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KOMATSU WA500-3 WHEEL LOADER Operation & Maintenance Manual (SN:WA500-3 52001 – 52379) KOMATSU WA500-3 – PDF DOWNLOAD
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- KOMATSU WA500-3 WHEEL LOADER Operation & Maintenance Manual
- SERIAL NUMBER:WA500-3 52001 – 52379
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Description
KOMATSU WA500-3 WHEEL LOADER Operation & Maintenance Manual (SN:WA500-3 52001 – 52379) KOMATSU WA500-3
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KOMATSU WA500-3 WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:WA500-3 52001 – 52379) KOMATSU WA500-3 – PDF DOWNLOAD:
TABLE OF CONTENTS:
KOMATSU WA500-3 WHEEL LOADER Operation & Maintenance Manual (SN:WA500-3 52001 – 52379) KOMATSU WA500-3
MAIN MENU....................................................................................... 0 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 WITH TRAILERS...................................................136 LIFTING MACHINE.........................................................................138 COLD WEATHER OPERATION......................................................................141 PRECAUTIONS FOR LOW TEMPERATURE.........................................................141 PRECAUTIONS AFTER COMPLETION OF WORK....................................................142 AFTER COLD WEATHER......................................................................143 WARMING-UP OPERATION FOR STEERING HYDRAULIC CIRCUIT IN COLD WEATHER.....................143 LONG-TERM STORAGE...........................................................................144 BEFORE STORAGE..........................................................................144 DURING STORAGE..........................................................................144 AFTER STORAGE...........................................................................144 TROUBLESHOOTING.............................................................................145 WHEN MACHINE RUNS OUT OF FUEL...........................................................145 TOWING THE MACHINE......................................................................146 IF BATTERY IS DISCHARGED................................................................149 OTHER TROUBLE...........................................................................152 MAINTENANCE.....................................................................................164 GUIDES TO MAINTENANCE.......................................................................165 OUTLINES OF SERVICE.........................................................................167 HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC..................................167 OUTLINE OF ELECTRIC SYSTEM..............................................................170 WEAR PARTS..................................................................................171 WEAR PARTS LIST.........................................................................171 RECOMMENDED FUEL, COOLANT, AND LUBRICANT....................................................172 USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE....................173 RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL ....174 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS..............................................175 TORQUE LIST.............................................................................175 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...............................................176 MAINTENANCE SCHEDULE CHART..................................................................178 MAINTENANCE SCHEDULE CHART..............................................................178 SERVICE PROCEDURE...........................................................................180 INITIAL 250 HOURS SERVICE...............................................................180 REPLACE TRANSMISSION OIL FILTER ELEMENT.............................................215 CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC FILTER ELEMENT......................222 WHEN REQUIRED...........................................................................181 CHECK, CLEAN, OR REPLACE AIR CLEANER ELEMENT........................................181 CLEAN INSIDE OF COOLING SYSTEM......................................................184 CHECK TRANSMISSION OIL LEVEL, ADD OIL...............................................187 CHECK AXLE OIL LEVEL, ADD OIL.......................................................189 CLEAN AXLE CASE BREATHER............................................................190 CLEAN AIR CONDITIONER CONDENSER.....................................................190 CHECK WINDOW WASHING FLUID LEVEL, ADD FLUID.........................................190 CLEAN RADIATOR FINS AND OIL COOLER FINS.............................................191 CHECK ELECTRICAL INTAKE AIR HEATER..................................................192 REPLACE BUCKET TEETH................................................................192 REPLACE BUCKET TOOTH WITH SEGMENT EDGE..............................................194 TURN, REPLACE BOLT-ON CUTTING EDGE..................................................195 LUBRICATE WORK EQUIPMENT CONTROL VALVE LINKAGE (2 PLACES)...........................195 CHECK AIR CONDITIONER...............................................................196 REPLACE SLOW BLOW FUSE..............................................................197 SELECTION AND INSPECTION OF TIRES...................................................198 CHECK BEFORE STARTING...................................................................200 EVERY 50 HOURS SERVICE..................................................................201 DRAIN WATER, SEDIMENT FROM FUEL TANK................................................201 EVERY 100 HOURS SERVICE.................................................................202 LUBRICATE REAR AXLE PIVOT PIN.......................................................202 CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL..........................................202 CLEAN ELEMENT IN AIR CONDITIONER FRESH AIR FILTER...................................203 EVERY 250 HOURS SERVICE.................................................................204 CHECK BATTERY ELECTROLYTE LEVEL.....................................................204 CHECK PARKING BRAKE.................................................................206 CHECK ALTERNATOR BELT TENSION, ADJUST...............................................206 CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST...............................207 CHECK FOR LOOSE WHEEL HUB NUTS, TIGHTEN.............................................207 CLEAN ELEMENT IN AIR CONDITIONER RECIRCULATION FILTER...............................208 LUBRICATING.........................................................................208 EVERY 500 HOURS SERVICE.................................................................211 REPLACE FUEL FILTER CARTRIDGE.......................................................211 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE...................213 REPLACE TRANSMISSION OIL FILTER ELEMENT.............................................215 LUBRICATE CENTER DRIVE SHAFT SPLINE.................................................216 CHECK FAN BELT FOR