Komatsu Avance WA500-3 Manual

.
1 - 1

.
FOREWORD
FOREWORD
FOREWORD
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. Most
accidents are caused by the failure to follow fundamental safety rules for the operation and maintenance of
machines. Accidents can be prevented by knowing beforehand conditions that may cause a hazard when
performing operation and maintenance.
WARNING
Operators and maintenance personnel must always do as follows before beginning operation or maintenance.
Always be sure to read and understand this manual thoroughly before performing operation and maintenance.
Read the safety messages given in this manual and the safety labels affixed to the machine thoroughly and be sure that you
understand them fully.
Keep this manual in the storage location for the operation and maintenance manual given below, and have all personnel read it
periodically.
If this manual has been lost or has become dirty and cannot be read, request a replacement manual immediately from Komatsu
or your Komatsu distributor.
If you sell the machine, be sure to give this manual to the new owners together with the machine.
Komatsu delivers machines that comply with all applicable regulations and standards of the country to which it has been shipped.
If this machine has been purchased in another country or purchased from someone in another country, it may lack certain safety
devices and specifications that are necessary for use in your country. If there is any question about whether your product
complies with the applicable standards and regulations of your country, consult Komatsu or your Komatsu distributor before
operating the machine.
Storage location for the Operation and Maintenance Manual:
Pocket (1) at rear of operator's seat
1 - 2

.
FOREWORD FOREWORD
1 - 3

.
FOREWORD
FOREWORD
1 - 4

.
FOREWORD SAFETY INFORMATION
SAFETY INFORMATION
To enable you to use this machine safely, safety precautions and labels are given in this manual and affixed to the
machine to give explanations of situations involving potential hazards and of the methods of avoiding such
situations.
Signal words
The following signal words are used to inform you that there is a potential hazardous situation that may lead to
personal injury or damage.
In this manual and on machine labels, the following signal words are used to express the potential level of hazard.
Indicates an imminently hazardous situation which, if not avoided, will result in death or
serious injury.
Indicates a potentially hazardous situation which, if not avoided, could result in death or
serious injury.
Indicates a potentially hazardous situation which, if not avoided, may result in minor or
moderate injury. This word is used also to alert against unsafe practices that may cause
property damage.
Example of safety message using signal word
WARNING
When standing up from the operator's seat, always place the safety lock lever in the LOCK position.
If you accidentally touch the control levers when they are not locked, this may cause a serious injury or death.
Other signal words
In addition to the above, the following signal words are used to indicate precautions that should be followed to
protect the machine or to give information that is useful to know.
This word is used for precautions that must be taken to avoid actions which could shorten
the life of the machine.
This word is used for information that is useful to know.
1 - 5

.
FOREWORD
SAFETY INFORMATION
Safety labels
Safety labels are affixed to the machine to inform the operator or maintenance worker on the spot when carrying out
operation or maintenance of the machine that may involve hazard.
This machine uses "Safety labels using words" and "Safety labels using pictograms" to indicate safety procedures.
Example of safety label using words
Safety labels using pictogram
Safety pictograms use a picture to express a level of hazardous
condition equivalent to the signal word. These safety pictograms
use pictures in order to let the operator or maintenance worker
understand the level and type of hazardous condition at all times.
Safety pictograms show the type of hazardous condition at the top
or left side, and the method of avoiding the hazardous condition at
the bottom or right side. In addition, the type of hazardous condition
is displayed inside a triangle and the method of avoiding the
hazardous condition is shown inside a circle.
Komatsu cannot predict every circumstance that might involve a potential hazard in operation and maintenance.
Therefore, the safety messages in this manual and on the machine may not include all possible safety precautions.
If any procedures or actions not specifically recommended or allowed in this manual are used, it is your responsibility
to take the necessary steps to ensure safety.
In no event should you engage in prohibited uses or actions described in this manual.
The explanations, values, and illustrations in this manual were prepared based on the latest information available
at that time. Continuing improvements in the design of this machine can lead to changes in detail which may not
be reflected in this manual. Consult Komatsu or your Komatsu distributor for the latest available information of your
machine or for questions regarding information in this manual.
The numbers in circles in the illustrations correspond to the numbers in ( ) in the text. (For example: 1J(1))
1 - 6

