KOMATSU WA65-5 WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:H50051 & UP) KOMATSU WA65-5 – PDF DOWNLOAD

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KOMATSU WA65-5 WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:H50051 & UP) KOMATSU WA65-5

KOMATSU WA65-5 WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:H50051 & UP) KOMATSU WA65-5 – PDF DOWNLOAD:

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TABLE OF CONTENTS:

KOMATSU WA65-5 WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:H50051 & UP) KOMATSU WA65-5

MAIN MENU........................................................................................................  0
Cover............................................................................................................  1
1. Introduction.................................................................................................  2
	1.1. Product publications information.......................................................................  3
	1.2. Foreword...............................................................................................  5
		EU Directives............................................................................................  6
	1.3. Safety information.....................................................................................  8
	1.4. Introduction........................................................................................... 10
		1.4.1. Intended use..................................................................................... 10
		1.4.2. Breaking-in the machine.......................................................................... 11
	1.5. Location of plates..................................................................................... 12
		1.5.1. Machine identification plate (PIN)............................................................... 12
		1.5.2. Engine name-plate................................................................................ 12
		1.5.3. Axle serial no. plate............................................................................ 13
		1.5.4. Transmission serial no. plate.................................................................... 13
		1.5.5. ROPS/FOPS-Cab serial no. plate................................................................... 13
		1.5.6. Seat operator serial no. plate................................................................... 14
		1.5.7. Table to enter serial no. and distributor........................................................ 14
	1.6. Emission control warranty.............................................................................. 15
		1.6.1. Emission control warranty statement (Applies to Canada only)..................................... 15
	1.7. Garantie sur le contrôle des émissions................................................................. 16
		1.7.1. Énoncé de garantie sur le contrôle des émissions (applicable au Canada seulement)............... 16
	1.8. Table of contents...................................................................................... 17
	1.9. Dimensions, weights and operating data................................................................. 24
	1.10. CE-conforming equipment............................................................................... 25
		1.10.1. CE-conforming equipment – part 1................................................................ 25
		1.10.2. CE-conforming equipment – part 2................................................................ 25
		1.10.3. Manufacturer-supplied CE-conforming equipment, according to document 42T9321080.............. 26
	1.11. Loading and securing.................................................................................. 29
Table of contents................................................................................................ 17
2. Safety....................................................................................................... 32
	2.1. General safety measures................................................................................ 33
		2.1.1. Safety instructions.............................................................................. 33
		2.1.2. Safety devices................................................................................... 33
		2.1.3. Emergency exit................................................................................... 33
		2.1.4. Clothing and personal protection................................................................. 34
		2.1.5. Machine modifications............................................................................ 34
		2.1.6. Before you leave the driver’s seat............................................................... 34
		2.1.7. Mounting and dismounting......................................................................... 35
		2.1.8. Fire prevention and fire fighting................................................................ 35
		2.1.9. Protection against asbestos dust................................................................. 36
		2.1.10. Protection against injuries..................................................................... 36
		2.1.11. Working at high temperatures.................................................................... 37
		2.1.12. Roll-over protection system (ROPS).............................................................. 37
		2.1.13. Attachment for protection against falling objects (FOPS)........................................ 37
		2.1.14. Attachments..................................................................................... 38
		2.1.15. Battery......................................................................................... 38
	2.2. Safety precautions during operation.................................................................... 39
		2.2.1. Prior to daily starting up....................................................................... 39
			Workplace safety..................................................................................... 39
			In the driver's cab.................................................................................. 39
			Indoor operation..................................................................................... 40
			Gas, dust, and inflammable vapours................................................................... 40
			Mirrors, windows and lighting........................................................................ 40
		2.2.2. Machine operation................................................................................ 41
			Before you start the engine.......................................................................... 41
			Reversing............................................................................................ 41
			Driving.............................................................................................. 42
			Driving on slopes.................................................................................... 42
			Emergency Lowering System............................................................................ 43
			Working close to power lines......................................................................... 44
			Loading.............................................................................................. 45
			Good Vision.......................................................................................... 45
			Working on snow...................................................................................... 45
			Height limitation.................................................................................... 46
			Brakes............................................................................................... 46
			Working on loose soil................................................................................ 46
			Working with the forklift truck attachment........................................................... 46
			Parking the machine.................................................................................. 48
		2.2.3. Transport........................................................................................ 49
