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Komatsu
Compact Loader
WA75-3
Komatsu WA75-3 User Manual
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TROUBLESHOOTING
6-17
CHECKING
THE
SERVICE
BRAKE
•
Danger
o
f
accid
ents!
Always
put
on
the
safety
b
elt.
Dri
v
e
the
machine
on
a
flat,
dr
y
and
solid
road
a
t
a
spe
ed
of
20
km/h
and
apply
brakes.
F
or
this
pur
pose,
releas
e
the
accelerator
pedal
and
quickly
s
tep
on
the
brake
pe
dal.
The
braking
distan
ce
must
no
t
exceed
5m.
☞
•
All
repairs
on
the
brake
system
must
be
performed
by
a
garage
which
i
s
authorised
b
y
K
omatsu.
158
160
Table of Contents
Table of Contents
5
Introduction
13
Forword
14
Safety Information
15
Introduction
17
Features
17
Breaking in a New Machine
17
Location of Plates, Table to Enter Serial No. and Distributor
18
Machine Serial No. Plate Position
18
Engine Serial No. Plate Position
18
Emission Control Warranty
19
Emission Control Warranty Statement (Applies to Canada Only)
19
Engine Data Plate
20
Garantie Sur le Contrôle des Émissions
21
Énoncé de Garantie Sur le Contrôle des Émissions (Applicable au Canada Seulement)
21
Engine Data Plate
23
Why You Should Read These Operating Instructions
24
Notes on Safety Regulations
26
Correct Use
26
Safety Notes in the Operating Instructions
26
Equipment
27
Loading and Transporting the Machine
29
Securing the Articulated Steering
30
Lifting the Machine
30
Driving Machine Onto Loading Area of Transport Vehicle
32
Securing the Machine During Transport
33
After Transport
33
Safety
35
General Safety Measures
37
Safety Instructions
37
Safety Devices
37
Emergency Exit
37
Clothing and Personal Protection
38
Machine Modifications
38
Before You Leave the Driver's Seat
38
Mounting and Dismounting
39
Fire Prevention and Fire Fighting
40
Fire Extinguisher and First-Aid Kit
41
Protection against Asbestos Dust
41
Protection against Injuries
42
Working at High Temperatures
42
Roll-Over Protection System (Rops)
43
Attachment for Protection against Falling Objects (Fops)
43
Attachments
43
Battery
44
Safety Measures During Operation
45
Before You Start the Engine
45
Workplace Safety
45
In the Driver's Cab
45
In-Door Operation
46
Gas, Dust, and Inflammable Vapours
46
Mirrors, Windows, and Lighting
46
Machine Operation
47
Before You Start the Engine
47
Reversing
47
Driving
48
Driving on Slopes
48
Emergency Lowering System
49
Working Close to Overhead Power Transmission Lines
49
Loading
50
Good Vision
50
Working on Snow
50
Height Limitation
51
Brakes
51
Working on Loose Soil
51
Working with the Forklift Truck Attachment
52
Parking the Machine
53
Transport
54
Loading and Unloading the Machine
54
Transport
55
Safety Measures During Maintenance
56
Personnel
56
Prior to Start of Maintenance Measures
56
Warning Sign
56
Tools
56
Safety-Related Parts
56
Prior to Start of Inspection and Maintenance
57
Securing the Articulated Steering
57
Supporting the Boom
58
During Maintenance
59
Attachments
59
Working under the Machine
59
Keeping the Machine Clean
59
Specific Measures
59
Refueling and Topping off Oil
60
Coolant
60
Use of Lighting
61
High-Pressure Hoses
61
Handling High-Pressure Oil
61
Handling of the Pressure Accumulator
62
Fan and Belts
62
Waste Material
62
Tires
63
Storing Tires
64
Labeling
65
Position of Safety Labels
65
Information Labels
67
Controls and Indicators
69
Overall View of Machine
70
Controls and Indicators
71
Switches and Controls
72
Instrument Panel
73
Warning Lights
74
Control Lamps
77
Measuring Indicators
81
Switches
83
Control Levers, Pedals
90
Articulated Steering Catch
96
Traction Device
96
Socket
96
Door Unlocking System
97
Alarm Horn for Reverse Driving
97
Running in the Machine
100
Preparing the Machine Start
101
Visual Checks
101
Before You Start the Engine
101
Before Starting Working with the Machine
101
Adjustments Prior to Machine Start
104
Adjusting the Driver's Seat
104
Adjusting the Steering Column
105
Adjusting the Armrest
105
Adjusting the Rear-View Mirrors
