24H_7KK CC Engine Task Guidelines

Task (Job Code): 010 - Remove and Install

Model: 24H
Serial No: XXX
CC + MC: 1000 – Engine

JOB SUMMARY

Budget Budget Skill Level Complete

Activity Activity Description
Man hours Duration Yes / No

1 Remove Engine Enclosure & Radiator Support Guard

2 Remove Drive Shaft – upper

3 Remove Engine

4 Install Engine

5 Install Drive Shaft – upper

6 Install Engine Enclosure & Radiator Support Guard

7 Engine Performance Test

BUDGET TOTAL:

Special Tools Bill of Material Ref

Qty Part Number Description Qty Description Part Number
2 - Wheel Chock 1 7KK1000TBP R & I Engine
2 1387574 Link Bracket
4 1410288 Lifting Sling
1 2P8250 Filter Strap
1 1U7113 Ratchet ½”

Workscope Reference Material

No Description Task Guidelines Doc. No Task Record Doc. No
1 Remove and Install Engine 24H_7KK_1000_010_TG_003_TBP 24H_7KK_1000_010_TR_003_TBP
2 Engine Performance Test 24H_7KK_1000_036_TG_001_TBP 24H_7KK_1000_036_TR_001_TBP

MSDS
Ref No MSDS Reference

24H_7KK_1000_010_TG_004_TBP 1 of 33
 24H_7KK CC Engine Task Guidelines
Document No: Process : Issued Checked Approved
R & I Engine Strategy
24K_XXX_1000_010_TG_003_TBP
Safety
Section Model : Contamination Control
Rev/Date Planning
Page
24H_7KK Daily Ops

TASK DESCRIPTION HORN SIGNAL

• 1 sound 2sec, 10 sec before Engine Running
SCOPE OF R & I ENGINE
• 2 sound 2 sec each, 3 sec apart, 10 sec before Machine moving
• R & I ENGINE ENCLOSURE & RADIATOR GUARD & SUPPORT
Forward
• R & I DRIVE SHAFT UPPER
• 3 sound 2sec each, 3 sec apart, 10 sec before Machine moving
• R & I ENGINE
Reverse
• PAPERWORK

PERSONAL SAFETY REQUIREMENT

• HARD HAT
• SAFETY GLASSES
• REFLECTIVE VEST
• SAFETY SHOES
• EAR PLUG

Key to Symbols
START
Memulai tugas • Menunjukkan, tugas dimulai dengan aktivitas ini.
Starting of Task Indicates that the task is begun with this activity

Melanjutkan • Menunjukkan aktivitas masih dilanjutkan

Continue Indicates that the activity still continues.
• Menunjukkan bahwa tugas harus disetujui oleh supervisor sebelum melanjutkan
Keputusan aktivitas berikutnya.
Decision Indicates that the task must be approved by supervisor before continue the next
activity

END Akhir sebuah tugas • Menunjukkan bahwa tugas telah selesai.

End of task Indicates that the task has finished
Membutuhkan tool khusus
• Menunjukkan bahwa ada tool tertentu yang di butuhkan untuk aktivitas tersebut.
Special Required Tools
Indicates that there is a special tools to perform the activity
Penggantian part
• Menunjukkan bahwa ada penggantian part yang di butuhkan pada aktivitas ini.
Parts Replacement
Indicates that there is parts replacement required in this activity

Literature pendukung • Menunjukkan bahwa ada literature pendukung yang dibutuhkan

Support Literature Indicates that there is support literature to perform the task

Workscope tertentu
• Menunjukkan bahwa ada workscope tertentu untuk tugas tersebut.
Refer to other workscope
Indicates that there is a certain workscope to perform the task

• Tanda ini digunakan untuk mengingatkan bahaya dan praktek-praktek yang tidak
aman yang dapat menyebabkan luka parah atau kematian jika prosedure yang
Peringatan
benar tidak di ikuti
Warning
This prompt is used to warn against hazards and unsafe practices that COULD
result in severe personal injury or death if correct procedures are not followed.
• Tanda ini digunakan ketika sebuah operasi, kondisi atau informasi penting untuk
Catatan
warrant highlighting.
Note
This prompt is used when an operation, condition, or information is of sufficient
importance to warrant highlighting

Text Color Legend

Semua Instruksi safety.
All Safety instructions.

Semua torque, berat atau spesifikasi tekanan

All Torque, Weight or Pressure Specification

Instruksi umum
General Instruction

Contamination Control
Contamination Control

24H_7KK_1000_010_TG_004_TBP 2 of 33
 24H_7KK CC Engine Task Guidelines
*Refer to Key Symbol Legend on Top

STEP* ACTIVITY DESCRIPTION PICTURES

Service Event scope Header

Manual
&
Parts Book
1. Persiapan Workshop • Unit masuk mundur ke dalam
START Workshop Preparation workshop
This done with machine reversed
on to apron in the workshop

• Parkirkan unit pada tempat yang

rata
Park the machine on a surface
that is flat and level

2. Posisi unit • Pasang 2 wheel chock pada depan

Positioning the machine ban dan belakang ban
Install two wheel chocks on 1 at
the front of a tyre & 1 at the back
of a tyre

• Pasang etiket personal danger

Attach personal danger tag

• Pasang etiket Machine Tag

Attach machine tag

3. Amankan unit • Turunkan semua attachment ke

Secure the machine lantai
Lower all attachments to the
ground.

• Luruskan articulation unit

Center the articulation of the
machine

• Pasang articulation lock. Frame

lock link harus bisa bergerak
bebas pada frame
Install the articulation lock. The
frame lock link must move freely
in the frame.
• Gerakkan front wheel sehingga
lurus vertical dan pasang wheel
lean lock bolt
Move the front wheels to vertical
and install the wheel lean locking
bolt.
• Pasang parking brake. Matikan
engine
Engage the parking brake. Stop
the engine.

Pastikan sebelumnya semua langkah no 1

sampai 3 sudah lengkap kemudian
melanjutkan
Ensure all previous steps no 1 to 3 have
been completed then proceed
4. Buang oli hydraulic.
Drain the hydraulic oil.
• Lepaskan plug pembuangan pada
bagian bawah hydraulic tank.
Buang dalam tempat yang telah
ditentukan.
Remove the drain plug at the
bottom of hydraulic tank. Drain
the oil into a suitable container.

24H_7KK_1000_010_TG_004_TBP 3 of 33
 24H_7KK CC Engine Task Guidelines
STEP* ACTIVITY DESCRIPTION PICTURES

Part yang di perlukan: • Pasang kembali plug dengan seal

Parts Required: baru setelah pengeringan selesai.
Torque plugs ke spesifikasi
Qty P/N Description Reinstall plug, with new seals,
after draining is complete. Torque
1 5M2057 Seal O Ring plugs to specification.
1 8T3298 Seal O Ring
Pastikan drain container
mempunyai kapasitas yang cukup
untuk menampung semua oli dari
Transmission.
Ensure the drain container has
enough capacity to take all of the Drain Plug
oil from the transmission.

