PDF Operation & Maintenance Manual Komatsu WA500-6H Wheel Loader - 1 MB
This comprehensive manual provides all the necessary information for the operation and maintenance of the Komatsu WA500-6H Wheel Loader.
It details daily checks, lubrication schedules, and correct operating procedures to maximize performance.
Following this guide is the best way to ensure the longevity and reliability of your equipment.
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SEAM014506T
Operation & Maintenance
Manual
WA500-3
WHEEL LOADER
SERIAL NUMBERS WA500-3 52001 - 52379
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 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, revisions may be made to this publication. It is
recommended that customers contact their distributor for information on the latest revision.
Copyright 2005 Komatsu
Printed in U.S.A.
Komatsu America Corp.
April 2005
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CONTENTS FOREWORD
CONTENTS
FOREWORD 1- 1
FOREWORD 1- 2
SAFETY INFORMATION 1- 5
INTRODUCTION 1- 7
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE 1- 7
NECESSARY INFORMATION 1- 8
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE 1- 8
ENGINE SERIAL NO. PLATE AND POSITION 1- 8
POSITION OF SERVICE METER 1- 9
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR 1- 9
SAFETY 2- 1
SAFETY 2- 2
SAFETY LABELS 2- 5
LOCATION OF SAFETY LABELS 2- 6
GENERAL PRECAUTIONS 2- 13
PRECAUTIONS FOR OPERATION 2- 22
STARTING ENGINE 2- 22
OPERATION 2- 24
TRANSPORTATION 2- 30
BATTERY 2- 31
TOWING 2- 33
PRECAUTIONS FOR MAINTENANCE 2- 34
PRECAUTIONS WITH TIRES 2- 41
OPERATION 3- 1
GENERAL VIEW 3- 2
GENERAL VIEW OF MACHINE 3- 2
GENERAL VIEW OF CONTROLS AND GAUGES 3- 3
EXPLANATION OF COMPONENTS 3- 5
MACHINE MONITOR 3- 5
SWITCHES 3- 17
CONTROL LEVERS, PEDALS 3- 25
STEERING COLUMN TILT LEVER 3- 30
CAP WITH LOCK 3- 31
SAFETY BAR 3- 32
TOWING PIN 3- 32
GREASE PUMP 3- 32
BACKUP ALARM 3- 33
DUST INDICATOR 3- 33
FUSE 3- 33
SLOW BLOW FUSE 3- 34
POWER OUTLET 3- 34
OPERATION 3- 35
CHECK BEFORE STARTING ENGINE, ADJUST 3- 35
STARTING ENGINE 3- 49
OPERATIONS AND CHECKS AFTER STARTING ENGINE 3- 52
STOPPING ENGINE 3- 54
CHECK AFTER STOPPING ENGINE 3- 54
MOVING THE MACHINE (DIRECTIONAL, SPEED), STOPPING THE MACHINE 3- 55
TURNING 3- 60
1 - 10
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SAFETY LABELS SAFETY
(7) Caution for going close to electric cables (09801-13001)
(8) Caution when coolant is at high temperature
(9) Caution when oil is at high temperature
2-8
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GENERAL PRECAUTIONS SAFETY
ACTION IF FIRE OCCURS
If a fire occurs, escape from the machine as follows.
Turn the start switch OFF to stop the engine.
Use the handrails and steps to get off the machine.
WINDOW WASHER LIQUID
Use an ethyl alcohol base washer liquid.
Methyl alcohol base washer liquid may irritate your eyes, so do not use it.
PRECAUTIONS WHEN USING ROPS (Roll Over Protective Structure)
Install ROPS when working in places where there is danger of
falling rocks, such as in mines and quarries, or in places where
there is danger of rolling over.
If ROPS is installed, do not remove it when operating the
machine.
ROPS is installed to protect the operator when machine rolls
over. When machine rolls over, ROPS supports its weight and
absorbs its impact energy.
If the ROPS is welded, or holes are drilled in it, or it is modified
in any other way, its strength may drop. Consult your Komatsu
distributor before carrying out any modification.
If ROPS is damaged or deformed by falling objects or by rolling
over, its strength will be reduced and it will not be able to fulfill
its function properly. In such cases, always Komatsu contact
your distributor for advice of the method of repair.
Even if ROPS is installed, always fasten your seat belt properly
when operating the machine. If you do not use your fasten your
seat belt properly, it cannot display its effect.
PRECAUTIONS FOR ATTACHMENTS, OPTIONS
When installing optional parts or attachments, there may be problems with safety or legal restrictions. Therefore
contact your Komatsu distributor for advice.
