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Komatsu WA95-3 User Manual

Komatsu WA95-3
198 pages
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NOTICE
Komatsu has had the operating and maintenance in-
structions 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.
VEAM980500
Operation & Maintenance
Manual
WA95-3
WHEEL LOADER
SERIAL NUMBERS
HA980376
and up
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.

Table of Contents

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Komatsu WA95-3 Specifications

General IconGeneral
Engine Power55.4 kW
Net Horsepower75 HP
Travel Speed30 km/h
Overall Width2.05 m
Ground Clearance300 mm

Summary

Information on Operating Instructions

Why Read Operating Instructions

Explains the importance of the manual for safe and trouble-free operation, covering regulations and directives.

Notes on Safety Regulations

Covers safety regulations and directives relevant to machine operation and maintenance.

Correct Use

Defines the loader's intended purpose and standard working cycle.

Safety Notes in Operating Instructions

Emphasizes reading and adhering to all safety notes and warnings in the manual and on the machine.

Loading and Transporting the Machine

Loading and Transporting Machine Procedures

Provides instructions for transporting the machine over distances using loaders or wagons.

Securing Articulated Steering

Details how to secure the articulated steering before lifting or repair.

Lifting the Machine Safely

Explains how to safely lift the machine, highlighting dangers and precautions.

Driving Machine onto Transport Vehicle

Guides on safely driving the machine onto a transport vehicle, including ramp safety.

Securing Machine During Transport

Outlines methods to secure the machine on a transport vehicle to prevent movement.

After Transport Procedures

Instructions for removing securing devices after transport.

Dimensions, Weights, and Operating Values

Provides technical data on dimensions, weights, and operating values of the machine.

Technical Data

Contains technical data related to the machine's specifications.

Safety Precautions

General Safety Measures

Covers fundamental safety instructions, devices, and personal protection measures.

Safety Instructions

Provides essential safety rules for operating and servicing the machine.

Safety Devices

Emphasizes checking and maintaining safety devices and covers on the machine.

Emergency Exit

Details the emergency exit route from the driver's cab.

Clothing and Personal Protection

Advises on appropriate clothing and personal protective equipment for safe operation.

Machine Modifications

States Komatsu's liability regarding machine modifications.

Before Leaving Driver's Seat

Lists steps to follow before leaving the driver's seat for safety.

Mounting and Dismounting

Provides instructions for safely mounting and dismounting the machine.

Fire Prevention and Fire Fighting

Details measures for preventing fires and actions to take during a fire.

Protection Against Asbestos Dust

Advises on protection against asbestos dust, though the machine is free of it.

Protection Against Injuries

Warns against inserting body parts into moving machine areas.

Working at High Temperatures

Addresses safety precautions when working with hot engine components and fluids.

Roll-Over Protection System (ROPS)

Explains the function and importance of the ROPS for operator protection.

Attachment for Protection Against Falling Objects (FOPS)

Describes the FOPS and its role in protecting against falling objects.

Attachments

Advises on reading manuals and using approved attachments.

Battery Safety

Provides safety guidelines for handling and working with the machine's battery.

Before Starting the Engine

Details essential checks to perform before starting the engine for safe operation.

Driver's Cab Safety

Covers safety precautions related to the driver's cab environment.

In-Door Operation Safety

Warns about dangers of intoxication during indoor operation without ventilation.

Gas, Dust, and Inflammable Vapours

Addresses risks associated with operating in environments with flammable gases or dust.

Mirrors, Windows, and Lighting

Emphasizes clean windows, mirrors, and proper lighting for visibility.

Machine Operation Safety

Lists safety precautions for operating the machine.

Reversing Safety

Outlines safety rules to observe when reversing the machine.

Driving Safety

Provides guidance on safe driving practices, including transport position.

Driving On Slopes Safety

Details safety measures and precautions for driving on slopes.

Emergency Lowering System

Explains the function and use of the emergency lowering system for the work unit.

Working Near Overhead Power Lines

Provides safety distances and procedures for working near overhead power lines.

Loading Safety

Describes the process of loading material, including safety precautions.

Good Vision Safety

Emphasizes maintaining good vision by using lights and stopping if visibility is poor.

