Komatsu GALEO WA700-3 User manual

CONTENTS
1. Drawings of removed units ..................................................................................... 1
2. Dimensions of removed units ................................................................................. 2
3. Transportation of removed units ............................................................................. 3
4. Assembly procedure, necessary equipment, and schedule ................................... 4
5. Layout of work space.............................................................................................. 5
6. Necessary tools and equipments............................................................................ 6
7. Assembly procedure
A-0 Positioning front and rear axles and bare machine........................................ 12
A-1 Positioning chassis on bare machine (Frame stand) ..................................... 13
A-2 Installing rear axle .......................................................................................... 15
A-3 Installing rear drive shaft ................................................................................ 20
A-4 Installing front axle assembly ......................................................................... 21
A-5 Installing front drive shaft ............................................................................... 23
A-6 Installing rear tires and wheel assembly ........................................................ 24
A-7 Installing front tires and wheel assembly........................................................ 25
A-8 Installing bucket.............................................................................................. 26
A-9 Installing cab assembly .................................................................................. 31
A-10 Installing ROPS canopy assembly ................................................................. 38
A-11 Installing front lamp assembly ........................................................................ 40
A-12 Installing floor handrail assembly (right)......................................................... 41
A-13 Installing muffler stack.................................................................................... 42
A-14 Installing counterweight.................................................................................. 43
A-15 Installing ladder assembly .............................................................................. 45
A-16 Installing front fender...................................................................................... 46
A-17 Installing floor handrail and rear access step................................................. 47
A-18 Installing floor mat .......................................................................................... 53
M-1 Bleeding air from brake line............................................................................ 54
M-2 Greasing work equipment and chassis .......................................................... 55
M-3 Adjusting bucket positioner ............................................................................ 56
M-4 Adjusting boom kick-out ................................................................................. 57
M-5 Inspection of all parts ..................................................................................... 58
M-6 Starting engine ............................................................................................... 59
M-7 Bleeding air from piston pump........................................................................ 61
M-8 Bleeding air from work equipment hydraulic circuit ........................................ 62
Appendix
Field assembly inspection report

1
1. Drawings of removed units
1. Front axle assembly
5. Cab assembly
9. Muffler stack
12. Ladder assembly
16. Bucket mounting lock pin 17. Floor mat 18. Bare machine
13. Front fender (1 piece) 15. Step assembly14. Front drive shaft
Installed to center support
10. Counterweight 11. Rear drive shaft
6. ROPS canopy assembly 7. Floor handrail and rear
access step assembly 8. Front lamp assembly (1 piece)
3. Wheel and tire assembly 4. Bucket assembly2. Rear axle assembly
(Axle support)

2
2. Dimensions of removed units
Completed machine – (1 + 2 + ······ 17)
Unit name Weight (kg) Overall length
L (mm)
Overall width
W (mm)
Overall height
H (mm)
1 Front axle assembly 5,532 3,832 1,256 925
2Rear axle assembly
(Axle support)
5,454
(331) 3,832 1,351 872
3 Wheel and tire assembly (×1) 9,948
(2,487) 4,080 2,420 2,420
4 Bucket assembly 7,090 4,564 2,535 2,116
5 Cab assembly 449 1,757 1,480 1,639
6 ROPS canopy assembly 1,050 1,692 2,345 2,000
7 Floor handrail and rear access step assembly 400
8 Front lamp assembly 74
(37) 1,200 800 300
9 Muffler stack 21 1,251 370 370
10 Counterweight 2,510 2,790 634 580
11 Rear drive shaft 83 730 302 302
12 Ladder assembly 36 2,050 650 350
13 Front fender (1 piece) 162
(81) 1,400 1,330 1,100
14 Front drive shaft 112 950 300 300
15 Step assembly 36
(18) 760 360 360
16 Bucket mounting lock pin (1 piece) 243
(81) 493 480 160
17 Floor mat 11 1,203 1,286 18
18 Bare machine 37,589 10,800 3,200 3,350

