Komatsu WA800-1 Manual

Operation & Maintenance

Manual

SEAM042801 02

WA800-I

WHEEL LOADER

SERIAL NUMBERS wA80()-10()()1 and UP

FOREWORD

This manual describes procedures for operation, handling, lubrication,

maintenance, checking, and adjustment. It will help the operator or anyone

realize peak performance through effective, economical and safe machine

operation and maintenance.

Please read this manual carefully BEFORE operating the machine.

Please continue studying this manual until proper operation is completely

reinforced into personal habit.

This manual describes the basic techniques. Skill is performed as the

operator or anyone get the correct knowledge and performance of the

machine.

Operation, inspection, and maintenance should be carefully carried out,

and the safety must be given the first priority. Safety precautions are in-

dicated with A marks and technical precautions with * marks in this

manual. The safety information contained in this manual is intended only

to supplement safety codes, insurance requirements, local laws, rules

and regulations.

Some photographs and illustration pictures are different from your ma-

chine as technical improvement is continuously reflected on it. Revision

to up-to-date manual’s content is performed in later editions.

This operation & maintenance manual may contain attachments and op-

tional equipment that are not available in your area. Please consult your

local Komatsu distributor for those items you may require.

Materials and specifications are subject to change without notice.

ww -02595 -l-

BREAKING IN YOUR NEW MACHINE

Each machine is carefully adjusted and tested before shipment. However,

a new machine requires careful operation during the first 100 hours to

break in the various parts.

If a machine is subjected to unreasonably hard use at the initial operation

stage, the potential of performance will prematurely deteriorate and the ser-

vice life will be reduced. A new machine must be operated with care, partic-

ularly with regard to the following items.

After starting, let the engine idle

for 5 minutes to allow proper

engine warm-up prior to actual

operation.

Avoid operation with heavy loads

or at high speeds.

Sudden starting or acceleration,

unnecessarily abrupt braking and

sharp turning should be avoided.

l At the first 250 hours of *

operation, the machine should be

maintained in the following

manner in addition to usual 250

hours service:

I) Replacement of fuel filter car- *

tridge and transmission oil filter

element

2) Checking and adjustment of

engine valve clearance

For replacement procedure and

details, see maintenance table in

the maintenance section.

When replacing oil filter elements

(cartridges), check their interiors

for dirt and dust. If heavily

collected, check for possible

cause before starting operation.

Hours of operation are indicated

by the service meter.

-2- w-01239

CONTENTS

OPERATION MAINTENANCE

GENERAL LOCATIONS AND SPECIFICATIONS 4 PERIODIC MAINTENANCE .................... Bg

INSTRUMENTS AND CONTROLS .............. 5 BLEEDING AIR FROM CIRCUIT .............. 70

REMOVAL AND INSTALLATION OF BUCKET .... 34 PERIODICAL REPLACEMENT OF

USING ACCUMULATORS ..................... 38 SAFETY PARTS ......................... 73

CHECK BEFORE STARTING .................... 3g MAINTENANCE TABLE .................... 74

OPERATING YOUR MACHINE .................. 45 OIL FILLER AND LEVEL GAUGE POSITIONS . 78

ADJUSTMENT OF WORK EQUIPMENT ......... 54 EVERY 50 HOURS SERVICE ................ 7g

HANDLING THE TIRES ......................... 56 EVERY 100 HOURS SERVICE. .............. 80

TOWING.. ................................... 5g INITIAL 250 HOURS SERVICE .............. 83

TRANSPORTATION ........................... 6 1 EVERY 250 HOURS SERVICE ............... 83

COLD WEATHER OPERATION ................. 62 EVERY 500 HOURS SERVICE ............... 87

EVERY 1000 HOURS SERVICE ............. g0

EVERY 2000 HOURS SERVICE ............. 96

EVERY 4000 HOURS SERVICE ............. 104

WHEN REQUIRED ......................... 105

ADJUSTMENT .............................. 1 1B

TROUBLE SHOOTING GUIDE .................. 120

SERVICE METER ............................. 124

MACHtNE AND ENGINE SERIAL NUMBERS ..... 125

FUEL, COOLANT AND LUBRICANTS ........... 126

w-04273 -3-

GENERAL LOCATIONS AND SPECIFICATIONS

1. Bucket

2. Lift arm

3. Head lamp

4. Turn signal lamp

5. Rear wheel

6. Front wheel

7. Lift cylinder

8. Dump cylinder

9. Tilt lever

PERFORMANCE

1. Bucket capacity (Heaped)

2. Travel speeds

Forward

Reverse

With cab and ROPS canopy

10.5 m3

Max. 28.0 km/h

Max. 28.3 km/h

OPERATING WEIGHT 86800 kg

ENGINE

1. Model Komatsu SA8V170-1 C diesel engine

2. Flywheel horsepower (at 2000 rpm) 789 HP

NOTE:

Specifications are subject to change without notice

- W-02007

INSTRUMENTS AND CQNTROLS

INSTRUMENTS AND CONTROLS

MONITOR PANEL

This monitor system consists of monitor lamp groups @X$$@), meter group

@I and warning lamp @J.

l To check the monitor system,

turn the starting switch to ON

before starting the engine. Then

all the monitor lamps, the gauges

and the warning lamp light up for

about 3 seconds and the alarm

buzzer sounds for about 2

seconds. Three figures, 188, are

displayed on the speedometer

while the monitor system is

being checked. After -that all

lamps go off and the buzzer

stops. If any monitor lamp does

not light up, ask your Komatsu

distributor to inspect that monitor

lamp.

