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Komatsu Wheel Loader GALEO WA900L-3 Operation & Maintenance Manual SN 52001 and up – PDF DOWNLOAD
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Komatsu Wheel Loader GALEO WA900L-3 Operation & Maintenance Manual
Book Code : TEN00009-02
SERIAL NUMBERS WA900L-52001 and up
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Description
Komatsu Wheel Loader GALEO WA900L-3 Operation & Maintenance Manual
FILE DETAILS:
Komatsu Wheel Loader GALEO WA900L-3 Operation & Maintenance Manual
Size : 6.41 MB
Format : PDF
Language : English
Number of Pages: 282 Pages
Brand: Komatsu
Type of machine: Wheel Loader
Type of document: Operation & Maintenance Manual
Model: WA900L-3
Serial: 52001 and up
KOMATSU WHEEL LOADER GALEO WA900L-3 OPERATION & MAINTENANCE MANUAL SN 52001 AND UP – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu Wheel Loader GALEO WA900L-3 Operation & Maintenance Manual
FOREWORD:
This manual provides rules and guidelines which will help you use this machine safely and effectively. The precautions in this manual must be followed at all times when performing operation and maintenance. Most accidents are caused by the failure to follow fundamental safety rules forthe operation and maintenance of machines. Accidents can be prevented by knowing beforehand conditions that may cause hazard when performing operation and maintenance.
TABLE OF CONTENTS:
Komatsu Wheel Loader GALEO WA900L-3 Operation & Maintenance Manual
COVER............................................................................................................. 1 FOREWORD.......................................................................................................... 2 FOREWORD...................................................................................................... 3 SAFETY INFORMATION............................................................................................ 6 INTRODUCTION.................................................................................................. 8 FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE.............................................................. 8 VISIBILITY FROM OPERATOR'S SEAT........................................................................... 9 NECESSARY INFORMATION......................................................................................... 10 PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE.............................................. 10 ENGINE SERIAL NO. PLATE AND POSITION...................................................................... 10 POSITION OF SERVICE METER................................................................................. 11 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR................................................................. 11 CONTENTS.......................................................................................................... 12 SAFETY............................................................................................................ 15 SAFETY........................................................................................................ 16 SAFETY LABELS................................................................................................. 18 LOCATION OF SAFETY LABELS................................................................................. 18 GENERAL PRECAUTIONS........................................................................................... 24 SAFETY RULES.............................................................................................. 24 IF ABNORMALITIES ARE FOUND................................................................................ 24 CLOTHING AND PERSONAL PROTECTIVE ITEMS.................................................................... 24 FIRE EXTINGUISHER AND FIRST AID KIT....................................................................... 24 SAFETY FEATURES........................................................................................... 24 KEEP MACHINE CLEAN........................................................................................ 25 INSIDE OPERATOR'S COMPARTMENT............................................................................. 25 ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT............................................................ 26 HANDRAILS AND STEPS....................................................................................... 27 MOUNTING AND DISMOUNTING.................................................................................. 27 NO PEOPLE ON ATTACHMENTS.................................................................................. 27 DO NOT GET CAUGHT IN ARTICULATED PORTION.................................................................. 28 PREVENTION OF BURNS....................................................................................... 28 FIRE PREVENTION........................................................................................... 29 ACTION IF FIRE OCCURS..................................................................................... 30 WINDOW WASHER LIQUID...................................................................................... 30 PRECAUTIONS WHEN USING ROPS (ROLL OVER PROTECTIVE STRUCTURE).............................................. 30 PRECAUTIONS FOR ATTACHMENTS, OPTIONS...................................................................... 30 UNAUTHORIZED MODIFICATION................................................................................. 30 SAFETY AT WORKSITE........................................................................................ 31 WORKING ON LOOSE GROUND................................................................................... 31 DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES.................................................................... 32 ENSURE GOOD VISIBILITY.................................................................................... 32 PRECAUTIONS RELATED TO VENTILATION EXHAUST GAS............................................................ 33 CHECKING SIGNALMAN'S SIGNALS AND SIGNS.................................................................... 33 EMERGENCY EXIT FROM OPERATOR'S CAB........................................................................ 33 BE CAREFUL ABOUT ASBESTOS DUST............................................................................ 33 PRECAUTIONS FOR OPERATION..................................................................................... 34 STARTING ENGINE........................................................................................... 34 CHECKS BEFORE STARTING ENGINE......................................................................... 34 PRECAUTIONS WHEN STARTING............................................................................. 34 PRECAUTIONS IN COLD AREAS............................................................................. 