Komatsu WF550-3 Trash Loader Operation & Maintenance Manual VEAM100200 – PDF DOWNLOAD

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Komatsu WF550-3 Trash Loader Operation & Maintenance Manual VEAM100200 – PDF DOWNLOAD

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DESCRIPTION:

Komatsu WF550-3 Trash Loader Operation & Maintenance Manual VEAM100200 – PDF DOWNLOAD

SERIAL NUMBERS W089-50001 AND UP

Foreword:

This manual takes into account legal directives and regulations necessary to ensure the safe and effective use of the machine. A brochure with instructions is available for operation on public roads in Germany. Keep this manual within reach at all times and ensure that operating personnel read it at regular intervals.

• Call Komatsu or your local Komatsu dealer and request a replacement if this manual is lost or is no longer legible because of soiling. Pass the manual on to the new owner if selling the machine. Our constant efforts to improve the design of our machines can result in changes to construction which may differ slightly from the details in this manual.
• Please contact Komatsu or your local Komatsu dealer if you require the latest available information on your machine or if you have questions regarding the contents of this manual. Auxiliary equipment and accessories named in this manual may not be available in your region. If this is so, please contact Komatsu or your local Komatsu dealer with enquiries about the equipment you require.

TABLE OF CONTENTS:

Komatsu WF550-3 Trash Loader Operation & Maintenance Manual VEAM100200 – PDF DOWNLOAD

