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Komatsu Wheel Loader WA500-1L Operation & Maintenance Manual SN A20854 and up – PDF DOWNLOAD
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Komatsu Wheel Loader WA500-1L Operation & Maintenance Manual
Book Code: CEAMW2501O
SERIAL NUMBERS:
WA500-1 L A20854 and up
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Description
Komatsu Wheel Loader WA500-1L Operation & Maintenance Manual
TABLE OF CONTENTS:
Komatsu Wheel Loader WA500-1L Operation & Maintenance Manual
MAIN MENU......................................................................... 0 FORWARD........................................................................... 5 SAFETY INFORMATION................................................................ 6 INTRODUCTION...................................................................... 7 BREAKING IN THE NEW MACHINE................................................... 7 MACHINE AND ENGINE SERIAL NUMBERS............................................. 8 QUICK REFERENCE INFORMATION................................................... 9 CONTENTS.......................................................................... 10 SAFETY PRECAUTIONS -- SECTION 1................................................... 17 GENERAL PRECAUTIONS .......................................................... 18 PERSONNEL PRECAUTIONS .................................................... 18 MACHINE PRECAUTIONS ...................................................... 18 OPERATION .................................................................... 19 BEFORE STARTING .......................................................... 19 START-UP ................................................................. 20 GENERAL OPERATING PRECAUTIONS ............................................ 20 DRIVING THE MACHINE ...................................................... 21 OPERATING THE ATTACHMENTS ................................................ 22 PULLING/TOWING ........................................................... 22 SHUTDOWN ................................................................. 23 MAINTENANCE .................................................................. 23 GENERAL MACHINE PRECAUTIONS .............................................. 23 GENERAL WORK PRECAUTIONS ................................................. 24 ACCUMULATORS ............................................................. 25 ATTACHMENTS .............................................................. 26 BRAKES ................................................................... 26 CAB/ROPS ................................................................. 26 COOLING .................................................................. 26 ELECTRICAL ............................................................... 26 ENGINE ................................................................... 27 FUEL SYSTEM .............................................................. 28 HYDRAULICS ............................................................... 28 TIRES AND RIMS ........................................................... 28 TURBOCHARGER ............................................................. 28 SAFETY PRODUCT GRAPHICS AND LOCATIONS ........................................ 30 OPERATION -- SECTION 2............................................................ 37 GENERAL VIEW.................................................................. 38 INSTRUMENTS AND CONTROLS ..................................................... 39 MONITOR PANEL ............................................................ 39 SYSTEM CHECK.......................................................... 40 CHECK MONITOR LAMP GROUP.............................................. 41 Brake Oil Level Monitor .......................................... 41 Engine Oil Level Monitor.......................................... 42 Engine Coolant Level Monitor...................................... 42 CAUTION MONITOR LAMP GROUP............................................ 42 Charge Monitor.................................................... 42 Fuel Level Monitor................................................ 43 Transmission Oil Filter Monitor................................... 43 CAUTION MONITOR LAMP GROUP............................................ 43 Brake Line Failure Monitor........................................ 43 Engine Oil Pressure Monitor....................................... 44 Engine Coolant Level Monitor...................................... 44 Air Pressure Monitor.............................................. 44 Engine Coolant Temperature Monitor................................ 44 Torque Converter Oil Temperature Monitor.......................... 45 Ground Driven Steering Operation Monitor - If Equiped............. 45 METER AND PILOT LAMP GROUP............................................ 46 Parking Brake Pilot Lamp.......................................... 46 Working Lamp Pilot Lamp........................................... 47 Engine pre-heating pilot lamp..................................... 47 Transmission Cut-Off Selector Pilot Lamp.......................... 47 Air Pressure Gauge................................................ 48 Engine Coolant Temperature Gauge.................................. 48 Torque Converter Oil Temperature Gauge............................ 48 Fuel Level Guage.................................................. 49 Turn Signal Pilot Lamp............................................ 49 High Beam Pilot Lamp.............................................. 49 Speedometer ...................................................... 