Spec: 50 + 5 lb/ft
Capacity: 128 litres

5. Kuras Oli Engine CATATAN :

Drain the engine oil Jika untuk PCR drain oli, Jika
untuk R & I jangan drain oli
NOTE:
If for PCR drain oil, if for R&I do
not drain oil

• Alirkan oli engine ke container,

yang cocok jika waktu sudah
habis. Tutup valve drain setelah
oli habis mengalir.
Drain the engine oil into a suitable
container, if due. Close the drain
valve after oil finished draining.

Pastikan container yang di

gunakan untuk pengaliran oli
mempunyai kapasitas yang cukup
untu k menampung oli..
Ensure the container used for
draining the oil into has enough
capacity to take all of the oil.

Spec: 68 lts (18 US gal) engine oil

6. Menguras Radiator PERHATIAN

Drain Radiator Pada temperature operasi, coolant
Tank
dalam keadaan panas dan
Assembly
bertekanan
WARNING:
At operating temperature, the
engine coolant is hot and under
pressure.

• Posisikan tempat yang pantas

dibawah radiator.
Position a suitable container
under the radiator.
Radiator Cap
• Lepaskan radiator cap dari tank
assembly
Remove radiator cap from tank
assembly

• Lepaskan drain plug dari plug

adapter dan kuras radiator.
Remove drain plug from plug
adapter and drain the radiator.

Specifications:
Kapaitas dari cooling system
adalah 142 L (37 U.S. gal)
The capacity of the cooling system
is 142 L (37 U.S. gal)

24H_7KK_1000_010_TG_004_TBP 4 of 33
 24H_7KK CC Engine Task Guidelines
STEP* ACTIVITY DESCRIPTION PICTURES

REMOVE ENGINE ENCLOSURE

7. Melepas Dust Ejector • Longgarkan clamp assembly.
Remove Dust Ejector Loosen clamp assembly.
Body Assembly
• Lepaskan hose clamp dan hose
dari body assembly.
Remove hose clamp and hose
from body assembly.
Clamp
• Lepaskan body assembly dari air
cleaner.
Remove body assembly from air
cleaner. Hose

8. Melepas Exhaust Extension • Lepas bolt dan locknut.

Remove Exhaust Extension Loosen bolt and the locknut.

• Lepas clamp dan exhaust ejector

assembly dari muffler assembly.
Remove clamp and exhaust
ejector assembly from muffler
assembly
Clamp

9. Melepas Grate Assembly For Modification :

Remove Grate Assembly • Buka grate dengan melepas
delapan baut yang mengikatnya
Remove grate assembly by
removing eight bolts that secure it.

For Original :
• Buka grate dengan melepas Grate
empat baut yang mengikatnya
Remove grate assembly by
removing four bolts that secure it

10. Buka dua top hood • Buka delapan baut yang mengunci
Remove two top hoods top hood
Remove eight bolts that secure top
hoods

11. Lepaskan pintu kecil pada sebelah kiri • Buka satu baut yang menahan
dan kanan engine enclosure pintu pada engine enclosure
Remove the small door for both side of Remove one bolt that hold the
engine enclosure doors to the engine enclosure

12. Melepas Sambungan Hose dari tanki air • Berikan tanda pada dua hose (1)
Disconnect Hose from tank assembly dan (2) untuk keperluan instalasi.
Mark and identify two hose (1) and
(2) for installation purposes.

• Longgarkan clamp (1) dan (2).

Loosen clamp (1) and (2).
1 2
• Putuskan sambungan hose (1)
dan (2) dari tank assembly.
Disconnect hose (1) and (2) from
tank assembly.

24H_7KK_1000_010_TG_004_TBP 5 of 33
 24H_7KK CC Engine Task Guidelines
STEP* ACTIVITY DESCRIPTION PICTURES
• Longgarkan clamp dan putuskan
sambungan hose (3) dari tank
assembly.
Loosen clamp and disconnect
hose (3) from tank assembly.

13. Lepaskan fire extinguisher lines dari • Lepaskan sambungan ke fire

engine enclosure extinguisher lines pada connector
Disarm fire extinguisher lines from utamanya
engine enclosure Disarm connection to fire
extinguisher line at the main
connector

14. Buka baut yang mengikat tube pada
frame
Remove all bolt that secure the tube to
frame
CATATAN :
AFFF System akan berbeda di
masing-masing site
NOTE:
AFFF System will be different
between site
• Buka dua baut pada masing-
masing tube (1), (2), (3) dan (4)
Remove two bolts of each tube (1),
(2), (3) and (4)

• Lakukan pada kedua sisi kiri dan

kanan
Perform the above step for both 1
side left hand and right hand 2 3

• Lepaskan dua baut pada tube (1)

dan (2)
Remove four bolts that secure
tube (1) and (2) 2
1

15. Lepaskan engine enclosure • Pasang alat angkat pada engine

Remove engine enclosure enclosure. Lepaskan engine
enclosure dari rear frame
Position a lifting device on engine
enclosure. Remove engine
enclosure from rear assembly

The weight of engine enclosure

579 kg

CATATAN:
Hood dan grade sudah dilepas,
angkat langsung dari frame
NOTE:
The hood and grade
alreadyremove, lifting directly from
frame only

24H_7KK_1000_010_TG_004_TBP 6 of 33
 24H_7KK CC Engine
STEP* ACTIVITY
REMOVE RADIATOR GUARD GP
16. Melepas Air Conditioning Condenser
(jika ada).
Remove Air Conditioning Condenser (if
equipped)
17. Lepaskan electrical connection pada AC
compressor (jika ada).
Disconnect electrical connection at the
AC Compressor (if equipped)
24H_7KK_1000_010_TG_004_TBP
Task Guidelines
DESCRIPTION PICTURES
CATATAN:
Untuk remove dan install dari fan,
air conditioning condenser tidak
perlu dipindahkan, air conditioning
condenser dapat dilepas tanpa
memutus sambungan hose
assemblies.
NOTE:
For the remove dan installation of
the fan, air conditioning condenser
does not need to be evacuate, air
conditioning condenser can be
removed without disconnecting
hose assemblies .
• Longgarkan tapi jangan dilepas
dua bolt pada tiap sisi dari air
conditioning condenser yang
menahan bracket ke radiator
guard dan support.
Loosen, but do not remove two
bolts on each side of air-
conditioning condenser that hold
brackets to the radiator guard and
support.
• Gunakan dua orang, lepas empat
bolt dan washer dari tiap sisi dari
air conditioning condenser.
Using two people, remove four
bolts and the washers from each
side of air conditioning condenser
CATATAN:
Buka Condenser dan
compressor sebagai satu
group dan jangan ada
hose/sambungan yang
terbuka untuk mencegah
keluarnya gas
NOTE:
Remove the condenser &
compressor as a group
and try not to break the
system by releasing the
gas
• Lepas air conditioning condenser
dari radiator.
Remove air conditioning
condenser from radiator.
• Tempatkan air conditioning
condenser di ke bagian luar rear
frame assembly.
Set air conditioning condenser
outside of rear frame assembly
CATATAN :
Tandai dan identifikasi semua
kabel untuk mempermudah
pemasangan 1
NOTE:
Mark and identify all the cable
assemblies for installation
purpose. 2
• Lepaskan dua wire harness (1)
dan (2) pada sambungannya
Disconnect two wire harness (1)
and (2) at the electrical connection
7 of 33
 24H_7KK CC Engine Task Guidelines
STEP* ACTIVITY DESCRIPTION PICTURES

