PDF Operation & Maintenance Manual Komatsu WA500-1L Wheel Loader - 1 MB
This is the Operation and Maintenance Manual for the Komatsu WA500-1L wheel loader, covering serial numbers A20854 and up.
It provides operators with essential instructions on proper machine operation, safety procedures, and daily maintenance checks.
Consistently following the guidelines in this manual is the key to maximizing the loader's service life and ensuring a safe work environment.
It is a fundamental resource for every operator.
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--- Page 1 ---
SERIAL NUMBERS
WA500-1 L A20854 and up
This material is proprietary to Komatsu Dresser Company and is not to be reproduced, used, or disclosed except
in accordance with written authorization from Komatsu Dresser Company.
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 recommended that customers contact their distributor for information on the latest revision.
SEP 93 COPYRIGHT 1993 KOMATSU DRESSER COMPANY
--- Page 3 ---
CONTENTS
Brake Line Failure Monitor ..................................................... 2-7
Engine Oil Pressure Monitor .................................................... 2-8
Engine Coolant Level Monitor. .................................................. 2-8
Air Pressure Monitor ......................................................... 2-8
Engine Coolant Temperature Monitor ............................................. 2-8
Torque Converter Oil Temperature Monitor ......................................... 2-9
Ground Driven Steering Operation Monitor - If Equipped ............................... 2-9
METER AND PILOT LAMP GROUP ............................................... 2-10
Parking Brake Pilot Lamp ..................................................... 2-10
Working Lamp Pilot Lamp .................................................... 2-11
Engine pre-heating pilot lamp .................................................. 2-11
Transmission Cut-Off Selector Pilot Lamp ......................................... 2-11
Air Pressure Gauge ......................................................... 2-w
Engine Coolant Temperature Gauge ............................................. 2-w
Torque Converter Oil Temperature Gauge ......................................... 2-12
FuelLevelGauge .......................................................... 2-13
Turn Signal Pilot Lamp ....................................................... 2-13
High Beam Pilot Lamp ....................................................... 2-13
Speedometer .............................................................. 2-14
Service Meter ............................................................. 2-14
SWITCHES.. .................................................................. 2-15
TRANSMISSION CUT-OFF SELECTOR SWITCH ...................................... 2-15
HORN BUTTON ............................................................. 2-15
HAZARDLAMPSWITCH.. ..................................................... 2-16
PARKING BRAKE SWITCH ..................................................... 2-16
WORKING LAMP SWITCH ...................................................... 2-17
PRE-HEATING SWITCH 2-17
STARTINGSWITCH ... . . . . . . ::::::::::::::::::::::::::::::::::::::::::::::::: 2-17
LAMP SWITCHES ............................................................ 2-18
Lampswitch .............................................................. 2-18
Turn signal lever ........................................................... 2-18
Dimmer switch 2-18
CIGARETTELIGHT’E’R’::::::::::::::::::::::::::::::::::::::::::::::::::::::::: 2-19
TRANSMISSION KICKDOWN SWITCH ............................................. 2-19
FRONTWIPERSWITCH ....................................................... 2-20
REAR WIPER SWITCH ........................................................ 2-20
CAB DOME LAMP SWITCH.. ................................................... 2-21
LEVERSANDPEDALS ........................................................... 2-22
DIRECTIONALLEVER ......................................................... 2-22
SPEED CONTROLLEVER.. .................................................... 2-23
SPEEDCONTROLLEVERSTOPPER .............................................. 2-23
STEERING COLUMN TILT LEVER ................................................ 2-23
ACCELERATOR PEDAL ........................................................ 2-24
BRAKE PEDALS ............................................................. 2-24
Right brake pedal .......................................................... 2-24
Left brake pedal ........................................................... 2-24
LIFTARM CONTROLLEVER .................................................... 2-25
BUCKETCONTROLLEVER ..................................................... 2-25
FRONT ATTACHMENT CONTROL LEVER - IF EQUIPPED 2-26
WORK EQUIPMENT CONTROL LEVER LOCK ......... :::::::::::::::: ::::: ::::::::: 2-26
CAB DOOR HOLD OPEN LOCK - IF EQUIPPED ........................................ 2-26
AIR CLEANER SERVICE INDICATOR ................................................. 2-26
FRAME LOCKING BAR ........................................................... 2-27
MAIN CIRCUIT BREAKER ......................................................... 2-27
FUSE BOXES .................................................................. 2-27
OPERATOR’SSEAT ............................................................. 230
FORWARD-BACKWARD ADJUSTMENT ............................................ 230
SEATANGLEADJUSTMENT .................................................... 230
WEIGHTADJUSTMENT ....................................................... 2-30
BACKREST TILT ADJUSTMENT .................................................. 2-30
HEIGHTADJUSTMENT.. ...................................................... 2-30
o-7
--- Page 4 ---
SAFETY PRECAUTIONS
NEVER allow anyone near the center articulation pivot. If the machine turned, they could be crushed.
