Komatsu Wheel Loader WA500-3 Operation & Maintenance Manual SN A70001 and up – PDF DOWNLOAD

Description

Komatsu Wheel Loader WA500-3 Operation & Maintenance Manual

TABLE OF CONTENTS:

Komatsu Wheel Loader WA500-3 Operation & Maintenance Manual

MAIN MENU............................................................................................  0
INTRODUCTION.........................................................................................  4
	1. FORWARD.......................................................................................  5
	2. SAFETY INFORMATION............................................................................  6
	3. INTRODUCTION..................................................................................  7
		3.1 INTENDED USE.............................................................................  7
		3.2 FEATURES.................................................................................  7
		3.3 BREAKING IN THE MACHINE..................................................................  7
	4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NUMBER AND DISTRIBUTOR..............................  8
		4.1 MACHINE SERIAL NUMBER PLATE POSITION.....................................................  8
		4.2 ENGINE SERIAL NUMBER PLATE POSITION......................................................  8
		4.3 TABLE TO ENTER SERIAL NUMBERS AND DISTRIBUTOR............................................  8
	5. CONTENTS......................................................................................  9
SAFETY............................................................................................... 15
	6. GENERAL PRECAUTIONS........................................................................... 16
	7. PRECAUTIONS DURING OPERATION ................................................................. 21
		7.1 BEFORE STARTING ENGINE .................................................................. 21
		7.2 OPERATING MACHINE ....................................................................... 23
		7.3 TRANSPORTATION .......................................................................... 28
		7.4 BATTERY ................................................................................. 29
		7.5 TOWING .................................................................................. 30
	8. PRECAUTIONS FOR MAINTENANCE .................................................................. 31
		8.1 BEFORE CARRYING OUT MAINTENANCE.......................................................... 31
		8.2 DURING MAINTENANCE ...................................................................... 33
		8.3 TIRES ................................................................................... 38
	9. POSITION FOR ATTACHING SAFETY LABELS ......................................................... 40
OPERATION............................................................................................ 45
	10. GENERAL VIEW ................................................................................ 46
		10.1 GENERAL VIEW OF MACHINE ................................................................ 46
		10.2 GENERAL VIEW OF CONTROLS AND GAUGES .................................................... 47
			10.2.1 Controls.......................................................................... 47
			10.2.2 Main Monitor...................................................................... 47
			10.2.3 Maintenance Monitor............................................................... 48
	11. EXPLANATION OF COMPONENTS ................................................................... 49
		11.1 MACHINE MONITORS ....................................................................... 49
			11.1.1 WARNING DISPLAYS.................................................................. 51
			11.1.2 METER DISPLAY PORTION............................................................. 55
		11.2 SWITCHES ............................................................................... 59
		11.3 CONTROL LEVERS, PEDALS ................................................................. 66
		11.4 STEERING COLUMN TILT LEVER ............................................................. 71
		11.5 CAP WITH LOCK .......................................................................... 72
			11.5.1 METHOD OF OPENING AND CLOSING CAP WITH LOCK....................................... 72
		11.6 SAFETY BAR ............................................................................. 73
		11.7 TOWING PIN ............................................................................. 73
		11.8 GREASE PUMP ............................................................................ 73
		11.9 BACK-UP ALARM .......................................................................... 73
		11.10 FUSE .................................................................................. 74
			11.10.1 FUSE CAPACITY AND NAME OF CIRCUIT................................................ 74
		11.11 SLOW-BLOW FUSE ........................................................................ 75
		11.12 TAKING OFF POWER ...................................................................... 76
	12. OPERATION ................................................................................... 77
		12.1 CHECKS BEFORE STARTING ................................................................. 77
