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

CONTENTS1 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 Page

0010 Oil, grease and coolant 100020 Oil, grease and coolant level 110030 Setting rear frame in place 120040 Setting front frame in place 130050 Joining front and rear frames 140060 Front and rear frames joining procedure 15

0070 Assembling the steering pin 160080 Assembling the center drive shat (Center support – Transmission) 170090 Connecting the pipes - Part 1 180100 Connecting the pipe - Part 2 190105 Connection of piping (Part 2) (Riotinto specification: If equipped) 200110 Connecting the auto-greasing pipe 21

0120 Setting the axle in place and assembling the support 220130 Setting the bare machine in place 230140 Assembling the rear axle 240150 Rear axle rear side cover assembling procedure 250160 Connecting the rear axle pipe 260165 Fixing of rear axle piping (Brake cooling specification: If equipped) 27

0166 Connection of rear axle piping (Riotinto specification: If equipped) 280167 Fixing of rear axle piping (Brake cooling specification: If equipped) 290168 Connection of cooling line piping (Brake cooling specification: If equipped) 300170 Assembling the rear drive shat (Transmission – Rear axle) 310180 Assembling the front axle 320182 Fixing of front axle piping (Brake cooling specification: If equipped) 33

0185 Connection of front axle piping (Brake cooling specification: If equipped) 340190 Connecting the front axle pipe 350195 Connection of front axle piping (Riotinto specification: If equipped) 360200 Connecting the front drive shat (Front axle – Center support) 370210 Connecting the axle oil temperature sensor (For VHMS specification only) 38

0220 Assembling the tires 390230 Assembling the fuel tank 400235 Installation of fuel tank (Riotinto specification: If equipped) 410240 Fixing the drain pipe 420245 Fixing of torque converter cooler drain piping (Riotinto specification: If equipped) 430250 Connecting the fuel pipe 44

0260 Fixing the engine drain hoses 450270 Assembling the hydraulic tank ladder 460280 Assembling the floor and cab assembly 470290 Connecting the air conditioner hose 480300 Connecting the brake line 490310 Connecting the window washer hose 50

0320 Connecting the PPC line hose 510330 Connecting the floor wiring harness 520333 Connection of floor wiring harness -1 (Riotinto specification: If equipped) 530334 Connection of floor wiring harness -2 (Riotinto specification: If equipped) 540340 Connecting the link for AJSS (For AJSS specification only) 550345 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) 570360 Assembling the floor cover 580370 Refilling the window washer 590380 Assembling the battery box 60

Appendix: Field assembly inspection report

0390 Connecting and fixing the battery wiring 610393 Wiring on right side of battery (Riotinto specification: If equipped) 620394 Wiring on left side of battery -1 (Riotinto specification: If equipped) 630395 Wiring on left side of battery -2 (Riotinto specification: If equipped) 640396 Wiring on left side of battery -3 (Riotinto specification: If equipped) 650397 Connection of ground cable on left side of battery (Riotinto specification: If equipped) 66

0400 Assembling the battery step 670403 Installation of oil cooler assembly (Brake cooling specification: If equipped) 680404 Installation and connection of oil cooler assembly piping (Brake cooling specification: If equipped) 690406 Installation of oil cooler assembly piping -1 (Brake cooling specification: If equipped) 700407 Installation of oil cooler assembly piping -2 (Brake cooling specification: If equipped) 710410 Assembling the handrail (On the right hand platform) 72

0411 Installation of handrail (Right platform area) (Brake cooling specification: If equipped) 730420 Assembling the handrail (On the hood top face) 740430 Assembling the handrail (On the right hand battery box) 750440 Assembling the rear access step 760450 Assembling the left handrail (Part 1) 770460 Assembling the left handrail (Part 2) 78

0461 Installation of left handrail (Part 2) (Brake cooling specification: If equipped) 790470 Assembling the rearview mirror 800471 Installation of rearview mirrors (Brake cooling specification: If equipped) 810480 Assembling the exhaust pipe 820485 Installation of oil cooler guard assembly (Brake cooling specification: If equipped) 830486 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) 850490 Applying the counterweight anti-slip 860500 Assembling the counterweight (WA900-3E0 standard specification) 870505 Assembling the counterweight (WA900-3E0 High-lift arm specification) 880510 Assembling the counterweight (WA800-3E0 Overseas general, optional specification and North American specification) 890520 Assembling the counterweight (WA800-3E0 Overseas general standard specification) 90

0530 Assembling the front axle lamp and connecting the harness 910540 Assembling the front lamp assembly 920550 Assembling the ROPS canopy assembly 930560 Assembling the antenna and work lamp 940570 Assembling the VHMS antenna (For VHMS specification only) 95

0580 Assembling the floor mat 960590 Assembling the front fender 970600 Engine starting procedure 980610 Bleeding the brake air 990615 Bleeding air from hydraulic circuit 1000620 Assembling the lift arm assembly (Part 1) 101

0630 Assembling the lift arm assembly (Part 2) 1020640 Connecting the remote grease tube 1030650 Assembling the bucket (Part 1) 1040660 Assembling the bucket (Part 2) 1050670 Assembling the bucket (Part 3) 1060680 Assembling the cover (Bottom of the counterweight) 107

0690 Feeding the grease 1080700 Work equipment hydraulic circuit air bleeding procedure 1090710 Adjusting the bucket positioner 1100720 Adjusting the new 2 stage (Overseas general standard) 1110730 Adjusting the new 2 stage (North American standard specification) 1120740 Assembling the lift arm angle sensor 113

0750 Adjusting the active working system and boom kick-out switch (Overseas general standard and domestic standard) 1140760 Touchup work 1150770 Applying the decal (For the overseas-directed products only) 116

No. Item Page

1

1 Dividing Process Overview (Major components alone)

1. Front frame subassembly

4. Rear axle assembly (With rear axle support)

7. Lift arm assembly

10. Floor handrail assembly

14. Muffler stack 15. Fuel tank assembly 16. Battery box assembly 17. Counterweight

11. Ladder assembly 12. Front fender 13. Front lamp assembly

8. Floor and cab assembly 9. ROPS canopy assembly

5. Wheel and tire assembly 6. Bucket assembly

2. Rear frame subassembly 3. Front axle assembly

2

2 Major Components Table of Dimensions

Unit name Q'ty Weight (kg)

L: Overall length (mm)

W: Overall width (mm)

H: Overall height (mm)

1 Front frame subassembly 1 11,500 4,830 2,250 3,150 2 Rear frame subassembly 1 26,000 6,425 3,200 3,155 3 Front axle assembly 1 8,514 4400 1600 1000

4 Rear axle assembly (with axle support) 1 8,500 4400 1800 1000

5 Wheel and tire assembly 4 14,380 1200 2800 28006 Bucket assembly 1 12,290 5200 2900 250078 Floor and cab assembly 1 1,000 2300 1800 21009 ROPS canopy assembly 1 1,387 2500 1900 2200

10 Floor handrail and rear access step assembly 1 650 1820 3940 1100

11 Ladder assembly 1 60 500 700 240012 Front fender 2 170 800 1700 140013 Front lamp assembly 2 65 800 700 130014 Muffler stack 2 50 400 400 170015 Fuel tank assembly 1 790 1800 1900 110016 Battery box assembly 1 580 900 900 800

17-1 Counterweight 1 2,900 3200 1200 600

17-2 Additional counterweight(Dimensions depend on ATT) 1 2,600 375 3,200 600

3

2 Major Components Table of Dimensions

Land transportation

Transportation means

Relevant specifications Provisions required for transportationWeight

(kg)Overall length

(mm)Overall width

(mm)Overall height

(mm)

Front frame assembly in

transportation by trailer

11,500 4,830 2,250 3,150

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]

Rear frame assembly in

transportation by trailer

26,000 6,425 3,200 3,155

Style

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

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

4

3 Work Space Layout

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

Tire and wheelassembly

Rear axle assembly

Front axle assembly

Front tankassembly

Counterweight assembly

ROPS canopy assembly

Bucket assembly

Light-weight units storage place

Front fenderLadder and muffler stackFront lampFloor handle

Compressor parts

Jigs and tools storage place

Floor and cabinassembly

Lift arm assembly

Bare machine

50 ton crane

50 to

n cr

ane

5

4 Schedule Table for Field Assembly

Day

Hou

r

Day

Hou

r

Con

ditio

n of

chas

sis

Rou

ghas

sem

bly

wor

kP

ositi

onin

g ch

assi

s

5 w

orke

rs

5 w

orke

rs2

wor

kers

5 w

orke

rs

Cou

plin

g fra

mes

Inst

allin

g co

unte

rwei

ght,

RO

PS

, and

lift

arm

Inst

allin

g, c

heck

ing,

and

adju

stin

g bu

cket

Che

ckin

g an

d to

uchu

p pa

intin

g

Pos

ition

ing

axle

sIn

stal

ling

tires

Inst

allin

g fu

el ta

nkan

d ca

bIn

stal

ling

step

han

drai

lsan

d ba

ttery

box

Cra

ne

Wor

ker

Con

ditio

n of

chas

sis

Rou

ghas

sem

bly

wor

k

Cra

ne

Wor

ker

1st d

ay

4th

day

5th

day

2nd

day

3rd

day

Cra

ne: 2

5 to

nC

rane

: 50

ton

Fram

e as

sem

bly

stan

dM

ount

ont

oco

unte

rwei

ght

mou

ntin

g en

dpl

ate.

Cra

ne: 2

5 to

nC

rane

: 50

ton

Fram

e as

sem

bly st

and

Mou

nt o

nto

coun

terw

eight

mou

nting

end

plate

.

6

5 Facility, Jigs and Tools

Drawing of frame deck

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

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

r RE

AR

/FR

ON

T(64

8)

For R

EA

R/F

RO

NT(

680)

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

Quantity For front 2 pieces For rear 2 pieces

7

5 Facility, Jigs and Tools

Tools used

No. Tool name Specification Q’ty Remarks

1 List of standard general toolsSpanner, ring spanner and box spanner chisel 2Screwdriver, hammer, monkey wrench, hex wrench, etc.

2 Power wrench 16 time 1 Front and rear axle mounts, ROPS canopy mount

3 Power wrench 4 time 1 Fuel tank mount4 Socket 60T (Entry point 38.1) × L: 84 1 For front and rear axle mounts

5 Socket 36T (Entry point 25.4) × L: 68 1 For rear axle support cover, tire and counterweight

6 Socket 46T (Entry point 25.4) × L: 72 1 For fuel tank and counterweight7 Socket 55T (Entry point 38.1) × L: 82 1 ROPS mount8 Socket 55T (Entry point 25.4) × L: 82 1 ROPS mount9 Extension bar Entry corner 12.7 × L:150 1 For fuel tank

10 Adapter Entry corner 19 × 12.7 × L:55 1 For fuel tank

11 Extension bar Entry corner 25.4 × L:160 1 For tire, counterweight and ROPS canopy

12 Preset torque wrench (Box type) 39.2 – 274.6 Nm {4 – 28 kgm} 1 For power wrench

13 Head replacement type preset torque wrench 58.8 – 137.3 Nm {6 – 14 kgm} 1 For connecting hoses and tubes

14 Head replacement type preset torque wrench 19.6 – 44.1 Nm {2 – 4.5 kgm} 1 For connecting hoses and tubes

15 Head replacement type preset torque wrench 29.4 – 68.6 Nm {3 – 7 kgm} 1 For connecting hoses and tubes

16 Head replacement type preset torque wrench (Spanner type)

Width across flats: 27 (Entry point: ø15) 19 (Entry point: ø12) 1 each For connecting hoses and tubes22 (Entry point: ø12) 24 (Entry point: ø12), 36, 41

17 Preset type torque wrench (Box type) 196.1 – 1,372.9 Nm {20 – 140 kgm} 1 For rear axle support cover,

counterweight

18 Preset type torque wrench (Box type) 490.3 – 2,059.4 Nm {50 – 210 kgm} 1 For counterweight

19 Preset type torque wrench (Box type) 58.8 – 411.9 Nm {6 – 42 kgm} 1 For rear axle support cover

20 Impact wrench GT-P8M or equivalent 121 Impact wrench GT-P14M or equivalent 122 Impact wrench GT-S22M or equivalent 1 For tire and ROPS canopy

