Assembling an Excavator

CONTENTS
1 Block outline................................................................................................................. 1
2 Principal component dimension table .......................................................................... 2
3 Work space layout ....................................................................................................... 3
4 General assembly schedule......................................................................................... 4
5 Operating equipment, jigs and tools ............................................................................ 5
6 Oil, grease and paints .................................................................................................. 8
7 Assembly procedure .................................................................................................... 9
No. Item Page No. Item 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 0320 Air bleeding of work equipment hydraulic circuit and
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 0440 Adjustment
angle
of work equipment controller lift arm 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
0230 Installing counterweight (Standard and 1 ton heavier
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 0590 On use of starter kit (dummy harness) and
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)
1. Bare machine 2. Front axle assembly
3. Lift arm and bell crank assembly 4. Tire and rim assembly 5. Counterweight
6. Front light support assembly 7. Step 8. Rear access ladder (Left)
9. Platform 10. Cab 11. Bucket
12. Handrail 13. Fender 14. Muffler stack
15. Rear fender (if equipped)
1
2 Principal component dimension table
No. Unit name Weight (kg) Overall length Overall width Overall height
(mm) (mm) (mm)
1 Bare machine 27,720 8,470 3,390 3,095
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
5 Counterweight (1 ton heavier) 3,780 2,670 865 630
Counterweight (Load and carry) 4,785 2,670 865 862
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
Related dimensions
Specifications
Weight (kg) Overall length (mm) Overall width (mm) Overall height (mm)
WA600-6 52,700 11,985 3,685 4,460

(Operating weight) (Bucket width) (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 × 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
Tire and wheel Lift arm and bell crank

assembly assembly Bucket assembly
Front axle assembly
Bare machine
50 ton crane
30 m
Cab assembly
Storage area for the lighter units

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
Day 1st day 2nd day 3rd day
Time
Machine body
conditions
Setting of front axle to Installing tire Installing exterior parts Installing lift arm Maintenance and adjustment
stationary position
Outline of Installing the cab on board Installing counterweight Installing bucket Inspection
Setting the main unit to
assembly contents a stationary position
Installing ladder and
Assembly of front axle Installing inside the cab
platform
4 General assembly schedule
Crane
Forklift
Worker 3 persons
5 List of equipment, jigs, tools and consumables
No. Item Specifications Q’ty Application
1 Crane 25 ton 1 Refer to the assembly procedure
4 Forklift 2.5 ton 1
5 Tire pressure gauge No. 2252 1
6 Grease pump and gun for 20 kg container 1
7 Grease G2-LI 5 kg
8 Stool 4 steps 2
9 Stool 6 steps 1
10 Blue sheet 5 m × 10 m 5 Equipment protection
11 Square bar 300 mm square, 1.2 m long 16 For setting the bare machine to stationary position
12 Square bar 300 mm square, 0.6 m long 4 For setting the bare machine to stationary position
13 Oil jug 5l 1 For filling oil
14 Oil Refer to the assembly procedure – Refer to the assembly procedure
15 Oil pan and wash can 2
16 Waste oil container Empty drum 1
17 Rag 5 kg
18 Fuel oil Refer to the assembly procedure For replenishing machines
19 Antifreeze 5l For replenishing the sub-tank (concentration varying by area)
20 Air hose 6ø × 1 m 2 For bleeding air
21 Air compressor 3.5 m3/min, 7 kg/cm2 and above 1
22 Air hose 12ø with fitting 5 For an impact grinder
23 Impact wrench For M6 – M12 3
24 Impact wrench For M14 – M20 1
25 Impact wrench For M24 and M27 1 For installing the cab
26 For 1 · 1/2 extension 500 mm long 1
27 Socket 10 mm 1
28 Socket 13 mm 1
29 Socket 17 mm 1
30 Socket 19 mm 1
31 Socket 22 mm 1
32 Socket 24 mm 1
33 Socket 30 mm 1
34 Socket 36 mm 1
35 Socket 41 mm 1
36 Socket 55 mm 1
37 Socket 60 mm 1
38 Torque wrench Set 19.6 Nm {2.0 kgm} 1
39 Torque wrench Set 927 Nm {94.5 kgm} 1 For tire and cab
40 Torque wrench Set 1,300 Nm {132.6 kgm} 1 For the cab
41 Torque wrench Set 31.8 Nm {3.2 kgm}, width across flats 36 mm 1 For the sensor
42 Torque wrench Set 2,745 Nm {279.9 kgm} 1 For counterweight
43 Torque wrench Set 3,260 Nm {332.4 kgm} 1 For front axle
44 Torque wrench Set 277 Nm {28.2 kgm} 1 For drive shaft
45 Convex 5m 1
46 Locktight LT-2 1
47 Vinyl tape 1 For arranging the harnesses
48 Standard tools (for ISO) 700SX 2
49 Bar 1m 1
50 Pick 1 For hole alignment
51 Large hammer 10 lb 1
52 Shackle For 2.5 to 3 ton crane 4 For the bucket
53 Shackle BC40 for 10 ton 4 For the frame
54 Chain For 2.5 to 3 ton crane, 2 m 2 General purpose
55 Nylon sling 1 ton and above 2 General purpose
56 Nylon sling 6 ton and above 2 For installing the lift arm
57 Nylon sling 100 mm wide × 12 m long 1 For installing the front tire
58 Balance lifting tool ATW-600-036 2 For lifting the frame
59 Axle assembly lifting tool ATW-600-103 2 For lifting of front axle
60 Wire 7 m 28ø 2 For lifting the chassis
61 Wire 4 m 28ø 2 For installing the body
62 Wire 5 m 28ø 2 For installing the body
63 Eye bolt For M16 4 For installing the cabin
64 Chain lifting tool 4 points, 2 m 1 For installing the cabin
65 Chain lifting tool ø 20 mm diameter, 2 slings of 2 m 1 For the frame
66 Chain lifting tool 2 m × 4 slings (1.5 ton and above) 1 For installing the cab
67 Chain lifting tool 4 m × 4 slings (6 ton and above) 1 For the bucket
68 Vinyl hose ø6×1m 2 For bleeding the brake air
69 Square bar 150 mm × H350 mm 2 For receiving lift cylinder
70 Square bar 300 mm square 1 For receiving the bucket cylinder
71 Spanner 17 mm (width across flats) 1
5
6
AS–00362 Machine #11 additionally
for application.
WA1200 front frame lifting tool
Drawing for additional machining of section A S = 1 : 2.5

(2 locations, right and left)
Part Number Part Name Material Q'ty Remarks P

Balance AS-00362
01 Conversion part 1
(additional machining required) Part Number 2
02
03
04 Sling fitting E Kito 4 VE200
05 Link chain Kito 2 SV200 L=3.1 m
06 Shackle JIS 2 SC40
name
Balanced lifting tools for shipment

Machine
Date '04--01--29
1
No.
ATW--600--036
name
K21 (WA600 M/C)

Scale
Machine
Drawing
15
Developed shape
In white paint: Machine model,

machine name
Stamp: Drawing No.
SV100 90° lifting 4,500 kg
2-26 drilled hole
Corners shall be smoothly grind-finished.
Part Number Part Name Material Q'ty Remarks P

