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KOMATSU WA480-5H WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:H50051 & UP) KOMATSU WA480-5H – PDF DOWNLOAD
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- KOMATSU WA480-5H WHEEL LOADER OPERATION & MAINTENANCE MANUAL
- PUBLICATION NUMBER:VEAM190100
- SERIAL NUMBER:H50051 & UP
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KOMATSU WA480-5H WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:H50051 & UP) KOMATSU WA480-5H
KOMATSU WA480-5H WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:H50051 & UP) KOMATSU WA480-5H – PDF DOWNLOAD:
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KOMATSU WA480-5H WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:H50051 & UP) KOMATSU WA480-5H
- 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 at 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.
TABLE OF CONTENTS:
KOMATSU WA480-5H WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:H50051 & UP) KOMATSU WA480-5H
WA480-5H............................................................................................. 1 FOREWORD............................................................................................. 3 FOREWORD......................................................................................... 4 SAFETY INFORMATION............................................................................... 5 INTRODUCTION..................................................................................... 7 FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE................................................. 7 NECESSARY INFORMATION............................................................................ 8 MACHINE SERIAL NO. PLATE AND POSITION........................................................ 8 ENGINE SERIAL NO. PLATE AND POSITION......................................................... 8 POSITION OF SERVICE METER.................................................................... 9 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR.................................................... 9 CONTENTS......................................................................................... 10 SAFETY............................................................................................... 18 SAFETY........................................................................................... 19 SAFETY LABELS.................................................................................... 21 LOCATION OF SAFETY LABELS.................................................................... 21 SAFETY LABELS................................................................................ 22 GENERAL PRECAUTIONS.............................................................................. 23 PRECAUTIONS FOR OPERATION........................................................................ 31 BEFORE STARTING ENGINE....................................................................... 31 OPERATION.................................................................................... 32 TRANSPORTATION............................................................................... 38 BATTERY...................................................................................... 39 TOWING....................................................................................... 41 PRECAUTIONS FOR MAINTENANCE...................................................................... 42 PRECAUTIONS WITH TIRES........................................................................... 49 OPERATION............................................................................................ 50 GENERAL VIEW..................................................................................... 51 GENERAL VIEW OF MACHINE...................................................................... 51 GENERAL VIEW OF CONTROLS AND GAUGES.......................................................... 52 EXPLANATION OF COMPONENTS........................................................................ 55 MACHINE MONITOR.............................................................................. 55 TYPES OF WARNING......................................................................... 56 CENTRAL WARNING LAMP..................................................................... 56 CHARACTER DISPLAY PORTION................................................................ 57 EMERGENCY STOP ITEM...................................................................... 63 CAUTION ITEMS............................................................................ 66 INSPECTION AND MAINTENANCE ITEM.......................................................... 69 PILOT DISPLAY PORTION.................................................................... 73 METER DISPLAY PORTION.................................................................... 78 OTHER FUNCTIONS OF MACHINE MONITOR....................................................... 80 SWITCHES..................................................................................... 85 CONTROL LEVERS, PEDALS.......................................................................100 STEERING TILT LOCK LEVER.....................................................................106 CAP WITH LOCK................................................................................107 METHOD OF OPENING AND CLOSING CAP WITH LOCK(FOR THE FUEL TANK FILLER PORT)...............107 METHOD OF OPENING AND CLOSING CAP WITH LOCK(FOR THE HYDRAURIC TANK FILLER PORT)..........108 SAFETY BAR...................................................................................109 TOWING PIN...................................................................................109 GREASE PUMP..................................................................................109 CAB DOOR OPEN LOCK...........................................................................110 CAB WINDOW OPEN LOCK CANCEL KNOB.............................................................110 BACKUP ALARM.................................................................................110 FUSE.........................................................................................111 FUSE CAPACITY AND NAME OF CIRCUIT........................................................112 SLOW-BLOW FUSE...............................................................................113 TAKING OFF POWER.............................................................................113 HANDLING CAB WIPER...........................................................................114 PREVENTING DAMAGE TO WIPER ARM BRACKET...................................................114 DUST INDICATOR...............................................................................114 OPERATION........................................................................................115 