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Komatsu WA180-3 PARALLEL TOOL CARRIER Operation & Maintenance Manual - PDF
Komatsu WA180-3 PARALLEL TOOL CARRIER Operation & Maintenance Manual
Description:
- Komatsu WA180-3 PARALLEL TOOL CARRIER Operation & Maintenance Manual
- SERIAL NUMBERS-A85001 and up
- This manual describes procedures for operation, handling, lubrication, maintenance, checking, and adjustment. It will help the operator and maintenance personnel realize peak performance through effective, economical and safe machine operation and maintenance.
- Keep this manual handy and have all personnel read it periodically. If this manual is lost or becomes dirty and can not be read, request a replacement manual from your local distributor.
- If you sell the machine, be sure to give this manual to the new owner.
- Continuing improvements in the design of this machine can lead to changes in detail, which may not be reflected in this manual. Consult your local distributor or Komatsu America International Company for the latest available information on your machine or for questions regarding information in this manual.
Table of Contents:
- Komatsu WA180-3 PARALLEL TOOL CARRIER Operation & Maintenance Manual
- SERIAL NUMBERS-A85001 and up
MAIN MENU..................................................................................................................... 0 INTRODUCTION.................................................................................................................. 4 1. FORWARD................................................................................................................ 5 2. SAFETY INFORMATION..................................................................................................... 6 3. INTRODUCTION........................................................................................................... 7 3.1 INTENDED USE...................................................................................................... 7 3.2 FEATURES.......................................................................................................... 7 3.3 BREAKING IN A NEW MACHINE......................................................................................... 7 4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR.......................................................... 8 4.1 MACHINE SERIAL NO. PLATE POSITION................................................................................. 8 4.2 ENGINE SERIAL NO. PLATE POSITION.................................................................................. 8 4.3 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR......................................................................... 8 5. CONTENTS............................................................................................................... 9 SAFETY........................................................................................................................ 15 6. GENERAL PRECAUTIONS.................................................................................................... 16 7. PRECAUTIONS DURING OPERATION........................................................................................... 22 7.1 BEFORE STARTING ENGINE............................................................................................ 22 7.2 AFTER STARTING ENGINE............................................................................................. 25 7.3 TRANSPORTATION.................................................................................................... 34 7.4 BATTERY........................................................................................................... 35 7.5 TOWING............................................................................................................ 38 8. PRECAUTIONS FOR MAINTENANCE............................................................................................ 39 8.1 BEFORE CARRYING OUT MAINTENANCE................................................................................... 39 8.2 DURING MAINTENANCE................................................................................................ 44 8.3 TIRES............................................................................................................. 49 9. POSITION FOR ATTACHING SAFETY LABELS................................................................................... 51 9.1 POSITION FOR ATTACHING SAFETY LABELS.............................................................................. 51 OPERATION..................................................................................................................... 57 10. GENERAL VIEW.......................................................................................................... 58 10.1 GENERAL VIEW OF MACHINE.......................................................................................... 58 10.2 GENERAL VIEW OF CONTROLS AND GAUGES.............................................................................. 59 11. EXPLANATION OF COMPONENTS............................................................................................. 61 11.1 METER, LAMPS..................................................................................................... 61 11.2 SWITCHES......................................................................................................... 65 11.3 CONTROL LEVERS, PEDAL............................................................................................ 71 11.4 CAP WITH LOCK.................................................................................................... 75 11.4.1 METHOD OF OPENING AND CLOSING CAP WITH LOCK................................................................ 75 11.5 SAFETY BAR....................................................................................................... 75 11.6 TOWING PIN....................................................................................................... 76 11.7 GREASE PUMP CLAMP AND RUBBER RING................................................................................ 76 11.8 BACKUP ALARM..................................................................................................... 