KOMATSU WA90-5-M Maintenance Manual
VEAM270101
Operation & Maintenance
Manual
WHEEL LOADER
SERIAL NUMBERS H50051 AND UP
DANGER
Incorrect operation and maintenance of this machine
may be hazardous and cause injuries. The operator and
maintenance personnel must read this manual before
commencing operation or maintenance. Keep this
manual within reach at all times and ensure that
operating personnel read it at regular intervals.
-5
NOTE
Komatsu has had the operating and maintenance
instructions translated into all the languages of the
European Union. Should you require a copy in another
language please inquire at your local dealer’s.
© 2006 Komatsu Hanomag GmbH
All Rights Reserved
Printed in Europe 11-06
Introduction
1. Introduction
WA90-5 – VEAM270101 1-1
1.1. Foreword Introduction
1.1. 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 instructions 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 are physically and mentally fit to perform 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 have completely read 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.
1-2 WA90-5 – VEAM270101
Introduction 1.1. Foreword
Please note:
If the owner modifies safety-related parts of the machine, the certificate of conformity of the manufacturer will lapse and the person
who has performed the modification has to issue a new certificate. Should you have any questions concerning this point,
please do not hesitate to ask Komatsu.
Our continuous effort to improve the machine’s design may lead
to changes of machine details. However, the introduction of these
improvements does not oblige us to perform them on machines
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 instructions.
Should you require new available information about your machine
or have any questions concerning the information given in the
operating instructions, please do not hesitate to contact either
Komatsu or your responsible Komatsu dealer.
These operating instructions may refer to attachments and special equipment not available from your local Komatsu dealer.
Should you require attachments or special equipment, ask your
responsible Komatsu dealer.
EU Directives
This machine is labelled with the CE mark indicating that it meets
all basic requirements concerning safety and protection of health
of the EU Machinery Directive 89/392/EEC, its supplements 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 the machine. This fact is documented in the EU
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 safety of the machine is affected, the person
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 than that defined as correct use, you are
the person who has to ensure that safety is maintained. Modifications of the machine or use of the machine for any other purpose
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 other countries than Germany, it may be
possible that special national safety devices and specifications
are missing which may be required for the application in the relevant 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.
WA90-5 – VEAM270101 1-3
1.1. Foreword Introduction
Should you have any questions concerning standards and guidelines in the respective country the machine is to be used in,
please ask your Komatsu dealer before you start commissioning
the machine.
In addition to the operating instructions, you must also adhere to
all legal regulations on public traffic and all applicable regulations
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 electromagnetic radiation which may influence the
proper function of electronic 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 later comply with the valid version of the 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 (e.g. radio, telephone):
● 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 such a way that it is physically separated
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, adhere to all information about installation and connection of cables and maximum power input indicated in the manufacturer’s installation instructions of the machine.
1-4 WA90-5 – VEAM270101
Introduction 1.2. Safety information
1.2. Safety information
The procedures and precautionary measures concerning operation and maintenance only 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 notes and warnings in these operating
instructions and on the machine, before you start operation or
maintenance of the machine and always adhere to these safety
notes and warnings.
The following words are used in this manual and on stickers 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 messages 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 messages 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 which 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 shortening the
service lift of the machine.
The safety instructions are listed in the chapter "2. Safety" on
page 2-1 and following.
WA90-5 – VEAM270101 1-5
1.2. Safety information Introduction
The transport of persons in the work equipment is strictly
forbidden!
We cannot foresee all circumstances which could result in potential danger during maintenance and operation. The safety instructions in this manual and on the machine, therefore, do not
necessarily contain all possible safety precautions. If you are
using a procedure or measure not explicitly permitted and recommended in this manual, you must ensure that 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.
1-6 WA90-5 – VEAM270101
Introduction 1.3. Introduction
1.3. Introduction
1.3.1. Intended use
This loader is a machine with independent transmission, moving
on wheels. Driving in forward direction, the loader can load 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 3-58 for more details.
WA90-5 – VEAM270101 1-7
1.3. Introduction Introduction
1.3.2. 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 in and maintained very carefully 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 in this manual for operating, maintenance,
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 operations is the responsibility of the user.
Operations that are prohibited in this manual must never be carried out under any circumstances.
