Komatsu WA115-3 Wheel Loader Operation and Maintenance Manual (WA115H30051 and up) - VEAM120100

This manual PDF download describes procedures for operation, handling, lubrication, maintenance, checking, and adjustment for the WA115-3 Komatsu Wheel Loader (SN: WA115H30051 and up). It will help the operator or anyone realize peak performance through effective, economical and safe machine operation and maintenance.


APPLICABLE MODELS :

Komatsu WA115-3 Wheel Loader
Serial Numbers : WA115H30051 and up


TABLE OF CONTENTS :

1. Introduction
2. Safety
3. Operation
4. Troubleshooting
5. Maintenance
6. Technical data
7. Special equipment and attachments
8. Index


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Bookmarked : Yes
Searchable : Yes
Printable : Yes
Product Code : VEAM120100
Total Pages : 251


This manual provides rules and guidelines which will help you use this machine safely and effectively. The precautions in this manual must be followed at all times when performing operation and maintenance.

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1.Introduction
1.1.Foreword
EU Directives
1.2.Safety information
1.3.Introduction
1.3.1.Intended use
1.3.2.Breaking-in the machine
1.4.Location of plates
1.4.1.Machine identification plate
1.4.2.Vehicle identification number
1.4.3.Engine name-plate with serial no.
1.4.4.Table to enter serial no. and distributor
1.5.Table of contents
1.6.Dimensions, weights and operating data
1.7.CE-conforming equipment
1.7.1.CE-conforming equipment – part 1
1.7.2.CE-conforming equipment – part 2
1.7.3.CE-conforming equipment – part 3
1.7.4.Manufacturer-supplied CE-conforming equipment, according to document 42R 93 19080
1.8.Loading and securing

2.Safety
2.1.General safety measures
2.1.1.Safety instructions
2.1.2.Safety devices
2.1.3.Emergency exit
2.1.4.Clothing and personal protection
2.1.5.Machine modifications
2.1.6.Before you leave the driver's seat
2.1.7.Mounting and dismounting
2.1.8.Fire prevention and fire fighting
2.1.9.Protection against asbestos dust
2.1.10.Protection against injuries
2.1.11.Working at high temperatures
2.1.12.Roll-over protection system (ROPS)
2.1.13.Attachment for protection against falling objects (FOPS)
2.1.14.Attachments with auxiliary function
2.1.15.Battery
2.2.Safety precautions during operation
2.2.1.Prior to daily starting up
Workplace safety
In the driver's cab
Indoor operation
Gas, dust, and inflammable vapours
Mirrors, windows and lighting
2.2.2.Machine operation
Before you start the engine
Reversing
Driving
Driving on slopes
Emergency lowering system
Working close to power lines
Loading
Good vision
Working on snow
Height limitation
Brakes
Working on loose soil
Working with the forklift truck attachment
Parking the machine
2.3.Safety measures during transport
2.3.1.Loading and unloading the machine
2.3.2.Transport
2.4.Precautions for maintenance
2.4.1.Personnel
2.4.2.Before carrying out maintenance
2.4.3.During maintenance
2.4.4.Tyres
2.5.Labels on the machine
2.5.1.Positions and order numbers of safety labels
2.5.2.Positions and order numbers of information labels

3.Operation
3.1.General view
3.1.1.General view of the machine
3.1.2.Controls and Indicators
3.2.Controls
3.2.1.Switches
Instrument Panel
Switches – Cab top left/right
Switches – on direction indicator lever
Switches – on the multifunction lever
Switches – to the right of the driver’s seat
Switches – to the left of the driver’s seat
Switch – battery main switch
3.2.2.Operating and control levers
3.2.3.Pedals
3.2.4.Miscellaneous controls
3.3.Control lamps, measuring indicators und warning lights
3.3.1.Overview
3.3.2.Control lamps
3.3.3.Measuring indicators
3.3.4.Warning lights
3.4.Description of individual elements
3.4.1.Safety bar
3.4.2.Towing pin
3.4.3.Alarm horn for reverse driving – option
3.4.4.Fuses
3.4.5.Slow-Blowing Fuses
3.4.6.Heater and ventilation system
3.5.Checks and adjustments prior to starting work
3.5.1.Visual inspection
3.5.2.Control checks
Cooling system – checking the coolant level, topping up coolant
Checking the engine oil level – topping up oil
Checking the fuel level – refuelling
Checking the controls
Checking the electrical connections
Heater/air conditioning – checking rate of air flow
Miscellaneous tests before starting work
3.5.3.Adjustments
Adjusting the driver’s seat
Adjusting the steering column
Adjusting the armrest
Adjusting the rear-view mirrors
Putting on the safety belt
3.6.Operation
3.6.1.Starting the engine
Warming up the engine
3.6.2.Switching off the engine
3.6.3.Driving with the machine
Start-up
Switching high-speed gear on/off – option
Changing the driving direction
Turning and steering
Braking
Stopping
Longer-distance driving
3.6.4.Actuating working attachment
Multifunctional lever
Control lever for auxiliary functions
3.6.5.Raise/lower working attachment
Select working attachment
Raise working attachment
Lower working attachment
3.6.6.Working with the wheeled loader
Tyre-appropriate operation
Level indicator for the bucket
Adjusting the bucket positioner
Loading work
Removal work
Excavation work
Transporting
Unloading
Planing
Working with the forklift truck attachment
3.6.7.Precautions For Special Operations
Permissible water depth
Working on snow
Dumping on steep slopes
Working in the vicinity of electrical overhead lines
Operation on slopes
Working on loose soil
3.6.8.If wheel brake fails to work
3.6.9.Check after stopping the engine
3.6.10.Locking
3.6.11.Tyre handling
Precautionary measures when handling tyres
Tyre pressure
3.7.Transport
3.7.1.Securing the articulated steering
3.7.2.Loading and securing the machine
3.7.3.Driving machine onto loading area of transport vehicle
3.7.4.Securing machine for transport
3.7.5.Transporting the machine
3.7.6.After Transport
3.8.Cold weather operation
3.8.1.Precautions for low temperatures
Fuel and lubricants
Coolant
Battery
3.8.2.Precautions after completion of work
3.8.3.After the cold weather period
3.9.Long-term storage
3.9.1.Before storage
3.9.2.During storage
3.9.3.After storage

