KOMATSU WA800-2 WHEEL LOADER Operation & Maintenance Manual (SN:A20020 & UP) KOMATSU WA800-2 – PDF DOWNLOAD

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KOMATSU WA800-2 WHEEL LOADER Operation & Maintenance Manual (SN:A20020 & UP) KOMATSU WA800-2

KOMATSU WA800-2 WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:A20020 & UP) KOMATSU WA800-2 – PDF DOWNLOAD:

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KOMATSU WA800-2 WHEEL LOADER Operation & Maintenance Manual (SN:A20020 & UP) KOMATSU WA800-2

• This manual describes procedures for operation, handling, lubrication, maintenance, checking, and adjustment. It will help the operator and maintenance personnel realize peak performance through effective, economical and safe machine operation and maintenance. Keep this manual handy and have all personnel read it periodically.
• If this manual is lost or becomes dirty and can not be read, request a replacement manual from your local distributor. If you sell the machine, be sure to give this manual to the new owner. Continuing improvements in the design of this machine can lead to changes in detail, which may not be reflected in this manual.
• Consult your local distributor or Komatsu America International Company for the latest available information on your machine or for questions regarding information in this manual.

TABLE OF CONTENTS:

KOMATSU WA800-2 WHEEL LOADER Operation & Maintenance Manual (SN:A20020 & UP) KOMATSU WA800-2

MAIN MENU....................................................................................  0
INTRODUCTION.................................................................................  5
	1. FORWARD...............................................................................  6
	2. SAFETY INFORMATION....................................................................  7
	3. INTRODUCTION..........................................................................  8
		3.1 INTENDED USE.....................................................................  8
		3.2 FEATURES.........................................................................  8
		3.3 BREAKING IN A NEW MACHINE........................................................  8
	4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRUBUTOR.........................  9
		4.1 MACHINE SERIAL NO. PLATE POSITION................................................  9
		4.2 ENGINE SERIAL NO. PLATE POSITION.................................................  9
		4.3 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR........................................  9
	5. TABLE OF CONTENTS..................................................................... 10
SAFETY....................................................................................... 17
	6. GENERAL PRECAUTIONS................................................................... 18
	7. PRECAUTIONS DURING OPERATION.......................................................... 24
		7.1 BEFORE STARTING ENGINE .......................................................... 24
		7.2 AFTER STARTING ENGINE ........................................................... 27
		7.3 TRANSPORTATION .................................................................. 36
		7.4 BATTERY ......................................................................... 37
		7.5 TOWING........................................................................... 40
	8. PRECAUTIONS FOR MAINTENANCE .......................................................... 41
		8.1 BEFORE CARRYING OUT MAINTENANCE  I .............................................. 41
		8.2 DURING MAINTENANCE .............................................................. 46
		8.3 TIRES ........................................................................... 52
	9. POSITION FOR ATTACHING SAFETY LABELS ................................................. 54
		9.1 POSITION FOR ATTACHING SAFETY LABELS ............................................ 54
OPERATION.................................................................................... 59
	10. GENERAL VIEW ........................................................................ 60
		10.1 GENERAL VIEW OF MACHINE ........................................................ 60
		10.2 GENERAL VIEW OF CONTROLS AND GAUGES ............................................ 61
	11. EXPLANATION OF COMPONENTS ........................................................... 62
		11.1 METER, LAMPS ................................................................... 62
			11.1.1  WARNING DISPLAYS......................................................... 64
			11.1.2 D: METER DISPLAY PORTION.................................................. 68
		11.2 ENGINE MALFUNCTION & DIAGNOSTIC  WARNING LIGHTS ................................ 72
			11.2.1 Explanation of the three engine diagnostic lights......................... 72
			11.2.2 Engine fault diagnostics.................................................. 72
		11.3 SWITCHES ....................................................................... 73
		11.4 CONTROL LEVERS, PEDALS ......................................................... 80
		11.5 DUST INDICATOR ................................................................. 85