Any injuries, accidents, or product failures resulting from the use of unauthorized attachments or parts will not be
the responsibility of Komatsu.
When installing and using optional attachments, read the instruction manual for the attachment, and the general
information related to attachments in this manual.
UNAUTHORIZED MODIFICATION
Any modification made without authorization from Komatsu can create hazards. Before making a modification,
consult your Komatsu distributor.
Komatsu will not be responsible for any injuries, accidents, product failures or other property damages resulting
from modifications made without authorization from Komatsu.
2 - 18
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PRECAUTIONS FOR OPERATION SAFETY
When handling unstable loads, such as round or cylindrical
objects, or piled sheets, if the work equipment is raised high,
there is danger that the load may fall on top of the operator'
compartment and cause serious injury or damage.
When handling unstable loads, be careful not to raise the work
equipment too high or tip the bucket back too much.
If the work equipment is suddenly lowered or suddenly stopped,
the reaction may cause the machine to tip over. Particularly
when carrying a load, be sure to operate the work equipment
carefully.
When operating in tunnels, under bridges, under electric wires,
or other places where the height is limited, be extremely careful
not to let the work equipment hit anything.
To prevent accidents caused by hitting other objects, always
operate the machine at a speed which is safe for operation,
particular in confined spaces, indoors, and in places where there
are other machines.
METHODS OF USING BRAKE
When the machine is traveling, do not rest your foot on the brake pedal. If you travel with your foot resting on the
pedal, the brake will always be applied, and this will cause the brakes to overheat and fail.
Do not depress the brake pedal repeatedly if not necessary.
When traveling downhill, use the braking force of the engine, and always use the right brake pedal at the same
time.
OPERATE CAREFULLY ON SNOW
Snow-covered or frozen surfaces are slippery, so be extremely careful when traveling or operating the machine,
and do not operate the levers suddenly. Even a slight slope may cause the machine to slip, so be particularly
careful when working on slopes.
With frozen ground surfaces, the ground becomes soft when the temperature rises, and this may cause the
machine to tip over.
If the machine enters deep snow, there is a hazard that it may tip over or become buried in the snow. Be careful
not to leave the road shoulder or to get trapped in a snow drift.
When clearing snow, the road shoulder and objects placed beside the road are buried in the snow and cannot be
seen. There is a hazard of the machine tipping over or hitting covered objects, so always carry out operations
carefully.
When traveling on snow-covered roads, always fit tire chains.
When traveling on snow-covered slopes, never apply the foot brake suddenly. Reduce the speed and use the
engine as a brake while applying the foot brake intermittently (depress the brake intermittently several times). If
necessary, lower the bucket to the ground to stop the machine.
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PRECAUTIONS FOR MAINTENANCE SAFETY
ATTACHMENTS
Appoint a leader before starting removal or installation
operations for attachments.
Place attachments that have been removed from the machine in
a stable condition so that they do not fall. And take steps to
prevent unauthorized persons from entering the storage area.
NOISE
If the noise from the machine is too loud, it may cause temporary or permanent hearing problems. When carrying
out maintenance of the engine and you are exposed to noise for long periods of time, wear ear covers or ear plugs
while working.
PRECAUTIONS WHEN USING HAMMER
When using a hammer, pins may fly out or metal particles may be
scattered. This may lead to serious injury. Always do as follows.
If hard metal parts such as pins, bucket teeth, cutting edges, or
bearings are hit with a hammer, there is a hazard that pieces
might be scattered and cause injury. Always wear safety
goggles and gloves.
When hitting pins or bucket teeth, there is a hazard that broken
pieces might be sent flying and injure people in the surrounding
area. Always check that there is no one in the surrounding area.
There is a hazard that the pin hit with strong force may fly out
and injure people in the surrounding area.
REPAIR WELDING
Welding operations must always be carried out by a qualified welder and in a place equipped with proper equipment.
There is a hazard of gas, fire, or electrocution when carrying out welding, so never allow any unqualified personnel
to carry out welding.
REMOVING BATTERY TERMINAL
When repairing the electrical system or when carrying out electrical welding, remove the negative (-) terminal of the
battery to prevent the flow of current.
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EXPLANATION OF COMPONENTS OPERATION
METER DISPLAY PORTION
See (A, C, D) "METER DISPLAY PORTION (PAGE 3-12)".
These consist of the meters (speedometer, fuel gauge, engine water temperature gauge, torque converter oil
temperature gauge, service meter, transmission shift indicator) and the pilot lamps (turn signal indicator, head lamp
Hi beam, preheating, front working lamp, rear working lamp, transmission cut-off, parking brake, transmission auto
shift/manual selector).
