Komatsu WA90-5 Wheel Loader Operation and Maintenance Manual (H50051 and up) – PDF DOWNLOAD

Description

Komatsu WA90-5 Wheel Loader Operation and Maintenance Manual (H50051 and up)

FILE DETAILS:

Komatsu WA90-5 Wheel Loader Operation and Maintenance Manual

File Format : PDF
Language : English
Bookmarked : Yes
Searchable : Yes
Printable : Yes
Product Code : VEAM270101
Total Pages : 257

DESCRIPTION:

Komatsu WA90-5 Wheel Loader Operation and Maintenance Manual

FOREWORD:
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.

TABLE OF CONTENTS:

Komatsu WA90-5 Wheel Loader Operation and Maintenance Manual

1. Introduction..................................................................................................  2
	1.1. Foreword................................................................................................  3
		EU Directives............................................................................................  4
	1.2. Safety information......................................................................................  6
	1.3. Introduction............................................................................................  8
		1.3.1. Intended use......................................................................................  8
		1.3.2. Breaking-in the machine...........................................................................  9
	1.4. Location of plates...................................................................................... 10
		1.4.1. Machine identification plate...................................................................... 10
		1.4.2. Engine name-plate................................................................................. 10
		1.4.3. Axle serial no. plate............................................................................. 11
		1.4.4. Transmission serial no. plate..................................................................... 11
		1.4.5. ROPS/FOPS-Cab serial no. plate.................................................................... 11
		1.4.6. Operator’s seat serial no. plate.................................................................. 12
		1.4.7. Table to enter serial no. and distributor......................................................... 12
	1.5. Table of contents....................................................................................... 13
	1.6. Dimensions, weights and operating data.................................................................. 20
	1.7. CE-conforming equipment................................................................................. 21
		1.7.1. CE-conforming equipment - part 1.................................................................. 21
		1.7.2. CE-conforming equipment - part 2.................................................................. 22
		1.7.3. Manufacturer-supplied CE-conforming equipment..................................................... 23
	1.8. Loading and securing.................................................................................... 26
2. Safety........................................................................................................ 28
	2.1. General safety measures................................................................................. 29
		2.1.1. Safety instructions............................................................................... 29
		2.1.2. Safety devices.................................................................................... 29
		2.1.3. Emergency exit.................................................................................... 29
		2.1.4. Clothing and personal protection.................................................................. 30
		2.1.5. Machine modifications............................................................................. 30
		2.1.6. Before you leave the driver’s seat................................................................ 30
		2.1.7. Mounting and dismounting.......................................................................... 31
		2.1.8. Fire prevention and fire fighting................................................................. 31
		2.1.9. Protection against asbestos dust.................................................................. 32
		2.1.10. Protection against injuries...................................................................... 32
		2.1.11. Working at high temperatures..................................................................... 33
		2.1.12. Roll-over protection system (ROPS)............................................................... 33
		2.1.13. Attachment for protection against falling objects (FOPS)......................................... 33
		2.1.14. Attachments...................................................................................... 34
		2.1.15. Battery.......................................................................................... 34
	2.2. Safety precautions during operation..................................................................... 35
		2.2.1. Prior to daily starting up........................................................................ 35
			Workplace safety..................................................................................... 35
			In the driver's cab.................................................................................. 35
			Indoor operation..................................................................................... 36
			Gas, dust, and inflammable vapours................................................................... 36
			Mirrors, windows and lighting........................................................................ 36
		2.2.2. Machine operation................................................................................. 37
			Before you start the engine.......................................................................... 37
			Reversing............................................................................................ 37
			Driving.............................................................................................. 38
			Driving on slopes.................................................................................... 38
			Emergency Lowering System............................................................................ 39
			Working close to power lines......................................................................... 40
			Loading.............................................................................................. 41
			Good Vision.......................................................................................... 41
			Working on snow...................................................................................... 41
			Height limitation.................................................................................... 42
			Brakes............................................................................................... 42
			Working on loose soil................................................................................ 42
			Working with the forklift truck attachment........................................................... 42
			Parking the machine.................................................................................. 44
		2.2.3. Transport......................................................................................... 45
			Loading and unloading the machine.................................................................... 45
			Transport............................................................................................ 45
	2.3. Precautions for maintenance............................................................................. 46
		2.3.1. Personnel......................................................................................... 46
