Komatsu WA180-3 WA180L-3 Wheel Loader Operation & Maintenance Manual – PDF Download

Description

Komatsu WA180-3 WA180L-3 Wheel Loader Operation & Maintenance Manual

Description:

Komatsu WA180-3 WA180L-3 Wheel Loader Operation & Maintenance Manual

• This manual describes procedures for operation, handling, lubrication, maintenance, checking, and adjustment. It will help the operator and maintenance personnel realize peak performance through effective, economical and safe machine operation and maintenance. Keep this manual handy and have all personnel read it periodically.
• If this manual is lost or becomes dirty and can not be read, request a replacement manual from your local distributor. If you sell the machine, be sure to give this manual to the new owner. Continuing improvements in the design of this machine can lead to changes in detail, which may not be reflected in this manual. Consult your local distributor or Komatsu America International Company for the latest available information on your machine or for questions regarding information in this manual.

Table Of Contents:

Komatsu WA180-3 WA180L-3 Wheel Loader Operation & Maintenance Manual

MAIN MENU........................................................................................  0
INTRODUCTION.....................................................................................  4
	1. FORWARD...................................................................................  5
	2. SAFETY INFORMATION........................................................................  6
	3. INTRODUCTION..............................................................................  7
		3.1 INTENDED USE.........................................................................  7
		3.2 FEATURES.............................................................................  7
		3.3 BREAKING IN A NEW MACHINE............................................................  7
	4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR.............................  8
		4.1 MACHINE SERIAL NO. PLATE POSITION....................................................  8
		4.2 ENGINE SERIAL NO. PLATE POSITION.....................................................  8
		4.3 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR............................................  8
	5. CONTENTS..................................................................................  9
SAFETY........................................................................................... 14
	6. GENERAL PRECAUTIONS....................................................................... 15
	7. PRECAUTIONS DURING OPERATION.............................................................. 21
		7.1 BEFORE STARTING ENGINE............................................................... 21
		7.2 AFTER STARTING ENGINE................................................................ 24
		7.3 TRANSPORTATION....................................................................... 33
		7.4 BATTERY.............................................................................. 34
		7.5 TOWING............................................................................... 37
	8. PRECAUTIONS FOR MAINTENANCE............................................................... 38
		8.1 BEFORE CARRYING OUT MAINTENANCE...................................................... 38
		8.2 DURING MAINTENANCE................................................................... 43
		8.3 TIRES................................................................................ 48
	9. POSITION FOR ATTACHING SAFETY LABELS...................................................... 50
		9.1 POSITION FOR ATTACHING SAFETY LABELS................................................. 50
OPERATION........................................................................................ 55
	10. GENERAL VIEW............................................................................. 56
		10.1 GENERAL VIEW OF MACHINE............................................................. 56
		10.2 GENERAL VIEW OF CONTROLS AND GAUGES................................................. 57
	11. EXPLANATION OF COMPONENTS................................................................ 59
		11.1 METER, LAMPS........................................................................ 59
		11.2 SWITCHES............................................................................ 63
		11.3 CONTROL LEVERS, PEDAL............................................................... 69
		11.4 CAP WITH LOCK....................................................................... 73
			11.4.1 METHOD OF OPENING AND CLOSING CAP WITH LOCK................................... 73
		11.5 SAFETY BAR.......................................................................... 73
		11.6 TOWING PIN.......................................................................... 74
		11.7 GREASE PUMP CLAMP AND RUBBER RING................................................... 74
		11.8 BACKUP ALARM........................................................................ 74
		11.9 FUSE................................................................................ 75
			11.9.1 FUSE CAPACITY AND NAME OF CIRCUIT............................................. 75
		11.10 SLOW BLOW FUSE..................................................................... 76
		11.11 STORAGE PLACE FOR THIS MANUAL...................................................... 77
		11.12 AUXILIARY POWER SOURCE............................................................. 77
			11.12.1 FOR MACHINES EQUIPPED WITH ROPS CAB.......................................... 77
	12. CHECK BEFORE STARTING ENGINE............................................................. 78
