Komatsu WA95-3 Wheel Loader - Operation & Maintenance Manual

KOMATSU WA95-3 WHEEL LOADER - OPERATION & MAINTENANCE MANUAL

- English Operation & Maintenance Manual to Wheel Loader Komatsu WA95-3.

 

INDEX:

Introduction
Forword 1-2
Safety Information 1-3
Introduction 1-5
- Features 1-5
- Breaking in a New Machine 1-5
Location of Plates, Table to Enter Serial No. and Distributor 1-6
- Machine Serial No. Plate position 1-6
- Engine Serial No. Plate Position 1-6
- Table to Enter Serial No. and Distributor 1-6
EMISSION CONTROL WARRANTY 1-7
- EMISSION CONTROL WARRANTY STATEMENT (APPLIES TO CANADA ONLY) 1-7
Engine Data Plate 1-8
GARANTIE SUR LE CONTRÔLE DES ÉMISSIONS 1-9
- ÉNONCÉ DE GARANTIE SUR LE CONTRÔLE DES ÉMISSIONS (APPLICABLE AU CANADA SEULEMENT): 1-9
Engine Data Plate 1-11
Why You Should Read these Operating Instructions 1-12
Notes on Safety Regulations 1-14
- Correct Use 1-14
- Safety Notes in the Operating Instructions 1-14
Equipment 1-15
- Loading and Transporting the Machine
Loading and Transporting the Machine 2-2
- Securing the Articulated Steering 2-2
- Lifting the Machine 2-2
- Driving Machine Onto Loading Area of Transport Vehicle 2-4
- Securing the Machine During Transport 2-5
- After Transport 2-5
- Safety
General Safety Measures 3-3
- Safety Instructions 3-3
- Safety Devices 3-3
- Emergency Exit 3-3
- Clothing and Personal Protection 3-4
- Machine Modifications 3-4
- Before You Leave the Driver's Seat 3-4
- Mounting and Dismounting 3-5
- Fire Prevention and Fire Fighting 3-6
- Fire Extinguisher and First-Aid Kit 3-7
- Protection Against Asbestos Dust 3-7
- Protection Against Injuries 3-8
- Working at High Temperatures 3-8
- Roll-Over Protection System (ROPS) 3-9
- Attachment for Protection Against Falling Objects (FOPS) 3-9
- Attachments 3-9
- Battery 3-10
Safety Measures during Operation 3-11
- Before You Start the Engine 3-11
- Workplace Safety 3-11
- In the Driver's Cab 3-11
- In-Door Operation 3-12
- Gas, Dust, and Inflammable Vapours 3-12
- Mirrors, Windows, and Lighting 3-12
- Machine Operation 3-13
- Before You Start the Engine 3-13
- Reversing 3-13
- Driving 3-14
- Driving On Slopes 3-14
- Emergency Lowering System 3-15
- Working Close to Overhead Power Transmission Lines 3-15
- Loading 3-16
- Good Vision 3-16
- Working On Snow 3-16
- Height Limitation 3-17
- Brakes 3-17
- Working On Loose Soil 3-17
- Working with the Forklift Truck Attachment 3-18
- Parking the Machine 3-19
- Transport 3-20
- Loading and Unloading the Machine 3-20
- Transport 3-21
Safety Measures During Maintenance 3-22
- Personnel 3-22
- Prior to Start of Maintenance Measures 3-22
- Warning Sign 3-22
- Tools 3-22
- Safety-Related Parts 3-22
- Prior to Start of Inspection and Maintenance 3-23
- Securing the Articulated Steering 3-23
- Supporting the boom 3-24
- During Maintenance 3-25
- Attachments 3-25
- Working Under the Machine 3-25
- Keeping the Machine Clean 3-25
- Specific Measures 3-25
- Refueling and Topping Off Oil 3-26
- Coolant 3-26
- Use of Lighting 3-27
- High-Pressure Hoses 3-27
- Handling High-Pressure Oil 3-27
- Handling of the pressure accumulator 3-28
- Fan and Belts 3-28
- Waste Material 3-28
- Tires 3-29
- Storing Tires 3-30
Labeling 3-31
- Position of Safety Labels 3-31
- Information Labels 3-33
- Controls and InDicators
Overall View of Machine 4-2
Controls and Indicators 4-3
- SWITCHES AND CONTROLS 4-4
- Instrument Panel 4-5
- Warning Lights 4-6
- Control Lamps 4-9
- Measuring Indicators 4-13
- Switches 4-15
- Control Levers, Pedals 4-22
- Articulated Steering Catch 4-28
- Traction Device 4-28
- Socket 4-28
- Door Unlocking System 4-29
- Alarm Horn for Reverse Driving 4-29
- Operation
Running in the Machine 5-2
Preparing the Machine Start 5-3
- Visual Checks 5-3
- Before you start the engine 5-3
- Before starting working with the machine 5-3
Adjustments Prior to Machine Start 5-6