			12.1.1 WALK AROUND CHECK................................................................. 77
			12.1.2 CHECK BEFORE STARTING............................................................. 80
			12.1.3 ADJUSTMENT BEFORE OPERATION....................................................... 85
			12.1.4 OPERATIONS AND CHECKS BEFORE STARTING ENGINE...................................... 89
		12.2 STARTING ENGINE ........................................................................ 90
			12.2.1 NORMAL STARTING................................................................... 90
			12.2.2 SPECIAL STARTING.................................................................. 90
			12.2.3 COLD WEATHER STARTING............................................................. 91
		12.3 OPERATIONS AND CHECKS AFTER STARTING  ENGINE ........................................... 92
		12.4 MOVING MACHINE OFF ..................................................................... 93
		12.5 CHANGING GEAR SPEED .................................................................... 95
		12.6 CHANGING DIRECTION ..................................................................... 95
		12.7 TURNING ................................................................................ 96
		12.8 STOPPING MACHINE ....................................................................... 97
		12.9 OPERATION OF WORK EQUIPMENT ............................................................ 98
		12.10 WORK POSSIBLE USING WHEEL LOADER ...................................................... 99
			12.10.1 DIGGING OPERATIONS............................................................... 99
			12.10.2 LEVELING OPERATION...............................................................102
			12.10.3 PUSHING OPERATION................................................................102
			12.10.4 LOAD AND CARRY OPERATIONS........................................................102
			12.10.5 LOADING OPERATIONS...............................................................103
		12.11 PRECAUTIONS FOR OPERATION .............................................................104
			12.11.1 PERMISSIBLE WATER DEPTH..........................................................104
			12.11.2 IF WHEEL BRAKE DOES NOT WORK.....................................................104
			12.11.3 PRECAUTIONS WHEN DRIVING UP OR DOWN SLOPES.......................................104
			12.11.4 PRECAUTIONS WHEN DRIVING MACHINE.................................................105
		12.12 ADJUSTING WORK EQUIPMENT POSITIONERS ..................................................106
			12.12.1 ADJUSTING BOOM KICK-OUT..........................................................106
			12.12.2 ADJUSTING BUCKET POSITIONER......................................................107
			12.12.3 BUCKET LEVEL INDICATOR...........................................................107
		12.13 PARKING MACHINE .......................................................................108
		12.14 CHECKS AFTER COMPLETION OF OPERATION ..................................................109
		12.15 STOPPING ENGINE .......................................................................109
		12.16 CHECK AFTER STOPPING ENGINE ...........................................................110
		12.17 LOCKING ...............................................................................110
		12.18 HANDLING THE TIRES ....................................................................111
			12.18.1 PRECAUTIONS WHEN HANDLING TIRES..................................................111
			12.18.2 TIRE PRESSURE....................................................................111
		12.19 REMOVAL AND INSTALLATION OF THE BUCKET ................................................113
			12.19.1 REMOVING THE BUCKET..............................................................113
			12.19.2 INSTALLING THE BUCKET............................................................114
	13. TRANSPORTATION ..............................................................................116
		13.1 LOADING, UNLOADING WORK ................................................................116
		13.2 PRECAUTIONS FOR LOADING ................................................................117
		13.3 LIFTING MACHINE ........................................................................117
			13.3.1 POSITION FOR STICKING LIFTING POSITION DECAL......................................118
			13.3.2 WEIGHT TABLE......................................................................118
			13.3.3 LIFTING PROCEDURE.................................................................119
		13.4 PRECAUTIONS FOR TRANSPORTATION .........................................................120
	14. COLD WEATHER OPERATION ......................................................................120
		14.1 PRECAUTIONS FOR LOW TEMPERATURES .......................................................120
			14.1.1 FUEL AND LUBRICANTS...............................................................120
			14.1.2 COOLANT...........................................................................120
			14.1.3 BATTERY...........................................................................121
		14.2 PRECAUTIONS AFTER COMPLETION OF WORK ...................................................121
