Komatsu WA150PZ-5 Wheel Loader Operation and Maintenance Manual (H50051 and up) - VEAM420100

This manual PDF download describes procedures for operation, handling, lubrication, maintenance, checking, and adjustment for the WA150PZ-5 Komatsu Wheel Loader (SN: H50051 and up). It will help the operator or anyone realize peak performance through effective, economical and safe machine operation and maintenance.


APPLICABLE MODELS :

Komatsu WA150PZ-5 Wheel Loader
Serial Numbers : H50051 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 : VEAM420100
Total Pages : 289


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. Foreword
1.1 Foreword
1.1.1 EU Directives
1.2 Safety information
1.2.1 Signal words
1.2.2 Safety labels
1.3 Introduction
1.3.1 Intended use
1.3.2 Directions of machine
1.4 Necessary information
1.4.1 PIN/Machine serial no. plate and position
1.4.2 Engine serial no. plate and position
1.4.3 ROPS/FOPS-Cab serial no. plate
1.4.4 Axle serial no. plate
1.4.5 Transmission serial no. plate
1.4.6 Seat operator serial no. plate
1.4.7 Position of service meter
1.4.8 Table to enter serial no. and distributor
1.5 Contents
1.6 Dimensions, weights and operating data
1.6.1 WA150PZ-5: Dimensions, weights and operating data
1.7 CE-Conforming equipment
1.7.1 CE-Conforming equipment
1.7.2 Manufacturer-supplied CE-Conforming equipment, according to document 419-93-H1250

2. Safety
2.1 Safety labels
2.1.1 Location of safety labels
2.1.2 Presentation of safety labels
2.2 General precautions
2.3 Precautions for operation
2.3.1 Starting engine
2.3.2 Operation
2.3.3 Transportation
2.3.4 Battery
2.3.5 Towing
2.4 Precautions for maintenance
2.5 Precautions with tires

3. Operation
3.1 General view
3.1.1 General view of machine
3.1.2 General view of controls and gauges
3.2 Explanation of components
3.2.1 Machine monitor
Monitor system
Types of warning
Central warning lamp
Character display portion
Emergency stop item
Caution items
Warning/Limit functions for travel speed
Inspection and maintenance item
Pilot display portion
Meter display portion
Other functions of machine monitor
3.2.2 Switches
3.2.3 Control levers, pedals
3.2.4 Steering tilt lock lever
3.2.5 Cap and cover with lock
3.2.6 Safety bar
3.2.7 Towing pin
3.2.8 Grease pump
3.2.9 Cab door inner lock
3.2.10 Cab door open lock
3.2.11 Cab window open lock cancel knob
3.2.12 Fuse
Fuse capacity and name of circuit
3.2.13 Slow blow fuse
3.2.14 Power outlet
3.2.15 Storage box
3.2.16 Air conditioner
General locations and function of control panel
Method of operation
Precautions when using
3.2.17 Handling cab wiper
Preventing damage to wiper arm bracket
3.3 Operation
3.3.1 Check before starting engine, adjust
Walk-around check
Check before starting
Adjustment
Safety belt
Operations and checks before starting engine
3.3.2 Starting engine
Normal starting
Starting in cold weather
3.3.3 Operations and checks after starting engine
Breaking-in the machine
Normal operation
3.3.4 Stopping engine
3.3.5 Moving the machine (directional, speed), stopping the machine
Moving the machine
Changing direction
Using switch to change between forward and reverse
Stopping the machine
3.3.6 Turning
Emergency steering
3.3.7 Operation of work equipment
3.3.8 Handling hydraulic quick coupler
3.3.9 Work possible using wheel loader
Digging operations
Leveling operation
Pushing operation
Load and carry operations
Loading operations
3.3.10 Precautions for operation
Permissible water depth
If wheel brake does not work
Precautions when driving up or down slopes
3.3.11 Adjusting work equipment posture
Adjusting boom kickout
Adjusting bucket positioner
Bucket level indicator
3.3.12 Parking machine
3.3.13 Check after stopping engine
3.3.14 Checks after completion of operation
3.3.15 Locking
3.3.16 Handling the tires
Precautions when handling tires
Tire pressure
Precautions for using load and carry method
3.4 Transportation
3.4.1 Transportation procedure
3.4.2 Loading, unloading work with trailers
Loading
Securing machine
Unloading
3.4.3 Lifting machine
Location of lifting position mark
Weight table
Lifting procedure
3.5 Cold weather operation
3.5.1 Precautions for low temperature
Fuel and lubricants
Coolant
Battery
3.5.2 Precautions after completion of work
3.5.3 After cold weather
3.5.4 Warming-up operation for steering hydraulic circuit in cold weather
3.6 Long-term storage
3.6.1 Before storage
3.6.2 During storage
3.6.3 After storage
3.7 Troubleshooting
3.7.1 When machine runs out of fuel
3.7.2 Towing the machine
When engine can be used
When engine cannot be used
Emergency travel operation
3.7.3 If battery is discharged
Removal and installation of battery
Precautions for charging battery
Starting engine with booster cable
3.7.4 Other trouble
Electrical system
Chassis
Engine

