KOMATSU WA70-5-M Maintenance Manual
VEAM320200
Operation & Maintenance
Manual
WA70-5
WHEEL LOADER
SERIAL NUMBERS
WARNING
Unsafe use of this machine may cause serious injury or
death. Operators and maintenance personnel must read
this manual before operating or maintaining this
machine. This manual should be kept near the machine
for reference and periodically reviewed by all personnel
who will come into contact with it.
NOTICE
Komatsu has had the operating and maintenance instructions translated into all the languages of the member states in the European Union. Should you wish to
have a version of the operating instructions in another
language, please don’t hesitate to ask at your local
dealer’s.
H50051
and up
© 2004 Komatsu Hanomag GmbH
All Rights Reserved
Printed in Europe 10-04
Introduction
1. Introduction
WA70-5 – VEAM320200 1-1
1.1. Product publications information Introduction
1.1. Product publications information
VARIOUS PRODUCT PARTS & SERVICE PUBLICATIONS ARE AVAILABLE TO ALL KOMATSU CONSTRUCTION EQUIPMENT OWNERS, INCLUDING OPERATION & MAINTENANCE MANUALS, PARTS BOOKS AND
SHOP MANUALS.
SPECIAL PUBLICATIONS SUCH AS SERVICE TOOL, AIR CONDITIONING, AND TURBOCHARGER SHOP
MANUALS ARE ALSO AVAILABLE AS WELL AS SELECTED OPERATION & MAINTENANCE AND SHOP
MANUALS IN FOREIGN LANGUAGES.
THE PUBLICATIONS LISTED BELOW ARE AVAILABLE FOR THIS PARTICULAR MACHINE(S).
DESCRIPTION
FORM NUMBER
PARTS BOOK - PAPER:
Engine and Chassis VZPB193200
OPERATION & MAINTENANCE MANUAL:
Chassis
VEAM320200
SHOP MANUAL:
Engine
Chassis
SAFETY MANUAL:
CU3666417-00
VEBM250100
___________
PARTS AND SERVICE PUBLICATIONS CAN ONLY BE ACQUIRED BY AUTHORIZED KOMATSU DISTRIBUTORS, USING THE KOMATSU AMERICA INTERNATIONAL COMPANY PARTS INVENTORY PROCESSING SYSTEM (PIPS).
IF THE PIPS SYSTEM IS NOT AVAILABLE AT THE DISTRIBUTOR LOCATION, THEN THE FOLLOWING
REQUISITION FOR TECHNICAL SERVICE PUBLICATIONS AND SERVICE FORMS CAN BE USED. FORM
KDC91D IS SHOWN ON THE REVERSE SIDE OF THIS PAGE.
1-2 WA70-5 – VEAM320200
Introduction 1.1. Product publications information
REQUISITION FOR TECHNICAL SERVICE PUBLICATIONS AND SERVICE FORMS
COMPLETE FORM
AND RETURN TO ——>
Komatsu America International Company
440 North Fairway Drive
Vernon Hills, IL 60061-8112 U.S.A.
Attn: Technical Publications
Fax No. (847) 970-4186
Tel No. (847) 970-5887
COMPANY NAME
SHIP TO ——————>
ATTN.
STREET ADDRESS
TYPE or PRINT
ONLY ———————>
PHONE NO. FAX NO. SHIPPING METHOD DISTR/BRANCH CODE
CITY. STATE. ZIP CODE
COUNTRY
PURCHASE ORDER NO.
ORDRER DATE
IMPORTANT - TO ASSURE SHIPMENT OF THE CORRECT PUBLICATION(S), THE MODEL NUMBER AND
MACHINE SERIAL NUMBER MUST BE SHOWN.
QTY. PUBLICAT ION FORM NO.
PARTS BOOK
➥
P-PAPER
M-MICROFICHE
PUBLICATION
DESCRIPTION
MODEL NUMBER SERIAL NUMBER
WA70-5 – VEAM320200 1-3
1.2. Foreword Introduction
1.2. Foreword
The machine must be operated , cleaned, and maintained very
carefully to ensure safe and troublefree operation. If you operate
the machine correctly , these operating instructions will help you to
avoid injuries and damage to property. To ensure this, these operating instructions take into account all applicable legal regulations
and directives; the operating instructio ns comprise the following
information:
● Notes on the Operating Instructions
● Notes on Transport
● Notes on Safety Regulations
● Operating Instructions
● Troubleshooting
● Maintenance Instructions
● Technical Data
● Notes on Lubricants and Operating Agents
The operating manual belongs to the machine and is stored in the
lid of the hinged console, on the left of the driver's cab.
The operating instructions are part of the machine and must
always be available at hand in the machine.
If the operating instructions have been lost or if they have become
unreadable, because they are dirty, you may receive a new copy
from Komatsu or your local Komatsu dealer. If the machine is
resold, the operating instructions, the EU Declaration of Conformity (CE), and the licence are to be handed over to the new
owner.
The owner of the machine has to ensure that
● all persons driving the machine have the legally required min-
imum age and ar e physicall y and me ntally fit to p erform the
tasks they are charged with.
● all persons in charge with operating or maintaining the
machine are appropriately instructed before operation or
maintenance is started. They must hav e compl etely rea d and
understood these operating instructions. In particular, this
applies to the following section "Notes on Safety Regulations"
and the chapter "Safety".
● the machine is correctly operated.
● the machine is not improperly modified.
1-4 WA70-5 – VEAM320200
Introduction 1.2. Foreword
Please note:
If the owner modifie s saf ety -re late d parts of the m ac hi ne, t he c ertificate of conformity of the manufacturer will lapse and the person
who has performed the modification has to issue a new cer tificate. Should you have any questions concerning this poin t,
please do not hesitate to ask Komatsu.
Our continuous effort to improve the machine's design may lead
to changes of machine details. Howev er, the introduction of these
improvements does not oblige us to perfor m them on machin es
which have already been delivered and are already in use.
