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
  Complete PDF Bookmark Tree

  Complete Bookmarks

  The complete bookmarks in the “Komatsu WA800-3E0 & WA900-3E0 Wheel Loader Operation & Maintenance Manual – TEN00162-02” are as follows:

  COVERp. 1

  +FOREWORDp. 2

  FOREWORDp. 3

  SAFETY INFORMATIONp. 6

  +INTRODUCTIONp. 8

  FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINEp. 8

  VISIBILITY FROM OPERATOR'S SEATp. 9

  +NECESSARY INFORMATIONp. 11

  PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATEp. 11

  EPA REGULATIONS, ENGINE NUMBER PLATEp. 11

  POSITION OF SERVICE METERp. 12

  TABLE TO ENTER SERIAL NO. AND DISTRIBUTORp. 12

  CONTENTSp. 13

  +SAFETYp. 16

  SAFETYp. 17

  +SAFETY LABELSp. 19

  LOCATION OF SAFETY LABELSp. 20

  SAFETY LABELSp. 21

  +GENERAL PRECAUTIONSp. 26

  SAFETY RULESp. 26

  IF ABNORMALITIES ARE FOUNDp. 26

  CLOTHING AND PERSONAL PROTECTIVE ITEMSp. 26

  FIRE EXTINGUISHER AND FIRST AID KITp. 26

  SAFETY FEATURESp. 26

  KEEP MACHINE CLEANp. 27

  INSIDE OPERATOR'S COMPARTMENTp. 27

  ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEATp. 28

  HANDRAILS AND STEPSp. 29

  PRECAUTIONS WHEN CLEANING CAB GLASSp. 29

  MOUNTING AND DISMOUNTINGp. 30

  NO PEOPLE ON ATTACHMENTSp. 30

  DO NOT GET CAUGHT IN ARTICULATED PORTIONp. 30

  PREVENTION OF BURNSp. 30

  FIRE PREVENTIONp. 31

  ACTION IF FIRE OCCURSp. 32

  WINDOW WASHER LIQUIDp. 32

  PRECAUTIONS WHEN USING ROPS (ROLL OVER PROTECTIVE STRUCTURE)p. 32

  PRECAUTIONS FOR ATTACHMENTS, OPTIONSp. 32

  UNAUTHORIZED MODIFICATIONp. 32

  SAFETY AT WORKSITEp. 33

  WORKING ON LOOSE GROUNDp. 33

  DO NOT GO CLOSE TO HIGH-VOLTAGE CABLESp. 34

  ENSURE GOOD VISIBILITYp. 34

  PRECAUTIONS RELATED TO VENTILATION EXHAUST GASp. 35

  CHECKING SIGNALMAN'S SIGNALS AND SIGNSp. 35

  EMERGENCY EXIT FROM OPERATOR'S CABp. 35

  BE CAREFUL ABOUT ASBESTOS DUSTp. 35

  +PRECAUTIONS FOR OPERATIONp. 36

  +STARTING ENGINEp. 36

  CHECKS BEFORE STARTING ENGINEp. 36

  PRECAUTIONS WHEN STARTINGp. 36

  PRECAUTIONS IN COLD AREASp. 37

  +OPERATIONp. 38

  CHECKS BEFORE OPERATIONp. 38

  PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSEp. 38

  PRECAUTIONS WHEN TRAVELINGp. 39

  TRAVELING ON SLOPESp. 40

  PROHIBITED OPERATIONSp. 41

  PRECAUTIONS WHEN OPERATINGp. 42

  METHODS OF USING BRAKEp. 43

  OPERATE CAREFULLY ON SNOWp. 43

  PARKING MACHINEp. 44

  +TRANSPORTATIONp. 46

  LOADING AND UNLOADINGp. 46

  SHIPPINGp. 46

  +BATTERYp. 47

  BATTERY HAZARD PREVENTIONp. 47

  STARTING WITH BOOSTER CABLESp. 48

  TOWINGp. 49

