WA1200-3 Sec30 (D&A)

30 DISASSEMBLY AND ASSEMBLY 1
How to read this manual ............................................................................................................................ 30-2

Coating materials list.................................................................................................................................. 30-4
Removal and installation of hood assembly............................................................................................... 30-7
Removal and installation of radiator and hydraulic oil cooler assembly..................................................... 30-8
Removal and installation of fuel cooler assembly .................................................................................... 30-10
Removal and installation of torque converter oil cooler assembly ........................................................... 30-11
Removal and installation of engine assembly .......................................................................................... 30-12
Removal and installation of damper assembly ........................................................................................ 30-16
Removal and installation of bumper and fuel tank assembly ................................................................... 30-17
Removal and installation of bulkhead assembly ...................................................................................... 30-19
Removal and installation of transmission assembly ................................................................................ 30-20
Removal and installation of front axle assembly ...................................................................................... 30-26
Removal and installation of rear axle assembly....................................................................................... 30-28
Removal and installation of steering cylinder assembly .......................................................................... 30-30
Removal and installation of steering demand valve assembly ................................................................ 30-32
Removal and installation of brake oil cooler assembly ............................................................................ 30-33
Removal and installation of brake oil tank assembly ............................................................................... 30-34
Removal and installation of emergency steering pump assembly ........................................................... 30-35
Removal and installation of emergency diverter valve assembly ............................................................ 30-36
Removal and installation of steering pump and control pump and PPC pump assembly........................ 30-37
Removal and installation of switching pump assembly ............................................................................ 30-38
Removal and installation of transmission and brake cooling and brake pump assembly ........................ 30-39
Removal and installation of work equipment control valve assembly ...................................................... 30-40
Removal and installation of work equipment pump assembly (Right side) .............................................. 30-42
Removal and installation of work equipment pump assembly (Left side) ................................................ 30-43
Removal and installation of hydraulic tank and filter case assembly ....................................................... 30-44
Removal and installation of bucket cylinder assembly............................................................................. 30-46
Removal and installation of lift cylinder assembly.................................................................................... 30-48
Removal and installation of work equipment assembly ........................................................................... 30-50
Removal and installation of air conditioner unit assembly ....................................................................... 30-54
Removal and installation of operator's cab and floor assembly ............................................................... 30-56
Removal and installation of operator's cab assembly .............................................................................. 30-59
Removal and installation of controller assemblies ................................................................................... 30-60
WA1200-3 30-1
(12)
DISASSEMBLY AND ASSEMBLY HOW TO READ THIS MANUAL
How to read this manual 1
1. Removal and installation of assemblies
Special tools Removal

q Special tools which are deemed neces- q The [Removal] section contains procedures
sary for removal or installation of parts are and precautions for implementing the work,
described as A1,•••X1 etc. and their part know how and the amount of oil or coolant to
names, part numbers and quantities are be drained.
described in the special tool list. q Various symbols used in the Removal Section
q Also the following information is described are explained and listed below.
in the special tool list. k : This mark indicates safety-related pre-
1) Necessity cautions that must be followed when
t : Special tools that cannot be substi- implementing the work.
tuted and should always be used a : Know-how or precautions for work
(installed). [*1] : This mark shows that there are instructions
q : Special tools that will be useful if avail- or precautions for installing parts.
able and are substitutable with com- 6 : This mark shows the amount of oil or coolant
mercially available tools. to be drained.
2) Distinction of new and existing special 4 : Weight of part or component
tools
N: Tools newly developed for this
model. They respectively have a Installation
new part number.
q Except where otherwise instructed, installation
R: Tools with upgraded part numbers.
of parts is done in the r evers e order of
They are remodeled from already
removal.
available tools for other models.
q Instructions and precautions for installing parts
Blank: Tools already available for other
are shown with [*1] mark in the Installation
models. They can be used without
Section, identifying which step the instructions
any modification.
are intended for.
3) Circle mark Q in sketch column: q Marks shown in the Installation Section stand
q The sketch of the special tool is pre- for the following.
k : Precautions related to safety in execu-
sented in the section of “Sketches of
special tools”. tion of work.
q Part No. of special tools starting with a : This mark gives guidance or precautions
* *** ****
79 T- - : when doing the procedure.
2 : Type of coating material
means that they can not be supplied
3 : Tightening torque
from Komatsu in Japan (i.e. locally
made parts).
5 : Quantity of oil or coolant to be added
a General tools that are necessary for
Sketches of special tools
removal or installation are described as
[1],[2]•••etc. and their part names, part q Various special tools are illustrated for the con-
numbers and quantities are not described. venience of local manufacture.
30-2 WA1200-3
(12)
DISASSEMBLY AND ASSEMBLY HOW TO READ THIS MANUAL
2. Disassembly and assembly of assemblies Disassembly

q In Disassembly section, the work procedures,
Special tools precautions and know-how for carrying out
q Special tools which are deemed neces- those procedures, and quantity of the oil and
sary for removal or installation of parts are coolant drained are described.
described as A1,•••X1 etc. and their part q The meanings of the symbols used in Disas-
names, part numbers and quantities are sembly section are as follows.
described in the special tool list. k : This mark indicates safety-related pre-
q Also the following information is described cautions that must be followed when
in the special tool list. implementing the work.
1) Necessity a : Know-how or precautions for work
t : Special tools that cannot be substi- 6 : Quantity of oil or coolant drained
tuted and should always be used
(installed).
q : Special tools that will be useful if avail-
able and are substitutable with com- Assembly
mercially available tools. q In Assembly section, the work procedures, pre-
2) Distinction of new and existing special cautions and know-how for carrying out those
tools procedures, and quantity of the oil and coolant
N : Tools newly developed for this added are described.
model. They respectively have a q The meanings of the symbols used in Assem-
new part number. bly section are as follows.
R : Tools with upgraded part numbers. k : Precautions related to safety in execu-
They are remodeled from already tion of work.
available tools for other models. a : This mark gives guidance or precautions
Blank : Tools already available for other when doing the procedure.
models. They can be used without 2 : Type of coating material
4
any modification.
: Tightening torque
3) Circle mark Q in sketch column:
5 : Quantity of oil or coolant to be added
q The sketch of the special tool is pre-
sented in the section of “Sketches of
Sketches of special tools
special tools”.
q Part No. of special tools starting with q Various special tools are illustrated for the con-
venience of local manufacture.
* *** ****
79 T- - :
means that they can not be supplied
from Komatsu in Japan (i.e. locally
made parts).
a General tools that are necessary for

removal or installation are described
as [1],[2]•••etc. and their part names,
part numbers and quantities are not
described.
WA1200-3 30-3
(12)
DISASSEMBLY AND ASSEMBLY COATING MATERIALS LIST
Coating materials list 1
a The recommended coating materials such as adhesives, gasket sealants, and greases used for disas-
sembly and assembly are listed below.
a For coating materials not listed below, use the equivalent of products shown in this manual.
Cate- Komatsu
Part number Q'ty Container Main features and applications
gory code
• Used to prevent rubber gaskets, rubber cush-
LT-1A 790-129-9030 150 g Tube
ions, and cork plugs from coming out.
• Used for plastic (except polyethylene,
polypropylene, tetrafluoroethylene and vinyl
20 g Polyethylene
LT-1B 790-129-9050 chloride), rubber, metal, and non-metal parts
(2 pcs.) container
which require immediate and strong adhe-
sion.
Polyethylene • Features: Resistance to heat and chemicals.
LT-2 09940-00030 50 g
container • Used to fix and seal bolts and plugs.
790-129-9060
Adhesive: 1 kg • Used to stick and seal metal, glass, and plas-
LT-3 (Set of adhesive Can
Hardener: 500 g tics.
and hardener)
Adhesive
Polyethylene
LT-4 790-129-9040 250 g • Used to seal plugs.
container
Holtz MH 705 790-129-9120 75 g Tube • Heat-resistant seal used to repair engines.
• Quick-setting adhesive.
ThreeBond Polyethylene • Setting time: Within 5 sec. to 3 min.
790-129-9140 50 g
1735 container • Used mainly to stick metals, rubbers, plastics,
and woods.
• Quick-setting adhesive.
• Quick-setting type.
Aron-alpha Polyethylene
790-129-9130 2g (max. strength is obtained after 30 minutes)
201 container
• Used mainly to stick rubbers, plastics, and
metals.
• Features: Resistance to heat and chemicals.
Loctite Polyethylene
79A-129-9110 50 cc • Used for fitted portions used at high tempera-
648-50 container
tures.
• Used to stick or seal gaskets and packings of
LG-1 790-129-9010 200 g Tube
power train case, etc.
• Used to seal various threaded portions, pipe
Polyethylene joints, and flanges.
LG-5 790-129-9080 1 kg
container • Used to seal tapered plugs, elbows, and nip-
ples of hydraulic piping.
• Features: Silicon-based heat and cold-resis-
tant sealant.
Gasket sealant
LG-6 790-129-9020 200 g Tube • Used to seal flange surfaces and threaded
portions.
• Used to seal oil pan, final drive case, etc.
• Features: Silicon-based quick-setting sealant.
LG-7 790-129-9070 1 kg Tube • Used to seal flywheel housing, intake mani-
fold, oil pan, thermostat housing, etc.
ThreeBond
790-129-9090 100 g Tube • Gasket sealant used to repair engine.
1211
• Features: Silicon-based, heat and cold-resis-
ThreeBond tant, vibration-resistant, impact-resistant seal-
419-15-18131 100 g Tube
1207B ant.
• Used to seal transfer case, etc.
30-4 WA1200-3
(12)
Cate-
Komatsu code Part number Q'ty Container Main features and applications
gory
• Used to lubricate sliding portions.
disulfide lubricant
LM-G 09940-00051 60 g Can

