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Komatsu WA470-6 2006, Operation & Maintenance Manual

The Komatsu WA470-6 2006 is a reliable and efficient wheel loader designed for heavy duty tasks. Make sure to download the free Operation & Maintenance Manual for this model from manualshive.com to ensure proper care and operation of your machine. The manual is essential for maximizing productivity and lifespan.

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4.9  Service procedure
Every 4000 hours service

Maintenance

4-88

WA470-6H – VEAM946100

Check for loose engine high-pressure piping clamps, hardening of rubber

Check clamps (1) to (15) for loose bolts and hardening of the
rubber parts. If there are any loose bolts or hardened rubber,
please contact your KOMATSU distributor for replacement.

Checking for missing fuel spray prevention cap, hardening of rubber

Check for any missing fuel spray prevention caps (1) to (11) or
fuel spray prevention cover (12), and check also for any hard-
ened rubber portions. If there are any missing caps or cover or
the rubber is hardened, please contact your KOMATSU distribu-
tor for repairs.

GK047057

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

GK047058

1

2

3

4

5

6

7

8

9

10

11

12

Summary of Contents for WA470-6 2006

Page 1: ...hould be kept near the machine for reference and periodically reviewed by all personnel who will come into contact with it NOTICE Komatsu has had the operating and maintenance in structions translated...

Page 2: ......

Page 3: ...Foreword WA470 6H VEAM946100 1 1 1 Foreword...

Page 4: ...re that you understand them fully Keep this manual at the storage location for the Operation and Maintenance Manual given below and have all person nel read it periodically If this manual has been los...

Page 5: ...instructions are observed If you are installing electrical or electronic equipment and or components in the machine and connect them to the vehicle electrical system you must check at own responsibil...

Page 6: ...used to express the potential level of hazard DANGER Indicates an imminently hazardous situation which if not avoided will result in death or serious injury WARNING Indicates a potentially hazardous s...

Page 7: ...al words are used to indicate precautions that should be followed to protect the machine or to give information that is useful to know NOTE This word is used for precautions that must be taken to avoi...

Page 8: ...is displayed inside a triangle and the method of avoiding the hazardous condition is shown inside a circle KOMATSU cannot predict every circumstance that might involve a potential hazard in operation...

Page 9: ...of the operating procedure see Work possible using wheel loader 3 130 1 3 1 Intended use If you use the machine for any other purpose than specified above we will not accept any responsibility for sa...

Page 10: ...achine require a view shown in the diagram on the right side Visibility in immediate area The visibility of this machine in the area 1 m from the outside surface of the machine at a height of 1 5 m is...

Page 11: ...dius of 12 m from the machine is as shown in the diagram below The hatched areas B show the areas where the view is blocked when mirrors or other aids to visibility are installed as standard Please be...

Page 12: ...form your KOMATSU distributor of the following items 1 4 1 Product Identification Number PIN Machine serial no plate and position On the center right of the front frame 1 4 2 Engine serial no plate an...

Page 13: ...is located on the right inside cab on the rear beam 1 4 4 Axle serial no plate This plate is located on the right of front axle and on the left of rear axle 1 4 5 Transmission serial no plate This pl...

Page 14: ...ered by the bellows 1 4 7 Position of service meter The service meter is displayed on the character display at the bottom center of the machine monitor 1 4 8 Table to enter serial no and distributor G...

Page 15: ...e 1 11 1 4 6 Seat operator serial no plate 1 12 1 4 7 Position of service meter 1 12 1 4 8 Table to enter serial no and distributor 1 12 1 5 Contents 1 13 1 6 Dimensions weights and operating data 1 2...

Page 16: ...8 Grease pump 3 66 3 2 9 Cab door 3 67 3 2 10 Cab door open lock 3 67 3 2 11 Cab window open lock 3 68 Cab left window open lock reset knob 3 68 Cab right window open lock reset knob 3 68 Reset right...

Page 17: ...r speed 3 117 Changing direction 3 118 Using switch to change between forward and reverse 3 120 Stopping the machine 3 122 Transmission cut off function 3 123 3 3 7 Turning 3 125 Emergency steering 3...

Page 18: ...156 Coolant 3 156 Battery 3 157 3 5 2 Precautions after completion of work 3 158 3 5 3 After cold weather 3 158 3 5 4 Warming up operation for steering hydraulic circuit in cold weather 3 159 3 6 Long...

Page 19: ...4 6 Periodic replacement of safety critical parts 4 25 4 7 Maintenance schedule chart 4 27 4 7 1 Maintenance schedule chart 4 27 4 8 Replace injector assembly 4 30 4 9 Service procedure 4 31 4 9 1 In...

Page 20: ...replace engine oil filter cartridge 4 68 Replace fuel pre filter cartridge 4 70 4 9 10 Every 1000 hours service 4 72 Replace fuel main filter cartridge 4 72 Change oil in transmission case and transmi...

Page 21: ...imit function 6 7 6 3 Handling machines equipped with KOMTRAX 6 8 6 3 1 Basic precautions 6 9 6 4 Joystick steering system 6 10 6 4 1 Components 6 10 6 4 2 Structure and function 6 13 Operation using...

Page 22: ...1 5 Contents Foreword 1 20 WA470 6H VEAM946100 7 Index 7 1 7 1 Index 7 2 8 Notes 8 1...

Page 23: ...e kg 16 720 Breakout force effective kN 186 Lifting capacity effective on ground kN 203 Operating weight kg 22 910 a Reach at 45 discharge mm 1 280 b Dumping height at 45 discharge mm 3 085 c Lift hei...

Page 24: ...5 421 75 H2850 4 6 8 280 2 305 421 75 H2860 4 6 8 280 2 460 421 75 H2840 4 75 8 550 2 500 421 75 H2870 4 75 8 550 2 545 421 75 H2700 4 1 7 380 1 860 421 75 H2710 4 1 7 380 2 015 421 75 H2720 4 25 7 65...

Page 25: ...re deemed to have been fulfilled when the manufacturer of the equipment confirms fulfilment of the form 419 93 H1250 along side The certification must be sent to the customer and the wheel loader manu...

Page 26: ...1 7 CE Conforming equipment Foreword 1 24 WA470 6H VEAM946100 GK032014 D1 C1 B1 1 D2 C2 B2 Sh H1 H2 J 2 Sh A2 A1 G d1 d2 3 3 b3 b4 b1 b2 e d2 h c d1 X1 Y1 Y2 X2...

Page 27: ...headlight centre front axle horizontal D2 Distance headlight centre front axle vertical G Weight of equipment and working load H1 Distance bucket pivoting point bucket upper edge vertical carrying po...

Page 28: ...1 7 CE Conforming equipment Foreword 1 26 WA470 6H VEAM946100...

Page 29: ...1 2 Safety WARNING Please read and make sure that you fully understand the precautions described in this manual and the safety labels on the machine When operating or servicing the machine always foll...

Page 30: ...aning 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 par...

Page 31: ...A470 6H VEAM946100 2 3 2 1 2 Presentation of safety labels 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 GK032018 GK032019 GK032020 GK032021 GK032022 GK032023 GK032024 GK032025 GK032026...

Page 32: ...ty labels Safety 2 4 WA470 6H VEAM946100 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 GK032018 GK032019 GK032020 GK032021 GK032022 GK032023 GK032024 GK032025 GK032026 GK032027 GK032028...

Page 33: ...warning 421 93 H1300 There is a hazard of explosion injury Do not disassembly the accumulator make holes in it weld it cut it hit it roll it or bring it near flame 10 Do not climb on fender 421 93 H14...

Page 34: ...pipe 09817 A0753 Sign indicates a burn hazard from touching heated parts such as engine motor or muffler during or right after operation Never touch when hot 21 Caution for common rail high pressure 6...

Page 35: ...ine during operation or maintenance noise vibration smell incorrect gauges smoke oil leakage etc or any abnormal display on the warning devices or monitor report to the person in charge and have the n...

Page 36: ...r sons that you need to contact in an emergency Safety features Be sure that all guards and covers are in their proper posi tion Have guards and covers repaired immediately if they are damaged Underst...

Page 37: ...tment when driving or operating the machine Never bring any dangerous objects such as flammable or explosive items into the operator s compartment Always apply lock when leaving operator s seat When s...

Page 38: ...u support yourself When entering the cab stand on the top step before opening the door Do not grip the control levers or work equipment lock lever when getting on or off the machine Never climb on the...

Page 39: ...ne hand with the handrail and steps to ensure that you support yourself Clean the cab glass only on the side to which the machine is articulated When cleaning the glass on the other side articulate th...

Page 40: ...us injury If you have to go into a movable portion always take action to secure the work equipment and ensure that it cannot move Prevention of burns Hot coolant To prevent burns from hot water or ste...

Page 41: ...ork on the chas sis move any flammable materials to a safe place before starting When washing parts with oil use a non flammable oil Diesel oil and gasoline may catch fire so do not use them Put greas...

Page 42: ...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 cause s...

Page 43: ...ithout permission or damaged its stabil ity is impaired In this case the FOPS must be replaced since its correct function can no longer be guaranteed Precautions for attachments options When installin...

Page 44: ...facilities will not be damaged When working with water or crossing sand banks first check the subsoil and depth and flow rate of the water Ensure that the permitted water depth will not be exceeded T...

