Komatsu WA600-3 User manual

SEAW006000
FieldAssembly
Manual
-3
WHEEL LOADER
SERIAL NUMBERS WA600-3 50001 and up
This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in
accordance with written authorization from Komatsu America Corp.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make
changes or improvements at any time without incurring any obligation to install such changes on products sold
previously.
Due to this continuous program of research and development, revisions may be made to this publication. It is
recommended that customers contact their distributor for information on the latest revision.
Copyright 2004 Komatsu
Printed in U.S.A.
Komatsu America Corp.
August 2004

1
CONTENTS
[1] Drawings of units divided for delivery........................................................................................................... 3
[2] Weight and dimensions table of units divided for delivery............................................................................ 3
[3] Assembly work schedule.............................................................................................................................. 4
[4] Necessary devices and tools........................................................................................................................ 4
[5] Assembly procedure..................................................................................................................................... 5
(1) Installation of tire and wheel assembly .................................................................................................. 5
1) Positioning of vehicle ..................................................................................................................... 5
2) Removal of axle stand ................................................................................................................... 5
3) Slinging of tire and wheel assembly............................................................................................... 5
4) Installation of tire and wheel assembly .......................................................................................... 6
(2) Installation of muffler stack..................................................................................................................... 7
(3) Installation of cab assembly ................................................................................................................... 8
1) Removal of floor frame undercovers .............................................................................................. 8
2) Removal of cover in cab assembly ................................................................................................ 8
3) Slinging of cab assembly ............................................................................................................... 8
4) Loosening of steering post lower bolt ............................................................................................ 9
5) Operation of steering tilt lever ........................................................................................................ 9
6) Installation of seal .......................................................................................................................... 9
7) Lowering of cab assembly ........................................................................................................... 10
8) Temporary tightening of steering post fixing bolts........................................................................ 10
9) Temporary tightening of cab assembly mounting bolts................................................................ 11
10) Permanent tightening of steering post lower bolt ......................................................................... 11
11) Permanent tightening of steering post fixing bolt ......................................................................... 11
12) Connection of wiring connectors and washer vinyl tubes ............................................................ 12
13) Installation of troubleshooting switch ........................................................................................... 12
14) Installation of cover in cab assembly ........................................................................................... 12
15) Installation of steering post lower bellows.................................................................................... 13
16) Installation of cab assembly right-hand cover .............................................................................. 13
17) Installation of floor frame lower cover .......................................................................................... 14
18) Installation of mirrors and mirror stays ......................................................................................... 14
(4) Installation of ROPS canopy ................................................................................................................ 15
1) Removal of antenna ..................................................................................................................... 15
2) Removal of rear frame ROPS support bolts tightened temporarily .............................................. 15
3) Slinging of ROPS canopy ............................................................................................................ 15
4) Installation of ROPS canopy ........................................................................................................ 16
5) Installation of antenna to ROPS canopy ......................................................................................16
6) Installation of antennal wire hole grommet................................................................................... 16

2
(5) Installation of bucket ............................................................................................................................ 17
1) Installation of cord ring................................................................................................................. 17
2) Aligning of bucket assembly and hinge pin holes ........................................................................ 17
3) Selection of shim for bucket hinge pin ......................................................................................... 17
4) Insertion of bucket hinge pin........................................................................................................ 18
5) Installation of bucket hinge pin stopper ....................................................................................... 18
6) Installation of bucket hinge pin and retainer ................................................................................ 18
7) Lowering of cord ring to groove ................................................................................................... 19
8) Installation of bucket link pin........................................................................................................ 19
9) Installation of grease nipple and plug .......................................................................................... 20
10) Measurement of steering wheel operating effort ......................................................................... 20

3
[1] DRAWINGS OF UNITS DIVIDED FOR DELIVERY
[2] WEIGHT AND DIMENSIONS TABLE OF UNITS DIVIDED FOR
DELIVERY
No. Unit name Weight
(kg)
Overall length
(mm)
Overall width
(mm)
Overall height
(mm)
1 Bare machine 29,500 9,270 3,500 3,000
2 Bucket assembly 4,000 3,700 1,900 2,000
3 Tire and wheel assembly 1,700 2,100 2,100 900
4 Cab assembly 440 1,800 1,500 1,700
5 ROPS canopy assembly 810 1,800 2,200 1,800
6 Small parts other than above