		2.3.2. Before carrying out maintenance................................................................... 46
		2.3.3. During maintenance................................................................................ 49
		2.3.4. Tyres............................................................................................. 53
	2.4. Safety labels on the machine............................................................................ 55
		2.4.1. Positions and order numbers of safety labels...................................................... 55
3. Operation..................................................................................................... 58
	3.1. General view............................................................................................ 59
		3.1.1. General view of the machine....................................................................... 59
		3.1.2. Controls and indicators........................................................................... 60
			Overall view......................................................................................... 60
			Switches, controls and warning lights................................................................ 61
	3.2. Description of the individual elements.................................................................. 62
		3.2.1. Instrument panel.................................................................................. 62
			Warning lights....................................................................................... 63
			Control lamps........................................................................................ 65
			Measuring indicators................................................................................. 70
		3.2.2. Switches.......................................................................................... 72
		3.2.3. Control levers and pedals......................................................................... 80
		3.2.4. Articulated steering locking...................................................................... 85
		3.2.5. Traction device................................................................................... 85
		3.2.6. Socket (12 V)..................................................................................... 86
		3.2.7. Door unlocking system............................................................................. 86
		3.2.8. Alarm horn for reverse driving - option........................................................... 86
		3.2.9. Fuses............................................................................................. 87
		3.2.10. Slow-blowing fuses............................................................................... 88
		3.2.11. Adjusting the heater and ventilation system...................................................... 89
		3.2.12. Air-conditioning................................................................................. 90
	3.3. Operation............................................................................................... 91
		3.3.1. Pre-start checks.................................................................................. 91
			Visual inspection.................................................................................... 91
			Pre-start checks..................................................................................... 93
			Adjustments prior to machine start................................................................... 98
			Adjusting the driver’s seat.......................................................................... 98
		3.3.2. Starting the engine...............................................................................102
			Warming up the engine................................................................................103
		3.3.3. Driving with the machine..........................................................................104
			Start-up.............................................................................................104
			Limiting the maximum speed...........................................................................105
		3.3.4. Changing the driving direction....................................................................107
		3.3.5. Turning and steering..............................................................................108
		3.3.6. Braking...........................................................................................109
		3.3.7. Stopping the machine..............................................................................111
		3.3.8. Operating the work equipment......................................................................112
			Multifunctional lever................................................................................112
			Control lever for special equipment..................................................................113
			Switching lever of bucket............................................................................114
		3.3.9. Working with the wheel loader.....................................................................115
			Tyre-appropriate operation...........................................................................115
			Switching on the 100 % differential lock (if equipped)...............................................115
			Loading work.........................................................................................116
			Removal work.........................................................................................116
			Excavation work......................................................................................118
			Planing..............................................................................................119
			Transporting.........................................................................................120
			Unloading............................................................................................120
			Working with the forklift truck attachment...........................................................121
		3.3.10. Precautions for special operations...............................................................123
			Permissible water depth..............................................................................123
			Working on snow......................................................................................123
			Dumping on steep slopes..............................................................................123
			Working in the vicinity of electrical overhead lines.................................................123
			Operation on slopes..................................................................................123
			Working on loose soil................................................................................123
			If the service brake breaks down.....................................................................123
			Precautionary measures when driving up or down.......................................................124
			Precautionary measures during machine travel.........................................................125
		3.3.11. Adjusting the position of the work equipment.....................................................126
			Selecting a work unit................................................................................126
			Removing the work unit...............................................................................128
			Picking up the multi-purpose bucket..................................................................129
			Removing the multi-purpose bucket....................................................................131
			Level indicator for the bucket.......................................................................131
