Komatsu GALEO WA700-3 Field Assembly Instructions
  1. Manuals
  2. Brands
  3. Komatsu Manuals
  4. Compact Loader
  5. GALEO WA700-3
  6. Field assembly instructions

Komatsu GALEO WA700-3 Field Assembly Instructions

Wheel loader
Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual

Advertisement

Table of Contents
loading

Related Manuals for Komatsu GALEO WA700-3

Summary of Contents for Komatsu GALEO WA700-3

  • Page 2: Table Of Contents

    CONTENTS 1. Drawings of removed units ..................2. Dimensions of removed units ................. 3. Transportation of removed units ................4. Assembly procedure, necessary equipment, and schedule ........5. Layout of work space....................6. Necessary tools and equipments................7. Assembly procedure A-0 Positioning front and rear axles and bare machine ........

  • Page 4: Drawings Of Removed Units

    1. Drawings of removed units 1. Front axle assembly 2. Rear axle assembly 3. Wheel and tire assembly 4. Bucket assembly (Axle support) 5. Cab assembly 6. ROPS canopy assembly 7. Floor handrail and rear 8. Front lamp assembly access step assembly (1 piece) 9.

  • Page 5: Dimensions Of Removed Units

    2. Dimensions of removed units Overall length Overall width Overall height Unit name Weight (kg) L (mm) W (mm) H (mm) Front axle assembly 5,532 3,832 1,256 Rear axle assembly 5,454 3,832 1,351 (Axle support) (331) 9,948 Wheel and tire assembly (×1) 4,080 2,420 2,420...

  • Page 6: Transportation Of Removed Units

    3. Transportation of removed units Land transportation Related specifications Means of transportation and necessary work Specification for transportation Overall length Overall width Overall height Weight (ton) (mm) (mm) (mm) 70.8 12,500 4,040 4,790 Self-propelled travel (Operating weight) (Bucket width) (Top of ROPS) 35-ton trailer ×1 [Chassis, excluding following parts to be removed] 15-ton trailers ×3 [Bucket, front axle, rear...

  • Page 7: Assembly Procedure, Necessary Equipment, And Schedule

    4. Assembly precedure, necessary equipment and schedule...

  • Page 8: Layout Of Work Space

    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 45-ton crane Bare machine Cab assembly Place for keeping light units.

  • Page 9: Necessary Tools And Equipments

    6. Necessary tools and equipments (1) Necessary tools Tool name Specification Q’ty Remarks Spanner, ring wrench, socket wrench, General standard tools chisel, screwdriver, hammer, adjustable wrench, Hexagonal wrench, etc. Front and rear axle mounts, Power wrench 16-time ROPS canopy mount Socket 60 (Insertion angle: 38.1), L: 84 For front and rear axle mounts...
  • Page 10 (2) Necessary slings Sling name Specification Q’ty Remarks 2-point sling (L:2,250, Chain diameter: Front frame sling See figure below ø20, Sling hook) (SL) Balance 2-point sling (Chain diameter: Rear frame sling See figure below ø20, Sling hook) (SL) 2-point sling (L:5,500, Chain diameter: Rear axle sling See figure below ø16, Crab hook) (G)
  • Page 11 (3) Necessary equipment Tool name Specification Q’ty Remarks Min. 45 ton Crane Min. 30 ton Unloading relatively light components Forklift Min. 2 ton and parts Impact wrench, bleeding air from Compressor Capacity: Min. 32 brake system Lever block 1 ton For cylinder and drive shaft Stepladder (Work bench) 4 steps (About 1.6 m)
  • Page 12 Axle sling Drawing No. Material Q'ty SS419 AS-0059 STS41...
  • Page 14 Part No. Part Name Material Q’ty Applicable Balance SS400 Lifting tool D VD250 Connecting tool B VB200 Shackle N VN200 Lifting tool E VE200 Note Link chain SV200, L = 3.5 m 1. Attach inspection result sheet. Link chain SV200, L = 1.5 m 2.

  • Page 15: Positioning Front And Rear Axles And Bare Machine

    Assembly procedure No. Positioning front and rear axles and bare machine Set dimension 4,800m Wheelbase Positioning front and rear axles Ground Steel plate Steel plate Fig. 1 30-ton crane 45-ton crane Positioning bare Frame assembly stand machine on supports Mount onto counterweight mounting end plate.

