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KOMATSU AVANCE LOADER WA500-3 WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:52380 & UP) – PDF DOWNLOAD
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- KOMATSU AVANCE LOADER WA500-3 WHEEL LOADER OPERATION & MAINTENANCE MANUAL
- SERIAL NUMBER:52380 & UP
- PUBLICATION NUMBER:TEN00065-01
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Description
KOMATSU AVANCE LOADER WA500-3 WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:52380 & UP)
KOMATSU AVANCE LOADER WA500-3 WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:52380 & UP) – PDF DOWNLOAD:
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KOMATSU AVANCE LOADER WA500-3 WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:52380 & UP)
This manual provides rules and guidelines which will help you use this machine safely and effectively. The precautions in this manual must be followed at all times when performing operation and maintenance. Most accidents are caused by the failure to follow fundamental safety rules for the operation and maintenance of machines. Accidents can be prevented by knowing beforehand conditions that may cause a hazard when performing operation and maintenance.
TABLE OF CONTENTS:
KOMATSU AVANCE LOADER WA500-3 WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:52380 & UP)
COVER.......................................................................................... 1 FOREWORD....................................................................................... 2 FOREWORD................................................................................... 3 SAFETY INFORMATION......................................................................... 6 INTRODUCTION............................................................................... 8 FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE........................................... 8 NECESSARY INFORMATION...................................................................... 9 PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE........................... 9 ENGINE SERIAL NO. PLATE AND POSITION................................................... 9 POSITION OF SERVICE METER.............................................................. 10 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR.............................................. 10 CONTENTS....................................................................................... 11 SAFETY......................................................................................... 14 SAFETY..................................................................................... 15 SAFETY LABELS.............................................................................. 18 LOCATION OF SAFETY LABELS.............................................................. 19 GENERAL PRECAUTIONS........................................................................ 26 SAFETY RULES........................................................................... 26 IF ABNORMALITIES ARE FOUND............................................................. 26 CLOTHING AND PERSONAL PROTECTIVE ITEMS................................................. 26 FIRE EXTINGUISHER AND FIRST AID KIT.................................................... 26 SAFETY FEATURES........................................................................ 26 KEEP MACHINE CLEAN..................................................................... 27 INSIDE OPERATOR'S COMPARTMENT.......................................................... 27 ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT......................................... 27 HANDRAILS AND STEPS.................................................................... 28 MOUNTING AND DISMOUNTING............................................................... 28 NO PEOPLE ON ATTACHMENTS............................................................... 28 DO NOT GET CAUGHT IN ARTICULATED PORTION............................................... 29 PREVENTION OF BURNS.................................................................... 29 FIRE PREVENTION........................................................................ 30 ACTION IF FIRE OCCURS.................................................................. 31 WINDOW WASHER LIQUID................................................................... 31 PRECAUTIONS WHEN USING ROPS (ROLL OVER PROTECTIVE STRUCTURE)........................... 31 PRECAUTIONS FOR ATTACHMENTS, OPTIONS................................................... 31 UNAUTHORIZED MODIFICATION.............................................................. 31 SAFETY AT WORKSITE..................................................................... 32 WORKING ON LOOSE GROUND................................................................ 32 DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES................................................. 32 ENSURE GOOD VISIBILITY................................................................. 33 PRECAUTIONS RELATED TO VENTILATION EXHAUST GAS......................................... 33 CHECKING SIGNALMAN'S SIGNALS AND SIGNS................................................. 33 EMERGENCY EXIT FROM OPERATOR'S CAB..................................................... 33 BE CAREFUL ABOUT ASBESTOS DUST......................................................... 34 PRECAUTIONS FOR OPERATION.................................................................. 35 STARTING ENGINE........................................................................ 35 CHECKS BEFORE STARTING ENGINE...................................................... 35 PRECAUTIONS WHEN STARTING.......................................................... 35 PRECAUTIONS IN COLD AREAS.......................................................... 36 OPERATION.............................................................................. 37 CHECKS BEFORE OPERATION............................................................ 37 PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE................................... 37 PRECAUTIONS WHEN TRAVELING......................................................... 38 TRAVELING ON SLOPES................................................................ 39 PROHIBITED OPERATIONS.............................................................. 40 PRECAUTIONS WHEN OPERATING......................................................... 40 METHODS OF USING BRAKE............................................................. 41 OPERATE CAREFULLY ON SNOW.......................................................... 41 PARKING MACHINE.................................................................... 