			Loading and unloading the machine.................................................................... 49
			Transport............................................................................................ 49
	2.3. Precautions for maintenance............................................................................ 50
		2.3.1. Personnel........................................................................................ 50
		2.3.2. Before carrying out maintenance................................................................. 50
		2.3.3. During maintenance............................................................................... 57
		2.3.4.  Tires............................................................................................ 61
	2.4. Safety labels on the machine........................................................................... 63
		2.4.1. Positions and order numbers of information labels................................................ 63
		2.4.2. Positions and order numbers of safety labels..................................................... 64
3. Operation.................................................................................................... 66
	3.1. General view........................................................................................... 67
		3.1.1. General view of the machine...................................................................... 67
		3.1.2. Controls and indicators.......................................................................... 68
			Overall view......................................................................................... 68
			Switches, controls and warning lights................................................................ 69
	3.2. Description of the individual elements................................................................. 70
		3.2.1. Instrument panel................................................................................. 70
			Warning lights....................................................................................... 71
			Control lamps........................................................................................ 73
			Measuring indicators................................................................................. 77
		3.2.2. Switches......................................................................................... 79
		3.2.3. Control levers and pedals........................................................................ 86
		3.2.4. Articulated steering catch....................................................................... 91
		3.2.5. Traction device.................................................................................. 91
		3.2.6. Socket (12 V).................................................................................... 92
		3.2.7. Door unlocking system............................................................................ 92
		3.2.8. Alarm horn for reverse driving – option.......................................................... 92
		3.2.9. Fuses............................................................................................ 93
		3.2.10. Slow-blowing fuses.............................................................................. 94
		3.2.11. Adjusting the heater and ventilation system..................................................... 95
		3.2.12. Air-conditioning................................................................................ 96
	3.3. Operation.............................................................................................. 97
		3.3.1. Pre-start checks................................................................................. 97
			Visual inspection.................................................................................... 97
			Pre-start checks..................................................................................... 99
			Adjustments prior to machine start...................................................................104
			Adjusting the driver’s seat..........................................................................104
		3.3.2. Starting the engine..............................................................................108
			Warming up the engine................................................................................109
		3.3.3. Driving with the machine.........................................................................110
			Start-up.............................................................................................110
		3.3.4. Changing the driving direction...................................................................112
		3.3.5. Turning and steering.............................................................................113
		3.3.6. Braking..........................................................................................114
		3.3.7. Stopping the machine.............................................................................116
		3.3.8. Operating the work equipment.....................................................................117
			Multifunctional lever................................................................................117
			Control lever for special equipment..................................................................118
			Switching lever of bucket............................................................................119
		3.3.9. Working with the wheeled loader..................................................................120
			Tire-appropriate operation...........................................................................120
			Switching on the 100 % differential lock (if equipped)...............................................120
			Loading work.........................................................................................121
			Removal work.........................................................................................121
			Excavation work......................................................................................123
			Planing..............................................................................................124
			Transporting.........................................................................................125
			Unloading............................................................................................125
			Working with the forklift truck attachment...........................................................126
		3.3.10. Precautions for special operations..............................................................128
			Permissible water depth..............................................................................128
			Working on snow......................................................................................128
			Dumping on steep slopes..............................................................................128
			Working in the vicinity of electrical overhead lines.................................................128
			Operation on slopes..................................................................................128
			Working on loose soil................................................................................128
			If the service brake breaks down.....................................................................128
			Precautionary measures when driving up or down.......................................................129
			Precautionary measures during machine travel.........................................................130
		3.3.11. Adjusting the position of the work equipment....................................................131
			Selecting a work unit................................................................................131
			Removing the work unit...............................................................................133
			Picking up the multi-purpose bucket..................................................................134
			Removing the multi-purpose bucket....................................................................136
			Level indicator for the bucket.......................................................................136
