Komatsu Trash Loader WF550-3 Operation & Maintenance Manual VEAM100200 – PDF DOWNLOAD

Komatsu Trash Loader WF550-3 Operation & Maintenance Manual VEAM100200 – PDF DOWNLOAD

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Komatsu Trash Loader WF550-3 Operation & Maintenance Manual VEAM100200 – PDF DOWNLOAD

Language : English
Pages : 255
Downloadable : Yes
File Type : PDF
Size: 9.99 MB

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Komatsu Trash Loader WF550-3 Operation & Maintenance Manual VEAM100200 – PDF DOWNLOAD

SERIAL NUMBERS W089-50001 AND UP

Foreword:

 This manual takes into account legal directives and regulations necessary to ensure the safe and effective use of the machine. A brochure with instructions is available for operation on public roads in Germany. Keep this manual within reach at all times and ensure that operating personnel read it at regular intervals.

• Call Komatsu or your local Komatsu dealer and request a replacement if this manual is lost or is no longer legible because of soiling. Pass the manual on to the new owner if selling the machine. Our constant efforts to improve the design of our machines can result in changes to construction which may differ slightly from the details in this manual.
• Please contact Komatsu or your local Komatsu dealer if you require the latest available information on your machine or if you have questions regarding the contents of this manual. Auxiliary equipment and accessories named in this manual may not be available in your region. If this is so, please contact Komatsu or your local Komatsu dealer with enquiries about the equipment you require.

TABLE OF CONTENTS:

Komatsu Trash Loader WF550-3 Operation & Maintenance Manual VEAM100200 – PDF DOWNLOAD