42 TRANSPORTATION......................................................................... 43 LOADING AND UNLOADING.............................................................. 43 SHIPPING........................................................................... 43 BATTERY................................................................................ 44 BATTERY HAZARD PREVENTION.......................................................... 44 STARTING WITH BOOSTER CABLES....................................................... 45 TOWING................................................................................. 46 PRECAUTIONS FOR MAINTENANCE................................................................ 47 WARNING TAG............................................................................ 47 KEEP WORK PLACE CLEAN AND TIDY......................................................... 47 APPOINT LEADER WHEN WORKING WITH OTHERS................................................ 47 STOP ENGINE BEFORE CARRYING OUT MAINTENANCE............................................ 48 TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING..................................... 49 INSPECTION AND MAINTENANCE AFTER TURNING E.C.S.S. SWITCH OFF........................... 49 PROPER TOOLS........................................................................... 50 WORK UNDER THE MACHINE................................................................. 50 ACCUMULATOR............................................................................ 50 PERSONNEL.............................................................................. 50 ATTACHMENTS............................................................................ 51 NOISE.................................................................................. 51 PRECAUTIONS WHEN USING HAMMER.......................................................... 51 REPAIR WELDING......................................................................... 51 REMOVING BATTERY TERMINAL.............................................................. 51 PRECAUTIONS WITH HIGH-PRESSURE OIL..................................................... 52 PRECAUTIONS FOR HIGH-PRESSURE FUEL..................................................... 52 HANDLING HIGH-PRESSURE HOSES........................................................... 52 PRECAUTIONS FOR HIGH VOLTAGE........................................................... 52 WASTE MATERIALS........................................................................ 53 MAINTENANCE OF AIR CONDITIONER......................................................... 53 COMPRESSED AIR......................................................................... 53 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS.......................................... 53 PRECAUTIONS WITH TIRES..................................................................... 54 HANDLING TIRES......................................................................... 54 PRECAUTIONS WHEN STORING TIRES......................................................... 54 OPERATION...................................................................................... 56 GENERAL VIEW............................................................................... 57 GENERAL VIEW OF MACHINE................................................................ 57 GENERAL VIEW OF CONTROLS AND GAUGES.................................................... 58 EXPLANATION OF COMPONENTS.................................................................. 60 MACHINE MONITOR........................................................................ 60 SWITCHES............................................................................... 72 CONTROL LEVERS, PEDALS................................................................. 80 STEERING COLUMN TILT LEVER............................................................. 85 CAP WITH LOCK.......................................................................... 86 SAFETY BAR............................................................................. 87 TOWING PIN............................................................................. 87 GREASE PUMP............................................................................ 87 BACKUP ALARM........................................................................... 88 DUST INDICATOR......................................................................... 88 FUSE................................................................................... 88 SLOW BLOW FUSE......................................................................... 89 POWER OUTLET........................................................................... 89 OPERATION.................................................................................. 90 CHECK BEFORE STARTING ENGINE, ADJUST................................................... 90 STARTING ENGINE........................................................................104 OPERATIONS AND CHECKS AFTER STARTING ENGINE............................................107 STOPPING ENGINE........................................................................109 CHECK AFTER STOPPING ENGINE............................................................109 MOVING THE MACHINE (DIRECTIONAL, SPEED), STOPPING THE MACHINE..........................110 TURNING................................................................................115 OPERATION OF WORK EQUIPMENT............................................................116 WORK POSSIBLE USING WHEEL LOADER.......................................................118 PRECAUTIONS FOR OPERATION..............................................................124 ADJUSTING WORK EQUIPMENT POSTURE.......................................................126 REMOVAL AND INSTALLATION OF THE BUCKET.................................................128 PARKING MACHINE........................................................................131 CHECKS AFTER COMPLETION OF OPERATION...................................................133 LOCKING................................................................................133 HANDLING THE TIRES.....................................................................134 TRANSPORTATION.............................................................................136 TRANSPORTATION PROCEDURE...............................................................136 LOADING, UNLOADING WORK................................................................136 METHOD OF SECURING MACHINE.............................................................137 METHOD OF LIFTING