01 Sling fitting SS400 2
02
03 Hexagon bolt JIS 12 M24 × 75
04 Double sling Kito 1 DD-2SL ø=10 L=2.4 m
name
Axle assembly lifting tool

Machine
Note: Inspection report shall be attached. Date '05--09--21

1
No.
ATW--600--103
name
WA600-6
Scale
Machine
Drawing
7
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
List of grease
No. Part Name Unit Q’ty
Grease with molybdenum disulfide for
1 addition under extreme pressure (KES LM-P equivalent) 1l
Lithium grease with molybdenum
2 disulfide added (KES LM-P equivalent) 10 l
3 Fuel Adequate quantity of fuel oil –

(757 l when full)
4 Windshield washer solution Commercially available product 2l
5 Detergent Spraying can 6 pieces
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 sys-
tem” in non-periodical maintenance in Operation & Maintenance Manual.
Cautions Special tool Necessary Equipment

Name Q’ty Name Q’ty
a For details of the notes (e.g., Note. 1,
Note. 2 ...) in the table, see the Opera-
tion and Maintenance Manual.
Others
9
Assembly procedure
Oil and coolant capacity
No. 0020
Specified Volume of Volume of

Lubricating points Types of oil
oil level (l) replaced oil (l) refilled oil (l)
Engine oil pan Engine oil 97 86 0
Transmission case Power train oil 120 83 0
Hydraulic fluid
(Synthetic oil)
Power train oil
Hydraulic oil system 592 443 98
Hydraulic oil (150 l are to be prepared)
Engine oil
Biological hydraulic oil
Front axle 155 155 0
Axle oil
Rear axle 155 155 0
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.

Others
10
Assembly procedure
Setting the front axle and bare machine
No. 0030 to stationary position
1. Setting the front axle to stationary position a Axle body shall not be directly lifted.
1. Set the front axle assembly as shown in the figure below.
No direct lifting in this position
Lifting tool: Front axle assembly lifting tool (ATW-600-103)
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
Front Rear
7 ton 26 ton
Crane: 50 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)

1. Whenever lifting the front axle assem-
Shackle (For 10 ton) 4 Crane 50 ton 2
bly, the specified lifting tool must be
Sling hook type chain lifting tool
used. (Rope diameter ø20 mm, 2 slings and L 2,000) 1
It is strictly prohibited to use an unspec- Balance-type lifting tool (ATW-600-036) 1
ified lifting tool as well as lifting the front Axle assembly lifting tool (ATW-600-103)
axle directly. Square bar
(300 mm square and L=0.6m) 2
Square bar
(300 mm square and L=1.0m) 2
Square bar
(150 mm, H=350 mm) 2
Others
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
1. Lift the front axle assembly with the crane.

Bolt (1)
Lifting tool: Axle assembly lifting tool (ATW-600-103) 2,890 -- 3,630 Nm {295 -- 370 kgm}
2. Assemble the front axle assembly to the front frame.
No. Part No. Part name Q’ty Parts conditions

1 427-46-12130 Bolt 12 Temporarily attached to machine body
2 01580-03931 Nut 12 Temporarily attached to machine body
3 01643-33990 Washer 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
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)

1. Whenever lifting the front axle assem-
Shackle (For 10 ton) 4 Crane for 50 ton 2
bly, the specified lifting tool must be
used. Torque wrench (Set 3,260 Nm) {332.4 kgm} 1 Sling hook type chain lifting tool 1
It is strictly prohibited to use an unspec- (Rope diameter ø20 mm, 2 slings and L 2,000)
ified lifting tool as well as lifting the front Axle assembly lifting tool (ATW-600-103) 1
axle directly. Square bar
(300 mm square and L=1.0 m) 4
Square bar
(300 mm square and L=0.6 m) 2
Square bar
(150 mm, H= 350 mm) 2
Others
12
Assembly procedure
Connecting the drive shaft
No. 0060
1. Connecting the drive shaft

Fig. 1
1 01050-61675 Bolt 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
Greasing fitting
that on the center drive shaft are faced in the same direction. (See Fig.1) position
<Point>
1. The mounting surface shall be free from rusts, foreign substances or dents. Positional relation of grease fitting
2. Insert four bolts temporarily and then tighten them also temporarily until (Viewed from rear side of machine body)
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 Bolt (1) 245 -- 309 Nm
contacted. If acceptable, apply a check mark using a white felt pen. Front frame
{25 -- 31.5 kgm}
View Z: Front frame viewed from left side
Front axle
Front frame
Connect
Front axle
Grease fitting

Torque wrench (Set 277 Nm) {28.2 kgm} 1
Others
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

Spanner (17 mm) 1
Others
14
Assembly procedure
Connecting the brake pipe
No. 0066 (Brake cooling specification)
2. Connecting the brake pipe (Brake cooling specification)

2 07000-B3038 O-ring 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.
X view Y view Sction A-A
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
Tube between bolts
Connect: Check O-ring. A and B
Hose between plugs C and E Connect: Check O-ring.
Hose between plugs D and F
Section A-A
Z view
Slack adjuster

Spanner (17 mm) 1
Others
15
Assembly procedure
Installing tire and rim assembly
No. 0070
1. Installing tire and rim assembly <How to hoist the tire and wheel assembly>
No. Part No. Part name Q’ty Parts conditions Apply the lifting tool so that
the tire will be level.
1 426-30-31030 Tire and wheel assembly 4 Independent product (Separately packed)
2 01010-62490 Bolt 148 Independent product (Separately packed) Apply choking knot
3 01643-32460 Washer 148 Independent product (Separately packed)
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. Tire weight: 1,518 kg
4. Tighten the bolt by applying the following torque.
5. Touch up the tightened portion. (For preventing rust) <Tire loading images>
(Apply the yellow paint as used for coating the machine body.)
6. Apply chocks to the tires.
Bolt (2) : 824 -- 1,030 Nm

{84 -- 105 kgm}
Target: 927 Nm {94.5 kgm}
Secure the tire with wire to prevent falling.

1. Don’t step under the hoisted body when
Impact wrench (For M24) 1 Crane for 50 ton 1
lifting the machine body.
2. Take care not to drop the tire during Torque wrench (Set 927 Nm {94.5 kgm}) 1 Forklift: 2.5 ton 1
Nylon sling
transportation. Socket (36 mm) 1 (Withstand load of 1 ton and above) 1
Wire 1
Others
16
Assembly procedure
Installing step
No. 0080
1. Installing step
1 426-54-35182 Step 1 Independent product (Separately packed)
2 01024-D1230 Bolt 4 Temporarily attached to the machine body
1. Install the step to the hydraulic tank.

Impact wrench (For M12) 1
Socket (19 mm) 1
Others
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

1 426-56-21330 Seal 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.