3
3. Transportation of removed units
Land transportation
Specification
Related specifications Means of transportation and necessary work
for transportation
Weight (ton) Overall length
(mm)
Overall width
(mm)
Overall height
(mm)
Self-propelled travel 70.8
(Operating weight)
12,500 4,040
(Bucket width)
4,790
(Top of ROPS)
Transportation on trailer (Bare machine)
10,800 3,200 3,350
35-ton trailer ×1 [Chassis, excluding following
parts to be removed]
15-ton trailers ×3 [Bucket, front axle, rear
axle, (including swivel support), tires and
rims, cab assembly,
Exterior parts (handrail, light support),
counterweight, rear drive shaft, exhaust pipe,
ROPS support.]
Restrictions
Self-
propelled
travel
Less than 20 ton More than 12 m Less than 2.5 m Less than 3.8 m
Trailer Hauling capacity Machine length
× 1.1 Trailer width Less than 3.8 m
Self-propelled travel
Transportation on trailer
(Without wood block)
(Reference) Trailer dimensions
JIS posture for self-propelled travel (with claws)
Set wood block under front and rear frame
support to prevent the trailer body from
interfering with fuel tank, if necessary.
Type
A Overall length mm 11,900
B Length of carrier mm 6,300
C Length of gooseneck mm 2,500
Width of carrier mm 3,200
Hauling capacity ton 36

4
4. Assembly precedure, necessary equipment and schedule
1 2 3 4 5 6 7 8 91011121314151617181920212223
A
ssembly procedure, necessary equipment, and schedule Encircled Nos. are names of removed units.
Day
Hour 1st day 2nd day 3rd day
Assembly unit
Assembly procedure No.
Crane
(Hydraulic, with operator)
Air compressor
Number of workers
Forklift
Remarks
(Operator included in number of workers above)
A - 0 A - 1 A - 2 to 5,7 A- 6, 9, 12, 15 A - 13, 14, 16
M - 1 A - 10, 11, 17
M - 2, 5 A - 8, 18
M - 2, 3, 4
Maintenance (Adjustment) No.
Positioning front and rear axles
Positioning chassis on bare machine
Positioning bare machine on front and rear axles and stand
Rear axles assembly Cab assembly Counterweight Front lamp assembly Bucket assembly
Floor mat Bucket MTG lockpin
ROPS canopy assembly Handrail & rear access step
Muffer stack Front fender
Bleeding air from brake line Check oil, water levels,
add oil and water
Adjusting bucket positioner, boom kick-out Check all parts for oil leakage Checking functions Cleaning machine
Starting engine Greasing work equipment and chassis
Tighten wheel mounting nuts to specified torque
Floor handrail Wheel & tire assembly (Rear wheel & tire) Ladder assembly
Front axles assembly (F tire & wheel assembly) F · R drive shaft
30 t 45 t
(1 unit)
30 ton crane (20 ton crane OK)
(Previous experience has shown that using a forklift truck is more efficient, so we strongly recommend use of a forklift truck)
(KOMATSU EC35ZS or equivalent)
5 persons
2 t
Meeting before work Unloading Starting assembly
Removing wood blocks Starting engine Completion of assembly

5
5. Layout of work space
The wider the work space is, the more easily you can work.
At least the following space 25m × 30m is necessary.
Bucket assembly Front axle assembly Rear axle assembly
Wheel and tire
assembly
Bare machine
45-ton crane
30-ton crane
Cab assembly
Counterweight
ROPS canopy assembly
Place for keeping compressor,
parts and tools
Place for keeping
light units.

