Komatsu Wheel Loader WA150-5H Operation & Maintenance Manual SN H50051 and up – PDF DOWNLOAD

Description

Komatsu Wheel Loader WA150-5H Operation & Maintenance Manual

DESCRIPTION:

Komatsu Wheel Loader WA150-5H 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.

KOMATSU WHEEL LOADER WA150-5H OPERATION & MAINTENANCE MANUAL SN H50051 AND UP – PDF DOWNLOAD:

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TABLE OF CONTENTS:

Komatsu Wheel Loader WA150-5H Operation & Maintenance Manual

MAIN MENU...............................................................................................  0
COVER...................................................................................................  1
1. Foreword............................................................................................  2
	1.1 Foreword.......................................................................................  3
		1.1.1 EU Directives............................................................................  4
	1.2 Safety information.............................................................................  5
		1.2.1 Signal words.............................................................................  5
		1.2.2 Safety labels............................................................................  6
	1.3 Introduction...................................................................................  7
		1.3.1 Intended use.............................................................................  7
		1.3.2 Directions of machine....................................................................  7
	1.4 Necessary information..........................................................................  8
		1.4.1 PIN/Machine serial no. plate and position................................................  8
		1.4.2 Engine serial no. plate and position.....................................................  8
		1.4.3 ROPS/FOPS-Cab serial no. plate...........................................................  9
		1.4.4 Axle serial no. plate....................................................................  9
		1.4.5 Transmission serial no. plate............................................................  9
		1.4.6 Seat operator serial no. plate........................................................... 10
		1.4.7 Position of service meter................................................................ 10
		1.4.8 Table to enter serial no. and distributor................................................ 10
	1.5 Contents....................................................................................... 11
	1.6 Dimensions, weights and operating data......................................................... 18
		1.6.1 WA150-5H: Dimensions, weights and operating data......................................... 18
	1.7 CE-Conforming equipment........................................................................ 19
		1.7.1 CE-Conforming equipment.................................................................. 19
		1.7.2 Manufacturer-supplied CE-Conforming equipment, according to document 416-93-H1120........ 20
2. Safety.............................................................................................. 24
	2.1 Safety labels.................................................................................. 25
		2.1.1 Location of safety labels................................................................ 25
		2.1.2 Presentation of safety labels............................................................ 26
	2.2 General precautions............................................................................ 29
	2.3 Precautions for operation...................................................................... 39
		2.3.1 Starting engine.......................................................................... 39
		2.3.2 Operation................................................................................ 41
		2.3.3 Transportation........................................................................... 48
		2.3.4 Battery.................................................................................. 49
		2.3.5 Towing................................................................................... 51
	2.4 Precautions for maintenance.................................................................... 52
	2.5 Precautions with tires......................................................................... 60
3. Operation........................................................................................... 62
	3.1 General view................................................................................... 63
		3.1.1 General view of machine.................................................................. 63
		3.1.2 General view of controls and gauges...................................................... 64
	3.2 Explanation of components...................................................................... 66
		3.2.1 Machine monitor.......................................................................... 66
			Monitor system.............................................................................. 67
			Types of warning............................................................................ 68
			Central warning lamp........................................................................ 68
			Character display portion................................................................... 69
			Emergency stop item......................................................................... 75
			Caution items............................................................................... 78
			Warning/Limit functions for travel speed.................................................... 80
			Inspection and maintenance item............................................................. 81
			Pilot display portion....................................................................... 83
			Meter display portion....................................................................... 86
			Other functions of machine monitor.......................................................... 88
		3.2.2 Switches................................................................................. 91
		3.2.3 Control levers, pedals...................................................................100
		3.2.4 Steering tilt lock lever.................................................................105
		3.2.5 Cap and cover with lock..................................................................105
		3.2.6 Safety bar...............................................................................106
		3.2.7 Towing pin...............................................................................107
		3.2.8 Grease pump..............................................................................107
		3.2.9 Cab door inner lock......................................................................107
		3.2.10 Cab door open lock......................................................................108
		3.2.11 Cab window open lock cancel knob........................................................108
		3.2.12 Fuse....................................................................................109
			Fuse capacity and name of circuit...........................................................109
		3.2.13 Slow blow fuse..........................................................................110
		3.2.14 Power outlet............................................................................111
		3.2.15 Storage box.............................................................................111
		3.2.16 Air conditioner.........................................................................112
			General locations and function of control panel.............................................112
			Method of operation.........................................................................114
			Precautions when using......................................................................115
		3.2.17 Handling cab wiper......................................................................115
			Preventing damage to wiper arm bracket......................................................115
	3.3 Operation......................................................................................116
		3.3.1 Check before starting engine, adjust.....................................................116
			Walk-around check...........................................................................116
			Check before starting.......................................................................119
			Adjustment..................................................................................124
			Safety belt.................................................................................125
			Operations and checks before starting engine................................................127