OPTION DISPLAY PORTION
(F)
This consists of the monitor lamps and switches for the E.C.S.S., auto-greasing system, and remote positioner.
For details of each system or component, see "ATTACHMENTS, OPTIONS (PAGE 6-1)".
TESTING ACTUATION OF MACHINE MONITOR SYSTEM
When the starting switch is turned to the ON position before starting the engine, all monitor lamps, gauges, and
centralized warning lamps will light up for approx. 3 seconds, and the alarm buzzer will sound for approx. 1 second.
When this happens, 88 is displayed on the speedometer, and 8 is displayed on the transmission shift indicator.
Finally, there will be 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, so please contact your Komatsu
distributor for inspection.
When the starting switch is turned to the ON position, if the directional lever is not at the neutral position, the central
warning lamp (CAUTION) will flash and the alarm buzzer will sound intermittently. If this happens, return the lever
to the neutral position, and the lamps will go out and the buzzer will stop.
The monitor check cannot be carried out for at least 30 seconds after the engine has been stopped.
3-6
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EXPLANATION OF COMPONENTS OPERATION
SPEEDOMETER
This meter (13) indicates the travel speed of the machine.
TRANSMISSION SHIFT INDICATOR
This indicator (14) shows the present speed range of the
transmission.
When the directional lever is at the N position, N is displayed on the
indicator.
When the directional lever is at the F or R position, the shift position
of the speed control lever is displayed as a numeral.
When the auto shift is being used, the transmission speed range is
displayed.
WHEN USING JOYSTICK STEERING SYSTEM
(If equipped)
This indicator (14) shows the present speed range of the transmission.
When the F. N. R. switch at the top of the joystick lever is set to the N position, N is displayed on the indicator. (F
and R are displayed in the small window at the bottom of the speedometer.)
When the FNR switch on the head of the joystick lever is set to the
F or R position, F or R is displayed in the small window at the
bottom of the speedometer and the shift indicator displays the
transmission speed range and N.
3 - 16
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EXPLANATION OF COMPONENTS OPERATION
REMARK
The length of the lever can be adjusted to 3 stages (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.
(The lever is installed to position (B) when it is shipped from the
factory.)
AUTOMATIC SHIFT
Automatic gear shifting can be carried out in the 2nd through 4th
speed range of the four forward and reverse speeds depending on
the travel conditions.
Position (a): 1st
Position (b): 2nd
Position (c): 3rd
Position (d): 4th
The range of speeds during automatic gear shifting is determined
by the position of the gearshift lever as shown in the chart on the
right.
3 - 26
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OPERATION OPERATION
8. Check for damage to gauges, lamps on the instrument panel and loose bolts.
Check for damage to the panel, gauges and lamps. If any abnormality is found, replace the parts. Clean off any
dirt on the surface. Tighten any loose bolts.
9. Check for loose air cleaner mounting bolts.
Check for the loose bolts. If loose, tighten them.
10. Check for loose battery terminals.
Tighten any loose terminal.
11. Check for damage to the seat belt and mounting clamps.
WARNING
Even if there appears to be no abnormality with the seat belt, replace it once every three years.
REMARK
The date of manufacture of the seat belt is marked on the belt at the
place indicated by the arrow in the diagram on the right.
Check that there are no loose bolts on the equipment mounting the
seat belt to the machine, and tighten if necessary.
Tightening torque: 24.5 ± 4.9 N·m (2.5 ± 0.5 kgf·m, 18.1 ± 3.6 lbft)
If the belt is damaged or fluff is starting to form, or if there is any
damage or deformation of the seat belt holders, replace the seat
belt.
12. Check for loose ROPS mounting bolts.
Check for any loose or damaged bolts.
If any loose bolts are found tighten them to 927 ± 103 N·m (94.5 ± 10.5 kgf·m, 683.5 ± 75.9 lbft).
If any bolts are damaged, replace them with genuine Komatsu bolts.
13. Clean cab window.
Clean the cab window to ensure good visibility when operating the machine.
3 - 36
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OPERATION OPERATION
WRIST REST HEIGHT ADJUSTMENT LEVER
The height of lift rest (1) can be adjusted easily with adjustment
lever (2). Turn adjustment lever (2) in the loosening direction and
adjust the height of lift rest (1) properly, then turn adjustment lever
(2) to the fixing direction.
Position (a): Loosening direction
Position (b): Fixing direction
REMARK
If adjustment lever (2) is pulled towards the seat, the lever
becomes free and faces directly down.
ADJUST REAR VIEW MIRROR
Sit in the operator's seat and adjust the rear view mirror so that you
can see properly to the rear.
