KOMATSU WA600-5 GALEO WHEEL LOADER FIELD ASSEMBLY INSTRUCTION MANUAL(SN:60001 & UP) KOMATSU WA600-5

CONTENTS 1 2 3 4 5 6 7

Block outline.................................................................................................................

Principal component dimension table ..........................................................................

Work space layout .......................................................................................................

General assembly schedule.........................................................................................

Operating equipment, jigs and tools ............................................................................

Oil, grease and paints ..................................................................................................

Assembly procedure ....................................................................................................

No.

Item

Page

No.

Item

1 2 3 4 5 8 9

Page

0010 Oil and coolant

9

0280 Installing the rear fender mudguard plate

43

0020 Oil and coolant capacity

10

0290 Installing rear fender

44

0030 Setting the front axle and bare machine to stationary position

11

0300 Installing cab undercover

45

0040 Installing the front axle

12

0310 Checking of sections

46

0060 Connecting the drive shaft

13

bleeding of work equipment hydraulic circuit and 0320 Air respective cylinders

47

0065 Connecting the brake pipe

14

0330 Starting engine (1/2)

48

0066 Connecting the brake pipe (Brake cooling specification)

15

0340 Starting engine (2/2)

49

0070 Installing tire and rim assembly

16

0345 Bleeding air from brake system

50

0080 Installing step

17

0350 Installing lift arm and bell crank assembly

51

0090 Installing cab (1)

18

0360 Installing bucket cylinder (Bell crank side)

52

0100 Installing cab (2) (AJSS specification)

19

0370 Installing bucket (1/3)

53

0110 Installing cab (2) (Steering wheel specification)

20

0380 Installing bucket (2/3)

54

0115 Installing cab (2) (AJSS and steering wheel specification)

21

0390 Installing bucket (3/3)

55

0120 Installing cab (3)

22

0400 Greasing (1st time)

56

0130 Installing cab (4) (AJSS specification)

23

0410 Installing lift arm positioner

57

0140 Installing cab (4) (Steering wheel specification)

24

0420 Contents of adjustment items

58

0141 Installing cab (5) (Steering wheel specification)

25

0430 Setting of machine monitor

59

0145 Installing cab (6) (AJSS and steering wheel specification)

26

of work equipment controller lift arm 0440 Adjustment angle

60

0150 Installing cab harness (1/2)

27

0450 Adjustment of work equipment EPC starting current (1/2)

61

0160 Installing cab harness (2/2)

28

0460 Adjustment of work equipment EPC starting current (2/2)

62

0170 Installing cab duct (1/3)

29

0470 Adjustment of bucket positioner (1/2)

63

0180 Installing cab duct (2/3)

30

0480 Adjustment of bucket positioner (2/2)

64

0190 Installing cab duct (3/3)

31

0490 Adjustment of load meter lift arm angle

65

0195 Installation of yellow rotary lamp

32

0500 Load meter no-load calibration

66

0200 Installing front fender

33

0510 Deleting the electrical system failure history (1/2)

67

0210 Installing front light support and connection

34

0520 Deleting the electrical system failure history (2/2)

68

0220 Installing muffler stack and mirror

35

0530 Installing the floor mat (AJSS specification)

69

counterweight (Standard and 1 ton heavier 0230 Installing counterweight specifications)

36

0540 Installing the floor mat (Steering wheel specification)

70

0235 Installing counterweight (Load and carry specification)

37

0550 Running-in procedure (1/2)

71

0240 Installing pin (Standard and EU specifications)

38

0560 Running-in procedure (2/2)

72

0250 Installing rear access ladder and L.H. platform

39

0570 Greasing (2nd time)

73

0260 Installing the left handrail

40

0580 Touch up work

74

0270 Installing right platform and R.H. handrail

41

use of starter kit (dummy harness) and 0590 On precaution on its use

75

0275 Installing fire extinguisher

42

0600 Starter kit (dummy harness) assembling procedure

76

Appendix Field assembly inspection report

1

Block outline (for principal components only)

2. Front axle assembly

1. Bare machine

3. Lift arm and bell crank assembly

6. Front light support assembly

9. Platform

12. Handrail

4. Tire and rim assembly

7. Step

5. Counterweight

8. Rear access ladder (Left)

10. Cab

11. Bucket

13. Fender

14. Muffler stack

15. Rear fender (if equipped)

1

2 Principal component dimension table No.

Unit name

Overall length (mm) 27,720 8,470

Weight (kg)

Overall width Overall height (mm) (mm) 3,390 3,095

1

Bare machine

2

Front axle assembly

3,635

3,315

1,015

900

3

Lift arm and bell crank assembly

5,510

4,175

1,460

1,640

4

Tire and rim assemblies (1 set)

1,590

905

2,075

2,075

Counterweight (Standard)

2,780

2,670

865

630

Counterweight (1 ton heavier)

3,780

2,670

865

630

Counterweight (Load and carry)

4,785

2,670

865

862

5 6

Front light support assembly

40

1,500

850

350

7

Step

10

1,550

535

260

8

Rear access ladder

180

2,000

890

825

9

Platform

210

2,410

890

630

10

Cab

1,100

1,880

1,650

1,750

11

Bucket

4,910

3,900

2,340

2,025

12

Handrail

130

2,200

1,700

1,000

13

Fender

70

1,525

740

770

14

Muffler stack

20

370

370

1,075

15

Rear fender

60

1,350

770

1,000

Bare machine trailer loading chart

Bare machine

Reference Dimensions of completed machine Specifications WA600-6

Related dimensions Weight (kg) 52,700 (Operating weight)

Overall length (mm)

Overall width (mm)

Overall height (mm)

11,985

3,685 (Bucket width)

4,460 (Cab top surface)

a The weight may somewhat differ depending on the specification (OP).

2

3

Work space layout

(The wider the work space, the better the operability. The space of 25 m Ă— 30 m as shown in the diagram below represents a minimum area required, however.)

Note: Select a flat location free of puddles for the work space.

25 m Lift arm and bell crank assembly

Bucket assembly

Front axle assembly Bare machine

50 ton crane

Cab assembly

Storage area for the lighter units

30 m

Tire and wheel assembly

Front fender, ladder, muffler stack, step, floor mat, front light support, handrail, etc.

Counterweight

Compressor parts Storage for jigs and tools 50 ton crane

Forklift

3

4

Setting of front axle to stationary position

Worker

Forklift

Crane

3 persons

Assembly of front axle

Outline of Setting the main unit to assembly contents a stationary position

Machine body conditions

Day Time

Installing counterweight Installing ladder and platform

Installing inside the cab

Installing exterior parts

Installing the cab on board

Installing tire

1st day

Installing bucket

Installing lift arm

2nd day

Inspection

Maintenance and adjustment

3rd day

4 General assembly schedule

5

List of equipment, jigs, tools and consumables

No. 1

Crane

25 ton

Q’ty 1

2

Crane

50 ton

2

Refer to the assembly procedure

3 4

Crane Forklift

10 ton 2.5 ton

1 1

Refer to the assembly procedure

5 6 7 8

Tire pressure gauge Grease pump and gun Grease Stool

No. 2252 for 20 kg container G2-LI 4 steps

9 10 11

Stool Blue sheet Square bar

6 steps 5 m × 10 m 300 mm square, 1.2 m long

1 5 16

Equipment protection For setting the bare machine to stationary position

12 13 14

Square bar Oil jug Oil

300 mm square, 0.6 m long 5l Refer to the assembly procedure

4 1 –

For setting the bare machine to stationary position For filling oil Refer to the assembly procedure

15 16 17 18 19

Oil pan and wash can Waste oil container Rag Fuel oil Antifreeze

Item

Specifications

Empty drum

Application Refer to the assembly procedure

1 1 5 kg 2

2 1 5 kg

Refer to the assembly procedure 5l

For replenishing machines For replenishing the sub-tank (concentration varying by area) For bleeding air

20

Air hose

6ø × 1 m

2

21 22 23

Air compressor Air hose Impact wrench

3.5 m3/min, 7 kg/cm2 and above 12ø with fitting For M6 – M12

1 5 3

For an impact grinder

24 25 26

Impact wrench Impact wrench For 1 · 1/2 extension

For M14 – M20 For M24 and M27 500 mm long

1 1 1

For installing the cab

27 28 29 30 31 32 33 34 35 36 37 38

Socket Socket Socket Socket Socket Socket Socket Socket Socket Socket Socket Torque wrench

10 mm 13 mm 17 mm 19 mm 22 mm 24 mm 30 mm 36 mm 41 mm 55 mm 60 mm Set 19.6 Nm {2.0 kgm}

1 1 1 1 1 1 1 1 1 1 1 1

39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71

Torque wrench Torque wrench Torque wrench Torque wrench Torque wrench Torque wrench Convex Locktight Vinyl tape Standard tools (for ISO) Bar Pick Large hammer Shackle Shackle Chain Nylon sling Nylon sling Nylon sling Balance lifting tool Axle assembly lifting tool Wire Wire Wire Eye bolt Chain lifting tool Chain lifting tool Chain lifting tool Chain lifting tool Vinyl hose Square bar Square bar Spanner

Set 927 Nm {94.5 kgm} Set 1,300 Nm {132.6 kgm} Set 31.8 Nm {3.2 kgm}, width across flats 36 mm Set 2,745 Nm {279.9 kgm} Set 3,260 Nm {332.4 kgm} Set 277 Nm {28.2 kgm} 5m LT-2

1 1 1 1 1 1 1 1 1 2 1 1 1 4 4 2 2 2 1 2 2 2 2 2 4 1 1 1 1 2 2 1 1

700SX 1m 10 lb For 2.5 to 3 ton crane BC40 for 10 ton For 2.5 to 3 ton crane, 2 m 1 ton and above 6 ton and above 100 mm wide × 12 m long ATW-600-036 ATW-600-103 7 m 28ø 4 m 28ø 5 m 28ø For M16 4 points, 2 m ø 20 mm diameter, 2 slings of 2 m 2 m × 4 slings (1.5 ton and above) 4 m × 4 slings (6 ton and above) ø6×1m 150 mm × H350 mm 300 mm square 17 mm (width across flats)

For tire and cab For the cab For the sensor For counterweight For front axle For drive shaft

For arranging the harnesses

For hole alignment For the bucket For the frame General purpose General purpose For installing the lift arm For installing the front tire For lifting the frame For lifting of front axle For lifting the chassis For installing the body For installing the body For installing the cabin For installing the cabin For the frame For installing the cab For the bucket For bleeding the brake air For receiving lift cylinder For receiving the bucket cylinder

5

Drawing for additional machining of section A S = 1 : 2.5 (2 locations, right and left)

Sling fitting E Link chain Shackle

Kito Kito JIS

1 15

K21 (WA600 M/C)

'04--01--29

VE200 SV200 L=3.1 m SC40

ATW--600--036

Date

4 2 2

Part Name Material Q'ty Remarks Balance AS-00362 Conversion part 1 Part Number 2 (additional machining required)

WA1200 front frame lifting tool

Balanced lifting tools for shipment

02 03 04 05 06

01

Part Number

Machine name

Machine name Scale

AS–00362 Machine #11 additionally for application.

Drawing No.

6 P

7

Corners shall be smoothly grind-finished.

2-26 drilled hole

Note: Inspection report shall be attached.

1 6

12 1 JIS Kito

WA600-6

Remarks

ATW--600--103

'05--09--21

M24 × 75 DD-2SL ø=10 L=2.4 m

Date

Q'ty 2

Material SS400

SV100 90° lifting 4,500 kg

Axle assembly lifting tool

Part Number Part Name Sling fitting 01 02 Hexagon bolt 03 Double sling 04

Machine name Scale

In white paint: Machine model, machine name Stamp: Drawing No.

Machine name

Developed shape

Drawing No.

P

6 Oil, grease and paints List of touch-up paints No.

Part Name

Unit

Q’ty

1

Natural yellow

Spraying can

6

2

Black gray

Spraying can

6

3

Heat resistant black

Spraying can

1

Unit

Q’ty

(KES LM-P equivalent)

1l

2

Part Name Grease with molybdenum disulfide for addition under extreme pressure Lithium grease with molybdenum disulfide added

(KES LM-P equivalent)

10 l

3

Fuel

–

4

Windshield washer solution

Adequate quantity of fuel oil (757 l when full) Commercially available product

2l

5

Detergent

Spraying can

6 pieces

List of grease No. 1

a Lithium grease 2 (Specification: Equivalent to KES G2-LI) may be used partly instead of molybdenum disulfide lithium grease No. 2 (Specification: Equivalent to KES LM-G) in the oil and grease list.

8

Assembly procedure

Oil and coolant

No. 0010

How to use fuel and lubricating oil and grease by the ambient temperature t Fuel and oil Use as indicated in the table below according to the ambient temperature: a Specified oil capacity refers to a total oil capacity including oil in the piping portions of respective devices. Refill oil capacity refers to a quantity of oil to be replaced at an inspection and/or service time. a When starting engine under the ambient temperature of 0°C or less, always fill the engine oil pan with EO10W30-DH or EO15W40-DH oil if the daytime temperature should rise to 10°C. t Coolant Since coolant is added with Komatsu genuine super coolant (AF-NAC), it is not necessary to change the coolant until the temperature drops to -10°C. If it drops to under -10°C, adjust concentration by referring to the item on the “Cleaning of the inside of the cooling system” in non-periodical maintenance in Operation & Maintenance Manual.

Cautions

Special tool Name

Q’ty

Name

Q’ty

Others

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

Necessary Equipment

9

Assembly procedure

Oil and coolant capacity

No. 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

97

86

0

Transmission case

Power train oil

120

83

0

592

443

98 (150 l are to be prepared)

155

155

0

155

155

0

Hydraulic fluid (Synthetic oil) Power train oil Hydraulic oil system

Hydraulic oil Engine oil Biological hydraulic oil

Front axle Rear axle

Axle oil

Fuel tank

Diesel fuel

718

—

0

Cooling system

Coolant

182

147

0

Note) Always check each capacity of oil and coolant before and after starting the engine.

Cautions

Special tool

Others

Name

10

Necessary Equipment Q’ty

Name

Q’ty

Assembly procedure

Setting the front axle and bare machine to stationary position

No. 0030

1. Setting the front axle to stationary position 1. Set the front axle assembly as shown in the figure below.

Lifting tool: Front axle assembly lifting tool (ATW-600-103)

a Axle body shall not be directly lifted.

No direct lifting in this position

Axle Front axle 4 ton Crane: 50 ton

Min. 800

Front view Axle lower end position Square bar

Square bar

2. Setting the bare machine to stationary position Rear 26 ton Crane: 50 ton

Front 7 ton Crane: 50 ton

Axle lower end Square bar

1. Attach cloth or equivalent to protect the machine body from damages in its lifting.

2. Using two 50 ton cranes, lift the bare machine by use of the lifting eye on the front and rear frames.

Lifting tool Front frame side: Sling hook type chain lifting tool (Rope diameter ø20 mm, 2 slings) Rear frame side: Balance-type lifting tool (ATW-600-036)

Cautions

Name Shackle (For 10 ton)

Necessary Equipment Q’ty 4

Name

Q’ty

Crane 50 ton

2

Sling hook type chain lifting tool (Rope diameter ø20 mm, 2 slings and L 2,000)

1

Balance-type lifting tool (ATW-600-036)

1

Axle assembly lifting tool (ATW-600-103) Square bar (300 mm square and L=0.6m) Square bar (300 mm square and L=1.0m) Square bar (150 mm, H=350 mm)

2 2 2

Others

1. Whenever lifting the front axle assembly, the specified lifting tool must be used.

It is strictly prohibited to use an unspecified lifting tool as well as lifting the front axle directly.

