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Komatsu WA500-6 Wheel Loader Operation & Maintenance Manual A93001 and up – PDF DOWNLOAD
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Komatsu WA500-6 Wheel Loader Operation & Maintenance Manual
SERIAL NUMBERS : WA500-6 A93001 and up
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Description
Komatsu WA500-6 Wheel Loader Operation & Maintenance Manual
FILE DETAILS:
Komatsu WA500-6 Wheel Loader Operation & Maintenance Manual
Language : English
Pages : 372
Downloadable : Yes
File Type : PDF
Size: 32.3 MB
Book Code: CEAM023403
DESCRIPTION:
Komatsu WA500-6 Wheel Loader Operation & Maintenance Manual
FOREWORD:
- This manual describes procedures for operation, handling, lubrication, maintenance, checking, and adjustment. It will help the operator and maintenance personnel achieve peak performance through efi‘ective, economical, and safe machine operation and maintenance.
- Keep this manual handy and have all personnel read it periodically. Ifthis manual is lost, damaged, or becomes dirty and can not be read, request a replacement manual from your local distributor. Ifyou sell the machine, be sure to give this manual to the new owner.
- The explanations, values, and illustrations in this manual have been prepared based on the latest information available at the date of its publication. Continuing improvements in the design of this machine may lead to additional changes that are not reflected in this manual.
- Consult Komatsu or your Komatsu distributor for the latest available information concerning your machine or with questions regarding information contained in this manual, This manual may contain attachments and optional equipment that are not available in your area. Consult your local Komatsu distributor for items that you may require. The numbers in the illustrations correspond to the numbers in the text.
TABLE OF CONTENTS:
Komatsu WA500-6 Wheel Loader Operation & Maintenance Manual
WA500-6 - CEAM023403 s/n A93001 and up................................................... 0 INTRODUCTION............................................................................. 5 FOREWORD............................................................................. 6 SAFETY INFORMATION................................................................... 7 APPROVED AND NON-APPROVED USES....................................................... 8 Approved Functions............................................................... 8 Non-Approved Functions........................................................... 8 VISIBILITY STANDARD.................................................................. 9 Visibility in Immediate Area..................................................... 9 12 Meter Radius Visibility....................................................... 9 PRODUCT IDENTIFICATION............................................................... 10 Directions Of Machine............................................................ 10 Machine Serial Number............................................................ 10 Engine Serial Number, EPA Regulations............................................ 11 Service Meter Location........................................................... 11 SERIAL NUMBERS AND DEALER INFORMATION................................................ 12 Model: WA500-6................................................................... 12 TABLE OF CONTENTS.................................................................... 13 SAFETY................................................................................... 27 SAFETY AND WARNING DECALS............................................................ 28 Location of the Safety Decals.................................................... 28 Safety Labels.................................................................... 30 GENERAL SAFETY RULES AND PRECAUTIONS................................................. 37 General Safety Rules............................................................. 37 Safety at Job Site............................................................... 37 Safety Features.................................................................. 38 Clothing and Protective Equipment................................................ 38 Keep Machine Clean............................................................... 38 Fire and Explosion Prevention.................................................... 39 Fire Caused by Fuel, Oil, Antifreeze, or Window Washer Fluid................. 39 Fire Caused by Accumulation of Flammable Material............................ 40 Fire Caused by Electrical Wiring............................................. 40 Fire Caused by Piping........................................................ 40 Explosion Caused by Lighting Equipment....................................... 40 Action if Fire Occurs............................................................ 40 Fire Extinguisher and First Aid Kit.............................................. 41 Mounting and Dismounting......................................................... 41 Inside Operator’s Compartment.................................................... 42 Emergency Escape from Operator’s Cab............................................. 43 Precautions When Standing Up from Operator’s Seat................................ 43 Leaving Operator’s Compartment................................................... 44 Parking the Machine.............................................................. 45 Precautions When Using ROPS...................................................... 46 Unauthorized Modification........................................................ 46 Precautions for Attachments and Options.......................................... 46 Precautions When Cleaning Cab Glass.............................................. 47 Asbestos Hazard Alert............................................................ 47 Crush or Pinch-Point Dangers..................................................... 48 Precautions for Ventilation Exhaust Gas.......................................... 48 PRECAUTIONS BEFORE STARTING OPERATIONS............................................... 49 Pre-Operational Checks........................................................... 49 Ensure Good Visibility....................................................... 49 Signs and Signals............................................................ 49 Precaution for Warning Tag................................................... 50 Checks Before Starting Engine, Adjustments................................... 50 Precautions When Starting.................................................... 51 Precautions in Cold Areas.................................................... 51 Seat Belt Inspection............................................................. 51 Precautions for Job Site......................................................... 52 Work Site Hazards............................................................ 52 Working on Loose or Unstable Ground.......................................... 53 Prohibited Operations........................................................ 