Page 45: ...local power company about safe operating procedure before starting operations To prepare for any possible emergencies wear rubber shoes and gloves Lay a rubber sheet on top of the seat and be careful...

Page 46: ...nt 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 Check the mirrors on the mach...

Page 47: ...ition 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 as...

Page 48: ...ing 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 pe...

Page 49: ...machine For machines equipped with a back up alarm check that the alarm works properly Precautions in cold areas Carry out the warming up operation thoroughly If the machine is not thoroughly warmed u...

Page 50: ...re travelling check again that there is no one in the sur rounding area and that there are no obstacles Before travelling sound the horn to warn people in the area Always operate the machine only when...

Page 51: ...to the ground and travel at low speed Never travel over obstacles which make the machine tilt strongly to one side When traveling or carrying out operations always keep a safe distance from people st...

Page 52: ...fallen leaves or wet steel plates with low speed Even with slight slopes there is a hazard that the machine may slip If the engine stops depress the brake pedal immediately lower the bucket to the gr...

Page 53: ...ns on a downhill slope An excessive load will be brought to bear on the machine and this will cause damage to the machine It is dangerous to use the bucket or lift arm for crane opera tions so do not...

Page 54: ...ush the first pile The load suddenly becomes lighter when the soil is pushed over a cliff or when the machine reaches the top of a slope When this happens there is danger that the travel speed will su...

Page 55: ...e slippery so be extremely careful when travelling or operating the machine and do not operate the levers suddenly Even a slight slope may cause the machine to slip so be particularly careful when wor...

Page 56: ...ng brake switch 2 to the ON position then stop the engine Lock all points that can be locked and store the key in a safe place When parking the machine on public roads ensure that it does not obstruct...

Page 57: ...ovide a safe loading slope Take suitable steps to prevent the ramps from moving out of position or coming off Be sure the ramp surface is clean and free of grease oil ice and loose materials Remove di...

Page 58: ...sing over bridges or structures on private land check first that the structure is strong enough to support the weight of the machine When traveling on public roads check first with the relevant author...

Page 59: ...flush the area with large amount of water If acid gets into your eyes flush them immediately with large amount of water and seek medical attention Before working with batteries turn the starting switc...

Page 60: ...hine and problem machine There is a hazard that the machine will move when the power is connected Be sure to connect the positive cable first when installing the booster cables Disconnect the negative...

Page 61: ...towing is ample for the weight of the towed machine Never use a wire rope which has cut strands A reduced diameter B or kinks C There is danger that the rope may break during the towing operation Alw...

Page 62: ...ile you are performing service or main tenance you could suffer serious injury or property damage Keep work place clean and tidy Do not leave hammers or other tools lying around in the work place Wipe...

Page 63: ...OWER directions 2 3 times to release the remaining pressure in the hydraulic circuit then set work equipment lock lever 2 to the LOCK position After releasing the remaining pressure in the hydraulic c...

Page 64: ...n contact with the other workers When carrying out operations near the fan fan belt or other rotating parts there is a hazard of being caught in the parts so be careful not to come close Never drop or...

Page 65: ...ccumulator WARNING Danger of injury Pressure accumulator is filled with highly pres surised nitrogen Do not open or damage the pressure accumu lator The accumulator is charged with high pressure nitro...

Page 66: ...safety reasons a raised boom must be secured against dropping before you pass or stand under it The boom must be secured against moving if any work is to be carried out under it when it is in a raise...

Page 67: ...eces might be sent flying and injure people in the sur rounding area Always check that there is no one in the surrounding area There is a hazard that the pin hit with strong force may fly out and inju...

Page 68: ...y penetrate your skin or cause blindness if it con tacts your eyes directly If you are hit by a jet of high pres sure oil and suffer injury to your skin or eyes wash the place with clean water and con...

Page 69: ...able damage to the outer layer through to the intermediate layer brittleness in the outer layer distortions in pressurised or unpressurised state not con forming with the original shape of the install...

Page 70: ...ance at periodic intervals In order to further increase safety components with a strong relationship to safety such as hoses and seat belts must be replaced at periodic intervals Replacement of safety...

Page 71: ...too low the tyres may heat up and burst If the tyre pressure is too high there is also danger that the tyre may burst If a tyre heats up considerably inflammable gases are pro duced A burning tyre may...

Page 72: ...at can not be accessed by unauthorised persons Place the tyres on an even surface and incline them 60 to 70 against a solid stopper Secure the tyres with wheel chocks so that they cannot roll away tip...

Page 73: ...Operation WA470 6H VEAM946100 3 1 3 Operation WARNING Please read and make sure that you understand the SAFETY section before reading this section...

Page 74: ...1 General view of machine 1 Bucket 8 Turn signal lamp 2 Tilt lever 9 Head lamp 3 Front wheel 10 Lift cylinder 4 Bucket cylinder 11 Lift arm 5 Front working lamp 12 Rear working lamp 6 ROPS cab 13 Rea...

Page 75: ...ional selector switch 5 Front switch panel 17 Lift arm control lever 6 Directional lever 18 Hold switch 7 E C S S switch 19 Bucket control lever 8 Horn button 20 Starting switch 9 Monitor 21 Right swi...

Page 76: ...l view Operation 3 4 WA470 6H VEAM946100 Front switch panel 1 Monitor panel mode selector switch 1 2 Monitor panel mode selector switch 2 3 Front working lamp switch 4 Rear working lamp switch GK03801...

Page 77: ...switch 2 Transmission cut off switch 3 Transmission cut off set switch 4 Directional selector switch actuation switch 5 Emergency steering switch 6 Engine power mode selector switch 7 Torque converter...

Page 78: ...aution lamp 10 Axle oil temperature caution lamp 31 Engine coolant temperature gauge 11 Cooling fan reverse rotation pilot lamp Option 32 Engine coolant temperature caution lamp 12 Maintenance caution...

Page 79: ...mp caution lamps and pilot lamps light up for 2 seconds to check the system After the alarm buzzer sounds for 2 seconds it goes off if the condition is normal The shift indicator display shows 88 for...

Page 80: ...setting is incorrect The central warning lamp on the monitor and the caution lamp for the location of the abnormality light up and at the same time the alarm buzzer sounds and action code E03 is disp...

Page 81: ...cycle 0 2 sec ON 0 05 sec OFF The ON and OFF cycles have a different length Inspection and maintenance This warning is given if it is necessary to carry out inspection and maintenance of wear parts o...

Page 82: ...ter or changing the oil is reached after completion of the system check with the starting switch at the ON position the maintenance monitor caution lamps flash or light up and at the same time the fil...

Page 83: ...inspection 2 Action code display WARNING If action code E03 is displayed stop the machine immediately and check the failure code For details see Failure code display 3 13 Inform your KOMATSU distribut...

Page 84: ...RK The top line of the character display displays E02 and the bot tom line displays the condition of the machine related to over heating E01 When a failure occurs in the mechanical system such as a dr...

Page 85: ...re code is displayed with the first 6 digits on the left side of the character display The code displayed after the space on the right side of the failure code indicates the controller that detected t...

Page 86: ...s not shown on the char acter display if an action code is being displayed If there are two or more items to be displayed they are dis played repeatedly in turn If there are more than 10 items all the...

Page 87: ...lter Replace fuel main filter cartridge 4 72 Corrosion resistor Replace corrosion resistor cartridge 4 76 Transmission oil Change oil in transmission case and transmission oil filter cartridge clean s...

Page 88: ...und intermittently and the lamp for the loca tion of the abnormality and the central warning lamp will light up At the same time the top line of the character display displays E03 and the bottom line...

Page 89: ...parking brake applied to prevent the machine from moving In addition when the accumulator is being charged immediately after starting the engine the brake oil pressure caution lamp will light up but...

Page 90: ...lays CHECK RIGHT NOW and CALL alternately for 3 seconds each so stop the machine immediately in a safe place stop the engine and carry out inspection 4 Steering oil pressure caution lamp Red This lamp...

Page 91: ...hese lamps light up stop operations quickly and carry out the following action 1 Axle oil temperature caution lamp 2 Torque converter oil temperature caution lamp 3 Engine coolant temperature caution...

Page 92: ...keep the brake pedal depressed continuously use the brake only intermittently When using the left brake pedal turn the transmission cut off switch ON to carry out operations If use of the brake is red...

Page 93: ...out 4 Hydraulic oil temperature caution lamp This lamp 4 lights up to warn the operator that the hydraulic oil temperature has risen During checks before starting when the starting switch is turned t...

Page 94: ...and carry out the following action Machines eqipped with KOMTRAX 1 Radiator coolant level caution lamp 2 Engine oil level caution lamp 3 Battery electrolyte level caution lamp 4 Maintenance caution la...

Page 95: ...ay displays E01 and the bottom line displays COOLANT LOW so stop the engine check the water level in the radiator and add water 2 Engine oil level caution lamp This lamp 2 lights up to warn the operat...

Page 96: ...3 14 After replacing the filter or changing the oil reset time for the replacement For details see Reset method for filter oil replacement time 3 36 5 Air cleaner clogging caution lamp Machines eqipp...