Working On Snow Safety

Provides safety advice for operating the machine in snowy conditions.

Height Limitation Awareness

Highlights the need to be aware of height limitations in areas like tunnels.

Brake Usage

Explains the correct usage of brake pedals and engine braking.

Working On Loose Soil Safety

Warns about operating near edges of hills and deep ditches due to soil instability.

Forklift Truck Attachment Operation

Provides safety and operational guidance for using the forklift attachment.

Parking the Machine Safely

Details procedures for safely parking the machine on level ground or slopes.

Transport Safety

Outlines safe procedures for loading and unloading the machine.

Safety Measures During Maintenance

Covers essential safety protocols and requirements for maintenance personnel.

Tyre Safety and Maintenance

Provides guidelines for checking tyres for damage, wear, and pressure.

Labeling Information

Shows the location and types of safety and information labels on the machine.

Controls and Indicators

Overall Machine View

Shows a general overview of the machine's main components.

Controls and Indicators Overview

Provides an overall view of all controls and indicators on the machine.

Instrument Panel Layout

Details the layout and components of the instrument panel.

Warning Lights Explained

Lists and explains all warning lights on the instrument panel.

Control Lamps Explained

Explains the function of various control lamps on the instrument panel.

Measuring Indicators Explained

Details the fuel gauge, hour meter, and coolant temperature indicator.

Machine Switches

Identifies and explains the function of various switches on the machine.

Control Levers and Pedals

Identifies and describes the function of control levers and pedals.

Articulated Steering Catch

Explains the function of the articulated steering catch.

Traction Device Function

Describes the use of the traction device for towing.

Socket Usage and Safety

Details the function and safety precautions for using the socket.

Door Unlocking System

Explains the mechanism for unlocking the doors.

Reverse Driving Alarm Horn (Option)

Describes the function of the optional alarm horn for reverse driving.

Machine Operation

Running in the Machine

Provides instructions and important points for the initial running-in period of a new machine.

Preparing Machine for Start

Details daily visual checks and preparations before starting the machine.

Adjusting Driver's Seat

Guides on adjusting the driver's seat for optimal comfort and safety.

Adjusting Steering Column

Explains how to adjust the steering column for better ergonomics.

Adjusting Armrest

Details the procedure for adjusting the armrest height.

Adjusting Rear-View Mirrors

Provides guidance on adjusting rear-view mirrors for optimal visibility.

Heating and Ventilation System Adjustment

Explains how to adjust the heating and ventilation system for cabin comfort.

Operating Air Conditioning

Details the steps for switching on and operating the air conditioning system.

Putting on Safety Belt

Instructs on the correct procedure for putting on and using the safety belt.

Starting and Switching Off Engine

Provides step-by-step instructions for starting and switching off the engine safely.

Driving Procedures

Outlines the steps for starting the machine and preparing for driving.

Starting Machine on Slopes

Details safety precautions for starting the machine on slopes.

Driving with High-Speed Gear

Explains how to engage and disengage the high-speed gear safely.

Changing Driving Direction

Provides safety warnings and procedures for changing the machine's driving direction.

Reverse Driving

Offers tips and safety advice for driving the machine in reverse.

Turning Procedures

Explains safe turning practices, especially at high speeds or on slopes.

Braking Procedures

Explains the function of the service brake and parking brake.

Stopping the Machine

Provides the correct procedure for stopping the machine safely.

Parking Machine on Slope

Details how to safely park the machine when on a slope.

Long-Distance Driving Tips

Offers advice for driving the machine over long distances, including tyre pressure checks.

Operating the Machine

Covers procedures for attaching and removing work units like buckets.

Tyre-Appropriate Operation

Offers advice on operating the machine to minimize tyre wear.

Adjusting Bucket Positioner

Guides on adjusting the bucket positioner for optimal digging angles.

Loading Procedures

Details the process of removing piled soil and excavation works.

Transporting Loads

Covers safe practices for transporting loads with the machine.

Dumping/Unloading Procedures

Explains safe procedures for dumping and unloading material.

Piling Up Material

Advises on proper bucket positioning for piling material.

Planing Operations

Explains planing operations for ground levelling.

Prospecting Operations

Explains prospecting operations for wearing off topsoil.

