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KOMATSU WA95-3 WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:H20672 and up) KOMATSU WA95-3 – PDF DOWNLOAD
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- KOMATSU WA95-3 WHEEL LOADER OPERATION & MAINTENANCE MANUAL
- PUBLICATION NUMBER:VEAM980800
- SERIAL NUMBER:H20672 and up
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Description
KOMATSU WA95-3 WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:H20672 and up) KOMATSU WA95-3
KOMATSU WA95-3 WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:H20672 AND UP) KOMATSU WA95-3 – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU WA95-3 WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:H20672 and up) KOMATSU WA95-3
- 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
TABLE OF CONTENTS:
KOMATSU WA95-3 WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:H20672 and up) KOMATSU WA95-3
Table of Contents.................................................................................. 5 Introduction................................................................................... 5 Forword 1-2.................................................................................... 5 Safety Information 1-3......................................................................... 5 Introduction 1-5............................................................................... 5 Features 1-5............................................................................... 5 Breaking in a New Machine 1-5.............................................................. 5 Location of Plates, Table to Enter Serial No. and Distributor 1-6............................. 5 Machine Serial No. Plate position 1-6...................................................... 5 Engine Serial No. Plate Position 1-6....................................................... 5 Table to Enter Serial No. and Distributor 1-6.............................................. 5 EMISSION CONTROL WARRANTY 1-7.................................................................. 5 EMISSION CONTROL WARRANTY STATEMENT (APPLIES TO CANADA ONLY) 1-7........................... 5 Engine Data Plate 1-8.......................................................................... 5 GARANTIE SUR LE CONTRÔLE DES ÉMISSIONS 1-9..................................................... 5 ÉNONCÉ DE GARANTIE SUR LE CONTRÔLE DES ÉMISSIONS (APPLICABLE AU CANADA SEULEMENT): 1-9.... 5 Engine Data Plate 1-11......................................................................... 5 Why You Should Read these Operating Instructions 1-12.......................................... 5 Notes on Safety Regulations 1-14............................................................... 5 Correct Use 1-14........................................................................... 5 Safety Notes in the Operating Instructions 1-14............................................ 5 Equipment 1-15................................................................................. 5 Loading and Transporting the Machine..................................................... 5 Loading and Transporting the Machine 2-2....................................................... 5 Securing the Articulated Steering 2-2...................................................... 5 Lifting the Machine 2-2.................................................................... 5 Driving Machine Onto Loading Area of Transport Vehicle 2-4................................. 5 Securing the Machine During Transport 2-5.................................................. 5 After Transport 2-5........................................................................ 5 Safety..................................................................................... 5 General Safety Measures 3-3.................................................................... 5 Safety Instructions 3-3.................................................................... 5 Safety Devices 3-3......................................................................... 5 Emergency Exit 3-3......................................................................... 5 Clothing and Personal Protection 3-4....................................................... 5 Machine Modifications 3-4.................................................................. 5 Before You Leave the Driver's Seat 3-4..................................................... 5 Mounting and Dismounting 3-5............................................................... 5 Fire Prevention and Fire Fighting 3-6...................................................... 5 Fire Extinguisher and First-Aid Kit 3-7.................................................... 5 Protection Against Asbestos Dust 3-7....................................................... 5 Protection Against Injuries 3-8............................................................ 5 Working at High Temperatures 3-8........................................................... 5 Roll-Over Protection System (ROPS) 3-9..................................................... 5 Attachment for Protection Against Falling Objects (FOPS) 3-9............................... 5 Attachments 3-9............................................................................ 5 Battery 3-10............................................................................... 5 Safety Measures during Operation 3-11.......................................................... 5 Before You Start the Engine 3-11........................................................... 5 Workplace Safety 3-11.................................................................. 6 In the Driver's Cab 3-11............................................................... 6 In-Door Operation 3-12................................................................. 6 Gas, Dust, and Inflammable Vapours 3-12................................................ 6 Mirrors, Windows, and Lighting 3-12.................................................... 6 Machine Operation 3-13..................................................................... 6 Before You Start the Engine 3-13....................................................... 6 Reversing 3-13......................................................................... 6 Driving 3-14........................................................................... 6 Driving On Slopes 3-14................................................................. 6 Emergency Lowering System 3-15......................................................... 6 Working Close to Overhead Power Transmission Lines 3-15................................ 6 Loading 3-16........................................................................... 6 Good Vision 3-16....................................................................... 6 Working On Snow 3-16................................................................... 6 Height Limitation 3-17................................................................. 6 Brakes 3-17............................................................................ 6 Working On Loose Soil 3-17............................................................. 