Komatsu Wheel Loader WA95-3 Operation & Maintenance Manual SN HA980051 and up – PDF DOWNLOAD

Description

Komatsu Wheel Loader WA95-3 Operation & Maintenance Manual

TABLE OF CONTENTS:

Komatsu Wheel Loader WA95-3 Operation & Maintenance Manual 

MAIN MENU.......................................................................................................  0
COVER...........................................................................................................  1
Table of Contents...............................................................................................  7
Introduction.................................................................................................... 15
	1. Forword.................................................................................................. 16
	2. Safety Information....................................................................................... 17
	3. Introduction............................................................................................. 18
		3.1 Features............................................................................................ 18
		3.2 Breaking in a New Machine........................................................................... 18
	4. Location of Plates, Table to Enter Serial No. and Distributor............................................ 19
		4.1 Machine Serial No. Plate position................................................................... 19
		4.2 Engine Serial No. Plate Position.................................................................... 19
		4.3 Table to Enter Serial No. and Distributor........................................................... 19
	5. Why You Should Read these Operating Instructions......................................................... 20
	6. Notes on Safety Regulations.............................................................................. 21
		6.1 Correct Use......................................................................................... 21
		6.2 Safety Notes in the Operating Instructions.......................................................... 21
	7. Equipment................................................................................................ 22
Loading and Transporting the Machine............................................................................ 25
	8. Loading and Transporting the Machine..................................................................... 26
		8.1 Securing the Articulated Steering................................................................... 26
		8.2 Lifting the Machine................................................................................. 26
		8.3 Driving Machine Onto Loading Area of Transport Vehicle.............................................. 28
		8.4 Securing the Machine During Transport............................................................... 29
		8.5 After Transport..................................................................................... 29
Safety.......................................................................................................... 31
	9. General Safety Measures.................................................................................. 33
		9.1 Safety Instructions................................................................................. 33
		9.2 Safety Devices...................................................................................... 33
		9.3 Emergency Exit...................................................................................... 33
		9.4 Clothing and Personal Protection.................................................................... 34
		9.5 Machine Modifications............................................................................... 34
		9.6 Before You Leave the Driver's Seat.................................................................. 34
		9.7 Mounting and Dismounting............................................................................ 34
		9.8 Fire Prevention and Fire Fighting................................................................... 35
			9.8.1 Fire Extinguisher and First-Aid Kit........................................................... 36
		9.9 Protection Against Asbestos Dust.................................................................... 36
		9.10 Protection Against Injuries........................................................................ 37
		9.11 Working at High Temperatures....................................................................... 37
		9.12 Roll-Over Protection System (ROPS)................................................................. 38
		9.13 Attachment for Protection Against Falling Objects (FOPS)........................................... 38
		9.14 Attachments........................................................................................ 38
		9.15 Battery............................................................................................ 39
	10. Safety Measures during Operation........................................................................ 40
		10.1 Before You Start the Engine........................................................................ 40
			10.1.1 Workplace Safety............................................................................. 40
			10.1.2 In the Driver's Cab.......................................................................... 40
			10.1.3 In-Door Operation............................................................................ 41
			10.1.4 Gas, Dust, and Inflammable Vapours........................................................... 41
			10.1.5 Mirrors, Windows, and Lighting............................................................... 41
		10.2 Machine Operation.................................................................................. 42
			10.2.1 Before You Start the Engine.................................................................. 42
			10.2.2 Reversing.................................................................................... 42
			10.2.3 Driving...................................................................................... 43
			10.2.4 Driving On Slopes............................................................................ 43
			10.2.5 Emergency Lowering System.................................................................... 44
			10.2.6 Working Close to Overhead Power Transmission Lines........................................... 44
			10.2.7 Loading...................................................................................... 45
			10.2.8 Good Vision.................................................................................. 45
			10.2.9 Working On Snow.............................................................................. 45
			10.2.10 Height Limitation........................................................................... 45
			10.2.11 Brakes...................................................................................... 46
			10.2.12 Working On Loose Soil....................................................................... 46
			10.2.13 Working with the Forklift Truck Attachment.................................................. 47
			10.2.14 Parking the Machine......................................................................... 48