  • Page 16: Positioning Chassis On Bare Machine (Frame Stand)

    Assembly procedure No. Positioning chassis on bare machine (Frame stand) (1/2) 30 ton crane 45 ton crane Using lifting eyes of front and rear frames, sling bare machine with 2 cranes having capacities of 30 ton and 45 ton. Chain diameter Front frame Rear frame Hanging load: 18 ton...
  • Page 17 Assembly procedure No. Positioning chassis on bare machine (Frame stand) (2/2) Precautions Necessary tools Necessary equipment Name Q’ty Name Q’ty...

  • Page 18: Installing Rear Axle

    Assembly procedure No. Installing rear axle (1/5) Clean pivot packing in rear frame axle support (front) and inside of seal with cloths, and then apply grease again. Mounting bolt Spacer (×2) Attached to stand 01643-33690 (×2) Washer attached to stand Cap cover 01011-63650 (×2) Rear frame...
  • Page 19 Assembly procedure No. Installing rear axle (2/5) Change the position of the lifting tool. Raise the rear axle, and insert the rear axle mount into the rear support. a Before installing the rear axle, clean the mating surfaces of the rear axle support and frame. •...
  • Page 20 Assembly procedure No. Installing rear axle (3/5) Rear axle assembly Axle support 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. To rear frame axle support Part No.
  • Page 21 Assembly procedure No. Installing rear axle (4/5) Connect the hoses coming from the slack adjuster to the tubes on the right and left of the rear axle. (See the following figure.) 3 Hose nut: 58.8 – 98.0 Nm {6 – 10 kgm} (HEX: 27 mm) REAR AXLE Slack adjuster Rear frame...
  • Page 22 Assembly procedure No. Installing rear axle (5/5) Connecting axle support remote grease tube Connection After installing the axle assembly (rear) to the rear frame, connect the remote grease tube to the axle support and thrust cover. 3 Tube nut mounting bolt: 9.8 – 24.5 Nm {1.0 – 2.5 kgm} Connection View X Precautions...

  • Page 23: Installing Rear Drive Shaft

    Assembly procedure No. Installing rear drive shaft 1. Pass a nylon sling (50 × 5,000) through the center of the frame, raise with a crane from the top of the rear platform, adjust the position, and install. Fitting (Straight) Fitting (45°) REAR AXLE Part No.

  • Page 24: Installing Front Axle Assembly

    Assembly procedure No. Installing front axle assembly (1/2) 1. Raise the front axle and install it to the front frame. 4 Front axle: 5,800kg Part A : Position for fixing lifting tool a Tighten the wire when fitting. a Sling the axle so that the axle pad face will be level.
  • Page 25 Assembly procedure No. Installing front axle assembly (2/2) 3. Connect the brake hoses coming from the slack adjuster to the tubes on the right and left of the front axle. 3 Connect hose: 78.4 ± 19.6 Nm {8 ± 2 kgm} (Width across flats: 27) 4.

  • Page 26: Installing Front Drive Shaft

    Assembly procedure No. Installing front drive shaft 1. Hold the drive shaft with a lever block so that it will be di- rected up a little (about 10°). (Lifting up) a Before assembling the drive shaft, clean the mounting surface. a Assemble so that the grease nipples of the front and rear drive shafts face in the same direction at the grease nipple of the center shaft.

  • Page 27: Installing Rear Tires And Wheel Assembly

    Assembly procedure No. Installing rear tires and wheel assembly 1. Lift up tire (1) with a crane, install it to the axle, and install the mounting nuts. 4 Tire: 2,487 kg/piece Lifting tool: Nylon sling (150 × 10,000) a Set the air valve down. a When positioning the tire and wheel assembly, be careful not to damage the tire inflation tube.

  • Page 28: Installing Front Tires And Wheel Assembly

    Assembly procedure No. Installing front tires and wheel assembly 1. The tire nuts are installed temporarily to the front axle as- sembly when delivered. Remove and clean them. Install sling so that it will choke tire. 2. Lift up tire (1) with a crane, install it to the axle, and install the mounting nuts.

