Komatsu Wheel Loader WA500-3 Operation & Maintenance Manual
TABLE OF CONTENTS:
Komatsu Wheel Loader WA500-3 Operation & Maintenance Manual
MAIN MENU............................................................................................ 0 INTRODUCTION......................................................................................... 4 1. FORWARD....................................................................................... 5 2. SAFETY INFORMATION............................................................................ 6 3. INTRODUCTION.................................................................................. 7 3.1 INTENDED USE............................................................................. 7 3.2 FEATURES................................................................................. 7 3.3 BREAKING IN THE MACHINE.................................................................. 7 4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NUMBER AND DISTRIBUTOR.............................. 8 4.1 MACHINE SERIAL NUMBER PLATE POSITION..................................................... 8 4.2 ENGINE SERIAL NUMBER PLATE POSITION...................................................... 8 4.3 TABLE TO ENTER SERIAL NUMBERS AND DISTRIBUTOR............................................ 8 5. CONTENTS...................................................................................... 9 SAFETY............................................................................................... 15 6. GENERAL PRECAUTIONS........................................................................... 16 7. PRECAUTIONS DURING OPERATION ................................................................. 21 7.1 BEFORE STARTING ENGINE .................................................................. 21 7.2 OPERATING MACHINE ....................................................................... 23 7.3 TRANSPORTATION .......................................................................... 28 7.4 BATTERY ................................................................................. 29 7.5 TOWING .................................................................................. 30 8. PRECAUTIONS FOR MAINTENANCE .................................................................. 31 8.1 BEFORE CARRYING OUT MAINTENANCE.......................................................... 31 8.2 DURING MAINTENANCE ...................................................................... 33 8.3 TIRES ................................................................................... 38 9. POSITION FOR ATTACHING SAFETY LABELS ......................................................... 40 OPERATION............................................................................................ 45 10. GENERAL VIEW ................................................................................ 46 10.1 GENERAL VIEW OF MACHINE ................................................................ 46 10.2 GENERAL VIEW OF CONTROLS AND GAUGES .................................................... 47 10.2.1 Controls.......................................................................... 47 10.2.2 Main Monitor...................................................................... 47 10.2.3 Maintenance Monitor............................................................... 48 11. EXPLANATION OF COMPONENTS ................................................................... 49 11.1 MACHINE MONITORS ....................................................................... 49 11.1.1 WARNING DISPLAYS.................................................................. 51 11.1.2 METER DISPLAY PORTION............................................................. 55 11.2 SWITCHES ............................................................................... 59 11.3 CONTROL LEVERS, PEDALS ................................................................. 66 11.4 STEERING COLUMN TILT LEVER ............................................................. 71 11.5 CAP WITH LOCK .......................................................................... 72 11.5.1 METHOD OF OPENING AND CLOSING CAP WITH LOCK....................................... 72 11.6 SAFETY BAR ............................................................................. 73 11.7 TOWING PIN ............................................................................. 73 11.8 GREASE PUMP ............................................................................ 73 11.9 BACK-UP ALARM .......................................................................... 73 11.10 FUSE .................................................................................. 74 11.10.1 FUSE CAPACITY AND NAME OF CIRCUIT................................................ 74 11.11 SLOW-BLOW FUSE ........................................................................ 75 11.12 TAKING OFF POWER ...................................................................... 76 12. OPERATION ................................................................................... 77 12.1 CHECKS BEFORE STARTING ................................................................. 77 12.1.1 WALK AROUND CHECK................................................................. 