Komatsu WA65-6 WA70-6 WA80-6 WA90-6 WA100M-6 Wheel Loader Operation & Maintenance Manual SN 00051, 60051 and up – PDF DOWNLOAD

Description

Komatsu WA65-6 WA70-6 WA80-6 WA90-6 WA100M-6 Wheel Loader Operation & Maintenance Manual

TABLE OF CONTENTS:

Komatsu WA65-6 WA70-6 WA80-6 WA90-6 WA100M-6 Wheel Loader Operation & Maintenance Manual

1. Foreword...............................................................................................  3
	1.1 Foreword..........................................................................................  4
		1.1.1 EU Directives...............................................................................  6
	1.2 Safety information................................................................................  7
		1.2.1 Signal words................................................................................  7
		1.2.2 Safety labels...............................................................................  9
	1.3 Introduction...................................................................................... 10
		1.3.1 Intended use................................................................................ 10
	1.4 Key data of the machine........................................................................... 12
		1.4.1 Product identification number (PIN)/Machine serial no. plate and position................... 12
		1.4.2 Engine serial no. plate..................................................................... 13
		1.4.3 Axle serial no. plate....................................................................... 13
		1.4.4 Transmission serial no. plate............................................................... 13
		1.4.5 ROPS/FOPS cab serial no. plate.............................................................. 14
		1.4.6 Operator's seat serial no. plate............................................................ 14
		1.4.7 Table to enter serial number and distributor................................................ 15
		1.4.8 Declaration of conformity (for machines placed on the market as from 29th December 2009).... 16
	1.5 Emission control warranty......................................................................... 17
		1.5.1 Emission control warranty statement (Applies to Canada only)................................ 17
	1.6 Garantie sur le contrôle des émissions............................................................ 18
		1.6.1 Énoncé de garantie sur le contrôle des émissions (applicable au Canada seulement)........... 18
	1.7 Table of contents................................................................................. 19
	1.8 Dimensions, weights, and operating data........................................................... 26
		1.8.1 WA65-6, WA70-6, WA80-6...................................................................... 26
		1.8.2 WA90-6, WA100M-6............................................................................ 28
	1.9 CE-conforming equipment........................................................................... 30
		1.9.1 CE-conforming equipment - part 1............................................................ 30
		1.9.2 CE-conforming equipment - part 2............................................................ 32
		1.9.3 Manufacturer-supplied CE-conforming equipment............................................... 33
2. Safety................................................................................................. 39
	2.1 Safety labels..................................................................................... 40
		2.1.1 Position of the safety labels (for Europe).................................................. 40
		2.1.2 Position of the safety labels (for USA)..................................................... 42
	2.2 General precautions............................................................................... 45
	2.3 Precautions during operation...................................................................... 57
		2.3.1 Starting the engine......................................................................... 57
		2.3.2 Operation................................................................................... 59
		2.3.3 Transport................................................................................... 66
		2.3.4 Battery..................................................................................... 67
	2.4 Precautions for maintenance....................................................................... 69
3. Operation.............................................................................................. 81
	3.1 General view...................................................................................... 82
		3.1.1 General view of the machine................................................................. 82
		3.1.2 Controls.................................................................................... 84
			General view.................................................................................. 84
		3.1.3 Machine monitor............................................................................. 86
		3.1.4 Switches.................................................................................... 88
	3.2 Descriptions of the individual elements........................................................... 90
		3.2.1 Machine monitor............................................................................. 90
			Caution lamps................................................................................. 91
			Pilot lamps................................................................................... 94
			Gauges........................................................................................100
		3.2.2 Switches....................................................................................102
		3.2.3 Control levers and pedals...................................................................112
		3.2.4 Steering lock...............................................................................117
		3.2.5 Tow hitch...................................................................................117
		3.2.6 Power outlet................................................................................118
		3.2.7 Door and window detent release..............................................................118
		3.2.8 Back-up alarm...............................................................................118
		3.2.9 Fuses.......................................................................................119
		3.2.10 Slow-blow fuses............................................................................121
		3.2.11 Adjusting the heating and ventilation system...............................................122
		3.2.12 Air conditioner............................................................................123
	3.3 Operation.........................................................................................125
		3.3.1 Checks before starting......................................................................125
			Visual checks.................................................................................125
			Checks before starting the engine.............................................................128
			Adjustments before starting...................................................................138
		3.3.2 Starting the engine.........................................................................142
			Ambient temperature range for operation and storage...........................................143
			Checks after starting the engine..............................................................144
		3.3.3 Driving the machine.........................................................................145
			Starting......................................................................................145
			Limiting the maximum speed....................................................................146
		3.3.4 Changing direction..........................................................................148
		3.3.5 Turning and steering........................................................................149
		3.3.6 Braking.....................................................................................150
			Engaging the parking brake....................................................................150
			Disengaging the parking brake.................................................................150
			Braking with the service brake................................................................150
			If the service brake fails....................................................................151
			Braking on slopes.............................................................................151
		3.3.7 Stopping and parking the machine............................................................152
		3.3.8 Operating the work equipment................................................................153
			Multi-function lever..........................................................................153
		3.3.9 Return to dig...............................................................................154
		3.3.10 Working with the wheel loader..............................................................155
			Saving the tyres..............................................................................155
			Switching on the 100 % differential lock......................................................156
			Loading.......................................................................................157