		3.3.12. Parking the machine.............................................................................137
		3.3.13. Switching off the engine........................................................................138
		3.3.14. Check after stopping the engine.................................................................138
		3.3.15. Locking.........................................................................................138
		3.3.16.  Tire handling...................................................................................139
			Precautionary measures when handling tires...........................................................139
			Tire pressure........................................................................................139
	3.4. Transporting the machine...............................................................................141
		3.4.1. Securing the articulated steering................................................................141
		3.4.2. Lifting the machine..............................................................................142
		3.4.3. Driving the machine onto loading area of transport vehicle.......................................143
		3.4.4. Securing the machine during the transport........................................................144
		3.4.5. After transport..................................................................................144
	3.5. Cold weather operation.................................................................................145
		3.5.1. Before the cold season...........................................................................145
		3.5.2. Precautions after completion of work.............................................................146
		3.5.3. After the cold season............................................................................146
	3.6. Long-term storage......................................................................................147
		3.6.1. Before storage...................................................................................147
		3.6.2. During storage...................................................................................147
		3.6.3. After storage....................................................................................148
4. Troubleshooting..............................................................................................150
	4.1. Towing the machine.....................................................................................151
	4.2. Starting the engine with a booster cable...............................................................155
	4.3. For insufficient braking effect........................................................................157
		4.3.1. Checking the service brake.......................................................................157
		4.3.2. Checking the parking brake function..............................................................157
	4.4. Emergency steering properties..........................................................................158
	4.5. Emergency lowering.....................................................................................158
	4.6. Other troubles.........................................................................................159
		4.6.1. Electrical system................................................................................159
		4.6.2. Engine...........................................................................................160
		4.6.3. Hydraulic system.................................................................................163
		4.6.4. Brakes...........................................................................................165
		4.6.5. Steering.........................................................................................165
		4.6.6. Axles............................................................................................166
		4.6.7. Driver's cab.....................................................................................166
5. Maintenance..................................................................................................168
	5.1. Maintenance guide......................................................................................169
	5.2. Maintenance basics.....................................................................................176
		5.2.1. Oil, fuel and coolant specifications.............................................................176
			Oil..................................................................................................176
			Fuel.................................................................................................177
			Coolant..............................................................................................178
			Grease...............................................................................................178
			Storing oil and fuel.................................................................................179
			Filters..............................................................................................179
			Biodegradable hydraulic oil and lubricants..........................................................179
		5.2.2. Specifications of the electrical system..........................................................180
		5.2.3. Wearing parts list...............................................................................181
	5.3. Lubricants, fuels and filling capacities...............................................................182
		5.3.1. Lubrication chart................................................................................183
	5.4. Tools and standard tightening torques (bolts,nuts)....................................................184
		5.4.1. Introduction of recommended tools................................................................184
		5.4.2. Torque list......................................................................................185
	5.5. Periodical replacement of safety-critical parts........................................................187
	5.6. Maintenance schedule chart.............................................................................188
	5.7. Service procedure......................................................................................190
		5.7.1. Pre-start checklist..............................................................................190
			Cooling system – checking the coolant level, topping up coolant......................................190
			Cleaning the radiator segments.......................................................................191
			V-Belt, checking the condition.......................................................................191
			Engine, checking the oil level, topping up oil.......................................................191
			Checking the fuel level – refuelling.................................................................193
			Water separator at the fuel filter – Draining water and dirt sediments...............................194
			Hand pump - Checking the oil level...................................................................194
			Checking the controls................................................................................195
			Checking the electrical connections..................................................................195
			Heater/air conditioning – checking rate of air flow..................................................196
			Miscellaneous tests before starting work.............................................................196
		5.7.2. Maintenance upon demand..........................................................................197
			Checking the air-conditioning system.................................................................197
			Checking the window washing-fluid level, adding fluid................................................198
			Re-charging a built-in battery.......................................................................199
		5.7.3. Maintenance after the first 50 operating hours...................................................200
			Hydraulic system, replacing the filter insert........................................................200
