GEN00011-04

Field Assembly Instruction

WHEEL LOADER WA1200 -3

SERIAL NUMBERS 50001 and up
 191
192 201
202
Installation of Engine Hood (920-1000 – 1190)
Perform following procedures after 920-0140 "Connection and Fixing of Brake Line Piping".

920 –1000 – Installation of Radiator Guard

920 –1010 – Installation of Engine Compartment Lamp
920 –1020 – Installation of Battery Box
920 –1030 – Installation of Battery Box Channel
920 –1040 – Installation of Engine Hood Bracket
920 –1050 – Installation of Engine Hood Bracket (B-BOX-Radiator Guard)
920 –1060 – Installation of Engine Air Cleaner Hose
920 –1070 – Installation of Bulkhead
920 –1080 – Fixing of Air Cleaner Hose
920 –1090 – Fixing of Cables Under Bulkhead
920 –1100 – Connection of Hoses Under Bulkhead
920 –1110 – Fixing of Air Conditioner Hose
920 –1120 – Fixing of Heater Hose
920 –1130 – Installation of Engine Side Cover in Front of Radiator Guard
920 –1140 – Installation of Engine Side Cover
920 –1150 – Installation of Hood
920 –1160 – Installation of Air Cleaner Tube
920 –1161 – Installation of Air Cleaner Tube (2XB06-A Air Conditioner, Large Capacity)
920 –1170 – Installation of Top Hood
920 –1180 – Installation of Top Panel
920 –1190 – Installation of Wiring Harnesses Supplied Together with Engine
 Installation of Radiator Guard (920-1000-Z1)

UNIT PARTS PATTERN PARENTS PARTS PARTS (PROCESS) PARTS (PROCESS)

No. No. QTY Preparation to install radiator guard
FOR SHIPMENT No. No. NAME
1 Supplied together with sub-assembly (620-1070-Z1) GUARD RADIATOR ASS'Y 001
2 Installed to frame temporarily 01011-82415 BOLT 012
3 Installed to frame temporarily 01643-32460 WASHER 012
4 Installed to frame temporarily 42C-54-14990 BLOCK 012

Remove plates from radiator (right and left). Remove baffle plate from radiator guard.

Take care of interference.

171
Procedure for installing
radiator guard
1. Remove the above baffle plate
from the radiator and radiator
guard to prepare to install the
radiator guard.
2. Install the radiator guard.
(Take care that the radiator
WORK CONTENT EQUIPMENT, JIGS, TOOLS, SLINGS guard will not interfere with the
CRANE : radiator upper hose.)
SLING : 3. Install the baffle plate removed
IMPACT WRENCH : in 1 above.
TORQUE WRENCH : Tightening torque for bolt :
SOCKET : 824 – 1,030 Nm {84 – 105 kgm}
ETC. :
 Installation of Engine Compartment Lamp (920-1010-Z1)

UNIT PARTS PATTERN PARENTS PARTS PARTS (PROCESS) PARTS (PROCESS) Apply contact restorer to wiring joints.
No. No. QTY
FOR SHIPMENT No. No. NAME
• Ring terminal · · · Apply to both chassis and terminal. Apply again after installation.
1 Supplied together with sub-assembly 42C-06-11440 PLATE 002 • Connector · · · Apply to both connector pieces before connecting them
2 Installed to radiator guard temporarily 01435-01220 BOLT 004
3 Supplied together with sub-assembly 421-06-23360 WORKING LAMP 002
4 Supplied together with sub-assembly 01435-01025 BOLT 002
5 Supplied together with sub-assembly 01643-31032 WASHER 004
6 Supplied together with sub-assembly 01580-11008 NUT 002
7 Supplied together with sub-assembly 08053-01512 CLIP 002

Set water drain hole down.

