Komatsu WA470-6 Wheel Loader Operation & Maintenance Manual – PDF Download

Description

Komatsu WA470-6 Wheel Loader Operation & Maintenance Manual

Description:

Komatsu WA470-6 Wheel Loader Operation & Maintenance Manual

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.

Table of Contents:

Komatsu WA470-6 Wheel Loader Operation & Maintenance Manual

1. Foreword............................................................................................  3
	1.1 Foreword.......................................................................................  4
		1.1.1 EU Directives............................................................................  5
	1.2 Safety information.............................................................................  6
		1.2.1 Signal words.............................................................................  6
		1.2.2 Safety labels............................................................................  8
	1.3 Introduction...................................................................................  9
		1.3.1 Intended use.............................................................................  9
		1.3.2 Directions of machine.................................................................... 10
		1.3.3 Visibility from operator's seat.......................................................... 10
	1.4 Necessary information.......................................................................... 12
		1.4.1 Product Identification Number (PIN)/Machine serial no. plate and position................ 12
		1.4.2 Engine serial no. plate and position..................................................... 12
		1.4.3 ROPS/FOPS-Cab serial no. plate........................................................... 13
		1.4.4 Axle serial no. plate.................................................................... 13
		1.4.5 Transmission serial no. plate............................................................ 13
		1.4.6 Seat operator serial no. plate........................................................... 14
		1.4.7 Position of service meter................................................................ 14
		1.4.8 Table to enter serial no. and distributor................................................ 14
	1.5 Contents....................................................................................... 15
	1.6 Dimensions, weights and operating data......................................................... 23
		1.6.1 WA470-6H: Dimensions, weights and operating data......................................... 23
	1.7 CE-Conforming equipment........................................................................ 24
		1.7.1 CE-Conforming equipment.................................................................. 24
		1.7.2 Manufacturer-supplied CE-Conforming equipment, according to document 419-93-H1250........ 25
2. Safety.............................................................................................. 29
	2.1 Safety labels.................................................................................. 30
		2.1.1 Location of safety labels................................................................ 30
		2.1.2 Presentation of safety labels............................................................ 31
	2.2 General precautions............................................................................ 35
	2.3 Precautions for operation...................................................................... 48
		2.3.1 Starting engine.......................................................................... 48
		2.3.2 Operation................................................................................ 50
		2.3.3 Transportation........................................................................... 57
		2.3.4 Battery.................................................................................. 59
		2.3.5 Towing................................................................................... 61
	2.4 Precautions for maintenance.................................................................... 62
	2.5 Precautions with tires......................................................................... 71
3. Operation........................................................................................... 73
	3.1 General view................................................................................... 74
		3.1.1 General view of machine.................................................................. 74
		3.1.2 General view of controls and gauges...................................................... 75
	3.2 Explanation of components...................................................................... 79
		3.2.1 Machine monitor.......................................................................... 79
			Types of warning........................................................................... 80
			Central warning lamp....................................................................... 81
			Character display portion.................................................................. 82
			Emergency stop item........................................................................ 88
			Caution items.............................................................................. 91
			Inspection and maintenance item............................................................ 94
			Pilot display portion...................................................................... 98
			Meter display portion......................................................................104
			Other functions of machine monitor.........................................................107
		3.2.2 Switches.................................................................................112
		3.2.3 Control levers, pedals...................................................................128
		3.2.4 Steering tilt lock lever.................................................................135
		3.2.5 Cap with lock............................................................................136
		3.2.6 Safety bar...............................................................................137
		3.2.7 Towing pin...............................................................................138
		3.2.8 Grease pump..............................................................................138
		3.2.9 Cab door.................................................................................139
		3.2.10 Cab door open lock......................................................................139
		3.2.11 Cab window open lock....................................................................140
			Cab left window open lock reset knob.......................................................140
			Cab right window open lock reset knob......................................................140
			Reset right window open lock for escape....................................................140
		3.2.12 Backup alarm............................................................................141
		3.2.13 Fuse....................................................................................142
			Fuse capacity and name of circuit..........................................................142
		3.2.14 Slow blow fuse..........................................................................143
		3.2.15 Power outlet............................................................................144
		3.2.16 Air conditioner (standard)..............................................................145
			General locations and function of control panel............................................145
			Method of operation........................................................................148