53 Avoiding Dangerous Situations................................................ 53 Working Near High Voltage Cables............................................. 55 RULES FOR ROAD TRAVEL................................................................ 56 Travel Precautions............................................................... 56 Traveling on Slopes.............................................................. 57 Using the Brakes................................................................. 58 Traveling in Reverse............................................................. 58 Operating on Snow or Frozen Surfaces............................................. 59 PRECAUTIONS DURING INSPECTION AND MAINTENANCE........................................ 60 Warning Tags..................................................................... 60 Systems Equipped with ECSS....................................................... 60 Equipment Storage................................................................ 60 Working Under the Machine........................................................ 61 Using Drop Lights................................................................ 61 Using Proper Tools............................................................... 61 Keeping the Machine Clean........................................................ 62 Precautions When Welding......................................................... 62 Precautions When Using Hammer.................................................... 62 Noise............................................................................ 62 Stopping Engine During Inspection and Maintenance................................ 63 Running the Machine During Maintenance........................................... 64 Rules for Refueling the Machine.................................................. 65 Cooling System Precautions....................................................... 65 Battery Information.............................................................. 66 Precautions.................................................................. 66 Hazards...................................................................... 66 Using Booster Cables......................................................... 67 Starting the Machine with Booster Cables..................................... 68 High-Pressure Precautions........................................................ 68 Precautions for High-Pressure Oil............................................ 68 Safe Handling of High-Pressure Hoses......................................... 69 Precautions for High-Pressure Fuel........................................... 69 High-Temperature Precautions..................................................... 69 High-Temperature Areas....................................................... 69 High-Temperature Coolant..................................................... 69 High-Temperature Oil......................................................... 70 High Voltage..................................................................... 70 Accumulator...................................................................... 70 Inflating Tires.................................................................. 71 Using Compressed Air............................................................. 71 Disposal of Waste Materials...................................................... 71 Critical Parts................................................................... 72 Maintenance of Air Conditioner................................................... 72 OPERATION................................................................................ 73 GENERAL VIEW......................................................................... 74 General View of Machine.......................................................... 74 General View of Controls and Gauges.............................................. 75 Front Switch Panel........................................................... 76 Right Switch Panel........................................................... 77 Overhead Portion and Behind Seat............................................. 78 Machine Monitor.............................................................. 79 EXPLANATION OF COMPONENTS............................................................ 81 Machine Monitor.................................................................. 81 Types of Warnings................................................................ 82 Emergency Stop............................................................... 82 Caution...................................................................... 82 Mistaken Operation........................................................... 82 Inspection and Maintenance................................................... 82 Central Warning Lamp......................................................... 83 Character Display Portion........................................................ 83 Service Meter................................................................ 84 Clock........................................................................ 84 Action Code Display.......................................................... 84 Failure Code Display......................................................... 85 Method of Displaying Failure Code............................................ 86 Filter, Oil Replacement Time Display......................................... 86 Items for Display of Filter, Oil Replacement Time........................ 88 Engine Speed or Travel Speed Display......................................... 89 Emergency Stop Items............................................................. 89 Brake Oil Pressure Caution Lamp.............................................. 90 Engine Oil Pressure Caution Lamp............................................. 90 Battery Charge Circuit Caution Lamp.......................................... 91 Steering Oil Pressure Caution Lamp - Red..................................... 91 Caution Items.................................................................... 92 Brake Oil Temperature Caution Lamp........................................... 93 Torque Converter Oil Temperature Caution Lamp................................ 94 Engine Coolant Temperature Caution Lamp...................................... 94 Hydraulic Oil Temperature Caution Lamp....................................... 94 Fuel Level Caution Lamp...................................................... 94 Modulation Clutch Temperature Caution Lamp................................... 95 Inspection and Maintenance Items................................................. 95 Engine Oil Level Caution Lamp................................................ 96 Radiator Coolant Level Caution Lamp.......................................... 96 Air Cleaner Clogging Caution Lamp............................................ 96 Maintenance Caution Lamp..................................................... 97 Battery Electrolyte Level Caution Lamp....................................... 97 Fuel Filter Water Detection Caution Lamp..................................... 97 Transmission Oil Filter Clogging Caution Lamp................................ 98 Pilot Display Portion............................................................ 