Page 97: ...2 Explanation of components WA470 6H VEAM946100 3 25 6 Transmission oil filter clogging caution lamp This lamp 6 is not used 7 Fuel filter water detection caution lamp This lamp 7 is not used GK03210...

Page 98: ...utput mode pilot lamp power mode 5 Preheating pilot lamp 6 Semi auto digging pilot lamp Option 7 Auto greasing pilot lamp Option 8 Joystick pilot lamp Option 9 Directional selector pilot lamp 10 Econo...

Page 99: ...fferent so the cooling fan reverse rota tion pilot lamp flashes Return the switch to its original position or stop the engine and operate the switch 3 Emergency steering pilot lamp Green This lamp 3 l...

Page 100: ...reheating pilot lamp This lamp 5 lights up when the engine preheating electric heater is actuated In cold weather when the starting switch is turned to the ON position this lamp lights up and when the...

Page 101: ...switch at the side of the lift arm control lever For details see Changing direction 3 118 10 Economy operation display lamp This lamp 10 lights up to show that the economy mode is being used economy...

Page 102: ...lights up when the torque converter lock up is engaged and the transmission actually enters direct drive For details see Handling torque converter lock up 6 3 14 Shift hold pilot lamp This lamp 14 lig...

Page 103: ...this lamp 16 also flashes REMARK If there is a disconnection in the turn signal lamp the flashing interval becomes shorter 17 Head lamp high beam pilot lamp This lamp 17 lights up when the head lamp...

Page 104: ...on 3 32 WA470 6H VEAM946100 Meter display portion 1 Torque converter oil temperature gauge 2 Engine cooling water temperature gauge 3 Hydraulic temperature gauge 4 Fuel gauge 5 Speedometer 6 Meter dis...

Page 105: ...ange A If the indicator enters red range B during operations caution lamp C inside the engine coolant temperature gauge lights up At the same time the central warning lamp lights up and the alarm buzz...

Page 106: ...rs 7 13 US gal caution lamp A inside the fuel gauge lights up If it lights up check the fuel level and add fuel 5 Speedometer This meter 5 indicates the travel speed of the machine The display unit is...

Page 107: ...when checking the total distance that the machine has traveled 1 Check that the character display is showing the service meter or the action code If it is giving any other display turn the starting sw...

Page 108: ...switch 2 to display the item filter or oil which has reached the replacement time 5 Press the portion of the character display mode selector switch The screen switches to the display shown on the righ...

Page 109: ...2 digits can be displayed for the telephone number Input from the first digits The cursor is displayed at the input position Press or of monitor panel mode selector switch 2 and display 0 to 9 To leav...

Page 110: ...ed 4 Press or of monitor panel mode selector switch 2 and select the language NOTE The available languages are English Japanese German French Italian Spanish and Swedish 5 After selecting the language...

Page 111: ...crystal display press the or of monitor panel mode selector switch 2 to switch the display to LCD PANEL 4 Press the of monitor panel mode selector switch 1 The screen will change to the display shown...

Page 112: ...3 2 Explanation of components Operation 3 40 WA470 6H VEAM946100 3 2 2 Switches GK038020 20 19 21 7 8 6 9 24 18 14 15 11 10 17 16 13 12 3 4 5 25 22 1 23 26 2...

Page 113: ...azard lamp switch 9 Parking brake switch 10 Front working lamp switch 11 Rear working lamp switch 12 Monitor panel mode selector switch 1 13 Monitor panel mode selector switch 2 14 Kickdown switch 15...

Page 114: ...the key immediately after the engine has been started The key will return to ON posi tion B when released 2 Power mode selector switch This switch 2 can be used to switch the engine output to match th...

Page 115: ...Automatic shift 3 57 4 Transmission cut off switch WARNING When starting the machine off up a hill turn the transmission cut off switch to the OFF position depress the brake pedal then gradually depr...

Page 116: ...witch is released it automatically returns to its origi nal position For details of the method of adjusting the cut off position see Adjusting transmission cut off position 3 124 6 Lamp switch This sw...

Page 117: ...o flashes When the steering wheel is turned back the lever automatically returns to its original position If it does not return return it man ually 6 Dimmer switch This switch 6 is used to switch the...

Page 118: ...switch to apply the brakes when traveling except in an emergency The parking brake may be damaged and this may lead to a serious accident Apply the parking brake only after the machine has stopped If...

Page 119: ...If the lamp switch is not at the ON position for the side clearance lamp or head lamp the working lamp will not light up 11 Rear working lamp switch WARNING Always turn the working lamp off before tra...

Page 120: ...Position Press here to cancel each mode or operation 13 Monitor panel mode selector switch 2 This switch 13 is used to switch the function of the character display When the switch is released it autom...

Page 121: ...g in either forward or in reverse the kick down switch is actuated and it is possible to shift down to 1st This makes it easy to carry out load and carry operations Even if the travel speed is more th...

Page 122: ...uch as grading REMARK When canceling the shift hold operate the directional lever or gearshift lever or operate the transmission shift mode selector switch to MANUAL It is also possible to cancel the...

Page 123: ...ight a cigarette 19 Room lamp switch The switch 19 is used to turn the room lamp ON and OFF Position a OFF Position b Lights up when the cab door opens Position c Lights up REMARK The room lamp lights...

Page 124: ...er the work equipment to the ground then turn the E C S S switch OFF before starting the inspection and maintenance operation When carrying out leveling work turn the E C S S switch OFF This switch 21...

Page 125: ...um of 60 seconds When using the emergency steering travel at a speed of less than 5 km h 3 1 MPH For details see Emergency steering 3 126 23 Cooling fan reverse rotation switch This switch 23 is used...

Page 126: ...reverse rotation pilot lamp on the machine monitor lights up For details of the procedure for cleaning see Clean radiator fins and cooler fins 4 43 Position c Neutral OFF The cooling fan is constantly...

Page 127: ...is switch 25 is turned on the directional selector switch on the side of the lift arm control lever is actuated Position a ON The directional selector switch is actuated The directional selector pilot...

Page 128: ...A470 6H VEAM946100 3 2 3 Control levers pedals 1 Gearshift lever 2 Directional lever 3 Gearshift lever stopper 4 Work equipment lock lever 5 Bucket control lever 6 Lift arm control lever 7 Brake pedal...

Page 129: ...being used it is impossible to shift to 3rd or 4th Disengage the gearshift lever stopper before trying to shift gear Position a 1st Position b 2nd Position c 3rd Position d 4th REMARK The lever length...

Page 130: ...travel speed is more than 10 5 km h 6 5 MPH this switch can be used to shift the transmission down Each time the kick down switch is pressed the speed range will shift down one range at a time when i...

Page 131: ...up and the buzzer will sound Return the gearshift lever to the N position and start the engine Position F FORWARD Position N NEUTRAL Position R REVERSE REMARK The lever length can be set to 2 levels...

Page 132: ...a serious accident or personal injury Check that the lever is in the LOCK position When operating the work equipment lock lever check that the work equipment control lever is held securely at the HOL...

Page 133: ...o not use the FLOAT position when lowering the bucket Use the FLOAT position when leveling see Leveling operation 3 134 Position a RAISE When the lift arm control lever is pulled further from the RAIS...

Page 134: ...e right brake pedal for normal braking operations The left brake pedal operates the wheel brakes When the transmission cut off switch is at the ON position the brakes are applied and the transmission...

Page 135: ...s accident or personal injury This lever is used to unlock and lock the steering column when adjusting the position of the steering column to the front or rear or up or down F FREE position Steering w...

Page 136: ...pped with locks Method of opening and closing cap with lock for the fuel tank filler port To open the cap 1 Insert the key into the key slot 2 Turn the key clockwise align the key slot with the match...

Page 137: ...oved the steering wheel cannot be used for steering and this may lead to serious damage or injury The safety bar is a device to lock the front frame and rear frame so that machine does not articulate...

Page 138: ...eft of the rear frame After using the pump wipe off all the grease from the outside of the pump and stow the pump in the toolbox 1 Turn the grease pump so that lever 2 of grease pump 1 faces the outsi...

Page 139: ...or center pillar When there is any person inside the cab always call out a warning before opening or closing the door 3 2 10 Cab door open lock When getting in or out of the operator s compartment or...

Page 140: ...ed position Pull open lock knob 1 towards the inside of the machine to release the lock push open lock knob 1 up along the rail to move to the lock position then release the knob There are 2 lock posi...

Page 141: ...de then secure at the LOCK position CAUTION It is dangerous to carry out operations with the emergency escape window lock released The right window will extend beyond the outermost wheel There is also...

Page 142: ...two places then remove cover 2 The fuse boxes are A and B Fuse capacity and name of circuit Fuse box A GK038052 1 2 A B GK032161 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 No Fuse capacity Name of circuit 1...

Page 143: ...rcuit 1 5A Engine control B 2 20A Rear heated wire glass 3 10A Air suspension seat 4 20A Yellow rotating lamp Option 5 10A Turn signal indicator 6 20A Car radio cigarette lighter 12V power source 7 10...

Page 144: ...use such as using 24V as the power source for 12V equipment will cause failure of the equipment When using the electric power source do not install any equipment which will exceed the maximum amperage...

Page 145: ...raise the pressure inside the cab This makes it possible to pro vide a pleasant working environment even on dusty jobsites General locations and function of control panel 1 Main power switch 2 Fan sw...

