KOMATSU WA800-3E0 WA900-3E0 WHEEL LOADER OPERATION & MAINTENANCE MANUAL (TEN00162-03) – PDF DOWNLOAD

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KOMATSU WA800-3E0 WA900-3E0 WHEEL LOADER OPERATION & MAINTENANCE MANUAL (TEN00162-03)

KOMATSU WA800-3E0 WA900-3E0 WHEEL LOADER OPERATION & MAINTENANCE MANUAL (TEN00162-03) – PDF DOWNLOAD:

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KOMATSU WA800-3E0 WA900-3E0 WHEEL LOADER OPERATION & MAINTENANCE MANUAL (TEN00162-03)

• This manual gives details of the operation and methods of inspection and maintenance for this machine that must be obeyed in order to use the machine safely. Most accidents are caused by the failure to follow fundamental safety rules for the operation and maintenance of machines. Read, understand and follow all precautions and warnings in this manual and on the machine before performing operation and maintenance.
• Failure to do so may result in serious injury or death. Komatsu cannot predict every circumstance that might involve a potential hazard when the machine is used. Therefore, the safety messages in this manual and on the machine may not include all possible safety precautions. If you carry out any operation, inspection, or maintenance under conditions that are not described in this manual, understand that it is your responsibility to take the necessary precautions to ensure safety.
• In no event should you or others engage in the prohibited uses or actions described in this manual. Improper operation and maintenance of the machine can be hazardous and could result in serious injury or death. If you sell the machine, be sure to give this manual to the new owner together with the machine. Always keep this Operation and Maintenance Manual in the location shown on the right so that all relevant personnel can read it at any time.
• Storage location for the Operation and Maintenance Manual: Pocket (1) at rear of operator’s seat If this manual is lost or damaged, contact your distributor immediately to arrange for its replacement. For details regarding the machine serial No. you will need to provide your Komatsu distributor, see “TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR (PAGE 1-10)”. This manual uses the international units (SI) for units of measurement. For reference, units that have been used in the past are given in ( ).
• The explanations, values, and illustrations in this manual have been prepared based on the latest information available as of the date of its publication. Continuing improvements in the design of this machine may lead to additional changes that are not reflected in this manual. Consult Komatsu or your Komatsu distributor for the latest available information concerning your machine or with questions regarding information contained in this manual.
• The numbers in circles in the illustrations correspond to the numbers in ( ) in the text. (For example:1 → (1)) Komatsu delivers machines that comply with all applicable regulations and standards of the country to which it has been shipped. If this machine has been purchased in another country, it may lack certain safety devices and specifications that are necessary for use in your country. If there is any question about whether your product complies with the applicable standards and regulations of your country, consult Komatsu or your Komatsu distributor before operating the machine.

TABLE OF CONTENTS:

KOMATSU WA800-3E0 WA900-3E0 WHEEL LOADER OPERATION & MAINTENANCE MANUAL (TEN00162-03)

COVER................................................................................................  1
FOREWORD.............................................................................................  2
	BEFORE READING THIS MANUAL.......................................................................  3
	SAFETY INFORMATION...............................................................................  6
	INTRODUCTION.....................................................................................  7
		USE OF MACHINE...............................................................................  7
		FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE.................................................  7
		VISIBILITY FROM OPERATOR'S SEAT..............................................................  8
	NECESSARY INFORMATION............................................................................ 10
		PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE................................. 10
		EPA REGULATIONS, ENGINE NUMBER PLATE......................................................... 10
		POSITION OF SERVICE METER.................................................................... 11
		TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR.................................................... 11
CONTENTS............................................................................................. 12
SAFETY............................................................................................... 16
	SAFETY........................................................................................... 17
	SAFETY LABELS.................................................................................... 20
		LOCATION OF SAFETY LABELS.................................................................... 21
		SAFETY LABELS................................................................................ 22
	GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE.......................................... 27
		PRECAUTIONS BEFORE STARTING OPERATION........................................................ 27
			ENSURING SAFE OPERATION.................................................................. 27
			UNDERSTANDING THE MACHINE................................................................ 27
		PREPARATIONS FOR SAFE OPERATION.............................................................. 27
			PRECAUTIONS REGARDING SAFETY-RELATED EQUIPMENT........................................... 27
			INSPECTING MACHINE....................................................................... 27
			WEAR WELL-FITTING CLOTHES AND PROTECTIVE EQUIPMENT....................................... 27
			KEEP MACHINE CLEAN....................................................................... 28
