Komatsu WA480-6 wheel loader pdf operation and maintenance manual

Table of Contents for KOMATSU-CEAM009104 manual

• FOREWORD
• SAFETY INFORMATION
• APPROVED AND NON-APPROVED USES
  • Approved Functions
  • Non-Approved Functions
• VISIBILITY STANDARD
  • Visibility in Immediate Area
  • 12-M Radius Visibility
  • Front/Rear, Left/Right Directions of Machine
  • Machine Serial Number/Product Identification Number (PIN)
  • Engine Serial Number, EPA Regulations
  • Position of Service Meter
  • Serial Numbers and Dealer Information
• TABLE OF CONTENTS
• SAFETY AND WARNING DECALS
  • Location of Safety Decals
  • Safety Labels
• GENERAL SAFETY RULES AND PRECAUTIONS
  • General Safety Rules
  • General Safety at Job Site
  • Working on Loose Ground
  • Safety Features
  • Personal Protective Equipment
  • Keep Machine Clean
  • Fire and Explosion Prevention
  • Fire Caused by Fuel, Oil, Antifreeze, or Window Washer Fluid
  • Fire Caused by Accumulation of Flammable Material
  • Fire Coming from Electric Wiring
  • Fire Coming from Hydraulic Line
  • Windshield Washer Fluid
  • Action If Fire Occurs
  • Fire Extinguisher and First Aid Kit
  • Fire Prevention and Suppression
  • Fire Prevention Steps
  • Fixed Fire Detection System
  • Fixed Fire Suppression System
  • Fire Prevention Procedures
  • Precautions When Cleaning Cab Glass
  • Dust Hazards Precautions
  • Keep Operator's Cab Clean
  • Unauthorized Modifications
  • Leaving Operator's Compartment
  • Mounting and Dismounting
  • Crush or Pinch Point Dangers
  • Inside Operator's Compartment
  • Precautions When Using ROPS
  • Emergency Escape From Operator's Cab
• PRECAUTIONS BEFORE STARTING OPERATIONS
  • Pre-Operational Checks
  • Starting Your Work Operations
  • Seat Belt Inspection
  • Work Site Hazards
  • Avoiding Dangerous Situations
  • Working Clearances
  • Operating on Snow or Icy Surfaces
  • Precautions in Cold Areas
  • Asbestos Hazard Alert
• RULES FOR ROAD TRAVEL
  • Traveling in Reverse
  • Travel on Slopes
  • Parking the Machine
• PRECAUTIONS DURING MAINTENANCE OPERATIONS
  • Warning Tags
  • Equipment Storage
  • Working Under the Machine
  • Using Drop Lamps
  • Keeping the Machine Clean
• HANDLING TIRES
  • Precautions When Storing Tires
• PERFORMING GENERAL MAINTENANCE PROCEDURES
  • Running the Engine During Maintenance
  • Proper Tools
  • Engine System High-Voltage
  • Welding, Grinding or Cutting
  • When Using Hammer
  • Refueling the Machine
  • Cooling System Precautions
  • Battery Precautions
  • Starting the Machine
  • High-Pressure Hoses
  • Safety Handling High-Pressure Hoses
  • Precaution For High Fuel Pressure
  • High Temperature Areas
  • Disposal of Waste Materials
  • Inflating Tires
  • Accumulator
  • Critical Parts
• TRANSPORTING THE MACHINE
  • Loading and Unloading a Trailer
  • Loading Machine
• TOWING THE MACHINE
• GENERAL VIEW
  • General View Of Machine
  • General View of Controls and Gauges
  • Machine Monitor
  • Switch Panel
• EXPLANATION OF COMPONENTS
  • Machine Monitor
  • Types of Warnings
  • Emergency Stop
  • Caution
  • Mistaken Operation
  • Inspection and Maintenance
  • Central Warning Lamp
  • Character Display Portion
  • Service Meter
  • Action Code Display
  • Failure Code Display
  • Filter, Oil Replacement Time Display
  • Emergency Stop Items
  • Brake Oil Pressure Caution Lamp
  • Engine Oil Pressure Caution Lamp
  • Battery Charge Circuit Caution Lamp
  • Steering Oil Pressure Caution Lamp (if equipped)
  • Caution Items
• Meter Display Portion
  • Torque Converter Oil Temperature Gauge
  • Engine Coolant Temperature Gauge
  • Hydraulic Temperature Gauge
  • Fuel Gauge
  • Speedometer
  • Meter Display Pilot Lamp