If these improvements result in minor changes, these minor
changes will not be described in the operating instructio ns.
Should you require new available information about your machine
or have any questions conce rning the information given in the
operating instruct ions, please do not he sitate to contact either
Komatsu or your responsible Komatsu dealer.
These operating instructions may refer to attachments and special equipment not avail able from your loca l Komatsu dealer.
Should you requ ire attachments or special equip ment, ask your
responsible Komatsu dealer.
EU Directives
This machine is l ab ell ed wit h th e CE m ar k in dic ati ng tha t i t me ets
all basic requir ements con cernin g safety an d prote ction of he alth
of the EU Machinery Directive 89/392/EEC, its supple ments 91/
368 EEC and 93/44 EEC for Europe, and the regulation 95/27/
EEC. In addition, the harmonised European standards EN 292-2
and EN 474/1 of 1994, and EN 474-3 of 1996 were applied for
manufacture of th e machi ne. Th is fact i s docu mented i n the E U
Declaration of Conformity (CE) which is supplied together with the
machine.
This means that in those cases in which the machine is modified
in such a way that safe ty of the m achine i s affected, the p erson
responsible for safety of the machine is the one who has
arranged for the machine to be modified. If you use the machine
for any other purpose t han that de fined as c orrect use , you are
the person who has to ens ur e t hat s afe ty is mai ntaine d. Mo dif ic ations of the mach ine or u se of the mac hine for a ny oth er purpo se
than that specified as correct use may require a new CE mark
and thus new issuing of an EU Declaration of Conformity.
If a machine is used in oth er countries than Germany, it may be
possible that special national safety devices and specifications
are missing which may be requ ired for the ap plicati on in the rel evant country. For example, for Komatsu machines, the manufacturer has to design the cab roof in such a way that a warning
beacon can be attached to the roof. However, when driving the
machine on roads, this warning beacon must be covered.
Should you hav e any questi ons conce rnin g standar ds and g uid elines in the respective country the machine is to be used in,
please ask your Komatsu dealer before you start commissioning
the machine.
WA70-5 – VEAM320200 1-5
1.2. Foreword Introduction
In addition to the operating instructions, you must also adhere to
all legal regula tions on public traffic a nd all appli cable r egulat ions
on prevention of accidents.
Notes on later installation of electrical and electronical
devices and components
Electrical or electronical devices and/or components installed
later emit electro magnetic radiation which may influence the
proper function of el ectronic components and parts of the
machine. This may impair safety of the machine and endanger
persons. For this reason, strictly adhere to the following safety
notes.
If you later install electrical and electronical devices and/or components in the machine and connect them to the vehicle electrical
system, you are responsible for any malfunctions of the vehicle
electronics or other components resulting from this installation.
Above all, check that all electrical and electronical components
which you install lat er comply wi th the valid version of t he EMC
directive 89/336/EEC and that they are labelled with the CE mark.
The following requirements must additionally be met for a later
installation of mobile communication systems.
● Only install devices which have a licence referring to valid
national regulations.
● The device must be stationary.
● Only use portable or mobile devices in the cab, if they are
connected to a stationary external aerial.
● Install the sender in s uc h a wa y that it is physic al ly s epara ted
from the vehicle electronics.
● When installing the aerial, make sure that it is installed cor-
rectly with a good chassis earth connection between the
aerial and the chassis of the vehicle.
In addition, adh ere to all info rmation about i nstallation and c onnection of cables and maximum power input indicated in the manufacturer's installation instructions of the machine.
1-6 WA70-5 – VEAM320200
Introduction 1.3. Safety information
1.3. Safety information
The procedures and precautionary measures concerning operation and maintenance onl y apply on the provision that the
machine is used as intended.
Most accidents are caused by disregard of basic safety regulations during operation and maintenance of machines. In order to
avoid accidents and thus damage to persons and property, read
all applicable safety not es and warnings in these operating
instructions and on the mac hine, before y ou start operati on or
maintenance of the machine an d always adh ere to the se safety
notes and warnings.
The following words are used in this ma nual and on stic kers on
the machine to signify safety instructions and enable them to be
recognized as such at a glance:
DANGER
This word is used for safety mess ages and safety label
where there is a probability of serious injury if the danger is
not avoided. The safety instruction or sticker contains precautions which must be observed in order to avoid the danger. Failure to do so can also result in damage to the
machine.
WARNING
This word is used for safety mess ages and safety label
where there is a potentially dangerous situation which could
lead to serious injury if the danger is not avoided. The safety
instruction or sticker contains precautions w hich must be
observed in order to avoid the danger. Failure to do so can
also result in damage to the machine.
CAUTION
This word is used for safety messages and safety label in the
event of danger which could result in minor or partly serious
injuries if the danger is not avoided. It may also relate to dangers which may only result in damage to the machine.
NOTE
This word is used for precautions which have to be taken in
order to avoid situations which could result in short ening th e
service lift of the machine.
The safety in structions are listed in th e chapter "2. Safety" on
page 2-1 and following.
WA70-5 – VEAM320200 1-7
1.3. Safety information Introduction
The transport of persons in the work equipment is strictly
forbidden!
We cannot foresee all c ircum stances which could r esul t in p otential danger during maintenanc e and operati on. T he sa fety ins truc tions in this manual and on the machine, therefore, do not
necessarily contain all possible safety precautions. If you are
using a procedure or me as ure no t ex pli c itly p er mitted and recommended in this manual, y ou must ensure th at you and anyone
else can use any such procedure without any danger or damage
to the machine whatsoever. Please contact your local Komatsu
dealer if you have any doubts about the safety of any procedures.
1-8 WA70-5 – VEAM320200
Introduction 1.4. Introduction
1.4. Introduction
1.4.1. Intended use
This loader is a machine with independent transmission, moving
on wheels. Driving in for ward di rection , the lo ader can lo ad or dig
material using its attachments intended for loading operations (i.e.
bucket).