Page 146: ...The fan stops When the switch is turned ON the setting displayed is the same as when the air conditioner was turned OFF 2 Fan switch Use this switch 2 to adjust the air flow from the fan The air flow...

Page 147: ...displayed on the display monitor If the switch is pressed again the switch is turned OFF and dis play monitor A goes out 4 Temperature control switch Use this switch 4 to adjust the temperature betwe...

Page 148: ...is prevents the entry of dirt The higher the position of the fan switch the more efficient this becomes Method of operation Cooling operation 1 Press main power switch 1 of the air conditioner to turn...

Page 149: ...esired temperature REMARK Heating is carried out using the engine cooling water so it can be carried out when the cooling water temperature is high Drying heating and demisting operation 1 Press main...

Page 150: ...temperature when you enter the cab Do not make the temperature inside the cab too low or direct the air flow directly onto your skin Be extremely careful to select the appropriate temperature When co...

Page 151: ...keeping drinks and other things cool When the heating is being used it can be used to keep things warm When using the box open the vent grill When not using the box close the grill Do not use the cool...

Page 152: ...re inside the cab This makes it possible to pro vide a pleasant working environment even on dusty jobsites General locations and function of control panel 1 Main power switch 2 Fan switch 3 Air condit...

Page 153: ...The fan stops When the switch is turned ON the setting displayed is the same as when the air conditioner was turned OFF 2 Fan switch Use this switch 2 to adjust the air flow from the fan The air flow...

Page 154: ...tion of the cooling and dehumidifying heating functions stopping operation When the main power switch is turned ON and the AUTO air conditioner switch is pressed the air conditioner is turned ON and t...

Page 155: ...ir inside the cab is circulated Use this position when it is needed to carry out quick heating or cooling of the cab or when the outside air is dirty smells or is dusty FRESH Fresh air is taken in fro...

Page 156: ...tioner is run for a long time with the air flow at Lo in rare cases the evapo rator may freeze If it freezes and no cold air comes out turn the air conditioner switch OFF raise the temperature setting...

Page 157: ...ON 2 Press fan switch 2 and set the air flow to the desired set ting 3 Press temperature control switch 3 to set to the desired temperature 4 Press RECIRC FRESH selector switch 4 to select FRESH 5 Pre...

Page 158: ...temperature when you enter the cab Do not make the temperature inside the cab too low or direct the air flow directly onto your skin Be extremely careful to select the appropriate temperature When co...

Page 159: ...er arm 1 to the front check that the wiper blade is hanging free When angling the wiper arm 1 to the front such as when wip ing the glass clean if the wiper arm 1 is angled with the wiper blade 2 lock...

Page 160: ...the handrails and steps and tighten any loose bolts Failure to do this may cause workers to fall and suffer serious personal injury If the machine is at an angle reposition it level before checking Ca...

Page 161: ...loose bolts on handrail and steps Repair any damage and tighten any loose bolts 8 Check for damage to gauges lamps on instrument panel and loose bolts Check for damage to the panel gauges and lamps If...

Page 162: ...he rear view can be seen clearly from the operator s platform 14 Inspect tires WARNING If worn or damaged tires are used they may burst and cause serious injury or death To ensure safety do not use th...

Page 163: ...efore starting the engine for the day s work Check monitor panel 1 Turn starting switch to the ON position B 2 Check that all the monitors gauges and the central warning lamp light up for approx 2 sec...

Page 164: ...emoving it CAUTION When adding coolant use the step and handrail provided and support your body securely 1 Open cover 1 of the platform on the right side of the machine 2 Check that the coolant level...

Page 165: ...ipstick G fully in the oil filler pipe then take it out again 4 The oil level should be between the H and L marks on dip stick G If the oil level is below the L mark add oil through oil filler F If th...

Page 166: ...r and sediment 1 Open the engine side cover on the right side of the machine The water separator forms one unit with the fuel pre filter and is at the bottom 2 It is possible to judge the condition of...

Page 167: ...g 2 4 Coat O ring portion 5 with a suitable amount of grease When doing this be careful not to let the grease get on the drain valve water drain port a or the plug thread 5 Screw in plug 2 by hand unt...

Page 168: ...dust indicator to reset it 4 If the yellow piston enters the red range 7 5 kPa soon after the dust indicator is reset it is necessary to replace the ele ment For details see Replacing element 4 34 Ele...

Page 169: ...ter cartridge 4 72 Take care not to let the engine stop because of lack of fuel If the engine has run out of fuel the air bleeding operation can be carried out more quickly if the fuel tank is complet...

Page 170: ...there is any accumulation of flammable material around the bat tery and remove such flammable material Please contact your KOMATSU distributor for investigation and correction Check parking brake Chec...

Page 171: ...djustment Lift lever and move seat forwards backwards Release the lever to lock the seat B Height and Slope adjustment Pull lever and adjust the seat position in height and slope by loading unloading...

Page 172: ...ty belt before you start work and do not take it off during work Put on the safety belt in such a way that it is not twisted and fits tightly The machine is provided with a lap belt which automaticall...

Page 173: ...and angle of wrist rest The height and angle of wrist rest 1 can be adjusted by loosen lock lever 2 Height adjustment amount 30 mm Angle adjustment amount 44 degrees REMARK Set lock lever 2 to the FRE...

Page 174: ...possible to see the ground around the machine at a range of 1 m from the operator s seat If the movement of the mirror is stiff when adjusting it loosen bolt 2 of the mirror Install the mirrors at the...

Page 175: ...ition If directional lever 2 is not set to the N position the engine will not start REMARK If the directional lever is not at the N position the alarm buzzer will emit short sounds 3 Check that the bu...

Page 176: ...monitors gauges and central warning lamp light up for approx 2 seconds and the alarm buzzer sounds for approx 2 sec If any monitor does not light up there is probably a failure or disconnection so con...

Page 177: ...engine parts may be damaged Do not keep the starting motor rotating continuously for more than 20 seconds If the engine does not start wait for at least 2 minutes before trying to start the engine aga...

Page 178: ...ically return to the ON position B 5 After the engine starts if the engine water temperature is low below 20 C the warming up operation engine speed 1020 rpm is automatically carried out 6 For details...

Page 179: ...he accelerator pedal fully depressed There is danger that the engine parts may be damaged When starting the engine after the machine has been left for more than half a day in temperatures near 20 C it...

Page 180: ...1 at the START posi tion C to keep the starting motor running until the engine starts 4 Method of starting engine in temperatures of approx 20 C Keep the engine starting motor running for the max 20...

Page 181: ...r starting the engine if the engine water temperature is below 20 C the automatic warming up operation engine speed 1020 rpm is carried out and is cancelled when the engine water temperature goes abov...

Page 182: ...hydraulic oil temperature is low do not carry out oper ations under heavy load or at high speed There is danger that the pump may be broken Breaking in the machine CAUTION Your KOMATSU machine has be...

Page 183: ...weather 2 Depress accelerator pedal 1 lightly and run the engine with no load at midrange speed for about 5 minutes To warm up the hydraulic oil in cold areas do as follows 3 After completing the war...

Page 184: ...g up operation check that the gauges and pilot lamps are normal If there is any abnormality carry out maintenance or repair Run the engine under a light load until engine cooling water temperature gau...

Page 185: ...lly then stop it 1 Run the engine at low idling for about 5 minutes to cool down gradually 2 Turn the key of starting switch 1 to the OFF position A to stop the engine 3 Remove the key from starting s...

Page 186: ...o not allow people to get near the machine Clear the machine s travel path of any obstacle Pay particular attention to the blind spot at the rear of the machine when traveling in reverse When starting...

Page 187: ...the right 4 Depress right brake pedal 5 and turn parking brake switch 6 to the OFF position B to release the parking brake Keep right brake pedal 5 depressed REMARK If the parking brake is still actu...

Page 188: ...KOMATSU distributor for repairs 7 Release right brake pedal 5 then depress accelerator pedal 9 to move the machine REMARK When moving the machine off on a hill turn transmission cut off switch 10 OFF...

Page 189: ...r so that the gearshifting is com pleted within 2 seconds This machine is equipped with kickdown switch 3 When travel ing in 2nd if kickdown switch 3 is pressed the transmission shifts down to 1st For...

Page 190: ...RSE If the backup alarm does not sound please contact your KOMATSU distributor for repairs REMARK If the directional lever is operated slowly or is stopped midway between the forward and reverse direc...

Page 191: ...ges A or B in the chart the central warning lamp will light up and the buzzer will sound At the same time E00 is displayed on the top line of the char acter display and OVERRUN PROTECT is displayed on...

Page 192: ...erating When this is done the central warning lamp lights up and the alarm buzzer sounds Set the directional lever and directional selector switch at the side of the work equipment control lever to th...

Page 193: ...his condition the machine will move forward or in reverse according to the set position of the directional lever Return the directional lever to the Neutral position N When directional selector switch...

Page 194: ...epressed NOTE Never use the parking brake lever to brake the machine when traveling except in an emergency Apply the parking brake only after the machine has stopped 1 Release accelerator pedal 1 then...

Page 195: ...ch the following type of work adjust the set position to cut off the transmission at a smaller or larger angle When carrying out scooping up work lower the brake pedal depression position for the cut...