4. Maintenance
4.1 Guides to maintenance
4.2 Outlines of service
4.2.1 Handling oil, fuel, coolant, grease and carrying out KOWA (KOMATSU Oil Wear Analysis)
Oil
Fuel
Coolant
Grease
Carrying out KOWA (KOMATSU Oil Wear Analysis)
Storing oil and fuel
Filters
Biodegradable hydraulic oil and lubricants
4.2.2 Outline of electric system
4.3 Wear parts
4.3.1 Wear parts list
4.4 Fuel, coolant and lubricants
4.4.1 Lubrication chart
4.4.2 Proper selection of fuel, coolant and lubricants
4.5 Standard tightening torques for bolts and nuts
4.5.1 Torque list
4.6 Periodic replacement of safety critical parts
4.7 Maintenance schedule chart
4.7.1 Maintenance schedule chart
4.8 Service procedure
4.8.1 Initial 250 hours service (only after the first 250 hours)
4.8.2 When required
Check, clean, or replace air cleaner element
Dust pre-cleaner "Turbo II": Check, clean
Clean inside of cooling system
Check oil level in transfer case, add oil
Check axle oil level, add oil
Clean axle case breather
Clean slack adjuster
Clean air conditioner condenser
Check window washing fluid level, add fluid
Clean radiator fins and cooler fins
Check electrical intake air heater
Replace bolt on cutting edge
Replace bucket teeth
Check air conditioner
Replace slow blow fuse
Selection and inspection of tires
4.8.3 Check before starting
Check before starting
4.8.4 Every 50 hours service
Drain water, sediment from fuel tank
4.8.5 Every 100 hours service
Lubricate rear axle pivot pin
Clean element in air conditioner fresh air filter
Check oil level in hydraulic tank, add oil
Lubricating
4.8.6 Every 250 hours service
Check battery electrolyte level
Check parking brake
Check air conditioner compressor belt tension, adjust
Check for loose wheel hub bolts, tighten
Clean element in air conditioner recirculation filter
Lubricating
4.8.7 Every 500 hours service
Change oil in engine oil pan, replace engine oil filter cartridge
Replace fuel filter cartridge
Replacement of filter cartridge for poor-quality fuel
Clean water separator strainer
Lubricating
4.8.8 Every 1000 hours service
Change oil in transfer case
Clean transfer case breather
Replace HST oil filter element
Lubricating
Check tightening parts of turbocharger
Check play of turbocharger rotor
Check alternator driving belt tension and replacement
4.8.9 Every 2000 hours service
Change oil in hydraulic tank, replace hydraulic filter element
Replace hydraulic tank breather element
Cleaning the strainer of the brake filter
Change axle oil
Replace element in air conditioner recirculation air filter, fresh air filter
Check alternator, starting motor
Check engine valve clearance, adjust
Check brake disc wear
Clean and check turbocharger
Check accumulator gas pressure
Check vibration damper
4.8.10 Every 4000 hours service
Lubricating
Check water pump

5. Technical Data
5.1 Technical data
5.2 Noise emission levels
5.3 Vibration level

6. Attachments, Options
6.1 Selecting bucket and tires
6.2 Method of using 2 levers
6.2.1 Explanation of components
6.2.2 Operation
Using switch to change between forward and reverse
6.3 Handling fork tool
6.3.1 Explanation of components
Work equipment lever
6.3.2 Operation
Loading operation
Loading
Transporting
Unloading
6.4 Method of using 3 levers
6.4.1 Explanation of components
6.4.2 Operation
Using switch to change between forward and reverse
6.5 Central lubrication system
6.5.1 Operating the central lubrication system
6.5.2 Display and control unit
LED-display
Pushbuttons
6.5.3 Changing the lubrication interval times

7. Index
7.1 Index

8. Notes

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