Transcript
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.
Item
0010 Oil, grease and coolant
Page 10
0020 Oil, grease and coolant level
11
0030 Setting rear frame in place
12
0040 Setting front frame in place
13
0050 Joining front and rear frames
14
0060 Front and rear frames joining procedure
15
0070 Assembling the steering pin
16
0080 Assembling the center drive shat (Center support – Transmission)
17
0090 Connecting the pipes - Part 1
18
0100 Connecting the pipe - Part 2
19
0105 Connection of piping (Part 2) (Riotinto specification: If equipped)
20
0110 Connecting the auto-greasing pipe
21
0120 Setting the axle in place and assembling the support
22
0130 Setting the bare machine in place
23
0140 Assembling the rear axle
24
0150 Rear axle rear side cover assembling procedure
25
0160 Connecting the rear axle pipe
26
0165 Fixing of rear axle piping (Brake cooling specification: If equipped)
27
0166 Connection of rear axle piping (Riotinto specification: If equipped)
28
0167 Fixing of rear axle piping (Brake cooling specification: If equipped)
29
0168 Connection of cooling line piping (Brake cooling specification: If equipped)
30
0170 Assembling the rear drive shat (Transmission – Rear axle)
31
0180 Assembling the front axle
32
0182 Fixing of front axle piping (Brake cooling specification: If equipped)
33
0185 Connection of front axle piping (Brake cooling specification: If equipped)
34
0190 Connecting the front axle pipe
35
0195 Connection of front axle piping (Riotinto specification: If equipped)
36
0200 Connecting the front drive shat (Front axle – Center support)
37
0210 Connecting the axle oil temperature sensor (For VHMS specification only)
38
0220 Assembling the tires
39
0230 Assembling the fuel tank
40
0235 Installation of fuel tank (Riotinto specification: If equipped)
41
0240 Fixing the drain pipe
42
0245 Fixing of torque converter cooler drain piping (Riotinto specification: If equipped)
43
0250 Connecting the fuel pipe
44
0260 Fixing the engine drain hoses
45
0270 Assembling the hydraulic tank ladder
46
0280 Assembling the floor and cab assembly
47
0290 Connecting the air conditioner hose
48
0300 Connecting the brake line
49
0310 Connecting the window washer hose
50
0320 Connecting the PPC line hose
51
0330 Connecting the floor wiring harness
52
0333 Connection of floor wiring harness -1 (Riotinto specification: If equipped)
53
0334 Connection of floor wiring harness -2 (Riotinto specification: If equipped)
54
0340 Connecting the link for AJSS (For AJSS specification only)
55
0345 Calibration of the AJSS angle and frame offset angle
56
0350 Assembling the auto-greasing pump and connecting the pipe (WA900-3E0 North American specification)
57
0360 Assembling the floor cover
58
0370 Refilling the window washer
59
0380 Assembling the battery box
60
No.
Item
0390 Connecting and fixing the battery wiring
Page 61
0393 Wiring on right side of battery (Riotinto specification: If equipped)
62
0394 Wiring on left side of battery -1 (Riotinto specification: If equipped)
63
0395 Wiring on left side of battery -2 (Riotinto specification: If equipped)
64
0396 Wiring on left side of battery -3 (Riotinto specification: If equipped)
65
0397 Connection of ground cable on left side of battery (Riotinto specification: If equipped)
66
0400 Assembling the battery step
67
0403 Installation of oil cooler assembly (Brake cooling specification: If equipped)
68
0404 Installation and connection of oil cooler assembly piping (Brake cooling specification: If equipped)
69
0406 Installation of oil cooler assembly piping -1 (Brake cooling specification: If equipped)
70
0407 Installation of oil cooler assembly piping -2 (Brake cooling specification: If equipped)
71
0410 Assembling the handrail (On the right hand platform)
72
0411 Installation of handrail (Right platform area) (Brake cooling specification: If equipped)
73
0420 Assembling the handrail (On the hood top face)
74
0430 Assembling the handrail (On the right hand battery box)
75
0440 Assembling the rear access step
76
0450 Assembling the left handrail (Part 1)
77
0460 Assembling the left handrail (Part 2)
78
0461 Installation of left handrail (Part 2) (Brake cooling specification: If equipped)
79
0470 Assembling the rearview mirror
80
0471 Installation of rearview mirrors (Brake cooling specification: If equipped)
81
0480 Assembling the exhaust pipe
82
0485 Installation of oil cooler guard assembly (Brake cooling specification: If equipped)
83
0486 Installation of fan motor piping cover -1 (Brake cooling specification: If equipped)
84
0487 Installation of fan motor piping cover -2 (Brake cooling specification: If equipped)
85
0490 Applying the counterweight anti-slip
86
0500 Assembling the counterweight (WA900-3E0 standard specification)
87
0505 Assembling the counterweight (WA900-3E0 High-lift arm specification)
88
0510 Assembling the counterweight (WA800-3E0 Overseas general, optional specification and North American specification)
89
0520 Assembling the counterweight (WA800-3E0 Overseas general standard specification)
90
0530 Assembling the front axle lamp and connecting the harness
91
0540 Assembling the front lamp assembly
92
0550 Assembling the ROPS canopy assembly
93
0560 Assembling the antenna and work lamp
94
0570 Assembling the VHMS antenna (For VHMS specification only)
95
0580 Assembling the floor mat
96
0590 Assembling the front fender
97
0600 Engine starting procedure
98
0610 Bleeding the brake air
99
0615 Bleeding air from hydraulic circuit
100
0620 Assembling the lift arm assembly (Part 1)
101
0630 Assembling the lift arm assembly (Part 2)
102
0640 Connecting the remote grease tube
103
0650 Assembling the bucket (Part 1)
104
0660 Assembling the bucket (Part 2)
105
0670 Assembling the bucket (Part 3)
106
0680 Assembling the cover (Bottom of the counterweight)
107
0690 Feeding the grease
108
0700 Work equipment hydraulic circuit air bleeding procedure
109
0710 Adjusting the bucket positioner
110
0720 Adjusting the new 2 stage (Overseas general standard)
111
0730 Adjusting the new 2 stage (North American standard specification)
112
0740 Assembling the lift arm angle sensor
113
0750 Adjusting the active working system and boom kick-out switch (Overseas general standard and domestic standard)
114
0760 Touchup work
115
0770 Applying the decal (For the overseas-directed products only)
116
Appendix: Field assembly inspection report
1
Dividing Process Overview (Major components alone)
1. Front frame subassembly
2. Rear frame subassembly
4. Rear axle assembly (With rear axle support)
5. Wheel and tire assembly
7. Lift arm assembly
10. Floor handrail assembly
14. Muffler stack
3. Front axle assembly
8. Floor and cab assembly
11. Ladder assembly
15. Fuel tank assembly
6. Bucket assembly
9. ROPS canopy assembly
12. Front fender
16. Battery box assembly
13. Front lamp assembly
17. Counterweight
1
2 Major Components Table of Dimensions
1
Front frame subassembly
1
Weight (kg) 11,500
2
Rear frame subassembly
1
26,000
6,425
3,200
3,155
3
1
8,514
4400
1600
1000
1
8,500
4400
1800
1000
5
Front axle assembly Rear axle assembly (with axle support) Wheel and tire assembly
4
14,380
1200
2800
2800
6
Bucket assembly
1
12,290
5200
2900
2500
Floor and cab assembly
1
1,000
2300
1800
2100
1
1,387
2500
1900
2200
1
650
1820
3940
1100
Unit name
4
Q'ty
L: Overall length (mm) 4,830
W: Overall width (mm) 2,250
H: Overall height (mm) 3,150
7 8 9
ROPS canopy assembly Floor handrail and rear access step 10 assembly 11 Ladder assembly
1
60
500
700
2400
12 Front fender
2
170
800
1700
1400
13 Front lamp assembly
2
65
800
700
1300
14 Muffler stack
2
50
400
400
1700
15 Fuel tank assembly
1
790
1800
1900
1100
16 Battery box assembly
1
580
900
900
800
1
2,900
3200
1200
600
1
2,600
375
3,200
600
17-1 Counterweight 17-2 Additional counterweight (Dimensions depend on ATT)
2
2
Major Components Table of Dimensions
Land transportation Transportation means
Weight (kg)
Relevant specifications Overall length Overall width (mm) (mm)
Provisions required for transportation
Overall height (mm)
Front frame assembly in transportation by trailer
11,500
4,830
2,250
3,150
Rear frame assembly in transportation by trailer
26,000
6,425
3,200
3,155
One 36 ton trailer [For the machine body excluding the following removed parts] Four 15 ton trailers [Bucket, loader link, front axle, rear axle (including swivel support), tire and rim, parts around cab and operator's seat, exterior parts (hood grille, fender, ladder, platform, handrail, light support), counterweight, fuel tank (including (fuel) and exhaust pipe]
Style Packing style in transportation by trailer (Application for the Special-purpose Vehicle Passage may be required)
Maximum loading mass
ton
36
Loading space length
mm
6,300
Loading space width
mm
3,200
Overall length
mm
11,900
Gooseneck length
mm
2,500
3
3 Work Space Layout (A larger workspace provides better workability. 25 m × 30 m shown in the figure below is the minimum required space.)
Tire and wheel assembly
Lift arm assembly
50 ton crane
Bare machine
Front axle assembly
Light-weight units storage place Front fender Ladder and muffler stack Front lamp Floor handle
Front tank Floor and cabin assembly assembly
Rear axle assembly
50 ton crane
Counterweight assembly
Bucket assembly
ROPS canopy assembly
Compressor parts Jigs and tools storage place
4
Day
Hour
Worker
Crane
Rough assembly work
Condition of chassis
Worker
Crane
Rough assembly work
Condition of chassis
Hour
Day
5 workers
Installing counterweight, ROPS, and lift arm
5 workers
Installing, checking, and adjusting bucket
4th day
Coupling frames
Mount onto counterweight mounting end plate.
Frame assembly stand
Crane: 50 ton
Positioning chassis
Crane: 25 ton
1st day
2 workers
Checking and touchup painting
5th day
Installing tires
Mount onto counterweight mounting end plate.
Frame assembly stand
Crane: 50 ton
5 workers
Positioning axles
Crane: 25 ton
2nd day
Installing fuel tank and cab
Installing step handrails and battery box
3rd day
4 Schedule Table for Field Assembly
5
5 Facility, Jigs and Tools Drawing of frame deck Drill hole of 4-22 (Machining is not necessarily required)
(Note) The joint indicated in the figure must be welded at 9
6
For REAR/FRONT(680)
For REAR/FRONT(648)
Either above or a component made of welded t12 flat steel is acceptable
.
Quantity For front 2 pieces For rear 2 pieces
5
Facility, Jigs and Tools
Tools used No.
Tool name
Specification Spanner, ring spanner and box spanner chisel Screwdriver, hammer, monkey wrench, hex wrench, etc.
Q’ty
Remarks
1
List of standard general tools
2
2
Power wrench
16 time
1
3
Power wrench
4 time
1
4
Socket
60T (Entry point 38.1) × L: 84
1
5
Socket
36T (Entry point 25.4) × L: 68
1
6
Socket
46T (Entry point 25.4) × L: 72
1
For front and rear axle mounts For rear axle support cover, tire and counterweight For fuel tank and counterweight
7
Socket
55T (Entry point 38.1) × L: 82
1
ROPS mount
8
Socket
55T (Entry point 25.4) × L: 82
1
ROPS mount
Front and rear axle mounts, ROPS canopy mount Fuel tank mount
9
Extension bar
Entry corner 12.7 × L:150
1
For fuel tank
10
Adapter
Entry corner 19 × 12.7 × L:55
1
11
Extension bar
Entry corner 25.4 × L:160
1
12
Preset torque wrench (Box type) Head replacement type preset torque wrench Head replacement type preset torque wrench Head replacement type preset torque wrench
39.2 – 274.6 Nm {4 – 28 kgm}
1
For fuel tank For tire, counterweight and ROPS canopy For power wrench
58.8 – 137.3 Nm {6 – 14 kgm}
1
For connecting hoses and tubes
19.6 – 44.1 Nm {2 – 4.5 kgm}
1
For connecting hoses and tubes
29.4 – 68.6 Nm {3 – 7 kgm}
1
For connecting hoses and tubes
Width across flats: 27 (Entry point: ø15) 19 (Entry point: ø12) 22 (Entry point: ø12) 24 (Entry point: ø12), 36, 41
1 each
For connecting hoses and tubes
13 14 15
16
Head replacement type preset torque wrench (Spanner type)
196.1 – 1,372.9 Nm {20 – 140 kgm}
1
For rear axle support cover, counterweight
490.3 – 2,059.4 Nm {50 – 210 kgm}
1
For counterweight
58.8 – 411.9 Nm {6 – 42 kgm}
1
For rear axle support cover
GT-P8M or equivalent
1
20
Preset type torque wrench (Box type) Preset type torque wrench (Box type) Preset type torque wrench (Box type) Impact wrench
21
Impact wrench
GT-P14M or equivalent
1
22
Impact wrench
GT-S22M or equivalent
1
23
Adapter
Entry corner 19 × 25.4 × L:71
1
24
Adapter
Entry corner 12.7 × 9.5 × L:41
1
25
Large hammer
10 pounds
26
Air grinder
27
Bar
17 18 19
For tire and ROPS canopy For power wrench and torque wrench For power wrench and torque wrench
1 —
1
28
Round mandrel
2
For adjustment of holes and moving heavy stuff For adjustment of holes
29
Grease gun (Hand pump type)
Capacity about 300 cc
1
For applying grease to pins
30
Oil jack
1
For bleeding air from brake line
31
Vinyl hose
Capacity 1,000 – 2,000 cc Inside diameter: ø6.5 – ø7.0, L: 1,000 – 1,500
1
For bleeding air from brake line
196.1 Nm {20 kgm}
1
For connecting hoses and tubes
176.5 Nm {18 kgm}
1
For connecting hoses and tubes
32 33
Head replacement type preset torque wrench Head replacement type preset torque wrench
Large, medium and small —
2 each
7
5 Facility, Jigs and Tools Facilities used Tools and facilities used No.
Tool name
1
Crane
2 3
Specification
Q’ty
Min. 50 ton
2
Forklift
Min. 2 ton
1
Compressor
Capacity: Min. 32l
1
Remarks
For impact wrench and bleeding air
4
Lever block
1 ton
3
For holding cylinder and drive shaft
5
Footstall (Work table)
4 stage (About 1.5 m high)
3
For work
6
Steel plate
(Large) 9 × 1,219 × 2,438
4
For setting bare machine in place
7
Steel plate
(Large) 25 × 250 × 600
4
For setting bare machine in place
8
Crosstie
400 × 400 × 900
14
For setting bare machine in place
200 × 400 × 800
4
For setting bare machine in place
9
Air grease gun
Capacity: 18l
1
10
Air conditioner gas charge
Gauge manifold, leak detector
1
11
Tester
1
Lifting tools used No.
9
Specification 2 point lift Front frame lifting tool (Sling hook (SL) of L = 2,250 and ø20 in chain diameter)) Balance 2 point lift Rear frame lifting tool (Sling hook (SL) of ø20 in chain diameter)) 2 point lift Rear axle lifting tool (Club hook (G) of L = 5,500 and ø16 in chain diameter)) Nylon sling 50 × 2,000 Balance 2 point lift (Sling hook (SL) of ø16 in chain diameter)) Front and Rear axle lifting tool Balance 2-point lift (Club hook (G) of ø12.5 in chain diameter)) Nylon sling for drive shaft 50 × 5,000 2 point lift Fuel tank lifting tool (Sling hook (SL) of L = 5,000 and ø6.3 in chain diameter)) Floor and cab assembly lifting tool 2 point lift (Sling hook (SL) of L = 2,000 and ø6.3 in chain diameter)) Nylon sling 150 × 10,000
10
Wire sling
1 2 3 4 5 6 7 8
Sling name
1
See the figure below
1
See the figure below
2
Holding axle support and cylinder
1 1
See the figure below
2
See the figure below
2 1
1
Shackle
For 2 ton, 5 ton, 10 ton and 15 ton (Top) 2 and (bottom ) 1
13
Nylon sling
25 × 2,000 2. Rear frame sling
See the figure below
1
Withstand load 11 tons and L = 2,000
Eyebolt
Chain diameter
See the figure below
2
11
Remarks
1
Withstand load 15 tons and L = 2,500
12
1. Front frame sling
Q’ty
Tire lifting tool For removing crossties under machine body (Front lifting) Lift arm lifting tool
2 each Lift arm lifting tool
3. Rear axle sling
Chain diameter Chain diameter
Chain diameter
5. Front/Rear axle sling
7. Fuel tank sling 8. Floor and cab assembly sling
Chain diameter Chain diameter
Chain diameter
8
6
List of Oil, Grease and Paints
Oil, grease, paints and others No.
3
Oil, grease and paints Extreme-pressure added with molybdenum disulfide Extreme-pressure added with molybdenum disulfide Fuel
4
Paint for touchup
Black
5
Air conditioner gas
R134A gas can (400 g)
6
Window washer liquid
1 2
Specification
Quantity
(KES LM-P or equivalent)
500 ml
(KES LM-P or equivalent)
10l Appropriate amount (Full capacity is 1,200 l)
Diesel fuel
1 1l container × 2
When the front and rear frames were divided, following must be additionally used. No. 1
Oil, grease and paints Hydraulic oil
Specification (KES EO10-CD or equivalent)
Quantity 1,000l
Protective gear Work uniform, safety boots, helmet, cotton gloves, goggles and rain coat
9
Assembly procedure
No. 0010
Oil, grease and coolant
Selective use of fuel and lubricating oil depending on the given atmospheric temperature t Fuel and oil Use them selectively depending on the given atmospheric temperature. a The specified oil level denotes the total volume of oil used on the machine including that is contained in the pipes of respective equipment. And the amount of replacement oil refers to the amount of oil to be replaced in the inspection and maintenance. a Whenever starting the engine with atmospheric temperature at 0°C or below, EOS0W30 or EOS5W40 must be used for the engine oil pan although the temperature may usually rise up to 10°C or above. t Coolant Since the Komatsu genuine Super Coolant (AF-NAC) is added to the coolant, change of the coolant is unnecessary as long as atmospheric temperature remains at -10°C or above. If it went below -10°C, adjust the density referencing the section "Cleaning of inside of coolant system" in the Operation and Maintenance Manual.
a For details of the notes (e.g., Note. 1, Note. 2 ...) in the table, see the Operation and Maintenance Manual.