1-8 WA90-5 – VEAM270101
Introduction 1.4. Location of plates
1.4. Location of plates
1.4.1. Machine identification plate
Position of the identification plate (1) (see enlargement)
Serial no. stamp marking (2)
Machine identification plate (PIN)
1.4.2. Engine name-plate
Engine name-plate with serial no.
WA90-5 – VEAM270101 1-9
1.4. Location of plates Introduction
1.4.3. Axle serial no. plate
This plate is located on the right of front axle and on the left of
rear axle (1).
1.4.4. Transmission serial no. plate
This plate is located in travel direction front, above the transmission output (1).
1.4.5. ROPS/FOPS-Cab serial no. plate
This plate is located on the right inside cab on the rear beam (1).
1-10 WA90-5 – VEAM270101
Introduction 1.4. Location of plates
1.4.6. Operator’s seat serial no. plate
This plate is located in front of seat, covered by the bellows.
1.4.7. Table to enter 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
WA90-5 – VEAM270101 1-11
1.5. Table of contents Introduction
1.5. Table of contents
1. Introduction .................................................................................................1-1
1.1. Foreword....................................................................................................................................................... 1-2
EU Directives .................................................................................................................................... 1-3
1.2. Safety information........................................................................................................................................ 1-5
1.3. Introduction .................................................................................................................................................. 1-7
1.3.1. Intended use ..................................................................................................................................... 1-7
1.3.2. Breaking-in the machine ................................................................................................................... 1-8
1.4. Location of plates ........................................................................................................................................ 1-9
1.4.1. Machine identification plate .............................................................................................................. 1-9
1.4.2. Engine name-plate............................................................................................................................ 1-9
1.4.3. Axle serial no. plate ........................................................................................................................ 1-10
1.4.4. Transmission serial no. plate .......................................................................................................... 1-10
1.4.5. ROPS/FOPS-Cab serial no. plate................................................................................................... 1-10
1.4.6. Operator’s seat serial no. plate ....................................................................................................... 1-11
1.4.7. Table to enter serial no. and distributor .......................................................................................... 1-11
1.5. Table of contents ....................................................................................................................................... 1-12
1.6. Dimensions, weights and operating data ................................................................................................ 1-19
1.7. CE-conforming equipment ........................................................................................................................ 1-20
1.7.1. CE-conforming equipment – part 1 ................................................................................................. 1-20
1.7.2. CE-conforming equipment – part 2 ................................................................................................. 1-21
1.7.3. Manufacturer-supplied CE-conforming equipment ......................................................................... 1-22
1.8. Loading and securing................................................................................................................................ 1-25
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
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
1-12 WA90-5 – VEAM270101
Introduction 1.5. Table of contents
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........................................................................................................................ 2-22
2.3.4. Tyres............................................................................................................................................... 2-26
2.4. Safety labels on the machine.................................................................................................................... 2-28
2.4.1. Positions and order numbers of safety labels................................................................................. 2-28
3. Operation ..................................................................................................... 3-1
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
WA90-5 – VEAM270101 1-13
1.5. Table of contents Introduction
Measuring indicators....................................................................................................................... 3-13
3.2.2. Switches ......................................................................................................................................... 3-15
3.2.3. Control levers and pedals ............................................................................................................... 3-23
3.2.4. Articulated steering locking ........................................................................................................ 3-28
3.2.5. Traction device ............................................................................................................................... 3-28
3.2.6. Socket (12 V) .................................................................................................................................. 3-29
3.2.7. Door unlocking system ................................................................................................................... 3-29
3.2.8. Alarm horn for reverse driving – option........................................................................................... 3-29
3.2.9. Fuses.............................................................................................................................................. 3-30
3.2.10. Slow-blowing fuses ......................................................................................................................... 3-31
3.2.11. Adjusting the heater and ventilation system ................................................................................... 3-32
3.2.12. Air-conditioning ............................................................................................................................... 3-33
3.3. Operation .................................................................................................................................................... 3-34
3.3.1. Pre-start checks.............................................................................................................................. 3-34
Visual inspection ............................................................................................................................. 3-34
Pre-start checks .............................................................................................................................. 3-36
Adjustments prior to machine start ................................................................................................. 3-41
Adjusting the driver’s seat............................................................................................................... 3-41
3.3.2. Starting the engine.......................................................................................................................... 3-45
