KOMATSU WA1200-3 WHEEL LOADER FIELD ASSEMBLY INSTRUCTION MANUAL (SN:50001 & up) – PDF DOWNLOAD

GEN00011-04

Field Assembly Instruction

WHEEL LOADER

WA1200 -3 SERIAL NUMBERS

50001

and up

191 192

201 202

Installation of Engine Hood (920-1000 – 1190) Perform following procedures after 920-0140 "Connection and Fixing of Brake Line Piping".

920 920 920 920 920 920 920 920 920 920 920 920 920 920 920 920 920 920 920 920 920

–1000 –1010 –1020 –1030 –1040 –1050 –1060 –1070 –1080 –1090 –1100 –1110 –1120 –1130 –1140 –1150 –1160 –1161 –1170 –1180 –1190

– – – – – – – – – – – – – – – – – – – – –

Installation of Radiator Guard Installation of Engine Compartment Lamp Installation of Battery Box Installation of Battery Box Channel Installation of Engine Hood Bracket Installation of Engine Hood Bracket (B-BOX-Radiator Guard) Installation of Engine Air Cleaner Hose Installation of Bulkhead Fixing of Air Cleaner Hose Fixing of Cables Under Bulkhead Connection of Hoses Under Bulkhead Fixing of Air Conditioner Hose Fixing of Heater Hose Installation of Engine Side Cover in Front of Radiator Guard Installation of Engine Side Cover Installation of Hood Installation of Air Cleaner Tube Installation of Air Cleaner Tube (2XB06-A Air Conditioner, Large Capacity) Installation of Top Hood Installation of Top Panel Installation of Wiring Harnesses Supplied Together with Engine

171

Supplied together with sub-assembly

Installed to frame temporarily

Installed to frame temporarily

Installed to frame temporarily

1

2

3

4

No.

WORK CONTENT

UNIT PARTS PATTERN FOR SHIPMENT

No.

BLOCK

WASHER

BOLT

ETC. :

SOCKET :

TORQUE WRENCH :

IMPACT WRENCH :

SLING :

CRANE :

012

012

012

GUARD RADIATOR ASS'Y 001

EQUIPMENT, JIGS, TOOLS, SLINGS

42C-54-14990

01643-32460

01011-82415

(620-1070-Z1)

PARENTS PARTS PARTS (PROCESS) PARTS (PROCESS) QTY No. No. NAME

Installation of Radiator Guard (920-1000-Z1)

1. Remove the above baffle plate from the radiator and radiator guard to prepare to install the radiator guard.

2. Install the radiator guard.

(Take care that the radiator guard will not interfere with the radiator upper hose.)

3. Install the baffle plate removed in 1 above.

Procedure for installing radiator guard

Take care of interference.

Remove baffle plate from radiator guard.

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

Remove plates from radiator (right and left).

Preparation to install radiator guard

172

Supplied together with sub-assembly

Installed to radiator guard temporarily

Supplied together with sub-assembly

Supplied together with sub-assembly

Supplied together with sub-assembly

Supplied together with sub-assembly

Supplied together with sub-assembly

1

2

3

4

5

6

7

No.

WORK CONTENT

UNIT PARTS PATTERN FOR SHIPMENT

No.

CLIP

NUT

WASHER

BOLT

WORKING LAMP

BOLT

PLATE

ETC. :

SOCKET :

TORQUE WRENCH :

IMPACT WRENCH :

SLING :

CRANE :

EQUIPMENT, JIGS, TOOLS, SLINGS

08053-01512

01580-11008

01643-31032

01435-01025

421-06-23360

01435-01220

42C-06-11440

002

002

004

002

002

004

002

PARENTS PARTS PARTS (PROCESS) PARTS (PROCESS) QTY No. No. NAME

Installation of Engine Compartment Lamp (920-1010-Z1) Apply contact restorer to wiring joints.

View X

Set water drain hole down.

• Ring terminal · · · Apply to both chassis and terminal. Apply again after installation.

• Connector · · · Apply to both connector pieces before connecting them

173

Supplied together with sub-assembly

Supplied together with sub-assembly

Installed to frame temporarily

Installed to frame temporarily

1

2

4

5

No.

WORK CONTENT

UNIT PARTS PATTERN FOR SHIPMENT

No.

