PDF Operation and Maintenance Manual Komatsu WA90 5 Wheel Loader - 2 MB
This manual provides complete operation and maintenance instructions for the Komatsu WA90-5 wheel loader, serial numbers H50051 and up.
It is designed to help owners and operators perform routine service and operate the machine safely.
Proper use of this guide will help maximize the performance and lifespan of your loader.
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Operation & Maintenance VEAM270101
Manual
WHEEL LOADER
-5
SERIAL NUMBERS H50051 AND UP
DANGER
Incorrect operation and maintenance of this machine
may be hazardous and cause injuries. The operator and
maintenance personnel must read this manual before
commencing operation or maintenance. Keep this
manual within reach at all times and ensure that
operating personnel read it at regular intervals.
NOTE
Komatsu has had the operating and maintenance
instructions translated into all the languages of the
European Union. Should you require a copy in another
language please inquire at your local dealerβs.
Β© 2006 Komatsu Hanomag GmbH
All Rights Reserved
Printed in Europe 11-06
--- Page 3 ---
1.4. Location of plates Introduction
1.4.3. Axle serial no. plate
This plate is located on the right of front axle and on the left of
rear axle (1).
1.4.4. Transmission serial no. plate
This plate is located in travel direction front, above the transmis-
sion output (1).
1.4.5. ROPS/FOPS-Cab serial no. plate
This plate is located on the right inside cab on the rear beam (1).
1-10 WA90-5 β VEAM270101
--- Page 4 ---
1.7. CE-conforming equipment Introduction
1.7. CE-conforming equipment
1.7.1. CE-conforming equipment β part 1
CE-conforming equipment
1 2 3 4 β
Volume Hydr. pressure Weight
Type Part No.
mΒ³ bar kg
42W-70-22020 1,05 --- 355
42W-70-22030 1,05 --- 376,5
Bucket WA90-5
42W-70-22080 1,60 --- 461
42W-70-22061 0,90 250
1-20 WA90-5 β VEAM270101
--- Page 5 ---
2.1. General safety measures Safety
2.1.7. Mounting and dismounting
β Do not jump on or off the machine. Do not mount on or dis-
mount from a moving machine.
β Always use the handle bars and tread steps for mounting or
dismounting the machine. Do not hold onto the control levers
while mounting and dismounting.
β To ensure safe hold, hold the handle bar with one hand and
stand on the tread steps with both feet. Optionally, stand on
the tread steps with one foot and hold the handle bars with
both hands.
2.1.8. Fire prevention and fire fighting
β Fuel, oil, and antifreezing compound are highly inflammable
and could cause a fire.
β Do not approach inflammable material with naked light.
β Prior to refuelling, switch off the engine and stop smoking.
β Refuelling and refilling of oil are to be performed in sufficiently
ventilated places.
β Store oil and fuel in special places appropriate for this pur-
pose. Ensure that unauthorised persons do not have access
to these places.
β Tightly close all cover caps.
β Check the fuel system, the lubrication system, and the
hydraulic system for leaks. Have leaks repaired. Remove any
excess oil, fuel, or other inflammable substances.
β Carefully and completely remove wooden chippings, leaves,
paper, and other highly inflammable materials that may have
collected in the engine compartment, since they could cause
a fire.
β Do not operate the machine in the vicinity of naked light.
2-4 WA90-5 β VEAM270101
--- Page 6 ---
2.2. Safety precautions during operation Safety
Loading
β Proceed as follows to fill embankments, to backfill ditches, or
to deposit earth over the edge of a hill:
1. First, dump a heap of earth in front of the hill.
2. Fill the bucket with earth again and drive the machine into
the heap of earth. Dump the bucket contents behind the first
heap of earth.
β The load is relieved very suddenly when the heap of earth is
pushed over the edge of the hill or when the machine reaches
the edge of the hill. If this happens, the driving speed may
suddenly increase. For this reason, drive particularly slowly
and carefully at these points.
β If possible, perform all load operations with a following wind to
protect yourself against dust and impaired vision.
β Avoid sudden starts, turns, or stops when the bucket is full.
Good Vision
β When working in dark areas, switch on the working lights of
the machine and provide additional lighting for the working
area.
β If vision is impaired, e.g. due to mist, snow, or rain, interrupt
work and wait until vision has improved to such an extent that
safe work is ensured again.