Page 196: ...sed the buzzer will sound with a repeated short sound and the cut off position is set Method of canceling cut off position 5 After the buzzer sounds in Step 4 of the adjustment proce dure the transmis...

Page 197: ...use steering wheel 1 to turn the machine With this machine the front frame is joined to the rear frame at the center of the machine by the center pin The front and rear frames bend at this point and t...

Page 198: ...starting switch is at the ON position The steering oil pressure is low or there is no pressure When the engine has stopped or there is a failure in the steering oil pressure pump etc When the startin...

Page 199: ...y actuated for approx 3 seconds to check that the emergency steering is functioning properly When this happens steering oil pressure caution lamp red 1 and emergency steering pilot lamp green 2 light...

Page 200: ...and this may lead to serious personal injury Always check that the condition is as shown in the diagram Never raise the boom with the bucket fully loaded when the machine is articulated There is dange...

Page 201: ...t and the lever is returned to the HOLD position Position b HOLD The lift arm is kept in the same position Position c LOWER Position d FLOAT The lift arm moves freely under external force Bucket opera...

Page 202: ...ve NOTE If the tires slip the tire life will be reduced so do not allow the tires to slip during operation Loading piled soil or blasted rock When loading piled soil or blasted rock drive the machine...

Page 203: ...res come off the ground and slip Try to keep the load in the center of the bucket if the load is on one side of the bucket the load will be unbalanced Stock pile Blasted rock 4 At the same time as thr...

Page 204: ...load the bucket fully REMARK If the bucket edge is moved up and down while pushing in the bucket and digging the front tires will come off the ground and this will cause the tires to slip 6 If there...

Page 205: ...out in 1st gear CAUTION Do not set the bucket facing down more than 20 degrees 1 Set the edge of the bucket facing slightly down 2 Drive the machine forward and operate the work equipment control leve...

Page 206: ...ground by moving backward Pushing operation CAUTION Never set the bucket to the DUMP position when carrying out pushing operation When carrying out pushing operations set the bottom of the bucket para...

Page 207: ...k equipment is raised the moment that the E C S S switch is turned ON the work equipment will move If operations are carried out with the E C S S switch left at the ON position the moment that the tra...

Page 208: ...m height first shake the bucket to stabilize the load before raising the bucket This will prevent the load from spilling to the rear Precautions when piling up loads When forming products into a pile...

Page 209: ...lower the work equipment to lower the center of gravity before turning It is dangerous to turn the machine suddenly on slopes Breaking on downhill slope If the foot brake is used frequently when trav...

Page 210: ...on of the travel surface Contact your KOMATSU distributor or tire dealer for information When traveling on a paved road surface using normal tires 26 5 R25 the guideline for the appropriate tire infla...

Page 211: ...e machine s braking capacity may be exceeded and the brakes may overheat The table below shows a guideline of the values for this machine If the braking capacity limit is exceeded a forced cooling sys...

Page 212: ...ps at the desired dig ging angle The setting can be adjusted to match the working conditions Adjusting boom kickout 1 Raise the bucket to the desired height set the lift arm control lever at HOLD then...

Page 213: ...6 is 0 5 to 2 mm then tighten bolts 5 to hold in position 4 Loosen 2 nuts 7 adjust so that the clearance between bar 2 and the sensing surface of proximity switch 3 is 3 to 5 mm then tighten the nuts...

Page 214: ...ly and this may lead to a serious accident Before leaving the operator s compart ment always set the safety lock lever securely to the LOCK position Even if the parking brake switch is turned ON there...

Page 215: ...ing brake is applied the transmission is automati cally returned to neutral 4 Operate lift arm control lever 5 to lower the bucket to the ground 5 Check that the lift arm control lever 5 and bucket co...

Page 216: ...engine has overheated do not stop it suddenly Run the engine at a midrange speed to allow the engine to cool down before stopping it After stopping engine 1 Walk around the machine and check the work...

Page 217: ...ck the following parts 1 Fuel tank filler cap 2 Engine side cover 2 places 3 Cab door 4 Rear grille 5 Air conditioner fresh air filter 6 Transmission filler cover REMARK The starting switch key is use...

Page 218: ...p the machine without taking due care Tire pressure Measure the tire pressure before starting operations when the tires are cool If the tire inflation pressure is too low there will be overload if it...

Page 219: ...n the limits given in the table to give a suitable deflec tion see deflection ratio Manufacturer Tire size Pattern Inflation pressure Front wheels Rear wheels bar psi bar psi BRIDGESTONE 26 5R25 EM VM...

Page 220: ...ockpile operations mean the loading of sand and other loose materials Precautions for using load and carry method When traveling continuously with load and carry operations choose the correct tires to...

Page 221: ...eep well away from the road shoulder Use ramps of ample width length thickness and strength and install them securely at an angle of less than 15 When using an embankment compact the fill soil thoroug...

Page 222: ...nter of the tires If the ramp sags appreciably reinforce it with blocks etc 3 Determine the direction of the ramp then slowly load the machine 4 Load the machine correctly in the specified position on...

Page 223: ...r 6 Put blocks in front and behind the wheels and secure the machine with chains or wire rope to prevent the machine from moving during transportation In particular attach the machine securely to prev...

Page 224: ...nce between the ramps to match the center of the tires If the ramp sags appreciably reinforce it with blocks etc 3 Remove the chains and wire ropes fastening the machine 4 Set the frame lock bar to FR...

Page 225: ...Never raise the machine with any worker on it Always make sure that the wire rope used for lifting the machine is of ample strength for the weight of the machine Never try to lift the machine at any...

Page 226: ...4 places on the machine as shown in the diagram on the right Use only these 4 places when lifting do not use any other places There is a serious danger that the machine will lose its balance Weight ta...

Page 227: ...lock lever to the LOCK position 3 Stop the engine check that the area around the operator s compartment is safe then lock with the safety bar so that the front frame and rear frame do not articulate 4...

Page 228: ...ng coolant con taining antifreeze that has been drained when repairing the radiator please contact your KOMATSU distributor Anti freeze is toxic so do not let it flow into drainage ditches or spray it...

Page 229: ...perature drops the capacity of the battery will also drop If the battery charge ratio is low the battery elec trolyte may freeze Maintain the battery charge as close as pos sible to 100 and insulate i...

Page 230: ...lp protect the wheels from being frozen in soil and the machine can start next morning Open the drain valve and drain any water collected in the fuel system to prevent it from freezing Fill the fuel t...

Page 231: ...up the hydraulic oil in the circuit continuously for more than 5 seconds When the temperature is low do not start the operation of the machine immediately after starting the engine Warming up steering...

Page 232: ...safety lock lever in the LOCK position To prevent corrosion be sure to fill the cooling system with Supercoolant AF NAC or permanent type antifreeze den sity between 30 and 68 3 6 2 During storage WAR...

Page 233: ...r KOMATSU distributor When using the machine after long term storage do as follows before using it Wipe off the grease from the hydraulic cylinder rods Add oil and grease to all lubrication points Whe...

Page 234: ...lt if there is any mistake in the selection of wire rope or method of towing a disabled machine Check that the wire rope is of ample strength for the weight of the machine being towed Never use a wire...

Page 235: ...long distances use a transporter To protect the operator if the towing rope or bar should break install a protector plate to the machine being towed If it is impossible to operate the steering and br...

Page 236: ...s possible to prevent the machine from losing control and turning over Towing may be carried out under various differing conditions so it is impossible to determine beforehand the requirements for tow...

Page 237: ...and rear drive shafts If necessary block the tires to prevent the machine from moving 2 The steering cannot be operated so remove the steering cylinder Even if the brakes are in good condition the br...

Page 238: ...by using emergency parking brake cancel switch CAUTION When the parking brake switch is at the OFF position and the emergency parking brake release valve is opened the parking brake is released immedi...

Page 239: ...ease valve then turn locknut 1 clockwise to lock it Tightening torque Grip 2 20 5 Nm Locknut 1 20 5 Nm 6 Move the parking brake switch to the ON a position The parking brake is applied To release the...

Page 240: ...e removed and tighten uniformly until they stop 4 This releases the parking brake A Plug mounting hole Taper mounting hole B Therad hole M12 for releasing Emergency travel operation The normal gear sh...

Page 241: ...it out with fresh water and consult a doctor When handling batteries always wear protective goggles and rubber gloves When removing the battery first disconnect the cable from the ground normally the...

Page 242: ...ng the charger and do as follows Do not use or charge the battery if the battery electrolyte level is below the LOWER LEVEL line This may cause an explosion Always check the battery electrolyte level...

Page 243: ...there is no mistake in the booster cable con nections The final connection is to the engine block of the problem machine but sparks will be generated when this is done so connect to a place as far as...

Page 244: ...re the clips are firmly connected to the battery termi nals 2 Start the engine of the normal machine and keep it to run at high idling speed 3 Turn the starting switch of the problem machine to the ST...

Page 245: ...alternator Defective alternator Replace Starting motor does not turn when starting switch is turned to START Defective wiring Insufficient battery charge Defective starting motor Check repair Charge C...

Page 246: ...r too little oil Machine is not traveling in correct speed range Torque converter is stalled for long periods Engine is overheating Add or drain oil to specified level See WHEN REQUIRED Place in corre...

