Komatsu avance plus WA500-3LK Operation & Maintenance Manual
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Komatsu avance plus WA500-3LK Operation & Maintenance Manual

Komatsu avance plus WA500-3LK Operation & Maintenance Manual

Wheel loader
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Operation & Maintenance
Manual
WA500
WHEEL LOADER
SERIAL NUMBERS
This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in accordance
with written authorization from Komatsu America Corp.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make changes or
add improvements at any time without incurring any obligation to install such changes on products sold previously.
Due to this continuous program of research and development, periodic revisions may be made to this publication. It is recom-
mended that customers contact their distributor for information on the latest revision.
May 2009
WA500-3LK
-3LK
A71001
and UP
Copyright 2009 Komatsu
Published in USA
Komatsu America Corp.
CEAM008101

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  • Page 1 SERIAL NUMBERS and UP This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in accordance with written authorization from Komatsu America Corp. It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make changes or add improvements at any time without incurring any obligation to install such changes on products sold previously.
  • Page 3 0INTRODUCTION WA500-3LK...

  • Page 4: Introduction

    Consult your local Komatsu distributor for the latest available information on your machine or for questions regarding information in this manual. This manual may contain attachments and optional equipment that are not available in your area. Consult your local Komatsu distributor for items that you may require.

  • Page 5: Safety Information

    Safety precautions are described in the SAFETY section (Section 1). KOMATSU AMERICA CORP. cannot predict every circumstance that might involve a potential hazard in operation and maintenance. Therefore the safety message in this manual and on the machine may not include all possible safety precautions.

  • Page 6: Approved And Non-Approved Uses

    It is impossible to predict all the possible improper uses. If the machine is used for any particular application other than those listed in the Approved Functions list, it is important to contact your authorized Komatsu dealer before carrying out the work operations.

  • Page 7: Visibility Standard

    INTRODUCTION VISIBILITY STANDARD The visibility standards (ISO 5006) for this machine require a view shown in this diagram. Visibility in Immediate Area The visibility of this machine in the area 1 meter (1.1 yd) from the outside surface of the machine at a height of 1.5 m (1.6 yd) is shown in the diagram.

  • Page 8: Product Identification

    INTRODUCTION PRODUCT IDENTIFICATION The serial numbers and model numbers on the components are the only numbers that your dealer needs when you require assistance or order replacement parts. It is a good idea to record this information in this manual. See “SERIAL NUMBERS AND DEALER INFORMATION” on page 0-9.

  • Page 9: Machine Serial Number

    INTRODUCTION Machine Serial Number The machine serial number is stamped on the right side, center of the front frame. Engine Serial Number, EPA Regulations The engine serial number is on a plate on the upper left side of the cylinder block, on the right side of the machine. ★...

  • Page 10: Service Meter Location

    INTRODUCTION Service Meter Location The service meter is part of the maintenance monitor and is located on the console to the right of the operator’s seat. WA500-3LK...

  • Page 11: Serial Numbers And Dealer Information

    INTRODUCTION SERIAL NUMBERS AND DEALER INFORMATION Model: WA500-3LK Machine # Engine # Dealer: Address: Phone # Contacts: NOTES: WA500-3LK...
  • Page 12 INTRODUCTION MEMORANDUM 0-10 WA500-3LK...

  • Page 13: Table Of Contents

    INTRODUCTION TABLE OF CONTENTS INTRODUCTION FOREWORD ..............0-2 SAFETY INFORMATION .
  • Page 14 INTRODUCTION Crush or Pinch-Point Dangers ........... . 1-19 Precautions for Ventilation Exhaust Gas .
  • Page 15 INTRODUCTION Maintenance Monitor ............2-5 EXPLANATION OF COMPONENTS .
  • Page 16 INTRODUCTION Gearshift Lever ............2-27 Directional Lever .
  • Page 17 INTRODUCTION Starting Engine ............. . . 2-56 Normal Starting .
  • Page 18 INTRODUCTION Removing the Bucket ............2-93 Installing the Bucket .
  • Page 19 Fuel, Coolant, and Lubricant Ambient Temperature Chart ......3-12 Recommended Brands, Other Than Komatsu Genuine Oil ......3-13 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS .
  • Page 20 INTRODUCTION PERIODIC REPLACEMENT OF SAFETY-CRITICAL PARTS ......3-16 MAINTENANCE SCHEDULE CHART ..........3-18 SERVICE PROCEDURE .
  • Page 21 INTRODUCTION Replace Corrosion Resistor Cartridge ......... . . 3-62 Clean Radiator Subtank Breather .
  • Page 22 INTRODUCTION Setting the Greasing Time ............5-10 Setting Greasing Time in Cold Areas .
  • Page 23 INTRODUCTION Sound System Components ............5-40 Power Switch/Volume .
  • Page 24 INTRODUCTION MEMORANDUM 0-22 WA500-3LK...
  • Page 25 1SAFETY Read and follow all safety precautions. Failure to do so may result in serious injury or death. This safety section also contains precautions for optional equipment and attachments. WA500-3LK...

  • Page 26: Safety

    • Your Komatsu Dealer can provide new replacement decals if the ones on the machine are damaged or missing. • For part numbers of the safety decals, see this manual or check the actual decal then order the new decals from your Komatsu distributor.

  • Page 27: Safety Labels

    Follow instructions and warning in manual and in labels on machine. Keep manual in machine cab near operator. Contact Komatsu distributor for a replacement manual. Cautions for leaving the operator’s seat (09654-03001). To avoid hitting unlocked operation levers, lower equipment to ground and move SAFETY LOCK LEVER (located near seat) to LOCK position before standing up from operator’s seat.
  • Page 28 SAFETY Cautions for parking brake. If the switch is set to RELEASE, a serious accident could result, as this operation releases the parking brake and the machine may move off suddenly. Never set the switch to RELEASE except when towing a disabled machine.
  • Page 29 SAFETY Cautions for working close to electric cables (09801-13001). Hazardous voltage hazard Serious injury or death can occur if machine or attachments are not kept safe distance away from electric lines. Voltage Safe Distance 100V - 200V 2 m (7 ft.) Voltage 6,600V 2 m (7 ft.)
  • Page 30 SAFETY 10. Cautions when handling battery cables (09808-03000). Improper use of booster cables and battery cables can cause an explosion resulting in serious injury or death. Follow instructions in manual when using booster cables and battery cables. 11. Caution when handling battery. Keep sparks, flame, cigarettes away.
  • Page 31 SAFETY 15. Do not open when the engine is running (09667-03001). While engine is running: 1. Do not open cover. 2. Keep away from fan and fan-belt. 16. Do not come near the machine (09812-13000). Keep a safe distance. 17. Do not modify ROPS (09620-A2000). •...

  • Page 32: Additional Safety Decals

    SAFETY 19. Jump start prohibited (09842-A0481). • Start the engine only after sitting in the operator’s seat. • Do not attempt to start the engine by short-circuiting the starter circuit. Serious injury or fire may result. 20. Cautions when handling batteries (09664-30010). EXPLOSIVE GASES •...
  • Page 33 SAFETY Emergency escape (425-93-51110). • Sign indicates the doors on the machine through which you can escape in an emergency. • Sign indicates the lock knob on the emergency escape door. WA500-3LK...

  • Page 34: General Safety Rules And Precautions

    • Komatsu requires that if your equipment is designed for operation by one person, it is for one person only. Never allow other personnel to ride on your machine in any manner. •...

  • Page 35: General Safety At Job Site

    SAFETY General Safety at Job Site • Before starting operations, thoroughly check the area for any unusual conditions that could be dangerous. • Know where to report an accident or fire. In case of an emergency, have a local emergency phone number available. •...

  • Page 36: Personal Protective Equipment

    SAFETY Personal Protective Equipment • If your machine is equipped with safety equipment, Komatsu requires this equipment to be used when operating your machine. • Avoid loose fitting clothing, jewelry, and loose long hair. These can catch on controls or in moving parts and cause serious injury.

  • Page 37: Fire Caused By Accumulation Of Flammable Material

    SAFETY • Use well-ventilated areas for adding or storing oil and fuel. • Keep oil and fuel in the determined place and do not allow unauthorized persons to enter. • After adding fuel or oil, wipe up any spilled fuel or oil. •...

  • Page 38: Fire Extinguisher And First Aid Kit

    SAFETY Fire Extinguisher and First Aid Kit As a precaution in case a fire or an injury occurs, always keep a fire extinguisher and first aid kit on your machine and take the following precautions: • Be sure that the fire extinguisher is in good condition. Read the label on it to ensure you know how to use it.

  • Page 39: Mounting And Dismounting

    SAFETY Mounting and Dismounting • When mounting or dismounting this machine, always be sure the work equipment is fully lowered to the ground; the engine is OFF; and the parking brake is set. • Use all hand holds and step plates on your machine. •...

  • Page 40: Inside Operator's Compartment

    SAFETY Inside Operator’s Compartment • When entering the operator’s compartment, always remove mud and oil from the soles of your shoes. • If you operate the brake pedal with mud or oil on your shoes, your foot may slip and may cause an accident. •...

  • Page 41: Precautions When Using Rops

    SAFETY Precautions When Using ROPS The ROPS (Roll Over Protective Structure) must never be removed from the machine. The ROPS is installed to protect the operator if the machine rolls over. It is designed not only to support the load if the machine rolls over, but also to absorb the impact of the energy.

  • Page 42: Leaving Operator's Compartment

    SAFETY Leaving Operator’s Compartment These procedures must be followed when exiting the operator’s cab. Park the machine in a level area. Lower the work equipment completely to the ground. Set safety lock lever (1) to the LOCK position. Set parking brake switch (2) to ON. Turn the engine OFF.

  • Page 43: Asbestos Hazard Alert

    SAFETY Asbestos Hazard Alert Asbestos dust in the air can cause lung cancer, if it is inhaled. There is danger of inhaling asbestos materials when working on job sites handling industrial waste. Always observe the following precautions. • Spray water to keep down the dust when cleaning. Do not use compressed air for cleaning.

  • Page 44: Precautions Before Starting Operations

    As an operator, you are responsible for the safe operation of this machine at all times, regardless of the situation. Although Komatsu cannot cover all operating conditions that pose a major hazard, here are a few basic situations to avoid when using the loader during work or travel operations.

  • Page 45: Precaution For Warning Tag

    SAFETY Precaution for Warning Tag If there is a “DO NOT OPERATE” warning sign on the work equipment control levers, it means that someone is performing inspection and maintenance of the machine. • Do not start the engine or touch the levers (1). •...

  • Page 46: Checks Before Starting Engine, Adjustments

    SAFETY Checks Before Starting Engine, Adjustments Before starting the engine, perform the following checks and adjustments to confirm that there is no problem with operating the machine. If this step is not performed properly, there is a danger of serious personal injury to the operator or damage to the machine during operation.

  • Page 47: Precautions When Starting

    SAFETY • Check that the parking brake switch is in the ON position (2) Precautions When Starting • Do not start the engine if warning tags have been attached to the steering wheel or control levers. • Before starting the machine, always be in a seated position only, with the seat belt fastened snugly around your waist. •...

  • Page 48: Avoiding Dangerous Situations

    SAFETY Avoiding Dangerous Situations • Avoid traveling with the bucket raised. • Raising the bucket raises the center of gravity on the machine. Traveling with a raised bucket, especially a loaded bucket, may result in loss of control or a rollover situation. •...

  • Page 49: Working Clearances

    SAFETY • Never work under overhangs or excavated bank areas. • These could collapse and damage the machine or injure the operator. • Do not approach too close to the edge of cliffs. • When doing landfills or when dropping soil over a cliff, dump one pile then use the next pile of soil to push the first pile.

  • Page 50: Working Near High Voltage Cables

    SAFETY Working Near High Voltage Cables • Electrocution can result from contacting or approaching underground or overhead power cables. • NEVER approach overhead power lines with any part of the machine. • ALWAYS use extreme caution. • Before starting work in the vicinity of electric cables, inform the local power company of the work to be performed.

  • Page 51: Rules For Road Travel

    SAFETY RULES FOR ROAD TRAVEL Traveling with your machine may pose some hazards. When traveling, always travel in a safe manner and remain alert at all times. A safety-conscious operator is the most important insurance when traveling with the machine. The operator should be aware of the following situations and information.