CHECK BEFORE STARTING ENGINE, ADJUST.........................................................115 WALK-AROUND CHECK........................................................................115 CHECK BEFORE STARTING....................................................................118 ADJUSTMENT...............................................................................123 OPERATIONS AND CHECKS BEFORE STARTING ENGINE.............................................128 STARTING ENGINE..............................................................................130 AUTOMATIC WARMING-UP OPERATION...........................................................132 OPERATIONS AND CHECKS AFTER STARTING ENGINE..................................................133 BREAKING IN THE MACHINE..................................................................133 NORMAL OPERATION.........................................................................133 STOPPING ENGINE..............................................................................135 CHECK AFTER STOPPING ENGINE..................................................................135 MOVING MACHINE OFF (DIRECTIONAL, SPEED), STOPPING............................................136 PREPARATIONS FOR MOVING MACHINE..........................................................136 CHANGING GEAR SPEED......................................................................139 CHANGING DIRECTION.......................................................................140 STOPPING MACHINE.........................................................................142 TURNING......................................................................................145 EMERGENCY STEERING.......................................................................145 OPERATION OF WORK EQUIPMENT..................................................................147 WORK POSSIBLE USING WHEEL LOADER.............................................................149 DIGGING OPERATIONS.......................................................................149 LEVELING OPERATIONS......................................................................153 PUSHING OPERATION........................................................................153 LOAD AND CARRY OPERATIONS................................................................153 LOADING OPERATIONS.......................................................................154 PRECAUTIONS FOR OPERATION....................................................................156 PERMISSIBLE WATER DEPTH..................................................................156 IF WHEEL BRAKE DOES NOT WORK.............................................................156 PRECAUTIONS WHEN DRIVING UP OR DOWN SLOPES...............................................156 PRECAUTIONS REGARDING BRAKE FUNCTION.....................................................157 ADJUSTING WORK EQUIPMENT POSTURE.............................................................158 ADJUSTING BOOM KICKOUT...................................................................158 ADJUSTING BUCKET POSITIONER..............................................................160 BUCKET LEVEL INDICATOR...................................................................160 PARKING MACHINE..............................................................................161 CHECKS AFTER COMPLETION OF OPERATION.........................................................163 LOCKING......................................................................................163 HANDLING THE TIRES...........................................................................164 PRECAUTIONS WHEN HANDLING TIRES..........................................................164 TIRE PRESSURE............................................................................164 PRECAUTIONS WHEN LOAD AND CARRY METHOD...................................................165 TRANSPORTATION...................................................................................166 TRANSPORTATION PROCEDURE.....................................................................166 LOADING, UNLOADING WORK WITH TRAILERS........................................................166 LOADING..................................................................................166 SECURING MACHINE.........................................................................167 UNLOADING................................................................................167 LIFTING MACHINE..............................................................................168 POSITION FOR STICKING LIFTING POSITION MARK..............................................169 WEIGHT TABLE.............................................................................169 LIFTING PROCEDURE........................................................................170 COLD WEATHER OPERATION...........................................................................171 PRECAUTIONS FOR LOW TEMPERATURE..............................................................171 FUEL AND LUBRICANTS......................................................................171 COOLANT..................................................................................171 BATTERY..................................................................................172 PRECAUTIONS AFTER COMPLETION OF WORK.........................................................172 AFTER COLD WEATHER...........................................................................172 WARMING-UP OPERATION FOR STEERING HYDRAURIC CIRCUIT IN COLD WEATHER..........................173 LONG-TERM STORAGE................................................................................174 BEFORE STORAGE...............................................................................174 DURING STORAGE...............................................................................174 AFTER STORAGE................................................................................174 TROUBLESHOOTING..................................................................................175 WHEN MACHINE RUNS OUT OF FUEL................................................................175 TOWING THE MACHINE...........................................................................176 WHEN ENGINE CAN BE USED..................................................................177 WHEN ENGINE CANNOT BE USED...............................................................177 RELEASING PARKING BRAKE..................................................................177 EMERGENCY TRAVEL OPERATION...............................................................179 IF BATTERY IS DISCHARGED.....................................................................180 REMOVAL AND INSTALLATION OF