Page 247: ...s play Add oil to specified level See EVERY 100 HOURS SERVICE Hydraulic system Bucket lacks lifting power Bucket takes time to go up Lack of oil Clogged hydraulic filter Add oil to specified level See...

Page 248: ...Loose radiator filler cap high altitude operation Defective monitor Check add cooling water repair See WHEN REQUIRED Check repair Change cooling water clean inside of cooling system See WHEN REQUIRED...

Page 249: ...See defective compression above Clean or replace turbocharger Combustion noise occasionally makes breathing sound Defective nozzle Replace nozzle Abnormal noise generated combustion or mechanical Low...

Page 250: ...3 7 Troubleshooting Operation 3 178 WA470 6H VEAM946100...

Page 251: ...Maintenance WA470 6H VEAM946100 4 1 4 Maintenance WARNING Please read and make sure that you understand the SAFETY section before reading this section...

Page 252: ...per viscosities specified for ambient tempera ture Always use clean washer fluid Use automobile window washer fluid and be careful not to let any dirt get into it Always use clean oil and grease Use c...

Page 253: ...o stop the flow of electric current Do not drop things inside machine When opening inspection windows or the oil filler port of the tank to carry out inspection be careful not to drop nuts bolts or to...

Page 254: ...use injury to the worker Bleeding air from hydraulic circuit After repairing or replacing the parts of hydraulic circuit or removing the piping of hydraulic circuit it is necessary to bleed the air fr...

Page 255: ...rried out correctly Have any tools or parts been dropped inside the machine It is particularly dangerous if parts are dropped inside the machine and get caught in the lever linkage mechanism Is there...

Page 256: ...me There is no problem if the small amount of oil remaining in the piping mixes with the new oil Unless there is any specific request the oil fuel and coolant used on the machine when it is shipped fr...

Page 257: ...y of problems with machines are caused by the entry of such impurities Take particular care not to let any impurities get in when stor ing or adding oil Never mix oils of different grades or brands Al...

Page 258: ...uch as a drop in output To prevent the moisture in the air from condensing and form ing water inside the fuel tank always fill the fuel tank after completing the day s work Before starting the engine...

Page 259: ...er such as a river water or well water hard water contains large amounts of minerals calcium magne sium etc and this makes it easier for scale to form inside the engine or radiator Once scale is depos...

Page 260: ...hen greasing Be particularly careful to wipe off the old grease in places where sand or dirt sticking in the grease would cause wear of the rotating parts Carrying out KOWA KOMATSU Oil Wear Analysis K...

Page 261: ...5 or more enabling early detection of failures Others Measurements are made of items such as the ratio of water in the oil density of the antifreeze coolant ratio of fuel in the oil and dynamic viscos...

Page 262: ...first in first out use the oldest oil or fuel first Filters Filters are extremely important safety parts They prevent impurities in the fuel and air circuits from entering important equipment and caus...

Page 263: ...to the electrical components Service relating to the electric system is checking fan belt tension checking damage or wear in the fan belt and check ing battery fluid level Never install any electric c...

Page 264: ...ar parts list The parts in parentheses are to be replaced at the same time See Part No in Parts Book KOMATSU Item Part No Part Name Q ty Replacement frequency Engine oil filter Cartridge 1 EVERY 500 H...

Page 265: ...Bolt on cutting edge Standard type Center edge Side edge Bolt Nut Washer 2 2 18 18 18 Long life type Center edge Side edge Bolt Nut Washer 2 2 18 18 18 Segment type Center edge Side edge Bolt Nut Was...

Page 266: ...he total amount of oil including the oil in the tank and the piping Refill capacity means the amount of oil needed to refill the system during inspection and maintenance When starting the engine in te...

Page 267: ...TBN of oil frequently by TBN handy checker etc and change oil based on the result Always be aware that oil change interval is extremely shorter than standard Be sure to carry out periodic engine inspe...

Page 268: ...eviations EO Engine Oil G Lithium Grease No 2 F Diesel Fuel AXO Axle Oil HO Hydraulic Oil 3 Numbers at the left side of the chart indicate the number of lubrication points Refer to the above illustrat...

Page 269: ...Power train oil Note 2 TO10 Hydraulic system Power train oil TO10 Hydraulic oil HO46 HM Engine oil KOMATSU EO10W30 DH KOMATSU EO15W40 DH Axle Axle oil Note 3 AXO80 Power train oil Note 4 TO50 Note 3 P...

Page 270: ...TSU genuine AXO80 or equivalent Note 4 When the ambient temperature is higher than 45 C and the machine operation hour is longer than 12 hours day then the use of TO50 instead of AXO80 is recommended...

Page 271: ...rcoolant AF NAC may be supplied in premix In this case always top off with premix solution never dilute with water When the machine is shipped from the factory it may be filled with coolant containing...

Page 272: ...oil Maintenance 4 22 WA470 6H VEAM946100 4 4 3 Recommended brands recommended quality for products other than KOMATSU genuine oil When using commercially available oils other than KOMATSU genuine oil...

Page 273: ...ead diameter of bolt a mm Width across flats b mm Tightening torque Target value Service limit Nm kgfm lbft Nm kgfm lbft 6 8 10 12 14 10 13 17 19 22 13 2 31 66 113 172 1 35 3 2 6 7 11 5 17 5 9 8 23 1...

Page 274: ...ghtening torque Target value Permissible range Nm kgfm lbft Nm kgfm lbft 9 16 18UNF 19 44 4 5 32 5 35 63 3 5 6 5 25 3 47 0 11 16 16UN 22 74 7 5 54 2 54 93 5 5 9 5 39 8 68 7 13 16 16UN 27 103 10 5 75 9...

Page 275: ...them with new ones regardless of their condition after a certain period of usage This is important to ensure that these parts maintain their full performance at all times Furthermore should anything...

Page 276: ...hydraulic tank 2 16 Steering hose steering valve centralized drain block 1 17 Steering hose steering pump hydraulic tank 3 18 Steering hose steering pump fan pump 1 19 Steering oil pressure check lin...

Page 277: ...ace air cleaner element 4 32 Clean inside of cooling system 4 35 Check transmission oil level add oil 4 39 Check axle oil level add oil 4 40 Clean axle case breather 4 41 Clean air conditioner condens...

Page 278: ...72 Change oil in transmission case and transmission oil filter cartridge clean strainer 4 74 Clean transmission case breather 4 75 Lubricating 4 76 Check of engine air intake piping clamps for loosene...

Page 279: ...or adjust 4 87 Check for loose engine high pressure piping clamps hardening of rubber 4 88 Checking for missing fuel spray prevention cap hardening of rubber 4 88 Check starting motor 4 89 4 9 13 Ever...

Page 280: ...its performance keep to the following periodic maintenance intervals when adjusting the injector If the periodic maintenance intervals are not observed correctly the engine may not be able to display...

Page 281: ...ck Tightening torque 927 103 Nm 2 If any stud bolt is broken replace all the stud bolts for that wheel 4 9 2 Initial 250 hours service only after the first 250 hours Carry out the following maintenanc...

Page 282: ...or maintenance is carried out with the engine running dirt will get into the engine and damage it Always stop the engine before carrying out these operations When using compressed air there is danger...

Page 283: ...hecked by shining a light through it after cleaning replace the element NOTE When cleaning the element do not hit or beat it against any thing Do not use an element whose folds gasket or seal are dam...

Page 284: ...at this time however 4 Clean the inside of the air cleaner body and dust cup 5 Remove inner element 5 then install a new inner element immediately 6 Fit new outer element 4 replace O ring 7 with a ne...

Page 285: ...ine adjust 3 88 and Starting engine 3 105 in the OPERATION section of the Operation and Maintenance Manual When the undercover is removed there is danger of touch ing the fan Never go to the rear of t...

Page 286: ...ed use the special cover 600 411 9000 Please consult your KOMATSU distributor about the method of installing When deciding the ratio of antifreeze to water check the lowest temperature in the past and...

Page 287: ...distributor We recommend use of an antifreeze density gauge to control the mixing proportions Prepare a container whose capacity is larger than the speci fied coolant volume to catch drained coolant...

Page 288: ...tions for the clean ing agent 9 Replace the corrosion resistor cartridge then open 2 valves 1 For details of the procedure for replacing the corrosion resis tor see Replace corrosion resistor cartridg...

Page 289: ...the engine and run it at low idling for at least 5 minutes 2 Open the cap of oil filler port F remove dipstick G and wipe the oil off with a cloth 3 Insert dipstick G fully in the oil filler pipe F t...

Page 290: ...1 REMARK Remove the mud and dirt from around plug 1 then remove the plug 2 Wipe off any oil adhering to the oil level gauge attached to plug 1 with cloth 3 Set the oil level gauge G as shown in the ri...

Page 291: ...with the safety bar A Front B Rear Remove all mud and dirt from around the breather with a brush After removing the mud or dirt from around the breather remove the breather immerse it in cleaning flui...

Page 292: ...nt flying there is danger of personal injury Always wear pro tective glasses dust mask and other protective equipment If there is mud or dust on the air conditioner condenser clean it with water If th...