172
WORK CONTENT EQUIPMENT, JIGS, TOOLS, SLINGS
CRANE :
SLING :
IMPACT WRENCH :
TORQUE WRENCH :
SOCKET : View X
ETC. :
 Installation of Battery Box (920-1020-Z1)

UNIT PARTS PATTERN PARENTS PARTS PARTS (PROCESS) PARTS (PROCESS) Tightening torque : 245 – 309 Nm {25.0 – 31.5 kgm}
No. No. QTY
FOR SHIPMENT No. No. NAME
1 Supplied together with sub-assembly (620-1140-Z1-L) BATTERY BOX L 001
2 Supplied together with sub-assembly (620-1140-Z1-R) BATTERY BOX R 001

4 Installed to frame temporarily 01010-81665 BOLT 016

5 Installed to frame temporarily 01643-31645 WASHER 016

173
WORK CONTENT EQUIPMENT, JIGS, TOOLS, SLINGS
CRANE :
SLING :
IMPACT WRENCH :
TORQUE WRENCH :
SOCKET :
ETC. :
 Installation of Battery Box Channel (920-1030-Z1)

UNIT PARTS PATTERN PARENTS PARTS PARTS (PROCESS) PARTS (PROCESS)

No. No. QTY
FOR SHIPMENT No. No. NAME
1 Supplied together with sub-assembly (620-1650-Z1-2) CHANNEL ASSY 001
2 Loose-supply item 42C-54-14440 CHANNEL 001

6 Installed to B-BOX temporarily 01010-81640 BOLT 016

7 Installed to B-BOX temporarily 01643-31645 WASHER 016

174
WORK CONTENT EQUIPMENT, JIGS, TOOLS, SLINGS
CRANE :
SLING :
IMPACT WRENCH :
TORQUE WRENCH : View Z
SOCKET :
ETC. :
 Installation of Engine Hood Bracket (920-1040-Z1)

UNIT PARTS PATTERN PARENTS PARTS PARTS (PROCESS) PARTS (PROCESS)

No. No. QTY
FOR SHIPMENT No. No. NAME Adjust shim so that engine hood bracket mounting seats – will be level.
1 Loose-supply item 42C-54-11244 BRACKET LH 001
2 Loose-supply item 42C-54-12241 BRACKET RH 001
3 Loose-supply item 42C-54-11253 BRACKET LH 001
4 Loose-supply item 42C-54-12251 BRACKET RH 001
5 Loose-supply item 42C-54-11263 BRACKET LH 001
6 Loose-supply item 42C-54-11182 BRACKET RH 001
7 Installed to frame temporarily 01010-81640 BOLT 024
Install bolt temporarily.
8 Installed to frame temporarily 01643-31645 WASHER 024
9 Installed to frame temporarily 426-09-11410 SHIM 036

Install with notched side on

inside of machine ( – ).

175
WORK CONTENT EQUIPMENT, JIGS, TOOLS, SLINGS
CRANE :
SLING :
IMPACT WRENCH :
TORQUE WRENCH :
SOCKET :
ETC. :
 Installation of Engine Hood Bracket (B-BOX-Radiator Guard) (920-1050-Z1)

UNIT PARTS PATTERN PARENTS PARTS PARTS (PROCESS) PARTS (PROCESS)

No. No. QTY a Install bolt 㽲 temporarily.
FOR SHIPMENT No. No. NAME
Installed to ⑦, ⑧, B-BOX and guard
1 temporarily 01011-82015 BOLT 010 Radiator
Engine hood bracket
Installed to ⑦, ⑧, B-BOX and guard guard
2 temporarily 424-975-1141 WASHER 020
Installed to ⑦, ⑧, B-BOX and guard
3 temporarily 566-54-12213 CUSHION 020
Installed to ⑦, ⑧, B-BOX and guard
4 temporarily 566-54-21910 BUSHING 010 Engine hood
Installed to ⑦, ⑧, B-BOX and guard bracket
5 temporarily 566-54-21920 PLATE 020
Installed to ⑦, ⑧, B-BOX and guard
6 temporarily 01580-12016 NUT 010
Detail of part C
7 Supplied together with sub-assembly 42C-54-11215 BRACKET LH 001 (2 places on right and left sides)
Battery
8 Supplied together with sub-assembly 42C-54-11225 BRACKET RH 001
box
9 Loose-supply item 42C-54-13221 BRACKET 001 Detail of part B
10 Installed to ⑦ and ⑧ temporarily 42C-54-13230 SHIM 008 (3 places on left side/
3 places on right side)
11 Installed to ⑦ and ⑧ temporarily 01010-81650 BOLT 008
Detail of part A
12 Installed to ⑦ and ⑧ temporarily 01643-31645 WASHER 008 (2 places on right and left sides)

176
Battery box

View from right rear below. Note: Installed direction of bracket 䢆

View from right rear above.