23 Adapter Entry corner 19 × 25.4 × L:71 1 For power wrench and torque wrench

24 Adapter Entry corner 12.7 × 9.5 × L:41 1 For power wrench and torque wrench

25 Large hammer 10 pounds 126 Air grinder — 1

27 Bar Large, medium and small 2 each For adjustment of holes and moving heavy stuff

28 Round mandrel — 2 For adjustment of holes29 Grease gun (Hand pump type) Capacity about 300 cc 1 For applying grease to pins30 Oil jack Capacity 1,000 – 2,000 cc 1 For bleeding air from brake line

31 Vinyl hose Inside diameter: ø6.5 – ø7.0, L: 1,000 – 1,500 1 For bleeding air from brake line

32 Head replacement type preset torque wrench 196.1 Nm {20 kgm} 1 For connecting hoses and tubes

33 Head replacement type preset torque wrench 176.5 Nm {18 kgm} 1 For connecting hoses and tubes

8

5 Facility, Jigs and ToolsFacilities used

Tools and facilities used

Lifting tools used

No. Tool name Specification Q’ty Remarks1 Crane Min. 50 ton 22 Forklift Min. 2 ton 13 Compressor Capacity: Min. 32l 1 For impact wrench and bleeding air4 Lever block 1 ton 3 For holding cylinder and drive shaft5 Footstall (Work table) 4 stage (About 1.5 m high) 3 For work6 Steel plate (Large) 9 × 1,219 × 2,438 4 For setting bare machine in place7 Steel plate (Large) 25 × 250 × 600 4 For setting bare machine in place

8 Crosstie400 × 400 × 900 14 For setting bare machine in place200 × 400 × 800 4 For setting bare machine in place

9 Air grease gun Capacity: 18l 110 Air conditioner gas charge Gauge manifold, leak detector 111 Tester 1

No. Sling name Specification Q’ty Remarks

1 Front frame lifting tool 2 point lift (Sling hook (SL) of L = 2,250 and ø20 in chain diameter)) 1 See the figure below

2 Rear frame lifting tool Balance 2 point lift (Sling hook (SL) of ø20 in chain diameter)) 1 See the figure below

3 Rear axle lifting tool 2 point lift (Club hook (G) of L = 5,500 and ø16 in chain diameter)) 1 See the figure below

4 Nylon sling 50 × 2,000 2 Holding axle support and cylinder

5 Front and Rear axle lifting tool

Balance 2 point lift (Sling hook (SL) of ø16 in chain diameter)) 1

See the figure belowBalance 2-point lift (Club hook (G) of ø12.5 in chain diameter)) 1

6 Nylon sling for drive shaft 50 × 5,000 1 See the figure below

7 Fuel tank lifting tool 2 point lift (Sling hook (SL) of L = 5,000 and ø6.3 in chain diameter)) 2 See the figure below

8 Floor and cab assembly lifting tool 2 point lift (Sling hook (SL) of L = 2,000 and ø6.3 in chain diameter)) 2

9 Nylon sling 150 × 10,000 1 Tire lifting tool

10 Wire slingWithstand load 15 tons and L = 2,500 2 For removing crossties under

machine body (Front lifting)Withstand load 11 tons and L = 2,000 1 Lift arm lifting tool

11 Shackle For 2 ton, 5 ton, 10 ton and 15 ton 2 each Lift arm lifting tool12 Eyebolt (Top) 2 and (bottom ) 113 Nylon sling 25 × 2,000

1. Front frame sling

5. Front/Rear axle sling 7. Fuel tank sling8. Floor and cab assembly sling

2. Rear frame sling 3. Rear axle sling

Chain diameter

Chain diameter

Chain diameter

Chain diameter

Chain diameter

Chain diameter

Chain diameter

9

6 List of Oil, Grease and Paints

Oil, grease, paints and others

When the front and rear frames were divided, following must be additionally used.

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

No. Oil, grease and paints Specification Quantity

1 Extreme-pressure added with molybdenum disulfide (KES LM-P or equivalent) 500 ml

2 Extreme-pressure added with molybdenum disulfide (KES LM-P or equivalent) 10l

3 Fuel Diesel fuel Appropriate amount (Full capacity is 1,200 l)4 Paint for touchup Black5 Air conditioner gas R134A gas can (400 g) 16 Window washer liquid 1l container × 2

No. Oil, grease and paints Specification Quantity1 Hydraulic oil (KES EO10-CD or equivalent) 1,000l

10

Selective use of fuel and lubricating oil depending on the given atmospheric temperaturet 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 inspectionand maintenance.

a Whenever starting the engine with atmospheric temperature at 0°C or below, EOS0W30 or EOS5W40 must be usedfor the engine oil pan although the temperature may usually rise up to 10°C or above.

t CoolantSince the Komatsu genuine Super Coolant (AF-NAC) is added to the coolant, change of the coolant is unnecessary as longas 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 Operationand Maintenance Manual.

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

Assembly procedureOil, grease and coolantNo. 0010

11

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.)

Assembly procedureOil, grease and coolant levelNo. 0020

Lubricating points Types of oil Specified oil level (l)

Volume of replaced oil (l)

Volume of refilled oil (l)

Engine oil pan Engine oil 140 130

Transmission case Power train oil 164 140

Hydraulic oil systemHydraulic oil

1,065 725Engine oil

Brake oil tank Power train oil 42 31

Front axleAxle oil

360 each 360 each

Rear axle 360 each 360 each

Fuel tank Diesel fuel 1,555 —

Cooling system Super coolant 337 —

Cautions Special tool Necessary EquipmentName Q’ty Name Q’ty

Oth

ers

12

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.

Assembly procedureSetting rear frame in placeNo. 0030

No. Part No. Part name Q’ty State of part (Parts list No.)(1) 427-46-2295A Rear frame assembly 1 Separately packed (No.W9E-030)


Lifting tool: 2 point lift (L = 2,250, ø20) 1

Oth

ers

13

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.

Assembly procedureSetting front frame in placeNo. 0040

No. Part No. Part name Q’ty State of part (Parts list No.)(1) 427-N96-215A Front frame assembly 1 Separately packed (No.W9E-040)


Lifting tool: 2 point lift (L = 2,250, ø20) 1

Oth

ers

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

Lumber

Deck

Steel plate

1,000 mm

14

Assembly procedureJoining front and rear framesNo. 0050

Cautions Special tool Necessary Equipment

w Be sure, in the assembly, to apply sufficientamount of grease to the inside of the bearing.

w Fill the upper hinge and lower hinge shaftswith grease until it flows out the dust seal afterassembly.

w Touch up the black bolt and the machined sur-face.

Name Q’ty Name Q’tyImpact wrench (Socket #17, #30, #36, and #46) 50 ton crane 2Torque wrench (Set 549, 927, and 1,715 Nm) Lifting tool (For front frame and rear frame) 1 eachJack, thickness gauge and copper hammer Air compressor 1Others

Tightening torque : 490 – 608 Nm {50 – 62 kgm}

Coating with LM-P

Coating with LM-P

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

Coating with LT-2

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

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

Coating with LT-2Coating with LT-2

No. Part No. Part name Q’ty State of part (Parts list No.)(1) 427-46-11161 Shaft 1 Temporarily installed on the rear frame(2) 427-46-11190 Retainer 1 Temporarily installed on the rear frame(3) 427-46-11440 Bushing 1 Temporarily installed on the rear frame(4) 01010-62065 Bolt 4 Temporarily installed on the rear frame(5) 01010-62070 Bolt 6 Temporarily installed on the rear frame(6) 01643-32060 Washer 10 Temporarily installed on the rear frame(7) 427-46-11312 Shaft 1 Separately packed (No.W9E-050)(8) 01010-63075 Bolt 1 Separately packed (No.W9E-050)(9) 427-46-11480 Bushing 1 Press fitted to the rear frame(10) 427-46-11490 Bushing 1 Press fitted to the rear frame(11) 427-46-11391 Bushing 1 Temporarily installed on the rear frame(12) 427-46-11411 Shim t = 0.1 20 Temporarily installed on the rear frame(13) 427-46-11421 Shim t = 0.5 24 Temporarily installed on the rear frame(14) 427-46-11431 Retainer 1 Temporarily installed on the rear frame(15) 01011-63065 Bolt 4 Temporarily installed on the rear frame(16) 01643-33080 Washer 4 Temporarily installed on the rear frame(17) 01010-62495 Bolt 10 Temporarily installed on the rear frame(18) 01643-32460 Washer 10 Temporarily installed on the rear frame(19) 427-46-11330 Plate 2 Temporarily installed on the front frame(20) 01010-61025 Bolt 4 Temporarily installed on the front frame(21) 01643-31032 Washer 4 Temporarily installed on the front frame(22) 427-46-11321 Bushing 1 Temporarily installed on the front frame

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

15

a Front frame and rear frame joining procedure1. Make sure bushings ((9): 427-46-11480 and (10): 427-46-11490) are press fitted to the rear frame.2. Assemble bushing ((22): 427-46-11321) to the lower hinge of the front frame.3. Assemble bushing ((3): 427-46-11440) to the upper hinge of the rear frame.4. 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}

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 removingthe 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 timesusing 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 frameat 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 Step10 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.

Assembly procedureFront and rear frames joining procedureNo. 0060


w Be sure, in the assembly, to apply sufficientamount of grease to the inside of the bearing.

w Fill the upper hinge and lower hinge shaftswith grease until it flows out the dust seal afterassembly.

w Touch up the black bolt and the machined sur-face.

Name Q’ty Name Q’tyImpact wrench (Socket #17, #30, #36, and #46) 50 ton crane 2Torque wrench (Set 549, 927, and 1,715 Nm) Lifting tool (For front frame and rear frame) 1 eachJack, thickness gauge and copper hammer Air compressor 1

Oth

ers

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.

16

Assembly procedureAssembling the steering pinNo. 0070


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

Name Q’ty Name Q’tyImpact wrench 1 Air compressor 1Socket (22 mm, 24 mm) 1 eachSpanner (10 mm, 14 mm) 1 eachTorque wrench (385 Nm {39.3 kgm} set) 1

Oth

ers

Tightening torque : 343 – 427 Nm {35.0 – 43.5 kgm}

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.

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.

Machine front side

Machine center

Rear fram

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

e

Steering cylinder

FITTING (07020-00900) DIRECTIONTO BE SYMMETRICAL.

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.

For the grease fitting mounting direction, see the figure below.

No. Part No. Part name Q’ty State of part (Parts list No.)(1) 427-46-12410 Shaft 2 Temporarily installed on the rear frame(2) 427-46-12420 Plate 2 Temporarily installed on the rear frame(3) 427-46-12430 Plate 2 Temporarily installed on the rear frame(4) 427-46-12440 Bushing 2 Temporarily installed on the rear frame(5) 427-46-12450 Bushing 2 Temporarily installed on the rear frame(6) 421-70-11331 Shim 16 Temporarily installed on the rear frame(7) 01010-81475 Bolt 12 Temporarily installed on the rear frame(8) 01643-31445 Washer 12 Temporarily installed on the rear frame(9) 01010-81635 Bolt 2 Temporarily installed on the rear frame

(10) 01643-31645 Washer 4 Temporarily installed on the rear frame(11) 421-70-11280 Washer 2 Temporarily installed on the rear frame(12) 6141-55-5630 Nipple 2 Temporarily installed on the rear frame(13) 07020-00900 Fitting 2 Temporarily installed on the rear frame

17

Assembly procedure Assembling the center drive shat (Center support – Transmission)No. 0080


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.

Name Q’ty Name Q’tyImpact wrench 1 Air compressor 1Socket (27 mm, 30 mm) 1 eachTorque wrench (385 Nm {39.3 kgm} set) 1

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Coating with LT-2.


Coating with LT-2.

Center support

Grease nipple position

Grease nipple position

Assemble setting the longer side to the transmission

Assemble setting the shorter side to the center supportBoth the front and rear must be

directed in the same direction.

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

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

Grease nipple position(Viewed from the machine rear side)

Points to notice1. 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.

No. Part No. Part name Q’ty State of part (Parts list No.)(1) 427-46-22531 Guard 1 Temporarily installed on the rear frame(2) 01010-82045 Bolt 2 Temporarily installed on the rear frame(3) 01643-32060 Washer 2 Temporarily installed on the rear frame(4) 427-20-12211 Shaft 1 Separately packed (No.W9E-080)(5) 01050-61895 Bolt 4 Separately packed (No.W9E-080)(6) 01050-61895 Bolt 4 Separately packed (No.W9E-080)

1. Remove (1) and (3) being temporari-ly 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.

18

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.)