Page 293: ...to fly it may lead to personal injury Always wear safety glasses dust mask or other pro tective equipment Clean the radiator if mud or dirt is stuck to it Clean fins by rotating cooling fan in reverse...

Page 294: ...ON of cooling fan reverse rotation switch 1 5 After the cooling fan reverse rotation pilot lamp on the machine monitor flashes check that it lights up At the same time COOLING FAN REVERSE ROTATION is...

Page 295: ...verse rotation switch 1 3 Check that pilot lamp inside of the switch and the cooling fan reverse rotation pilot lamp on the machine monitor light up The fan automatically rotates in reverse for 2 minu...

Page 296: ...ough conditions Injection pressure Max 9 8 MPa Nozzle diameter Max 2 mm Distance between nozzle and radiator fins Min 100 mm Examine the rubber hoses and if any hose is cracked or deterio rated replac...

Page 297: ...own Raise the bucket so that the bottom surface of the bucket is horizontal 2 Remove nuts and bolts 1 then remove cutting edge 2 3 Clean the mounting surface of cutting edge 2 4 Turn cutting edge 2 an...

Page 298: ...they wear down as far as the adapter 1 Raise the bucket to a suitable height then put blocks under the bucket to prevent the bucket from coming down Raise the bucket so that the bottom surface of the...

Page 299: ...he door and window fully 6 Press air conditioner switch 4 to turn the air conditioner switch ON 7 Use sight glass 6 inspection window of receiver drier 5 to check the condition of the refrigerant gas...

Page 300: ...ation Item to check for Maintenance interval Check before operating 6 months Replacement interval Filter Clogging dirt Carry out check 2 years Condenser Clogging dirt Carry out check Belt Looseness da...

Page 301: ...vers 1 2 and 3 of the slow blow fuse box Covers 2 and 3 can be removed easily by using protru sion A on the body as a fulcrum and levering the catch of the cover with a flat headed screwdriver to rele...

Page 302: ...opped Please contact your KOMATSU distributor to have the accumu lator inspected REMARK Carry out the inspection with the speed range set to 2 4 with the machine traveling at a speed of at least 5 km...

Page 303: ...installed Do not make a fire near the tire Selection of tires WARNING Select the tires according to the conditions of use and the weight of the attachments on the machine Use only specified tires and...

Page 304: ...carry out repairs Be sure to observe the specified inflation pressure Do not adjust the inflation pressure of the tires just after high speed travel or heavy duty work Check Measure the inflation pres...

Page 305: ...olant level add coolant Check oil level in engine oil pan add oil Check fuel level add fuel Check electric wiring Check parking brake Check brake pedal Check inflation pressure of tires Check air clea...

Page 306: ...emperature to go down before starting the work When removing the oil filler cap turn it slowly to release the internal pressure then remove it 1 Lower the bucket horizontally to the ground and stop th...

Page 307: ...rting key into key slot 1 release the lock loosen knob 2 and open cover 3 2 Remove element 4 and clean it 3 Direct dry compressed air less than 0 69 MPa to the ele ment from inside along its folds the...

Page 308: ...The battery generates flammable gas and there is danger of explosion so do not bring fire or sparks near the battery Battery electrolyte is dangerous If it gets in your eyes or on your skin wash it of...

Page 309: ...y is wiped with a dry cloth static electricity may cause a fire or explosion 3 If the electrolyte level is below the midway point between the UPPER LEVEL U L and LOWER LEVEL L L lines remove cap 1 and...

Page 310: ...d water also to the other cells Use the diagram below for reference and check if the electrolyte reaches the bottom of the sleeve 4 After adding distilled water tighten cap 1 securely REMARK If distil...

Page 311: ...brake hold the machine in position 2 If any problem is found please contact your KOMATSU dis tributor Check alternator belt tension adjust Before starting the operation or remove cover 1 Checking The...

Page 312: ...h pulley for damage wear of the V groove and wear of the V belt In particular be sure to check that the V belt is not touching the bottom of the V groove In case any of the following occurs ask the KO...

Page 313: ...25 to 26 mm When a belt tension gauge is used the standard tension is within a range of 294 to 441 N Check when changing the V belt The standard deflection between the air conditioner compressor pulle...

Page 314: ...damage wear of the V groove and wear of the V belt In particular be sure to check that the V belt is not touching the bottom of the V groove In case any of the following occurs ask the KOMATSU dis tr...

Page 315: ...oken replace all the stud bolts for that wheel Clean element in air conditioner recirculation filter 1 Loosen knob 1 then remove filter inspection cover 2 2 Remove filter 3 in the direction shown by t...

Page 316: ...minute then stop the engine 4 Turn the starting switch key to the ON position and depress the brake pedal repeatedly If the brake oil pressure caution lamp does not light up even when the brake is dep...

Page 317: ...tly 1 Put the work equipment horizontally in contact with the ground then stop the engine 2 Using a grease pump pump in grease through the grease fittings marked by the arrows 3 After greasing wipe of...

Page 318: ...1 Open the engine side cover on the right side of the chassis 2 Open oil filler F 3 Place a container to catch the oil under drain plug P 4 Loosen drain plug P and drain the oil Be careful not to get...

Page 319: ...cartridge add oil through oil filler F until the oil level is between the H and L marks on the dip stick G 11 Run the engine at idling for short time then stop the engine and check that the oil is be...

Page 320: ...art The common rail fuel injection system used on this machine consists of more precise parts than the conventional injec tion pump and nozzle If any part other than a genuine KOMATSU filter cartridge...

Page 321: ...filter cartridge with oil 11 Remove filter cartridge cap A and install to the filter holder 12 When installing tighten until the packing surface contacts the seal surface of the filter holder then ti...

Page 322: ...the filter cartridge always use a genuine KOMATSU part The common rail fuel injection system used on this machine consists of more precise parts than the conventional injec tion pump and nozzle If any...

Page 323: ...k with fuel 2 After replacing filter cartridge 1 loosen air bleed plug 2 Do not loosen the plug at the filter stand of the fuel prefilter If it is loosened air is not bled 3 Loosen wing bolt 4 which i...

Page 324: ...nd remove it gradually 3 After draining the oil install drain plug P Tightening torque 68 6 9 8 Nm 4 Set a container to catch the oil under the transmission filter 5 Remove drain plug 3 of the transmi...

Page 325: ...transmission oil level add oil 4 39 14 Check that there is no leakage of oil from the transmission case or oil filter Clean transmission case breather 1 Loosen bolt 1 and remove cover 3 2 Remove the m...

Page 326: ...ATSU distributor to check the tightening of the clamps between the air cleaner turbocharger aftercooler engine Replace corrosion resistor cartridge 1 Close a valve 1 of the corrosion resistor at two p...

Page 327: ...n it slowly to release the internal pressure then remove it Refill capacity 173 liters 1 Remove mounting bolts 2 of cover 1 at the top of the tank then remove the cover 2 Lower the bucket horizontally...

Page 328: ...d remove strainer 15 15 Remove any dirt stuck to strainer 15 then wash it in flush ing oil If strainer 15 is damaged replace it with a new part 16 When installing the cover bolts push down the cover a...

Page 329: ...l and add oil to the specified level For details see Check oil level in hydraulic tank add oil 4 56 22 Next increase the engine speed and repeat the procedure in Step 19 to bleed the air Continue this...

Page 330: ...go down before starting the work When removing the oil filler cap turn it slowly to release the internal pressure then remove it 1 Remove mounting bolts 2 of cover 1 at the top of the tank then remove...

Page 331: ...ers A Front B Rear 1 Set a container to catch the oil under drain plug P 2 Remove front and rear oil filler plugs 1 then remove drain plug P to drain the oil REMARK Remove the mud and dirt from around...

Page 332: ...he safety bar Make sure that the brake oil temperature is less than 60 C before checking the brake wear If the disc is near the wear limit carry out inspection at shorter intervals regardless of the s...

Page 333: ...d inspection inter val 4 Install cap nut 1 Tightening torque 29 4 to 39 2 Nm REMARK On new machines the position of the guide is adjusted so that the end face of rod 2 comes to the end face of guide 3...

Page 334: ...ck lever in the FREE position 5 Check that the area around the machine is safe then oper ate the lift arm control lever to FLOAT position d and lower the work equipment to a point 1m above the ground...

Page 335: ...If the engine is started frequently carry out inspection every 1000 hours Check engine valve clearance adjust As special tool is required for removing and adjusting the parts request your KOMATSU dist...

Page 336: ...cover 2 Using a grease pump pump in grease through the grease fittings marked by the arrows 3 After greasing wipe off any old grease that was pushed out 4 When lubricating stop the drive shaft so that...

Page 337: ...aces View from rear of machine Check water pump Check the water pump and its relative parts for water leak and if anything abnormal is found call on your KOMATSU distributor for repairs or replacement...

Page 338: ...ubber please contact your KOMATSU distributor for replacement Checking for missing fuel spray prevention cap hardening of rubber Check for any missing fuel spray prevention caps 1 to 11 or fuel spray...

Page 339: ...ce for every 50 250 500 1000 2000 and 4000 hours service should be carried out at the same time Replace high pressure piping clamp Ask your KOMATSU distributor to carry out this work Replace fuel spra...

Page 340: ...4 9 Service procedure Every 12000 hours service Maintenance 4 90 WA470 6H VEAM946100...