The standard operation cycle of a loader includes filling up and
loading of the bucket, transporting the material and emptying the
bucket.
In combination with the forklift truck attachment the picking up,
transporting and putting down of stacked material is also
considered to be part of the machine’s intended use.
If you use the machine for any other purpose than specified
above, we will not accept any responsibility for safety. All
considerations concerning safety will then be up to the owner or
the operating and maintenance personnel. In any case, neither
you nor any other person are/is authorised to perform work and
functions explicitly prohibited in these operating instructions.
Refer to chapter "3.3.9. Working with the wheel loader" on
page 3-55 for more details.
WA70-5 – VEAM320200 1-9
1.4. Introduction Introduction
1.4.2. Breaking-in the machine
Before the shipment, each machine was carefully checked and
adjusted. A machine that is to be newly commissioned has to be
treated with utmost care during its first 100 operating hours.
If the machine is used for work involving loads exceeding the
specified maximum load for the running-in period, its performance
may be impaired prematurely and its service life may be shortened. A new machine must be run i n and maintained very c arefully and thoroughly.
The following points are particularly important:
● Idle the engine for 5 minutes after starting it up.
● Avoid operation with heavy loads or at high speeds.
● Avoid sudden starts, sudden acceleration, sudden steering
und sudden stops except in cases of emergency.
The precautions given i n this manu al for opera ting, m ainten ance,
and safety procedures are only those that apply when this product
is used for the specified purpose. If the machine is used for a purpose that is not listed in this manual Komatsu cannot bear any
responsibility for safety. All consideration of safety in such opera tions is the responsibility of the user.
Operations that are prohibited in this manual must never be carried out under any circumstances.
1-10 WA70-5 – VEAM320200
Introduction 1.5. Location of plates
1.5. Location of plates
1.5.1. Machine identification plate (PIN)
Position of the identification plate (1) (see enlargement)
1
Serial no. stamp marking (2)
2
Machine identification plate (PIN)
1.5.2. Engine name-plate
Engine name-plate with serial no.
WA70-5 – VEAM320200 1-11
1.5. Location of plates Introduction
1.5.3. Axle serial no. plate
This plate is located on the right of front axle and on the left of
rear axle (1).
1
1.5.4. Transmission serial no. plate
This plate is located in travel direction front, above the transmission output (1).
1.5.5. ROPS/FOPS-Cab serial no. plate
This plate is located on the right inside cab on the rear beam (1).
1
1
1-12 WA70-5 – VEAM320200
Introduction 1.5. Location of plates
1.5.6. Seat operator serial no. plate
This plate is located in front of seat, covered by the bellows.
1.5.7. Table to ente r serial no. and distributor
Must be filled in before machine is put into service:
Machine serial No.:
Engine serial No.:
Name of Dealer:
Address:
Service Personnel for your machine:
Phone:
Fax:
E-mail
WA70-5 – VEAM320200 1-13
1.6. Emission Control Warranty Introduction
1.6. Emission Control Warranty
1.6.1. Emission control warranty statement (Applies to Canada only)
1. Products Warranted
Komatsu America Internati onal Company, Komatsu Mining Systems Inc. and Komatsu Utility Corporation (collectively
"Komatsu") produce and/or market products under brand names
of Komatsu, Dresser, Dressta, Haulpak and Galion. This emission
warranty applies to new engines bearing the Komatsu name
installed in these products and used in Canada in machines
designed for industrial off-highway use. This warranty applies
only to these engi nes produ ced on or a fter Jan uary 1, 2000. Thi s
warranty will be administered by Komatsu distribution in Canada.
2. Coverage
Komatsu warrants to the ultimate purchaser and each subsequent purchaser that the engine is designed, built and equipped
so as to conform, at the time o f sale by Komatsu, with all U.S.
Federal emission regulations applicable at the time of man ufacture and that is free from defects in workmansh ip or material
which would caus e it not m eet these r egul ation s wit hin f ive ye ars
or 3,000 hours of operation, whichever occurs first, as measured
from the date of delivery of the engine to the ultimate purchaser.
3. Limitations
Failures, other than those resulting from defects in materials or
workmanship, are not covered by this warranty. Komatsu is not
responsible for failures or damage resulting fr om what Koma tsu
determines to be abuse or neglect, including, but not limited to:
operation without adequa te coolant or lubricants; over fu eling;
over speeding; lack of maintenanc e of lubricating, cooling or
intake systems; impr oper storage , starting, warm- up, run-in o r
shutdown practices; un authorized modifications of the engi ne.
Komatsu is also not r esponsible for failures caused by incorre ct
fuel or by water, dirt or other co ntamina nts in the fuel. Komatsu is
not responsible for non-engine re pairs, "downtime" expense,
related damage, fines , all busi ness cos ts or other l oss es re su lti ng
from a warrantable failure.
KOMATSU IS NOT RESPONSIBLE FOR INCIDENTAL OR
CONSEQUENTIAL DAMAGES.
This warranty, together with the express commercial warranties,
are the sole warranties of Komatsu. THERE ARE NO OTHER
WARRANTIES, EXPRESS OR IMPLIED, OR OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.
1-14 WA70-5 – VEAM320200
Introduction 1.7. Garantie sur le contrôle des émissions
1.7. Garantie sur le contrôle des émissions
1.7.1. Énoncé de garantie sur le contrôle des émissions (applicable au
Canada seulement)
1. Produits garantis:
Komatsu America Internation al Company, Komatsu Mining Systems Inc. et Komatsu Utility Corporation (collectivement Komatsu)
produisent et/ou font la mise en marché de produits portant les
noms de marque Komatsu, Dresser, Dressta, Haulpak et Galion.
Cette garantie sur le émissions s’applique à tous les nouveaux
moteurs portant le no m Komatsu, installés dans ces prod uits et
utilisés au Canada dans des machines conçues pour utilisation
industrielle non-routière. Cette garantie s’applique seulement sur
les moteurs produits à partir du 1 er Ja nvier 2000. Cet te garantie
sera administrée par la distribution de Komatsu au Canada.