Molybdenum
(to prevent squeaking)

• Used to prevent scuffing and seizure of press-
fitted portions, shrink-fitted portions, and
LM-P 09940-00040 200 g Tube
threaded portions.
• Used to lubricate linkages, bearings, etc.
SYG2-400LI
G2-LI SYG2-350LI
G0-LI (*) SYG2-400LI-A
SYG2-160LI Various Various • General purpose type.
*: For cold dis- SYGA-160CNLI
trict SYG0-400LI-A (*)
SYG0-16CNLI (*)
SYG2-400CA
SYG2-350CA • Used for bearings used at normal temperature
G2-CA SYG2-400CA-A Various Various
SYG2-160CA under light load in contact with water or steam.
SYGA-160CNCA
• Used for parts under heavy load.
Caution:
Grease
Molybdenum SYG2-400M 400 g x 10 Bellows-type • Do not apply grease to ball bearings like swing
disulfide grease SYG2-400M-A 400 g x 20 container circle bearings, etc.
LM-G (G2-M) SYGA-16CNM 16 kg Can
• The grease should be applied to work equip-
ment pins at their assembly only, not applied for
greasing afterwards.
Hyper White • Seizure resistance and heat resistance higher
Grease G2-T, SYG2-400T-A 400 g Bellows-type
SYG2-16CNT than molybdenum disulfide grease.
G0-T (*) container
*: For cold dis- SYG0-400T-A (*) 16 kg Can • Not conspicuous on machine since color is
trict SYG0-16CNT (*) white.
Biogrease
G2-B, G2-BT (*) SYG2-400B
*: For use at SYGA-16CNB 400 g Bellows-type • Since this grease is decomposed by natural
high tempera- SYG2-400BT (*) container bacteria in short period, it has less effects on
ture and under SYGA-16CNBT 16 kg Can microorganisms, animals, and plants.
high load (*)
SUNSTAR • Used as primer for cab side.

Glass con-
PAINT PRIMER 20 ml tainer (Using limit: 4 months after date of manu-
580 SUPER facture)
417-926-3910
SUNSTAR • Used as primer for glass side.
GLASS Glass con-
PRIMER 580 20 ml tainer (Using limit: 4 months after date of manu-
SUPER facture)
Adhesive for cab glass
• Used as primer for painted surface on cab

SUNSTAR Glass con- side.
PAINT PRIMER 22M-54-27230 20 ml
Primer
tainer (Using limit: 4 months after date of manu-

435-95
facture)
• Used as primer for black ceramic-coated
SUNSTAR surface on glass side and for hard polycar-
GLASS
PRIMER 22M-54-27240 150 ml Can bonate-coated surface.
435-41 (Using limit: 4 months after date of manu-
facture)
SUNSTAR • Used as primer for sash (Almite).
Glass con-
SASH PRIMER 22M-54-27250 20 ml tainer (Using limit: 4 months after date of manu-
GP-402 facture)
WA1200-3 30-5
(12)
Cate-
gory Komatsu code Part number Q'ty Container Main features and applications
SUNSTAR • “S” is used for high-temperature season

PENGUINE Polyethyl- and “W” for low-temperature season as
SEAL 580 417-926-3910 320 ml ene con- adhesive for glass.
SUPER “S” or tainer (Using limit: 4 months after date of manu-
“W” facture)
Adhesive
Polyethyl- • Used as adhesive for glass.

Sika Japan,
Sikaflex 256HV 20Y-54-39850 310 ml ene con- (Using limit: 6 months after date of manu-
tainer
Adhesive for cab glass

facture)
SUNSTAR Ecocart • Used as adhesive for glass.
PENGUINE 22M-54-27210 320 ml (Special (Using limit: 6 months after date of manu-
SUPER 560 container) facture)
SUNSTAR Polyethyl- • Used to seal joints of glass parts.
PENGUINE 417-926-3920 320 ml ene con- (Using limit: 4 months after date of manu-
SEAL No. 2505 tainer facture)
Caulking material
SEKISUI SILI- Polyethyl- • Used to seal front window.

CONE SEAL- 20Y-54-55130 333 ml ene con- (Using limit: 6 months after date of manu-
ANT tainer facture)
• Used to seal joint of glasses.
GE TOSHIBA Translucent white seal.
SILICONES 22M-54-27220 333 ml Cartridge
TOSSEAL 381 (Using limit: 12 months after date of manu-
facture)
30-6 WA1200-3
(12)
DISASSEMBLY AND ASSEMBLY HOOD ASSEMBLY
Removal and installation of hood Installation

assembly 1
q Carry out installation in the reverse order to
Removal removal.
k Stop the machine on a level ground, lower [*1]

the bucket to the ground, apply the parking 3 Hood and radiator guard connecting nut:
brake, and lock the tires with chocks. 490 – 608 Nm {50 – 62 kgm}
k Disconnect the cable from the negative (–)
terminal of the battery. [*2]
3 Bracket (7) mounting nut:
1. Lift off handrail (1) and right and left handrails 490 – 608 Nm {50 – 62 kgm}
(2).
2. Lift off 2 exhaust pipes (3).

4 Exhaust pipe: 30 kg x 2 pieces
3. Remove right and left side covers (4).
4. Remove the mounting bolts and lift off hood

assembly (5). [*1]
5. Lift off right and left brackets (6). [*2]
WA1200-3 30-7
(12)
DISASSEMBLY AND ASSEMBLY RADIATOR AND HYDRAULIC OIL COOLER ASSEMBLY
Removal and installation of 7. Disconnect radiator outlet tube (6).

radiator and hydraulic oil cooler
8. Disconnect coolant drain hose (7).
assembly 1
9. Disconnect hose clamp (8).

Removal
k Stop the machine on a level ground, lower

the bucket to the ground, apply the parking
brake, and lock the tires with chocks.
terminal of the battery.
1. Drain the coolant.

