WA1200-6 Work Equipment

Pins
Procedure to Test and Adjust
Work Equipment Pin Installation
on WA1200-6
 SAFETY FIRST !
Be sure machine is properly shut down, brakes set, and locked out.
Bucket is lowered to the ground and all stored energy released.
Wheel chocks in place on all vehicles as required.
Make sure all PPE is in place, check fall protection harness.
Check safety and operation of man-lift.
Check all rigging, lifting apparatus, crane safety functions.
 WA 1200-6 Work Equipment Pin Assembly Components
1. Lift Arm to Front 2. Lift Arm Cylinder 3. Lift Arm Cylinder 4. Bucket Cylinder to 5. Bucket Cylinder to 6. Bell Crank to Lift
7. Bell Crank to Link 8. Link to Bucket 9. Lift Arm to Bucket
Frame to Front Frame to Lift Arm Front Frame bellcrank Arm

280MM 240MM 240MM 180MM 180MM 240MM 180MM 180MM 240MM

Pin 42C-70-11284(2) 42C-70-11234(2) 42C-70-11224(2) 42C-70-11254(2) 42C-70-11245(2) 42C-70-11214(2) 42C-70-11264(2) 42C-70-11274(2) 42C-70-11214(2)
Pin Flange Bolts 01010-83080(12) 01010-83080(8) 01010-83080(8) 01010-82470(8) 01010-82470(8) 01010-83080(8) 01010-82470(8) 01010-82470(8) 01010-83080(8)
Spacer 42C-70-11631(12) 42C-70-11631(8) 42C-70-11631(8) 42C-70-11621(8) 42C-70-11621(8) 42C-70-11631(8) 42C-70-11621(8) 42C-70-11621(8) 42C-70-11631(8)
Oil Plug 07052-31624(4) 07052-31624(4) 07052-31624(4) 07052-31624(4) 07052-31624(4) 07052-31624(4) 07052-31624(4) 07052-31624(4) 07052-31624(4)
Cover Plate 42C-70-11460(2) 42C-70-11451(2) 42C-70-11451(2) 42C-70-11440(2) 42C-70-11440(2) 42C-70-11451(2) 42C-70-11440(2) 42C-70-11440(2) 42C-70-11451(2)
Cover Plate Bolt 01010-83080(8) 01010-83070(8) 01010-83070(8) 01010-82470(8) 01010-82470(8) 01010-83070(8) 01010-82470(8) 01010-82470(8) 01010-83070(8)
Cover Plate Washer 01643-33080(8) 01643-33080(8) 01643-33080(8) 01643-32460(8) 01643-32460(8) 01643-33080(8) 01643-32460(8) 01643-32460(8) 01643-33080(8)
Cover Plate O-Ring 07000-15170(2) 07000-15130(2) 07000-15130(2) 07000-12100(2) 07000-12100(2) 07000-15130(2) 07000-12100(2) 07000-12100(2) 07000-15130(2)
Collar A 42C-70-11395(2) 42C-70-11385(2) 42C-70-11713(2) 42C-70-11365(2) 42C-70-11355(2) 42C-70-11375(2) 42C-70-11355(2) 42C-70-11365(2) 42C-70-11375(2)
Collar B 42C-70-11395(2) 42C-70-11375(2) 42C-70-11713(2) 42C-70-11365(2) 42C-70-11355(2) 42C-70-11375(2) 42C-70-11355(2) 42C-70-11365(2) 42C-70-11375(2)
Bushing Seal 42C-70-11431(4) 42C-70-11421(4) 42C-70-11421(4) 42C-70-11411(4) 42C-70-11411(4) 42C-70-11421(4) 42C-70-11411(4) 42C-70-11411(4) 42C-70-11421(4)
Collar O-Ring 07000-A6280(4) 07000-A6240(4) 07000-A6240(4) 07000-A6180(4) 07000-A6180(4) 07000-A6240(4) 07000-A6180(4) 07000-A6180(4) 07000-A6240(4)
Dust Seal 42C-70-11760(4) 42C-70-11750(4) 42C-70-11750(4) 42C-70-11740(4) 42C-70-11740(4) 42C-70-11750(4) 42C-70-11740(4) 42C-70-11740(4) 42C-70-11750(4)
Shim - Pin Flange - 0.5MM 42C-70-12940 42C-70-12930 42C-70-12920 42C-70-12910 42C-70-12910 42C-70-11920 42C-70-12910 42C-70-12910 42C-70-12920
Shim - Collar - 0.5MM 42C-70-11890 42C-70-11880 42C-70-11880 42C-70-11870 42C-70-11870 42C-70-11880 42C-70-11870 42C-70-11870 42C-70-11880
Shim - Collar - 0.3MM 42C-70-11790 42C-70-11780 42C-70-11780 42C-70-11770 42C-70-11770 42C-70-11780 42C-70-11770 42C-70-11770 42C-70-11780
Shim - Pin End - 0.5MM 42C-70-11820 42C-70-11840 42C-70-11840 42C-70-11860 42C-70-11860 42C-70-11840 42C-70-11860 42C-70-11860 42C-70-11840
Shim - Pin End - 0.3MM 42C-70-11810 42C-70-11830 42C-70-11830 42C-70-11850 42C-70-11850 42C-70-11830 42C-70-11850 42C-70-11850 42C-70-11830
Bushing 42C-70-11346 42C-70-11322 42C-70-11322 42C-70-11293 42C-70-11293 42C-70-11335 42C-70-11314 42C-70-11314 42C-70-11335
Oil Capacities - Per Pin (GAL) 2.96 1.49 1.27 0.48 0.45 1.48 0.50 0.53 1.48