		10.3 Transport.......................................................................................... 49
			10.3.1 Loading and Unloading the Machine............................................................ 49
			10.3.2 Transport.................................................................................... 49
	11. Safety Measures During Maintenance...................................................................... 50
		11.1 Personnel.......................................................................................... 50
		11.2 Prior to Start of Maintenance Measures............................................................. 50
			11.2.1 Warning Sign................................................................................. 50
			11.2.2 Tools........................................................................................ 50
			11.2.3 Safety-Related Parts......................................................................... 50
			11.2.4 Prior to Start of Inspection and Maintenance................................................. 51
			11.2.5 Securing the Articulated Steering............................................................ 51
			11.2.6 Supporting the Work Unit..................................................................... 51
		11.3 During Maintenance................................................................................. 52
			11.3.1 Attachments.................................................................................. 52
			11.3.2 Working Under the Machine.................................................................... 52
			11.3.3 Keeping the Machine Clean.................................................................... 52
			11.3.4 Specific Measures............................................................................ 52
			11.3.5 Refueling and Topping Off Oil................................................................ 53
			11.3.6 Coolant...................................................................................... 53
			11.3.7 Use of Lighting.............................................................................. 54
			11.3.8 High-Pressure Hoses.......................................................................... 54
			11.3.9 Handling High-Pressure Oil................................................................... 54
			11.3.10 Fan and Belts............................................................................... 55
			11.3.11 Waste Material.............................................................................. 55
		11.4 Tires.............................................................................................. 56
			11.4.1 Storing Tires................................................................................ 56
	12. Labeling................................................................................................ 57
		12.1 Position of Safety Labels.......................................................................... 57
		12.2 Position of Standard Labels........................................................................ 59
Controls and Indicators......................................................................................... 61
	13. General View of the Machine............................................................................. 62
	14. Controls and Indicators................................................................................. 63
		14.1 General View....................................................................................... 63
			14.1.1 SWITCHES AND CONTROLS........................................................................ 64
		14.2 Instrument Panel................................................................................... 65
		14.3 Warning Lights..................................................................................... 66
		14.4 Control Lamps...................................................................................... 69
		14.5 Measuring Indicators............................................................................... 72
		14.6 Switches........................................................................................... 74
		14.7 Control Levers, Pedals............................................................................. 80
		14.8 Articulated Steering Catch......................................................................... 85
		14.9 Traction Device.................................................................................... 85
		14.10 Socket............................................................................................ 85
		14.11 Door Unlocking System............................................................................. 86
		14.12 Alarm Horn for Reverse Driving.................................................................... 86
Operation....................................................................................................... 87
	15. Running in the Machine.................................................................................. 88
	16. Preparing the Machine Start............................................................................. 89
		16.1 Visual Checks...................................................................................... 89
			16.1.1 Before you start the engine.................................................................. 89
			16.1.2 Before starting working with the machine..................................................... 89
	17. Adjustments Prior to Machine Start...................................................................... 91
		17.1 Adjusting the Driver’s Seat........................................................................ 91
		17.2 Adjusting the Steering Column...................................................................... 92
		17.3 Adjusting the Armrest.............................................................................. 92
		17.4 Adjusting the Rear-View Mirrors.................................................................... 92
		17.5 Adjusting the Heating and Ventilation System....................................................... 93
			17.5.1 Adjusting the ventilation system............................................................. 93
			17.5.2 Adjusting the heating system................................................................. 93
		17.6 Putting on the Safety Belt......................................................................... 94
			17.6.1 Putting on the safety belt................................................................... 94
			17.6.2 Taking off the safety belt................................................................... 94
	18. Starting and Switching Off the Engine................................................................... 95
		18.1 Starting the Engine................................................................................ 95
			18.1.1 Warming up the engine........................................................................ 96
		18.2 Switching Off the Engine........................................................................... 97
	19. Driving................................................................................................. 98
		19.1 Start-Up........................................................................................... 98
