Komatsu WA500-6H Wheel Loader Operation & Maintenance Manual (H60051 and up) - VEAM430100

This manual PDF download describes procedures for operation, handling, lubrication, maintenance, checking, and adjustment for the WA500-6H Komatsu Wheel Loader (SN: H60051 and up). It will help the operator or anyone realize peak performance through effective, economical and safe machine operation and maintenance.


APPLICABLE MODELS :

Komatsu WA500-6H Wheel Loader
Serial Numbers : H60051 and up


TABLE OF CONTENTS :

1. Foreword
2. Safety
3. Operation
4. Maintenance
5. Technical Data
6. Attachments, Options
7. Index
8. Notes


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Bookmarked : Yes
Searchable : Yes
Printable : Yes
Product Code : VEAM430100
Total Pages : 412


This manual provides rules and guidelines which will help you use this machine safely and effectively. The precautions in this manual must be followed at all times when performing operation and maintenance.

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1. Foreword
1.1 Foreword
1.1.1 EU Directives
1.2 Safety information
1.2.1 Signal words
1.2.2 Safety labels
1.3 Introduction
1.3.1 Intended use
1.3.2 Directions of machine
1.3.3 Visibility from operator's seat
1.4 Necessary information
1.4.1 Product Identification Number (PIN)/Machine serial no. plate and position
1.4.2 Engine serial no. plate and position
1.4.3 ROPS/FOPS-Cab serial no. plate
1.4.4 Axle serial no. plate
1.4.5 Transmission serial no. plate
1.4.6 Seat operator serial no. plate
1.4.7 Position of service meter
1.4.8 Table to enter serial no. and distributor
1.5 Contents
1.6 Dimensions, weights and operating data
1.6.1 WA500-6: Dimensions, weights and operating data
1.7 CE-Conforming equipment
1.7.1 CE-Conforming equipment
1.7.2 Manufacturer-supplied CE-Conforming equipment, according to document 419-93-H1250

2. Safety
2.1 Safety labels
2.1.1 Location of safety labels
2.1.2 Presentation of safety labels
2.2 General precautions
2.3 Precautions for operation
2.3.1 Starting engine
2.3.2 Operation
2.3.3 Transportation
2.3.4 Battery
2.3.5 Towing
2.4 Precautions for maintenance
2.5 Precautions with tires

3. Operation
3.1 General view
3.1.1 General view of machine
3.1.2 General view of controls and gauges
3.2 Explanation of components
3.2.1 Machine monitor
Types of warning
Central warning lamp
Character display portion
Emergency stop item
Caution items
Inspection and maintenance item
Pilot display portion
Meter display portion
Other functions of machine monitor
3.2.2 Switches
3.2.3 Control levers, pedals
3.2.4 Steering tilt lock lever
3.2.5 Cap with lock
3.2.6 Safety bar
3.2.7 Towing pin
3.2.8 Backup alarm
3.2.9 Opening cab, window door
Open lock cancel knob for right cab door
Cab left door open lock
Cab left door open knob
Open lock cancel knob for left cab window
3.2.10 Handling cab wiper
Preventing damage to wiper arm bracket
3.2.11 Dust indicator
3.2.12 Fuse
Fuse capacity and name of circuit
3.2.13 Slow blow fuse
3.2.14 Power outlet
3.2.15 Air conditioner
General locations and function of control panel
Method of operation
Cool box
Precautions when using
Inspection and maintenance
3.3 Operation
3.3.1 Check before starting engine, adjust
Walk-around check
Check before starting
Adjustment
Safety belt
Operations and checks before starting engine
3.3.2 Starting engine
Automatic warming-up operation
3.3.3 Operations and checks after starting engine
Breaking-in the machine
Normal operation
3.3.4 Stopping engine
3.3.5 Check after stopping engine
3.3.6 Moving the machine (directional, speed), stopping the machine
Preparations for moving the machine
Changing gear speed
Changing direction
Automatic shift
Stopping the machine
Transmission cut-off function
3.3.7 Turning
3.3.8 Operation of work equipment
Lift arm operation
Bucket operation
3.3.9 Semi auto digging operations
3.3.10 Remote positioner
Operating remote bucket positioner
Operating remote boom positioner
3.3.11 Work possible using wheel loader
Recommended combination of switches for operation
Digging operations
Leveling operation
Pushing operation
Load and carry operations
Loading operations
Precautions when handling blasted rock
3.3.12 Precautions for operation
Permissible water depth
If wheel brake does not work
Precautions when driving up or down slopes
3.3.13 Removal and installation of the bucket
Removing the bucket
Installing the bucket
3.3.14 Parking machine
3.3.15 Checks after completion of operation
3.3.16 Locking
3.3.17 Handling the tires
Precautions when handling tires
Tire pressure
Precautions for using load and carry method
3.4 Transportation
3.4.1 Transportation procedure
3.4.2 Loading, unloading work with trailers
Loading
Securing machine
Unloading
3.4.3 Lifting machine
Location of lifting position mark
Lifting procedure
3.5 Cold weather operation
3.5.1 Precautions for low temperature
Fuel and lubricants
Coolant
Battery
3.5.2 Precautions after completion of work
3.5.3 After cold weather
3.5.4 Warming-up operation for steering hydraulic circuit in cold weather
3.6 Long-term storage
3.6.1 Before storage
3.6.2 During storage
3.6.3 After storage
3.7 Troubleshooting
3.7.1 When machine runs out of fuel
3.7.2 Towing the machine
When engine can be used
When engine cannot be used
Releasing parking brake
Emergency travel operation
3.7.3 If battery is discharged
Removal and installation of battery
Precautions for charging battery
Starting engine with booster cable
3.7.4 Method for lowering work equipment when engine has stopped
3.7.5 Other trouble
Electrical system
Chassis
Engine

