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KOMATSU WA480-5H WHEEL LOADER Operation & Maintenance Manual (SN:H60409 and up) KOMATSU WA480 5H – PDF DOWNLOAD
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- KOMATSU WA480-5H WHEEL LOADER Operation & Maintenance Manual
- SERIAL NUMBER:H60409 and up
- PUBLICATION NUMBER:VEAM190200
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Description
KOMATSU WA480-5H WHEEL LOADER Operation & Maintenance Manual (SN:H60409 and up) KOMATSU WA480 5H
KOMATSU WA480-5H WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:H60409 AND UP) KOMATSU WA480 5H – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU WA480-5H WHEEL LOADER Operation & Maintenance Manual (SN:H60409 and up) KOMATSU WA480 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 WA480-5H WHEEL LOADER Operation & Maintenance Manual (SN:H60409 and up) KOMATSU WA480 5H
COVER................................................................................................ 1 FOREWORD............................................................................................. 2 FOREWORD......................................................................................... 3 SAFETY INFORMATION............................................................................... 5 INTRODUCTION..................................................................................... 7 INTENDED USE................................................................................. 7 DIRECTIONS OF MACHINE........................................................................ 7 NECESSARY INFORMATION............................................................................ 8 PIN/MACHINE SERIAL NO. PLATE AND POSITION.................................................... 8 ENGINE SERIAL NO. PLATE AND POSITION......................................................... 8 ROPS/FOPS-CAB SERIAL NO. PLATE............................................................... 9 AXLE SERIAL NO. PLATE........................................................................ 9 TRANSMISSION SERIAL NO. PLATE................................................................ 9 SEAT OPERATOR SERIAL NO. PLATE............................................................... 9 POSITION OF SERVICE METER.................................................................... 10 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR.................................................... 10 CONTENTS......................................................................................... 11 DIMENSIONS, WEIGHTS AND OPERATING DATA........................................................... 18 WA480-5H: DIMENSIONS, WEIGHTS AND OPERATING DATA............................................. 18 CE-CONFORMING EQUIPMENT.......................................................................... 19 CE-CONFORMING EQUIPMENT - PART 1............................................................. 19 MANUFACTURER-SUPPLIED CE-CONFORMING EQUIPMENT, ACCORDING TO DOCUMENT 421-93-H1900................ 20 SAFETY............................................................................................... 24 SAFETY LABELS.................................................................................... 26 LOCATION OF SAFETY LABELS.................................................................... 26 SAFETY LABELS................................................................................ 27 GENERAL PRECAUTIONS.............................................................................. 28 PRECAUTIONS FOR OPERATION........................................................................ 36 BEFORE STARTING ENGINE....................................................................... 36 OPERATION.................................................................................... 37 TRANSPORTATION............................................................................... 44 BATTERY...................................................................................... 45 TOWING....................................................................................... 47 PRECAUTIONS FOR MAINTENANCE...................................................................... 48 PRECAUTIONS WITH TIRES........................................................................... 55 OPERATION............................................................................................ 56 GENERAL VIEW..................................................................................... 57 GENERAL VIEW OF MACHINE...................................................................... 57 GENERAL VIEW OF CONTROLS AND GAUGES.......................................................... 58 MACHINE MONITOR WITH ANALOG SPEEDOMETER (STANDARD)....................................... 59 MACHINE MONITOR WITH DIGITAL SPEEDOMETER (IF EQUIPPED)................................... 60 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..................................................................................... 93 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.............................................133 STARTING ENGINE..............................................................................135 AUTOMATIC WARMING-UP OPERATION...........................................................137 OPERATIONS AND CHECKS AFTER STARTING ENGINE..................................................138 BREAKING IN THE MACHINE..................................................................138 NORMAL OPERATION.........................................................................138 STOPPING ENGINE..............................................................................140 CHECK AFTER STOPPING ENGINE..................................................................140 MOVING MACHINE OFF (DIRECTIONAL, SPEED), STOPPING............................................141 PREPARATIONS FOR MOVING MACHINE..........................................................141 CHANGING GEAR SPEED......................................................................144 CHANGING DIRECTION.......................................................................145 STOPPING MACHINE.........................................................................147 TURNING......................................................................................150 EMERGENCY STEERING.......................................................................150 OPERATION OF WORK EQUIPMENT..................................................................152 WORK POSSIBLE USING WHEEL LOADER.............................................................154 DIGGING OPERATIONS.......................................................................154 LEVELING