WORK CONTENT EQUIPMENT, JIGS, TOOLS, SLINGS

CRANE :
SLING :
IMPACT WRENCH :
TORQUE WRENCH :
SOCKET :
ETC. :
 Installation of Engine Air Cleaner Hose (920-1060-Z1)

UNIT PARTS PATTERN PARENTS PARTS PARTS (PROCESS) PARTS (PROCESS)

No. No. QTY
FOR SHIPMENT No. No. NAME a Perform this process before installing the bulkhead.

Install 2 hose clamp 180° apart

from each other.
3 Installed to engine temporarily 42C-01-11263 HOSE 004
4 Installed to engine temporarily 07299-00160 CLAMP 012
Tighten
temporarily.

7 Installed to engine temporarily 42C-01-13190 COVER 002 Tighten

8 Installed to engine temporarily 07289-00170 CLAMP HOSE 006 temporarily.

Tighten
temporarily.

177
Tighten
temporarily.
Direct hose up (4 places).

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

Detail of part P
WORK CONTENT EQUIPMENT, JIGS, TOOLS, SLINGS
(2 places only)
CRANE :
SLING :
IMPACT WRENCH :
TORQUE WRENCH :
SOCKET :
ETC. :
 Installation of Bulkhead (920-1070-Z1)

UNIT PARTS PATTERN PARENTS PARTS PARTS (PROCESS) PARTS (PROCESS)

No. No. QTY
FOR SHIPMENT No. No. NAME
Tightening torque :
1 Supplied together with sub-assembly (620-0990-Z1) BULKHEAD ASS'Y 001
157 – 196 Nm {16 – 20 kgm}
2 Installed to bracket temporarily 01010-81435 BOLT 006
3 Installed to bracket temporarily 01643-31445 WASHER 006
4 Installed to bulkhead temporarily 427-54-21740 SPACER 006
5 Installed to bulkhead temporarily 427-54-21730 CUSHION 006
Tightening torque :
Bulkhead in hood
6 Installed to bulkhead temporarily 427-54-21720 CUSHION 012 8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
7 Installed to bulkhead temporarily 419-43-17920 WASHER 012 Tighten permanently
8 Installed to bulkhead temporarily 01435-01250 BOLT 006 after installing bulkhead.

Rubber mount area

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

178
Bracket mounting area
Tightening torque :
245 – 309 Nm {25 – 31.5 kgm}

Rear frame
Mark = C (6 places)

1810 ± 3
(Adjust shims to obtain above dimension)

View Z

WORK CONTENT EQUIPMENT, JIGS, TOOLS, SLINGS Section of part C

CRANE :
SLING :
IMPACT WRENCH :
TORQUE WRENCH :
SOCKET :
ETC. :
 Fixing of Air Cleaner Hose (920-1080-Z1)

UNIT PARTS PATTERN PARENTS PARTS PARTS (PROCESS) PARTS (PROCESS)

No. No. QTY
FOR SHIPMENT No. No. NAME
1 Installed to bracket temporarily 04434-51510 CLIP 003
2 Installed to bracket temporarily 01435-01016 BOLT 003

Bulkhead

179
WORK CONTENT EQUIPMENT, JIGS, TOOLS, SLINGS
CRANE : View X
SLING :
IMPACT WRENCH :
TORQUE WRENCH : Detail of A
SOCKET :
ETC. :
 Fixing of Cables Under Bulkhead (920-1090-Z1)

UNIT PARTS PATTERN PARENTS PARTS PARTS (PROCESS) PARTS (PROCESS)

No. No. QTY
FOR SHIPMENT No. No. NAME
1 Supplied together with sub-assembly 427-43-11340 BRACKET 002
a Install Ԙ to bulkhead temporarily.
2 Supplied together with sub-assembly 01435-01020 BOLT 004
3 Supplied together with sub-assembly 04434-52512 CLIP 004
4 Supplied together with sub-assembly 07095-20318 CUSHION 004
5 Supplied together with sub-assembly 01435-01016 BOLT 002

View Z

180
WORK CONTENT EQUIPMENT, JIGS, TOOLS, SLINGS
CRANE :
SLING :
IMPACT WRENCH :
TORQUE WRENCH :
SOCKET :
ETC. :
 Connection of Hoses Under Bulkhead (920-1100-Z1)

UNIT PARTS PATTERN PARENTS PARTS PARTS (PROCESS) PARTS (PROCESS)

No. No. QTY
FOR SHIPMENT No. No. NAME

Tightening torque for clamp :

