wheel loader · 2019. 12. 4. · komatsu delivers machines that comply with all applicable...

Komatsu has had the operating and maintenance instructions

translated into all the languages of the European Union.

Should you require a copy in another language please inquire

at your local dealer’s.

Operation & MaintenanceManual

Incorrect operation and maintenance of this machinemay be hazardous and cause injuries. The operator andmaintenance personnel must read this manual beforecommencing operation or maintenance. Keep thismanual within reach at all times and ensure thatoperating personnel read it at regular intervals.

SERIAL NUMBERS WA470H50051 AND UP

-5H

VEAM180100

WHEEL LOADER

NOTE

DANGER

FOREWORD11

FOREWORD FOREWORD

FOREWORD 0.This manual provides rules and guidelines which will help you use this machine safely and effectively. The pre-cautions in this manual must be followed at all times when performing operation and maintenance. Most accidentsare caused by the failure to follow fundamental safety rules for the operation and maintenance of machines. Acci-dents can be prevented by knowing beforehand conditions that may cause hazard when performing operation andmaintenance.

WARNINGOperators and maintenance personnel must always do as follows before beginning operation or mainte-nance.

! Always be sure to read and understand this manual thoroughly before performing operation andmaintenance.

! Read the safety messages given in this manual and the safety labels affixed to the machine thor-oughly and be sure that you understand them fully.

Keep this manual at the storage location for the Operation and Maintenance Manual given below, andhave all personnel read it periodically.

If this manual has been lost or has become dirty and cannot be read, request a replacement manualimmediately 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 towhich it has been shipped. If this machine has been purchased in another country or purchased fromsomeone in another country, it may lack certain safety devices and specifications that are necessary foruse in your country. If there is any question about whether your product complies with the applicablestandards and regulations of your country, consult Komatsu or your Komatsu distributor before operat-ing the machine.

Storage location for the Operation and Maintenance Manual: Pocket (1) at rear of operators seat

1-2

FOREWORD FOREWORD

EU DIRECTIVES 0.

Machines supplied by us fulfil the Directive for Machinery 89/392/EEC and its supplements. If the machine is beingused in another country, it is possible that certain safety regulations and specifications may not be fulfilled for usein that country. For example, priority vehicle warning lamps may be used in some countries, but are forbidden inothers.Please contact our dealer before using the machine if you have any questions regarding the fulfilment of standardsand regulations in a specific country.

Notes on subsequent installation of electrical and electronic equipment and componentsElectrical and electronic equipment and/or components which have been installed subsequently, emit electromag-netic radiation which can influence the function of the electronic components and sections of the machine. Thiscan have an influence on the safety of the machine and endanger persons. For this reason, please ensure that thefollowing safety instructions are observed.If you are installing electrical or electronic equipment and/or components in the machine and connect them to thevehicle electrical system, you must check at own responsibility that the installations do not cause any disturbanceto the vehicles electronic system or other components. Above all, you must ensure that any subsequently installedelectrical and electronic components comply with the EMV Directive 89/336/EEC in its current edition and bear theCE mark.The following requirements also have to be met for subsequent installation of mobile communication systems (e.g.radio, telephone):

! Only equipment approved by national legislation (e.g. BZT approval for Germany) may be used! The unit must be fixed in position! Portable or mobile units may only be used inside the vehicles if they are connected to a fixed outside

antenna! The transmitter unit must be spatially separated from the vehicles electronic system! Make sure when installing the antenna that this is installed correctly with good earth connection between

antenna and vehicle massAlso observe Komatsu and manufacturers installation instructions for wiring, installation and maximum permittedpower consumption

1-3

SAFETY INFORMATION FOREWORD

SAFETY INFORMATION 0.To enable you to use this machine safely, safety precautions and labels are given in this manual and affixed to themachine to give explanations of situations involving potential hazards and of the methods of avoiding such situa-tions.

Signal words

The following signal words are used to inform you that there is a potential hazardous situation that may lead to per-sonal injury or damage.In this manual and on machine labels, the following signal words are used to express the potential level of hazard.

Indicates an imminently hazardous situation which, if not avoided, will result in death or seri-ous injury. This signal word is to be limited to most extreme situations.Indicates a potentially hazardous situation which, if not avoided, could result in death orserious injury.Indicates a potentially hazardous situation which, if not avoided, may result in minor or mod-erate injury. It may also be used to alert against unsafe practices.

Example of safety message using signal word

WARNINGWhen standing up from the operators seat, always place the safety lock lever in the LOCK position.If you accidentally touch the levers when they are not locked, this may cause a serious injury or damage.

Other signal words

In addition to the above, the following signal words are used to indicate precautions that should be followed to pro-tect the machine or to give information that is are useful to know.

This word is used for precautions that must be taken to avoid actions which could shortenthe life of the machine.This word is used for information that is useful to know.

1-4

FOREWORD SAFETY INFORMATION

Safety labelsSafety labels are affixed to the machine to inform the operator or maintenance worker on the spot when carryingout operation or maintenance of the machine that may involve hazard.This machine uses Safety labels using pictograms to indicate safety procedures.For details of safety labels, see "SAFETY LABELS ( 2-3 )".

Safety labels using pictogramSafety pictograms use a picture to express a level of hazard-ous condition equivalent to the signal word. These safety picto-grams use pictures in order to let the operator or maintenanceworker understand the level and type of hazardous condition atall times. Safety pictograms show the type of hazardous condi-tion at the top or left side, and the method of avoiding the haz-ardous condition at the bottom or right side. In addition, thetype of hazardous condition is displayed inside a triangle andthe method of avoiding the hazardous condition is showninside a circle.Komatsu cannot predict every circumstance that might involvea potential hazard in operation and maintenance. Therefore,the safety messages in this manual and on the machine maynot include all possible safety precautions. If any procedures or actions not specifically recommended orallowed in this manual are used, it is your responsibility to takethe necessary steps to ensure safety. In no event should you engage in prohibited uses or actionsdescribed in this manual.

The explanations, values, and illustrations in this manual wereprepared based on the latest information available at that time.Continuing improvements in the design of this machine canlead to changes in detail which may not be reflected in thismanual. Consult Komatsu or your Komatsu distributor for thelatest available information of your machine or for questionsregarding information in this manual.

The numbers in circles in the illustrations correspond to thenumbers in ( ) in the text. (For example: 1 ->1)

1-5

INTRODUCTION FOREWORD

INTRODUCTION 0.This loader is a machine with independent transmission, moving on chains or wheels. Driving in forward direction,the loader can load or dig material using its attachments intended for loading operations (i.e. bucket).The standard operation cycle of a loader includes filling up and loading of the bucket, transporting the material andemptying the bucket.

INTENDED USE 0.If you use the machine for any other purpose than specified above, we will not accept any responsibility for safety.All considerations concerning safety will then be up to the owner or the operating and maintenance personnel. Inany case, neither you nor any other person are/is authorised to perform work and functions explicitly prohibited inthese operating instructions.The transport of persons in the work equipment is strictly forbidden!For details of the operating procedure, see WORK POSSIBLE USING WHEEL LOADER ( 3-100 ).

DIRECTIONS OF MACHINE 0.

In this manual, the directions of the machine (front, rear, left, right) are determined according to the view from theoperators seat in the direction of travel (front) of the machine.

1-6

FOREWORD NECESSARY INFORMATION

NECESSARY INFORMATION 0.When requesting service or ordering replacement parts, please inform your Komatsu distributor of the followingitems.

MACHINE SERIAL NO. PLATE AND POSITION 0.On the center right of the front frame.

ENGINE SERIAL NO. PLATE AND POSITION 0.This is at the top of the side face of the engine of the cylinder block on the left side of the machine and on the muf-fler bracket on the right side of the machine.