2. Couverture
Komatsu garantit à l’acheteur ultime et chaque acheteur subséquent que le mot eur est conçu, co nstruit et equip é en toute
conformité, au moment de la vente par Komatsu, avec toutes les
Réglementations fédérales américaines sur les émissions applicables au moment de la fabrication et qu’il est exempt de défaults
de constructio n ou de matéri aux qui aur aient pour effet de contrevenir à ces r égle mentations en ded ans d e 5 a ns ou 3000 heures d’opération, mes uré à partir de la da te de l ivrais on du moteur
au client ultime.
3. Limitations
Les bris, autres que ceux ré sultant de défaults de mat ériaux ou
de constr uction, ne sont pas couverts par cette Garantie.
Komatsu n’est pas responsable pour b ris ou do mma ges ré su ltant
de ce que Komatsu détermine comme étant de l’abus ou négligence, incluant mais ne se limitant pas à: l’operation sans lubrifiants ou agent refroidissants adéquats; la suralimentation
d’essence; la survitesse; le manque d’entretien des systémes de
lubrification, de refroidissement ou d’entree; de pratiques nonpropices d’entrepos age, de mi se en ma rche, de r échauffement,
de conditionnement o u d’arrêt; les modi fications non autoris ées
du moteur. De plus Komatsu n’est pas responsable de bris
causés par de l’essence inadéquate ou de l’eau, des saletés ou
autres contaminants dans l´essence. Komatsu n´est pas responsable des réparations non-reliées au mote ur, des dépenses
encourues suite aux temps d´arrêts, des dommages relatifs,
amendes, et de tout autre coût d’affaires ou autres pertes résultant d’un bris couvert par la garantie.
KOMATSU N’EST PAS RESPONSABLE DES INCIDENTS OU
DOMMAGES CONSÉQUENTS.
Cette garantie ainsi que les garanties ex presses co mmerciales ,
sont les seules garanties Komatsu. IL N’Y A AUCUNE AUTRE
GARANTIE, EXPRESSE OU SOUS-ENTENDUE, MARCHANDABLE OU PROPICE A UNE UTILISATION PARTICULIÈRE.
WA70-5 – VEAM320200 1-15
1.8. Table of contents Introduction
1.8. Table of contents
1. Introduction.................................................................................................1-1
1.1. Product publications information............................................................................................................... 1-2
1.2. Foreword....................................................................................................................................................... 1-4
EU Directives....................................................................................................................................1-5
1.3. Safety information........................................................................................................................................ 1-7
1.4. Introduction.................................................................................................................................................. 1-9
1.4.1. Intended use......................................... ...... ....... ...... ....... ...... ...... ....... ...... .........................................1-9
1.4.2. Breaking-in the machine.................................................................................................................1-10
1.5. Location of plates ...................................................................................................................................... 1-11
1.5.1. Machine identification plate (PIN)................................................................................................... 1-11
1.5.2. Engine name-plate.......................................................................................................................... 1-11
1.5.3. Axle serial no. plate .............................. ...... ....... ...... ....... ...... ...... ....... ...... ....... ...... ..........................1-12
1.5.4. Transmission serial no. plate..........................................................................................................1-12
1.5.5. ROPS/FOPS-Cab serial no. plate................................................................................................... 1-12
1.5.6. Seat operator serial no. plate.......................................................................................................... 1-13
1.5.7. Table to enter serial no. and distributor ......................................................................................... 1-13
1.6. Emission Control Warranty.......................................................................................................................1-14
1.6.1. Emission control warranty statement (Applies to Canada only) ..................................................... 1-14
1.7. Garantie sur le contrôle des émissions................................................................................................... 1-15
1.7.1. Énoncé de garantie sur le contrôle des émissions (applicable au Canada seulement) .................1-15
1.8. Table of contents .......................................................................................................................................1-16
1.9. Dimensions, weights and operating data................................................................................................ 1-23
1.10.CE-conforming equipment....................................................................................................................... 1-24
1.10.1. CE-conforming equipment – part 1................................................................................................. 1-24
1.10.2. CE-conforming equipment – part 2................................................................................................. 1-24
1.10.3. Manufacturer-supplied CE-conforming equipment. ........................................................................ 1-25
1.11.Loading and securing...............................................................................................................................1-28
2. Safety ...........................................................................................................2-1
2.1. General safety measures....................................... ....... ...................................... ....... ...... ............................ 2-2
2.1.1. Safety instructions ................................ ...... ....... ...... ....... ...... ...... ....... ...... ....... .................................. 2-2
2.1.2. Safety devices ............................... ....... ...... ....... ...... ....... ...... ...... ....... ...... ....... .................................. 2-2
2.1.3. Emergency exit.................................................................................................................................2-2
2.1.4. Clothing and personal protection......................................................................................................2-3
2.1.5. Machine modifications ......................................................................................................................2-3
2.1.6. Before you leave the driver’s seat ....................................................................................................2-3
2.1.7. Mounting and dismounting................................................................................................................ 2-4
1-16 WA70-5 – VEAM320200
Introduction 1.8. Table of contents
2.1.8. Fire prevention and fire fighting ........................................................................................................ 2-4
2.1.9. Protection against asbestos dust...................................................................................................... 2-5
2.1.10. Protection against injuries................................................................................................................. 2-5
2.1.11. Working at high temperatures........................................................................................................... 2-6
2.1.12. Roll-over protection system (ROPS)................................................................................................. 2-6
2.1.13. Attachment for protection against falling objects (FOPS).................................................................2-6
2.1.14. Attachments...................................................................................................................................... 2-7
2.1.15. Battery .............................................................................................................................................. 2-7
2.2. Safety precautions during operation ......................................................................................................... 2-8
2.2.1. Prior to daily starting up.................................................................................................................... 2-8
Workplace safety.............................................................................................................................. 2-8
In the driver's cab ............................................................................................................................. 2-8
Indoor operation ............................................................................................................................... 2-9
Gas, dust, and inflammable vapours................................................................................................2-9
Mirrors, windows and lighting ..................... ...... ....................................... ...... ....... ...... ....... ............... 2-9
2.2.2. Machine operation............................... ....... ...... ....................................... ...... ....... ...... .. .................. 2-10
Before you start the engine.................. ....... ...... ....... ...... ...... ....................................... ....... ............. 2-10
Reversing........................................................................................................................................ 2-10
Driving..............................................................................................................................................2-11
Driving on slopes .............................................................................................................................2-11
Emergency Lowering System......................................................................................................... 2-12
Working close to power lines.......................................................................................................... 2-13
Loading........................................................................................................................................... 2-14
Good Vision...................... ...... ....... ...... ....... ...... ....... ...... ...... ....... .................................................... 2-14
Working on snow............................................................................................................................ 2-14