NEVER allow anyone to stand on the ladder when the bucket is raised or the machine is moving or turning to
prevent injury from falling, crushing or falling material.
NEVER get on or off the machine while it is moving because serious injury or death could result.
After starting and while operating, observe instruments and warning lights frequently. Investigate any unusual
indications or noises in the machine.
If the engine has a tendency to stall, investigate immediately. Do not operate the machine until the cause has been
corrected.
If noise exposure exceeds 90 dBA for eight hours, wear ear protective equipment.
DRIVING THE MACHINE
Carry the bucket low for maximum visibility and stability when traveling.
Before operating in areas with overhead obstructions, carefully check overhead clearance. Obstructions, such as
guy wires, power lines, tree branches, bridges and building doors could cause a rollover accident.
Drive slowly enough to insure complete control. Slow down when traveling in congested areas or on mud, ice or
other slippery surfaces. Keep a safe distance away from other vehicles, according to the load and ground conditions.
Avoid crossing obstacles, such as ridges, curbs, logs and rocks. If you cannot avoid them, reduce speed and cross
at an angle. Ease up to the breakover point, pass the balance point slowly and ease down on the other side.
Cross ditches and gullies slowly and at an angle after checking that the ground will safely support the machine.
Avoid sidehill travel whenever possible. Drive straight up and down the hill. If the machine starts slipping sideways,
turn downhill immediately.
When traveling on hills with a loaded bucket, travel forward up the hill and in reverse down the hill.
Stop, look and listen before entering a highway. Stay on the right side of the road. Slow down and signal when
turning off.
When roading the machine, engage the hydraulic control lever lock to guard against accidental actuation of the
levers. Personal injury could result if the bucket catches on a ledge in the road.
Do not use the transmission disconnect brake pedal when traveling fast or going downhill because this shlls the
transmission into neutral. Loss of control or damage to the power train could result when the pedal is released and
the transmission is re-engaged.
Never shift the transmission into neutral (N) when traveling downhill. The machine could go out of control or the
power train could be damaged when the transmission is shifted into gear again.
Do not overspeed the engine. Excessive speeds can be hazardous and harmful to the power train. Select the proper
gear before starting downhill. Control speed with the brakes.
Never use the bucket as a brake except in an emergency. It might catch on the ground and result in personal injury.
If the main steering light comes on, IMMEDIATELY stop the machine in a safe place. Shut off the engine and apply
the parking brake. Correct the cause before operating again.
If the brake system warning light or buzzer comes on during operation, IMMEDIATELY stop the machine in a safe
place. Apply the parking brake. Correct the cause before operating again.
1-5
--- Page 5 ---
SAFETY PRECAUTIONS
10
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VIEW A
4 11
1
VIEW B 8
VIEW C
L02AD070
Always keep these product graphics clean. If they are missing or damaged, replace them with a new product
graphic. Replacement product graphics can be ordered from your distributor.
In addition to safety product graphics, the machine has instructional and identification product graphics, which
should be treated in the same manner as described above.
Safety product graphics may be available in languages other than English. To find out more information about
foreign language product graphics, contact your distributor.
I-15
--- Page 6 ---
OPERATION
A. CHECK MONITOR LAMP GROUP
(Check items before starting)
* When the engine is started, these monitor lamps will go off even if there are abnormalities.
* Do not rely on the “CHECK MONITOR LAMP GROUP (Check items before starting)” only for the check before
starting. Always make the checks by referring to the section on ‘CHECKS BEFORE STARTING”.
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1. Brake Oil Level Monitor
This monitor indicates a low brake oil level.
If the monitor lamp flashes, check the oil level in the
brake oil tank and add oil as required.
(0) A
2-5
--- Page 7 ---
OPERATION
SWITCHES
1. TRANSMISSION CUT-OFF SELECTOR SWITCH
This switch selects the operation of the left brake pedal.
Normally, put this switch in ON position.