35 OPERATION................................................................................................. 36 CHECKS BEFORE OPERATION............................................................................... 36 PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE...................................................... 36 PRECAUTIONS WHEN TRAVELING............................................................................ 37 TRAVELING ON SLOPES................................................................................... 38 PROHIBITED OPERATIONS................................................................................. 39 PRECAUTIONS WHEN OPERATING............................................................................ 40 METHODS OF USING BRAKE................................................................................ 40 OPERATE CAREFULLY ON SNOW............................................................................. 41 PARKING MACHINE ...................................................................................... 42 TRANSPORTATION............................................................................................ 44 LOADING AND UNLOADING................................................................................. 44 SHIPPING.............................................................................................. 44 BATTERY................................................................................................... 45 BATTERY HAZARD PREVENTION............................................................................. 45 STARTING WITH BOOSTER CABLES.......................................................................... 46 TOWING.................................................................................................... 47 PRECAUTIONS FOR MAINTENANCE................................................................................... 48 WARNING TAG............................................................................................... 48 KEEP WORK PLACE CLEAN AND TIDY............................................................................ 48 APPOINT LEADER WHEN WORKING WITH OTHERS................................................................... 48 STOP ENGINE BEFORE CARRYING OUT MAINTENANCE............................................................... 49 TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING........................................................ 51 PROPER TOOLS.............................................................................................. 52 WORK EQUIPMENT SUPPORT.................................................................................... 52 ACCUMULATOR............................................................................................... 52 PERSONNEL................................................................................................. 52 ATTACHMENTS............................................................................................... 53 NOISE..................................................................................................... 53 PRECAUTIONS WHEN USING HAMMER ............................................................................ 53 REPAIR WELDING ........................................................................................... 53 REMOVING BATTERY TERMINAL................................................................................. 53 PRECAUTIONS WITH HIGH-PRESSURE OIL........................................................................ 54 HANDLING HIGH-PRESSURE HOSES.............................................................................. 54 WASTE MATERIALS........................................................................................... 54 MAINTENANCE OF AIR CONDITIONER............................................................................ 54 COMPRESSED AIR............................................................................................ 55 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS ............................................................ 55 PRECAUTIONS WITH TIRES........................................................................................ 56 HANDLING TIRES............................................................................................ 56 PRECAUTIONS WHEN STORING TIRES............................................................................ 56 OPERATION......................................................................................................... 57 GENERAL VIEW.................................................................................................. 58 GENERAL VIEW OF MACHINE................................................................................... 58 GENERAL VIEW OF CONTROLS AND GAUGES....................................................................... 59 EXPLANATION OF COMPONENTS..................................................................................... 61 MACHINE MONITOR........................................................................................... 61 SWITCHES.................................................................................................. 74 CONTROL LEVERS, PEDALS.................................................................................... 85 MAIN MONITOR TILT LEVER................................................................................... 89 CAP WITH LOCK............................................................................................. 90 SAFETY BAR................................................................................................ 91 TOWING PIN................................................................................................ 91 ENGINE SHUT-DOWN SWITCH................................................................................... 91 FUEL STOP LEVER........................................................................................... 92 GREASE PUMP............................................................................................... 92 BACKUP ALARM.............................................................................................. 92 CAB DOOR OPEN LOCK........................................................................................ 92 TOOL BOX.................................................................................................. 93 FUSE...................................................................................................... 94 SLOW BLOW FUSE............................................................................................ 95 LUNCH BOX TRAY............................................................................................ 96 POWER OUTLET.............................................................................................. 96 AM/FM RADIO-CASSETTE STEREO............................................................................... 