Komatsu WA800-2 User manual

FieldAssembly
Instruction
SEAW04280202
WHEEL LOADER
SERIALNUMBERS WA8004 -10540 andUP
This material is proprietary to Komatsu Dresser Company and is not to be reproduced, used, or disclosed except
in accordance with written authorization from Komatsu Dresser Company.
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 add 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, periodic revisions may be made to this publication.
It is recommended that customers contact their distributor for information on the latest revision.
March 1995 Copyright 1995 Komatsu Dresser Company

CONTENTS
1.
2.
3.
4.
5.
6.
7.
CHART OF SEPARATED UNITS ............................................... 3
DIMENSIONS OF SEPARATED UNITS .......................................... 3
ORDER FOR ASSEMBLY, FACILITIES TO USE, SCHEDULE FOR ASSEMBLY .......... 4
WORK SPACE LAYOUT DIAGRAM ............................................. 5
TOOLS AND EQUIPMENT TO USE ............................................. 6
PARTS LIST FOR FIELD ASSEMBLY ........................................... 14
PROCEDURE FOR FIELD ASSEMBLY .......................................... 21
Assembly processNo.
A-l Setting bare machine on supports ........................................... 21
A-2 Assembly of rear axle .................................................... 23
A-3 Assembly of front and rear drive shaft ....................................... 27
A-4 Assembly of front axle ................................................... 29
A-5 Assembly of fuel tank .................................................... 33
A-6 Assembly of ladder (Left, Right) ............................................ 41
A-7 Assembly of floor and cab assembly ......................................... 42
A-8 Assembly of floor hand rail ................................................ 52
A-9 Assembly of tire and wheel assembly ........................................ 53
A-10 Assembly of battery box assembly .......................................... 55
1OA Assembly of counterweight assembly ........................................ 60
A-l 1
A-12
A-13
A-14
A-15
A-16
M-l
M-2
M-3
M-4
M-5
M-6
M-7
M-8
M-9
Assembly of muffler pipe ................................................. 61
Assembly of lift arm assembly .............................................. 62
Assembly of front fender ................................................. 66
Assembly of front lamp assembly ........................................... 67
Assembly of ROPS canopy assembly ......................................... 68
Assemblyofbucket ...................................................... 70
Bleeding air from brake line ............................................... 74
Greasing work equipment and chassis ........................................ 75
Adjusting bucket positioner ............................................... 76
Adjusting boom kick-out .................................................. 77
Inspection of all parts .................................................... 78
Procedure for starting engine ............................................... 7g
Procedure for bleeding air from piston pump ................................... 80
Procedure for bleeding air from work equipment hydraulic circuit .................. 81
Charging air conditioner gas ............................................... 82
APPENDIX
FIELD ASSEMBLY INSPECTION REPORT

1. CHART OF SEPARATED UNITS 2. DIMENSIONS OF SEPARATED UNITS
12. ler stack.
8. Floor hand rail ass’y
6. Floor and cab ass’v ass’y
13. Fuel tank ass’y
w 5. Lift arm ass’y 16. Bare machine
‘Y
1
4. Bucket ass’y . Ladder ass’y (each) 3. Wheel and tire ass’y (each) 1. Front axle ass’y
2 Rear axle ass’y 8610 4340 1700 960
(axle support) (300) (1354) (230) (605)
3 Wheel and tire ass’y 13900 4800 2720 2720
(each 1 (3475) (1200) (2720) (2720)
4 Bucket ass’y 9485 5030 2350 2430
5 Lift arm ass’y 11090 5200 1900 1460
6 Floor and cab ass’y 950 1515 1400 1950
7 ROPS canopy ass’y 1295 1633 2330 2197
8 Floor hand rail ass’y 20 1200 1100 350
20 1400 1200 350
12 Muffler stack (2 PCS) 50 1450 520 260
13 Fuel tank ass’y i 790 2000 1900 850
14 Battery box ass’y 700 1800 1520 650
15 Counterweight 2500 I 350 3200 610
16 Bare machine 32570 I I
Total 90700
3

