear. (Check them on both the right and left sides. (Check them on the four wheels. There is no clearance at the drive shaft yoke mounting portion.) No oil leakage is detected from the transmission and the torque converter. No oil leakage is detected. Counterweight mounting bolts are free from looseness and scuffing.) Battery cables are tightly connected. Battery box mounting pin bolts are tightened certainly and are free from looseness and scuffing.) Battery holder is mounted tightly. (Check them on the four wheels.) Step mounting bolts on the battery box front side are tightened certainly and are free from scuffing. Lift ladder mounting bolts are tightened certainly and are free from scuffing. The rear axle support is greased certainly. (Check them on both the right and left sides. (R. (Check the boxes on both the right and left sides. Access ladder mounting bolts are tightened certainly and are free from scuffing. (Check them on the four wheels. (Check it on both the right and left sides. No fuel leakage is detected from the fuel tank. GEN00056-01 ©2007 KOMATSU All Rights Reserved Printed In Japan 07-07 . WA900-3E0 GALEO WHEEL LOADER Form No.WA800-3E0. 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