Komatsu WA800-1 Manual

Operation & Maintenance
Manual
SEAM042801 02
WA800-I
WHEEL LOADER
SERIAL NUMBERS wA80()-10()()1 and UP

FOREWORD
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
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
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
l-
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
A:
*
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
0
&
A
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
El
-+ 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

INSTRUMENTS AND CONTROLS
2. ENGINE OIL PRESSURE
MONITOR
This monitor indicates a low
engine oil pressure.
If the lamp flashes, the engine oil
pressure is below the lower limit. Im-
mediately stop the engine.
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.
3. COOLANT LEVEL MONITOR
8
This monitor indicates a low
radiator coolant level.
Check the coolant level when the
monitor lamp flashes, stop engine
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 distributor to inspect that monitor lamp.
4. AIR PRESSURE MONITOR
I 1
....
‘.‘..
49
This monitor indicates a drop in
the air pressure in the air tank.
If the lamp flashes, increase the
engine speed and wait until the
lamp goes out.
- IO- w-01254

INSTRUMENTS AND CONTROLS
5. COOLANT TEMPERATURE
MONITOR 6. TORQUE CONVERTER OIL
TEMPERATURE MONITOR 7.
This monitor indicates a rise in
the cooling water temperature.
When the monitor lamp flashes,
run the engine with no load at mi-
drange speed until the green range
of the engine water temperature
gauge lights.
This monitor indicates a rise in
the torque converter oil temperature.
When the monitor lamp flashes,
stop the machine and run the
engine with no load at midrange
speed until the green range of the
temperature gauge lights.
Sr 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 distributor to inspect that monitor lamp.
EMERGENCY STEERING
OPERATION MONITOR
If the engine stops while the ma-
chine is traveling or an abnormality
occurs in the pump circuit, the oper-
ator will be warned that the
emergency steering is in operation.
When flashing begins, stop the ma-
chine immediately.
w-02011 - 11 -

INSTRUMENTS AND CONTROLS
D: METER GROUP
PILOT DISPLAY
When the starting
turned to ON, this lights
cate that the display
working.
1. PARKING BRAKE PILOT LAMP
switch is
up to indi-
items are
I J
This lamp lights up when the
parking brake is applied.
2. PILOT LAMP FOR WORKING
LAMP rl
0
hll
This lamp lights up when the
working lamps are switched on.
3. ENGINE PRE-HEATING
MONITOR
When using APS (automatic
priming system) and when starting,
switch on lamp and you will be in-
formed that pre-heating has started.
W-01256

INSTRUMENTS AND CONTROLS
4. AFTERHEATING MONITOR
When using APS (automatic
priming system) in cold weather,
and when starting, after the engine
starts, the lamp will flash until the
water temperature reaches 2O”C,
informing you that afterheating has
started.
5. TRANSMISSION CUT-OFF
SELECTOR PILOT LAMP
I 1
This lamp lights up when the
transmission cut-off selector switch
is turned to ON.
* If the monitor lamp is ON and the
left brake pedal is depressed, the
transmission will be returned to
neutral.
6. AIR PRESSURE GAUGE
Redw
Green
Red
This gauge indicates the air pres-
sure in the air tank. The green range
should be lighted during normal
operation.
If the red range lights up during
operations, the alarm buzzer will
sound, the warning lamp will flash,
and the air pressure monitor lamp
will flash.
If this happens, stop the
machine, increase the engine speed
and wait until the green range lights
up.
Sr If the air pressure drops even
low,er, the parking brake will be
automatically applied.
W-02012 - 13-

INSTRUMENTS AND CONTROLS
7. ENGINE COOLING WATER
TEMPERATURE GAUGE
Red
Green
White
This gauge indicates the tem-
perature of the cooling water. If the
temperature is normal during
operation, the green range will light.
If the red range lights during
operation, the alarm buzzer will
sound, the warning lamp will flash
and the coolant temperature moni-
tor lamp will flash at the same time.
If this occurs, stop the machine and
run the engine with no load at mi-
drange speed until the green range
lights.
8. TORQUE CONVERTER OIL
TEMPERATURE GAUGE
Red
Green
This gauge indicates the tem-
perature of the torque converter oil.
If the temperature is normal during
operation, the green range will light.
If the red range lights during
operation, the alarm buzzer will
sound, the warning lamp will flash
and the torque converter oil tem-
perature monitor lamp will flash at
the same time. If this occurs, stop
the machine and run the engine
with no load at midrange speed until
the green range lights.
9. FUEL GAUGE
Green
Red /
This gauge indicates the amount
of fuel in the fuel tank. If there is
enough fuel in the tank while the
engine is running, the green range
lights. If the red range lights, there is
less than 155 liters of fuel in the
tank.
When the red range lights, add
fuel.
- 14- w-02013

