Komatsu WA600-3 Field Assembly Instructions
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Komatsu WA600-3 Field Assembly Instructions

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Field Assembly
Manual
WHEEL LOADER
SERIAL NUMBERS
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.
August 2004
WA600-3
Copyright 2004 Komatsu
Printed in U.S.A.
Komatsu America Corp.
SEAW006000
-3
50001
and up

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  • Page 1 SERIAL NUMBERS 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.

  • Page 2: Table Of Contents

    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 ........................
  • Page 3 (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 ..................

  • Page 4: Drawings Of Units Divided For Delivery

    [1] DRAWINGS OF UNITS DIVIDED FOR DELIVERY [2] WEIGHT AND DIMENSIONS TABLE OF UNITS DIVIDED FOR DELIVERY Weight Overall length Overall width Overall height Unit name (kg) (mm) (mm) (mm) Bare machine 29,500 9,270 3,500 3,000 Bucket assembly 4,000 3,700 1,900 2,000 Tire and wheel assembly...

  • Page 5: Assembly Work Schedule

    [3] ASSEMBLY WORK SCHEDULE Section Specification Q'ty 1st day 2nd day Assembly unit Positioning of bare machine (Contents of Installation of tire and wheel Installation of bucket assembly work) assembly Installation of muffler stack Installation of cab assembly and ROPS canopy Crane 25 Ton 1 unit...

  • Page 6: Assembly Procedure

    [5] ASSEMBLY PROCEDURE (1) Installation of tire and wheel assembly 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.

  • Page 7: Installation Of Tire And Wheel Assembly

    [5] ASSEMBLY PROCEDURE (1) Installation of tire and wheel assembly 4) Installation of tire and wheel assembly • Necessary parts Part No. Part name Q'ty 426-22-12931 01643-32460 Washer 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.

  • Page 8: Installation Of Muffler Stack

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

  • Page 9: Installation Of Cab Assembly

    [5] ASSEMBLY PROCEDURE (3) Installation of cab assembly 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.

  • Page 10: Loosening Of Steering Post Lower Bolt

    [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.

  • Page 11: Lowering Of Cab Assembly

    [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 Part No. Part name Q'ty 01435-01020 Bolt 01643-31032 Washer 1. Drive the 2 steering post fixing bolts tem- porarily (2 –...

  • Page 12: Temporary Tightening Of Cab Assembly Mounting Bolts

    [5] ASSEMBLY PROCEDURE (3) Installation of cab assembly 9) Temporary tightening of cab assembly mount- ing bolts • Necessary parts Part No. Part name Q'ty 01010-81240 Bolt 01643-31232 Washer 418-46-12310 Shim (t = 1.0) 01010-82050 Bolt 01643-32060 Washer 1. Drive 2 cab assembly mounting bolts (10) and 4 intermediate bolts and 4 rear bolts (11) (2 –...

  • Page 13: Connection Of Wiring Connectors And Washer Vinyl Tubes

    [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].

  • Page 14: Installation Of Steering Post Lower Bellows

    [5] ASSEMBLY PROCEDURE (3) Installation of cab assembly 15) Installation of steering post lower bellows • Necessary parts Part No. Part name Q'ty 421-09-21240 Plug 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.

  • Page 15: Installation Of Floor Frame Lower Cover

    [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 Part No. Part name Q'ty 426-54-25710 Stay (Left) 426-54-25720 Stay (Right)

  • Page 16: Installation Of Rops Canopy

    [5] ASSEMBLY PROCEDURE (4) Installation of ROPS canopy 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.

  • Page 17: Installation Of Rops Canopy

    [5] ASSEMBLY PROCEDURE (4) Installation of ROPS canopy 4) Installation of ROPS canopy • Necessary parts Part No. Part name Q'ty 01011-63015 Bolt 01643-33080 Washer 1. Lowering the ROPS canopy to the mount- ing position, taking care that it will not interfere with the cab.

  • Page 18: Installation Of Bucket

    [5] ASSEMBLY PROCEDURE (5) Installation of bucket INSTALLATION OF BUCKET 1) Installation of cord ring • Necessary parts Part No. Part name Q'ty 426-70-12530 (O-ring) Cord ring 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.

  • Page 19: Insertion Of Bucket Hinge Pin

    [5] ASSEMBLY PROCEDURE (5) Installation of bucket 4) Insertion of bucket hinge pin • Necessary parts Part No. Part name Q'ty 426-853-1110 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.

  • Page 20: Lowering Of Cord Ring To Groove

    [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). 426-70-11470 Shim (t = 0.5 mm) 425-70-11250...

  • Page 21: Installation Of Grease Nipple And Plug

    [5] ASSEMBLY PROCEDURE (5) Installation of bucket 9) Installation of grease nipple and plug 1. Apply LM-G (lithium grease containing molybdenum disulfide) to the bucket hinge pin and bucket link pin. • Necessary parts Part No. Part name Q'ty 07049-01620 Bucket link pin 07020-00000 Bucket hinge pin...

This manual is also suitable for:

50001

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