OPERATIONS......................................................................158 PUSHING OPERATION........................................................................158 LOAD AND CARRY OPERATIONS................................................................158 LOADING OPERATIONS.......................................................................159 PRECAUTIONS FOR OPERATION....................................................................161 PERMISSIBLE WATER DEPTH..................................................................161 IF WHEEL BRAKE DOES NOT WORK.............................................................161 PRECAUTIONS WHEN DRIVING UP OR DOWN SLOPES...............................................161 PRECAUTIONS REGARDING BRAKE FUNCTION.....................................................162 ADJUSTING WORK EQUIPMENT POSTURE.............................................................163 ADJUSTING BOOM KICKOUT...................................................................163 ADJUSTING BUCKET POSITIONER..............................................................165 BUCKET LEVEL INDICATOR...................................................................165 PARKING MACHINE..............................................................................166 CHECKS AFTER COMPLETION OF OPERATION.........................................................168 LOCKING......................................................................................168 HANDLING THE TIRES...........................................................................169 PRECAUTIONS WHEN HANDLING TIRES..........................................................169 TIRE PRESSURE............................................................................169 PRECAUTIONS WHEN LOAD AND CARRY METHOD...................................................170 TRANSPORTATION...................................................................................171 TRANSPORTATION PROCEDURE.....................................................................171 LOADING, UNLOADING WORK WITH TRAILERS........................................................171 LOADING..................................................................................171 SECURING MACHINE.........................................................................172 UNLOADING................................................................................172 LIFTING MACHINE..............................................................................173 POSITION FOR STICKING LIFTING POSITION MARK..............................................174 WEIGHT TABLE.............................................................................174 LIFTING PROCEDURE........................................................................175 COLD WEATHER OPERATION...........................................................................176 PRECAUTIONS FOR LOW TEMPERATURE..............................................................176 FUEL AND LUBRICANTS......................................................................176 COOLANT..................................................................................176 BATTERY..................................................................................177 PRECAUTIONS AFTER COMPLETION OF WORK.........................................................177 AFTER COLD WEATHER...........................................................................177 WARMING-UP OPERATION FOR STEERING HYDRAURIC CIRCUIT IN COLD WEATHER..........................178 LONG-TERM STORAGE................................................................................179 BEFORE STORAGE...............................................................................179 DURING STORAGE...............................................................................179 AFTER STORAGE................................................................................179 TROUBLESHOOTING..................................................................................180 WHEN MACHINE RUNS OUT OF FUEL................................................................180 TOWING THE MACHINE...........................................................................181 WHEN ENGINE CAN BE USED..................................................................182 WHEN ENGINE CANNOT BE USED...............................................................182 RELEASING PARKING BRAKE..................................................................182 EMERGENCY TRAVEL OPERATION...............................................................184 IF BATTERY IS DISCHARGED.....................................................................185 REMOVAL AND INSTALLATION OF BATTERY......................................................185 PRECAUTIONS FOR CHARGING BATTERY.........................................................186 STARING ENGINE WITH BOOSTER CABLE........................................................186 OTHER TROUBLE................................................................................188 ELECTRICAL SYSTEM........................................................................188 CHASSIS..................................................................................189 ENGINE...................................................................................191 MAINTENANCE..........................................................................................194 GUIDES TO MAINTENANCE............................................................................195 OUTLINES OF SERVICE..............................................................................197 OUTLINE OF OIL, FUEL, COOLANT................................................................197 OIL......................................................................................197 FUEL.....................................................................................197 COOLANT..................................................................................197 GREASE...................................................................................198 CARRYING OUT KOWA (Komatsu Oil Wear Analysis)............................................198 STORING OIL AND FUEL.....................................................................199 FILTERS..................................................................................199 OUTLINE OF ELECTRIC SYSTEM...................................................................199 WEAR PARTS LIST..................................................................................200 THE PARTS IN PARENTHESES ARE TO BE REPLACED AT THE SAME TIME.................................200 LUBRICANTS AND OPERATING MEANS...................................................................201 