10. TURN SIGNAL PILOT LAMP
When the turn signal lamp
flashes, the pilot lamp also flashes.
+ If the wiring of the turn signal
lamp is disconnected, the pilot
lamp will flash faster.
11. HIGH BEAM PILOT LAMP
12. SPEEDOMETER
INSTRUMENTS AND CONTROLS
13. SERVICE METER
This meter indicates the running
speed of the machine.
* A speedometer for MPH is also
available.
This meter shows the total
operation hours of the machine.
The service meter advances while
the engine is running - even if the
machine is not traveling.
Refer to the section “SERVICE
METER”.
* While engine is running, green
pilot lamp on the service meter
flashes to show the service
meter advances.
This lamp lights up when the
head lamp is at high beam.
w-01259 - 15-

INSTRUMENTS AND CONTROLS
SWITCHES
1. TRANSMISSION CUT-OFF
SELECTOR SWITCH This switch selects the operation
of the left brake pedal. Normally, A If the machine has to be
put this switch in ON position.
@ OFF:
Acts as normal brake (like right
brake pedal).
@ ON:
Acts as normal brake, but also
switches transmission to NEUTRAL.
* If the switch is at ON, the trans-
mission cut-off selector pilot
lamp will light up.
started on a slope, always turn
the transmission cut-off selec-
tor switch to OFF and depress
the left brake pedal. Then dep-
ress the accelerator pedal
while releasing the left brake
pedal to start the machine off
slowly.
Put the switch to the desired po-
sition according to working con-
dition to make operation easy.
- 16- ww -02014

2. FUEL CUT-OFF SWITCH
Engine fuel consumption will be
cut.
When using APS (automatic
priming system) in cold weather,
use when starting.
OFF:
Fuel is not supplied to the engine.
ON:
Fuel is supplied to the engine.
When hand is removed from OFF
position, switch returns to ON
position.
For detailed method of usage,
refer to “starting in cold
weather”.
3. ENGINE LOW IDLING
SELECTOR SWITCH
The engine low idling speed can
be switched between two levels.
0 ON:
The engine low idling speed is set
to approx. 850 rpm. This is used
on busy jobsites where it is
necessary to reduce the cycle
time.
@ OFF:
This sets the engine low idling
speed to approx. 650 rpm. This
is used for normal operations at
low idling, such as when waiting
for dump trucks.
INSTRUMENTS AND CONTROLS
4. HAZARD LAMP SWITCH
This switch is used in
emergencies, such as when the ma-
chine breaks down.
ON: All turn signal lamps flash.
* All turn signal lamps and pilot
lamp on the steering column
flash.
A Do not use this switch unless
abnormality is occured.
ww -02015 - 17-

INSTRUMENTS AND CONTROLS
5. PARKING BRAKE SWITCH
This switch operates the parking A Always apply the parking
brake.
@I ON position: brake when leaving the ma-
chine or parking it.
The parking brake is applied, and
the parking brake pilot lamp lights
$OFF position:
The parking brake is released.
If the directional lever is placed in
F (FORWARD) or R (~~EVERSE)
with the parking brake applied,
the warning lamp will flash and
the alarm buzzer will sound.
When the starting switch is
turned to OFF, the parking brake
is automatically applied.
Before starting the engine, turn
the parking brake switch to ON,
then turn it to OFF.
The machine does not start
when the directional lever is
operated with parking brake
applied.
- 18 - ww -02016

INSTRUMENTS AND CONTROLS
6. WORKING LAMP SWITCH
/
/- OFF
/ ON
When the front and rear working
lamps are turned ON, the pilot lamp
and illumination lamp for monitor
panel will also light up.
ON: Working lamps are ON.
A When travelling on public
roads, turn the working lamps
OFF.
7. PREHEATER SWITCH
(APS (automatic priming
system) switch)
When using APS, engine intake
air is heated. Usually, the switch is
in the OFF position.
@ OFF position:
The pre-heat function is not
working.
@ AUTO position:
When engine water temperature
is below 13”C, APS starts.
After starting, maintain this posi-
tion until the lamp of the after-
heating monitor goes out.
* Before starting APS, put the
switch to ON and then put it to
this position.
@ ON oosition:
If the switch is moved again from
AUTO position and upward to
ON, APS operation will begin.
If the switch is released when at
the ON position, it will automati-
cally return to AUTO.
Method of using preheater
switch, refer to the section
“starting in cold weather”.
When the engine settle down
after starting, put the preheater
switch in OFF position.
WW -02017 - 19-