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KOMATSU WA470-5H WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:H50051 & UP) KOMATSU WA470 5H – PDF DOWNLOAD
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- KOMATSU WA470-5H WHEEL LOADER OPERATION & MAINTENANCE MANUAL
- SERIAL NUMBER:H50051 & UP
- PUBLICATION NUMBER:VEAM180100
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Description
KOMATSU WA470-5H WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:H50051 & UP) KOMATSU WA470 5H
KOMATSU WA470-5H WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:H50051 & UP) KOMATSU WA470 5H – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU WA470-5H WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:H50051 & UP) KOMATSU WA470 5H
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 hazard when performing operation and maintenance.
TABLE OF CONTENTS:
KOMATSU WA470-5H WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:H50051 & UP) KOMATSU WA470 5H
WA470-5.............................................................................................. 1 FOREWORD............................................................................................. 3 FOREWORD......................................................................................... 4 SAFETY INFORMATION............................................................................... 6 INTRODUCTION..................................................................................... 8 INTENDED USE................................................................................. 8 DIRECTIONS OF MACHINE........................................................................ 8 NECESSARY INFORMATION............................................................................ 9 MACHINE SERIAL NO. PLATE AND POSITION........................................................ 9 ENGINE SERIAL NO. PLATE AND POSITION......................................................... 9 ROPS/FOPS-CAB SERIAL NO. PLATE............................................................... 10 AXLE SERIAL NO. PLATE........................................................................ 10 TRANSMISSION SERIAL NO. PLATE................................................................ 10 SEAT OPERATOR SERIAL NO. PLATE............................................................... 10 POSITION OF SERVICE METER.................................................................... 11 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR.................................................... 11 CONTENTS......................................................................................... 12 DIMENSIONS, WEIGHTS AND OPERATING DATA........................................................... 19 WA470-5H: DIMENSIONS, WEIGHTS AND OPERATING DATA............................................. 19 CE-CONFORMING EQUIPMENT.......................................................................... 20 CE-CONFORMING EQUIPMENT - PART 1............................................................. 20 MANUFACTURER-SUPPLIED CE-CONFORMING EQUIPMENT, ACCORDING TO DOCUMENT 421-93-H1900............ 21 SAFETY............................................................................................... 25 SAFETY LABELS.................................................................................... 27 LOCATION OF SAFETY LABELS.................................................................... 27 SAFETY LABELS................................................................................ 28 GENERAL PRECAUTIONS.............................................................................. 29 PRECAUTIONS FOR OPERATION........................................................................ 37 BEFORE STARTING ENGINE....................................................................... 37 OPERATION.................................................................................... 38 TRANSPORTATION............................................................................... 45 BATTERY...................................................................................... 46 TOWING....................................................................................... 48 PRECAUTIONS FOR MAINTENANCE...................................................................... 49 PRECAUTIONS WITH TIRES........................................................................... 56 OPERATION............................................................................................ 57 GENERAL VIEW..................................................................................... 58 GENERAL VIEW OF MACHINE...................................................................... 58 GENERAL VIEW OF CONTROLS AND GAUGES.......................................................... 59 EXPLANATION OF COMPONENTS........................................................................ 62 MACHINE MONITOR.............................................................................. 62 TYPES OF WARNING......................................................................... 63 CENTRAL WARNING LAMP..................................................................... 63 CHARACTER DISPLAY PORTION................................................................ 64 EMERGENCY STOP ITEM...................................................................... 70 CAUTION ITEMS............................................................................ 73 INSPECTION AND MAINTENANCE ITEM.......................................................... 76 PILOT DISPLAY PORTION.................................................................... 80 METER DISPLAY PORTION.................................................................... 85 OTHER FUNCTIONS OF MACHINE MONITOR....................................................... 87 SWITCHES..................................................................................... 92 CONTROL LEVERS, PEDALS.......................................................................107 STEERING TILT LOCK LEVER.....................................................................113 CAP WITH LOCK................................................................................114 METHOD OF OPENING AND CLOSING CAP WITH LOCK (FOR THE FUEL TANK FILLER PORT)..............114 METHOD OF OPENING AND CLOSING CAP WITH LOCK (FOR THE HYDRAURIC TANK FILLER PORT).........115 SAFETY BAR...................................................................................116 TOWING PIN...................................................................................116 GREASE PUMP..................................................................................116 CAB DOOR OPEN LOCK...........................................................................117 CAB WINDOW OPEN LOCK CANCEL KNOB.............................................................117 BACKUP ALARM.................................................................................117 FUSE.........................................................................................118 FUSE CAPACITY AND NAME OF CIRCUIT........................................................119 SLOW-BLOW FUSE...............................................................................120 TAKING OFF