6
6. Necessary tools and equipments
(1) Necessary tools
No. Tool name Specification Q’ty Remarks
1 General standard tools
Spanner, ring wrench, socket wrench,
chisel, screwdriver, hammer, adjustable
wrench, Hexagonal wrench, etc.
2
2 Power wrench 16-time 1 Front and rear axle mounts,
ROPS canopy mount
4 Socket 60 (Insertion angle: 38.1), L: 84 1 For front and rear axle mounts
5 Socket 36 (Insertion angle: 25.4), L: 63 1
7 Socket 46 (Insertion angle: 38.1), L: 82 1 ROPS mount
8 Socket 46 (Insertion angle: 25.4), L: 82 1 ROPS mount
9 Extension bar Insertion angle: 12.7, L: 150 1
10 Adapter Insertion angle: 19, 12.7, L: 55 1
11 Extension bar Insertion angle: 25.4, L: 160 1 For tire, counterweight,
and ROPS canopy
12 Preset-type torque wrench (socket type) 39.2 – 274.6 Nm {4 – 28 kgm} 1 For power wrench
13 Preset-type torque wrench with
replaceable head 58.8 – 137.3 Nm {6 – 14 kgm} 1 For connecting hose/tube
14 Preset-type torque wrench with
replaceable head 19.6 – 44.1 Nm {2 – 4.5 kgm} 1 For connecting hose/tube
15 Preset-type torque wrench with
replaceable head 29.4 – 682.6 Nm {3 – 7 kgm} 1 For connecting hose/tube
16 Preset-type torque wrench with
replaceable head (for spanner)
Width across flats: 27(Socket:ø15),
19 (Socket:ø12), 22(Socket:ø12),
24 (Socket:ø12)
1 each For connecting hose/tube
17 Preset-type torque wrench (socket type) 196.1 – 1372.9 Nm {20 – 140 kgm} 1
18 Preset-type torque wrench (socket type) 490.3 – 2059.4 Nm {50 – 210 kgm} 1
19 Preset-type torque wrench (socket type) 58.8 – 411.9 Nm {6 – 42 kgm} 1
20 Impact wrench GT-P8M or equivalent 1
21 Impact wrench GT-P14M or equivalent 1
22 Impact wrench GT-S22M or equivalent 1 For tire and ROPS canopy
23 Adapter Insertion angle: 19, 25.4, L: 71 1 For power wrench and torque wrench
24 Adapter Insertion angle: 12.7, 9.5, L41 1 For power wrench and torque wrench
25 Large hammer 10 lb 1
26 Pneumatic grinder — 1
27 Bar Large, medium, and small 2 each For adjusting hole moving heavy part
28 Pointed steel bar — 2 For adjusting hole
29 Grease gun (Hand pomp type) Capacity: About 300 cc 1 Filling pin with oil
30 Oil pitcher Capacity: About 1,000 – 2,000 cc 1 Bleeding air from brake line
31 Vinyl hose
Inside diameter:
ø6.5
– ø7.0, L:1,000 – 1,500
1 Bleeding air from brake line
32 Engine tachometer Digital 1
33 Cleaning pan — 1
34 Air gun — 1 Using after cleaning bolts and nuts

7
(2) Necessary slings
No. Sling name Specification Q’ty Remarks
1 Front frame sling 2-point sling (L:2,250, Chain diameter:
ø20, Sling hook) (SL) 1 See figure below
2 Rear frame sling Balance 2-point sling (Chain diameter:
ø20, Sling hook) (SL) 1 See figure below
3 Rear axle sling 2-point sling (L:5,500, Chain diameter:
ø16, Crab hook) (G) 1 See figure below
4 Nylon sling 50 × 2,000 2 Holding axle support and cylinder
5 Front/Rear axle sling
Balance 2-point sling
(Chain diameter: ø16, Sling hook(SL))
(Chain diameter: ø12.5, Crab hook(SL))
1 See figure below
6 Drive shaft nylon sling 50 × 5,000 1
7 Cab assembly sling 2-point sling (L:2,000, Chain diameter:
ø6.3, Sling hook(SL)) 2 See figure below
8 Nylon sling 150 × 10,000 1 Tire sling.
Wire ropes may be used (for 3.5 t).
9 Wire sling Capacity: 147 kN {15 t}, L = 2,500
Capacity: 107.8 kN {11 t}, L = 2,000
2
1
Removing wood block from chassis
(Raising front)
Lift arm sling
10 Shackle For 2 ton, 5 ton, 10 ton, and 15 ton 2 each
Chain diameter Chain diameter
Chain diameter
Chain diameter
2. Rear frame sling
Chain diameter
Chain diameter
1. Front frame sling
3. Rear axle sling
5. Front/Rear axle sling
7. Cab assembly sling
Drawing No. AS-00296
See attached drawing
See attached drawing
Drawing No. AS-00059