Each
Impact wrench (For M12, M25, M27) one Crane for 50 ton 1
Each
Socket (19mm, 36 mm, 41 mm) one Sling hook type chain lifting tool
Torque wrench (Set 932 Nm {95 kgm}) 1 (2,000 mm × 4 slings, hoisted by 4 slings) 1
Torque wrench (Set 1,300 Nm {132.6 kgm}) 1
Others
18
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
Top view of floor
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.
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 Step 2
Cab side Floor side

Others
19
Assembly procedure
Installing cab (2) (Steering wheel specification)
No. 0110
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

Socket (19mm) 1
Others
20
Assembly procedure
Installing cab (2)
No. 0115 (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

Impact wrench (for M8) 1
Socket (13 mm) 1
Others
21
Assembly procedure
Installing cab (3)
No. 0120
4. Assembling the cab (cab assembly bolts tightening procedure)

No. Part No. Part name Q’ty Parts conditions Table 1
1 01010-62480 Bolt a 4 Temporarily attached to the machine body
3 Bolt (1) (5):
2 01643-32450 Washer a 4 Temporarily attached to the machine body
3 01011-62705 Bolt E 8 Temporarily attached to the machine body
883 – 981 Nm {90 – 100 kgm}
3 Bolt (3):
4 01643-32780 Washer E 8 Temporarily attached to the machine body Target: 932 Nm {95.0 kgm}
5 01011-62490 Bolt w 2 Temporarily attached to the machine body
6 01643-32460 Washer w 2 Temporarily attached to the machine body 1,157 – 1,442 Nm {118 – 147 kgm}
7 01024-81235 Bolt 12 Temporarily attached to the machine body
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

Each
Impact wrench (For M12, M25, M27) one Crane for 50 ton 1
Each
Socket (19mm, 36 mm, 41 mm) one Sling hook type chain lifting tool
Torque wrench (Set 932 Nm {95 kgm}) 1 (2,000 mm × 4 slings, hoisted by 4 slings) 1
Torque wrench (Set 1,300 Nm {132.6 kgm}) 1
Others
22
Assembly procedure
Installing cab (4) (AJSS specification)
No. 0130
5. Connecting the AJSS link (rod)
Connect
Adjustment nut
Lever position
when freed Stopper When freed
When locked
Lamp lighting range

Adjustment nut Stop valve
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) When locked: Lamp goes off
Make sure that the lamp comes on in its lighting range (When engine is stopped)
when the AJSS lock lever is shifted from the lock side When freed: Lamp comes on
to the free side while the engine is run.

Others
23
Assembly procedure
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.) Section A-A
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)
(Male) Both of the two locks

(Female) must be checked. Connect
GOOD N.G
Lock is Not locked sufficiently. GOOD N.G
kept horizontal Locked slanted. Lock Not sufficiently locked
There is There is Cab viewed from the front side

a gap no gap
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

Socket (19mm) 1
Others
24
Assembly procedure
No. 0141
(6)-1. Fixing steering

1. Fix bracket (1) with bolts.
Inside of cab seen from left (Sectional view)
View Z

1 01024-81020 Bolt 2 Loose-supply item (Separately packed)

Socket (17 mm) 1
Others
25
Assembly procedure
Installing cab (6)
No. 0145 (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 pedal
• Accelerator +5V (CN C30)
Accelerator +5V
(CN C30)
Accelerator microswitch
(CN C17)
Floor seen from right front
Accelerator pedal
Floor seen from right rear

Socket (13 mm) 1
Others
26
Assembly procedure
Installing cab harness (1/2)
No. 0150
1. Fastening cab harness

1 285-02-11320 Clips a 6 Temporarily attached to the machine body
2 04434-51210 Clips a 6 Temporarily attached to the machine body
4 08036-01814 Clips w 6 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 A-A Section B-B

Impact wrench 1
Socket (17 mm) 1
Others
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.)
(See the figure below)
(8-pole) (12-pole)
Both of the two locks
must be checked.
(Female) (Male)
(Male) Both of the two locks

(Female) must be checked.
GOOD N.G
Lock is Not locked sufficiently. GOOD N.G
kept horizontal Locked slanted. Lock Not sufficiently locked
There is There is
a gap no gap
View of the cab from below View of the cab from below and right
Connection: CN C52
(ambient temperature) Connection:
CN V34 (Orbcomm)
Connection: CN CL11
Connection: CN CL13
Connection: CN CL12

Others
28
Assembly procedure
Installing cab duct (1/3)
No. 0170
1. Installing duct piping

1 426-07-32461 Hose 2 Independent product (Separately packed) Tightening torque (1):
2 426-07-32630 Pipe 2 Independent product (Separately packed) 6.8 ± 0.49 Nm
3 07281-01159 Clamp 4 Independent product (Separately packed) {0.69 ± 0.05 kgm}
4 426-56-31580 Clamp 2 Independent product (Separately packed)
6 426-56-31310 Seat 2 Independent product (Separately packed)
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 loca-
tion where interference
can result between the
bolt and hose.
Section A-A
(from the end of the hose)

2. Installing cab cover
1 426-56-31563 Cover 1 Independent product (Separately packed)
2 01024-D0616 Bolt 12 Independent product (Separately packed)
4 01024-D0625 Bolt a 2 Independent product (Separately packed)
5 11Y-979-2420 Washer 14 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

Socket (10mm) 1
Others
29
Assembly procedure
No. 0180
(1) Installing L.H. side cover
No. Part No. Part name Q’ty Parts conditions Install side cover (1) (L) with screw (3) and
1 426-926-3773 Side cover (L.H.) 1 Independent product (Separately packed) washer (2).
2 418-926-3490 Washer 2 Temporarily attached to cab
(2) Installing filter box
3 01225-70616 Screw 2 Independent product (Separately packed)
4 426-07-3200A Filter box assembly 1 Independent product (Separately packed)
Install box assembly (4) with filter (5) and
5 426-07-32450 Filter 1 Independent product (Separately packed) bolts (6)(7).
6 01024-81016 Bolt 3 Independent product (Separately packed) (3) Installing R.H. side cover
7 01024-80616 Bolt 2 Independent product (Separately packed) Install side cover (8) (R) with screw (10) and
8 426-926-3781 Side cover (R.H.) 1 Independent product (Separately packed)
washer (9).
9 418-926-3490 Washer 2 Temporarily attached to cab
10 01225-70616 Screw 2 Temporarily attached to cab
(4) Installing duct cover
11 426-07-3200B Rear duct assembly 1 Independent product (Separately packed) Install rear duct assembly (11) with bolts
12 01024-D0616 Bolt 10 Independent product (Separately packed) (12) and washers (15).
13 426-07-32472 Cover 1 Independent product (Separately packed) (5) Installing filter box cover
14 566-54-8A680 Screw 2 Independent product (Separately packed)
Install cover (13) with screw (14).
15 11Y-979-2420 Washer 7 Independent product (Separately packed)
View of the cab from the front

Each
Impact wrench (for M6 and M10) one
Each
Socket (10 mm, 17 mm) one
Others
30
Assembly procedure
No. 0190
1. Installing filter cover

1 426-56-3100A Cover assembly 1 Independent product (Separately packed)
2 426-07-32440 Filter 1 Independent product (Separately packed)
3 426-07-3213A Box assembly 1 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
1 426-926-300A Cover assembly 1 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

Clamp (9):
the cooler box piping 4.4 ± 0.5 Nm
No. Part No. Part name Q’ty Parts conditions {0.45 ± 0.05 kgm}
1 426-54-3200A Air-conditioner box 1 Independent product (Separately packed)
3 426-07-38111 Hose 1 Independent product (Separately packed)
4 04434-53211 Clips 1 Independent product (Separately packed) Z view
6 22D-62-18450 Collar 1 Independent product (Separately packed)
7 01580-11008 Nut 1 Independent product (Separately packed)
9 07281-00359 Clamp 2 Independent product (Separately packed)
1. Install air-conditioner box (1) with bolt (2).

