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KOMATSU AVANCE LOADER WA800L-3 WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:52001 & UP) – PDF DOWNLOAD
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- KOMATSU AVANCE LOADER WA800L-3 WHEEL LOADER OPERATION & MAINTENANCE MANUAL
- SERIAL NUMBER:52001 & UP
- PUBLICATION NUMBER:TEN00007-02
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Description
KOMATSU AVANCE LOADER WA800L-3 WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:52001 & UP)
KOMATSU AVANCE LOADER WA800L-3 WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:52001 & UP) – PDF DOWNLOAD:
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KOMATSU AVANCE LOADER WA800L-3 WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:52001 & UP)
This manual provides rules and guidelines which will help you use this machine safely and effectively. The precautions in this manual must be followed at all times when performing operation and maintenance. Most accidents are caused by the failure to follow fundamental safety rules for the operation and maintenance of machines. Accidents can be prevented by knowing beforehand conditions that may cause a hazard when performing operation and maintenance
TABLE OF CONTENTS:
KOMATSU AVANCE LOADER WA800L-3 WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:52001 & UP)
COVER............................................................................................................. 1 FOREWORD.......................................................................................................... 2 FOREWORD...................................................................................................... 3 SAFETY INFORMATION............................................................................................ 6 INTRODUCTION.................................................................................................. 8 FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE.............................................................. 8 VISIBILITY FROM OPERATOR'S SEAT........................................................................... 9 NECESSARY INFORMATION......................................................................................... 10 PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE.............................................. 10 ENGINE SERIAL NO. PLATE AND POSITION...................................................................... 10 POSITION OF SERVICE METER................................................................................. 11 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR................................................................. 11 CONTENTS.......................................................................................................... 12 SAFETY............................................................................................................ 15 SAFETY........................................................................................................ 16 SAFETY LABELS................................................................................................. 18 LOCATION OF SAFETY LABELS................................................................................. 18 GENERAL PRECAUTIONS........................................................................................... 24 SAFETY RULES.............................................................................................. 24 IF ABNORMALITIES ARE FOUND................................................................................ 24 CLOTHING AND PERSONAL PROTECTIVE ITEMS.................................................................... 24 FIRE EXTINGUISHER AND FIRST AID KIT....................................................................... 24 SAFETY FEATURES........................................................................................... 24 KEEP MACHINE CLEAN........................................................................................ 25 INSIDE OPERATOR'S COMPARTMENT............................................................................. 25 ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT............................................................ 26 HANDRAILS AND STEPS....................................................................................... 27 MOUNTING AND DISMOUNTING.................................................................................. 27 NO PEOPLE ON ATTACHMENTS.................................................................................. 27 DO NOT GET CAUGHT IN ARTICULATED PORTION.................................................................. 28 PREVENTION OF BURNS....................................................................................... 28 FIRE PREVENTION........................................................................................... 29 ACTION IF FIRE OCCURS..................................................................................... 30 WINDOW WASHER LIQUID...................................................................................... 30 PRECAUTIONS WHEN USING ROPS (ROLL OVER PROTECTIVE STRUCTURE).............................................. 30 PRECAUTIONS FOR ATTACHMENTS, OPTIONS...................................................................... 30 UNAUTHORIZED MODIFICATION................................................................................. 30 SAFETY AT WORKSITE........................................................................................ 31 WORKING ON LOOSE GROUND................................................................................... 31 DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES.................................................................... 32 ENSURE GOOD VISIBILITY.................................................................................... 32 PRECAUTIONS RELATED TO VENTILATION EXHAUST GAS............................................................ 33 CHECKING SIGNALMAN'S SIGNALS AND SIGNS.................................................................... 33 EMERGENCY EXIT FROM OPERATOR'S CAB........................................................................ 33 BE CAREFUL ABOUT ASBESTOS DUST............................................................................ 33 PRECAUTIONS FOR OPERATION..................................................................................... 34 STARTING ENGINE........................................................................................... 34 CHECKS BEFORE STARTING ENGINE......................................................................... 34 PRECAUTIONS WHEN STARTING............................................................................. 34 PRECAUTIONS IN COLD AREAS............................................................................. 35 OPERATION................................................................................................. 36 CHECKS BEFORE OPERATION............................................................................... 