Working With Forklift Truck Attachment

Provides safety and operational guidance for using the forklift attachment.

Precautions For Special Operations

Covers safety measures for operating in specific environments like water or slopes.

Instructions for Winter Operation

Details preparatory measures for trouble-free winter operation.

Longer Standstill Periods

Lists actions for machine shutdown, storage maintenance, and retrieval.

Troubleshooting Guide

General Troubleshooting

General introduction to troubleshooting the machine and locating fault tables.

Warning Lights and Indicators Troubleshooting

Lists troubleshooting tables for warning lights and indicators.

Electrical System Troubleshooting

Provides troubleshooting steps for electrical system faults.

Engine Troubleshooting

Offers solutions for common engine-related faults.

Hydraulic System Troubleshooting

Details troubleshooting for hydrostatic and work hydraulic systems.

Brake System Troubleshooting

Covers troubleshooting for service and parking brakes.

Steering System Troubleshooting

Addresses issues related to steering reactions and wobbling.

Axle Troubleshooting

Provides troubleshooting for axle noise.

Driver's Cab Troubleshooting

Addresses issues related to the driver's cab, such as insufficient airflow.

Emergency Steering Characteristics

Explains steering capabilities when the engine breaks down.

Emergency Lowering System

Details the use of the emergency lowering system for the work unit.

Starting Engine with Jumper Cables

Guides on safely starting the engine using jumper cables.

Towing the Machine

Provides instructions and warnings for towing the machine.

Towing Machine with Defective Brakes

Details safety measures for towing a machine with faulty brakes.

Inadequate Braking Effect Check

Describes how to check the parking brake and service brake effectiveness.

Maintenance Procedures

Maintenance Basics

Covers fundamental principles and preparations for maintenance work.

Cleaning the Machine

Provides instructions for cleaning the machine and safety precautions.

Working-Area-Dependent Maintenance

Details maintenance adjustments based on working environment (muddy, dusty).

Lubricants and Operating Agents

Lists required lubricants, operating agents, and their specifications.

Fuel Handling and Storage

Provides guidance on fuel types, storage, and handling.

Coolant Usage and Preparation

Explains the proper preparation, use, and properties of coolants.

Replacing Safety-Related Parts

Details safety-related parts that require regular replacement.

Spare Parts and Consumables

Lists essential spare parts and their replacement intervals.

Electrical System Maintenance

Covers maintenance aspects of the electrical system, including fuses.

Tyre Maintenance and Safety

Provides guidelines for checking tyres for damage, wear, and pressure.

Tools for Maintenance

Lists essential tools for maintenance and repair.

Torque Values for Nuts and Bolts

Provides torque values for tightening nuts and bolts.

Maintenance Schedule Overview

Outlines the maintenance schedule based on operating hours.

Maintenance Prior to Start

Lists checks and procedures to perform before starting machine operations.

Engine Oil Level Check and Top-Up

Explains how to check and top up engine oil.

Engine Oil Draining

Provides steps for draining engine oil.

Fuel Level Check and Refueling

Guides on checking fuel level and refueling safely.

Checking Machine Controls

Details checks for all control indicators and alarms before starting.

Electrical Connections Check

Advises on checking electrical connections for tightness.

Heater/Air Conditioning Air Flow Check

Explains how to check the air flow from the heater/AC system.

Other Pre-Start Maintenance

Lists additional checks before starting operation.

Maintenance Upon Demand

Outlines maintenance tasks that are performed as needed.

Air Conditioning System Check

Provides steps for checking the air conditioning system.

Maintenance Every 10 Operating Hours

Lists maintenance tasks to be performed every 10 operating hours.

Lubrication Points

Details lubrication points and procedures.

Maintenance Every 50 Operating Hours

Lists maintenance tasks to be performed every 50 operating hours.

Cooling System Check

Guides on checking coolant levels in the radiator and expansion tank.

Fuel Tank Water/Dirt Draining

Explains how to drain water and dirt from the fuel tank.

Service Brake Oil Check and Refill

Details checking the service brake oil level and refilling.

Battery and Acid Level Check

Guides on checking the battery and its acid level.

Re-Charging the Battery

Explains how to recharge the machine's battery.