6 Coolant: Approx. 540 l
2. Remove the hood assembly. For details, see

"Removal and installation of hood assembly".
3. Open grille (1). 10. Disconnect connector (GR6) of coolant level

sensor wiring harness (9).
4. Disconnect connector (GR6) of wiring harness
(2). 11. Remove the 3 clamps and disconnect hose
(10).
5. Sling radiator guard (3), remove its mounting
bolts (4), and lift it off. [*1] 12. Disconnect hoses (11) and (12).
4 Radiator guard: 905 kg 13. Remove brackets (13) and (14).
14. Loosen the hose clamp on the radiator side

and disconnect HTC radiator inlet tube (15),
LTC radiator outlet tube (16), HTC radiator inlet
tube (17) and LTC radiator inlet tube (18). [*2]
6. Disconnect 2 hydraulic oil cooler pipings (5).
30-8 WA1200-3
(12)
DISASSEMBLY AND ASSEMBLY RADIATOR AND HYDRAULIC OIL COOLER ASSEMBLY
15. Remove fan pulley cover (19). Installation

16. Lift off fan guard (20). q Carry out installation in the reverse order to
removal.
[*1]
3 Radiator guard mounting bolt:
824 – 1,030 Nm {84 – 105 kgm}
[*2]
2 Hose insertion part:
Gasket sealant (Threebond 1208E)
a Install the hose clamps 180° apart from each
other.
[*3]
3 Radiator support mounting bolt:
17. Remove right and left covers (21) and lift off 490 – 608 Nm {50 – 62 kgm}
right and left radiator supports (22). [*3]
[*4]
18. Sling radiator and hydraulic oil cooler assem- 3 Radiator and hydraulic oil cooler mounting
bly (23), remove its 10 mounting bolts, and lift it bolt: 490 – 608 Nm {50 – 62 kgm}
off. [*4]
4 Radiator and hydraulic oil cooler
q Refilling with coolant
assembly: 2,750 kg
Add coolant to the specified level. Run the
engine to circulate the coolant through the sys-
tem. Then, check the coolant level again.
WA1200-3 30-9
(12)
DISASSEMBLY AND ASSEMBLY FUEL COOLER ASSEMBLY
Removal and installation of fuel Installation

cooler assembly 1
Removal removal.

1. Lift off mask (1).
2. Remove front cover (2) and rear cover (3).
3. Remove top cover (4), bottom cover (5), front

cover (6) and rear cover (7).
4. Disconnect tubes (8) and (9) and disconnect

bracket (10) from the cooler.
5. Disconnect tubes (11) and (12).
6. Sling fuel cooler assembly (13), remove its

mounting bolts, and lift it off.
4 Fuel cooler assembly: 338 kg
30-10 WA1200-3
(12)
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER OIL COOLER ASSEMBLY
Removal and installation of Installation

torque converter oil cooler
assembly 1
removal.
Removal
[*1]
3
k Stop the machine on a level ground, lower Torque converter oil cooler mounting bolt:
the bucket to the ground, apply the parking 157 – 196 Nm {16 – 20 kgm}
1. Drain the coolant. q Refilling with coolant

6 Coolant: Approx. 540 l engine to circulate the coolant through the sys-
2. Lift off screens (1) and (2).
3. Disconnect hoses (3) and (4).
4. Remove tubes (5) and (6).
5. Sling the right and left ends of torque converter

oil cooler assembly (7), remove its mounting
bolts (8), and lift it off while moving it forward.
[*1]
4 Torque converter oil cooler assembly:
285 kg
WA1200-3 30-11
(12)
DISASSEMBLY AND ASSEMBLY ENGINE ASSEMBLY
Removal and installation of 7. Disconnect hoses (7) and (8).

engine assembly 1
8. Remove brackets (9) and (10).
Removal
9. Loosen the hose clamp and remove HTC radi-
k Stop the machine on a level ground, lower ator inlet tube (11), LTC radiator outlet tube
the bucket to the ground, apply the parking (12), HTC radiator inlet tube (13) and LTC radi-
brake, and lock the tires with chocks. ator inlet tube (8). [*2]

2. Drain the engine oil.

6 Engine oil: Approx. 260 l

4. Remove the radiator guard. For details, see 10. Loosen the hose clamp and remove tubes (14)
"Removal and installation of radiator and and (15). [*3]
hydraulic oil cooler assembly".
11. Remove fan pulley cover (16).
5. Remove the bulkhead assembly. For details,
see "Removal and installation of bulkhead 12. Remove fan guard (17).
assembly".
13. Disconnect fuel hose (18).
6. Remove brackets (1), (2), (3), (4), (5) and (6).
[*1]
30-12 WA1200-3
(12)
14. Disconnect wiring harness connector E10 (19). 20. Disconnect hose (29).
15. Remove cover (20). 21. Loosen hose clamp (30) and remove tubes
(31) and (32).
16. Loosen bolt (21) and belt tension adjustment
bolt (22) and remove belt (23). [*4] 22. Disconnect heater hose (32).
17. Remove 4 mounting bolts (24) and move air 23. Disconnect suction tube (33).
compressor assembly (25) outward.
24. Disconnect hose (34).
25. Remove hose clamp (35) and disconnect

hoses (36) and (37).
27. Remove hose (39).
28. Remove the hose clamp and disconnect hose

(40).
18. Loosen the hose clamp and disconnect fuel 30. Disconnect hose (42).
19. Disconnect wiring harness connector (28).
WA1200-3 30-13
(12)
31. Disconnect wiring harness connector BR1 35. Disconnect centralized wiring harness connec-
(43). tors ER1, ER3, ER4, ER5, ER6, ER7 and ER8
(50).
32. Disconnect ground cables (44) and (45).

36. Disconnect engine drain hose (51).
33. Disconnect starting motor cables (46), (47) and
(48).
37. Sling upper drive shaft (52), remove its mount-

ing bolts, and lift it off. [*5]
34. Disconnect heater hose (49). a When removing the drive shaft, make a
match mark on the coupling to indicate the
mounting position.
4 Upper drive shaft: 115 kg
30-14 WA1200-3
(12)
38. Remove 4 engine front mounting bolts (53). Installation

[*6]
39. Remove 4 engine rear mounting bolts (54). removal.
[*7]
[*1]
3 Bracket mounting bolt:
245 – 309 Nm {25 – 31.5 kgm}
[*2], [*3]
2 Hose insertion part:
Gasket sealant (Threebond 1208E)
a Install the hose clamps 180 degrees apart from
each other.
[*4]
Adjust the belt tension. For details, see Testing and
adjusting, "Testing and adjusting air conditioner
compressor belt tension".
40. Sling engine assembly (55) gradually to
remove. [*5]
a When removing the engine assembly, 3 Drive shaft mounting bolt:
check that all the wiring harnesses and 157 – 196 Nm {16 – 20 kgm}
pipings are disconnected.
[*6]
4
3
Engine assembly: 7,700 kg
Front mounting bolt:
824 – 1,030 Nm {84.0 – 105 kgm}
[*7]
3 Rear mounting bolt:
824 – 1,030 Nm {84.0 – 105 kgm}

engine to circulate the coolant through the sys-
q Refilling with oil (Engine)

Add oil through the oil filler to the specified
level. Run the engine to circulate the oil
through the system. Then, check the oil level
again.
WA1200-3 30-15
(12)
DISASSEMBLY AND ASSEMBLY DAMPER ASSEMBLY
Removal and installation of 6. Sling cover assembly (4), remove mounting

damper assembly 1
bolts (5), and lift off the cover assembly. [*2]
4 Cover assembly: 160 kg
Removal
k Stop the machine on a level ground, lower 7. Remove upper 2 bolts (7) of damper assembly
the bucket to the ground, apply the parking (6) and install eyebolts. Sling the damper
brake, and lock the tires with chocks. assembly, remove mounting bolts (8), and lift
off the damper assembly. [*3]
1. Remove the hood assembly. For details, see 4 Damper assembly: 360 kg

see "Removal and installation of bulkhead
assembly".
3. Remove all of partition covers (1).
Installation

removal.
[*1]
3 Drive shaft mounting bolt:
5. Sling drive shaft (3), remove the bolts on the 157 – 196 Nm {16 – 20 kgm}
damper side, and lift off the drive shaft. [*1]
[*2]
4 Upper drive shaft: 112 kg 3 Flange mounting bolt:
245 – 309 Nm {25 – 31.5 kgm}
[*3]
2 Apply molybdenum disulfide dry lubricant #1
to shaft spline (Q) (and dry it in air for 2 – 3
minutes) and then install.
3 Cover mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
30-16 WA1200-3
(12)
DISASSEMBLY AND ASSEMBLY BUMPER AND FUEL TANK ASSEMBLY
Removal and installation of 8. Lift off steps (9) and (10).

bumper and fuel tank assembly 1
9. Remove step covers (11), (12), (13) and (14).
Removal
10. Disconnect hoses (15), (16) and (17).
the bucket to the ground, apply the parking 11. Disconnect fuel level sensor wiring harness
brake, and lock the tires with chocks. connector R05 (18).
1. Drain the fuel.

