Komatsu WA150-5H - User Manual

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Overview

Function Description
Important Technical Specifications
Usage Features
Maintenance Features

This document is the Operation & Maintenance Manual for the Komatsu WA150-5H Wheel Loader, serial numbers H50051 and up, with document number VEAM934100, printed in Europe in November 2004.

Function Description:

The Komatsu WA150-5H is a wheel loader designed for loading and digging operations. It features an independent transmission and moves on wheels. Its standard operation cycle involves filling and loading the bucket, transporting material, and emptying the bucket. The machine is equipped with various attachments for loading operations, primarily a bucket. The manual explicitly states that the transport of persons in the work equipment is strictly forbidden.

Important Technical Specifications:

Model: WA150-5H
Operating Weight (including 1 operator: 75 kg): 7,845 kg
Normal Load: 2,700 kg
Bucket Capacity: 1.5 m³ (to ISO 7546, without teeth and without BOC)
Material Density: 1.8 t/m³
Bucket Weight (without teeth): 640 kg
Static Tipping Load (straight): 6,370 kg
Breakout Force (hydraulic): 76 kN
Lifting Capacity (hydraulic, on ground): 88 kN
Engine Model: Komatsu SAA4D102E-2 diesel engine
Flywheel Horsepower: 71 kW (97 HP) at 2000 rpm
Overall Length (bucket on ground): 6,316 mm
Overall Height: 3,063 mm
Max. Dimension when Shaking Bucket: 4,688 mm
Overall Width: 2,228 mm (with 17.5R25 tires)
Min. Ground Clearance: 270 mm
Bucket Width: 2,400 mm
Clearance BOC Tip: 2,731 mm
Reach BOC Tip: 369 mm
Dump Angle: 45°
Min. Turning Radius (out of chassis): 5,170 mm
Min. Turning Radius (center of outside tire): 4,470 mm
Travel Speed (km/h):
- Forward: 1st (5.1), 2nd (14.0), 3rd (22.1), 4th (39.1)
- Reverse: 1st (5.2), 2nd (14.0), 3rd (21.9), 4th (39.0)
Hydraulic Pressure: 210 bar (Lift circuit, Tilt circuit, Third control circuit)
Fuel Tank Capacity: 133 liters (35.14 US gal)
Engine Oil Pan Refill Capacity: 12.5 liters (3.30 US gal)
Transfer Case Refill Capacity: 4.4 liters (1.16 US gal)
Hydraulic Tank Refill Capacity: 47 liters (12.42 US gal)
Cooling System Capacity: 17 liters
Air Conditioner Refrigerant: R134a (CFC-free), 860 g
Tires: Standard 17.5 R25 XHA L3, with inflation pressure 3.5 bar (50 PSI) for front and 2.5 bar (36 PSI) for rear.

Usage Features:

The WA150-5H is designed for safe and effective operation.

Operator Compartment: Features a safety lock lever for work equipment, parking brake lever, and adjustable operator's seat. The manual emphasizes maintaining three-point contact when entering/exiting the cab and keeping the compartment clear of tools or flammable objects.
Machine Monitor: Provides critical information through a character display, pilot lamps, and gauges. It alerts the operator to emergency stop items (e.g., brake oil pressure, engine oil pressure, battery charge, steering oil pressure), caution items (e.g., axle oil temperature, parking brake reminder, HST oil temperature, engine coolant temperature, fuel level), and maintenance items (e.g., radiator coolant level, HST oil filter clogging). Action codes (E00, E01, E02, E03) are displayed for various issues, with E03 indicating a serious failure requiring immediate shutdown.
Controls: Includes a starting switch with OFF, ON, and START positions. A speed range selector switch offers 1st to 4th gears for operations and travel. A variable shift control switch allows adjusting maximum speed in 1st gear. Directional selector switches (lever and actuation switch) control forward, neutral, and reverse travel. A traction control switch reduces drive force in higher gears to prevent tire slip.
Work Equipment Operation: The work equipment control lever operates the lift arm (RAISE, HOLD, LOWER, FLOAT) and bucket (TILT, HOLD, DUMP). The FLOAT position is recommended for leveling.
Adjustments: Boom kickout and bucket positioner can be adjusted to automatically stop the work equipment at desired heights and angles. The steering wheel tilt can be adjusted for operator comfort. Rearview mirrors are adjustable for clear visibility.
Safety Features: ROPS/FOPS-Cab for operator protection. Safety labels are affixed throughout the machine. Emergency steering system allows steering at low speeds if the main system fails.
Cold Weather Operation: Specific precautions for fuel, lubricants, coolant, and battery are provided, including recommendations for low-viscosity fluids and thorough warming-up procedures.
Transportation: Detailed procedures for loading, unloading, and securing the machine on a trailer, including the use of ramps and safety bars. Lifting points and weight distribution are specified.

Maintenance Features:

The manual provides comprehensive maintenance guidelines to ensure safe and prolonged machine life.

Periodic Maintenance: A detailed schedule chart outlines maintenance intervals (Initial 250 hours, When required, Every 50, 100, 250, 500, 1000, 2000, and 4000 hours).
Daily Checks (Before Starting Engine): Includes inspecting work equipment, cylinders, linkage, hoses for damage/wear/play; removing dirt/dust from engine, battery, radiator; checking for coolant/oil leakage; inspecting tires and rims; checking handrails and steps; verifying gauges and lamps; checking battery terminals; and cleaning cab windows.
Fluid Management: Instructions for checking and adding engine oil, axle oil, hydraulic oil, fuel, and coolant. Emphasizes using KOMATSU genuine oils and proper viscosities. Includes procedures for draining water/sediment from the fuel tank and bleeding air from the fuel system.
Filter Maintenance: Procedures for checking, cleaning, and replacing air cleaner elements, fuel filter cartridges, HST oil filter elements, and hydraulic tank filter elements.
Brake System: Checks for parking brake function, brake pedal operation, and brake disc wear.
Electrical System: Checks for electric wiring damage, fuse integrity, and battery electrolyte level. Instructions for handling batteries, including safe removal, installation, and charging.
Cooling System: Procedures for cleaning the radiator fins, cooler fins, and the inside of the cooling system, as well as checking and adding coolant.
Lubrication: Detailed instructions for lubricating various pins (rear axle pivot, bucket, lift cylinder, lift arm pivot, tilt lever, steering cylinder, drive shaft) using a grease pump.
Wear Parts: A list of wear parts (filters, cutting edges, bucket teeth) with recommended replacement frequencies.
Special Checks: Includes checking air conditioner compressor belt tension, turbocharger tightening parts and rotor play, alternator, starting motor, engine valve clearance, accumulator gas pressure, and vibration damper.
Safety Critical Parts: A list of safety-critical parts (hoses, packings, seals, O-rings) that must be replaced periodically (every 2 years or 4000 hours, whichever comes first) regardless of their apparent condition, due to material deterioration over time.
Troubleshooting: Provides a guide for common problems related to the HST, axle, brake, steering, hydraulic system, and engine, along with main causes and remedies.
Environmental Considerations: Emphasizes proper disposal of waste materials like oil, fuel, coolant, solvents, filters, and batteries to prevent pollution.