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Komatsu WA75-3 Wheel Loader Operation & Maintenance Manual HA950318 and up – PDF DOWNLOAD
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Komatsu WA75-3 Wheel Loader Operation & Maintenance Manual
Book Code:VEAM950400
SERIAL NUMBER: VEAM950400 HA950318 and up
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Description
Komatsu WA75-3 Wheel Loader Operation & Maintenance Manual
TABLE OF CONTENTS:
Komatsu WA75-3 Wheel Loader Operation & Maintenance Manual
Main Menu.................................................................................................... 0 Cover........................................................................................................ 1 Product Publications Information............................................................................. 3 Table of Contents............................................................................................ 5 Introduction................................................................................................. 13 Forword.................................................................................................. 14 Safety Information....................................................................................... 15 Introduction............................................................................................. 16 Features............................................................................................. 16 Breaking in a New Machine............................................................................ 16 Location of Plates, Table to Enter Serial No. and Distributor............................................ 17 Machine Serial No. Plate position.................................................................... 17 Engine Serial No. Plate Position..................................................................... 17 Table to Enter Serial No. and Distributor............................................................ 17 EMISSION CONTROL WARRANTY................................................................................ 18 EMISSION CONTROL WARRANTY STATEMENT (APPLIES TO CANADA ONLY)......................................... 18 Engine Data Plate........................................................................................ 19 GARANTIE SUR LE CONTRÔLE DES ÉMISSIONS................................................................... 20 ÉNONCÉ DE GARANTIE SUR LE CONTRÔLE DES ÉMISSIONS (APPLICABLE AU CANADA SEULEMENT):................... 20 Engine Data Plate........................................................................................ 21 Why You Should Read these Operating Instructions......................................................... 22 Notes on Safety Regulations.............................................................................. 23 Correct Use.......................................................................................... 23 Safety Notes in the Operating Instructions........................................................... 23 Equipment................................................................................................ 24 Loading and Transporting the Machine......................................................................... 27 Loading and Transporting the Machine..................................................................... 29 Securing the Articulated Steering.................................................................... 29 Lifting the Machine.................................................................................. 29 Driving Machine Onto Loading Area of Transport Vehicle............................................... 31 Securing the Machine During Transport................................................................ 32 After Transport...................................................................................... 32 Safety....................................................................................................... 33 General Safety Measures.................................................................................. 35 Safety Instructions.................................................................................. 35 Safety Devices....................................................................................... 35 Emergency Exit....................................................................................... 35 Clothing and Personal Protection..................................................................... 36 Machine Modifications................................................................................ 36 Before You Leave the Driver's Seat................................................................... 36 Mounting and Dismounting............................................................................. 36 Fire Prevention and Fire Fighting.................................................................... 37 Fire Extinguisher and First-Aid Kit.............................................................. 38 Protection Against Asbestos Dust..................................................................... 38 Protection Against Injuries.......................................................................... 39 Working at High Temperatures......................................................................... 39 Roll-Over Protection System (ROPS)................................................................... 40 Attachment for Protection Against Falling Objects (FOPS)............................................. 40 Attachments.......................................................................................... 40 Battery.............................................................................................. 41 Safety Measures during Operation......................................................................... 42 Before You Start the Engine.......................................................................... 42 Workplace Safety................................................................................. 42 In the Driver's Cab.............................................................................. 42 In-Door Operation................................................................................ 43 Gas, Dust, and Inflammable Vapours............................................................... 43 Mirrors, Windows, and Lighting................................................................... 43 Machine Operation.................................................................................... 44 Before You Start the Engine...................................................................... 44 Reversing........................................................................................ 44 Driving.......................................................................................... 45 Driving On Slopes............................................................................ 45 Emergency Lowering System........................................................................ 46 Working Close to Overhead Power Transmission Lines........................................... 46 Loading.......................................................................................... 47 Good Vision...................................................................................... 47 Working On Snow.................................................................................. 47 Height Limitation................................................................................ 47 Brakes........................................................................................... 48 Working On Loose Soil............................................................................ 48 Working with the Forklift Truck Attachment................................................... 49 Parking the Machine.............................................................................. 50 Transport............................................................................................ 51 Loading and Unloading the Machine................................................................ 51 Transport........................................................................................ 51 Safety Measures During Maintenance....................................................................... 52 Personnel............................................................................................ 52 Prior to Start of Maintenance Measures............................................................... 52 Warning Sign..................................................................................... 52 Tools............................................................................................ 52 Safety-Related Parts............................................................................. 52 Prior to Start of Inspection and Maintenance................................................. 53 Securing the Articulated Steering............................................................ 53 Supporting the boom.......................................................................... 54 During Maintenance................................................................................... 55 Attachments...................................................................................... 55 Working Under the Machine........................................................................ 