6 Fuel: Approx. 5,100 l
(Specified capacity)
2. Lift off handrail (1).
3. Lift off ladder (2).

4 Ladder: 115 kg
4. Lift off handrails (3) and (4). 12. Disconnect wiring harness connector GR1
(19).
5. Lift off step (5).
6. Lift off handrails (6) and (7).
7. Remove step (8).
WA1200-3 30-17
(12)
DISASSEMBLY AND ASSEMBLY BUMPER AND FUEL TANK ASSEMBLY
13. Set stand [1] under the bumper. Installation

14. Sling the right and left ends of the bumper with q Carry out installation in the reverse order to
nylon slings and remove mounting bolts (20) removal.
and bumper and fuel tank assembly (21). [*1]
a Apply pads to the corners of the bumper to [*1]
protect the nylon slings. 3 Fuel tank mounting bolt:
4 Bumper and fuel tank assembly: 1,127 – 1,911 Nm {115 – 195 kgm}
6,470 kg
15. Remove side fuel tanks (23) and (24) and cen-
ter fuel tank (25) from bumper (22).
4 Side fuel tanks (23) and (24):
520 kg (1 piece)
Center fuel tank (25): 610 kg
30-18 WA1200-3
(12)
DISASSEMBLY AND ASSEMBLY BULKHEAD ASSEMBLY
Removal and installation of 8. Loosen the hose clamp and remove tubes (13)
bulkhead assembly 1
and (14). [*1]
Removal 9. Disconnect the battery cable bracket.
k Stop the machine on a level ground, lower 10. Disconnect hose, tube and wiring harness con-
the bucket to the ground, apply the parking nectors (ETH1 and ETH39) of the ether starter
brake, and lock the tires with chocks. cartridge adapter.
terminal of the battery. 11. Remove 4 air cleaner assemblies (15).
1. Remove the hood assembly. For details, see 12. Sling bulkhead assembly (16), remove its
"Removal and installation of hood assembly". mounting bolts, and remove it. [*2]
4 Bulkhead and air cleaner assembly:
2. Remove the right handrail. 330 kg
3. Remove all of partition covers (1).
4. Disconnect wiring harness connectors B08 (2),

B07 (3), B08 (4) and B09 (5) to disconnect wir-
ing harness (6).
Installation

5. Loosen the clamp and remove hoses (7) and removal.
(8).
[*1]
6. Disconnect brackets (9) and (10). 3 Hose clamp: 8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
7. Loosen the hose clamp and remove tubes (11) [*2]

and (12). 3 Bulkhead mounting bolt:
157 – 196 Nm {16 – 20 kgm}
WA1200-3 30-19
(12)
DISASSEMBLY AND ASSEMBLY TRANSMISSION ASSEMBLY
Removal and installation of 8. Remove steps (1) and (2).

transmission assembly 1
Special tools
Necessity
Symbol
Sketch
Q’ty
N/R
Part number Part name
799-703-1200 Service tool kit t 1

Vacuum pump
799-703-1100 t 1
(100 V)
Vacuum pump
X 1 799-703-1111 t 1
(220 V)
Vacuum pump
799-703-1121 t 1
(240 V) 9. Lift off drive shaft guards (3) and (4).
799-703-1401 Gas leak detector t 1
10. Lift off underguards (5) and (6).
Removal

1. Drain the hydraulic oil.

6 Hydraulic oil: Approx. 1,125 l
2. Drain the transmission oil.

11. Disconnect wiring harness connector R31 (7).
6 Transmission oil: Approx. 350 l
12. Disconnect air conditioner hose (8). [*1]
"Removal and installation of hood assembly". 13. Remove air conditioner condenser assembly
(9) and bracket together.
see "Removal and installation of bulkhead
assembly".
5. Remove the operator's cab. For details, see

"Removal and installation of operator's cab".
6. Using tool X1, collect the air conditioner refrig-

erant gas.
7. Lift off the floor cover from the top of the trans-
mission.
15. Disconnect hose clamp and tubes (12) and

(13).
30-20 WA1200-3
(12)
16. Remove the U-bolt and suction tube (14). 24. Remove suction tubes (29) and (30).
17. Remove hoses (15) and (16).
18. Remove the U-bolt and tubes (17) and (18).
21. Remove the U-bolt and tube (22).
26. Remove hose clamp (33) and disconnect 9

hoses (34).
22. Disconnect hoses (23), (24), (25) and (26).
23. Disconnect suction tubes (27) and (28).
WA1200-3 30-21
(12)
27. Remove hose clamp (35) and disconnect 36. Disconnect hoses (50), (51) and (52) and lift off
hoses (36) and (37). lower emergency steering pump assembly
(53).
28. Disconnect hoses (38) and (39). a Remove the upper emergency steering
pump assembly similarly to the above.
29. Disconnect wiring harness connectors T24

(40) and MT3 (41). 37. Disconnect hoses (54) and (55) and remove
transmission oil filler (56).
31. Remove hose clamp (44) and disconnect hose

(45).
32. Remove valve assembly (46). [*2]
33. Remove tube (47).
34. Disconnect tube (48).
35. Remove tube (49).
30-22 WA1200-3
(12)
39. Disconnect 6 hoses (60). 48. Disconnect tube (75).
40. Remove hose clamp (61) and disconnect hose 49. Disconnect hose (76).
(62).
50. Remove suction tube (77).
41. Remove hose clamp (63) and disconnect
51. Remove wiring harness clamp and disconnect

wiring harnesses TM1 (78) and TM2 (79).
47. Remove the U-bolt and remove suction tube

(74).
WA1200-3 30-23
(12)
53. Disconnect hoses (81) and (82). 59. Sling transmission assembly (86) gradually to
remove it.
a When removing the transmission assem-
bly, check that all the wiring harnesses
and pipings are disconnected.
4 Transmission assembly: 5,100 kg
54. Sling upper drive shaft (83), remove its mount-

a When removing the drive shaft, make a
mounting position.
4 Upper drive shaft: 115 kg
55. Sling rear drive shaft (84), remove its mounting

bolts, and lift it off. [*4]
mounting position.
4 Rear drive shaft: 215 kg
56. Sling center drive shaft (85), remove its mount-

mounting position.
4 Center drive shaft: 185 kg
57. Sling transmission assembly (86) and remove

rear mount mounting bolts (87). [*6]
58. Remove mounting bolts (89) and (90) and right

and left front mount brackets (88). [*7]
30-24 WA1200-3
(12)
Installation [*7]
3 Front mount bracket mounting bolt:
q Carry out installation in the reverse order to q Bolt (89):
removal. 824 – 1,030 Nm {84 – 105 kgm}
q Bolt (90):
[*1] 490 – 608 Nm {50 – 62 kgm}
2 O-ring (fitted to hose adapter):
Apply compressor oil (ND-OIL8) q Refilling with oil (Transmission)
for new refrigerant. Add oil through the oil filler to the specified
a Use a double spanner to fix the nut securely. level. Run the engine to circulate the oil
(Fix the device side and turn only the flare nut through the system. Then, check the oil level
of the hose with the spanner.) again.
3 Connection of piping q Refilling with oil (Hydraulic tank)

again.
q Precautions for charging air conditioner

with refrigerant
1) Keep the ambient temperature above 3°C.
(If the ambient temperature is below 3°C,
the system does not operate.)
2) Use Freon gas (R134a) as refrigerant.
3) Before charging the air conditioner with
refrigerant, be sure to evacuate it suffi-
a After tightening, if gas leaks, clean the flared ciently by repeated evacuation method.
part and apply ND-OIL8 and then tighten to the (The degree of vacuum must be –100 kPa
above torque. {–750 mm Hg} or higher.)
4) The standard quantity of refrigerant is 1.3
[*2] – 1.5 kg.
3 Valve assembly mounting bolt: 5) Take care that the Freon liquid will not
44.1 – 53.9 Nm {4.5 – 5.5 kgm} enter the refrigeration system from the
refrigerant can reversed by mistake.
[*3] 6) Do not operate the compressor before
3 Upper drive shaft mounting bolt: charging the air conditioner system with
157 – 196 Nm {16 – 20 kgm} the refrigerant.
[*4] q Bleeding air

3 Rear drive shaft mounting bolt: Bleed air from the piston pump and work
343 – 427 Nm {35 – 43.5 kgm} equipment circuit. For details, see Testing and
adjusting, "Bleeding air from each part".
[*5]
3 Center drive shaft mounting bolt:
343 – 427 Nm {35 – 43.5 kgm}
[*6]
3 Rear mount mounting bolt:
824 – 1,030 Nm {84 – 105 kgm}
WA1200-3 30-25
(12)
DISASSEMBLY AND ASSEMBLY FRONT AXLE ASSEMBLY
Removal and installation of front 6. Lift off front drive shaft (3). [*2]
axle assembly 1
match mark on the drive shaft coupling to
Removal indicate the installed position.
4 Front drive shaft: 210 kg
the bucket to the ground, and apply the
parking brake.
1. Drain the oil from the brake oil tank.

