Komatsu WA800L-3 Wheel Loader Operation and Maintenance Manual (TEN00007-02)
On a WA800L-3 working in a quarry or large mining pit, this manual is what I keep close to keep the loader earning instead of parked. It walks you through how to run the machine correctly day to day, and how to stay ahead of wear so you don’t find problems only when something breaks. If, for example, the operator reports sluggish lift or uneven bucket response at the start of a shift, I’d use this book to verify the basic checks, trace through the recommended inspection points, and confirm whether it’s an operating issue or time for scheduled service.
Applications & Use Cases
- Plan preventive maintenance so you can schedule downtime around production instead of emergencies.
- Set up daily and weekly inspections that catch leaks, loose hardware, or misalignment early.
- Guide new operators on proper warm-up, shutdown, and loading technique to reduce stress on the machine.
- Verify service tasks after a repair or component change to be sure everything is routed, tightened, and tested correctly.
- Support troubleshooting by ruling out basic operating or maintenance oversights before calling in major work.
FAQ
Q: Can I use this manual on a tablet in the field?
A: Yes, it’s practical to keep a digital copy on a rugged tablet so you can zoom diagrams and follow procedures right at the machine.
Q: Is it worth printing parts of this manual?
A: I’d print the routine checklists and key service pages and keep them in the service truck for quick reference during shift checks.
Safety Note
Always follow the manual’s safety instructions and lockout procedures before inspecting, adjusting, or servicing the loader.
📘 Show Index
Komatsu WA800L-3 Wheel Loader Index:
- COVER
- FOREWORD
- FOREWORD
- SAFETY INFORMATION
- INTRODUCTION
- FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE
- VISIBILITY FROM OPERATOR’S SEAT
- NECESSARY INFORMATION
- PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE
- ENGINE SERIAL NO. PLATE AND POSITION
- POSITION OF SERVICE METER
- TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR
- CONTENTS
- SAFETY
- SAFETY
- SAFETY LABELS
- LOCATION OF SAFETY LABELS
- GENERAL PRECAUTIONS
- SAFETY RULES
- IF ABNORMALITIES ARE FOUND
- CLOTHING AND PERSONAL PROTECTIVE ITEMS
- FIRE EXTINGUISHER AND FIRST AID KIT
- SAFETY FEATURES
- KEEP MACHINE CLEAN
- INSIDE OPERATOR’S COMPARTMENT
- ALWAYS APPLY LOCK WHEN LEAVING OPERATOR’S SEAT
- HANDRAILS AND STEPS
- MOUNTING AND DISMOUNTING
- NO PEOPLE ON ATTACHMENTS
- DO NOT GET CAUGHT IN ARTICULATED PORTION
- PREVENTION OF BURNS
- FIRE PREVENTION
- ACTION IF FIRE OCCURS
- WINDOW WASHER LIQUID
- PRECAUTIONS WHEN USING ROPS (ROLL OVER PROTECTIVE STRUCTURE)
- PRECAUTIONS FOR ATTACHMENTS, OPTIONS
- UNAUTHORIZED MODIFICATION
- SAFETY AT WORKSITE
- WORKING ON LOOSE GROUND
- DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES
- ENSURE GOOD VISIBILITY
- PRECAUTIONS RELATED TO VENTILATION EXHAUST GAS
- CHECKING SIGNALMAN’S SIGNALS AND SIGNS
- EMERGENCY EXIT FROM OPERATOR’S CAB
- BE CAREFUL ABOUT ASBESTOS DUST
- PRECAUTIONS FOR OPERATION
- STARTING ENGINE
- OPERATION
- TRANSPORTATION
- BATTERY
- TOWING
- PRECAUTIONS FOR MAINTENANCE
