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KOMATSU WA500-1 WHEEL LOADER Operation & Maintenance Manual (SN:A61001 & UP) KOMATSU WA500 1 – PDF DOWNLOAD
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- KOMATSU WA500-1 WHEEL LOADER Operation & Maintenance Manual
- SERIAL NUMBER:A61001 & UP
- PUBLICATION NUMBER:CEAM000300
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Description
KOMATSU WA500-1 WHEEL LOADER Operation & Maintenance Manual (SN:A61001 & UP) KOMATSU WA500 1
KOMATSU WA500-1 WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:A61001 & UP) KOMATSU WA500 1 – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU WA500-1 WHEEL LOADER Operation & Maintenance Manual (SN:A61001 & UP) KOMATSU WA500 1
- This manual provides rules and guidelines, which will help you use this machine safely and effectively.
- 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 are the owner or end user or from Komatsu America International Company if you are a 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 if you are the owner or end user or consult Komatsu America International Company if you are a distributor for the latest available information on your machine or for questions regarding information in this manual.
TABLE OF CONTENTS:
KOMATSU WA500-1 WHEEL LOADER Operation & Maintenance Manual (SN:A61001 & UP) KOMATSU WA500 1
MAIN MENU................................................................... 0 FORWARD..................................................................... 5 SAFETY INFORMATION.......................................................... 6 INTRODUCTION................................................................ 7 BREAKING IN THE NEW MACHINE............................................. 7 MACHINE AND ENGINE SERIAL NUMBERS....................................... 8 QUICK REFERENCE INFORMATION............................................. 9 CONTENTS.................................................................... 10 SAFETY PRECAUTIONS -- SECTION 1............................................. 19 GENERAL PRECAUTIONS..................................................... 20 PERSONNEL PRECAUTIONS............................................... 20 MACHINE PRECAUTIONS................................................. 20 OPERATION .............................................................. 21 BEFORE STARTING .................................................... 21 START-UP ........................................................... 22 GENERAL OPERATING PRECAUTIONS ...................................... 22 DRIVING THE MACHINE ................................................ 23 OPERATING THE ATTACHMENTS .......................................... 24 PULLING/TOWING ..................................................... 25 SHUTDOWN ........................................................... 25 MAINTENANCE ............................................................ 26 GENERAL MACHINE PRECAUTIONS ........................................ 26 GENERAL WORK PRECAUTIONS ........................................... 27 ACCUMULATORS ....................................................... 28 ATTACHMENTS ........................................................ 28 BRAKES ............................................................. 29 CAB/ROPS ........................................................... 29 COOLING ............................................................ 29 ELECTRICAL ......................................................... 29 ENGINE.............................................................. 30 FUEL SYSTEM ........................................................ 31 HYDRAULICS ......................................................... 31 TIRES AND RIMS ..................................................... 31 TURBOCHARGER ....................................................... 31 SAFETY PRODUCT GRAPHICS AND LOCATIONS .................................. 32 OPERATION -- SECTION 2...................................................... 39 GENERAL VIEW............................................................ 40 INSTRUMENTS AND CONTROLS ............................................... 41 MONITOR PANEL ...................................................... 41 SYSTEM CHECK.................................................... 42 CHECK MONITOR LAMP GROUP........................................ 43 Brake Oil Level Monitor..................................... 43 Engine Oil Level Monitor.................................... 44 Engine Coolant Level Monitor................................ 44 CAUTION MONITOR LAMP GROUP ..................................... 44 Charge Monitor ............................................. 44 Fuel Level Monitor ......................................... 45 Transmission Oil Filter Monitor ............................ 45 CAUTION MONITOR LAMP GROUP .................................... 45 Brake Line Failure Monitor ................................. 45 Engine Oil Pressure Monitor ................................ 46 Engine Coolant Level Monitor ............................... 46 Air Pressure Monitor ....................................... 46 Engine Coolant Temperature Monitor ......................... 47 Torque Converter Oil Temperature Monitor ................... 47 Ground Driven Steering Operation Monitor - If Equipped .... 