			Checking and tightening the wheel nuts...............................................................201
		5.7.4. Maintenance after the first 250 operating hours..................................................202
			Front and rear axle – oil change.....................................................................202
			Transfer box gearing – changing oil..................................................................203
			Checking and adjusting the valve play................................................................203
		5.7.5. Maintenance every 10 operating hours.............................................................204
			Lubrication, articulated steering....................................................................204
		5.7.6. Maintenance every 50 operating hours.............................................................205
			Checking the service brake and oil level, refilling oil..............................................205
			Battery – checking the acid level....................................................................206
			Lubrication..........................................................................................207
		5.7.7. Maintenance every 250 operating hours............................................................208
			V-Belt, generator – checking and adjusting the tension...............................................208
			Air filter, removing and re-installing the filter insert, checking and cleaning the filter insert....209
			Lubrication, steering cylinder.......................................................................212
			Lubrication, self-aligning bearings of rear axle.....................................................213
		5.7.8. Maintenance every 500 operating hours............................................................214
			Engine – changing oil and replacing the oil filter cartridge.........................................214
			Replacing the oil filter cartridge...................................................................215
			Changing the fuel filter and filter element..........................................................216
			Purging the fuel system..............................................................................217
			Purging the low pressure side........................................................................217
			Purging the high pressure side.......................................................................217
			Air filter, replacing the filter insert, replacing the safety filter.................................218
			Heater/air conditioning – cleaning/replacing filter fleece or cleaning condenser.....................219
			E.C.S.S.-pressure accumulator (Option) - checking gas pressure.......................................220
			Front and rear axle – checking the oil level.........................................................221
			Transfer box gearing – checking and changing oil.....................................................222
		5.7.9. Maintenance every 1000 operating hours...........................................................223
			V-Belt, generator – checking and adjusting the tension...............................................223
			Service Brake - Checking and adjusting oil...........................................................223
			Checking and adjusting system pressures..............................................................223
			Have the system pressures checked and adjusted at an authorized Komatsu garage.......................223
			Hydraulics – Exchanging the venting filters..........................................................224
			Hydraulic system, replacing the filter insert........................................................225
		5.7.10. Maintenance every 1500 operating hours..........................................................226
			Front and rear axle – oil change.....................................................................226
			Transfer box gearing – checking and changing oil.....................................................227
		5.7.11. Maintenance every 2000 operating hours..........................................................228
			Cooling system – exchanging coolant and cleaning the system..........................................228
			Checking and adjusting the valve play................................................................230
			Hydraulic system, oil change.........................................................................231
			Ventilating the hydraulic oil tank...................................................................232
			Checking the fuel pump...............................................................................233
			Checking the fuel and coolant tubes, replacing the tubes (if required)...............................233
			Checking the water pump..............................................................................233
		5.7.12. Maintenance every 4000 operating hours..........................................................234
			Lubrication, cardan shaft............................................................................234
6. Technical data...............................................................................................236
	6.1. Technical data.........................................................................................237
	6.2. Noise emission levels..................................................................................238
	6.3. Vibration level........................................................................................238
	6.4. Limit values for slopes................................................................................238
7. Special equipment and attachments............................................................................240
	7.1. E.C.S.S................................................................................................241
		7.1.1. Structure and functioning principle of the E.C.S.S...............................................241
		7.1.2. Precautionary measures for switching on the E.C.S.S..............................................241
		7.1.3. Operating the E.C.S.S............................................................................242
			Switching ON the E.C.S.S.............................................................................242
			Switching OFF the E.C.S.S............................................................................242
		7.1.4. Precautions when handling the accumulator.......................................................243
8. Index........................................................................................................244
9. Notes........................................................................................................250

DESCRIPTION:

KOMATSU WA65-5 WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:H50051 & UP) KOMATSU WA65-5

The machine must be operated, cleaned, and maintained very carefully to ensure safe and troublefree operation. If you operate the machine correctly, these operating instructions will help you to avoid injuries and damage to property. To ensure this, these operating instructions take into account all applicable legal regulations and directives; the operating instructions comprise the following information:
● Notes on the Operating Instructions
● Notes on Transport
● Notes on Safety Regulations
● Operating Instructions
● Troubleshooting
● Maintenance Instructions
● Technical Data
● Notes on Lubricants and Operating Agents
The operating manual belongs to the machine and is stored in the lid of the hinged console, on the left of the driver’s cab. The operating instructions are part of the machine and must always be available at hand in the machine.
If the operating instructions have been lost or if they have become unreadable, because they are dirty, you may receive a new copy from Komatsu or your local Komatsu dealer. If the machine is resold, the operating instructions, the EU Declaration of Conformity (CE), and the licence are to be handed over to the new owner.

PLEASE NOTE:

⦁ This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
⦁ Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.