		3.3.12. Parking the machine..............................................................................132
		3.3.13. Switching off the engine.........................................................................133
		3.3.14. Check after stopping the engine..................................................................133
		3.3.15. Locking..........................................................................................133
		3.3.16. Tyre handling....................................................................................134
			Precautionary measures when handling tyres...........................................................134
			Tyre pressure........................................................................................134
	3.4. Transporting the machine................................................................................136
		3.4.1. Securing the articulated steering.................................................................136
		3.4.2. Lifting the machine...............................................................................137
		3.4.3. Driving the machine onto loading area of transport vehicle........................................138
		3.4.4. Securing the machine during the transport.........................................................139
		3.4.5. After transport...................................................................................139
	3.5. Cold weather operation..................................................................................140
		3.5.1. Before the cold season............................................................................140
		3.5.2. Precautions after completion of work..............................................................141
		3.5.3. After the cold season.............................................................................141
	3.6. Long-term storage.......................................................................................142
		3.6.1. Before storage....................................................................................142
		3.6.2. During storage....................................................................................142
		3.6.3. After storage.....................................................................................143
4. Troubleshooting...............................................................................................144
	4.1. Towing the machine......................................................................................145
	4.2. Starting the engine with a booster cable................................................................149
	4.3. For insufficient braking effect.........................................................................151
		4.3.1. Checking the service brake........................................................................151
		4.3.2. Checking the parking brake function...............................................................151
	4.4. Emergency steering properties...........................................................................152
	4.5. Emergency lowering......................................................................................152
	4.6. Other troubles..........................................................................................153
		4.6.1. Electrical system.................................................................................153
		4.6.2. Engine............................................................................................154
		4.6.3. Hydraulic system..................................................................................157
		4.6.4. Brakes............................................................................................159
		4.6.5. Steering..........................................................................................159
		4.6.6. Axles.............................................................................................160
		4.6.7. Driver's cab......................................................................................160
5. Maintenance...................................................................................................162
	5.1. Maintenance guide.......................................................................................163
	5.2. Maintenance basics......................................................................................173
		5.2.1. Oil, fuel and coolant specifications..............................................................173
			Oil..................................................................................................173
			Fuel.................................................................................................174
			Coolant..............................................................................................175
			Grease...............................................................................................175
			Storing oil and fuel.................................................................................176
			Filters..............................................................................................176
			Biodegradable hydraulic oil and lubricants...........................................................176
		5.2.2. Specifications of the electrical system...........................................................177
		5.2.3. Wearing parts list................................................................................178
	5.3. Lubricants, fuels and filling capacities................................................................179
	5.4. Tools...................................................................................................180
		5.4.1. Introduction of recommended tools.................................................................180
	5.5. Periodical replacement of safety-critical parts.........................................................181
	5.6. Maintenance schedule chart..............................................................................182
	5.7. Service procedure.......................................................................................184
		5.7.1. Pre-start checklist...............................................................................184
			Cooling system - checking the coolant level, topping up coolant......................................184
			Cleaning the radiator segments.......................................................................185
			V-Belt, checking the condition.......................................................................185
			Engine, checking the oil level, topping up oil.......................................................186
			Checking the fuel level - refuelling.................................................................188
			Additional water separator (optional)................................................................189
			Water separator at the fuel filter - Draining water and dirt sediments...............................189
			Checking the controls................................................................................190
			Checking the electrical connections..................................................................190
			Heater/air conditioning - checking rate of air flow..................................................191
			Miscellaneous tests before starting work.............................................................191
		5.7.2. Maintenance upon demand...........................................................................192
			Checking the air-conditioning system.................................................................192
			Checking the window washing-fluid level, adding fluid................................................193
			Re-charging a built-in battery.......................................................................194
