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Operation & Maintenance
Manual
WA75
WA85
WHEEL LOADER
SERIAL NUMBERS
This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in
accordance with written authorization from Komatsu America Corp.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make
changes or improvements at any time without incurring any obligation to install such changes on products sold
previously.
Due to this continuous program of research and development, revisions may be made to this publication. It is
recommended that customers contact their distributor for information on the latest revision.
December 2004
-3
WA75-3 HA950857 – HA951433
WA75-3 H21408
WA85-3 HA960166 – HA960218
WA85-3 H20219
Copyright 2005 Komatsu
Printed in U.S.A.
Komatsu America Corp.
-3
and up
and up
VEAM950600
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Table of Contents
Related Manuals for Komatsu WA85-3
Summarization of Contents
Operation & Maintenance Manual
Machine Identification and Serial Numbers
Details for identifying the machine model and its serial number range.
Safety Information
Signal Word Definitions
Explanation of signal words like Danger, Warning, Caution, Important, and Note.
Introduction to the Machine
Machine Features
Overview of the machine's key features and benefits.
Breaking In a New Machine
Guidelines for the initial 100 hours of machine operation.
Location of Plates and Serial Number Entry
Machine and Engine Serial Number Plate Positions
Details on the location of machine and engine serial number plates.
Serial Number and Distributor Entry Table
Table for recording machine serial number and distributor information.
Emission Control Warranty
Warranty Coverage and Limitations
Details on emission warranty coverage, terms, and limitations.
Importance of Operating Instructions
Owner Responsibilities for Safe Operation
Key responsibilities of the machine owner for safe operation.
Safety Regulations and Correct Use
Notes on Safety Regulations
Adherence to safety regulations for machine use.
Safety Notes in Operating Instructions
Importance of following safety notes in operating instructions.
Loading and Transporting the Machine
Securing Articulated Steering
Procedure to secure the articulated steering before lifting or repair.
Lifting the Machine Safely
Precautions and steps for safely lifting the machine.
Safety
Safety Instructions
General safety instructions for operation and maintenance.
Safety Devices
Importance and use of safety devices.
General Safety Measures
Safety Instructions
Adherence to instructions, measures, and safety guidelines.
Safety Devices
Checking and ensuring correct installation of safety devices.
Emergency Exit
Identifying the emergency exit route from the driver's cab.
Safety Measures During Operation
Workplace Safety Precautions
Ensuring safety in the working area before starting operation.
Driver's Cab Safety
Maintaining safety within the driver's cab.
Machine Operation Procedures
Before Starting the Engine
Pre-start checks and procedures before operating the engine.
Reversing Safety
Safety rules to observe when reversing the machine.
Driving Operations
Driving on Slopes Safely
Guidelines for safe driving on slopes, embankments, and hill flanks.
Loading Operations
Removing Piled Up Soil
Procedure for removing piled up soil safely.
Working with Forklift Truck Attachment
Picking Up the Load Safely
Procedure for safely picking up loads with forklift attachment.
Transport Procedures
Loading and Unloading the Machine
Safe procedures for loading and unloading the machine.
Safety Measures During Maintenance
Personnel Qualifications
Requirement for trained and qualified personnel for maintenance.
Pre-Maintenance Procedures
Steps to take before starting maintenance operations.
Tools and Safety-Related Parts
Using correct tools and replacing safety-related parts.
Prior to Start of Inspection and Maintenance
Securing Articulated Steering
Securing the articulated steering before maintenance.
During Maintenance Operations
Safe Storage of Attachments
Ensuring safe storage of removed attachments.
Working Under the Machine Safely
Precautions for performing maintenance under the machine.
Keeping the Machine Clean
Importance of maintaining machine cleanliness.
Specific Safety Measures
Safety measures for specific tasks like grinding or welding.
Tires Safety and Maintenance
Tire Components
Identification of tire components.
Checking the Tires for Damage
Inspection of tires for damage, wear, and fissures.
Checking Tire Pressure
Importance and procedure for checking tire pressure.
Labeling Information
Position of Safety Labels
Diagram showing the location of safety labels on the machine.
Machine Controls and Indicators
Main Control Levers and Pedals
Identification of primary control levers and pedals.