.
FOREWORD INTRODUCTION
INTRODUCTION
This Komatsu machine is designed to be used mainly for the following work:
Digging work
Smoothing
Pushing work
Loading work
For details of the operating procedure, see "WORK POSSIBLE USING WHEEL LOADER (PAGE 3-63)".
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE
In this manual, the directions of the machine (front, rear, left, right) are determined according to the view from the
operator's seat in the direction of travel (front) of the machine.
1 - 7

.
FOREWORD
NECESSARY INFORMATION
NECESSARY INFORMATION
When requesting service or ordering replacement parts, please inform your Komatsu distributor of the following
items.
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE
On the center right of the front frame.
The design of the nameplate differs according to the territory.
ENGINE SERIAL NO. PLATE AND POSITION
On the upper left of the cylinder block, when seen from the fan side.
1 - 8

.
FOREWORD NECESSARY INFORMATION
POSITION OF SERVICE METER
On the lower right of maintenance monitor.
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR
Machine serial No.
Engine serial No.
Product identification number (PIN)
Distributor name
Address
Service Personnel
Phone/Fax
1 - 9

.
FOREWORD
CONTENTS
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

.
FOREWORD CONTENTS
OPERATION OF WORK EQUIPMENT 3- 61
WORK POSSIBLE USING WHEEL LOADER 3- 63
PRECAUTIONS FOR OPERATION 3- 69
ADJUSTING WORK EQUIPMENT POSTURE 3- 71
REMOVAL AND INSTALLATION OF THE BUCKET 3- 73
PARKING MACHINE 3- 76
CHECKS AFTER COMPLETION OF OPERATION 3- 78
LOCKING 3- 78
HANDLING THE TIRES 3- 79
TRANSPORTATION 3- 81
TRANSPORTATION PROCEDURE 3- 81
LOADING, UNLOADING WORK 3- 81
METHOD OF SECURING MACHINE 3- 82
METHOD OF LIFTING MACHINE 3- 84
COLD WEATHER OPERATION 3- 87
PRECAUTIONS FOR LOW TEMPERATURE 3- 87
PRECAUTIONS AFTER COMPLETION OF WORK 3- 88
AFTER COLD WEATHER 3- 89
WARMING-UP OPERATION FOR STEERING HYDRAULIC CIRCUIT IN COLD WEATHER 3- 89
LONG-TERM STORAGE 3- 90
BEFORE STORAGE 3- 90
DURING STORAGE 3- 90
AFTER STORAGE 3- 90
TROUBLESHOOTING 3- 91
WHEN MACHINE RUNS OUT OF FUEL 3- 91
METHOD OF TOWING MACHINE 3- 92
IF BATTERY IS DISCHARGED 3- 96
OTHER TROUBLE 3- 99
MAINTENANCE 4- 1
GUIDES TO MAINTENANCE 4- 2
OUTLINES OF SERVICE 4- 4
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC 4- 4
OUTLINE OF ELECTRIC SYSTEM 4- 7
WEAR PARTS 4- 8
WEAR PARTS LIST 4- 8
RECOMMENDED FUEL, COOLANT, AND LUBRICANT 4- 9
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE 4- 10
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN
KOMATSU GENUINE OIL 4- 11
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS 4- 12
TORQUE LIST 4- 12
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS 4- 13
MAINTENANCE SCHEDULE CHART 4- 15
MAINTENANCE SCHEDULE CHART 4- 15
SERVICE PROCEDURE 4- 17
INITIAL 250 HOURS SERVICE 4- 17
WHEN REQUIRED 4- 18
CHECK BEFORE STARTING 4- 37
EVERY 50 HOURS SERVICE 4- 38
EVERY 100 HOURS SERVICE 4- 39
1 - 11