			PRECAUTIONS INSIDE OPERATOR'S COMPARTMENT................................................ 28
			PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT.............................................. 28
			IF ANY PROBLEM IS FOUND.................................................................. 28
		FIRE PREVENTION.............................................................................. 29
			ACTION IF FIRE OCCURS.................................................................... 29
			PRECAUTIONS TO PREVENT FIRE.............................................................. 29
		PRECAUTIONS WHEN GETTING ON OR OFF MACHINE................................................... 30
			USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF MACHINE................................... 30
			NO JUMPING ON OR OFF MACHINE............................................................. 30
			NO PEOPLE ON ATTACHMENTS................................................................. 31
			PRECAUTIONS WHEN STANDING UP FROM OPERATOR'S SEAT........................................ 31
			PRECAUTIONS WHEN LEAVING MACHINE......................................................... 32
			EMERGENCY EXIT FROM OPERATOR'S CAB....................................................... 32
			PRECAUTIONS WHEN CLEANING CAB GLASS...................................................... 33
		DO NOT GET CAUGHT IN ARTICULATING PORTION.................................................... 33
		PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES................................................. 34
		UNAUTHORIZED MODIFICATION.................................................................... 34
		PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS............................................... 34
		PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING.............................................. 35
	PRECAUTIONS FOR OPERATION........................................................................ 36
		PRECAUTIONS FOR JOBSITE...................................................................... 36
			INVESTIGATE AND CONFIRM JOBSITE CONDITIONS............................................... 36
			WORKING ON LOOSE GROUND.................................................................. 36
			DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES................................................... 37
			ENSURE GOOD VISIBILITY................................................................... 37
			CHECKING SIGNS AND SIGNALMAN'S SIGNALS................................................... 37
			BEWARE OF ASBESTOS DUST.................................................................. 38
		STARTING ENGINE.............................................................................. 38
			WARNING TAG.............................................................................. 38
			INSPECTION AND MAINTENANCE BEFORE STARTING ENGINE ....................................... 39
			PRECAUTIONS WHEN STARTING ENGINE......................................................... 39
			PRECAUTIONS IN COLD AREAS................................................................ 39
			STARTING WITH BOOSTER CABLES............................................................. 40
			STARTING WITH STARTING AID CONNECTOR (IF EQUIPPED)....................................... 40
		OPERATION.................................................................................... 41
			CHECKS BEFORE OPERATION.................................................................. 41
			PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE......................................... 41
			PRECAUTIONS WHEN TRAVELING............................................................... 42
			TRAVELING ON SLOPES...................................................................... 43
			METHOD OF USING BRAKES................................................................... 43
			PRECAUTIONS WHEN OPERATING............................................................... 44
			PROHIBITED OPERATIONS.................................................................... 45
			TRAVELING ON SNOW-COVERED OR FROZEN SURFACES............................................. 45
			PARKING MACHINE.......................................................................... 46
		TRANSPORTATION............................................................................... 48
			LOADING AND UNLOADING.................................................................... 48
		TOWING....................................................................................... 49
			PRECAUTIONS WHEN TOWING ................................................................. 49
	PRECAUTIONS FOR MAINTENANCE...................................................................... 50
		PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE ...................................... 50
			DISPLAY WARNING TAG DURING INSPECTION AND MAINTENANCE.................................... 50
			KEEP WORKPLACE CLEAN AND TIDY............................................................ 50
			SELECT SUITABLE PLACE FOR INSPECTION AND MAINTENANCE..................................... 50
			ONLY AUTHORIZED PERSONNEL................................................................ 50
			APPOINT LEADER WHEN WORKING WITH OTHERS.................................................. 50
			STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE .............................. 51
			TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING....................................... 53
			INSTALLING, REMOVING, OR STORING ATTACHMENTS............................................. 54
			PRECAUTIONS WHEN WORKING AT HIGH PLACES.................................................. 54
			PRECAUTIONS WHEN WORKING UNDER MACHINE OR WORK EQUIPMENT ................................ 54
			PROPER TOOLS............................................................................. 54
		PRECAUTIONS FOR INSPECTION AND MAINTENANCE................................................... 55
			PRECAUTIONS WHEN WELDING................................................................. 55
			HANDLING BATTERY......................................................................... 55