Lubrication of Work Unit

Details lubrication points on the work unit.

Maintenance Every 100 Operating Hours

Lists maintenance tasks for every 100 operating hours.

Draining Water Separator

Explains how to drain the water separator.

Maintenance Every 250 Operating Hours

Lists maintenance tasks for every 250 operating hours.

Engine Oil and Filter Change

Refers to procedure for changing engine oil and filter.

V-Belt Condition Check

Refers to procedure for checking V-belt condition.

V-Belt Tension Check and Adjustment

Refers to procedure for adjusting V-belt tension.

Front and Rear Axle Oil Level Check

Guides on checking oil levels in front and rear axles.

Air Filter Maintenance

Details procedures for air filter maintenance, including cleaning.

Cleaning Radiator Segments

Explains how to clean radiator segments.

Lubrication Points

Details lubrication points on steering cylinders and shafts.

Maintenance Every 500 Operating Hours

Lists maintenance tasks for every 500 operating hours.

Fuel Filter and Element Change

Details how to change the fuel filter and element.

Purging the Fuel System

Explains how to purge the fuel system after filter replacement.

Hydraulic System Filter Cartridge Change

Refers to procedure for changing hydraulic filter cartridge.

Cleaning the Water Separator

Details how to clean the water separator.

Lubrication of Hinges

Details lubrication points for door and bonnet hinges.

Transfer Box Gearing Oil Check

Guides on checking and refilling transfer box oil.

Air Filter Replacement

Details replacing air filter inserts and safety filters.

Heater/Air Conditioning Maintenance

Explains cleaning or replacing heater/AC filter fleece and condenser.

ALS-Accumulator Gas Pressure Check

Advises checking ALS-accumulator gas pressure via dealer.

Maintenance Every 1000 Operating Hours

Lists maintenance tasks for every 1000 operating hours.

Cooling System Coolant Exchange

Details exchanging coolant and cleaning the cooling system.

Front Axle Oil Change

Refers to procedure for front axle oil change.

Rear Axle Oil Change

Refers to procedure for rear axle oil change.

Transfer Box Gearing Oil Change

Refers to procedure for transfer box gearing oil change.

Service Brake Maintenance Notes

Notes that brake system repairs must be done by authorized garages.

System Pressure Check/Adjustment

Notes that brake system repairs must be done by authorized garages.

Valve Play Check/Adjustment

Notes that valve play adjustment requires an authorized garage.

Injection Nozzle Check/Adjustment

Notes that nozzle checks require an authorized garage.

Accumulator Gas Pressure Check

Advises checking accumulator gas pressure via dealer.

Maintenance Every 2000 Operating Hours

Lists maintenance tasks for every 2000 operating hours.

Hydraulic System Oil Change

Details the procedure for changing hydraulic system oil.

Ventilating Hydraulic Oil Tank

Explains how to ventilate the hydraulic oil tank.

Coolant Antifreeze Content Check

Guides on checking the antifreeze content of the coolant.

Cooling System Checks

Notes that cooling system checks require an authorized garage.

Fuel Pump Checks

Notes that fuel pump checks require an authorized garage.

Fuel/Coolant Tube Checks

Notes that tube checks/replacements require an authorized garage.

Water Pump Checks

Notes that water pump checks require an authorized garage.

Fuel Injection Timing Check

Notes that fuel injection checks require an authorized garage.

Technical Data

Machine Specifications

Provides detailed technical specifications for the machine's engine and driving systems.

Noise Emission Levels

Details the machine's noise emission levels as per EC directive.

Vibration Level Information

Provides information on vibration levels transmitted to the operator.

Limit Values for Slopes

Outlines the maximum permissible slope angles for safe operation.

Special Equipment and Attachments

ALS-Electronics System

Introduces the ALS-Electronics system and its functioning principle.

ALS-Electronics Structure and Function

Explains how the ALS-Electronics system absorbs vibrations for a smoother ride.

ALS-Electronics Switching Precautions

Warns about potential movement of attachments when ALS system is active.

ALS-Electronics Operation

Details the preconditions and steps for switching on the ALS-Electronics.

Pressure Accumulator Handling Safety

Provides crucial safety warnings for handling the pressure accumulator.

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