  +PRECAUTIONS FOR MAINTENANCEp. 50

  WARNING TAGp. 50

  KEEP WORK PLACE CLEAN AND TIDYp. 50

  APPOINT LEADER WHEN WORKING WITH OTHERSp. 50

  STOP ENGINE BEFORE CARRYING OUT MAINTENANCEp. 51

  TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNINGp. 53

  PROPER TOOLSp. 54

  ACCUMULATORp. 54

  PERSONNELp. 54

  ATTACHMENTSp. 54

  WORK UNDER THE MACHINEp. 55

  NOISEp. 55

  PRECAUTIONS WHEN USING HAMMERp. 55

  REPAIR WELDINGp. 55

  REMOVING BATTERY TERMINALp. 55

  PRECAUTIONS WITH HIGH-PRESSURE OILp. 56

  PRECAUTIONS FOR HIGH-PRESSURE FUELp. 56

  HANDLING HIGH-PRESSURE HOSESp. 56

  WASTE MATERIALSp. 56

  MAINTENANCE OF AIR CONDITIONERp. 57

  COMPRESSED AIRp. 57

  PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTSp. 57

  +PRECAUTIONS WITH TIRESp. 58

  HANDLING TIRESp. 58

  PRECAUTIONS WHEN STORING TIRESp. 58

  +OPERATIONp. 60

  +GENERAL VIEWp. 61

  GENERAL VIEW OF MACHINEp. 61

  GENERAL VIEW OF CONTROLS AND GAUGESp. 62

  +EXPLANATION OF COMPONENTSp. 66

  MACHINE MONITORp. 66

  SWITCHESp. 82

  CONTROL LEVERS, PEDALSp. 97

  MAIN MONITOR TILT LEVERp. 103

  CAP WITH LOCKp. 104

  FRAME LOCK BARp. 105

  TOWING PINp. 106

  ENGINE SHUT-DOWN SWITCHp. 106

  FUEL STOP LEVERp. 106

  BACKUP ALARMp. 106

  CAB DOOR OPEN LOCKp. 107

  HANDLING CAB WIPERp. 107

  DUST INDICATORp. 108

  FUSEp. 109

  CIRCUIT BREAKERp. 111

  SLOW BLOW FUSEp. 111

  LUNCH BOX TRAYp. 112

  TOOL BOXp. 112

  GREASE PUMPp. 112

  LOCATION OF FIRE EXTINGUISHERp. 112

  POWER OUTLETp. 113

  AM/FM RADIO-CASSETTE STEREOp. 114

  AIR CONDITIONERp. 123

  HANDLING MACHINES EQUIPPED WITH VHMSp. 128

  HANDLING WIRELESSp. 130

  +OPERATIONp. 131

  CHECK BEFORE STARTING ENGINE, ADJUSTp. 131

  STARTING ENGINEp. 148

  OPERATIONS AND CHECKS AFTER STARTING ENGINEp. 151

  STOPPING ENGINEp. 153

  CHECK AFTER STOPPING ENGINEp. 153

  MOVING THE MACHINE (DIRECTIONAL, SPEED), STOPPING THE MACHINEp. 154

  TURNINGp. 166

  OPERATION OF WORK EQUIPMENTp. 167

  REMOTE POSITIONERp. 169

  WORK POSSIBLE USING WHEEL LOADERp. 172

  PRECAUTIONS FOR OPERATIONp. 191

  ADJUSTING WORK EQUIPMENT POSTUREp. 193

  REMOVAL AND INSTALLATION OF THE BUCKETp. 195

  PARKING MACHINEp. 199

  CHECKS AFTER COMPLETION OF OPERATIONp. 201

  LOCKINGp. 201

  HANDLING THE TIRESp. 202

  +TRANSPORTATIONp. 205

  TRANSPORTATION PROCEDUREp. 205

  LOADING, UNLOADING WORKp. 205

  METHOD OF SECURING MACHINEp. 205

  METHOD OF LIFTING MACHINEp. 207

  +COLD WEATHER OPERATIONp. 211

  PRECAUTIONS FOR LOW TEMPERATUREp. 211

  PRECAUTIONS AFTER COMPLETION OF WORKp. 212