Working on snow
β When working on snow or ice-covered surfaces, there is dan-
ger of the machine starting to skid even at a very flat angle.
For this reason, drive slowly and avoid sudden starts, turns,
or stops.
β Very often snow hides the edges of roads and other objects.
For this reason, proceed very carefully when removing snow.
β When driving on hill flanks covered with snow do not brake
abruptly to stop the machine. To stop the machine, lower the
bucket onto the ground.
β The load may vary considerably, depending on the structure
of the snow. For this reason, reduce the load and pay atten-
tion that the machine does not start to skid.
2-14 WA90-5 β VEAM270101
--- Page 7 ---
2.3. Precautions for maintenance Safety
Use of lighting
Always use explosion-proof lighting when checking fuel, oil,
coolant, or battery acid.
High-pressure hoses
β Neither bend high-pressure hoses nor hit them with hard
objects. Do not use piping or hoses with fissures, cracks, or
bends, since they may burst during operation.
β Immediately replace any loose or damaged fuel or oil hoses.
Leaking fuel or oil involves danger of fire and slipping.
β Replace all hoses every six years at the latest.
Handling high-pressure oil
β Always take into account that the hydraulic lines are
subjected to high pressure.
β Do not top up oil, drain oil, or perform maintenance or
inspection measures unless the work unit is completely
lowered and the system is depressurised.
β If oil comes out under high pressure, this involves danger of
an oil jet penetrating the skin or getting into the eyes. For this
reason, always wear safety goggles and thick safety gloves,
and use a piece of cardboard or wood when checking for oil
leaks.
β If you have been hit by an oil jet, immediately go and see a
doctor and explain what has happened.
2-24 WA90-5 β VEAM270101
--- Page 8 ---
3.1. General view Operation
Switches, controls and warning lights
29 33 27 25 20 32 22 24 21 18 23 19 44
34 40 31 30
41
G0065034A
39 42 43 45
37 28
36 26
35 38
l
18 Brake fluid reservoir warning light 32 High beam control lamp
19 Air filter warning light 33 Warning light: Water separator
20 Parking brake control lamp 34 Fuel gauge
21 Charging current warning light 35 Wiper and washer system switch (rear window)
22 Direction indicator switch control lamp 36 Wiper and washer system switch (windscreen)
23 Engine oil pressure warning light 37 Hazard warning lights switch and control lamp
24 Flasher signal control lamp 38 E.C.S.S. switch with control lampβ option
25 Intake air pre-heater control lamp 39 Warning beacon switch with control lamp β option
26 Heated rear window control lamp 40 Meter display pilot lamp
27 E.C.S.S. control lamp β option 41 Air conditioning switch with control lampβ option
28 Working lights switch and control lamp 42 Control lamp in the switch of the 3rd control circuit
- Optional
29 Switch and control lamp differential lock 43 Control lamp in Sprayer switch
100% - Optional
30 Coolant temperature indicator 44 Control lamp: Speed range 2
31 Operating hour meter 45 Switch with fan reversal control lamp
3-4 WA90-5 β VEAM270101
--- Page 9 ---
3.2. Description of the individual elements Operation
3. Temperaturanzeige KΓΌhlmittel
If you set the start switch to position βIβ, the temperature display
shows the temperature of the coolant.
β The background lights up in green if the coolant temperature
is normal.
β The background lights up red when the coolant temperature
is too high. The acoustic warning signal sounds.
Eliminate the malfunction as described in Chapter "4.6. Other GK100849A
troubles" on page 4-10.
β If only the two bars on the right of the temperature display are
lit, there is no electrical contact with the temperature sensor.
3-14 WA90-5 β VEAM270101
--- Page 10 ---
3.2. Description of the individual elements Operation
1. Brake pedal
WARNING
β If you are driving downhill, let the engine run and use the
braking effect of the engine. If required, brake
additionally using the brake pedal.
β Danger of accidents due to unintentional braking!
β Do not use the brake pedal as a foot rest.
The brake is operated via a combined brake/inch pedal. The inch-
ing exerts an additional braking effect on the hydrostatic drive
system.
2. Parking brake
As soon as you pull the parking brake lever from its normal posi-
tion, the braking action comes into effect. If the start switch is set
to the βIβ operating position, the parking brake warning light lights
up in the instrument panel. The machine will drive again, if you re-
loosen the parking brake.