2. Connect hose (3).

Each
Impact wrench (For M6 and M10) one
Each
Socket (10 mm, 13 mm, 17 mm) one
Others
31
Assembly procedure
Installation of yellow rotary lamp
No. 0195
(1) Installation of yellow rotary lamp

1 426-957-3120 Bracket 1 Temporarily installed to cab
2 01024-80860 Bolt 4 Temporarily installed to cab
3 416-S56-1120 Cushion 4 Temporarily installed to cab
4 01643-30823 Washer 8 Temporarily installed to cab
5 01580-10806 Nut 8 Temporarily installed to cab
6 423-957-4120 Caution lamp 1 Loose-supply item (Separately packed)
7 423-43-18430 Grommet 1 Installed to bracket (1)
8 04434-51008 Clip 1 Installed to bracket (1)
9 01024-80816 Bolt 1 Installed to bracket (1)
1. Remove parts (1) – (5) from the cab.

2. Pass the wiring harness of caution lamp (6) through grommet (7) of bracket (1) and fix it to the clip.
3. Install caution lamp (6) and bracket (1) with cushions (3), washers (4) and nuts (5) removed in step 1.
4. Fix the wiring harness of caution lamp (6) with clip (8) and bolt (9) installed temporarily to the back side of bracket (1).
5. 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.

Each
Impact wrench (for M8) one
Each
Socket (13 mm) one
Others
32
Assembly procedure
Installing front fender
No. 0200
1. Installing front fender

1 426-54-34131 Fender (L.H.) 1 Independent product (Separately packed)
2 426-54-34141 Fender (R.H.) 1 Independent product (Separately packed)
3 425-54-24210 Seat 2 Independent product (Separately packed)
4 426-54-34190 Guard 2 Independent product (Separately packed)
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.)

Impact wrench (For M10 and M12) Each
one
Socket (17 mm, 19 mm) Each
one
Others
33
Assembly procedure
Installing front light support and connection
No. 0210
1. Installing front light support

1 426-06-33012 Headlamp assembly (L.H.) 1 Independent product (Separately packed)
2 426-06-33022 Headlamp assembly (R.H.) 1 Independent product (Separately packed)
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

1 04434-51010 Clips 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. (8-pole) (12-pole)
(3 places in each of left and right side) Both of the two locks
must be checked.
2. Connect the wiring connectors [F01] and [F02] and (Female) (Male)
then fix them to the sheet metal clip.

a Since they are DT type connectors, don’t apply the (Male) Both of the two locks
(Female)
contact conduction restorer to them. GOOD N.G
must be checked.
GOOD N.G
Make sure before connection that inside of the connector Lock is
kept horizontal
Not locked sufficiently.
Locked slanted. Lock Not sufficiently locked
is free from dirt, dusts, oil or water.

Clean them, if any.
Also make sure that DT type connectors are locked as mated. There is There is
(Clicking sound is emitted when locked. A lock is provided for a gap no gap
up to 6 poles and two locks for 8 or more poles.)

(See the figure to the right)
Fixing with clip Fixing with clip
Tighten together with

L.H. positioner harness
Connection:
Connection: CN F01 (R.H.)
CN F02 (L.H.)
Front frame viewed from rear side

Impact wrench (For M10 and M12) 1
one
Others
34
Assembly procedure
Installing muffler stack and mirror
No. 0220
1. Installing muffler stack

1 426-02-31150 Muffler stack 1 Independent product (Separately packed)
1. Install the muffler stack to the upper left side of the engine hood.
2. Installing mirror
1 23S-54-36270 Mirror 1 Independent product (Separately packed)
2 426-54-35210 Stay 1 Independent product (Separately packed)
1. Install the mirror to the upper right side of the engine hood.

Socket (19 mm) 1
Others
35
Assembly procedure
Installing counterweight
No. 0230 (Standard and 1 ton heavier counterweight specifications)
1. Assembling the counterweight

Standard counterweight specification
Independent product (Separately packed) , Bolt (2):
1 426-46-33711 Counterweight 1 Weight: 2,780 kg
2,450 -- 3,040 Nm
2 01011-63680 Bolt 6 Temporarily attached to the frame
3 01643-33690 Washer 6 Temporarily attached to the frame
{250 -- 310 kgm}
Specification of 1 ton heavier counterweight

Independent product (Separately packed) ,
1 426-46-33730 Counterweight 1 Weight: 3,780 kg
2 01011-63680 Bolt 6 Temporarily attached to the frame
3 01643-33690 Washer 6 Temporarily attached to the frame
a It is advisable to
use the lever block
1. Check the part number of the counterweight. (Fig.1)
on one side for the
adjustment.
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
Deep Shallow
Holes Without
provided hole
Deep Shallow
Fig. 2
Lifting position
Fig. 1
Standard counterweight Specification of 1 ton heavier
specification counterweight
Counterweight
lifting position
kg kg

Torque wrench Crane 25 ton 1
(Set 2,745 Nm) {279.9 kgm} 1 Balance-type lifting tool 1
Socket (55 mm) 1
Others
36
Assembly procedure
Installing counterweight
No. 0235 (Load and carry specification)
(1) Installation of counterweight
No. Part No. Part name Q’ty Parts conditions Tightening torque
1 426-46-33760 Counterweight 1 Loose-supply item (Separately packed), 2,450 – 3,040 Nm
Weight: 4,785 kg
2 01011-63680 Bolt 6 Temporarily installed to frame {250 – 310 kgm}
3 01643-33690 Washer 6 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

How to distinguish counterweight
for either side
to adjust.
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

Torque wrench (Set, 2,745 Nm {280 kgm}) 1 25 ton crane 1
Socket (55 mm) 1 Spreader bar sling 1
Others
37
Assembly procedure
Installing pin (Standard and EU specifications)
No. 0240
1. Assembling the pin and lynch pin
Standard specification
1 426-46-33720 Pin 1 Independent product (Separately packed)
2 425-46-13130 Lynch pin 1 Independent product (Separately packed)
EU specification (Sales code: 6XX44)

1 426-46-33740 Pin 1 Independent product (Separately packed)
2 426-46-33750 Lynch pin 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

Socket (12 mm) 1
Others
38
Assembly procedure
Installing rear access ladder and L.H. platform
No. 0250
1. Assembling the rear access ladder assembly

Independent product (Separately packed),
1 426-54-3400A Rear access ladder 1 Weight: 100 kg
3 01643-31645 Washer 4 Temporarily attached to the machine body
1. Tighten rear access ladder assembly (1) using (2) to (5).
2. Assembling the L.H. platform assembly

1 426-54-3400B Platform assembly L.H. 1 Weight: 120 kg
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

1 426-54-34353 Cover (L.H.) 1 Temporarily attached to the rear access ladder
2 01024-81225 Bolt 4 Temporarily attached to the rear access ladder
1. Assemble cover L.H. (1) using (2).