		3.3.2 Starting engine..........................................................................129
			Normal starting.............................................................................129
			Starting in cold weather....................................................................131
		3.3.3 Operations and checks after starting engine..............................................133
			Breaking-in the machine.....................................................................133
			Normal operation............................................................................134
		3.3.4 Stopping engine..........................................................................135
		3.3.5 Moving the machine (directional, speed), stopping the machine............................136
			Moving the machine..........................................................................136
			Changing direction..........................................................................138
			Using switch to change between forward and reverse..........................................139
			Stopping the machine........................................................................141
		3.3.6 Turning..................................................................................142
			Emergency steering..........................................................................143
		3.3.7 Operation of work equipment..............................................................144
		3.3.8 Work possible using wheel loader.........................................................146
			Digging operations..........................................................................146
			Leveling operation..........................................................................148
			Pushing operation...........................................................................148
			Load and carry operations...................................................................149
			Loading operations..........................................................................149
		3.3.9 Precautions for operation................................................................151
			Permissible water depth.....................................................................151
			If wheel brake does not work................................................................151
			Precautions when driving up or down slopes..................................................151
		3.3.10 Adjusting work equipment posture........................................................153
			Adjusting boom kickout......................................................................153
			Adjusting bucket positioner.................................................................154
			Bucket level indicator......................................................................154
		3.3.11 Parking machine.........................................................................155
		3.3.12 Check after stopping engine.............................................................157
		3.3.13 Checks after completion of operation....................................................157
		3.3.14 Locking.................................................................................157
		3.3.15 Handling the tires......................................................................158
			Precautions when handling tires.............................................................158
			Tire pressure...............................................................................158
			Precautions for using load and carry method.................................................159
	3.4 Transportation.................................................................................160
		3.4.1 Transportation procedure.................................................................160
		3.4.2 Loading, unloading work with trailers....................................................160
			Loading.....................................................................................161
			Securing machine............................................................................161
			Unloading...................................................................................162
		3.4.3 Lifting machine..........................................................................163
			Location of lifting position mark...........................................................164
			Weight table................................................................................164
			Lifting procedure...........................................................................165
	3.5 Cold weather operation.........................................................................166
		3.5.1 Precautions for low temperature..........................................................166
			Fuel and lubricants.........................................................................166
			Coolant.....................................................................................166
			Battery.....................................................................................167
		3.5.2 Precautions after completion of work.....................................................168
		3.5.3 After cold weather.......................................................................168
		3.5.4 Warming-up operation for steering hydraulic circuit in cold weather......................168
	3.6 Long-term storage..............................................................................169
		3.6.1 Before storage...........................................................................169
		3.6.2 During storage...........................................................................169
		3.6.3 After storage............................................................................169
	3.7 Troubleshooting................................................................................171
		3.7.1 When machine runs out of fuel............................................................171
		3.7.2 Towing the machine.......................................................................171
			When engine can be used.....................................................................172
			When engine cannot be used..................................................................173
			Emergency travel operation..................................................................173
		3.7.3 If battery is discharged.................................................................174
			Removal and installation of battery.........................................................174
			Precautions for charging battery............................................................175
			Starting engine with booster cable..........................................................176
		3.7.4 Other trouble............................................................................178
			Electrical system...........................................................................178
			Chassis.....................................................................................179
			Engine......................................................................................181
4. Maintenance.........................................................................................182
	4.1 Guides to maintenance..........................................................................183
	4.2 Outlines of service............................................................................186
		4.2.1 Handling oil, fuel, coolant, grease and carrying out KOWA (KOMATSU Oil Wear Analysis)....186
			Oil.........................................................................................186
			Fuel........................................................................................186
			Coolant.....................................................................................187
			Grease......................................................................................187
			Carrying out KOWA (KOMATSU Oil Wear Analysis)...............................................188
			Storing oil and fuel........................................................................189
			Filters.....................................................................................189
			Biodegradable hydraulic oil and lubricants..................................................190
		4.2.2 Outline of electric system...............................................................190
	4.3 Wear parts.....................................................................................191
		4.3.1 Wear parts list..........................................................................191
	4.4 Fuel, coolant and lubricants...................................................................192
		4.4.1 Lubrication chart........................................................................192
