Komatsu Wheel Loader WA65 (Parallel Lift), WA75, WA85, WA90, WA95 Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Wheel Loader WA65-3, WA65-3 Parallel Lift, WA75-3, WA85-3, WA90-3, WA95-3, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Komatsu Wheel Loader WA65-3, WA65-3 Parallel Lift, WA75-3, WA85-3, WA90-3, WA95-3 workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
VEBM950201 - Wheel Loader WA65-3, WA65-3 Parallel Lift, WA75-3, WA85-3, WA90-3, WA95-3 Shop Manual.pdf
VEAM250200 - Wheel Loader WA65-5 Operation & Maintenance Manual.pdf
VEAM940200 - Wheel Loader WA65-3 Operation & Maintenance Manual.pdf
VEAM940400 - Wheel Loader WA65-3 Operation & Maintenance Manual.pdf
VEAM940600 - Wheel Loader WA65-3 Operation & Maintenance Manual.pdf
VEAM950200 - Wheel Loader WA75-3 Operation & Maintenance Manual.pdf
VEAM950400 - Wheel Loader WA75-3 Operation & Maintenance Manual.pdf
VEAM950600 - Wheel Loader WA75-3, WA85-3 Operation & Maintenance Manual.pdf
VEAM960200 - Wheel Loader WA85-3 Operation & Maintenance Manual.pdf
VEAM960400 - Wheel Loader WA85-3 Operation & Maintenance Manual.pdf
VEAM960600 - Wheel Loader WA85-3 Operation & Maintenance Manual.pdf
VEAM980200 - Wheel Loader WA95-3 Operation & Maintenance Manual.pdf
VEAM980400 - Wheel Loader WA95-3 Operation & Maintenance Manual.pdf
VEAM980500 - Wheel Loader WA95-3 Operation & Maintenance Manual.pdf
VEAM980600 - Wheel Loader WA95-3 Operation & Maintenance Manual.pdf
VEAM980800 - Wheel Loader WA95-3 Operation & Maintenance Manual.pdf
PRODUCT DETAILS:
Total Pages: 3,611 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
VEAM250200 - Wheel Loader WA65-5 Operation & Maintenance Manual....3
Cover....3
1. Introduction....4
1.1. Product publications information....5
1.2. Foreword....7
EU Directives....8
1.3. Safety information....10
1.4. Introduction....12
1.4.1. Intended use....12
1.4.2. Breaking-in the machine....13
1.5. Location of plates....14
1.5.1. Machine identification plate (PIN)....14
1.5.2. Engine name-plate....14
1.5.3. Axle serial no. plate....15
1.5.4. Transmission serial no. plate....15
1.5.5. ROPS/FOPS-Cab serial no. plate....15
1.5.6. Seat operator serial no. plate....16
1.5.7. Table to enter serial no. and distributor....16
1.6. Emission control warranty....17
1.6.1. Emission control warranty statement (Applies to Canada only)....17
1.7. Garantie sur le contrôle des émissions....18
1.7.1. Énoncé de garantie sur le contrôle des émissions ( applicable au Canada seulement)....18
1.8. Table of contents....19
1.9. Dimensions, weights and operating data....26
1.10. CE-conforming equipment....27
1.10.1. CE-conforming equipment – part 1....27
1.10.2. CE-conforming equipment – part 2....27
1.10.3. Manufacturer-supplied CE-conforming equipment, according to document 42T 93 21080....28
1.11. Loading and securing....31
Table of contents....19
2. Safety....34
2.1. General safety measures....35
2.1.1. Safety instructions....35
2.1.2. Safety devices....35
2.1.3. Emergency exit....35
2.1.4. Clothing and personal protection....36
2.1.5. Machine modifications....36
2.1.6. Before you leave the driver’s seat....36
2.1.7. Mounting and dismounting....37
2.1.8. Fire prevention and fire fighting....37
2.1.9. Protection against asbestos dust....38
2.1.10. Protection against injuries....38
2.1.11. Working at high temperatures....39
2.1.12. Roll-over protection system (ROPS)....39
2.1.13. Attachment for protection against falling objects (FOPS)....39
2.1.14. Attachments....40
2.1.15. Battery....40
2.2. Safety precautions during operation....41
2.2.1. Prior to daily starting up....41
Workplace safety....41
In the driver's cab....41
Indoor operation....42
Gas, dust, and inflammable vapours....42
Mirrors, windows and lighting....42
2.2.2. Machine operation....43
Before you start the engine....43
Reversing....43
Driving....44
Driving on slopes....44
Emergency Lowering System....45
Working close to power lines....46
Loading....47
Good Vision....47
Working on snow....47
Height limitation....48
Brakes....48
Working on loose soil....48
Working with the forklift truck attachment....48
Parking the machine....50
2.2.3. Transport....51
Loading and unloading the machine....51
Transport....51
2.3. Precautions for maintenance....52
2.3.1. Personnel....52
2.3.2. Before carrying out maintenance ....52
2.3.3. During maintenance....59
2.3.4. Tires....63
2.4. Safety labels on the machine....65
2.4.1. Positions and order numbers of information labels....65
2.4.2. Positions and order numbers of safety labels....66
3. Operation....68
3.1. General view....69
3.1.1. General view of the machine....69
3.1.2. Controls and indicators....70
Overall view....70
Switches, controls and warning lights....71
3.2. Description of the individual elements....72
3.2.1. Instrument panel....72
Warning lights....73
Control lamps....75
Measuring indicators....79
3.2.2. Switches....81
3.2.3. Control levers and pedals....88
3.2.4. Articulated steering catch....93
3.2.5. Traction device....93
3.2.6. Socket (12 V)....94
3.2.7. Door unlocking system....94
3.2.8. Alarm horn for reverse driving – option....94
3.2.9. Fuses....95
3.2.10. Slow-blowing fuses....96
3.2.11. Adjusting the heater and ventilation system....97
3.2.12. Air-conditioning....98
3.3. Operation....99
3.3.1. Pre-start checks....99
Visual inspection....99
Pre-start checks....101
Adjustments prior to machine start....106
Adjusting the driver’s seat....106
3.3.2. Starting the engine....110
Warming up the engine....111
3.3.3. Driving with the machine....112
Start-up....112
3.3.4. Changing the driving direction....114
3.3.5. Turning and steering....115
3.3.6. Braking....116
3.3.7. Stopping the machine....118
3.3.8. Operating the work equipment....119
Multifunctional lever....119
Control lever for special equipment....120
Switching lever of bucket....121
3.3.9. Working with the wheeled loader....122
Tire-appropriate operation....122
Switching on the 100 % differential lock (if equipped)....122
Loading work....123
Removal work....123
Excavation work....125
Planing....126
Transporting....127
Unloading....127
Working with the forklift truck attachment....128
3.3.10. Precautions for special operations....130
Permissible water depth....130
Working on snow....130
Dumping on steep slopes....130
Working in the vicinity of electrical overhead lines....130
Operation on slopes....130
Working on loose soil....130
If the service brake breaks down....130
Precautionary measures when driving up or down....131
Precautionary measures during machine travel....132
3.3.11. Adjusting the position of the work equipment....133
Selecting a work unit....133
Removing the work unit....135
Picking up the multi-purpose bucket....136
Removing the multi-purpose bucket....138
Level indicator for the bucket....138
3.3.12. Parking the machine....139
3.3.13. Switching off the engine....140
3.3.14. Check after stopping the engine....140
3.3.15. Locking....140
3.3.16. Tire handling....141
Precautionary measures when handling tires....141
Tire pressure....141
3.4. Transporting the machine....143
3.4.1. Securing the articulated steering....143
3.4.2. Lifting the machine....144
3.4.3. Driving the machine onto loading area of transport vehicle....145
3.4.4. Securing the machine during the transport....146
3.4.5. After transport....146
3.5. Cold weather operation....147
3.5.1. Before the cold season....147
3.5.2. Precautions after completion of work....148
3.5.3. After the cold season....148
3.6. Long-term storage....149
3.6.1. Before storage....149
3.6.2. During storage....149
3.6.3. After storage....150
4. Troubleshooting....152
4.1. Towing the machine....153
4.2. Starting the engine with a booster cable....157
4.3. For insufficient braking effect....159
4.3.1. Checking the service brake....159
4.3.2. Checking the parking brake function....159
4.4. Emergency steering properties....160
4.5. Emergency lowering....160
4.6. Other troubles....161
4.6.1. Electrical system....161
4.6.2. Engine....162
4.6.3. Hydraulic system....165
4.6.4. Brakes....167
4.6.5. Steering....167
4.6.6. Axles....168
4.6.7. Driver's cab....168
5. Maintenance....170
5.1. Maintenance guide....171
5.2. Maintenance basics....178
5.2.1. Oil, fuel and coolant specifications....178
Oil....178
Fuel....179
Coolant....180
Grease....180
Storing oil and fuel....181
Filters....181
Biodegradable hydraulic oil and lubricants....181
5.2.2. Specifications of the electrical system....182
5.2.3. Wearing parts list....183
5.3. Lubricants, fuels and filling capacities....184
5.3.1. Lubrication chart....185
5.4. Tools and standard tightening torques (bolts, nuts)....186
5.4.1. Introduction of recommended tools....186
5.4.2. Torque list....187
5.5. Periodical replacement of safety-critical parts....189
5.6. Maintenance schedule chart....190
5.7. Service procedure....192
5.7.1. Pre-start checklist....192
Cooling system – checking the coolant level, topping up coolant....192
Cleaning the radiator segments....193
V-Belt, checking the condition....193
Engine, checking the oil level, topping up oil....193
Checking the fuel level – refuelling....195
Water separator at the fuel filter – Draining water and dirt sediments....196
Hand pump - Checking the oil level....196
Checking the controls....197
Checking the electrical connections....197
Heater/air conditioning – checking rate of air flow....198
Miscellaneous tests before starting work....198
5.7.2. Maintenance upon demand....199
Checking the air-conditioning system....199
Checking the window washing-fluid level, adding fluid....200
Re-charging a built-in battery....201
5.7.3. Maintenance after the first 50 operating hours....202
Hydraulic system, replacing the filter insert....202
Checking and tightening the wheel nuts....203
5.7.4. Maintenance after the first 250 operating hours....204
Front and rear axle – oil change....204
Transfer box gearing – changing oil....205
Checking and adjusting the valve play....205
5.7.5. Maintenance every 10 operating hours....206
Lubrication, articulated steering....206
5.7.6. Maintenance every 50 operating hours....207
Checking the service brake and oil level, refilling oil....207
Battery – checking the acid level....208
Lubrication....209
5.7.7. Maintenance every 250 operating hours....210
V-Belt, generator – checking and adjusting the tension....210
Air filter, removing and re-installing the filter insert, checking and cleaning the filter insert....211
Lubrication, steering cylinder....214
Lubrication, self-aligning bearings of rear axle....215
5.7.8. Maintenance every 500 operating hours....216
Engine – changing oil and replacing the oil filter cartridge....216
Replacing the oil filter cartridge....217
Changing the fuel filter and filter element....218
Purging the fuel system....219
Purging the low pressure side....219
Purging the high pressure side....219
Air filter, replacing the filter insert, replacing the safety filter....220
Heater/air conditioning – cleaning/replacing filter fleece or cleaning condenser....221
E.C.S.S.-pressure accumulator (Option) - checking gas pressure....222
Front and rear axle – checking the oil level....223
Transfer box gearing – checking and changing oil....224
5.7.9. Maintenance every 1000 operating hours....225
V-Belt, generator – checking and adjusting the tension....225
Service Brake - Checking and adjusting oil....225
Checking and adjusting system pressures....225
Have the system pressures checked and adjusted at an authorized Komatsu garage...225
Hydraulics – Exchanging the venting filters....226
Hydraulic system, replacing the filter insert....227
5.7.10. Maintenance every 1500 operating hours....228
Front and rear axle – oil change....228
Transfer box gearing – checking and changing oil....229
5.7.11. Maintenance every 2000 operating hours....230
Cooling system – exchanging coolant and cleaning the system....230
Checking and adjusting the valve play....232
Hydraulic system, oil change....233
Ventilating the hydraulic oil tank....234
Checking the fuel pump....235
Checking the fuel and coolant tubes, replacing the tubes (if required)....235
Checking the water pump....235
5.7.12. Maintenance every 4000 operating hours....236
Lubrication, cardan shaft....236
6. Technical data....238
6.1. Technical data....239
6.2. Noise emission levels....240
6.3. Vibration level....240
6.4. Limit values for slopes....240
7. Special equipment and attachments....242
7.1. E.C.S.S...243
7.1.1. Structure and functioning principle of the E.C.S.S...243
7.1.2. Precautionary measures for switching on the E.C.S.S...243
7.1.3. Operating the E.C.S.S...244
Switching ON the E.C.S.S...244
Switching OFF the E.C.S.S...244
7.1.4. Precautions when handling the accumulator....245
8. Index....246
9. Notes....252
VEAM940200 - Wheel Loader WA65-3 Operation & Maintenance Manual....258
COVER....258
Table of Contents....264
Introduction....272
1. Forword....273
2. Safety Information....274
3. Introduction....275
3.1 Features....275
3.2 Breaking in a New Machine....275
4. Location of Plates, Table to Enter Serial No. and Distributor....276
4.1 Machine Serial No. Plate position....276
4.2 Engine Serial No. Plate Position....276
4.3 Table to Enter Serial No. and Distributor....276
5. Why You Should Read these Operating Instructions....277
6. Notes on Safety Regulations....278
6.1 Correct Use....278
6.2 Safety Notes in the Operating Instructions....278
7. Equipment....279
Loading and Transporting the Machine....282
8. Loading and Transporting the Machine....283
8.1 Securing the Articulated Steering....283
8.2 Lifting the Machine....283
8.3 Driving Machine Onto Loading Area of Transport Vehicle....285
8.4 Securing the Machine During Transport....286
8.5 After Transport....286
Safety....288
9. General Safety Measures....290
9.1 Safety Instructions....290
9.2 Safety Devices....290
9.3 Emergency Exit....290
9.4 Clothing and Personal Protection....291
9.5 Machine Modifications....291
9.6 Before You Leave the Driver's Seat....291
9.7 Mounting and Dismounting....291
9.8 Fire Prevention and Fire Fighting....292
9.8.1 Fire Extinguisher and First-Aid Kit....293
9.9 Protection Against Asbestos Dust....293
9.10 Protection Against Injuries....294
9.11 Working at High Temperatures....294
9.12 Roll-Over Protection System (ROPS)....295
9.13 Attachment for Protection Against Falling Objects (FOPS)....295
9.14 Attachments....295
9.15 Battery....296
10. Safety Measures during Operation....297
10.1 Before You Start the Engine....297
10.1.1 Workplace Safety....297
10.1.2 In the Driver's Cab....297
10.1.3 In-Door Operation....298
10.1.4 Gas, Dust, and Inflammable Vapours....298
10.1.5 Mirrors, Windows, and Lighting....298
10.2 Machine Operation....299
10.2.1 Before You Start the Engine....299
10.2.2 Reversing....299
10.2.3 Driving....300
10.2.4 Driving On Slopes....300
10.2.5 Emergency Lowering System....301
10.2.6 Working Close to Overhead Power Transmission Lines....301
10.2.7 Loading....302
10.2.8 Good Vision....302
10.2.9 Working On Snow....302
10.2.10 Height Limitation....302
10.2.11 Brakes....303
10.2.12 Working On Loose Soil....303
10.2.13 Working with the Forklift Truck Attachment....304
10.2.14 Parking the Machine....305
10.3 Transport....306
10.3.1 Loading and Unloading the Machine....306
10.3.2 Transport....306
11. Safety Measures During Maintenance....307
11.1 Personnel....307
11.2 Prior to Start of Maintenance Measures....307
11.2.1 Warning Sign....307
11.2.2 Tools....307
11.2.3 Safety-Related Parts....307
11.2.4 Prior to Start of Inspection and Maintenance....308
11.2.5 Securing the Articulated Steering....308
11.2.6 Supporting the Work Unit....308
11.3 During Maintenance....309
11.3.1 Attachments....309
11.3.2 Working Under the Machine....309
11.3.3 Keeping the Machine Clean....309
11.3.4 Specific Measures....309
11.3.5 Refueling and Topping Off Oil....310
11.3.6 Coolant....310
11.3.7 Use of Lighting....311
11.3.8 High-Pressure Hoses....311
11.3.9 Handling High-Pressure Oil....311
11.3.10 Fan and Belts....312
11.3.11 Waste Material....312
11.4 Tires....313
11.4.1 Storing Tires....313
12. Labeling....314
12.1 Position of Safety Labels....314
12.2 Position of Standard Labels....316
Controls and Indicators....318
13. General View of the Machine....319
14. Controls and Indicators....320
14.1 General View....320
14.1.1 Switches and Controls....321
14.2 Instrument Panel....322
14.3 Warning Lights....323
14.4 Control Lamps....326
14.5 Measuring Indicators....329
14.6 Switches....331
14.7 Control Levers, Pedals....337
14.8 Articulated Steering Catch....342
14.9 Traction Device....342
14.10 Socket....342
14.11 Door Unlocking System....343
14.12 Alarm Horn for Reverse Driving....343
Operation....344
15. Running in the Machine....345
16. Preparing the Machine Start....346
16.1 Visual Checks....346
16.1.1 Before you start the engine....346
16.1.2 Before starting working with the machine....346
17. Adjustments Prior to Machine Start....348
17.1 Adjusting the Driver’s Seat....348
17.2 Adjusting the Steering Column....349
17.3 Adjusting the Armrest....349
17.4 Adjusting the Rear-View Mirrors....349
17.5 Adjusting the Heating and Ventilation System....350
17.5.1 Adjusting the ventilation system....350
17.5.2 Adjusting the heating system....350
17.6 Putting on the Safety Belt....351
17.6.1 Putting on the safety belt....351
17.6.2 Taking off the safety belt....351
18. Starting and Switching Off the Engine....352
18.1 Starting the Engine....352
18.1.1 Warming up the engine....353
18.2 Switching Off the Engine....354
19. Driving....355
19.1 Start-Up....355
19.1.1 Starting the machine on slopes....356
19.2 Changing the Driving Direction....356
19.3 Reverse Driving....357
19.4 Turning....357
19.4.1 Turning on slopes, embankments or hill flanks....357
19.5 Braking....358
19.5.1 Pulling the parking brake....358
19.5.2 Releasing the parking brake....358
19.5.3 Braking with the service brake....358
19.5.4 If the service brake breaks down....358
19.5.5 Braking on slopes....359
19.6 Stopping....359
19.6.1 Parking the machine on a slope....359
19.7 Longer-Distance Driving....360
20. Operating the Machine....361
20.1 Preparing the Work Equipment....361
20.1.1 Selecting a work unit....361
20.1.2 Picking up the work unit (except multi-purpose bucket)....361
20.1.3 Removing the work unit....362
20.1.4 Picking up the multi-purpose bucket....362
20.1.5 Removing the multi-purpose bucket....364
20.2 Tire Service Life....365
20.2.1 Level indicator for the bucket....365
20.3 Loading....366
20.3.1 Removing piled up soil....366
20.3.2 Excavation works....368
20.4 Transporting....369
20.5 Dumping / Unloading....369
20.5.1 Loading in diagonal direction....369
20.5.2 V-shaped loading....370
20.5.3 Piling up material....370
20.6 Planing....371
20.6.1 Filling up....371
20.6.2 Taking off soil....371
20.6.3 Cutting the Ground....371
20.7 Working With the Forklift Truck Attachment....372
20.7.1 Picking up the load....372
20.8 Precautions For Special Operations....373
20.8.1 Working in water....373
20.8.2 Working on snow....373
20.8.3 Dumping on steep slopes....373
20.8.4 Working in the vicinity of electrical overhead lines....373
20.8.5 Operation on slopes....373
20.8.6 Working on loose soil....373
20.9 After the work is finished....373
20.10 Instructions for Winter Operation....374
20.10.1 Before the cold season....374
20.10.2 After Operation....374
20.10.3 After the cold season....374
20.11 Longer Standstill Periods of the Machine....374
20.11.1 Before the standstill....374
20.11.2 During the standstill....375
20.11.3 After the standstill....375
Troubleshooting....376
21. Troubleshooting....377
21.1 Warning Lights and Indicators....377
21.2 Electrical System....378
21.3 Engine....379
21.4 Hydraulic system....382
21.5 Brakes....384
21.6 Axles....385
21.7 Emergency Steering Characteristics....386
21.8 Emergency Lowering System....386
21.9 Starting the Engine with a Battery Jumper Cable....387
21.9.1 Connecting the Jumper Cable....387
21.10 Starting the Engine....388
21.10.1 Disconnecting the Battery Jumper Cable....388
21.11 Towing the Machine....389
21.12 Towing a Machine with Defective Brakes....390
Maintenance....392
22. Maintenance Basics....393
22.1 Preparing the Machine for Maintenance....393
22.2 Cleaning the Machine....394
22.2.1 Precautionary Measures When Cleaning the Machine....394
22.2.2 Fire Prevention....394
22.3 Working-Area-Dependent Maintenance....394
22.3.1 Muddy or Wet Working Areas....394
22.3.2 Dusty Working Areas....394
22.4 Lubricants and Operating Agents....395
22.4.1 Draining Hot Lubricants and Fluids....395
22.4.2 Checking the Oil Level and Changing Oil....395
22.4.3 Changing Filters....395
22.4.4 Refuelling and Topping off Oil....395
22.4.5 Oil....395
22.4.6 Lubricating Grease....396
22.4.7 Biodegradable Hydraulic Oil and Lubricating Grease....396
22.4.8 Fuel....396
22.4.9 Storage of Oil and Fuel....396
22.4.10 Coolants....397
22.4.11 Windscreen Washer Liquid....397
22.4.12 Table of Lubricants and Operating Agents....399
22.4.13 Lubrication chart....400
22.5 Replacing Safety-Related Parts....401
22.5.1 Welding Instructions....401
22.6 Spare Parts and Consumable Components....402
22.7 Electrical System....403
22.7.1 Fuses....403
22.7.2 Fuse Assignment....403
22.7.3 Slow-Blowing Fuses....404
22.8 Tires....405
22.8.1 Tire Components....405
22.8.2 Checking the Tires....405
22.8.3 Checking the Tire Pressure....405
22.9 Tools....407
22.10 Torque for Standard Nuts and Bolts....408
23. Maintenance Schedule....410
24. Maintenance Prior to Start....412
24.1 Visual Checks....412
24.2 Cooling System, Checking the Coolant Level, Topping off Coolant....412
24.3 Engine, Checking the Oil Level, Topping off Oil....413
24.4 Engine, Draining Off Oil....414
24.5 Checking the Fuel Level, Refueling....415
24.6 Checking the Controls....416
24.7 Checking the Parking Brake....417
24.7.1 Test Conditions....417
24.7.2 Test Procedure....417
24.8 Checking the Service Brake....417
24.9 Checking the Electrical Connections....418
24.10 Other Maintenance Measures Prior to Start....418
25. Maintenance Every 10 Operating Hours....419
25.1 Lubrication....419
26. Maintenance After the First 50 Operating Hours....420
26.1 Engine, Changing Oil and Replacing the Oil Filter Cartridge....420
26.1.1 Replacing the Oil Filter Cartridge....421
26.2 V-Belt, Checking the Condition....422
26.3 V-Belt, Checking and Adjusting the Tension....422
26.4 Hydraulic System, Replacing the Filter Insert....423
26.5 Checking and Tightening the Wheel Nuts....424
26.6 Front and Rear Axle, Changing Oil....425
26.6.1 Planet gear....425
26.6.2 Differential....425
26.7 Transfer Gear - Changing Oil....426
27. Maintenance Every 50 Operating Hours....427
27.1 Checking the cooling system, coolant level in the radiator and expansion tank....427
27.2 Draining Off Water and Dirt Deposits From the Fuel Tank....428
27.3 Checking the Service Brake and Oil Level, Refilling Oil....428
27.4 Checking the Battery and Acid Level....429
27.4.1 Re-charging a built-in battery....430
27.5 Lubrication....431
27.5.1 Lubricating points of the work equipment....431
28. Maintenance Every 100 Operating Hours....432
28.1 Draining the Water Separator, Removing Water and Dirt Deposits....432
29. Maintenance Every 250 Operating Hours....433
29.1 Changing the Engine Oil and Oil Filter Cartridge....433
29.2 Checking the V-Belt Condition....433
29.3 Checking and Adjusting the V-belt Tension....433
29.4 Lubrication....433
29.4.1 Lubricating points of the steering cylinder....433
29.5 Front and Rear Axle, Checking the Oil Level....434
29.5.1 Planet gear....434
29.5.2 Differential....434
29.6 Air Filter, Removing and Re-Installing the Filter Insert, Checking and Cleaning the Filter I...435
29.6.1 Structure of the air filter....435
29.6.2 Maintenance demand....435
29.6.3 Removing the filter cartridge....435
29.6.4 Cleaning or exchanging the filter cartridge....436
29.6.5 Checking the filter cartridge....437
29.6.6 Assembling the air filter cartridge....437
29.7 Cleaning the Radiator Segments....437
30. Maintenance Every 500 Operating Hours....438
30.1 Changing the Fuel Filter and Filter Element....438
30.1.1 Bleeding the Fuel System....439
30.2 Changing the Filter Cartridge of the Hydraulic System....440
30.3 Cleaning the Water Separator....440
30.4 Lubrication....441
30.5 Transfer Gear, Checking the Oil Level and Refilling Oil....441
30.6 Air Filter, Replacing the Filter Insert, Replacing the Safety Filter....442
30.6.1 Replacing the Filter Insert....442
30.6.2 Replacing the Safety Filter....442
31. Maintenance Every 1000 Operating Hours....443
31.1 Cooling System, Exchanging Coolant and Cleaning the System....443
31.1.1 Draining off the coolant....443
31.1.2 Cleaning the Cooling System....444
31.1.3 Filling off Coolant....444
31.2 Front Axle, Oil Change....445
31.3 Rear Axle, Oil Change....445
31.4 Transfer Gear, Oil Change....445
31.5 Service Brake....445
31.5.1 Changing oil....445
31.5.2 Checking tubes and lines....445
31.5.3 Checking the brake disks for wear and tear....445
31.5.4 Adjusting the clearance of the brake disks....445
31.6 Checking and Adjusting System Pressures....445
31.7 Checking and Adjusting the Valve clearance....445
31.8 Checking and Adjusting the Injection Nozzles, Nozzle Pressure and Fuel-Jet Pattern....445
32. Maintenance Every 2000 Operating Hours....446
32.1 Hydraulic System, Oil Change....446
32.2 Bleeding the Hydraulic Oil Tank....447
32.3 Cooling System, Checking the Antifreeze Content of the Coolant....447
32.4 Checking the Cooling System....447
32.5 Checking the Fuel Pump....447
32.6 Checking the Fuel and Coolant Tubes, Replacing the Tubes (if required)....447
32.7 Checking the Water Pump....448
32.8 Checking and Adjusting the Fuel Injection and Injection time....448
32.9 Engine, Intake Valves and Outlet Valves - Grinding In the Valve Bases....448
Technical Data....450
33. Technical Data....451
33.1 Noise Emission Levels....452
33.2 Vibration Level....452
33.3 Limit Values for Slopes....453
33.3.1 Maximum slope angle for operating the machine....453
33.3.2 Tilting/tipping angle....453
VEAM940400 - Wheel Loader WA65-3 Operation & Maintenance Manual....456
Cover....456
Product Publications Information....458
Table of Contents....460
Introduction....468
Forword....469
Safety Information....470
Introduction....471
Features....471
Breaking in a New Machine....471
Location of Plates, Table to Enter Serial No. and Distributor....472
Machine Serial No. Plate position....472
Engine Serial No. Plate Position....472
Table to Enter Serial No. and Distributor....472
EMISSION CONTROL WARRANTY....473
EMISSION CONTROL WARRANTY STATEMENT (APPLIES TO CANADA ONLY)....473
Engine Data Plate....474
GARANTIE SUR LE CONTRÔLE DES ÉMISSIONS....475
ÉNONCÉ DE GARANTIE SUR LE CONTRÔLE DES ÉMISSIONS (APPLICABLE AU CANADA SEULEMENT):....475
Engine Data Plate....476
Why You Should Read these Operating Instructions....477
Notes on Safety Regulations....478
Correct Use....478
Safety Notes in the Operating Instructions....478
Equipment....479
Loading and Transporting the Machine....482
Loading and Transporting the Machine....484
Securing the Articulated Steering....484
Lifting the Machine....484
Driving Machine Onto Loading Area of Transport Vehicle....486
Securing the Machine During Transport....487
After Transport....487
Safety....488
General Safety Measures....490
Safety Instructions....490
Safety Devices....490
Emergency Exit....490
Clothing and Personal Protection....491
Machine Modifications....491
