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Komatsu Wheel Loader WA500-1LC Operation & Maintenance Manual SN A60001 and up – PDF DOWNLOAD
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Komatsu Wheel Loader WA500-1LC Operation & Maintenance Manual
Book Code: CEAMW25050
SERIAL NUMBERS : WA5004 LC A60001 and up
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Description
Komatsu Wheel Loader WA500-1LC Operation & Maintenance Manual
TABLE OF CONTENTS:
Komatsu Wheel Loader WA500-1LC 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 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 Equipped.... 45 METER AND PILOT LAMP GROUP.................................... 46 Working Lamp Pilot Lamp................................... 47 Transmission Cut-Off Selector Pilot Lamp.................. 47 Air Pressure Gauge........................................ 47 Engine Coolant Temperature Gauge.......................... 47 Torque Converter Oil Temperature Gauge.................... 48 Fuel Level Gauge.......................................... 48 Turn Signal Pilot Lamp.................................... 48 Parking Brake Pilot Lamp.................................. 46 High Beam Pilot Lamp...................................... 48 Speedometer............................................... 49 Service Meter............................................. 49 SWITCHES ......................................................... 50 TRANSMISSION CUT-OFF SELECTOR SWITCH.......................... 50 ETHER START SWITCH............................................ 50 HORN BUTTON................................................... 51 HAZARD LAMP SWITCH............................................ 51 PARKING BRAKE SWITCH.......................................... 52 WORKING LAMP SWITCH........................................... 53 STARTING SWITCH............................................... 53 LAMP SWITCHES................................................. 53 Lamp switch............................................... 53 Turn signal lever......................................... 54 Dimmer switch............................................. 54 CIGARETTE LIGHTER............................................. 55 TRANSMISSION KICKDOWN SWITCH.................................. 55 FRONT WIPER SWITCH - IF EQUIPPED.............................. 56 REAR WIPER SWITCH - IF EQUIPPED............................... 56 CAB DOME LAMP SWITCH - IF EQUIPPED............................ 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............................. 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............................................... 71 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 MACHINE.................................................. 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 BATTERY .................................104 REMOVAL AND INSTALLATION OF BATTERY ..............................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 WEAR PARTS REPLACEMENT ...............................................115 PERIODICAL PART REPLACEMENT ..........................................116 LUBRICANTS, FUEL AND COOLANT .........................................117 PROPER SELECTION TABLE ...........................................117 ENGINE OIL....................................................118 Normal Operation..........................................118 Arctic Operation..........................................118 AXLE OIL......................................................119 GREASE........................................................119 DIESEL FUEL...................................................119 COOLANT.......................................................119 SCHEDULED MAINTENANCE GUIDE ..........................................125 FILLER AND LEVEL GAUGE POSITIONS .....................................130 INITIAL 250 HOURS SERVICE ONLY .......................................132 TRANSMISSION OIL FILTER ..........................................132 WHEN REQUIRED ........................................................132 COOLANT ADDITIVE CONCENTRATION - DCA4 ............................132 AIR CLEANER ELEMENTS .............................................132 CHECKING......................................................132 CLEANING OR REPLACING OUTER ELEMENT...........................132 REPLACING INNER ELEMENT.......................................133 CLEANING OUTER ELEMENT........................................133 Using Compressed Air......................................133 Using Water...............................................133 Using Water With Cleaning Agent...........................133 TRANSMISSION OIL LEVEL ...........................................134 RADIATOR CORE ....................................................135 DRIVE AXLE OIL LEVEL .............................................136 DRIVE AXLE HOUSING BREATHERS .....................................137 LUBRICATION ......................................................138 HYDRAULIC TANK ...................................................139 PPC (PROPORTIONAL PRESSURE CONTROL) CIRCUIT ......................139 WHEEL BRAKE HYDRAULIC CIRCUIT ....................................140 PARKING BRAKE ....................................................141 BUCKET TEETH - IF EQUIPPED .......................................142 BUCKET EQUIPPED WITH BOLT-ON TEETH............................142 BUCKET EQUIPPED WITH REPLACEABLE TOOTH TIP....................142 BUCKET BOLT-ON CUTTING EDGE - IF EQUIPPED ........................143 WINDOW WASHER TANKS - IF EQUIPPED ................................143 AIR CONDITIONER CONDENSER - IF EQUIPPED ..........................144 AIR CONDITIONER REFRIGERANT CHARGE - IF EQUIPPED .................144 ALTERNATOR DRIVE BELT ............................................145 FAN DRIVE BELT ...................................................145 WATER PUMP DRIVE BELT ............................................145 ALTERNATOR .......................................................145 CRANKING MOTOR ...................................................145 AIR GOVERNOR .....................................................145 TRANSMISSION CONTROL LEVERS ......................................146 CHECKS BEFORE STARTING ENGINE ........................................147 COOLANT LEVEL ....................................................147 ENGINE OIL LEVEL .................................................147 FUEL LEVEL .......................................................148 AIR CLEANER SERVICE INDICATOR ....................................149 AIR TANKS ........................................................149 BRAKE OIL LEVEL ..................................................150 FUEL FILTER/WATER SEPARATOR ......................................150 ENGINE FAN .......................................................151 DRIVE BELTS ......................................................151 BELT INSPECTION...............................................151 BELT TENSION CHECK............................................151 MONITOR PANEL ....................................................152 ADDITIONAL CHECKS ................................................153 EVERY 50 HOURS SERVICE ...............................................153 FUEL TANK ........................................................153 TIRES ............................................................153 ENGINE AIR INTAKE SYSTEM .........................................154 EVERY 100 HOURS SERVICE ..............................................154 HYDRAULIC TANK OIL LEVEL .........................................154 LUBRICATION ......................................................155 CAB AIR FILTER IF EQUIPPED ......................................155 EVERY 250 HOURS SERVICE ..............................................156 ENGINE OIL AND FILTERS ...........................................156 FUEL FILTERS .....................................................158 GENERAL.......................................................158 REPLACEMENT...................................................158 COOLANT FILTER....................................................160 GENERAL.......................................................160 REPLACEMENT...................................................160 ENGINE CRANKCASE BREATHER AND TUBE ...............................161 BATTERY ELECTROLYTE LEVELS .......................................161 LUBRICATION ......................................................162 WHEEL HUB NUTS ...................................................165 AIR CONDITIONER COMPRESSOR DRIVE BELT - IF EQUIPPED ..............165 EVERY 500 HOURS SERVICE ..............................................167 TRANSMISSION OIL FILTER ..........................................167 LUBRICATION ......................................................167 AIR DRYER - IF EQUIPPED ..........................................168 EVERY 1000 HOURS SERVICE .............................................168 TRANSMISSION OIL AND STRAINER ....................................168 TRANSMISSION CASE BREATHER .......................................169 LUBRICATION ......................................................169 EVERY 1500 HOURS SERVICE .............................................171 ENGINE VALVES AND INJECTORS ......................................171 EVERY 2000 HOURS SERVICE .............................................172 ENGINE ...........................................................172 ENGINE MOUNTED HOSES .............................................172 ENGINE MOUNTING HARDWARE..........................................172 ENGINE CRANKSHAFT END CLEARANCE ..................................173 TURBOCHARGER MOUNTING ............................................173 BATTERIES ........................................................173 VISUAL INSPECTION.............................................173 STATE OF CHARGE TEST..........................................174 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 ....................................176 DRIVE AXLE OIL ...................................................177 PARKING BRAKE DISC ...............................................178 AIR DRYER - IF EQUIPPED ..........................................178 ACCUMULATOR.......................................................179 COOLING SYSTEM....................................................179 COOLANT RECOMMENDATIONS/SPECiFiCATlONS........................179 CHANGING COOLANT AND FLUSHING SYSTEM..........................179 EVERY 6000 HOURS SERVICE .............................................181 FUEL PUMP ........................................................181 FUEL INJECTORS ...................................................181 ENGINE FAN HUB ...................................................181 ENGINE IDLER PULLEY ..............................................181 WATER PUMP .......................................................181 TURBOCHARGER .....................................................181 AIR COMPRESSOR ...................................................181 ENGINE VIBRATION DAMPER ..........................................181 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 WA500-1LC OPERATION & MAINTENANCE MANUAL SN A60001 AND UP – PDF DOWNLOAD:
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Komatsu Wheel Loader WA500-1LC 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.
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2 reviews for Komatsu Wheel Loader WA500-1LC Operation & Maintenance Manual SN A60001 and up – PDF DOWNLOAD
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Maison Ford –
would have been better with an INDEX.
Leon Kairo –