Special tool

11

Assembly procedure

Installing the front axle

No. 0040

1. Setting the front axle to stationary position Front axle 4 ton Crane: 50 ton

Axle lower end Square bar

Square bar

1. Lift the front axle assembly with the crane.

Lifting tool: Axle assembly lifting tool (ATW-600-103) 2. Assemble the front axle assembly to the front frame.

No. 1 2 3

Part No. 427-46-12130 01580-03931 01643-33990

Part name Bolt Nut Washer

Bolt (1) 2,890 -- 3,630 Nm {295 -- 370 kgm}

Q’ty Parts conditions 12 Temporarily attached to machine body 12 Temporarily attached to machine body 24 Temporarily attached to machine body

2. Setting the bare machine (equipped with front axle) to stationary position Front 7 ton Crane: 50 ton

Axle lower end Square bar

Square bar

Modification of square bar position a Change of square bar to L=1.0 m: For ground contacting position, see No.0030 Front View.

1. Attach cloth or equivalent to protect the machine body from damages in its lifting.

2. Using a 50 ton crane, lift the bare machine by use of the lifting eye on the front frame and then place the square bar under the front axle lower end position.

Lifting tool Front frame side: Sling hook type chain lifting tool (Rope diameter ø20 mm, 2 slings) Cautions

Name

12

Necessary Equipment Q’ty

Name

Q’ty

Shackle (For 10 ton)

4

Crane for 50 ton

2

Torque wrench (Set 3,260 Nm) {332.4 kgm}

1

Sling hook type chain lifting tool

1

(Rope diameter ø20 mm, 2 slings and L 2,000)

Others

1. Whenever lifting the front axle assembly, the specified lifting tool must be used.

It is strictly prohibited to use an unspecified lifting tool as well as lifting the front axle directly.

Special tool

Axle assembly lifting tool (ATW-600-103)

1

Square bar (300 mm square and L=1.0 m) Square bar (300 mm square and L=0.6 m) Square bar (150 mm, H= 350 mm)

4 2 2

Assembly procedure

Connecting the drive shaft

No. 0060 1. Connecting the drive shaft No. 1

Part No. 01050-61675

Part name Bolt

Fig. 1

Q’ty Parts conditions 4 Independent product (Separately packed)

1. Connect drive shaft using bolt (1).

2. Make sure in the assembly that the grease fitting on the front drive shaft and that on the center drive shaft are faced in the same direction. (See Fig.1) <Point> 1. The mounting surface shall be free from rusts, foreign substances or dents.

2. Insert four bolts temporarily and then tighten them also temporarily until the seating surface is closely contacted.

3. As a general rule, tightening of the bolts must be done diagonally.

Be sure to tighten them more than the second round.

4. Retighten the bolts with the specified torque.

5. Check with your eyes whether or not the seating surface is closely contacted. If acceptable, apply a check mark using a white felt pen.

Greasing fitting position Positional relation of grease fitting (Viewed from rear side of machine body)

Front frame

Bolt (1) 245 -- 309 Nm {25 -- 31.5 kgm}

View Z: Front frame viewed from left side

Front axle

Front frame Connect

Front axle Grease fitting

Cautions

Special tool Name

Q’ty

Name

Q’ty

1

Others

Torque wrench (Set 277 Nm) {28.2 kgm}

Necessary Equipment

13

Assembly procedure

Connecting the brake pipe

No. 0065 2. Connecting the brake pipe

1. Connect the pipe of the slack adjuster on the front axle. a When connecting the pipe, make sure the O-ring is provided.

Target pipe of connection

Slack adjuster

Connection: Check of O-ring

Section A-A

Cautions

Special tool Name

Others

Spanner (17 mm)

14

Necessary Equipment Qâ&#x20AC;&#x2122;ty 1

Name

Qâ&#x20AC;&#x2122;ty

Assembly procedure

Connecting the brake pipe (Brake cooling specification)

No. 0066

2. Connecting the brake pipe (Brake cooling specification) No. 1 2

Part No. 07375-21040 07000-B3038

Part name Bolt O-ring

Q’ty Parts conditions 4 Independent product (Separately packed) 1 Independent product (Separately packed)

1. Before connecting the front axle brake pipe, remove bolts A and B and then remove the parts indicated with A mark.

Abolish A marked parts. They are not used again.

Sction A-A

Y view

X view

2. Connect the pipe of the front axle brake. (Section A-A: 1 place, Z view: 2 places) a Hose between plugs C and E, hose between plugs D and F, and tube between bolts A and B For View Z ª marked position alone, however, independently delivered bolt (1) and O-ring (2) shall be used in place of bolts A and B to connect the tube. (Z view ª mark: 1 place) a When connecting the pipe, make sure the O-ring is provided.

Y view Slack adjuster

Destination of connection

Connect: Check O-ring.

Connect Tube between bolts A and B

Connect: Check O-ring.

Hose between plugs C and E

Hose between plugs D and F

Section A-A

Z view

Slack adjuster Cautions

Special tool Name

Q’ty

Name

Q’ty

1

Others

Spanner (17 mm)

Necessary Equipment

15

Assembly procedure

Installing tire and rim assembly

No. 0070 1. Installing tire and rim assembly No. 1 2 3

Part No. 426-30-31030 01010-62490 01643-32460

<How to hoist the tire and wheel assembly> Apply the lifting tool so that the tire will be level.

Part name Q’ty Parts conditions Tire and wheel assembly 4 Independent product (Separately packed) Bolt 148 Independent product (Separately packed) Washer 148 Independent product (Separately packed)

Apply choking knot Nylon sling

1. Hoist tire and wheel assembly (1) with the crane.

2. Install the tire with the forklift and install bolt (2) and washer (3).

(Additional tightening of the air valve) Note) Take care not to drop the tire from the forklift.

Care should be taken not to give damages to the air inlet valve when positioning the tire.

3. Install the bolt for 3 ridges and above to prevent scuffing.

4. Tighten the bolt by applying the following torque.

5. Touch up the tightened portion. (For preventing rust) (Apply the yellow paint as used for coating the machine body.)

6. Apply chocks to the tires.

Tire weight: 1,518 kg <Tire loading images>

Bolt (2) : 824 -- 1,030 Nm {84 -- 105 kgm} Target: 927 Nm {94.5 kgm} Secure the tire with wire to prevent falling.

Cautions

Name

16

Necessary Equipment Q’ty

Name

Q’ty

Impact wrench (For M24)

1

Crane for 50 ton

1

Torque wrench (Set 927 Nm {94.5 kgm})

1

Forklift: 2.5 ton

1

Socket (36 mm)

1

Nylon sling (Withstand load of 1 ton and above)

1

Wire

1

Others

1. Don’t step under the hoisted body when lifting the machine body.

2. Take care not to drop the tire during transportation.

Special tool

Assembly procedure

Installing step

No. 0080 1. Installing step No. 1 2

Part No. 426-54-35182 01024-D1230

Part name Step Bolt

Q’ty Parts conditions 1 Independent product (Separately packed) 4 Temporarily attached to the machine body

1. Install the step to the hydraulic tank.

Cautions

Special tool Name

Necessary Equipment Q’ty 1

Socket (19 mm)

1

Q’ty

Others

Impact wrench (For M12)

Name

17

Assembly procedure

Installing cab (1)

No. 0090 1. Hoisting cab assembly 1. Hoist the cab assembly with a 50 ton crane.

Lifting tool: sling hook type chain lifting tool (2,000 mm × 4 slings, M16 eyebolt × 4)

Cab assembly

Weight: 1,100 kg

2. Installing cab seal No. 1

Part No. 426-56-21330

Part name Seal

Q’ty Parts conditions 1 Independent product (Separately packed)

1. Attach the seal along the periphery of the floor frame’s top surface.

2. Remove oil, grease or dusts from the seal application surface. k Insufficient sealing brings about deficient cab pressurizing performance as well as increased noise level in the cab.

(Important) For sealing effect, have these portions tightly in contact with each other without any gap.

Detailed view of section A

Top view of the floor fram e

Note: Don’t try to cut off the bent portion of the seal.

It must be pasted up.

Cautions

Special tool Name

Q’ty

Impact wrench (For M12, M25, M27)

Each one Each one

Socket (19mm, 36 mm, 41 mm) Torque wrench (Set 932 Nm {95 kgm})

1

Torque wrench (Set 1,300 Nm {132.6 kgm})

1

Others

18

Necessary Equipment Name Crane for 50 ton

Q’ty 1

Sling hook type chain lifting tool (2,000 mm × 4 slings, hoisted by 4 slings)

1

Assembly procedure

Installing cab (2) (AJSS specification)

No. 0100

3. Check of AJSS lock lever position 1. Shift AJSS lock lever to the lock side (LOCKED state) and link for AJSS to the cab side. a Use care so that AJSS lock lever may not shifted to the floor side beyond the boundary.

Top view of floor

2. Shift AJSS rod to OPEN state side with your hands.

(Set it to the floor side.)

Following position must be observed in order to prevent damages of rod

Boundary

Lever side (LOCKED state)

Rod side (OPEN state)

Provide some clearance Step 1

Cab side

Cautions

Step 2

Floor side

Special tool Qâ&#x20AC;&#x2122;ty

Name

Qâ&#x20AC;&#x2122;ty

Others

Name

Necessary Equipment

19

Assembly procedure

No. 0110

Installing cab (2) (Steering wheel specification)

3. Tilting back of the steering ✻ It is necessary to prevent interference with cab side wiper motor 1. Loosens bolts indicated with a mark.

2. Shift the steering lock lever from LOCK position to UNLOCK position.

3. Tilt the steering backward.

Floor viewed from left side

Steering lock lever Tilt it backward

Cautions

Special tool Name

Q’ty

Impact wrench (For M12)

1

Socket (19mm)

1

Others

20

Necessary Equipment Name

Q’ty

Assembly procedure

No. 0115

Installing cab (2) (AJSS and steering wheel specification)

(3)-1. Removal of accelerator pedal ª For prevention of interference when cab is installed

1. Remove bolts marked with a. (5 places) 2. Remove the following connected connectors from the cab wiring harness. ª Remove these connectors from the fixing clips.

• •

Accelerator pedal

Accelerator microswitch (CN C17) Accelerator +5V (CN C30)

3. Remove the accelerator pedal.

Accelerator +5V (CN C30) Accelerator microswitch (CN C17)

Floor seen from right front

Accelerator pedal

Floor seen from right rear Cautions

Special tool Name

Necessary Equipment Q’ty 1

Socket (13 mm)

1

Q’ty

Others

Impact wrench (for M8)

Name

21

Assembly procedure

Installing cab (3)

No. 0120

4. Assembling the cab (cab assembly bolts tightening procedure) No. 1 2 3 4 5 6 7

Part No. 01010-62480 01643-32450 01011-62705 01643-32780 01011-62490 01643-32460 01024-81235

Part name Bolt a Washer a Bolt E Washer E Bolt w Washer w Bolt

Q’ty 4 4 8 8 2 2 12

Parts conditions Temporarily attached to the machine body Temporarily attached to the machine body Temporarily attached to the machine body Temporarily attached to the machine body Temporarily attached to the machine body Temporarily attached to the machine body Temporarily attached to the machine body

Table 1

3 Bolt (1) (5): 883 – 981 Nm {90 – 100 kgm} Target: 932 Nm {95.0 kgm} 3 Bolt (3): 1,157 – 1,442 Nm {118 – 147 kgm} Target: 1,300 Nm {132.6 kgm}

1. Tighten the bolts in 14 locations in the figure below sequentially in the order of 1 to 14 with the tightening torque 147 Nm {15 kgm}. Above tightens the viscous in 4 locations almost uniformly. (Above operation is needed to prevent tilt of the mount plate.) ✻ Assembly of (1) and (2) (marked with a), (3) and (4) (marked with E) and (7) (marked with u) shall be started from below the floor. ✻ Assembly of (5) and (7) (not marked with u) shall be started from above the floor.

2. Then tighten the bolts in 14 locations sequentially in the order of 1 to 14 according to the specified torque (see Table 1).

Cab viewed from the bottom Cautions

Special tool Name

Q’ty

Impact wrench (For M12, M25, M27)

Each one Each one

Socket (19mm, 36 mm, 41 mm) Torque wrench (Set 932 Nm {95 kgm})

1

Torque wrench (Set 1,300 Nm {132.6 kgm})

1

Others

22

Necessary Equipment Name Crane for 50 ton

Q’ty 1

Sling hook type chain lifting tool (2,000 mm × 4 slings, hoisted by 4 slings)

1

Assembly procedure

Installing cab (4) (AJSS specification)

No. 0130 5. Connecting the AJSS link (rod)

Connect

Adjustment nut Lever position when freed

Stopper

When locked

When freed

Lamp lighting range Stop valve

Adjustment nut

Standard length 455

Lever position when locked

1. Connect the link (rod) for AJSS. (When removing the cab, dismount the link for AJSS at this point.)

2. Set the lever to the lock side and then adjust the rod so that the stop valve side lever may be positively contacted against the stopper. (Standard rod length: 455 mm) 3. Continued from above state 2, rotate the adjustment nut backward by a turn and then fix it to the locknut in that state.

(Provide 1 mm clearance from the stopper.)

4. Check of AJSS pilot lamp (in the monitor panel) Make sure that the lamp comes on in its lighting range when the AJSS lock lever is shifted from the lock side to the free side while the engine is run.

Cautions

When locked: Lamp goes off (When engine is stopped) When freed: Lamp comes on

Special tool Qâ&#x20AC;&#x2122;ty

Name

Qâ&#x20AC;&#x2122;ty

Others

Name

Necessary Equipment

23

Assembly procedure

Installing cab (4) (Steering wheel specification)

No. 0140

5. Connecting the cab harness to the steering harnes 1. Connect wiring connectors [CN CL16], [CN CL17] and [CN CL18]. a Since they are DT type connectors, don’t apply the contact conduction restorer to them.

Make sure before connection that inside of the connector is free from dirt, dusts, oil or water.

Clean them, if any.

Also make sure that DT type connectors are locked as mated.

(Clicking sound is emitted when locked. A lock is provided for up to 6 poles and two locks for 8 or more poles.)

Make sure the lock is applied from the sound or using your eyes.

(See the figure below) (8-pole)

Section A-A

(12-pole)

Both of the two locks must be checked.

(Female)

(Male) (Female) N.G GOOD Not locked sufficiently.

Lock is Locked slanted. kept horizontal

(Male)

Both of the two locks must be checked.

GOOD N.G Not sufficiently locked Lock

There is a gap

There is no gap

Connect

Cab viewed from the front side

6. Returning the tilted steering to the original position 1. Return the tilted steering to the original position.

2. Shift the steering lock lever from UNLOCK position to LOCK position.

3. Tighten bolts indicated with a mark.

Return to the original position

Steering lock lever

Floor viewed from left side Cautions

Special tool Name

Q’ty

Impact wrench (For M12)

1

Socket (19mm)

1

Others

24

Necessary Equipment Name

Q’ty

Assembly procedure

Installing cab (5) (Steering wheel specification)

No. 0141 (6)-1. Fixing steering 1. Fix bracket (1) with bolts.

Inside of cab seen from left (Sectional view)

View Z

Part No. 01024-81020

Part name Bolt

Q’ty Parts conditions 2 Loose-supply item (Separately packed)

Cautions

Special tool Name

Necessary Equipment Q’ty

Impact wrench (for M10)

1

Socket (17 mm)

1

Name

Q’ty

Others

No. 1

25

Assembly procedure

No. 0145

Installing cab (6) (AJSS and steering wheel specification)

(6)-2. Reinstallation of accelerator pedal 1. Install the bolts marked with a. (5 places) 2. Install the connectors to the clip and connect them to the cab wiring harness. ª Check the connection point of the connectors.