Assembly procedureConnecting the pipes - Part 1No. 0090


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

Name Q’ty Name Q’tyImpact wrench 1 Air compressor 1Socket (19 mm, 22 mm) 1 each

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1. Remove the blind parts on the pipe.2. Make sure they are free from foreign substances.3. Connect the hose.4. 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.

Assembly procedureConnecting the pipe - Part 2No. 0100


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

Name Q’ty Name Q’tyTorque wrench (49 Nm {5 kgm}, 78.5 Nm {8 kgm} set) 1 each

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(1) – (6) Tightening torque : 54 – 93 Nm {5.5 – 9.5 kgm}

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

PPC control valve (P4) lineYellow band

PPC control valve (P2) lineRed band

PPC control valve (P1) lineOrange band

PPC control valve (P3) lineBlue band

S/T (L) line

S/T (R) line

Brake (Slack adjuster A) line

Brake (Slack adjuster) line

Brake (Valve T) line

Brake (Valve P) line

Viewed from the machine right side

Viewed from the machine left side

Viewed from the machine right side

20

1. Remove the pipe blocking parts.2. Check that no foreign matter is sticking.3. Connect the hoses.4. Do not connect the hoses of all lines (1) – (11) at a time but perform work 1 – 3 securely for them one by one.

Assembly procedure Connection of piping (Part 2) (Riotinto specification: If equipped)No. 0105


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

Name Q’ty Name Q’tyTorque wrench (49 Nm {5 kgm}, 78.5 Nm {8 kgm} set) 1 each

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PPC control valve (P4) lineYellow band

PPC control valve (P2) lineRed band

PPC control valve (P1) lineOrange band

PPC control valve (P3) lineBlue band

Steering (L) line

Steering (R) line

Breather remote line

Brake (Slack adjuster A) line

Brake (Slack adjuster) line

Brake (Valve T) line

Brake (Valve P) line

Tightening torque54 – 93 Nm {5.5 – 9.5 kgm}



–

Machine seen from right

Machine seen from right

–

21

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

Assembly procedureConnecting the auto-greasing pipeNo. 0110


Torque wrench (103 Nm {10.5 kgm} set) 1

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Connect

Frame connection viewed from the left side

Connect

View Z

22

1. Set the front axle assembly and rear axle assembly (with axle support) in the machine body assembling area in the 5,450mm 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.

Assembly procedureSetting the axle in place and assembling the supportNo. 0120


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

Name Q’ty Name Q’ty

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Setting the front and rear axles in place

Ground levelFront axle Rear axle

Setting dimension 5,450 mm

Setting dimension 5,450 mm

SupportLifting load: 300 kg, 50 × 2,000 2 nylon slings

Wheelbase

Steel plateSteel plate

8,404 kg 7,912 kg

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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 depressionof 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 situ-ation allows.(Leaned machine makes the pinhole adjustment difficult when installing the lift arm.)

Assembly procedureSetting the bare machine in placeNo. 0130


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Crane: 50 ton

Ground levelFront axle Rear axle

Crane: 50 ton

2,250

3,900

2,8502,50

0

Details of lifting tool

For front frameLifting Load: 11.5 tonCrane: 50 ton

For rear frameLifting Load: 20 tonCrane: 50 ton

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Assembly procedureAssembling the rear axleNo. 0140


Power wrench 1Torque wrench 1Socket 60 mm 1Socket 36 mm 1

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(See No.0150)

(See No.0150)


Rear axle assembly

Axle support assembly

Weight = 7,914 kg

Coat the front and rear face of thrust washer (9) with grease (G2-LI).

When assembling, care must be exercised not to collapse the brake pipe on both side.(Space between the frame and rear axle is limited.)

No. Part No. Part name Q’ty State of part (Parts list No.)(1) 427-23-20200 Rear axle assy 1 Separately packed (No.W9E-140)(2) 427-46-12130 Bolt 4 Temporarily installed on the rear axle(3) 01643-33990 Washer 8 Temporarily installed on the rear axle(4) 01580-03931 Nut 4 Temporarily installed on the rear axle(5) 427-46-12180 Cover thrust 1 Separately packed (No.W9E-140)(6) 01011-82400 Bolt 16 Temporarily installed on the machine(7) 01643-32460 Washer 16 Temporarily installed on the machine(8) 04530-11018 Bolt eye 1 Separately packed (No.W9E-140)(9) 07029-00000 Valve 1 Separately packed (No.W9E-140)

(10) 427-46-12161 Washer thrust 2 Temporarily installed on the rear axle(11) 427-46-12171 Plate thrust 1 Temporarily installed on the rear axle(12) 01011-82420 Bolt 16 Temporarily installed on the rear axle(13) 01643-32460 Washer 16 Temporarily installed on the rear axle

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).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.

25

Assembly procedureRear axle rear side cover assembling procedureNo. 0150


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


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Portion A

View Y

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.)

Move the cover to the bottom of the installation position using the forklift and then install it aligning position ofthe 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

26

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.

Assembly procedureConnecting the rear axle pipeNo. 0160


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Torque converter Rear axle

Top view of rear axle Connection tightening torque : 84 – 132 Nm {8.5 – 13.5 kgm}

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

Connect the breather hose to the rear axle side connector.

27

1. Fix plate (1) to the rear axle with the rear axle bolt.

2. Tighten parts (2) – (5) permanently.

Assembly procedure Fixing of rear axle piping (Brake cooling specification: If equipped)No. 0165

No. Part No. Part name Q’ty State of part (Parts list No.)(1) 427-S05-6250 Plate 1 Temporarily installed on the machine(2) 07283-33450 Clip 2 Temporarily installed on the machine(3) 07283-53444 Seat 2 Temporarily installed on the machine(4) 01597-01009 Nut 4 Temporarily installed on the machine(5) 01643-31032 Washer 4 Temporarily installed on the machine


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Rear axle seen from rearFixing: Fix together with axle bolt.

28

1. Connect the piping to elbow (1) installed to the rear axle.

Assembly procedure Connection of rear axle piping (Riotinto specification: If equipped)No. 0166

No. Part No. Part name Q’ty State of part (Parts list No.)(1) 427-Z89-3880 Elbow 1 Installed to rear axle


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Rear frame seen from left View Z: Rear frame seen from above

Rear frame seen from left rear.

29

1. Connect hose (1) installed to the rear axle.

Assembly procedure Fixing of rear axle piping (Brake cooling specification: If equipped)No. 0167

No. Part No. Part name Q’ty State of part (Parts list No.)(1) 07296-21213 Hose 1 Installed to rear axle(2) 07371-31255 Flange 2 Separately packed (No. W9E-167)(3) 07375-21035 Bolt, sems 4 Separately packed (No. W9E-167)(4) 07000-F3038 O-ring 1 Separately packed (No. W9E-167)


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Connection

Lower part of rear axle

To rear axle

30

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.

Assembly procedure Connection of cooling line piping (Brake cooling specification: If equipped)No. 0168

No. Part No. Part name Q’ty State of part (Parts list No.)(1) 02896-21018 O-ring 1 Installed to machine(2) 07371-31255 Flange 2 Temporarily installed on the machine(3) 07375-21035 Bolt, sems 4 Temporarily installed on the machine(4) 07000-F3038 O-ring 1 Installed to machine(5) 01643-31032 Washer 1 Temporarily installed on the machine(6) 01011-81020 Bolt 1 Temporarily installed on the machine(7) 07095-20627 Cushion 1 Temporarily installed on the machine(8) 04434-53412 Clip 1 Temporarily installed on the machine(9) 01596-01009 Nut 1 Temporarily installed on the machine


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Connection: Check O-ring.


Inside of rear frame seen from left

Fixing

31

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 ofthe front, center and rear drive shafts.)

3. Feed grease (molybdenum disulfide grease) to the grease fitting for the axle support and drive shaft.

Assembly procedure Assembling the rear drive shat (Transmission – Rear axle)No. 0170

No. Part No. Part name Q’ty State of part (Parts list No.)(1) 427-20-12211 Rear drive shaft 1 Separately packed (No.W9E-170)(2) 01050-61895 Bolt 8 Separately packed (No.W9E-170)


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When assemble, set the male side in the front (transmission side).

Rear axle

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.

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




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Assembly procedureAssembling the front axle No. 0180


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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)

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

Weight =

Position of lifting tool

a

8,404 kg

No. Part No. Part name Q’ty State of part (Parts list No.)(1) 427-22-2020A Front axle 1 Separately packed (No.W9E-180)(2) 427-46-11452 Bolt 16 Temporarily installed on the axle skid(3) 01643-33990 Washer 32 Temporarily installed on the axle skid(4) 01580-03931 Nut 16 Temporarily installed on the axle skid

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.

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1. Fix the front axle piping.

Assembly procedure Fixing of front axle piping (Brake cooling specification: If equipped)No. 0182

No. Part No. Part name Q’ty State of part (Parts list No.)(1) 427-S05-3661 Bracket 1 Installed to machine(2) 01024-81230 Bolt, sems 2 Installed to machine(3) 07283-33450 Clip 1 Separately packed (No. W9E-182)(4) 07283-53444 Seat 1 Separately packed (No. W9E-182)(5) 01597-01009 Nut 2 Separately packed (No. W9E-182)(6) 01643-31032 Washer 2 Separately packed (No. W9E-182)(7) 01024-81225 Bolt, sems 2 Separately packed (No. W9E-182)


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Control valve

To mounting position on left inside of front frame

Mounting position

Left side view of front frame

34

Assembly procedure Connection of front axle piping (Brake cooling specification: If equipped)No. 0185


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Front frame seen from left

Front frame seen from above


To right front wheel brake

To front axle

To left front wheel brakeView Z

Connection: Check O-ring

1. Connect front axle piping.

35

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.

Assembly procedureConnecting the front axle pipeNo. 0190


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Connect the hose to the parking cylinder

Fix it to the clip.

Connect the hose to the front axle brake tube (1 each on both sides)

Front view of front axle


36

Assembly procedure Connection of front axle piping (Riotinto specification: If equipped)No. 0195

No. Part No. Part name Q’ty State of part (Parts list No.)(1) 56B-61-13760 Elbow 1 Installed to hose


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Front frame seen from right

Front frame seen from above

1. Connect the piping to the front axle.

37

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 thefront, center and rear drive shafts.))

3. Feed grease (molybdenum disulfide grease) to the grease fitting for the axle support and drive shaft.

Assembly procedure Connecting the front drive shat (Front axle – Center support)No. 0200

No. Part No. Part name Q’ty State of part (Parts list No.)(1) 01050-61895 Bolt 4 Separately packed (No.W9E-200)


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

Front Axle

Front drive shaft

Thicker one is set on the front axle side

Center support




38

Assembly procedure Connecting the axle oil temperature sensor (For VHMS specification only)No. 0210

No. Part No. Part name Q’ty State of part (Parts list No.)(1) 01024-81055 Bolt 2 Temporarily installed on the front axle(2) 04434-51010 Clip 2 Temporarily installed on the front axle


Impact wrench 1Socket (17 mm) 1

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Connect

Front axle

View Z

Top view of front frame

Detail of backside of A section

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.

39

Assembly procedureAssembling the tiresNo. 0220

No. Part No. Part name Q’ty State of part (Parts list No.)(1) 427-30-1240A Wheel and tire assembly 4 Separately packed (No.W9E-220)(2) 426-22-12930 Nut 212 Separately packed (No.W9E-220)(3) 01643-32460 Washer 212 Separately packed (No.W9E-220)


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.

Name Q’ty Name Q’ty36 T socket 1Torque wrench 1Extension bar 1

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Tightening torque : 736 – 912 Nm {75 – 93 kgm}

Nylon sling

Hitch in the squeezing manner

(Weight of tire and wheel assembly: 3,500 kg)

(150 × 10,000)

Assembling of wheel and tire assembly

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

1. Prior to assembling, remove the grease on the stud bolt.

2. Lift a tire using the crane, install on the axle and then assemble the nut to it.(Use care not to damage the tire air injection tube.)