6 Working with the Forklift Truck Attachment 3-18....................................... 6 Parking the Machine 3-19............................................................... 6 Transport 3-20............................................................................. 6 Loading and Unloading the Machine 3-20................................................. 6 Transport 3-21......................................................................... 6 Safety Measures During Maintenance 3-22........................................................ 6 Personnel 3-22............................................................................. 6 Prior to Start of Maintenance Measures 3-22................................................ 6 Warning Sign 3-22...................................................................... 6 Tools 3-22............................................................................. 6 Safety-Related Parts 3-22.............................................................. 6 Prior to Start of Inspection and Maintenance 3-23..................................... 6 Securing the Articulated Steering 3-23................................................. 6 Supporting the boom 3-24............................................................... 6 During Maintenance 3-25.................................................................... 6 Attachments 3-25....................................................................... 6 Working Under the Machine 3-25......................................................... 6 Keeping the Machine Clean 3-25......................................................... 6 Specific Measures 3-25................................................................. 6 Refueling and Topping Off Oil 3-26..................................................... 6 Coolant 3-26........................................................................... 6 Use of Lighting 3-27................................................................... 6 High-Pressure Hoses 3-27............................................................... 6 Handling High-Pressure Oil 3-27........................................................ 6 Handling of the pressure accumulator 3-28.............................................. 6 Fan and Belts 3-28..................................................................... 6 Waste Material 3-28.................................................................... 6 Tires 3-29................................................................................. 6 Storing Tires 3-30..................................................................... 6 Labeling 3-31.................................................................................. 6 Position of Safety Labels 3-31............................................................. 6 Information Labels 3-33.................................................................... 6 Controls and InDicators................................................................... 6 Overall View of Machine 4-2.................................................................... 6 Controls and Indicators 4-3.................................................................... 6 SWITCHES AND CONTROLS 4-4.................................................................. 6 Instrument Panel 4-5....................................................................... 6 Warning Lights 4-6......................................................................... 6 Control Lamps 4-9.......................................................................... 6 Measuring Indicators 4-13.................................................................. 7 Switches 4-15.............................................................................. 7 Control Levers, Pedals 4-22................................................................ 7 Articulated Steering Catch 4-28............................................................ 7 Traction Device 4-28....................................................................... 7 Socket 4-28................................................................................ 7 Door Unlocking System 4-29................................................................. 7 Alarm Horn for Reverse Driving 4-29........................................................ 7 Operation.................................................................................. 7 Running in the Machine 5-2..................................................................... 7 Preparing the Machine Start 5-3................................................................ 7 Visual Checks 5-3.......................................................................... 7 Before you start the engine 5-3........................................................ 7 Before starting working with the machine 5-3.......................................... 7 Adjustments Prior to Machine Start 5-6......................................................... 7 Adjusting the Driver’s Seat 5-6............................................................ 7 Adjusting the Steering Column 5-7.......................................................... 7 Adjusting the Armrest 5-7.................................................................. 7 Adjusting the Rear-View Mirrors 5-7........................................................ 7 Adjusting the Heating and Ventilation System 5-8........................................... 7 Adjusting the ventilation system 5-8................................................... 7 Adjusting the heating system 5-9....................................................... 7 Operating the Air Conditioning 5-10........................................................ 7 Switching on the air-conditioning 5-10................................................. 7 Putting on the Safety Belt 5-12............................................................ 7 Putting on the safety belt 5-12........................................................ 7 Taking off the safety belt 5-12........................................................ 7 Starting and Switching Off the Engine 5-13..................................................... 7 Starting the Engine 5-13................................................................... 7 Warming up the engine 5-14................................................................. 7 Switching Off the Engine 5-15.............................................................. 7 Driving 5-16................................................................................... 7 Start-Up 5-16.............................................................................. 7 Starting the machine on slopes 5-18.................................................... 7 Driving with the high-Speed gear 5-18.................................................. 7 Changing the Driving Direction 5-19........................................................ 7 Reverse Driving 5-20....................................................................... 7 Turning 5-20............................................................................... 