  • Page 52: Working On Loose Or Unstable Ground

    SAFETY Working on Loose or Unstable Ground To limit the risk when working in these areas: • Avoid operating the machine too close to the edge of a cliff, open trenches, or ditch lines. These areas may collapse under the weight of your machine causing serious damage to the machine or injury to the operator. •...

  • Page 53: Travel On Slopes

    SAFETY Travel on Slopes Traveling on slopes may pose a hazard. In order to prevent tipping the machine or losing control, it is important to follow some basic simple rules. • When traveling over rough ground, travel at a slow, controllable speed.
  • Page 54 SAFETY • Always travel straight up or straight down a slope. • Traveling at an angle on a slope may cause the machine to tip or possibly roll over. • Do not turn on slopes or travel across slopes. Always go down to a flat place to change the position of the machine then travel on to the slope again.

  • Page 55: Parking The Machine

    SAFETY Parking the Machine When parking the machine, it is important to follow several basic safety rules. You are responsible for the security of the machine when it is parked. • Always park the machine on a flat, level location away from moving equipment, pedestrians, or traffic.

  • Page 56: Precautions During Maintenance Operations

    SAFETY PRECAUTIONS DURING MAINTENANCE OPERATIONS All maintenance performed on this machine must be performed only by trained and authorized personnel. When performing maintenance it is important to follow the outlined maintenance procedures and safety information outlined in this manual and in the Shop Manual for this machine.

  • Page 57: Working Under The Machine

    SAFETY Working Under the Machine • Always use approved jack stands to support the machine when performing maintenance under the chassis. • Never rely on hydraulic jacks or the machine’s work equipment to support the machine when working under or on the machine. •...

  • Page 58: Running The Machine During Maintenance

    SAFETY Running the Machine During Maintenance • If during maintenance you must run the engine, have someone remain in the operator’s seat while the engine is running. • One worker must be ready to stop the engine at all times. •...

  • Page 59: Rules For Refueling The Machine

    • Never dump used coolant on the ground, in a lake, stream, or in a sewer system. • Komatsu requires these fluids to be captured and recycled properly. Battery Precautions • When working on the electrical system, disconnect the negative (-) battery cable first then the positive (+) battery cable last.

  • Page 60: Battery Hazard Prevention

    SAFETY Battery Hazard Prevention Danger of Battery Exploding When charging the battery, flammable hydrogen gas is generated from the poles. If the gas ignites, it may explode and cause serious injury or fire. • DO NOT use or charge a battery if the electrolyte is below the LOWER LEVEL mark.

  • Page 61: Using Jumper Cables

    SAFETY Using Jumper Cables When using jumper cables to start the machine, attach the positive (+) jumper first then the negative (-) jumper last to a remote location on the chassis, as shown in the following figure. For additional information, see “Starting Engine With Booster Cable”...

  • Page 62: High-Pressure Hoses

    If any loose bolts are found, stop work and tighten to the specified torque. • If any damaged hoses are found, stop operations immediately and contact your Komatsu distributor. • Replace the hose if any of the following problems are found: •...

  • Page 63: High-Temperature Areas

    SAFETY High-Temperature Areas When you stop the machine at the end of a job, remember that the engine coolant, oil, all engine parts, exhaust stack, and the hydraulic system are still hot and under pressure. If you attempt to drain engine coolant, hydraulic fluid, or engine oil under these conditions, you expose yourself to various dangers, including the risk of serious burns.

  • Page 64: Inflating Tires

    SAFETY Inflating Tires Always remember that tires can burst while being inflated, causing serious accidents. Before servicing the tires, observe the following precautions. • Before inflating tires, always check the wheel rims, tire walls, and tread for cuts, broken cords, or other damage. •...

  • Page 65: High Voltage

    Never touch the injector terminal or inside the engine controller. • If it is necessary to touch the injector terminal or the inside of the engine controller, please contact your Komatsu distributor. Maintenance of Air Conditioner • NEVER touch the refrigerant.
  • Page 66 SAFETY MEMORANDUM 1-42 WA500-3LK...
  • Page 67 2OPERATION WA500-3LK...

  • Page 68: General View

    OPERATION GENERAL VIEW General View of Machine Bucket Turn signal lamp Lift arm Headlamp Tilt lever 10. Lift cylinder Bucket cylinder 11. Front wheel Front working lamp 12. Rear working lamp ROPS cab 13. Rear combination lamp Rear wheel WA500-3LK...

  • Page 69: Controls And Gauges

    OPERATION Controls and Gauges Front wiper switch 13. Starting switch Rear wiper switch 14. Car radio (if equipped) Gearshift lever stopper 15. Kickdown switch Air conditioner panel (if equipped) 16. Hold switch Gearshift lever 17. Lift arm control lever Directional lever 18.

  • Page 70: Main Monitor

    OPERATION Main Monitor ECSS* switch (switch, pilot lamp) (if equipped) Auto-greasing switch (if equipped) Emergency steering pilot lamp (if equipped) Turn signal pilot lamp Headlamp high beam pilot lamp Central check lamp Engine preheating pilot lamp Front working lamp (switch, pilot lamp) Rear working lamp (switch, pilot lamp) 10.

  • Page 71: Maintenance Monitor

    OPERATION Maintenance Monitor Fuel level Engine water temperature gauge Torque converter oil temperature gauge Remote positioner LOWER position set switch (if equipped) Remote positioner RAISE position set switch (if equipped) Remote positioner RAISE position/LOWER selector (if equipped) Service meter Air cleaner clogging caution lamp Battery electrolyte level caution lamp 10.

  • Page 72: Explanation Of Components

    OPERATION EXPLANATION OF COMPONENTS This section provides an explanation of the devices needed for operating the machine. To perform suitable operations correctly and safely, it is important to completely understand methods of operating the equipment and the meaning of the displays. Machine Monitor System The machine monitor system consists of the main monitor (in front of the operator’s seat) and the maintenance monitor (on the right side of the operator’s seat).
  • Page 73 When this happens, “88” is displayed on the speedometer and “8” is displayed on the transmission shift indicator. Finally, there are two beeps to indicate that the monitor check has been completed. If the monitor lamps do not light up, there is probably a failure or disconnection. Contact your Komatsu distributor for inspection.

  • Page 74: Warning Display

    OPERATION Warning Display Central check lamp (CHECK) Central caution lamp (CAUTION) Engine water level caution pilot lamp Engine oil level caution pilot lamp Brake oil pressure caution pilot lamp Engine oil pressure caution pilot lamp Battery charge caution pilot lamp Air cleaner clogging caution pilot lamp Emergency steering pilot lamp (red) (if equipped) WA500-3LK...

  • Page 75: Central Check Lamp (Check)

    OPERATION Central Check Lamp (CHECK) If this monitor flashes, carry out inspection and maintenance of the appropriate location as soon as possible. • If any abnormality is found in the CHECK items before starting the engine (engine oil level, engine water level), the monitor lamp for the abnormal location will flash and the central check lamp (CHECK) (1) will also flash.

  • Page 76: Engine Water Level Caution Pilot Lamp

    OPERATION Engine Water Level Caution Pilot Lamp The engine water level caution pilot lamp (3) warns the operator that the coolant level in the radiator has dropped. When carrying out the checks before starting (starting switch ON, engine stopped): • If the level of coolant in the radiator is low, the caution pilot lamp and central CHECK lamp will flash.

  • Page 77: Brake Oil Pressure Caution Pilot Lamp

    OPERATION Brake Oil Pressure Caution Pilot Lamp The brake oil pressure caution pilot lamp (5) warns the operator that the brake oil pressure has dropped. When carrying out checks before starting: • When the engine is stopped, the brake oil pressure circuit is not actuated;...

  • Page 78: Air Cleaner Clogging Caution Pilot Lamp

    OPERATION Air Cleaner Clogging Caution Pilot Lamp When the engine is running, the air cleaner clogging caution pilot lamp (8) warns the operator that the air cleaner element is clogged. Check before starting: • When operating: • If the air cleaner becomes clogged, the caution pilot lamp and central CHECK lamp will flash.

  • Page 79: Meter Display Portion

    OPERATION Meter Display Portion When the starting switch is ON, the pilot display lights up when the display items are functioning. Parking brake pilot lamp Transmission auto-shift/manual selector pilot lamp Engine preheating pilot lamp Fuel gauge Front working lamp pilot lamp 10.

  • Page 80: Parking Brake Pilot Lamp

    OPERATION Parking Brake Pilot Lamp The parking brake pilot lamp (1) lights up when the parking brake is applied. Engine Preheating Pilot Lamp The engine preheating pilot lamp (2) informs the operator of the preheating status of the electrical intake air heater. The lamp lights up when the starting switch is turned to the ON position and goes out when the preheating is completed.

  • Page 81: Transmission Cutoff Pilot Lamp

    OPERATION Transmission Cutoff Pilot Lamp The transmission cutoff pilot lamp (5) lights up when the transmission cutoff switch is turned ON. If the monitor lamp is ON and the left brake pedal is depressed, the transmission will return to neutral. Turn Signal Pilot Lamp When the turn signal lamp flashes, the turn signal pilot lamp (6) also flashes.

  • Page 82: Fuel Gauge

    OPERATION Fuel Gauge The fuel gauge (9) indicates the amount of fuel in the fuel tank. • E: Tank is EMPTY. • F: Tank is FULL. The lamp should light up in the green range during operation. • If the red range lights during operation, the fuel gauge lamp and central CAUTION lamp will flash.

  • Page 83: Service Meter

    OPERATION Service Meter The service meter (12) shows the total operation hours of the machine. The service meter advances while the engine is running - even if the machine is not traveling. While the engine is running, the green pilot lamp on the service meter flashes to show the service meter advances.

  • Page 84: Switches

    OPERATION Switches Starting switch Kickdown switch Transmission cutoff switch 10. Front wiper switch Front working lamp switch 11. Rear wiper switch Rear working lamp switch 12. Cigarette lighter (if equipped) Transmission auto-shift/manual selector switch 13. Room lamp switch Lamp switch 14.

  • Page 85: Starting Switch

    OPERATION Starting Switch The starting switch (1) is used to start or stop the engine. OFF position • The key can be inserted and removed at this position. When the key is turned to this position, the electric circuits are turned off and the engine stops.

  • Page 86: Front Working Lamp Switch

    OPERATION Front Working Lamp Switch Always turn the working lamp OFF before traveling on public roads. When turning on the front work lamp, turn the front working lamp switch to the ON position for the side clearance lamp or the ON position for the headlamp, then operate the switch (3).

  • Page 87: Lamp Switch

    OPERATION Lamp Switch The lamp switch (6) is used to light up the front lamps, side clearance lamps, tail lamps, and instrument panel. • Position (a): OFF • Position (b): Side clearance lamp, tail lamps, and instrument panel light up. •...

  • Page 88: Hazard Lamp Switch

    OPERATION Hazard Lamp Switch • Use the hazard lamps only for emergencies. • Using the hazard lamps when traveling will cause problems for other machine operators. The hazard switch (8) is used in emergencies, such as when the machine breaks down and has to be parked on the road. •...

  • Page 89: Rear Wiper Switch

    OPERATION Rear Wiper Switch Turn lever (C) on the rear wiper switch (11) to operate the rear wiper. • Position (a): Washer liquid is sprayed out. • Position (b): OFF • Position (c): Wiper is operated. • Position (d): Washer fluid is sprayed out; wiper is operated. Cigarette Lighter (if equipped) The cigarette lighter (12) is used to light cigarettes.

  • Page 90: Parking Brake Switch

    If the parking brake has been used as an emergency brake when traveling at high speed (near the maximum speed), contact your Komatsu distributor to have the parking brake checked for any abnormality. The parking brake switch (14) is used to actuate the parking brake.

  • Page 91: Hold Switch

    OPERATION Hold Switch To fix the speed range when traveling and using the automatic transmission, press the hold switch (17) at the side of the lift arm control lever knob. The transmission will be fixed in the speed range displayed on the shift indicator and the HOLD display lights up. When the switch is pressed again, the display goes out.

  • Page 92: Control Levers, Pedals

    OPERATION Control Levers, Pedals Gearshift lever Directional lever Gearshift lever stopper Safety lock lever (for work equipment lever) Bucket control lever Lift arm control lever Brake pedals Acclerator pedal 2-26 WA500-3LK...

  • Page 93: Gearshift Lever

    OPERATION Gearshift Lever The gearshift lever (1) changes the speed range of the transmission. Manual Shift This machine has a 4-FORWARD, 4-REVERSE speed transmission. Place the gearshift lever in a suitable position to obtain the desired speed range. • 1st and 2nd speeds are used for working. •...