NOTE
You cannot start the machine with the parking brake being
applied. If you set the driving direction switch to the βFβ posi-
tion (forward driving) or βRβ (reversing) with the parking brake
still being applied, the alarm buzzer will sound.
3. Steering column adjustment
The lever (2) for adjusting the steering column (1) position permits
to incline the steering column smoothly in two directions (front or
back). The adjustment range is 125 mm.
Proceed as described in chapter "Adjusting the steering column"
on page 3-43
3-24 WA90-5 β VEAM270101
--- Page 11 ---
3.3. Operation Operation
3.3. Operation
3.3.1. Pre-start checks
Visual inspection
WARNING
Danger of fire! Oil or fuel leaking out or accumulated com-
bustible materials may catch fire at hot parts of the machine,
e.g. the exhaust!
Prior to starting the machine, check the oil and fuel lines for
leaks and immediately repair any leaks. Store combustible
material in a safe place.
Before you start the engine
Check that there are no loose nuts or screws lying around the
machine. Check that neither oil, nor fuel nor coolant are leaking
out. Check the condition of the work unit and the hydraulic sys-
tem. Check that there are no loose cables and accumulated dirt.
Remove accumulated dirt and eliminate faults.
Before starting working with the machine
Perform daily the following measures:
1. Check work unit
Check work unit, cylinder, connecting rods, and hoses for
cracks, premature wear and tear, and play. Repair damaged
parts.
2. Remove dirt and dust
Check the area around the engine and the radiator for accu-
mulated dirt or dust. Additionally check whether combustible
material has accumulated near the battery or near hot parts of
the machine, e.g. the exhaust. Remove completely any accu-
mulated dirt or dust.
3. Check for leakage of water or oil around engine
Check that there is no oil leakage from the engine or water
leakage from the cooling system. If any abnormality is found,
repair it.
4. Check the gear unit, axles, hydraulic tank and hoses and
the connecting points
Check whether oil is leaking out of the gear unit, axles,
hydraulic tank and hoses, and connecting points. Repair
damaged parts.
5. Check brake hoses
Check that there is no oil leaking out at the brake hoses.
Repair damaged parts.
3-34 WA90-5 β VEAM270101
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3.3. Operation Operation
Adjusting the rear-view mirrors
Sit down on the driverβs seat and adjust the rear-view mirrors to
their required positions. You should be able to view the traffic
coming from behind without having to change your seating posi-
tion.
Putting on the safety belt
WARNING
β Danger of injury! A damaged safety belt, a safety belt that
has been stretched in an accident, or a safety belt the
belt fixings or fastening screws of which have not been
mounted correctly will not protect you sufficiently in
case of accident!
β Replace the safety belt, if it is damaged, or if the machine
has been involved in an accident. Check that the belt
fixings and fastening screws are in perfect condition,
before you put on the safety belt.
β If you have not put on the safety belt and are involved in
an accident, this may lead to severe injuries!
β Put on the safety belt, before you start work and do not
take it off during work. Put on the safety belt in such a
way that it is not twisted and fits tightly.
The machine is provided with a lap belt which automatically
retracts. When pulled slowly, automatic belts ensure full freedom
of action, but block immediately, if you suddenly brake or
accelerate, or if you drive downhill or take corners.
Putting on the safety belt
1. Sit down on the driver's seat.
2. Slowly and continuously pull out the belt.
3. Insert the lock tongue into the lock socket until the lock
engages.
4. Then, pull the belt to check whether or not the lock tongue is
fully engaged.
NOTE
The belt cannot be pulled out unless it is completely wound
up.
Taking off the safety belt
Press the orange button to release the lock of the safety belt and
allow the belt to wind up.
3-44 WA90-5 β VEAM270101
--- Page 13 ---
3.3. Operation Operation
3.3.7. Stopping the machine
Avoid abrupt stopping. Proceed as follows, if you want to stop the
machine:
1. Release the accelerator pedal and press down the brake
pedal.
2. Set the drive direction switch into its neutral position βNβ.
3. Apply the parking brake.
4. Lower the work unit onto the ground.
WARNING
β Unintentional activation of the multifunctional-lever or
moving of the equipment may lead to accidents!