3. ORDER FOR ASSEMBLY, FACILITIES TO USE, SCHEDULE FOR ASSEMBLY
Assembly unit 1. Set chassison supports 1. Rear axle ass’y
2. Front axle ass’y
(front wheel and tire ass’y)
3. Front, rear drive shaft
1. Fuel tank ass’y
4. Floor handle ass’y
5. Wheel and tire ass’y
(rear wheel and tire)
* (Tighten wheel mounting
nuts to specified torque)
1. Muffler stack
2. Lift arm ass’y
* Check oil, water levels;
add oil and water
* Grease work equipment
* Charge air conditioner with
1. Front fender
2. Front lamp ass’y
3. ROPS canopy ass’y
I., Bucket ass’y
*“Adjust bucket positioner,
boom kick-out
* Check all parts for oil
Assembly Procedure No.
Maintenance (adjust-
ment) No. A-10, IOA, M-l (A-9) A-11 -A-l2
M-2 M-6 - M-9 A-13-A-15 M-3 - M-5
Air compressor
No. of workers
Forklift truck
(operator included in
number of workers
above)
5 persons
Remarks
Meeting before starting
operation,
unloading parts,
start of assembly
Remove supports Start engine Completion of assembly
4

4. WORK SPACE LAYOUT DIAGRAM
(The larger the work space is, the easier it is to carry out operations. The area shown in the diagram below (25 m x $I m)
is the minimum size needed.)
25 m
Tire and wheelass’y
Rear axle ass’y
Front axle ass’y
I72
c
5

5. TOOLS AND EQUIPMENT TO USE
1. Tools required
N
IO. Name Specification O’ty Remarks
Spanners, two-ended ring wench, box
1 Set of common standard tools wrench, cold chisel, screwdrivers, hammer, 2
adjustable wrench, hexagon wrenches, etc.
2 Power wrench 16 times
3 Power wrench 4 times
4 Socket 60 (Insertion angle; 38.1) x L: 84
5 Socket 36 (Insertion angle; 25.4) x L: 68
1 Front, rear axle mounts,
ROPS canopy mount
1 Fuel tank mount
1 For front, rear axle mount
1 For rear axle support cover, tire,
counterweight (lower)
6 Socket
7 Socket
8 Socket
9 Extension bar
IO Adapter
II Extenson bar
46 (Insertion angle; 25.4) x L: 72
55 (Insertion angle; 38.1) x L: 82
55 (Insertion angle; 25.4) x L: 82
Insertion angle: 12.7 x L: 150
Insertion angle: 19 x 12.7 x L: 55
Insertion angle: 25.4 x L: 160
1 For fuel tank, counterweight
1 ROPS mount
1 ROPS mount
1 For fuel tank
1 For fuel tank
1 For tire, counterweight,
ROPS canopy
12 Preset torque wrench (box type) 4 - 28 kgm 1 For power wrench
I 3 Interchangeable head type preset
torque wrench 6 - 14 kgm 1 For connecting hoses and tubes
,4 Interchangeable head type preset
torque wrench 2 - 4.5 kgm 1 For connecting hoses and tubes
,5 Interchangeable head type preset
torque wrench 3 - 7 kgm 1 For connecting hoses and tubes
Width across flats: 27 (insertion hole: $15) One
,6 Heads (spanner type) for inter- Width across flats: 19 (insertion hole: 912)
changeable head type preset Width across flats: 22 (insertion hole: Q12) each For connecting hoses and tubes
Width across flats: 24 (insertion hole: $12)
17 Preset torque wrench (box type) 20 - 140 kgm 1 For rear axle support cover,
counterweight
18 Preset torque wrench (box type) 50 - 210 kgm 1 For counterweight
19 Preset torque wrench (box type) 6 - 42 kgm 1 For rear axle support cover
20 Impact wrench Capacity: 1.5 - 7.5 kgm 1
21 Impact wrench Capacity: 5.5 - 31.5 kgm 1
6

40. Name
22 Impact wrench
23 Adapter
24 Adapter
25 Large hammer
26 Air grinder
27 Bars
Specification Q’ty Remarks
Capacity: 20.5 - 84.5 kgm 1 For tire, ROPS canopy
Insertion angle: 19 x 25.4 x L: 71 1 For power wrench, torque wrenc
Insertion angle: 12.7 x 9.5 x L: 41 1 For power wrench, torque wrenc
10 pounds 1
1
Large, medium, small Two Hole adjustment,
each for moving heavy things
28 Bar - 2 Hole adjustment
29 Grease gun (hand pump type) Capacity: Approx. 300 cc 1 For oiling to pin
30 Oil container Capacity: 1000 - 2000 cc 1 For bleeding air from brake line
31 Vinyl hose I.D. $6.5 - 47.0 x L: 1000 - 1500 1 For bleeding air from brake line
2. Equipment required
lo. Name Specification Q’ty Remarks
1 Truck crane 45 ton 1
2 Truck crane 30 ton 1
For comparatively
3 Forklift truck 2 unloading light ton 1 components and parts, assembling
fuel tank
4 Compressor Capacity: 32Q I I
1 Impact wrench,
bleeding air from brake
5 Roller for moving rear axle to side I I
1 See page 10,4-6
6 Lever block 1 ton 3 For supporting cylinder,
drive shaft
7 Stand (for worker) 4 steps (approx. 1.5 m) 3 For use during operation
8 Steel sheet (t) 9x 1219x 2438 4 For positioning bare machine
7