36 PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE...................................................... 36 PRECAUTIONS WHEN TRAVELING............................................................................ 37 TRAVELING ON SLOPES................................................................................... 38 PROHIBITED OPERATIONS................................................................................. 39 PRECAUTIONS WHEN OPERATING............................................................................ 40 METHODS OF USING BRAKE................................................................................ 40 OPERATE CAREFULLY ON SNOW............................................................................. 41 PARKING MACHINE ...................................................................................... 42 TRANSPORTATION............................................................................................ 44 LOADING AND UNLOADING................................................................................. 44 SHIPPING.............................................................................................. 44 BATTERY................................................................................................... 45 BATTERY HAZARD PREVENTION............................................................................. 45 STARTING WITH BOOSTER CABLES.......................................................................... 46 TOWING.................................................................................................... 47 PRECAUTIONS FOR MAINTENANCE................................................................................... 48 WARNING TAG .............................................................................................. 48 KEEP WORK PLACE CLEAN AND TIDY............................................................................ 48 APPOINT LEADER WHEN WORKING WITH OTHERS................................................................... 48 STOP ENGINE BEFORE CARRYING OUT MAINTENANCE............................................................... 49 TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING........................................................ 51 PROPER TOOLS.............................................................................................. 52 WORK EQUIPMENT SUPPORT.................................................................................... 52 ACCUMULATOR............................................................................................... 52 PERSONNEL................................................................................................. 52 ATTACHMENTS ............................................................................................. 53 NOISE..................................................................................................... 53 PRECAUTIONS WHEN USING HAMMER............................................................................. 53 REPAIR WELDING ........................................................................................... 53 REMOVING BATTERY TERMINAL ................................................................................ 53 PRECAUTIONS WITH HIGH-PRESSURE OIL........................................................................ 54 HANDLING HIGH-PRESSURE HOSES.............................................................................. 54 WASTE MATERIALS .......................................................................................... 54 MAINTENANCE OF AIR CONDITIONER............................................................................ 54 COMPRESSED AIR............................................................................................ 55 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS ............................................................ 55 PRECAUTIONS WITH TIRES........................................................................................ 56 HANDLING TIRES............................................................................................ 56 PRECAUTIONS WHEN STORING TIRES............................................................................ 56 OPERATION......................................................................................................... 57 GENERAL VIEW.................................................................................................. 58 GENERAL VIEW OF MACHINE................................................................................... 58 GENERAL VIEW OF CONTROLS AND GAUGES....................................................................... 59 EXPLANATION OF COMPONENTS..................................................................................... 61 MACHINE MONITOR........................................................................................... 61 SWITCHES.................................................................................................. 74 CONTROL LEVERS, PEDALS.................................................................................... 85 MAIN MONITOR TILT LEVER................................................................................... 89 CAP WITH LOCK............................................................................................. 90 SAFETY BAR................................................................................................ 91 TOWING PIN................................................................................................ 91 ENGINE SHUT-DOWN SWITCH................................................................................... 91 FUEL STOP LEVER........................................................................................... 92 GREASE PUMP............................................................................................... 92 BACKUP ALARM.............................................................................................. 92 CAB DOOR OPEN LOCK........................................................................................ 92 TOOL BOX.................................................................................................. 93 FUSE...................................................................................................... 94 SLOW BLOW FUSE............................................................................................ 95 LUNCH BOX TRAY............................................................................................ 96 POWER OUTLET.............................................................................................. 96 AM/FM RADIO-CASSETTE STEREO............................................................................... 