  • Page 94: Directional Lever

    OPERATION The range of speeds during automatic gearshifting is determined by the position of the gearshift lever as shown in the chart on the right. Remark The first position for the gearshift lever fixes the transmission in 1st. There is no automatic shifting of the transmission. When shifting down from 2nd to 1st, press the kickdown switch on the lift arm control lever.

  • Page 95: Gearshift Lever Stopper

    OPERATION Remark The length of the lever can be adjusted to three positions (A), (B), (C). To adjust the length, remove the screw at the bottom of the lever knob; slide the knob to the desired position; then tighten the screw again.

  • Page 96: Bucket Control Lever

    OPERATION Bucket Control Lever The bucket control lever (5) operates the bucket. • Position (a): TILT When the lever is pulled further from the TILT position, the lever is stopped in this position until the bucket reaches the preset position of the positioner, and the lever is returned to the HOLD position.

  • Page 97: Brake Pedals

    OPERATION Brake Pedals • When traveling downhill, always use the right brake pedal. Use the braking force of the engine together with the brake. • Do not use the brake pedal more than necessary. If the brake is used too frequently, the brake will overheat. If this happens, the brakes will not work and may lead to a serious accident.

  • Page 98: Security Locks And Safety Features

    OPERATION SECURITY LOCKS AND SAFETY FEATURES This machine is equipped with several security locks and safety features designed to protect the operator, persons performing service, repair, or inspections on the machine, as well as the general public when the machine is not in use and unattended. It is important for the operator of the machine to know where these features are located and when to use them.

  • Page 99: Locking The Cap

    OPERATION Turn the starting switch key counterclockwise and align the groove in the rotor with the countermark on the cap. Turn the key slowly until you hear a clicking sound. This releases the cap and it can be opened. Locking the Cap Screw the cap into place.

  • Page 100: Towing Pin

    OPERATION Towing Pin Insert towing pin (1) into hole (2) in the counterweight. Set linch pin (3) so that the towing pin does not come out. ★ Carry out this operation in reverse to remove the pin. Backup Alarm This alarm sounds when the directional lever is set to the R position. The alarm warns people behind the machine that the machine will travel in reverse.

  • Page 101: Machine Features

    OPERATION MACHINE FEATURES Cab Door Emergency Escape Right Door • The right cab door is provided as an emergency escape from the cab when it is impossible to leave the cab from the left cab door. Do not use the right cab door for getting in or out of the operator’s compartment. •...
  • Page 102 OPERATION ★ The gas damper is not a lock device to keep the cab door open. Door Operating as Emergency Escape If the left door of the cab does not open or if it is dangerous to get off the machine from the left side, use the right emergency door. Release the open lock of the right door to open the door fully and use it as an emergency escape route.

  • Page 103: Left Cab Door, Opening Lock

    OPERATION Open the right door fully and escape through the door. To return the open lock to its original position, use your hand to hold lock knob (1) open and pull it gradually to align the open lock guide rail with the guide and then push the open lock knob to the front.

  • Page 104: Left Cab Door, Opening Knob

    OPERATION When closing the door from the operator’s seat, push knob (2) to release the catch. When closing the door after getting off the machine, pull knob (3) to release the catch. Left Cab Door, Opening Knob Pull open knob (1) to open the left door fully. Left Cab Window (Open, Lock, Cancel Knob) Use this knob when you want to move the door window glass up or down to open or close it.

  • Page 105: Cab Wiper

    OPERATION Cab Wiper Preventing Wiper Arm Bracket Damage Remark When angling the wiper arm to the front, check that the wiper blade is hanging free. If, when angling the wiper arm to the front, the wiper arm is angled with the wiper blade locked to the arm (the bottom of the blade is caught on the arm), abnormal force is brought to bear on the mounting bracket.

  • Page 106: Electrical

    OPERATION ELECTRICAL Fuses Before replacing a fuse, be sure to turn off the starting switch The fuses protect the electrical equipment and wiring from a short circuit or overload condition. Replace the fuse if any of the following conditions are present: •...

  • Page 107: Slow-Blow Fuses

    OPERATION Fuse Box 2 Fuse Capacity Circuit Front working lamp Rear working lamp Air conditioner 1 Air conditioner 2 Wiper, washer Auto-shift Cigarette lighter (if equipped) Radio (if equipped) Rotating lamp (if equipped) Air suspension (if equipped) Auto-greasing (if equipped) Spare Power window (L.H.) Power window (R.H.)

  • Page 108: Work Operations

    Accumulation of flammable materials and leakage of fuel or oil around the battery or high-temperature parts of the engine, such as the engine muffler and turbocharger, may cause fire on the machine. Check thoroughly and repair any problems that are found, or contact your Komatsu distributor. •...
  • Page 109 OPERATION Check for oil leakage from the transmission case, axle, hydraulic tank, hoses, joints. • Check that there is no oil leakage. If there is a problem, repair the leakage. Check for oil leakage from the brake line. • Check that there is no oil leakage. If there is a problem, repair the leakage. Check for damage to the lamps.
  • Page 110 If any loose bolts are found, tighten them to 927 ±103 N•m (683.7 ±76.0 lbf ft). • If bolts are damaged, replace them with genuine Komatsu bolts. 14. Check for damage and loose bolts on the handrail and steps. •...

  • Page 111: Check Before Starting Engine

    If the lamps do not illuminate, there is probably a failure or disconnection. Contact your Komatsu distributor for inspection. Check Dust Indicator If the air cleaner clogging caution lamp pilot lamp (1) on the maintenance monitor flashes, clean the air cleaner element.

  • Page 112: Check Coolant Level, Add Coolant

    OPERATION Check Coolant Level, Add Coolant • Do not open the radiator cap unless necessary. • Wait for the engine to cool down before checking the coolant in the subtank. The coolant remains at high temperature and the radiator is under high internal pressure immediately after the engine has stopped. If the cap is removed to check the coolant level in this condition, there is a hazard of burns.

  • Page 113: Check Oil Level In Engine Oil Pan, Add Oil

    OPERATION Check Oil Level in Engine Oil Pan, Add Oil The parts and oil are at high temperature immediately after the engine is stopped and may cause serious burns. Wait for the temperature to go down before starting the operation. ★...

  • Page 114: Check Fuel Level, Add Fuel

    OPERATION Check Fuel Level, Add Fuel • When filling with fuel, never let the fuel overflow. This may cause a fire. If too much fuel is added, there is danger that the fuel may expand because of the rise in the ambient temperature and cause the fuel to overflow. •...

  • Page 115: Check Electric Wiring

    Komatsu distributor to have the brake adjusted. Check Brake Pedal • Drive the machine forward and check the effect of the brakes. • If there is any problem in the functioning of the brakes, contact your Komatsu distributor to have the brakes adjusted. WA500-3LK 2-49...

  • Page 116: Check Waterproof/Fireproof Dividing Walls

    • If the wall or rubber sheet is damaged or missing, contact your Komatsu distributor for repairs. •...

  • Page 117: Adjust Seat

    OPERATION Adjust Seat • Park the machine in a safe place and stop the engine when adjusting the operator’s seat. • Adjust the seat position at the beginning of each shift or when operators change. • Adjust the seat so that you can depress the brake pedal fully while sitting with your back against the backrest. (A) Fore-and-aft adjustment •...

  • Page 118: Adjust Seat Belt

    OPERATION (G) Adjusting headrest angle • Rotate the headrest to the front or rear. (H) Adjusting armrest angle • Rotate knob (5) and adjust the angle of the armrest (left side only). Adjustment range: ......30 degrees Forward tilt: .

  • Page 119: Adjust Wrist Rest Height

    OPERATION Adjust Wrist Rest Height The height of wrist rest (1) can be adjusted easily with adjustment lever (2). • Position (a): Loosening position • Position (b): Fixing direction Turn adjustment lever (2) in the loosening direction and adjust the height of lift rest (1).

  • Page 120: Final Checks Before Starting Engine

    OPERATION Final Checks Before Starting Engine • Before starting the engine, check that the safety lock lever is securely at the LOCK position. • If the work equipment control lever is touched accidently when the engine starts, the work equipment may move unexpectedly, leading to serious damage or personal injury.
  • Page 121 When this happens, 88 is displayed on the speedometer and 8 is displayed on the transmission shift indicator. If any monitor lamps do not illuminate, there is probably a failure or disconnection. Contact your Komatsu distributor for inspection. WA500-3LK 2-55...

  • Page 122: Starting Engine

    OPERATION Starting Engine Normal Starting • Sit down in the operator’s seat before starting the engine. • Do not attempt to start the engine by short-circuiting the engine-starting circuit. Such an act may cause serious bodily injury or fire. • Check that there are no persons or obstacles in the surrounding area and then sound the horn and start the engine.
  • Page 123 OPERATION After the preheating pilot lamp (2) goes out, release the accelerator pedal; then turn the key in starting switch (1) to the START position. The engine starts. After the engine starts, release the key in starting switch (1). The key automatically returns to the ON position.

  • Page 124: Automatic Warming-Up Operation

    OPERATION Automatic Warming-Up Operation If the engine water temperature is low after the engine starts, the automatic warming-up operation is actuated. When the water temperature rises above 50°C (122°F), the warming-up operation is canceled. Remark The automatic warming-up operation changes according to the engine water temperature (shown in the diagram to the right).

  • Page 125: Operations And Checks After Starting Engine

    Set the machine on level ground with no obstacles in the surrounding area. Drive the machine slowly forward and in reverse and check the braking effect of the brakes. • If there is any abnormality in the operation of the brakes, ask your Komatsu distributor to carry out adjustments. Check Travel of Brake Pedal •...
  • Page 126 When there is an abnormal noise at engine start-up and if that condition continues, the engine may be damaged. In that case, ask your Komatsu distributor to check the engine as soon as possible. Check Engine at Low Speed and When Accelerating •...

  • Page 127: Normal Operation

    Run the engine under light load until engine water temperature gauge (2) and torque converter oil temperature gauge (3) are in the green range. Check for abnormal exhaust gas color, noise, or vibration. If any problem is found, contact your Komatsu distributor. WA500-3LK 2-61...

  • Page 128: Stopping Engine

    OPERATION Stopping Engine Remark If the engine is abruptly stopped before it has cooled down, engine life may be greatly shortened. Do not abruptly stop the engine except for an emergency. If the engine has overheated, do not abruptly stop it but run it at medium speed to allow it to cool gradually and then stop it.

  • Page 129: Moving The Machine (Directional, Speed), Stopping The Machine

    OPERATION Moving the Machine (Directional, Speed), Stopping the Machine • Always remove the safety bar for travel operations. If it is not removed, the steering wheel cannot be used for steering. This may lead to serious damage or injury. • When moving the machine, check that the area around the machine is safe and then sound the horn before starting.
  • Page 130 OPERATION Operate lift arm control lever (6) to set the work equipment to travel posture (A). (A): ....... 40 – 50 cm (16 – 20 in) Depress right brake pedal (8) and then turn parking brake switch (9) to the OFF (RELEASE) position to release the parking brake.
  • Page 131 OPERATION Release right brake pedal (8) and then depress accelerator pedal (3) to move the machine off. • (A) Right brake pedal • (B) Accelerator pedal Remark When starting off on a slope, turn the transmission cutoff switch (1) to the OFF position; depress left brake pedal (2); and operate the gearshift lever to the low speed range.

  • Page 132: Changing Gear Speed

    OPERATION Changing Gear Speed When traveling at high speed, do not shift gear suddenly. Use the brake to reduce the travel speed before shifting gear. ★ Shifting gear • When shifting gear, move the gearshift lever (1) to the desired position.

  • Page 133: Changing Direction

    OPERATION Changing Direction • When changing direction between FORWARD and REVERSE, check that the new direction of travel is safe. There is a blind spot behind the machine. Be particularly careful when changing direction to travel in reverse. • Do not switch between FORWARD and REVERSE when traveling at high speed.

  • Page 134: Stopping The Machine

    OPERATION Stopping the Machine • Avoid stopping suddenly. Allow ample room when stopping. • Do not park the machine on a slope. If it is necessary to park the machine on a slope, stop the machine facing directly down the slope;...

  • Page 135: Turning

    Check that there is a play of 50 to 100 mm (2.0 to 3.9 in) in the steering wheel. Check that the steering works properly. If any abnormality is found, contact your Komatsu distributor for inspection. WA500-3LK 2-69...