3 - 46
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OPERATION OPERATION
4. Depress right brake pedal (8) and turn parking brake switch (9)
to the OFF (RELEASE) position to release the parking brake.
Keep right brake pedal (8) depressed.
REMARK
If the parking brake is still actuated when parking brake switch (9)
is at the OFF (RELEASE) position, turn the parking brake switch
ON, then turn it OFF again.
5. Set gearshift lever (10) to the desired position.
6. Set directional lever (11) to the desired position.
7. Release right brake pedal (8), then depress accelerator pedal
(3) to move the machine off.
REMARK
When moving the machine off on a hill, turn transmission cut-off
switch (1) OFF, depress left brake pedal (2), operate the gearshift
lever to the low speed range, then depress accelerator pedal (3)
and gradually release left brake pedal (2) to let the machine move
off. This makes it possible to prevent the machine from rolling
back.
3 - 56
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OPERATION OPERATION
LEVELING OPERATIONS
NOTICE
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.
1. Scoop soil into the bucket. Move the machine backward while
spreading soil from the bucket little by little.
2. Go over the spread soil with the bucket teeth touching the
ground and level the ground by back-dragging.
3. Scoop some more soil into the bucket, put the lift arm control
lever in FLOAT position, level the bucket at ground level, and
smooth the ground by moving backward.
PUSHING OPERATION
CAUTION
Never set the bucket to the DUMP position when carrying out pushing operation.
When carrying out pushing operations, set the bottom of the bucket parallel to the ground surface.
LOAD AND CARRY OPERATIONS
WARNING
When carrying a load, lower the bucket to lower the center of gravity when
traveling.
The load and carry method for wheel loaders consists of a cycle of
scooping -> hauling -> loading (into a hopper, truck, etc.).
Always keep the travel path properly maintained.
When using the load and carry method, see "PRECAUTIONS
FOR USING LOAD AND CARRY METHOD (PAGE 3-80)".
3 - 66
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OPERATION OPERATION
PARKING MACHINE
WARNING
Avoid stopping suddenly. Give yourself ample room when stopping.
Do not park the machine on slopes.
If the machine has to be parked on a slope, set it facing directly down the
slope, then dig the bucket into the ground and put blocks under the tires
to prevent the machine from moving.
If the control lever is touched by accident, the work equipment or the
machine may move suddenly,and this may lead to a serious accident.
Before leaving the operator's compartment, always set the safety lock
lever securely to the LOCK position.
Even if the parking brake switch is turned ON, there is danger until the
parking brake pilot lamp lights up, so keep the brake pedal depressed.
NOTICE
Never use the parking brake switch to brake the machine when traveling
except in an emergency. Apply the parking brake only after the machine
has stopped.
1. Release accelerator pedal (1), then depress brake pedal (2) to
stop the machine.
2. Place directional lever (3) in N (neutral) position.
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COLD WEATHER OPERATION OPERATION
COLD WEATHER OPERATION
PRECAUTIONS FOR LOW TEMPERATURE
If the temperature becomes low, it becomes difficult to start the engine, and the coolant may freeze, so do as follows.
FUEL AND LUBRICANTS
Change to fuel and oil with low viscosity for all components.
For details of the specified viscosity, see "RECOMMENDED FUEL, COOLANT, AND LUBRICANT (PAGE 4-9)".
COOLANT
WARNING
Antifreeze is toxic. Be careful not to get it into your eyes or on your skin. If it should get into your eyes or on your skin, wash
it off with large amounts of fresh water and see a doctor at once.
When changing the coolant or when handling coolant containing antifreeze that has been drained when repairing the radiator,
please contact your Komatsu distributor or request a specialist company to carry out the operation. Antifreeze is toxic. Do not
let it flow into drainage ditches or spray it onto the ground surface.
Antifreeze is flammable. Do not bring any flame close. Do not smoke when handling antifreeze.
NOTICE
Use Komatsu Supercoolant wherever available, or use permanent type antifreeze coolant.
Never use methanol, ethanol, or propanol-based antifreeze.
Do not use any water leakage prevention agent, either alone, or in combination with antifreeze.
Do not mix one brand of antifreeze with a different brand.
For details of the antifreeze mixture when changing the coolant, see "CLEAN INSIDE OF COOLING SYSTEM
(PAGE 4-21)".
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TROUBLESHOOTING OPERATION
CONNECTING THE BOOSTER CABLE
Keep the starting switch of the normal machine and problem machine in the OFF position.
Connect the booster cable as follows, in the order of the numbers marked in the diagram.
1. Connect one clip of booster cable (A) to the positive (+)
terminal of the problem machine.