10
Assembly procedure
Oil, grease and coolant level
No. 0020
Lubricating points
Types of oil
Specified oil level (l)
Volume of replaced oil (l)
Engine oil pan
Engine oil
140
130
Transmission case
Power train oil
164
140
1,065
725
42
31
Hydraulic oil system Brake oil tank Front axle Rear axle
Hydraulic oil Engine oil Power train oil Axle oil
360 each
360 each
360 each
360 each
Fuel tank
Diesel fuel
1,555
—
Cooling system
Super coolant
337
—
Volume of refilled oil (l)
Caution: Whenever started or stopped the engine, be sure to check the level of oil, grease and coolant. Before the suspension adjustment is complete, don't try to turn the steering in a large angle. (Otherwise, the pipe can be damaged.)
Cautions
Special tool
Necessary Equipment Q’ty
Name
Q’ty
Others
Name
11
Assembly procedure
Setting rear frame in place
No. 0030
1. Hitch the lifting tool on the position indicated in the figure and lift rear frame (1). 2. Set rear frame assembly (1) in place using the steel plate and deck as shown in the figure. No. (1)
Part No. 427-46-2295A
Part name Q’ty State of part (Parts list No.) Rear frame assembly 1 Separately packed (No.W9E-030)
Cautions
Special tool
Others
Name
12
Necessary Equipment Q’ty
Name Q’ty Lifting tool: 2 point lift (L = 2,250, ø20) 1
Assembly procedure
Setting front frame in place
No. 0040
Wrap the pins with a piece of rag and then hitch the lifting tool on the front frame.
Lumber
1,000 mm
Deck
Steel plate
1. When lifting front frame assembly (1), protect the pins from damage by wrapping a piece of rag around them. 2. Lift front frame assembly (1). 3. Set front frame assembly (1) in place using the deck and lumber as shown in the figure. Part No. 427-N96-215A
Part name Front frame assembly
Q’ty State of part (Parts list No.) 1 Separately packed (No.W9E-040)
Cautions
Special tool Name
Necessary Equipment Q’ty
Name Q’ty Lifting tool: 2 point lift (L = 2,250, ø20) 1
Others
No. (1)
13
Assembly procedure
Joining front and rear frames
No. 0050 No. (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15) (16) (17) (18) (19) (20) (21) (22)
Part No. Part name 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 = 0.1 427-46-11421 Shim t = 0.5 427-46-11431 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
State of part (Parts list No.) Temporarily installed on the rear frame Temporarily installed on the rear frame Temporarily installed on the rear frame Temporarily installed on the rear frame Temporarily installed on the rear frame Temporarily installed on the rear frame Separately packed (No.W9E-050) Separately packed (No.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, see NO.0060.
Coating with LT-2 Tightening torque : 490 – 608 Nm {50 – 62 kgm}
Use care not to foul the internal tapered portion with lubricant agent such as grease. Coating with LM-P
Coating with LM-P
Coating with LT-2 Tightening torque : 824 – 1,030 Nm {84 – 105 kgm}
Cautions
Special tool
Coating with LT-2 Tightening torque : 1,520 – 1,910 Nm {155 – 195 kgm}
Necessary Equipment
Name Q’ty Name Q’ty w Be sure, in the assembly, to apply sufficient 50 ton crane 2 amount of grease to the inside of the bearing. Impact wrench (Socket #17, #30, #36, and #46) w Fill the upper hinge and lower hinge shafts Torque wrench (Set 549, 927, and 1,715 Nm) Lifting tool (For front frame and rear frame) 1 each with grease until it flows out the dust seal after Jack, thickness gauge and copper hammer Air compressor 1 assembly. w Touch up the black bolt and the machined sur- Others face.
14
Assembly procedure
No. 0060
Front and rear frames joining procedure
a Front frame and rear frame joining procedure 1. 2. 3. 4.
Make sure bushings ((9): 427-46-11480 and (10): 427-46-11490) are press fitted to the rear frame. Assemble bushing ((22): 427-46-11321) to the lower hinge of the front frame. Assemble bushing ((3): 427-46-11440) to the upper hinge of the rear frame. Assemble retainer ((2): 427-46-11190) to upper pin ((1): 427-46-11161). Tightening torque 490 – 608 Nm {50 – 62 kgm} 5. Place the front frame between the rear frame hinges and then insert the upper pin. Tightening torque 490 – 608 Nm {50 – 62 kgm} Initially, tighten the bolts diagonally in the order of 1 o 2 o 3 o 4 o 5 o 6. Then tighten them in the order on the circumference, namely 1 o 3 o 5 o 2 o 4 o 6 o 1 o . Be sure to tighten the bolts paying attention to their behavior. Tighten the bolts to the specified torque. Repeat tightening until they are firmly fixed and don't move. 6. Insert lower pin ((7): 427-46-11312) and bushing ((11): 427-46-11391) to the lower hinge and then install retainer ((14): 427-46-11431). 7. Set the jack under the lower hinge of the front frame to contact the rear frame and bushing closely to each other by removing the clearance between them. 8. Tighten retainer mounting bolts ((15): 01011-63065 and (17):01010-62495) of the lower hinge with M24: 824 – 1,030 Nm {84 – 105 kgm} and M30: 1,520 – 1,910Nm {155 – 195 kgm}, respectively, and then strike the lower pin head 3 – 5 times using the copper hammer. 9. Repeat Step 8 three times so that respective contact regions may fit well. Then retighten bolts ((15) and (17)) with M24: 824 – 1,030 Nm {84 – 105 kgm} and M30: 1,520 – 1,910 Nm {155 – 195 kgm}. 10. Remove all bolts ((17)) and then measure, using the thickness gauge, clearance between retainers ((2) and (14)) and frame at three points (in 120° intervals) to calculate the average clearance. Combine shims in such that the average clearance is adjusted to 0.08 – 0.18 mm. Note that thickness of the shims must not exceed the thickness of the individual clearances measured. 11. Remove bolts ((15) and (17)) from the front frame while holding it in place and then insert the shims being combined in Step 10 above. 12. Proceed to Step 8 and 9. 13. Pull out bolts ((15) and (17)) one by one, coat them with Locktite #262 and then tighten them with the specified torque. (Degrease the threaded and tapped portions completely.) 14. Conduct Steps 8 and 9 on the upper pin bolts ((4): 01010-62065 and (5): 01010-62070) (tightening torque used in this case should be that for M20 [490 – 608 Nm {50 – 62 kgm}]). And then conduct Step 13 on them. 15. Remove the jack from the lower hinge of the front frame. [Caution] a After the work, fix the machine in place with the safety lock bar to prevent articulation. a Be sure, in the assembly, to apply sufficient amount of grease to the inside of the bearing. a Fill the upper hinge and lower hinge shafts with grease until it flows out the dust seal after assembly.
Cautions
Special tool
Necessary Equipment
Others
Name Q’ty Name Q’ty w Be sure, in the assembly, to apply sufficient 50 ton crane 2 amount of grease to the inside of the bearing. Impact wrench (Socket #17, #30, #36, and #46) w Fill the upper hinge and lower hinge shafts Torque wrench (Set 549, 927, and 1,715 Nm) Lifting tool (For front frame and rear frame) 1 each with grease until it flows out the dust seal after Jack, thickness gauge and copper hammer Air compressor 1 assembly. w Touch up the black bolt and the machined surface.
15
Assembly procedure
Assembling the steering pin
No. 0070
The slit shall be set in the longitudinal direction of the machine body. Use care not to foul the internal tapered surface with lubricant agent such as grease.
The slit shall be set in the longitudinal direction of the machine body. Use care not to foul the internal tapered surface with lubricant agent such as grease.
Tightening torque : 343 – 427 Nm {35.0 – 43.5 kgm} Before assembling the pin, coat the bushing inner periphery and dust seal lip on the cylinder side with LM-P. Make sure the dust seal is assembled being faced outward.
For the grease fitting mounting direction, see the figure below. FITTING (07020-00900) DIRECTION TO BE SYMMETRICAL. Machine front side
Steering cylinder
No. (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13)
Part No. 427-46-12410 427-46-12420 427-46-12430 427-46-12440 427-46-12450 421-70-11331 01010-81475 01643-31445 01010-81635 01643-31645 421-70-11280 6141-55-5630 07020-00900
Part name Q’ty State of part (Parts list No.) Shaft 2 Temporarily installed on the rear frame Plate 2 Temporarily installed on the rear frame Plate 2 Temporarily installed on the rear frame Bushing 2 Temporarily installed on the rear frame Bushing 2 Temporarily installed on the rear frame Shim 16 Temporarily installed on the rear frame Bolt 12 Temporarily installed on the rear frame Washer 12 Temporarily installed on the rear frame Bolt 2 Temporarily installed on the rear frame Washer 4 Temporarily installed on the rear frame Washer 2 Temporarily installed on the rear frame Nipple 2 Temporarily installed on the rear frame Fitting 2 Temporarily installed on the rear frame
Cautions 1. Clean the mounting surface of the steering cylinder and pin. Make sure the surface is free from foreign substances.
Machine center Rear frame
Top view of the joint of the front frame and rear frame
Special tool Q’ty 1
Socket (22 mm, 24 mm)
1 each
Spanner (10 mm, 14 mm)
1 each
Others
Torque wrench (385 Nm {39.3 kgm} set)
16
Necessary Equipment
Name Impact wrench
1
Name Air compressor
Q’ty 1
Assembly procedure
Assembling the center drive shat (Center support – Transmission)
No. 0080
1. Remove (1) and (3) being temporarily installed on the rear frame. 2. Assemble drive shaft (4) as shown in the figure. (When assembling the drive shaft, pay attention to its direction.) 3. Assemble (1) – (3) to their original positions. No. (1) (2) (3) (4) (5) (6)
Part No. Part name Q’ty State of part (Parts list No.) 427-46-22531 Guard 1 Temporarily installed on the rear frame 01010-82045 Bolt 2 Temporarily installed on the rear frame 01643-32060 Washer 2 Temporarily installed on the rear frame 427-20-12211 Shaft 1 Separately packed (No.W9E-080) 01050-61895 Bolt 4 Separately packed (No.W9E-080) 01050-61895 Bolt 4 Separately packed (No.W9E-080)
Coating with LT-2. Tightening torque : 343 – 427 Nm {35.0 – 43.5 kgm}
Grease nipple position in the spider of 427-20-12211
Coating with LT-2. Tightening torque : 343 – 427 Nm {35.0 – 43.5 kgm}
Grease nipple position (Viewed from the machine rear side) Center support Grease nipple position Both the front and rear must be directed in the same direction. Assemble setting the longer side to the transmission Grease nipple position
Assemble setting the shorter side to the center support
Both the front and rear must be directed in the same direction.
Points to notice 1. Mounting surface shall be free from rusts, foreign substances and dents. 2. Insert 4 bolts temporarily and tighten them temporarily until the seating face is closely contacted. 3. The bolts must be basically tightened diagonally. Sequential tightening of the bolts must be repeated 2 rounds minimum. 4. Must be retightened to the specified torque. 5. Visually inspect the seating face and then apply a check mark using a white felt pen.
Cautions
Necessary Equipment
Name Impact wrench
Q’ty 1
Socket (27 mm, 30 mm)
1 each
Torque wrench (385 Nm {39.3 kgm} set)
Name Air compressor
Q’ty 1
1
Others
1. Clean the mounting surface of the drive shaft. Make sure the surface is free from foreign substances. 2. After the work, apply touchup coating on the black bolt to prevent its getting rusty.
Special tool
17
Assembly procedure
Connecting the pipes - Part 1
No. 0090
a A hose is connected (1) – (6) hoses. (Be sure to implement and complete the following 1 – 4 steps on a line basis. Don't try to start working on 6 lines at a time.) 1. Remove the blind parts on the pipe. 2. Make sure they are free from foreign substances. 3. Make sure the O-rings are not damaged. Note: A single green mark is applied to the O-ring in the connection of (4) alone. For other O-rings, 2 green marks are applied. 4. Connect the hose. (The bolt tightening torque must conform to KES 04.123.2 Impact wrench.)
Cautions
18
Necessary Equipment
Name Impact wrench
Q’ty 1
Socket (19 mm, 22 mm)
1 each
Others
1. After connecting the pipe, clean oil being deposited in the surroundings, if any.
Special tool
Name Air compressor
Q’ty 1
Assembly procedure
Connecting the pipe - Part 2
No. 0100
PPC control valve (P4) line Yellow band PPC control valve (P2) line Red band PPC control valve (P1) line Orange band PPC control valve (P3) line Blue band S/T (L) line S/T (R) line
(1) – (6) Tightening torque : 54 – 93 Nm {5.5 – 9.5 kgm} Viewed from the machine right side
Brake (Slack adjuster A) line Brake (Slack adjuster) line
Brake (Valve T) line Brake (Valve P) line
(7) – (10) Tightening torque : 84 – 132 Nm {8.5 – 13.5 kgm}
Viewed from the machine left side
Viewed from the machine right side
1. 2. 3. 4.
Remove the blind parts on the pipe. Make sure they are free from foreign substances. Connect the hose. When connecting the hose, don't try to start the work on (1) – (10) lines at a time. Be sure to implement Steps (1) – (3) on a line basis. Cautions
Name Torque wrench (49 Nm {5 kgm}, 78.5 Nm {8 kgm} set)
Necessary Equipment Q’ty
Name
Q’ty
1 each
Others
1. After connecting the pipe, clean oil being deposited in the surroundings, if any.
Special tool
19
Assembly procedure
Connection of piping (Part 2) (Riotinto specification: If equipped)
No. 0105
PPC control valve (P4) line Yellow band PPC control valve (P2) line Red band PPC control valve (P1) line Orange band PPC control valve (P3) line Blue band Steering (L) line Steering (R) line
–
Tightening torque 54 – 93 Nm {5.5 – 9.5 kgm}
Machine seen from right
Breather remote line Brake (Slack adjuster A) line Brake (Slack adjuster) line
Brake (Valve T) line Brake (Valve P) line
–
Tightening torque 84 – 132 Nm {8.5 – 13.5 kgm}
Tightening torque 54 – 93 Nm {5.5 – 9.5 kgm}
Machine seen from right 1. 2. 3. 4.
Remove the pipe blocking parts. Check that no foreign matter is sticking. Connect the hoses. Do not connect the hoses of all lines (1) – (11) at a time but perform work 1 – 3 securely for them one by one. Cautions
Name Torque wrench (49 Nm {5 kgm}, 78.5 Nm {8 kgm} set)
Others
1. After connecting the piping, wipe off oil sticking around it, if there is any.
Special tool
20
Necessary Equipment Q’ty 1 each
Name
Q’ty
Assembly procedure
No. 0110
Connecting the auto-greasing pipe
1. Connect the auto-greasing pipe from the front frame to the tube on the rear frame.
Connect
Frame connection viewed from the left side
Connect
View Z Cautions
Special tool
Necessary Equipment Name
Q’ty
Others
Name Q’ty Torque wrench (103 Nm {10.5 kgm} set) 1
21
Assembly procedure
Setting the axle in place and assembling the support
No. 0120
Setting dimension 5,450 mm Wheelbase
8,404 kg
Setting the front and rear axles in place
7,912 kg
Steel plate Ground level
Steel plate
Front axle
Rear axle
Setting dimension 5,450 mm
Support Lifting load: 300 kg,
50 × 2,000 2 nylon slings
1. Set the front axle assembly and rear axle assembly (with axle support) in the machine body assembling area in the 5,450 mm space between the wheelbases. See the figure. 2. Clean inside of the axle support and apply grease (G2-LI). (Clean inside of the axle support using a piece of rag and then coat the bushing inner surface with grease (G2-LI)). 3. Fit the rear axle support to the rear axle and then fix it with a wire to prevent its detachment.
Cautions
Special tool Name
Others
Q The support must be fixed with a wire and the like. (It is needed to prevent its detachment due to vibrations)
22
Necessary Equipment Q’ty
Name
Q’ty
Assembly procedure
Setting the bare machine in place
No. 0130 Crane: 50 ton
Crane: 50 ton
Ground level Front axle
Rear axle
1. Using the lifting eye on the frame, lift the bare machine with two 50 ton cranes. 2. Set it secure on the upside of the front and rear axle assembly. 3. Set the bare machine in place by use of the frame deck in such that assembling of the tire and wheel assembly is available. When setting it on the ground, spread steel plates under the crossties to prevent leaning of the machine due to depression of the ground surface. (Dimensions: 1,219 × 2,438 × 9 (t) = 2 plates) a Set the machine in a flat place in order to prevent leaning of the machine in the longitudinal direction as much as the situation allows. (Leaned machine makes the pinhole adjustment difficult when installing the lift arm.)
Details of lifting tool For front frame Lifting Load: 11.5 ton Crane: 50 ton
2,250
For rear frame Lifting Load: 20 ton Crane: 50 ton
Cautions
2,500
3,900
2,850
Special tool
Necessary Equipment Q’ty
Name
Q’ty
Others
Name
23
Assembly procedure
Assembling the rear axle
No. 0140
1. Remove the parts being temporarily installed on the machine and rear axle. 2. Hitch the lifting tool to rear axle assembly (1) and lift it as shown in the following figure. (Hitch the lifting tool in a squeezing manner to lift the axle support horizontally.) 3. Assemble rear axle assembly (1). Tightening torque : 3,170 – 3,870 Nm {323 – 395 kgm} 4. For assembling of cover (5), reference No.0150 Rear axle side rear cover assembling procedure. 5. After the assembly, touch up the lifting traces. Tightening torque : 824 – 1,030 Nm {84 – 105 kgm}
(See No.0150)
(See No.0150)
Tightening torque : 824 – 1,030 Nm {84 – 105 kgm} Coat the front and rear face of thrust washer (9) with grease (G2-LI). Weight = 7,914 kg When assembling, care must be exercised not to collapse the brake pipe on both side. (Space between the frame and rear axle is limited.)