WASHER

BOLT

BATTERY BOX R

BATTERY BOX L

ETC. :

SOCKET :

TORQUE WRENCH :

IMPACT WRENCH :

SLING :

CRANE :

EQUIPMENT, JIGS, TOOLS, SLINGS

01643-31645

01010-81665

(620-1140-Z1-R)

(620-1140-Z1-L)

016

016

001

001

PARENTS PARTS PARTS (PROCESS) PARTS (PROCESS) QTY No. No. NAME

Installation of Battery Box (920-1020-Z1) Tightening torque : 245 – 309 Nm {25.0 – 31.5 kgm}

174

Supplied together with sub-assembly

Loose-supply item

Installed to B-BOX temporarily

Installed to B-BOX temporarily

1

2

6

7

No.

WORK CONTENT

UNIT PARTS PATTERN FOR SHIPMENT

No.

WASHER

BOLT

CHANNEL

CHANNEL ASSY

ETC. :

SOCKET :

TORQUE WRENCH :

IMPACT WRENCH :

SLING :

CRANE :

EQUIPMENT, JIGS, TOOLS, SLINGS

01643-31645

01010-81640

42C-54-14440

(620-1650-Z1-2)

016

016

001

001

PARENTS PARTS PARTS (PROCESS) PARTS (PROCESS) QTY No. No. NAME

Installation of Battery Box Channel (920-1030-Z1)

View Z

175

Loose-supply item

Loose-supply item

Loose-supply item

Loose-supply item

Loose-supply item

Installed to frame temporarily

Installed to frame temporarily

Installed to frame temporarily

2

3

4

5

6

7

8

9

No.

WORK CONTENT

Loose-supply item

UNIT PARTS PATTERN FOR SHIPMENT

1

No.

SHIM

WASHER

BOLT

BRACKET RH

BRACKET LH

BRACKET RH

BRACKET LH

BRACKET RH

BRACKET LH

ETC. :

SOCKET :

TORQUE WRENCH :

IMPACT WRENCH :

SLING :

CRANE :

EQUIPMENT, JIGS, TOOLS, SLINGS

426-09-11410

01643-31645

01010-81640

42C-54-11182

42C-54-11263

42C-54-12251

42C-54-11253

42C-54-12241

42C-54-11244

036

024

024

001

001

001

001

001

001

PARENTS PARTS PARTS (PROCESS) PARTS (PROCESS) QTY No. No. NAME

Installation of Engine Hood Bracket (920-1040-Z1)

temporarily.

so that engine hood bracket mounting seats

Install bolt

Adjust shim

will be level.

Install with notched side on inside of machine ( – ).

–

176

Supplied together with sub-assembly

Supplied together with sub-assembly

Loose-supply item

7

8

9

10 WASHER

Installed to ⑦ and ⑧ temporarily

WORK CONTENT

010

008

008

008

001

001

001

010

020

010

020

020

ETC. :

SOCKET :

TORQUE WRENCH :

IMPACT WRENCH :

SLING :

CRANE :

EQUIPMENT, JIGS, TOOLS, SLINGS

View from right rear above.

Note: Installed direction of bracket 䢆

BOLT

01010-81650 01643-31645

Installed to ⑦ and ⑧ temporarily

11

12

View from right rear below.

SHIM

42C-54-13230

BRACKET RH

BRACKET LH

NUT

PLATE

BUSHING

CUSHION

WASHER

BOLT

Installed to ⑦ and ⑧ temporarily

42C-54-11225

42C-54-11215

01580-12016

566-54-21920

566-54-21910

566-54-12213

424-975-1141

01011-82015

PARENTS PARTS PARTS (PROCESS) PARTS (PROCESS) QTY No. No. NAME

BRACKET

No.

42C-54-13221

6

5

4

3

2

1

UNIT PARTS PATTERN FOR SHIPMENT

Installed to ⑦, ⑧, B-BOX and guard temporarily Installed to ⑦, ⑧, B-BOX and guard temporarily Installed to ⑦, ⑧, B-BOX and guard temporarily Installed to ⑦, ⑧, B-BOX and guard temporarily Installed to ⑦, ⑧, B-BOX and guard temporarily Installed to ⑦, ⑧, B-BOX and guard temporarily

No.

Detail of part B (3 places on left side/ 3 places on right side) Detail of part A (2 places on right and left sides)

Battery box

Battery box

Engine hood bracket

a Install bolt 㽲 temporarily.