7 Turning on slopes, embankments or hill flanks 5-20..................................... 7 Braking 5-21................................................................................... 7 Pulling the parking brake 5-21............................................................. 7 Releasing the parking brake 5-21....................................................... 7 Braking with the service brake 5-21.................................................... 7 If the service brake breaks down 5-22.................................................. 7 Braking on slopes 5-22................................................................. 7 Stopping 5-23.............................................................................. 7 Parking the machine on a slope 5-23.................................................... 7 Longer-Distance Driving 5-24............................................................... 7 Operating the Machine 5-25..................................................................... 7 Preparing the Work Equipment 5-25.......................................................... 7 Selecting a work unit 5-25............................................................. 7 Picking up the work unit (except multi-purpose bucket) 5-25............................ 7 Removing the work unit 5-26............................................................ 7 Picking up the multi-purpose bucket 5-26............................................... 7 Removing the multi-purpose bucket 5-28................................................. 7 Tire Service Life 5-29..................................................................... 7 Level indicator for the bucket 5-29........................................................ 8 Adjusting the Bucket Positioner 5-30....................................................... 8 Loading 5-31............................................................................... 8 Removing piled up soil 5-31............................................................ 8 Excavation works 5-33.................................................................. 8 Transporting 5-34.......................................................................... 8 Dumping / Unloading 5-34................................................................... 8 Loading in diagonal direction 5-34..................................................... 8 V-shaped loading 5-35.................................................................. 8 Piling up material 5-35................................................................ 8 Planing 5-36............................................................................... 8 Filling up 5-36........................................................................ 8 Taking off soil 5-36................................................................... 8 Cutting the Ground 5-37................................................................ 8 Working With the Forklift Truck Attachment 5-38............................................ 8 Picking up the load 5-38............................................................... 8 Precautions For Special Operations 5-39.................................................... 8 Working in water 5-39.................................................................. 8 Working on snow 5-39................................................................... 8 Dumping on steep slopes 5-39........................................................... 8 Working in the vicinity of electrical overhead lines 5-39.............................. 8 Operation on slopes 5-39............................................................... 8 Working on loose soil 5-39............................................................. 8 After the work is finished 5-39............................................................ 8 Instructions for Winter Operation 5-40......................................................... 8 Before the cold season 5-40................................................................ 8 After Operation 5-40....................................................................... 8 After the cold season 5-41................................................................. 8 Longer Standstill Periods of the Machine 5-42.............................................. 8 Before the standstill 5-42............................................................. 8 During the standstill 5-42............................................................. 8 After the standstill 5-43.............................................................. 8 Troubleshooting............................................................................ 8 Troubleshooting 6-2............................................................................ 8 Warning Lights and Indicators 6-2.......................................................... 8 Electrical System 6-3...................................................................... 8 Engine 6-4................................................................................. 8 Hydraulic system 6-7....................................................................... 8 Brakes 6-9................................................................................. 8 Axles 6-10................................................................................. 8 driver’s cab 6-10.......................................................................... 8 Emergency Steering Characteristics 6-11.................................................... 8 Emergency Lowering System 6-11............................................................. 8 Starting the Engine with a Battery Jumper Cable 6-12....................................... 8 Connecting the Jumper Cable 6-12....................................................... 8 Starting the Engine 6-13............................................................... 8 Disconnecting the Battery Jumper Cable 6-13........................................... 8 Towing the Machine 6-14.................................................................... 8 Towing a Machine with Defective Brakes 6-15............................................ 8 Inadequate Braking Effect 6-16............................................................. 8 Checking the Parking Brake 6-16........................................................ 8 Checking the Service Brake 6-17........................................................ 8 Maintenance................................................................................ 8 Maintenance Basics 7-2......................................................................... 8 Preparing the Machine for Maintenance 7-2.................................................. 8 Cleaning the Machine 7-3................................................................... 8 Precautionary Measures When Cleaning the Machine 7-3................................... 9 Fire Prevention 7-3.................................................................... 9 Working-Area-Dependent Maintenance 7-4..................................................... 9 Muddy or Wet Working Areas 7-4......................................................... 