4
[3] ASSEMBLY WORK SCHEDULE
[4] NECESSARY DEVICES AND TOOLS
Section Specification Q'ty 1st day 2nd day
Assembly unit
(Contents of
work)
Positioning of bare machine
Installation of tire and wheel
assembly
Installation of muffler stack
Installation of cab assembly and
ROPS canopy
Installation of bucket assembly
Crane 25 Ton
50 Ton
1 unit
1 unit
Number workers 2
No. Device/Tool name Specification Q'ty Remarks
1 Crane (including operator) 1 each
2 Balance sling 1 Sling for rear side
3 Chain sling of sling hook
type
Wire : 20 mm, 2-wire sling 1 4,000 mm long for chassis
4 Chain sling of sling hook
type
Wire : 6.3 mm, 4-wire sling 1 2,000 mm long for cab
5 Endless chain sling Wire : 6.3 mm 2 6,000 mm long for tire
6 Chock 4
7 Wood block 300×300×900 10
8 Air compressor 1
9Airhose 1
10 Impact wrench GTP-4200 or equivalent 1
11 Socket 36 mm Insertion angle 25.4 mm 1 Bucket pin for tire
12 Socket 46 mm Insertion angle 25.4 mm 1 For ROPS
13 Spanner 36 mm 1 Bucket pin
14 Torque wrench 21000QLE or equivalent
(1,520 –1,910 Nm)
1 For ROPS and tire
15 Protective sheet 2
16 Push-pull gauge Measurement: Max. 19.6 N {2 kg} 1
17 Hammer Plastic 1
18 Hammer Copper (Large) 1
19 Grease gun 1
20 Feeler gauge 1
21 Sealant 1 CEMEDINE 366-E or
equivalent
22 Grease LM-G 1 (Lithium grease contain-
ing molybdenum disulfide)

5
[5] ASSEMBLY PROCEDURE (1) Installation of tire and wheel assembly
(1) INSTALLATION OF TIRE AND WHEEL ASSEMBLY
1) Positioning of vehicle
1. Sling the front side and rear side of the
chassis with a crane.
2. Position the vehicle on wood blocks, etc.
by the underside of the axle housing.
Set the vehicle so that the center of the
axle will be 1.1 – 1.2 m above the
ground.
3. Since the rear axle oscillates, put wood
blocks between the rear axle and rear
frame to prevent the axle from leaning.
2) Removal of axle stand
1. Remove the stand (Jig No. AZ-001-051)
installed to the axle.
3) Slinging of tire and wheel assembly
1. Sling the tire and wheel assembly with the
crane. At this time, match the mounting
holes of the wheel to the studs on the axle
side.
Sling: Endless chain sling or endless ny-
lon sling: 2 pcs
2. Sling the tire and wheel assembly slowly
so that it will not lean.
Precautions Special tools Necessary devices
1. Apply the parking brake.
2. Do not stand under the slung
vehicle.
Name Q'ty Name Q'ty
Crane (25 ton), 50 Ton 1 each
Endless chain sling 2
Other remarks

6
[5] ASSEMBLY PROCEDURE (1) Installation of tire and wheel assembly
4) Installation of tire and wheel assembly
• Necessary parts
1. Check that each part is free from foreign
matter.
2. Drive each nut at least 3 threads with your
fingers to prevent it from biting the hub
bolt.
3. Install the right and left tire and wheel
assemblies alternately.
4. Tighten the nuts to the torque shown at
right.
5. Remove the wood blocks under the axle
housing.
6. After finishing the work, touch up the nuts
and unpainted parts.
7. Put chocks under the wheels.
No. Part No. Part name Q'ty
1 426-22-12931 Nut 124
2 01643-32460 Washer 124
Precautions Special tools Necessary devices
1. Do not stand under the slung
vehicle.
Name Q'ty Name Q'ty
Socket (36 mm) 1 Crane (25 ton), 50 Ton 1 each
Endless chain sling 1
Chock 4
Other remarks

