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Komatsu WA700-3 Wheel Loader Operation & Maintenance Manual SN 51001 and up – PDF DOWNLOAD
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Komatsu WA700-3 Wheel Loader Operation & Maintenance Manual
Book Code : TEN00001-03
SERIAL NUMBERS WA700-3 51001 and up
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Description
Komatsu WA700-3 Wheel Loader Operation & Maintenance Manual
FILE DETAILS:
Komatsu WA700-3 Wheel Loader Operation & Maintenance Manual
Model Specification: KOMATSU WA700-3 WHEEL LOADER
Language: English
File Format: PDF
Total Pages: 287
Requirements: Adobe PDF Reader
ZOOM IN/OUT: YES
Downloadable: YES
KOMATSU WA700-3 WHEEL LOADER OPERATION & MAINTENANCE MANUAL SN 51001 AND UP – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu WA700-3 Wheel Loader Operation & Maintenance Manual
FOREWORD:
This manual provides rules and guidelines which will help you use this machine safely and effectively. The precautions in this manual must be followed at all times when performing operation and maintenance. Most accidents are caused by the failure to follow fundamental safety rules forthe operation and maintenance of machines. Accidents can be prevented by knowing beforehand conditions that may cause hazard when performing operation and maintenance.
TABLE OF CONTENTS:
Komatsu WA700-3 Wheel Loader Operation & Maintenance Manual
MAIN MENU...................................................................................... 0 COVER.......................................................................................... 1 FOREWORD....................................................................................... 2 FOREWORD................................................................................... 3 SAFETY INFORMATION......................................................................... 6 INTRODUCTION............................................................................... 8 FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE........................................... 8 VISIBILITY FROM OPERATOR'S SEAT........................................................ 9 NECESSARY INFORMATION...................................................................... 10 PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE........................... 10 ENGINE SERIAL NO. PLATE AND POSITION................................................... 10 POSITION OF SERVICE METER.............................................................. 11 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR.............................................. 11 CONTENTS....................................................................................... 12 SAFETY......................................................................................... 15 SAFETY..................................................................................... 16 SAFETY LABELS.............................................................................. 18 LOCATION OF SAFETY LABELS.............................................................. 19 GENERAL PRECAUTIONS........................................................................ 25 SAFETY RULES........................................................................... 25 IF ABNORMALITIES ARE FOUND............................................................. 25 CLOTHING AND PERSONAL PROTECTIVE ITEMS................................................. 25 FIRE EXTINGUISHER AND FIRST AID KIT.................................................... 25 SAFETY FEATURES........................................................................ 25 KEEP MACHINE CLEAN..................................................................... 26 INSIDE OPERATOR'S COMPARTMENT.......................................................... 26 ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT......................................... 26 HANDRAILS AND STEPS.................................................................... 27 MOUNTING AND DISMOUNTING............................................................... 27 NO PEOPLE ON ATTACHMENTS............................................................... 27 DO NOT GET CAUGHT IN ARTICULATED PORTION............................................... 28 PREVENTION OF BURNS.................................................................... 28 FIRE PREVENTION........................................................................ 29 ACTION IF FIRE OCCURS.................................................................. 30 WINDOW WASHER LIQUID................................................................... 30 PRECAUTIONS WHEN USING ROPS (ROLL OVER PROTECTIVE STRUCTURE)........................... 30 PRECAUTIONS FOR ATTACHMENTS, OPTIONS................................................... 30 UNAUTHORIZED MODIFICATION.............................................................. 30 SAFETY AT WORKSITE..................................................................... 31 WORKING ON LOOSE GROUND................................................................ 31 DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES................................................. 32 ENSURE GOOD VISIBILITY................................................................. 32 PRECAUTIONS RELATED TO VENTILATION EXHAUST GAS......................................... 33 CHECKING SIGNALMAN'S SIGNALS AND SIGNS................................................. 33 EMERGENCY EXIT FROM OPERATOR'S CAB..................................................... 33 BE CAREFUL ABOUT ASBESTOS DUST......................................................... 33 PRECAUTIONS FOR OPERATION.................................................................. 34 STARTING ENGINE........................................................................ 34 CHECKS BEFORE STARTING ENGINE...................................................... 34 PRECAUTIONS WHEN STARTING.......................................................... 34 PRECAUTIONS IN COLD AREAS.......................................................... 35 OPERATION.............................................................................. 36 CHECKS BEFORE OPERATION............................................................ 36 PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE................................... 36 PRECAUTIONS WHEN TRAVELING......................................................... 