			19.1.1 Starting the machine on slopes............................................................... 99
		19.2 Changing the Driving Direction..................................................................... 99
		19.3 Reverse Driving....................................................................................100
		19.4 Turning............................................................................................100
			19.4.1 Turning on slopes, embankments or hill flanks................................................100
		19.5 Braking............................................................................................101
			19.5.1 Pulling the parking brake....................................................................101
			19.5.2 Releasing the parking brake..................................................................101
			19.5.3 Braking with the service brake...............................................................101
			19.5.4 If the service brake breaks down.............................................................101
			19.5.5 Braking on slopes............................................................................102
		19.6 Stopping...........................................................................................102
			19.6.1 Parking the machine on a slope...............................................................102
		19.7 Longer-Distance Driving............................................................................103
	20. Operating the Machine...................................................................................104
		20.1 Preparing the Work Equipment.......................................................................104
			20.1.1 Selecting a work unit........................................................................104
			20.1.2 Picking up the work unit (except multi-purpose bucket).......................................104
			20.1.3 Removing the work unit.......................................................................105
			20.1.4 Picking up the multi-purpose bucket..........................................................105
			20.1.5 Removing the multi-purpose bucket............................................................107
		20.2 Tire Service Life..................................................................................108
			20.2.1 Level indicator for the bucket...............................................................108
		20.3 Loading............................................................................................109
			20.3.1 Removing piled up soil.......................................................................109
			20.3.2 Excavation works.............................................................................111
		20.4 Transporting.......................................................................................112
		20.5 Dumping / Unloading................................................................................112
			20.5.1 Loading in diagonal direction................................................................112
			20.5.2 V-shaped loading.............................................................................113
			20.5.3 Piling up material...........................................................................113
		20.6 Planing............................................................................................114
			20.6.1 Filling up...................................................................................114
			20.6.2 Taking off soil..............................................................................114
			20.6.3 Cutting the Ground...........................................................................114
		20.7 Working With the Forklift Truck Attachment.........................................................115
			20.7.1 Picking up the load..........................................................................115
		20.8 Precautions For Special Operations.................................................................116
			20.8.1 Working in water.............................................................................116
			20.8.2 Working on snow..............................................................................116
			20.8.3 Dumping on steep slopes......................................................................116
			20.8.4 Working in the vicinity of electrical overhead lines.........................................116
			20.8.5 Operation on slopes..........................................................................116
			20.8.6 Working on loose soil........................................................................116
		20.9 After the work is finished.........................................................................116
		20.10 Instructions for Winter Operation.................................................................117
			20.10.1 Before the cold season......................................................................117
			20.10.2 After Operation.............................................................................117
			20.10.3 After the cold season.......................................................................117
		20.11 Longer Standstill Periods of the Machine..........................................................117
			20.11.1 Before the standstill.......................................................................117
			20.11.2 During the standstill.......................................................................118
			20.11.3 After the standstill........................................................................118
Troubleshooting.................................................................................................119
	21. Troubleshooting.........................................................................................120
		21.1 Warning Lights and Indicators......................................................................120
		21.2 Electrical System..................................................................................121
		21.3 Engine.............................................................................................122
		21.4 Hydraulic system...................................................................................125
		21.5 Brakes.............................................................................................127
		21.6 Axles..............................................................................................128
		21.7 Emergency Steering Characteristics.................................................................129
		21.8 Emergency Lowering System..........................................................................129
		21.9 Starting the Engine with a Battery Jumper Cable....................................................130
			21.9.1 Connecting the Jumper Cable..................................................................130
		21.10 Starting the Engine...............................................................................131
			21.10.1 Disconnecting the Battery Jumper Cable......................................................131
		21.11 Towing the Machine................................................................................132
		21.12 Towing a Machine with Defective Brakes............................................................133