1. After adjustment of the clearance be-
Impact wrench (For M12 and M16) Each Nylon sling
tween the rear access ladder assembly one
Socket (19 mm, 24 mm) Each (Withstand load of 100 kg and above) 2
and platform assembly L.H , tighten the one
bolt fully. Crane 10 ton 1
Others
39
Assembly procedure
Installing the left handrail
No. 0260
1. Assembling the handrail
1 426-54-35133 Rear handrail (L.H.) 1 Independent product Fig. 1 Edge side
Top
Temporarily attached to the rear comes to the top
2 561-54-61910 Clamp (at e marked position) 5
access ladder assembly body
Temporarily attached to the rear
3 01010-D1630 Bolt (at e marked position) 10
4 01643-71645 Washer (at e marked position) 10 Temporarily attached to the rear
5 426-54-3510A Handrail assembly LH-1 1 Independent product
6 426-54-3510B Handrail assembly LH-2 1 Independent product
7 421-54-25610 Mirror 1 Independent product
8 04025-00632 Pin spring 1 Temporarily attached to (7)
Temporarily attached to platform
9 561-54-61910 Clamp (at a marked position) 7
assembly L.H. Rear side
10 01010-D1630 Bolt (at a marked position) Temporarily attached to platform comes to the bottom
14
assembly L.H.
Temporarily attached to platform External view of clamps (2) and (9)
11 01643-71645 Washer (at a marked position) 14
assembly L.H.
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

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
Assembly procedure
Installing right platform and R.H. handrail
No. 0270
1. Assembling the R.H. platform assembly

Platform assembly Independent product (Separately packed),
1 426-54-3400C 1
R.H. Weight: 150kg
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

1 426-54-3510C Handrail assembly RH-1 1 Independent product (Separately packed)
2 426-54-3520A Handrail assembly RH-2 1 Independent product (Separately packed) Edge side
3 421-54-25610 Mirror 1 Independent product (Separately packed) Top comes to the top
4 04025-00632 Pin spring 1 Temporarily attached to (3)
Clamp Temporarily attached to platform
5 561-54-61910 (at a marked position) 6 assembly R.H.
Bolt Temporarily attached to platform
6 01010-D1630 (at a marked position) 12 assembly R.H.
7 01643-71645 Washer Temporarily attached to platform
(at a marked position) 12 assembly R.H.
Bolt Temporarily attached to platform Fig. 1 Rear side
8 01024-D1230
(at q marked position) 2 assembly R.H. 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

1. When assembling R.H. platform assem-
bly (2) and No.0220 rear fender assem-
bly (1), the R.H. platform shall be Socket (24 mm) 1 (Withstand load of 100 kg and above) 2
attached temporarily at this stage. Crane 10 ton 1
Tighten it fully after assembling the rear
fender.
Others
41
Assembly procedure
Installing fire extinguisher
No. 0275
(1) Installation of fire extinguisher to right platform

Handrail assembly RH-2
1 (426-54-3520A) (Fire extinguisher specification) 1 Loose-supply item (Separately packed)
2 09495-40000 Fire extinguisher 1 Loose-supply item (Separately packed)
3 01010-80620 Bolt 4 Installed to handrail
4 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

Socket (10 mm) 1
Others
42
Assembly procedure
Installing the rear fender mudguard plate
No. 0280
1. Assembly of rear fender mudguard plate

1 426-54-4200A Plate assembly 1 Independent product (Separately packed)
1. Assemble plate assembly (1) using bolt (2).
Shape is changed.

one
one
Others
43
Assembly procedure
Installing rear fender
No. 0290
1. Installing rear fender

1 426-54-3400F Rear fender assembly 1 Independent product (Separately packed)
2 01024-D1230 Bolt 4 Temporarily attached to the platform
3 01010-81690 Bolt 1 Temporarily attached to the platform Rear fender
4 01643-31645 Washer 2 Temporarily attached to the platform
5 01580-11613 Nut 2 Temporarily attached to the platform
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

1 421-54-31782 Gas spring 2 Temporarily install it to rear fender
2 01643-30823 Washer 8 Temporarily install it to rear fender
3 04050-12015 Cotter pin 4 Temporarily install it to rear fender
4 04205-10830 Pin 4 Temporarily install it to rear fender
5 07260-02650 Hose 2 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. Assembly on both ends
must be implemented
at the same time.

Impact wrench (For M12 and M16) Each Nylon sling
one
Socket (19 mm, 24 mm) Each (withstand load shall be 100 kg and above) 2
one
10 ton crane 1
Others
44
Assembly procedure
Installing cab undercover
No. 0300
1. Installing cab undercover (Front)

1 426-54-3200C Cover assembly 1 Weight: 12kg
2 01024-81225 Bolt 10 Temporarily attached to cab
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)

1 426-54-3200B Cover assembly 1 Weight: 7 kg
3 124-54-26540 Washer 4 Temporarily attached to the machine body
1. Install the cover assembly (1) to the cab using the bolt (2)
and washer (3).

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

Others
46
Assembly procedure
Air bleeding of work equipment hydraulic circuit
No. 0320 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 re-
spective 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.

Others
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.

Others
48
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 on-
board 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.

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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.
1. 3 places of rear brake <Procedure for bleeding air from rear brake>
Left wheel brake: 1 place 1. Start the engine and check that the oil levels in the transmission case and
Right wheel brake: 1 place brake sub-tank are normal.
Front brake slack adjuster: 1 place 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.
Common to right and left
1. 3 places of front brake <Procedure for bleeding air from front brake>
Left wheel brake: 1 place 1. Start the engine and check that the oil levels in the transmission case and
Right wheel brake: 1 place brake sub-tank are normal.
Front brake slack adjuster: 1 place 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.
Common to right and left
a After bleeding air, add oil to the transmission case and brake sub-tank.

1. When bleeding air, stop the machine on
Air hose (6ø × 1 m) 1
a flat place and lock the tires with chocks.
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Assembly procedure
Installing lift arm and bell crank assembly
No. 0350
1. Installing lift arm and bell crank assembly

Lift arm and bell crank Independent product (Separately packed),
1 426-70-3010A assemblies 1 Weight: 5,670 kg
2 426-70-31991 Pin 2 Temporarily attached to the machine body,

Weight: 84.6 kg
5 428-70-11440 Shim (t = 1.5) 4 Independent product (Separately packed)
6 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. Part name Q’ty Parts conditions View of the lift arm from inside
Temporarily attached to the machine body, Lift arm
1 426-70-31970 Pin 2
Weight: 42.2 kg
4 21T-72-17580 Nipple 2 Temporarily attached to the machine body
5 07020-00000 Fitting 2 Temporarily attached to the machine body
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

1 421-09-12540 Elbow 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.)

