Komatsu avance plus WA500-3LK Manuals

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Komatsu avance plus WA500-3LK Operation & Maintenance Manual (340 pages)

WHEEL LOADER

Brand: Komatsu | Category: Compact Loader | Size: 10 MB

Introduction
4
Foreword
4
Safety Information
5
Approved and Non-Approved Uses
6
Approved Functions
6
Non-Approved Functions
6
Visibility Standard
7
Visibility in Immediate Area
7
12-M Radius Visibility
7
Product Identification
8
Directions of Machine
8
Machine Serial Number
9
Engine Serial Number, EPA Regulations
9
Service Meter Location
10
Serial Numbers and Dealer Information
11
Model: WA500-3LK
11
Table of Contents
13
Safety
26
Safety and Warning Decals
26
Location of the Safety Decals
26
Safety Labels
27
Additional Safety Decals
32
General Safety Rules and Precautions
34
General Safety Rules
34
Unauthorized Modifications
34
General Safety at Job Site
35
Working on Loose Ground
35
Safety Features
35
Personal Protective Equipment
36
Fire and Explosion Prevention
36
Fire Caused by Fuel or Oil
36
Fire Caused by Accumulation of Flammable Material
37
Fire Coming from Electrical Wiring
37
Fire Coming from Hydraulic Line
37
Windshield Washer Fluid
37
Action if Fire Occurs
37
Fire Extinguisher and First Aid Kit
38
Mounting and Dismounting
39
Inside Operator's Compartment
40
Precautions When Standing up from Operator's Seat
40
Precautions When Using ROPS
41
Emergency Escape from Operator's Cab
41
Leaving Operator's Compartment
42
Asbestos Hazard Alert
43
Crush or Pinch-Point Dangers
43
Precautions for Ventilation Exhaust Gas
43
Precautions before Starting Operations
44
Pre-Operational Checks
44
Ensure Good Visibility
44
Confirmation of Marks
44
Precaution for Warning Tag
45
Checks before Starting Engine, Adjustments
46
Precautions When Starting
47
Work Site Hazards
47
Avoiding Dangerous Situations
48
Working Clearances
49
Working Near High Voltage Cables
50
Rules for Road Travel
51
Traveling in Reverse
51
Working on Loose or Unstable Ground
52
Operating on Snow or Frozen Surfaces
52
Travel on Slopes
53
Parking the Machine
55
Precautions During Maintenance Operations
56
Warning Tags
56
Equipment Storage
56
Working under the Machine
57
Using Drop Lamps
57
Keeping the Machine Clean
57
Running the Machine During Maintenance
58
Rules for Refueling the Machine
59
Cooling System Precautions
59
Battery Precautions
59
Battery Hazard Prevention
60
Using Jumper Cables
61
Starting the Machine
61
High-Pressure Hoses
62
Safe Handling of High-Pressure Hoses
62
Precautions for High-Pressure Fuel
62
High-Temperature Areas
63
Disposal of Waste Materials
63
Inflating Tires
64
Accumulator
64
Critical Parts
64
High Voltage
65
Maintenance of Air Conditioner
65
General View
68
General View of Machine
68
Controls and Gauges
69
Main Monitor
70
Maintenance Monitor
71
Explanation of Components
72
Machine Monitor System
72
Warning Display
74
Central Check Lamp (CHECK)
75
Central Caution Lamp (CAUTION)
75
Engine Water Level Caution Pilot Lamp
76
Engine Oil Level Caution Pilot Lamp
76
Brake Oil Pressure Caution Pilot Lamp
77
Engine Oil Pressure Caution Pilot Lamp
77
Battery Charge Caution Pilot Lamp
77
Air Cleaner Clogging Caution Pilot Lamp
78
Emergency Steering Pilot Lamp (if Equipped)
78
Front Axle Oil Temperature Warning Lamp (if Equipped)
78
Meter Display Portion
79
Parking Brake Pilot Lamp
80
Engine Preheating Pilot Lamp
80
Front Working Lamp Pilot Lamp
80
Rear Working Lamp Pilot Lamp
80
Transmission Cutoff Pilot Lamp
81
Turn Signal Pilot Lamp
81
High Beam Pilot Lamp
81
Transmission Auto-Shift/Manual Selector Pilot Lamp
81
Fuel Gauge
82
Engine Water Temperature Gauge
82
Torque Converter Oil Temperature Gauge
82
Service Meter
83
Speedometer
83
Transmission Shift Indicator
83
Switches
84
Starting Switch
85
Transmission Cutoff Switch
85
Front Working Lamp Switch
86
Rear Working Lamp Switch
86
Transmission Auto-Shift/Manual Selector Switch
86
Lamp Switch
87
Turn Signal Lever
87
Dimmer Switch
87
Horn Button
87
Hazard Lamp Switch