Switches and Indicator Layout
Overview of switches, control lamps, warning lights, and indicators.
Instrument Panel Components
Detailed breakdown of instrument panel elements.
Warning Lights
Brake Fluid Warning Light
Function and troubleshooting for the brake fluid warning light.
Air Filter Warning Light
Function and troubleshooting for the air filter warning light.
Parking Brake Warning Light
Function and troubleshooting for the parking brake warning light.
Charging Current Warning Light
Function and troubleshooting for the charging current warning light.
Control Lamps Explained
Driving Direction Switch Indicators
Indicators for selected driving direction (forward/backward).
Direction Indicator Control Lamp
Function of the direction indicator control lamp.
Air Preheater Control Lamp
Function of the air preheater control lamp.
Heated Rear Windscreen Indicator
Indicator for the heated rear windscreen.
Measuring Indicators
Fuel Level Indicator
Operation and display of the fuel level indicator.
Operating Hour Meter
Function and display of the operating hour meter.
Coolant Temperature Indicator
Function and display of the coolant temperature indicator.
Switches and Controls Overview
Primary Operation Switches
Hazard flashers, wipers, washer, indicators, lights, driving direction, start switch.
Climate Control Switches
Fan, temperature, rear windscreen, and A/C switches.
Special Function Switches
Driving range, working lights, battery, high-speed gear, ALS, beacon switches.
Control Levers and Pedals
Brake and Accelerator Pedals
Operation and function of brake and accelerator pedals.
Parking Brake and Safety Lever
Operation of parking brake and safety lever for hydraulics.
Steering Column and Armrest Adjustment
Adjusting steering column position and armrest height.
Machine Operation
Running In the Machine
Procedures for running in the machine during the first 100 hours.
Preparing Machine for Start
Pre-start checks and preparations before operating the machine.
Adjustments Prior to Machine Start
Adjusting the driver's seat for optimal comfort and safety.
Adjusting Heating and Ventilation
Adjusting the cabin's heating and ventilation system.
Operating the Air Conditioning
Steps for switching on and operating the air conditioning system.
Putting On and Taking Off Safety Belt
Instructions for using the safety belt correctly.
Starting and Switching Off the Engine
Procedures for starting, warming up, and switching off the engine.
Driving Operations
Start-up procedures and general driving guidelines.
Changing Driving Direction
Safe procedures for changing the machine's driving direction.
Turning and Slope Operation
Safe practices for turning and operating on slopes.
Braking Procedures
Using service and parking brakes, and braking on slopes.
Stopping and Parking Safely
Procedures for stopping the machine and parking on slopes.
Longer-Distance Driving
Guidelines for driving the machine over long distances.
Preparing Work Equipment
Steps for selecting and attaching work equipment.
Removing and Attaching Work Units
Procedures for removing and attaching work units like buckets.
Tire Service Life Considerations
Tips to maximize tire service life and avoid wear.
Adjusting the Bucket Positioner
Procedure for adjusting the bucket positioner settings.
Loading Operations
Safe procedures for loading materials.
Excavation Works
Techniques for performing excavation tasks safely.
Transporting and Dumping/Unloading
Procedures for transporting and dumping materials safely.
V-Shaped Loading
Method for V-shaped loading of material.
Piling Up Material
Techniques for piling up material efficiently.
Planing and Ground Leveling
Procedures for planing and leveling the ground.
Cutting the Ground
Technique for cutting the ground surface layer.
Working with Forklift Truck Attachment
Safe operation guidelines for forklift truck attachment.
Precautions for Special Operations
Safety guidelines for specific operating conditions.
After the Work is Finished
Post-operation checks and cleaning procedures.
Winter Operation Instructions
Preparations and procedures for winter operation.
Longer Standstill Periods of the Machine
Procedures for machine storage and maintenance during standstill.
Troubleshooting Guide
Warning Lights and Indicators
Troubleshooting for warning lights and indicators.
Electrical System Faults
Troubleshooting common issues in the electrical system.
Engine Troubleshooting
Diagnosing and resolving engine-related problems.
Hydraulic System Troubleshooting
Diagnosing and resolving hydraulic system issues.