BATTERY......................................................180 PRECAUTIONS FOR CHARGING BATTERY.........................................................181 STARING ENGINE WITH BOOSTER CABLE........................................................181 OTHER TROUBLE................................................................................183 ELECTRICAL SYSTEM........................................................................183 CHASSIS..................................................................................184 ENGINE...................................................................................186 MAINTENANCE..........................................................................................188 GUIDES TO MAINTENANCE............................................................................189 OUTLINES OF SERVICE..............................................................................191 OUTLINE OF OIL, FUEL, COOLANT................................................................191 OIL......................................................................................191 FUEL.....................................................................................191 COOLANT..................................................................................191 GREASE...................................................................................192 CARRYING OUT KOWA (Komatsu Oil Wear Analysis)............................................192 STORING OIL AND FUEL.....................................................................193 FILTERS..................................................................................193 OUTLINE OF ELECTRIC SYSTEM...................................................................193 WEAR PARTS LIST..................................................................................194 THE PARTS IN PARENTHESES ARE TO BE REPLACED AT THE SAME TIME.................................194 LUBRICANTS, FUELS AND FILLING CAPACITIES.........................................................195 PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS.............................................195 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS...................................................199 TORQUE LIST..................................................................................199 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS....................................................200 MAINTENANCE SCHEDULE CHART.......................................................................202 MAINTENANCE SCHEDULE CHART...................................................................202 SERVICE PROCEDURE................................................................................204 INITIAL 250 HOURS SERVICE....................................................................204 WHEN REQUIRED................................................................................205 CHECK, CLEAN, OR REPLACE AIR CLEANER ELEMENT.............................................205 CLEAN INSIDE OF COOLING SYSTEM...........................................................208 CHECK TRANSMISSION OIL LEVEL, ADD OIL....................................................211 CHECK AXLE OIL LEVEL, ADD OIL............................................................212 CHECK AXLE CASE BREATHER.................................................................213 CLEAN CONDENSER OF AIR CONDENSER.........................................................213 CHECK WINDOW WASHING FLUID LEVEL, ADD FLUID..............................................214 CLEAN RADIATOR FINS AND COOLER FINS......................................................215 CHECK ELECTRICAL INTAKE AIR HEATER.......................................................218 REPLACE BOLT ON CUTTING EDGE.............................................................218 REPLACE BUCKET TEETH.....................................................................219 CHECK AIR CONDITIONER....................................................................220 REPLACE SLOW BLOW FUSE...................................................................221 SELECTION AND INSPECTION OF TIRES........................................................222 CHECK BEFORE STARTING........................................................................224 EVERY 50 HOURS SERVICE.......................................................................225 DRAIN WATER, SEDIMENT FROM FUEL TANK.....................................................225 EVERY 100 HOURS SERVICE......................................................................226 CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL...............................................226 CLEAN ELEMENT IN AIR CONDITIONER FRESH AIR FILTER........................................227 EVERY 250 HOURS SERVICE......................................................................228 CHECK ENGINE ELECTROLYTE LEVEL...........................................................228 CHECK PARKING BRAKE......................................................................229 CHECK ALTERNATOR BELT TENSION, ADJUST....................................................230 CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST....................................231 CHECK FOR LOOSE WHEEL HAB NUTS, TIGHTEN..................................................231 CLEAN ELEMENT IN AIR CONDITIONER RECIRCULATION FILTER....................................232 EVERY 500 HOURS SERVICE......................................................................234 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE........................234 REPLACE FUEL FILTER CARTRIDGE............................................................235 CLEAN FUEL STRAINER......................................................................237 EVERY 1000 HOURS SERVICE.....................................................................238 CHANGE OIL IN TRANSMISSION CASE AND TRANSMISSION OIL FILTER CARTRIDGE, CLEAN STRAINER....238 CLEAN TRANSMISSION CASE BREATHER.........................................................239 CHECK TIGTENING PARTS OF TURBOCHARGER....................................................239 CHECK PLAY OF TURBOCHARGER ROTOR.........................................................239 REPLACE CORROSION RESISTOR CARTRIDGE.....................................................239 EVERY 2000 HOURS SERVICE.....................................................................240 CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC FILTER ELEMENT...........................240 REPLACE HYDRAULIC TANK BREATHER ELEMENT..................................................242 CHANGE AXLE OIL..........................................................................243 REPLACE ELEMENT IN AIR CONDITIONER RECIRCULATION AIR FILTER, FRESH AIR FILTER............243 CLEAN PPC CIRCUIT