88
Kickdown Switch
88
Front Wiper Switch
88
Rear Wiper Switch
89
Cigarette Lighter (if Equipped)
89
Room Lamp Switch
89
Parking Brake Switch
90
Power Window Switch
90
Hold Switch
91
Control Levers, Pedals
92
Gearshift Lever
93
Directional Lever
94
Gearshift Lever Stopper
95
Safety Lock Lever (for Work Equipment Lever)
95
Bucket Control Lever
96
Lift Arm Control Lever
96
Brake Pedals
97
Accelerator Pedal
97
Security Locks and Safety Features
98
Steering Column Tilt Lever
98
Cap with Lock
98
Opening the Cap
98
Locking the Cap
99
Safety Bar
99
Towing Pin
100
Backup Alarm
100
Machine Features
101
Cab Door
101
Emergency Escape Right Door
101
Left Cab Door, Opening Lock
103
Left Cab Door, Opening Knob
104
Left Cab Window (Open, Lock, Cancel Knob)
104
Cab Wiper
105
Grease Pump
105
Dust Indicator
105
Electrical
106
Fuses
106
Fuse Capacity and Circuits
106
Slow-Blow Fuses
107
Power Outlet
107
Work Operations
108
Walk-Around Check
108
Precautions before Starting Work Operations
108
Check before Starting Engine
111
Check Machine Monitor
111
Check Dust Indicator
111
Check Coolant Level, Add Coolant
112
Check Oil Level in Engine Oil Pan, Add Oil
113
Check Fuel Level, Add Fuel
114
Check Electric Wiring
115
Check Inflation Pressure of Tires
115
Check Parking Brake
115
Check Brake Pedal
115
Check Waterproof/Fireproof Dividing Walls
116
Adjust Seat
117
Adjust Seat Belt
118
Adjust Wrist Rest Height
119
Adjust Rearview Mirrors
119
Final Checks before Starting Engine
120
Starting Engine
122
Normal Starting
122
Automatic Warming-Up Operation
124
Operations and Checks after Starting Engine
125
Breaking in the Machine
125
Checks after Starting Engine
125
Normal Operation
127
Stopping Engine
128
Check after Stopping Engine
128
Moving the Machine (Directional, Speed), Stopping the Machine
129
Moving the Machine
129
Changing Gear Speed
132
Changing Direction
133
Stopping the Machine
134
Turning
135
Operation of Work Equipment
136
Lift Arm Operation
136
Bucket Operation
137
Work Possible Using Wheel Loader
138
Digging Operations
138
Loading Piled Soil or Blasted Rock
138
Digging and Loading on Level Ground
140
Leveling Operations
141
Pushing Operations
141
Load-And-Carry Operations
141
Loading Operations
142
Cross-Drive Loading
142
V-Shape Loading
142
Preparations for Loading, Gathering Rocks
143
Approaching Facing
143
Digging
144
Traveling in Reverse after Excavation
146
Approaching Dump Truck
147
Loading Dump Truck
147
Reversing Away from Dump Truck
148
Precautions
150
When Piling up Loads
150
When Handling Blasted Rock
150
During Cutting Face Operations
154
When Switching between Forward and Reverse
154
When Turning When Tires Are Stationary
154
Permissible Water Depth
155
When Wheel Brake Does Not Work
155
When Driving up or down Slopes
155
When Driving the Machine
156
Adjusting Work Equipment
157
Adjusting Boom Kickout
157
Adjusting Bucket Positioner
158
Bucket Level Indicator
158
Removing the Bucket
159
Installing the Bucket
160
Parking the Machine
162
Checks after Completion of Operation
164
Before Stopping Engine
164
After Stopping Engine
164
Locking the Machine
164
Handling Tires
165
Precautions When Handling Tires
165
Tire Pressure
166
Precautions for Using Load-And-Carry Method
167
Precautions When Storing Tires
167
Transportation
168
Transportation Procedure
168
Loading and Unloading Trailers
168
Loading Machine
168
Securing Machine
169
Unloading Machine
170
Lifting Machine
171
Lifting Position Marks
172
Lifting Procedure
173
Cold Weather Operation
175
Precautions for Low Temperature
175
Fuel and Lubricants
175
Coolant
175
Battery
176
Warming-Up Operation for Steering Hydraulic Circuit
177
Precautions after Completion of Work
177
When Cold Weather Ends
177
Long-Term Storage
178
Before Storage
178
During Storage
178
After Storage
179
Troubleshooting
180
When Machine Runs out of Fuel
180
Bleeding Air from Fuel Line
180
Towing the Machine
182
When Engine Can be Used
183
When Engine Cannot be Used
183
Releasing Parking Brake
184