Installation of Engine Hood Bracket (B-BOX-Radiator Guard) (920-1050-Z1)

Detail of part C (2 places on right and left sides)

Engine hood bracket

Radiator guard

177

Installed to engine temporarily

Installed to engine temporarily

Installed to engine temporarily

Installed to engine temporarily

3

4

7

8

No.

WORK CONTENT

UNIT PARTS PATTERN FOR SHIPMENT

No.

CLAMP HOSE

COVER

CLAMP

HOSE

EQUIPMENT, JIGS, TOOLS, SLINGS

ETC. :

SOCKET :

TORQUE WRENCH :

IMPACT WRENCH :

SLING :

CRANE :

006

002

012

004

Direct hose up (4 places).

07289-00170

42C-01-13190

07299-00160

42C-01-11263

PARENTS PARTS PARTS (PROCESS) PARTS (PROCESS) QTY No. No. NAME

Installation of Engine Air Cleaner Hose (920-1060-Z1)

Tighten temporarily.

Tighten temporarily.

Tighten temporarily.

Tightening torque : 10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}

Install 2 hose clamp 180° apart from each other.

a Perform this process before installing the bulkhead.

Detail of part P (2 places only)

Tighten temporarily.

178

Supplied together with sub-assembly

Installed to bracket temporarily

Installed to bracket temporarily

Installed to bulkhead temporarily

Installed to bulkhead temporarily

Installed to bulkhead temporarily

Installed to bulkhead temporarily

Installed to bulkhead temporarily

1

2

3

4

5

6

7

8

No.

WORK CONTENT

UNIT PARTS PATTERN FOR SHIPMENT

No.

BOLT

WASHER

CUSHION

CUSHION

SPACER

WASHER

BOLT

006

012

012

006

006

006

006

BULKHEAD ASS'Y 001

ETC. :

SOCKET :

TORQUE WRENCH :

IMPACT WRENCH :

SLING :

CRANE :

EQUIPMENT, JIGS, TOOLS, SLINGS

View Z

1810 ± 3 (Adjust shims to obtain above dimension)

01435-01250

419-43-17920

427-54-21720

427-54-21730

427-54-21740

01643-31445

01010-81435

(620-0990-Z1)

PARENTS PARTS PARTS (PROCESS) PARTS (PROCESS) QTY No. No. NAME

Installation of Bulkhead (920-1070-Z1)

Bracket mounting area Tightening torque : 245 – 309 Nm {25 – 31.5 kgm}

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

Tighten permanently after installing bulkhead.

Tightening torque : 8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}

Tightening torque : 157 – 196 Nm {16 – 20 kgm}

Rear frame

Mark

Section of part C

= C (6 places)

Bulkhead in hood

179

Installed to bracket temporarily

Installed to bracket temporarily

1

2

No.

WORK CONTENT

UNIT PARTS PATTERN FOR SHIPMENT

No.

BOLT

CLIP

ETC. :

SOCKET :

TORQUE WRENCH :

IMPACT WRENCH :

SLING :

CRANE :

EQUIPMENT, JIGS, TOOLS, SLINGS

01435-01016

04434-51510 003

003

PARENTS PARTS PARTS (PROCESS) PARTS (PROCESS) QTY No. No. NAME

Fixing of Air Cleaner Hose (920-1080-Z1)

View X

Bulkhead

Detail of A

180

Supplied together with sub-assembly

Supplied together with sub-assembly

Supplied together with sub-assembly

Supplied together with sub-assembly

Supplied together with sub-assembly

1

2

3

4

5

No.

WORK CONTENT

UNIT PARTS PATTERN FOR SHIPMENT

No.

BOLT

CUSHION

CLIP

BOLT

BRACKET

ETC. :

SOCKET :

TORQUE WRENCH :

IMPACT WRENCH :

SLING :

CRANE :

EQUIPMENT, JIGS, TOOLS, SLINGS

01435-01016

07095-20318

04434-52512

01435-01020

427-43-11340

002

004

004

004

002

PARENTS PARTS PARTS (PROCESS) PARTS (PROCESS) QTY No. No. NAME

Fixing of Cables Under Bulkhead (920-1090-Z1)

View Z

a Install Ô˜ to bulkhead temporarily.

181

No.

No.