		5.7.3. Maintenance after the first 50 operating hours....................................................195
			Hydraulic system, replacing the filter insert........................................................195
			Checking and tightening the wheel nuts...............................................................196
		5.7.4. Maintenance after the first 250 operating hours...................................................197
			Front and rear axle - oil change.....................................................................197
			Transfer box - changing oil..........................................................................198
			Checking and adjusting the valve clearance...........................................................199
		5.7.5. Maintenance every 10 operating hours..............................................................199
			Lubrication of articulated steering..................................................................199
		5.7.6. Maintenance every 50 operating hours..............................................................200
			Battery - checking the acid level....................................................................200
			Lubrication of work unit.............................................................................201
		5.7.7. Maintenance every 250 operating hours.............................................................202
			Service brake - Checking the brake pads..............................................................202
			V-Belt, generator - checking and adjusting the tension...............................................202
			Air filter, removing and re-installing the filter insert, checking and cleaning the filter insert....204
			Lubrication, steering cylinder.......................................................................207
			Lubrication, self-aligning bearings of rear axle.....................................................208
			Checking and tightening the wheel nuts...............................................................209
		5.7.8. Maintenance every 500 operating hours.............................................................210
			Hand pump - Checking the oil level...................................................................210
			Service brake - Checking the brake pads and brake discs, checking the oil level......................210
			Engine - changing oil................................................................................212
			Replacing the oil filter cartridge...................................................................213
			Changing the fuel filter element.....................................................................214
			Bleeding the fuel system.............................................................................215
			Bleeding the low pressure side:......................................................................215
			Bleeding the high pressure side:.....................................................................215
			Air filter, replacing the filter insert, replacing the safety filter.................................216
			Heater/air conditioning - cleaning/replacing filter fleece...........................................217
			Multi-functional lever accumulator - checking gas pressure...........................................218
			E.C.S.S.-pressure accumulator (Option) - checking gas pressure.......................................218
			Front and rear axle - checking the oil level.........................................................219
			Transfer box - checking and refilling oil............................................................220
		5.7.9. Maintenance every 1000 operating hours............................................................221
			V-Belt, generator - checking and adjusting the tension...............................................221
			Service Brake - Checking and refilling oil...........................................................221
			Checking and adjusting system pressures..............................................................221
			Hydraulic - Exchanging the venting filter............................................................222
			Hydraulic system, replacing the filter insert........................................................223
		5.7.10. Maintenance every 1500 operating hours...........................................................224
			Front and rear axle - changing oil...................................................................224
			Transfer box - changing oil..........................................................................225
		5.7.11. Maintenance every 2000 operating hours...........................................................226
			Cooling system - exchanging coolant and cleaning the system..........................................226
			Checking and adjusting the valve clearance...........................................................228
			Hydraulic system - changing oil......................................................................229
			Ventilating the hydraulic oil tank...................................................................230
			Checking the fuel pump...............................................................................231
			Checking the fuel and coolant tubes, replacing the tubes (if required)...............................231
			Checking the water pump..............................................................................231
		5.7.12. Maintenance every 4000 operating hours...........................................................232
			Lubrication, drive shaft.............................................................................232
6. Technical data................................................................................................234
	6.1. Technical data..........................................................................................235
	6.2. Noise emission levels...................................................................................236
	6.3. Vibration levels........................................................................................236
		Operating condition......................................................................................236
		Guide to Reduce Vibration Levels on Machine..............................................................236
	6.4. Limit values for slopes.................................................................................238
7. Special equipment and attachments.............................................................................240
	7.1. E.C.S.S-electronics.....................................................................................241
		7.1.1. Structure and functioning principle of the E.C.S.S-electronics....................................241
		7.1.2. Precautionary measures for switching on the E.C.S.S-electronics...................................241
		7.1.3. Operating the E.C.S.S-electronics.................................................................242
			Switching ON the E.C.S.S.-electronics................................................................242
			Switching OFF the E.C.S.S-electronics................................................................242
		7.1.4. Precautions when handling the accumulator.........................................................243
	7.2. Bucket position indicator...............................................................................244
8. Index.........................................................................................................246
9. Notes.........................................................................................................252

KOMATSU WA90-5 WHEEL LOADER OPERATION AND MAINTENANCE MANUAL (H50051 AND UP) – PDF DOWNLOAD:

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