1-7

NECESSARY INFORMATION FOREWORD

ROPS/FOPS-CAB SERIAL NO. PLATE 0.This plate is located on the right inside cab on the rear beam.

AXLE SERIAL NO. PLATE 0.This plate is located on the right of front axle and on the left ofrear axle.

TRANSMISSION SERIAL NO. PLATE 0.This plate is located in travel direction front, above thetransmission output.

SEAT OPERATOR SERIAL NO. PLATE 0.This plate is located in front of seat, covered by the bellows.

1-8

FOREWORD NECESSARY INFORMATION

POSITION OF SERVICE METER 0.It is at the center bottom of the machine monitor.

For details of the service meter display, see SERVICE METERin EXPLANATION OF COMPONENTS SERVICE METER ( 3-8 ).

TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR 0.

Machine serial No.

Engine serial No.

Distributor name

Address

Service Personal

Phone/Fax

1-9

CONTENTS FOREWORD

CONTENTS 0.

FOREWORDFOREWORD ......................................................................................................................................................... 1-2

SAFETY INFORMATION...................................................................................................................................... 1-4

INTRODUCTION................................................................................................................................................... 1-6INTENDED USE .............................................................................................................................................. 1-6DIRECTIONS OF MACHINE ........................................................................................................................... 1-6

NECESSARY INFORMATION ............................................................................................................................. 1-7MACHINE SERIAL NO. PLATE AND POSITION ............................................................................................ 1-7ENGINE SERIAL NO. PLATE AND POSITION............................................................................................... 1-7ROPS/FOPS-CAB SERIAL NO. PLATE.......................................................................................................... 1-8AXLE SERIAL NO. PLATE .............................................................................................................................. 1-8TRANSMISSION SERIAL NO. PLATE ............................................................................................................ 1-8SEAT OPERATOR SERIAL NO. PLATE......................................................................................................... 1-8POSITION OF SERVICE METER.................................................................................................................... 1-9TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR ................................................................................... 1-9

CONTENTS ........................................................................................................................................................ 1-10

DIMENSIONS, WEIGHTS AND OPERATING DATA ........................................................................................ 1-17WA470-5H: DIMENSIONS, WEIGHTS AND OPERATING DATA................................................................. 1-17

CE-CONFORMING EQUIPMENT....................................................................................................................... 1-18CE-CONFORMING EQUIPMENT - PART 1.................................................................................................. 1-18MANUFACTURER-SUPPLIED CE-CONFORMING EQUIPMENT, ACCORDING TO DOCUMENT 421-93-

H1900 ....................................................................................................................................................... 1-19

SAFETYSAFETY LABELS................................................................................................................................................. 2-3

LOCATION OF SAFETY LABELS ................................................................................................................... 2-3SAFETY LABELS............................................................................................................................................. 2-4

GENERAL PRECAUTIONS ................................................................................................................................. 2-5

PRECAUTIONS FOR OPERATION ................................................................................................................... 2-13BEFORE STARTING ENGINE ...................................................................................................................... 2-13OPERATION.................................................................................................................................................. 2-14TRANSPORTATION...................................................................................................................................... 2-21BATTERY....................................................................................................................................................... 2-22TOWING ........................................................................................................................................................ 2-24

PRECAUTIONS FOR MAINTENANCE .............................................................................................................. 2-25

PRECAUTIONS WITH TIRES ............................................................................................................................ 2-32

1-10

FOREWORD CONTENTS

OPERATIONGENERAL VIEW .................................................................................................................................................. 3-2

GENERAL VIEW OF MACHINE ...................................................................................................................... 3-2GENERAL VIEW OF CONTROLS AND GAUGES.......................................................................................... 3-3

EXPLANATION OF COMPONENTS.................................................................................................................... 3-6MACHINE MONITOR ...................................................................................................................................... 3-6

TYPES OF WARNING................................................................................................................................ 3-7CENTRAL WARNING LAMP...................................................................................................................... 3-7CHARACTER DISPLAY PORTION............................................................................................................ 3-8EMERGENCY STOP ITEM ...................................................................................................................... 3-14CAUTION ITEMS...................................................................................................................................... 3-17INSPECTION AND MAINTENANCE ITEM............................................................................................... 3-20PILOT DISPLAY PORTION...................................................................................................................... 3-24METER DISPLAY PORTION.................................................................................................................... 3-29OTHER FUNCTIONS OF MACHINE MONITOR...................................................................................... 3-31

SWITCHES .................................................................................................................................................... 3-36CONTROL LEVERS, PEDALS ...................................................................................................................... 3-51STEERING TILT LOCK LEVER..................................................................................................................... 3-57CAP WITH LOCK........................................................................................................................................... 3-58

METHOD OF OPENING AND CLOSING CAP WITH LOCK(FOR THE FUEL TANK FILLER PORT)................................................................................................... 3-58METHOD OF OPENING AND CLOSING CAP WITH LOCK(FOR THE HYDRAURIC TANK FILLER PORT)....................................................................................... 3-59

SAFETY BAR................................................................................................................................................. 3-60TOWING PIN ................................................................................................................................................. 3-60GREASE PUMP............................................................................................................................................. 3-60CAB DOOR OPEN LOCK.............................................................................................................................. 3-61CAB WINDOW OPEN LOCK CANCEL KNOB .............................................................................................. 3-61BACKUP ALARM........................................................................................................................................... 3-61FUSE ............................................................................................................................................................. 3-62

FUSE CAPACITY AND NAME OF CIRCUIT............................................................................................ 3-63SLOW-BLOW FUSE ...................................................................................................................................... 3-64TAKING OFF POWER................................................................................................................................... 3-64HANDLING CAB WIPER ............................................................................................................................... 3-65

PREVENTING DAMAGE TO WIPER ARM BRACKET ............................................................................ 3-65DUST INDICATOR ........................................................................................................................................ 3-65

OPERATION....................................................................................................................................................... 3-66CHECK BEFORE STARTING ENGINE, ADJUST......................................................................................... 3-66

WALK-AROUND CHECK ......................................................................................................................... 3-66CHECK BEFORE STARTING .................................................................................................................. 3-69ADJUSTMENT.......................................................................................................................................... 3-74OPERATIONS AND CHECKS BEFORE STARTING ENGINE................................................................ 3-79

STARTING ENGINE ...................................................................................................................................... 3-81AUTOMATIC WARMING-UP OPERATION.............................................................................................. 3-83

OPERATIONS AND CHECKS AFTER STARTING ENGINE ........................................................................ 3-84BREAKING IN THE MACHINE................................................................................................................. 3-84NORMAL OPERATION ............................................................................................................................ 3-84

STOPPING ENGINE...................................................................................................................................... 3-86CHECK AFTER STOPPING ENGINE ........................................................................................................... 3-86MOVING MACHINE OFF (DIRECTIONAL, SPEED), STOPPING ................................................................ 3-87

PREPARATIONS FOR MOVING MACHINE............................................................................................ 3-87CHANGING GEAR SPEED ...................................................................................................................... 3-90CHANGING DIRECTION.......................................................................................................................... 3-91STOPPING MACHINE.............................................................................................................................. 3-93

TURNING....................................................................................................................................................... 3-96EMERGENCY STEERING ....................................................................................................................... 3-96

1-11

CONTENTS FOREWORD

OPERATION OF WORK EQUIPMENT ......................................................................................................... 3-98WORK POSSIBLE USING WHEEL LOADER ............................................................................................. 3-100

DIGGING OPERATIONS........................................................................................................................ 3-100LEVELING OPERATIONS...................................................................................................................... 3-104PUSHING OPERATION ......................................................................................................................... 3-104LOAD AND CARRY OPERATIONS ....................................................................................................... 3-104LOADING OPERATIONS ....................................................................................................................... 3-105