98 Parking Brake Pilot Lamp..................................................... 99 Cooling Fan Reverse Rotation Pilot Lamp...................................... 99 Emergency Steering Pilot Lamp - Green........................................ 99 Output Mode Pilot Lamp (Power Mode).......................................... 99 Preheating Pilot Lamp........................................................100 Auto-Greasing Pilot Lamp.....................................................100 Joystick Pilot Lamp..........................................................100 Shift Indicator Lamp.........................................................100 Auto-Shift Pilot Lamp........................................................101 Lock-Up Pilot Light..........................................................101 Shift Hold Pilot Lamp........................................................101 Shift Lever Position Pilot Lamp..............................................101 Turn Signal Pilot Lamp.......................................................102 Head Lamp High-Beam Pilot Lamp...............................................102 Directional Selector Pilot Lamp (if equipped)................................102 ECSS Pilot Lamp..............................................................102 Economy Operation Display Lamp...............................................103 Semi-Auto Digging Pilot Lamp.................................................103 Meter Display Portion............................................................103 Torque Converter Oil Temperature Gauge.......................................104 Engine Coolant Temperature Gauge.............................................104 Hydraulic Temperature Gauge..................................................104 Fuel Gauge...................................................................104 Load Meter (if equipped).....................................................105 Speedometer/Tachometer.......................................................105 OTHER FUNCTIONS OF MACHINE MONITOR...................................................106 Overall Menu.....................................................................106 Displaying Odometer..........................................................108 Resetting Filter, Oil Replacement Time.......................................108 Entering Telephone Number....................................................109 Selecting Language...........................................................111 Adjusting Monitor Brightness.................................................112 Adjusting Clock..............................................................114 Switching Travel Speed/Engine Speed Display..................................115 Switching Travel Speed/Engine Speed Display/ Non-Display.....................116 SWITCHES AND CONTROLS................................................................118 General View.....................................................................118 Ignition Switch..............................................................120 Rear Wiper Switch............................................................120 Front Wiper Switch...........................................................120 Load Meter Display Selector Switch...........................................121 Load Meter Mode Selector Switch..............................................121 Machine Monitor Mode Selector Switch 1.......................................121 Machine Monitor Mode Selector Switch 2.......................................121 ECSS Switch..................................................................122 Horn Button..................................................................122 Hazard Lamp Switch...........................................................123 Parking Brake Switch.........................................................123 Front Work Light Switch......................................................124 Rear Work Light Switch.......................................................124 Beacon Lamp Switch...........................................................124 Cigarette Lighter............................................................124 Lamp Switch..................................................................125 Turn Signal Lever............................................................125 Dimmer Switch................................................................125 Load Meter Cancel Switch.....................................................125 Kickdown Switch..............................................................126 Hold Switch..................................................................126 Load Meter Subtotal Switch...................................................127 Directional Selector Switch..................................................127 Transmission Auto-Shift/Manual Shift Selector Switch.........................127 Transmission Cutoff Switch...................................................128 Transmission Cut-Off Set Switch..............................................128 Remote Positioner Raise/Lower Set Switch.....................................129 Remote Positioner Bucket Angle Set Switch....................................129 RPM Set ON/OFF Switch........................................................130 RPM Set Idle UP/DOWN Selector Switch.........................................131 Cooling Fan Reverse Rotation Switch..........................................131 Semi-Auto Digging Switch.....................................................132 Directional Selector ON/OFF Switch...........................................132 Torque Converter Lock-Up Switch..............................................132 Engine Power Mode Selector Switch............................................133 Rear Heated Wire Glass Switch................................................133 Auto-Greasing Switch.........................................................134 Emergency Parking Brake Cancel Switch........................................134 Room Lamp Switch.............................................................134 CONTROL LEVERS, PEDALS...............................................................135 General View.....................................................................135 Gearshift Lever..............................................................136 Directional Lever............................................................137 Gearshift Lever Stopper......................................................138 Work Equipment Lock Lever....................................................138 Bucket Control Lever.........................................................138 Boom Control Lever...........................................................139 Brake Pedals.................................................................139 Accelerator Pedal............................................................140 Fore-and-Aft Adjustment Handle...............................................140 Right Armrest UP/DOWN