Komatsu WA450-3 Wheel Loader Operation & Maintenance Manual A31001 and up – PDF DOWNLOAD

Description

Komatsu WA450-3 Wheel Loader Operation & Maintenance Manual

FILE DETAILS:

Komatsu WA450-3 Wheel Loader Operation & Maintenance Manual 

Language : English
Pages : 249
Downloadable : Yes
File Type : PDF
Size: 2.53 MB
Book Code: CEAM003800

KOMATSU WA450-3 WHEEL LOADER OPERATION & MAINTENANCE MANUAL A31001 AND UP – PDF DOWNLOAD:

DESCRIPTION:

Komatsu WA450-3 Wheel Loader Operation & Maintenance Manual 

FOREWORD :

• This manual describes the procedures for the operation, handling, lubrication, maintenance, checking, and adjustment. The manual 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 becomes lost or illegible, request a replacement manual from your local distributor. If you sell the machine, give this manual to the new owner. Because of continual design changes in this machine, the changes may not be reflected in this manual. Consult your local distributor or Komatsu America International Company for the latest available information in this manual.

TABLE OF CONTENTS:

Komatsu WA450-3 Wheel Loader Operation & Maintenance Manual 

MAIN MENU.............................................................................................................................  0
COVER.................................................................................................................................  1
INTRODUCTION..........................................................................................................................  4
	1.  FOREWARD......................................................................................................................  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
			4.1.1  POSITION OF PLATE (A)..............................................................................................  8
			4.1.2  POSITION OF STAMP(B)...............................................................................................  8
		4.2  ENGINE SERIAL NO. PLATE POSITION.........................................................................................  8
		4.3  TABLE TO ENTER SERIAL NO. DISTRIBUTOR....................................................................................  8
	5.  TABLE OF CONTENTS............................................................................................................. 10
SAFETY................................................................................................................................ 17
	6.  GENERAL PRECAUTIONS........................................................................................................... 18
	7.  PRECAUTIONS DURING OPERATION.................................................................................................. 24
		7.1  BEFORE STARTING ENGINE................................................................................................... 24
		7.2  OPERATING MACHINE........................................................................................................ 25
		7.3  TRANSPORTATION........................................................................................................... 34
		7.4  BATTERY.................................................................................................................. 35
		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
OPERATION............................................................................................................................. 57
	10.  GENERAL VIEW................................................................................................................. 58
		10.1  GENERAL VIEW OF MACHINE................................................................................................. 58
		10.2  GENERAL VIEW OF CONTROLS AND GAUGES..................................................................................... 59
	11.  COMPONENT EXPLANATION........................................................................................................ 60
		11.1  MACHINE MONITOR......................................................................................................... 60
			11.1.1  WARNING DISPLAYS.................................................................................................. 62
			11.1.2  METER DISPLAY PORTION............................................................................................. 66
		11.2  SWITCHES................................................................................................................ 71
		11.3  CONTROL LEVERS, PEDALS.................................................................................................. 79
		11.4  STEERING COLUMN TILT LEVER.............................................................................................. 84
		11.5  CAP WITH LOCK........................................................................................................... 85
			11.5.1  METHOD OF OPENING AND CLOSING THE CAP WITH LOCK................................................................... 85
		11.6  SAFETY BAR.............................................................................................................. 86
		11.7  TOWING PIN.............................................................................................................. 86
		11.8  GREASE PUMP............................................................................................................. 87
		11.9  BACKUP ALARM............................................................................................................ 87
		11.10  FUSE................................................................................................................... 88
			11.10.1  FUSE CAPACITY AND CIRCUIT NAME................................................................................... 88
		11.11  SLOW-BLOW FUSE......................................................................................................... 89
		11.12  MANUAL STORAGE PLACE................................................................................................... 90
		11.13  ELECTRIC POWER (with ROPS CAB)......................................................................................... 90
	12.  OPERATION.................................................................................................................... 91
		12.1  CHECKS BEFORE STARTING.................................................................................................. 91
			12.1.1  WALK AROUND CHECK................................................................................................. 91
			12.1.2  CHECK BEFORE STARTING............................................................................................. 95