POWER.............................................................................120 HANDLING CAB WIPER...........................................................................121 PREVENTING DAMAGE TO WIPER ARM BRACKET...................................................121 DUST INDICATOR...............................................................................121 OPERATION........................................................................................122 CHECK BEFORE STARTING ENGINE, ADJUST.........................................................122 WALK-AROUND CHECK........................................................................122 CHECK BEFORE STARTING....................................................................125 ADJUSTMENT...............................................................................130 OPERATIONS AND CHECKS BEFORE STARTING ENGINE.............................................135 STARTING ENGINE..............................................................................137 AUTOMATIC WARMING-UP OPERATION...........................................................139 OPERATIONS AND CHECKS AFTER STARTING ENGINE..................................................140 BREAKING IN THE MACHINE..................................................................140 NORMAL OPERATION.........................................................................140 STOPPING ENGINE..............................................................................142 CHECK AFTER STOPPING ENGINE..................................................................142 MOVING MACHINE OFF (DIRECTIONAL, SPEED), STOPPING............................................143 PREPARATIONS FOR MOVING MACHINE..........................................................143 CHANGING GEAR SPEED......................................................................146 CHANGING DIRECTION.......................................................................147 STOPPING MACHINE.........................................................................149 TURNING......................................................................................152 EMERGENCY STEERING.......................................................................152 OPERATION OF WORK EQUIPMENT..................................................................154 WORK POSSIBLE USING WHEEL LOADER.............................................................156 DIGGING OPERATIONS.......................................................................156 LEVELING OPERATIONS......................................................................160 PUSHING OPERATION........................................................................160 LOAD AND CARRY OPERATIONS................................................................160 LOADING OPERATIONS.......................................................................161 PRECAUTIONS FOR OPERATION....................................................................163 PERMISSIBLE WATER DEPTH..................................................................163 IF WHEEL BRAKE DOES NOT WORK.............................................................163 PRECAUTIONS WHEN DRIVING UP OR DOWN SLOPES...............................................163 PRECAUTIONS REGARDING BRAKE FUNCTION.....................................................164 ADJUSTING WORK EQUIPMENT POSTURE.............................................................165 ADJUSTING BOOM KICKOUT...................................................................165 ADJUSTING BUCKET POSITIONER..............................................................167 BUCKET LEVEL INDICATOR...................................................................167 PARKING MACHINE..............................................................................168 CHECKS AFTER COMPLETION OF OPERATION.........................................................170 LOCKING......................................................................................170 HANDLING THE TIRES...........................................................................171 PRECAUTIONS WHEN HANDLING TIRES..........................................................171 TIRE PRESSURE............................................................................171 PRECAUTIONS WHEN LOAD AND CARRY METHOD...................................................172 TRANSPORTATION...................................................................................173 TRANSPORTATION PROCEDURE.....................................................................173 LOADING, UNLOADING WORK WITH TRAILERS........................................................173 LOADING..................................................................................173 SECURING MACHINE.........................................................................174 UNLOADING................................................................................174 LIFTING MACHINE..............................................................................175 POSITION FOR STICKING LIFTING POSITION MARK..............................................176 WEIGHT TABLE.............................................................................176 LIFTING PROCEDURE........................................................................177 COLD WEATHER OPERATION...........................................................................178 PRECAUTIONS FOR LOW TEMPERATURE..............................................................178 FUEL AND LUBRICANTS......................................................................178 COOLANT..................................................................................178 BATTERY..................................................................................179 PRECAUTIONS AFTER COMPLETION OF WORK.........................................................179 AFTER COLD WEATHER...........................................................................179 WARMING-UP OPERATION FOR STEERING HYDRAURIC CIRCUIT IN COLD WEATHER..........................180 LONG-TERM STORAGE................................................................................181 BEFORE STORAGE...............................................................................181 DURING STORAGE...............................................................................181 AFTER STORAGE................................................................................181 TROUBLESHOOTING..................................................................................182 WHEN MACHINE RUNS OUT OF FUEL................................................................182 TOWING THE MACHINE...........................................................................183 WHEN ENGINE CAN BE USED..................................................................184 WHEN ENGINE CANNOT BE USED...............................................................184 RELEASING PARKING BRAKE..................................................................184 EMERGENCY TRAVEL OPERATION...............................................................186 IF BATTERY IS DISCHARGED.....................................................................187 REMOVAL AND INSTALLATION OF