8
(3) Necessary equipment
(4) Oils, greases, etc.
No. Tool name Specification Q’ty Remarks
1
Crane
Min. 45 ton 1
2 Min. 30 ton 1
3 Forklift Min. 2 ton 1 Unloading relatively light components
and parts
4 Compressor Capacity: Min. 32 l1Impact wrench, bleeding air from
brake system
5 Lever block 1 ton 3 For cylinder and drive shaft
6 Stepladder (Work bench) 4 steps (About 1.6 m) 3 For work
7 Steel plate (t) 9 × 1219 × 2438 4 For positioning bare machine
8 Steel plate (t) 25 × 250 × 600 4 For positioning bare machine
9 Wood block 400 × 400 × 900
200 × 400 × 800
14
4For positioning bare machine
10 Pneumatic grease gun Capacity: 18 l1
11 Air conditioner refrigerant charger Gauge manifold, leak tester 1 If there is refrigerant charger, use it
according to its instruction manual.
12 Circuit tester 1
13 Sunshade sheet For parts and tools 2 (Approx. 5 m wide)
No. Oil / Grease Specification Remarks
1Extreme pressure molybdenum disulfide
grease (KES LM-P) 500 ml
2 Molybdenum disulphide lithium grease (KES LM-G) 10 l
3 Fuel Diesel fuel Proper quantity (Full: 1,100 l)
4 Touchup paint Natural yellow
Cloud gray
5 Protection wear Work clothes, safety boots, helmet,
cotton gloves, goggles, and raincoat
6 Windshield washer fluid Product of SEIKEN KAGAKU 1 lcan × 2
7 Cleaning with trichloroethylene, 20 lCleaning removed parts

9
Axle sling
AS-0059 SS419
STS41 1
Drawing No. Material Q'ty

10

11
Note
1. Attach inspection result sheet.
2. Paint colored numbers in M15-308 (yellow).
Part No. Part Name Material Q’ty Applicable
1 Balance SS400 1
2 Lifting tool D 1 VD250
3 Connecting tool B 2 VB200
4 Shackle N 8 VN200
5 Lifting tool E 4 VE200
6 Link chain 4 SV200, L = 3.5 m
7 Link chain 4 SV200, L = 1.5 m
8 Shackle JIS 2 BB55
101 Sling hook 2 OKN-26-8
102 Shackle JIS 4 BB50
103 Lifting tool D 4 VD200
104 Link chain 4 SV200, L = 1.5 m
Drawing No. AS-00296

12
Work procedure
1. Position the front axle assembly and rear axle assembly (having the axle support) to the wheelbase of 4,800 mm in the
body assembly area as shown in Fig. 1 above.
2. Sling the bare machine of the front and rear frames with 2 cranes and position it onto the frame and rear axles. (Fig. 2)
For the procedure for positioning the bare machine, see assembly procedure “A-1 (1/2)”.
3. Sling the rear axle assembly (having the axle support) with the crane and mount it onto the rear frame.
4. Sling the front axle assembly with the crane and mount it onto the front frame.
For the detailed procedure for mounting the front and rear axle assemblies, see assembly procedure “A-2 (2/4) to A-4 (2/2)”.
Assembly procedure No.
Positioning front and rear axles and bare machine
A-0
Precautions Necessary tools Necessary equipment
Name Q’ty Name Q’ty
Others
Positioning front and
rear axles
Positioning bare
machine on supports
Ground
Set dimension 4,800m
Wheelbase
Steel plate Steel plate
Fig. 1
Fig. 2
30-ton crane 45-ton crane
Frame assembly stand
Mount onto counterweight
mounting end plate.

13
Set the bare machine as shown above. (Raise from the ground the amount shown in the diagram so that the wheel and tire
assemblies can be installed.)
When setting on an earth surface, put steel plates under the wooden blocks to prevent the bare machine from sinking into the
ground or from tilting to one side. Use three steel sheets. (One sheet is for sling the rear axle to the side.)
Assembly procedure No.
Positioning chassis on bare machine (Frame stand) (1/2)
A-1
Precautions Necessary tools Necessary equipment
Name Q’ty Name Q’ty
Impact wrench 1 30 ton crane 1
Socket: 60 mm 1 45 ton crane 1
Steel plate t9 × 1219 × 2438 3
t25 × 250 × 600 4
Wood block 400 × 400 × 700 14
200 × 400 × 800 4
Others
30 ton crane 45 ton crane
Front frame
Hanging load: 18 ton
Crane: 30 ton
Rear frame
Hanging load: 18 ton
Crane: 30 ton
Chain diameter
Chain diameter
Chain diameter
Movement
Using lifting eyes of front and rear frames,
sling bare machine with 2 cranes having
capacities of 30 ton and 45 ton.
Axle support mounting bolts are used for positioning.
After removing them, use them for work inA-2 (1/5).
(Use only 2 pieces)

