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