CEAW000200
WHEEL LOADER SERIAL NUMBERS
and UP
This material is proprietary to Komatsu Mining Systems and is not to be reproduced, used, or disclosed except in accordance with written authorization from Komatsu Mining Systems. 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 2000
Copyright 2000 Komatsu DataKom Publishing Corporation
TABLE OF CONTENTS
TABLE OF CONTENTS
FIELD ASSEMBLY MANUAL
TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 CHART OF SEPERATED UNITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 DIMENSIONS AND WEIGHTS OF SEPARATED UNITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 TRANSPORTATION BY LAND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 WHEN TRAVELING UNDER OWN POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 TRANSPORTATION BY TRAILER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 TRAILERS REQUIRED TO MOVE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 SERVICE REFILL CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 ORDER OF ASSEMBLY, FACILITIES TO USE, SCHEDULE FOR ASSEMBLY . . . . . . . . . . . . . . . 8 WORK SPACE LAYOUT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 TOOLS AND EQUIPMENT REQUIRED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 TOOLS REQUIRED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 EQUIPMENT REQUIRED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 LIFTING TOOLS REQUIRED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 OIL, GREASE, FUEL, PAINT, ETC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 PROTECTIVE WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 LOCAL MANUFACTURING DIAGRAM FOR LIFTING TOOLS AND ROLLER . . . . . . . . 18 PROCEDURE FOR FIELD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 A-1 SETTING BARE MACHINE ON SUPPORTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 A-2 ASSEMBLY OF REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 A-3 ASSEMBLY OF FRONT AND REAR DRIVE SHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . 30 A-4 INSTALLATION OF FRONT AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 A-5 ASSEMBLY OF FUEL TANK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 A-6 ASSEMBLY OF LADDER (LEFT/RIGHT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 A-7 ASSEMBLY OF CAB. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 A-8 ASSEMBLY OF HAND RAIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 A-9 ASSEMBLY OF REAR TIRE AND WHEEL ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . 51 A-10 ASSEMBLY OF BATTERY BOXES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 A-11 ASSEMBLY OF COUNTERWEIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 A-12 ASSEMBLY OF EXHAUST PIPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 A-13 ASSEMBLY OF HANDRAILS AND REAR ACCESS STEPS . . . . . . . . . . . . . . . . . . . . 65 WA900-3LC
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FIELD ASSEMBLY MANUAL
TABLE OF CONTENTS
A-14 ASSEMBLY OF BOOM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 A-15 ASSEMBLY OF FRONT FENDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 A-16 ASSEMBLY OF FRONT LAMP ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 A-17 ASSEMBLY OF ROPS CANOPY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 A-18 ASSEMBLY OF BUCKET. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 A-19 ASSEMBLY OF FLOOR MAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 PROCEDURE FOR TESTING ASSEMBLED MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 M-1 BLEEDING AIR FROM WHEEL BRAKE CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 M-2 GREASING WORK EQUIPMENT AND CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 M-3 ADJUSTING BUCKET POSITIONER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 M-4 ADJUSTING BOOM KICK-OUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 M-5 PROCEDURE FOR STARTING ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 M-6 INSPECTION OF ALL PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 M-7 PROCEDURE FOR BLEEDING AIR FROM PISTON PUMP . . . . . . . . . . . . . . . . . . . . 103 M-8 BLEEDING AIR FROM WORK EQUIPMENT CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . 104 INSPECTION REPORT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
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WA900-3LC
CHART OF SEPERATED UNITS
CHART OF SEPERATED UNITS
WA900-3LC
FIELD ASSEMBLY MANUAL
Page 4
FIELD ASSEMBLY MANUAL
DIMENSIONS AND WEIGHTS OF SEPARATED UNITS
DIMENSIONS AND WEIGHTS OF SEPARATED UNITS No.