47 METER AND PILOT LAMP GROUP ..................................... 48 Parking Brake Pilot Lamp ................................... 48 Working Lamp Pilot Lamp .................................... 49 Transmission Cut-Off Selector Pilot Lamp ................... 49 Air Pressure Gauge ......................................... 49 Engine Coolant Temperature Gauge ........................... 50 Torque Converter Oil Temperature Gauge ..................... 50 Fuel Level Gauge ........................................... 50 Turn Signal Pilot Lamp ..................................... 51 High Beam Pilot Lamp ....................................... 51 Speedometer................................................. 51 Service Meter .............................................. 52 SWITCHES ........................................................... 53 TRANSMISSION CUT-OFF SELECTOR SWITCH ........................... 53 ETHER START SWITCH ............................................. 54 HORN BUTTON..................................................... 54 HAZARD LAMP SWITCH.............................................. 54 PARKING BRAKE SWITCH............................................ 55 WORKING LAMP SWITCH............................................. 56 STARTING SWITCH................................................. 56 LAMP SWITCH .................................................... 56 Lamp switch ................................................ 56 Turn signal lever .......................................... 57 Dimmer switch .............................................. 57 CIGARETTE LIGHTER............................................... 58 TRANSMISSION KICKDOWN SWITCH.................................... 58 FRONT WIPER SWITCH - IF EQUIPPED ............................... 59 REAR WIPER SWITCH - IF EQUIPPED ................................ 59 CAB DOME LAMP SWITCH - IF EQUIPPED ............................. 60 LEVERS AND PEDALS .................................................. 61 DIRECTIONAL LEVER .............................................. 61 SPEED CONTROL LEVER............................................. 62 SPEED CONTROL LEVER STOPPER..................................... 62 STEERING COLUMN TILT LEVER...................................... 62 ACCELERATOR PEDAL............................................... 63 BRAKE PEDALS.................................................... 63 Right brake pedal........................................... 63 Left brake pedal............................................ 63 LIFT ARM CONTROL LEVER.......................................... 64 BUCKET CONTROL LEVER............................................ 64 FRONT ATTACHMENT CONTROL LEVER.................................. 65 WORK EQUIPMENT CONTROL LEVER LOCK............................... 65 CAB DOOR HOLD OPEN LOCK - IF EQUIPPED............................... 65 AIR CLEANER SERVICE INDICATOR ...................................... 66 FRAME LOCKING BAR .................................................. 66 MAIN CIRCUIT BREAKER ............................................... 66 FUSE BOXES ......................................................... 67 OPERATOR’S SEAT .................................................... 70 FORWARD-BACKWARD ADJUSTMENT .................................... 70 SEAT ANGLE ADJUSTMENT .......................................... 70 WEIGHT ADJUSTMENT .............................................. 70 BACKREST TILT ADJUSTMENT ....................................... 70 HEIGHT ADJUSTMENT .............................................. 70 RIGHT SIDE ARMREST.................................................. 70 HEIGHT ADJUSTMENT .............................................. 70 ANGLE ADJUSTMENT ............................................... 70 SEAT BELT .......................................................... 71 CAB HEATER AND DEFROSTER - IF EQUIPPED ................................. 72 CONTROL PANEL ...................................................... 72 FAN SPEED SWITCH ............................................... 72 TEMPERATURE CONTROL KNOB ....................................... 72 AIR INTAKE SELECTOR ............................................ 72 METHOD OF OPERATION ................................................ 73 CAB HEATER, DEFROSTER AND AIR CONDITIONER - IF EQUIPPED ................ 74 CONTROL PANEL ...................................................... 74 FAN SPEED SWITCH ............................................... 74 TEMPERATURE CONTROL KNOB........................................ 74 AIR INTAKE SELECTOR KNOB........................................ 74 AIR CONDITIONER SWITCH.......................................... 74 METHOD OF OPERATION ................................................ 75 PRECAUTIONS FOR USING AIR CONDITIONER........................... 76 HANDLING AIR CONDITIONER IN SEASON.............................. 76 HANDLING AIR CONDITIONER IN OFF-SEASONS......................... 76 LOCKING FILLER CAPS .................................................... 77 FUEL TANK FILLER CAP ............................................... 77 HYDRAULIC TANK FILLER CAP........................................... 78 CHECKS BEFORE STARTING ENGINE .......................................... 79 WALK AROUND CHECK .................................................. 