WORK CONTENT

UNIT PARTS PATTERN FOR SHIPMENT

ETC. :

SOCKET :

TORQUE WRENCH :

IMPACT WRENCH :

SLING :

CRANE :

EQUIPMENT, JIGS, TOOLS, SLINGS

PARENTS PARTS PARTS (PROCESS) PARTS (PROCESS) QTY No. No. NAME

Connection of Hoses Under Bulkhead (920-1100-Z1)

From air cleaner

Tightening torque for clamp : 5.4 – 6.4 Nm {0.55 – 0.65 kgm}

182

Installed to bracket temporarily

Installed to bracket temporarily

Installed to bracket temporarily

Installed to bracket temporarily

1

2

3

4

No.

WORK CONTENT

UNIT PARTS PATTERN FOR SHIPMENT

No.

BOLT

CLIP

CUSHION

CLIP

ETC. :

SOCKET :

TORQUE WRENCH :

IMPACT WRENCH :

SLING :

CRANE :

EQUIPMENT, JIGS, TOOLS, SLINGS

01435-01016

04435-52110

07095-20420

04434-52712

009

008

002

002

PARENTS PARTS PARTS (PROCESS) PARTS (PROCESS) QTY No. No. NAME

Fixing of Air Conditioner Hose (920-1110-Z1)

(8 places marked with

)

Side view of rear frame

Top view of rear frame

a Install Ԙ – ԛ to the back side of the support.

Section A-A

183

Installed to bracket temporarily

Installed to bracket temporarily

Installed to bracket temporarily

Installed to bracket temporarily

Installed to bracket temporarily

Installed to bracket temporarily

Installed to bracket temporarily

1

2

3

4

5

6

7

No.

WORK CONTENT

BOLT

CLIP

BOLT

CLIP

BOLT

CUSHION

CLIP

ETC. :

SOCKET :

TORQUE WRENCH :

IMPACT WRENCH :

SLING :

CRANE :

EQUIPMENT, JIGS, TOOLS, SLINGS

01435-01016

421-07-11550

01435-01016

04434-52512

01435-01016

07095-20523

04434-53212

002

002

005

005

002

002

002

PARENTS PARTS PARTS (PROCESS) PARTS (PROCESS) QTY No. No. NAME

Connect to air conditioner.

UNIT PARTS PATTERN FOR SHIPMENT

No.

Fixing of Heater Hose (920-1120-Z1)

View X

(5 places marked with A)

View Y

(5 places marked with A)

a Install Ԙ – Ԟ to the back side of the support.

184

Supplied together with sub-assembly

Installed to bracket and guard temporarily

Installed to bracket and guard temporarily

1

2

3

No.

WORK CONTENT

UNIT PARTS PATTERN FOR SHIPMENT

No.

WASHER

BOLT

ETC. :

SOCKET :

TORQUE WRENCH :

IMPACT WRENCH :

SLING :

CRANE :

014

014

ENG SIDE COVER A 002

EQUIPMENT, JIGS, TOOLS, SLINGS

01643-31232

01435-01225

(620-1100-Z1)

PARENTS PARTS PARTS (PROCESS) PARTS (PROCESS) QTY No. No. NAME

Installation of Engine Side Cover in front of Radiator Guard (920-1130-Z1)

185 42C-54-11516

Installed to bracket temporarily

Installed to bracket temporarily

Supplied together with sub-assembly

Loose-supply item

Loose-supply item

16

17

18

19

WORK CONTENT

(620-1100-Z1)

Installed to bracket temporarily

14

15

SIDE PANEL RH

SIDE PANEL LH

ETC. :

SOCKET :

TORQUE WRENCH :

IMPACT WRENCH :

SLING :

CRANE :

012

012

005

005

001

005

005

001

004

004

001

004

004

001

006

006

001

001

ENG SIDE COVER A 002

WASHER

BOLT

WASHER

BOLT

EQUIPMENT, JIGS, TOOLS, SLINGS

42C-54-11525

01643-31232

01435-01225

01643-31232

01435-01225

SIDE PANEL RH

Installed to bracket temporarily

42C-54-11563

13

WASHER

WASHER

10

01643-31232

01643-31232

Loose-supply item

9

BOLT

Loose-supply item

Installed to bracket temporarily

8

01435-01225

SIDE PANEL RH

WASHER

Installed to bracket temporarily

Installed to bracket temporarily

7

01643-31232 42C-54-11545

11

Loose-supply item

6

BOLT

12

Installed to bracket temporarily

5

01435-01225

SIDE PANEL LH

BOLT

Installed to bracket temporarily

4

42C-54-11535

WASHER

BOLT

01435-01225

Loose-supply item

3

01643-31232

01435-01225

Installed to bracket temporarily

Installed to B-BOX temporarily

2

PARENTS PARTS PARTS (PROCESS) PARTS (PROCESS) QTY No. No. NAME

SIDE PANEL LH

Installed to B-BOX temporarily

1

No.