			Precautions when using.....................................................................150
			Precautions for inspection and maintenance.................................................150
			Cool box...................................................................................151
		3.2.17 Air conditioner (automatic).............................................................152
			General locations and function of control panel............................................152
			Method of operation........................................................................156
			Precautions when using.....................................................................158
			Precautions for inspection and maintenance.................................................158
		3.2.18 Handling cab wiper......................................................................159
			Preventing damage to wiper arm bracket.....................................................159
	3.3 Operation......................................................................................160
		3.3.1 Check before starting engine, adjust.....................................................160
			Walk-around check..........................................................................160
			Check before starting......................................................................163
			Adjustment.................................................................................171
			Safety belt................................................................................172
			Adjust lever stand.........................................................................173
			Adjusting mirrors..........................................................................174
			Operations and checks before starting engine...............................................175
		3.3.2 Starting engine..........................................................................177
			Normal starting............................................................................177
			Starting in cold weather...................................................................179
			Automatic warming-up operation.............................................................181
		3.3.3 Operations and checks after starting engine..............................................182
			Breaking-in the machine....................................................................182
			Normal operation...........................................................................183
		3.3.4 Stopping engine..........................................................................185
		3.3.5 Check after stopping engine..............................................................185
		3.3.6 Moving the machine (directional, speed), stopping the machine............................186
			Preparations for moving the machine........................................................186
			Changing gear speed........................................................................189
			Changing direction.........................................................................190
			Using switch to change between forward and reverse.........................................192
			Stopping the machine.......................................................................194
			Transmission cut-off function..............................................................195
		3.3.7 Turning..................................................................................197
			Emergency steering.........................................................................198
		3.3.8 Operation of work equipment..............................................................200
			Lift arm operation.........................................................................201
			Bucket operation...........................................................................201
		3.3.9 Work possible using wheel loader.........................................................202
			Digging operations.........................................................................202
			Leveling operation.........................................................................206
			Pushing operation..........................................................................206
			Load and carry operations..................................................................206
			Loading operations.........................................................................207
		3.3.10 Precautions for operation...............................................................209
			Permissible water depth....................................................................209
			If wheel brake does not work...............................................................209
			Precautions when driving up or down slopes.................................................209
		3.3.11 Adjusting work equipment posture........................................................212
			Adjusting boom kickout.....................................................................212
			Adjusting bucket positioner................................................................213
			Bucket level indicator.....................................................................213
		3.3.12 Parking machine.........................................................................214
		3.3.13 Checks after completion of operation....................................................216
			Before stopping engine.....................................................................216
			After stopping engine......................................................................216
		3.3.14 Locking.................................................................................217
		3.3.15 Handling the tires......................................................................218
			Precautions when handling tires............................................................218
			Tire pressure..............................................................................218
			Precautions for using load and carry method................................................220
	3.4 Transportation.................................................................................221
		3.4.1 Transportation procedure.................................................................221
		3.4.2 Loading, unloading work with trailers....................................................221
			Loading....................................................................................222
			Securing machine...........................................................................222
			Unloading..................................................................................224
		3.4.3 Lifting machine..........................................................................225
			Location of lifting position mark..........................................................226
			Weight table...............................................................................226
			Lifting procedure..........................................................................227
	3.5 Cold weather operation.........................................................................228
		3.5.1 Precautions for low temperature..........................................................228
			Fuel and lubricants........................................................................228
			Coolant....................................................................................228
			Battery....................................................................................229
		3.5.2 Precautions after completion of work.....................................................230
