Komatsu WA480-5L Wheel Loader Operation and Maintenance Manual CEAM009002

Description

• Model List:
  • WA480-5L Wheel Loader

• 1. INTRODUCTION
• 1.1. FOREWORD
• 1.2. SAFETY INFORMATION
• 1.3. APPROVED AND NONAPPROVED USES
• 1.3.1. NONAPPROVED
• 1.4. PRODUCT IDENTIFICATION
• 1.4.1. MACHINE SERIAL NUMBER
• 1.4.2. ENGINE SERIAL NUMBER AND EMISSION LABEL
• 1.4.3. SERVICE METER LOCATION
• 1.5. SERIAL NUMBERS AND DEALER INFORMATION
• 2. CONTENTS
• 3. SAFETY
• 3.1. GENERAL SAFETY RULES AND PRECAUTIONS
• 3.1.1. GENERAL SAFETY RULES
• 3.1.2. SAFETY FEATURES
• 3.1.3. PERSONAL PROTECTIVE EQUIPMENT
• 3.1.4. UNAUTHORIZED MODIFICATIONS
• 3.1.5. LEAVING OPERATORS COMPARTMENT
• 3.1.6. MOUNTING AND DISMOUNTING
• 3.1.7. FIRE PREVENTION FOR FUEL AND OIL
• 3.1.8. DUST HAZARD PRECAUTIONS
• 3.1.9. CRUSH OR PINCH POINT DANGERS
• 3.1.10. FIRE EXTINGUISHER AND FIRST AID KIT
• 3.1.11. INSIDE OPERATORS COMPARTMENT
• 3.1.12. PRECAUTIONS WHEN USING ROPS
• 3.1.13. PRECAUTIONS FOR ATTACHMENTS
• 3.2. STARTING YOUR WORK OPERATIONS
• 3.2.1. WORK SITE HAZARDS
• 3.2.2. AVOIDING DANGEROUS SITUATIONS
• 3.2.3. WORKING CLEARANCES
• 3.3. RULES FOR ROAD TRAVEL
• 3.3.1. TRAVELING IN REVERSE
• 3.3.2. TRAVELING ON ICY OR SNOWCOVERED SURFACES
• 3.3.3. WORKING ON LOOSE OR UNSTABLE GROUND
• 3.3.4. TRAVEL ON SLOPES
• 3.3.5. PARKING THE MACHINE
• 3.4. PRECAUTIONS DURING MAINTENANCE OPERATIONS
• 3.4.1. WARNING TAGS
• 3.4.2. EQUIPMENT STORAGE
• 3.4.3. WORKING UNDER THE MACHINE
• 3.4.4. USING DROP LAMPS
• 3.4.5. KEEPING THE MACHINE CLEAN
• 3.4.6. RUNNING THE MACHINE DURING MAINTENANCE
• 3.4.7. RULES FOR REFUELING THE MACHINE
• 3.4.8. COOLING SYSTEM PRECAUTIONS
• 3.4.9. BATTERY PRECAUTIONS
• 3.4.10. STARTING THE MACHINE
• 3.4.11. HIGH PRESSURE HOSES
• 3.4.12. HIGH TEMPERATURES AREAS
• 3.4.13. DISPOSAL OF WASTE MATERIALS
• 3.4.14. INFLATING TIRES
• 3.4.15. ACCUMULATOR
• 3.4.16. CRITICAL PARTS
• 3.4.17. VIBRATIONS TO WHICH THE OPERATOR IS EXPOSED
• 3.5. SAFETY AND WARNING DECALS
• 3.5.1. LOCATION OF THE SAFETY DECALS
• 3.5.2. LOCATION OF SAFETY LABELS
• 4. OPERATION
• 4.1. GENERAL VIEW OF MACHINE
• 4.1.1. OUTSIDE VIEW OF THE MACHINE
• 4.1.2. INSIDE VIEW OF THE CAB
• 4.2. DESCRIPTION OF ALERTS, GAUGES AND SWITCHED SYSTEMS
• 4.2.1. INSTRUMENT BEZEL
• 4.2.2. SWITCH PANELS
• 4.3. DESCRIPTION OF ALERTS, GAUGES AND MONITOR SYSTEM
• 4.3.1. INSTRUMENT BEZEL
• 4.4. MACHINE ELECTRONIC MONITORING DISPLAY
• 4.4.1. MONITOR MODE SELECTOR SWITCHES
• 4.4.2. MONITOR DISPLAY INFORMATION
• 4.4.3. EMERGENCY STOP WARNING SYSTEM