Height limitation......... ....... ...... ....... ...... ....................................... ...... ....... ...... ....... ...... .... ................ 2-15
Brakes ............................................................................................................................................ 2-15
Working on loose soil...................................................................................................................... 2-15
Working with the forklift truck attachment ....................................................................................... 2-15
Parking the machine....................................................................................................................... 2-17
2.2.3. Transport........................................................................................................................................ 2-18
Loading and unloading the machine...............................................................................................2-18
Transport ........................................................................................................................................ 2-18
2.3. Precautions for maintenance.................................................................................................................... 2-19
2.3.1. Personnel ....................................................................................................................................... 2-19
2.3.2. Before carrying out maintenance.................................................................................................... 2-19
2.3.3. During maintenance........................................................................................................................ 2-26
2.3.4. Tyres............................................................................................................................................... 2-30
2.4. Safety labels on the machine.................................................................................................................... 2-32
2.4.1. Positions and order numbers of information labels.........................................................................2-32
2.4.2. Positions and order numbers of safety labels................................................................................. 2-33
3. Operation.....................................................................................................3-1
WA70-5 – VEAM320200 1-17
1.8. Table of contents Introduction
3.1. General view..................................................... ...... ....... ...... ....... ...... ...... ....... ...... ....... .................................. 3-2
3.1.1. General view of the machine ............................................................................................................ 3-2
3.1.2. Controls and indicators.....................................................................................................................3-3
Overall view ...................................................................................................................................... 3-3
Switches, controls and warning lights............................................................................................... 3-4
3.2. Description of the individual elements ...................................................................................................... 3-5
3.2.1. Instrument panel............................................................................................................................... 3-5
Warning lights...................................................................................................................................3-6
Control lamps.................................................................................................................................... 3-8
Measuring indicators....................................................................................................................... 3-12
3.2.2. Switches ......................................................................................................................................... 3-14
3.2.3. Control levers and pedals...............................................................................................................3-21
3.2.4. Articulated steering catch............................................................................................................ 3-26
3.2.5. Traction device ............................................................................................................................... 3-26
3.2.6. Socket (12 V)..................................................................................................................................3-27
3.2.7. Door unlocking system ................................................................................................................... 3-27
3.2.8. Alarm horn for reverse driving – option........................................................................................... 3-27
3.2.9. Fuses..............................................................................................................................................3-28
3.2.10. Slow-blowing fuses ......................................................................................................................... 3-29
3.2.11. Adjusting the heater and ventilation system ................................................................................... 3-30
3.2.12. Air-conditioning...............................................................................................................................3-31
3.3. Operation....................................................................................................................................................3-32
3.3.1. Pre-start checks.............................................................................................................................. 3-32
Visual inspection.............................................................................................................................3-32
Pre-start checks... ....... ...... ....... ...... ....... ...... ....................................... ...... ....... ...... ....... ...................3-34
Adjustments prior to machine start ................................................................................................. 3-39
Adjusting the driver’s seat............................................................................................................... 3-39
3.3.2. Starting the engine.......................................................................................................................... 3-43
Warming up the engine................................................................................................................... 3-44
3.3.3. Driving with the machine.................................................................................................................3-45
Start-up........................................................................................................................................... 3-45
3.3.4. Changing the driving direction ........................................................................................................3-47
3.3.5. Turning and steering....................................................................................................................... 3-48
3.3.6. Braking............................................................................................................................................3-49
3.3.7. Stopping the machine.....................................................................................................................3-51
3.3.8. Operating the work equipment........................................................................................................ 3-52
Multifunctional lever........................................................................................................................3-52
Control lever for special equipment ................................................................................................ 3-53
Switching lever of bucket................................................................................................................3-54
3.3.9. Working with the wheel loader........................................................................................................ 3-55
Tyre-appropriate operation ............................................................................................................. 3-55
Switching on the 100 % differential lock (if equipped) .................................................................... 3-55
Loading work ..................................................................................................................................3-56
Removal work................................................................................................................................. 3-56
Excavation work.............................................................................................................................. 3-58
Planing............................................................................................................................................ 3-59
1-18 WA70-5 – VEAM320200
Introduction 1.8. Table of contents
Transporting.................................................................................................................................... 3-60
Unloading ....................................................................................................................................... 3-60
Working with the forklift truck attachment ....................................................................................... 3-61
3.3.10. Precautions for special operations.................................................................................................. 3-63
Permissible water depth ................................................................................................................. 3-63
Working on snow............................................................................................................................ 3-63
Dumping on steep slopes ............................................................................................................... 3-63
Working in the vicinity of electrical overhead lines ......................................................................... 3-63
Operation on slopes....................... ...... ....................................... ...... ....... ...... ....... ...... ....... . ............ 3-63
Working on loose soil...................................................................................................................... 3-63
If the service brake breaks down.................................................................................................... 3-63