6 Brake oil tank: Approx. 45 l
2. Set a steel plate on the ground under the front

axle.
3. Start the engine, raise the machine with the

work equipment, and set stand [1] under the
front frame.
a Set steel plate [2] between the stand and
ground. 7. Disconnect brake hoses (4), (5) and (6).
a Lock the rear tires with chocks.
4. Remove right and left fenders (1).
5. Sling each tire (2), remove its mounting nuts,

and lift it off. Remove the right and left tires
similarly. [*1]
4 Tire (1 piece): 9,150 kg
8. Sling front axle assembly (7), remove its 16

mounting bolts (8), and lower it onto the steel
plate. [*3]
9. Pull out the front axle assembly with a crane,

etc.
4 Front axle assembly: 16,500 kg
30-26 WA1200-3
(12)
DISASSEMBLY AND ASSEMBLY FRONT AXLE ASSEMBLY
Installation

removal.
[*1]
3 Tire mounting nut:
1,470 – 1,810 Nm {150 – 185 kgm}
[*2]
343 – 427 Nm {35 – 43.5 kgm}
[*3]
3 Axle assembly mounting nut:
4,510 – 5,490 Nm {460 – 560 kgm}
q Refilling with oil (Brake oil tank)

level.
q Bleeding air
Bleed air from the wheel brake circuit. For
details, see Testing and adjusting, “Bleeding
air from each part”.
After bleeding air, add oil to the specified level
of the brake oil tank.
WA1200-3 30-27
(12)
DISASSEMBLY AND ASSEMBLY REAR AXLE ASSEMBLY
Removal and installation of rear 6. Lift off rear drive shaft (2). [*2]
axle assembly 1
match mark on the drive shaft coupling to
Removal indicate the installed position.
4 Rear drive shaft: 215 kg
the bucket to the ground, and apply the
parking brake.

2. Set a steel plate on the ground under the rear

axle.
3. Start the engine, raise the machine with the

work equipment, and set stands [1] and [2]
under the rear frame and bumper.
a Set steel plates [3] and [4] between the
stands and ground. 7. Disconnect axle support grease hoses (3) and
a Lock the front tires with chocks. (4).
4. Remove the step cover above the left tire.
5. Sling each tire (1), remove its mounting nuts,

and lift it off. Remove the right and left tires
similarly. [*1]
4 Tire (1 piece): 9,150 kg
8. Disconnect brake hoses (5), (6) and (7).
30-28 WA1200-3
(12)
DISASSEMBLY AND ASSEMBLY REAR AXLE ASSEMBLY
9. Sling rear axle assembly (8), remove 18 sup- Installation

port mounting bolts (9), and lower the rear axle
assembly onto the steel plate. [*3] q Carry out installation in the reverse order to
removal.
10. Pull out the rear axle assembly with a crane,
etc. [*1]
3
4 Rear axle assembly: 16,655 kg Tire mounting nut:
1,470 – 1,810 Nm {150 – 185 kgm}
[*2]
343 – 427 Nm {35 – 43.5 kgm}
[*3]
3 Support mounting nut:
4,510 – 5,490 Nm {460 – 560 kgm}

level.
q Bleeding air
Bleed air from the wheel brake circuit. For
details, see Testing and adjusting, “Bleeding
air from each part”.
After bleeding air, add oil to the specified level
of the brake oil tank.
WA1200-3 30-29
(12)
DISASSEMBLY AND ASSEMBLY STEERING CYLINDER ASSEMBLY
Removal and installation of 6. Disconnect bottom hose (9) and head hose
steering cylinder assembly 1
(10).
Removal
k Fully extend the piston rod of the steering

cylinder to be removed, lower the bucket to
the ground, apply the parking brake, and
lock the tires with chocks.
1. Disconnect grease hose (1) and remove the

nipple.
7. Disconnect grease hose (11) and remove the

nipple.
2. Remove 10 mounting bolts (2) and plate (3).

[*1]

[*2]
4. Remove taper bushings (6) and (7) and pull 8. Sling steering cylinder assembly (12).
out pin (8). [*3]
5. Start the engine and retract the piston rod. [*4]

[*5]
11. Remove taper bushings (17) and (18) and pull

out pin (8). [*6]
12. While moving steering cylinder assembly (12)

backward, lift it off.
4 Steering cylinder assembly: 590 kg
30-30 WA1200-3
(12)
DISASSEMBLY AND ASSEMBLY STEERING CYLINDER ASSEMBLY
Installation

removal.
[*1] [*2] [*4] [*5]

3 Plate mounting bolt:
824 – 1,030 Nm {84 – 105 kgm}
[*3] [*6]
a Do not apply grease or other lubricants to the
contacting surfaces of the pin, taper bushing
and cylinder bushing.
a Set the slit of the taper bushing in the lateral
direction of the machine.
a Set the grease hole of the pin toward inside of
the machine.
k When aligning the pin holes, use a bar.

Never insert your fingers in the pin holes.
WA1200-3 30-31
(12)
DISASSEMBLY AND ASSEMBLY STEERING DEMAND VALVE ASSEMBLY
Removal and installation of

steering demand valve assembly 1
Removal

k Loosen the oil filler cap to release the pres-
sure in the hydraulic tank.


Installation
4. Remove the U-bolt and remove tubes (6) and removal.
(7).
[*1]
5. Sling steering demand valve assembly (8), 3 Valve assembly mounting bolt:
remove 3 mounting bolts (9), and lift off the 235 – 285 Nm {23.5 – 29.5 kgm}
valve assembly and bracket together. [*1]
Refilling with oil (Hydraulic tank)
4
q
Steering demand valve assembly: 70 kg Add oil through the oil filler to the specified
a The above removal procedure is for the left level. Run the engine to circulate the oil
steering demand valve assembly. Remove the through the system. Then, check the oil level
right steering demand valve assembly to this again.
procedure, too.
q Bleeding air
Bleed air from the piston pump and work
equipment circuit. For details, see Testing and
30-32 WA1200-3
(12)
DISASSEMBLY AND ASSEMBLY BRAKE OIL COOLER ASSEMBLY
Removal and installation of brake 5. Disconnect hoses (4) and (5).

