Komatsu WA180-3 PARALLEL TOOL CARRIER Operation & Maintenance Manual – PDF Download

Description

Komatsu WA180-3 PARALLEL TOOL CARRIER Operation & Maintenance Manual

Description:

• Komatsu WA180-3 PARALLEL TOOL CARRIER Operation & Maintenance Manual
• SERIAL NUMBERS-A85001 and up
• This manual describes procedures for operation, handling, lubrication, maintenance, checking, and adjustment. It will help the operator and maintenance personnel realize peak performance through effective, economical and safe machine operation and maintenance.
• Keep this manual handy and have all personnel read it periodically. If this manual is lost or becomes dirty and can not be read, request a replacement manual from your local distributor.
• If you sell the machine, be sure to give this manual to the new owner.
• Continuing improvements in the design of this machine can lead to changes in detail, which may not be reflected in this manual. Consult your local distributor or Komatsu America International Company for the latest available information on your machine or for questions regarding information in this manual.

Table of Contents:

• Komatsu WA180-3 PARALLEL TOOL CARRIER Operation & Maintenance Manual
• SERIAL NUMBERS-A85001 and up

MAIN MENU.....................................................................................................................  0
INTRODUCTION..................................................................................................................  4
	1. FORWARD................................................................................................................  5
	2. SAFETY INFORMATION.....................................................................................................  6
	3. INTRODUCTION...........................................................................................................  7
		3.1 INTENDED USE......................................................................................................  7
		3.2 FEATURES..........................................................................................................  7
		3.3 BREAKING IN A NEW MACHINE.........................................................................................  7
	4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR..........................................................  8
		4.1 MACHINE SERIAL NO. PLATE POSITION.................................................................................  8
		4.2 ENGINE SERIAL NO. PLATE POSITION..................................................................................  8
		4.3 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR.........................................................................  8
	5. CONTENTS...............................................................................................................  9
SAFETY........................................................................................................................ 15
	6. GENERAL PRECAUTIONS.................................................................................................... 16
	7. PRECAUTIONS DURING OPERATION........................................................................................... 22
		7.1 BEFORE STARTING ENGINE............................................................................................ 22
		7.2 AFTER STARTING ENGINE............................................................................................. 25
		7.3 TRANSPORTATION.................................................................................................... 34
		7.4 BATTERY........................................................................................................... 35
		7.5 TOWING............................................................................................................ 38
	8. PRECAUTIONS FOR MAINTENANCE............................................................................................ 39
		8.1 BEFORE CARRYING OUT MAINTENANCE................................................................................... 39
		8.2 DURING MAINTENANCE................................................................................................ 44
		8.3 TIRES............................................................................................................. 49
	9. POSITION FOR ATTACHING SAFETY LABELS................................................................................... 51
		9.1 POSITION FOR ATTACHING SAFETY LABELS.............................................................................. 51
OPERATION..................................................................................................................... 57
	10. GENERAL VIEW.......................................................................................................... 58
		10.1 GENERAL VIEW OF MACHINE.......................................................................................... 58
		10.2 GENERAL VIEW OF CONTROLS AND GAUGES.............................................................................. 59
	11. EXPLANATION OF COMPONENTS............................................................................................. 61
		11.1 METER, LAMPS..................................................................................................... 61
		11.2 SWITCHES......................................................................................................... 65
		11.3 CONTROL LEVERS, PEDAL............................................................................................ 71
		11.4 CAP WITH LOCK.................................................................................................... 75
			11.4.1 METHOD OF OPENING AND CLOSING CAP WITH LOCK................................................................ 75
		11.5 SAFETY BAR....................................................................................................... 75
		11.6 TOWING PIN....................................................................................................... 76
		11.7 GREASE PUMP CLAMP AND RUBBER RING................................................................................ 76
		11.8 BACKUP ALARM..................................................................................................... 76