55 Keeping the Machine Clean........................................................................ 55 Specific Measures................................................................................ 55 Refueling and Topping Off Oil.................................................................... 56 Coolant.......................................................................................... 56 Use of Lighting.................................................................................. 57 High-Pressure Hoses.............................................................................. 57 Handling High-Pressure Oil....................................................................... 57 Handling of the pressure accumulator............................................................. 58 Fan and Belts.................................................................................... 58 Waste Material................................................................................... 58 Tires................................................................................................ 59 Storing Tires.................................................................................... 59 Labeling................................................................................................. 60 Position of Safety Labels............................................................................ 60 Information Labels................................................................................... 62 Controls and InDicators...................................................................................... 63 Overall View of Machine.................................................................................. 64 Controls and Indicators.................................................................................. 65 SWITCHES AND CONTROLS................................................................................ 66 Instrument Panel..................................................................................... 67 Warning Lights....................................................................................... 68 Control Lamps........................................................................................ 71 Measuring Indicators................................................................................. 75 Switches............................................................................................. 77 Control Levers, Pedals............................................................................... 84 Articulated Steering Catch........................................................................... 89 Traction Device...................................................................................... 89 Socket............................................................................................... 89 Door Unlocking System................................................................................ 90 Alarm Horn for Reverse Driving....................................................................... 90 Operation.................................................................................................... 91 Running in the Machine................................................................................... 92 Preparing the Machine Start.............................................................................. 93 Visual Checks........................................................................................ 93 Before you start the engine...................................................................... 93 Before starting working with the machine......................................................... 93 Adjustments Prior to Machine Start....................................................................... 95 Adjusting the Driver’s Seat.......................................................................... 95 Adjusting the Steering Column........................................................................ 96 Adjusting the Armrest................................................................................ 96 Adjusting the Rear-View Mirrors...................................................................... 96 Adjusting the Heating and Ventilation System......................................................... 97 Adjusting the ventilation system................................................................. 97 Adjusting the heating system..................................................................... 97 Putting on the Safety Belt........................................................................... 98 Putting on the safety belt....................................................................... 98 Taking off the safety belt....................................................................... 98 Starting and Switching Off the Engine.................................................................... 99 Starting the Engine.................................................................................. 99 Warming up the engine............................................................................100 Switching Off the Engine.............................................................................101 Driving..................................................................................................102 Start-Up.............................................................................................102 Starting the machine on slopes...................................................................103 Driving with the high-Speed gear.................................................................103 Changing the Driving Direction.......................................................................104 Reverse Driving......................................................................................105 Turning..............................................................................................105 Turning on slopes, embankments or hill flanks....................................................105 Braking..............................................................................................106 Pulling the parking brake........................................................................106 Releasing the parking brake......................................................................106 Braking with the service brake...................................................................106 If the service brake breaks down.................................................................106 Braking on slopes................................................................................107 Stopping.............................................................................................107 Parking the machine on a slope...................................................................107 Longer-Distance Driving..............................................................................108 Operating the Machine....................................................................................109 Preparing the Work Equipment.........................................................................109 Selecting a work unit............................................................................109 Picking up the work unit (except multi- purpose bucket)..........................................109 Removing the work unit...........................................................................110 Picking up the multi-purpose bucket..............................................................110 Removing the multi-purpose bucket................................................................112 Tire Service Life....................................................................................113 Level indicator for the bucket...................................................................113 Loading..............................................................................................114 Removing piled up soil...........................................................................114 Excavation works.................................................................................116 Transporting.........................................................................................117 Dumping / Unloading..................................................................................117 Loading in diagonal direction....................................................................117 V-shaped loading.................................................................................118 Piling up material...............................................................................118 Planing..............................................................................................119 Filling up.......................................................................................119 Taking off soil..............................................................................119 Cutting the Ground...........................................................................119 Working With the Forklift Truck Attachment...........................................................120 Picking up the load..............................................................................120 Precautions For Special Operations...................................................................121 Working in water.................................................................................121 