		4.4.2 Proper selection of fuel, coolant and lubricants.........................................193
	4.5 Standard tightening torques for bolts and nuts.................................................198
		4.5.1 Torque list..............................................................................198
	4.6 Periodic replacement of safety critical parts..................................................200
	4.7 Maintenance schedule chart.....................................................................201
		4.7.1 Maintenance schedule chart...............................................................201
	4.8 Service procedure..............................................................................203
		4.8.1 Initial 250 hours service (only after the first 250 hours)...............................203
		4.8.2 When required............................................................................203
			Check, clean, or replace air cleaner element................................................203
			Dust pre-cleaner "Turbo II": Check, clean...................................................206
			Clean inside of cooling system..............................................................207
			Check oil level in transfer case, add oil...................................................210
			Check axle oil level, add oil...............................................................211
			Clean axle case breather....................................................................212
			Clean slack adjuster........................................................................212
			Clean air conditioner condenser.............................................................213
			Check window washing fluid level, add fluid.................................................213
			Clean radiator fins and cooler fins.........................................................214
			Check electrical intake air heater..........................................................214
			Replace bolt on cutting edge................................................................215
			Replace bucket teeth........................................................................216
			Check air conditioner.......................................................................217
			Replace slow blow fuse......................................................................218
			Selection and inspection of tires...........................................................219
		4.8.3 Check before starting....................................................................221
			Check before starting.......................................................................221
		4.8.4 Every 50 hours service...................................................................221
			Drain water, sediment from fuel tank........................................................221
		4.8.5 Every 100 hours service..................................................................222
			Lubricate rear axle pivot pin...............................................................222
			Clean element in air conditioner fresh air filter...........................................222
			Check oil level in hydraulic tank, add oil..................................................223
			Lubricating.................................................................................224
		4.8.6 Every 250 hours service..................................................................225
			Check battery electrolyte level.............................................................225
			Check parking brake.........................................................................227
			Check air conditioner compressor belt tension, adjust.......................................228
			Check for loose wheel hub bolts, tighten....................................................229
			Clean element in air conditioner recirculation filter.......................................229
			Lubricating.................................................................................230
		4.8.7 Every 500 hours service..................................................................231
			Change oil in engine oil pan, replace engine oil filter cartridge...........................231
			Replace fuel filter cartridge...............................................................233
			Replacement of filter cartridge for poor-quality fuel.......................................234
			Clean water separator strainer..............................................................235
			Lubricating.................................................................................236
		4.8.8 Every 1000 hours service.................................................................237
			Change oil in transfer case.................................................................237
			Clean transfer case breather................................................................238
			Replace HST oil filter element..............................................................239
			Lubricating.................................................................................240
			Check tightening parts of turbocharger......................................................240
			Check play of turbocharger rotor............................................................240
			Check alternator driving belt tension and replacement.......................................240
		4.8.9 Every 2000 hours service.................................................................241
			Change oil in hydraulic tank, replace hydraulic filter element..............................241
			Replace hydraulic tank breather element.....................................................242
			Cleaning the strainer of the brake filter...................................................243
			Change axle oil.............................................................................244
			Replace element in air conditioner recirculation air filter, fresh air filter...............245
			Check alternator, starting motor............................................................245
			Check engine valve clearance, adjust........................................................245
			Check brake disc wear.......................................................................246
			Clean and check turbocharger................................................................247
			Check accumulator gas pressure..............................................................247
			Check vibration damper......................................................................247
		4.8.10 Every 4000 hours service................................................................248
			Lubricating.................................................................................248
			Check water pump............................................................................248
5. Technical Data......................................................................................250
	5.1 Technical data.................................................................................251
	5.2 Noise emission levels..........................................................................253
	5.3 Vibration level................................................................................253
6. Attachments, Options................................................................................254
	6.1 Selecting bucket and tires.....................................................................255
	6.2 Method of using 2 levers.......................................................................256
		6.2.1 Explanation of components................................................................256
		6.2.2 Operation................................................................................259
			Using switch to change between forward and reverse..........................................259
	6.3 Central lubrication system.....................................................................261
		6.3.1 Operating the central lubrication system.................................................261
		6.3.2 Display and control unit.................................................................261
			LED-display.................................................................................262
			Pushbuttons.................................................................................262
		6.3.3 Changing the lubrication interval times..................................................263
7. Index...............................................................................................264
	7.1 Index..........................................................................................265
8. Notes...............................................................................................270

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