4.Troubleshooting
4.1.When the machine runs out of fuel
4.2.Towing the machine
4.3.If battery is discharged
4.3.1.Precautions for charging the battery
4.3.2.Starting the engine with a booster cable
4.4.For insufficient braking effect
4.4.1.Checking the brake function
4.4.2.Checking the parking brake function
4.5.Emergency steering properties
4.6.Emergency lowering
4.7.Other troubles
4.7.1.Electrical system
4.7.2.Engine
4.7.3.Hydraulic system
4.7.4.Brakes
4.7.5.Steering
4.7.6.Axles
4.7.7.Driver's Cab

5.Maintenance
5.1.Maintenance guide
5.2.Maintenance basics
5.2.1.Oil, fuel and coolant specifications
Oil
Fuel
Coolant
Grease
Storing oil and fuel
Filters
Biodegradable hydraulic oil and lubricants
5.2.2.Specifications of the electrical system
5.3.Wearing parts list
5.4.Lubricants, fuels and filling capacities
5.5.Tools and standard tightening torques (bolts, nuts)
5.5.1.Introduction of recommended tools
5.5.2.Torque list
5.6.Periodical replacement of safety-critical parts
5.7.Maintenance schedule chart
5.8.Service procedure
5.8.1.Pre-start checklist
Cooling system – checking the coolant level, toping up coolant
Checking the engine oil level – topping up oil
Checking the fuel level – refuelling
Checking the controls
Checking the electrical connections
Heater/air conditioning – checking rate of air flow
Miscellaneous tests before starting work
5.8.2.Maintenance upon demand
Checking the air-conditioning system
Checking the window washing-fluid level, adding fluid
5.8.3.Maintenance after first 50 service hours
Engine – changing oil and replacing the oil filter cartridge
Check condition of V-belt
Check tension of generator V-belt and adjust
Check and adjust tension of air conditioning (option) compressor V-belt
Hydraulic system – replacing the filter insert
Check and tighten wheel nuts
Front and rear axle – oil change
Transfer box gearing – changing oil
5.8.4.Maintenance every 50 operating hours
Cooling system – checking the cooling system, coolant level in the radiator and expanion tank
Fuel tank – draining off water and dirt deposits
Service brake – checking the oil level, refilling oil
Battery – checking the acid level
Battery – re-charging the battery
Check and tighten wheel nuts
Lubrication
5.8.5.Maintenance every 100 operating hours
Water separator – removing water and dirt deposits
5.8.6.Maintenance after the first 250 operating hours
Engine – changing oil and replacing the oil filter cartridge
Check condition of V-belt
Check tension of generator V-belt and adjust
Check and adjust tension of air conditioning (option) compressor V-belt
Front and rear axle – checking the oil level
Air filter – checking and cleaning the filter insert
Radiator – cleaning the radiator segments
Lubrication
5.8.7.Maintenance every 500 operating hours
Fuel filter – changing the fuel filter and filter element
Purging the fuel system
Cleaning the water separator
Transfer box gearing – checking the oil level and refilling oil
Air filter – replacing the filter insert, replacing the safety filter
Heater/air conditioning – cleaning/replacing filter fleece or cleaning condenser
ALS-pressure accumulator (Option) - checking gas pressure
Lubrication
5.8.8.Maintenance every 1000 operating hours
Cooling system – exchanging coolant and cleaning the system
Hydraulic – ventilating the hydraulic oil tank
Hydraulic system – replacing the filter insert
Checking the tightening parts of the turbo-charger
Checking the play of the turbo-charger rotor
Service Brake – checking, testing, changing oil
System pressures – checking and adjusting
Valve play – checking and adjusting
Injection nozzles – checking and adjusting the , nozzle pressure and fuel-jet pattern
Check pressure accumulator – gas pressure
Front and rear axle – oil change
Transfer box gearing – changing oil
5.8.9.Maintenance every 2000 operating hours
Hydraulic system – oil change
Cooling system – checking the antifreeze content of the coolant
Checking the cooling system
Checking the fuel pump
Checking the fuel and coolant tubes, replacing the tubes (if required)
Checking the water pump
Checking and adjusting the fuel injection and Injection time

6.Technical data
6.1.Technical data
6.2.Noise emission levels
6.3.Vibration level
6.4.Limit values for slopes

7.Special equipment and attachments
7.1.ALS-electronics
7.1.1.Structure and functioning principle of the ALS-electronics
7.1.2.Precautionary measures for switching on the ALS-electronics
7.1.3.Operating the ALS-electronics
Switching ON the ALS?electronics
Switching OFF the ALS-electronics
7.1.4.Precautions when handling the accumulator
7.2.Air condition

8.Index

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