  • Page 136: Operation Of Work Equipment

    OPERATION Operation of Work Equipment • When standing up from the operator's seat, always set the safety lock lever securely to the LOCK position. If the safety lock lever is not locked and work equipment control lever (A) is touched by mistake, this may lead to a serious accident.

  • Page 137: Bucket Operation

    OPERATION Bucket Operation The bucket control lever is used to operate the bucket. Set the work equipment lock lever to the FREE position before operating the control lever. • Position (a): TILT • Position (b): HOLD • The bucket is stopped and held in position. •...

  • Page 138: Work Possible Using Wheel Loader

    OPERATION Work Possible Using Wheel Loader This section explains general operations. Be sure to operate the machine correctly. In addition to the following operations, it is possible to further increase the range of applications by using various attachments. Digging Operations •...
  • Page 139 OPERATION When the material is in a stockpile, keep the cutting edge of the bucket horizontal; when loading blasted rock, have the bucket tilting slightly down. • Be careful not to get blasted rock under the bucket. This will make the front tires come off the ground and slip. •...

  • Page 140: Digging And Loading On Level Ground

    OPERATION Digging and Loading on Level Ground • Do not set the bucket facing down more than 20 degrees. • If the bucket hits rocks in the ground first, a large shock is generated; this may damage the machine. Remark When digging and loading on level ground, set the bucket edge facing down slightly and drive the machine forward.

  • Page 141: Leveling Operations

    OPERATION Leveling Operations Remark Always operate the machine in reverse when carrying out leveling operations. If it is necessary to carry out leveling operations when traveling forward, do not set the bucket dumping angle to more than 20 degrees. Scoop soil into the bucket. Move the machine backward while spreading soil from the bucket, little by little.

  • Page 142: Loading Operations

    OPERATION Loading Operations Select the method of operation which will give the minimum amount of turning and travel in order to provide the most efficient method for the job site. • Always keep the working area flat. Do not turn suddenly or apply the brakes suddenly while traveling with a raised load. This is dangerous.

  • Page 143: Preparations For Loading, Gathering Rocks

    OPERATION Preparations for Loading, Gathering Rocks ★ Always keep the job area level and remove any rocks or boulders. • When gathering rocks, if the operation is carried out over an area longer than the length of the machine, there is danger that the machine will ride up on boulders and incur cuts to the tires.

  • Page 144: Digging

    OPERATION Drive forward at right angles to the rock and change the direction that the machine is facing. Operate the accelerator to match the condition of the road surface so that the tires do not slip. Scoop up the gathered rock. Load hard-cutting rock or boulders in the middle of the bucket.
  • Page 145 OPERATION After loading the rock completely into the bucket, operate the bucket tilt and lift two to three times repeatedly to fill the bucket. Let back the accelerator pedal; operate the control levers slowly; and tilt the bucket back fully. To prevent the load from falling out of the bucket, after completing the scooping-up operation operate in the dump and tilt direction when the bucket is near the full tilt in order to stabilize the load.

  • Page 146: Traveling In Reverse After Excavation

    OPERATION Traveling in Reverse After Excavation • Do not operate the steering immediately after starting to travel in reverse. The bucket is still thrust into the rock. If the steering is operated, excessive force will be placed on the bucket or frame. There is danger of damage to the frame. •...

  • Page 147: Approaching Dump Truck

    OPERATION Approaching Dump Truck Do not operate the steering suddenly when the bucket is raised. If the steering is operated when the bucket is raised, there is danger that the machine may tip over and cause serious personal injury. Remark •...

  • Page 148: Reversing Away From Dump Truck

    OPERATION • When loading the dump truck, do not push forcibly with the bucket. The machine and the dump truck will suffer impact shock, resulting in damage. When pushing the load with the bucket to prevent rocks from falling, carry out the operation gently. •...
  • Page 149 OPERATION Switch to R2 and drive in reverse. While driving in reverse, lower the lift arm and operate the steering to face the position for scooping up. Depress the brake pedal and stop the machine. Ease off the accelerator pedal to reduce the engine speed and then switch from R2 to F2.

  • Page 150: Precautions

    OPERATION Precautions When Piling Up Loads • When forming products into a pile, be careful not to let the rear counterweight come into contact with the ground. • Do not set the bucket to the DUMP position when piling up loads. Remark As much as possible, do not use the transmission cutoff function during scraping-up operations.
  • Page 151 OPERATION Articulating Machine During Digging Operations • Do not carry out operations with the machine articulated. If the machine is articulated, the direction of force will be different for the front wheels and rear wheels. As a result, the power, when traveling, will not be transmitted fully to the front wheels.
  • Page 152 OPERATION • If leveling operations are carried out with the machine traveling forward, do not make angle (a) between the cutting edge of the bucket and the ground surface facing down more than 8°. If leveling operations are carried out when driving forward with angle (a) between the cutting edge of the bucket and the ground surface facing down more than 8°, the bucket cylinder will be pushed by the pushing force of the machine.
  • Page 153 OPERATION When the scooping-up operation is completed, operate the bucket tilt and dump. Apply the brakes when traveling in reverse to stabilize the load inside the bucket and prevent spillage of the load. Remark To reduce the generation of heat by the torque converter, keep the target time for the digging operation within 10 seconds from the start of thrusting in to the completion of scooping up.

  • Page 154: During Cutting Face Operations

    OPERATION During Cutting Face Operations • Do not excavate cutting faces. If the cutting face is excavated, excessive force will be applied to the machine. There is danger that this may damage the bucket, work equipment, or frame. • In particular, do not excavate with the bucket raised to a height above the travel posture.

  • Page 155: Permissible Water Depth

    If the machine does not stop when you depress the brake pedal, use the parking brake to stop the machine. Remark If the parking brake has been used as an emergency brake, contact your Komatsu distributor to have the parking brake checked for any abnormality.

  • Page 156: When Driving The Machine

    • The most suitable tire pressure, travel speed, or tire type differ according to the condition of the travel surface. Contact your Komatsu distributor or tire dealer for information. • The following table is a guide to suitable tire inflation pressures and appropriate speeds when traveling on a paved surface with the standard tires.

  • Page 157: Adjusting Work Equipment

    OPERATION Adjusting Work Equipment • Stop the machine on flat ground and put blocks in front and behind the wheels. • Apply the parking brake. • Secure the front and rear frames with the safety bar. • Attach the warning tag to the work equipment control lever. •...

  • Page 158: Adjusting Bucket Positioner

    OPERATION Adjusting Bucket Positioner Lower the bucket to the ground; set to the desired digging angle. Return the bucket control lever to the HOLD position; lock the work equipment control lever; and stop the engine. Loosen two bolts (1) and adjust mounting bracket (4) of the proximity switch so that the rear tip of angle (2) is in line with the center of the sensing surface of the proximity switch (3).

  • Page 159: Removing The Bucket

    OPERATION Removing the Bucket • When removing pins, do not stand behind the bucket. • Do not put your foot under the bucket while standing at the side for the work. • If pins are hit with a strong force, there is a hazard that the pin may fly out and injure people in the surrounding area. Make sure that there is no one in the surrounding area before starting the operation.

  • Page 160: Installing The Bucket

    OPERATION Pull out and remove bucket hinge pin (4) on both sides of the bucket. Disconnect the lift arm and bucket. Installing the Bucket Read the safety instructions; see “Removing the Bucket” on page 2-93. Remark Before installing the bucket, remove all grease, mud, or sand and clean the pin, pin hole, and area around the boss.
  • Page 161 Assemble a pin that has no grease hole at the bucket link. Coat the bucket hinge pin and bucket link pin with grease. For details, see “Lubricating” on page 3-50. ★ For additional details about removing and installing the bucket, contact your Komatsu distributor. WA500-3LK 2-95...

  • Page 162: Parking The Machine

    OPERATION Parking the Machine • Avoid stopping suddenly. Give yourself ample room when stopping. • Do not park the machine on a slope. If the machine must be parked on a slope, set it facing directly down the slope; dig the bucket into the ground;...
  • Page 163 OPERATION Turn parking brake switch (4) ON to apply the parking brake. Remark When the parking brake is applied, the transmission is automatically returned to neutral. Operate lift arm control lever (5) to lower the bucket to the ground. Lock lift arm control lever (5) and bucket control lever (6) with safety lock lever (7).

  • Page 164: Checks After Completion Of Operation

    OPERATION Checks After Completion of Operation Before Stopping Engine • Use the meters and lamps on the machine monitor to check the engine water temperature, engine oil pressure, torque converter oil temperature, and fuel level. • If the engine has overheated, do not stop it suddenly. Run the engine at a mid-range speed to allow the engine time to cool down before stopping it.

  • Page 165: Handling Tires

    Remark It is dangerous to jack up the machine without taking proper care. Contact your Komatsu distributor when replacing the tires. After replacing the tires, carry out the breaking-in operation for approximately 30 hours (the time displayed on the service meter) until the tires and rims are settled.

  • Page 166: Tire Pressure

    OPERATION Tire Pressure • Measure the tire pressure before starting operations, when the tires are cool. If the tire inflation pressure is too low, there will be overload; if it is too high, it will cause tire cuts and shock burst. To prevent these problems, adjust the tire inflation pressure according to the Air Pressure chart on this page.

  • Page 167: Precautions For Using Load-And-Carry Method

    If this is not done, the tires will be damaged. • Contact your Komatsu distributor or tire dealer when selecting tires. Precautions when Storing Tires Tires for construction equipment are extremely heavy and may cause serious personal injury if handled improperly.

  • Page 168: Transportation

    OPERATION TRANSPORTATION When transporting the machine, observe all applicable laws and regulations and be careful to assure safety. Transportation Procedure As a general rule, always transport the machine on a trailer. When selecting a trailer and transporting the machine, choose the optimum transportation method in reference to the weight and dimensions shown in “SPECIFICATIONS”...

  • Page 169: Securing Machine

    OPERATION Securing Machine Secure the machine to the trailer in the following manner. Lower the work equipment slowly. Set the safety lock lever to LOCK to lock the work equipment control levers securely. Set the parking brake switch to the ON position to apply the parking brake.

  • Page 170: Unloading Machine

    OPERATION Retract the antenna fully. 10. Adjust the mirrors so that they are within the width of the trailer. 11. Protect the exhaust stack from moisture, if necessary. Unloading Machine ★ When unloading the machine, always use ramps or a platform. ★...

  • Page 171: Lifting Machine

    ★ The method of lifting may differ depending on the attachments and options installed. ★ For details of the procedure for machines that do not conform to standard specifications, contact your Komatsu distributor. ★ For details of the weight, see “SPECIFICATIONS” on page 4-2.

  • Page 172: Lifting Position Marks

    OPERATION Lifting Position Marks Weight Table Center of Gravity Operating Weight Front Wheel Load Rear Wheel Load (from front axle) 28.220 kg 13,090 kg 15,130 kg 1,920 mm WA500-3LK (62,214 lb) (28,859 lb) (33,356 lb) (6.3 ft) 2-106 WA500-3LK...

  • Page 173: Lifting Procedure

    OPERATION Lifting Procedure ★ Lifting work can be carried out only for machines with hook mark labels (lifting marks). ★ Before starting the lifting operation, stop the machine on level ground. Use the following procedure to set the machine in the proper posture and use the lifting equipment when lifting the machine. Start the engine;...
  • Page 174 OPERATION Use wire ropes, slings, spreader bars, and other lifting equipment that match the weight of the machine. • Fit the lifting equipment to the lifting hooks (indicated by hook marks) at the front of the front frame and the rear of the rear frame.

  • Page 175: Cold Weather Operation

    Use Komatsu Supercoolant (AF-NAC). We do not recommend the use of any coolant other than Komatsu genuine supercoolant. When using Komatsu Supercoolant (AF-NAC), there is no need to use a corrosion resistor; see “Clean Inside of Cooling System” on page 3-24.

  • Page 176: Battery

    OPERATION Battery • The battery generates flammable gas. Do not bring fire or sparks near the battery. • Battery electrolyte is dangerous. If it gets in your eyes or on your skin, wash it off with a large amount of water and consult a doctor immediately.

  • Page 177: Warming-Up Operation For Steering Hydraulic Circuit

    OPERATION Warming-Up Operation for Steering Hydraulic Circuit • If the oil temperature is low, when the steering wheel is turned and stopped there may be a time lag before the machine turns and stops. • Set the safety bar to the LOCK position to ensure safety. •...