97 AIR CONDITIONER...........................................................................................105 PRECAUTIONS WHEN HANDLING ACCUMULATOR.....................................................................110 OPERATION.....................................................................................................112 CHECK BEFORE STARTING ENGINE, ADJUST......................................................................112 STARTING ENGINE...........................................................................................129 OPERATIONS AND CHECKS AFTER STARTING ENGINE...............................................................132 STOPPING ENGINE...........................................................................................134 CHECK AFTER STOPPING ENGINE...............................................................................134 MOVING THE MACHINE (DIRECTIONAL, SPEED), STOPPING THE MACHINE.............................................135 TURNING...................................................................................................143 OPERATION OF WORK EQUIPMENT...............................................................................144 WORK POSSIBLE USING WHEEL LOADER..........................................................................146 PRECAUTIONS FOR OPERATION.................................................................................152 ADJUSTING WORK EQUIPMENT POSTURE..........................................................................154 REMOVAL AND INSTALLATION OF THE BUCKET....................................................................156 PARKING MACHINE...........................................................................................159 CHECKS AFTER COMPLETION OF OPERATION......................................................................161 LOCKING...................................................................................................161 HANDLING THE TIRES........................................................................................162 OPERATING AUTO-GREASING SYSTEM............................................................................164 TRANSPORTATION................................................................................................177 TRANSPORTATION PROCEDURE..................................................................................177 LOADING, UNLOADING WORK...................................................................................177 METHOD OF SECURING MACHINE................................................................................177 METHOD OF LIFTING MACHINE.................................................................................179 COLD WEATHER OPERATION........................................................................................183 PRECAUTIONS FOR LOW TEMPERATURE...........................................................................183 PRECAUTIONS AFTER COMPLETION OF WORK......................................................................184 AFTER COLD WEATHER........................................................................................185 WARMING-UP OPERATION FOR STEERING HYDRAULIC CIRCUIT IN COLD WEATHER.......................................185 LONG-TERM STORAGE.............................................................................................186 BEFORE STORAGE............................................................................................186 DURING STORAGE............................................................................................186 AFTER STORAGE.............................................................................................186 TROUBLESHOOTING...............................................................................................187 WHEN MACHINE RUNS OUT OF FUEL.............................................................................187 METHOD OF TOWING MACHINE..................................................................................188 IF BATTERY IS DISCHARGED..................................................................................192 OTHER TROUBLE.............................................................................................196 MAINTENANCE.......................................................................................................201 GUIDES TO MAINTENANCE.........................................................................................202 OUTLINES OF SERVICE...........................................................................................204 HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC....................................................204 OUTLINE OF ELECTRIC SYSTEM................................................................................207 WEAR PARTS....................................................................................................208 WEAR PARTS LIST...........................................................................................208 USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE..........................................209 PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS..........................................................209 FUEL, OIL AND COOLANT SPECIFICATIONS..........................................................................211 ENGINE OIL SPECIFICATIONS.................................................................................211 TRANSMISSION, CONVERTER, TRANSFER CASE, COOLER, SERVICE BRAKES AND HYDRAULIC SYSTEM OIL SPECIFICATIONS....212 DRIVE AXLE OIL SPECIFICATIONS.............................................................................212 DIESEL FUEL SPECIFICATIONS................................................................................212 COOLANT SPECIFICATIONS....................................................................................213 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS................................................................219 TORQUE LIST...............................................................................................219 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS.................................................................220 MAINTENANCE SCHEDULE CHART....................................................................................222 MAINTENANCE SCHEDULE CHART................................................................................222 SERVICE PROCEDURE.........................................................................................224 INITIAL 250 HOURS SERVICE.............................................................................224 WHEN REQUIRED.........................................................................................225 CHECK, CLEAN, OR REPLACE AIR CLEANER ELEMENT......................................................225 CLEAN INSIDE OF COOLING SYSTEM....................................................................227 CHECK TRANSMISSION OIL LEVEL, ADD OIL.............................................................229 