97 AIR CONDITIONER...........................................................................................105 PRECAUTIONS WHEN HANDLING ACCUMULATOR.....................................................................110 OPERATION.....................................................................................................112 CHECK BEFORE STARTING ENGINE, ADJUST......................................................................112 STARTING ENGINE...........................................................................................129 OPERATIONS AND CHECKS AFTER STARTING ENGINE...............................................................132 STOPPING ENGINE...........................................................................................134 CHECK AFTER STOPPING ENGINE...............................................................................134 MOVING THE MACHINE (DIRECTIONAL, SPEED), STOPPING THE MACHINE.............................................135 TURNING...................................................................................................143 OPERATION OF WORK EQUIPMENT...............................................................................144 WORK POSSIBLE USING WHEEL LOADER..........................................................................146 PRECAUTIONS FOR OPERATION.................................................................................152 ADJUSTING WORK EQUIPMENT POSTURE..........................................................................154 REMOVAL AND INSTALLATION OF THE BUCKET....................................................................156 PARKING MACHINE...........................................................................................159 CHECKS AFTER COMPLETION OF OPERATION......................................................................161 LOCKING...................................................................................................161 HANDLING THE TIRES........................................................................................162 OPERATING AUTO-GREASING SYSTEM............................................................................164 TRANSPORTATION................................................................................................177 TRANSPORTATION PROCEDURE..................................................................................177 LOADING, UNLOADING WORK...................................................................................177 METHOD OF SECURING MACHINE................................................................................177 METHOD OF LIFTING MACHINE.................................................................................179 COLD WEATHER OPERATION........................................................................................183 PRECAUTIONS FOR LOW TEMPERATURE...........................................................................183 PRECAUTIONS AFTER COMPLETION OF WORK......................................................................185 AFTER COLD WEATHER........................................................................................186 WARMING-UP OPERATION FOR STEERING HYDRAULIC CIRCUIT IN COLD WEATHER.......................................186 LONG-TERM STORAGE.............................................................................................187 BEFORE STORAGE............................................................................................187 DURING STORAGE............................................................................................187 AFTER STORAGE.............................................................................................187 TROUBLESHOOTING...............................................................................................188 WHEN MACHINE RUNS OUT OF FUEL.............................................................................188 METHOD OF TOWING MACHINE..................................................................................189 IF BATTERY IS DISCHARGED..................................................................................193 OTHER TROUBLE.............................................................................................197 MAINTENANCE.......................................................................................................202 GUIDES TO MAINTENANCE.........................................................................................203 OUTLINES OF SERVICE...........................................................................................205 HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC....................................................205 OUTLINE OF ELECTRIC SYSTEM................................................................................208 WEAR PARTS....................................................................................................209 WEAR PARTS LIST...........................................................................................209 USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE..........................................210 PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS..........................................................210 FUEL, OIL AND COOLANT SPECIFICATIONS..........................................................................212 ENGINE OIL SPECIFICATIONS.................................................................................212 TRANSMISSION, CONVERTER, TRANSFER CASE, COOLER, SERVICE BRAKES AND HYDRAULIC SYSTEM OIL SPECIFICATIONS....213 DRIVE AXLE OIL SPECIFICATIONS.............................................................................213 DIESEL FUEL SPECIFICATIONS................................................................................213 COOLANT SPECIFICATIONS....................................................................................214 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS................................................................220 TORQUE LIST...............................................................................................220 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS.................................................................221 MAINTENANCE SCHEDULE CHART....................................................................................223 MAINTENANCE SCHEDULE CHART................................................................................223 SERVICE PROCEDURE.............................................................................................225 INITIAL 250 HOURS SERVICE.................................................................................225 WHEN REQUIRED.............................................................................................226 CHECK, CLEAN, OR REPLACE AIR CLEANER ELEMENT..........................................................226 CLEAN INSIDE OF COOLING SYSTEM........................................................................228 CHECK TRANSMISSION OIL LEVEL, ADD OIL.................................................................230 CHECK AXLE OIL LEVEL, ADD OIL.........................................................................232 CLEAN AXLE CASE BREATHER..............................................................................232 