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KOMATSU GALEO WA470-5 WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:70001 & UP) KOMATSU WA470-5 – PDF DOWNLOAD
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- KOMATSU GALEO WA470-5 WHEEL LOADER OPERATION & MAINTENANCE MANUAL
- SERIAL NUMBER:70001 & UP
- PUBLICATION NUMBER:TEN00091-00
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Description
KOMATSU GALEO WA470-5 WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:70001 & UP) KOMATSU WA470-5
KOMATSU GALEO WA470-5 WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:70001 & UP) KOMATSU WA470-5 – PDF DOWNLOAD:
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TABLE OF CONTENTS:
KOMATSU GALEO WA470-5 WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:70001 & UP) KOMATSU WA470-5
COVER................................................................................................ 1 FOREWORD............................................................................................. 2 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...................................................................... 9 POSITION OF SERVICE METER.................................................................... 10 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR.................................................... 10 CONTENTS............................................................................................. 11 SAFETY............................................................................................... 14 SAFETY........................................................................................... 15 SAFETY LABELS.................................................................................... 18 LOCATION OF SAFETY LABELS.................................................................... 18 SAFETY LABELS................................................................................ 19 GENERAL PRECAUTIONS.............................................................................. 24 SAFETY RULES................................................................................. 24 IF ABNORMALITIES ARE FOUND................................................................... 24 CLOTHING AND PERSONAL PROTECTIVE ITEMS....................................................... 24 FIRE EXTINGUISHER AND FIRST AID KIT.......................................................... 24 SAFETY FEATURES.............................................................................. 24 KEEP MACHINE CLEAN........................................................................... 25 INSIDE OPERATOR'S COMPARTMENT................................................................ 25 ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT............................................... 25 HANDRAILS AND STEPS.......................................................................... 26 MOUNTING AND DISMOUNTING..................................................................... 27 NO PEOPLE ON ATTACHMENTS..................................................................... 27 DO NOT GET CAUGHT IN ARTICULATED PORTION..................................................... 27 PREVENTION OF BURNS.......................................................................... 27 FIRE PREVENTION.............................................................................. 28 ACTION IF FIRE OCCURS........................................................................ 29 WINDOW WASHER LIQUID......................................................................... 29 PRECAUTIONS WHEN USING ROPS (ROLL OVER PROTECTIVE STRUCTURE)................................. 29 PRECAUTIONS FOR ATTACHMENTS, OPTIONS......................................................... 29 UNAUTHORIZED MODIFICATION.................................................................... 29 SAFETY AT WORKSITE........................................................................... 30 WORKING ON LOOSE GROUND...................................................................... 30 DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES....................................................... 30 ENSURE GOOD VISIBILITY....................................................................... 31 VENTILATION FOR ENCLOSED AREAS............................................................... 31 CHECKING SIGNALMAN'S SIGNALS AND SIGNS....................................................... 31 EMERGENCY EXIT FROM OPERATOR'S CAB........................................................... 31 BE CAREFUL ABOUT ASBESTOS DUST............................................................... 32 PRECAUTIONS FOR OPERATION........................................................................ 33 STARTING ENGINE.............................................................................. 33 CHECKS BEFORE STARTING ENGINE............................................................ 33 PRECAUTIONS WHEN STARTING................................................................ 33 PRECAUTIONS IN COLD AREAS................................................................ 34 OPERATION.................................................................................... 35 CHECKS BEFORE OPERATION.................................................................. 35 PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE......................................... 35 PRECAUTIONS WHEN TRAVELING............................................................... 36 TRAVELING ON SLOPES...................................................................... 37 PROHIBITED OPERATIONS.................................................................... 38 PRECAUTIONS WHEN OPERATING............................................................... 38 METHODS OF USING BRAKE................................................................... 39 OPERATE CAREFULLY ON SNOW................................................................ 39 PARKING MACHINE.......................................................................... 40 TRANSPORTATION............................................................................... 41 LOADING AND UNLOADING.................................................................... 41 SHIPPING................................................................................. 41 BATTERY...................................................................................... 42 BATTERY HAZARD PREVENTION................................................................ 