		14.3 AFTER COLD WEATHER .....................................................................122
		14.4 WARMING-UP OPERATION FOR STEERING  HYDRAULIC CIRCUIT IN COLD WEATHER ...................122
	15. LONG TERM STORAGE ...........................................................................123
		15.1 BEFORE STORAGE .........................................................................123
		15.2 DURING STORAGE .........................................................................123
		15.3 AFTER STORAGE ..........................................................................123
	16. TROUBLESHOOTING .............................................................................124
		16.1 WHEN MACHINE RUNS OUT OF FUEL ..........................................................124
		16.2 TOWING THE MACHINE .....................................................................125
			16.2.1 WHEN ENGINE CAN BE USED...........................................................126
			16.2.2 WHEN ENGINE CANNOT BE USED........................................................126
			16.2.3 RELEASING PARKING BRAKE...........................................................127
			16.2.4 EMERGENCY TRAVEL OPERATION........................................................129
		16.3 IF BATTERY IS DISCHARGED ...............................................................130
			16.3.1 REMOVAL AND INSTALLATION OF BATTERY...............................................130
			16.3.2 PRECAUTIONS FOR CHARGING BATTERY..................................................131
			16.3.3 STARTING ENGINE WITH BOOSTER CABLES...............................................132
		16.4 OTHER TROUBLE ..........................................................................134
			16.4.1 ELECTRICAL SYSTEM.................................................................134
			16.4.2 CHASSIS...........................................................................135
			16.4.3 ENGINE............................................................................138
			16.4.4 RELATIONSHIP OF ELECTRONIC CONTROL SYSTEM.........................................140
MAINTENANCE..........................................................................................143
	17. GUIDES TO MAINTENANCE .......................................................................144
	18. OUTLINES OF SERVICE .........................................................................147
		18.1 OUTLINE OF OIL, FUEL, AND COOLANT ......................................................147
			18.1.1 OIL...............................................................................147
			18.1.2 FUEL..............................................................................148
			18.1.3 COOLANT...........................................................................148
			18.1.4 GREASE............................................................................149
			18.1.5 STORING OIL AND FUEL..............................................................149
			18.1.6 FILTERS...........................................................................149
		18.2  FUEL INJECTION PUMP ...................................................................149
		18.3 OUTLINE OF ELECTRIC SYSTEM .............................................................150
	19. WEAR PARTS LIST .............................................................................151
	20. LUBRICANTS, FUEL, AND COOLANT ...............................................................152
		20.1 PROPER SELECTION TABLE .................................................................152
		20.2 ENGINE OIL .............................................................................153
			20.2.1 NORMAL OPERATION..................................................................153
			20.2.2 ARCTIC OPERATION..................................................................153
		20.3 TRANSMISSION, HYDRAULIC SYSTEM, BRAKE SYSTEM OIL .......................................154
		20.4 AXLE OIL ...............................................................................154
		20.5 GREASE .................................................................................154
		20.6 DIESEL FUEL ............................................................................154
		20.7 COOLANT SPECIFICATIONS .................................................................155
			20.7.1 GENERAL...........................................................................155
			20.7.2 WATER.............................................................................155
			20.7.3 ANTIFREEZE........................................................................155
			20.7.4 SUPPLEMENTAL COOLANT ADDITIVES....................................................156
			20.7.5 TOOLS.............................................................................159
	21. STANDARD TIGHTENING TORQUE FOR NUTS AND BOLTS ...............................................160
		21.1 INTRODUCTION OF NECESSARY TOOLS ........................................................160
		21.2 TORQUE LIST ............................................................................161
	22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS ...............................................162
	23. MAINTENANCE SCHEDULE CHART ..................................................................166
