Komatsu WA70-5 Wheel Loader Operation & Maintenance Manual H50051 and up – PDF DOWNLOAD

Description

Komatsu WA70-5 Wheel Loader Operation & Maintenance Manual

TABLE OF CONTENTS:

Komatsu WA70-5 Wheel Loader Operation & Maintenance Manual 

WA70-5_VEAM320200_USA................................................................................................  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................................................... 26
		1.11. Loading and securing.................................................................................. 29
	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. Tyres............................................................................................ 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 wheel loader....................................................................120
				Tyre-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. Tyre handling...................................................................................139
				Precautionary measures when handling tyres...........................................................139
				Tyre 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
			5.1.1. Guidelines.......................................................................................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 clearance...........................................................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, work unit...............................................................................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................................................................................214
				Replacing the oil filter cartridge...................................................................215
				Changing the fuel filter element.....................................................................216
				Bleeding the fuel system.............................................................................217
				Bleeding the low pressure side:......................................................................217
				Bleeding the high pressure side:.....................................................................217
				Air filter, replacing the filter insert, replacing the safety filter.................................218
				Heater/air conditioning – cleaning/replacing filter fleece...........................................219
				Cleaning the condenser of air conditioning...........................................................220
				E.C.S.S.-pressure accumulator (Option) - checking gas pressure.......................................220
				Front and rear axle – checking the oil level.........................................................221
				Transfer box gearing – checking the oil level........................................................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 authorised 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 – 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 clearance...........................................................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, universal joint.........................................................................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

KOMATSU WA70-5 WHEEL LOADER OPERATION & MAINTENANCE MANUAL H50051 AND UP – PDF DOWNLOAD:

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DESCRIPTION:

Komatsu WA70-5 Wheel Loader Operation & Maintenance Manual

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.

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• This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
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