5.4 – 6.4 Nm {0.55 – 0.65 kgm}

From air cleaner

181
WORK CONTENT EQUIPMENT, JIGS, TOOLS, SLINGS
CRANE :
SLING :
IMPACT WRENCH :
TORQUE WRENCH :
SOCKET :
ETC. :
 Fixing of Air Conditioner Hose (920-1110-Z1)

UNIT PARTS PATTERN PARENTS PARTS PARTS (PROCESS) PARTS (PROCESS)

No. No. QTY
FOR SHIPMENT No. No. NAME
1 Installed to bracket temporarily 04434-52712 CLIP 002
2 Installed to bracket temporarily 07095-20420 CUSHION 002 a Install Ԙ – ԛ to the back side of the support.
3 Installed to bracket temporarily 04435-52110 CLIP 008
4 Installed to bracket temporarily 01435-01016 BOLT 009

(8 places marked with )

Top view of rear frame

182
WORK CONTENT EQUIPMENT, JIGS, TOOLS, SLINGS
CRANE : Side view of rear frame
SLING : Section A-A
IMPACT WRENCH :
TORQUE WRENCH :
SOCKET :
ETC. :
 Fixing of Heater Hose (920-1120-Z1)

UNIT PARTS PATTERN PARENTS PARTS PARTS (PROCESS) PARTS (PROCESS)

No. No. QTY
FOR SHIPMENT No. No. NAME
1 Installed to bracket temporarily 04434-53212 CLIP 002
a Install Ԙ – Ԟ to the
2 Installed to bracket temporarily 07095-20523 CUSHION 002
back side of the support.
3 Installed to bracket temporarily 01435-01016 BOLT 002
4 Installed to bracket temporarily 04434-52512 CLIP 005
5 Installed to bracket temporarily 01435-01016 BOLT 005
6 Installed to bracket temporarily 421-07-11550 CLIP 002
7 Installed to bracket temporarily 01435-01016 BOLT 002

(5 places marked with A)

183
View Y
(5 places marked with A)

Connect to air conditioner.

WORK CONTENT EQUIPMENT, JIGS, TOOLS, SLINGS

CRANE :
SLING :
IMPACT WRENCH :
TORQUE WRENCH :
View X
SOCKET :
ETC. :
 Installation of Engine Side Cover in front of Radiator Guard (920-1130-Z1)

UNIT PARTS PATTERN PARENTS PARTS PARTS (PROCESS) PARTS (PROCESS)

No. No. QTY
FOR SHIPMENT No. No. NAME
1 Supplied together with sub-assembly (620-1100-Z1) ENG SIDE COVER A 002
2 Installed to bracket and guard temporarily 01435-01225 BOLT 014
3 Installed to bracket and guard temporarily 01643-31232 WASHER 014

184
WORK CONTENT EQUIPMENT, JIGS, TOOLS, SLINGS
CRANE :
SLING :
IMPACT WRENCH :
TORQUE WRENCH :
SOCKET :
ETC. :
 Installation of Engine Side Cover (920-1140-Z1)

UNIT PARTS PATTERN PARENTS PARTS PARTS (PROCESS) PARTS (PROCESS)

No. No. QTY
FOR SHIPMENT No. No. NAME
1 Installed to B-BOX temporarily 01435-01225 BOLT 006
2 Installed to B-BOX temporarily 01643-31232 WASHER 006
3 Loose-supply item 42C-54-11535 SIDE PANEL LH 001
4 Installed to bracket temporarily 01435-01225 BOLT 004
5 Installed to bracket temporarily 01643-31232 WASHER 004
6 Loose-supply item 42C-54-11545 SIDE PANEL RH 001
7 Installed to bracket temporarily 01435-01225 BOLT 004
8 Installed to bracket temporarily 01643-31232 WASHER 004
9 Loose-supply item 42C-54-11553 SIDE PANEL LH 001
10 Installed to bracket temporarily 01435-01225 BOLT 005
11 Installed to bracket temporarily 01643-31232 WASHER 005
12 Loose-supply item 42C-54-11563 SIDE PANEL RH 001
13 Installed to bracket temporarily 01435-01225 BOLT 005
14 Installed to bracket temporarily 01643-31232 WASHER 005

185
15 Installed to bracket temporarily 01435-01225 BOLT 012
16 Installed to bracket temporarily 01643-31232 WASHER 012
17 Supplied together with sub-assembly (620-1100-Z1) ENG SIDE COVER A 002
18 Loose-supply item 42C-54-11516 SIDE PANEL LH 001
19 Loose-supply item 42C-54-11525 SIDE PANEL RH 001