Angle Adjustment Lever.................................140 SECURITY LOCKS AND SAFETY FEATURES...................................................141 Steering Tilt Lock Lever.........................................................141 Cap with Lock....................................................................141 Fuel Tank Filler Port Cap....................................................141 Hydraulic Tank Fill and Transmission Fill Cap................................142 Frame Lock Bar...................................................................143 Backup Alarm.....................................................................143 Towing Pin.......................................................................144 Fire Extinguisher................................................................144 MACHINE FEATURES.....................................................................145 Cab Door.........................................................................145 Emergency Escape Right Door..................................................145 Left Cab Door, Lock..........................................................147 Left Cab Door, Knob..........................................................147 Left Cab Door, Handle........................................................147 Left Cab Sliding Window, Lock Release Knob...................................148 Cab Wiper........................................................................148 Preventing Wiper Arm Bracket Damage..........................................148 Dust Indicator...................................................................148 ELECTRICAL...........................................................................149 Power Outlet.....................................................................149 Fuses............................................................................149 Slow-Blow Fuse...............................................................150 Fuse Capacity and Name of Circuit............................................150 WORK OPERATIONS......................................................................152 Check Before Starting Engine, Adjust.............................................152 Walk-Around Check............................................................152 Check Before Starting Engine.....................................................154 Check Machine Monitor........................................................154 Check Dust Indicator.........................................................155 Drain Water from Fuel Prefilter..............................................155 Check Coolant Level, Add Coolant.............................................156 Check Oil Level in Engine Oil Pan, Add Oil...................................156 Check Fuel Level, Add Fuel...................................................157 Check Radiator Fins..........................................................158 Check Electric Wiring........................................................160 Check Parking Brake..........................................................160 Check Brake Pedal............................................................160 Check Inflation Pressure of Tires............................................160 Adjustments......................................................................161 Adjusting Seat...............................................................161 Removing or Installing Headrest..............................................163 Adjusting Seat Belt..........................................................163 Adjusting Mirrors............................................................164 Final Checks Before Starting Engine..............................................164 Starting Engine..................................................................166 Normal Starting..............................................................166 Automatic Warming-Up Operation...............................................167 Operations and Checks After Starting Engine......................................168 Breaking in the Machine......................................................168 Checks After Starting Engine.................................................168 Check Location of Abnormalities from Previous Days.......................169 Normal Operation.............................................................169 Stopping Engine..................................................................170 Check After Stopping Engine..................................................170 Moving the Machine, Stopping the Machine.........................................170 Moving the Machine...........................................................170 Changing Gear Speed..........................................................173 Changing Direction...........................................................174 Stopping the Machine.........................................................175 Transmission Cutoff Function.................................................177 Turning......................................................................179 Emergency Steering...........................................................179 Operation of Work Equipment......................................................180 Work Equipment Lock Lever....................................................180 Boom.........................................................................181 Bucket.......................................................................181 Semi-Auto Digging............................................................182 Starting Semi-Auto Digging...............................................182 Remote Bucket Positioner.....................................................182 Remote Boom Positioner.......................................................183 Operating Raise Remote Boom Positioner...................................183 Checking Actuation.......................................................184 Cancelling Lower Remote Boom Positioner..................................184 Work Possible Using Wheel Loader.................................................184 Recommended Combination of Switches for Operation............................184 Digging Operations...........................................................185 Loading Piled Soil or Blasted Rock...........................................185 Digging and Loading on Level Ground..........................................187 Leveling Operations..........................................................188 Pushing Operations...........................................................188 Load-and-Carry Operations....................................................188 Loading Operations...............................................................188 Cross-Drive Loading..........................................................189 V-Shape Loading..............................................................189 Preparations for Loading, Gathering Rocks....................................189 Approaching Facing...........................................................190 Digging......................................................................190 