  AFTER COLD WEATHERp. 212

  WARMING-UP OPERATION FOR STEERING HYDRAULIC CIRCUIT IN COLD WEATHERp. 213

  +LONG-TERM STORAGEp. 214

  BEFORE STORAGEp. 214

  DURING STORAGEp. 214

  AFTER STORAGEp. 214

  +TROUBLESHOOTINGp. 215

  WHEN MACHINE RUNS OUT OF FUELp. 215

  METHOD OF TOWING MACHINEp. 217

  IF BATTERY IS DISCHARGEDp. 221

  METHOD FOR LOWERING WORK EQUIPMENT WHEN ENGINE HAS STOPPEDp. 225

  PRELUBE SKIP FUNCTION WHEN STARTING IN EMERGENCYp. 226

  OTHER TROUBLEp. 228

  +MAINTENANCEp. 236

  GUIDES TO MAINTENANCEp. 237

  +OUTLINES OF SERVICEp. 239

  HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINICp. 239

  OUTLINE OF ELECTRIC SYSTEMp. 243

  +WEAR PARTSp. 244

  WEAR PARTS LISTp. 244

  +RECOMMENDED FUEL, COOLANT, AND LUBRICANTp. 245

  USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATUREp. 246

  RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OILp. 248

  +STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTSp. 249

  TORQUE LISTp. 249

  +PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTSp. 251

  SAFETY CRITICAL PARTSp. 252

  +MAINTENANCE SCHEDULE CHARTp. 254

  MAINTENANCE SCHEDULE CHARTp. 254

  +SERVICE PROCEDUREp. 256

  INITIAL 10 HOURS SERVICE (SERVICE FOR FIRST 50 HOURS ON NEW MACHINE)p. 256

  INITIAL 250 HOURS SERVICEp. 256

  +WHEN REQUIREDp. 257

  CHECK, CLEAN, OR REPLACE AIR CLEANER ELEMENTp. 257

  CLEAN INSIDE OF COOLING SYSTEMp. 260

  CHECK TRANSMISSION OIL LEVEL, ADD OILp. 264

  CHECK AXLE OIL LEVEL, ADD OILp. 265

  CLEAN AXLE CASE BREATHERp. 265

  CLEAN AIR CONDITIONER CONDENSERp. 266

  CHECK WINDOW WASHING FLUID LEVEL, ADD FLUIDp. 266

  CLEAN RADIATOR, OIL COOLER, AFTERCOOLER FINSp. 267

  REPLACE BUCKET TEETHp. 268

  LUBRICATINGp. 269

  CHECK AIR CONDITIONERp. 270

  BLEEDING AIR FROM BRAKE HYDRAULIC CIRCUITp. 271

  REPLACE SLOW BLOW FUSEp. 272

  BLEEDING AIR FROM HYDRAULIC TANKp. 273

  REPLACE FAN BELT, ADJUST AUTO-TENSIONERp. 275

  SELECTION AND INSPECTION OF TIRESp. 277

  CHECK BEFORE STARTINGp. 279

  +EVERY 50 HOURS SERVICEp. 280

  DRAIN WATER, SEDIMENT FROM FUEL TANKp. 280

  +EVERY 100 HOURS SERVICEp. 281

  LUBRICATINGp. 281

  CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OILp. 283

  CLEAN ELEMENT IN AIR CONDITIONER FRESH AIR FILTERp. 284

  +EVERY 250 HOURS SERVICEp. 285

  CHECK BATTERY ELECTROLYTE LEVELp. 285

  CHECK PARKING BRAKEp. 286

  CHECK ALTERNATOR BELT TENSION, ADJUSTp. 287

  CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUSTp. 288

  CHECK FOR LOOSE WHEEL HUB NUTS, TIGHTENp. 289

  CLEAN ELEMENT IN AIR CONDITIONER RECIRCULATION FILTERp. 289