Working on snow..................................................................................121 Dumping on steep slopes..........................................................................121 Working in the vicinity of electrical overhead lines.............................................121 Operation on slopes..............................................................................121 Working on loose soil............................................................................121 After the work is finished...........................................................................121 Instructions for Winter Operation....................................................................122 Before the cold season...........................................................................122 After Operation..................................................................................122 After the cold season............................................................................122 Longer Standstill Periods of the Machine.............................................................122 Before the standstill............................................................................122 During the standstill............................................................................123 After the standstill.............................................................................123 Troubleshooting..............................................................................................125 Troubleshooting..........................................................................................126 Warning Lights and Indicators........................................................................126 Electrical System....................................................................................127 Engine...............................................................................................128 Hydraulic system.....................................................................................131 Brakes...............................................................................................133 Axles................................................................................................134 driver’s cab.........................................................................................134 Emergency Steering Characteristics...................................................................135 Emergency Lowering System............................................................................135 Starting the Engine with Battery Jumper CableS.......................................................136 Connecting the Jumper CableS.....................................................................136 Starting the Engine..................................................................................137 Disconnecting the Battery Jumper CableS..........................................................137 Towing the Machine...................................................................................138 Towing a Machine with Defective Brakes...............................................................139 Maintenance..................................................................................................141 Maintenance Basics.......................................................................................142 Preparing the Machine for Maintenance................................................................142 Cleaning the Machine.................................................................................143 Precautionary Measures When Cleaning the Machine.................................................143 Fire Prevention..................................................................................143 Working-Area-Dependent Maintenance...................................................................143 Muddy or Wet Working Areas.......................................................................143 Dusty Working Areas..............................................................................143 Lubricants and Operating Agents......................................................................144 Draining Hot Lubricants and Fluids...............................................................144 Checking the Oil Level and Changing Oil..........................................................144 Changing Filters.................................................................................144 Refuelling and Topping off Oil...................................................................144 Oil..............................................................................................144 Lubricating Grease...............................................................................145 Biodegradable Hydraulic Oil and Lubricating Grease...............................................145 Fuel.............................................................................................145 Storage of Oil and Fuel..........................................................................145 Coolants.........................................................................................146 Windscreen Washer Liquid.........................................................................146 Table of Lubricants and Operating Agents.........................................................148 Lubrication chart................................................................................149 Axles................................................................................................150 Released axle oil brands.........................................................................150 Replacing Safety-Related Parts.......................................................................150 Welding Instructions.............................................................................150 Spare Parts and Consumable Components................................................................151 Electrical System....................................................................................152 Fuses............................................................................................152 Fuse Assignment..................................................................................152 Slow-Blow Fuses..................................................................................153 Tires................................................................................................154 Tire Components..................................................................................154 Checking the Tires...............................................................................154 Checking the Tire Pressure.......................................................................154 Torque for Standard Nuts and Bolts...................................................................156 Maintenance Schedule.....................................................................................158 Maintenance Prior to Start...............................................................................160 Visual Checks........................................................................................160 Cooling System, Checking the Coolant Level, Topping off Coolant......................................160 Engine, Checking the Oil Level, Topping off Oil......................................................161 Engine, Draining off Oil.............................................................................162 Checking the Fuel Level, Refueling...................................................................163 Checking the Controls................................................................................164 Checking the Parking Brake...........................................................................165 Test Conditions..................................................................................165 Test Procedure...................................................................................165 CHecking the Service Brake...........................................................................165 Checking the Electrical Connections..................................................................166 Heater / ventilation: check blower...................................................................166 Other Maintenance Measures Prior to Start............................................................166 Maintenance Every 10 Operating Hours.....................................................................167 Lubrication..........................................................................................167 Maintenance After the First 50 Operating Hours...........................................................168 Engine, Changing Oil and Replacing the Oil Filter Cartridge..........................................168 Replacing the Oil Filter Cartridge...............................................................169 V-Belt, Checking the Condition.......................................................................170 V-Belt, Checking and Adjusting the Tension...........................................................170 Hydraulic System, Replacing the Filter Insert........................................................171 Checking and Tightening the Wheel Nuts...............................................................172 Front and Rear Axle, Changing Oil....................................................................173 