• Accelerator microswitch (CN C17) • Accelerator +5V (CN C30)

Accelerator pedal

Accelerator +5V (CN C30) Accelerator microswitch (CN C17)

Floor seen from right front

Accelerator pedal

Floor seen from right rear

Cautions

Special tool Name

Q’ty

Impact wrench (for M8)

1

Socket (13 mm)

1

Others

26

Necessary Equipment Name

Q’ty

Assembly procedure

Installing cab harness (1/2)

No. 0150 1. Fastening cab harness No. 1 2 3 4 5

Part No. 285-02-11320 04434-51210 01024-81020 08036-01814 01024-81025

Part name Clips a Clips a Bolt Clips w Bolt

Q’ty 6 6 10 6 1

Parts conditions Temporarily attached to the machine body Temporarily attached to the machine body Temporarily attached to the machine body Temporarily attached to the machine body Temporarily attached to the machine body

1. Fasten the cab harness, air-conditioner harness, and the washer hose with clips (1)(2)(4) and bolts (3)(5).

For the fastening method, see the diagram to the right and the sections A-A and B-B. (Clip (1)(2) marked with a , clip (4) marked with w )

View of the cab from below

Floor Floor

Section B-B

Section A-A

Cautions

Special tool Name

Necessary Equipment Q’ty 1

Socket (17 mm)

1

Q’ty

Others

Impact wrench

Name

27

Assembly procedure

Installing cab harness (2/2)

No. 0160 2. Connecting cab harness

1. Connect wiring connectors [CN C52] and [CN V34].

2. Connect wiring connectors [CN CL11], [CN CL12] and [CN CL13]. a Since they are DT type connectors, don’t apply the contact conduction restorer to them.

Make sure before connection that inside of the connector is free from dirt, dusts, oil or water.

Clean them, if any.

Also make sure that DT type connectors are locked as mated.

(Clicking sound is emitted when locked. A lock is provided for up to 6 poles and two locks for 8 or more poles.)

Make sure the lock is applied from the sound or using your eyes.

(See the figure below) (8-pole)

(12-pole)

Both of the two locks must be checked.

(Female)

(Male) (Female) N.G GOOD Not locked sufficiently.

Lock is Locked slanted. kept horizontal

(Male)

Both of the two locks must be checked.

GOOD N.G Not sufficiently locked Lock

There is a gap

View of the cab from below

Connection: CN C52 (ambient temperature)

There is no gap

View of the cab from below and right

Connection: CN V34 (Orbcomm)

Connection: CN CL11 Connection: CN CL13 Connection: CN CL12

Cautions

Special tool

Others

Name

28

Necessary Equipment Q’ty

Name

Q’ty

Assembly procedure

Installing cab duct (1/3)

No. 0170 1. Installing duct piping No. 1 2 3 4 5 6

Part No. 426-07-32461 426-07-32630 07281-01159 426-56-31580 01024-80612 426-56-31310

Part name Hose Pipe Clamp Clamp Bolt Seat

Q’ty 2 2 4 2 1 2

Parts conditions Independent product (Separately packed) Independent product (Separately packed) Independent product (Separately packed) Independent product (Separately packed) Independent product (Separately packed) Independent product (Separately packed)

Tightening torque (1): 6.8 ± 0.49 Nm {0.69 ± 0.05 kgm}

1. Install pipe (2) before installing hose (1). a Always insert pipe (2), or the duct will be crushed.

2. Install hose (1) with clamp (3).

3. Install clamp (4) and bolt (5).

4. Install seat (6) by seeing the diagram to the right.

Detail of seat (6) position (View of the cab from left)

Caution Apply a seal to the location where interference can result between the bolt and hose.

Section A-A

(from the end of the hose)

2. Installing cab cover No. 1 2 3 4 5

Part No. 426-56-31563 01024-D0616 426-56-31572 01024-D0625 11Y-979-2420

Part name Cover Bolt Cover Bolt a Washer

Q’ty 1 12 1 2 14

Parts conditions Independent product (Separately packed) Independent product (Separately packed) Independent product (Separately packed) Independent product (Separately packed) Independent product (Separately packed)

1. Install cover (1) from outside of the cab.

2. Fix cover (1) with bolts (2), washers (5), bolts (4) (marked with a) and washers (5).

3. Install cover (3) with bolts (2) and washers (5).

Caution Care must be exercised in assembling the cover so that it may not be damaged.

View of the cab from above Cautions

Special tool Name

Necessary Equipment Q’ty 1

Socket (10mm)

1

Q’ty

Others

Impact wrench (For M6)

Name

29

Assembly procedure

Installing cab duct (2/3)

No. 0180 No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Part No. 426-926-3773 418-926-3490 01225-70616 426-07-3200A 426-07-32450 01024-81016 01024-80616 426-926-3781 418-926-3490 01225-70616 426-07-3200B 01024-D0616 426-07-32472 566-54-8A680 11Y-979-2420

Part name Side cover (L.H.) Washer Screw Filter box assembly Filter Bolt Bolt Side cover (R.H.) Washer Screw Rear duct assembly Bolt Cover Screw Washer

Q’ty 1 2 2 1 1 3 2 1 2 2 1 10 1 2 7

Parts conditions Independent product (Separately packed) Temporarily attached to cab Independent product (Separately packed) Independent product (Separately packed) Independent product (Separately packed) Independent product (Separately packed) Independent product (Separately packed) Independent product (Separately packed) Temporarily attached to cab Temporarily attached to cab Independent product (Separately packed) Independent product (Separately packed) Independent product (Separately packed) Independent product (Separately packed) Independent product (Separately packed)

(1) Installing L.H. side cover Install side cover (1) (L) with screw (3) and washer (2).

(2) Installing filter box Install box assembly (4) with filter (5) and bolts (6)(7).

(3) Installing R.H. side cover Install side cover (8) (R) with screw (10) and washer (9).

(4) Installing duct cover Install rear duct assembly (11) with bolts (12) and washers (15).

(5) Installing filter box cover Install cover (13) with screw (14).

View of the cab from the front

Cautions

Special tool Name

Q’ty

Impact wrench (for M6 and M10)

Each one Each one

Others

Socket (10 mm, 17 mm)

30

Necessary Equipment Name

Q’ty

Assembly procedure

Installing cab duct (3/3)

No. 0190 1. Installing filter cover No. 1 2 3 4

Part No. 426-56-3100A 426-07-32440 426-07-3213A 01024-80620

Part name Cover assembly Filter Box assembly Bolt

Q’ty 1 1 1 4

Parts conditions Independent product (Separately packed) Independent product (Separately packed) Independent product (Separately packed) Independent product (Separately packed)

1. Install cover assembly (1), filter (2) and box (3) assembly using bolts (4).

View of the cab from left 2. Installing cover No. 1 2

Part No. Part name 426-926-300A Cover assembly 01024-80816 Bolt

Q’ty Parts conditions 1 Independent product (Separately packed) 4 Independent product (Separately packed)

1. Install cover (1) with bolt (2).

View of the cab from right 3. Installing heater and cooler box and connecting the cooler box piping No. 1 2 3 4 5 6 7 8 9

Part No. 426-54-3200A 01024-D0616 426-07-38111 04434-53211 01024-81070 22D-62-18450 01580-11008 01643-31032 07281-00359

Part name Air-conditioner box Bolt Hose Clips Bolt Collar Nut Washer Clamp

Q’ty 1 4 1 1 1 1 1 1 2

Parts conditions Independent product (Separately packed) Independent product (Separately packed) Independent product (Separately packed) Independent product (Separately packed) Independent product (Separately packed) Independent product (Separately packed) Independent product (Separately packed) Independent product (Separately packed) Independent product (Separately packed)

Clamp (9): 4.4 ± 0.5 Nm {0.45 ± 0.05 kgm}

Z view

1. Install air-conditioner box (1) with bolt (2).

2. Connect hose (3).

Cautions

Special tool

Necessary Equipment

Name

Q’ty

Impact wrench (For M6 and M10)

Each one Each one

Q’ty

Others

Socket (10 mm, 13 mm, 17 mm)

Name

31

Assembly procedure

Installation of yellow rotary lamp

No. 0195 (1) Installation of yellow rotary lamp No. 1 2 3 4 5 6 7 8 9

1.

2.

3.

4.

5.

Part No. 426-957-3120 01024-80860 416-S56-1120 01643-30823 01580-10806 423-957-4120 423-43-18430 04434-51008 01024-80816

Part name Bracket Bolt Cushion Washer Nut Caution lamp Grommet Clip Bolt

Q’ty 1 4 4 8 8 1 1 1 1

Parts conditions Temporarily installed to cab Temporarily installed to cab Temporarily installed to cab Temporarily installed to cab Temporarily installed to cab Loose-supply item (Separately packed) Installed to bracket (1) Installed to bracket (1) Installed to bracket (1)

Remove parts (1) – (5) from the cab.

Pass the wiring harness of caution lamp (6) through grommet (7) of bracket (1) and fix it to the clip.

Install caution lamp (6) and bracket (1) with cushions (3), washers (4) and nuts (5) removed in step 1.

Fix the wiring harness of caution lamp (6) with clip (8) and bolt (9) installed temporarily to the back side of bracket (1).

Connect connector (CN C43) and fix caution lamp (6) and bracket (1) with bolts (2) removed in step 1.

Fix to clip.

Pass wiring harness.

Connect connector: CN C43.

Cautions

Special tool Name Impact wrench (for M8)

Others

Socket (13 mm)

32

Necessary Equipment Q’ty Each one Each one

Name

Q’ty

Assembly procedure

Installing front fender

No. 0200 1. Installing front fender No. 1 2 3 4 5 6

Part No. 426-54-34131 426-54-34141 425-54-24210 426-54-34190 01024-D1025 01024-81230

Part name Fender (L.H.) Fender (R.H.) Seat Guard Bolt Bolt

Qâ&#x20AC;&#x2122;ty 1 1 2 2 6 10

Parts conditions Independent product (Separately packed) Independent product (Separately packed) Independent product (Separately packed) Independent product (Separately packed) Independent product (Separately packed) Temporarily attached to the machine body

1. Install seat (3) and guard (4) to fender (L.H.) (1) and fender (R.H.) (2) using bolt (5).

2. Install the fenders being assembled in 1 above to the front frame.

(R.H. and L.H. must be assembled at the same time)

Identical work for the left and right hand sides (this diagram showing L.H.)

Cautions

Special tool Name

Necessary Equipment Qâ&#x20AC;&#x2122;ty

Name

Qâ&#x20AC;&#x2122;ty

Others

Impact wrench (For M10 and M12) Each one Each Socket (17 mm, 19 mm) one

33

Assembly procedure

Installing front light support and connection

No. 0210

1. Installing front light support No. 1 2 3

Part No. 426-06-33012 426-06-33022 01024-81230

Part name Q’ty Parts conditions Headlamp assembly (L.H.) 1 Independent product (Separately packed) Headlamp assembly (R.H.) 1 Independent product (Separately packed) Bolt 8 Temporarily attached to the machine body

1. Install the headlamp assembly using the bolt.

2. Bring the harness of the headlamp assembly into the front frame.

2. Fixing and connection of harness No. 1 2

Part No. 04434-51010 01024-81016

Part name Clips Bolt

Q’ty Parts conditions 6 Temporarily attached to the machine body 6 Temporarily attached to the machine body

1. Using the clip, fix the harness being brought into front frame in “1. Installing front light support” above.

(3 places in each of left and right side) 2. Connect the wiring connectors [F01] and [F02] and then fix them to the sheet metal clip. a Since they are DT type connectors, don’t apply the contact conduction restorer to them.

Make sure before connection that inside of the connector is free from dirt, dusts, oil or water.

Clean them, if any.

Also make sure that DT type connectors are locked as mated.

(Clicking sound is emitted when locked. A lock is provided for up to 6 poles and two locks for 8 or more poles.)

Make sure the lock is applied from the sound or using your eyes.

(See the figure to the right)

Fixing with clip

(8-pole)

(12-pole)

Both of the two locks must be checked.

(Female)

(Male) (Female) N.G GOOD Not locked sufficiently.

Lock is Locked slanted. kept horizontal

(Male)

Both of the two locks must be checked.

GOOD N.G Not sufficiently locked Lock

There is a gap

There is no gap

Fixing with clip

Tighten together with L.H. positioner harness Connection: CN F01 (R.H.)

Connection: CN F02 (L.H.)

Front frame viewed from rear side Cautions

Special tool Name Impact wrench (For M10 and M12)

Others

Socket (17 mm, 19 mm)

34

Necessary Equipment Q’ty 1 Each one

Name

Q’ty

Assembly procedure

No. 0220

Installing muffler stack and mirror

1. Installing muffler stack No. 1 2

Part No. 426-02-31150 01024-D1240

Part name Muffler stack Bolt

Q’ty Parts conditions 1 Independent product (Separately packed) 4 Temporarily attached to the machine body

1. Install the muffler stack to the upper left side of the engine hood.

2. Installing mirror No. 1 2 3

Part No. Part name 23S-54-36270 Mirror 426-54-35210 Stay 01024-D1225 Bolt

Q’ty Parts conditions 1 Independent product (Separately packed) 1 Independent product (Separately packed) 4 Temporarily attached to the machine body

1. Install the mirror to the upper right side of the engine hood.

Cautions

Special tool Name

Necessary Equipment Q’ty 1

Socket (19 mm)

1

Q’ty

Others

Impact wrench (For M12)

Name

35

Assembly procedure

No. 0230

Installing counterweight (Standard and 1 ton heavier counterweight specifications)

1. Assembling the counterweight Standard counterweight specification No.

Part No.

1

426-46-33711

Counterweight

Part name

Q’ty 1

2 3

01011-63680 01643-33690

Bolt Washer

6 6

Parts conditions Independent product (Separately packed) , Weight: 2,780 kg Temporarily attached to the frame Temporarily attached to the frame

Bolt (2): 2,450 -- 3,040 Nm {250 -- 310 kgm}

Specification of 1 ton heavier counterweight No.

Part No.

1

426-46-33730

Counterweight

Part name

Q’ty 1

2 3

01011-63680 01643-33690

Bolt Washer

6 6

Parts conditions Independent product (Separately packed) , Weight: 3,780 kg Temporarily attached to the frame Temporarily attached to the frame

a It is advisable to use the lever block on one side for the adjustment.

1. Check the part number of the counterweight. (Fig.1) 2. Using the balance-type lifting tool, lift counterweight (1) at the lifting position (Fig.2) and then assemble it with bolt (2) and washer (3).

How to identify two types of counterweights Standard counterweight

1 ton heavier counterweight

Shallow

Deep Holes provided

Shallow

Deep

Without hole

Fig. 2 Lifting position

Fig. 1 Standard counterweight specification

Counterweight lifting position

kg

Cautions

Special tool Name

Q’ty

(Set 2,745 Nm) {279.9 kgm}

1

Socket (55 mm)

1

Others

kg

Necessary Equipment

Torque wrench

36

Specification of 1 ton heavier counterweight

Name

Q’ty

Crane 25 ton

1

Balance-type lifting tool

1

Assembly procedure

Installing counterweight (Load and carry specification)

No. 0235 (1) Installation of counterweight No.

Part No.