		3.5.3 After cold weather.......................................................................230
		3.5.4 Warming-up operation for steering hydraulic circuit in cold weather......................231
	3.6 Long-term storage..............................................................................232
		3.6.1 Before storage...........................................................................232
		3.6.2 During storage...........................................................................232
		3.6.3 After storage............................................................................233
	3.7 Troubleshooting................................................................................234
		3.7.1 When machine runs out of fuel............................................................234
		3.7.2 Towing the machine.......................................................................234
			When engine can be used....................................................................237
			When engine cannot be used.................................................................237
			Releasing parking brake....................................................................238
			Emergency travel operation.................................................................240
		3.7.3 If battery is discharged.................................................................241
			Removal and installation of battery........................................................242
			Precautions for charging battery...........................................................242
			Starting engine with booster cable.........................................................243
		3.7.4 Other trouble............................................................................245
			Electrical system..........................................................................245
			Chassis....................................................................................246
			Engine.....................................................................................248
4. Maintenance.........................................................................................251
	4.1 Guides to maintenance..........................................................................252
	4.2 Outlines of service............................................................................256
		4.2.1 Handling oil, fuel, coolant, grease and carrying out KOWA (KOMATSU Oil Wear Analysis)....257
			Oil........................................................................................257
			Fuel.......................................................................................258
			Coolant and water for dilution.............................................................259
			Grease.....................................................................................260
			Carrying out KOWA (KOMATSU Oil Wear Analysis)..............................................260
			Storing oil and fuel.......................................................................262
			Filters....................................................................................262
		4.2.2 Outline of electric system...............................................................263
	4.3 Wear parts.....................................................................................264
		4.3.1 Wear parts list..........................................................................264
	4.4 Fuel, coolant and lubricants...................................................................266
		4.4.1 Lubrication chart........................................................................268
		4.4.2 Use of fuel, coolant and lubricants according to ambient temperature.....................269
		4.4.3 Recommended brands, recommended quality for products other than KOMATSU genuine oil......272
	4.5 Standard tightening torques for bolts and nuts.................................................273
		4.5.1 Torque list..............................................................................273
	4.6 Periodic replacement of safety critical parts..................................................275
	4.7 Maintenance schedule chart.....................................................................277
		4.7.1 Maintenance schedule chart...............................................................277
	4.8 Replace injector assembly......................................................................280
	4.9 Service procedure..............................................................................281
		4.9.1 Initial 50 hours service (only after the first 50 hours).................................281
			Check for loose wheel hub bolts, tighten...................................................281
		4.9.2 Initial 250 hours service (only after the first 250 hours)...............................281
			Replace transmission oil filter cartridge..................................................281
			Replace hydraulic tank filter element......................................................281
		4.9.3 Initial 1000 hours service (only after the first 1000 hours).............................281
			Check engine valve clearance, adjust.......................................................281
		4.9.4 When required............................................................................282
			Clean, replace air cleaner element.........................................................282
			Clean inside of cooling system.............................................................285
			Check transmission oil level, add oil......................................................289
			Check axle oil level, add oil..............................................................290
			Clean axle case breather...................................................................291
			Clean air conditioner condenser............................................................292
			Check window washing fluid level, add fluid................................................293
			Clean radiator fins and cooler fins........................................................293
			Turn, replace bolt on cutting edge.........................................................297
			Replace bucket teeth.......................................................................298
			Check air conditioner......................................................................299
			Replace slow blow fuse.....................................................................301
			Checking function of accumulator...........................................................302
			Selection and inspection of tires..........................................................303
		4.9.5 Check before starting....................................................................305
			Check before starting......................................................................305
		4.9.6 Every 50 hours service...................................................................305
			Drain water, sediment from fuel tank.......................................................305
		4.9.7 Every 100 hours service..................................................................306
			Lubricate rear axle pivot pin..............................................................306
			Check oil level in hydraulic tank, add oil.................................................306
			Clean element in air conditioner fresh air filter..........................................307
		4.9.8 Every 250 hours service..................................................................308
			Check battery electrolyte level............................................................308