oil cooler assembly 1
6. Disconnect drain hose (6).
Removal



3. Remove screens (1) and (2). 7. Loosen hose clamps (7) and (8) and remove
tubes (9) and (10).
8. Sling brake oil cooler assembly (11), remove

its mounting bolts, and lift it off while moving it
to the right of the machine.
4. Remove fan pulley cover (3).
Installation

removal.
q Refilling with oil

level.
WA1200-3 30-33
(12)
DISASSEMBLY AND ASSEMBLY BRAKE OIL TANK ASSEMBLY
Removal and installation of brake

oil tank assembly 1
Removal


2. Disconnect level sensor wiring connectors Installation

HR6 and HR10 (1) of the brake oil tank.
removal.
[*1]
3 Brake oil tank mounting bolt:
824 – 1,030 Nm {84 – 105 kgm}

level.
q Bleeding air
Referring to Testing and adjusting, "Bleeding
air from each part", bleed air from the wheel
3. Disconnect suction tube (2). brake circuit. Then, check the oil level again.
4. Disconnect brake return tube (3).
5. Disconnect brake cooler suction tube (4).
6. Disconnect brake cooler return tube (5).
7. Disconnect drain hose (6).
8. Sling brake oil tank assembly (7), remove its

mounting bolts, and lift it off. [*1]
4 Brake oil tank assembly: 225 kg
30-34 WA1200-3
(12)
DISASSEMBLY AND ASSEMBLY EMERGENCY STEERING PUMP ASSEMBLY

emergency steering pump
assembly 1
removal.
Removal
[*1]
3
k Stop the machine on a level ground, lower Pump assembly mounting bolt:
the bucket to the ground, apply the parking 245 – 309 Nm {25 – 31.5 kgm}
k Loosen the oil filler cap to release the pres- q Refilling with oil (Hydraulic tank)
sure in the hydraulic tank. Add oil through the oil filler to the specified
1. Drain the hydraulic oil. through the system. Then, check the oil level
again.
q Bleeding air
2. Disconnect hose (1). Bleed air from the piston pump and work
3. Disconnect hose (2). adjusting, "Bleeding air from each part".
5. Sling emergency steering pump assembly (4),

remove its mounting bolts, and lift it off. [*1]
a Similarly to the above procedure, remove
the lower emergency steering pump
assembly.
4 Emergency steering pump assembly
(1 piece): 50 kg
WA1200-3 30-35
(12)
DISASSEMBLY AND ASSEMBLY EMERGENCY DIVERTER VALVE ASSEMBLY
Removal and installation of 3. Removal of diverter valve assembly (lower

emergency diverter valve side).
1) Disconnect wiring harness connector R11
assembly 1
(8).
Removal


2. Removal of diverter valve assembly (upper 2) Remove suction tube (9).

side). 3) Disconnect hoses (10), (11), (12) and (13).
1) Disconnect wiring harness connector R12 4) Sling diverter valve assembly (14),
(1). remove its mounting bolts, and lift it off.
2) Remove suction tube (2).

3) Disconnect hoses (3), (4), (5) and (6). Installation
4) Sling diverter valve assembly (7), remove
its mounting bolts, and lift it off. q Carry out installation in the reverse order to
removal.
q Refilling with oil (Hydraulic tank)

again.
q Bleeding air
30-36 WA1200-3
(12)
STEERING PUMP AND CONTROL PUMP AND PPC
DISASSEMBLY AND ASSEMBLY PUMP ASSEMBLY

steering pump and control pump
and PPC pump assembly 1
removal.
Removal
[*1]
3
the bucket to the ground, apply the parking 455 – 565 Nm {46.5 – 58 kgm}
k Loosen the oil filler cap to release the pres- q Refilling with oil (Hydraulic tank)
sure in the hydraulic tank. Add oil through the oil filler to the specified
1. Drain the hydraulic oil. through the system. Then, check the oil level
again.
q Bleeding air
2. Open the upper step cover. Bleed air from the piston pump and work
3. Disconnect hoses (1) and (2). adjusting, "Bleeding air from each part".
4. Disconnect tubes (3), (4), (5) and (6).
5. Remove clamp (7) and disconnect hose (8).
7. Disconnect suction tube (10).
8. Sling pump assembly (11), remove its mount-

4 Pump assembly: 195 kg
WA1200-3 30-37
(12)
DISASSEMBLY AND ASSEMBLY SWITCHING PUMP ASSEMBLY

switching pump assembly 1
Removal removal.
k Stop the machine on a level ground, lower [*1]

the bucket to the ground, apply the parking 3 Pump assembly mounting bolt:
brake, and lock the tires with chocks. 455 – 565 Nm {46.5 – 58 kgm}
sure in the hydraulic tank. q Refilling with oil (Hydraulic tank)
1. Drain the hydraulic oil. level. Run the engine to circulate the oil
6 Hydraulic oil: Approx. 1,125 l again.
2. Open the upper step cover. q Bleeding air

3. Disconnect hoses (1) and (2). equipment circuit. For details, see Testing and
5. Remove U-bolt (5) and disconnect suction tube

(6).
8. Sling switching pump assembly (10), remove

its mounting bolts, and lift it off. [*1]
4 Switching pump assembly: 190 kg
30-38 WA1200-3
(12)
TRANSMISSION AND BRAKE COOLING AND
DISASSEMBLY AND ASSEMBLY BRAKE PUMP ASSEMBLY

transmission and brake cooling
and brake pump assembly 1
removal.
Removal
[*1]
3
the bucket to the ground, apply the parking 98 – 123 Nm {10.0 – 12.5 kgm}
1. Drain the oil from the brake oil tank. Add oil through the oil filler to the specified
level.
q Bleeding air
2. Open the upper step cover. Referring to Testing and adjusting, "Bleeding
air from each part", bleed air from the wheel
3. Disconnect hose (1) and tube (2). brake circuit. Then, check the oil level again.
4. Disconnect hose (3) and tube (4).
7. Sling pump assembly (9), remove its mounting

bolts, and lift it off. [*1]
4 Pump assembly: 75 kg
WA1200-3 30-39
(12)
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT CONTROL VALVE ASSEMBLY
Removal and installation of work 4. Remove the center work equipment valve
equipment control valve assembly according to the following proce-
dure.
assembly 1
1) Remove tubes (13), (14), (15), (16), (17)
and (18).
Removal
2) Disconnect hoses (19), (20), (21) and
k
(22).
Stop the machine on a level ground, lower
3) Remove the 3 mounting bolts of valve
assembly (23) and lift off the valve assem-
k
bly. [*2]
Loosen the oil filler cap to release the pres-
sure in the hydraulic tank. 4 Center work equipment valve assembly:
95 kg
2. Remove front frame cover (1).
5. Remove the rear work equipment valve

assembly according to the following proce-
dure.
1) Referring to "Removal of center work
equipment valve assembly", remove the
3. Remove the front work equipment valve
tubes.
assembly according to the following proce-
2) Remove tubes (24), (25) and (26).
dure.
3) Remove the U-bolt, bracket (27) and tube
1) Remove tubes (2), (3), (4), (5), (6) and (7).
(28).
2) Disconnect hoses (8), (9), (10), and (11).
4) Disconnect hose (29).
5) Disconnect hoses (30), (31) and (32).
assembly (12) and lift off the valve assem-
bly. [*1]
assembly (33) and lift off the valve. [*3]
4
4
Front work equipment valve assembly:
Rear work equipment valve assembly:
95 kg
95 kg
30-40 WA1200-3
(12)
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT CONTROL VALVE ASSEMBLY
Installation

removal.
[*1], [*2], [*3]

3 Work equipment valve assembly mounting
bolt: 235 – 285 Nm {23.5 – 29.5 kgm}

again.
q Bleeding air
WA1200-3 30-41
(12)
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT PUMP ASSEMBLY (RIGHT SIDE)
Removal and installation of work 4. Remove U-bolt (8).

equipment pump assembly (Right
5. Disconnect suction tube (9).
side) 1
Removal


2. Open the upper step cover and remove step

(1). 6. Disconnect hoses (10) and (11).
7. Sling work equipment pump assembly (12),

remove its mounting bolts, and lift it off. [*1]
4 Work equipment pump assembly:
195 kg
3. Disconnect hoses (2), (3), (4), (5), (6) and (7).
Installation

removal.
[*1]
3 Pump assembly mounting bolt:
455 – 565 Nm {46.5 – 58 kgm}

again.
q Bleeding air
30-42 WA1200-3
(12)
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT PUMP ASSEMBLY (LEFT SIDE)
Removal and installation of work

equipment pump assembly (Left
side) 1
Removal


Installation
2. Open the upper step cover.
3. Disconnect hoses (1), (2), (3), (4) and (5). removal.
4. Disconnect tubes (6) and (7). [*1]

3 Pump assembly mounting bolt:
5. Disconnect pump outlet hoses (8) and (9). 455 – 565 Nm {46.5 – 58 kgm}
6. Disconnect suction tube (10). q Refilling with oil (Hydraulic tank)