42 STARTING WITH BOOSTER CABLES............................................................. 43 TOWING....................................................................................... 44 WHEN TOWING.............................................................................. 44 PRECAUTIONS FOR MAINTENANCE.................................................................. 45 WARNING TAG.............................................................................. 45 KEEP WORK PLACE CLEAN AND TIDY........................................................... 45 APPOINT LEADER WHEN WORKING WITH OTHERS.................................................. 45 STOP ENGINE BEFORE CARRYING OUT MAINTENANCE.............................................. 45 TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING....................................... 47 INSPECTION AND MAINTENANCE AFTER TURNING E.C.S.SWITCH OFF................................ 47 PROPER TOOLS............................................................................. 48 ACCUMULATOR.............................................................................. 48 PERSONNEL................................................................................ 48 ATTACHMENTS.............................................................................. 48 WORK UNDER THE MACHINE................................................................... 49 NOISE.................................................................................... 49 PRECAUTIONS WHEN USING HAMMER............................................................ 49 REPAIR WELDING........................................................................... 49 REMOVING BATTERY TERMINAL................................................................ 49 PRECAUTIONS WITH HIGH-PRESSURE OIL....................................................... 50 PRECAUTIONS FOR HIGH-PRESSURE FUEL....................................................... 50 HANDLING HIGH-PRESSURE HOSES............................................................. 50 PRECAUTIONS FOR HIGH VOLTAGE............................................................. 50 WASTE MATERIALS.......................................................................... 51 MAINTENANCE OF AIR CONDITIONER........................................................... 51 COMPRESSED AIR........................................................................... 51 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS............................................ 51 PRECAUTIONS WITH TIRES....................................................................... 52 HANDLING TIRES........................................................................... 52 PRECAUTIONS WHEN STORING TIRES........................................................... 52 OPERATION............................................................................................ 53 GENERAL VIEW..................................................................................... 54 GENERAL VIEW OF MACHINE...................................................................... 54 GENERAL VIEW OF CONTROLS AND GAUGES.......................................................... 55 EXPLANATION OF COMPONENTS........................................................................ 58 MACHINE MONITOR.............................................................................. 58 SWITCHES..................................................................................... 88 CONTROL LEVERS, PEDALS.......................................................................103 STEERING TILT LOCK LEVER.....................................................................108 CAP WITH LOCK................................................................................109 FRAME LOCK BAR...............................................................................111 TOWING PIN...................................................................................111 GREASE PUMP..................................................................................112 CAB DOOR OPEN LOCK...........................................................................112 CAB WINDOW OPEN LOCK CANCEL KNOB.............................................................112 FUSE.........................................................................................113 SLOW BLOW FUSE...............................................................................114 POWER OUTLET.................................................................................115 AM/FM RADIO..................................................................................116 AM/FM RADIO-CASSETTE STEREO..................................................................122 AIR CONDITIONER..............................................................................130 HANDLING AUTO AIR CONDITIONER................................................................135 HANDLING CAB WIPER...........................................................................142 OPERATION........................................................................................143 CHECK BEFORE STARTING ENGINE, ADJUST.........................................................143 STARTING ENGINE..............................................................................159 OPERATIONS AND CHECKS AFTER STARTING ENGINE..................................................164 STOPPING ENGINE..............................................................................166 MOVING THE MACHINE (DIRECTIONAL, SPEED), STOPPING THE MACHINE................................167 TURNING......................................................................................178 OPERATION OF WORK EQUIPMENT..................................................................180 WORK POSSIBLE USING WHEEL LOADER.............................................................182 PRECAUTIONS FOR OPERATION....................................................................189 ADJUSTING WORK EQUIPMENT POSTURE.............................................................191 PARKING MACHINE..............................................................................193 CHECKS AFTER COMPLETION OF OPERATION.........................................................195 LOCKING......................................................................................195 HANDLING THE TIRES...........................................................................196 TRANSPORTATION...................................................................................198 TRANSPORTATION PROCEDURE.....................................................................198 