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

4. Tighten the nut to the specified torque using the torque wrench.

5. Apply chocks to the tires and remove the crossties under the machine.

40

Assembly procedureAssembling the fuel tankNo. 0230


Impact wrench 1Power wrench (×4 wrench) 1Torque wrench (44 Nm set) 1Extension 1Socket 46 mm 1

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1) Remove

2) Loosen

3) Remove beforehand


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

Fuel level sensor

Connect fuel tank level sensor connector (CN R08)

Fuel tank

View ZNo. Part No. Part name Q’ty State of part (Parts list No.)(1) 01011-63000 Bolt 6 Temporarily installed on the fuel tank(2) 01643-33080 Washer 6 Temporarily installed on the fuel tank(3) 416-855-1190 Shim 10 Separately packed (No.W9E-230)

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

2. Prior to the assembling, clean the contact face of the mount.

3. 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.

41

Assembly procedure Installation of fuel tank (Riotinto specification: If equipped)No. 0235


Impact wrench 1Power wrench (×4 wrench) 1Torque wrench (44 Nm set) 1Extension 1Socket 46 mm 1

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1) Remove.

Tightening torque1,520 – 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 ZConnect fuel level sensor connector (CN R08).

No. Part No. Part name Q’ty State of part (Parts list No.)(1) 01011-63000 Bolt 6 Temporarily installed on the fuel tank(2) 01643-33080 Washer 6 Temporarily installed on the fuel tank(3) 416-855-1190 Shim 10 Separately packed (No.W9E-235)

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.

42

Assembly procedureFixing the drain pipeNo. 0240


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Engine oil pan drain

Fuel tank viewed from the left side

Fuel tank viewed from the left side

Torque converteroil cooler

Torque converter cooler drain

Radiator drain

Radiator

No. Part No. Part name Q’ty State of part (Parts list No.)(1) 01024-81035 Bolt 2 Temporarily installed on the fuel tank(2) 01435-01035 Bolt 4 Temporarily installed on the fuel tank(3) 08036-20314 Clip 5 Temporarily installed on the fuel tank(4) 01024-81020 Bolt 5 Temporarily installed on the fuel tank

1. Fix the engine oil pan drain.2. Fix the torque converter cooler drain.3. Fix the radiator drain.4. Fix the torque converter cooler drain pipe

and radiator drain pipe.

43

1. Fix the torque converter cooler drain piping.

Assembly procedure Fixing of torque converter cooler drain piping (Riotinto specification: If equipped)No. 0245

No. Part No. Part name Q’ty State of part (Parts list No.)(1) 424-06-12780 Clip 2 Temporarily installed on the fuel tank(2) 01024-81020 Bolt 2 Temporarily installed on the fuel tank


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Torque converter oil cooler Torque converter cooler drain

Fuel tank seen from left

Rear frame

Engine oil pan drain

Radiator drain

Torque converter cooler drain

Detail of part P

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

44

Assembly procedureConnecting the fuel pipeNo. 0250



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Connection of the fuel return hose

Connection of the spill hose

Engine viewed from the left side

Engine viewed from the right side

Connection of the suction hose

Connection of the fuel return hose

Connection of the suction hose

Connection of the spill hose

No. Part No. Part name Q’ty State of part (Parts list No.)(1) 04434-52110 Clip 2 Temporarily installed on the frame(2) 07095-20314 Cushion 2 Temporarily installed on the frame(3) 04434-51410 Clip 2 Temporarily installed on the frame(4) 01024-81020 Bolt 3 Temporarily installed on the frame(5) 04434-53412 Clip 2 Temporarily installed on the frame(6) 07095-20625 Cushion 2 Temporarily installed on the frame(7) 04434-52712 Clip 3 Temporarily installed on the frame(8) 04434-52110 Clip 2 Temporarily installed on the frame(9) 07095-20314 Cushion 2 Temporarily installed on the frame(10) 01024-81020 Bolt 4 Temporarily installed on the frame

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)

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

45

Assembly procedureFixing the engine drain hosesNo. 0260



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Connect

ConnectMachine left sideDetail of connection

Machine right sideDetail of connection

Rear frame viewed from the left side

Connect

Connect

Fuel tank

Detail of rear side

Breather drain (Machine right side)

Breather drain (Machine left side)

Muffler drain (Machine left side)

630(clamp position)

290(clamp position)

No. Part No. Part name Q’ty State of part (Parts list No.)(1) 04434-52512 Clip 1 Temporarily installed on the rear frame(2) 04434-51510 Clip 1 Temporarily installed on the rear frame(3) 01024-81016 Bolt 2 Temporarily installed on the rear frame(4) 07285-00220 Clip 2 Temporarily installed on the drain hose(5) 07285-00130 Clip 1 Temporarily installed on the drain hose

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

46

1. Remove (2) – (4) being temporarily installed on the hydraulic tank.

2. Assemble ladder (1).

Assembly procedureAssembling the hydraulic tank ladderNo. 0270

No. Part No. Part name Q’ty State of part (Parts list No.)(1) 427-54-26950 Ladder (R.H.) 1 Separately packed (No.W9E-270)(2) 01010-81635 Bolt 2 Temporarily installed on the hydraulic tank(3) 01643-31645 Washer 2 Temporarily installed on the hydraulic tank(4) 01024-D1225 Bolt 2 Temporarily installed on the hydraulic tank


Impact wrench 1Socket (19 mm, 24 mm) 1 each

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Hydraulic tank

47

1. Remove (2) – (4) being temporarily installed on the machine.

2. Assemble cab assembly (1).

Assembly procedureAssembling the floor and cab assemblyNo. 0280

No. Part No. Part name Q’ty State of part (Parts list No.)(1) 427-56-2130A Cab assembly 1 Separately packed (No.W9E-280)(2) 421-54-23260 Plate 4 Temporarily installed on the machine(3) 01596-01615 Nut lock 4 Temporarily installed on the machine(4) 425-70-11290 Washer 4 Temporarily installed on the machine


Torque wrench (277 Nm {28.2 kgm} set) 1

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

Remove the undercover in the cab rear side beforehand.

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

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

In cab

a

a

48

1. Connect the hot water hose.2. Connect the air conditioner hose.3. Connect the drain hose.

Assembly procedureConnecting the air conditioner hoseNo. 0290


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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)

Inside of the rear frame viewed from the side face

Drain hose To be fixed with the welded clip in 3 places

Note: Confirm the hose size

Connect the air conditioner coupler

Detail of A section

View Z

49

Assembly procedureConnecting the brake lineNo. 0300


Torque wrench 1

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Connect

Cab viewed from the left side


Connect


Connect


ConnectRouted to the rear brake


ConnectRouted to the front brake

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.

50

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.)

Assembly procedureConnecting the window washer hoseNo. 0310


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View Z

Front washer hose(Red taping)

Connect(Match the color)

Cab viewed from the top

Rear washer hose

51

Assembly procedureConnecting the PPC line hoseNo. 0320


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PPC control valve

Frame connection viewed from the top

Connect

ConnectFrom hydraulic oil cooler From PPC

relief valve

Connect

Connect

Connect

Connect

View Z

View X

Front side of

machine

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.

52

Assembly procedureConnecting the floor wiring harnessNo. 0330


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Connect

ConnectConnect

Connect

Connect

Connect

Connect View Z

View X

Top view of the floor frame

Ground cableConnect

No. Part No. Part name Q’ty State of part (Parts list No.)

(1) 01024-81016 Bolt 1 Installed temporarily on the floor support

(2) 04434-51410 Clip 1 Installed temporarily on the floor support


(4) 04434-51010 Clip 2 Installed temporarily on the floor support


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)

53

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

Assembly procedure Connection of floor wiring harness -1 (Riotinto specification: If equipped)No. 0333


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Floor

Connection: CN CAB

Connection: CN CB1

Floor seen from rear

54

1. Remove parts (1) – (3) installed to the cab.

2. Fix the wiring harness with parts (1) – (3).

3. Connect the connector. (CN RF)

Assembly procedure Connection of floor wiring harness -2 (Riotinto specification: If equipped)No. 0334

No. Part No. Part name Q’ty State of part (Parts list No.)(1) 421-877-2250 Spacer 3 Temporarily installed on the machine(2) 04434-51010 Clip 3 Temporarily installed on the machine(3) 01024-81060 Bolt, sems 3 Temporarily installed on the machine


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Connection: CN RF

Cab seen from rear

Marked : 3 places

55

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.

Assembly procedure Connecting the link for AJSS (For AJSS specification only)No. 0340

No. Part No. Part name Q’ty State of part (Parts list No.)(1) 01643-31445 Washer 1 Temporarily installed on the lever(2) 01595-01411 Nut 1 Temporarily installed on the lever


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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.

a This process is required for the AJSS specification only.

56

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.)

Assembly procedureCalibration of the AJSS angle and frame offset angleNo. 0345


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Adjusting connector

Front side of the right hand console

Front side of machine

57

Assembly procedure Assembling the auto-greasing pump and connecting the pipe (WA900-3E0 North American specification)No. 0350


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Grease pump

Top view of the left platform

Section A-A

Connect

Connect

No. Part No. Part name Q’ty State of part (Parts list No.)(1) 427-S95-A24A Hydraulic pump assembly 1 Separately packed (No.W9E-350)(2) 01435-01045 Bolt 4 Temporarily installed on the platform(3) 415-64-13120 Washer 8 Temporarily installed on the platform(4) 415-64-13130 Cushion 4 Temporarily installed on the platform(5) 421-62-18560 Spacer 4 Temporarily installed on the platform(6) 419-43-17930 Cushion 4 Temporarily installed on the platform

1. Remove (2) – (6) being temporarily installed on the platform.

2. Assemble the grease pump.

3. Connect 4 pipes.

58

Assembly procedureAssembling the floor coverNo. 0360

No. Part No. Part name Q’ty State of part (Parts list No.)(1) 427-54-24311 Cover 1 Separately packed (No.W9E-360)(2) 01024-81020 Bolt 4 Temporarily installed on the floor(3) 427-54-24321 Cover (L.H.) 1 Separately packed (No.W9E-360)(4) 427-54-24331 Cover (R.H.) 1 Separately packed (No.W9E-360)(5) 01024-81025 Bolt 6 Temporarily installed on the floor(6) 424-09-12650 Washer 6 Temporarily installed on the floor(7) 427-S95-5250 Cover 1 Temporarily installed on the floor(8) 01024-81020 Bolt 7 Temporarily installed on the floor



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Floor frame

Floor support

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

2. Assemble floor cover (1).

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

59

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.

Assembly procedureRefilling the window washerNo. 0370


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Washer tank position(In the bulkhead)

Water filler port

60

Assembly procedureAssembling the battery boxNo. 0380



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View X

View Z

Rear frame

No. Part No. Part name Q’ty State of part (Parts list No.)(1) 427-06-2463A Battery box, L.H. 1 Separately packed (No.W9E-380)(2) 427-06-2464A battery box, R.H. 1 Separately packed (No.W9E-380)(3) 01011-62450 Bolt 4 Temporarily installed on the rear frame(4) 01011-62470 Bolt 4 Temporarily installed on the rear frame(5) 01643-32460 Washer 8 Temporarily installed on the rear frame(6) 01024-D1225 Bolt 4 Separately packed (No.W9E-380)

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.

61

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

Assembly procedureConnecting and fixing the battery wiringNo. 0390

Cautions

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

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No. Part No. Part name Q’ty State of part (Parts list No.)(1) 08038-00035 Cap 2 Separately packed (No.W9E-390)(2) 424-09-12530 Cap 2 Temporarily installed on the battery box(3) 04434-51410 Clip 3 Temporarily installed on the battery box(4) 04434-51710 Clip 1 Temporarily installed on the battery box(5) 04434-51910 Clip 3 Temporarily installed on the battery box(6) 04434-52310 Clip 1 Temporarily installed on the battery box(7) 01024-81020 Bolt 6 Temporarily installed on the battery box

Left side of the battery box

Connect

Connect

View X

View A

View Y

View B

Right side of the battery box

62

1. Connect the wiring on the right side of the battery.

Assembly procedure Wiring on right side of battery (Riotinto specification: If equipped)No. 0393

No. Part No. Part name Q’ty State of part (Parts list No.)(1) 08038-00035 Cap 1 Temporarily installed on the machine(2) 04434-51710 Clip 1 Temporarily installed on the machine(3) 01024-81020 Bolt, sems 1 Temporarily installed on the machine


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


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Connection: Check mark "4".

Connection: Check mark "2".Wiring harness

ConnectionR.H. battery box

Detail of R.H. battery box

View X

Connection: CN RA1

Connection: Check mark "6".