• 4.4.4. CAUTION ALERT WARNING SYSTEM
• 4.4.5. INSPECTION AND MAINTENANCE ALERT WARNING SYSTEM
• 4.4.6. MODE ALERT LAMPS
• 4.4.7. GAUGE DISPLAY
• 4.4.8. MACHINE MONITOR
• 4.5. MACHINE SWITCHES AND CONTROLS
• 4.5.1. SWITCH LOCATION
• 4.6. SOUND SYSTEM
• 4.6.1. DIGITAL ESPERIA RADIO SERIAL NUMBER A37001 A37046
• 4.6.2. BLAUPUNKT CALAIS RADIO SERIAL NUMBER A37047 AND UP
• 4.6.3. AIR CONDITIONER CONTROL PANEL
• 4.6.4. CONTROL LEVERS, PEDALS
• 4.7. SECURITY AND LOCKS
• 4.7.1. IGNITION KEY LOCKED AREAS
• 4.7.2. PADLOCKED AREAS
• 4.8. SAFETY FEATURES
• 4.8.1. PASSIVE SAFETY FEATURES
• 4.8.2. ACTIVE SAFETY FEATURES
• 4.9. MACHINE FEATURES
• 4.9.1. CAB DOORS
• 4.9.2. ELECTRICAL
• 4.9.3. MACHINE CAB AND CHASSIS
• 4.10. PRECAUTIONS BEFORE STARTING WORK OPERATIONS
• 4.10.1. PREOPERATIONAL CHECKS
• 4.10.2. STARTUP PROCEDURES
• 4.11. OPERATIONS AND CHECKS AFTER STARTING ENGINE
• 4.11.1. BREAKING IN THE MACHINE
• 4.12. TRAVELING, STOPPING AND PARKING THE MACHINE
• 4.12.1. TRAVELING
• 4.12.2. STOPPING AND PARKING THE MACHINE
• 4.13. EMERGENCY STEERING
• 4.13.1. USING THE EMERGENCY STEERING
• 4.14. STARTING YOUR WORK OPERATIONS
• 4.14.1. WORK EQUIPMENT
• 4.14.2. SCOOPING A LOAD OR CUTTING A GRADE
• 4.14.3. LEVELING OPERATIONS
• 4.14.4. PUSHING OPERATION
• 4.14.5. LOAD AND CARRY OPERATIONS
• 4.14.6. LOADING OPERATIONS
• 4.15. PRECAUTIONS DURING OPERATION
• 4.15.1. PERMISSIBLE WATER DEPTH
• 4.15.2. IF WHEEL BRAKE DOES NOT WORK
• 4.15.3. PRECAUTIONS WHEN DRIVING UP OR DOWN SLOPES
• 4.15.4. PRECAUTIONS WHEN DRIVING THE MACHINE
• 4.15.5. PRECAUTIONS REGARDING BRAKE FUNCTION
• 4.16. WORK EQUIPMENT AND MACHINE POSTURE
• 4.16.1. ADJUSTING BUCKET
• 4.17. TRANSPORTING THE MACHINE
• 4.17.1. LOADING AND SECURING THE MACHINE
• 4.18. LIFTING THE MACHINE
• 4.18.1. LIFTING LOCATIONS AND PROCEDURES
• 4.18.2. USING WIRE ROPE
• 4.19. TOWING THE MACHINE
• 4.20. COLD WEATHER OPERATION
• 4.20.1. FUEL AND LUBRICANTS
• 4.20.2. COOLANT
• 4.20.3. PRECAUTIONS AFTER COMPLETION OF WORK
• 4.20.4. AFTER COLD WEATHER
• 4.20.5. WARMING UP THE STEERING
• 5. MAINTENANCE
• 5.1. GUIDES TO MAINTENANCE
• 5.1.1. CHECK SERVICE METER
• 5.1.2. KOMATSU GENUINE REPLACEMENT PARTS
• 5.1.3. KOMATSU GENUINE OILS
• 5.1.4. ALWAYS USE CLEAN WASHER FLUID
• 5.1.5. ALWAYS USE CLEAN OIL AND GREASE
• 5.1.6. CHECKING FOR FOREIGN MATERIALS IN DRAINED OIL AND ON FILTERS
• 5.1.7. FUEL STRAINER
• 5.1.8. WELDING INSTRUCTIONS
• 5.1.9. DO NOT DROP THINGS INSIDE THE MACHINE
• 5.1.10. DUSTY WORKSITES
• 5.1.11. AVOID MIXING OIL