			PRECAUTIONS WHEN USING HAMMER............................................................ 56
			PRECAUTIONS WITH HIGH-TEMPERATURE COOLANT................................................ 56
			PRECAUTIONS WITH HIGH-TEMPERATURE OIL.................................................... 57
			PRECAUTIONS WITH HIGH-PRESSURE OIL....................................................... 58
			PRECAUTIONS WITH HIGH-PRESSURE FUEL...................................................... 58
			HANDLING HIGH-PRESSURE HOSES AND PIPING.................................................. 58
			NOISE.................................................................................... 58
			HANDLING ACCUMULATOR AND GAS SPRING ..................................................... 59
			PRECAUTIONS WITH COMPRESSED AIR ......................................................... 59
			MAINTENANCE OF AIR CONDITIONER........................................................... 59
			DISPOSING OF WASTE MATERIALS............................................................. 59
			METHOD OF SELECTING WINDOW WASHER FLUID.................................................. 59
			PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS............................................ 60
		TIRES........................................................................................ 61
			HANDLING TIRES........................................................................... 61
			PRECAUTIONS WHEN STORING TIRES........................................................... 62
OPERATION............................................................................................ 64
	GENERAL VIEW..................................................................................... 65
		GENERAL VIEW OF MACHINE...................................................................... 65
		GENERAL VIEW OF CONTROLS AND GAUGES.......................................................... 66
	EXPLANATION OF COMPONENTS........................................................................ 70
		MACHINE MONITOR.............................................................................. 70
		SWITCHES..................................................................................... 86
		CONTROL LEVERS, PEDALS.......................................................................101
		MAIN MONITOR TILT LEVER......................................................................107
		CAP WITH LOCK................................................................................108
		FRAME LOCK BAR...............................................................................109
		TOWING PIN...................................................................................110
		ENGINE SHUT-DOWN SWITCH......................................................................110
		FUEL STOP LEVER..............................................................................110
		BACKUP ALARM.................................................................................110
		CAB DOOR OPEN LOCK...........................................................................111
		HANDLING CAB WIPER...........................................................................111
		DUST INDICATOR...............................................................................112
		FUSE.........................................................................................113
		CIRCUIT BREAKER..............................................................................115
		SLOW BLOW FUSE...............................................................................115
		LUNCH BOX TRAY...............................................................................116
		TOOL BOX.....................................................................................116
		GREASE PUMP..................................................................................116
		LOCATION OF FIRE EXTINGUISHER................................................................116
		POWER OUTLET.................................................................................117
		AM/FM RADIO-CASSETTE STEREO..................................................................118
		AIR CONDITIONER..............................................................................127
		HANDLING MACHINES EQUIPPED WITH VHMS.........................................................132
		HANDLING WIRELESS............................................................................134
	OPERATION........................................................................................135
		CHECK BEFORE STARTING ENGINE, ADJUST.........................................................135
		STARTING ENGINE..............................................................................152
		OPERATIONS AND CHECKS AFTER STARTING ENGINE..................................................155
		STOPPING ENGINE..............................................................................157
		CHECK AFTER STOPPING ENGINE..................................................................157
		MOVING THE MACHINE (DIRECTIONAL, SPEED), STOPPING THE MACHINE................................158
		TURNING......................................................................................170
		OPERATION OF WORK EQUIPMENT..................................................................171
		REMOTE POSITIONER............................................................................173
		WORK POSSIBLE USING WHEEL LOADER.............................................................176
		PRECAUTIONS FOR OPERATION....................................................................195
		ADJUSTING WORK EQUIPMENT POSTURE.............................................................197
		REMOVAL AND INSTALLATION OF THE BUCKET.......................................................199
		PARKING MACHINE..............................................................................203
		CHECKS AFTER COMPLETION OF OPERATION.........................................................205
		LOCKING......................................................................................205
		HANDLING THE TIRES...........................................................................206
	TRANSPORTATION...................................................................................209