9 Dusty Working Areas 7-4................................................................ 9 Lubricants and Operating Agents 7-5........................................................ 9 Draining Hot Lubricants and Fluids 7-5................................................. 9 Checking the Oil Level and Changing Oil 7-5............................................ 9 Changing Filters 7-5................................................................... 9 Refuelling and Topping off Oil 7-5..................................................... 9 Oil 7-6................................................................................ 9 Lubricating Grease 7-6................................................................. 9 Biodegradable Hydraulic Oil and Lubricating Grease 7-6................................. 9 Fuel 7-7............................................................................... 9 Storage of Oil and Fuel 7-7............................................................ 9 Coolants 7-8........................................................................... 9 Windscreen Washer Liquid 7-8........................................................... 9 Table of Lubricants and Operating Agents 7-10.......................................... 9 Lubrication chart 7-11................................................................. 9 Axles 7-12................................................................................. 9 Released axle oil brands 7-12.......................................................... 9 Replacing Safety-Related Parts 7-12........................................................ 9 Welding Instructions 7-13.................................................................. 9 Spare Parts and Consumable Components 7-14................................................. 9 Electrical System 7-15..................................................................... 9 Fuses 7-16............................................................................. 9 Fuse Assignment 7-16................................................................... 9 Slow-Blowing Fuses 7-17................................................................ 9 Tires 7-18................................................................................. 9 Tire Components 7-18................................................................... 9 Checking the Tires 7-18................................................................ 9 Checking the Tire Pressure 7-18........................................................ 9 Torque for Standard Nuts and Bolts 7-20.................................................... 9 Maintenance Schedule 7-22...................................................................... 9 Maintenance Prior to Start 7-24................................................................ 9 Visual Checks 7-24......................................................................... 9 Cooling System, Checking the Coolant Level, Topping off Coolant 7-24....................... 9 Engine, Checking the Oil Level, Topping off Oil 7-25....................................... 9 Engine, Draining off Oil 7-26.............................................................. 9 Checking the Fuel Level, Refueling 7-27.................................................... 9 Checking the Controls 7-28................................................................. 9 Checking the Electrical Connections 7-28................................................... 9 Heater / air conditioning: checking rate of air flow 7-29.................................. 9 Other Maintenance Measures Prior to Start 7-29............................................. 9 Maintenance upon demand 7-30................................................................... 9 Checking the air-conditioning system 7-30.................................................. 9 Checking the coolant level 7-30........................................................ 9 Maintenance Every 10 Operating Hours 7-31...................................................... 9 Lubrication 7-31........................................................................... 9 Maintenance After the First 50 Operating Hours 7-32............................................ 9 Engine, Changing Oil and Replacing the Oil Filter Cartridge 7-32........................... 9 Replacing the Oil Filter Cartridge 7-33................................................ 9 V-Belt, Checking the Condition 7-34........................................................ 9 V-Belt, Checking and Adjusting the Tension 7-34............................................ 9 Hydraulic System, Replacing the Filter Insert 7-35......................................... 9 Checking and Tightening the Wheel Nuts 7-36................................................ 9 Front and Rear Axle, Changing Oil 7-37..................................................... 9 Planet gear 7-37....................................................................... 10 Differential 7-37...................................................................... 10 Transfer Gear - Changing Oil 7-38.......................................................... 10 Maintenance Every 50 Operating Hours 7-40...................................................... 10 Checking cooling System, coolant level in the radiator and expansion tank 7-40............. 10 Draining Off Water and Dirt Deposits From the Fuel Tank 7-41............................... 10 Checking the Service Brake and Oil Level, Refilling Oil 7-41............................... 10 Checking the Battery and Acid Level 7-42................................................... 10 Re-charging a built-in battery 7-43.................................................... 10 Lubrication 7-44........................................................................... 10 Lubricating points of the work equipment 7-44......................................... 10 Maintenance Every 100 Operating Hours 7-45..................................................... 10 Draining the Water Separator, Removing Water and Dirt Deposits 7-45........................ 10 Maintenance Every 250 Operating Hours 7-46..................................................... 10 Changing the Engine Oil and Oil Filter Cartridge 7-46...................................... 10 Checking the V-Belt Condition 7-46......................................................... 10 Checking and Adjusting the V-belt Tension 7-46............................................. 10 Front and Rear Axle, Checking the Oil Level 7-47........................................... 10 Planet gear 7-47....................................................................... 10 differential 7-48...................................................................... 10 Air Filter, Removing/Re-Installing AND Checking/Cleaning the Filter Insert 7-49............ 10 Structure of the air filter 7-49....................................................... 10 Maintenance demand 7-49................................................................ 10 Removing the filter cartridge 7-49..................................................... 10 Cleaning or exchanging the filter cartridge 7-50....................................... 