• OTHER FUNCTIONS OF MACHINE MONITOR
  • Overall Menu
  • Displaying Odometer
  • Resetting Filter, Oil Replacement Time
  • Entering Telephone Number
  • Selecting Language
  • Adjusting Monitor Brightness
  • Switching Travel Speed/Engine Speed Display
  • Switching Travel Speed/Engine Speed Display/Non-Display
• SWITCHES AND CONTROLS
  • General View
  • Ignition Switch
  • Power Mode Selector Switch
  • Transmission Shift Mode Selector Switch
  • Transmission Cutoff Switch
  • Transmission Cutoff Set Switch
  • Lamp Switch
  • Turn Signal Lever
  • Dimmer Switch
  • Horn Button
  • Hazard Lamp Switch
  • Parking Brake Switch
  • Front Working Lamp Switch
  • Rear Working Lamp Switch
  • Machine Monitor Mode Selector Switch 1
  • Machine Monitor Mode Selector Switch 2
  • Kickdown Switch
  • Hold Switch
  • Front Wiper Switch
  • Rear Wiper Switch
  • Cigarette Lighter
  • Room Lamp Switch
  • Rear Heated Wire Glass Switch
  • ECSS Switch
  • Emergency Steering Switch (if equipped)
  • Cooling Fan Reverse Rotation Switch (If Equipped)
  • Cooling Fan Auto-Reverse Rotation Switch (If Equipped)
  • Conditions for Switching Fan Rotation
  • Torque Converter Lockup Switch (if equipped)
• CONTROL LEVERS, PEDALS
  • General View
  • Gearshift Lever
  • Manual Shift
  • Automatic Shift
  • Directional Lever
  • Gearshift Lever Stopper
  • Work Equipment Lock Lever
  • Bucket Control Lever
  • Lift Arm Control Lever
  • Brake Pedals
  • Accelerator Pedal
• SECURITY LOCKS AND SAFETY FEATURES
  • Steering Tilt Lock Lever
  • Frame Lock Bar
  • Cap with Lock
  • Fuel Tank Filler Port Cap
  • Back-Up Alarm
• MACHINE FEATURES
  • Towing Pin
  • Grease Pump
  • Cab Door
  • Emergency Escape Right Door
  • Left Cab Door, Door Open Lock
  • Left Cab Door, Knob
  • Left Cab Door, Handle
  • Left Cab Sliding Window (Lock Release Knob)
  • Cab Wiper
• ELECTRICAL
  • Power Outlet
  • Fuses
  • Fuse Capacity and Name of Circuit
  • Slow-Blow Fuse
• WORK OPERATIONS
  • Walk-Around Check
  • Precautions Before Starting Work Operations
  • Check Before Starting Engine
  • Check Machine Monitor
  • Check Coolant Level, Add Coolant
  • Check Oil Level in Engine Oil Pan, Add Oil
  • Check Water Separator, Drain Water
  • Check Air Cleaner
  • Electric Air Cleaner Clogging Sensor
  • Check Fuel Level, Add Fuel
  • Check Electric Wiring
  • Check Inflation Pressure of Tires
  • Check Condition of Window Washer Spray
  • Check Wiping Efficiency of Wiper
  • Check Horn
  • Check Defroster Function
  • Check Locks
  • Check Emergency Exit
  • Adjustments
  • Adjusting Seat
  • Removing or Installing Headrest
  • Adjusting Seat Belt
  • Adjusting Lever Stand
  • Adjusting Mirrors
  • Final Checks Before Starting Engine
  • Starting Engine
  • Normal Starting
  • Starting in Cold Weather
  • Automatic Warming-Up Operation
  • Operations and Checks After Starting Engine
  • Checks After Starting Engine
  • Breaking in the Machine
  • Normal Operation
  • Stopping Engine
  • Check After Stopping Engine
  • Moving the Machine (Directional, Speed), Stopping the Machine
  • Moving the Machine
  • Changing Gear Speed
  • Changing Direction
  • Automatic Shift
  • Stopping the Machine
  • Transmission Cut-Off Function
  • Adjusting Transmission Cut-Off Position
  • Canceling Transmission Cut-Off Position
  • Stopping When Transmission Cut-Off Is On
  • Turning
  • Emergency Steering (if equipped)
  • Emergency Steering Self-Check Function
  • Operation of Work Equipment
  • Work Equipment Lock Lever
  • Lift Arm Control lever
  • Bucket Control Lever
  • Work Possible Using Wheel Loader
  • Digging Operations
• HANDLING TIRES
  • Precautions When Handling Tires
  • Tire Pressure
• TRANSPORTATION