7
[5] ASSEMBLY PROCEDURE (2) Installation of muffler stack
(2) INSTALLATION OF MUFFLER STACK
• Necessary parts
1. Install the muffler stack to the left top of the
engine hood.
No. Part No. Part name Q'ty
1 426-02-2110 Muffler stack 1
2 01435-01240 Bolt 4
3 01643-31232 Washer 4
Precautions Special tools Necessary devices
Name Q'ty Name Q'ty
Other remarks

8
[5] ASSEMBLY PROCEDURE (3) Installation of cab assembly
(3) INSTALLATION OF CAB ASSEMBLY
1) Removal of floor frame undercovers
(1 each on right and left sides, 1 on front side,
and 3 each on upper and lower sides)
2) Removal of cover in cab assembly
1. Unpack the cab assembly and remove the
right-hand cover.
2. Remove the 2 screws from the front plate.
3) Slinging of cab assembly
1. Sling the cab assembly with a 25-ton
crane.
Sling: Chain sling of spring hook type
(2,000 mm x 4 pieces)
Precautions Special tools Necessary devices
Name Q'ty Name Q'ty
Crane (25 ton) 1
Chain sling (2,000 mm x 4 pieces) 1
Other remarks

9
[5] ASSEMBLY PROCEDURE (3) Installation of cab assembly
4) Tuck up the bellows at the lower part of the
steering post and loosen the 4 bolts.
5) Set the steering tilt lever free and turn down
the steering post fully toward to operator's
seat.
6) Installation of seal
• Necessary parts
1. Stick the seal to the underside of the
cab assembly.
2. When sticking the seal, press it
against the inside face of the cab
assembly.
Part No. Part name Q'ty
426-56-21330 Seal 1
Precautions Special tools Necessary devices
Name Q'ty Name Q'ty
Other remarks
Seal may be stuck
joint. Apply adhesive
to joint, however.
(Use adhesive
CEMEDINE 366E or
equivalent.)

10
[5] ASSEMBLY PROCEDURE (3) Installation of cab assembly
7) While keeping the cab assembly level, lower it
slowly.
8) Temporary tightening of steering post fixing
bolts
• Necessary parts
1. Drive the 2 steering post fixing bolts tem-
porarily (2 – 3 threads with your fingers).
Part No. Part name Q'ty
01435-01020 Bolt 2
01643-31032 Washer 2
Precautions Special tools Necessary devices
1. Take care that the cab assem-
bly will not interfere with the
electric wires, connectors, hot
air ducts, etc. on the right, front,
and rear sides of the floor
frame.
2. Cover the steering post and
plastic cover with seats to
protect them.
Name Q'ty Name Q'ty
Other remarks

11
[5] ASSEMBLY PROCEDURE (3) Installation of cab assembly
9) Temporary tightening of cab assembly mount-
ing bolts
• Necessary parts
1. Drive 2 cab assembly mounting bolts (10)
and 4 intermediate bolts and 4 rear bolts
(11) (2 – 3 threads with your fingers).
10) Move the steering post to the front end of the
cab assembly and tighten the steering post
lower bolts which were loosened in step 4).
11) Lift down the cab assembly and tighten the
steering post fixing bolts which were driven
lightly in stop 8), and then tighten the bolts to
fix to the floor.
No. Part No. Part name Q'ty
1 01010-81240 Bolt 2
2 01643-31232 Washer 2
3 418-46-12310 Shim (t = 1.0) 4
4 01010-82050 Bolt 8
5 01643-32060 Washer 8
1 each on
right and left
side
[Caution]
Set bolts to
bottom of
oblong hole
at part A and
to top of
oblong hole
at part B.
(Set them as
set when
delivered.)
Precautions Special tools Necessary devices
Name Q'ty Name Q'ty
Other remarks