Rear axle assembly
Axle support assembly
No. (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13)
Cautions
Part No. 427-23-20200 427-46-12130 01643-33990 01580-03931 427-46-12180 01011-82400 01643-32460 04530-11018 07029-00000 427-46-12161 427-46-12171 01011-82420 01643-32460
Q’ty 1 4 8 4 1 16 16 1 1 2 1 16 16
Special tool Name Power wrench
State of part (Parts list No.) Separately packed (No.W9E-140) Temporarily installed on the rear axle Temporarily installed on the rear axle Temporarily installed on the rear axle Separately packed (No.W9E-140) Temporarily installed on the machine Temporarily installed on the machine Separately packed (No.W9E-140) Separately packed (No.W9E-140) Temporarily installed on the rear axle Temporarily installed on the rear axle Temporarily installed on the rear axle Temporarily installed on the rear axle
Necessary Equipment Q’ty 1
Torque wrench
1
Socket 60 mm
1
Socket 36 mm
1
Others
24
Part name Rear axle assy Bolt Washer Nut Cover thrust Bolt Washer Bolt eye Valve Washer thrust Plate thrust Bolt Washer
Name
Q’ty
Assembly procedure
No. 0150
Rear axle rear side cover assembling procedure
Portion A
View Z a Place bolt (6) and washer (7) beforehand in the hole being drilled when assembling cover (5) (view Z). (Installation of the bolt in a later step is unavailable.)
View Y
Move the cover to the bottom of the installation position using the forklift and then install it aligning position of the hole. Aligning position of the hole requires about two workers. a Caution • This operation must be carried out carefully exchanging signals with the forklift operator. • Cover weight: 119 kg
Cautions
Special tool Name
Name
Q’ty
Others
a Reasonable care must be exercised in the assembling since the cover weighs 119 kg.
Necessary Equipment Q’ty
25
Assembly procedure
Connecting the rear axle pipe
No. 0160
Torque converter
Rear axle
Connect the brake line hose to the rear axle side tube. (2 on both sides)
Top view of rear axle
Connection tightening torque : 84 – 132 Nm {8.5 – 13.5 kgm}
Connect the breather hose to the rear axle side connector.
1. Connect the brake line hose to the rear axle side right and left tubes. 2. Connect the breather hose to the rear axle side connector.
Cautions
Special tool
Others
Name
26
Necessary Equipment Q’ty
Name
Q’ty
Assembly procedure
Fixing of rear axle piping (Brake cooling specification: If equipped)
No. 0165
Fixing: Fix together with axle bolt. Rear axle seen from rear
1. Fix plate (1) to the rear axle with the rear axle bolt. 2. Tighten parts (2) – (5) permanently. Part No. 427-S05-6250 07283-33450 07283-53444 01597-01009 01643-31032
Part name Plate Clip Seat Nut Washer
Q’ty 1 2 2 4 4
Cautions
State of part (Parts list No.) Temporarily installed on the machine Temporarily installed on the machine Temporarily installed on the machine Temporarily installed on the machine Temporarily installed on the machine
Special tool Name
Necessary Equipment Q’ty
Name
Q’ty
Others
No. (1) (2) (3) (4) (5)
27
Assembly procedure
Connection of rear axle piping (Riotinto specification: If equipped)
No. 0166
View Z: Rear frame seen from above
Rear frame seen from left
Rear frame seen from left rear. 1. Connect the piping to elbow (1) installed to the rear axle. No. (1)
Part No. 427-Z89-3880
Part name Elbow
Q’ty State of part (Parts list No.) 1 Installed to rear axle
Cautions
Special tool
Others
Name
28
Necessary Equipment Q’ty
Name
Q’ty
Assembly procedure
Fixing of rear axle piping (Brake cooling specification: If equipped)
No. 0167
Connection
To rear axle
Lower part of rear axle
1. Connect hose (1) installed to the rear axle. Part No. 07296-21213 07371-31255 07375-21035 07000-F3038
Part name Hose Flange Bolt, sems O-ring
Q’ty 1 2 4 1
Cautions
State of part (Parts list No.) Installed to rear axle Separately packed (No. W9E-167) Separately packed (No. W9E-167) Separately packed (No. W9E-167)
Special tool Name
Necessary Equipment Q’ty
Name
Q’ty
Others
No. (1) (2) (3) (4)
29
Assembly procedure
Connection of cooling line piping (Brake cooling specification: If equipped)
No. 0168
Connection: Check O-ring.
Fixing
Connection: Check O-ring.
Inside of rear frame seen from left
1. Remove temporarily installed parts (2), (3), (5), (6), (7), (8) and (9). 2. Connect and fix the cooling line with the parts removed in 1 above. No. (1) (2) (3) (4) (5) (6) (7) (8) (9)
Part No. 02896-21018 07371-31255 07375-21035 07000-F3038 01643-31032 01011-81020 07095-20627 04434-53412 01596-01009
Part name O-ring Flange Bolt, sems O-ring Washer Bolt Cushion Clip Nut
Q’ty 1 2 4 1 1 1 1 1 1
Cautions
State of part (Parts list No.) Installed to machine Temporarily installed on the machine Temporarily installed on the machine Installed to machine Temporarily installed on the machine Temporarily installed on the machine Temporarily installed on the machine Temporarily installed on the machine Temporarily installed on the machine
Special tool
Others
Name
30
Necessary Equipment Q’ty
Name
Q’ty
Assembly procedure
Assembling the rear drive shat (Transmission – Rear axle)
No. 0170
Grease nipple position in the spider of 427-20-12211
Rear axle
Tightening torque : 343 – 426 Nm {35 – 43.5 kgm}
Grease nipple position (Viewed from the machine rear side)
Lead the nylon sling (50 × 5,000) through the frame center and then lift the shaft from the right platform by use of the crane. Then adjust the position and assemble it. When assemble, set the male side in the front (transmission side).
Points to notice 1. Mounting surface shall be free from rusts, foreign substances and dents. 2. Insert 4 bolts temporarily and tighten them temporarily until the seating face is closely contacted. 3. The bolts must be basically tightened diagonally. Sequential tightening of the bolts must be repeated 2 rounds minimum. 4. Must be retightened to the specified torque. 5. Visually inspect the seating face and then apply a check mark using a white felt pen.
1. Prior to assembling, clean drive shaft (1) mounting surface. 2. Assemble drive shaft (1). (When assembling drive shaft (1), pay attention to its direction as well as that of the grease nipple situated in the spider of the front, center and rear drive shafts.) 3. Feed grease (molybdenum disulfide grease) to the grease fitting for the axle support and drive shaft. Part No. 427-20-12211 01050-61895
Part name Rear drive shaft Bolt
Q’ty State of part (Parts list No.) 1 Separately packed (No.W9E-170) 8 Separately packed (No.W9E-170)
Cautions
Special tool Name
Necessary Equipment Q’ty
Name
Q’ty
Others
No. (1) (2)
31
Assembly procedure
Assembling the front axle
No. 0180
Tightening torque : 3,170 – 3,870 Nm {323 – 395 kgm}
Weight = 8,404 kg a Clean the contact face of the mount before assembling the front axle.
Position of lifting tool Note: Hitch the lifting tool in the squeezing manner Lift the front axle in such that the axle pad is set horizontal. (Lifting load: 8,404 kg)
1. Remove (2) – (4) being temporarily installed on the axle skid. 2. Clean the contact face before assembling the front axle assembly (1). 3. When lifting front axle assembly (1), hitch the lifting tool to it as shown in the figure to the left. 4. Assemble front axle assembly (1). 5. After the assembly, touch up the lifting traces.
No. (1) (2) (3) (4)
Part No. 427-22-2020A 427-46-11452 01643-33990 01580-03931
Part name Front axle Bolt Washer Nut
Q’ty 1 16 32 16
Cautions
State of part (Parts list No.) Separately packed (No.W9E-180) Temporarily installed on the axle skid Temporarily installed on the axle skid Temporarily installed on the axle skid
Special tool
Others
Name
32
Necessary Equipment Q’ty
Name
Q’ty
Assembly procedure
Fixing of front axle piping (Brake cooling specification: If equipped)
No. 0182
Control valve
To mounting position on left inside of front frame
Mounting position Left side view of front frame 1. Fix the front axle piping. Part No. 427-S05-3661 01024-81230 07283-33450 07283-53444 01597-01009 01643-31032 01024-81225
Part name Bracket Bolt, sems Clip Seat Nut Washer Bolt, sems
Q’ty 1 2 1 1 2 2 2
Cautions
State of part (Parts list No.) Installed to machine Installed to machine Separately packed (No. W9E-182) Separately packed (No. W9E-182) Separately packed (No. W9E-182) Separately packed (No. W9E-182) Separately packed (No. W9E-182)
Special tool Name
Necessary Equipment Q’ty
Name
Q’ty
Others
No. (1) (2) (3) (4) (5) (6) (7)
33
Assembly procedure
No. 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. Connect front axle piping.
Connection: Check O-ring
To right front wheel brake To front axle
View Z Cautions
Special tool
Others
Name
34
To left front wheel brake Necessary Equipment Q’ty
Name
Q’ty
Assembly procedure
Connecting the front axle pipe
No. 0190
Connect the hose to the parking cylinder Tightening torque : 84 – 132 Nm {8.5 – 13.5 kgm}
Fix it to the clip.
Front view of front axle
Connect the hose to the front axle brake tube (1 each on both sides) Tightening torque : 84 – 132 Nm {8.5 – 13.5 kgm}
1. Connect the hose from the slack adjuster to the brake tube on the front axle. 2. Connect the hose from the brake valve to the parking brake cylinder. 3. Fix the hose from the parking brake cylinder with the clip.
Cautions
Special tool
Necessary Equipment Q’ty
Name
Q’ty
Others
Name
35
Assembly procedure
Connection of front axle piping (Riotinto specification: If equipped)
No. 0195
Front frame seen from right
1. Connect the piping to the front axle.
Front frame seen from above
No. (1)
Part No. 56B-61-13760
Part name Elbow
Q’ty State of part (Parts list No.) 1 Installed to hose
Cautions
Special tool
Others
Name
36
Necessary Equipment Q’ty
Name
Q’ty
Assembly procedure
Connecting the front drive shat (Front axle – Center support)
No. 0200
Center support
Tightening torque : 343 – 426 Nm {35 – 43.5 kgm}
Grease nipple position in the spider of 427-20-12211
Grease nipple position (Viewed from the machine rear side)
Front drive shaft Front Axle
Thicker one is set on the front axle side
Points to notice 1. Mounting surface shall be free from rusts, foreign substances and dents. 2. Insert 4 bolts temporarily and tighten them temporarily until the seating face is closely contacted. 3. The bolts must be basically tightened diagonally. Sequential tightening of the bolts must be repeated 2 rounds minimum. 4. Must be retightened to the specified torque. 5. Visually inspect the seating face and then apply a check mark using a white felt pen.
1. Prior to assembling the drive shaft, clean the mounting surface. 2. Assemble the drive shaft to the front axle. (When assembling drive shaft, pay attention to its direction as well as that of the grease nipple situated in the spider of the front, center and rear drive shafts.)) 3. Feed grease (molybdenum disulfide grease) to the grease fitting for the axle support and drive shaft. Part No. 01050-61895
Part name Bolt
Q’ty State of part (Parts list No.) 4 Separately packed (No.W9E-200)
Cautions
Special tool Name
Necessary Equipment Q’ty
Name
Q’ty
Others
No. (1)
37
Assembly procedure
No. 0210
Connecting the axle oil temperature sensor (For VHMS specification only)
a This process is required for the VHMS specification only. 1. Fix the wiring harness of the axle oil temperature sensor, (To be tightened along with the mud guard fixing bolt.) 2. Connect CN F25.
Top view of front frame
Connect
Front axle
Detail of backside of A section
View Z No. (1) (2)
Part No. 01024-81055 04434-51010
Part name Bolt Clip
Q’ty State of part (Parts list No.) 2 Temporarily installed on the front axle 2 Temporarily installed on the front axle
Cautions
Special tool Name Impact wrench
Others
Socket (17 mm)
38
Necessary Equipment Q’ty 1 1
Name
Q’ty
Assembly procedure
Assembling the tires
No. 0220
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.)
Assembling of wheel and tire assembly
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}
Lifting a tire Hitch the lifting tool on the tire and lift it in such that the tire is hung flat.
Hitch in the squeezing manner Nylon sling (150 × 10,000)
(Weight of tire and wheel assembly: 3,500 kg) No. (1) (2) (3)
Part No. 427-30-1240A 426-22-12930 01643-32460
Part name Wheel 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)
Cautions
Name 36 T socket
Necessary Equipment Q’ty 1
Torque wrench
1
Extension bar
1
Name
Q’ty
Others
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.
Special tool
39
Assembly procedure
Assembling the fuel tank
No. 0230 2) Loosen
1. Prior to assembling, remove the breather tube. (Be sure to return it to the original position before assembling the fuel tank.)
1) Remove
2. Prior to the assembling, clean the contact face of the mount. 3) Remove beforehand
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 tank
Fuel level sensor
Connect fuel tank level sensor connector (CN R08)
View Z No. (1) (2) (3)
Part No. 01011-63000 01643-33080 416-855-1190
Part name Bolt Washer 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)
Cautions
Special tool Name Impact wrench Power wrench (×4 wrench)
1
Torque wrench (44 Nm set)
1
Extension
1
Socket 46 mm
1
Others
40
Necessary Equipment Q’ty 1
Name
Q’ty
Assembly procedure
Installation of fuel tank (Riotinto specification: If equipped)
No. 0235 1) Remove.
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). Part No. 01011-63000 01643-33080 416-855-1190
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)
Cautions
Special tool Name Impact wrench
Necessary Equipment Q’ty 1
Power wrench (×4 wrench)
1
Torque wrench (44 Nm set)
1
Extension
1
Socket 46 mm
1
Name
Q’ty
Others
No. (1) (2) (3)
41
Assembly procedure
Fixing the drain pipe
No. 0240
Engine oil pan drain Fuel tank viewed from the left side
Torque converter oil cooler Radiator
Torque converter cooler drain
Radiator drain
Fuel tank viewed from the left side
1. 2. 3. 4.
Fix the engine oil pan drain. Fix the torque converter cooler drain. Fix the radiator drain. Fix the torque converter cooler drain pipe and radiator drain pipe.
Cautions
No. (1) (2) (3) (4)
Part No. 01024-81035 01435-01035 08036-20314 01024-81020
Special tool
Others
Name
42
Part name Bolt Bolt Clip Bolt
Q’ty 2 4 5 5
State of part (Parts list No.) Temporarily installed on the fuel tank Temporarily installed on the fuel tank Temporarily installed on the fuel tank Temporarily installed on the fuel tank
Necessary Equipment Q’ty
Name
Q’ty
Assembly procedure
Fixing of torque converter cooler drain piping (Riotinto specification: If equipped)
No. 0245
Torque converter oil cooler
Torque converter cooler drain
Fuel tank seen from left
1. Fix the torque converter cooler drain piping. No. (1) (2)
Part No. 424-06-12780 01024-81020
Part name Clip Bolt
Q’ty State of part (Parts list No.) 2 Temporarily installed on the fuel tank 2 Temporarily installed on the fuel tank
2. Open the drain valves. • Engine oil pan drain • Torque converter cooler drain • Radiator drain
Engine oil pan drain Radiator drain
Torque converter cooler drain
Detail of part P
Rear frame
Cautions
Special tool
Necessary Equipment Q’ty
Name
Q’ty
Others
Name
43
Assembly procedure
Connecting the fuel pipe
No. 0250 1. Connect and fix the suction hose. (2 on the machine right side) 2. Connect and fix the fuel spill hose. (1 each on the machine right and left sides)
Connection of the spill hose
Connection of the fuel return hose
3. Connect and fix the fuel return hose. (1 each on the machine right and left sides)
No. (1) (2) (3) (4) (5) (6) (7) (8) (9) (10)
Part No. 04434-52110 07095-20314 04434-51410 01024-81020 04434-53412 07095-20625 04434-52712 04434-52110 07095-20314 01024-81020
Part name Clip Cushion Clip Bolt Clip Cushion Clip Clip Cushion Bolt
Q’ty 2 2 2 3 2 2 3 2 2 4
State of part (Parts list No.) Temporarily installed on the frame Temporarily installed on the frame Temporarily installed on the frame Temporarily installed on the frame Temporarily installed on the frame Temporarily installed on the frame Temporarily installed on the frame Temporarily installed on the frame Temporarily installed on the frame Temporarily installed on the frame
Engine viewed from the left side
Connection of the suction hose
Connection of the suction hose
Connection of the spill hose
Connection of the fuel return hose
Engine viewed from the right side
Cautions
Special tool Name Impact wrench
Others
Socket (17 mm)
44
Necessary Equipment Q’ty 1 1
Name
Q’ty
Assembly procedure
Fixing the engine drain hoses
No. 0260
1. Fix the breather drain hose (on the machine left side) and the muffler drain hose. 2. Connect the respective drain hoses.
Connect
Connect
Machine left side Detail of connection Rear frame viewed from the left side Connect
Connect
630 (clamp position)
290 (clamp position)
Machine right side Detail of connection
Fuel tank Breather drain (Machine right side) Breather drain (Machine left side) Muffler drain (Machine left side)
Detail of rear side
No. (1) (2) (3) (4) (5)
Cautions
Part No. 04434-52512 04434-51510 01024-81016 07285-00220 07285-00130
Part name Clip Clip Bolt Clip Clip
Q’ty 1 1 2 2 1
Special tool Name Impact wrench
Necessary Equipment Q’ty 1
Name
Q’ty
1
Others
Socket (10 mm)
State of part (Parts list No.) Temporarily installed on the rear frame Temporarily installed on the rear frame Temporarily installed on the rear frame Temporarily installed on the drain hose Temporarily installed on the drain hose
45
Assembly procedure
Assembling the hydraulic tank ladder
No. 0270
Hydraulic tank
1. Remove (2) – (4) being temporarily installed on the hydraulic tank. 2. Assemble ladder (1). No. (1) (2) (3) (4)
Part No. 427-54-26950 01010-81635 01643-31645 01024-D1225
Part name Ladder (R.H.) Bolt Washer Bolt
Q’ty 1 2 2 2
Cautions
Special tool
Necessary Equipment
Name Impact wrench
Q’ty 1
Socket (19 mm, 24 mm)
1 each
Others
46
State of part (Parts list No.) Separately packed (No.W9E-270) Temporarily installed on the hydraulic tank Temporarily installed on the hydraulic tank Temporarily installed on the hydraulic tank
Name
Q’ty
Assembly procedure
Assembling the floor and cab assembly
No. 0280
Lifting load: 950 kg Lifting tool: 2 point lift × 2
Tightening torque : 245.0 – 308.7 Nm {25 – 31.5 kgm}
a Remove the undercover in the cab rear side beforehand. a Return it to the original position after the piping under the cab is finished.