Warming up the engine................................................................................................................... 3-46
3.3.3. Driving with the machine................................................................................................................. 3-47
Start-up ........................................................................................................................................... 3-47
Limiting the maximum speed .......................................................................................................... 3-48
3.3.4. Changing the driving direction ........................................................................................................ 3-50
3.3.5. Turning and steering....................................................................................................................... 3-51
3.3.6. Braking............................................................................................................................................ 3-52
3.3.7. Stopping the machine ..................................................................................................................... 3-54
3.3.8. Operating the work equipment........................................................................................................ 3-55
Multifunctional lever ........................................................................................................................ 3-55
Control lever for special equipment ................................................................................................ 3-56
Switching lever of bucket ................................................................................................................ 3-57
3.3.9. Working with the wheel loader ........................................................................................................ 3-58
Tyre-appropriate operation ............................................................................................................. 3-58
Switching on the 100 % differential lock (if equipped) .................................................................... 3-58
Loading work .................................................................................................................................. 3-59
Removal work ................................................................................................................................. 3-59
Excavation work.............................................................................................................................. 3-61
Planing ............................................................................................................................................ 3-62
Transporting.................................................................................................................................... 3-63
Unloading........................................................................................................................................ 3-63
Working with the forklift truck attachment ....................................................................................... 3-64
3.3.10. Precautions for special operations.................................................................................................. 3-66
Permissible water depth ................................................................................................................. 3-66
Working on snow ............................................................................................................................ 3-66
Dumping on steep slopes ............................................................................................................... 3-66
Working in the vicinity of electrical overhead lines.......................................................................... 3-66
Operation on slopes........................................................................................................................ 3-66
1-14 WA90-5 – VEAM270101
Introduction 1.5. Table of contents
Working on loose soil...................................................................................................................... 3-66
If the service brake breaks down .................................................................................................... 3-66
Precautionary measures when driving up or down......................................................................... 3-67
Precautionary measures during machine travel ............................................................................. 3-68
3.3.11. Adjusting the position of the work equipment ................................................................................. 3-69
Selecting a work unit....................................................................................................................... 3-69
Removing the work unit .................................................................................................................. 3-71
Picking up the multi-purpose bucket............................................................................................... 3-72
Removing the multi-purpose bucket ...............................................................................................3-74
Level indicator for the bucket.......................................................................................................... 3-74
3.3.12. Parking the machine....................................................................................................................... 3-75
3.3.13. Switching off the engine.................................................................................................................. 3-76
3.3.14. Check after stopping the engine ..................................................................................................... 3-76
3.3.15. Locking ........................................................................................................................................... 3-76
3.3.16. Tyre handling .................................................................................................................................. 3-77
Precautionary measures when handling tyres................................................................................ 3-77
Tyre pressure.................................................................................................................................. 3-77
3.4. Transporting the machine......................................................................................................................... 3-79
3.4.1. Securing the articulated steering .................................................................................................... 3-79
3.4.2. Lifting the machine.......................................................................................................................... 3-80
3.4.3. Driving the machine onto loading area of transport vehicle............................................................ 3-81
3.4.4. Securing the machine during the transport..................................................................................... 3-82
3.4.5. After transport................................................................................................................................. 3-82
3.5. Cold weather operation ............................................................................................................................. 3-83
3.5.1. Before the cold season ................................................................................................................... 3-83
3.5.2. Precautions after completion of work.............................................................................................. 3-84
3.5.3. After the cold season ...................................................................................................................... 3-84
3.6. Long-term storage ..................................................................................................................................... 3-85