LOADING, UNLOADING WORK WITH TRAILERS........................................................198 LIFTING MACHINE..............................................................................202 COLD WEATHER OPERATION...........................................................................204 PRECAUTIONS FOR LOW TEMPERATURE..............................................................204 PRECAUTIONS AFTER COMPLETION OF WORK.........................................................205 AFTER COLD WEATHER...........................................................................205 WARMING-UP OPERATION FOR STEERING HYDRAULIC CIRCUIT IN COLD WEATHER..........................206 LONG-TERM STORAGE................................................................................207 BEFORE STORAGE...............................................................................207 DURING STORAGE...............................................................................207 AFTER STORAGE................................................................................207 TROUBLESHOOTING..................................................................................208 WHEN MACHINE RUNS OUT OF FUEL................................................................208 METHOD OF TOWING MACHINE.....................................................................209 IF BATTERY IS DISCHARGED.....................................................................214 OTHER TROUBLE................................................................................217 MAINTENANCE..........................................................................................222 GUIDES TO MAINTENANCE............................................................................223 OUTLINES OF SERVICE..............................................................................225 HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC.......................................225 OUTLINE OF ELECTRIC SYSTEM...................................................................228 WEAR PARTS.......................................................................................229 WEAR PARTS LIST..............................................................................229 RECOMMENDED FUEL, COOLANT, AND LUBRICANT.........................................................230 USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE.........................231 RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL..........232 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS...................................................233 TORQUE LIST..................................................................................233 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS....................................................234 MAINTENANCE SCHEDULE CHART.......................................................................235 MAINTENANCE SCHEDULE CHART...................................................................235 ADJUST INJECTOR..............................................................................237 SERVICE PROCEDURE................................................................................238 INITIAL 250 HOURS SERVICE....................................................................238 WHEN REQUIRED................................................................................239 CHECK, CLEAN, OR REPLACE AIR CLEANER ELEMENT.............................................239 CLEAN INSIDE OF COOLING SYSTEM...........................................................243 CHECK WATER SEPARATOR, DRAIN WATER.......................................................246 CHECK TRANSMISSION OIL LEVEL, ADD OIL....................................................247 CHECK AXLE OIL LEVEL, ADD OIL............................................................248 CLEAN AXLE CASE BREATHER.................................................................249 CLEAN AIR CONDITIONER CONDENSER..........................................................250 CHECK WINDOW WASHING FLUID LEVEL, ADD FLUID..............................................250 CLEAN RADIATOR FINS AND COOLER FINS......................................................251 CHECK ELECTRICAL INTAKE AIR HEATER.......................................................254 TURN, REPLACE BOLT-ON CUTTING EDGE.......................................................255 REPLACE BUCKET TEETH.....................................................................256 CHECK AIR CONDITIONER....................................................................258 REPLACE SLOW BLOW FUSE...................................................................259 CHECKING FUNCTION OF ACCUMULATOR.........................................................260 SELECTION AND INSPECTION OF TIRES........................................................261 CHECK BEFORE STARTING........................................................................263 EVERY 50 HOURS SERVICE.......................................................................264 DRAIN WATER, SEDIMENT FROM FUEL TANK.....................................................264 EVERY 100 HOURS SERVICE......................................................................265 LUBRICATE REAR AXLE PIVOT PIN............................................................265 CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL...............................................265 CLEAN ELEMENT IN AIR CONDITIONER FRESH AIR FILTER........................................266 EVERY 250 HOURS SERVICE......................................................................267 CHECK BATTERY ELECTROLYTE LEVEL..........................................................267 CHECK PARKING BRAKE......................................................................269 CHECK ALTERNATOR BELT TENSION, ADJUST....................................................269 CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST....................................270 CHECK FOR LOOSE WHEEL HUB BOLTS, TIGHTEN.................................................271 CLEAN ELEMENT IN AIR CONDITIONER RECIRCULATION FILTER....................................271 CHECKING FUNCTION OF ACCUMULATOR.........................................................272 LUBRICATING .............................................................................272 EVERY 500 HOURS SERVICE......................................................................274 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE........................274 