18. Pindahkan AC compressor (jika ada) • Kendorkan dua baut pada

Move the AC Compressor (if equipped) compressor bracket
Loosen two bolts and the washers
from compressor bracket

Bolt
Compressor Bracket

• Kendorkan tegangan V-belt

dengan mengendorkan dua nut
pada block Block
To release the V-belt tension, Nut
loosen two nuts from block

• Buka block dari bracket

compressor dengan membuka
baut pengikatnya.
Remove block from bracket by Block
removing bolt and full nut.
Bolt
Bracket

• Kendorkan guard assembly dari

clutch dan ac compressor dengan Guard
membuka tiga baut dan full nut
Loosen the guard assembly from
clutch and ac compressor by
loosing three bolts and full nut
Bolt

• Buka dua baut, washer dan clutch

dan ac compressor dari bracket Bracket
Remove two bolts and the washers
and clutch and AC compressor Bolt
from compressor bracket

• Tempatkan clutch dan AC

compressor kesamping
Set clutch and AC Compressor
aside

AC Compressor

19. Melepas Top Fan Guard Assembly.
Remove Top Fan Guard Assembly
• Lepas bolt dan washer yang
menahan bracket pada tiap sisi
dari radiator guard dan support.
Remove bolts, and the washers
that hold brackets to each side of
radiator guard and support.

• Lepas dua bolt, washer dan dua

nut pada tiap sisi dari top fan
guard assembly.
Remove two bolts, the hard
washers and the two nuts from
each side of top fan guard
assembly.

24H_7KK_1000_010_TG_004_TBP 8 of 33
 24H_7KK CC Engine Task Guidelines
STEP* ACTIVITY DESCRIPTION PICTURES

• Lepas bolt dan washer yang

menahan bracket pada tiap sisi
dari radiator guard dan support.
Remove bolts, and the washers
that hold brackets to each side of
radiator guard and support.

• Lepas dua bolt, washer dan dua

nut pada tiap sisi dari top fan
guard assembly.
Remove two bolts, the hard
washers and the two nuts from
each side of top fan guard
assembly.

• Lepas top fan guard assembly dari

bottom fan guard assembly.
Remove top fan guard assembly
from bottom fan guard assembly

Jika tidak ada AC maka akan

terdapat 4 x ¼ guard yang harus
dilepas
If there is NO AC, there are 4 x ¼
guard that need to be removed

20. Melepas Spider Assembly dan Fan CATATAN:

Adapter. Harus berhati-hati ketika
Remove Spider Assembly and Fan memindahkan spider assembly.
Hindari kontak dengan semua Spider
Adapter.
radiator core. Kontak dapat Assembly
mengakibatkan kerusakan
komponen.
NOTE:
Care must be taken when
removing spider assembly. Avoid
making contact with any of the
radiator cores. Contact may cause
component damage.
1
• Posisikan suitable lifting device
pada spider assembly.
Position a suitable lifting device on
spider assembly.

• Amankan lifting device ke hoist.

Secure the lifting device to a hoist.

• Lepas delapan bolt (1), dan

washer yang menahan fan adapter
ke fan pulley hub.
Remove eight bolts (1), and the
hard washers that hold fan adapter
to fan pulley hub.

• Biarkan spider assembly dan fan

adapter pada tempatnya
Leave it laying inside the radiator
group

Specifications:
Berat dari spider assembly dan fan
adapter sebagai satu unit adalah
57 kg (125 lb)
The weight of spider assembly dan
fan adapter as a unit is 57 kg (125
lb).

24H_7KK_1000_010_TG_004_TBP 9 of 33
 24H_7KK CC Engine
STEP* ACTIVITY
21. Memutus Sambungan Wire Harness
dari flood lamp
Disconnect Wire Harness from flood
lamp
22. Memutus Sambungan Wire Harness di
Electrical Connection.
Disconnect Wire Harness at The
Electrical Connection.
23. Melepas Elbow Dan Hose Dari Radiator
Remove Elbow And Hose From The
Radiator
24H_7KK_1000_010_TG_004_TBP
Task Guidelines
DESCRIPTION PICTURES
• Berikan tanda pada wire harness
(1) untuk keperluan instalasi.
Mark and identify wire harness (1)
for installation purposes.
1
• Longgarkan dua screw dan
putuskan sambungan wire harness
(1) dari flood lamp. Flood Lamp
Loosen two screws and disconnect
wire harness (1) from flood lamp.
• Tarik wire harness (1) melewati
grommet.
Pull wire harness (1) through 2
grommet.
• Lepas dua bolt dan washer dari
radiator. Radiator
Remove two bolts and the
washers from radiator
• Atur wire harness (2) disamping.
Set wire harness (2) aside.
• Ulangi langkah di atas untuk sisi
lainnya.
Repeat steps the above step the
remaining side.
• Berikan tanda pada wire harness
untuk keperluan instalasi.
Mark and identify wire harness for
installation purposes.
• Putuskan sambungan wire
harness di electrical connection.
Disconnect wire harness at the
electrical connection.
• Lepas empat bolt (1) dan (2),
elbow dan gasket dari radiator.
Remove two bolts (1) and (2),
elbow and gasket from radiator. 1
Elbow
2
• Longgarkan dua hose clamp dan
jauhkan hose dari radiator. Clamp
Loosen the 2 hose clamps and
slide hose away from radiator. Hose
Radiator
10 of 33
 24H_7KK CC Engine Task Guidelines
STEP* ACTIVITY DESCRIPTION PICTURES

24. Melepas Radiator Guard dan Support. • Pasang link bracket pada posisi di
Remove Radiator Guard and Support. radiator guard dan support.
Put link bracket on position on
Tool yang di perlukan: radiator guard and support Link Bracket
Tools Required:
• Pasang alat angkat pada radiator
guard dan support.
Qty P/N Description
Position a suitable lifting device on
2 1387574 Link Bracket radiator guard and support.

• Amankan lifting device ke hoist.

Secure the lifting device to a hoist.

• Lepas empat bolt dan washer dari

masing-masing sisi dari rear frame
assembly.
Remove four bolts and the
washers from each side of rear
frame assembly.

• Lepas radiator guard dan support

dari rear frame assembly.
Remove radiator guard and
support from rear frame assembly.

Specifications:
Berat dari radiator guard dan
support adalah 640 kg (1410
lb)
The weight of radiator guard and Rear Frame
support is 640 kg (1410 lb).

REMOVE UPPER DRIVE SHAFT

Upper Drive shaft terletak dibelakang pintu enclosure engine sebelah kiri dan kanan dekat dengan fuel tank dan
terpasang diantara Torque Converter dan Transmission
The upper drive shaft is located behind left and right hand engine enclosure doors, located next to the fuel tank
and installed between Torque converter and transmission

25. Melepas Upper Drive Shaft
Remove upper drive shaft
• Gunakan strap dan alat angkat
untuk menahan berat driveshaft
Use a suitable strap and lifting
device to support the weight of
the driveshaft

Berat dari Driveshaft 40 kg

Weight of Driveshaft 40 kg
A
• Buka delapan bolt (A) yang
melekatkan spider driveshaft ke
TC yoke dan Transmission Input
Yoke
Remove eight bolt (A) securing
the driveshaft spider to the torque
converter yoke and to the
transmission input yoke

• Gunakan prybar untuk

membebaskan driveshaft dari
kedua yoke sebelum diangkat
Using a prybar to free the
driveshaft before lifting

Ikat spider dengan tali atau kabel

karena spider cap akan terlepas
jika tidak ditahan
Care must be taken not to remove
the spider caps. Use cable ties to
tie the two caps to each other.

