Komatsu WA900-3LC WHEEL LOADER Field Assembly Manual - PDF

Komatsu WA900-3LC WHEEL LOADER Field Assembly Manual

Description:

• Komatsu WA900-3LC WHEEL LOADER Field Assembly Manual
• SERIAL NUMBERS A50001 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.

Table Of Contents:

• Komatsu WA900-3LC WHEEL LOADER Field Assembly Manual
• SERIAL NUMBERS A50001 and UP

MAIN MENU......................................................................  0
COVER..........................................................................  1
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
		Front Frame Lifting Tool............................................... 15
		Rear Frame Lifting Tool................................................ 15
		Rear Axle Lifting Tool................................................. 15
		Front, Rear Axle Lifting Tool.......................................... 15
		Fuel Tank Lifting Tool................................................. 16
		Floor and Cab Lifting Tool............................................. 16
	OIL, GREASE, FUEL, PAINT, ETC.............................................. 17
	PROTECTIVE WEAR............................................................ 17
	LOCAL MANUFACTURING DIAGRAM FOR LIFTING TOOLS AND ROLLER................... 18
		1. Axle Lifting Tool................................................... 18
		2. Frame Lifting Tool.................................................. 19
		3. Roller for Moving Axle to Side...................................... 21
PROCEDURE FOR FIELD ASSEMBLY................................................... 22
	A-1 SETTING BARE MACHINE ON SUPPORTS....................................... 22
		Tools and Materials Required........................................... 22
		Steel Stand Drawing.................................................... 24
	A-2 ASSEMBLY OF REAR AXLE.................................................. 25
		OUTLINE................................................................ 25
		ASSEMBLY PROCEDURE..................................................... 27
	A-3 ASSEMBLY OF FRONT AND REAR DRIVE SHAFTS................................ 30
		OUTLINE................................................................ 30
		ASSEMBLY PROCEDURE..................................................... 31
	A-4 INSTALLATION OF FRONT AXLE............................................. 32
		OUTLINE (INSTALLING FRONT AXLE)........................................ 32
		ASSEMBLY PROCEDURE..................................................... 33
		OUTLINE (INSTALLING FRONT TIRE AND WHEEL ASSEMBLIES)................... 35
		ASSEMBLY PROCEDURE (FRONT TIRE AND WHEEL ASSEMBLY)..................... 36
	A-5 ASSEMBLY OF FUEL TANK.................................................. 37
		OUTLINE................................................................ 37
		OPERATION FOR CONNECTING FUEL SUCTION AND RETURN HOSES................. 39
		OPERATION FOR SECURING ENGINE DRAIN LINES.............................. 41
		OPERATION FOR SECURING FUEL TANK VENT LINE............................. 43
		ASSEMBLY PROCEDURE..................................................... 44
	A-6 ASSEMBLY OF LADDER (LEFT/RIGHT)........................................ 46
	A-7 ASSEMBLY OF CAB........................................................ 47
		ASSEMBLY PROCEDURE..................................................... 47
	A-8 ASSEMBLY OF HAND RAIL.................................................. 50
	A-9 ASSEMBLY OF REAR TIRE AND WHEEL ASSEMBLIES............................. 51
		ASSEMBLY PROCEDURE (REAR TIRE AND WHEEL ASSEMBLY)...................... 51
	A-10 ASSEMBLY OF BATTERY BOXES............................................. 53
		PROCEDURE FOR CONNECTING AND SECURING WIRING INSIDE BATTERY BOX........ 54
		CIRCUIT DIAGRAM........................................................ 55
		OPERATION FOR INSTALLING BATTERY BOX COVERS............................ 56
		ASSEMBLY OF STEP ASSEMBLIES............................................ 57
	A-11 ASSEMBLY OF COUNTERWEIGHT............................................. 58
		(STANDARD BOOM)........................................................ 58
		(HI-LIFT BOOM)......................................................... 60
	A-12 ASSEMBLY OF EXHAUST PIPE.............................................. 63
	A-13 ASSEMBLY OF HANDRAILS AND REAR ACCESS STEPS........................... 65
		ASSEMBLY OF HANDRAILS (RIGHT SIDE AND TOP OF HOOD)..................... 65
		ASSEMBLY OF REAR ACCESS STEP........................................... 67
		ASSEMBLY OF HANDRAIL (LEFT SIDE) AND MUDGUARD COVER.................... 69
		ASSEMBLY OF SAFETY CABLE AND MIRRORS................................... 71
	A-14 ASSEMBLY OF BOOM...................................................... 73
		ASSEMBLY OF BOOM....................................................... 73
		CONNECTION OF REMOTE GREASE TUBE....................................... 75
		ASSEMBLY PROCEDURE..................................................... 76
	A-15 ASSEMBLY OF FRONT FENDERS............................................. 79
	A-16 ASSEMBLY OF FRONT LAMP ASSEMBLIES..................................... 81
	A-17 ASSEMBLY OF ROPS CANOPY............................................... 82
		Operation for removal and installation of ROPS canopy support cover.... 82
		Operation for installing ROPS canopy and wiring........................ 83
		ASSEMBLY PROCEDURE..................................................... 85
	A-18 ASSEMBLY OF BUCKET.................................................... 87
		Operation for Installation of Bucket Link.............................. 87
		ASSEMBLY PROCEDURE..................................................... 89
	A-19 ASSEMBLY OF FLOOR MAT................................................. 92
PROCEDURE FOR TESTING ASSEMBLED MACHINE........................................ 93
	M-1 BLEEDING AIR FROM WHEEL BRAKE CIRCUIT.................................. 93
		Procedure for filling with oil......................................... 94
		Bleeding Air From Brake Circuit........................................ 95
	M-2 GREASING WORK EQUIPMENT AND CHASSIS.................................... 96
		OUTLINE................................................................ 96
	M-3 ADJUSTING BUCKET POSITIONER............................................ 97
		OUTLINE................................................................ 97
	M-4 ADJUSTING BOOM KICK-OUT................................................ 99
		OUTLINE................................................................ 99
	M-5 PROCEDURE FOR STARTING ENGINE..........................................101
		OUTLINE................................................................101
		LONG TERM STORAGE......................................................101
	M-6 INSPECTION OF ALL PARTS................................................102
		OUTLINE................................................................102
	M-7 PROCEDURE FOR BLEEDING AIR FROM PISTON PUMP............................103
		Procedure for bleeding air from piston pump............................103
	M-8 BLEEDING AIR FROM WORK EQUIPMENT CIRCUIT...............................104
		Bleeding air from bucket and boom cylinders............................104
		Bleeding air from PPC circuit..........................................104
INSPECTION REPORT..............................................................105

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