1. OFF POSITION:
Depressing the left brake pedal operates the wheel
brakes only, like the right brake pedal.
2. ON POSITION:
Depressing the left brake pedal operates the wheel
brakes and also returns the transmission to NEU-
TRAL.
* If the switch is in the ON position, the transmission
cut-off selector pilot lamp will light up.
If the machine has to be started on a slope, always turn the transmission cutoff selector switch to OFF and depress
the left brake pedal. Then depress the accelerator pedal while releasing the left brake pedal to start the machine off
slowly.
2. HORN BUTTON
When the button in the center of the steering wheel is
pressed, the horn will sound.
2-15
--- Page 8 ---
OPERATION
7. LIFT ARM CONTROL LEVER
This lever is used to operate the lift arm.
1 Raise
2 Hold: The lift arm is kept in the same position.
3 Lower
4 Float: The lift arm moves freely under external force.
When the lift arm control lever is pulled further from 1
position, the lever is stopped in this position until lift arm
reaches the preset position of kick-out, and the lever is
returned to the hold position.
8. BUCKET CONTROL LEVER
This lever operates the bucket.
1 Tilt
2 Hold: The bucket is kept in the same position.
3 Dump
When the bucket control lever is pulled further from 1
Tilt
position, the lever is stopped in this position until bucket
reaches the preset position of positioner, and the lever
is returned to the hold position.
Dump
2-25
--- Page 9 ---
OPERATION
METHOD OF OPERATION
OPERATION OF CONTROL PANEL
SWITCH AND LEVER POSITIONS
PURPOSE
Fan Speed Switch Air Conditioner Temperature Air Intake Se-
Switch Control Lever lector Lever
HI ON Full left Left
Cooling
HI - LO ON Full left to near center Right
Dehumidfying and HI - LO ON Center to near right Right
heating
HI OFF Full to near right Left
Heating
HI - LO OFF Center to near right Right
Center to near right - Full
Defrosting HI ON right when carrying out Right
quick defrosting or de-
misting
Ventilation or Pres- HI - LO OFF Full left Right
surizing
AIR VENT SELECTION
VENT POSITION
PURPOSE
Face (1) Foot (2) Defrost (3)
Cooling Open Open or closed Closed
Heating Open or closed Open Open or closed
Defrosting Closed Open or closed Open
Ventilation Open Open Open
* The effectiveness of the heating air conditioning system can be increased by selecting the most suitable vent.
* Do not turn the fan speed switch on when all the vents are closed.
2-35
--- Page 10 ---
OPERATION
* Run the engine with the throttle at the l/3 position or below.
5) Raise the bucket 10 - 30 cm (3.7 - 11.8 in) from the ground, operate the bucket control lever to the tilt
position, relieve the circuit for approximately 5 seconds, then return the lever to the neutral position and hold
it for approximately 2 seconds. Repeat this operation to warm up the work equipment circuit.
* Raise the engine speed gradually from the idling speed.
3. Warm up the steering circuit as follows.
WARNING! If this operation is carried out when the oil temperature is still low, even when the steering
wheel is turned and stopped, there may be a time lag before the chassis turns or stops. In such cases,
a
carry out the warming-up operation in a large open area. In addition, use the safety bar to ensure
safety. In this case, do not relieve the circuit for more than 5 seconds.
4. Turn the steering wheel slowly to the left and right to warm up the oil inside the steering valve. Repeat this
operation about 10 times.
* Turn the steering wheel a short distance, then stop it, and check that the chassis stops according to the amount
the steering wheel is turned.
* The recommended oil for the work equipment hydraulic system depends on the ambient temperature. Select
oil according to the table under “LUBRICANTS, FUEL AND COOLANT” in Section 3.
MOVING MACHINE OFF
1. Check that a warning item is not displayed on the
monitor panel.
2. Free the work equipment control lever lock for the m
equipment control levers. Place the work equipment
in the traveling position.
3. Depress right brake pedal (l), and turn parking
brake switch (2) to OFF to release the parking
brake.
2-45
--- Page 12 ---
OPERATION
PARKING MACHINE
WARNING1 Never leave the machine with the
A engine running or the bucket raised. When
parking the machine, stop the engine, lower
the bucket to the ground, place the
transmission in neutral (N), apply the parking
brake, turn off the electrical starting switch,
and remove the key.
A
WARNING! Park the machine in a non-traffic
area. If parking in traffic lanes cannot be
avoided, provide appropriate flags, barriers,
flares and warning signals. Also provide advance warning signals in the traffic lane for approaching
traffic.