76 11.9 FUSE............................................................................................................. 77 11.9.1 FUSE CAPACITY AND NAME OF CIRCUIT.......................................................................... 77 11.10 SLOW BLOW FUSE.................................................................................................. 78 11.11 STORAGE PLACE FOR THIS MANUAL................................................................................... 79 11.12 AUXILIARY POWER SOURCE.......................................................................................... 79 11.12.1 FOR MACHINES EQUIPPED WITH ROPS CAB....................................................................... 79 12. CHECK BEFORE STARTING ENGINE.......................................................................................... 80 12.1 WALK AROUND CHECK................................................................................................ 80 12.2 CHECK BEFORE STARTING............................................................................................ 83 12.2.1 CHECK COOLANT LEVEL, ADD COOLANT........................................................................... 83 12.2.2 CHECK FUEL LEVEL, ADD FUEL................................................................................. 83 12.2.3 CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL................................................................. 84 12.2.4 CHECK AND REFILL OF OIL IN BRAKE OIL TANK.................................................................. 84 12.2.5 CHECK DUST INDICATOR....................................................................................... 85 12.2.6 CHECK ELECTRICAL WIRING.................................................................................... 85 12.2.7 DRAIN THE WATER FROM THE FUEL-WATER SEPARATOR.............................................................. 86 12.2.8 CHECK EFFECT OF PARKING BRAKE.............................................................................. 86 12.2.9 CHECK EFFECT OF WHEEL BRAKES............................................................................... 87 12.2.10 CHECK SOUND OF HORN AND BACKUP ALARM...................................................................... 87 12.2.11 CHECK FLASHING OF LAMPS, CHECK FOR DIRT AND DAMAGE........................................................ 87 12.2.12 CHECK ENGINE EXHAUST COLOR AND SOUND...................................................................... 87 12.2.13 CHECK OPERATIONS OF GAUGES................................................................................ 87 12.2.14 CHECK PLAY OF STEERING WHEEL, CHECK OPERATION OF STEERING................................................. 87 12.2.15 CHECK DIRECTION OF REAR VIEW MIRROR, CHECK FOR DIRT OR DAMAGE............................................. 87 12.2.16 CHECK LOCK OF CAB DOOR FOR MACHINES EQUIPPED WITH CAB..................................................... 87 12.3 ADJUSTMENT BEFORE OPERATION...................................................................................... 88 12.3.1 OPERATOR'S SEAT............................................................................................ 88 12.3.2 ADJUST SEAT BELT........................................................................................... 90 12.3.3 ADJUST REAR VEIW MIRRORS................................................................................... 91 12.4 OPERATIONS AND CHECKS BEFORE STARTING ENGINE..................................................................... 92 12.5 STARTING ENGINE.................................................................................................. 93 12.5.1 NORMAL STARTING PROCEDURES IN COLD AND WARM CONDITIONS..................................................... 93 12.5.2 STARTING PROCEDURES AFTER EXTENDED SHUTDOWN OR OIL CHANGE.................................................. 94 12.5.3 STARTING PROCEDURES AFTER CHANGING FUEL FILTERS............................................................ 94 12.5.4 STARTING PROCEDURES AFTER RUNNING OUT OF FUEL.............................................................. 94 12.6 OPERATIONS AND CHECKS AFTER STARTING ENGINE...................................................................... 95 12.7 MOVING MACHINE OFF............................................................................................... 96 12.8 CHANGING GEAR SPEED.............................................................................................. 98 12.9 CHANGING DIRECTION............................................................................................... 98 12.10 TURNING......................................................................................................... 99 12.11 STOPPING MACHINE................................................................................................100 12.12 OPERATION OF WORK EQUIPMENT (WITH BUCKET TOOL)..................................................................101 12.12.1 LIFT ARM OPERATION (LEVER)................................................................................101 12.12.2 BUCKET OPERATION (LEVER)..................................................................................101 12.13 OPERATION OF WORK EQUIPMENT (WITH FORK TOOL)....................................................................102 12.13.1 LIFT ARM OPERATION (LEVER)................................................................................102 12.13.2 FORK OPERATION (LEVER)....................................................................................102 12.14 OPERATION OF WORK EQUIPMENT (WITH MULTI- PURPOSE BUCKET TOOL)...................................................103 12.14.1 LIFT ARM OPERATION (LEVER)................................................................................103 12.14.2 BUCKET OPERATION (LEVER)..................................................................................103 12.14.3 AUXILIARY OPERATION (LEVER)...............................................................................104 12.14.4 POSITION INDICATOR........................................................................................104 