Unit
Dimensions Weight kg / (lbs)
1
Front Axle Assembly
8,200 (18,078)
2
Rear Axle Assembly (axle support)
7,990 (17,615) 300 (662)
3
Wheel and Tire Assembly (each)
14,260 (31,438) 3,565 (7,860)
4
Bucket Assembly
11,690 (25,772)
5
Boom Assembly
11,106 (24,485)
6
Floor and Cab Assembly
760 (1,676)
7
ROPS Canopy Assembly
1,350 (2,976)
8
Floor Hand Rail Assembly and rear access step
650 (1,433)
9
Ladder Assembly
60 (132)
10
Front Fender (each)
170 (375)
11
Front Lamp Assembly (each)
65 (143)
12
Muffler Stack
50 (110)
13
Fuel Tank Assembly
790 (1,742)
14
Battery Box Assembly
580 (1,279)
15
Counterweight Counterweight, additional
2,900 (6,394) 2,600 (5,732) 1,600 (3,528)
Bare Machine
38,435 (84,735)
16 Total
Page 5
Length mm / (Inch)
Width mm / (Inch)
Height mm / (Inch)
10435 (411)
3260 (128)
3180 (125)
107,121 (236,161)
WA900-3LC
TRANSPORTATION BY LAND
FIELD ASSEMBLY MANUAL
TRANSPORTATION BY LAND SPECIFICATIONS Specifications
Related values Weight
Overall length
Overall width
Overall height
When traveling under own power
102,880 kg (226,810 lbs) (Operating weight)
14,065 mm (46 2")
4,815 mm (15 10") (Bucket width)
5,275 mm (17 4") (Top of ROPS)
Transportation by trailer (see note 1 and 2)
(Bare machine)
9.900 mm (32 5")
3,200 mm (10 5")
3,300 mm (10 9")
Traveling under own power
Less than 20 tons
More than 12 m (39 4")
Less than 2.5 m (8 2")
Less than 3.8 m (12 5")
Traveling by trailer
Maximum payload
Machine length x 1.1
Trailer width
Less than 3.8 m (12 5")
WHEN TRAVELING UNDER OWN POWER JIS posture for traveling under own power (with teeth). A
Overall length (Standard boom) Overall length (Hi-lift boom)
14,065 mm (46 2") 14,780 mm (48 6")
B
Overall height (with ROPS)
5,275 mm (17 4")
TRANSPORTATION BY TRAILER Posture of load when transporting by trailer. C
Length of bare machine.
10,450 mm (34 3")
D
Height from ground to top of machine.
4,000 mm (13 2")
E
Height from ground to top of platform.
500 mm (1 7")
F
Height from bottom of front frame to top of front frame.
3,180 mm (10 4")
WA900-3LC
Page 6
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FIELD ASSEMBLY MANUAL
SERVICE REFILL CAPACITIES
Trailer dimensions (36 ton, low platform type). G
Overall length
11,900 mm (39 1")
H
Length of platform
6,300 mm (20 7")
J
Length of gooseneck
2,500 mm (8 2")
K
Height from ground to top of gooseneck
1,500 mm (4 9")
L
Height from ground to top of platform.
500 mm (1 7")
-
Width of platform.
3,200 mm (10 5")
-
Maximum payload.
36 ton
TRAILERS REQUIRED TO MOVE MACHINE Trailer Size
Qty.
Remarks
36 ton
1
For machine body excluding removed parts.
15 ton
4
For bucket, loader link, front axle, rear axle (including swivel support), tire and wheel assemblies, cab and operator s compartment, bodywork (hood, grille, fender, ladder, platforms, handrails, light supports), counterweight, fuel tank (including fuel), exhaust pipe.
SERVICE REFILL CAPACITIES Cooling system
319 liters (79.5 U.S. gal)
Fuel Tank
1,425 liters (376.5 U.S. gal)
Engine Oil
132 liters (34.9 U.S. gal)
Hydraulic system
725 liters (191.5 U.S. gal)
Axle (each front and rear)
360 liters (95.1 U.S. gal)
Torque Converter and Transmission
140 liters (37.0 U.S. gal)
Brake Oil
18 liters (4.8 U.S. gal)
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WA900-3LC
ORDER OF ASSEMBLY, FACILITIES TO USE, SCHEDULE FOR ASSEMBLY
FIELD ASSEMBLY MANUAL
ORDER OF ASSEMBLY, FACILITIE S TO USE, SCHEDULE FOR ASSEMBLY
WA900-3LC
Page 8
FIELD ASSEMBLY MANUAL
Page 9
ORDER OF ASSEMBLY, FACILITIES TO USE, SCHEDULE
WA900-3LC
WORK SPACE LAYOUT DIAGRAM
WORK SPACE LAYOUT DIAGRAM
FIELD ASSEMBLY MANUAL
Use as large a work space as possible, it is easier to assembly the machine. The area shown in diagram below (25 m/82 ft x 30 m/98.5 ft) is the minimum size required.