No. Equipment Specification I I Q’ty Remarks
9 Steel sheet (t)25 x 250 x 600 4 For positioning bare machine
10 Wooden blocks 400x400x900 14
200x400x800 4 For positioning bare machine
11 Air type grease gun Capacity: 189 1
I I
If another gas charger is used.,
12 Air compressor gas charger Charge manifold, leak detector 1 f$l;$the mstructlons supplled
13 Tester 1
I *
3. Lifting tools required
No. Name Specification Q’ty Remarks
1 Front frame lifting tool 2-point suspension (L=2250 1 See diagram below.
chain diameter=@20, sling hook=(
2 Rear frame lifting tool
3 Rear axle lifting tool
4 Nylon sling
Balanced 2-point suspension
(Chain diameter=@20, sling hook=( ’ See diagram below.
2-point suspension (L=5500
chain diameter=@1 6, grab hook(G)) ’ See diagram below.
50 x 2000 2 Axle support, cylinder sling
5 Front, rear axle lifting tool ~~~~~~~~~~~~~~~~~ook=~SL)) 1 See diagram below.
(Chain diameter=$12:5, grab hook=(G))
6 Nylon sling for drive shaft 50 x 5000 1
I I
7 Fuel tank lifting tool 2-point suspension (L=5000
chain diameter = 46.3, sling hook=( i I
2 See diagram below.
8 Floor and cab lifting tool
9 Nylon sling
10 Wire sling
2-point suspension (L=2000,
chain diameter=o6.3, sling hook=( 2 See diagram below.
150 x 10000 1 Lifting tool for tire
Capacity: 15 ton L=2500 2 Lifting tool for lift arm (lifting
Capacity: 11 ton L=2000 1 front) when removing blocks
under chassis
11 Shackle For 2 ton, 5 ton, 10 ton, 15 ton Two
each
8

[Lifting tools]
1. Front frame lifting tool
Chain diameter
2. Rear frame lifting tool
Chain diameter
20 mm i
t d
(SL)
3. Rear axle lifting tool 5. Front, rear axle lifting tool
--r
f \
‘m
Chain diameter ! \Cr
16mm \“o
i
/L
\
\
\
(G)
7.8. Fuel tank, floor and cab lifting tool
I\ i
Chain diameter,
Chain
Chain diameter
12.5 mm
(G)
9

4. Oil, grease, fuel, paint, etc.
No. Kind of fluid Specification Quantity
1 Oil . .. Brake oil SAEI OW CD IO Q
2 Molybdenum disulphide grease with (KES LM-P, SAEJBI Oa
high pressure additive NLGI: No. 1 or equivalent) 500 mQ
3 Molybdenum disulphide lithium (KES LM-G, SAEJ31 Oa
grease NLGI: No. 2 (or No. 1) or equivalent 10 Q
4 Fuel Diesel fuel As necessary
(Fuel tank: 1200 Q)
5 Paint for touching up Komatsu yellow spray can 3 cans
Komatsu blue 4 litre can
6 1Air conditioner gas / Freon gas can (400 g) 1 can
7 Window washer solvent 2 cans
All the above items except No. 4 Fuel are shiped together with the machine.
(1) Others
Roller for
Angle 50 x 50 x 850 (x 4)
5. Protective wear
Work clothes, safety boots, helmet, thick gloves, goggles, raincoat
10

Local manufacturing diagram for lifting tool and roller
(1 ) Rear frame lifting tool
12.5 ton chain
w 2850
12.5 ton chain
I STK 50, 656323 SAW5 or \\, ^
Note
(1 ) There must be no burrs at the machined places.
(2) Paint with Mansell system 2.5Y - 8/12 paint. (Yellow)
2650
11

(2) Lifting tool for front, rear axle
Note
(1) After cutting, it is possible to finish the machined material
with a grinder.
(2) Paint with yellow paint.
16
<
12