12.15 OPERATION OF WORK EQUIPMENT (WITH MATERIAL HANDLING ARM)........................................................106 12.15.1 LIFT ARM OPERATION (LEVER)................................................................................106 12.16 HYDRAULIC QUICK COUPLER.........................................................................................107 12.16.1 COUPLING THE ATTACHMENT...................................................................................107 12.16.2 UNCOUPLING FROM THE ATTACHMENT............................................................................108 12.16.3 ATTACHMENTS REQUIRING HYDRAULIC POWER.....................................................................109 12.17 WORK POSSIBLE USING PARALLEL TOOL CARRIER.......................................................................110 12.17.1 DIGGING OPERATIONS WITH ROCK PILES........................................................................110 12.17.2 DIGGING OPERATIONS ON LEVEL GROUND........................................................................111 12.17.3 LEVELING OPERATION........................................................................................112 12.17.4 PUSHING OPERATIONS........................................................................................112 12.17.5 LOAD AND CARRY OPERATIONS.................................................................................112 12.17.6 LOADING OPERATIONS........................................................................................113 12.17.7 MULTI-PURPOSE BUCKET......................................................................................114 12.17.8 PALLET FORKS..............................................................................................119 12.17.9 MATERIAL HANDLING ARM.....................................................................................122 12.18 PRECAUTIONS FOR OPERATION.......................................................................................123 12.18.1 PERMISSIBLE WATER DEPTH...................................................................................123 12.18.2 IF WHEEL BRAKE DOES NOT WORK..............................................................................123 12.18.3 PRECAUTIONS WHEN DRIVING UP OR DOWN SLOPES................................................................123 12.18.4 PRECAUTIONS WHEN DRIVING MACHINE..........................................................................124 12.19 ADJUSTING BOOM KICK-OUT POSITIONER..............................................................................125 12.19.1 ADJUSTING BOOM KICK OUT...................................................................................125 12.19.2 ADJUSTING BUCKET / FORK POSITIONER........................................................................126 12.20 PARKING MACHINE.................................................................................................127 12.21 CHECKS AFTER COMPLETION OF ENGINE OPERATION.....................................................................128 12.22 STOPPING ENGINE.................................................................................................128 12.23 CHECKS AFTER STOPPING ENGINE....................................................................................129 12.24 LOCKING.........................................................................................................129 12.25 HANDLING THE TIRES..............................................................................................130 12.25.1 PRECAUTIONS WHEN HANDLING THE TIRES.......................................................................130 12.25.2 TIRE PRESSURE.............................................................................................130 13. TRANSPORTATION........................................................................................................132 13.1 LOADING, UNLOADING WORK..........................................................................................132 13.2 PRECAUTION FOR LOADING...........................................................................................133 13.3 PRECAUTION FOR LIFTING UP THE VEHICLE............................................................................133 13.3.1 THE LOCATION OF DECALS REFERRING TO LIFTING POSITIONS......................................................134 13.3.2 WEIGHT LIST................................................................................................134 13.3.3 LIFTING PROCEDURE..........................................................................................135 14. COLD WEATHER OPERATIONS...............................................................................................136 14.1 PRECAUTIONS FOR LOW TEMPERATURE..................................................................................136 14.1.1 FUEL AND LUBRICANTS........................................................................................136 14.1.2 COOLANT....................................................................................................136 14.1.3 BATTERY....................................................................................................137 14.2 PRECAUTIONS AFTER COMPLETION OF WORK.............................................................................138 14.3 AFTER COLD WEATHER...............................................................................................138 15. LONG TERM STORAGE.....................................................................................................139 15.1 BEFORE STORAGE...................................................................................................139 15.2 DURING STORAGE...................................................................................................139 15.3 AFTER STORAGE....................................................................................................139 16. TROUBLESHOOTING.......................................................................................................140 16.1 WHEN MACHINE RUNS OUT OF FUEL....................................................................................140 