79 CHECKS BEFORE STARTING ............................................. 79 OPERATING MACHINE ...................................................... 80 OPERATIONS BEFORE STARTING ENGINE .................................. 80 STARTING ENGINE .................................................... 82 NORMAL STARTING ................................................ 82 SPECIAL STARTING ............................................... 82 COLD WEATHER STARTING .......................................... 83 OPERATIONS AFTER STARTING ENGINE ................................... 84 COLD WEATHER WARM-UP PROCEDURE ..................................... 84 MOVING MACHINE OFF ................................................. 85 SHIFTING GEAR ...................................................... 87 SHIFTING BETWEEN FORWARD AND REVERSE ............................... 88 STEERING MACHINE.................................................... 88 STOPPING MACHINE ................................................... 89 OPERATIONAL PRECAUTIONS............................................. 90 PERMISSIBLE WATER DEPTH ........................................ 90 IF WHEEL BRAKES DO NOT WORK .................................... 90 WHEN TRAVELING UP OR DOWN SLOPES ............................... 90 Lower Center of Gravity When Turning ....................... 90 Braking on Downhill Slopes ................................. 90 If Engine Stops ............................................ 91 POSSIBLE WORK USING LOADER ......................................... 92 EXCAVATION ..................................................... 92 LEVELING ....................................................... 94 LOAD AND CARRY OPERATIONS ...................................... 95 LOADING ........................................................ 95 Cross Drive Loading ........................................ 95 V-Shape Loading ............................................ 96 PARKING MACHINE .................................................... 96 STOPPING ENGINE .................................................... 97 OPERATIONS AFTER STOPPING ENGINE ................................... 97 ADJUSTMENT OF WORK EQUIPMENT ........................................... 98 ADJUSTING BOOM KICKOUT ............................................. 98 ADJUSTING BUCKET POSITIONER ........................................ 99 BUCKET LEVEL INDICATOR ............................................. 99 HANDLING TIRES .........................................................100 PRECAUTIONS WHEN HANDLING TIRES ....................................100 PRECAUTIONS WHEN DRIVING MACHINE ...................................100 NORMAL OPERATING INFLATION PRESSURE ................................101 INFLATING TIRES.................................................101 PROPER BUCKET AND TIRE SELECTION TABLE .............................103 TOWING .................................................................104 TOWING THE MACHINE .................................................104 WHEN ENGINE CAN BE USED.........................................104 WHEN ENGINE CANNOT BE USED......................................104 RELEASING PARKING BRAKE ............................................104 TRANSPORTATION .........................................................105 COLD WEATHER OPERATION .................................................106 PREPARATION FOR LOW TEMPERATURE ....................................106 FUEL AND LUBRICANTS ............................................106 COOLANT ........................................................106 BATTERY ........................................................106 CAUTIONS AFTER COMPLETION OF WORK ..................................107 AFTER COLD WEATHER .................................................107 LONG TERM STORAGE ......................................................108 BEFORE STORAGE .....................................................108 DURING STORAGE .....................................................108 AFTER STORAGE ......................................................108 HANDLING OF BATTERY ....................................................109 PRECAUTIONS FOR CHARGING BATTERY ...................................109 REMOVAL AND INSTALLATION OF BATTERY ................................109 STARTING ENGINE WITH BOOSTER CABLES ................................110 BEFORE CONNECTING BOOSTER CABLES ...................................110 CONNECTING BOOSTER CABLES ..........................................110 STARTING ENGINE ....................................................110 DISCONNECTING BOOSTER CABLES .......................................111 TROUBLESHOOTING ........................................................112 ELECTRICAL SYSTEM ..................................................112 ENGINE .............................................................112 CHASSIS ............................................................113 TRANSMISSION ...................................................113 DRIVE AXLES.....................................................113 WHEEL BRAKES....................................................113 PARKING BRAKE...................................................113 STEERING........................................................113 