In cab
1. Remove (2) – (4) being temporarily installed on the machine. 2. Assemble cab assembly (1). Part No. 427-56-2130A 421-54-23260 01596-01615 425-70-11290
Part name Cab assembly Plate Nut lock Washer
Q’ty 1 4 4 4
Cautions
State of part (Parts list No.) Separately packed (No.W9E-280) Temporarily installed on the machine Temporarily installed on the machine Temporarily installed on the machine
Special tool Name Q’ty Torque wrench (277 Nm {28.2 kgm} set) 1
Necessary Equipment Name
Q’ty
Others
No. (1) (2) (3) (4)
47
Assembly procedure
Connecting the air conditioner hose
No. 0290 1. Connect the hot water hose. 2. Connect the air conditioner hose. 3. Connect the drain hose.
Inside of the rear frame viewed from the side face
Air conditioner unit
Connect the heater hose IN and OUT (match the color) Remove the joint parts on which IN and OUT are bypassed as the shipping parts. (To be discarded)
Detail of A section
Drain hose
To be fixed with the welded clip in 3 places
Note: Confirm the hose size
Connect the air conditioner coupler
View Z Cautions
Special tool
Others
Name
48
Necessary Equipment Q’ty
Name
Q’ty
Assembly procedure
Connecting the brake line
No. 0300 1. Connect 3 hoses to the tube to be routed to the component box. 2. Connect 2 hoses to the joint hose to be routed to the front brake and rear brake. 3. Connect 1 hose to the tube to be routed to the PPC pump.
Connect Tightening torque : 177 – 245 Nm {18.0 – 25.0 kgm}
Cab viewed from the left side
Connect Tightening torque : 84 – 132 Nm {8.5 – 13.5 kgm}
Connect Tightening torque : 177 – 245 Nm {18.0 – 25.0 kgm}
Connect Routed to the rear brake Tightening torque : 84 – 132 Nm {8.5 – 13.5 kgm}
Connect Routed to the front brake Tightening torque : 84 – 132 Nm {8.5 – 13.5 kgm}
Cautions
Special tool
Necessary Equipment Q’ty 1
Name
Q’ty
Others
Name Torque wrench
49
Assembly procedure
No. 0310
Connecting the window washer hose
Cab viewed from the top
Front washer hose (Red taping)
Rear washer hose
Connect (Match the color)
View Z 1. Connect the washer hose (for the front and rear) being exit from the cab bottom to the frame side hose. (Confirm the red tape attached on the front washer hose.)
Cautions
Special tool
Others
Name
50
Necessary Equipment Q’ty
Name
Q’ty
Assembly procedure
Connecting the PPC line hose
No. 0320
PPC control valve f eo sid ine t n h Fro mac
Connect
Frame connection viewed from the top
Connect Connect
Connect 1. Connect 4 PPC line hoses. Make sure the Nos. (P1, P2, P3 and P4) are matching the band colors. 2. Connect a hose from the PPC relief valve. 3. Connect a hose from the hydraulic oil cooler.
View X
Connect From hydraulic oil cooler
Connect From PPC relief valve
View Z
Cautions
Special tool
Necessary Equipment Q’ty
Name
Q’ty
Others
Name
51
Assembly procedure
Connecting the floor wiring harness
No. 0330
1. Remove (1) – (5) being temporarily installed on the floor support. 2. Connect the ground cable. (Before connecting the cable, check the connection for paint and rusts. If present, remove it before connecting the cable.) 3. Fix the steering lock switch harness. 4. Connect the connectors. (CN L39, CN L27)
Ground cable Connect Top view of the floor frame
No.
Part No.
Part name Q’ty
(1) 01024-81016
Bolt
1
(2) 04434-51410
Clip
1
(3) 01024-81020
Bolt
1
(4) 04434-51010
Clip
2
(5) 01024-81020
Bolt
1
State of part (Parts list No.) Installed temporarily on the floor support Installed temporarily on the floor support Installed temporarily on the floor support Installed temporarily on the floor support Installed temporarily on the floor support
Connect
Connect
View X
Connect Connect
Connect Connect
Connect
View Z
Cautions
Special tool
Others
Name
52
Necessary Equipment Q’ty
Name
Q’ty
Assembly procedure
No. 0333
Connection of floor wiring harness -1 (Riotinto specification: If equipped)
Floor
Connection: CN CAB
Connection: CN CB1
Floor seen from rear
1. Connect the connectors. (CN CAB, CN CB1)
Cautions
Special tool
Necessary Equipment Q’ty
Name
Q’ty
Others
Name
53
Assembly procedure
Connection of floor wiring harness -2 (Riotinto specification: If equipped)
No. 0334
Marked
: 3 places
Connection: CN RF
Cab seen from rear
1. Remove parts (1) – (3) installed to the cab. 2. Fix the wiring harness with parts (1) – (3). 3. Connect the connector. (CN RF) No. (1) (2) (3)
Part No. 421-877-2250 04434-51010 01024-81060
Part name Spacer Clip Bolt, sems
Q’ty State of part (Parts list No.) 3 Temporarily installed on the machine 3 Temporarily installed on the machine 3 Temporarily installed on the machine
Cautions
Special tool
Others
Name
54
Necessary Equipment Q’ty
Name
Q’ty
Assembly procedure
Connecting the link for AJSS (For AJSS specification only)
No. 0340
a This process is required for the AJSS specification only. Tightening torque : 48 – 62 Nm {4.8 – 6.3 kgm}
Tightening torque : 156.9 – 196.1 Nm {16.0 – 20.0 kgm}
Front frame
For calibration procedure of the AJSS lever angle and frame offset angle, see No.0345. 1. Remove (1) and (2) being temporarily installed on the lever. 2. Connect the coupling rod connecting the front frame. 3. Connect the joint connecting the floor. Part No. 01643-31445 01595-01411
Part name Washer Nut
Q’ty State of part (Parts list No.) 1 Temporarily installed on the lever 1 Temporarily installed on the lever
Cautions
Special tool Name
Necessary Equipment Q’ty
Name
Q’ty
Others
No. (1) (2)
55
Assembly procedure
No. 0345
Calibration of the AJSS angle and frame offset angle
Adjusting connector Front side of machine
Front side of the right hand console
1. Set the machine and steering lever to the straight-travel state. 2. Stop the engine (set the starting switch to the OFF position) and set the steering lock lever to the lock position. 3. Pull out connector JL3 for neutral position adjustment situated in the right hand console. (See the figure above.) 4. Start the engine setting the starting switch to the 1st stage ON. 5. Connect the connector JL3 for the neutral position adjustment. 6. If beep of the buzzer is heard 1 second after, the adjustment is completed. a Don't try to operate the steering lever as long as the operations of Steps 4 – 6 are continued. (If the adjustment did not end normally, repeat from Step 1 again after making sure that the output voltage from both the steering lever angle sensor and the frame angle sensor is between 2.40 – 2.60 V.)
Cautions
Special tool
Others
Name
56
Necessary Equipment Q’ty
Name
Q’ty
Assembly procedure
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. 2. Assemble the grease pump. 3. Connect 4 pipes.
Grease pump
Top view of the left platform
Connect
Connect
Section A-A
Part No. 427-S95-A24A 01435-01045 415-64-13120 415-64-13130 421-62-18560 419-43-17930
Part name Q’ty State of part (Parts list No.) Hydraulic pump assembly 1 Separately packed (No.W9E-350) Bolt 4 Temporarily installed on the platform Washer 8 Temporarily installed on the platform Cushion 4 Temporarily installed on the platform Spacer 4 Temporarily installed on the platform Cushion 4 Temporarily installed on the platform
Cautions
Special tool Name
Necessary Equipment Q’ty
Name
Q’ty
Others
No. (1) (2) (3) (4) (5) (6)
57
Assembly procedure
Assembling the floor cover
No. 0360
Floor frame
1. Remove (2) and (5) – (8) being temporarily installed on the floor. 2. Assemble floor cover (1).
Floor support
3. Assemble floor covers (3) and (4).
No. (1) (2) (3) (4) (5) (6) (7) (8)
Part No. 427-54-24311 01024-81020 427-54-24321 427-54-24331 01024-81025 424-09-12650 427-S95-5250 01024-81020
Part name Cover Bolt Cover (L.H.) Cover (R.H.) Bolt Washer Cover Bolt
Q’ty 1 4 1 1 6 6 1 7
Cautions
State of part (Parts list No.) Separately packed (No.W9E-360) Temporarily installed on the floor Separately packed (No.W9E-360) Separately packed (No.W9E-360) Temporarily installed on the floor Temporarily installed on the floor Temporarily installed on the floor Temporarily installed on the floor Special tool
Name Impact wrench
Others
Socket (17 mm)
58
Necessary Equipment Q’ty 1 1
Name
Q’ty
Assembly procedure
Refilling the window washer
No. 0370
Washer tank position (In the bulkhead)
Water filler port
1. Open the cover in the front side of the bulkhead, and then pour 2l of washer liquid (KES product) and tap water (soft water) to the window washer tank.
Cautions
Special tool
Necessary Equipment Q’ty
Name
Q’ty
Others
Name
59
Assembly procedure
Assembling the battery box
No. 0380
1. Remove (3) – (5) being temporarily installed on the rear frame. 2. Assemble battery box assemblies (1) and (2) to the frame. 3. Assemble bolt (6) situated in the disaster prevention cover.
View X
Rear frame
View Z No. (1) (2) (3) (4) (5) (6)
Part No. 427-06-2463A 427-06-2464A 01011-62450 01011-62470 01643-32460 01024-D1225
Part name Battery box, L.H. battery box, R.H. Bolt Bolt Washer Bolt
Q’ty 1 1 4 4 8 4
Cautions
Special tool
Necessary Equipment
Name Impact wrench
Q’ty 1
Socket (19 mm, 36 mm)
1 each
Others
60
State of part (Parts list No.) Separately packed (No.W9E-380) Separately packed (No.W9E-380) Temporarily installed on the rear frame Temporarily installed on the rear frame Temporarily installed on the rear frame Separately packed (No.W9E-380)
Name
Q’ty
Assembly procedure
Connecting and fixing the battery wiring
No. 0390
1. Referencing the following figure, connect and fix the wiring in the battery box.
Left side of the battery box
Right side of the battery box
Connect Connect
View X
View Y
View A
Q After wiring the ground cable, connect it to the battery just before starting the engine.
No. (1) (2) (3) (4) (5) (6) (7)
Part No. 08038-00035 424-09-12530 04434-51410 04434-51710 04434-51910 04434-52310 01024-81020
Part name Cap Cap Clip Clip Clip Clip Bolt
Q’ty 2 2 3 1 3 1 6
State of part (Parts list No.) Separately packed (No.W9E-390) Temporarily installed on 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
Cautions
View B
61
Assembly procedure
Wiring on right side of battery (Riotinto specification: If equipped)
No. 0393
Connection: Check mark "4". Removal of boot and connection: Check mark "1".
Connection: Check mark "2". Wiring harness
Connection R.H. battery box
View X Detail of R.H. battery box
Connection: CN RA1
Connection: CN RA3
Connection: Check mark "6".
L.H. battery box
Fixing: Use bolts and clips installed temporarily.
Detail of part P
View Z
1. Connect the wiring on the right side of the battery. No. (1) (2) (3)
Part No. 08038-00035 04434-51710 01024-81020
Part name Cap Clip Bolt, sems
Q’ty State of part (Parts list No.) 1 Temporarily installed on the machine 1 Temporarily installed on the machine 1 Temporarily installed on the machine
Cautions
Special tool Name
Others
1. Install each wiring harnesses so that it will not cross other wiring harnesses, and then clamp and connect it to the correct position.
62
Necessary Equipment Q’ty
Name
Q’ty
Assembly procedure
Wiring on left side of battery -1 (Riotinto specification: If equipped)
No. 0394
Pull wiring harness into L.H. battery box
Shorter end
L.H. battery box Longer end
Pull cable into L.H. battery box
Marked : 4 places
Check mark "1". Check mark "2". Check mark "3".
Check mark "4". Check mark "5".
View Z: Machine seen from below
1. Pull the wiring into the battery on the left side. No. (1) (2)
Part No. 6151-53-8280 01024-81020
Part name Clip Bolt, sems
Q’ty State of part (Parts list No.) 4 Temporarily installed on the machine 4 Temporarily installed on the machine
Cautions
Special tool Name
Necessary Equipment Q’ty
Name
Q’ty
Others
1. Install each wiring harnesses so that it will not cross other wiring harnesses, and then clamp and connect it to the correct position.
63
Assembly procedure
Wiring on left side of battery -2 (Riotinto specification: If equipped)
No. 0395
L.H. battery box
Removal and connection of boot: Check mark "1". Removal and connection of boot: Check mark "2".
Fixing: Use bolt and clip installed temporarily.
Fixing: Use bolt and clip installed temporarily.
Connection: CN RA4 Connection: CN RA2
Connection: CN R09 Fixing: Use bolt and clip installed temporarily.
Detail
Section A-A Fixing: Use bolt and clip installed temporarily.
Fixing: Use bolt and clip installed temporarily. Removal and connection of boot: Check mark "4". Removal and connection of boot: Check mark "3".
1. Connect the wiring in the L.H. battery.
View Z
Removal and connection of boot: Check mark "5".
Cautions
Special tool Name
Others
1. Install each wiring harnesses so that it will not cross other wiring harnesses, and then clamp and connect it to the correct position.
64
Necessary Equipment Q’ty
Name
Q’ty
Assembly procedure
Wiring on left side of battery -3 (Riotinto specification: If equipped)
No. 0396
R.H. battery box
L.H. battery box
Connection: CN V101 Black (–)
Connection: CN V102 Red (+)
Connection: CN EM41 Connection: CN EM42
Section A-A 1. Connect the wiring on the left side of the battery No. (1) (2)
Part No. 6151-53-8280 01024-81020
Part name Clip Bolt, sems
Q’ty State of part (Parts list No.) 2 Temporarily installed on the machine 2 Temporarily installed on the machine
Cautions
Special tool Name
Necessary Equipment Q’ty
Name
Q’ty
Others
1. Install each wiring harnesses so that it will not cross other wiring harnesses, and then clamp and connect it to the correct position.
65
Assembly procedure
No. 0397
Connection of ground cable on left side of battery (Riotinto specification: If equipped)
View Z: Machine seen from below
L.H. battery box seen from rear
1. Connect the ground cable on the left side of the battery. No. (1)
Part No. 01024-81020
Part name Bolt, sems
Q’ty State of part (Parts list No.) 2 Temporarily installed on the machine
Cautions
Special tool Name
1. Install each wiring harnesses so that it will not cross other wiring harnesses, and clamp and connect it to the correct position.
Others
2. The ground cable connecting areas must be free from dirt and paint.
66
Necessary Equipment Q’ty
Name
Q’ty
Assembly procedure
Assembling the battery step
No. 0400
1. Remove (3), (4) and (6) being temporarily installed on the rear frame, fuel tank and battery box. 2. Assemble the step to the right side of the machine.
Battery box R.H. Fuel tank
3. Assemble the step to the left side of the machine.
Battery box L.H.
Fuel tank
Part No. 427-54-26770 427-54-26780 01024-D1235 01024-D1245 427-54-2933A 01024-81235
Part name Step (R.H.) Step (L.H.) Bolt Bolt Step assembly Bolt
Q’ty 1 1 6 2 2 8
Cautions
State of part (Parts list No.) Separately packed (No.W9E-400) Separately packed (No.W9E-400) Temporarily installed on the rear frame Temporarily installed on the fuel tank Separately packed (No.W9E-400) Temporarily installed on the battery box Special tool
Name Impact wrench Socket (19 mm)
Necessary Equipment Q’ty 1
Name
Q’ty
1
Others
No. (1) (2) (3) (4) (5) (6)
67
Assembly procedure
Installation of oil cooler assembly (Brake cooling specification: If equipped)
No. 0403
Tightening torque 54 – 123 Nm {5.5 – 12.5 kgm}
Oil cooler
Tightening torque 54 – 123 Nm {5.5 – 12.5 kgm} Tightening torque 54 – 123 Nm {5.5 – 12.5 kgm}
1. Install oil cooler assembly (1) to the right platform. No. (1) (2) (3)
Part No. 427-S05-489A 01024-81245 01024-81235
Part name Q’ty State of part (Parts list No.) Oil cooler assembly 1 Separately packed (No. W9E-403) Bolt, sems 4 Separately packed (No. W9E-403) Bolt, sems 2 Separately packed (No. W9E-403)
Cautions
Special tool
Others
Name
68
Necessary Equipment Q’ty
Name
Q’ty
Assembly procedure
No. 0404
Installation and connection of oil cooler assembly piping (Brake cooling specification: If equipped)
Connection: Check O-ring. Connection: Check O-ring.
View Z
1. Connect the oil cooler assembly piping. No. (1) (2)
Part No. 07000-F3035 01024-81035
Part name O-ring Bolt, sems
(3)
07371-31255
Flange
(4)
07375-21035
Bolt, sems
Q’ty State of part (Parts list No.) 2 Separately packed (No. W9E-404) 4 Separately packed (No. W9E-404) Temporarily installed on the 4 oil cooler assembly 8
Cautions
Temporarily installed on the oil cooler assembly
Special tool
Necessary Equipment Q’ty
Name
Q’ty
Others
Name
69
Assembly procedure
Installation of oil cooler assembly piping -1 (Brake cooling specification: If equipped)
No. 0406 Connection: O-ring
Connection: Check O-ring.
Connection: Check O-ring.
Bulkhead Right platform
Rear frame seen from right Oil cooler
Connection
Rear frame seen from front 1. Connect the oil cooler assembly piping. No. (1) (2) (3) (4) (9)
Part No. 427-S05-5630 427-S05-5590 427-S05-5650 427-S05-5580 02896-21018
Part name Tube Tube Tube Tube O-ring
Q’ty 1 1 1 1 3
Cautions
State of part (Parts list No.) Separately packed (No. W9E-406) Separately packed (No. W9E-406) Separately packed (No. W9E-406) Installed to machine Separately packed (No. W9E-406)
Special tool
Others
Name
70
Necessary Equipment Q’ty
Name
Q’ty
Assembly procedure
No. 0407
Installation of oil cooler assembly piping -2 (Brake cooling specification: If equipped)
a Connect each tube (8 places in total).
Connection (4 pieces): Check O-ring.
Check mark (white tape).