		11.9 FUSE............................................................................................................. 77
			11.9.1 FUSE CAPACITY AND NAME OF CIRCUIT.......................................................................... 77
		11.10 SLOW BLOW FUSE.................................................................................................. 78
		11.11 STORAGE PLACE FOR THIS MANUAL................................................................................... 79
		11.12 AUXILIARY POWER SOURCE.......................................................................................... 79
			11.12.1 FOR MACHINES EQUIPPED WITH ROPS CAB....................................................................... 79
	12. CHECK BEFORE STARTING ENGINE.......................................................................................... 80
		12.1 WALK AROUND CHECK................................................................................................ 80
		12.2 CHECK BEFORE STARTING............................................................................................ 83
			12.2.1 CHECK COOLANT LEVEL, ADD COOLANT........................................................................... 83
			12.2.2 CHECK FUEL LEVEL, ADD FUEL................................................................................. 83
			12.2.3 CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL................................................................. 84
			12.2.4 CHECK AND REFILL OF OIL IN BRAKE OIL TANK.................................................................. 84
			12.2.5 CHECK DUST INDICATOR....................................................................................... 85
			12.2.6 CHECK ELECTRICAL WIRING.................................................................................... 85
			12.2.7 DRAIN THE WATER FROM THE FUEL-WATER SEPARATOR.............................................................. 86
			12.2.8 CHECK EFFECT OF PARKING BRAKE.............................................................................. 86
			12.2.9 CHECK EFFECT OF WHEEL BRAKES............................................................................... 87
			12.2.10 CHECK SOUND OF HORN AND BACKUP ALARM...................................................................... 87
			12.2.11 CHECK FLASHING OF LAMPS, CHECK FOR DIRT AND DAMAGE........................................................ 87
			12.2.12 CHECK ENGINE EXHAUST COLOR AND SOUND...................................................................... 87
			12.2.13 CHECK OPERATIONS OF GAUGES................................................................................ 87
			12.2.14 CHECK PLAY OF STEERING WHEEL, CHECK OPERATION OF STEERING................................................. 87
			12.2.15 CHECK DIRECTION OF REAR VIEW MIRROR, CHECK FOR DIRT OR DAMAGE............................................. 87
			12.2.16 CHECK LOCK OF CAB DOOR FOR MACHINES EQUIPPED WITH CAB..................................................... 87
		12.3 ADJUSTMENT BEFORE OPERATION...................................................................................... 88
			12.3.1 OPERATOR'S SEAT............................................................................................ 88
			12.3.2 ADJUST SEAT BELT........................................................................................... 90
			12.3.3 ADJUST REAR VEIW MIRRORS................................................................................... 91
		12.4 OPERATIONS AND CHECKS BEFORE STARTING ENGINE..................................................................... 92
		12.5 STARTING ENGINE.................................................................................................. 93
			12.5.1 NORMAL STARTING PROCEDURES IN COLD AND WARM CONDITIONS..................................................... 93
			12.5.2 STARTING PROCEDURES AFTER EXTENDED SHUTDOWN OR OIL CHANGE.................................................. 94
			12.5.3 STARTING PROCEDURES AFTER CHANGING FUEL FILTERS............................................................ 94
			12.5.4 STARTING PROCEDURES AFTER RUNNING OUT OF FUEL.............................................................. 94
		12.6 OPERATIONS AND CHECKS AFTER STARTING ENGINE...................................................................... 95
		12.7 MOVING MACHINE OFF............................................................................................... 96
		12.8 CHANGING GEAR SPEED.............................................................................................. 98
		12.9 CHANGING DIRECTION............................................................................................... 98
		12.10 TURNING......................................................................................................... 99
		12.11 STOPPING MACHINE................................................................................................100
		12.12 OPERATION OF WORK EQUIPMENT (WITH BUCKET TOOL)..................................................................101
			12.12.1 LIFT ARM OPERATION (LEVER)................................................................................101
			12.12.2 BUCKET OPERATION (LEVER)..................................................................................101
		12.13 OPERATION OF WORK EQUIPMENT (WITH FORK TOOL)....................................................................102
			12.13.1 LIFT ARM OPERATION (LEVER)................................................................................102
			12.13.2 FORK OPERATION (LEVER)....................................................................................102
		12.14 OPERATION OF WORK EQUIPMENT (WITH MULTI- PURPOSE BUCKET TOOL)...................................................103
			12.14.1 LIFT ARM OPERATION (LEVER)................................................................................103
			12.14.2 BUCKET OPERATION (LEVER)..................................................................................103
			12.14.3 AUXILIARY OPERATION (LEVER)...............................................................................104
			12.14.4 POSITION INDICATOR........................................................................................104