  • Transportation Procedure
  • Loading and Unloading Trailers
  • Loading Machine
  • Securing Machine
  • Unloading Machine
• LIFTING MACHINE
  • Lifting Position
  • Lifting Procedure
• COLD WEATHER OPERATION
  • Precautions for Low Temperature
  • Fuel and Lubricants
  • Coolant
  • Battery
  • Precautions After Completion of Work
  • After Cold Weather
• LONG-TERM STORAGE
  • Before Storage
  • During Storage
  • After Storage
• AUTOMATIC AIR CONDITIONER
  • Control Panel
  • Main Power Switch
  • Fan Switch
  • Air Conditioner Switch
  • Auto Switch
  • Temperature Switch
  • FRESH/RECIRC Selector Switch
  • Mode Selector Switch
  • Method of Operation
  • Cooling Operation
  • Heating Operation
  • Drying-Heating and Demisting Operation
  • When Not Using the Air Conditioner Regularly
  • Precautions When Using Air Conditioner
  • Inspection and Maintenance
  • Cool Box
• KOMTRAX
  • Basic Precautions
• TROUBLESHOOTING
  • When Machine Runs Out of Fuel
  • Towing the Machine
  • When Engine Can Be Used
  • When Engine Cannot Be Used
  • Releasing Parking Brake
  • Emergency Travel Operation
  • If Battery is Discharged
  • Precautions
  • Removal and Installation of Battery
  • Precautions for Charging Battery
  • Starting Engine With Booster Cables
  • Precautions When Connecting or Disconnecting Booster Cable
  • Connecting Booster Cable
  • Starting Engine
  • Disconnecting Booster Cable
  • Lowering Work Equipment When Engine Has Stopped
  • Other Troubleshooting
  • Electrical System
  • Chassis
  • Engine
• GUIDES TO MAINTENANCE
  • Check Service Meter
  • Komatsu Genuine Replacement Parts
  • Komatsu Genuine Oils
  • Always Use Clean Washer Fluid
  • Always Use Clean Oil And Grease
  • Checking For Foreign Materials In Drained Oil And On Filters
  • Fuel Strainer
  • Welding Instructions
  • Do Not Drop Things Inside Machine
  • Dusty Work Sites
  • Avoid Mixing Oil
  • Locking Inspection Covers
  • Bleeding Air From Hydraulic Circuit
  • Precautions When Installing Hydraulic Hoses
  • Checks After Inspection and Maintenance
• OUTLINES OF SERVICE
  • Handling Oil, Fuel, Coolant, And Performing Oil Clinic
• WEAR PARTS
  • Wear Parts List
• RECOMMENDED FUEL, COOLANT, AND LUBRICANT
  • Fuel, Coolant, and Lubricant Ambient Temperature Chart
  • Recommended Brands, Other Than Komatsu Genuine Oil
  • Biodiesel Usage
  • Biodiesel Recommendation for Komatsu Engines
  • Biodiesel Terminology
  • Certification and Standards
  • Warranty and Use of Biodiesel Fuel in Komatsu Engines
  • Requirements for Using Biodiesel Fuel in Komatsu Engines
  • Properties of Biodiesel
  • Komatsu Biodiesel Blend Specification for B5 to B20
  • Summary of Recommendations
• STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS
  • Torque List
• PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS
  • Safety Critical Parts List
• MAINTENANCE SCHEDULE CHART
• SERVICE PROCEDURE
  • Initial 250 Hours Service
  • Initial 1000 Hours Service
  • When Required
• Every 50 Hours Service
  • Drain Water, Sediment from Fuel Tank
• Every 100 Hours Service
  • Lubricate Rear Axle Pivot Pin
  • Check Oil Level in Hydraulic Tank, Add Oil
• Every 250 Hours Service
  • Check Battery Electrolyte Level
  • Check Parking Brake
  • Check Alternator Belt Tension, Adjust
  • Check Air Conditioner Compressor Belt Tension, Adjust
  • Check for Loose Wheel Hub Nuts, Tighten
  • Clean Element in Air Conditioner Recirculation Filter
  • Check Function of Brake Accumulator
  • Lubricating
• Every 500 Hours Service
  • Change Oil in Engine Oil Pan, Replace Engine Oil Filter Cartridge
  • Replace Fuel Prefilter Cartridge
• Every 1000 Hours Service
  • Replace Fuel Main Filter Cartridge