Part name

Q’ty

1

426-46-33760

Counterweight

1

2 3

01011-63680 01643-33690

Bolt Washer

6 6

Tightening torque 2,450 – 3,040 Nm {250 – 310 kgm}

Parts conditions Loose-supply item (Separately packed), Weight: 4,785 kg Temporarily installed to frame Temporarily installed to frame

1. Check the part No. of the counterweight (Fig. 1).

2. Sling counterweight (1) with the spreader bar sling and install it with bolts (2) and washers (3).

Use lever block for either side to adjust.

How to distinguish counterweight Counterweight of load and carry specification High High

Shallow No holes Shallow

Fig. 2 Lift points

Fig. 1 Load and carry specification Lift points of counterweight

Cautions

Special tool Name

Necessary Equipment Q’ty

Name

Q’ty

1

25 ton crane

1

Socket (55 mm)

1

Spreader bar sling

1

Others

Torque wrench (Set, 2,745 Nm {280 kgm})

37

Assembly procedure

No. 0240

Installing pin (Standard and EU specifications)

1. Assembling the pin and lynch pin Standard specification No. 1 2

Part No. 426-46-33720 425-46-13130

Part name Pin Lynch pin

Q’ty Parts conditions 1 Independent product (Separately packed) 1 Independent product (Separately packed)

EU specification (Sales code: 6XX44) No. 1 2 3

Part No. 426-46-33740 426-46-33750 01024-D0820

Part name Pin Lynch pin Bolt

Q’ty Parts conditions 1 Independent product (Separately packed) 1 Independent product (Separately packed) 1 Independent product (Separately packed)

1. Open the radiator grill and then assemble pin (1) and lynch pin (2).

2. Assembly pin (1) using bolt (3). (EU specification alone)

Standard specification

EU specification

Z view

Cautions

Special tool Name

Q’ty

Impact wrench (For M8)

1

Socket (12 mm)

1

Others

38

Necessary Equipment Name

Q’ty

Assembly procedure

Installing rear access ladder and L.H. platform

No. 0250

1. Assembling the rear access ladder assembly No.

Part No.

Part name

Q’ty

1

426-54-3400A Rear access ladder

1

2 3 4 5

01010-81635 01643-31645 01010-81635 01643-31645

4 4 3 3

Bolt Washer Bolt Washer

Parts conditions Independent product (Separately packed), Weight: 100 kg Temporarily attached to the machine body Temporarily attached to the machine body Independent product (Separately packed) Independent product (Separately packed)

1. Tighten rear access ladder assembly (1) using (2) to (5).

2. Assembling the L.H. platform assembly No.

Part No.

Part name

Q’ty

1

426-54-3400B Platform assembly L.H.

1

2 3 4

01010-81635 01010-81640 01643-31645

3 4 7

Bolt Bolt Washer

Parts conditions Independent product (Separately packed), Weight: 120 kg Independent product (Separately packed) Independent product (Separately packed) Independent product (Separately packed)

1. Tighten platform assembly L.H. (1) using (2) to (4).

2. Adjust the clearance between the rear access ladder assembly and platform assembly L.H. 3. After the clearance adjustment, fully tighten the bolts of the rear access ladder assembly and platform assembly L.H.

3. Installing mudguard cover No. 1 2

Part No. 426-54-34353 01024-81225

Part name Cover (L.H.) Bolt

Q’ty Parts conditions 1 Temporarily attached to the rear access ladder 4 Temporarily attached to the rear access ladder

1. Assemble cover L.H. (1) using (2).

Cautions

Name

Necessary Equipment Q’ty

Impact wrench (For M12 and M16) Each one Each Socket (19 mm, 24 mm) one

Name

Q’ty

(Withstand load of 100 kg and above)

2

Crane 10 ton

1

Nylon sling

Others

1. After adjustment of the clearance between the rear access ladder assembly and platform assembly L.H , tighten the bolt fully.

Special tool

39

Assembly procedure

Installing the left handrail

No. 0260 1. Assembling the handrail No. 1 2 3 4 5 6 7 8 9 10 11

Part No. 426-54-35133

Part name Rear handrail (L.H.)

Qâ&#x20AC;&#x2122;ty Parts conditions 1 Independent product Temporarily attached to the rear 5 561-54-61910 Clamp (at e marked position) access ladder assembly body Temporarily attached to the rear 10 01010-D1630 Bolt (at e marked position) access ladder assembly body 01643-71645 Washer (at e marked position) 10 Temporarily attached to the rear access ladder assembly body 426-54-3510A Handrail assembly LH-1 1 Independent product 426-54-3510B Handrail assembly LH-2 1 Independent product 421-54-25610 Mirror 1 Independent product 04025-00632 Pin spring 1 Temporarily attached to (7) Temporarily attached to platform 7 561-54-61910 Clamp (at a marked position) assembly L.H. Temporarily attached to platform 01010-D1630 Bolt (at a marked position) 14 assembly L.H. Temporarily attached to platform 01643-71645 Washer (at a marked position) 14 assembly L.H.

Fig. 1

Top

Edge side comes to the top

Rear side comes to the bottom

External view of clamps (2) and (9)

1. After confirming assembling direction of clamp (2), assemble rear handrail (L.H.) (1) using (2) to (4).

Using the same procedure, assemble handrail assembly LH-1 (5) and handrail assembly LH-2 (6) using (9) to (11). a For the confirming method, see Fig.1 to the right.

2. Assemble mirror (7) to handrail assembly (5) by use of pin spring assembly (8).

3. Connect the chain. (See Fig.2)

Connect

Fig. 2

marked position marked position Left side of machine body Cautions

Special tool Name

Qâ&#x20AC;&#x2122;ty

Name

Qâ&#x20AC;&#x2122;ty

Impact wrench (For M16)

1

Nylon sling

Socket (24 mm)

1

(Withstand load of 100 kg and above)

2

Crane 10 ton

1

Others

40

Necessary Equipment

Assembly procedure

No. 0270

Installing right platform and R.H. handrail

1. Assembling the R.H. platform assembly No.

Part No.

1

426-54-3400C

2 3 4 5

01010-81635 01010-81640 01643-31645 01643-31645

Part name Platform assembly R.H. Bolt Bolt Washer Washer

Q’ty 1 3 4 3 4

Parts conditions Independent product (Separately packed), Weight: 150kg Independent product (Separately packed) Independent product (Separately packed) Independent product (Separately packed) Independent product (Separately packed)

1. Assemble platform assembly R.H (1) using (2) to (5). a When the rear fender is to be assembled, tighten the bolt temporarily.

2. Assembling the R.H. handrail No. 1 2 3 4

Part No. 426-54-3510C 426-54-3520A 421-54-25610 04025-00632

5

561-54-61910

6

01010-D1630

7

01643-71645

8

01024-D1230

Part name Q’ty Parts conditions Handrail assembly RH-1 1 Independent product (Separately packed) Handrail assembly RH-2 1 Independent product (Separately packed) Mirror 1 Independent product (Separately packed) Pin spring 1 Temporarily attached to (3) Temporarily attached to platform Clamp (at a marked position) 6 assembly R.H. Temporarily attached to platform Bolt (at a marked position) 12 assembly R.H. Washer Temporarily attached to platform (at a marked position) 12 assembly R.H. Bolt Temporarily attached to platform (at q marked position) 2 assembly R.H.

Edge side comes to the top

Top

Fig. 1

Rear side comes to the bottom

1. Using (5) to (8), assemble handrail assemblies RH (1) and (2) to the platform assembly R.H. (See Fig.2 for (8)) a Check the clamp for its direction.

For the checkup procedure, see Fig.1.

2. Assemble mirror (3) to handrail assembly RH-1 (1) by use of pin spring assembly (4).

3. Connect the chain. (See Fig.2)

marked position Connect

marked position

Fig. 2 Cautions

Name

Necessary Equipment Q’ty

Name

Q’ty

Impact wrench (For M16)

1

Nylon sling

Socket (24 mm)

1

(Withstand load of 100 kg and above)

2

Crane 10 ton

1

Others

1. When assembling R.H. platform assembly (2) and No.0220 rear fender assembly (1), the R.H. platform shall be attached temporarily at this stage.

Tighten it fully after assembling the rear fender.

Special tool

41

Assembly procedure

Installing fire extinguisher

No. 0275

(1) Installation of fire extinguisher to right platform No. 1 2 3 4

Part No.

Part name Q’ty Parts conditions Handrail assembly RH-2 (426-54-3520A) (Fire extinguisher specification) 1 Loose-supply item (Separately packed) 09495-40000 Fire extinguisher 1 Loose-supply item (Separately packed) 01010-80620 Bolt 4 Installed to handrail 01643-30623 Washer 4 Installed to handrail

1. Install fire extinguisher (2) to the bracket of handrail assembly RH-2 (1) (Fire extinguisher specification) with bolts (3) and washers (4).

With fire extinguisher bracket

20 mm

View Z: Machine seen from right Cautions

Special tool Name

Q’ty

Impact wrench (for M6)

1

Socket (10 mm)

1

Others

42

Necessary Equipment Name

Q’ty

Assembly procedure

No. 0280

Installing the rear fender mudguard plate

1. Assembly of rear fender mudguard plate No. 1 2

Part No. Part name 426-54-4200A Plate assembly 01024-D1230 Bolt

Q’ty Parts conditions 1 Independent product (Separately packed) 3 Temporarily attached to the machine body

1. Assemble plate assembly (1) using bolt (2).

Shape is changed.

Cautions

Special tool Name

Necessary Equipment Q’ty

Name

Q’ty

Others

Impact wrench (For M12 and M16) Each one Each Socket (19 mm, 24 mm) one

43

Assembly procedure

Installing rear fender

No. 0290 1. Installing rear fender No. 1 2 3 4 5

Part No. 426-54-3400F 01024-D1230 01010-81690 01643-31645 01580-11613

Part name Q’ty Parts conditions Rear fender assembly 1 Independent product (Separately packed) Bolt 4 Temporarily attached to the platform Bolt 1 Temporarily attached to the platform Washer 2 Temporarily attached to the platform Nut 2 Temporarily attached to the platform

Rear fender

1. Install the fender assembly (1) using the bolt (2).

2. Install the rod using the bolt (3), washer (4) and nut (5).

(See the detailed view of section A)

View of the rear fender from below

Detailed view of section A

External view of rear fender assembly (1)

2. Installing gas spring No. 1 2 3 4 5

Part No. 421-54-31782 01643-30823 04050-12015 04205-10830 07260-02650

Part name Gas spring Washer Cotter pin Pin Hose

Q’ty 2 8 4 4 2

Parts conditions Temporarily install it to rear fender Temporarily install it to rear fender Temporarily install it to rear fender Temporarily install it to rear fender Temporarily install it to rear fender

1. Remove the parts being temporarily installed to section Q. 2. Insert hose (5) from the side to which gas spring (1) not assembled.

3. Lead washer (2) and pin (4) through gas spring (1) and then fix them to section P using cotter pin (3).

(1 location/pin) 4. Implement the same assembly in the opposite side, too.

Cautions

Assembly on both ends must be implemented at the same time.

Special tool Name

Necessary Equipment Q’ty

Others

Impact wrench (For M12 and M16) Each one Each Socket (19 mm, 24 mm) one

44

Name

Q’ty

Nylon sling (withstand load shall be 100 kg and above)

2

10 ton crane

1

Assembly procedure

Installing cab undercover

No. 0300 1. Installing cab undercover (Front) No.

Part No.

Part name

1

426-54-3200C Cover assembly

2

01024-81225

Bolt

Q’ty

Parts conditions Independent product (Separately packed), Weight: 12kg 10 Temporarily attached to cab 1

1. Assemble cover assembly (1) under the cab by use of bolt (2). ( a marked positions: Five places)

marked positions: Five places (Two bolts / place)

2. Installing cab undercover (2) (Rear) No.

Part No.

Part name

Q’ty

1

426-54-3200B Cover assembly

1

2 3

01010-81230 124-54-26540

4 4

Bolt Washer

Parts conditions Independent product (Separately packed), Weight: 7 kg Temporarily attached to the machine body Temporarily attached to the machine body

1. Install the cover assembly (1) to the cab using the bolt (2) and washer (3).

Cautions

Name

Necessary Equipment Q’ty

Name

Q’ty

Impact wrench (For M10 and M12) Each one Each Socket (17 mm, 19 mm) one

Others

1. Install the cab undercover (Rear) from the rear.

Special tool

45

Assembly procedure

Checking of sections

No. 0310 Checkups prior to Start of Engine

1. Check of the assembled parts for interference and oil leakage 2. Check of radiator coolant level, engine oil, transmission oil, hydraulic oil, window washer liquid and front axle oil. a When refilling oil, be sure to confirm the type of oil referencing No.0010.

Cautions

Special tool

Others

Name

46

Necessary Equipment Qâ&#x20AC;&#x2122;ty

Name

Qâ&#x20AC;&#x2122;ty

Assembly procedure

No. 0320

Air bleeding of work equipment hydraulic circuit and respective cylinders

Air bleeding of piston pump and cylinders a Implement the checkup prior to start of engine.

Air bleeding procedures of piston pump 1. Fill up the hydraulic oil tank with the oil.

2. Loosen the plug on the top face of the piston pump (work equipment pump) and the plug (steering pump) at the joint of the case drain hose of the piston pump.

3. After making sure the air is completely bled and oil is leaking from the plug, tighten the plug (work equipment pump) and also the plug at the joint of the case drain hose of the piston pump (steering pump).

Work equipment pump Loosen this plug to bleed air.

Steering pump Loosen this plug to bleed air.

Air bleeding procedures of cylinders 1. Drive the cylinder back and forth two to five times between two points being set at approximately 100 mm away from respective stroke ends.

2. After that, drive the cylinder back and forth three to five times between the stroke ends and then relieve it at respective stroke ends.

Cautions

Special tool Qâ&#x20AC;&#x2122;ty

Name

Qâ&#x20AC;&#x2122;ty

Others

Name

Necessary Equipment

47

Assembly procedure

Starting engine (1/2)

No. 0330

Operations to be carried out prior to start of engine (1) Supply oil and coolant to respective parts.

• Coolant level • Oil level of the engine oil pan • Oil level of hydraulic oil tank • Fuel level • Brake cooling oil level (See the following for the oil refilling procedure) a For the gauge position as well as the oil and coolant level, see the Operation and Maintenance Manual.

(2) Start the engine.

1. For the starting procedures, see the Operation and Maintenance Manual. a Check the Manual for the engine stopping procedure, too.

2. Run the engine for 10 minutes at low idle. a Don’t try to operate the control lever during this period. a If any trouble such as oil leakage or abnormal sounds is detected, stop the engine immediately.

Procedure for adding brake cooling oil (1) After starting the engine, remove plugs (1) and (2) and then refill oil through plug (2).

(2) After making sure the air is bled from the plug (1) and oil is leaking, tighten the plug (1).

Remove this plug (1).

Remove this plug (2) to refill oil.

Cautions

Special tool

Others

Name

48

Necessary Equipment Q’ty

Name

Q’ty

Assembly procedure

Starting engine (2/2)

No. 0340

(3) Confirmation of engine default mode. a All models: E mode (Check that ECO lamp is turned ON) If the ECO lamp is turned OFF, select an option.

1. Turn on the optional device selection function screen from the service mode and then press U switch on the screen to select the optional device.

Optional device selection function screen

2. Pressing U switch will cause transition to the setup screen. Hold down U switch for five seconds or longer.

The select lift arm model optional device screen appears succeeding to the transition.

Select lift arm model optional device screen

3. Select 14. ECO LAMP using < or > switch.

4. Select ADD using U switch. As the change operation is accepted, beep will be sounded.

5. Return to the optional device selection function screen using t switch. a In order to enable the optional device setting, turn the starting switch OFF once to completely turn off power of the onboard controllers (approximately 15 seconds will be required) and then turn the starting switch ON again.