10 Checking the filter cartridge 7-51..................................................... 10 Assembling the air filter cartridge 7-51............................................... 10 Cleaning the Radiator Segments 7-51........................................................ 10 Lubrication 7-52........................................................................... 10 Maintenance Every 500 Operating Hours 7-53..................................................... 10 Changing the Fuel Filter and Filter Element 7-53........................................... 10 Bleeding the Fuel System 7-54.......................................................... 10 Changing the Filter Cartridge of the Hydraulic System 7-55................................. 10 Cleaning the Water Separator 7-55.......................................................... 10 Lubrication 7-56........................................................................... 10 Transfer Gear, Checking the Oil Level and Refilling Oil 7-56............................... 10 Air Filter, Replacing the Filter Insert, Replacing the Safety Filter 7-57.................. 10 Replacing the Filter Insert 7-57....................................................... 10 Replacing the Safety Filter 7-57....................................................... 10 Heater/air conditioning: clean filter fleece of heater unit 7-58........................... 10 Heater/air conditioning: Cleaning the condenser 7-59....................................... 10 ECSS-Pressure Accumulator (Option): Checking the Gas Pressure 7-59......................... 10 Maintenance Every 1000 Operating Hours 7-60.................................................... 10 Cooling System, Exchanging Coolant and Cleaning the System 7-60........................... 10 Draining off the coolant 7-61.......................................................... 10 Cleaning the Cooling System 7-61....................................................... 10 Filling off Coolant 7-61............................................................... 10 Front Axle, Oil Change 7-62................................................................ 10 Rear Axle, Oil Change 7-62................................................................. 10 Transfer Gear, Oil Change 7-62............................................................. 10 Service Brake 7-62......................................................................... 10 Changing oil 7-62...................................................................... 10 Checking tubes and lines 7-62.......................................................... 10 Checking the brake disks for wear and tear 7-62........................................ 10 Adjusting the clearance of the brake disks 7-62........................................ 10 Checking and Adjusting System Pressures 7-62............................................... 10 Checking and Adjusting the Valve clearance 7-62............................................ 10 Checking/Adjusting the Injection Nozzles, Nozzle Pressure/Fuel-Jet Pattern 7-63............ 11 Checking the Accumulator Gas Pressure OF THIRD CONTROL CIRCUIT 7-63........................ 11 Checking the tightening parts of the Turbo-charger 7-63.................................... 11 Checking the gap of the Turbo-charger rotor 7-63........................................... 11 Maintenance Every 2000 Operating Hours 7-64.................................................... 11 Hydraulic System, Oil Change 7-64.......................................................... 11 Bleeding the Hydraulic Oil Tank 7-65....................................................... 11 Cooling System, Checking the Antifreeze Content of the Coolant 7-65........................ 11 Checking the Cooling System 7-65........................................................... 11 Checking the Fuel Pump 7-65................................................................ 11 Checking the Fuel and Coolant Tubes, Replacing the Tubes (if required) 7-65................ 11 Checking the Water Pump 7-66............................................................... 11 Checking and Adjusting the Fuel Injection and Injection time 7-66.......................... 11 Technical Data............................................................................. 11 Technical Data 8-2............................................................................. 11 Noise Emission Levels 8-3.................................................................. 11 Vibration Level 8-3........................................................................ 11 Limit Values for Slopes 8-4................................................................ 11 Maximum slope angle for operating the machine 8-4...................................... 11 Tilt angle 8-4......................................................................... 11 special equipment and attachments.......................................................... 11 ECSS 9-2....................................................................................... 11 Structure and Functioning Principle of the ECSS 9-2........................................ 11 Precautionary Measures for Switching on the ECSS 9-2...................................... 11 Operation of the ECSS 9-3.................................................................. 11 Switching on the ECSS 9-3.............................................................. 11 Switching off the ECSS 9-3............................................................. 11 Handling of the Pressure Accumulator 9-4................................................... 11 Index...................................................................................... 11 Introduction....................................................................................... 13 Forword........................................................................................ 14 Safety Information............................................................................. 15 Introduction................................................................................... 17 Features................................................................................... 17 Breaking in a New Machine.................................................................. 17 Location of Plates, Table to Enter Serial No. and Distributor................................. 18 Machine Serial No. Plate position.......................................................... 18 Engine Serial No. Plate Position........................................................... 18 Table to Enter Serial No. and Distributor.................................................. 18 EMISSION CONTROL WARRANTY...................................................................... 19 EMISSION CONTROL WARRANTY STATEMENT (APPLIES TO CANADA ONLY)............................... 19 Engine Data Plate.............................................................................. 20 GARANTIE SUR LE CONTRÔLE DES ÉMISSIONS......................................................... 21 ÉNONCÉ DE GARANTIE SUR LE CONTRÔLE DES ÉMISSIONS (APPLICABLE AU CANADA SEULEMENT):........ 