WARNING! Avoid parking on a slop because unexpected machine movement may occur. If necessary
to park on a slope, park at a right angle to the slope and block the tires.
A
WARNING! Before starting the engine or when the machine is standing with the engine running: Place
the transmission in neutral (N), apply the parking brake, and lower all raised work equipment.
A
Park machine in an area free of grease and fuel puddles which cause tire deterioration.
Lower hydraulically supported equipment to the ground to avoid unexpected movement and damage possibilities.
Park on level ground to obtain accurate coolant, lubricant and fuel level checks.
A
WARNINGI Always lock up the machine, including any anti-vandalism attachment, when leaving it
unattended.
2-55
--- Page 13 ---
OPERATION
COLD WEATHER OPERATION
PREPARATION FOR LOW TEMPERATURE
If the temperature becomes low, it may be difficult to start the engine, so do as follows.
FUEL AND LUBRICANTS
Change to fuel and oil with low viscos*ky for all components. For details of the specified viscosity, see “LUBRICANTS,
FUEL AND COOLANT” in Section 3.
COOLANT
l In climates where the temperature is above -37°C (-34°F) use a coolant mixture that contains 50 percent
antifreeze. Antifreeze is essential in any climate. It broadens the operating temperature range by lowering the
coolant freezing point and by raising its boiling point. Do not use more than 50 percent antifreeze in the mixture
unless additional freeze protection is required. Never use more than 88 percent antifreeze under any condition.
A
WARNlNGf Antifreeze is flammable, so keep it away from any flame.
Care in using antifreeze
Use a Permanent Antifreeze (ethylene glycol mixed with corrosion inhibitor, antifoam agent, etc.) meeting the
standard requirements as shown below. With permanent antifreeze, no change of coolant is required for a year.
If it is doubtful that an available antifreeze meets the standard requirements, ask the supplier of that antifreeze
for information.
Standard requirements for permanent antifreeze:
l SAE J1034
. FEDERAL STANDARD 0A-548D
* Never use methanol, ethanol or propanol based antifreeze.
* Where no permanent antifreeze is available, an ethylene glycol antifreeze without corrosion inhibitor may be used
only for the cold season. In this case, clean the cooling system twice a year (in spring and autumn). When
refilling the cooling system, add antifreeze in autumn, but do not add any in spring.
* Absolutely avoid using any water leak preventing agent irrespective of whether it is used independently or mixed
with an antifreeze.
* Do not mix one antifreeze with a different brand.
* For details of changing the coolant, refer to “COOLING SYSTEM” in Section 3.
BATTERY
l As ambient temperature drops, battery capacity will drop, and electrolyte may sometimes freeze if battery charge
is low. Maintain battery at a charge level of approximately 100% and insulate it against cold temperature so that
machine can be easily started.
2-65
--- Page 14 ---
MAINTENANCE
Fire prevention:
Use a nonflammable cleaner or light oil for cleaning parts. Keep flame or cigarette light away from cleaning fluid.
Clamping faces:
When O-rings or gaskets are removed, clean the clamping faces and replace the O-rings and gaskets with new
ones. Be sure to properly fii the O-rings and gaskets when assembling.
Objects in your pockets:
Keep your pockets free of loose objects which can fall out and drop into the machinery; especially when you
work on the machinery while bending over it.
Cleaning machine:
l Do not direct a high-pressure jet directly at the radiator.
l Do not splash water on the electrical components.
Pre- and post-work checks:
Before starting work in mud, rain, snow or at the seashore, check plugs and drain valves for tightness. Wash
the machine immediately after the work to protect components from rusting. Lubricate components more
frequently than usual. Be sure to lubricate work equipment pins daily if they are submerged in water.
Dusty worksites:
When working at dusty worksites, do as follows:
l Check the air cleaner for clogging more frequently. Clean the air cleaner at shorter intervals than specified.
l Clean the radiator core frequently to avoid clogging.
l Replace the fuel filter(s) frequently.
l Clean electrical components, especially the cranking motor and alternator, to avoid accumulation of dust.
Avoid mixing oils:
Never mix oils of different brands. If you have only oil which is a different brand from the one that is used in the
machine, do not add it but replace all the oil.