PRECAUTIONS FOR OPERATION ............................................................................................................ 3-107PERMISSIBLE WATER DEPTH............................................................................................................. 3-107IF WHEEL BRAKE DOES NOT WORK.................................................................................................. 3-107PRECAUTIONS WHEN DRIVING UP OR DOWN SLOPES.................................................................. 3-107PRECAUTIONS REGARDING BRAKE FUNCTION .............................................................................. 3-108

ADJUSTING WORK EQUIPMENT POSTURE............................................................................................ 3-109ADJUSTING BOOM KICKOUT............................................................................................................... 3-109ADJUSTING BUCKET POSITIONER..................................................................................................... 3-111BUCKET LEVEL INDICATOR ................................................................................................................ 3-111

PARKING MACHINE ................................................................................................................................... 3-112CHECKS AFTER COMPLETION OF OPERATION .................................................................................... 3-114LOCKING..................................................................................................................................................... 3-114HANDLING THE TIRES............................................................................................................................... 3-115

PRECAUTIONS WHEN HANDLING TIRES........................................................................................... 3-115TIRE PRESSURE ................................................................................................................................... 3-115PRECAUTIONS WHEN LOAD AND CARRY METHOD ........................................................................ 3-116

TRANSPORTATION......................................................................................................................................... 3-117TRANSPORTATION PROCEDURE............................................................................................................ 3-117LOADING, UNLOADING WORK WITH TRAILERS..................................................................................... 3-117

LOADING................................................................................................................................................ 3-117SECURING MACHINE ........................................................................................................................... 3-118UNLOADING........................................................................................................................................... 3-118

LIFTING MACHINE...................................................................................................................................... 3-119POSITION FOR STICKING LIFTING POSITION MARK........................................................................ 3-120WEIGHT TABLE ..................................................................................................................................... 3-120LIFTING PROCEDURE .......................................................................................................................... 3-121

COLD WEATHER OPERATION ...................................................................................................................... 3-122PRECAUTIONS FOR LOW TEMPERATURE ............................................................................................. 3-122

FUEL AND LUBRICANTS ...................................................................................................................... 3-122COOLANT............................................................................................................................................... 3-122BATTERY ............................................................................................................................................... 3-123

PRECAUTIONS AFTER COMPLETION OF WORK ................................................................................... 3-123AFTER COLD WEATHER ........................................................................................................................... 3-123WARMING-UP OPERATION FOR STEERING HYDRAURIC CIRCUIT IN COLD WEATHER .................. 3-124

LONG-TERM STORAGE.................................................................................................................................. 3-125BEFORE STORAGE.................................................................................................................................... 3-125DURING STORAGE .................................................................................................................................... 3-125AFTER STORAGE....................................................................................................................................... 3-125

TROUBLESHOOTING...................................................................................................................................... 3-126WHEN MACHINE RUNS OUT OF FUEL..................................................................................................... 3-126TOWING THE MACHINE............................................................................................................................. 3-127

WHEN ENGINE CAN BE USED............................................................................................................. 3-128WHEN ENGINE CANNOT BE USED ..................................................................................................... 3-128RELEASING PARKING BRAKE ............................................................................................................. 3-128EMERGENCY TRAVEL OPERATION.................................................................................................... 3-130

IF BATTERY IS DISCHARGED................................................................................................................... 3-131REMOVAL AND INSTALLATION OF BATTERY.................................................................................... 3-131PRECAUTIONS FOR CHARGING BATTERY ....................................................................................... 3-132

1-12

FOREWORD CONTENTS

STARING ENGINE WITH BOOSTER CABLE........................................................................................ 3-132OTHER TROUBLE ...................................................................................................................................... 3-134

ELECTRICAL SYSTEM.......................................................................................................................... 3-134CHASSIS ................................................................................................................................................ 3-135ENGINE .................................................................................................................................................. 3-137

MAINTENANCEGUIDES TO MAINTENANCE............................................................................................................................... 4-2

OUTLINES OF SERVICE ..................................................................................................................................... 4-4OUTLINE OF OIL, FUEL, COOLANT .............................................................................................................. 4-4

OIL .............................................................................................................................................................. 4-4FUEL........................................................................................................................................................... 4-4COOLANT................................................................................................................................................... 4-4GREASE..................................................................................................................................................... 4-5CARRYING OUT KOWA (Komatsu Oil Wear Analysis) ............................................................................. 4-5STORING OIL AND FUEL.......................................................................................................................... 4-6FILTERS ..................................................................................................................................................... 4-6

OUTLINE OF ELECTRIC SYSTEM................................................................................................................. 4-6

WEAR PARTS LIST ............................................................................................................................................. 4-7THE PARTS IN PARENTHESES ARE TO BE REPLACED AT THE SAME TIME ......................................... 4-7

LUBRICANTS AND OPERATING MEANS.......................................................................................................... 4-8LUBRICATION CHART ................................................................................................................................... 4-8LUBRICANTS, FUELS AND FILLING CAPACITIES ....................................................................................... 4-9

STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS..................................................................... 4-13TORQUE LIST ............................................................................................................................................... 4-13

PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS .......................................................................... 4-14

MAINTENANCE SCHEDULE CHART ............................................................................................................... 4-15MAINTENANCE SCHEDULE CHART........................................................................................................... 4-15

SERVICE PROCEDURE .................................................................................................................................... 4-17INITIAL 250 HOURS SERVICE ..................................................................................................................... 4-17WHEN REQUIRED ........................................................................................................................................ 4-18

CHECK, CLEAN, OR REPLACE AIR CLEANER ELEMENT ................................................................... 4-18CLEAN INSIDE OF COOLING SYSTEM.................................................................................................. 4-21CHECK TRANSMISSION OIL LEVEL, ADD OIL...................................................................................... 4-24CHECK AXLE OIL LEVEL, ADD OIL........................................................................................................ 4-25CHECK AXLE CASE BREATHER............................................................................................................ 4-26CLEAN CONDENSER OF AIR CONDENSER......................................................................................... 4-26CHECK WINDOW WASHING FLUID LEVEL, ADD FLUID...................................................................... 4-27CLEAN RADIATOR FINS AND COOLER FINS ....................................................................................... 4-28CHECK ELECTRICAL INTAKE AIR HEATER.......................................................................................... 4-31REPLACE BOLT ON CUTTING EDGE .................................................................................................... 4-31REPLACE BUCKET TEETH..................................................................................................................... 4-32CHECK AIR CONDITIONER .................................................................................................................... 4-33REPLACE SLOW BLOW FUSE ............................................................................................................... 4-34SELECTION AND INSPECTION OF TIRES ............................................................................................ 4-35

CHECK BEFORE STARTING ....................................................................................................................... 4-37EVERY 50 HOURS SERVICE ....................................................................................................................... 4-38

DRAIN WATER, SEDIMENT FROM FUEL TANK.................................................................................... 4-38EVERY 100 HOURS SERVICE ..................................................................................................................... 4-39

CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL ............................................................................. 4-39

1-13

CONTENTS FOREWORD

CLEAN ELEMENT IN AIR CONDITIONER FRESH AIR FILTER............................................................. 4-40EVERY 250 HOURS SERVICE ..................................................................................................................... 4-41

CHECK ENGINE ELECTROLYTE LEVEL ............................................................................................... 4-41CHECK PARKING BRAKE ....................................................................................................................... 4-42CHECK ALTERNATOR BELT TENSION, ADJUST ................................................................................. 4-43CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST .............................................. 4-44CHECK FOR LOOSE WHEEL HAB NUTS, TIGHTEN............................................................................. 4-44CLEAN ELEMENT IN AIR CONDITIONER RECIRCULATION FILTER................................................... 4-45