			12.1.3  ADJUSTMENT BEFORE OPERTION........................................................................................101
			12.1.4  OPERATIONS AND CHECKS AFTER STARTING THE ENGINE...................................................................104
		12.2  STARTING THE ENGINE.....................................................................................................106
			12.2.1  COLD WEATHER STARTING.............................................................................................107
		12.3  OPERATIONS AND CHECKS AFTER STARTING THE ENGINE.........................................................................108
		12.4  MOVING THE MACHINE......................................................................................................110
		12.5  CHANGING GEAR SPEED.....................................................................................................112
		12.6  CHANGING DIRECTION......................................................................................................113
		12.7  TURNING.................................................................................................................114
		12.8  STOPPING THE MACHINE....................................................................................................115
		12.9  WORK EQUIPMENT OPERATION................................................................................................116
			12.9.1  STANDRD WORK EQUIPMENT CONTROLS...................................................................................116
			12.9.2  MONO-LEVER WORK EQUIPMENT CONTROLS................................................................................117
		12.10  WORK POSSIBLE USING A WHEEL LOADER.....................................................................................119
			12.10.1  DIGGING OPERATIONS...............................................................................................119
			12.10.2  LEVELING OPERATION...............................................................................................122
			12.10.3  PUSHING OPERATION................................................................................................122
			12.10.4  LOAD AND CARRY OPERATIONS........................................................................................122
			12.10.5  LOADING OPERATIONS...............................................................................................123
		12.11  PRECAUTION FOR OPERATION...............................................................................................123
			12.11.1  PERMISSIBLE WATER DEPTH..........................................................................................123
			12.11.2  IF WHEEL BRAKES DO NOT WORK......................................................................................124
			12.11.3  PRECAUTIONS WHEN DRIVING UP OR DOWN SLOPES.......................................................................124
			12.11.4  PRECAUTIONS WHEN DRIVING THE MACHINE.............................................................................125
		12.12  ADJUSTING THE WORK EQUIPMENT POSTURE...................................................................................126
			12.12.1  ADJUSTING THE BOOM KICKOUT.......................................................................................126
			12.12.2  ADJUSTING THE BUCKET POSITIONER..................................................................................127
			12.12.3  BUCKET LEVEL INDICATOR...........................................................................................127
		12.13  PARKING THE MACHINE....................................................................................................128
		12.14  CHECKS AFTER COMPLETION OF OPERATION...................................................................................129
		12.15  STOPPING THE ENGINE....................................................................................................129
		12.16  CHECK AFTER STOPPING THE ENGINE........................................................................................130
		12.17  LOCKING................................................................................................................130
		12.18  HANDLING THE TIRES.....................................................................................................131
			12.18.1  PRECAUTIONS WHEN HANDLING TIRES..................................................................................131
			12.18.2  TIRE PRESSURE....................................................................................................131
	13.  TRANSPORTATION...............................................................................................................133
		13.1  LOADING, UNLOADING WORK.................................................................................................133
		13.2  LOADING PRECAUTIONS.....................................................................................................134
		13.3  LIFTING THE MACHINE.....................................................................................................134
			13.3.1  POSITION FOR STICKING THE LIFTING POSITION MARK...................................................................135
			13.3.2  WEIGHT TABLE......................................................................................................135
			13.3.3  LIFTING PROCEDURE.................................................................................................136
		13.4  TRANSPORTATION PRECUATIONS..............................................................................................137
	14.  COLD WEATHER OPERATION.......................................................................................................138
		14.1  LOW TEMPERATURE PRECAUTIONS.............................................................................................138
			14.1.1 FUEL AND LUBRICANTS................................................................................................138
			14.1.2  COOLANT...........................................................................................................138
			14.1.3  BATTERY...........................................................................................................138
		14.2  PRECAUTIONS AFTER WORK COMPLETION.......................................................................................139
		14.3 AFTER COLD WEATHER.......................................................................................................139
	15.  LONG-TERM STORAGE............................................................................................................139