WF550-3………………………………………………………………………………. 1
1. Introduction………………………………………………………………………. 3
1.1. Foreword…………………………………………………………………….. 4
EU Directives………………………………………………………………….. 5
1.2. Safety information……………………………………………………………. 6
1.3. Introduction…………………………………………………………………. 8
1.3.1. Intended use……………………………………………………………. 8
1.3.2. Features……………………………………………………………….. 8
1.3.3. Breaking-in the machine………………………………………………….. 9
1.4. Location of plates, table to enter serial no. and distributor…………………….. 10
1.4.1. Machine identification plate……………………………………………… 10
1.4.2. Engine identification plate………………………………………………. 10
1.4.3. Position of service meter………………………………………………… 11
1.4.4. Table to enter serial no. and distributor………………………………….. 11
1.5. Table of contents…………………………………………………………….. 12
1.6. Dimensions, weights and operating data………………………………………….. 16
Noise emission levels…………………………………………………………… 16
2. Safety……………………………………………………………………………. 17
2.1. General safety measures……………………………………………………….. 18
2.1.1. Safety instructions……………………………………………………… 18
2.1.2. Safety devices………………………………………………………….. 18
2.1.3. Emergency exit………………………………………………………….. 18
2.1.4. Clothing and personal protection…………………………………………. 18
2.1.5. Machine modifications……………………………………………………. 19
2.1.6. Before you leave the driver’s seat………………………………………… 19
2.1.7. Mounting and dismounting…………………………………………………. 20
2.1.8. Fire prevention and fire fighting…………………………………………. 21
2.1.9. Protection against asbestos dust………………………………………….. 23
2.1.10. Protection against injuries……………………………………………… 23
2.1.11. Working at high temperatures…………………………………………….. 24
2.1.12. Roll-over protection system (ROPS)……………………………………….. 24
2.1.13. Attachment for protection against falling objects (FOPS)…………………… 25
2.1.14. Attachments……………………………………………………………. 25
2.1.15. Battery……………………………………………………………….. 26
2.2. Safety precautions during operation…………………………………………….. 27
2.2.1. Before you start the engine………………………………………………. 27
Workplace safety……………………………………………………………. 27
In the driver’s cab…………………………………………………………. 27
In-door operation…………………………………………………………… 28
Gas, dust, and inflammable vapours……………………………………………. 28
Mirrors, windows and lighting………………………………………………… 28
2.2.2. Machine operation……………………………………………………….. 29
Before you start the engine………………………………………………….. 29
Reversing………………………………………………………………….. 29
Driving……………………………………………………………………. 30
Working close to power lines…………………………………………………. 31
Good vision………………………………………………………………… 32
Working on loose soil……………………………………………………….. 32
Parking the machine…………………………………………………………. 32
Driving with joystick steering……………………………………………….. 33
2.2.3. Transport………………………………………………………………. 34
Loading and unloading the machine…………………………………………….. 34
Transport………………………………………………………………….. 35
2.3. Precautions for maintenance……………………………………………………. 36
2.3.1. Personnel………………………………………………………………. 36
2.3.2. Before carrying out maintenance………………………………………….. 36
2.3.3. During maintenance………………………………………………………. 38
2.4. Safety labels………………………………………………………………… 44
3. Operation…………………………………………………………………………. 47
3.1. General view…………………………………………………………………. 48
3.1.1. General view of the machine………………………………………………. 48
3.1.2. Control elements and measuring instruments…………………………………. 49
Standard type………………………………………………………………. 49
3.2. Description of the individual elements………………………………………….. 51
3.2.1. Control monitor…………………………………………………………. 51
Testing actuation of machine monitor system……………………………………. 52
Warning indicators………………………………………………………….. 53
Measuring instruments and control elements…………………………………… 57
3.2.2. Switches……………………………………………………………….. 62
3.2.3. Control levers and pedals………………………………………………… 71
3.2.4. Steering column tilt lever……………………………………………….. 77
3.2.5. Cap with lock…………………………………………………………… 77
Fuel tank filler port……………………………………………………….. 77
Hydraulic tank filler port…………………………………………………… 78
3.2.6. Safety bar……………………………………………………………… 78
3.2.7. Towing pin……………………………………………………………… 79
3.2.8. Backup alarm……………………………………………………………. 79
3.2.9. Fuses………………………………………………………………….. 80
Fuse capacity and circuit designations……………………………………….. 80
3.2.10. Slow-blow fuses………………………………………………………… 82
3.2.11. Storaging place of this manual…………………………………………… 82
3.2.12. Taking off power……………………………………………………….. 82
3.2.13. Air conditioning……………………………………………………….. 83
Layout and functions of the control panel…………………………………….. 83
Operating instructions………………………………………………………. 85
Cool box…………………………………………………………………… 85
3.2.14. Hydraulic cooling fan…………………………………………………… 86
Explanation of components……………………………………………………. 86
3.3. Operation……………………………………………………………………. 91
3.3.1. Pre-start checks………………………………………………………… 91
Walk-around check…………………………………………………………… 91
Check before starting……………………………………………………….. 94
Adjustment before starting the operation………………………………………. 98
Operations and checks before starting the engine………………………………..101
3.3.2. Starting the engine………………………………………………………103
3.3.3. Operation and checks after starting the engine………………………………105
3.3.4. Driving the machine………………………………………………………107