21 Engine Data Plate.............................................................................. 23 Why You Should Read these Operating Instructions............................................... 24 Notes on Safety Regulations.................................................................... 26 Correct Use................................................................................ 26 Safety Notes in the Operating Instructions................................................. 26 Equipment...................................................................................... 27 Loading and Transporting the Machine............................................................. 29 Loading and Transporting the Machine........................................................... 30 Securing the Articulated Steering.......................................................... 30 Lifting the Machine........................................................................ 30 Driving Machine Onto Loading Area of Transport Vehicle..................................... 32 Securing the Machine During Transport...................................................... 33 After Transport............................................................................ 33 Safety............................................................................................. 35 General Safety Measures........................................................................ 37 Safety Instructions........................................................................ 37 Safety Devices............................................................................. 37 Emergency Exit............................................................................. 37 Clothing and Personal Protection........................................................... 38 Machine Modifications...................................................................... 38 Before You Leave the Driver's Seat......................................................... 38 Mounting and Dismounting................................................................... 39 Fire Prevention and Fire Fighting.......................................................... 40 Fire Extinguisher and First-Aid Kit........................................................ 41 Protection Against Asbestos Dust........................................................... 41 Protection Against Injuries................................................................ 42 Working at High Temperatures............................................................... 42 Roll-Over Protection System (ROPS)......................................................... 43 Attachment for Protection Against Falling Objects (FOPS)................................... 43 Attachments................................................................................ 43 Battery.................................................................................... 44 Safety Measures during Operation............................................................... 45 Before You Start the Engine................................................................ 45 Machine Operation.......................................................................... 47 Transport.................................................................................. 54 Safety Measures During Maintenance............................................................. 56 Personnel.................................................................................. 56 Prior to Start of Maintenance Measures..................................................... 56 During Maintenance......................................................................... 59 Tires...................................................................................... 63 Labeling....................................................................................... 65 Position of Safety Labels.................................................................. 65 Information Labels......................................................................... 67 Controls and InDicators........................................................................... 69 Overall View of Machine........................................................................ 70 Controls and Indicators........................................................................ 71 Control Lamps.............................................................................. 77 Measuring Indicators....................................................................... 81 Switches................................................................................... 83 Control Levers, Pedals..................................................................... 90 Articulated Steering Catch................................................................. 96 Traction Device............................................................................ 96 Socket..................................................................................... 96 Door Unlocking System...................................................................... 97 Alarm Horn for Reverse Driving............................................................. 97 Operation.......................................................................................... 99 Running in the Machine.........................................................................100 Preparing the Machine Start....................................................................101 Visual Checks..............................................................................101 Adjustments Prior to Machine Start.............................................................104 Adjusting the Driver’s Seat................................................................104 Adjusting the Steering Column..............................................................105 Adjusting the Armrest......................................................................105 Adjusting the Rear-View Mirrors............................................................105 Adjusting the Heating and Ventilation System...............................................106 Operating the Air Conditioning.............................................................108 Putting on the Safety Belt.................................................................110 Starting and Switching Off the Engine..........................................................111 Starting the Engine........................................................................111 Warming up the engine......................................................................112 Switching Off the Engine...................................................................113 Driving........................................................................................114 Start-Up...................................................................................114 Changing the Driving Direction.............................................................117 Reverse