37 TRAVELING ON SLOPES................................................................ 38 PROHIBITED OPERATIONS.............................................................. 39 PRECAUTIONS WHEN OPERATING......................................................... 40 METHODS OF USING BRAKE............................................................. 40 OPERATE CAREFULLY ON SNOW.......................................................... 41 PARKING MACHINE ................................................................... 42 TRANSPORTATION......................................................................... 43 LOADING AND UNLOADING.............................................................. 43 SHIPPING........................................................................... 43 BATTERY................................................................................ 44 BATTERY HAZARD PREVENTION.......................................................... 44 STARTING WITH BOOSTER CABLES....................................................... 45 TOWING................................................................................. 46 PRECAUTIONS FOR MAINTENANCE................................................................ 47 WARNING TAG ........................................................................... 47 KEEP WORK PLACE CLEAN AND TIDY......................................................... 47 APPOINT LEADER WHEN WORKING WITH OTHERS................................................ 47 STOP ENGINE BEFORE CARRYING OUT MAINTENANCE............................................ 48 TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING..................................... 49 PROPER TOOLS........................................................................... 50 WORK EQUIPMENT SUPPORT................................................................. 50 ACCUMULATOR............................................................................ 50 PERSONNEL.............................................................................. 50 ATTACHMENTS .......................................................................... 51 NOISE.................................................................................. 51 PRECAUTIONS WHEN USING HAMMER ......................................................... 51 REPAIR WELDING ........................................................................ 51 REMOVING BATTERY TERMINAL ............................................................. 51 PRECAUTIONS WITH HIGH-PRESSURE OIL..................................................... 52 HANDLING HIGH-PRESSURE HOSES........................................................... 52 WASTE MATERIALS ....................................................................... 52 MAINTENANCE OF AIR CONDITIONER......................................................... 52 COMPRESSED AIR......................................................................... 53 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS ......................................... 53 PRECAUTIONS WITH TIRES..................................................................... 54 HANDLING TIRES......................................................................... 54 PRECAUTIONS WHEN STORING TIRES......................................................... 54 OPERATION...................................................................................... 55 GENERAL VIEW............................................................................... 56 GENERAL VIEW OF MACHINE................................................................ 56 GENERAL VIEW OF CONTROLS AND GAUGES.................................................... 57 EXPLANATION OF COMPONENTS.................................................................. 59 MACHINE MONITOR........................................................................ 59 SWITCHES............................................................................... 72 CONTROL LEVERS, PEDALS................................................................. 81 STEERING COLUMN TILT LEVER............................................................. 85 CAP WITH LOCK.......................................................................... 86 FUEL STOP LEVER FOR EMERGENCY ENGINE STOP.............................................. 87 SAFETY BAR............................................................................. 87 TOWING PIN............................................................................. 88 GREASE PUMP............................................................................ 88 BACKUP ALARM........................................................................... 88 CAB DOOR OPEN LOCK..................................................................... 89 TOOL BOX............................................................................... 89 DUST INDICATOR......................................................................... 89 FUSE................................................................................... 89 SLOW BLOW FUSE......................................................................... 91 LUNCH BOX TRAY......................................................................... 91 POWER OUTLET........................................................................... 91 PRECAUTIONS WHEN HANDLING ACCUMULATOR.................................................. 92 OPERATION.................................................................................. 94 CHECK BEFORE STARTING ENGINE, ADJUST................................................... 