12
[5] ASSEMBLY PROCEDURE (3) Installation of cab assembly
12) Connection of wiring connectors and
washer vinyl tubes
1. Connect the 2 windshield washer
vinyl tubes under the right side of
the cab assembly, matching their
colors.
2. Connect wiring connectors [CL2],
[CL3], [CL4], and [CL1].
3. If the vehicle is equipped with the
joystick, connect the wiring har-
nesses of the F, N, and R indicator
lamps on the front left side of the
cab assembly.
13) Installation of troubleshooting switch
14) Installation of cover in cab assembly
Install the cover which was removed in
step 2).
Precautions Special tools Necessary devices
1. When connecting the wind-
shield washer tubes, match
their colors.
Name Q'ty Name Q'ty
Other remarks

13
[5] ASSEMBLY PROCEDURE (3) Installation of cab assembly
15) Installation of steering post lower bellows
• Necessary parts
1. Install bellows (6) to the bottom of the
steering post with plug (19).
2. Insert the plug in the hole of bellows (6)
and lightly hit the screw head installed
temporarily to the plug with a hammer to
drive in the plug.
16) Install the cab assembly right-hand cover
which was removed in step 2).
No. Part No. Part name Q'ty
19 421-09-21240 Plug 16
Precautions Special tools Necessary devices
Name Q'ty Name Q'ty
Other remarks

14
[5] ASSEMBLY PROCEDURE (3) Installation of cab assembly
17) Install the floor frame lower cover.
18) Install the mirrors and mirror stays to the right
and left of the cab assembly.
• Necessary parts
No. Part No. Part name Q'ty
1 426-54-25710 Stay (Left) 1
2 426-54-25720 Stay (Right) 1
3 01435-01025 Bolt 8
4 363-54-31450 Cap 8
5 421-54-25610 Mirror 2
6 04025-00632 Spring pin 2
Precautions Special tools Necessary devices
Name Q'ty Name Q'ty
Other remarks

15
[5] ASSEMBLY PROCEDURE (4) Installation of ROPS canopy
(4) INSTALLATION OF ROPS CANOPY
1) Removal of antenna
1. Remove the antenna from the right side of
the cab assembly. Install screws (1) to the
antenna mounting holes on the cab side to
fill the holes.
2. Apply sealant (366E or equivalent) to the
removed screws and install them again.
3. Draw in the antenna wire at least 100 mm.
2) Removal of rear frame ROPS support bolts
tightened temporarily
1. Remove 4 bolts tightened temporarily into
the right and left ROPS canopy mounting
parts of the rear frame ROPS support.
(Keep the bolts and washers to use
again.)
2. Check that the rear frame ROPS support
mounting holes are matched to the holes
on the floor.
3) Slinging of ROPS canopy
1. Sling the ROPS canopy with a 25-ton
crane.
Sling: Chain sling of spring hook type
(2,000 mm x 4 pieces)
Precautions Special tools Necessary devices
1. When installing the screws to fill
the screw holes, apply synthetic
rubber adhesive (366E or
equivalent) to their threads to
prevent entry of rainwater.
Name Q'ty Name Q'ty
Crane (25 ton) 1
Chain sling (2,000 mm x 4 pieces) 1
Other remarks

16
[5] ASSEMBLY PROCEDURE (4) Installation of ROPS canopy
4) Installation of ROPS canopy
• Necessary parts
1. Lowering the ROPS canopy to the mount-
ing position, taking care that it will not
interfere with the cab.
2. Tighten the 20 ROPS canopy mounting
bolts (4 removed bolts + 16 bolts installed
to the ROPS canopy).
5) Install the antenna to the mounting position on
the right side of the ROPS canopy with the
screws.
(01220-70412 Screw 2)
• Necessary parts
6) Installation of antennal wire hole grommet
• Necessary parts
1. Install the grommet to antenna wire hole of
the cab assembly with the slit down.
2. Fill the clearance around the grommet and
the slit with synthetic rubber adhesive
(366E or equivalent).
No. Part No. Part name Q'ty
2 01011-63015 Bolt 16
3 01643-33080 Washer 16
No. Part No. Part name Q'ty
4 01220-70412 Screw 2
No. Part No. Part name Q'ty
4 421-921-2410 Grommet 1
Precautions Special tools Necessary devices
1. Fill the clearance around the
grommet installed to the
antenna wire on the cab side
with synthetic rubber adhesive
to prevent entry of rainwater.
Name Q'ty Name Q'ty
Socket (46 mm) 1
Torque wrench 21000QLE 1
(1,720 – 1,910 Nm)
Impact wrench GT4200 1
or equivalent
Other remarks