(4) Start checkup after stopping the engine. a Check presence of oil leakage.

Cautions

Special tool Qâ&#x20AC;&#x2122;ty

Name

Qâ&#x20AC;&#x2122;ty

Others

Name

Necessary Equipment

49

Assembly procedure

Bleeding air from brake system

No. 0345 Bleeding air from brake system

a Bleed air from the rear brake first and then bleed from the front brake. <Procedure for bleeding air from rear brake> 1. Start the engine and check that the oil levels in the transmission case and brake sub-tank are normal.

2. Remove the cap of bleeder screw (1) of the slack adjuster and insert either end of the air hose. Prepare a container filled with oil and put the other end of the air hose in the oil to a depth of 50 mm.

3. Press the brake pedal, loosen bleeder screw (1), and keep pressing the brake pedal until the bubbles do not come out of the air hose any more.

4. After bleeding air, tighten bleeder screw (2) securely and put the cap.

5. Release the brake pedal slowly. a Before releasing the brake pedal, tighten bleeder screw (1) or (2).

6. Bleed air from the wheel brake by loosening and tightening bleeder screw (2) similarly to steps 2, 3, 4 and 5.

7. After finishing the above procedure, work on the opposite side similarly.

1. 3 places of rear brake Left wheel brake: 1 place Right wheel brake: 1 place Front brake slack adjuster: 1 place

Common to right and left

<Procedure for bleeding air from front brake> 1. Start the engine and check that the oil levels in the transmission case and brake sub-tank are normal.

2. Remove the cap of bleeder screw (3) of the slack adjuster and insert either end of the air hose. Prepare a container filled with oil and put the other end of the air hose in the oil to a depth of 50 mm.

3. Press the brake pedal, loosen bleeder screw (3), and keep pressing the brake pedal until the bubbles do not come out of the air hose any more.

4. After bleeding air, tighten bleeder screw (3) securely and put the cap.

5. Release the brake pedal slowly. a Before releasing the brake pedal, tighten bleeder screw (3) or (4).

6. Bleed air from the wheel brake by loosening and tightening bleeder screw (4) similarly to steps 2, 3, 4 and 5.

7. After finishing the above procedure, work on the opposite side similarly.

1. 3 places of front brake Left wheel brake: 1 place Right wheel brake: 1 place Front brake slack adjuster: 1 place

Common to right and left

a After bleeding air, add oil to the transmission case and brake sub-tank.

Cautions

Name Air hose (6ø × 1 m)

Others

1. When bleeding air, stop the machine on a flat place and lock the tires with chocks.

Special tool

50

Necessary Equipment Q’ty 1

Name

Q’ty

Assembly procedure

Installing lift arm and bell crank assembly

No. 0350

1. Installing lift arm and bell crank assembly No. 1 2 3 4 5 6

Part No. Part name Q’ty Parts conditions Independent product (Separately packed), Lift arm and bell crank 426-70-3010A assemblies 1 Weight: 5,670 kg 426-70-31991 Pin 2 Temporarily attached to the machine body, Weight: 84.6 kg 01010-82040 Bolt 2 Temporarily attached to the machine body 427-70-11290 Washer 2 Temporarily attached to the machine body 428-70-11440 Shim (t = 1.5) 4 Independent product (Separately packed) 07049-03342 Plug 2 Temporarily attached to the machine body

1. Lift the bucket cylinder by use of the nylon sling (Crane: 10 ton).

2. Wipe out grease and paint in the pin hole and clean.

3. Before installing the pins (2), apply lubricant paste added with molybdenum disulfide (KES LM-P equivalent) to all over the inside surface of the bushing. a Before applying the lubricating oil, make sure that the rust preventives on the inner surface of the bushing is cleaned off.

(If rust preventives remains, it will prevent molybdenum components to settle on the bushing surface, thereby inhibiting the scuffing preventive effect of the lubricating oil.)

4. Hoist the lift arm cylinder and bell crank assemblies with nylon slings.

5. For the shim adjustment instructions, refer to 1., Para. 4, “Assembly Procedure No. 0040”.

2. Installing the lift arm cylinder to lift arm and bell crank assemblies No.

Part No.

1

426-70-31970

Pin

Part name

Q’ty 2

2 3 4 5

01010-81630 425-70-11290 21T-72-17580 07020-00000

Bolt Washer Nipple Fitting

2 2 2 2

Parts conditions Temporarily attached to the machine body, Weight: 42.2 kg Temporarily attached to the machine body Temporarily attached to the machine body Temporarily attached to the machine body Temporarily attached to the machine body

Lift arm

View of the lift arm from inside

Lift arm cylinder

a For the installation method, refer to “1. Installing lift arm and bell crank assembly”, Para. 1 to 2.

(Install pin (1) from inside to outside.) a Take care not to drop pin (1) when inserting.

3. Connecting grease piping No. 1

Part No. 421-09-12540

Part name Elbow

Q’ty Parts conditions 2 Temporarily attached to the machine body

1. Install elbow (1) to the pin.

Identical work for the left and right hand sides (this diagram showing R.H.)

Cautions

Special tool Name

Necessary Equipment Q’ty

Name

Impact wrench (For M16 and M20) Each one Each Socket (24 mm, 30 mm) one

Crane: 10 ton, 50 ton

Large hammer

(Withstand load of 1 ton and above)

1

Q’ty Each one

Nylon sling 3

Nylon sling (Withstand load of 50 kg and above)

2

Nylon sling 1

Others

(Withstand load of 6 tons and above)

51

Assembly procedure

Installing bucket cylinder (Bell crank side)

No. 0360

1. Installing bucket cylinder assembly (Installing bell crank) No.

Part No.

1

426-70-31940

Pin

Part name

Q’ty 1

2

01010-82035

Bolt

1

3

427-70-11290

Washer

1

4

07049-03342

Plug

1

Parts conditions Attached temporarily to the bell crank assembly. Weight: 80 kg.

Attached temporarily to the bell crank assembly.

Attached temporarily to the bell crank assembly.

Attached temporarily to the bell crank assembly.

1. Wipe out grease and paint in the pin hole and clean.

2. Before installing pins (1), apply lubricant paste added with molybdenum disulfide (KES LM-P equivalent) to all over the inside surface of the bushing. a Before applying the lubricating oil, make sure that the rust preventives on the inner surface of the bushing is cleaned off.

(If rust preventives remains, it will prevent molybdenum components to settle on the bushing surface, thereby inhibiting the scuffing preventive effect of the lubricating oil.)

3. Hoist the bucket cylinder assembly with nylon slings.

Bell crank

2. Connecting grease piping No. 1

Part No. 426-70-13270

Part name Elbow

Q’ty Parts conditions 1 Temporarily attached to the machine body

1. Install elbows (1) to the pin.

Bell crank

Cautions

Special tool Name

Necessary Equipment Q’ty

Name

Impact wrench (For M14 and M20) Each one

Crane for 50 ton

Torque wrench

Nylon sling

Socket (22 mm, 30 mm) Large hammer

1 Each one

1

(Withstand load of 500 kg and above)

Others

1

2

Nylon sling (Withstand load of 50 kg and above)

52

Q’ty

2

Assembly procedure

Installing bucket (1/3)

No. 0370 1. Installing the bucket No. 2

Part No. 427-70-12530

Part name (O-ring) cord ring

Q’ty Parts conditions 4 Independent product (Separately packed)

1) Installing cord ring.

1. Place cord ring (O-ring) (2) on the lift arm boss section (1).

2. Apply sufficient volume of LM-G (lithium grease with molybdenum disulfide) to the circumference of the cord ring installing groove.

3. Lower the cord ring (2) to the groove after installing the bucket and adjusting the shims.

4. Apply LM-G (lithium grease added with molybdenum disulfide) to all over the inner surface of the dust seal lip (3).

Bucket assembly

View of the bucket assembly from left

2) Matching of the bucket assembly and hinge pin hole.

1. Hoist the bucket assembly with a 25 ton crane.

Lifting tool: spring hook type chain lifting tool (4,000 mm, 2 slings) Shackle: for 2.5 to 3 ton 2. Align the pin hole on the side of L.H. and R.H. bucket hinges to the pin hole on the side of the lift arm.

Cord ring installation groove

Bucket hinge pin section (Section A-A)

3) Selection of shim for the bucket hinge pin section.

No. –

Part No. 426-70-11320

Part name Shim (t = 1.5)

Q’ty Parts conditions 4 Independent product (Separately packed)

1. Shim adjustment instructions.

1-1. Insert shims so that clearance (A) is equal on the left and right.

(Adjust so that clearance (A) will be below 1.5 mm on each side.)

Bucket assembly Weight: 5,115kg

1-2. Hold the shims with a standard driver (–) or other tools. k Absolutely do not insert fingers into the pin pivot hole.

Bucket hinge pin section (Section A-A)

Cautions

Special tool Name

1. Don’t try to align the holes by hand or fingers after matching the pin hole.

2. G2-LI (lithium grease 2) may be used partly instead of LM-G (molybdenum disulfide lithium grease).

Necessary Equipment Q’ty

Name Crane for 50 ton

Q’ty 1

Chain lifting tool: 1

Shackle: for 2.5 to 3 ton

2

Others

4,000 mm, 2 slings

53

Assembly procedure

Installing bucket (2/3)

No. 0380 4) Inserting the bucket hinge pin.

No.

Part No.

5

426-70-31910

Part name Pin

Q’ty 2

Parts conditions Independent product (Separately packed), Weight: 54 kg

1. Install the shims selected in Para. 3), match the pin holes and insert the bucket hinge pin. Apply grease to the pin before insertion.

2. Take care not to damage dust seal when inserting bucket hinge pin (5).

Lower the dust seal to the groove after inserting the pin.

5) Installing the bucket hinge pin.

No. 6 7

Part No. 01010-81630 425-70-11290

Part name Bolt Washer

Q’ty Parts conditions 2 Independent product (Separately packed) 2 Independent product (Separately packed)

1. Assemble the bucket hinge pin (5) with bolt (6) and washer (7).

6) Lower cord ring (2) to the groove.

Bucket hinge pin section (Section A-A)

Cautions

Special tool Name

Q’ty

Name

Q’ty

1

Impact wrench (For M16)

1

Nylon sling

Socket (36 mm)

1

(Withstand load of 50 kg and above)

Wrench (36 mm)

1

Large hammer

1

Others

54

Necessary Equipment

Assembly procedure

Installing bucket (3/3)

No. 0390

7) Lower cord ring (2) to the groove.

Assemble the bucket link pin in the same manner as step 1) through 7).

No. – – – – –

Part No. 427-70-12530 426-70-11320 426-70-31920 01010-81630 425-70-11290

Part name O-ring Shim (t = 1.5) Pin Bolt Washer

Q’ty 2 2 1 1 1

Parts conditions Independent product (Separately packed) Independent product (Separately packed) Independent product (Separately packed) Independent product (Separately packed) Independent product (Separately packed)

Shim adjustment instructions 1. Select shims so that clearance is equal on the left and right.

(Adjust so that clearance will be below 1.5 mm on each side) 2. Hold the shims with a standard driver (–) or other tools. k Absolutely do not insert fingers into the pin pivot hole.

8) Installing the grease nipple and plug.

1. Apply LM-G (lithium grease added with molybdenum disulfide ) to the bucket hinge pin and bucket link pin.

2. After greasing, set the engine to low idle and then repeat the lift arm LOW – HI and the bucket tilt – dump operations two or three times in order to uniformly apply grease to the pin.

Part No. 07049-01620 07020-00000

Part name Plug Fitting

Q’ty Parts conditions 9 Independent product (Separately packed) 2 Independent product (Separately packed)

Greasing position

Bucket link Bucket hinge (2 locations)

Cautions

Special tool Name

Necessary Equipment Q’ty

Name

Q’ty

1

Impact wrench (For M16)

1

Nylon sling

Socket (24 mm)

1

(Withstand load of 50 kg and above)

Others

No. – –

55

Assembly procedure

Greasing (1st time)

No. 0400

After the assembly, feed the molybdenum disulfide lubricant (KES LM-G) until grease flows out of the joint. a Implement this operation setting the machine to the state shown in Fig. 1.

Target portion of front lubrication (Rear right side portion of front frame)

LM-G is applied (1) Lift arm cylinder (L.H.) (2) Lift arm cylinder (R.H.) (3) Lift arm pin (R.H.) (4) Bucket cylinder (5) Lift arm pin (L.H.)

Fig. 1

Lift the front wheels

Lower the lift arm Cautions

Special tool Name

Others

Grease gun (Hand pump type)

56

Necessary Equipment Qâ&#x20AC;&#x2122;ty 1

Name

Qâ&#x20AC;&#x2122;ty

Assembly procedure

Installing lift arm positioner

No. 0410 1. Assembling the lift arm positioner No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14

Part No. 7861-93-8710 01024-81030 01024-D1020 01602-20825 426-43-39321 01024-D1230 426-43-39341 01024-D1225 04434-51010 01024-81016 04010-00310 426-43-39312 01010-80835 01602-20825

Part name Sensor Bolt Bolt Washer Cover Bolt Cover Bolt Clip Bolt Key Lever Bolt Washer

Q’ty 1 3 1 1 1 3 1 4 1 1 1 1 1 1

Parts conditions Installed to machine body Installed to machine body Attached temporarily to the lift arm and bell crank assembly Attached temporarily to the lift arm and bell crank assembly Independent product (Separately packed) Attached temporarily to the lift arm and bell crank assembly Temporarily attached to machine body Temporarily attached to machine body Temporarily attached to machine body Temporarily attached to machine body Independent product (Separately packed) Independent product (Separately packed) Independent product (Separately packed) Independent product (Separately packed)

Z view

1. Assemble key (11), lever (12), bolt (13) and washer (14) to sensor (1).

In the same manner, assemble the lever using bolt (3) and washer (4).

2. Adjust the positioner voltage.

(See No. 0440 Adjustment of work equipment controller lift arm angle.)

3. Install cover (5) with bolt (6).

4. Install cover (7) with bolt (8).

5. Fasten the harness with clip (9) and bolt (10).

6. Connect the harness. (CN F13)

Connect

Fasten

X view

CN F13 Lift arm angle sensor

2. Checkup of the plug No. 1

Part No. 07049-03342

Part name Plug

Q’ty Parts conditions 3 Installing the plug to the pin

1. Confirm that the plug (1) is assembled to the right side pin (opposite side of the positioner).

Cautions

Special tool Name Impact wrench (for M8, M10, and M12)

Q’ty

Name

Q’ty

1 Each one

Others

Socket (13 mm, 17 mm, 19 mm)

Necessary Equipment

57

Adjustment procedure

Contents of adjustment items

No. 0420

No. 0430 Setting of machine monitor.............................................................

1. Machine monitor operating method 2. How to turn on service mode 3. How to input ID

59

No. 0440 Adjustment of work equipment controller lift arm angle .............

1. Lift arm angle adjustment procedure

60

No. 0450 Adjustment of work equipment EPC starting current (1/2) ..........

Work equipment EPC calibration adjustment procedure

61

No. 0460 Adjustment of work equipment EPC starting current (2/2) ..........

Lift arm LOWER Bucket DUMP Lift arm RAISE Bucket TILT

62

No. 0470 Adjustment of bucket positioner (1/2)............................................

Adjustment of bucket positioner Adjustment of the bucket levelness detection switch Adjustment of the maximum tilt detection switch

63

No. 0480 Adjustment of bucket positioner (2/2)............................................