CLEAN AIR CONDITIONER CONDENSER.......................................................................233 CHECK WINDOW WASHING FLUID LEVEL, ADD FLUID...........................................................233 CLEAN RADIATOR FINS...................................................................................234 CHECK ELECTRICAL INTAKE AIR HEATER....................................................................234 REPLACE BUCKET TEETH..................................................................................235 LUBRICATE WORK EQUIPMENT CONTROL VALVE LINKAGE (2 PLACES).............................................238 CHECK AIR CONDITIONER.................................................................................238 BLEEDING AIR FROM BRAKE HYDRAULIC CIRCUIT.............................................................239 BLEEDING AIR FROM PPC CIRCUIT.........................................................................239 REPLACE SLOW BLOW FUSE................................................................................240 BLEEDING AIR FROM HYDRAULIC TANK......................................................................241 REPLACE FAN BELT......................................................................................242 SELECTION AND INSPECTION OF TIRES.....................................................................244 DRAIN WATER FROM WATER SEPARATOR......................................................................246 CHECK BEFORE STARTING.....................................................................................247 EVERY 50 HOURS SERVICE....................................................................................248 DRAIN WATER, SEDIMENT FROM FUEL TANK..................................................................248 EVERY 100 HOURS SERVICE...................................................................................249 CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL............................................................249 CLEAN ELEMENT IN AIR CONDITIONER FRESH AIR FILTER.....................................................250 EVERY 250 HOURS SERVICE...................................................................................251 CHECK BATTERY ELECTROLYTE LEVEL.......................................................................251 CHECK PARKING BRAKE...................................................................................252 CHECK ALTERNATOR BELT TENSION, ADJUST.................................................................253 CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST.................................................254 CHECK FOR LOOSE WHEEL HUB NUTS, TIGHTEN...............................................................255 CLEAN ELEMENT IN AIR CONDITIONER RECIRCULATION FILTER.................................................255 EVERY 500 HOURS SERVICE...................................................................................256 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE.....................................256 REPLACE FUEL FILTER CARTRIDGE.........................................................................258 REPLACE TRANSMISSION OIL FILTER ELEMENT...............................................................260 LUBRICATE CENTER DRIVE SHAFT..........................................................................261 CHECK FAN BELT FOR WEAR ..............................................................................261 EVERY 1000 HOURS SERVICE..................................................................................262 CHANGE OIL IN TRANSMISSION CASE, CLEAN STRAINER.......................................................262 CLEAN TRANSMISSION CASE BREATHER......................................................................264 LUBRICATING...........................................................................................264 CHECK TIGHTENING PARTS OF TURBOCHARGER................................................................265 CLEAN FUEL STRAINER...................................................................................265 TIGHTEN ROPS CANOPY...................................................................................265 REPLACE CORROSION RESISTOR CARTRIDGE..................................................................266 EVERY 2000 HOURS SERVICE..................................................................................267 CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC FILTER ELEMENT........................................267 CLEAN HYDRAULIC TANK STRAINER.........................................................................270 REPLACE HYDRAULIC TANK BREATHER ELEMENT...............................................................271 CHANGE AXLE OIL.......................................................................................272 REPLACE FILTER ELEMENT IN BRAKE OIL TANK..............................................................274 REPLACE BRAKE OIL TANK BREATHER.......................................................................275 REPLACE ELEMENT IN AIR CONDITIONER RECIRCULATION AIR FILTER, FRESH AIR FILTER.........................275 CLEAN PPC CIRCUIT STRAINER............................................................................275 CHECK ALTERNATOR, STARTING MOTOR......................................................................275 CHECK ENGINE VALVE CLEARANCE, ADJUST..................................................................276 CHECK BRAKE DISC WEAR.................................................................................276 CLEAN AND CHECK TURBOCHARGER..........................................................................276 CHECK PLAY OF TURBOCHARGER ROTOR......................................................................276 CHECK ACCUMULATOR FUNCTION............................................................................277 CHECK ACCUMULATOR GAS PRESSURE........................................................................277 LUBRICATE ENGINE FRONT TRUNNION.......................................................................277 EVERY 4000 HOURS SERVICE..................................................................................278 CHECK WATER PUMP......................................................................................278 CHECK VIBRATION DAMPER................................................................................278 CHECK FAN PULLEY AND TENSION PULLEY...................................................................278 SPECIFICATIONS....................................................................................................279 SPECIFICATIONS................................................................................................280 INDEX.............................................................................................................281
PLEASE NOTE:
⦁ This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
⦁ Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.