105
Adjusting the Heating and Ventilation System
106
Adjusting the Ventilation System
106
Adjusting the Heating System
107
Operating the Air Conditioning
108
Switching on the Air-Conditioning
108
Putting on the Safety Belt
110
Taking off the Safety Belt
110
Starting and Switching off the Engine
111
Starting the Engine
111
Warming up the Engine
112
Switching off the Engine
113
Driving
114
Start-Up
114
Starting the Machine on Slopes
116
Driving with the High-Speed Gear
116
Changing the Driving Direction
117
Reverse Driving
118
Turning
118
Turning on Slopes, Embankments or Hill Flanks
118
Braking
119
Pulling the Parking Brake
119
Releasing the Parking Brake
119
Braking with the Service Brake
119
If the Service Brake Breaks down
120
Braking on Slopes
120
Stopping
121
Parking the Machine on a Slope
121
Longer-Distance Driving
122
Operating the Machine
123
Preparing the Work Equipment
123
Selecting a Work Unit
123
Picking up the Work Unit (Except Multi-Purpose Bucket)
123
Removing the Work Unit
124
Picking up the Multi-Purpose Bucket
124
Removing the Multi-Purpose Bucket
126
Tire Service Life
127
Level Indicator for the Bucket
127
Adjusting the Bucket Positioner
128
Loading
129
Removing Piled up Soil
129
Excavation Works
131
Transporting
132
Dumping / Unloading
132
Loading in Diagonal Direction
132
V-Shaped Loading
133
Piling up Material
133
Planing
134
Filling up
134
Taking off Soil
134
Cutting the Ground
135
Working with the Forklift Truck Attachment
136
Picking up the Load
136
Precautions for Special Operations
137
Working in Water
137
Working on Snow
137
Dumping on Steep Slopes
137
Working in the Vicinity of Electrical Overhead Lines
137
Operation on Slopes
137
Working on Loose Soil
137
After the Work Is Finished
137
Instructions for Winter Operation
138
Before the Cold Season
138
After Operation
138
After the Cold Season
139
Longer Standstill Periods of the Machine
140
Before the Standstill
140
During the Standstill
140
After the Standstill
141
Troubleshooting
143
Warning Lights and Indicators
144
Electrical System
145
Engine
146
Hydraulic System
149
Brakes
151
Axles
152
Driver's Cab
152
Emergency Steering Characteristics
153
Emergency Lowering System
153
Starting the Engine with a Battery Jumper Cable
154
Connecting the Jumper Cable
154
Starting the Engine
155
Disconnecting the Battery Jumper Cable
155
Towing the Machine
156
Towing a Machine with Defective Brakes
157
Inadequate Braking Effect
158
Checking the Parking Brake
158
Checking the Service Brake
159
Maintenance Basics
162
Preparing the Machine for Maintenance
162
Cleaning the Machine
163
Precautionary Measures When Cleaning the Machine
163
Fire Prevention
163
Working-Area-Dependent Maintenance
164
Muddy or Wet Working Areas
164
Dusty Working Areas
164
Lubricants and Operating Agents
165
Draining Hot Lubricants and Fluids
165
Checking the Oil Level and Changing Oil
165
Changing Filters
165
Refuelling and Topping off Oil
165
Oil
166
Lubricating Grease
166
Biodegradable Hydraulic Oil and Lubricating Grease
166
Fuel
167
Storage of Oil and Fuel
167
Coolants
168
Windscreen Washer Liquid
168
Table of Lubricants and Operating Agents
170
Lubrication Chart
171
Axles
172
Released Axle Oil Brands
172
Replacing Safety-Related Parts
172
Welding Instructions
173
Spare Parts and Consumable Components
174
Electrical System
175
Fuses
176
Fuse Assignment
176
Slow-Blowing Fuses
177
Tires
178
Tire Components
178
Checking the Tires
178
Checking the Tire Pressure
178
Torque for Standard Nuts and Bolts
180
Maintenance Schedule
182
Maintenance Prior to Start
184
Visual Checks
184
Cooling System, Checking the Coolant Level, Topping off Coolant
184
Engine, Checking the Oil Level, Topping off Oil
185
Engine, Draining off Oil
186
Checking the Fuel Level, Refueling
187
Checking the Controls
188
Checking the Electrical Connections
188
Heater / Air Conditioning: Checking Rate of Air Flow
189
Other Maintenance Measures Prior to Start
189