50 Service Meter .................................................... 50 SWITCHES ................................................................. 51 TRANSMISSION CUT-OFF SELECTOR SWITCH.................................. 51 HORN BUTTON........................................................... 51 HAZARD LAMP SWlTCH.................................................... 52 PARKING BRAKE SWITCH.................................................. 52 WORKING LAMP SWITCH................................................... 53 PRE-HEATING SWITCH.................................................... 53 STARTING SWITCH....................................................... 53 LAMP SWITCHES......................................................... 54 Lamp switch ...................................................... 54 Turn signal lever ................................................ 54 Dimmer switch..................................................... 54 CIGARETTE LIGHTER..................................................... 55 TRANSMISSION KICKDOWN SWITCH.......................................... 55 FRONT WIPER SWITCH.................................................... 56 REAR WIPER SWITCH..................................................... 56 CAB DOME LAMP SWITCH.................................................. 57 LEVERS AND PEDALS ........................................................ 58 DIRECTIONAL LEVER..................................................... 58 SPEED CONTROL LEVER................................................... 59 SPEED CONTROL LEVER STOPPER........................................... 59 STEERING COLUMN TILT LEVER............................................ 59 ACCELERATOR PEDAL..................................................... 60 BRAKE PEDALS.......................................................... 60 Right brake pedal................................................. 60 Left brake pedal.................................................. 60 LIFT ARM CONTROL LEVER................................................ 61 BUCKET CONTROL LEVER.................................................. 61 FRONT ATTACHMENT CONTROL LEVER - IF EQUIPPED.......................... 62 WORK EQUIPMENT CONTROL LEVER LOCK Free a ............................ 62 CAB DOOR HOLD OPEN LOCK - IF EQUIPPED .................................... 62 AIR CLEANER SERVICE INDICATOR ............................................ 62 FRAME LOCKING BAR ........................................................ 63 MAIN CIRCUIT BREAKER ..................................................... 63 FUSE BOXES ............................................................... 63 OPERATOR’S SEAT .......................................................... 66 FORWARD-BACKWARD ADJUSTMENT........................................... 66 SEAT ANGLE ADJUSTMENT................................................. 66 WEIGHT ADJUSTMENT..................................................... 66 BACKREST TILT ADJUSTMENT.............................................. 66 HEIGHT ADJUSTMENT..................................................... 66 RIGHT SIDE ARMREST ................................................... 66 HEIGHT ADJUSTMENT................................................. 66 ANGLE ADJUSTMENT.................................................. 66 SEAT BELT ............................................................ 67 CAB HEATER AND DEFROSTER - IF EQUIPPED ....................................... 68 CONTROL PANEL ............................................................ 68 FAN SPEED SWITCH...................................................... 68 TEMPERATURE CONTROL LEVER............................................. 68 AIR INTAKE SELECTOR LEVER............................................. 68 METHOD OF OPERATION....................................................... 69 CAB HEATER, DEFROSTER AND AIR CONDITIONER - IF EQUIPPED ...................... 70 CONTROL PANEL ............................................................ 70 FAN SPEED SWITCH...................................................... 70 AIR CONDITIONER SWITCH................................................ 70 TEMPERATURE CONTROL LEVER............................................. 70 AIR INTAKE SELECTOR LEVER............................................. 70 METHOD OF OPERATION....................................................... 71 PRECAUTIONS FOR USING AIR CONDITIONER................................. 72 HANDLING AIR CONDITIONER IN SEASON.................................... 72 HANDLING AIR CONDITIONER IN OFF-SEASONS............................... 72 LOCKING FILLER CAPS .......................................................... 73 FUEL TANK FILLER CAP ..................................................... 73 HYDRAULIC TANK FILLER CAP ................................................ 74 CHECKS BEFORE STARTING ENGINE ................................................ 75 WALK AROUND CHECK ........................................................ 75 CHECKS BEFORE STARTING ................................................... 75 OPERATING MACHINE ............................................................ 76 OPERATIONS BEFORE STARTING ENGINE ........................................ 76 STARTING ENGINE .......................................................... 78 NORMAL STARTING....................................................... 78 SPECIAL STARTING...................................................... 78 COLD WEATHER STARTING................................................. 