Driving the machine on site using the steering wheel…………………………….107
Driving the machine with joystick steering on site………………………………110
3.3.5. Gear change……………………………………………………………..113
3.3.6. Changing direction……………………………………………………….114
Manual shift 3rd and 4th speed, and automatic shift……………………………..115
3.3.7. Turning and steering……………………………………………………..116
3.3.8. Stopping the machine……………………………………………………..117
3.3.9. Operating the work equipment………………………………………………118
3.3.10. Trash loader operations………………………………………………….119
Digging…………………………………………………………………….119
Levelling…………………………………………………………………..121
Pushing…………………………………………………………………….121
Loading…………………………………………………………………….122
Waste dump operation…………………………………………………………123
3.3.11. Precautionary measures during operation……………………………………124
Permissible water depth………………………………………………………124
If wheel brake fails to work………………………………………………….124
Precautionary measures when driving up or down………………………………….125
Precautions when traveling on hard road surfaces………………………………..125
3.3.12. Adjusting the position of the work equipment……………………………….126
Adjusting the boom kickout……………………………………………………126
3.3.13. Parking the machine……………………………………………………..127
3.3.14. Check after completion of work……………………………………………129
3.3.15. Stopping the engine……………………………………………………..129
3.3.16. Check after stopping the engine…………………………………………..130
3.3.17. Locking………………………………………………………………..130
3.4. Transport…………………………………………………………………….131
3.4.1. Loading and securing……………………………………………………..131
3.5. Cold weather operation…………………………………………………………132
3.5.1. Precautions for low temperatures…………………………………………..132
Fuel and lubricants………………………………………………………….132
Coolant…………………………………………………………………….132
Battery…………………………………………………………………….133
3.5.2. Precautions after completion of work……………………………………….134
3.5.3. After the cold weather period……………………………………………..134
3.5.4. Warming-up operation for steering hydraulic circuit in cold weather……………135
3.6. Long-term storage……………………………………………………………..136
3.6.1. Before storage…………………………………………………………..136
3.6.2. During storage…………………………………………………………..136
3.6.3. After storage……………………………………………………………137
4. Troubleshooting…………………………………………………………………….139
4.1. When the machine runs out of fuel……………………………………………….140
Procedure for bleeding air……………………………………………………….140
4.1.1. Central lubrication system………………………………………………..141
4.1.2. No grease emerging at the lubrication points………………………………..141
4.1.3. The pump does not switch on……………………………………………….141
4.2. Towing the machine…………………………………………………………….142
4.2.1. Engine can still be used………………………………………………….144
4.2.2. Engine cannot be used…………………………………………………….144
4.2.3. Releasing the parking brake……………………………………………….145
4.2.4. Emergency travel operation………………………………………………..147
4.3. If battery is discharged……………………………………………………….148
4.3.1. Removal and installation of battery………………………………………..149
4.3.2. Precautions for charging the battery……………………………………….150
4.3.3. Starting the engine with a booster cable……………………………………151
Precautions for connecting and disconnecting the booster cable……………………151
Connecting the booster cables…………………………………………………152
Starting the engine………………………………………………………….152
Disconnecting the booster cables………………………………………………152
4.4. Other troubles………………………………………………………………..153
4.4.1. Electrical system………………………………………………………..153
4.4.2. Chassis…………………………………………………………………154
4.4.3. Engine………………………………………………………………….157
4.4.4. RELATIONSHIP OF ELECTRONIC CONTROL SYSTEM…………………………………..159
Main monitor failure display………………………………………………….159
Transmission control system…………………………………………………..160
5. Maintenance………………………………………………………………………..161
5.1. Maintenance guide……………………………………………………………..162
5.2. Maintenance basics…………………………………………………………….165
5.2.1. Oil, fuel and coolant specifications……………………………………….165
Oil………………………………………………………………………..165
Fuel……………………………………………………………………….166
Coolant…………………………………………………………………….166
Grease……………………………………………………………………..167
Storing oil and fuel…………………………………………………………167
Filters…………………………………………………………………….167
5.2.2. Specifications of the electrical system…………………………………….168
5.3. Wearing parts list…………………………………………………………….169
5.4. Use of fuel, coolant and lubricants according to ambient temperature………………..170
Proper selection of fuel, coolant and lubricants……………………………………170
5.5. Tools and grease pump………………………………………………………….174
5.5.1. Included tools…………………………………………………………..174
5.5.2. Grease pump……………………………………………………………..174
5.6. Standard tightening torques (bolts, nuts)………………………………………..175
5.7. Periodical replacement of safety-critical parts…………………………………..176
5.8. Maintenance schedule chart……………………………………………………..177
5.9. Service procedure……………………………………………………………..179
5.9.1. Initial 250 hours service…………………………………………………179
5.9.2. Maintenance upon demand…………………………………………………..180
Check, clean or replace air cleaner element……………………………………180
Cleaning the interior of the cooling system…………………………………..183
Checking the transmission oil level, adding oil………………………………..186