Precautionary measures when driving up or down......................................................................... 3-64
Precautionary measures during machine travel ............................................................................. 3-65
3.3.11. Adjusting the position of the work equipment................................................................................. 3-66
Selecting a work unit....................................................................................................................... 3-66
Removing the work unit................. ...... ....... ...... ....... ...... ...... ....... ...... ....... ....................................... 3-68
Picking up the multi-purpose bucket............................................................................................... 3-69
Removing the multi-purpose bucket...............................................................................................3-71
Level indicator for the bucket.......................................................................................................... 3-71
3.3.12. Parking the machine....................................................................................................................... 3-72
3.3.13. Switching off the engine.................................................................................................................. 3-73
3.3.14. Check after stopping the engine..................................................................................................... 3-73
3.3.15. Locking ........................................................................................................................................... 3-73
3.3.16. Tyre handling.................................................................................................................................. 3-74
Precautionary measures when handling tyres................................................................................ 3-74
Tyre pressure.................................................................................................................................. 3-74
3.4. Transporting the machine......................................................................................................................... 3-76
3.4.1. Securing the articulated steering .................................................................................................... 3-76
3.4.2. Lifting the machine.......................................................................................................................... 3-77
3.4.3. Driving the machine onto loading area of transport vehicle............................................................ 3-78
3.4.4. Securing the machine during the transport..................................................................................... 3-79
3.4.5. After transport................................................................................................................................. 3-79
3.5. Cold weather operation............................................................................................................................. 3-80
3.5.1. Before the cold season................................................................................................................... 3-80
3.5.2. Precautions after completion of work.............................................................................................. 3-81
3.5.3. After the cold season...................................................................................................................... 3-81
3.6. Long-term storage....................... ...... ....... ...... ....... ...... ....... ...... ...... ....... .................................................... 3-82
3.6.1. Before storage................................................................................................................................ 3-82
3.6.2. During storage................................................................................................................................ 3-82
3.6.3. After storage................................................................................................................................... 3-83
4. Troubleshooting .........................................................................................4-1
WA70-5 – VEAM320200 1-19
1.8. Table of contents Introduction
4.1. Towing the machine..................................................................................................................................... 4-2
4.2. Starting the engine with a booster cable................................................................................................... 4-6
4.3. For insufficient braking effect..................................................................................................................... 4-8
4.3.1. Checking the service brake ........................ ....... ...... ....... ...... ...... ....... ...... ....... ...... ....... ...... ...............4-8
4.3.2. Checking the parking brake function ................. ...... ....... ...... ...... ....... ...... ....... ...... ....... .....................4-8
4.4. Emergency steering properties ..................................................................................................................4-9
4.5. Emergency lowering.................................................................................................................................... 4-9
4.6. Other troubles ..... ...... ...... ....... ...... ....... ...... ....... ...... ....... ...... ....... ...... ...... ....................................................4-10
4.6.1. Electrical system............................................................................................................................. 4-10
4.6.2. Engine............................................................................................................................................. 4-11
4.6.3. Hydraulic system ........................... ....... ...... ....... ...... ....... ...... ...... ....... ...... ....... ................................ 4-14
4.6.4. Brakes............................................................................................................................................. 4-16
4.6.5. Steering .......................................................................................................................................... 4-16
4.6.6. Axles............................................................................................................................................... 4-17
4.6.7. Driver's cab..................................................................................................................................... 4-17
5. Maintenance ................................................................................................5-1
5.1. Maintenance guide....................................................................................................................................... 5-2
5.1.1. Guidelines......................................................................................................................................... 5-2
5.2. Maintenance basics..................................................................................................................................... 5-9
5.2.1. Oil, fuel and coolant specifications ................................................................................................... 5-9
Oil ..................................................................................................................................................... 5-9
Fuel.................................................................................................................................................5-10
Coolant ........................................................................................................................................... 5-11
Grease............................................................................................................................................ 5-11
Storing oil and fuel.......................................................................................................................... 5-12
Filters.............................................................................................................................................. 5-12
Biodegradable hydraulic oil and lubricants ..................................................................................... 5-12
5.2.2. Specifications of the electrical system ............................................................................................ 5-13
5.2.3. Wearing parts list. ....... ...... ....... ...... ....................................... ...... ....... ...... ....... ...... ..... ..................... 5-14
5.3. Lubricants, fuels and filling capacities.................................................................................................... 5-15
5.3.1. Lubrication chart .............................................................................................................................5-16
5.4. Tools and standard tightening torques (bolts, nuts).............................................................................. 5-17
5.4.1. Introduction of recommended tools ................................................................................................ 5-17
5.4.2. Torque list.......................................................................................................................................5-18
5.5. Periodical replacement of safety-critical parts .......................................................................................5-20
5.6. Maintenance schedule chart.....................................................................................................................5-21
5.7. Service procedure...................................................................................................................................... 5-23
5.7.1. Pre-start checklist........................................................................................................................... 5-23
Cooling system – checking the coolant level, topping up coolant................................................... 5-23
1-20 WA70-5 – VEAM320200
Introduction 1.8. Table of contents
Cleaning the radiator segments...................................................................................................... 5-24
V-Belt, checking the condition......................................................................................................... 5-24
Engine, checking the oil level, topping up oil..................................................................................5-24
Checking the fuel level – refuelling................................................................................................. 5-26
Water separator at the fuel filter – Draining water and dirt sediments............................................ 5-27