2. Connect the other clip of booster cable (A) to the positive (+)
terminal of the normal machine.
3. Connect one clip of booster cable (B) to the negative (-)
terminal of the normal machine.
4. Connect the other clip of booster cable (B) to the engine block
of the problem machine.
STARTING ENGINE
CAUTION
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 also that all the control levers are at the HOLD or neutral position.
1. Make sure the clips are firmly connected to the battery terminals.
2. Start engine of the normal machine and run it at high idling speed.
3. Turn the starting switch of the problem machine to the START position and start the engine.
If the engine doesn't start at first, wait for at least 2 minutes before trying again.
DISCONNECTING THE BOOSTER CABLE
After the engine has started, disconnect booster cables in the reverse order in which they were connected.
1. Remove one clip of booster cable (B) from the engine block of
the problem machine.
2. Remove the other clip of booster cable (B) from the negative (-)
terminal of the normal machine.
3. Remove one clip of booster cable (A) from the positive (+)
terminal of the normal machine.
4. Remove the other clip of booster cable (A) from the positive (+)
terminal of the problem machine.
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TROUBLESHOOTING OPERATION
TRANSMISSION CONTROL SYSTEM
Error Problem system
Item
Code Short circuit Disconnection
10 Back-up lamp relay o o
11 None – –
12 F ECMV Sol. o o
13 R ECMV Sol. o o
14 1st ECMV Sol. o o
15 2nd ECMV Sol. o o
16 3rd ECMV Sol. o o
17 4th ECMV Sol. o o
18 None – –
19 Joystick direction switch signal o o
20 Direction switch signal o o
21 Range switch signal o o
22 Travel speed sensor x o
23 Engine speed sensor o o
24 Abnormality in EEP RAM o o
25 Transmission oil pressure sensor o x
26 F ECMV fill switch o x
27 R ECMV fill switch o x
28 1st ECMV fill switch o x
29 2nd ECLMV fill switch o x
30 3rd ECMV fill switch o x
31 4th ECMV fill switch o x
32 F or R ECMV fill switch x o
33 1st, 2nd 3rd, or 4th ECMV fill switch x o
E.C.S.S. CONTROL SYSTEM
Error Problem system
Item
Code Short circuit Disconnection
d0 ECSS relay o o
3 - 106
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WEAR PARTS MAINTENANCE
WEAR PARTS
Wear parts such as the filter element, air cleaner element, buckt tooth, etc. are to be replaced at the time of periodic
maintenance or before their abrasion limits.
The wear parts should be changed correctly in order to use the machine economically.
For part change, Komatsu genuine parts of excellent quality should be used.
When ordering parts, please check the part number in the parts book.
WEAR PARTS LIST
The parts in parentheses are to be replaced at the same time.
Replacement
Item Part No. Part Name Q'ty
frequency
Engine oil filter 600-211-1340 Cartridge 1 EVERY 500 HOURS
Fuel filter 600-319-3110 Cartridge 1 EVERY 500 HOURS
424-16-11140 Element 1
Transmission oil filter (424-16-11630) (O-ring) (4) EVERY 500 HOURS
(424-16-11130) (O-ring) (2)
Corrosion resistor 600-411-1161 Cartridge 1 EVERY 1000 HOURS
07063-01383 Element 1
Hydraulic filter EVERY 2000 HOURS
(07000-15210) (O-ring) (1)
600-185-6100 Element ass'y 1
Air cleaner -
600-185-6110 Outer element ass'y 1
Air conditioner air filter 421-07-12312 Element 2 -
425-70-13212 Tooth 6
02091-11610 Bolt 18
1-piece bucket tooth 02290-11625 Nut 18 -
155-70-14240 Shim (0.5 mm) 12
155-70-14230 Shim (1.0 mm) 6
425-70-13232 Right corner tooth 1
425-70-13222 Left corner tooth 1
02091-11600 Bolt 2
09218-12723 Nut 2
1-piece corner tooth 01643-32780 Washer 2 -
02091-11610 Bolt 4
02290-11625 Nut 4
425-70-13250 Shim (0.5 mm) 4
425-70-13260 Shim (1.0 mm) 2
426-847-1110 Tooth 8
Tip tooth -
(426-847-1130) Pin 8
425-838-1110 Edge 7
02091-12015 Bolt 14
Segment edge -
01643-33380 Washer 14
02290-12031 Nut 14
4-8
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SERVICE PROCEDURE MAINTENANCE
WHEN REQUIRED
CHECK, CLEAN, OR REPLACE AIR CLEANER ELEMENT
WARNING
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.
When using compressed air, there is danger that dirt may be blown around and cause serious injury.