7. Sling work equipment pump assembly (11), level. Run the engine to circulate the oil
remove its mounting bolts, and lift it off. [*1] through the system. Then, check the oil level
again.
4 Work equipment pump assembly:
170 kg q Bleeding air
WA1200-3 30-43
(12)
DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK AND FILTER CASE ASSEMBLY
Removal and installation of 6. Disconnect hydraulic oil temperature sensor

hydraulic tank and filter case connector HJ1 (6).
assembly 1
7. Remove couplings (7) and (8).
Removal
8. Sling suction tube (9), disconnect bracket (10),
k
and remove the suction tube.
Stop the machine on a level ground, lower

2. Lift off handrails (1) and (2).
3. Lift of step (3).
4. Sling ladder (4), remove its mounting bolts,

and lift it off. 10. Disconnect tubes (13), (14) and (15).
4 Ladder: 75 kg
5. Remove cover (5).
30-44 WA1200-3
(12)
DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK AND FILTER CASE ASSEMBLY
11. Disconnect hoses (16), (17) and (18). Installation

12. Disconnect tube (19) from the intermediate q Carry out installation in the reverse order to
joint. removal.
13. Sling hydraulic tank and filter case assembly [*1]

(20), remove its mounting bolts (21), and lift it 3 Hydraulic tank mounting bolt:
off. [*1] 824 – 1,030 Nm {84 – 105 kgm}
4 Hydraulic tank and filter case assembly:
1,370 kg q Refilling with oil (Hydraulic tank)
again.
q Bleeding air
WA1200-3 30-45
(12)
DISASSEMBLY AND ASSEMBLY BUCKET CYLINDER ASSEMBLY
Removal and installation of 6. Disconnect wiring harness connector F13 (8).

bucket cylinder assembly 1
Removal
8. Remove 4 mounting bolts (11) and cover (12).
the bucket to the ground, apply the parking 9. Remove 4 mounting bolts (13) and pull out pin
brake, and lock the tires with chocks. (14). [*3]
terminal of the battery. 10. Remove bucket control cylinder assembly (1).
4 Bucket control cylinder assembly:
1. Sling bucket cylinder assembly (1). 1,400 kg
2. Remove 4 mounting bolts (2) and cover (3). 11. Remove collars (15) and (16). [*4]
3. Remove 4 mounting bolts (4) and pull out pin

(5). [*1]
4. Start the engine and retract the piston rod.

k After retracting the piston rod, stop the
engine and release the residual pres-
sure in the piping.
5. Remove collars (6) and (7). [*2]
30-46 WA1200-3
(12)
DISASSEMBLY AND ASSEMBLY BUCKET CYLINDER ASSEMBLY
Installation

removal.
[*1] [*3]
a Do not drive in the pin with a hammer to pre-
vent the seal of the collar from falling.
[*2] [*4]
a When installing the bucket cylinder, retract the
collar. (If it is projected, it can scratch the
seal.)
a Take care of the installed direction of the dust
seal.
q Refilling with oil (Pin)

For refilling the oil lubricated pin with oil, see
"Assembly procedure for oil lubricated pin".

Run the engine to circulate the oil through the
cylinders and piping. Then, add oil through the
oil filler to the specified level.
WA1200-3 30-47
(12)
DISASSEMBLY AND ASSEMBLY LIFT CYLINDER ASSEMBLY
Removal and installation of lift 4. Sling lift cylinder assembly (2).

cylinder assembly 1
Removal
k Stop the machine on a level ground, lower (6). [*1]
brake, and lock the tires with chocks. 7. Start the engine and retract the piston rod.
1. Remove the bucket. For details, see "Removal engine and release the residual pres-
and installation of work equipment assembly". sure in the piping.
2. Lift off fender (1). 8. Remove collars (7) and (8). [*2]
4 Fender: 140 kg
3. Raise the lift arm to a position where the lift cyl-

inder head pin can be pulled out and then set
stand [1].
k Stop the engine and lower the lift arm
slowly to eliminate the load on the lift
cylinder. Loosen the hydraulic tank
cap gradually to release the residual
pressure in the tank.

(14). [*3]
12. Start the engine and retract the piston rod.

engine and release the residual pres-
sure in the piping.
30-48 WA1200-3
(12)
DISASSEMBLY AND ASSEMBLY LIFT CYLINDER ASSEMBLY
13. Remove collars (15) and (16). [*4] Installation

14. Lift off lift cylinder assembly (2). q Carry out installation in the reverse order to
4 Lift cylinder assembly: 2,950 kg removal.
[*1] [*3]
[*2] [*4]
a When installing the lift cylinder, retract the col-
lar. (If it is projected, it can scratch the seal.)
seal.


WA1200-3 30-49
(12)
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT ASSEMBLY
Removal and installation of work

equipment assembly 1
Removal

k Loosen the oil filler cap to release the resid-
ual pressure in the hydraulic tank, and then
operate the work control lever 2 – 3 times to
release the residual pressure in the piping.
1. Sling link (1).

3. Remove 4 mounting bolts (4) and pull out pin (17). [*5]
(5). [*1]
13. Remove the other pin according to steps 10 –
5. Remove 4 mounting bolts (8) and cover (9). 12.
6. Remove 4 mounting bolts (10) and pull out pin 14. Remove bucket (21).
4
(11). [*3] Bucket: 23,840 kg
7. Remove link (1).
4 Link: 650 kg
9. Remove the other link according to steps 1 – 8.
30-50 WA1200-3
(12)
15. Put a block between the bell crank and lift arm 21. Sling bell crank (29).
to fix the bell crank.
a If the bucket cylinder pin is pulled out, the 22. Remove 4 mounting bolts (30) and cover (31).
bell crank falls. Accordingly, be sure to fix
the bell crank. 23. Remove 4 mounting bolts (32) and pull out pin
(33). [*9]
16. Sling bucket cylinder (22).
25. Lift off bell crank (29).
4
Bell crank: 2,440 kg
(26). [*7]
a After removing the pin, put a block
between the cylinder bottom and frame to 26. Remove the other bell crank according to
fix the cylinder. steps 21 – 25.
20. Pull out the pin on the other cylinder piston rod
side according to steps 15 – 19.
WA1200-3 30-51
(12)
27. Sling lift cylinder (36).

(40). [*11]
a After removing the pin, put a block
between the cylinder and frame to fix the
cylinder.
31. Pull out the pin on the other cylinder piston rod
side according to steps 20 – 30.
36. Sling lift arm (49).

(53). [*15]
40. Pull out the other pin according to steps 36 –

39.
41. Lift off lift arm (49).

4 Lift arm: 18,320 kg
32. Remove cover (43).
33. Remove proximity switch (44). [*13]
34. Disconnect wiring harness connectors F04

(45) and F05 (46) and remove clamp (47).
35. Remove kick-out positioner assembly (48).

[*14]
30-52 WA1200-3
(12)
Installation

removal.
[*1] [*3] [*5] [*7] [*9] [*11] [*15]

[*2] [*4] [*6] [*8] [*10] [*12] [*16]

a When installing the lift cylinder, retract the col-
lar. (If it is projected, it can scratch the seal.)
seal.
[*13]
Adjust the proximity switch. For details, see Testing
and adjusting, "Adjusting boom level sensor
switch".
[*14]
Adjust the boom potentiometer. For details, see
Testing and adjusting, "Adjusting boom potentiome-
ter".