24H_7KK_1000_010_TG_004_TBP 11 of 33
 24H_7KK CC Engine Task Guidelines
STEP* ACTIVITY DESCRIPTION PICTURES
• Angkat drive shaft dengan
menggunakan overhead crane
Remove the drive shaft by using
overhead crane

REMOVE ENGINE & TORQUE CONVERTER

26. Lepaskan fuel lines • Putar dua valve ball (1) pada
Disconnect fuel lines posisi OFF 1
Turn two ball valves (1) to the
"Off" position
• Lepaskan hose (2) dan (3) dari
bulkhead fitting pada firewall
Disconnect hose assemblies (2),
and (3) from bulkhead fitting at
firewall 1
• Tempatkan hose (2) dan (3)
sehingga tidak mengganggu. Ikat
pada fuel tank
Position hose (2) and (3) to avoid
interfere with removal of engine. 2
Tie them back up to the fuel tank

Segera tutup semua bagian yang

terbuka untuk mencegah
kontaminasi 3
Cap or plug the openings
immediately to prevent
contaminant enter the system

27. Buka Hose yang terhubung ke steering • Buka hose (1), (5) dan (6) dari
pump dan implement pump bagian atas pump 6 5
Disconnect the hoses from the steering Disconnect all top hoses (1), (5) 4
and implement pumps and (6) from the pump
• Buka hose (2), (3) dan (4) dari
bagian bawah pump
1
Disconnect all bottom hoses (2),
(3) and (4) from the pump
2
Segera tutup semua bagian yang
terbuka untuk mencegah
kontaminasi
Cap or plug the openings 3
immediately to prevent
contaminant enter the system

Tandai lokasi semua hose dan

kabel untuk memudahkan
pemasangan.
Identify the location of all hoses
and harness to assist
reassembly
28. Buka hose yang terhubung ke torque • Buka hose (1), (2) dan (3) dari
converter housing dan transmission filter Torque Converter Housing
Disconnect hose assemblies from Disconnect hose (1), 2) and (3)
Torque Converter housing and from Torque Converter Housing
transmission filter
• Buka hose (4) dari Transmission
filter
Disconnect hose (4) from
transmission filter

• Lepaskan hose (5) dari tube (6) TC

oil cooler
Disconnect hose assembly (5)
from TC Oil cooler tube assembly
(6)

Segera tutup semua bagian yang

terbuka untuk mencegah
kontaminasi
Cap or plug the openings
immediately to prevent
contaminant enter the system

24H_7KK_1000_010_TG_004_TBP 12 of 33
 24H_7KK CC Engine Task Guidelines
STEP* ACTIVITY DESCRIPTION PICTURES

Tandai lokasi semua hose dan

kabel untuk memudahkan
pemasangan.
Identify the location of all hoses
and harness to assist reassembly
4

3
4

5 6

29. Buka hose dari diff lock filter, brake
screen dan brake filter
Disconnect hose assemblies from diff
lock filter, brake filter and brake screen
• Buka hose (1) dari diff lock filter
Disconnect hose (1) from diff lock
filter
• Buka hose (2) dan (3) dari brake
filter dan screen
Disconnect hose (1) from brake
filter and screen

Segera tutup semua bagian yang

terbuka untuk mencegah 1
kontaminasi 2
Cap or plug the openings
immediately to prevent
contaminant enter the system

Tandai lokasi semua hose dan

kabel untuk memudahkan
pemasangan. 3
Identify the location of all hoses
and harness to assist reassembly

24H_7KK_1000_010_TG_004_TBP 13 of 33
 24H_7KK CC Engine Task Guidelines
STEP* ACTIVITY DESCRIPTION PICTURES

OLD

NEW

24H_7KK_1000_010_TG_004_TBP 14 of 33
 24H_7KK CC Engine Task Guidelines
STEP* ACTIVITY DESCRIPTION PICTURES

30. Buka turbocharger pipe dari muffler • Buka satu baut (1), lock nut dan
washer dari clamp
Remove one bolts (1), locknut and
the washer from clamp assembly

• Kendorkan clamp (2) dan lepaskan

turbocharger pipe dari muffler
Loosen clamp (2) and remove 1
turbocharger pipe assembly from Clamp
muffler assembly

Segera tutup semua bagian yang Aftercooler cover

terbuka untuk mencegah
kontaminasi
Cap or plug the openings
immediately to prevent
contaminant enter the system
Muffler
Weight of pipe: 8.4351Kg 2

Turbo Pipe

OLD

NEW

31. Lepaskan engine harness • Lepaskan engine harness (1) pada

Disconnect engine harness electrical connectionnya 1
Disconnect engine harness (1) at
the electrical connection

• Buka baut (2), washer dan clip (3)

dari rear frame
Remove bolt (2), washer and clip 3
(3) from rear frame. 2

24H_7KK_1000_010_TG_004_TBP 15 of 33
 24H_7KK CC Engine Task Guidelines
STEP* ACTIVITY DESCRIPTION PICTURES

32. Lepaskan kabel dari electric starting Tandai lokasi semua hose dan
motor kabel untuk memudahkan
Remove cable assembly from electric pemasangan.
starting motor Identify the location of all hoses
and harness to assist reassembly 1

• Buka dua nut, washer dan kabel

(1) dan (2) dari electric starting
motor
Remove two nuts, the washers
and cable assemblies (1) and (2)
from electric staring motor

• Buka kabel yang sama pada

electric starting motor yang lain,
jika ada 2
Remove the same cable
assemblies from the remaining
electric starting motor, if equipped

33. Lepaskan water line • Putar valve pada posisi OFF

Disconnect water line Turn the valves to the OFF
position
2
• Kendorkan dua clamp (1) dan (2)
dan lepaskan heater hose (3) dan 4
1
(4) dari engine
Loosen two clamp (1) and (2) and 3
disconnect two hoses (3) and (4)
from the engine

34. Lepaskan wiggins lines dari bracket • Kendorkan locknut (1) dan
Remove wiggins lines from the bracket lepaskan hose (2) dari bracket
1
Loosen locknut (1) and remove
hose assembly (2) from bracket

35. Lepaskan grease line dari belt tightener • Lepaskan hose (1) dan (2) dari
dan fan drive filler bracket
Disconnect grease lines from belt Disconnect hose assembly (1) and 2
tightener and fan drive (2) from filler bracket

Pastikan hal-hal berikut ini :

Ensure the following items:
• Hose, electrical connection sudah
dibuka atau dilepas dari engine yang
dapat mengganggu pelepasan engine
dan dalam keadaan tertutup
The hoses, electrical connections,
components have been removed or
disconnected from the engine that
may interfere with removal of the
engine and require plug and cap
• Alat pengangkat telah terpasang
dengan baik
The lifting device has been installed
properly

