Komatsu WA90-5 Wheel Loader Operation and Maintenance Manual (H50051 and up) - VEAM270101

This manual PDF download describes procedures for operation, handling, lubrication, maintenance, checking, and adjustment for the WA90-5 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 WA90-5 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
9. Notes


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Bookmarked : Yes
Searchable : Yes
Printable : Yes
Product Code : VEAM270101
Total Pages : 257


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. Engine name-plate
1.4.3. Axle serial no. plate
1.4.4. Transmission serial no. plate
1.4.5. ROPS/FOPS-Cab serial no. plate
1.4.6. Operator’s seat serial no. plate
1.4.7. 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. Manufacturer-supplied CE-conforming equipment
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
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
2.2.3. Transport
Loading and unloading the machine
Transport
2.3. Precautions for maintenance
2.3.1. Personnel
2.3.2. Before carrying out maintenance
2.3.3. During maintenance
2.3.4. Tyres
2.4. Safety labels on the machine
2.4.1. Positions and order numbers of safety labels

3. Operation
3.1. General view
3.1.1. General view of the machine
3.1.2. Controls and indicators
Overall view
Switches, controls and warning lights
3.2. Description of the individual elements
3.2.1. Instrument panel
Warning lights
Control lamps
Measuring indicators
3.2.2. Switches
3.2.3. Control levers and pedals
3.2.4. Articulated steering locking
3.2.5. Traction device
3.2.6. Socket (12 V)
3.2.7. Door unlocking system
3.2.8. Alarm horn for reverse driving - option
3.2.9. Fuses
3.2.10. Slow-blowing fuses
3.2.11. Adjusting the heater and ventilation system
3.2.12. Air-conditioning
3.3. Operation
3.3.1. Pre-start checks
Visual inspection
Pre-start checks
Adjustments prior to machine start
Adjusting the driver’s seat
3.3.2. Starting the engine
Warming up the engine
3.3.3. Driving with the machine
Start-up
Limiting the maximum speed
3.3.4. Changing the driving direction
3.3.5. Turning and steering
3.3.6. Braking
3.3.7. Stopping the machine
3.3.8. Operating the work equipment
Multifunctional lever
Control lever for special equipment
Switching lever of bucket
3.3.9. Working with the wheel loader
Tyre-appropriate operation
Switching on the 100 % differential lock (if equipped)
Loading work
Removal work
Excavation work
Planing
Transporting
Unloading
Working with the forklift truck attachment
3.3.10. 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
If the service brake breaks down
Precautionary measures when driving up or down
Precautionary measures during machine travel
3.3.11. Adjusting the position of the work equipment
Selecting a work unit
Removing the work unit
Picking up the multi-purpose bucket
Removing the multi-purpose bucket
Level indicator for the bucket
3.3.12. Parking the machine
3.3.13. Switching off the engine
3.3.14. Check after stopping the engine
3.3.15. Locking
3.3.16. Tyre handling
Precautionary measures when handling tyres
Tyre pressure
3.4. Transporting the machine
3.4.1. Securing the articulated steering
3.4.2. Lifting the machine
3.4.3. Driving the machine onto loading area of transport vehicle
3.4.4. Securing the machine during the transport
3.4.5. After transport
3.5. Cold weather operation
3.5.1. Before the cold season
3.5.2. Precautions after completion of work
3.5.3. After the cold season
3.6. Long-term storage
3.6.1. Before storage
3.6.2. During storage
3.6.3. After storage

4. Troubleshooting
4.1. Towing the machine
4.2. Starting the engine with a booster cable
4.3. For insufficient braking effect
4.3.1. Checking the service brake
4.3.2. Checking the parking brake function
4.4. Emergency steering properties
4.5. Emergency lowering
4.6. Other troubles
4.6.1. Electrical system
4.6.2. Engine
4.6.3. Hydraulic system
4.6.4. Brakes
4.6.5. Steering
4.6.6. Axles
4.6.7. 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
5.2.3. Wearing parts list
5.3. Lubricants, fuels and filling capacities
5.4. Tools
5.4.1. Introduction of recommended tools
5.5. Periodical replacement of safety-critical parts
5.6. Maintenance schedule chart
5.7. Service procedure
5.7.1. Pre-start checklist
Cooling system - checking the coolant level, topping up coolant
Cleaning the radiator segments
V-Belt, checking the condition
Engine, checking the oil level, topping up oil
Checking the fuel level - refuelling
Additional water separator (optional)
Water separator at the fuel filter - Draining water and dirt sediments
Checking the controls
Checking the electrical connections
Heater/air conditioning - checking rate of air flow
Miscellaneous tests before starting work
5.7.2. Maintenance upon demand
Checking the air-conditioning system
Checking the window washing-fluid level, adding fluid
Re-charging a built-in battery
5.7.3. Maintenance after the first 50 operating hours
Hydraulic system, replacing the filter insert
Checking and tightening the wheel nuts
5.7.4. Maintenance after the first 250 operating hours
Front and rear axle - oil change
Transfer box - changing oil
Checking and adjusting the valve clearance
5.7.5. Maintenance every 10 operating hours
Lubrication of articulated steering
5.7.6. Maintenance every 50 operating hours
Battery - checking the acid level
Lubrication of work unit
5.7.7. Maintenance every 250 operating hours
Service brake - Checking the brake pads
V-Belt, generator - checking and adjusting the tension
Air filter, removing and re-installing the filter insert, checking and cleaning the filter insert
Lubrication, steering cylinder
Lubrication, self-aligning bearings of rear axle
Checking and tightening the wheel nuts
5.7.8. Maintenance every 500 operating hours
Hand pump - Checking the oil level
Service brake - Checking the brake pads and brake discs, checking the oil level
Engine - changing oil
Replacing the oil filter cartridge
Changing the fuel filter element
Bleeding the fuel system
Bleeding the low pressure side:
Bleeding the high pressure side:
Air filter, replacing the filter insert, replacing the safety filter
Heater/air conditioning - cleaning/replacing filter fleece
Multi-functional lever accumulator - checking gas pressure
E.C.S.S.-pressure accumulator (Option) - checking gas pressure
Front and rear axle - checking the oil level
Transfer box - checking and refilling oil
5.7.9. Maintenance every 1000 operating hours
V-Belt, generator - checking and adjusting the tension
Service Brake - Checking and refilling oil
Checking and adjusting system pressures
Hydraulic - Exchanging the venting filter
Hydraulic system, replacing the filter insert
5.7.10. Maintenance every 1500 operating hours
Front and rear axle - changing oil
Transfer box - changing oil
5.7.11. Maintenance every 2000 operating hours
Cooling system - exchanging coolant and cleaning the system
Checking and adjusting the valve clearance
Hydraulic system - changing oil
Ventilating the hydraulic oil tank
Checking the fuel pump
Checking the fuel and coolant tubes, replacing the tubes (if required)
Checking the water pump
5.7.12. Maintenance every 4000 operating hours
Lubrication, drive shaft

6. Technical data
6.1. Technical data
6.2. Noise emission levels
6.3. Vibration levels
Operating condition
Guide to Reduce Vibration Levels on Machine
6.4. Limit values for slopes

7. Special equipment and attachments
7.1. E.C.S.S-electronics
7.1.1. Structure and functioning principle of the E.C.S.S-electronics
7.1.2. Precautionary measures for switching on the E.C.S.S-electronics
7.1.3. Operating the E.C.S.S-electronics
Switching ON the E.C.S.S.-electronics
Switching OFF the E.C.S.S-electronics
7.1.4. Precautions when handling the accumulator
7.2. Bucket position indicator

8. Index

9. Notes

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