  • Page 178: Long-Term Storage

    Disconnect the negative terminals of the battery. Cover the battery or remove it from the machine and store it separately. • Set the lock lever to the LOCK position to prevent the machine from moving. • To prevent corrosion, fill the cooling system with Komatsu genuine Supercoolant (AF-NAC) (density between 30% and 68%). During Storage •...

  • Page 179: After Storage

    After Storage Remark If the machine has been stored without carrying out the monthly rust-prevention operation, contact your Komatsu distributor before returning the machine to operation. Before returning the machine to operation after a long-term period of storage, do the following procedure.

  • Page 180: Troubleshooting

    OPERATION TROUBLESHOOTING When Machine Runs Out of Fuel Always watch the fuel level and be careful not to run out of fuel. • This engine is made off higher precision parts than on the conventional fuel injection pump and nozzle. If dirt gets into the fuel system, it will cause problems.
  • Page 181 OPERATION Loosen the knob of priming pump (3), then pump the knob and check that the fuel comes out from air bleed plug (2). Tighten air bleed plug (2). Tightening torque: ... 7.8 to 9.8 N•m (69.0 to 86.7 lbf in) Loosen air bleeder (4) of the supply pump.

  • Page 182: Towing The Machine

    “SPECIFICATIONS” on page 4-2. Do not tow any load greater than this. For details about the procedure for towing a machine when it has broken down, contact your Komatsu distributor. ★ This machine must not be towed except in emergencies. When towing the machine, take the following precautions.

  • Page 183: When Engine Can Be Used

    OPERATION • When towing a machine, tow it at a low speed of less than 2 km/h (1.2 mph) and for a distance of a few meters to a place where repairs can be carried out. The machine should be towed only in emergencies. If the machine must be moved long distances, use a transporter. •...

  • Page 184: Releasing Parking Brake

    OPERATION Releasing Parking Brake • When releasing the parking brake, stop the machine on level ground and check that the surrounding area is safe. If it is necessary to release the brake on a slope in an emergency, block the tires before starting the operation. •...

  • Page 185: Emergency Travel Operation

    The normal gearshifting operation is carried out by electric signals. If there is a failure in the electrical system and the machine does not move, contact your Komatsu distributor to have the machine moved. Remark Always ask your Komatsu distributor to carry out the emergency travel operation. WA500-3LK 2-119...

  • Page 186: If Battery Is Discharged

    OPERATION If Battery is Discharged Precautions • It is dangerous to charge a battery when it is mounted on a machine. Make sure that it is removed before charging. • When checking or handling the battery, stop the engine and turn the starting switch key to the OFF position. •...

  • Page 187: Precautions For Charging Battery

    OPERATION Precautions for Charging Battery • If you do not handle the battery correctly when charging it, there is danger that the battery may explode. • Always follow the instructions in “If Battery is Discharged” on page 2-120 and the instruction manual accompanying the charger.

  • Page 188: Starting Engine With Booster Cable

    OPERATION Starting Engine With Booster Cable Precautions When Connecting or Disconnecting Booster Cable • When connecting the cables, never let the positive (+) and negative (-) terminals contact each other. • When starting the engine with a booster cable, always wear safety glasses and rubber gloves. •...

  • Page 189: Starting Engine

    OPERATION Starting Engine • Always check that the safety lock lever is set to the LOCK position, regardless of whether the machine is working normally or has failed. • Check that all the control levers are at the HOLD or neutral position. Make sure the clips are firmly connected to the battery terminals.
  • Page 190 OPERATION MEMORANDUM 2-124 WA500-3LK...

  • Page 191: Other Troubleshooting

    Electrical System • ( ): Always contact your Komatsu distributor when dealing with these items. • In cases of abnormalities or causes which are not listed below, contact your Komatsu distributor for repairs. Problem Main Causes Remedy Lamp does not glow brightly even •...

  • Page 192: Chassis

    OPERATION Chassis • ( ): Always contact your Komatsu distributor when dealing with these items. • In cases of abnormalities or causes which are not listed below, contact your Komatsu distributor for repairs. Problem Main Causes Remedy Transmission • Parking brake applied.
  • Page 193 OPERATION Problem Main Causes Remedy Steering • Defective hydraulic system • (Check, repair.) Steering wheel is heavy. • Lack of oil • Add oil to specified level. * See EVERY 100 HOURS SERVICE. • Play in steering cylinder pin • Grease bearing or replace pin and bushing where there is play.

  • Page 194: Engine

    Engine • ( ): Always contact your Komatsu distributor when dealing with these items. • In cases of abnormalities or causes which are not listed below, contact your Komatsu distributor for repairs. Problem Main Causes Remedy • Engine oil pan level is low (sucking in air).
  • Page 195 OPERATION Notes * See “Check Before Starting Engine” on page 2-45. ** See “Every 500 Hours Service” on page 3-53. *** See “When Required” on page 3-21. **** See “ELECTRICAL” on page 2-40. WA500-3LK 2-129...

  • Page 196: Relationship Of Electronic Control System

    OPERATION Relationship of Electronic Control System If an error code is displayed on the main monitor portion (normally the speedometer display) of the machine monitor, follow the corresponding table to carry out self-diagnostic troubleshooting. Option Transmission Control System Error ECSS Control System Work Equipment Control System Code Problem...
  • Page 197 OPERATION Option Error Joystick Control System Electronic Governor System Alarm Action by Operator Code Buzzer Problem Condition of Problem Condition of System Machine system machine Disconnection, Returns to short circuit, or neutral short circuit (possible to Normal work possible with with ground in manual switch) manual operation...
  • Page 198 OPERATION Option Transmission Control System Error ECSS Control System Work Equipment Control System Code Problem Condition of Problem Condition of Problem Condition of System Machine System Machine System Machine E01 + CALL 2-132 WA500-3LK...
  • Page 199 OPERATION Option Error Joystick Control System Electronic Governor System Alarm Action by Operator Code Buzzer Problem Condition of Problem Condition of System Machine system machine Short circuit in Drop in output Boost pressure Drop in output; sensor black smoke when accelerating Common rail Deterioration in...
  • Page 200 OPERATION Option Transmission Control System Error ECSS Control System Work Equipment Control System Code Problem Condition of Problem Condition of Problem Condition of System Machine System Machine System Machine Fill switch short Becomes neutral; Wiring harness on Remote circuiting with travel impossible damping solenoid positioner...
  • Page 201 OPERATION Option Error Joystick Control System Electronic Governor System Alarm Action by Operator Code Buzzer Problem Condition of Problem Condition of System Machine system machine Power supply Engine stops Drive circuit Drop in performance; deterioration in emission; engine stops; black smoke; white smoke Stop machine;...

  • Page 202: Transmission Control System

    OPERATION Transmission Control System Problem System Error Code Item Short Circuit Disconnection Backup lamp relay None – – F ECMV Solenoid R ECMV Solenoid 1st ECMV Solenoid 2nd ECMV Solenoid 3rd ECMV Solenoid 4th ECMV Solenoid None Joystick direction switch signal Direction switch signal Range switch signal Travel speed sensor...

  • Page 203: Ecss Control System

    OPERATION ECSS Control System Problem System Error Code Item Short Circuit Disconnection ECSS relay Joystick Control System Problem System Error Code Item Short Circuit Disconnection Joystick caution relay Steering R (right) solenoid Steering L (left) solenoid Steering R (right) short circuit at solenoid HOT end Steering L (left) short circuit at solenoid HOT end Steering solenoid cut relay Abnormality in joystick neutral switch...

  • Page 204: Electronic Governor Control System

    OPERATION Electronic Governor Control System Electronic Governor Error Code Item Controller Fault Code Power source abnormality 1 Abnormality in common rail pressure (control system 2nd stage) No-force feed of pump (2nd stage) Abnormality in controller (drive circuit) Abnormality in Ne sensor Abnormality in G sensor Abnormality in accelerator sensor Abnormality in boost pressure sensor...
  • Page 205 3MAINTENANCE WA500-3LK...

  • Page 206: Guides To Maintenance

    Check service meter reading every day to see if it is time for any necessary maintenance to be performed. Komatsu Genuine Replacement Parts • Use Komatsu genuine parts specified in the Parts Book as replacement parts. Komatsu Genuine Oils •...

  • Page 207: Welding Instructions

    MAINTENANCE Welding Instructions • Turn the engine starting switch off; wait for approximately one minute; then disconnect the battery negative (-) terminal. • Do not apply more than 200V continuously. • Connect grounding cable within 1 m (3.3 ft) of the area to be welded. •...

  • Page 208: Precautions When Installing Hydraulic Hoses

    MAINTENANCE Precautions When Installing Hydraulic Hoses • When removing parts at locations where there are O-rings or gasket seals, clean the mounting surface and replace with new parts. • When doing this, do not forget to assemble the O-rings and gaskets when installing the hoses. •...

  • Page 209: Outlines Of Service

    • If the oil in the work equipment is not clear, there is probably water or air getting into the circuit. ★ In such cases, contact your Komatsu distributor for inspection and repair. • When changing the oil, always replace the related filters at the same time.

  • Page 210: Fuel

    • When using commercially available oil, it may be necessary to reduce the oil change interval. • We recommend that you use the Komatsu oil clinic to carry out a detailed check of the characteristics of the oil. Fuel •...

  • Page 211: Grease

    MAINTENANCE • When diluting the antifreeze coolant, use distilled water or tap water (soft water). • Natural water, such as river water or well water (hard water), contains large amounts of minerals (calcium, magnesium, etc.). This makes it easier for scale to form inside the engine or radiator. Once scale is deposited inside the engine or radiator, it is extremely difficult to remove it.

  • Page 212: Performing Kowa (Komatsu Oil Wear Analysis)

    Performing KOWA (Komatsu Oil Wear Analysis) KOWA (Komatsu Oil Wear Analysis) is a maintenance service that makes it possible to prevent machine failures and downtime. With KOWA, the oil is periodically sampled and analyzed. This enables early detection of wear of the machine drive parts and other abnormalities.

  • Page 213: Storing Oil And Fuel

    • External electromagnetic interference may cause malfunction of the control system controller. • Before installing a radio receiver or other wireless equipment, contact your Komatsu distributor. • When working at the seashore, carefully clean the electrical system to prevent corrosion.

  • Page 214: Wear Parts

    As a result of Komatsu’s continuous efforts to improve product quality, part numbers may change. • When ordering parts, always inform your Komatsu distributor of your machine serial number so he can check for the latest part number. Wear Parts List The parts in parentheses are to be replaced at the same time.

  • Page 215: Recommended Fuel, Coolant, And Lubricants

    MAINTENANCE RECOMMENDED FUEL, COOLANT, AND LUBRICANTS • Komatsu genuine oils are formulated to maintain the reliability and durability of Komatsu construction equipment and components. • In order to keep your machine in the best condition for long periods of time, it is essential to follow the instructions in this manual.

  • Page 216: Fuel, Coolant, And Lubricant Ambient Temperature Chart

    MAINTENANCE Fuel, Coolant, and Lubricant Ambient Temperature Chart Axle Engine Oil Transmission Hydraulic Fuel Cooling Reservoir Capacity (front and Pins Case System Tank System rear) (each) Specified Liters – US gal 11.1 18.5 75.0 20.6 – 118.9 26.2 Refill Liters –...

  • Page 217: Recommended Brands, Other Than Komatsu Genuine Oil

    • To maintain the anticorrosion properties of Supercoolant (AF-NAC), always keep the density of Supercoolant between 30% and 68%. Recommended Brands, Other Than Komatsu Genuine Oil When using commercially available oils other than Komatsu genuine oil, consult your Komatsu distributor. WA500-3LK 3-13...

  • Page 218: Standard Tightening Torques For Bolts And Nuts

    Unless otherwise specified, tighten the metric nuts and bolts to the torque shown in the following table. • If it is necessary to replace any nut or bolt, always use a Komatsu genuine part of the same size as the part that was replaced. Tightening Torque Table...
  • Page 219 MAINTENANCE ★ Use the following table for hydraulic hoses. Taper Seal Width Tightening Torque Thread across Diameter Flats Target Value Permissible Range N•m lbf ft N•m lbf ft 14.7 10.8 12.7 – 16.7 1.3 – 1.7 9.4 – 12.3 29.4 21.7 27.5 –...