WORK CONTENT EQUIPMENT, JIGS, TOOLS, SLINGS

CRANE :
SLING :
IMPACT WRENCH :
TORQUE WRENCH :
SOCKET :
ETC. :
 Installation of Hood (920-1150-Z1)

UNIT PARTS PATTERN PARENTS PARTS PARTS (PROCESS) PARTS (PROCESS)

No. No. QTY
FOR SHIPMENT No. No. NAME
1 Loose-supply item 42C-54-11123 HOOD, SIDE LH 001
2 Loose-supply item 42C-54-11133 HOOD, SIDE RH 001
3 Installed to bulkhead and bracket temporarily 01435-01230 BOLT 016
4 Installed to bulkhead and bracket temporarily 01435-01225 BOLT 004
Radiator guard

5 Installed to bulkhead and bracket temporarily 01643-31232 WASHER 020

6 Installed to radiator guard temporarily 01011-82010 BOLT 004
7 Installed to radiator guard temporarily 01643-32060 WASHER 008
8 Installed to radiator guard temporarily 566-54-21920 PLATE 008
9 Installed to radiator guard temporarily 566-54-12213 CUSHON 008 Detailed installation of
ԝ – Ԣ and ԧ – 
10 Installed to radiator guard temporarily 566-54-21910 BUSHING 004
(Sectional view)
11 Installed to radiator guard temporarily 01580-12016 NUT 004

186
WORK CONTENT EQUIPMENT, JIGS, TOOLS, SLINGS
CRANE :
SLING :
IMPACT WRENCH :
TORQUE WRENCH :
SOCKET :
ETC. :
 Installation of Air Cleaner Tube (920-1160-Z1)

UNIT PARTS PATTERN PARENTS PARTS PARTS (PROCESS) PARTS (PROCESS)

No. No. QTY
FOR SHIPMENT No. No. NAME See 630-1840-Z1.
1 42C-01-11371 BRACKET 003
2 42C-01-11382 BRACKET 001
3 01024-81230 BOLT 008
4 01010-81230 BOLT 008
5 130-43-64260 WASHER 008

7 42C-01-11254 TUBE 001

8 42C-01-11244 TUBE 001

187
Tightening torque for
bolt marked with a :
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}

WORK CONTENT EQUIPMENT, JIGS, TOOLS, SLINGS

CRANE :
SLING :
IMPACT WRENCH :
TORQUE WRENCH :
SOCKET :
ETC. :
 Installation of Air Cleaner Tube (A/C, Large Capacity) (920-1161-Z1)

UNIT PARTS PATTERN PARENTS PARTS PARTS (PROCESS) PARTS (PROCESS)

No. No. QTY
FOR SHIPMENT No. No. NAME
See 920-1170-Z1.
1 42C-01-11371 BRACKET 003
2 42C-01-11382 BRACKET 001
3 01024-81230 BOLT 008
4 01010-81230 BOLT 008
5 130-43-64260 WASHER 008

7 42C-01-1345A TUBE ASS'Y 001

8 42C-01-1346A TUBE ASS'Y 001

Part P

188
mark
Tightening torque :
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}

Part P

Install dust indicator to tube.

WORK CONTENT EQUIPMENT, JIGS, TOOLS, SLINGS Point
Apply LG-1. Part P
Install the air cleaner tube assembly. CRANE :
Rotate nipple to tighten. View Z
Install the dust indicator to the tube. (2 places) SLING :
IMPACT WRENCH :
TORQUE WRENCH :
SOCKET :
ETC. :
 Installation of Top Hood (920-1170-Z1)

UNIT PARTS PATTERN PARENTS PARTS PARTS (PROCESS) PARTS (PROCESS)

No. No. QTY
FOR SHIPMENT No. No. NAME
1 Supplied together with sub-assembly 42C-54-11116 FRAME,TOP HOOD 001
2 Installed to bulkhead and bracket temporarily 01435-01225 BOLT 005
3 Installed to bulkhead and bracket temporarily 01435-01250 BOLT 010
Radiator
4 Installed to bulkhead and bracket temporarily 01643-31232 WASHER 015
guard
To be installed in next process.
6 Installed to bulkhead and bracket temporarily 01011-82010 BOLT 003
7 Installed to radiator guard temporarily 01643-32060 WASHER 006
8 Installed to radiator guard temporarily 566-54-21920 PLATE 006
9 Installed to radiator guard temporarily 566-54-12213 CUSHON 006 Detailed installation of ԝ – Ԣ
(Sectional view)
10 Installed to radiator guard temporarily 566-54-21910 BUSHING 003
11 Installed to radiator guard temporarily 01580-12016 NUT 003

