Komatsu WA800-2 Wheel Loader Operation and Maintenance Manual (SEAD004001)

On a WA800-2 working in a quarry or large mine, this Operation and Maintenance Manual is what I’d keep close to keep the loader earning and not parked. It walks you through how to run the machine correctly and how to set a steady service rhythm so you’re not guessing on inspections or greasing. If, for example, you notice slower hydraulic response or uneven bucket lift, this book helps you trace the issue logically—starting with basic checks you can do in the yard before calling in major repairs.

Applications & Use Cases

• Plan preventive maintenance so you can schedule downtime between production shifts instead of during them.
• Set up daily and weekly walk‑around inspections to catch leaks, loose hardware, or tire damage early.
• Verify correct operating procedures for new operators so they don’t abuse the drivetrain or brakes.
• Trace abnormal noises, heat, or vibration to likely areas before you start tearing parts off.
• Align maintenance records with the recommended service rhythm to support warranty and resale value.

FAQ

Q: Is this manual practical to use on a tablet in the field?

A: Yes, it’s well-suited to digital use; you can zoom diagrams and search terms instead of flipping pages with dirty gloves.

Q: Should I still print sections of it?

A: I’d print the key maintenance and inspection pages to keep in the service truck for quick reference in dusty or wet conditions.

Safety Note

Always lock out, tag out, and verify the machine is fully secured before performing any inspection or service.

Komatsu WA800-2 Wheel Loader Index:

• MAIN MENU
• 1. FOREWORD
• 2. SAFETY INFORMATION
• 3. INTRODUCTION
• 4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR
• 5. CONTENTS
• SAFETY
  • 6. GENERAL PRECAUTIONS
  • 7. PRECAUTIONS DURING OPERATION
    • 7.1 BEFORE STARTING ENGINE
    • 7.2 OPERATING MACHINE
    • 7.3 TRANSPORTATION
    • 7.4 BATTERY
    • 7.5 TOWING
  • 8. PRECAUTIONS FOR MAINTENANCE
    • 8.1 BEFORE CARRYING OUT MAINTENANCE
    • 8.2 DURING MAINTENANCE
    • 8.3 TIRES
  • 9. POSITION FOR ATTACHING SAFETY LABELS
• OPERATION
  • 10. GENERAL VIEW
    • 10.1 GENERAL VIEW OF MACHINE
    • 10.2 GENERAL VIEW OF CONTROLS AND GAUGES
  • 11. EXPLANATION OF COMPONENTS
    • 11.1 MACHINE MONITOR
    • 11.2 SWITCHES
    • 11.3 CONTROL LEVERS, PEDALS
    • 11.4 DUST INDICATOR
    • 11.5 CIRCUIT BREAKER (MAIN)
    • 11.6 SAFETY BAR
    • 11.7 STEERING COLUMN TILT LEVER
    • 11.8 DOOR-OPEN LOCK
    • 11.9 CAP WITH LOCK
    • 11.10 FUEL STOP LEVER
    • 11.11 AIR PICK-UP PORT
    • 11.12 FUSE
    • 11.13 CAR RADIO
    • 11.14 AIR CONDITIONER
    • 11.15 CAR HEATER
    • 11.16 USING ACCUMULATOR
  • 12. OPERATION
    • 12.1 CHECK BEFORE STARTING ENGINE
    • 12.2 STARTING ENGINE
    • 12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE
    • 12.4 MOVING MACHINE OFF
    • 12.5 CHANGING GEAR SPEED
    • 12.6 CHANGING DIRECTION
    • 12.7 TURNING
    • 12.8 STOPPING MACHINE
    • 12.9 OPERATION OF WORK EQUIPMENT
    • 12.10 WORK POSSIBLE USING WHEEL LOADER
    • 12.11 PRECAUTIONS FOR OPERATION
    • 12.12 ADJUSTING WORK EQUIPMENT POSTURE
    • 12.13 PARKING MACHINE
    • 12.14 CHECKS AFTER COMPLETION OF OPERATION
    • 12.15 STOPPING ENGINE
    • 12.16 CHECK AFTER STOPPING ENGINE
    • 12.17 LOCKING
    • 12.18 HANDLING THE TIRES
    • 12.19 REMOVAL AND INSTALLATION OF THE BUCKET
  • 13. TRANSPORTATION
  • 14. COLD WEATHER OPERATION
    • 14.1 PRECAUTIONS FOR LOW TEMPERATURE
    • 14.2 PRECAUTIONS AFTER COMPLETION OF
    • 14.3 AFTER COLD WEATHkR
  • 15. LONG-TERM STORAGE
    • 15.1 BEFORE STORAGE
    • 15.2 DURING STORAGE
    • 15.3. AFTER STORAGE
  • 16. TROUBLESHOOTING
    • 16.1 WHEN MACHINE RUNS OUT OF FUEL
    • 16.2 TOWING THE MACHINE
    • 16.3 IF BATTERY IS DISCHARGED
    • 16.4 OTHER TRUOBLE
• MAINTENANCE
  • 17. GUIDES TO MAINTENANCE
  • 18. OUTLINES OF SERVICE
    • 18.1 OUTLINE OF OIL, FUEL, COOLANT
    • 18.2 OUTLINE OF ELECTRIC SYSTEM
  • 19. WEAR PARTS LIST
  • 20.USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE
  • 21. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS
    • 21.1 INTRODUCTION OF NECESSARY TOOLS
    • 21.2 TORQUE LIST
  • 22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS
  • 23. MAINTENANCE SCHEDULE CHART
    • 23.1 MAINTENANCE SCHEDULE CHART
  • 24. SERVICE PROCEDURE
    • 24.1 INITIAL 250 HOURS SERVICE
    • 24.2 WHEN REQUIRED
    • 24.3 CHECK BEFORE STARTING
    • 24.4 EVERY 50 HOURS SERVICE
    • 24.5 EVERY 100 HOURS SERVICE
    • 24.6 EVERY 250 HOURS SERVICE
    • 24.7 EVERY 500 HOURS SERVICE
    • 24.8 EVERY 1000 HOURS SERVICE
    • 24.9 EVERY 2000 HOURS SERVICE
    • 24.10 EVERY 4000 HOURS SERVICE
• SPECIFICATIONS
  • 25. SPECIFICATIONS
• OPTIONS, ATTACHMENTS
  • 26. OPTIONAL PART AND ATTACHMENTS
  • 27. SELECTING BUCKETS AND TIRES
  • 28. EXPLANATION OF OPERATION OF JOY STICK STEERING SYSTEM
    • 28.1 FUNCTIONS AND STRUCTURE OF JOY STICK STEERING
    • 28.2 OPERATION METHOD OF JOY STICK STEERING SYSTEM
    • 28.3 PRECAUTIONS FOR STEERING WITH JOY
    • 28.4 ADJUSTMENT OF JOY STICK CONSOLE
    • 28.5 ADJUSTMENT OF SEAT

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