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Komatsu WA500-6H Wheel Loader Operation & Maintenance Manual – PDF Download
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Komatsu WA500-6H Wheel Loader Operation & Maintenance Manual
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Description
Komatsu WA500-6H Wheel Loader Operation & Maintenance Manual
Description:
Komatsu WA500-6H Wheel Loader Operation & Maintenance Manual
This manual provides rules and guidelines which will help you use this machine safely and effectively. The precautions in this manual must be followed at all times when performing operation and maintenance. Most accidents are caused by the failure to follow fundamental safety rules for the operation and maintenance of machines. Accidents can be prevented by knowing beforehand conditions that may cause a hazard when performing operation and maintenance.
Table Of Contents:
Komatsu WA500-6H Wheel Loader Operation & Maintenance Manual
1. Foreword............................................................................................ 3 1.1 Foreword....................................................................................... 4 1.1.1 EU Directives............................................................................ 5 1.2 Safety information............................................................................. 6 1.2.1 Signal words............................................................................. 6 1.2.2 Safety labels............................................................................ 7 1.3 Introduction................................................................................... 8 1.3.1 Intended use............................................................................. 8 1.3.2 Directions of machine.................................................................... 9 1.3.3 Visibility from operator's seat.......................................................... 10 1.4 Necessary information.......................................................................... 11 1.4.1 Product Identification Number (PIN)/Machine serial no. plate and position................ 11 1.4.2 Engine serial no. plate and position..................................................... 11 1.4.3 ROPS/FOPS-Cab serial no. plate........................................................... 12 1.4.4 Axle serial no. plate.................................................................... 12 1.4.5 Transmission serial no. plate............................................................ 12 1.4.6 Seat operator serial no. plate........................................................... 13 1.4.7 Position of service meter................................................................ 13 1.4.8 Table to enter serial no. and distributor................................................ 13 1.5 Contents....................................................................................... 14 1.6 Dimensions, weights and operating data......................................................... 21 1.6.1 WA500-6: Dimensions, weights and operating data.......................................... 21 1.7 CE-Conforming equipment........................................................................ 22 1.7.1 CE-Conforming equipment.................................................................. 22 1.7.2 Manufacturer-supplied CE-Conforming equipment, according to document 419-93-H1250........ 23 2. Safety.............................................................................................. 27 2.1 Safety labels.................................................................................. 28 2.1.1 Location of safety labels................................................................ 28 2.1.2 Presentation of safety labels............................................................ 29 2.2 General precautions............................................................................ 32 2.3 Precautions for operation...................................................................... 43 2.3.1 Starting engine.......................................................................... 43 2.3.2 Operation................................................................................ 45 2.3.3 Transportation........................................................................... 52 2.3.4 Battery.................................................................................. 54 2.3.5 Towing................................................................................... 56 2.4 Precautions for maintenance.................................................................... 57 2.5 Precautions with tires......................................................................... 66 3. Operation........................................................................................... 67 3.1 General view................................................................................... 68 3.1.1 General view of machine.................................................................. 68 3.1.2 General view of controls and gauges...................................................... 69 3.2 Explanation of components...................................................................... 74 3.2.1 Machine monitor.......................................................................... 74 Types of warning........................................................................... 75 Central warning lamp....................................................................... 76 Character display portion.................................................................. 77 Emergency stop item........................................................................ 83 Caution items.............................................................................. 86 Inspection and maintenance item............................................................ 90 Pilot display portion...................................................................... 94 Meter display portion......................................................................100 Other functions of machine monitor.........................................................103 3.2.2 Switches.................................................................................112 3.2.3 Control levers, pedals...................................................................133 3.2.4 Steering tilt lock lever.................................................................140 3.2.5 Cap with lock............................................................................141 3.2.6 Safety bar...............................................................................142 3.2.7 Towing pin...............................................................................143 3.2.8 Backup alarm.............................................................................143 3.2.9 Opening cab, window door.................................................................144 Open lock cancel knob for right cab door...................................................144 Cab left door open lock....................................................................145 Cab left door open knob....................................................................145 Open lock cancel knob for left cab window..................................................146 3.2.10 Handling cab wiper......................................................................146 Preventing damage to wiper arm bracket.....................................................146 3.2.11 Dust indicator..........................................................................147 3.2.12 Fuse....................................................................................147 Fuse capacity and name of