)r When the starting switch is

turned to ON, if the directional

lever is not at neutral, the warning

lamp will flash and the alarm

buzzer will continue to sound. If

this happens, return the lever to

neutral. The lamp will go out and

the buzzer will stop.

W-02008 -5-

INSTRUMENTS AND CONTROLS

Sr To check the monitor immediate-

ly when the engine is stopped,

wait for at least 30 seconds after

the engine is stopped.

@CHECK MONITOR

GROUP

(Check items before

starting)

If there is any abnormality, the

appropriate monitor lamp will flash.

* When the engine is started, these

monitor lamps will go off even if

there are abnormalities.

@CAUTION MONITOR

GROUP

(Caution items)

If any abnormality occurs while

the engine is running, the appropri-

ate monitor lamp will flash to indi-

cate the abnormality.

* Even if any monitor lamp flashes,

the machine can operate, but it

should be repaired as soon as

possible.

@CAUTION MONITOR

GROUP

(Emergency stop items)

If any abnormality occurs while

the engine is running, the appropri-

ate monitor lamp will flash and the

alarm buzzer will sound intermittent-

ly at the same time.

* However, when the emergency

steering is being operated, only

the monitor will flash. The alarm

buzzer will not sound, and the

central warning lamp will not

light up.

* If any monitor lamp flashes, stop

the engine or run it at a low idling

speed, and repair it immediately.

@J METER GROUP

This group consists of air pres-

sure gauge, engine water tempera-

ture gauge, torque converter oil tem-

perature gauge, fuel gauge,

speedometer, service meter and

pilot display.

@ WARNING LAMP

The warning lamp will flash

when there is an abnormality in any

@ group item.

The warning lamp will flash and

the alarm buzzer will sound when

there is an abnormality in any @

group item or when the parking

brake is applied, but the directional

lever is not at neutral.

-6- w-02009

INSTRUMENTS AND CONTROLS

CHECK MONITOR GROUP

(Check items before

starting)

Do not rely on the “CHECK MONI-

TOR GROUP (Check before

starting)” only for the check

before starting. Always make the

check by referring to the section

on CHECK BEFORE STARTING.

1. BRAKE OIL LEVEL MONITOR

This monitor indicates a low

brake oil level.

If the monitor lamp flashes,

check the oil level and add brake oil

as required.

2. ENGINE OIL LEVEL MONITOR

This monitor indicates a low oil

level in the engine oil pan.

If the monitor lamp flashes,

check the oil level in the engine oil

pan and add oil as required.

3. RADIATOR COOLANT LEVEL

MONITOR

L?_J

This monitor indicates a low

radiator coolant level.

If the monitor lamp flashes,

check the coolant level and add

water as required.

* Park the machine on level ground

and check the monitor lamps.

* Confirm that these monitor

lamps light for about 3 seconds

after turning the starting switch

to ON. If any monitor lamp does

not light, ask your Komatsu dis-

tributor to inspect that monitor

lamp.

W-01251 -7-

INSTRUMENTS AND CONTROLS

B: CAUTION MONITOR

GROUP

(Caution items)

If any abnormality occurs while

the engine is running, the appropri-

ate monitor lamp and the warning

lamp will flash to indicate the abnor-

mality at the same time.

1. CHARGE MONITOR 2. FUEL LEVEL MONITOR

-+ m

I I I I

This monitor indicates an abnor- This monitor indicates there is

mality in the charging system while less than 155 liters of fuel in the

the engine is running. tank.

If the monitor lamp flashes, If the monitor lamp flashes, add

check the charging circuit. fuel.

* This monitor lamp flashes and

the alarm buzzer sounds, when

the starting switch is turned to

ON immediately after the engine

is started or immediately before

the engine is stopped. It does not

indicate an abnormality.

-8 - w-02010

INSTRUMENTS AND CONTROLS

3. TRANSMISSION OIL FILTER

MONITOR

1131

This monitor indicates clogging

of the transmission oil filter.

If the monitor lamp flashes, re-

place the filter element.

Park the machine on level ground

and check the monitor lamps.

Confirm that these monitor

lamps light for about 3 seconds

after turning the starting switch

to ON. If any monitor lamp does

not light, ask your Komatsu dis-

tributor to inspect that monitor

lamp.

c: CAUTION MONITOR

GROUP

(Emergency stop items)

If any abnormality occurs while

the engine is running, the appropri-

ate monitor lamp and the warning

lamp will flash and the alarm buzzer

will sound intermittently at the same

time.

1. BRAKE LINE FAILURE

MONITOR

I I

/ ( t

This monitor indicates a drop in

the brake oil pressure when the

brakes are operated.

If the lamp flashes, stop the ma-

chine immediately and check the

brake system.

* After checking and repair of

brake system, push in over-stroke

sensor rod. If this operation is not

done, a buzzer and lamp will con-

tinue to warn of brake line

trouble.

w-01253

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