189
WORK CONTENT EQUIPMENT, JIGS, TOOLS, SLINGS
CRANE :
SLING :
IMPACT WRENCH :
TORQUE WRENCH :
SOCKET :
ETC. :
 Installation of Top Panel (920-1180-Z1)

UNIT PARTS PATTERN PARENTS PARTS PARTS (PROCESS) PARTS (PROCESS)

No. No. QTY
FOR SHIPMENT No. No. NAME
1 Loose-supply item 42C-54-11143 PANEL TOP LH 001
2 Loose-supply item 42C-54-11153 PANEL TOP RH 001
3 Installed to frame top hood temporarily 01435-01220 BOLT 018
4 Installed to frame top hood temporarily 01643-31232 WASHER 018
5 Loose-supply item 42C-54-11161 SCREEN TOP 002
6 Installed to frame top hood temporarily 01435-01235 BOLT 008
7 Installed to frame top hood temporarily 01643-31232 WASHER 008

190
WORK CONTENT EQUIPMENT, JIGS, TOOLS, SLINGS
CRANE :
SLING :
IMPACT WRENCH :
TORQUE WRENCH :
SOCKET :
ETC. :
 Installation of Wiring Harnesses Supplied Together with Engine (920-1190-Z1)

UNIT PARTS PATTERN PARENTS PARTS PARTS (PROCESS) PARTS (PROCESS)

No. No. QTY
FOR SHIPMENT No. No. NAME

3 Installed to bracket temporarily 04434-51410 CLIP 004

4 Installed to bracket temporarily 01435-01016 BOLT 002

Supplied sensor

191
Supplied wiring harness

View Y Detail of R
Secure both parts with bolts (2 places).

View X Detail of P

Detail of S
192
193
194
195
196
197
198
199
200
201
202
 40CE

Check after releasing accumulator pressure

Cooling oil level
200

11 Oil quantity in work Oil should come out of the upper plug when level the
equipment pin bucket on the ground.

･Frame side of boom (Left Right )

･Bucket side of boom (Left Right )
･Boom cylinder bottom side (Left Right )
･Boom cylinder head side (Left Right )
･Bucket cylinder bottom side (Left Right )
･Bucket cylinder head side (Left Right )
･Bell crank (Left Right )
･Bell crank side of bucket link (Left Right )
･Bucket side of bucket link (Left Right )
start.
 There shall be no return time lag and abnormal shock after T/M cutoff.
6

8
9
10

11

12

13

14

15

16

15

15 Presence abnormal Check for unusual noise and vibration from engine, axle, transmission, work
noise of engine equipment, or steering while pressure is applied.
18

19

20

21
22 AJSS work

23 Actuation of Speed Does the lamp light up when the travel speed control switch is turned to the ON
control dial The modulation clutch is controlled to change machine speed.
position?
Dial
Fully operates in speed
turn the travel 1st orcontrol
2nd atdialtravel speed of 1.5
counterclockwise (Setkm/h or above.
it to minimum). Set
Check
the byforce
driving traveling in F1. (fully turn it clockwise).
dial to maximum
When performing measurement, confirm that the system lamp lights up and the
The modulation clutch is controlled to change machine speed.
transmission cut-off switch is in the ON position.
Dialsetoperates
Can speed be only in 1st at speed 1.5 km/h or below.
obtained?
F1: 1.5 to 3 km/h
Depress right brake and check change of engine speed in F1.
24 Actuation of Driving Fully turn the travel speed control dial clockwise (Set it to maximum). Set the
driving force dial to maximum (fully turn it clockwise).
force control dial
When performing measurement, confirm that the system lamp lights up and the
transmission cut-off switch is in the ON position.
Display the real-time MOD/C current on the CGC screen.
Keep in F1, below 1.5 km/h at low idle.
Note the current.
Set the driving force dial to maximum (fully turn it clockwise) (Approx. 700 mmA)
Set the driving force dial to minimum (fully turn it counterclockwise) (660 to 136
mmA)
Does the control rate change?
25 Operation and Engine idle RMP-set must be able to be operated.
canceling of engine An actuation lamp should be illuminated after setting.
idle RPM set Hand throttle should be released by pressing the right brake pedal once.
26 Operation of wall Alarm sounds under following condition.
cutting control (1) Raise the boom upper limit.
(2) Fully dump bucket (Extend the cylinder piston rods to the stroke end).
(3) Release parking brake.
(4) Travel in forward 1st.