	24. SERVICE PROCEDURE ...........................................................................170
		24.1 INITIAL 250 HOURS SERVICE ..............................................................170
		24.2 WHEN REQUIRED ..........................................................................171
			24.2.1 CHECK, CLEAN, OR REPLACE AIR CLEANER ELEMENT......................................171
			24.2.2 CHECK TRANSMISSION OIL LEVEL, ADD OIL.............................................173
			24.2.3 CHECK AXLE OIL LEVEL, ADD OIL.....................................................175
			24.2.4 CHECK AXLE CASE BREATHER..........................................................176
			24.2.5 CLEAN RADIATOR CORE...............................................................176
			24.2.6 REPLACE BOLT-ON CUTTING EDGE......................................................177
			24.2.7 REPLACE BUCKET TEETH..............................................................178
			24.2.8 REPLACE BUCKET TEETH, SEGMENT EDGE................................................179
			24.2.9 CHECK AIR CONDITIONER.............................................................180
			24.2.10 CLEAN CONDENSER OF AIR CONDITIONER...............................................181
			24 .2.11 CHECK WINDOW WASHING FLUID LEVEL, ADD FLUID.....................................181
			24.2.12 LUBRICATE WORK EQUIPMENT CONTROL VALVE LINKAGE (2 POINTS)........................181
			24.2.13 REPLACE SLOW BLOW FUSE...........................................................182
		24.3 CHECKS BEFORE STARTING ENGINE ..........................................................183
		24.4 EVERY 50 HOURS SERVICE  ................................................................183
			24.4.1 CHECK THE TIRE INFLATION PRESSURE.................................................183
			24.4.2 DRAIN WATER, SEDIMENT FROM FUEL TANK..............................................183
			24.4.3 CHECK ENGINE AIR INTAKE SYSTEM....................................................183
		24.5 EVERY 100 HOURS SERVICE ................................................................184
			24.5.1 CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL........................................184
			24.5.2 CLEAN ELEMENT IN AIR CONDITIONER FRESH AIR FILTER.................................185
			24.5.3 LUBRICATE REAR AXLE PIVOT PIN (3 PLACES)..........................................185
		24.6 EVERY 250 HOURS SERVICE ................................................................186
			24.6.1 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE.................186
			24.6.2 REPLACE FUEL FILTERS..............................................................188
			24.6.3 CHECK FOR LOOSE WHEEL HUB NUTS, TIGHTEN...........................................189
			24.6.4 CLEAN ELEMENT IN AIR CONDITIONER RECIRCULATION FILTER.............................189
			24.6.5 CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST.............................190
			24.6.6 CHECK BATTERY ELECTROLYTE LEVEL...................................................191
			24.6.7 LUBRICATING.......................................................................192
			24.6.8 REPLACE COOLANT CORROSION RESISTOR CARTRIDGE......................................195
		24.7 EVERY 500 HOURS SERVICE ................................................................197
			24.7.1 REPLACE TRANSMISSION OIL FILTER...................................................197
		24.8 EVERY 1000 HOURS SERVICE ...............................................................198
			24.8.1 CHANGE OIL IN TRANSMISSION CASE, CLEAN STRAINER...................................198
			24.8.2 CLEAN TRANSMISSION CASE BREATHER..................................................199
			24.8.3 LUBRICATING (DRIVE TRAIN).........................................................200
		24.9 EVERY 1500 HOURS SERVICE  ..............................................................202
			24.9.1 CHECK AND ADJUST ENGINE VALVES AND INJECTORS......................................202
			24.9.2 STEM CLEAN THE ENGINE.............................................................202
			24.9.3 CHECK AND REPLACE (AS REQUIRED) ENGINE MOUNTED HOSES..............................202
			24.9.4 CHECK AND RETIGHTEN ENGINE MOUNTING HARDWARE......................................203
			24.9.5 CHECK TURBOCHARGER MOUNTING.......................................................203
			24.9.6 CHECK WATER PUMP..................................................................203
			24.9.7 CHECK TENSION OF DRIVE BELT.......................................................204
			24.9.8 CHECK DRIVE BELT TENSIONER BEARING AND FAN HUB BEARING............................204
		24.10 EVERY 2000 HOURS SERVICE ..............................................................206
			24.10.1 CHANGE OIL IN HYDRAULIC TANK, REPLACE FILTER ELEMENT.............................206
			24.10.2 REPLACE HYDRAULIC TANK BREATHER ELEMENT..........................................208
			24.10.3 CHANGE, CLEAN, AND FLUSH COOLING SYSTEM..........................................209
			24.10.4 CHANGE AXLE OIL..................................................................211
			24.10.5 REPLACE ELEMENT IN AIR CONDITIONER RECIRCULATION AIR FILTER, FRESH AIR FILTER....212
			24.10.6 CLEAN PPC (PROPORTIONAL PRESSURE CONTROL) CIRCUIT STRAINER.......................212
