Komatsu WA800-3E0, WA900-3E0 Wheel Loader Field Assembly Instruction GEN00056-10

Description

• Model List:
  • WA800-3E0 Wheel Loader
  • WA900-3E0 Wheel Loader

• 1. COVER
• 2. CONTENTS
• 3. Dividing Process Overview (Major components alone)
• 4. Major Components Table of Dimensions
• 5. Work Space Layout
• 6. Schedule Table for Field Assembly
• 7. Facility, Jigs and Tools
• 8. List of Oil, Grease and Paints
• 9. Assembly procedure
• 9.1. Oil, grease and coolant
• 9.2. Oil, grease and coolant level
• 9.3. Setting rear frame in place
• 9.4. Setting front frame in place
• 9.5. Joining front and rear frames
• 9.6. Front and rear frames joining procedure
• 9.7. Assembling the steering pin
• 9.8. Assembling the center drive shat (Center support Transmission)
• 9.9. Connection of piping Part 1
• 9.10. Connection of piping Part 2
• 9.11. Connection of piping (Part 2) (7XC47 Front and rear frame combination load figure)
• 9.12. Connection of piping (Part 2) (Riotinto specification If equipped)
• 9.13. Connecting the autogreasing pipe
• 9.14. Setting the axle in place and assembling the support
• 9.15. Setting the bare machine in place
• 9.16. Assembling the rear axle
• 9.17. Rear axle rear side cover assembling procedure
• 9.18. Connecting the rear axle pipe
• 9.19. Fixing of rear axle piping (Brake cooling specification If equipped)
• 9.20. Connection of rear axle piping (Riotinto specification If equipped)
• 9.21. Fixing of rear axle piping (Brake cooling specification If equipped)
• 9.22. Connection of cooling line piping (Brake cooling specification If equipped)
• 9.23. Assembling the rear drive shaft (Transmission Rear axle)
• 9.24. Assembling the front axle
• 9.25. Fixing of front axle piping (Brake cooling specification If equipped)
• 9.26. Connection of front axle piping (Brake cooling specification If equipped)
• 9.27. Connecting the front axle pipe
• 9.28. Connection of front axle piping (Riotinto specification If equipped)
• 9.29. Connecting the front drive shat (Front axle . Center support)
• 9.30. Connection of front axle brake oil temperature sensor
• 9.31. Connecting the axle oil temperature sensor (For VHMS specification only)
• 9.32. Assembling the tires
• 9.33. Assembling the fuel tank
• 9.34. Installation of fuel tank (Riotinto specification If equipped)
• 9.35. Fixing the drain pipe
• 9.36. Fixing of torque converter cooler drain piping (Riotinto specification If equipped)
• 9.37. Connecting the fuel pipe
• 9.38. Fixing of breather hose
• 9.39. Fixing the engine drain hoses
• 9.40. Assembling the hydraulic tank ladder
• 9.41. Assembling the floor and cab assembly
• 9.42. Connecting the air conditioner hose
• 9.43. Connecting the brake line
• 9.44. Connecting the window washer hose
• 9.45. Connecting the PPC line hose
• 9.46. Connecting the floor wiring harness
• 9.47. Connecting the floor wiring harness (Steering wheel specification If equipped)
• 9.48. Connection of floor wiring harness 1 (Riotinto specification If equipped)
• 9.49. Connection of floor wiring harness 2 (Riotinto specification If equipped)
• 9.50. Connecting the steering line (Steering wheel specification If equipped)
• 9.51. Connecting the link for AJSS (For AJSS specification only)
• 9.52. Calibration of the AJSS lever angle and frame offset angle
• 9.53. Assembling the autogreasing pump and connecting the pipe (WA9003E0 North American specification)
• 9.54. Assembling the floor cover
• 9.55. Refilling the window washer
• 9.56. Assembling the battery box
• 9.57. Connecting and fixing the battery wiring
• 9.58. Wiring on right side of battery (Riotinto specification If equipped)
• 9.59. Wiring on left side of battery 1 (Riotinto specification If equipped)