		12.15 OPERATION OF WORK EQUIPMENT (WITH MATERIAL HANDLING ARM)........................................................106
			12.15.1 LIFT ARM OPERATION (LEVER)................................................................................106
		12.16 HYDRAULIC QUICK COUPLER.........................................................................................107
			12.16.1 COUPLING THE ATTACHMENT...................................................................................107
			12.16.2 UNCOUPLING FROM THE ATTACHMENT............................................................................108
			12.16.3 ATTACHMENTS REQUIRING HYDRAULIC POWER.....................................................................109
		12.17 WORK POSSIBLE USING PARALLEL TOOL CARRIER.......................................................................110
			12.17.1 DIGGING OPERATIONS WITH ROCK PILES........................................................................110
			12.17.2 DIGGING OPERATIONS ON LEVEL GROUND........................................................................111
			12.17.3 LEVELING OPERATION........................................................................................112
			12.17.4 PUSHING OPERATIONS........................................................................................112
			12.17.5 LOAD AND CARRY OPERATIONS.................................................................................112
			12.17.6 LOADING OPERATIONS........................................................................................113
			12.17.7 MULTI-PURPOSE BUCKET......................................................................................114
			12.17.8 PALLET FORKS..............................................................................................119
			12.17.9 MATERIAL HANDLING ARM.....................................................................................122
		12.18 PRECAUTIONS FOR OPERATION.......................................................................................123
			12.18.1 PERMISSIBLE WATER DEPTH...................................................................................123
			12.18.2 IF WHEEL BRAKE DOES NOT WORK..............................................................................123
			12.18.3 PRECAUTIONS WHEN DRIVING UP OR DOWN SLOPES................................................................123
			12.18.4 PRECAUTIONS WHEN DRIVING MACHINE..........................................................................124
		12.19 ADJUSTING BOOM KICK-OUT POSITIONER..............................................................................125
			12.19.1 ADJUSTING BOOM KICK OUT...................................................................................125
			12.19.2 ADJUSTING BUCKET / FORK POSITIONER........................................................................126
		12.20 PARKING MACHINE.................................................................................................127
		12.21 CHECKS AFTER COMPLETION OF ENGINE OPERATION.....................................................................128
		12.22 STOPPING ENGINE.................................................................................................128
		12.23 CHECKS AFTER STOPPING ENGINE....................................................................................129
		12.24 LOCKING.........................................................................................................129
		12.25 HANDLING THE TIRES..............................................................................................130
			12.25.1 PRECAUTIONS WHEN HANDLING THE TIRES.......................................................................130
			12.25.2 TIRE PRESSURE.............................................................................................130
	13. TRANSPORTATION........................................................................................................132
		13.1 LOADING, UNLOADING WORK..........................................................................................132
		13.2 PRECAUTION FOR LOADING...........................................................................................133
		13.3 PRECAUTION FOR LIFTING UP THE VEHICLE............................................................................133
			13.3.1 THE LOCATION OF DECALS REFERRING TO LIFTING POSITIONS......................................................134
			13.3.2 WEIGHT LIST................................................................................................134
			13.3.3 LIFTING PROCEDURE..........................................................................................135
	14. COLD WEATHER OPERATIONS...............................................................................................136
		14.1 PRECAUTIONS FOR LOW TEMPERATURE..................................................................................136
			14.1.1 FUEL AND LUBRICANTS........................................................................................136
			14.1.2 COOLANT....................................................................................................136
			14.1.3 BATTERY....................................................................................................137
		14.2 PRECAUTIONS AFTER COMPLETION OF WORK.............................................................................138
		14.3 AFTER COLD WEATHER...............................................................................................138
	15. LONG TERM STORAGE.....................................................................................................139
		15.1 BEFORE STORAGE...................................................................................................139
		15.2 DURING STORAGE...................................................................................................139
		15.3 AFTER STORAGE....................................................................................................139
	16. TROUBLESHOOTING.......................................................................................................140
		16.1 WHEN MACHINE RUNS OUT OF FUEL....................................................................................140
		16.2 TOWING THE MACHINE...............................................................................................141