  • Change Oil in Transmission Case, Replace Oil Filter Cartridge, Clean Strainer
  • Clean Transmission Case Breather
  • Lubricating
  • Replace Corrosion Resistor Cartridge
  • Check Engine Air Intake Piping Clamps for Looseness
• Every 2000 Hours Service
  • Change Oil in Hydraulic Tank, Replace Hydraulic Filter Element
  • Replace Hydraulic Tank Breather Element
  • Change Axle Oil
  • Replace Element in Air Conditioner Recirculation Filter, Fresh Air Filter
  • Check Brake Disc Wear
  • Check Function of PPC Accumulator
  • Check Alternator
  • Check Engine Valve Clearance, Adjust
  • Check Starting Motor
  • Check Vibration Damper
• Every 4000 Hours Service
  • Lubricating
  • Check Water Pump
  • Check Air Conditioner Compressor, Adjust
  • Check for Loose Engine High-Pressure Piping Clamps, Hardening of Rubber
  • Check for Missing Fuel Spray Prevention Cap, Hardening of Rubber
• Every 8000 Hours Service
  • Replace High-Pressure Piping Clamps
  • Replace Fuel Spray Prevention Cap
• SPECIFICATIONS
• JOYSTICK STEERING SYSTEM
  • Structure and Function
  • Components
  • Shift UP, Shift DOWN Switches
  • Directional Selector Switch
  • Joystick Steering Lever
  • Joystick ON/OFF Switch
  • HI/LOW Selector Switch
  • Horn Switch
  • Console Tilt Lever
  • Console Fore-and-Aft Adjustment Lever
  • Joystick Pilot Lamp
  • Armrest Adjustment Lever
  • Steering with Joystick Lever or Steering Wheel
  • Precautions for Steering with Joystick
  • Operating the Joystick Steering System
  • Getting In and Out of Operator's Cab
  • Adjustments
  • Adjusting Joystick Console
  • Adjusting Seat
• LOAD METER
  • Outline of Load Meter
  • Principle of Load Meter Measurement
  • Conditions for Starting Measurement
  • Conditions for Completing Measurement
  • Conditions for Successful Measurement
  • Method of Calculation and Display
  • Points to Remember to Ensure High Accuracy
  • Calibration
  • When Measuring
  • Using Load Meter
  • Setting Addition Mode
  • Setting Subtraction Mode
  • Total Load Data Display
  • Clearing Total Load
  • Stopping Load Meter Calculation
  • Selecting Load Material Category Display
  • Calibrating With Empty Bucket
  • Calibrating with 1/2 Rated Load
  • Calibrating With Rated Load
  • Resetting Calibration
  • Method of Using Addition Mode
  • Method of Using Subtraction Mode
  • Printout from Load Meter
  • Selection of Printout Mode
• TORQUE CONVERTER LOCK-UP
  • Components
  • Torque Converter Lock-Up Switch
  • Torque Converter Lock-Up Pilot Lamp
  • Shift Indicator
  • Character Display
  • Method of Operation
  • Warning/Limit Functions for Travel Speed
  • Travel Speed Warning Function
  • Travel Speed Limit Function
• AM/FM RADIO CASSETTE STEREO SOUND SYSTEM
  • Sound System Components
  • Power Switch/Volume
  • Auto-Store/Preset Scan Button
  • Bass Control Knob
  • Treble Control Knob
  • Loudness Button
  • Time/Radio Display Selector Button
  • Tape Eject Button
  • Cassette Door
  • Fast-Forward, Rewind Buttons
  • Preset Buttons
  • Metal Tape Button
  • Manual Tuning Buttons
  • Seek Tuning Buttons
  • Band Selector Button
  • Method of Operation
  • Setting Preset Buttons
  • Using Auto-Preset
  • Using Manual Preset
  • Listening to Radio
  • Listening to Cassette Tape
  • Reversing the Tape
  • Precautions When Using
  • Handling Cassette Tape
• MULTI-FUNCTION LEVER
  • Components
  • Work Equipment Lever
  • Kickdown Switch
  • Hold Switch
  • FNR Switch
  • Directional Selector Switch Actuation Switch
  • Directional Selector Pilot Lamp
  • Work Equipment Lock Switch
  • Using FNR Switch to Change Between Forward and Reverse
• BUCKET AND TIRES
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