Komatsu WA800-3 and WA900-3 4WD Wheeled Loaders (Japan) Field Assembly Manual (GEN00056-09)

Illustrated factory Field Assembly Manual for Komatsu 4WD Wheeled Loaders Models WA800-3 and WA900-3.

This manual will assist you in for your 4wd wheeled loader.
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Covered Models (Japan):
   WA800-3 (SN: 70001-)
   WA900-3 (SN: 60001-)

Format: PDF, 154 pages
Language: English
Table of Contents:
   Dividing Process Overview (Major components alone)
   Major Components Table of Dimensions
   Work Space Layout
   Schedule Table for Field Assembly
   Facility, Jigs and Tools
   List of Oil, Grease and Paints
   Assembly procedure
      Oil, grease and coolant
      Oil, grease and coolant level
      Setting rear frame in place
      Setting front frame in place
      Joining front and rear frames
      Front and rear frames joining procedure
      Assembling the steering pin
      Assembling the center drive shat (Center support - Transmission)
      Connection of piping Part 1
      Connection of piping Part 2
      Connection of piping (Part 2) (7XC47: Front and rear frame combination load figure)
      Connection of piping (Part 2) (Riotinto specification: If equipped)
      Connecting the auto-greasing pipe
      Setting the axle in place and assembling the support
      Setting the bare machine in place
      Assembling the rear axle
      Rear axle rear side cover assembling procedure
      Connecting the rear axle pipe
      Fixing of rear axle piping (Brake cooling specification: If equipped)
      Connection of rear axle piping (Riotinto specification: If equipped)
      Fixing of rear axle piping (Brake cooling specification: If equipped)
      Connection of cooling line piping (Brake cooling specification: If equipped)
      Assembling the rear drive shaft (Transmission - Rear axle)
      Assembling the front axle
      Fixing of front axle piping (Brake cooling specification: If equipped)
      Connection of front axle piping (Brake cooling specification: If equipped)
      Connecting the front axle pipe
      Connection of front axle piping (Riotinto specification: If equipped)
      Connecting the front drive shat (Front axle . Center support)
      Connection of front axle brake oil temperature sensor
      Connecting the axle oil temperature sensor (For VHMS specification only)
      Assembling the tires
      Assembling the fuel tank
      Installation of fuel tank (Riotinto specification: If equipped)
      Fixing the drain pipe
      Fixing of torque converter cooler drain piping (Riotinto specification: If equipped)
      Connecting the fuel pipe
      Fixing of breather hose
      Fixing the engine drain hoses
      Assembling the hydraulic tank ladder
      Assembling the floor and cab assembly
      Connecting the air conditioner hose
      Connecting the brake line
      Connecting the window washer hose
      Connecting the PPC line hose
      Connecting the floor wiring harness
      Connecting the floor wiring harness (Steering wheel specification: If equipped)
      Connection of floor wiring harness -1 (Riotinto specification: If equipped)
      Connection of floor wiring harness -2 (Riotinto specification: If equipped)
      Connecting the steering line (Steering wheel specification :If equipped)
      Connecting the link for AJSS (For AJSS specification only)
      Calibration of the AJSS angle and frame offset angle
      Assembling the auto-greasing pump and connecting the pipe (WA900-3E0 North American specification)
      Assembling the floor cover
      Refilling the window washer
      Assembling the battery box
      Connecting and fixing the battery wiring
      Wiring on right side of battery (Riotinto specification: If equipped)
      Wiring on left side of battery -1 (Riotinto specification: If equipped)
      Wiring on left side of battery -2 (Riotinto specification: If equipped)
      Wiring on left side of battery -3 (Riotinto specification: If equipped)
      Connection of ground cable on left side of battery (Riotinto specification: If equipped)
      Assembling the battery step
      Installation of oil cooler assembly (Brake cooling specification: If equipped)
      Installation and connection of oil cooler assembly piping (Brake cooling specification: If equipped)
      Installation of oil cooler assembly piping -1 (Brake cooling specification: If equipped)
      Installation of oil cooler assembly piping -2 (Brake cooling specification: If equipped)
      Assembling the handrail (On the right hand platform)
      Installation of handrail (Right platform area) (Brake cooling specification: If equipped)
      Assembling the handrail (On the hood top face)
      Installation of handrail to step in front of CABPDI specification If equipped
      Installation of mirror to step in front of CAB PDI specification If equipped
      Installation of handrail to upper surface of HOOD PDI specification If equipped
      Installation of switch to upper surface of HOOD PDI specification If equipped
      Assembling the handrail (On the right hand battery box)
      Assembling the rear access step
      Assembling the left handrail (Part 1)
      Assembling the left handrail (Part 2)
      Installation of left handrail (Part 2) (Brake cooling specification: If equipped)
      Assembling the rearview mirror
      Installation of rearview mirrors (Brake cooling specification: If equipped)
      Assembling the exhaust pipe
      Installation of oil cooler guard assembly (Brake cooling specification: If equipped)
      Installation of fan motor piping cover -1 (Brake cooling specification: If equipped)
      Installation of fan motor piping cover -2 (Brake cooling specification: If equipped)
      Applying the counterweight anti-slip
      Assembling the counterweight (WA900-3E0 standard specification)
      Assembling the counterweight (WA900-3E0 High-lift arm specification)
      Assembling the counterweight (WA800-3E0 Overseas general, optional specification and North American specification)
      Assembling the counterweight (WA800-3E0 Overseas general standard specification)
      Assembling the front axle lamp and connecting the harness
      Assembling the front lamp assembly
      Assembling the ROPS canopy assembly
      Assembling the antenna and work lamp
      Assembling the VHMS antenna (For VHMS specification only)
      Assembling the floor mat
      Assembling the front fender
      Engine starting procedure
      Bleeding the brake air
      Bleeding air from hydraulic circuit
      Assembling the lift arm assembly (Part 1)
      Assembling the lift arm assembly (Part 2)
      Connecting the remote grease tube
      Assembling the bucket (Part 1)
      Assembling the bucket (Part 2)
      Assembling the bucket (Part 3)
      Assembling the cover (Bottom of the counterweight)
      Assembling the cover (Bottom of the counterweight) (For KAL PDI)
      Feeding the grease
      Work equipment hydraulic circuit air bleeding procedure
      Adjusting the bucket positioner
      Adjusting the new 2 stage (Overseas general standard)
      Adjusting the new 2 stage (North American standard specification)
      Assembling the lift arm angle sensor
      Adjusting the active working system and boom kick-out switch(Overseas general standard and domestic standard)"
      Touchup work
      Applying the decal (For the overseas-directed products only)
   Appendix: Field assembly inspection report