24H_7KK_1000_010_TG_004_TBP 16 of 33
 24H_7KK CC Engine Task Guidelines
STEP* ACTIVITY DESCRIPTION PICTURES

36. Pasang lifting chain ke bracket pada • Pasang alat angkat pada engine di
engine empat titik bracket
Attach the lifting chain to the lifting Put a suitable lifting device in
bracket on the engine. position on engine at the four
bracket point
Tool yang di perlukan:
Tools Required:
The weight of the engine is 3042
Qty PN Description kg.
4 - Lifting Chain

37. Buka engine dan torque converter group • Buka empat baut (1), empat
Remove engine and torque converter 3
group. washer (2), empat mounting (3)
dan empat sleeve (4) dari
mounting engine depan dan 2
belakang
1
Remove four bolts (1), four
washers (2), four mount
assemblies (4) and four sleeve (4)
4
from two front engine mounts and
one each side at the rear of
engine/torque converter gp. Flywheel Housing End
• Angkat engine dan torque
1
converter dari rear frame
Remove engine and torque
converter from rear frame
assembly

• Tempatkan engine dan torque

converter pada stand yang sesuai
Position engine and torque Rear Frame
converter on suitable stand

Front Housing End

Rear Frame

38. Pasang Stand Di Engine •

Install Engine On Stand

39. Catat TU ID • Lokasi TUID Stamp lihat di Stamp

Record TU ID Location Guidance
See Stamp Location Guidance to
identify location of TUID stamp

INSTALL ENGINE
Pastikan hal-hal berikut ini :
Ensure the following items:
• Hose, electrical connection sudah
dibuka atau dilepas dari engine yang
dapat mengganggu pemasangan
engine
The hoses, electrical connections,
components have been removed or
disconnected from the engine that
may interfere with install of the
engine
• Alat pengangkat telah terpasang
dengan baik
The lifting device has been installed
properly

24H_7KK_1000_010_TG_004_TBP 17 of 33
 24H_7KK CC Engine Task Guidelines
STEP* ACTIVITY DESCRIPTION PICTURES

40. Yakinkan bahwa semua component

engine dan torque converter bersih dan
bebas dari material asing sebelum
pemasangan
Verify that all of the components of the
engine and torque converter are clean
and free of foreign material prior to
installation.

41. Bersihkan chassis dengan air
bertekanan
Steam pressure clean chassis
• Cuci bagian dalam frame agar
bersih dari debu, grease dan
Lumpur
Wash the inside area of the frame
in order to remove the following
items: dirt, grease and mud

42. Periksa retakan pada engine mounting

Inspect rear engine mounts for

43. Catat TU ID • Lokasi TUID Stamp lihat di Stamp

Record TU ID Location Guidance
See Stamp Location Guidance to
identify location of TUID stamp

44. Pasang engine pada posisinya di rear • Ganti engine mount dan baut
frame depan dan belakang
Position engine on its position at the Replace engine mounts & bolts
rear frame front and rear

• Pasang empat baut baru (1),

empat washer baru (2), empat
mounting baru (3) dan empat
Part yang di perlukan: sleeve baru (4) pada dua mounting
Parts Required: engine depan dan belakang
Install four new bolts (1), four new
Qty PN Description washers (2), four new mount
assemblies (4) and four new
4 6Y9980 Mount As sleeve (4) of two front engine Flywheel Housing End
4 9W7385 Sleeve mounts and one each side at the
rear of engine/torque converter gp.
1
4 9W7388 Washer
4 8T0670 Bolt
4 6V8237 Washer
Torque for four bolts . . . 800 ± 100
N·m (590 ± 75 lb ft)

Rear Frame

Front Housing End

Rear Frame

24H_7KK_1000_010_TG_004_TBP 18 of 33
 24H_7KK CC Engine Task Guidelines
STEP* ACTIVITY DESCRIPTION PICTURES

Pastikan engine tidak menjepit hose,

electrical connection dan komponen lain
ketika menempatkannya ke chassis
Ensure that engine not interfere with
hoses, electrical connection and others
component while locating into the chassis

45. Pasang grease line dari belt tightener • Pasang hose (1) dan (2) pada filler
dan fan drive bracket
Connect grease lines from belt tightener Connect hose assembly (1) and 2
and fan drive (2) to filler bracket

46. Pasang wiggins lines pada bracket • Pasang hose (2) pada bracket.
Install wiggins lines to the bracket Install hose assembly (2) to
1
bracket

• Kencangkan locknut (1)

Tighten locknut (1)

47. Pasang water line • Pasang heater hose (3) dan (4)
Connect water line
pada engine. Kencangkan dua
clamp (1) dan (2) 2
Part yang di perlukan:
Parts Required: Connect two hoses (3) and (4) to
the engine Tighten two clamp (1) 4
1
Qty PN Description and (2)
1 9X7408 Seal O RIng 3
• Putar valve pada posisi ON
Turn the valves to the ON position

48. Pasang engine harness • Pasang engine harness (1) pada 1

Install engine harness
electrical connectionnya
Connect engine harness (1) at the
electrical connection

• Pasang baut (2), washer dan clip

(3) pada rear frame 3
Install bolt (2), washer and clip (3) 2
to rear frame.

24H_7KK_1000_010_TG_004_TBP 19 of 33
 24H_7KK CC Engine Task Guidelines
STEP* ACTIVITY DESCRIPTION PICTURES

49. Pasang kabel pada electric starting • Pasang dua nut, washer dan kabel
motor
Install cable assembly to electric starting (1) dan (2) pada electric starting
motor motor
1
Install two nuts, the washers and
cable assemblies (1) and (2) to
electric staring motor

Torque Specs Nut (A): 31± 4 N.m

(22 ± 3 lb ft)

• Pasang kabel yang sama pada

electric starting motor yang lain
jika ada
Install the same cable assemblies
from the remaining electric starting 2
motor, if equipped

50. Pasang hose yang terhubung ke torque • Pasang hose (5) pada tube (6) TC
converter housing dan transmission filter oil cooler
Connect hose assemblies from Torque Connect hose assembly (5) to TC
Converter housing and transmission Oil cooler tube assembly (6)
filter
• Pasang hose (4) pada
Transmission filter
Connect hose (4) to transmission
filter

• Pasang hose (1), (2) dan (3) pada

Torque Converter Housing
Connect hose (1), 2) and (3) to
Torque Converter Housing

Segera tutup semua bagian yang

terbuka untuk mencegah
kontaminasi
Cap or plug the openings
immediately to prevent
contaminant enter the system

CATATAN:
Tandai lokasi semua hose dan
kabel untuk memudahkan
pemasangan.
NOTE:
Identify the location of all hoses
and harness to assist reassembly

Part yang di perlukan:

Parts Required:

Qty PN Description
4 4J0524 Seal O Ring
1 6V8397 Seal O Ring
1 4J0527 Seal O Ring

5 6

24H_7KK_1000_010_TG_004_TBP 20 of 33
 24H_7KK CC Engine Task Guidelines
STEP* ACTIVITY DESCRIPTION PICTURES