		TRANSPORTATION PROCEDURE.....................................................................209
		LOADING, UNLOADING WORK......................................................................209
		METHOD OF SECURING MACHINE...................................................................209
		METHOD OF LIFTING MACHINE....................................................................211
	COLD WEATHER OPERATION...........................................................................215
		PRECAUTIONS FOR LOW TEMPERATURE..............................................................215
		PRECAUTIONS AFTER COMPLETION OF WORK.........................................................216
		AFTER COLD WEATHER...........................................................................216
		WARMING-UP OPERATION FOR STEERING HYDRAULIC CIRCUIT IN COLD WEATHER..........................217
	LONG-TERM STORAGE................................................................................218
		BEFORE STORAGE...............................................................................218
		DURING STORAGE...............................................................................218
		AFTER STORAGE................................................................................218
	TROUBLESHOOTING..................................................................................219
		WHEN MACHINE RUNS OUT OF FUEL................................................................219
		METHOD OF TOWING MACHINE.....................................................................221
		IF BATTERY IS DISCHARGED.....................................................................225
		METHOD FOR LOWERING WORK EQUIPMENT WHEN ENGINE HAS STOPPED...................................229
		PRELUBE SKIP FUNCTION WHEN STARTING IN EMERGENCY ............................................230
		OTHER TROUBLE................................................................................232
MAINTENANCE..........................................................................................240
	GUIDES TO MAINTENANCE............................................................................241
	OUTLINES OF SERVICE..............................................................................243
		HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC.......................................243
		OUTLINE OF ELECTRIC SYSTEM...................................................................247
	WEAR PARTS.......................................................................................248
		WEAR PARTS LIST..............................................................................248
	RECOMMENDED FUEL, COOLANT, AND LUBRICANT.........................................................249
		USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE.........................250
		RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL..........252
	STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS...................................................253
		TORQUE LIST..................................................................................253
	PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS....................................................255
		SAFETY CRITICAL PARTS........................................................................256
	MAINTENANCE SCHEDULE CHART.......................................................................258
		MAINTENANCE SCHEDULE CHART...................................................................258
	SERVICE PROCEDURE................................................................................260
		INITIAL 10 HOURS SERVICE (SERVICE FOR FIRST 50 HOURS ON NEW MACHINE).........................260
		INITIAL 250 HOURS SERVICE....................................................................260
		WHEN REQUIRED................................................................................261
			CHECK, CLEAN, OR REPLACE AIR CLEANER ELEMENT.............................................261
			CLEAN INSIDE OF COOLING SYSTEM...........................................................264
			CHECK TRANSMISSION OIL LEVEL, ADD OIL....................................................268
			CHECK AXLE OIL LEVEL, ADD OIL............................................................269
			CLEAN AXLE CASE BREATHER.................................................................269
			CLEAN AIR CONDITIONER CONDENSER..........................................................270
			CHECK WINDOW WASHING FLUID LEVEL, ADD FLUID..............................................270
			CLEAN RADIATOR, OIL COOLER, AFTERCOOLER FINS.............................................271
			REPLACE BUCKET TEETH.....................................................................272
			LUBRICATING..............................................................................273
			CHECK AIR CONDITIONER....................................................................274
			BLEEDING AIR FROM BRAKE HYDRAULIC CIRCUIT................................................275
			REPLACE SLOW BLOW FUSE...................................................................276
			BLEEDING AIR FROM HYDRAULIC TANK.........................................................277
			REPLACE FAN BELT, ADJUST AUTO-TENSIONER..................................................279
			SELECTION AND INSPECTION OF TIRES........................................................281
		CHECK BEFORE STARTING........................................................................283
		EVERY 50 HOURS SERVICE.......................................................................284
			DRAIN WATER, SEDIMENT FROM FUEL TANK.....................................................284
		EVERY 100 HOURS SERVICE......................................................................285
			LUBRICATING..............................................................................285
			CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL...............................................287
			CLEAN ELEMENT IN AIR CONDITIONER FRESH AIR FILTER........................................288
		EVERY 250 HOURS SERVICE......................................................................289