Detail of part P View Z

L.H. battery boxFixing: Use bolts and clips installed temporarily.

Connection: CN RA3

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

63

1. Pull the wiring into the battery on the left side.

Assembly procedure Wiring on left side of battery -1 (Riotinto specification: If equipped)No. 0394

No. Part No. Part name Q’ty State of part (Parts list No.)(1) 6151-53-8280 Clip 4 Temporarily installed on the machine(2) 01024-81020 Bolt, sems 4 Temporarily installed on the machine




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Pull wiring harness into L.H. battery box

Pull cable into L.H. battery box

Shorter end

L.H. battery box

View Z: Machine seen from below

Check mark "1".

Check mark "2".

Check mark "3".

Check mark "4".

Check mark "5".

Longer end

Marked : 4 places

64





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L.H. battery box

Connection: CN RA4

Connection: CN RA2

Connection: CN R09

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



Section A-A

View Z

Detail

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.

Fixing: Use bolt and clip installed temporarily.



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

65

1. Connect the wiring on the left side of the battery


No. Part No. Part name Q’ty State of part (Parts list No.)(1) 6151-53-8280 Clip 2 Temporarily installed on the machine(2) 01024-81020 Bolt, sems 2 Temporarily installed on the machine




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R.H. battery box

L.H. battery box

Connection: CN V102Red (+)

Section A-A

Connection: CN EM41

Connection: CN EM42

Connection: CN V101Black (–)

66

1. Connect the ground cable on the left side of the battery.

Assembly procedure Connection of ground cable on left side of battery(Riotinto specification: If equipped)No. 0397

No. Part No. Part name Q’ty State of part (Parts list No.)(1) 01024-81020 Bolt, sems 2 Temporarily installed on the machine


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

2. The ground cable connecting areas must be free from dirt and paint.


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View Z: Machine seen from below

L.H. battery box seen from rear

67

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.

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

Assembly procedureAssembling the battery stepNo. 0400

No. Part No. Part name Q’ty State of part (Parts list No.)(1) 427-54-26770 Step (R.H.) 1 Separately packed (No.W9E-400)(2) 427-54-26780 Step (L.H.) 1 Separately packed (No.W9E-400)(3) 01024-D1235 Bolt 6 Temporarily installed on the rear frame(4) 01024-D1245 Bolt 2 Temporarily installed on the fuel tank(5) 427-54-2933A Step assembly 2 Separately packed (No.W9E-400)(6) 01024-81235 Bolt 8 Temporarily installed on the battery box



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Fuel tank

Battery box R.H.

Fuel tank

Battery box L.H.

68

1. Install oil cooler assembly (1) to the right platform.

Assembly procedure Installation of oil cooler assembly (Brake cooling specification: If equipped)No. 0403

No. Part No. Part name Q’ty State of part (Parts list No.)(1) 427-S05-489A Oil cooler assembly 1 Separately packed (No. W9E-403)(2) 01024-81245 Bolt, sems 4 Separately packed (No. W9E-403)(3) 01024-81235 Bolt, sems 2 Separately packed (No. W9E-403)


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Oil cooler



69

1. Connect the oil cooler assembly piping.

Assembly procedure Installation and connection of oil cooler assembly piping (Brake cooling specification: If equipped)No. 0404

No. Part No. Part name Q’ty State of part (Parts list No.)(1) 07000-F3035 O-ring 2 Separately packed (No. W9E-404)(2) 01024-81035 Bolt, sems 4 Separately packed (No. W9E-404)

(3) 07371-31255 Flange 4 Temporarily installed on the oil cooler assembly

(4) 07375-21035 Bolt, sems 8 Temporarily installed on the oil cooler assembly


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

View Z

70


Assembly procedure Installation of oil cooler assembly piping -1 (Brake cooling specification: If equipped)No. 0406

No. Part No. Part name Q’ty State of part (Parts list No.)(1) 427-S05-5630 Tube 1 Separately packed (No. W9E-406)(2) 427-S05-5590 Tube 1 Separately packed (No. W9E-406)(3) 427-S05-5650 Tube 1 Separately packed (No. W9E-406)(4) 427-S05-5580 Tube 1 Installed to machine(9) 02896-21018 O-ring 3 Separately packed (No. W9E-406)


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


Bulkhead

Right platform

Oil cooler

Connection

Rear frame seen from right

Rear frame seen from front

71

Assembly procedure Installation of oil cooler assembly piping -2 (Brake cooling specification: If equipped)No. 0407


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a Connect each tube (8 places in total).

Connection (4 pieces): Check O-ring.

Check mark (white tape).


72

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).

Assembly procedureAssembling the handrail (On the right hand platform)No. 0410

No. Part No. Part name Q’ty State of part (Parts list No.)(1) 427-54-29270 Handrail 1 Separately packed (No.W9E-410)(2) 01024-D1235 Bolt 11 Temporarily installed on the right platform(3) 427-54-25861 Handrail 1 Separately packed (No.W9E-410)(4) 01024-D1235 Bolt 11 Temporarily installed on the right platform(5) 426-54-42310 Hose 1 Temporarily installed on the handrail (3)(6) 426-54-35220 Cable 1 Temporarily installed on the handrail (3)(7) 426-54-35320 Joint 1 Temporarily installed on the handrail (3)(8) 23S-07-11160 Catcher 1 Temporarily installed on the handrail (3)



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Rear frame

73

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).

Assembly procedure Installation of handrail (Right platform area) (Brake cooling specification: If equipped)No. 0411

No. Part No. Part name Q’ty State of part (Parts list No.)(1) 427-54-2952A Handrail 1 Separately packed (No. W9E-411)(2) 01024-D1235 Bolt, sems 11 Temporarily installed on the right platform(3) 427-S05-5790 Handrail 1 Separately packed (No. W9E-411)(4) 01024-D1235 Bolt, sems 2 Temporarily installed on the right platform(5) 01024-D1235 Bolt, sems 2 Separately packed (No. W9E-411)(6) 426-54-42310 Hose 1 Temporarily installed on the handrail (3)(7) 426-54-35220 Cable 1 Temporarily installed on the handrail (3)(8) 426-54-35320 Joint 1 Temporarily installed on the handrail (3)(9) 23S-07-11160 Catcher 1 Temporarily installed on the handrail (3)


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74


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.

Assembly procedureAssembling the handrail (On the hood top face)No. 0420

No. Part No. Part name Q’ty State of part (Parts list No.)(1) 427-54-25870 Handrail 1 Separately packed (No.W9E-420)(2) 01024-D1235 Bolt 6 Temporarily installed on the machine(3) 207-62-54770 Clamp 2 Temporarily installed on the handrail(4) 01024-D1030 Bolt 1 Temporarily installed on the handrail(5) 01643-31032 Washer 1 Temporarily installed on the handrail(6) 01580-11008 Nut 1 Temporarily installed on the handrail(7) 427-54-29370 Handrail 2 Separately packed (No.W9E-420)(8) 01024-D1235 Bolt 16 Temporarily installed on the machine(9) 427-54-25880 Handrail 1 Separately packed (No.W9E-420)(10) 01024-D1235 Bolt 12 Temporarily installed on the machine



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Insert handrail (7) to handrail (9).

Rear frame

75


2. Assemble handrails (1) and (4) as shown in the figure above.

Assembly procedure Assembling the handrail (On the right hand battery box)No. 0430

No. Part No. Part name Q’ty State of part (Parts list No.)(1) 427-54-25821 Handrail R.H. 1 Separately packed (No.W9E-430)(2) 01024-D1230 Bolt 4 Temporarily installed on the right battery box(3) 01024-D1235 Bolt 4 Temporarily installed on the right battery step and rear frame(4) 427-54-25180 Handrail R.H. 1 Separately packed (No.W9E-430)(5) 01024-D1235 Bolt 4 Temporarily installed on the right battery box



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Rear frame

76

Assembly procedureAssembling the rear access stepNo. 0440



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Detail of the bolts assembling in the floor and step connections

Detail of the bolts assembling in the step and battery box connections

View from the bottom

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

Fix the covers to each other

8 places

No. Part No. Part name Q’ty State of part (Parts list No.)(1) 427-54-2592A Floor assembly 1 Separately packed (No.W9E-440)(2) 01010-81435 Bolt 8 Temporarily installed on the machine(3) 01643-31445 Washer 8 Temporarily installed on the machine(4) 427-54-2475A Step assembly 1 Separately packed (No.W9E-440)(5) 427-54-25340 Bracket 1 Temporarily installed on the step assembly (4)(6) 01010-81435 Bolt 8 Temporarily installed on the step assembly (4)(7) 01010-81445 Bolt 2 Temporarily installed on the step assembly (4)(8) 01643-31445 Washer 10 Temporarily installed on the step assembly (4)(9) 01010-81635 Bolt 6 Temporarily installed on the left battery box(10) 01643-31645 Washer 6 Temporarily installed on the left battery box(11) 427-54-24191 Cover 1 Separately packed (No.W9E-440)

(12) 01024-81225 Bolt 6 Temporarily installed on the machine and floor assembly (1)

(13) 124-54-26540 Washer 6 Temporarily installed on the machine and floor assembly (1)

(14) 01024-81220 Bolt 6 Temporarily installed on the step assembly (4)

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

installed on the left hand battery box.5. Assemble step assembly (4) using (6) – (10).

In this step, assemble bracket (5), too, referencing the figure above.

6. Remove (14) being temporarily installed on step assembly (4) cover.

7. Remove (12) and (13) being temporarily installed on the machine and floor assembly (1).

8. Assemble cover (11) using (12) and (13).9. Fix cover (11) and step assembly (4) cover

to each other using bolt (14).

77

Assembly procedureAssembling the left handrail (Part 1)No. 0450

No. Part No. Part name Q’ty State of part (Parts list No.)(1) 427-54-25170 Handrail 1 Separately packed (No.W9E-450)(2) 01024-D1235 Bolt 4 Temporarily installed on the machine(3) 427-54-21560 Plate 1 Separately packed (No.W9E-450)(4) 427-54-21571 Rubber 1 Separately packed (No.W9E-450)(5) 01024-D1025 Bolt 3 Separately packed (No.W9E-450)(6) 427-54-29280 Handrail 1 Separately packed (No.W9E-450)(7) 01024-D1230 Bolt 2 Separately packed (No.W9E-450)(8) 01024-D1235 Bolt 6 Temporarily installed on the machine(9) 07283-33450 Clip 1 Temporarily installed on the bracket(10) 07283-53444 Seat 1 Separately packed (No.W9E-450)(11) 01597-01009 Nut 2 Temporarily installed on the bracket(12) 01643-31032 Washer 2 Temporarily installed on the bracket



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View Z

Detail of A1. Remove (2) being temporarily installed on the machine.

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).

78

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

2. Assemble handrail (1) using (2).





Assembly procedureAssembling the left handrail (Part 2)No. 0460

No. Part No. Part name Q’ty State of part (Parts list No.)(1) 427-54-29260 Handrail 1 Separately packed (No.W9E-460)(2) 01024-D1235 Bolt 10 Temporarily installed on the machine(3) 427-54-25851 Handrail 1 Separately packed (No.W9E-460)(4) 01024-D1235 Bolt 22 Temporarily installed on the machine(5) 427-54-25811 Handrail 1 Separately packed (No.W9E-460)(6) 01024-D1230 Bolt 14 Temporarily installed on the machine



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79

1. Remove part (2) installed to the machine.

2. Install handrail (1) with part (2).





Assembly procedure Installation of left handrail (Part 2) (Brake cooling specification: If equipped)No. 0461

No. Part No. Part name Q’ty State of part (Parts list No.)(1) 427-54-2951A Handrail 1 Separately packed (No.W9E-461)(2) 01024-D1235 Bolt 10 Temporarily installed on the machine(3) 427-54-25851 Handrail 1 Separately packed (No.W9E-461)(4) 01024-D1235 Bolt 22 Temporarily installed on the machine(5) 427-54-25811 Handrail 1 Separately packed (No.W9E-461)(6) 01024-D1230 Bolt 14 Temporarily installed on the machine



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Detail of B (2 places)

80

Assembly procedureAssembling the rearview mirrorNo. 0470

No. Part No. Part name Q’ty State of part (Parts list No.)(1) 426-54-25710 Stay (L.H.) 1 Separately packed (No.W9E-470)(2) 426-54-25720 Stay (R.H.) 1 Separately packed (No.W9E-470)(3) 01435-01025 Bolt 8 Temporarily installed on the cab(4) 363-54-31450 Cap 8 Temporarily installed on the cab(5) 421-54-25610 Mirror 2 Separately packed (No.W9E-470)(6) 04025-00632 Spring pin 2 Separately packed (No.W9E-470)


Spanner (17 mm)

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Detail of the mirror adjustment

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).