			16.2.1 WHEN ENGINE CAN BE USED....................................................................................143
			16.2.2 WHEN ENGINE CANNOT BE USED.................................................................................143
		16.3 IF BATTERY IS DISCHARGED.........................................................................................144
			16.3.1 REMOVAL AND INSTALLATION OF BATTERY........................................................................144
			16.3.2 PRECAUTIONS FOR CHARGING BATTERY...........................................................................145
			16.3.3 STARTING ENGINE WITH BOOSTER CABLE.........................................................................146
		16.4 OTHER TROUBLE....................................................................................................148
			16.4.1 ELECTRICAL SYSTEM..........................................................................................148
			16.4.2 CHASSIS....................................................................................................149
			16.4.3 ENGINE.....................................................................................................152
MAINTENANCE...................................................................................................................155
	17. GUIDES TO MAINTENANCE.................................................................................................156
	18. OUTLINES OF SERVICE...................................................................................................159
		18.1 OUTLINE OF OIL, FUEL, COOLANT....................................................................................159
			18.1.1 OIL........................................................................................................159
			18.1.2 FUEL.......................................................................................................159
			18.1.3 COOLANT....................................................................................................160
			18.1.4 GREASE.....................................................................................................161
			18.1.5 STORING OIL AND FUEL.......................................................................................161
			18.1.6 FILTERS....................................................................................................161
		18.2 OUTLINE OF ELECTRIC SYSTEM.......................................................................................162
	19. WEAR PARTS LIST.......................................................................................................163
	20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE..................................................164
		20.1 ENGINE OIL SPECIFICATIONS........................................................................................165
		20.2 DIESEL FUEL SPECIFICATIONS.......................................................................................166
		20.3 COOLANT SPECIFICATIONS...........................................................................................167
	21. STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS.........................................................................173
		21.1 INTRODUCTION OF NECESSARY TOOLS..................................................................................173
		21.2 TORQUE LIST......................................................................................................174
	22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS.........................................................................176
	23. MAINTENANCE SCHEDULE CHART............................................................................................180
		23.1 MAINTENANCE SCHEDULE CHART.......................................................................................180
	24. SERVICE PROCEDURES....................................................................................................184
		24.1 INITIAL 250 HOURS SERVICE........................................................................................184
			24.1.1 REPLACE FUEL FILTERS “EVERY 500 HOURS SERVICE..............................................................184
			24.1.2 REPLACE TRANSMISSION OIL FILTER ELEMENT EVERY 500 HOURS SERVICE............................................184
			24.1.3 REPLACE HYDRAULIC TANK FILTER ELEMENT EVERY 1000 HOURS SERVICE.............................................184
		24.2 WHEN REQUIRED....................................................................................................185
			24.2.1 CHECK, CLEAN OR REPLACE AIR CLEANER ELEMENT................................................................185
			24.2.2 CHECK TRANSMISSION OIL LEVEL, ADD OIL......................................................................187
			24.2.3 CHECK AXLE OIL LEVEL , ADD OIL.............................................................................188
			24.2.4 CLEAN THE AXLE CASE BREATHER...............................................................................189
			24.2.5 CLEAN RADIATOR FINS........................................................................................189
			24.2.6 REPLACE THE BOLT-ON CUTTING EDGES..........................................................................190
			24.2.7 REPLACE BUCKET TEETH (IF EQUIPPED).........................................................................191
			24.2.8 CHECK AIR CONDITIONER (IF EQUIPPED)........................................................................192
			24.2.9 CHECK THE AIR CONDITIONER CONDENSER (IF EQUIPPED)..........................................................193
			24.2.10 CHECK WINDOW WASHING FLUID................................................................................193
			24.2.11 ADJUST PARKING BRAKE......................................................................................194
			24.2.12 REPLACE SLOW BLOW FUSE....................................................................................195
			24.2.13 CHECK AIR INTAKE HEATER...................................................................................195
		24.3 CHECK BEFORE STARTING............................................................................................196