42C-54-11553

UNIT PARTS PATTERN FOR SHIPMENT

No.

Installation of Engine Side Cover (920-1140-Z1)

186

Loose-supply item

Installed to bulkhead and bracket temporarily

Installed to bulkhead and bracket temporarily

Installed to bulkhead and bracket temporarily

Installed to radiator guard temporarily

Installed to radiator guard temporarily

Installed to radiator guard temporarily

Installed to radiator guard temporarily

Installed to radiator guard temporarily

Installed to radiator guard temporarily

3

4

5

6

7

8

9

10

11

No.

WORK CONTENT

Loose-supply item

2

UNIT PARTS PATTERN FOR SHIPMENT

1

No.

BUSHING NUT

566-54-21910 01580-12016

ETC. :

SOCKET :

TORQUE WRENCH :

IMPACT WRENCH :

SLING :

CRANE :

EQUIPMENT, JIGS, TOOLS, SLINGS

CUSHON

PLATE

WASHER

BOLT

WASHER

BOLT

BOLT

HOOD, SIDE RH

HOOD, SIDE LH

566-54-12213

566-54-21920

01643-32060

01011-82010

01643-31232

01435-01225

01435-01230

42C-54-11133

42C-54-11123

004

004

008

008

008

004

020

004

016

001

001

PARENTS PARTS PARTS (PROCESS) PARTS (PROCESS) QTY No. No. NAME

Installation of Hood (920-1150-Z1)

Detailed installation of ԝ – Ԣ and ԧ – (Sectional view)

Radiator guard

187

42C-01-11244

8

TUBE

TUBE

WASHER

BOLT

BOLT

BRACKET

ETC. :

SOCKET :

TORQUE WRENCH :

IMPACT WRENCH :

SLING :

CRANE :

EQUIPMENT, JIGS, TOOLS, SLINGS

42C-01-11254

7

WORK CONTENT

01010-81230 130-43-64260

5

01024-81230

4

42C-01-11382

3

BRACKET

001

001

008

008

008

001

003

PARENTS PARTS PARTS (PROCESS) PARTS (PROCESS) QTY No. No. NAME

2

No. 42C-01-11371

UNIT PARTS PATTERN FOR SHIPMENT

1

No.

Installation of Air Cleaner Tube (920-1160-Z1)

See 630-1840-Z1.

Tightening torque for bolt marked with a : 8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}

188

42C-01-1346A

8

WORK CONTENT

TUBE ASS'Y

42C-01-1345A

7

SLING :

Install the dust indicator to the tube. (2 places)

ETC. :

SOCKET :

TORQUE WRENCH :

IMPACT WRENCH :

CRANE :

Install the air cleaner tube assembly.

EQUIPMENT, JIGS, TOOLS, SLINGS

TUBE ASS'Y

WASHER

BOLT

01010-81230 130-43-64260

BOLT

BRACKET

5

01024-81230

4

42C-01-11382

3

BRACKET

001

001

008

008

008

001

003

PARENTS PARTS PARTS (PROCESS) PARTS (PROCESS) QTY No. No. NAME

2

No. 42C-01-11371

UNIT PARTS PATTERN FOR SHIPMENT

1

No.

Installation of Air Cleaner Tube (A/C, Large Capacity) (920-1161-Z1)

Install dust indicator to tube.

Point Apply LG-1.

Rotate nipple to tighten.

Part P

Part P

See 920-1170-Z1.

View Z

Part P

mark Tightening torque : 8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}

189

Supplied together with sub-assembly

Installed to bulkhead and bracket temporarily

Installed to bulkhead and bracket temporarily

Installed to bulkhead and bracket temporarily

Installed to bulkhead and bracket temporarily

Installed to radiator guard temporarily

Installed to radiator guard temporarily

Installed to radiator guard temporarily

Installed to radiator guard temporarily

Installed to radiator guard temporarily

1

2

3

4

6

7

8

9

10

11

No.

WORK CONTENT

UNIT PARTS PATTERN FOR SHIPMENT

No.