- Adjusting the Driver’s Seat 5-6
- Adjusting the Steering Column 5-7
- Adjusting the Armrest 5-7
- Adjusting the Rear-View Mirrors 5-7
- Adjusting the Heating and Ventilation System 5-8
- Adjusting the ventilation system 5-8
- Adjusting the heating system 5-9
- Operating the Air Conditioning 5-10
- Switching on the air-conditioning 5-10
- Putting on the Safety Belt 5-12
- Putting on the safety belt 5-12
- Taking off the safety belt 5-12
Starting and Switching Off the Engine 5-13
- Starting the Engine 5-13
- Warming up the engine 5-14
- Switching Off the Engine 5-15
Driving 5-16
- Start-Up 5-16
- Starting the machine on slopes 5-18
- Driving with the high-Speed gear 5-18
- Changing the Driving Direction 5-19
- Reverse Driving 5-20
- Turning 5-20
- Turning on slopes, embankments or hill flanks 5-20
Braking 5-21
- Pulling the parking brake 5-21
- Releasing the parking brake 5-21
- Braking with the service brake 5-21
- If the service brake breaks down 5-22
- Braking on slopes 5-22
- Stopping 5-23
- Parking the machine on a slope 5-23
- Longer-Distance Driving 5-24
Operating the Machine 5-25
- Preparing the Work Equipment 5-25
- Selecting a work unit 5-25
- Picking up the work unit (except multi-purpose bucket) 5-25
- Removing the work unit 5-26
- Picking up the multi-purpose bucket 5-26
- Removing the multi-purpose bucket 5-28
- Tire Service Life 5-29
- Level indicator for the bucket 5-29
- Adjusting the Bucket Positioner 5-30
- Loading 5-31
- Removing piled up soil 5-31
- Excavation works 5-33
- Transporting 5-34
- Dumping / Unloading 5-34
- Loading in diagonal direction 5-34
- V-shaped loading 5-35
- Piling up material 5-35
- Planing 5-36
- Filling up 5-36
- Taking off soil 5-36
- Cutting the Ground 5-37
- Working With the Forklift Truck Attachment 5-38
- Picking up the load 5-38
- Precautions For Special Operations 5-39
- Working in water 5-39
- Working on snow 5-39
- Dumping on steep slopes 5-39
- Working in the vicinity of electrical overhead lines 5-39
- Operation on slopes 5-39
- Working on loose soil 5-39
- After the work is finished 5-39
Instructions for Winter Operation 5-40
- Before the cold season 5-40
- After Operation 5-40
- After the cold season 5-41
- Longer Standstill Periods of the Machine 5-42
- Before the standstill 5-42
- During the standstill 5-42
- After the standstill 5-43
- Troubleshooting
Troubleshooting 6-2
- Warning Lights and Indicators 6-2
- Electrical System 6-3
- Engine 6-4
- Hydraulic system 6-7
- Brakes 6-9
- Axles 6-10
- driver’s cab 6-10
- Emergency Steering Characteristics 6-11
- Emergency Lowering System 6-11
- Starting the Engine with a Battery Jumper Cable 6-12
- Connecting the Jumper Cable 6-12
- Starting the Engine 6-13
- Disconnecting the Battery Jumper Cable 6-13
- Towing the Machine 6-14
- Towing a Machine with Defective Brakes 6-15
- Inadequate Braking Effect 6-16
- Checking the Parking Brake 6-16
- Checking the Service Brake 6-17
- Maintenance
Maintenance Basics 7-2
- Preparing the Machine for Maintenance 7-2
- Cleaning the Machine 7-3
- Precautionary Measures When Cleaning the Machine 7-3
- Fire Prevention 7-3
- Working-Area-Dependent Maintenance 7-4
- Muddy or Wet Working Areas 7-4
- Dusty Working Areas 7-4
- Lubricants and Operating Agents 7-5
- Draining Hot Lubricants and Fluids 7-5
- Checking the Oil Level and Changing Oil 7-5
- Changing Filters 7-5
- Refuelling and Topping off Oil 7-5
- Oil 7-6
- Lubricating Grease 7-6
- Biodegradable Hydraulic Oil and Lubricating Grease 7-6
- Fuel 7-7
- Storage of Oil and Fuel 7-7
- Coolants 7-8
- Windscreen Washer Liquid 7-8
- Table of Lubricants and Operating Agents 7-10
- Lubrication chart 7-11
- Axles 7-12
- Released axle oil brands 7-12
- Replacing Safety-Related Parts 7-12
- Welding Instructions 7-13
- Spare Parts and Consumable Components 7-14
- Electrical System 7-15
- Fuses 7-16
- Fuse Assignment 7-16
- Slow-Blowing Fuses 7-17