4
1
5

3
6

7
2
9
 Service Tips

Disassembly / Assembly
TIP 1: When disassembling pins from Bell
Crank ends, it is a good idea to remove the pin
cover next to the pin you are removing. The
clearance is necessary when removing the pin.
TIP 2: Remove hydraulic lines from bucket tilt cylinders as they interfere with the
removal of cylinder to frame pins. Be sure to cap all lines to keep contamination out.
TIP 3: Inspect all bushings during disassembly. Check for wear to determine if part is
being re-used.
TIP 4: Inspect pins for wear and cracking inside at oil ports.
TIP 5: When installing bucket or boom, use
care to not over tighten bolts (step 4). This
will put stress on boom arms that could
effect the shimming of the related pin.
 Work Equipment Pin
Shimming Procedures
 Disassemble one pin joint at a time (or pair when
removing bucket or boom) per Komatsu Service Manual.

After disassembling and cleaning all parts, proceed with

the following steps for assembly and shimming.

1. Install collar (flange side) without seals

2. Install pin into bore. Use plenty of pin oil to

lubricate surfaces and push using hands only.
3. Insert a spacer (S) of known measurement
(.250 key stock is suggested) between pin
flange and collar.

(S)

4. Tighten pin flange bolts evenly by hand until

snug.

(Do not over tighten and cause stress when

shimming both pins at bucket or boom heel)
5. Measure the clearance (G), between the
pin flange and the collar boss.

6. Subtract the clearance measurement (G),

from the spacer measurement (S)
(S) – (G) = (T)

(The TOTAL(T) side to side bushing /

component movement between the collar
bosses)

7. Divide (T) in half (T) / 2 = (X)

(X) = (The clearance between the collar on BUSHING

the flange end of the pin and the
bushing/component with NO shims in place.)
At this step; the bushing / component is now
MEASURE CLEARANCE (G)
NOTE: The component can be cylinders,
bell crank arms, bucket, boom, etc.

centered between the two bosses. The bushing is an interference fit and
does not move with in the component.

Recommended clearance for the seal is .020

to .027 inch.
 BUSHING COMPONENT
MEASURE CLEARANCE (G)

NOTE: The component can be cylinders,

bell crank arms, bucket, boom, etc.

The bushing is an interference fit and

does not move with in the component.

COLLAR

BOSS

If X = .020 - .027 : No shims are needed

If X > .020 - .027 : Install shims between the pin flange and the collar, to move the collar closer
to the bushing thus achieving required seal clearance.

If X < .020 - .027 : Install shims between the pin flange and the collar boss, to allow the collar to
move away from the bushing thus achieving required seal clearance.
8. Remove pin from boss.

9. Add shims as calculated (if needed)

10. Remove collar from boss.

11. Install O-ring seal and dust seal into collar.

12. Install seal into groove (check for proper

orientation)

Use pin oil liberally on all parts for ease of

installation.
13. Install pin with both collars completely
assembled; seals, O-rings, and dust seals.

(At this time, shims have been installed on

the flange side of pin, which centers the
bushing / component between the bosses.
It will facilitate the process by installing the
second collar because the pin will not be
removed again. Proceed to the next steps
for shimming collar to pin cover)
You will now observe the pin installed in the
bores with the fully assembled collar.

NOTE: Three different size pins (180, 240,

280 mm) will require three covers to be
modified per tool modification supplement.
(see separate instruction). The covers will
need to be procured from a Komatsu Dealer

These modified covers now become Service

Tools to be used for future shimming
procedures.
Record the thickness of all three machined
cover plates. You will refer to this dimension
in later steps.
L = Cover Thickness

14. Bolt machined cover to the end of pin.

15. Turn bolts by hand until cover is tight.

(This has now closed all the clearance
between the pin, bushing, and collars).
16. Using a depth micrometer, through the
hole drilled in the modified cover, measure
the distance from the machined cover face
to the pin face (D). This will indicate the
relation of the collar to the pin.

With the thickness of the machined cover

(L), it can be determined where the collar
and bushing are in relation to the pin end.

17. Determine the shims needed on the

cover / pin to allow the collar a clearance
of .040 to .054”.
 BUSHING

NOTE: The component can be cylinders,

bell crank arms, bucket, boom, etc.

The bushing is an interference fit and

does not move with in the component.

COVER
(L)

COLLAR

If Cover Thickness (L) is equal to Depth Measurement (D) then pin and collar stack up are flush
If L < D then pin is shorter then collar stack up – shim pin
If L > D then pin is longer then collar stack up – shim collar

If L = D + (.040 - .054”) No shims

If L < D + (.040 - .054”) Shim collar
If L > D + (.040 - .054”) Shim pin
18. After determining correct amount of shims,
remove Service Tool Cover, install new O-ring on
cover, install shims as needed, when installing
cover.

19. Refer to Komatsu Service Manual for all bolt

torque specs. Torque all fasteners as required.

20. Refer to Komatsu OMM for pin refill capacities

and the specified lubricant to be used in pins.
THE END