circuit..........................................................148 3.2.13 Slow blow fuse..........................................................................149 3.2.14 Power outlet............................................................................149 3.2.15 Air conditioner.........................................................................150 General locations and function of control panel............................................150 Method of operation........................................................................152 Cool box...................................................................................154 Precautions when using.....................................................................154 Inspection and maintenance.................................................................155 3.3 Operation......................................................................................156 3.3.1 Check before starting engine, adjust.....................................................156 Walk-around check..........................................................................156 Check before starting......................................................................160 Adjustment.................................................................................169 Safety belt................................................................................170 Operations and checks before starting engine...............................................172 3.3.2 Starting engine..........................................................................174 Automatic warming-up operation.............................................................175 3.3.3 Operations and checks after starting engine..............................................176 Breaking-in the machine....................................................................176 Normal operation...........................................................................177 3.3.4 Stopping engine..........................................................................178 3.3.5 Check after stopping engine..............................................................178 3.3.6 Moving the machine (directional, speed), stopping the machine............................179 Preparations for moving the machine........................................................179 Changing gear speed........................................................................182 Changing direction.........................................................................183 Automatic shift............................................................................184 Stopping the machine.......................................................................185 Transmission cut-off function..............................................................186 3.3.7 Turning..................................................................................188 3.3.8 Operation of work equipment..............................................................189 Lift arm operation.........................................................................190 Bucket operation...........................................................................190 3.3.9 Semi auto digging operations.............................................................191 3.3.10 Remote positioner.......................................................................192 Operating remote bucket positioner.........................................................192 Operating remote boom positioner...........................................................192 3.3.11 Work possible using wheel loader........................................................194 Recommended combination of switches for operation..........................................194 Digging operations.........................................................................195 Leveling operation.........................................................................198 Pushing operation..........................................................................198 Load and carry operations..................................................................199 Loading operations.........................................................................199 Precautions when handling blasted rock.....................................................201 3.3.12 Precautions for operation...............................................................213 Permissible water depth....................................................................213 If wheel brake does not work...............................................................213 Precautions when driving up or down slopes.................................................213 3.3.13 Removal and installation of the bucket..................................................216 Removing the bucket........................................................................216 Installing the bucket......................................................................217 3.3.14 Parking machine.........................................................................220 3.3.15 Checks after completion of operation....................................................221 3.3.16 Locking.................................................................................222 3.3.17 Handling the tires......................................................................223 Precautions when handling tires............................................................223 Tire pressure..............................................................................223 Precautions for using load and carry method................................................224 3.4 Transportation.................................................................................225 3.4.1 Transportation procedure.................................................................225 3.4.2 Loading, unloading work with trailers....................................................225 Loading....................................................................................226 Securing machine...........................................................................226 Unloading..................................................................................228 3.4.3 Lifting machine..........................................................................229 Location of lifting position mark..........................................................230 Lifting procedure..........................................................................231 3.5 Cold weather operation.........................................................................232 3.5.1 Precautions for low temperature..........................................................232 Fuel and lubricants........................................................................232 Coolant....................................................................................232 Battery....................................................................................233 3.5.2 Precautions after completion of work.....................................................234 3.5.3 After cold weather.......................................................................234 3.5.4 Warming-up operation for steering hydraulic circuit in cold weather......................235 3.6 Long-term storage..............................................................................236 3.6.1 Before storage...........................................................................236 3.6.2 During storage...........................................................................236 3.6.3 After storage............................................................................237 3.7 