94 STARTING ENGINE........................................................................111 OPERATIONS AND CHECKS AFTER STARTING ENGINE............................................113 STOPPING ENGINE........................................................................115 CHECK AFTER STOPPING ENGINE............................................................115 MOVING THE MACHINE (DIRECTIONAL, SPEED), STOPPING THE MACHINE..........................116 TURNING................................................................................121 OPERATION OF WORK EQUIPMENT............................................................122 WORK POSSIBLE USING WHEEL LOADER.......................................................124 PRECAUTIONS FOR OPERATION..............................................................130 ADJUSTING WORK EQUIPMENT POSTURE.......................................................132 REMOVAL AND INSTALLATION OF THE BUCKET.................................................134 PARKING MACHINE........................................................................138 CHECKS AFTER COMPLETION OF OPERATION...................................................140 LOCKING................................................................................140 HANDLING THE TIRES.....................................................................141 TRANSPORTATION.............................................................................143 TRANSPORTATION PROCEDURE...............................................................143 LOADING, UNLOADING WORK................................................................143 METHOD OF SECURING MACHINE.............................................................143 METHOD OF LIFTING MACHINE..............................................................145 COLD WEATHER OPERATION.....................................................................148 PRECAUTIONS FOR LOW TEMPERATURE........................................................148 PRECAUTIONS AFTER COMPLETION OF WORK...................................................149 AFTER COLD WEATHER.....................................................................150 WARMING-UP OPERATION FOR STEERING HYDRAULIC CIRCUIT IN COLD WEATHER....................150 LONG-TERM STORAGE..........................................................................151 BEFORE STORAGE.........................................................................151 DURING STORAGE.........................................................................151 AFTER STORAGE..........................................................................151 TROUBLESHOOTING............................................................................152 WHEN MACHINE RUNS OUT OF FUEL..........................................................152 METHOD OF TOWING MACHINE...............................................................154 IF BATTERY IS DISCHARGED...............................................................158 OTHER TROUBLE..........................................................................162 MAINTENANCE....................................................................................166 GUIDES TO MAINTENANCE......................................................................167 OUTLINES OF SERVICE........................................................................169 HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC.................................169 OUTLINE OF ELECTRIC SYSTEM.............................................................172 WEAR PARTS.................................................................................173 WEAR PARTS LIST........................................................................173 RECOMMENDED FUEL, COOLANT, AND LUBRICANT...................................................174 USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE...................175 RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL....176 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS.............................................177 TORQUE LIST............................................................................177 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS..............................................178 SAFETY CRITICAL PARTS..................................................................178 MAINTENANCE SCHEDULE CHART.................................................................179 MAINTENANCE SCHEDULE CHART.............................................................179 SERVICE PROCEDURE..........................................................................181 INITIAL 250 HOURS SERVICE..............................................................181 INITIAL 2000 HOURS SERVICE.............................................................181 CHECK INJECTOR SETTING LOAD, ADJUST................................................181 WHEN REQUIRED..........................................................................182 CHECK, CLEAN, OR REPLACE AIR CLEANER ELEMENT.......................................182 CLEAN INSIDE OF COOLING SYSTEM.....................................................185 CHECK TRANSMISSION OIL LEVEL, ADD OIL..............................................188 CHECK AXLE OIL LEVEL, ADD OIL......................................................190 CLEAN AXLE CASE BREATHER...........................................................191 CLEAN AIR CONDITIONER CONDENSER....................................................191 CHECK WINDOW WASHING FLUID LEVEL, ADD FLUID........................................192 CLEAN RADIATOR FINS AND OIL COOLER FINS............................................192 CHECK ELECTRICAL INTAKE AIR HEATER.................................................193 REPLACE BUCKET TEETH...............................................................193 LUBRICATE WORK EQUIPMENT CONTROL VALVE LINKAGE (2 PLACES)..........................194 CHECK AIR CONDITIONER..............................................................194 REPLACE SLOW BLOW FUSE.............................................................195 BLEEDING AIR FROM HYDRAULIC TANK...................................................196 REPLACE FAN BELT, ADJUST AUTO-TENSIONER............................................198 BLEEDING AIR FROM BRAKE HYDRAULIC CIRCUIT..........................................200 BLEEDING AIR FROM PPC CIRCUIT......................................................200 SELECTION AND INSPECTION OF TIRES..................................................201 CHECK BEFORE STARTING..................................................................203 EVERY 50 HOURS SERVICE.................................................................204 DRAIN WATER, SEDIMENT FROM FUEL TANK...............................................204 EVERY 100 HOURS SERVICE................................................................205 LUBRICATING........................................................................205 CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL.........................................207 CLEAN ELEMENT IN AIR CONDITIONER FRESH AIR FILTER..................................208 EVERY 250 HOURS SERVICE................................................................209 CHECK BATTERY ELECTROLYTE LEVEL....................................................209 