Maintenance Upon Demand
190
Checking the Air-Conditioning System
190
Checking the Coolant Level
190
Maintenance Every 10 Operating Hours
191
Lubrication
191
Maintenance after the First 50 Operating Hours
192
Engine, Changing Oil and Replacing the Oil Filter Cartridge
192
Replacing the Oil Filter Cartridge
193
V-Belt, Checking the Condition
194
V-Belt, Checking and Adjusting the Tension
194
Hydraulic System, Replacing the Filter Insert
195
Checking and Tightening the Wheel Nuts
196
Front and Rear Axle, Changing Oil
197
Planet Gear
197
Differential
197
Transfer Gear - Changing Oil
198
Maintenance Every 50 Operating Hours
200
Checking Cooling System, Coolant Level in the Radiator and Expansion Tank
200
Draining off Water and Dirt Deposits from the Fuel Tank
201
Checking the Service Brake and Oil Level, Refilling Oil
201
Checking the Battery and Acid Level
202
Re-Charging a Built-In Battery
203
Lubrication
204
Lubricating Points of the Work Equipment
204
Maintenance Every 100 Operating Hours
205
Draining the Water Separator, Removing Water and Dirt Deposits
205
Maintenance Every 250 Operating Hours
206
Changing the Engine Oil and Oil Filter Cartridge
206
Checking the V-Belt Condition
206
Checking and Adjusting the V-Belt Tension
206
Front and Rear Axle, Checking the Oil Level
207
Planet Gear
207
Differential
208
Air Filter, Removing/Re-Installing and Checking/Cleaning the Filter Insert
209
Structure of the Air Filter
209
Maintenance Demand
209
Removing the Filter Cartridge
209
Cleaning or Exchanging the Filter Cartridge
210
Checking the Filter Cartridge
211
Assembling the Air Filter Cartridge
211
Cleaning the Radiator Segments
211
Lubrication
212
Maintenance Every 500 Operating Hours
213
Changing the Fuel Filter and Filter Element
213
Bleeding the Fuel System
214
Changing the Filter Cartridge of the Hydraulic System
215
Cleaning the Water Separator
215
Lubrication
216
Transfer Gear, Checking the Oil Level and Refilling Oil
216
Air Filter, Replacing the Filter Insert, Replacing the Safety Filter
217
Replacing the Filter Insert
217
Replacing the Safety Filter
217
Heater/Air Conditioning: Clean Filter Fleece of Heater Unit
218
Heater/Air Conditioning: Cleaning the Condenser
219
Maintenance Every 1000 Operating Hours
220
Cooling System, Exchanging Coolant and Cleaning the System
220
Draining off the Coolant
221
Cleaning the Cooling System
221
Filling off Coolant
221
Front Axle, Oil Change
222
Rear Axle, Oil Change
222
Transfer Gear, Oil Change
222
Service Brake
222
Changing Oil
222
Checking Tubes and Lines
222
Checking the Brake Disks for Wear and Tear
222
Adjusting the Clearance of the Brake Disks
222
Checking and Adjusting System Pressures
222
Checking and Adjusting the Valve Clearance
222
Checking/Adjusting the Injection Nozzles, Nozzle Pressure/Fuel-Jet Pattern
223
Checking the Accumulator Gas Pressure
223
Maintenance Every 2000 Operating Hours
224
Hydraulic System, Oil Change
224
Bleeding the Hydraulic Oil Tank
225
Cooling System, Checking the Antifreeze Content of the Coolant
225
Checking the Cooling System
225
Checking the Fuel Pump
225
Checking the Fuel and Coolant Tubes, Replacing the Tubes (if Required)
225
Checking the Water Pump
226
Checking and Adjusting the Fuel Injection and Injection Time
226
Technical Data
227
Noise Emission Levels
229
Vibration Level
229
Limit Values for Slopes
229
Maximum Slope Angle for Operating the Machine
229
Special Equipment and Attachments
231
Als-Electronics
232
Structure and Functioning Principle of the Als-Electronics
232
Precautionary Measures for Switching on the Als-Electronics
232
Operation of the Als-Electronics
233
Switching on the Als-Electronics
233
Switching off the Als-Electronics
233
Handling of the Pressure Accumulator
234
5
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Komatsu WA75-3 Specifications
General
Brand
Komatsu
Model
WA75-3
Category
Compact Loader
Language
English
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