		24.4 EVERY 50 HOURS SERVICE...........................................................................................197
			24.4.1 CHECK THE TIRE INFLATION PRESSURE..........................................................................197
			24.4.2 DRAIN WATER, SEDIMENT FROM FUEL TANK.......................................................................197
		24.5 EVERY 100 HOURS SERVICE..........................................................................................198
			24.5.1 CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL.................................................................198
			24.5.2 CLEAN ELEMENT IN AIR CONDITIONER FRESH AIR FILTER..........................................................199
			24.5.3 LUBRICATING................................................................................................200
		24.6 EVERY 250 HOURS SERVICE..........................................................................................201
			24.6.1 CHANGE OIL IN ENGINE OIL PAN AND REPLACE ENGINE OIL FILTER.................................................201
			24.6.2 CHECK FOR LOOSE WHEEL HUB NUTS. TIGHTEN....................................................................202
			24.6.3 CLEAN ELEMENT IN AIR CONDITIONER RECIRCULATION FILTER......................................................202
			24.6.4 CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST......................................................203
			24.6.5 CHECK BATTERY ELECTROLYTE LEVEL............................................................................204
			24.6.6 CHECK AIR INTAKE SYSTEM....................................................................................204
			24.6.7 LUBRICATING................................................................................................205
		24.7 EVERY 500 HOURS SERVICE..........................................................................................206
			24.7.1 REPLACE FUEL FILTERS.......................................................................................206
			24.7.2 REPLACE TRANSMISSION OIL FILTER ELEMENT....................................................................208
			24.7.3 LUBRICATE..................................................................................................209
		24.8 EVERY 1000 HOURS SERVICE.........................................................................................210
			24.8.1 CHANGE OIL IN TRANSMISSION CASE, CLEAN STRAINER............................................................210
			24.8.2 CLEAN TRANSMISSION CASE BREATHER...........................................................................211
			24.8.3 LUBRICATE..................................................................................................212
			24.8.4 CHANGE OIL IN HYDRAULIC OIL TANK, REPLACE HYDRAULIC FILTER ELEMENT.........................................213
			24.8.5 ADJUST ENGINE VALVE LASH CLEARANCE After the first 1000 hours only thereafter evey 2000 hour intervals.....214
			24.8.6 CHECK FAN BELT TENSION.....................................................................................215
			24.8.7 CHECK FAN BELT TENSIONER BEARING & FAN HUB BEARING & INSPECT FAN BELT......................................215
		24.9 EVERY 2000 HOURS SERVICE.........................................................................................216
			24.9.1 COOLING SYSTEM, REPLACE COOLANT AND FLUSH THE SYSTEM.......................................................216
			24.9.2 REPLACE HYDRAULIC TANK BREATHER ELEMENT....................................................................219
			24.9.3 CHANGE AXLE OIL............................................................................................219
			24.9.4 CHECK BRAKE DISC WEAR......................................................................................220
			24.9.5 CHECK ALTERNATOR...........................................................................................220
			24.9.6 CHECK STARTER MOTOR........................................................................................220
			24.9.7 CHECK VIBRATION DAMPER.....................................................................................220
			24.9.8 REPLACE ELEMENT IN AIR COND. RECIRCULATION AIR FILTER AND FRESH AIR FILTER.................................220
			24.9.9 ADJUST ENGINE VALVE LASH CLEARANCE.........................................................................221
SPECIFICATIONS................................................................................................................223
	25. SPECIFICATIONS........................................................................................................224
OPTIONS, ATTACHMENTS..........................................................................................................231
	26. AVAILABLE ATTACHMENTS.................................................................................................232
	27. SELECTING ATTACHMENTS AND TIRES.......................................................................................233
	28. HEATER AND AIR CONDITIONING (IF EQUIPPED).............................................................................234
		28.1 GENERAL LOCATION AND FUNCTION OF CONTROL PANEL...................................................................234
		28.2 COOL BOX COMPARTMENT.............................................................................................235
	29. HANDLING E.C.S.S. (ELECTRONIC CONTROLLED SUSPENSION SYSTEM)...........................................................236
		29.1 STRUCTURE AND FUNCTION OF E.C.S.S................................................................................236
		29.2 METHOD OF OPERATING E.C.S.S......................................................................................237
		29.3 PRECAUTIONS WHEN OPERATING E.C.S.S...............................................................................237
		29.4 PRECAUTIONS WHEN HANDLING ACCUMULATOR............................................................................238

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KOMATSU WA180-3 PARALLEL TOOL CARRIER OPERATION & MAINTENANCE MANUAL – PDF DOWNLOAD:

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