CHECK AXLE OIL LEVEL, ADD OIL.....................................................................231 CLEAN AXLE CASE BREATHER..........................................................................231 CLEAN AIR CONDITIONER CONDENSER...................................................................232 CHECK WINDOW WASHING FLUID LEVEL, ADD FLUID.......................................................232 CLEAN RADIATOR FINS...............................................................................233 CHECK ELECTRICAL INTAKE AIR HEATER................................................................233 REPLACE BUCKET TEETH..............................................................................234 LUBRICATE WORK EQUIPMENT CONTROL VALVE LINKAGE (2 PLACES).........................................237 CHECK AIR CONDITIONER.............................................................................237 BLEEDING AIR FROM BRAKE HYDRAULIC CIRCUIT.........................................................238 BLEEDING AIR FROM PPC CIRCUIT.....................................................................238 REPLACE SLOW BLOW FUSE............................................................................239 BLEEDING AIR FROM HYDRAULIC TANK..................................................................240 REPLACE FAN BELT..................................................................................241 SELECTION AND INSPECTION OF TIRES.................................................................243 DRAIN WATER FROM WATER SEPARATOR..................................................................245 CHECK BEFORE STARTING.................................................................................246 EVERY 50 HOURS SERVICE................................................................................247 DRAIN WATER, SEDIMENT FROM FUEL TANK..............................................................247 EVERY 100 HOURS SERVICE...............................................................................248 CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL........................................................248 CLEAN ELEMENT IN AIR CONDITIONER FRESH AIR FILTER.................................................249 EVERY 250 HOURS SERVICE...............................................................................250 CHECK BATTERY ELECTROLYTE LEVEL...................................................................250 CHECK PARKING BRAKE...............................................................................251 CHECK ALTERNATOR BELT TENSION, ADJUST.............................................................252 CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST.............................................253 CHECK FOR LOOSE WHEEL HUB NUTS, TIGHTEN...........................................................254 CLEAN ELEMENT IN AIR CONDITIONER RECIRCULATION FILTER.............................................254 EVERY 500 HOURS SERVICE...............................................................................255 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE.................................255 REPLACE FUEL FILTER CARTRIDGE.....................................................................257 REPLACE TRANSMISSION OIL FILTER ELEMENT...........................................................259 LUBRICATE CENTER DRIVE SHAFT......................................................................260 CHECK FAN BELT FOR WEAR ..........................................................................260 EVERY 1000 HOURS SERVICE..............................................................................261 CHANGE OIL IN TRANSMISSION CASE, CLEAN STRAINER...................................................261 CLEAN TRANSMISSION CASE BREATHER..................................................................263 LUBRICATING.......................................................................................263 CHECK TIGHTENING PARTS OF TURBOCHARGER............................................................264 CLEAN FUEL STRAINER...............................................................................264 TIGHTEN ROPS CANOPY...............................................................................264 REPLACE CORROSION RESISTOR CARTRIDGE..............................................................265 EVERY 2000 HOURS SERVICE..............................................................................266 CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC FILTER ELEMENT....................................266 CLEAN HYDRAULIC TANK STRAINER.....................................................................269 REPLACE HYDRAULIC TANK BREATHER ELEMENT...........................................................270 CHANGE AXLE OIL...................................................................................271 REPLACE FILTER ELEMENT IN BRAKE OIL TANK..........................................................273 REPLACE BRAKE OIL TANK BREATHER...................................................................274 REPLACE ELEMENT IN AIR CONDITIONER RECIRCULATION AIR FILTER, FRESH AIR FILTER.....................274 CLEAN PPC CIRCUIT STRAINER........................................................................274 CHECK ALTERNATOR, STARTING MOTOR..................................................................274 CHECK ENGINE VALVE CLEARANCE, ADJUST..............................................................275 CHECK BRAKE DISC WEAR.............................................................................275 CLEAN AND CHECK TURBOCHARGER......................................................................275 CHECK PLAY OF TURBOCHARGER ROTOR..................................................................275 CHECK ACCUMULATOR FUNCTION........................................................................276 CHECK ACCUMULATOR GAS PRESSURE....................................................................276 LUBRICATE ENGINE FRONT TRUNNION...................................................................276 EVERY 4000 HOURS SERVICE..............................................................................277 CHECK WATER PUMP..................................................................................277 CHECK VIBRATION DAMPER............................................................................277 CHECK FAN PULLEY AND TENSION PULLEY...............................................................277 SPECIFICATIONS....................................................................................................278 SPECIFICATIONS................................................................................................279 INDEX.............................................................................................................280
PLEASE NOTE:
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- 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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