β Before you leave the cab, turn the locking lever for the
work hydraulic system into position β1β. As a result, the
work hydraulic system is blocked.
5. Protect the work hydraulic system against unintentional
activation by turning the locking lever of the work hydraulic
system into position β1β..
Position 1 = working hydraulics locked
Position 2 = working hydraulics released
Parking the machine on a slope
Whenever possible, stop the machine on level ground.
β If you have to park the machine on a slope, it is required that
you park it in such a way that the front section (work unit)
points downhill.
β Lower the work unit onto the ground.
β Block the wheels with wheel chocks (1).
3-54 WA90-5 β VEAM270101
--- Page 15 ---
3.3. Operation Operation
V-shaped loading
Position the dump truck in such a way that the angle between the
dump and the dump truck is approx. 60Β°. Fill the bucket and
shake it. This leads to a better distribution of the cargo in the
bucket and prevents that material falls down to the back. Drive the
machine backwards from the heap and align the machine with the
dump truck. Raise the bucket to its maximum height. Drive up
forward to the dump truck and unload the material.
If you keep the turning angle of the machine as small as possible,
the work will be more efficiently.
Piling up material
Do not position the bucket in its maximum tip-in or dumping posi-
tion while piling up material. Instead, use the required mining
angle. The rear counterweight must not touch the ground.
Working with the forklift truck attachment
Operations with an forklift truck attachment on a wheel loader dif-
fer from operations with the bucket or a forklift truck. Take into
account the following notes and the instructions indicated in the 19.685 in
chapter "2.1. General safety measures" on page 2-2. (500 mm)
β Do not take up loads which are so high that you cannot see
19.685 in
onto the route.
(500 mm)
β Hold the fork tines of the forklift truck attachment as horizontal
as possible when you take up the load.
75_156
β During the ride, hold the load as low as possible in order to
have free sight onto the route.
β Always drive slowly (speed range 1) with the load.
β The boom performs a semicircular stroke while performing
the lifting movement. Raise the boom only immediately in
front of the place at which you want unload to the height at
which you want to unload. In such a way, you prevent that you
damage the load while lifting it.
β Hold the forklift truck attachment as horizontal as possible
while piling up.
3-64 WA90-5 β VEAM270101
--- Page 16 ---
3.3. Operation Operation
Removing the multi-purpose bucket
1. Lower the multi-purpose bucket onto level ground.
2. Switch off the engine.
3. Set the control lever for special equipment first to position β1β
and then to position β2β (figure G0065018.eps).
4. Turn the change-over lever for the supplementary control cir-
cuit to position β2β until it reaches the limit stop (figure
75_160). 2
5. Disconnect the multi-purpose bucket hoses from the quick
couplings.
6. Restart the engine. 1
7. Unlock the quick-change unit by setting the control lever for
special equipment into position β1β (fig. G0065018.eps).
75_160
8. Set the quick-change unit into the dumping position βAβ (fig.
G0065021.eps) using the multi-function lever, until the quick-
change unit is unhooked of the work unit's pickup hooks.
9. Make sure that nobody is behind the machine and drive the
machine away from the work unit.
Level indicator for the bucket
On both sides of the bucket the upper edges (see arrow) are
arranged in parallel to the bucket edge and can be used as a level
indicator for the bucket.
You can recognise the position of the cutting edge of the bucket
from the driverβs seat with the help of the level indicators.
3-74 WA90-5 β VEAM270101
--- Page 17 ---
3.5. Cold weather operation Operation
3.5.2. Precautions after completion of work
Realise the following actions to make sure that the machine can
be started the next time without problems:
β Remove mud and water from the car body. This prevents that
sealings are damaged due to freezing.
β Park the machine on hard and dry ground. If this is not possi-
ble, you must park the machine on wooden planks. The
planks prevent that the wheels are freezing to the ground.
β Drain off collected water from the fuel system.
β The battery capacity drops clearly at low temperatures.
Therefore, dismount the battery in frost periods and store it in
a warm place. Re-install it the next morning, before starting to
work.
3.5.3. After the cold season
If the weather becomes warmer, you must fill up the prescribed
fuel and use oils with prescribed viscosities (see chapter
"5.3. Lubricants, fuels and filling capacities" on page 5-18.