		12.1 WALK AROUND CHECK................................................................... 78
		12.2 CHECK BEFORE STARTING............................................................... 81
			12.2.1 CHECK COOLANT LEVEL, ADD COOLANT.............................................. 81
			12.2.2 CHECK FUEL LEVEL, ADD FUEL.................................................... 81
			12.2.3 CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL.................................... 82
			12.2.4 CHECK AND REFILL OF OIL IN BRAKE OIL TANK..................................... 82
			12.2.5 CHECK DUST INDICATOR.......................................................... 83
			12.2.6 CHECK ELECTRICAL WIRING....................................................... 83
			12.2.7 DRAIN THE WATER FROM THE FUEL-WATER SEPARATOR................................. 84
			12.2.8 CHECK EFFECT OF PARKING BRAKE................................................. 84
			12.2.9 CHECK EFFECT OF WHEEL BRAKES.................................................. 85
			12.2.10 CHECK SOUND OF HORN AND BACKUP ALARM......................................... 85
			12.2.11 CHECK FLASHING OF LAMPS, CHECK FOR DIRT AND DAMAGE........................... 85
			12.2.12 CHECK ENGINE EXHAUST COLOR AND SOUND......................................... 85
			12.2.13 CHECK OPERATIONS OF GAUGES................................................... 85
			12.2.14 CHECK PLAY OF STEERING WHEEL, CHECK OPERATION OF STEERING.................... 85
			12.2.15 CHECK DIRECTION OF REAR VIEW MIRROR, CHECK FOR DIRT OR DAMAGE................ 85
			12.2.16 CHECK LOCK OF CAB DOOR FOR MACHINES EQUIPPED WITH CAB........................ 85
		12.3 ADJUSTMENT BEFORE OPERATION......................................................... 86
			12.3.1 OPERATOR'S SEAT............................................................... 86
			12.3.2 ADJUST SEAT BELT.............................................................. 88
			12.3.3 ADJUST REAR VEIW MIRRORS...................................................... 89
		12.4 OPERATIONS AND CHECKS BEFORE STARTING ENGINE........................................ 90
		12.5 STARTING ENGINE..................................................................... 91
			12.5.1 NORMAL STARTING PROCEDURES IN COLD AND WARM CONDITIONS........................ 91
			12.5.2 STARTING PROCEDURES AFTER EXTENDED SHUTDOWN OR OIL CHANGE..................... 92
			12.5.3 STARTING PROCEDURES AFTER CHANGING FUEL FILTERS............................... 92
			12.5.4 STARTING PROCEDURES AFTER RUNNING OUT OF FUEL................................. 92
		12.6 OPERATIONS AND CHECKS AFTER STARTING ENGINE......................................... 93
		12.7 MOVING MACHINE OFF.................................................................. 94
		12.8 CHANGING GEAR SPEED................................................................. 96
		12.9 CHANGING DIRECTION.................................................................. 96
		12.10 TURNING............................................................................ 97
		12.11 STOPPING MACHINE................................................................... 98
		12.12 OPERATION OF WORK EQUIPMENT........................................................ 99
		12.13 WORK POSSIBLE USING WHEEL LOADER...................................................100
			12.13.1 DIGGING OPERATIONS WITH ROCK PILES...........................................100
			12.13.2 DIGGING OPERATIONS ON LEVEL GROUND...........................................101
			12.13.3 LEVELING OPERATION...........................................................102
			12.13.4 PUSHING OPERATIONS...........................................................102
			12.13.5 LOAD AND CARRY OPERATIONS....................................................102
			12.13.6 LOADING OPERATIONS...........................................................103
		12.14 PRECAUTIONS FOR OPERATION..........................................................104
			12.14.1 PERMISSIBLE WATER DEPTH......................................................104
			12.14.2 IF WHEEL BRAKE DOES NOT WORK.................................................104
			12.14.3 PRECAUTIONS WHEN DRIVING UP OR DOWN SLOPES...................................104
			12.14.4 PRECAUTIONS WHEN DRIVING MACHINE.............................................105
		12.15 ADJUSTING WORK EQUIPMENT POSTURE...................................................106
			12.15.1 ADJUSTING BOOM KICKOUT.......................................................106
			12.15.2 ADJUSTING BUCKET POSITIONER..................................................107
			12.15.3 BUCKET LEVEL INDICATOR.......................................................107
		12.16 PARKING MACHINE....................................................................108
		12.17 CHECKS AFTER COMPLETION OF ENGINE OPERATION........................................109
		12.18 STOPPING ENGINE....................................................................109
		12.19 CHECKS AFTER STOPPING ENGINE.......................................................110
		12.20 LOCKING............................................................................110
			REMARKS..............................................................................110
		12.21 HANDLING THE TIRES.................................................................111
			12.21.1 PRECAUTIONS WHEN HANDLING THE TIRES..........................................111
			12.21.2 TIRE PRESSURE................................................................111
	13. TRANSPORTATION...........................................................................113