		11.6 CIRCUIT BREAKER (MAIN) ......................................................... 85
		11.7 SAFETY BAR ..................................................................... 86
		11.8 STEERING COLUMN TILT LEVER ..................................................... 86
		11.9 DOOR-OPEN LOCK ................................................................. 86
		11.10 CAP WITH LOCK.................................................................. 87
		11.11 FUEL STOP LEVER................................................................ 88
		11.12 AIR PICK-UP PORT............................................................... 88
		11.13 FUSES ......................................................................... 90
			11.13.1 FUSE CAPACITY AND NAME OF CIRCUIT........................................ 90
		11.14 RADIO ......................................................................... 92
			11.14.1 HOW TO SET STATION SELECTOR BUTTONS...................................... 93
			11.14.2 PRECAUTIONS WHEN USING THE RADIO......................................... 94
			11.14.3 TROUBLESHOOTING GUIDE.................................................... 94
		11.15 STORAGE LOCATION FOR OPERATION AND  MAINTENANCE MANUAL ........................ 95
		11.16 POWER SOURCE .................................................................. 95
		11.17 CAB HEATER AND AIR CONDITIONER ................................................ 96
			11.17.1 LOCATIONS AND FUNCTIONS OF CONTROL PANEL................................. 96
			11.17.2 AIR INTAKE SELECTOR LEVER................................................ 97
		11.18 USING ACCUMULATOR ............................................................. 98
		11.19 OPERATION OF JOY STICK STEERING SYSTEM ........................................100
			11.19.1 FUNCTIONS AND STRUCTURE OF JOY STICK STEERING............................100
			11.19.2 WARNING FOR TROUBLE......................................................102
			11.19.3 PRECAUTIONS FOR STEERING WITH JOY STICK..................................102
			11.19.4 OPERATION METHOD OF JOY STICK STEERING SYSTEM............................103
			11.19.5 WARM-UP OPERATION........................................................104
			11.19.6 ADJUSTMENT OF JOY STICK CONSOLE..........................................105
			11.19.7 ADJUSTMENT OF OPERATOR’S SEAT............................................106
	12. OPERATION............................................................................108
		12.1 CHECKS BEFORE STARTING ENGINE ..................................................108
			12.1.1 WALK AROUND CHECK.........................................................108
			12.1.2 CHECK BEFORE STARTING.....................................................111
			12.1.3 ADJUSTMENT BEFORE OPERATION...............................................117
			12.1.4 OPERATIONS AND CHECKS BEFORE STARTING ENGINE..............................119
		12.2 STARTING ENGINE ................................................................121
			12.2.1 NORMAL STARTING...........................................................121
			12.2.2 SPECIAL STARTING..........................................................121
			12.2.3 STARTING IN COLD WEATHER..................................................122
		12.3 OPERATIONS AFTER STARTING ENGINE ...............................................123
			12.3.1 WARM-UP PROCEDURE.........................................................123
			12.3.2 COLD WEATHER WARM-UP PROCEDURE............................................124
		12.4  MOVING MACHINE OFF ............................................................126
		12.5 SHIFTING GEAR ..................................................................127
		12.6 SHIFTING BETWEEN FORWARD AND  REVERSE ..........................................128
		12.7 STEERING MACHINE ...............................................................128
		12.8 STOPPING MACHINE................................................................129
		12.9 OPERATION OF WORK EQUIPMENT ....................................................130
			12.9.1 BOOM OPERATION (LEVER)....................................................130
			12.9.2 BUCKET OPERATION (LEVER)..................................................130
		12.10  WORK POSSIBLE USING WHEEL LOADER .............................................131
			12.10.1 DIGGING OPERATIONS.......................................................131
			12.10.2 LEVELING OPERATIONS......................................................134
			12.10.3 PUSHING OPERATIONS.......................................................134
			12.10.4 LOAD AND CARRY OPERATIONS................................................134
			12.10.5 LOADING OPERATIONS.......................................................135
		12.11 PRECAUTIONS FOR OPERATION......................................................136
			12.11.1 PERMISSIBLE WATER DEPTH..................................................136
			12.11.2 IF WHEEL BRAKE DOES NOT WORK.............................................136
			12.11.3 PRECAUTIONS WHEN DRIVING UP OR DOWN SLOPES...............................136
			12.11.4 PRECAUTIONS WHEN DRIVING MACHINE.........................................137