• 5.1.12. LOCKING INSPECTION COVERS
• 5.1.13. BLEEDING AIR FROM HYDRAULIC CIRCUIT
• 5.1.14. PRECAUTIONS WHEN INSTALLING HYDRAULIC HOSES
• 5.1.15. CHECKS AFTER INSPECTION AND MAINTENANCE
• 5.2. SYSTEMS TROUBLESHOOTING CHARTS
• 5.2.1. ELECTRICAL SYSTEM
• 5.2.2. CHASSIS
• 5.2.3. ENGINE
• 5.3. OUTLINES OF SERVICE
• 5.3.1. HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC
• 5.3.2. PERFORMING KOWA (KOMATSU OIL WEAR ANALYSIS)
• 5.3.3. KOWA ANALYSIS ITEMS
• 5.3.4. OUTLINE OF ELECTRIC SYSTEM
• 5.4. WEAR PARTS LIST
• 5.5. FUEL, COOLANT AND LUBRICANTS
• 5.5.1. PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS
• 5.5.2. LUBRICANT AND COOLANT SUPPLIER RECOMMENDATIONS
• 5.6. STANDARD TIGHTENING TORQUES FOR FASTNERS AND HOSES
• 5.6.1. TORQUE LIST
• 5.7. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS
• 5.8. MAINTENANCE SCHEDULE CHART
• 5.8.1. INITIAL 250 HOURS SERVICE
• 5.8.2. WHEN REQUIRED
• 5.8.3. EVERY 50 HOURS SERVICE
• 5.8.4. EVERY 100 HOURS SERVICE
• 5.8.5. EVERY 250 HOURS SERVICE
• 5.8.6. EVERY 500 HOURS SERVICE
• 5.8.7. EVERY 1000 HOURS SERVICE
• 5.8.8. EVERY 2000 HOURS SERVICE
• 5.8.9. EVERY 4000 HOURS SERVICE
• 5.8.10. EVERY 8000 HOURS SERVICE
• 5.9. GENERAL MAINTENANCE AND INSPECTION
• 5.9.1. INITIAL 250 HOURS SERVICE
• 5.9.2. WHEN REQUIRED
• 5.10. EVERY SPECIFIC HOURS SERVICE
• 5.10.1. EVERY 50 HOURS SERVICE
• 5.10.2. EVERY 100 HOURS SERVICE
• 5.10.3. EVERY 250 HOURS SERVICE
• 5.10.4. EVERY 500 HOURS SERVICE
• 5.10.5. EVERY 1000 HOURS SERVICE
• 5.10.6. EVERY 2000 HOURS SERVICE
• 5.10.7. EVERY 4000 HOURS SERVICE
• 5.10.8. EVERY 8000 HOURS SERVICE
• 6. SPECIFICATIONS
• 6.1. SPECIFICATIONS
• 6.1.1. WA4805L WITH BOLTON CUTTING EDGE
• 6.1.2. MACHINE DIMENSIONS AND WEIGHTS
• 6.2. MACHINE SYSTEMS SPECIFICATIONS
• 6.2.1. ENGINE
• 6.2.2. TRANSMISSION
• 6.2.3. AXLES AND FINAL DRIVES
• 6.2.4. BRAKES
• 6.2.5. STEERING SYSTEM
• 6.2.6. SERVICE REFILL CAPACITIES
• 7. OPTIONS, ATTACHMENTS
• 7.1. MONITOR WITH LOAD METER
• 7.1.1. LOAD METER
• 7.1.2. SWITCHES
• 7.1.3. LOAD METER FUNCTIONS
• 7.1.4. USING LOAD METER DISPLAY
• 7.1.5. PRINTER OUTPUT
• 7.2. TORQUE CONVERTER LOCKUP
• 7.2.1. GENERAL LOCATIONS
• 7.2.2. WARNING/LIMIT FUNCTIONS FOR TRAVEL SPEED
• 7.3. WASTE HANDLER ENGINE COOLING FAN CONTROL SYSTEM
• 7.3.1. FAN SYSTEM OPERATION
• 7.4. HANDLING JOYSTICK STEERING SYSTEM
• 7.4.1. EXPLANATION OF COMPONENTS
• 7.4.2. STRUCTURE AND FUNCTION OF JOYSTICK STEERING
• 7.4.3. EPC WORK EQUIPMENT LEVER
• 7.5. AUTOGREASING SYSTEM
• 7.5.1. OPERATING AUTOGREASING SYSTEM