EVERY 500 HOURS SERVICE ..................................................................................................................... 4-46CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE ............................. 4-46REPLACE FUEL FILTER CARTRIDGE ................................................................................................... 4-47CLEAN FUEL STRAINER......................................................................................................................... 4-49

EVERY 1000 HOURS SERVICE ................................................................................................................... 4-50CHANGE OIL IN TRANSMISSION CASE AND TRANSMISSION OIL FILTER CARTRIDGE, CLEAN STRAINER................................................................................................................................................ 4-50CLEAN TRANSMISSION CASE BREATHER .......................................................................................... 4-51CHECK TIGTENING PARTS OF TURBOCHARGER .............................................................................. 4-51CHECK PLAY OF TURBOCHARGER ROTOR........................................................................................ 4-51REPLACE CORROSION RESISTOR CARTRIDGE ................................................................................ 4-51

EVERY 2000 HOURS SERVICE ................................................................................................................... 4-52CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC FILTER ELEMENT............................... 4-52REPLACE HYDRAULIC TANK BREATHER ELEMENT .......................................................................... 4-54CHANGE AXLE OIL.................................................................................................................................. 4-55REPLACE ELEMENT IN AIR CONDITIONER RECIRCULATION AIR FILTER,FRESH AIR FILTER ................................................................................................................................. 4-55CLEAN PPC CIRCUIT STRAINER........................................................................................................... 4-56CLEAN ENGINE BREATHER ELEMENT................................................................................................. 4-56CHEK ALTERNATOR, STARTING MOTOR ............................................................................................ 4-56CHECK ENGINE VALVE CLEARANCE, ADJUST ................................................................................... 4-56CLEAN AND CHECK TURBOCHARGER ................................................................................................ 4-56CHECK INJECTOR .................................................................................................................................. 4-57CHECK ACCUMULATOR GAS PRESSURE ........................................................................................... 4-57CHECK VIBRATION DAMPER................................................................................................................. 4-57CHECK BRAKE DISC WEAR................................................................................................................... 4-58

EVERY 4000 HOURS SERVICE ................................................................................................................... 4-59LUBRICATING.......................................................................................................................................... 4-59CHECK WATER PUMP ............................................................................................................................ 4-59CHECK AIR CONDITIONER COMPRESSOR, ADJUST ......................................................................... 4-60CHECK INJECTOR NOZZLE TIP............................................................................................................. 4-60CHECKING FOR LOOSENESS OF HIGH-PRESSURE CLAMP, HARDENING OF RUBBER ............... 4-60CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER................. 4-61

EVERY 8000 HOURS SERVICE ................................................................................................................... 4-62REPLACE HIGH-PRESSURE PIPING CLAMP........................................................................................ 4-62REPLACE FUEL SPRAY PREVENTION CAP ......................................................................................... 4-62CHECK INJECTOR NOZZLE TIP, REPLACE IF NECESSARY .............................................................. 4-62

TECHNICAL DATATECHNICAL DATA .............................................................................................................................................. 5-2

NOISE EMISSION LEVELS ................................................................................................................................. 5-4

VIBRATION LEVEL .............................................................................................................................................. 5-4

LIMIT VALUES FOR SLOPES ............................................................................................................................. 5-5

1-14

FOREWORD CONTENTS

ATTACHMENTS, OPTIONSHANDLING LOAD METER .................................................................................................................................. 6-2

GENERAL LOCATIONS .................................................................................................................................. 6-2MACHINE MONITOR WITH LOAD METER............................................................................................... 6-2SWITCHES................................................................................................................................................. 6-3

LOAD METER FUNCTIONS............................................................................................................................ 6-4HANDLING LOAD METER DISPLAY.............................................................................................................. 6-7

SETTING ADDITION MODE ...................................................................................................................... 6-7SETTING REMAIN MODE.......................................................................................................................... 6-9TOTAL LOAD DATA DISPLAY................................................................................................................. 6-12STOPPING CALCULATION ..................................................................................................................... 6-14CARRYING OUT CALIBRATION (ADJUSTING 0 POINT) WHEN EMPTY ............................................. 6-15CARRYING OUT CALIBRATION (ADJUSTING 0 POINT) WHEN LOADED........................................... 6-17SUBTRACTION FUNCTION..................................................................................................................... 6-20

METHOD OF SETTING TIME ON CLOCK ................................................................................................... 6-22PRINTER OUTPUT ....................................................................................................................................... 6-24

PRINTOUT MODE.................................................................................................................................... 6-24METHOD OF SELECTING PRINTOUT MODE........................................................................................ 6-25

HANDLING TORQUE CONVERTER LOCK-UP................................................................................................ 6-27GENERAL LOCATIONS ................................................................................................................................ 6-27METHOD OF OPERATION ........................................................................................................................... 6-28WARNING/LIMIT FUNCTIONS FOR TRAVEL SPEED................................................................................. 6-29

AIR CONDITIONER............................................................................................................................................ 6-30GENERAL LOCATIONS AND FUNCTION OF CONTROL PANEL .............................................................. 6-30METHOD OF OPERATION ........................................................................................................................... 6-33PRECAUTIONS WHEN USING..................................................................................................................... 6-34

HANDLING AUTOMATIC AIR-CONDITIONER ................................................................................................. 6-35GENERAL LOCATIONS AND FUNCTIONS OF CONTROL PANEL ............................................................ 6-35METHOD OF OPERATION ........................................................................................................................... 6-39PRECAUTIONS WHEN USING..................................................................................................................... 6-41INSPECTION AND MAINTENANCE ............................................................................................................. 6-41

CENTRAL LUBRICATION ................................................................................................................................. 6-42OPERATION.................................................................................................................................................. 6-42DISPLAY AND CONTROL UNIT ................................................................................................................... 6-43

LED-DISPLAY........................................................................................................................................... 6-43PUSHBUTTONS....................................................................................................................................... 6-43

CHANGING THE LUBRICATION INTERVAL TIMES.................................................................................... 6-44

HANDLING JOYSTICK STEERING SYSTEM ................................................................................................... 6-45EXPLANATION OF COMPONENTS ............................................................................................................. 6-45

SHIFT UP, SHIFT DOWN SWITCHES..................................................................................................... 6-45FNR SWITCH ........................................................................................................................................... 6-46JOYSTICK STEERING LEVER ................................................................................................................ 6-46JOYSTICK ON/OFF SWITCH................................................................................................................... 6-46HI/LOW SELECTOR SWITCH.................................................................................................................. 6-46HORN SWITCH ........................................................................................................................................ 6-47CONSOLE LOCK LEVER......................................................................................................................... 6-47HEIGHT ADJUSTMENT LOCK LEVER.................................................................................................... 6-47ANGLE, FORE/AFT ADJUSTMENT LOCK LEVER ................................................................................. 6-47

STRUCTURE AND FUNCTION OF JOYSTICK STEERING......................................................................... 6-47GETTING IN OR OUT OF OPERATORS CAB............................................................................................. 6-49ADJUSTMENT OF JOYSTICK CONSOLE.................................................................................................... 6-49OPERATION METHOD OF JOYSTICK STEERING SYSTEM ..................................................................... 6-50

1-15

CONTENTS FOREWORD

INDEX ................................................................................................................................................................... 7-1

NOTESNOTES .................................................................................................................................................................. 8-2

1-16

FOREWORD DIMENSIONS, WEIGHTS AND OPERATING DATA

DIMENSIONS, WEIGHTS AND OPERATING DATA 0.WA470-5H: DIMENSIONS, WEIGHTS AND OPERATING DATA 0.