3-3
--- Page 15 ---
MAINTENANCE
4. AXLE OIL
For axle oil, use only the recommended oil as follows:
SHELL: DONAX lT or TD
CALTEX: RPM TRACTOR HYDRAULIC FLUID
CHEVRON: TRACTOR HYDRAULIC FLUID
TEXACO: TDH OIL
MOBIL: MOBIL AND SUPER UNIVERSAL
* It is possible to substitute engine oil SAE 30W API classification CD for axle oil. Although increased brake noise
may result, durability should not be affected.
5. GREASE
The recommended lubricating grease is No. 2 multi-purpose lithium grease with 3% molybdenum disulfide.
6. DIESEL FUEL
A
WARNING! Do not mix gasoline or alcohol with diesel fuel. This mixture can cause an explosion.
IMPORTANT: Due to the precise tolerances of diesel injection systems, it is extremely important that the fuel be kept
clean and free of dirt or water. Dirt or water in the system can cause severe damage to both the injection pump and
nozzles.
For normal service above -12°C (+ 10” F), the use of ASTM Grade No. 2-D diesel fuel with a minimum Cetane
number of 40 is recommended. The use of No. 2-D diesel fuel will result in optimum engine performance under most
operating conditions. Fuels with Cetane numbers higher than 40 may be needed in high altitudes or extremely low
ambient temperatures to prevent misfires and excessive smoke.
At operating temperatures below -12°C (+ 10” F), use ASTM Grade No. 1-D diesel fuel. The use of lighter fuels can
reduce fuel economy.
Where a winterized blend of Grade No. 2-D and No. 1-D fuels is available, it may be substituted for Grade No. 1-D
fuel. However, it is the supplier’s responsibilty to provide the fuel for the anticipated ambient temperature.
Use a low sulfur content fuel having a cloud point that is at least 10 degrees below the lowest expected fuel
temperature. Cloud point is the temperature at which crystals begin to form in the fuel.
The viscosity of the fuel must be kept above 1.3 cSt to provide adequate fuel system lubrication.
7. COOLANT
General
Selection and maintenance of the engine coolant is important to long engine life. The following information provides
recommendations for selecting the engine coolant and maintaining the coolant inhibitors.
Heavy duty diesel engines require a balanced coolant mixture of water, antifreeze, and supplemental coolant
additives. Supplemental coolant additive recommendations are included in the section entitled “Inhibiiors/Conditione-
rs”. The coolant mixture must be drained and replaced at the specified service interval shown in the “SCHEDULED
MAINTENANCE GUIDE” or every two years of operation, whichever comes first.
Water
Use water which has a low mineral content. Water used in conjunction with antifreeze, coolant filters and inhibited
water must meet the following standards:
3-13
--- Page 16 ---
MAINTENANCE
9 8
LO2ZZO7C
LO222071
3-23
--- Page 17 ---
MAINTENANCE
AIR CONDITIONER REFRIGERANT CHARGE - IF EQUIPPED
Check the air conditioner refrigerant charge twice a year, in spring and autumn.
Operate the air conditioner for 5 - 10 minutes at the coolest setting, then touch the high pressure hose and low
pressure hoses at the refrigerant compressor by hand. Next, check the flow of refrigerant gas (freon 12) through the
sight glass to check the gas level.
Contact your distributor for this inspection.
The sight glass is located on the air conditioner dryer receiver, which is located on the right side of the machine next
to the condenser.
A
WARNING! Air conditioner refrigerant is colorless and odorless and does not cause pollution of the
atmosphere, if handled properly. However, it may cause injury if it gets in the eyes or on the hands,
so never loosen any parts of the refrigerant system.
CONDITION NORMAL ABNORMAL
Temperature of high & High pressure line is hot High pressure line is Almost no difference in
low pressure lines Low pressure line is cold warm temperature between
Clear difference in tem- Low pressure line is cold high & low pressure
perature Liile difference in tem- lines
perature
Sight glass Almost transparent. Any Bubbles are always flow- Misty substance is flow-
bubbles disappear if ing. Sometimes becomes ing.
engine speed is raised or transparent or white
lowered. bubbles appear.
(ZJ @ @
System line connections Properly connected Some parts dirty with oil Some parts very dirty
with oil
General condition of air Refrigerant level correct, May have refrigerant Almost all refrigerant
conditioner no abnomalities. Ready leak. Contact your dis- has leaked out. Contact
for use. tributor for inspection your distributor for im-
and repair. mediate repair.
3-33
--- Page 18 ---
MAINTENANCE
AIR TANKS
Upon completion of work, stop the engine, open drain
valves (l), (2) and (3) and drain water out of the tanks.