Hand pump - Checking the oil level................................................................................................ 5-27
Checking the controls ..................................................................................................................... 5-28
Checking the electrical connections ............................................................................................... 5-28
Heater/air conditioning – checking rate of air flow.......................................................................... 5-29
Miscellaneous tests before starting work........................................................................................5-29
5.7.2. Maintenance upon demand............................................................................................................ 5-30
Checking the air-conditioning system............................................................................................. 5-30
Checking the window washing-fluid level, adding fluid................................................................... 5-31
Re-charging a built-in battery.......................................................................................................... 5-32
5.7.3. Maintenance after the first 50 operating hours............................................................................... 5-33
Hydraulic system, replacing the filter insert .................................................................................... 5-33
Checking and tightening the wheel nuts......................................................................................... 5-34
5.7.4. Maintenance after the first 250 operating hours............................................................................. 5-35
Front and rear axle – oil change..................................................................................................... 5-35
Transfer box gearing – changing oil ............................................................................................... 5-36
Checking and adjusting the valve clearance ................................................................................. 5-36
5.7.5. Maintenance every 10 operating hours .......................................................................................... 5-37
Lubrication, articulated steering...................................................................................................... 5-37
5.7.6. Maintenance every 50 operating hours .......................................................................................... 5-38
Checking the service brake and oil level, refilling oil ...................................................................... 5-38
Battery – checking the acid level.................................................................................................... 5-39
Lubrication, work unit...................................................................................................................... 5-40
5.7.7. Maintenance every 250 operating hours ........................................................................................ 5-41
V-Belt, generator – checking and adjusting the tension.................................................................. 5-41
Air filter, removing and re-installing the filter insert, checking and cleaning the filter insert............ 5-42
Lubrication, steering cylinder.......................................................................................................... 5-45
Lubrication, self-aligning bearings of rear axle............................................................................... 5-46
5.7.8. Maintenance every 500 operating hours ........................................................................................ 5-47
Engine – changing oil ..................................................................................................................... 5-47
Replacing the oil filter cartridge ...................................................................................................... 5-48
Changing the fuel filter element...................................................................................................... 5-49
Bleeding the fuel system................................................................................................................. 5-50
Bleeding the low pressure side:...................................................................................................... 5-50
Bleeding the high pressure side: .................................................................................................... 5-50
Air filter, replacing the filter insert, replacing the safety filter........................................................... 5-51
Heater/air conditioning – cleaning/replacing filter fleece ................................................................ 5-52
Cleaning the condenser of air conditioning..................................................................................... 5-53
E.C.S.S.-pressure accumulator (Option) - checking gas pressure................................................ 5-53
Front and rear axle – checking the oil level....................................................................................5-54
Transfer box gearing – checking the oil level ................................................................................. 5-55
5.7.9. Maintenance every 1000 operating hours ...................................................................................... 5-56
V-Belt, generator – checking and adjusting the tension.................................................................. 5-56
Service Brake - Checking and adjusting oil .................................................................................... 5-56
WA70-5 – VEAM320200 1-21
1.8. Table of contents Introduction
Checking and adjusting system pressures ..................................................................................... 5-56
Have the system pressures checked and adjusted at an authorised Komatsu garage..................5-56
Hydraulics – Exchanging the venting filters.................................................................................... 5-57
Hydraulic system, replacing the filter insert .......................... ...... ....... ....................................... ...... 5-58
5.7.10. Maintenance every 1500 operating hours ...................................................................................... 5-59
Front and rear axle – oil change..................................................................................................... 5-59
Transfer box gearing – changing oil................................................................................................ 5-60
5.7.11. Maintenance every 2000 operating hours ...................................................................................... 5-61
Cooling system – exchanging coolant and cleaning the system ....................................................5-61
Checking and adjusting the valve clearance ................................................................................. 5-63
Hydraulic system, oil change......... ....... ...... ....... ...... ....................................... ...... ....... ...... ...... .......5-64
Ventilating the hydraulic oil tank .....................................................................................................5-65
Checking the fuel pump........................ ...... ....... ...................................... ....... ...... ....... ...... .............5-66
Checking the fuel and coolant tubes, replacing the tubes (if required)........................................... 5-66
Checking the water pump..................... ...... ....... ...... ....... ...... ...... ....... ...... ....................................... 5-66
5.7.12. Maintenance every 4000 operating hours ...................................................................................... 5-67
Lubrication, universal joint .............................................................................................................. 5-67
6. Technical data............. .. .............. ... .. ............... .. .. ............... .. ... .............. .. ... .6-1
6.1. Technical data..................................... ...... ....... ...... ....... ...... ....... ...... ...... ....... ...... .........................................6-2
6.2. Noise emission levels.................................................................................................................................. 6-3
6.3. Vibration level............................................................................................................................................... 6-3
6.4. Limit values for slopes................................................................................................................................ 6-3
7. Special equipment and attachments.........................................................7-1
7.1. E.C.S.S. .........................................................................................................................................................7-2
7.1.1. Structure and functioning principle of the E.C.S.S............................................................................7-2
7.1.2. Precautionary measures for switching on the E.C.S.S..................................................................... 7-2
7.1.3. Operating the E.C.S.S. .....................................................................................................................7-3
Switching ON the E.C.S.S. ...............................................................................................................7-3
Switching OFF the E.C.S.S. ....................................................... ....... ...... ....... .................................. 7-3
7.1.4. Precautions when handling the accumulator.................................................................................... 7-4
8. Index.............................................................................................................8-1
9. Notes............................................................................................................9-1
1-22 WA70-5 – VEAM320200
Introduction 1.9. Dimensions, weights and operating data
1.9. Dimensions, weights and operating data
Dimensions, weights and operating data
Bucket capacity to ISO 7546 0,85 m³ 30.017 cuft
Material density 1,8 t/m³ 3.033 pound/cubic yard
Static tipping load, straight 3700 kg 8157 pound
Static tipping load, 40° angle 3140 kg 6922 pound
Working load without CTW 1900 kg 4188 pound
Working load with CTW 2100 kg 4629 pound
Breakout force, hydraulic 40,6 kN 40.6 kN
Lifting capacity, hydraulic, on ground 41,10 kN 41.10 kN
Operating weight 4820 kg 10626 pound
Turning radius over bucket 4175 mm 13’ 7" ft. in.
L Bucket length in transport position 5250 mm 17’ 3" ft. in.
A Bucket length during planing 5320 mm 17’ 5" ft. in.