77 12.1.2 CHECK BEFORE STARTING............................................................. 80 12.1.3 ADJUSTMENT BEFORE OPERATION....................................................... 85 12.1.4 OPERATIONS AND CHECKS BEFORE STARTING ENGINE...................................... 89 12.2 STARTING ENGINE ........................................................................ 90 12.2.1 NORMAL STARTING................................................................... 90 12.2.2 SPECIAL STARTING.................................................................. 90 12.2.3 COLD WEATHER STARTING............................................................. 91 12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE ........................................... 92 12.4 MOVING MACHINE OFF ..................................................................... 93 12.5 CHANGING GEAR SPEED .................................................................... 95 12.6 CHANGING DIRECTION ..................................................................... 95 12.7 TURNING ................................................................................ 96 12.8 STOPPING MACHINE ....................................................................... 97 12.9 OPERATION OF WORK EQUIPMENT ............................................................ 98 12.10 WORK POSSIBLE USING WHEEL LOADER ...................................................... 99 12.10.1 DIGGING OPERATIONS............................................................... 99 12.10.2 LEVELING OPERATION...............................................................102 12.10.3 PUSHING OPERATION................................................................102 12.10.4 LOAD AND CARRY OPERATIONS........................................................102 12.10.5 LOADING OPERATIONS...............................................................103 12.11 PRECAUTIONS FOR OPERATION .............................................................104 12.11.1 PERMISSIBLE WATER DEPTH..........................................................104 12.11.2 IF WHEEL BRAKE DOES NOT WORK.....................................................104 12.11.3 PRECAUTIONS WHEN DRIVING UP OR DOWN SLOPES.......................................104 12.11.4 PRECAUTIONS WHEN DRIVING MACHINE.................................................105 12.12 ADJUSTING WORK EQUIPMENT POSITIONERS ..................................................106 12.12.1 ADJUSTING BOOM KICK-OUT..........................................................106 12.12.2 ADJUSTING BUCKET POSITIONER......................................................107 12.12.3 BUCKET LEVEL INDICATOR...........................................................107 12.13 PARKING MACHINE .......................................................................108 12.14 CHECKS AFTER COMPLETION OF OPERATION ..................................................109 12.15 STOPPING ENGINE .......................................................................109 12.16 CHECK AFTER STOPPING ENGINE ...........................................................110 12.17 LOCKING ...............................................................................110 12.18 HANDLING THE TIRES ....................................................................111 12.18.1 PRECAUTIONS WHEN HANDLING TIRES..................................................111 12.18.2 TIRE PRESSURE....................................................................111 12.19 REMOVAL AND INSTALLATION OF THE BUCKET ................................................113 12.19.1 REMOVING THE BUCKET..............................................................113 12.19.2 INSTALLING THE BUCKET............................................................114 13. TRANSPORTATION ..............................................................................116 13.1 LOADING, UNLOADING WORK ................................................................116 13.2 PRECAUTIONS FOR LOADING ................................................................117 13.3 LIFTING MACHINE ........................................................................117 13.3.1 POSITION FOR STICKING LIFTING POSITION DECAL......................................118 13.3.2 WEIGHT TABLE......................................................................118 13.3.3 LIFTING PROCEDURE.................................................................119 13.4 PRECAUTIONS FOR TRANSPORTATION .........................................................120 14. COLD WEATHER OPERATION ......................................................................120 14.1 PRECAUTIONS FOR LOW TEMPERATURES .......................................................120 14.1.1 FUEL AND LUBRICANTS...............................................................120 14.1.2 COOLANT...........................................................................120 14.1.3 BATTERY...........................................................................121 14.2 PRECAUTIONS AFTER COMPLETION OF WORK ...................................................121 14.3 AFTER COLD WEATHER .....................................................................122 14.4 WARMING-UP OPERATION FOR STEERING HYDRAULIC CIRCUIT IN COLD