81

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.

Assembly procedure Installation of rearview mirrors (Brake cooling specification: If equipped)No. 0471

No. Part No. Part name Q’ty State of part (Parts list No.)(1) 56B-54-17311 Mirror 2 Separately packed (No. W9E-471)(2) (56B-54-17311) Nut 4 Accessory to part (1)(3) (56B-54-17311) Washer 4 Accessory to part (1)


Spanner (24 mm) 1

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a Work on right and left sides similarly.

82

1. Remove (2) being temporarily installed on the hood.

2. Assemble exhaust pipe (1) using (2).

Assembly procedureAssembling the exhaust pipeNo. 0480

No. Part No. Part name Q’ty State of part (Parts list No.)(1) 427-02-21140 Exhaust pipe 2 Separately packed (No.W9E-480)(2) 01024-81240 Bolt 12 Temporarily installed on the front hood



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83

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.

Assembly procedure Installation of oil cooler guard assembly (Brake cooling specification: If equipped)No. 0485

No. Part No. Part name Q’ty State of part (Parts list No.)(1) 41F-S05-173A Guard assembly 1 Separately packed (No. W9E-485)(2) 01024-81225 Bolt, sems 6 Separately packed (No. W9E-485)


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

84

1. Install the oil cooler piping cover.

Assembly procedure Installation of fan motor piping cover -1 (Brake cooling specification: If equipped)No. 0486

No. Part No. Part name Q’ty State of part (Parts list No.)(1) 427-S05-3410 Cover 1 Separately packed (No. W9E-486)(2) 427-S05-3391 Cover 1 Separately packed (No. W9E-486)(3) 427-S05-3441 Cover 1 Separately packed (No. W9E-486)(4) 01024-81225 Bolt, sems 12 Separately packed (No. W9E-486)(5) 01024-81230 Bolt, sems 4 Separately packed (No. W9E-486)


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1. Install the cover to the right platform bottom.

Assembly procedure Installation of fan motor piping cover -2 (Brake cooling specification: If equipped)No. 0487

No. Part No. Part name Q’ty State of part (Parts list No.)(1) 427-S05-5190 Cover 1 Separately packed (No. W9E-487)(2) 01024-D1025 Bolt, sems 8 Separately packed (No. W9E-487)(3) 41F-S05-1491 Cover 1 Separately packed (No. W9E-487)(4) 01024-D1225 Bolt, sems 4 Separately packed (No. W9E-487)


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

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

86

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.

Assembly procedureApplying the counterweight anti-slipNo. 0490

No. Part No. Part name Q’ty State of part (Parts list No.)(1) 417-06-11321 Plate 4 Separately packed (No.W9E-490)


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87

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).


4. Assemble cover (7) using (8).

5. Insert pin (9).

Assembly procedure Assembling the counterweight (WA900-3E0 standard specification)No. 0500

No. Part No. Part name Q’ty State of part (Parts list No.)(1) 427-46-25311 Counterweight 1 Separately packed (No.W9E-500)(2) 427-46-25150 Bolt 4 Temporarily installed on the rear part of the rear frame(3) 01643-33080 Washer 4 Temporarily installed on the rear part of the rear frame(4) 427-46-25321 Counterweight 1 Separately packed (No.W9E-500)(5) 198-30-37320 Bolt 6 Temporarily installed on the rear part of the rear frame(6) 01643-33080 Washer 6 Temporarily installed on the rear part of the rear frame(7) 427-54-25332 Cover 1 Separately packed (No.W9E-500)(8) 01024-D1230 Bolt 4 Temporarily installed on the rear part of the rear frame(9) 427-46-13120 Pin 1 Separately packed (No.W9E-500)


Torque wrench 1Socket 46 mm 1Extension 1Impact wrench (for M30) 1

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

Rear frame 2,890 kg

2,890 kg

88

Assembly procedure Assembling the counterweight (WA900-3E0 High-lift arm specification)No. 0505


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2,890 kg 1,600 kg

1,298 kgRear frame

No. Part No. Part name Q’ty State of part (Parts list No.)(1) 427-46-25370 Counterweight 1 Separately packed (No.W9E-505)(2) 425-974-1171 Bolt 4 Temporarily installed on the rear part of the rear frame(3) 01643-33080 Washer 4 Temporarily installed on the rear part of the rear frame(4) 427-46-25321 Counterweight 1 Separately packed (No.W9E-505)(5) 427-T88-1131 Bolt 6 Temporarily installed on the rear part of the rear frame(6) 01643-33080 Washer 6 Temporarily installed on the rear part of the rear frame(7) 427-975-2110 Counterweight 1 Separately packed (No.W9E-505)(8) 427-97-51120 Spacer 4 Temporarily installed on the rear part of the rear frame(9) 419-09-11180 Bolt 4 Temporarily installed on the rear part of the rear frame

(10) 426-09-11510 Washer 4 Temporarily installed on the rear part of the rear frame(11) 427-46-13120 Pin 1 Separately packed (No.W9E-505)(12) 427-46-25350 Cover 1 Temporarily installed on the rear part of the rear frame(13) 01024-D1225 Bolt 2 Temporarily installed on the rear part of the rear frame

1. Remove (2), (3), (5), (6), (8), (9), (10) and (13) being temporarily installed in the rear part of the rear frame.



4. Assemble spacer (8).


5. Insert pin (11).

6. Assemble cover (12) using (13).

89

1. Remove (2), (3), (5), (6) and (7) being temporarily installed in the rear part of the rear frame.


3. Assemble spacer (5).


5. Insert pin (8).

Assembly procedure Assembling the counterweight (WA800-3E0 Overseas general, optional specification

and North American specification)No. 0510

No. Part No. Part name Q’ty State of part (Parts list No.)(1) 427-46-25321 Counterweight 1 Separately packed (No.W9E-510)(2) 198-30-37320 Bolt 6 Temporarily installed on the rear part of the rear frame(3) 01643-33080 Washer 6 Temporarily installed on the rear part of the rear frame(4) 427-975-2110 Counterweight 1 Separately packed (No.W9E-510)(5) 427-975-1120 Spacer 4 Temporarily installed on the rear part of the rear frame(6) 419-09-11180 Bolt 4 Temporarily installed on the rear part of the rear frame(7) 426-09-11510 Washer 4 Temporarily installed on the rear part of the rear frame(8) 427-46-13120 Pin 1 Separately packed (No.W9E-510)



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2,890 kg

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

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

Rear frame

1,600 kg

90

1. Remove (2) and (3) being temporarily installed in the rear part of the rear frame.


3. Insert pin (4).

Assembly procedure Assembling the counterweight (WA800-3E0 Overseas general standard specification)No. 0520

No. Part No. Part name Q’ty State of part (Parts list No.)(1) 427-46-25321 Counterweight 1 Separately packed (No.W9E-520)(2) 198-30-37320 Bolt 6 Temporarily installed on the rear frame(3) 01643-33080 Washer 6 Temporarily installed on the rear frame(4) 427-46-13120 Pin 1 Separately packed (No.W9E-520)



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Rear frame

2,890 kg

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

91

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.

Assembly procedure Assembling the front axle lamp and connecting the harnessNo. 0530

No. Part No. Part name Q’ty State of part (Parts list No.)(1) 427-06-2525A Work lamp 1 Separately packed (No.W9E-530)(2) 01024-81225 Bolt 4 Temporarily installed on the front frame


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Front frame

Connect CN FAL

View ZConnect CN FAR

92

Assembly procedureAssembling the front lamp assemblyNo. 0540

No. Part No. Part name Q’ty State of part (Parts list No.)(1) 427-06-2311A Left front lamp 1 Separately packed (No.W9E-540)(2) 427-06-2312A Right front lamp 1 Separately packed (No.W9E-540)(3) 01024-81245 Bolt 8 Temporarily installed on the right and left of front frame



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Connect CN F04, CN HF1


Front frame viewed from the inner left side

Front frame viewed from the inner right side


Fix here

Fix here


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.

93

Assembly procedureAssembling the ROPS canopy assemblyNo. 0550

No. Part No. Part name Q’ty State of part (Parts list No.)(1) 427-54-25951 Cover 2 Temporarily installed on the machine(2) 01024-D1230 Bolt 8 Temporarily installed on the machine(3) 427-921-229A ROPS canopy 1 Separately packed (No.W9E-550)(4) 01011-63650 Bolt 20 Temporarily installed on the machine(5) 01643-33690 Washer 20 Temporarily installed on the machine


Power wrench (×16 wrench) 1Socket (55 mm) 1Extension 1Torque wrench 1

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2 different colors are used for the ROPS canopyWA800-3E0 - Natural yellowWA900-3E0 - 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)


Clean the contact face of the mount before assembling.a

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.

94

Assembly procedureAssembling the antenna and work lampNo. 0560


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Step lamp (Backside of upper left side of ROPS)

Side lamp (On both side of ROPS)

Connect CN SL5 Connect CN C17

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

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

Lamp assemblyTightening torque : 17.6 – 19.6 Nm {1.8 – 2.0 kgm}

Extend the antenna line from the cab

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

Assembled to the bracket being already assembled to the cab assembly

Assembled to the bracket being already assembled to the cab assembly

No. Part No. Part name Q’ty State of part (Parts list No.)(1) 22B-06-11690 Lamp assembly 3 Separately packed (No.W9E-560)

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.

95

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.

Assembly procedure Assembling the VHMS antenna (For VHMS specification only)No. 0570

No. Part No. Part name Q’ty State of part (Parts list No.)(1) 04434-50810 Clip 7 Temporarily installed on the ROPS canopy assembly(2) 01024-81020 Bolt 7 Temporarily installed on the ROPS canopy assembly(3) 8A13-10-2100 Antenna sat 1 Separately packed (No.W9E-570)(4) 7826-21-1210 Bracket 1 Separately packed (No.W9E-570)(5) 01024-81020 Bolt 2 Temporarily installed on the ROPS canopy assembly



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7 places with mark

Cab viewed from the left side

Connect

View Z

96

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.

Assembly procedureAssembling the floor matNo. 0580

No. Part No. Part name Q’ty State of part (Parts list No.)(1) 427-54-26480 Sheet 1 Separately packed (No.W9E-580)(2) 427-54-26460 Mat 1 Separately packed (No.W9E-580)


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97

Assembly procedureAssembling the front fenderNo. 0590



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81.6 kg

View Z (Detail of bolts assembling position)

81.6 kg

No. Part No. Part name Q’ty State of part (Parts list No.)(1) 427-54-26810 Fender (L.H.) 1 Separately packed (No.W9E-590)(2) 427-54-26820 Fender (R.H.) 1 Separately packed (No.W9E-590)(3) 01010-81635 Bolt 6 Temporarily installed on the front frame(4) 01643-31645 Washer 6 Temporarily installed on the front frame(5) 427-54-13380 Bracket (L.H.) 1 Temporarily installed on the front frame(6) 427-54-13410 Bracket (R.H.) 1 Temporarily installed on the front frame(7) 01010-81245 Bolt 4 Temporarily installed on the front frame(8) 01010-81230 Bolt 4 Temporarily installed on the front frame(9) 01643-31232 Washer 8 Temporarily installed on the front frame(10) 01010-81230 Bolt 16 Temporarily installed on the front fender (right and left)(11) 124-54-26540 Washer 16 Temporarily installed on the front fender (right and left)(12) 09415-05016 Cap 6 Temporarily installed on the front fender (right and left)

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.

98

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 tankReference: Total amount of lubricating oil: When engine is stopped Low level: 118l

High level: 138lLubricating 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 fuelSupply fuel.Reference (Tank capacity: 1,604l)

• Amount of hydraulic oilSupply 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 minutesa 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 leakagea Check and supply oil and coolant to respective components

Assembly procedureEngine starting procedureNo. 0600


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99

(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.)

(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.

Assembly procedureBleeding the brake airNo. 0610


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Bleeding plug

Slack adjuster (2 places in the front and rear) Axle (2 places in the front and rear)

(Bleeding on the axle is conducted in the complete machine assembling process.)