Measurements, operating dataBucket capacity to ISO 7546 m³ 4,1Material density t/m³ 1,8Bucket weight without teeth kg 1.690Static tipping load, straight kg 18.400Static tipping load, 40° angle kg 16.520Breakout force, hydraulic kN 184Lifting capacity, hydraulic, on ground kN 238Operating weight *) kg 23.200

a Reach at 45° discharge mm 1.325b Dumping height at 45° discharge mm 3.132c Lift height, hinge pin mm 4.341d Height to upper edge of bucket mm 6.017e Digging depth mm 63A Overall length, bucket on ground mm 8.862B Wheel base mm 3.450C Bucket width mm 3.000

These values refer to machines with 26,5 R25 XHAD Width over tyres mm 2.915

E Gauge mm 2.240F Ground clearance mm 581 *) Machine without additional counterweightH Overall height mm 3.538

AB

F

H

ad

c

b

CDE

e

WA470-5Abm

1-17

CE-CONFORMING EQUIPMENT FOREWORD

CE-CONFORMING EQUIPMENT 0.CE-CONFORMING EQUIPMENT - PART 1 0.

CE-conforming equipment1 2 3 4 5

Type Part No. Volumem³

LoadCapacity

kg

Hydraulic pressure

bar

Weightkg

Bucket WA470-5H

421-70-H2B20 6,0 -421-70-H2B60 3,8 2.050421-70-H2B71 3,8 2.215421-70-H2E52 4,35 2.186421-70-H2E63 4,35 2.328421-70-H2E73 4,75 2.450421-70-H2E84 4,75 2.590421-70-H2E91 4,35 2.340421-70-H2F92 4,75 2.542421-70-H2G71 4,5 2.349421-70-H2G82 4,9 2.712421-70-H2K52 4,2 2.107421-70-H2K62 4,2 2.243421-70--H2K73 4,6 2.360421-70-H2K84 4,6 2.590421-70-H2P12 4,1 2.340421-70-H2P22 4,1 2.480421-70-H2P31 4,25 2.549421-70-H2S02 4,1 2.350421-70-H2S12 4,1 2.485421-70-H2S21 4,25 2.559421-71-H2001 4,1 1.750421-71-H2010 4,25 1.915421-71-H2C40 4,1 1.690421-71-H2D31 4,5 1.951421-71-H2E20 4,5 1.890421-71-H2E30 4,65 2.135

GK100392-A

5

4

3

2

1

1-18

FOREWORD CE-CONFORMING EQUIPMENT

MANUFACTURER-SUPPLIED CE-CONFORMING EQUIPMENT, ACCORDING TO DOCUMENT 421-93-H1900 0.

The responsibility for observing valid regulations in the case ofwheel loaders with "interchangeable equipment" (e.g. bucket orfork-lift) which was not supplied from works lies with thecustomer which was subsequently fitted to the machine.The directives for CE conformity and road-traffic registrationare deemed to have been fulfilled when the manufacturer of theequipment confirms fulfilment of the form 421-93-H1900alongside.The certification must be sent to the customer and the wheelloader manufacturer. The CE conformity declaration for aspecific wheel loader is only legally valid once this has takenplace.The dimensions X1, X2, Y1 and Y2 must be provided by thecustomer for approval for use on public roads. (valid inGermany)The dimension Sh (smallest tyre radius) must be added to thedimension D2.The figure G (in kg) represents the maximum load (equipmentand operating load) which may act upon this point.

D2

Sh

X1Y1

Y2

X2

Sh

A2

A1

G

GK100395b

1-19


D1

C1B1

1

D2

C2

B2

Sh

H1 H2

J

2S

h

A2

A1

G

d1=d2

3

3

b3

b4

b1

b2

e

d2

h

cd1

GK100395

1-20

FOREWORD CE-CONFORMING EQUIPMENT

MANUFACTURER- SUPPLIED CE-CONFORMING EQUIP-MENT, ACCORDING TO DOCUMENT 421-93-H1900 WA470-5H 421-93-H1900

A1 2245

A2 1345

Sh 809

B1 2100

B2 2201

C1 1665

C2 1801

D1 486

D2 1447

G 9800

H1 1675

H2 1643

J 270

X1 2957

X2 1268

Y1 3152

Y2 1459

b1 1038

b2 122

b3 143

b4 447.5

c 400

d1 95

d2 95

e 0

h 240

l 90

1 Drivers eye

2 Vision line

3 Bolts

Tyres MICHELIN26.5R25 XHA

Bucket 4.2 m³421-70-H2K62

A1 Distance: bucket pivoting point - front axle, horizontalA2 Distance: bucket pivoting point - front axle, verticalSh Distance: road level - front axleB1 Distance: driver's eye (1) - front axle, horizontalB2 Distance: driver's eye (1) - front axle, verticalC1 Distance: centre steering wheel - centre front axle,

horizontalC2 Distance: center steering wheel - centre front axle,

verticalD1 Distance: headlight - centre front axle, horizontalD2 Distance: headlight - centre front axle, verticalG Weight of equipment and working loadH1 Distance: bucket pivoting point - bucket upper edge, verti-

cal (carrying position)H2 Distance: bucket pivoting point - vision line, vertical (carry-

ing position)J Distance: road level - bucket bottom edge (carrying posi-

tion)X1 Distance: cutter protection - front axle, horizontalX2 Distance: cutter protection - road level, verticalY1 Distance: teeth protection - front axle, horizontalY2 Distance: teeth protection - road level, verticalb1 Bucket connection dimension, boom width insideb2 Bucket connection dimension, boom armb3 Bucket connection dimension, tilt rodb4 Bucket connection dimension, temporary sizec Bucket connection dimension between d1 and d2, verticald1 Bucket connection dimension, bolt (3) for boomd2 Bucket connection dimension, bolt (3) for tilt rode Bucket connection dimension d1 - d2, horizontally dis-

placedh Distance: bucket bottom edge - boom bolt holel Distance: centre of bolt -- centre of fastening screw

1-21


1-22

SAFETY22

SAFETY

2-2

SAFETY SAFETY LABELS

SAFETY LABELS 0.The following safety labels are used on this machine. Be sure that you fully understand the correct position andcontent of these safety labels.

To ensure that the content of these safety labels can be read properly, be sure that they are in the correct placeand always keep them clean. When cleaning them, use soap and water. Do not use organic solvents or gasoline. These may cause the safety labels to peel off.

If the safety labels are damaged or lost, or cannot be read, replace them with new parts. For details of the partnumbers, see this manual or check on the actual part, and order the new part from your Komatsu distributor.

There are also other labels in addition to the safety labels. Handle these labels in the same way.

LOCATION OF SAFETY LABELS 0.

The rear full fender is available only as an option, so (8) indicates only machines with equipped with full fender.

9JM0398A

2-3

SAFETY LABELS SAFETY

32

SAFETY LABELS 0.

1 Danger of explosion due to pressure accumulatorP/N: 421-93-H1300

8 Do not stand on fenderP/N: 421-93-H1400

2 Keep a safe distance to the bucket cylinderP/N: 421-93-H1380

9 Caution, hot water/oilP/N: 421-93-H1280

3 Keep a safe distance to the machine´s articulated jointP/N: 421-93-H1320

10 Use Komatsu oil only

P/N: 421-93-H13904 Secure articulated joint during transport or when

loadingP/N: 421-93-H1330

11 Keep a safe distance to the attachments

P/N: 421-93-H13705 Do not open when engine is running

P/N: 09667-A088012 Instructions prior to operation/maintenance

P/N: 421-93-H18406 Do not stand to close to the machine

P/N: 421-93-H136013 Precautionary measures when leaving the machine

P/N: 421-93-H18607 Caution when using jump leads

P/N: 421-93-H131014 Only start machine from drivers seat

P/N: 0942-A048115 Safety measures before starting work

P/N: 421-93-H1850

9jm03988-2

421-93-H1860

421-93-H1850

421-93-H1840

2-4

SAFETY GENERAL PRECAUTIONS

42GENERAL PRECAUTIONS 0.SAFETY RULES 0.! Only trained and authorized personnel can operate and maintain the machine.! Follow all safety rules, precautions and instructions when operating or performing maintenance on the

machine.! If you are under the influence of alcohol or medication, your ability to safely operate or repair your machine may

be severly impaired putting yourself and everyone else on your jobsite in danger.! When working with another operator or with a person on worksite traffic duty, be sure that all personnel under-

stand all hand signals that are to be used.