1. Connect the oil cooler assembly piping.
Cautions
Special tool
Necessary Equipment Q’ty
Name
Q’ty
Others
Name
71
Assembly procedure
No. 0410
Assembling the handrail (On the right hand platform)
Rear frame
1. Remove the parts being temporarily installed. 2. Assemble handrails (1) and (3) to the right side of the machine. 3. Hitch the cable on handrail (1). No. (1) (2) (3) (4) (5) (6) (7) (8)
Part No. 427-54-29270 01024-D1235 427-54-25861 01024-D1235 426-54-42310 426-54-35220 426-54-35320 23S-07-11160
Part name Handrail Bolt Handrail Bolt Hose Cable Joint Catcher
Q’ty 1 11 1 11 1 1 1 1
Cautions
State of part (Parts list No.) Separately packed (No.W9E-410) Temporarily installed on the right platform Separately packed (No.W9E-410) Temporarily installed on the right platform Temporarily installed on the handrail (3) Temporarily installed on the handrail (3) Temporarily installed on the handrail (3) Temporarily installed on the handrail (3) Special tool
Name Impact wrench
Others
Socket (19 mm)
72
Necessary Equipment Q’ty 1 1
Name
Q’ty
Assembly procedure
Installation of handrail (Right platform area) (Brake cooling specification: If equipped)
No. 0411
1. Remove the parts installed temporarily. 2. Install handrails (1) and (3) to the right side of the machine. 3. Hook the cable to handrail (1). Part No. 427-54-2952A 01024-D1235 427-S05-5790 01024-D1235 01024-D1235 426-54-42310 426-54-35220 426-54-35320 23S-07-11160
Part name Handrail Bolt, sems Handrail Bolt, sems Bolt, sems Hose Cable Joint Catcher
Q’ty 1 11 1 2 2 1 1 1 1
Cautions
State of part (Parts list No.) Separately packed (No. W9E-411) Temporarily installed on the right platform Separately packed (No. W9E-411) Temporarily installed on the right platform Separately packed (No. W9E-411) Temporarily installed on the handrail (3) Temporarily installed on the handrail (3) Temporarily installed on the handrail (3) Temporarily installed on the handrail (3) Special tool Name
Necessary Equipment Q’ty
Name
Q’ty
Others
No. (1) (2) (3) (4) (5) (6) (7) (8) (9)
73
Assembly procedure
No. 0420
Assembling the handrail (On the hood top face) Insert handrail (7) to handrail (9).
Rear frame
1. Remove the parts being temporarily installed. 2. Insert handrail (7) to handrail (9) as shown in the figure above and then assemble them. 3. Assemble handrail (1). 4. Using (3) – (6), fix handrail (1) and handrail (7) as shown in the figure above. No. (1) (2) (3) (4) (5) (6) (7) (8) (9) (10)
Part No. 427-54-25870 01024-D1235 207-62-54770 01024-D1030 01643-31032 01580-11008 427-54-29370 01024-D1235 427-54-25880 01024-D1235
Part name Handrail Bolt Clamp Bolt Washer Nut Handrail Bolt Handrail Bolt
Q’ty 1 6 2 1 1 1 2 16 1 12
Cautions
Special tool
Necessary Equipment
Name Impact wrench
Q’ty 1
Socket (17 mm, 19 mm)
1 each
Others
74
State of part (Parts list No.) Separately packed (No.W9E-420) Temporarily installed on the machine Temporarily installed on the handrail Temporarily installed on the handrail Temporarily installed on the handrail Temporarily installed on the handrail Separately packed (No.W9E-420) Temporarily installed on the machine Separately packed (No.W9E-420) Temporarily installed on the machine
Name
Q’ty
Assembly procedure
Assembling the handrail (On the right hand battery box)
No. 0430
Rear frame
1. Remove the parts being temporarily installed. 2. Assemble handrails (1) and (4) as shown in the figure above. Part No. 427-54-25821 01024-D1230 01024-D1235 427-54-25180 01024-D1235
Part name Handrail R.H. Bolt Bolt Handrail R.H. Bolt
Q’ty 1 4 4 1 4
Cautions
State of part (Parts list No.) Separately packed (No.W9E-430) Temporarily installed on the right battery box Temporarily installed on the right battery step and rear frame Separately packed (No.W9E-430) Temporarily installed on the right battery box
Special tool Name Impact wrench Socket (19 mm)
Necessary Equipment Q’ty 1
Name
Q’ty
1
Others
No. (1) (2) (3) (4) (5)
75
Assembly procedure
Assembling the rear access step
No. 0440
Detail of the bolts assembling in the floor and step connections
(They are tightened together with bracket (5).)
8 places
Fix the covers to each other Detail of the bolts assembling in the step and battery box connections View from the bottom
1. Remove (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).
No. (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11)
Part No. 427-54-2592A 01010-81435 01643-31445 427-54-2475A 427-54-25340 01010-81435 01010-81445 01643-31445 01010-81635 01643-31645 427-54-24191
(12)
01024-81225
(13)
124-54-26540
Washer
6
(14)
01024-81220
Bolt
6
Temporarily installed on the machine and floor assembly (1) Temporarily installed on the step assembly (4)
Cautions
Special tool Q’ty 1
Socket (19 mm, 22 mm)
1 each
Others
76
Necessary Equipment
Name Impact wrench
Name
Q’ty
Assembly procedure
Assembling the left handrail (Part 1)
No. 0450
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).
Part No. 427-54-25170 01024-D1235 427-54-21560 427-54-21571 01024-D1025 427-54-29280 01024-D1230 01024-D1235 07283-33450 07283-53444 01597-01009 01643-31032
Part name Handrail Bolt Plate Rubber Bolt Handrail Bolt Bolt Clip Seat Nut Washer
Q’ty 1 4 1 1 3 1 2 6 1 1 2 2
Cautions
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
Name Impact wrench
Q’ty 1
Socket (17 mm, 19 mm)
1 each
Name
Q’ty
Others
No. (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12)
77
Assembly procedure
Assembling the left handrail (Part 2)
No. 0460
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
Part name Handrail Bolt Handrail Bolt Handrail Bolt
Q’ty 1 10 1 22 1 14
Cautions
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
Others
Socket (19 mm)
78
Necessary Equipment Q’ty 1 1
Name
Q’ty
Assembly procedure
Installation of left handrail (Part 2) (Brake cooling specification: If equipped)
No. 0461
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). Part No. 427-54-2951A 01024-D1235 427-54-25851 01024-D1235 427-54-25811 01024-D1230
Part name Handrail Bolt Handrail Bolt Handrail Bolt
Q’ty 1 10 1 22 1 14
Cautions
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)
Necessary Equipment Q’ty 1
Name
Q’ty
1
Others
No. (1) (2) (3) (4) (5) (6)
79
Assembly procedure
Assembling the rearview mirror
No. 0470
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
Cautions
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)
Special tool
Others
Name Spanner (17 mm)
80
Necessary Equipment Q’ty
Name
Q’ty
Assembly procedure
Installation of rearview mirrors (Brake cooling specification: If equipped)
No. 0471
a Work on right and left sides similarly.
1. Remove parts (2) and (3) installed to rearview mirror (1). 2. Install rearview mirror (1) to the handrail and fix it with parts (2) and (3). (Work on the right and left sides similarly.) 3. Adjust the mirror angle. Part No. 56B-54-17311 (56B-54-17311) (56B-54-17311)
Part name Mirror Nut Washer
Q’ty State of part (Parts list No.) 2 Separately packed (No. W9E-471) 4 Accessory to part (1) 4 Accessory to part (1)
Cautions
Special tool Name Spanner (24 mm)
Necessary Equipment Q’ty 1
Name
Q’ty
Others
No. (1) (2) (3)
81
Assembly procedure
Assembling the exhaust pipe
No. 0480
1. Remove (2) being temporarily installed on the hood. 2. Assemble exhaust pipe (1) using (2). No. (1) (2)
Part No. 427-02-21140 01024-81240
Part name Exhaust pipe Bolt
Q’ty State of part (Parts list No.) 2 Separately packed (No.W9E-480) 12 Temporarily installed on the front hood
Cautions
Special tool Name Impact wrench
Others
Socket (19 mm)
82
Necessary Equipment Q’ty 1 1
Name
Q’ty
Assembly procedure
Installation of oil cooler guard assembly (Brake cooling specification: If equipped)
No. 0485
Tightening torque: 54 – 122.5 Nm {5.5 – 12.5 kgm}
1. Remove the front cover of the oil cooler guard assembly. 2. Install the oil cooler guard assembly with bolts (2). 3. Install the cover removed in 1 again. Part No. 41F-S05-173A 01024-81225
Part name Guard assembly Bolt, sems
Q’ty State of part (Parts list No.) 1 Separately packed (No. W9E-485) 6 Separately packed (No. W9E-485)
Cautions
Special tool Name
Necessary Equipment Q’ty
Name
Q’ty
Others
No. (1) (2)
83
Assembly procedure
Installation of fan motor piping cover -1 (Brake cooling specification: If equipped)
No. 0486
1. Install the oil cooler piping cover. No. (1) (2) (3) (4) (5)
Part No. 427-S05-3410 427-S05-3391 427-S05-3441 01024-81225 01024-81230
Part name Cover Cover Cover Bolt, sems Bolt, sems
Q’ty 1 1 1 12 4
Cautions
State of part (Parts list No.) Separately packed (No. W9E-486) Separately packed (No. W9E-486) Separately packed (No. W9E-486) Separately packed (No. W9E-486) Separately packed (No. W9E-486)
Special tool
Others
Name
84
Necessary Equipment Q’ty
Name
Q’ty
Assembly procedure
Installation of fan motor piping cover -2 (Brake cooling specification: If equipped)
No. 0487
Tightening torque: 34 – 74 Nm {3.5 – 7.5 kgm} Tightening torque: 34 – 74 Nm {3.5 – 7.5 kgm}
1. Install the cover to the right platform bottom. Part No. 427-S05-5190 01024-D1025 41F-S05-1491 01024-D1225
Part name Cover Bolt, sems Cover Bolt, sems
Q’ty 1 8 1 4
Cautions
State of part (Parts list No.) Separately packed (No. W9E-487) Separately packed (No. W9E-487) Separately packed (No. W9E-487) Separately packed (No. W9E-487)
Special tool Name
Necessary Equipment Q’ty
Name
Q’ty
Others
No. (1) (2) (3) (4)
85
Assembly procedure
Applying the counterweight anti-slip
No. 0490
1. Sufficiently clean the application surface and dry it. If the surface if fouled with oil, clean it off using detergent, too. 2. It is advisable to give a mark, using a felt pen, on the application position. 3. Remove the protective cover on the backside. 4. Apply the anti-slip decal. Use care when applying it so that fingers may not touch the adhesive. 5. In order to paste it up securely, press the anti-slip plate using a roller from the center of the plate toward the brim. 6. Apply adhesive "LT-1A" in the perimeter of the anti-slip plate. No. (1)
Part No. 417-06-11321
Part name Plate
Q’ty State of part (Parts list No.) 4 Separately packed (No.W9E-490)
Cautions
Special tool
Others
Name
86
Necessary Equipment Q’ty
Name
Q’ty
Assembly procedure
Assembling the counterweight (WA900-3E0 standard specification)
No. 0500
Tightening torque: 1,520 – 1,910 Nm {155 – 195 kgm}
2,890 kg
Rear frame
2,890 kg 1. Remove (2), (3), (5), (6) and (8) being temporarily installed in the rear part of the rear frame. 2. Assemble counterweight (1) using (2) and (3). 3. Assemble counterweight (4) using (5) and (6). 4. Assemble cover (7) using (8). 5. Insert pin (9). Part No. 427-46-25311 427-46-25150 01643-33080 427-46-25321 198-30-37320 01643-33080 427-54-25332 01024-D1230 427-46-13120
Part name Counterweight Bolt Washer Counterweight Bolt Washer Cover Bolt Pin
Q’ty 1 4 4 1 6 6 1 4 1
State of part (Parts list No.) Separately packed (No.W9E-500) Temporarily installed on the rear part of the rear frame Temporarily installed on the rear part of the rear frame Separately packed (No.W9E-500) Temporarily installed on the rear part of the rear frame Temporarily installed on the rear part of the rear frame Separately packed (No.W9E-500) Temporarily installed on the rear part of the rear frame Separately packed (No.W9E-500)
Cautions
Special tool Name Torque wrench
Necessary Equipment Q’ty 1
Socket 46 mm
1
Extension
1
Impact wrench (for M30)
1
Name
Q’ty
Others
No. (1) (2) (3) (4) (5) (6) (7) (8) (9)
87
Assembly procedure
Assembling the counterweight (WA900-3E0 High-lift arm specification)
No. 0505
1,600 kg
2,890 kg
1,298 kg Rear frame
1. Remove (2), (3), (5), (6), (8), (9), (10) and (13) being temporarily installed in the rear part of the rear frame. 2. Assemble counterweight (1) using (2) and (3). 3. Assemble counterweight (4) using (5) and (6). 4. Assemble spacer (8). 4. Assemble counterweight (7) using (9) and (10). 5. Insert pin (11). 6. Assemble cover (12) using (13).
No. (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13)
Part No. 427-46-25370 425-974-1171 01643-33080 427-46-25321 427-T88-1131 01643-33080 427-975-2110 427-97-51120 419-09-11180 426-09-11510 427-46-13120 427-46-25350 01024-D1225
Part name Counterweight Bolt Washer Counterweight Bolt Washer Counterweight Spacer Bolt Washer Pin Cover Bolt
Cautions
Q’ty 1 4 4 1 6 6 1 4 4 4 1 1 2
State of part (Parts list No.) Separately packed (No.W9E-505) Temporarily installed on the rear part of the rear frame Temporarily installed on the rear part of the rear frame Separately packed (No.W9E-505) Temporarily installed on the rear part of the rear frame Temporarily installed on the rear part of the rear frame Separately packed (No.W9E-505) Temporarily installed on the rear part of the rear frame Temporarily installed on the rear part of the rear frame Temporarily installed on the rear part of the rear frame Separately packed (No.W9E-505) Temporarily installed on the rear part of the rear frame Temporarily installed on the rear part of the rear frame
Special tool
Others
Name
88
Necessary Equipment Q’ty
Name
Q’ty
Assembly procedure
No. 0510
Assembling the counterweight (WA800-3E0 Overseas general, optional specification and North American specification)
Tightening torque: 1,520 – 1,910 Nm {155 – 195 kgm}
1,600 kg
Tightening torque: 823 – 1,030 Nm {84 – 94.5 kgm}
Rear frame
2,890 kg 1. Remove (2), (3), (5), (6) and (7) being temporarily installed in the rear part of the rear frame. 2. Assemble counterweight (1) using (2) and (3). 3. Assemble spacer (5). 4. Assemble counterweight (4) using (6) and (7). 5. Insert pin (8). Part No. 427-46-25321 198-30-37320 01643-33080 427-975-2110 427-975-1120 419-09-11180 426-09-11510 427-46-13120
Part name Counterweight Bolt Washer Counterweight Spacer Bolt Washer Pin
Q’ty 1 6 6 1 4 4 4 1
State of part (Parts list No.) Separately packed (No.W9E-510) Temporarily installed on the rear part of the rear frame Temporarily installed on the rear part of the rear frame Separately packed (No.W9E-510) Temporarily installed on the rear part of the rear frame Temporarily installed on the rear part of the rear frame Temporarily installed on the rear part of the rear frame Separately packed (No.W9E-510)
Cautions
Special tool Name Torque wrench
Necessary Equipment Q’ty 1
Socket 46 mm
1
Extension
1
Impact wrench (for M30)
1
Name
Q’ty
Others
No. (1) (2) (3) (4) (5) (6) (7) (8)
89
Assembly procedure
Assembling the counterweight (WA800-3E0 Overseas general standard specification)
No. 0520
Tightening torque: 1,520 – 1,910 Nm {155 – 195 kgm}
Rear frame
2,890 kg
1. Remove (2) and (3) being temporarily installed in the rear part of the rear frame. 2. Assemble counterweight (1) using (2) and (3). 3. Insert pin (4). No. (1) (2) (3) (4)
Part No. 427-46-25321 198-30-37320 01643-33080 427-46-13120
Part name Counterweight Bolt Washer Pin
Q’ty 1 6 6 1
State of part (Parts list No.) Separately packed (No.W9E-520) Temporarily installed on the rear frame Temporarily installed on the rear frame Separately packed (No.W9E-520)
Cautions
Special tool Name Torque wrench Socket 46 mm
1
Extension
1
Impact wrench (for M30)
1
Others
90
Necessary Equipment Q’ty 1
Name
Q’ty
Assembly procedure
Assembling the front axle lamp and connecting the harness
No. 0530
Front frame
Connect CN FAR
Connect CN FAL
View Z
1. Remove (2) being temporarily installed on the front frame. 2. Assemble front axle lamp assembly (1) using (2). 3. Referencing view Z, connect the harness. Part No. 427-06-2525A 01024-81225
Part name Work lamp Bolt
Q’ty State of part (Parts list No.) 1 Separately packed (No.W9E-530) 4 Temporarily installed on the front frame
Cautions
Special tool Name
Necessary Equipment Q’ty
Name
Q’ty
Others
No. (1) (2)
91
Assembly procedure
Assembling the front lamp assembly
No. 0540
1. Remove (3) being temporarily installed on the front frame. 2. Assemble right and left front lamp assemblies (1) and (2) using (3). 3. Fix the harness of the front lamp and then connect the connector referencing the figure below.