		15.1 BEFORE STORAGE...........................................................................................................139
		15.2  DURING STORAGE..........................................................................................................139
		15.3  AFTER STORAGE...........................................................................................................139
	16.  TROUBLESHOOTING..............................................................................................................140
		16.1  WHEN THE MACHINE RUNS OUT OF FUEL.......................................................................................140
		16.2  TOWING THE MACHINE......................................................................................................140
			16.2.1  WHEN ENGINE CAN BE USED...........................................................................................141
			16.2.2  WHEN ENGINE CANNOT BE USED........................................................................................141
			16.2.3  RELEASING THE PARKING BRAKE.......................................................................................142
			16.2.4  EMERGENCY TRAVEL OPERATION........................................................................................144
		16.3  IF BATTERY IS DISCHARGED................................................................................................145
			16.3.1  BATTERY INSTALLATION AND REMOVAL..................................................................................145
			16.3.2  PRECAUTION FOR CHARGING THE BATTERY...............................................................................146
			16.3.3  STARTING THE ENGINE WITH BOOSTER CABLE............................................................................147
		16.4  OTHER TROUBLE...........................................................................................................149
			16.4.1 ELECTRICAL SYSTEM..................................................................................................149
			16.4.2  CHASSIS...........................................................................................................150
			16.4.3  ENGINE............................................................................................................153
MAINTENANCE...........................................................................................................................155
	17.  GUIDES TO MAINTENANCE........................................................................................................156
	18.  OUTLINES OF SERVICE..........................................................................................................158
		18.1  OUTLINE OF OIL, FUEL, COOLANT...........................................................................................158
			18.1.1  OIL...............................................................................................................158
			18.1.2  FUEL..............................................................................................................159
			18.1.3  COOLANT...........................................................................................................159
			18.1.4  GREASE............................................................................................................159
			18.1.5  STORING OIL AND FUEL..............................................................................................160
			18.1.6  FILTERS...........................................................................................................160
		18.2  FUEL INJECTION PUMP.....................................................................................................160
		18.3  OUTLINE OF ELECTRIC SYSTEM..............................................................................................160
		18.4  OUTLINE OF HYDRAULIC SYSTEM.............................................................................................161
	19.  WEAR PARTS LIST..............................................................................................................162
	20.  FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE................................................................163
		20.1  PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS........................................................................163
		20.2  ENGINE OIL SPECIFICATIONS...............................................................................................164
			20.2.1  NORMAL OPERATION..................................................................................................164
			20.2.2 ARCTIC OPERATION...................................................................................................164
		20.3  TRANSMISSION, TORQUE CONVERTER, TRANSFER CASE AND OIL COOLER, SERVICE BRAKES AND HYDRAULIC SYSTEM OIL SPECIFICATIONS....165
		20.4  DRIVE AXLE OIL SPECIFICATIONS...........................................................................................165
		20.5  DIESEL FUEL SPECIFICATIONS..............................................................................................165
		20.6  COOLANT SPECIFICATIONS..................................................................................................166
			20.6.1  GENERAL...........................................................................................................166
			20.6.2  WATER.............................................................................................................166
			20.6.3  ANTIFREEZE........................................................................................................166
			20.6.4  SUPPLEMENTAL COOLANT ADDITIVES....................................................................................167
	21.  STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS...............................................................................171
		21.1  INTRODUCTION OF NECESSARY TOOLS.........................................................................................171
		21.2  TORQUE LIST.............................................................................................................172
	22.  PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS................................................................................173
	23.  MAINTENANCE SCHEDULE CHART...................................................................................................177
		23.1  SCHEDULED MAINTENANCE CHART.............................................................................................177
	24.  INITIAL 250 HOURS SERVICE....................................................................................................180