- WARNING TAG
- KEEP WORK PLACE CLEAN AND TIDY
- APPOINT LEADER WHEN WORKING WITH OTHERS
- STOP ENGINE BEFORE CARRYING OUT MAINTENANCE
- TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING
- PROPER TOOLS
- WORK EQUIPMENT SUPPORT
- ACCUMULATOR
- PERSONNEL
- ATTACHMENTS
- NOISE
- PRECAUTIONS WHEN USING HAMMER
- REPAIR WELDING
- REMOVING BATTERY TERMINAL
- PRECAUTIONS WITH HIGH-PRESSURE OIL
- HANDLING HIGH-PRESSURE HOSES
- WASTE MATERIALS
- MAINTENANCE OF AIR CONDITIONER
- COMPRESSED AIR
- PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS
- PRECAUTIONS WITH TIRES
- HANDLING TIRES
- PRECAUTIONS WHEN STORING TIRES
- OPERATION
- GENERAL VIEW
- GENERAL VIEW OF MACHINE
- GENERAL VIEW OF CONTROLS AND GAUGES
- EXPLANATION OF COMPONENTS
- MACHINE MONITOR
- SWITCHES
- CONTROL LEVERS, PEDALS
- MAIN MONITOR TILT LEVER
- CAP WITH LOCK
- SAFETY BAR
- TOWING PIN
- ENGINE SHUT-DOWN SWITCH
- FUEL STOP LEVER
- GREASE PUMP
- BACKUP ALARM
- CAB DOOR OPEN LOCK
- TOOL BOX
- FUSE
- SLOW BLOW FUSE
- LUNCH BOX TRAY
- POWER OUTLET
- AM/FM RADIO-CASSETTE STEREO
- AIR CONDITIONER
- PRECAUTIONS WHEN HANDLING ACCUMULATOR
- OPERATION
- CHECK BEFORE STARTING ENGINE, ADJUST
- STARTING ENGINE
- OPERATIONS AND CHECKS AFTER STARTING ENGINE
- STOPPING ENGINE
- CHECK AFTER STOPPING ENGINE
- MOVING THE MACHINE (DIRECTIONAL, SPEED), STOPPING THE MACHINE
- TURNING
- OPERATION OF WORK EQUIPMENT
- WORK POSSIBLE USING WHEEL LOADER
- PRECAUTIONS FOR OPERATION
- ADJUSTING WORK EQUIPMENT POSTURE
- REMOVAL AND INSTALLATION OF THE BUCKET
- PARKING MACHINE
- CHECKS AFTER COMPLETION OF OPERATION
- LOCKING
- HANDLING THE TIRES
- OPERATING AUTO-GREASING SYSTEM
- TRANSPORTATION
- TRANSPORTATION PROCEDURE
- LOADING, UNLOADING WORK
- METHOD OF SECURING MACHINE
- METHOD OF LIFTING MACHINE
- COLD WEATHER OPERATION
- PRECAUTIONS FOR LOW TEMPERATURE
- PRECAUTIONS AFTER COMPLETION OF WORK
- AFTER COLD WEATHER
- WARMING-UP OPERATION FOR STEERING HYDRAULIC CIRCUIT IN COLD WEATHER
- LONG-TERM STORAGE
- BEFORE STORAGE
- DURING STORAGE
- AFTER STORAGE
- TROUBLESHOOTING
- WHEN MACHINE RUNS OUT OF FUEL
- METHOD OF TOWING MACHINE
- IF BATTERY IS DISCHARGED
- OTHER TROUBLE
- MAINTENANCE
- GUIDES TO MAINTENANCE
- OUTLINES OF SERVICE
- HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC
- OUTLINE OF ELECTRIC SYSTEM
- WEAR PARTS
- USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE
- PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS
- FUEL, OIL AND COOLANT SPECIFICATIONS
- ENGINE OIL SPECIFICATIONS
- TRANSMISSION, CONVERTER, TRANSFER CASE, COOLER, SERVICE BRAKES AND HYDRAULIC SYSTEM OIL SPECIFICATIONS
- DRIVE AXLE OIL SPECIFICATIONS
- DIESEL FUEL SPECIFICATIONS
- COOLANT SPECIFICATIONS
- STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS
- PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS
- MAINTENANCE SCHEDULE CHART
- MAINTENANCE SCHEDULE CHART
- SERVICE PROCEDURE
- INITIAL 250 HOURS SERVICE
- WHEN REQUIRED
- CHECK BEFORE STARTING
- EVERY 50 HOURS SERVICE
- EVERY 100 HOURS SERVICE
- EVERY 250 HOURS SERVICE
- EVERY 500 HOURS SERVICE
- EVERY 1000 HOURS SERVICE
- EVERY 2000 HOURS SERVICE
- EVERY 4000 HOURS SERVICE
- SPECIFICATIONS
- INDEX
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