Before You Leave the Driver's Seat....491
Mounting and Dismounting....491
Fire Prevention and Fire Fighting....492
Fire Extinguisher and First-Aid Kit....493
Protection Against Asbestos Dust....493
Protection Against Injuries....494
Working at High Temperatures....494
Roll-Over Protection System (ROPS)....495
Attachment for Protection Against Falling Objects (FOPS)....495
Attachments....495
Battery....496
Safety Measures during Operation....497
Before You Start the Engine....497
Workplace Safety....497
In the Driver's Cab....497
In-Door Operation....498
Gas, Dust, and Inflammable Vapours....498
Mirrors, Windows, and Lighting....498
Machine Operation....499
Before You Start the Engine....499
Reversing....499
Driving....500
Driving On Slopes....500
Emergency Lowering System....501
Working Close to Overhead Power Transmission Lines....501
Loading....502
Good Vision....502
Working On Snow....502
Height Limitation....502
Brakes....503
Working On Loose Soil....503
Working with the Forklift Truck Attachment....504
Parking the Machine....505
Transport....506
Loading and Unloading the Machine....506
Transport....506
Safety Measures During Maintenance....507
Personnel....507
Prior to Start of Maintenance Measures....507
Warning Sign....507
Tools....507
Safety-Related Parts....507
Prior to Start of Inspection and Maintenance....508
Securing the Articulated Steering....508
Supporting the boom....509
During Maintenance....510
Attachments....510
Working Under the Machine....510
Keeping the Machine Clean....510
Specific Measures....510
Refueling and Topping Off Oil....511
Coolant....511
Use of Lighting....512
High-Pressure Hoses....512
Handling High-Pressure Oil....512
Handling of the pressure accumulator....513
Fan and Belts....513
Waste Material....513
Tires....514
Storing Tires....514
Labeling....515
Position of Safety Labels....515
Information Labels....517
Controls and InDicators....518
Overall View of Machine....519
Controls and Indicators....520
SWITCHES AND CONTROLS....521
Instrument Panel....522
Warning Lights....523
Control Lamps....526
Measuring Indicators....529
Switches....531
Control Levers, Pedals....537
Articulated Steering Catch....542
Traction Device....542
Socket....542
Door Unlocking System....543
Alarm Horn for Reverse Driving....543
Operation....544
Running in the Machine....545
Preparing the Machine Start....546
Visual Checks....546
Before you start the engine....546
Before starting working with the machine....546
Adjustments Prior to Machine Start....548
Adjusting the Driver’s Seat....548
Adjusting the Steering Column....549
Adjusting the Armrest....549
Adjusting the Rear-View Mirrors....549
Adjusting the Heating and Ventilation System....550
Adjusting the ventilation system....550
Adjusting the heating system....550
Putting on the Safety Belt....551
Putting on the safety belt....551
Taking off the safety belt....551
Starting and Switching Off the Engine....552
Starting the Engine....552
Warming up the engine....553
Switching Off the Engine....554
Driving....555
Start-Up....555
Starting the machine on slopes....556
Changing the Driving Direction....556
Reverse Driving....557
Turning....557
Turning on slopes, embankments or hill flanks....557
Braking....558
Pulling the parking brake....558
Releasing the parking brake....558
Braking with the service brake....558
If the service brake breaks down....558
Braking on slopes....559
Stopping....559
Parking the machine on a slope....559
Longer-Distance Driving....560
Operating the Machine....561
Preparing the Work Equipment....561
Selecting a work unit....561
Picking up the work unit (except multi- purpose bucket)....561
Removing the work unit....562
Picking up the multi-purpose bucket....562
Removing the multi-purpose bucket....564
Tire Service Life....565
Level indicator for the bucket....565
Loading....566
Removing piled up soil....566
Excavation works....568
Transporting....569
Dumping / Unloading....569
Loading in diagonal direction....569
V-shaped loading....570
Piling up material....570
Planing....571
Filling up....571
Taking off soil....571
Cutting the Ground....571
Working With the Forklift Truck Attachment....572
Picking up the load....572
Precautions For Special Operations....573
Working in water....573
Working on snow....573
Dumping on steep slopes....573
Working in the vicinity of electrical overhead lines....573
Operation on slopes....573
Working on loose soil....573
After the work is finished....573
Instructions for Winter Operation....574
Before the cold season....574
After Operation....574
After the cold season....574
Longer Standstill Periods of the Machine....574
Before the standstill....574
During the standstill....575
After the standstill....575
Troubleshooting....576
Troubleshooting....577
Warning Lights and Indicators....577
Electrical System....578
Engine....579
Hydraulic system....582
Brakes....584
Axles....585
driver’s cab....585
Emergency Steering Characteristics....586
Emergency Lowering System....586
Starting the Engine with a Battery Jumper Cable....587
Connecting the Jumper Cable....587
Starting the Engine....588
Disconnecting the Battery Jumper Cable....588
Towing the Machine....589
Towing a Machine with Defective Brakes....590
Maintenance....592
Maintenance Basics....593
Preparing the Machine for Maintenance....593
Cleaning the Machine....594
Precautionary Measures When Cleaning the Machine....594
Fire Prevention....594
Working-Area-Dependent Maintenance....594
Muddy or Wet Working Areas....594
Dusty Working Areas....594
Lubricants and Operating Agents....595
Draining Hot Lubricants and Fluids....595
Checking the Oil Level and Changing Oil....595
Changing Filters....595
Refuelling and Topping off Oil....595
Oil....595
Lubricating Grease....596
Biodegradable Hydraulic Oil and Lubricating Grease....596
Fuel....596
Storage of Oil and Fuel....596
Coolants....597
Windscreen Washer Liquid....597
Table of Lubricants and Operating Agents....599
Lubrication chart....600
Axles....601
Released axle oil brands....601
Replacing Safety-Related Parts....601
Welding Instructions....601
Spare Parts and Consumable Components....602
Electrical System....603
Fuses....603
Fuse Assignment....603
Slow-Blowing Fuses....604
Tires....605
Tire Components....605
Checking the Tires....605
Checking the Tire Pressure....605
Torque for Standard Nuts and Bolts....607
Maintenance Schedule....609
Maintenance Prior to Start....611
Visual Checks....611
Cooling System, Checking the Coolant Level, Topping off Coolant....611
Engine, Checking the Oil Level, Topping off Oil....612
Engine, Draining off Oil....613
Checking the Fuel Level, Refueling....614
Checking the Controls....615
Checking the Parking Brake....616
Test Conditions....616
Test Procedure....616
CHecking the Service Brake....616
Checking the Electrical Connections....617
Heater / ventilation: check blower....617
Other Maintenance Measures Prior to Start....617
Maintenance Every 10 Operating Hours....618
Lubrication....618
Maintenance After the First 50 Operating Hours....619
Engine, Changing Oil and Replacing the Oil Filter Cartridge....619
Replacing the Oil Filter Cartridge....620
V-Belt, Checking the Condition....621
V-Belt, Checking and Adjusting the Tension....621
Hydraulic System, Replacing the Filter Insert....622
Checking and Tightening the Wheel Nuts....623
Front and Rear Axle, Changing Oil....624
Planet gear....624
Differential....624
Transfer Gear - Changing Oil....625
Maintenance Every 50 Operating Hours....626
Checking the cooling System, coolant level in the radiator and expansion tank....626
Draining Off Water and Dirt Deposits From the Fuel Tank....627
Checking the Service Brake and Oil Level, Refilling Oil....627
Checking the Battery and Acid Level....628
Re-charging a built-in battery....629
Lubrication....630
Lubricating points of the work equipment....630
Maintenance Every 100 Operating Hours....631
Draining the Water Separator, Removing Water and Dirt Deposits....631
Maintenance Every 250 Operating Hours....632
Changing the Engine Oil and Oil Filter Cartridge....632
Checking the V-Belt Condition....632
Checking and Adjusting the V-belt Tension....632
Front and Rear Axle, Checking the Oil Level....633
Planet gear....633
Differential....633
Air Filter, Removing and Re-Installing the Filter Insert, Checking and Cleaning the Filter Insert....634
Structure of the air filter....634
Maintenance demand....634
Removing the filter cartridge....634
Cleaning or exchanging the filter cartridge....635
Checking the filter cartridge....636
Assembling the air filter cartridge....636
Cleaning the Radiator Segments....636
Lubrication....637
Maintenance Every 500 Operating Hours....638
Changing the Fuel Filter and Filter Element....638
Bleeding the Fuel System....639
Changing the Filter Cartridge of the Hydraulic System....640
Cleaning the Water Separator....640
Lubrication....641
Transfer Gear, Checking the Oil Level and Refilling Oil....641
Air Filter, Replacing the Filter Insert, Replacing the Safety Filter....642
Replacing the Filter Insert....642
Replacing the Safety Filter....642
Heater / ventilation: cleaning / replacing blower filter....643
Clean filter fleece....643
Maintenance Every 1000 Operating Hours....644
Cooling System, Exchanging Coolant and Cleaning the System....644
Draining off the coolant....644
Cleaning the Cooling System....645
Filling off Coolant....645
Front Axle, Oil Change....646
Rear Axle, Oil Change....646
Transfer Gear, Oil Change....646
Service Brake....646
Changing oil....646
Checking tubes and lines....646
Checking the brake disks for wear and tear....646
Adjusting the clearance of the brake disks....646
Checking and Adjusting System Pressures....646
Checking and Adjusting the Valve clearance....646
Checking and Adjusting the Injection Nozzles, Nozzle Pressure and Fuel-Jet Pattern....646
Checking the Accumulator Gas Pressure....647
Maintenance Every 2000 Operating Hours....648
Hydraulic System, Oil Change....648
Bleeding the Hydraulic Oil Tank....649
Cooling System, Checking the Antifreeze Content of the Coolant....649
Checking the Cooling System....649
Checking the Fuel Pump....649
Checking the Fuel and Coolant Tubes, Replacing the Tubes (if required)....649
Checking the Water Pump....650
Checking and Adjusting the Fuel Injection and Injection time....650
Technical Data....652
Technical Data....653
Noise Emission Levels....654
Vibration Level....654
Limit Values for Slopes....655
Maximum slope angle for operating the machine....655
VEAM940600 - Wheel Loader WA65-3 Operation & Maintenance Manual....656
Cover....656
Table of Contents....659
Introduction....667
Forword....668
Safety Information....669
Introduction....671
Features....671
Breaking in a New Machine....671
Location of Plates, Table to Enter Serial No. and Distributor....672
Machine Serial No. Plate position....672
Engine Serial No. Plate Position....672
Table to Enter Serial No. and Distributor....672
EMISSION CONTROL WARRANTY....673
EMISSION CONTROL WARRANTY STATEMENT (APPLIES TO CANADA ONLY)....673
Engine Data Plate....674
GARANTIE SUR LE CONTRÔLE DES ÉMISSIONS....675
ÉNONCÉ DE GARANTIE SUR LE CONTRÔLE DES ÉMISSIONS ( APPLICABLE AU CANADA SEULEMENT):....675
Engine Data Plate....677
Why You Should Read these Operating Instructions....678
Notes on Safety Regulations....680
Correct Use....680
Safety Notes in the Operating Instructions....680
Equipment....681
Loading and Transporting the Machine....683
Loading and Transporting the Machine....684
Securing the Articulated Steering....684
Lifting the Machine....684
Driving Machine Onto Loading Area of Transport Vehicle....686
Securing the Machine During Transport....687
After Transport....687
Safety....689
General Safety Measures....691
Safety Instructions....691
Safety Devices....691
Emergency Exit....691
Clothing and Personal Protection....692
Machine Modifications....692
Before You Leave the Driver's Seat....692
Mounting and Dismounting....693
Fire Prevention and Fire Fighting....694
Fire Extinguisher and First-Aid Kit....695
Protection Against Asbestos Dust....695
Protection Against Injuries....696
Working at High Temperatures....696
Roll-Over Protection System (ROPS)....697
Attachment for Protection Against Falling Objects (FOPS)....697
Attachments....697
Battery....698
Safety Measures during Operation....699
Before You Start the Engine....699
Machine Operation....701
Transport....708
Safety Measures During Maintenance....710
Personnel....710
Prior to Start of Maintenance Measures....710
During Maintenance....713
Tires....717
Labeling....719
Position of Safety Labels....719
Information Labels....721
Controls and Indicators....723
Overall View of Machine....724
Controls and Indicators....725
Control Lamps....731
Measuring Indicators....735
Switches....737
Control Levers, Pedals....744
Articulated Steering Catch....750
Traction Device....750
Socket....750
Door Unlocking System....751
Alarm Horn for Reverse Driving....751
Operation....753
Running in the Machine....754
Preparing the Machine Start....755
Visual Checks....755
Adjustments Prior to Machine Start....758
Adjusting the Driver’s Seat....758
Adjusting the Steering Column....759
Adjusting the Armrest....759
Adjusting the Rear-View Mirrors....759
Adjusting the Heating and Ventilation System....760
Operating the Air Conditioning....762
Putting on the Safety Belt....764
Starting and Switching Off the Engine....765
Starting the Engine....765
Warming up the engine....766
Switching Off the Engine....767
Driving....768
Start-Up....768
Changing the Driving Direction....770
Reverse Driving....771
Turning....771
Braking....772
Pulling the parking brake....772
Stopping....774
Longer-Distance Driving....775
Operating the Machine....776
Preparing the Work Equipment....776
Tire Service Life....780
Level indicator for the bucket....780
Adjusting the Bucket Positioner....781
Loading....782
Transporting....785
Dumping / Unloading....785
Planing....787
Working With the Forklift Truck Attachment....789
Precautions For Special Operations....790
After the work is finished....790
Instructions for Winter Operation....791
Longer Standstill Periods of the Machine....793
Troubleshooting....795
Troubleshooting....796
Warning Lights and Indicators....796
Electrical System....797
Engine....798
Hydraulic system....801
Brakes....803
Axles....804
driver’s cab....804
Emergency Steering Characteristics....805
Emergency Lowering System....805
Starting the Engine with a Battery Jumper Cable....806
Towing the Machine....808
Inadequate Braking Effect....810
Maintenance....813
Maintenance Basics....814
Preparing the Machine for Maintenance....814
Cleaning the Machine....815
Working-Area-Dependent Maintenance....816
Lubricants and Operating Agents....817
Axles....824
Replacing Safety-Related Parts....824
Welding Instructions....825
Spare Parts and Consumable Components....826
Electrical System....827
Tires....830
Torque for Standard Nuts and Bolts....832
Maintenance Schedule....834
Maintenance Prior to Start....836
Visual Checks....836
Cooling System, Checking the Coolant Level, Topping off Coolant....836
Engine, Checking the Oil Level, Topping off Oil....837
Engine, Draining off Oil....838
Checking the Fuel Level, Refueling....839
Checking the Controls....840
Checking the Electrical Connections....840
Heater / air conditioning: checking rate of air flow....841
Other Maintenance Measures Prior to Start....841
Maintenance upon demand....842
Checking the air-conditioning system....842
Maintenance Every 10 Operating Hours....843
Lubrication....843
Maintenance After the First 50 Operating Hours....844
Engine, Changing Oil and Replacing the Oil Filter Cartridge....844
V-Belt, Checking the Condition....846
V-Belt, Checking and Adjusting the Tension....846
Hydraulic System, Replacing the Filter Insert....847
Checking and Tightening the Wheel Nuts....848
Front and Rear Axle, Changing Oil....849
Transfer Gear - Changing Oil....850
Maintenance Every 50 Operating Hours....851
Checking cooling System, coolant level in the radiator and expansion tank....851
Draining Off Water and Dirt Deposits From the Fuel Tank....852
Checking the Service Brake and Oil Level, Refilling Oil....852
Checking the Battery and Acid Level....853
Lubrication....855
Maintenance Every 100 Operating Hours....856
Draining the Water Separator, Removing Water and Dirt Deposits....856
Maintenance Every 250 Operating Hours....857
Changing the Engine Oil and Oil Filter Cartridge....857
Checking the V-Belt Condition....857
Checking and Adjusting the V-belt Tension....857
Front and Rear Axle, Checking the Oil Level....858
Air Filter, Removing/Re-Installing AND Checking/Cleaning the Filter Insert....860
Cleaning the Radiator Segments....862
Lubrication....863
Maintenance Every 500 Operating Hours....864
Changing the Fuel Filter and Filter Element....864
Changing the Filter Cartridge of the Hydraulic System....866
Cleaning the Water Separator....866
Lubrication....867
Transfer Gear, Checking the Oil Level and Refilling Oil....867
Air Filter, Replacing the Filter Insert, Replacing the Safety Filter....868
Heater/air conditioning: clean filter fleece of heater unit....869
Heater/air conditioning: Cleaning the condenser....870
Maintenance Every 1000 Operating Hours....871
Cooling System, Exchanging Coolant and Cleaning the System....871
Front Axle, Oil Change....873
Rear Axle, Oil Change....873
Transfer Gear, Oil Change....873
Service Brake....873
Checking and Adjusting System Pressures....873
Checking and Adjusting the Valve clearance....873
Checking/Adjusting the Injection Nozzles, Nozzle Pressure/ Fuel-Jet Pattern....874
Checking the Accumulator Gas Pressure....874
Maintenance Every 2000 Operating Hours....875
Hydraulic System, Oil Change....875
Bleeding the Hydraulic Oil Tank....876
Cooling System, Checking the Antifreeze Content of the Coolant....876
Checking the Cooling System....876
Checking the Fuel Pump....876
Checking the Fuel and Coolant Tubes, Replacing the Tubes (if required)....876
Checking the Water Pump....877
Checking and Adjusting the Fuel Injection and Injection time....877
Technical Data....879
Technical Data....880
Noise Emission Levels....881
Vibration Level....881
Limit Values for Slopes....881
Special Equipment and Attachments....883
ALS-Electronics....884
Structure and Functioning Principle of the ALS-Electronics....884
Precautionary Measures for Switching on the ALS Electronics....884
Operation of the ALS-Electronics....885
Handling of the Pressure Accumulator....886
Index....887
VEAM950200 - Wheel Loader WA75-3 Operation & Maintenance Manual....893
COVER....893
Table of Contents....899
Introduction....907
1. Forword....908
2. Safety Information....909
3. Introduction....910
3.1 Features....910
3.2 Breaking in a New Machine....910
4. Location of Plates, Table to Enter Serial No. and Distributor....911
4.1 Machine Serial No. Plate position....911
4.2 Engine Serial No. Plate Position....911
4.3 Table to Enter Serial No. and Distributor....911
5. Why You Should Read these Operating Instructions....912
6. Notes on Safety Regulations....913
6.1 Correct Use....913
6.2 Safety Notes in the Operating Instructions....913
7. Equipment....914
Loading and Transporting the Machine....917
8. Loading and Transporting the Machine....918
8.1 Securing the Articulated Steering....918
8.2 Lifting the Machine....918
8.3 Driving Machine Onto Loading Area of Transport Vehicle....920
8.4 Securing the Machine During Transport....921
8.5 After Transport....921
Safety....923
9. General Safety Measures....925
9.1 Safety Instructions....925
9.2 Safety Devices....925
9.3 Emergency Exit....925
9.4 Clothing and Personal Protection....926
9.5 Machine Modifications....926
9.6 Before You Leave the Driver's Seat....926
9.7 Mounting and Dismounting....926
9.8 Fire Prevention and Fire Fighting....927
9.8.1 Fire Extinguisher and First-Aid Kit....928
9.9 Protection Against Asbestos Dust....928
9.10 Protection Against Injuries....929
9.11 Working at High Temperatures....929
9.12 Roll-Over Protection System (ROPS)....930
9.13 Attachment for Protection Against Falling Objects (FOPS)....930
9.14 Attachments....930
9.15 Battery....931
10. Safety Measures during Operation....932
10.1 Before You Start the Engine....932
10.1.1 Workplace Safety....932
10.1.2 In the Driver's Cab....932
10.1.3 In-Door Operation....933
10.1.4 Gas, Dust, and Inflammable Vapours....933
10.1.5 Mirrors, Windows, and Lighting....933
10.2 Machine Operation....934
10.2.1 Before You Start the Engine....934
10.2.2 Reversing....934
10.2.3 Driving....935
10.2.4 Driving On Slopes....935
10.2.5 Emergency Lowering System....936
10.2.6 Working Close to Overhead Power Transmission Lines....936
10.2.7 Loading....937
10.2.8 Good Vision....937
10.2.9 Working On Snow....937
10.2.10 Height Limitation....937
10.2.11 Brakes....938
10.2.12 Working On Loose Soil....938
10.2.13 Working with the Forklift Truck Attachment....939
10.2.14 Parking the Machine....940
10.3 Transport....941
10.3.1 Loading and Unloading the Machine....941
10.3.2 Transport....941
11. Safety Measures During Maintenance....942
11.1 Personnel....942
11.2 Prior to Start of Maintenance Measures....942
11.2.1 Warning Sign....942
11.2.2 Tools....942
11.2.3 Safety-Related Parts....942
11.2.4 Prior to Start of Inspection and Maintenance....943
11.2.5 Securing the Articulated Steering....943
11.2.6 Supporting the Work Unit....943
11.3 During Maintenance....944
11.3.1 Attachments....944
11.3.2 Working Under the Machine....944
11.3.3 Keeping the Machine Clean....944
11.3.4 Specific Measures....944
11.3.5 Refueling and Topping Off Oil....945
11.3.6 Coolant....945
11.3.7 Use of Lighting....946
11.3.8 High-Pressure Hoses....946
11.3.9 Handling High-Pressure Oil....946
11.3.10 Fan and Belts....947
11.3.11 Waste Material....947
11.4 Tires....948
11.4.1 Storing Tires....948
12. Labeling....949
12.1 Position of Safety Labels....949
12.2 Position of Standard Labels....951
Controls and InDicators....953
13. General View of Machine....954
14. Controls and Indicators....955
14.1 General View....955
14.1.1 Switches and Controls....956
14.2 Instrument Panel....957
14.3 Warning Lights....958
14.4 Control Lamps....961
14.5 Measuring Indicators....964
14.6 Switches....966
14.7 Control Levers, Pedals....972
14.8 Articulated Steering Catch....977
14.9 Traction Device....977
14.10 Socket....977
14.11 Door Unlocking System....978
14.12 Alarm Horn for Reverse Driving....978
Operation....979
15. Running in the Machine....980
16. Preparing the Machine Start....981
16.1 Visual Checks....981
16.1.1 Before you start the engine....981
16.1.2 Before starting working with the machine....981
17. Adjustments Prior to Machine Start....983
17.1 Adjusting the Driver’s Seat....983
17.2 Adjusting the Steering Column....984
17.3 Adjusting the Armrest....984
17.4 Adjusting the Rear-View Mirrors....984
17.5 Adjusting the Heating and Ventilation System....985
17.5.1 Adjusting the ventilation system....985
17.5.2 Adjusting the heating system....985
17.6 Putting on the Safety Belt....986
17.6.1 Putting on the safety belt....986
17.6.2 Taking off the safety belt....986
18. Starting and Switching Off the Engine....987
18.1 Starting the Engine....987
18.1.1 Warming up the engine....988
18.2 Switching Off the Engine....989
19. Driving....990
19.1 Start-Up....990
19.1.1 Starting the machine on slopes....991
19.2 Changing the Driving Direction....991
19.3 Reverse Driving....992
19.4 Turning....992
19.4.1 Turning on slopes, embankments or hill flanks....992
19.5 Braking....993
19.5.1 Pulling the parking brake....993
19.5.2 Releasing the parking brake....993
19.5.3 Braking with the service brake....993
19.5.4 If the service brake breaks down....993
19.5.5 Braking on slopes....994
19.6 Stopping....994
19.6.1 Parking the machine on a slope....994
19.7 Longer-Distance Driving....995
20. Operating the Machine....996
20.1 Preparing the Work Equipment....996
20.1.1 Selecting a work unit....996
20.1.2 Picking up the work unit (except multi-purpose bucket)....996
20.1.3 Removing the work unit....997
20.1.4 Picking up the multi-purpose bucket....997
20.1.5 Removing the multi-purpose bucket....999
20.2 Tire Service Life....1000
20.2.1 Level indicator for the bucket....1000
20.3 Loading....1001
20.3.1 Removing piled up soil....1001
20.3.2 Excavation works....1003
20.4 Transporting....1004
20.5 Dumping / Unloading....1004
20.5.1 Loading in diagonal direction....1004
20.5.2 V-shaped loading....1005
20.5.3 Piling up material....1005
20.6 Planing....1006
20.6.1 Filling up....1006
20.6.2 Taking off soil....1006
20.6.3 Cutting the Ground....1006
20.7 Working With the Forklift Truck Attachment....1007
20.7.1 Picking up the load....1007
20.8 Precautions For Special Operations....1008
20.8.1 Working in water....1008
20.8.2 Working on snow....1008
20.8.3 Dumping on steep slopes....1008
20.8.4 Working in the vicinity of electrical overhead lines....1008
20.8.5 Operation on slopes....1008
20.8.6 Working on loose soil....1008
20.9 After the work is finished....1008
20.10 Instructions for Winter Operation....1009
20.10.1 Before the cold season....1009
20.10.2 After Operation....1009
20.10.3 After the cold season....1009
20.11 Longer Standstill Periods of the Machine....1009
20.11.1 Before the standstill....1009
20.11.2 During the standstill....1010
20.11.3 After the standstill....1010
Troubleshooting....1011
21. Troubleshooting....1012
21.1 Warning Lights and Indicators....1012
21.2 Electrical System....1013
21.3 Engine....1014
21.4 Hydraulic system....1017
21.5 Brakes....1019
21.6 Axles....1020
21.7 Emergency Steering Characteristics....1021
21.8 Emergency Lowering System....1021
21.9 Starting the Engine with a Battery Jumper Cable....1022
21.9.1 Connecting the Jumper Cable....1022
21.10 Starting the Engine....1023
21.10.1 Disconnecting the Battery Jumper Cable....1023
21.11 Towing the Machine....1024
21.12 Towing a Machine with Defective Brakes....1025
Maintenance....1027
22. Maintenance Basics....1028
22.1 Preparing the Machine for Maintenance....1028
22.2 Cleaning the Machine....1029
22.2.1 Precautionary Measures When Cleaning the Machine....1029
22.2.2 Fire Prevention....1029
22.3 Working-Area-Dependent Maintenance....1029
22.3.1 Muddy or Wet Working Areas....1029
22.3.2 Dusty Working Areas....1029
22.4 Lubricants and Operating Agents....1030
22.4.1 Draining Hot Lubricants and Fluids....1030
22.4.2 Checking the Oil Level and Changing Oil....1030
22.4.3 Changing Filters....1030
22.4.4 Refuelling and Topping off Oil....1030
22.4.5 Oil....1030
22.4.6 Lubricating Grease....1031
22.4.7 Biodegradable Hydraulic Oil and Lubricating Grease....1031
22.4.8 Fuel....1031
22.4.9 Storage of Oil and Fuel....1031
22.4.10 Coolants....1032
22.4.11 Windscreen Washer Liquid....1032
22.4.12 Table of Lubricants and Operating Agents....1034
22.4.13 Lubrication chart....1035
22.5 Replacing Safety-Related Parts....1036
22.5.1 Welding Instructions....1036
22.6 Spare Parts and Consumable Components....1037
22.7 Electrical System....1038
22.7.1 Fuses....1038
22.7.2 Fuse Assignment....1038
22.7.3 Slow-Blowing Fuses....1039
22.8 Tires....1040
22.8.1 Tire Components....1040
22.8.2 Checking the Tires....1040
22.8.3 Checking the Tire Pressure....1040
22.9 Tools....1042
22.10 Torque for Standard Nuts and Bolts....1043
23. Maintenance Schedule....1045
24. Maintenance Prior to Start....1047
24.1 Visual Checks....1047
24.2 Cooling System, Checking the Coolant Level, Topping off Coolant....1047
24.3 Engine, Checking the Oil Level, Topping off Oil....1048