		24.1  INITIAL 250 HOURS SERVICE...............................................................................................180
		24.2  WHEN REQUIRED...........................................................................................................180
			24.2.1  CHECK, CLEAN, AND REPLACE AIR CLEANER ELEMENT.....................................................................180
			24.2.2  CHECK TRANSMISSION OIL LEVEL, ADD OIL.............................................................................183
			24.2.3  CHECK AXLE OIL LEVEL, AD OIL......................................................................................184
			24.2.4  CLEAN THE AXLE CASE BREATHER......................................................................................185
			24.2.5  CLEAN THE RADIATOR FINS...........................................................................................185
			24.2.6  REPLACE THE BOLT-ON CUTTING EDGES.................................................................................186
			24.2.7  REPLACE BUCKET TEETH..............................................................................................187
			24.2.8  CHECK AIR CONDITIONER.............................................................................................188
			24.2.9  CLEAN THE AIR CONDITIONER CONDENSER...............................................................................189
			24.2.10  LUBRICATE WORK EQUIPMENT CONTROL VALVE LINKAGE...................................................................189
			24.2.11  REPLACE THE SLOW-BLOW FUSE.......................................................................................189
			24.2.12  DRAIN WATER FROM WATER SEPARATOR (if equipped)...................................................................190
			24.2.13  SELECTION AND INPECTION OF TIRES.................................................................................190
		24.3  CHECKS BEFORE STARTING..................................................................................................192
		24.4  EVERY 50 HOURS SERVICE..................................................................................................192
			24.4.1  DRAIN WATER, SEDIMENT FROM FUEL TANK..............................................................................192
		24.5  EVERY 100 HOURS SERVICE.................................................................................................192
			24.5.1  CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL........................................................................192
			24.5.2    CLEAN ELEMENT IN AIR CONDITIONER FRESH AIR FILTER...............................................................193
			24.5.3  LUBRICATE REAR AXLE PIVOT PIN (3 PLACES)..........................................................................194
		24.6  EVERY 250 HOURS SERVICE.................................................................................................194
			24.6.1  CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE.................................................194
			24.6.2  CHECK TENSION OF FAN BELT, ALTERNATOR BELT, ADJUST................................................................196
			24.6.3  CHECK FOR LOOSE WHEEL HUB NUT, TIGHTEN............................................................................197
			24.6.4  CLEAN ELEMENT IN AIR CONDITIONER RECIRCULATION FILTER.............................................................197
			24.6.5  CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST.............................................................198
			24.6.6  CHECK BATTERY ELECTROLYTE LEVEL...................................................................................199
			24.6.7  LUBRICATING.......................................................................................................200
		24.7  EVERY 500 HOURS.........................................................................................................201
			24.7.1 REPLACE THE FUEL FILTER CARTRIDGE..................................................................................201
			24.7.2  REPLACE TRANSMISSION OIL FILTER ELEMENT...........................................................................202
			24.7.3  LUBRICATE CENTER DRIVE SHAFT SPLINE...............................................................................203
		24.8  EVERY 1000..............................................................................................................204
			24.8.1  CHANGE OIL INTRANSMISSION, CLEAN STRAINER.........................................................................204
			24.8.2  CLEAN TRANSMISSION CASE BREATHER..................................................................................205
			24.8.3  LUBRICATE.........................................................................................................206
			24.8.4  CHECK TIGHTENING PARTS OF TURBOCHARGER............................................................................208
			24.8.5  CHECK PLAY OF TURBOCHARGER ROTOR..................................................................................208
			24.8.6  REPLACE CORROSION RESISTOR CARTRIDGE..............................................................................208
		24.9  EVERY 2000 HOURS SERVICE................................................................................................209
			24.9.1  CHANGE OIN IN HYDRAULIC TANK......................................................................................209
			24.9.2  REPLACE THE HYDRAULIC TANK BREATHER ELEMENT.......................................................................211
			24.9.3  CHANGE AXLE OIL...................................................................................................212
			24.9.4  CHECK BRAKE DISC WEAR.............................................................................................213
			24.9.5  CHECK ALTERNATOR, STARTING MOTOR..................................................................................213
			24.9.6  CHECK ENGINE VALVE CLEARANCE, ADJUST..............................................................................213
			24.9.7  CHECK VIBRATION DAMPER............................................................................................213
			24.9.8  REPLACE THE ELEMENT IN AIR CONDITIONER RECIRCULATION AIR FILTER, FRESH AIR FILTER.................................213
			24.9.9  CLEAN AND CHECK TURBOCHARGER......................................................................................213
			24.9.10  CLEAN PPC CIRCUIT STRAINER.......................................................................................213
			24.9.11  CHECK ACCUMULATOR GAS PRESSURE...................................................................................213