  • Page 220: Periodic Replacement Of Safety-Critical Parts

    In addition, to further improve safety, the parts in the Safety Critical Parts List must also be replaced at the specified interval. These parts are closely related to safety and fire prevention; please contact your Komatsu distributor to have them replaced.
  • Page 221 MAINTENANCE Safety Critical Parts List Safety Critical Parts for Periodic Replacement Replacement Interval Fuel hose (fuel tank - fuel strainer) Fuel hose (fuel strainer - injection pump) Fuel return hose (injection pump - fuel tank) Fuel hose (injection nozzle - fuel filter) Fuel spill hose (engine output connector - fuel tank) Steering hose (pump - steering valve) Steering hose (steering valve - steering cylinder)

  • Page 222: Maintenance Schedule Chart

    MAINTENANCE MAINTENANCE SCHEDULE CHART This schedule outlines the maintenance to be performed on the machine according to the hours accumulated on the machine. Following this schedule will prolong the life of the machine. Section - Page Maintenance Interval and Item INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS) REPLACE TRANSMISSION OIL FILTER ELEMENT.

  • Page 223: Replace Transmission Oil Filter Element

    MAINTENANCE EVERY 500 HOURS SERVICE CHANGE OIL IN ENGINE PAN, REPLACE ENGINE OIL FILTER CARTRIDGE ....3-53 REPLACE FUEL FILTER CARTRIDGE ..........3-55 REPLACE TRANSMISSION OIL FILTER ELEMENT.

  • Page 224: Service Procedure

    MAINTENANCE SERVICE PROCEDURE Initial 10 Hours Service Carry out the following maintenance every 10 hours for the first 50 hours of operation of a new machine. • Lubricating • For details, see “Every 100 Hours Service” on page 3-44 and “Every 250 Hours Service” on page 3-46. Initial 250 Hours Service Perform the following maintenance only after the first 250 hours.

  • Page 225: When Required

    MAINTENANCE When Required Check, Clean, Replace Air Cleaner Element • If inspection, cleaning, or maintenance is carried out with the engine running, dirt will get into the engine and damage it. Always stop the engine before carrying out these operations. •...
  • Page 226 MAINTENANCE Remove lock (1) from the cover, then remove cover (2). Remove outer element (4). Clean the inside and the cover of the air cleaner body. Direct dry compressed air (less than 0.69 MPa (100.1 psi)) from the inside of the outer element along its folds. Then direct the compressed air from the outside along the folds, and again from the inside.
  • Page 227 MAINTENANCE Install cover (2). 10. Return the red display of the dust indicator to its original position. Replacing Inner Element Remark The inner element must not be used again even after cleaning. When replacing the outer element, replace the inner element at the same time. Since the inner element is replaced every time that you replace the outer element, the cover has already been removed, the outer element is outside the air cleaner, and...

  • Page 228: Clean Inside Of Cooling System

    4,000 hours. • As a basic rule, we do not recommend the use of any coolant other than Komatsu genuine Supercoolant (AF-NAC). • If you use another coolant, it may cause serious problems such as corrosion of the engine and parts of the cooling system that use light medals, such as aluminum.
  • Page 229 MAINTENANCE • When deciding the proportions for mixing the coolant with water, check the lowest recorded temperature for your area and use the Water and Supercoolant Mix Ratio table to decide the mixing ratio. Water and Supercoolant Mix Ratio Table °C Min.
  • Page 230 MAINTENANCE Check that the surface of the radiator cap is cool enough to be touched by hand. Turn radiator cap (2) slowly to release the pressure. Remove the radiator cap. Set a container in position to catch the antifreeze mix. Open drain valve (3) at the radiator lower tank and drain plug (4) of the engine;...
  • Page 231 MAINTENANCE 17. Add coolant mixed with antifreeze until it overflows from the water filler. • Determine the proportions of antifreeze and water according to the “Water and Supercoolant Mix Ratio Table” on page 3- 18. To bleed air from the cooling system, run the engine at low idle for five minutes, and for a further five minutes at high idle.

  • Page 232: Check Transmission Oil Level, Add Oil

    MAINTENANCE Check Transmission Oil Level, Add Oil • The parts and oil are VERY HOT immediately after the engine is stopped and may cause burns, if touched. • Wait for the temperature to drop before starting the work. ★ Do this procedure if there is any sign of oil on the transmission case or if there is oil mixed with the cooling water. Remark Wait for at least eight hours after stopping the engine before carrying out the inspection.
  • Page 233 MAINTENANCE Fully insert dipstick (G) into filler pipe (F) and then remove it. ★ The oil level should be between the H and L marks on dipstick (G). • If the oil level is below the L mark: add oil through oil filler (F).

  • Page 234: Check Axle Oil Level, Add Oil

    MAINTENANCE Check Axle Oil Level, Add Oil • When checking the oil level, apply the parking brake and lock the front and rear frames with the safety bar. • After stopping the engine, the parts and oil are VERY HOT. Wait for the temperature to go down before starting this operation.

  • Page 235: Clean Axle Case Breather

    MAINTENANCE Clean Axle Case Breather When cleaning the axle breather, apply the parking brake and lock the front and rear frames with the safety bar. Park the machine on a horizontal surface. Stop the engine. Use a brush to clean off the mud and dirt from around the breather. Remove the breather.

  • Page 236: Clean Air Conditioner Condenser

    MAINTENANCE Clean Air Conditioner Condenser • Do not wash the condenser using a steam cleaner. There is danger that the condenser could overheat. • If high-pressure water hits your body directly or the water sends dirt flying, there is danger of personal injury. •...

  • Page 237: Clean Radiator Fins And Oil Cooler Fins

    If you removed the fan net, replace it before replacing the radiator grill. Replace radiator grill (2) and tighten bolts (1). Check Electrical Intake Air Heater Before the start of the cold season, ask your Komatsu distributor to check the electrical intake air heater for dirt or disconnections. WA500-3LK 3-33...

  • Page 238: Replace Bucket Teeth (If Equipped)

    MAINTENANCE Replace Bucket Teeth (if equipped) • It is extremely dangerous if the work equipment moves when the teeth are being replaced. Set the work equipment in a stable position; stop the engine; and set the safety lock for the work equipment control lever to the LOCK position. •...
  • Page 239 Remove tooth (2). Remark If the tooth cannot be removed by this method, for safety reasons always contact your Komatsu distributor to have the replacement carried out. Clean bucket and adapter (3). Fit new tooth (2) in bucket adapter (3).

  • Page 240: Replace Bucket Tooth With Segment Edge

    MAINTENANCE Replace Bucket Tooth with Segment Edge • It is dangerous if the work equipment moves by mistake when the teeth are being replaced. Set the work equipment in a stable condition; stop the engine; and set the safety lock for the work equipment control lever securely to the LOCK position.

  • Page 241: Turn, Replace Bolt-On Cutting Edge

    MAINTENANCE Turn, Replace Bolt-On Cutting Edge It is extremely dangerous if the work equipment moves by mistake when doing this procedure. Set the work equipment in a stable condition; stop the engine; and set the safety lock for the work equipment control lever securely to the LOCK position. Remark Turn or replace the cutting edge before the wear reaches the edge of the bucket.

  • Page 242: Check Air Conditioner

    ★ If the condition of sight glass (2) is insufficient as shown in the diagram on the right, there is lack of refrigerant. Ask your Komatsu distributor to charge with refrigerant. (After the air conditioner switch is turned ON, bubbles can be seen continuously.)

  • Page 243: Replace Slow-Blow Fuse

    MAINTENANCE Replace Slow-Blow Fuse Remark Always turn the power OFF when replacing the slow-blow fuse (turn the starting switch to the OFF position). Always replace the slow-blow fuse with one of the same capacity. Turn the starting switch to the OFF position. Remove the slow-blow fuse box from the chassis.

  • Page 244: Select Tires

    Use the following table to select the tires according to the conditions of use and the weight of the attachments of the machine. • Since the travel speed indicated on the speedometer varies with the tire size, consult your Komatsu distributor when using optional tires. Maximum Load [kg (lb)]...

  • Page 245: Check Tire Pressure

    MAINTENANCE Check Tire Pressure • When inflating a tire, check that no one enters the working area. • Use an air chuck which has a clip and can be fixed to the air valve. • While inflating the tire, check the inflation pressure occasionally so that it does not rise too high. •...

  • Page 246: Check Before Starting

    MAINTENANCE Check Before Starting For the following items, see “Check Before Starting Engine” on page 2-45. • Check machine monitor • Check dust indicator • Check coolant level, add coolant • Check oil level in engine oil pan, add oil •...

  • Page 247: Every 50 Hours Service

    MAINTENANCE Every 50 Hours Service Drain Water, Sediment from Fuel Tank ★ The fuel tank is located on the right side of the machine. Prepare a container to catch the fuel and place it under the drain valve of the fuel tank. Loosen drain valve (1) on the right side of the fuel tank.

  • Page 248: Every 100 Hours Service

    MAINTENANCE Every 100 Hours Service ★ Maintenance for every 50 hours service should be performed at the same time. Lubricate Rear Axle Pivot Pin Remark There are three lubrication points. Using a grease pump, pump grease in through the grease fittings marked by the arrows.

  • Page 249: Check Oil Level In Hydraulic Tank, Add Oil

    MAINTENANCE Check Oil Level in Hydraulic Tank, Add Oil • The parts and oil are VERY HOT immediately after stopping the engine and may cause burns. Wait for the temperature to decrease before starting the work. • When removing the oil filler cap, turn it slowly to release any internal pressure and then remove it. ★...

  • Page 250: Every 250 Hours Service

    Neutralize the fluid that is removed with baking soda (sodium bicarbonate) and then flush it away with a large amount of water, or consult your Komatsu distributor or battery manufacturer. 3-46...
  • Page 251 UPPER LEVEL (UL) line. Neutralize the removed fluid with baking soda (sodium bicarbonate) and then flush it away with a large amount of water, or consult your Komatsu distributor or battery manufacturer. When It Is Possible to Use Indicator to Check Electrolyte Level If it is possible to use an indicator to check the electrolyte level, follow the instructions provided with the indicator.

  • Page 252: Check Parking Brake

    • Position (b): OFF • The parking brake is released. If there is a problem, contact your Komatsu distributor. Check Alternator Belt Tension, Adjust Checking The standard deflection (a) between the drive pulley and alternator pulley is about 13 to 16 mm (0.51 to 0.63 in) when pressed by a thumb force of 98.1 N (22.1 lbf) at a point midway between the drive pulley...

  • Page 253: Check Air Conditioner Compressor Belt Tension, Adjust

    MAINTENANCE Check Air Conditioner Compressor Belt Tension, Adjust Checking The standard deflection (a) between the air conditioner compressor pulley and the drive pulley should be 8.5 to 11 mm (0.33 to 0.43 in) when pressed with a thumb force of approximately 58.8 N (13.2 lbf) at a midway point.

  • Page 254: Clean Element In Air Conditioner Recirculation Filter

    MAINTENANCE Clean Element in Air Conditioner Recirculation Filter Open filter inspection cover (1) and remove the filter cover (2). Pull out filter (3) in the direction of the arrow. ★ When removing the filter to the side, put your weight on the seat and push down.
  • Page 255 MAINTENANCE ★ (1) Bucket pin (two places) ★ (2) Bucket link pin (two places) ★ (3) Tilt lever pin (one place) ★ (4) Dump cylinder pin (one place) WA500-3LK 3-51...
  • Page 256 MAINTENANCE ★ (5) Lift cylinder pin (four places) ★ (6) Lift arm pivot pin (two places) ★ (7) Dump cylinder bottom pin (one place) ★ (8) Steering cylinder bottom pin (two places) ★ (9) Steering cylinder rod (two places) 3-52 WA500-3LK...

  • Page 257: Every 500 Hours Service

    Loosen drain plug (P) and drain the oil. Check the drained oil. ★ If there are excessive metal particles or foreign material, contact your Komatsu distributor. Install drain plug (P). Using the filter wrench, turn filter cartridge (1) counterclockwise to remove it.
  • Page 258 MAINTENANCE 11. Install the new filter cartridge to the filter holder. ★ When installing the cartridge, bring the seal surface into contact with the filter holder and then tighten a further 3/4 to 1 turn by hand. ★ If you use a filter wrench to tighten the filter, be careful not to scratch or deform the filter.