24.4 Engine, Draining Off Oil....1049
24.5 Checking the Fuel Level, Refueling....1050
24.6 Checking the Controls....1051
24.7 Checking the Parking Brake....1052
24.7.1 Test Conditions....1052
24.7.2 Test Procedure....1052
24.8 Checking the Service Brake....1052
24.9 Checking the Electrical Connections....1053
24.10 Other Maintenance Measures Prior to Start....1053
25. Maintenance Every 10 Operating Hours....1054
25.1 Lubrication....1054
26. Maintenance After the First 50 Operating Hours....1055
26.1 Engine, Changing Oil and Replacing the Oil Filter Cartridge....1055
26.1.1 Replacing the Oil Filter Cartridge....1056
26.2 V-Belt, Checking the Condition....1057
26.3 V-Belt, Checking and Adjusting the Tension....1057
26.4 Hydraulic System, Replacing the Filter Insert....1058
26.5 Checking and Tightening the Wheel Nuts....1059
26.6 Front and Rear Axle, Changing Oil....1060
26.6.1 Planet gear....1060
26.6.2 Differential....1060
26.7 Transfer Gear - Changing Oil....1061
27. Maintenance Every 50 Operating Hours....1062
27.1 Checking the cooling System, coolant level in the radiator and expansion tank....1062
27.2 Draining Off Water and Dirt Deposits From the Fuel Tank....1063
27.3 Checking the Service Brake and Oil Level, Refilling Oil....1063
27.4 Checking the Battery and Acid Level....1064
27.4.1 Re-charging a built-in battery....1065
27.5 Lubrication....1066
27.5.1 Lubricating points of the work equipment....1066
28. Maintenance Every 100 Operating Hours....1067
28.1 Draining the Water Separator, Removing Water and Dirt Deposits....1067
29. Maintenance Every 250 Operating Hours....1068
29.1 Changing the Engine Oil and Oil Filter Cartridge....1068
29.2 Checking the V-Belt Condition....1068
29.3 Checking and Adjusting the V-belt Tension....1068
29.4 Lubrication....1068
29.4.1 Lubricating points of the steering cylinder....1068
29.5 Front and Rear Axle, Checking the Oil Level....1069
29.5.1 Planet gear....1069
29.5.2 Differential....1069
29.6 Air Filter, Removing and Re-Installing the Filter Insert, Checking and Cleaning the Filter I...1070
29.6.1 Structure of the air filter....1070
29.6.2 Maintenance demand....1070
29.6.3 Removing the filter cartridge....1070
29.6.4 Cleaning or exchanging the filter cartridge....1071
29.6.5 Checking the filter cartridge....1072
29.6.6 Assembling the air filter cartridge....1072
29.7 Cleaning the Radiator Segments....1072
30. Maintenance Every 500 Operating Hours....1073
30.1 Changing the Fuel Filter and Filter Element....1073
30.1.1 Bleeding the Fuel System....1074
30.2 Changing the Filter Cartridge of the Hydraulic System....1075
30.3 Cleaning the Water Separator....1075
30.4 Lubrication....1076
30.5 Transfer Gear, Checking the Oil Level and Refilling Oil....1076
30.6 Air Filter, Replacing the Filter Insert, Replacing the Safety Filter....1077
30.6.1 Replacing the Filter Insert....1077
30.6.2 Replacing the Safety Filter....1077
31. Maintenance Every 1000 Operating Hours....1078
31.1 Cooling System, Exchanging Coolant and Cleaning the System....1078
31.1.1 Draining off the coolant....1078
31.1.2 Cleaning the Cooling System....1079
31.1.3 Filling off Coolant....1079
31.2 Front Axle, Oil Change....1080
31.3 Rear Axle, Oil Change....1080
31.4 Transfer Gear, Oil Change....1080
31.5 Service Brake....1080
31.5.1 Changing oil....1080
31.5.2 Checking tubes and lines....1080
31.5.3 Checking the brake disks for wear and tear....1080
31.5.4 Adjusting the clearance of the brake disks....1080
31.6 Checking and Adjusting System Pressures....1080
31.7 Checking and Adjusting the Valve clearance....1080
31.8 Checking and Adjusting the Injection Nozzles, Nozzle Pressure and Fuel-Jet Pattern....1080
32. Maintenance Every 2000 Operating Hours....1081
32.1 Hydraulic System, Oil Change....1081
32.2 Bleeding the Hydraulic Oil Tank....1082
32.3 Cooling System, Checking the Antifreeze Content of the Coolant....1082
32.4 Checking the Cooling System....1082
32.5 Checking the Fuel Pump....1082
32.6 Checking the Fuel and Coolant Tubes, Replacing the Tubes (if required)....1082
32.7 Checking the Water Pump....1083
32.8 Checking and Adjusting the Fuel Injection and Injection time....1083
32.9 Engine, Intake Valves and Outlet Valves - Grinding In the Valve Bases....1083
Technical Data....1085
33. Technical Data....1086
33.1 Noise Emission Levels....1087
33.2 Vibration Level....1087
33.3 Limit Values for Slopes....1088
33.3.1 Maximum slope angle for operating the machine....1088
33.3.2 Tilting/tipping angle....1088
VEAM950400 - Wheel Loader WA75-3 Operation & Maintenance Manual....1091
Cover....1091
Product Publications Information....1093
Table of Contents....1095
Introduction....1103
Forword....1104
Safety Information....1105
Introduction....1106
Features....1106
Breaking in a New Machine....1106
Location of Plates, Table to Enter Serial No. and Distributor....1107
Machine Serial No. Plate position....1107
Engine Serial No. Plate Position....1107
Table to Enter Serial No. and Distributor....1107
EMISSION CONTROL WARRANTY....1108
EMISSION CONTROL WARRANTY STATEMENT (APPLIES TO CANADA ONLY)....1108
Engine Data Plate....1109
GARANTIE SUR LE CONTRÔLE DES ÉMISSIONS....1110
ÉNONCÉ DE GARANTIE SUR LE CONTRÔLE DES ÉMISSIONS (APPLICABLE AU CANADA SEULEMENT):....1110
Engine Data Plate....1111
Why You Should Read these Operating Instructions....1112
Notes on Safety Regulations....1113
Correct Use....1113
Safety Notes in the Operating Instructions....1113
Equipment....1114
Loading and Transporting the Machine....1117
Loading and Transporting the Machine....1119
Securing the Articulated Steering....1119
Lifting the Machine....1119
Driving Machine Onto Loading Area of Transport Vehicle....1121
Securing the Machine During Transport....1122
After Transport....1122
Safety....1123
General Safety Measures....1125
Safety Instructions....1125
Safety Devices....1125
Emergency Exit....1125
Clothing and Personal Protection....1126
Machine Modifications....1126
Before You Leave the Driver's Seat....1126
Mounting and Dismounting....1126
Fire Prevention and Fire Fighting....1127
Fire Extinguisher and First-Aid Kit....1128
Protection Against Asbestos Dust....1128
Protection Against Injuries....1129
Working at High Temperatures....1129
Roll-Over Protection System (ROPS)....1130
Attachment for Protection Against Falling Objects (FOPS)....1130
Attachments....1130
Battery....1131
Safety Measures during Operation....1132
Before You Start the Engine....1132
Workplace Safety....1132
In the Driver's Cab....1132
In-Door Operation....1133
Gas, Dust, and Inflammable Vapours....1133
Mirrors, Windows, and Lighting....1133
Machine Operation....1134
Before You Start the Engine....1134
Reversing....1134
Driving....1135
Driving On Slopes....1135
Emergency Lowering System....1136
Working Close to Overhead Power Transmission Lines....1136
Loading....1137
Good Vision....1137
Working On Snow....1137
Height Limitation....1137
Brakes....1138
Working On Loose Soil....1138
Working with the Forklift Truck Attachment....1139
Parking the Machine....1140
Transport....1141
Loading and Unloading the Machine....1141
Transport....1141
Safety Measures During Maintenance....1142
Personnel....1142
Prior to Start of Maintenance Measures....1142
Warning Sign....1142
Tools....1142
Safety-Related Parts....1142
Prior to Start of Inspection and Maintenance....1143
Securing the Articulated Steering....1143
Supporting the boom....1144
During Maintenance....1145
Attachments....1145
Working Under the Machine....1145
Keeping the Machine Clean....1145
Specific Measures....1145
Refueling and Topping Off Oil....1146
Coolant....1146
Use of Lighting....1147
High-Pressure Hoses....1147
Handling High-Pressure Oil....1147
Handling of the pressure accumulator....1148
Fan and Belts....1148
Waste Material....1148
Tires....1149
Storing Tires....1149
Labeling....1150
Position of Safety Labels....1150
Information Labels....1152
Controls and InDicators....1153
Overall View of Machine....1154
Controls and Indicators....1155
SWITCHES AND CONTROLS....1156
Instrument Panel....1157
Warning Lights....1158
Control Lamps....1161
Measuring Indicators....1165
Switches....1167
Control Levers, Pedals....1174
Articulated Steering Catch....1179
Traction Device....1179
Socket....1179
Door Unlocking System....1180
Alarm Horn for Reverse Driving....1180
Operation....1181
Running in the Machine....1182
Preparing the Machine Start....1183
Visual Checks....1183
Before you start the engine....1183
Before starting working with the machine....1183
Adjustments Prior to Machine Start....1185
Adjusting the Driver’s Seat....1185
Adjusting the Steering Column....1186
Adjusting the Armrest....1186
Adjusting the Rear-View Mirrors....1186
Adjusting the Heating and Ventilation System....1187
Adjusting the ventilation system....1187
Adjusting the heating system....1187
Putting on the Safety Belt....1188
Putting on the safety belt....1188
Taking off the safety belt....1188
Starting and Switching Off the Engine....1189
Starting the Engine....1189
Warming up the engine....1190
Switching Off the Engine....1191
Driving....1192
Start-Up....1192
Starting the machine on slopes....1193
Driving with the high-Speed gear....1193
Changing the Driving Direction....1194
Reverse Driving....1195
Turning....1195
Turning on slopes, embankments or hill flanks....1195
Braking....1196
Pulling the parking brake....1196
Releasing the parking brake....1196
Braking with the service brake....1196
If the service brake breaks down....1196
Braking on slopes....1197
Stopping....1197
Parking the machine on a slope....1197
Longer-Distance Driving....1198
Operating the Machine....1199
Preparing the Work Equipment....1199
Selecting a work unit....1199
Picking up the work unit (except multi- purpose bucket)....1199
Removing the work unit....1200
Picking up the multi-purpose bucket....1200
Removing the multi-purpose bucket....1202
Tire Service Life....1203
Level indicator for the bucket....1203
Loading....1204
Removing piled up soil....1204
Excavation works....1206
Transporting....1207
Dumping / Unloading....1207
Loading in diagonal direction....1207
V-shaped loading....1208
Piling up material....1208
Planing....1209
Filling up....1209
Taking off soil....1209
Cutting the Ground....1209
Working With the Forklift Truck Attachment....1210
Picking up the load....1210
Precautions For Special Operations....1211
Working in water....1211
Working on snow....1211
Dumping on steep slopes....1211
Working in the vicinity of electrical overhead lines....1211
Operation on slopes....1211
Working on loose soil....1211
After the work is finished....1211
Instructions for Winter Operation....1212
Before the cold season....1212
After Operation....1212
After the cold season....1212
Longer Standstill Periods of the Machine....1212
Before the standstill....1212
During the standstill....1213
After the standstill....1213
Troubleshooting....1215
Troubleshooting....1216
Warning Lights and Indicators....1216
Electrical System....1217
Engine....1218
Hydraulic system....1221
Brakes....1223
Axles....1224
driver’s cab....1224
Emergency Steering Characteristics....1225
Emergency Lowering System....1225
Starting the Engine with Battery Jumper CableS....1226
Connecting the Jumper CableS....1226
Starting the Engine....1227
Disconnecting the Battery Jumper CableS....1227
Towing the Machine....1228
Towing a Machine with Defective Brakes....1229
Maintenance....1231
Maintenance Basics....1232
Preparing the Machine for Maintenance....1232
Cleaning the Machine....1233
Precautionary Measures When Cleaning the Machine....1233
Fire Prevention....1233
Working-Area-Dependent Maintenance....1233
Muddy or Wet Working Areas....1233
Dusty Working Areas....1233
Lubricants and Operating Agents....1234
Draining Hot Lubricants and Fluids....1234
Checking the Oil Level and Changing Oil....1234
Changing Filters....1234
Refuelling and Topping off Oil....1234
Oil....1234
Lubricating Grease....1235
Biodegradable Hydraulic Oil and Lubricating Grease....1235
Fuel....1235
Storage of Oil and Fuel....1235
Coolants....1236
Windscreen Washer Liquid....1236
Table of Lubricants and Operating Agents....1238
Lubrication chart....1239
Axles....1240
Released axle oil brands....1240
Replacing Safety-Related Parts....1240
Welding Instructions....1240
Spare Parts and Consumable Components....1241
Electrical System....1242
Fuses....1242
Fuse Assignment....1242
Slow-Blow Fuses....1243
Tires....1244
Tire Components....1244
Checking the Tires....1244
Checking the Tire Pressure....1244
Torque for Standard Nuts and Bolts....1246
Maintenance Schedule....1248
Maintenance Prior to Start....1250
Visual Checks....1250
Cooling System, Checking the Coolant Level, Topping off Coolant....1250
Engine, Checking the Oil Level, Topping off Oil....1251
Engine, Draining off Oil....1252
Checking the Fuel Level, Refueling....1253
Checking the Controls....1254
Checking the Parking Brake....1255
Test Conditions....1255
Test Procedure....1255
CHecking the Service Brake....1255
Checking the Electrical Connections....1256
Heater / ventilation: check blower....1256
Other Maintenance Measures Prior to Start....1256
Maintenance Every 10 Operating Hours....1257
Lubrication....1257
Maintenance After the First 50 Operating Hours....1258
Engine, Changing Oil and Replacing the Oil Filter Cartridge....1258
Replacing the Oil Filter Cartridge....1259
V-Belt, Checking the Condition....1260
V-Belt, Checking and Adjusting the Tension....1260
Hydraulic System, Replacing the Filter Insert....1261
Checking and Tightening the Wheel Nuts....1262
Front and Rear Axle, Changing Oil....1263
Planet gear....1263
Differential....1263
Transfer Gear - Changing Oil....1264
Maintenance Every 50 Operating Hours....1265
Checking the cooling System, coolant level in the radiator and expansion tank....1265
Draining Off Water and Dirt Deposits From the Fuel Tank....1266
Checking the Service Brake and Oil Level, Refilling Oil....1266
Checking the Battery and Acid Level....1267
Re-charging a built-in battery....1268
Lubrication....1269
Lubricating points of the work equipment....1269
Maintenance Every 100 Operating Hours....1270
Draining the Water Separator, Removing Water and Dirt Deposits....1270
Maintenance Every 250 Operating Hours....1271
Changing the Engine Oil and Oil Filter Cartridge....1271
Checking the V-Belt Condition....1271
Checking and Adjusting the V-belt Tension....1271
Front and Rear Axle, Checking the Oil Level....1272
Planet gear....1272
Differential....1272
Air Filter, Removing and Re-Installing the Filter Insert, Checking and Cleaning the Filter Insert....1273
Structure of the air filter....1273
Maintenance demand....1273
Removing the filter cartridge....1273
Cleaning or exchanging the filter cartridge....1274
Checking the filter cartridge....1275
Assembling the air filter cartridge....1275
Cleaning the Radiator Segments....1275
Lubrication....1276
Maintenance Every 500 Operating Hours....1277
Changing the Fuel Filter and Filter Element....1277
Bleeding the Fuel System....1278
Changing the Filter Cartridge of the Hydraulic System....1279
Cleaning the Water Separator....1279
Lubrication....1280
Transfer Gear, Checking the Oil Level and Refilling Oil....1280
Air Filter, Replacing the Filter Insert, Replacing the Safety Filter....1281
Replacing the Filter Insert....1281
Replacing the Safety Filter....1281
Heater / ventilation: cleaning / replacing blower filter....1282
Clean filter fleece....1282
Maintenance Every 1000 Operating Hours....1283
Cooling System, Exchanging Coolant and Cleaning the System....1283
Draining off the coolant....1283
Cleaning the Cooling System....1284
Filling off Coolant....1284
Front Axle, Oil Change....1285
Rear Axle, Oil Change....1285
Transfer Gear, Oil Change....1285
Service Brake....1285
Changing oil....1285
Checking tubes and lines....1285
Checking the brake disks for wear and tear....1285
Adjusting the clearance of the brake disks....1285
Checking and Adjusting System Pressures....1285
Checking and Adjusting the Valve clearance....1285
Checking and Adjusting the Injection Nozzles, Nozzle Pressure and Fuel-Jet Pattern....1285
Checking the Accumulator Gas Pressure....1286
Maintenance Every 2000 Operating Hours....1287
Hydraulic System, Oil Change....1287
Bleeding the Hydraulic Oil Tank....1288
Cooling System, Checking the Antifreeze Content of the Coolant....1288
Checking the Cooling System....1288
Checking the Fuel Pump....1288
Checking the Fuel and Coolant Tubes, Replacing the Tubes (if required)....1288
Checking the Water Pump....1289
Checking and Adjusting the Fuel Injection and Injection time....1289
Technical Data....1291
Technical Data....1292
Noise Emission Levels....1293
Vibration Level....1293
Limit Values for Slopes....1294
Maximum slope angle for operating the machine....1294
Special Equipment and Attachments....1295
ALS-Electronics....1296
Structure and Functioning Principle of the ALS-Electronics....1296
PRECAUTIONARY MEASURES FOR SWITCHING ON THE ALS-ELECTRONICS....1296
Operation of the ALS-Electronics....1297
Switching on the ALS-Electronics....1297
Switching off the ALS-Electronics....1297
Handling of the Pressure Accumulator....1298
VEAM950600 - Wheel Loader WA75-3, WA85-3 Operation & Maintenance Manual....1299
Cover....1299
Table of Contents....1303
Introduction....1311
Forword....1312
Safety Information....1313
Introduction....1315
Features....1315
Breaking in a New Machine....1315
Location of Plates, Table to Enter Serial No. and Distributor....1316
Machine Serial No. Plate position....1316
Engine Serial No. Plate Position....1316
Table to Enter Serial No. and Distributor....1316
EMISSION CONTROL WARRANTY....1317
EMISSION CONTROL WARRANTY STATEMENT (APPLIES TO CANADA ONLY)....1317
Engine Data Plate....1318
GARANTIE SUR LE CONTRÔLE DES ÉMISSIONS....1319
ÉNONCÉ DE GARANTIE SUR LE CONTRÔLE DES ÉMISSIONS ( APPLICABLE AU CANADA SEULEMENT):....1319
Engine Data Plate....1321
Why You Should Read these Operating Instructions....1322
Notes on Safety Regulations....1324
Correct Use....1324
Safety Notes in the Operating Instructions....1324
Equipment....1325
Loading and Transporting the Machine....1327
Loading and Transporting the Machine....1328
Securing the Articulated Steering....1328
Lifting the Machine....1328
Driving Machine Onto Loading Area of Transport Vehicle....1330
Securing the Machine During Transport....1331
After Transport....1331
Safety....1333
General Safety Measures....1335
Safety Instructions....1335
Safety Devices....1335
Emergency Exit....1335
Clothing and Personal Protection....1336
Machine Modifications....1336
Before You Leave the Driver's Seat....1336
Mounting and Dismounting....1337
Fire Prevention and Fire Fighting....1338
Fire Extinguisher and First-Aid Kit....1339
Protection Against Asbestos Dust....1339
Protection Against Injuries....1340
Working at High Temperatures....1340
Roll-Over Protection System (ROPS)....1341
Attachment for Protection Against Falling Objects (FOPS)....1341
Attachments....1341
Battery....1342
Safety Measures during Operation....1343
Before You Start the Engine....1343
Machine Operation....1345
Transport....1352
Safety Measures During Maintenance....1354
Personnel....1354
Prior to Start of Maintenance Measures....1354
During Maintenance....1357
Tires....1361
Labeling....1363
Position of Safety Labels....1363
Information Labels....1365
Controls and Indicators....1367
Overall View of Machine....1368
Controls and Indicators....1369
Control Lamps....1375
Measuring Indicators....1379
Switches....1381
Control Levers, Pedals....1388
Articulated Steering Catch....1394
Traction Device....1394
Socket....1394
Door Unlocking System....1395
Alarm Horn for Reverse Driving....1395
Operation....1397
Running in the Machine....1398
Preparing the Machine Start....1399
Visual Checks....1399
Adjustments Prior to Machine Start....1402
Adjusting the Driver’s Seat....1402
Adjusting the Steering Column....1403
Adjusting the Armrest....1403
Adjusting the Rear-View Mirrors....1403
Adjusting the Heating and Ventilation System....1404
Operating the Air Conditioning....1406
Putting on the Safety Belt....1408
Starting and Switching Off the Engine....1409
Starting the Engine....1409
Warming up the engine....1410
Switching Off the Engine....1411
Driving....1412
Start-Up....1412
Changing the Driving Direction....1415
Reverse Driving....1416
Turning....1416
Braking....1417
Pulling the parking brake....1417
Stopping....1419
Longer-Distance Driving....1420
Operating the Machine....1421
Preparing the Work Equipment....1421
Tire Service Life....1425
Level indicator for the bucket....1425
Adjusting the Bucket Positioner....1426
Loading....1427
Transporting....1430
Dumping / Unloading....1430
Planing....1432
Working With the Forklift Truck Attachment....1434
Precautions For Special Operations....1435
After the work is finished....1435
Instructions for Winter Operation....1436
Longer Standstill Periods of the Machine....1438
Troubleshooting....1441
Troubleshooting....1442
Warning Lights and Indicators....1442
Electrical System....1443
Engine....1444
Hydraulic system....1447
Brakes....1449
Axles....1450
driver’s cab....1450
Emergency Steering Characteristics....1451
Emergency Lowering System....1451
Starting the Engine with a Battery Jumper Cable....1452
Towing the Machine....1454
Inadequate Braking Effect....1456
Maintenance....1459
Maintenance Basics....1460
Preparing the Machine for Maintenance....1460
Cleaning the Machine....1461
Working-Area-Dependent Maintenance....1462
Lubricants and Operating Agents....1463
Axles....1470
Replacing Safety-Related Parts....1470
Welding Instructions....1471
Spare Parts and Consumable Components....1472
Electrical System....1473
Tires....1476
Torque for Standard Nuts and Bolts....1478
Maintenance Schedule....1480
Maintenance Prior to Start....1482
Visual Checks....1482
Cooling System, Checking the Coolant Level, Topping off Coolant....1482
Engine, Checking the Oil Level, Topping off Oil....1483
Engine, Draining off Oil....1484
Checking the Fuel Level, Refueling....1485
Checking the Controls....1486
Checking the Electrical Connections....1486
Heater / air conditioning: checking rate of air flow....1487
Other Maintenance Measures Prior to Start....1487
Maintenance upon demand....1488
Checking the air-conditioning system....1488
Maintenance Every 10 Operating Hours....1489
Lubrication....1489
Maintenance After the First 50 Operating Hours....1490
Engine, Changing Oil and Replacing the Oil Filter Cartridge....1490
V-Belt, Checking the Condition....1492
V-Belt, Checking and Adjusting the Tension....1492
Hydraulic System, Replacing the Filter Insert....1493
Checking and Tightening the Wheel Nuts....1494
Front and Rear Axle, Changing Oil....1495
Transfer Gear - Changing Oil....1496
Maintenance Every 50 Operating Hours....1498
Checking cooling System, coolant level in the radiator and expansion tank....1498
Draining Off Water and Dirt Deposits From the Fuel Tank....1499
Checking the Service Brake and Oil Level, Refilling Oil....1499
Checking the Battery and Acid Level....1500
Lubrication....1502
Maintenance Every 100 Operating Hours....1503
Draining the Water Separator, Removing Water and Dirt Deposits....1503
Maintenance Every 250 Operating Hours....1504
Changing the Engine Oil and Oil Filter Cartridge....1504
Checking the V-Belt Condition....1504
Checking and Adjusting the V-belt Tension....1504
Front and Rear Axle, Checking the Oil Level....1505
Air Filter, Removing/Re-Installing AND Checking/Cleaning the Filter Insert....1507
Cleaning the Radiator Segments....1509
Lubrication....1510
Maintenance Every 500 Operating Hours....1511
Changing the Fuel Filter and Filter Element....1511
Changing the Filter Cartridge of the Hydraulic System....1513
Cleaning the Water Separator....1513
Lubrication....1514
Transfer Gear, Checking the Oil Level and Refilling Oil....1514
Air Filter, Replacing the Filter Insert, Replacing the Safety Filter....1515
Heater/air conditioning: clean filter fleece of heater unit....1516
Heater/air conditioning: Cleaning the condenser....1517
Maintenance Every 1000 Operating Hours....1518
Cooling System, Exchanging Coolant and Cleaning the System....1518
Front Axle, Oil Change....1520
Rear Axle, Oil Change....1520
Transfer Gear, Oil Change....1520
Service Brake....1520
Checking and Adjusting System Pressures....1520
Checking and Adjusting the Valve clearance....1520
Checking/Adjusting the Injection Nozzles, Nozzle Pressure/ Fuel-Jet Pattern....1521
Checking the Accumulator Gas Pressure....1521
Maintenance Every 2000 Operating Hours....1522
Hydraulic System, Oil Change....1522
Bleeding the Hydraulic Oil Tank....1523
Cooling System, Checking the Antifreeze Content of the Coolant....1523
Checking the Cooling System....1523
Checking the Fuel Pump....1523
Checking the Fuel and Coolant Tubes, Replacing the Tubes (if required)....1523
Checking the Water Pump....1524
Checking and Adjusting the Fuel Injection and Injection time....1524
Technical Data....1525
Technical Data....1526
Noise Emission Levels....1527
Vibration Level....1527
Limit Values for Slopes....1527
Special Equipment and Attachments....1529
ALS-Electronics....1530
Structure and Functioning Principle of the ALS-Electronics....1530
Precautionary Measures for Switching on the ALS Electronics....1530
Operation of the ALS-Electronics....1531
Handling of the Pressure Accumulator....1532
Index....1533
VEAM960200 - Wheel Loader WA85-3 Operation & Maintenance Manual....1538
COVER....1538
Table of Contents....1544
Introduction....1552
1. Forword....1553
2. Safety Information....1554
3. Introduction....1555
3.1 Features....1555
3.2 Breaking in a New Machine....1555
4. Location of Plates, Table to Enter Serial No. and Distributor....1556
4.1 Machine Serial No. Plate position....1556
4.2 Engine Serial No. Plate Position....1556
4.3 Table to Enter Serial No. and Distributor....1556
5. Why You Should Read these Operating Instructions....1557
6. Notes on Safety Regulations....1558
6.1 Correct Use....1558
6.2 Safety Notes in the Operating Instructions....1558
7. Equipment....1559
Loading and Transporting the Machine....1562
8. Loading and Transporting the Machine....1563
8.1 Securing the Articulated Steering....1563
8.2 Lifting the Machine....1563
8.3 Driving Machine Onto Loading Area of Transport Vehicle....1565
8.4 Securing the Machine During Transport....1566
8.5 After Transport....1566
Safety....1568
9. General Safety Measures....1570
9.1 Safety Instructions....1570
9.2 Safety Devices....1570
9.3 Emergency Exit....1570
9.4 Clothing and Personal Protection....1571
9.5 Machine Modifications....1571
9.6 Before You Leave the Driver's Seat....1571
9.7 Mounting and Dismounting....1571
9.8 Fire Prevention and Fire Fighting....1572
9.8.1 Fire Extinguisher and First-Aid Kit....1573
9.9 Protection Against Asbestos Dust....1573
9.10 Protection Against Injuries....1574
9.11 Working at High Temperatures....1574
9.12 Roll-Over Protection System (ROPS)....1575
9.13 Attachment for Protection Against Falling Objects (FOPS)....1575
9.14 Attachments....1575
9.15 Battery....1576
10. Safety Measures during Operation....1577
10.1 Before You Start the Engine....1577
10.1.1 Workplace Safety....1577
10.1.2 In the Driver's Cab....1577
10.1.3 In-Door Operation....1578
10.1.4 Gas, Dust, and Inflammable Vapours....1578
10.1.5 Mirrors, Windows, and Lighting....1578
10.2 Machine Operation....1579
10.2.1 Before You Start the Engine....1579
10.2.2 Reversing....1579
10.2.3 Driving....1580