BUSHING NUT

566-54-21910 01580-12016

ETC. :

SOCKET :

TORQUE WRENCH :

IMPACT WRENCH :

SLING :

CRANE :

EQUIPMENT, JIGS, TOOLS, SLINGS

CUSHON

PLATE

WASHER

BOLT

WASHER

BOLT

BOLT

FRAME,TOP HOOD

566-54-12213

566-54-21920

01643-32060

01011-82010

01643-31232

01435-01250

01435-01225

42C-54-11116

003

003

006

006

006

003

015

010

005

001

PARENTS PARTS PARTS (PROCESS) PARTS (PROCESS) QTY No. No. NAME

Installation of Top Hood (920-1170-Z1)

To be installed in next process.

Detailed installation of ԝ – Ԣ (Sectional view)

Radiator guard

190

Loose-supply item

Installed to frame top hood temporarily

Installed to frame top hood temporarily

Loose-supply item

Installed to frame top hood temporarily

Installed to frame top hood temporarily

3

4

5

6

7

No.

WORK CONTENT

Loose-supply item

2

UNIT PARTS PATTERN FOR SHIPMENT

1

No.

WASHER

BOLT

SCREEN TOP

WASHER

BOLT

PANEL TOP RH

PANEL TOP LH

ETC. :

SOCKET :

TORQUE WRENCH :

IMPACT WRENCH :

SLING :

CRANE :

EQUIPMENT, JIGS, TOOLS, SLINGS

01643-31232

01435-01235

42C-54-11161

01643-31232

01435-01220

42C-54-11153

42C-54-11143

008

008

002

018

018

001

001

PARENTS PARTS PARTS (PROCESS) PARTS (PROCESS) QTY No. No. NAME

Installation of Top Panel (920-1180-Z1)

191

Installed to bracket temporarily

Installed to bracket temporarily

3

4

No.

Secure both parts with bolts (2 places).

Detail of R

BOLT

CLIP

Detail of S

01435-01016

04434-51410 002

004

PARENTS PARTS PARTS (PROCESS) PARTS (PROCESS) QTY No. No. NAME

View Y

UNIT PARTS PATTERN FOR SHIPMENT

No.

Installation of Wiring Harnesses Supplied Together with Engine (920-1190-Z1)

View X

Supplied sensor

Detail of P

Supplied wiring harness

192

193

194

195

196

197

198

199

200

201

202

40CE

200

Check after releasing accumulator pressure Cooling oil level

11 Oil quantity in work equipment pin ･Frame side of boom ･Bucket side of boom ･Boom cylinder bottom side ･Boom cylinder head side ･Bucket cylinder bottom side ･Bucket cylinder head side ･Bell crank ･Bell crank side of bucket link ･Bucket side of bucket link

Oil should come out of the upper plug when level the bucket on the ground.

(Left (Left (Left (Left (Left (Left (Left (Left (Left

Right Right Right Right Right Right Right Right Right

) ) ) ) ) ) ) ) )

start.

There shall be no return time lag and abnormal shock after T/M cutoff.

6 7

8 9 10

11

12 13

14 15 16 15

15 Presence abnormal

noise of engine 18 19 20 21

Check for unusual noise and vibration from engine, axle, transmission, work equipment, or steering while pressure is applied.

22

AJSS work

23

Actuation of Speed control dial

24

Actuation of Driving force control dial

25

Operation and canceling of engine idle RPM set

26

Operation of wall cutting control

Does the lamp light up when the travel speed control switch is turned to the ON

The modulation clutch is controlled to change machine speed. position?

Dial in speed 1st orcontrol 2nd atdialtravel speed of 1.5 or above.

Fully operates turn the travel counterclockwise (Setkm/h it to minimum).

Set the driving dial to maximum Check byforce traveling in F1. (fully turn it clockwise).

When performing measurement, confirm that the system lamp lights up and the The modulation clutch is controlled to change machine speed. transmission cut-off switch is in the ON position.

Can speed be only obtained?

Dialsetoperates in 1st at speed 1.5 km/h or below.

F1: 1.5 to 3 km/h Depress right brake and check change of engine speed in F1.

Fully turn the travel speed control dial clockwise (Set it to maximum). Set the driving force dial to maximum (fully turn it clockwise).

When performing measurement, confirm that the system lamp lights up and the transmission cut-off switch is in the ON position.

Display the real-time MOD/C current on the CGC screen.

Keep in F1, below 1.5 km/h at low idle.

Note the current.

Set the driving force dial to maximum (fully turn it clockwise) (Approx. 700 mmA) Set the driving force dial to minimum (fully turn it counterclockwise) (660 to 136 mmA) Does the control rate change?