3.6.1. Before storage ................................................................................................................................ 3-85
3.6.2. During storage ................................................................................................................................ 3-85
3.6.3. After storage ................................................................................................................................... 3-86
4. Troubleshooting .........................................................................................4-1
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
WA90-5 – VEAM270101 1-15
1.5. Table of contents Introduction
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
5.2. Maintenance basics ................................................................................................................................... 5-12
5.2.1. Oil, fuel and coolant specifications ................................................................................................. 5-12
Oil ................................................................................................................................................... 5-12
Fuel................................................................................................................................................. 5-13
Coolant ........................................................................................................................................... 5-14
Grease ............................................................................................................................................ 5-14
Storing oil and fuel .......................................................................................................................... 5-15
Filters .............................................................................................................................................. 5-15
Biodegradable hydraulic oil and lubricants ..................................................................................... 5-15
5.2.2. Specifications of the electrical system ............................................................................................ 5-16
5.2.3. Wearing parts list ............................................................................................................................ 5-17
5.3. Lubricants, fuels and filling capacities .................................................................................................... 5-18
5.4. Tools............................................................................................................................................................ 5-19
5.4.1. Introduction of recommended tools ................................................................................................ 5-19
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
Cleaning the radiator segments ...................................................................................................... 5-24
V-Belt, checking the condition......................................................................................................... 5-24
Engine, checking the oil level, topping up oil ..................................................................................5-25
Checking the fuel level – refuelling ................................................................................................. 5-27
Additional water separator (optional) .............................................................................................. 5-28
Water separator at the fuel filter – Draining water and dirt sediments ............................................ 5-28
Checking the controls ..................................................................................................................... 5-29
Checking the electrical connections ............................................................................................... 5-29
Heater/air conditioning – checking rate of air flow .......................................................................... 5-30
Miscellaneous tests before starting work ........................................................................................5-30
5.7.2. Maintenance upon demand ............................................................................................................ 5-31
Checking the air-conditioning system ............................................................................................. 5-31
Checking the window washing-fluid level, adding fluid ................................................................... 5-32
Re-charging a built-in battery.......................................................................................................... 5-33
5.7.3. Maintenance after the first 50 operating hours ............................................................................... 5-34
1-16 WA90-5 – VEAM270101
Introduction 1.5. Table of contents
Hydraulic system, replacing the filter insert .................................................................................... 5-34
Checking and tightening the wheel nuts ......................................................................................... 5-35
5.7.4. Maintenance after the first 250 operating hours ............................................................................. 5-36
Front and rear axle – oil change ..................................................................................................... 5-36
Transfer box – changing oil ............................................................................................................ 5-37
Checking and adjusting the valve clearance ................................................................................. 5-38
5.7.5. Maintenance every 10 operating hours .......................................................................................... 5-38
Lubrication of articulated steering................................................................................................... 5-38
5.7.6. Maintenance every 50 operating hours .......................................................................................... 5-39
Battery – checking the acid level .................................................................................................... 5-39
Lubrication of work unit ................................................................................................................... 5-40
5.7.7. Maintenance every 250 operating hours ........................................................................................ 5-41
Service brake – Checking the brake pads ...................................................................................... 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 ............ 5-43
Lubrication, steering cylinder .......................................................................................................... 5-46
Lubrication, self-aligning bearings of rear axle ............................................................................... 5-47
Checking and tightening the wheel nuts ......................................................................................... 5-48
5.7.8. Maintenance every 500 operating hours ........................................................................................ 5-49
Hand pump - Checking the oil level ................................................................................................ 5-49
Service brake - Checking the brake pads and brake discs, checking the oil level ......................... 5-49
Engine – changing oil ..................................................................................................................... 5-51
Replacing the oil filter cartridge ...................................................................................................... 5-52
Changing the fuel filter element ...................................................................................................... 5-53
Bleeding the fuel system................................................................................................................. 5-54