Driving............................................................................118 Turning....................................................................................118 Braking........................................................................................119 Pulling the parking brake..................................................................119 Stopping...................................................................................121 Longer-Distance Driving....................................................................122 Operating the Machine..........................................................................123 Preparing the Work Equipment...............................................................123 Tire Service Life..........................................................................127 Level indicator for the bucket.............................................................127 Adjusting the Bucket Positioner............................................................128 Loading....................................................................................129 Transporting...............................................................................132 Dumping / Unloading........................................................................132 Planing....................................................................................134 Working With the Forklift Truck Attachment.................................................136 Precautions For Special Operations.........................................................137 After the work is finished.................................................................137 Instructions for Winter Operation..............................................................138 Longer Standstill Periods of the Machine...................................................140 Troubleshooting....................................................................................143 Troubleshooting................................................................................144 Warning Lights and Indicators..............................................................144 Electrical System..........................................................................145 Engine.....................................................................................146 Hydraulic system...........................................................................149 Brakes.....................................................................................151 Axles......................................................................................152 driver’s cab...............................................................................152 Emergency Steering Characteristics.........................................................153 Emergency Lowering System..................................................................153 Starting the Engine with a Battery Jumper Cable............................................154 Towing the Machine.........................................................................156 Inadequate Braking Effect..................................................................158 Maintenance........................................................................................161 Maintenance Basics.............................................................................162 Preparing the Machine for Maintenance......................................................162 Cleaning the Machine.......................................................................163 Working-Area-Dependent Maintenance.........................................................164 Lubricants and Operating Agents............................................................165 Axles......................................................................................172 Replacing Safety-Related Parts.............................................................172 Welding Instructions.......................................................................173 Spare Parts and Consumable Components......................................................174 Electrical System..........................................................................175 Tires......................................................................................178 Torque for Standard Nuts and Bolts.........................................................180 Maintenance Schedule...........................................................................182 Maintenance Prior to Start.....................................................................184 Visual Checks..............................................................................184 Cooling System, Checking the Coolant Level, Topping off Coolant............................184 Engine, Checking the Oil Level, Topping off Oil............................................185 Engine, Draining off Oil...................................................................186 Checking the Fuel Level, Refueling.........................................................187 Checking the Controls......................................................................188 Checking the Electrical Connections........................................................188 Heater / air conditioning: checking rate of air flow.......................................189 Other Maintenance Measures Prior to Start..................................................189 Maintenance upon demand........................................................................190 Checking the air-conditioning system.......................................................190 Maintenance Every 10 Operating Hours...........................................................191 Lubrication................................................................................191 Maintenance After the First 50 Operating Hours.................................................192 Engine, Changing Oil and Replacing the Oil Filter Cartridge................................192 V-Belt, Checking the Condition.............................................................194 V-Belt, Checking and Adjusting the Tension.................................................194 Hydraulic System, Replacing the Filter Insert..............................................195 Checking and Tightening the Wheel Nuts.....................................................196 Front and Rear Axle, Changing Oil..........................................................197 Transfer Gear - Changing Oil...............................................................198 Maintenance Every 50 Operating Hours...........................................................200 Checking cooling System, coolant level in the radiator and expansion tank..................200 Draining Off Water and Dirt Deposits From the Fuel Tank....................................201 Checking the Service Brake and Oil Level, Refilling Oil....................................201 Checking the Battery and Acid Level........................................................202 Lubrication................................................................................204 