			24.10.7 CHECK ACCUMULATOR................................................................213
			24.10.8 CHECK ACCUMULATOR GAS PRESSURE...................................................213
		24.11 EVERY 6000 HOURS SERVICE...............................................................214
			24.11.1 CLEAN AND CALIBRATE FUEL PUMP....................................................214
			24.11.2 CLEAN AND CALIBRATE FUEL INJECTORS...............................................214
			24.11.3 CHECK ENGINE FAN HUB.............................................................214
			24.11.4 CHECK ENGINE IDLER PULLER........................................................214
			24.11.5 CHECK TURBOCHARGER...............................................................214
			24.11.6 CHECK AIR COMPRESSOR.............................................................214
			24.11.7 CHECK ENGINE VIBRATION DAMPER....................................................214
SPECIFICATIONS.......................................................................................215
	25. SPECIFICATIONS ..............................................................................216
OPTIONS, ATTACHMENTS.................................................................................218
	26. OPTIONAL PARTS AND ATTACHMENTS ..............................................................219
	27. SELECTING BUCKETS AND TIRES .................................................................220
	28. RADIO .......................................................................................221
		28.1 EXPLANATION OF PARTS ...................................................................221
		28.2 METHOD OF USE ..........................................................................223
		28.3 PRECAUTIONS WHEN USING  . ..............................................................224
	29. AIR CONDITIONER .............................................................................225
		29.1 GENERAL LOCATION AND FUNCTION OF CONTROL  PANEL ........................................225
		29.2 METHOD OF OPERATION ....................................................................227
		29.3 COOL BOX................................................................................227
	30. HANDLING AUTO-GREASING SYSTEM ...............................................................228
		30.1 METHOD OF OPERATING AUTO-GREASING SYSTEM ...............................................228
			30.1.1 ACTUATION OF AUTO-GREASING........................................................230
			30.1.2 SETTING GREASING TIME.............................................................231
			30.1.3 METHOD OF SETTING.................................................................232
			30.1.4 REPLACEMENT OF GREASE CARTRIDGE...................................................234
			30.1.5 METHOD OF FILLING AUTO-GREASING SYSTEM WITH GREASE................................235
		30.2 PRECAUTIONS WHEN HANDLING AUTO-GREASING SYSTEM..........................................237
		30.3 TROUBLESHOOTING (AUTO-GREASING SYSTEM) .................................................238
		30.4 SPECIFICATIONS .........................................................................238
	31. HANDLING E.C.S.S. (ELECTRONIC CONTROLLED SUSPENSION  SYSTEM .................................239
		31.1 STRUCTURE AND FUNCTION OF E.C.S.S. .....................................................239
		31.2 METHOD OF OPERATING E.C.S.S. ...........................................................240
		31.3 PRECAUTIONS WHEN OPERATING E.C.S.S. SWITCH .............................................240
		31.4 PRECAUTIONS WHEN HANDLING ACCUMULATOR 1 ................................................241
		31.5 REMOVAL OF TRAVEL DAMPER PIPING ........................................................242
	32. HANDLING JOYSTICK STEERING SYSTEM ...........................................................243
		32.1 STRUCTURE AND FUNCTION OF JOYSTICK STEERING ............................................243
		32.2 OPERATION METHOD OF JOYSTICK STEERING  SYSTEM ..........................................246
		32.3 PRECAUTIONS FOR STEERING WITH JOYSTICK .................................................247
		32.4 ADJUSTMENT OF JOYSTICK CONSOLE .........................................................248
		32.5 ADJUSTMENT OPERATOR’S SEAT .............................................................249
	33. GROUND DRIVEN STEERING (IF EQUIPPED) ........................................................250

KOMATSU WHEEL LOADER WA500-3 OPERATION & MAINTENANCE MANUAL SN A70001 AND UP – PDF DOWNLOAD:

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Komatsu Wheel Loader WA500-3 Operation & Maintenance Manual

FOREWORD:

• This manual describes procedures for operation, handling, lubrication, maintenance, checking, and adjustment. It will help the operator and maintenance personnel realize peak performance through effective, economical and safe machine operation and maintenance.
• 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 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 or Komatsu America International Company 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 troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
• Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.