Bleeding the low pressure side:...................................................................................................... 5-54
Bleeding the high pressure side: .................................................................................................... 5-54
Air filter, replacing the filter insert, replacing the safety filter........................................................... 5-55
Heater/air conditioning – cleaning/replacing filter fleece ................................................................ 5-56
Multi-functional lever accumulator - checking gas pressure ......................................................... 5-57
E.C.S.S.-pressure accumulator (Option) - checking gas pressure ................................................ 5-57
Front and rear axle – checking the oil level ....................................................................................5-58
Transfer box – checking and refilling oil ......................................................................................... 5-59
5.7.9. Maintenance every 1000 operating hours ...................................................................................... 5-60
V-Belt, generator – checking and adjusting the tension.................................................................. 5-60
Service Brake - Checking and refilling oil ....................................................................................... 5-60
Checking and adjusting system pressures ..................................................................................... 5-60
Hydraulic – Exchanging the venting filter........................................................................................ 5-61
Hydraulic system, replacing the filter insert .................................................................................... 5-62
5.7.10. Maintenance every 1500 operating hours ...................................................................................... 5-63
Front and rear axle – changing oil .................................................................................................. 5-63
Transfer box – changing oil ............................................................................................................ 5-64
5.7.11. Maintenance every 2000 operating hours ...................................................................................... 5-65
Cooling system – exchanging coolant and cleaning the system .................................................... 5-65
Checking and adjusting the valve clearance ................................................................................. 5-67
Hydraulic system - changing oil ...................................................................................................... 5-68
Ventilating the hydraulic oil tank ..................................................................................................... 5-69
Checking the fuel pump .................................................................................................................. 5-70
WA90-5 – VEAM270101 1-17
1.5. Table of contents Introduction
Checking the fuel and coolant tubes, replacing the tubes (if required)........................................... 5-70
Checking the water pump ............................................................................................................... 5-70
5.7.12. Maintenance every 4000 operating hours ...................................................................................... 5-71
Lubrication, drive shaft.................................................................................................................... 5-71
6. Technical data .............................................................................................6-1
6.1. Technical data .............................................................................................................................................. 6-2
6.2. Noise emission levels.................................................................................................................................. 6-3
6.3. Vibration levels............................................................................................................................................. 6-3
Operating condition .......................................................................................................................... 6-3
Guide to Reduce Vibration Levels on Machine................................................................................. 6-3
6.4. Limit values for slopes ................................................................................................................................ 6-5
7. Special equipment and attachments.........................................................7-1
7.1. E.C.S.S-electronics ...................................................................................................................................... 7-2
7.1.1. Structure and functioning principle of the E.C.S.S-electronics ......................................................... 7-2
7.1.2. Precautionary measures for switching on the E.C.S.S-electronics................................................... 7-2
7.1.3. Operating the E.C.S.S-electronics .................................................................................................... 7-3
Switching ON the E.C.S.S.-electronics ............................................................................................. 7-3
Switching OFF the E.C.S.S-electronics ............................................................................................ 7-3
7.1.4. Precautions when handling the accumulator .................................................................................... 7-4
7.2. Bucket position indicator ............................................................................................................................ 7-5
8. Index.............................................................................................................8-1
9. Notes ............................................................................................................9-1
1-18 WA90-5 – VEAM270101
Introduction 1.6. Dimensions, weights and operating data
1.6. Dimensions, weights and operating data
Dimensions, weights and operating data
Bucket capacity to ISO 7546 m³ 1,05
Material density t/m³ 1,8
Static tipping load, straight kg 4890
Static tipping load, 40° angle kg 4115
Working load kg 2400
Breakout force, hydraulic kN 63,5
Lifting capacity, hydraulic, on ground kN 59,8
Operating weight kg 6400
Turning radius over bucket mm 4390
L Bucket length in transport position mm 5560 with teeth 5645
A Bucket length during planing mm 5590 with teeth 5730
T1 Width with bucket mm 2050
T2 Width without bucket (above wheels) mm 1990
G Height, including ROPS mm 2820
D Track mm 1590
B Width over tyres mm 2300
H Distance articulated steer. - front axle mm 1100
Ground clearance, axle /transfer gear
E
ground clearance, drive shaft
F Centre of gravity, height above axle centre mm
I Centre of gravity, distance to front axle mm
mm
mm
350
460
385
1452
405/70 R20 SPT9 tyres
CTW = additional counterweight
WA90-5 – VEAM270101 1-19
1.7. CE-conforming equipment Introduction
1.7. CE-conforming equipment
1.7.1. CE-conforming equipment – part 1
CE-conforming equipment
1234–
Type Par t No .
Bucket WA90-5
Volu m e m³Hydr. pressure
bar
42W-70-22020 1,05 --- 355
42W-70-22030 1,05 --- 376,5
42W-70-22080 1,60 --- 461
42W-70-22061 0,90 250
Weight
kg
1-20 WA90-5 – VEAM270101
Introduction 1.7. CE-conforming equipment
1.7.2. CE-conforming equipment – part 2
CE-conforming equipment
12 3 4 –
Work load of
Type P a rt N o.
Fork carrier WA90-5 42W-70-22050 2000 2200 304
fork carrier STD
kg / pair
Work load of fork
carrier with CTW
kg / pair
Weight
kg
WA90-5 – VEAM270101 1-21
1.7. CE-conforming equipment Introduction
1.7.3. Manufacturer-supplied CE-conforming equipment
The responsibility for observing valid regulations in the case of
wheel loaders with "interchangeable 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 CE Conformity and road-traffic registration are
deemed to have been fulfilled when the manufacturer of the
equipment confirms fulfilment of the document.