IF ABNORMALITIES ARE FOUND 0.If you find any abnormality in the machine during operation or maintenance (noise, vibration, smell, incorrectgauges, smoke, oil leakage, etc., or any abnormal display on the warning devices or monitor), report to the personin charge and have the necessary action taken. Do not operate the machine until the abnormality has been cor-rected.

CLOTHING AND PERSONAL PROTECTIVE ITEMS 0.! Do not wear loose clothing and accessories. There is a hazard that they may catch on control levers or other

protruding parts.! If you have long hair and it hangs out from your hard hat,

there is a hazard that it may get caught up in the machine,so tie your hair up and be careful not to let it get caught.

! Always wear a hard hat and safety shoes. If the nature ofthe work requires it, wear safety glasses, mask, gloves, earplugs, and safety belt when operating or maintaining themachine.

! Check that all protective equipment functions properlybefore using it.

FIRE EXTINGUISHER AND FIRST AID KIT 0.Always follow the precautions below to prepare for action if any injury or fire should occur.! The fire extinguisher is located on the rear cab frame on the

left inside the operators cab. Two fasteners are provided onthe lower left strut of the cab for fastening the fire extin-guisher in place.

! If, in the course of certain operations, there is danger of fire,fire extinguishers must be at hand. Familiarise with the useof the fire extinguishers.

! Inform yourself on measures to be taken in the event of afire.

! The first-aid kit is located in the compartment under thedriver's seat.

SAFETY FEATURES 0.! Be sure that all guards and covers are in their proper position. Have guards and covers repaired immediately if

they are damaged.! Understand the method of use of safety features and use them properly.! Never remove any safety features. Always keep them in good operating condition.

2-5

GENERAL PRECAUTIONS SAFETY

KEEP MACHINE CLEAN 0.! If water gets into the electrical system, there is a hazard that it will cause malfunctions or misoperation. Do not

use water or steam to wash the electrical system (sensors, connectors).! If inspection and maintenance is carried out when the

machine is still dirty with mud or oil, there is a hazard thatyou will slip and fall, or that dirt or mud will get into youreyes. Always keep the machine clean.

INSIDE OPERATORS COMPARTMENT 0.! When entering the operators compartment, always remove all mud and oil from the soles of your shoes.

If you operate the pedal with mud or oil affixed to your shoes, your foot may slip and this may cause a seriousaccident.

! Do not leave parts or tools lying around the operators compartment.! Do not stick suction pads to the window glass. Suction pads act as a lens and may cause fire.! Do not use cellular telephones inside the operators compartment when driving or operating the machine.! Never bring any dangerous objects such as flammable or explosive items into the operators cab.

ALWAYS APPLY LOCK WHEN LEAVING OPERATORS SEAT 0.! Before standing up from the operators seat to adjust the

operators seat, always lower the work equipment, setsafety lock lever (1) to the LOCK position and parking brakeswitch (2) to the ON position, then stop the engine.If you accidentally touch the travel or swing lever when theyare not locked. The work equipment may suddenly moveand cause serious injury.

! When leaving the machine, always lower the work equip-ment to the ground, set safety lock lever (1) to the LOCKposition and parking brake switch (2) to the ON position,then stop the engine. Lock all places and always take thekey with you and leave it in the specified location.

2-6


HANDRAILS AND STEPS 0.To prevent personal injury caused by slipping or falling off the machine, always do as follows.! Use the handrails and steps marked by arrows in the dia-

gram on the right when getting on or off the machine.

! To ensure safety, always face the machine and maintainthree-point contact (both feet and one hand, or both handsand one foot) with the handrails and steps to ensure thatyou support yourself.

! When entering the cab, open the cab door, push the doorsecurely into catcher (1) to hold in position, then use the handrail on theinside to get on the machine.For details of the method of releasing the door lock, seeCAB DOOR OPEN LOCK (3-61).

! Do not grip the control levers when getting on or off themachine.

! Never climb on the engine hood or covers where there areno non-slip pads.

! Never move from the step at the rear of the machine or thestep at the side of the cab to stand on top of the tire.

! Before getting on or off the machine, check the handrails and steps, and if there is any oil, grease, or mud onthem, wipe it off immediately. In addition, repair any damage and tighten any loose bolts.

! Do not get on or off the machine while holding tools in your hand.

MOUNTING AND DISMOUNTING 0.! Never jump on or off the machine. Never get on or off a moving machine.! If the machine starts to move when there is no operator on the machine, do not jump on to the machine and try

to stop it.

NO PEOPLE ON ATTACHMENTS 0.Never let anyone ride on the bucket, grapple, clamshell, or other attachments. There is a hazard of falling and suf-fering serious injury.

2-7


DO NOT GET CAUGHT IN ARTICULATED PORTION 0.! If the clearance at the articulating portion changes, it will

lead to serious personal injury.Do not allow anyone to come inside the articulation range.

! Never enter or put your hand, arm, or any part of your bodyin the movable portion between the work equipment andmachine or between the cylinder and the work equipment.If someone operates the control levers by mistake, the gapbetween the work equipment and machine and between thecylinder and work equipment will change, and you, yourhand, or arm will be caught and you may suffer seriousinjury.If you have to go into a movable portion, always take actionto secure the work equipment and ensure that it cannotmove.

PREVENTION OF BURNS 0.Hot coolant! To prevent burns from hot water or steam spurting out when

checking or draining the coolant, wait for the water to cool toa temperature where it is possible to touch the radiator capby hand before starting the operation. Even when the cool-ant has cooled down, loosen the cap slowly to relieve thepressure inside the radiator before removing the cap.

Hot oil! To prevent burns when checking or draining the oil, wait for

the oil to cool to a temperature where it is possible to touchthe plug by hand before starting the operation. Even whenthe oil has cooled down, loosen the plug slowly to relievethe internal pressure before removing the plug.

2-8


FIRE PREVENTION 0.! Fire caused by fuel or oil

Fuel, oil, antifreeze, and window washer liquid are particu-larly flammable and can be hazardous. To prevent fire,always observe the following:! Do not smoke or use any flame near fuel or oil.! Stop the engine before refueling.! Do not leave the machine while adding fuel or oil.! Tighten all fuel and oil caps securely.! Do not spill fuel on overheated surfaces or on parts of

the electrical system.! Use well-ventilated areas for adding or storing oil and

fuel.! Keep oil and fuel in the determined place and do not

allow unauthorized persons to enter.! After adding fuel or oil, wipe up any spilled fuel or oil.! When carrying out grinding or welding work on the chas-

sis, move any flammable materials to a safe placebefore starting.

! When washing parts with oil, use a non-flammable oil.Diesel oil and gasoline may catch fire, so do not usethem.

! Put greasy rags and other flammable materials into asafe container to maintain safety at the work place.

! Do not weld or use a cutting torch to cut any pipes ortubes that contain flammable liquids.

! Fire caused by accumulation of flammable material. Remove any dry leaves, chips, pieces of paper, dust, or any other flammable materials accumulated or affixedaround the engine, exhaust manifold, muffler, or battery, or inside the undercovers.

! Fire coming from electric wiringShort circuits in the electrical system can cause fire.! Always keep electric wiring connections clean and securely tightened.! Check the wiring every day for looseness or damage. Tighten any loose connectors or wiring clamps.