100

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

(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.

Assembly procedureBleeding air from hydraulic circuitNo. 0615


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Switching pump Loader pump

Steering pump

101

Assembly procedureAssembling the lift arm assembly (Part 1)No. 0620


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.

Name Q’ty Name Q’tyImpact wrench 1 Cranes 10 ton, 25 ton 1 eachSocket (36 mm) 1 Nylon sling (Withstand load min. 1 ton) 3Large hammer 1 Nylon sling (Withstand load min. 50 kg) 2

Nylon sling (Withstand load min. 6 ton) 1

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Nylon sling

Lever block

Hinge it on the lifting eye of the cabin

Hold the cylinder using the square timber Fig. 1

Fig. 2

Fig. 3

Fig. 4 Front frame Adjustment using shims

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.

Shim

Clearance 1.5 mm max.

Shim

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

(5) 01010-82450 Bolt 2 Temporarily installed on the front frame pivot

(6) 427-70-11480 Washer 2 Temporarily installed on the front frame pivot

(7) 07049-01620 Plug 6 Temporarily installed on the lift arm assembling pin

[1] Assembling of the lift arm assembly1. Using the nylon sling (crane 10-ton), lift the dump and lift cylinders.

(See Fig.1)

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.

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.

102

Assembly procedureAssembling the lift arm assembly (Part 2)No. 0630

No. Part No. Part name Q’ty State of part (Parts list No.)(1) 427-70-11972 Pin 2 Separately packed (No.W9E-630)(2) 01010-82035 Bolt 2 Separately packed (No.W9E-630)(3) 427-70-11290 Washer 2 Separately packed (No.W9E-630)(4) 07049-01620 Plug 6 Temporarily installed on the lift cylinder assembling pin(5) 427-70-11942 Pin 1 Separately packed (No.W9E-630)(6) 01010-82035 Bolt 1 Separately packed (No.W9E-630)(7) 427-70-11290 Washer 1 Separately packed (No.W9E-630)(8) 07049-01620 Plug 3 Temporarily installed on the bucket cylinder assembling pin


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.

Name Q’ty Name Q’tyImpact wrench 1 Crane 25 ton 1Torque wrench 1 Nylon sling (Withstand load min. 500 kg) 2Socket (30 mm) 1 Nylon sling (Withstand load min. 50kg) 2Large hammer 1

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Lift arm

Lift cylinder

Bucket cylinder

Bell crank

Care must be exercised to prevent assembling a wrong pin.

Care must be exercised to prevent assembling a wrong pin.

Fig. 1

Fig. 2

[2] Assembling of the lift cylinder to the lift arm assembly (see Fig. 1)


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.)

3. Adjust the position of the lift arm assembly and the lift cylinder and then insert lift cylinder head pin (1) to them.

[3] Assembling of the bucket cylinder to the lift arm assembly(Assembling of the bell crank) (See Fig. 2)


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.)

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

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.

103

1. Connect the remote grease tube in 5 places

Assembly procedureConnecting the remote grease tubeNo. 0640


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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

Connect

Connect

Connect

104

Assembly procedureAssembling the bucket (Part 1)No. 0650


Impact wrench 1 Crane 25 ton 1Socket (10 mm) 1 Wire sling (Withstand load 11 ton, L=2,000) 1Spanner 10 mm 1 Shackle: 5 ton 2

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Bucket assembly

Bucket assembly viewed from the left side

Cord ring assembling groove

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

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

Fig. 1

Fig. 2

Fig. 3

Fig. 4

Bucket assemblyWeight: 8,600 kg

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)

(5)427-70-11450 Shim (3.0 mm) 4 Separately packed (No.W9E-650)427-70-11440 Shim (1.5 mm) 6 Separately packed (No.W9E-650)

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)

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)

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

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 procedure1-1. 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.

105



Impact wrench 1 Nylon sling (Withstand load min. 50 kg) 1Socket (30 mm) 1 Crane 10 ton 1Spanner 30 mm 1Large hammer 1

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Weight: 112.8 kg

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

No. Part No. Part name Q’ty State of part (Parts list No.)(6) 427-N42-1161 Pin 2 Separately packed (No.W9E-660)(7) 01010-82035 Bolt 2 Separately packed (No.W9E-660)(8) 427-70-11290 Washer 2 Separately packed (No.W9E-660)

4) Insertion of bucket hinge pin1. 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.

5) Assembling of the bucket hinge pin1. Assemble bucket hinge pin (6) using bolt (7) and washer (8).

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

106



Torque wrench 1 Nylon sling (Withstand load min. 50 kg) 1Socket (10 mm, 30 mm) 1 Crane 10 ton 1

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Fig. 1

Fig. 2

Grease positionBucket link

Bucket hinge (2 places)

Fig. 3

No. Part No. Part name Q’ty State of part (Parts list No.)(1) 427-N42-1151 Pin 1 Separately packed (No.W9E-670)(2) 01010-82035 Bolt 1 Separately packed (No.W9E-670)(3) 427-70-11290 Washer 1 Separately packed (No.W9E-670)(4) 427-70-11450 Shim (3.0 mm) 2 Separately packed (No.W9E-670)(5) 427-70-11440 Shim (1.5 mm) 4 Separately packed (No.W9E-670)(6) 427-N42-1140 Ring 2 Separately packed (No.W9E-670)(7) 426-09-11150 Bolt 2 Separately packed (No.W9E-670)(8) 01596-00606 Nut 2 Separately packed (No.W9E-670)(9) 01640-20610 Washer 4 Separately packed (No.W9E-670)

No. Part No. Part name Q’ty State of part (Parts list No.)(10) 07049-01620 Plug 9 Separately packed (No.W9E-670)(11) 07020-00000 Fitting 2 Separately packed (No.W9E-670)

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).

a Shim-based adjustment procedure1. 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.)

9) Feed LM-G (molybdenum disulfide lithium grease) to the buckethinge 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 tospread the grease evenly on the pin.

107

1. Remove (2) and (3) being temporarily installed on the rear frame.

2. Assemble cover (1) using (2) and (3).

Assembly procedureAssembling the cover (Bottom of the counterweight)No. 0680

No. Part No. Part name Q’ty State of part (Parts list No.)(1) 427-46-25341 Cover 1 Separately packed (No.W9E-680)(2) 01010-82045 Bolt 4 Temporarily installed on the rear frame(3) 01643-32060 Washer 4 Temporarily installed on the rear frame



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108

Assembly procedureFeeding the greaseNo. 0690


Grease gun (Hand pump type) 1

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

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

Front frame

Rear frame

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

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

109

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.

Assembly procedure Work equipment hydraulic circuit air bleeding procedureNo. 0700


Spanner 1

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110

Assembly procedureAdjusting the bucket positionerNo. 0710


Impact wrench 1Socket 19 mm 1Torque wrench 1Spanner 1

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Bucket cylinder

Detection bar

Min. 1/2 displacement should be present

Proximity switch mounting bracket

Detection bar(1,032) 2 in nominal

clearance

427-43-19233

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

Protector

Fig. 1

Section A-A

3 – 5

Sensor sensing surface

No. Part No. Part name Q’ty State of part (Parts list No.)(1) 427-43-19233 Plate 1 Separately packed (No.W9E-710)(2) 01435-01245 Bolt 2 Temporarily installed on the cylinder(3) 01596-01211 Nut 2 Temporarily installed on the cylinder(4) 01643-31232 Washer 2 Temporarily installed on the cylinder(5) 427-44-11113 Support 1 Separately packed (No.W9E-710)(6) 01024-81225 Bolt 4 Temporarily installed on the cylinder(7) 56B-06-15610 Switch 1 Temporarily installed on the plate(8) 08193-20010 Clip 1 Temporarily installed on the plate(9) 01435-01025 Bolt 1 Temporarily installed on the plate

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 is8.7 mm/1°.)

(5) When the positioner is activated and the bucket is set near the ground surface, fluctuation due to the engine speedshall be 4° maximum.

ª Confirm magnitude of the displacement. (Make sure the displacement is 1/2 minimum. See Fig. 1.)

111

Assembly procedureAdjusting the new 2 stage (Overseas general standard)No. 0720


Impact wrench 1Socket (17mm, 19 mm) 1 eachTorque wrench 1Spanner 1

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

Distance between the switch center and sensor plate top end is 0 – 5 mm

When the bucket is set horizontal

When raised to the highest position

Front frame

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

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

View Z

No. Part No. Part name Q’ty State of part (Parts list No.)(1) 427-43-29110 Bracket 1 Separately packed (No.W9E-720)(2) 01435-01020 Bolt 2 Separately packed (No.W9E-720)(3) 428-43-29210 Bracket 1 Temporarily installed on the front frame(4) 01435-01225 Bolt 2 Temporarily installed on the front frame(5) 56B-06-15610 Switch 1 Temporarily installed on the front frame(6) 08193-21012 Clip 2 Temporarily installed on the front frame(7) 01435-01020 Bolt 2 Temporarily installed on the front frame(8) 01643-31032 Washer 2 Temporarily installed on the front frame(9) 01580-11008 Nut 2 Temporarily installed on the front frame

Boom kick out adjusting procedure(1) Raise the lift arm to the highest position and

then fix the sensor plate in such that the distance between the switch center and sensor plate top end becomes 0 – 5 mm.

(2) Fix the switch in such that the clearance between the switch sensing surface and plate in horizontal direction becomes 3 – 5 mm.

112

Assembly procedure Adjusting the new 2 stage (North American standard specification)No. 0730



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Front frame

When the bucket is set horizontal


View Z

No. Part No. Part name Q’ty State of part (Parts list No.)(1) 427-62-21330 Bracket 1 Separately packed (No.W9E-730)(2) 01435-01220 Bolt 2 Separately packed (No.W9E-730)(3) 56B-06-15610 Switch 1 Temporarily installed on the 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.

113

Assembly procedureAssembling the lift arm angle sensorNo. 0740

View A

Connect CN FB4

Front lamp assembly

Clip and bolt already assembledFix the harness here.

Assemble the respective parts to the assembled bracket.

Lift arm assemblyDetail of assembling

No. Part No. Part name Q’ty State of part (Parts list No.)(1) 427-43-28221 Lever 1 Separately packed (No.W9E-740)(2) 421-64-15140 Shim t = 0.5 1 Temporarily installed on the front frame(3) 06124-01416 Bearing 1 Temporarily installed on the front frame(4) 425-S31-2120 Case 1 Temporarily installed on the front frame(5) 421-S30-2250 Shaft 1 Temporarily installed on the front frame(6) 427-S33-3190 Spring 1 Temporarily installed on the front frame

(7) 56B-06-11630 Sensor potentio- meter 1 Temporarily installed on the front frame

(8) 01023-10412 Screw 2 Temporarily installed on the front frame(9) 01315-20812 Screw 2 Temporarily installed on the lever (1)

(10) 419-S30-2510 Plate 1 Temporarily installed on the front frame(11) 01024-81025 Bolt 3 Temporarily installed on the front frame

(12) 01024-81225 Bolt 4 Temporarily installed on the lift arm assembly and front frame

(13) 427-43-28212 Cover 1 Temporarily installed on the lift arm assembly and front frame

(14) 01024-81230 Bolt 1 Temporarily installed on the lift arm assembly and front frame

(15) 04434-51010 Clip 1 Temporarily installed on the front lamp assembly

(16) 01024-81016 Bolt 1 Temporarily installed on the front lamp assembly

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. Assemble (1) – (11) as show in the detail of the assembling.

4. Assemble (12) – (14) as show in the detail of the assembling.

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

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

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

114

Assembly procedure Adjusting the active working system and boom kick-out switch (Overseas general standard and domestic standard)No. 0750



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


Front frame

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


View Z

No. Part No. Part name Q’ty State of part (Parts list No.)(1) 427-62-21330 Bracket 1 Separately packed (No.W9E-750)(2) 01435-01220 Bolt 2 Separately packed (No.W9E-750)(3) 56B-06-15610 Switch 1 Temporarily installed on the front frame

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.

115

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.)

Assembly procedureTouchup workNo. 0760

Cautions1. Paint color shall conform to the following. Except the sections where face coating is provided.

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.