		12.12 ADJUSTING WORK EQUIPMENT POSTURE ..............................................138
			12.12.1 ADJUSTING BOOM KICKOUT...................................................138
			12.12.2 ADJUSTING BUCKET POSITIONER..............................................139
			12.12.3 BUCKET LEVEL INDICATOR...................................................139
		12.13 PARKING MACHINE ...............................................................140
		12.14 CHECKS AFTER COMPLETION OF OPERATION ..........................................141
		12.15 STOPPING ENGINE ...............................................................141
		12.16 CHECK AFTER STOPPING ENGINE ...................................................142
		12.17 LOCKING .......................................................................142
		12.18 HANDLING THE TIRES ............................................................144
			12.18.1 PRECAUTIONS WHEN HANDLING TIRES..........................................144
			12.18.2 TIRE PRESSURE............................................................144
		12.19 REMOVAL AND INSTALLATION OF THE  BUCKET .......................................146
			12.19.1 REMOVING THE BUCKET......................................................146
			12.19.2 INSTALLING THE BUCKET....................................................148
	13. TRANSPORTATION.......................................................................150
		13.1 LIFTING MACHINE ................................................................150
	14. COLD WEATHER OPERATION...............................................................150
		14.1 PRECAUTIONS FOR LOW TEMPERATURE ................................................150
			14.1.1 FUEL AND LUBRICANTS.......................................................150
			14.1.2 COOLANT...................................................................150
			14.1.3 BATTERY...................................................................151
		14.2 PRECAUTIONS AFTER COMPLETION OF  WORK ..........................................152
		14.3 AFTER COLD WEATHER .............................................................152
	15. LONG TERM STORAGE....................................................................153
		15.1 BEFORE STORAGE .................................................................153
		15.2 DURING STORAGE .................................................................153
		15.3 AFTER STORAGE  .................................................................153
	16. TROUBLESHOOTING......................................................................154
		16.1 WHEN MACHINE RUNS OUT OF FUEL ..................................................154
		16.2 TOWING THE MACHINE .............................................................154
			16.2.1 WHEN ENGINE CAN BE USED...................................................156
			16.2.2 WHEN ENGINE CANNOT BE USED................................................156
			16.2.3 RELEASING PARKING BRAKE...................................................157
		16.3 IF BATTERY IS DISCHARGED .......................................................158
			16.3.1 REMOVAL AND INSTALLATION OF BATTERY.......................................158
			16.3.2 PRECAUTIONS FOR CHARGING BATTERY..........................................159
			16.3.3 STARTING ENGINE WITH BOOSTER CABLE........................................160
		16.4 OTHER TROUBLE...................................................................162
			16.4.1 ELECTRICAL SYSTEM.........................................................162
			16.4.2 ENGINE....................................................................162
			16.4.3 CHASSIS...................................................................163
			PARKING BRAKE....................................................................163
MAINTENANCE..................................................................................165
	17. GUIDES TO MAINTENANCE................................................................166
	18. OUTLINES OF SERVICE..................................................................169
		18.1 OUTLINE OF OIL, FUEL, COOLANT ..................................................169
			18.1.1 OIL.......................................................................169
			18.1.2 FUEL......................................................................170
			18.1.3 COOLANT...................................................................170
			18.1.4 GREASE....................................................................171
			18.1.5 STORING OIL AND FUEL......................................................171
			18.1.6 FILTERS...................................................................171
		18.2 OUTLINE OF ELECTRIC SYSTEM .....................................................172
	19. WEAR PARTS LIST......................................................................173
	20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE.................174
		20.1 PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS................................174
		20.2 ENGINE OIL SPECIFICATIONS ......................................................175
			20.2.1 Normal operation..........................................................175