		13.1 LOADING, UNLOADING WORK.............................................................113
		13.2 PRECAUTION FOR LOADING..............................................................114
		13.3 PRECAUTION FOR LIFTING UP THE VEHICLE...............................................114
			13.3.1 THE LOCATION OF DECALS REFERRING TO LIFTING POSITIONS.........................115
			13.3.2 WEIGHT LIST...................................................................115
			13.3.3 LIFTING PROCEDURE.............................................................116
	14. COLD WEATHER OPERATIONS..................................................................117
		14.1 PRECAUTIONS FOR LOW TEMPERATURE.....................................................117
			14.1.1 FUEL AND LUBRICANTS...........................................................117
			14.1.2 COOLANT.......................................................................117
			14.1.3 BATTERY.......................................................................118
		14.2 PRECAUTIONS AFTER COMPLETION OF WORK................................................119
		14.3 AFTER COLD WEATHER..................................................................119
	15. LONG TERM STORAGE........................................................................120
		15.1 BEFORE STORAGE......................................................................120
		15.2 DURING STORAGE......................................................................120
		15.3 AFTER STORAGE.......................................................................120
	16. TROUBLESHOOTING..........................................................................121
		16.1 WHEN MACHINE RUNS OUT OF FUEL.......................................................121
		16.2 TOWING THE MACHINE..................................................................122
			16.2.1 WHEN ENGINE CAN BE USED.......................................................124
			16.2.2 WHEN ENGINE CANNOT BE USED....................................................124
		16.3 IF BATTERY IS DISCHARGED............................................................125
			16.3.1 REMOVAL AND INSTALLATION OF BATTERY...........................................125
			16.3.2 PRECAUTIONS FOR CHARGING BATTERY..............................................126
			16.3.3 STARTING ENGINE WITH BOOSTER CABLE............................................127
		16.4 OTHER TROUBLE.......................................................................129
			16.4.1 ELECTRICAL SYSTEM.............................................................129
			16.4.2 CHASSIS.......................................................................130
			16.4.3 ENGINE........................................................................133
MAINTENANCE......................................................................................135
	17. GUIDES TO MAINTENANCE....................................................................136
	18. OUTLINES OF SERVICE......................................................................139
		18.1 OUTLINE OF OIL, FUEL, COOLANT.......................................................139
			18.1.1 OIL...........................................................................139
			18.1.2 FUEL..........................................................................139
			18.1.3 COOLANT.......................................................................140
			18.1.4 GREASE........................................................................141
			18.1.5 STORING OIL AND FUEL..........................................................141
			18.1.6 FILTERS.......................................................................141
		18.2 OUTLINE OF ELECTRIC SYSTEM..........................................................142
	19. WEAR PARTS LIST..........................................................................143
	20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE.....................144
		20.1 ENGINE OIL SPECIFICATIONS...........................................................145
		20.2 DIESEL FUEL SPECIFICATIONS..........................................................146
		20.3 COOLANT SPECIFICATIONS..............................................................147
	21.STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS.............................................153
		21.1 INTRODUCTION OF NECESSARY TOOLS.....................................................153
		21.2 TORQUE LIST.........................................................................154
	22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS............................................156
	23. MAINTENANCE SCHEDULE CHART...............................................................160
		23.1 MAINTENANCE SCHEDULE CHART..........................................................160
	24.SERVICE PROCEDURES........................................................................164
		24.1 INITIAL 250 HOURS SERVICE...........................................................164
			24.1.1 REPLACE FUEL FILTERS EVERY 500 HOURS SERVICE”.................................164
			24.1.2 REPLACE TRANSMISSION OIL FILTER ELEMENT EVERY 500 HOURS SERVICE”..............164
			24.1.3 REPLACE HYDRAULIC TANK FILTER ELEMENT EVERY 1000 HOURS SERVICE................164
		24.2 WHEN REQUIRED.......................................................................165
			24.2.1 CHECK, CLEAN OR REPLACE AIR CLEANER ELEMENT...................................165
			24.2.2 CHECK TRANSMISSION OIL LEVEL, ADD OIL.........................................167
			24.2.3 CHECK AXLE OIL LEVEL , ADD OIL................................................168
			24.2.4 CLEAN THE AXLE CASE BREATHER..................................................169