Connect CN F01, CN HF1 Connect CN F04, CN HF1
Fix here Fix here Connect CN F03, CN HF2
Connect CN F02, CN HF2 Front frame viewed from the inner right side
Front frame viewed from the inner left side No. (1) (2) (3)
Part No. 427-06-2311A 427-06-2312A 01024-81245
Part name Left front lamp Right front lamp Bolt
Q’ty State of part (Parts list No.) 1 Separately packed (No.W9E-540) 1 Separately packed (No.W9E-540) 8 Temporarily installed on the right and left of front frame
Cautions
Special tool Name Impact wrench
Others
Socket (19 mm)
92
Necessary Equipment Q’ty 1 1
Name
Q’ty
Assembly procedure
Assembling the ROPS canopy assembly
No. 0550
2 different colors are used for the ROPS canopy WA800-3E0 - Natural yellow WA900-3E0 - Black gray Lifting tool: 2 point lift (Lifting load: 1.42 t) (The lifting tool used for the tool and cab assembly is also used here)
Tightening torque : 2,450 – 3,040 Nm {250 – 310 kgm}
1. Remove cover (1) being temporarily installed on the machine using (2). 2. Remove (4) and (5) being temporarily installed on the machine. 3. Clean the contact face of ROPS canopy assembly (3) mount. 4. Assemble ROPS canopy (3) using (4) and (5). 5. Using (2), assemble cover (1) currently being removed to the original position.
a Clean the contact face of the mount before assembling. Part No. 427-54-25951 01024-D1230 427-921-229A 01011-63650 01643-33690
Part name Cover Bolt ROPS canopy Bolt Washer
Q’ty 2 8 1 20 20
State of part (Parts list No.) Temporarily installed on the machine Temporarily installed on the machine Separately packed (No.W9E-550) Temporarily installed on the machine Temporarily installed on the machine
Cautions
Special tool Name Power wrench (×16 wrench) Socket (55 mm)
Necessary Equipment Q’ty 1
Name
Q’ty
1
Extension
1
Torque wrench
1
Others
No. (1) (2) (3) (4) (5)
93
Assembly procedure
Assembling the antenna and work lamp
No. 0560
Remove the antenna being temporarily installed on the cab and assemble it to the canopy.
Extend the antenna line from the cab
Step lamp (Backside of upper left side of ROPS)
Install it setting the slit at the bottom and then coat the entire perimeter with Cemedine 366E or equivalent.
Lamp assembly Tightening torque : 17.6 – 19.6 Nm {1.8 – 2.0 kgm} Assembled to the bracket being already assembled to the cab assembly
Side lamp (On both side of ROPS) Assembled to the bracket being already assembled to the cab assembly
Connect CN SL5
Lead the harness on the cab ceiling to connect it to the lamp.
Connect CN C17
1. Assemble lamp (1) and tighten it to the specified torque. 2. Lead the harness on the cab ceiling to connect it to the lamp. 3. Remove the antenna being temporarily installed on the cab and assemble it to the ROPS. No. (1)
Part No. 22B-06-11690
Part name Lamp assembly
Cautions
Q’ty State of part (Parts list No.) 3 Separately packed (No.W9E-560) Special tool
Others
Name
94
Necessary Equipment Q’ty
Name
Q’ty
Assembly procedure
Assembling the VHMS antenna (For VHMS specification only)
No. 0570
Connect
7 places with mark
View Z
Cab viewed from the left side 1. Remove (1) and (2) being temporarily installed on the ROPS canopy assembly. 2. Fix the VHMS antenna harness as shown in the figure above. 3. Assemble bracket (4) using (5) as shown in the view Z. 4. Fix antenna (3) to the bucket. 5. Connecting the VHMS harness to the antenna. Part No. 04434-50810 01024-81020 8A13-10-2100 7826-21-1210 01024-81020
Part name Clip Bolt Antenna sat Bracket Bolt
Q’ty 7 7 1 1 2
Cautions
State of part (Parts list No.) Temporarily installed on the ROPS canopy assembly Temporarily installed on the ROPS canopy assembly Separately packed (No.W9E-570) Separately packed (No.W9E-570) Temporarily installed on the ROPS canopy assembly
Special tool Name Impact wrench Socket (17 mm)
Necessary Equipment Q’ty 1
Name
Q’ty
1
Others
No. (1) (2) (3) (4) (5)
95
Assembly procedure
Assembling the floor mat
No. 0580
1. Fit in sheet (1) to the floor frame as shown in the above figure. 2. Spread floor mat (2) as shown in the above figure. No. (1) (2)
Part No. 427-54-26480 427-54-26460
Part name Sheet Mat
Q’ty State of part (Parts list No.) 1 Separately packed (No.W9E-580) 1 Separately packed (No.W9E-580)
Cautions
Special tool
Others
Name
96
Necessary Equipment Q’ty
Name
Q’ty
Assembly procedure
Assembling the front fender
No. 0590
1. Remove (3) – (9) being temporarily installed on the front frame. 2. Remove (10) – (12) being temporarily installed on right and left front fenders (1) and (2). 3. Assemble right and left front fenders (1) and (2) to the front frame using (3) and (4). 4. Assemble right and left brackets (5) and (6) to the front fender using (7) – (11). 5. Assemble (12) to the original position.
81.6 kg
81.6 kg Part No. 427-54-26810 427-54-26820 01010-81635 01643-31645 427-54-13380 427-54-13410 01010-81245 01010-81230 01643-31232 01010-81230 124-54-26540 09415-05016
Part name Fender (L.H.) Fender (R.H.) Bolt Washer Bracket (L.H.) Bracket (R.H.) Bolt Bolt Washer Bolt Washer Cap
Q’ty 1 1 6 6 1 1 4 4 8 16 16 6
State of part (Parts list No.) Separately packed (No.W9E-590) Separately packed (No.W9E-590) Temporarily installed on the front frame Temporarily installed on the front frame 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)
Cautions
Special tool
View Z (Detail of bolts assembling position) Necessary Equipment
Name Impact wrench
Q’ty 1
Socket (19 mm, 24 mm)
1 each
Name
Q’ty
Others
No. (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12)
97
Assembly procedure
Engine starting procedure
No. 0600
1. Check the current oil and coolant level and supply them to respective components • Amount of coolant 1. Supply coolant until the radiator is filled up. 2. Make sure that 40l of coolant is contained in the sub-tank after the radiator has been filled up. • Amount of oil in the engine oil pan and brake oil tank Reference: Total amount of lubricating oil: When engine is stopped Low level: 118l High level: 138l Lubricating oil refill capacity: When engine is stopped Low level: 110l High level: 130l • Amount of oil in the brake tank 1. Fill oil up to the center of the upper sight gauge. 2. Bleed air. (See No.0610) 3. Fully charge the accumulator. 4. Make sure oil is filled up to the center of the sight gauge in the state of “3” above. • Amount of fuel Supply fuel. Reference (Tank capacity: 1,604l) • Amount of hydraulic oil Supply oil up to the top of the sight gauge. Reference (Tank capacity: 1,065l) • Amount of oil in transmission (Specified oil level 164l) Refill capacity 140l Atmospheric temperature 0°C or above: TO30 Atmospheric temperature 10°C or below: TO10 a For the gauge position and the standard oil and coolant level, see the Operation and Maintenance Manual. a The axle and cab are shipped after being disassembled, thus supply of hydraulic oil is necessary. Confirm the oil level constantly while starting the engine. 2. For the starting procedure, reference the Operation and Maintenance Manual. a And also confirm the engine stop procedure in the Operation and Maintenance Manual. a Run the engine at low idle for 10 minutes a Don't try to operate the control lever as long as the engine is run. a Stop the engine immediately if a trouble such as oil leakage and abnormal noise is detected. 3. Check the engine after it has been stopped. a Check the engine for oil leakage a Check and supply oil and coolant to respective components
Cautions
Special tool
Others
Name
98
Necessary Equipment Q’ty
Name
Q’ty
Assembly procedure
Bleeding the brake air
No. 0610
(1) Start the engine and fill up the accumulator chamber with oil. (2) Loosen the air bleeding plug (in the axle brake chamber). (3) Feed brake oil by stepping down the brake pedal and then drain air from the bleeding plug. (Keep the brake pedal being stepped down.) (4) Tighten the bleeding plug and release the brake pedal. Then loosen the bleeding plug and then step down the brake pedal again to repeat step (3) above. (5) Repeat (2) - (4) until the air is completely bled through the bleeding plug and the flowing out oil is free from bubbles. (Feed the brake oil constantly to maintain the chamber being filled up.)
Bleeding plug
Axle (2 places in the front and rear)
Slack adjuster (2 places in the front and rear)
(Bleeding on the axle is conducted in the complete machine assembling process.) (6) Run the engine at low idle for about 2 minutes in order to fully charge the accumulator. (7) Make sure in this state that oil is filled up to the center of the sight gauge.
Cautions
Special tool
Necessary Equipment Q’ty
Name
Q’ty
Others
Name
99
Assembly procedure
No. 0615
Bleeding air from hydraulic circuit
(1) Before starting the engine, loosen the plug installed to the suction tube.
Switching pump
Loader pump
Steering pump
(2) Check that all air has been bled through the plug and oil has started flowing out, and then tighten the plug. (3) Leave the machine for 10 minutes as it is so that the pump will be filled with hydraulic oil. (4) If the hydraulic oil level is low, add new hydraulic oil to the specified level and loosen the plug installed to the top of the piston pump.
(5) Check that all air has been bled through the plug and oil has started flowing out, and then tighten the plug. (6) Run the engine at low idle for about 5 minutes to check each part for oil leakage. (7) Loosen the plug at the top of the piston pump. Check that oil flows out and then tighten the plug. (8) Close the oil filler cap of the hydraulic tank.
Cautions
Special tool
Others
Name
100
Necessary Equipment Q’ty
Name
Q’ty
Assembly procedure
Assembling the lift arm assembly (Part 1)
No. 0620
[1] Assembling of the lift arm assembly 1. Using the nylon sling (crane 10-ton), lift the dump and lift cylinders. (See Fig.1)
Nylon sling
Hinge it on the lifting eye Lever block of the cabin
2. Hold the dump and lift cylinders in the current position using the lever block. (See Fig.1) 3. Eliminate and clean the grease and paint deposited in the pinhole. 4. Before assembling pin (2), coat the entire inner surface of the bushing with the molybdenum disulfide lubricating oil in paste form (KES.LM-P or equivalent). a Prior to coating, make sure the rust retardant on the bushing inner surface is washed off. (If the rust retardant is left unwashed, molybdenum component does not adhere on the bushing surface and the oil loses its effect as an anti-scuffing measure.) 5. Lift the lift arm assembly using the crane and then move it over the front frame (see Fig.2). Then, after the positioning, insert the lift arm hinge pin.
Hold the cylinder using the square timber
Fig. 1
6. Assemble pin (4). a When inserting the pin, coat the seal with grease to protect it from damage. (See Fig.3) 7. For the adjustment procedure using shims, see Fig. 4. No. Part No. Part name Q’ty State of part (Parts list No.) (1) 427-N42-209A Lift arm assembly 1 Separately packed (No.W9E-620) (2) 427-70-11460 Shim 1.5 mm 4 Separately packed (No.W9E-620) (3) 427-70-11470 Shim 3.0 mm 2 Separately packed (No.W9E-620) (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
Fig. 4 Adjustment using shims
Shim
Fig. 2
Front frame
Shim
Before inserting the pin, adjust the clearance to 1.5 mm or less using the shims. Clearance on the right and left side must be equal. Fig. 3
Clearance 1.5 mm max.
Cautions Q Before inserting the pin, clean the pin and entire internal perimeter of the pinhole using a piece of rag and then coat that portion with molybdenum disulfide LM-P in paste form.
Special tool Name Impact wrench
Necessary Equipment Q’ty 1
Name Cranes 10 ton, 25 ton
Q’ty 1 each
Socket (36 mm)
1
Nylon sling (Withstand load min. 1 ton)
3
Large hammer
1
Nylon sling (Withstand load min. 50 kg)
2
Nylon sling (Withstand load min. 6 ton)
1
Q When inserting the pin, coat the seal with grease to protect it from damage.
Others
Q When aligning the pinhole, don't try to insert a finger in the pinhole.
101
Assembly procedure
Assembling the lift arm assembly (Part 2)
No. 0630
[2] Assembling of the lift cylinder to the lift arm assembly (see Fig. 1) 1. Eliminate and clean the grease and paint deposited in the pinhole.
Lift arm
2. Before assembling pin (1), coat the entire inner surface of the bushing with the molybdenum disulfide lubricating oil in paste form (KES.LM-P or equivalent).
Lift cylinder
a Prior to coating, make sure the rust retardant on the bushing inner surface is washed off. (If the rust retardant is left unwashed, molybdenum component does not adhere on the bushing surface and the oil loses its effect as an anti-scuffing measure.) 3. Adjust the position of the lift arm assembly and the lift cylinder and then insert lift cylinder head pin (1) to them. Care must be exercised to
Fig. 1
prevent assembling a wrong pin. [3] Assembling of the bucket cylinder to the lift arm assembly (Assembling of the bell crank) (See Fig. 2) 1. Eliminate and clean the grease and paint deposited in the pinhole.
2. Before assembling pin (1), coat the entire inner surface of the bushing with the molybdenum disulfide lubricating oil in paste form (KES.LM-P or equivalent). a Prior to coating, make sure the rust retardant on the bushing inner surface is washed off. (If the rust retardant is left unwashed, molybdenum component does not adhere on the bushing surface and the oil loses its effect as an anti-scuffing measure.) (If the rust retardant is left unwashed, molybdenum component does not adhere on the bushing surface and the oil loses its effect as an anti-scuffing measure.)
Bucket cylinder
Bell crank
Care must be exercised to prevent assembling a wrong pin.
3. Lift the cylinder head using the crane and then insert bucket cylinder pin (5) while adjusting the cylinder head position.
Fig. 2
a When inserting the pin, coat the seal with grease to protect it from damage. a Start the engine, lift the lift arm and adjust the pinhole position.
No. (1) (2) (3) (4) (5) (6) (7) (8)
Part No. 427-70-11972 01010-82035 427-70-11290 07049-01620 427-70-11942 01010-82035 427-70-11290 07049-01620
Part name Pin Bolt Washer Plug Pin Bolt Washer Plug
Q’ty 2 2 2 6 1 1 1 3
Cautions
102
Special tool Name Impact wrench
Necessary Equipment Q’ty 1
Name Crane 25 ton
Q’ty 1
Torque wrench
1
Nylon sling (Withstand load min. 500 kg)
2
Socket (30 mm)
1
Nylon sling (Withstand load min. 50kg)
2
Large hammer
1
Others
Q Before inserting the pin, clean the pin and entire internal perimeter of the pinhole using a piece of rag and then coat that portion with molybdenum disulfide LM-P in paste form. Q When inserting the pin, coat the seal with grease to protect it from damage. Q When aligning the pinhole, don't try to insert a finger in the pinhole. Q Care must be exercised to prevent assembling a lift cylinder pin or bucket cylinder pin.
State of part (Parts list No.) Separately packed (No.W9E-630) Separately packed (No.W9E-630) Separately packed (No.W9E-630) Temporarily installed on the lift cylinder assembling pin Separately packed (No.W9E-630) Separately packed (No.W9E-630) Separately packed (No.W9E-630) Temporarily installed on the bucket cylinder assembling pin
Assembly procedure
Connecting the remote grease tube
No. 0640
1. Connect the remote grease tube in 5 places
Connect
Connect Connect Connect
Connect
Feed grease (KES LM-G) to the grease feed fitting for the pins on the lift arm. Note: This process is not required when the auto-greasing specification is employed
Cautions
Special tool
Necessary Equipment Q’ty
Name
Q’ty
Others
Name
103
Assembly procedure
Assembling the bucket (Part 1)
No. 0650
No. Part No. Part name Q’ty State of part (Parts list No.) (1) 427-N42-1140 (O-ring) cord ring 4 Separately packed (No.W9E-650) (2) 426-09-11150 Bolt 4 Separately packed (No.W9E-650) (3) 01596-00606 Nut 4 Separately packed (No.W9E-650) (4) 01640-20610 Washer 8 Separately packed (No.W9E-650) 427-70-11450 Shim (3.0 mm) 4 Separately packed (No.W9E-650) (5) 427-70-11440 Shim (1.5 mm) 6 Separately packed (No.W9E-650)
Bucket assembly
1) Installation of the cord ring 1. Place cord ring (O-ring) (1) on the lift arm boss 1. (See Fig.2) 2. Coat the entire perimeter of the cord ring assembling-groove sufficiently with LM-G (molybdenum disulfide lithium grease). (See Fig.2)
Bucket assembly viewed from the left side
Fig. 1
3. Place the cord ring 2 in the groove after assembling of the bucket and adjustment with shims are complete. (See Fig.2) 4. Coat the entire inner surface 3 of the dust tool lip with LM-G (molybdenum disulfide lithium grease). (See Fig.2) Cord ring assembling groove
2) Alignment of hinge pin holes on the bucket assembly 1. Lift the bucket assembly using a 25 ton crane. Lifting tool: Wire sling (Withstand load 11 tons, two 4,000 mm slings are used for lifting) Shackle: For 5 tons
Cross section of bucket hinge pin section (Cross section A-A)
Fig. 2
2. Align the hole of the right and left hinge pins on the bucket to the pinholes on the lift arm. 3) Selecting of shims for the bucket hinge pin section 1. Shim-based adjustment procedure 1-1. Select shim (5) in such that clearance (T) in the right and left side becomes even. (Adjust clearance (T) to 1.5 mm max.) 1-2. Use a screwdriver (-) for holding the shim. a Don't try to insert a finger into the pin inserting pivot.
Bucket assembly Weight: 8,600 kg Fig. 3
Cross section of bucket hinge pin section (Cross section A-A) Cautions
Special tool Name Impact wrench
Necessary Equipment Q’ty 1
Name Crane 25 ton
Q’ty 1
Socket (10 mm)
1
Wire sling (Withstand load 11 ton, L=2,000)
1
Spanner 10 mm
1
Shackle: 5 ton
2
Others
104
Fig. 4
Assembly procedure
Assembling the bucket (Part 2)
No. 0660
4) Insertion of bucket hinge pin 1. Assemble the shim being selected in 3) above, align the pinhole and then insert the buck hinge pin. Before inserting the pin, coat it with grease. 2. Care must be exercised when inserting bucket hinge pin (6) not to damage the dust seal. After coating, place the pin in the groove.
Weight: 112.8 kg
5) Assembling of the bucket hinge pin 1. Assemble bucket hinge pin (6) using bolt (7) and washer (8).
6) Place cord ring (1) in the groove.