Troubleshooting................................................................................238 3.7.1 When machine runs out of fuel............................................................238 3.7.2 Towing the machine.......................................................................240 When engine can be used....................................................................241 When engine cannot be used.................................................................242 Releasing parking brake....................................................................242 Emergency travel operation.................................................................244 3.7.3 If battery is discharged.................................................................245 Removal and installation of battery........................................................245 Precautions for charging battery...........................................................246 Starting engine with booster cable.........................................................247 3.7.4 Method for lowering work equipment when engine has stopped...............................249 3.7.5 Other trouble............................................................................250 Electrical system..........................................................................250 Chassis....................................................................................251 Engine.....................................................................................253 4. Maintenance.........................................................................................255 4.1 Guides to maintenance..........................................................................256 4.2 Outlines of service............................................................................259 4.2.1 Handling oil, fuel, coolant, grease and carrying out KOWA (KOMATSU Oil Wear Analysis)....259 Oil........................................................................................259 Fuel.......................................................................................260 Coolant and water for dilution.............................................................261 Grease.....................................................................................262 Carrying out KOWA (KOMATSU Oil Wear Analysis)..............................................262 Storing oil and fuel.......................................................................263 Filters....................................................................................264 4.2.2 Outline of electric system...............................................................264 4.3 Wear parts.....................................................................................265 4.3.1 Wear parts list..........................................................................265 4.4 Fuel, coolant and lubricants...................................................................267 4.4.1 Lubrication chart........................................................................268 4.4.2 Use of fuel, coolant and lubricants according to ambient temperature.....................269 4.4.3 Recommended brands, recommended quality for products other than KOMATSU genuine oil......272 4.5 Standard tightening torques for bolts and nuts.................................................273 4.5.1 Torque list..............................................................................273 4.6 Periodic replacement of safety critical parts..................................................275 4.7 Maintenance schedule chart.....................................................................277 4.7.1 Maintenance schedule chart...............................................................277 4.8 Replace injector assembly......................................................................280 4.9 Service procedure..............................................................................281 4.9.1 Initial 50 hours service (only after the first 50 hours).................................281 Check for loose wheel hub bolts, tighten...................................................281 4.9.2 Initial 250 hours service (only after the first 250 hours)...............................282 Replace transmission oil filter element....................................................282 Replace hydraulic filter element...........................................................282 4.9.3 When required............................................................................282 Check, clean, or replace air cleaner element...............................................282 Clean inside of cooling system.............................................................285 Check transmission oil level, add oil......................................................290 Check axle oil level, add oil..............................................................292 Clean axle case breather...................................................................293 Clean air conditioner condenser............................................................294 Check window washing fluid level, add fluid................................................294 Clean radiator fins with compressed air....................................................294 Replace bucket teeth.......................................................................296 Replace bucket tooth with segment edge.....................................................297 Check air conditioner......................................................................298 Replace slow blow fuse.....................................................................299 Bleeding air from hydraulic tank...........................................................301 Checking function of accumulator...........................................................303 Selection and inspection of tires..........................................................304 4.9.4 Check before starting....................................................................306 Check before starting......................................................................306 4.9.5 Every 50 hours service...................................................................306 Drain water, sediment from fuel tank.......................................................306 4.9.6 Every 100 hours service..................................................................307 Lubricate rear axle pivot pin..............................................................307 Check oil level in hydraulic tank, add oil.................................................307 Clean element in air conditioner fresh air filter..........................................308 4.9.7 Every 250 hours service..................................................................309 Check battery electrolyte level............................................................309 Check parking brake........................................................................311 Check alternator belt tension, adjust......................................................312 Check air conditioner compressor belt tension, adjust......................................313 Check for loose wheel hub bolts, tighten...................................................313 Clean element in air conditioner recirculation filter......................................314 Checking function of accumulator...........................................................314 Lubricating................................................................................315 4.9.8 Every 500 hours service..................................................................318 Change oil in engine oil pan, replace engine oil filter cartridge..........................318 Replace fuel pre-filter