10.2.4 Driving On Slopes....1580
10.2.5 Emergency Lowering System....1581
10.2.6 Working Close to Overhead Power Transmission Lines....1581
1 - Do not leave the driver's cab. The driver's cab is a "Faraday cage" protecting you from elect...1582
2 - Warn other persons and tell them to stay far away from both the power line and your machine...1582
3 - Try to move the machine out of the range of influence of the overhead power transmission line...1582
4 - Have the power in the line switched off...1582
10.2.7 Loading....1582
1 - First, dump a heap of earth in front of the hill...1582
2 - Fill the bucket with earth again and drive the machine into the heap of earth. Dump the bucke...1582
10.2.8 Good Vision....1582
10.2.9 Working On Snow....1582
10.2.10 Height Limitation....1582
10.2.11 Brakes....1583
10.2.12 Working On Loose Soil....1583
10.2.13 Working with the Forklift Truck Attachment....1584
10.2.14 Parking the Machine....1585
10.3 Transport....1586
10.3.1 Loading and Unloading the Machine....1586
10.3.2 Transport....1586
11. Safety Measures During Maintenance....1587
11.1 Personnel....1587
11.2 Prior to Start of Maintenance Measures....1587
11.2.1 Warning Sign....1587
11.2.2 Tools....1587
11.2.3 Safety-Related Parts....1587
11.2.4 Prior to Start of Inspection and Maintenance....1588
11.2.5 Securing the Articulated Steering....1588
11.2.6 Supporting the Work Unit....1588
1 - Park the machine on even ground...1588
2 - Apply the parking brake...1588
3 - Place wheel chocks in front of the wheels to prevent the machine from rolling away...1588
4 - Lower the cutting edge or the teeth of the completely empty bucket onto the ground...1588
11.3 During Maintenance....1589
11.3.1 Attachments....1589
11.3.2 Working Under the Machine....1589
11.3.3 Keeping the Machine Clean....1589
11.3.4 Specific Measures....1589
11.3.5 Refueling and Topping Off Oil....1590
11.3.6 Coolant....1590
11.3.7 Use of Lighting....1591
11.3.8 High-Pressure Hoses....1591
11.3.9 Handling High-Pressure Oil....1591
11.3.10 Fan and Belts....1592
11.3.11 Waste Material....1592
11.4 Tires....1593
11.4.1 Storing Tires....1593
12. Labeling....1594
12.1 Position of Safety Labels....1594
12.2 Position of Standard Labels....1596
1 - Instrument panel....1600
2 - Horn button....1600
3 - Light switch....1600
4 - Direction indicator lever....1600
5 - Inch-brake pedal....1600
6 - Unlocking system of left door....1600
7 - Parking brake....1600
8 - Safety lever for work hydraulic system....1600
9 - Steering column adjustment....1600
10 - Driving direction switch....1600
11 - Multifunctional lever....1600
12 - Control lever for special equipment....1600
13 - Accelerator pedal....1600
14 - Socket....1600
15 - Unlocking system of right door....1600
16 - Car radio (Option)....1600
17 - Lever of emergency lowering system....1600
1 - Rocker arm....1599
2 - Bucket cylinder....1599
3 - Bucket....1599
4 - Boom....1599
5 - Front wheel....1599
6 - Lift cylinder....1599
7 - Head lamp....1599
8 - Rear wheel....1599
Controls and InDicators....1598
13. General View of Machine....1599
14. Controls and Indicators....1600
14.1 General View....1600
14.1.1 SWITCHES AND CONTROLS....1601
14.2 Instrument Panel....1602
14.3 Warning Lights....1603
1 - Brake fluid warning light....1603
2 - Air filter warning light....1603
3 - Parking brake warning light....1603
4 - Charging current warning light....1603
5 - Engine oil-pressure warning light....1603
14.4 Control Lamps....1606
1 - Driving direction switch indicator....1606
2 - Direction indicator control lamp....1606
3 - Air preheater control lamp....1606
4 - Heated rear windscreen indicator....1606
5 - High beam control lamp....1606
6 - Low beam control lamp....1606
14.5 Measuring Indicators....1609
1 - Fuel level indicator....1609
2 - Operating hour meter....1609
3 - Coolant temperature indicator....1609
14.6 Switches....1611
1 - Switch and control lamp of hazard flashers....1611
2 - Switch of front windscreen wiper and washer....1611
3 - Switch of rear windscreen wiper and washer....1611
4 - Direction indicator lever....1611
5 - Horn button....1611
6 - Light switch....1611
7 - Driving direction switch....1611
8 - Start switch....1611
9 - Fan rotary switch, for ventilation and heating....1611
10 - Heating temperature switch....1611
11 - Heated rear windscreen switch....1611
12 - Switch and control lamp for driving range up to 12.43 mph (20 km/h)....1611
13 - Working lights switch and control lamp....1611
14 - Switch for inside lighting (without fig.)....1611
15 - Battery main switch (option, without fig.)....1611
14.7 Control Levers, Pedals....1617
1 - Brake pedal....1617
2 - Parking brake....1617
3 - Safety lever to close or open the work hydraulic system....1617
4 - Steering column adjustment....1617
5 - Accelerator pedal....1617
6 - Multifunctional lever....1617
7 - Control lever for special equipment....1617
8 - Switching lever for bucket (without fig.)....1617
14.8 Articulated Steering Catch....1622
14.9 Traction Device....1622
14.10 Socket....1622
14.11 Door Unlocking System....1623
14.12 Alarm Horn for Reverse Driving....1623
20 - Brake fluid warning light....1601
21 - Air filter warning light....1601
22 - Parking brake warning light....1601
23 - Charging current warning light....1601
24 - Driving direction switch indicators....1601
25 - Engine oil-pressure warning light....1601
26 - Direction indicator control lamp....1601
27 - Air preheater control lamp....1601
28 - Heated rear windscreen indicator....1601
29 - Working lights switch and control lamp....1601
30 - Driving range switch and control lamp for speed up to 12.43 mph (20 km/h)....1601
31 - Coolant temperature indicator....1601
32 - Operating hour meter....1601
33 - High beam control lamp....1601
34 - Low beam control lamp....1601
35 - Fuel supply indicator....1601
36 - Rear windscreen wiper switch and washer....1601
37 - Front windscreen wiper switch and washer....1601
38 - Hazard flasher switch and control lamp....1601
Operation....1624
15. Running in the Machine....1625
16. Preparing the Machine Start....1626
16.1 Visual Checks....1626
16.1.1 Before you start the engine....1626
16.1.2 Before starting working with the machine....1626
17. Adjustments Prior to Machine Start....1628
17.1 Adjusting the Driver’s Seat....1628
17.2 Adjusting the Steering Column....1629
1 - Push down the locking lever (2)...1629
2 - Adjust it in such a way that you can reach the steering wheel from a comfortable seating posi...1629
3 - Pull up the locking lever again to lock the steering column in this position...1629
17.3 Adjusting the Armrest....1629
1 - Loosen the screw (2)...1629
2 - Either pull out or push back the armrest to reach the multifunctional lever. Your forearm sho...1629
3 - Re-tighten the screw...1629
17.4 Adjusting the Rear-View Mirrors....1629
17.5 Adjusting the Heating and Ventilation System....1630
17.5.1 Adjusting the ventilation system....1630
17.5.2 Adjusting the heating system....1630
17.6 Putting on the Safety Belt....1631
17.6.1 Putting on the safety belt....1631
1 - Sit down on the driver's seat...1631
2 - Slowly and continuously pull out the belt...1631
3 - Insert the lock tongue into the lock socket until the lock engages...1631
4 - Then, pull the belt to check whether or not the lock tongue is fully engaged...1631
17.6.2 Taking off the safety belt....1631
18. Starting and Switching Off the Engine....1632
18.1 Starting the Engine....1632
1 - Ensure parking brake is engaged...1632
2 - Set the drive direction switch to its neutral position ‘N’...1632
3 - Turn the ignition key into the operating position ‘I’. The fuel supply (1) is indicated. The ...1632
4 - Press down slightly the accelerator pedal...1632
5 - If the control lamp of the air preheater has gone out, you can turn the ignition key to the s...1632
6 - Release the ignition key as soon as the engine started. It automatically returns to the opera...1632
7 - Check whether all warning lights have gone out...1632
18.1.1 Warming up the engine....1633
1 - Press down slightly the accelerator pedal and let the engine run without load at medium speed...1633
2 - Proceed as follows in order to heat up the hydraulic oil at low ambient temperatures: Allow t...1633
3 - While the engine is warming up, observe all measuring instruments and warning lights and elim...1633
4 - Let the engine run with lightweight load further until the engine coolant temperature indicat...1633
5 - Ensure that the exhaust gas colour is normal and that the exhaust pipe produces neither abnor...1633
18.2 Switching Off the Engine....1634
1 - Check the temperature of the engine with the help of the coolant temperature indicator (1)...1634
2 - If the engine is overheated, you must let it run at medium speed or 5 minutes before you swit...1634
3 - Lower the work unit...1634
4 - Turn the ignition key into its stop position ‘0’ in order to switch off the engine...1634
5 - Pull the ignition key from the start switch...1634
19. Driving....1635
19.1 Start-Up....1635
1 - Start up the engine as described in chapter "18.1 Starting the Engine"...1635
2 - Release the work hydraulic system by setting the locking lever of the work hydraulic system t...1635
3 - Raise the work unit to its transport position. If the work unit is in transport position, the...1635
4 - Press down the brake pedal and hold it in this position...1635
5 - Release the parking brake. Press the celebration adjustment knob to this at the parking brake...1635
6 - Set the drive direction switch to the desired direction setting...1635
7 - Release the brake pedal and press down the accelerator pedal at the same time in order to sta...1635
19.1.1 Starting the machine on slopes....1636
1 - Start up the engine as described in chapter "18. Starting and Switching Off the Engine"...1636
2 - Make sure that the parking brake is pulled. The parking brake warning light lights up...1636
3 - Press down the brake pedal...1636
4 - Release the parking brake...1636
5 - Set the drive direction switch to the desired direction setting...1636
6 - Press down the accelerator pedal and release slowly the brake pedal at the same time in order...1636
19.2 Changing the Driving Direction....1636
19.3 Reverse Driving....1637
19.4 Turning....1637
19.4.1 Turning on slopes, embankments or hill flanks....1637
19.5 Braking....1638
19.5.1 Pulling the parking brake....1638
1 - Press the locking button...1638
2 - Pull up the parking brake lever...1638
3 - Release the locking button. The control lamp of the parking brake lights up...1638
19.5.2 Releasing the parking brake....1638
1 - Lift up the parking brake lever a little...1638
2 - Press the locking button...1638
3 - Push the parking brake lever down...1638
4 - Release the locking button. The control lamp of the parking brake goes out...1638
19.5.3 Braking with the service brake....1638
19.5.4 If the service brake breaks down....1638
19.5.5 Braking on slopes....1639
19.6 Stopping....1639
1 - Release the accelerator pedal and press down the brake pedal...1639
2 - Set the drive direction switch into its neutral position ‘N’...1639
3 - Apply the parking brake...1639
4 - Lower the work unit onto the ground...1639
5 - Protect the work hydraulic system against unintentional activation by turning the locking lev...1639
19.6.1 Parking the machine on a slope....1639
19.7 Longer-Distance Driving....1640
20. Operating the Machine....1641
20.1 Preparing the Work Equipment....1641
20.1.1 Selecting a work unit....1641
20.1.2 Picking up the work unit (except multi-purpose bucket)....1641
1 - Make sure that the change-over lever for the additional control unit is in position '2' (fig....1641
2 - Start the engine...1641
3 - Unlock the quick-change unit by setting the control lever for special equipment into position...1641
4 - Lift the boom slightly by setting the multi-function lever into position ‘H’ (fig. 75_016)...1641
5 - Tilt the quick-change unit slightly to the front by setting the multi-function lever into pos...1641
6 - Drive the machine to the work unit until the quick-change unit (3) is below the pickup hooks ...1641
7 - Tip in the quick-change unit until the work unit is connected to the limit stops on the the q...1641
8 - Lock the quick-change unit by setting the control lever for special equipment into position ‘...1641
9 - Check whether the work unit is completely locked in by tipping it in and then dumping it...1641
20.1.3 Removing the work unit....1642
1 - Lower the work unit onto level ground...1642
2 - Unlock the quick-change unit by setting the control lever for special equipment into position...1642
3 - Set the quick-change unit into the dumping position ‘A’ (fig. 75_016) using the multi-functio...1642
4 - Make sure that nobody is behind the machine and drive the machine away from the work unit...1642
20.1.4 Picking up the multi-purpose bucket....1642
1 - Set the change-over lever for the additional control unit into position '2' (fig. 75_160)...1642
2 - Start the engine...1642
3 - Unlock the quick-change unit by setting the control lever for special equipment into position...1642
4 - Lift the boom slightly by setting the multi-function lever into position ‘H’ (fig. 75_016)...1642
5 - Tilt the quick-change unit slightly to the front by setting the multi-function lever into pos...1642
6 - Drive the machine to the work unit until the quick-change unit (1) is below the pickup hooks ...1642
7 - Tip in the quick-change unit until the work unit is connected to the limit stops on the the q...1642
8 - Lock the quick-change unit by setting the control lever for special equipment into position ‘...1642
9 - Connect the hydraulic hoses of the multi-purpose bucket to the quick attach couplers (2) (fig...1643
10 - Lock the quick-change unit by setting the control lever for special equipment into position ...1643
11 - Set the change-over lever for the additional control circuit into position '1' (fig. 75_160)...1643
12 - Check whether the work unit is completely locked in by tipping it in and then dumping it...1643
20.1.5 Removing the multi-purpose bucket....1644
1 - Lower the multi-purpose bucket onto level ground...1644
2 - Turn the change-over lever for the additional control circuit to position ‘2’ (fig. 75_160)...1644
3 - Unlock the quick-change unit by setting the control lever for special equipment into position...1644
4 - Loosen the hydraulic hoses of the multi-purpose bucket from the quick attach couplers...1644
5 - Set the quick-change unit into the dumping position ‘A’ (fig. 75_016) using the multi-functio...1644
6 - Make sure that nobody is behind the machine and drive the machine away from the work unit...1644
20.2 Tire Service Life....1645
20.2.1 Level indicator for the bucket....1645
20.3 Loading....1646
20.3.1 Removing piled up soil....1646
1 - Drive in straight line to the piled up soil...1646
2 - While driving forward, lower the bucket rapidly until it reaches a height of approx. 11.8 in ...1646
3 - Then, proceed with slowly lowering the bucket onto the ground...1646
4 - Brake right in front of the material to be removed using the service brake, while pressing do...1646
5 - Press down the accelerator pedal and drive the bucket into the material to be removed. In ord...1647
6 - To prevent that the bucket digs in too deep into the material to be removed, you must lift th...1647
7 - Tip in the bucket...1647
8 - If there is too much material inside the bucket, you must briefly tip it in, dump it and lowe...1647
20.3.2 Excavation works....1648
1 - Drive up to the soil heap in a straight line...1648
2 - Slow down the machine using the service brake while keeping the accelerator pedal pressed dow...1648
3 - Bend the bucket edge slightly down...1648
4 - While driving forward, move slightly the multi-function lever of the boom in order to remove ...1648
5 - Move the multi-function lever of the boom slightly up and down to reduce the resistance durin...1648
20.4 Transporting....1649
20.5 Dumping / Unloading....1649
20.5.1 Loading in diagonal direction....1649
20.5.2 V-shaped loading....1650
20.5.3 Piling up material....1650
20.6 Planing....1651
20.6.1 Filling up....1651
20.6.2 Taking off soil....1651
20.6.3 Cutting the Ground....1651
20.7 Working With the Forklift Truck Attachment....1652
20.7.1 Picking up the load....1652
1 - Approach slowly the load to be picked up...1652
2 - Drive so far under the load until it touches the fork back of the forklift truck attachment...1652
3 - Tip in slightly the forklift truck attachment so that the load cannot fall down...1652
4 - Lower the boom to its transport position. The two red arrows of the transport position markin...1652
5 - Then lift the load to the appropriate height only shortly before you reach the stacking surfa...1652
6 - Set the load surface slowly and from above onto the stacking...1652
7 - Slowly lower the boom so far that you can pull out the fork tines below the load...1652
8 - Make sure that nobody is behind the machine and drive off backwards from the deposit surface...1652
20.8 Precautions For Special Operations....1653
20.8.1 Working in water....1653
20.8.2 Working on snow....1653
20.8.3 Dumping on steep slopes....1653
20.8.4 Working in the vicinity of electrical overhead lines....1653
20.8.5 Operation on slopes....1653
20.8.6 Working on loose soil....1653
20.9 After the work is finished....1653
1 - Walk around the machine and visually inspect the work unit, the car body and the chassis. In ...1653
2 - Fill up the fuel tank...1653
3 - Remove highly flammable material from the engine room since it represents a fire risk...1653
4 - Clean roughly the chassis landing gear...1653
20.10 Instructions for Winter Operation....1654
20.10.1 Before the cold season....1654
20.10.2 After Operation....1654
20.10.3 After the cold season....1654
20.11 Longer Standstill Periods of the Machine....1654
20.11.1 Before the standstill....1654
20.11.2 During the standstill....1655
20.11.3 After the standstill....1655
Troubleshooting....1656
21. Troubleshooting....1657
21.1 Warning Lights and Indicators....1657
21.2 Electrical System....1658
21.3 Engine....1659
21.4 Hydraulic system....1662
21.5 Brakes....1664
21.6 Axles....1665
21.7 Emergency Steering Characteristics....1666
21.8 Emergency Lowering System....1666
1 - Ensure that nobody is standing under the work unit...1666
2 - Turn the lever of the emergency lowering system to position '2'. The work unit is lowered, or...1666
3 - Turn the lever of the emergency lowering system back to position '1'...1666
21.9 Starting the Engine with a Battery Jumper Cable....1667
21.9.1 Connecting the Jumper Cable....1667
1 - Turn the start switch of the defective machine to '0' (OFF)...1667
2 - Connect one clamp of the battery jumper cable to the positive terminal (+) of the discharged ...1667
3 - Connect the other clamp of the battery jumper cable to the positive terminal (+) of the charg...1667
4 - Connect one clamp of the battery jumper cable to the negative terminal (-) of the charged bat...1667
5 - Connect the other clamp of the battery jumper cable to the engine block of the machine with t...1667
21.10 Starting the Engine....1668
21.10.1 Disconnecting the Battery Jumper Cable....1668
1 - Disconnect one clamp of the battery jumper cable from the engine block...1668
2 - Disconnect the other clamp of the battery jumper cable from the negative terminal (-) of the ...1668
3 - Disconnect the clamp of the battery jumper cable from the positive terminal (+) of the charge...1668
4 - Disconnect the other clamp of the battery jumper cable from the positive terminal (+) of the ...1668
21.11 Towing the Machine....1669
1 - Set the driving-direction switch to position 'N'...1669
2 - Loosen both screws (1) and remove the cover plate (2)...1669
3 - Remove protecting caps from the valves...1669
4 - Hold the valve (3) in position, using a wrench...1669
5 - Loosen the counter-nut (4) an re-insert the threaded stud (5) clockwise, using a hexagonal so...1669
6 - Re-tighten firmly the counter-nut (4). Perform these operations on both valves...1669
21.12 Towing a Machine with Defective Brakes....1670
Maintenance....1672
22. Maintenance Basics....1673
22.1 Preparing the Machine for Maintenance....1673
1 - Park the machine on solid and level ground...1673
2 - Set the machine to the specified position for maintenance and repair...1673
3 - Lower the work unit to the ground and position it as shown in the drawing...1673
4 - Set all control levers to either the neutral or the hold position '0'...1673
5 - Turn the safety lever of the work hydraulic system to position '1'...1673
6 - Take out the start key and store it in a safe place...1673
7 - Apply the parking brake...1673
8 - Apply the warning sign you received together with the tools at the start switch...1673
9 - Put wheel chocks in front and behind the wheels...1673
10 - Secure the articulated steering with the articulated steering catch...1673
11 - If required, remove dirt...1673
22.2 Cleaning the Machine....1674
1 - Park the machine on level ground...1674
2 - Apply the parking brake...1674
3 - Place wheel chocks in front of the wheels to prevent the machine from rolling away...1674
4 - With the bucket in its dumping position, lower the bucket onto the ground with either its cut...1674
22.2.1 Precautionary Measures When Cleaning the Machine....1674
22.2.2 Fire Prevention....1674
22.3 Working-Area-Dependent Maintenance....1674
22.3.1 Muddy or Wet Working Areas....1674
22.3.2 Dusty Working Areas....1674
22.4 Lubricants and Operating Agents....1675
22.4.1 Draining Hot Lubricants and Fluids....1675
22.4.2 Checking the Oil Level and Changing Oil....1675
22.4.3 Changing Filters....1675
22.4.4 Refuelling and Topping off Oil....1675
22.4.5 Oil....1675
22.4.6 Lubricating Grease....1676
22.4.7 Biodegradable Hydraulic Oil and Lubricating Grease....1676
22.4.8 Fuel....1676
22.4.9 Storage of Oil and Fuel....1676
22.4.10 Coolants....1677
22.4.11 Windscreen Washer Liquid....1677
22.4.12 Table of Lubricants and Operating Agents....1679
22.4.13 Lubrication chart....1680
22.5 Replacing Safety-Related Parts....1681
22.5.1 Welding Instructions....1681
22.6 Spare Parts and Consumable Components....1682
22.7 Electrical System....1683
1 - Checking the tension of the generator belt,....1683
2 - Checking the generator belt for damage and wear, and....1683
3 - Checking the acid level in the battery...1683
22.7.1 Fuses....1683
22.7.2 Fuse Assignment....1683
22.7.3 Slow-Blowing Fuses....1684
22.8 Tires....1685
22.8.1 Tire Components....1685
1 - Steel Cord Belt....1685
2 - Radial Carcass....1685
3 - Bead Core....1685
4 - Liner....1685
5 - Diagonal Carcass....1685
6 - Bead Cores....1685
22.8.2 Checking the Tires....1685
22.8.3 Checking the Tire Pressure....1685
22.9 Tools....1687
22.10 Torque for Standard Nuts and Bolts....1688
23. Maintenance Schedule....1690
24. Maintenance Prior to Start....1692
24.1 Visual Checks....1692
24.2 Cooling System, Checking the Coolant Level, Topping off Coolant....1692
1 - Open the engine hood...1692
2 - Check whether the coolant level in the expansion tank is between the FULL and LOW markings. I...1692
3 - Remove the cover cap of the overflow tank...1692
4 - Top coolant until the level reaches up to the FULL marking...1692
5 - After topping, firmly close the cover cap. If the expansion tank is empty again after a short...1692
24.3 Engine, Checking the Oil Level, Topping off Oil....1693
1 - Pull out the oil dipstick (1) and wipe off the oil with a clean cloth...1693
2 - Completely re-insert the oil dipstick and pull it out again after a few seconds. The oil leve...1693
3 - If the oil level does not reach up to the (L) marking, top off engine oil...1693
4 - Wait three minutes before you check the oil level again. If the oil level is above the (H) ma...1693
5 - Close the oil filler (2)...1693
24.4 Engine, Draining Off Oil....1694
1 - Loosen the screw (1) at the bottom cover plate (2) and swivel the cover plate to the side...1694
2 - Put the oil trough to pan...1694
3 - Remove the cover cap (3) of the drain screw...1694
4 - Unscrew the drain screw (4)...1694
5 - Let the excess oil flow off...1694
6 - Screw in the drain screw...1694
7 - Check the oil level again...1694
8 - Put on the cover cap...1694
9 - Fasten the bottom cover plate with the screw...1694
24.5 Checking the Fuel Level, Refueling....1695
1 - Turn the start switch to the operating position 'I' and check the fuel level indicated on the...1695
2 - Then, return the start switch to the stop position '0'...1695
3 - If required, refuel via the filler (1)...1695
4 - After refueling, firmly close the filler...1695
24.6 Checking the Controls....1696
1 - Turn the start switch to the operating position 'I'...1696
2 - Check that the following alarm and control indicators are on until the engine is started:....1696
3 - Check that the fuel level indicator (5) indicates the fuel level in the fuel tank...1696
24.7 Checking the Parking Brake....1697
24.7.1 Test Conditions....1697
24.7.2 Test Procedure....1697
1 - Start the engine, set the machine to straight driving, and drive the machine with an empty bu...1697
2 - Stop the machine with the service brake and do not release your foot again to keep the servic...1697
3 - Lower the bucket...1697
4 - Set the driving direction switch (1) to its neutral position 'N'...1697
5 - Switch off the engine...1697
6 - Apply the parking brake (2) and slowly release the pedal of the service brake...1697
24.8 CHecking the Service Brake....1697
24.9 Checking the Electrical Connections....1698
24.10 Other Maintenance Measures Prior to Start....1698
25. Maintenance Every 10 Operating Hours....1699
25.1 Lubrication....1699
1 - Before you start maintenance work, park and secure the machine as described in the chapter "1...1699
2 - Clean the grease nipples marked by arrows...1699
3 - Use a grease gun to fill the grease nipples with a sufficient volume of lubricating grease...1699
4 - Remove the used lubricating grease that is pressed out of the bearings...1699
26. Maintenance After the First 50 Operating Hours....1700
26.1 Engine, Changing Oil and Replacing the Oil Filter Cartridge....1700
1 - Before you start maintenance work, park and secure the machine as described in the chapter "2...1700
2 - Loosen the screw (1) at the bottom cover plate (2) and swivel the cover plate to the side...1700
3 - Put the oil trough under the drain screw (4)...1700
4 - Remove the cover cap (3) of the drain screw...1700
5 - Screw the drain hose (5) onto the drain plug (4). This will at the same time cause the drain ...1700
6 - Let the oil drain off into the oil trough...1700
7 - Check the removed oil for metal parts or undesired material. If the oil contains such particl...1700
8 - Remove the drain hose (5), this will cause the drain valve (4) to close...1700
9 - Screw on the cover cap (3)...1700
10 - Fasten the bottom cover plate with the screw...1700
26.1.1 Replacing the Oil Filter Cartridge....1701
11 - Turn the filter screwdriver counterclockwise to unscrew the filter cartridge (1)...1701
12 - Clean the filter holder. Completely fill up the new filter cartridge with engine oil. Slight...1701
13 - When installing the filter cartridge, make sure that the sealing surface of the cartridge sl...1701
14 - After replacing the filter cartridge, fill in clean engine oil until the oil level reaches u...1701
15 - Close the oil filler (2)...1701
16 - Let the engine run in idle for about five minutes and check whether oil is leaking out...1701