17
[5] ASSEMBLY PROCEDURE (5) Installation of bucket
(5) INSTALLATION OF BUCKET
1) Installation of cord ring
• Necessary parts
1. Place cord ring (O-ring) (2) on lift arm boss
(1).
2. After installing the bucket and adjusting
the shim, lower cord ring (2) to the groove.
3. Apply LM-G (lithium grease containing
molybdenum disulfide) to the inside of dust
seal lip (3).
2) Aligning of bucket assembly and hinge pin
holes
1. Sling the bucket assembly with a 25-ton
crane.
Sling: Chain sling of spring hook type
(4,000 mm x 2 pieces)
2. Match the pin holes on the right and left
bucket hinge pin sides to those on the lift
arm side.
3) Selection of shim for bucket hinge pin
• Necessary parts
1. Decide the number of the shims so that
clearance A between the hinge pin of
bucket assembly (4) and the boss of lift
arm (1) will be 1.5 mm of less on each
side.
No. Part No. Part name Q'ty
2 426-70-12530 (O-ring) Cord ring 4
No. Part No. Part name Q'ty
– 426-70-11330 Shim (t = 1.5) 6
Precautions Special tools Necessary devices
1. Do not align the pin holes with
your hands or fingers.
Name Q'ty Name Q'ty
Crane (25 ton) 1
Chain sling (4,000 mm x 2 pieces) 1
Other remarks

18
[5] ASSEMBLY PROCEDURE (5) Installation of bucket
4) Insertion of bucket hinge pin
• Necessary parts
1. Insert the shim selected in step 3), align
the pin holes, and insert the bucket hinge
pins.
At this time, apply grease to the pins.
2. When inserting bucket hinge pins (5), take
care not to damage the dust seals.
5) Installation of bucket hinge pin stopper
• Necessary parts
1. Put the lock plate of bucket hinge pin (5) to
the block of the bucket hinge plate and
secure it with cam (6).
2. Put cam (6) to the plate of bucket hinge
pin (5) and tighten the bolt.
6) Installation of bucket hinge pin and retainer
• Necessary parts
1. Install retainer (7) to bucket hinge pin (5)
and decide the number of the shims so
that clearance B between the retainer and
the boss of the bucket hinge will be 0.2
mm or less.
No. Part No. Part name Q'ty
5 426-853-1110 Pin 2
No. Part No. Part name Q'ty
6 425-70-11250 Cam 2
6 01010-82475 Bolt 2
6 01643-32460 Washer 4
6 01580-12419 Nut 2
No. Part No. Part name Q'ty
7 426-70-11261 Retainer 2
7 01010-81645 Bolt 6
7 01643-31645 Washer 6
8 426-70-11280 Shim (t = 0.5) 12
426-70-11270 Shim (t = 0.2) 6
Precautions Special tools Necessary devices
Name Q'ty Name Q'ty
Impact wrench GTP-800P 1
or equivalent
Socket (36 mm) 1
Spanner, 36 mm 1
Other remarks

19
[5] ASSEMBLY PROCEDURE (5) Installation of bucket
2. Tighten the 3 bolts of retainer (7).
7) Lower cord ring (2) to the groove.
8) Installation of bucket link pin
Install the bucket link pin according to steps 1)
– 8).
5 426-70-11470 Shim (t = 0.5 mm) 8
6 425-70-11250 Cam 1
6 01010-82480 Bolt 1
6 01643-32460 Washer 2
6 01580-12419 Nut 1
7 426-70-11391 Retainer 1
7 01010-81645 Bolt 3
7 01643-31645 Washer 3
8 426-70-11460 Shim (t = 0.2 mm) 3
8 426-70-11470 Shim (t = 0.5 mm) 12
Precautions Special tools Necessary devices
Name Q'ty Name Q'ty
Other remarks