T1 Wi dth with bucke t 1800 mm 5’ 9" ft. in.
T2 Width without bucket (above wheels) - mm - ft. in.
G Height, including ROPS 2470 mm 8’ 1" ft. in.
D Track 1360 mm 4’ 5" ft. in.
B Width over tyres 2050 mm 6’ 8" ft. in.
H Distance articulated steer. - front axle 1025 mm 3’ 4" ft. in.
Ground clearance, axle /transfer gear
E
ground clearance, cardan shaft
F Centre of gravity, height above axle centre - mm - ft. in.
I Centre of gravity, distance to front axle - mm - ft. in.
305
425
mmmm12"
1’ 4"
ft. in.
ft. in.
These values refer to
machines with
12.5 - 18 tires
CTW = additional
counterweight
WA70-5 – VEAM320200 1-23
1.10. CE-conforming equipment Introduction
1.10. CE-conforming equipment
1.10.1. CE-conforming equipment – part 1
CE-conforming equipment
12 3 4–
Type Part No.
Bucket WA70-5
Volume
cuft (m³)
42U-70-22010 30.017 (0,85) - 604 (274)
42U-70-22020 30.017 (0,85) - 650 (295)
42T-70-22080 26.485 (0,75) - 659 (299)
42U-70-22120 44.143 (1,25) - 760 (345)
42U-70-22140 35.314 (1,0) - 683 (310)
Hydr. pressure
bar
Weight
lb (kg)
1.10.2. CE-conforming equipment – part 2
CE-conforming equipment
12 3 4 –
Work load of fork
Type Part No.
Fork carrier WA70-5 42U-70-22050 3,968 (1,800) - 476 (216)
carrier STD
lb (kg) / pair
Work load of fork
carrier with CTW
kg / pair
Weight
lb (kg)
1-24 WA70-5 – VEAM320200
Introduction 1.10. CE-conforming equipment
1.10.3. Manufacturer-supplied CE-conforming equipment.
The responsibility for observing valid regulations in the case of
wheel loaders with "int erchangeabl e equipment" (e.g. bucket or
fork-lift) which was not supplied from works lies with the customer
which was subsequently fitted to the machine.
The guidelines for C E Con formity and road- traffic reg istrati on a re
deemed to have been fulfilled when the manufacturer of the
equipment confirms fulfilment.
The certification must be sent to the customer and the wheel
loader manufactur er. The CE co nformi ty d ec larat ion fo r a s pecific
wheel loader is only legally valid once this has taken place.
The dimensio ns X1, X2, Y1 and Y2 must be provid ed by the
manufacturer of the equipment for approval for use on public
roads.
The dimension Sh (sm allest tyre radi us) must be add ed to the
dimension D2.
The figure G (in k g) represents the m aximum load (e quipment
and operating load) which may act upon this point.
WA70-5 – VEAM320200 1-25
1.10. CE-conforming equipment Introduction
1-26 WA70-5 – VEAM320200
Introduction 1.10. CE-conforming equipment
Manufacturer-supplied CE-conforming equipment.
A1 Distance: bucket pivoting point - front axle, horizontal
A2 Distance: bucket pivoting point - front axle, vertical
B1 Distance: driver's eye - front axle, horizontal
B2 Distance: driver's eye - front axle, vertical
D1 Distance front axle- lower edge of headlights, horizontal
D2 Distance front axle- lower edge of headlights, vertical
Weight of the equipment and carrying load without
G
additional counterwe ig ht
H1 Distance: bucket pivoting point - bucket upper edge, vertical
(carrying position)
H2 Distance: bucket pivoting point - vision line, vertical
(carrying position)
J Distance road level - lower edge of bucket in carrying posi-
tion (to be considered during driving on public roads)
Sh Distance: road level - front axle
a Tip-in angle
b1 Bucket connection dimension boom width, interior
c Bucket connection dimension between d1 and d2, vertical
d1 Bucket connection dimension bolts for boom
mm
WA70-5
ft. in. mm
A1 5’ 4" 1.625
A2 3’ 7" 1.125
Sh 1’ 5" 450
B1 6’ 1.820
B2 5’ 4" 1.650
C1 4’ 4" 1.330
C2 4’ 2" 1.280
D1 1’ 2" 375
D2 3’ 5" 1.070
G 5’ 2" 1.570
H1 2’ 9" 875
H2 4’ 1.215
J 10.62" 270
X1 - X2 - Y1 - Y2 - -
d2 Bucket connection dimension bolt for tip-in rod
e Bucket connection dimension d1- d2 horizontally displaced
h Distance lower edge of bucket - drill hole of boom bolt
a51°
b1 2’ 8" 860
c 12.28" 312
d1 ø 1.574 ø 40
d2 ø 1.574 ø 40
e0.59"15
h 7.87" 200
T yre 12.5 - 18 Dunlop
Bucket
42U-70-22010
30.017 cuft (0.85 m3)
WA70-5 – VEAM320200 1-27
1.11. Loading and securing Introduction
1.11. Loading and securing
Observe all safety instructions carefully in or der to prevent accidents with severe injury. See "3.4. Transporting the machine" on
page 3-76.
DANGER
● Always secure articulated joint if maintenance or repair
work is to be carried out or if the machine is going to be
lifted or transported.
● An articulated joint may jack-knife unexpectedly if not
secured. Danger of injury if joint jack-knifes.
1-28 WA70-5 – VEAM320200
Introduction 1.11. Loading and securing
1. Set the machine to straight driving.
2. On the left: Loosen the spring bolt and remove the bolt (1).
3. On the right: Insert the bolt (2) and secure by means of the
spring bolt.
NOTE
Due to safety reasons and to avoid consequential damages,
it is prohibited to attach other points (such as axles, cardan
shafts, articulated joint, bucket teeth) than those specified
for lifting and securing. It is also prohibited to atta ch ropes
etc. to th e driver's cabin.
1
2
WA70-5 – VEAM320200 1-29
Loading...