17 - Switch off the engine...1701
18 - Wait about ten minutes, then check the oil level again. The oil level must be between the 'H...1701
26.2 V-Belt, Checking the Condition....1702
26.3 V-Belt, Checking and Adjusting the Tension....1702
1 - Before you start maintenance work, park and secure the machine as described in the chapter "2...1702
2 - Press down the V-belt in the middle of the longest straight part. You should be able to press...1702
3 - Loosen the fastening screw (1) at the generator...1702
4 - Loosen the connecting screw (2) between the generator and the guide rail...1702
5 - Loosen the fastening screw (3) at the guide rail...1702
6 - Tilt the generator to adjust the tension of the V-belt...1702
7 - Fasten the generator and the guide rail...1702
8 - Check the tension of the V-belt and re-adjust it, if required...1702
26.4 Hydraulic System, Replacing the Filter Insert....1703
1 - Lower the work equipment onto the floor...1703
2 - Park the machine...1703
3 - Turn the inlet and ventilation screw (1) several revolutions to let the pressure escape...1703
4 - Clean the surface of the filter cap (2) and the area around the filter cap...1703
5 - Unscrew the filter cap...1703
6 - Pull out the filter element (3) at the handle (4) ...1703
7 - Pull the filter element off the handle and dispose of the filter element...1703
8 - Clean the inner surface of the filter housing. Before you start cleaning, check that there is...1703
9 - Put the handle onto the new filter element...1703
10 - Insert the new filter element into the housing...1703
11 - Screw on the filter cap and tighten it with 2.039 kgm (20 Nm)...1703
12 - Ventilate the system at the tank according to the specification (see "32.2 Bleeding the Hydr...1703
13 - Perform a test run and check that the system is tight...1703
26.5 Checking and Tightening the Wheel Nuts....1704
26.6 Front and Rear Axle, Changing Oil....1705
26.6.1 Planet gear....1705
1 - Move the machine until the check drill hole (1) of the planet gear at the wheel that you want...1705
2 - Put the oil trough under the oil discharge hole...1705
3 - Unscrew the screw plug (1) and let the oil flow off...1705
4 - Turn the wheel to bring the drill hole of the planet gear into horizontal position...1705
5 - Top up the planet gear with oil, until the oil reaches up to the bottom edge of the check dri...1705
6 - Clean the screw plug and replace the gaskets...1705
7 - Re-tighten firmly the screw plug...1705
8 - Change the oil in the planet gear for the other wheel as described under the points 3 through 7...1705
26.6.2 Differential....1705
1 - Unscrew the screw plugs (1) and (2) at the front axle and let the oil flow off...1705
2 - Clean the screw plugs and replace the gaskets...1705
3 - Re-tighten firmly the screw plug...1705
4 - Top up with oil, until the oil reaches up to the bottom edge of the check drill hole of screw...1705
5 - Re-tighten firmly the screw plug (2)...1705
6 - Unscrew the screw plugs (4) and (5) at the rear axle and let the oil flow off. Then, proceed ...1705
26.7 Transfer Gear - Changing Oil....1706
1 - Before you start maintenance work, park and secure the machine as described in the chapter "2...1706
2 - Clean the surfaces of the screw plugs (1) and (2) and the area around the screw plugs...1706
3 - Unscrew the screw plugs...1706
4 - Let the oil flow off...1706
5 - Clean the screw plugs and replace the gaskets...1706
6 - Tightly screw in the screw plug (2)...1706
7 - Fill in oil via the check drill hole (1), until the oil reaches up to the bottom edge of the ...1706
8 - Tightly screw in the screw plug (1)...1706
27. Maintenance Every 50 Operating Hours....1707
27.1 Checking the cooling System, coolant level in the radiator and expansion tank....1707
1 - Stop the engine and let it cool down...1707
2 - Open the engine cover...1707
3 - Turn the radiator cap (arrow) slowly to the first stop and let the pressure escape. Then pres...1707
4 - Check that the radiator is filled up to the overflow with coolant. If not then top off to the...1707
5 - After topping off, fit the radiator cap and tighten...1707
6 - Check that the coolant level in the expansion tank is between the marks full and low...1707
7 - Top off to the full mark if required...1707
8 - After topping off, refit the tank cap and tighten...1707
27.2 Draining Off Water and Dirt Deposits From the Fuel Tank....1708
1 - Place a container under the drain plug of the fuel tank (see arrow)...1708
2 - Open the drain plug, drain off water and dirt...1708
3 - Close the drain plug when clean fuel starts to leak out...1708
27.3 Checking the Service Brake and Oil Level, Refilling Oil....1708
1 - For maintenance operations, park and secure machine as described in chapter "22.1 Preparing t...1708
2 - Check the brake fluid level at the expansion tank. The oil level must be 0.394 in (10 mm) to ...1708
3 - If the oil level is too low, fill prescribed oil into the expansion tank...1708
4 - If you detect a significant oil loss, inform your local Komatsu dealer...1708
27.4 Checking the Battery and Acid Level....1709
1 - For maintenance operations, park and secure the machine as described in chapter "22.1 Prepari...1709
2 - Check the battery and pole terminals for proper fit...1709
3 - Clean the environment of the plugs...1709
4 - Remove all plugs and check whether the battery acid is at the acid level markings. Refill dis...1709
5 - Measure the specific density of the battery acid and read off the battery charging using the ...1709
6 - Recharge insufficiently charged batteries...1709
7 - Lock the cells with the cleaned plugs.Re-Charging the Battery....1709
27.4.1 Re-charging a built-in battery....1710
1 - The battery may be overheated....1710
2 - Decrease in the battery acid volume....1710
3 - Damage of the electrode plates...1710
27.5 Lubrication....1711
27.5.1 Lubricating points of the work equipment....1711
1 - Park and secure machine for the maintenance operations as described in chapter "22.1 Preparin...1711
2 - Clean the grease nipples which are indicated by the arrows...1711
3 - Use a grease gun to press sufficient grease into the grease nipples...1711
4 - Remove the old grease which is extruding at the bearings...1711
28. Maintenance Every 100 Operating Hours....1712
28.1 Draining the Water Separator, Removing Water and Dirt Deposits....1712
1 - Screw out the drain plug (2)...1712
2 - Let the water run off...1712
3 - Screw in the drain plug and tight it...1712
4 - Check for tightness...1712
29. Maintenance Every 250 Operating Hours....1713
29.1 Changing the Engine Oil and Oil Filter Cartridge....1713
29.2 Checking the V-Belt Condition....1713
29.3 Checking and Adjusting the V-belt Tension....1713
29.4 Lubrication....1713
29.4.1 Lubricating points of the steering cylinder....1713
1 - For maintenance operations, park the machine as described in chapter "22.1 Preparing the Mach...1713
2 - Clean the grease nipples which are indicated by the arrows...1713
3 - Use a grease gun to press sufficient grease into the grease nipples...1713
4 - Remove the old grease which is extruding at the bearings...1713
29.5 Front and Rear Axle, Checking the Oil Level....1714
29.5.1 Planet gear....1714
1 - Move the machine until the oil level marking at the planetary gearing of the wheel which you ...1714
2 - Unscrew the locking screw (1) of the drill hole...1714
3 - Check the oil level. The oil level must reach up to the bottom edge of the check drill hole...1714
4 - If the oil level is too low, top off oil via the check drill hole of the screw plug. For deta...1714
5 - Tightly screw in the screw plug...1714
6 - Check the oil level at the other wheel of the front and rear axle. For this purpose, proceed ...1714
29.5.2 Differential....1714
1 - Unscrew the locking screw (2) of the drill hole at the front axle. Check the oil level as des...1714
2 - Unscrew the locking screw (2) of the drill hole at the rear axle. Check the oil level as desc...1714
29.6 Air Filter, Removing and Re-Installing the Filter Insert, Checking and Cleaning the Filter I...1715
29.6.1 Structure of the air filter....1715
29.6.2 Maintenance demand....1715
29.6.3 Removing the filter cartridge....1715
1 - For maintenance operations, park and secure machine as described in chapter "22.1 Preparing t...1715
2 - Open the twistlocks on the cover of the air filter housing (2)...1715
3 - Remove the cover of air filter housing...1715
4 - Pull out the filter cartridge (3)...1715
29.6.4 Cleaning or exchanging the filter cartridge....1716
29.6.5 Checking the filter cartridge....1717
29.6.6 Assembling the air filter cartridge....1717
1 - Check the safety filter for proper fit...1717
2 - Insert the filter cartridge into filter housing in such a way that the seal of the insert loc...1717
3 - Assemble the air filter cap...1717
29.7 Cleaning the Radiator Segments....1717
30. Maintenance Every 500 Operating Hours....1718
30.1 Changing the Fuel Filter and Filter Element....1718
1 - For maintenance operations, park and secure machine as described in chapter "22.1 Preparing t...1718
2 - Clean the area around the fuel filter (1)...1718
3 - Unscrew the filter element counterclockwise with the filter screwdriver...1718
4 - Clean the filter head...1718
5 - Fill up the new filter element with clean fuel...1718
6 - Lubricate the sealing faces of the filter element lightly with engine oil...1718
7 - During reassembly, re-tighten the filter element manually, until the seal is fitting. Then re...1718
8 - Then purge the fuel system...1718
9 - Start the engine and check for leaks...1718
30.1.1 Bleeding the Fuel System....1719
1 - For maintenance operations, park and secure machine as described in chapter "22.1 Preparing t...1719
2 - Loosen the vent screw (1) at the water separator...1719
3 - Unlock the fuel pump (2) by pressing the cover down and swivelling it out of the way...1719
4 - Operate fuel pump until bubble-free fuel leaks out at the vent screw...1719
5 - Re-tighten the vent screw...1719
6 - Loosen the vent screw (4) at the fuel filter (3)...1719
7 - Operate the fuel pump until bubble-free fuel leaks out at the vent screw...1719
8 - Re-tighten vent screw...1719
9 - Re-lock the cover of the fuel pump...1719
10 - Start up the engine and bleed the lines, one after the other, while engine is running until ...1719
30.2 Changing the Filter Cartridge of the Hydraulic System....1720
30.3 Cleaning the Water Separator....1720
1 - Loosen the drain plug (2)...1720
2 - Let the water and fuel run off...1720
3 - Loosen the screw (4) at the bottom side...1720
4 - Remove the housing (5) from the cover...1720
5 - Remove the gasket (6)...1720
6 - Remove the filter element (7), the gasket (8) and the spiral spring (9)...1720
7 - Remove water and dirt from the housing...1720
8 - Clean the filter element and blow-dry it with compressed air...1720
9 - Check the filter element and replace it, if it is damaged...1720
10 - Re-insert the spiral spring, the gasket (8) and the filter element...1720
11 - Position the gasket (6) and the housing...1720
12 - Insert a new o-ring (10)...1720
13 - Re-tighten the drain plug at the bottom side...1720
14 - Remove the attachment screw (3)...1720
15 - Fill up the water separator with fuel...1720
16 - Re-tighten firmly the attachment screw...1720
30.4 Lubrication....1721
1 - For maintenance operations, park and secure machine as described in chapter "22.1 Preparing t...1721
2 - Clean the grease nipples...1721
3 - Use a grease gun to press sufficient grease into the grease nipples...1721
4 - Remove the old grease which is extruding at the bearings...1721
30.5 Transfer Gear, Checking the Oil Level and Refilling Oil....1721
1 - For maintenance operations, park and secure machine as described in chapter "22.1 Preparing t...1721
2 - Clean the screw plug (1) and the adjacent environment...1721
3 - Unscrew the screw plug...1721
4 - Check the oil level. The oil level must be at the lower edge of the control drill hole of the...1721
5 - If the oil level is too low, fill up with oil using the control drill hole of the screw plug...1721
6 - Clean the screw plug and insert a new packing ring...1721
7 - Re-tighten firmly the screw plug...1721
30.6 Air Filter, Replacing the Filter Insert, Replacing the Safety Filter....1722
30.6.1 Replacing the Filter Insert....1722
1 - Open the air filter and remove the air-filter insert (1). Proceed as described in chapter "29...1722
2 - Use a lamp to check the new air filter for damages...1722
3 - Re-install the air-filter insert as described in chapter "29.6 Air Filter, Removing and Re-In...1722
30.6.2 Replacing the Safety Filter....1722
1 - Open the air filter and remove the air-filter insert (1). Proceed as described in chapter "29...1722
2 - Pull out the safety filter (2)...1722
3 - In order to prevent that dust enters the interior of the engine, it is required to the air as...1722
4 - Clean the interior of the air-filter enclosure and remove the cloth from the air aspiration o...1722
5 - Use a lamp to check the new safety filter for damages. If it is in perfect condition, press i...1722
6 - Re-install the air-filter insert as described in chapter "29.6 Air Filter, Removing and Re-In...1722
31. Maintenance Every 1000 Operating Hours....1723
31.1 Cooling System, Exchanging Coolant and Cleaning the System....1723
31.1.1 Draining off the coolant....1723
1 - Switch off the engine and let it cool down...1723
2 - Turn the radiator cap (arrow) slowly to the side, up to the first fixed stop, and let the pre...1723
3 - Stretch a tube onto the drain opening (1) of the discharge cock and insert the other tube end...1723
4 - Open the discharge cock and let the coolant run off...1723
5 - Close the discharge cock...1723
31.1.2 Cleaning the Cooling System....1724
6 - Fill up the cooling system slowly with cleaning fluid....1724
7 - With the radiator cap opened, let the engine run for 5 minutes with a coolant temperature of ...1724
8 - After the cleaning, switch off the engine and open the drain valve to let the entire cooling ...1724
9 - Let the engine run for five minutes with a coolant temperature of approx. 176F (80 C)...1724
10 - Then, let the cooling system run empty again. If the extruding water is not clean, the cooli...1724
11 - Close the drain valve...1724
31.1.3 Filling off Coolant....1724
12 - Empty and clean the expansion tank...1724
13 - Prepare the coolant as prescribed...1724
14 - Fill off the coolant slowly into the cooling system up to the overflow shoot of the radiator...1724
15 - To bleed the cooling system while the radiator cap is removed, let the engine run idle for f...1724
16 - Switch off the engine, wait approx. three minutes and then refill coolant up to overflow sho...1724
17 - Fill off coolant into the expansion tank, until the coolant level is between the FULL and LO...1724
31.2 Front Axle, Oil Change....1725
31.3 Rear Axle, Oil Change....1725
31.4 Transfer Gear, Oil Change....1725
31.5 Service Brake....1725
31.5.1 Changing oil....1725
31.5.2 Checking tubes and lines....1725
31.5.3 Checking the brake disks for wear and tear....1725
31.5.4 Adjusting the clearance of the brake disks....1725
31.6 Checking and Adjusting System Pressures....1725
31.7 Checking and Adjusting the Valve clearance....1725
31.8 Checking and Adjusting the Injection Nozzles, Nozzle Pressure and Fuel-Jet Pattern....1725
32. Maintenance Every 2000 Operating Hours....1726
32.1 Hydraulic System, Oil Change....1726
1 - Park the machine on level ground...1726
2 - Lower the work unit onto the ground...1726
3 - Switch off the engine...1726
4 - Secure the articulated steering with the articulated steering lock (1)...1726
5 - Unlock the feeding and ventilation screw (2) by turning it slowly to let the pressure escape...1726
6 - Loosen the screw plug (4) of the hydraulic oil tank and let the oil run off...1726
7 - Re-tighten the screw plug with its seal being in perfect condition...1726
8 - Unscrew the feeding and ventilation screw...1726
9 - Fill up oil until the oil level is between the center and top edge of the inspection glass (3)...1726
10 - Start up the engine...1726
11 - Raise and lower the work equipment several times, while operating the bucket at the same time...1726
12 - Lower the bucket onto the ground and bring it into mining position...1726
13 - Check the oil level with the engine running idle in its low speed position...1726
14 - Ventilate the hydraulic oil tank (see section "32.2 Bleeding the Hydraulic Oil Tank")...1726
32.2 Bleeding the Hydraulic Oil Tank....1727
1 - Loosen the feeding and ventilation screw by turning it a couple of rotations...1727
2 - Start up the engine...1727
3 - Bring the boom into its highest position...1727
4 - Bring bucket into its tip-in position (up to its limit stop)...1727
5 - Re-tighten the feeding and ventilation screw...1727
32.3 Cooling System, Checking the Antifreeze Content of the Coolant....1727
32.4 Checking the Cooling System....1727
32.5 Checking the Fuel Pump....1727
32.6 Checking the Fuel and Coolant Tubes, Replacing the Tubes (if required)....1727
32.7 Checking the Water Pump....1728
32.8 Checking and Adjusting the Fuel Injection and Injection time....1728
32.9 Engine, Intake Valves and Outlet Valves - Grinding In the Valve Bases....1728
Technical Data....1730
33. Technical Data....1731
33.1 Noise Emission Levels....1732
33.2 Vibration Level....1732
33.3 Limit Values for Slopes....1733
33.3.1 Maximum slope angle for operating the machine....1733
33.3.2 Tilting/tipping angle....1733
VEAM960400 - Wheel Loader WA85-3 Operation & Maintenance Manual....1736
Cover....1736
Table of Contents....1740
Introduction....1748
Forword....1749
Safety Information....1750
Introduction....1751
Features....1751
Breaking in a New Machine....1751
Location of Plates, Table to Enter Serial No. and Distributor....1752
Machine Serial No. Plate position....1752
Engine Serial No. Plate Position....1752
Table to Enter Serial No. and Distributor....1752
EMISSION CONTROL WARRANTY....1753
EMISSION CONTROL WARRANTY STATEMENT (APPLIES TO CANADA ONLY)....1753
Engine Data Plate....1754
GARANTIE SUR LE CONTRÔLE DES ÉMISSIONS....1755
ÉNONCÉ DE GARANTIE SUR LE CONTRÔLE DES ÉMISSIONS (APPLICABLE AU CANADA SEULEMENT):....1755
Engine Data Plate....1756
Why You Should Read these Operating Instructions....1757
Notes on Safety Regulations....1758
Correct Use....1758
Safety Notes in the Operating Instructions....1758
Equipment....1759
Loading and Transporting the Machine....1762
2....1763
Loading and Transporting the Machine....1764
Securing the Articulated Steering....1764
Lifting the Machine....1764
Driving Machine Onto Loading Area of Transport Vehicle....1766
Securing the Machine During Transport....1767
After Transport....1767
Safety....1768
3....1768
General Safety Measures....1770
Safety Instructions....1770
Safety Devices....1770
Emergency Exit....1770
Clothing and Personal Protection....1771
Machine Modifications....1771
Before You Leave the Driver's Seat....1771
Mounting and Dismounting....1771
Fire Prevention and Fire Fighting....1772
Fire Extinguisher and First-Aid Kit....1773
Protection Against Asbestos Dust....1773
Protection Against Injuries....1774
Working at High Temperatures....1774
Roll-Over Protection System (ROPS)....1775
Attachment for Protection Against Falling Objects (FOPS)....1775
Attachments....1775
Battery....1776
Safety Measures during Operation....1777
Before You Start the Engine....1777
Workplace Safety....1777
In the Driver's Cab....1777
In-Door Operation....1778
Gas, Dust, and Inflammable Vapours....1778
Mirrors, Windows, and Lighting....1778
Machine Operation....1779
Before You Start the Engine....1779
Reversing....1779
Driving....1780
Driving On Slopes....1780
Emergency Lowering System....1781
Working Close to Overhead Power Transmission Lines....1781
Loading....1782
Good Vision....1782
Working On Snow....1782
Height Limitation....1782
Brakes....1783
Working On Loose Soil....1783
Working with the Forklift Truck Attachment....1784
Parking the Machine....1785
Transport....1786
Loading and Unloading the Machine....1786
Transport....1786
Safety Measures During Maintenance....1787
Personnel....1787
Prior to Start of Maintenance Measures....1787
Warning Sign....1787
Tools....1787
Safety-Related Parts....1787
Prior to Start of Inspection and Maintenance....1788
Securing the Articulated Steering....1788
Supporting the boom....1789
During Maintenance....1790
Attachments....1790
Working Under the Machine....1790
Keeping the Machine Clean....1790
Specific Measures....1790
Refueling and Topping Off Oil....1791
Coolant....1791
Use of Lighting....1792
High-Pressure Hoses....1792
Handling High-Pressure Oil....1792
Handling of the pressure accumulator....1793
Fan and Belts....1793
Waste Material....1793
Tires....1794
Storing Tires....1794
Labeling....1795
Position of Safety Labels....1795
Information Labels....1797
Controls and InDicators....1798
4....1798
Overall View of Machine....1799
Controls and Indicators....1800
SWITCHES AND CONTROLS....1801
Instrument Panel....1802
Warning Lights....1803
Control Lamps....1806
Measuring Indicators....1810
Switches....1812
Control Levers, Pedals....1819
Articulated Steering Catch....1824
Traction Device....1824
Socket....1824
Door Unlocking System....1825
Alarm Horn for Reverse Driving....1825
Operation....1826
5....1826
Running in the Machine....1827
Preparing the Machine Start....1828
Visual Checks....1828
Before you start the engine....1828
Before starting working with the machine....1828
Adjustments Prior to Machine Start....1830
Adjusting the Driver’s Seat....1830
Adjusting the Steering Column....1831
Adjusting the Armrest....1831
Adjusting the Rear-View Mirrors....1831
Adjusting the Heating and Ventilation System....1832
Adjusting the ventilation system....1832
Adjusting the heating system....1832
Putting on the Safety Belt....1833
Putting on the safety belt....1833
Taking off the safety belt....1833
Starting and Switching Off the Engine....1834
Starting the Engine....1834
Warming up the engine....1835
Switching Off the Engine....1836
Driving....1837
Start-Up....1837
Starting the machine on slopes....1838
Driving with the high-Speed gear....1838
Changing the Driving Direction....1839
Reverse Driving....1840
Turning....1840
Turning on slopes, embankments or hill flanks....1840
Braking....1841
Pulling the parking brake....1841
Releasing the parking brake....1841
Braking with the service brake....1841
If the service brake breaks down....1841
Braking on slopes....1842
Stopping....1842
Parking the machine on a slope....1842
Longer-Distance Driving....1843
Operating the Machine....1844
Preparing the Work Equipment....1844
Selecting a work unit....1844
Picking up the work unit (except multi- purpose bucket)....1844
Removing the work unit....1845
Picking up the multi-purpose bucket....1845
Removing the multi-purpose bucket....1847
Tire Service Life....1848
Level indicator for the bucket....1848
Loading....1849
Removing piled up soil....1849
Excavation works....1851
Transporting....1852
Dumping / Unloading....1852
Loading in diagonal direction....1852
V-shaped loading....1853
Piling up material....1853
Planing....1854
Filling up....1854
Taking off soil....1854
Cutting the Ground....1854
Working With the Forklift Truck Attachment....1855
Picking up the load....1855
Precautions For Special Operations....1856
Working in water....1856
Working on snow....1856
Dumping on steep slopes....1856
Working in the vicinity of electrical overhead lines....1856
Operation on slopes....1856
Working on loose soil....1856
After the work is finished....1856
Instructions for Winter Operation....1857
Before the cold season....1857
After Operation....1857
After the cold season....1857
Longer Standstill Periods of the Machine....1857
Before the standstill....1857
During the standstill....1858
After the standstill....1858
Troubleshooting....1860
6....1860
Troubleshooting....1861
Warning Lights and Indicators....1861
Electrical System....1862
Engine....1863
Hydraulic system....1866
Brakes....1868
Axles....1869
driver’s cab....1869
Emergency Steering Characteristics....1870
Emergency Lowering System....1870
Starting the Engine with a Battery Jumper Cable....1871
Connecting the Jumper Cable....1871
Starting the Engine....1872
Disconnecting the Battery Jumper Cable....1872
Towing the Machine....1873
Towing a Machine with Defective Brakes....1874
Maintenance....1876
7....1876
Maintenance Basics....1877
Preparing the Machine for Maintenance....1877
Cleaning the Machine....1878
Precautionary Measures When Cleaning the Machine....1878
Fire Prevention....1878
Working-Area-Dependent Maintenance....1878
Muddy or Wet Working Areas....1878
Dusty Working Areas....1878
Lubricants and Operating Agents....1879
Draining Hot Lubricants and Fluids....1879
Checking the Oil Level and Changing Oil....1879
Changing Filters....1879
Refuelling and Topping off Oil....1879
Oil....1879
Lubricating Grease....1880
Biodegradable Hydraulic Oil and Lubricating Grease....1880
Fuel....1880
Storage of Oil and Fuel....1880
Coolants....1881
Windscreen Washer Liquid....1881
Table of Lubricants and Operating Agents....1883
Lubrication chart....1884
Axles....1885
Released axle oil brands....1885
Replacing Safety-Related Parts....1885
Welding Instructions....1885
Spare Parts and Consumable Components....1886
Electrical System....1887
Fuses....1887
Fuse Assignment....1887
Slow-Blowing Fuses....1888
Tires....1889
Tire Components....1889
Checking the Tires....1889
Checking the Tire Pressure....1889
Torque for Standard Nuts and Bolts....1891
Maintenance Schedule....1893
Maintenance Prior to Start....1895
7....1895
Visual Checks....1895
Cooling System, Checking the Coolant Level, Topping off Coolant....1895
Engine, Checking the Oil Level, Topping off Oil....1896
Engine, Draining off Oil....1897
Checking the Fuel Level, Refueling....1898
Checking the Controls....1899
Checking the Parking Brake....1900
Test Conditions....1900
Test Procedure....1900
CHecking the Service Brake....1900
Checking the Electrical Connections....1901
Heater / ventilation: check blower....1901
Other Maintenance Measures Prior to Start....1901
Maintenance Every 10 Operating Hours....1902
Lubrication....1902
Maintenance After the First 50 Operating Hours....1903
Engine, Changing Oil and Replacing the Oil Filter Cartridge....1903
Replacing the Oil Filter Cartridge....1904
V-Belt, Checking the Condition....1905
V-Belt, Checking and Adjusting the Tension....1905
Hydraulic System, Replacing the Filter Insert....1906
Checking and Tightening the Wheel Nuts....1907
Front and Rear Axle, Changing Oil....1908
Planet gear....1908
Differential....1908
Transfer Gear - Changing Oil....1909
Maintenance Every 50 Operating Hours....1910
Checking the cooling System, coolant level in the radiator and expansion tank....1910
Draining Off Water and Dirt Deposits From the Fuel Tank....1911
Checking the Service Brake and Oil Level, Refilling Oil....1911
Checking the Battery and Acid Level....1912
Re-charging a built-in battery....1913
Lubrication....1914
Lubricating points of the work equipment....1914
Maintenance Every 100 Operating Hours....1915
Draining the Water Separator, Removing Water and Dirt Deposits....1915
Maintenance Every 250 Operating Hours....1916
Changing the Engine Oil and Oil Filter Cartridge....1916
Checking the V-Belt Condition....1916
Checking and Adjusting the V-belt Tension....1916
Front and Rear Axle, Checking the Oil Level....1917
Planet gear....1917
Differential....1917