			Check parking brake........................................................................311
			Check alternator belt tension, adjust......................................................311
			Check air conditioner compressor belt tension, adjust......................................313
			Check for loose wheel hub bolts, tighten...................................................315
			Clean element in air conditioner recirculation filter......................................315
			Checking function of accumulator...........................................................316
			Lubricating................................................................................317
		4.9.9 Every 500 hours service..................................................................318
			Change oil in engine oil pan, replace engine oil filter cartridge..........................318
			Replace fuel pre-filter cartridge..........................................................320
		4.9.10 Every 1000 hours service................................................................322
			Replace fuel main filter cartridge.........................................................322
			Change oil in transmission case and transmission oil filter cartridge, clean strainer......324
			Clean transmission case breather...........................................................325
			Lubricating................................................................................326
			Check of engine air intake piping clamps for looseness.....................................326
			Replace corrosion resistor cartridge.......................................................326
		4.9.11 Every 2000 hours service................................................................327
			Change oil in hydraulic tank, replace hydraulic filter element.............................327
			Replace hydraulic tank breather element....................................................330
			Change axle oil............................................................................331
			Replace element in air conditioner recirculation air filter, fresh air filter..............332
			Check brake disc wear......................................................................332
			Checking function of accumulator...........................................................334
			Check alternator...........................................................................335
			Check engine valve clearance, adjust.......................................................335
			Check vibration damper.....................................................................335
		4.9.12 Every 4000 hours service................................................................336
			Lubricating................................................................................336
			Check water pump...........................................................................337
			Check air conditioner compressor, adjust...................................................337
			Check for loose engine high-pressure piping clamps, hardening of rubber....................338
			Checking for missing fuel spray prevention cap, hardening of rubber........................338
			Check starting motor.......................................................................339
		4.9.13 Every 8000 hours service................................................................339
			Replace high-pressure piping clamp.........................................................339
			Replace fuel spray prevention cap..........................................................339
		4.9.14 Every 12000 hours service...............................................................339
			Replace injector assembly..................................................................339
5. Technical Data......................................................................................341
	5.1 Technical data.................................................................................342
	5.2 Noise emission levels..........................................................................344
	5.3 Vibration level................................................................................345
	5.4 Limit values for slopes........................................................................347
6. Attachments, Options................................................................................349
	6.1 Selecting bucket and tires.....................................................................350
	6.2 Handling torque converter lock-up..............................................................351
		6.2.1 General locations........................................................................352
		6.2.2 Method of operation......................................................................354
		6.2.3 Warning/limit functions for travel speed.................................................355
			Travel speed warning function..............................................................355
			Travel speed limit function................................................................355
	6.3 Handling machines equipped with KOMTRAX........................................................356
		6.3.1 Basic precautions........................................................................357
	6.4 Joystick steering system.......................................................................358
		6.4.1 Components...............................................................................358
		6.4.2 Structure and function...................................................................361
			Operation using joystick lever and operation using steering wheel..........................362
			Getting in or out..........................................................................363
			Adjustment of joystick console.............................................................364
		6.4.3 Operation method of joystick steering system.............................................365
	6.5 Multi-function lever (with/without auxiliary control lever)....................................368
		6.5.1 Explanation of components................................................................368
		6.5.2 Operation................................................................................373
			Using switch to change between forward and reverse.........................................373
	6.6 3-lever control................................................................................375
		6.6.1 Explanation of components................................................................375
	6.7 Central lubrication system.....................................................................378
		6.7.1 Operating the central lubrication system.................................................378
		6.7.2 Display and control unit.................................................................378
			LED-display................................................................................379
			Pushbuttons................................................................................379
		6.7.3 Changing the lubrication interval times..................................................380
7. Index...............................................................................................381
	7.1 Index..........................................................................................382
8. Notes...............................................................................................387

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KOMATSU WA470-6 WHEEL LOADER OPERATION & MAINTENANCE MANUAL – PDF DOWNLOAD:

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