EQUIPMENT HYDRAULIC SYSTEM .....................................113 MAINTENANCE -- SECTION 3....................................................115 PERIODIC MAINTENANCE ...................................................116 MAINTENANCE GUIDELINES .................................................116 OUTLINES OF SERVICE ....................................................118 LUBRICATION WHEN SHIPPED ...........................................118 RELATING TO ENGINE .................................................118 ENGINE OIL......................................................118 COOLANT.........................................................119 DIESEL FUEL.....................................................119 RELATING TO HYDRAULIC SYSTEM .......................................119 RELATING TO ELECTRICAL SYSTEM ......................................119 RELATING TO LUBRICATION ............................................120 WEAR PARTS REPLACEMENT .................................................121 PERIODICAL PART REPLACEMENT ............................................122 LUBRICANTS, FUEL AND COOLANT ...........................................123 PROPER SELECTION TABLE .............................................123 ENGINE OIL......................................................124 Normal Operation............................................124 Arctic Operation............................................124 TRANSMISSION, HYDRAULIC SYSTEM AND BRAKE SYSTEM OIL.............125 AXLE OIL........................................................125 GREASE..........................................................125 DIESEL FUEL.....................................................125 COOLANT.........................................................126 SCHEDULED MAINTENANCE GUIDE ............................................131 FILLER AND LEVEL GAUGE POSITIONS .......................................136 INITIAL 250 HOURS SERVICE ONLY .........................................138 TRANSMISSION OIL FILTER ............................................138 WHEN REQUIRED ..........................................................138 SUPPLEMENTAL COOLANT ADDITIVE CONCENTRATION - SCA ..................138 AIR CLEANER ELEMENTS ...............................................138 CHECKING........................................................138 CLEANING OR REPLACING OUTER ELEMENT.............................138 REPLACING INNER ELEMENT.........................................139 CLEANING OUTER ELEMENT..........................................139 Using Compressed Air........................................139 Using Water.................................................139 Using Water With Cleaning Agent.............................140 TRANSMISSION OIL LEVEL..............................................140 RADIATOR CORE ......................................................141 DRIVE AXLE OIL LEVEL ...............................................142 DRIVE AXLE HOUSING BREATHERS .......................................143 LUBRICATION ........................................................144 HYDRAULIC TANK .....................................................145 PPC (PROPORTIONAL PRESSURE CONTROL) CIRCUIT ........................145 WHEEL BRAKE HYDRAULIC CIRCUIT ......................................146 PARKING BRAKE.......................................................147 BUCKET TEETH - IF EQUIPPED .........................................148 BUCKET EQUIPPED WITH BOLT-ON TEETH..............................148 BUCKET EQUIPPED WITH REPLACEABLE TOOTH TIP......................148 BUCKET BOLT-ON CUTTING EDGE - IF EQUIPPED...........................149 WINDOW WASHER TANKS - IF EQUIPPED ..................................150 AIR CONDITIONER CONDENSER - IF EQUIPPED ............................150 AIR CONDITIONER REFRIGERANT CHARGE - IF EQUIPPED ...................150 ALTERNATOR DRIVE BELT ..............................................151 FAN DRIVE BELT .....................................................151 WATER PUMP DRIVE BELT ..............................................151 ALTERNATOR .........................................................151 CRANKING MOTOR .....................................................151 AIR GOVERNOR .......................................................152 TRANSMISSION CONTROL LEVERS ........................................152 CHECKS BEFORE STARTING ENGINE ..........................................153 COOLANT LEVEL ......................................................153 ENGINE OIL LEVEL ...................................................153 FUEL LEVEL .........................................................154 AIR CLEANER SERVICE INDICATOR ......................................155 AIR TANKS ..........................................................155 BRAKE OIL LEVEL ....................................................156 FUEL FILTER/WATER SEPARATOR ........................................156 ENGINE FAN .........................................................157 DRIVE BELTS ........................................................157 BELT INSPECTION.................................................157 BELT TENSION CHECK..............................................157 MONITOR PANEL ......................................................158 