Maintenance Every 100 Operating Hours..........................................................205 Draining the Water Separator, Removing Water and Dirt Deposits.............................205 Maintenance Every 250 Operating Hours..........................................................206 Changing the Engine Oil and Oil Filter Cartridge...........................................206 Checking the V-Belt Condition..............................................................206 Checking and Adjusting the V-belt Tension..................................................206 Front and Rear Axle, Checking the Oil Level................................................207 Air Filter, Removing/Re-Installing AND Checking/Cleaning the Filter Insert.................209 Cleaning the Radiator Segments.............................................................211 Lubrication................................................................................212 Maintenance Every 500 Operating Hours..........................................................213 Changing the Fuel Filter and Filter Element................................................213 Changing the Filter Cartridge of the Hydraulic System......................................215 Cleaning the Water Separator...............................................................215 Lubrication................................................................................216 Transfer Gear, Checking the Oil Level and Refilling Oil....................................216 Air Filter, Replacing the Filter Insert, Replacing the Safety Filter.......................217 Heater/air conditioning: clean filter fleece of heater unit................................218 Heater/air conditioning: Cleaning the condenser............................................219 ECSS-Pressure Accumulator (Option): Checking the Gas Pressure..............................219 Maintenance Every 1000 Operating Hours.........................................................220 Cooling System, Exchanging Coolant and Cleaning the System................................220 Front Axle, Oil Change.....................................................................222 Rear Axle, Oil Change......................................................................222 Transfer Gear, Oil Change..................................................................222 Service Brake..............................................................................222 Checking and Adjusting System Pressures....................................................222 Checking and Adjusting the Valve clearance.................................................222 Checking/Adjusting the Injection Nozzles, Nozzle Pressure/ Fuel-Jet Pattern................223 Checking the Accumulator Gas Pressure OF THIRD CONTROL CIRCUIT.............................223 Checking the tightening parts of the Turbo-charger.........................................223 Checking the gap of the Turbo-charger rotor................................................223 Maintenance Every 2000 Operating Hours.........................................................224 Hydraulic System, Oil Change...............................................................224 Bleeding the Hydraulic Oil Tank............................................................225 Cooling System, Checking the Antifreeze Content of the Coolant.............................225 Checking the Cooling System................................................................225 Checking the Fuel Pump.....................................................................225 Checking the Fuel and Coolant Tubes, Replacing the Tubes (if required).....................225 Checking the Water Pump....................................................................226 Checking and Adjusting the Fuel Injection and Injection time...............................226 Technical Data.....................................................................................227 Technical Data.................................................................................228 Noise Emission Levels......................................................................229 Vibration Level............................................................................229 Limit Values for Slopes....................................................................230 special equipment and attachments..................................................................231 ECSS...........................................................................................232 Structure and Functioning Principle of the ECSS............................................232 Precautionary Measures for Switching on the ECSS..........................................232 Operation of the ECSS......................................................................233 Handling of the Pressure Accumulator.......................................................234 Index..............................................................................................235 A..............................................................................................235 B..............................................................................................235 C..............................................................................................235 D..............................................................................................235 E..............................................................................................235 F..............................................................................................235 G..............................................................................................236 H..............................................................................................236 I..............................................................................................236 L..............................................................................................236 M..............................................................................................236 O..............................................................................................237 P..............................................................................................238 R..............................................................................................238 S..............................................................................................238 T..............................................................................................238 V..............................................................................................238 W..............................................................................................238
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2 reviews for KOMATSU WA95-3 WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:H20672 and up) KOMATSU WA95-3 – PDF DOWNLOAD
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Ira Bruce –
So far so good.
Kevin Jaxxon –
Great product