Brakes and Steering Troubleshooting
Diagnosing and resolving brake and steering system issues.
Axles and Driver's Cab Faults
Troubleshooting issues related to axles and the driver's cab.
Emergency Steering and Lowering Systems
Troubleshooting emergency steering and lowering systems.
Starting Engine with Jumper Cables
Procedure for starting the engine using jumper cables.
Towing the Machine
Safe procedures and precautions for towing the machine.
Inadequate Braking Effect
Troubleshooting for inadequate braking performance.
Maintenance Procedures
Maintenance Basics
General principles and preparations for maintenance.
Cleaning the Machine
Procedures and precautions for cleaning the machine.
Working-Area-Dependent Maintenance
Maintenance adjustments based on working environment.
Lubricants and Operating Agents
Information on oils, greases, fuels, and coolants.
Tires Safety and Maintenance
Inspection and maintenance of tires and pressure.
Torque for Standard Nuts and Bolts
Torque specifications for standard nuts and bolts.
Maintenance Schedule
Overview of maintenance intervals and tasks.
Cooling System Coolant Level Check
Procedure for checking and topping off coolant.
Engine Oil Level Check and Topping Off
Procedure for checking and topping off engine oil.
Engine Oil Draining
Procedure for draining excess engine oil.
Fuel Level Check and Refueling
Procedure for checking fuel level and refueling.
Checking Controls and Electrical Connections
Pre-start checks of machine controls and electrical connections.
Heater/Air Conditioning Air Flow Check
Checking the air flow rate of the heater/A/C system.
Other Pre-Start Maintenance Measures
Additional checks required before starting maintenance.
Maintenance Upon Demand
Maintenance tasks performed as needed.
Maintenance Every 10 Operating Hours
Lubrication tasks required every 10 operating hours.
Maintenance After First 50 Operating Hours
Maintenance tasks after the first 50 operating hours.
V-Belt Checks and Adjustments
Checking V-belt condition and adjusting belt tension.
Hydraulic System Filter Replacement
Procedure for replacing the hydraulic system filter insert.
Wheel Nuts Check and Tightening
Procedure for checking and tightening wheel nuts.
Front and Rear Axle Oil Change
Procedure for changing oil in front and rear axles.
Transfer Gear Oil Change
Procedure for changing oil in the transfer gear.
Air Filter Replacement and Cleaning
Procedures for replacing and cleaning air filter components.
Lubrication Points of Work Equipment
Identification of lubrication points on the work equipment.
Fuel Filter Replacement
Procedure for changing the fuel filter element.
Hydraulic System Filter Cartridge Change
Procedure for changing the hydraulic system filter cartridge.
Water Separator Cleaning
Procedure for cleaning the water separator.
Transfer Gear Oil Level Check
Procedure for checking and refilling transfer gear oil.
Heater Unit Filter Fleece Cleaning
Procedure for cleaning the filter fleece of the heater unit.
Air Conditioning Condenser Cleaning
Procedure for cleaning the air conditioning condenser.
Cooling System Coolant Exchange
Procedure for exchanging and cleaning the cooling system.
Service Brake Maintenance
Brake system checks, oil changes, and adjustments.
Injection Nozzle Checks
Checking injection nozzles, pressure, and fuel-jet pattern.
Accumulator Gas Pressure Check
Procedure for checking accumulator gas pressure.
Hydraulic System Oil Change
Procedure for changing hydraulic system oil.
Hydraulic Oil Tank Bleeding
Procedure for bleeding the hydraulic oil tank.
Cooling and Fuel System Checks
Checks for antifreeze content, fuel pump, and tubes.
Technical Data
Machine Specifications
Key specifications including engine, speed, and tractive force.
Noise Emission Levels
Information on sound pressure and power levels.
Vibration Level Data
Data on vibration levels transmitted to the operator's seat.
Maximum Slope Angle Limits
Limit values for operating the machine on slopes.
Special Equipment and Attachments
ALS-Electronics System
Structure, function, and precautions for ALS-Electronics.
ALS-Electronics Operation
Steps for switching the ALS-Electronics system on and off.
Handling of the Pressure Accumulator
Safety precautions for handling the pressure accumulator.
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