3
4

51. Pasang hose pada diff lock filter, brake • Pasang hose (1) pada diff lock
screen dan brake filter filter
Connect hose assemblies to diff lock Connect hose (1) to diff lock filter
filter, brake filter and brake screen
• Pasang hose (2) dan (3) pada
brake filter dan screen
Part yang di perlukan:
Connect hose (1) to brake filter
Parts Required:
and screen
Qty PN Description
• Ganti seal o ring 1
3 3D2824 Seal O Ring Replace seal o ring
2 6V8397 Seal O Ring Segera tutup semua bagian yang
terbuka untuk mencegah
1 6V8398 Seal O Ring
kontaminasi
Cap or plug the openings
immediately to prevent
contaminant enter the system

CATATAN: 2
Tandai lokasi semua hose dan
kabel untuk memudahkan
pemasangan.
NOTE:
Identify the location of all hoses 3
and harness to assist reassembly

24H_7KK_1000_010_TG_004_TBP 21 of 33
 24H_7KK CC Engine Task Guidelines
STEP* ACTIVITY DESCRIPTION PICTURES

52. Pasang turbocharger pipe pada muffler
Install turbocharger pipe assembly to
muffler assembly
• Pasang turbocharger pipe pada
muffler. Kencangkan clamp (2)
yang mengikat pipe pada muffler
Install turbocharger pipe assembly
to muffler assembly. Tighten clamp
(2) that hold pipe to muffler.

• Pasang plate pada aftercooler

cover. kencangkan dua baut (1)
dan washer 1
Install plate to aftercooler cover. Clamp
Install two bolts (1) and the
washers
Aftercooler cover

Muffler
2

Turbo Pipe

53. Pasang Hose yang terhubung ke CATATAN:

steering pump dan implement pump
Connect the hoses to the steering pump
and the implement pump
Part yang di perlukan:
Parts Required:
Pastikan case drain pump telah 6 5
terisi oli sebelum memasang hose 1 4
NOTE:
Ensure that the case drain of pump
has been filled oil before installing
hoses 2

Qty P/N Description • Pasang hose (1), (5) dan (6) pada
bagian atas pump
1 3J1907 Seal O Ring Connect all top hoses (1), (5) and
1 2M9780 Seal O Ring (6) to the pump 3
1 4J0522 Seal O Ring
• Pasang hose (2), (3) dan (4) pada
2 6J2680 Seal O Ring
bagian bawah pump
Connect all bottom hoses (2), (3)
and (4) to the pump

24H_7KK_1000_010_TG_004_TBP 22 of 33
 24H_7KK CC Engine Task Guidelines
STEP* ACTIVITY DESCRIPTION PICTURES

54. Pasang Fuel Lines • Pasang hose (2) dan (3) pada
Connect Fuel Lines
bulkhead fitting di firewall 3
Part yang di perlukan: Connect hose assemblies (2) and
Parts Required: (3) to bulkhead fitting on firewall

• Ganti seal o ring

Qty P/N Description 2
Replace seal o ring
2 6V8398 Seal O Ring
2 6V8397 Seal O Ring
• Putar dua valve ball (1) pada
posisi ON
Turn two ball valves (1) to the ON
position

1
1

55. Pasang AC compressor (jika ada) • Kendorkan dua baut pada

Install the AC Compressor (if equipped) compressor bracket
Loosen two bolts and the washers
from compressor bracket

Bolt
Compressor Bracket

• Tempatkan clutch dan AC

compressor ke posisinya
Set clutch and AC Compressor to
its position

AC Compressor

• Pasang clutch dan ac compressor

serta dua baut dan washer pada
bracket Bracket
Install clutch and AC compressor, Bolt
two bolts and the washers and to
compressor bracket

24H_7KK_1000_010_TG_004_TBP 23 of 33
 24H_7KK CC Engine Task Guidelines
STEP* ACTIVITY DESCRIPTION PICTURES
• Pasang V-belt dan kencangkan
guard serta tiga baut, tiga full nut Guard
dan washer pada clutch dan AC
Compressor
Install V-Belt and tighten guard
assembly, three bolts, the three full
nuts and the washers to clutch and Bolt
AC compressor

• Pasang block pada bracket

compressor dengan
mengencangkan baut pengikatnya.
Install block to bracket by tighten Block
the bolt that hold it.
Bolt
Bracket

• Kendorkan tegangan V-belt

dengan mengendorkan dua nut
pada block Block
To release the V-belt tension, Nut
loosen two nuts from block

INSTALL DRIVE SHAFT

56. Yakinkan bahwa semua component
drive shaft bersih dan bebas dari
material asing sebelum pemasangan
Verify that all of the components of the
drive shaft are clean and free of foreign
material prior to installation.

57. Memasang Upper Drive Shaft
Install upper drive shaft
• Ganti spider & bearing pada drive
shaft dan gunakan baut yang
baru
Replace spider & bearing of the
driveshaft and using new bolts

• Gunakan strap dan alat angkat A

Part yang di perlukan:
untuk menahan berat driveshaft
Parts Required:
Use a suitable strap and lifting
device to support the weight of
the driveshaft
Qty PN Description
8 OS0484 Bolt Berat dari Driveshaft 20 kg
Weight of Driveshaft 20 kg A

• Pasang delapan bolt baru (A)

yang melekatkan spider
driveshaft ke TC yoke dan
Transmission Input Yoke
Install eight new bolt (A) securing
the driveshaft spider to the torque
converter yoke and to the
transmission input yoke

Torque specs: 156 ± 7 N·m (115 ± 5

lb ft).

Pastikan baut yang mengunci drive shaft

spider telah mendapatkan torque yang
benar
Ensure that the bolts securing the drive
shaft spider have got the correct torque

24H_7KK_1000_010_TG_004_TBP 24 of 33
 24H_7KK CC Engine Task Guidelines
STEP* ACTIVITY DESCRIPTION PICTURES

INSTALL RADIATOR GUARD GP

58. Memasang radiator guard dan support • Cek seluruh komponen dari
Install radiator guard and support keausan atau kerusakan dan ganti
jika diperlukan.
Check all components for wear or Link Bracket
damage, and replace if necessary
Tool yang di perlukan:
Tools Required:
• Pasang Link Bracket pada posisi di
radiator guard dan support.
Qty P/N Description
Put link bracket in position on
2 1387574 Link Bracket radiator guard and support.

• Posisikan suitable lifting device

pada link bracket
Position a suitable lifting device to
the link bracket

• Amankan lifting device ke hoist.

Secure the lifting device to a hoist.

• Pasang radiator guard dan support

ke rear frame assembly.
Secure the lifting device to a hoist.

Specifications:
Berat dari radiator guard dan
support adalah 640 kg (1410 lb)

• Pasang empat bolt dan washer ke

masing-masing sisi dari rear frame
assembly.
Install four bolts and the washers
to each side of rear frame
assembly.
Rear Frame
• Lepaskan link brakcet dan suitable
lifting device dari radiator guard
dan support
Remove link bracket and the
suitable lifting device from radiator
guard and support.