Adjustment of installation position (stopping position)

64

No. 0490 Adjustment of load meter lift arm angle ........................................

Lift arm angle adjustment procedure

65

No. 0500 Load meter no-load calibration.......................................................

Implementation of no-load calibration (Zero point adjustment)

66

No. 0510 Deleting the electrical system failure history (1/2) .......................

1. Deleting the electrical system failure history 1-1. Deleting the history when only one failure is recorded in the electrical system failure history

67

No. 0520 Deleting the electrical system failure history (2/2) .......................

1-2. Deleting the history when two or more failures are recorded in the electrical system failure history

68

Cautions

Special tool

Others

Name

58

Necessary Equipment Qâ&#x20AC;&#x2122;ty

Name

Qâ&#x20AC;&#x2122;ty

Adjustment procedure

Setting of machine monitor

No. 0430 1. Machine monitor operating method

When implementing the initial setting or option setting of the sensor, you must turn on the service mode for the machine monitor before starting the operation.

Monitor panel selector switch

2. How to turn on service mode Operating method Turn on the machine's starting switch and then turn on the machine monitor power.

When the machine monitor’s character display is showing the ordinary service meter screen or the alarm screen, you can open the service ID input screen by holding down the machine monitor mode selector switch 1 (t) and the machine monitor mode selector switch 2 ( ) simultaneously for 5 seconds or more.

Symbols in the figure indicate the following

Service ID Input Screen

Cursor Most significant digit Least significant digit

3. How to input ID (1) Pressing < / > switch increases or decreases the number at the cursor position. Using this switch, set the specified value and then press U switch.

(2) As the operation of (1) is completed for four digits, the electric system failure history screen will appear.

The space attached with displays the failure history.

(Up to 20 failures are storable)

(3) When you have entered a wrong value, press t switch to return the cursor to the most significant digit and start the entry again from that digit.

(4) If you press t switch while the cursor is at the most significant digit, the screen returns to the ordinary service meter screen or the alarm screen.

(5) If no entry from the switch is made for 60 seconds or longer after input of ID has started, the ordinary service meter screen or alarm screen will be restored.

“6491” is used as the ID when turning on the service mode.

Supplementary explanation: If you turn off the starting switch while the service mode is turned on, the ordinary service meter screen or alarm screen will be restored as you turn on the starting switch next time.

Cautions

Special tool Q’ty

Name

Q’ty

Others

Name

Necessary Equipment

59

Adjustment procedure

No. 0440

Adjustment of work equipment controller lift arm angle

Press switch several times from the electric system failure history screen of the service mode.

The adjustment function screen will appear.

(See No.0360 “2. How to turn on Service Mode”)

Monitor panel selector switch

Adjustment function screen

1. Lift arm angle adjustment procedure

Symbols in the figure indicate the following

(1) Press U switch to display Item No.01: Transmission trigger adjustment and selection screen. a You must hold down U switch for 5 seconds or more to cause the transition to Item No.01.

Adjustment function screen

Cancel Item No.01: Transmission trigger adjustment and selection screen

(2) Using < / > switch, select Item No.05: Work equipment controller lift arm angle adjustment.

Item No.05: Work equipment controller lift arm angle adjustment screen

(3) Press U switch to validate the adjustment item. After the validation, the work equipment controller lift arm angle adjustment screen will appear.

Item No.05: Work equipment controller lift arm angle adjustment screen

(4) Raise the lift arm to the upper limit (cylinder stroke end) and then press U switch from that state.

(5) If the buzzer is sounded twice, the setup procedure is complete.

(6) A second-long buzzer sounds indicate that the currently used lift arm angle voltage is not in compliance with the specified value. In this case, the adjustment is not carried out.

(7) Press t switch to end the adjustment mode. If you press t switch while the calibration is carried on, the operation will be ended even if it is still in process.

(8) When the adjustment is not available, check the lift arm angle sensor voltage from the real time monitor.

Adjust the lift arm angle sensor installation position so that the voltage displayed on the real time monitor may fall within the following range. Then start the sensor adjustment again.

Specification of lift arm A B

Position of lift arm Upper limit position (Raise cylinder stroke end)

Voltage range 3.80 ± 0.3V 3.87 ± 0.3V

Lift arm length by lift arm specification WA600-6

A

B

3,850 mm

3,990 mm

Cautions

Special tool

Others

Name

60

Necessary Equipment Q’ty

Name

Q’ty

Adjustment procedure

Adjustment of work equipment EPC starting current (1/2)

No. 0450

Press switch several times from the electric system failure history screen of the service mode. The adjustment function screen will appear.

Monitor panel selector switch

Adjustment function screen

1. Work equipment EPC calibration adjustment procedure (1) Press U switch to display Item No.01: Transmission trigger adjustment and selection screen. a You must hold down U switch for 5 seconds or more to cause the transition to Item No.01.

Symbols in the figure indicate the following

Adjustment function screen

Cancel Item No.01: Transmission trigger adjustment and selection screen

(2) Using

switch and

switch, display the work equipment EPC adjustment screen of Item No.6 to No.9.

Fig.1: Work equipment EPC adjustment screen Lift arm RAISE

Lift arm LOWER

Bucket TILT

Lift arm RAISE : No. 6 Lift arm LOWER : No. 7 Bucket TILT : No. 8 Bucket DUMP

Respective items must be set up independently

: No. 9

Bucket DUMP

(3) Pressing U switch from this state displays the work equipment EPC setup screen.

Fig.2: Work equipment EPC setup screen Lift arm RAISE

Lift arm LOWER

Bucket TILT

Bucket DUMP

Cautions

Special tool Q’ty

Name

Q’ty

Others

Name

Necessary Equipment

61

Adjustment procedure

Adjustment of work equipment EPC starting current (2/2)

No. 0460 Adjustment of respective EPC

Monitor panel selector switch

[Lift arm LOWER] This correction is done while the engine is run. a After finishing (1) to (3) of the adjustment procedures of No.450 work equipment EPC calibration, proceed to the following operation. (Items of “Lift arm LOWER”) (4)-1 Set the lift arm roughly aligned to horizontally, and lower the lift arm gradually at engine hi-idle.

(5)-1 Return the lever through fine operation until the lift arm is stopped. As the lift arm is stopped, hold the lever at that position.

(6)-1 Press U switch from this state to store the difference between the commanded EPC value and the loaded standard value as the offset value.

(7)-1 If the buzzer is sounded twice and the item display screen (see No.450 Fig.1: Lift arm LOWER) is restored, the setup is complete.

(8)-1 Pressing U switch when the lever is at the neutral clears the adjusted value. In this case, the buzzer is sounded twice and the item display screen (see No.450 Fig.1: Lift arm LOWER) will be restored.

Symbols in the figure indicate the following

[Bucket DUMP] This correction is done while the engine is run. a After finishing (1) to (3) of the adjustment procedures of No.450 work equipment EPC calibration, proceed to the following operation. (“Items of "Bucket DUMP”) (4)-2 Set the lift arm roughly aligned to horizontally, and dump the bucket gradually at engine hi-idle.

(5)-2 Return the lever through fine operation until the bucket is stopped. As the bucket is stopped, hold the lever at that position.

(6)-2 Press U switch from this state to store the difference between the commanded EPC value and the loaded standard value as the offset value.

(7)-2 If the buzzer is sounded twice and the item display screen (see No.450 Fig.1: Bucket DUMP) is restored, the setup is complete.

(8)-2 Pressing U switch when the lever is at the neutral clears the adjusted value. In this case, the buzzer is sounded twice and the item display screen (see No.450 Fig.1: Bucket DUMP) will be restored.

[Lift arm RAISE] This correction is done while the engine is run. a After finishing (1) to (3) of the adjustment procedures of No.450 work equipment EPC calibration, proceed to the following operation. (Items of “Lift arm RAISE”) (4)-3 Dump the bucket, lower the lift arm and then lift the front tire.

Lift the lift arm gradually, (lower the machine), at engine hi-idle.

(5)-3 Return the lever through fine operation until the lift arm is stopped (tires are floated from ground). As the lift arm is stopped, hold the lever at that position.

(6)-3 Press U switch from this state to store the difference between the commanded EPC value and the loaded standard value as the offset value.

(7)-3 If the buzzer is sounded twice and the item display screen (see No.450 Fig.1: Lift arm RAISE) is restored, the setup is complete.

(8)-3 Pressing U switch when the lever is at the neutral clears the adjusted value. In this case, the buzzer is sounded twice and the item display screen (see No.450 Fig.1: Lift arm RAISE) will be restored.

[Bucket TILT] This correction is done while the engine is run. a After finishing (1) to (3) of the adjustment procedures of No.450 work equipment EPC calibration, proceed to the following operation. (Items of “Bucket TILT”) (4)-4 Dump the bucket, lower the lift arm and then lift the front tires.

Tilt the bucket gradually, (lower the machine), at engine hi-idle.

(5)-4 Return the lever through fine operation until the lift arm is stopped (tires are floated from ground). As the lift arm is stopped, hold the lever at that position.

(6)-4 Press U switch from this state to store the difference between the commanded EPC value and the loaded standard value as the offset value.

(7)-4 If the buzzer is sounded twice and the item display screen (see No.450 Fig.1: Bucket TILT) is restored, the setup is complete.

(8)-4 Pressing U switch when the lever is at the neutral clears the adjusted value. In this case, the buzzer is sounded twice and the item display screen (see No.450 Fig.1: Bucket TILT) will be restored.

Cautions

Special tool

Others

Name

62

Necessary Equipment Q’ty

Name

Q’ty

No. 0470

Adjustment of bucket positioner (1/2) All the surfaces traveled Clearance of 3 to 5

Adjustment procedure

Sensor sensing surface

Detection bar

Detailed view of section P

Top view of bucket positioner

For detection of maximum tilt Proximity switch

For detection of bucket level to ground Proximity switch

At maximum tilt

When bucket is level to ground 50 Nominal value

Bucket positioner viewed from the left side

Nominal value

Proximity switch mounting bracket

Detection bar

Adjustment of bucket positioner 1. Lower the bucket to the ground and set it horizontal. (The ground must be flat and level.)

2. Push in the sensing surface of the proximity switch 0.5 to 1.0 mm from the protector edge and then fix the switch. (2 places) 3. The detection bar moves crosswise relative to the sensor's sensing surface. Thus, the adjustment must provide a clearance of 3 to 5 mm along all the surfaces it travels. (2 places)

Adjustment of bucket levelness detection switch 1. Operate the positioner running the engine at medium speed (1,500 rpm) and then adjust the proximity switch mounting bracket in such that the bucket angle when the bucket is placed on the ground becomes 0 to 1° downward. (Repeat above operation three times.)

See above figure for the nominal position of the bracket.

2. Variations in the positioner operation due to the engine speeds shall be within ±1° when the bucket is moved to near the ground.

Adjustment of the maximum tilt detection switch 1. The pin height (H) at the lift arm end shall be 1,000 mm minimum.

2. Set the bucket cylinder to the maximum length.

3. Set the sensor at a position 50 mm away from the detection bar end.

Cautions

Special tool Q’ty

Name

Q’ty

Others

Name

Necessary Equipment

63

Adjustment procedure

No. 0480

Adjustment of bucket positioner (2/2)

Adjustment of installation position (stopping position) (1) (2) (3) (4) (5)

Park the vehicle on a level paved ground and then start the engine.

Using the remote positioner bucket angle set switch, set the stop position to ± 0.

Set the engine mode to the Power and then raise the lift arm until it becomes roughly level.

Set the bucket to the full dump state.

Set the engine to high idle, set the tilt lever to detent and then start operation of the remote bucket positioner.

After this operation, it is prohibited to operate the bucket until the adjustment is complete or its use is permitted.

(6) Lower the bucket to the ground and make sure the bucket is at the level position.

If the bucket is level, the adjustment is complete.

If not, repeat the adjustment from Step (7) and on.

(7) Stop the engine once and then measure the distance from the sensing surface of the bucket level position detecting proximity switch to the detection bar’s tip.

Measurement result: a (8) Turn on the starting switch to lower the bucket bottom to the ground and then set the bucket level.

(9) Turn off the starting switch and then measure the distance from the sensing surface of the bucket level position detecting proximity switch to the detection bar's tip.

Measurement result: b (10)Move the proximity switch position by the differential of c when a – b = c is assumed.

When c is + (a positive value), move the proximity switch mounting bracket backward by the value of c.

When c is – (a negative value), move the proximity switch mounting bracket forward by the value of c.

(11)After conducting above (3) to (6), confirm again that the bucket is horizontal.

Cautions

Special tool

Others

Name

64

Necessary Equipment Q’ty

Name

Q’ty

Adjustment procedure

No. 0490

Adjustment of load meter lift arm angle

Press switch several times from the electric system failure history screen of the service mode. The adjustment function screen will appear.

Adjustment function screen

1.

Monitor panel selector switch

Lift arm angle adjustment procedure (1) Press U switch to display Item No.01: Transmission trigger adjustment and selection screen. a You must hold down U switch for 5 seconds or more to cause the transition to Item No.01.

Symbols in the figure indicate the following

Adjustment function screen

Cancel Item No.01: Transmission trigger adjustment and selection screen

(2) Using < / > switch, select Item No.18: Load meter lift arm angle (Raise) adjustment.

Item No.18: Adjustment items of the load meter lift arm angle (Raise)

(3) Press U switch to validate the adjustment item. As the item is validated, the load meter lift arm angle (Raise) adjustment screen will appear.

Load meter lift arm angle (top) adjustment screen

(4) Raise the lift arm to the upper limit (cylinder stroke end) and then press U switch from that state.

(5) If the buzzer is sounded twice, the setup procedure is complete.

(6) A second-long buzzer sounds indicate that the currently used lift arm angle voltage is not in compliance with the specified value. In this case, the adjustment is not carried out.

(7) Press t switch to end the adjustment mode. If you press t switch while the calibration is carried on, the operation will be ended even if it is still in process.

(8) When the adjustment is not available, check the lift arm angle sensor voltage from the real time monitor. Adjust the lift arm angle sensor installation position so that the voltage displayed on the real time monitor may fall within the following range. Then start the sensor adjustment again.

Position of lift arm Upper limit position (Raise cylinder stroke end)

Voltage range 0.5 to 4.5V

(9) Using < / > switch, select Item No.19: Load meter lift arm angle (Lower) adjustment.

Item No.19: Adjustment items of the load meter lift arm angle (Lower)

(10) Press U switch to validate the adjustment item. As the item is validated, the load meter lift arm angle (Lower) adjustment screen will appear.

Load meter lift arm angle (Lower) adjustment screen

(11) Lower the lift arm to the lower limit (cylinder stroke end) and then press U switch from that state.

(12) If the buzzer is sounded twice, the setup procedure is complete.

(13) A second-long buzzer sounds indicate that the currently used lift arm angle voltage is not in compliance with the specified value. In this case, the adjustment is not carried out.

(14) Press t switch to end the adjustment mode. If you press t switch while the calibration is carried on, the operation will be ended even if it is still in process.

(15) When the adjustment is not available, check the lift arm angle sensor voltage from the real time monitor.

Position of lift arm Lower limit position (Lower cylinder stroke end)

Cautions

Voltage range 0.5 to 4.5V

Special tool Name

Qâ&#x20AC;&#x2122;ty

Name

Qâ&#x20AC;&#x2122;ty

Others

1. This process shall be implemented only for the machines manufactured to the load meter specification.

Necessary Equipment

65

Adjustment procedure

Load meter no-load calibration

No. 0500

1. Implementation of empty load calibration (zero point adjustment)

• Temperature of hydraulic oil: Temperature of the hydraulic oil shall be maintained in the range being employed for ordinary operation. (To be maintained in the range of approximately 60 to 85°C: At or near the white range of the hydraulic oil temperature gauge.)