No. Part No. (6) 427-N42-1161 (7) 01010-82035 (8) 427-70-11290
Part name Pin Bolt Washer
Q’ty State of part (Parts list No.) 2 Separately packed (No.W9E-660) 2 Separately packed (No.W9E-660) 2 Separately packed (No.W9E-660)
Cross section of bucket hinge pin section (Cross section A-A)
Cautions
Special tool Name Impact wrench
Necessary Equipment Q’ty 1 1
Spanner 30 mm
1
Large hammer
1
Crane 10 ton
Q’ty 1 1
Others
Socket (30 mm)
Name Nylon sling (Withstand load min. 50 kg)
105
Assembly procedure
Assembling the bucket (Part 3)
No. 0670
7) Installation of bucket link pin (See Fig. 1.) Install the bucket link in the same procedure as 1) – 6) (See No.0650 and No.0660). No. (1) (2) (3) (4) (5) (6) (7) (8) (9)
Part No. 427-N42-1151 01010-82035 427-70-11290 427-70-11450 427-70-11440 427-N42-1140 426-09-11150 01596-00606 01640-20610
Part name Pin Bolt Washer Shim (3.0 mm) Shim (1.5 mm) Ring Bolt Nut Washer
Q’ty 1 1 1 2 4 2 2 2 4
Fig. 1
State of part (Parts list No.) Separately packed (No.W9E-670) Separately packed (No.W9E-670) Separately packed (No.W9E-670) Separately packed (No.W9E-670) Separately packed (No.W9E-670) Separately packed (No.W9E-670) Separately packed (No.W9E-670) Separately packed (No.W9E-670) Separately packed (No.W9E-670)
a Shim-based adjustment procedure 1. Select the shim in such that the clearance on both sides is even and adjusted to max. 1.5 mm. 2. Use a flat-blade screwdriver for holding the shim. (Don't try to insert a finger into the pin-inserting pivot.) 8) Assembling of the grease nipple and plug • Assembling to the bucket link pin (See Fig. 1.) • Assembling to the bucket hinge pin (See Fig. 3.) No. (10) (11)
Part No. 07049-01620 07020-00000
Part name Plug Fitting
Q’ty State of part (Parts list No.) 9 Separately packed (No.W9E-670) 2 Separately packed (No.W9E-670)
9) Feed LM-G (molybdenum disulfide lithium grease) to the bucket hinge pin and bucket link pin (See Fig.2). a After feeding the grease, run the engine at low idle and then repeat lift arm LOW – Hi and bucket tilt – dump 2 – 3 times to spread the grease evenly on the pin.
Fig. 2
Fig. 3
Grease position Bucket link
Bucket hinge (2 places)
Cautions
Special tool Name Torque wrench
Others
Socket (10 mm, 30 mm)
106
Necessary Equipment Q’ty 1 1
Name Nylon sling (Withstand load min. 50 kg) Crane 10 ton
Q’ty 1 1
Assembly procedure
No. 0680
Assembling the cover (Bottom of the counterweight)
1. Remove (2) and (3) being temporarily installed on the rear frame. 2. Assemble cover (1) using (2) and (3). Part No. 427-46-25341 01010-82045 01643-32060
Part name Cover Bolt Washer
Q’ty State of part (Parts list No.) 1 Separately packed (No.W9E-680) 4 Temporarily installed on the rear frame 4 Temporarily installed on the rear frame
Cautions
Special tool Name Impact wrench Socket (30 mm)
Necessary Equipment Q’ty 1
Name
Q’ty
1
Others
No. (1) (2) (3)
107
Assembly procedure
Feeding the grease
No. 0690
1. After the assembly, feed molybdenum disulfide lubricating agent (KES LM-G) until the grease spills out of the joint. Front frame: 6 places
Front frame
Detail of A portion (Rear right side of the front frame)
2. After the assembly, feed molybdenum disulfide lubricating agent (KES LM-G) until the grease spills out of the joint. Rear frame: 4 places
Rear frame
Detail of B portion (Front left side of the rear frame)
Cautions
Special tool
Others
Name Grease gun (Hand pump type)
108
Necessary Equipment Q’ty 1
Name
Q’ty
Assembly procedure
No. 0700
Work equipment hydraulic circuit air bleeding procedure
1. Bleeding of air from the cylinder (1) Engine at low idle and cylinder up to 100 mm in front of the stroke end: 3 – 4 times of reciprocating motion (2) Engine at mid idle and cylinder up to 100 mm in front of the stroke end: 3 – 4 times of reciprocating motion (3) Engine at high idle and cylinder up to 100 mm in front of the stroke end: 3 – 4 times of reciprocating motion (4) Engine at low idle and cylinder relieved at 100 mm in front of the stroke end: 3 – 4 times of reciprocating motion (5) Engine at mid idle and cylinder relieved at 100 mm in front of the stroke end: 3 – 4 times of reciprocating motion (6) Engine at high idle and cylinder relieved at 100 mm in front of the stroke end: 3 – 4 times of reciprocating motion
2. Air bleeding from the PPC circuit (1) Set the bucket control lever to "Tilt" and lift arm control lever to "Float". Maintain the cylinder at its stroke end for 1 minute. (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.
Cautions
Special tool Name
Name
Q’ty
Others
Spanner
Necessary Equipment Q’ty 1
109
Assembly procedure
Adjusting the bucket positioner
No. 0710
Bucket cylinder
(1,032) Detection bar
2 in nominal clearance
Detection bar Proximity switch mounting bracket Fig. 1
427-43-19233 Tightening torque: 14.7 – 19.6 Nm {1.5 – 2.0 kgm}
Min. 1/2 displacement should be present No. (1) (2) (3) (4) (5) (6) (7) (8) (9)
Part No. 427-43-19233 01435-01245 01596-01211 01643-31232 427-44-11113 01024-81225 56B-06-15610 08193-20010 01435-01025
Part name Plate Bolt Nut Washer Support Bolt Switch Clip Bolt
Q’ty 1 2 2 2 1 4 1 1 1
State of part (Parts list No.) Separately packed (No.W9E-710) Temporarily installed on the cylinder Temporarily installed on the cylinder Temporarily installed on the cylinder Separately packed (No.W9E-710) Temporarily installed on the cylinder Temporarily installed on the plate Temporarily installed on the plate Temporarily installed on the plate
Sensor sensing surface
Section A-A Protector
3–5
Bucket positioner adjusting procedure (1) Lower the bucket on the ground and set it horizontal. (The ground surface must be even.) (2) Adjust the proximity switch in such that its sensing surface is pulled in ª0.5 – 1.0 mm from the protector end. Then fix the proximity switch. (3) Since the detection bar moves laterally to the switch sensing-surface, adjust the clearance along the entire passing surface to 3 – 5 mm. (4) Run the engine at mid speed (1,500 rpm) and activate the positioner. Then adjust the proximity switch mounting bracket (427-43-19233) in such that the bucket angle is set downward by 0 – 1° when the bucket was placed on the ground. (When the bucket is set horizontal near the ground surface, relation between the bucket angle and cylinder length is 8.7 mm/1°.) (5) When the positioner is activated and the bucket is set near the ground surface, fluctuation due to the engine speed shall be 4° maximum. ª Confirm magnitude of the displacement. (Make sure the displacement is 1/2 minimum. See Fig. 1.)
Cautions
Special tool Name Impact wrench Socket 19 mm
1
Torque wrench
1
Spanner
1
Others
110
Necessary Equipment Q’ty 1
Name
Q’ty
Assembly procedure
No. 0720
Adjusting the new 2 stage (Overseas general standard)
Clearance between the switch sensing surface and plate in horizontal direction is 3 – 5 mm
Tightening torque: 14.7 – 19.6 Nm {1.5 – 2.0 kgm}
View Z No. (1) (2) (3) (4) (5) (6) (7) (8) (9)
Boom kick out adjusting procedure (1) Raise the lift arm to the highest position and then fix the sensor plate in such that the distance between the switch center and sensor plate top end becomes 0 – 5 mm. (2) Fix the switch in such that the clearance between the switch sensing surface and plate in horizontal direction becomes 3 – 5 mm. Distance between the switch center and sensor plate top end is 0 – 5 mm
Part No. 427-43-29110 01435-01020 428-43-29210 01435-01225 56B-06-15610 08193-21012 01435-01020 01643-31032 01580-11008
When raised to the highest position
Part name Bracket Bolt Bracket Bolt Switch Clip Bolt Washer Nut
Q’ty 1 2 1 2 1 2 2 2 2
State of part (Parts list No.) Separately packed (No.W9E-720) Separately packed (No.W9E-720) Temporarily installed on the front frame Temporarily installed on the front frame Temporarily installed on the front frame Temporarily installed on the front frame Temporarily installed on the front frame Temporarily installed on the front frame Temporarily installed on the front frame
Position of the plate when the lift arm was raised to the highest position
When the bucket is set horizontal
Front frame
Cautions
Special tool
Necessary Equipment
Name Impact wrench
Q’ty 1
Socket (17mm, 19 mm)
1 each 1
Spanner
1
Q’ty
Others
Torque wrench
Name
111
Assembly procedure
No. 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: 14.7 – 19.6 Nm {1.5 – 2.0 kgm}
View Z No. (1) (2) (3)
Part No. 427-62-21330 01435-01220 56B-06-15610
Part name Bracket Bolt Switch
Q’ty State of part (Parts list No.) 1 Separately packed (No.W9E-730) 2 Separately packed (No.W9E-730) 1 Temporarily installed on the front frame
When raised to the highest position When the bucket is set horizontal
Front frame
Adjustment of boom kick out (1) Fix the switch in such that the clearance between the switch sensing surface and plate in horizontal direction becomes 3 – 5 mm. Cautions
Special tool Name Impact wrench
Others
Socket (19 mm)
112
Necessary Equipment Q’ty 1 1
Name
Q’ty
Assembly procedure
No. 0740
Assembling the lift arm angle sensor
View A
Connect CN FB4
Front lamp assembly
Assemble the respective parts to the assembled bracket. Clip and bolt already assembled Fix the harness here.
1. Remove (2) – (8) and (10) – (14) being temporarily installed on the lift arm assembly of the front frame. 2. Remove (9) being temporarily installed on lever (1). 3. 4. 5. 6. 7.
Lift arm assembly
Detail of assembling No. (1) (2) (3) (4) (5) (6)
Part No. 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.) Lever 1 Separately packed (No.W9E-740) Assemble (1) – (11) as show in the detail of Shim t = 0.5 1 Temporarily installed on the front frame the assembling. 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. Spring 1 Temporarily installed on the front frame Remove (15) and (16) being temporarily potentio- 1 Temporarily installed on the front frame (7) 56B-06-11630 Sensor meter installed on the front lamp assembly. (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. (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. 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
Assembly procedure
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: 14.7 – 19.6 Nm {1.5 – 2.0 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.
No. (1) (2) (3)
Part No. 427-62-21330 01435-01220 56B-06-15610
Part name Bracket Bolt Switch
When raised to the highest position
Q’ty State of part (Parts list No.) 1 Separately packed (No.W9E-750) 2 Separately packed (No.W9E-750) 1 Temporarily installed on the front frame
Position of the plate when the lift arm was raised to the highest position
Distance between the switch center and sensor plate bottom end is 115 mm
Front frame
Cautions
Special tool Name Impact wrench
Others
Socket (19 mm)
114
Necessary Equipment Q’ty 1 1
Name
Q’ty
Assembly procedure
Touchup work
No. 0760
1. Paint can be peeled off in the sections where lifting tools were used as well as machined sections and dented sections. If such is recognized, touch up the damaged portions. (Touchup in the following (1) – (10) sections is a must. For other sections, touch up the location where paint is peeled off.) (1) (2) (3) (4) (5) (6) (7) (8) (9) (10)
Lift arm: The section where the nylon sling was used for lifting Lift arm: The section where dents from assembling of the pin are left Lift cylinder: The section where the nylon sling was used for lifting Lift cylinder: The section where dents from assembling of the pin are left Bucket cylinder: The section where the nylon sling was used for lifting Bucket cylinder: The section where dents from assembling of the pin are left Bell crank: The section where the nylon sling was used for lifting Bell crank: The section where dents from assembling of the pin are left Machined portion on the tires Counterweight section Right and left Right and left
Right and left
View Z Cautions 1. Paint color shall conform to the following. Except the sections where face coating is provided.
Black gray
Black heat resistant paint
Natural yellow
2. Grease nipple shall be painted in red. Following lists the places and number of the nipples used. (1) Loader linkage 13 places (4) Drive shaft 7 places (2) Center pin 2 places (5) Rear axle support 2 places (3) Steering cylinder 4 places 3. Bare outside sections: Following hose for hydraulic tank shall not be painted (1) Hose from the front plate exit of the front frame to the bucket cylinder (2 pieces) (2) Hose to the lift arm cylinder (4 pieces both right and left) (3) Hose for the 3-spool valve on the right and left lift arm plates (2 pieces) 4. Bolts and washers in the external bare portion shall be painted in the same color as the exterior parts.
115
Assembly procedure
Applying the decal (For the overseas-directed products only)
No. 0770
1. Apply the decal to the lift arm top end (Caution for falling off of the work equipment) ((o) in the figure indicates the upward direction of the decal)
Top view of the lift arm
The same process is employed for both the right and left side
View Z
No. (1)
Part No. 09807-C1683
Part name Mark
Q’ty State of part (Parts list No.) 2 Separately packed (No.W9E-770)
Cautions
Special tool
Others
Name
116
Necessary Equipment Q’ty
Name
Q’ty
1/9
1/9
WA800-3E0 WA900-3E0
KOMATSU SAA12V140E-3
GEN00056-01
a Carefully read the Operation and Maintenance Manual in advance to understand safety, operation, machine operations and controls, and then carry out the following inspections. Date of Inspection
Inspector
Service meter Start
Inspection items
: Acceptable (
) : Enter numeric values.
: Unacceptable Empty column : Uninspected
: Not applicable
Finish H
No.
2/9 List of check marks for inspection results
H
: No check is required.
Check relevant items after maintenance. When the result is acceptable, circle any of the above marks. (Example: )
Judgment procedures and criteria
Check
Maintenance Remarks
Recording the Serial No. of built-in parts. The number is stamped on the right upper part of the lift arm. Stamp
1
Lift arm No.
2 Checking oil and water levels. (Check them before starting the engine.) 3
Engine oil level (while the engine is at a stop.)
4
Brake oil level (When the check is difficult while the engine is at a stop, start the engine to check the level.)
5
Hydraulic oil level
6
Transmission oil level
The level shall be in the range between (H) and (L). (Check the level by comparing it with the stamp [ENGINE STOPPED] on the dipstick more than 15 minutes later after the engine stopped.)
The level shall be at the ENGINE STOP level. The level shall be at the ENGINE RUNNING level.
With the measurement gauge 10 hours later after the engine stopped. With the measurement gauge 5 minutes later after the engine started.
Lower the bucket on the ground, level it. And the level shall be in the range of the inspection window. (Check the level after the engine stopped.)
The level shall be in the range A at the ENGINE STOP position of the level gauge.
A
a Check the level more than 60 minutes later after the engine stopped. 7
Coolant level
The level shall be above the middle between Full and Low on the sub tank.
8
Electrolyte level
The level shall be at 10 – 12 mm above the polar plate.
9
Window washer level
The level shall be above the 2/3 level of the tank capacity.
10
Check of antifreeze density in coolant
Check the antifreeze density. The density shall satisfy the standard. Area A: -33 – -43°C Areas B: -24 – -34°C Areas C: -14 – -24°C Measured value ( ) °C
Preparation before function check 11
Satisfaction of failure code.
Before the machine inspection, the failure code on the display, which can be found after the monitor panel and the lunch box are removed, shall be satisfied.
Turn the key switch ON. 12 13 14 15
When the starting switch is set to ON, the buzzer 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. When the starting switch is set to ON, the [CHECK] lamp Function of centralized inspection lamp does not go on. When the starting switch is set to ON, the pilot lamp blinks Function of emergency steering pilot lamp (and goes out after the engine starts). The sound volume is satisfactory without vibrating tone Function of horn (sensory).
Check the safety function at the start of engine. (Check safety around in advance so that everything is in order even if the engine starts.) 16
Safety function of transmission neutral
17
Safety function of steering lever set to neutral
Even when key switch is set to START by using the transmission rear and forward switch F or R of the joystick lever, the engine does not start. (The engine does not start when the transmission is set to other than neutral.) When the joystick lever is lowered to the right or left, the engine does not start. Also, when the lever is lowered, the buzzer sounds. (When the lever is set to other than neutral, the engine does not start.) (When the lever is returned to the N position, the buzzer stops sounding.)
3/9 No.
Inspection items
Judgment procedures and criteria
Start the engine. (Check safety around and then start the engine. Start each measurement only after warning-up run.) 18
Function of centralized warning lamp
19
Function of accelerator pedal
20
Exhaust color
21
Abnormal noise of engine
When the engine starts, the [CAUTION] lamp does not blink. 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). (Sensory evaluation) No abnormal noise is heard. (Sensory check) Check low idle and high idle at each stall.
Initial setting of AJSS (joystick steering) ª Check each function after the initial setting. Initial setting
(1) Set machine and steering in straight travel position.
a Do not move lever during procedures No. (4) – (7) at right.
22
(2) Stop engine (Turn starting switch OFF) and set steering lock lever in LOCK position. (3) Disconnect neutral position adjustment connector "JL3" <> in right console. When no pip sound in (7) is heard, carry out the initial setting again. (4) Turn starting switch to ON position and start engine. If the pip sound does not occur even after re-initial setting, the joystick steering is out of (5) Connect neutral position adjustment connector "JL3". order. Troubleshoot it and carry out the initial setting. (Check that both output voltages of steering angle (6) Reset steering lock lever. sensor and frame angle sensor are 2.40 – 2.60 V (7) After 1 second, buzzer beeps 3 times and adjustment is and then repeat procedures from No. 1.) completed.
Measuring the engine speed. Engine revolution (Measuring conditions) ª Engine coolant temperature: Within the green range ª Engine oil temperature: 80 – 90 °C ª Torque converter oil temperature: 60 – 80 °C ª Work equipment oil temperature: 45 – 55 °C ª
23
When the engine speed measuring method is not clear, refer to the paragraph of [Measurement of Engine Speed] in Part: “Testing and adjusting” in the Shop Manual.
Before measuring the engine speed, apply the parking brake, release the accelerator pedal and set the secondary switch to OFF. Standard: 620 – 710 rpm ) rpm Measure value of low idle speed: ( Before measuring the speed, apply the parking brake, release the accelerator pedal and set the secondary switch to ON. Standard: 820 – 910 rpm Measure value of low idle (secondary) speed: ( ) rpm Before measuring the speed, apply the parking brake and step on the accelerator pedal. Standard: 2,170 – 2,220 rpm Measure value of high idle speed: ( ) rpm Before measuring the speed, step on the brake pedal, release the parking brake, set the transmission lever to F3 speed and step down the accelerator pedal. Standard: 1,940 – 2,140 rpm (WA800) 2,020 – 2,220 rpm (WA900) Measured value of engine speed at stalling T/C: ( ) rpm Before measuring the speed, apply the parking brake, step on the accelerator pedal and release the work equipment. For recording only, Measured value of engine speed at ) rpm stalling the work equipment: ( Before measuring the speed, step on the brake pedal, release the parking brake, set the transmission lever to F3 speed, release the work equipment and step on the accelerator pedal. For recording only, Measured value of engine speed at full stall: ( ) rpm
Make checks related to the work equipment. (1) Set the lever to the [Raise] position, and the lift arm rises.