Black gray Black heat resistant paint

Natural yellow

Right and left

Right and left

Right and left

View Z

(1) Lift arm: The section where the nylon sling was used for lifting(2) Lift arm: The section where dents from assembling of the pin are left(3) Lift cylinder: The section where the nylon sling was used for lifting(4) Lift cylinder: The section where dents from assembling of the pin are left(5) Bucket cylinder: The section where the nylon sling was used for lifting(6) Bucket cylinder: The section where dents from assembling of the pin are left(7) Bell crank: The section where the nylon sling was used for lifting(8) Bell crank: The section where dents from assembling of the pin are left(9) Machined portion on the tires(10) Counterweight section

116

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)

Assembly procedure Applying the decal (For the overseas-directed products only)No. 0770

No. Part No. Part name Q’ty State of part (Parts list No.)(1) 09807-C1683 Mark 2 Separately packed (No.W9E-770)


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Top view of the lift arm

View Z

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

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GEN00056-01

WA800-3E0WA900-3E0

KOMATSU SAA12V140E-3

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No. Inspection items Judgment procedures and criteria Check Maintenance Remarks

Recording the Serial No. of built-in parts.

1 Lift arm No.

The number is stamped on the right upper part of the lift arm.

2

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

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

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.)

4Brake oil level (When the check is difficult while the engine is at a stop, start the engine to check the level.)

5 Hydraulic oil levelLower 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.)

6 Transmission oil level

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 coolantCheck the antifreeze density. The density shall satisfy the standard.Area A: -33 – -43°C Areas B: -24 – -34°C Areas C: -14 – -24°CMeasured 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 Valve check function of main monitor and sub-monitorWhen the starting switch is set to ON, the buzzer sounds for a second and the lamps of the main monitor and the sub-monitor go on.

13 Function of centralized inspection lamp When the starting switch is set to ON, the [CHECK] lamp does not go on.

14 Function of emergency steering pilot lamp When the starting switch is set to ON, the pilot lamp blinks (and goes out after the engine starts).

15 Function of horn The sound volume is satisfactory without vibrating tone (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

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.)

17 Safety function of steering lever set to 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.)

List of check marks for inspection results

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

: Acceptable: Enter numeric values.: Not applicable

: UnacceptableEmpty column : Uninspected : No check is required.

( )

Date of Inspection Inspector Service meter

Start Finish

H H

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.

Stamp

The level shall be at the ENGINE STOP level.The level shall be at the ENGINE RUNNING level.

With the measurement gauge 5 minutes later after the engine started.

With the measurement gauge 10 hours later after the engine stopped.

A

The level shall be in the range A at the ENGINE STOP position of the level gauge.

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

a

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

19 Function of accelerator pedal The accelerator pedal shall be free from double stepping and counter bounce and return smoothly.

20 Exhaust color Is the exhaust color satisfactory at a sudden acceleration (Li o Hi). (Sensory evaluation)

21 Abnormal noise of engine 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.

22

(1) Set machine and steering in straight travel position.

(2) Stop engine (Turn starting switch OFF) and set steering lock lever in LOCK position.

(3) Disconnect neutral position adjustment connector "JL3" in right console.

(4) Turn starting switch to ON position and start engine.

(5) Connect neutral position adjustment connector "JL3".

(6) Reset steering lock lever.

(7) After 1 second, buzzer beeps 3 times and adjustment is completed.

Measuring the engine speed.

23

Before measuring the engine speed, apply the parking brake, release the accelerator pedal and set the secondary switch to OFF.Standard: 620 – 710 rpmMeasure value of low idle speed: ( ) rpmBefore measuring the speed, apply the parking brake, release the accelerator pedal and set the secondary switch to ON.Standard: 820 – 910 rpmMeasure value of low idle (secondary) speed: ( ) rpmBefore measuring the speed, apply the parking brake and step on the accelerator pedal.Standard: 2,170 – 2,220 rpmMeasure value of high idle speed: ( ) rpmBefore 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: ( ) rpmBefore measuring the speed, apply the parking brake, step on the accelerator pedal and release the work equipment.For recording only, Measured value of engine speed at stalling the work equipment: ( ) rpmBefore 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.

24 Function of lift arm control lever

(1) Set the lever to the [Raise] position, and the lift arm rises.

(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.

Initial setting

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

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

Engine revolution

(Measuring conditions)ª Engine coolant temperature:

Within the green rangeª Engine oil temperature: 80 – 90 °Cª Torque converter oil temperature: 60 – 80 °Cª Work equipment oil temperature: 45 – 55 °C

ª 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.

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25 Function of bucket control lever

(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.

(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.

26 Function of remote positionerDoes the remote positioner switch enable to set the Down Position and the UP Position freely? Does the remote positioner return automatically to neutral at the set position?

27 Function of lock lever (for work equipment control lever)

When the work equipment lock lever is set to ON (the lever is lowered), the work equipment does not lower even if the work equipment control lever is moved.

28 Function of work equipment accumulator Stop the engine after an engine high idle and lower the lift arm control lever, and the lift arm comes down.

29

Lift arm raising time (without load)Standard lever raising: 9.9 – 10.9 sec.Measured value: ( ) sec.Lift arm lowering time (without load)Standard lever lowering: 4.3 – 5.3 sec.Measured value: ( ) sec.Bucket tilted back time (Measure the time without load at the lift arm highest position.)Standard lever tilting: 3.5 – 4.1 sec.Measured value: ( ) sec.Bucket dumping time(Measure the time without load at the lift arm highest position.)Standard lever dumping: 2.2 – 2.8 sec.Measured value: ( ) sec.

30

The pilot lamp of the proximity switch for powerful mode goes on at the lift arm hinge pin height of 1.4 – 2.0 m.When a metal piece is stuck to the proximity switch for powerful mode (and fixed with rubber tape) at the lift arm highest position, the transmission is set to F3 speed and the work equipment is released, the loader pump solenoid has the voltage of 24 V.

31 Check of lift arm hydraulic drift (without load)

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

32

Check of bucket natural dump (without load)

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

Measurement of work equipment speed in the normal mode

(Work equipment speed and oil temperature: 45 – 55 °C)

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

Check of active mode

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

Measurement of solenoid voltage

Proximity switch for active mode

Posture for measuring hydraulics drift

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Making checks related to the steering.

33 Safety function of joystick steering lock leverBring 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.

34 Function of steering

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 the left.The steering angle changes only as much as the joystick lever is moved.

35 Check of adjustment of steering stopper bolt

Bring the joystick lever to the stroke end while idle the engine at low speed, and there occurs the clearance of 20 – 30 mm between the front frame and the rear one. (Check the clearance on both the right and left sides.)

36Measurement of steering operation time

(Work equipment speed and oil temperature: 45 – 55°C)

Measure the full stroke time in idle the engine at high speed.Standard left swing: 3.2 – 4.3 sec.Measured value: ( )Measure the full stroke time in idle the engine at high speed.Standard right swing: 3.2 – 4.3 sec.Measured value: ( )The above measured swing times do not differ more than 10% on the right and the left sides.

37 Function of emergency steeringWhen the engine stopped while traveling downhill, the steering angle changes. (Check it on both the right and left sides.)

Making checks of travel and brake.

38 Safety function of joystick steering lock lever Set the transmission to F or R at the locked position, and the buzzer sounds and the machine does not travel.

39 Transmission control function of joystick lever

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.

40 Shock to and time lag of transmissionChange 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.

41 Function of kick-down switch

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.

42 Function of transmission cut-off switch

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.

43 Auto and manual shift changeover function of transmission

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.)

44 Function of transmission manual shift mode The shift display on the monitor panel agrees with the gear shift selected with the transmission shift up/down switch.

45 Function of transmission auto shift mode

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).

46 Function of hold switch

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.

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47 Heat accumulation in brake disc After traveling the machine, touch the brake chamber by hand. No abnormal heat can be felt (on the four wheels).

48 Safety function of parking brakeTurn on the parking switch, set the joystick lever T/M forward-reverse switch to F or R, and the centralized warning lamp blinks and the warning buzzer sounds.

49 Function of parking brake This brake enables to stop the machine on slopes of 1/5 gradient.

50 Braking force of service brake

Apply the brake suddenly at the initial speed of 20 km/h, and the machine stops within 7.5 m.Step on the brake while the engine is idle at high speed or at the F2 speed, and the machine does not start.

51 Pull of brake Travel the machine at more than 20 km/h and apply the brake suddenly, and the machine stops one a straight line.

52 Check of emergency brake

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 pressure drops and the parking brake works.)When the emergency brake works, the parking brake pilot lamp goes on.

53 Check of the time when the brake accumulator pressure drops

Step on the brake pedal to sound the caution buzzer for oil pressure drop. Then, idle the engine at high speed until the accumulator is fully charged. Stop the engine and restart the engine 30 minutes later, and the caution lamp for the oil pressure of the brake accumulator does not go on.

54

Standard F1 speed: 6 – 8 km/h Measured value: ( ) km/hStandard F2 speed: 11 – 13 km/h Measured value: ( ) km/hStandard F3 speed: 26 – 30 km/h Measured value: ( ) km/hStandard R1 speed: 6 – 8 km/h Measured value: ( ) km/hStandard R2 speed: 11 – 13 km/h Measured value: ( ) km/hStandard R3 speed: 26 – 30 km/h Measured value: ( ) km/h

Checking all lamps.

55 Internal lighting of main monitor and sub monitor

Set the lamp switches (on the 1st and 2nd stages) to ON, and the internal lightings go on.

56 Function of clearance lamp Set the light switches (on the 1st and 2nd stages) to ON, and the right and left front lights go on.

57 Function of head lamp 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.

58 Function of turn signal lamp Move the turn signal lever, and the front and rear turn signal lamps corresponding to the intended direction blink.

59 Function of hazard lamp Set the hazard switch to ON, and the right and left turn signal lamps and the pilot lamp (arrow) inside the cab blink.

60 Function of tail lamp Set the light switches (on the 1st and 2nd stages) to ON, and the right and left rear lights go on.

61 Function of back-up lamp Set the transmission shift lever to R, and the back-up lamp goes on.

62 Function of brake lamp

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.)

63 Function of working lamp

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.

64 Function of step lamp Set the switch to ON, and the light goes on and goes out automatically about a minute later.

65 Function of room lamp Set the switch to ON, and the light goes on. Also, the lights at the doors light when the cab door are opened.

66 Function of back-up buzzer The sound volume is satisfactory without vibrating tone. (Sensory)

Check of travel speed

When the bucket is empty, check the travel speed at each gear speed with the machine-mounted meter on the main monitor.

Since F3 and R3 require long approach distance, they are regarded as reference values.

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Check gauge performance.

67 Function of torque converter oil temperature gauge

During operation, the gauge indicates any point in the green range.

68 Function of engine coolant temperature gauge During operation, the gauge indicates any point in the green range.

69 Function of fuel gauge During operation, the gauge indicates the exact level in the 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

72

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

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 spurting-out 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

45/65-45-46PR L-5Standard value: 5.25 kg/cm2

Measured value: Front left ( ) kg/cm2

Measured value: Front right ( ) kg/cm2

Measured value: Rear left ( ) kg/cm2

Measured value: Rear right ( ) kg/cm2

Checking failure code

76 Check of failure codeMake sure that no failure code is displayed on the monitor panel after completion of the function check.Check of failure code ( )

Function of air conditioner

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.

8/9


Carry out inspection of every part.

77 Check of cabCab lining is free from flaw and stain.

Cab glass is free from flaw.

78 Check of ROPS structure

Mounting bolts are free from looseness and scuffing.

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.

79 Inspection around machine upper side

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.

80

Inspection of loader link and bucket

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.

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 supportLight support mounting bolts are lightened certainly and are free from scuffing.(Check them on both the right and left sides.)

83 Inspection of front fenderFront fender mounting bolts are tightened certainly and are free from scuffing.(Check them on both the right and left sides.)

84 Inspection around center pin

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.

445

Ф180

435

Ф180Pin on bell crank side

Pin on lift arm cylinder side

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

9/9


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

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.)

88 Inspection of fuel tank

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 Counterweight mounting bolts are free from looseness and scuffing.

91 Inspection around hydraulic tank

Lift ladder mounting bolts are tightened certainly and are free from scuffing.

No oil leakage is detected.

92 Inspection of tire and wheel

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.)

93 Inspection of lower parts

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.

WA800-3E0, WA900-3E0 GALEO WHEEL LOADER

©2007 KOMATSUAll Rights ReservedPrinted In Japan 07-07

Form No. GEN00056-01

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

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