WA1200-3 30-53
(12)
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER UNIT ASSEMBLY
Removal and installation of air 5. Remove case (2).

conditioner unit assembly 1
6. Remove covers (3), (4), (5) and (6).
Special tools
7. Remove console box (7).
Necessity
Symbol
Sketch
Q’ty
N/R
Part number Part name
799-703-1200 Service tool kit t 1

Vacuum pump
799-703-1100 t 1
(100 V)
Vacuum pump
X 1 799-703-1111 t 1
(220 V)
Vacuum pump
799-703-1121 t 1
(240 V)
799-703-1401 Gas leak detector t 1
8. Disconnect wiring harness connectors A8A (8),

Removal A8B (9), A6 (10), A7 (11), A5 (12), A14 (13)
and A15 (14).
the bucket to the ground, apply the parking 9. Disconnect wiring harness clamps (15) and
brake, and lock the tires with chocks. (16).
1. Using tool X1, collect the air conditioner refrig-

erant.
2. Remove the ROPS. For details, see "Removal

and installation of operator's cab and floor
assembly".
3. Remove the operator's cab assembly. For

details, see "Removal and installation of opera-
tor's cab assembly".
4. Remove the mounting bolts and lift off opera-

tor's seat assembly (1).
4 Operator's seat assembly: 55 kg
30-54 WA1200-3
(12)
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER UNIT ASSEMBLY
10. Disconnect heater hoses (17) and (18). Installation

11. Disconnect air conditioner hoses (19) and (20). q Carry out installation in the reverse order to
[*1] removal.
12. Remove the mounting bolts of air conditioner [*1]

unit assembly (21) and lift off the air condi- 2 O-ring (Fitted to flange coupling part):
tioner unit assembly (21). Apply compressor oil (ND-OIL8)
4 Air conditioner unit assembly: 55 kg for new refrigerant.
q Precautions for charging air conditioner

with refrigerant
1) Keep the ambient temperature above 3°C.
(If the ambient temperature is below 3°C,
the system does not operate.)
2) Use Freon gas (R134a) as refrigerant.
3) Before charging the air conditioner with
refrigerant, be sure to evacuate it suffi-
ciently by repeated evacuation method.
(The degree of vacuum must be –100 kPa
{–750 mm Hg} or higher.)
4) The standard quantity of refrigerant is 1.3
– 1.5 kg.
5) Take care that the Freon liquid will not
enter the refrigeration system from the
refrigerant can reversed by mistake.
6) Do not operate the compressor before
charging the air conditioner system with
the refrigerant.
WA1200-3 30-55
(12)
DISASSEMBLY AND ASSEMBLY OPERATOR’S CAB AND FLOOR ASSEMBLY
Removal and installation of 5. Disconnect antenna wiring harness connector

operator's cab and floor assembly1 C25.
Removal 6. Sling ROPS (6), remove mounting bolts (7),

and lift off the ROPS. [*1]
k Stop the machine on a level ground, lower 4 ROPS: 3,240 kg
1. Lift off handrail (1).
2. Sling cover (2), remove its 8 mounting bolts,

and lift it off.
7. Disconnect air conditioner hoses (8) and (9).
8. Disconnect wiring harness connectors FR1,

FR2, LR1, LR2, LR3, FL1 and FL2 (10).
9. Disconnect wiring harness connectors LR4,

LR5, LR6, LR7, LR8 and LR9 (11).
3. Remove covers (3) and (4). 10. Disconnect wiring harness connectors CE1
(12) and CAB (13).
4. Remove condenser upper cover (5).
30-56 WA1200-3
(12)
11. Disconnect wiring harness connector L30 (14). 14. Disconnect pilot valve hoses (23), (24), (25),
(26) and (27).

13. Disconnect PPC valve hoses (17), (18), (19),

(20), (21) and (22). 16. Disconnect joint (29).
WA1200-3 30-57
(12)
17. Disconnect window washer hose (30). Installation

removal.
[*1]
3 ROPS mounting bolt:
5,000 ± 10% Nm {510 ± 10% kgm}
[*2]
3 Operator's cab and floor mounting nut:
245 – 309 Nm {25.0 – 31.5 kgm}
18. Remove 4 cab mounting nuts (31).
19. Lift off operator's cab assembly and floor (32).

a When removing the operator's cab and
floor assembly, check that all the pipings
and wiring harnesses are disconnected.
4 Operator's cab and floor assembly:
540 kg
30-58 WA1200-3
(12)
DISASSEMBLY AND ASSEMBLY OPERATOR'S CAB ASSEMBLY
Removal and installation of 5. Remove the mounting bolts of operator's cab

operator's cab assembly 1
assembly (3) and lift up the operator's cab
assembly gradually to remove.
Removal a When removing the operator's cab assem-
bly, check that all the pipings and wiring
k Stop the machine on a level ground, lower harnesses are disconnected.
the bucket to the ground, apply the parking 4 Operator's cab assembly: 540 kg
1. Remove the ROPS. For details, see "Removal

and installation of operator's cab and floor
assembly".
2. Remove the cab bottom cover.
3. Disconnect 3 washer hoses (1) inside the cab.
Installation

removal.

Supply coolant into the washer tank up to the
specified level.
4. Disconnect 7 wiring harness connectors CL1,

CL2, CL3, GND1, GND2, OP4A and OP5A (2).
WA1200-3 30-59
(12)
DISASSEMBLY AND ASSEMBLY CONTROLLER ASSEMBLIES
Removal and installation of q VSM controller assembly

controller assemblies 1
5. Remove controller front cover (7).
Removal

q Transmission controller assembly

MOD/C controller assembly
Work equipment and joystick steering control-
ler assembly
1. Remove covers (1), (2) and (3).

6. Disconnect wiring harness connectors V1,
V2A, V2B, V3A, V3B, V4A and V4B and
remove the mounting bolts and VSM controller
assembly (8).
2. Disconnect wiring harness connectors C1, C2,

C3A, C3B, C4 and C5 and remove the mount-
ing bolts and transmission controller assembly
(4).
q Engine controller assembly
3. Disconnect wiring harness connectors M01,
M02A and M02B and remove the mounting 7. Disconnect fuel hoses (9) and (10).
bolts and MOD/C controller assembly (5).
8. Disconnect wiring harness connectors (11) and
4. Disconnect wiring harness connectors L26, (12) and remove the mounting bolts and
L27 and L28 and remove the mounting bolts engine controller assembly (13).
and work equipment and joystick steering con-
troller assembly (6).
30-60 WA1200-3
(12)
DISASSEMBLY AND ASSEMBLY CONTROLLER ASSEMBLIES
Installation

removal.
WA1200-3 30-61
(12)

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What components does the manual cover removal and installation instructions for?

What components does the manual cover removal and installation instructions for?

What are the steps to remove the operator's cab assembly?

What are the steps to remove the operator's cab assembly?

30 DISASSEMBLY AND ASSEMBLY 1

How to read this manual ............................................................................................................................ 30-2

How to read this manual 1

1. Removal and installation of assemblies

Special tools Removal

2. Disassembly and assembly of assemblies Disassembly

a General tools that are necessary for

Coating materials list 1

LM-G 09940-00051 60 g Can

(to prevent squeaking)

SUNSTAR • Used as primer for cab side.

• Used as primer for painted surface on cab

tainer (Using limit: 4 months after date of manu-

SUNSTAR • “S” is used for high-temperature season

Polyethyl- • Used as adhesive for glass.

Adhesive for cab glass

SEKISUI SILI- Polyethyl- • Used to seal front window.

Removal and installation of hood Installation

k Stop the machine on a level ground, lower [*1]

2. Lift off 2 exhaust pipes (3).

3. Remove right and left side covers (4).

4. Remove the mounting bolts and lift off hood

5. Lift off right and left brackets (6). [*2]

Removal and installation of 7. Disconnect radiator outlet tube (6).

9. Disconnect hose clamp (8).

k Stop the machine on a level ground, lower

1. Drain the coolant.

2. Remove the hood assembly. For details, see

3. Open grille (1). 10. Disconnect connector (GR6) of coolant level

4 Radiator guard: 905 kg 13. Remove brackets (13) and (14).

14. Loosen the hose clamp on the radiator side

6. Disconnect 2 hydraulic oil cooler pipings (5).

15. Remove fan pulley cover (19). Installation

Removal and installation of fuel Installation

k Stop the machine on a level ground, lower

1. Lift off mask (1).

2. Remove front cover (2) and rear cover (3).

3. Remove top cover (4), bottom cover (5), front

4. Disconnect tubes (8) and (9) and disconnect

5. Disconnect tubes (11) and (12).

6. Sling fuel cooler assembly (13), remove its

Removal and installation of Installation

1. Drain the coolant. q Refilling with coolant

3. Disconnect hoses (3) and (4).

4. Remove tubes (5) and (6).

5. Sling the right and left ends of torque converter

Removal and installation of 7. Disconnect hoses (7) and (8).

1. Drain the coolant.

2. Drain the engine oil.

3. Remove the hood assembly. For details, see

25. Remove hose clamp (35) and disconnect

26. Disconnect hose (38).

27. Remove hose (39).

28. Remove the hose clamp and disconnect hose

29. Disconnect hose (41).