.
FOREWORD
CONTENTS
EVERY 250 HOURS SERVICE 4- 41
EVERY 500 HOURS SERVICE 4- 48
EVERY 1000 HOURS SERVICE 4- 54
EVERY 2000 HOURS SERVICE 4- 61
EVERY 4000 HOURS SERVICE 4- 68
EVERY 8000 HOURS SERVICE 4- 70
SPECIFICATIONS 5- 1
SPECIFICATIONS 5- 2
ATTACHMENTS, OPTIONS 6- 1
SELECTING BUCKET AND TIRES 6- 2
HANDLING E.C.S.S.(ELECTRONIC CONTROLLED SUSPENSION SYSTEM) 6- 3
METHOD OF OPERATING E.C.S.S. 6- 3
PRECAUTIONS WHEN OPERATING E.C.S.S. SWITCH 6- 3
PRECAUTIONS WHEN HANDLING ACCUMULATOR 6- 4
REMOVAL OF E.C.S.S. PIPING 6- 4
HANDLING AUTO-GREASING SYSTEM 6- 5
METHOD OF OPERATING AUTO-GREASING SYSTEM 6- 5
PRECAUTIONS WHEN HANDLING AUTO-GREASING SYSTEM 6- 10
TROUBLESHOOTING 6- 11
HANDLING REMOTE POSITIONER 6- 12
GENERAL LOCATIONS 6- 12
METHOD OF OPERATING REMOTE POSITIONER 6- 13
METHOD OF SETTING REMOTE POSITIONER STOP POSITION 6- 14
SENSOR ADJUSTMENT FUNCTION 6- 14
ADJUSTING REMOTE POSITIONER 6- 14
HANDLING JOYSTICK STEERING SYSTEM 6- 15
STRUCTURE AND FUNCTION OF JOYSTICK STEERING 6- 15
OPERATION METHOD OF JOYSTICK STEERING SYSTEM 6- 18
PRECAUTIONS FOR STEERING WITH JOYSTICK 6- 20
ADJUSTMENT OF JOYSTICK CONSOLE 6- 21
HANDLING JOYSTICK 6- 24
EXPLANATION OF COMPONENTS 6- 24
HANDLING AIR-SUSPENSION SEAT 6- 27
SEAT ADJUSTMENT 6- 27
CAR RADIO 6- 29
EXPLANATION OF COMPONENTS 6- 29
METHOD OF USE 6- 32
PRECAUTIONS WHEN USING 6- 34
AM/FM RADIO-CASSETTE STEREO 6- 35
EXPLANATION OF COMPONENTS 6- 35
METHOD OF OPERATION 6- 40
PRECAUTIONS FOR USE 6- 42
AIR CONDITIONER 6- 43
GENERAL LOCATIONS AND FUNCTION OF CONTROL PANEL 6- 43
METHOD OF OPERATION 6- 46
HANDLING BRAKE COOLING SYSTEM 6- 48
WHEN REQUIRED 6- 48
EVERY 2000 HOURS SERVICE 6- 50
INDEX 7- 1
1 - 12

.
2 - 1

.
SAFETY
SAFETY
SAFETY
SAFETY LABELS 2- 5
LOCATION OF SAFETY LABELS 2- 6
GENERAL PRECAUTIONS
SAFETY RULES 2- 13
IF ABNORMALITIES ARE FOUND 2- 13
CLOTHING AND PERSONAL PROTECTIVE ITEMS 2- 13
FIRE EXTINGUISHER AND FIRST AID KIT 2- 13
SAFETY FEATURES 2- 13
KEEP MACHINE CLEAN 2- 14
INSIDE OPERATOR'S COMPARTMENT 2- 14
ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT 2- 14
HANDRAILS AND STEPS 2- 15
MOUNTING AND DISMOUNTING 2- 15
NO PEOPLE ON ATTACHMENTS 2- 15
DO NOT GET CAUGHT IN ARTICULATED PORTION 2- 16
PREVENTION OF BURNS 2- 16
FIRE PREVENTION 2- 17
ACTION IF FIRE OCCURS 2- 18
WINDOW WASHER LIQUID 2- 18
PRECAUTIONS WHEN USING ROPS (Roll Over Protective Structure) 2- 18
PRECAUTIONS FOR ATTACHMENTS, OPTIONS 2- 18
UNAUTHORIZED MODIFICATION 2- 18
SAFETY AT WORKSITE 2- 19
WORKING ON LOOSE GROUND 2- 19
DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES 2- 19
ENSURE GOOD VISIBILITY 2- 20
PRECAUTIONS RELATED TO VENTILATION EXHAUST GAS 2- 20
CHECKING SIGNALMAN'S SIGNALS AND SIGNS 2- 20
EMERGENCY EXIT FROM OPERATOR'S CAB 2- 20
BE CAREFUL ABOUT ASBESTOS DUST 2- 21
2 - 2