Air Filter, Removing and Re-Installing the Filter Insert, Checking and Cleaning the Filter Insert....1918
Structure of the air filter....1918
Maintenance demand....1918
Removing the filter cartridge....1918
Cleaning or exchanging the filter cartridge....1919
Checking the filter cartridge....1920
Assembling the air filter cartridge....1920
Cleaning the Radiator Segments....1920
Lubrication....1921
Maintenance Every 500 Operating Hours....1922
Changing the Fuel Filter and Filter Element....1922
Bleeding the Fuel System....1923
Changing the Filter Cartridge of the Hydraulic System....1924
Cleaning the Water Separator....1924
Lubrication....1925
Transfer Gear, Checking the Oil Level and Refilling Oil....1925
Air Filter, Replacing the Filter Insert, Replacing the Safety Filter....1926
Replacing the Filter Insert....1926
Replacing the Safety Filter....1926
Heater / ventilation: cleaning / replacing blower filter....1927
Clean filter fleece....1927
Maintenance Every 1000 Operating Hours....1928
Cooling System, Exchanging Coolant and Cleaning the System....1928
Draining off the coolant....1928
Cleaning the Cooling System....1929
Filling off Coolant....1929
Front Axle, Oil Change....1930
Rear Axle, Oil Change....1930
Transfer Gear, Oil Change....1930
Service Brake....1930
Changing oil....1930
Checking tubes and lines....1930
Checking the brake disks for wear and tear....1930
Adjusting the clearance of the brake disks....1930
Checking and Adjusting System Pressures....1930
Checking and Adjusting the Valve clearance....1930
Checking and Adjusting the Injection Nozzles, Nozzle Pressure and Fuel-Jet Pattern....1930
Checking the Accumulator Gas Pressure....1931
Maintenance Every 2000 Operating Hours....1932
Hydraulic System, Oil Change....1932
Bleeding the Hydraulic Oil Tank....1933
Cooling System, Checking the Antifreeze Content of the Coolant....1933
Checking the Cooling System....1933
Checking the Fuel Pump....1933
Checking the Fuel and Coolant Tubes, Replacing the Tubes (if required)....1933
Checking the Water Pump....1934
Checking and Adjusting the Fuel Injection and Injection time....1934
Technical Data....1936
8....1936
Technical Data....1937
Noise Emission Levels....1938
Vibration Level....1938
Limit Values for Slopes....1939
Maximum slope angle for operating the machine....1939
Special Equipment and Attachments....1940
9....1940
ALS-Electronics....1941
Structure and Functioning Principle of the ALS-Electronics....1941
PRECAUTIONARY MEASURES FOR SWITCHING ON THE ALS-ELECTRONICS....1941
Operation of the ALS-Electronics....1942
Switching on the ALS-Electronics....1942
Switching off the ALS-Electronics....1942
Handling of the Pressure Accumulator....1943
VEAM960600 - Wheel Loader WA85-3 Operation & Maintenance Manual....1944
Cover....1944
Table of Contents....1947
Introduction....1955
Forword....1956
Safety Information....1957
Introduction....1959
Features....1959
Breaking in a New Machine....1959
Location of Plates, Table to Enter Serial No. and Distributor....1960
Machine Serial No. Plate position....1960
Engine Serial No. Plate Position....1960
Table to Enter Serial No. and Distributor....1960
EMISSION CONTROL WARRANTY....1961
EMISSION CONTROL WARRANTY STATEMENT (APPLIES TO CANADA ONLY)....1961
Engine Data Plate....1962
GARANTIE SUR LE CONTRÔLE DES ÉMISSIONS....1963
ÉNONCÉ DE GARANTIE SUR LE CONTRÔLE DES ÉMISSIONS ( APPLICABLE AU CANADA SEULEMENT):....1963
Engine Data Plate....1965
Why You Should Read these Operating Instructions....1966
Notes on Safety Regulations....1968
Correct Use....1968
Safety Notes in the Operating Instructions....1968
Equipment....1969
Loading and Transporting the Machine....1971
Loading and Transporting the Machine....1972
Securing the Articulated Steering....1972
Lifting the Machine....1972
Driving Machine Onto Loading Area of Transport Vehicle....1974
Securing the Machine During Transport....1975
After Transport....1975
Safety....1977
General Safety Measures....1979
Safety Instructions....1979
Safety Devices....1979
Emergency Exit....1979
Clothing and Personal Protection....1980
Machine Modifications....1980
Before You Leave the Driver's Seat....1980
Mounting and Dismounting....1981
Fire Prevention and Fire Fighting....1982
Fire Extinguisher and First-Aid Kit....1983
Protection Against Asbestos Dust....1983
Protection Against Injuries....1984
Working at High Temperatures....1984
Roll-Over Protection System (ROPS)....1985
Attachment for Protection Against Falling Objects (FOPS)....1985
Attachments....1985
Battery....1986
Safety Measures during Operation....1987
Before You Start the Engine....1987
Machine Operation....1989
Transport....1996
Safety Measures During Maintenance....1998
Personnel....1998
Prior to Start of Maintenance Measures....1998
During Maintenance....2001
Tires....2005
Labeling....2007
Position of Safety Labels....2007
Information Labels....2009
Controls and InDicators....2011
Overall View of Machine....2012
Controls and Indicators....2013
Control Lamps....2019
Measuring Indicators....2023
Switches....2025
Control Levers, Pedals....2032
Articulated Steering Catch....2038
Traction Device....2038
Socket....2038
Door Unlocking System....2039
Alarm Horn for Reverse Driving....2039
Operation....2041
Running in the Machine....2042
Preparing the Machine Start....2043
Visual Checks....2043
Adjustments Prior to Machine Start....2046
Adjusting the Driver’s Seat....2046
Adjusting the Steering Column....2047
Adjusting the Armrest....2047
Adjusting the Rear-View Mirrors....2047
Adjusting the Heating and Ventilation System....2048
Operating the Air Conditioning....2050
Putting on the Safety Belt....2052
Starting and Switching Off the Engine....2053
Starting the Engine....2053
Warming up the engine....2054
Switching Off the Engine....2055
Driving....2056
Start-Up....2056
Changing the Driving Direction....2059
Reverse Driving....2060
Turning....2060
Braking....2061
Pulling the parking brake....2061
Stopping....2063
Longer-Distance Driving....2064
Operating the Machine....2065
Preparing the Work Equipment....2065
Tire Service Life....2069
Level indicator for the bucket....2069
Adjusting the Bucket Positioner....2070
Loading....2071
Transporting....2074
Dumping / Unloading....2074
Planing....2076
Working With the Forklift Truck Attachment....2078
Precautions For Special Operations....2079
After the work is finished....2079
Instructions for Winter Operation....2080
Longer Standstill Periods of the Machine....2082
Troubleshooting....2085
Troubleshooting....2086
Warning Lights and Indicators....2086
Electrical System....2087
Engine....2088
Hydraulic system....2091
Brakes....2093
Axles....2094
Driver’s cab....2094
Emergency Steering Characteristics....2095
Emergency Lowering System....2095
Starting the Engine with a Battery Jumper Cable....2096
Towing the Machine....2098
Inadequate Braking Effect....2100
Maintenance....2103
Maintenance Basics....2104
Preparing the Machine for Maintenance....2104
Cleaning the Machine....2105
Working-Area-Dependent Maintenance....2106
Lubricants and Operating Agents....2107
Axles....2114
Replacing Safety-Related Parts....2114
Welding Instructions....2115
Spare Parts and Consumable Components....2116
Electrical System....2117
Tires....2120
Torque for Standard Nuts and Bolts....2122
Maintenance Schedule....2124
Maintenance Prior to Start....2126
Visual Checks....2126
Cooling System, Checking the Coolant Level, Topping off Coolant....2126
Engine, Checking the Oil Level, Topping off Oil....2127
Engine, Draining off Oil....2128
Checking the Fuel Level, Refueling....2129
Checking the Controls....2130
Checking the Electrical Connections....2130
Heater / air conditioning: checking rate of air flow....2131
Other Maintenance Measures Prior to Start....2131
Maintenance upon demand....2132
Checking the air-conditioning system....2132
Maintenance Every 10 Operating Hours....2133
Lubrication....2133
Maintenance After the First 50 Operating Hours....2134
Engine, Changing Oil and Replacing the Oil Filter Cartridge....2134
V-Belt, Checking the Condition....2136
V-Belt, Checking and Adjusting the Tension....2136
Hydraulic System, Replacing the Filter Insert....2137
Checking and Tightening the Wheel Nuts....2138
Front and Rear Axle, Changing Oil....2139
Transfer Gear - Changing Oil....2140
Maintenance Every 50 Operating Hours....2142
Checking cooling System, coolant level in the radiator and expansion tank....2142
Draining Off Water and Dirt Deposits From the Fuel Tank....2143
Checking the Service Brake and Oil Level, Refilling Oil....2143
Checking the Battery and Acid Level....2144
Lubrication....2146
Maintenance Every 100 Operating Hours....2147
Draining the Water Separator, Removing Water and Dirt Deposits....2147
Maintenance Every 250 Operating Hours....2148
Changing the Engine Oil and Oil Filter Cartridge....2148
Checking the V-Belt Condition....2148
Checking and Adjusting the V-belt Tension....2148
Front and Rear Axle, Checking the Oil Level....2149
Air Filter, Removing/Re-Installing AND Checking/Cleaning the Filter Insert....2151
Cleaning the Radiator Segments....2153
Lubrication....2154
Maintenance Every 500 Operating Hours....2155
Changing the Fuel Filter and Filter Element....2155
Changing the Filter Cartridge of the Hydraulic System....2157
Cleaning the Water Separator....2157
Lubrication....2158
Transfer Gear, Checking the Oil Level and Refilling Oil....2158
Air Filter, Replacing the Filter Insert, Replacing the Safety Filter....2159
Heater/air conditioning: clean filter fleece of heater unit....2160
Heater/air conditioning: Cleaning the condenser....2161
Maintenance Every 1000 Operating Hours....2162
Cooling System, Exchanging Coolant and Cleaning the System....2162
Front Axle, Oil Change....2164
Rear Axle, Oil Change....2164
Transfer Gear, Oil Change....2164
Service Brake....2164
Checking and Adjusting System Pressures....2164
Checking and Adjusting the Valve clearance....2164
Checking/Adjusting the Injection Nozzles, Nozzle Pressure/ Fuel-Jet Pattern....2165
Checking the Accumulator Gas Pressure....2165
Maintenance Every 2000 Operating Hours....2166
Hydraulic System, Oil Change....2166
Bleeding the Hydraulic Oil Tank....2167
Cooling System, Checking the Antifreeze Content of the Coolant....2167
Checking the Cooling System....2167
Checking the Fuel Pump....2167
Checking the Fuel and Coolant Tubes, Replacing the Tubes (if required)....2167
Checking the Water Pump....2168
Checking and Adjusting the Fuel Injection and Injection time....2168
Technical Data....2169
Technical Data....2170
Noise Emission Levels....2171
Vibration Level....2171
Limit Values for Slopes....2171
Special Equipment and Attachments....2173
ALS-Electronics....2174
Structure and Functioning Principle of the ALS-Electronics....2174
Precautionary Measures for Switching on the ALS Electronics....2174
Operation of the ALS-Electronics....2175
Handling of the Pressure Accumulator....2176
Index....2177
VEAM980200 - Wheel Loader WA95-3 Operation & Maintenance Manual....2182
COVER....2182
Table of Contents....2188
Introduction....2196
1. Forword....2197
2. Safety Information....2198
3. Introduction....2199
3.1 Features....2199
3.2 Breaking in a New Machine....2199
4. Location of Plates, Table to Enter Serial No. and Distributor....2200
4.1 Machine Serial No. Plate position....2200
4.2 Engine Serial No. Plate Position....2200
4.3 Table to Enter Serial No. and Distributor....2200
5. Why You Should Read these Operating Instructions....2201
6. Notes on Safety Regulations....2202
6.1 Correct Use....2202
6.2 Safety Notes in the Operating Instructions....2202
7. Equipment....2203
Loading and Transporting the Machine....2206
8. Loading and Transporting the Machine....2207
8.1 Securing the Articulated Steering....2207
8.2 Lifting the Machine....2207
8.3 Driving Machine Onto Loading Area of Transport Vehicle....2209
8.4 Securing the Machine During Transport....2210
8.5 After Transport....2210
Safety....2212
9. General Safety Measures....2214
9.1 Safety Instructions....2214
9.2 Safety Devices....2214
9.3 Emergency Exit....2214
9.4 Clothing and Personal Protection....2215
9.5 Machine Modifications....2215
9.6 Before You Leave the Driver's Seat....2215
9.7 Mounting and Dismounting....2215
9.8 Fire Prevention and Fire Fighting....2216
9.8.1 Fire Extinguisher and First-Aid Kit....2217
9.9 Protection Against Asbestos Dust....2217
9.10 Protection Against Injuries....2218
9.11 Working at High Temperatures....2218
9.12 Roll-Over Protection System (ROPS)....2219
9.13 Attachment for Protection Against Falling Objects (FOPS)....2219
9.14 Attachments....2219
9.15 Battery....2220
10. Safety Measures during Operation....2221
10.1 Before You Start the Engine....2221
10.1.1 Workplace Safety....2221
10.1.2 In the Driver's Cab....2221
10.1.3 In-Door Operation....2222
10.1.4 Gas, Dust, and Inflammable Vapours....2222
10.1.5 Mirrors, Windows, and Lighting....2222
10.2 Machine Operation....2223
10.2.1 Before You Start the Engine....2223
10.2.2 Reversing....2223
10.2.3 Driving....2224
10.2.4 Driving On Slopes....2224
10.2.5 Emergency Lowering System....2225
10.2.6 Working Close to Overhead Power Transmission Lines....2225
10.2.7 Loading....2226
10.2.8 Good Vision....2226
10.2.9 Working On Snow....2226
10.2.10 Height Limitation....2226
10.2.11 Brakes....2227
10.2.12 Working On Loose Soil....2227
10.2.13 Working with the Forklift Truck Attachment....2228
10.2.14 Parking the Machine....2229
10.3 Transport....2230
10.3.1 Loading and Unloading the Machine....2230
10.3.2 Transport....2230
11. Safety Measures During Maintenance....2231
11.1 Personnel....2231
11.2 Prior to Start of Maintenance Measures....2231
11.2.1 Warning Sign....2231
11.2.2 Tools....2231
11.2.3 Safety-Related Parts....2231
11.2.4 Prior to Start of Inspection and Maintenance....2232
11.2.5 Securing the Articulated Steering....2232
11.2.6 Supporting the Work Unit....2232
11.3 During Maintenance....2233
11.3.1 Attachments....2233
11.3.2 Working Under the Machine....2233
11.3.3 Keeping the Machine Clean....2233
11.3.4 Specific Measures....2233
11.3.5 Refueling and Topping Off Oil....2234
11.3.6 Coolant....2234
11.3.7 Use of Lighting....2235
11.3.8 High-Pressure Hoses....2235
11.3.9 Handling High-Pressure Oil....2235
11.3.10 Fan and Belts....2236
11.3.11 Waste Material....2236
11.4 Tires....2237
11.4.1 Storing Tires....2237
12. Labeling....2238
12.1 Position of Safety Labels....2238
12.2 Position of Standard Labels....2240
Controls and Indicators....2242
13. General View of the Machine....2243
14. Controls and Indicators....2244
14.1 General View....2244
14.1.1 SWITCHES AND CONTROLS....2245
14.2 Instrument Panel....2246
14.3 Warning Lights....2247
14.4 Control Lamps....2250
14.5 Measuring Indicators....2253
14.6 Switches....2255
14.7 Control Levers, Pedals....2261
14.8 Articulated Steering Catch....2266
14.9 Traction Device....2266
14.10 Socket....2266
14.11 Door Unlocking System....2267
14.12 Alarm Horn for Reverse Driving....2267
Operation....2268
15. Running in the Machine....2269
16. Preparing the Machine Start....2270
16.1 Visual Checks....2270
16.1.1 Before you start the engine....2270
16.1.2 Before starting working with the machine....2270
17. Adjustments Prior to Machine Start....2272
17.1 Adjusting the Driver’s Seat....2272
17.2 Adjusting the Steering Column....2273
17.3 Adjusting the Armrest....2273
17.4 Adjusting the Rear-View Mirrors....2273
17.5 Adjusting the Heating and Ventilation System....2274
17.5.1 Adjusting the ventilation system....2274
17.5.2 Adjusting the heating system....2274
17.6 Putting on the Safety Belt....2275
17.6.1 Putting on the safety belt....2275
17.6.2 Taking off the safety belt....2275
18. Starting and Switching Off the Engine....2276
18.1 Starting the Engine....2276
18.1.1 Warming up the engine....2277
18.2 Switching Off the Engine....2278
19. Driving....2279
19.1 Start-Up....2279
19.1.1 Starting the machine on slopes....2280
19.2 Changing the Driving Direction....2280
19.3 Reverse Driving....2281
19.4 Turning....2281
19.4.1 Turning on slopes, embankments or hill flanks....2281
19.5 Braking....2282
19.5.1 Pulling the parking brake....2282
19.5.2 Releasing the parking brake....2282
19.5.3 Braking with the service brake....2282
19.5.4 If the service brake breaks down....2282
19.5.5 Braking on slopes....2283
19.6 Stopping....2283
19.6.1 Parking the machine on a slope....2283
19.7 Longer-Distance Driving....2284
20. Operating the Machine....2285
20.1 Preparing the Work Equipment....2285
20.1.1 Selecting a work unit....2285
20.1.2 Picking up the work unit (except multi-purpose bucket)....2285
20.1.3 Removing the work unit....2286
20.1.4 Picking up the multi-purpose bucket....2286
20.1.5 Removing the multi-purpose bucket....2288
20.2 Tire Service Life....2289
20.2.1 Level indicator for the bucket....2289
20.3 Loading....2290
20.3.1 Removing piled up soil....2290
20.3.2 Excavation works....2292
20.4 Transporting....2293
20.5 Dumping / Unloading....2293
20.5.1 Loading in diagonal direction....2293
20.5.2 V-shaped loading....2294
20.5.3 Piling up material....2294
20.6 Planing....2295
20.6.1 Filling up....2295
20.6.2 Taking off soil....2295
20.6.3 Cutting the Ground....2295
20.7 Working With the Forklift Truck Attachment....2296
20.7.1 Picking up the load....2296
20.8 Precautions For Special Operations....2297
20.8.1 Working in water....2297
20.8.2 Working on snow....2297
20.8.3 Dumping on steep slopes....2297
20.8.4 Working in the vicinity of electrical overhead lines....2297
20.8.5 Operation on slopes....2297
20.8.6 Working on loose soil....2297
20.9 After the work is finished....2297
20.10 Instructions for Winter Operation....2298
20.10.1 Before the cold season....2298
20.10.2 After Operation....2298
20.10.3 After the cold season....2298
20.11 Longer Standstill Periods of the Machine....2298
20.11.1 Before the standstill....2298
20.11.2 During the standstill....2299
20.11.3 After the standstill....2299
Troubleshooting....2300
21. Troubleshooting....2301
21.1 Warning Lights and Indicators....2301
21.2 Electrical System....2302
21.3 Engine....2303
21.4 Hydraulic system....2306
21.5 Brakes....2308
21.6 Axles....2309
21.7 Emergency Steering Characteristics....2310
21.8 Emergency Lowering System....2310
21.9 Starting the Engine with a Battery Jumper Cable....2311
21.9.1 Connecting the Jumper Cable....2311
21.10 Starting the Engine....2312
21.10.1 Disconnecting the Battery Jumper Cable....2312
21.11 Towing the Machine....2313
21.12 Towing a Machine with Defective Brakes....2314
Maintenance....2316
22. Maintenance Basics....2317
22.1 Preparing the Machine for Maintenance....2317
22.2 Cleaning the Machine....2318
22.2.1 Precautionary Measures When Cleaning the Machine....2318
22.2.2 Fire Prevention....2318
22.3 Working-Area-Dependent Maintenance....2318
22.3.1 Muddy or Wet Working Areas....2318
22.3.2 Dusty Working Areas....2318
22.4 Lubricants and Operating Agents....2319
22.4.1 Draining Hot Lubricants and Fluids....2319
22.4.2 Checking the Oil Level and Changing Oil....2319
22.4.3 Changing Filters....2319
22.4.4 Refuelling and Topping off Oil....2319
22.4.5 Oil....2319
22.4.6 Lubricating Grease....2320
22.4.7 Biodegradable Hydraulic Oil and Lubricating Grease....2320
22.4.8 Fuel....2320
22.4.9 Storage of Oil and Fuel....2320
22.4.10 Coolants....2321
22.4.11 Windscreen Washer Liquid....2321
22.4.12 Table of Lubricants and Operating Agents....2323
22.4.13 Lubrication chart....2324
22.5 Replacing Safety-Related Parts....2325
22.5.1 Welding Instructions....2325
22.6 Spare Parts and Consumable Components....2326
22.7 Electrical System....2327
22.7.1 Fuses....2327
22.7.2 Fuse Assignment....2327
22.7.3 Slow-Blowing Fuses....2328
22.8 Tires....2329
22.8.1 Tire Components....2329
22.8.2 Checking the Tires....2329
22.8.3 Checking the Tire Pressure....2329
22.9 Tools....2331
22.10 Torque for Standard Nuts and Bolts....2332
23. Maintenance Schedule....2334
24. Maintenance Prior to Start....2336
24.1 Visual Checks....2336
24.2 Cooling System, Checking the Coolant Level, Topping off Coolant....2336
24.3 Engine, Checking the Oil Level, Topping off Oil....2337
24.4 Engine, Draining Off Oil....2338
24.5 Checking the Fuel Level, Refueling....2339
24.6 Checking the Controls....2340
24.7 Checking the Parking Brake....2341
24.7.1 Test Conditions....2341
24.7.2 Test Procedure....2341
24.8 Checking the Service Brake....2341
24.9 Checking the Electrical Connections....2342
24.10 Other Maintenance Measures Prior to Start....2342
25. Maintenance Every 10 Operating Hours....2343
25.1 Lubrication....2343
26. Maintenance After the First 50 Operating Hours....2344
26.1 Engine, Changing Oil and Replacing the Oil Filter Cartridge....2344
26.1.1 Replacing the Oil Filter Cartridge....2345
26.2 V-Belt, Checking the Condition....2346
26.3 V-Belt, Checking and Adjusting the Tension....2346
26.4 Hydraulic System, Replacing the Filter Insert....2347
26.5 Checking and Tightening the Wheel Nuts....2348
26.6 Front and Rear Axle, Changing Oil....2349
26.6.1 Planet gear....2349
26.6.2 Differential....2349
26.7 Transfer Gear - Changing Oil....2350
27. Maintenance Every 50 Operating Hours....2351
27.1 Checking the cooling System, coolant level in the radiator and expansion tank....2351
27.2 Draining Off Water and Dirt Deposits From the Fuel Tank....2352
27.3 Checking the Service Brake and Oil Level, Refilling Oil....2352
27.4 Checking the Battery and Acid Level....2353
27.4.1 Re-charging a built-in battery....2354
27.5 Lubrication....2355
27.5.1 Lubricating points of the work equipment....2355
28. Maintenance Every 100 Operating Hours....2356
28.1 Draining the Water Separator, Removing Water and Dirt Deposits....2356
29. Maintenance Every 250 Operating Hours....2357
29.1 Changing the Engine Oil and Oil Filter Cartridge....2357
29.2 Checking the V-Belt Condition....2357
29.3 Checking and Adjusting the V-belt Tension....2357
29.4 Lubrication....2357
29.4.1 Lubricating points of the steering cylinder....2357
29.5 Front and Rear Axle, Checking the Oil Level....2358
29.5.1 Planet gear....2358
29.5.2 Differential....2358
29.6 Air Filter, Removing and Re-Installing the Filter Insert, Checking and Cleaning the Filter I...2359
29.6.1 Structure of the air filter....2359
29.6.2 Maintenance demand....2359
29.6.3 Removing the filter cartridge....2359
29.6.4 Cleaning or exchanging the filter cartridge....2360
29.6.5 Checking the filter cartridge....2361
29.6.6 Assembling the air filter cartridge....2361
29.7 Cleaning the Radiator Segments....2361
30. Maintenance Every 500 Operating Hours....2362
30.1 Changing the Fuel Filter and Filter Element....2362
30.1.1 Bleeding the Fuel System....2363
30.2 Changing the Filter Cartridge of the Hydraulic System....2364
30.3 Cleaning the Water Separator....2364
30.4 Lubrication....2365
30.5 Transfer Gear, Checking the Oil Level and Refilling Oil....2365
30.6 Air Filter, Replacing the Filter Insert, Replacing the Safety Filter....2366
30.6.1 Replacing the Filter Insert....2366
30.6.2 Replacing the Safety Filter....2366
31. Maintenance Every 1000 Operating Hours....2367
31.1 Cooling System, Exchanging Coolant and Cleaning the System....2367
31.1.1 Draining off the coolant....2367
31.1.2 Cleaning the Cooling System....2368
31.1.3 Filling off Coolant....2368
31.2 Front Axle, Oil Change....2369
31.3 Rear Axle, Oil Change....2369
31.4 Transfer Gear, Oil Change....2369
31.5 Service Brake....2369
31.5.1 Changing oil....2369
31.5.2 Checking tubes and lines....2369
31.5.3 Checking the brake disks for wear and tear....2369
31.5.4 Adjusting the clearance of the brake disks....2369
31.6 Checking and Adjusting System Pressures....2369
31.7 Checking and Adjusting the Valve clearance....2369
31.8 Checking and Adjusting the Injection Nozzles, Nozzle Pressure and Fuel-Jet Pattern....2369
32. Maintenance Every 2000 Operating Hours....2370
32.1 Hydraulic System, Oil Change....2370
32.2 Bleeding the Hydraulic Oil Tank....2371
32.3 Cooling System, Checking the Antifreeze Content of the Coolant....2371
32.4 Checking the Cooling System....2371
32.5 Checking the Fuel Pump....2371
32.6 Checking the Fuel and Coolant Tubes, Replacing the Tubes (if required)....2371
32.7 Checking the Water Pump....2372
32.8 Checking and Adjusting the Fuel Injection and Injection time....2372
32.9 Engine, Intake Valves and Outlet Valves - Grinding In the Valve Bases....2372
Technical Data....2374
33. Technical Data....2375
33.1 Noise Emission Levels....2376
33.2 Vibration Level....2376
33.3 Limit Values for Slopes....2377
33.3.1 Maximum slope angle for operating the machine....2377
33.3.2 Tilting/tipping angle....2377
VEAM980400 - Wheel Loader WA95-3 Operation & Maintenance Manual....2380
Cover....2380
Product Publications Information....2381
Table of Contents....2383
Introduction....2391
Forword....2392
Safety Information....2393
Introduction....2394
Features....2394
Breaking in a New Machine....2394
Location of Plates, Table to Enter Serial No. and Distributor....2395
Machine Serial No. Plate position....2395
Engine Serial No. Plate Position....2395
Table to Enter Serial No. and Distributor....2395
EMISSION CONTROL WARRANTY....2396
EMISSION CONTROL WARRANTY STATEMENT (APPLIES TO CANADA ONLY)....2396
Engine Data Plate....2397
GARANTIE SUR LE CONTRÔLE DES ÉMISSIONS....2398
ÉNONCÉ DE GARANTIE SUR LE CONTRÔLE DES ÉMISSIONS (APPLICABLE AU CANADA SEULEMENT):....2398
Engine Data Plate....2399
Why You Should Read these Operating Instructions....2400
Notes on Safety Regulations....2401
Correct Use....2401
Safety Notes in the Operating Instructions....2401
Equipment....2402
Loading and Transporting the Machine....2404
Loading and Transporting the Machine....2405
Securing the Articulated Steering....2405
Lifting the Machine....2405
Driving Machine Onto Loading Area of Transport Vehicle....2407
Securing the Machine During Transport....2408
After Transport....2408
Safety....2409
General Safety Measures....2411
Safety Instructions....2411
Safety Devices....2411
Emergency Exit....2411
Clothing and Personal Protection....2412
Machine Modifications....2412
Before You Leave the Driver's Seat....2412
Mounting and Dismounting....2412
Fire Prevention and Fire Fighting....2413
Fire Extinguisher and First-Aid Kit....2414
Protection Against Asbestos Dust....2414
Protection Against Injuries....2415
Working at High Temperatures....2415
Roll-Over Protection System (ROPS)....2416
Attachment for Protection Against Falling Objects (FOPS)....2416
Attachments....2416
Battery....2417
Safety Measures during Operation....2418
Before You Start the Engine....2418
Workplace Safety....2418
In the Driver's Cab....2418
In-Door Operation....2419
Gas, Dust, and Inflammable Vapours....2419
Mirrors, Windows, and Lighting....2419
Machine Operation....2420
Before You Start the Engine....2420
Reversing....2420
Driving....2421
Driving On Slopes....2421
Emergency Lowering System....2422
Working Close to Overhead Power Transmission Lines....2422
Loading....2423
Good Vision....2423
Working On Snow....2423
Height Limitation....2423
Brakes....2424
Working On Loose Soil....2424
Working with the Forklift Truck Attachment....2425
Parking the Machine....2426
Transport....2427
Loading and Unloading the Machine....2427
Transport....2427
Safety Measures During Maintenance....2428
Personnel....2428
Prior to Start of Maintenance Measures....2428
Warning Sign....2428
Tools....2428
Safety-Related Parts....2428
Prior to Start of Inspection and Maintenance....2429
Securing the Articulated Steering....2429