MACHINE..............................................................139 COLD WEATHER OPERATION.....................................................................142 PRECAUTIONS FOR LOW TEMPERATURE........................................................142 PRECAUTIONS AFTER COMPLETION OF WORK...................................................143 AFTER COLD WEATHER.....................................................................144 WARMING-UP OPERATION FOR STEERING HYDRAULIC CIRCUIT IN COLD WEATHER....................144 LONG-TERM STORAGE..........................................................................145 BEFORE STORAGE.........................................................................145 DURING STORAGE.........................................................................145 AFTER STORAGE..........................................................................145 TROUBLESHOOTING............................................................................146 WHEN MACHINE RUNS OUT OF FUEL..........................................................146 METHOD OF TOWING MACHINE...............................................................147 IF BATTERY IS DISCHARGED...............................................................151 OTHER TROUBLE..........................................................................154 MAINTENANCE....................................................................................166 GUIDES TO MAINTENANCE......................................................................167 OUTLINES OF SERVICE........................................................................169 HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC.................................169 OUTLINE OF ELECTRIC SYSTEM.............................................................172 WEAR PARTS.................................................................................173 WEAR PARTS LIST........................................................................173 RECOMMENDED FUEL, COOLANT, AND LUBRICANT...................................................174 USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE...................175 RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL....176 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS.............................................177 TORQUE LIST............................................................................177 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS..............................................178 MAINTENANCE SCHEDULE CHART.................................................................180 MAINTENANCE SCHEDULE CHART.............................................................180 SERVICE PROCEDURE..........................................................................182 INITIAL 250 HOURS SERVICE..............................................................182 WHEN REQUIRED..........................................................................183 CHECK, CLEAN, OR REPLACE AIR CLEANER ELEMENT.......................................183 CLEAN INSIDE OF COOLING SYSTEM.....................................................186 CHECK TRANSMISSION OIL LEVEL, ADD OIL..............................................189 CHECK AXLE OIL LEVEL, ADD OIL......................................................191 CLEAN AXLE CASE BREATHER...........................................................192 CLEAN AIR CONDITIONER CONDENSER....................................................192 CHECK WINDOW WASHING FLUID LEVEL, ADD FLUID........................................192 CLEAN RADIATOR FINS AND OIL COOLER FINS............................................193 CHECK ELECTRICAL INTAKE AIR HEATER.................................................194 REPLACE BUCKET TEETH...............................................................194 REPLACE BUCKET TOOTH WITH SEGMENT EDGE.............................................196 TURN, REPLACE BOLT-ON CUTTING EDGE.................................................197 LUBRICATE WORK EQUIPMENT CONTROL VALVE LINKAGE (2 PLACES)..........................197 CHECK AIR CONDITIONER..............................................................198 REPLACE SLOW BLOW FUSE.............................................................199 SELECTION AND INSPECTION OF TIRES..................................................200 CHECK BEFORE STARTING..................................................................202 EVERY 50 HOURS SERVICE.................................................................203 DRAIN WATER, SEDIMENT FROM FUEL TANK...............................................203 EVERY 100 HOURS SERVICE................................................................204 LUBRICATE REAR AXLE PIVOT PIN......................................................204 CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL.........................................204 CLEAN ELEMENT IN AIR CONDITIONER FRESH AIR FILTER..................................205 EVERY 250 HOURS SERVICE................................................................206 CHECK BATTERY ELECTROLYTE LEVEL....................................................206 CHECK PARKING BRAKE................................................................208 CHECK ALTERNATOR BELT TENSION, ADJUST..............................................208 CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST..............................209 CHECK FOR LOOSE WHEEL HUB NUTS, TIGHTEN............................................209 CLEAN ELEMENT IN AIR CONDITIONER RECIRCULATION FILTER..............................210 LUBRICATING........................................................................210 EVERY 500 HOURS SERVICE................................................................213 REPLACE ADDITIONAL FUEL FILTER CARTRIDGE...........................................213 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE..................215 REPLACE TRANSMISSION OIL FILTER ELEMENT............................................217 LUBRICATE CENTER DRIVE SHAFT SPLINE................................................218 CHECK FAN BELT FOR WEAR............................................................218 EVERY 1000 HOURS SERVICE...............................................................219 REPLACE FUEL FILTER CARTRIDGE......................................................219 CHANGE OIL IN TRANSMISSION CASE, CLEAN STRAINER....................................221 CLEAN TRANSMISSION CASE BREATHER...................................................222 LUBRICATING........................................................................222 CHECK TIGHTENING PARTS OF TURBOCHARGER.............................................224 