WA900-3LC
Page 10
FIELD ASSEMBLY MANUAL
TOOLS AND EQUIPMENT REQUIRED
TOOLS AND EQUIPMENT REQUIRED
TOOLS REQUIRED
1
Set of common standard tools
Spanners, two-ended ring wrench, box wrench, cold chisel, screwdrivers, hammer, adjustable wrench, hexagon wrench, etc.
2
2
Power wrench
16 times
1
Front, rear axle mounts, ROPS canopy mount
3
Power wrench
4 times
1
Fuel tank
4
Socket
60 (insertion angle; 38.1) x L: 84
1
Front and rear axle mount
5
Socket
36 (insertion angle; 25.4) x L: 68
1
Rear axle support cover, tires, counterweight (lower)
6
Socket
46 (insertion angle; 25.4) x L: 72
1
Fuel tank, counterweight
7
Socket
55 (insertion angle; 38.1) x L: 82
1
ROPS mount
8
Socket
55 (insertion angle; 25.4) x L: 82
1
ROPS mount
9
Extension bar
Intersection angle: 12.7 x L: 150
1
Fuel tank
10
Adapter
Intersection angle: 19 x 12.7 x L: 55
1
Fuel tank
11
Extension bar
Intersection angle: 25.4 x L: 160
1
Tires, counterweight, ROPS canopy
12
Preset torque wrench (box type)
4 - 28 kgf m (29 - 203 lbf ft) {39 - 275 N m}
1
Power wrench
13
Interchangeable head type preset torque wrench
6 - 14 kgf m (43 - 101 lbf ft) {20 - 44 N m}
1
Connecting hoses and tubes
14
Interchangeable head type preset torque wrench
2 - 4.5 kgf m (14 - 33 lbf ft) {20 - 40 N m}
1
Connecting hoses and tubes
15
Interchangeable head type preset torque wrench
3 - 7 kgf m (21 - 51 lbf ft) {29 - 69 N m}
1
Connecting hoses and tubes
16
Heads (spanner type) for interchangeable head type preset
Width across flats: 27 (intersection hole: 15) Width across flats: 19 (intersection hole: 12) Width across flats: 22 (intersection hole: 12) Width across flats: 24 (intersection hole: 12)
One each
Connecting hoses and tubes
17
Preset torque wrench (box type)
20- 140 kgf m (144 - 1013 lbf ft) {196 - 1373 N m}
1
Rear axle support cover, counterweight
Page 11
WA900-3LC
TOOLS AND EQUIPMENT REQUIRED
FIELD ASSEMBLY MANUAL
18
Preset torque wrench (box type)
50 - 210 kgf m (362 - 1519 lbf ft) 1 {490 - 2060 N m}
Counterweight
19
Preset torque wrench (box type)
6 - 42 kgf m (43 - 304 lbf ft) {59 - 412 N m}
1
Rear axle support cover
20
Impact wrench
Capacity: 1.5 - 7.5 kgf m (11 55 lbf ft) {15 - 74 N m}
1
21
Impact wrench
Capacity: 5.5 - 31.5 kgf m (40 228 lbf ft) {54 - 309 N m}
1
22
Impact wrench
Capacity: 20.5 - 84.5 kgf m (148 - 611 lbf ft) {201 - 829 N m}
1
Tires, ROPS canopy
23
Adapter
Intersection angle: 19 x 25.4 x L: 71
1
Power wrench, torque wrench
24
Adapter
Intersection angle: 12.7 x 9.5 x L: 41
1
Power wrench, torque wrench
25
Large hammer
10 pounds
1
26
Air grinder
27
Bars
28
Bar
29
Grease gun (hand pump type)
30
1 Two each
Hole adjustment, moving heavy things
2
Hole adjustment
Capacity: 300 cc (10 fl oz.)
1
Oiling to pin
Oil container
Capacity: 1000 - 2000 cc (34 - 68 fl oz.)