			20.2.2 Arctic Operation..........................................................175
		20.3 TRANSMISSION, SERVICE BRAKE SYSTEM AND HYDRAULIC SYSTEM OIL  SPECIFICATIONS ....176
		20.4 AXLE OIL SPECIFICATIONS ........................................................176
		20.5 DIESEL FUEL SPECIFICATIONS .....................................................176
		20.6 COOLANT SPECIFICATIONS .........................................................177
			20.6.1 GENERAL...................................................................177
			20.6.2 WATER.....................................................................177
			20.6.3 ANTIFREEZE................................................................177
			20.6.4 COOLANT TESTING FOR CONDITIONER CONCENTRATION.............................180
	21. STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS........................................185
		21.1 INTRODUCTION OF NECESSARY TOOLS ................................................185
		21.2 TORQUE LIST ....................................................................186
	22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS........................................187
	23. MAINTENANCE SCHEDULE CHART...........................................................190
		23.1 MAINTENANCE SCHEDULE CHART......................................................190
	24. SERVICE PROCEDURE....................................................................195
		24.1 INITIAL 250 HOURS SERVICE ......................................................195
		24.2 WHEN REQUIRED ..................................................................196
			24.2.1 CHECK, CLEAN, OR REPLACE AIR CLEANER ELEMENT..............................196
			24.2.2 CLEAN AND FLUSH THE COOLING SYSTEM........................................198
			24.2.3 CHECK TRANSMISSION OIL LEVEL, ADD OIL.....................................198
			24.2.4 CHECK AXLE OIL LEVEL, ADD OIL.............................................199
			24.2.5 CHECK AXLE CASE BREATHER..................................................199
			24.2.6 CLEAN CONDENSER OF AIR CONDITIONER........................................200
			24.2.7 CHECK WINDOW WASHING FLUID LEVEL, ADD FLUID...............................200
			24.2.8 CLEAN RADIATOR FINS.......................................................200
			24.2.9 CHECK ELECTRICAL INTAKE AIR HEATER........................................200
			24.2.10 REPLACE BUCKET TEETH.....................................................201
			24.2.11 LUBRICATING..............................................................204
			24.2.12 CHECK AIR CONDITIONER....................................................205
			24.2.13 ADJUST PARKING BRAKE.....................................................206
			24.2.14 BLEEDING AIR FROM BRAKE HYDRAULIC CIRCUIT................................207
			24.2.15 BLEEDING AIR FROM PPC CIRCUIT............................................207
			24.2.16 BLEEDING AIR FROM HYDRAULIC TANK.........................................208
		24.3 DAILY - CHECK BEFORE STARTING ..................................................210
			24.3.1 CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL................................210
			24.3.2 CHECK COOLANT LEVEL, ADD COOLANT..........................................211
			24.3.3 DRAlN WATER AND SEDIMENT FROM FUEL FILTER.................................211
			24.3.4 INSPECT ENGINE............................................................212
			24.3.5 CHECK ELECTRONIC ENGINE PROTECTION SYSTEM (FAULT CODE LAMPS)..............212
			24.3.6 CHECK MONITOR PANEL.......................................................212
			24.3.7 CHECK BRAKE OIL TANK LEVEL, ADD OIL.......................................213
			24.3.8 CHECK DUST INDICATOR......................................................213
			24.3.9 CHECK FUEL LEVEL, ADD FUEL................................................214
			24.3.10 DRAIN WATER FROM AIR TANK................................................214
			24.3.11 CHECK ELECTRIC WIRING....................................................215
			24.3.12 CHECK EFFECT OF PARKING BRAKE............................................215
			24.3.13 CHECK EFFECT OF BRAKE....................................................216
			24.3.14 CHECK SOUND OF HORN AND BACK-UP ALARM....................................216
			24.3.15 CHECK FLASHING OF LAMPS, CHECK FOR DIRT OR DAMAGE........................216
			24.3.16 CHECK DIRECTION OF REAR VIEW MIRROR, CHECK FOR DIRT OR DAMAGE............216
			24.3.17 CHECK OPERATION OF GAUGES................................................216
			24.3.18 CHECK PLAY OF STEERING WHEEL, CHECK OPERATION OF STEERING................216
		24.4 WEEKLY .........................................................................216
			24.4.1 CHECK AIR INTAKE PIPING...................................................216
			24.4.2 CHECK AIR CLEANER ELEMENT, CLEAN OR REPLACE...............................216
		24.5 EVERY 50 HOURS SERVICE .........................................................216
			24.5.1 CHECK TIRE INFLATION PRESSURE.............................................216
			24.5.2 DRAlN WATER, SEDIMENT FROM FUEL TANK......................................217
