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Compact Loader
Avance WA500-3
Komatsu Avance WA500-3 User Manual
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MAINTENANCE
RECOMMENDED FUEL, COOLANT, AND LUBRICANT
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE
Reservoir
Capacity
Engine o
il
pan
Transmission
case
Hydraulic
system
Axle
(front and
rear)

(eac
h)
Pins
Cooling
system
Fuel tank
Specified
Liters
42
70
284
78
–
99
450
US gal
11.1
18.5
7
5.0
20.6
–
26.2
118.9
Refill
Lite
rs
37
62
175
78
–
–
–
US gal
9.8
16
.4
46.2
20
.6
–
–
–
4 - 10
174
176
Table of Contents
Table of Contents
11
Foreword
3
Safety Information
6
Introduction
8
Front/Rear, Left/Right Directions of Machine
8
Necessary Information
9
Product Identification Number (Pin)/Machine Serial No. Plate
9
Engine Serial No. Plate and Position
9
Position of Service Meter
10
Table of Contents
11
Safety
15
Safety Labels
18
Location of Safety Labels
19
Clothing and Personal Protective Items
26
Safety Features
26
Fire Extinguisher and First Aid Kit
26
If Abnormalities Are Found
26
Safety Rules
26
General Precautions
26
Keep Machine Clean
27
Inside Operator's Compartment
27
Always Apply Lock When Leaving Operator's Seat
27
No People on Attachments
28
Mounting and Dismounting
28
Handrails and Steps
28
Do Not Get Caught in Articulated Portion
29
Prevention of Burns
29
Fire Prevention
30
Action if Fire Occurs
31
Window Washer Liquid
31
PRECAUTIONS WHEN USING ROPS (Roll over Protective Structure)
31
Precautions for Attachments, Options
31
Unauthorized Modification
31
Do Not Go Close to High-Voltage Cables
32
Working on Loose Ground
32
Safety at Worksite
32
Ensure Good Visibility
33
Precautions Related to Ventilation Exhaust Gas
33
Checking Signalman's Signals and Signs
33
Emergency Exit from Operator's Cab
33
Be Careful about Asbestos Dust
34
Precautions When Starting
35
Starting Engine
35
Checks before Starting Engine
35
Precautions for Operation
35
Precautions in Cold Areas
36
Operation
37
Checks before Operation
37
Precautions When Traveling in Forward or Reverse
37
Precautions When Traveling
38
Traveling on Slopes
39
Prohibited Operations
40
Precautions When Operating
40
Methods of Using Brake
41
Operate Carefully on Snow
41
Parking Machine
42
Transportation
43
Loading and Unloading
43
Shipping
43
Battery
44
Battery Hazard Prevention
44
Starting with Booster Cables
45
Towing
46
Precautions for Maintenance
47
Warning Tag
47
Keep Work Place Clean and Tidy
47
Appoint Leader When Working with Others
47
Stop Engine before Carrying out Maintenance
48
Inspection and Maintenance after Turning E.C.s.s. Switch off
49
Two Workers for Maintenance When Engine Is Running
49
Proper Tools
50
Work under the Machine
50
Accumulator
50
Personnel
50
Attachments
51
Noise
51
Precautions When Using Hammer
51
Repair Welding
51
Removing Battery Terminal
51
Precautions with High-Pressure Oil
52
Precautions for High-Pressure Fuel
52
Handling High-Pressure Hoses
52
Precautions for High Voltage
52
Periodic Replacement of Safety Critical Parts
53
Compressed Air
53
Maintenance of Air Conditioner
53
Waste Materials
53
Precautions with Tires
54
Operation
57
General View
57
General View of Machine
57
General View of Controls and Gauges
58
Explanation of Components
60
Machine Monitor
60
Switches
72
Control Levers, Pedals
80
Steering Column Tilt Lever
85
Cap with Lock
86
Safety Bar
87
Towing Pin
87
Grease Pump
87
Fuse
88
Dust Indicator
88
Backup Alarm
88
Slow Blow Fuse
89
Power Outlet
89
Operation
90
Check before Starting Engine, Adjust
90
Starting Engine
104
Operations and Checks after Starting Engine
107
Stopping Engine
109
Check after Stopping Engine
109
Moving the Machine (Directional, Speed), Stopping the Machine
110
Turning
115
Operation of Work Equipment
116
Work Possible Using Wheel Loader
118
Precautions for Operation
124
Adjusting Work Equipment Posture
126
Removal and Installation of the Bucket
128
Parking Machine
131
Checks after Completion of Operation
133
Locking
133
Handling the Tires
134
Transportation
136
Transportation Procedure
136
Loading, Unloading Work
136
Method of Securing Machine
137
Method of Lifting Machine
139
Cold Weather Operation
142
Precautions for Low Temperature
142
Precautions after Completion of Work
143
After Cold Weather
144
Warming-Up Operation for Steering Hydraulic Circuit in Cold Weather
144
Long-Term Storage
145
Before Storage
145
During Storage
145
After Storage
145
When Machine Runs out of Fuel
146
Troubleshooting
146
Method of Towing Machine
147
If Battery Is Discharged
151
Other Trouble
154
Maintenance
167
Guides to Maintenance
167
Outlines of Service
169
Handling Oil, Fuel, Coolant, and Performing Oil Clinic
169
Outline of Electric System
172
Wear Parts
173
Wear Parts List
173
Recommended Fuel, Coolant, and Lubricant
174