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

27 Operation of auto- The monitor panel Indicator lights up. (when normal: light up, during
greasing system greasing: blink)
Interval set: 11.25 minutes (blue dial 3)
Operating set: 15 seconds (red dial 2)
Injector set: Return all injectors 5 turns.
Grease level indicator of grease can should be 1/2 or higher.
Not to blink abnormally. (Rapid blinking: Once/0.5 sec)
Supply pressure: 21 kg/cm2 ( ), Grease line pressure 210 kg/cm 2 ( )
Grease comes out of grease line (Check it by steering cylinder line).

3.0
 Judgement
Cor-
No. Items Judging Methods and Criteria Measured Value Correction rection
Check
Joystick S/T swing speed
H. Performance, Function

1 Right swing time (Engine Hi) 5.2 ± 0.4 sec. ( sec.)

2 Right swing time (Engine Li) 6.0 ± 0.5 sec. ( sec.)
3 Left swing time (Engine Hi) 5.2 ± 0.4 sec. ( sec.)
4 Left swing time (Engine Li) 6.0 ± 0.5 sec. ( sec.)
Adjustment and check of steering stopper bolt
1 Clearrance of frame When machine is steered with engine speed at low idle,
clearance of frame end stopper must be 37 to 40 mm.
Hydraulic pressure Confirms on the CGC-monitor screen
1 Work equipment pressure 317 - 330 kgm/cm 2 (31.0 - 32.3 Mpa) ( kgm/cm 2)
2 S/T pressure 317 - 330 kgm/cm 2 (31.0 - 32.3 Mpa) ( kgm/cm 2)
T/M, T/C, hydraulic pressure Engine Hi
3 T/M main hydraulic pressure 27.2 ± 2 kgm/cm2 (2.5 - 2.8 MPa) ( kgm/cm 2)
4 T/C outlet hydraulic pressure 9 ± 1 kgm/cm2 (0.8 - 1.0 MPa) ( kgm/cm 2)
Brake hydraulic pressure
5 Cut-in 180 - 186 kgm/cm 2 (17.7 - 18.2 Mpa) ( kgm/cm 2)
6 Cut-out 210 - 225 kgm/cm 2 (20.6 - 22.1 Mpa) ( kgm/cm 2)
Hydraulic drift
7 Boom hydraulic drift 250 mm max./15 min. ( mm)
8 Bucket hydraulic drift 100 mm max./15 min. ( mm)
1 Light switches work

2 Parking light
3 Clearance lamp
4 Tail lamp
5 Monitor dash lamp
6 Headlamp
7 Working lamp
8 Brake lamp
9 Ba
10
11
12
13
14
15

16
17

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

Does screen change to load meter, remote positioner, fuel consumption
mode screen, and maintenance screen?
Does screen change to service screen? (Inputting of ID No.)
Does screen change to abnormality record screen? Can abnormality
record be cleared?
Can error screen be canceled?
 Judgement
Classification
Cor-
No. Items Judging Methods and Criteria Measured Value Correction rection
Check
23 Actuation of auto grease Indicator of monitor panel lights up.
(When normal : light up, when greasing : frash)
Illumination of the monitor panel
Interval setting …………… 11.25 mnutes (Blue dial 3)
Operation setting ………… 15 seconds (Red dial 2)
Injector setting …………… Reverse all by 5 turns
J. Lights

The remaining grease indicator should read 1/2 or more.

No abnormal blinging allowed.
Not to flash abnormally. (Rapid flashing: Once/0.5 sec)
Supply pressure: 21 kg/cm 2 ( )
Grease line pressure: 210 kg/cm 2 ( )
Does grease come out of grease line?
(Check by steering cylinder line)

Judgement
Classification

Cor-
No. Items Correction rection
Check

1
2
3
4
Machine Front Upper Section

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

9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
There must be clearance between frame and retainer of upper center pin (Check in four directions).
WA1200-3 WHEEL LOADER

Form No GEN00011-04

©2011 KOMATSU
All Rights Reserved
Printed In Japan 08-11