WEATHER ...................122 15. LONG TERM STORAGE ...........................................................................123 15.1 BEFORE STORAGE .........................................................................123 15.2 DURING STORAGE .........................................................................123 15.3 AFTER STORAGE ..........................................................................123 16. TROUBLESHOOTING .............................................................................124 16.1 WHEN MACHINE RUNS OUT OF FUEL ..........................................................124 16.2 TOWING THE MACHINE .....................................................................125 16.2.1 WHEN ENGINE CAN BE USED...........................................................126 16.2.2 WHEN ENGINE CANNOT BE USED........................................................126 16.2.3 RELEASING PARKING BRAKE...........................................................127 16.2.4 EMERGENCY TRAVEL OPERATION........................................................129 16.3 IF BATTERY IS DISCHARGED ...............................................................130 16.3.1 REMOVAL AND INSTALLATION OF BATTERY...............................................130 16.3.2 PRECAUTIONS FOR CHARGING BATTERY..................................................131 16.3.3 STARTING ENGINE WITH BOOSTER CABLES...............................................132 16.4 OTHER TROUBLE ..........................................................................134 16.4.1 ELECTRICAL SYSTEM.................................................................134 16.4.2 CHASSIS...........................................................................135 16.4.3 ENGINE............................................................................138 16.4.4 RELATIONSHIP OF ELECTRONIC CONTROL SYSTEM.........................................140 MAINTENANCE..........................................................................................143 17. GUIDES TO MAINTENANCE .......................................................................144 18. OUTLINES OF SERVICE .........................................................................147 18.1 OUTLINE OF OIL, FUEL, AND COOLANT ......................................................147 18.1.1 OIL...............................................................................147 18.1.2 FUEL..............................................................................148 18.1.3 COOLANT...........................................................................148 18.1.4 GREASE............................................................................149 18.1.5 STORING OIL AND FUEL..............................................................149 18.1.6 FILTERS...........................................................................149 18.2 FUEL INJECTION PUMP ...................................................................149 18.3 OUTLINE OF ELECTRIC SYSTEM .............................................................150 19. WEAR PARTS LIST .............................................................................151 20. LUBRICANTS, FUEL, AND COOLANT ...............................................................152 20.1 PROPER SELECTION TABLE .................................................................152 20.2 ENGINE OIL .............................................................................153 20.2.1 NORMAL OPERATION..................................................................153 20.2.2 ARCTIC OPERATION..................................................................153 20.3 TRANSMISSION, HYDRAULIC SYSTEM, BRAKE SYSTEM OIL .......................................154 20.4 AXLE OIL ...............................................................................154 20.5 GREASE .................................................................................154 20.6 DIESEL FUEL ............................................................................154 20.7 COOLANT SPECIFICATIONS .................................................................155 20.7.1 GENERAL...........................................................................155 20.7.2 WATER.............................................................................155 20.7.3 ANTIFREEZE........................................................................155 20.7.4 SUPPLEMENTAL COOLANT ADDITIVES....................................................156 20.7.5 TOOLS.............................................................................159 21. STANDARD TIGHTENING TORQUE FOR NUTS AND BOLTS ...............................................160 21.1 INTRODUCTION OF NECESSARY TOOLS ........................................................160 21.2 TORQUE LIST ............................................................................161 22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS ...............................................162 23. MAINTENANCE SCHEDULE CHART ..................................................................166 24. SERVICE PROCEDURE ...........................................................................170 24.1 INITIAL 250 HOURS SERVICE ..............................................................170 