16.2 TOWING THE MACHINE...............................................................................................141 16.2.1 WHEN ENGINE CAN BE USED....................................................................................143 16.2.2 WHEN ENGINE CANNOT BE USED.................................................................................143 16.3 IF BATTERY IS DISCHARGED.........................................................................................144 16.3.1 REMOVAL AND INSTALLATION OF BATTERY........................................................................144 16.3.2 PRECAUTIONS FOR CHARGING BATTERY...........................................................................145 16.3.3 STARTING ENGINE WITH BOOSTER CABLE.........................................................................146 16.4 OTHER TROUBLE....................................................................................................148 16.4.1 ELECTRICAL SYSTEM..........................................................................................148 16.4.2 CHASSIS....................................................................................................149 16.4.3 ENGINE.....................................................................................................152 MAINTENANCE...................................................................................................................155 17. GUIDES TO MAINTENANCE.................................................................................................156 18. OUTLINES OF SERVICE...................................................................................................159 18.1 OUTLINE OF OIL, FUEL, COOLANT....................................................................................159 18.1.1 OIL........................................................................................................159 18.1.2 FUEL.......................................................................................................159 18.1.3 COOLANT....................................................................................................160 18.1.4 GREASE.....................................................................................................161 18.1.5 STORING OIL AND FUEL.......................................................................................161 18.1.6 FILTERS....................................................................................................161 18.2 OUTLINE OF ELECTRIC SYSTEM.......................................................................................162 19. WEAR PARTS LIST.......................................................................................................163 20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE..................................................164 20.1 ENGINE OIL SPECIFICATIONS........................................................................................165 20.2 DIESEL FUEL SPECIFICATIONS.......................................................................................166 20.3 COOLANT SPECIFICATIONS...........................................................................................167 21. STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS.........................................................................173 21.1 INTRODUCTION OF NECESSARY TOOLS..................................................................................173 21.2 TORQUE LIST......................................................................................................174 22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS.........................................................................176 23. MAINTENANCE SCHEDULE CHART............................................................................................180 23.1 MAINTENANCE SCHEDULE CHART.......................................................................................180 24. SERVICE PROCEDURES....................................................................................................184 24.1 INITIAL 250 HOURS SERVICE........................................................................................184 24.1.1 REPLACE FUEL FILTERS “EVERY 500 HOURS SERVICE..............................................................184 24.1.2 REPLACE TRANSMISSION OIL FILTER ELEMENT EVERY 500 HOURS SERVICE............................................184 24.1.3 REPLACE HYDRAULIC TANK FILTER ELEMENT EVERY 1000 HOURS SERVICE.............................................184 24.2 WHEN REQUIRED....................................................................................................185 24.2.1 CHECK, CLEAN OR REPLACE AIR CLEANER ELEMENT................................................................185 24.2.2 CHECK TRANSMISSION OIL LEVEL, ADD OIL......................................................................187 24.2.3 CHECK AXLE OIL LEVEL , ADD OIL.............................................................................188 24.2.4 CLEAN THE AXLE CASE BREATHER...............................................................................189 24.2.5 CLEAN RADIATOR FINS........................................................................................189 24.2.6 REPLACE THE BOLT-ON CUTTING EDGES..........................................................................190 24.2.7 REPLACE BUCKET TEETH (IF EQUIPPED).........................................................................191 24.2.8 CHECK AIR CONDITIONER (IF EQUIPPED)........................................................................192 24.2.9 CHECK THE AIR CONDITIONER CONDENSER (IF EQUIPPED)..........................................................193 24.2.10 CHECK WINDOW WASHING FLUID................................................................................193 24.2.11 ADJUST PARKING BRAKE......................................................................................194 24.2.12 REPLACE SLOW BLOW FUSE....................................................................................195 24.2.13 CHECK AIR INTAKE