79 OPERATIONS AFTER STARTING ENGINE ......................................... 80 COLD WEATHER WARM-UP PROCEDURE ........................................... 80 MOVING MACHINE OFF ....................................................... 81 SHIFTING GEAR ............................................................ 83 SHIFTING BETWEEN FORWARD AND REVERSE ..................................... 84 STEERING MACHINE.......................................................... 84 STOPPING MACHlNE.......................................................... 85 OPERATIONAL PRECAUTIONS .................................................. 86 PERMISSIBLE WATER DEPTH............................................... 86 IF WHEEL BRAKES DO NOT WORK........................................... 86 WHEN TRAVELING UP OR DOWN SLOPES...................................... 86 Lower Center of Gravity When Turning.............................. 86 Braking on Downhill Slopes........................................ 86 If Engine Stops................................................... 86 POSSIBLE WORK USING LOADER ............................................... 87 EXCAVATION ........................................................... 87 LEVELING.............................................................. 89 LOAD AND CARRY OPERATIONS ............................................ 90 LOADING .............................................................. 90 Cross Drive Loading .............................................. 90 V-Shape Loading .................................................. 90 PARKING MACHINE ...................................................... 91 STOPPING ENGINE ...................................................... 92 OPERATIONS AFTER STOPPING ENGINE ..................................... 92 ADJUSTMENT OF WORK EQUIPMENT ................................................. 93 ADJUSTING BOOM KICKOUT ................................................... 93 ADJUSTING BUCKET POSITIONER .............................................. 94 BUCKET LEVEL INDICATOR ................................................... 94 HANDLING TIRES ............................................................... 95 PRECAUTIONS WHEN HANDLING TIRES .......................................... 95 PRECAUTIONS WHEN DRIVING MACHINE ......................................... 95 NORMAL OPERATING INFLATION PRESSURE ...................................... 96 INFLATING TIRES....................................................... 96 PROPER BUCKET AND TIRE SELECTION TABLE ................................... 98 TOWING ....................................................................... 99 TOWING THE MACHINE ....................................................... 99 WHEN ENGINE CAN BE USED............................................... 99 WHEN ENGINE CANNOT BE USED........................................... 99 RELEASING PARKING BRAKE .................................................. 99 TRANSPORTATION ...............................................................100 COLD WEATHER OPERATION .......................................................101 PREPARATION FOR LOW TEMPERATURE ..........................................101 FUEL AND LUBRICANTS...................................................101 COOLANT...............................................................101 BATTERY...............................................................101 CAUTIONS AFTER COMPLETION OF WORK ........................................102 AFTER COLD WEATHER .......................................................102 LONG TERM STORAGE ............................................................103 BEFORE STORAGE ...........................................................103 DURING STORAGE ...........................................................103 AFTER STORAGE ............................................................103 HANDLING OF BATTERY ..........................................................104 PRECAUTIONS FOR CHARGING BAlTERY .........................................104 REMOVAL AND INSTALLATION OF BAlTERY ......................................104 STARTING ENGINE WITH BOOSTER CABLES ......................................105 BEFORE CONNECTING BOOSTER CABLES......................................105 CONNECTING BOOSTER CABLES.............................................105 STARTING ENGINE.......................................................105 DISCONNECTING BOOSTER CABLES..........................................106 TROUBLESHOOTING ..............................................................107 ELECTRICAL SYSTEM ........................................................107 ENGINE....................................................................107 CHASSIS ..................................................................108 TRANSMISSION..........................................................108 DRIVE AXLES...........................................................108 WHEEL BRAKES..........................................................108 PARKING BRAKE.........................................................108 STEERING..............................................................108 EQUIPMENT HYDRAULIC SYSTEM............................................108 MAINTENANCE -- SECTION 3..........................................................109 PERIODIC MAINTENANCE .........................................................110 MAINTENANCE GUIDELINES .......................................................110 OUTLINES OF SERVICE ..........................................................112 