  • Page 259: Replace Fuel Filter Cartridge

    The common rail fuel injection system used on this machine consists of more precise parts than the conventional injection pump and nozzle. If any part other than a genuine Komatsu filter cartridge is used, dust or dirt may get in and cause problems with the injection system. Never use substitute parts.
  • Page 260 MAINTENANCE ★ The cap (A) covers the large hole (C) at the top of the filter and prevents you from pouring fuel through that hole and into the clean side of the filter. The cap forces you to add the fuel through the eight holes in the dirty side of the filter.

  • Page 261: Replace Transmission Oil Filter Element

    MAINTENANCE Replace Transmission Oil Filter Element • Immediately after the engine is stopped, all parts are VERY HOT. Do not replace the filter immediately. Wait for the engine to cool down before cleaning the engine breather. • High pressure is generated inside the engine fuel piping system when the engine is running. When replacing the filter, wait for at least 30 seconds after the engine stops to let the internal pressure go down before replacing the filter.

  • Page 262: Lubricate Center Drive Shaft Spline

    MAINTENANCE Lubricate Center Drive Shaft Spline ★ One grease point Using a grease pump, pump in grease through the grease fittings marked by the arrow. After greasing, wipe off any grease that was pushed out. Check Fan Belt for Wear •...

  • Page 263: Every 1000 Hours Service

    MAINTENANCE Every 1000 Hours Service Change Oil in Transmission Case, Clean Strainer • Immediately after stopping the engine, the parts and oil are VERY HOT and may cause burns. Wait for the temperature to go down before starting the work. •...

  • Page 264: Clean Transmission Case Breather

    MAINTENANCE 10. Pour in the specified amount of engine oil from oil filler (F). 11. After filling with oil, check that the oil is at the specified level. For details, see “Check Transmission Oil Level, Add Oil” on page 3- 12.
  • Page 265 MAINTENANCE ★ (3) Front drive shaft (three places) ★ (4) Rear drive shaft (three places) ★ (5) Center drive shaft (three places) ★ (6) Upper drive shaft (two places) WA500-3LK 3-61...

  • Page 266: Check Tightening Parts Of Turbocharger

    ★ (9) Fan pulley (one place) ★ (10) Tension pulley (one place) Check Tightening Parts of Turbocharger ★ Contact your Komatsu distributor to have the tightening portions checked. Replace Corrosion Resistor Cartridge ★ Only when corrosion resistor is used. Open the engine side cover located on the right of the engine hood.

  • Page 267: Clean Radiator Subtank Breather

    MAINTENANCE Clean Radiator Subtank Breather Remove all mud and dirt from around the breather. Remove the breather. Immerse the breather in cleaning fluid and clean it. ★ Be careful not to let dirt enter through the mount while the breather is removed.

  • Page 268: Tighten Rops Canopy

    MAINTENANCE Tighten ROPS Canopy Check that there are no loose mounting bolts (1) on the ROPS canopy. ★ Tighten any loose bolts. Tightening torque: ... 927 ±103 N•m (683.7 ±76.0 lbf ft) 3-64 WA500-3LK...

  • Page 269: Every 2000 Hours Service

    MAINTENANCE Every 2000 Hours Service ★ Maintenance for every 50, 100, 250, 500, and 1,000 hours service should be performed at the same time. Change Oil in Hydraulic Tank, Replace Hydraulic Tank Filter Element • The parts and oil are at high temperature immediately after the engine is stopped and may cause burns. Wait for the temperature to go down before starting the work.
  • Page 270 MAINTENANCE Remove mounting bolts (4) of filter cover (3) at one place at the top of the tank, then remove the cover. ★ When the cover is removed, the force of spring (5) may make the cover fly off; keep the cover pushed down when removing the bolts.

  • Page 271: Replace Hydraulic Tank Breather Element

    MAINTENANCE Replace Hydraulic Tank Breather Element • The parts and oil are VERY HOT immediately after the engine is stopped, and may cause serious burns. Wait for the temperature to go down before starting the work. • When removing the oil filler cap, turn it slowly to release the internal pressure and then remove it. Lower the bucket horizontally to the ground and turn the parking brake switch ON.

  • Page 272: Change Axle Oil

    MAINTENANCE Change Axle Oil • Immediately after stopping the engine, the parts and oil are VERY HOT and may cause serious burns. Wait for the temperature to go down before starting the operation. • When the plug is removed, oil may spurt out. Turn the plug slowly to release the internal pressure and then remove the plug carefully.

  • Page 273: Replace Element In Air Conditioner Recirculation Air Filter, Fresh Air Filter

    MAINTENANCE Stop the machine so that drain plug (4) of the final drive is at the bottom. Remove oil filler plug (5) and drain plug (4) and drain the oil. After draining the oil, clean drain plugs (2), (3), and (4) and then install them.

  • Page 274: Clean Engine Breather Element

    Check Alternator, Starting Motor • The brush may be worn or have no grease on the bearing; contact your Komatsu distributor for inspection or repair. ★ If the engine is started frequently, carry out inspection every 1,000 hours. Check Engine Valve Clearance, Adjust ★...

  • Page 275: Check Accumulator Function

    Komatsu distributor to check the accumulator gas pressure. Check Injector Check the exhaust gas color visually. If there is any abnormality in the exhaust gas color, contact your Komatsu distributor for inspection or replacement.

  • Page 276: Every 4000 Hours Service

    ★ If any problem is found, please contact your Komatsu distributor. Check Air Conditioner Compressor, Adjust ★ As a special tool is required for checking and adjusting the parts of the air conditioner compressor, ask your Komatsu distributor for service.

  • Page 277: Check For Loose Engine High-Pressure Piping Clamps, Hardening Of Rubber

    • Check if there is any hardening of the rubber parts. ★ If any problem is found, the part must be replaced. Ask your Komatsu distributor to carry out the replacement. Remark If the engine continues to be used when there are loose bolts, hardened rubber, or missing parts, there is danger of damage or breakage occurring due to vibration and wear at the connections of the high-pressure piping.

  • Page 278: Check For Missing Fuel Spray Prevention Caps, Hardening Of Rubber

    Install rubber caps (1) to (10) with the slit facing the cylinder block. • Install rubber caps (11) to (16) with the slit facing down. ★ If there are any missing caps or cover or the rubber is hardened, please contact your Komatsu distributor for repairs. 3-74 WA500-3LK...

  • Page 279: Every 8000 Hours Service

    ★ Maintenance for every 50, 250, 500, 1,000, 2,000, and 4,000 hours service should be performed at the same time. Replace High-Pressure Piping Clamps ★ Contact your Komatsu distributor to replace the engine high-pressure clamps. Replace Fuel Spray Prevention Caps ★ Contact your Komatsu distributor to replace the fuel spray prevention caps. WA500-3LK 3-75...
  • Page 280 MAINTENANCE MEMORANDUM 3-76 WA500-3LK...
  • Page 281 4SPECIFICATIONS WA500-3LK...

  • Page 282: Specifications

    SPECIFICATIONS SPECIFICATIONS Item Unit WA500-3 Operating weight (including one operator: 75 kg (165 lb)) kg (lb) 28,220 (62,214) Normal load kg (lb) 8,100 (17,857) Bucket capacity (with tip tooth) 4.3 (5.6) (cu.yd) Engine model – SAA6D140E-3E Flywheel horsepower kW(HP)/rpm 235 (316)/2,100 A Overall length (without tooth) mm (ft in) 9,055 (29 ft 9 in)
  • Page 283 SPECIFICATIONS WA500-3LK...
  • Page 284 SPECIFICATIONS MEMORANDUM WA500-3LK...
  • Page 285 5OPTIONS, ATTACHMENTS WA500-3LK...

  • Page 286: Options, Attachments

    ★ BOC indicates a bolt-on cutting edge ★ The displayed travel speed changes according to the tire size. When installing optional tires, contact your Komatsu distributor. ★ On job sites where there are boulders or sharp rocks, install tire protectors (mesh chain).

  • Page 287: Tire Chains

    OPTIONS, ATTACHMENTS TIRE CHAINS When installing tire chains you must be careful that there is sufficient clearance for the tire chain. ★ Refer to “Clearance between Front Fender and Tire” on page 5-3 and “Clearance between Hydraulic Tank and Tire, between Platform and Tire”...
  • Page 288 OPTIONS, ATTACHMENTS Clearance between Hydraulic Tank and Tire, between Platform and Tire Unit: mm Clearances Machine Model Tire Size Tread WA500-3 Standard 26.5–25 1770 – 2400 Large 29.5–25 1870 – 2400 diameter Design 80 or more; 80 or more; standard 65 or more 65 or more when using...

  • Page 289: Electronic-Controlled Suspension System

    Removal of ECSS Piping Do not remove the piping or parts of the ECSS. If they must be removed, ask your Komatsu distributor to carry out the operation.

  • Page 290: Precautions When Handling Accumulator

    Do not make holes in it, weld it, or cut it with a gas cutter. • Do not hit it, roll it, or subject it to any impact. • When disposing of the accumulator, the gas must be removed. Ask your Komatsu distributor to carry out this operation. WA500-3LK...

  • Page 291: Auto-Greasing System

    The lubrication controller is located inside a box under the step on the left side of the machine. If any abnormality occurs in the lubrication controller, inform your Komatsu distributor of the symptoms and ask for repairs. Method of Operation •...

  • Page 292: Lubrication Controller Display

    OPTIONS, ATTACHMENTS Lubrication Controller Display 7-Segment LED Cancel key Level selector key Blade-type fuse Power source LED Greasing LED Warning LED Setting LED Starting key 10. Item selector key Remaining Number for Greasing ★ If the remaining number of times for greasing is less than 10, the 7- segment LED flashes and displays the number.

  • Page 293: Lubrication Controller Display Table

    OPTIONS, ATTACHMENTS Lubrication Controller Display Table Type Item Symptom LED Display 7-Segment Display Counting Power source LED Flashes or numeral When normal lights up flashes Greasing LED I Pump operating lights up Greasing LED II Maintaining pressure flashes slowly (1 time/sec.) When normal Greasing Greasing LED...

  • Page 294: Setting The Greasing Time

    ★ For example, if the machine is used at temperatures below -20°C (-4°F), set the greasing time to 20 minutes (code No. 7). In addition, use lithium-based grease No. 0. When changing the set value, consult your Komatsu distributor. Remark When using the machine at ambient temperatures of below -20°C (-4°F), set to greasing time (b) at code No.

  • Page 295: Procedure For Setting Greasing Time

    OPTIONS, ATTACHMENTS Procedure for Setting Greasing Time ★ When setting the various items, the value is not input directly. Select the code number from the Set Code table; see “Set Code Table” on page 5-10. Stop the working machine on flat, hard ground and stop the engine. Set the safety lock lever at the LOCK position.

  • Page 296: Checking Amount Of Grease

    Replacing Grease Cartridge • Bleeding air from the pump is dangerous because of the high pressure. Ask your Komatsu distributor to bleed the air. • Be careful of the force exerted by spring (2) which is located inside the cover.

  • Page 297: Precautions When Handling Auto-Greasing System

    OPTIONS, ATTACHMENTS Detach cap (5) and middle plug (6) from the new grease cartridge and tightly screw it into the suction port connector. ★ Screw the cartridge in tightly to make sure that no air enters. If when fixing the cartridge to the connector the grease cartridge is pressed slightly so that grease comes out and deposits in a heaped shape, no air will enter if the grease cartridge is screwed into the suction port connector under these conditions.

  • Page 298: Troubleshooting Auto-Greasing System

    OPTIONS, ATTACHMENTS Troubleshooting Auto-Greasing System If any abnormality occurs in the greasing system, the error codes will flash alternately to display the type of abnormality. Error Code Item Cause Remedy E → a Defective • Air in main piping • Run pump as necessary and release grease from pressurizing of end of piping to bleed air.

  • Page 299: Remote Positioner

    OPTIONS, ATTACHMENTS REMOTE POSITIONER This machine is equipped with a remote positioner. From the operator’s seat it is possible to use the remote positioner to set the stopping position of the lift arm and to slow down and stop the lift arm. This feature is designed to increase the operating efficiency and to reduce operator fatigue.

  • Page 300: Operating Remote Positioner

    If the lever is held in position, the lift arm is set to the STOP condition. Adjusting Remote Positioner When the lift arm has been removed or the setting does not work efficiently, contact your Komatsu distributor for adjustment. 5-16 WA500-3LK...

  • Page 301: Setting Remote Positioner Stop Position

    OPTIONS, ATTACHMENTS Setting Remote Positioner Stop Position When RAISE stop display lamp (1) is illuminated, operate the boom lever to raise the lift arm to the desired height (above horizontal), then return the control lever to HOLD and press RAISE position set switch (2). ★...