Supporting the boom....2430
During Maintenance....2431
Attachments....2431
Working Under the Machine....2431
Keeping the Machine Clean....2431
Specific Measures....2431
Refueling and Topping Off Oil....2432
Coolant....2432
Use of Lighting....2433
High-Pressure Hoses....2433
Handling High-Pressure Oil....2433
Handling of the pressure accumulator....2434
Fan and Belts....2434
Waste Material....2434
Tires....2435
Storing Tires....2435
Labeling....2436
Position of Safety Labels....2436
Information Labels....2438
Controls and InDicators....2439
Overall View of Machine....2440
Controls and Indicators....2441
SWITCHES AND CONTROLS....2442
Instrument Panel....2443
Warning Lights....2444
Control Lamps....2447
Measuring Indicators....2451
Switches....2453
Control Levers, Pedals....2460
Articulated Steering Catch....2465
Traction Device....2465
Socket....2465
Door Unlocking System....2466
Alarm Horn for Reverse Driving....2466
Operation....2467
Running in the Machine....2468
Preparing the Machine Start....2469
Visual Checks....2469
Before you start the engine....2469
Before starting working with the machine....2469
Adjustments Prior to Machine Start....2471
Adjusting the Driver’s Seat....2471
Adjusting the Steering Column....2472
Adjusting the Armrest....2472
Adjusting the Rear-View Mirrors....2472
Adjusting the Heating and Ventilation System....2473
Adjusting the ventilation system....2473
Adjusting the heating system....2473
Putting on the Safety Belt....2474
Putting on the safety belt....2474
Taking off the safety belt....2474
Starting and Switching Off the Engine....2475
Starting the Engine....2475
Warming up the engine....2476
Switching Off the Engine....2477
Driving....2478
Start-Up....2478
Starting the machine on slopes....2479
Driving with the high-Speed gear....2479
Changing the Driving Direction....2480
Reverse Driving....2481
Turning....2481
Turning on slopes, embankments or hill flanks....2481
Braking....2482
Pulling the parking brake....2482
Releasing the parking brake....2482
Braking with the service brake....2482
If the service brake breaks down....2482
Braking on slopes....2483
Stopping....2483
Parking the machine on a slope....2483
Longer-Distance Driving....2484
Operating the Machine....2485
Preparing the Work Equipment....2485
Selecting a work unit....2485
Picking up the work unit (except multi- purpose bucket)....2485
Removing the work unit....2486
Picking up the multi-purpose bucket....2486
Removing the multi-purpose bucket....2488
Tire Service Life....2489
Level indicator for the bucket....2489
Loading....2490
Removing piled up soil....2490
Excavation works....2492
Transporting....2493
Dumping / Unloading....2493
Loading in diagonal direction....2493
V-shaped loading....2494
Piling up material....2494
Planing....2495
Filling up....2495
Taking off soil....2495
Cutting the Ground....2495
Working With the Forklift Truck Attachment....2496
Picking up the load....2496
Precautions For Special Operations....2497
Working in water....2497
Working on snow....2497
Dumping on steep slopes....2497
Working in the vicinity of electrical overhead lines....2497
Operation on slopes....2497
Working on loose soil....2497
After the work is finished....2497
Instructions for Winter Operation....2498
Before the cold season....2498
After Operation....2498
After the cold season....2498
Longer Standstill Periods of the Machine....2498
Before the standstill....2498
During the standstill....2499
After the standstill....2499
Troubleshooting....2500
Troubleshooting....2501
Warning Lights and Indicators....2501
Electrical System....2502
Engine....2503
Hydraulic system....2506
Brakes....2508
Axles....2509
driver’s cab....2509
Emergency Steering Characteristics....2510
Emergency Lowering System....2510
Starting the Engine with a Battery Jumper Cable....2511
Connecting the Jumper Cable....2511
Starting the Engine....2512
Disconnecting the Battery Jumper Cable....2512
Towing the Machine....2513
Towing a Machine with Defective Brakes....2514
Maintenance....2516
Maintenance Basics....2517
Preparing the Machine for Maintenance....2517
Cleaning the Machine....2518
Precautionary Measures When Cleaning the Machine....2518
Fire Prevention....2518
Working-Area-Dependent Maintenance....2518
Muddy or Wet Working Areas....2518
Dusty Working Areas....2518
Lubricants and Operating Agents....2519
Draining Hot Lubricants and Fluids....2519
Checking the Oil Level and Changing Oil....2519
Changing Filters....2519
Refuelling and Topping off Oil....2519
Oil....2519
Lubricating Grease....2520
Biodegradable Hydraulic Oil and Lubricating Grease....2520
Fuel....2520
Storage of Oil and Fuel....2520
Coolants....2521
Windscreen Washer Liquid....2521
Table of Lubricants and Operating Agents....2523
Lubrication chart....2524
Axles....2525
Released axle oil brands....2525
Replacing Safety-Related Parts....2525
Welding Instructions....2525
Spare Parts and Consumable Components....2526
Electrical System....2527
Fuses....2527
Fuse Assignment....2527
Slow-Blowing Fuses....2528
Tires....2529
Tire Components....2529
Checking the Tires....2529
Checking the Tire Pressure....2529
Torque for Standard Nuts and Bolts....2531
Maintenance Schedule....2533
Maintenance Prior to Start....2535
Visual Checks....2535
Cooling System, Checking the Coolant Level, Topping off Coolant....2535
Engine, Checking the Oil Level, Topping off Oil....2536
Engine, Draining off Oil....2537
Checking the Fuel Level, Refueling....2538
Checking the Controls....2539
Checking the Parking Brake....2540
Test Conditions....2540
Test Procedure....2540
CHecking the Service Brake....2540
Checking the Electrical Connections....2541
Heater / ventilation: check blower....2541
Other Maintenance Measures Prior to Start....2541
Maintenance Every 10 Operating Hours....2542
Lubrication....2542
Maintenance After the First 50 Operating Hours....2543
Engine, Changing Oil and Replacing the Oil Filter Cartridge....2543
Replacing the Oil Filter Cartridge....2544
V-Belt, Checking the Condition....2545
V-Belt, Checking and Adjusting the Tension....2545
Hydraulic System, Replacing the Filter Insert....2546
Checking and Tightening the Wheel Nuts....2547
Front and Rear Axle, Changing Oil....2548
Planet gear....2548
Differential....2548
Transfer Gear - Changing Oil....2549
Maintenance Every 50 Operating Hours....2550
Checking the cooling System, coolant level in the radiator and expansion tank....2550
Draining Off Water and Dirt Deposits From the Fuel Tank....2551
Checking the Service Brake and Oil Level, Refilling Oil....2551
Checking the Battery and Acid Level....2552
Re-charging a built-in battery....2553
Lubrication....2554
Lubricating points of the work equipment....2554
Maintenance Every 100 Operating Hours....2555
Draining the Water Separator, Removing Water and Dirt Deposits....2555
Maintenance Every 250 Operating Hours....2556
Changing the Engine Oil and Oil Filter Cartridge....2556
Checking the V-Belt Condition....2556
Checking and Adjusting the V-belt Tension....2556
Front and Rear Axle, Checking the Oil Level....2557
Planet gear....2557
Differential....2557
Air Filter, Removing and Re-Installing the Filter Insert, Checking and Cleaning the Filter Insert....2558
Structure of the air filter....2558
Maintenance demand....2558
Removing the filter cartridge....2558
Cleaning or exchanging the filter cartridge....2559
Checking the filter cartridge....2560
Assembling the air filter cartridge....2560
Cleaning the Radiator Segments....2560
Lubrication....2561
Maintenance Every 500 Operating Hours....2562
Changing the Fuel Filter and Filter Element....2562
Bleeding the Fuel System....2563
Changing the Filter Cartridge of the Hydraulic System....2564
Cleaning the Water Separator....2564
Lubrication....2565
Transfer Gear, Checking the Oil Level and Refilling Oil....2565
Air Filter, Replacing the Filter Insert, Replacing the Safety Filter....2566
Replacing the Filter Insert....2566
Replacing the Safety Filter....2566
Heater / ventilation: cleaning / replacing blower filter....2567
Clean filter fleece....2567
Maintenance Every 1000 Operating Hours....2568
Cooling System, Exchanging Coolant and Cleaning the System....2568
Draining off the coolant....2568
Cleaning the Cooling System....2569
Filling off Coolant....2569
Front Axle, Oil Change....2570
Rear Axle, Oil Change....2570
Transfer Gear, Oil Change....2570
Service Brake....2570
Changing oil....2570
Checking tubes and lines....2570
Checking the brake disks for wear and tear....2570
Adjusting the clearance of the brake disks....2570
Checking and Adjusting System Pressures....2570
Checking and Adjusting the Valve clearance....2570
Checking and Adjusting the Injection Nozzles, Nozzle Pressure and Fuel-Jet Pattern....2570
Checking the Accumulator Gas Pressure....2571
Maintenance Every 2000 Operating Hours....2572
Hydraulic System, Oil Change....2572
Bleeding the Hydraulic Oil Tank....2573
Cooling System, Checking the Antifreeze Content of the Coolant....2573
Checking the Cooling System....2573
Checking the Fuel Pump....2573
Checking the Fuel and Coolant Tubes, Replacing the Tubes (if required)....2573
Checking the Water Pump....2574
Checking and Adjusting the Fuel Injection and Injection time....2574
Technical Data....2576
Technical Data....2577
Noise Emission Levels....2578
Vibration Level....2578
Limit Values for Slopes....2579
Maximum slope angle for operating the machine....2579
Special Equipment and Attachments....2580
ALS-Electronics....2581
Structure and Functioning Principle of the ALS-Electronics....2581
PRECAUTIONARY MEASURES FOR SWITCHING ON THE ALS-ELECTRONICS....2581
Operation of the ALS-Electronics....2582
Switching on the ALS-Electronics....2582
Switching off the ALS-Electronics....2582
Handling of the Pressure Accumulator....2583
VEAM980500 - Wheel Loader WA95-3 Operation & Maintenance Manual....2584
Contents....2586
Information on these Operating Instructions....2590
Why You Should Read these Operating Instructions....2592
Notes on Safety Regulations....2593
CE-Conforming Equipment....2597
Loading and Transporting the Machine....2602
Loading and Transporting the Machine....2604
Dimensions, Weights, and Operating Values....2607
Technical Data....2608
Safety....2610
General Safety Measures....2611
Before You Start the Engine....2617
Machine Operation....2619
Transport....2625
Safety Measures During Maintenance....2626
Labeling....2633
Controls and Indicators....2636
Overall View of the Machine....2638
Controls and Indicators....2639
Instrument Panel....2640
Warning Lights....2641
Control Lamps....2643
Measuring Indicators....2646
Switches....2648
Control Levers, Pedals....2654
Operation....2660
Running in the Machine....2662
Preparing the Machine Start....2663
Adjustments Prior to Machine Start....2665
Starting and Switching Off the Engine....2670
Driving....2672
Operating the Machine....2679
Troubleshooting....2692
Troubleshooting....2694
Electrical System....2695
Engine....2696
Hydraulic System....2699
Brakes....2701
Axles....2702
Driver's cab....2702
Maintenance....2710
Maintenance Basics....2712
Maintenance Schedule....2730
Maintenance Prior to Start....2732
Maintenance upon Demand....2736
Maintenance Every 10 Operating Hours....2737
Maintenance After the First 50 Operating Hours....2738
Maintenance Every 50 Operating Hours....2744
Maintenance Every 100 Operating Hours....2749
Maintenance Every 250 Operating Hours....2750
Maintenance Every 500 Operating Hours....2755
Maintenance Every 1000 Operating Hours....2762
Maintenance Every 2000 Operating Hours....2765
Technical Data....2768
Technical Data....2769
Special Equipment and Attachments....2772
ALS-Electronics....2774
Index....2776
VEAM980600 - Wheel Loader WA95-3 Operation & Maintenance Manual....2782
Cover....2782
Table of Contents....2786
Introduction....2794
Forword....2795
Safety Information....2796
Introduction....2798
Features....2798
Breaking in a New Machine....2798
Location of Plates, Table to Enter Serial No. and Distributor....2799
Machine Serial No. Plate position....2799
Engine Serial No. Plate Position....2799
Table to Enter Serial No. and Distributor....2799
EMISSION CONTROL WARRANTY....2800
EMISSION CONTROL WARRANTY STATEMENT (APPLIES TO CANADA ONLY)....2800
Engine Data Plate....2801
GARANTIE SUR LE CONTRÔLE DES ÉMISSIONS....2802
ÉNONCÉ DE GARANTIE SUR LE CONTRÔLE DES ÉMISSIONS ( APPLICABLE AU CANADA SEULEMENT):....2802
Engine Data Plate....2804
Why You Should Read these Operating Instructions....2805
Notes on Safety Regulations....2807
Correct Use....2807
Safety Notes in the Operating Instructions....2807
Equipment....2808
Loading and Transporting the Machine....2810
Loading and Transporting the Machine....2811
Securing the Articulated Steering....2811
Lifting the Machine....2811
Driving Machine Onto Loading Area of Transport Vehicle....2813
Securing the Machine During Transport....2814
After Transport....2814
Safety....2816
General Safety Measures....2818
Safety Instructions....2818
Safety Devices....2818
Emergency Exit....2818
Clothing and Personal Protection....2819
Machine Modifications....2819
Before You Leave the Driver's Seat....2819
Mounting and Dismounting....2820
Fire Prevention and Fire Fighting....2821
Fire Extinguisher and First-Aid Kit....2822
Protection Against Asbestos Dust....2822
Protection Against Injuries....2823
Working at High Temperatures....2823
Roll-Over Protection System (ROPS)....2824
Attachment for Protection Against Falling Objects (FOPS)....2824
Attachments....2824
Battery....2825
Safety Measures during Operation....2826
Before You Start the Engine....2826
Machine Operation....2828
Transport....2835
Safety Measures During Maintenance....2837
Personnel....2837
Prior to Start of Maintenance Measures....2837
During Maintenance....2840
Tires....2844
Labeling....2846
Position of Safety Labels....2846
Information Labels....2848
Controls and InDicators....2850
Overall View of Machine....2851
Controls and Indicators....2852
Control Lamps....2858
Measuring Indicators....2862
Switches....2864
Control Levers, Pedals....2871
Articulated Steering Catch....2877
Traction Device....2877
Socket....2877
Door Unlocking System....2878
Alarm Horn for Reverse Driving....2878
Operation....2880
Running in the Machine....2881
Preparing the Machine Start....2882
Visual Checks....2882
Adjustments Prior to Machine Start....2885
Adjusting the Driver’s Seat....2885
Adjusting the Steering Column....2886
Adjusting the Armrest....2886
Adjusting the Rear-View Mirrors....2886
Adjusting the Heating and Ventilation System....2887
Operating the Air Conditioning....2889
Putting on the Safety Belt....2891
Starting and Switching Off the Engine....2892
Starting the Engine....2892
Warming up the engine....2893
Switching Off the Engine....2894
Driving....2895
Start-Up....2895
Changing the Driving Direction....2898
Reverse Driving....2899
Turning....2899
Braking....2900
Pulling the parking brake....2900
Stopping....2902
Longer-Distance Driving....2903
Operating the Machine....2904
Preparing the Work Equipment....2904
Tire Service Life....2908
Level indicator for the bucket....2908
Adjusting the Bucket Positioner....2909
Loading....2910
Transporting....2913
Dumping / Unloading....2913
Planing....2915
Working With the Forklift Truck Attachment....2917
Precautions For Special Operations....2918
After the work is finished....2918
Instructions for Winter Operation....2919
Longer Standstill Periods of the Machine....2921
Troubleshooting....2924
Troubleshooting....2925
Warning Lights and Indicators....2925
Electrical System....2926
Engine....2927
Hydraulic system....2930
Brakes....2932
Axles....2933
driver’s cab....2933
Emergency Steering Characteristics....2934
Emergency Lowering System....2934
Starting the Engine with a Battery Jumper Cable....2935
Towing the Machine....2937
Inadequate Braking Effect....2939
Maintenance....2942
Maintenance Basics....2943
Preparing the Machine for Maintenance....2943
Cleaning the Machine....2944
Working-Area-Dependent Maintenance....2945
Lubricants and Operating Agents....2946
Axles....2953
Replacing Safety-Related Parts....2953
Welding Instructions....2954
Spare Parts and Consumable Components....2955
Electrical System....2956
Tires....2959
Torque for Standard Nuts and Bolts....2961
Maintenance Schedule....2963
Maintenance Prior to Start....2965
Visual Checks....2965
Cooling System, Checking the Coolant Level, Topping off Coolant....2965
Engine, Checking the Oil Level, Topping off Oil....2966
Engine, Draining off Oil....2967
Checking the Fuel Level, Refueling....2968
Checking the Controls....2969
Checking the Electrical Connections....2969
Heater / air conditioning: checking rate of air flow....2970
Other Maintenance Measures Prior to Start....2970
Maintenance upon demand....2971
Checking the air-conditioning system....2971
Maintenance Every 10 Operating Hours....2972
Lubrication....2972
Maintenance After the First 50 Operating Hours....2973
Engine, Changing Oil and Replacing the Oil Filter Cartridge....2973
V-Belt, Checking the Condition....2975
V-Belt, Checking and Adjusting the Tension....2975
Hydraulic System, Replacing the Filter Insert....2976
Checking and Tightening the Wheel Nuts....2977
Front and Rear Axle, Changing Oil....2978
Transfer Gear - Changing Oil....2979
Maintenance Every 50 Operating Hours....2981
Checking cooling System, coolant level in the radiator and expansion tank....2981
Draining Off Water and Dirt Deposits From the Fuel Tank....2982
Checking the Service Brake and Oil Level, Refilling Oil....2982
Checking the Battery and Acid Level....2983
Lubrication....2985
Maintenance Every 100 Operating Hours....2986
Draining the Water Separator, Removing Water and Dirt Deposits....2986
Maintenance Every 250 Operating Hours....2987
Changing the Engine Oil and Oil Filter Cartridge....2987
Checking the V-Belt Condition....2987
Checking and Adjusting the V-belt Tension....2987
Front and Rear Axle, Checking the Oil Level....2988
Air Filter, Removing/Re-Installing AND Checking/Cleaning the Filter Insert....2990
Cleaning the Radiator Segments....2992
Lubrication....2993
Maintenance Every 500 Operating Hours....2994
Changing the Fuel Filter and Filter Element....2994
Changing the Filter Cartridge of the Hydraulic System....2996
Cleaning the Water Separator....2996
Lubrication....2997
Transfer Gear, Checking the Oil Level and Refilling Oil....2997
Air Filter, Replacing the Filter Insert, Replacing the Safety Filter....2998
Heater/air conditioning: clean filter fleece of heater unit....2999
Heater/air conditioning: Cleaning the condenser....3000
Maintenance Every 1000 Operating Hours....3001
Cooling System, Exchanging Coolant and Cleaning the System....3001
Front Axle, Oil Change....3003
Rear Axle, Oil Change....3003
Transfer Gear, Oil Change....3003
Service Brake....3003
Checking and Adjusting System Pressures....3003
Checking and Adjusting the Valve clearance....3003
Checking/Adjusting the Injection Nozzles, Nozzle Pressure/ Fuel-Jet Pattern....3004
Checking the Accumulator Gas Pressure....3004
Maintenance Every 2000 Operating Hours....3005
Hydraulic System, Oil Change....3005
Bleeding the Hydraulic Oil Tank....3006
Cooling System, Checking the Antifreeze Content of the Coolant....3006
Checking the Cooling System....3006
Checking the Fuel Pump....3006
Checking the Fuel and Coolant Tubes, Replacing the Tubes (if required)....3006
Checking the Water Pump....3007
Checking and Adjusting the Fuel Injection and Injection time....3007
Technical Data....3008
Technical Data....3009
Noise Emission Levels....3010
Vibration Level....3010
Limit Values for Slopes....3010
Special Equipment and Attachments....3012
ALS-Electronics....3013
Structure and Functioning Principle of the ALS-Electronics....3013
Precautionary Measures for Switching on the ALS Electronics....3013
Operation of the ALS-Electronics....3014
Handling of the Pressure Accumulator....3015
Index....3016
VEAM980800 - Wheel Loader WA95-3 Operation & Maintenance Manual....3021
Table of Contents....3025
Introduction....3025
Forword 1-2....3025
Safety Information 1-3....3025
Introduction 1-5....3025
Features 1-5....3025
Breaking in a New Machine 1-5....3025
Location of Plates, Table to Enter Serial No. and Distributor 1-6....3025
Machine Serial No. Plate position 1-6....3025
Engine Serial No. Plate Position 1-6....3025
Table to Enter Serial No. and Distributor 1-6....3025
EMISSION CONTROL WARRANTY 1-7....3025
EMISSION CONTROL WARRANTY STATEMENT (APPLIES TO CANADA ONLY) 1-7....3025
Engine Data Plate 1-8....3025
GARANTIE SUR LE CONTRÔLE DES ÉMISSIONS 1-9....3025
ÉNONCÉ DE GARANTIE SUR LE CONTRÔLE DES ÉMISSIONS ( APPLICABLE AU CANADA SEULEMENT): 1-9....3025
Engine Data Plate 1-11....3025
Why You Should Read these Operating Instructions 1-12....3025
Notes on Safety Regulations 1-14....3025
Correct Use 1-14....3025
Safety Notes in the Operating Instructions 1-14....3025
Equipment 1-15....3025
Loading and Transporting the Machine....3025
Loading and Transporting the Machine 2-2....3025
Securing the Articulated Steering 2-2....3025
Lifting the Machine 2-2....3025
Driving Machine Onto Loading Area of Transport Vehicle 2-4....3025
Securing the Machine During Transport 2-5....3025
After Transport 2-5....3025
Safety....3025
General Safety Measures 3-3....3025
Safety Instructions 3-3....3025
Safety Devices 3-3....3025
Emergency Exit 3-3....3025
Clothing and Personal Protection 3-4....3025
Machine Modifications 3-4....3025
Before You Leave the Driver's Seat 3-4....3025
Mounting and Dismounting 3-5....3025
Fire Prevention and Fire Fighting 3-6....3025
Fire Extinguisher and First-Aid Kit 3-7....3025
Protection Against Asbestos Dust 3-7....3025
Protection Against Injuries 3-8....3025
Working at High Temperatures 3-8....3025
Roll-Over Protection System (ROPS) 3-9....3025
Attachment for Protection Against Falling Objects (FOPS) 3-9....3025
Attachments 3-9....3025
Battery 3-10....3025
Safety Measures during Operation 3-11....3025
Before You Start the Engine 3-11....3025
Workplace Safety 3-11....3026
In the Driver's Cab 3-11....3026
In-Door Operation 3-12....3026
Gas, Dust, and Inflammable Vapours 3-12....3026
Mirrors, Windows, and Lighting 3-12....3026
Machine Operation 3-13....3026
Before You Start the Engine 3-13....3026
Reversing 3-13....3026
Driving 3-14....3026
Driving On Slopes 3-14....3026
Emergency Lowering System 3-15....3026
Working Close to Overhead Power Transmission Lines 3-15....3026
Loading 3-16....3026
Good Vision 3-16....3026
Working On Snow 3-16....3026
Height Limitation 3-17....3026
Brakes 3-17....3026
Working On Loose Soil 3-17....3026
Working with the Forklift Truck Attachment 3-18....3026
Parking the Machine 3-19....3026
Transport 3-20....3026
Loading and Unloading the Machine 3-20....3026
Transport 3-21....3026
Safety Measures During Maintenance 3-22....3026
Personnel 3-22....3026
Prior to Start of Maintenance Measures 3-22....3026
Warning Sign 3-22....3026
Tools 3-22....3026
Safety-Related Parts 3-22....3026
Prior to Start of Inspection and Maintenance 3-23....3026
Securing the Articulated Steering 3-23....3026
Supporting the boom 3-24....3026
During Maintenance 3-25....3026
Attachments 3-25....3026
Working Under the Machine 3-25....3026
Keeping the Machine Clean 3-25....3026
Specific Measures 3-25....3026
Refueling and Topping Off Oil 3-26....3026
Coolant 3-26....3026
Use of Lighting 3-27....3026
High-Pressure Hoses 3-27....3026
Handling High-Pressure Oil 3-27....3026
Handling of the pressure accumulator 3-28....3026
Fan and Belts 3-28....3026
Waste Material 3-28....3026
Tires 3-29....3026
Storing Tires 3-30....3026
Labeling 3-31....3026
Position of Safety Labels 3-31....3026
Information Labels 3-33....3026
Controls and InDicators....3026
Overall View of Machine 4-2....3026
Controls and Indicators 4-3....3026
SWITCHES AND CONTROLS 4-4....3026
Instrument Panel 4-5....3026
Warning Lights 4-6....3026
Control Lamps 4-9....3026
Measuring Indicators 4-13....3027
Switches 4-15....3027
Control Levers, Pedals 4-22....3027
Articulated Steering Catch 4-28....3027
Traction Device 4-28....3027
Socket 4-28....3027
Door Unlocking System 4-29....3027
Alarm Horn for Reverse Driving 4-29....3027
Operation....3027
Running in the Machine 5-2....3027
Preparing the Machine Start 5-3....3027
Visual Checks 5-3....3027
Before you start the engine 5-3....3027
Before starting working with the machine 5-3....3027
Adjustments Prior to Machine Start 5-6....3027
Adjusting the Driver’s Seat 5-6....3027
Adjusting the Steering Column 5-7....3027
Adjusting the Armrest 5-7....3027
Adjusting the Rear-View Mirrors 5-7....3027
Adjusting the Heating and Ventilation System 5-8....3027
Adjusting the ventilation system 5-8....3027
Adjusting the heating system 5-9....3027
Operating the Air Conditioning 5-10....3027
Switching on the air-conditioning 5-10....3027
Putting on the Safety Belt 5-12....3027
Putting on the safety belt 5-12....3027
Taking off the safety belt 5-12....3027
Starting and Switching Off the Engine 5-13....3027
Starting the Engine 5-13....3027
Warming up the engine 5-14....3027
Switching Off the Engine 5-15....3027
Driving 5-16....3027
Start-Up 5-16....3027
Starting the machine on slopes 5-18....3027
Driving with the high-Speed gear 5-18....3027
Changing the Driving Direction 5-19....3027
Reverse Driving 5-20....3027
Turning 5-20....3027
Turning on slopes, embankments or hill flanks 5-20....3027
Braking 5-21....3027
Pulling the parking brake 5-21....3027
Releasing the parking brake 5-21....3027
Braking with the service brake 5-21....3027
If the service brake breaks down 5-22....3027
Braking on slopes 5-22....3027
Stopping 5-23....3027
Parking the machine on a slope 5-23....3027
Longer-Distance Driving 5-24....3027
Operating the Machine 5-25....3027
Preparing the Work Equipment 5-25....3027
Selecting a work unit 5-25....3027
Picking up the work unit (except multi-purpose bucket) 5-25....3027
Removing the work unit 5-26....3027
Picking up the multi-purpose bucket 5-26....3027
Removing the multi-purpose bucket 5-28....3027
Tire Service Life 5-29....3027
Level indicator for the bucket 5-29....3028
Adjusting the Bucket Positioner 5-30....3028
Loading 5-31....3028
Removing piled up soil 5-31....3028
Excavation works 5-33....3028
Transporting 5-34....3028
Dumping / Unloading 5-34....3028
Loading in diagonal direction 5-34....3028
V-shaped loading 5-35....3028
Piling up material 5-35....3028
Planing 5-36....3028
Filling up 5-36....3028
Taking off soil 5-36....3028
Cutting the Ground 5-37....3028
Working With the Forklift Truck Attachment 5-38....3028
Picking up the load 5-38....3028
Precautions For Special Operations 5-39....3028
Working in water 5-39....3028
Working on snow 5-39....3028
Dumping on steep slopes 5-39....3028
Working in the vicinity of electrical overhead lines 5-39....3028
Operation on slopes 5-39....3028
Working on loose soil 5-39....3028
After the work is finished 5-39....3028
Instructions for Winter Operation 5-40....3028
Before the cold season 5-40....3028
After Operation 5-40....3028
After the cold season 5-41....3028
Longer Standstill Periods of the Machine 5-42....3028
Before the standstill 5-42....3028
During the standstill 5-42....3028
After the standstill 5-43....3028
Troubleshooting....3028
Troubleshooting 6-2....3028
Warning Lights and Indicators 6-2....3028
Electrical System 6-3....3028
Engine 6-4....3028
Hydraulic system 6-7....3028
Brakes 6-9....3028
Axles 6-10....3028
driver’s cab 6-10....3028
Emergency Steering Characteristics 6-11....3028
