Komatsu Wheel Loader WA65-3 Operation & Maintenance Manual
TABLE OF CONTENTS:
Komatsu Wheel Loader WA65-3 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
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DESCRIPTION:
Komatsu Wheel Loader WA65-3 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 the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
- Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.