HEATER...................................................................................195 24.3 CHECK BEFORE STARTING............................................................................................196 24.4 EVERY 50 HOURS SERVICE...........................................................................................197 24.4.1 CHECK THE TIRE INFLATION PRESSURE..........................................................................197 24.4.2 DRAIN WATER, SEDIMENT FROM FUEL TANK.......................................................................197 24.5 EVERY 100 HOURS SERVICE..........................................................................................198 24.5.1 CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL.................................................................198 24.5.2 CLEAN ELEMENT IN AIR CONDITIONER FRESH AIR FILTER..........................................................199 24.5.3 LUBRICATING................................................................................................200 24.6 EVERY 250 HOURS SERVICE..........................................................................................201 24.6.1 CHANGE OIL IN ENGINE OIL PAN AND REPLACE ENGINE OIL FILTER.................................................201 24.6.2 CHECK FOR LOOSE WHEEL HUB NUTS. TIGHTEN....................................................................202 24.6.3 CLEAN ELEMENT IN AIR CONDITIONER RECIRCULATION FILTER......................................................202 24.6.4 CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST......................................................203 24.6.5 CHECK BATTERY ELECTROLYTE LEVEL............................................................................204 24.6.6 CHECK AIR INTAKE SYSTEM....................................................................................204 24.6.7 LUBRICATING................................................................................................205 24.7 EVERY 500 HOURS SERVICE..........................................................................................206 24.7.1 REPLACE FUEL FILTERS.......................................................................................206 24.7.2 REPLACE TRANSMISSION OIL FILTER ELEMENT....................................................................208 24.7.3 LUBRICATE..................................................................................................209 24.8 EVERY 1000 HOURS SERVICE.........................................................................................210 24.8.1 CHANGE OIL IN TRANSMISSION CASE, CLEAN STRAINER............................................................210 24.8.2 CLEAN TRANSMISSION CASE BREATHER...........................................................................211 24.8.3 LUBRICATE..................................................................................................212 24.8.4 CHANGE OIL IN HYDRAULIC OIL TANK, REPLACE HYDRAULIC FILTER ELEMENT.........................................213 24.8.5 ADJUST ENGINE VALVE LASH CLEARANCE After the first 1000 hours only thereafter evey 2000 hour intervals.....214 24.8.6 CHECK FAN BELT TENSION.....................................................................................215 24.8.7 CHECK FAN BELT TENSIONER BEARING & FAN HUB BEARING & INSPECT FAN BELT......................................215 24.9 EVERY 2000 HOURS SERVICE.........................................................................................216 24.9.1 COOLING SYSTEM, REPLACE COOLANT AND FLUSH THE SYSTEM.......................................................216 24.9.2 REPLACE HYDRAULIC TANK BREATHER ELEMENT....................................................................219 24.9.3 CHANGE AXLE OIL............................................................................................219 24.9.4 CHECK BRAKE DISC WEAR......................................................................................220 24.9.5 CHECK ALTERNATOR...........................................................................................220 24.9.6 CHECK STARTER MOTOR........................................................................................220 24.9.7 CHECK VIBRATION DAMPER.....................................................................................220 24.9.8 REPLACE ELEMENT IN AIR COND. RECIRCULATION AIR FILTER AND FRESH AIR FILTER.................................220 24.9.9 ADJUST ENGINE VALVE LASH CLEARANCE.........................................................................221 SPECIFICATIONS................................................................................................................223 25. SPECIFICATIONS........................................................................................................224 OPTIONS, ATTACHMENTS..........................................................................................................231 26. AVAILABLE ATTACHMENTS.................................................................................................232 27. SELECTING ATTACHMENTS AND TIRES.......................................................................................233 28. HEATER AND AIR CONDITIONING (IF EQUIPPED).............................................................................234 28.1 GENERAL LOCATION AND FUNCTION OF CONTROL PANEL...................................................................234 28.2 COOL BOX COMPARTMENT.............................................................................................235 29. HANDLING E.C.S.S. (ELECTRONIC CONTROLLED SUSPENSION SYSTEM)...........................................................236 29.1 STRUCTURE AND FUNCTION OF E.C.S.S................................................................................236 29.2 METHOD OF OPERATING E.C.S.S......................................................................................237 29.3 PRECAUTIONS WHEN OPERATING E.C.S.S...............................................................................237 29.4 PRECAUTIONS WHEN HANDLING ACCUMULATOR............................................................................238
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