  • Page 29: Installing Bucket

    Assembly procedure No. Installing bucket (1/5) 1. Sling the bucket with a crane and position it to the front of the truck. 4 Bucket: 7,090 kg Lifting : Use the upper part of the balance of the balance sling for the rear axle. 2.
  • Page 30 Assembly procedure No. Installing bucket (2/5) 4. Installing bucket to boom (Sling the bucket with a crane and adjust the positions of the holes.) 1). Bring the bucket near the lift arm and match the buck- et mounting pins. 2). Select shims so that clearance T between the boom pivot and bucket pivot will be 1.5mm or less.
  • Page 31 Assembly procedure No. Installing bucket (3/5) 6). Tighten the bolt temporarily so that cam (5) will touch the pin. a After installing retainer (10), tighten the bolt per- manently. 7). Install retainer (10) and measure clearance C, and then select shims so that clearance C will be below the standard.
  • Page 32 Assembly procedure No. Installing bucket (4/5) Before installing pin, apply LM-P molybdenum disulfide paste to pin and inside of bushing. Boom pivot pin Plug Bucket link pivot pin Fitting Plug For left hand For right hand Flange for right hand is directed opposite to flange for left hand.
  • Page 33 Assembly procedure No. Installing bucket (5/5) Part No. Parts name Q’ty State of parts (620-3890) Pin assembly Loose-supply item 425-70-11250 Loose-supply item 01011-82430 Bolt Loose-supply item 01011-82425 Bolt (Lot) Loose-supply item 01643-32460 Washer Loose-supply item 01580-12419 Loose-supply item 427-70-11260 Retainer (Lot) Loose-supply item 427-70-11270 Shim (t = 0.2)

  • Page 34: Installing Cab Assembly

    Assembly procedure No. Installing cab assembly (1/7) Warning Stop the machine on a level ground, install the safety bar to the frame, lower the bucket to the ground, stop the engine, apply the parking brake, and put chocks under the tires. 1.
  • Page 35 Assembly procedure No. Installing cab assembly (2/7) 4. Tuck up the bellows at the lower part of the steering post and loosen the 4 bolts, turn down the steering post fully toward to operator’s seat. 4 bolts (4) (2 each on right and left sides) (Inside of rubber) Rubber (3) Steering post viewed from left of machine...
  • Page 36 Assembly procedure No. Installing cab assembly (3/7) 8. While keeping the cab assembly level, lower it slowly. a Be careful that there is no interference with the elec- tric wiring at the rear right of the floor frame. a Cover the steering post and plastic cover with seats to protect them.
  • Page 37 Assembly procedure No. Installing cab assembly (4/7) 11. Drive 2 cab assembly mounting bolts (7) and 4 intermedi- ate bolts and 4 rear bolts (8) (2 – 3 threads with your fin- gers). Part No. Part name Q’ty 01010-81240 Bolt 01643-31232 Washer 418-46-12310...
  • Page 38 Assembly procedure No. Installing cab assembly (5/7) 15. Permanently tighten 2 cab assembly mounting bolts (7) and 4 intermediate bolts and 4 rear bolts (8) which were tightened temporarily in 11. 16. Raise the bucket about 400 mm, remove the safety lock Push-pull gauge bar of the frame and chocks, and release the parking brake.
  • Page 39 Assembly procedure No. Installing cab assembly (6/7) 18. Connect electric wiring connectors (10). 19. Install the window washer hose (11). a Match the colors of the hoses. Connect the wiring harness of the joystick lamp. (Machine with joystick) From floor wiring harness 20.
  • Page 40 Assembly procedure No. Installing cab assembly (7/7) 22. Check the operations of the air conditioner, radio, ciga- rette lighter, front and rear wipers, windshield washer, and working lamp. 23. Install the mirrors and mirror stays to the right and left of the cab assembly.

  • Page 41: Installing Rops Canopy Assembly

    Assembly procedure No. Installing ROPS canopy assembly (1/2) A-10 Remove cover, install ROPS canopy, and return cover. Part No. Part name Q’ty Condition of parts 428-54-24140 Cover Installed to body temporarily 01435-01220 Bolt Installed to body temporarily 4 ROPS canopy: 1,086 kg Sling: 2-point sling (Use sling for floor and cab assembly.) Before installing ROPS canopy, clean mounting faces.
  • Page 42 Assembly procedure No. Installing ROPS canopy assembly (2/2) A-10 Remove antenna installed to cab assembly temporarily and install it to canopy. 1,520.0 - 1,912.2 Nm {155 - 195 kgm} (Target: 1,716.1 Nm {175 kgm}) Connect wiring with connector (CNSL5) Extend the antenna wiring from which is from cab ceiling in left rear.

  • Page 43: Installing Front Lamp Assembly

    Assembly procedure No. Installing front lamp assembly A-11 After connecting connector, fix wiring harness to clip welded to inside of front frame. (Both right and left sides) Connect connectors. Insert connector in clip and fix it. (Both right and left sides) Inside of front frame (Both right and left sides) R.H.