Emergency Travel Operation
185
If Battery Is Discharged
186
Precautions
186
Removing the Battery
186
Installing the Battery
186
Precautions for Charging Battery
187
Starting Engine with Booster Cable
188
Precautions When Connecting or Disconnecting Booster Cable
188
Connecting Booster Cable
188
Starting Engine
189
Disconnecting Booster Cable
189
Other Troubleshooting
191
Electrical System
191
Chassis
192
Engine
194
Relationship of Electronic Control System
196
Transmission Control System
202
ECSS Control System
203
Joystick Control System
203
Electronic Governor Control System
204
Guides to Maintenance
206
Check Service Meter
206
Komatsu Genuine Replacement Parts
206
Komatsu Genuine Oils
206
Always Use Clean Washer Fluid
206
Always Use Clean Oil and Grease
206
Checking for Foreign Materials in Drained Oil and on Filters
206
Fuel Strainer
206
Welding Instructions
207
Do Not Drop Things Inside Machine
207
Dusty Work Sites
207
Avoid Mixing Oil
207
Locking Inspection Covers
207
Bleeding Air from Hydraulic Circuit
207
Precautions When Installing Hydraulic Hoses
208
Checks after Inspection and Maintenance
208
Outlines of Service
209
Handling Oil, Fuel, Coolant, and Performing Oil Clinic
209
Oil
209
Fuel
210
Coolant and Water for Dilution
210
Grease
211
Performing KOWA (Komatsu Oil Wear Analysis)
212
KOWA Analysis Items
212
Oil Sampling
212
Storing Oil and Fuel
213
Filters
213
Outline of Electric System
213
Wear Parts
214
Wear Parts List
214
Recommended Fuel, Coolant, and Lubricants
215
Fuel, Coolant, and Lubricant Ambient Temperature Chart
216
Recommended Brands, Other than Komatsu Genuine Oil
217
Standard Tightening Torques for Bolts and Nuts
218
Periodic Replacement of Safety-Critical Parts
220
Maintenance Schedule Chart
222
Replace Transmission Oil Filter Element
223
Service Procedure
224
Initial 10 Hours Service
224
Initial 250 Hours Service
224
Change Oil in Hydraulic Tank, Replace Hydraulic Tank Filter Element
224
When Required
225
Check, Clean, Replace Air Cleaner Element
225
Clean Inside of Cooling System
228
Check Transmission Oil Level, Add Oil
232
Check Axle Oil Level, Add Oil
234
Clean Axle Case Breather
235
Clean Air Conditioner Condenser
236
Check Window Washing Fluid Level, Add Fluid
236
Clean Radiator Fins and Oil Cooler Fins
237
Check Electrical Intake Air Heater
237
Replace Bucket Teeth (if Equipped)
238
Replace Bucket Teeth
238
Replace Bucket Tooth with Segment Edge
240
Turn, Replace Bolt-On Cutting Edge
241
Lubricate Work Equipment Control Valve Linkage
241
Check Air Conditioner
242
Replace Slow-Blow Fuse
243
Select Tires
244
Check Tire Pressure
245
Check before Starting
246
Every 50 Hours Service
247
Drain Water, Sediment from Fuel Tank
247
Every 50 Hours Service Drain Water, Sediment from Fuel Tank
247
Every 100 Hours Service
248
Lubricate Rear Axle Pivot Pin
248
Clean Element in Air Conditioner Fresh Air Filter
248
Check Oil Level in Hydraulic Tank, Add Oil
249
Every 250 Hours Service
250
Check Battery Electrolyte Level
250
Check Parking Brake
252
Check Alternator Belt Tension, Adjust
252
Check Air Conditioner Compressor Belt Tension, Adjust
253
Check for Loose Wheel Hub Nuts, Tighten
253
Clean Element in Air Conditioner Recirculation Filter
254
Lubricating
254
Every 500 Hours Service
257
Change Oil in Engine Oil Pan, Replace Engine Oil Filter Cartridge
257
Replace Fuel Filter Cartridge
259
Replace Transmission Oil Filter Element
261
Lubricate Center Drive Shaft Spline
262
Check Fan Belt for Wear
262
Every 1000 Hours Service
263
Change Oil in Transmission Case, Clean Strainer
263
Every 1000 Hours Service Change Oil in Transmission Case, Clean Strainer
263
Clean Transmission Case Breather
264
Lubricating
264
Check Tightening Parts of Turbocharger
266
Replace Corrosion Resistor Cartridge
266
Clean Radiator Subtank Breather
267
Clean Fuel Strainer
267
Wash Fuel Tank Breather
267
Tighten ROPS Canopy
268
Every 2000 Hours Service
269
Change Oil in Hydraulic Tank, Replace Hydraulic Tank Filter Element
269