Maintenance.....................................................................................................135
	22. Maintenance Basics......................................................................................136
		22.1 Preparing the Machine for Maintenance..............................................................136
		22.2 Cleaning the Machine...............................................................................137
			22.2.1 Precautionary Measures When Cleaning the Machine.............................................137
			22.2.2 Fire Prevention..............................................................................137
		22.3 Working-Area-Dependent Maintenance.................................................................137
			22.3.1 Muddy or Wet Working Areas...................................................................137
			22.3.2 Dusty Working Areas..........................................................................137
		22.4 Lubricants and Operating Agents....................................................................138
			22.4.1 Draining Hot Lubricants and Fluids...........................................................138
			22.4.2 Checking the Oil Level and Changing Oil......................................................138
			22.4.3 Changing Filters.............................................................................138
			22.4.4 Refuelling and Topping off Oil...............................................................138
			22.4.5 Oil..........................................................................................138
			22.4.6 Lubricating Grease...........................................................................139
			22.4.7 Biodegradable Hydraulic Oil and Lubricating Grease...........................................139
			22.4.8 Fuel.........................................................................................139
			22.4.9 Storage of Oil and Fuel......................................................................139
			22.4.10 Coolants....................................................................................140
			22.4.11 Windscreen Washer Liquid....................................................................140
			22.4.12 Table of Lubricants and Operating Agents....................................................142
			22.4.13 Lubrication chart...........................................................................143
		22.5 Replacing Safety-Related Parts.....................................................................144
			22.5.1 Welding Instructions.........................................................................144
		22.6 Spare Parts and Consumable Components..............................................................145
		22.7 Electrical System..................................................................................146
			22.7.1 Fuses........................................................................................146
			22.7.2 Fuse Assignment..............................................................................146
			22.7.3 Slow-Blowing Fuses...........................................................................147
		22.8 Tires..............................................................................................148
			22.8.1 Tire Components..............................................................................148
			22.8.2 Checking the Tires...........................................................................148
			22.8.3 Checking the Tire Pressure...................................................................148
		22.9 Tools..............................................................................................150
		22.10 Torque for Standard Nuts and Bolts................................................................151
	23. Maintenance Schedule....................................................................................153
	24. Maintenance Prior to Start..............................................................................155
		24.1 Visual Checks......................................................................................155
		24.2 Cooling System, Checking the Coolant Level, Topping off Coolant....................................155
		24.3 Engine, Checking the Oil Level, Topping off Oil....................................................156
		24.4 Engine, Draining Off Oil...........................................................................157
		24.5 Checking the Fuel Level, Refueling.................................................................158
		24.6 Checking the Controls..............................................................................159
		24.7 Checking the Parking Brake.........................................................................160
			24.7.1 Test Conditions..............................................................................160
			24.7.2 Test Procedure...............................................................................160
		24.8 Checking the Service Brake.........................................................................160
		24.9 Checking the Electrical Connections................................................................161
		24.10 Other Maintenance Measures Prior to Start.........................................................161
	25. Maintenance Every 10 Operating Hours....................................................................162
		25.1 Lubrication........................................................................................162
	26. Maintenance After the First 50 Operating Hours..........................................................163
		26.1 Engine, Changing Oil and Replacing the Oil Filter Cartridge........................................163
			26.1.1 Replacing the Oil Filter Cartridge...........................................................164
		26.2 V-Belt, Checking the Condition.....................................................................165
		26.3 V-Belt, Checking and Adjusting the Tension.........................................................165
		26.4 Hydraulic System, Replacing the Filter Insert......................................................166
		26.5 Checking and Tightening the Wheel Nuts.............................................................167
		26.6 Front and Rear Axle, Changing Oil..................................................................168
			26.6.1 Planet gear..................................................................................168
			26.6.2 Differential.................................................................................168
		26.7 Transfer Gear - Changing Oil.......................................................................169
	27. Maintenance Every 50 Operating Hours....................................................................170
		27.1 Checking the cooling System, coolant level in the radiator and expansion tank......................170
		27.2 Draining Off Water and Dirt Deposits From the Fuel Tank............................................171
		27.3 Checking the Service Brake and Oil Level, Refilling Oil............................................171
		27.4 Checking the Battery and Acid Level................................................................172