  CHECKING FUNCTION OF ACCUMULATORp. 289

  +EVERY 500 HOURS SERVICEp. 290

  CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGEp. 290

  REPLACE FUEL PRE-FILTER CARTRIDGEp. 292

  REPLACE TRANSMISSION OIL FILTER ELEMENTp. 294

  LUBRICATE CENTER DRIVE SHAFTp. 295

  CHECK FAN BELT FOR WEARp. 295

  +EVERY 1000 HOURS SERVICEp. 296

  CHANGE OIL IN TRANSMISSION CASE, CLEAN STRAINERp. 296

  CLEAN TRANSMISSION CASE BREATHERp. 297

  REPLACE FUEL MAIN FILTER CARTRIDGEp. 298

  LUBRICATINGp. 300

  TIGHTEN ROPS CANOPYp. 303

  REPLACE CORROSION RESISTOR CARTRIDGE (ONLY WHEN CORROSION RESISTOR CARTRIDGE IS USED)p. 303

  CHECK OF ENGINE AIR INTAKE PIPING CLAMPS FOR LOOSENESSp. 304

  +EVERY 2000 HOURS SERVICEp. 305

  CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC FILTER ELEMENTp. 305

  CLEAN HYDRAULIC TANK STRAINERp. 308

  REPLACE HYDRAULIC TANK BREATHER ELEMENTp. 309

  CHANGE AXLE OILp. 310

  CHANGE BRAKE OILp. 312

  REPLACE FILTER ELEMENT IN BRAKE OIL TANKp. 313

  REPLACE BRAKE OIL TANK BREATHERp. 314

  REPLACE ELEMENT IN AIR CONDITIONER RECIRCULATION AIR FILTER, FRESH AIR FILTERp. 314

  CLEAN PPC CIRCUIT STRAINERp. 314

  CHECK ALTERNATOR, STARTING MOTORp. 315

  CHECK ENGINE VALVE CLEARANCE, ADJUSTp. 315

  CHECK BRAKE DISC WEARp. 315

  CHECKING FUNCTION OF ACCUMULATORp. 316

  +EVERY 4000 HOURS SERVICEp. 317

  CHECK WATER PUMPp. 317

  CHECK STARTING MOTORp. 317

  CHECK FAN PULLEY AND TENSION PULLEYp. 317

  CHECK FOR LOOSE ENGINE HIGH-PRESSURE PIPING CLAMPS, HARDENING OF RUBBERp. 318

  CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBERp. 319

  +EVERY 8000 HOURS SERVICEp. 320

  REPLACE ENGINE HIGH-PRESSURE PIPING CLAMPSp. 320

  REPLACE FUEL SPRAY PREVENTION CAPp. 320

  OVERHAUL STARTING MOTOR AND ALTERNATORp. 320

  +SPECIFICATIONSp. 322

  SPECIFICATIONSp. 323

  +ATTACHMENTS, OPTIONSp. 326

  SELECTING BUCKET AND TIRESp. 327

  +HANDLING AUTO-GREASING SYSTEMp. 328

  METHOD OF OPERATING AUTO-GREASING SYSTEMp. 329

  PRECAUTIONS WHEN HANDLING AUTO-GREASING SYSTEMp. 329

  METHOD OF ADJUSTING DISCHARGE FROM INJECTORp. 336

  METHOD OF SETTING TIMERp. 338

  METHOD OF CHARGING WITH GREASEp. 341

  SERVICE CENTERp. 342

  EMERGENCY ENGINE STOP SWITCHp. 347

  +HANDLING BATTERY DISCONNECTOR SWITCH AND STARTING MOTOR DISCONNECTOR SWITCHp. 349

  EXPLANATION OF COMPONENTSp. 349

  HANDLINGp. 350

  HANDLING STARTING AID CONNECTORp. 351

  CENTRALIZED BREATHERp. 353

  HYDRAULIC OIL LEVEL WARNING DISPLAYp. 354

  INDEXp. 356

• 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.