Replace Hydraulic Tank Breather Element
271
Change Axle Oil
272
Change Axle Oil (*)
272
Replace Element in Air Conditioner Recirculation Air Filter, Fresh Air Filter
273
Clean PPC Circuit Strainer
273
Clean Engine Breather Element
274
Check Alternator, Starting Motor
274
Check Engine Valve Clearance, Adjust
274
Check Brake Disc Wear
274
Clean and Check Turbocharger
274
Check Play of Turbocharger Rotor
274
Check Accumulator Function
275
Check Accumulator Gas Pressure
275
Check Injector
275
Every 4000 Hours Service
276
Check Water Pump
276
Check Vibration Damper
276
Check Fan Pulley and Tension Pulley
276
Check Air Conditioner Compressor, Adjust
276
Replace Injector
276
Check for Loose Engine High-Pressure Piping Clamps, Hardening of Rubber
277
Check for Missing Fuel Spray Prevention Caps, Hardening of Rubber
278
Every 8000 Hours Service
279
Replace High-Pressure Piping Clamps
279
Replace Fuel Spray Prevention Caps
279
Specifications
282
Options, Attachments
286
Bucket and Tires
286
Tire Chains
287
Electronic-Controlled Suspension System
289
Operating ECSS
289
Precautions When Using ECSS Switch
289
Removal of ECSS Piping
289
Precautions When Handling Accumulator
290
Auto-Greasing System
291
Method of Operation
291
Starting Auto-Greasing
291
Lubrication Controller Display
292
Lubrication Controller Display Table
293
Setting the Greasing Time
294
Setting Greasing Time in Cold Areas
294
Procedure for Setting Greasing Time
295
Checking Amount of Grease
296
Replacing Grease Cartridge
296
Precautions When Handling Auto-Greasing System
297
Troubleshooting Auto-Greasing System
298
Remote Positioner
299
General Locations
299
Operating Remote Positioner
300
Adjusting Remote Positioner
300
Setting Remote Positioner Stop Position
301
Adjusting Sensor
301
Joystick Steering System
302
Structure and Function
302
Components
304
Joystick Steering Lever
305
Kickdown Switch
306
Hold Switch
306
Steering with Joystick Lever or Steering Wheel
307
Precautions for Steering with Joystick
308
Operating the Joystick Steering System
309
Getting in and out of Operator's Cab
311
Adjustments
312
Adjusting Console
312
Adjusting Height of Armrest
312
Adjusting Air-Suspension Seat
313
Car Radio
315
Components
315
Power Switch/Volume
316
Tone Control Knob
316
Display
316
Clock Button/Displaying Frequency
316
Ast
317
Preset Button
317
Seek
317
Band Selector Switch
317
Tuning Switch
318
Method of Operation
318
Listening to Radio
318
Automatic Tuning
318
Manual Tuning
318
Setting Preset Buttons
319
Automatic Memory
319
Automatic Switching of Monaural/Stereo Reception
320
Adjusting Time
320
Precautions When Using
320
Am/Fm Radio Cassette Stereo Sound System
322
Sound System Components
324
Auto-Store/Preset Scan Button
324
Bass Control Knob
324
Treble Control Knob
325
Loudness Button
325
Time/Radio Display Selector Button
325
Tape Eject Button
326
Cassette Door
326
Fast-Forward, Rewind Buttons
326
Preset Buttons
326
Metal Tape Button
327
Manual Tuning Buttons
327
Seek Tuning Buttons
327
Band Selector Button
327
Method of Operation
328
Setting Preset Buttons
328
Using Auto-Preset
328
Using Manual Preset
328
Listening to Radio
329
Listening to Cassette Tape
329
Reversing the Tape
330
Precautions When Using
330
Handling Cassette Tape
330
Air Conditioner
331
Control Panel
331
Fan Switch
332
Air Conditioner Switch
332
Mode Selector Switch
332
FRESH/RECIRC Selector Switch
332
Temperature Control Switch
333
Method of Operation
334
When Not Using the Air Conditioner Regularly
335
Precautions When Using Air Conditioner
335
Inspection and Maintenance
335
Cool Box
336
Brake Cooling System
337
When Required
337
Check Axle Oil Level, Add Oil
337
Clean Axle Case Breather
338
Clean Brake Cooling Oil Cooler Fins
338
Every 2000 Hours Service
339
Replace Axle Oil and Brake Cooling Oil Filter Cartridge
339

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Komatsu avance plus WA500-3LK Operation & Maintenance Manual (340 pages)

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