3-84 WA90-5 β VEAM270101
--- Page 18 ---
4.3. For insufficient braking effect Troubleshooting
4.3. For insufficient braking effect
4.3.1. Checking the service brake
Drive the machine at a speed of 20 km/h on a dry flat concrete
road surface, and check whether the stopping distance is less
than 5 m.
NOTE
All repairs conducted on the braking system must be con-
ducted at a Komatsu workshop.
4.3.2. Checking the parking brake function
1. Start the engine, set the machine to straight driving, and drive
the machine with an empty bucket up a gradient of 25%.
2. Stop the machine with the service brake and do not release
your foot again to keep the service brake applied.
3. Lower the bucket.
4. Set the driving direction switch (1) to its neutral position βNβ.
5. Switch off the engine.
6. Apply the parking brake (2) and slowly release the pedal of
the service brake.
2 1
The machine must stand still.
NOTE
All repairs conducted on the braking system must be con-
ducted at a Komatsu workshop.
4-8 WA90-5 β VEAM270101
--- Page 19 ---
4.6. Other troubles Troubleshooting
4-18 WA90-5 β VEAM270101
--- Page 20 ---
5 Maintenance
Welding instructions
β Turn off the engine start switch (OFF position).
β Disconnect the negative terminal on the battery.
β Do not apply more than 200V continuously.
β Connect grounding cable within 1 m from the area to be
welded.
β No seals or bearings may be between the area to be welded
and the grounding point.
β Never weld any pipe or tube containing fuel or oil.
β Keep a safety distance of min. 1 m between the area to be
welded and the battery.
Fire prevention
Use nonflammable cleaners or light oil for cleaning parts. Keep
flame or cigarette light away from light oil.
Clamp faces
When O rings or gaskets are removed, clean the clamp faces and
replace the O rings and gaskets with new ones. Be sure to fit O
rings and gaskets during re-assembly!
Objects in your pockets
Keep your pockets free of loose objects which can fall out and
drop into the machine (especially when bending over the
machine).
Tyres check
When working in rocky areas, check the tyres for damage and for
looseness, flaws, wear and tear. Re-tighten loose bolts and nuts.
Precautions when washing the machine
β Place the machine on a plane, even surface.
β Lower the work equipment to the ground.
β Apply the parking brake.
β Lock the wheels using support wedges to prevent the
machine from rolling away.
Proceed the following general measures, if you want to clean the
machine:
β Never spray steam or water directly on the radiator.
β Do not allow water to get on any electrical component.
5-10 WA90-5 β VEAM270101
--- Page 21 ---
5 Maintenance
5.5. Periodical replacement of safety-critical parts
To ensure trouble-free operation of the machine, the user of the
machine must always carry out periodic maintenance. In addition,
to maintain safety standards, the user should also periodically
replace all safety related parts, which are particularly closely
connected to safety and fire prevention.
β The standard service life under normal conditions should not
exceed 6 years.
β Hoses must be replaced as soon as the following damage is
noticeable:
β damage to the outer layer through to the intermediate
layer,
β brittleness in the outer layer,
β distortions in pressurised or unpressurised state not
conforming with the original shape of the installed hose,
β leakages,
β damage to the hose fittings or to the connection between
fittings and hose,
β storage damage (the shelf life of the hose should not
exceed 2 years).
When replacing the hoses, always replace the O-rings, gaskets,
and other such parts at the same time.
Ask your Komatsu distributor to replace the safety critical parts.
5-20 WA90-5 β VEAM270101
--- Page 22 ---
5 Maintenance
Heater/air conditioning β checking rate of air flow
1. Turn start switch to position βONβ.
G0065181.eps
2. Open all air circulation nozzles and air outlet nozzles (see
arrows).
3. Switch blower on.
4. Check whether sufficient air flows out of the air outlet nozzles.
5. If insufficient air is coming out of the jets, either the filter
fleece in the heating/air conditioning unit is dirty and will have
to be cleaned or replaced or the condenser in the air condi-
tioning system is dirty and will have to be cleaned; see
"Heater/air conditioning β cleaning/replacing filter fleece" on
page 5-56.
Miscellaneous tests before starting work
β Check that the lighting equipment operates correctly; check it
for dirt and damage.
β Check the measuring instruments.
β Check both the horn and the reversing warning horn.
β Check both clearance and operation of the steering wheel.