LUBRICATION CHART............................................................................201 LUBRICANTS, FUELS AND FILLING CAPACITIES.....................................................202 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS...................................................206 TORQUE LIST..................................................................................206 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS....................................................207 MAINTENANCE SCHEDULE CHART.......................................................................208 MAINTENANCE SCHEDULE CHART...................................................................208 SERVICE PROCEDURE................................................................................210 INITIAL 250 HOURS SERVICE....................................................................210 WHEN REQUIRED................................................................................211 CHECK, CLEAN, OR REPLACE AIR CLEANER ELEMENT.............................................211 CLEAN INSIDE OF COOLING SYSTEM...........................................................214 CHECK TRANSMISSION OIL LEVEL, ADD OIL....................................................217 CHECK AXLE OIL LEVEL, ADD OIL............................................................218 CHECK AXLE CASE BREATHER.................................................................219 CLEAN CONDENSER OF AIR CONDENSER.........................................................219 CHECK WINDOW WASHING FLUID LEVEL, ADD FLUID..............................................220 CLEAN RADIATOR FINS AND COOLER FINS......................................................221 CHECK ELECTRICAL INTAKE AIR HEATER.......................................................224 REPLACE BOLT ON CUTTING EDGE.............................................................224 REPLACE BUCKET TEETH.....................................................................225 CHECK AIR CONDITIONER....................................................................226 REPLACE SLOW BLOW FUSE...................................................................227 SELECTION AND INSPECTION OF TIRES........................................................228 CHECK BEFORE STARTING........................................................................230 EVERY 50 HOURS SERVICE.......................................................................231 DRAIN WATER, SEDIMENT FROM FUEL TANK.....................................................231 EVERY 100 HOURS SERVICE......................................................................232 CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL...............................................232 CLEAN ELEMENT IN AIR CONDITIONER FRESH AIR FILTER........................................233 EVERY 250 HOURS SERVICE......................................................................234 CHECK ENGINE ELECTROLYTE LEVEL...........................................................234 CHECK PARKING BRAKE......................................................................235 CHECK ALTERNATOR BELT TENSION, ADJUST....................................................236 CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST....................................237 CHECK FOR LOOSE WHEEL HAB NUTS, TIGHTEN..................................................237 CLEAN ELEMENT IN AIR CONDITIONER RECIRCULATION FILTER....................................238 EVERY 500 HOURS SERVICE......................................................................239 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE........................239 REPLACE FUEL FILTER CARTRIDGE............................................................240 CLEAN FUEL STRAINER......................................................................242 EVERY 1000 HOURS SERVICE.....................................................................243 CHANGE OIL IN TRANSMISSION CASE AND TRANSMISSION OIL FILTER CARTRIDGE, CLEAN STRAINER....243 CLEAN TRANSMISSION CASE BREATHER.........................................................244 CHECK TIGTENING PARTS OF TURBOCHARGER....................................................244 CHECK PLAY OF TURBOCHARGER ROTOR.........................................................244 REPLACE CORROSION RESISTOR CARTRIDGE.....................................................244 EVERY 2000 HOURS SERVICE.....................................................................245 CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC FILTER ELEMENT...........................245 REPLACE HYDRAULIC TANK BREATHER ELEMENT..................................................247 CHANGE AXLE OIL..........................................................................248 REPLACE ELEMENT IN AIR CONDITIONER RECIRCULATION AIR FILTER, FRESH AIR FILTER............248 CLEAN PPC CIRCUIT STRAINER...............................................................249 CLEAN ENGINE BREATHER ELEMENT............................................................249 CHEK ALTERNATOR, STARTING MOTOR..........................................................249 CHECK ENGINE VALVE CLEARANCE, ADJUST.....................................................249 CLEAN AND CHECK TURBOCHARGER.............................................................249 CHECK INJECTOR...........................................................................250 CHECK ACCUMULATOR GAS PRESSURE...........................................................250 CHECK VIBRATION DAMPER...................................................................250 CHECK BRAKE DISC WEAR....................................................................251 EVERY 4000 HOURS SERVICE.....................................................................252 LUBRICATING..............................................................................252 CHECK WATER PUMP.........................................................................252 CHECK AIR CONDITIONER COMPRESSOR, ADJUST.................................................253 CHECK INJECTOR NOZZLE TIP................................................................253 CHECKING FOR LOOSENESS OF HIGH-PRESSURE CLAMP, HARDENING OF RUBBER.......................253 CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER......................254 EVERY 8000 HOURS SERVICE.....................................................................255 REPLACE HIGH-PRESSURE PIPING CLAMP.......................................................255 REPLACE FUEL SPRAY PREVENTION CAP........................................................255 CHECK INJECTOR NOZZLE TIP, REPLACE IF NECESSARY..........................................255 