Planet gear......................................................................................173 Differential.....................................................................................173 Transfer Gear - Changing Oil.........................................................................174 Maintenance Every 50 Operating Hours.....................................................................175 Checking the cooling System, coolant level in the radiator and expansion tank........................175 Draining Off Water and Dirt Deposits From the Fuel Tank..............................................176 Checking the Service Brake and Oil Level, Refilling Oil..............................................176 Checking the Battery and Acid Level..................................................................177 Re-charging a built-in battery...................................................................178 Lubrication..........................................................................................179 Lubricating points of the work equipment.........................................................179 Maintenance Every 100 Operating Hours....................................................................180 Draining the Water Separator, Removing Water and Dirt Deposits.......................................180 Maintenance Every 250 Operating Hours....................................................................181 Changing the Engine Oil and Oil Filter Cartridge.....................................................181 Checking the V-Belt Condition........................................................................181 Checking and Adjusting the V-belt Tension............................................................181 Front and Rear Axle, Checking the Oil Level..........................................................182 Planet gear......................................................................................182 Differential.....................................................................................182 Air Filter, Removing and Re-Installing the Filter Insert, Checking and Cleaning the Filter Insert....183 Structure of the air filter......................................................................183 Maintenance demand...............................................................................183 Removing the filter cartridge....................................................................183 Cleaning or exchanging the filter cartridge..................................................184 Checking the filter cartridge....................................................................185 Assembling the air filter cartridge..............................................................185 Cleaning the Radiator Segments.......................................................................185 Lubrication..........................................................................................186 Maintenance Every 500 Operating Hours....................................................................187 Changing the Fuel Filter and Filter Element..........................................................187 Bleeding the Fuel System.........................................................................188 Changing the Filter Cartridge of the Hydraulic System................................................189 Cleaning the Water Separator.........................................................................189 Lubrication..........................................................................................190 Transfer Gear, Checking the Oil Level and Refilling Oil..............................................190 Air Filter, Replacing the Filter Insert, Replacing the Safety Filter.................................191 Replacing the Filter Insert......................................................................191 Replacing the Safety Filter......................................................................191 Heater / ventilation: cleaning / replacing blower filter.............................................192 Clean filter fleece..............................................................................192 Maintenance Every 1000 Operating Hours...................................................................193 Cooling System, Exchanging Coolant and Cleaning the System...........................................193 Draining off the coolant.........................................................................193 Cleaning the Cooling System......................................................................194 Filling off Coolant..............................................................................194 Front Axle, Oil Change...............................................................................195 Rear Axle, Oil Change................................................................................195 Transfer Gear, Oil Change............................................................................195 Service Brake........................................................................................195 Changing oil.....................................................................................195 Checking tubes and lines.........................................................................195 Checking the brake disks for wear and tear.......................................................195 Adjusting the clearance of the brake disks.......................................................195 Checking and Adjusting System Pressures..............................................................195 Checking and Adjusting the Valve clearance...........................................................195 Checking and Adjusting the Injection Nozzles, Nozzle Pressure and Fuel-Jet Pattern...................195 Checking the Accumulator Gas Pressure................................................................196 Maintenance Every 2000 Operating Hours...................................................................197 Hydraulic System, Oil Change.........................................................................197 Bleeding the Hydraulic Oil Tank......................................................................198 Cooling System, Checking the Antifreeze Content of the Coolant.......................................198 Checking the Cooling System..........................................................................198 Checking the Fuel Pump...............................................................................198 Checking the Fuel and Coolant Tubes, Replacing the Tubes (if required)...............................198 Checking the Water Pump..............................................................................199 Checking and Adjusting the Fuel Injection and Injection time.........................................199 Technical Data...............................................................................................201 Technical Data...........................................................................................202 Noise Emission Levels................................................................................203 Vibration Level......................................................................................203 Limit Values for Slopes..............................................................................204 Maximum slope angle for operating the machine....................................................204 Special Equipment and Attachments............................................................................205 ALS-Electronics..........................................................................................206 Structure and Functioning Principle of the ALS-Electronics...........................................206 PRECAUTIONARY MEASURES FOR SWITCHING ON THE ALS-ELECTRONICS..........................................206 Operation of the ALS-Electronics.....................................................................207 Switching on the ALS-Electronics.................................................................207 Switching off the ALS-Electronics................................................................207 Handling of the Pressure Accumulator.................................................................208
KOMATSU WA75-3 WHEEL LOADER OPERATION & MAINTENANCE MANUAL HA950318 AND UP – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu WA75-3 Wheel Loader Operation & Maintenance Manual
FOREWORD:
- This manual describes procedures for operation, handling, lubrication, maintenance, checking, and adjustment. It will help the operator and maintenance personnel realize peak performance through effective, economical and safe machine operation and maintenance.
- Keep this manual handy and have all personnel read it periodically. If this manual is lost or becomes dirty and can not be read, request a replacement manual from your local distributor. If you sell the machine, be sure to give this manual to the new owner.
- Continuing improvements in the design of this machine can lead to changes in detail, which may not be reflected in this manual. Consult your local distributor or Komatsu America International Company for the latest available information on your machine or for questions regarding information in this manual.
PLEASE NOTE:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
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