		24.6 EVERY 100 HOURS SERVICE ........................................................217
			24.6.1 LUBRICATING...............................................................217
			24.6.2 CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL................................219
			24.6.3 CLEAN CAB AIR FILTER ELEMENT..............................................220
		24.7 EVERY 250 HOURS SERVICE ........................................................222
			24.7.1 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE.........222
			24.7.2 FUEL FILTERS..............................................................224
			24.7.3 CORROSION RESISTOR CARTRIDGE..............................................225
			24.7.4 CRANKCASE BREATHER TUBE...................................................226
			24.7.5 ENGINE FAN................................................................226
			24.7.6 DRIVE BELTS...............................................................226
			24.7.7 ALTERNATOR BELT TENSION CHECK.............................................226
			24.7.8 CHECK, ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION.....................228
			24.7.9 BATTERY ELECTROLYTE LEVELS................................................229
			24.7.10 SUPPLEMENTAL COOLANT ADDITIVE (SCA)......................................229
			24.7.11 CHECK FOR LOOSE WHEEL HUB NUTS, TIGHTEN..................................230
			24.7.12 CHECK FRAME AND BOOM.....................................................230
		24.8 EVERY 500 HOURS OF SERVICE .....................................................232
			24.8.1 REPLACE TRANSMISSION OIL FILTER ELEMENT...................................232
			24.8.2 LUBRICATE CENTER DRIVE SHAFT (3 points)...................................233
			24.8.3 CHECK AIR DRYER...........................................................233
		24.9 EVERY 1000 HOURS SERVICE .......................................................234
			24.9.1 CHANGE OIL IN TRANSMISSION CASE, CLEAN STRAINER...........................234
			24.9.2 CLEAN TRANSMISSION CASE BREATHER..........................................235
			24.9.3 LUBRICATING...............................................................236
			24.9.4 CLEAN FUEL STRAINER.......................................................238
			24.9.5 TIGHTEN ROPS CANOPY.......................................................238
		24.10 EVERY 2000 HOURS OF SERVICE ...................................................239
			24.10.1 STEAM CLEAN ENGINE.......................................................239
			24.10.2 OVERHEAD SET.............................................................239
			24.10.3 Crosshead adjustment.....................................................242
			24.10.4 Valve Adjustment.........................................................243
			24.10.5 MEASURE CRANKSHAFT END CLEARANCE.........................................244
			24.10.6 CHECK ENGINE MOUNTS......................................................245
			24.10.7 GREASE FAN DRIVE IDLER PIVOT ARM ASSEMBLY................................245
			24.10.8 ENGINE OIL HEATER (IF EQUIPPED)..........................................245
			24.10.9 COOLANT HEATER (IF EQUIPPED).............................................245
			24.10.10 CHECK ENGINE HOSES......................................................246
			24.10.11 CHECK BATTERIES.........................................................246
			24.10.12 CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC FILTER ELEMENT..........248
			24.10.13 CLEAN HYDRAULIC TANK STRAINER...........................................251
			24.10.14 REPLACE HYDRAULIC TANK BREATHER ELEMENT.................................251
			24.10.15 CHANGE AXLE OIL.........................................................252
			24.10.16 CLEAN PPC CIRCUIT STRAINER..............................................253
			24.10.17 CHECK ALTERNATOR, STARTING MOTOR........................................254
			24.10.18 CHECK BRAKE DISC WEAR...................................................254
			24.10.19 CHECK ACCUMULATOR.......................................................254
			24.10.20 INTERNAL PART OF AIR DRYER..............................................254
		24.11 EVERY 6000 HOURS OF SERVICE (OR 2  YEARS) .....................................255
			24.11.1 CLEAN AND CHECK TURBOCHARGER.............................................255
			24.11.2 CHECK ENGINE VIBRATION DAMPER............................................255
			24.11.3 CHECK WATER PUMP.........................................................255
			24.11.4 COOLANT THERMOSTATS AND SEALS............................................256
			24.11.5 CHECK AIR COMPRESSOR CARBON BUILD-UP.....................................259
			24.11.6 CLEAN AND FLUSH THE COOLING SYSTEM.......................................260
			24.11.7 CHECK BELT DRIVEN FAN HUB................................................261
			24.11.8 FAN DRIVE IDLER PULLEY ASSEMBLY..........................................261
SPECIFICATIONS...............................................................................263
	25. SPECIFICATIONS.......................................................................264

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