Engine idle RMP-set must be able to be operated.

An actuation lamp should be illuminated after setting.

Hand throttle should be released by pressing the right brake pedal once.

Alarm sounds under following condition.

(1) Raise the boom upper limit.

(2) Fully dump bucket (Extend the cylinder piston rods to the stroke end).

(3) Release parking brake.

(4) Travel in forward 1st.

* Alarm does not sound in case of the specification ready for installation of the wall cutting control (specification without the wall cutting control).

27

Operation of autogreasing system

The monitor panel Indicator lights up. (when normal: light up, during greasing: blink) Interval set: 11.25 minutes (blue dial 3) Operating set: 15 seconds (red dial 2) Injector set: Return all injectors 5 turns.

Grease level indicator of grease can should be 1/2 or higher.

Not to blink abnormally. (Rapid blinking: Once/0.5 sec) Supply pressure: 21 kg/cm2 ( ), Grease line pressure 210 kg/cm 2 ( ) Grease comes out of grease line (Check it by steering cylinder line).

3.0

H. Performance, Function

Items

Judging Methods and Criteria

Joystick S/T swing speed 1 Right swing time (Engine Hi) 5.2 ± 0.4 sec.

2 Right swing time (Engine Li) 6.0 ± 0.5 sec.

3 Left swing time (Engine Hi) 5.2 ± 0.4 sec.

6.0 ± 0.5 sec.

4 Left swing time (Engine Li) Adjustment and check of steering stopper bolt When machine is steered with engine speed at low idle, 1 Clearrance of frame clearance of frame end stopper must be 37 to 40 mm.

Hydraulic pressure Confirms on the CGC-monitor screen 1 Work equipment pressure 317 - 330 kgm/cm 2 (31.0 - 32.3 Mpa) 2 S/T pressure 317 - 330 kgm/cm 2 (31.0 - 32.3 Mpa) T/M, T/C, hydraulic pressure Engine Hi 3 T/M main hydraulic pressure 27.2 ± 2 kgm/cm2 (2.5 - 2.8 MPa) 4 T/C outlet hydraulic pressure 9 ± 1 kgm/cm2 (0.8 - 1.0 MPa) Brake hydraulic pressure 5 Cut-in 180 - 186 kgm/cm 2 (17.7 - 18.2 Mpa) 6 Cut-out 210 - 225 kgm/cm 2 (20.6 - 22.1 Mpa) Hydraulic drift 7 Boom hydraulic drift 250 mm max./15 min.

8 Bucket hydraulic drift 100 mm max./15 min.

1 Light switches work 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Measured Value

( ( ( (

sec.) sec.) sec.) sec.)

( (

kgm/cm 2) kgm/cm 2)

( (

kgm/cm 2) kgm/cm 2)

( (

kgm/cm 2) kgm/cm 2)

( (

mm) mm)

Parking light Clearance lamp Tail lamp Monitor dash lamp Headlamp Working lamp Brake lamp Ba

16 17

Is display normal? (Does display start in about 1 minute?)

Does screen change to load meter, remote positioner, fuel consumption mode screen, and maintenance screen?

Does screen change to service screen? (Inputting of ID No.) Does screen change to abnormality record screen? Can abnormality record be cleared?

Can error screen be canceled?

Judgement

No.

Correction

Correction Check

J. Lights

23 Actuation of auto grease

Judging Methods and Criteria

Classification

1 2 3 Machine Front Upper Section

4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 Machine Rear Upper Section

8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

Correction

Correction Check

Correction

Correction Check

Indicator of monitor panel lights up.

(When normal : light up, when greasing : frash) Illumination of the monitor panel Interval setting …………… 11.25 mnutes (Blue dial 3) Operation setting ………… 15 seconds (Red dial 2) Injector setting …………… Reverse all by 5 turns The remaining grease indicator should read 1/2 or more.

No abnormal blinging allowed.

Not to flash abnormally. (Rapid flashing: Once/0.5 sec) Supply pressure: 21 kg/cm 2 ( Grease line pressure: 210 kg/cm 2 ( Does grease come out of grease line?

(Check by steering cylinder line)

No.

Measured Value

Judgement

Items

Judgement

Classification

No.

Items

) )

There must be clearance between frame and retainer of upper center pin (Check in four directions).

WA1200-3

WHEEL LOADER

Form No GEN00011-04

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