Page 341: ...Technical Data WA470 6H VEAM946100 5 1 5 Technical Data...

Page 342: ...ll length mm 8 970 B Overall height mm 3 470 C Max dimension when shaking bucket mm 5 975 D Overall width mm 2 975 E Min ground clearance mm 505 F Bucket width mm 2 990 G Clearance Cutting edge BOC ti...

Page 343: ...Technical Data 5 1 Technical data WA470 6H VEAM946100 5 3 GK032301 A B H I G C E F D...

Page 344: ...the noise level produced z Sound pressure level at the operator s station measured according to ISO6396 Dynamic test method simulated working cycle z Sound power level emitted by the machine measured...

Page 345: ...lowing guides can help an operator of this machine to reduce the whole body vibration levels 1 Use the correct equipment and attachments 2 Maintain the machine according to this manual Tire pressures...

Page 346: ...us of traveling path as large as pos sible Travel at low speed when traveling around sharp curves 7 Minimize vibrations for long work cycle or long distance trav eling Reduce speed to prevent bounce T...

Page 347: ...e is a calculated value This states the angle at which the machine at rest can stand on a slope without tipping over You must not work with the machine at these angles as the motor transmission hydrau...

Page 348: ...5 4 Limit values for slopes Technical Data 5 8 WA470 6H VEAM946100...

Page 349: ...Attachments Options WA470 6H VEAM946100 6 1 6 Attachments Options WARNING Please read and make sure that you understand the SAFETY section before reading this section...

Page 350: ...cts Loading and carrying products Stockpile bucket with bolt on cutting edge 4 2 m Sockpile bucket without teeth 3 9 m Light material bucket with bolt on cutting edge 5 2 m General ground conditions 2...

Page 351: ...23 5 20 is shown in The travel speed is subject to the using condition and road con dition NOTE To prevent overrunning when traveling at high speed in the following cases do not shift down gear When t...

Page 352: ...ated according to the travel speed While the lock up is engaged the lock up pilot lamp on the machine monitor lights up Position b OFF The lock up does not function 2 Torque converter lock up pilot la...

Page 353: ...Handling torque converter lock up WA470 6H VEAM946100 6 5 3 Shift indicator For details see Shift indicator 3 29 4 Character display For details see Character display portion 3 10 GK043113 E 0 0 O V...

Page 354: ...e is 3rd The lock up is actuated only when the actual speed range is 4th When the lock up is actually actuated the lock up pilot lamp on the machine monitor lights up 3 To cancel the lock up press the...

Page 355: ...rm buzzer sounds At the same time E00 OVERRUN PROTECT is displayed on the character display If the alarm buzzer sounds depress the brake immediately to slow the machine down When the travel speed goes...

Page 356: ...is necessary to obtain authorization and conform to the laws of the country or territory where the machine equipped with KOMTRAX is being used Always contact your KOMATSU distributor before selling or...

Page 357: ...ra tion of the pacemaker NOTE Even when the key in the starting switch of the KOMTRAX system is at the OFF position a small amount of electric power is consumed When putting the machine into long term...

Page 358: ...and efficiently please read the following before using it 6 4 1 Components 1 Shift up switch 2 Shift down switch 3 FNR switch 4 Joystick steering lever 5 Joystick ON OFF switch 6 HI LOW selector swit...

Page 359: ...een FORWARD and REVERSE F position FORWARD N position NEUTRAL R position REVERSE Use the shift up and shift down switches at the top of the joystick to change the speed range 3 Joystick steering lever...

Page 360: ...relationship to the operation of the joystick so this setting is suitable for opera tions loading loose materials and materials that easily spill 6 Horn switch Press this switch 7 at the top of the jo...

Page 361: ...es equipped with joystick steering the transmission auto shift function is also included The differences between operation using the joystick and opera tion using the steering wheel are as follows Doe...

Page 362: ...oystick operation or steering wheel operation according to the work Steering using joystick This is suited for continuous loading operations on jobsites with ample space where the loading operation ca...

Page 363: ...rator s cab If the joystick is moved accidentally when the engine is running the machine may articulate unexpectedly To prevent this dan ger always spring the joystick console up when not using the jo...

Page 364: ...st the console Adjusting height 1 Operate lever 1 in the cancel direction and loosen the lock 2 Adjust the height of the console and set joystick 2 to the desired position Amount of adjustment 30 mm 3...

Page 365: ...ust 3 88 1 Before starting the engine check the operation of the joy stick lever steering check that the transmission directional lever is at N and that the surrounding area is safe REMARK Under the f...

Page 366: ...raight line operate the joystick in the opposite direction from the N position for example when the machine is articulated to the right operate the joystick to the left 7 Use the FNR switch at the top...

Page 367: ...s at 4th the central warning lamp lights up and the alarm buzzer sounds At the same time E00 SHIFT LEVER is displayed on the char acter display Set the gearshift lever within the range from 1st to 3rd...

Page 368: ...without auxiliary control lever 6 5 1 Explanation of components NOTE Detail A shows machine equipment multi function lever with auxiliary control lever 1 Work equipment lever 2 Kickdown switch 3 Hold...

Page 369: ...is stopped in this position until the lift arm reaches the preset position of the kickout and the lever is returned to the HOLD position Position b HOLD The lift arm and bucket stop and remain in the...

Page 370: ...2nd It is also possible to cancel the kick down by turning the starting switch OFF In auto shift if the travel speed becomes high after the kick down the gear will be shifted up by the auto shift In...

Page 371: ...d Position a ON The pilot lamp inside the switch and the directional selection pilot lamp on the machine monitor light up and the FNR switch is activated Position b OFF The FNR switch is not activated...

Page 372: ...6H VEAM946100 7 Auxiliary control lever adjacent to the multi function lever When multi purpose bucket is used This lever 7 operates the multi purpose bucket Position a CLOSE Clam closes Position b HO...

Page 373: ...el Max speed for changing direction 12 km h When the directional selector switch actuation switch 3 is at the ON position if the directional lever 1 is operated to FORWARD or REVERSE the machine will...

Page 374: ...lay Set the FNR switch to the N position When the engine is started if the directional selector switch is at the ON position and the directional lever is at N and the FNR switch is operated to F or R...

Page 375: ...achments Options 6 6 3 lever control WA470 6H VEAM946100 6 27 6 6 3 lever control 6 6 1 Explanation of components 1 Lift arm control lever 2 Bucket control lever 3 Auxiliary control lever GK043255 1 2...

Page 376: ...of the kickout and the lever is returned to the HOLD position Position b HOLD The lift arm is kept in the same position Position c LOWER Position d FLOAT The lift arm moves freely under external forc...

Page 377: ...29 3 Auxiliary control lever 3 lever control When multi purpose bucket is used This lever 3 operates the multi purpose bucket Position a CLOSE Clam closes Position b HOLD The clam stops and remains i...

Page 378: ...he grease container through the rear window If the mixer blades are turning inside the grease container the lubrication system is OK If the mixer blades are not turning no automatic lubrication is tak...

Page 379: ...Monitoring of system function by means of an external cycle switch CS 5 Monitoring of system function by means of an external pres sure switch PS 6 Fault message FAULT Pushbuttons 1 Turn on display D...

Page 380: ...ication system Attachments Options 6 32 WA470 6H VEAM946100 6 7 3 Changing the lubrication interval times The settings when shipping from factory are as follows Greasing interval after 1 hour Greasing...

Page 381: ...Index WA470 6H VEAM946100 7 1 7 Index...

Page 382: ...en lock 3 67 Cab window open lock 3 68 Cap wiper handling 3 87 Cap with lock 3 64 Caution lamps explanation 3 16 3 19 3 22 Cautions lamps overview 3 6 CE Conforming equipment 1 21 Central lubrication...

Page 383: ...0 Lever stand 3 101 Lift arm control lever 3 61 Lift arm control lever 3 lever control 6 28 Lift arm operation 3 129 Lifting machine 3 153 Load and carry operations 3 134 Loading operations 3 135 Lock...

Page 384: ...Moving machine 3 114 Parking machine 3 142 Precautions 2 20 3 137 Starting engine 3 105 Stopping engine 3 113 Stopping machine 3 122 3 123 Turning 3 125 Walk around check 3 88 Work equipment 3 128 Ope...

Page 385: ...tch 3 49 6 22 Lamp switch 3 44 Monitor panel mode selector switch 1 3 48 Monitor panel mode selector switch 2 3 48 Parking brake switch 3 46 Power mode selector switch 3 42 Rear heated wire glass swit...

Page 386: ...dex Index 7 6 WA470 6H VEAM946100 Work equipment Adjusting boom kickout 3 140 Adjusting bucket positioner 3 141 Bucket level indicator 3 141 Work equipment lock lever 2 9 3 60 Work equipment operation...

Page 387: ...Notes WA470 6H VEAM946100 8 1 8 Notes...

Page 388: ...Notes 8 2 WA470 6H VEAM946100...

Page 389: ...Notes WA470 6H VEAM946100 8 3...

Page 390: ...Notes 8 4 WA470 6H VEAM946100...

Page 391: ...Notes WA470 6H VEAM946100 8 5...

Page 392: ...Notes 8 6 WA470 6H VEAM946100...

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