59. Pasang elbow dan hose pada radiator • Pasang hose baru (3) pada
Install elbow and hose from the radiator radiator dan kencangkan kedua Clamp
clampnya
Part yang di perlukan: Slide hose (3) on radiator. Tighten 3
Parts Required: two hose clamp

Qty P/N Description

• Ganti hose-hose yang berkenaan
1 7N4932 Gasket dengan radiator Radiator
Replace all hoses that connected
4 2094590 Clamp
to radiator
4 2086054 Clamp
12.7 5P1268 Hose
• Ganti gasket pada permukaan
1 4N7431 Hose elbow.
Replace all gasket at the mating 1
1 6N8400 Hose
surface of elbow
Elbow
• Pasang gasket, elbow, empat baut
2
(1) dan (2) pada radiator
Install gasket, elbow, four bolts (1)
and (2) to radiator

24H_7KK_1000_010_TG_004_TBP 25 of 33
 24H_7KK CC Engine Task Guidelines
STEP* ACTIVITY DESCRIPTION PICTURES

60. Pasang Sambungan Wire Harness di

Electrical Connection. • Pasang sambungan wire harness
Connect Wire Harness at The Electrical di electrical connection.
Connection. Connect wire harness at the
electrical connection.

61. Pasang Sambungan Wire Harness pada
flood lamp
Connect Wire Harness to flood lamp
• Tarik wire harness (1) melewati
grommet.
Pull wire harness (1) through
grommet.
1
• Hubungkan wire harness (1) pada
flood lamp dan pasang dua screw.
Connect wire harness (1) to flood Flood Lamp
lamp and install two screws

• Tempatkan wire harness (2) pada

radiator. Pasang dua baut dan
washernya 2
Put wire harness (2) in position on
radiator. Install two bolts and the
washer to radiator
Radiator
• Ulangi langkah di atas untuk sisi
lainnya.
Repeat steps the above step the
remaining side.
62. Pasang Spider Assembly dan Fan • Hati-hati memposisikan spider
Adapter. assembly dan fan adapter sebagai
Spider
Install Spider Assembly and Fan satu unit.
Assembly
Adapter. Carefully position spider assembly
and fan adapter as a unit.

24H_7KK_1000_010_TG_004_TBP 26 of 33
 24H_7KK CC Engine Task Guidelines
STEP* ACTIVITY DESCRIPTION PICTURES
• Pasang delapan bolt baru (1), dan
washer yang menahan fan adapter
Part yang di perlukan: ke fan pulley hub.
Parts Required:
1
Install eight bolts (1), and the hard
washers that hold fan adapter to
Qty P/N Description fan pulley hub.

8 1A2029 Bolt

Specifications:
Torque specs: 47 ± 9 N.m (35 ± 7 lb
ft)

Berat dari spider assembly dan fan

adapter sebagai satu unit adalah
57 kg (125 lb)
The weight of spider assembly dan
fan adapter as a unit is 57 kg (125
lb).

63. Memasang Top Fan Guard Assembly.
Install Top Fan Guard Assembly
• Letakkan top fan guard assembly
pada posisi di bawah fan guard
assembly.
Put top fan guard assembly from
bottom fan guard assembly.
2
• Pasang dua bolt (1), washer dan 1
dua nut pada tiap sisi dari top fan
guard assembly.
Install two bolts (1), the hard
washers and the two nuts from
each side of top fan guard
assembly.

• Pasang bolt (2) dan washer yang

menahan bracket pada tiap sisi
dari radiator guard dan support.
Remove bolts (2), and the washers
that hold brackets to each side of
radiator guard and support.

CATATAN:
Jika tidak ada AC maka akan
terdapat 4 x ¼ guard yang harus
dipasang
NOTE:
If there is NO AC, there are 4 x ¼
guard that need to be installed

64. Pindahkan AC compressor (jika ada) • Tempatkan clutch dan AC

Move the AC Compressor (if equipped) compressor pada posisinya
Set clutch and AC Compressor to
its position

AC Compressor

• Pasang dua baut, washer dan

clutch dan AC compressor pada Bracket
bracket Bolt
Install two bolts and the washers
and clutch and AC compressor to
compressor bracket

24H_7KK_1000_010_TG_004_TBP 27 of 33
 24H_7KK CC Engine Task Guidelines
STEP* ACTIVITY DESCRIPTION PICTURES
• Kencangkan guard assembly dari
clutch dan ac compressor dengan Guard
memasang tiga baut dan full nut
Tighten the guard assembly from
clutch and ac compressor by
tightening three bolts and full nut
Bolt

• Pasang block pada bracket

compressor dengan memasang
baut pengikatnya.
Install block to bracket by installing Block
bolt and full nut.
Bolt
Bracket

• Kencangkan dua baut pada

compressor bracket
Tighten two bolts and the washers
from compressor bracket

Bolt
Compressor Bracket

65. Atur tegangan V-belt AC Compressor • Gunakan alat pengukur tegangan

Adjust the tension on the AC belt untuk memeriksanya
Use a belt tension tool in order to Guard
Compressor V-Belt
check the tension of the belt.

Belt bekas 667 ± 44 N (150 ± 10 lb)

Used belt 667 ± 44 N (150 ± 10 lb)
Bolt

Belt baru 801 ± 44 N (180 ± 25 lb)

New belt 801 ± 44 N (180 ± 25 lb)

• Kencangkan dua nut (1) pada

block sesuai dengan torque
specs. Block
Tighten two nuts (1) to its specs
torque Bolt
Bracket
150 ± 20 N·m (110 ± 15 lb ft).

• Kencangkan dua baut (3) dan

washer pada compressor bracket
Tighten two bolts (3) and the
washer to compressor bracket Block
Nut

66. Memasang electrical connection pada • Pasang dua wire harness (1) dan
AC compressor (jika ada). (2) pada sambungannya
Connect electrical connection at the AC Connect two wire harness (1) and 1
Compressor (if equipped) (2) at the electrical connection

24H_7KK_1000_010_TG_004_TBP 28 of 33
 24H_7KK CC Engine
STEP* ACTIVITY
67. Memasang Air Conditioning Condenser
(jika ada)
Install Air Conditioning Condenser (if
equipped)
INSTALL ENGINE ENCLOSURE
68. Pasang engine enclosure
Install engine enclosure
69. Pasang baut yang mengikat tube pada
frame
Install all bolt that secure the tube to
frame
24H_7KK_1000_010_TG_004_TBP
Task Guidelines
DESCRIPTION PICTURES
• Gunakan dua orang, letakkan air-
conditioning condenser pada
posisi di radiator guards dan 1
support.
Using two people, put air
conditioning condenser in position
on the radiator guard and support.
• Pasang empat baut (2) dan
washer di tiap sisi air conditioning
condenser 2
Install four bolts (2) and the
washers to each side of air
conditioning condenser
• Kencangkan dua bolt (1) pada tiap
sisi dari air conditioning condenser
yang menahan bracket ke radiator
guard dan support.
Tighten two bolts (1) on each side
of air-conditioning condenser that
hold brackets to the radiator guard
and support.
• Pasang alat angkat pada engine
enclosure. Tempatkan engine
enclosure pada rear frame
Position a lifting device on engine
enclosure. Position engine
enclosure to rear frame assembly
The weight of engine enclosure
579 kg
• Pasang dua baut pada tube (1)
dan (2)
Install four bolts that secure tube
(1) and (2) 2
1
• Pasang dua baut pada masing-
masing tube (1), (2), (3) dan (4)
Install two bolts of each tube (1),
(2), (3) and (4)
• Lakukan pada kedua sisi kiri dan
kanan
Perform the above step for both 1
side left hand and right hand 2 3
29 of 33
 24H_7KK CC Engine Task Guidelines
STEP* ACTIVITY DESCRIPTION PICTURES

70. Pasang fire extinguisher lines pada • Pasang sambungan ke fire

engine enclosure extinguisher lines pada connector
Connect fire extinguisher lines to engine utamanya
enclosure Connect connection to fire
extinguisher line at the main
connector

71. Pasang Sambungan Hose pada tanki air • Sambungkan hose (1) dan (2)
Connect Hose to tank assembly pada tank assembly.
Connect hose (1) and (2) to tank
assembly.