BATTERY......................................................187 PRECAUTIONS FOR CHARGING BATTERY.........................................................188 STARING ENGINE WITH BOOSTER CABLE........................................................188 OTHER TROUBLE................................................................................190 ELECTRICAL SYSTEM........................................................................190 CHASSIS..................................................................................191 ENGINE...................................................................................193 MAINTENANCE..........................................................................................195 GUIDES TO MAINTENANCE............................................................................196 OUTLINES OF SERVICE..............................................................................198 OUTLINE OF OIL, FUEL, COOLANT................................................................198 OIL......................................................................................198 FUEL.....................................................................................198 COOLANT..................................................................................198 GREASE...................................................................................199 CARRYING OUT KOWA (Komatsu Oil Wear Analysis)............................................199 STORING OIL AND FUEL.....................................................................200 FILTERS..................................................................................200 OUTLINE OF ELECTRIC SYSTEM...................................................................200 WEAR PARTS LIST..................................................................................201 THE PARTS IN PARENTHESES ARE TO BE REPLACED AT THE SAME TIME.................................201 LUBRICANTS AND OPERATING MEANS...................................................................202 LUBRICATION CHART............................................................................202 LUBRICANTS, FUELS AND FILLING CAPACITIES.....................................................203 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS...................................................207 TORQUE LIST..................................................................................207 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS....................................................208 MAINTENANCE SCHEDULE CHART.......................................................................209 MAINTENANCE SCHEDULE CHART...................................................................209 SERVICE PROCEDURE................................................................................211 INITIAL 250 HOURS SERVICE....................................................................211 WHEN REQUIRED................................................................................212 CHECK, CLEAN, OR REPLACE AIR CLEANER ELEMENT.............................................212 CLEAN INSIDE OF COOLING SYSTEM...........................................................215 CHECK TRANSMISSION OIL LEVEL, ADD OIL....................................................218 CHECK AXLE OIL LEVEL, ADD OIL............................................................219 CHECK AXLE CASE BREATHER.................................................................220 CLEAN CONDENSER OF AIR CONDENSER.........................................................220 CHECK WINDOW WASHING FLUID LEVEL, ADD FLUID..............................................221 CLEAN RADIATOR FINS AND COOLER FINS......................................................222 CHECK ELECTRICAL INTAKE AIR HEATER.......................................................225 REPLACE BOLT ON CUTTING EDGE.............................................................225 REPLACE BUCKET TEETH.....................................................................226 CHECK AIR CONDITIONER....................................................................227 REPLACE SLOW BLOW FUSE...................................................................228 SELECTION AND INSPECTION OF TIRES........................................................229 CHECK BEFORE STARTING........................................................................231 EVERY 50 HOURS SERVICE.......................................................................232 DRAIN WATER, SEDIMENT FROM FUEL TANK.....................................................232 EVERY 100 HOURS SERVICE......................................................................233 CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL...............................................233 CLEAN ELEMENT IN AIR CONDITIONER FRESH AIR FILTER........................................234 EVERY 250 HOURS SERVICE......................................................................235 CHECK ENGINE ELECTROLYTE LEVEL...........................................................235 CHECK PARKING BRAKE......................................................................236 CHECK ALTERNATOR BELT TENSION, ADJUST....................................................237 CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST....................................238 CHECK FOR LOOSE WHEEL HAB NUTS, TIGHTEN..................................................238 CLEAN ELEMENT IN AIR CONDITIONER RECIRCULATION FILTER....................................239 EVERY 500 HOURS SERVICE......................................................................240 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE........................240 REPLACE FUEL FILTER CARTRIDGE............................................................241 CLEAN FUEL STRAINER......................................................................243 EVERY 1000 HOURS SERVICE.....................................................................244 CHANGE OIL IN TRANSMISSION CASE AND TRANSMISSION OIL FILTER CARTRIDGE, CLEAN STRAINER....244 CLEAN TRANSMISSION CASE BREATHER.........................................................245 CHECK TIGTENING PARTS OF TURBOCHARGER....................................................245 CHECK PLAY OF TURBOCHARGER ROTOR.........................................................245 REPLACE CORROSION RESISTOR CARTRIDGE.....................................................245 EVERY 2000 HOURS SERVICE.....................................................................246 CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC FILTER ELEMENT...........................246 REPLACE HYDRAULIC TANK BREATHER ELEMENT..................................................248 CHANGE AXLE OIL..........................................................................249 REPLACE ELEMENT IN AIR CONDITIONER RECIRCULATION AIR FILTER, FRESH AIR FILTER............249 CLEAN PPC CIRCUIT STRAINER...............................................................250 CLEAN ENGINE BREATHER ELEMENT............................................................250 CHEK ALTERNATOR, STARTING MOTOR..........................................................250 CHECK ENGINE VALVE CLEARANCE, ADJUST.....................................................250 