STRAINER...............................................................244 CLEAN ENGINE BREATHER ELEMENT............................................................244 CHEK ALTERNATOR, STARTING MOTOR..........................................................244 CHECK ENGINE VALVE CLEARANCE, ADJUST.....................................................244 CLEAN AND CHECK TURBOCHARGER.............................................................244 CHECK INJECTOR...........................................................................245 CHECK ACCUMULATOR GAS PRESSURE...........................................................245 CHECK VIBRATION DAMPER...................................................................245 CHECK BRAKE DISC WEAR....................................................................246 EVERY 4000 HOURS SERVICE.....................................................................247 LUBRICATING..............................................................................247 CHECK WATER PUMP.........................................................................247 CHECK AIR CONDITIONER COMPRESSOR, ADJUST.................................................248 REPLACE INJECTOR NOZZLE TIP..............................................................248 CHECKING FOR LOOSENESS OF HIGH-PRESSURE CLAMP, HARDENING OF RUBBER.......................248 CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER......................249 EVERY 8000 HOURS SERVICE.....................................................................250 REPLACE HIGH-PRESSURE PIPING CLAMP.......................................................250 REPLACE FUEL SPRAY PREVENTION CAP........................................................250 SPECIFICATIONS.......................................................................................252 SPECIFICATIONS...................................................................................253 ATTACHMENTS, OPTIONS.................................................................................254 HANDLING LOAD METER..............................................................................255 GENERAL LOCATIONS............................................................................255 MACHINE MONITOR WITH LOAD METER..........................................................255 SWITCHES.................................................................................256 LOAD METER FUNCTIONS.........................................................................257 HANDLING LOAD METER DISPLAY..................................................................260 SETTING ADDITION MODE....................................................................260 SETTING REMAIN MODE......................................................................262 TOTAL LOAD DATA DISPLAY..................................................................265 STOPPING CALCULATION.....................................................................267 CARRYING OUT CALIBRATION (ADJUSTING 0 POINT) WHEN EMPTY..................................268 CARRYING OUT CALIBRATION (ADJUSTING 0 POINT) WHEN LOADED.................................270 SUBTRACTION FUNCTION.....................................................................273 METHOD OF SETTING TIME ON CLOCK..............................................................275 PRINTER OUTPUT...............................................................................277 PRINTOUT MODE............................................................................277 METHOD OF SELECTING PRINTOUT MODE........................................................278 HANDLING TORQUE CONVERTER LOCK-UP................................................................280 GENERAL LOCATIONS............................................................................280 METHOD OF OPERATION..........................................................................281 WARNING/LIMIT FUNCTIONS FOR TRAVEL SPEED.....................................................282 AIR CONDITIONER..................................................................................283 GENERAL LOCATIONS AND FUNCTION OF CONTROL PANEL..............................................283 METHOD OF OPERATION..........................................................................286 PRECAUTIONS WHEN USING.......................................................................287 HANDLING AUTOMATIC AIR-CONDITIONER...............................................................288 GENERAL LOCATIONS AND FUNCTIONS OF CONTROL PANEL.............................................288 METHOD OF OPERATION..........................................................................292 PRECAUTIONS WHEN USING.......................................................................294 INSPECTION AND MAINTENANCE...................................................................294 HANDLING AUTO-GREASING SYSTEM....................................................................295 METHOD OF OPERATING AUTO-GREASING SYSTEM.....................................................295 HANDLING JOYSTICK STEERING SYSTEM................................................................296 EXPLANATION OF COMPONENTS....................................................................296 SHIFT UP, SHIFT DOWN SWITCHES............................................................296 FNR SWITCH...............................................................................297 JOYSTICK STEERING LEVER..................................................................297 JOYSTICK ON/OFF SWITCH...................................................................297 HI/LOW SELECTOR SWITCH...................................................................297 HORN SWITCH..............................................................................298 CONSOLE LOCK LEVER.......................................................................298 HEIGHT ADJUSTMENT LOCK LEVER.............................................................298 ANGLE, FORE/AFT ADJUSTMENT LOCK LEVER....................................................298 STRUCTURE AND FUNCTION OF JOYSTICK STEERING..................................................298 GETTING IN OR OUT OF OPERATOR‘S CAB..........................................................300 ADJUSTMENT OF JOYSTICK CONSOLE...............................................................300 OPERATION METHOD OF JOYSTICK STEERING SYSTEM.................................................301 INDEX................................................................................................304 INDEX...........................................................................................306
PLEASE NOTE:
⦁ This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
⦁ Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.
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