- Tires 7-18
- Tire Components 7-18
- Checking the Tires 7-18
- Checking the Tire Pressure 7-18
- Torque for Standard Nuts and Bolts 7-20
Maintenance Schedule 7-22
Maintenance Prior to Start 7-24
- Visual Checks 7-24
- Cooling System, Checking the Coolant Level, Topping off Coolant 7-24
- Engine, Checking the Oil Level, Topping off Oil 7-25
- Engine, Draining off Oil 7-26
- Checking the Fuel Level, Refueling 7-27
- Checking the Controls 7-28
- Checking the Electrical Connections 7-28
- Heater / air conditioning: checking rate of air flow 7-29
- Other Maintenance Measures Prior to Start 7-29
Maintenance upon demand 7-30
- Checking the air-conditioning system 7-30
- Checking the coolant level 7-30
Maintenance Every 10 Operating Hours 7-31
- Lubrication 7-31
Maintenance After the First 50 Operating Hours 7-32
- Engine, Changing Oil and Replacing the Oil Filter Cartridge 7-32
- Replacing the Oil Filter Cartridge 7-33
- V-Belt, Checking the Condition 7-34
- V-Belt, Checking and Adjusting the Tension 7-34
- Hydraulic System, Replacing the Filter Insert 7-35
- Checking and Tightening the Wheel Nuts 7-36
- Front and Rear Axle, Changing Oil 7-37
- Planet gear 7-37
- Differential 7-37
- Transfer Gear - Changing Oil 7-38
Maintenance Every 50 Operating Hours 7-40
- Checking cooling System, coolant level in the radiator and expansion tank 7-40
- Draining Off Water and Dirt Deposits From the Fuel Tank 7-41
- Checking the Service Brake and Oil Level, Refilling Oil 7-41
- Checking the Battery and Acid Level 7-42
- Re-charging a built-in battery 7-43
- Lubrication 7-44
- Lubricating points of the work equipment 7-44
Maintenance Every 100 Operating Hours 7-45
- Draining the Water Separator, Removing Water and Dirt Deposits 7-45
Maintenance Every 250 Operating Hours 7-46
- Changing the Engine Oil and Oil Filter Cartridge 7-46
- Checking the V-Belt Condition 7-46
- Checking and Adjusting the V-belt Tension 7-46
- Front and Rear Axle, Checking the Oil Level 7-47
- Planet gear 7-47
- differential 7-48
- Air Filter, Removing/Re-Installing AND Checking/Cleaning the Filter Insert 7-49
- Structure of the air filter 7-49
- Maintenance demand 7-49
- Removing the filter cartridge 7-49
- Cleaning or exchanging the filter cartridge 7-50
- Checking the filter cartridge 7-51
- Assembling the air filter cartridge 7-51
- Cleaning the Radiator Segments 7-51
- Lubrication 7-52
Maintenance Every 500 Operating Hours 7-53
- Changing the Fuel Filter and Filter Element 7-53
- Bleeding the Fuel System 7-54
- Changing the Filter Cartridge of the Hydraulic System 7-55
- Cleaning the Water Separator 7-55
- Lubrication 7-56
- Transfer Gear, Checking the Oil Level and Refilling Oil 7-56
- Air Filter, Replacing the Filter Insert, Replacing the Safety Filter 7-57
- Replacing the Filter Insert 7-57
- Replacing the Safety Filter 7-57
- Heater/air conditioning: clean filter fleece of heater unit 7-58
- Heater/air conditioning: Cleaning the condenser 7-59
- ECSS-Pressure Accumulator (Option): Checking the Gas Pressure 7-59
Maintenance Every 1000 Operating Hours 7-60
- Cooling System, Exchanging Coolant and Cleaning the System 7-60
- Draining off the coolant 7-61
- Cleaning the Cooling System 7-61
- Filling off Coolant 7-61
- Front Axle, Oil Change 7-62
- Rear Axle, Oil Change 7-62
- Transfer Gear, Oil Change 7-62
- Service Brake 7-62
- Changing oil 7-62
- Checking tubes and lines 7-62
- Checking the brake disks for wear and tear 7-62
- Adjusting the clearance of the brake disks 7-62
- Checking and Adjusting System Pressures 7-62
- Checking and Adjusting the Valve clearance 7-62
- Checking/Adjusting the Injection Nozzles, Nozzle Pressure/Fuel-Jet Pattern 7-63
- Checking the Accumulator Gas Pressure OF THIRD CONTROL CIRCUIT 7-63
- Checking the tightening parts of the Turbo-charger 7-63
- Checking the gap of the Turbo-charger rotor 7-63