(3) Roller for moving rear axle to side
View @
, 1
Secure with nuts and bolts
Angle 1000
(350)
or by weilding (total 24 places)
(Specifications for securing with
nuts and bolts)
. Size of drill hole: 10
- Size of nut and bolt
d I..
Bolt: MB x 1.25 x 25
Nut: MB x 1.25
Plain washer: MB
/Roller conveyor
OKURA HR15075-IOOOB
or equivalent
Width of roller: 150 - 160 mm
Width of roller frame: 210 - 220 mm 3
Note
(1) Considering transportation and replacement of broken
parts, it is a better idea to secure the angle and roller
conveyor with nuts and bolts, as this will allow disassembly
of the angle and roller conveyor.
13

6 PARTS LIST FOR FIELD ASSEMBLY
No. Part No. Part name
1. Rear axle assembly components
O’ty Assembly
Process No. Remarks
Ill 427-46-l 2130 ) Bolt ) 4 ) A-2 1 Sent as individual parts I
121 01643-33990 Washer 1 8 1 A-2 1 Sent as individual parts -1
3 01580-03931 Nut 4 A-2 Sent as individual parts
4 427-46-l 2170 Plate 1 A-2 Already temporarily installed to rear axle
151 0101 I-52420 Bolt /161A-2 I Already temporarily installed to rear axle I
6 01643-32460 Washer 16 A-2 Already temporarily installed to rear axle
7 427-46-l 2161 Washer (thrust) 1 A-2 Already temporarily installed to rear axle
1 8 / 427-46-12180 I Cover (thrust) / 1 1 A-2 1 Sent as individual parts -1
191 0101 I-52400 / Bolt 1161~-2 / Already temporarily installed to rear frame
10 01643-32460 Washer 16 A-2 Already temporarily installed to rear frame
I *. Drive shaft (front, rear) components I
I 1 I 427-20-I 2111 1 Drive shaft (rear) / 1 1 A-3 1 Sent as individual part I
2 427-20-I 3112 Drive shaft (front) 1 A-3 Temporarily installed to center support
3 01050-61895 Bolt 12 A-3 Already temporarily installed to axle
and transmission yoke
I 3. Front axle assembly components ~_I
1 427-46-11451 Bolt 16 A-4 Sent as individual parts
2 01643-33990 Washer 32 A-4 Sent as individual parts
3 / 01580-03931 1 Nut j 16 1 A-4 / Sent as individual parts I
4. Fuel tank assembly components

33 08036-01814 Clip 2 A-5 Already temporarily installed to fuel hose
34 01435-01016 Bolt 2 A-5 Alread temporarily installed
to ins1 e of rear frameJ
35 424-06-I 2790 Clip 1 A-5 Already temporarily installed to fuel hose
36 01435-01030 Bolt 2 A-5 Already temporarily installed
to engine drain tube
37 01435-01030 Bolt 4 A-5 Already temporarily installed
to radiator drain, 011cooler drain tube
5. Ladder assembly components
1 01010-51635 Bolt 4 A-6 Already temporarily installed
to hydraulic tank and air component box
2 01643-31645 Washer 4 A-6 Already temporarily installed
to hydraulic tank and air component box
3 0101 O-51 230 Bolt 4 A-6 Already temporarily installed
to hydraulic tank and air component box
4 01643-31232 Washer 4 A-6 Already temporarily installed
to hydraulic tank and air component box
6. Floor frame and cab assemblv comoonents
I .
1 425-54-l 3160 Cushion 8 A-7 Already temporarily installed
to lower support
2 425-54-l 3170 Plate 8 A-7 Already temporarily installed
to lower support
3 01011-51610 Bolt 4 A-7 Already temporarily installed
to lower support
4 01643-31645 Washer 4 A-7 Already temporarily installed
to lower support
5 421-40-I 1510 Locknut 4 A-7 Already temporarily installed
to lower support
6 416-40-11150 Washer 4 A-7 Already temporarily installed
to lower support
15

Remarks
7. Handrail components
1 427-54-14110 Handrail (front L.H.) 1 A-8 Set as individual part
16