REPLACE ADDITIONAL FUEL FILTER CARTRIDGE.................................................275 EVERY 1000 HOURS SERVICE.....................................................................277 CHANGE OIL IN TRANSMISSION CASE AND TRANSMISSION OIL FILTER CARTRIDGE, CLEAN STRAINER....277 CLEAN TRANSMISSION CASE BREATHER.........................................................278 LUBRICATING..............................................................................278 CHECK TIGHTENING PARTS OF TURBOCHARGER...................................................279 CHECK PLAY OF TURBOCHARGER ROTOR.........................................................279 REPLACE CORROSION RESISTOR CARTRIDGE.....................................................279 REPLACE FUEL FILTER CARTRIDGE............................................................280 EVERY 2000 HOURS SERVICE.....................................................................282 CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC FILTER ELEMENT...........................282 REPLACE HYDRAULIC TANK BREATHER ELEMENT..................................................284 CHANGE AXLE OIL..........................................................................285 REPLACE ELEMENT IN AIR CONDITIONER RECIRCULATION AIR FILTER, FRESH AIR FILTER............285 CLEAN PPC CIRCUIT STRAINER...............................................................286 CLEAN ENGINE BREATHER ELEMENT............................................................286 CHECK BRAKE DISC WEAR....................................................................287 CHECKING FUNCTION OF ACCUMULATOR.........................................................288 CHECK ALTERNATOR, STARTING MOTOR.........................................................288 CHECK ENGINE VALVE CLEARANCE, ADJUST.....................................................288 CLEAN AND CHECK TURBOCHARGER.............................................................288 CHECK INJECTOR...........................................................................288 CHECK VIBRATION DAMPER...................................................................288 EVERY 4000 HOURS SERVICE.....................................................................289 LUBRICATING..............................................................................289 CHECK WATER PUMP.........................................................................290 CHECK AIR CONDITIONER COMPRESSOR, ADJUST.................................................290 CHECK INJECTOR...........................................................................290 REPLACE INJECTOR ASSEMBLY................................................................290 CHECKING FOR LOOSENESS OF HIGH-PRESSURE CLAMP, HARDENING OF RUBBER.......................290 CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER......................291 EVERY 8000 HOURS SERVICE.....................................................................292 REPLACE INJECTOR NOZZLE TIP..............................................................292 REPLACE HIGH-PRESSURE PIPING CLAMP.......................................................292 REPLACE FUEL SPRAY PREVENTION CAP........................................................292 SPECIFICATIONS.......................................................................................293 SPECIFICATIONS...................................................................................294 ATTACHMENTS, OPTIONS.................................................................................295 HANDLING LOAD METER..............................................................................296 GENERAL LOCATIONS............................................................................296 LOAD METER FUNCTIONS.........................................................................298 HANDLING LOAD METER DISPLAY..................................................................301 METHOD OF SETTING TIME ON CLOCK..............................................................317 PRINTER OUTPUT...............................................................................319 HANDLING TORQUE CONVERTER LOCK-UP................................................................322 GENERAL LOCATIONS............................................................................322 METHOD OF OPERATION .........................................................................323 WARNING/LIMIT FUNCTIONS FOR TRAVEL SPEED.....................................................324 HANDLING AUTO-GREASING SYSTEM....................................................................325 METHOD OF OPERATING AUTO-GERASING SYSTEM.....................................................325 PRECAUTIONS WHEN HANDLING AUTO-GREASING SYSTEM...............................................331 TROUBLESHOOTING..............................................................................331 HANDLING JOYSTICK STEERING SYSTEM ...............................................................332 EXPLANATION OF COMPONENTS....................................................................332 STRUCTURE AND FUNCTION OF JOYSTICK STEERING..................................................334 GETTING IN OR OUT OF OPERATOR'S CAB..........................................................336 ADJUSTMENT OF JOYSTICK CONSOLE...............................................................336 OPERATION METHOD OF JOYSTICK STEERING SYSTEM.................................................337 HANDLING EPC WORK EQUIPMENT LEVER................................................................340 OPERATIONAL FEATURES.........................................................................340 SWITCHES.....................................................................................340 SEMI AUTO DIGGING OPERATIONS.................................................................341 METHOD OF REMOTE POSITIONER..................................................................343 HANDLING MULTI-FUNCTION LEVER....................................................................345 EXPLANATION OF COMPONENTS....................................................................345 USING FNR SWITCH TO CHANGE BETWEEN FORWARD AND REVERSE.......................................349 INDEX................................................................................................351
DESCRIPTION:
KOMATSU GALEO WA470-5 WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:70001 & UP) KOMATSU WA470-5
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
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