Maintenance Every 2000 Operating Hours 7-64
- Hydraulic System, Oil Change 7-64
- Bleeding the Hydraulic Oil Tank 7-65
- Cooling System, Checking the Antifreeze Content of the Coolant 7-65
- Checking the Cooling System 7-65
- Checking the Fuel Pump 7-65
- Checking the Fuel and Coolant Tubes, Replacing the Tubes (if required) 7-65
- Checking the Water Pump 7-66
- Checking and Adjusting the Fuel Injection and Injection time 7-66
- Technical Data
Technical Data 8-2
- Noise Emission Levels 8-3
- Vibration Level 8-3
- Limit Values for Slopes 8-4
- Maximum slope angle for operating the machine 8-4
- Tilt angle 8-4
- special equipment and attachments
ECSS 9-2
- Structure and Functioning Principle of the ECSS 9-2
- Precautionary Measures for Switching on the ECSS 9-2
- Operation of the ECSS 9-3
- Switching on the ECSS 9-3
- Switching off the ECSS 9-3
- Handling of the Pressure Accumulator 9-4
- Index
Introduction
Forword
Safety Information
Introduction
- Features
- Breaking in a New Machine
Location of Plates, Table to Enter Serial No. and Distributor
- Machine Serial No. Plate position
- Engine Serial No. Plate Position
- Table to Enter Serial No. and Distributor
EMISSION CONTROL WARRANTY
- EMISSION CONTROL WARRANTY STATEMENT (APPLIES TO CANADA ONLY)
Engine Data Plate
GARANTIE SUR LE CONTRÔLE DES ÉMISSIONS
- ÉNONCÉ DE GARANTIE SUR LE CONTRÔLE DES ÉMISSIONS (APPLICABLE AU CANADA SEULEMENT):
Engine Data Plate
Why You Should Read these Operating Instructions
Notes on Safety Regulations
- Correct Use
- Safety Notes in the Operating Instructions
Equipment
Loading and Transporting the Machine
Loading and Transporting the Machine
- Securing the Articulated Steering
- Lifting the Machine
- Driving Machine Onto Loading Area of Transport Vehicle
- Securing the Machine During Transport
- After Transport
Safety
General Safety Measures
- Safety Instructions
- Safety Devices
- Emergency Exit
- Clothing and Personal Protection
- Machine Modifications
- Before You Leave the Driver's Seat
- Mounting and Dismounting
- Fire Prevention and Fire Fighting
- Fire Extinguisher and First-Aid Kit
- Protection Against Asbestos Dust
- Protection Against Injuries
- Working at High Temperatures
- Roll-Over Protection System (ROPS)
- Attachment for Protection Against Falling Objects (FOPS)
- Attachments
- Battery
Safety Measures during Operation
- Before You Start the Engine
- Machine Operation
- Transport
Safety Measures During Maintenance
- Personnel
- Prior to Start of Maintenance Measures
- During Maintenance
- Tires
Labeling
- Position of Safety Labels
- Information Labels
Controls and InDicators
Overall View of Machine
Controls and Indicators
- Control Lamps
- Measuring Indicators
- Switches
- Control Levers, Pedals
- Articulated Steering Catch
- Traction Device
- Socket
- Door Unlocking System
- Alarm Horn for Reverse Driving
Operation
Running in the Machine
Preparing the Machine Start
- Visual Checks
Adjustments Prior to Machine Start
- Adjusting the Driver’s Seat
- Adjusting the Steering Column
- Adjusting the Armrest
- Adjusting the Rear-View Mirrors
- Adjusting the Heating and Ventilation System
- Operating the Air Conditioning
- Putting on the Safety Belt
Starting and Switching Off the Engine
- Starting the Engine
- Warming up the engine
- Switching Off the Engine
Driving
- Start-Up
- Changing the Driving Direction
- Reverse Driving
- Turning
Braking
- Pulling the parking brake
- Stopping
- Longer-Distance Driving
Operating the Machine
- Preparing the Work Equipment
- Tire Service Life
- Level indicator for the bucket
- Adjusting the Bucket Positioner
- Loading
- Transporting
- Dumping / Unloading
- Planing
- Working With the Forklift Truck Attachment
- Precautions For Special Operations
- After the work is finished
Instructions for Winter Operation
- Longer Standstill Periods of the Machine
Troubleshooting
Troubleshooting
- Warning Lights and Indicators