β Check the function of the rear-view mirror; check it for dirt and
damage.
5-30 WA90-5 β VEAM270101
--- Page 23 ---
5 Maintenance
Lubrication of work unit
Lubricating points of the work unit
DANGER
β If you perform maintenance operations at a machine
which is not properly parked and secured, severe acci-
dents may occur!
β Park the machine on firm, level ground and secure it
before starting the maintenance operations.
1. Park and secure machine for the maintenance operations as
described in chapter "5.1. Maintenance guide" on page 5-2.
2. Clean the grease nipples which are indicated by the arrows.
3. Use a grease gun to press sufficient grease into the grease
nipples.
(1) Lifting cylinder right and left side (4 locations)
(2) Rocker arm (2 locations)
(3) Boom (2 locations)
(4) Tipping cylinder (2 locations)
(5) Quick-change unit (2 locations)
(6) Clamshell bucket (6 locations)
4. Remove the old grease which is extruding at the bearings. 5
NOTE
If you operate in humid conditions or in a salty environment,
you must reduce the lubricating intervals.
6
6
75_263
5-40 WA90-5 β VEAM270101
--- Page 24 ---
5 Maintenance
Alll repairs on the brake system must be performed by a garage
which is authorised by Komatsu. max
1. For maintenance operations, park and secure machine as
described in chapter "5.1. Maintenance guide" on page 5-2 .
min
2. Check the brake fluid level at the expansion tank. The oil level
must be 0.394 - 0.787 inch (10 - 20 mm) below the upper
edge of the expansion tank (marking).
3. If you detect a significant oil loss, inform the responsible
Komatsu dealer.
4. Check the brake discs and brake pads for wear and damage.
5. Only move the sub-tank to position (1) to refill it.
POS 1
5-50 WA90-5 β VEAM270101
--- Page 25 ---
5 Maintenance
5.7.9. Maintenance every 1000 operating hours
All maintenance operations to be performed after 10, 50, 100, 250
and 500 hours of operation also fall into this maintenance cate-
gory.
V-Belt, generator β checking and adjusting the ten-
sion
DANGER
β There is danger of severe accidents, if you perform main-
tenance work at a machine that has not been parked and
secured correctly!
β Park the machine on a solid, even surface and secure it,
before you start to perform maintenance work.
β Danger of injuries! When the engine is in operation, there
is danger of severe injuries by moving parts within the
engine compartment! Do not work within the engine com-
partment, while the engine is in operation.
1. Before you start maintenance work, park and secure the
machine as described in the chapter "5.1Maintenance guide
5-2".
2. Press down the V-belt in the middle of the longest straight
part. You should be able to press the V-belt down about 10-15
mm.
If you can press down the V-belt more than 10-15 mm, adjust
the tension as follows: 10-15mm
3. Loosen the fastening screw (1) at the generator.
4. Loosen the connecting screw (2) between the generator and
the guide rail.
5. Loosen the fastening screw (3) at the guide rail. 2
6. Tilt the generator to adjust the tension of the V-belt. 3
7. Fasten the generator and the guide rail.
8. Check the tension of the V-belt and re-adjust it, if required.
1
Service Brake - Checking and refilling oil
Alll repairs on the brake system must be performed by a garage
which is authorised by Komatsu.
β Changing oil.
β Checking tubes and lines.
β Check the brake discs and brake pads for wear and damage.
β Adjusting the clearance of the brake disks.
Checking and adjusting system pressures
5-60 WA90-5 β VEAM270101
--- Page 26 ---
5 Maintenance
Checking the fuel pump
Let the fuel pump be checked at a garage which is authorised by
Komatsu.
Checking the fuel and coolant tubes, replacing the
tubes (if required)
Have the fuel and coolant tubes checked and replaced, if
required, at an authorised Komatsu garage.
Checking the water pump
Let the water pump be checked at a garage which is authorised
by Komatsu
5-70 WA90-5 β VEAM270101
--- Page 27 ---
7.1. E.C.S.S-electronics Special equipment and attachments
7.1. E.C.S.S-electronics
Always read this section before installing and operating the
E.C.S.S-electronics as safe as possible.
7.1.1. Structure and functioning principle of the E.C.S.S-electronics
β The E.C.S.S-electronics uses the hydraulic spring effect of
the hydraulic accumulator installed to the circuit at the lift