4. Maintenance
4.1 Guides to maintenance
4.2 Outlines of service
4.2.1 Handling oil, fuel, coolant, grease and carrying out KOWA (KOMATSU Oil Wear Analysis)
Oil
Fuel
Coolant and water for dilution
Grease
Carrying out KOWA (KOMATSU Oil Wear Analysis)
Storing oil and fuel
Filters
4.2.2 Outline of electric system
4.3 Wear parts
4.3.1 Wear parts list
4.4 Fuel, coolant and lubricants
4.4.1 Lubrication chart
4.4.2 Use of fuel, coolant and lubricants according to ambient temperature
4.4.3 Recommended brands, recommended quality for products other than KOMATSU genuine oil
4.5 Standard tightening torques for bolts and nuts
4.5.1 Torque list
4.6 Periodic replacement of safety critical parts
4.7 Maintenance schedule chart
4.7.1 Maintenance schedule chart
4.8 Replace injector assembly
4.9 Service procedure
4.9.1 Initial 50 hours service (only after the first 50 hours)
Check for loose wheel hub bolts, tighten
4.9.2 Initial 250 hours service (only after the first 250 hours)
Replace transmission oil filter element
Replace hydraulic filter element
4.9.3 When required
Check, clean, or replace air cleaner element
Clean inside of cooling system
Check transmission oil level, add oil
Check axle oil level, add oil
Clean axle case breather
Clean air conditioner condenser
Check window washing fluid level, add fluid
Clean radiator fins with compressed air
Replace bucket teeth
Replace bucket tooth with segment edge
Check air conditioner
Replace slow blow fuse
Bleeding air from hydraulic tank
Checking function of accumulator
Selection and inspection of tires
4.9.4 Check before starting
Check before starting
4.9.5 Every 50 hours service
Drain water, sediment from fuel tank
4.9.6 Every 100 hours service
Lubricate rear axle pivot pin
Check oil level in hydraulic tank, add oil
Clean element in air conditioner fresh air filter
4.9.7 Every 250 hours service
Check battery electrolyte level
Check parking brake
Check alternator belt tension, adjust
Check air conditioner compressor belt tension, adjust
Check for loose wheel hub bolts, tighten
Clean element in air conditioner recirculation filter
Checking function of accumulator
Lubricating
4.9.8 Every 500 hours service
Change oil in engine oil pan, replace engine oil filter cartridge
Replace fuel pre-filter cartridge
4.9.9 Every 1000 hours service
Change oil in transmission case, clean strainer
Replace transmission oil filter element
Replace fuel filter cartridge
Clean transmission case breather
Wash fuel tank breather
Lubricating
Replace corrosion resistor cartridge
Check of engine air intake piping clamps for looseness
4.9.10 Every 2000 hours service
Change oil in hydraulic tank, replace hydraulic filter element
Clean hydraulic tank strainer
Replace hydraulic tank breather element
Change axle oil
Replace element in air conditioner recirculation air filter, fresh air filter
Clean PPC circuit strainer
Check alternator
Check engine valve clearance, adjust
Check brake disc wear
Check function of accumulator
4.9.11 Every 4000 hours service
Check water pump
Check starting motor
Lubricating
Checking for loose engine high-pressure piping clamps, hardening of rubber
Checking for missing fuel spray prevention cap, hardening of rubber
4.9.12 Every 8000 hours service
Replace high-pressure piping clamp
Replace fuel spray prevention cap
Overhaul starting motor and alternator
4.9.13 Every 12000 hours service
Replace injector assembly

5. Technical Data
5.1 Technical data
5.2 Noise emission levels
5.3 Vibration level
5.4 Limit values for slopes

6. Attachments, Options
6.1 Handling load meter
6.1.1 Outline of load meter
6.1.2 Principle of load meter measurement
6.1.3 Points to remember to ensure high accuracy
Calibration
When measuring
6.1.4 Using load meter
Setting addition mode
Setting subtraction mode
Total load data display
Clearing total load
Stopping load meter calculation
Selecting load material category display
Calibration with empty bucket
Calibration with loaded bucket
Resetting calibration
Method of using addition mode
Method of using subtraction mode
Printout from load meter
Selection of printout mode
6.2 Joystick steering system
6.2.1 Components
6.2.2 Structure and function
Operation using joystick lever and operation using steering wheel
Getting in or out of operator's cab
Adjustment of joystick console
Seat adjustment
6.2.3 Precautions for steering with joystick
6.2.4 Operation method of joystick steering system
6.3 Handling machines equipped with KOMTRAX
6.3.1 Basic precautions
6.4 Central lubrication system
6.4.1 Operating the central lubrication system
6.4.2 Display and control unit
LED-display
Pushbuttons
6.4.3 Changing the lubrication interval times

7. Index
7.1 Index

8. Notes

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