  • Page 302: Joystick Steering System

    OPTIONS, ATTACHMENTS JOYSTICK STEERING SYSTEM To enable you to use the joystick steering safely and efficiently, read the information in this section before using the system. Structure and Function The joystick steering system is used to steer wheel loaders with a lever instead of a steering wheel.
  • Page 303 OPTIONS, ATTACHMENTS ★ *1: Manual switch • Press the pushbutton switch to turn OFF/ON. • When the switch is pressed once, the pilot lamp lights up and the system is turned ON; when the switch is pressed again, the pilot lamp goes out and the system is switched OFF. •...

  • Page 304: Components

    OPTIONS, ATTACHMENTS Components Normally two control levers are used to operate the bucket and lift arm. With the joystick, the bucket and lift arm can both be operated with the same lever. This makes operation easier because there is no need to switch between levers when carrying out operations.

  • Page 305: Joystick Steering Lever

    OPTIONS, ATTACHMENTS Joystick Steering Lever This lever (1) is used to operate the bucket and lift arm. Operating Bucket • Position (a): Dump • Position (b): HOLD The bucket is kept in the same position. • Position (c): Tilt If the lever is pulled further from the TILT position, the lever stops at that position.

  • Page 306: Kickdown Switch

    OPTIONS, ATTACHMENTS Kickdown Switch When the machine is traveling in F2 and the kickdown switch (2) on the head of the joystick is pressed, the transmission is shifted down to Use this switch when you need to increase the drawbar pull in digging operations.

  • Page 307: Steering With Joystick Lever Or Steering Wheel

    OPTIONS, ATTACHMENTS Steering with Joystick Lever or Steering Wheel • If the directional lever and FNR button on the joystick are not both at the neutral position, the forward and reverse directions of the transmission cannot be switched (from the directional lever to the FNR button on the joystick when the joystick ON/ OFF switch is ON, or from the FNR button on the joystick to the directional lever when the joystick ON/OFF switch is OFF).

  • Page 308: Precautions For Steering With Joystick

    • Before restarting the operation of the machine, find and repair the problem part and confirm that the function is normal. For troubleshooting and repair, contact your Komatsu distributor. • Never operate the machine before it is repaired completely.

  • Page 309: Operating The Joystick Steering System

    OPTIONS, ATTACHMENTS Operating the Joystick Steering System • It is dangerous to turn the machine suddenly at high speed, or to turn on steep hills. Do not operate the steering in such conditions. • When turning, the articulation stops at the position to which the steering wheel is turned. If the joystick is held in the tilted position, the body of the machine will articulate fully.
  • Page 310 OPTIONS, ATTACHMENTS If joystick (4) is turned to the right, the machine turns to the right; if the joystick is turned to the left, the machine turns to the left. ★ The sharper the angle of the joystick, the faster the machine turns.

  • Page 311: Getting In And Out Of Operator's Cab

    OPTIONS, ATTACHMENTS Getting In and Out of Operator’s Cab • Before getting in or out of the operator's cab, turn the joystick ON/OFF switch to the OFF position. • Slide the joystick console backward. If the console is slid backward, safety switch (3) is turned off and operation of the joystick is automatically turned off.

  • Page 312: Adjustments

    OPTIONS, ATTACHMENTS Adjustments • Stop the machine on level ground in a safe place when carrying out the adjustment. • Carry out the adjustment before starting operations or when changing operator shifts. • Put your back against the backrest of the operator's seat and adjust the seat so that it is possible to depress the brake fully before starting the console adjustment.

  • Page 313: Adjusting Air-Suspension Seat

    OPTIONS, ATTACHMENTS Adjusting Air-Suspension Seat • Stop the machine in a safe place before adjusting the operator's seat. • Adjust the seat position at the beginning of each shift or when operators change. • Put your back against the backrest of the operator's seat and adjust the seat so that it is possible to depress the brake fully. •...
  • Page 314 OPTIONS, ATTACHMENTS • (E) Adjusting seat height Move lever (2) up/down, then move the seat up or down as desired. Since lever (2) is also used for adjusting the seat angle, set the seat to the desired height while adjusting the angle. Adjustment range: .

  • Page 315: Car Radio

    OPTIONS, ATTACHMENTS CAR RADIO Components Power switch/volume Tone control knob Display Clock button/Displaying frequency Preset button SEEK Band selector switch Tuning switch WA500-3LK 5-31...

  • Page 316: Power Switch/Volume

    OPTIONS, ATTACHMENTS Power Switch/Volume The power switch (1) turns on the power to the radio and adjusts the volume. • Turn the switch to the right to turn on the power; you will hear a click. • Turn the switch further to the right to adjust the speaker volume. Tone Control Knob The tone control knob (2) controls the tone.

  • Page 317: Ast

    OPTIONS, ATTACHMENTS The AST button (5) is used to call up preset stations. • Press the AST button to call up preset stations in turn. • Press the button again to stop at a broadcasting station. ★ If you keep the button pressed continuously for two seconds, the station is set to auto-memory.

  • Page 318: Tuning Switch

    OPTIONS, ATTACHMENTS Tuning Switch The tuning switch (9) is used t o change the frequency. Press the TUNE ▲ button to increase the frequency. • Press the TUNE ▼ button to decrease the frequency. • • Keep the button pressed to change the frequency continuously. Method of Operation Listening to Radio Use power switch (1) to turn on the power for the radio.

  • Page 319: Setting Preset Buttons

    OPTIONS, ATTACHMENTS Setting Preset Buttons It is possible to preset six AM (MW) stations and six FM stations. Remark If the battery is replaced or the power is switched off, all the preset settings are deleted. It is necessary to repeat the presetting operation to reselect the stations.

  • Page 320: Automatic Switching Of Monaural/Stereo Reception

    OPTIONS, ATTACHMENTS Automatic Switching of Monaural/Stereo Reception If the reception of the FM stereo broadcast is weak (when you are far from the broadcasting station or are surrounded by hills), the radio is automatically switched from stereo to monaural to reduce the interference.
  • Page 321 OPTIONS, ATTACHMENTS MEMORANDUM WA500-3LK 5-37...

  • Page 322: Am/Fm Radio Cassette Stereo Sound System

    OPTIONS, ATTACHMENTS AM/FM RADIO CASSETTE STEREO SOUND SYSTEM Your machine may be equipped with an AM/FM radio-cassette system. Using the radio during machine operations may lead to distractions. When using the radio, always be aware of what you are doing and your operating environment. Do not allow yourself to become distracted. 5-38 WA500-3LK...
  • Page 323 OPTIONS, ATTACHMENTS Power switch/Volume Auto-store/Preset scan button Bass control knob Treble control knob Loudness button Time/Radio display selector button Tape eject button Cassette door Fast forward/Rewind buttons 10. Preset buttons 11. Metal tape button 12. Manual tuning buttons 13. Seek tuning buttons 14.

  • Page 324: Sound System Components

    OPTIONS, ATTACHMENTS Sound System Components Power Switch/Volume Turn the power switch/volume knob (1) to the right to turn the power ON; you will hear a click. • To increase the volume, turn the knob to the right. • To decrease the volume, turn the knob to the left. Auto-Store/Preset Scan Button Use the auto-store/preset scan button (2) to actuate the preset scan and auto-store functions.

  • Page 325: Treble Control Knob

    OPTIONS, ATTACHMENTS Treble Control Knob Use the treble control knob (4) to the control the high tones. • Direction (a): High tone reduced • Direction (b): High tone emphasized Loudness Button Use the loudness button (5) to play the stereo at low volume. This makes it possible to hear more easily by emphasizing the low tone when the low tones are weak.

  • Page 326: Tape Eject Button

    OPTIONS, ATTACHMENTS Tape Eject Button Use the tape eject button (7) to stop the tape and to eject the cassette. When the tape is ejected, the radio plays. Cassette Door Set the cassette with the exposed portion of the tape on the right side and insert it in cassette door (8).

  • Page 327: Metal Tape Button

    OPTIONS, ATTACHMENTS Metal Tape Button Use the metal tape button (11) to play a metal or chrome tape. When it is pressed, “MTL” appears on the display. Remark This button is used also for preset button No. 5. Manual Tuning Buttons Use the manual tuning buttons (12) to change the frequency manually.

  • Page 328: Method Of Operation

    OPTIONS, ATTACHMENTS Method of Operation Setting Preset Buttons It is possible to preset six MW (AM) stations and 12 FM stations (FM1: six stations, FM2: six stations). Remark If you are playing the cassette, press the tape eject button to stop the tape.

  • Page 329: Listening To Radio

    OPTIONS, ATTACHMENTS Listening to Radio Turn the starting switch ON and then turn power switch (1) ON. Set band selector button (2) to AM or FM. Select the station with the preset buttons or manual tuning button (3). Remark In case you do not remember the number assigned to a certain preset station, press the auto-store/preset scan button (4) for less than 0.5 second.

  • Page 330: Reversing The Tape

    • If you cannot hear any sound or nothing is displayed, or any other problem occurs, turn off the power switch and ask your Komatsu distributor to make repairs without delay. • Stow the antenna when traveling in places with low overhead clearance.

  • Page 331: Air Conditioner

    OPTIONS, ATTACHMENTS AIR CONDITIONER Control Panel Fan switch Air conditioner switch Mode selector switch FRESH/RECIRC selector switch Temperature control switch Temperature level indicator lamp WA500-3LK 5-47...

  • Page 332: Fan Switch

    OPTIONS, ATTACHMENTS Fan Switch The fan switch (1) is used to adjust the airflow in four stages. It also acts as the main switch for the air conditioner. • When the OFF switch is pressed, the fan stops. • When the switch is pressed, the indicator lamp above the switch lights up to display the airflow.

  • Page 333: Temperature Control Switch

    OPTIONS, ATTACHMENTS Temperature Control Switch The temperature control switch (5) is used to adjust the air temperature. Press and hold the UP or DOWN button to make the adjustment. The temperature level indicator lamps light up to display the temperature of the air coming from the vents. The more the blue lamps light up, the lower the temperature.

  • Page 334: Method Of Operation

    OPTIONS, ATTACHMENTS Method of Operation Switch Air Conditioner Temperature FRESH/RECIRC Mode Selector Fan Switch Condition of Use Switch Control Switch Selector Switch Switch Rapid All blue RECIRC FACE Cooling More than half are Normal HI - LO FRESH FACE blue Dehumidifying, More than half are HI - LO...

  • Page 335: When Not Using The Air Conditioner Regularly

    Element in Air Conditioner Fresh Air Filter” on page 3-44, and “Clean Element in Air Conditioner Recirculation Filter” on page 3-50. To enable the air conditioner to perform to the fullest and maintain a pleasant working environment, always contact your Komatsu distributor to have the air conditioner refilled with refrigerant and carry out other checks. WA500-3LK 5-51...

  • Page 336: Cool Box

    OPTIONS, ATTACHMENTS Cool Box • When the cooling is being used, this function can be used for keeping drinks and other things cool. • When the heating is being used, it can be used to keep things warm. • When using the box, open the vent grill. •...

  • Page 337: Brake Cooling System

    OPTIONS, ATTACHMENTS BRAKE COOLING SYSTEM An air-cooled oil cooler may be installed to improve the cooling efficiency for the brake cooling oil (axle oil). For machines equipped with the brake cooling system, carry out the following inspection and maintenance. When Required Check Axle Oil Level, Add Oil •...

  • Page 338: Clean Axle Case Breather

    OPTIONS, ATTACHMENTS Clean Axle Case Breather When checking the oil, apply the parking brake and lock the front and rear frames with the safety bar. Park the machine on a horizontal surface. Stop the engine. Use a brush to remove all mud and dirt from around the breather. Remove the breather.

  • Page 339: Every 2000 Hours Service

    OPTIONS, ATTACHMENTS Every 2000 Hours Service Replace Axle Oil and Brake Cooling Oil Filter Cartridge • The parts and oil are at high temperature immediately after the engine is stopped and may cause serious burns. Wait for the temperature to go down before starting the work. •...
  • Page 340 OPTIONS, ATTACHMENTS Stop the machine so that drain plug (4) of the final drive is at the bottom. Remove oil filler plug (5) and drain plug (4), and drain the oil. After draining the oil, clean drain plugs (2), (3), and (4), then install them.

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