• Engine speed: The engine speed being employed for ordinary operation (roughly the rated speed) shall be used for the calibration. Be sure to maintain the constant speed.

(Constant speed is required to maintain the lift arm raise speed constant.)

• Bucket posture: When conducting the calibration, the bucket must be set to the full tilt state.

This full tilt state is needed when measuring the weight, too.

If the bucket is set to a posture other than the full tilt, you can’t get accurate measurement since the load’s center of gravity becomes movable.

• Work equipment speed: During the calibration, climbing speed of the work equipment shall be kept constant in the range of -30° to 30°.

• The empty load calibration shall be conducted three times.

(1) Make sure that the usually displayed service meter and clock are shown on the character display unit..

Monitor panel selector switch

Symbols in the figure indicate the following

(2) Display "Load meter" by pressing U of the monitor panel mode selector switch 1.

(3) Select “Calibration” by pressing (U)of the monitor panel mode selector switch 1 and then pressing (>) or (<) of the monitor panel mode selector switch 2.

(4) Press (U) of the monitor panel mode selector switch 1 to display “Empty bucket”.

(5) Press (U) of the monitor panel mode selector switch 1 to display “STEP 1”. In the line below this, “Fully roll back” and “At carry posi” will be alternately displayed in 3 second intervals.

(6) Following the screen instructions, fully tilt back the empty bucket and then set it to the traveling posture.

(7) As the lift arm is lowered, the display will change to “STEP 1 Raise to top”, indicating the preparations for the setting are complete.

(8) Following the screen instruction, raise the lift arm to the upper limit. When raising it, be sure to use as much as possible the practices being employed in actual operations.

(9) As the setting of the empty load calibration is finished, the buzzer will be sounded intermittently, restoring the ordinary display of the service meter and clock. (See (1)) (10) If the empty load calibration is ended in failure, the buzzer will be sounded once, restoring display of “Empty bucket” in the line below the “Calibration”. (See (4)) (11) In the case, repeat the operations from Step (5) and after.

Cautions

Special tool Name

Others

1. This process shall be implemented only for the machines manufactured to the load meter specification.

66

Necessary Equipment Q’ty

Name

Q’ty

Adjustment procedure

No. 0510

Deleting the electrical system failure history (1/2)

1. Deleting the electrical system failure history Turn on the electrical system failure history screen from the service mode.

Then select the electrical system failure history option from the screen by use of U switch.

Monitor panel selector switch

Electrical system failure history screen The field attached with ✻✻ displays the number of failures being stored up to present.

(Up to 20 failures are storable) Symbols in the figure indicate the following

0 displayed in ✻✻ field indicates that there is no recorded failure in the electrical system failure history. In this case, therefore, deleting operation is not necessary. Pressing U switch from this state turns on the following screen that appears when there is no failure history.

Electrical system failure history screen - When there is no history

1-1. Deleting the history when only one failure is recorded in the electrical system failure history 1. Select the electrical system failure history option using U switch. Following screen will appear.

Display electrical system failure history screen ✻✻✻: ######: $$$: %%%%%:

Cancel

Indicates the chronological order of the failure concerned Indicates the unified failure code (6 digits) Indicates frequency of failures occurred Indicates the time elapsed since the occurrence of displayed failure (The value obtained by subtracting the service meter value when the failure occurred the first time from the current service meter value.) @@@@@: Indicates the time elapsed since the occurrence of displayed failure (The value obtained by subtracting the service meter value at the latest occurrence from the current service meter value.)

2. Pressing U switch displays the history deletion screen.

Display electrical system failure history deletion screen

3. Move the cursor to YES position using < or > switch and then press t switch to delete the history.

4. As failures are deleted, the failure history screen will be restored. Make sure 0 is indicated for the history.

Make sure 0 is displayed for ✻✻.

However, it is not available to delete a currently developing failure from the history.

As for a currently developing failure (error), make sure the error announcement is stopped before deleting it.

Cautions

Special tool Q’ty

Name

Q’ty

Others

Name

Necessary Equipment

67

Adjustment procedure

No. 0520

Deleting the electrical system failure history (2/2)

1-2. Deleting the history when two or more failures are recorded in the electrical system failure history

Monitor panel selector switch

1. Select the electrical system failure history option using U switch. Following screen will appear.

Display electrical system failure history screen

Symbols in the figure indicate the following

✻✻✻: ######: $$$: %%%%%:

Indicates the chronological order of the failure concerned Indicates the unified failure code (6 digits) Indicates frequency of failures occurred Indicates the time elapsed since the occurrence of displayed failure (The value obtained by subtracting the service meter value when the failure occurred the first time from the current service meter value.) @@@@@: Indicates the time elapsed since the occurrence of displayed failure (The value obtained by subtracting the service meter value at the latest occurrence from the current service meter value.)

2. Select the electrical system failure history all clear item screen using U switch.

Display electrical system failure history all clear screen

Cancel 3. Pressing < or > switch displays the electrical system failure history all clear screen.

Display electrical system failure history all clear screen

4. Move the cursor to YES position using < or > switch and then press t switch to delete the history.

5. As failures are deleted, the failure history screen will be restored. Make sure 0 is indicated for the history.

Make sure 0 is displayed for ✻✻.

However, it is not available to delete a currently developing failure from the history.

As for a currently developing failure (error), make sure the error announcement is stopped before deleting it.

Cautions

Special tool

Others

Name

68

Necessary Equipment Q’ty

Name

Q’ty

Adjustment procedure

No. 0530

Installing the floor mat (AJSS specification)

1. Installing floor mat No. 1 2

Part No. 426-54-32473 426-54-32161

Part name Mat (For AJSS) Seat (For AJSS)

Q’ty Parts conditions 1 Independent product (Separately packed) 1 Independent product (Separately packed)

1. Install the mat (1) and seat (2) to the floor.

Cautions

Special tool Q’ty

Name

Q’ty

Others

Name

Necessary Equipment

69

Adjustment procedure

No. 0540

Installing the floor mat (Steering wheel specification)

1. Installing the floor mat No. 1 2

Part No. 426-54-32571 426-54-32170

Part name Mat (For steering wheel) Seat (For steering wheel)

Q’ty Parts conditions 1 Independent product (Separately packed) 1 Independent product (Separately packed)

1. Install mat (1) and seat (2) on the floor.

Cautions

Special tool

Others

Name

70

Necessary Equipment Q’ty

Name

Q’ty

Adjustment procedure

Running-in procedure (1/2)

No. 0550 Running-in procedure

(1) Before starting the engine, loosen the plug on the top face of the piston pump (Fig. A, indicated with U mark) and the plug at the joint of the case drain hose of the piston pump (Fig. A, indicated with E mark). After making sure the air is completely bled and oil is leaking from the plug, tighten the plug (Fig. A, indicated with U mark) and also the plug at the joint of the case drain hose of the piston pump (Fig. A, indicated with E mark).

Work equipment pump

Fig. A

Steering pump

(2) Start the engine and run it at low idle for approximately 5 minutes. Then check leakage of oil from relevant parts.

(3) Run the engine at low idle and then turn on the work equipment operations from a to e (see below).

Work equipment operation Operation a Operation b Operation c

Operation d

Move the lift arm up and down using the lift arm lever to operate the bucket between the ground – the rear at the level position. ···Five times Raise the lift arm up using the lift arm lever to operate the bucket between the ground – the rear just short of the lifting height limit position (approximately 100 mm before the stroke end of the lift arm). ···Five times Set the lift arm level and then repeat the tilt – dump operation using the bucket lever. ···Five times (In both tilt and dump, the operation shall be stopped at a position approximately 100 mm before the bucket cylinder stroke end.)

Move the lift arm up and down using the lift arm lever to operate the lift arm cylinder between MIN stroke and MAX stroke. ···Five times (In MIN stroke, lower the lift arm until the bucket is pushed against the ground and the front wheels are lifted up. See Fig. B.)

Fig. B

Lift the front wheels

Lower the lift arm

Set the lift arm level and then repeat the tilt – dump operation using the bucket tilt lever. ···Five times (In both tilt and dump, operate the bucket cylinder to its stroke end.)

Cautions

Special tool Name

Necessary Equipment Q’ty

Name

Q’ty

Others

Operation e

71

Adjustment procedure

Running-in procedure (2/2)

No. 0560

(4) Stop the engine and then loosen the air bleeding plug ( Q marked plug in Fig. C) situated on the top of the filter case of the hydraulic tank.

(5) After making sure the air is completely bled and oil is leaking from the plug, tighten the plug. (Fig. C, indicated with Q mark) (6) Stop the engine after setting the machine to the oil level check posture (bucket horizontal to the ground) and then feed oil up to the oil level of the tank. (HI level of the level gauge) (7) Start the engine and increase the speed up to approximately 1,500 rpm and then turn on the work equipment operations from a to e (see above). Bleed air from the tank again according to the procedure described in (4) and (5) above. Check the oil level according to the procedure of (6) above and, if insufficient, feed oil again.

(8) Increase the engine speed to high idle and then perform the operation described in (7) above.

(9) Stop the engine and then loosen the plug (Fig. A, indicated with U mark) on the top face of the piston pump and the plug (Fig. A, indicated with E mark) at the joint of the case drain hose of the piston pump.

After making sure the air is completely bled from the plug and oil is leaking, tighten the plug (Fig. A, indicated with U mark) and also the plug (Fig. A, indicated with E mark) at the joint of the case drain hose of the piston pump.

Fig. C Hydraulic tank

Filter case

Cautions

Special tool

Others

Name

72

Necessary Equipment Qâ&#x20AC;&#x2122;ty

Name

Qâ&#x20AC;&#x2122;ty

Adjustment procedure

Greasing (2nd time)

No. 0570

After the running in, feed the molybdenum disulfide lubricant (KES LM-G) until grease flows out of the joint. a Implement this operation setting the machine to the state shown in Fig.1.

Target portion of front lubrication (Rear right side portion of front frame)

LM-G is applied (1) Lift arm cylinder (L.H.) (2) Lift arm cylinder (R.H.) (3) Lift arm pin (R.H.) (4) Bucket cylinder (5) Lift arm pin (L.H.)

Fig. 1

Lift the front wheels

Lower the lift arm

Cautions

Special tool Name

Qâ&#x20AC;&#x2122;ty

Name

Qâ&#x20AC;&#x2122;ty

1

Others

Grease gun (Hand pump type)

Necessary Equipment

73

Adjustment procedure

Touch up work

No. 0580

a If coating of a part is peeled off due to use of the lifting tool, machine work or hitting, be sure to touch up such portion.

(Touch up work for the following (1) to (8) are indispensable. Touch up for others is also required when peeling is found.)

(1) Lift arm: Nylon sling lifting section (2) Lift arm: Sections being dented in the process of assembling the pin (3) Lift arm cylinder: Nylon sling lifting section (4) Lift arm cylinder: Sections being dented in the process of assembling the pin (5) Bucket cylinder: Nylon sling lifting section (6) Bucket: Sections being dented in the process of assembling the pin (7) Machined sections on tire (8) The section where the counterweight has been placed

Cautions

Special tool

Others

Name

74

Necessary Equipment Qâ&#x20AC;&#x2122;ty

Name

Qâ&#x20AC;&#x2122;ty

Adjustment procedure

No. 0590

On use of starter kit (dummy harness) and precaution on its use

1. On use of starter kit (dummy harness) •

•

When a machine is not movable into the maintenance shop without removing its operator cab or when it is needed to move a machine to a safer place for damages on its operator cab, using the starter kit (dummy harness) allows the machine to a desired location.

In the operation, the starting switch and parking brake switch of the starter kit (dummy harness) are used in place of the starting switch and parking brake switch on the machine body.

2. Precaution on use of starter kit (dummy harness) The starter kit (dummy harness) is used for moving a machine in to the maintenance shop or moving it from a worksite to a safe repairing place.

It is strictly prohibited to use the kit in actual work.

3. Precaution on removing or installing the operator cab or the starter kit (dummy harness)

• • • •

Park the machine in a level and solid ground.

The selected place shall be free from risks such as collapse of dirt and dust, falling of rocks or submersion under water.

Lower the work equipment to the ground and then stop the engine.

Turn on the parking brake switch and then apply chocks to the front and rear side of tires.

Lock the front and rear frames using the frame lock lever.

When AJSS is used, shift the steering lock lever to the lock position.

Cautions

Special tool Name

Necessary Equipment Q’ty

Name

Q’ty

Others

• •

75

Adjustment procedure

No. 0600

Starter kit (dummy harness) assembling procedure

1. Assembling the starter kit (dummy harness) Caution: Prior to installation or re-connection a Be sure to perform the operation described in Adjustment procedure No. 590, carry out the following procedure.

No. 1 2 3

Part No. 426-06-31540 09056-04613 426-98-33410

Part name Wiring harness Bag Plate

Qâ&#x20AC;&#x2122;ty Parts conditions 1 Contained in bag (2) 1 Independent product (Separately packed) 1 Contained in bag (2)

1.

2.

3.

4.

Connect connector CL12 of the dummy harness to the floor harness.

Connect connector C17 of the dummy harness to the accelerator pedal connector.

Connect connector CL16 of the dummy harness to the steering harness.

After connecting the harnesses, turn on the starting switch to start the engine and then turn off the parking brake switch to move the machine to a maintenance factory or move the machine from a worksite to a safe repairing place.

5. After moving the machine to the intended place, turn on the parking brake and turn off the starting switch.

6. Apply chocks to the front and rear side of tires.

7. Remove the dummy harness and then connect the original harness to the connector.

Parking brake ON

Parking brake OFF Starting switch Parking brake switch

CN CL12: Connected CN C17: Connected

Dummy harness

Z view

Cautions

Special tool

Others

Name

76

Necessary Equipment Qâ&#x20AC;&#x2122;ty

Name

Qâ&#x20AC;&#x2122;ty

1/7

B Oil and coolant capacity

A

Specifications

Item

No error of machine serial number or stamping ?

Must be legible from 1 meter away (Model name

)

Correct stamping error with (K)

)

Is the stamping on machine nameplate correct ?

Acceptable if legible

Verification of specifications

(Serial No.

Concordant with the machine serial number ?

Matching the manufacturing instructions ?

Any changes made during the delivery inspection process ?

Radiator coolant level

Higher than the lower end of the coolant filler

Capacity of radiator sub-tank

L–H

Hydraulic oil level

Side gauge 3/4 to 4/4

[

]

Transmission oil level

Between H and L and up to H

[H±

]

Engine oil level

Between H and L and up to H

[H±

]

Fuel level

3 segments or higher

[

]

[

]

Lighting and specifying the pilot and indicator (Bench inspection) [

]

(Delivery inspection) [

]

Sounding of horn Neutral safety function Performance and reading of hour meter

Before starting engine

Measured value

Judgement procedure & standard

Recording the main switch key No.

C

Judgement

No.

Sound volume and abnormal sound Engine to start only with the gear at neutral position

Engine startability

Is engine startability normal ?

Any abnormal sound during start ?

Performance of parking brake

Must light up when turned ON; but not start traveling; transmission lever (button) must sound buzzer in forward or reverse with the caution lamp flashing

Performance of the main monitor panel self-checking

All monitors and gauges to light up for 3 seconds upon main switch ON, and warning buzzer to sound for 1 second

Performance of emergency steering pilot lamp

To light up upon main switch ON

Performance of starting inspection monitor

No warning lamps or buzzer will be lit or sounded for coolant temperature gauge, T/C oil temperature gauge, oil and coolant level meter, engine oil pressure gauge, brake oil pressure gauge, charging and air cleaner

Seat position adjustable ?