Traveling in Reverse After Excavation........................................191 Approaching Dump Truck.......................................................192 Loading Dump Truck...........................................................193 Reversing Away From Dump Truck...............................................193 Precautions During Work Operations...............................................194 Piling Up Loads..............................................................194 Handling Blasted Rock........................................................194 Handling Bucket..........................................................194 Shifting Transmission When Thrusting Bucket Into Facing..................194 Articulating Machine During Digging Operations...........................194 Bucket Dump Angle When Digging or Lowering Roadbed.......................195 Bucket Dump Angle When Leveling..........................................195 Loading Bucket...........................................................196 Bucket Dump Operation When Digging.......................................196 Front Wheels Going on Blasted Rock.......................................197 Loosened Boulders............................................................197 Pit Excavation...............................................................197 Cutting Face Operations......................................................197 Switching Between Forward and Reverse........................................198 Turning When Tires Are Stationary............................................198 Permissible Water Depth......................................................198 Wheel Brake Does Not Work....................................................198 Driving Up or Down Slopes....................................................198 Lower the Center of Gravity When Turning.................................198 Braking on Downhill Slope................................................198 If Engine Stops..........................................................199 Driving the Machine..........................................................199 Adjusting Work Equipment.........................................................200 Removing the Bucket..........................................................200 Installing the Bucket........................................................201 Measuring Dump Angle.............................................................203 Measuring Bucket Dump Angle..................................................203 Inclinometer Required....................................................203 Measuring Coupler Dump Angle.................................................205 Inclinometer Required....................................................205 Parking the Machine..............................................................208 Checks After Completion of Operation.............................................210 Before Stopping Engine.......................................................210 After Stopping Engine........................................................210 Locking the Machine..............................................................211 HANDLING TIRES.......................................................................212 Precautions When Handling Tires..................................................212 Tire Pressure................................................................213 Air Pressure Chart.......................................................213 Precautions for Using Load-and-Carry Method..................................213 TRANSPORTATION.......................................................................214 Transportation Procedure.........................................................214 Loading and Unloading Trailers...................................................215 Loading Machine..............................................................215 Securing Machine.............................................................215 Fastening Positions......................................................216 Unloading Machine............................................................217 LIFTING MACHINE......................................................................218 Lifting Position.................................................................218 Lifting Procedure................................................................219 COLD WEATHER OPERATION...............................................................220 Precautions for Low Temperature..................................................220 Fuel and Lubricants..........................................................220 Coolant......................................................................220 Battery......................................................................220 Precautions After Completion of Work.........................................221 After Cold Weather...........................................................221 Warming-Up Operation for Steering Hydraulic Circuit..........................221 LONG-TERM STORAGE....................................................................222 Before Storage...................................................................222 During Storage...................................................................222 After Storage....................................................................222 AUTOMATIC AIR CONDITIONER............................................................223 Control Panel....................................................................223 Main Power Switch............................................................224 Fan Switch...................................................................224 Air Conditioner Switch.......................................................225 Auto Switch..................................................................225 Temperature Switch...........................................................225 FRESH/RECIRC Selector Switch.................................................226 Mode Selector Switch.........................................................226 Method of Operation..............................................................227 Cooling Operation............................................................227 Heating Operation............................................................227 Drying-Heating and Demisting Operation.......................................227 When Not Using the Air Conditioner Regularly.................................228 Precautions When Using Air Conditioner...........................................228 Inspection and Maintenance.......................................................228 Cool Box.........................................................................228 TORQUE CONVERTER LOCK-UP.............................................................229 Components.......................................................................229 Torque Converter Lock-Up Switch..............................................230 Torque Converter Lock-Up Pilot Lamp..........................................230 Shift