- Electrical System
- Engine
- Hydraulic system
- Brakes
- Axles
- driver’s cab
- Emergency Steering Characteristics
- Emergency Lowering System
- Starting the Engine with a Battery Jumper Cable
- Towing the Machine
- Inadequate Braking Effect
Maintenance
Maintenance Basics
- Preparing the Machine for Maintenance
- Cleaning the Machine
- Working-Area-Dependent Maintenance
- Lubricants and Operating Agents
- Axles
- Replacing Safety-Related Parts
- Welding Instructions
- Spare Parts and Consumable Components
- Electrical System
- Tires
- Torque for Standard Nuts and Bolts
Maintenance Schedule
Maintenance Prior to Start
- Visual Checks
- Cooling System, Checking the Coolant Level, Topping off Coolant
- Engine, Checking the Oil Level, Topping off Oil
- Engine, Draining off Oil
- Checking the Fuel Level, Refueling
- Checking the Controls
- Checking the Electrical Connections
- Heater / air conditioning: checking rate of air flow
- Other Maintenance Measures Prior to Start
Maintenance upon demand
- Checking the air-conditioning system
Maintenance Every 10 Operating Hours
- Lubrication
Maintenance After the First 50 Operating Hours
- Engine, Changing Oil and Replacing the Oil Filter Cartridge
- V-Belt, Checking the Condition
- V-Belt, Checking and Adjusting the Tension
- Hydraulic System, Replacing the Filter Insert
- Checking and Tightening the Wheel Nuts
- Front and Rear Axle, Changing Oil
- Transfer Gear - Changing Oil
Maintenance Every 50 Operating Hours
- Checking cooling System, coolant level in the radiator and expansion tank
- Draining Off Water and Dirt Deposits From the Fuel Tank
- Checking the Service Brake and Oil Level, Refilling Oil
- Checking the Battery and Acid Level
- Lubrication
Maintenance Every 100 Operating Hours
- Draining the Water Separator, Removing Water and Dirt Deposits
Maintenance Every 250 Operating Hours
- Changing the Engine Oil and Oil Filter Cartridge
- Checking the V-Belt Condition
- Checking and Adjusting the V-belt Tension
- Front and Rear Axle, Checking the Oil Level
- Air Filter, Removing/Re-Installing AND Checking/Cleaning the Filter Insert
- Cleaning the Radiator Segments
- Lubrication
Maintenance Every 500 Operating Hours
- Changing the Fuel Filter and Filter Element
- Changing the Filter Cartridge of the Hydraulic System
- Cleaning the Water Separator
- Lubrication
- Transfer Gear, Checking the Oil Level and Refilling Oil
- Air Filter, Replacing the Filter Insert, Replacing the Safety Filter
- Heater/air conditioning: clean filter fleece of heater unit
- Heater/air conditioning: Cleaning the condenser
- ECSS-Pressure Accumulator (Option): Checking the Gas Pressure
Maintenance Every 1000 Operating Hours
- Cooling System, Exchanging Coolant and Cleaning the System
- Front Axle, Oil Change
- Rear Axle, Oil Change
- Transfer Gear, Oil Change
- Service Brake
- Checking and Adjusting System Pressures
- Checking and Adjusting the Valve clearance
- Checking/Adjusting the Injection Nozzles, Nozzle Pressure/ Fuel-Jet Pattern
- Checking the Accumulator Gas Pressure OF THIRD CONTROL CIRCUIT
- Checking the tightening parts of the Turbo-charger
- Checking the gap of the Turbo-charger rotor
Maintenance Every 2000 Operating Hours
- Hydraulic System, Oil Change
- Bleeding the Hydraulic Oil Tank
- Cooling System, Checking the Antifreeze Content of the Coolant
- Checking the Cooling System
- Checking the Fuel Pump
- Checking the Fuel and Coolant Tubes, Replacing the Tubes (if required)
- Checking the Water Pump
- Checking and Adjusting the Fuel Injection and Injection time
Technical Data
Technical Data
- Noise Emission Levels
- Vibration Level
- Limit Values for Slopes
special equipment and attachments
ECSS
- Structure and Functioning Principle of the ECSS
- Precautionary Measures for Switching on the ECSS
- Operation of the ECSS
- Handling of the Pressure Accumulator
Index