Komatsu WA800-3E0 & WA900-3E0 Wheel Loader Operation & Maintenance Manual – TEN00162-02

Description

Komatsu WA800-3E0 & WA900-3E0 Operation & Maintenance Manual — TEN00162-02

This is the complete Operation & Maintenance Manual for the Komatsu GALEO WA800-3E0 and WA900-3E0 wheel loaders. It is the same document Komatsu issues with these machines — form number TEN00162-02 — and it covers machine serial numbers WA800-70001 and up and WA900-60001 and up. Everything an operator, service technician or fleet maintenance planner needs to run, service and troubleshoot these large mining-class loaders is contained in a single 359-page reference.

The WA800-3E0 & WA900-3E0 Operation & Maintenance Manual is written for the two machines as a pair. Because both share the same basic architecture, engine family, monitor system and service logic, Komatsu combined the procedures into one manual. Where a value, dimension or procedure differs between the WA800-3E0 and the WA900-3E0, the manual states it separately — for example, the tire size and inflation pressure tables, bucket capacities, operating weights and engine horsepower ratings.

File Details

• Manual type: Operation & Maintenance Manual (O&MM)
• Brand: Komatsu / GALEO
• Models covered: WA800-3E0, WA900-3E0 wheel loaders
• Serial number range: WA800-70001 and up; WA900-60001 and up
• Document number: TEN00162-02
• Publication date: 09-2007 (printed in Japan)
• Language: English
• Page count: 359 pages
• File format: PDF

Chapters Covered

The Komatsu WA800-3E0 & WA900-3E0 Operation & Maintenance Manual is organised into the standard Komatsu O&MM chapter structure:

• Foreword & Warranty
  • Products warranted, coverage and limitations
  • Emissions warranty (Canada)
• Safety Information
  • Signal words, safety labels using words and pictograms
• Introduction & Machine Orientation
  • Front / rear / left / right conventions
  • Operator visibility (ISO 5006), 1 m and 12 m radius diagrams
  • Product Identification Number (PIN) plate
  • EPA engine number plate, service meter location
• Safety (General Precautions)
  • Location of safety labels and their contents
  • Safety rules, clothing, fire extinguisher and first aid
  • Getting on and off, handrails and steps, cab glass cleaning
  • Fire prevention, action if fire occurs
  • ROPS precautions, articulated portion crush hazard
  • High-voltage cable distances, ventilation, asbestos dust
  • Precautions for maintenance, warning tag, high-pressure oil and fuel
  • Accumulator handling, tyre handling and storage
• Operation
  • General view of machine, general view of controls and gauges
  • Machine monitor system — warning displays, meter displays, character display
  • Warning pilot lamps, pilot display lamps, meters and gauges
  • Switches — starting switch, transmission cut-off, working lamps, directional selector
  • Control levers and pedals — bucket, lift arm, brake, accelerator
  • Operator seat adjustment, seat belt, mirror adjustment
  • Check before starting, walk-around check, checks before operation
  • Starting engine, prelube system, automatic warming-up
  • Moving the machine, shifting, changing direction, stopping
  • Transmission cut-off function and adjustment
  • Steering (AJSS lever), remote positioner
  • Work possible using wheel loader — digging, loading, leveling, load and carry
  • Precautions when handling blasted rock
  • Parking the machine, checks after stopping
  • Transportation, loading, unloading, lifting, weight table
  • Cold weather operation, long-term storage
  • Troubleshooting — running out of fuel, air bleeding, towing, booster cable, emergency travel
  • Action codes and failure code display
• Maintenance
  • Guides to maintenance, outlines of service, wear parts list
  • Recommended fuel, coolant and lubricant
  • Standard tightening torques for bolts and nuts
  • Periodic replacement of safety critical parts
  • Maintenance schedule chart (initial, 50, 100, 250, 500, 1000, 2000, 4000 and 8000 hours)
  • Service procedures — air cleaner, cooling system, transmission, axles, brakes, hydraulic tank
  • Lubrication points and intervals
  • Check brake disc wear, valve clearance, accumulators
• Specifications
  • WA800-3E0 and WA900-3E0 dimensions, weights, travel speeds
• Attachments and Options
  • Selecting bucket and tyres
  • Handling auto-greasing system, injector adjustment, timer setting
  • Service centre (WA900-3E0)
  • Emergency engine stop switch (WA900-3E0)
  • Battery and starting motor disconnector switches
  • Starting aid connector, centralized breather, hydraulic oil level warning display
• Index

What This Manual Gives You

Working through the Komatsu WA800-3E0 & WA900-3E0 Operation & Maintenance Manual gives you the full Komatsu service logic in one document. The operation chapter is unusually detailed — it does not just explain what the levers do, it walks through the machine monitor system screen by screen, the prelube cycle, the automatic warming-up routine, the transmission cut-off behaviour and the remote positioner setting procedure. That is the kind of material that is often missing from third-party summaries, and it is what lets an operator or technician understand why the machine behaves the way it does.

The maintenance chapter carries the full Komatsu schedule chart from the initial 10-hour and 250-hour services right through the recurring 50, 100, 250, 500, 1000, 2000, 4000 and 8000-hour intervals. Each service procedure is written with capacities, torque figures, tightening sequences and inspection criteria. There is a dedicated safety critical parts list — fuel hoses, brake hoses, steering hoses, hydraulic hoses, seat belts, high-pressure piping clamps — with two-year / 4000-hour replacement intervals, so a fleet planner can schedule component replacement rather than react to failures.

The troubleshooting chapter covers electrical, chassis, transmission, axle, brake, steering and hydraulic problems with a symptom-cause-remedy layout, and it also documents the electronic control system action codes (E01, E02, E03) and how to read the failure code from the character display. That alone saves significant diagnostic time when the machine is down.

Who This Manual Is For

This Komatsu WA800-3E0 and WA900-3E0 manual suits operators, mine maintenance technicians, independent heavy equipment workshops, fleet owners and anyone responsible for keeping a GALEO WA800-3E0 or WA900-3E0 running. The safe operating procedures, daily and periodic checks, specification tables and system explanations apply directly to both machines within the stated serial ranges.

Note that the specifications, torque values and tire pressures differ between the two models. The manual lists WA800-3E0 and WA900-3E0 values separately throughout, so always confirm which model column you are reading before applying a figure.

Put the Manual to Work

With the Komatsu WA800-3E0 & WA900-3E0 Operation & Maintenance Manual on hand you can carry out daily walk-around checks correctly, run the prelube and warming-up sequence as Komatsu intended, set and adjust the transmission cut-off position, service the air cleaner, cooling system, transmission, axles, brakes and hydraulic tank at the right intervals, bleed air from the fuel and hydraulic circuits, interpret monitor warnings and action codes, and reference the exact specification for your machine before ordering parts or setting torque. Correct procedures and correct specification values are what protect the engine, torque converter, transmission, axles and frame on a machine of this size.

IMAGES PREVIEW

The document is delivered as an instant PDF download after payment. No shipping, no waiting for a physical book. You can open it on any laptop, tablet or phone, search or scroll to the section you need, and print the pages you want to keep in the workshop. Keep a copy near the machine so the operators and maintenance crew can refer to it whenever a check or repair is due.