Impact wrench (For M16 and M20) Each Crane: 10 ton, 50 ton Each
one one
Socket (24 mm, 30 mm) Each Nylon sling
one
Large hammer 1 (Withstand load of 1 ton and above) 3
Nylon sling
(Withstand load of 50 kg and above) 2
Nylon sling
(Withstand load of 6 tons and above) 1
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Assembly procedure
Installing bucket cylinder (Bell crank side)
No. 0360
1. Installing bucket cylinder assembly (Installing bell crank)

Attached temporarily to the bell crank
1 426-70-31940 Pin 1 assembly. Weight: 80 kg.
2 01010-82035 Bolt 1 Attached temporarily to the bell crank
assembly.
3 427-70-11290 Washer 1 Attached temporarily to the bell crank
assembly.
Attached temporarily to the bell crank
4 07049-03342 Plug 1
assembly.
1. Wipe out grease and paint in the pin hole and clean. Bell crank
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.
2. Connecting grease piping

1 426-70-13270 Elbow 1 Temporarily attached to the machine body
1. Install elbows (1) to the pin.
Bell crank

Impact wrench (For M14 and M20) Each Crane for 50 ton 1
one
Torque wrench 1 Nylon sling
Socket (22 mm, 30 mm) Each (Withstand load of 500 kg and above) 2
one
Large hammer 1 Nylon sling
(Withstand load of 50 kg and above) 2
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Assembly procedure
Installing bucket (1/3)
No. 0370
1. Installing the bucket

2 427-70-12530 (O-ring) cord ring 4 Independent product (Separately packed)
1) Installing cord ring.

1. Place cord ring (O-ring) (2) on the lift arm boss section (1). Bucket assembly
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. View of the bucket assembly from left
4. Apply LM-G (lithium grease added with molybdenum disulfide)
to all over the inner surface of the dust seal lip (3).
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 Cord ring installation groove
(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.
Bucket hinge pin section (Section A-A)
3) Selection of shim for the bucket hinge pin section.
– 426-70-11320 Shim (t = 1.5) 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
1-2. Hold the shims with a standard driver (–) or other tools. Weight: 5,115kg
k Absolutely do not insert fingers into the pin pivot hole.

1. Don’t try to align the holes by hand or
Crane for 50 ton 1
fingers after matching the pin hole.
2. G2-LI (lithium grease 2) may be used Chain lifting tool:
partly instead of LM-G (molybdenum 4,000 mm, 2 slings 1
disulfide lithium grease). Shackle: for 2.5 to 3 ton 2
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Assembly procedure
No. 0380
4) Inserting the bucket hinge pin.

5 426-70-31910 Pin 2 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.

7 425-70-11290 Washer 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.

Wrench (36 mm) 1
Large hammer 1
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54
Assembly procedure
No. 0390
7) Lower cord ring (2) to the groove.

Assemble the bucket link pin in the same manner as step 1) through 7).
– 427-70-12530 O-ring 2 Independent product (Separately packed)
– 426-70-11320 Shim (t = 1.5) 2 Independent product (Separately packed)
– 426-70-31920 Pin 1 Independent product (Separately packed)
– 01010-81630 Bolt 1 Independent product (Separately packed)
– 425-70-11290 Washer 1 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.
– 07049-01620 Plug 9 Independent product (Separately packed)
– 07020-00000 Fitting 2 Independent product (Separately packed)
Greasing
position
Bucket link
Bucket hinge
(2 locations)

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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

Grease gun (Hand pump type) 1
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Assembly procedure
Installing lift arm positioner
No. 0410
1. Assembling the lift arm positioner

1 7861-93-8710 Sensor 1 Installed to machine body
2 01024-81030 Bolt 3 Installed to machine body
3 01024-D1020 Bolt 1 Attached temporarily to the lift arm and bell crank assembly
4 01602-20825 Washer 1 Attached temporarily to the lift arm and bell crank assembly
6 01024-D1230 Bolt 3 Attached temporarily to the lift arm and bell crank assembly
7 426-43-39341 Cover 1 Temporarily attached to machine body
8 01024-D1225 Bolt 4 Temporarily attached to machine body
9 04434-51010 Clip 1 Temporarily attached to machine body
10 01024-81016 Bolt 1 Temporarily attached to machine body
11 04010-00310 Key 1 Independent product (Separately packed)
12 426-43-39312 Lever 1 Independent product (Separately packed)
13 01010-80835 Bolt 1 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.)
5. Fasten the harness with clip (9) and bolt (10).
6. Connect the harness. (CN F13)
Connect
CN F13
Lift arm
Fasten angle sensor
X view
2. Checkup of the plug

1 07049-03342 Plug 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).

Impact wrench (for M8, M10, and M12) 1
Socket (13 mm, 17 mm, 19 mm) Each
one
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Adjustment procedure
Contents of adjustment items
No. 0420
No. 0430 Setting of machine monitor............................................................. 59

1. Machine monitor operating method
2. How to turn on service mode
3. How to input ID
No. 0440 Adjustment of work equipment controller lift arm angle ............. 60
1. Lift arm angle adjustment procedure
No. 0450 Adjustment of work equipment EPC starting current (1/2) .......... 61
Work equipment EPC calibration adjustment procedure
No. 0460 Adjustment of work equipment EPC starting current (2/2) .......... 62
Lift arm LOWER
Bucket DUMP
Lift arm RAISE
Bucket TILT
No. 0470 Adjustment of bucket positioner (1/2)............................................ 63

Adjustment of bucket positioner
Adjustment of the bucket levelness detection switch
Adjustment of the maximum tilt detection switch
No. 0480 Adjustment of bucket positioner (2/2)............................................ 64

Adjustment of installation position (stopping position)
No. 0490 Adjustment of load meter lift arm angle ........................................ 65

Lift arm angle adjustment procedure
No. 0500 Load meter no-load calibration....................................................... 66

Implementation of no-load calibration (Zero point adjustment)
No. 0510 Deleting the electrical system failure history (1/2) ....................... 67
1. Deleting the electrical system failure history
1-1. Deleting the history when only one failure is recorded
in the electrical system failure history
No. 0520 Deleting the electrical system failure history (2/2) ....................... 68
1-2. Deleting the history when two or more failures are recorded
in the electrical system failure history

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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 Monitor panel
selector switch
mode for the machine monitor before starting the operation.
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 Symbols in the figure
indicate the following
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.
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.

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Adjustment of work equipment controller lift arm angle
No. 0440
Press switch several times from the electric system failure history screen of the service mode.
Monitor panel
The adjustment function screen will appear. selector switch
(See No.0360 “2. How to turn on Service Mode”)
Adjustment function screen
1. Lift arm angle adjustment procedure Symbols in the figure

(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.
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 Position of lift arm Voltage range
A 3.80 ± 0.3V
Upper limit position (Raise cylinder stroke end)
B 3.87 ± 0.3V
Lift arm length by lift arm specification
A B
WA600-6 3,850 mm 3,990 mm

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Adjustment of work equipment
No. 0450 EPC starting current (1/2)
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
1. Work equipment EPC calibration adjustment procedure Symbols in the figure

(1) Press U switch to display Item No.01: Transmission trigger adjustment and selection screen. indicate the following
Cancel
(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 Lift arm RAISE : No. 6

Lift arm LOWER : No. 7 Respective items
must be set up
Bucket TILT : No. 8 independently
Bucket TILT Bucket DUMP : 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

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Adjustment of work equipment
No. 0460 EPC starting current (2/2)
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, pro-
ceed 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 Symbols in the figure
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.
[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 oper-
ation. (“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 com-
plete.
(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.
ation. (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,
(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.
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.

ation. (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,
(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 com-
plete.
the item display screen (see No.450 Fig.1: Bucket TILT) will be restored.