WF550-3 1
1  Introduction 3
1 1  Foreword 4
EU Directives 5
1 2  Safety information 6
1 3  Introduction 8
1 3 1  Intended use 8
1 3 2  Features 8
1 3 3  Breaking-in the machine 9
1 4  Location of plates, table to enter serial no and distributor 10
1 4 1  Machine identification plate 10
1 4 2  Engine identification plate 10
1 4 3  Position of service meter 11
1 4 4  Table to enter serial no and distributor 11
1 5  Table of contents 12
1 6  Dimensions, weights and operating data 16
Noise emission levels 16
2  Safety 17
2 1  General safety measures 18
2 1 1  Safety instructions 18
2 1 2  Safety devices 18
2 1 3  Emergency exit 18
2 1 4  Clothing and personal protection 18
2 1 5  Machine modifications 19
2 1 6  Before you leave the driver’s seat 19
2 1 7  Mounting and dismounting 20
2 1 8  Fire prevention and fire fighting 21
2 1 9  Protection against asbestos dust 23
2 1 10  Protection against injuries 23
2 1 11  Working at high temperatures 24
2 1 12  Roll-over protection system (ROPS) 24
2 1 13  Attachment for protection against falling objects (FOPS) 25
2 1 14  Attachments 25
2 1 15  Battery 26
2 2  Safety precautions during operation 27
2 2 1  Before you start the engine 27
Workplace safety 27
In the driver’s cab 27
In-door operation 28
Gas, dust, and inflammable vapours 28
Mirrors, windows and lighting 28
2 2 2  Machine operation 29
Before you start the engine 29
Reversing 29
Driving 30
Working close to power lines 31
Good vision 32
Working on loose soil 32
Parking the machine 32
Driving with joystick steering 33
2 2 3  Transport 34
Loading and unloading the machine 34
Transport 35
2 3  Precautions for maintenance 36
2 3 1  Personnel 36
2 3 2  Before carrying out maintenance 36
2 3 3  During maintenance 38
2 4  Safety labels 44
3  Operation 47
3 1  General view 48
3 1 1  General view of the machine 48
3 1 2  Control elements and measuring instruments 49
Standard type 49
3 2  Description of the individual elements 51
3 2 1  Control monitor 51
Testing actuation of machine monitor system 52
Warning indicators 53
Measuring instruments and control elements 57
3 2 2  Switches 62
3 2 3  Control levers and pedals 71
3 2 4  Steering column tilt lever 77
3 2 5  Cap with lock 77
Fuel tank filler port 77
Hydraulic tank filler port 78
3 2 6  Safety bar 78
3 2 7  Towing pin 79
3 2 8  Backup alarm 79
3 2 9  Fuses 80
Fuse capacity and circuit designations 80
3 2 10  Slow-blow fuses 82
3 2 11  Storaging place of this manual 82
3 2 12  Taking off power 82
3 2 13  Air conditioning 83
Layout and functions of the control panel 83
Operating instructions 85
Cool box 85
3 2 14  Hydraulic cooling fan 86
Explanation of components 86
3 3  Operation 91
3 3 1  Pre-start checks 91
Walk-around check 91
Check before starting 94
Adjustment before starting the operation 98
Operations and checks before starting the engine 101
3 3 2  Starting the engine 103
3 3 3  Operation and checks after starting the engine 105
3 3 4  Driving the machine 107
Driving the machine on site using the steering wheel 107
Driving the machine with joystick steering on site 110
3 3 5  Gear change 113
3 3 6  Changing direction 114
Manual shift 3rd and 4th speed, and automatic shift 115
3 3 7  Turning and steering 116
3 3 8  Stopping the machine 117
3 3 9  Operating the work equipment 118
3 3 10  Trash loader operations 119
Digging 119
Levelling 121
Pushing 121
Loading 122
Waste dump operation 123
3 3 11  Precautionary measures during operation 124
Permissible water depth 124
If wheel brake fails to work 124
Precautionary measures when driving up or down 125
Precautions when traveling on hard road surfaces 125
3 3 12  Adjusting the position of the work equipment 126
Adjusting the boom kickout 126
3 3 13  Parking the machine 127
3 3 14  Check after completion of work 129
3 3 15  Stopping the engine 129
3 3 16  Check after stopping the engine 130
3 3 17  Locking 130
3 4  Transport 131
3 4 1  Loading and securing 131
3 5  Cold weather operation 132
3 5 1  Precautions for low temperatures 132
Fuel and lubricants 132
Coolant 132
Battery 133
3 5 2  Precautions after completion of work 134
3 5 3  After the cold weather period 134
3 5 4  Warming-up operation for steering hydraulic circuit in cold weather 135
3 6  Long-term storage 136
3 6 1  Before storage 136
3 6 2  During storage 136
3 6 3  After storage 137
4  Troubleshooting 139
4 1  When the machine runs out of fuel 140
Procedure for bleeding air 140
4 1 1  Central lubrication system 141
4 1 2  No grease emerging at the lubrication points 141
4 1 3  The pump does not switch on 141
4 2  Towing the machine 142
4 2 1  Engine can still be used 144
4 2 2  Engine cannot be used 144
4 2 3  Releasing the parking brake 145
4 2 4  Emergency travel operation 147
4 3  If battery is discharged 148
4 3 1  Removal and installation of battery 149
4 3 2  Precautions for charging the battery 150
4 3 3  Starting the engine with a booster cable 151
Precautions for connecting and disconnecting the booster cable 151
Connecting the booster cables 152
Starting the engine 152
Disconnecting the booster cables 152