CHECK PARKING BRAKE................................................................210 CHECK ALTERNATOR BELT TENSION, ADJUST..............................................211 CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST..............................212 CHECK FOR LOOSE WHEEL HUB NUTS, TIGHTEN............................................212 CLEAN ELEMENT IN AIR CONDITIONER RECIRCULATION FILTER..............................213 EVERY 500 HOURS SERVICE................................................................214 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE..................214 REPLACE FUEL FILTER CARTRIDGE......................................................216 REPLACE TRANSMISSION OIL FILTER ELEMENT............................................217 LUBRICATE CENTER DRIVE SHAFT.......................................................218 CHECK FAN BELT FOR WEAR ...........................................................218 EVERY 1000 HOURS SERVICE...............................................................219 CHANGE OIL IN TRANSMISSION CASE, CLEAN STRAINER....................................219 CLEAN TRANSMISSION CASE BREATHER...................................................220 LUBRICATING........................................................................221 CHECK TIGHTENING PARTS OF TURBOCHARGER.............................................223 CLEAN FUEL STRAINER................................................................223 REPLACE CORROSION RESISTOR CARTRIDGE...............................................223 TIGHTEN ROPS CANOPY................................................................224 EVERY 2000 HOURS SERVICE...............................................................225 CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC FILTER ELEMENT.....................225 REPLACE HYDRAULIC TANK BREATHER ELEMENT............................................227 CLEAN HYDRAULIC TANK STRAINER......................................................228 CHANGE AXLE OIL....................................................................229 REPLACE FILTER ELEMENT IN BRAKE OIL TANK...........................................230 REPLACE BRAKE OIL TANK BREATHER....................................................231 REPLACE ELEMENT IN AIR CONDITIONER RECIRCULATION AIR FILTER, FRESH AIR FILTER......231 CLEAN PPC CIRCUIT STRAINER.........................................................231 CLEAN ENGINE BREATHER ELEMENT......................................................232 CHECK ALTERNATOR, STARTING MOTOR...................................................232 CHECK ENGINE VALVE CLEARANCE, ADJUST...............................................232 CHECK BRAKE DISC WEAR..............................................................232 CLEAN AND CHECK TURBOCHARGER.......................................................232 CHECK ACCUMULATOR FUNCTION.........................................................233 CHECK ACCUMULATOR GAS PRESSURE.....................................................233 EVERY 4000 HOURS SERVICE...............................................................234 CHECK WATER PUMP...................................................................234 CHECK VIBRATION DAMPER.............................................................234 CHECK FAN PULLEY AND TENSION PULLEY................................................234 CHECK AIR CONDITIONER COMPRESSOR, ADJUST...........................................234 SPECIFICATIONS.................................................................................235 SPECIFICATIONS.............................................................................236 ATTACHMENTS, OPTIONS...........................................................................238 SELECTING BUCKET AND TIRES.................................................................239 HANDLING AUTO-GREASING SYSTEM..............................................................240 METHOD OF OPERATING AUTO-GREASING SYSTEM...............................................241 PRECAUTIONS WHEN HANDLING AUTO-GREASING SYSTEM.........................................242 METHOD OF ADJUSTING DISCHARGE FROM INJECTOR............................................249 METHOD OF SETTING TIMER................................................................250 HANDLING AUTOMATIC SHIFT SYSTEM............................................................253 METHOD OF OPERATION....................................................................253 PRECAUTION WHEN CHANGING DIRECTION.....................................................254 HANDLING AJSS (ADVANCED JOYSTICK STEERING SYSTEM)..........................................255 EXPLANATION OF COMPONENTS..............................................................255 STRUCTURE AND FUNCTION OF JOYSTICK STEERING............................................256 OPERATION METHOD OF JOYSTICK STEERING SYSTEM...........................................259 ADJUSTMENT OF JOYSTICK CONSOLE.........................................................262 ADJUSTMENT OF AIR SUSPENSION SEAT......................................................263 FAILURE DISPLAY ON MAIN MONITOR............................................................265 FAILURE CODE ON MAIN MONITOR...........................................................265 CAR RADIO..................................................................................266 EXPLANATION OF COMPONENTS..............................................................266 METHOD OF USE..........................................................................269 PRECAUTIONS WHEN USING.................................................................271 AM/FM RADIO-CASSETTE STEREO................................................................272 EXPLANATION OF COMPONENTS..............................................................272 METHOD OF OPERATION....................................................................277 PRECAUTIONS FOR USE....................................................................279 AIR CONDITIONER............................................................................280 GENERAL LOCATIONS AND FUNCTION OF CONTROL PANEL........................................280 METHOD OF OPERATION....................................................................282 INDEX..........................................................................................284
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