The certification must be sent to the customer and the wheel
loader manufacturer. The CE conformity declaration for a specific
wheel loader is only legally valid once this has taken place.
The dimensions X1, X2, Y1 and Y2 must be provided by the
manufacturer of the equipment for approval for use on public
roads.
The dimension Sh (smallest tyre radius) must be added to the
dimension D2.
The figure G (in kg) represents the maximum load (equipment
and operating load) which may act upon this point.
1-22 WA90-5 – VEAM270101
Introduction 1.7. CE-conforming equipment
WA90-5 – VEAM270101 1-23
1.7. CE-conforming equipment Introduction
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 counterweight
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
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
WA90-5 mm
A1 1780
A2 1273
Sh 518
B1 1846
B2 1951
C1 1356
C2 1578
D1 225
D2 1103
G 2250
H1 886
H2 1480
J270
X1 2035
X2 890
Y1 2115
Y2 975
a50
b1 960
c423
d1 40
d2 40
e98
h230
Tyre 405/70 R20 SPT9
Bucket 1,05 m³ (42W-70-22020)
1-24 WA90-5 – VEAM270101
Introduction 1.8. Loading and securing
1.8. Loading and securing
Observe all safety instructions carefully in order to prevent accidents with severe injury. See "3.4. Transporting the machine" on
page 3-79.
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.
WA90-5 – VEAM270101 1-25
1.8. Loading and securing Introduction
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, drive
shafts, articulated joint, bucket teeth) than those specified
for lifting and securing. It is also prohibited to attach ropes
etc. to the driver’s cabin.
1-26 WA90-5 – VEAM270101
Safety
2. Safety
DANGER
Failure to adhere to these safety instructions can lead to
accidents with serious injuries!
Read and adhere to all safety instructions.
This chapter also contains safety instructions for special equipment and attachments.
WA90-5 – VEAM270101 2-1
2.1. General safety measures Safety
2.1. General safety measures
2.1.1. Safety instructions
● Do not operate or service the machine unless you have been
trained and are authorised to do so.
● Always adhere to all instructions, measures, and safety
instructions when operating or servicing the machine.
● When working together with other persons, agree beforehand
on all hand signals that you want to use to avoid accidents
due to misunderstandings.
2.1.2. Safety devices
● Check that all safety devices and covers of the machine are
correctly installed.
● Ensure that damaged safety devices and covers are repaired
before you start the machine.
● Use all safety devices as prescribed, e.g. the safety lever for
the work hydraulic system and the safety belt.
● Do not remove any of the safety devices. Safety devices
must be kept in perfect condition.
2.1.3. Emergency exit
In an emergency situation, you can use the window on the righthand side of the driver’s cab (2) (seen from the driving direction)
as an emergency exit.
2-2 WA90-5 – VEAM270101
Safety 2.1. General safety measures
2.1.4. Clothing and personal protection
● Do not wear loose-fitting clothing, jewellery, or open long hair.
There is danger that you get caught by control elements or
moving parts leading to serious injuries.
● Immediately replace clothing stained with highly inflammable
substances.
● When operating and servicing the machine, wear the appro-
priate protective equipment, e.g. safety helmet, safety goggles, safety shoes, dust protection mask, and safety gloves.
● Always wear safety goggles, safety helmet, and protective
clothing, if it is likely that chippings or splinters will be produced while operating the machine (e.g. when removing or
driving in bolts or cleaning with compressed air).
● Ensure that no unauthorised person is within the danger
zone.
2.1.5. Machine modifications
● Komatsu will not be liable for modifications performed without
prior expressed consent by the manufacturer.
● Komatsu will not be liable for any injuries or damage resulting
from unapproved modifications.
2.1.6. Before you leave the driver’s seat
1. Lower the work unit onto the ground
2. Press slowly the multi-function lever to the front into position
’S’. The remaining hydraulics pressure will be reduced.
3. Switch off the engine.
4. Remove the ignition key before you leave the driver’s seat.
Store the ignition key in a safe place.
5. Close the cabin door.
WA90-5 – VEAM270101 2-3
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