24.2 WHEN REQUIRED ..........................................................................171 24.2.1 CHECK, CLEAN, OR REPLACE AIR CLEANER ELEMENT......................................171 24.2.2 CHECK TRANSMISSION OIL LEVEL, ADD OIL.............................................173 24.2.3 CHECK AXLE OIL LEVEL, ADD OIL.....................................................175 24.2.4 CHECK AXLE CASE BREATHER..........................................................176 24.2.5 CLEAN RADIATOR CORE...............................................................176 24.2.6 REPLACE BOLT-ON CUTTING EDGE......................................................177 24.2.7 REPLACE BUCKET TEETH..............................................................178 24.2.8 REPLACE BUCKET TEETH, SEGMENT EDGE................................................179 24.2.9 CHECK AIR CONDITIONER.............................................................180 24.2.10 CLEAN CONDENSER OF AIR CONDITIONER...............................................181 24 .2.11 CHECK WINDOW WASHING FLUID LEVEL, ADD FLUID.....................................181 24.2.12 LUBRICATE WORK EQUIPMENT CONTROL VALVE LINKAGE (2 POINTS)........................181 24.2.13 REPLACE SLOW BLOW FUSE...........................................................182 24.3 CHECKS BEFORE STARTING ENGINE ..........................................................183 24.4 EVERY 50 HOURS SERVICE ................................................................183 24.4.1 CHECK THE TIRE INFLATION PRESSURE.................................................183 24.4.2 DRAIN WATER, SEDIMENT FROM FUEL TANK..............................................183 24.4.3 CHECK ENGINE AIR INTAKE SYSTEM....................................................183 24.5 EVERY 100 HOURS SERVICE ................................................................184 24.5.1 CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL........................................184 24.5.2 CLEAN ELEMENT IN AIR CONDITIONER FRESH AIR FILTER.................................185 24.5.3 LUBRICATE REAR AXLE PIVOT PIN (3 PLACES)..........................................185 24.6 EVERY 250 HOURS SERVICE ................................................................186 24.6.1 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE.................186 24.6.2 REPLACE FUEL FILTERS..............................................................188 24.6.3 CHECK FOR LOOSE WHEEL HUB NUTS, TIGHTEN...........................................189 24.6.4 CLEAN ELEMENT IN AIR CONDITIONER RECIRCULATION FILTER.............................189 24.6.5 CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST.............................190 24.6.6 CHECK BATTERY ELECTROLYTE LEVEL...................................................191 24.6.7 LUBRICATING.......................................................................192 24.6.8 REPLACE COOLANT CORROSION RESISTOR CARTRIDGE......................................195 24.7 EVERY 500 HOURS SERVICE ................................................................197 24.7.1 REPLACE TRANSMISSION OIL FILTER...................................................197 24.8 EVERY 1000 HOURS SERVICE ...............................................................198 24.8.1 CHANGE OIL IN TRANSMISSION CASE, CLEAN STRAINER...................................198 24.8.2 CLEAN TRANSMISSION CASE BREATHER..................................................199 24.8.3 LUBRICATING (DRIVE TRAIN).........................................................200 24.9 EVERY 1500 HOURS SERVICE ..............................................................202 24.9.1 CHECK AND ADJUST ENGINE VALVES AND INJECTORS......................................202 24.9.2 STEM CLEAN THE ENGINE.............................................................202 24.9.3 CHECK AND REPLACE (AS REQUIRED) ENGINE MOUNTED HOSES..............................202 24.9.4 CHECK AND RETIGHTEN ENGINE MOUNTING HARDWARE......................................203 24.9.5 CHECK TURBOCHARGER MOUNTING.......................................................203 24.9.6 CHECK WATER PUMP..................................................................203 24.9.7 CHECK TENSION OF DRIVE BELT.......................................................204 24.9.8 CHECK DRIVE BELT TENSIONER BEARING AND FAN HUB BEARING............................204 24.10 EVERY 2000 HOURS SERVICE ..............................................................206 24.10.1 CHANGE OIL IN HYDRAULIC TANK, REPLACE FILTER ELEMENT.............................206 24.10.2 REPLACE HYDRAULIC TANK BREATHER ELEMENT..........................................208 24.10.3 CHANGE, CLEAN, AND FLUSH COOLING SYSTEM..........................................209 24.10.4 CHANGE AXLE OIL..................................................................211 24.10.5 REPLACE ELEMENT IN AIR CONDITIONER RECIRCULATION AIR FILTER, FRESH AIR FILTER....212 24.10.6 CLEAN PPC (PROPORTIONAL PRESSURE CONTROL) CIRCUIT STRAINER.......................212 24.10.7 CHECK ACCUMULATOR................................................................213 24.10.8 CHECK ACCUMULATOR GAS PRESSURE...................................................213 24.11 EVERY 6000 HOURS