Indicator..............................................................230 Character Display............................................................230 Method of Operation..............................................................230 Travel Speed Warning Function....................................................231 KOMTRAX..............................................................................232 Basic Precautions................................................................232 TROUBLESHOOTING......................................................................233 When Machine Runs Out of Fuel....................................................233 Bleeding Air from Fuel Line..................................................233 Towing the Machine...............................................................234 When Engine Can Be Used......................................................235 When Engine Cannot Be Used...................................................235 Releasing Parking Brake......................................................235 Emergency Travel Operation...................................................237 If Battery is Discharged.........................................................237 Precautions..................................................................237 Removal and Installation of Battery..........................................237 Precautions for Charging Battery.............................................238 Starting Engine With Booster Cables..............................................238 Precautions When Connecting or Disconnecting Booster Cable...................238 Connecting Booster Cable.....................................................239 Starting Engine..............................................................239 Disconnecting Booster Cable..................................................239 Lowering Work Equipment When Engine Has Stopped..................................240 Other Troubleshooting............................................................241 Electrical System............................................................241 Chassis......................................................................242 Engine.......................................................................244 MAINTENANCE..............................................................................245 GUIDES TO MAINTENANCE................................................................246 Check Service Meter..............................................................246 Komatsu Genuine Replacement Parts................................................246 Komatsu Genuine Oils.............................................................246 Always Use Clean Washer Fluid....................................................246 Always Use Clean Oil and Grease..................................................246 Checking for Foreign Materials in Drained Oil and On Filters.....................246 Fuel Strainer....................................................................246 Welding Instructions.............................................................246 Do Not Drop Things Inside Machine................................................247 Dusty Work Sites.................................................................247 Avoid Mixing Oil.................................................................247 Locking Inspection Covers........................................................247 Bleeding Air from Hydraulic Circuit..............................................247 Precautions When Installing Hydraulic Hoses......................................247 Checks After Inspection and Maintenance..........................................247 Checks after Operation, with engine stopped..................................247 Checks When Engine is Running................................................248 OUTLINES OF SERVICE..................................................................249 Handling Oil, Fuel, Coolant, and Performing Oil Clinic...........................249 Oil..........................................................................249 Fuel.........................................................................249 Coolant and Water for Dilution...............................................250 Grease.......................................................................250 Performing KOWA, Komatsu Oil Wear Analysis.......................................251 KOWA Analysis Items..........................................................251 Oil Sampling.................................................................251 Storing Oil and Fuel.........................................................251 Filters......................................................................252 Outline of Electric System...................................................252 WEAR PARTS...........................................................................253 Wear Parts List..................................................................253 RECOMMENDED FUEL, COOLANT, AND LUBRICANTS............................................254 Fuel, Coolant, and Lubricant Ambient Temperature Chart...........................255 Recommended Brands, Other Than Komatsu Genuine Oil...............................256 Biodiesel Usage..................................................................257 Biodiesel Recommendation for Komatsu Engines.................................257 Biodiesel Terminology........................................................258 Certification and Standards..................................................258 Warranty and Use of Biodiesel Fuel in Komatsu Engines........................259 Requirements for Using Biodiesel Fuel in Komatsu Engines.....................259 Oil Sampling.............................................................259 Fuel Water Separation....................................................259 Biodiesel Fuel Storage...................................................259 Properties of Biodiesel......................................................259 Energy Content...........................................................259 Engine Material Compatibility............................................260 Low Temperature Performance..............................................260 Microbial Growth.........................................................260 Komatsu Biodiesel Blend Specification for B5 to B20..........................260 Summary of Recommendations...................................................261 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS.......................................262 Torque List......................................................................262 Face Seal....................................................................263 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS........................................264 Safety-Critical Parts List.......................................................264 MAINTENANCE SCHEDULE CHART...........................................................266 SERVICE PROCEDURE....................................................................268 Initial 