			Digging.......................................................................................157
			Excavating....................................................................................159
			Levelling.....................................................................................160
			Carrying......................................................................................161
			Loading.......................................................................................162
			Working with the forklift attachment..........................................................163
		3.3.11 Operating precautions......................................................................165
			Permissible water depth.......................................................................165
			Working on snow...............................................................................165
			Dumping on steep slopes.......................................................................165
			Working near high-voltage cables..............................................................165
			Working on road shoulders.....................................................................165
			Working on loose ground.......................................................................165
			If the service brake fails....................................................................165
			Precautions for driving uphill or downhill....................................................166
			Precautions when driving......................................................................166
		3.3.12 Adjusting the work equipment...............................................................167
			Selecting the work equipment..................................................................167
			Attaching the work equipment..................................................................167
			Removing the work equipment...................................................................170
			Removing the multi-purpose bucket.............................................................171
			Bucket level indicator........................................................................171
		3.3.13 Switching off the engine...................................................................172
		3.3.14 Checks after switching off the engine......................................................172
		3.3.15 Locking....................................................................................172
		3.3.16 Handling tyres.............................................................................173
			Precautions when handling tyres...............................................................173
			Tyre pressure.................................................................................173
			Standard tyres................................................................................174
	3.4 Transport.........................................................................................175
		3.4.1 Transporting procedure......................................................................175
			Ensure machine stability......................................................................175
		3.4.2 Loading the machine.........................................................................175
			Loading the machine...........................................................................176
			Securing the machine..........................................................................177
			Unloading the machine.........................................................................179
		3.4.3 Lifting the machine.........................................................................180
			Lifting procedure.............................................................................183
	3.5 Operation in cold weather.........................................................................184
		3.5.1 Precautions for operation in cold weather...................................................184
		3.5.2 Precautions after work......................................................................185
		3.5.3 After the cold weather period...............................................................185
	3.6 Long-term storage.................................................................................186
		3.6.1 Before storage..............................................................................186
		3.6.2 During storage..............................................................................186
		3.6.3 After storage...............................................................................187
	3.7 Machines equipped with KOMTRAX....................................................................188
		3.7.1 Basic precautions...........................................................................188
	3.8 Reading error codes...............................................................................190
		3.8.1 Setting the monitor.........................................................................191
4. Troubleshooting........................................................................................193
	4.1 Towing machine....................................................................................194
	4.2 Starting the engine with booster cables...........................................................198
	4.3 In case of insufficient brake power...............................................................201
		4.3.1 Checking the service brake..................................................................201
		4.3.2 Checking the parking brake..................................................................201
	4.4 Emergency steering properties.....................................................................202
	4.5 Emergency lowering................................................................................203
	4.6 Other troubles....................................................................................204
		4.6.1 Electrical system...........................................................................204
		4.6.2 Engine......................................................................................205
		4.6.3 Hydraulic...................................................................................208
		4.6.4 Brakes......................................................................................210
		4.6.5 Steering....................................................................................211
		4.6.6 Axles.......................................................................................211
		4.6.7 Operator's cab..............................................................................211
5. Maintenance............................................................................................213
	5.1 Maintenance guide.................................................................................214
		5.1.1 Tipping up the operator's cab...............................................................215
		5.1.2 Tipping down the operator's cab.............................................................217
	5.2 Basic maintenance guidelines......................................................................222
		5.2.1 Fuel, coolant and lubricant specifications..................................................223
			Oil...........................................................................................223
			Fuel..........................................................................................224
			Coolant.......................................................................................225
			Grease........................................................................................226
			Storing oil and fuel..........................................................................226
			Filters.......................................................................................227
			Biodegradable hydraulic oil and lubricants....................................................227
		5.2.2 Outlines of the electrical system...........................................................228
	5.3 Wear parts list...................................................................................229
		5.3.1 Wear parts list.............................................................................229
	5.4 Fuel, lubricants, and coolants; quantities........................................................230
		5.4.1 Lubrication table...........................................................................230
		5.4.2 Recommended brands, recommended quality for products other than KOMATSU genuine oil.........233
	5.5 Tools.............................................................................................234
		5.5.1 List of required tools......................................................................234
	5.6 Periodic replacement of safety-critical parts.....................................................235
	5.7 Maintenance schedule..............................................................................236
	5.8 Maintenance procedure.............................................................................238
		5.8.1 Checks before starting the engine...........................................................238
		5.8.2 Corrective maintenance......................................................................239
			Checking the air conditioner..................................................................239