WEAR.............................................................216 EVERY 1000 HOURS SERVICE................................................................217 CHANGE OIL IN TRANSMISSION CASE, CLEAN STRAINER.....................................217 CLEAN TRANSMISSION CASE BREATHER....................................................218 LUBRICATING.........................................................................218 CHECK TIGHTENING PARTS OF TURBOCHARGER..............................................220 REPLACE CORROSION RESISTOR CARTRIDGE................................................220 CLEAN RADIATOR SUB-TANK BREATHER....................................................220 CLEAN FUEL STRAINER.................................................................221 WASH FUEL TANK BREATHER.............................................................221 TIGHTEN ROPS CANOPY.................................................................221 EVERY 2000 HOURS SERVICE................................................................222 CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC FILTER ELEMENT......................222 REPLACE HYDRAULIC TANK BREATHER ELEMENT.............................................224 CHANGE AXLE OIL.....................................................................225 REPLACE ELEMENT IN AIR CONDITIONER RECIRCULATION AIR FILTER, FRESH AIR FILTER.......226 CLEAN PPC CIRCUIT STRAINER..........................................................226 CLEAN ENGINE BREATHER ELEMENT.......................................................227 CHECK ALTERNATOR, STARTING MOTOR....................................................227 CHECK ENGINE VALVE CLEARANCE, ADJUST................................................227 CHECK BRAKE DISC WEAR...............................................................227 CLEAN AND CHECK TURBOCHARGER........................................................227 CHECK PLAY OF TURBOCHARGER ROTOR....................................................227 CHECK ACCUMULATOR FUNCTION..........................................................228 CHECK ACCUMULATOR GAS PRESSURE......................................................228 CHECK INJECTOR......................................................................228 EVERY 4000 HOURS SERVICE................................................................229 CHECK WATER PUMP....................................................................229 CHECK VIBRATION DAMPER..............................................................229 CHECK FAN PULLEY AND TENSION PULLEY.................................................229 CHECK AIR CONDITIONER COMPRESSOR, ADJUST............................................229 REPLACE INJECTOR....................................................................229 CHECKING FOR LOOSENESS OF HIGH-PRESSURE CLAMP, HARDENING OF RUBBER..................229 CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER.................230 EVERY 8000 HOURS SERVICE................................................................231 REPLACE HIGH-PRESSURE PIPING CLAMP..................................................231 REPLACE FUEL SPRAY PREVENTION CAP...................................................231 SPECIFICATIONS..................................................................................232 SPECIFICATIONS..............................................................................233 ATTACHMENTS, OPTIONS............................................................................234 SELECTING BUCKET AND TIRES..................................................................235 HANDLING E.C.S.S.(ELECTRONIC CONTROLLED SUSPENSION .........................................236 METHOD OF OPERATING E.C.S.S.............................................................236 PRECAUTIONS WHEN OPERATING E.C.S.S. SWITCH..............................................236 PRECAUTIONS WHEN HANDLING ACCUMULATOR...................................................237 REMOVAL OF E.C.S.S. PIPING..............................................................237 HANDLING AUTO-GREASING SYSTEM...............................................................238 METHOD OF OPERATING AUTO-GREASING SYSTEM................................................238 PRECAUTIONS WHEN HANDLING AUTO-GREASING SYSTEM..........................................243 TROUBLESHOOTING.........................................................................244 HANDLING REMOTE POSITIONER..................................................................245 GENERAL LOCATIONS.......................................................................245 METHOD OF OPERATING REMOTE POSITIONER...................................................246 METHOD OF SETTING REMOTE POSITIONER STOP POSITION.......................................247 SENSOR ADJUSTMENT FUNCTION..............................................................247 ADJUSTING REMOTE POSITIONER.............................................................247 HANDLING JOYSTICK STEERING SYSTEM...........................................................248 STRUCTURE AND FUNCTION OF JOYSTICK STEERING.............................................248 OPERATION METHOD OF JOYSTICK STEERING SYSTEM............................................251 PRECAUTIONS FOR STEERING WITH JOYSTICK..................................................253 ADJUSTMENT OF JOYSTICK CONSOLE..........................................................254 HANDLING JOYSTICK...........................................................................257 EXPLANATION OF COMPONENTS...............................................................257 HANDLING AIR-SUSPENSION SEAT................................................................260 SEAT ADJUSTMENT.........................................................................260 CAR RADIO...................................................................................262 EXPLANATION OF COMPONENTS...............................................................262 METHOD OF USE...........................................................................265 PRECAUTIONS WHEN USING..................................................................267 AM/FM RADIO-CASSETTE STEREO.................................................................268 EXPLANATION OF COMPONENTS...............................................................268 METHOD OF OPERATION.....................................................................273 PRECAUTIONS FOR USE.....................................................................275 AIR CONDITIONER.............................................................................276 GENERAL LOCATIONS AND FUNCTION OF CONTROL PANEL.........................................276 METHOD OF OPERATION.....................................................................279 HANDLING BRAKE COOLING SYSTEM...............................................................281 WHEN REQUIRED...........................................................................281 EVERY 2000 HOURS SERVICE................................................................283 INDEX...........................................................................................286
DESCRIPTION:
KOMATSU WA500-3 WHEEL LOADER Operation & Maintenance Manual (SN:WA500-3 52001 – 52379) KOMATSU WA500-3
- 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.
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