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Adjustment of bucket positioner (1/2)
No. 0470
All the surfaces
Clearance
Sensor sensing surface
of 3 to 5
traveled
Detection bar
Detailed view
Top view of bucket positioner of section P
For detection of For detection of

maximum tilt bucket level to ground
Proximity switch Proximity switch
At maximum tilt
When bucket is
level to ground
50 Nominal value Proximity switch
Nominal
value mounting bracket
Detection bar
Bucket positioner viewed from the left side
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.

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63
Adjustment of bucket positioner (2/2)
No. 0480
Adjustment of installation position (stopping position)

(1) Park the vehicle on a level paved ground and then start the engine.
(2) Using the remote positioner bucket angle set switch, set the stop position to ± 0.
(3) Set the engine mode to the Power and then raise the lift arm until it becomes roughly level.
(4) Set the bucket to the full dump state.
(5) 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 prox-
imity 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.

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Adjustment of load meter lift arm angle
No. 0490
Press switch several times from the electric system failure history screen of the service mode. The adjustment function
screen will appear.
Monitor panel
Adjustment function screen selector switch
1. Lift arm angle adjustment procedure

(1) Press U switch to display Item No.01: Transmission trigger adjustment and selection screen.
Symbols in the figure
Adjustment function screen indicate the following
Cancel
(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.
(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 instal-
lation 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 Voltage range
Upper limit position (Raise cylinder stroke end) 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.
(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 Voltage range
Lower limit position (Lower cylinder stroke end) 0.5 to 4.5V

1. This process shall be implemented only
for the machines manufactured to the
load meter specification.
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65
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 Monitor panel
for ordinary operation. (To be maintained in the range of approximately 60 to 85°C: At or near the white range selector switch
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 Symbols in the figure
center of gravity becomes movable. indicate the following
• 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..
(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.
1. This process shall be implemented only
for the machines manufactured to the
load meter specification.
Others
66
Deleting the electrical system failure history (1/2)
No. 0510
1. Deleting the electrical system failure history

Turn on the electrical system failure history screen from the service mode. Monitor panel
selector switch
Then select the electrical system failure history option from the screen by use of U 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)
0 displayed in ✻✻ field indicates that there is no recorded failure in the electrical system failure indicate the following
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
✻✻✻: 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
Cancel (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.

Others
67
Deleting the electrical system failure history (2/2)
No. 0520
1-2. Deleting the history when two or more failures are recorded in the electrical
Monitor panel
system failure history selector switch
1. Select the electrical system failure history option using U switch. Following screen will appear.
Display electrical system failure history screen

✻✻✻: Indicates the chronological order of the failure concerned indicate the following
######: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.

Others
68
Installing the floor mat (AJSS specification)
No. 0530
1. Installing floor mat

1 426-54-32473 Mat (For AJSS) 1 Independent product (Separately packed)
2 426-54-32161 Seat (For AJSS) 1 Independent product (Separately packed)
1. Install the mat (1) and seat (2) to the floor.

Others
69
Installing the floor mat (Steering wheel specification)
No. 0540
1. Installing the floor mat

1 426-54-32571 Mat (For steering wheel) 1 Independent product (Separately packed)
2 426-54-32170 Seat (For steering wheel) 1 Independent product (Separately packed)
1. Install mat (1) and seat (2) on the floor.

Others
70
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 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
Operation b 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
Operation c 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.)
Operation d 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
Lower the lift arm
Operation e 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.)
Others
71
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

Others
72
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
Lower the lift arm

Grease gun (Hand pump type) 1
Others
73
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

Others
74
On use of starter kit (dummy harness)
No. 0590 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.

Others
75
Starter kit (dummy harness) assembling procedure
No. 0600
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.

1 426-06-31540 Wiring harness 1 Contained in bag (2)
2 09056-04613 Bag 1 Independent product (Separately packed)
3 426-98-33410 Plate 1 Contained in bag (2)
1. Connect connector CL12 of the dummy harness to the floor harness.

2. Connect connector C17 of the dummy harness to the accelerator pedal connector.
3. Connect connector CL16 of the dummy harness to the steering harness.
4. 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 OFF Parking brake ON

Starting switch
Parking brake switch
CN CL12: Connected
CN C17: Connected
Dummy harness
Z view

Others
76
1/7
2/7
Confirmation
Category
Judgement
Nature of
of repair
Measured
repair
No. Item Judgement procedure & standard
value
No error of machine serial number or Must be legible from 1 meter away (Model name )
Specifications
stamping ? Correct stamping error with (K) (Serial No. )

Is the stamping on machine nameplate Acceptable if legible
correct ? Concordant with the machine serial number ?
Matching the manufacturing instructions ?
Verification of specifications
A
Any changes made during the delivery inspection process ?

Radiator coolant level Higher than the lower end of the coolant filler
B Oil and coolant
Capacity of radiator sub-tank L–H

capacity
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 [ ]
Recording the main switch key No. [ ]
Sounding of horn Sound volume and abnormal sound
Neutral safety function Engine to start only with the gear at neutral position
Lighting and specifying the pilot and indicator (Bench inspection) [ ]
Performance and reading of hour meter
(Delivery inspection) [ ]
Is engine startability normal ?
Engine startability
Any abnormal sound during start ?
Must light up when turned ON; but not start traveling;
Performance of parking brake transmission lever (button) must sound buzzer in forward
or reverse with the caution lamp flashing
Performance of the main monitor panel All monitors and gauges to light up for 3 seconds upon main
self-checking switch ON, and warning buzzer to sound for 1 second
Performance of emergency steering
To light up upon main switch ON
pilot lamp
No warning lamps or buzzer will be lit or sounded for
Performance of starting inspection coolant temperature gauge, T/C oil temperature gauge, oil
Before starting engine
monitor and coolant level meter, engine oil pressure gauge, brake
oil pressure gauge, charging and air cleaner
Fore-aft adjustment, reclining adjustment, headrest angle
adjustment, seat cushion up-down adjustment, seat angle
Seat position adjustable ? 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 ?
Are the length adjustment and locking and unlocking
C
Seat belt check

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 ?
Is armrest angle adjustable (10°) ?
AJSS lever adjustment
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.
3/7
Confirmation
Category
Judgement
Nature of
of repair
Measured
repair
value
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
Is operating effort normal ?
lever
Performance of work equipment control No spontaneous unlocking, and the lift arm and bucket not
lever lock to be lowered
3 mm or under by the cylinder stroke
Performance and adjustment of kick-out (when lift arm is not attached, apply a metal piece to senser
and checking)
Is the winker reset when machine body steered to opposite
Automatic reset of winkers
direction by 10° and over ?
(when lift arm is not attached, apply a metal piece to senser
Performance and adjustment of leveler
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
Abnormal engine noise, color of emission,
Shall be normal
and hunting
Engine pick-up performance Engine to pick up during low idle with load
Performance, Function
Engine stall performance No stalling during low idle with load

Performance of shift lever Is selection normal ? No shifting error ?
No shifting to 2nd speed when selecting forward-reverse in
Forward-reverse button function
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 ?
D
Transmission modulation function Find out a checking method with production machines
Abnormal noise from near the axle during sudden braking
Abnormal noise from rear axle
and forward-reverse travel
Don’t start traveling in F3 after applying emergency
Performance of parking brake
performance to the machine
Machine must stop upon applying braking while traveling in
Braking force
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]
19.3 to below 21.3 km/h (onboard gauge);
Forward 3rd gear speed [ km/h]
tempa spare tire not measured
Forward 4th gear speed [ 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 [ km/h]
Forward 4th gear speed [ km/h]
Travel speed during lockup Should be slightly faster than when the lockup is OFF
4/7
Confirmation
Category
Judgement
Nature of
of repair
Measured
repair
value
Travel in F2 at 5 km/h or higher and check that the lift arm