Fore-aft adjustment, reclining adjustment, headrest angle adjustment, seat cushion up-down adjustment, seat angle adjustment, headrest up-down adjustment, armrest height adjustment, armrest angle adjustment and lumbar support adjustment

Performance of air suspension seat

Are the seat up-down and weight adjustable ?

Seat belt check

Are the length adjustment and locking and unlocking function normal ?

Is the lever locking function normal ?

Work equipment control lever adjustment Is armrest angle adjustable (10°) ?

Is armrest height adjustable (50 mm) ?

Is the AJSS lever locking function normal ?

AJSS lever adjustment

Is armrest angle adjustable (10°) ?

Is armrest adjustable up-down (50 mm) ?

Is AJSS lever adjustable fore-aft (160 mm) ?

Engine not to start unless AJSS lever is in neutral position Warning buzzer to sound peeping if the lever is not in neutral.

Neutral safety function

Engine not to start unless forward-reverse switch is in neutral position Warning buzzer to sound peeping if the lever is not in neutral.

Confirmation of repair Nature of repair

Category

2/7

Item

Measured value

Judgement procedure & standard

Accelerator pedal pressing effort

The pedal not to be caught when returned slowly

Adjusting accelerator pedal stopper

0 – 2 mm

Play and return of brake pedal

No dragging

Operating effort of transmission operation N o F, R1.3 ± 0.1 F, R o N; 0.7 ± 0.1 button Shift up-down; 0.7 ± 0.1 (sensory) Performance of work equipment control lever

Is operating effort normal ?

Performance of work equipment control lever lock

No spontaneous unlocking, and the lift arm and bucket not to be lowered

Performance and adjustment of kick-out

3 mm or under by the cylinder stroke (when lift arm is not attached, apply a metal piece to senser and checking)

Automatic reset of winkers

Is the winker reset when machine body steered to opposite direction by 10° and over ?

Performance and adjustment of leveler

(when lift arm is not attached, apply a metal piece to senser and checking)

Lifting with lift arm locked up

Must rise

Adjustment of frame steering angle

Not to be interfered by the front and/or rear frames

Steering lever operating effort

Operating effort 1.4 ± 0.5 kg (sensory)

Abnormal sound during steering swing

No clattering from the cylinder

D

Performance, Function

Abnormal engine noise, color of emission, Shall be normal and hunting Engine pick-up performance

Engine to pick up during low idle with load

Engine stall performance

No stalling during low idle with load

Performance of shift lever

Is selection normal ? No shifting error ?

Forward-reverse button function

No shifting to 2nd speed when selecting forward-reverse in 1st speed

Checking on transmission shock and time Check by selecting forward-reverse in 1st and 2nd speeds lag slipping and accelerating and decelerating on each gear speed Kick-down switch performance

Will change to F1 upon switch ON during travel in F2 ?

Transmission modulation function

Find out a checking method with production machines

Abnormal noise from rear axle

Abnormal noise from near the axle during sudden braking and forward-reverse travel

Performance of parking brake

Don’t start traveling in F3 after applying emergency performance to the machine

Braking force

Machine must stop upon applying braking while traveling in F2P mode with engine at full speed

Emergency steering function

Is performance normal ?

Speedometer performance

Isn’t there any error indication ?

Travel speed

Forward 1st gear speed 6.3 to below 7.1 km/h (onboard gauge)

[

km/h]

Power mode

Forward 2nd gear speed 11.1 to below 12.3 km/h (onboard gauge)

[

km/h]

Forward 3rd gear speed

19.3 to below 21.3 km/h (onboard gauge); tempa spare tire not measured

[

km/h]

Forward 4th gear speed

32.1 to below 35.5 km/h (onboard gauge); tempa spare tire not measured

[

km/h]

Travel speed

Forward 1st gear speed 6.2 to below 7.0 km/h (onboard gauge)

[

km/h]

ECO mode

Forward 2nd gear speed 10.9 to below 12.1 km/h (onboard gauge)

[

km/h]

Forward 3rd gear speed

18.4 to below 20.4 km/h (onboard gauge); tempa spare tire not measured

[

km/h]

Forward 4th gear speed

29.9 to below 33.1 km/h (onboard gauge); tempa spare tire not measured

[

km/h]

Travel speed during lockup

Should be slightly faster than when the lockup is OFF

Judgement

No.

Confirmation of repair Nature of repair

Category

3/7

Item

Measured value

Judgement procedure & standard Travel in F2 at 5 km/h or higher and check that the lift arm operates

Function of E.C.S.S.

Must be manually operable during manual operation

Travel function

Transmission automatic shifting function

From 2nd speed to 3rd speed during L (change gear during travel at 5 to 7 km/h)

[

km/h]

From 3rd speed to 4th speed during L (change gear during travel at 13 to 16 km/h)

[

km/h]

From 2nd speed to 3rd speed during H (change gear during travel at 7 to 9 km/h)

[

km/h]

From 3rd speed to 4th speed during H (change gear during travel at 15 to 18 km/h)

[

km/h]

Must not change to 2nd speed when selecting forwardreverse travel in 1st speed.

F4 to be selected when traveling in R4 at 17 km/h with engine revolution at 2,000 rpm or higher. ➡ R4 o F4 o F3 o F2 o F3 o F4

High speed shift

Peeping is sounded

Will the pilot turn ON-OFF with the lift arm lever switch ?

Is the shift held with the switch at ON position ?

(Hold the shift in F2, set the transmission lever in F4 and check the holding)

Shift hold function

Kick-down switch performance

Will gear shift to 1st speed when the switch is ON during travel in 2nd speed, or will the gear reset to F2 after 4 seconds ?

Travel must change to F1 at 9 km/h or lower in 3rd and 4th speeds Can indication be changed with the load meter select switch ?

Can the work object be changed with A/B switch ?

Function of load meter (optional)

+/- Can addition/subtraction mode be selected using the switch ?

Can total weight be indicated with the load meter indication select switch ?

D

Performance, Function

AJSS

Must be steered to the right when AJSS lever is tilted to the right Must be steered to the left when AJSS lever is tilted to the left AJSS lever function

Has AJSS been initialized ?

Will machine stop when AJSS lever is tilted to the left (or right) and held

Working speed

Lift arm RAISE

8.6 – 9.6 sec

[

sec]

(ECO mode)

Lift arm LOWER 3.7 – 4.7 sec

[

sec]

DUMP

2.2 – 2.8 sec

[

sec]

TILT

2.7 – 3.5 sec

[

sec]

Working speed

Lift arm RAISE

8.1 – 9.1 sec

[

sec]

(Power mode)

Lift arm LOWER 3.6 – 4.67 sec

[

sec]

FLOAT

3.5 – 4.5 sec

[

sec]

DUMP

2.0 – 2.6 sec

[

sec]

TILT

AJSS lever swing time

2.7 – 3.3 sec

[

sec]

Left 2.8 – 3.5 sec (High idle)

[

sec]

Right 2.8 – 3.5 sec (High idle)

[

sec]

Left 5.8 – 6.6 sec (Low idle)

[

sec]

Right 5.8 – 6.6 sec (Low idle)

[

sec]

Engine speed:

Low idle

775 – 825 rpm

[

rpm]

Engine speed:

High idle

1,850 – 1,950 rpm

[

rpm]

(Economy)

T/C stall

1,630 – 1,830 rpm

[

rpm]

Stall during working 1,730 – 1,930 rpm

[

rpm]

Engine speed: (Power mode)

Full stall

1,490 – 1,690 rpm

[

rpm]

High idle

1,950 – 2,050 rpm

[

rpm]

T/C stall

1,700 – 1,900 rpm

[

rpm]

Stall during working 1,840 – 2,040 rpm

[

rpm]

Full stall

[

rpm]

1,580 – 1,780 rpm

Judgement

No.

Confirmation of repair Nature of repair

Category

4/7

D

Performance, Function

Item

Judgement procedure & standard

Indicator must light up when the rotation set switch is turned ON When the switch is turned ON (depressed) at an rpm desired for setting accelerator pedal to, the throttle must be locked at that rpm If the switch is kept depressed for 0.5 sec. or over, the rpm rises. When you stop pressing the switch, the engine rotation must be locked at that rpm The rpm set above should return to low idle speed automatically unless the work equipment control lever is operated for 5 to 10 sec. with transmission in neutral position.

Throttle locking function If the accelerator pedal is stepped on from the above state, and the set rpm is exceeded, the rpm must automatically return to the set value Other than above-mentioned, rpm should return to the set rpm when the work equipment is operated When the lower side of the switch is depressed, the rpm keeps on dropping and must be locked at a position when the pressing is stopped Stepping on the R.H. brake pedal must bring the rpm to low idle speed Lifting mode: Turn the lifting switch ON and depress the lifting switch when the lift arm is at higher position than level. Will the position be set with blip sound ?

(Stretched peeping will sound if setting fails) Lifting mode: Does the lift arm automatically stop at the set position above ?

Verification of remote positioner function Lowering mode: Turn the lowering switch ON and depress the switch when the lift arm is at lower position than level.

Will the position be set with blip sound ?

(Stretched peeping will sound if setting fails) Lowering mode: Does the lift arm automatically stop at the set position above ?

Can depressing the remote positioner bucket angle setting switch once to the tilt side display +1°, another depressing Verification of remote positioner bucket indicate +2° and so on until +5° ? angle setting function Does the bucket cutting edge stop on the tilt side when the a If successfully set, blip sounds after bucket angle is set as above ?

2.5 seconds and the setting is memorized. Also, if the switch is not Can depressing the remote positioner bucket angle setting operated for 3 seconds, the setting switch once to the dump side display -1°, another returns to the original speed and rpm depressing indicate -2° and so on until -5° ? indication.

Does the bucket cutting edge stop on the dump side when the bucket angle is set as above ?

Turn the starting switch ON when the engine is not running. o Turn reverse switch ON. o Machine monitor pilot lamp lights up. o Start the engine. o Verify that the fan is reversing (distinguish normal or reverse rotation by the Verification of cooling fan reversing blowing direction of the fan) Engine at low speed. o Engine stop. o Starting switch ON. o Reverse switch OFF. Start engine. Is the fan rotating normally ? (check by the wind direction) Set the dial (Variable Traction Control) to the lowest and step on the R.H. brake in F1 and increase the engine Verification of drive force control function speed. Then T/C stall must follow. Also, when the dial is set to the highest, the machine should travel slowly without T/C stall.

OFF o Normal lever operation ?

Does the pilot lamp light when the switch is turned ON (Hard or Soft) ?

Machine must perform automatic digging under the Vefification of semiautomatic digging following conditions: mode (1) When the lift arm is near the ground level (2) When kick-down switch is operated from forward 2nd speed (3) When the work equipment lever is operated for the lifting If the above is hard switch, several digging must follow.

In the case of soft switch, only one digging should follow Stop the engine with the parking brake switch OFF and Verification of emergency parking brake then turn the starting switch ON again. The parking brake unlocking function then remains ON. Will the parking brake turn OFF when this emergency unlocking switch is turned ON ?

Procedures ➡ Step on L.H. brake about 50% and set the Verification of modulation clutch direct machine in F1. When engine speed is raised from 1,400 to switch 1,500 rpm later, the machine does not move. It should start traveling only upon turning the direct switch ON

Measured value

Judgement

No.

Confirmation of repair Nature of repair

Category

5/7

Item

Judgement procedure & standard

D

Performance, Function

While traveling forward in 1st speed, L.H. brake is gradually stepped on. Will the machine travel speed gradually drop and does the machine stop at the end ?

Verification of modulation clutch slip

If the machine remains in the above-mentioned condition (clutch slipping) for an extended period of time, the hydraulic oil temperature rises. Then will the caution lamp light up ?, and if the oil temperature continues to rise, will the caution buzzer start sounding ? (Once buzzer sounds, return the clutch to the neutral immediately and reduce rpm simultaneously)

Verification of E.C.S.S. damper function

Travel in F2 or faster at 5 km/h or higher and turn the E.C.S.S. switch ON. Then the lift arm must rise slightly

Performance of work equipment accumulator

Stop engine with the lift arm raised to level or higher position. Then turn the main switch ON and lower the lift arm lever. Will the lift arm be lowered ?

Performance of battery isolator (Optional)

Engine should be disabled to start when the isolator switch is turned OFF

No oil leakage from each joint ?

Verification of locally assembled portions

No water leakage from each joint ?

No fuel leakage from each joint ?

Is paint touch-up work of locally assembled portions acceptable ?

Are the locally assembled portions securely tightened ?

Are there any oil attached to locally assembled portions ? (Machines washed completely ?)

Measured value

Judgement

No.

Confirmation of repair Nature of repair

Category

6/7

Judgement procedure & standard

Performance of fuel gauge

Must be located within the operation range (Check the fuel when the tank is full)

Performance of torque converter hydraulic oil temperature gauge

Must be located within the operation range

Performance of engine coolant temperature gauge

Must be located within the operation range

Performance of various light switches

Any loose mounting or resistance to smooth switching ?

Lighting of dash lamp

Cluster, speedometer and hour meter

Lighting of headlamp

Lo-Hi selection and the lighting of pilot lamp

Lighting of clearance lamp

Lighting of left and right lamps (lighting should follow one stage before the switch)

Lighting of number plate lamp

Should light up even one stage before the switch

Lighting of braking lamp

Lighting of the left and right lamps

Lighting of tail lamp

Lighting of left and right lamps (lighting should follow one stage before the switch)

Lighting of backup lamp

Lighting of the left and right lamps

Lighting of working lamp

Lighting of the left and right lamps and pilot lamp

Flashing of turn signal lamps

Flashing of the front, rear, left, right and the pilot lamps

Flashing of hazard signal lamps

Front, rear, left, right signal lamps and the pilot lamp to start flashing upon main switch OFF

Sounding of backup buzzer

Must sound

Check lighting of step lamps

Do the step lamps light ?

(Enabled to turn OFF below when lit up above or vice versa ?)

Measured value

Inspection of electrical equipment (using a harness checker) Caution: Fuse will blow if the harness checker and machine connectors are connected wrong way.

Verification of initial power supply

Will EVER 24 V light up with the main switch OFF ?

Performance of power windows

Performance of console box switches and the lamp lighting Left positions of the harness check must coincide Right (be careful for the right side and wrong side)

Verification of air-conditioner and heater Performance of ON-OFF switches

Warm wind should come out Set the air-conditioner to COOL with engine Hi, and cool wind should come out of the cool box.

The condenser fans should turn (left and right fans)

Air-conditioner performance

No bubbles should appear in the receiver inspection window No gas leak ?

The air flow rate switch position must match the spurting air volume

F

Cab air-conditioner

Performance of heater selector switch

Wind should blow out to the cool box Cool wind should come out

Front wiper switch INT. o F WIPER Lo lights up. Pressing front wiper switch P1 turns the light out. The switch is lit several seconds later.

Front wiper switch Lo. o Front wiper switch Lo must light up Performance of wiper and washer

Front wiper switch Hi. o Front wiper switch Hi must light up Depress front washer switch. o Washer motor whining should be audible Rear wiper switch ON. o Rear wiper switch Lo must light up

E Lights

Depress rear washer switch. o Washer motor whining should be audible Performance of radio

Radio 24V should light up

Verification of front working lamps

Turn the front working lamp switch ON with the stage 1 of the headlamp switch. o Working lamps light up

Verification of warning lamps

Working lamps must light up

Judgement

Item

Confirmation of repair Nature of repair

No.

E

Gauges and lights

Category

7/7

GEN00036-02