SERVICE...............................................................214 24.11.1 CLEAN AND CALIBRATE FUEL PUMP....................................................214 24.11.2 CLEAN AND CALIBRATE FUEL INJECTORS...............................................214 24.11.3 CHECK ENGINE FAN HUB.............................................................214 24.11.4 CHECK ENGINE IDLER PULLER........................................................214 24.11.5 CHECK TURBOCHARGER...............................................................214 24.11.6 CHECK AIR COMPRESSOR.............................................................214 24.11.7 CHECK ENGINE VIBRATION DAMPER....................................................214 SPECIFICATIONS.......................................................................................215 25. SPECIFICATIONS ..............................................................................216 OPTIONS, ATTACHMENTS.................................................................................218 26. OPTIONAL PARTS AND ATTACHMENTS ..............................................................219 27. SELECTING BUCKETS AND TIRES .................................................................220 28. RADIO .......................................................................................221 28.1 EXPLANATION OF PARTS ...................................................................221 28.2 METHOD OF USE ..........................................................................223 28.3 PRECAUTIONS WHEN USING . ..............................................................224 29. AIR CONDITIONER .............................................................................225 29.1 GENERAL LOCATION AND FUNCTION OF CONTROL PANEL ........................................225 29.2 METHOD OF OPERATION ....................................................................227 29.3 COOL BOX................................................................................227 30. HANDLING AUTO-GREASING SYSTEM ...............................................................228 30.1 METHOD OF OPERATING AUTO-GREASING SYSTEM ...............................................228 30.1.1 ACTUATION OF AUTO-GREASING........................................................230 30.1.2 SETTING GREASING TIME.............................................................231 30.1.3 METHOD OF SETTING.................................................................232 30.1.4 REPLACEMENT OF GREASE CARTRIDGE...................................................234 30.1.5 METHOD OF FILLING AUTO-GREASING SYSTEM WITH GREASE................................235 30.2 PRECAUTIONS WHEN HANDLING AUTO-GREASING SYSTEM..........................................237 30.3 TROUBLESHOOTING (AUTO-GREASING SYSTEM) .................................................238 30.4 SPECIFICATIONS .........................................................................238 31. HANDLING E.C.S.S. (ELECTRONIC CONTROLLED SUSPENSION SYSTEM .................................239 31.1 STRUCTURE AND FUNCTION OF E.C.S.S. .....................................................239 31.2 METHOD OF OPERATING E.C.S.S. ...........................................................240 31.3 PRECAUTIONS WHEN OPERATING E.C.S.S. SWITCH .............................................240 31.4 PRECAUTIONS WHEN HANDLING ACCUMULATOR 1 ................................................241 31.5 REMOVAL OF TRAVEL DAMPER PIPING ........................................................242 32. HANDLING JOYSTICK STEERING SYSTEM ...........................................................243 32.1 STRUCTURE AND FUNCTION OF JOYSTICK STEERING ............................................243 32.2 OPERATION METHOD OF JOYSTICK STEERING SYSTEM ..........................................246 32.3 PRECAUTIONS FOR STEERING WITH JOYSTICK .................................................247 32.4 ADJUSTMENT OF JOYSTICK CONSOLE .........................................................248 32.5 ADJUSTMENT OPERATOR’S SEAT .............................................................249 33. GROUND DRIVEN STEERING (IF EQUIPPED) ........................................................250
VIDEO PREVIEW OF THE MANUAL:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu Wheel Loader WA500-3 Operation & Maintenance Manual
FOREWORD:
- This manual describes procedures for operation, handling, lubrication, maintenance, checking, and adjustment. It will help the operator and maintenance personnel realize peak performance through effective, economical and safe machine operation and maintenance.
- Keep this manual handy and have all personnel read it periodically. If this manual is lost or becomes dirty and can not be read, request a replacement manual from your local distributor. If you sell the machine, be sure to give this manual to the new owner.
- Continuing improvements in the design of this machine can lead to changes in detail, which may not be reflected in this manual. Consult your local distributor or Komatsu America International Company for the latest available information on your machine or for questions regarding information in this manual.
PLEASE NOTE:
- This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
- Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.