cartridge..........................................................319 4.9.9 Every 1000 hours service.................................................................322 Change oil in transmission case, clean strainer............................................322 Replace transmission oil filter element....................................................324 Replace fuel filter cartridge..............................................................325 Clean transmission case breather...........................................................327 Wash fuel tank breather....................................................................328 Lubricating................................................................................328 Replace corrosion resistor cartridge.......................................................329 Check of engine air intake piping clamps for looseness.....................................329 4.9.10 Every 2000 hours service................................................................330 Change oil in hydraulic tank, replace hydraulic filter element.............................330 Clean hydraulic tank strainer..............................................................332 Replace hydraulic tank breather element....................................................333 Change axle oil............................................................................334 Replace element in air conditioner recirculation air filter, fresh air filter..............335 Clean PPC circuit strainer.................................................................336 Check alternator...........................................................................337 Check engine valve clearance, adjust.......................................................337 Check brake disc wear......................................................................337 Check function of accumulator..............................................................338 4.9.11 Every 4000 hours service................................................................339 Check water pump...........................................................................339 Check starting motor.......................................................................339 Lubricating................................................................................339 Checking for loose engine high-pressure piping clamps, hardening of rubber.................341 Checking for missing fuel spray prevention cap, hardening of rubber........................342 4.9.12 Every 8000 hours service................................................................343 Replace high-pressure piping clamp.........................................................343 Replace fuel spray prevention cap..........................................................343 Overhaul starting motor and alternator.....................................................343 4.9.13 Every 12000 hours service...............................................................343 Replace injector assembly..................................................................343 5. Technical Data......................................................................................345 5.1 Technical data.................................................................................346 5.2 Noise emission levels..........................................................................348 5.3 Vibration level................................................................................348 5.4 Limit values for slopes........................................................................351 6. Attachments, Options................................................................................353 6.1 Handling load meter............................................................................354 6.1.1 Outline of load meter....................................................................354 6.1.2 Principle of load meter measurement......................................................356 6.1.3 Points to remember to ensure high accuracy...............................................357 Calibration................................................................................357 When measuring.............................................................................359 6.1.4 Using load meter.........................................................................360 Setting addition mode......................................................................360 Setting subtraction mode...................................................................361 Total load data display....................................................................364 Clearing total load........................................................................365 Stopping load meter calculation............................................................366 Selecting load material category display...................................................367 Calibration with empty bucket..............................................................368 Calibration with loaded bucket.............................................................370 Resetting calibration......................................................................372 Method of using addition mode..............................................................373 Method of using subtraction mode...........................................................376 Printout from load meter...................................................................380 Selection of printout mode.................................................................381 6.2 Joystick steering system.......................................................................384 6.2.1 Components...............................................................................384 6.2.2 Structure and function...................................................................388 Operation using joystick lever and operation using steering wheel..........................389 Getting in or out of operator's cab........................................................390 Adjustment of joystick console.............................................................391 Seat adjustment............................................................................391 6.2.3 Precautions for steering with joystick...................................................392 6.2.4 Operation method of joystick steering system.............................................393 6.3 Handling machines equipped with KOMTRAX........................................................396 6.3.1 Basic precautions........................................................................397 6.4 Central lubrication system.....................................................................398 6.4.1 Operating the central lubrication system.................................................398 6.4.2 Display and control unit.................................................................398 LED-display................................................................................399 Pushbuttons................................................................................399 6.4.3 Changing the lubrication interval times..................................................400 7. Index...............................................................................................401 7.1 Index..........................................................................................402 8. Notes...............................................................................................407
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KOMATSU WA500-6H WHEEL LOADER OPERATION & MAINTENANCE MANUAL – PDF DOWNLOAD:
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