1
Bleeding air from brake line
31
Vinyl hose
I.D. 6.5 - 7.0 x L: 1000 - 1500 (I.D. 1/4" x 1/4" x 39 - 60")
1
Bleeding air from brake line
32
Interchangeable head type preset torque wrench
15 - 25 kgf m (108 - 181 lbf ft) {147 - 245 N m}
1
Connecting hoses and tubes
33
Interchangeable head type preset torque wrench
13 - 23 kgf m (94 - 167 lbf ft) {128 - 226 N m}
1
Connecting hoses and tubes
WA900-3LC
Large, medium, small
Page 12
FIELD ASSEMBLY MANUAL
TOOLS AND EQUIPMENT REQUIRED
EQUIPMENT REQUIRED
1
Truck crane
45 ton
1
2
Truck crane
30 ton
1
3
Forklift truck
2 ton
1
Unloading comparatively light components and parts, assembling fuel tank
4
Compressor
Capacity: 8.5 gal (32 liter)
1
Impact wrench, bleeding air from brake
5
Roller (for moving rear axle to side)
6
Lever block
1 ton
3
Supporting cylinders, drive shafts
7
Stand (for worker)
4 steps (approx. 1.5 m)
3
Use during operation
8
Steel sheet
(t) 9 x 1219 x 2438 (3/8" x 48" x 96")
4
Positioning bare machine
9
Steel sheet
(t)25 x 250 600 (1" x 10" x 24")
4
Positioning bare machine
10
Wooden blocks
400 x 400 x 900 (16" x 16" x 36") 200 x 400 x 800 (8" x 16" x 32")
14 4
Positioning bare machine
11
Air type grease gun
Capacity: 18 liter (5 gal)
1
12
Air compressor gas charger
Charge manifold, leak detector
1
13
Tester
Page 13
1
If another gas charger is used, follow instructions supplied with it
1
WA900-3LC
TOOLS AND EQUIPMENT REQUIRED
FIELD ASSEMBLY MANUAL
LIFTING TOOLS REQUIRED
1
Front frame lifting tool
2-point suspension (L=2250 chain diameter = 20, sling hook = (SL)
1
(See page -15)
2
Rear frame lifting tool
Balanced 2-point suspension (L=2250 chain diameter = 20, sling hook = (SL)
1
(See page -15)
3
Rear axle lifting tool
2-point suspension (L=5500 chain diameter = 16, grab hook = (G)
1
(See page -15)
4
Nylon sling
50 x 2000 mm (2" x 7 )
2
Axle support, cylinder sling
5
Front, rear axle lifting tool
Balanced 2-point suspension (chain diameter = 16, sling hook = (SL) (diameter = 12.5, grab hook = (G)
1
(See page -15)
6
Nylon sling for drive shaft
50 x 5000 mm (2" x 16.5 )
1
7
Fuel tank lifting tool
2-point suspension (L=5000 chain diameter = 6.3, sling hook = (SL)
2
(See page -16)
8
Floor and cab lifting tool
2-point suspension (L=2000 chain diameter = 6.3, sling hook = (SL)
2
(See page -16)
9
Nylon sling
150 x 10000 mm (6" x 33 )
1
Lifting tool for tires
10
Wire sling
Capacity: 15 ton L=8 (2500 mm) Capacity: 11 ton L=7 (2000 mm)
2 1
Lifting tool for boom (lifting front) when removing blocks under chassis
11
Shackle
2, 5, 10, and 15 ton
Two each
WA900-3LC
Page 14
FIELD ASSEMBLY MANUAL
TOOLS AND EQUIPMENT REQUIRED
Front Frame Lifting Tool
Rear Frame Lifting Tool Dimension B Dimension C Dimension D
3900 mm (13 ) 2850 mm (9.5 ) 2500 mm (8 )
Chain diameter
1) 20 mm (7/8") 2) 20 mm (7/8")
Hook type
SL (sling hook)
Rear Axle Lifting Tool Dimension E
5500 mm (18 )
Chain diameter
16 mm (5/8")
Hook type
G (grab hook)
Front, Rear Axle Lifting Tool Dimension F Dimension G Dimension H
2000 mm (7 ) 2000 mm (7 ) 5500 mm (18 )
Chain diameter
3) 16 mm (5/8") 4) 12.5 mm (1/2")
Hook type
SL (sling hook) G (grab hook)
Page 15
WA900-3LC
This is the sample of the manual Click on the download link for complete manual
Download Link