• Kencangkan clamp (1) dan (2).

Tighten clamp (1) and (2).
1 2

• Sambungkan hose (3) pada tanki

dan kencangkan clampnya
Connect hose (3) to tank assembly
and tighten the clamp.

72. Pasang pintu kecil pada sebelah kiri dan • Pasang satu baut yang menahan
kanan engine enclosure pintu pada engine enclosure
Install the small door for both side of Install one bolt that hold the doors
engine enclosure to the engine enclosure

73. Pasang dua top hood • Pasang delapan baut yang

Install two top hoods mengunci top hood
Install eight bolts that secure top
hoods

Torque Specs: 100 ± 20 N.m (75 ±

15 lb ft)

74. Pasang Grate Assembly • Pasang grate dengan melepas

Install Grate Assembly delapan baut yang mengikatnya
Install grate assembly by removing
eight bolts that secure it.

Grate

24H_7KK_1000_010_TG_004_TBP 30 of 33
 24H_7KK CC Engine Task Guidelines
STEP* ACTIVITY DESCRIPTION PICTURES

• Pasang empat baut pada bagian

bawah grate
Install four bolts under the grate

75. Memasang Exhaust Extension • Pasang exhaust ejector assembly

Install Exhaust Extension pada muffler assembly dan
clampnya
Install exhaust ejector assembly to
muffler assembly and the clamp

• Kencangkan bolt dan locknut.

Tighten bolt and the locknut.
Clamp

76. Pasang Dust Ejector • Pasang body assembly pada air

Install Dust Ejector cleaner. Body Assembly
Install body assembly to air
cleaner.

• Pasang hose clamp dan hose

pada body assembly.
Install hose clamp and hose to Clamp
body assembly.

• Kencangkan clamp assembly. Hose

Tighten clamp assembly.

77. Isi Ulang Radiator • Kencangkan drain plug radiator

Refill The Radiator Tighten radiator drain plug

• Isi kembali coolant kedalam

radiator.
Refill coolant into radiator

• Periksa level pendingin yang

dapat dilihat di sight gauge
dibagian kiri unit.
Check the coolant level so that
coolant is visible in sight gauge is
located on the left side at the rear
of the machine Tank
Assembly

Radiator Cap

78. Isi Oli Hydraulic • Isi oli ke hydraulic melalui filler

Refill The Hydraulic Oil tube.
Fill the hydraulic tank with oil.

Spec: 128 Ltr (34 US gal)

24H_7KK_1000_010_TG_004_TBP 31 of 33
 24H_7KK CC Engine Task Guidelines
STEP* ACTIVITY DESCRIPTION PICTURES

79. Periksa Level Oli Engine • Bersihkan area sekitar dipstick

Check Engine Oil Level dan filler cap sebelum
membukanya
Clean the area around the
dipstick and the filler cap before
the dipstick and the filler cap are
removed.

• Tambah oli engine jika diperlukan

Add engine oil if required

Spec: 68 lts (18 US gal) engine oil

Oil type: DEO/CG-4 SAE 15W-40

80. Menghampakan fuel system • Periksa bahwa valve fuel supply Valve
Prime Fuel System telah terbuka. Valve terletak pada
bagian kanan engine
Check that fuel supply valves are
open. The fuel supply valves are
positioned in the engine
compartment on the right side of
the engine

• Buka drain valve pada water

separator bowl yang terletak Plunger
dibawah water separator elemen.
Tampung fuel yang keluar
Open drain valve on water
separator bowl. The water
separator bowl is under water
separator element. Catch the fuel
in a suitable container.

• Buka priming pump plunger

dengan memutarnya berlawanan
arah jarum jam. Tarik keluar
plunger Water Separator Bowl
Unlock priming pump plunger by
turning priming pump plunger
counter clockwise. Pull out priming
pump plunger

• Pompa plunger sampai fuel bebas

dari gelembung udara. Biarkan fuel
keluar ke penampungan
Operate priming pump plunger
until fuel that is free of air bubbles
flows out of drain. Allow the fuel to
flow into a suitable container.

• Bersihkan water separator bowl

dengan larutan bersih. Gunakan
udara bertekanan untuk
mengeringkannya
Lock priming pump plunger (4) by
turning priming pump plunger (4)
clockwise.

• Kunci plunger dengan memutar

searah jarum jam
Lock priming pump plunger by
turning priming pump plunger
clockwise.

• Tutup drain valve pada water

separator bowl
Close drain valve on the water
separator bowl

24H_7KK_1000_010_TG_004_TBP 32 of 33
 24H_7KK CC Engine Task Guidelines
STEP* ACTIVITY DESCRIPTION PICTURES

81. Ganti Filter Udara Primer Dan Sekunder • Lepaskan cover dan primary filter
Replace Air Filter Primary and dari air filter.
Secondary Remove cover and remove
primary filter element from the air
Part yang di perlukan: filter housing.
Parts Required
• Lepaskan filter udara sekunder
Qty P/N Description dan ganti.
Filter Element Remove air filter secondary and
1 106-3969 As Air replace.
(Primary)
Filter Element • Bersihkan bagian dalam housing
1 106-3973 As Air filter udara. Dan ganti filter udara
(Secondary) primer.
Clean the inside of the air filter
housing. And replace air filter
primary.

CATATAN
Jangan menggunakan filter udara
dengan pleat, gasket atau seal
yang rusak. Kotoran yang masuk
kemesin akan menyebabkan
kerusakan pada komponen-
komponen mesin.
NOTE
Do not use air filters with
damaged pleats, gaskets, or
seals. Dirt entering the engine will
cause damage to engine
components.

• Pasang filter udara sekunder

yang baru.
Install a new secondary element.

• Pasang elemen filter udara primer

dan cover ke housing.
Install a clean primary air filter
element. Install the cover for the
air filter housing.

• Set ulang indicator service filter

udara.
Reset the engine air filter service
indicator.

82. Tes performan Machine

Machine Performance Test

Mengacu pada workscope machine

performance test (Doc. No.
24H_XXX_7000_036_TG_001_TBP) Refer
to Machine Performance Test Workscope
END (Doc. No.
24H_XXX_7000_036_TG_001_TBP)

24H_7KK_1000_010_TG_004_TBP 33 of 33