Komatsu WA500-3LK Wheel Loader Operation and Maintenance Manual CEAM008102

Description

• Model List:
  • WA500-3LK Wheel Loader

• 1. INTRODUCTION
• 1.1. FOREWORD
• 1.2. SAFETY INFORMATION
• 1.3. APPROVED AND NONAPPROVED USES
• 1.3.1. Approved Functions
• 1.3.2. NonApproved Functions
• 1.4. VISIBILITY STANDARD
• 1.4.1. Visibility in Immediate Area
• 1.4.2. M Radius Visibility
• 1.5. PRODUCT IDENTIFICATION
• 1.5.1. Directions of Machine
• 1.5.2. Machine Serial Number
• 1.5.3. Engine Serial Number, EPA Regulations
• 1.5.4. Service Meter Location
• 1.6. SERIAL NUMBERS AND DEALER INFORMATION
• 1.6.1. Model WA5003LK
• 1.7. TABLE OF CONTENTS
• 2. SAFETY
• 2.1. SAFETY AND WARNING DECALS
• 2.1.1. Location of the Safety Decals
• 2.1.2. Safety Labels
• 2.1.3. Additional Safety Decals
• 2.2. GENERAL SAFETY RULES AND PRECAUTIONS
• 2.2.1. General Safety Rules
• 2.2.2. Safety Features
• 2.2.3. Personal Protective Equipment
• 2.2.4. Fire and Explosion Prevention
• 2.2.5. Windshield Washer Fluid
• 2.2.6. Action if Fire Occurs
• 2.2.7. Fire Extinguisher and First Aid Kit
• 2.2.8. Mounting and Dismounting
• 2.2.9. Inside Operators Compartment
• 2.2.10. Precautions When Standing Up from Operators Seat
• 2.2.11. Precautions When Using ROPS
• 2.2.12. Emergency Escape from Operators Cab
• 2.2.13. Leaving Operators Compartment
• 2.2.14. Asbestos Hazard Alert
• 2.2.15. Crush or PinchPoint Dangers
• 2.2.16. Precautions for Ventilation Exhaust Gas
• 2.3. PRECAUTIONS BEFORE STARTING OPERATIONS
• 2.3.1. PreOperational Checks
• 2.3.2. Work Site Hazards
• 2.3.3. Avoiding Dangerous Situations
• 2.3.4. Working Clearances
• 2.3.5. Working Near High Voltage Cables
• 2.4. RULES FOR ROAD TRAVEL
• 2.4.1. Traveling in Reverse
• 2.4.2. Working on Loose or Unstable Ground
• 2.4.3. Operating on Snow or Frozen Surfaces
• 2.4.4. Travel on Slopes
• 2.4.5. Parking the Machine
• 2.5. PRECAUTIONS DURING MAINTENANCE OPERATIONS
• 2.5.1. Warning Tags
• 2.5.2. Equipment Storage
• 2.5.3. Working Under the Machine
• 2.5.4. Using Drop Lamps
• 2.5.5. Keeping the Machine Clean
• 2.5.6. Running the Machine During Maintenance
• 2.5.7. Rules for Refueling the Machine
• 2.5.8. Cooling System Precautions
• 2.5.9. Battery Precautions
• 2.5.10. Starting the Machine
• 2.5.11. HighPressure Hoses
• 2.5.12. Precautions for HighPressure Fuel
• 2.5.13. HighTemperature Areas
• 2.5.14. Disposal of Waste Materials
• 2.5.15. Inflating Tires
• 2.5.16. Accumulator
• 2.5.17. Critical Parts
• 2.5.18. High Voltage
• 2.5.19. Maintenance of Air Conditioner
• 3. OPERATION
• 3.1. GENERAL VIEW
• 3.1.1. General View of Machine
• 3.1.2. Controls and Gauges
• 3.2. EXPLANATION OF COMPONENTS
• 3.2.1. Machine Monitor System
• 3.2.2. Warning Display
• 3.2.3. Meter Display Portion
• 3.2.4. Switches
• 3.2.5. Control Levers, Pedals
• 3.3. SECURITY LOCKS AND SAFETY FEATURES
• 3.3.1. Steering Column Tilt Lever
• 3.3.2. Cap with Lock
• 3.3.3. Safety Bar
• 3.3.4. Towing Pin
• 3.3.5. Backup Alarm
• 3.4. MACHINE FEATURES
• 3.4.1. Cab Door
• 3.4.2. Power Outlet
• 3.5. WORK OPERATIONS
• 3.5.1. WalkAround Check
• 3.5.2. Precautions Before Starting Work Operations
• 3.5.3. Check Before Starting Engine
• 3.5.4. Final Checks Before Starting Engine
• 3.5.5. Starting Engine
• 3.5.6. Operations and Checks After Starting Engine
• 3.5.7. Stopping Engine
• 3.5.8. Moving the Machine (Directional, Speed), Stopping the Machine
• 3.5.9. Operation of Work Equipment
• 3.5.10. Work Possible Using Wheel Loader
• 3.5.11. Loading Operations
• 3.5.12. Precautions
• 3.5.13. Adjusting Work Equipment
• 3.5.14. Parking the Machine
• 3.5.15. Checks After Completion of Operation
• 3.5.16. Locking the Machine
• 3.6. HANDLING TIRES
• 3.6.1. Precautions When Handling Tires
• 3.7. TRANSPORTATION
• 3.7.1. Transportation Procedure
• 3.7.2. Loading and Unloading Trailers