10 Hours Service.........................................................268 Initial 250 Hours Service........................................................268 When Required....................................................................268 Check, Clean, Replace Air Cleaner Element....................................268 Checking.................................................................268 Cleaning or Replacing Outer Element......................................269 Replacing Inner Element..................................................270 Clean Inside of Cooling System...............................................270 Water and Supercoolant Mix Ratio Table...................................271 Required.................................................................272 Check Transmission Oil, Add Oil..............................................273 Check Axle Oil Level, Add Oil................................................275 Clean Axle Case Breather.....................................................275 Clean Air Conditioner Condenser..............................................276 Check Window Washing Fluid Level, Add Fluid..................................276 Clean Radiator Fins..........................................................277 Replace Bucket Teeth.........................................................277 One-Piece Tooth..........................................................278 Bucket with Tip Tooth....................................................278 Bucket Tooth with Segment Edge...............................................279 Check Air Conditioner........................................................279 Check Level of Refrigerant (Gas).........................................279 Operating the Air Conditioner Off-Season.................................280 Replace Slow-Blow Fuse.......................................................280 Replacing Slow-Blow Fuses A and B........................................280 Replacing Slow-Blow Fuse C...............................................281 Bleeding Air from Hydraulic Tank.............................................282 Bleeding Air from Piston Pump............................................282 Bleeding Air from Hydraulic Circuit......................................282 Check Function of ECSS Accumulator...........................................283 Select Tires.................................................................283 Check Tire Pressure..........................................................284 Inflation of Tires.......................................................284 Check Before Starting............................................................285 Additional Checks............................................................285 Every 50 Hours Service...........................................................286 Drain Water, Sediment from Fuel Tank.........................................286 Every 100 Hours Service..........................................................287 Lubricating..................................................................287 Lubricate Rear Axle Pivot Pin................................................288 Check Oil Level in Hydraulic Tank, Add Oil...................................288 Clean Element in Air Conditioner Fresh Air Filter............................289 Every 250 Hours Service..........................................................290 Check Battery Electrolyte Level..............................................290 When Checking Electrolyte Level from Side of Battery.....................290 When It Is Impossible to Check Electrolyte Level from Side of Battery....291 When It Is Possible to Use Indicator to Check Electrolyte Level..........291 Check Parking Brake..........................................................291 Check Alternator Belt Tension, Adjust........................................292 Checking.................................................................292 Adjusting................................................................292 Check AC Compressor Belt Tension, Adjust.....................................292 Checking.................................................................292 Adjusting................................................................292 Check for Loose Wheel Hub Nuts, Tighten......................................293 Clean Element in Air Conditioner Recirculation Filter........................293 Check Function of Brake Accumulator..........................................293 Lubricating..................................................................294 Every 500 Hours Service..........................................................296 Change Oil in Engine Oil Pan, Replace Engine Oil Filter Cartridge............296 Required.................................................................296 Replace Fuel Prefilter Cartridge.............................................297 Required.................................................................297 Clean the Filter Holder......................................................298 Replace Transmission Oil Filter Element......................................298 Every 1000 Hours Service.........................................................300 Change Oil in Transmission Case, Clean Strainer..............................300 Required.....................................................................300 Replace Fuel Filter Cartridge................................................302 Required.................................................................302 Bleeding Air from Fuel Line..............................................303 Clean Transmission Case Breather.............................................303 Wash Fuel Tank Breather......................................................304 Lubricating..................................................................304 Replace Corrosion Resistor Cartridge (S/N A93001-A93028).....................305 Check Engine Air Intake Piping Clamps for Looseness..........................305 Every 2000 Hours Service.........................................................306 Change Oil in Hydraulic Tank, Replace Hydraulic Filter Element...............306 Required.................................................................306 Clean Hydraulic Tank Strainer................................................308 Replace Hydraulic Tank Breather Element......................................308 Change Axle Oil..............................................................308 Required.................................................................309 Replace Element in Air Conditioner Recirculation Filter, Fresh Air Filter....310 Clean PPC Circuit Strainer...................................................310 Check Alternator.............................................................310 Check Engine Valve Clearance, Adjust.........................................310 Check Brake Disc Wear........................................................310 Check Function of PPC Accumulator............................................311 Every 4000 Hours Service.........................................................312 Check Water Pump and Starting