24
Function of lift arm control lever
(2) Pull the lever further from the [Raise] position, and the lever is clutched at the notch and stops there. Then, bring the lift arm to the position adjusted with the kick-out, and the lever returns to the [Hold] position at the same time. (3) Bring the lever to the [Hold] position, and the lift arm keeps staying at the position where it stopped. (4) Set the lever to the [Lower] position, and the lift arm falls and the work equipment is released at the lowest position. (5) Set the lever to the [Float] position, the lever is clutched at the notch and the lift arm can freely move as external force is applied. (6) Set the lift lever to the [Float] position, and the work equipment is not released. (7) When the lever is released from the notch as the lift arm is kicked out and the lever is pulled further to the [Raise] position until the work equipment is released, the lift arm cylinder stroke shall be within 5 mm. a When the kick-out height is adjusted as requested by user, the lever works at the height.
Check
Maintenance Remarks
4/9 No.
25
26 27 28
29
Inspection items
Judgment procedures and criteria
(1) Set the lever to the [Tilt] position, and the bucket moves in the tilt direction. (2) Pull the lever further from the [Tilt] position when the bucket is dumped, and the lever is clutched at the notch and stops there and then returns to the [Hold] position at the same time when the bucket comes to the position adjusted with the bucket positioner. (3) Bring the lever to the [Hold] position, and the bucket keeps staying at the position where it stopped. Function of bucket control lever (4) Set the lever to the [Dump] position, and the bucket moves in the dump direction. (5) The bucket positioner has been adjusted so that the bucket is level with the ground or is slightly tilted down forward. (Note that a poor switch adjustment causes the bucket to be released from the notch before the working position sometimes.) a When the bucket positioner is adjusted as requested by user, the bucket shall work at the position. Does the remote positioner switch enable to set the Down 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), the work equipment does not lower even if the (for work equipment control lever) work equipment control lever is moved. Stop the engine after an engine high idle and lower the lift Function of work equipment accumulator arm control lever, and the lift arm comes down. Measurement of work equipment speed in the Lift arm raising time (without load) Standard lever raising: 9.9 – 10.9 sec. normal mode Measured value: ( ) sec. (Work equipment speed and oil temperature: Lift arm lowering time (without load) Standard lever lowering: 4.3 – 5.3 sec. 45 – 55 °C) Measured value: ( ) sec. Bucket tilted back time (Measure the time without load at the lift arm highest position.) Set the Active Working Switch on the right Standard lever tilting: 3.5 – 4.1 sec. side of the dashboard to Normal Loading Measured value: ( ) sec. and start the measurement. Bucket dumping time (Measure the time without load at the lift arm highest position.) Standard lever dumping: 2.2 – 2.8 sec. Measured value: ( ) sec. The pilot lamp of the proximity switch for powerful mode goes Check of active mode on at the lift arm hinge pin height of 1.4 – 2.0 m. When a metal piece is stuck to the proximity switch for 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, the transmission is set to F3 speed and the and start the measurement. work equipment is released, the loader pump solenoid has the voltage of 24 V.
30
Proximity switch for active mode
Measurement of solenoid voltage
31
Check of lift arm hydraulic drift (without load)
Check of bucket natural dump (without load)
32
Make the lift arm hinge pin and the bucket mounting pin horizontal with the ground, start the measurement 5 minutes later after the engine stopped and measure the fall of the lift cylinder rod 15 minutes later. (Oil temperature: 45 – 55 °C) Standard value: 50 mm/15 minutes Measured value: ( ) mm Make the lift arm hinge pin and the bucket mounting pin horizontal with the ground and also, make the bucket bottom horizontal with the ground. Start the measurement 5 minutes later after the engine stopped and measure the fall of the dump cylinder rod 15 minutes later. (Oil temperature: 45 – 55 °C) Standard value: 30 mm/15 minutes Measured value: ( ) mm
Posture for measuring hydraulics drift
Check
Maintenance Remarks
5/9 No.
Inspection items
Judgment procedures and criteria
Making checks related to the steering. 33
34
35
36
37
Bring the steering lock lever to the lock position after starting the engine and lower the joystick lever to the right or left, and the buzzer sounds but the steering is not disengaged. Lower the joystick lever to the right, and the machine turns to the right. Lower the joystick lever to the left, and the machine turns to Function of steering the left. The steering angle changes only as much as the joystick lever is moved. Bring the joystick lever to the stroke end while idle the engine at low speed, and there occurs the clearance of 20 – 30 mm Check of adjustment of steering stopper bolt between the front frame and the rear one. (Check the clearance on both the right and left sides.) Measure the full stroke time in idle the engine at high speed. Standard left swing: 3.2 – 4.3 sec. Measured value: ( ) Measurement of steering operation time Measure the full stroke time in idle the engine at high speed. Standard right swing: 3.2 – 4.3 sec. (Work equipment speed and oil temperature: 45 – 55°C) Measured value: ( ) The above measured swing times do not differ more than 10% on the right and the left sides. When the engine stopped while traveling downhill, the Function of emergency steering steering angle changes. (Check it on both the right and left sides.)
Safety function of joystick steering lock lever
Making checks of travel and brake. 38
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
Set the transmission to F or R at the locked position, and the buzzer sounds and the machine does not travel. Set the forward-reverse selector switch of the joystick lever to the F position, and the machine travels forward. Set the forward-reverse selector switch of the joystick lever to the R position, and the machine travels backward. Set the forward-reverse selector switch of the joystick lever to the N position, and the machine does not travel. Press the shift-up switch (+) of the joystick lever, and the transmission speed increases. Press the shift-down switch (-) of the joystick lever, and the transmission speed decreases. Change the machine travel direction to forward or backward at the 1st or 2nd speed, and the transmission does not get any shock nor cause any time lag. Press the switch on the head of the lift arm control lever while traveling the machine at the F2 speed, the machine comes to travel at the 1st speed. Set the transmission to reverse travel (R), and the machine returns to the 2nd speed. Set the transmission cut-off switch on the main monitor panel to ON, the pilot lamp of the transmission cut-off switch on the monitor goes on. Step on the left brake, and the transmission is set to neutral. Set the selector switch on the main monitor to ON (to turn on the pilot lamp), and the transmission gets in the manual shift mode. Set the selector switch to OFF (to turn off the pilot lamp), and the transmission gets in the auto shift mode. When the transmission is in the auto shift mode, the indicator lamp on the left dashboard for the selected automatic transmission maximum speed gear goes on. (In the manual shift mode, the pilot lamp does not go on.) The shift display on the monitor panel agrees with the gear shift selected with the transmission shift up/down switch. The lighted transmission indicator lamp agrees with the automatic gear shift range and the machine starts traveling at the 2nd speed when the forward and backward travels are changed over. (1st speed pilot lamp o Automatic gear shift to 1st speed, 2nd speed pilot lamp o Automatic gear shift to 2nd speed, 3rd speed pilot lamp o Automatic gear shift to 2nd speed - 3rd speed) When the F3 speed is changed over to R3 speed while the engine is idle at high speed, pip sounds occurs. Press the switch on the head of the lift arm control lever while traveling the machine at the F2 speed, the machine comes to travel at F1 speed, and returns to the 2nd speed about 4 seconds later (in the auto shift mode only). When the transmission in the auto shift mode, press the switch beside the lift arm lever knob, the transmission is fixed to the gear shift being displayed with the transmission indicator on the main monitor and the hold indication on the main monitor goes on. Press the switch once again, and the hold is released and the display disappears.
Check
Maintenance Remarks
6/9 No. 47 48 49 50 51
52
53
54
Inspection items
Judgment procedures and criteria
After traveling the machine, touch the brake chamber by hand. No abnormal heat can be felt (on the four wheels). Turn on the parking switch, set the joystick lever T/M Safety function of parking brake forward-reverse switch to F or R, and the centralized warning lamp blinks and the warning buzzer sounds. This brake enables to stop the machine on slopes of 1/5 Function of parking brake gradient. Apply the brake suddenly at the initial speed of 20 km/h, and the machine stops within 7.5 m. Braking force of service brake Step on the brake while the engine is idle at high speed or at the F2 speed, and the machine does not start. Travel the machine at more than 20 km/h and apply the Pull of brake brake suddenly, and the machine stops one a straight line. When the pressure in the accumulator drops, the parking brake works automatically. (The engine stops, the starting switch gets set to ON and the parking brake works.) Step on the service brake pedal several times, and the accumulator Check of emergency brake pressure drops and the parking brake works.) When the emergency brake works, the parking brake pilot lamp goes on. Step on the brake pedal to sound the caution buzzer for oil pressure drop. Then, idle the engine at high speed until the Check of the time when the brake accumulator accumulator is fully charged. Stop the engine and restart the pressure drops engine 30 minutes later, and the caution lamp for the oil pressure of the brake accumulator does not go on. Standard F1 speed: 6 – 8 km/h Measured value: ( ) km/h Check of travel speed Standard F2 speed: 11 – 13 km/h ) km/h When the bucket is empty, 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. Standard R1 speed: 6 – 8 km/h Measured value: ( ) km/h Since F3 and R3 require long approach Standard R2 speed: 11 – 13 km/h distance, they are regarded as reference Measured value: ( ) km/h values. Standard R3 speed: 26 – 30 km/h Measured value: ( ) km/h Heat accumulation in brake disc
Checking all lamps. 55
Internal lighting of main monitor and sub monitor
56
Function of clearance lamp
57
Function of head lamp
58
Function of turn signal lamp
59
Function of hazard lamp
60
Function of tail lamp
61
Function of back-up lamp
62
Function of brake lamp
63
Function of working lamp
64
Function of step lamp
65
Function of room lamp
66
Function of back-up buzzer
Set the lamp switches (on the 1st and 2nd stages) to ON, and the internal lightings go on. Set the light switches (on the 1st and 2nd stages) to ON, and the right and left front lights go on. Set the lamp switches (on the 2nd stages) to ON, and the head lamps (2 lamps each on the right and left sides) go on. Move the turn signal lever, and the front and rear turn signal lamps corresponding to the intended direction blink. Set the hazard switch to ON, and the right and left turn signal lamps and the pilot lamp (arrow) inside the cab blink. Set the light switches (on the 1st and 2nd stages) to ON, and the right and left rear lights go on. Set the transmission shift lever to R, and the back-up lamp goes on. Step on the brake pedal, and the red brake lamps (right and left) go on. Set the light switches to ON and apply the brake, and brightness of the brake lamp changes. (The lamp becomes brighter.) Set the light switches (on the 1st and 2nd stages) to ON and set the F working light switch to ON, and the pilot lamp F goes on and the working light on the cab front head goes on. Set the light switches (on the 1st and 2nd stages) to ON and set the R working light switch to ON, and the pilot lamp goes on and the rear right and left working lights on the radiator grille go on. Set the light switches (on the 1st and 2nd stages) to ON and set the R working light switch to ON, and the pilot lamp goes on, the right and left working lights on the roll-over protective structure and on the radiator guard go on. Set the switch to ON, and the light goes on and goes out automatically about a minute later. Set the switch to ON, and the light goes on. Also, the lights at the doors light when the cab door are opened. The sound volume is satisfactory without vibrating tone. (Sensory)
Check
Maintenance Remarks
7/9 No.
Inspection items
Judgment procedures and criteria
Check gauge performance. 67 68 69
Function of torque converter oil temperature gauge
During operation, the gauge indicates any point in the green range. During operation, the gauge indicates any point in the green Function of engine coolant temperature gauge range. During operation, the gauge indicates the exact level in the Function of fuel gauge fuel tank.
Checking the power window 70
Function of power window
L. H. side: Press the switch front, and the window glass lowers. Press its rear side, and the window glass rises. R. H. side: Press the switch front, and the window glass lowers. Press its rear side, and the window glass rises.
Checking the windshield wiper
71
Function of windshield wiper
Press the push-button on the side of the switch, and the washer liquid is sprayed over the front glass and the front wiper interlocks. Turn the rotary switch, and the front wiper corresponds to [OFF], [INT], [Low Speed] and [High Speed] in this order. Turn the wiper switch lever backward, and the rear washer liquid is sprayed. Turn it forward to the 1st step, and the rear wiper works, turn it forward to the 2nd step, and the rear washer and the rear wiper interlock.
Checking air conditioner The air flow rate corresponds to that on the fan switch. Function of air conditioner 72
Since the air conditioner does not work when the temperature in the cab is low, warm the air inside the cab before starting the check.
Press the external/internal air changeover switch, and the indicator lamp on the upper side of the switch goes on. The mode selector switch corresponds to the wind spurtingout position. When the level indicator of the temperature adjustment switch shows green, you can get cool wind, and when it shows red, you can get warm wind. Press the air conditioner switch, and the indicator lamp on the upper side of the switch goes on. The capacitor fan is rotating during operation of the air conditioner.
Checking the AM/FM radio cassette stereo
73
Function of AM/FM radio cassette stereo
Turn the power switch to the right, and the radio is switched on. Keep turning it, and the speaker volume increases. What is effective are auto store, preset scanner, tone (low and high), loudness, manual tuning, seek tuning, band changeover and manual memory. After inserting a cassette tape (arranging the side where the tape can be seen to the right), replay, rapid forwarding and rewinding can be made smoothly. Display the clock (by pressing the DIPS button) and check that it shows the correct time.
Checking cigarette lighter 74
Check of cigarette lighter
The cigarette lighter is heated red and returns to where it was several second later.
Checking tire air pressure
75
Tire size and criteria
Measured value: Front left ( Measured value: Front right (
) kg/cm2 ) kg/cm2
45/65-45-46PR L-5 Standard value: 5.25 kg/cm2
Measured value: Rear left ( Measured value: Rear right (
) kg/cm2 ) kg/cm2
Checking failure code 76
Check of failure code
Make sure that no failure code is displayed on the monitor panel after completion of the function check. Check of failure code ( )
Check
Maintenance Remarks
8/9 No.
Inspection items
Judgment procedures and criteria
Carry out inspection of every part. Cab lining is free from flaw and stain. 77
Check of cab Cab glass is free from flaw. Mounting bolts are free from looseness and scuffing.
78
Check of ROPS structure
79
Inspection around machine upper side
The antenna is installed tightly, and the screws are free from scuffing. Side working lights and step lights are installed tightly, and the harness is fixed to the clip. Mounting bolts of each handrail are tightened together with washers. Mounting bolts of each handrail are tightened certainly and are free from scuffing. Harness connectors below the floor are certainly locked to the claws, and harnesses do not sway. The throttle cable is connected straight and tightly.
Inspection of loader link and bucket
80
Ф180
Mounting pin bolts of the loader link and bucket are tightened certainly and are free from scuffing. Mounting pins of the loader link and bucket are greased certainly. Bell crank upper pins and lift arm cylinder pins (on the rod side) are assembled correctly.
Pin on bell crank side
44 5
Ф180
Pin on lift arm cylinder side
43 5 Their diameters are the same but their lengths are different by 10 mm.
81
Inspection around front axle
Front axle mounting bolts are free from looseness and scuffing. No oil leakage is detected in the brake system.
82
Inspection of light support
83
Inspection of front fender
84
Inspection around center pin
Light support mounting bolts are lightened certainly and are free from scuffing. (Check them on both the right and left sides.) Front fender mounting bolts are tightened certainly and are free from scuffing. (Check them on both the right and left sides.) Center pin mounting bolts are tightened certainly and are free from scuffing. (Check both upper and lower pins.) There is some clearance between the upper center pin lock plate and the rear frame. Center pins are greased certainly. (Check both the upper and lower pins.) Steering cylinder mounting pin bolts are tightened certainly and are free from scuffing. (Check them on both the right and left sides.) Steering cylinder mounting pins are greased certainly. (Check them on both the right and left sides.) No oil leakage is detected in the hydraulic line, steering line and brake line systems. The PPC valve hose connecting portion is not loose. At the time or right swing, there is not interference between the steering link and the harness to the front. Floor frame mounting bolts are tightened certainly and are free from scuffing.
Check
Maintenance Remarks
9/9 No.
Inspection items
Judgment procedures and criteria
85
Inspection of exterior parts
Cab skirt panel mounting bolts are tightened certainly and are free from scuffing. Access ladder mounting bolts are tightened certainly and are free from scuffing.
86
Inspection around engine
No oil leakage nor water leakage are detected.
87
Inspection around battery box
88
Inspection of fuel tank
Battery box mounting pin bolts are tightened certainly and are free from looseness and scuffing. (Check the boxes on both the right and left sides.) Battery holder is mounted tightly. (Check it on both the right and left sides.) Battery cables are tightly connected. (Check them on both the right and left sides.) Step mounting bolts on the battery box front side are tightened certainly and are free from scuffing. (R. H. side) Belt step mounting bolts are tightened certainly and are free from scuffing. (Check them on both the right and left sides.) Fuel tank mounting bolts are free from looseness and scuffing. The breather tube is not deformed. No fuel leakage is detected from the fuel tank.
89
Inspection around rear axle
Rear axle mounting bolts are free from looseness and scuffing. No oil leakage is detected in the brake system.
90
Inspection of counterweight
91
Inspection around hydraulic tank
Counterweight mounting bolts are free from looseness and scuffing. Lift ladder mounting bolts are tightened certainly and are free from scuffing. No oil leakage is detected.
92
Inspection of tire and wheel
93
Inspection of lower parts
Hub nuts are mounted tightly and are free from scuffing. (Check them on the four wheels.) Tires are free from flaw and tear. (Check them on the four wheels.) Air valve caps are installed certainly. (Check them on the four wheels.) No oil leakage is detected from the transmission and the torque converter. Front drive shaft mounting bolts are tightened certainly and are free from looseness and scuffing. Rear drive shaft mounting bolts are tightened certainly and are free from looseness and scuffing. There is no clearance at the drive shaft yoke mounting portion. Rear axle rear cover mounting bolts are tightened certainly and are free from scuffing. The rear axle support is greased certainly. No oil leakage is detected in the brake system and hydraulic system.
Check
Maintenance Remarks
WA800-3E0, WA900-3E0 GALEO WHEEL LOADER Form No. GEN00056-01
©2007 KOMATSU All Rights Reserved Printed In Japan 07-07