ADDITIONAL CHECKS ..................................................159 EVERY 50 HOURS SERVICE .................................................159 FUEL TANK ..........................................................159 TIRES ..............................................................159 ENGINE AIR INTAKE SYSTEM ...........................................160 EVERY 100 HOURS SERVICE ................................................160 HYDRAULIC TANK OIL LEVEL ...........................................160 LUBRICATION ........................................................161 CAB AIR FILTER - IF EQUIPPED .......................................161 EVERY 250 HOURS SERVICE ................................................163 ENGINE OIL AND FILTER ..............................................163 FUEL FILTERS........................................................165 GENERAL.........................................................165 REPLACEMENT.....................................................165 COOLANT FILTER .....................................................166 GENERAL.........................................................166 REPLACEMENT.....................................................167 ENGINE CRANKCASE BREATHER AND TUBE .................................168 BATTERY ELECTROLYTE LEVELS .........................................168 LUBRICATION ........................................................168 WHEEL HUB NUTS .....................................................173 AIR CONDITIONER COMPRESSOR DRIVE BELT - IF EQUIPPED ................173 EVERY 500 HOURS SERVICE ................................................174 TRANSMISSION OIL FILTER - S/N A61017 AND BELOW .....................174 TRANSMISSION OIL FILTER - S/N A61018 AND UP ........................175 LUBRICATION ........................................................176 AIR DRYER - IF EQUIPPED ............................................176 EVERY 1000 HOURS SERVICE ...............................................176 TRANSMISSION OIL AND STRAINER ......................................176 TRANSMISSION CASE BREATHER .........................................177 LUBRICATION ........................................................178 EVERY 1500 HOURS SERVICE ...............................................180 ENGINE VALVES AND INJECTORS ........................................180 ENGINE .............................................................180 ENGINE MOUNTED HOSES ...............................................181 ENGINE MOUNTING HARDWARE ...........................................181 TURBOCHARGER MOUNTING ..............................................181 WATER PUMP .........................................................181 EVERY 2000 HOURS SERVICE ...............................................182 BATTERIES ..........................................................182 VISUAL INSPECTION...............................................182 STATE OF CHARGE TEST............................................182 Specific Gravity Hydrometer Test............................182 Stabilized Open Circuit Voltage Test........................183 HYDRAULIC TANK OIL AND FILTERS .....................................184 HYDRAULIC TANK BREATHER ............................................185 PPC CIRCUIT STRAINER ...............................................185 CAB AIR FILTER - IF EQUIPPED .......................................186 DRIVE AXLE OIL .....................................................186 PARKING BRAKE DISC .................................................187 AIR DRYER - IF EQUIPPED ............................................187 ACCUMULATOR ........................................................188 COOLING SYSTEM .....................................................188 COOLANT RECOMMENDATlONS/SPEClFlCATlONS..........................188 CHANGING COOLANT AND FLUSHING SYSTEM............................188 EVERY 6000 HOURS SERVICE ...............................................190 FUEL PUMP ..........................................................190 FUEL INJECTORS .....................................................190 ENGINE FAN HUB .....................................................190 ENGINE IDLER PULLEY ................................................190 TURBOCHARGER .......................................................190 AIR COMPRESSOR .....................................................190 ENGINE VIBRATION DAMPER ............................................190 SPECIFICATIONS -- SECTION 4.................................................191 GENERAL SPECIFICATIONS .................................................192 OPERATING WEIGHT....................................................192 PERFORMANCE.........................................................192 ENGINE..............................................................192 DIMENSIONS .............................................................193 STANDARD TIGHTENING TORQUES.............................................196 STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS........................196 TIGHTENING TORQUE OF SPLIT FLANGE BOLTS.............................196 TIGHTENING TORQUE FOR NUTS OF FLARED FITTINGS.......................197
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