Use of Fuel, Coolant and Lubricants According to Ambient Temperature
175
Recommended Brands, Recommended Quality for Products Other than Komatsu Genuine Oil
176
Standard Tightening Torques for Bolts and Nuts
177
Torque List
177
Periodic Replacement of Safety Critical Parts
178
Maintenance Schedule Chart
180
Initial 250 Hours Service
182
Initial 250 Hours Service (Only after the First 250 Hours)
182
Replace Transmission Oil Filter Element
182
Service Procedure
182
Check, Clean, or Replace Air Cleaner Element
183
When Required
183
Clean Inside of Cooling System
186
Check Transmission Oil Level, Add Oil
189
Check Axle Oil Level, Add Oil
191
Check Window Washing Fluid Level, Add Fluid
192
Clean Radiator Fins and Oil Cooler Fins
193
Check Electrical Intake Air Heater
194
Replace Bucket Teeth
194
Replace Bucket Tooth with Segment Edge
196
Lubricate Work Equipment Control Valve Linkage
197
Turn, Replace Bolt-On Cutting Edge
197
Check Air Conditioner
198
Replace Slow Blow Fuse
199
Selection and Inspection of Tires
200
Check before Starting
202
Drain Water, Sediment from Fuel Tank
203
Every 50 Hours Service
203
Check Oil Level in Hydraulic Tank, Add Oil
204
Every 100 Hours Service
204
Lubricate Rear Axle Pivot Pin
204
Clean Element in Air Conditioner Fresh Air Filter
205
Check Battery Electrolyte Level
206
Every 250 Hours Service
206
Check Alternator Belt Tension, Adjust
208
Check Parking Brake
208
Check Air Conditioner Compressor Belt Tension, Adjust
209
Check for Loose Wheel Hub Nuts, Tighten
209
Clean Element in Air Conditioner Recirculation Filter
210
Lubricating
210
Every 500 Hours Service
213
Replace Additional Fuel Filter Cartridge
213
Change Oil in Engine Oil Pan, Replace Engine Oil Filter Cartridge
215
Replace Transmission Oil Filter Element
217
Check Fan Belt for Wear
218
Lubricate Center Drive Shaft Spline
218
Every 1000 Hours Service
219
Replace Fuel Filter Cartridge
219
Change Oil in Transmission Case, Clean Strainer
221
Clean Transmission Case Breather
222
Lubricating
222
Check Tightening Parts of Turbocharger
224
Clean Radiator Sub-Tank Breather
224
Replace Corrosion Resistor Cartridge
224
Clean Fuel Strainer
225
Tighten Rops Canopy
225
Wash Fuel Tank Breather
225
Change Oil in Hydraulic Tank, Replace Hydraulic Filter Element
226
Every 2000 Hours Service
226
Replace Hydraulic Tank Breather Element
228
Change Axle Oil
229
Clean Ppc Circuit Strainer
230
Replace Element in Air Conditioner Recirculation Air Filter, Fresh Air Filter
230
Check Alternator, Starting Motor
231
Check Brake Disc Wear
231
Check Engine Valve Clearance, Adjust
231
Check Play of Turbocharger Rotor
231
Clean and Check Turbocharger
231
Clean Engine Breather Element
231
Check Accumulator Function
232
Check Accumulator Gas Pressure
232
Check Injector
232
Check Air Conditioner Compressor, Adjust
233
Check Fan Pulley and Tension Pulley
233
Check Vibration Damper
233
Check Water Pump
233
Checking for Looseness of High-Pressure Clamp, Hardening of Rubber
233
Every 4000 Hours Service
233
Replace Injector
233
Checking for Missing Fuel Spray Prevention Cap, Hardening of Rubber
234
Every 8000 Hours Service
235
Replace Fuel Spray Prevention Cap
235
Replace High-Pressure Piping Clamp
235
Specifications
237
Attachments, Options
239
Selecting Bucket and Tires
239
Handling E.C.s.s.(Electronic Controlled Suspension System)
240
Method of Operating E.C.s.s
240
Precautions When Operating E.C.s.s. Switch
240
Precautions When Handling Accumulator
241
Removal of E.C.s.s. Piping
241
Handling Auto-Greasing System
242
Method of Operating Auto-Greasing System
242
Precautions When Handling Auto-Greasing System
247
Troubleshooting
248
General Locations
249
Handling Remote Positioner
249
Method of Operating Remote Positioner
250
Adjusting Remote Positioner
251
Method of Setting Remote Positioner Stop Position
251
Sensor Adjustment Function
251
Handling Joystick Steering System
252
Structure and Function of Joystick Steering
252
Operation Method of Joystick Steering System
255
Precautions for Steering with Joystick
257
Adjustment of Joystick Console
258
Explanation of Components
261
Handling Joystick
261
Handling Air-Suspension Seat
264
Seat Adjustment
264
Car Radio
266
Explanation of Components
266
Method of Use
269
Precautions When Using
271
Am/Fm Radio-Cassette Stereo
272
Explanation of Components
272
Method of Operation
277
Precautions for Use
279
Air Conditioner
280
General Locations and Function of Control Panel
280
Method of Operation
283
Handling Brake Cooling System
285
When Required
285
Every 2000 Hours Service
287
Index
290
5
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Komatsu Avance WA500-3 Specifications
General
Brand
Komatsu
Model
Avance WA500-3
Category
Compact Loader
Language
English
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