Function of E.C.S.S.
operates
Must be manually operable during manual operation
From 2nd speed to 3rd speed during L
[ km/h]
(change gear during travel at 5 to 7 km/h)
From 3rd speed to 4th speed during L
[ km/h]
Transmission automatic shifting function (change gear during travel at 13 to 16 km/h)
From 2nd speed to 3rd speed during H
[ km/h]
From 3rd speed to 4th speed during H
[ km/h]
Must not change to 2nd speed when selecting forward-
reverse travel in 1st speed.
Peeping is
High speed shift F4 to be selected when traveling in R4 at 17 km/h with
Travel function
sounded
engine revolution at 2,000 rpm or higher.
➡ R4 o F4 o F3 o F2 o F3 o F4
Will the pilot turn ON-OFF with the lift arm lever switch ?
Shift hold function 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)
Will gear shift to 1st speed when the switch is ON during
travel in 2nd speed, or will the gear reset to F2 after
Kick-down switch performance 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 ?
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
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 2.7 – 3.3 sec [ sec]
Left 2.8 – 3.5 sec (High idle) [ sec]
Right 2.8 – 3.5 sec (High idle) [ sec]
AJSS lever swing time
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]
D
(Economy) T/C stall 1,630 – 1,830 rpm [ rpm]

Stall during working 1,730 – 1,930 rpm [ rpm]
Full stall 1,490 – 1,690 rpm [ rpm]
Engine speed: High idle 1,950 – 2,050 rpm [ rpm]
(Power mode) T/C stall 1,700 – 1,900 rpm [ rpm]
Stall during working 1,840 – 2,040 rpm [ rpm]
Full stall 1,580 – 1,780 rpm [ rpm]
5/7
Confirmation
Category
Judgement
Nature of
of repair
Measured
repair
value
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
Throttle locking function operated for 5 to 10 sec. with transmission in neutral position.
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
a If successfully set, blip sounds after Does the bucket cutting edge stop on the tilt side when the
2.5 seconds and the setting is bucket angle is set as above ?
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.
D
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
6/7
Confirmation
Category
Judgement
Nature of
of repair
Measured
repair
value
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 ?
If the machine remains in the above-mentioned condition
Verification of modulation clutch slip (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)
Travel in F2 or faster at 5 km/h or higher and turn the
Verification of E.C.S.S. damper function
E.C.S.S. switch ON. Then the lift arm must rise slightly
Stop engine with the lift arm raised to level or higher
Performance of work equipment
D
position. Then turn the main switch ON and lower the lift
accumulator
arm lever. Will the lift arm be lowered ?
Engine should be disabled to start when the isolator switch
Performance of battery isolator (Optional)
is turned OFF
No oil leakage from each joint ?
No water leakage from each joint ?
Verification of locally assembled portions
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 ?)
7/7
Confirmation
Category
Judgement
Nature of
of repair
Measured
repair
value
Must be located within the operation range

Performance of fuel gauge
(Check the fuel when the tank is full)
Performance of torque converter
hydraulic oil temperature gauge
Performance of engine coolant
temperature gauge
Performance of various light switches Any loose mounting or resistance to smooth switching ?
Lighting of dash lamp Cluster, speedometer and hour meter
Gauges and lights
Lighting of headlamp Lo-Hi selection and the lighting of pilot lamp

Lighting of left and right lamps
Lighting of clearance lamp
(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 left and right lamps
Lighting of tail lamp
(lighting should follow one stage before the switch)
E
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
Front, rear, left, right signal lamps and the pilot lamp to start
Flashing of hazard signal lamps
flashing upon main switch OFF
Sounding of backup buzzer Must sound
Do the step lamps light ?
Check lighting of step lamps
(Enabled to turn OFF below when lit up above or vice versa ?)
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 console box switches and the lamp lighting Left
Performance of power windows positions of the harness check must coincide
(be careful for the right side and wrong side) Right
Verification of air-conditioner and heater
Performance of ON-OFF switches Wind should blow out to the cool box
Cool wind should come out
Performance of heater selector switch
Warm wind should come out
Cab air-conditioner
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
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
Front wiper switch Hi. o Front wiper switch Hi must light up
Performance of wiper and washer
Depress front washer switch. o Washer motor whining
should be audible
Rear wiper switch ON. o Rear wiper switch Lo must light up
Depress rear washer switch. o Washer motor whining
should be audible
Performance of radio Radio 24V should light up
Turn the front working lamp switch ON with the stage 1 of
E Lights
Verification of front working lamps

the headlamp switch. o Working lamps light up
Verification of warning lamps Working lamps must light up

GEN00073-01

Assembling an Excavator

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Assembling an Excavator

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CONTENTS

1. Bare machine 2. Front axle assembly

6. Front light support assembly 7. Step 8. Rear access ladder (Left)

9. Platform 10. Cab 11. Bucket

12. Handrail 13. Fender 14. Muffler stack

15. Rear fender (if equipped)

Bare machine trailer loading chart

WA600-6 52,700 11,985 3,685 4,460

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

Tire and wheel Lift arm and bell crank

Front axle assembly

Storage area for the lighter units

WA1200 front frame lifting tool

Drawing for additional machining of section A S = 1 : 2.5

Part Number Part Name Material Q'ty Remarks P

Balanced lifting tools for shipment

K21 (WA600 M/C)

In white paint: Machine model,

SV100 90° lifting 4,500 kg

2-26 drilled hole

Corners shall be smoothly grind-finished.

Part Number Part Name Material Q'ty Remarks P

Axle assembly lifting tool

Note: Inspection report shall be attached. Date '05--09--21

List of touch-up paints

3 Fuel Adequate quantity of fuel oil –

Cautions Special tool Necessary Equipment

Specified Volume of Volume of

Cautions Special tool Necessary Equipment

Axle lower end position

Square bar Square bar

2. Setting the bare machine to stationary position

Axle lower end

Cautions Special tool Necessary Equipment

1. Setting the front axle to stationary position

Axle lower end

Square bar Square bar

1. Lift the front axle assembly with the crane.

No. Part No. Part name Q’ty Parts conditions

2. Setting the bare machine (equipped with front axle) to

Axle lower end

Square bar Square bar

Modification of square bar position

Cautions Special tool Necessary Equipment

1. Connecting the drive shaft

View Z: Front frame viewed from left side

Cautions Special tool Necessary Equipment

2. Connecting the brake pipe

Connection: Check of O-ring

Cautions Special tool Necessary Equipment

No. Part No. Part name Q’ty Parts conditions

X view Y view Sction A-A

Cautions Special tool Necessary Equipment

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

Bolt (2) : 824 -- 1,030 Nm

Secure the tire with wire to prevent falling.

Cautions Special tool Necessary Equipment

1. Install the step to the hydraulic tank.

Cautions Special tool Necessary Equipment

1. Hoisting cab assembly

2. Installing cab seal

Detailed view of section A