			Checking the window washer fluid level - adding fluid.........................................241
			Battery - charging the built-in battery.......................................................241
			Cleaning the air grille.......................................................................242
			Cleaning the radiator fins....................................................................242
		5.8.3 Maintenance after the first 50 service hours................................................243
			Hydraulic system - change filter insert.......................................................243
			Wheel nuts - check and retighten..............................................................243
			Lubrication - rear axle.......................................................................244
		5.8.4 Maintenance after the first 250 service hours...............................................245
			Front and rear axle - change oil..............................................................245
			Transfer case - change oil....................................................................245
			Valve clearance - check and adjust............................................................245
		5.8.5 Maintenance every 10 service hours..........................................................246
			Lubrication - articulated steering............................................................246
		5.8.6 Maintenance every 50 service hours..........................................................247
			Battery - check fluid level...................................................................247
			Lubrication - work equipment..................................................................248
		5.8.7 Maintenance every 250 service hours.........................................................250
			Service brake - check brake pads..............................................................250
			Alternator v-belt - check and adjust tension..................................................251
			Air cleaner - checking, cleaning, or replacing................................................252
			Lubrication - steering cylinder...............................................................255
			Lubrication - rear axle.......................................................................256
			Wheel nuts - check and retighten..............................................................257
		5.8.8 Maintenance every 500 service hours.........................................................258
			Manual pump - check oil level.................................................................258
			Service brake - check brake pads and brake disc, check oil level..............................259
			Engine - change engine oil....................................................................260
			Changing the oil filter cartridge.............................................................261
			Fuel filter - change filter cartridge.........................................................262
			Bleeding the fuel system......................................................................264
			Changing the filter insert of the air cleaner, changing the safety filter.....................265
			Heating/air conditioner - clean/renew filter cloth, clean condenser...........................266
			Checking the gas pressure in the pressure accumulator for the multi-function lever............267
			E.C.S.S. pressure accumulator - check gas pressure............................................267
			Front and rear axle - check oil level.........................................................268
			Transfer case - check oil level, add oil......................................................269
		5.8.9 Maintenance every 1000 service hours........................................................270
			Alternator v-belt - check and adjust tension..................................................270
			Service brake - check, change brake fluid.....................................................271
			System pressures - check and adjust...........................................................271
			Hydraulic system - change venting filters.....................................................272
			Hydraulic system - change filter insert.......................................................273
		5.8.10 Maintenance every 1500 service hours.......................................................274
			Front and rear axle - change oil..............................................................274
			Transfer case - change oil....................................................................276
		5.8.11 Maintenance every 2000 service hours.......................................................277
			Cooling system - change coolant and clean cooling system......................................277
			Valve clearance - check and adjust............................................................280
			Hydraulic system - change hydraulic oil.......................................................281
			Checking the fuel pump........................................................................283
			Fuel and coolant hoses - check, replace if required...........................................283
			Checking the water pump.......................................................................283
		5.8.12 Maintenance every 4000 service hours.......................................................284
			Lubrication - cardan shaft....................................................................284
6. Technical data.........................................................................................285
	6.1 Technical data....................................................................................286
		6.1.1 WA65-6......................................................................................286
		6.1.2 WA70-6......................................................................................286
		6.1.3 WA80-6......................................................................................287
		6.1.4 WA90-6......................................................................................287
		6.1.5 WA100M-6....................................................................................288
	6.2 Noise emission level..............................................................................289
	6.3 Vibration levels..................................................................................290
	6.4 Limit values for slopes...........................................................................292
7. Special equipment, attachments.........................................................................293
	7.1 E.C.S.S...........................................................................................294
		7.1.1 Design and functional principle of the E.C.S.S..............................................294
		7.1.2 Precautions when switching on the E.C.S.S...................................................294
		7.1.3 Operating the E.C.S.S.......................................................................295
			Switching on the E.C.S.S......................................................................295
			Switching off the E.C.S.S.....................................................................295
		7.1.4 Precautions when handling the pressure accumulator..........................................295
	7.2 Bucket position indicator.........................................................................296
	7.3 Central lubrication system........................................................................297
		7.3.1 Operating the central lubrication system....................................................297
		7.3.2 Display and operating unit..................................................................297
			LED display...................................................................................298
			Buttons.......................................................................................298
		7.3.3 Changing the lubrication intervals and duration.............................................299
	7.4 Multi-function lever with 3rd control circuit.....................................................300
		7.4.1 Operating the switch........................................................................300
8. Index..................................................................................................303
	8.1 Index.............................................................................................304
9. Notes..................................................................................................309

KOMATSU WA65-6 WA70-6 WA80-6 WA90-6 WA100M-6 WHEEL LOADER OPERATION & MAINTENANCE MANUAL SN 00051, 60051 AND UP – PDF DOWNLOAD:

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Komatsu WA65-6 WA70-6 WA80-6 WA90-6 WA100M-6 Wheel Loader Operation & Maintenance Manual

FOREWORD:

This manual provides rules and guidelines to help you use this machine safely and effectively. The precautions in this manual must be followed at all times during the operation and maintenance of the machine. The majority of accidents are caused by a failure to follow fundamental safety rules for the operation and maintenance of machines. Accidents can be prevented by knowing beforehand the conditions that may create hazards during operation or maintenance.

PLEASE NOTE:

• This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
• This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
• Require some other service manual or have any queries: please WRITE to us at [email protected]