			CHECK BATTERY ELECTROLYTE LEVEL..........................................................289
			CHECK PARKING BRAKE......................................................................290
			CHECK ALTERNATOR BELT TENSION, ADJUST....................................................291
			CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST....................................292
			CHECK FOR LOOSE WHEEL HUB NUTS, TIGHTEN..................................................293
			CLEAN ELEMENT IN AIR CONDITIONER RECIRCULATION FILTER....................................293
			CHECKING FUNCTION OF ACCUMULATOR.........................................................293
		EVERY 500 HOURS SERVICE......................................................................294
			CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE........................294
			REPLACE FUEL PRE-FILTER CARTRIDGE........................................................296
			REPLACE TRANSMISSION OIL FILTER ELEMENT..................................................298
			LUBRICATE CENTER DRIVE SHAFT.............................................................299
			CHECK FAN BELT FOR WEAR .................................................................299
		EVERY 1000 HOURS SERVICE.....................................................................300
			CHANGE OIL IN TRANSMISSION CASE, CLEAN STRAINER..........................................300
			CLEAN TRANSMISSION CASE BREATHER.........................................................301
			REPLACE FUEL MAIN FILTER CARTRIDGE.......................................................302
			LUBRICATING..............................................................................304
			TIGHTEN ROPS CANOPY......................................................................307
			REPLACE CORROSION RESISTOR CARTRIDGE (ONLY WHEN CORROSION RESISTOR CARTRIDGE IS USED)....307
			CHECK OF ENGINE AIR INTAKE PIPING CLAMPS FOR LOOSENESS...................................308
		EVERY 2000 HOURS SERVICE.....................................................................309
			CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC FILTER ELEMENT...........................309
			CLEAN HYDRAULIC TANK STRAINER............................................................312
			REPLACE HYDRAULIC TANK BREATHER ELEMENT..................................................313
			CHANGE AXLE OIL..........................................................................314
			CHANGE BRAKE OIL.........................................................................316
			REPLACE FILTER ELEMENT IN BRAKE OIL TANK.................................................317
			REPLACE BRAKE OIL TANK BREATHER..........................................................318
			REPLACE ELEMENT IN AIR CONDITIONER RECIRCULATION AIR FILTER, FRESH AIR FILTER............318
			CLEAN PPC CIRCUIT STRAINER...............................................................318
			HECK ALTERNATOR, STARTING MOTOR..........................................................319
			CHECK ENGINE VALVE CLEARANCE, ADJUST.....................................................319
			CHECK BRAKE DISC WEAR....................................................................319
			CHECKING FUNCTION OF ACCUMULATOR.........................................................320
		EVERY 4000 HOURS SERVICE.....................................................................321
			CHECK WATER PUMP.........................................................................321
			CHECK STARTING MOTOR.....................................................................321
			CHECK FAN PULLEY AND TENSION PULLEY......................................................321
			CHECK FOR LOOSE ENGINE HIGH-PRESSURE PIPING CLAMPS, HARDENING OF RUBBER..................322
			CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER......................323
		EVERY 8000 HOURS SERVICE.....................................................................324
			REPLACE ENGINE HIGH-PRESSURE PIPING CLAMPS...............................................324
			REPLACE FUEL SPRAY PREVENTION CAP........................................................324
			OVERHAUL STARTING MOTOR AND ALTERNATOR...................................................324
SPECIFICATIONS.......................................................................................326
	SPECIFICATIONS...................................................................................327
ATTACHMENTS, OPTIONS.................................................................................330
	SELECTING BUCKET AND TIRES.......................................................................331
	HANDLING AUTO-GREASING SYSTEM....................................................................332
		METHOD OF OPERATING AUTO-GREASING SYSTEM.....................................................333
		PRECAUTIONS WHEN HANDLING AUTO-GREASING SYSTEM...............................................333
		METHOD OF ADJUSTING DISCHARGE FROM INJECTOR..................................................340
		METHOD OF SETTING TIMER......................................................................342
		METHOD OF CHARGING WITH GREASE...............................................................345
	SERVICE CENTER...................................................................................346
	EMERGENCY ENGINE STOP SWITCH.....................................................................351
	HANDLING BATTERY DISCONNECTOR SWITCH AND STARTING MOTOR DISCONNECTOR SWITCH......................353
		EXPLANATION OF COMPONENTS....................................................................353
		HANDLING.....................................................................................354
	HANDLING STARTING AID CONNECTOR..................................................................355
	CENTRALIZED BREATHER.............................................................................357
	HYDRAULIC OIL LEVEL WARNING DISPLAY..............................................................358
INDEX................................................................................................360

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