TECHNICAL DATA.......................................................................................256 TECHNICAL DATA...................................................................................257 NOISE EMISSION LEVELS............................................................................259 VIBRATION LEVEL..................................................................................259 LIMIT VALUES FOR SLOPES..........................................................................260 ATTACHMENTS, OPTIONS.................................................................................262 HANDLING LOAD METER..............................................................................263 GENERAL LOCATIONS............................................................................263 MACHINE MONITOR WITH LOAD METER..........................................................263 SWITCHES.................................................................................264 LOAD METER FUNCTIONS.........................................................................265 HANDLING LOAD METER DISPLAY..................................................................268 SETTING ADDITION MODE....................................................................268 SETTING REMAIN MODE......................................................................270 TOTAL LOAD DATA DISPLAY..................................................................273 STOPPING CALCULATION.....................................................................275 CARRYING OUT CALIBRATION (ADJUSTING 0 POINT) WHEN EMPTY..................................276 CARRYING OUT CALIBRATION (ADJUSTING 0 POINT) WHEN LOADED.................................278 SUBTRACTION FUNCTION.....................................................................281 METHOD OF SETTING TIME ON CLOCK..............................................................283 PRINTER OUTPUT...............................................................................285 PRINTOUT MODE............................................................................285 METHOD OF SELECTING PRINTOUT MODE........................................................286 HANDLING TORQUE CONVERTER LOCK-UP................................................................288 GENERAL LOCATIONS............................................................................288 METHOD OF OPERATION..........................................................................289 WARNING/LIMIT FUNCTIONS FOR TRAVEL SPEED.....................................................290 AIR CONDITIONER..................................................................................291 GENERAL LOCATIONS AND FUNCTION OF CONTROL PANEL..............................................291 METHOD OF OPERATION..........................................................................294 PRECAUTIONS WHEN USING.......................................................................295 AUTOMATIC AIR-CONDITIONER........................................................................296 GENERAL LOCATIONS AND FUNCTIONS OF CONTROL PANEL.............................................296 METHOD OF OPERATION..........................................................................300 PRECAUTIONS WHEN USING.......................................................................302 INSPECTION AND MAINTENANCE...................................................................302 CENTRAL LUBRICATION..............................................................................303 OPERATION....................................................................................303 DISPLAY AND CONTROL UNIT.....................................................................304 LED-DISPLAY..............................................................................304 PUSHBUTTONS..............................................................................304 CHANGING THE LUBRICATION INTERVAL TIMES......................................................305 MULTIFUNCTION LEVER..............................................................................306 EXPLANATION OF COMPONENTS....................................................................306 WORK EQUIPMENT LEVER.....................................................................307 DIRECTIONAL SELECTOR SWITCH ACTUATION....................................................308 DIRECTIONAL SELECTOR PILOT LAMP..........................................................309 OPERATION....................................................................................310 USING SWITCH TO CHANGE BETWEEN FORWARD AND REVERSE.......................................310 KICKDOWN SWITCH..........................................................................312 HOLD SWITCH..............................................................................312 JOYSTICK STEERING SYSTEM.........................................................................313 EXPLANATION OF COMPONENTS....................................................................313 SHIFT UP, SHIFT DOWN SWITCHES............................................................313 FNR SWITCH...............................................................................314 JOYSTICK STEERING LEVER..................................................................314 JOYSTICK ON/OFF SWITCH...................................................................314 HI/LOW SELECTOR SWITCH...................................................................314 HORN SWITCH..............................................................................315 CONSOLE LOCK LEVER.......................................................................315 HEIGHT ADJUSTMENT LOCK LEVER.............................................................315 ANGLE, FORE/AFT ADJUSTMENT LOCK LEVER....................................................315 STRUCTURE AND FUNCTION OF JOYSTICK STEERING..................................................315 GETTING IN OR OUT OF OPERATOR‘S CAB..........................................................317 ADJUSTMENT OF JOYSTICK CONSOLE...............................................................317 OPERATION METHOD OF JOYSTICK STEERING SYSTEM.................................................318 INDEX................................................................................................322 INDEX...........................................................................................324 NOTES................................................................................................326 NOTES............................................................................................327
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