CLEAN AND CHECK TURBOCHARGER.............................................................250 CHECK INJECTOR...........................................................................251 CHECK ACCUMULATOR GAS PRESSURE...........................................................251 CHECK VIBRATION DAMPER...................................................................251 CHECK BRAKE DISC WEAR....................................................................252 EVERY 4000 HOURS SERVICE.....................................................................253 LUBRICATING..............................................................................253 CHECK WATER PUMP.........................................................................253 CHECK AIR CONDITIONER COMPRESSOR, ADJUST.................................................254 CHECK INJECTOR NOZZLE TIP................................................................254 CHECKING FOR LOOSENESS OF HIGH-PRESSURE CLAMP, HARDENING OF RUBBER.......................254 CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER......................255 EVERY 8000 HOURS SERVICE.....................................................................256 REPLACE HIGH-PRESSURE PIPING CLAMP.......................................................256 REPLACE FUEL SPRAY PREVENTION CAP........................................................256 CHECK INJECTOR NOZZLE TIP, REPLACE IF NECESSARY..........................................256 TECHNICAL DATA.......................................................................................257 TECHNICAL DATA...................................................................................258 NOISE EMISSION LEVELS............................................................................260 VIBRATION LEVEL..................................................................................260 LIMIT VALUES FOR SLOPES..........................................................................261 ATTACHMENTS, OPTIONS.................................................................................263 HANDLING LOAD METER..............................................................................264 GENERAL LOCATIONS............................................................................264 MACHINE MONITOR WITH LOAD METER..........................................................264 SWITCHES.................................................................................265 LOAD METER FUNCTIONS.........................................................................266 HANDLING LOAD METER DISPLAY..................................................................269 SETTING ADDITION MODE....................................................................269 SETTING REMAIN MODE......................................................................271 TOTAL LOAD DATA DISPLAY..................................................................274 STOPPING CALCULATION.....................................................................276 CARRYING OUT CALIBRATION (ADJUSTING 0 POINT) WHEN EMPTY..................................277 CARRYING OUT CALIBRATION (ADJUSTING 0 POINT) WHEN LOADED.................................279 SUBTRACTION FUNCTION.....................................................................282 METHOD OF SETTING TIME ON CLOCK..............................................................284 PRINTER OUTPUT...............................................................................286 PRINTOUT MODE............................................................................286 METHOD OF SELECTING PRINTOUT MODE........................................................287 HANDLING TORQUE CONVERTER LOCK-UP................................................................289 GENERAL LOCATIONS............................................................................289 METHOD OF OPERATION..........................................................................290 WARNING/LIMIT FUNCTIONS FOR TRAVEL SPEED.....................................................291 AIR CONDITIONER..................................................................................292 GENERAL LOCATIONS AND FUNCTION OF CONTROL PANEL..............................................292 METHOD OF OPERATION..........................................................................295 PRECAUTIONS WHEN USING.......................................................................296 HANDLING AUTOMATIC AIR-CONDITIONER...............................................................297 GENERAL LOCATIONS AND FUNCTIONS OF CONTROL PANEL.............................................297 METHOD OF OPERATION..........................................................................301 PRECAUTIONS WHEN USING.......................................................................303 INSPECTION AND MAINTENANCE...................................................................303 CENTRAL LUBRICATION..............................................................................304 OPERATION....................................................................................304 DISPLAY AND CONTROL UNIT.....................................................................305 LED-DISPLAY..............................................................................305 PUSHBUTTONS..............................................................................305 CHANGING THE LUBRICATION INTERVAL TIMES......................................................306 HANDLING JOYSTICK STEERING SYSTEM................................................................307 EXPLANATION OF COMPONENTS....................................................................307 SHIFT UP, SHIFT DOWN SWITCHES............................................................307 FNR SWITCH...............................................................................308 JOYSTICK STEERING LEVER..................................................................308 JOYSTICK ON/OFF SWITCH...................................................................308 HI/LOW SELECTOR SWITCH...................................................................308 HORN SWITCH..............................................................................309 CONSOLE LOCK LEVER.......................................................................309 HEIGHT ADJUSTMENT LOCK LEVER.............................................................309 ANGLE, FORE/AFT ADJUSTMENT LOCK LEVER....................................................309 STRUCTURE AND FUNCTION OF JOYSTICK STEERING..................................................309 GETTING IN OR OUT OF OPERATOR‘S CAB..........................................................311 ADJUSTMENT OF JOYSTICK CONSOLE...............................................................311 OPERATION METHOD OF JOYSTICK STEERING SYSTEM.................................................312 INDEX............................................................................................315 NOTES................................................................................................317 NOTES............................................................................................318
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