  • Page 44: Installing Floor Handrail Assembly (Right)

    Assembly procedure No. Installing floor handrail assembly (right) A-12 Mounting bolt (M12) 53.9 - 122.5 Nm {5.5 - 12.5 kgm} Part No. Part name Q’ty Condition of parts Assemble parts for floor handrail 428-54-25121 Handrail (Front, L.H.) Loose-supply item 01435-01230 Bolt Installed temporarily to right and left of floor 428-54-25131...

  • Page 45: Installing Muffler Stack

    Assembly procedure No. Installing muffler stack A-13 53.9 - 122.5 Nm {5.5 - 12.5 kgm} Part No. Part name Q’ty Condition of parts Assemble parts for muffler stack 428-02-21110 Muffler stack Loose-supply item 01010-81235 Bolt Installed to top hood upper face temporarily 1643-31232 Washer Installed to top hood upper face temporarily...

  • Page 46: Installing Counterweight

    Assembly procedure No. Installing counterweight (1/2) A-14 2,451.6 - 3,040.0 Nm {250 - 310 kgm} Rear frame Part No. Part name Q’ty Condition of parts Assemble parts for counterweight 428-46-23210 Counterweight Loose-supply item 01011-63690 Bolt Installed to rear frame end plate temporarily 01643-33670 Washer Installed to rear frame end plate temporarily...
  • Page 47 Assembly procedure No. Installing counterweight (2/2) A-14 • Install the additional weight to the standard weight with the mounting bolts. Install this additional weight if it is delivered as an optional kit together with the machine. Use pin for 823.7 - 1,029.6 Nm {84 - 105 kgm} standard machine.

  • Page 48: Installing Ladder Assembly

    Assembly procedure No. Installing ladder assembly A-15 147.0 - 308.9 Nm {15 - 31.5 kgm} Hydraulic tank (right) 53.9 - 122.5 Nm {5.5 - 12.5 kgm} Installed ladder to hydraulic tank (right) Part No. Part name Q’ty Condition of parts Right and left Ladder assembly Loose-supply item...

  • Page 49: Installing Front Fender

    Assembly procedure No. Installing front fender A-16 1. Sling the front fenders with a crane (30 ton) and install them to the right and left of the front frame. Mounting bolt 83.3 - 196.1 Nm {8.5 - 20 kgm} Part No. Part name Q’ty Condition of parts...

  • Page 50: Installing Floor Handrail And Rear Access Step

    Assembly procedure No. Installation of handrail and rear access step (1/6) A-17 View T: Wiring harness connection of rear lamp (if equipped) Decal location of rear lamp (if equipped) Precautions Necessary tools Necessary equipment Name Q’ty Name Q’ty Impact wrench 30 ton crane Socket (17 mm) Nylon sling...
  • Page 51 Assembly procedure No. Installation of handrail and rear access step (2/6) A-17 Part No. Part name Q’ty Condition of parts Part No. Part name Q’ty Condition of parts Loose-supply item Loose-supply item 428-54-24133 Floor 428-54-24471 Fender (Separately packed) (Separately packed) Loose-supply item 17A-04-12550 Cushion...
  • Page 52 Assembly procedure No. Installation of handrail and rear access step (3/6) A-17 Installation of left handrail Part No. Part name Q’ty Condition of parts Part No. Part name Q’ty Condition of parts Loose-supply item Loose-supply item 620-3860-T1 Step assembly 428-54-25350 Bracket (Separately packed) (Separately packed)
  • Page 53 Assembly procedure No. Installation of handrail and rear access step (4/6) A-17 Installation of right handrail 1. Remove bolts (2) installed to the machine. 2. Install step assembly (1) with removed bolts (2). 3. Remove bolts (4) installed to the machine. 4.
  • Page 54 Assembly procedure No. Installation of handrail and rear access step (5/6) A-17 1. Remove the bolts installed to the machine. 2. Install handrails (1), (3) and (5) with the removed bolts. Part No. Part name Q’ty Condition of parts 428-Z90-2411 Handrail Separately packed (Loose-supply item) 01024-81235...
  • Page 55 Assembly procedure No. Installation of handrail and rear access step (6/6) A-17 Insert in Insert in handrail pin. Detail T View Z Detail R handrail pin. Pass hose. Front of chassis Right-hand of chassis Part No. Part name Q’ty Condition of parts 428-T86-1710 Cable Installed to handrail temporarily...