REPLACE CORROSION RESISTOR CARTRIDGE...............................................224 CLEAN RADIATOR SUB-TANK BREATHER...................................................224 CLEAN FUEL STRAINER................................................................225 WASH FUEL TANK BREATHER............................................................225 TIGHTEN ROPS CANOPY................................................................225 EVERY 2000 HOURS SERVICE...............................................................226 CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC FILTER ELEMENT.....................226 REPLACE HYDRAULIC TANK BREATHER ELEMENT............................................228 CHANGE AXLE OIL....................................................................229 REPLACE ELEMENT IN AIR CONDITIONER RECIRCULATION AIR FILTER, FRESH AIR FILTER......230 CLEAN PPC CIRCUIT STRAINER.........................................................230 CLEAN ENGINE BREATHER ELEMENT......................................................231 CHECK ALTERNATOR, STARTING MOTOR...................................................231 CHECK ENGINE VALVE CLEARANCE, ADJUST...............................................231 CHECK BRAKE DISC WEAR..............................................................231 CLEAN AND CHECK TURBOCHARGER.......................................................231 CHECK PLAY OF TURBOCHARGER ROTOR...................................................231 CHECK ACCUMULATOR FUNCTION.........................................................232 CHECK ACCUMULATOR GAS PRESSURE.....................................................232 CHECK INJECTOR.....................................................................232 EVERY 4000 HOURS SERVICE...............................................................233 CHECK WATER PUMP...................................................................233 CHECK VIBRATION DAMPER.............................................................233 CHECK FAN PULLEY AND TENSION PULLEY................................................233 CHECK AIR CONDITIONER COMPRESSOR, ADJUST...........................................233 REPLACE INJECTOR...................................................................233 CHECKING FOR LOOSENESS OF HIGH-PRESSURE CLAMP, HARDENING OF RUBBER.................233 CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER................234 EVERY 8000 HOURS SERVICE...............................................................235 REPLACE HIGH-PRESSURE PIPING CLAMP.................................................235 REPLACE FUEL SPRAY PREVENTION CAP..................................................235 SPECIFICATIONS.................................................................................236 SPECIFICATIONS.............................................................................237 ATTACHMENTS, OPTIONS...........................................................................238 SELECTING BUCKET AND TIRES.................................................................239 HANDLING E.C.S.S.(ELECTRONIC CONTROLLED SUSPENSION SYSTEM).................................240 METHOD OF OPERATING E.C.S.S............................................................240 PRECAUTIONS WHEN OPERATING E.C.S.S. SWITCH.............................................240 PRECAUTIONS WHEN HANDLING ACCUMULATOR..................................................241 REMOVAL OF E.C.S.S. PIPING.............................................................241 HANDLING AUTO-GREASING SYSTEM..............................................................242 METHOD OF OPERATING AUTO-GREASING SYSTEM...............................................242 PRECAUTIONS WHEN HANDLING AUTO-GREASING SYSTEM.........................................247 TROUBLESHOOTING........................................................................248 HANDLING REMOTE POSITIONER.................................................................249 GENERAL LOCATIONS......................................................................249 METHOD OF OPERATING REMOTE POSITIONER..................................................250 METHOD OF SETTING REMOTE POSITIONER STOP POSITION......................................251 SENSOR ADJUSTMENT FUNCTION.............................................................251 ADJUSTING REMOTE POSITIONER............................................................251 HANDLING JOYSTICK STEERING SYSTEM..........................................................252 STRUCTURE AND FUNCTION OF JOYSTICK STEERING............................................252 OPERATION METHOD OF JOYSTICK STEERING SYSTEM...........................................255 PRECAUTIONS FOR STEERING WITH JOYSTICK.................................................257 ADJUSTMENT OF JOYSTICK CONSOLE.........................................................258 HANDLING JOYSTICK..........................................................................261 EXPLANATION OF COMPONENTS..............................................................261 HANDLING AIR-SUSPENSION SEAT...............................................................264 SEAT ADJUSTMENT........................................................................264 CAR RADIO..................................................................................266 EXPLANATION OF COMPONENTS..............................................................266 METHOD OF USE..........................................................................269 PRECAUTIONS WHEN USING.................................................................271 AM/FM RADIO-CASSETTE STEREO................................................................272 EXPLANATION OF COMPONENTS..............................................................272 METHOD OF OPERATION....................................................................277 PRECAUTIONS FOR USE....................................................................279 AIR CONDITIONER............................................................................280 GENERAL LOCATIONS AND FUNCTION OF CONTROL PANEL........................................280 METHOD OF OPERATION....................................................................283 HANDLING BRAKE COOLING SYSTEM..............................................................285 WHEN REQUIRED..........................................................................285 EVERY 2000 HOURS SERVICE...............................................................287 INDEX..........................................................................................290
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