LUBRICATION WHEN SHIPPED .................................................112 RELATING TO ENGINE .......................................................112 ENGINE OIL............................................................112 COOLANT...............................................................112 DIESEL FUEL...........................................................113 RELATING TO HYDRAULIC SYSTEM .............................................113 RELATING TO ELECTRICAL SYSTEM ............................................113 RELATING TO LUBRICATION ..................................................114 BLEEDING AIR .............................................................114 BLEEDING AIR FROM HYDRAULIC TANK......................................114 BLEEDING AIR FROM THE PPC (PROPORTIONAL PRESSURE CONTROL) CIRCUIT ....115 BLEEDING AIR FROM THE WHEEL BRAKE HYDRAULIC CIRCUIT ..................116 WEAR PARTS REPLACEMENT .......................................................117 PERIODICAL PART REPLACEMENT ..................................................118 LUBRICANTS, FUEL AND COOLANT .................................................119 PROPER SELECTION TABLE ...................................................119 Normal Operation .....................................................120 Arctic Operation .....................................................120 AXLE OIL..................................................................121 GREASE....................................................................121 DIESEL FUEL...............................................................121 COOLANT...................................................................121 SCHEDULED MAINTENANCE GUIDE ..................................................125 FILLER AND LEVEL GAUGE POSITIONS .............................................130 INITIAL 250 HOURS SERVICE ONLY ...............................................132 TRANSMISSION OIL FILTER ..................................................132 FUEL FILTER ..............................................................132 ENGINE VALVE CLEARANCE ...................................................132 WHEN REQUIRED ................................................................132 COOLING SYSTEM ...........................................................132 AIR CLEANER ELEMENTS .....................................................135 CHECKING..............................................................135 CLEANING OR REPLACING OUTER ELEMENT...................................135 REPLACING INNER ELEMENT ..............................................136 CLEANING OUTER ELEMENT ...............................................136 Using Compressed Air .............................................136 Using Water ......................................................136 Using Water With Cleaning Agent ..................................136 TRANSMISSION OIL LEVEL ...................................................137 RADIATOR CORE ............................................................138 DRIVE AXLE OIL LEVEL .....................................................139 DRIVE AXLE HOUSING BREATHERS .............................................140 AIR CONDITIONER REFRIGERANT CHARGE - IF EQUIPPED .........................141 LUBRICATION ..............................................................142 BUCKET TEETH - IF EQUIPPED ...............................................143 BUCKET EQUIPPED WITH BOLT-ON TEETH....................................143 BUCKET EQUIPPED WITH REPLACEABLE TOOTH TIP............................143 BUCKET BOLT-ON CUTTING EDGE - IF EQUIPPED ................................144 ELECTRICAL INTAKE AIR HEATER .............................................145 WATER SEPARATOR ..........................................................145 WINDOW WASHER TANKS - IF EQUIPPED ........................................146 AIR CONDITIONER CONDENSER - IF EQUIPPED ..................................146 TRANSMISSION CONTROL LEVERS ..............................................147 CHECKS BEFORE STARTING ENGINE ................................................148 MONITOR PANEL ............................................................148 COOLANT LEVEL ............................................................148 ENGINE OIL LEVEL .........................................................149 FUEL LEVEL ...............................................................150 AIR CLEANER SERVICE INDICATOR ............................................150 AIR TANKS ................................................................151 BRAKE OIL LEVEL ..........................................................151 FUEL FILTER/WATER SEPARATOR ..............................................152 EVERY 50 HOURS SERVICE .......................................................153 FUEL TANK ................................................................153 TIRES ....................................................................153 EVERY 100 HOURS SERVICE ......................................................153 HYDRAULIC TANK OIL LEVEL .................................................153 LUBRICATION ..............................................................154 CAB AIR FILTER - IF EQUIPPED .............................................154 EVERY 250 HOURS SERVICE ......................................................156 ENGINE OIL AND FILTERS ...................................................156 FAN BELT .................................................................157 ALTERNATOR BELT ..........................................................158 AIR CONDITIONER COMPRESSOR BELT ........................................159 LUBRICATION ..............................................................160 WHEEL HUB NUTS ...........................................................163 BAlTERY ELECTROLYTE LEVELS ...............................................163 EVERY 500 HOURS SERVICE ......................................................164 FUEL FILTER ..............................................................164 TRANSMISSION OIL FILTER...................................................164 LUBRICATION ..............................................................165 AIR DRYER - IF EQUIPPED ..................................................165 EVERY 1000 HOURS SERVICE .....................................................166 TRANSMISSION OIL AND STRAINER.............................................166 TRANSMISSION CASE BREATHER................................................167 LUBRICATION...............................................................167 PARKING BRAKE.............................................................170 CORROSION RESISTOR........................................................171 TURBOCHARGER VARIOUS FASTENERS............................................171 EVERY 2000 HOURS SERVICE .....................................................172 ENGINE ...................................................................172 ENGINE MOUNTED HOSES .....................................................172 ENGINE MOUNTING HARDWARE .................................................172 BATTERIES.................................................................173 VISUAL INSPECTION.....................................................173 STATE OF CHARGE TEST..................................................173 Specific Gravity Hydrometer Test..................................174 Stabilized Open Circuit Voltage Test..............................174 HYDRAULIC TANK OIL AND FILTERS ...........................................175 HYDRAULIC TANK BREATHER ..................................................176 PPC CIRCUIT STRAINER .....................................................176 CAB AIR FILTER - IF EQUIPPED .............................................177 DRIVE AXLE OIL ...........................................................178 ENGINE BREATHER ..........................................................179 TURBOCHARGER ROTOR PLAY ..................................................179 TURBOCHARGER .............................................................180 ALTERNATOR AND STARTING MOTOR ............................................180 ENGINE VALVE CLEARANCE ...................................................180 BRAKE DISC ...............................................................180 ENGINE VIBRATION DAMPER ..................................................180 AIR DRYER - IF EQUIPPED ..................................................181 ACCUMULATOR ..............................................................181 EVERY 4000 HOURS SERVICE .....................................................182 WATER PUMP ...............................................................182 FAN PULLEY AND TENSION PULLEY ............................................182 AIR COMPRESSOR ...........................................................182 SPECIFICATIONS -- SECTION 4.......................................................183 GENERAL SPECIFICATIONS .......................................................184 OPERATING WEIGHT..........................................................184 PERFORMANCE...............................................................184 ENGINE....................................................................184 DIMENSIONS ...................................................................185 STANDARD TIGHTENING TORQUES ..................................................188 STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS .............................188 TIGHTENING TORQUE OF SPLIT FLANGE BOLTS ..................................188 TIGHTENING TORQUE FOR NUTS OF FLARED FITTINGS ............................189
KOMATSU WHEEL LOADER WA500-1L OPERATION & MAINTENANCE MANUAL SN A20854 AND UP – PDF DOWNLOAD:
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DESCRIPTION:
Komatsu Wheel Loader WA500-1L Operation & Maintenance Manual
FOREWORD:
- This manual provides rules and guidelines, which will help you use this machine safely and effectively. Keep this manual handy and have all personnel read it periodically. If this manual is lost or becomes dirty and can not be read, request a replacement manual from your local distributor if you are the owner or end user or from Komatsu Dresser Co. if you are a distributor.
- If you sell the machine, be sure to give this manual to the new owner. Continuing improvements in the design of this machine can lead to changes in detail, which may not be reflected in this manual.
- Consult your local distributor if you are the owner or end user or consult Komatsu Dresser Co. if you are a distributor for the latest available information on your machine or for questions regarding information in this manual.
PLEASE NOTE:
- This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
- You will be directed to the download page as soon as the purchase is completed. The whole payment and downloading process will take anywhere between 2-5 minutes
- Need any other service / repair / parts manual, please feel free to contact [email protected] . We still have 50,000 manuals unlisted