14
Assembly procedure No.
Positioning chassis on bare machine (Frame stand) (2/2)
A-1
Precautions Necessary tools Necessary equipment
Name Q’ty Name Q’ty
Others

15
Assembly procedure No.
Installing rear axle (1/5)
A-2
Precautions Necessary tools Necessary equipment
Name Q’ty Name Q’ty
Power wrench (×16) 1 30 ton crane 1
Torque wrench (Set: 215.7 Nm {22 kgm}) 1 For rear axle sling 1
Socket: 60 mm 1 (Lifting capacity: Min. 6 ton)
Socket: 30 mm 1
Others
Mounting bolt
Rear frame
AJ-T01-004
Upper stand
(Special for disassembly)
F/T
01643-33690 (×2)
01011-63650 (×2)
Clean pivot packing in rear frame
axle support (front) and inside of
seal with cloths, and then apply
grease again.
Cap cover
To rear frame
axle support
Before installing rear axle assembly
to bare machine, temporarily
remove cap cover of axle support
shown in above figure.
(To prevent interference with front
side of fuel tank)
Spacer (×2)
Attached to stand
Washer attached to stand
Mounting bolt attached
to stand
After positioning machine, fix
this bolt into counterweight
mounting hole of rear frame
end plate.
(×2 on outside)

16
Change the position of the lifting tool. Raise the rear axle, and
insert the rear axle mount into the rear support.
aBefore installing the rear axle, clean the mating surfaces
of the rear axle support and frame.
• Insert the mounting bolts (3) of the axle support and tighten
temporarily.
Part A : Position for fixing lifting tool
aTighten the wire when fitting.
aSling the axle so that the axle support will
be level.
Using a power wrench, tighten the mounting bolts of the front
support to the specified torque.
3Mounting bolts: 3,520.5 ± 353.0 Nm {359 ± 36 kgm}
(Width across flats: 60)
Connect the brake hoses coming from the slack adjuster to
the brake tubes on the right and left of the rear axle.
For details, see Procedure for Assembly Procedure No. A-2 (4/5).
Assembly procedure No.
Installing rear axle (2/5)
A-2
Precautions Necessary tools Necessary equipment
Name Q’ty Name Q’ty
Others
Position to install sling when coupling
rear axle assembly with frame
To rear frame axle support

17
Assembly procedure No.
Installing rear axle (3/5)
A-2
Precautions Necessary tools Necessary equipment
Name Q’ty Name Q’ty
Power wrench (×16) 30 ton crane 1
Torque wrench (Set: 215.7 Nm {22 kgm})
Torque wrench (Set: 549.2 Nm {56 kgm})
Socket: 60 mm
Socket: 30 mm
Others
Position to install sling when coupling
rear axle assembly with frame
Rear axle assembly
Axle support
Note
Note
When installing rear axle support assembly,
remove (11) and (12) temporarily and install
them to rear frame.
After installing rear frame, install (11) and
(12) again.
Use choke hitch and lift up so that mounting
face of axle support will be horizontal.
To rear frame
axle support No. Part No. Parts name Q’ty State of parts
Assemble parts for rear axle
1 428-23-10003 Rear axle assembley 1 Loose-supply unit
2 428-46-17110 Support (Rear axle) 1 Installed to axle support
3 427-46-12130 Bolt 6
Installed to axle support temporarily
4 01643-33990 Washer 12 Installed to axle support temporarily
5 01580-03931 Nut 6 Installed to axle support temporarily
6
7 428-46-17130 Thrust plate 1 Installed to axle support
8 01011-82000 Bolt 11 Installed to axle support
9 01643-32060 Washer 16 Installed to axle support
10 428-46-17140 Thrust washer 2 Installed to axle support
11 428-46-17120 Thrust cover 1 Installed to axle support
12 01010-82075 Bolt 16 Installed to axle support
13 01643-32060 Washer 16 Installed to axle support
14 04530-11018 Bolt 1 Installed to axle support