4 4  Other troubles 153
4 4 1  Electrical system 153
4 4 2  Chassis 154
4 4 3  Engine 157
4 4 4  RELATIONSHIP OF ELECTRONIC CONTROL SYSTEM 159
Main monitor failure display 159
Transmission control system 160
5  Maintenance 161
5 1  Maintenance guide 162
5 2  Maintenance basics 165
5 2 1  Oil, fuel and coolant specifications 165
Oil 165
Fuel 166
Coolant 166
Grease 167
Storing oil and fuel 167
Filters 167
5 2 2  Specifications of the electrical system 168
5 3  Wearing parts list 169
5 4  Use of fuel, coolant and lubricants according to ambient temperature 170
Proper selection of fuel, coolant and lubricants 170
5 5  Tools and grease pump 174
5 5 1  Included tools 174
5 5 2  Grease pump 174
5 6  Standard tightening torques (bolts, nuts) 175
5 7  Periodical replacement of safety-critical parts 176
5 8  Maintenance schedule chart 177
5 9  Service procedure 179
5 9 1  Initial 250 hours service 179
5 9 2  Maintenance upon demand 180
Check, clean or replace air cleaner element 180
Cleaning the interior of the cooling system 183
Checking the transmission oil level, adding oil 186
Checking the axle oil level, adding oil 188
Checking axle case breather 189
Cleaning radiator fins 190
Replacing the bucket teeth 191
Checking the air-conditioning system 192
Clean condenser of air conditioner 193
Check electrical intake air heater 193
Checking the window washing-fluid level, adding fluid 194
Lubricate work equipment control valve linkage 194
Clean top surface of underguard 195
Replace slow blow fuse 196
Topping up the grease reservoir of the central lubrication system 197
5 9 3  Checks before starting 199
5 9 4  Every 50 hours service 200
Draining water and deposits from fuel tank 200
5 9 5  Every 100 hours service 201
Checking the oil level in the hydraulic tank, adding oil 201
Cleaning the inserts of the fresh air filter of the air- conditioning system 202
Lubricate rear axle pivot pin (3 points) 202
5 9 6  Every 250 service hours 203
Changing oil in the engine oil pan, replacing engine oil filter cartridge 203
Checking the battery electrolyte level 205
Check parking brake 205
Checking and adjusting fan belt tension 206
Checking and adjusting alternator belt tension 207
Checking and adjusting the compressor belt tension of the air-conditioning system 208
Checking for loose wheel hub nuts, tightening the nuts 209
Cleaning the inserts of the recirculation filter of the airconditioning system 209
5 9 7  Every 500 service hours 210
Replacing the fuel filter cartridge 210
Replacing transmission oil filter element 212
Lubricate center drive shaft spline (1 point) 213
5 9 8  Every 1000 service hours 214
Changing the oil in the transmission case, cleaning the strainer 214
Cleaning the transmission case breather 215
Lubrication 216
Checking the tightening parts of the turbo-charger 218
Replacing the anti-corrosive filter cartridge 218
5 9 9  Every 2000 service hours 219
Changing the oil in the hydraulic tank, replacing the hydraulic filter inserts 219
Replacing the hydraulic tank breather element 222
Changing the axle oil 223
Replace element in air conditioner recirculation air filter, fresh air filter 224
Clean PPC circuit strainer 225
Clean engine breather element 225
Checking the alternator starter motor 226
Checking and adjusting the valve clearance of the engine 226
Checking the brake disc wear 226
Cleaning and checking the turbocharger 226
Check play of turbocharger rotor 226
Check accumulator 227
Check accumulator gas pressure 227
5 9 10  Every 4000 service hours 228
Checking the water pump 228
Check fan pulley and tension pulley 228
Check vibration damper 228
6  Special equipment and attachments 229
6 1  Protective ventilation system SBL30 230
6 1 1  Design and function of the protective ventilation system 230
Label at front of protective ventilation unit 231
6 1 2  Operating the machine 232
6 1 3  Starting up the protective ventilation system 233
6 1 4  Working with protective ventilation system switched on 234
6 1 5  After use 234
6 1 6  Operating and monitoring display 235
Overall display 235
Displays on the monitoring display 237
Displays and fault messages on the monitoring display 238
6 1 7  Signal lamp (on the cab roof) 240
6 1 8  Escape aid device and emergency hammer 240
Description and ordering details 240
Selection and use 241
Application 241
Maintenance and storage 241
6 1 9  Combination filter WP21 242
Area of use 242
Function of the combination filter 242
Transport and storage of the combination filter WP21 243
Filter log 244
Disposal of used filters 246
Combination filter technical details: 246
Filter change 247
6 1 10  Inspecting and/or exchanging the circulating air filter 249
6 1 11  Safety inspection 249
6 1 12  Technical details and dimensions SBL 30 250
7  Index 251

Contact us: [email protected]

PLEASE NOTE:

• This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
• This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
• Require some other service manual or have any queries: please WRITE to us at [email protected]

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