		24.10  EVERY 4000 HOURS SERVICE...............................................................................................214
			24.10.1  CHECK WATER PUMP.................................................................................................214
SPECIFICATIONS........................................................................................................................215
	25.  SPECIFICATIONS...............................................................................................................216
		25.1  GENERAL.................................................................................................................216
OPTIONS, ATTACHMENTS..................................................................................................................218
	26.  OPTIONAL PARTS AND ATTACHMENTS...............................................................................................219
	27.  SELECTING BUCKETS AND TIRES..................................................................................................220
	28.  AIR CONDITIONING.............................................................................................................221
		28.1  GENERAL LOCATIONS AND FUNCTION OF CONTROL PANEL.........................................................................221
			28.1.1  FAN SWITCH........................................................................................................221
			28.1.2  AIR CONDITIONER SWITCH............................................................................................221
			28.1.3  MODE SELECTOR SWITCHES............................................................................................222
			28.1.4  FRESH/RECIRC.SELECTOR SWITCH......................................................................................222
			28.1.5  TEMPERATURE CONTROL SWITCH........................................................................................222
		28.2  METHOD OF OPERATION.....................................................................................................223
			28.2.1  WHEN NOT USING THE AIR CONDITIONER REGULARLY......................................................................223
		28.3  COOL BOX................................................................................................................223
	29.  HANDLING ECSS................................................................................................................224
		29.1  STRUCTURE AND FUNCTION OF ECSS..........................................................................................224
		29.2  METHOD OF OPERATING ECSS................................................................................................225
		29.3  PRECAUTIONS WHEN OPERATING ECSS SWITCH..................................................................................225
		29.4  PRECAUTIONS WHEN HANDLING ACCUMULATOR...................................................................................226
		29.5  DISCONNECTING THE ECSS PIPING...........................................................................................227
	30.  OPTION DISPLAY...............................................................................................................228
		30.1  EMERGENCY STEERING PILOT LAMP...........................................................................................228
		30.2  RADIO...................................................................................................................229
			30.2.1  OPERATION.........................................................................................................229
			30.2.2  SETTING THE CLOCK.................................................................................................231
			30.2.3  REMOTE CONTROL UNIT...............................................................................................232
			30.2.4  BATTERY REPLACEMENT...............................................................................................232
			30.2.5  PRECAUTIONS WHEN USING............................................................................................232
	31.  LOAD METER...................................................................................................................233
		31.1  GENERAL LOCATIONS.......................................................................................................233
		31.2  ADJUSTING LOAD MEASUREMENTS POINTS......................................................................................235
		31.3  CALIBRATION (ADJUSTING 0 POINT).........................................................................................236
			31.3.1  CHECK BEFORE ADJUSTING............................................................................................236
			31.3.2  ADJUSTING.........................................................................................................237
			31.3.3  CHECKING CALIBRATION..............................................................................................237
		31.4  MEASURING...............................................................................................................238
			31.4.1  MEASURING SUBTOTAL................................................................................................238
			31.4.2  MEASURING REMAIN..................................................................................................238
		31.5  SETTING TARGET AMOUNT IN REMAIN MODE....................................................................................240
		31.6  PRINTING DATA...........................................................................................................241
			31.6.1  PRINTING SUBTOTAL ................................................................................................241
			31.6.2  PRINTING TOTAL....................................................................................................241
		31.7  DELETING DATA FROM STORAGE DEVICE.......................................................................................242
		31.8  SETTING TIME ON CLOCK...................................................................................................243
		31.9  REPLACING PRINTER PAPER.................................................................................................244
		31.10  TROUBLESHOOTING FUNCTION...............................................................................................246
		31.11 SPARE PARTS.............................................................................................................246

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