Checking the axle oil level, adding oil……………………………………….188
Checking axle case breather…………………………………………………..189
Cleaning radiator fins……………………………………………………….190
Replacing the bucket teeth……………………………………………………191
Checking the air-conditioning system………………………………………….192
Clean condenser of air conditioner…………………………………………….193
Check electrical intake air heater…………………………………………….193
Checking the window washing-fluid level, adding fluid……………………………194
Lubricate work equipment control valve linkage………………………………….194
Clean top surface of underguard……………………………………………….195
Replace slow blow fuse……………………………………………………….196
Topping up the grease reservoir of the central lubrication system…………………197
5.9.3. Checks before starting……………………………………………………199
5.9.4. Every 50 hours service……………………………………………………200
Draining water and deposits from fuel tank……………………………………..200
5.9.5. Every 100 hours service…………………………………………………..201
Checking the oil level in the hydraulic tank, adding oil…………………………201
Cleaning the inserts of the fresh air filter of the air- conditioning system……….202
Lubricate rear axle pivot pin (3 points)……………………………………….202
5.9.6. Every 250 service hours…………………………………………………..203
Changing oil in the engine oil pan, replacing engine oil filter cartridge………….203
Checking the battery electrolyte level…………………………………………205
Check parking brake………………………………………………………….205
Checking and adjusting fan belt tension………………………………………..206
Checking and adjusting alternator belt tension………………………………….207
Checking and adjusting the compressor belt tension of the air-conditioning system….208
Checking for loose wheel hub nuts, tightening the nuts…………………………..209
Cleaning the inserts of the recirculation filter of the airconditioning system…….209
5.9.7. Every 500 service hours…………………………………………………..210
Replacing the fuel filter cartridge……………………………………………210
Replacing transmission oil filter element………………………………………212
Lubricate center drive shaft spline (1 point)…………………………………..213
5.9.8. Every 1000 service hours………………………………………………….214
Changing the oil in the transmission case, cleaning the strainer…………………214
Cleaning the transmission case breather………………………………………..215
Lubrication…………………………………………………………………216
Checking the tightening parts of the turbo-charger………………………………218
Replacing the anti-corrosive filter cartridge…………………………………218
5.9.9. Every 2000 service hours………………………………………………….219
Changing the oil in the hydraulic tank, replacing the hydraulic filter inserts……..219
Replacing the hydraulic tank breather element…………………………………..222
Changing the axle oil………………………………………………………..223
Replace element in air conditioner recirculation air filter, fresh air filter………224
Clean PPC circuit strainer……………………………………………………225
Clean engine breather element…………………………………………………225
Checking the alternator starter motor………………………………………….226
Checking and adjusting the valve clearance of the engine………………………..226
Checking the brake disc wear………………………………………………….226
Cleaning and checking the turbocharger………………………………………..226
Check play of turbocharger rotor………………………………………………226
Check accumulator……………………………………………………………227
Check accumulator gas pressure………………………………………………..227
5.9.10. Every 4000 service hours…………………………………………………228
Checking the water pump………………………………………………………228
Check fan pulley and tension pulley……………………………………………228
Check vibration damper……………………………………………………….228
6. Special equipment and attachments…………………………………………………….229
6.1. Protective ventilation system SBL30……………………………………………..230
6.1.1. Design and function of the protective ventilation system……………………..230
Label at front of protective ventilation unit…………………………………..231
6.1.2. Operating the machine…………………………………………………….232
6.1.3. Starting up the protective ventilation system……………………………….233
6.1.4. Working with protective ventilation system switched on……………………….234
6.1.5. After use……………………………………………………………….234
6.1.6. Operating and monitoring display…………………………………………..235
Overall display……………………………………………………………..235
Displays on the monitoring display…………………………………………….237
Displays and fault messages on the monitoring display……………………………238
6.1.7. Signal lamp (on the cab roof)……………………………………………..240
6.1.8. Escape aid device and emergency hammer……………………………………..240
Description and ordering details………………………………………………240
Selection and use……………………………………………………………241
Application…………………………………………………………………241
Maintenance and storage………………………………………………………241
6.1.9. Combination filter WP21…………………………………………………..242
Area of use…………………………………………………………………242
Function of the combination filter…………………………………………….242
Transport and storage of the combination filter WP21…………………………….243
Filter log………………………………………………………………….244
Disposal of used filters……………………………………………………..246
Combination filter technical details:………………………………………….246
Filter change……………………………………………………………….247
6.1.10. Inspecting and/or exchanging the circulating air filter……………………..249
6.1.11. Safety inspection……………………………………………………….249
6.1.12. Technical details and dimensions SBL 30……………………………………250
7. Index……………………………………………………………………………..251