  • Page 56: Installing Floor Mat

    Assembly procedure No. Installing floor mat A-18 Install the floor mat to the floor frame. Part No. Part name Q’ty Condition of parts 426-54-22832 Loose-supply item Precautions Necessary tools Necessary equipment Name Q’ty Name Q’ty...

  • Page 57: Bleeding Air From Brake Line

    Assembly procedure No. Bleeding air from brake line 1. Oil filling procedure (1) Fill oil to center of upper sight gauge. Brake oil to be KES 07.B51 EO10-CD. (2) Operate air bleeding. (See Step 2) (3) Fill in accumulator full by oil. (Charge accumulator about 2 minutes at engine low idle.) (4) Confirm oil level locates center of lower sight gauge.

  • Page 58: Greasing Work Equipment And Chassis

    Assembly procedure No. Greasing work equipment and chassis 1. Coat the lift arm hinge, bucket cylinder head, and lift arm cylinder head with grease. 2. Grease the front and rear drive shafts. 3. Grease the rear axle support. Precautions Necessary tools Necessary equipment Name Q’ty...

  • Page 59: Adjusting Bucket Positioner

    Assembly procedure No. Adjusting bucket positioner Proximity switch mounting bracket 1. Adjusting bucket positioner (1) Lower the bucket to the ground and set it to a level. (Lower it to the level ground.) (2) Adjust and fix the proximity switch so that its sensing face can be pulled in about 0.5 – 1.0 mm from the end of the protector.

  • Page 60: Adjusting Boom Kick-Out

    Assembly procedure No. Adjusting boom kick-out Censer mounting bolt: 14.7 - 19.6 Nm {1.5 - 2.0 kgm} 1. Adjusting boom kick-out (1) Raise the boom to the stroke end and fix the plate so that the distance between the center of the switch and the top of the sensor plate will be 0 –...

  • Page 61: Inspection Of All Parts

    Assembly procedure No. Inspection of all parts 1. Inspect the assembled parts for interference, oil leakage, and air leakage. 2. Check the radiator coolant level, engine oil level, transmission oil level, hydraulic oil level, brake oil, and window washer fluid level. Precautions Necessary tools Necessary equipment...

  • Page 62: Starting Engine

    Assembly procedure No. Starting engine (1/2) 1. Check all oil and coolant levels, and add if necessary. • Radiator coolant level. • Engine oil pan oil level • Hydraulic tank oil level • Fuel level a For details of the gauge positions and oil and coolant levels, see the Operation & Maintenance Manual. 2.
  • Page 63 Assembly procedure No. Starting engine (2/2) a When starting the engine of machines (completed machines or semi-completed machines) that have been kept in long-term storage of six months or more, carry out the following procedure. 1. Disconnect the Econoseal connector of the engine stop wiper motor installed inside the rear frame on the right side of the engine.

  • Page 64: Bleeding Air From Piston Pump

    Assembly procedure No. Bleeding air from piston pump If the hydraulic oil has been completely drained Compressed air inlet port from the hydraulic tank, carry out the following (oil filler) procedure as necessary to prevent seizure of the piston pump. Plug (As the machine is shipped with the hydraulic tank full of oil, there is no particular need to carry out...

  • Page 65: Bleeding Air From Work Equipment Hydraulic Circuit

    Assembly procedure No. Bleeding air from work equipment hydraulic circuit 1. Bleeding air from cylinders (1) Run the engine at low idle and operate the cylinder to about 100mm from the end of its stroke....3 – 4 times (2) Run the engine at midrange speed and operate the cylinder to about 100mm from the end of its stroke ... 3 – 4 times (3) Run the engine at high idle and operate the cylinder to about 100mm from the end of its stroke ....
  • Page 68 When glow switch is set in OFF and main switch is set in ON, Operation of glow switch lamp must not be lighted up. When glow switch is set in AUTO or FORCED and main switch is set in ON If coolant temperature is above 20°C, lamp must be lighted up for 12 seconds and then flashed If coolant temperature is above 20°C, lamp must be lighted up...
  • Page 74 Secondary...
  • Page 79 WA700-3 GALEO WHEEL LOADER Form No. GEN00038-01 ©2007 KOMATSU All Rights Reserved Printed In Japan 06-07 (01)

This manual is also suitable for:

5001

Table of Contents