			24.2.5 CLEAN RADIATOR FINS...........................................................169
			24.2.6 REPLACE THE BOLT-ON CUTTING EDGES.............................................170
			24.2.7 REPLACE BUCKET TEETH (IF EQUIPPED)............................................171
			24.2.8 CHECK AIR CONDITIONER (IF EQUIPPED)...........................................172
			24.2.9 CHECK THE AIR CONDITIONER CONDENSER (IF EQUIPPED).............................173
			24.2.10 CHECK WINDOW WASHING FLUID...................................................173
			24.2.11 ADJUST PARKING BRAKE.........................................................174
			24.2.12 REPLACE SLOW BLOW FUSE.......................................................175
			24.2.13 CHECK AIR INTAKE HEATER......................................................175
		24.3 CHECK BEFORE STARTING...............................................................176
		24.4 EVERY 50 HOURS SERVICE..............................................................177
			24.4.1 CHECK THE TIRE INFLATION PRESSURE.............................................177
			24.4.2 DRAIN WATER, SEDIMENT FROM FUEL TANK..........................................177
		24.5 EVERY 100 HOURS SERVICE.............................................................178
			24.5.1 CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL....................................178
			24.5.2 CLEAN ELEMENT IN AIR CONDITIONER FRESH AIR FILTER.............................179
			24.5.3 LUBRICATING...................................................................180
		24.6 EVERY 250 HOURS SERVICE.............................................................181
			24.6.1 CHANGE OIL IN ENGINE OIL PAN AND REPLACE ENGINE OIL FILTER....................181
			24.6.2 CHECK FOR LOOSE WHEEL HUB NUTS. TIGHTEN.......................................182
			24.6.3 CLEAN ELEMENT IN AIR CONDITIONER RECIRCULATION FILTER.........................182
			24.6.4 CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST.........................183
			24.6.5 CHECK BATTERY ELECTROLYTE LEVEL...............................................184
			24.6.6 CHECK AIR INTAKE SYSTEM.......................................................184
			24.6.7 LUBRICATING...................................................................185
		24.7 EVERY 500 HOURS SERVICE.............................................................186
			24.7.1 REPLACE FUEL FILTERS..........................................................186
			24.7.2 REPLACE TRANSMISSION OIL FILTER ELEMENT.......................................188
			24.7.3 LUBRICATE.....................................................................189
		24.8 EVERY 1000 HOURS SERVICE............................................................190
			24.8.1 CHANGE OIL IN TRANSMISSION CASE, CLEAN STRAINER...............................190
			24.8.2 CLEAN TRANSMISSION CASE BREATHER..............................................191
			24.8.3 LUBRICATE.....................................................................192
			24.8.4 CHANGE OIL IN HYDRAULIC OIL TANK, REPLACE HYDRAULIC FILTER ELEMENT............193
			24.8.5 ADJUST ENGINE VALVE LASH CLEARANCE............................................194
			24.8.6 CHECK FAN BELT TENSION........................................................195
			24.8.7 CHECK FAN BELT TENSIONER BEARING & FAN HUB BEARING & INSPECT FAN BELT.........195
		24.9 EVERY 2000 HOURS SERVICE............................................................196
			24.9.1 COOLING SYSTEM, REPLACE COOLANT AND FLUSH THE SYSTEM..........................196
			24.9.2 REPLACE HYDRAULIC TANK BREATHER ELEMENT.......................................199
			24.9.3 CHANGE AXLE OIL...............................................................199
			24.9.4 CHECK BRAKE DISC WEAR.........................................................200
			24.9.5 CHECK ALTERNATOR..............................................................200
			24.9.6 CHECK STARTER MOTOR...........................................................200
			24.9.7 CHECK VIBRATION DAMPER........................................................200
			24.9.8 REPLACE ELEMENT IN AIR COND. RECIRCULATION AIR FILTER AND FRESH AIR FILTER....200
			24.9.9 ADJUST ENGINE VALVE LASH CLEARANCE............................................201
SPECIFICATIONS...................................................................................204
	25.SPECIFICATIONS............................................................................204
OPTIONS, ATTACHMENTS.............................................................................207
	26. AVAILABLE ATTACHMENTS....................................................................208
	27. HEATER AND AIR CONDITIONING (IF EQUIPPED)................................................210
		27.1 GENERAL LOCATION AND FUNCTION OF CONTROL PANEL......................................210
		27.2 COOL BOX COMPARTMENT................................................................211
	28.HANDLING E.C.S.S. (ELECTRONIC CONTROLLED SUSPENSION SYSTEM)...............................212
		28.1 STRUCTURE AND FUNCTION OF E.C.S.S...................................................212
		28.2 METHOD OF OPERATING E.C.S.S.........................................................213
		28.3 PRECAUTIONS WHEN OPERATING E.C.S.S..................................................213
		28.4 PRECAUTIONS WHEN HANDLING ACCUMULATOR...............................................214

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KOMATSU WA180-3 WA180L-3 WHEEL LOADER OPERATION & MAINTENANCE MANUAL – PDF DOWNLOAD:

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