• 3.8. LIFTING MACHINE
• 3.8.1. Lifting Position Marks
• 3.8.2. Lifting Procedure
• 3.9. COLD WEATHER OPERATION
• 3.9.1. Precautions for Low Temperature
• 3.10. LONGTERM STORAGE
• 3.10.1. Before Storage
• 3.10.2. During Storage
• 3.10.3. After Storage
• 3.11. TROUBLESHOOTING
• 3.11.1. When Machine Runs Out of Fuel
• 3.11.2. Towing the Machine
• 3.11.3. If Battery is Discharged
• 3.11.4. Starting Engine With Booster Cable
• 3.11.5. Other Troubleshooting
• 3.11.6. Relationship of Electronic Control System
• 4. MAINTENANCE
• 4.1. GUIDES TO MAINTENANCE
• 4.1.1. Check Service Meter
• 4.1.2. Komatsu Genuine Replacement Parts
• 4.1.3. Komatsu Genuine Oils
• 4.1.4. Always Use Clean Washer Fluid
• 4.1.5. Always Use Clean Oil and Grease
• 4.1.6. Checking for Foreign Materials in Drained Oil and On Filters
• 4.1.7. Fuel Strainer
• 4.1.8. Welding Instructions
• 4.1.9. Do Not Drop Things Inside Machine
• 4.1.10. Dusty Work Sites
• 4.1.11. Avoid Mixing Oil
• 4.1.12. Locking Inspection Covers
• 4.1.13. Bleeding Air from Hydraulic Circuit
• 4.1.14. Precautions When Installing Hydraulic Hoses
• 4.1.15. Checks After Inspection and Maintenance
• 4.2. OUTLINES OF SERVICE
• 4.2.1. Handling Oil, Fuel, Coolant, and Performing Oil Clinic
• 4.2.2. Performing KOWA (Komatsu Oil Wear Analysis)
• 4.2.3. Storing Oil and Fuel
• 4.2.4. Filters
• 4.2.5. Outline of Electric System
• 4.3. WEAR PARTS
• 4.3.1. Wear Parts List
• 4.4. RECOMMENDED FUEL, COOLANT, AND LUBRICANTS
• 4.4.1. Fuel, Coolant, and Lubricant Ambient Temperature Chart
• 4.4.2. Recommended Brands, Other Than Komatsu Genuine Oil
• 4.5. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS
• 4.6. PERIODIC REPLACEMENT OF SAFETYCRITICAL PARTS
• 4.7. MAINTENANCE SCHEDULE CHART
• 4.8. SERVICE PROCEDURE
• 4.8.1. Initial 10 Hours Service
• 4.8.2. Initial 250 Hours Service
• 4.8.3. When Required
• 4.8.4. Check Before Starting
• 4.8.5. Every 50 Hours Service
• 4.8.6. Every 100 Hours Service
• 4.8.7. Every 250 Hours Service
• 4.8.8. Every 500 Hours Service
• 4.8.9. Every 1000 Hours Service
• 4.8.10. Every 2000 Hours Service
• 4.8.11. Every 4000 Hours Service
• 4.8.12. Every 8000 Hours Service
• 5. SPECIFICATIONS
• 5.1. SPECIFICATIONS
• 6. OPTIONS, ATTACHMENTS
• 6.1. BUCKET AND TIRES
• 6.2. TIRE CHAINS
• 6.3. ELECTRONICCONTROLLED SUSPENSION SYSTEM
• 6.3.1. Operating ECSS
• 6.3.2. Precautions When Using ECSS Switch
• 6.3.3. Removal of ECSS Piping
• 6.3.4. Precautions When Handling Accumulator
• 6.4. AUTOGREASING SYSTEM
• 6.4.1. Method of Operation
• 6.4.2. Starting AutoGreasing
• 6.4.3. Lubrication Controller Display
• 6.4.4. Setting the Greasing Time
• 6.4.5. Checking Amount of Grease
• 6.4.6. Replacing Grease Cartridge
• 6.4.7. Precautions When Handling AutoGreasing System
• 6.4.8. Troubleshooting AutoGreasing System
• 6.5. REMOTE POSITIONER
• 6.5.1. General Locations
• 6.5.2. Operating Remote Positioner
• 6.5.3. Adjusting Remote Positioner
• 6.5.4. Setting Remote Positioner Stop Position
• 6.5.5. Adjusting Sensor
• 6.6. JOYSTICK STEERING SYSTEM
• 6.6.1. Structure and Function
• 6.6.2. Components
• 6.6.3. Steering with Joystick Lever or Steering Wheel
• 6.6.4. Precautions for Steering with Joystick
• 6.6.5. Operating the Joystick Steering System
• 6.6.6. Getting In and Out of Operators Cab
• 6.6.7. Adjustments
• 6.7. CAR RADIO
• 6.7.1. Components
• 6.7.2. Method of Operation
• 6.7.3. Precautions When Using
• 6.8. AM/FM RADIO CASSETTE STEREO SOUND SYSTEM
• 6.8.1. Sound System Components
• 6.8.2. Method of Operation
• 6.8.3. Precautions When Using
• 6.8.4. Handling Cassette Tape
• 6.9. AIR CONDITIONER
• 6.9.1. Control Panel
• 6.9.2. Method of Operation
• 6.9.3. Precautions When Using Air Conditioner
• 6.9.4. Inspection and Maintenance
• 6.9.5. Cool Box
• 6.10. BRAKE COOLING SYSTEM
• 6.10.1. When Required
• 6.10.2. Every 2000 Hours Service