Repair or replace any damaged wiring.

! Fire coming from hydraulic lineCheck that all the hose and tube clamps, guards, and cushions are securely fixed in position.If they are loose, they may vibrate during operation and rub against other parts. This may lead to damage to thehoses, and cause high-pressure oil to spurt out, leading to fire damage or serious injury.

! Explosion caused by lighting equipment! When checking fuel, oil, battery electrolyte, window washer fluid, or coolant, always use lighting with anti-

explosion specifications. If such lighting equipment is not used, there is danger of explosion that may causeserious injury.

! When taking the electrical power for the lighting from the machine itself, follow the instructions in this man-ual.

ACTION IF FIRE OCCURS 0.If a fire occurs, escape from the machine as follows.! Turn the start switch OFF to stop the engine.! Use the handrails and steps to get off the machine.

WINDOW WASHER LIQUID 0.Use an ethyl alcohol base washer liquid. Methyl alcohol base washer liquid may irritate your eyes, so do not use it.

2-9


ROPS (Roll Over Protective Structure) 0.The roll-over protection system (ROPS) protects the operator and absorbs load and impact energy, if the machineshould roll over.The ROPS is a fixed component of the cab. The machine must not be operated without this roll-over protectionsystem.The ROPS meets the regulations of all member states of the EU. If, however, the ROPS is modified, damaged, orrepaired without permission, its stability is impaired. In this case, the ROPS must be replaced, since its correctfunction can no longer be guaranteed.The ROPS can only provide maximum protection, if the driver wears the safety belt correctly. For this reason, thesafety belt is to be worn when the machine is in operation.

ATTACHMENT FOR PROTECTION AGAINST FALLING OBJECTS (FOPS) 0.NOTICEFOPS is a fixed component of the cab.When you work on a site where there is danger of falling rocks or other objects, the machines must be equippedwith a FOPS. If the FOPS is modified without permission or damaged, its stability is impaired. In this case, theFOPS must be replaced, since its correct function can no longer be guaranteed.

PRECAUTIONS FOR ATTACHMENTS 0.! When installing optional parts or attachments, there may be problems with safety or legal restrictions, There-

fore contact your Komatsu distributor for advice.! Any injuries, accidents, or product failures resulting from the use of unauthorized attachments or parts will not

be the responsibility of Komatsu.! When installing and using optional attachments, read the instruction manual for the attachment, and the gen-

eral information related to attachments in this manual.

UNAUTHORIZED MODIFICATION 0.Any modification mode without authorization from Komatsu can create hazards. Before making a modification,consult your Komatsu distributor.! Komatsu will not be responsible for any injuries, accidents, or product failures resulting from modifications

made without authorization from Komatsu.

SAFETY AT WORKSITE 0.Before starting operations, thoroughly check the area for any unusual conditions that could be dangerous.! When carrying out operations near combustible materials such as thatched roofs, dry leaves or dry grass, there

is a hazard of fire, so be careful when operating.! Check the terrain and condition of the ground at the worksite, and determine the safest method of operation.

Do not carry out operations at places where there is a hazard of landslides or falling rocks.! If water lines, gas lines, or high-voltage electrical lines may

be buried under the worksite, contact each utility and iden-tify their locations. Be careful not to sever or damage any ofthese lines.

! Take action to prevent unauthorized people from approach-ing the jobsite.When working on public roads, position flagmen and erectbarriers to ensure the safety of passing traffic and pedestri-ans.

! When traveling or operating in shallow water or on softground, check the shape and condition of the bedrock, andthe depth and speed of flow of the water before startingoperations.

! Always design and maintain the roads on the jobsite so thatthe machines can travel safely.

2-10


WORKING ON LOOSE GROUND 0.! Avoid traveling or operating your machine too close to the edge of cliffs, overhangs, and deep ditches. The

ground may be weak in such areas. If the ground should collapse under the weight or vibration of the machine,there is a hazard that the machine may fall or tip over. Remember that the soil after heavy rain or blasting orafter earthquakes is weak in these areas.

! When working on embankments or near excavated ditches, there is a hazard that the weight and vibration ofthe machine will cause the soil to collapse. Before starting operations, take steps to ensure that the ground issafe and to prevent the machine from rolling over or falling.

DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES 0.Do not travel or operate the machine near electric cables.There is a hazard of electric shock, which may cause seriousinjury or property damage. On jobsites where the machine maygo close to electric cables, always do as follows.! Before starting work near electric cables, inform the local

power company of the work to be performed, and ask themto take the necessary action.

! Even going close to high-voltage cables can cause electricshock, which may cause serious burns or even death.Always maintain a safe distance (see the table on the right)between the machine and the electric cable. Check with thelocal power company about safe operating procedurebefore starting operations.

! To prepare for any possible emergencies, wear rubbershoes and gloves. Lay a rubber sheet on top of the seat,and be careful not to touch the chassis with any exposedpart of your body.

! Use a signalman to give warning if the machine approachestoo close to the electric cables.

! When carrying out operations near high voltage cables, donot let anyone come close to the machine.

! If the machine should come too close or touch the electriccable, to prevent electric shock, the operator should notleave the operators compartment until it has been con-firmed that the electricity has been shut off.Also, do not let anyone come close to the machine.

ENSURE GOOD VISIBILITY 0.Check for any persons or obstacles in the area around the machine and check the conditions of the jobsite toensure that operations and travel can be carried out safely. Always do as follows.! Position a signalman if there are areas at the rear of the machine where the visibility is not good.! When working in dark places, turn on the working lamp and front lamps installed to the machine, and set up

additional lighting in the work area if necessary.! Stop operations if the visibility is poor, such as in mist, snow, rain, or dust.

A0060820

Nominal Voltage Safety Distance

up to 1000 V 1 m

over 1 kV up to 110 kV 3 m



with unknown nominal voltage 5 m

2-11


VENTILATION FOR ENCLOSED AREASExhaust fumes from the engine can kill.! If it is necessary to start the engine within an enclosed area,

or when handling fuel, flushing oil, or paint, open the doorsand windows to ensure that adequate ventilation is providedto prevent gas poisoning.

CHECKING SIGNALMANS SIGNALS AND SIGNS 0.! Set up signs to inform of road shoulders and soft ground. If the visibility is not good, position a signalman if

necessary. Operators should pay careful attention to the signs and follow the instructions from the signalman.! Only one signalman should give signals.! Make sure that all workers understand the meaning of all signals and signs before starting work.

EMERGENCY EXIT FROM OPERATORS CAB 0.Machines equipped with a cab have doors on the left and right sides. If the door on the one side does not open,escape from the door on the other side.

BE CAREFUL ABOUT EXHAUST DUST 0.Asbestos dust in the air can cause lung cancer if it is inhaled.There is danger of inhaling asbestos when working on jobsiteshandling demolition work or work handling industrial waste.Always observe the following.! Spray water to keep down the dust when cleaning. ! Do not use compressed air for cleaning.! If there is danger that there may be asbestos dust in the air,

always operate the machine from an upwind position. ! All workers should use an approved respirator.! Do not allow other persons to approach during the opera-

tion.

! Always observe the rules and regulations for the work site and environmental standards.This machine does not use asbestos, but there is a danger that imitation parts may contain asbestos, so alwaysuse genuine Komatsu parts.

2-12

SAFETY PRECAUTIONS FOR OPERATION

PRECAUTIONS FOR OPERATION 0.BEFORE STARTING ENGINE 0.If there is a warning tag hanging from the work equipment con-trol lever, do not start the engine or touch the levers (1).