No. Part No. Part name Q’ty Assembly
Process No. Remarks
2 427-54-14120 Handrail (front R.H.) 1 A-8 Sent as individual part
r-i I 427-54-14130 1Handrail (rear L.H.) / 1 1 A-8 / Sent as individual part
I41 427-54-14141 / Handrail (rear R.H.) 1 1 / A-8 1 Sent as individual part
5 0101 O-51 230 Bolt 24 A-8 Already temporarily installed
to left and right of floor
6 01643-31232 Washer 32 A-8 Already temporaril installed
to left and right of Yloor
7 01010-51235 Bolt 8 A-8 Already temporaril installed
to left and right of Yloor
8. Tire and wheel assembly components
1 426-22-l 2930 Nut 212 A-4, A-9 Already temporarily installed
to front and rear axles
2 01643-32460 Washer 212 A-4, A-9 Already temporarily installed
to front and rear axles
1r9. Batterv box assemblv components
nounting
lrarily installed to
two each, left and right)
lrarily installed
.,.lt battery boxes
lporarily installed
m
Iporarily installed
iaht battery boxes
;;yily installed
14 427-06-14570 Cover L.H. 1 A-IO Sent as individual part
15 427-06-I 4580 Cover R.H. 1 A-10 Sent as individual part
16 427-06-I 4540 Cover L.H. 1 A-IO Sent as individual part
17 427-06-I 4550 Cover R.H. 1 A-IO Sent as individual part
18 427-06-l 4560 Cover 2 A-10 Already temporarily installed
to left and right battery boxes
19 427-06-I 4530 Cover 1 A-10 Sent as individual part
20 427-06-l 3132 Cover 1 A-10 Already tern oraril installed
to cover (42?-06-ll530)
21 427-06-l 3141 Cover 1 A-10 ,“d~~~~Yr~~~~_r~~5~~~lled
22 01435-01230 Bolt 6 A-10 Already temporarily installed
to battery box and cover
23 01435-01025 Bolt 8 A-10 Already temporarily installed
to battery box and cover
24 01435-01020 Bolt 8 A-10 Already temporarily installed to cover
of left and riaht batterv boxes
17

No. Part No. Part name I I
O’ty Assembly
Prnnmc Nn Remarks
25 0101 o-52045 Bolt 4 A-10 Already tern1porarily installed
to rear frame mounting
26 01643-32060 Washer 4 A-10 Already temporarily installed
to rear frame mounting
27 01435-01225 Bolt 8 A-10 Pd~~~“,Y,T~~pPd~_r~~5~~~Iled
28 (620-3860-SC) Step ass’y ;,e$ A-10 I se
nt as individual parts
29 0101 O-51 225 Bolt 8 A-10 Already tern1
to left and ris
30 01643-31232 Washer 8 A-10
porarily installed
ght fuel tanks
porarily installed
ght fuel tanks
10. Counterweight components
1 427-46-l 5121 Counterweight 1 A-l OA Sent as individual part
2 427-46-l 3120 Pin (drawbar) 1 A-IOA Sent as individual part
(assembled to counterweight)
3 425-974-l 160 Bolt (for mounting
counterweight) 6 A-l OA Already temporarily installed
to rear of rear frame
4 01643-33080 Washer (for mounting
counterweight) 6 A-IOA Already temporarily installed
to rear of rear frame
111. Lift arm assembly components
12 07049-01620 Plug 15 A-12 Sent as individual parts
13 0101 o-52035 Bolt 1 A-12 Already temporarily installed
to bellcrank pivot boss
14 427-70-I 1290 Washer 1
12. Muffler pipe components
1 427-02-l 1121 Exhaust pipe 2 A-11 Sent as individual parts
2 427-02-I 1130 Plate 1 A-l 1 Already temporarily installed
to top of center hood
3 01435-01230 Bolt 6 A-II Already temporarily installed
to top of center hood
4 01435-01250 Bolt 6 A-11 Already temporarily installed
to top of center hood
18

I I
No. Part No. I Part name Assembly
Process No. Remarks
13. Front lamp assembly components
1 01435-01240 Bolt 8 A-14 Already temporarily installed to
left and right of front frame
2 424-06-I 2720 Clip 2 A-14 Already temporarily installed to
left and right of front frame
3 0101 o-51 020 Bolt 2 A-14 Already temporarily installed to
left and right of front frame
4 01643-31032 Washer 2 A-14 Already temporarily installed to
left and right of front frame
Front fender components
10 427-54-l 3370 Fender L.H. 1 A-13 Sent as individual part
11 427-54-13380 Fender R.H. 1 A-13 Sent as individual part
12 01010-51230 Bolt 16 A-13 Sent as individual parts
13 01643-31232 Washer 4 A-13 Sent as insividual parts
14 424-54-l 4220 Washer 12 A-13 Sent as individual parts
16. Bucket assembly components
1 427-809-I 310 Bucket ass’y 1 A-16 Sent as individual part
2 (620-3930-X) Flange ass’y 6 A-16 Sent as individual parts
19

No. Part No. Part Name Remarks
20