Motor..........................................312 Lubricating..................................................................312 Required.................................................................312 Check for Loose Engine High-Pressure Piping Clamps, Hardening of Rubber......313 Check for Missing Fuel Spray Prevention Cap, Hardening of Rubber.............313 Every 8000 Hours Service.........................................................314 Replace High-Pressure Piping Clamps..........................................314 Replace Fuel Spray Prevention Cap............................................314 Overhaul Starting Motor and Alternator.......................................314 SPECIFICATIONS...........................................................................315 SPECIFICATIONS.......................................................................316 Weights and Measures.............................................................316 Travel Speeds....................................................................317 OPTIONS, ATTACHMENTS.....................................................................319 OUTLINE OF LOAD METER................................................................320 Principle of Load Meter Measurement..............................................321 Conditions for Starting Measurement..........................................321 Conditions for Completing Measurement........................................321 Conditions for Successful Measurement........................................321 Method of Calculation and Display............................................322 Points to Remember to Ensure High Accuracy.......................................322 Calibration..................................................................322 When Measuring...............................................................323 Using Load Meter.................................................................323 Setting Addition Mode........................................................323 Setting Subtraction Mode.....................................................324 Total Load Data Display..........................................................327 Clearing Total Load..............................................................328 Stopping Load Meter Calculation..................................................329 Selecting Load Material Category Display.........................................330 Calibrating With Empty Bucket....................................................331 Calibrating with 1/2 Rated Load..................................................333 Calibrating With Rated Load......................................................336 Resetting Calibration............................................................339 Method of Using Addition Mode....................................................340 Method of Using Subtraction Mode.................................................342 Printout from Load Meter.........................................................346 Selection of Printout Mode.......................................................348 JOYSTICK STEERING SYSTEM.............................................................350 Structure and Function...........................................................350 Components.......................................................................352 Shift UP, Shift DOWN Switches................................................353 Directional Selector Switch..................................................353 Joystick Steering Lever......................................................353 Joystick ON/OFF Switch.......................................................353 HI/LOW Selector Switch.......................................................354 Horn Switch..................................................................354 Console Tilt Lever...........................................................354 Console Fore-and-Aft Adjustment Lever........................................354 Joystick Pilot Lamp..........................................................355 Armrest Adjustment Lever.....................................................355 Steering with Joystick Lever or Steering Wheel...................................356 Steering Using Joystick......................................................356 Steering Using Steering Wheel................................................356 Precautions for Steering with Joystick...........................................356 Operating the Joystick Steering System...........................................357 Getting In and Out of Operator’s Cab.............................................359 Adjustments......................................................................360 Adjusting Joystick Console...................................................360 Adjusting Seat...............................................................360 AM/FM RADIO CASSETTE STEREO SOUND SYSTEM.............................................364 Sound System Components..........................................................365 Power Switch/Volume..........................................................365 Auto-Store/Preset Scan Button................................................365 Bass Control Knob............................................................365 Treble Control Knob..........................................................366 Loudness Button..............................................................366 Time/Radio Display Selector Button...........................................366 Tape Eject Button............................................................367 Cassette Door................................................................367 Fast-Forward, Rewind Buttons.................................................367 Preset Buttons...............................................................367 Metal Tape Button............................................................368 Manual Tuning Buttons........................................................368 Seek Tuning Buttons..........................................................368 Band Selector Button.........................................................368 Method of Operation..............................................................369 Setting Preset Buttons.......................................................369 Using Auto-Preset............................................................369 Using Manual Preset..........................................................369 Listening to Radio...........................................................370 Listening to Cassette Tape...................................................370 Reversing the Tape...........................................................371 Precautions When Using...........................................................371 Handling Cassette Tape...........................................................371 MP3 AM/FM RADIO CD UNIT..............................................................372
KOMATSU WA500-6 WHEEL LOADER OPERATION & MAINTENANCE MANUAL A93001 AND UP – PDF DOWNLOAD:
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