Emergency Lowering System 6-11....3028
Starting the Engine with a Battery Jumper Cable 6-12....3028
Connecting the Jumper Cable 6-12....3028
Starting the Engine 6-13....3028
Disconnecting the Battery Jumper Cable 6-13....3028
Towing the Machine 6-14....3028
Towing a Machine with Defective Brakes 6-15....3028
Inadequate Braking Effect 6-16....3028
Checking the Parking Brake 6-16....3028
Checking the Service Brake 6-17....3028
Maintenance....3028
Maintenance Basics 7-2....3028
Preparing the Machine for Maintenance 7-2....3028
Cleaning the Machine 7-3....3028
Precautionary Measures When Cleaning the Machine 7-3....3029
Fire Prevention 7-3....3029
Working-Area-Dependent Maintenance 7-4....3029
Muddy or Wet Working Areas 7-4....3029
Dusty Working Areas 7-4....3029
Lubricants and Operating Agents 7-5....3029
Draining Hot Lubricants and Fluids 7-5....3029
Checking the Oil Level and Changing Oil 7-5....3029
Changing Filters 7-5....3029
Refuelling and Topping off Oil 7-5....3029
Oil 7-6....3029
Lubricating Grease 7-6....3029
Biodegradable Hydraulic Oil and Lubricating Grease 7-6....3029
Fuel 7-7....3029
Storage of Oil and Fuel 7-7....3029
Coolants 7-8....3029
Windscreen Washer Liquid 7-8....3029
Table of Lubricants and Operating Agents 7-10....3029
Lubrication chart 7-11....3029
Axles 7-12....3029
Released axle oil brands 7-12....3029
Replacing Safety-Related Parts 7-12....3029
Welding Instructions 7-13....3029
Spare Parts and Consumable Components 7-14....3029
Electrical System 7-15....3029
Fuses 7-16....3029
Fuse Assignment 7-16....3029
Slow-Blowing Fuses 7-17....3029
Tires 7-18....3029
Tire Components 7-18....3029
Checking the Tires 7-18....3029
Checking the Tire Pressure 7-18....3029
Torque for Standard Nuts and Bolts 7-20....3029
Maintenance Schedule 7-22....3029
Maintenance Prior to Start 7-24....3029
Visual Checks 7-24....3029
Cooling System, Checking the Coolant Level, Topping off Coolant 7-24....3029
Engine, Checking the Oil Level, Topping off Oil 7-25....3029
Engine, Draining off Oil 7-26....3029
Checking the Fuel Level, Refueling 7-27....3029
Checking the Controls 7-28....3029
Checking the Electrical Connections 7-28....3029
Heater / air conditioning: checking rate of air flow 7-29....3029
Other Maintenance Measures Prior to Start 7-29....3029
Maintenance upon demand 7-30....3029
Checking the air-conditioning system 7-30....3029
Checking the coolant level 7-30....3029
Maintenance Every 10 Operating Hours 7-31....3029
Lubrication 7-31....3029
Maintenance After the First 50 Operating Hours 7-32....3029
Engine, Changing Oil and Replacing the Oil Filter Cartridge 7-32....3029
Replacing the Oil Filter Cartridge 7-33....3029
V-Belt, Checking the Condition 7-34....3029
V-Belt, Checking and Adjusting the Tension 7-34....3029
Hydraulic System, Replacing the Filter Insert 7-35....3029
Checking and Tightening the Wheel Nuts 7-36....3029
Front and Rear Axle, Changing Oil 7-37....3029
Planet gear 7-37....3030
Differential 7-37....3030
Transfer Gear - Changing Oil 7-38....3030
Maintenance Every 50 Operating Hours 7-40....3030
Checking cooling System, coolant level in the radiator and expansion tank 7-40....3030
Draining Off Water and Dirt Deposits From the Fuel Tank 7-41....3030
Checking the Service Brake and Oil Level, Refilling Oil 7-41....3030
Checking the Battery and Acid Level 7-42....3030
Re-charging a built-in battery 7-43....3030
Lubrication 7-44....3030
Lubricating points of the work equipment 7-44....3030
Maintenance Every 100 Operating Hours 7-45....3030
Draining the Water Separator, Removing Water and Dirt Deposits 7-45....3030
Maintenance Every 250 Operating Hours 7-46....3030
Changing the Engine Oil and Oil Filter Cartridge 7-46....3030
Checking the V-Belt Condition 7-46....3030
Checking and Adjusting the V-belt Tension 7-46....3030
Front and Rear Axle, Checking the Oil Level 7-47....3030
Planet gear 7-47....3030
differential 7-48....3030
Air Filter, Removing/Re-Installing AND Checking/Cleaning the Filter Insert 7-49....3030
Structure of the air filter 7-49....3030
Maintenance demand 7-49....3030
Removing the filter cartridge 7-49....3030
Cleaning or exchanging the filter cartridge 7-50....3030
Checking the filter cartridge 7-51....3030
Assembling the air filter cartridge 7-51....3030
Cleaning the Radiator Segments 7-51....3030
Lubrication 7-52....3030
Maintenance Every 500 Operating Hours 7-53....3030
Changing the Fuel Filter and Filter Element 7-53....3030
Bleeding the Fuel System 7-54....3030
Changing the Filter Cartridge of the Hydraulic System 7-55....3030
Cleaning the Water Separator 7-55....3030
Lubrication 7-56....3030
Transfer Gear, Checking the Oil Level and Refilling Oil 7-56....3030
Air Filter, Replacing the Filter Insert, Replacing the Safety Filter 7-57....3030
Replacing the Filter Insert 7-57....3030
Replacing the Safety Filter 7-57....3030
Heater/air conditioning: clean filter fleece of heater unit 7-58....3030
Heater/air conditioning: Cleaning the condenser 7-59....3030
ECSS-Pressure Accumulator (Option): Checking the Gas Pressure 7-59....3030
Maintenance Every 1000 Operating Hours 7-60....3030
Cooling System, Exchanging Coolant and Cleaning the System 7-60....3030
Draining off the coolant 7-61....3030
Cleaning the Cooling System 7-61....3030
Filling off Coolant 7-61....3030
Front Axle, Oil Change 7-62....3030
Rear Axle, Oil Change 7-62....3030
Transfer Gear, Oil Change 7-62....3030
Service Brake 7-62....3030
Changing oil 7-62....3030
Checking tubes and lines 7-62....3030
Checking the brake disks for wear and tear 7-62....3030
Adjusting the clearance of the brake disks 7-62....3030
Checking and Adjusting System Pressures 7-62....3030
Checking and Adjusting the Valve clearance 7-62....3030
Checking/Adjusting the Injection Nozzles, Nozzle Pressure/Fuel-Jet Pattern 7-63....3031
Checking the Accumulator Gas Pressure OF THIRD CONTROL CIRCUIT 7-63....3031
Checking the tightening parts of the Turbo-charger 7-63....3031
Checking the gap of the Turbo-charger rotor 7-63....3031
Maintenance Every 2000 Operating Hours 7-64....3031
Hydraulic System, Oil Change 7-64....3031
Bleeding the Hydraulic Oil Tank 7-65....3031
Cooling System, Checking the Antifreeze Content of the Coolant 7-65....3031
Checking the Cooling System 7-65....3031
Checking the Fuel Pump 7-65....3031
Checking the Fuel and Coolant Tubes, Replacing the Tubes (if required) 7-65....3031
Checking the Water Pump 7-66....3031
Checking and Adjusting the Fuel Injection and Injection time 7-66....3031
Technical Data....3031
Technical Data 8-2....3031
Noise Emission Levels 8-3....3031
Vibration Level 8-3....3031
Limit Values for Slopes 8-4....3031
Maximum slope angle for operating the machine 8-4....3031
Tilt angle 8-4....3031
special equipment and attachments....3031
ECSS 9-2....3031
Structure and Functioning Principle of the ECSS 9-2....3031
Precautionary Measures for Switching on the ECSS 9-2....3031
Operation of the ECSS 9-3....3031
Switching on the ECSS 9-3....3031
Switching off the ECSS 9-3....3031
Handling of the Pressure Accumulator 9-4....3031
Index....3031
Introduction....3033
Forword....3034
Safety Information....3035
Introduction....3037
Features....3037
Breaking in a New Machine....3037
Location of Plates, Table to Enter Serial No. and Distributor....3038
Machine Serial No. Plate position....3038
Engine Serial No. Plate Position....3038
Table to Enter Serial No. and Distributor....3038
EMISSION CONTROL WARRANTY....3039
EMISSION CONTROL WARRANTY STATEMENT (APPLIES TO CANADA ONLY)....3039
Engine Data Plate....3040
GARANTIE SUR LE CONTRÔLE DES ÉMISSIONS....3041
ÉNONCÉ DE GARANTIE SUR LE CONTRÔLE DES ÉMISSIONS ( APPLICABLE AU CANADA SEULEMENT):....3041
Engine Data Plate....3043
Why You Should Read these Operating Instructions....3044
Notes on Safety Regulations....3046
Correct Use....3046
Safety Notes in the Operating Instructions....3046
Equipment....3047
Loading and Transporting the Machine....3049
Loading and Transporting the Machine....3050
Securing the Articulated Steering....3050
Lifting the Machine....3050
Driving Machine Onto Loading Area of Transport Vehicle....3052
Securing the Machine During Transport....3053
After Transport....3053
Safety....3055
General Safety Measures....3057
Safety Instructions....3057
Safety Devices....3057
Emergency Exit....3057
Clothing and Personal Protection....3058
Machine Modifications....3058
Before You Leave the Driver's Seat....3058
Mounting and Dismounting....3059
Fire Prevention and Fire Fighting....3060
Fire Extinguisher and First-Aid Kit....3061
Protection Against Asbestos Dust....3061
Protection Against Injuries....3062
Working at High Temperatures....3062
Roll-Over Protection System (ROPS)....3063
Attachment for Protection Against Falling Objects (FOPS)....3063
Attachments....3063
Battery....3064
Safety Measures during Operation....3065
Before You Start the Engine....3065
Machine Operation....3067
Transport....3074
Safety Measures During Maintenance....3076
Personnel....3076
Prior to Start of Maintenance Measures....3076
During Maintenance....3079
Tires....3083
Labeling....3085
Position of Safety Labels....3085
Information Labels....3087
Controls and InDicators....3089
Overall View of Machine....3090
Controls and Indicators....3091
Control Lamps....3097
Measuring Indicators....3101
Switches....3103
Control Levers, Pedals....3110
Articulated Steering Catch....3116
Traction Device....3116
Socket....3116
Door Unlocking System....3117
Alarm Horn for Reverse Driving....3117
Operation....3119
Running in the Machine....3120
Preparing the Machine Start....3121
Visual Checks....3121
Adjustments Prior to Machine Start....3124
Adjusting the Driver’s Seat....3124
Adjusting the Steering Column....3125
Adjusting the Armrest....3125
Adjusting the Rear-View Mirrors....3125
Adjusting the Heating and Ventilation System....3126
Operating the Air Conditioning....3128
Putting on the Safety Belt....3130
Starting and Switching Off the Engine....3131
Starting the Engine....3131
Warming up the engine....3132
Switching Off the Engine....3133
Driving....3134
Start-Up....3134
Changing the Driving Direction....3137
Reverse Driving....3138
Turning....3138
Braking....3139
Pulling the parking brake....3139
Stopping....3141
Longer-Distance Driving....3142
Operating the Machine....3143
Preparing the Work Equipment....3143
Tire Service Life....3147
Level indicator for the bucket....3147
Adjusting the Bucket Positioner....3148
Loading....3149
Transporting....3152
Dumping / Unloading....3152
Planing....3154
Working With the Forklift Truck Attachment....3156
Precautions For Special Operations....3157
After the work is finished....3157
Instructions for Winter Operation....3158
Longer Standstill Periods of the Machine....3160
Troubleshooting....3163
Troubleshooting....3164
Warning Lights and Indicators....3164
Electrical System....3165
Engine....3166
Hydraulic system....3169
Brakes....3171
Axles....3172
driver’s cab....3172
Emergency Steering Characteristics....3173
Emergency Lowering System....3173
Starting the Engine with a Battery Jumper Cable....3174
Towing the Machine....3176
Inadequate Braking Effect....3178
Maintenance....3181
Maintenance Basics....3182
Preparing the Machine for Maintenance....3182
Cleaning the Machine....3183
Working-Area-Dependent Maintenance....3184
Lubricants and Operating Agents....3185
Axles....3192
Replacing Safety-Related Parts....3192
Welding Instructions....3193
Spare Parts and Consumable Components....3194
Electrical System....3195
Tires....3198
Torque for Standard Nuts and Bolts....3200
Maintenance Schedule....3202
Maintenance Prior to Start....3204
Visual Checks....3204
Cooling System, Checking the Coolant Level, Topping off Coolant....3204
Engine, Checking the Oil Level, Topping off Oil....3205
Engine, Draining off Oil....3206
Checking the Fuel Level, Refueling....3207
Checking the Controls....3208
Checking the Electrical Connections....3208
Heater / air conditioning: checking rate of air flow....3209
Other Maintenance Measures Prior to Start....3209
Maintenance upon demand....3210
Checking the air-conditioning system....3210
Maintenance Every 10 Operating Hours....3211
Lubrication....3211
Maintenance After the First 50 Operating Hours....3212
Engine, Changing Oil and Replacing the Oil Filter Cartridge....3212
V-Belt, Checking the Condition....3214
V-Belt, Checking and Adjusting the Tension....3214
Hydraulic System, Replacing the Filter Insert....3215
Checking and Tightening the Wheel Nuts....3216
Front and Rear Axle, Changing Oil....3217
Transfer Gear - Changing Oil....3218
Maintenance Every 50 Operating Hours....3220
Checking cooling System, coolant level in the radiator and expansion tank....3220
Draining Off Water and Dirt Deposits From the Fuel Tank....3221
Checking the Service Brake and Oil Level, Refilling Oil....3221
Checking the Battery and Acid Level....3222
Lubrication....3224
Maintenance Every 100 Operating Hours....3225
Draining the Water Separator, Removing Water and Dirt Deposits....3225
Maintenance Every 250 Operating Hours....3226
Changing the Engine Oil and Oil Filter Cartridge....3226
Checking the V-Belt Condition....3226
Checking and Adjusting the V-belt Tension....3226
Front and Rear Axle, Checking the Oil Level....3227
Air Filter, Removing/Re-Installing AND Checking/Cleaning the Filter Insert....3229
Cleaning the Radiator Segments....3231
Lubrication....3232
Maintenance Every 500 Operating Hours....3233
Changing the Fuel Filter and Filter Element....3233
Changing the Filter Cartridge of the Hydraulic System....3235
Cleaning the Water Separator....3235
Lubrication....3236
Transfer Gear, Checking the Oil Level and Refilling Oil....3236
Air Filter, Replacing the Filter Insert, Replacing the Safety Filter....3237
Heater/air conditioning: clean filter fleece of heater unit....3238
Heater/air conditioning: Cleaning the condenser....3239
ECSS-Pressure Accumulator (Option): Checking the Gas Pressure....3239
Maintenance Every 1000 Operating Hours....3240
Cooling System, Exchanging Coolant and Cleaning the System....3240
Front Axle, Oil Change....3242
Rear Axle, Oil Change....3242
Transfer Gear, Oil Change....3242
Service Brake....3242
Checking and Adjusting System Pressures....3242
Checking and Adjusting the Valve clearance....3242
Checking/Adjusting the Injection Nozzles, Nozzle Pressure/ Fuel-Jet Pattern....3243
Checking the Accumulator Gas Pressure OF THIRD CONTROL CIRCUIT....3243
Checking the tightening parts of the Turbo-charger....3243
Checking the gap of the Turbo-charger rotor....3243
Maintenance Every 2000 Operating Hours....3244
Hydraulic System, Oil Change....3244
Bleeding the Hydraulic Oil Tank....3245
Cooling System, Checking the Antifreeze Content of the Coolant....3245
Checking the Cooling System....3245
Checking the Fuel Pump....3245
Checking the Fuel and Coolant Tubes, Replacing the Tubes (if required)....3245
Checking the Water Pump....3246
Checking and Adjusting the Fuel Injection and Injection time....3246
Technical Data....3247
Technical Data....3248
Noise Emission Levels....3249
Vibration Level....3249
Limit Values for Slopes....3250
special equipment and attachments....3251
ECSS....3252
Structure and Functioning Principle of the ECSS....3252
Precautionary Measures for Switching on the ECSS ....3252
Operation of the ECSS....3253
Handling of the Pressure Accumulator....3254
Index....3255
A....3255
B....3255
C....3255
D....3255
E....3255
F....3255
G....3256
H....3256
I....3256
L....3256
M....3256
O....3257
P....3258
R....3258
S....3258
T....3258
V....3258
W....3258
VEBM950201 - Wheel Loader WA65-3, WA65-3 Parallel Lift, WA75-3, WA85-3, WA90-3, WA95-3 Shop Manual....3260
SAFETY....3266
Safety notice....3267
Preparations for work....3268
Precautions during work....3269
Foreword....3271
How to read the shop manual....3272
Volumes....3272
Distribution and updating....3272
Filing method....3272
Symbols....3273
Hoisting instructions....3274
GENERAL....3276
Dimensions, weights and operating data – WA65-3....3279
Dimensions, weights and operating data – WA65-3 Parallel Lift....3280
Specifications – WA65-3/WA65-3 Parallel Lift....3281
Dimensions, weights and operating data – WA75-3....3284
Specifications – WA75-3....3285
Dimensions, weights and operating data – WA85-3....3288
Specifications – WA85-3....3289
Dimensions, weights and operating data – WA90-3....3292
Specifications – WA90-3....3293
Dimensions, weights and operating data – WA95-3....3296
Specifications – WA95-3....3297
Weight table – WA65-3/WA65-3 Parallel Lift....3299
Deviating weights for WA65-3 Parallel Lift....3299
Weight table – WA75-3/WA85-3....3300
Weight table – WA90-3/95-3....3301
Lubricants and operating mediums – WA65-3....3302
Lubricants and operating mediums – WA75-3/WA85-3....3303
Lubricants and operating mediums – WA90-3/WA95-3....3304
Basic procedures of maintenance....3305
Oil....3305
Fuel....3305
Coolant....3306
Grease....3306
Storing oil and fuel....3306
Filters....3307
Biodegradable hydraulic oils and lubricants....3307
Outline of electric system....3307
Torque list – screws and nuts....3308
STRUCTURE AND FUNCTION....3310
Powertrain....3312
Closed circuit....3313
Hydraulic drive system, 20 km/h – WA65-3 bis WA95-3....3314
Hydraulic drive system, 30 km/h – WA75-3 bis WA95-3 (option)....3315
Variable displacement pump....3316
Regulating valve....3319
Charge pressure limiting valve....3319
Control cylinder....3320
4/3 Way valve with direction control solenoids....3320
Pressure cut-off valve....3321
Safety-/charge valve....3321
Towing....3322
Variable displacement motor....3323
Drive shaft....3326
Axle mounting – front and rear axle....3327
Front axle with drum brake – WA65-3....3328
Front axle – WA75-3/WA85-3....3329
Front axle – WA90-3/WA95-3....3330
Rear axle with distributor box – WA65-3....3331
Rear axle with distributor box – WA75-3/WA85-3....3332
Rear axle with distributor box – WA90-3/WA95-3....3333
Distributor box, single stage (20 km/h) – WA65-3/WA75-3/ WA85-3....3334
Distributor box, single stage (20 km/h) – WA90-3/WA95-3....3335
Distributor box, double stage (30 km/h) – WA75-3/WA 85-3/ WA90-3/WA95-3....3336
Limited slip differential (locking value 25%), front and rear axle – WA65-3/WA75-3/WA85-3....3337
Wheel hub, front and rear axle – WA65-3/WA75-3/WA85-3....3339
Service and parking brake with slack adjuster, front axle – WA65-3/WA75-3/WA85-3....3340
Service and parking brake....3341
Automatical adjuster....3342
Service and parking brake, rear axle – WA75-3/WA85-3....3343
Service and parking brake, rear axle – WA90-3/WA95-3....3345
Sevice and parking brake circuit – WA65-3....3347
Sevice and parking brake circuit – WA75-3/WA85-3/ WA90 3/WA95-3....3348
Inch-brake valve....3349
Steering articulation joint....3350
Steering system....3352
Hydraulic circuit diagram of steering system – WA65-3/WA75-3/WA85-3....3352
Hydraulic circuit diagram of steering system – WA90-3/WA95-3....3353
Priority valve....3354
Orbit-roll-valve....3355
Steering relief valve....3356
Work equipment hydraulic....3359
Travel, steering and work hydraulics – WA65 3....3359
Travel, steering and work hydraulics – WA65 3....3361
Travel, steering and work hydraulics – WA65 3 Parallel Lift....3363
Travel, steering and work hydraulics – WA75 3/WA85-3....3365
Travel, steering and work hydraulics – WA75 3/WA85-3....3367
Travel, steering and work hydraulics – WA90 3/WA95-3....3369
Travel, steering and work hydraulics – WA90 3/WA95-3....3371
PPC-Valve....3373
Operation of PPC-valve....3374
Servo pressure regulating valve....3375
Main control valve....3377
Control circuit for tilt-in/tilt-out (cross section)....3378
Pressure regulating valve....3379
Shock-anticavitation valve....3379
Anticavitation valve....3380
Lift cylinder – WA65-3....3381
Lift cylinder – WA75-3/WA85-3....3382
Lift cylinder – WA90-3/WA95-3....3383
Dump cylinder – WA65-3....3384
Dump cylinder – WA65-3 Parallel Lift....3385
Dump cylinder – WA75-3/WA85-3....3386
Dump cylinder – WA90/WA95-3....3387
Steering cylinder – WA65-3/WA75-3/WA85-3....3388
Steering cylinder – WA90-3/WA95-3....3389
Lifting frame with quick-coupler....3390
Quick-coupler....3391
Lifting with quick-coupler – WA65-3 Parallel Lift....3392
Bucket positioner....3394
Function....3395
Operation of proximity switch....3395
Adjusting the bucket positioner....3396
Monitor display....3398
Sensors....3399
Engine oil pressure sensor....3399
Fuel level sensor....3400
Engine coolant temperature sensor....3401
Brake oil reservoir sensor....3402
Ribbon heater temperature sender unit....3403
Ribbon heater....3404
Engine stop/start/preheating circuit....3405
Driver's cab....3407
Fuses (1)....3407
Relais (2)....3407
Engine room....3408
Wiring diagrams....3410
Wiring diagram – Fig. 1....3411
Wiring diagram – Fig. 2....3414
Wiring diagram – Fig. 3....3415
Wiring diagram – Fig. 4....3418
Air conditioner (option)....3432
Introduction....3432
Function....3432
The coolant circuit....3432
The condenser....3435
The vaporizer....3436
The filter dryer....3437
Design of air conditioner....3438
Installation of air conditioner....3439
Safety when handling coolants....3440
Operating the air conditioner....3442
Maintenance of the air conditioner....3443
Regular maintenance....3444
Instructions for filling....3446
Exchange of magnetic clutch....3449
Exchange of compressor....3450
Troubleshooting....3452
TESTING AND ADJUSTING....3456
Standard value table for engine – WA65-3....3458
Standard value table for chassis – WA65-3....3459
Standard value table for electrical parts – WA65-3....3462
Test certificate – WA65-3....3463
Test certificate – WA65-3 Parallel Lift....3464
Standard value table for engine – WA75-3/WA85-3....3465
Standard value table for chassis – WA75-3/WA85-3....3466
Standard value table for electrical parts – WA75-3/WA85-3....3469
Test certificate – WA75-3....3471
Test certificate – WA85-3....3472
Standard value table for engine – WA90-3/WA95-3....3473
Standard value table for chassis – WA90-3/WA95-3....3474
Standard value table for electrical parts – WA90-3/WA95-3....3477
Test certificate WA90-3....3479
Test certificate WA95-3....3480
Valve clearance, testing and adjusting....3482
Engine compression test....3483
Injection nozzle pressure....3484
Fuel injection timing....3485
Fan belt....3486
Engine RPM....3487
RPM-dependant drive take-up....3488
Engine stall torque RPM....3489
Engine stall torque RPM, test with the hydrostatic drive....3489
Engine stall torque RPM, test with the hydrostatic drive and working hydraulics....3490
Feed pump and servo oil pressure....3491
Hydraulic pressure cut-off....3492
Working hydraulic pressure....3494
Steering oil pressure....3495
Operating time for steering wheel....3496
Operating force of steering wheel....3497
Brake....3498
Brake lining, wear test – WA65-3....3498
Brake disc, wear test – WA75-3/WA85 3/ WA90-3/WA95-3....3498
Brake disc clearance – WA75-3/WA85-3....3499
Brake disc clearance – WA90-3/WA95-3....3500
Bleeding the brake system – WA65-3 up to WA95-3....3501
Inch valve – basic adjustment....3502
Parking brake....3503
Basic adjustment – WA75-3 through WA95 3....3503
Brake efficiency....3504
Measuring the stopping distance....3504
Parking brake efficiency....3505
Travel speed....3506
DISASSEMBLY AND ASSEMBLY....3508
Comments....3510
Starter assembly....3511
Removal of starter assembly....3511
Installation of starter assembly....3512
Alternator assembly....3513
Removal of alternator assembly....3513
Installation of alternator assembly....3514
Water pump assembly....3515
Removal of water pump assembly....3515
Installation of water pump assembly....3517
Engine cover assembly....3518
Removal of engine cover assembly....3518
Installation of engine cover assembly....3519
Engine cover support assembly....3520
Removal of engine cover support assembly....3520
Installation of engine cover support assembly....3522
Engine assembly....3523
Removal of engine assembly....3523
Installation of engine assembly....3528
Clutch assembly....3531
Removal of clutch assembly....3531
Installation of clutch assembly....3532
Radiator assembly....3533
Removal of radiator assembly....3533
Installation of radiator assembly....3535
Fan and pulley assembly....3536
Removal of fan and pulley assembly....3536
Installation of fan and pulley assembly....3537
Inch brake valve assembly....3538
Removal of inch brake valve assembly....3538
Installation of inch brake valve assembly....3539
Priority valve assembly....3540
Removal of priority valve assembly....3540
Installation of priority valve assembly....3541
Steering valve assembly....3542
Removal of steering valve assembly....3542
Installation of steering valve assembly....3544
Counterweight assembly....3545
Removal of counterweight assembly....3545
Installation of counterweight assembly....3546
Main control valve assembly....3547
Removal of main control valve assembly....3547
Installation of main control valve assembly....3548
Pilot valve assembly....3549
Removal of pilot valve assembly....3549
Installation of pilot valve assembly....3551
Monitor assembly....3552
Removal of monitor assembly....3552
Installation of monitor assembly....3553
Articulated joint assembly....3554
Removal of articulated joint assembly....3554
Installation of articulated joint assembly....3555
Variable motor assembly....3556
Removal of variable motor assembly....3556
Installation of variable motor assembly....3557
Rear axle assembly....3558
Removal of rear axle assembly....3558
Installation of rear axle assembly....3560
Front axle assembly....3561
Removal of front axle assembly....3561
Installation of front axle assembly....3563
Rear axle (WA65-3/WA75-3/WA85-3)....3564
Brake (WA75-3/WA85-3)....3564
Wheel hub....3566
Wheel hub onto axle housing....3567
Planetary gear....3568
Bevel pinion support....3569
Adjustments of bevel gear set....3574
Taper roller bearings of differential....3575
Disassembly of differential....3577
Limited slip differential....3579
Special tools....3580
Rear axle (WA90-3/WA95-3)....3588
Checking wear and replacing the braking discs....3588
Assembling of braking units....3591
Disassembly of planetary reduction and axle shaft....3594
Assembling of planetary reduction and axle shift....3600
Disassembly of bevel pinion....3606
Assembly and adjustment of bevel pinion....3610
Special tools....3619
Disassembly of mechanic parking brake unit....3624
Assembly of mechanic parking brake unit....3627
Reduction gear V 30 km/h (WA75-3 through WA95-3)....3630
Disassembly of integrated reduction gear....3630
Assembly of integrated reduction gear....3641
Variable displacement pump assembly....3654
Removal of variable displacement pump assembly....3654
Installation of variable displacement pump assembly....3656
Hydraulic pump assembly....3657
Removal of hydraulic pump assembly....3657
Installation of hydraulic pump assembly....3658
Quick-attach coupler assembly....3659
Removal of quick-attach coupler assembly....3659
Installation of quick-attach coupler assembly....3660
Steering cylinder assembly....3661
Removal of steering cylinder assembly....3661
Installation of steering cylinder assembly....3662
Lift cylinder assembly....3663
Removal of lift cylinder assembly....3663
Installation of lift cylinder assembly....3664
Dump cylinder assembly....3665
Removal of dump cylinder assembly....3665
Installation of dump cylinder assembly....3666
Replacing of windows in driver’s cab....3667
APPENDIX....3670
Komatsu Wheel Loader WA65 (Parallel Lift), WA75, WA85, WA90, WA95 Repair Service Manual