• 9.60. Wiring on left side of battery 2 (Riotinto specification If equipped)
• 9.61. Wiring on left side of battery 3 (Riotinto specification If equipped)
• 9.62. Connection of ground cable on left side of battery (Riotinto specification If equipped)
• 9.63. Assembling the battery step
• 9.64. Installation of oil cooler assembly (Brake cooling specification If equipped)
• 9.65. Installation and connection of oil cooler assembly piping (Brake cooling specification If equipped)
• 9.66. Installation of oil cooler assembly piping 1 (Brake cooling specification If equipped)
• 9.67. Installation of oil cooler assembly piping 2 (Brake cooling specification If equipped)
• 9.68. Assembling the handrail (On the right hand platform)
• 9.69. Installation of handrail (Right platform area) (Brake cooling specification If equipped)
• 9.70. Assembling the handrail (On the hood top face)
• 9.71. Installation of handrail to step in front of CABPDI specification If equipped
• 9.72. Installation of mirror to step in front of CAB PDI specification If equipped
• 9.73. Installation of handrail to upper surface of HOOD PDI specification If equipped
• 9.74. Installation of switch to upper surface of HOOD PDI specification If equipped
• 9.75. Assembling the handrail (On the right hand battery box)
• 9.76. Assembling the rear access step
• 9.77. Assembling the left handrail (Part 1)
• 9.78. Assembling the left handrail (Part 2)
• 9.79. Installation of left handrail (Part 2) (Brake cooling specification If equipped)
• 9.80. Assembling the rearview mirror
• 9.81. Installation of rearview mirrors (Brake cooling specification If equipped)
• 9.82. Assembling the exhaust pipe
• 9.83. Installation of oil cooler guard assembly (Brake cooling specification If equipped)
• 9.84. Installation of fan motor piping cover 1 (Brake cooling specification If equipped)
• 9.85. Installation of fan motor piping cover 2 (Brake cooling specification If equipped)
• 9.86. Applying the counterweight antislip
• 9.87. Assembling the counterweight (WA9003E0 standard specification)
• 9.88. Assembling the counterweight (WA9003E0 Highlift arm specification)
• 9.89. Assembling the counterweight (WA8003E0 Overseas general, optional specification and North American specification)
• 9.90. Assembling the counterweight (WA8003E0 Overseas general standard specification)
• 9.91. Assembling the front axle lamp and connecting the harness
• 9.92. Assembling the front lamp assembly
• 9.93. Assembling the ROPS canopy assembly
• 9.94. Assembling the antenna and work lamp
• 9.95. Assembling the VHMS antenna (For VHMS specification only)
• 9.96. Assembling the floor mat
• 9.97. Assembling the front fender
• 9.98. Engine starting procedure
• 9.99. Bleeding the brake air
• 9.100. Bleeding air from hydraulic circuit
• 9.101. Assembling the lift arm assembly (Part 1)
• 9.102. Assembling the lift arm assembly (Part 2)
• 9.103. Connecting the remote grease tube
• 9.104. Assembling the bucket (Part 1)
• 9.105. Assembling the bucket (Part 2)
• 9.106. Assembling the bucket (Part 3)
• 9.107. Assembling the cover (Bottom of the counterweight)
• 9.108. Assembling the cover (Bottom of the counterweight) (For KAL PDI)
• 9.109. Feeding the grease
• 9.110. Work equipment hydraulic circuit air bleeding procedure
• 9.111. Adjusting the bucket positioner
• 9.112. Adjusting the new 2 stage (Overseas general standard)
• 9.113. Adjusting the new 2 stage (North American standard specification)
• 9.114. Assembling the lift arm angle sensor
• 9.115. Adjusting the active working system and boom kickout switch(Overseas general standard and domestic standard)
• 9.116. Touchup work
• 9.117. Applying the decal (For the overseasdirected products only)
• 10. Appendix Field assembly inspection report