.
SAFETY SAFETY
PRECAUTIONS FOR OPERATION 2- 22
STARTING ENGINE 2- 22
CHECKS BEFORE STARTING ENGINE 2- 22
PRECAUTIONS WHEN STARTING 2- 22
PRECAUTIONS IN COLD AREAS 2- 23
OPERATION 2- 24
CHECKS BEFORE OPERATION 2- 24
PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE 2- 24
PRECAUTIONS WHEN TRAVELING 2- 25
TRAVELING ON SLOPES 2- 26
PROHIBITED OPERATIONS 2- 27
PRECAUTIONS WHEN OPERATING 2- 27
METHODS OF USING BRAKE 2- 28
OPERATE CAREFULLY ON SNOW 2- 28
PARKING MACHINE 2- 29
TRANSPORTATION 2- 30
LOADING AND UNLOADING 2- 30
SHIPPING 2- 30
BATTERY 2- 31
BATTERY HAZARD PREVENTION 2- 31
STARTING WITH BOOSTER CABLES 2- 32
TOWING 2- 33
PRECAUTIONS FOR MAINTENANCE 2- 34
WARNING TAG 2- 34
KEEP WORK PLACE CLEAN AND TIDY 2- 34
APPOINT LEADER WHEN WORKING WITH OTHERS 2- 34
STOP ENGINE BEFORE CARRYING OUT MAINTENANCE 2- 35
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING 2- 36
INSPECTION AND MAINTENANCE AFTER TURNING E.C.S.S. SWITCH OFF 2- 36
PROPER TOOLS 2- 37
WORK UNDER THE MACHINE 2- 37
ACCUMULATOR 2- 37
PERSONNEL 2- 37
ATTACHMENTS 2- 38
NOISE 2- 38
PRECAUTIONS WHEN USING HAMMER 2- 38
REPAIR WELDING 2- 38
REMOVING BATTERY TERMINAL 2- 38
PRECAUTIONS WITH HIGH-PRESSURE OIL 2- 39
PRECAUTIONS FOR HIGH-PRESSURE FUEL 2- 39
HANDLING HIGH-PRESSURE HOSES 2- 39
PRECAUTIONS FOR HIGH VOLTAGE 2- 39
WASTE MATERIALS 2- 40
MAINTENANCE OF AIR CONDITIONER 2- 40
COMPRESSED AIR 2- 40
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS 2- 40
2 - 3

.
SAFETY
SAFETY
PRECAUTIONS WITH TIRES 2- 41
HANDLING TIRES 2- 41
PRECAUTIONS WHEN STORING TIRES 2- 41
2 - 4

.
SAFETY SAFETY LABELS
SAFETY LABELS
The following safety labels are used on this machine. Be sure that you fully understand the correct position and
content of these safety labels.
To ensure that the content of these safety labels can be read properly, be sure that they are in the correct place and
always keep them clean. When cleaning them, use soap and water. Do not use organic solvents or gasoline.
These may cause the safety labels to peel off.
If the safety labels are damaged or lost, or cannot be read, replace them with new parts. For details of the part
numbers, see this manual or check on the actual part, and order the new part from your Komatsu distributor.
There are also other labels in addition to the safety labels. Handle these labels in the same way.
2 - 5

.
SAFETY
SAFETY LABELS
LOCATION OF SAFETY LABELS
(1) Caution before starting
(2) Caution for safety lock lever
(3) Caution when traveling in reverse
2 - 6

.
SAFETY SAFETY LABELS SAFETY SAFETY LABELS
(4) Caution for parking brake
(5) Do not enter
(6) Caution for safety bar
2 - 7