			27.4.1 Re-charging a built-in battery...............................................................173
		27.5 Lubrication........................................................................................174
			27.5.1 Lubricating points of the work equipment.....................................................174
	28. Maintenance Every 100 Operating Hours...................................................................175
		28.1 Draining the Water Separator, Removing Water and Dirt Deposits.....................................175
	29. Maintenance Every 250 Operating Hours...................................................................176
		29.1 Changing the Engine Oil and Oil Filter Cartridge...................................................176
		29.2 Checking the V-Belt Condition......................................................................176
		29.3 Checking and Adjusting the V-belt Tension..........................................................176
		29.4 Lubrication........................................................................................176
			29.4.1 Lubricating points of the steering cylinder..................................................176
		29.5 Front and Rear Axle, Checking the Oil Level........................................................177
			29.5.1 Planet gear..................................................................................177
			29.5.2 Differential.................................................................................177
		29.6 Air Filter, Removing and Re-Installing the Filter Insert, Checking and Cleaning the Filter I.......178
			29.6.1 Structure of the air filter..................................................................178
			29.6.2 Maintenance demand...........................................................................178
			29.6.3 Removing the filter cartridge................................................................178
			29.6.4 Cleaning or exchanging the filter cartridge..................................................179
			29.6.5 Checking the filter cartridge................................................................180
			29.6.6 Assembling the air filter cartridge..........................................................180
		29.7 Cleaning the Radiator Segments.....................................................................180
	30. Maintenance Every 500 Operating Hours...................................................................181
		30.1 Changing the Fuel Filter and Filter Element........................................................181
			30.1.1 Bleeding the Fuel System.....................................................................182
		30.2 Changing the Filter Cartridge of the Hydraulic System..............................................183
		30.3 Cleaning the Water Separator.......................................................................183
		30.4 Lubrication........................................................................................184
		30.5 Transfer Gear, Checking the Oil Level and Refilling Oil............................................184
		30.6 Air Filter, Replacing the Filter Insert, Replacing the Safety Filter...............................185
			30.6.1 Replacing the Filter Insert..................................................................185
			30.6.2 Replacing the Safety Filter..................................................................185
	31. Maintenance Every 1000 Operating Hours..................................................................186
		31.1 Cooling System, Exchanging Coolant and Cleaning the System.........................................186
			31.1.1 Draining off the coolant.....................................................................186
			31.1.2 Cleaning the Cooling System..................................................................187
			31.1.3 Filling off Coolant..........................................................................187
		31.2 Front Axle, Oil Change.............................................................................188
		31.3 Rear Axle, Oil Change..............................................................................188
		31.4 Transfer Gear, Oil Change..........................................................................188
		31.5 Service Brake......................................................................................188
			31.5.1 Changing oil.................................................................................188
			31.5.2 Checking tubes and lines.....................................................................188
			31.5.3 Checking the brake disks for wear and tear...................................................188
			31.5.4 Adjusting the clearance of the brake disks...................................................188
		31.6 Checking and Adjusting System Pressures............................................................188
		31.7 Checking and Adjusting the Valve clearance.........................................................188
		31.8 Checking and Adjusting the Injection Nozzles, Nozzle Pressure and Fuel-Jet Pattern.................188
	32. Maintenance Every 2000 Operating Hours..................................................................189
		32.1 Hydraulic System, Oil Change.......................................................................189
		32.2 Bleeding the Hydraulic Oil Tank....................................................................190
		32.3 Cooling System, Checking the Antifreeze Content of the Coolant.....................................190
		32.4 Checking the Cooling System........................................................................190
		32.5 Checking the Fuel Pump.............................................................................190
		32.6 Checking the Fuel and Coolant Tubes, Replacing the Tubes (if required).............................190
		32.7 Checking the Water Pump............................................................................191
		32.8 Checking and Adjusting the Fuel Injection and Injection time.......................................191
		32.9 Engine, Intake Valves and Outlet Valves - Grinding In the Valve Bases..............................191
Technical Data..................................................................................................193
	33. Technical Data..........................................................................................194
		33.1 Noise Emission Levels..............................................................................195
		33.2 Vibration Level....................................................................................195
		33.3 Limit Values for Slopes............................................................................196
			33.3.1 Maximum slope angle for operating the machine................................................196
			33.3.2 Tilting/tipping angle........................................................................196

KOMATSU WHEEL LOADER WA95-3 OPERATION & MAINTENANCE MANUAL SN HA980051 AND UP – PDF DOWNLOAD:

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Komatsu Wheel Loader WA95-3 Operation & Maintenance Manual 

FOREWORD:

• 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.

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]