CHECKS BEFORE STARTING ENGINE 0.Carry out the following checks before starting the engine at the beginning of the days work. ! Remove all dirt from the surface of the window glass to ensure a good view.! Remove all dirt from the surface of the lens of the front lamps, working lamps, and rear combination lamp, and

check that they light up correctly.! Check the coolant level, fuel level, and oil level in engine oil pan, check for clogging of the air cleaner, and

check for damage to the electric wiring.! Check that there is no mud or dust accumulated around the movable parts of the accelerator pedal or brake

pedal, and check that the pedals work properly.! Adjust the operators seat to a position where it is easy to carry out operations, and check that there is no dam-

age or wear to the seat belt or mounting clamps.! Check that the gauges work properly, check the angle of the lights and working lamps, and check that the con-

trol levers are all at the neutral position.! Before starting the engine, make sure that the safety lock lever is in the LOCK position.! Adjust the mirrors so that the rear of the machine can be seen clearly from the operators seat. See ADJUST

REAR VIEW MIRROR (3-78).! Check that there are no persons or obstacles above, below, or in the area around the machine.

PRECAUTIONS WHEN STARTING 0.! Only start and operate the machine from the seat. Never try to start the engine by hot-wiring the ignition. This

can cause fire, grave injuries or death.! When starting the engine, sound the horn as a warning.! Do not allow anyone apart from the operator to ride on the machine.! Do not short circuit the starting motor circuit to start the engine. It is not only dangerous, but will also cause

damage to the equipment.! For machines equipped with a back-up alarm, check that the alarm works properly.

PRECAUTIONS IN COLD AREAS 0.! Carry out the warming-up operation thoroughly. If the machine is not thoroughly warmed up before the control

levers are operated, the reaction of the machine will be slow, and this may lead to unexpected accidents.! If the battery electrolyte is frozen, do not charge the battery or start the engine with a different power source.

There is a hazard that this will ignite the battery.

2-13

PRECAUTIONS FOR OPERATION SAFETY

Before charging or starting the engine with a different power source, melt the battery electrolyte and check forfrost and leakage of battery electrolyte before starting.

OPERATION 0.CHECKS BEFORE STARTING ENGINE 0.When carrying out the checks, move the machine to a wide area where there are no obstructions, and operateslowly. Do not allow anyone near the machine.! Always fasten your seat belt.! Check for any abnormality in the sound of the

machine,vibration, heat, smell, or gauges; check also thatthere is no leakage of oil or fuel.

! Check for any abnormality in the sound of the machine,vibration, heat, smell, or gauges; check also that there is noleakage of oil or fuel.

! If any abnormality is found, carry out repairs immediately.

! Before driving the machine or starting operations, checkthat safety bar (1) is securely fixed at the FREE position.

PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE 0.! Before travelling, check again that there is no one in the surrounding area, and that there are no obstacles.! Before travelling, sound the horn to warn people in the area.! Always operate the machine only when seated.! Do not allow anyone apart from the operator to ride on the machine.! Check that the back-up alarm (alarm buzzer when machine travels in reverse) works properly.! Always lock the door and windows of the operators compartment in position (open or closed).

On jobsites where there is a hazard of flying objects or of objects entering the operators compartment, checkthat the door and windows are securely closed.

! If there is an area to the rear of the machine which cannotbe seen, position a signal person. Take special care not tohit other machines or people when turning or swinging themachine.

Always be sure to carry out the above precautions even whenthe machine is equipped with mirrors.

2-14


PRECAUTIONS WHEN TRAVELING 0.! Never turn the key in the starting switch to the OFF position. It is dangerous if the engine stops when the

machine is traveling, because the steering becomes heavy. If the engine stops, depress the brake pedal imme-diately to stop the machine.

! When traveling on level ground, keep the work equipment atheight of 27 cm from the ground.When traveling, do not operate the work equipment controllevers. If the work equipment control levers have to be oper-ated, stop the machine first, then operate the levers.

! When traveling on rough ground, travel at low speed and donot operate the steering suddenly. There is danger that themachine may turn over. The work equipment may hit theground surface and cause the machine to lose its balance,or may damage the machine or structures in the area.

! Avoid traveling over obstacles when possible. If themachine has to travel over an obstacle, keep the workequipment close to the ground and travel at low speed.Never travel over obstacles which make the machine tiltstrongly to one side.

! When traveling or carrying out operations, always keep asafe distance from people, structures, or other machines toavoid coming into contact with them.

! When passing over bridges or structures, check first that thestructure is strong enough to support the weight of themachine. When traveling on public roads, check first withthe relevant authorities and follow their instructions.

! When operating in tunnels, under bridges, under electricwires, or other places where the height is limited, operateslowly and be extremely careful not to let the work equip-ment hit anything.

! Always obey the traffic regulations when traveling on publicroads. This machine travels at a lower speed than normalautomobiles, so keep to the side of the road and be carefulto leave the center of the road free for other vehicles.

! If you drive the machine at high speed continuously for along time, the tires will overheat and the internal pressurewill become abnormally high. This may cause the tires toburst. If a tire bursts, it produces an extremely largedestructive force, and this may cause serious injury or acci-dent.If you are going to travel continuously, please consult yourKomatsu distributor.

2-15


TRAVELING ON SLOPES 0.To prevent the machine from tipping over or slipping to theside, always do as follows.

! Keep the work equipment approx. 20 to 30 cm (8 to 12 in)above the ground. In case of emergency, lower the workequipment to the ground immediately to help stop themachine.

! Always travel straight up or down a slope. Traveling at anangle or across the slope is extremely dangerous.

! Do not turn on slopes or travel across slopes. Always godown to a flat place to change the position of the machine,then travel on to the slope again.

! Travel on grass, fallen leaves, or wet steel plates with low speed. Even with slight slopes there is a hazard thatthe machine may slip.

! If the engine stops, depress the brake pedal immediately, lower the bucket to the ground, and apply the parkingbrake to stop the machine.

! When traveling downhill, never shift gear or place the transmission at neutral. It is dangerous not to use thebraking force of the engine. Always place the transmission in a low gear before starting to travel downhill.

! When traveling downhill, travel slowly. If necessary, use the braking force of the engine together with the brakepedal to control the travel speed.

! When traveling up or down hills with a loaded bucket, always travel with the bucket facing uphill. If the machinetravels with the bucket facing downhill, there is danger that the machine may tip over.

PROHIBITED OPERATIONS 0.! It is dangerous to excavate the bottom of a rock face. Never

do this.

2-16


! It is dangerous to use the bucket or lift arm for crane opera-tions, so do not carry out such operations.

! Do not pass the bucket over the head of other workers orover the operators seat of dump trucks or other haulingequipment. The load may spill or the bucket may hit thedump truck and cause serious injury or property damage.

EMERGENCY LOWERING SYSTEM 0.When the engine is not running, you can lower the work unit bymeans of the pilot control lever.! PPC control leverTo achieve this, slowly press the pilot control lever (2) forwardto the "LOWER" position.

! EPC control lever1. Turn the key in ignition switch (1) to ON.2. Then slowly press the pilot control lever (2) forward to the

"LOWER" position.

9JA03282B

2

9JA03272A

2

1

2-17


PRECAUTIONS WHEN OPERATING 0.! When using the machine, to prevent the machine from overturning due to overloading and to avoid damage to

the work equipment, do not exceed the maximum permitted load or performance of the machine.! If the engine cannot be started again after it has stopped, immediately operate the work equipment control

levers to lower the work equipment to the ground. (After the engine stops, the accumulator allows the workequipment to be operated for a limited time.)

! Be careful not to approach too close to the edge of cliffs. When making embankments or landfills, or whendropping soil over a cliff, dump one pile, then use the next pile of soil to push the first pile.

! The

wheel loader · 2019. 12. 4. · komatsu delivers machines that comply with all applicable...

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